NINJA 650R
ER-6f ABS
ER-6f

Motorcycle
Service ManualQuick Reference Guide

This quick reference guide will assist
you in locating a desired topic or procedure.
•Bend the pages back to match theblack tab of the desired chapter number with the black tab on the edge ateach table of contents page.
•Refer to the sectional table of contents
for the exact pages to locate the specific topic required.

General Information

1 j

Periodic Maintenance

2 jFuel System (DFI)

3 j

Cooling System

4 j

Engine Top End

5 j

Clutch6 jEngine Lubrication System

7 j

Engine Removal/Installation

8 j

Crankshaft/Transmission

9 j

Wheels/Tires

10 j

Final Drive

11 j

Brakes

12 j

Suspension

13 j

Steering

14 j

Frame

15 j

Electrical System

16 jAppendix

17 j

NINJA 650R
ER-6f
ER-6f ABS

Motorcycle
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, ortransmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki
Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your Motorcycle dealer for the latest
information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the timeof publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.

© 2005 Kawasaki Heavy Industries, Ltd.

First Edition (1) : Nov. 2, 2005 (M)EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of
the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliancewith applicable regulations of the California Air Resources Board on vehicles sold in California
only.
1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors
are routed through an oil separator to the inlet side of the engine. While the engine is operating,the vapors are drawn into combustion chamber, where they are burned along with the fuel and air
supplied by the fuel injection system.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaustof this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully
designed and constructed to ensure an efficient engine with low exhaust pollutant levels.
The exhaust system of this model motorcycle manufactured primarily for sale in California includes a catalytic converter system.
3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister whenthe engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what iscommonly referred to as the Act’s “tampering provisions”.
“Sec. 203(a) The following acts and the causing thereof are prohibited.
(3)(A) for any person to remove or render inoperative any device or element of design installed
on or in a motor vehicle or motor vehicle engine in compliance with regulations under thistitle prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer
knowingly to remove or render inoperative any such device or element of design after such
sale and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading
motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a
motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser...”

NOTE
The
phrase“removeorrenderinoperative
any
device or element of design” has been generally○interpreted as follows.
1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance.
2. Tampering could include.
a.Maladjustment of vehicle components such that the emission standards are exceeded.
b.Use of replacement parts or accessories which adversely affect the performanceor durability of the motorcycle.
c.Addition of components or accessories that result in the vehicle exceeding the standards.
d.Permanently removing, disconnecting, or rendering inoperative any component orelement of design of the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW,
THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10000 PER VIOLATION.

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering
inoperative by any person other than for purposes of maintenance, repair, or replacement, of any
device or element of design incorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of thevehicle after such device or element of design has been removed or rendered inoperative by
any person.
Among those acts presumed to constitute tampering are the acts listed below.
Replacement of the original exhaust system or muffler with a component not in compliancewith Federal regulations.
Removal of the muffler(s) or any internal portion of the muffler(s).
Removal of the air box or air box cover.
Modifications to the muffler(s) or air inlet system by cutting, drilling, or other means if suchmodifications result in increased noise levels.

•
•
•
•

Foreword
This manual is designed primarily for use bytrained 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 andrepair work. A basic knowledge of mechanics,
the proper use of tools, and workshop procedures must be understood in order to carry out
maintenance and repair satisfactorily. Whenever the owner has insufficient experience or
doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.
In order to perform the work efficiently andto avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures
before starting work, and then do the work carefully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurements
can only be made if the proper instruments areused, and the use of substitute tools may adversely affect safe operation.
For the duration of the warranty period,
we recommend that all repairs and scheduled
maintenance be performed in accordance withthis service manual. Any owner maintenance orrepair procedure not performed in accordancewith this manual may void the warranty.
To get the longest life out of your vehicle.
Follow the Periodic Maintenance Chart in theService Manual.
Be alert for problems and non-scheduled
maintenance.
Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, andtesters that are necessary when servicing
Kawasaki motorcycles are introduced by theService Manual. Genuine parts provided asspare parts are listed in the Parts Catalog.
Follow the procedures in this manual carefully. Don’t take shortcuts.
Remember to keep complete records of maintenance and repair with dates and any newparts installed.

•
•
•

•
•

How to Use This Manual
In this manual, the product is divided into
its major systems and these systems make up
the manual’s chapters. The Quick Reference

Guide shows you all of the product’s system
and assists in locating their chapters. Eachchapter in turn has its own comprehensive Table of Contents.
For example, if you want ignition coil information, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use theTable of Contents on the first page of the chapter to find the Ignition Coil section.
Whenever you see these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenancepractices.

WARNING
This warning symbol identifies special
instructions or procedures which, if notcorrectly followed, could result in personal injury, or loss of life.

CAUTION
This caution symbol identifies special
instructions or procedures which, if notstrictly observed, could result in damage to or destruction of equipment.
This manual contains four more symbols (inaddition to WARNING and CAUTION) which will
help you distinguish different types of information.

NOTE○This note symbol indicates points of par-ticular interest for more efficient and convenient operation.

a procedural step or work to be• Indicatesdone.

○Indicates a procedural sub-step or how to do

the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action totake based on the results of the test or inspection in the procedural step or sub-step it follows.
In most chapters an exploded view illustrationof the system components follows the Table ofContents. In these illustrations you will find the
instructions indicating which parts require specified tightening torque, oil, grease or a locking
agent during assembly.

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 centerbottom dead center
before top dead center
degree(s) Celsius
direct current
farad(s)degree(s) Fahrenheit
foot, feetgram(s)hour(s)liter(s)

lb
m
min
N
Pa
PS
psi
r
rpm
TDC
TIR
V
W
Ω

pound(s)meter(s)minute(s)newton(s)pascal(s)horsepower
pound(s) per square inch
revolution
revolution(s) per minutetop dead center
total indicator readingvolt(s)watt(s)ohm(s)

COUNTRY AND AREA CODES
AT
CA
CAL
CH

Austria
CanadaCalifornia
Switzerland

DE
GB
US
WVTA

Germany
United Kingdom
United States
Whole Vehicle Type Approval

GENERAL INFORMATION 1-1

General Information
Table of Contents
Before Servicing .....................................................................................................................
Model Identification.................................................................................................................
General Specifications............................................................................................................
Technical Information - Cassette Type Transmission .............................................................
Technical Information - Inlet Air Pressure Sensor .................................................................
Technical Information – ABS (Anti – Lock Brake System)......................................................
Unit Conversion Table ............................................................................................................

1-2
1-7
1-10
1-13
1-14
1-15
1-27

1

1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherevernecessary. This section explains the items that require particular attention during the removal andreinstallation or disassembly and reassembly of general parts.
Especially note the following:

Battery Ground
Before completing any service on the motorcycle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the groundcable (–) first and then the positive (+). When completedwith the service, first connect the positive (+) cable to thepositive (+) terminal of the battery then the negative (–) cable to the negative terminal.

Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.

Solvent
Use a high-flush point solvent when cleaning parts. High-flush point solvent should be used according to directionsof the solvent manufacturer.

Cleaning Vehicle before Disassembly
Clean the vehicle thoroughly before disassembly. Dirt orother foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease
performance of the vehicle.

GENERAL INFORMATION 1-3
Before Servicing
Arrangement and Cleaning of Removed Parts
Disassembled parts are easy to confuse. Arrange theparts according to the order the parts were disassembled
and clean the parts in order prior to assembly.

Storage of Removed Parts
After all the parts including subassembly parts have beencleaned, store the parts in a clean area. Put a clean clothor plastic sheet over the parts to protect from any foreignmaterials that may collect before re-assembly.

Inspection
Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sectionsof this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is beyond its service limit.

Replacement Parts
Replacement parts must be KAWASAKI genuine orrecommended by KAWASAKI. Gaskets, O-rings, oil seals,
grease seals, circlips or cotter pins must be replaced withnew ones whenever disassembled.

Assembly OrderIn most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service
Manual, follow the procedures given.

1-4 GENERAL INFORMATION
Before Servicing
Tightening Sequence
Generally, when installing a part with several bolts, nuts,
or screws, start them all in their holes and tighten them toa snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which canlead to malfunction. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.

Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench. Often, thetightening sequence is followed twice-initial tightening andfinal tightening with torque wrench.

Force
Use common sense during disassembly and assembly,
excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ringHardening, shrinkage, or damage of both gaskets
and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing
surfaces thoroughly so that no gasket material or othermaterial remains. Install new gaskets and replace used
O-rings when re-assembling

Liquid Gasket, Non-permanent Locking Agent
For applications that require Liquid Gasket or a
Non-permanent Locking Agent, clean the surfaces sothat no oil residue remains before applying liquid gasket or
non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages andcause serious damage.

GENERAL INFORMATION 1-5
Before Servicing
Press
For items such as bearings or oil seals that must bepressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and usesmooth movements when installing.

Ball Bearing and Needle Bearing
Do not remove pressed ball or needle unless removal isabsolutely necessary. Replace with new ones wheneverremoved. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by puttingpressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.

Oil Seal, Grease Seal
Do not remove pressed oil or grease seals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facingout. Make sure the seal is aligned properly when installing.

Apply specified grease to the lip of seal before installingthe seal.

Circlips, Cotter Pins
Replace circlips or cotter pins that were removed with new
ones. Take care not to open the clip excessively when installing to prevent deformation.

1-6 GENERAL INFORMATION
Before Servicing
Lubrication
It is important to lubricate rotating or sliding parts duringassembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply
the specific oil or grease as specified.

Direction of Engine Rotation
When rotating the crankshaft by hand, the free playamount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed
from output side).

Electrical Wires
A two-color wire is identified first by the primary color andthen the stripe color. Unless instructed otherwise, electricalwires must be connected to those of the same color.

Instrument
Use a meter that has enough accuracy for an accurate
measurement. Read the manufacture’s instructions thoroughly before using the meter. Incorrect values may leadto improper adjustments.

GENERAL INFORMATION 1-7
Model Identification
EX650A6F (United States and Canada) Left Side View

EX650A6F (United States and Canada) Right Side View

1-8 GENERAL INFORMATION
Model Identification
EX650A6F (Europe) Left Side View

EX650A6F (Europe) Right Side View

GENERAL INFORMATION 1-9
Model Identification
EX650B6F Left Side View

EX650B6F Right Side View

Frame Number

Engine Number

1-10 GENERAL INFORMATION
General Specifications
Items
Dimensions
Overall Length
Overall Width
Overall Height
WheelbaseRoad Clearance
Seat Height
Dry Mass:
EX650A6F
EX650B6F
Curb Mass:
Front:
EX650A6F
EX650B6F
Rear:
EX650A6F
EX650B6F
Fuel Tank Capacity
Performance
Minimum Turning RadiusEngineType
Cooling System
Bore and Stroke
Displacement
Compression Ratio
Maximum Horsepower
Maximum TorqueCarburetion System
Starting System
Ignition System
Timing Advance
Ignition Timing
Spark Plug
Cylinder Numbering Method
Firing Order
Valve Timing:
Inlet:
Open
Close
Duration

EX650A6F, EX650B6F
2 105 mm (82.9 in.)
760 mm (29.9 in.)
1 210 mm (47.6 in.)
1 410 mm (55.5 in.)
145 mm (5.7 in.)
790 mm (31.1 in.)
178 kg (392.5 lb)(CAL) 178.5 kg (393.6 lb)
182 kg (401.3 lb)

101 kg (222.7 lb)
103 kg (227.1 lb)
99 kg (216.1 lb)(CAL) 99.5 kg (219.4 lb)
101 kg (222.7 lb)
15.5 L (4.1 US gal.)
2.7 m (8.9 ft)
4-stroke, DOHC, 2-cylinder
Liquid-cooled
83 × 60 mm (3.3 × 2.4 in.)
649 cm³ (39.60 cu in.)11.3 : 1
53 kW (72 PS) @8 500 r/min (rpm),
66 N·m (6.7 kgf·m, 49 ft·lb) @7 000 r/min (rpm),
FI (Fuel Injection) KEIHIN TTK38 × 2
Electric starter
Battery and coil (transistorized)
Electronically advanced (digital igniter)
From 10° BTDC @1 300 r/min (rpm) to 35° BTDC @4 800
r/min (rpm)NGK CR9EIA-9
Left to right, 1-2
1-2

31° BTDC
61° ABDC
272°

GENERAL INFORMATION 1-11
General Specifications
Items
Exhaust:Open
Close
Duration
Lubrication System
Engine Oil:Type
Viscosity
Capacity
Drive Train
Primary Reduction System:
Type
Reduction Ratio
Clutch TypeTransmission:
Type
Gear Ratios:
1st
2nd
3rd
4th
5th
6th
Final Drive System:
Type
Reduction Ratio
Overall Drive Ratio
Frame
Type
Caster (Rake Angle)
Trail
Front Tire:
Type
Size
Rim Size
Rear Tire:
Type
Size
Rim Size
Front Suspension:
Type
Wheel Travel
Rear Suspension:

EX650A6F, EX650B6F
50° BBDC
30° ATDC
260°
Forced lubrication (semi-dry sump)
API SE, SF or SG
API SH, SJ or SL with JASO MA
SAE 10W-40
2.4 L (2.5 US qt)

Gear
2.095 (88/42)
Wet multi disc
6-speed, constant mesh, return shift
2.438 (39/16)
1.714 (36/21)
1.333 (32/24)
1.111 (30/27)
0.966 (28/29)
0.852 (23/27)
Chain drive
3.067 (46/15)
5.473 @Top gear
Tubular, diamond25°
106 mm (4.2 in.)Tubeless
120/70 ZR17 M/C (58W)
17 × 3.50
Tubeless
160/60 ZR17 M/C (69W)
17 × 4.50
Telescopic fork
120 mm (4.7 in.)

1-12 GENERAL INFORMATION
General Specifications
Items
Type
Wheel Travel
Brake Type:
Front
Rear
Electrical Equipment
Battery
Headlight:
Type
Bulb
Tail/Brake Light
Alternator:
Type
Rated Output

EX650A6F, EX650B6F
Swingarm
125 mm (4.9 in.)
Dual discs
Single disc
12 V 10 Ah
Semi-sealed beam
12 V 55 W × 2/55 W (Hi/Lo)
12 V 5/21 W
Three-phase AC
24 A/14 V @5 000 r/min (rpm)Specifications are subject to change without notice, and may not apply to every country.

GENERAL INFORMATION 1-13
Technical Information - Cassette Type Transmission
Cassette Type Transmission
The transmission of the current model is unable to be removed without disassembling upper andlower crankcase halves.
The EX650A/B enables transmission to be removed from the right side of engine as an assy, without
disassembling crankcase halves (see Transmission Assy Removal in the Crankshaft/Transmission
chapter).
Transmission Assy:
Drive Shaft [A]Output Shaft [B]Shift Rods [C]Shift Dram [D]Shift Forks [E]Transmission Case [F]1-14 GENERAL INFORMATION
Technical Information - Inlet Air Pressure Sensor
Atmospheric pressure sensor and camshaft position sensor are not equipped with the EX650A/B.
As a substitute of these sensors above, the EX650A/B recognizes atmospheric pressure and intake
stroke of #1 by the signal of inlet air pressure sensor.
The ECU detects atmospheric pressure when the ignition is switched ON. While the engine is running, the ECU also presumes atmospheric pressure by analyzing the waveform of boost pressure overfixed period. The intake stroke is recognized by waveform of boost pressure, therefore the system
can recognize the difference of each stroke.

GENERAL INFORMATION 1-15
Technical Information – ABS (Anti – Lock Brake System)
OutlineABS controls the brake caliper fluid pressure by means of mechatronics - a combination of electronicand hydraulic control technology in order to keep the friction force between the tires and the roadsurfaces close to the maximum value and prevent wheel lock. But it does not operate during cruising.

ABS Total System

1. ECU
2. ABS Indicator Light (LED)
3. Pump Motor
4. Pump
5. Front Reservoir
6. Front Inlet Solenoid Valve
7. Front Outlet Solenoid Valve
8. Rear Inlet Solenoid Valve
9. Rear Outlet Solenoid Valve
10. Brake Lever
11. Brake Pedal
12. ABS Hydraulic Unit

13. Front Brake Caliper
14. Front Wheel Rotation Sensor
15. Front Wheel Rotation Sensor Rotor
16. Rear Brake Caliper
17. Rear Wheel Rotation Sensor
18. Rear Wheel Rotation Sensor Rotor
19. ABS Kawasaki Self-diagnosis System Connector
20. ABS Solenoid Valve Relay
21. ABS Motor Relay
22. Rear Reservoir

1-16 GENERAL INFORMATION
Technical Information – ABS (Anti – Lock Brake System)
ABS System Block Diagram

1. Power Source
2. Ignition Power Source
3. Battery Power Source
4. Indicator Light Output
5. ABS Indicator Light (LED)6. ECU
7. ABS Solenoid Valve Relay
8. Output
9. Monitor Input
10. Valve Output
11. Outlet Solenoid Valve

12. Inlet Solenoid Valve
13. ABS Motor Relay
14. Pump Motor
15. Hydraulic Unit
16. ABS Controller
17. ABS Hydraulic Unit
18. ABS Kawasaki Self-diagnosis System Connector
19. Wheel Rotation Input
20. Wheel Rotation Sensor

GENERAL INFORMATION 1-17
Technical Information – ABS (Anti – Lock Brake System)
Related Parts and Function

1. Front Wheel Rotation Sensor
2. Front Wheel Rotation Sensor Rotor
3. Rear Wheel Rotation Sensor
4. Rear Wheel Rotation Sensor Rotor
5. ABS Indicator Light (LED)6. ABS Hydraulic Unit
7. ABS Fuse Box
8. ABS Kawasaki Self-diagnosis System Connector
Wheel Rotation Sensor
The wheel rotation sensors output the rotation speed of each wheel to the ECU in the ABS hydraulicunit. The wheel rotation sensor is installed to the front fork and rear caliper bracket, and the sensor
rotor is pressed into the brake disc. The number of teeth on the front and rear sensor rotor is 50.
ABS Indicator Light (LED)The condition or the failure of the ABS system is indicated by various patterns of the ABS indicatorlight (LED) blinking.

1-18 GENERAL INFORMATION
Technical Information – ABS (Anti – Lock Brake System)
ABS Hydraulic Unit
The outlet and inlet solenoid valves, reservoir, pump motor, solenoid valve relay, motor relay, andECU are built in the ABS hydraulic unit.

1. Brake Lever
2. Brake Pedal
3. Pump Motor
4. Rear Inlet Solenoid Valve
5. Rear Outlet Solenoid Valve
6. Rear Reservoir
7. Rear Caliper
8. Front Inlet Solenoid Valve
9. Front Outlet Solenoid Valve
10. Front Caliper
11. Front Reservoir
12. Orifice
13. Filter
14. Check ValveGENERAL INFORMATION 1-19
Technical Information – ABS (Anti – Lock Brake System)
Inlet Solenoid Valve
Inlet solenoid valves control the brake pressure of each wheel by combining the operation of theoutlet solenoid valve. The ECU changes the electric current in the solenoids of the inlet solenoid
valve (2 way, 2 position electromagnetic valve) to move the tappet and change the fluid pressure to“Increase Mode”, “Hold Mode”, or “Decrease Mode”.

1. Increase Mode
2. Hold and Decrease Mode
3. Tappet
4. Valve Body
5. From Master Cylinder
Outlet Solenoid Valve
Outlet solenoid valves control the brake pressure of each wheel by combining the operation of theinlet solenoid valve. The ECU changes the electric current in the solenoids of the outlet solenoid
valve (2 way, 2 position electromagnetic valve) to move the armature and change the fluid pressure
to “Increase Mode”, “Hold Mode”, or “Decrease Mode”.

1. Decrease Mode
2. Increase and Hold Mode
3. Armature
4. Valve
5. To Reservoir

1-20 GENERAL INFORMATION
Technical Information – ABS (Anti – Lock Brake System)
Reservoir
When the passage opens between the caliper and the reservoir with the outlet solenoid valve in“Decrease Mode”, the brake fluid flows into the reservoir by pushing the piston, stays there temporarily, and then returns to the master cylinder. With the outlet solenoid valve “Increase or Hold Mode”,
the pump returns the remaining brake fluid in the reservoir to the master cylinder.

1. From Outlet Solenoid Valve
2. To Pump
Pump Motor
The pump motor operates the pump, supply or return the brake fluid from the pump.
Pump
The pump operates continuously when the ABS is activated. The pump is driven by the motor andsupply the brake fluid to the caliper or return the brake fluid in the reservoir to the master cylinder.
The piston is reciprocated by the eccentric cam [A] on the end of the motor shaft and the pump sucksin or discharge the brake fluid.
When the pump pulls fluid in, the piston [B] is moved right by the force of the spring [C]. At this time,
the spring [D] is compressed by the pressure of the brake fluid in the reservoir to open the inlet valve[E] and the brake fluid flows into the cylinder [F]. The outlet valve [G] is held closed by the force of thespring [H].

When the pump discharges the brake fluid, the inlet valve [E] is closed by the spring [D], and thepiston [B] is moved left by the cam [A], producing pressure in the cylinder [F]. The pressure pushes
the spring [H], opens the outlet valve [G], and the brake fluid returns to the master cylinder.
Spring [C]GENERAL INFORMATION 1-21
Technical Information – ABS (Anti – Lock Brake System)
ABS Solenoid Valve Relay
ABS solenoid valve relay supply or intercept the power to the inlet or outlet solenoid valves.
ABS Motor Relay
ABS motor relay supply or intercept the power to the pump motor.
ECU
ECU inputs the sensor signal.
ECU calculates the wheel condition for the slip.
ECU controls the hydraulic unit.
ECU sends the actuating signals to the ABS indicator light (LED).

1-22 GENERAL INFORMATION
Technical Information – ABS (Anti – Lock Brake System)
ABS Operation
The ABS has two independent hydraulic lines, one for the front wheel and the other for the rear
wheel. The front wheel system is explained here and is identical to the rear wheel system.
ABS in Action(Increase Mode)
When the caliper fluid pressure is to be increased, first the tappet of inlet solenoid valve opens(normally open). The brake fluid flows through the valve body as shown in the diagram below toincrease the brake fluid pressure in the caliper. The master cylinder pressurizes to the brake caliper
directly, increasing the braking force.

1. Brake Lever
2. Front Inlet Solenoid Valve
3. Pump Motor
4. Pump
5. Front Reservoir
6. Front Outlet Solenoid Valve
7. Front Caliper

GENERAL INFORMATION 1-23
Technical Information – ABS (Anti – Lock Brake System)(Hold Mode)
When the caliper fluid pressure is to be hold, the tappet of inlet solenoid valve closes, and thepassage (master cylinder side) to the valve body is intercepted. No matter how hard the brake leveris pulled, the brake fluid pressure in the caliper is maintained at a given level.

1. Brake Lever
2. Front Inlet Solenoid Valve
3. Pump Motor
4. Pump
5. Front Reservoir
6. Front Outlet Solenoid Valve
7. Front Caliper

1-24 GENERAL INFORMATION
Technical Information – ABS (Anti – Lock Brake System)(Decrease Mode)
When the caliper fluid pressure is to be decreased, the tappet of inlet solenoid valve closes, and thepassage to the valve body is intercepted. The valve of outlet solenoid valve is opened by the operationof the armature, and the brake fluid flows to the reservoir. ECU operates pump, and the pump returns
the brake fluid in the reservoir to the master cylinder. The brake fluid pressure is decreased, and thewheel is prevented from locking.

1. Brake Lever
2. Front Inlet Solenoid Valve
3. Pump Motor
4. Pump
5. Front Reservoir
6. Front Outlet Solenoid Valve
7. Front Caliper

GENERAL INFORMATION 1-25
Technical Information – ABS (Anti – Lock Brake System)
ABS Disabled (Conventional Mode)
During cruising (without braking) or in case of a malfunction with the ABS, the ECU stops operating.
This is “Conventional Mode”.
When the caliper fluid pressure is to be increased, first the tappet of inlet solenoid valve opens(normally open). The brake fluid flows through the valve body as shown in the diagram below toincrease the brake fluid pressure in the caliper. The master cylinder pressurizes to the brake caliper
directly, increasing the braking force.

1. Brake Lever
2. Front Inlet Solenoid Valve
3. Pump Motor
4. Pump
5. Front Reservoir
6. Front Outlet Solenoid Valve
7. Front Caliper

1-26 GENERAL INFORMATION
Technical Information – ABS (Anti – Lock Brake System)
Riding Characteristics of ABS
ABS is designed to help prevent the wheels from locking up when hard brakes are applied whilerunning straight. The ABS automatically regulates brake force. Intermittently gaining gripping force
and braking force helps prevent wheel lock-up and allows stable steering control while stopping.
Brake control function is identical to that of a conventional motorcycle. The brake lever is used forthe front brake and the brake pedal for the rear brake.
Although the ABS provides stability while stopping by preventing wheel lock-up, remember the following characteristics:○ABS cannot compensate for adverse road conditions, misjudgement or improper application of
brakes. You must take the same care as with motorcycles not equipped with ABS.
○ABS is not designed to shorten the braking distance. On loose, uneven or downhill surfaces, thestopping distance of a motorcycle with ABS may be longer than that of an equivalent motorcycle
without ABS. Use special caution in such areas.
○ABS will help prevent wheel lock-up during straight-up braking, but it cannot control wheel slip which
may be caused by braking during cornering. When turning a corner, it is better to limit braking to
the light application of both brakes or not to brake at all. Reduce your speed before you get into thecorner.
○The ECU integrated in the ABS compare vehicle speed with wheel speed. Since non-recommended
tires can affect wheel speed, they may confuse the ECU, which can extend braking distance.

WARNINGUse of non-recommended tires may cause malfunctioning of ABS and can lead to extended
braking distance. The rider could have an accident as a result. Always use recommended
standard tires for this motorcycle.

NOTE○When the ABS is functioning, you may feel a pulsing in the brake lever or pedal. This is normal.
You need not suspend applying brakes.
○Immediately after turning the ignition switch on, you may hear a click of the relay operating. Thisis the sound of self-checking and is quite normal.
○ABS does not function at the speed of approx. 6 km/h or below.
○ABS does not function if the battery is discharged.

GENERAL INFORMATION 1-27
Unit Conversion Table
Prefixes for Units:
Prefix
mega
kilo
centi
milli
micro

SymbolMkcmµUnits 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

Units of Volume:
L
L
L
L
L
L
mL
mL
mL

×
×
×
×
×
×
×
×
×

0.26420.22001.057
0.87992.113
1.816
0.033810.02816
0.06102××××

0.10200.2248
9.807
2.205

Units of Temperature:×××

0.62143.281
0.03937

=
=
=

mile
ft
in

=
=
=
=
=
=

kgf·m
ft·lb
in·lb
N·m
ft·lb
in·lb

=
=
=
=
=
=

kgf/cm²
psi
cmHg
kPa
psi
kPa

=

mph

=
=
=
=

PS
HP
kW
HP

Units of Torque:
N·m
N·m
N·m
kgf·m
kgf·m
kgf·m

×
×
×
×
×
×

0.10200.7376
8.851
9.807
7.233
86.80

Units of Pressure:
=
=
=
=
=
=
=
=
=

gal (US)gal (imp)
qt (US)qt (imp)pint (US)pint (imp)oz (US)oz (imp)
cu in

=
=
=
=

kg
lb
N
lb

Units of Force:
N
N
kg
kg

km
m
mm

kPa
kPa
kPa
kgf/cm²
kgf/cm²
cmHg

×
×
×
×
×
×

0.010200.14500.7501
98.07
14.22
1.333

Units of Speed:km/h

×0.6214

Units of Power:
kW
kW
PS
PS

×
×
×
×

1.360
1.341
0.73550.9863

PERIODIC MAINTENANCE 2-1

Periodic Maintenance
Table of Contents
Periodic Maintenance Chart ...................................................................................................
Torque and Locking Agent......................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Periodic Maintenance Procedures..........................................................................................
Fuel System (DFI)................................................................................................................
Air Cleaner Element Cleaning...........................................................................................
Throttle Control System Inspection...................................................................................
Engine Vacuum Synchronization Inspection.....................................................................
Idle Speed Inspection .......................................................................................................
Idle Speed Adjustment......................................................................................................
Fuel Hose Inspection (fuel leak, damage, installation condition) ......................................
Evaporative Emission Control System (California Model) ...................................................
Evaporative Emission Control System Inspection ............................................................
Cooling System....................................................................................................................
Coolant Level Inspection...................................................................................................
Radiator Hose Damage and Installation Condition Inspection..........................................
Air Suction System ..............................................................................................................
Air Suction System Damage Inspection............................................................................
Engine Top End ...................................................................................................................
Valve Clearance Inspection ..............................................................................................
Valve Clearance Adjustment.............................................................................................
Clutch...................................................................................................................................
Clutch Operation Inspection..............................................................................................
Wheels/Tires ........................................................................................................................
Air Pressure Inspection.....................................................................................................
Wheel/Tire Damage Inspection.........................................................................................
Tire Tread Wear, Abnormal Wear Inspection ....................................................................
Wheel Bearing Damage Inspection ..................................................................................
Drive Train ...........................................................................................................................
Drive Chain Lubrication Condition Inspection ...................................................................
Drive Chain Slack Inspection ............................................................................................
Drive Chain Slack Adjustment ..........................................................................................
Wheel Alignment Inspection .............................................................................................
Drive Chain Wear Inspection ............................................................................................
Chain Guide Inspection.....................................................................................................
Brake System ......................................................................................................................
Brake Fluid Leak (Brake Hose and Pipe) Inspection ........................................................
Brake Hose and Pipe Damage and Installation Condition Inspection...............................
Brake Operation Inspection ..............................................................................................
Brake Fluid Level Inspection.............................................................................................
Brake Pad Wear Inspection ..............................................................................................
Brake Light Switch Operation Inspection ..........................................................................
Suspensions ........................................................................................................................
Front Forks/Rear Shock Absorber Operation Inspection ..................................................
Front Fork Oil Leak Inspection..........................................................................................
Rear Shock Absorber Oil Leak Inspection ........................................................................
Steering System ..................................................................................................................
Steering Play Inspection ...................................................................................................
Steering Play Adjustment..................................................................................................

2-3
2-6
2-11
2-13
2-14
2-14
2-14
2-15
2-16
2-18
2-18
2-19
2-19
2-19
2-20
2-20
2-21
2-21
2-21
2-21
2-21
2-23
2-26
2-26
2-26
2-26
2-27
2-27
2-28
2-28
2-28
2-29
2-29
2-30
2-31
2-31
2-32
2-32
2-32
2-33
2-33
2-34
2-34
2-35
2-35
2-35
2-35
2-36
2-36
2-36

2

2-2 PERIODIC MAINTENANCE
Steering Stem Bearing Lubrication ...................................................................................
Electrical System .................................................................................................................
Spark Plug Condition Inspection.......................................................................................
Lights and Switches Operation Inspection........................................................................
Headlight Aiming Inspection .............................................................................................
Sidestand Switch Operation Inspection ............................................................................
Engine Stop Switch Operation Inspection.........................................................................
Others ..................................................................................................................................
Chassis Parts Lubrication .................................................................................................
Bolts, Nuts and Fasteners Tightness Inspection...............................................................
Replacement Parts ..............................................................................................................
Air Cleaner Element Replacement....................................................................................
Fuel Hose Replacement ...................................................................................................
Coolant Change ................................................................................................................
Radiator Hose and O-ring Replacement...........................................................................
Engine Oil Change............................................................................................................
Oil Filter Replacement ......................................................................................................
Brake Hose and Pipe Replacement..................................................................................
Brake Fluid Change ..........................................................................................................
Master Cylinder Rubber Parts Replacement ....................................................................
Caliper Rubber Parts Replacement ..................................................................................
Spark Plug Replacement ..................................................................................................

2-37
2-37
2-37
2-38
2-40
2-41
2-42
2-43
2-43
2-44
2-45
2-45
2-45
2-46
2-48
2-49
2-49
2-50
2-51
2-52
2-54
2-56

PERIODIC MAINTENANCE 2-3
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the motorcycle ingood running condition.The initial maintenance is vitally important and must not be neglected.

Periodic Inspection
FREQUENCY Whichever
comes
first

* ODOMETER READING
× 1 000 km(× 1 000 mile)
1

INSPECTION
Fuel System

Every

year

Fuel leak (fuel hose and pipe) - inspect

year

Fuel hose and pipe damage - inspect

year

Fuel hose and pipe installation condition inspect
Evaporative Emission Control System(CAL)
Evaporative emission control system
function - inspect
Cooling System

year

Coolant level - inspect
Coolant leak (radiator hose and pipe) inspect

year

Radiator hose damage - inspect

year

Radiator hose installation condition inspect
Air Suction System

year

Tire air pressure - inspect

Drive chain wear - inspect #36• • • • • • •

2-19

•
•
•
•

•
•
•
•
•

•
year

Tire tread wear, abnormal wear - inspect
Drive Train
Drive chain lubrication condition - inspect #Drive chain slack - inspect #

30

•
•
•
•
•
•
•

•
•
•
•
•
•
•

year

2-15
2-16
2-18
2-19
2-19
2-19

•
•
•
•

•
•
•
•

•
•
•
•

2-20

•

•

•

2-21

Every 42 000 km (26 000 mile)

Wheel/tire damage - inspect
Wheel bearing damage - inspect

24

2-14

Air suction system damage - inspect
Engine Top End
Valve clearance - inspect
ClutchClutch operation (play, disengagement,
engagement) - inspect
Wheels and Tires

18

•
•
•
•
•
•
•

Engine vacuum synchronization - inspect
Idle speed - inspect

12(0.6) (4) (7.5) (12) (15) (20) (24)Air cleaner element - clean
Throttle control system (play, smooth
return, no drag) - inspect

6

See
Page

2-21
2-21
2-21

2-21

•

•

•

2-26

•
•
•
•

•
•
•
•

•
•
•
•

2-26

•

2-27
2-28
2-28
2-29

Every 600 km (400 mile)
Every 1 000 km (600 mile)

•

2-27

•

2-31

2-4 PERIODIC MAINTENANCE
Periodic Maintenance Chart
FREQUENCY Whichever
comes
first

* ODOMETER READING
× 1 000 km(× 1 000 mile)
1

INSPECTION

Every

6

•

•
Brake hose and pipe damage - inspect
year•
Brake hose and pipe installation conditionyear•- inspect
Brake operation (effectiveness, play, noyear•drag) - inspect
Brake fluid level - inspect
6 months •year

Brake pad wear - inspect #Brake light switch operation - inspect
Suspensions
Front forks/rear shock absorber operation(damping and smooth stroke) - inspect
Front forks/rear shock absorber oil leak inspect
Steering System

•
•
•
•
•
•
• •

year

Steering play - inspect

year

Steering stem bearings - lubricate

2 years

•

•
•
•
•
•
•
•

Spark plug condition - inspect
Lights and switches operation - inspect

year

Headlight aiming - inspect

year

Sidestand switch operation - inspect

year

Engine stop switch operation - inspect

year

OthersBolts and nuts tightness - inspect

24

30

36

year

•

•
•
•
•
•
•
•
•

•
•
•
•
•
•
•

•
•
•
•
•
•
•

•

2-31

•
•
•
•
•
•
•

2-32
2-32
2-32
2-33
2-33
2-34
2-34

•
•

•
•

•
•

2-35

•

•
•

•

2-36

•
•
•
•
•

•
•
•
•
•

•
•
•
•
•

2-37

•
•

•
•

•
•

2-43

Electrical System

Chassis parts - lubricate

18(0.6) (4) (7.5) (12) (15) (20) (24)Drive chain guide wear - inspect
Brake System
Brake fluid leak (brake hose and pipe) inspect

12

See
Page

2-35

2-37

2-38
2-40
2-41
2-42

2-44

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or
frequent starting/stopping.
*: For higher odometer readings, repeat at the frequency interval established here.

PERIODIC MAINTENANCE 2-5
Periodic Maintenance Chart
Periodic Replacement Parts
FREQUENCY Whichever
comes
first

* ODOMETER READING
× 1 000 km(× 1 000 mile)
1

CHANGE/REPLACE ITEM
Air cleaner element #Every
2 years

Fuel hose

4 years

Coolant

3 years

Radiator hose and O-ring

3 years

Engine oil #year

Oil filter

year

Brake hose and pipe

4 years

Brake fluid

2 years

Rubber parts of master cylinder and caliper

4 years

Spark plug

12

24

36

48

(0.6) (7.5) (15)

(24)

(30)

See
Page

2-45

•
•

•
•

•
•

•
•
•
•

•
•

•

•

•

2-45
2-46
2-48

•
•
•
•
•
•

2-49
2-49
2-50
2-51
2-52,
2-54
2-56

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or
frequent starting/stopping.
*: For higher odometer readings, repeat at the frequency interval established here.

2-6 PERIODIC MAINTENANCE
Torque and Locking Agent
The following tables list the tightening torque for the major fasteners requiring use of anon-permanent locking agent or silicone sealant etc.
Letters used in the “Remarks” column mean:
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
EO: Apply engine oil.
L: Apply a non-permanent locking agent to the threads.
Lh: Left-hand threads
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)
R: Replacement Parts
S: Follow the specified tightening sequence.
Si: Apply silicone grease (ex. PBC grease).
SS: Apply silicone sealant.
Fastener
Fuel System (DFI)
Water Temperature Sensor
Speed Sensor Bolt
Fuel Pump Bolts
Oxygen Sensor (Europe Models)
Cooling System
Radiator Hose Clamp Screws
Water Pump Impeller Bolt
Water Pump Cover Bolts
Water Pump Drain Bolt
Thermostat Housing Bolts
Water Temperature Sensor
Baffle Plate Bolts
Engine Top End
Air Suction Valve Cover Bolts
Cylinder Head Cover Bolts
Camshaft Cap Bolts
Cylinder Head Bolts (M10 New Bolts)
Cylinder Head Bolts (M10 Used Bolts)
Cylinder Bolt (M8)
Cylinder Nut (M10)
Cylinder Head Bolts (M6)
Cylinder Bolts (M6)
Throttle Body Holder Bolts
Rear Camshaft Chain Guide Bolt
Camshaft Chain Tensioner Mounting Bolts
Camshaft Chain Tensioner Cap Bolt
Camshaft Sprocket Bolts
Spark Plugs
Exhaust Pipe Manifold Holder Nuts
Muffler Body Mounting Bolt (Front)

N·m

Torque
kgf·m

ft·lb

12
7.8
9.8
44.1

1.2
0.80
1.0
4.50

106 in·lb
69 in·lb
87 in·lb
32.5

2.0
9.8
9.8
7.0
9.8
12
5.9

0.20
1.0
1.0
0.70
1.0
1.2
0.60

17 in·lb
87 in·lb
87 in·lb
62 in·lb
87 in·lb
106 in·lb
52 in·lb

9.8
9.8
12
54
49
27.5
49
12
12
12
20
9.8
20
15
15
17
20

1.0
1.0
1.2
5.5
5.0
2.8
5.0
1.2
1.2
1.2
2.0
1.0
2.0
1.5
1.5
1.7
2.0

87 in·lb
87 in·lb
106 in·lb
40
36
20
36
106 in·lb
106 in·lb
106 in·lb
15
87 in·lb
15
11
11
12
15

Remarks

L
L, S

S
MO, S
MO, S
MO, S
MO, S
S
S
L

L

PERIODIC MAINTENANCE 2-7
Torque and Locking Agent
Fastener
Muffler Body Mounting Bolt (Rear)
Baffle Plate Bolts
ClutchUpper Cap on Clutch Cover
Lower Cap on Clutch CoverOil Filler Plug
Clutch Cover Mounting Bolts
Clutch Spring Bolts
Clutch Hub Nut
Clutch Lever Clamp Bolts
Oil Pump Chain Guide Bolts
Clutch Cable Holder Bolts
Clutch Cable Clamp Bolt
Engine Lubrication
Engine Oil Drain Bolt
Filter Plate Bolts
Oil Filter
Holder Mounting Bolt
Oil Pan Bolts
Oil Pump Chain Guide Bolts
Oil Pipe Plate Bolt
Oil Pressure Relief ValveOil Pressure Switch
Oil Pump Cover Bolts
Lower Fairing Bracket Bolts
Oil Pump Sprocket Bolt
Oil Passage PlugOil Plate Bolts
Engine Removal/Installation
Rear Engine Mounting Nuts
Engine Mounting Bracket Bolts
Front Engine Mounting Bolts
Crankshaft/Transmission
Oil Plate Bolts
Breather Plate Bolts
Crankcase Bolts (M9, L = 113 mm)
Crankcase Bolts (M9, L = 83 mm)
Crankcase Bolts (M8, L = 73 mm)
Crankcase Bolts (M8, L = 60 mm)
Crankcase Bolts (M8, L = 110 mm)
Crankcase Bolts (M8, L = 50 mm)
Crankcase Bolts (M6)
Upper Crankcase Bolts

N·m
20
5.9

Torque
kgf·m
2.0
0.60

ft·lb
15
52 in·lb

3.9
–
–
9.8
9.8
132
7.8
12
9.8
9.8

0.40
–
–
1.0
1.0
13.5
0.80
1.2
1.0
1.0

35 in·lb––
87 in·lb
87 in·lb
98
69 in·lb
106 in·lb
87 in·lb
87 in·lb

30
9.8
17.2
25
12
12
9.8
15
15
9.8
12
12
20
9.8

3.0
1.0
1.75
2.5
1.2
1.2
1.0
1.5
1.5
1.0
1.2
1.2
2.0
1.0

22
87 in·lb
13
18
106 in·lb
106 in·lb
87 in·lb
11
11
87 in·lb
106 in·lb
106 in·lb
15
89 in·lb

44
25
44

4.5
2.5
4.5

32
18
32

S
S
S

9.8
9.8
44
44
35
35
27.5
27.5
19.6
27.5

1.0
1.0
4.5
4.5
3.6
3.6
2.8
2.8
2.0
2.8

87 in·lb
87 in·lb
32
32
26
26
20
20
15
20

L
L
MO, S
MO, S
MO, S
MO, S
S
S
S
S

Remarks

Hand-tighten
Hand-tighten

R
S
L
L

L
EO, R
L
L
L
L
SS
L
L
L, Lh
L
L

2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
Shift Drum Bearing Holder Screw
Connecting Rod Big End Nuts
Timing Rotor Bolt
Oil Pressure Switch
Oil Passage Plug
Gear Positioning Lever Bolt
Shift Shaft Return Spring pin
Shift Drum Cam Bolt
Neutral Switch
Transmission Case Bolts
Shift Rod Plate Bolt
Neutral Switch Holder Screw
Shift Shaft Cover Bolts
Shift Shaft Cover Screw
Wheels/Tires
Front Axle
Front Axle Clamp Bolt
Rear Axle Nut
Final Drive
Engine Sprocket Nut
Rear Axle Nut
Rear Sprocket Nuts
Speed Sensor Bolt
Speed Sensor Bracket Bolts
BrakesBleed Valve
Brake Hose Banjo Bolts
Brake Lever Pivot Bolt
Brake Lever Pivot Bolt Locknut
Brake Pedal Bolt
Brake Pipe Joint Nuts (EX650B Models)Front Brake Disc Mounting Bolts
Front Brake Light Switch Screw
Front Brake Reservoir Cap Screws
Front Caliper Mounting Bolts
Front Master Cylinder Clamp Bolts
Rear Brake Disc Mounting Bolts
Rear Caliper Mounting Bolts
Rear Master Cylinder Mounting Bolts
Rear Master Cylinder Push Rod Locknut
Suspension
Front Axle Clamp Bolt
Front Fork Bottom Allen Bolts

N·m
4.9
see Text
40
15
20
12
29
12
15
20
9.8
4.9
9.8
4.9

Torque
kgf·m
0.50
←
4.1
1.5
2.0
1.2
2.9
1.2
1.5
2.0
1.0
0.50
1.0
0.50

ft·lb
43 in·lb←
30
1115
106 in·lb
22
106 in·lb
11
15
87 in·lb
43 in·lb
87 in·lb
43 in·lb

108
34
108

11.0
3.5
11.0

80
25
80

125
108
59
7.8
9.8

12.7
11.0
6.0
0.80
1.0

92
80
44
69 in·lb
87 in·lb

7.8
25
1.0
5.9
8.8
18
27
1.0
1.0
34
8.8
27
25
25
18

0.80
2.5
0.10
0.60
0.90
1.8
2.8
0.10
0.10
3.5
0.90
2.8
2.5
2.5
1.8

69 in·lb
18
9 in·lb
52 in·lb
78 in·lb
13
20
9 in·lb
9 in·lb
25
78 in·lb
20
18
18
13

34
30

3.5
3.1

25
22

Remarks
L
MO
SS
L
L
L
L

L
L (2)
L

MO

L

Si

L

S
L

L

PERIODIC MAINTENANCE 2-9
Torque and Locking Agent
Fastener
Front Fork Clamp Bolts (Lower)
Front Fork Clamp Bolts (Upper)
Front Fork Top Plugs
Rear Shock Absorber Bolt
Rear Shock Absorber Nut
Swingarm Pivot Shaft Nut
Steering
Front Fork Clamp Bolts (Lower)
Front Fork Clamp Bolts (Upper)
Handlebar Holder Bolts
Left Switch Housing Screws
Right Switch Housing Screws
Steering Stem Head Bolt
Steering Stem Nut
Frame
Footpeg Stay Bolts
Front Fender Bolts
Front Fender Bracket Bolts
Front Turn Signal Light Mounting Screws
Grab Rail Mounting Bolts
Seat Lock Mounting Screws
Sidestand Bolt
Sidestand Switch Bolt
Electrical System
Alternator Cover Bolts
Alternator Lead Holding Plate Bolt
Alternator Rotor Bolt
Crankshaft Sensor Bolts
Engine Ground Cable Terminal Bolt
Front Brake Light Switch Screw
Front Turn Signal Light Mounting Screws
Left Switch Housing Screws
License Plate Light Cover Screws
License Plate Light Mounting Screws
Meter Screws
Neutral Switch
Oil Pressure Switch
Oxygen Sensor
Regulator/Rectifier Bolts
Right Switch Housing Screws
Sidestand Switch Bolt
Spark Plugs
Speed Sensor Bolt

N·m
20
20
25
59
59
108

Torque
kgf·m
2.0
2.0
2.5
6.0
6.0
11.0

ft·lb
15
15
18
44
44
80

20
20
25
3.5
3.5
108
20

2.0
2.0
2.5
0.36
0.36
11.0
2.0

15
15
18
31 in·lb
31 in·lb
80
15

34
3.9
8.8
1.2
25
1.2
44
8.8

3.5
0.40
0.90
0.12
2.5
0.12
4.5
0.90

25
35 in·lb
78 in·lb
11 in·lb
18
11 in·lb
32
78 in·lb

9.8
9.8
155
6.0
9.8
1.2
1.2
3.5
0.90
1.2
1.2
15
15
44.1
8.8
3.5
8.8
15
7.8

1.0
1.0
15.8
0.60
1.0
0.12
0.12
0.36
0.090
0.12
0.12
1.5
1.5
4.50
0.90
0.36
0.90
1.5
0.80

87 in·lb
87 in·lb
114
53 in·lb
87 in·lb
11 in·lb
11 in·lb
31 in·lb
8 in·lb
11 in·lb
11 in·lb
1111
32.5
78 in·lb
31 in·lb
78 in·lb
11
69 in·lb

Remarks
AL

AL
S

L

L

L
MO

SS

L
L

2-10 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
Starter Motor Cable Terminal Nut
Starter Motor Clutch Bolts
Starter Motor Mounting Bolts
Starter Motor Terminal Locknut
Starter Motor Through Bolts
Stator Coil Bolts
Timing Rotor Bolt
Water Temperature Sensor

N·m
6.0
34
9.8
11
4.9
12
40
12

Torque
kgf·m
0.60
3.5
1.0
1.1
0.50
1.2
4.1
1.2

ft·lb
53 in·lb
25
87 in·lb
97 in·lb
43 in·lb
106 in·lb
30
106 in·lb

Remarks

L
L

L

The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts andnuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of thevalues are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners
Threads Diameter
(mm)
5
6
8
10
12
14
16
18
20

N·m
3.4 ∼ 4.9
5.9 ∼ 7.8
14 ∼ 1925 ∼ 3444 ∼ 6173 ∼ 98
115 ∼ 155
165 ∼ 225
225 ∼ 325

Torquekgf·m
0.35 ∼ 0.50
0.60 ∼ 0.80
1.4 ∼ 1.9
2.6 ∼ 3.5
4.5 ∼ 6.2
7.4 ∼ 10.0
11.5 ∼ 16.0
17.0 ∼ 23.0
23.0 ∼ 33.0

ft·lb
30 ∼ 43 in·lb
52 ∼ 69 in·lb
10.0 ∼ 13.5
19.0 ∼ 25
33 ∼ 4554 ∼ 72
83 ∼ 115
125 ∼ 165
165 ∼ 240

PERIODIC MAINTENANCE 2-11
Specifications
Item
Standard
Fuel System (DFI)
Throttle Grip Free Play2 ∼ 3 mm (0.08 ∼ 0.12 in.)
Idle Speed
1 300 ±50 r/min (rpm)Bypass Screws (Turn Out) 0 ∼ 2 1/2 (for reference)
Engine Vacuum
35.3 ±1.3 kPa (265 ±10 mmHg)
Air Cleaner Element
Polyurethane Foam
Cooling System
Coolant:
Type (recommended)
Permanent type of antifreeze
Color
Green
Mixed Ratio
Soft water 50%, Coolant 50%
Freezing Point–35°C (–31°F)
Total Amount
1.2 L (1.3 US qt)
Engine Top End
Valve Clearance:
Exhaust0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.)Inlet
0.15 ∼ 0.21 mm (0.0059 ∼ 0.0083 in.)
ClutchClutch Lever Free Play2 ∼ 3 mm (0.08 ∼ 0.12 in.)Engine Lubrication System
Engine Oil:Type
API SE, SF or SG
API SH, SJ or SL with JASO MA
Viscosity
SAE 10W-40
Capacity
1.7 L (1.8 US qt) (when filter is notremoved)1.9 L (2.0 US qt) (when filter is removed)
2.4 L (2.5 US qt) (when engine iscompletely dry)
Level
Between upper and lower level lines(after idling or running)
Wheels/Tires
Tread Depth:
Front
4.3 mm (0.17 in.)

Rear

Air Pressure (when Cold):
Front
Rear

7.0 mm (0.28 in.)

Up to 180 kg (397 lb) load:
225 kPa (2.25 kgf/cm², 32 psi)
Up to 180 kg (397 lb) load:
250 kPa (2.50 kgf/cm², 36 psi)

Service Limit
– – –
– – –
– – –
– – –
– – –

– – –
– – –
– – –
– – –
– – –

– – –
– – –
– – –

– – –
– – –
– – –
– – –
– – –
– – –

1 mm (0.04 in.),(AT, CH, DE)
1.6 mm (0.06 in.)
Up to 130 km/h (80 mph):
2 mm (0.08 in.),Over 130 km/h (80 mph):
3 mm (0.12 in.)
– – –
– – –

2-12 PERIODIC MAINTENANCE
Specifications
Item
Final Drive
Drive Chain Slack
Drive Chain Wear (20-link
Length)Standard Chain:
Make
Type
Link
BrakesBrake Fluid:
Grade
Brake Pad Lining
Thickness:
Front
Rear
Brake Light Timing:
Front
Rear
Electrical System
Spark Plug Gap

Standard

Service Limit

30 ∼ 40 mm (1.2 ∼ 1.6 in.)
317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)– – –323 mm (12.7 in.)

ENUMA
EK520MVXL1
114 links

– – –
– – –
– – –

DOT4

– – –

4.5 mm (0.18 in.)
5.0 mm (0.20 in.)

1 mm (0.04 in.)
1 mm (0.04 in.)

Pulled ON
ON after about 10 mm (0.39 in.) of
pedal travel– – –0.8 ∼ 0.9 mm (0.03 ∼ 0.04 in.)

– – –

– – –

PERIODIC MAINTENANCE 2-13
Special Tools
Inside Circlip Pliers:
57001-143

Extension Tube:
57001-1578

Steering Stem Nut Wrench:
57001-1100

Pilot Screw Adjuster, E:
57001-1603

Oil Filter Wrench:
57001-1249

2-14 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Fuel System (DFI)
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 dust is allowed to pass through into thethrottle assy, the throttle may become stuck, possibly causing accident.

CAUTION
If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.

• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System(DFI) chapter)
Air Switching Valve Hose [A] (Disconnect)
Air Cleaner Element Screw [B]
Air Cleaner Element [C]• Remove:
Upper Plastic Holder [A]Element [B]

NOTE○The wire screen [A] is fastened with an adhesive for the
shaded portion [B]. Do not remove the wire screen.

PERIODIC MAINTENANCE 2-15
Periodic Maintenance Procedures
WARNING
Clean the element in a well-ventilated area, andmake sure that there are no sparks or flame anywhere near the working area.
Because of the danger of highly flammable liquids,
do not use gasoline or a low-flash point solvent toclean the element.
the element [A] in a bath of high-flash point solvent,• Cleanand then dry it with compressed air or by shaking it.
cleaning, saturate a clean, lint-free towel with SE,• AfterSF, or SG class SAE 30 oil and apply the oil to the element••by tapping the element outside with the towel.
Visually check the element for tears or breaks.
If the element has any tears or breaks, replace the element.

the element unit [A] with the foam element side
• Install(gray) [B] facing down.

Throttle Control System Inspectionthat the throttle grip moves smoothly from full open
• Check
to close [A], and the throttle closes quickly and completelyby the return spring in all steering positions.
If the throttle grip doesn’t return properly, check the throttle cable routing, grip free play, and cable damage. Thenlubricate the throttle cable.

the throttle grip free play [A].
• Check
If the free play is incorrect, adjust the throttle cable.
Throttle Grip Free Play
Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

2-16 PERIODIC MAINTENANCE
Periodic Maintenance Procedures••

If necessary, adjust the throttle cable as follows.
Loosen the locknut [A] at the upper end of the accelerator
cable.
Turn the adjuster [B] in completely so as to give the throttle
grip plenty of play.

the right center fairing (see Center Fairing Re• Remove
moval in the Frame chapter).
the locknut [A] at the middle of the decelerator• Loosencable.
the adjuster [B] until there is no play when the throttle• Turngrip is completely closed.
the locknut.
• TightenTurnthecable adjuster until the proper• amount of accelerator
throttle grip free play is obtained.
Tightenthelocknut.
•

Engine Vacuum Synchronization Inspection
NOTE○These procedures are explained on the assumption thatthe inlet and exhaust systems of the engine are in goodcondition.

the motorcycle so that it is vertical.
• Situate
the center fairings (see Center Fairing Removal• Removein the Frame chapter).
off the rubber caps [A] from the fitting of each throttle• Pullbody (In the photo, the throttle body has been removed
for clarity.).

CAUTION
Do not remove the inlet air pressure sensor hose[B] on the left fitting of the throttle body.
a commercially available vacuum gauge and• Connect
hoses [A] to the fittings of the throttle body as shown.
a highly accurate tachometer to one of the stick• Connect
coil primary leads.

PERIODIC MAINTENANCE 2-17
Periodic Maintenance Procedures
the engine and warm it up thoroughly.
• StartCheck
the idle speed.
• Tachometer[A]and close the throttle.
• OpenIf the idle speed is out of the specified range, adjust it.

CAUTION
Do not measure the idle speed by the tachometer ofthe meter unit.
idling the engine, inspect the engine vacuum, using• Whilethe vacuum gauge [B].
Engine Vacuum
Standard: 35.3 ±1.3 kPa (265 ±10 mmHg) at Idle
Speed 1 300 ±50 r/min (rpm)

If any one vacuum is not within the specification, turn inthe bypass screws until it seats fully but not tightly.
Special Tool - Pilot Screw Adjuster, E [A]: 57001-1603

CAUTION
Do not over tighten them. They could be damaged,
requiring replacement.

out the bypass screw of the higher vacuum between• Turn#1 [A] and #2 [B] to the lower vacuum.
and close the throttle valves after each measure• Openment and adjust the idle speed as necessary.
the vacuums as before.
• Inspect
If both vacuums are within the specification, finish the engine vacuum synchronization.
If any vacuum can not be adjusted within the specification,
remove the bypass screws #1, #2 and clean them.
the bypass screw [A], spring [B], washer [C] and• Remove
O-ring [D].

○Check the bypass screw and its hole for carbon deposits.

If any carbon accumulates, wipe the carbon off the bypass
screw and the hole, using a cotton pad penetrated with ahigh-flash point solvent.
○Replace the O-ring with a new one.
○Check the tapered portion [E] of the bypass screw for
wear or damage.
If the bypass screw is worn or damaged, replace it.
Turn in the bypass screw until it seats fully but not tightly.

•

2-18 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the same procedure for other bypass screws.
• Repeat
Repeatthe synchronization.
• If the vacuums
are correct, check the output voltage ofthe main throttle sensor (see Main Throttle Sensor Output
Voltage Inspection in the Fuel System (DFI) chapter).
Main Throttle Sensor Output Voltage
Connections to ECUMeter (+) → Y/W lead (terminal 7)
Meter (–) → BR/BK lead (terminal 28)
Standard:
1.055 ∼ 1.095 V DC (at idle throttle opening)•

If the output voltage is out of the range, check the throttle input voltage (see Main Throttle Sensor Input Voltage
Inspection in the Fuel System (DFI) chapter).
Remove the vacuum gauge hoses and install the vacuum
hoses and rubber caps.

Idle Speed Inspection

the engine and warm it up thoroughly.
• StartWiththe• [A]. engine idling, turn the handlebar to both sides
If handlebar movement changes the idle speed, thethrottle cables may be improperly adjusted or incorrectly
routed or damaged. Be sure to correct any of these
conditions before riding (see Throttle Control System
Inspection or Cable, Wire, and Hose Routing section in
the Appendix chapter).

WARNING
Operation with improperly adjusted, incorrectly
routed or damaged cables could result in an unsafe
riding condition.
idle speed.
• Check
If the idle speed is out of the specified range, adjust it.
Idle Speed
Standard:

1 300 ±50 r/min (rpm)Idle Speed Adjustment

the engine and warm it up thoroughly.
• StartTurnthescrew [A] until the idle speed is correct.
•○Open andadjustingclose the throttle a few times to make sure thatthe idle speed is within the specified range. Readjust if
necessary.

PERIODIC MAINTENANCE 2-19
Periodic Maintenance Procedures
Fuel Hose Inspection (fuel leak, damage,installation condition)○The fuel hose is designed to be used throughout the mo-torcycle’s life without any maintenance. However, if the
motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose toburst. Remove the fuel tank (see Fuel Tank Removal in
the Fuel System (DFI) chapter) and check the fuel hose.
Replace the fuel hose if any fraying, cracks [B] or bulges[C] are noticed.

that the hoses are routed according to Cable, Wire,• Checkand Hose Routing section in the Appendix chapter.
Replace the hose if it has been sharply bent or kinked.
Hose Joints [A]Fuel Hose [B]that the hose joints are securely connected.
•○Check
Push and pull [A] the hose joint [B] back and forth morethan two times, and make sure it is locked.
If it does not locked, reinstall the hose joint.

WARNING
Make sure the hose joint is installed correctly on thedelivery pipe by sliding the joint, or the fuel could
leak.

Evaporative Emission Control System (California Model)
Evaporative Emission Control System Inspection
the canister as follows.
•○Inspect
Remove:Left Center Fairing (see Center Fairing Removal in the
Frame chapter)○Remove the canister [A], and disconnect the hoses fromthe canister.
○Visually inspect the canister for cracks or other damage.
If the canister has any cracks or bad damage, replace itwith a new one.

NOTE

○The canister is designed to work well through the motor-

cycle’s life without any maintenance if it is used undernormal conditions.

2-20 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the liquid/vapor separator as follows.
•○Check
Remove:Left Center Fairing (see Center Fairing Removal in the
Frame chapter)○Disconnect the hoses from the separator, and remove theseparator [A] from the motorcycle left side.
○Visually inspect the separator for cracks and other damage.
If the separator has any cracks or damage, replace it witha new one.
○To prevent the gasoline from flowing into or out of thecanister, hold the separator perpendicular to the ground.
Check the hoses of the evaporative emission control system as follows.
○Check that the hoses are securely connected and clips
are in position.
○Replace any kinked, deteriorated or damaged hoses.
○Route the hoses according to Cable, Wire, and Hose
Routing section in the Appendix chapter.
○When installing the hoses, avoid sharp bending, kinking,flattening or twisting, and route the hoses with a minimumof bending so that the emission flow will not be obstructed.

•

Cooling System
Coolant Level Inspection
NOTE○Check the level when the engine is cold (room or ambient temperature).

the coolant level in the reserve tank [A] with the• Check
motorcycle held perpendicular (Do not use the sidestand).
If the coolant level is lower than the “L” level line [B], remove the right center fairing (see Center Fairing Removal
in the Frame chapter) and unscrew the reserve tank cap,
and add coolant to the “F” level line [C].
“L”: low“F”: full

CAUTIONFor refilling, add the specified mixture of coolant
and soft water. Adding water alone dilutes thecoolant and degrades its anticorrosion properties.
The diluted coolant can attack the aluminum engine parts. In an emergency, soft water alone canbe added. But the diluted coolant must be returnedto the correct mixture ratio within a few days.
If coolant must be added often or the reservoir tankhas run completely dry, there is probably leakage inthe cooling system. Check the system for leaks.
Coolant ruins painted surfaces. Immediately wash
away any coolant that spills on the frame, engine,
wheels or other painted parts.

PERIODIC MAINTENANCE 2-21
Periodic Maintenance Procedures
Radiator Hose Damage and Installation Condition
Inspection○The high pressure inside the radiator hose and pipe can••cause coolant to leak [A] or the hose to burst if the line is
not properly maintained.
Visually inspect the hoses for signs of deterioration.
Squeeze the hoses. A hose should not be hard andbrittle, nor should it be soft or swollen.
Replace the hose if any fraying, cracks [B] or bulges [C]
are noticed.
Check that the hoses are securely connected and clamps
are tightened correctly.
Torque - Radiator Hose Clamp Screws: 2.0 N·m (0.20 kgf·m,
17 in·lb)

Air Suction System
Air Suction System Damage Inspection

the fuel tank (see Fuel Tank Removal in the Fuel
• Remove
System (DFI) chapter).
the fuel hose (see Fuel Hose Replacement).
• Remove• Connect:
Fuel Pump Lead Connector [A]Extension Tube [B]Special Tool - Extension Tube: 57001-1578

the air switching valve hose [C] out of the air cleaner• Pullhousing.
the engine and run it at idle speed.
• StartPlug[A]
air switching valve hose end with your finger• and feel thevacuum pulsing in the hose.
If there is no vacuum pulsation, check the hose line forleak. If there is no leak, check the air switching valve(see Air Switching Valve Unit Test in the Electrical System chapter) or air suction valve (see Air Suction Valve
Inspection in the Engine Top End chapter).

Engine Top End
Valve Clearance Inspection
NOTE○Valve clearance must be checked and adjusted whenthe engine is cold (room temperature).

• Remove:
Cylinder Head Cover (see Cylinder Head Cover Re•

moval in the Engine Top End chapter)
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Unscrew the upper [A] and lower [B] caps on the clutch
cover.

2-22 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the valve clearance when the pistons are at TDC.
•○Check
The pistons are numbered beginning with the engine left

•

side.
Using a wrench [A] on the crankshaft rotation bolt, turnthe crankshaft clockwise until the "1/T" mark on the timing
rotor is aligned with the notch [B] in the edge of the upper
hole in the clutch cover for #1 piston and "2/T" mark for#2 piston.

1/T Mark [A]
2/T Mark [B]Hole [C] of Upper Cap
Notch [D] in Edge of Upper Hole○Measure the valve clearance of the valves for which thecam [A] are turned away from each other.

the thickness gauge [A], measure the valve clear• Using
ance between cam and valve lifter.
Valve ClearanceStandard:
Exhaust 0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.)Inlet

0.15 ∼ 0.21 mm (0.0059 ∼ 0.0083 in.)○Each piston has two inlet and two exhaust valves. Measure these two inlet or exhaust valves at the same crankshaft position.
Valve Clearance Measuring Position#1 Piston TDC at End of Compression Stroke →Inlet valve clearances of #1 piston, andExhaust valve clearances of #1 piston

NOTE○Check the valve clearance using this method only.

Checking the clearance at any other cam position may
result in improper valve clearance.

PERIODIC MAINTENANCE 2-23
Periodic Maintenance Procedures
Valve Clearance Measuring Position#2 Piston TDC at End of Compression Stroke →Inlet valve clearances of #2 piston, andExhaust valve clearances of #2 piston

If the valve clearance is not with in the specified range,
first record the clearance, and adjust it.

Valve Clearance Adjustmentchange the valve clearance, remove the camshaft• To
chain tensioner, camshafts and valve lifters. Replace theshim with one of a different thickness.

NOTE○Mark and record the valve lifter and shim locations sothey can be reinstalled in their original positions.

○If there is no clearance, select a shim which is several
sizes smaller and then measure the clearance.

select a new shim which brings the valve clearance• To
within the specified range, refer to the Valve Clearance•••

Adjustment Charts.
Apply a thin coat of molybdenum disulfide grease to thevalve lifters.
Install the camshafts. Be sure to time the camshafts properly (see Camshaft Installation in the Engine Top End
chapter).
Remeasure any valve clearance that was adjusted.
Readjust if necessary.

CAUTION
Do not put shim stock under the shim. This may
cause the shim to pop out at high rpm, causing extensive engine damage.
Do not grind the shim. This may cause it to fracture,causing extensive engine damage.

2-24 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE

1. Measure the clearance (when engine is cold).
2. Check present shim size.
3. Match clearance in vertical column with present shim size in horizontal column.
4. Install the shim specified where the lines intersect. This shim will give the proper clearance.
Example:Present shim is 2.95 mm.
Measured clearance is 0.45 mm.
Replace 2.95 mm shim with 3.20 mm shim.

5. Remeasure the valve clearance and readjust if necessary.

PERIODIC MAINTENANCE 2-25
Periodic Maintenance Procedures
VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE

1. Measure the clearance (when engine is cold).
2. Check present shim size.
3. Match clearance in vertical column with present shim size in horizontal column.
4. Install the shim specified where the lines intersect. This shim will give the proper clearance.
Example:Present shim is 2.95 mm.
Measured clearance is 0.47 mm.
Replace 2.95 mm shim with 3.15 mm shim.

5. Remeasure the valve clearance and readjust if necessary.

2-26 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
ClutchClutch Operation Inspection

the clutch lever just enough to take up the free play
• Pull[A].
the gap between the lever and the lever holder.
• MeasureIf the gap is too wide, the clutch may not release fully. If
the gap is too narrow, the clutch may not engage fully. In
either case, adjust it.
Clutch Lever Free Play
Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)WARNINGTo avoid a serious burn, never touch the engine or
exhaust pipe during clutch adjustment.
the adjuster [A] so that 5 ∼ 6 mm (0.20 ∼ 0.24 in.) [B]• Turnof threads are visible.

the right center fairing (see Center Fairing Re• Remove
moval in the Frame chapter).
the dust cover [A] at the middle of the clutch cable• Slideout of place.
the locknut [B] at the middle of clutch cable.
• Loosen• Turn the adjusting nut [C] until the free play is correct.

WARNINGBe sure that the outer cable end at the clutch leveris fully seated in the adjuster at the clutch lever, or
it could slip into place later, creating enough cableplay to prevent clutch disengagement.
the adjustment, tighten the locknut and start the en• After
gine and check that the clutch does not slip and that it
releases properly.

Wheels/Tires
Air Pressure Inspection

the air valve cap.
• Remove
the tire air pressure with an air pressure gauge• Measure[A] when the tires are cold (that is, when the motorcycle•

has not been ridden more than a mile during the past 3
hours).
Install the air valve cap.
Adjust the tire air pressure according to the specifications
if necessary.

Air Pressure (when Cold)
Front:Up to 180 kg (397 lb)
225 kPa (2.25 kgf/cm², 32 psi)Rear:

Up to 180 kg (397 lb)
250 kPa (2.50 kgf/cm², 36 psi)

PERIODIC MAINTENANCE 2-27
Periodic Maintenance Procedures
Wheel/Tire Damage Inspection

any imbedded stones [A] or other foreign parti• Removecles [B] from tread.
inspect the tire for cracks and cuts, and replace• Visually
the tire if necessary. Swelling or high spots indicate inter-•

nal damage, requiring tire replacement.
Visually inspect the wheel for cracks, cuts and dents damage.
If any damage is found, replace the wheel if necessary.

Tire Tread Wear, Abnormal Wear Inspection
As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate isthat 90% of all tire failures occur during the last 10% of tread
life (90% worn). So it is false economy and unsafe to use
the tires until they are bald.
Measure the tread depth at the center of the tread with adepth gauge [A]. Since the tire may wear unevenly, takemeasurement at several places.
If any measurement is less than the service limit, replace
the tire (see Tire Removal/Installation in the Wheels/Tires
chapter).

•

Tread DepthStandard:
Front

4.3 mm (0.17 in.)Rear

7.0 mm (0.28 in.)Service Limit:
Front

1 mm (0.04 in.)
(AT, CH, DE) 1.6 mm (0.06 in.)Rear

2 mm (0.08 in.)
(Up to 130 km/h (80 mph))
3 mm (0.12 in.)(Over 130 km/h (80 mph))WARNINGTo ensure safe handling and stability, use only therecommended standard tires for replacement, inflated to the standard pressure.

NOTE○Most countries may have their own regulations a mini-

mum tire tread depth: be sure to follow them.
○Check and balance the wheel when a tire is replacedwith a new one.

2-28 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Wheel Bearing Damage Inspection

the front wheel off the ground with jack (see Front• RaiseWheel Removal in the Wheels/Tires chapter).
the handlebar all the way to the right or left.
• TurnInspectroughness of the front wheel bearing by push• ing and thepulling [A] the wheel.
[B] the front wheel lightly, and check for smoothly• Spinturn, roughness, binding or noise.
If roughness, binding or noise is found, remove the front
wheel and inspect the wheel bearing (see Front Wheel
Removal, Hub Bearing Inspection in the Wheels/Tires
chapter).
the rear wheel off the ground with stand (see Rear
• RaiseWheel Removal in the Wheels/Tires chapter).
the roughness of the rear wheel bearing by push• Inspect
ing and pulling [A] the wheel.
[B] the rear wheel lightly, and check for smoothly• Spinturn, roughness, binding or noise.
If roughness, binding or noise is found, remove the rear
wheel and inspect the wheel bearing (see Rear Wheel Removal, Hub Bearing Inspection in the Wheels/Tires chapter) and coupling (see Coupling Bearing Inspection in the
Final Drive chapter).

Drive Train
Drive Chain Lubrication Condition Inspectiona special lubricant is not available, a heavy oil such as• IfSAE
90 is preferred to a lighter oil because it will stay on•

the chain longer and provide better lubrication.
If the chain appears especially dirty, clean it before lubrication.

CAUTIONThe O-rings between the side plates seal in the lubricant between the pin and the bushing. To avoid
damaging the O-rings and resultant loss of lubricant, observe the following rules.
Use only kerosene or diesel oil for cleaning an O
-ring drive chain. Any other cleaning solution suchas gasoline or trichloroethylene will cause deterioration and swelling of the O-ring. Immediately blow
the chain dry with compressed air after cleaning.
Complete cleaning and drying the chain within 10
minutes.

PERIODIC MAINTENANCE 2-29
Periodic Maintenance Procedures
oil to the sides of the rollers so that oil will penetrate• Apply
to the rollers and bushings. Apply the oil to the O-rings so•that the O-rings will be coated with oil.
Wipe off any excess oil.
Oil Applied Areas [A]O-rings [B]

Drive Chain Slack Inspection
NOTE○Check the slack with the motorcycle setting on its sidestand.

○Clean the chain if it is dirty, and lubricate it if it appears
dry.

the wheel alignment (see Wheel Alignment Inspec• Checktion).
the rear wheel to find the position where the chain• Rotate
is tightest.
the vertical movement (chain slack) [A] midway• Measure
between the sprockets.
If the chain slack exceeds the standard, adjust it.
Chain SlackStandard:

30 ∼ 40 mm (1.2 ∼ 1.6 in.)

Drive Chain Slack Adjustment

the cotter pin [A], and loosen the axle nut [B].
• Remove
Loosenthechain adjuster locknuts [C].
• If the chain bothis too loose, turn in the left and right chain•

adjuster nuts [D] evenly.
If the chain is too tight, turn out the left and right chain
adjuster nuts evenly, and kick the wheel forward.
Turn both chain adjuster nuts evenly until the drive chain
has the correct amount of slack. To keep the chain andwheel properly aligned, the value [E] on the left wheelalignment adjuster [F] should align with the same (left or
right) edge [G] of inspection window on the swingarm thatthe right wheel alignment adjuster value aligns with.

WARNING
Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.
both chain adjuster locknuts securely.
• Tighten
Tightenthe axle nut.
•

Torque - Rear Axle Nut: 108 N·m (11.0 kgf·m, 80 ft·lb)

the wheel, measure the chain slack again at the tight• Turnest position, and readjust if necessary.

2-30 PERIODIC MAINTENANCE
Periodic Maintenance Procedures• Insert a new cotter pin [A].

NOTE

○When inserting the cotter pin, if the slots in the nut do
not align with the cotter pin hole in the axle, tighten the
nut clockwise [B] up to next alignment.
○It should be within 30°.
○Loosen once and tighten again when the slot goes past
the nearest hole.

• Bend the cotter pin [A] over the nut [B].
WARNING

If the rear axle nut is not securely tightened or thecotter pin is not installed, an unsafe riding condition may result.

Wheel Alignment Inspectionthat the value [A] on the left wheel alignment ad• Checkjuster [B] aligns with the same (left or right) edge [C] of
inspection window on the swingarm that the right wheelalignment adjuster value aligns with.
If they do not, adjust the chain slack and align the wheelalignment (see Drive Chain Slack Adjustment).

NOTE○Wheel alignment can be also checked using thestraightedge or string method.

WARNING
Misalignment of the wheel will result in abnormal
wear, and may result in an unsafe riding condition.

PERIODIC MAINTENANCE 2-31
Periodic Maintenance Procedures
Drive Chain Wear Inspection• Remove:
Chain Cover (see Swingarm Removal in the Suspension•••

chapter)
Rotate the rear wheel to inspect the drive chain for damaged rollers, and loose pins and 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 (10 kg, 20 lb)
weight [A] on the chain.
Measure the length of 20 links [B] on the straight part [C] of
the chain from the pin center of the 1st pin to the pin centerof the 21st pin. Since the chain may wear unevenly, takemeasurements at several places.
If any measurements exceed the service limit, replace thechain. Also, replace the front and rear sprockets when thedrive chain is replaced.
Drive Chain 20-link Length
Standard:
317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)Service Limit:

323 mm (12.7 in.)WARNING
If the drive chain wear exceeds the service limit, replace the chain or an unsafe riding condition may
result. A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock therear wheel, severely damaging the motorcycle andcausing it to go out of control.
For safely, use only the standard chain. It is an endless type and should not be cut for installation.
Standard Chain
Make:
ENUMA
Type:

EK520MVXL1

Link:

114 links

Chain Guide Inspection• Remove:
Swingarm (see Swingarm Removal in the Suspension•

chapter)
Visually inspect the chain guide [A].
Replace the chain guide if it shows any signs of abnormal
wear or damage.

2-32 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Brake System
Brake Fluid Leak (Brake Hose and Pipe) Inspection
the brake lever or pedal and inspect the brake fluid• Applyleak from the brake hoses [A], fittings [B] and pipes [C].

If the brake fluid leaked from any position, inspect or replace the problem part.

Brake Hose and Pipe Damage and Installation
Condition Inspection

the brake hoses, fittings and pipes for deteriora• Inspecttion, cracks and signs of leakage.

○The high pressure inside the brake line can cause fluid toleak [A] or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while examiningit.
Replace the hose and pipe if any crack [B], bulge [C] orleakage is noticed.
Tighten any brake hose banjo bolts and brake pipe joint
nuts.
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
Brake Pipe Joint Nuts: 18 N·m (1.8 kgf·m, 13 ft·lb)(EX650B Models)

the brake hose routing.
• Inspect
If any brake hose routing is incorrect, route the brake hoseaccording to Cable, Wire, and Hose Routing section in the
Appendix chapter.

PERIODIC MAINTENANCE 2-33
Periodic Maintenance Procedures
Brake Operation Inspection

the operation of the front and rear brake by run• Inspectning the vehicle on the dry road.
If the brake operation is insufficiency, inspect the brakesystem.

WARNING
When inspecting by running the vehicle, note asurrounding traffic situation enough in the place ofsafety.

Brake Fluid Level Inspectionthat the brake fluid level in the front brake reservoir• Check[A] is above the lower level line [B].

NOTE

○Hold the reservoir horizontal by turning the handlebar
when checking brake fluid level.

If the fluid level is lower than the lower level line, fill thereservoir to the upper level line [C] in the reservoir.

the seat (see Seat Removal in the Frame chap• Remove
ter).
that the brake fluid level in the rear brake reservoir• Check[A] is above the lower level line [B].
If the fluid level is lower than the lower level line, fill thereservoir to the upper level line [C].

WARNING
Change the brake fluid in the brake line completely
if the brake fluid must be refilled but the type andbrand of the brake fluid that is already in the reservoir are unidentified. After changing the fluid, use
only the same type and brand of fluid thereafter.
Recommended Disc Brake Fluid
Grade:
DOT4

2-34 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the procedure below to install the rear brake fluid• Followreservoir cap correctly.

○First, tighten the rear brake fluid reservoir cap [B] clockwise [C] by hand until slight resistance is felt indicatingthat the cap is seated on the reservoir body, then tighten
the cap an additional 1/6 turn [D] while holding the brakefluid reservoir body [A].

Brake Pad Wear Inspection

the lining thickness [A] of the pads in each caliper.
• Check
If the lining thickness of either pad is less than the service
limit [B], replace both pads in the caliper as a set.
Pad Lining Thickness
Standard:
Front

4.5 mm (0.18 in.)Rear

5.0 mm (0.20 in.)Service Limit:

1 mm (0.04 in.)Brake Light Switch Operation Inspection

on the ignition switch.
• TurnThe
brake[A] should go on when the brake lever is• applied or lightafter the brake pedal is depressed about 10
mm (0.39 in.).

•••If it does not, adjust the brake light switch.
Disconnect the connector [A].
Turn the brake light switch to adjust the switch.
Connect the connector.

If it does not go on, inspect or replace the following items.
Battery (see Charging Condition Inspection in the Electrical System chapter)
Brake Light (see Tail/Brake Light Removal in the Electrical System chapter)
Main Fuse 30 A and Taillight Fuse 10 A (see Fuse Inspection in the Electrical System chapter)
Front Brake Light Switch [A] (see Switch Inspection in
the Electrical System chapter)
Rear Brake Light Switch (see Switch Inspection in theElectrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)PERIODIC MAINTENANCE 2-35
Periodic Maintenance Procedures
Suspensions
Front Forks/Rear Shock Absorber Operation
Inspection

the forks down and up [A] 4 or 5 times, and inspect• Pumpthe smooth stroke.
If the forks do not smoothly or noise is found, inspect thefork oil level or fork clamps (see Front Fork Oil Change in
the Suspension chapter).

the seat down and up [A] 4 or 5 times, and inspect• Pumpthe smooth stroke.
If the shock absorber does not smoothly stroke or noise
is found, inspect the oil leak (see Rear Shock Absorber
Oil Leak Inspection).

Front Fork Oil Leak Inspection

inspect the front forks [A] for oil leakage.
• VisuallyReplace or repair any defective parts, if necessary.

Rear Shock Absorber Oil Leak Inspection

inspect the shock absorber [A] for oil leakage.
• Visually
If the oil leakage is found on it, replace the shock absorberwith a new one.

2-36 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Steering System
Steering Play Inspection

the front wheel off the ground with jack (see Front• RaiseWheel Removal in the Wheels/Tires chapter).
the front wheel pointing straight ahead, alternately• Withtap each end of the handlebar. The front wheel should•

swing fully left and right from the force of gravity until thefork hits the stop.
If the wheel binds or catches before the stop, the steering
is too tight.
Feel for steering looseness by pushing and pulling theforks.
If you feel looseness, the steering is too loose.

NOTE○The cables and wiring will have some effect on the motion of the fork which must be taken into account.

○Be sure the wires and cables are properly routed.
○The bearings must be in good condition and properly
lubricated in order for any test to be valid.

Steering Play Adjustment• Remove:
Upper Inner Fairings (see Upper Inner Fairing Removal
in the Frame chapter)
Handlebar (see Handlebar Removal in the Steering
chapter)Upper Fork Clamp Bolts [A]Steering Stem Head Bolt Plug [B]Stem Head Bolt [C]Remove the steering stem head [D].

•the claws [A] of the claw washer straighten.
• BendRemove• [C]. the steering stem locknut [B] and claw washer• Adjust the steering.

Special Tool - Steering Stem Nut Wrench [A]: 57001-1100

If the steering is too tight, loosen the stem nut [B] a fractionof a turn.
If the steering is too loose, tighten the stem nut a fractionof a turn.

NOTE○Turn the stem nut 1/8 turn at time maximum.

PERIODIC MAINTENANCE 2-37
Periodic Maintenance Procedures
the claw washer [A] so that its bent side [B] faces• Install
upward, and engage the bent claws with the grooves of

•
•
•
•
•

stem locknut [C].
Hand tighten the stem locknut until it touches the claw
washer.
Tighten the stem locknut clockwise until the claws arealigned with the grooves (ranging from 2nd to 4th) of stemnut [D], and bend the 2 claws downward [E].
Install the steering stem head.
Install the washer, and tighten the stem head bolt.
Tighten:
Torque - Steering Stem Head Bolt: 108 N·m (11.0 kgf·m, 80
ft·lb)
Front Fork Clamp Bolts (Upper): 20 N·m (2.0kgf·m, 15 ft·lb)

the steering again.
• Check
If the steering is still too tight or too loose, repeat the ad-•justment.
Install the removed parts (see appropriate chapters).

Steering Stem Bearing Lubrication

the steering stem (see Stem, Stem Bearing Re• Remove
moval in the Steering chapter).
a high-flash point solvent, wash the upper and• Using
lower ball bearings in the cages, and wipe the upper and

•
•
•
•

lower outer races, which are press-fitted into the frame
head pipe, clean off grease and dirt.
Visually check the outer races and the ball bearings.
Replace the bearing assemblies if they show wear ordamage.
Pack the upper and lower ball bearings [A] in the cageswith grease, and apply a light coat of grease to the upperand lower outer races.
Install the steering stem (see Stem, Stem Bearing Installation in the Steering chapter).
Adjust the steering (see Steering Play Adjustment).

Electrical System
Spark Plug Condition Inspection

the spark plugs (see Spark Plug Replacement).
• Remove
Visuallyinspect
spark plugs.
• If the spark plugthecenterelectrode [A] and/or side elec-•

trode [B] are corroded or damaged, or if the insulator [C]is cracked, replace the plug.
If the spark plug is dirtied or the carbon is accumulated,
replace the spark plug.
Measure the gap [D] with a wire-type thickness gauge.
If the gap is incorrect, replace the spark plug.
Spark Plug Gap:

0.8 ∼ 0.9 mm (0.03 ∼ 0.04 in.)Spark Plug:

CR9EIA-9• Use the standard spark plug or its equivalent.

2-38 PERIODIC MAINTENANCE
Periodic Maintenance ProceduresLights and Switches Operation Inspection
First Step
Turn on the ignition switch.
The following lights should go on according to below table.

••

City Light [A]goes on

Taillight [B]goes onLicense Plate Light [C]goes onMeter Panel LCD [D]goes on

Neutral Indicator Light (LED) [E]goes onOil Pressure Warning Indicator Light (LED)[F]

goes onWater Temperature Warning Indicator
Light (LED) [G]goes onFI Indicator Light (LED) [H]goes on(about 2 seconds)

EX650B Models
ABS Indicator Light (LED) [I]goes onIf the light does not go on, inspect or replace the following
item.
Battery (see Charging Condition Inspection in the Electrical System chapter)
Applicable Bulb (see Wiring Diagram in the Electrical
System chapter)
Meter Unit for Meter Panel LCD (see Electronic Combination Meter Unit Inspection in the Electrical System
chapter)
Meter Unit for Neutral Indicator Light (LED) (see Electronic Combination Meter Unit Inspection in the Electrical System chapter)
Meter Unit for Oil Pressure Warning Indicator Light(LED) (see Electronic Combination Meter Unit Inspection in the Electrical System chapter)
Meter Unit for FI Indicator Light (LED) (see Electronic
Combination Meter Unit Inspection in the Electrical System chapter)
Meter Unit for Water Temperature Warning Indicator
Light (LED) (see Electronic Combination Meter Unit
Inspection in the Electrical System chapter)
Meter Unit for ABS Indicator Light (LED) (see ABS Indicator Light (LED) Inspection in the Brakes chapter)(EX650B Models)ECU (see ECU Power Supply Inspection in the Fuel System (DFI) chapter)
Main Fuse 30 A and Taillight Fuse 10 A (see Fuse Inspection in the Electrical System chapter)
Ignition Switch (see Switch Inspection in the Electrical
System chapter)
Neutral Switch (see Switch Inspection in the Electrical
System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)PERIODIC MAINTENANCE 2-39
Periodic Maintenance Procedures
off the ignition switch.
• TurnThe
alllights should go off.
• If the light
does not go off, replace the ignition switch.
Second Step
Turn the ignition switch to P (Park) position.
The city light, taillight and license plate light should go on.
If the light does not go on, inspect or replace the following
item.
Ignition Switch (see Switch Inspection in the Electrical
System chapter)••

Third Step
Turn on the turn signal switch [A] (left or right position).
The left or right turn signal lights [B] (front and rear) according to the switch position should flash.
The turn signal indicator light (LED) [C] in the meter unit
should flash.
If the each light does not flash, inspect or replace thefollowing item.
Turn Signal Light Bulb (see Turn Signal Light Bulb Replacement in the Electrical System chapter)
Meter Unit for Turn Signal Light Indicator Light (LED)(see Electronic Combination Meter Unit Inspection in theElectrical System chapter)
Turn Signal Relay Fuse 10 A (see Fuse Inspection in theElectrical System chapter)
Turn Signal Switch (see Switch Inspection in the Electrical System chapter)
Turn Signal Relay (see Turn Signal Relay Inspection in
the Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
Push the turn signal switch.
The turn signal lights and indicator light (LED) should go
off.
If the light does not go off, inspect or replace the following
item.
Turn Signal Switch (see Switch Inspection in the Electrical System chapter)
Turn Signal Relay (see Turn Signal Relay Inspection in
the Electrical System chapter)

•
•
•

•
•

2-40 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Fourth Step
Set the dimmer switch [A] to low beam position.
Start the engine.
The low beam headlight should go on.
If the low beam headlight does not go on, inspect or replace the following item.
Headlight Low Beam Bulb (see Headlight Bulb Replacement in the Electrical System chapter)
Headlight Fuse 10 A (see Fuse Inspection in the Electrical System chapter)
Dimmer Switch (see Switch Inspection in the Electrical
System chapter)
Headlight Relay in Relay Box (see Relay Circuit Inspection in the Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)•••the dimmer switch to high beam position.
• Set
The
• go on.low beam [A] and high beam [B] headlights shouldhigh beam indicator light (LED) [C] should go on.
• The
If the high beam headlight and/or high beam indicator light

•
•

•
•

(LED) does not go on, inspect or replace the following
item.
Headlight High Beam Bulb (see Headlight Bulb Replacement in the Electrical System chapter)
Dimmer Switch (see Switch Inspection in the Electrical
System chapter)
Turn off the engine stop switch.
The low beam and high beam headlights should stay going on.
If the headlights and high beam indicator light (LED) does
go off, inspect or replace the following item.
Headlight Relay in Relay Box (see Relay Circuit Inspection in the Electrical System chapter)
Turn off the ignition switch.
The headlights and high beam indicator light (LED) should
go off.

Headlight Aiming Inspection

the headlight beam for aiming.
• Inspect
If the headlight beam points to one side rather thanstraight ahead, adjust the horizontal beam.
Headlight Beam Horizontal Adjustment
Turn the horizontal adjuster [A] on the headlight with thescrewdriver in or out until the beam points straight ahead.
If the headlight beam points too low or high, adjust thevertical beam.

•

PERIODIC MAINTENANCE 2-41
Periodic Maintenance Procedures
Headlight Beam Vertical Adjustment
Turn the vertical adjuster [A] on the headlight with thescrewdriver in or out to adjust the headlight vertically.

•

NOTE

○ON high beam, the brightest points should be slightly
below horizontal with the motorcycle on its wheels andthe rider seated. Adjust the headlight to the proper angle according to local regulations.
○For US model, the proper angle is 0.4 degrees below
horizontal. This is 50 mm (2 in.) drop at 7.6 m (25ft) measured from the center of the headlight with the
motorcycle on its wheels and the rider seated.
50 mm (2 in.) [A]Center of Brightest Spot [B]
7.6 m (25 ft) [C]
Low Beam [D]Height of Headlight Center [E]High Beam [F]Sidestand Switch Operation Inspection

the sidestand switch [A] operation accordance to• Inspect
below table.
Sidestand Switch Operation
Sidestand

Gear
Position

ClutchLever

EngineStart

EngineRunUp

NeutralReleased

StartsContinuerunning

Up

NeutralPulled inStartsContinuerunningUp

In Gear

Released

Doesn’t
start

Stops

Up

In GearPulled inStartsContinuerunning

Down

NeutralReleased

StartsContinuerunning

Down

NeutralPulled inStartsContinuerunning

Down

In Gear

Released

Doesn’t
start

Stops

Down

In GearPulled in

Doesn’t
start

Stops

2-42 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
If the sidestand switch operation does not work, inspect
or replace the following item.
Battery (see Charging Condition Inspection in the Electrical System chapter)
Main Fuse 30 A (see Fuse Inspection in the Electrical
System chapter)
Ignition Fuse 10 A (see Fuse Inspection in the Electrical
System chapter)
Ignition Switch (see Switch Inspection in the Electrical
System chapter)
Sidestand Switch (see Switch Inspection in the Electrical
System chapter)
Engine Stop Switch (see Switch Inspection in the Electrical System chapter)
Starter Button (see Switch Inspection in the Electrical
System chapter)
Neutral Switch (see Switch Inspection in the Electrical
System chapter)
Starter Relay (see Starter Relay Inspection in the Electrical System chapter)
Relay Box (see Relay Circuit Inspection in the Electrical
System chapter)
Starter Circuit Relay (see Relay Circuit Inspection in theElectrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)If the all parts are good condition, replace the ECU (seeECU Removal/Installation in the Fuel System (DFI) chapter).

Engine Stop Switch Operation Inspection
First Step
Turn on the ignition switch.
Set the neutral position.
Turn the engine stop switch to stop position [A].
Push the starter button.
The engine does not start.
If the engine starts, inspect or replace the following item.
Engine Stop Switch (see Switch Inspection in the Electrical System chapter)

•
•
•
•
•

Second Step
Turn on the ignition switch.
Set the neutral position.
Turn the engine stop switch to run position [A].
Push the starter button and run the engine.
Turn the engine stop switch to stop position.
Immediately the engine should be stop.
If the engine does not stop, inspect or replace the following item.
Engine Stop Switch (see Switch Inspection in the Electrical System chapter)
If the engine stop switch is good condition, replace theECU (see ECU Removal/Installation in the Fuel System(DFI) chapter).

•
•
•
•
•
•

PERIODIC MAINTENANCE 2-43
Periodic Maintenance Procedures
OthersChassis Parts Lubrication

lubricating each part, clean off any rusty spots with
• Beforerust remover and wipe off any grease, oil, dirt, or grime.
• Lubricate the points listed below with indicated lubricant.

NOTE○Whenever the vehicle has been operated under
wet or rainy conditions, or especially after using ahigh-pressure water spray, perform the general lubrication.
Pivots: Lubricate with Grease.
Brake Lever
Brake Pedal
Clutch Lever
Rear Brake Joint Pin
Sidestand
Points: Lubricate with Grease.
Clutch Inner Cable Upper and Lower Ends [A]Throttle Inner Cable Upper and Lower Ends

Cables: Lubricate with Rust Inhibitor.
Clutch Cable
Throttle Cables
Lubricate the cables by seeping the oil between the cableand housing.
○The cable may be lubricated by using a commerciallyavailable pressure cable lubricator with an aerosol cablelubricant.

•the cable disconnected at both ends, the inner cable• Withshould move freely [A] within the cable housing.
If cable movement is not free after lubricating, if the cableis frayed [B], or if the cable housing is kinked [C], replace
the cable.

2-44 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Bolts, Nuts and Fasteners Tightness Inspection

the tightness of the bolts and nuts listed here. Also,• Check
check to see that each cotter pin is in place and in goodcondition.

NOTE○For the engine fasteners, check the tightness of themwhen the engine is cold (at room temperature).
If there are loose fasteners, retighten them to the specified torque following the specified tightening sequence.
Refer to the appropriate chapter for torque specifications.
If torque specifications are not in the appropriate chapter,see the Standard Torque Table. For each fastener, firstloosen it by 1/2 turn, then tighten it.
If cotter pins are damaged, replace them with new ones.
Bolt, Nut and Fastener to be checked
Engine:Clutch Lever Pivot Nut
Engine Mounting Bolts and Nuts
Exhaust Pipe Manifold Holder Nuts
Muffler Body Mounting Bolts
Wheels:Front Axle
Front Axle Clamp Bolt
Rear Axle Nut
Rear Axle Nut Cotter Pin
Brakes:Brake Lever Pivot Nut
Brake Pedal Bolt
Brake Rod Joint Cotter Pin
Caliper Mounting Bolts
Front Master Cylinder Clamp Bolts
Rear Master Cylinder Mounting Bolts
Suspension:
Front Fork Clamp Bolts
Rear Shock Absorber Bolt and Nut
Swingarm Pivot Shaft Nut
Steering:
Steering Stem Head Bolt
Handlebar Holder Bolts
Others:Footpeg Stay Bolts
Front Fender Bolts
Sidestand Bolt

PERIODIC MAINTENANCE 2-45
Periodic Maintenance Procedures
Replacement Parts
Air Cleaner Element Replacement• Refer to the Air Cleaner Element Cleaning.
Fuel Hose Replacement
CAUTION
When removing and installing the fuel hose joint, do
not apply strong force to the outlet pipe on the fuelpump and delivery pipe on the throttle body assy.
The pipes made from resin could be damaged.

• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System••(DFI) chapter)
Left Center Fairing (see Center Fairing Removal in the
Frame chapter)Be sure to place a piece of cloth [A] around the fuel hose
joint.
Insert a minus screw driver [B] into the slit [C] on the joint
lock.

[A] the driver to disconnect the joint lock [B].
• TurnPull[C]
the fuel hose joint [D] out of the delivery pipe.
•

WARNINGBe prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
When the fuel hose is disconnected, fuel spills out
from the hose and the pipe. Cover the hose connection with a clean shop towel to prevent fuel spillage.
the new fuel hose.
• Install
Insert[A]
fuel hose joint [B] straight onto the delivery• pipe until thethe hose joint clicks.
• Push [C] the joint lock [D].

and pull [A] the fuel hose joint [B] back and forth• Pushmore than two times and make sure it is locked anddoesn’t come off.

WARNING
Make sure the fuel hose joint is installed correctlyon the delivery pipe or the fuel could leak.

•••

If it comes off, reinstall the hose joint.
Run the fuel hose correctly (see Cable, Wire, and Hose
Routing section in the Appendix chapter).
Install the removed parts (see appropriate chapters).
Start the engine and check the fuel hose for leaks.

2-46 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Coolant Change

WARNINGTo avoid burns, do not remove the radiator cap or
try to change the coolant when the engine is still
hot. Wait until it cools down. Coolant on tires will
make them slippery and can cause an accident
and injury. Immediately wipe up or wash away any
coolant that spills on the frame, engine, or otherpainted parts.
Since coolant is harmful to the human body, do notuse for drinking.

• Remove:
Right Center Fairing (see Center Fairing Removal in the
Frame chapter)
Reserve Tank Bolts [A]Reserve Tank [B][A] the projection [B] on the reserve tank into the hole• Put
[C] on the frame bracket, and place the reserve tank on
the right side of frame.

a container under the water pump drain bolt [A],• Placethen remove the drain bolt.

PERIODIC MAINTENANCE 2-47
Periodic Maintenance Procedures
the radiator cap [A] in two steps. First turn the• Removecap counterclockwise to the first stop. Then push and turnit further in the same direction and remove the cap.
○The coolant will drain from the radiator and engine.

over [A] the reserve tank, remove the cap, and pour• Turnthe coolant into a suitable container.
the reserve tank on the right side of frame.
• PlaceTightendrain bolt with the gasket.
•○Replacethe
the drain bolt gasket with a new one.
Torque - Water Pump Drain Bolt: 7.0 N·m (0.70 kgf·m, 62
in·lb)

filling the coolant, choose a suitable mixture ratio• Whenby referring to the coolant manufacturer’s directions.

CAUTION
Soft or distilled water must be used with the antifreeze in the cooling system.
If hard water is used in the system, it causes scales
accumulation in the water passages, and considerably reduces the efficiency of the cooling system.
Water and Coolant Mixture Ratio (Recommended)
Soft Water:
50%
Coolant:

50%

Freezing Point:–35°C (–31°F)

Total Amount:

1.2 L (1.3 US qt)• Fill the radiator up to the filler neck [A] with coolant.
NOTE○Pour in the coolant slowly so that it can expel the airfrom the engine and radiator.

the cooling system for leaks.
• CheckTap
the• inside. radiator hoses to force any air bubbles caught• Fill the radiator up to the filler neck with coolant.

2-48 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
install the reserve tank to the frame with two• Temporarilybolts.
the reserve tank up to the “F” (full) level line [A] with
• Fillcoolant and install the cap [B].
the engine, warm it up thoroughly until the radiator• Startfan turns on and then stop the engine.
the coolant level in the reserve tank after the en• Checkgine cools down.
If the coolant level is lower than the “L” level line, add
coolant to the “F” level line.

CAUTION
Do not add more coolant above the “F” level line.

Radiator Hose and O-ring Replacement

the coolant (see Coolant Change).
• Drain• Remove:
Thermostat Housing [A] (see Water Pump Removal in

•
•
•
•

the Cooling System chapter)
Water Pump Cover [B] (see Water Pump Removal in the
Cooling System chapter)
Hoses [C]O-rings [D]Apply grease to the new O-rings and install them.
Install the new hoses and tighten the clamps securely.
Fill the coolant (see Coolant Change).
Check the cooling system for leaks.

PERIODIC MAINTENANCE 2-49
Periodic Maintenance Procedures
Engine Oil Change

the motorcycle so that it is vertical after warming• Situate
up the engine.
the oil filler plug [A].
• Unscrew
Placeon
oil pan beneath the engine.
•the engine oil drain bolt [A] to drain the oil.
•○Remove
The oil in the oil filter can be drained by removing the filter•(see Oil Filter Replacement).
Replace the drain bolt gasket [B] with a new one.
Tighten the drain bolt.

Torque - Engine Oil Drain Bolt: 30 N·m (3.0 kgf·m, 22 ft·lb)• Pour in the specified type and amount of oil.
Recommended Engine Oil
Type:
API SE, SF or SG

API SH, SJ or SL with JASO MA
Viscosity:

SAE 10W-40

Capacity:

1.7 L (1.8 US qt) (when filter is notremoved)1.9 L (2.0 US qt) (when filter is removed)
2.4 L (2.5 US qt) (when engine iscompletely dry)

NOTE

○Although 10W-40 engine oil is the recommended oilfor most conditions, the oil viscosity may need to bechanged to accommodate atmospheric conditions inyour riding area.

the oil level (see Oil Level Inspection in the Engine• Check
Lubrication System chapter).

Oil Filter Replacement

the engine oil (see Engine Oil Change).
• Drain
Removethe oil filter [A] with the oil filter wrench [B].
•Special Tool - Oil Filter Wrench: 57001-1249

2-50 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the filter with a new one.
• ReplaceApplyengineoil to the gasket [A] before installation.
• Tighten the filter
with the oil filter wrench.
•
Torque - Oil Filter: 17.2 N·m (1.75 kgf·m, 13 ft·lb)

NOTE○Hand tightening of the oil filter can not be allowed since
it does not reach to this tightening torque.

in the specified type and amount of oil (see Engine• PourOil Change).

Brake Hose and Pipe Replacement
CAUTION
Brake fluid quickly ruins painted plastic surfaces;
any spilled fluid should be completely washed away
immediately.
the banjo bolts [A].
• RemoveWhenremovingbrake hose, take care not to spill the• brake fluid on thethepainted
or plastic parts.
removing the brake hoses [B], temporarily secure• Whenthe end of the brake hose to some high place to keep fluid•

loss to a minimum.
Immediately wash away any brake fluid that spills.

PERIODIC MAINTENANCE 2-51
Periodic Maintenance Procedures• Remove:
Rear Fender Front (see Rear Fender Front Removal in

•
•
•
•

the Frame chapter) (EX650B Models)
Right Center Fairing (see Center Fairing Removal in the
Frame chapter) (EX650B Models)
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter) (EX650B Models)
Remove the brake pipe joint nuts [C] (EX650B Models).
Remove the bracket bolt [D] and bracket [E] (EX650B
Models).
There are washers on each side of the brake hose fitting.
Replace them with new ones when installing.
Tighten:
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
Brake Pipe Joint Nuts: 18 N·m (1.8 kgf·m, 13 ft·lb)(EX650B Models)installing the hoses, avoid sharp bending, kink• Whening, flatting or twisting, and route the hoses according to•Cable, Wire, and Hose Routing section in the Appendix
chapter.
Fill the brake line after installing the brake hose (seeBrake Fluid Change).

Brake Fluid Change
NOTE○The procedure to change the front brake fluid is as fol-lows. Changing the rear brake fluid is the same as forthe front brake.

the brake fluid reservoir.
• LevelRemovereservoir cap and diaphragm.
• Remove the• caliper. the rubber cap from the bleed valve [A] on thea clear plastic hose [B] to the bleed valve, and run• Attachthe other end of the hose into a container.
• Fill the reservoir with fresh specified brake fluid.

2-52 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the brake fluid.
•○Change
Repeat this operation until fresh brake fluid comes out
from the plastic hose or the color of the fluid changes.
1. Open the bleed valve [A].
2. Apply the brake and hold it [B].
3. Close the bleed valve [C].
4. Release the brake [D].

NOTE○The fluid level must be checked often during the chang-

ing operation and replenished with fresh brake fluid. If
the fluid in the reservoir runs out any time during thechanging operation, the brakes will need to be bledsince air will have entered the brake line.
○Front Brake: Repeat the above steps for the othercaliper.
the clear plastic hose.
• Removethe diaphragm and reservoir cap.
• Install
Tighten:•

Torque - Front Brake Reservoir Cap Screws: 1.0 N·m (0.10
kgf·m, 9 in·lb)

the procedure below to install the rear brake fluid• Followreservoir cap correctly.

○First, tighten the rear brake fluid reservoir cap [B] clockwise [C] by hand until slight resistance is felt indicatingthat the cap is seated on the reservoir body, then tighten
the cap an additional 1/6 turn [D] while holding the brakefluid reservoir body [A].

• Tighten the bleed valve, and install the rubber cap.
Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

changing the fluid, check the brake for good braking• After
power, no brake drag, and no fluid leakage.
If necessary, bleed the air from the lines.

Master Cylinder Rubber Parts Replacement
Front Master Cylinder Disassembly
Remove the front master cylinder (see Front Master Cylinder Removal in the Brakes chapter).
Remove the reservoir cap and diaphragm, and pour thebrake fluid into a container.
Unscrew the locknut and pivot bolt, and remove the brakelever.
Pull the dust cover [A] out of place, and remove the circlip
[B].

•
•
•
•

Special Tool - Inside Circlip Pliers: 57001-143

out the piston [C], secondary cup [D], primary cup [E],• Pulland return spring [F].

CAUTION
Do not remove the secondary cup from the piston
since removal will damage it.

PERIODIC MAINTENANCE 2-53
Periodic Maintenance Procedures
Rear Master Cylinder Disassembly

NOTE○Do not remove the push rod clevis for master cylinder

disassembly since removal reguires brake position adjustment.

the rear master cylinder (see Rear Master Cylin• Remove
der Removal in the Brakes chapter).
the dust cover on the push rod out of place, and• Slideremove the circlip.
Special Tool - Inside Circlip Pliers: 57001-143

out the push rod with the piston stop.
• PullTake
off the piston [A], secondary cup [B], primary cup [C]• and return
spring [D].

CAUTION
Do not remove the secondary cup from the piston
since removal will damage it.

Master Cylinder Assembly
Before assembly, clean all parts including the mastercylinder with brake fluid or alcohol.

•

CAUTION
Except for the disc pads and disc, use only discbrake fluid, isopropyl alcohol, or ethyl alcohol forcleaning brake parts. Do not use any other fluid forcleaning these parts. Gasoline, engine oil, or any
other petroleum distillate will cause deterioration of
the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the disc brake.
brake fluid to the new parts and to the inner wall of• Apply
the cylinder.
care not to scratch the piston or the inner wall of the• Takecylinder.
the brake lever pivot bolt and locknut.
• Tighten
silicone grease.
• Apply
Brake Lever Pivot Bolt
• Tighten:
Torque - Brake Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 9in·lb)
Brake Lever Pivot Bolt Locknut: 5.9 N·m (0.60
kgf·m, 52 in·lb)

2-54 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Caliper Rubber Parts Replacement
Front Caliper Disassembly
Remove:Front Caliper (see Front Caliper Removal in the Brakes
chapter)Brake Pads (see Front Brake Pad Removal in the Brakes
chapter)
Using compressed air, remove the pistons.
○Cover the piston area with a clean, thick cloth [A].
○Blow compressed air [B] into the hole for the banjo bolt toremove the piston.

••WARNINGTo 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 handor fingers.

○Pull out the pistons by hand.

the dust seals [A] and fluid seals [B].
• Remove• Remove the bleed valve [C] and rubber cap [D].

NOTE

○If compressed air is not available, with the brake hose
still attached, apply the brake lever to remove the piston. The remaining process is as described above.

Front Caliper Assembly
Clean the caliper parts except for the pads.

•

CAUTIONFor 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)

the fluid seals [A] with new ones.
•○Replace
Apply brake fluid to the fluid seals, and install them into

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.

•

PERIODIC MAINTENANCE 2-55
Periodic Maintenance Procedures
brake fluid to the outside of the pistons, and push
• Apply
them into each cylinder by hand.
the shaft rubber friction boot [A] and the dust cover• Check[B] replace them with new ones if they are damaged.
a thin coat of PBC (Poly Butyl Cuprysil) grease to• Apply
the caliper holder shafts [C] and holder holes [D] (PBC isa special high-temperature, water-resistance grease).

the anti-rattle spring [A].
• Install
Installpads (see Front Brake Pad Installation in the• Brakesthechapter).
up any spilled brake fluid on the caliper with wet• Wipecloth.

Rear Caliper Disassembly
Remove the rear caliper (see Rear Caliper Removal in
the Brakes chapter).
Remove the pads and anti-rattle spring (see Rear Brake
Pad Removal in the Brakes chapter).
Using compressed air, remove the piston.
○Cover the piston area with a clean, thick cloth [B].
○Blow compressed air [A] into the hole for the banjo bolt toremove the piston.

•••WARNINGTo avoid serious injury, never place your fingers or
palm inside the caliper opening. If you apply compressed air into the caliper, the piston may crush
your hand or fingers.
the dust seal and fluid seal.
• Remove
Removethebleed valve and rubber cap.
•

NOTE

○If compressed air is not available, with the brake hose
still attached, apply the brake pedal to remove the piston. The remaining process is as described above.

Rear Caliper Assembly
Clean the caliper parts except for the pads.

•

CAUTIONFor cleaning of 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)

2-56 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the fluid seal [A] with a new one.
•○Replace
Apply brake fluid to the fluid seal, and install it into thecylinder by hand.
Replace the dust seal [B] with a new one if it is damaged.
○Apply brake fluid to the dust seal, and install it into thecylinder by hand.

•brake fluid to the outside of the piston, and push it• Apply
into the cylinder by hand.
the shaft rubber friction boot [A] and dust cover• Replace[B] if they are damaged.
a thin coat of PBC (Poly Butyl Cuprysil) grease to• Apply
the caliper holder shafts [C] and holder holes [D] (PBC isa special high-temperature, water-resistance grease).

the anti-rattle spring [A] in the caliper as shown.
• Install
Installpads (see Rear Brake Pad Installation in the• Brakesthechapter).
up any spilled brake fluid on the caliper with wet• Wipecloth.

Spark Plug Replacement• Remove:
Stick Coils (see Stick Coil (Ignition Coil together with•

Spark Plug Cap) Removal in the Electrical System chapter)
Remove the spark plugs using the 16 mm plug wrench[A].
Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-1132

the spark plug vertically into the plug hole with the• Insert
spark plug installed in the plug wrench [A].
Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-1132• Tighten:

Torque - Spark Plugs: 15 N·m (1.5 kgf·m, 11 ft·lb)• Install:
Stick Coils (see Stick Coil (Ignition Coil together with
Spark Plug Cap) Installation in the Electrical System
chapter)FUEL SYSTEM (DFI) 3-1

Fuel System (DFI)
Table of Contents
Exploded View........................................................................................................................
DFI System.............................................................................................................................
DFI System.............................................................................................................................
DFI Parts Location..................................................................................................................
Specifications .........................................................................................................................
Special Tools and Sealant ......................................................................................................
DFI Servicing Precautions ......................................................................................................
DFI Servicing Precautions ................................................................................................
Troubleshooting the DFI System ............................................................................................
Outline .................................................................................................................................
Outline...............................................................................................................................
Inquiries to Rider..................................................................................................................
Inquiries to Rider...............................................................................................................
DFI System Troubleshooting Guide .......................................................................................
Self-Diagnosis ........................................................................................................................
Self-diagnosis Outline..........................................................................................................
Self-diagnosis Outline .......................................................................................................
Self-diagnosis Procedures...................................................................................................
Self-diagnosis Procedures ................................................................................................
Service Code Clearing Procedures .....................................................................................
Service Code Clearing Procedures...................................................................................
How to Read Service Codes................................................................................................
How to Read Service Codes.............................................................................................
How to Erase Service Codes...............................................................................................
How to Erase Service Codes ............................................................................................
Service Code Table..............................................................................................................
Service Code Table...........................................................................................................
Backups ...............................................................................................................................
Backups ............................................................................................................................
Main Throttle Sensor (Service Code 11) ................................................................................
Main Throttle Sensor Removal/Adjustment ......................................................................
Main Throttle Sensor Input Voltage Inspection .................................................................
Main Throttle Sensor Output Voltage Inspection ..............................................................
Main Throttle Sensor Resistance Inspection ....................................................................
Inlet Air Pressure Sensor (Service Code 12)..........................................................................
Inlet Air Pressure Sensor Removal...................................................................................
Inlet Air Pressure Sensor Installation................................................................................
Inlet Air Pressure Sensor Input Voltage Inspection...........................................................
Inlet Air Pressure Sensor Output Voltage Inspection........................................................
Inlet Air Temperature Sensor (Service Code 13)....................................................................
Inlet Air Temperature Sensor Removal/Installation...........................................................
Inlet Air Temperature Sensor Output Voltage Inspection ..................................................
Inlet Air Temperature Sensor Resistance Inspection ........................................................
Water Temperature Sensor (Service Code 14) ......................................................................
Water Temperature Sensor Removal/Installation .............................................................
Water Temperature Sensor Output Voltage Inspection.....................................................
Water Temperature Sensor Resistance Inspection...........................................................
Crankshaft Sensor (Service Code 21)....................................................................................
Crankshaft Sensor Removal/Installation...........................................................................
Crankshaft Sensor Inspection...........................................................................................

3-4
3-10
3-12
3-15
3-16
3-18
3-20
3-20
3-22
3-22
3-22
3-26
3-26
3-29
3-37
3-37
3-37
3-37
3-37
3-38
3-38
3-40
3-40
3-40
3-40
3-41
3-41
3-42
3-42
3-44
3-44
3-44
3-45
3-46
3-47
3-47
3-47
3-47
3-48
3-52
3-52
3-52
3-53
3-54
3-54
3-54
3-55
3-56
3-56
3-56

3

3-2 FUEL SYSTEM (DFI)
Speed Sensor (Service Code 24, 25).....................................................................................
Speed Sensor Removal/Installation..................................................................................
Speed Sensor Inspection..................................................................................................
Speed Sensor Input Voltage Inspection............................................................................
Speed Sensor Output Voltage Inspection .........................................................................
Vehicle-down Sensor (Service Code 31)................................................................................
Vehicle-down Sensor Removal .........................................................................................
Vehicle-down Sensor Installation ......................................................................................
Vehicle-down Sensor Inspection.......................................................................................
Subthrottle Sensor (Service Code 32)....................................................................................
Subthrottle Sensor Removal/Adjustment ..........................................................................
Subthrottle Sensor Input Voltage Inspection.....................................................................
Subthrottle Sensor Output Voltage Inspection ..................................................................
Subthrottle Sensor Resistance Inspection ........................................................................
Oxygen Sensor-not activated (Service Code 33) (Europe Models)........................................
Oxygen Sensor Removal/Installation................................................................................
Oxygen Sensor Inspection................................................................................................
Stick Coils #1, #2: (Service Code 51, 52) ..............................................................................
Stick Coil Removal/Installation..........................................................................................
Stick Coil Input Voltage Inspection....................................................................................
Radiator Fan Relay (Service Code 56)...................................................................................
Radiator Fan Relay Removal/Installation..........................................................................
Radiator Fan Relay Inspection..........................................................................................
Subthrottle Valve Actuator (Service Code 62) ........................................................................
Subthrottle Valve Actuator Removal .................................................................................
Subthrottle Valve Actuator Audible Inspection ..................................................................
Subthrottle Valve Actuator Inspection ...............................................................................
Subthrottle Valve Actuator Resistance Inspection ............................................................
Subthrottle Valve Actuator Input Voltage Inspection .........................................................
Air Switching Valve (Service Code 64) ...................................................................................
Air Switching Valve Removal/Installation ..........................................................................
Air Switching Valve Inspection ..........................................................................................
Oxygen Sensor Heater (Service Code 67) (Europe Models) .................................................
Oxygen Sensor Heater Removal/Installation ....................................................................
Oxygen Sensor Heater Inspection ...................................................................................
Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Europe Models) .....................
Oxygen Sensor Removal/Installation................................................................................
Oxygen Sensor Inspection................................................................................................
FI Indicator Light (LED) ..........................................................................................................
FI Indicator Light (LED) Inspection ...................................................................................
ECU ........................................................................................................................................
ECU Removal ...................................................................................................................
ECU Installation ................................................................................................................
ECU Power Supply Inspection..........................................................................................
Fuel Line.................................................................................................................................
Fuel Pressure Inspection ..................................................................................................
Fuel Flow Rate Inspection ................................................................................................
Fuel Pump ..............................................................................................................................
Fuel Pump Removal .........................................................................................................
Fuel Pump Installation ......................................................................................................
Fuel Pump Operation Inspection ......................................................................................
Fuel Pump Operating Voltage Inspection .........................................................................
Pressure Regulator Removal............................................................................................
Pump Screen, Fuel Filter Cleaning ...................................................................................
Fuel Injectors ..........................................................................................................................
Removal/Installation..........................................................................................................
Audible Inspection.............................................................................................................

3-57
3-57
3-57
3-57
3-57
3-59
3-59
3-59
3-59
3-62
3-62
3-62
3-63
3-64
3-66
3-66
3-66
3-68
3-68
3-68
3-70
3-70
3-70
3-71
3-71
3-71
3-71
3-71
3-72
3-73
3-73
3-73
3-74
3-74
3-74
3-76
3-76
3-76
3-78
3-79
3-80
3-80
3-80
3-81
3-83
3-83
3-85
3-87
3-87
3-87
3-88
3-88
3-89
3-89
3-91
3-91
3-91

FUEL SYSTEM (DFI) 3-3
Fuel Injector Power Source Voltage Inspection ................................................................
Fuel Injector Output Voltage Inspection ............................................................................
Injector Signal Test............................................................................................................
Injector Resistance Inspection ..........................................................................................
Injector Unit Test ...............................................................................................................
Injector Fuel Line Inspection .............................................................................................
Throttle Grip and Cables ........................................................................................................
Throttle Grip Free Play Inspection ....................................................................................
Throttle Grip Free Play Adjustment...................................................................................
Throttle Cable Installation .................................................................................................
Throttle Cable Lubrication.................................................................................................
Throttle Body Assy .................................................................................................................
Idle Speed Inspection .......................................................................................................
Engine Vacuum Synchronization Inspection/Adjustment..................................................
High Altitude Performance Adjustment .............................................................................
Throttle Body Assy Removal.............................................................................................
Throttle Body Assy Installation..........................................................................................
Throttle Body Assy Disassembly ......................................................................................
Throttle Body Assy Assembly ...........................................................................................
Air Cleaner..............................................................................................................................
Air Cleaner Element Removal/Installation ........................................................................
Air Cleaner Element Inspection ........................................................................................
Air Cleaner Oil Draining ....................................................................................................
Air Cleaner Housing Removal...........................................................................................
Air Cleaner Housing Installation........................................................................................
Fuel Tank ................................................................................................................................
Fuel Tank Removal ...........................................................................................................
Fuel Tank Installation ........................................................................................................
Fuel Tank and Cap Inspection ..........................................................................................
Fuel Tank Cleaning ...........................................................................................................
Evaporative Emission Control System (California Model) ......................................................
Parts Removal/Installation ................................................................................................
Hose Inspection ................................................................................................................
Separator Inspection.........................................................................................................
Separator Operation Test..................................................................................................
Canister Inspection ..........................................................................................................

3-91
3-92
3-92
3-93
3-94
3-94
3-96
3-96
3-96
3-96
3-96
3-97
3-97
3-97
3-97
3-97
3-98
3-99
3-100
3-101
3-101
3-101
3-101
3-101
3-102
3-103
3-103
3-105
3-106
3-107
3-108
3-108
3-108
3-108
3-109
3-109

3-4 FUEL SYSTEM (DFI)
Exploded View

FUEL SYSTEM (DFI) 3-5
Exploded View
No.
1

Fastener
Fuel Pump Bolts

2. FI Indicator Light (LED)
3. Throttle Cable (Accelerator)
4. Throttle Cable (Decelerator)
5. Throttle Body Assy
6. Injectors
7. Meter Unit (EX650B Models)
CL: Apply cable lubricant.
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.

N·m
9.8

Torque
kgf·m
1.0

ft·lb
87 in·lb

Remarks
L, S

3-6 FUEL SYSTEM (DFI)
Exploded View

FUEL SYSTEM (DFI) 3-7
Exploded View
No.
1
2
3

Fastener
Water Temperature Sensor
Speed Sensor Bolt
Oxygen Sensor (Europe Models)

4. Inlet Air Pressure Sensor
5. Air Switching Valve
6. Inlet Air Temperature Sensor
7. Crankshaft Sensor
8. Battery
9. Relay Box
10. Stick Coil
11. Vehicle-down Sensor
12. ECU (Electronic Control Unit)
13. California Model
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
SS: Apply silicone sealant.

N·m
12
7.8
44.1

Torque
kgf·m
1.2
0.80
4.50

ft·lb
106 in·lb
69 in·lb
32.5

RemarksL

3-8 FUEL SYSTEM (DFI)
Exploded View
California ModelFUEL SYSTEM (DFI) 3-9
Exploded View
1. Tube (Green)
2. Tube (Blue)
3. Tube (White)
4. Tube (Blue)
5. Tube (Red)3-10 FUEL SYSTEM (DFI)DFI System
DFI System

FUEL SYSTEM (DFI) 3-11
DFI System
1. Ignition Switch
2. Starter Lockout Switch
3. Starter Relay
4. Tachometer
5. FI Indicator Light (LED)6. Inlet Air Pressure Sensor
7. Spark Plug
8. Crankshaft Sensor
9. Injector
10. Main Throttle Sensor
11. Delivery Pipe
12. Subthrottle Sensor
13. Subthrottle Valve
14. Main Throttle Valve
15. Subthrottle Valve Actuator
16. Fuel Pump
17. Pressure Regulator
18. Fuel Tank
19. Air Cleaner Element
20. Air Switching Valve
21. Inlet Air Temperature Sensor
22. Air Cleaner Housing
23. Neutral Switch
24. Speed Sensor
25. Vehicle-down Sensor
26. Oxygen Sensor (Europe Models)
27. ECU (Electronic Control Unit)
28. Battery
29. Air Flow
30. Fuel Flow
31. Water Temperature Sensor

3-12 FUEL SYSTEM (DFI)DFI System
DFI System Wiring Diagram

FUEL SYSTEM (DFI) 3-13
DFI System
Part Name
1. Oxygen Sensor (Europe Models)
2. Crankshaft Sensor
3. Inlet Air Temperature Sensor
4. Water Temperature Sensor
5. Water-proof Joint E
6. Injectors
7. Vehicle-down Sensor
8. Water-proof Joint D
9. Inlet Air Pressure Sensor
10. Main Throttle Sensor
11. Subthrottle Sensor
12. Subthrottle Valve Actuator
13. Speed Sensor
14. Air Switching Valve
15. Water-proof Joint C
16. Stick Coils
17. Fan Motor
18. Engine Stop Switch
19. Ignition Switch
20. FI Indicator Light (LED)21. Water Temperature Gauge
22. Tachometer
23. Speedometer
24. Water-proof Joint A
25. Water-proof Joint B
26. Oxygen Sensor Heater Fuse 10 A
27. Radiator Fan Fuse 15 A
28. ECU Fuse 15 A
29. Ignition Fuse 10 A
30. Radiator Fan Relay
31. ECU Main Relay
32. Fuel Pump Relay
33. Relay Box
34. Main Fuse 30 A
35. Battery
36. Frame Ground
37. Fuel Pump
38. Diagnosis Connector
39. Self-diagnosis Terminal
40. Joint Connector
41. ECU3-14 FUEL SYSTEM (DFI)DFI System

Terminal Names
1. Subthrottle Valve Actuator Drive Signal 2
2. Subthrottle Valve Actuator Drive Signal 1
3. Water Temperature Warning Light Signal
4. Unused
5. Oxygen Sensor Signal (Europe Models)
6. Speed Sensor Signal
7. Main Throttle Sensor Signal
8. Inlet Air Pressure Sensor Signal
9. Unused
10. Power Supply to Sensors
11. Vehicle-down Sensor Signal
12. Neutral Switch Signal
13. Crankshaft Sensor (+) Signal
14. Unused
15. Unused
16. Power Supply to ECU (from ECU Main Relay)
17. Power Supply to ECU (from Battery)
18. Subthrottle Valve Actuator Drive Signal 4
19. Subthrottle Valve Actuator Drive Signal 3
20. Water Temperature Sensor Signal
21. Unused
22. Self-diagnosis Terminal
23. Unused
24. Subthrottle Sensor Signal
25. Unused
26. Inlet Air Temperature Sensor Signal

27. Unused
28. Ground to Sensors
29. Oxygen Sensor Heater Signal (Europe
Models)30. Crankshaft Sensor (–) Signal
31. Unused
32. External Diagnosis System Signal
33. Unused
34. Ground to ECU
35. Engine Stop Switch Signal
36. Starter Lockout Switch Signal
37. Starter Button Signal
38. Unused
39. Fuel Pump Relay Signal
40. Air Switching Valve Signal
41. Fuel Injector #2 Signal
42. Fuel Injector #1 Signal
43. Stick Coil #1 Signal
44. Sidestand Switch Signal
45. Radiator Fan Relay Signal
46. External Communication Line (ModeSwitch)47. Tachometer Signal
48. FI Indicator Light (LED)49. –50. Ground for Fuel System
51. Ground for Ignition System
52. Stick Coil #2 Signal

FUEL SYSTEM (DFI) 3-15
DFI Parts Location

DFI: Digital Fuel Injection Parts
1. FI Indicator Light (LED)
2. Ignition Switch
3. Throttle Body Assy
4. Inlet Air Temperature Sensor
5. Injectors
6. Fuel Pump
7. Relay Box (ECU Main Relay, Fuel Pump
Relay, Radiator Fan Relay)
8. Fuse Box (ECU Fuse 15 A, Oxygen Sensor Heater Fuse 10 A)
9. ECU
10. Battery
11. Oxygen Sensor (Europe Models)

12. Speed Sensor
13. Neutral Switch
14. Water Temperature Sensor
15. Subthrottle Sensor
16. Main Throttle Sensor
17. Subthrottle Valve Actuator
18. Stick Coils
19. Inlet Air Pressure Sensor
20. Diagnosis Connector
21. Self-diagnosis Terminal
22. Air Switching Valve
23. Crankshaft Sensor
24. Vehicle-down Sensor

3-16 FUEL SYSTEM (DFI)
Specifications
Item
Digital Fuel Injection System
Idle Speed
Throttle Assy:
Type
Bore
ECU (Electronic Control Unit):
Make
Type
Usable Engine Speed

Standard
1 300 ±50 r/min (rpm)Two barrel type
38 mm (1.50 in.)
Denso
Digital memory type, with built in IC igniter, sealedwith resin
100 ∼ 11 000 r/min (rpm) (Europe Models)
100 ∼ 11 160 r/min (rpm) (Other than Europe Models)

Fuel Pressure (High Pressure Line):
Right after Ignition Switch ON
323 kPa (3.3 kgf/cm², 47 psi) with fuel pump running
After 3 Seconds from Ignition Switch ON 265 kPa (2.7 kgf/cm², 38 psi) with fuel pump stopped
With Engine Idling
333 kPa (3.4 kgf/cm², 48 psi) with fuel pump running
Fuel Pump:
Type
In-tank friction pump
Discharge
60 mL or more for 3 seconds
Fuel Injectors:
Type
INP-287Nozzle TypeOne spray type with 12 holes
Resistance
About 11.7 ∼ 12.3 Ω at 20°C (68°F)
Main Throttle Sensor:
Non-adjustable and non-removable
Input Voltage
4.75 ∼ 5.25 V DC between BL and BR/BK leads
Output Voltage at Idle Throttle Opening 1.073 ∼ 1.077 V DC between Y/W and BR/BK leads
Output Voltage at Full Throttle Opening 4.29 ∼ 4.49 V DC between Y/W and BR/BK leads
Resistance4 ∼ 6 kΩ
Inlet Air Pressure Sensor:
Input Voltage
4.75 ∼ 5.25 V DC between BL and BR/BK leads
Output Voltage
3.80 ∼ 4.20 V DC at standard atmospheric pressure(see this text for details)
Inlet Air Temperature Sensor:
Resistance
5.4 ∼ 6.6 kΩ at 0°C (32°F)
0.29 ∼ 0.39 kΩ at 80°C (176°F)
Output Voltage at ECU
About 2.25 ∼ 2.50 V at 20°C (68°F)
Water Temperature Sensor:
Resistancesee Electrical System chapter
Output Voltage at ECU
About 2.80 ∼ 2.97 V at 20°C (68°F)
Speed Sensor:
Input Voltage at Sensor
About 9 ∼ 11 V DC at Ignition Switch ON
Output Voltage at Sensor
About 0.05 ∼ 0.07 V DC at Ignition Switch ON and 0
km/h
Vehicle-down Sensor:
Detection Method
Magnetic flux detection method
Detection Angle
more than 60 ∼ 70° for each bank

FUEL SYSTEM (DFI) 3-17
Specifications
Item
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
Oxygen Sensor (Europe Models):
Output Voltage (Rich)
Output Voltage (Lean)
Heater ResistanceThrottle Grip and Cables
Throttle Grip Free Play

Standard
with the sensor tilted 60 ∼ 70° or more: 0.65 ∼ 1.35 V
with sensor arrow mark pointed up: 3.55 ∼ 4.45 V
Non-adjustable and non-removal
4.75 ∼ 5.25 V DC between BL and BR/BK leads
0.4 ∼ 0.6 V DC between BL/W and BR/BK leads
3.625 ∼ 3.775 V DC between BL/W and BR/BK leads
4 ∼ 6 kΩ
About 5.5 ∼ 7.5 Ω
About 8.5 ∼ 10.5 V DC
0.7 V or more
0.2 V or less11.7 ∼ 14.5 Ω at 20°C (68°F)
2 ∼ 3 mm (0.08 ∼ 0.12 in.)

3-18 FUEL SYSTEM (DFI)
Special Tools and Sealant
Oil Pressure Gauge, 5 kgf/cm²:
57001-125

Needle Adapter Set:
57001-1457

Fork Oil Level Gauge:
57001-1290

Throttle Sensor Setting Adapter:
57001-1538

Hand Tester:
57001-1394

Sensor Harness Adapter:
57001-1561

Throttle Sensor Setting Adapter #1:
57001-1400

Fuel Pressure Gauge Adapter:
57001-1593

Peak Voltage Adapter:
57001-1415

Fuel Hose:
57001-1607

FUEL SYSTEM (DFI) 3-19
Special Tools and SealantKawasaki Bond (Silicone Sealant):
56019-120

3-20 FUEL SYSTEM (DFI)DFI Servicing Precautions
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 power source.
○Do not reverse the battery cable connections. This will
damage the ECU.
○To prevent damage to the DFI parts, do not disconnect thebattery cables or any other electrical connections when
the ignition switch is on or while the engine is running.
○Take care not to short the leads that are directly connected to the battery positive (+) terminal to the chassis
ground.
○When charging, remove the battery from the motorcycle.
This is to prevent ECU damage by excessive voltage.
○Do not turn the ignition switch ON while any of the DFI
electrical connectors are disconnected. The ECU memorizes service codes.
○Do not spray water on the electrical parts, DFI parts, connectors, leads, and wiring.

○Whenever the DFI electrical connections are to be dis-connected, first turn off the ignition switch, and disconnect
the battery (–) terminal. Do not pull the lead, only the connector. Conversely, make sure that all the DFI electricalconnections are firmly reconnected before starting the engine.
○Connect these connectors until they click [A]○If a transceiver is installed on the motorcycle, make surethat the operation of the DFI system is not influenced byelectric wave radiated from the antenna. Check operationof the system with the engine at idle. Locate the antenna
as far as possible away from the ECU.
○When any fuel hose is disconnected, fuel may spout out
by residual pressure in the fuel line. Cover the hose joint
with a piece of clean cloth to prevent fuel spillage.
○When any fuel hose is disconnected, do not turn on theignition switch. Otherwise, the fuel pump will operate andfuel will spout from the fuel hose.
○Do not operate the fuel pump if the pump is completely
dry. This is to prevent pump seizure.
○Before removing the fuel system parts, blow the outer surfaces of these parts clean with compressed air.
○To prevent corrosion and deposits in the fuel system, do
not add to fuel any fuel antifreeze chemicals.

FUEL SYSTEM (DFI) 3-21
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]Torque - Oil Filler Plug: Hand-tighten

3-22 FUEL SYSTEM (DFI)
Troubleshooting the DFI System
OutlineOutlineWhen an abnormality in the system occurs, the FI indicator light (LED) 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 unit). With theengine stopped and turned in the self-diagnosis mode, theservice code [A] is indicated by the number of times the FI
indicator light (LED) blinks.
When due to a malfunction, the FI indicator light (LED) remains lit, ask the rider about the conditions [B] under which
the problem occurred and try to determine the cause [C].
First, conduct a self-diagnosis inspection and then a non-self-diagnosis inspection. The non-self-diagnosis items
are not indicated by the FI indicator light (LED). Don’t rely
solely on the DFI self-diagnosis function, use common
sense.

•

Even when the DFI system is operating normally, the FI
indicator light (LED) [A] may light up under strong electricalinterference. No repair needed. Turn the ignition switch
OFF to stop the indicator light.
When the FI indicator light (LED) goes on and the motorcycle is brought in for repair, check the service codes.
When the repair has been done, the light (LED) doesn’t go
on. But the service codes stored in memory are not erased
to preserve the problem history, and the light (LED) can
display the codes in the self-diagnosis mode. The problem
history is referred when solving unstable problems.
When the motorcycle is down, the vehicle-down sensor
is turned OFF and the ECU shuts off the fuel injectors andignition system. The FI indicator light (LED) blinks but theservice code cannot be displayed. The ignition switch is left
ON. If the starter button is pushed, the electric starter turns
but the engine doesn’t start. To start the engine again, raise
the motorcycle, turn the ignition switch OFF, and then ON.
The vehicle-down sensor is turned ON and the light (LED)goes OFF.

FUEL SYSTEM (DFI) 3-23
Troubleshooting the DFI System○The DFI part connectors [A] have seals [B], including the•

ECU.
Join the connector and insert the needle adapters [C]inside the seals [B] from behind the connector until theadapter reaches the terminal.
Special Tool - Needle Adapter Set: 57001-1457

CAUTION
Insert the needle adapter straight along the terminalin the connector to prevent short-circuit between
terminals.
sure that measuring points are correct in the con• Make
nector, noting the position of the lock [D] and the lead••color before measurement. Do not reverse connectionsof the hand tester or a digital meter.
Be careful not to short-circuit the leads of the DFI or electrical system parts by contact between adapters.
Turn the ignition switch ON and measure the voltage withthe connector joined.

CAUTION
Incorrect, reverse connection or short circuit byneedle adapters could damage the DFI or electricalsystem parts.

○After measurement, remove the needle adapters and ap-

ply silicone sealant to the seals [A] of the connector [B]for waterproofing.
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

check battery condition before replacing the DFI• Alwaysparts. A fully charged battery is a must for conducting
accurate tests of the DFI system.

may involve one or in some cases all items.
• Trouble
Never replace a defective part without determining what••

CAUSED the problem. If the problem was caused bysome other item or items, they too must be repaired or
replaced, or the new replacement part will soon fail again.
Measure coil winding resistance when the DFI part is cold
(at room temperature).
Make sure all connectors in the circuit are clean and tight,
and examine wires for signs of burning, fraying, short,etc. Deteriorated wires and bad connections can cause
reappearance of problems and unstable operation of the
DFI system.
If any wiring is deteriorated, replace the wiring.

3-24 FUEL SYSTEM (DFI)
Troubleshooting the DFI Systemeach connector [A] apart and inspect it for corrosion,• Pulldirt, and damage.
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 wiring diagram to find the ends of the lead which
is suspected of being a problem.
○Connect the hand tester between the ends of the leads.
○Set the tester to the × 1 Ω range, and read the tester.
If the tester does not read 0 Ω, the lead is defective. Replace the lead or the main harness or the sub harness.

•○If both ends of a harness [A] are far apart, ground [B] theone end [C], using a jumper lead [D] and check the continuity between the end [E] and the ground [F]. This enables to check a long harness for continuity. If the harness
is open, repair or replace the harness.

○When checking a harness [A] for short circuit, open one

end [B] and check the continuity between the other end[C] and ground [D]. If there is continuity, the harness has
a short circuit to ground, and it must be repaired or replaced.

down suspicious locations by repeating the con• Narrowtinuity tests from the ECU connectors.
If no abnormality is found in the wiring or connectors, theDFI parts are the next likely suspects. Check the part,starting with input and output voltages. However, there is
no way to check the ECU itself.
If an abnormality is found, replace the affected DFI part.
If no abnormality is found in the wiring, connectors, andDFI parts, replace the ECU.

○Lead Color Codes:
BK: Black
BL: Blue
BR: Brown
CH: Chocolate
DG: Dark Green

G: Green
GY: Gray
LB: Light Blue
LG: Light Green
O: Orange

P: Pink
PU: Purple
R: Red
W: White
Y: Yellow

FUEL SYSTEM (DFI) 3-25
Troubleshooting the DFI System○There are two ways to inspect the DFI system. One isvoltage 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 voltage [C]from the sensor.
○Sometimes this method can detect a fault of the ECU.
Refer to each sensor inspection section for detail in thischapter.
Use a fully charged battery and a digital meter [D] which
can be read two decimal places voltage or resistance.

••(Resistance Check Method)○This method is simple. No need for a fully charged battery
and the needle adapter. Just do the following especiallywhen a sensor [A] is suspect.
Turn the ignition switch OFF and disconnect the connectors.
Inspect the sensor resistance, using a digital meter (seeeach sensor inspection).
Inspect the wiring and connectors [B] for continuity, using
the hand tester [C] (analog tester) rather than a digitalmeter.

•••

Special Tool - Hand Tester: 57001-1394

If the sensor, the wiring and connections are good, inspect
the ECU for its ground and power supply (see ECU Power
Supply Inspection). If the ground and power supply are
good, the ECU is suspect. Replace the ECU.

3-26 FUEL SYSTEM (DFI)
Troubleshooting the DFI System
DFI Diagnosis Flow Chart

Inquiries to Rider
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 conditions by asking the rider;knowing this information may help you reproduce the problem.
○The following sample diagnosis sheet will help prevent you from overlooking any areas, and will
help you decide if it is a DFI system problem, or a general engine problem.

FUEL SYSTEM (DFI) 3-27
Troubleshooting the DFI System
Sample Diagnosis Sheet
Rider name:Year of initial registration:
Engine No.:
Date problem occurred:
WeatherTemperature
Problemfrequency
Road
AltitudeFI indicatorlight (LED)Starting
difficulty

Engine stops

Poor runningat low speed

Registration No. (license plate No.):
Model:
Frame No.:
Mileage:
Environment when problem occurred.
□fine, □cloudy,□rain, □snow, □always, □other:□hot, □warm, □cold, □very cold, □always□chronic, □often, □once□street, □highway, □mountain road (□uphill, □downhill), □bumpy, □pebble□normal, □high (about 1 000 m or more)
Motorcycle conditions when problem occurred.
□light up immediately after ignition switch ON, and goes off after 1 ∼ 2 seconds(normal)□lights blinks immediately after ignition switch ON, and stays on (DFI problem)□lights up immediately after ignition switch ON, but goes off after about 10 seconds(DFI problem)□unlights (light (LED), ECU or its wiring fault)□sometimes lights up (probably wiring fault)□starter motor not rotating□starter motor rotating but engine doesn’t turn over□starter motor and engine don’t turn over□no fuel flow (□no fuel in tank, □no fuel pump sound)□engine flooded (do not crank engine with throttle opened, which promotes engine
flooding)□no spark□other□right after starting□when opening throttle grip
□when closing throttle grip
□when moving off□when stopping the motorcycle□when cruising□other□very low idle speed, □very high idle speed, □rough idle speed□battery voltage is low (charge the battery)□spark plug loose (tighten it)□spark plug dirty, broken, or gap maladjusted (remedy it)□backfiring□afterfiring□hesitation when acceleration□engine oil viscosity too high□brake dragging□engine overheating□clutch slipping3-28 FUEL SYSTEM (DFI)
Troubleshooting the DFI System□otherPoor running □spark plug loose (tighten it)
or no power at □spark plug dirty, broken, or gap maladjusted (remedy it)high speed□spark plug incorrect (replace it)□knocking (fuel poor quality or incorrect, → use high-octane gasoline)□brake dragging□clutch slipping□engine overheating□engine oil level too high□engine oil viscosity too high□otherFUEL SYSTEM (DFI) 3-29
DFI System Troubleshooting Guide
NOTE○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 difficulties.
○The ECU may be involved in the DFI electrical and ignition system troubles. If these parts andcircuits are checked out good, be sure to check the ECU for ground and power supply. If theground and power supply are checked good, replace the ECU.

Engine Doesn’t Start, Starting Difficulty
Symptoms or possible Causes
Starter motor not rotating:Ignition and engine stop switches not ON
Starter lockout switch or neutral switch trouble
Starter motor trouble
Battery voltage low
Starter relays not contacting or operating
Starter button not contacting
Starter system wiring open or shorted
Ignition switch trouble
Engine stop switch trouble
Main 30A or ignition fuse blown
Starter motor rotating but engine doesn’tturn over:Starter clutch trouble
Starter idle gear trouble
Engine won’t turn over:
Valve seizure
Cylinder, piston seizure
Camshaft seizure
Connecting rod small end seizure
Connecting rod big end seizure
Crankshaft seizure
Transmission gear or bearing seizure
Balancer bearing seizure
No fuel flow:
No or little fuel in tank
Fuel pump not rotating
Fuel injector trouble
Fuel tank air vent obstructed
Fuel filter or pump screen clogged
Fuel pressure regulator clogged
Fuel line clogged
Engine flooded:
Spark plug dirty, broken or gap maladjusted
Starting technique faulty
No spark or spark weak:
Ignition and engine stop switches not ON

Actions (chapter)
Turn both switches ON.
Inspect (see chapter 16).
Inspect (see chapter 16).
Inspect and charge (see chapter 16).
Inspect the starter relay (see chapter 16).
Inspect and replace (see chapter 16).
Inspect the wiring (see chapter 16).
Inspect and replace (see chapter 16).
Inspect and repair or replace (see chapter 16).
Inspect and replace (see chapter 16).

Inspect (see chapter 16).
Inspect (see chapter 16).
Inspect and replace (see chapter 5).
Inspect and replace (see chapter 5).
Inspect and replace (see chapter 5).
Inspect and replace (see chapter 9).
Inspect and replace (see chapter 9).
Inspect and replace (see chapter 9).
Inspect and replace (see chapter 9).
Inspect and replace (see chapter 9).
Supply fuel (see Owner’s Manual).
Inspect (see chapter 3).
Inspect and replace (see chapter 3).
Inspect and repair (see chapter 3).
Inspect and replace fuel pump (see chapter 3).
Inspect and replace fuel pump (see chapter 3).
Inspect and repair (see chapter 3).
Replace (see chapter 2).
When flooded, don’t crank engine with throttle
fully opened.
Turn both switches ON .

3-30 FUEL SYSTEM (DFI)DFI System Troubleshooting Guide
Symptoms or possible Causes
Clutch lever not pulled in and gear not in neutral
whether sidestand up or not
Though clutch lever pulled in, sidestand up andgear not in neutral
Vehicle-down-sensor coming off
Vehicle-down-sensor trouble
ECU ground or power supply trouble
Battery voltage low
Spark plug dirty, broken or gap maladjusted
Stick coil trouble
Stick coil shorted or not in good contact
Spark plug incorrect
IC igniter in ECU trouble
Neutral, starter lockout or sidestand switch
troubleCrankshaft sensor trouble
Stick coil trouble
Ignition switch shorted
Engine stop switch shorted
Starter system wiring shorted or open
Main 30A or ignition fuse blown
Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed or missing
Leak from oil filler cap, crankcase breather hoseor air cleaner drain hose
Water or foreign matter in fuel
Fuel pressure regulator trouble
Main throttle sensor trouble
Fuel pressure may be low
Fuel pump trouble
Fuel injector trouble
Inlet air pressure sensor trouble
Inlet air temperature sensor trouble
Water temperature sensor trouble
Crankshaft sensor trouble
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened down
Cylinder, piston worn
Piston ring bad (worn, weak, broken or sticking)Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped

Actions (chapter)
Pull the lever in and shift the gear in neutral.
Sidestand down and clutch lever pulled inwhether gear in neutral or not
Reinstall (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect and charge (see chapter 16).
Replace (see chapter 2).
Inspect stick coil (see chapter 16).
Reinstall or inspect stick coil (see chapter 16).
Replace it with the correct plug (see chapter 16).
Inspect (see chapter 16).
Inspect each switch (see chapter 16).
Inspect (see chapter 16).
Inspect (see chapter 16).
Inspect and replace (see chapter 16).
Inspect and repair or replace (see chapter 2).
Inspect and repair or replace (see chapter 16).
Inspect and replace (see chapter 16).
Clean or reinstall (see chapter 3).
Inspect and repair or replace (see chapter 3).
Change fuel. Inspect and clean fuel system (seechapter 3).
Inspect fuel pressure and replace fuel pump (seechapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Reinstall (see chapter 16).
Tighten (see chapter 5).
Inspect and replace (see chapter 5).
Inspect and replace (see chapter 5).
Inspect and replace (see chapter 5).
Replace (see chapter 5).
Inspect and replace (see chapter 5).

FUEL SYSTEM (DFI) 3-31
DFI System Troubleshooting Guide
Symptoms or possible Causes
No valve clearance
Valve guide worn
Valve spring broken or weak
Valve not seating properly (valve bent, worn or
carbon accumulating on seating surface)

Actions (chapter)
Adjust (see chapter 2).
Inspect and replace (see chapter 5).
Inspect and replace (see chapter 5).
Inspect and repair or replace (see chapter 5).

Poor Running at Low Speed
Symptoms or Possible Causes
Spark weak:
Battery voltage low
Spark plug dirty, broken or gap maladjusted
Stick coil trouble
Stick coil shorted or not in good contact
Spark plug incorrect
IC igniter in ECU trouble
Crankshaft sensor trouble
Stick coil trouble
Fuel/air mixture incorrect:
Little fuel in tank
Air cleaner clogged, poorly sealed, or missing
Air cleaner duct loose
Air cleaner O-ring damaged
Fuel tank air vent obstructed
Throttle body assy loose
Throttle body assy O-ring damage
Fuel filter or pump screen clogged
Fuel pressure regulator clogged
Fuel line clogged
Inlet air pressure sensor trouble
Inlet air temperature sensor trouble
Thermostat trouble
Unstable (rough) idling:
Fuel injector trouble
Main throttle sensor trouble
Crankshaft sensor trouble
Throttle valves not synchronizing
Inlet air temperature sensor trouble
Water temperature sensor trouble
Fuel pressure too low or too highBattery voltage low
Incorrect idle speed:
Water temperature sensor trouble
Main throttle sensor trouble

Actions (chapter)
Inspect and charge (see chapter 16).
Replace (see chapter 2).
Inspect the stick coil (see chapter 16).
Reinstall or inspect stick coil (see chapter 16).
Replace it with the correct plug (see chapter 16).
Inspect (see chapter 16).
Inspect (see chapter 16).
Inspect (see chapter 16).
Supply fuel (see Owner’s Manual).
Clean element or inspect sealing (see chapter2, 3).
Reinstall (see chapter 3).
Replace (see chapter 3).
Inspect and repair (see chapter 3).
Reinstall (see chapter 3).
Replace (see chapter 3).
Inspect and replace fuel pump (see chapter 3).
Inspect fuel pressure and replace fuel pump (seechapter 3).
Inspect and repair (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect and replace (see chapter 4).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 2).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect and charge (see chapter 16).
Inspect (see chapter 3).
Inspect (see chapter 3).

3-32 FUEL SYSTEM (DFI)DFI System Troubleshooting Guide
Symptoms or Possible Causes
Engine stalls easily:
Fuel pump trouble
Fuel injector trouble
Main throttle sensor trouble
Fuel pressure too low or too highInlet air pressure sensor trouble
Water temperature sensor trouble
Inlet air temperature sensor trouble
Fuel line clogged
Fuel pressure too low or too high
Fuel pressure regulator trouble
Crankshaft sensor trouble
Stick coil trouble
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 gasket damaged
Cylinder head warped
Valve guide worn or stem seal damaged
Valve spring broken or weak
Valve not seating properly (valve bent, worn or
carbon accumulating on seating surface)Camshaft cam worn
Hesitation:
Too low fuel pressure
Clogged fuel line
Cracked or obstructed inlet air pressure sensor
hose
Fuel pump trouble
Fuel injector trouble
Inlet air temperature sensor trouble
Main throttle sensor trouble
Subthrottle sensor trouble
Subthrottle valve actuator trouble
Water temperature sensor trouble
Inlet air pressure sensor trouble
Loose injector connectors
Crankshaft sensor trouble
Stick coil trouble

Actions (chapter)
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect and repair (see chapter 3).
Inspect (see chapter 3).
Inspect fuel pressure and replace fuel pump (seechapter 3).
Inspect (see chapter 16).
Inspect (see chapter 16).
Reinstall (see chapter 16).
Tighten (see chapter 5).
Adjust (see chapter 2).
Inspect and replace (see chapter 5).
Inspect and replace (see chapter 5).
Inspect and replace (see chapter 5).
Replace (see chapter 5).
Inspect and replace (see chapter 5).
Inspect and replace (see chapter 5).
Inspect and replace (see chapter 5).
Inspect and repair or replace (see chapter 5).
Inspect and replace (see chapter 5).
Inspect (see chapter 3).
Inspect and repair (see chapter 3).
Inspect and repair or replace (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Remedy (see chapter 3).
Inspect and repair or replace (see chapter 16).
Inspect and repair or replace (see chapter 16).

FUEL SYSTEM (DFI) 3-33
DFI System Troubleshooting Guide
Symptoms or Possible Causes
Loose terminal of battery (–) cable or engine
ground lead
Delay of ignition timing
Poor acceleration:
Too low fuel pressure
Water or foreign matter in fuelClogged fuel filter or pump screen
Fuel pump trouble
Fuel injector trouble
Inlet air temperature sensor trouble
Water temperature sensor trouble
Subthrottle sensor trouble
Subthrottle valve actuator trouble
Stick coil trouble
Engine oil level to highSpark plug dirty, broken or gap maladjusted
Stumble:Too low fuel pressure
Fuel injector trouble
Main throttle sensor malfunction
Subthrottle sensor trouble
Subthrottle valve actuator trouble
Water temperature sensor trouble
Inlet air pressure sensor trouble
Surge:
Unstable fuel pressure

Fuel injector trouble
Water temperature sensor trouble
Backfiring when deceleration:
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
Inlet air pressure sensor trouble
Air switching valve broken
Air suction valve trouble
After fire:
Crankshaft sensor trouble
Spark plug burned or gap maladjusted

Actions (chapter)
Inspect and repair (see chapter 16).
Inspect crankshaft sensor and IC igniter in ECU(see chapter 16).
Inspect (see chapter 3).
Change fuel. Inspect and clean fuel system (seechapter 3).
Inspect and replace fuel pump (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect and replace (see chapter 16).
Repair (see chapter 7).
Replace (see chapter 2).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Fuel pressure regulator trouble (Inspect andreplace fuel pump) or kinked fuel line (Inspect
and repair fuel line) (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Replace (see chapter 2).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect and replace (see chapter 5).
Inspect and replace (see chapter 5).
Inspect (see chapter 16).
Replace (see chapter 2).

3-34 FUEL SYSTEM (DFI)DFI System Troubleshooting Guide
Symptoms or Possible Causes
Inlet air temperature sensor trouble
Water temperature sensor trouble
Inlet air pressure sensor trouble
Fuel injector trouble
Run-on (dieseling):
Ignition switch trouble
Engine stop switch trouble
Fuel injector trouble
Loose terminal of battery (–) cable or ECU
ground lead
Carbon accumulating on valve seating surface
Engine overheating
Other:Engine oil viscosity too highDrive train trouble
Brake dragging
Clutch slipping
Engine overheating
Air switching valve trouble
Air suction valve trouble
Intermittent any DFI fault and its recovery

Actions (chapter)
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect and replace (see chapter 16).
Inspect and repair or replace (see chapter 2).
Inspect (see chapter 3).
Inspect and repair (see chapter 16).
Repair (see chapter 5).
(see Overheating of Troubleshooting Guide, seechapter 17)
Change (see chapter 2).
Inspect drive chain (see chapter 2) and sprocket(see chapter 11).
Inspect caliper fluid seal damage or clogging
of master cylinder relief and supply ports (seechapter 12).
Inspect friction plates for wear (see chapter 6).
(see Overheating of Troubleshooting Guide, seechapter 17)
Inspect and replace (see chapter 5).
Inspect and replace (see chapter 5).
Check that DFI connectors are clean and tight,
and examine wires for signs of burning or fraying(see chapter 3).

Poor Running or No Power at High Speed:
Symptoms or Possible Causes
Firing incorrect:
Spark plug dirty, broken or maladjusted
Stick coil trouble
Stick coil shorted or not in good contact
Spark plug incorrect
IC igniter in ECU trouble
Crankshaft sensor trouble
Stick coil trouble
Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed, or missing
Air cleaner duct loose
Air cleaner O-ring damaged
Water or foreign matter in fuelThrottle body assy loose

Actions (chapter)
Replace (see chapter 2).
Inspect stick coil (see chapter 16).
Reinstall or inspect stick coil (see chapter 16).
Replace it with the correct plug (see chapter 16).
Inspect (see chapter 16).
Inspect (see chapter 16).
Inspect (see chapter 16).
Clean element or inspect sealing (see chapter 3).
Reinstall (see chapter 3).
Replace (see chapter 3).
Change fuel. Inspect and clean fuel system (seechapter 3).
Reinstall (see chapter 3).

FUEL SYSTEM (DFI) 3-35
DFI System Troubleshooting Guide
Symptoms or Possible Causes
Throttle body assy O-ring damaged
Fuel tank air vent obstructed
Fuel line clogged
Fuel pump operates intermittently and often DFI
fuse blows.
Fuel pump trouble
Inlet air temperature sensor trouble
Main throttle sensor trouble
Inlet air pressure sensor trouble
Cracked or obstructed inlet air pressure sensor
hose
Injector clogged
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 gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent , worn or
carbon accumulating on the seating surface)
Knocking:
Carbon built up in combustion chamber
Fuel poor quality or incorrect (Use the gasoline
recommended in the Owner’s Manual)
Spark plug incorrect
Stick coil trouble
IC igniter in ECU trouble
Inlet air temperature sensor trouble
Miscellaneous:
Subthrottle sensor trouble
Subthrottle valve actuator trouble
Speed sensor trouble
Throttle valves won’t fully open

Actions (chapter)
Replace (see chapter 3).
Inspect and repair (see chapter 3).
Inspect and repair (see chapter 3).
Pump bearings may wear. Replace the pump(see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect and repair or replace (see chapter 3).
Visually inspect and replace (see chapter 3).
Reinstall (see chapter 16).
Tighten (see chapter 5).
Adjust (see chapter 2).
Inspect and replace (see chapter 5).
Inspect and replace (see chapter 5).
Inspect and replace (see chapter 5).
Replace (see chapter 5).
Inspect and replace (see chapter 5).
Inspect and replace (see chapter 5).
Inspect and repair or replace (see chapter 5).

Repair (see chapter 5).
Change fuel (see chapter 3).
Replace it with the correct plug (see chapter 16).
Inspect (see chapter 16).
Inspect (see chapter 16).
Inspect (see chapter 3).

Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect throttle cable and lever linkage (seechapter 3).
Brake dragging
Inspect caliper fluid seal damage or clogging
of master cylinder relief and supply ports (seechapter 12).
Clutch slipping
Inspect friction plates for wear (see chapter 6).
Engine overheating - Water temperature sensor, (see Overheating of Troubleshooting Guide in
crankshaft sensor or speed sensor trouble
chapter 17).
Engine oil level too highRepair (see chapter 7).
Engine oil viscosity too highChange (see chapter 2).

3-36 FUEL SYSTEM (DFI)DFI System Troubleshooting Guide
Symptoms or Possible Causes
Drive train trouble
Camshaft cam worn
Air switching valve trouble
Air suction valve trouble
Catalytic converters melt down due to muffler
overheating
Exhaust Smokes Excessively:(White smokes)
Piston oil ring worn
Cylinder worn
Valve oil seal damaged
Valve guide worn
Engine oil level too high(Black smoke)
Air cleaner clogged
Too high fuel pressure
Injector stuck open
Water temperature sensor trouble
Inlet air temperature sensor trouble(Brown smoke)
Air cleaner duct loose
Air cleaner O-ring damaged
Too low fuel pressure
Water temperature sensor trouble
Inlet air temperature sensor trouble

Actions (chapter)
Inspect drive chain (see chapter 2) and sprockets(see chapter 11).
Inspect and replace (see chapter 5).
Inspect and replace (see chapter 5).
Inspect and replace (see chapter 5).
Replace muffler (see chapter 5).

Inspect and replace (see chapter 5).
Inspect and replace (see chapter 5).
Replace (see chapter 5).
Replace the guide (see chapter 5).
Repair (see chapter 7).
Clean (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect and replace (see chapter 3).
Inspect and replace (see chapter 3).
Reinstall (see chapter 3).
Replace (see chapter 3).
Inspect fuel line and fuel pump (see chapter 3).
Inspect and replace (see chapter 3).
Inspect and replace (see chapter 3).

FUEL SYSTEM (DFI) 3-37
Self-Diagnosis
Self-diagnosis Outline
Self-diagnosis Outline
The self-diagnosis system has three modes and can beswitched to another mode by grounding the self-diagnosis
terminal.
User Mode
The ECU notifies the rider of troubles in DFI system andignition system by lighting the FI indicator when DFI system
and ignition system parts are faulty, and initiates fail-safe
function. In case of serious troubles, the ECU stops theinjection/ignition/starter motor operation.
Dealer Mode 1
The FI indicator light (LED) emits service code(s) to show
the problem(s) which the DFI system, and ignition system
has at the moment of diagnosis.
Dealer Mode 2
The FI indicator light (LED) emits service code(s) to show
the problem(s) which the DFI system, and ignition system
had in the past.

Self-diagnosis Procedures
Self-diagnosis Procedures○When a problem occurs with the DFI system and ignition
system, the FI indicator light (LED) [A] goes on.

NOTE○Use a fully charged battery when conducting
self-diagnosis.
Otherwise, the light (LED) blinks
very slowly or doesn’t blink.
○Keep the self-diagnosis terminal grounded during self
-diagnosis, with an auxiliary lead.
the seat (see Seat Removal in the Frame chap• Removeter).
[A] the self-diagnosis terminal [B] (Orange/Black• Groundlead) to the battery (–) terminal [C] or battery (–) lead connector, using a wire.

on the ignition switch.
• TurnConnect
an auxiliary lead [E] to the self-diagnosis terminal• [G] for grounding.
enter the self-diagnosis dealer mode 1, ground [A] the• To
self-diagnosis indicator terminal to the battery (–) terminal
for more than 2 seconds [C], and then keep it grounded
continuously [D].
○Count the blinks of the light (LED) to read the service
code. Keep the auxiliary lead ground until you finish reading the service code.

3-38 FUEL SYSTEM (DFI)
Self-Diagnosis
enter the self-diagnosis dealer mode 2, open [B] and• Toground [A] the lead more than five times [F] within 2 seconds [C] after the lead is first grounded, and then keep it
grounded continuously [D] for more than 2 seconds.
○Count the blinks of the light (LED) to read the service
code. Keep the auxiliary lead ground until you finish reading the service code.
Auxiliary Lead [E]Self-diagnosis Terminal [G]NOTE○To enter the dealer mode 2 from the dealer mode 1, turnoff the ignition switch once.

Service Code Clearing Procedures
Service Code Clearing Procedures

the self-diagnosis dealer mode 2 (see Self
• Enter-diagnosis Procedures).

NOTE○Make sure to keep the grounding until the following
opening and grounding starts.

the clutch lever in more than 5 seconds, and then
• Pullrelease it.
opening [B] and grounding [A] the lead
• Repeat(self-diagnosis terminal) more than five times [F] within 2
seconds [C] after the lead is grounded, and then keep it
grounded continuously [D] for more than 2 seconds.
Auxiliary Lead [E]Self-diagnosis Terminal [G]FUEL SYSTEM (DFI) 3-39
Self-Diagnosis

3-40 FUEL SYSTEM (DFI)
Self-Diagnosis
How to Read Service Codes
How to Read Service Codes○Service codes are shown by a series of long and short blinks of the FI indicator light (LED) as shown

below.
○Read 10th digit and unit digit as the FI indicator light (LED) blinks.
○When there are a number of problems, all the service codes can be stored and the display will
begin starting from the lowest number service code in the numerical order. Then after completing
all codes, the display is repeated until the self-diagnosis indicator terminal is open.
○If there is no problem, no code and unlight.
○For example, if two problems occurred in the order of 21, 12, the service codes are displayed fromthe lowest number in the order listed.
(12 → 21) → (12 → 21) → · · · (repeated)○If the problem is with the following parts, the ECU cannot memorize these problems, the FI indicatorlight (LED) doesn’t go on, and no service codes can be displayed.
FI Indicator Light (LED)
Fuel Pump
Fuel Pump Relay
DFI Main RelayECU Power Source Wiring and Ground Wiring (see ECU Inspection)
Fuel Injectors

How to Erase Service Codes
How to Erase Service Codes○Even if the ignition switch is turned OFF, the battery or the ECU are disconnected or the problem issolved, all service codes remain in the ECU.

○Refer to the Service Code Clearing Procedure for the service code erasure.

FUEL SYSTEM (DFI) 3-41
Self-Diagnosis
Service Code Table
Service Code Table
Service
Code

FI Indicator Light (LED)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 temperature sensor
malfunction, wiring open or short
Crankshaft sensor malfunction, wiring
open or short

11
12
13
14
21
24
and
25
31
32
33
51
52

Problems+

Speed sensor malfunction, wiring
open or shortFirst 24 is displayed and then 25,
repeatedly
Vehicle-down sensor, malfunction,
wiring open or short
Subthrottle sensor malfunction, wiring
open or short
Oxygen sensor inactivation, wiring
open or short (Europe Models)
Stick (Ignition) coil #1 malfunction,
wiring open or short
Stick (Ignition) coil #2 malfunction,
wiring open or short

56

Radiator fan relay malfunction, wiring
open or short

62

Subthrottle valve actuator
malfunction, wiring open or short64

Air switching valve malfunction, wiring
open or short67

Oxygen sensor heater malfunction,
wiring open or short (Europe Models)94

Oxygen sensor malfunction, wiring
open or short (Europe Models)Notes:○The ECU may be involved in these problems. If all the parts and circuits checked out good, be sure
to check the ECU for ground and power supply. If the ground and power supply are checked good,
replace the ECU.
○When no service code is displayed, the electrical parts of the DFI system has no fault, and themechanical parts of the DFI system and the engine are suspect.

3-42 FUEL SYSTEM (DFI)
Self-Diagnosis
Backups
Backups○The ECU takes the following measures to prevent engine damage when the DFI or the ignition
system parts have troubles.

Service
Codes

11

12

13

14

21

24
and
25

31

32

33

Parts

Output Signal Usable
Range or Criteria

Backups by ECU

If the main throttle sensor system fails (thesignal is out of the usable range, wiring shortor open), the ECU locks ignition timing into theignition timing at closed throttle position and
Main Throttle Sensor
Main Throttle
sets the DFI in the D-J method.
Output Voltage
SensorAlso, the main throttle sensor system and0.20 ∼ 4.8 V
inlet air pressure fails, the ECU locks ignition
timing into the ignition timing at closed throttle
position and sets the DFI in the α-N method.
Inlet Air Pressure
If the inlet air pressure sensor system fails (theInlet Air(absolute)
signal Pv is out of the usable range, wiring
Pressure
Pv = 150 mmHg ∼ 800 short or open), the ECU sets the DFI in the α
SensormmHg- N method.
Inlet Air
If the inlet air temperature sensor fails (theInlet Air Temperature
Temperature
signal is out of the usable range, wiring short
Ta = –30°C ∼ +120°C
Sensoror open), the ECU sets Ta at 40°C.
Water
If the water temperature sensor system fails
Water Temperature
Temperature(the signal is out of the usable range, wiring
Tw = –30°C ∼ +120°C
Sensorshort or open), the ECU sets Tw at 80°C.
Crankshaft sensor must
Crankshaft
send 22 signals (output If crankshaft sensor generates other than 22
Sensorsignals, the engine stops by itself.
signal) to the ECU at
the one cranking.
Speed sensor must
send 4 signals (output
signal) to the ECU at
If the speed sensor system fails (no signal,
the one rotation of the
Speed Sensor
wiring short or open), the speedometer showsengine sprocket.
0, and the ECU sets the top (6) gear position.
The gear position isdecided by the signal of
the speed sensor.
If the vehicle-down sensor system has failures
Vehicle-down Sensor(the output voltage Vd is more than usable
Vehicle-down
Output Voltage (signal) range, wiring open), the ECU shuts off theSensor
Vd = 0.65 V ∼ 4.45 V
fuel pump, the fuel injectors and the ignition
system.
If the subthrottle sensor system fails (theSubthrottle Sensor
Subthrottle
signal is out of the usable range, wiring short
Output Voltage
Sensoror open), the actuator locks sub throttle valve
0.15 ∼ 4.85 V
at full open position.
The oxygen sensor is
Oxygen Sensor active and sensor must
If the oxygen sensor is not activated, the ECU(Europesend signals (output
stops oxygen sensor feedback mode.
Models)voltage) continuously to
the ECU.

FUEL SYSTEM (DFI) 3-43
Self-Diagnosis
Service
Codes

51

52

62

67

94

Output Signal Usable
Backups by ECU
Range or Criteria
The stick coil primary
If the ignition primary winding #1 has failures
winding must send
Stick Coil #1(no signal, wiring short or open), the ECU
signals (output voltage)(Ignition Coil)*shuts off the injector #1 to stop fuel to thecontinuously to thecylinder #1, though the engine keeps running.
ECU.
The stick coil primary
If the ignition primary winding #2 has failures
winding must send(no signal, wiring short or open), the ECU
Stick Coil #2
signals (output voltage)
shuts off the injector #2 to stop fuel to the(Ignition Coil)*continuously to thecylinder #2, though the engine keeps running.
ECU.
The actuator operates
If the subthrottle valve actuator fails (theopen and close of theSubthrottle
signal is out of the usable range, wiring shortsubthrottle valve by the
Valve Actuator
or open), the ECU stops the current to thepulse signal from theactuator.
ECU.
The oxygen sensor
heater raise
Oxygen Sensor
If the oxygen sensor heater fails (wiring shorttemperature of the(Europeor open), the ECU stops the current to thesensor for its earlier
Models)heater.
activation. 12V-6.6W,
0.55A
The oxygen sensor
Oxygen Sensor must send signals
If the oxygen sensor output voltage is incorrect,(Europe(output voltage)
the ECU stops oxygen sensor feed back mode.
Models)continuously to the
ECU
Parts

Note:
(1) D-J Method and α - N Method: When the engine load is light like at idling or low speed, the ECU
determines the injection quantity by calculating from the throttle vacuum (inlet air pressure sensor
output voltage) and engine speed (crankshaft sensor output voltage). This method is called D-J
method (low-speed mode). As the engine speed increases, and the engine load turns middle toheavy, the ECU determines the injection quantity by calculating from the throttle opening (throttle
sensor output voltage) and the engine speed. This method is called α - N method (high-speedmode).
(*) This depends on the number of stopped cylinders.

3-44 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 throttle body assy, especially on ahard surface. Such a shock to the sensor can damage it.

Main Throttle Sensor Input Voltage Inspection
NOTE○Be sure the battery is fully charged.

the ignition switch OFF.
• TurnRemovethe left center fairings (see Center Fairing Re• moval in the
Frame chapter).
Disconnectthethrottle sensor connector and con• nect the harnessmain
adapter [A] between these connectors.
• Connect a digital meter to the harness adapter lead.

Special Tool - Throttle Sensor Harness Adapter: 57001-1538

the sensor input voltage with the engine stopped• Measureand with the connector joined.
• Turn the ignition switch ON.
Main Throttle Sensor Input Voltage
Connections to Adapter
Meter (+) → R (sensor BL) lead
Meter (–) → BK (sensor BR/BK) lead
Standard: 4.75 ∼ 5.25 V DC

the ignition switch OFF.
• TurnIf the input voltage is normal, check the sensor output
voltage.
If the input voltage is less than the standard, remove the
ECU and check the wiring between these connectors.
○Disconnect the ECU and sensor connectors.
Wiring Connection
ECU Connector [A] ←→ Throttle Sensor Connector [B]BL lead (ECU terminal 10)
BR/BK lead (ECU terminal 28)

If the wiring is good, check the ECU for its ground andpower supply (see ECU Power Supply Inspection).

FUEL SYSTEM (DFI) 3-45
Main Throttle Sensor (Service Code 11)
Main Throttle Sensor Output Voltage Inspection

the output voltage at the main throttle sensor• Measurein the same way as input voltage inspection, Note the•following.
Disconnect the main throttle sensor connector and connect the harness adapter [A] between these connectors.
Special Tool - Throttle Sensor Harness Adapter: 57001-1538

the engine and warm it up thoroughly.
• StartCheck
idle speed to ensure the throttle opening is correct.
•
Idle Speed
Standard:•••

1 300 ±50 r/min (rpm)

If the idle speed is out of the specified range, adjust it(see Idle Speed Inspection in the Periodic Maintenancechapter).
Turn off the ignition switch.
Measure the output voltage of the sensor with the engine
stopped, and with the connector joined.
Turn the ignition switch ON.
Main Throttle Sensor Output Voltage
Connections to Adapter
Meter (+) → R (sensor Y/W) lead
Meter (–) → W (sensor BR/BK) lead
Standard:
1.073 ∼ 1.077 V DC (at idle throttle opening)
4.29 ∼ 4.49 V DC (at full throttle opening)

If the output voltage is out of the standard, inspect themain throttle sensor resistance.
If the output voltage is normal, check the wiring for continuity.
Wiring Connection
ECU Connector [A] ←→ Throttle Sensor Connector [B]Y/W lead (ECU terminal 7)
BR/BK lead (ECU terminal 28)

If the wiring is good, check the ECU for its ground andpower supply (see ECU Power Supply Inspection).

3-46 FUEL SYSTEM (DFI)
Main Throttle Sensor (Service Code 11)
Main Throttle Sensor Resistance Inspection

the ignition switch OFF.
• TurnDisconnect
the main throttle sensor connector.
• Connect a digital• connector [B]. meter [A] to the main throttle sensor• Measure the main throttle sensor resistance.
Main Throttle Sensor ResistanceConnections:
BL lead [C] ←→ BR/BK lead [D]Standard:

4 ∼ 6 kΩIf the reading is out of the range, replace the throttle bodyassy.
If the reading is within the range, but the problem still
exists, replace the ECU (see ECU Removal/Installation).

Main Throttle Sensor Circuit

1. ECU
2. Water-proof Joint E
3. Water-proof Joint D
4. Main Throttle Sensor

FUEL SYSTEM (DFI) 3-47
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.

Inlet Air Pressure Sensor Removal• Remove:
Left Upper Inner Fairing (see Upper Inner Fairing Re••

moval in the Frame chapter)
Disconnect the inlet air pressure sensor connector [A] andthe vacuum hose.
Pull up the inlet air pressure sensor [B].

Inlet Air Pressure Sensor Installation• Install:
Vacuum Hose

Inlet Air Pressure Sensor

Inlet Air Pressure Sensor Input Voltage Inspection
NOTE○Be sure the battery is fully charged.
○The inspection is the same as “Input Voltage Inspection”
of the main throttle sensor.

the ignition switch OFF.
• TurnRemoveECU (see ECU Removal). Do not disconnect• the ECU theconnectors.
a digital voltmeter [A] to the connector [B] with• Connect
the needle adapter set.
Special Tool - Needle Adapter Set: 57001-1457

the input voltage with the engine stopped, and• Measurewith the connectors joined.
• Turn the ignition switch ON.
Inlet Air Pressure Sensor Input Voltage
Connections to ECUMeter (+) → BL lead (terminal 10)
Meter (–) → BR/BK lead (terminal 28)
Standard:

4.75 ∼ 5.25 V DC

If the reading is within the standard range, check the sensor output voltage.
If the reading is less than the standard range, remove the
ECU and check the wiring between these connectors.
If the wiring is good, check the ECU for its ground andpower supply (see ECU Power Supply Inspection).

3-48 FUEL SYSTEM (DFI)
Inlet Air Pressure Sensor (Service Code 12)
Inlet Air Pressure Sensor Output Voltage
Inspection
NOTE○The output voltage changes according to the local atmospheric pressure.

the output voltage at the ECU in the same way• Measureas input voltage inspection. Note the following.
Inlet Air Pressure Sensor Output Voltage
Connections to ECUMeter (+) → Y/BL lead (terminal 8)
Meter (–) → BR/BK lead (terminal 28)
Usable Range:

3.74 ∼ 4.26 V DC at the standard
atmospheric pressure (101.32 kPa,
76 cmHg abs.)

the ignition switch OFF.
• TurnIf the output voltage is within the usable range, check the
ECU for its ground, and power supply (see ECU Power
Supply Inspection).
If the output voltage is out of the usable range, remove
the fuel tank and check the wiring. If the output voltage is
4.8 V, the ECU is normal.
If the wiring is good, check the sensor for various vacuum.
If the output voltage for various vacuum is normal, check
the ECU for its ground, and power supply (see ECUPower Supply Inspection).
Remove the inlet air pressure sensor [A] and disconnect
the vacuum hose from the sensor.
○Do not disconnect the sensor connector.
Connect an auxiliary hose [B] to the inlet air pressure sensor.
Temporarily install the inlet air pressure sensor.
○Connect a commercially available digital meter [C], vacuum gauge [D], the fork oil level gauge [E] and the harness adapter to the inlet air pressure sensor.

•••

Special Tools - Fork Oil Level Gauge: 57001-1290
Sensor Harness Adapter: 57001-1561
Inlet Air Pressure Sensor Output Voltage
Connection to Adapter
Meter (+) → G (sensor Y/BL) lead
Meter (–) → BK (sensor BR/BK) lead

○Turn the ignition switch ON.
○Measure the inlet air pressure sensor output voltage from various vacuum readings, while pullingthe handle of the fork oil level gauge.
○Check the inlet air pressure sensor output voltage, using the following formula and chart.
Suppose:Pg: Vacuum Pressure (gauge) to Sensor
Pl: Local Atmospheric Pressure (absolute) measured by a barometer
Pv: Vacuum Pressure (absolute) to Sensor
Vv: Sensor Output Voltage (V)FUEL SYSTEM (DFI) 3-49
Inlet Air Pressure Sensor (Service Code 12)
then
Pv = Pl – Pg
For example, suppose the following data is obtained:
Pg = 8 cmHg (Vacuum gauge reading)
Pl = 70 cmHg (Varometer reading)
Vv = 3.2 V (Digital volt meter reading)then
Pv = 70 – 8 = 62 cmHg (Abs.)
Plot this Pv (62 cmHg) at a point [1] on the chart and draw a vertical line through the point. Then, you
can get the usable range [2] of the sensor output voltage.
Usable range = 3.04 ∼ 3.49 V
Plot Vv (3.2 V) on the vertical line. → Point [3].
Results: In the chart, Vv is within the usable range and the sensor is normal.

Pv = 24 ∼ 55 cmHg

3-50 FUEL SYSTEM (DFI)
Inlet Air Pressure Sensor (Service Code 12)
Pv = 55 ∼ 86 cmHg

ID: IdlingPs: Standard Atmospheric Pressure (Absolute)
Pv: Throttle Vacuum Pressure (Absolute)
ST: Standard of Sensor Output Voltage (V)TO: Throttle Full Open
UR: Usable Range of Sensor Output Voltage (V)Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading)FUEL SYSTEM (DFI) 3-51
Inlet Air Pressure Sensor (Service Code 12)
Inlet Air Pressure Sensor Circuit

1. ECU
2. Water-proof Joint E
3. Water-proof Joint D
4. Inlet Air Pressure Sensor

3-52 FUEL SYSTEM (DFI)
Inlet Air Temperature Sensor (Service Code 13)
Inlet Air Temperature Sensor Removal/Installation
CAUTION
Never drop the sensor, especially on a hard surface.
Such a shock to the sensor can damage it.
the fuel tank (see Fuel Tank Removal).
• Remove
Disconnect• ture sensor.the connector [A] from the inlet air temperathe screw [B].
• Remove
Pull
out
the
air temperature sensor [C].
• Put the inletinlet
airtemperature
sensor into the air cleaner• housing.
• Tighten the screw securely.

Inlet Air Temperature Sensor Output Voltage
Inspection
NOTE○Be sure the battery is fully charged.
○The output voltage changes according to the inlet air
temperature.
the ECU (see ECU Removal). Do not disconnect• Remove
the ECU connectors.
a digital voltmeter to the ECU connector, using• Connect
needle adapter set.
Special Tool - Needle Adapter Set: 57001-1457

the sensor output voltage with the engine• Measure
stopped and the connector joined.
• Turn the ignition switch ON.
Inlet Air Temperature Sensor Output Voltage
Connections to ECU Connector
Meter (+) → Y lead (terminal 26)
Meter (–) → BR/BK lead (terminal 28)
Standard:

About 2.25 ∼ 2.50 V at inlet air temperature
20°C (68°F)

the ignition switch OFF.
• TurnIf the output voltage is out of the standard, remove thefuel tank and check the wiring. And if the output voltage
is 4.8 V, the ECU is normal.

•

If the output voltage is within the standard, check the ECU
for its ground, and power supply (see ECU Power Supply
Inspection).
If the wiring is good, check the sensor resistance.
Remove the needle adapter set, and apply silicone
sealant to the seals of the connector for waterproofing.
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

FUEL SYSTEM (DFI) 3-53
Inlet Air Temperature Sensor (Service Code 13)
Inlet Air Temperature Sensor Resistance
Inspection

the inlet air temperature sensor (see Inlet Air• Remove
Temperature Sensor Removal/Installation).
the sensor [A] in a container of machine oil so• Suspendthat the heat-sensitive portion is submerged.
a thermometer [B] with the heat-sensitive por• Suspend
tion [C] located in almost the same depth with the sensor.

NOTE○The sensor and thermometer must not touch the container side or bottom.
the container over a source of heat and gradually• Placeraise the temperature of the oil while stirring the oil gently•

for even temperature.
Using a digital meter, measure the internal resistanceof the sensor across the terminals at the temperatures
shown in the table.
Inlet Air Temperature Sensor ResistanceStandard:
5.4 ∼ 6.6 kΩ at 0°C (68°F)
0.29 ∼ 0.39 kΩ at 80°C (176°F)

If the measurement is out of the range, replace the sensor.
If the measurement is within the specified, replace the
ECU.

Inlet Air Temperature Sensor Circuit

1. ECU
2. Inlet Air Temperature Sensor
3. Water-proof Joint E

3-54 FUEL SYSTEM (DFI)
Water Temperature Sensor (Service Code 14)
Water Temperature Sensor Removal/Installation
CAUTION
Never drop the sensor, especially on a hard surface.
Such a shock to the sensor can damage it.
the coolant (see Coolant Change in the Periodic• Drain
Maintenance chapter).
the left center fairing (see Center Fairing Re• Remove
moval in the Frame chapter).
the sensor connector [A], and unscrew the• Disconnect
water temperature sensor [B].
Torque - Water Temperature Sensor: 12 N·m (1.2 kgf·m, 106
in·lb)

grease to new O-ring on the water temperature sen• Applysor.
the engine with coolant and bleed the air from the cool• Filling system (see Coolant Change in the Periodic Maintenance chapter).

Water Temperature Sensor Output Voltage
Inspection
NOTE○Be sure the battery is fully charged.

the ECU (see ECU Removal). Do not disconnect• Removethe connectors.
a digital voltmeter [A] to the ECU connector [B]• Connectwith the needle adapter set.
Special Tool - Needle Adapter Set: 57001-1457

the sensor output voltage with the engine• Measure
stopped and the connector joined.
• Turn the ignition switch ON.
Water Temperature Sensor Output Voltage
Connections to ECUMeter (+) → O lead (terminal 20)
Meter (–) → BR/BK lead (terminal 28)
Standard:

About 2.80 ∼ 2.97 V at 20°C (68°F)

NOTE○The output voltage changes according to the coolant
temperature in the engine.

the ignition switch OFF.
• TurnIf the output voltage is within the standard, check the ECU•

for its ground, and power supply (see ECU Power Supply
Inspection).
If the output voltage is out of the standard, check thewiring. And if the output voltage is 4.8 V, the ECU is normal.
If the wiring is good, check the water temperature sensor
resistance.
Remove the needle adapter set, and apply silicone
sealant to the seals of the connector for waterproofing.
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

FUEL SYSTEM (DFI) 3-55
Water Temperature Sensor (Service Code 14)
Water Temperature Sensor Circuit

1. ECU
2. Water Temperature Sensor
3. Water-proof Joint E
4. Meter Unit

Water Temperature Sensor Resistance Inspection

the water temperature sensor (see Water Tem• Remove
perature Sensor Removal/Installation).
to the Water Temperature Sensor Inspection in the• Refer
Electrical System chapter.

3-56 FUEL SYSTEM (DFI)
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 the crankshaft sensor. In this case, turn off the ignition switch and turn it on again to enter the Dealer 2 mode.
In this mode, the system tells all the troubles which the DFI
system had in both static and dynamic conditions.

Crankshaft Sensor Removal/Installation

to the Crankshaft Sensor Removal/Installation in• Referthe Electrical System chapter.

Crankshaft Sensor Inspection○The crankshaft sensor has no power source, and when••the engine stops, the crankshaft sensor generates no signals.
Crank the engine and measure the peak voltage of the
crankshaft sensor (see Crankshaft Sensor Inspection in
the Electrical System) in order to check the sensor.
Check the wiring for continuity, using the following diagram.

Crankshaft Sensor Circuit

1. ECU
2. Crankshaft Sensor

FUEL SYSTEM (DFI) 3-57
Speed Sensor (Service Code 24, 25)
Speed Sensor Removal/Installation

to the Speed Sensor Removal/Installation in the• Refer
Electrical System chapter.

Speed Sensor Inspection

to the Speed Sensor Inspection in the Electrical• Refer
System chapter.

Speed Sensor Input Voltage Inspection
NOTE○Be sure the battery is fully charged.

the ignition switch OFF.
• TurnRemovethe left center fairing (see Center Fairing Re• moval in the
Frame chapter).
Disconnect
thesensor connector and connect the• harness adapterspeed[A] between the harness connector and•speed sensor connector.
Connect a digital meter to the harness adapter leads.
Special Tool - Throttle Sensor Setting Adapter #1: 57001-1400

the sensor input voltage with the engine• Measure
stopped, and with the connector joined.
• Turn the ignition switch ON.
Speed Sensor Input Voltage
Connection to Adapter
Meter (+) → BL (sensor P) lead [C]Meter (−) → BK (sensor BK/Y) lead [D]Standard:•

About 9 ∼ 11 V DC at Ignition Switch ON

If the reading is out of the range, check the wiring (seewiring diagram in this section), and meter (see Electronic
Combination Meter Unit Inspection in the Electrical System chapter).
If the reading is good, check the output voltage.
Turn the ignition switch OFF.

Speed Sensor Output Voltage Inspection

this inspection, inspect the input voltage (see• Before
Speed Sensor Input Voltage Inspection).

NOTE○Be sure the battery is fully charged.

• Turn the ignition switch OFF.

3-58 FUEL SYSTEM (DFI)
Speed Sensor (Service Code 24, 25)
the speed sensor connector and connect the• Disconnect
harness adapter [A] between the harness connector and•speed sensor connector.
Connect a digital meter to the harness adapter leads.
Special Tool - Throttle Sensor Setting Adapter #1: 57001-1400

the sensor output voltage with the engine• Measure
stopped, and with the connector joined.
• Turn the ignition switch ON.
Speed Sensor Output Voltage at Sensor
Connections to Adapter
Meter (+) → Y/W (sensor LG/R) lead [C]Meter (–) → BK (sensor BK/Y) lead [D]Standard:

About 0.05 ∼ 0.07 V DC

NOTE

○If you rotate the engine sprocket, the output voltage will
be increased.

If the reading is out of the range, check the speed sensor
operation (see Speed Sensor Inspection in the Electrical
System chapter) and the wiring to ECU (see wiring diagram in this section).
If the reading, speed sensor operation and wiring aregood, check the ECU for its ground, and power supply(see ECU Power Supply Inspection).

Speed Sensor Circuit

1. ECU
2. Speed Sensor
3. Meter Unit
4. Water-proof Joint B
5. Frame Ground
6. Joint Connector

FUEL SYSTEM (DFI) 3-59
Vehicle-down Sensor (Service Code 31)
Vehicle-down Sensor Removal
CAUTION
Never drop the down-sensor, especially on a hardsurface. Such a shock to the sensor can damage it.

• Remove:
Bolts [A]Connector and Vehicle-down Sensor [B]Vehicle-down Sensor Installation• The UP mark [A] of the sensor should face upward.
WARNING

Incorrect installation of the vehicle-down sensor
could cause sudden loss of engine power. The
rider could lose balance during certain riding situations like leaning over in a turn with the potential
for an accident resulting in injury or death. Ensurethat the down sensor is held in place by the sensor
brackets.

Vehicle-down Sensor Inspection
NOTE○Be sure the battery is fully charged.
a digital volt meter [A] to the connector [B] of the• Connect
vehicle-down sensor [C] with the needle adapter set [D].
Vehicle-down Sensor Power Source Voltage
Connections to Sensor
Meter (+) → BL lead [E]Meter (–) → BR/BK lead [F]the ignition switch ON, and measure the power• Turnsource voltage with the connector joined.
Vehicle-down Sensor Input Voltage
Standard:
4.75 ∼ 5.25 V DC

the ignition switch OFF.
• TurnIf the reading of input voltage is less than the standard,
check the ECU for its ground, power supply and wiring
shorted.
If the power source is normal, check the output voltage.

3-60 FUEL SYSTEM (DFI)
Vehicle-down Sensor (Service Code 31)
the sensor (see Vehicle-down Sensor Removal).
• Remove
Connecta digital volt meter [A] to the connector with nee• dle adapter
set [B].
Special Tool - Needle Adapter Set: 57001-1457
Vehicle-down Sensor Output Voltage
Connections to Sensor
Meter (+) → Y/G lead [E]Meter (–) → BR/BK lead [F]the sensor vertically.
• HoldTurntheswitch ON, and measure the output volt• age with ignition
the connector joined.

○Tilt the sensor 60 ∼ 70° or more [C] right or left, then holdthe sensor almost vertical with the arrow mark pointed up[D], and measure the output voltage.
Output Voltage at Sensor
Standard:
with sensor tilted 60 ∼ 70° or more rightor left: 0.65 ∼ 1.35 V
with sensor arrow mark pointed up:
3.55 ∼ 4.45 V

NOTE○If you need to test again, turn the ignition switch OFF,and then ON.

the ignition switch OFF.
• TurnRemoveneedle adapter set, and apply silicone• sealant tothe
the seals of the connector for waterproofing.
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

If the output voltage is normal, the wiring is suspect.
Check the wiring.
If the wiring is good, check the ECU for its ground andpower supply (see ECU Power Supply Inspection).
If the output voltage is out of the specified, replace thevehicle-down sensor.

FUEL SYSTEM (DFI) 3-61
Vehicle-down Sensor (Service Code 31)
Vehicle-down Sensor Circuit

1. ECU
2. Water-proof Joint E
3. Vehicle-down Sensor
4. Water-proof Joint D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 throttle body assy, especially on ahard surface. Such a shock to the sensor can damage it.

Subthrottle Sensor Input Voltage Inspection
NOTE○Be sure the battery is fully charged.

the air cleaner housing (see Air Cleaner Housing• Remove
Removal).
the ignition switch OFF.
• TurnDisconnect
subthrottle sensor connector and connect• the harnessthe
adapter [A] between these connectors.
• Connect a digital meter to the harness adapter lead.

Special Tool - Throttle Sensor Harness Adapter: 57001-1400

the sensor input voltage with the engine stopped• Measureand with the connector joined.
• Turn the ignition switch ON.
Subthrottle Sensor Input Voltage
Connections to Adapter
Meter (+) → BL (sensor BL) lead
Meter (–) → BK (sensor BR/BK) lead
Standard: 4.75 ∼ 5.25 V DC

FUEL SYSTEM (DFI) 3-63
Subthrottle Sensor (Service Code 32)
the ignition switch OFF.
• TurnIf the input voltage is normal, check the sensor output
voltage.
If the input voltage is less than the standard, remove the
ECU and check the wiring between these connectors.
○Disconnect the ECU and sensor connectors.
Wiring Connection
ECU Connector [A] ←→Subthrottle Sensor Connector [B]BL lead (terminal 10)
BR/BK lead (terminal 28)

If the wiring is good, check the ECU for its ground andpower supply (see ECU Power Supply Inspection).

Subthrottle Sensor Output Voltage Inspection

the air cleaner housing (see Air Cleaner Housing• Remove
Removal).
the output voltage at the subthrottle sensor in• Measurethe same way as input voltage inspection. Note the fol-•lowing.
Disconnect the subthrottle sensor connector and (black)connect the harness adapter [A] between these connectors.
Special Tool - Throttle Sensor Harness Adapter: 57001-1400

the output voltage of the sensor with the engine• Measure
stopped, and with the connector joined.
the ignition switch ON.
• TurnMeasurethe output voltage when the subthrottle valve is• fully opened
or completely closed by hand.
Subthrottle Sensor Output Voltage
Connections to Adapter
Meter (+) → Y (sensor BL/W) lead
Meter (–) → BK (sensor BR/BK) lead
Standard:
0.4 ∼ 0.6 V DC (at idle throttle opening)
3.625 ∼ 3.775 V DC (at full throttle opening)3-64 FUEL SYSTEM (DFI)
Subthrottle Sensor (Service Code 32)
If the output voltage is out of the standard, inspect thesubthrottle sensor resistance.
If the output voltage is normal, check the wiring for continuity.
Wiring Connection
ECU Connector [A] ←→Subthrottle Sensor Connector [B]BL/W lead (terminal 24)
BR/BK lead (terminal 28)

If the wiring is good, check the ECU for its ground andpower supply (see ECU Power Supply Inspection).

Subthrottle Sensor Resistance Inspection

the ignition switch OFF.
• TurnDisconnect
the subthrottle sensor connector.
• Connect a digitalmeter [A] to the subthrottle sensor con• nector [B].
• Measure the subthrottle sensor resistance.
Throttle Sensor ResistanceConnections: BL lead [C] ←→ BK lead [D]Standard:

4 ∼ 6 kΩIf the reading is out of the range, replace the throttle bodyassy.
If the reading is within the range, but the problem still
exists, replace the ECU (see ECU Removal/Installation).

FUEL SYSTEM (DFI) 3-65
Subthrottle Sensor (Service Code 32)
Subthrottle Sensor Circuit

1. ECU
2. Water-proof Joint E
3. Water-proof Joint D
4. Subthrottle Sensor

3-66 FUEL SYSTEM (DFI)
Oxygen Sensor-not activated (Service Code 33) (Europe Models)
Oxygen Sensor Removal/Installation

to the Oxygen Sensor Removal/Installation in the• Refer
Electrical System chapter.

Oxygen Sensor Inspection

up the engine thoroughly until the radiator fan• Warmstarts.
the ignition switch OFF.
• Turn• Remove:
Left Lower Fairing (see Lower Fairing Removal in the•

Frame chapter)
Engine Sprocket Cover (see Engine Sprocket Removal
in the Final Drive chapter)
Connect a digital voltmeter [A] to the oxygen sensor connector [B] (main harness side), using the needle adapter
set [C].
Special Tool - Needle Adapter Set: 57001-1457
Oxygen Sensor Output Voltage
Connections to Oxygen Sensor Connector
Meter (+) → BL/Y lead
Meter (−) → BR/BK leadthe air switching valve hose from the fitting.
• Remove
Installthesuitable plugs [A] on the fitting [B] and shut off• the secondary
air.

the ignition switch ON.
• Turnthe engine, and let it idle.
• StartMeasurethe output voltage of the sensor with the con• nector joined.
Oxygen Sensor Output Voltage (with Plugs)
0.7 V or moreStandard:• Next, remove the plugs from the fitting [A] with idling.

FUEL SYSTEM (DFI) 3-67
Oxygen Sensor-not activated (Service Code 33) (Europe Models)the output voltage of the sensor with the con• Measurenector joined.
Oxygen Sensor Output Voltage (without Plugs)
0.2 V or lessStandard:

If the reading is within range (with plugs: 0.7 V or more,
without plugs: 0.2 V or less), the oxygen sensor is good.
If the reading is without range, replace the oxygen sensor(see Oxygen Sensor Removal/Installation in the Electrical
System chapter).

Oxygen Sensor Circuit

1. ECU
2. Oxygen Sensor
3. Water-proof Joint E
4. Water-proof Joint D
5. Oxygen Sensor Heater Fuse 10 A
6. Main Fuse 30 A
7. Battery
8. Frame Ground
9. Joint Connector

3-68 FUEL SYSTEM (DFI)
Stick Coils #1, #2: (Service Code 51, 52)
Stick Coil #1: Service Code 51
Stick Coil #2: Service Code 52

Stick Coil Removal/Installation
CAUTION
Never drop the stick coils, especially on a hard surface. Such a shock to the stick coil can damage it.
to the Stick Coil (Ignition Coil together with Spark• Refer
Plug Cap) Removal/Installation in the Electrical System
chapter.

Stick Coil Input Voltage Inspection
NOTE○Be sure the battery is fully charged.
the ignition switch OFF.
• Turnthe ECU (see ECU Removal). Do not disconnect• Remove
the ECU connector.
a digital voltmeter [A] as shown, with the needle• Connect
adapter set [B].

○Measure the input voltage to each primary winding of the•ignition coils with the engine stopped, and with the connectors joined.
Turn the ignition switch ON.
Stick Coil Input Voltage at ECU
Connections for Stick Coil #1
Meter (+) → BK lead (terminal 43)
Meter (–) → BK/Y lead (terminal 51)
Connections for Stick Coil #2
Meter (+) → BK/G lead (terminal 52)
Meter (–) → BK/Y lead (terminal 51)
Input Voltage at ECU
Standard:
Battery Voltage (12.8 V or more)

If the reading is out of the standard, check the wiring (seenext wiring diagram).
If the reading is good, the input voltage is normal. Crankthe engine, and check the peak voltage of the stick coils(see Stick Coil Primary Peak Voltage in the Electrical System chapter) in order to check the primary coils.

FUEL SYSTEM (DFI) 3-69
Stick Coils #1, #2: (Service Code 51, 52)
Stick Coil Circuit

1. ECU
2. Water-proof Joint C
3. Stick Coils
4. Engine Stop Switch
5. Ignition Switch
6. Ignition Fuse 10 A
7. Main Fuse 30 A
8. Battery
9. Frame Ground
10. Joint Connector

3-70 FUEL SYSTEM (DFI)
Radiator Fan Relay (Service Code 56)
Radiator Fan Relay Removal/Installation

fan relay is built in the relay box.
• Radiator
Removerelay box (see Relay Box Removal in the• Electrical the
System chapter).

Radiator Fan Relay Inspection

to the Relay Circuit Inspection in the Electrical Sys• Refertem chapter.
the relay box and ECU (see ECU Removal). Do• Remove
not disconnect the relay box and ECU connectors. Check
the wiring for continuity, using the following diagram.
If wiring and radiator fan relay are good, check the ECU
for its ground, and power supply (see ECU Power Supply
Inspection). If the ground and power supply are good,
replace the ECU (see ECU Removal/Installation).

Radiator Fan Relay Circuit

1. ECU
2. Water-proof Joint C
3. Water-proof Joint B
4. Radiator Fan Fuse 15 A
5. Relay Box
6. Radiator Fan Relay
7. Main Fuse 30 A
8. Battery
9. Frame Ground
10. Joint Connector

FUEL SYSTEM (DFI) 3-71
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 precisionat the factory.
Never drop the throttle body assy, especially on ahard surface. Such a shock to the actuator candamage it.

Subthrottle Valve Actuator Audible Inspection
NOTE○Be sure the battery is fully charged.

the ignition switch ON and ensure that the actuator• Turnvalves open and close (make light sounds) several times•

within seconds, and then close at the idle throttle opening
position.
Turn the ignition switch OFF.
If the actuator does not work as described above, do thevisual inspection.

Subthrottle Valve Actuator Inspection

the air cleaner housing (see Air Cleaner Housing• Remove
Removal).
the ignition switch ON.
• TurnCheck
to see that all the subthrottle valves [A] open and• close smoothly.
If the subthrottle valves do not operate, check the actuatorinternal resistance (see Subthrottle Valve Actuator Resistance Inspection).

Subthrottle Valve Actuator Resistance Inspection

the ignition switch OFF.
• Turnthe air cleaner housing (see Air Cleaner Housing• Remove
Removal).
• Disconnect the subthrottle valve actuator connector [A].

a digital meter to the subthrottle valve actuator• Connectconnector [A].
• Measure the subthrottle valve actuator resistance.
Subthrottle Valve Actuator ResistanceConnections: BK lead [1] ←→ P lead [2]G lead [3] ←→ W/BL lead [4]Standard:

About 5.5 ∼ 7.5 kΩ

Special Tool - Hand Tester: 57001-1394

If the reading is out of the range, replace the actuatoralong with the throttle body assy.
If the reading is within the range, check the input voltage(see Subthrottle Valve Actuator Input Voltage Inspection).

3-72 FUEL SYSTEM (DFI)
Subthrottle Valve Actuator (Service Code 62)
Subthrottle Valve Actuator Input Voltage
Inspection
NOTE○Be sure the battery is fully charged.

the ignition switch OFF.
• TurnConnect
peak voltage adapter [A] and a digital meter• [B] to thethe
connector [C], using the needle adapter set [D].
Special Tools - Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
Brand: KOWA SEIKI
Needle Adapter Set: 57001-1457
Subthrottle Valve Actuator Input Voltage
Connections to Harness Connector(I)

Meter (+) → BK/BL lead [1]Meter (–) → P lead [2](II)Meter (+) → W/BL lead [3]Meter (–) → G/Y lead [4]the actuator input voltage with the engine• Measure
stopped, and with the connector joined.
• Turn the ignition switch ON.
Input Voltage at Actuator
Standard:
About 8.5 ∼ 10.5 V DC

If the reading is within the standard but the actuator
doesn’t operate, replace it.
If the reading is out of the range, check the wiring to ECU(see wiring diagram in this section).
If the wiring is good, check the ECU for its ground andpower supply (see ECU Power Supply Inspection).

Subthrottle Valve Actuator Circuit

1. ECU
2. Subthrottle Valve Actuator

FUEL SYSTEM (DFI) 3-73
Air Switching Valve (Service Code 64)
Air Switching Valve Removal/Installation

to the Air Switching Valve Removal/Installation in• Referthe Engine Top End chapter.

Air Switching Valve Inspection

to the Air Switching Valve Operation Test/Unit Test
• Referin the Electrical System chapter.
the fuel tank (see Fuel Tank Removal) and check• Remove
the wiring continuity, using the following diagram.

Air Switching Valve Circuit

1. ECU
2. Air Switching Valve
3. Water-proof Joint C
4. Ignition Switch
5. Water-proof Joint A
6. ECU Fuse 15 A
7. ECU Main Relay
8. Relay Box
9. Main Fuse 30 A
10. Battery
11. Frame Ground
12. Joint Connector

3-74 FUEL SYSTEM (DFI)
Oxygen Sensor Heater (Service Code 67) (Europe Models)
Oxygen Sensor Heater Removal/Installation
The oxygen sensor heater is built in the oxygen sensor.
So, the heater itself can not be removed. Remove the oxygen sensor (see Oxygen Sensor Removal in the Electrical
System chapter).

Oxygen Sensor Heater Inspection

the engine sprocket cover (see Engine Sprocket• Remove
Removal in the Final Drive chapter).
• Disconnect the oxygen sensor lead connector [A].

hand tester [A] to the × 1 Ω range and connect it• toSetthetheterminals
in the oxygen sensor lead connector [B].
Black [C]Black [D]Special Tool - Hand Tester: 57001-1394
Oxygen Sensor ResistanceStandard:
11.7 ∼ 14.5 Ω at 20°C (68°F)

If the tester reading is not as specified, replace the oxygen
sensor with a new one.
If the tester reading is specified, check the power source
voltage Inspection.

NOTE○Be sure the battery is fully charged.

a digital voltmeter [A] to the oxygen sensor con• Connect
nector [B], using the needle adapter [C].
Special Tool - Needle Adapter Set: 57001-1457

the power source voltage with the engine• Measure
stopped, and with the oxygen sensor connector joined.
Oxygen Sensor Power Source Voltage
Connections to Oxygen Sensor Connector
Tester (+) → W/Y lead [D]Tester (−) → Battery (−) Terminal [E]Standard:

Battery Voltage (12.8 V or more)

Oxygen Sensor [F]
If the reading is incorrect, check the following.
Battery
Main Fuse 30 A
Oxygen Sensor Heater Fuse 10 A
If the reading is good, the power source voltage is normal,
Inspect the Red/Black lead between the oxygen sensor
connector and the ECU for continuity, using the following
diagram.
If the wiring is good, inspect the ECU for its ground, andpower supply (see ECU Power Supply Inspection). If theground and power supply are good, replace the ECU (seeECU Removal/Installation).

FUEL SYSTEM (DFI) 3-75
Oxygen Sensor Heater (Service Code 67) (Europe Models)
Oxygen Sensor Circuit

1. ECU
2. Oxygen Sensor
3. Water-proof Joint E
4. Water-proof Joint D
5. Oxygen Sensor Heater Fuse 10 A
6. Main Fuse 30 A
7. Battery
8. Frame Ground
9. Joint Connector

3-76 FUEL SYSTEM (DFI)
Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Europe Models)
Oxygen Sensor Removal/Installation

to the Oxygen Sensor Removal/Installation in the• Refer
Electrical System chapter.

Oxygen Sensor Inspection

up the engine thoroughly until the radiator fan• Warmstarts.
the ignition switch OFF.
• Turn• Remove:
Left Lower Fairing (see Lower Fairing Removal in the•

Frame chapter)
Engine Sprocket Cover (see Engine Sprocket Removal
in the Final Drive chapter)
Connect a digital voltmeter [A] to the oxygen sensor connector [B] (main harness side), using the needle adapter
set [C].
Special Tool - Needle Adapter Set: 57001-1457
Oxygen Sensor Output Voltage
Connections to Oxygen Sensor Connector
Meter (+) → BL/Y lead
Meter (−) → BR/BK leadthe air switching valve hose from the fitting.
• Remove
Installthesuitable plugs [A] on the fitting [B] and shut off• the secondary
air.

the ignition switch ON.
• Turnthe engine, and let it idle.
• StartMeasurethe output voltage of the sensor with the con• nector joined.
Oxygen Sensor Output Voltage (with Plugs)
0.7 V or moreStandard:• Next, remove the plugs from the fitting [A] with idling.

FUEL SYSTEM (DFI) 3-77
Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Europe Models)the output voltage of the sensor with the con• Measurenector joined.
Oxygen Sensor Output Voltage (without Plugs)
0.2 V or lessStandard:

If the reading is within range (with plugs: 0.7 V or more,
without plugs: 0.2 V or less), the oxygen sensor is good.
If the reading is without range, inspect the engine and fuelsupply system.
If the engine and fuel supply system good, replace theoxygen sensor (see Oxygen Sensor Removal/Installationin the Electrical System chapter).

Oxygen Sensor Circuit

1. ECU
2. Oxygen Sensor
3. Water-proof Joint E
4. Water-proof Joint D
5. Oxygen Sensor Heater Fuse 10 A
6. Main Fuse 30 A
7. Battery
8. Frame Ground
9. Joint Connector

3-78 FUEL SYSTEM (DFI)FI Indicator Light (LED)
Inspection Flow ChartFUEL SYSTEM (DFI) 3-79
FI Indicator Light (LED)FI Indicator Light (LED) Inspection

the meter unit (see Meter Unit Removal in the• Remove
Electrical System chapter).
two auxiliary leads, supply battery power to the FI• Using
indicator light (LED) [A].
12 V Battery [B]FI Indicator Light (LED) Check
Connector:
Meter Connector [C] (disconnected)
Connection:

W/BK Lead Terminal [10] of the Meter→ Battery (+) Terminal
BR/R Lead Terminal [6] of the Meter →Battery (–) Terminal

Criterion:

The light (LED) should light.

If the light (LED) does not go on, replace the meter unit
(see Meter Unit Removal/Installation in the Electrical System chapter).

FI Indicator Light (LED) Circuit

1. ECU
2. Water-proof Joint C
3. Ignition Switch
4. Meter Unit
5. Ignition Fuse 10 A
6. Main Fuse 30 A
7. Battery
8. Frame Ground
9. Joint Connector

3-80 FUEL SYSTEM (DFI)ECU
CAUTION
Never drop the ECU, especially on a hard surface.
Such a shock to the ECU can damage it.

ECU Removal• Remove:
Seat (see Seat Removal in the Frame chapter)
Grab Rails [A] (see Seat Cover Removal in the Frame
chapter)
Center Seat Cover [B] (see Seat Cover Removal in the
Frame chapter)
Seat Covers [C] (see Seat Cover Removal in the Frame
chapter)
Rear Fender Rear Bolts [D]• Pull down the rear fender rear [A].

the ECU bracket bolts [A].
• RemoveTake
theout along with the harness.
• DisconnectECUthe[B]ECU
lead connectors.
•

ECU Installation• Fit [A] the bracket on the ECU as shown.

FUEL SYSTEM (DFI) 3-81
ECU
ECU Power Supply Inspection

inspect the terminals [A] of the ECU connectors.
• Visually
If the connector is clogged with mud or dust, blow it off
with compressed air.
Replace the main harness if the terminals of the main
harness connectors are cracked, bent, or otherwise damaged.
Replace the ECU if the terminals of the ECU connectors
are cracked, bent, or otherwise damaged.
the ECU connectors [A] connected, check the fol• Withlowing ground lead for continuity with the ignition switch
OFF, using a tester and needle adapter set.
Battery [B]Tester [C]Special Tool - Needle Adapter Set: 57001-1457
ECU Grounding Inspection
34, 50, or 51 (BK/Y)←→ Battery (–) Terminal: 0 Ω
Terminal
Engine Ground←→ Battery (–) Terminal: 0 Ω

If no continuity, check the connector, the engine ground
lead, or main harness, and repair or replace them if necessary.
the ECU power source voltage with a digital meter• Check[A].

○Position the terminal in accordance with terminal numbersof ECU connectors [B] in this chapter figure.
Battery [C]ECU Power Source Inspection
Meter Connections:
Between Terminal 16 (BR/W) and Battery (–) Terminal
Between Terminal 17 (W/BK) and Battery (–) Terminal
Ignition Switch OFF:
Terminal 16 (BR/W): 0 V
Terminal 17 (W/BK): Battery Voltage (12.8 V or more)
Ignition Switch ON:
Both: Battery Voltage (12.8 V or more)

If the meter does not read as specified, check the following:
Main Fuse 30 A (see Fuse Inspection in the Electrical
System chapter)
ECU Fuse 15 A (see Fuse Inspection in the Electrical
System chapter)
ECU Main Relay (see Relay Circuit Inspection in theElectrical System chapter)
Power Source Wiring (see wiring diagram below)
If the inspection checks good, the ECU is damaged. Replace the ECU (see ECU Removal/Installation). The ECU
itself cannot be checked or serviced.

3-82 FUEL SYSTEM (DFI)ECUECU Power Source Circuit

1. ECU
2. Water-proof Joint C
3. Ignition Switch
4. Water-proof Joint A
5. ECU Main Fuse 15 A
6. ECU Main Relay
7. Relay Box
8. Main Fuse 30 A
9. Battery
10. Frame Ground
11. Joint Connector

FUEL SYSTEM (DFI) 3-83
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 orderto know symptom well.
○Be sure the battery is fully charged.

the fuel tank (see Fuel Tank Removal).
• Remove
Removethe left center fairing (see Center Fairing Re• moval in the
Frame chapter).
sure to place a piece of cloth around the fuel hose joint• Be
and the delivery pipe.
a minus screw driver [A] into the slit on the joint lock
• Insert[B].
the driver to disconnect the joint lock.
• Turn• Remove the fuel hose [C].

WARNINGBe prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
When the fuel hose is disconnected, fuel spills out
from the hose and the pipe because of residualpressure. Cover the hose connection with a pieceof clean cloth to prevent fuel spillage.
the fuel pressure gauge adapter [A] and fuel hoses• Install
between the fuel pump outlet pipe [B] and the delivery•

pipe [C].
Connect the pressure gauge [D] to the fuel pressuregauge adapter.
Special Tools - Oil Pressure Gauge, 5 kgf/cm²: 57001-125
Fuel Pressure Gauge Adapter: 57001-1593
Fuel Hose: 57001-1607

WARNING
Do not try to start the engine with the fuel hoses
disconnected.
install the fuel tank [E].
• Temporarily,
Clamps [F]3-84 FUEL SYSTEM (DFI)
Fuel Line
the ignition switch ON. The fuel pump will turn for 3• Turnseconds, and then stop.

CAUTION
Do not drive the fuel pump without the fuel in thefuel tank.

• Measure the fuel pressure with the engine stopped.
Fuel Pressure
Right after Ignition Switch ON, with pump running:Standard:

323 kPa (3.3 kgf/cm², 47 psi)

After 3 seconds from Ignition Switch ON, with pumpstopped:Standard:

265 kPa (2.7 kgf/cm², 38 psi) (residual
fuel pressure)
The system should hold the residualpressure about 30 seconds.

the engine, and let it idle.
• StartMeasurethe fuel pressure with the engine idling.
•
Fuel Pressure (Idling)Standard:
333 kPa (3.4 kgf/cm², 48 psi)

NOTE

○The gauge needle will fluctuate. Read the pressure at

the average of the maximum and minimum indications.

••

If the fuel pressure is normal, the fuel circulation system(fuel pump, pressure regulator, and fuel passage) is nofaults. Check the DFI electronic control system (injectors,
sensors, crankshaft sensor, and ECU).
If the fuel pressure is much lower than specified, checkthe following.
Fuel Line Leakage
Fuel Pump Operation (check the sound of the pump)Amount of Fuel Flow (see Fuel Flow Rate Inspection)
If the fuel pressure is much higher than specified, checkthe following.
Delivery Pipe Clogging
Injector Clogging
Remove the fuel pressure gauge and adapter.
Install the removed parts (see appropriate chapters).

FUEL SYSTEM (DFI) 3-85
Fuel Line
Fuel Flow Rate Inspection
NOTE○Be sure the battery is fully charged.
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 flameor sparks; this includes any appliance with a pilot
light. Do not smoke. Turn the ignition switch OFF.
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
the ignition switch, and engine stop switch OFF.
• TurnWait
until
engine cools down.
• Prepare atheplastic
hose of the inside diameter 7.5 mm• (0.30 in.) and a measuringcylinder.
Remove
the
fuel
tank
bolt
(see
Fuel Tank Removal).
•
the fuel tank cap [A] to lower the pressure in the• Opentank.

WARNINGBe prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
When the fuel hose is disconnected, fuel spills out
from the hose and the pipe because of residualpressure. Cover the hose connection with a pieceof clean cloth to prevent fuel spillage.
the plastic hose [A] to the fuel pump outlet pipe.
• Connect
Securethehose with a clamp [B].
• Run the otherplastic
sideof the plastic hose into the measuring• cylinder [C].

WARNING
Wipe off spilled out fuel immediately.
Be sure to hold the measuring cylinder vertical.
install the fuel tank and close the fuel tank
• Temporarily
cap.
the engine stopped, turn the ignition switch ON. The• Withfuel pump should operate for 3 seconds, and then shouldstop. Repeat this several times until the plastic hose isfilled with fuel.

3-86 FUEL SYSTEM (DFI)
Fuel LineCAUTION
Do not drive the fuel pump without the fuel in thefuel tank.
the discharge for 3 seconds with the plastic hose
• Measurefilled with fuel.

○Repeat this operation several times.

Amount of Fuel Flow
Standard:
60 mL or more for 3 seconds••

If the fuel flow is much less than the specified, check thebattery condition (see Charging Condition Inspection in
the Electrical System chapter). If the battery is good, replace the fuel pump (see Fuel Pump Removal/Installation).
After inspection, install the fuel tank (see Fuel Tank Installation).
Start the engine and check for fuel leakage.

FUEL SYSTEM (DFI) 3-87
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 source of flameor sparks; this includes any appliance with a pilot
light. Do not smoke. Turn the ignition switch OFF.
Disconnect the battery (–) terminal.
To make fuel spillage minimum, draw the fuel out
from the fuel tank when the engine is cold. Be
prepared for fuel spillage; any spilled fuel must becompletely wiped up immediately.
the fuel out from the fuel tank with a commercially• Draw
available electric pump.
the fuel tank (see Fuel Tank Removal).
•○Remove
Be careful of fuel spillage from the fuel tank since fuel still•••

remains in the fuel tank and fuel pump. Plug the fuel pipeof the fuel tank.
Turn the fuel tank upside down.
Remove:Fuel Pump Bolts [A]Fuel Pump [B] and gasket
Discard the fuel pump gasket.

CAUTION
Do not pull the lead of the fuel pump. If they are
pulled, the lead terminals may be damaged.

Fuel Pump Installation

dirt or dust from the fuel pump [A] by lightly ap• Remove
plying compressed air.

3-88 FUEL SYSTEM (DFI)
Fuel Pump• Replace the fuel pump gasket [A] with a new one.

a non-permanent locking agent to the threads of• Apply
the fuel pump bolts.
the fuel pump bolts to a snug fit, tighten them
• Tighten
alternating diagonally.
Torque - Fuel Pump Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

the pump bolts again alternating diagonally to• Tighten
check the tightness.

Fuel Pump Operation Inspection
NOTE○Be sure the battery is fully charged.
○Just listen to the pump sound in the fuel tank to confirm
pump operation.

the ignition switch ON and make sure that the fuel• Turnpump operates (make light sounds) for 3 seconds, and•then stops.
Turn the ignition switch OFF.
If the pump does not work as described above, inspect
the operating voltage.

Fuel Pump Operating Voltage Inspection
NOTE○Be sure the battery is fully charged.

the ignition switch OFF.
• Turnthe left side cover (see Side Cover Removal in• Remove
the Frame chapter).

FUEL SYSTEM (DFI) 3-89
Fuel Pump
the hand tester (25 V DC) to the fuel pump con• Connect
nector [A] with needle adapter set.
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 the ignition switch ON.
○The tester needle should indicate battery voltage for 3
seconds, and then 0 V.

•

Pump Operating Voltage at Pump
Connections to Pump Connectors
Tester (+) → W/R Lead
Tester (–) → BK/Y Lead
Operating Voltage at Pump Connector
Standard:

Battery Voltage (12.8 V or more) for 3
seconds, and then 0 V.

If the reading stays on battery voltage, and never shows
0 V. Check the ECU and fuel pump relay.
If the voltage is in specification, but the pump doesn’t
work, replace the pump (see Fuel Pump Removal/Installation).
If there is still no battery voltage, check the pump relay(see Relay Box section in the Electrical System chapter).

Pressure Regulator Removal○The pressure regulator [A] is built into the fuel pump [B]and cannot be removed.

Pump Screen, Fuel Filter Cleaning○The fuel filter [A] is built into the pump and cannot becleaned or checked.
If the fuel filter is suspected of clogging or being damaged,
replace it with the fuel pump as a set.

3-90 FUEL SYSTEM (DFI)
Fuel Pump
Fuel Pump Circuit

1. ECU
2. Water-proof Joint C
3. Engine Stop Switch
4. Ignition Switch
5. Ignition Fuse 10 A
6. Fuel Pump Relay
7. Relay Box
8. Main Fuse 30 A
9. Battery
10. Frame Ground
11. Fuel Pump

FUEL SYSTEM (DFI) 3-91
Fuel Injectors
Removal/Installation• Refer to the Throttle Body Assy Disassembly/Assembly.
Audible Inspection

the engine.
• StartApplyof a screwdriver [A] to the injector [B]. Put• the griptheendtiponto
your ear, and listen whether the injector
is clicking or not.
○A sound scope [C] can also be used.
Do the same for the other injectors.
If all the injectors click at a regular intervals, the injectors are good. The trouble may be related to the fuel line,
requiring fuel pressure inspection (see Fuel Pressure Inspection).
○The click interval becomes shorter as the engine speed
rises.
If any injector(s) doesn’t click, the DFI circuit or the injector
is suspect. Perform “Fuel Injector Power Source Voltage
Inspection”, first.

•

Fuel Injector Power Source Voltage Inspection

the ECU (see ECU Removal).
•○Remove
Do not disconnect the ECU connector.
a digital meter [A] to the ECU connector [B], us• Connect
ing the needle adapter [C].
Special Tool - Needle Adapter Set: 57001-1457○Measure the power source voltage with the engine•

stopped, and with the connector joined.
Turn the ignition switch ON.

Injector Power Source Voltage at ECU
Connections: Meter (+) → W/Y (terminal 16)
Meter (–) → Battery (–) Terminal
Service Limit:

Battery Voltage (12.8 V or more)

If the meter doesn’t read as specified, check the following.
Main Fuse 30 A (see Fuse Inspection in the Electrical
System chapter)
Fuel Pump Relay (see Relay Circuit Inspection in theElectrical System chapter)
Power Source Wiring (see wiring diagram below)○To check the W/R leads between the injector connector
and the fuel pump relay, remove the fuel tank (see Fuel
Tank Removal) and the left side cover (see Side Cover
Removal in the Frame chapter).
If the power source voltage is normal, check the output
voltage of the injectors.

3-92 FUEL SYSTEM (DFI)
Fuel Injectors
Fuel Injector Output Voltage Inspection

the ignition switch OFF.
• TurnRemoveECU (see ECU Removal).
• Connect thea digital voltmeter [A] to the ECU connector [B]• with the needle
adapter set [C].
Special Tool - Needle Adapter Set: 57001-1457
Injector Output Voltage
Connections to Injector #1
Meter (+) → BL/R lead (terminal 42)
Meter (–) → Battery (–) Terminal
Connections to Injector #2
Meter (+) → BL/G lead (terminal 41)
Meter (–) → Battery (–) Terminal• Turn the ignition switch ON.

Output Voltage at Injector Connector
Standard:
Battery Voltage (12.8 V or more)

If the output voltage is normal, perform “Injector Signal
Test”.
If the output voltage is out of the standard, turn the ignition
switch OFF, remove the fuel tank, and check the injector
wiring for continuity.
Injector Wiring Inspection
ECU Connector
Injector Connectors••

Terminal 42→ Injector #1 Terminal (BL/R)

Terminal 41→ Injector #2 Terminal (BL/G)

If the wiring is good, inspect the resistance of the injectors(see Injector Resistance Inspection).
Remove the needle adapter.
Apply silicone sealant to the seals of the ECU connector
for waterproofing.
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

Injector Signal Test

two test light sets with male terminals as shown.
• Prepare
Rating of Bulb [A]: 12 V × 3 ∼ 3.4 W
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
larger terminal could damage the injector main harness connector (female), leading to harness repair
or replacement.
Be sure to connect bulbs in series. The bulb works
as a current limiter to protect the solenoid in theinjector from excessive current.

FUEL SYSTEM (DFI) 3-93
Fuel Injectors
the fuel tank (see Fuel Tank Removal).
• Remove
Removethe• Removal) air cleaner housing (see Air Cleaner Housing
connectors for injector [A].
• Remove
Connecteach• connector [C]. test light set [B] to the injector sub harness
the ignition switch ON.
• Turncranking the engine with the starter motor, watch• Whilethe test lights.
If the test lights flicker at regular intervals, the injector
circuit in the ECU, and the wiring are good. Perform the“Injector Resistance Inspection”.

○Injector signals can be also confirmed by connecting thehand tester (× 10 V AC) instead of the test light set tothe injector main harness (female) connector. Crank theengine with the starter motor, and check to see if the hand
oscillates at regular intervals.
Special Tool - Hand Tester: 57001-1394

If the test light doesn’t flicker (or the tester needle doesn’t
oscillates), check the wiring and connectors again. If thewiring is good, check the injector voltage. If the wiring isgood, inspect the ECU for its ground and power supply(see ECU Power Supply Inspection).

Injector Resistance Inspection

the fuel tank (see Fuel Tank Removal).
• Removethe air cleaner housing (see Air Cleaner Housing• Remove
Removal).
the connector from the injector [A].
• Disconnect
Measuretheinjector resistance with the hand tester [B].
•Special Tool - Hand Tester: 57001-1394
Injector ResistanceConnections to Injector
Meter (+)

Meter (–)

#1: W/R ←→ BL/R Terminal#2: W/R ←→ BL/G Terminal
Standard:

About 11.7 ∼ 12.3 Ω at 20°C (68°F)

If the reading is out of the range, perform the “Injector Unit
Test”.
If the reading is normal, perform the “Injector Unit Test”
for confirmation.

3-94 FUEL SYSTEM (DFI)
Fuel Injectors
Injector Unit Test

two leads [A] and the same test light set [B] as in• Use“Injector Signal Test”.
Rating of Bulb [C]: 12 V × (3 ∼ 3.4) W
12 V Battery [D]

CAUTIONBe sure to connect the bulb in series. The bulb
works as a current limiter to protect the solenoid
in the injector from excessive current.
the test light set to the injector [E] as shown.
• Connect
and connect [F] the end of the lead to the battery• Open(–) terminal repeatedly. The injector should click.
If the injector does not click, replace the injector.
If the injector clicks, check the wiring again. If the wiring
is good, replace the injector (may be clogged) or ECU.

Injector Fuel Line Inspection• Remove:
Fuel Tank (see Fuel Tank Removal)
Left Center Fairing (see Center Fairing Removal in the
Frame chapter)Be sure to place a piece of cloth around the fuel hose joint
and the delivery pipe.
Insert a minus screw driver [A] into the slit on the joint lock[B].
Turn the driver to disconnect the joint lock.
Pull the fuel hose joint [C] out of the delivery pipe.

••••
the injector fuel line for leakage as follows.
•○Check
Connect a commercially available vacuum/pressure

pump [A] to the nipple of the delivery pipe [B] with ahigh-pressure fuel hose [C] (both ends connected withthe clamps [D]) as shown.
Torque - Fuel Hose Clamp Screws: 1.5 N·m (0.15 kgf·m, 13
in·lb)○Apply soap and water solution to the areas [E] as shown.
○Watching the pressure gauge, squeeze the pump lever[F], and build up the pressure until the pressure reaches
the maximum pressure.
Injector Fuel Line Maximum PressureStandard:
333 kPa (3.4 kgf/cm², 48 psi)

CAUTION
During pressure testing, do not exceed the maximum pressure for which the system is designed.

FUEL SYSTEM (DFI) 3-95
Fuel Injectors
the gauge for at least 6 seconds.
• WatchIf the pressure holds steady, the system is good.
If the pressure drops at once or if bubbles are found in
the area, the line is leaking. Replace the delivery pipe,
injectors and related parts.
○Repeat the leak test, and check the fuel line for no leakage.
Install the pump outlet hose (see Fuel Tank Installation).
Run the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

••

Fuel Injector Circuit

1. ECU
2. Fuel Injectors
3. Water-proof Joint C
4. Engine Stop Switch
5. Ignition Switch
6. Ignition Fuse 10 A
7. Fuel Pump Relay (for fuel pump and injectors)
8. Relay Box
9. Main Fuse 30 A
10. Battery
11. Frame Ground
12. Joint Connector

3-96 FUEL SYSTEM (DFI)
Throttle Grip and Cables
Throttle Grip Free Play Inspection

to the Throttle Control System Inspection in the Pe• Refer
riodic Maintenance chapter.

Throttle Grip Free Play Adjustment

to the Throttle Control System Inspection in the Pe• Refer
riodic Maintenance chapter.

Throttle Cable Installation

the throttle cables in accordance with Cable, Wire,• Installand Hose Routing section in the Appendix chapter.
the lower ends of the throttle cables in the cable• Installbracket on the throttle body assy after installing the upper•ends of the throttle cables in the grip.
After installation, adjust each cable properly.

WARNING
Operation with incorrectly routed or improperly adjusted cables could result in an unsafe riding condition.

Throttle Cable Lubrication

to the Chassis Parts Lubrication in the Periodic• Refer
Maintenance chapter.

FUEL SYSTEM (DFI) 3-97
Throttle Body Assy
Idle Speed Inspection

to the Idle Speed Inspection in the Periodic Main• Refertenance chapter.

Engine Vacuum Synchronization Inspection/Adjustment

to the Engine Vacuum Synchronization Inspection• Referin the Periodic Maintenance chapter.

High Altitude Performance Adjustment

modification is not necessary in this model since• Any
the inlet air pressure sensor senses inlet air pressurechange due to high altitude and the ECU compensates
the change.

Throttle Body Assy Removal

WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition
switch OFF. Disconnect the battery (–) cable terminal. Do not smoke. Make sure the area iswell-ventilated and free from any source of flameor sparks; this includes any appliance with a pilot
light.
Be prepared for fuel spillage: any spilled fuel must
be completely wiped up immediately.

• Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal)
Center Fairings (see Center Fairing Removal in the
Frame chapter)• Disconnect:
Main Throttle Sensor Connector [A]Fuel Hose Lower End [B]Vacuum Hose [C]• Disconnect:#1, #2 Injector Connector [A]•Subthrottle Sensor Connector [B]Subthrottle Sensor Actuator Connector [C]
Loosen:Holder and Duct Clamp Bolts

3-98 FUEL SYSTEM (DFI)
Throttle Body Assythe locknut and screw in the throttle cable adjuster• Loosenfully to give the cables plenty of play.
the right switch housing and take out the acceler• Remove
ator cable upper end [A] and the decelerator cable upperend [B].

the throttle cable lower ends [A] from the throttle• Removepulley.

removing the throttle body assy, stuff pieces of lint
• After-free, clean cloth into the throttle body holders.

CAUTION
If dirt gets into the engine, excessive engine wear
and possible engine damage will occur.

Throttle Body Assy Installation

the holder clamp bolts [A] in the direction shown• Installwith each bolt heads [B], facing outwards.

the air cleaner duct clamp screws [A] so that their• Installscrew heads [B] face the right.
the vacuum hose (see Cable, Wire, and Hose Rout• Run
ing section in the Appendix chapter).

FUEL SYSTEM (DFI) 3-99
Throttle Body Assy
the accelerator cable end [A] and the decelerator cable• Fit
end [B] into the throttle pulley.
• Check fuel leakage from the throttle body assy.

WARNING

Fuel spilled from the carburetors is hazardous.

a thin coating of grease to the throttle cable upper• Applyends.
the upper ends of the throttle cables in the grip.
• InstallFitthe[A] of the right switch housing into the• hole [B]projectionof the handlebar.
Turnthethrottle grip and make sure that the throttle valves• move smoothly
and return by spring force.
Check
the
throttle
grip free play (see Throttle Control Sys• tem Inspection in the
Periodic Maintenance chapter).

WARNING
Operation with an incorrectly routed cable could result in an unsafe riding condition.

• Adjust:
Throttle Grip Free Play (see Throttle Control System Inspection in the Periodic Maintenance chapter)
Idle Speed (see Idle Speed Adjustment in the Periodic
Maintenance chapter)

Throttle Body Assy Disassembly
CAUTION
Do not remove, disassemble or adjust the main
throttle sensor [A], subthrottle sensor [B], subthrottle valve actuator [C], throttle link mechanism[D] and throttle body assy [E], because they are
adjusted or set at the manufacturer. Adjustmentof these parts could result in poor performance,
requiring replacement of the throttle body assy.
the throttle body assy (see Throttle Body Assy
• Remove
Removal).

CAUTION
Never drop the throttle body assy , especially on ahard surface. Such a shock to the body assy candamage it.

3-100 FUEL SYSTEM (DFI)
Throttle Body Assy

• Remove:
Screws [A]Delivery Pipe [B]Fuel Injectors [C]

Throttle Body Assy Assembly○Replace the O-rings [A] and seals [B] with the new ones.

assembling, blow away dirt or dust from the throttle• Beforebody and delivery pipe by applying compressed air.
engine oil to the new O-rings of each injector [C],• Apply
insert them into the delivery pipe and confirm whether the•

injectors turn smoothly or not.
Install the injectors along with the delivery pipe assy into
the throttle bodies.

the throttle body assy (see Throttle Body Assy In• Install
stallation).

FUEL SYSTEM (DFI) 3-101
Air Cleaner
Air Cleaner Element Removal/Installation

to the Air Cleaner Element Replacement in the Pe• Refer
riodic Maintenance chapter.

Air Cleaner Element Inspection

the air cleaner element (see Air Cleaner Element• Remove
Replacement in the Periodic Maintenance chapter).
check the element [A] for tears or breaks.
• Visually
If the element has any tears or breaks, replace the element.

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.
Remove the left center fairing (see Center Fairing Removal in the Frame chapter).
Visually check the drain hose [A] if the water or oil accumulates.
If any water or oil accumulates in the hose, remove theplug [B] from the drain hose and drain it.

••

WARNINGBe sure to reinstall the plug in the drain hose afterdraining. Oil on tires will make them slippery andcan cause an accident and injury.

Air Cleaner Housing Removal• Remove:
Fuel Tank (see Fuel Tank Removal)
Hose (Disconnect) [A]Inlet Air Temperature Sensor Connector [B]Screws [C]
Cover [D]• Disconnect the breather hose [A] on the upper crankcase.

3-102 FUEL SYSTEM (DFI)
Air Cleaner
the bolts [A] and remove the air cleaner housing• Unscrew[B].

Air Cleaner Housing Installation

the clamp on the hose [A] so that its pinch heads• Install[B] face the right.
the clamp on the breather hose [C] so that its pinch• Installheads [D] face the front.

FUEL SYSTEM (DFI) 3-103
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 flameor sparks; this includes any appliance with a pilot
light. Do not smoke. Turn the ignition switch OFF.
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
the ignition switch and engine stop switch OFF.
• Turnuntil the engine cools down.
• WaitOpen• tank. the fuel tank cap [A] to lower the pressure in the○During tank removal, keep the tank cap open to releasepressure in the tank. This makes fuel spillage less.

• Remove:
Seat (see Seat Removal in the Frame chapter)
Side Covers (see Side Cover Removal in the Frame
chapter)
Fuel Tank Bolts [A]the fuel out from the fuel tank with a commercially• Draw
available pump [A].

○Use a soft plastic hose [B] as a pump inlet hose in order

to insert the hose smoothly.
○Put the hose through the fill opening [C] into the tank anddraw the fuel out.
Front [D]WARNING
The fuel could not be removed completely from thefuel tank. Be careful for remained fuel spillage.

3-104 FUEL SYSTEM (DFI)
Fuel Tank
the fuel pump lead connector [A] and the tube
• Disconnect[B].
• Remove:
Fuel Return Hose [C] (Red, California Model)
Fuel Tank Breather Hose [D] (Blue, California Model)

sure to place a piece of cloth [A] around the fuel hose
• Be
joint.
a minus screw driver [B] into the slit [C]on the joint• Insert
lock.

[A] the driver to disconnect the joint lock [B].
• TurnPull[C]
the fuel hose joint out [D] of the outlet pipe.
•

CAUTION

When removing the fuel hose joint, do not apply
strong force to the outlet pipe on the fuel pump. The
pipe made from resin could be damaged.

WARNINGBe prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
When the fuel hose is disconnected, fuel spills out
from the hose and the pipe because of residualpressure . Cover the hose connection with a pieceof clean cloth to prevent fuel spillage.

FUEL SYSTEM (DFI) 3-105
Fuel Tank
the fuel tank cap.
• CloseRemovethe fuel tank, and place it on a flat surface.
•○Do not apply
the load to the fuel pump outlet portion [A]•especially the outlet pipe made from resin.
For California model, note the following.

CAUTIONFor California model, if gasoline, solvent, water or
any other liquid enters the canister, the canister’svapor absorbing capacity is greatly reduced. If thecanister does become contaminated, replace it witha new one.

○Be sure to plug the evaporative fuel return hose to prevent
fuel spilling before fuel tank removal.

WARNINGFor California model, be careful not to spill thegasoline through the return hose. Spilled fuel ishazardous.
If liquid or gasoline flows into the breather hose, remove
the hose and blow it clean with compressed air.
○Be careful of fuel spillage from the fuel tank since fuel still
remains in the fuel tank and fuel pump.

WARNINGStore the fuel tank in an area which is well-ventilated and free from any source of flameor sparks. Do not smoke in this area. Place thefuel tank on a flat surface and plug the fuel pipes
to prevent fuel leakage.

Fuel Tank Installation

the above WARNING (see Fuel Tank Removal).
• NoteRoutehoses correctly (see Cable, Wire, and Hose
• Routingthein the
Appendix chapter).
that the rubber dampers [A] are on the frame and• Checkthe fuel tank.

that the dampers [A] are in place on the fuel tank
• Check
as well.
If the dampers are damaged or deteriorated, replacethem.

3-106 FUEL SYSTEM (DFI)
Fuel Tank
sure that the trim seal [A] is on the fuel tank.
• BeReverse
Side of Fuel Tank [B]Side Cover [C]Approx. 17 mm (0.67 in.) [D]Front [E]
For California model, note the following.
○To prevent the gasoline from flowing into or out of thecanister, hold the separator perpendicular to the ground.
○Connect the hoses according to the diagram of the system (see Cable, Wire, and Hose Routing section in the
Appendix chapter). Make sure they do not get pinched or
kinked.
○Route hoses with a minimum of bending so that the air orvapor will not be obstructed.

•[A] the fuel hose joint [B] straight onto the delivery• Insert
pipe until the hose joint clicks.

CAUTION
When installing the fuel hose joint, do not apply
strong force to the outlet pipe on the fuel pump. The
pipe made from resin could be damaged.

• Push [C] the joint lock [D].
and pull [A] the hose joint [B] back and forth more
• Pushthan two times and make sure it is locked and doesn’tcome off.

WARNING
Make sure the hose joint is installed correctly on thedelivery pipe by sliding the joint, or the fuel could
leak.

•

If it comes off, reinstall the hose joint.
Connect the fuel pump and the fuel level sensor connectors and the battery (–) cable terminal.

Fuel Tank and Cap Inspection

inspect the gasket [A] on the tank cap for any• Visually
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 is not clogged. check the tank cap
breather also.
If they are clogged, remove the tank and drain it, and thenblow the breather free with compressed air.

CAUTION
Do not apply compressed air to the air vent holes[D] in the tank cap. This could cause damage andclogging of the labyrinth in the cap.

FUEL SYSTEM (DFI) 3-107
Fuel Tank
Fuel Tank Cleaning

WARNING
Clean the tank in a well-ventilated area, and takecare that there are no sparks or flame anywhere
near the working area. Because of the danger orhighly flammable liquids, do not use gasoline or
low-flash point solvents to clean the tank.
the fuel tank (see Fuel Tank Removal).
• Remove
Removethefuel pump inlet hose and the fuel pump (see• Fuel Pump Removal).
some high-flash point solvent into the fuel tank and• Pourshake the tank to remove dirt and fuel deposits.
the solvent out of the fuel tank.
• Draw
the tank with compressed air.
• Dry
Installfuel pump (see Fuel Pump Installation).
• Install thethefuel tank (see Fuel Tank Installation).
•3-108 FUEL SYSTEM (DFI)
Evaporative Emission Control System (California Model)
The Evaporative Emission Control System routes fuel vapors from the fuel system into the running engine or storesthe vapors in a canister when the engine is stopped. Although no adjustments are required, a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart.

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 iswell-ventilated and free from any source of flameor sparks; this includes any appliance with a pilot
light.

CAUTIONIf gasoline, solvent, water or any other liquid enters
the canister, the canister’s vapor absorbing capacity is greatly reduced. If the canister does becomecontaminated, replace it with a new one.
prevent the gasoline from flowing into or out of the• To
canister, hold the separator perpendicular to the ground.
the hoses according to the diagram of the sys• Connecttem (see Cable, Wire, and Hose Routing section in the
Appendix chapter). Make sure they do not get pinched or
kinked.

Hose Inspection

to the Evaporative Emission Control System In• Refer
spection in the Periodic Maintenance chapter.

Separator Inspection

to the Evaporative Emission Control System In• Refer
spection in the Periodic Maintenance chapter.
Separator [A]FUEL SYSTEM (DFI) 3-109
Evaporative Emission Control System (California Model)
Separator Operation TestWARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area iswell-ventilated and free from any source of flameor sparks; this includes any appliance with a pilot
light.
the hoses to the separator, and install the sepa• Connect
rator on the motorcycle.
the breather hose from the separator, and in• Disconnect
ject about 20 mL (0.68 US oz.) of gasoline [A] into the•••separator [B] through the hose fitting.
Disconnect the fuel return hose [C] from the fuel tank [D].
Run the open end of the return hose into the container
and hold it level with the tank top [E].
Start the engine, and let it idle.
If the gasoline in the separator comes out of the hose, theseparator works well. If it does not, replace the separator
with a new one.

Canister Inspection

to the Evaporative Emission Control System In• Refer
spection in the Periodic Maintenance chapter.

NOTE○The canister [A] is designed to work well through the

motorcycle’s life without any maintenance if it is used
under normal conditions.

COOLING SYSTEM 4-1

Cooling System
Table of Contents
Exploded View........................................................................................................................
Coolant Flow Chart.................................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Coolant ...................................................................................................................................
Coolant Deterioration Inspection.......................................................................................
Coolant Level Inspection...................................................................................................
Coolant Draining ...............................................................................................................
Coolant Filling ...................................................................................................................
Pressure Testing ...............................................................................................................
Cooling System Flushing ..................................................................................................
Coolant Reserve Tank Removal/Installation .....................................................................
Water Pump............................................................................................................................
Water Pump Removal .......................................................................................................
Water Pump Installation ....................................................................................................
Mechanical Seal Inspection ..............................................................................................
Water Pump Housing Disassembly ..................................................................................
Water Pump Housing Assembly .......................................................................................
Impeller Assembly.............................................................................................................
Pump Impeller Inspection .................................................................................................
Radiator ..................................................................................................................................
Radiator and Radiator Fan Removal ................................................................................
Radiator and Radiator Fan Installation .............................................................................
Radiator Inspection ...........................................................................................................
Radiator Cap Inspection ...................................................................................................
Radiator Filler Neck Inspection .........................................................................................
Thermostat .............................................................................................................................
Thermostat Removal.........................................................................................................
Thermostat Installation......................................................................................................
Thermostat Inspection ......................................................................................................
Hose and Pipes ......................................................................................................................
Hose Installation ...............................................................................................................
Hose Inspection ................................................................................................................
Water Temperature Sensor ....................................................................................................
Water Temperature Sensor Removal/Installation .............................................................
Water Temperature Sensor Inspection .............................................................................

4-2
4-4
4-6
4-7
4-8
4-8
4-8
4-8
4-8
4-8
4-9
4-9
4-10
4-10
4-10
4-11
4-11
4-11
4-12
4-12
4-13
4-13
4-14
4-14
4-14
4-15
4-16
4-16
4-16
4-16
4-18
4-18
4-18
4-19
4-19
4-19

4

4-2 COOLING SYSTEM
Exploded View

COOLING SYSTEM 4-3
Exploded View
No.
1
2
3
4
5
6
7

Fastener
Radiator Hose Clamp Screws
Water Pump Impeller Bolt
Water Pump Cover Bolts
Water Pump Drain Bolt
Thermostat Housing Bolts
Water Temperature Sensor
Baffle Plate Bolts

8. Reserve Tank
9. Baffle Plate
10. Cylinder Head Cover
11. Thermostat
12. Water Pump Impeller
13. Mechanical Seal
G: Apply grease.
HG: Apply high-temperature grease.
R: Replacement Parts

N·m
2.0
9.8
9.8
7.0
9.8
12
5.9

Torque
kgf·m
0.20
1.0
1.0
0.70
1.0
1.2
0.60

ft·lb
17 in·lb
87 in·lb
87 in·lb
62 in·lb
87 in·lb
106 in·lb
52 in·lb

Remarks

4-4 COOLING SYSTEM
Coolant Flow Chart

COOLING SYSTEM 4-5
Coolant Flow Chart
Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion.
When the engine starts, the water pump turns and the coolant circulates.
The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The
thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
When coolant temperature is below 80.5 ∼ 83.5°C (177 ∼ 182°F), the thermostat closes so that thecoolant flow is restricted through the air bleeder hole, causing the engine to warm up more quickly.
When coolant temperature is more than 80.5 ∼ 83.5°C, the thermostat opens and the coolant flows.
When the coolant temperature goes up beyond 93 ∼ 103°C (199 ∼ 217°F), the radiator fan relay
conducts to operate the radiator fan. The radiator fan draws air through the radiator core when there
is not sufficient air flow such as at low speeds. This increases up the cooling action of the radiator.
When the temperature is below 91°C (196°F) ∼ temperature less than ON temperature, the fan relay
opens and the radiator fan stops.
In this way, this system controls the engine temperature within narrow limits where the engine operates most efficiently even if the engine load varies.
The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles
which can cause engine overheating. As the engine warms up, the coolant in the radiator and thewater jacket expands. The excess coolant flows through the radiator cap and hose to the reserve tank
to be stored there temporarily. Conversely, as the engine cools down, the coolant in the radiator andthe water jacket contracts, and the stored coolant flows back to the radiator from the reserve tank.
The radiator cap has two valves. One is a pressure valve which holds the pressure in the system
when the engine is running. When the pressure exceeds 112.3 ∼ 141.7 kPa (1.15 ∼ 1.45 kgf/cm²,
16.3 ∼ 20.5 psi), the pressure valve opens and releases the pressure to the reserve tank. As soon
as pressure escapes, the valve closes, and keeps the pressure at 112.3 ∼ 141.7 kPa (1.15 ∼ 1.45
kgf/cm², 16.3 ∼ 20.5 psi). When the engine cools down, another small valve (vacuum valve) in thecap opens. As the coolant cools, the coolant contracts to form a vacuum in the system. The vacuum
valve opens and allows the coolant from the reserve tank to enter the radiator.

4-6 COOLING SYSTEM
Specifications
Item
Coolant Provided when Shipping
Type (Recommended)

Color
Mixed Ratio
Freezing Point
Total Amount
Radiator Cap
Relief Pressure
Thermostat
Valve Opening Temperature
Valve Full Opening Lift

Standard
Permanent type of antifreeze (soft water and ethylene glycol
plus corrosion and rust inhibitor chemicals for aluminumengines and radiators)
GreenSoft water 50%, coolant 50%−35°C (−31°F)
1.2 L (1.3 US qt) (reserve tank full level, including radiatorand engine)
112.3 ∼ 141.7 kPa (1.15 ∼ 1.45 kgf/cm², 16.3 ∼ 20.5 psi)
80.5 ∼ 83.5°C (177 ∼ 182°F)
8 mm (0.31 in.) or more at 95°C (203°F)

COOLING SYSTEM 4-7
Special Tools
Bearing Driver Set:
57001-1129

Oil Seal Driver:
57001-1660

4-8 COOLING SYSTEM
Coolant
Coolant Deterioration Inspection

the right center fairing (see Center Fairing Re• Remove
moval in the Frame chapter).
inspect the coolant [A] in the reserve tank.
• Visually
If whitish cotton-like wafts are observed, aluminum partsin the cooling system are corroded. If the coolant isbrown, iron or steel parts are rusting. In either case, flush
the cooling system.
If the coolant gives off an abnormal smell, check for acooling system leak. It may be caused by exhaust gas
leaking into the cooling system.

Coolant Level Inspection

to the Coolant Level in the Periodic Maintenance• Refer
chapter.

Coolant Draining

to the Coolant Change in the Periodic Maintenance• Refer
chapter.

Coolant Fillingto the Coolant Change in the Periodic Maintenance• Refer
chapter.

Pressure Testing

the reserve tank (see Coolant Change in the Pe• Remove
riodic Maintenance chapter).
the radiator cap, and install a cooling system• Removepressure tester [A] on the filler neck [B].

NOTE

○Wet the cap sealing surfaces with water or coolant toprevent pressure leaks.

up pressure in the system carefully until the pres• Build
sure reaches 141.7 kPa (1.45 kgf/cm², 20.5 psi).

CAUTION
During pressure testing, do not exceed the pressure for which the system is designed. The maximum pressure is 141.7 kPa (1.45 kgf/cm², 20.5 psi).
the gauge for at least 6 seconds.
• WatchIf the pressure holds steady, the system is all right.

•

If the pressure drops and no external source is found,
check for internal leaks. Droplets in the engine oil indicate
internal leakage. Check the cylinder head gasket and thewater pump.
Remove the pressure tester, replenish the coolant, andinstall the radiator cap.

COOLING SYSTEM 4-9
Coolant
Cooling System FlushingOver a period of time, the cooling system accumulates
rust, scale, and lime in the water jacket and radiator. When
this accumulation is suspected or observed, flush the cooling system. If this accumulation is not removed, it will clog
up the water passage and considerable reduce the efficiency of the cooling system.
Drain the cooling system (see Coolant Change in the Periodic Maintenance chapter).
Fill the cooling system with fresh water mixed with a flushing compound.

••

CAUTION
Do not use a flushing compound which is harmful tothe aluminum engine and radiator. Carefully follow
the instructions supplied by the manufacturer of thecleaning product.
up the engine, and run it at normal operating tem• Warm
perature for about ten minutes.
the engine, and drain the cooling system.
• StopFillthewith fresh water.
• Warm upsystemtheengineand drain the system.
• Repeat the previous two
steps once more.
• Fill the system with a permanent
type coolant and bleed• the air from the system (see Coolant
Change in the Periodic Maintenance chapter).

Coolant Reserve Tank Removal/Installation

coolant reserve tank is removed and installed dur• The
ing coolant change (see Coolant Change in the Periodic
Maintenance chapter).

4-10 COOLING SYSTEM
Water Pump
Water Pump Removal

the coolant (see Coolant Change in the Periodic• Drain
Maintenance chapter).
the clamp and remove the radiator hose [A] from
• Loosen
the water pump cover [B].
• Remove the water pump cover bolts [C].

the transmission into 1st gear.
• ShiftWhile
the rear brake, remove the water pump
• impellerapplying
bolt [A].
• Remove:
Impeller [B]Water Pump Housing [C]Water Pump Installation

installing the water pump impeller bolt, shift the• Whentransmission into 1st gear and apply the rear brake.
the O-rings [A] on the water pump housing with
• Replacenew ones and apply grease them.
high-temperature grease to the lips of the water• Applypump housing oil seal [B].

sure that the dowel pin [A] is in position.
• Be
Install• Tighten:the water pump housing.
•

Torque - Water Pump Impeller Bolt: 9.8 N·m (1.0 kgf·m, 87
in·lb)

the O-ring [A] on the water pump cover with a• Replacenew one and grease it.

COOLING SYSTEM 4-11
Water Pump
the water pump cover, being careful of the two• Install
dowel pins [A].
Torque - Water Pump Cover Bolts: 9.8 N·m (1.0 kgf·m, 87
in·lb)

Mechanical Seal Inspection

inspect the mechanical seal.
• VisuallyIf any one of the parts is damaged, replace the mechanical seal as a unit.
○The sealing seat and rubber seal may be removed easily
by hand.
Impeller Sealing Seat Surface [A]Rubber Seal [B]
Mechanical Seal Diaphragm [C]Water Pump Housing Disassembly
CAUTIONBe careful not to damage the sealing surface of themechanical seal.

• Take the oil seal [A] out of the housing [B] with a hook [C].
the mechanical seal [A] out of the housing with a• Press
bearing driver [B].
Special Tool - Bearing Driver Set: 57001-1129

Water Pump Housing Assembly

high-temperature grease [A] to the new oil seal [B].
• Apply
the oil seal into the housing with a bearing driver so• Pressthat the seal surface is flush [C] with the end of the hole.
the new mechanical seal into the housing with the• Press
oil seal driver [D] until its flange [E] touches the surface[F] of the housing.
Special Tool - Oil Seal Driver: 57001-1660

4-12 COOLING SYSTEM
Water Pump
Impeller Assembly

the sliding surface of the mechanical seal with a• Cleanhigh-flash point solvent, and apply a little coolant to the•sliding surface to give the mechanical seal initial lubrication.
Apply coolant to the surfaces of the rubber seal [A] andsealing seat [B], and install the rubber seal and sealing
seat into the impeller by pressing them by hand until theseat stops at the bottom of the hole.

Pump Impeller Inspection

check the impeller [A].
• Visually
If the surface is corroded, or if the blades are damaged,
replace the impeller (see Water Pump Removal).

COOLING SYSTEM 4-13
Radiator
Radiator and Radiator Fan Removal

the coolant (see Coolant Change in the Periodic• Drain
Maintenance chapter).
• Remove:
Center Fairings (see Center Fairing in the Frame chapter)
Reserve Tank (see Coolant Change in the Periodic Maintenance chapter)
Radiator Fan Motor Connector [A] (Disconnect)
Radiator Hose Clamp Screw [B] (Loosen)• Loosen:
Radiator Hose Clamp Screw [A]Remove:• Radiator Bolt [B][A] the radiator [B] toward the left, noting the baffle• Pullplate [C] on the cylinder head cover.

CAUTION
Do not touch the radiator core. This could damage
the radiator fins, resulting in loss of cooling efficiency.

necessary, remove:• IfRadiator
Fan Mounting Bolts [A]Radiator Fan [B]4-14 COOLING SYSTEM
Radiator
Radiator and Radiator Fan Installation

the radiator [A] to the frame.
•○Install
Align [B] the projection on the frame with the hole on theradiator.

○Tighten the radiator bolt [C].
○Note the baffle plate on the cylinder head cover when
installing the radiator.
○Position the radiator hose clamp screws [D] as shown.

Radiator Inspection

the radiator core.
• Check
If there are obstructions to air flow, remove them.
If the corrugated fins [A] are deformed, carefullystraighten them.
If the air passages of the radiator core are blocked morethan 20% by unremovable obstructions or irreparably deformed fins, replace the radiator with a new one.

CAUTION
When cleaning the radiator with steam cleaner, be
careful of the following to prevent radiator damage:
Keep the steam gun [A] away more than 0.5 m (1.6ft) [B] from the radiator core.
Hold the steam gun perpendicular [C] (not oblique[D]) to the core surface.
Run the steam gun, following the core fin direction.

Radiator Cap Inspection• Remove:
Reserve Tank (see Coolant Change in the Periodic Main•

tenance chapter)
Radiator Cap
Check the condition of the bottom [A] and top [B] valve
seals and valve spring [C].
If any one of them shows visible damage, replace the capwith a new one.

COOLING SYSTEM 4-15
Radiator• Install the cap [A] on a cooling system pressure tester [B].
NOTE

○Wet the cap sealing surfaces with water or coolant toprevent pressure leaks.

the pressure gauge, pump the pressure tester• Watching
to build up the pressure until the relief valve opens: thegauge needle flicks downward. Stop pumping and measure leak time at once. The relief valve must open within
the specified range in the table below and the gauge handmust remain within the same range at least 6 seconds.
Radiator Cap Relief PressureStandard: 112.3 ∼ 141.7 kPa (1.15 ∼ 1.45 kgf/cm², 16.3
∼ 20.5 psi)

If the cap can not hold the specified pressure or if it holds
too much pressure, replace it with a new one.

Radiator Filler Neck Inspection

the reserve tank (see Coolant Change in the Pe• Remove
riodic Maintenance chapter).
the radiator cap.
• Removethe radiator filler neck for signs of damage.
• Check
Checkcondition of the top and bottom sealing seats• [A] in thethefiller
neck. They must be smooth and clean for
the radiator cap to function properly.

4-16 COOLING SYSTEM
Thermostat
Thermostat Removal

the coolant (see Coolant Change in the Periodic• Drain
Maintenance chapter).
• Remove:
Left Center Fairing (see Center Fairing Removal in the
Frame chapter)
Thermostat Hosing Bolts [A]Thermostat Hosing [B]• Pull the thermostat [A] out of the cylinder head.

Thermostat Installation

the thermostat [A] in the cylinder head so that the• Install
air bleeder hole [B] is on top.
a new O-ring into the housing and apply grease it.
• Install
Tighten:•

Torque - Thermostat Hosing Bolts: 9.8 N·m (1.0 kgf·m, 87
in·lb)

the radiator with coolant (see Coolant Change in the• FillPeriodic Maintenance chapter).

Thermostat Inspection

the thermostat, and inspect the thermostat valve• Remove[A] at room temperature.
If the valve is open, replace the thermostat with a newone.

COOLING SYSTEM 4-17
Thermostat
check valve opening temperature, suspend the ther• To
mostat [A] in a container of water and raise the temperature 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 water so that the heat sensitive portions [C] are located in almost the same depth.
It must not touch the container, either.
If the measurement is out of the specified range, replace
the thermostat with a new one.
Thermostat Valve Opening Temperature
80.5 ∼ 83.5°C (177 ∼ 182°F)

4-18 COOLING SYSTEM
Hose and Pipes
Hose Installation

the hoses and pipes, being careful to follow bend• Installing direction. Avoid sharp bending, kinking, flattening or
twisting.
Run the hoses (see Cable, Wire, and Hose Routing section in the Appendix chapter).
Install the clamp [A] as near as possible to the hose end
to clear the raised rib of the fitting. This will prevent thehoses from working loose.
○The clamp screws should be positioned correctly to prevent the clamps from contacting the other parts.

••

Torque - Radiator Hose Clamp Screws: 2.0 N·m (0.20 kgf·m,
17 in·lb)

Hose Inspection

to the Radiator Hose Damage and Installation Con• Referdition Inspection in the Periodic Maintenance chapter.

COOLING SYSTEM 4-19
Water Temperature Sensor
CAUTION
The water temperature sensor should never be allowed to fall on a hard surface. Such a shock to thewater temperature sensor can damage it.

Water Temperature Sensor Removal/Installation

to the Water Temperature Sensor Removal/Instal• Refer
lation in the Fuel System (DFI) chapter.
Water Temperature Sensor [A]Water Temperature Sensor Inspection

to the Water Temperature Sensor Inspection in the• Refer
Electrical System chapter.

ENGINE TOP END 5-1

Engine Top End
Table of Contents
Exploded View........................................................................................................................
Exhaust System......................................................................................................................
Specifications .........................................................................................................................
Special Tools and Sealant ......................................................................................................
Clean Air System....................................................................................................................
Air Suction Valve Removal................................................................................................
Air Suction Valve Installation.............................................................................................
Air Suction Valve Inspection .............................................................................................
Air Switching Valve Removal ............................................................................................
Air Switching Valve Installation .........................................................................................
Air Switching Valve Operation Test ...................................................................................
Air Switching Valve Unit Test ............................................................................................
Clean Air System Hose Inspection ...................................................................................
Cylinder Head Cover ..............................................................................................................
Cylinder Head Cover Removal .........................................................................................
Cylinder Head Cover Installation ......................................................................................
Camshaft Chain Tensioner .....................................................................................................
Camshaft Chain Tensioner Removal ................................................................................
Camshaft Chain Tensioner Installation .............................................................................
Camshaft, Camshaft Chain ....................................................................................................
Camshaft Removal ...........................................................................................................
Camshaft Installation ........................................................................................................
Camshaft and Sprocket Assembly....................................................................................
Camshaft, Camshaft Cap Wear ........................................................................................
Camshaft Runout ..............................................................................................................
Cam Wear.........................................................................................................................
Camshaft Chain Removal .................................................................................................
Cylinder Head.........................................................................................................................
Cylinder Compression Measurement................................................................................
Cylinder Head Removal ....................................................................................................
Cylinder Head Installation .................................................................................................
Cylinder Head Warp..........................................................................................................
Valves .....................................................................................................................................
Valve Clearance Inspection ..............................................................................................
Valve Clearance Adjustment.............................................................................................
Valve Removal ..................................................................................................................
Valve Installation ...............................................................................................................
Valve Guide Removal .......................................................................................................
Valve Guide Installation ....................................................................................................
Valve-to-Guide Clearance Measurement (Wobble Method) .............................................
Valve Seat Inspection .......................................................................................................
Valve Seat Repair .............................................................................................................
Cylinder, Pistons.....................................................................................................................
Cylinder Removal..............................................................................................................
Cylinder Installation...........................................................................................................
Piston Removal.................................................................................................................
Piston Installation..............................................................................................................
Cylinder Wear ...................................................................................................................
Piston Wear ......................................................................................................................
Piston Ring, Piston Ring Groove Wear.............................................................................

5-3
5-8
5-10
5-12
5-14
5-14
5-14
5-14
5-14
5-14
5-15
5-15
5-15
5-16
5-16
5-16
5-18
5-18
5-18
5-19
5-19
5-19
5-22
5-22
5-23
5-23
5-23
5-24
5-24
5-25
5-26
5-28
5-29
5-29
5-29
5-29
5-29
5-29
5-30
5-30
5-31
5-31
5-36
5-36
5-36
5-36
5-37
5-38
5-38
5-39

5

5-2 ENGINE TOP END
Piston Ring Groove Width.................................................................................................
Piston Ring Thickness ......................................................................................................
Piston Ring End Gap ........................................................................................................
Throttle Body Holder...............................................................................................................
Throttle Body Holder Installation.......................................................................................
Muffler.....................................................................................................................................
Muffler Body Removal.......................................................................................................
Exhaust Pipe Removal......................................................................................................
Muffler Body and Exhaust Pipe Installation ......................................................................

5-39
5-39
5-40
5-41
5-41
5-42
5-42
5-42
5-43

ENGINE TOP END 5-3
Exploded View
Dummy Page

5-4 ENGINE TOP END
Exploded View

ENGINE TOP END 5-5
Exploded View
No.
1
2
3

Fastener

Air Suction Valve Cover Bolts
Cylinder Head Cover Bolts
Camshaft Cap Bolts
Cylinder Head Bolts (M10 New Bolts)
4
Cylinder Head Bolts (M10 Used Bolts)
5 Cylinder Head Bolts (M6)
6 Throttle Body Holder Bolts
7 Rear Camshaft Chain Guide Bolts
8 Camshaft Chain Tensioner Mounting Bolts
9 Camshaft Chain Tensioner Cap Bolt
10 Spark Plugs
11 Camshaft Sprocket Bolts
12 Baffle Plate Bolts

N·m
9.8
9.8
12
54
49
12
12
20
9.8
20
15
15
5.9

Torque
kgf·m
1.0
1.0
1.2
5.5
5.0
1.2
1.2
2.0
1.0
2.0
1.5
1.5
0.60

ft·lb
87 in·lb
87 in·lb
106 in·lb
40
36
106 in·lb
106 in·lb
15
87 in·lb
15
11
1152 in·lb

L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)
R: Replacement Parts
S: Follow the specified tightening sequence.
SS: Apply silicone sealant.

Remarks

S
MO, S
MO, S
S
L

L

5-6 ENGINE TOP END
Exploded View

ENGINE TOP END 5-7
Exploded View
No.
1
2
3
4
5
6

Fastener
Cylinder Bolt (M8)
Cylinder Nut (M10)
Cylinder Bolts (M6)
Exhaust Pipe Manifold Holder Nuts
Muffler Body Mounting Bolt (Front)
Muffler Body Mounting Bolt (Rear)

N·m
27.5
49
12
17
20
20

Torque
kgf·m
2.8
5.0
1.2
1.7
2.0
2.0

ft·lb
20
36
106 in·lb
1215
15

7. "R" marked side faces up.
8. "RN" marked side faces up.
9. Hollow mark faces forward.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)
R: Replacement Parts
S: Follow the specified tightening sequence.

Remarks
MO,S
MO,S
S

5-8 ENGINE TOP END
Exhaust System
Exhaust System EX650A6F/EX650B6F

Full: Full Power
H: Honeycomb Type Catalyst
Silencer [A] with Hole [B] for Oxygen Sensor [C]ENGINE TOP END 5-9
Exhaust System
Manifold Mark Position [A]Silencer Mark Position [A]5-10 ENGINE TOP END
Specifications
Item
Camshafts
Cam Height:
ExhaustInlet
Camshaft Journal, Camshaft
Cap Clearance
Camshaft Journal Diameter
Camshaft Bearing Inside
DiameterCamshaft Runout
Cylinder HeadCylinder Compression

Cylinder Head Warp
ValvesValve Clearance:
ExhaustInlet
Valve Head Thickness:
ExhaustInlet
Valve Stem Bend
Valve Stem Diameter:
ExhaustInlet
Valve Guide Inside Diameter:
ExhaustInlet
Valve/Valve Guide Clearance(Wobble Method):
ExhaustInlet
Valve Seat Cutting Angle
Valve Seating Surface:
Width:
ExhaustInlet
Outside Diameter:
Exhaust
Inlet

Standard

Service Limit

35.843 ∼ 35.957 mm (1.4111 ∼ 1.4156 in.) 35.74 mm (1.4071 in.)36.543 ∼ 36.657 mm (1.4387 ∼ 1.4432 in.) 36.44 mm (1.4346 in.)
0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in.)
0.16 mm (0.0063 in.)23.950 ∼ 23.972 mm(0.9429 ∼ 0.9438 in.)24.000 ∼ 24.021 mm(0.9449 ∼ 0.9457 in.)
TIR 0.02 mm (0.0008 in.) or less
(Usable Range)
961 ∼ 1 471 kPa (9.8 ∼ 15.0 kgf/cm², 139∼ 213 psi) at 400 r/min (rpm)–––0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.)
0.15 ∼ 0.21 mm (0.0059 ∼ 0.0083 in.)23.92 mm (0.942 in.)24.08 mm (0.948 in.)
TIR 0.1 mm (0.004 in.)– – –0.05 mm (0.002 in.)

– – –
– – –

0.8 mm (0.031 in.)
0.5 mm (0.020 in.)
TIR 0.01 mm (0.0004 in.) or less

0.5 mm (0.020 in.)0.25 mm (0.0098 in.)
TIR 0.05 mm(0.002 in.)

4.455 ∼ 4.470 mm (0.1754 ∼ 0.1760 in.)
4.475 ∼ 4.490 mm (0.1762 ∼ 0.1768 in.)

4.44 mm (0.175 in.)4.46 mm (0.176 in.)

4.500 ∼ 4.512 mm (0.1772 ∼ 0.1776 in.)
4.500 ∼ 4.512 mm (0.1772 ∼ 0.1776 in.)4.58 mm (0.180 in.)4.58 mm (0.180 in.)0.07 ∼ 0.14 mm (0.0028 ∼ 0.0055 in.)0.02 ∼ 0.08 mm (0.0008 ∼ 0.0032 in.)
32°, 45°, 55°, 60°

0.27 mm (0.0106 in.)
0.22 mm (0.0087 in.)– – –0.5 ∼ 1.0 mm (0.020 ∼ 0.039 in.)
0.5 ∼ 1.0 mm (0.020 ∼ 0.039 in.)

– – –
– – –

27.6 ∼ 27.8 mm (1.087 ∼ 1.094 in.)32.6 ∼ 32.8 mm (1.283 ∼ 1.291 in.)

– – –
– – –

ENGINE TOP END 5-11
Specifications
Item
Valve Spring Free Length:
Exhaust
Inlet
Cylinder, Pistons
Cylinder Inside Diameter
Piston DiameterStandard

Service Limit

41.91 mm (1.650 in.)
41.91 mm (1.650 in.)40.3 mm (1.587 in.)40.3 mm (1.587 in.)82.994 ∼ 83.006 mm(3.2675 ∼ 3.2679 in.)82.969 ∼ 82.984 mm(3.2665 ∼ 3.2671 in.)
0.010 ∼ 0.037 mm (0.0004 ∼ 0.0015 in.)83.10 mm (3.2716 in.)Piston/Cylinder Clearance
Piston Ring/Groove Clearance:Top
0.03 ∼ 0.07 mm (0.0012 ∼ 0.0028 in.)
Second0.02 ∼ 0.06 mm (0.0008 ∼ 0.0024 in.)Piston Ring Groove Width:Top
0.92 ∼ 0.94 mm (0.0362 ∼ 0.0370 in.)
Second
1.01 ∼ 1.03 mm (0.0398 ∼ 0.0406 in.)Piston Ring Thickness:
Top
0.87 ∼ 0.89 mm (0.0342 ∼ 0.0350 in.)
Second
0.97 ∼ 0.99 mm (0.0382 ∼ 0.0390 in.)Piston Ring End Gap:
Top
0.25 ∼ 0.40 mm (0.0098 ∼ 0.0157 in.)
Second
0.40 ∼ 0.55 mm (0.0157 ∼ 0.0217 in.)82.82 mm (3.2606 in.)– – –0.17 mm (0.0067 in.)
0.16 mm (0.0063 in.)1.02 mm (0.040 in.)1.11 mm (0.044 in.)
0.80 mm (0.031 in.)
0.90 mm (0.035 in.)
0.7 mm (0.028 in.)
0.8 mm (0.031 in.)

5-12 ENGINE TOP END
Special Tools and SealantCompression Gauge, 20 kgf/cm²:
57001-221

Valve Seat Cutter, 60° 57001-1123

30:

Valve Spring Compressor Assembly:
57001-241

Valve Seat Cutter Holder Bar:
57001-1128

Valve Seat Cutter, 45° 57001-1116

35:

Valve Seat Cutter, 45° 57001-1187

30:

Valve Seat Cutter, 32° 57001-1120

30:

Valve Seat Cutter, 55° 57001-1247

35:

Valve Seat Cutter, 32° 57001-1121

35:

Valve Spring Compressor Adapter,
57001-1272

21:

ENGINE TOP END 5-13
Special Tools and SealantCompression Gauge Adapter, M10 × 1.0:
57001-1317

Piston Pin Puller:
57001-1568

Valve Seat Cutter Holder,
57001-1330

Piston Pin Puller Adapter C:
57001-1657

Valve Guide Arbor,
57001-1331

Valve Guide Reamer,
57001-1333

4.5:

4.5:

4.5:

Kawasaki Bond (Silicone Sealant):
92104-0004

5-14 ENGINE TOP END
Clean Air System
Air Suction Valve Removal• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System(DFI) chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
Air Switching Valve with Hoses (see Air Switching Valve
Removal)Air Suction Valve Cover Bolts [A] and Clamp
Air Suction Valve Cover [B]
Air Suction Valve [C]

Air Suction Valve Installation

the air suction valve [A] so that its side where stop• Install
per is fixed with the screws [B] faces the front [C] .
• Tighten:
Torque - Air Suction Valve Cover Bolts: 9.8 N·m (1.0 kgf·m,
87 in·lb)

Air Suction Valve Inspection

the air suction valve (see Air Suction Valve Re• Remove
moval).
inspect the reeds for cracks, folds, warps, heat
• Visually
damage or other damage.

•••

If there is any doubt as to the condition of the reeds [A],replace the air suction valve as an assembly.
Check the reed contact areas [B] of the valve holder forgrooves, scratches, any signs of separation from theholder or heat damage.
If there is any doubt as to the condition of the reed contact
areas, replace the air suction valve as an assembly.
If any carbon or other foreign particles have accumulated
between the reed and the reed contact area, wash thevalve assembly clean with a high-flash point solvent.

CAUTION
Do not scrape off the deposits with a scraper as this
could damage the rubber, requiring replacement of
the suction valve assembly.

Air Switching Valve Removal• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System(DFI) chapter)
Air Switching Valve Connector [A] (Disconnect)
Air Switching Valve [B]

Air Switching Valve Installation

the hoses correctly (see Cable, Wire, and Hose
• RouteRouting section in the Appendix chapter).

ENGINE TOP END 5-15
Clean Air System
Air Switching Valve Operation Test

to the Air Switching Valve Operation Test in the• Refer
Electrical System chapter.

Air Switching Valve Unit Test

to the Air Switching Valve Unit Test in the Electrical• Refer
System chapter.

Clean Air System Hose Inspection

certain that all the hoses are routed without being flat• Be
tened or kinked, and are connected correctly to the aircleaner housing, air switching valve, #1 and #2 throttle
body holders and air suction valve covers.
If they are not, correct them. Replace them if they aredamaged.

5-16 ENGINE TOP END
Cylinder Head CoverCylinder Head Cover Removal• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System(DFI) chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
Air Suction Valve Cover [A] with Hose [B]Stick Coils [C]Baffle Plate [D]Throttle Cables [E]Clutch Cable Holder [F] with Bolt [G]Cylinder Head Cover Bolts [H]Cylinder Head Cover [I]
EX650B Models
Remove the radiator with radiator hoses and move it
forward (see Radiator and Radiator Fan Removal in the
Cooling System chapter).

•

Cylinder Head Cover Installation

the head cover gasket [A] with a new one.
• ReplaceApplysiliconesealant [B] to the cylinder head as shown.
•
Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004• Install:
Dowel Pins [C]Plug Hole Gaskets [D]• Install:
Washers [A]Cylinder Head Cover Bolts [B]○Install the washers with metal side [C] faces upward.

• Tighten:

Torque - Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87
in·lb)ENGINE TOP END 5-17
Cylinder Head Coverthe baffle plate [A].
• Install
Tighten:•

Torque - Baffle Plate Bolts [B]: 5.9 N·m (0.60 kgf·m, 52 in·lb)

5-18 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 tensioner, do not take out themounting bolts only halfway. Retightening themounting bolts from this position could damage
the tensioner and the camshaft chain. Once thebolts are loosened, the tensioner must be removed
and reset as described in “Camshaft Chain Tensioner Installation.”
Do not turn over the crankshaft while the tensioner
is removed. This could upset the camshaft chain
timing, and damage the valves.

• Remove:
Right Center Fairing (see Center Fairing Removal in the•

Frame chapter)
Cap Bolt [A]Washer [B]Spring [C]Remove the mounting bolts [D] and take off the camshaft
chain tensioner.

Camshaft Chain Tensioner Installation

the stopper [A] and push the push rod [B] into
• Release
the tensioner [C].
• Install the tensioner so that the stopper faces upward.

• Tighten the tensioner mounting bolts [A].

Torque - Camshaft Chain Tensioner Mounting Bolts: 9.8
N·m (1.0 kgf·m, 87 in·lb)

the spring and washer.
• Install
Tightenthe cap bolt [B].
•Torque - Camshaft Chain Tensioner Cap Bolt: 20 N·m (2.0kgf·m, 15 ft·lb)

the crankshaft 2 turns clockwise to allow the ten• Turnsioner to expand and recheck the camshaft chain timing.

ENGINE TOP END 5-19
Camshaft, Camshaft Chain
Camshaft Removal• Remove:
Cylinder Head Cover (see Cylinder Head Cover Removal)
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Position the crankshaft as follows.
○Remove the upper [A] and lower [B] caps on the clutch
cover.

•○Using a wrench on the crankshaft rotation bolt, turn the

crankshaft clockwise until the 2/T mark line [A] on the timing rotor is aligned with the notch [B] in the edge of theupper hole [C] in the clutch cover.

• Remove:Camshaft Chain Tensioner (see Camshaft Chain Tensioner Removal)
Camshaft Cap Bolts [A]Camshaft Caps [B]Camshafts [C]

CAUTION
The crankshaft may be turned while the camshafts
are removed. Always pull the chain taut while turning the crankshaft. This avoids kinking the chain
on the lower (crankshaft) sprocket. A kinked chain
could damage both the chain and the sprocket.

Camshaft Installation

sure to install the following parts.
• BePlug
Hole Gaskets [A]Dowel Pins [B]5-20 ENGINE TOP END
Camshaft, Camshaft Chain
molybdenum disulfide oil solution to all cams [A]• Applyjournals [B] and thrust blocks [C] with × marks.
a new camshaft is to be used, apply a thin coat of molyb• Ifdenum
disulfide grease to the cam surfaces.

NOTE○The exhaust camshaft has a 2 412 EX mark [D] and theinlet camshaft has a 2 412 IN mark [E]. Be careful not
to mix up these shafts.

the crankshaft as follows.
• Position
Pullthetension• install the chain. side (exhaust side) of the chain taut tothe camshaft chain with the camshaft sprockets• Engageso that the timing marks on the sprockets are positioned
as shown.
○Using a wrench on the crankshaft rotation bolt, turn the
crankshaft clockwise until the 2/T mark line [A] on the timing rotor is aligned with the notch [B] in the edge of theupper hole [C] in the clutch cover.
the clutch cover is removed, perform the next proce• Ifdure.

○Using a wrench on the crankshaft rotation bolt, turn the

crankshaft clockwise until the 1/T mark line [A] on thetiming rotor is aligned with the wating surface [B] of the
crankcase halves.

ENGINE TOP END 5-21
Camshaft, Camshaft Chain○The timing marks must be aligned with the cylinder head
upper surface [C].
EX Mark [D] (Between #1 Pin and #2 Pin)
IN Mark [E] (Between #31 Pin and #32 Pin)
#1 Pin [F]#2 Pin [G]#31 Pin [H]#32 Pin [J]the camshaft cap, while pushing the camshaft• Installchain, tighten all camshaft bolts and chain guide bolts.

NOTE○The exhaust cap has a “EX” mark [A] and the inlet cap

has a “IN” mark [B]. Be careful not to mix up these caps.

○First tighten all the camshaft cap bolts evenly to seat thecamshaft in place, then tighten all bolts following the specified tightening sequence.
Torque - Camshaft Cap Bolts (1 ∼ 12): 12 N·m (1.2 kgf·m,
106 in·lb)• Install:
Camshaft Chain Tensioner (see Camshaft Chain Tensioner Installation)
Cylinder Head Cover (see Cylinder Head Cover Installation)
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)5-22 ENGINE TOP END
Camshaft, Camshaft Chain
Camshaft and Sprocket Assembly○The inlet and exhaust sprockets are identical.

the sprockets so that the marked (“IN” and “EX”)• Installside faces to the right side.

CAUTION
Inlet sprocket must use “IN” marked bolts holes [A].
Exhaust sprocket must use “EX” marked bolts
holes [B].
a non-permanent locking agent to the camshaft• Applysprockets bolts and tighten them.
Torque - Camshaft Sprockets Bolts: 15 N·m (1.5 kgf·m, 11ft·lb)

If a new camshaft is to be used, apply a thin coat of amolybdenum disulfide grease to the cam surfaces.

Camshaft, Camshaft Cap Wear

• Remove:Camshaft Caps (see Camshaft Removal)
Cut
strips of plastigage to journal width. Place a strip• on eachjournal parallel to the camshaft installed in the••correct position.
Measure each clearance between the camshaft journal
and the camshaft cap using plastigage (press gauge) [A].
Tighten:
Torque - Camshaft Cap Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)

NOTE○Do not turn the camshaft when the plastigage is between the journal and camshaft cap.

Camshaft Journal, Camshaft Cap ClearanceStandard:
0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in.)Service Limit: 0.16 mm (0.0063 in.)If any clearance exceeds the service limit, measure thediameter of each camshaft journal with a micrometer.
Camshaft Journal DiameterStandard:
23.950 ∼ 23.972 mm (0.9429 ∼ 0.9438 in.)Service Limit: 23.92 mm (0.942 in.)If the camshaft journal diameter is less than the service
limit, replace the camshaft with a new one and measure
the clearance again.
If the clearance still remains out of the limit, replace thecylinder head unit.

ENGINE TOP END 5-23
Camshaft, Camshaft Chain
Camshaft Runout

the camshaft (see Camshaft Removal).
• RemoveSet
thecamshaftin a camshaft alignment jig or on V
• blocks.
runout with a dial gauge at the specified place• Measureas shown.
If the runout exceeds the service limit, replace the shaft.
Camshaft Runout
Standard:
TIR 0.02 mm (0.0008 in.) or lessService Limit: TIR 0.1 mm (0.004 in.)Cam Wearthe camshaft (see Camshaft Removal).
• Remove
Measure[A] of each cam with a micrometer.
• If the camstheareheightworn down past the service limit, replace
the camshaft.
Cam HeightStandard:
Exhaust35.843 ∼ 35.957 mm (1.4111 ∼ 1.4156 in.)Inlet

36.543 ∼ 36.657 mm (1.4387 ∼ 1.4432 in.)Service Limit:
Exhaust35.74 mm (1.4071 in.)Inlet

36.44 mm (1.4346 in.)Camshaft Chain Removal

the crankcase (see Crankcase Splitting in the Crank• Split
shaft/Transmission chapter).
the camshaft chain [A] from the crankshaft• Removesprocket.

5-24 ENGINE TOP END
Cylinder HeadCylinder Compression Measurement
NOTE○Use the battery which is fully charged.

up the engine thoroughly.
• Warmthe engine.
• StopRemove:• Fuel Tank (see Fuel Tank Removal in the Fuel System(DFI) chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
Stick Coils (see Stick Coil (Ignition Coil together with
Spark Plug Cap) Removal in the Electrical System chapter)
Spark Plugs (see Spark Plug Replacement in the Periodic Maintenance chapter)
Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-1132

NOTE○Reconnect the connectors of the air switching valve

lead and the inlet air temperature sensor lead. Whenthe ignition switch is turned ON with the above connectors disconnected, the service codes (13, 64) are storesin the ECU.

the compression gauge [A] and adapter [B] firmly• Attach
into the spark plug hole.

○Using the starter motor, turn the engine over with the throttle fully open until the compression gauge stops rising; thecompression is the highest reading obtainable.

Special Tools - Compression Gauge, 20 kgf/cm²: 57001-221
Compression Gauge Adapter, M10 × 1.0:
57001-1317
Cylinder Compression
Usable Range: 961 ∼ 1 471 kPa (9.8 ∼ 15.0 kgf/cm², 139∼ 213 psi) at 400 r/min (rpm)the measurement for the other cylinders.
• Repeat
Installthespark plugs.
•
Torque - Spark Plugs: 15 N·m (1.5 kgf·m, 11 ft·lb)

ENGINE TOP END 5-25
Cylinder Head○The following table should be consulted if the obtainable compression reading is not within the usable range.

ProblemDiagnosis
Cylinder compression Carbon accumulation on piston and inis higher than usable combustion chamber possibly due torange
damaged valve stem oil seal and/or
damaged piston oil rings (This may be
indicated by white exhaust smoke).
Incorrect cylinder head gasket
thickness
Cylinder compression
Gas leakage around cylinder headis lower than usable
range
Bad condition of valve seating
Incorrect valve clearance
Incorrect piston/cylinder clearance
Piston seizure
Bad condition of piston ring and/or
piston ring grooves

Cylinder Head Removal• Remove:
Exhaust Pipes (see Exhaust Pipe Removal)
Cylinder Head Cover (see Cylinder Head Cover Removal)
Camshafts (see Camshaft Removal)
Throttle Body Assy (see Throttle Body Assy Removal in
the Fuel System (DFI) chapter)
Throttle Body Holder
Water Hose
Water Temperature Sensor Connector
Front Camshaft Chain Guide

Remedy (Action)
Remove the carbon deposits
and replace damaged parts if
necessary.
Replace the gasket with a standard
part.
Replace damaged gasket andcheck cylinder head warp.
Repair if necessary.
Adjust the valve clearance.
Replace the piston and/or cylinder.
Inspect the cylinder andreplace/repair the cylinder and/or
piston as necessary.
Replace the piston and/or thepiston rings.

5-26 ENGINE TOP END
Cylinder Headremove the M6 cylinder head bolts and M6 cylinder• Firstlybolts [A].
remove the M8 bolts [B].
• Secondly,
remove the M10 nut [C].
• Thirdly,
Fourthly,
remove the M10 bolts [D].
•Cylinder Head Installation
NOTE○The camshaft cap is machined with the cylinder head,so if a new cylinder head is installed, use the cap thatis supplied with the new head.

• Install a new cylinder head gasket [A] and dowel pins [B].

ENGINE TOP END 5-27
Cylinder Headmolybdenum disulfide oil solution [A] to both sides• Applyof washers and the threads of bolts and nut.

•

M10 Cylinder Head Bolts [B]
M10 Cylinder Nut [C]
M8 Cylinder Bolt [D]Tighten the all the bolts and nut following the tightening
sequence [1 ∼ 8].
Torque - Cylinder Head Bolts (M10):First: 25 N·m (2.5 kgf·m, 18 ft·lb)
Final:
Used Bolts 49 N·m (5.0 kgf·m, 36 ft·lb)
New Bolts 54 N·m (5.5 kgf·m, 40 ft·lb)
Cylinder Nut (M10): 49 N·m (5.0 kgf·m, 36 ft·lb)
Cylinder Bolt (M8): 27.5 N·m (2.8 kgf·m, 20 ft·lb)

NOTE○The tightening sequence No.1 ∼ No.5 are the cylinder
head bolts that are tightened between the cylinder headwith the crankcase.
○The No.6 is the cylinder head bolt that is tightened between the cylinder head with the cylinder.
○The No.7 and No.8 are the cylinder nut and cylinder
bolt that are tightened between the cylinder and the
crankcase.

5-28 ENGINE TOP END
Cylinder Headthe M6 cylinder head bolts and M6 cylinder bolts• Tighten[A].
Torque - Cylinder Head Bolts (M6): 12 N·m (1.2 kgf·m, 106
in·lb)
Cylinder Bolts (M6): 12 N·m (1.2 kgf·m, 106 in·lb)

the front camshaft chain guide [A].
•○Install
Insert the end [B] of front camshaft chain guide into the•hollow on the lower crankcase half.
Install the removed parts (see appropriate chapters).

Cylinder Head Warp

the cylinder head.
• CleanLayastraightedge
across the lower surface of the cylinder• head at several positions.
a thickness gauge [A] to measure the space between• Use
the straightedge [B] and the head.
Cylinder Head Warp–––
Standard:
Service Limit: 0.05 mm (0.002 in.)If the cylinder head is warped more than the service limit,
replace it.
If the cylinder head is warped less than the service limit,
repair the head by rubbing the lower surface on emery
paper secured to a surface plate (first No. 200, then No.
400).

ENGINE TOP END 5-29
ValvesValve Clearance Inspection

to the Valve Clearance Inspection in the Periodic• Refer
Maintenance chapter.

Valve Clearance Adjustment

to the Valve Clearance Adjustment in the Periodic• Refer
Maintenance chapter.

Valve Removal

cylinder head (see Cylinder Head Removal).
• Remove
Removevalve lifter and shim.
•○Mark andthe
record the valve lifter and shim locations so they•

can be installed in their original positions.
Using the valve spring compressor assembly, remove thevalve.
Special Tools - Valve Spring Compressor Assembly [A]:57001-241
Valve Spring Compressor Adapter, 21 [B]:57001-1272

Valve Installation

the oil seal with a new one.
•○Replace
Apply engine oil to the oil seal lip.
a thin coat of molybdenum disulfide grease to the• Apply
valve stem before valve installation.
the springs so that the closed coil end faces down• Installwards (the side painted in green faces upwards).
Valve Stem [A]Oil Seal [B]Spring Seat [C]Closed Coil End [D]Valve Spring [E]Side Painted in Green [F]Retainer [G]Split Keepers [H]Valve Guide Removal• Remove:
Valve (see Valve Removal)•

Oil Seal
Spring Seat
Heat the area around the valve guide to 120 ∼ 150°C (248
∼ 302°F), and hammer lightly on the valve guide arbor [A]to remove the guide from the top of the head.

CAUTION
Do not heat the cylinder head with a torch. This will
warp the cylinder head. Soak the cylinder head inoil and heat the oil.
Special Tool - Valve Guide Arbor,

4.5: 57001-1331

5-30 ENGINE TOP END
ValvesValve Guide Installationengine oil to the valve guide outer surface before• Apply
installation.
the area around the valve guide hole to about 120 ∼• Heat150°C (248 ∼ 302°F).
the valve guide in from the top of the head using the• Drivevalve guide arbor. The flange stops the guide from goingin too far.
Special Tool - Valve Guide Arbor,

4.5: 57001-1331

until the cylinder head cools down and then ream the• Waitvalve guide with the valve guide reamer [A] even if the oldguide is reused.

○Turn the reamer in a clockwise direction until the reamer

turns freely in the guide. Never turn the reamer counterclockwise or it will be dulled.
○Once the guides are reamed they must be cleaned thoroughly.
Special Tool - Valve Guide Reamer,

4.5: 57001-1333

Valve-to-Guide Clearance Measurement (Wobble
Method)If a small bore gauge is not available, inspect the valve
guide wear by measuring the valve to valve guide clearancewith the wobble method as indicated below.
Insert a new valve [A] into the guide [B] and set a dialgauge against the stem perpendicular to it as close as
possible to the cylinder head mating surface.
Move the stem back and forth [C] to measure valve/valve
guide clearance.
Repeat the measurement in a direction at a right angle tothe first.
If the reading exceeds the service limit, replace the guide.

•
•
•

NOTE

○The reading is not actual valve/valve guide clearance
because the measuring point is above the guide.

Valve/Valve Guide Clearance (Wobble Method)Standard:
Exhaust0.07 ∼ 0.14 mm (0.0028 ∼ 0.0055 in.)Inlet

0.02 ∼ 0.08 mm (0.0008 ∼ 0.0032 in.)Service Limit:
Exhaust0.27 mm (0.0106 in.)Inlet

0.22 mm (0.0087 in.)

ENGINE TOP END 5-31
ValvesValve Seat Inspection

the valve (see Valve Removal).
• RemoveCheckthevalve seating surface [A] between the valve [B]• and valve seat[C].

○Measure the outside diameter [D] of the seating patternon the valve seat.
If the outside diameter is too large or too small, repair theseat (see Valve Seat Repair).
Valve Seating Surface Outside DiameterStandard:
Exhaust 27.6 ∼ 27.8 mm (1.087 ∼ 1.094 in.)Inlet

32.6 ∼ 32.8 mm (1.283 ∼ 1.291 in.)

○Measure the seat width [E] of the portion where there isno build-up carbon (white portion) of the valve seat with avernier caliper.
Good [F]If the width is too wide [G], too narrow [H] or uneven [J],repair the seat (see Valve Seat Repair).
Valve Seating Surface Width
Standard:
Exhaust 0.5 ∼ 1.0 mm (0.020 ∼ 0.039 in.)Inlet

0.5 ∼ 1.0 mm (0.020 ∼ 0.039 in.)Valve Seat Repair• Repair the valve seat with the valve seat cutters [A].

Special Tools - Valve Seat Cutter Holder Bar [C]: 57001-1128
Valve Seat Cutter Holder, 4.5 [B]: 57001-1330

For Exhaust Valve Seat
Valve Seat Cutter, 45° -30: 57001-1187

Valve Seat Cutter, 32° -30: 57001-1120

Valve Seat Cutter, 60° -30: 57001-1123

For Inlet Valve Seat
Valve Seat Cutter, 45° -35: 57001-1116

Valve Seat Cutter, 32° -35: 57001-1121

Valve Seat Cutter, 55° -35: 57001-1247

If the manufacturer’s instructions are not available, use
the following procedure.

5-32 ENGINE TOP END
ValvesSeat Cutter Operation Care
1. This valve seat cutter is developed to grind the valve forrepair. Therefore the cutter must not be used for otherpurposes than seat repair.
2. Do not drop or shock the valve seat cutter, or the diamond particles may fall off.
3. Do not fail to apply engine oil to the valve seat cutter
before grinding the seat surface. Also wash off groundparticles sticking to the cutter with washing oil.

NOTE

○Do not use a wire brush to remove the metal particles
from the cutter. It will take off the diamond particles.

4. Setting the valve seat cutter holder in position, operate
the cutter in one hand. Do not apply too much force tothe diamond portion.

NOTE○Prior to grinding, apply engine oil to the cutter and during the operation, wash off any ground particles sticking
to the cutter with washing oil.

5. After use, wash it with washing oil and apply thin layerof engine oil before storing.
Marks Stamped on the Cutter
The marks stamped on the back of the cutter [A] represent
the following.
60° ........................... Cutter angle [B]37.5 ....................... Outer diameter of cutter [C]Operating Procedures
Clean the seat area carefully.
Coat the seat with machinist’s dye.
Fit a 45° cutter into the holder and slide it into the valve
guide.
Press down lightly on the handle and turn it right or left.
Grind the seating surface only until it is smooth.

•
•
•
•

CAUTION
Do not grind the seat too much. Overgrinding will
reduce valve clearance by sinking the valve into thehead. If the valve sinks too far into the head, it will
be impossible to adjust the clearance, and the cylinder head must be replaced.

ENGINE TOP END 5-33
Valvesthe outside diameter of the seating surface with• Measurea 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
Ground Volume [B] by 32° cutter
32° [C]
Correct Width [D]Ground Volume [E] by 60° or 55° cutter
60° or 55° [F]the outside diameter of the seating surface with• Measurea vernier caliper.
If the outside diameter of the seating surface is too small,repeat the 45° grind [A] until the diameter is within thespecified range.
Original Seating Surface [B]NOTE○Remove all pittings of flaws from 45° ground surface.
○After grinding with 45° cutter, apply thin coat of machin-

ist’s dye to seating surface. This makes seating surface
distinct and 32° and 60° (or 55°) grinding operation easier.
○When the valve guide is replaced, be sure to grind with
45° cutter for centering and good contact.
If the outside diameter [A] of the seating surface is toolarge, make the 32° grind described below.
If the outside diameter of the seating surface is within thespecified range, measure the seat width as described below.
Grind the seat at a 32° angle [B] until the seat outside
diameter is within the specified range.
○To make the 32° grind, fit a 32° cutter into the holder, andslide it into the valve guide.
○Turn the holder one turn at a time while pressing down
very lightly. Check the seat after each turn.

•

CAUTION
The 32° cutter removes material very quickly.
Check the seat outside diameter frequently to prevent overgrinding.

○After making the 32° grind, return to the seat outside di-•ameter measurement step above.
To measure the seat width, use a vernier caliper to measure the width of the 45° angle portion of the seat at several places around the seat.
If the seat width is too narrow, repeat the 45° grind until
the seat is slightly too wide, and then return to the seatoutside diameter measurement step above.

5-34 ENGINE TOP END
ValvesIf the seat width is too wide, make the 60° or 55° [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° or 55° angle until the seat width iswithin the specified range.
○To make the 60° or 55° grind, fit 60° or 55° cutter into theholder, and slide it into the valve guide.
○Turn the holder, while pressing down lightly.
○After making the 60° or 55° grind, return to the seat width
measurement step above.
Correct Width [B]•the valve to the seat, once the seat width and outside• Lap
diameter are within the ranges specified above.

○Put a little coarse grinding compound on the face of thevalve in a number of places around the valve head.

○Spin the valve against the seat until the grinding com-pound produces a smooth, matched surface on both theseat and the valve.
○Repeat the process with a fine grinding compound.
Lapper [A]Valve Seat [B]Valve [C]The seating area should be marked about in the middleof the valve face.
If the seat area is not in the right place on the valve, checkto be sure the valve is the correct part. If it is, it may havebeen refaced too much; replace it.
Be sure to remove all grinding compound before assembly.
When the engine is assembled, be sure to adjust the valve
clearance (see Valve Clearance Adjustment in the Periodic Maintenance chapter).

•••ENGINE TOP END 5-35
Valves5-36 ENGINE TOP END
Cylinder, Pistons
Cylinder Removal• Remove:
Cylinder Head (see Cylinder Head Removal)
Front Engine Mounting Bolts (Both Side) [A] (see Engine
Removal in the Engine Removal/Installation chapter)
Front Engine Brackets (Both Side) [B] (see Engine Removal in the Engine Removal/Installation chapter)
Cylinder [C]

Cylinder Installation
NOTE○If a new cylinder is used, use new piston ring.

• Install the dowel pins [A] and new cylinder gasket [B].

piston ring openings must be positioned as shown in• The
the figure. The openings of the oil ring steel rails must be
about 30 ∼ 40° of angle from the opening of the top ring.
Top Ring [A]Second Ring [B]Oil Ring Steel Rails [C]
Oil Ring Expander [D]Hollow [E]30 ∼ 40° [F]molybdenum disulfide oil solution to the cylinder• Applybore, piston rings and piston.
two auxiliary head bolts with their head cut.
•○Prepare
Install the two bolts [A] diagonally in the crankcase.
the crankshaft so that all the piston heads are• Position
almost level.
the cylinder block.
•○Install
Insert the piston rings with your thumbs.

Piston Removal

the cylinder (see Cylinder Removal).
• Removea clean cloth under the pistons and remove the pis• Place
ton pin snap ring [A] from the outside of each piston.

ENGINE TOP END 5-37
Cylinder, Pistons• Remove the piston pins.

Special Tools - Piston Pin Puller [A]: 57001-1568
Piston Pin Puller Adapter C [D]: 57001-1657•

Center Bolt [B]Shall of Piston [C]Remove the pistons.

spread the ring opening with your thumbs and• Carefully
then push up on the opposite side of the ring [A] to remove•it.
Remove the 3-piece oil ring with your thumbs in the samemanner.

Piston Installation

the oil ring expander [A] in the bottom piston ring
• Installgroove so the ends [B] butt together.
the oil ring steel rails, one above the expander and• Install
one below it.

○Spread the rail with your thumbs, but only enough to fit
the rail over the piston.
○Release the rail into the bottom piston ring groove.

NOTE○The oil ring rails have no “top” or “bottom”.
not mix up the top and second ring.
• Do
Install
the top ring [A] so that the "R" mark [B] faces up.
• Install thesecond ring [C] so that the "RN" mark [D] faces• up.

5-38 ENGINE TOP END
Cylinder, Pistons
NOTE○If a new piston is used, use new piston ring.

the piston with its marking hollow facing forward.
• InstallFitanew
pin snap ring into the side of the piston• so that thepiston
ring opening [A] does not coincide with the slit
[B] of the piston pin hole.
○Apply molybdenum disulfide oil solution to the piston pins
and piston journals.
○When installing the piston pin snap ring, compress it only
enough to install it and no more.

CAUTION
Do not reuse snap rings, as removal weakens anddeforms them. They could fall out and score thecylinder wall.

• Install the cylinder (see Cylinder Installation).
Cylinder Wear

there is a difference in cylinder wear in different di• Since
rections, take a side-to-side and a front-to-back measurement at each of the two locations (total of four measurements) shown in the figure.
If any of the cylinder inside diameter measurements exceeds the service limit, replace the cylinder.
10 mm (0.39 in.) [A]
60 mm (2.36 in.) [B]Cylinder Inside DiameterStandard:
82.994 ∼ 83.006 mm (3.2675 ∼ 3.2679 in.)Service Limit: 83.10 mm (3.2716 in.)Piston Wear

the outside diameter [A] of each piston 18 mm• Measure(0.7087 in.) [B] up from the bottom of the piston at a rightangle to the direction of the piston pin.
If the measurement is under service limit, replace the piston.
Piston DiameterStandard:
82.969 ∼ 82.984 mm (3.2665 ∼ 3.2671 in.)Service Limit: 82.82 mm (3.2606 in.)

ENGINE TOP END 5-39
Cylinder, Pistons
Piston Ring, Piston Ring Groove Wearfor uneven groove wear by inspecting the ring seat• Checking.

•

The rings should fit perfectly parallel to groove surfaces.
If not, replace the piston and all the piston rings.
With the piston rings in their grooves, make several measurements with a thickness gauge [A] to determine piston
ring/groove clearance.
Piston Ring/Groove ClearanceTopStandard:

0.03 ∼ 0.07 mm (0.0012 ∼ 0.0028 in.)Service Limit: 0.17 mm (0.0067 in.)
SecondStandard:

0.02 ∼ 0.06 mm (0.0008 ∼ 0.0024 in.)Service Limit: 0.16 mm (0.0063 in.)Piston Ring Groove Width

the piston ring groove width.
•○Measure
Use a vernier caliper at several points around the piston.
Piston Ring Groove Width
Top [A]
Standard:

0.92 ∼ 0.94 mm (0.0362 ∼ 0.0370 in.)Service Limit: 1.02 mm (0.040 in.)
Second [B]Standard:

1.01 ∼ 1.03 mm (0.0398 ∼ 0.0406 in.)Service Limit: 1.11 mm (0.044 in.)If the width of any of the two grooves is wider than theservice limit at any point, replace the piston.

Piston Ring Thickness

the piston ring thickness.
•○Measure
Use the micrometer to measure at several points aroundthe ring.

Piston Ring Thickness
Top [A]
Standard:

0.87 ∼ 0.89 mm (0.0342 ∼ 0.0350 in.)Service Limit: 0.80 mm (0.031 in.)
Second [B]Standard:

0.97 ∼ 0.99 mm (0.0382 ∼ 0.0390 in.)Service Limit: 0.90 mm (0.035 in.)If any of the measurements is less than the service limit
on either of the rings, replace all the rings.

NOTE○When using new rings in a used piston, check for un-even groove wear. The rings should fit perfectly parallelto the groove sides. If not, replace the piston.

5-40 ENGINE TOP END
Cylinder, Pistons
Piston Ring End Gap

the piston ring [A] inside the cylinder, using the pis• Place
ton to locate the ring squarely in place. Set it close to the•bottom of the cylinder, where cylinder wear is low.
Measure the gap [B] between the ends of the ring with athickness gauge.
Piston Ring End Gap
TopStandard:

0.25 ∼ 0.40 mm (0.0098 ∼ 0.0157 in.)Service Limit: 0.7 mm (0.028 in.)
SecondStandard:

0.40 ∼ 0.55 mm (0.0157 ∼ 0.0217 in.)Service Limit: 0.8 mm (0.031 in.)If the end gap of either ring is greater than the service
limit, replace all the rings.

ENGINE TOP END 5-41
Throttle Body Holder
Throttle Body Holder Installation

sure to install the O-rings [A].
• Be
Install[B] as shown and so that their projec• tions fitthe[C]clamps
on the holes of the holders.

○Be sure that the clamp bolt heads [D] face outwards.

• Tighten:

Torque - Throttle Body Holder Bolts [E]: 12 N·m (1.2 kgf·m,
106 in·lb)

5-42 ENGINE TOP END
Muffler
Muffler Body Removal

WARNINGTo avoid a serious burn, do not remove the muffler
when the engine is still hot. Wait until the muffler
cool down.

• Remove:
Right Frame Cover (see Frame Cover Removal in the
Frame chapter)
Remove the bolts and lift up the right footpeg stay [A].

•the muffler body mounting bolts [A] and nut, and• Removepull the muffler body [B] backward.

Exhaust Pipe Removal• Remove:
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
Center Fairings (see Center Fairing Removal in the
Frame chapter)
Muffler Body Clamp Bolt [A]Exhaust Pipe Manifold Holder Nuts [B]Exhaust Pipe [C]Gaskets

ENGINE TOP END 5-43
Muffler
Muffler Body and Exhaust Pipe Installation

the exhaust pipe gaskets [A] and muffler body
• Replaceconnection gasket [B] with new ones and install them.

○Install the muffler body connection gasket until it is bot-••

tomed so that the chamfer side [C] feces muffler body [D].
Install:
Muffler Body
Exhaust Pipe [E]Tighten:
Torque - Exhaust Pipe Manifold Holder Nut [F]: 17 N·m (1.7kgf·m, 12 ft·lb)
Muffler Body Mounting Bolts (Front and Rear) [G]:20 N·m (2.0 kgf·m, 15 ft·lb)

the muffler body clamp bolt [H].
•○Tighten
Install the muffler body clamp bolt as shown.

warm up the engine, wait until the engine• Thoroughly
cools down, and retighten all the bolts and nuts.

CLUTCH 6-1

ClutchTable of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tool and Sealant ........................................................................................................
Clutch Lever and Cable ..........................................................................................................
Clutch Lever Free Play Inspection ....................................................................................
Clutch Lever Free Play Adjustment ..................................................................................
Clutch Cable Removal ......................................................................................................
Clutch Cable Installation ...................................................................................................
Clutch Cable Lubrication...................................................................................................
Clutch Lever Installation....................................................................................................
Clutch Lever Adjustment...................................................................................................
Clutch Cover...........................................................................................................................
Clutch Cover Removal ......................................................................................................
Clutch Cover Installation ...................................................................................................
Release Shaft Removal ....................................................................................................
Release Shaft Installation .................................................................................................
Clutch Cover Disassembly................................................................................................
Clutch Cover Assembly.....................................................................................................
Clutch .....................................................................................................................................
Clutch Removal.................................................................................................................
Clutch Installation..............................................................................................................
Clutch Plate, Wear, Damage Inspection ...........................................................................
Clutch Plate Warp Inspection............................................................................................
Clutch Spring Free Length Measurement .........................................................................
Clutch Housing Finger Inspection .....................................................................................
Clutch Housing Spline Inspection .....................................................................................

6-2
6-4
6-5
6-6
6-6
6-6
6-6
6-6
6-6
6-7
6-7
6-8
6-8
6-8
6-9
6-9
6-9
6-10
6-11
6-11
6-11
6-13
6-14
6-14
6-14
6-14

6

6-2 CLUTCH
Exploded View

CLUTCH 6-3
Exploded View
No.

Fastener

1
2
3
4
5
6
7
8
9
10
11

Upper Cap on Clutch Cover
Lower Cap on Clutch CoverOil Filler Plug
Clutch Cover Mounting Bolts
Clutch Spring Bolts
Clutch Hub Nut
Oil Pump Sprocket Bolt
Clutch Lever Clamp Bolts
Oil Pump Chain Guide Bolts
Clutch Cable Holder Bolts
Clutch Cable Clamp Bolt

CL: Apply cable lubricant.
EO: Apply engine oil.
G: Apply grease.
HG: Apply high-temperature grease.
L: Apply a non-permanent locking agent.
Lh: Left-hand threads
M: Apply molybdenum disulfide grease.
R: Replacement Parts
S: Follow the specified tightening sequence.
W: Apply water.

N·m
3.9
–
–
9.8
9.8
132
12
7.8
12
9.8
9.8

Torque
kgf·m
0.40
–
–
1.0
1.0
13.5
1.2
0.80
1.2
1.0
1.0

Remarks
ft·lb
35 in·lb–
Hand-tighten–
Hand-tighten
87 in·lb
87 in·lb
98R
106 in·lb
L, Lh
69 in·lbS
106 in·lb
L
87 in·lb
L
87 in·lb

6-4 CLUTCH
Specifications
Item
Clutch Lever Free Play
ClutchFriction Plate Thickness
Friction Plate Warp
Steel Plate Warp
Clutch Spring Free Length

Standard2 ∼ 3 mm (0.08 ∼ 0.12 in.)2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.)
0.15 mm (0.16 in.) or less
0.2 mm (0.008 in.) or less33.6 mm (1.32 in.)Service Limit– – –2.8 mm (0.110 in.)
0.3 mm (0.012 in.)
0.3 mm (0.012 in.)32.6 mm (1.28 in.)

CLUTCH 6-5
Special Tool and Sealant
Clutch Holder:
57001-1243

Kawasaki Bond (Silicone Sealant):
92104-0004

6-6 CLUTCH
Clutch Lever and Cable
Clutch Lever Free Play Inspection

to the Clutch Operation Inspection in the Periodic• Refer
Maintenance chapter.

Clutch Lever Free Play Adjustment

to the Clutch Operation Inspection in the Periodic• Refer
Maintenance chapter.

Clutch Cable Removal• Remove:
Right Frame Cover (see Frame Cover Removal in the••

Frame chapter)
Right Center Fairing (see Center Fairing Removal in the
Frame chapter)
Slide the dust cover [A] at the middle of clutch cable outof place.
Loosen the locknut [B], and turn the adjusting nut [C] togive the cable plenty of play.

in the adjuster.
• ScrewLineup[A] in the clutch lever and adjuster [B],• and thenthefreeslots
the cable from the lever.
Freetheclutch
inner cable tip from the clutch release• lever.

the clutch cable clamp [A] on the cylinder• Disconnect
head cover.
• Pull the clutch cable out of the frame.

Clutch Cable Installation

the clutch cable correctly (see Cable, Wire, and Hose
• Run
Routing section in the Appendix chapter).
the clutch cable (see Clutch Operation Inspection• Adjust
in the Periodic Maintenance chapter).

Clutch Cable Lubrication

to the Chassis Parts Lubrication in the Periodic• Refer
Maintenance chapter.

CLUTCH 6-7
Clutch Lever and Cable
Clutch Lever Installation

the clutch lever so that the mating surface [B] of the• Installclutch lever clamp is aligned with the punch mark [A].
the upper clamp bolt first, and then the lower• Tighten
clamp bolt. There will be a gap at the lower part of theclamp after tightening.
Torque - Clutch Lever Clamp Bolts: 7.8 N·m (0.80 kgf·m, 69
in·lb)

Clutch Lever Adjustment
The adjuster has 5 positions so that the clutch lever position can be adjusted to suit the operator’s hand.
Push the lever forward and turn the adjuster [A] to alignthe number with the arrow mark [B] on the lever holder.
○The distance from the grip to the lever is minimum at number 5 and maximum at number 1.

•

6-8 CLUTCH
Clutch CoverClutch Cover Removal• Remove:
Engine Oil (Drain, see Engine Oil Change in the Periodic
Maintenance chapter)
Right Frame Cover (see Frame Cover Removal in the
Frame chapter)
Right Center Fairing (see Center Fairing Removal in the
Frame chapter)
Clutch Cable Lower End [A]Clutch Cover Mounting Bolts [B]the release lever [A] toward the rear as shown, and• Turnremove the clutch cover [B].

•

About 90° [C]Push the release lever toward the front of the motorcycle
and tape the release lever to the clutch cover to preventthe release shaft from falling out.

Clutch Cover Installation

silicone sealant to the area [A] where the mating• Apply
surface of the crankcase touches the clutch cover gasket
and to the crankshaft sensor lead grommet [B].
Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004

sure that the dowel pins [C] are in position.
• Be
the clutch cover gasket [D] with a new one.
• Replace
Tightentheclutch cover mounting bolts.
•

Torque - Clutch Cover Mounting Bolts: 9.8 N·m (1.0 kgf·m,
87 in·lb)

CLUTCH 6-9
Clutch Cover
Release Shaft Removal
CAUTION
Do not remove the clutch release lever and shaft
assembly unless it is absolutely necessary. If removed, the oil seal replacement may be required.
the clutch cover (see Clutch Cover Removal).
• Removethe lever and shaft assembly straight out of the clutch• Pullcover.

Release Shaft Installation

high-temperature grease to the oil seal lips on the• Apply
upper ridge of the clutch cover.
engine oil to the needle bearings in the hole of the• Apply
clutch cover.
molybdenum disulfide grease to the pusher-holding• Apply
portion [A] on the release shaft.
the washer [B] and spring [C].
• Install
Inserttherelease shaft straight into the upper hole of the• clutch cover.

CAUTION
When inserting the release shaft, be careful not toremove the spring of the oil seal.
the spring [A] as shown.
• FitRelease
Shaft [B]Clutch Cover [C]Clutch Cover Disassembly• Remove:
Oil Seal [A]Needle Bearings [B]6-10 CLUTCH
Clutch Cover• Remove the oil level gauge [A].

Clutch Cover Assembly• Replace the needle bearings and oil seal with new ones.
NOTE○Install the needle bearings so that the manufacture’s
mark face out.

the needle bearings [A] and oil seal [B] position as• Installshown.
Press [C] the bearing so that the bearing surface [D] isflushwith the housing end of clutch cover [E].
water to the rubber of the oil gauge [A] and press• Apply[B] it so that the ring [C] face outside.

CLUTCH 6-11
ClutchClutch Removal• Remove:
Engine Oil (Drain, see Engine Oil Change in the 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:
Friction Plates, Steel Plates
Clutch Hub Nut [A]Holding
the clutch hub [B], remove the nut and washer.
○Special Tool - Clutch Holder [C]: 57001-1243• Remove:
Clutch Hub
Spacer• Remove the oil pump sprocket bolt [A].
NOTE○The oil pump sprocket bolt has a left-hand threads.

the hole [B], pull out the sleeve [C].
• Using
the following as a set.
• Remove
Clutch Housing [D]Oil Pump Chain [E]Oil Pump Sprocket [F]the bolts [A] and remove the oil pump chain• Unscrew
guide [B].

Clutch Installationa non-permanent locking agent to the oil pump
• Apply
chain guide bolts and tighten them.
Torque - Oil Pump Chain Guide Bolts: 12 N·m (1.2 kgf·m,
106 in·lb)

the oil pump chain [A] on the clutch housing gear [B]• Put
and the oil pump sprocket [C].

6-12 CLUTCH
Clutch• Be sure that the spacer [A] is in position.

the following on the drive shaft.
• Insert
Clutch Housing [A] with Chain [B] and Sprocket [C]•

Sleeve [D]Align [E] the hole on the oil pump sprocket with the oilpump shaft.

NOTE○Insert the sleeve into the clutch housing, noting its direction as shown.
Sleeve [A]Oil Holes [B]Long Distance [C]Short Distance [D]Clutch Housing [E]the following parts on the drive shaft.
• InstallSpacer [A]Clutch Hub [B]Washer [C]
Nut [D]○Install the washer so that the OUTSIDE mark [A] faces
outward.

CLUTCH 6-13
Clutch○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 - Clutch Hub Nut: 132 N·m (13.5 kgf·m, 98 ft·lb)

the friction plates and steel plates, starting with a• Install
friction plate and alternating them.

CAUTION
If new dry friction plates and steel plates are installed, apply engine oil to the surfaces of eachplate to avoid clutch plate seizure.

○For the first steel plate [A], its thickness is 2.6 mm (0.10in.). The others are 2.3 mm (0.09 in.).

○Install the last friction plate [A] fitting the tangs in thegrooves in the housing as shown.

molybdenum disulfide grease to the pusher ends
• Apply[A] and install it in the clutch spring plate [B].

○Apply engine oil to the bearing [C].

the clutch spring plate and springs [D], and tighten• Installthe clutch spring bolts [E].
Torque - Clutch Spring Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)• Install the clutch cover (see Clutch Cover Installation).
Clutch Plate, Wear, Damage Inspection

inspect the friction and steel plates for signs of• Visually
seizure, overheating (discoloration), or uneven wear.
the thickness of each friction plate [A] at several• Measurepoints.
If any plates show signs of damage, or if they have worn
past the service limit, replace them with new ones.
Friction Plate Thickness
Standard:
2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.)Service Limit: 2.8 mm (0.110 in.)

6-14 CLUTCH
ClutchClutch Plate Warp Inspection

each friction plate or steel plate on a surface plate• Placeand measure the gap between the surface plate [A] andeach friction plate or steel plate [B] with a thickness gauge[C]. The gap is the amount of friction or steel plate warp.
If any plate is warped over the service limit, replace it witha new one.
Friction and Steel Plate Warp
Standard:
0.15 mm (0.006 in.) or lessService Limit: 0.3 mm (0.012 in.)

Clutch Spring Free Length Measurement

the free length of the clutch springs [A].
• MeasureIf any spring is shorter than the service limit, it must be
replaced.
Clutch Spring Free Length
Standard:
33.6 mm (1.32 in.)Service Limit: 32.6 mm (1.28 in.)

Clutch Housing Finger Inspection

inspect the clutch housing fingers [A] where the• Visuallyfriction plate tangs [B] hit them.
If they are badly worn or if there are groove cuts where thetangs hit, replace the housing. Also, replace the friction
plates if their tangs are damaged.

Clutch Housing Spline Inspection

inspect where the teeth [A] on the steel plates• Visuallywear against the clutch hub splines [B].
If there are notches worn into the splines, replace theclutch hub. Also, replace the steel plates if their teeth aredamaged.

ENGINE LUBRICATION SYSTEM 7-1

Engine Lubrication System
Table of Contents
Exploded View........................................................................................................................
Engine Oil Flow Chart.............................................................................................................
Specifications .........................................................................................................................
Special Tools and Sealant ......................................................................................................
Engine Oil and Oil Filter..........................................................................................................
Oil Level Inspection...........................................................................................................
Engine Oil Change............................................................................................................
Oil Filter Replacement ......................................................................................................
Oil Pan....................................................................................................................................
Oil Pan Removal ...............................................................................................................
Oil Pan Installation ............................................................................................................
Oil Pressure Relief Valve........................................................................................................
Oil Pressure Relief Valve Removal ...................................................................................
Oil Pressure Relief Valve Installation ................................................................................
Oil Pressure Relief Valve Inspection.................................................................................
Oil Pump.................................................................................................................................
Oil Pump Removal ............................................................................................................
Oil Pump Installation .........................................................................................................
Oil Pressure Measurement.....................................................................................................
Oil Pressure Measurement ...............................................................................................
Oil Pressure Switch ................................................................................................................
Oil Pressure Switch Removal ...........................................................................................
Oil Pressure Switch Installation ........................................................................................

7-2
7-4
7-6
7-7
7-8
7-8
7-8
7-8
7-9
7-9
7-10
7-11
7-11
7-11
7-11
7-12
7-12
7-13
7-14
7-14
7-15
7-15
7-15

7

7-2 ENGINE LUBRICATION SYSTEM
Exploded View

ENGINE LUBRICATION SYSTEM 7-3
Exploded View
No.

Fastener

1
2
3
4
5
6
7
8
9
10
11
12
13
14

Engine Oil Drain Bolt
Filter Plate Bolts
Oil Filter
Holder Mounting Bolt
Oil Pan Bolts
Oil Pipe Plate Bolt
Oil Pressure Relief ValveOil Pressure Switch
Oil Pump Cover Bolts
Oil Pump Sprocket Bolt
Oil Passage Plug
Lower Fairing Bracket Bolts
Oil Pump Chain Guide Bolts
Oil Plate Bolts

N·m
30
9.8
17.2
25
12
9.8
15
15
9.8
12
20
12
12
9.8

Torque
kgf·m
ft·lb
3.0
22
1.0
87 in·lb
1.75
13
2.5
18
1.2
106 in·lb
1.0
87 in·lb
1.5
11
1.5
11
1.0
87 in·lb
1.2
106 in·lb
2.0
15
1.2
106 in·lb
1.2
106 in·lb
1.0
87 in·lb

Remarks

EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
Lh: Left-hand threads
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)
R: Replacement Parts
SS: Apply silicone sealant.

L
EO, R
L
L
L
SS
L
L, Lh
L
L
L
L

7-4 ENGINE LUBRICATION SYSTEM
Engine Oil Flow ChartENGINE LUBRICATION SYSTEM 7-5
Engine Oil Flow Chart

7-6 ENGINE LUBRICATION SYSTEM
Specifications
Item
Engine Oil
TypeViscosity
Capacity:Level
Oil Pressure Measurement
Oil PressureStandard
API SE, SF or SG
API SH, SJ or SL with JASO MA
SAE 10W-40
1.7 L (1.8 US gt) (when filter is not removed)
1.9 L (2.0 US gt) (when filter is removed)
2.4 L (2.5 US gt) (when engine is completely dry)
Between upper and lower level lines
216 ∼ 294 kPa (2.2 ∼ 3.0 kgf/cm², 31 ∼ 43 psi) at 4 000 r/min (rpm),
Oil Temperature 90°C (194°F)

ENGINE LUBRICATION SYSTEM 7-7
Special Tools and Sealant
Oil Pressure Gauge, 10 kgf/cm²:
57001-164

Oil Filter Wrench:
57001-1249

Oil Pressure Gauge Adapter, PT3/8:
57001-1233

Kawasaki Bond (Silicone Sealant):
56019-120

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 Inspectionthat the engine oil level is between the upper [A]• Check
and lower [B] levels in the gauge.

NOTE○Situate the motorcycle so that it is perpendicular to theground.
○If the motorcycle has just been used, wait several minutes for all the oil to drain down.
○If the oil has just been changed, start the engine andrun it for several minutes at idle speed. This fills the oil
filter with oil. Stop the engine, then wait several minutes
until the oil settles.

CAUTION
Racing the engine before the oil reaches every partcan cause engine seizure.
If the engine oil gets extremely low or if the oil pumpor oil passages clog up or otherwise do not function
properly, the oil pressure warning light will light. If
this light stays on when the engine is running above
idle speed, stop the engine immediately and find thecause.
If the oil level is too high, remove the excess oil, using asyring or some other suitable device.
If the oil level is too low, add the correct amount of oil
through the oil filter opening. Use the same type andmake of oil that is already in the engine.

NOTE○If the engine oil type and make are unknown, use any
brand of the specified oil to top off the level in preference
to running the engine with the oil level low. Then at yourearliest convenience, change the oil completely.
Engine Oil Change

to the Engine Oil Change in the Periodic Mainte• Refernance chapter.

Oil Filter Replacement

to the Oil Filter Replacement in the Periodic Main• Refertenance chapter.

ENGINE LUBRICATION SYSTEM 7-9
Oil PanOil Pan Removal• Remove:
Engine Oil (Drain, see Engine Oil Change in the Periodic
Maintenance chapter)
Exhaust Pipe (see Exhaust Pipe Removal in the Engine
Top End chapter)
Muffler Body (see Muffler Body Removal in the Engine
Top End chapter)
Oil Pan Bolts [A]Oil Pan [B]Gasket [C]Damper [D]the following from the oil pan as necessary.
• Remove
Filter Plate Bolts [A]Filter Plate [B]Filter [C]the following from the lower crankcase half as• Removenecessary.
Oil Screen [A]Oil Pipe Plate Bolt [B]Oil Pipe Plate [C]Oil Pipes [D]Oil Pressure Relief Valve [E]7-10 ENGINE LUBRICATION SYSTEM
Oil PanOil Pan Installation

grease to the O-rings on the oil pipes [A].
• Apply
Installthe oil pipe plate [B] so that its guide portion [C] fits
• the breather
pipe [D] as shown.
Applyanon-permanent
locking agent to the oil pipe plate• bolt.
Torque - Oil Pipe Plate Bolt [E]: 9.8 N·m (1.0 kgf·m, 87 in·lb)

If the oil pressure relief valve [F] was removed, install it.

○Apply a non-permanent locking agent to the threads [G]of the oil pressure relief valve, and tighten it.

CAUTION
Do not apply too much non-permanent locking
agent to the threads. This may block the oil passage.
Torque - Oil Pressure Relief Valve: 15 N·m (1.5 kgf·m, 11ft·lb)

grease to the O-ring [A] on the oil screen [B] and• Apply
install it on the lower crankcase half as shown.
sure the damper [C] is on the end of the breather pipe
• Be
[D].

the oil pan gasket with a new one.
• ReplaceWheninstallingalign [A] the damper [B] on• the breather pipethewithoilthepan,hollow[C] on the oil pan.
Tighten:•
Torque - Oil Pan Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)

ENGINE LUBRICATION SYSTEM 7-11
Oil Pressure Relief ValveOil Pressure Relief Valve Removal• Refer to the Oil Pan Removal.

Oil Pressure Relief Valve Installation• Refer to the Oil Pan Installation.

Oil Pressure Relief Valve Inspection

to see if the valve [A] slides smoothly when push• Checking it in with a wooden or other soft rod, and see if it comesback to its seat by spring [B] pressure.

NOTE○Inspect the valve in its assembled state. Disassembly
and assembly may change the valve performance.

If any rough spots are found during above inspection,
wash the valve clean with a high-flash point solvent andblow out any foreign particles that may be in the valve withcompressed air.

WARNING
Clean the oil pressure relief valve in a well-ventilated area, and take care that there is no
spark or flame anywhere near the working area.
Because of the danger of highly flammable liquids,
do not use gasoline or low-flash point solvent.
If cleaning does not solve the problem, replace the oilpressure relief valve as an assembly. The oil pressure
relief valve is precision made with no allowance for replacement of individual parts.

7-12 ENGINE LUBRICATION SYSTEM
Oil Pump
Oil Pump Removal• Drain:Engine Oil (see Engine Oil Change in the Periodic Main•

tenance chapter)
Remove:Clutch (see Clutch Removal in the Clutch chapter)
Oil Pump Cover Bolts [A]Oil Pump Cover [B]• Remove:
Inner Rotor [A] for Scavenge Pump
Outer Rotor [B] for Scavenge Pump

• Remove:
Dowel Pin [A]
Pin [B]Oil Pump Body [C] with Oil Pump Shaft [D] and Pin• Remove:
Inner Rotor [A] for Feed Pump
Outer Rotor [B] for Feed PumpENGINE LUBRICATION SYSTEM 7-13
Oil Pump
Oil Pump Installation

molybdenum disulfide grease to the portion [A] of• Apply
the oil pump shaft as shown.
• Install:
Outer Rotor [B] for Feed Pump
Inner Rotor [C] for Feed Pump
Oil Pump Shaft [D] and Pin [E]Dowel Pin [F]Oil Pump Body [G]Pin [H] and Inner Rotor [I] for Scavenge Pump
Outer Rotor [J] for Scavenge Pump
Oil Pump Cover [K]

NOTE○The scavenge pump rotors are wider than the feedpump rotors.

a non-permanent locking agent to the oil pump
• Apply
cover bolts and tighten them.
Torque - Oil Pump Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

7-14 ENGINE LUBRICATION SYSTEM
Oil Pressure Measurement
Oil Pressure Measurement

the right lower fairing (see Lower Fairing Re• Remove
moval in the Frame chapter).
the oil passage plug, and attach the adapter [A]• Removeand gauge [B] to the plug hole.
Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164
Oil Pressure Gauge Adapter, PT3/8: 57001-1233

the engine and warm up the engine.
• StartRun
theat the specified speed, and read the oil• pressureengine
gauge.
If the oil pressure is much lower than the standard, checkthe oil pump, relief valve, and/or crankshaft bearing insert
wear immediately.
If the reading is much higher than the standard, check theoil passages for clogging.
Oil PressureStandard:

216 ∼ 294 kPa (2.2 ∼ 3.0 kgf/cm², 31 ∼ 43psi) at 4 000 r/min (rpm), oil temperature.
90°C (194°F)

the engine.
• StopRemovethe oil pressure gauge and adapter.
•

WARNING

Take care against burns form hot engine oil thatwill drain through the oil passage when the gauge
adapter is removed.
a non-permanent locking agent to the oil passage• Applyplug, and install it.
Torque - Oil Passage Plug: 20 N·m (2.0 kgf·m, 15 ft·lb)

ENGINE LUBRICATION SYSTEM 7-15
Oil Pressure Switch
Oil Pressure Switch Removal• Remove:
Engine Oil (Drain, see Engine Oil Change in the Periodic
Maintenance chapter)
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Switch Cover [A]Switch Terminal Bolt [B]Oil Pressure Switch [C]Oil Pressure Switch Installation

silicone sealant to the threads of the oil pressure• Applyswitch and tighten it.
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120
Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb)

the terminal bolt securely.
• Tighten
Applyasmall amount grease to the terminal so that• grease should
not close two breather holes [A] for switch
diaphragm.

ENGINE REMOVAL/INSTALLATION 8-1

Engine Removal/Installation
Table of Contents
Exploded View........................................................................................................................
Engine Removal/Installation ...................................................................................................
Engine Removal................................................................................................................
Engine Installation.............................................................................................................

8-2
8-4
8-4
8-7

8

8-2 ENGINE REMOVAL/INSTALLATION
Exploded View

ENGINE REMOVAL/INSTALLATION 8-3
Exploded View
No.
1
2
3

Fastener
Rear Engine Mounting Nuts
Front Engine Mounting Bolts
Engine Mounting Bracket Bolts

4. Engine Mounting Brackets
5. Collar
S: Follow the specified tightening sequence.

N·m
44
44
25

Torque
kgf·m
4.5
4.5
2.5

ft·lb
32
32
18

RemarksS
SS

8-4 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
Engine Removal

the rear part of the swingarm with a stand.
• Support
Squeeze• [A]. the brake lever slowly and hold it with a band

WARNINGBe sure to hold the front brake when removing theengine, or the motorcycle may fall over. It could
cause an accident and injury.

CAUTIONBe sure to hold the front brake when removing theengine, or the motorcycle may fall over. The engine
or the motorcycle could be damaged.

• Drain:Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter)
Coolant (see Coolant Change in the Periodic Maintenance chapter)• Remove:
Seat (see Seat Removal in the Frame chapter)
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)Upper Inner Fairings (see Upper Inner Fairing Removal
in the Frame chapter)
Windshield (see Windshield Removal in the Frame
chapter)
Meter Cover (see Meter Unit Removal/Installation in theElectrical System chapter)
Center Fairings (see Center Fairing Removal in the
Frame chapter)
Side Covers (see Side Cover Removal in the Frame
chapter)
Frame Covers (see Frame Cover Removal in the Frame
chapter)
Radiator and Hoses (see Radiator and Radiator Fan Removal in the Cooling System chapter)the clamp [A] on the lower fairing bracket.
• PullUnscrew
the lower fairing bracket bolts (both sides) [B]• and remove
the brackets (both sides) [C].
Disconnect
theoil pressure switch terminal [D].
•ENGINE REMOVAL/INSTALLATION 8-5
Engine Removal/Installation• Disconnect the crankshaft sensor lead connector [A].

• Remove:
Exhaust Pipe (see Exhaust Pipe Removal in the Engine
Top End chapter)
Muffler Body (see Muffler Body Removal in the Engine
Top End chapter)
Fuel Tank (see Fuel Tank Removal in the Fuel System(DFI) chapter)
Air Switching Valve and Hose (see Air Switching Valve
Removal in the Engine Top End chapter)
Air Cleaner Housing (see Air Cleaner Housing
Removal in the Fuel System (DFI) chapter)
Throttle Body Assy (see Throttle Body Assy Removal in
the Fuel System (DFI) chapter)
Clutch Cable (see Clutch Cable Removal in the Clutch
chapter)• Remove:
Stick Coils [A]Baffle Plate [B]Hose [C]or Disconnect:• Remove
Water Temperature Sensor Lead Connector [A]Starter Motor Cable [B]Engine Ground Cable Terminal Bolt [C]Alternator Lead Connector [D]Sidestand Switch Lead Connector [E]Speed Sensor Lead Connector [F]8-6 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
the engine sprocket cover (see Engine Sprocket• Remove
Removal in the Final Drive chapter).
the shift pedal [A] (see Shift Pedal Removal in• Remove
the Crankshaft/Transmission chapter).
• Disconnect:
Oxygen Sensor Lead Connector [B] (Europe Models)•

Neutral Switch Lead Terminal [C]Remove the bracket [D] and the engine sprocket [E] (seeEngine Sprocket Removal in the Final Drive chapter).

the engine with a stand or jack [A].
•○Support
Put a wooden board [B] on the suitable stand.
the engine mounting bolts [C].
• Remove
Removethe engine mounting bracket bolts (both sides)• [D] and remove
the brackets [E].
Removetheengine[F].
•

ENGINE REMOVAL/INSTALLATION 8-7
Engine Removal/Installation
Engine Installation

insert the rear engine mounting bolts [A] from the• Firstly,left side of the engine.
temporally tighten the right engine mounting• Secondly,
bracket bolts [B] and then the right front engine mounting
bolt [C].

○Position the collar [D] as shown.

temporally tighten the left engine mounting• Thirdly,
bracket bolts [E] and then the left front engine mounting••

bolt [F].
Fourthly, temporally tighten the rear engine mounting nuts
[G].
Fifthly, tighten the rear engine mounting nuts.
Torque - Rear Engine Mounting Nuts: 44 N·m (4.5 kgf·m, 32
ft·lb)• Sixthly, tighten the right engine mounting bracket bolts.
Torque - Engine Mounting Bracket Bolts:
kgf·m, 18 ft·lb)

25 N·m (2.5

• Seventhly, tighten the right front engine mounting bolt.

Torque - Front Engine Mounting Bolt: 44 N·m (4.5 kgf·m, 32
ft·lb)• Eighthly, tighten the left engine mounting bracket bolts.
Torque - Engine Mounting Bracket Bolts:
kgf·m, 18 ft·lb)

25 N·m (2.5

• Lastly, tighten the left front engine mounting bolt.

Torque - Front Engine Mounting Bolt: 44 N·m (4.5 kgf·m, 32
ft·lb)

the engine sprocket (see Engine Sprocket Installa• Installtion in the Final Drive chapter).
the leads, cables, and hoses correctly (see Cable,• Run
Wire, and Hose Routing section in the Appendix chapter).
the removed parts (see appropriate chapters).
• Install
Adjust:• Throttle Cables (see Throttle Control System Inspection•••in the Periodic Maintenance chapter)
Clutch Cable (see Clutch Operation Inspection in the Periodic Maintenance chapter)
Drive Chain (see Drive Chain Slack Adjustment in the
Periodic Maintenance chapter)
Fill the engine with engine oil (see Engine Oil Change in
the Periodic Maintenance chapter).
Fill the engine with coolant and bleed the air from the cooling system (see Coolant Change in the Periodic Maintenance chapter).
Adjust the idling (see Idle Speed Adjustment in the Periodic Maintenance chapter).

CRANKSHAFT/TRANSMISSION 9-1

Crankshaft/Transmission
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools and Sealant ......................................................................................................
Crankcase Splitting.................................................................................................................
Crankcase Splitting ...........................................................................................................
Crankcase Assembly ........................................................................................................
Crankshaft and Connecting Rods...........................................................................................
Crankshaft Removal .........................................................................................................
Crankshaft Installation ......................................................................................................
Connecting Rod Removal .................................................................................................
Connecting Rod Installation ..............................................................................................
Crankshaft/Connecting Rod Cleaning...............................................................................
Connecting Rod Bend.......................................................................................................
Connecting Rod Twist .......................................................................................................
Connecting Rod Big End Side Clearance .........................................................................
Connecting Rod Big End Bearing Insert/Crankpin Wear ..................................................
Crankshaft Side Clearance ...............................................................................................
Crankshaft Runout ............................................................................................................
Crankshaft Main Bearing Insert/Journal Wear ..................................................................
Balancer .................................................................................................................................
Balancer Removal.............................................................................................................
Balancer Installation..........................................................................................................
Balancer Shaft Bearing Insert/Journal Clearance.............................................................
Transmission ..........................................................................................................................
Shift Pedal Removal .........................................................................................................
Shift Pedal Installation ......................................................................................................
External Shift Mechanism Removal ..................................................................................
External Shift Mechanism Installation ...............................................................................
External Shift Mechanism Inspection................................................................................
Transmission Assy Removal.............................................................................................
Transmission Assy Disassembly ......................................................................................
Transmission Assy Assembly ...........................................................................................
Transmission Assy Installation..........................................................................................
Transmission Shaft Removal ............................................................................................
Transmission Shaft Installation .........................................................................................
Transmission Shaft Disassembly ......................................................................................
Transmission Shaft Assembly...........................................................................................
Shift Drum and Fork Removal...........................................................................................
Shift Drum and Fork Installation........................................................................................
Shift Drum Disassembly....................................................................................................
Shift Drum Assembly ........................................................................................................
Shift Fork Bending ............................................................................................................
Shift Fork/Gear Groove Wear ...........................................................................................
Shift Fork Guide Pin/Drum Groove Wear..........................................................................
Gear Dog and Gear Dog Hole Damage............................................................................
Ball Bearing, Needle Bearing, and Oil Seal............................................................................
Ball and Needle Bearing Replacement .............................................................................
Ball and Needle Bearing Wear..........................................................................................
Oil Seal Inspection ............................................................................................................

9-2
9-6
9-9
9-10
9-10
9-11
9-17
9-17
9-17
9-17
9-18
9-21
9-21
9-22
9-22
9-22
9-24
9-24
9-24
9-27
9-27
9-27
9-27
9-29
9-29
9-29
9-29
9-30
9-31
9-32
9-33
9-33
9-34
9-35
9-35
9-36
9-36
9-39
9-39
9-39
9-39
9-39
9-39
9-40
9-40
9-41
9-41
9-41
9-41

9

9-2 CRANKSHAFT/TRANSMISSION
Exploded View

CRANKSHAFT/TRANSMISSION 9-3
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14

Fastener
Connecting Rod Big End Nuts
Timing Rotor Bolt
Oil Plate Bolts
Breather Plate Bolts
Shift Shaft Return Spring Pin
Oil Pipe Bolts
Crankcase Bolts (M9, L = 113 mm)
Crankcase Bolts (M9, L = 83 mm)
Crankcase Bolts (M8, L = 73 mm)
Crankcase Bolts (M8, L = 60 mm)
Crankcase Bolts (M8, L = 110 mm)
Crankcase Bolts (M8, L = 50 mm)
Crankcase Bolts (M6)
Upper Crankcase Bolts

N·msee Text
40
9.8
9.8
29
9.8
44
44
35
35
27.5
27.5
19.6
27.5

Torque
kgf·m
←
4.1
1.0
1.0
2.9
1.0
4.5
4.5
3.6
3.6
2.8
2.8
2.0
2.8

ft·lb
←
30
87 in·lb
87 in·lb
22
87 in·lb
32
32
26
26
20
20
15
20

Remarks

15. Do not apply any grease or oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
LG: Apply liquid gasket.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)
R: Replacement Parts
S: Follow the specified tightening sequence.
SS: Apply silicone sealant.

MO
L
L
L
L
MO, S
MO, S
MO, S
MO, S
S
S
S
S

9-4 CRANKSHAFT/TRANSMISSION
Exploded View

CRANKSHAFT/TRANSMISSION 9-5
Exploded View
No.
1
2
3
4
5
6
7
8
9

Fastener
Gear Positioning Lever Bolt
Transmission Case Bolts
Shift Drum Cam Bolt
Shift Drum Bearing Holder Screw
Shift Rod Plate Bolt
Neutral Switch Holder Screw
Neutral Switch
Shift Shaft Cover Bolts
Shift Shaft Cover Screw

N·m
12
20
12
4.9
9.8
4.9
15
9.8
4.9

Torque
kgf·m
1.2
2.0
1.2
0.50
1.0
0.50
1.5
1.0
0.50

ft·lb
106 in·lb
15
106 in·lb
43 in·lb
87 in·lb
43 in·lb
11
87 in·lb
43 in·lb

Remarks

EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)
R: Replacement Parts

L
L
L
L
L (2)
L

9-6 CRANKSHAFT/TRANSMISSION
Specifications
Item
Crankshaft, Connecting Rods
Connecting Rod Bend

Standard

Service Limit– – –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.)0.08 mm
(0.0031 in.)37.97 mm(1.4949 in.)– – –Connecting Rod Twist
Connecting Rod Big End Side Clearance
Connecting Rod Big End Bearing Insert/Crankpin
Clearance
Crankpin Diameter:
Marking:
None○
Connecting Rod Big End Inside Diameter:
Marking:
None○
Connecting Rod Big End Bearing Insert Thickness:
Brown
Black
Blue

0.13 ∼ 0.38 mm(0.0051 ∼ 0.0150 in.)
0.017 ∼ 0.041 mm(0.0007 ∼ 0.0016 in.)37.984 ∼ 38.000 mm(1.4954 ∼ 1.4961 in.)37.984 ∼ 37.992 mm(1.4954 ∼ 1.4957 in.)37.993 ∼ 38.000 mm(1.4958 ∼ 1.4961 in.)41.000 ∼ 41.016 mm(1.6142 ∼ 1.6148 in.)– – –41.000 ∼ 41.008 mm(1.6142 ∼ 1.6145 in.)41.009 ∼ 41.016 mm(1.6145 ∼ 1.6148 in.)

– – –1.475 ∼ 1.480 mm(0.05807 ∼ 0.05827 in.)
1.480 ∼ 1.485 mm(0.05827 ∼ 0.05846 in.)1.485 ∼ 1.490 mm(0.05846 ∼ 0.05866 in.)

– – –

– – –
– – –

– – –

– – –
– – –

Connecting Rod Big End Bearing Insert Selection:
Con-rod Big End
Bore Diameter
Marking

Bearing Insert

Crankpin Diameter
Marking

Size Color

Part Number

None

○

Brown

92139-0116

None

None

○

Black

92139-0115

None

Blue

92139-0114○○

Connecting Rod Bolt Stretch: (Usable Range)
New Connecting Rod
Used Connecting Rod
Crankshaft Side Clearance

0.24 ∼ 0.36 mm(0.0094 ∼ 0.0142 in.)
0.20 ∼ 0.32 mm(0.0079 ∼ 0.0126 in.)0.05 ∼ 0.20 mm(0.0020 ∼ 0.0079 in.)

– – –
– – –
0.40 mm
(0.0157 in.)

CRANKSHAFT/TRANSMISSION 9-7
Specifications
Item
Crankshaft Runout
Crankshaft Main Bearing Insert/Journal Clearance
Crankshaft Main Journal Diameter:
Marking:None
1
Crankcase Main Bearing Inside Diameter:

Standard
TIR 0.02 mm (0.0008 in.)or less
0.012 ∼ 0.036 mm(0.0005 ∼ 0.0014 in.)37.984 ∼ 38.000 mm(1.4954 ∼ 1.4961 in.)Service Limit
TIR 0.05 mm(0.0020 in.)0.07 mm
(0.0028 in.)37.96 mm(1.4945 in.)37.984 ∼ 37.992 mm(1.4954 ∼ 1.4957 in.)37.993 ∼ 38.000 mm(1.4958 ∼ 1.4961 in.)41.000 ∼ 41.016 mm(1.6142 ∼ 1.6148 in.)– – –41.000 ∼ 41.008 mm(1.6142 ∼ 1.6145 in.)41.009 ∼ 41.016 mm(1.6145 ∼ 1.6148 in.)

– – –1.490 ∼ 1.494 mm(0.0587 ∼ 0.0588 in.)1.494 ∼ 1.498 mm(0.0588 ∼ 0.0590 in.)1.498 ∼ 1.502 mm(0.0590 ∼ 0.0591 in.)

– – –

– – –
– – –

Marking:○

None
Crankshaft Main Bearing Insert Thickness:
Brown
Black
Blue

– – –

– – –
– – –

Crankshaft Main Bearing Insert Selection:
Crankcase Main
Bearing Inside
Diameter Marking○

Crankshaft Main
Journal Diameter
Marking

Size Color

Part Number

1

Brown

92028-1905

Black

92028-1904

Blue

92028-1903

None

1

○

None

None

None

Bearing Insert**The bearing inserts for Nos. 1, 2 and 3 journals have oil grooves.
Balancer Shaft
Balancer Shaft Bearing Insert/Journal Clearance
Balancer Shaft Journal Diameter:
Marking:
None○0.011 ∼ 0.033 mm(0.0004 ∼ 0.0013 in.)27.987 ∼ 28.000 mm(1.1019 ∼ 1.1024 in.)27.987 ∼ 27.993 mm(1.1019 ∼ 1.1021 in.)27.994 ∼ 28.000 mm(1.1021 ∼ 1.1024 in.)0.08 mm
(0.0031 in.)27.96 mm(1.1108 in.)
– – –
– – –

9-8 CRANKSHAFT/TRANSMISSION
Specifications
Item
Crankcase Bearing Bore Diameter:

Standard
31.000 ∼ 31.016 mm(1.2205 ∼ 1.2228 in.)Service Limit– – –Marking:○

31.000 ∼ 31.008 mm(1.2205 ∼ 1.2208 in.)31.009 ∼ 31.016 mm(1.2208 ∼ 1.2211 in.)

None
Balancer Shaft Bearing Insert Thickness:
Brown
Black
Blue

– – –
– – –

1.490 ∼ 1.494 mm(0.0587 ∼ 0.0588 in.)1.494 ∼ 1.498 mm(0.0588 ∼ 0.0590 in.)1.498 ∼ 1.502 mm(0.0590 ∼ 0.0591 in.)

– – –
– – –
– – –

Balancer Shaft Bearing Insert Selection:
Crankcase Bearing
Bore Diameter
Marking○○

Balancer Shaft
Journal Diameter
Marking○

None

Bearing Insert*
Size Color

Part Number

Brown

92139-0119

None

○

Black

92139-0118

None

None

Blue

92139-0117*The bearing inserts for Nos. 1,2 journals have oil grooves.
Transmission
Shift Fork Ear Thickness
Gear Groove Width
Shift Fork Guide Pin Diameter
Shift Drum Groove Width

5.9 ∼ 6.0 mm(0.232 ∼ 0.236 in.)6.05 ∼ 6.15 mm(0.238 ∼ 0.242 in.)
6.9 ∼ 7.0 mm(0.272 ∼ 0.276 in.)7.05 ∼ 7.20 mm(0.278 ∼ 0.283 in.)

5.8 mm(0.228 in.)6.25 mm(0.246 in.)
6.8 mm(0.268 in.)
7.3 mm(0.287 in.)

CRANKSHAFT/TRANSMISSION 9-9
Special Tools and SealantOutside Circlip Pliers:
57001-144

Bearing Driver Set:
57001-1129

Kawasaki Bond:
92104-1064

9-10 CRANKSHAFT/TRANSMISSION
Crankcase Splitting
Crankcase Splitting• Remove:
Engine (see Engine Removal in the Engine Removal/Installation chapter)
Cylinder (see Cylinder Removal in the Engine Top End
chapter)
Pistons (see Piston Removal in the Engine Top End
chapter)Stater Motor (see Starter Motor Removal in the Electrical
System chapter)
Clutch (see Clutch Removal in the Clutch chapter)
Transmission Assy (see Transmission Assy Removal)
Alternator Rotor (see Alternator Rotor Removal in theElectrical System chapter)• Remove the upper crankcase bolts [A] and the washers.

the oil pan, relief valve, oil screen and oil pipes• Remove(see Oil Pan Removal in the Engine Lubrication System
chapter).
Remove the lower crankcase bolts.
○Firstly loosen the M6 bolts, secondly the M8 bolts andlastly the M9 bolts.
M6 Bolts [A]
M8 Bolts [B]M9 Bolts [C] and Washers
Tap lightly around the crankcase mating surface with aplastic mallet, and split the crankcase. Take care not todamage the crankcase.

••

CRANKSHAFT/TRANSMISSION 9-11
Crankcase Splitting
If the oil pipe is to be removed, follow the next procedure.

○Unscrew the bolts [A] and remove the oil pipe [B].

○Prepare a 5 mm rod [A], and insert it to the hole of theupper crankcase half.

○Remove the oil pipe [B], tapping [C] the rod as shown.

If the breather plate [A] is to be removed, follow the next
procedure.
○Remove the oil pipe (see above).
○Cut the gasket around the plate [B].
○Remove:
Breather Plate Bolts [C]Breather Plate with Pipe

Crankcase Assembly
CAUTION
The upper and lower crankcase halves are machined at the factory in the assembled state, so the
crankcase halves must be replaced as a set.
a high-flash point solvent, clean off the mating sur• With
faces of the crankcases halves and wipe dry.
compressed air, blow out the oil passages in the• Using
crankcase halves.
the oil plate [A] on the upper crankcase half was re• Ifmoved,
install it as shown.
Applyanon-permanent
locking agent to the oil plate bolts• and torque them.
Torque - Oil Plate Bolts [B]: 9.8 N·m (1.0 N·m, 87 in·lb)

9-12 CRANKSHAFT/TRANSMISSION
Crankcase Splitting
and insert [A] the new needle bearing [B] for the• Press
shift drum until it is bottomed.
Special Tool - Bearing Driver Set: 57001-1129

and insert [C] the new needle bearing [D] for the• Press
shift shaft so that the bearing surface is flush with the endof the hole.
Special Tool - Bearing Driver Set: 57001-1129

Lower Crankcase Half [E]silicone sealant to the breather plate mating surface• Apply[A] 1 mm (0.04 in.) or more thick, and then install thebreather plate.
Sealant - Three Bond: TB1207B

NOTE○Make the application finish within 7 minutes when theliquid gasket to the mating surface of the breather plate
is applied.
○Moreover fit the plate and tighten the bolts just after
application of the liquid gasket.
a non-permanent locking agent to the threads and• Apply
tighten the bolts [A].
Torque - Breather Plate Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

the breather pipe [A].
•○Install
Align the white mark [B] on the pipe with the white mark[C] on the breather fittling.

○Install the clamp [D] so that the pinch portions [E] face thewhite marks.

the oil pipe [A] so that its flange [B] touches to the• Installsurface [C] of the upper crankcase half.
• Apply grease to the O-ring [D] on the oil pipe.

CRANKSHAFT/TRANSMISSION 9-13
Crankcase Splitting
the crankshaft assembly and the balancer shaft as• Install
sembly on the upper crankcase half.

○Align [A] the timing mark on the balancer gear [B] with thetiming mark on the balancer drive gear [C] of the crankshaft.

• Be sure to hang the camshaft chain [A] on the crankshaft.

• Be sure that the dowel pins [A] are in position.

the bearing groove [A] on the positioning ring [B] as• Setshown.

9-14 CRANKSHAFT/TRANSMISSION
Crankcase Splitting
liquid gasket [A] to the mating surface of the lower• Apply
crankcase half.
Sealant - Kawasaki Bond: 92104-1064

NOTE○Especially, apply a liquid gasket carefully so that it shallbe filled up on the grooves.

CAUTION
Do not apply liquid gasket around the crankshaft
main bearing inserts, and oil passage holes.

○Do not apply liquid gasket to the oil passage [B].

CRANKSHAFT/TRANSMISSION 9-15
Crankcase Splitting
the lower crankcase half to the upper crankcase half.
•○Fit
Insert [A] the breather pipe [B] on the upper crankcase
half through the hole [C] on the lower crankcase half.

NOTE○Make the application finish within 20 minutes when

the liquid gasket to the mating surface of the lower
crankcase half is applied.
○Moreover fit the case and tighten the case bolts justafter finishing the application of the liquid gasket.

○The M9 bolts [1 ∼ 6] (see the next figure) have copper•

plated washers. Replace them with new ones.
Apply molybdenum disulfide oil solution to both sides [A]of the M9 bolts washers and the threads [B] of the M9bolts.

molybdenum disulfide oil solution to flange [A] and• Apply
the threads [B] of the M8 bolts which is tightening order is[7 ∼ 10] only (see the next figure).

9-16 CRANKSHAFT/TRANSMISSION
Crankcase Splitting
the lower crankcase bolts using the following• Tighten
steps.

○Following the sequence numbers on the lower crankcase

half, tighten the M9 bolts [1, 2] L= 113 mm (4.45 in.) with
washers.
Torque - Crankcase Bolts (M9): 44 N·m (4.5 kgf·m, 32 ft·lb)○Tighten the M9 bolts [3, 4] L= 83 mm (3.27 in.) with washers.

Torque - Crankcase Bolts (M9): 44 N·m (4.5 kgf·m, 32 ft·lb)○Tighten the M9 bolts [5, 6] L= 113 mm (4.45 in.) with
washers.

Torque - Crankcase Bolts (M9): 44 N·m (4.5 kgf·m, 32 ft·lb)○Tighten the M8 bolts [7 ∼ 10].

Torque - Crankcase Bolts (M8): 35 N·m (3.6 kgf·m, 26 ft·lb)○Tighten the M8 bolts [A] (Do not apply molybdenum oil
solution).

Torque - Crankcase Bolts (M8): 27.5 N·m (2.8 kgf·m, 20
ft·lb)○Tighten the M6 bolts [B].

Torque - Crankcase Bolts (M6): 19.6 N·m (2.0 kgf·m, 15
ft·lb)

the upper crankcase bolts.
•○Tighten
The upper crankcase bolts have copper plated washers.
Replace them with new ones.

Torque - Upper Crankcase Bolts [A]: 27.5 N·m (2.8 kgf·m,
20 ft·lb)

tightening all crankcase bolts, check the following• After
items.

○Crankshaft and balancer shafts turn freely.

CRANKSHAFT/TRANSMISSION 9-17
Crankshaft and Connecting Rods
Crankshaft Removal

the crankcase (see Crankcase Splitting).
• Split
Removethe crankshaft [A].
•

Crankshaft Installation
CAUTION
If the crankshaft, bearing inserts, or crankcase
halves are replaced with new ones, select the bearing inserts and check clearance with a plastigage(press gauge) before assembling engine to be surethe correct bearing inserts are installed.
molybdenum disulfide oil solution to the crankshaft• Applymain bearing inserts.

○Align [A] the timing mark on the balancer gear [B] with thetiming mark on the balancer drive gear [C] of the crankshaft.

the crankshaft with the camshaft chain [A] hanging• Installon it.

Connecting Rod Removal

the crankcase (see Crankcase Splitting).
• Splitthe connecting rod nuts [A].
• Remove
Removethe crankshaft.
•

NOTE○Mark and record the locations of the connecting rods
and their big end caps so that they can be reassembled
in their original positions.

• Remove the connecting rods from the crankshaft.
CAUTION

Discard the connecting rod bolts. To prevent damage to the crankpin surfaces, do not allow the connecting rod bolts to bump against the crankpins.

9-18 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
Connecting Rod Installation
CAUTION
To minimize vibration, the connecting rods shouldhave the same weight mark.
Big End Cap [A]Connecting Rod [B]Weight Mark, Alphabet [C]Diameter Mark [D]: “○” or no mark

CAUTION
If the connecting rods, big end bearing inserts, or
crankshaft are replaced with new ones, select thebearing insert and check clearance with a plastigage (press gauge) before assembling engine to be
sure the correct bearing inserts are installed.
molybdenum disulfide grease [A] to the outer sur• Apply
face of the upper insert and the inner surface of the connecting rod big end.
Apply molybdenum disulfide oil solution [B] to the innersurfaces of upper and lower bearing inserts.
○The molybdenum disulfide oil solution is a mixture of engine oil and molybdenum disulfide grease with a weightratio (10 : 1).
○Do not apply any grease or oil [C] to the cap inside andcap insert outside.
○Install the inserts so that their nails [D] are on the sameside and fit them into the recess of the connecting rod andcap.

•

CAUTION
Wrong application of oil and grease could cause
bearing damage.

○When installing the inserts [A], be careful not to damage•••

the insert surface with the edge of the connecting rod [B]or the cap [C]. One way to install inserts is as follows.
Installation [D] to Cap
Installation [E] to Connecting Rod
Push [F]Spare Dowel Pin [G]Connecting Rod Bolts [H]Install the cap on the connecting rod, aligning the weightand diameter marks.
Remove debris and clean the surface of inserts.
Apply molybdenum disulfide oil solution [MO] to thethreads and seating surfaces of the big end nuts andbolts.

CRANKSHAFT/TRANSMISSION 9-19
Crankshaft and Connecting Rodsthe crankshaft (see Crankshaft Installation).
• Install
Installeach connecting rod on its original crankpin.
•

NOTE○Install each connecting rod so that its oil jet [A] faces theexhaust side (the front [B]) (see Engine Oil Flow Chartin the Engine Lubrication System chapter).

○The connecting rod big end is bolted using the “plastic
region fastening method”.

○This method precisely achieves the needed clamping

force without exceeding it unnecessarily, allowing theuse of thinner, lighter bolts further decreasing connecting
rod weight.
○There are two types of the plastic region fastening. One isa bolt length measurement method and other is a rotation
angle method. Observe one of the following two, but thebolt length measurement method is preferable because
this is a more reliable way to tighten the big end nuts.

CAUTION
The connecting rod bolts are designed to stretch
when tightened. Never reuse the connecting rod
bolts. See the table below for correct bolt and nut
usage.

CAUTIONBe careful not to overtighten the nuts.
The bolts must be positioned on the seating surface
correctly to prevent the bolt heads from hitting the
crankcase.
(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 ananti-rust solution.

•

WARNING
Clean the bolts, nuts, and connecting rods in a well-ventilated area, and take care that there is no sparkor flame anywhere near the working area. This includes any appliance with a pilot light. Because of
the danger of highly flammable liquids, do not use
gasoline or low-flash point solvents to clean them.

CAUTION
Immediately dry the bolts and nuts with compressed air after cleaning.
Clean and dry the bolts and nuts completely.

9-20 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
new bolts in reused connecting rods.
• InstallDent
bothbolt head and bolt tip with a punch as shown.
• Before tightening,
use a point micrometer [A] to measure• the length of new connecting
rod bolts and record the val-•••ues to find the bolt stretch.
Connecting Rod [B]Mark here with a punch [C].
Nuts [D]Fit micrometer pins into punch marks [E].
Apply a small amount of molybdenum disulfide oil solution
to the following.
Threads of Nuts and Bolts
Seating Surfaces of Nuts and Con-rods
Tighten the big end nuts until the bolt elongation reaches
the length specified in the table.
Check the length [F] of the connecting rod bolts.
If the stretch is more than the usable range, the bolt has
stretched too much. An overelongated bolt may break inuse.
Bolt Length
after tightening

Bolt Length
before tightening–

Connecting Rod
Assy

Bolt

Nut

New

Use the bolts
attached to
new con-rod.

Attached to
new con-rod
Used

Used

Replace thebolts with new
ones.

New
New

=

Bolt Stretch

Usable Range ofConnecting Rod
Bolt Stretch
0.24 ∼ 0.36 mm(0.0094 ∼ 0.0142 in.)
0.20 ∼ 0.32 mm(0.0079 ∼ 0.0126 in.)(2) Rotation Angle Method
If you don’t have a point micrometer, you may tighten thenuts 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 aretreated with an anti-rust solution.

•

WARNING
Clean the bolts and nuts in a well-ventilated area,
and take care that there is no spark or flame anywhere near the working area. This includes any appliance with a pilot light. Because of the danger
or highly flammable liquids, do not use gasoline or
low-flash point solvents to clean them.

CAUTION
Immediately dry the bolts and nuts with compressed air after cleaning.
Clean and dry the bolts and nuts completely.

CRANKSHAFT/TRANSMISSION 9-21
Crankshaft and Connecting Rods
new bolts in reused connecting rods.
• InstallApplyasmall amount of molybdenum disulfide oil solution• to the following.
Threads [A] of Nuts and Bolts
Seating Surfaces [B] of Nuts and Con-rods

tighten the nuts to the specified torque. See the• First,table below.
tighten the nuts 120° ±5° .
•○Next,Mark [A] the connecting rod big end caps and nuts so thatnuts can be turned 120° [B] properly.

Connecting Rod
Assy
New

Used

Bolt

Nut

Use the bolts Attached toattached to new con-rod
new con-rod.
New
Replace thebolts withnew ones.

Torque + Angle
N·m (kgf·m, ft·lb)
18 (1.8, 13.0) + 120°
20 (2.0, 14.5) + 120°Used

24 (2.4, 17.4) + 120°

New

25 (2.6, 18.8) + 120°

Crankshaft/Connecting Rod Cleaning

removing the connecting rods from the crankshaft,• Afterclean them with a high-flash point solvent.
the crankshaft oil passages with compressed air to• Blow
remove any foreign particles or residue that may haveaccumulated in the passages.

Connecting Rod Bend

the connecting rod big end bearing inserts, and• Removereinstall the connecting rod big end cap.
an arbor [A] of the same diameter as the connect• Selecting rod big end, and insert the arbor through the connect-•••

ing rod big end.
Select an arbor of the same diameter as the piston pin
and at least 100 mm (3.94 in.) long, and insert the arbor[B] through the connecting rod small end.
On a surface plate, set the big-end arbor on V block [C].
With the connecting rod held vertically, use a heightgauge to measure the difference in the height of thearbor above the surface plate over a 100 mm (3.94 in.)length to determine the amount of connecting rod bend.
If connecting rod bend exceeds the service limit, the connecting rod must be replaced.
Connecting Rod Bend
Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)

9-22 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
Connecting Rod Twist

the big-end arbor [A] still on V block [C], hold the• Withconnecting rod horizontally and measure the amount thatthe arbor [B] varies from being paralleled with the surface
plate over a 100 mm (3.94 in.) length of the arbor to determine the amount of connecting rod twist.
If connecting rod twist exceeds the service limit, the connecting rod must be replaced.
Connecting Rod Twist
Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)Connecting Rod Big End Side Clearance

connecting rod big end side clearance.
•○Measure
Insert a thickness gauge [A] between the big end and either crank web to determine clearance.

Connecting Rod Big End Side ClearanceStandard:
0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.)Service Limit: 0.58 mm (0.023 in.)If the clearance exceeds the service limit, replace the connecting rod with new one and then check clearance again.
If clearance is too large after connecting rod replacement,
the crankshaft also must be replaced.

Connecting Rod Big End Bearing Insert/Crankpin
Wear

the bearing insert/crankpin [B] clearance with• Measureplastigage [A].
the big end nuts to the specified torque (see Con• Tighten
necting Rod Installation).

NOTE○Do not move the connecting rod and crankshaft during
clearance measurement.

CAUTION
After measurement, replace the connecting rod
bolts.
Connecting Rod Big End Bearing Insert/Crankpin ClearanceStandard:
0.017 ∼ 0.041 mm (0.0001 ∼ 0.0016 in.)Service Limit: 0.08 mm (0.0031 in.)If the clearance is within the standard, no bearing replacement is required.
If the clearance is between 0.042 mm (0.00165 in.) andthe service limit (0.08 mm, 0.0031 in.), replace the bearing inserts [A] with inserts painted blue [B]. Check insert/crankpin clearance with the plastigage. The clearance may exceed the standard slightly, but it must not beless than the minimum in order to avoid bearing seizure.
If the clearance exceeds the service limit, measure thediameter of the crankpins.
Crankpin DiameterStandard:
37.984 ∼ 38.000 mm (1.4954 ∼ 1.4961 in.)Service Limit: 37.97 mm (1.4949 in.)

CRANKSHAFT/TRANSMISSION 9-23
Crankshaft and Connecting Rods
If any crankpin has worn past the service limit, replace thecrankshaft with a new one.
If the measured crankpin diameters are not less than theservice limit, but do not coincide with the original diametermarkings on the crankshaft, make new marks on it.
Crankpin Diameter Marks
None 37.984 ∼ 37.992 mm (1.4954 ∼ 1.4957 in.)○37.993 ∼ 38.000 mm (1.4958 ∼ 1.4961 in.)∆: Crankpin Diameter Marks, “○” or no mark.
the connecting rod big end inside diameter, and• Measuremark each connecting rod big end in accordance with the•inside diameter.
Tighten the connecting rod big end nuts to the specified
torque (see Connecting Rod Installation).

NOTE○The mark already on the big end should almost coincidewith the measurement.

Connecting Rod Big End Inside Diameter Marks
None 41.000 ∼ 41.008 mm (1.6142 ∼ 1.6145 in.)○41.009 ∼ 41.016 mm (1.6145 ∼ 1.6148 in.)

Big End Cap [A]Connecting Rod [B]Weight Mark, Alphabet [C]Diameter Mark (Around Weight Mark) [D]: “○” or nomark
the proper bearing insert [A] in accordance with the• Selectcombination of the connecting rod and crankshaft coding.
Size Color [B]Bearing Insert

Con-rod Big End
Inside Diameter
Marking

Crankpin
DiameterMarking

Size Color

Part Number

None

○

Brown

92139-0116

None

None

○
○

○

Black

92139-0115

None

Blue

92139-0114

the new inserts in the connecting rod and check• Install
insert/crankpin clearance with the plastigage.

9-24 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
Crankshaft Side Clearance

a thickness gauge [A] between the crankcase main
• Insert
bearing and the crank web at the No. 2 journal [B] todetermine clearance.
If the clearance exceeds the service limit, replace thecrankcase halves as a set.

NOTE

○The upper and lower crankcase halves are machinedat the factory in the assembled state, so the crankcase
halves must be replaced as a set.

Crankshaft Side ClearanceStandard:
0.05 ∼ 0.20 mm (0.0020 ∼ 0.0079 in.)Service Limit: 0.40 mm (0.0157 in.)

Crankshaft Runout

the crankshaft runout.
• MeasureIf the measurement exceeds the service limit, replace thecrankshaft.
Crankshaft Runout
Standard:
TIR 0.02 mm (0.0008 in.) or lessService Limit: TIR 0.05 mm (0.0020 in.)

Crankshaft Main Bearing Insert/Journal Weara plastigage (press gauge) [A], measure the bear• Usinging insert/journal [B] clearance.

NOTE○Tighten the crankcase bolts to the specified torque (seeCrankcase Assembly).

○Do not turn the crankshaft during clearance measurement.
○Journal clearance less than 0.025 mm (0.00098 in.) can
not be measured by plastigage, however, using genuine
parts maintains the minimum standard clearance.
Crankshaft Main Bearing Insert/Journal ClearanceStandard:
0.012 ∼ 0.036 mm (0.0005 ∼ 0.0014 in.)Service Limit: 0.07 mm (0.0028 in.)If the clearance is within the standard, no bearing replacement is required.
If the clearance is between 0.037 mm (0.0015 in.) and theservice limit (0.07 mm, 0.0028 in.), replace the bearing inserts [A] with inserts painted blue [B]. Check insert/journal
clearance with the plastigage. The clearance may exceed
the standard slightly, but it must not be less than the minimum in order to avoid bearing seizure.
If the clearance exceeds the service limit, measure thediameter of the crankshaft main journal.

CRANKSHAFT/TRANSMISSION 9-25
Crankshaft and Connecting Rods
Crankshaft Main Journal DiameterStandard:
37.984 ∼ 38.000 mm (1.4954 ∼ 1.4961 in.)Service Limit: 37.96 mm (1.4945 in.)If any journal has worn past the service limit, replace thecrankshaft with a new one.
If the measured journal diameters are not less than theservice limit, but do not coincide with the original diametermarkings on the crankshaft, make new marks on it.
Crankshaft Main Journal Diameter Marks
None 37.984 ∼ 37.992 mm (1.4954 ∼ 1.4957 in.)1

37.993 ∼ 38.000 mm (1.4958 ∼ 1.4961 in.)□: Crankshaft Main Journal Diameter Marks, “1” or nomark.

the main bearing inside diameter, and mark the• Measure
upper crankcase half in accordance with the inside diam-

•

eter.
Crankcase Main Bearing Inside Diameter Marks: “○” orno mark.
Tighten the crankcase bolts to the specified torque (seeCrankcase Assembly).

NOTE○The mark already on the upper crankcase half should
almost coincide with the measurement.
Crankcase Main Bearing Inside Diameter Marks
41.000 ∼ 41.008 mm (1.6142 ∼ 1.6145 in.)○None 41.009 ∼ 41.016 mm (1.6145 ∼ 1.6148 in.)□□□: Crankcase Main Bearing Inside Diameter Marks, “○”mark or no markNo.1 Journal [A]No.2 Journal [B]No.3 Journal [C]
the proper bearing insert [A] in accordance with the• Selectcombination of the crankcase and crankshaft coding.
Size Color [B]Crankcase Main Bearing
Inside Diameter Marking

Crankshaft Main Journal
Diameter Marking

○

1

None

1

○

None

None

None

Bearing Insert*
Size Color
Part Number
Brown

92028-1905

Black

92028-1904

Blue

92028-1903* The bearing inserts for Nos. 1, 2 and 3 journals have oil groove.

9-26 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
the new inserts in the crankcase halves and check• Install
insert/journal clearance with the plastigage.

CRANKSHAFT/TRANSMISSION 9-27
Balancer
Balancer Removal

the crankcase (see Crankcase Splitting).
• SplitPull
thebalancer shaft with the balancer gear out of the• crankcase.

Balancer Installation

molybdenum disulfide oil solution to the inside of• Apply
the balancer shaft bearing insert.
[A] the timing mark on the balancer gear [B] with the• Aligntiming mark on the balancer drive gear [C] of the crank-•

shaft.
Assemble the crankcase (see Crankcase Assembly).

Balancer Shaft Bearing Insert/Journal Clearance

the bearing insert/journal clearance using a• Measureplastigage.

○Split the crankcase and wipe each bearing insert and jour-

nal surface clean of oil.
○Cut strips of plastigage to bearing insert width, and placea strip on each journal parallel to the balancer shaft so thatthe plastigage will be compressed between the journal
and the bearing insert.
○Install the lower crankcase half, and tighten the case bolts
to the specified torque (see Crankcase Assembly).

NOTE○Do not turn the balancer shaft during clearance measurement.

○Remove the lower crankcase half and measure the plas-

tigage width [A] to determine the bearing insert/journal [B]clearance.
Balancer Shaft Bearing Insert/Journal ClearanceStandard:
0.011 ∼ 0.033 mm (0.0004 ∼ 0.0013 in.)Service Limit:

0.08 mm (0.0031 in.)If the clearance is within the standard, no bearing insert
replacement is required.
If the clearance is between 0.050 mm and the service
limit (0.09 mm), replace the bearing inserts [A] with inserts painted blue [B] Check insert/journal clearance witha plastigage. The clearance may exceed the standard
slightly, but it must not be less than the minimum in order
to avoid bearing seizure.
If the clearance exceeds the service limit, measure thediameter of the balancer shaft journal.
Balancer Shaft Journal DiameterStandard:
27.987 ∼ 28.000 mm (1.1019 ∼ 1.1024 in.)Service Limit: 27.96 mm (1.1008 in.)

9-28 CRANKSHAFT/TRANSMISSION
BalancerIf either journal has worn past the service limit, replace
the balancer shaft with a new one.
If the measured journal diameters are not less than theservice limit, but do not coincide with the original diametermarkings on the balancer shaft, write new marks on it.
Balancer Shaft Diameter Marks
None
27.987 ∼ 27.993 mm (1.1019 ∼ 1.1021 in.)○27.994 ∼ 28.000 mm (1.1021 ∼ 1.1024 in.)∆: Balancer Shaft Journal Diameter Marks, “○” mark or
no mark.
the lower crankcase half on the upper crankcase half
• Put
without bearing inserts, and tighten the case bolts to the•specified torque and sequence (see Crankcase Assembly).
Measure the crankcase bearing bore diameter for the balancer shaft, and mark the upper crankcase half in accordance with the bore diameter.

NOTE○The mark already on the upper crankcase half should
almost coincide with the measurement.

Crankcase Bearing Bore Diameter Marks
31.000 ∼ 31.008 mm (1.2205 ∼ 1.2208 in.)

○

None

31.009 ∼ 31.016 mm (1.2208 ∼ 1.2211 in.)□□: Crankcase Bearing Bore Diameter Marks, “○” markor no mark.

No.1 Journal [A]No.2 Journal [B]the proper bearing insert in accordance with the• Selectcombination of the crankcase and the balancer shaft cod-•ing.
Install the new inserts in the crankcase and check insert/journal clearance with a plastigage.

Balancer Shaft Bearing Insert Selection
Crankcase Main
Crankshaft Main
Bearing Bore Diameter
Journal Diameter Mark
Mark

○
○

○

None

Bearing Insert*
Size Color

Part Number

Brown

92139-0119

None

○

Black

92139-0118

None

None

Blue

92139-0117

CRANKSHAFT/TRANSMISSION 9-29
Transmission
Shift Pedal Removal• Remove:
Shift Lever Bolt [A]Shift Lever [B]Shift Pedal Installation

the mark [A] on the shift shaft with the slit [B] on the• Alignshift lever.
• Tighten the shift lever bolt securely.

sure the shift pedal position is as shown.
• BeShift
Pedal Damper [A]Bottom [B] of Left Footpeg Stay
Shift Lever [C]Bolt [D] of Left Footpeg Stay

External Shift Mechanism Removal• Remove:
Engine Oil (Drain, see Engine Oil Change in the Periodic
Maintenance chapter)
Shift Pedal (see Shift Pedal Removal)
Engine Sprocket (see Engine Sprocket Removal in the
Final Drive chapter)
Neutral Switch Lead Connector (Disconnect)
Shift Shaft Cover Bolts [A]Shift Shaft Cover Screw [B]Shift Shaft Cover [C]• Remove the shift shaft assembly [A].

9-30 CRANKSHAFT/TRANSMISSION
Transmission• Remove:
Clutch (see Clutch Removal in the Clutch chapter)
Gear Positioning Lever Bolt [A]Gear Positioning Lever [B], Spacer, Washer and Spring

External Shift Mechanism Installation

the gear positioning lever [A] as shown.
• Install
Spring [B]Washer [C]Spacer [D]Bolt [E]○Hook the spring at gear positioning lever, pushing up [F]the hook portion, as shown.
Apply a non-permanent locking agent to the gear positioning lever bolt and tighten it.

•

Torque - Gear Positioning Lever Bolt: 12 N·m (1.2 kgf·m,
106 in·lb)

the shift shaft assembly.
•○Install
Apply [A] molybdenum disulfide oil solution to the rubbing surface between the lever [B] and pawl [C] and movethem two or three times up and down to lubricate them.

○Be sure that the washer [A] is on the shaft.
○Be sure that the spring hook portions [B] are as shown.

CRANKSHAFT/TRANSMISSION 9-31
Transmission
the new needle bearing [A] is installed in the shift• Whenshaft cover [B], press and insert the new needle bearing
until it is bottomed.
Special Tool - Bearing Driver Set: 57001-1129

the new oil seal [C] is installed in the shift cover,• Whenpress and insert the new oil seal so that its surface is flushwith the end of the hole.
Special Tool - Bearing Driver Set: 57001-1129

the shift shaft cover.
•○Install
Be sure that the dowel pins [A] are in position.

○Install the new gasket [B].

a non-permanent locking agent to the shift shaft• Apply
cover screw [A] and bolts [B, C] and tighten them.

○Do not apply a non-permanent locking agent to the shift
shaft cover bolts [D, E].

○Tighten the cover screw lastly.
Torque - Shift Shaft Cover Bolts: 9.8 N·m (1.0 kgf·m, 87
in·lb)
Shift Shaft Cover Screw: 4.9 N·m (0.50 kgf·m, 43
in·lb)

External Shift Mechanism Inspection

the shift shaft [A] for any damage.
• Examine
If the shaft is bent, straighten or replace it.
If the serration [B] are damaged, replace the shaft.
If the springs [C] are damaged in any way, replace them.
If the shift mechanism arm [D] is damaged in any way,
replace the arm.

the return spring pin [A] is not loose.
• Check
If it is loose, unscrew it, apply a non-permanent locking
agent to the threads, and tighten it.
Torque - Shift Shaft Return Spring Pin: 29 N·m (2.9 kgf·m,
21 ft·lb)

9-32 CRANKSHAFT/TRANSMISSION
Transmission
the gear positioning lever [A] and its spring for• Check
breaks or distortion.

•

If the lever or spring are damaged in any way, replace
them.
Visually inspect the shift drum cam [B].
If they are badly worn or if they show any damage, replaceit.

Transmission Assy Removal• Remove:
Shift Shaft Assembly (see External Shift Mechanism Removal)
Neutral Switch Holder Bolt [A]Neutral Switch Holder [B] and Pin
Shift Drum Holder [C] and Pin• Remove:
Collar [A]O-ring [B]• Remove:
Clutch (see Clutch Removal in the Clutch chapter)
Transmission Case Bolts [A]
If the transmission assy is to be disassembed, remove thefollowing.
Shift Rod Plate Bolt [B]Shift Rod Plate [C]Gear Positioning Lever Bolt [D]Gear Positioning Lever [E] with Spring, Washer andSpacer• Pull the transmission assy [A] out of the crankcase.

CRANKSHAFT/TRANSMISSION 9-33
Transmission
Transmission Assy Disassembly

the transmission assy (see Transmission Assy
• Remove
Removal).
the following from the transmission case [A].
• Remove
Shift Rods [B]Shift Forks [C]
Drive Shaft [D]Output Shaft [E]• Remove:
Shift Drum Cam Bolt [A]Shift Drum [B] and Pin
Shift Drum [C]Transmission Assy Assembly

the new ball bearings [A] are installed in the trans• Whenmission case [B], press and insert them until they are bottomed.
Special Tool - Bearing Driver Set 57001-1129

9-34 CRANKSHAFT/TRANSMISSION
Transmission
the following on the transmission case [A].
• Install
Shift Drum [B]
Pin [C]
Shift Drum Cam [D]○Align the pin with the hole on the shift drum cam.
Apply a non-permanent locking agent to the shift drum
cam bolt [E] and tighten it.

•

Torque - Shift Drum Cam Bolt: 12 N·m (1.2 kgf·m, 106 in·lb)

the following as a set.
• Install
Drive Shaft [F]Output Shaft [G]Install the forks as shown.
○Position the one [H] with shortest ears on the drive shaft
and place the pin in the center groove in the shift drum.
○The two forks [J] on the output shaft are identical.
Install the shift rods, noting the groove position.
○The rod [K] length of the output shaft side is shorter than
the rod [L] length of the drive shaft side.
Apply molybdenum disulfide oil solution to the transmission gears shown with X marks [M].
Be sure that the spacer [N] is on the output shaft.

•
•
•
•

Transmission Assy Installation

the transmission assy (see Transmission Assy
• Assemble
Assembly).
sure that the dowel pins [A] are in position.
• Be
grease to the O-ring [B] on the oil pipe.
• Apply
Installassy on the crankcase.
• Tightenthethetransmission
transmission
case bolts.
•
Torque - Transmission Case Bolts: 20 N·m (2.0 kgf·m, 15
ft·lb)

CRANKSHAFT/TRANSMISSION 9-35
Transmission
the gear positioning lever (see External Shift Mech• Install
anism Installation).
• Install the shift rod plate.
Torque - Shift Rod Plate Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)

the gear positioning lever to the neutral position [A].
• Set
Check
that the drive and output shaft turn freely.
•• Install:
Pin [A]
Shift Drum Holder [B]
Pin [C]
Neutral Switch Holder [D]Neutral Switch Holder Screw [E]○Apply a non-permanent locking agent to the neutral switch
holder screw and tighten it.
Torque - Neutral Switch Holder Screw: 4.9 N·m (0.50 kgf·m,
43 in·lb)

grease to the O-ring [A] and install its position [B]• Applyon the output shaft.
grease to the lip of the oil seal [C].
• Apply• Install the collar [D].

Transmission Shaft Removal

the transmission assy (see Transmission Assy
• Remove
Removal).
• Remove:
Shift Rods [A]Shift Forks [B]
Drive Shaft [C] and Output Shaft [D]Transmission Shaft Installation• Be sure that the spacer [A] is on the output shaft [B].

9-36 CRANKSHAFT/TRANSMISSION
Transmission
the transmission assy on the crankcase (see Trans• Install
mission Assy Installation).
in the oil seal [A] onto collar [B] so that the surface• Pressof the oil seal is flush with the surface [C] of the crankcase.

○Apply oil to the outer circumference [D] of the oil seal sothat it will go into place smoothly.

○Apply grease to the lip [E] of the oil seal.

Transmission Shaft Disassembly

the transmission shafts (see Transmission Shaft• Remove
Removal).
the circlips, disassemble the transmission• Removeshafts.
Special Tool - Outside Circlip Pliers: 57001-144

5th gear [A] on the output shaft has three steel balls• The
assembled into it for the positive neutral finder mechanism. Remove the 5th gear.
○Set the output shaft in a vertical position holding the 3rdgear [B].
○Spin the 5th gear quickly [C] and pull it off upward.

Transmission Shaft Assembly

engine oil to the bushings, needle bearings and• Apply
shafts.
the gear bushings [A] on the shaft with their holes• Install[B] aligned.

any circlips removed with new ones.
• Replacethe circlips [A] so that the opening [B] is aligned• Installwith a spline groove [C].

CRANKSHAFT/TRANSMISSION 9-37
Transmission
drive shaft gears can be recognized by size: the gear
• The
with the smallest diameter is 1st gear, and the largest one

•
•
•
•
•

is 6th gear. Be sure that all parts are put back in the correct sequence and all circlips and washers are properly inplace.
Install the 3rd/4th gear onto the drive shaft with their oilholes aligned.
Install the 6th gear bushing onto the drive shaft with theiroil holes aligned.
The output shaft gears can be recognized by size: thegear with the largest diameter is 1st gear, and the smallest one is 6th gear. Be sure that all parts are put backin the correct sequence and all circlips and washers areproperly in place.
Install the 5th and 6th gears onto the output shaft with
their oil holes aligned.
Install the 3rd/4th gear bushings onto the output shaft with
their oil holes aligned.

the steel balls into the 5th gear holes in the output• Fit
shaft, aligning three oil holes.
5th Gear [A]Output Shaft [B]
Steel Balls [C]
Oil Holes [D]

CAUTION
Do not apply grease to the balls to hold them inplace. This will cause the positive neutral finder
mechanism to malfunction.

○After assembling the 5th gear with steel balls in place on•

the output shaft, check the ball-locking effect that the 5thgear doesn’t come out of the output shaft when moving it
up and down by hand.
Check that each gear spins or slides freely on the transmission shafts without binding after assembly.

9-38 CRANKSHAFT/TRANSMISSION
Transmission

1. 1st Gear
2. 2nd Gear
3. 3rd Gear
4. 4th Gear
5. 5th Gear
6. 6th (Top) Gear
7. Ball Bearing
8. Bushing
9. Toothed Washer, 34 mm (1.34 in.)10. Circlip
11. Bushing
12. Thrust Washer, 30 mm (1.18 in.)13. Needle Bearing
14. Circlip
15. Oil Seal

16. Collar
17. Washer
18. Nut
19. O-ring
20. Bearing
21. Spacer, 39 mm (1.54 in.)
22. Positioning Ring
23. Washer, 40 mm (1.57 in.)
24. Bushing
25. Toothed Washer, 38 mm (1.50 in.)
26. Shim, 28 mm (1.10 in.)27. Steel Ball
28. Circlip, 32.2 mm (1.268 in.)
29. Thrust Washer, 25 mm (0.98 in.)

CRANKSHAFT/TRANSMISSION 9-39
Transmission
Shift Drum and Fork Removal

the transmission assy (see Transmission Assy
• Remove
Removal).
the shift forks [A] and shift drum [B] (see Trans• Remove
mission Assy Disassembly).

Shift Drum and Fork Installation

to the Transmission Assy Assembly and Installa• Refertion.

Shift Drum Disassemblyto the Transmission Assy Removal and Disassem• Refer
bly.

Shift Drum Assemblyto the Transmission Assy Assembly and Installa• Refertion.

Shift Fork Bending

inspect the shift forks, and replace any fork that is• Visually
bent. A bent fork could cause difficulty in shifting, or allow
the transmission to jump out of gear when under power.
90° [A]

Shift Fork/Gear Groove Wear

the thickness of the shift fork ears [A], and mea• Measure
sure the width [B] of the gear grooves.
If the thickness of a shift fork ear is less than the service
limit, the shift fork must be replaced.
Shift Fork Ear Thickness
Standard:
5.9 ∼ 6.0 mm (0.232 ∼ 0.236 in.)Service Limit: 5.8 mm (0.228 in.)If the gear groove is worn over the service limit, the gear
must be replaced.
Gear Groove Width
Standard:
6.05 ∼ 6.15 mm (0.238 ∼ 0.242 in.)Service Limit: 6.25 mm (0.246 in.)

9-40 CRANKSHAFT/TRANSMISSION
Transmission
Shift Fork Guide Pin/Drum Groove Wear

the diameter of each shift fork guide pin [A], and• Measuremeasure the width [B] of each shift drum groove.
If the guide pin on any shift fork is less than the service
limit, the fork must be replaced.
Shift Fork Guide Pin DiameterStandard:
6.9 ∼ 7.0 mm (0.272 ∼ 0.276 in.)Service Limit: 6.8 mm (0.268 in.)If any shift drum groove is worn over the service limit, thedrum must be replaced.
Shift Drum Groove Width
Standard:
7.05 ∼ 7.20 mm (0.278 ∼ 0.283 in.)Service Limit: 7.3 mm (0.287 in.)Gear Dog and Gear Dog Hole Damage

inspect the gear dogs [A] and gear dog holes [B].
• VisuallyReplace any damaged gears or gears with excessively
worn dogs or dog holes.

CRANKSHAFT/TRANSMISSION 9-41
Ball Bearing, Needle Bearing, and Oil Seal
Ball and Needle Bearing Replacement
CAUTION
Do not remove the ball or needle bearings unless it
is necessary. Removal may damage them.
a press or puller, remove the ball bearing and/or• Using
needle bearings.

NOTE○In the absence of the above mentioned tools, satisfac-

tory results may be obtained by heating the case to approximately 93°C (200°F) max., and tapping the bearing
in or out.

CAUTION
Do not heat the case with a torch. This will warp thecase. Soak the case in oil and heat the oil.
a press and the bearing driver set [A], install the• Using
new ball bearing until it stops at the bottom of its housing.

○The new needle bearings must be pressed into the
crankcase so that the end is flush with the end of thehole.
Special Tool - Bearing Driver Set: 57001-1129

Ball and Needle Bearing Wear
CAUTION
Do not remove the bearings for inspection. Removal may damage them.
the ball bearings.
•○Check
Since the ball bearings are made to extremely close toler-

ances, the wear must be judged by feel rather than measurement. Clean each bearing in a high-flash point solvent, dry it (do not spin the bearing while it is dry), and oil
it with engine oil.

○Spin [A] the bearing by hand to check its condition.

If the bearing is noisy, does not spin smoothly, or has any
rough spots, replace it.
Check the needle bearings.
○The rollers in a needle bearing normally wear very little,
and wear is difficult to measure. Instead of measuring,inspect the bearing for abrasion, color change, or otherdamage.
If there is any doubt as to the condition of a needle bearing, replace it.

•

Oil Seal Inspection

the oil seals.
• Inspect
Replace it if the lips are misshapen, discolored (indicatingthat the rubber has deteriorated), hardened or otherwise
damaged.

WHEELS/TIRES 10-1

Wheels/Tires
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Wheels (Rims) ........................................................................................................................
Front Wheel Removal .......................................................................................................
Front Wheel Installation ....................................................................................................
Rear Wheel Removal........................................................................................................
Rear Wheel Installation.....................................................................................................
Wheel Inspection ..............................................................................................................
Axle Inspection..................................................................................................................
Balance Inspection............................................................................................................
Balance Adjustment ..........................................................................................................
Balance Weight Removal..................................................................................................
Balance Weight Installation...............................................................................................
Tires........................................................................................................................................
Air Pressure Inspection/Adjustment..................................................................................
Tire Inspection ..................................................................................................................
Tire Removal.....................................................................................................................
Tire Installation..................................................................................................................
Tire Repair ........................................................................................................................
Hub Bearing............................................................................................................................
Hub Bearing Removal.......................................................................................................
Hub Bearing Installation....................................................................................................
Hub Bearing Inspection.....................................................................................................
Hub Bearing Lubrication ...................................................................................................

10-2
10-4
10-5
10-6
10-6
10-6
10-8
10-8
10-10
10-10
10-11
10-11
10-11
10-11
10-13
10-13
10-13
10-13
10-13
10-15 10
10-16
10-16
10-16
10-16
10-17

10-2 WHEELS/TIRES
Exploded View

WHEELS/TIRES 10-3
Exploded View
No.
1
2
3

Fastener
Front Axle
Front Axle Clamp Bolt
Rear Axle Nut

4. Caliper Bracket (EX650B Models)
G: Apply grease.
HG: Apply high-temperature grease.
R: Replacement Parts
WL: Apply soap and water solution or rubber lubricant.

N·m
108
34
108

Torque
kgf·m
11.0
3.5
11.0

ft·lb
80
25
80

Remarks

10-4 WHEELS/TIRESSpecifications
Item
Wheels (Rims)
Rim Runout:
Axial
RadialAxle Runout/100 mm (3.94 in.)
Wheel Balance
Balance Weights
Rim Size:
Front
Rear
Tires
Air Pressure (when Cold):
Front
Rear
Tread Depth:
Front

Rear

Standard Tires:
Front
Rear

Standard

Service Limit

TIR 0.5 mm (0.02 in.) or less
TIR 0.8 mm (0.03 in.) or less
TIR 0.03 mm (0.0012 in.) or less10 g (0.35 oz.) or less10 g (0.35 oz.), 20 g (0.71 oz.), 30 g
(1.06 oz.)

TIR 1.0 mm (0.04 in.)
TIR 1.0 mm (0.04 in.)
TIR 0.2 mm (0.008 in.)
– – –
– – –

17 × 3.50
17 × 4.50

– – –
– – –

Up to 180 kg (397 lb) load: 225 kPa(2.25 kgf/cm², 32 psi)
Up to 180 kg (397 lb) load: 250 kPa(2.50 kgf/cm², 36 psi)
4.3 mm (0.17 in.)

– – –
– – –

1 mm (0.04 in.)
(AT, CH, DE) 1.6 mm(0.06 in.)
7.0 mm (0.28 in.)
Up to 130 km/h (80 mph):
2 mm (0.08 in.)Over 130 km/h (80 mph):
3 mm (0.12 in.)
Make, TypeSize
BRIDGESTONE, BATTLAX BT020F 120/70 ZR17 M/C (58 W)
RADIAL GG
BRIDGESTONE, BATTLAX BT020R 160/60 ZR17 M/C (69 W)
RADIALWARNING
Use the same manufacturer’s tires on both front and rear wheels.

WHEELS/TIRES 10-5Special Tools
Bearing Driver Set:
57001-1129

Bearing Remover Shaft,
57001-1377

Jack:
57001-1238

Jack Attachment:
57001-1608

Bearing Remover Head,
57001-1293

20 ×

22:

13:

10-6 WHEELS/TIRES
Wheels (Rims)
Front Wheel Removal• Remove:
Brake Caliper Mounting Bolts [A]Front Brake Calipers [B]• Loosen:
Axle Clamp Bolt [A]Removethe front axle [B].
•the lower fairings (see Lower Fairing Removal in• Remove
the Frame chapter).
• Raise the front wheel off the ground with jack.
Special Tools - Jack: 57001-1238
Jack Attachment: 57001-1608

out the axle to the right and drop the front wheel out• Pullof the forks.

CAUTION
Do not lay the wheel on the ground with the discs
facing down. This can damage or warp the disc.
Place wooden blocks under the wheel so that thedisc does not touch the ground.

Front Wheel Installation
NOTE○The direction of the wheel rotation [A] is shown by anarrow [B] on the wheel spoke.
the wheel rotation mark on the front wheel and• Check
install it.

WHEELS/TIRES 10-7
Wheels (Rims)
high-temperature grease to the grease seal lips.
• ApplyFit
thecollars [A] on the both sides of the hub.
•

• Insert the front axle, and tighten the axle.

Torque - Front Axle: 108 N·m (11.0 kgf·m, 80 ft·lb)

tightening the axle clamp bolt on the right front fork
• Beforeleg, pump the front fork up and down 4 or 5 times to allow
the right front fork leg to seat on the front axle.

NOTE○Put a block in front of the front wheel to stop moving.

• Tighten the axle clamp bolt [A].

Torque - Front Axle Clamp Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb)

the lower fairing (see Lower Fairing Installation in• Install
the Frame chapter).
the front brake calipers (see Caliper Installation in• Installthe Brakes chapter).
the front brake effectiveness (see Brake Operation• Check
Inspection in the Periodic Maintenance chapter).

WARNING
Do not attempt to drive the motorcycle until a fullbrake lever is obtained by pumping the brake leveruntil the pads are against the disc. The brake will
not function on the first application of the lever if
this is not done.

10-8 WHEELS/TIRES
Wheels (Rims)
Rear Wheel Removal• Raise the rear wheel off the ground with stand [A].

• Remove:
Brake Caliper Mounting Bolts [A]•Rear Brake Caliper [B]Remove the rear wheel rotation sensor from the caliper
bracket (see Rear Wheel Rotation Sensor Removal in the
Brakes chapter) (EX650B Models).

• Remove:
Cotter Pin [A]Axle Nut [B]Washer [C]Axle [D] with Washer

the drive chain [A] from the rear sprocket toward• Removethe left.
• Move the rear wheel back and remove it.

CAUTION

Do not lay the wheel on the ground with the discfacing down. This can damage or warp the disc.
Place wooden blocks under the wheel so that thedisc does not touch the ground.

Rear Wheel Installation

high-temperature grease to the grease seal lips.
• ApplyFit
thecollars [A] on the both sides of the hub.
•

WHEELS/TIRES 10-9
Wheels (Rims)
the drive chain with the rear sprocket.
• Engage
Installthecaliper bracket [A] onto the swingarm stop [B].
• Insert the axle
• the axle nut. from the right side of the wheel, and tighten
Torque - Rear Axle Nut: 108 N·m (11.0 kgf·m, 80 ft·lb)• Insert a new cotter pin [A].

NOTE

○When inserting the cotter pin, if the slots in the nut do
not align with the cotter pin hole in the axle, tighten the
nut clockwise [B] up to next alignment.
○It should be within 30°.
○Loosen once and tighten again when the slot goes past
the nearest hole.

• Bend the cotter pin [A] over the nut [B].
WARNING

If the rear axle nut is not securely tightened or thecotter pin is not installed, an unsafe riding condition may result.

the drive chain slack after installation (see Drive• Adjust
Chain Slack Inspection in the Periodic Maintenance chap-

•
•
•

ter).
Install the rear brake caliper (see Caliper Installation in
the Brakes chapter).
Install the rear wheel rotation sensor (see Rear Wheel Rotation Sensor Installation in the Brakes chapter) (EX650B
Models).
Check the rear brake effectiveness (see Brake Operation
Inspection in the Periodic Maintenance chapter).

WARNING
Do not attempt to drive the motorcycle until a fullbrake pedal is obtained by pumping the brake pedal
until the pads are against the disc. The brake will
not function on the first application of the pedal if
this is not done.

10-10 WHEELS/TIRES
Wheels (Rims)
Wheel Inspection• Raise the front/rear wheel off the ground with jack.
Special Tools - Jack: 57001-1238
Jack Attachment: 57001-1608

the wheel lightly, and check for roughness or binding.
• SpinIf roughness or binding is found, replace the hub bearings.
the wheel for small cracks, dents, bending, or• Inspect
warp.

•
•

If there is any damage to the wheel, replace the wheel.
Remove the wheel, and support it without the tire by theaxle.
Measure the rim runout, axial [A] and radial [B], with a dialgauge.
If rim runout exceeds the service limit, check the hub bearings.
If the problem is not due to the bearings, replace thewheel.
Rim Runout
Standard:
Axial

TIR 0.5 mm (0.02 in.) or less

Radial

TIR 0.8 mm (0.03 in.) or lessService Limit:
Axial

TIR 1.0 mm (0.04 in.)RadialTIR 1.0 mm (0.04 in.)WARNING
Never attempt to repair a damaged wheel. If there
is any damage besides wheel bearings, the wheel
must be replaced to insure safe operational condition.

Axle Inspection

the front and rear axles (see Front/Rear Wheel• Remove
Removal).
inspect the front and rear axle for damages.
• Visually
If the axle is damaged or bent, replace it.
the axle in V blocks that are 100 mm (3.94 in.) [A]• Placeapart, and set a dial gauge [B] on the axle at a point
halfway between the blocks. Turn [C] the axle to measure the runout. The difference between the highest andlowest dial readings is the amount of runout.
If axle runout exceeds the service limit, replace the axle.
Axle Runout/100 mm (3.94 in.)Standard:
TIR 0.03 mm (0.0012 in.) or lessService Limit:

TIR 0.2 mm (0.008 in.)

WHEELS/TIRES 10-11
Wheels (Rims)
Balance Inspection

the front and rear wheels (see Front/Rear Wheel• Remove
Removal).
the wheel so that it can be spun freely.
• SupportSpinthelightly, and mark [A] the wheel at the top• when thewheel
wheel stops.

○Repeat this procedure several times. If the wheel stops
of its own accord in various positions, it is well balanced.
If the wheel always stops in one position, adjust the wheelbalance (see Balance Adjustment).

Balance Adjustment

the wheel always stops in one position, provisionally• Ifattacha balance weight [A] on the rim at the marking using

•

•
•
•

adhesive tape.
Rotate the wheel 1/4 turn [B], and see whether or not thewheel stops in this position. If it does, the correct balance
weight is being used.
If the wheel rotates and the weight goes up, replace theweight with the next heavier size. If the wheel rotates andthe weight goes down, replace the weight with the next
lighter size. Repeat these steps until the wheel remains
at rest after being rotated 1/4 turn.
Rotate the wheel another 1/4 turn and then another 1/4
turn to see if the wheel is correctly balanced.
Repeat the entire procedure as many times as necessary
to achieve correct wheel balance.
Permanently install the balance weight.

Balance Weight Removala regular tip screwdrivers [A] [B] between the rib [C]• Insert
and the weight [D] as shown.
the balance weight with two screwdrivers and remove• Pry
the balance weight.
• Discard the used balance weight.

CAUTION

Do not tap the screwdrivers. The rim could be damaged.

Balance Weight Installation

if the weight portion has any play on the blade [A]• Check
and clip [B].
If it does, discard it.

WARNING
If the balance weight has any play on the rib of therim, the blade and/or clip have been stretched. Replace the loose balance weight. Do not reuse usedbalance weight. Unbalanced wheels can create anunsafe riding condition.

10-12 WHEELS/TIRES
Wheels (Rims)
Balance WeightPart Number

Weight41075-0007

10 g (0.35 oz.)

41075-0008

20 g (0.71 oz.)

41075-0009

30 g (1.06 oz.)

NOTE

○Balance weights are available from Kawasaki dealers in

10, 20, and 30 grams (0.35, 0.71, and 1.06 oz.) sizes.
An imbalance of less than 10 grams (0.35 oz.) will not
usually affect running stability.
○Do not use four or more balance weight (more than 90
gram, 3.17 oz.). If the wheel requires an excess balance weight, disassemble the wheel to find the cause.
the balance weight [A] onto the rib [B] by pushing or• Sliplightly hammering [C] the clip [D].
Left Side [E]Right Side [F]sure to install the balance weight.
•○Be
Check that the blade [A] and clip [B] are fully seated on
the rim [C] and that the clip is hooked over the rib [D].
Left Side [E]Right Side [F]WHEELS/TIRES 10-13
Tires
Air Pressure Inspection/Adjustment

to the Air Pressure Inspection in the Periodic Main• Refertenance chapter.

Tire Inspection

to the Wheel/Tire Damage Inspection in the Peri• Refer
odic Maintenance chapter.

Tire Removal• Remove:
Wheel (see Front/Rear Wheel Removal)•

Valve Core (Let out the air)
To maintain wheel balance, mark the valve stem positionon the tire with chalk so that the tire can be reinstalled in
the same position.
Chalk Mark or Yellow Mark [A]Air Valve [B]Align [C]the tire beads and rim flanges on both sides with• Lubricate
a soap and water solution or rubber lubricant. This helps
the tire beads slip off the rim flanges.

CAUTION
Never lubricate with engine oil or petroleum distillates because they will deteriorate the tire.
the tire from the rim using a suitable commer• Remove
cially available tire changer.

NOTE○The tires cannot be removed with hand tools because
they fit the rims too tightly.

Tire Installation

WARNING
Use the same manufacturer’s tires on both front andrear wheels.
the rim and tire, and replace them if necessary.
• Inspect
Cleanthesurfaces of the rim and tire, and smooth• the sealingsealing
surfaces of the rim with a fine emery cloth if•necessary.
Remove the air valve and discard it.

CAUTION
Replace the air valve whenever the tire is replaced.
Do not reuse the air valve.

10-14 WHEELS/TIRES
Tires
a new valve in the rim.
•○Install
Remove the valve cap, lubricate the stem seal [A] with asoap and water solution or rubber lubricant, and pull [B]the valve stem through the rim from the inside out until it
snaps into place.

CAUTION
Do not use engine oil or petroleum distillates to lubricate the stem because they will deteriorate therubber.

○The air valve is shown in the figure.
Valve Cap [A]
Valve Core [B]Stem Seal [C]
Valve Stem [D]Valve Seat [E]Valve Opened [F]the tire rotation mark on the front and rear tires and• Check
install them on the rim accordingly.
Tire Rotation Mark [A]Rotating Direction [B]the tire on the rim so that the valve [A] align with• Position
the tire balance mark [B] (the chalk mark made during•••

removal, or the yellow paint mark on a new tire).
Install the tire bead over the rim flange using a suitablecommercially available tire changer.
Lubricate the tire beads and rim flanges with a soap andwater solution or rubber lubricant to help seat the tirebeads in the sealing surfaces of the rim while inflating thetire.
Center the rim in the tire beads, and inflate the tire withcompressed air until the tire beads seat in the sealing
surfaces.

WARNINGBe sure to install the valve core whenever inflating
the tire, and do not inflate the tire to more than 400
kPa (4.0 kgf/cm², 57 psi). Overinflation can explodethe tire with possibility of injury and loss of life.

WHEELS/TIRES 10-15
Tires
to see that the rim lines [A] on both sides of the tire
• Check
sidewalls are parallel with the rim 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 the tire again.
After the tire beads seat in the rim flanges, check for air
leakage.
○Inflate the tire slightly above standard inflation.
○Use a soap and water solution or submerge the tire, andcheck for bubbles that would indicate leakage.
Adjust the air pressure to the specified pressure (see Air
Pressure Inspection in the Periodic Maintenance chapter).
Install the air valve cap.
Adjust the wheel balance (see Balance Adjustment).

•
•
•
•
•
•

Tire Repair
Currently two types of repair for tubeless tires have comeinto wide use. One type is called a temporary (external) repair which can be carried out without removing the tire fromthe rim, and the other type is called permanent (internal)
repair which requires tire removal. It is generally understood that higher running durability is obtained by permanent (internal) repairs than by temporary (external) ones.
Also, permanent (internal) repairs have the advantage of
permitting a thorough examination for secondary damage
not visible from external inspection of the tire. For thesereasons, Kawasaki does not recommend temporary (external) repair. Only appropriate permanent (internal) repairs
are recommended. Repair methods may vary slightly frommake to make. Follow the repair methods indicated by the
manufacturer of the repair tools and materials so that safe
results can be obtained.

10-16 WHEELS/TIRES
Hub Bearing
Hub Bearing Removal

the wheel (see Front/Rear Wheel Removal), and• Removetake out the following.
Collars
Coupling (Out of rear hub)Grease Seals• Use the bearing remover to remove the hub bearings [A].
CAUTION

Do not lay the wheel on the ground with the discfacing down. This can damage or warp the disc.
Place wooden blocks under the wheel so that thedisc does not touch the ground.
Special Tools - Bearing Remover Head,
57001-1293
Bearing Remover Shaft,
-1377

20 ×

22 [B]:

13 [C]: 57001

Hub Bearing Installation

installing the hub bearings, blow any dirt or foreign• Before
particles out of the hub with compressed air to prevent•

contamination of the bearings.
Replace the bearings with new ones.

NOTE○Install the bearings so that the marked side faces out.

the bearings by using the bearing driver set which• Installdoes not contact the bearing inner race.
• Press in each bearing [A] right until they are bottomed.
Special Tool - Bearing Driver Set [B]: 57001-1129

the grease seals with new ones.
• Replacein the grease seals [A] so that the seal surface is• Press
flush [B] with the end of the hole.

○Apply high-temperature grease to the grease seal lips.
Special Tool - Bearing Driver Set [C]: 57001-1129

Hub Bearing Inspection
Since the hub bearings are made to extremely close tolerances, the clearance can not normally be measured.

NOTE○Do not remove any bearings for inspection. If any bearings are removed, they will need to be replaced withnew ones.

each bearing in the hub back and forth [A] while• Turnchecking for plays, roughness or binding.

•

If bearing play, roughness or binding is found, replace thebearing.
Examine the bearing seal [B] for tears or leakage.
If the seal is torn or is leaking, replace the bearing.

WHEELS/TIRES 10-17
Hub Bearing
Hub Bearing Lubrication
NOTE○Since the hub bearings are packed with grease andsealed, lubrication is not required.

FINAL DRIVE 11-1

Final Drive
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Drive Chain.............................................................................................................................
Drive Chain Slack Inspection ............................................................................................
Drive Chain Slack Adjustment ..........................................................................................
Wheel Alignment Inspection/Adjustment ..........................................................................
Drive Chain Wear Inspection ............................................................................................
Drive Chain Lubrication.....................................................................................................
Drive Chain Removal ........................................................................................................
Drive Chain Installation .....................................................................................................
Sprocket, Coupling .................................................................................................................
Engine Sprocket Removal ................................................................................................
Engine Sprocket Installation .............................................................................................
Rear Sprocket Removal....................................................................................................
Rear Sprocket Installation.................................................................................................
Coupling Installation..........................................................................................................
Coupling Bearing Removal ...............................................................................................
Coupling Bearing Installation ............................................................................................
Coupling Bearing Inspection .............................................................................................
Coupling Bearing Lubrication............................................................................................
Coupling Damper Inspection.............................................................................................
Sprocket Wear Inspection.................................................................................................
Rear Sprocket Warp Inspection ........................................................................................

11-2
11-4
11-5
11-6
11-6
11-6
11-6
11-6
11-6
11-6
11-7
11-10
11-10
11-11
11-11
11-11
11-12
11-12
11-12
11-13
11-13
11-13 11
11-13
11-14

11-2 FINAL DRIVE
Exploded View

FINAL DRIVE 11-3
Exploded View
No.

Fastener

1
2
3
4
5

Engine Sprocket Nut
Rear Axle Nut
Rear Sprocket Nuts
Speed Sensor Bolt
Speed Sensor Bracket Bolts

N·m
125
108
59
7.8
9.8

Torque
kgf·m
12.7
11.0
6.0
0.80
1.0

ft·lb
92
80
44
69 in·lb
87 in·lb

G: Apply grease.
HG: Apply high-temperature grease.
HO: Apply heavy oil.
L: Apply a non-permanent locking agent.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)
R: Replacement Parts

RemarksMOL

11-4 FINAL DRIVE
Specifications
Item

Standard

Drive Chain
Drive Chain Slack
30 ∼ 40 mm (1.2 ∼ 1.6 in.)
Drive Chain Wear (20-link Length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)Standard Chain:
Make
ENUMA
Type
EK520MVXL1
Link
114 links
Sprockets
Rear Sprocket Warp
0.4 mm (0.016 in.) or lessService Limit– – –323 mm (12.7 in.)
– – –
– – –
– – –
0.5 mm (0.020 in.)

FINAL DRIVE 11-5
Special Tools
Inside Circlip Pliers:
57001-143

Bearing Driver Set:
57001-1129

11-6 FINAL DRIVE
Drive Chain
Drive Chain Slack Inspection

to the Drive Chain Slack Inspection in the Periodic• Refer
Maintenance chapter.

Drive Chain Slack Adjustment

to the Drive Chain Slack Adjustment in the Periodic• Refer
Maintenance chapter.

Wheel Alignment Inspection/Adjustment

to the Wheel Alignment Inspection in the Periodic• Refer
Maintenance chapter.

Drive Chain Wear Inspection

to the Drive Chain Wear Inspection in the Periodic• Refer
Maintenance chapter.

Drive Chain Lubrication

to the Drive Chain Lubrication Condition Inspection• Referin the Periodic Maintenance chapter.

Drive Chain Removal
NOTE○Since the drive chain is installed through the swingarm,the chain cannot be removed other than by cutting it.
Prepare the new link pin, link plate, grease seals, andtools for rejoining the chain.

a suitable tool, cut the drive chain by removing the• Usinglink pins.
Recommended Tool:

EK Joint Tool #50

CAUTION
Read the Tool Manual before removing.
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][A] the pin head to make it flat.
• GrindSet
thecutting and riveting pin [B] as shown.
•FINAL DRIVE 11-7
Drive Chain
the pin holder until it touches chain pin.
• ScrewBe
surethat the cutting pin hits center of chain pin.
•

the handlebar [A] into body.
• ScrewTurnthe• chain pin.pin holder with wrench [B] clockwise to extract

Drive Chain Installation

the new drive chain to the old drive chain and pull
• Engagethe end of the old drive chain until they are changing the

•
•
•
•
•
•
•
•

position.
Remove the old drive chain from the new drive chain.
Apply grease to the link pins [A] and grease seals [B] [C].
Engage the drive chain on the rear sprocket through theswingarm.
Insert the link pins in the drive chain ends.
Install the grease seals [C].
Install the link plate so that the mark [D] faces out.
Push the link plate by hand or plier to fix it.
In case of grease seal chain, be sure to set the grease
seals correctly.

the plate holder (a) [A] and plate holder (b) [B] on the
• Set
body.

11-8 FINAL DRIVE
Drive Chain
the plate holder (a) to link plate.
• Fit
Turn
the pin holder by hand until plate holder (b) touches• the otherlink plate.

the pin holder by wrench clockwise until two pins of• Turnlink come into groove of plate holder (a).
• Take off the plate holder (a).

the plate holder (b) [A] and cutting and riveting pin [B]• Set
as shown.

• Turn the pin holder until riveting pin touches link pin.

the wrench clockwise until tip of riveting pin hits of• Turnlink pin.
it.
• RivetSame
work for the other link pin.
•

FINAL DRIVE 11-9
Drive Chainstaking, check the staked area of the link pin for• After
cracks.
the outside diameter [A] of the link pin and link
• Measureplates width [B].
Link Pin Outside DiameterStandard: 5.7 ∼ 6.0 mm (0.22 ∼ 0.24 in.)
Link Plates Outside Width
Standard: 17.25 ∼ 17.45 mm (0.679 ∼ 0.687 in.)••If the reading exceeds the specified length, cut and rejoin
the chain again.
Check:
Movement of the Rollers
Adjust the drive chain slack after installing the chain (seeDrive Chain Slack Adjustment in the Periodic Maintenance chapter).

11-10 FINAL DRIVE
Sprocket, Coupling
Engine Sprocket Removal• Remove:
Engine Sprocket Cover Bolts [A]Engine Sprocket Cover [B]• Remove:
Speed Sensor Bracket Bolts [A]Speed Sensor Bracket [B]out the bended washer [A].
• Flatten
Removethe engine sprocket nut [B] and washer.
•

NOTE○When loosening the engine sprocket nut, hold the rear
brake on.

the rear wheel off the ground with stand.
• RaiseRemovethe axle cotter pin, and loosen the rear axle nut.
• Loosen thedrive chain (see Drive Chain Slack Adjust• ment in the Periodic
Maintenance chapter).
Remove
the
drive
chain
from the rear sprocket toward the• right.
the engine sprocket [A] with drive chain [B] off the• Pulloutput shaft [C].
• Disengage the drive chain from the engine sprocket.

FINAL DRIVE 11-11
Sprocket, Coupling
Engine Sprocket Installation

the sprocket washer and axle cotter pin.
• Replace
Installtheengine sprocket [A] so that “OUTSIDE” letters• face outward.
molybdenum disulfide oil solution to the threads• Applyof the output shaft and seating surface of the engine•

sprocket nut.
After torquing the engine sprocket nut, bend the one sideof the washer [B] over the nut.

NOTE

○Tighten the engine sprocket nut while applying the rear
brake.

• Tighten:

Torque - Engine Sprocket Nut: 125 N·m (12.7 kgf·m, 92 ft·lb)
Speed Sensor Bracket Bolts: 9.8 N·m (1.0 kgf·m,
87 in·lb)

the engine sprocket cover, and tighten the bolts.
• Install
Adjustthe drive chain slack after installing the sprocket• (see Drive
Chain Slack Adjustment in the Periodic Main-•

tenance chapter).
Bend the end of axle cotter pin surely after tightening theaxle nut (see Rear Wheel Installation in the Wheels/Tires
chapter).

Rear Sprocket Removal

the rear wheel (see Rear Wheel Removal in the• Remove
Wheels/Tires chapter).

CAUTION
Do not lay the wheel on the ground with the discfacing down. This can damage or warp the disc.
Place wooden blocks under the wheel so that thedisc does not touch the ground.
the rear sprocket nuts [A].
• Remove
Removethe rear sprocket [B].
•

Rear Sprocket Installation

the sprocket facing the tooth number marking [A]• Installoutward.
• Tighten the rear sprocket nuts.
Torque - Rear Sprocket Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb)

the rear wheel (see Rear Wheel Installation in the• Install
Wheels/Tires chapter).

11-12 FINAL DRIVE
Sprocket, Coupling
Coupling Installation

high-temperature grease to the coupling grease• Apply
seal lips [A].
• Apply grease to the coupling internal surface [B].

the following.
• Grease
Wheel Flange Portion [A]•O-ring [B]Install the collar [C].

Coupling Bearing Removal• Remove:
Coupling

Grease Seal
Circlip [A]Special Tool - Inside Circlip Pliers: 57001-143• Remove the bearing [A] by tapping from the wheel side.
Special Tool - Bearing Driver Set [B]: 57001-1129

Coupling Bearing Installation

the bearing with a new one.
• Replace• Press in the bearing [A] until it is bottomed.

Special Tool - Bearing Driver Set [B]: 57001-1129• Replace the circlip with a new one.

Special Tool - Inside Circlip Pliers: 57001-143

FINAL DRIVE 11-13
Sprocket, Coupling
the grease seal with a new one.
• Replace
Press
in
the
seal so that the seal surface is flush• with the end greaseof the hole.

○Apply high-temperature grease to the grease seal lips.
Special Tool - Bearing Driver Set: 57001-1129

Coupling Bearing Inspection
Since the coupling bearing is made to extremely close
tolerances, the clearance can not normally be measured.

NOTE○It is not necessary to remove the coupling bearing for

inspection. If the bearing is removed, it will need to be
replaced with a new one.

the bearing in the coupling back and forth [A] while• Turnchecking for plays, roughness or binding.

•If the bearing play, roughness or binding is found, replace
the bearing.
Examine the bearing seal [B] for tears or leakage.
If the seal is torn or is leaking, replace the bearing.

Coupling Bearing Lubrication
NOTE○Since the coupling bearing is packed with grease andsealed, lubrication is not required.

Coupling Damper Inspection

the rear wheel coupling, and inspect the rubber• Removedampers [A].
the damper if it appears damaged or deterio• Replace
rated.

Sprocket Wear Inspection

inspect the engine and rear sprocket teeth for• Visuallywear and damage.
If the teeth are worn as illustrated, replace the sprocket,
and inspect the drive chain wear (see Drive Chain Wear
Inspection in the Periodic Maintenance chapter).
Worn Tooth (Engine Sprocket) [A]Worn Tooth (Rear Sprocket) [B]
Direction of Rotation [C]NOTE○If a sprocket requires replacement, the chain is proba-

bly worn also. When replacing a sprocket, inspect the
chain.

11-14 FINAL DRIVE
Sprocket, Coupling
Rear Sprocket Warp Inspection

the rear wheel off the ground with stand so that it• Raisewill turn freely.
a dial gauge [A] against the rear sprocket [B] near the• Set
teeth as shown, and rotate [C] the rear wheel to measure
the sprocket runout (warp). The difference between thehighest and lowest dial gauge readings is the amount ofrunout (warp).
If the runout exceeds the service limit, replace the rearsprocket.
Rear Sprocket Warp
Standard:
0.4 mm (0.016 in.) or lessService Limit:

0.5 mm (0.020 in.)

BRAKES 12-1

BrakesTable of Contents
Exploded View...................................
Specifications ....................................
Special Tools .....................................
Brake Lever, Brake Pedal..................
Brake Lever Position Adjustment.
Brake Pedal Position Inspection ..
Brake Pedal Position Adjustment.
Brake Pedal Removal ..................
Brake Pedal Installation ...............
Calipers .............................................
Front Caliper Removal .................
Rear Caliper Removal..................
Caliper Installation .......................
Front Caliper Disassembly...........
Front Caliper Assembly................
Rear Caliper Disassembly ...........
Rear Caliper Assembly ................
Caliper Fluid Seal Damage ..........
Rear Caliper Dust Boot andFriction Boot Damage ...............
Caliper Piston and Cylinder
Damage.....................................
Rear Caliper Holder Shaft Wear ..
Brake Pads ........................................
Front Brake Pad Removal............
Front Brake Pad Installation.........
Rear Brake Pad Removal ............
Rear Brake Pad Installation .........
Brake Pad Wear Inspection .........
Master Cylinder .................................
Front Master Cylinder Removal ...
Front Master Cylinder Installation
Rear Master Cylinder Removal....
Rear Master Cylinder Installation.
Front Master Cylinder
Disassembly..............................
Rear Master Cylinder
Disassembly..............................
Master Cylinder Assembly ...........
Master Cylinder Inspection ..........
Brake Disc .........................................
Brake Disc Removal ....................
Brake Disc Installation .................
Brake Disc Wear ..........................
Brake Disc Warp ..........................
Brake Fluid ........................................
Brake Fluid Level Inspection........
Brake Fluid Change .....................
Brake Line Bleeding.....................
Brake Hose........................................

12-3
12-12
12-13
12-14
12-14
12-14
12-14
12-15
12-15
12-17
12-17
12-17
12-17
12-18
12-18
12-18
12-18
12-18
12-18
12-19
12-19
12-20
12-20
12-20
12-20
12-20
12-20
12-21
12-21
12-21
12-22
12-22
12-22
12-22
12-22
12-23
12-24
12-24
12-24
12-24
12-24
12-25
12-25
12-25
12-25
12-28

Brake Hose Removal/Installation.
Brake Hose Inspection.................
Anti-Lock Brake System ....................
ABS Servicing Precautions ..........
ABS Troubleshooting Outline.......
Inquiries to Rider..........................
Self-diagnosis Outline ..................
Self-diagnosis Procedures ...........
Service Code Clearing
Procedures................................
How to Read Service Codes........
How to Erase Service Codes .......
ABS Indicator Light (LED)
Inspection..................................
ABS Indicator Light (LED) is
Unlit (When the Ignition Switch
turned to ON) ............................
Solenoid Valve Inspection(Service Code 13,14,17,18) ......
ABS Solenoid Valve Relay
Inspection (Service Code 19)....
Front, Rear Wheel Rotation
Difference Abnormal (Service
Code 25) ...................................
ABS Pump Motor Relay
Inspection (Service Code 35)....
Front Wheel Rotation Sensor
Signal Abnormal (Service Code42) .............................................
Front Wheel Rotation Sensor
Wiring Inspection (Service Code43) .............................................
Rear Wheel Rotation Sensor
Signal Abnormal (Service Code44) .............................................
Rear Wheel Rotation Sensor
Wiring Inspection (Service Code45) .............................................
Power Supply Voltage Abnormal(Under-Voltage) (Service Code52) .............................................
Power Supply Voltage Abnormal(Over-Voltage) (Service Code53) .............................................
ECU Inspection (Service Code55) .............................................
ABS Hydraulic Unit Removal .......
ABS Hydraulic Unit Installation ....
ABS Hydraulic Unit Inspection .....

12-28
12-28
12-29
12-32
12-34
12-37
12-39
12-39
12-40
12-42
12-42
12-44
12-44
12-45
12-45
12-47 12
12-47
12-48
12-49
12-50
12-51
12-51
12-52
12-53
12-53
12-54
12-55

12-2 BRAKES
Front Wheel Rotation Sensor
Removal ....................................
Front Wheel Rotation Sensor
Installation .................................
Rear Wheel Rotation Sensor
Removal ....................................
Rear Wheel Rotation Sensor
Installation .................................
Wheel Rotation Sensor
Inspection..................................
Wheel Rotation Sensor Air Gap
Inspection..................................

12-55
12-56
12-56
12-56
12-57
12-57

Wheel Rotation Sensor Rotor
Inspection..................................
Brake Hose and Pipe
Removal/Installation..................
Brake Hose and Pipe Inspection..
ABS Solenoid Valve Relay Fuse
Removal ....................................
ABS Motor Relay Fuse Removal .
Fuse Installation...........................
Fuse Inspection............................

12-57
12-57
12-58
12-58
12-58
12-58
12-59

BRAKES 12-3
Exploded View
Dummy Page

12-4 BRAKES
Exploded View

BRAKES 12-5
Exploded View
No.
1
2
3
4
5
6
7
8
9

Fastener
Bleed Valve
Brake Hose Banjo Bolts
Brake Lever Pivot Bolt
Brake Lever Pivot Bolt Locknut
Front Brake Disc Mounting Bolts
Front Brake Light Switch Screw
Front Brake Reservoir Cap Screws
Front Caliper Mounting Bolts
Front Master Cylinder Clamp Bolts

B: Apply brake fluid.
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.
Si: Apply silicone grease (ex. PBC grease).

N·m
7.8
25
1.0
5.9
27
1.0
1.0
34
8.8

Torque
kgf·m
ft·lb
0.80
69 in·lb
2.5
18
0.10
9 in·lb
0.60
52 in·lb
2.8
20
0.10
9 in·lb
0.10
9 in·lb
3.5
25
0.90
78 in·lb

RemarksSi
LS

12-6 BRAKES
Exploded View

BRAKES 12-7
Exploded View
No.
1
2
3
4
5
6
7

Fastener
Bleed Valve
Brake Hose Banjo Bolts
Brake Pedal Bolt
Rear Brake Disc Mounting Bolts
Rear Caliper Mounting Bolts
Rear Master Cylinder Mounting Bolts
Rear Master Cylinder Push Rod Locknut

B: Apply brake fluid.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
Si: Apply silicone grease (ex. PBC grease).

N·m
7.8
25
8.8
27
25
25
18

Torque
kgf·m
ft·lb
0.80
69 in·lb
2.5
18
0.90
78 in·lb
2.8
20
2.5
18
2.5
18
1.8
13

Remarks

L12-8 BRAKES
Exploded View
EX650B Models

BRAKES 12-9
Exploded View
No.
1
2
3
4
5
6
7
8
9
10

Fastener
Bleed Valve
Brake Hose Banjo Bolts
Brake Lever Pivot Bolt
Brake Lever Pivot Bolt Locknut
Brake Pipe Joint Nuts
Front Brake Disc Mounting Bolts
Front Brake Light Switch Screw
Front Brake Reservoir Cap Screws
Front Caliper Mounting Bolts
Front Master Cylinder Clamp Bolts

B: Apply brake fluid.
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.
Si: Apply silicone grease (ex. PBC grease).

N·m
7.8
25
1.0
5.9
18
27
1.0
1.0
34
8.8

Torque
kgf·m
ft·lb
0.80
69 in·lb
2.5
18
0.10
9 in·lb
0.60
52 in·lb
1.8
13
2.8
20
0.10
9 in·lb
0.10
9 in·lb
3.5
25
0.90
78 in·lb

RemarksSi
LS

12-10 BRAKES
Exploded View

BRAKES 12-11
Exploded View
No.
1
2
3
4
5
6
7
8

Fastener
Bleed Valve
Brake Hose Banjo Bolts
Brake Pedal Bolt
Brake Pipe Joint Nuts
Rear Brake Disc Mounting Bolts
Rear Caliper Mounting Bolts
Rear Master Cylinder Mounting Bolts
Rear Master Cylinder Push Rod Locknut

B: Apply brake fluid.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
Si: Apply silicone grease (ex. PBC grease).

N·m
7.8
25
8.8
18
27
25
25
18

Torque
kgf·m
ft·lb
0.80
69 in·lb
2.5
18
0.90
78 in·lb
1.8
13
2.8
20
2.5
18
2.5
18
1.8
13

RemarksL12-12 BRAKESSpecifications
Item
Brake Lever, Brake Pedal
Brake Lever Position
Brake Lever Free Play
Pedal Free Play
Pedal Position
Brake Pads
Lining Thickness:
Front
Rear
Brake Disc
Thickness:
Front:
EX650A Models
EX650B Models
Rear
RunoutBrake Fluid
GradeStandard

Service Limit

5-way adjustable (to suit rider)
Non-adjustable
Non-adjustable
About 40 mm (1.6 in.) below top of footpeg

– – –
– – –
– – –
– – –

4.5 mm (0.18 in.)
5.0 mm (0.20 in.)

1 mm (0.04 in.)
1 mm (0.04 in.)4.3 ∼ 4.7 mm (0.17 ∼ 0.19 in.)
4.8 ∼ 5.2 mm (0.19 ∼ 0.20 in.)
4.8 ∼ 5.2 mm (0.19 ∼ 0.20 in.)
0.15 mm (0.006 in.) or less

4.0 mm (0.16 in.)
4.5 mm (0.18 in.)
4.5 mm (0.18 in.)
0.3 mm (0.01 in.)

DOT4

– – –

BRAKES 12-13
Special Tools
Inside Circlip Pliers:
57001-143

Hand Tester:
57001-1394

Jack:
57001-1238

Jack Attachment:
57001-1608

12-14 BRAKES
Brake Lever, Brake Pedal
Brake Lever Position Adjustment
The brake lever adjuster has 5 positions so that the brakelever position can be adjusted to suit the operator’s hand.
Push the lever forward and turn the adjuster [A] to alignthe number with the arrow mark [B] on the lever holder.
○The distance from the grip to the lever is minimum at number 5 and maximum at number 1.

•

Brake Pedal Position Inspectionthat the brake pedal [A] is in the correct position.
• Check
Footpeg [B]Pedal Position
Standard: About 40 mm (1.6 in.) [C] below top offootpeg

If it is incorrect, adjust the brake pedal position.

Brake Pedal Position Adjustment
NOTE○Usually it is not necessary to adjust the pedal position,

but always adjust it when the push rod locknut has beenloosened.

• Remove:
Frame Cover (see Frame Cover Removal in the Frame
chapter)
Bolts [A]Right Footpeg Stay [B]the locknut [A] and turn the push rod with the hex• Loosenhead [B] to achieve the correct pedal position.

•

If the length [C] shown is 70 ±1 mm (2.76 ±0.04 in.), thepedal position will be within the standard range.
Tighten:
Torque - Rear Master Cylinder Push Rod Locknut: 18 N·m(1.8 kgf·m, 13 ft·lb)• Install the footpeg stay, and tighten the bolts.

Torque - Footpeg Stay Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)

the brake light switch operation (see Brake Light• Check
Switch Operation Inspection in the Periodic Maintenancechapter).

BRAKES 12-15
Brake Lever, Brake Pedal
Brake Pedal Removal• Remove:
Frame Cover (see Frame Cover Removal in the Frame
chapter)
Bolts [A]Right Footpeg Stay [B]• Remove:
Cotter Pin [A]•Joint Pin [B]Rear Brake Light Switch Spring [C]Return Spring [D]Remove the mounting bolt [E] and take out the brake
pedal.

Brake Pedal Installation

grease to the pivot shaft [A] and install the washer• Apply[B].
• Install:
Brake Pedal [C]Washer [D]Brake Pedal Bolt [E]Torque - Brake Pedal Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)

the lower end of the rear brake light switch spring• Hook[A] on the pedal hook.
the upper end of the return spring [B] on the pedal• Hookhook.

the cotter pin with a new one.
• Replace
Insertthecotter pin [A] and bend the pin ends [B].
•

12-16 BRAKES
Brake Lever, Brake Pedal• Install the right footpeg stay, and tighten the bolts.

Torque - Footpeg Stay Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)○Depress the brake pedal [A] and then align the bolts holesof the master cylinder [B].

Torque - Rear Master Cylinder Mounting Bolts: 25 N·m (2.5kgf·m, 18 ft·lb)

the brake pedal position (see Brake Pedal Position• Check
Inspection).

BRAKES 12-17
Calipers
Front Caliper Removal

the banjo bolt [A] at the brake hose lower end,
• Loosenand tighten it loosely.
the caliper mounting bolts [B], and detach the• Unscrew
caliper [C] from the disc.
the banjo bolt and remove the brake hoses [D]• Unscrewfrom the caliper (see Brake Hose Removal/Installation).

CAUTION
Immediately wash away any brake fluid that spills.

NOTE○If the caliper is to be disassembled after removal and if
compressed air is not available, disassemble the caliper
before the brake hose is removed (see Front Caliper
Disassembly).

Rear Caliper Removal

the banjo bolt [A] at the brake hose lower end,
• Loosenand tighten it loosely.
the caliper mounting bolts [B], and detach the• Unscrew
caliper [C] from the disc.
the banjo bolt and remove the brake hose [D]• Unscrewfrom the caliper (see Brake Hose Removal/Installation).

CAUTION
Immediately wash away any brake fluid that spills.

NOTE○If the caliper is to be disassembled after removal and if
compressed air is not available, disassemble the caliper
before the brake hose is removed (see Rear Caliper
Disassembly).

Caliper Installation

the caliper and brake hose lower end.
•○Install
Replace the washers on each side of hose fitting with new

•

ones.
Tighten:

Torque - Caliper Mounting Bolts
Front: 34 N·m (3.5 kgf·m, 25 ft·lb)
Rear: 25 N·m (2.5 kgf·m, 18 ft·lb)
Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)

the fluid level in the brake reservoirs.
• Check
the brake line (see Brake Line Bleeding).
• BleedCheckbrake for good braking power, no brake drag,• and nothefluid leakage.

WARNING
Do not attempt to drive the motorcycle until a fullbrake lever or pedal is obtained by pumping thebrake lever or pedal until the pads are against thedisc. The brakes will not function on the first application of the lever or pedal if this is not done.

12-18 BRAKES
Calipers
Front Caliper Disassemblyto the Caliper Rubber Parts Replacement in the Pe• Refer
riodic Maintenance chapter.

Front Caliper Assemblyto the Caliper Rubber Parts Replacement in the Pe• Refer
riodic Maintenance chapter.

Rear Caliper Disassemblyto the Caliper Rubber Parts Replacement in the Pe• Refer
riodic Maintenance chapter.

Rear Caliper Assemblyto the Caliper Rubber Parts Replacement in the Pe• Refer
riodic Maintenance chapter.

Caliper Fluid Seal Damage
The fluid seal (piston seal) [A] is placed around the piston to maintain clearance between the pad and the disc. If
the seal is in a poor condition, it could lead the pad to wear
excessively or the brake to drag, which may cause the temperature of the discs or the brake fluid to increase.
Replace the fluid seal if it exhibits any of the conditions
listed below.
○Brake fluid leakage around the pad.
○Brakes overheat.
○Considerable difference in inner and outer pad wear.
○Seal and piston are stuck together.
If the fluid seal is replaced, replace the dust seal [B] as
well. Also, replace all seals every other time the pads arechanged.

•Rear Caliper Dust Boot and Friction Boot Damage

that the dust boot [A] and friction boot [B] are not• Check
cracked, worn, swollen, or otherwise damaged.
If they show any damage, replace it.

BRAKES 12-19
Calipers
Caliper Piston and Cylinder Damage

inspect the pistons [A] and cylinder surfaces [B].
• VisuallyReplace the caliper if the cylinder and piston are badly
scores or rusty.

Rear Caliper Holder Shaft Wear
The caliper body must slide smoothly on the caliper holder
shafts [A]. If the body does not slide smoothly, one pad will
wear more than the other, pad wear will increase, and constant drag on the disc will raise brake and brake fluid temperature.
Check to see that the caliper holder shafts are not badly
worn or stepped, and that the rubber friction boots are notdamaged.
If the rubber friction boot is damaged, replace the rubber
friction boot. To replace the friction boot, remove the pads
and the caliper bracket.
If the caliper holder shaft is damage, replace the caliper
bracket.

•12-20 BRAKES
Brake Pads
Front Brake Pad Removal

the front caliper with the hose installed (see Front• Remove
Caliper Removal).
out the holder shaft pin [A], and take off the holder• Draw
shaft [B].
the pad [C] on the piston side.
• RemovePush
the[D] towards the piston, and remove the• pad of theholder
other side [E] from the holder shaft [F].

Front Brake Pad Installation

the caliper pistons in by hand as far as they will go.
• PushInstallthe anti-rattle spring in its correct position.
• Install theon the piston side first, then install the other• pad on thepadholder.
• Install the front caliper (see Caliper Installation).

WARNING

Do not attempt to drive the motorcycle until a fullbrake lever is obtained by pumping the brake leveruntil the pads are against the disc. The brake will
not function on the first application of the lever if
this is not done.

Rear Brake Pad Removal

the rear caliper with the hose installed (see Rear
• Remove
Caliper Removal).
out the holder shaft pin [A], and take off the holder• Draw
shaft [B].
the pad [C] on the piston side.
• RemovePush
the[D] towards the piston, and remove the• pad of theholder
other side [E] from the holder shaft [F].

Rear Brake Pad Installation

the caliper piston in by hand as far as it will go.
• Pushthe anti-rattle spring in its correct position.
• Install
Installtheon the piston side first, then install the other• pad on thepadholder.
• Install the rear caliper (see Caliper Installation).

WARNING

Do not attempt to drive the motorcycle until a fullbrake pedal is obtained by pumping the brake pedal
until the pads are against the disc. The brake will
not function on the first application of the pedal if
this is not done.

Brake Pad Wear Inspection

to the Brake Pad Wear Inspection in the Periodic• Refer
Maintenance chapter.

BRAKES 12-21
Master Cylinder
Front Master Cylinder Removal

the banjo bolt [A] to disconnect the brake hose
• Removefrom the master cylinder [B] (see Brake Hose Removal/Installation).

the front brake light switch connectors [A].
• Disconnect
Unscrew
theclamp bolts [B], and take off the master cylin• der as an assemblywith the reservoir, brake lever andbrake switch installed.

CAUTION
Immediately wash away any brake fluid that spills.

• Remove:
Brake Lever Pivot Bolt [A] and Locknut
Brake Lever [B]Front Brake Light Switch [C]Front Master Cylinder Installation

the front master cylinder so that the punch mark [A]• Installof the handlebar is aligned with the mating surface [B] of
the master cylinder clamp to level the reservoir.

master cylinder clamp must be installed with the ar• The
row mark [A] upward.
the upper clamp bolt [B] first, and then the lower• Tighten
clamp bolt [C]. There will be a gap at the lower part of theclamp after tightening.
Torque - Front Master Cylinder Clamp Bolts: 8.8 N·m (0.90
kgf·m, 78 in·lb)

the washers on each side of the hose fitting with
• Replacenew ones.
• Tighten the brake hose banjo bolt.

Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

the brake line (see Brake Line Bleeding).
• BleedCheckbrake for good braking power, no brake drag,• and nothefluid leakage.

12-22 BRAKES
Master Cylinder
Rear Master Cylinder Removal

the brake hose banjo bolt [A] on the master cylin• Unscrew
der (see Brake Hose Removal/Installation).

the master cylinder mounting bolts [A].
• Unscrew
Removethecotter pin [B].
•NOTE

○Pull off the joint pin while pressing down the brake
pedal.

off the reservoir hose lower end [C], and drain the• Pullbrake fluid into a container.
• Remove the master cylinder.

Rear Master Cylinder Installation

the cotter pin [A] with a new one.
• Replace
Replacethewashers on each side of hose fitting with new• ones.
• Tighten the following bolts.

Torque - Rear Master Cylinder Mounting Bolts: 25 N·m (2.5kgf·m, 18 ft·lb)
Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

the brake line (see Brake Line Bleeding).
• BleedCheckbrake for good braking power, no brake drag,• and nothefluid leakage.

Front Master Cylinder Disassemblyto the Master Cylinder Rubber Parts Replacement• Referin the Periodic Maintenance chapter.

Rear Master Cylinder Disassemblyto the Master Cylinder Rubber Parts Replacement• Referin the Periodic Maintenance chapter.

Master Cylinder Assemblyto the Master Cylinder Rubber Parts Replacement• Referin the Periodic Maintenance chapter.

BRAKES 12-23
Master Cylinder
Master Cylinder Inspection

the master cylinders (see Front/Rear Master• Remove
Cylinder Removal).
the front and rear master cylinders.
• Disassemble
Check
that
there
are no scratches, rust or pitting on the• inner wall [A] of eachmaster cylinder and on the outside•of each piston [B].
If a master cylinder or piston shows any damage, replacethem.
Inspect the primary cup [C] and secondary cup [D].
If a cup is worn, damaged softened (rotted), or swollen,
the piston assembly should be replaced to renew thecups.
If fluid leakage is noted at the brake lever, the piston assembly should be replaced to renew the cups.
Front Master Cylinder [J]the dust covers [E] for damage.
• Check
If they are damaged, replace them.
the piston return springs [F] for any damage.
• Check
If the springs are damaged, replace them.
that relief port [G] and supply port [H] are not• Check
plugged.
If the relief port becomes plugged, the brake pads will
drag on the disc. Blow the ports clean with compressed
air.
Rear Master Cylinder [K]12-24 BRAKES
Brake Disc
Brake Disc Removal

the wheel (see Front/Rear Wheel Removal in the• Remove
Wheels/Tires chapter).
the mounting bolts, and take off the disc.
• Unscrew
Removethegaskets.
•

Brake Disc Installation

the gaskets with new ones.
• Replacethe brake disc on the wheel so that the marked side
• Install[A] faces out.
a non-permanent locking agent to the threads of• Apply
the front and rear brake disc mounting bolts [B].
• Tighten:
Torque - Brake Disc Mounting Bolts: 27 N·m (2.8 kgf·m, 20
ft·lb)

Brake Disc Wear

the thickness of each disc [A] at the point where• Measureit has worn the most.
If the disc has worn past the service limit, replace it.
Measuring Area [B]Brake Discs Thickness
Standard:
Front:
EX650A Models

4.3 ∼ 4.7 mm (0.17 ∼ 0.19 in.)

EX650B Models

4.8 ∼ 5.2 mm (0.19 ∼ 0.20 in.)
4.8 ∼ 5.2 mm (0.19 ∼ 0.20 in.)

Rear
Service Limit:
Front

4.0 mm (0.16 in.)Rear

4.5 mm (0.18 in.)Brake Disc Warp

the wheel off the ground with jack (see Front/Rear• RaiseWheel Removal in the Wheels/Tires chapter).
Special Tools - Jack: 57001-1238
Jack Attachment: 57001-1608○For front disc inspection, turn the handlebar fully to one

•

side.
Set up a dial gauge against the disc [A] as shown andmeasure disc runout, while turning [B] the wheel by hand.
If runout exceeds the service limit, replace the disc.
Disc Runout
Standard:
Service Limit:

0.15 mm (0.006 in.) or less
0.3 mm (0.01 in.)

BRAKES 12-25
Brake Fluid
Brake Fluid Level Inspection

to the Brake Fluid Level Inspection in the Periodic• Refer
Maintenance chapter.

Brake Fluid Change

to the Brake Fluid Change in the Periodic Mainte• Refernance chapter.

Brake Line Bleeding
The brake fluid has a very low compression coefficient sothat 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 enters the brakelines, brake lever or pedal movement will be partially usedin compressing the air. This will make the lever or pedal feelspongy, and there will be a loss in braking power.

WARNINGBe sure to bleed the air from the brake line whenever brake lever or pedal action feels soft orspongy after the brake fluid is changed, or whenever a brake line fitting has been loosened for any
reason.

NOTE○The procedure to bleed the front brake line is as follows.

Bleeding the rear brake line is the same as for the front
brake.

the reservoir cap [A] and diaphragm.
• RemoveFillthereservoir
with fresh brake fluid to the upper level• line in the reservoir.
pump the brake lever several times until no air• Slowly
bubbles can be seen rising up through the fluid from theholes at the bottom of the reservoir.
○Bleed the air completely from the master cylinder by thisoperation.

the rubber cap from the bleed valve [A] on the• Removecaliper.
a clear plastic hose [B] to the bleed valve, and run• Attachthe other end of the hose into a container.

12-26 BRAKES
Brake Fluidthe brake line and the caliper.
•○BleedRepeat this operation until no more air can be seen com-

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] the bleed valve while holding the brake applied.
3. Release the brake [C].

NOTE○The fluid level must be checked often during the bleeding operation and replenished with fresh brake fluid asnecessary. If the fluid in the reservoir runs completely
out any time during bleeding, the bleeding operationmust be done over again from the beginning since air
will have entered the line.
○Tap the brake hose lightly from the caliper to the reservoir for more complete bleeding.
○Front Brake: First bleeding the right caliper then repeat
the above steps for the left caliper.
the clear plastic hose.
• Removethe diaphragm and reservoir cap.
• Install
Tighten:•

Torque - Front Brake Reservoir Cap Screws: 1.0 N·m (0.10
kgf·m, 9 in·lb)

the procedure below to install the rear brake fluid• Followreservoir cap correctly.

○First, tighten the rear brake fluid reservoir cap [B] clockwise [C] by hand until slight resistance is felt indicatingthat the cap is seated on the reservoir body, then tighten
the cap an additional 1/6 turn [D] while holding the brakefluid reservoir body [A].

• Tighten the bleed valve, and install the rubber cap.
Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

the fluid level (see Brake Fluid Level Inspection in• Checkthe Periodic Maintenance chapter).
bleeding is done, check the brake for good braking• After
power, no brake drag, and no fluid leakage.

BRAKES 12-27
Brake Fluid
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 and brands of fluid for use in
the brake. This lowers the brake fluid boiling pointand could cause the brake to be ineffective. It may
also cause the rubber brake parts to deteriorate.
4. Don’t leave the reservoir cap off for any length oftime to avoid moisture contamination of the fluid.
5. Don’t change the fluid in the rain or when a strong
wind is blowing.
6. Except for the disc pads and disc, use only discbrake fluid, isopropyl alcohol, or ethyl alcohol forcleaning of the brake parts. Do not use any otherfluid for cleaning these parts. Gasoline, engine oil,or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will
be difficult to wash off completely and will eventually
deteriorate the rubber used in the disc brake.
7. When handling the disc pads or disc, be careful thatno disc brake fluid or any oil gets on them. Clean off
any fluid or oil that inadvertently gets on the pads ordisc with a high-flash point solvent. Do not use one
which will leave an oily residue. Replace the pads
with new ones if they cannot be cleaned satisfactorily.
8. Brake fluid quickly ruins painted surfaces; any
spilled fluid should be completely wiped up immediately.
9. If any of the brake line fittings or the bleed valve is
opened at any time, the AIR MUST BE BLED FROMTHE BRAKE LINE.

12-28 BRAKES
Brake Hose
Brake Hose Removal/Installation

to the Brake Hose and Pipe Replacement in the• Refer
Periodic Maintenance chapter.

Brake Hose Inspection

to the Brake Hose Damage and Installation Condi• Refertion Inspection in the Periodic Maintenance chapter.

BRAKES 12-29
Anti-Lock Brake System
Parts Location

1. Front Wheel Rotation Sensor
2. Front Wheel Rotation Sensor Rotor
3. Rear Wheel Rotation Sensor
4. Rear Wheel Rotation Sensor Rotor
5. ABS Indicator Light (LED)6. ABS Hydraulic Unit
7. ABS Fuse Box
8. ABS Kawasaki Self-diagnosis System Connector

12-30 BRAKES
Anti-Lock Brake System
ABS System Wiring Diagram

1. Ignition Switch
2. ABS Hydraulic Unit
3. ABS Self-diagnosis Terminal
4. ABS Kawasaki Self-diagnosis System Connector
5. Front Wheel Rotation Sensor
6. Rear Wheel Rotation Sensor
7. ABS Solenoid Valve Relay
8. ABS Motor Relay
9. Frame Ground
10. Meter Unit
11. Front Brake Switch
12. Water-proof Joint C
13. Ignition Fuse 10 A
14. Main Fuse 30 A
15. Battery 12 V 10 Ah
16. Frame Ground
17. Rear Brake Switch
18. Joint Connector

BRAKES 12-31
Anti-Lock Brake System
Terminal Names

1. Ground to Motor
2. Power Supply to ABS Motor Relay
3. Power Supply to ABS Solenoid Valve Relay
4. Ground
5. Front Wheel Rotation Sensor Signal
6. Unused
7. Power Supply to Rear Wheel Rotation Sensor
8. Unused
9. Unused
10. Unused
11. ABS Kawasaki Self-diagnosis System Terminal
12. ABS Indicator Light (LED)13. Unused
14. Unused
15. Unused
16. Power Supply to Front Wheel Rotation Sensor
17. Unused
18. Power Supply
19. Rear Wheel Rotation Sensor Signal
20. Front Brake Light Switch
21. Rear Brake Light Switch
22. Unused
23. Unused
24. Unused
25. ABS Self-diagnosis Terminal
26. Unused

12-32 BRAKES
Anti-Lock Brake System
ABS Servicing Precautions
There are a number of important precautions that should
be followed servicing the ABS system.
○This ABS system is designed to be used with a 12 V
sealed battery as its power source. Do not use anyother battery except for a 12 V sealed battery as a powersource.
○Do not reverse the battery cable connections. This will
damage the ABS hydraulic unit.
○To prevent damage to the ABS parts, do not disconnect
the battery cables or any other electrical connections
when the ignition switch is ON or while the engine isrunning.
○Take care not to short the leads that are directly connected to the battery positive (+) terminal to the chassis
ground.
○Do not turn the ignition switch ON while any of the ABS
electrical connectors are disconnected. The ABS hydraulic unit memorizes service codes.
○Do not spray water on the electrical parts, ABS parts, connectors, leads and wiring.
○If a transceiver is installed on the motorcycle, make surethat the operation of the ABS system is not influenced
by electric wave radiated from the antenna. Locate theantenna as far as possible away from the ABS hydraulicunit.
○Whenever the ABS electrical connections are to be disconnected, first turn off the ignition switch.
○The ABS parts should never be struck sharply, as witha hammer, or allowed to fall on a hard surface. Such ashock to the parts can damage them.
○The ABS parts cannot be disassembled. Even if a fault isfound, do not try to disassemble and repair the ABS parts,
replace it.
○The ABS has many brake lines, pipes, and leads. And
the ABS cannot detect problems with the conventional
braking system (brake disc wear, unevenly worn brakepad, and other mechanical faults). To prevent trouble,
check the brake lines and pipes for correct routing andconnection, the wiring for correct routing, and the brakes
for proper braking power. Be sure to check for fluid leakage, and bleed the brake line thoroughly.

WARNING
If any of the brake line fittings, including the ABS
hydraulic unit joint nuts, or the bleed valve is
opened at any time, the air must be bled completelyfrom the brake line.

CAUTION
Do not ride the motorcycle with air in the brake line,or the ABS could malfunction.

BRAKES 12-33
Anti-Lock Brake System○The ABS indicator light (LED) [A] may light if the tire pres-sure is incorrect, a non-recommended tire is installed, or
the wheel is deformed. If the indicator light lights, remedy
the problem and clear the service code.

WARNINGUse of non-recommended tires may cause malfunctioning of ABS and can lead to extended braking
distance. The rider could have an accident as a result. Always use recommended standard tires forthis motorcycle.

○The ABS indicator light (LED) may come on if the engine

is run with the motorcycle on its stand and the transmission in gear. If the indicator light comes on, just turn theignition switch OFF, then clear service code 42, which indicates a “Faulty front wheel speed sensor”.
○When the ABS operates, the ABS makes noise and therider feels the reaction force on the brake lever and brake
pedal. This is a normal condition. It informs the rider that
the ABS is operating normally.
○Service codes detected once by the ABS hydraulic unit
will be memorized in the ABS hydraulic unit. Therefore,
after maintenance work is finished, be sure to erase theservice codes. Do not erase the service codes during
troubleshooting. Wait until all the checks and repair work
are finished to prevent duplication of previous service
codes and unnecessary maintenance work.
○Before delivering the motorcycle to the customer, besure to erase any service codes which might be stored
in the ABS hydraulic unit. Using the self-diagnosis
feature, make sure that only start code 12 is shown. A
fully charged battery is a must for conducting reliableself-diagnosis. Test run the motorcycle at a speed ofmore than 20 km/h (12 mph) to see that the ABS indicatorlight (LED) does not come on. Finally, test run the motorcycle at a speed of more than 30 km/h (20 mph) andbrake suddenly to see that the motorcycle stops without
loss of steering control and the ABS operates normally(The reaction force generated is felt in the brake leverand pedal.). This completes the final inspection.
○Color Codes:
BK: Black
BL: Blue
BR: Brown
CH: Chocolate
DG: Dark Green

G: Green
GY: Gray
LB: Light Blue
LG: Light Green
O: Orange

P: Pink
PU: Purple
R: Red
W: White
Y: Yellow

12-34 BRAKES
Anti-Lock Brake System
ABS Troubleshooting Outline
When an abnormality in the system occurs, the ABS indicator light (LED) lights up to alert the rider. In addition,
the nature of the fault is stored in the memory of the ABS
hydraulic unit and when in the self-diagnosis mode, the service code [A] is indicated by the number of times the ABS
indicator light (LED) blinks. The service codes stored inmemory are not erased until the mode has been changed
to the fault erase mode after the fault has been corrected.
Therefore, after correcting the problem, always erase theservice codes and then run the self-diagnosis program toconfirm normal signal output. When, due to a malfunction,
the ABS indicator light (LED) remains lit, get a thoroughunderstanding of the background before starting the repair
work. Ask the rider about the conditions [B] under which
the problem occurred and try to determine the cause [C].
Do not rely solely on the ABS self-diagnosis function, usecommon sense; check the brakes for proper braking power,
and brake fluid level, search for leaks, etc.

Even when the ABS is operating normally, the ABS indicator light (LED) may light up under the conditions listed below. Turn the ignition switch OFF to stop blinking or lightingof the indicator light. If the motorcycle runs without erasing
the service code, the light may light up again.
○After continuous riding on a rough road.
○When the engine is started with the stand raised and thetransmission engaged, and the rear wheel turns.
○When accelerating so abruptly that the front wheel leaves
the ground.
○When the ABS has been subjected to strong electricalinterference.
○When tire pressure is abnormal. Adjust tire pressure.
○When a tire different in size from the standard size is being
used. Replace with standard size.
○When the wheel is deformed. Replace the wheel.
Much of the ABS troubleshooting work consists of confirming continuity of the wiring. The ABS parts are assembled and adjusted by the manufacturer, so there is no needto disassemble or repair them. Replace the ABS hydraulicunit.
The basic troubleshooting procedures are listed below.
Carry out pre-diagnosis inspections as a preliminary inspection.
Determine the fault using the self-diagnosis function.
Check wiring and connections from the ABS hydraulicunit connector to the suspected faulty ABS part, using thehand tester.

•••Special Tool - Hand Tester: 57001-1394

BRAKES 12-35
Anti-Lock Brake Systeminspect the wiring for signs of burning or fraying.
• VisuallyIf any wiring is poor, replace the damaged wiring.
each connector [A] apart and inspect it for corrosion,• Pulldirt and damage.
If the connector is corroded or dirty, clean it carefully. If it
is damaged, replace it.
Check the wiring for continuity.
○Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
○Connect the hand tester between the ends of the leads.

•

Special Tool - Hand Tester: 57001-1394○Set the tester to the × 1 Ω range, and read the tester.

If the tester does not read 0 Ω, the lead is defective. Replace the main harness [B] if necessary.

down suspicious parts and close in on the faulty• Narrow
ABS part by repeating the continuity tests.
If no abnormality is found in the wiring or connectors, theABS parts are the next likely suspects. Check each partone by one.
If an abnormality is found, replace the affected ABS part.

12-36 BRAKES
Anti-Lock Brake System
ABS Diagnosis Flow Chart

BRAKES 12-37
Anti-Lock Brake System
Inquiries to Rider○Each rider reacts to problems in different ways, so it is important to confirm what kind of condition
the rider is dissatisfied with.
○Try to find out exactly what problem occurs under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem in the shop.
○The diagnosis sheet will help prevent you from overlooking any keys, so always use it.

Sample Diagnosis Sheet
Rider name:Year of initial registration:
Engine No.:
Date problem occurred:
Weather:□ Brake □ Indicator
lever
light
vibration
blinksor noise

Registration No. (license plate No.):
Model:
Frame No.:
Frequency:
Mileage:□ Braking □ Abnor- □ ABS not □ ABS□ ABS opdistancemalworkingworks
erating
too longbrakebut
too freleverindicator
quently
movelight
Phenomement
doesn’tnonlight up
□ Pedal □ Indicator□ Abnorvibration
light
mal
or noiseremainspedal
lit upmovement
Engine conditions at□ At start-up□ After starting□ At 5 000 r/min (rpm)or moreproblem
Road conditions□ Slippery road(□ snow, □ gravel, □ other)□ Rough surface□ Other
Driving conditions□ High-speed cornering□ Driving 10 km/h (6 mph) or above□ Driving below 10 km/h (6 mph)
□ When stopping□ When turning
Brake application□ Gradual□ Abrupt
Other conditions□ Large brake lever stroke□ Large pedal stroke

12-38 BRAKES
Anti-Lock Brake System
Pre-Diagnosis Inspection 1

BRAKES 12-39
Anti-Lock Brake System
Pre-Diagnosis Inspection 2

Self-diagnosis Outline
When the indicator light has blinked or come on, the ABS hydraulic unit memorizes and stores theservice code (15 codes including “Normal Code”) for the service person to troubleshoot easily. The
service code memory is powered directly by the battery and cannot be canceled by the ignition switch.
The ABS hydraulic unit can memorize up to six service codes. Further service codes are memorized
after erasing the preceding six service codes. If there is no fault, only the start code 12 is shown,indicating that “The ABS is normal”

Self-diagnosis Procedures○When a problem occurs with the ABS system, the ABS
indicator light (LED) [A] is blinks and lights.

NOTE○Use a fully charged battery when conducting

self-diagnosis. Otherwise, the light blinks very slowly
or doesn’t blink.
○The motorcycle is stopped.
○Keep the self-diagnosis terminal grounded during self
-diagnosis, with an auxiliary lead.

12-40 BRAKES
Anti-Lock Brake System
the seat (see Seat Removal in the Frame chap• Removeter).
the self-diagnosis terminal [A] (Gray) to the bat• Groundtery (–) terminal or battery (–) lead connector, using alead.
Turn on the ignition switch.
○Count the blinks of the light to read the service code.
Keep the auxiliary lead ground until you finish reading theservice code.

•

Service Code Clearing Procedures

the service code erase mode with the following pro• Start
cedure.

○The erase mode starts when the ABS self-diagnosis ter-minal is disconnected from the ground terminal after starting the self-diagnosis mode.
○The service code can be erased by grounding and ungrounding (each time for at least one second) the ABS
self-diagnosis terminal three times or more within about
12.5 seconds after starting the erase mode.
○The ABS indicator light (LED) remains lit during the erase
mode and after erasing.
○Once erasing is finished, enter the self-diagnosis mode
again to confirm that the service codes have beenerased. If the ABS has been reset and all codes havebeen erased, only start code 12 will be shown.

BRAKES 12-41
Anti-Lock Brake System
Self-diagnosis Flow Chart

12-42 BRAKES
Anti-Lock Brake System
How to Read Service Codes○Service codes are shown by a series of long and short blinks of the ABS indicator light (LED) as

shown below.
○Read 10th digit and unit digit as the ABS indicator light (LED) blinks.
○When there are a number of faults, a maximum of six service codes can be stored and the display
will begin starting from the last service code entered.
○For the display pattern, first, start code 12 is shown, next up to six service codes starting with thelast one stored, then the display is repeated from the start code once again.

○If there is no fault, only the start code is shown.

How to Erase Service Codes○Even if the ignition switch is turned OFF, the battery or the ABS hydraulic unit are disconnected, allservice codes remain in the ABS hydraulic unit.
○Refer to the Service Code Clearing Procedure for the service code erasure.

BRAKES 12-43
Anti-Lock Brake System
Service Code Table
ServiceCode

ABS Indicator Light (LED)

Problems

Light State
After starts,
turn off

12

Start code (not fault)

13

Rear inlet solenoid valve trouble (open,
temperature abnormal)

ON

14

Rear outlet solenoid valve trouble (open,
temperature abnormal)

ON

17

Front inlet solenoid valve trouble (open,
temperature abnormal)

ON

18

Front outlet solenoid valve trouble (open,
temperature abnormal)

ON

19

25

ABS solenoid valve relay trouble (wiring
shorted or open, stuck relay (ON or OFF)or dropout)
Front, rear wheel rotation difference
abnormal (substandard tire, sensor rotor
teeth number wrong)

ON

ON

35

ABS motor relay trouble (wiring shorted oropen, stuck relay (ON or OFF)ON

42

Front wheel rotation sensor signal abnormal(sensor or rotor missing, too large
clearance, rotor tooth worn or missing)ON

43

Front wheel rotation sensor wiring (wiring
shorted or open, connector bad connection)

ON

44

Rear wheel rotation sensor signal abnormal(sensor or rotor missing, too large
clearance, rotor tooth worn or missing)ON

45

Rear wheel rotation sensor wiring (wiring
shorted or open, connector bad connection)ON

52

Power supply voltage abnormal(under-voltage)

ON

53

Power supply voltage abnormal(over-voltage)

ON

55

ECU trouble (ECU operation abnormal)ON12-44 BRAKES
Anti-Lock Brake System
ABS Indicator Light (LED) Inspection

the ignition switch ON.
• TurnIf the ABS indicator light (LED) [A] lights, it is normal.
If the ABS indicator light (LED) does not light, go to step
“ABS Indicator Light (LED) is Unlit (When the Ignition
Switch turned to ON)”.

the ignition switch OFF.
• TurnIf the ABS indicator light (LED) [A] does not light, it isnormal.
If the ABS indicator light (LED) lights, go to step “ABS Indicator Light (LED) Lights (When the Motorcycle is Running, - No Service Code)”.

ABS Indicator Light (LED) is Unlit (When the
Ignition Switch turned to ON)

the 1st step test.
•○Do
Check the terminal voltage between the orange/black andblack/yellow lead terminals of the meter connector [A].
Special Tool - Hand Tester: 57001-1394
Terminal Voltage
Standard:

About 9 V

If the terminal voltage is not within the specification, 2nd
step.
If the terminal voltage correct, replace the meter assembly.
the 2nd step test.
•○Do
Disconnect the ABS hydraulic unit connector and meter

connector.
○Check for continuity between the orange/black leadterminal of the main harness side connector [A] andorange/black lead terminal of the main harness sideconnector [B].
If there is the continuity in the lead, 3rd step.
If there is not the continuity in the lead, replace or repair
the main harness.
the 3rd step test.
•○Do
Check the battery terminal voltage (see 2nd Step in thePower Supply Voltage Abnormal (Under-Voltage) (Service Code 52)).
If the battery terminal voltage correct, replace the ABS
hydraulic unit.

BRAKES 12-45
Anti-Lock Brake System
ABS Indicator Light (LED) Lights (When the Motorcycle
is Running, - No Service Code)Do the 1st step test.
○Check the terminal voltage between the orange/black andblack/yellow lead terminals of the meter connector [A].

•Special Tool - Hand Tester: 57001-1394
Terminal Voltage
Standard:

About 9 ~ 12 V

If the terminal voltage is not within the specification, replace the meter assembly.
If the terminal voltage correct, 2nd step.
the 2nd step test.
•○Do
Disconnect the ABS hydraulic unit connector.

○Check the terminal voltage between the orange/black andblack/yellow lead terminals of the main harness side connector [A].
Special Tool - Hand Tester: 57001-1394

If the terminal voltage is about 9 ∼ 12 V, replace the main
harness.
If the terminal voltage is 0 V, replace the ABS hydraulicunit.

Solenoid Valve Inspection (Service Code13,14,17,18)

the 1st step test.
•○Do
Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, andretrieve the service code.
If the ABS indicator light (LED) [A] lit, faulty solenoid valve
in the ABS hydraulic unit. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) [A] unlit, ABS system isnormal (service code is not stored; temporary failure.).

ABS Solenoid Valve Relay Inspection (Service
Code 19)
the 1st step test.
•○Do
Check the ABS solenoid valve relay fuse [A].
If the fuse blown, 2nd step.
If the fuse correct, 4th step.

12-46 BRAKES
Anti-Lock Brake System
the 2nd step test.
•○Do
Disconnect the ABS hydraulic unit connector [A].

○Check for continuity between the white/red and black/yellow lead terminals of the ABS hydraulic unit connector.
If there is the continuity in the lead, replace the ABS hydraulic unit.
If there is not the continuity in the lead, 3rd step.

the 3rd step test.
•○Do
Check for continuity between the white/red lead terminalof the main harness side connector [A] and white/red leadterminal of the fuse box [B] .
If there is the continuity in the lead, replace the fuse.
If there is not the continuity in the lead, replace or repair
the main harness.

the 4th step test.
•○Do
Check the battery terminal voltage between the white/red
lead terminal of the fuse box [A] and ground.
Special Tool - Hand Tester 57001-1394
Battery Terminal Voltage
Battery Voltage
Standard:

If the battery terminal voltage is not within the specification, 5th step.
If the battery terminal voltage correct, 6th step.
the 5th step test.
•○Do
Check for continuity between the positive cable [A] of thebattery and white/red lead terminal of the main harness
side connector [B].
If there is the continuity in the lead, 4th step.
If there is not the continuity in the lead, replace or repair
the main harness.

the 6th step test.
•○Do
Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, andretrieve the service code.
If the ABS indicator light (LED) [A] lit, faulty ABS solenoid
valve relay in the ABS hydraulic unit. Replace the ABS
hydraulic unit.
If the ABS indicator light (LED) [A] unlit, ABS system isnormal (service code is not stored; temporary failure.).

BRAKES 12-47
Anti-Lock Brake System
Front, Rear Wheel Rotation Difference Abnormal(Service Code 25)
the 1st step test.
•○Do
Check the following and correct the faulty part.

Incorrect the tire pressure.
Tires not recommended for the motorcycle were installed(incorrect tire size).
Deformation of the wheel or tire.
Sensor rotor for missing teeth and clogging with foreign
matter.
If the all parts correct, 2nd step.

the 2nd step test.
•○Do
Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, andretrieve the service code.
If the ABS indicator light (LED) [A] lit, faulty ECU in the
ABS hydraulic unit. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) [A] unlit, ABS system isnormal (service code is not stored; temporary failure.).

ABS Pump Motor Relay Inspection (Service Code35)
the 1st step test.
•○Do
Check the ABS pump motor relay fuse [A].
If the fuse blown, 2nd step.
If the fuse correct, 4th step.

the 2nd step test.
•○Do
Disconnect the ABS hydraulic unit connector.

○Check for continuity between the red/white and black/yel-

low lead terminals of the ABS hydraulic unit connector [A].
If there is the continuity in the lead, replace the ABS hydraulic unit.
If there is not the continuity in the lead, 3rd step.

the 3rd step test.
•○Do
Check for continuity between the red/white lead terminalof the main harness side connector [A] and red/white leadterminal of the fuse box [B].
If there is the continuity in the lead, replace the fuse.
If there is not the continuity in the lead, replace or repair
the main harness.

12-48 BRAKES
Anti-Lock Brake System
the 4th step test.
•○Do
Check the battery terminal voltage between the red/whitelead terminal of the fuse box [A] and ground.
Special Tool - Hand Tester: 57001-1394
Battery Terminal Voltage
Standard:
Battery Voltage

If the battery terminal voltage is not within the specification, 5th step.
If the battery terminal voltage correct, 6th step.
the 5th step test.
•○Do
Check for continuity between the positive cable [A] of thebattery and red/white lead terminal of the main harness
side connector [B].
If there is the continuity in the lead, 4th step.
If there is not the continuity in the lead, replace or repair
the main harness.

the 6th step test.
•○Do
Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, andretrieve the service code.
If the ABS indicator light (LED) [A] lit, faulty ABS pump
motor relay in the ABS hydraulic unit. Replace the ABS
hydraulic unit.
If the ABS indicator light (LED) [A] unlit, ABS system isnormal (service code is not stored; temporary failure.).

Front Wheel Rotation Sensor Signal Abnormal(Service Code 42)

the 1st step test.
•○Do
Measure the air gap between the front wheel rotation sensor and sensor rotor.
Thickness Gauge [A]Air Gap
Standard:

1 mm (0.04 in.)If the measurement is over standard, check each partfor deformation and looseness and correct accordingly.
Recheck the air gap.
If the measurement is correct, 2nd step.

BRAKES 12-49
Anti-Lock Brake System
the 2nd step test.
•○Do
Check that there is iron or other magnetic deposits be-

tween the sensor [A] and sensor rotor [B], and the sensor
rotor slots for obstructions.
○Check the installation condition of the sensor for looseness.
○Check the sensor and sensor rotor tip for deformation ordamage (e.g., chipped sensor rotor teeth).
If the sensor and sensor rotor in bad condition, remove theany deposits. Install the properly or replace faulty part.
If the all correct, 3rd step.
the 3rd step test.
•○Do
Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, andretrieve the service code.
If the ABS indicator light (LED) [A] lit, faulty ECU in the
ABS hydraulic unit. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) [A] unlit, ABS system isnormal (service code is not stored; temporary failure.).

Front Wheel Rotation Sensor Wiring Inspection(Service Code 43)

the 1st step test.
•○Do
Disconnect the ABS hydraulic unit connector and front
wheel rotation sensor connector.

○Short the white and black lead terminals of the main har-ness side connector [A] with a jumper lead, and check forcontinuity between the white and black lead terminals of
the main harness side connector [B].
If there is the continuity in the lead, 2nd step.
If there is not the continuity in the lead, replace or repair
the main harness.

the 2nd step test.
•○Do
Check for continuity between the white lead terminal of
the sensor connector [A] and ground, and black lead terminal of the sensor connector and ground.
If there is the continuity in the lead, replace the front wheel
rotation sensor.
If there is not the continuity in the lead, 3rd step.

12-50 BRAKES
Anti-Lock Brake System
the 3rd step test.
•○Do
Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, andretrieve the service code.
If the ABS indicator light (LED) [A] lit, faulty ECU in the
ABS hydraulic unit. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) [A] unlit, ABS system isnormal (service code is not stored; temporary failure.).

Rear Wheel Rotation Sensor Signal Abnormal(Service Code 44)

the 1st step test.
•○Do
Measure the air gap between the rear wheel rotation sensor and sensor rotor.
Thickness Gauge [A]Air Gap
Standard:

1 mm (0.04 in.)If the measurement is over standard, check each partfor deformation and looseness and correct accordingly.
Recheck the air gap.
If the measurement is correct, 2nd step.
the 2nd step test.
•○Do
Check that there is iron or other magnetic deposits be-

tween the sensor [A] and sensor rotor [B], and the sensor
rotor slots for obstructions.
○Check the installation condition of the sensor for looseness.
○Check the sensor and sensor rotor tip for deformation ordamage (e.g., chipped sensor rotor teeth).
If the sensor and sensor rotor in bad condition, remove theany deposits. Install the properly or replace faulty part.
If the all correct, 3rd step.
the 3rd step test.
•○Do
Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, andretrieve the service code.
If the ABS indicator light (LED) [A] lit, faulty ECU in the
ABS hydraulic unit. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) [A] unlit, ABS system isnormal (service code is not stored; temporary failure.).

BRAKES 12-51
Anti-Lock Brake System
Rear Wheel Rotation Sensor Wiring Inspection(Service Code 45)

the 1st step test.
•○Do
Disconnect the ABS hydraulic unit connector and rear
wheel rotation sensor connector.

○Short the red and green lead terminals of the main har-ness side connector [A] with a jumper lead, and check forcontinuity between the red and green lead terminals of
the main harness side connector [B].
If there is the continuity in the lead, 2nd step.
If there is not the continuity in the lead, replace or repair
the main harness.

the 2nd step test.
•○Do
Check for continuity between the white lead terminal of

the sensor connector [A] and ground, and black lead terminal of the sensor connector and ground.
If there is the continuity in the lead, replace the rear wheel
rotation sensor.
If there is not the continuity in the lead, 3rd step.

the 3rd step test.
•○Do
Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, andretrieve the service code.
If the ABS indicator light (LED) [A] lit, faulty ECU in the
ABS hydraulic unit. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) [A] unlit, ABS system isnormal (service code is not stored; temporary failure.).

Power Supply Voltage Abnormal (Under-Voltage)(Service Code 52)

the 1st step test.
•○Do
Disconnect the ABS Kawasaki self-diagnosis system con-nector and ABS hydraulic unit connector.
○Check for continuity between the brown lead terminal ofthe main harness side connector [A] and brown lead terminal of the main harness side connector [B].
If there is the continuity in the lead, 2nd step.
If there is not the continuity in the lead, replace or repair
the main harness.

12-52 BRAKES
Anti-Lock Brake System
the 2nd step test.
•○Do
Connect the ABS Kawasaki self-diagnosis system con-nector and ABS hydraulic unit connector.
○Check the battery terminal voltage, connect thehand tester to the brown terminal of ABS Kawasaki
self-diagnosis system connector [A] and ground.
Special Tool - Hand Tester: 57001-1394
Battery Terminal Voltage
Standard:
Battery Voltage

If the battery terminal voltage is not within the specification, 3rd step.
If the battery terminal voltage correct, 4th step.
the 3rd step test.
•○Do
Charge or replace the battery.
the 4th step test.
•○Do
Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, andretrieve the service code.
If the ABS indicator light (LED) [A] lit, faulty ECU in the
ABS hydraulic unit. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) [A] unlit, ABS system isnormal (service code is not stored; temporary failure.).

Power Supply Voltage Abnormal (Over-Voltage)(Service Code 53)

the 1st step test.
•○Do
Check the battery terminal voltage, connect thehand tester to the brown terminal of ABS Kawasaki
self-diagnosis system connector [A] and ground.
Special Tool - Hand Tester: 57001-1394
Battery Terminal Voltage
Battery Voltage
Standard:

If the battery terminal voltage is not within the specification, 2nd step.
If the battery terminal voltage correct, 3rd step.
the 2nd step test.
•○Do
Check the battery condition and regulator/rectifier (seeCharging Condition Inspection, Regulator/Rectifier Inspection in the Electrical System chapter).

BRAKES 12-53
Anti-Lock Brake System
the 3rd step test.
•○Do
Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, andretrieve the service code.
If the ABS indicator light (LED) [A] lit, faulty ECU in the
ABS hydraulic unit. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) [A] unlit, ABS system isnormal (service code is not stored; temporary failure.).

ECU Inspection (Service Code 55)

the 1st step test.
•○Do
Recheck the service code indication; erase the service
code, perform the pre-diagnosis inspection 1 and 2, andretrieve the service code.
If the ABS indicator light (LED) [A] lit, faulty ECU in the
ABS hydraulic unit. Replace the ABS hydraulic unit.
If the ABS indicator light (LED) [A] unlit, ABS system isnormal (service code is not stored; temporary failure.).

ABS Hydraulic Unit Removal
CAUTION
The ABS hydraulic unit [A] has been adjusted
and set with precision at the factory. Therefore, it
should be handled carefully, never struck sharply,
as with a hammer, or allowed to fall on a hardsurface.
Be careful not to get water or mud on the ABS hydraulic unit.
the brake fluid from the front and rear brake lines.
•○Drain
Drain the brake fluid through the bleed valve by pumping••

the brake lever and pedal.
Remove:Left Frame Cover (see Frame Cover Removal in the
Frame chapter)
Rear Fender Front (see Rear Fender Front Removal in
the Frame chapter)
Regulator/Rectifier (see Regulator/Rectifier Removal in
the Electrical System chapter)
Clean the ABS hydraulic unit.

CAUTION
Clean all fittings on the ABS hydraulic unit and therear master cylinder because dirt around the banjo
bolts could contaminate the brake fluid in the line
during removal/installation.
Spread out a shop towel around the ABS hydraulicunit before removing the brake line so that brakefluid does not leak on the parts.

12-54 BRAKES
Anti-Lock Brake System• Remove:
Bolts [A]• Remove:
Brake Pipe Joint Nuts [A] [B] [C] [D]Tapethe brake line opening to prevent brake fluid leakage• or contamination
by foreign matter.
CAUTION
Brake fluid quickly ruins painted plastic surfaces;
any spilled fluid should be completely washed away
immediately.
the connector [A].
•○Disconnect
Pull the lever [B] as shown.
• Remove the ABS hydraulic unit with bracket.

• Remove:
Nuts [A] and Bracket [B]
CAUTION
The ABS hydraulic unit has been adjusted and set
with precision at the factory. Do not try to disassemble and repair the ABS hydraulic unit.

ABS Hydraulic Unit Installation• Install the ABS hydraulic unit to the bracket.
CAUTION

Brake fluid quickly ruins painted plastic surfaces;
any spilled fluid should be completely washed away
immediately.
the lead correctly, and join connector [A] securely.
•○RoutePull the lever [B] as shown.
the brake pipes correctly (see Cable, Wire, and• RouteHose Routing section in the Appendix chapter).
• Tighten the joint nuts.

Torque - Brake Pipe Joint Nuts: 18 N·m (1.8 kgf·m, 13 ft·lb)• Install the removed parts (see appropriate chapters).

BRAKES 12-55
Anti-Lock Brake System
ABS Hydraulic Unit Inspection

the ABS hydraulic unit (see ABS Hydraulic Unit
• Remove
Removal).
inspect the ABS hydraulic unit.
• VisuallyReplace the ABS hydraulic unit if any of them are cracked,
or otherwise damaged.
inspect the connector terminals [A].
• VisuallyReplace the ABS hydraulic unit or main harness if eitherof the terminals are cracked, bent, or otherwise damaged.
If the ABS hydraulic unit connector is clogged with mudor dust, blow it off with compressed air.

Front Wheel Rotation Sensor Removal
CAUTION
The wheel rotation sensor should be handled carefully, never struck sharply, as with a hammer, or allowed to fall on a hard surface since the wheel rotation sensor is precision made. Be careful not to getwater or mud on the wheel rotation sensor.
Do not try to disassemble or repair the wheel rotation sensor.

• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System(DFI) chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
Left Upper Inner Fairing (see Upper Inner Fairing Removal in the Frame chapter)
Bolt [A]Clamp [B]• Disconnect the connector [A].

12-56 BRAKES
Anti-Lock Brake System• Remove:
Clamp [A]
Bolt [B]
Front Wheel Rotation Sensor [C]

Front Wheel Rotation Sensor Installationis the reverse of removal.
•○Installation
Route the lead correctly (see Cable, Wire, and Hose
Routing section in the Appendix chapter).

Rear Wheel Rotation Sensor Removal
CAUTION
The wheel rotation sensor should be handled carefully, never struck sharply, as with a hammer, or allowed to fall on a hard surface since the wheel rotation sensor is precision made. Be careful not to getwater or mud on the wheel rotation sensor.
Do not try to disassemble or repair the wheel rotation sensor.

• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System•(DFI) chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
Disconnect the connector [A].

• Remove:
Bolt [A]Rear Wheel Rotation Sensor [B]Rear Wheel Rotation Sensor Installationis the reverse of removal.
•○Installation
Route the lead correctly (see Cable, Wire, and Hose
Routing section in the Appendix chapter).

BRAKES 12-57
Anti-Lock Brake System
Wheel Rotation Sensor Inspection

the front wheel rotation sensor [A] from the front• Removefork.
the rear wheel rotation sensor [B] from the• Removecaliper bracket.
inspect the wheel rotation sensors.
• VisuallyReplace the wheel rotation sensor if it is cracked, bent, orotherwise damaged.

Wheel Rotation Sensor Air Gap Inspection

the front/rear wheel off the ground (see Front/Rear• RaiseWheel Removal in the Wheels/Tires chapter).
the air gap between the sensor and sensor rotor• Measureat several points by turning the wheel slowly.
Thickness Gauge [A]Air Gap
Standard:
Front

1 mm (0.04 in.)Rear

1 mm (0.04 in.)

NOTE

○The sensor air gap cannot be adjusted.
If the air gap is not within the specification, inspect the hub
bearing (see Hub Bearing Inspection in the Wheels/Tires
chapter), sensor installation condition and sensor (seeWheel Rotation Sensor Inspection).

Wheel Rotation Sensor Rotor Inspection

the front/rear brake discs (see Brake Disc Re• Remove
moval).
inspect the wheel rotation sensor rotor.
• Visually
If the rotor is deformed or damaged (chipped teeth [A]),replace the sensor rotor with the brake disc.
If there is iron or other magnetic deposits [B], remove thedeposits.

Brake Hose and Pipe Removal/Installation

to the Brake Hose and Pipe Replacement in the• Refer
Periodic Maintenance chapter.

12-58 BRAKES
Anti-Lock Brake System
Brake Hose and Pipe Inspection

to the Brake Hose and Pipe Damage and Instal• Refer
lation Condition Inspection in the Periodic Maintenancechapter.

ABS Solenoid Valve Relay Fuse Removal

the seat (see Seat Removal in the Frame chap• Removeter).
• Unlock the hook [A] to lift up the lid [B].

out the relay fuse [A] from the fuse box with needle• Pullnose pliers.

ABS Motor Relay Fuse Removal

the seat (see Seat Removal in the Frame chap• Removeter).
• Unlock the hook [A] to lift up the lid [B].

out the relay fuse [A] from the fuse box with needle• Pullnose pliers.

Fuse Installation

fails during operation, inspect the electrical sys• Iftema fuse
to determine the cause, and then replace it with a
new fuse of proper amperage.

BRAKES 12-59
Anti-Lock Brake System
Fuse Inspection

the fuse (see ABS Solenoid Valve Relay/ABS• Remove
Motor Relay Fuse Removal).
the fuse element.
• Inspect
If it is blown out, replace the fuse. Before replacing a
blown fuse, always check the amperage in the affectedcircuit. If the amperage is equal to or greater than thefuse rating, check the wiring and related components fora short circuit.
Housing [A]Fuse Element [B]Terminals [C]
Blown Element [D]

CAUTION
When replacing a fuse, be sure the new fusematches the specified fuse rating for that circuit.
Installation of a fuse with a higher rating may cause
damage to wiring and components.

SUSPENSION 13-1

Suspension
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Front Fork ...............................................................................................................................
Front Fork Removal ..........................................................................................................
Front Fork Installation .......................................................................................................
Front Fork Oil Change ......................................................................................................
Front Fork Disassembly ....................................................................................................
Front Fork Assembly.........................................................................................................
Inner Tube Inspection .......................................................................................................
Dust Seal Inspection .........................................................................................................
Fork Spring Inspection ......................................................................................................
Rear Shock Absorber .............................................................................................................
Spring Preload Adjustment ...............................................................................................
Rear Shock Absorber Removal ........................................................................................
Rear Shock Absorber Installation .....................................................................................
Rear Shock Absorber Inspection ......................................................................................
Swingarm................................................................................................................................
Swingarm Removal...........................................................................................................
Swingarm Installation........................................................................................................
Swingarm Bearing Removal .............................................................................................
Swingarm Bearing Installation ..........................................................................................
Swingarm Bearing, Sleeve Inspection ..............................................................................
Swingarm Bearing Lubrication ..........................................................................................
Chain Guide Inspection.....................................................................................................

13-2
13-6
13-7
13-9
13-9
13-9
13-9
13-11
13-12
13-13
13-13
13-14
13-15
13-15
13-15
13-16
13-16
13-17
13-17
13-17
13-18
13-18
13-19
13-20
13-20

13

13-2 SUSPENSION
Exploded View

SUSPENSION 13-3
Exploded View
No.
1
2
3
4
5

Fastener
Front Axle Clamp Bolt
Front Fork Bottom Allen Bolts
Front Fork Clamp Bolts (Lower)
Front Fork Clamp Bolts (Upper)
Front Fork Top Plugs

N·m
34
30
20
20
25

Torque
kgf·m
3.5
3.1
2.0
2.0
2.5

ft·lb
25
22
15
15
18

6. Outer Tube (EX650B Models)
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts

RemarksLAL

13-4 SUSPENSION
Exploded View

SUSPENSION 13-5
Exploded View
No.
1
2
3

Fastener
Rear Shock Absorber Bolt
Rear Shock Absorber Nut
Swingarm Pivot Shaft Nut

G: Apply grease.
R: Replacement Parts

N·m
59
59
108

Torque
kgf·m
6.0
6.0
11.0

ft·lb
44
44
80

Remarks

13-6 SUSPENSION
Specifications
Item
Front Fork (Per One Unit)
Fork Inner Tube Outside Diameter
Air Pressure
Fork Spring Setting
Damper Setting
Fork Oil:
Viscosity
Amount:
EX650A Models

EX650B Models

Fork Oil Level:
EX650A Models
EX650B Models
Fork Spring Free Length
Rear Shock Absorber
Spring Preload
Gas PressureStandard
41 mm (1.6 in.)
Atmospheric pressure (Non-adjustable)
Non-adjustable
Non-adjustable
KAYABA KHL34-G10 or equivalentapprox. 415 mL (14.0 US oz.) (when changing oil)
489 ±4 mL (16.5 ±0.14 US oz.) (after disassembly andcompletely dry)
approx. 420 mL (14.2 US oz.) (when changing oil)
498 ±3 mL (16.8 ±0.10 US oz.) (after disassembly andcompletely dry)
98 ±2 mm (3.9 ±0.08 in.) (below from inner tube top withfully compressed, without fork spring)
89 ±2 mm (3.5 ±0.08 in.) (below from inner tube top withfully compressed, without fork spring)277.2 mm (10.91 in.) (Service limit 272 mm (10.7 in.))2nd position (Adjustable Range: 1st ∼ 7th position)
980 kPa (10 kgf/cm², 142 psi, Non-adjustable)

SUSPENSION 13-7
Special Tools
Inside Circlip Pliers:
57001-143

Jack:57001-1238

Fork Cylinder Holder Handle:
57001-183

Fork Oil Seal Driver,
57001-1288

Fork Cylinder Holder Adapter:
57001-1057

Fork Oil Level Gauge:
57001-1290

Oil Seal & Bearing Remover:
57001-1058

Jack Attachment:
57001-1608

Bearing Driver Set:
57001-1129

Stem Bearing Driver,
57001-1610

41:

28:

13-8 SUSPENSION
Special Tools
Spacer, 28:
57001-1663

SUSPENSION 13-9
Front Fork
Front Fork Removal• Remove:
Upper Inner Fairing (see Upper Inner Fairing Removal
in the Frame chapter)
Front Wheel (see Front Wheel Removal in the
Wheels/Tires chapter)
Front Fender (see Front Fender Removal in the Frame
chapter)
Front Wheel Rotation Sensor (see Front Wheel Rotation
Sensor Removal in the Brakes chapter) (EX650B Models)
Loosen the upper fork clamp bolt [A] and fork top plug [B]beforehand if the fork leg is to be disassembled.

NOTE○Loosen the top plug after loosening the upper forkclamp bolt.

the upper fork clamp bolt and lower fork clamp• Loosenbolts [C].
• With a twisting motion, work the fork leg down and out.

Front Fork Installation

the fork so that the top end [A] of the inner tube as• Installshown.

•

10 mm (0.40 in.) [B]Tighten:
Torque - Front Fork Clamp Bolts (Lower): 20 N·m (2.0kgf·m, 15 ft·lb)
Front Fork Top Plug: 25 N·m (2.5 kgf·m, 18 ft·lb)

NOTE○Tighten the top plug before tightening the upper forkclamp bolt.

○Tighten the two clamp bolts alternately two times to ensure even tightening torque.

• Tighten:

Torque - Front Fork Clamp Bolt (Upper): 20 N·m (2.0 kgf·m,
15 ft·lb)• Install the removed parts (see appropriate chapters).
Front Fork Oil Change

the front fork (see Front Fork Removal).
• Remove
Remove:• Top Plug [A] with O-ring
Collar [B]Fork Spring Seat [C]Fork Spring [D]13-10 SUSPENSION
Front Fork[A] the fork [B] upside down to draw out the oil• Compress
into the suitable container [C].
• Pour in the specified amount of oil.
Fork Oil
Viscosity:

KAYABA KHL34-G10 orequivalent

Amount (Per Side):
When changing oil:
EX650A Models

approx. 415 mL (14.0 US oz.)

EX650B Models

approx. 420 mL (14.2 US oz.)

After disassembly and completely dry:
EX650A Models

489 ±4 mL (16.5 ±0.14 US oz.)

EX650B Models

498 ±3 mL (16.8 ±0.10 US oz.)

NOTE

○Move the outer tube up and down a few times to remove
the air that is trapped in the fork oil in order to stabilize
the oil level.
the outer tube vertically in a vise and compress the• Holdfork completely.
until the oil level stabilizes.
• WaitUse
theoil level gauge [A] to measure the distance• betweenfork
the top of the inner tube to the oil level.
Special Tool - Fork Oil Level Gauge: 57001-1290○Set the oil level gauge stopper [B] so that the distance [C]from the bottom of the stopper to the lower end of the pipe
is the standard oil level distance.
○A correct measurement can not be obtained unless thelevel gauge pipe is placed in the center of the inner tube.
Oil Level (fully compressed, without spring)Standard:
EX650A Models

98 ±2 mm (3.9 ±0.08 in.)

EX650B Models

89 ±2 mm (3.5 ±0.08 in.)○Place the stopper of the level gauge at the top [D] of theinner tube [E] and pull the handle slowly to draw out theexcess oil from fork into the gauge, thus attaining the standard level.
○If not oil is drawn out, there is not enough oil in the fork.
Pour in some more oil and measure again.
the same procedure for adjusting the other fork.
• Repeat
Installthefork spring [A], fork spring seat [B] and collar• [C].
the top plug O-ring and replace it with a new one.
• Inspect
Installthefront fork (see Front Fork Installation).
•

SUSPENSION 13-11
Front Fork
Front Fork Disassembly

the front fork (see Front Fork Removal).
• Remove
Removethe top plug [A] with O-ring, take out the collar• [B], fork springseat [C], and fork spring [D].
Drain
the
fork
oil
(see Front Fork Oil Change).
•• Remove the Allen bolt [A] from the bottom of the fork.

Special Tools - Fork Cylinder Holder Handle [B]: 57001-183
Fork Cylinder Holder Adapter [C]: 57001
-1057

NOTE

○Hold the outer tube in a vise [D], stop the cylinder unit
[E] from turning by using the special tools, and unscrew
the Allen bolt.

the cylinder unit [A], washer, and the spring [B]• Removefrom the inner tube.

the following from the top of the outer tube.
• Remove
Dust Seal [A]Retaining Ring [B]• Separate the inner tube [A] from the outer tube [B].
NOTE

○From the compressed state, firmly pull down the outertube a few times towards the direction of elongation.

13-12 SUSPENSION
Front Fork
the following from the inner tube.
• Remove
Inner Guide Bushing [A]Outer Guide Bushing [B]Washer [C]
Oil Seal [D]the cylinder base [A] from the bottom of the outer• Remove
tube.

Front Fork Assembly

the top plug O-ring and replace it with a new one.
• Check
Replacefollowing parts with new ones.
• RetainingtheRing[A]
Dust Seal [B]Oil Seal [C]
Inner Guide Bushing [D]Outer Guide Bushing [E]Fork Bottom Allen Bolt Gasket [F]the guide bushing on the end of the inner tube.
• Install
Inserttheunit and the spring into the inner tube,• and installcylinder
the cylinder base [A] onto the cylinder end [B]that protrudes from the bottom.

○Install the cylinder base starting with its stepped end.

the inner tube, cylinder unit, washer, spring, and• Insert
cylinder base as a set into the outer tube.

the guide bushing into the outer tube.
• InstallAfter
installing
washer, install the oil seal [A] by using• the fork oil sealthedriver
[B].

•
•

Special Tool - Fork Oil Seal Driver,

41: 57001-1288

Install the retaining ring into the outer tube.
Install the dust seal by hand.

SUSPENSION 13-13
Front Fork
non-permanent locking agent to the threads of the• Applybottom Allen bolt [A].
the front fork horizontally in a vise [B].
• Holdthe cylinder unit [C] with the special tools and tighten• Holdthe bottom Allen bolt to secure the cylinder in place.
Torque - Front Fork Bottom Allen Bolt: 30 N·m (3.1 kgf·m,
22 ft·lb)
Special Tools - Fork Cylinder Holder Handle [D]: 57001-183
Fork Cylinder Holder Adapter [E]: 57001-1057

in the specified type of oil (see Front Fork Oil• PourChange).

Inner Tube Inspection

inspect the inner tube [A], and repair any dam• Visuallyage.
or rust damage can sometimes be repaired by using• Nicksa wet-stone to remove sharp edges or raised areas whichcause seal damage.
If the damage is not repairable, replace the inner tube.
Since damage to the inner tube damages the oil seal,
replace the oil seal whenever the inner tube is repairedor replaced.

CAUTION
If the inner tube is badly bent or creased, replace
it. Excessive bending, followed by subsequentstraightening, can weaken the inner tube.
assemble the inner and outer tubes, and• Temporarily
pump them back and forth manually to check for smooth•

operation.
If you feel binding or catching, the inner and outer tubes
must be replaced.

WARNINGA straightened inner or outer fork tube may fall inuse, possibly causing an accident. Replace a badly
bent or damaged inner or outer tube and inspect theother tube carefully before reusing it.

Dust Seal Inspection

the dust seal [A] for any signs of deterioration or• Inspectdamage.
Replace it if necessary.

13-14 SUSPENSION
Front Fork
Fork Spring Inspection

the free length [A] of the fork spring [B].
• MeasureIf the measured length is shorter than the service limit, thespring must be replaced. If the free length of the replacement spring and that of the remaining spring vary greatly,
the remaining spring should also be replaced in order tokeep the fork legs balanced to ensure stability.
Fork Spring Free Length
Standard:
277.2 mm (10.91 in.)Service Limit:

272 mm (10.7 in.)

SUSPENSION 13-15
Rear Shock Absorber
Spring Preload Adjustment

the hook wrench [A], turn the adjusting nut [B] to• Using
adjust the spring preload.

○The standard adjuster setting for average-build rider of 68

kg (150 Ib) with no passenger and no accessories is 2nd
position.
Spring Preload SettingStandard Position:

2nd position

Adjustable Range:

1st to 7th position

the compression of the spring is not suited to the op• Iferating
conditions, adjust it to an appropriate position byreferring to the table below.
Spring Preload Adjustment
Shock
Adjuster Damping
AbsorberPosition
Force
Hardness

Load

Road
Conditions

Driving
Speed

1st

Weak

Soft

Light

Good

Low

↑

↑

↑

↑

↑

↑

↓

↓

↓

↓

↓

↓

7th

Strong

Hard

Heavy

Bad

Highway

Rear Shock Absorber Removal• Remove:
Frame Covers (see Frame Cover Removal in the Frame•

chapter)
Muffler Body (see Muffler Body Removal in the Engine
Top End chapter)
Raise the rear wheel off the ground with jack.
Special Tools - Jack: 57001-1238
Jack Attachment: 57001-1608

the brake lever slowly and hold it with a band
• Squeeze[A].

WARNINGBe sure to hold the front brake when removing theshock absorber, or the motorcycle may tall over. It
could cause an accident and injury.

• Remove:
Right Stay Cover [A]13-16 SUSPENSION
Rear Shock Absorber• Remove:
Upper Shock Absorber Bolt [A]•Lower Shock Absorber Nut and Washer
Lower Shock Absorber Bolt [B]Remove the shock absorber [C] from backward.

Rear Shock Absorber Installationis the reverse of removal.
• Installation
Applygreaseto the lip of oil seals.
•○Be sure to install
the oil seals to the shock absorber.
• Tighten:

Torque - Rear Shock Absorber Bolt: 59 N·m (6.0 kgf·m, 44
ft·lb)
Rear Shock Absorber Nut: 59 N·m (6.0 kgf·m, 44
ft·lb)• Install the removed parts (see appropriate chapters).
Rear Shock Absorber Inspection

the rear shock absorber (see Rear Shock Ab• Remove
sorber Removal).
inspect the following items.
• Visually
Smooth Stroke•

Oil Leakage
Crack or Dent
If there is any damage to the rear shock absorber, replaceit.
Visually inspect the rubber bushing.
If it show any signs of damage, replace it.

SUSPENSION 13-17
Swingarm
Swingarm Removal• Remove:
Chain Cover Bolts [A] and Cover [B]• Remove:
Right Side Cover (see Side Cover Removal in the Frame••

chapter)
Frame Covers (see Frame Cover Removal in the Frame
chapter)
Remove the brake hose banjo bolt from the rear caliper,
free the brake hose [A] from the clamps [B], and remove
the footpeg stay with the rear master cylinder (see Rear
Caliper Removal in the Brakes chapter).
Remove:Muffler Body (see Muffler Body Removal in the Engine
Top End chapter)
Rear Wheel (see Rear Wheel Removal in the
Wheels/Tires chapter)• Raise the rear wheel off the ground with jack.
Special Tools - Jack: 57001-1238
Jack Attachment: 57001-1608• Remove the lower shock absorber nut and bolt [A].

the drive chain (see Drive Chain Removal in the• Remove
Final Drive chapter).
the swingarm pivot shaft nut [A].
• Unscrew
Pull
off
the
pivot shaft [B], and remove the swingarm.
•Swingarm Installationis the reverse of removal.
•○Installation
Apply grease to the lip of the oil seals.

○Be sure to install the oil seal and collar to the swingarm.

• Tighten the pivot shaft nut.

Torque - Swingarm Pivot Shaft Nut: 108 N·m (11.0 kgf·m,
80 ft·lb)• Install the removed parts (see appropriate chapters).

13-18 SUSPENSION
Swingarm
Swingarm Bearing Removal• Remove:
Swingarm (see Swingarm Removal)
Collar [A]Oil Seals [B]
Sleeve [C]Circlip [D]Special Tool - Inside Circlip Pliers: 57001-143• Remove the ball bearing and needle bearings.

Special Tool - Oil Seal & Bearing Remover [A]: 57001-1058

Swingarm Bearing Installation

the ball and needle bearings [A] with new ones.
• Replace
Installtheball and needle bearings so that the manufac• turer’s marks
face out.
Special Tools - Bearing Driver Set: 57001-1129
Stem Bearing Driver, 28 [B]: 57001-1610
Spacer, 28: 57001-1663

SUSPENSION 13-19
Swingarm
the needle bearings [A], ball bearing [B] and oil• Installseals [C] position as shown.
Circlip [D]
25 mm (0.98 in.) [E]
17 mm (0.67 in.) [F]
1 mm (0.04 in.) [G]
0.5 mm (0.02 in.) [H]
1 mm (0.04 in.) [I]
23.5 mm (0.93 in.) [J]
6 mm (0.24 in.) [K]

Swingarm Bearing, Sleeve Inspection
CAUTION
Do not remove the bearings for inspection. Removal may damage them.
the needle bearings [A] and ball bearing installed• Inspectin the swingarm.

○The rollers and ball in a bearing normally wear very little,

and wear is difficult to measure. Instead of measuring,visually inspect the bearing for abrasion, discoloration, orother damage.
If the needle bearing and sleeve [B] show any sings ofabnormal wear, discoloration, or damage, replace themas a set.

13-20 SUSPENSION
Swingarm
the bearing in the swingarm back and forth [A] while• Turnchecking for plays, roughness, or binding.

•If the bearing play, roughness, or binding is found, replace
the bearing.
Examine the bearing seal [B] for tears or leakage.
If the seal is torn or is leaking, replace the bearing.

Swingarm Bearing Lubrication
NOTE○Since the bearings are packed with grease and sealed,lubrication is not required.

Chain Guide Inspection

to the Chain Guide Wear Inspection in the Periodic• Refer
Maintenance chapter.

STEERING 14-1

Steering
Table of Contents
Exploded View........................................................................................................................
Special Tools ..........................................................................................................................
Steering ..................................................................................................................................
Steering Inspection ...........................................................................................................
Steering Adjustment..........................................................................................................
Steering Stem.........................................................................................................................
Stem, Stem Bearing Removal...........................................................................................
Stem, Stem Bearing Installation........................................................................................
Stem Bearing Lubrication..................................................................................................
Steering Stem Warp..........................................................................................................
Stem Cap Deterioration, Damage.....................................................................................
Handlebar ...............................................................................................................................
Handlebar Removal ..........................................................................................................
Handlebar Installation .......................................................................................................

14-2
14-4
14-5
14-5
14-5
14-6
14-6
14-7
14-9
14-9
14-9
14-10
14-10
14-10

14

14-2 STEERING
Exploded View

STEERING 14-3
Exploded View
No.
1
2
3
4
5
6
7

Fastener
Front Fork Clamp Bolts (Lower)
Front Fork Clamp Bolts (Upper)
Handlebar Holder Bolts
Left Switch Housing Screws
Right Switch Housing Screws
Steering Stem Head Bolt
Steering Stem Nut

N·m
20
20
25
3.5
3.5
108
20

Torque
kgf·m
2.0
2.0
2.5
0.36
0.36
11.0
2.0

ft·lb
15
15
18
31 in·lb
31 in·lb
80
15

AD: Apply adhesive.
AL: Tighten the two clamp bolts alternately two times to ensure even tighten torque.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.

RemarksALS

14-4 STEERING
Special Tools
Steering Stem Nut Wrench:
57001-1100

Steering Stem Bearing Driver,
57001-1344

42.5:

Bearing Driver Set:
57001-1129

Steering Stem Bearing Driver Adapter,
57001-1345

41.5:

STEERING 14-5
Steering
Steering Inspection

to the Steering Play Inspection in the Periodic Main• Refertenance chapter.

Steering Adjustment

to the Steering Play Adjustment in the Periodic• Refer
Maintenance chapter.

14-6 STEERING
Steering Stem
Stem, Stem Bearing Removal• Remove:
Upper Fairing (see Upper Fairing Removal in the Frame
chapter)
Under Bracket [A] (see Upper Fairing Bracket Removal
in the Frame chapter)• Remove:
Upper Fairing Bracket [A] (see Upper Fairing Bracket
Removal in the Frame chapter)• Remove:
Front Wheel (see Front Wheel Removal in the
Wheels/Tires chapter)
Front Forks (see Front Fork Removal in the Suspension
chapter)
Handlebar (see Handlebar Removal)
Steering Stem Head Bolt Plug [A]Steering Stem Head Bolt [B] and Washer
Front Fork Clamp Bolts (Upper) [C] (Loosen)
Steering Stem Head [D]the claws [A] of the claw washer straighten.
• Bendthe steering stem locknut [B] and claw washer• Remove[C].

up the stem base, and remove the steering stem
• Pushingnut [A] with stem cap [B].
Special Tool - Steering Stem Nut Wrench [C]: 57001-1100

the steering stem [D] under side.
• Remove
Removetheupper stem bearing inner race and bearing.
•STEERING 14-7
Steering Stemremove the bearing outer races [A] pressed into the• Tohead pipe [B], insert a bar [C] into the recesses of headpipe, 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 that both the upper and lower bearings (including outer races) should be replaced with new ones.
the lower bearing inner race [A] which is pressed• Remove
onto the steering stem with a suitable commercially available chisel [B].

Stem, Stem Bearing Installation

the bearing outer races with new ones.
• ReplaceApplygreaseto the outer races, and drive them into the• head pipe at thesame time.
Special Tool - Bearing Driver Set [A]: 57001-1129

the bearing inner races and oil seal with new• Replaceones.
grease to the oil seal.
• Apply
the lower ball bearing inner race applied the grease• Drive
onto the stem.
Special Tools - Steering Stem Bearing Driver, 42.5 [A]:57001-1344
Steering Stem Bearing Driver Adapter,
41.5 [B]: 57001-1345

grease to the lower ball bearing [A], and install it• Apply
onto the stem.
grease to the upper ball bearing [B] and inner race
• Apply[C].

14-8 STEERING
Steering Stemthe stem [A] through the head pipe and install the• Installball bearing [B] and inner race [C] on it.
• Install the stem cap [D] and steering stem nut [E].

the inner races in place as follows.
•○Settle
Tighten the steering stem nut with 39 N·m (4.0 kgf·m, 29

ft·lb) of torque first, and loosen it a fraction of a turn until
it turns lightly. Afterward tighten it again with specified
torque using a stem nut wrench [A] in the direction shown.
○Check that there is no play and the steering stem turns
smoothly without rattles. If not, the steering stem bearings
may be damaged.
Special Tool - Steering Stem Nut Wrench: 57001-1100
Torque - Steering Stem Nut: 20 N·m (2.0 kgf·m, 15 ft·lb)

the claw washer [A] so that its bent side [B] faces• Install
upward, and engage the bent claws with the grooves of

•
•
•
•
•

stem locknut [C].
Hand tighten the stem locknut until it touches the claw
washer.
Tighten the stem locknut clockwise until the claws arealigned with the grooves (ranging from 2nd to 4th) of stemnut [D], and bend the 2 claws downward [E].
Install the stem head.
Install the washer, and tighten the stem head bolt withspecified torque.
Install the front forks (see Front Fork Installation in the
Suspension chapter).

NOTE○Tighten the upper fork clamp bolts first, next the stem
head bolt, last the lower fork clamp bolts.
○Tighten the two clamp bolts alternately two times to ensure even tightening torque.
Torque - Front Fork Clamp Bolts (Upper): 20 N·m (2.0kgf·m, 15 ft·lb)
Steering Stem Head Bolt: 108 N·m (11.0 kgf·m, 80
ft·lb)
Front Fork Clamp Bolts (Lower): 20 N·m (2.0kgf·m, 15 ft·lb)

WARNING
Do not impede the handlebar turning by routing thecables, harnesses and hoses improperly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
the steering stem head bolt plug.
• Install
Installtheremoved parts (see appropriate chapters).
•

STEERING 14-9
Steering Stem
Stem Bearing Lubrication

to the Steering Stem Bearing Lubrication in the Pe• Refer
riodic Maintenance chapter.

Steering Stem Warp

the steering stem is removed, or if the steering• Whenevercannot be adjusted for smooth action, check the steeringstem for straightness.
If the steering stem [A] is bent, replace the steering stem.

Stem Cap Deterioration, Damage
Replace the stem cap if its oil seal [A] shows damage.

14-10 STEERING
Handlebar
Handlebar Removal• Remove:
Clutch Lever Assembly [A]Left Switch Housing [B]Left Handlebar Weight [C]• Remove:
Front Brake Master Cylinder [A] (see Front Master Cylinder Removal in the Brakes chapter)
Right Switch Housing [B]Right Handlebar Weight [C]Throttle Grip [D]the handlebar holder bolts [A].
• Remove
Remove• handlebar.the handlebar holder [B] and then pull out the

Handlebar Installation

the punch mark [A] on the handlebar and the corner• Alignedge [B] on the stem head.

the front holder bolts first, and then the rear holder• Tighten
bolts. There will be a gap [A] at the rear part of the handlebar holder after tightening.
Torque - Handlebar Holder Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)STEERING 14-11
Handlebar
the clutch lever (see Clutch Lever Installation in the• Install
Clutch chapter).
adhesive cement to the inside of the left handlebar• Applygrip.
a non-permanent locking agent to the left handlebar• Apply
weight bolt.
the left switch housing.
•○Install
Fit the projection [A] into a small hole [B] in the handlebar.
Torque - Left Switch Housing Screws: 3.5 N·m (0.36 kgf·m,
31 in·lb)• Install:
Throttle Grip
Throttle Cable Tips [A]Right Switch Housing○Fit the projection [B] into a small hole [C] in the handlebar.
Torque - Right Switch Housing Screws:
kgf·m, 31 in·lb)

3.5 N·m (0.36

a non-permanent locking agent to the right handle• Applybar weight bolt.
the front brake master cylinder (see Front Master• Install
Cylinder Installation in the Brakes chapter).

FRAME 15-1

Frame
Table of Contents
Exploded View........................................................................................................................
Seat ........................................................................................................................................
Seat Removal ...................................................................................................................
Seat Installation ................................................................................................................
Fairings...................................................................................................................................
Lower Fairing Removal .....................................................................................................
Lower Fairing Installation ..................................................................................................
Center Fairing Removal ....................................................................................................
Center Fairing Installation .................................................................................................
Windshield Removal .........................................................................................................
Windshield Installation ......................................................................................................
Upper Fairing Removal .....................................................................................................
Upper Fairing Disassembly...............................................................................................
Upper Fairing Assembly....................................................................................................
Upper Fairing Installation ..................................................................................................
Upper Inner Fairing Removal............................................................................................
Upper Inner Fairing Installation.........................................................................................
Upper Fairing Bracket Removal........................................................................................
Inner Fairing Removal.......................................................................................................
Inner Fairing Installation....................................................................................................
Side Covers ............................................................................................................................
Side Cover Removal .........................................................................................................
Side Cover Installation ......................................................................................................
Seat Covers............................................................................................................................
Seat Cover Removal.........................................................................................................
Seat Cover Installation......................................................................................................
Fenders ..................................................................................................................................
Front Fender Removal ......................................................................................................
Front Fender Installation ...................................................................................................
Flap and Rear Fender Rear Removal...............................................................................
Flap and Rear Fender Rear Installation............................................................................
Rear Fender Front Removal .............................................................................................
Rear Fender Front Installation ..........................................................................................
Frame .....................................................................................................................................
Frame Inspection ..............................................................................................................
Sidestand................................................................................................................................
Sidestand Removal...........................................................................................................
Sidestand Installation........................................................................................................
Frame Cover...........................................................................................................................
Frame Cover Removal......................................................................................................
Frame Cover Installation...................................................................................................

15-2
15-8
15-8
15-8
15-9
15-9
15-9
15-9
15-9
15-10
15-10
15-10
15-11
15-11
15-11
15-11
15-11
15-11
15-12
15-12
15-13
15-13
15-13
15-14
15-14
15-14
15-15
15-15
15-15
15-15
15
15-15
15-16
15-16
15-17
15-17
15-18
15-18
15-18
15-19
15-19
15-19

15-2 FRAME
Exploded View

FRAME 15-3
Exploded View
No.
1
2
3

Fastener
Footpeg Stay Bolts
Sidestand Bolt
Sidestand Switch Bolt

4. EX650B Models
5. EX650A Models
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts

N·m
34
44
8.8

Torque
kgf·m
3.5
4.5
0.90

ft·lb
25
33
78 in·lb

RemarksL15-4 FRAME
Exploded View

FRAME 15-5
Exploded View
No.
1
2
3

Fastener
Front Fender Bolts
Front Fender Bracket Bolts
Front Turn Signal Light Mounting Screws

L: Apply a non-permanent locking agent.

N·m
3.9
8.8
1.2

Torque
kgf·m
0.40
0.90
0.12

ft·lb
35 in·lb
78 in·lb
11 in·lb

RemarksL15-6 FRAME
Exploded View

FRAME 15-7
Exploded View
No.

Fastener

1
2

Grab Rail Mounting Bolts
Seat Lock Mounting Screws

N·m
25
1.2

3. Seat (United States and Canada Models)
4. Seat Lock Bracket (EX650B Models)
5. EX650B Models
6. Grab Rails (Other than United States and Canada Models)
7. Washers (United States and Canada Models)

Torque
kgf·m
2.5
0.12

ft·lb
18
11 in·lb

Remarks

15-8 FRAME
Seat
Seat Removal

the ignition switch key [A] into the seat lock, turning• Insert
the key clockwise, pulling up on the rear of the seat [B],and pulling the seat backward.

Seat Installation

the seat hook [A] under the brace [B] on the fuel tank
• Slipbracket.

the seat latch [A] into the latch hole [B].
• Insert
Push
down
the rear part of the seat until the lock clicks.
•

FRAME 15-9
Fairings
Lower Fairing Removal

up the core by the thin blade driver.
• PullRemovethe quick rivets [A].
• Remove the[B] with collar and washers.
• Clear the hookbolts
portionsfrom the slots.
• Separate the left lower fairingfrom the right lower fairing.
•

Lower Fairing Installation

the hook portions [A] into the slots [B].
• Insert
Setthequick rivet and push the core.
•

Center Fairing Removal• Remove:
Lower Fairings (see Lower Fairing Removal)
Upper Inner Fairing (see Upper Inner Fairing Removal)
Screw [A]
Bolt [B] with Washers

the meter cover (see Meter Unit Removal/Instal• Remove
lation in the Electrical System chapter).
the turn signal lead connector [A].
• Disconnect
the screw [B].
• RemovePull
thecenterfairing [C] evenly outward to clear the stop• pers.

the inner fairing (see Inner Fairing Removal).
• Remove
Removethe screw [A] and turn signal light [B].
•Center Fairing Installation

the turn signal light to the center fairing.
• Install• Install the inner fairing (see Inner Fairing Installation).

15-10 FRAME
Fairings• Insert the hook [A] into the slot [B].

the projection [A] into the hole [B].
• Insert
Connect
lead connector.
• Install thetheboltturnandsignal
screws.
•Windshield Removal• Remove:
Bolts [A] with Washers
Windshield [B]Dampers

Windshield Installation

the dampers.
• Install
Insertthe[A] into the slot [B].
• Tighten thehookbolts with washers.
•

Upper Fairing Removal• Remove:
Windshield (see Windshield Removal)•

Upper Inner Fairings (see Upper Inner Fairing Removal)
Lower Fairings (see Lower Fairing Removal)
Center Fairings (see Center Fairing Removal)
Headlight Lead Connectors
Rear View Mirror Nuts (Both Side) [A]Remove the upper fairing forward.

FRAME 15-11
Fairings
Upper Fairing Disassembly• Remove:
Headlight [A] (see Headlight Removal/Installation in theElectrical System chapter)

Upper Fairing Assembly

the headlight (see Headlight Removal/Installation• Installin the Electrical System chapter).

Upper Fairing Installation• Installation is the reverse of removal.
Upper Inner Fairing Removal

the bolts [A].
• Removethe upper inner fairing [B] backward, and clear the• Pullhooks.

Upper Inner Fairing Installation

the hook [A] into the slot [B].
• Insert
Tightenthe bolts.
•

Upper Fairing Bracket Removal• Remove:
Upper Fairing (see Upper Fairing Removal)
Meter Unit (see Meter Unit Removal/Installation in theElectrical System chapter)
Clamp [A]
Bolts [B]Horn Leads [C]Under Bracket [D]15-12 FRAME
Fairings• Remove:
Bolts [A]Clamps [B]Upper Fairing Bracket [C]Inner Fairing Removal• Remove:
Center Fairings (see Center Fairing Removal)
Mounting Screws [A]Inner Fairing [B]Inner Fairing Installation• Tighten the mounting screws.

Torque - Front Turn Signal Light Mounting Screws: 1.2 N·m(0.12 kgf·m, 11 in·lb)• Install the center fairings (see Center Fairing Installation).

FRAME 15-13
Side Covers
Side Cover Removal

the seat (see Seat Removal).
• Remove
Removethe bolt [A].
• Pull the side
cover [B] evenly outward to clear the stop• pers.

Side Cover Installation

the tabs [A] into the holes [B].
• Insert
Tightenbolt.
• Install thetheseat(see Seat Installation).
•15-14 FRAME
Seat Covers
Seat Cover Removal• Remove:
Seat (see Seat Removal)
Bolts [A]
Grab Rails [B] (Other than United States and Canada
Models)Screw Rivets [C]the central pin, and then remove the quick rivets [A].
• PushPull
theand rear portions of the seat cover outside,• and thenfront
remove the seat covers.

Seat Cover Installationis the reverse of removal.
• Installation
Put
theprojection[A] into the grommet [B] on the rear
• fender rear.

the projection [A] into the hole [B] of the seat cover.
• Put
Install:• Grab Rails (Other than United States and Canada Models) and Bolts
Torque - Grab Rail Mounting Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)

the projections [A] of the center seat cover into the• Insert
holes [B] of the side seat cover.
• Install:
Screw Rivets
Seat (see Seat Installation)

FRAME 15-15
Fenders
Front Fender Removal• Remove:
Brake Hose Clamps [A]•Bolts [B] with Collar (Both Side)
Remove the front fender [C].

Front Fender Installation• Tighten:

Torque - Front Fender Bolts: 3.9 N·m (0.40 kgf·m, 35 in·lb)• Install the brake hose clamps to the front fender holes.
Flap and Rear Fender Rear Removal• Remove:
Seat (see Seat Removal)

Seat Covers (see Seat Cover Removal)
Tail/Brake Light [A] (see Tail/Brake Light Removal in theElectrical System chapter)• Remove:
Nuts [A] and Bolts [B]Flap (with License Plate Light)• Remove:
Seat Lock Cable Lower End [A]••Quick Rivet [B]Free the clamps from the rear fender rear.
Pull out the rear fender rear backward and downward.

Flap and Rear Fender Rear Installation• Installation is the reverse of removal.

15-16 FRAME
Fenders
Rear Fender Front Removal• Remove:
Rear Fender Rear (see Flap and Rear Fender Rear Re-••

moval)
Battery (see Battery Removal in the Electrical System
chapter)
Relay Box (see Relay Box Removal in the Electrical System chapter)
Starter Relay (see Starter Relay Inspection in the Electrical System chapter)
Remove the fuse box from the rear fender front.
Remove:Bolt [A]Clamp [B]the clamp from the rear fender front.
• Free• Remove the rear fender front [A] backward and upward.

Rear Fender Front Installationis the reverse of removal.
• Installation
Installtheremovedparts (see appropriate chapters).
•

FRAME 15-17
Frame
Frame Inspection

inspect the frame for cracks, dents, bending or• Visuallywarp.

○If there is any damage to the frame, replace it.
WARNINGA repaired frame may fail in use, possibly causing
an accident. If the frame is bent, dented, cracked,
or warped, replace it.

15-18 FRAME
SidestandSidestand Removal

the rear wheel off the ground with stand.
• RaiseRemove:• Frame Cover (see Frame Cover Removal)
Bolts [A]Footpeg Stay [B]• Remove:
Sidestand Switch Bolt [A] with Clamp
Sidestand Switch [B]• Remove:Spring [A]Sidestand Nut [B]Sidestand Bolt [C]Sidestand [D]Sidestand Installation

grease to the sliding area [A] of the sidestand [B].
• Apply
Tightenthe bolt and lock them with the nut.
•
Torque - Sidestand Bolt: 44 N·m (4.5 kgf·m, 33 ft·lb)

the spring.
• Hookthe sidestand switch.
•○Install
Apply a non-permanent locking agent to the thread of theswitch bolt.

Torque - Sidestand Switch Bolt: 8.8 N·m (0.90 kgf·m, 78
in·lb)

the footpeg stay.
• Install
Tighten:•

Torque - Footpeg Stay Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)

FRAME 15-19
Frame Cover
Frame Cover Removal

the bolt [A].
• Remove
Pull
the
frame
cover [B] outward to clear the stoppers.
•

Frame Cover Installation

the projections [A] into the holes [B].
• Insert
Tightenthe bolt.
•

ELECTRICAL SYSTEM 16-1

Electrical System
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools and Sealants ....................................................................................................
Parts Location.........................................................................................................................
Wiring Diagram (Europe, Korea, Hong Kong and Kuwait) .....................................................
Wiring Diagram (United States, Canada, New Zealand and Malaysia)..................................
Wiring Diagram (Australia and South Africa)..........................................................................
Wiring Diagram (EX650B Models)..........................................................................................
Precautions.............................................................................................................................
Electrical Wiring......................................................................................................................
Wiring Inspection ..............................................................................................................
Battery ....................................................................................................................................
Battery Removal ...............................................................................................................
Battery Installation ............................................................................................................
Battery Activation ..............................................................................................................
Precautions .......................................................................................................................
Interchange .......................................................................................................................
Charging Condition Inspection..........................................................................................
Refreshing Charge............................................................................................................
Charging System ....................................................................................................................
Alternator Cover Removal.................................................................................................
Alternator Cover Installation..............................................................................................
Stator Coil Removal ..........................................................................................................
Stator Coil Installation .......................................................................................................
Alternator Rotor Removal .................................................................................................
Alternator Rotor Installation ..............................................................................................
Alternator Inspection .........................................................................................................
Regulator/Rectifier Inspection...........................................................................................
Charging Voltage Inspection .............................................................................................
Starter Motor Clutch ...............................................................................................................
Starter Motor Clutch Removal/Installation ........................................................................
Starter Motor Clutch Inspection ........................................................................................
Starter Motor Clutch Disassembly ....................................................................................
Starter Motor Clutch Assembly .........................................................................................
Ignition System .......................................................................................................................
Crankshaft Sensor Removal .............................................................................................
Crankshaft Sensor Installation ..........................................................................................
Crankshaft Sensor Inspection...........................................................................................
Crankshaft Sensor Peak Voltage Inspection.....................................................................
Timing Rotor Removal ......................................................................................................
Timing Rotor Installation ...................................................................................................
Stick Coil (Ignition Coil together with Spark Plug Cap) Removal......................................
Stick Coil (Ignition Coil together with Spark Plug Cap) Installation...................................
Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection....................................
Stick Coil Primary Peak Voltage .......................................................................................
Spark Plug Removal .........................................................................................................
Spark Plug Installation ......................................................................................................
Spark Plug Condition Inspection.......................................................................................
Interlock Operation Inspection ..........................................................................................
IC Igniter Inspection ..........................................................................................................

16-3
16-10
16-11
16-12
16-14
16-16
16-18
16-20
16-22
16-24
16-24
16-25
16-25
16-25
16-25
16-28
16-28
16-29
16-29
16-31
16-31
16-31
16-31
16-32
16-32
16-32
16-34
16-35
16-38
16-40
16-40
16-40 16
16-40
16-40
16-41
16-41
16-42
16-42
16-42
16-43
16-43
16-43
16-43
16-44
16-44
16-45
16-45
16-45
16-45
16-46

16-2 ELECTRICAL SYSTEMElectric Starter System ...........................................................................................................
Starter Motor Removal......................................................................................................
Starter Motor Installation...................................................................................................
Starter Motor Disassembly................................................................................................
Starter Motor Assembly ....................................................................................................
Brush Inspection ...............................................................................................................
Commutator Cleaning and Inspection...............................................................................
Armature Inspection..........................................................................................................
Brush Lead Inspection ......................................................................................................
Brush Plate and Terminal Bolt Inspection .........................................................................
Starter Relay Inspection....................................................................................................
Lighting System ......................................................................................................................
Headlight Beam Horizontal Adjustment ............................................................................
Headlight Beam Vertical Adjustment.................................................................................
Headlight Bulb Replacement ............................................................................................
City Light Bulb Replacement (Europe Models) .................................................................
Headlight Removal/Installation .........................................................................................
Tail/Brake Light Removal ..................................................................................................
Tail/Brake Light Installation ...............................................................................................
License Plate Light Bulb Replacement .............................................................................
Turn Signal Light Bulb Replacement ................................................................................
Turn Signal Relay Inspection ............................................................................................
Air Switching Valve .................................................................................................................
Air Switching Valve Operation Test ...................................................................................
Air Switching Valve Unit Test ............................................................................................
Radiator Fan System..............................................................................................................
Fan Motor Inspection ........................................................................................................
Meter, Gauge, Indicator Unit...................................................................................................
Meter Unit Removal/Installation ........................................................................................
Meter, Gauge Disassembly...............................................................................................
Electronic Combination Meter Unit Inspection ..................................................................
Switches and Sensors ............................................................................................................
Brake Light Timing Inspection...........................................................................................
Brake Light Timing Adjustment .........................................................................................
Switch Inspection ..............................................................................................................
Water Temperature Sensor Inspection .............................................................................
Speed Sensor Removal ....................................................................................................
Speed Sensor Installation .................................................................................................
Speed Sensor Inspection..................................................................................................
Oxygen Sensor Removal (Europe Models) ......................................................................
Oxygen Sensor Installation (Europe Models) ...................................................................
Oxygen Sensor Inspection (Europe Models) ....................................................................
Fuel Reserve Switch Inspection........................................................................................
Relay Box ...............................................................................................................................
Relay Box Removal ..........................................................................................................
Relay Circuit Inspection ....................................................................................................
Diode Circuit Inspection ....................................................................................................
Fuse........................................................................................................................................
30 A Main Fuse Removal..................................................................................................
Fuse Box Fuse Removal...................................................................................................
15 A ECU Fuse Removal..................................................................................................
Fuse Installation................................................................................................................
Fuse Inspection.................................................................................................................

16-49
16-49
16-49
16-50
16-50
16-51
16-51
16-52
16-52
16-52
16-53
16-55
16-55
16-55
16-55
16-56
16-56
16-56
16-56
16-57
16-58
16-59
16-61
16-61
16-61
16-63
16-63
16-64
16-64
16-64
16-65
16-73
16-73
16-73
16-73
16-74
16-74
16-74
16-75
16-75
16-75
16-76
16-76
16-77
16-77
16-77
16-78
16-80
16-80
16-80
16-80
16-81
16-81

ELECTRICAL SYSTEM 16-3
Exploded View
Dummy Page

16-4 ELECTRICAL SYSTEM
Exploded View

ELECTRICAL SYSTEM 16-5
Exploded View
No.
1
2
3
4

Fastener
Front Turn Signal Light Mounting Screws
License Plate Light Cover Screws
License Plate Light Mounting Screws
Meter Screws

5. Meter Unit (EX650B Models)
6. City Light (Europe Models)

N·m
1.2
0.90
1.2
1.2

Torque
kgf·m
0.12
0.090
0.12
0.12

ft·lb
11 in·lb
8 in·lb
11 in·lb
11 in·lb

Remarks

16-6 ELECTRICAL SYSTEM
Exploded View

ELECTRICAL SYSTEM 16-7
Exploded View
No.
1
2
3
4
5
6
7
8

Fastener
Front Brake Light Switch Screw
Left Switch Housing Screws
Right Switch Housing Screws
Starter Motor Cable Terminal Nut
Starter Motor Mounting Bolts
Starter Motor Terminal Locknut
Starter Motor Through Bolts
Engine Ground Cable Terminal Bolt

9. Main Harness (EX650B Models)
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts

N·m
1.2
3.5
3.5
6.0
9.8
11
4.9
9.8

Torque
kgf·m
0.12
0.36
0.36
0.60
1.0
1.1
0.50
1.0

ft·lb
11 in·lb
31 in·lb
31 in·lb
53 in·lb
87 in·lb
97 in·lb
43 in·lb
87 in·lb

Remarks

L16-8 ELECTRICAL SYSTEM
Exploded View

ELECTRICAL SYSTEM 16-9
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Fastener
Alternator Cover Bolts
Alternator Lead Holding Plate Bolt
Alternator Rotor Bolt
Crankshaft Sensor Bolts
Neutral Switch
Oil Pressure Switch
Oxygen Sensor
Regulator/Rectifier Bolts
Sidestand Switch Bolt
Spark Plugs
Speed Sensor Bolt
Starter Motor Clutch Bolts
Stator Coil Bolts
Timing Rotor Bolt
Water Temperature Sensor

N·m
9.8
9.8
155
6.0
15
15
44.1
8.8
8.8
15
7.8
34
12
40
12

Torque
kgf·m
1.0
1.0
15.8
0.60
1.5
1.5
4.50
0.90
0.90
1.5
0.80
3.5
1.2
4.1
1.2

ft·lb
87 in·lb
87 in·lb
114
53 in·lb
1111
32.5
78 in·lb
78 in·lb
11
69 in·lb
25
106 in·lb
30
106 in·lb

Remarks

16. EX650B Models
17. EX650A Models
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution.
(Mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)
R: Replacement Parts
SS: Apply silicone sealant.

L
MO

SS

L
L
L
L

16-10 ELECTRICAL SYSTEM
Specifications
Item
BatteryType
Model Name
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
Stick Coil:Primary Winding Resistance
Secondary Winding ResistancePrimary Peak Voltage
Spark Plug:
Spark Plug Gap
Electric Starter System
Starter Motor:
Brush Length
Commutator Diameter
Air Switching Valve
Resistance
Switch and Sensor
Rear Brake Light Switch Timing
Engine Oil Pressure Switch Connections
Water Temperature Sensor ResistanceStandard
Sealed Battery
YTX12-BS
12 V 10 Ah
12.8 V or moreThree-phase AC
42 V or more at 4 000 r/min (rpm)0.18 ∼ 0.27 Ω
14.2 ∼ 15.2 V

376 ∼ 564 Ω
1.9 V or more
1.1 ∼ 1.5 Ω
10.8 ∼ 16.2 kΩ
88 V or more
0.8 ∼ 0.9 mm (0.03 ∼ 0.04 in.)

12 mm (0.47 in.) (Service limit: 6.0 mm, 0.24 in.)
28 mm (1.10 in.) (Service limit: 27 mm, 1.06 in.)18 ∼ 22 Ω at 20°C (68°F)
ON after about 10 mm (0.39 in.) pedal travel
When engine is stopped: ON
When engine is running: OFFin the text

ELECTRICAL SYSTEM 16-11
Special Tools and Sealants
Hand Tester:
57001-1394

Grip:
57001-1591

Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5:
57001-1405

Flywheel & Pulley Holder:
57001-1605

Peak Voltage Adapter:
57001-1415

Rotor Holder:
57001-1658

Lead Wire - Peak Voltage Adapter:
57001-1449

Kawasaki Bond (Silicone Sealant):
56019-120

Needle Adapter Set:
57001-1457

Kawasaki Bond (Silicone Sealant):
92104-0004

16-12 ELECTRICAL SYSTEM
Parts Location

1. Air Switching Valve
2. Alternator
3. Battery 12 V 10 Ah
4. Crankshaft Sensor
5. ECU6. Fan Motor
7. Front Brake Light Switch
8. Fuse Box with ECU Main Fuse
9. Ignition Switch
10. Meter Unit
11. Neutral Switch
12. Oil Pressure Switch

13. Rear Brake Light Switch
14. Regulator/Rectifier
15. Relay Box
16. Sidestand Switch
17. Speed Sensor
18. Starter Lockout Switch
19. Starter Motor
20. Starter Relay with Main Fuse
21. Stick Coils
22. Turn Signal Relay
23. Water Temperature Sensor
24. Oxygen Sensor (Europe Models)ELECTRICAL SYSTEM 16-13
Parts Location
Dummy Page

16-14 ELECTRICAL SYSTEM
Wiring Diagram (Europe, Korea, Hong Kong and Kuwait)

ELECTRICAL SYSTEM 16-15
Wiring Diagram (Europe, Korea, Hong Kong and Kuwait)

16-16 ELECTRICAL SYSTEM
Wiring Diagram (United States, Canada, New Zealand and Malaysia)

ELECTRICAL SYSTEM 16-17
Wiring Diagram (United States, Canada, New Zealand and Malaysia)

16-18 ELECTRICAL SYSTEM
Wiring Diagram (Australia and South Africa)

ELECTRICAL SYSTEM 16-19
Wiring Diagram (Australia and South Africa)

16-20 ELECTRICAL SYSTEM
Wiring Diagram (EX650B Models)ELECTRICAL SYSTEM 16-21
Wiring Diagram (EX650B Models)16-22 ELECTRICAL SYSTEM
Precautions
There are a number of important precautions that aremusts when servicing electrical systems. Learn and observe all the rules below.
○Do not reverse the battery cable connections. This willburn out the diodes on the electrical parts.
○Always check battery condition before condemning otherparts of an electrical system. A fully charged battery is amust for conducting accurate electrical system tests.
○The electrical parts should never be struck sharply, aswith a hammer, or allowed to fall on a hard surface. Sucha shock to the parts can damage them.
○To prevent damage to electrical parts, do not disconnect
the battery cables or any other electrical connections
when the ignition switch is on, or while the engine isrunning.
○Because of the large amount of current, never keep thestarter button pushed when the starter motor will not turnover, or the current may burn out the starter motor windings.
○Do not use a meter illumination bulb rated for other thanvoltage or wattage specified in the wiring diagram, as themeter or gauge panel could be warped by excessive heatradiated from the bulb.
○Take care not to short the cables that are directly connected to the battery positive (+) terminal to the chassis
ground.
○Troubles may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the failure. If the failure was caused by someother item or items, they must be repaired or replaced, orthe new replacement will soon fail again.
○Make sure all connectors in the circuit are clean and tight,
and examine wires for signs of burning, fraying, etc. Poor
wires and bad connections will affect electrical system operation.
○Measure coil and winding resistance when the part is cold
(at room temperature).
○Color Codes:
BK: Black
BL: Blue
BR: Brown
CH: Chocolate
DG: Dark Green○Electrical Connectors

G: Green
GY: Gray
LB: Light Blue
LG: Light Green
O: Orange

Female Connectors [A]P: Pink
PU: Purple
R: Red
W: White
Y: Yellow

ELECTRICAL SYSTEM 16-23
Precautions
Male Connectors [B]16-24 ELECTRICAL SYSTEMElectrical Wiring
Wiring Inspection

inspect the wiring for signs of burning, fraying,• Visuallyetc.
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 it carefully. If it
is damaged, replace it.
Check the wiring for continuity.
○Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
○Connect the hand tester between the ends of the leads.

••

Special Tool - Hand Tester: 57001-1394○Set the tester to the × 1 Ω range, and read the tester.

If the tester does not read 0 Ω, the lead is defective. Replace the lead or the wiring harness [B] if necessary.

ELECTRICAL SYSTEM 16-25
Battery
Battery Removal• Remove:
Seat (see Seat Removal in the Frame chapter)the negative (–) cable [A].
• Disconnect
Slide
out
the
positive (+) terminal cap [B] and then discon• nect the positive(+) cable.
CAUTIONBe sure to disconnect the negative (–) cable first.

• Remove the battery.
Battery Installation

the battery into the rear fender front.
• Put
Apply
a light coat of grease on the terminals to prevent• corrosion.
the positive (+) cable [A] first.
• Installthe positive (+) terminal with the cap [B].
• Cover
Installthenegative (–) cable [C].
•Battery Activation
Electrolyte Filling
Make sure that the model name [A] of the electrolyte container matches the model name [B] of the battery. These
names must be the same.

•

Battery Model Name for EX650A/B: YTX12-BS

CAUTIONBe sure to use the electrolyte container with thesame model name as the battery since the electrolyte volume and specific gravity vary with thebattery type. This is to prevent overfilling of theelectrolyte, shorting the battery life, and deterioration of the battery performance.

CAUTION
Do not remove the aluminum sealing sheet [A] fromthe filler ports [B] until just prior to use. Be sure to
use the dedicated electrolyte container for correct
electrolyte volume.
the battery on a level surface.
• PlaceCheck• or holestoinseeit. that the sealing sheet has no peeling, tears,• Remove the sealing sheet.

NOTE○The battery is vacuum sealed. If the sealing sheet has
leaked air into the battery, it may require a longer initialcharge.

16-26 ELECTRICAL SYSTEM
Battery
the electrolyte container from the vinyl bag.
• Remove
Detachtheof caps [A] from the container and set• aside, thesestrip
will be used later to seal the battery.

NOTE○Do not pierce or otherwise open the sealed cells [B] of

the electrolyte container. Do not attempt to separate
individual cells.

the electrolyte container upside down with the six• Placesealed cells into the filler ports of the battery. Hold thecontainer level, push down to break the seals of all six
cells. You will see air bubbles rising into each cell as theports fill.

NOTE○Do not tilt the electrolyte container
the electrolyte flow.
• Check
If no air bubbles [A] are coming up from the filler ports, or•if the container cells have not emptied completely, tap thecontainer [B] a few times.
Keep the container in place for 20 minutes or more. Don’t
remove the container from the battery until it’s empty, thebattery requires all the electrolyte from the container for
proper operation.

CAUTION
Removal of the container before it is completely
empty can shorten the service life of the battery. Do
not remove the electrolyte container until it is completely empty and 20 minutes have elapsed.
remove the container from the battery.
• GentlyLetthebattery sit for 30 minutes prior to charging to allow• the electrolyte
to permeate into the plates for optimum
performance.

NOTE○Charging the battery immediately after filling canshorten service life. Let the battery sit for at least 30
minutes after filling.

ELECTRICAL SYSTEM 16-27
Battery
Initial Charge
Place the strip [A] of caps loosely over the filler ports.
Newly activated sealed batteries require an initial charge.

••

Standard Charge: 1.2 A × 5 ∼ 10 hours

If using a recommended battery charger, follow the
charger’s instructions for newly activated sealed battery.
Kawasaki-recommended chargers
Optimate III
Yuasa 1.5 Amp Automatic Charger
Battery Mate 150-9

If the above chargers are not available, use equivalent
one.

NOTE

○Charging rates will vary depending on how long thebattery has been stored, temperature, and the type of
charger used. Let battery sit 30 minutes after initialcharge, then check voltage using a voltmeter. If it is
not at least 12.8 V, repeat charging cycle.

charging is completed, press down firmly with both• Afterhands to seat the strip of caps [A] into the battery (don’t
pound or hammer.). When properly installed, the strip ofthe caps will be level with the top of the battery.

CAUTION
Once the strip of the caps [A] is installed onto thebattery, never remove the caps, nor add water orelectrolyte to the battery.

NOTE○To ensure maximum battery life and customer satisfac-

tion, it is recommended the battery be load tested atthree times its amp-hour rating for 15 seconds.
Re-check voltage and if less than 12.8 V repeat the
charging cycle and load test. If still below 12.8 V thebattery is defective.

16-28 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 seal cap to add water is very dangerous. Never do that.
2) Refreshing charge.
If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has beendischarged. Give refresh charge for 5 to 10 hours with charge current shown in the specification(see Specifications).
When a fast charge is inevitably required, do it following precisely the maximum charge current
and time conditions indicated on the battery.

CAUTION
This battery is designed to sustain no unusual deterioration if refresh-charged according
to the method specified above. However, the battery’s performance may be reduced noticeably if charged under conditions other than given above. Never remove the seal cap
during refresh charge.
If by chance an excessive amount of gas is generated due to overcharging, the relief valve
releases the gas to keep the battery normal.
3) When you do not use the motorcycle for months.
Give a refresh charge before you store the motorcycle and store it with the negative cable removed. Give a refresh charge once a month during storage.
4) Battery life.
If the battery will not start the engine even after several refresh charges, the battery has exceeded its useful life. Replace it (Provided, however, the vehicle’s starting system has no problem).

WARNING
Keep the battery away from sparks and open flames during charging, since the battery
gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger,
connect the battery to the charger before turning on the charger.
This procedure prevents sparks at the battery terminals which could ignite any battery
gases.
No fire should be drawn near the battery, or no terminals should have the tightening loosened.
The electrolyte contains sulfuric acid. Be careful not to have it touch your skin or eyes. If
touched, wash it off with liberal amount of water. Get medial attention if severe.

Interchange
A sealed battery can fully display its performance only when combined with a proper vehicle electric
system. Therefore, replace a sealed battery only on a motorcycle which was originally equipped witha sealed battery.
Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original
equipment, the sealed battery’s life will be shortened.

ELECTRICAL SYSTEM 16-29
Battery
Charging Condition Inspection○Battery charging condition can be checked by measuring••

battery terminal voltage with a digital voltmeter [A].
Remove:Seat (see Seat Removal in the Frame chapter)
Battery Cable Cap (see Battery Removal)
Disconnect the battery terminals.

CAUTIONBe sure to disconnect the negative (–) cable first.

• Measure the battery terminal voltage.
NOTE○Measure with a digital voltmeter which can be read one
decimal place voltage.

If the reading is 12.8 V or more, no refresh charge is required, however, if the read is below the specified, refresh
charge is required.
Battery Terminal Voltage
12.8 V or moreStandard:

Terminal Voltage (V) [A]Battery Charge Rate (%) [B]Good [C]
Refresh charge is required [D]Refreshing Charge

the battery [A] (see Battery Removal).
• RemoveDo
refreshcharge by following method according to the• battery terminal
voltage.

WARNING
This battery is sealed type. Never remove sealing
cap [B] even at charging. Never add water. Charge
with current and time as stated below.

16-30 ELECTRICAL SYSTEM
Battery
Terminal Voltage: 11.5 ∼ less than 12.8 V
Standard Charge 1.2 A × 5 ∼ 10 h (see following chart)
Quick Charge

5A×1h

CAUTION
If possible, do not quick charge. If quick charge isdone unavoidably, do standard charge later on.
Terminal Voltage: less than 11.5 V
1.2 A × 20 hCharging Method

NOTE○Increase the charging voltage to a maximum voltage of

25 V if the battery will not accept current initially. Charge
for no more than 5 minutes at the increased voltage thencheck if the battery is drawing current. If the battery
will accept current decrease the voltage and charge by
the standard charging method described on the battery
case. If the battery will not accept current after 5 minutes, replace the battery.

Battery [A]Battery Charger [B]Standard Value [C]Current starts to flow [D]the battery condition after refresh charge.
•○Determine
Determine the condition of the battery left for 30 minutes
after completion of the charge by measuring the terminal
voltage according to the table below.
Criteria

Judgement

12.8 V or higher

Good

12.0 ∼ lower than 12.8 V

Charge insufficient → Recharge

lower than 12.0 V

Unserviceable → Replace

ELECTRICAL SYSTEM 16-31
Charging System
Alternator Cover Removal• Remove:
Left Center Fairing (see Center Fairing Removal in the
Frame chapter)
Alternator Lead Connector [A]a suitable container under the alternator cover [A],• Placeand remove the cover bolts [B].
• Pull the alternator cover outside.

Alternator Cover Installation

silicone sealant to the alternator lead grommet and• Apply
crankcase halves mating surface [A] on the front and rearsides of the cover mount.
Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004

that dowel pins [B] are in place on the crankcase.
• Checka new gasket and the alternator cover.
• Install
Tighten:•

Torque - Alternator Cover Bolts: 9.8 N·m (1.0 kgf·m, 87
in·lb)

Stator Coil Removal• Remove:
Alternator Cover (see Alternator Cover Removal)•

Holding Plate Bolt [A] and Plate
Alternator Lead Grommet [B]Stator Coil Bolts [C]Remove the stator coil [D] from the alternator cover.

16-32 ELECTRICAL SYSTEM
Charging System
Stator Coil Installationa non-permanent locking agent to the threads of• Apply
the stator coil bolts and tighten them.
Torque - Stator Coil Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)

the alternator lead with a holding plate, and• Secure
tighten the bolt.

○Apply a non-permanent locking agent to the threads ofthe holding plate bolt.

Torque - Alternator Lead Holding Plate Bolt: 9.8 N·m (1.0kgf·m, 87 in·lb)

silicone sealant to the circumference of the alter• Applynator lead grommet, and fit the grommet into the notch of
the cover securely.
Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004

the alternator cover (see Alternator Cover Installa• Installtion).

Alternator Rotor Removal

the alternator cover (see Alternator Cover Re• Remove
moval).
the starter idle gear, torque limiter and shafts.
• Remove
Wipe
oil
off
the outer circumference of the rotor.
• Hold the alternatorsteady with the rotor holder [A],• and remove the rotorrotor
bolt [B] and washer.
Special Tools - Grip: 57001-1591
Rotor Holder: 57001-1658

the flywheel puller [A], remove the alternator rotor• Usingfrom the crankshaft.
Special Tool - Flywheel Puller Assembly, M38 × 1.5/M35 ×
1.5: 57001-1405

CAUTION
Do not attempt to strike the alternator rotor itself.
Striking the rotor can cause the magnets to lose
their magnetism.

Alternator Rotor Installationa cleaning fluid, clean off any oil or dirt on the fol• Using
lowing portions and dry them with a clean cloth.

•

Crankshaft Tapered Portion [A]Alternator Rotor Tapered Portion [B]Apply a thin coat of molybdenum disulfide grease to the
crankshaft [C].

ELECTRICAL SYSTEM 16-33
Charging System
the starter gear [A] and washer [B].
• Install
Again,• there. clean the crankshaft tapered portion [C] and dry

the alternator rotor [A] while turning [B] it counter• Install
clockwise.

• Install the washer [A].

NOTE

○Confirm the alternator rotor fit or not to the crankshaft
before tightening it with specified torque.

molybdenum disulfide oil solution to the threads• Applyand seating surface of the rotor bolt.
the rotor bolt [B] and tighten it with 70 N·m (7.0
• Install
kgf·m, 52 ft·lb) of torque.
the rotor bolt and washer.
• RemoveCheckthetorque with flywheel puller.
• If the rotortightening
is not pulled out with 20 N·m (2.0 kgf·m, 15•

ft·lb) of drawing torque, it is installed correctly.
If the rotor is pulled out with under 20 N·m (2.0 kgf·m, 15
ft·lb) of drawing torque, clean off any oil dirt or flaw of the
crankshaft and rotor tapered portion, and dry them witha clean cloth. Then, confirm that it is not pulled out withabove torque.
Tighten the alternator rotor bolt while holding the alternator rotor steady with the rotor holder.
Special Tools - Grip: 57001-1591
Rotor Holder: 57001-1658
Torque - Alternator Rotor Bolt: 155 N·m (15.8 kgf·m, 114
ft·lb)

16-34 ELECTRICAL SYSTEM
Charging Systema thin coat of molybdenum disulfide grease to the• Apply
shafts [A], and install them.
the torque limiter [B] and starter idle gear [C].
• Install
the alternator cover (see Alternator Cover Installa• Installtion).

Alternator Inspection
There are three types of alternator failures: short, open
(wire burned out), or loss in rotor magnetism. A short oropen in one of the coil wires will result in either a low output,
or no output at all. A loss in rotor magnetism, which may becaused by dropping or hitting the alternator, by leaving it
near an electromagnetic field, or just by aging, will result in
low output.
check the alternator output voltage, do the following• To
procedures.

○Turn off the ignition switch.
○Disconnect the alternator lead connector [A].
○Connect the hand tester as shown in the table 1.
○Start the engine.
○Run it at the rpm given in the table 1.
○Note the voltage readings (total 3 measurements).
Table 1 Alternator Output Voltage
TesterRange

Connections
Tester (+) to

Tester (–) to

Reading
at 4 000 rpm

250 V AC One Black lead Another Black lead 42 V or more

If the output voltage shows the value in the table, the alternator operates properly.
If the output voltage shows a much higher than the value
in the table, the regulator/rectifier is damaged. A much
lower reading than that given in the table indicates thatthe alternator is defective.
Check the stator coil resistance as follows.
○Stop the engine.
○Connect the hand tester as shown in the table 2.
○Note the readings (total 3 measurement).

•

Table 2 Stator Coil ResistanceConnections

TesterRange

Tester (+) to×1Ω

One Black lead Another Black lead 0.18 ∼ 0.27 Ω

Tester (–) to

Reading

ELECTRICAL SYSTEM 16-35
Charging System•

If there is more resistance than shown in the table, or nohand 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 highest resistance range of the hand tester,measure the resistance between each of the black leads
and chassis ground.
Any hand tester reading less than infinity (∞) indicates ashort, necessitating stator replacement.
If the stator coils have normal resistance, but the voltage
check showed the alternator to be defective; then the rotor
magnets have probably weakened, and the rotor must be
replaced.
Special Tool - Hand Tester: 57001-1394

Regulator/Rectifier Inspection
EX650A Models
Remove:Bolts [A]•the connector [A].
• Disconnect
Removetheregulator/rectifier [B].
•

EX650B Models
Remove the bolts [A].
Disconnect the connector [B].
Remove the regulator/rectifier [C].

•••

16-36 ELECTRICAL SYSTEM
Charging System
Rectifier Circuit Check
Check conductivity of the following pair of terminals.

•

Rectifier Circuit Inspection
Tester connection

W/BL-BK1,

W/BL-BK2,

W/BL-BK3

BK/Y-BK1,

BK/Y-BK2,

BK/Y-BK3

The resistance should be low in one direction and morethan ten times as much in the other direction. If any twoleads are low or high in both directions, the rectifier isdefective and the regulator/rectifier must be replaced.

NOTE○The actual meter reading varies with the meter used
and the individual rectifier, but, generally speaking thelower reading should be from zero to one half the scale.

Regulator Circuit Check
To test the regulator out of circuit, use three 12 V batteries
and a test light (12 V 3 ∼ 6 W bulb in a socket with leads).

CAUTION
The test light works as an indicator and also a current limiter to protect the regulator/rectifier from excessive current. Do not use an ammeter instead ofa test light.
to be sure the rectifier circuit is normal before con• Checktinuing.
the 1st step regulator circuit test.
•○Do
Connect the test light and the 12 V battery to the regula-

tor/rectifier as shown.
○Check the BK1, BK2 and BK3 terminal respectively.
If the test light turns on, the regulator/rectifier is defective.
Replace it.
If the test light does not turn on, continue the test.

the 2nd step regulator circuit test.
•○Do
Connect the test light and the 12 V battery in the samemanner as specified in the “Regulator Circuit Test-1st
Step”.
○Apply 12 V to the voltage BR terminal.
○Check the BK1, BK2 and BK3 terminal respectively.
If the test light turns on, the regulator/rectifier is defective.
Replace it.
If the test light does not turn on, continue the test.

ELECTRICAL SYSTEM 16-37
Charging System
the 3rd step regulator circuit test.
•○Do
Connect the test light and the 12 V battery in the samemanner as specified in the “Regulator Circuit Test-1st
Step”.
○Momentarily apply 24 V to the voltage BR terminal byadding a 12 V battery.
○Check the BK1, BK2 and BK3 terminals respectively.

CAUTION
Do not apply more than 24 V. If more than 24 V is applied, the regulator/rectifier may be damaged. Do
not apply 24 V more than a few seconds. If 24 V
is applied for more than a few seconds, the regulator/rectifier may be damaged.
If the test light did not light when the 24 V was applied
momentarily to the voltage monitoring terminal, the regulator/rectifier is defective. Replace it.
If the regulator/rectifier passes all of the tests described,
it may still be defective. If the charging system still does
not work properly after checking all of the components
and the battery, test the regulator/rectifier by replacing itwith a known good unit.

16-38 ELECTRICAL SYSTEM
Charging System
Charging Voltage Inspection

the battery condition (see Charging Condition In• Checkspection).
up the engine to obtain actual alternator operating• Warmconditions.
the seat (see Seat Removal in the Frame chap• Remove
ter).
that the ignition switch is turned off, and connect• Check
the hand tester [A] to the battery terminals [B].
Special Tool - Hand Tester: 57001-1394

the engine, and note the voltage readings at var• Start
ious engine speeds with the headlight turned on andthen turned off (To turn off the headlight, disconnect theheadlight connector on the headlight unit). The readings
should show nearly battery voltage when the engine
speed is low, and, as the engine speed rises, the readings should also rise. But they must be kept under the
specified voltage.
Charging Voltage
Tester Range
25 V DC

Connections
Tester (+) to

Tester (–) toBattery (+)

Battery (–)

Reading
14.2 ∼ 15.2 V

off the ignition switch to stop the engine, and discon• Turnnect the hand tester.
If the charging voltage is kept between the values given in
the table, the charging system is considered to be working
normally.
If the charging voltage is much higher than the values
specified in the table, the regulator/rectifier is defectiveor the regulator/rectifier leads are loose or open.
If the charging voltage does not rise as the engine speed
increases, then the regulator/rectifier is defective or thealternator output is insufficient for the loads. Check thealternator and regulator/rectifier to determine which partis defective.

ELECTRICAL SYSTEM 16-39
Charging System
Charging System Circuit

1. Ignition Switch
2. Alternator
3. Regulator/Rectifier
4. Water-proof Joint C
5. Main Fuse 30 A
6. Battery 12 V 10 Ah
7. Load16-40 ELECTRICAL SYSTEM
Starter Motor Clutch
Starter Motor Clutch Removal/Installation• Refer to the Alternator Rotor Removal/Installation.
Starter Motor Clutch Inspection• Remove:
Alternator Cover (see Alternator Cover Removal)••

Starter Idle Gear and Torque Limiter
ShaftsTurn the starter motor clutch gear [A] by hand. The starter
motor clutch gear should turn clockwise [B] freely, butshould not turn counterclockwise [C].
If the starter motor clutch does not operate as it should or
if it makes noise, go to the next step.
Disassemble the starter motor clutch, and visually inspect
the clutch parts.
If there is any worn or damaged part, replace it.

NOTE○Examine the starter motor clutch gear as well. Replace
it if it worn or damaged.
Starter Motor Clutch Disassembly• Remove:
Alternator Rotor (see Alternator Rotor Removal)
Starter Motor Clutch Bolts [A]• Remove:Starter Motor Clutch [A]Starter Motor Clutch Assembly

a non-permanent locking agent to the threads of• Apply
the starter motor clutch bolts and tighten them.
Torque - Starter Motor Clutch Bolts: 34 N·m (3.5 kgf·m, 25
ft·lb)ELECTRICAL SYSTEM 16-41
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 otherelectrical connections when the ignition switch ison, or while the engine is running. This is to prevent
ECU (Electric Control Unit) damage.
Do not install the battery backwards. The negativeside is grounded. This is to prevent damage to the
ECU.

Crankshaft Sensor Removal• Remove:
Lower Fairing (see Lower Fairing Removal in the Frame
chapter)
Right Frame Cover (see Frame Cover Removal in the
Frame chapter)
Crankshaft Sensor Lead Connector [A]• Remove:
Rubber Boot (Slide Out) [A]Oil Pressure Switch Lead Terminal [B]
Clutch Cover (see Clutch Cover Removal in the Clutch
chapter)• Remove:
Bolts [A]•

Crankshaft Sensor [B]Pull out the grommet [C].

16-42 ELECTRICAL SYSTEM
Ignition System
Crankshaft Sensor Installation

the crankshaft sensor lead correctly (see Cable,• RouteWire, and Hose Routing section in the Appendix chapter).
• Tighten:

Torque - Crankshaft Sensor Bolts: 6.0 N·m (0.60 kgf·m, 53
in·lb)

silicone sealant [A] to the crankshaft sensor lead
• Apply
grommet.
Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004• Install the removed parts (see appropriate chapters).
Crankshaft Sensor Inspection• Remove:
Right Frame Cover (see Frame Cover Removal in the•

Frame chapter)
Crankshaft Sensor Lead Connector [A]
Set the hand tester to the × 100 Ω range and connect (+)
lead to the black lead and (–) lead to the yellow lead in
the connector.
Special Tool - Hand Tester: 57001-1394

If there is more resistance than the specified value, thecoil has an open lead and must be replaced. Much lessthan this resistance means the coil is shorted, and must
be replaced.
Crankshaft Sensor Resistance: 376 ∼ 564 Ω

the highest resistance range of the tester, measure• Using
the resistance between the crankshaft sensor leads andchassis ground.
Any tester reading less than infinity (∞) indicates a short,necessitating replacement of the crankshaft sensor assembly.

Crankshaft Sensor Peak Voltage Inspection
NOTE○Be sure the battery is fully charged.
○Using the peak voltage adapter [A] is a more reliable
way to determine the condition of the crankshaft sensor than crankshaft sensor internal resistance measurements.

• Remove:
Crankshaft Sensor Lead Connector (see Crankshaft•••

Sensor Removal)
Set the hand tester [B] to the × DC 10 V range, and connect it peak voltage adapter.
Connect the black lead of the adapter to yellow lead andred lead to black lead in the crankshaft sensor connector.
Turn the ignition switch and engine stop switch ON.

ELECTRICAL SYSTEM 16-43
Ignition System
the starter button, turn the engine 4 ∼ 5 sec• Pushingonds with the transmission gear in neutral to measure the•crankshaft sensor peak voltage.
Repeat the measurement 5 or more times.
Crankshaft Sensor Peak Voltage
1.9 V or moreStandard:
Special Tools - Hand Tester: 57001-1394
Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B

If the tester reading is not specified one, check the crankshaft sensor.

Timing Rotor Removal• Remove:
Clutch Cover (see Clutch Cover Removal in the Clutch
chapter)
Crankshaft Sensor (see Crankshaft Sensor Removal)
Remove the timing rotor [A].
○Holding the timing rotor with the flywheel & pulley holder[B] and unscrew the rotor bolt [C].

•Special Tool - Flywheel & Pulley Holder: 57001-1605

Timing Rotor Installation

the rotor to the crankshaft.
• Fit
Tightenthe rotor bolt.
•

Torque - Timing Rotor Bolt: 40 N·m (4.1 kgf·m, 30 ft·lb)• Install the removed parts (see appropriate chapters).

Stick Coil (Ignition Coil together with Spark PlugCap) Removal

the air cleaner housing (see Air Cleaner Housing• Remove
Removal in the Fuel System (DFI) chapter).
the stick coil connectors [A].
• Disconnect• Pull the stick coils [B] off the spark plugs.

CAUTION

Do not pry the connector part of the coil while removing the coil.

Stick Coil (Ignition Coil together with Spark PlugCap) Installation

the coil as shown being careful of the coil heads [A]• Insert
direction.
• Connect the connectors.

CAUTION

Do not tap the coil head while installing the coil.
the hoses and harness correctly (see Cable, Wire,• Run
and Hose Routing section in the Appendix chapter).
• Install the removed parts (see appropriate chapters).

16-44 ELECTRICAL SYSTEM
Ignition System
Stick Coil (Ignition Coil together with Spark PlugCap) Inspection

the stick coils (see Stick Coil (Ignition Coil to• Remove
gether with Spark Plug Cap) Removal).
the primary winding resistance [A] as follows.
•○Measure
Connect the hand tester between the coil terminals.

○Set the tester to the × 1 Ω range, and read the tester.

the secondary winding resistance [B] as follows.
•○Measure
Connect the tester between the plug terminal and (–) coilterminal.

○Set the tester to the × 1 kΩ range and read the tester.
Ignition Coil Winding ResistancePrimary Windings:
1.1 ∼ 1.5 ΩSecondary Windings:

10.8 ∼ 16.2 kΩ

If the tester does not read as specified, replace the coil.

Stick Coil Primary Peak Voltage
NOTE○Be sure the battery is fully charged.
the stick coils (see Stick Coil (Ignition Coil to• Remove
gether with Spark Plug Cap) Removal), but do not remove
the spark plugs.
Measure the primary peak voltage as follows.
○Install the new spark plug [A] into each stick coil [B], andground them onto the engine.
○Connect the peak voltage adapter [C] into the hand tester[D] which is set to the × DC 250 V range.
○Connect the adapter to the lead wire-peak voltage
adapter [E] which is connected between the stick coilconnector and stick coil.
ECU [F]
Battery [G]•Special Tools - Hand Tester: 57001-1394
Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
Lead Wire-Peak Voltage Adapter:
-1449

57001

Primary Lead Connection
Adapter (R, +) to lead wire-peak voltage adapter (W)Adapter (BK, –) to lead wire-peak voltage adapter (R)ELECTRICAL SYSTEM 16-45
Ignition System
WARNINGTo avoid extremely high voltage shocks, do nottouch the spark plugs or tester connections.
the ignition switch and the engine stop switch ON.
• TurnPushing
starter button, turn the engine 4 ∼ 5 seconds• with the thetransmission in neutral to measure the primary•

peak voltage.
Repeat the measurements 5 times for one stick coil.
Stick Coil Primary Peak Voltage
88 V or moreStandard:

the test for the other stick coil.
• RepeatIf the reading is less than the specified value, check thefollowing.
Stick Coils (see Stick Coil (Ignition Coil together with
Spark Plug Cap) Inspection)
Crankshaft Sensor (see Crankshaft Sensor Inspection)
ECU (see ECU Power Supply Inspection in the Fuel System (DFI) chapter)

Spark Plug Removal

to the Spark Plug Replacement in the Periodic• Refer
Maintenance chapter.

Spark Plug Installation

to the Spark Plug Replacement in the Periodic• Refer
Maintenance chapter.

Spark Plug Condition Inspection

to the Spark Plug Condition Inspection in the Peri• Refer
odic Maintenance chapter.

Interlock Operation Inspection

the rear wheel off the ground with stand.
•1stRaiseCheck• Start the engine to the following conditions.
Condition
Transmission Gear → 1st Position
Clutch Lever → ReleaseSidestand → Down or Up○Turn the ignition switch ON and push the starter button.
○Then the starter motor should not turn when the starter

system circuit is normality.
If the engine is start, inspect the starter lockout switch,neutral switch and relay box.
If their parts are normality replace the ECU.

16-46 ELECTRICAL SYSTEM
Ignition System
2nd Check
Start the engine to the following conditions.

•

Condition
Transmission Gear → 1st Position
Clutch Lever → Pulled in
Sidestand → Up

○Turn the ignition switch ON and push the starter button.
○Then the starter motor should turn when the starter sys-

tem circuit is normality.
If the starter motor is not turn, inspect the starter lockout
switch, neutral switch and relay box.
If their parts are normality replace the ECU.

3rd Check
Inspect the engine for its secure stop after the following
operations are completed.
Run the engine to the following conditions.

••

Condition
Transmission Gear → 1st Position
Clutch Lever → Pulled in
Sidestand → Up

the sidestand on the ground, then the engine will stop.
• Set
If whichever may not be stopped, inspect the neutral
switch, starter lockout switch, sidestand switch and relaybox.
If their parts are normality, replace the ECU.

IC Igniter Inspection○The IC igniter is built in the ECU [A].

to the Interlock Operation Inspection, Ignition Sys• Refer
tem Troubleshooting chart and Fuel System (DFI) chapter
for ECU Power Supply Inspection.

ELECTRICAL SYSTEM 16-47
Ignition System

16-48 ELECTRICAL SYSTEM
Ignition System
Ignition System Circuit

1. Ignition Switch
2. Engine Stop Switch
3. Spark Plugs
4. Stick Coils
5. Water-proof Joint C
6. Speed Sensor
7. Subthrottle Sensor
8. Main Throttle Sensor
9. Water-proof Joint D
10. Vehicle-down Sensor
11. Water-proof Joint E

12. Water Temperature Sensor
13. Neutral Switch
14. Crankshaft Sensor
15. Oxygen Sensor
16. Meter Unit
17. Water-proof Joint A
18. Water-proof Joint B
19. Starter Lockout Switch
20. Oxygen Sensor Heater Fuse
10 A
21. ECU Fuse 15 A

22. Ignition Fuse 10 A
23. Fuse Box
24. ECU Main Relay
25. Relay Box
26. Main Fuse 30 A
27. Starter Relay
28. Battery 12 V 10 Ah
29. Frame Ground
30. Sidestand Switch
31. Joint Connector
32. ECU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.

• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System(DFI) chapter)
Right Center Fairing (see Center Fairing Removal in the
Frame chapter)
Slide back the rubber cap [A].
Remove the starter motor cable terminal nut [B].

••the mounting bolts [A].
• Remove
Pull
out
the
starter motor [B].
•Starter Motor Installation
CAUTION
Do not tap the starter motor shaft or body. Tapping
the shaft or body could damage the motor.
installing the starter motor, clean the starter mo• When
tor legs [A] and crankcase [B] where the starter motor isgrounded.
the O-ring [A] with a new one.
• ReplaceApplygreaseto the O-ring.
• Apply a non-permanent
agent to the threads of• the bolts and tighten the locking
bolts.
Torque - Starter Motor Mounting Bolts: 9.8 N·m (1.0 kgf·m,
87 in·lb)

the starter motor cable.
• Install
Tighten:•

Torque - Starter Motor Cable Terminal Nut: 6.0 N·m (0.60
kgf·m, 53 in·lb)

16-50 ELECTRICAL SYSTEMElectric Starter System
Starter Motor Disassembly

the starter motor (see Starter Motor Removal).
• Remove
Take
off
the
motor through bolts [A] and remove• the both endstartercovers [B] and pull the armature out of theyoke [C].

• Remove:
Terminal Locknut and Washers•

O-ringRemove the brush plate assy [A] from the yoke [B].

• Remove the brush plate [A] from the plate cover [B].
NOTE

○Do not remove the negative carbon brushes form thebrush plate.

Starter Motor Assembly

the brush plate [A] to the plate cover [B] as shown.
• Install
Installthe brush plate assy to the yoke.
•

the springs [A] with the clips [B].
• ClampFit
thearmature• Remove the clips.[C] to the brush plate assy [D].
•ELECTRICAL SYSTEM 16-51
Electric Starter System
the new O-ring [A] as shown.
• Install
Install:• Washers [B] and Terminal Locknut [C]• Tighten:

Torque - Starter Motor Terminal Locknut:
kgf·m, 97 in·lb)

11 N·m (1.1

the lines [A] on the yoke with the end cover lines [B].
• Align
Tightenthe through bolts.
•
Torque - Starter Motor Through Bolts: 4.9 N·m (0.50 kgf·m,
43 in·lb)

Brush Inspection

the length of each brush [A].
• MeasureIf any is worn down to the service limit, replace the brushplate assy [B] and the terminal bolt assy [C].
Starter Motor Brush Length
Standard:
12 mm (0.47 in.)Service Limit: 6.0 mm (0.24 in.)Commutator Cleaning and Inspection

the commutator surface [A] if necessary with fine
• Smoothemery cloth [B], and clean out the grooves.

the diameter [A] of the commutator [B].
• MeasureIf the commutator diameter is less than the service limit,
replace the starter motor with a new one .
Commutator DiameterStandard:
28 mm (1.10 in.)Service Limit:

27 mm (1.06 in.)

16-52 ELECTRICAL SYSTEMElectric Starter System
Armature Inspection

Using the × 1 Ω hand tester range, measure the resis• tance
between any two commutator segments [A].
Special Tool - Hand Tester: 57001-1394•

If there is a high resistance or no reading (∞) between any
two segments, a winding is open and the starter motor
must be replaced.
Using the highest hand tester range, measure the resistance between the segments and the shaft [B].
If there is any reading at all, the armature has a short andthe starter motor must be replaced.

NOTE○Even if the foregoing checks show the armature to begood, it may be defective in some manner not readily
detectable with the hand tester. If all other starter motorand starter motor circuit components check good, but
the starter motor still does not turn over or only turns
over weakly, replace the starter motor with a new one.

Brush Lead Inspection

Using the × 1 Ω hand tester range, measure the resis• tanceas shown.
Terminal Bolt and Positive Brushes [A]Brush Plate and Negative Brushes [B]Special Tool - Hand Tester: 57001-1394

If there is not close to zero ohms, the brush lead has an
open. Replace the terminal bolt assy and/or the brushplate assy.

Brush Plate and Terminal Bolt Inspection

the highest hand tester range, measure the resis• Usingtance as shown.
Terminal Bolt and Brush Plate [A]Terminal Bolt and Negative Brush Holders [B]Terminal Bolt and Yoke [C]Special Tool - Hand Tester: 57001-1394

If there is any reading, the brush plate assy and/or terminal bolt assy have a short. Replace the brush plate assy
and the terminal bolt assy.

ELECTRICAL SYSTEM 16-53
Electric Starter System
Starter Relay Inspection• Remove:
Bolt [A] and Cover [B]the connector [A].
• Disconnect
Disconnect
thestarter motor cable [B] and battery positive• (+) cable [C] fromthe starter relay [D].

CAUTIONThe battery positive (+) cable with the rubber cap isconnected directly to the battery positive (+) terminal even when the ignition switch off, so take care
not to short the removed cable to chassis ground.
the hand tester [A] and 12 V battery [B] to the• Connect
starter relay [C] as 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 Ω range
When battery is connected → 0 Ω
When battery is disconnected → ∞ Ω16-54 ELECTRICAL SYSTEMElectric Starter System
Electric Starter Circuit

1. Ignition Switch
2. Water-proof Joint B
3. Starter Lockout Switch
4. Ignition Fuse 10 A
5. Fuse Box
6. Starter Circuit Relay
7. Relay Box
8. Starter Motor
9. Starter Relay
10. Main Fuse 30 A
11. Battery 12 V 10 Ah
12. Sidestand Switch
13. Frame Ground
14. Joint Connector
15. Neutral Switch
16. Water-proof Joint C
17. Starter Button
18. Engine Stop Switch

ELECTRICAL SYSTEM 16-55
Lighting System
This motorcycle adopt the daylight system and have aheadlight relay in the relay box. 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 starterbutton is released and stays on until the ignition switch isturned off. The headlight will go out momentarily whenever
the starter button is pressed and come back on when the
button is released.

Headlight Beam Horizontal Adjustment

to the Headlight Aiming Inspection in the Periodic• Refer
Maintenance chapter.

Headlight Beam Vertical Adjustment

to the Headlight Aiming Inspection in the Periodic• Refer
Maintenance chapter.

Headlight Bulb Replacement• Remove:
Upper Inner Fairing (see Upper Inner Fairing Removal
in the Frame chapter)
Headlight Connector [A]Headlight Bulb Dust Cover [B]• Remove:
Hook [A]Headlight Bulb [B]

CAUTION
When handling the quartz-halogen bulb, nevertouch the glass portion with bare hands. Always
use a clean cloth. Oil contamination from hands or
dirty rags can reduce bulb life or cause the bulb to
explode.

NOTE○Clean off any contamination that inadvertently gets on
the bulb with alcohol or soap and water solution.

the headlight bulb.
• ReplaceFit
theprojection[A] of the bulb in the hollow [B] of the• headlight.
• Install the hook [C].

16-56 ELECTRICAL SYSTEM
Lighting System
the dust cover [A] onto the bulb [B] firmly as shown.
• FitGood[C]•

Bad [D]
After installation, adjust the headlight aim (see Headlight
Aiming Inspection in the Periodic Maintenance chapter).

City Light Bulb Replacement (Europe Models)the meter cover (see Meter Unit Removal/Instal• Remove
lation).
the connector [A].
• Disconnect• Pull out the socket [B] together with the bulb.

• Pull the bulb [A] out of the socket.
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.
Headlight Removal/Installation• Remove:
Upper Fairing (see Upper Fairing Removal in the Frame•

chapter)Mounting Bolts [A]Installation is the reverse of removal.

Tail/Brake Light Removal• Remove:
Seat Covers (see Seat Cover Removal in the Frame•••

chapter)
Disconnect the connector [A].
Unscrew the mounting bolts [B].
Remove the tail/brake light [C].

Tail/Brake Light Installation• Installation is the reverse of removal.

ELECTRICAL SYSTEM 16-57
Lighting System
License Plate Light Bulb Replacement• Remove:
Screws [A]•

License Plate Light Cover [B]Push and turn the bulb counterclockwise and remove it.

the new bulb [A] by aligning its upper and lower pins
• Insert[B] with the upper and lower grooves [C] in the socket, andturn the bulb clockwise.
○Turn the bulb about 15°.
Install the license plate light cover.
Tighten:••

Torque - License Plate Light Cover Screws:(0.090 kgf·m, 8 in·lb)

0.90 N·m

16-58 ELECTRICAL SYSTEM
Lighting System
Headlight/Tail Light Circuit

1. Ignition Switch
2. Water-proof Joint A
3. Water-proof Joint B
4. Position Light
5. Headlight (High Beam)
6. Headlight (Low Beam)
7. Dimmer Switch
8. Passing Switch
9. Headlight Relay
10. Relay Box
11. Starter Relay

Turn Signal Light Bulb Replacement

the screw [A] and remove the lens [B].
•○Unscrew
Turn the lens counterclockwise.

12. Main Fuse 30 A
13. Battery 12 V 10 Ah
14. Frame Ground
15. Tail/Brake Light
16. License Plate Light 12 V 5 W
17. Joint Connector
18. Water-proof Joint C
19. Regulator/Rectifier
20. Fuse Box
21. Headlight Fuse 10 A
22. Tail Light Fuse 10 A

ELECTRICAL SYSTEM 16-59
Lighting Systemand turn the bulb [A] counterclockwise and remove• Pushit.

the new bulb [A] by aligning its upper and lower pins
• Insert[B] with the upper and lower grooves [C] in the socket, andturn the bulb clockwise.
○Turn the bulb about 15°.
Install the projections of the lens to the dints of the turnsignal light.

•

Turn Signal Relay Inspection• Remove:
Left Upper Inner Fairing (see Upper Inner Fairing Removal in the Frame chapter)
Turn Signal Relay [A]one 12 V battery and turn signal lights as indi• Connectcated in the figure, and count how may times the lights
flash for one minute.
Turn Signal Relay [A]Turn Signal Lights [B]12 V Battery [C]
If the lights do not flash as specified, replace the turn signal relay.
Testing Turn Signal Relay
Load
The Number of Turn
Signal Lights

Wattage (W)Flashing Times(c/m*)

1**

21 or 23140 ∼ 250

2

42 or 4675 ∼ 95(*): Cycle(s) per minute(**): Corrected to “one light burned out”.

16-60 ELECTRICAL SYSTEM
Lighting System
Turn Signal Light Circuit

1. Meter Unit
2. Water-proof Joint A
3. Water-proof Joint B
4. Front Right Turn Signal Light
5. Front Left Turn Signal Light
6. Turn Signal Relay
7. Hazard Button
8. Turn Signal Switch
9. Fuse Box
10. Turn Signal Relay Fuse 10 A
11. Main Fuse 30 A
12. Battery 12 V 10 Ah
13. Frame Ground
14. Rear Right Turn Signal Light
15. Rear Left Turn Signal Light
16. Joint Connector
17. Water-proof Joint C
18. Ignition Switch
19. Frame GroundELECTRICAL SYSTEM 16-61
Air Switching Valve
Air Switching Valve Operation Test

the fuel tank (see Fuel Tank Removal in the Fuel
• Remove
System (DFI) chapter).
the air switching valve hose [A] out of the air cleaner• Pullbase.

the air switching valve hose end outside of the• Takeframe.
the fuel tank (see Fuel Tank Installation in the• Reinstall
Fuel System (DFI) chapter).
the engine and run it at idle speed.
• StartPlug[A]
switching valve hose [B] end with your• finger andthefeelairvacuum
pulsing in the hose.

•

If there is no vacuum pulsation, check the hose line forleak. If there is no leak, check the air switching valve (seeAir Switching Valve Unit Test).
Apply a soap and water solution or rubber lubricant to theend of the air switching hose and install the hose on thefitting.

Air Switching Valve Unit Test

the air switching valve (see Air Switching Valve• Remove
Removal in the Engine Top End chapter).
the hand tester [A] to the × Ω range and connect it to• Set
the air switching valve terminals as shown.
Special Tool - Hand Tester: 57001-1394
Air Switching Valve ResistanceStandard:
18 ∼ 22 Ω at 20°C (68°F)

If the resistance reading is except the specified value, replace it with a new one.
the 12 V battery [A] to the air switching valve• Connect
terminals as shown.

16-62 ELECTRICAL SYSTEMAir Switching Valvethe air to the inlet air duct [A], and make sure does
• Blow
not flow the blown air from the outlet air duct [B].

the 12 V battery.
• Disconnect
Blow
the
air
to the inlet air duct [A], and make sure does
• not flow the blown
air from the outlet air duct [B].
If the air switching value does not operate as described,
replace it with a new one.

NOTE

○To check air flow through the air switching valve, justblow through the air cleaner hose [C].

ELECTRICAL SYSTEM 16-63
Radiator Fan System
Fan Motor Inspection

the connector [A].
• Disconnect
Usinganauxiliaryleads, supply battery power to the fan• motor.
If the fan does not rotate, the fan motor is defective andmust be replaced.

Radiator Fan Circuit

1. Relay Box
2. Radiator Fan Relay
3. ECU Main Relay
4. Fuse Box
5. Fan Fuse 15 A
6. ECU Fuse 15 A
7. Main Fuse 30 A
8. Battery 12 V 10 Ah
9. Frame Ground

10. Joint Connector
11. ECU
12. Water Temperature Sensor
13. Water-proof Joint E
14. Water-proof Joint C
15. Radiator Fan
16. Ignition Switch
17. Water-proof Joint A
18. Water-proof Joint B

16-64 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
Meter Unit Removal/Installation• Remove:
Windshield (see Windshield Removal in the Frame
chapter)Upper Inner Fairings (see Upper Inner Fairing Removal
in the Frame chapter)
Screws [A] (Both Side) and Meter Cover [B]the dust cover [A] and remove the connector [B].
• SlideRemove• [C]. the meter unit by taking off the mounting nuts

CAUTION
Place the meter unit so that the face is up. If a meter
unit is left upside down or sideways for any lengthof time, it will malfunction.

is the reverse of removal.
• Installation
Insertthehooks[A] into the slots [B].
•

Meter, Gauge Disassembly• Remove:
Meter Unit (see Meter Unit Removal/Installation)
Screws [A]Lower Meter Cover [B]the meter assembly [A] and upper meter cover• Separate[B].

ELECTRICAL SYSTEM 16-65
Meter, Gauge, Indicator Unit
Electronic Combination Meter Unit Inspection

the meter unit [A] (see Meter Unit Removal/In• Remove
stallation).
[1] Ignition[2] Fuel Level Warning Indicator Light (LED) (–)[3] Unused (EX650A Models)
ABS Indicator Light (LED)(–)(EX650B Models)[4] Unused[5] Neutral Indicator Light (LED) (–)[6] FI Indicator Light (LED) (–)[7] Tachometer Signal[8] Water Temperature Sensor (–)[9] Ground (–)[10] Battery (+)[11] Oil Pressure Warning Indicator Light (LED) (–)[12] Speed Sensor Supply Voltage[13] Right Turn Signal Indicator Light (LED) (+)[14] Left Turn Signal Indicator Light (LED) (+)[15] High Beam Indicator Light (LED) (+)[16] Speed Sensor Signal

CAUTION
Do not drop the meter unit. Place the meter unit sothat it faces upward. If the meter unit is left upside
down or sideways for a long time or dropped, it will
malfunction. Do not short each terminals.
Liquid Crystal Display (LCD) Segment Check
Using the auxiliary wires, connect the 12 V battery to themeter unit connector as follows.
○Connect the battery positive terminal to the terminal [10].
○Connect the battery negative terminal to the terminal [9].
○The needles of the meter move.

•• Connect the terminal [1] to the terminal [10].

16-66 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit

○When the terminals are connected, the LCD segment [A]and LED warning lights [B] appear.
If the LCD segment and LED warning lights will not appear, replace the meter assembly.
Disconnect the terminal [1].
○The LCD segment and LED warning lights disappear.
If the segment do not disappear, replace the meter assembly.

•

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 CLOCK, ODO, TRIP
A and TRIP B displays each time the MODE button [A] ispressed.
○If the fuel level gauge flashed, display change to CLOCK,
FUEL, ODO, TRIP A and TRIP B.
If the display function does not work, replace the meter
assembly.

••

the clock mode.
• Indicate
Check
that
the RESET button in CLOCK mode is• pushed for whenmore than two seconds, the meter display
turns to the clock set mode.

○Both the hour and minute display start flashing.

ELECTRICAL SYSTEM 16-67
Meter, Gauge, Indicator Unit
the HOUR/MINUTE setting mode, press the RESET• Inbutton
again to effect the HOUR setting mode.

○The hour display flashes on the display.

• Press the MODE button to set the hour.

the HOUR setting mode, press the RESET button to• Ineffectthe MINUTE setting mode.

○The minute display flashes on the display.

• Press the MODE button to set the minute.

the MINUTE setting mode, press the RESET button to• Inreturnto the HOUR/MINUTE setting mode.
Press• process.the MODE button to complete the time setting○The clock starts counting the seconds as soon as the
MODE button is pressed.

Speedometer Check
Connect the 12 V battery and terminals in the same manner as specified in the “Liquid Crystal Display (LCD) Segments Check”.
The speed equivalent to the input frequency is indicated in
the oscillator [A], if the square wave (illustrated as shown)
would be input into the terminal [16].
○Indicates approximately 60 mph in case the input frequency would be approximately 169.0 Hz.
○Indicates approximately 60 km/h in case the input frequency would be approximately 105.6 Hz.

••

the oscillator is not available, the speedometer can be• Ifchecked
as follows.

○Install the meter unit.
○Raise the rear wheel off the ground with stand.
○Turn on the ignition switch.
○Rotate the rear wheel by hand.
○Check that the speedometer shows the speed.

If the speedometer does not work, check the speed sensor electric source voltage and speed sensor.
The electric source voltage and speed sensor are normal,
replace the meter assembly.

16-68 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
Speed Sensor Electric Source Check
Connect the 12 V battery and terminals in the same manner as specified in the “Liquid Crystal Display (LCD) Segments Check”.
Set the hand tester to the DC 25 V range and connect itto the terminals [12] and [9].
If the voltage is less than 8 V, replace the meter assembly.

••

Odometer Check
Check the odometer with the speedometer in the sameway.
If value indicated in the odometer is not added, replace
the meter assembly.

•

NOTE

○The data is maintained even if the battery is disconnected.

○When the figures come to 999999, they are stopped andlocked.

Trip A/B Meter Check
Check the trip A or B meters with the speedometer in thesame way.
If value indicated in the trip A/B meters is not added, replace the meter assembly.
Check that when the RESET button is pushed for morethan two seconds, the figure display turns to 0.0.
If the figure display does not indicate 0.0, replace the meter assembly.

••

Tachometer Check
Connect the 12 V battery and terminals in the same manner as specified in the “Liquid Crystal Display (LCD) Segments Check”.
The revolutions per minute (rpm) equivalent to the input
frequency is indicated in the oscillator [A] if the squarewave (illustrated as shown) would be input into the terminal [7].
○Indicates approximately 6 000 rpm in case the input frequency would be approximately 200 Hz.

••

the oscillator is not available, the tachometer can be• Ifchecked
as follows.

○Connect the 12 V battery and terminals in the same manner as specified in the “Liquid Crystal Display (LCD) Segments Check”.
○Using an auxiliary wire, quick open and connect the terminal [1] to the terminal [7] repeatedly.
○Then the tachometer needle [A] should flick [B].
If the needle does not flick, replace the meter assembly.

ELECTRICAL SYSTEM 16-69
Meter, Gauge, Indicator Unit
Indicator Lights Inspection
Connect the 12 V battery and terminals in the same manner as specified in the “Liquid Crystal Display (LCD) Segments check”.
Neutral Indicator Light (LED) [A]FI Indicator Light (LED) [B]Oil Pressure Warning Indicator Light (LED) [C]Right Turn Signal Indicator Light (LED) [D]Left Turn Signal Indicator Light (LED) [E]High Beam Indicator Light (LED) [F]Fuel Level Warning Indicator Light (LED) [G]Water Temperature Warning Indicator Light (LED)[H]
ABS Indicator Light (LED)(EX650B Models)[I]•the auxiliary leads, connect a 12 V battery to the• Usingmeter unit connector as follows.
Water Temperature Warning Indicator Light (LED)Battery Negative (–) Terminal to Terminal [8]Oil Pressure Warning Indicator Light (LED)Battery Negative (–) Terminal to Terminal [11]Fuel Level Warning Indictor Light (LED)Battery Negative (–) Terminal to Terminal [2]16-70 ELECTRICAL SYSTEM
Meter, Gauge, Indicator UnitHigh Beam Indicator Light (LED)Battery Positive (+) Terminal to Terminal [15]Neutral Indicator Light (LED)Battery Negative (–) Terminal to Terminal [5]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]FI Indicator Light (LED)Battery Negative (–) Terminal to Terminal [6]each lights (LED) does not go on, replace the meter• Ifassembly.

ELECTRICAL SYSTEM 16-71
Meter, Gauge, Indicator Unit
EX650B Models
ABS Indicator Light (LED)Battery Negative (–) Terminal to Terminal [3]the light (LED) keeps going on, replace the meter as• Ifsembly.

16-72 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
Meter Circuit

1. Ignition Switch
2. Frame Ground
3. Meter Unit
4. Water-proof Joint B
5. ECU Fuse 15 A
6. Ignition Fuse 10 A
7. Fuse Box
8. Main Fuse 30 A
9. Battery 12 V 10 Ah
10. Frame Ground

11. Fuel Reserve Switch
12. Joint Connector
13. ECU
14. Oil Pressure Switch
15. Neutral Switch
16. Water Temperature Sensor
17. Water-proof Joint E
18. Speed Sensor
19. Water-proof Joint C
20. ABS Hydraulic Unit (EX650B Models)ELECTRICAL SYSTEM 16-73
Switches and Sensors
Brake Light Timing Inspection

to the Brake Light Switch Operation Inspection in• Referthe Periodic Maintenance chapter.

Brake Light Timing Adjustment

to the Brake Light Switch Operation Inspection in• Referthe Periodic Maintenance chapter.

Switch Inspectiona hand tester, check to see that only the con• Using
nections shown in the table have continuity (about zeroohms).
○For the switch housings and the ignition switch, refer tothe tables in the Wiring Diagram.
If the switch has an open or short, repair it or replace itwith a new one.
Special Tool - Hand Tester: 57001-1394
Rear Brake Light Switch Connections

Sidestand Switch Connections

Neutral Switch Connections

Oil Pressure Switch Connections**: Engine lubrication system is in good condition.

16-74 ELECTRICAL SYSTEM
Switches and Sensors
Water Temperature Sensor Inspection

the water temperature sensor (see Removal/In• Remove
stallation in the Fuel System (DFI) chapter).
the sensor [A] in a container of coolant so that• Suspend
the temperature-sensing projection [C] and threaded por-•tion [C] are submerged.
Suspend an accurate thermometer [B] with temperature-sensing projection located in almost the same depth.

NOTE○The sensor and thermometer must not touch the container side or bottom.
the container over a source of heat and gradu• Place
ally raise the temperature of the coolant while stirring the•coolant gently.
Using the hand tester, measure the internal resistance ofthe sensor.
If the hand tester does not show the specified values, replace the sensor.

Water Temperature Sensor Resistance
Temperature

Resistance (kΩ)–20°C (–4°F)*18.80 ±2.37

0°C (32°F)*(about 6.544)

40°C (104°F)

1.136 ±0.095

100°C (212°F)

0.1553 ±0.0070*: Reference Information

Speed Sensor Removal

the left center fairing (see Center Fairing Re• Remove
moval in the Frame chapter).
the speed sensor lead connector [A].
• Disconnect
Removetheengine sprocket cover (see Engine Sprocket• Removal in the
Final Drive chapter).

• Remove:
Bolt [A]Speed Sensor [B]

Speed Sensor Installationis the reverse of removal.
• InstallationApplyanon-permanent
locking agent to the sensor bolt,• and tighten it.
Torque - Speed Sensor Bolt: 7.8 N·m (0.80 kgf·m, 69 in·lb)

ELECTRICAL SYSTEM 16-75
Switches and Sensors
Speed Sensor Inspection

the speed sensor (see Speed Sensor Removal).
• Remove
Connect
speed sensor connector [A] with the battery• [B], 10 kΩtheresistor[C] and hand tester [D] as shown.
Setthetestertothe
DC 25 V range.
•
Special Tool - Hand Tester: 57001-1394[A] each side of the speed sensor surface with the• Tracescrew driver.

○Then the tester indicator should flick [B].

If the tester indicator does not flick, replace the speed
sensor.

Oxygen Sensor Removal (Europe Models)• Remove:
Left Lower Fairing (see Lower Fairing Removal in the•

Frame chapter)
Disconnect the oxygen sensor lead connector [A].

• Remove the oxygen sensor [A].

Oxygen Sensor Installation (Europe Models)
CAUTION
Never drop the oxygen sensor [A], especially on ahard surface. Such a shock to the unit can damage
it. Do not touch the sensing part [B] and filter holes[C] of the sensor to prevent oil contact. Oil contamination from hands can reduce sensor performance.

• Tighten:

Torque - Oxygen Sensor: 44.1 N·m (4.50 kgf·m, 32.5 ft·lb)

the oxygen sensor lead correctly (see Cable, Wire,• Run
and Hose Routing section in the Appendix chapter).

16-76 ELECTRICAL SYSTEM
Switches and Sensors
Oxygen Sensor Inspection (Europe Models)to the Oxygen Sensor Inspection in the Fuel System• Refer(DFI) chapter.

Fuel Reserve Switch Inspection

the fuel tank with fuel.
• FillClose• Removethethefuelfueltanktankcap(seesurely.
• System (DFI) chapter). Fuel Tank Removal in the Fuelthe test light [A] (12 V 3.4 W bulb a socket with• Connect
leads) and the 12 V battery [B] to the fuel pump connector[C].
Connections:
Battery (+) → 12 V 3.4 W Bulb (One Side)
12 V 3.4 W Bulb (Other Side) → BL Lead Terminal
Battery (–) → BK Lead Terminal

If the test light turn on, the reserve switch is defective.
Replace the fuel level sensor.
the fuel pump (see Fuel Pump Removal in the• Remove
Fuel System (DFI) chapter).
the test light (12 V 3.4 W bulb in a socket with• Connect
leads) and the 12 V battery to the fuel pump connector as
shown.
12 V Battery [A]Test Light [B]Fuel Pump Connector [C]Fuel Reserve Switch [D]If the test light doesn’t light, replace the fuel pump.

NOTE○It may take a long time to turn on the test light in casethat the fuel reserve switch is inspected just after thefuel pump is removed. Leave the fuel reserve switch
with leads for inspection connected for few minutes.

ELECTRICAL SYSTEM 16-77
Relay Box
The relay box [A] has relays and diodes. The relays anddiodes can not be removed.

Relay Box Removal• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System•(DFI) chapter)
Take out the relay box [A] and disconnect the connectors[B].

Relay Circuit Inspection

the relay box (see Relay Box Removal).
• RemoveCheckconductivityof the following numbered terminals• by connecting the handtester and one 12 V battery to therelay box as shown (see Relay Box Internal Circuit in thissection).
If the tester does not read as specified, replace the relay
box.
Relay Circuit Inspection (with the battery disconnected)
Headlight Relay
ECU Main Relay
Fuel Pump Relay
Starter Circuit Relay
Fan Relay

Tester Connection

Tester Reading (Ω)

1-3

∞

7-6

∞

4-5

Not ∞*

7-8

∞

9-10

Not ∞*

11-16

∞

11-12

∞

17-20

∞

18-19

Not ∞**: The actual reading varies with the hand tester used.

16-78 ELECTRICAL SYSTEM
Relay Box
Relay Circuit Inspection (with the battery connected)
Battery
Connection(+) (–)

TesterConnection

TesterReading (Ω)

2-11

1-3

0

4-5

7-6

0

ECU Main Relay
Fuel Pump Relay

9-10

7-8

0

Fan Relay

18-19

17-20

0

Battery
Connection(+) (–)

Tester Connection
DC 25 V Range

TesterReading (V)

16-12

11-12

Battery
VoltageStarter
Circuit Relay(+): Apply positive lead.
(–): Apply negative lead.

Diode Circuit Inspection

the relay box (see Relay Box Removal).
• Removeconductivity of the following pairs of terminals (see• Check
Relay Box Internal Circuit in this section).
Diode Circuit Inspection
Tester Connection

1-11, 2-11, 12-13, 12-15, 12-16, 13-14,
13-15

The resistance should be low in one direction and morethan ten times as much in the other direction. If any diodeshows low or high in both directions, the diode is defective
and the relay box must be replaced.

NOTE○The actual meter reading varies with the meter or tester
used and the individual diodes, but generally speaking,the lower reading should be from zero to one half thescale.

ELECTRICAL SYSTEM 16-79
Relay Box
Relay Box Internal Circuit

A: Headlight Relay
B: ECU Main Relay
C: Fuel Pump Relay
D: Starter Circuit Relay
E: Fan Relay

16-80 ELECTRICAL SYSTEM
Fuse
30 A Main Fuse Removal• Remove:
Left Side Cover (see Side Cover Removal in the Frame•

chapter)
Cover (see Starter Relay Inspection)
Connector [A]Pull out the main fuse [B] from the starter relay with needle
nose pliers.

Fuse Box Fuse Removal

the seat (see Seat Removal in the Frame chap• Removeter).
• Unlock the hook [A] to lift up the lid [B].

the fuses [A] straight out of the fuse box with needle• Pullnose pliers.

15 A ECU Fuse Removal• Remove:
Seat (see Seat Removal in the Frame chapter)• Unlock the hook [A] to pull the lid [B].

• Pull out the ECU fuse [A] from the fuse box.

ELECTRICAL SYSTEM 16-81
Fuse
Fuse Installation

fails during operation, inspect the electrical sys• Iftema fuse
to determine the cause, and then replace it with a•

new fuse of proper amperage.
Install the fuse box fuses on the original position as specified on the lid.

Fuse Inspection

the fuse (see 30 A Main/Fuse Box /15 A ECU• Remove
Fuse Removal).
the fuse element.
• Inspect
If it is blown out, replace the fuse. Before replacing a
blown fuse, always check the amperage in the affectedcircuit. If the amperage is equal to or greater than thefuse rating, check the wiring and related components fora short circuit.
Housing [A]Fuse Element [B]Terminals [C]
Blown Element [D]

CAUTION
When replacing a fuse, be sure the new fusematches the specified fuse rating for that circuit.
Installation of a fuse with a higher rating may cause
damage to wiring and components.

APPENDIX 17-1

Appendix
Table of Contents
Cable, Wire, and Hose Routing ..............................................................................................
Troubleshooting Guide ...........................................................................................................

17-2
17-46

17

17-2 APPENDIX
Cable, Wire, and Hose Routing

APPENDIX 17-3
Cable, Wire, and Hose Routing
1. Clamp (From the on sequentially, through the ignition switch lead, left switch housing lead andmain harness.)
2. Left Switch Housing Lead Connector
3. Clamp (Insert the clamp from air cleaner side.)
4. Air Switching Valve Lead Connector
5. Main Harness
6. Clamp
7. Clamp (Insert the clamp in the frame.)
8. Clamp (Insert the clamp in the frame.)
9. Clamp
10. Inlet Temperature Sensor Lead Connector
11. Clamp (Insert the clamp from air cleaner side.)
12. Ignition Switch Lead Connector
13. Clamp (Clamp the left switch housing lead (main harness side), ignition switch lead (main harness side) and air switching valve lead.)
14. Through the air switching valve lead on the left switch housing lead.

17-4 APPENDIX
Cable, Wire, and Hose Routing

APPENDIX 17-5
Cable, Wire, and Hose Routing
1. Relay Box
2. Main Harness
3. Clamp (Insert the clamp in the bracket.)
4. Battery Negative Cable
5. Battery Positive Cable
6. ECU Connectors
7. Clamp
8. Clamp
9. Tail Light Connector
10. License Plate Light Connector
11. Rear Left Turn Signal Light Connector
12. Rear Right Turn Signal Light Connector
13. Clamp (Insert the clamp in the rear fender rear.)
14. Frame Ground
15. Clamp
16. Water-proof Joint
17. Clamp
18. Fuse Box
19. Clamp
20. Clamp
21. Band
22. Band23. Clamp
24. To the Vehicle-down Sensor, Crankshaft Sensor and Rear Brake Switch
25. Clamp (Clamp the regulator/rectifier lead, and insert the clamp in the rear fender front.)
26. Battery Negative Lead Connector
27. Fuel Pump Lead
28. Starter Motor Cable
29. To Starter Relay
30. Regulator/Rectifier Lead
31. View A

17-6 APPENDIX
Cable, Wire, and Hose Routing
EX650B Models

APPENDIX 17-7
Cable, Wire, and Hose Routing
1. To Main Harness
2. Battery Positive Cable
3. ABS Kawasaki Self-diagnosis System Connector (Insert the connector to the bracket.)
4. ABS Motor Relay Fuse
5. ABS Solenoid Valve Relay Fuse

17-8 APPENDIX
Cable, Wire, and Hose Routing

APPENDIX 17-9
Cable, Wire, and Hose Routing
1. Inlet Pressure Sensor
2. Turn Signal Relay
3. Air Cleaner Drain Tube
4. From this side, through the fuel tank drain tube, corrugated tube and air cleaner drain tube
between chain guide and engine.
5. To the Water Temperature Sensor
6. Oxygen Sensor Lead Connector
7. Clamp (Through the sidestand switch lead and oxygen sensor lead in the clamp.)
8. Oxygen Sensor Lead
9. Clamp (Through the drain hose in the clamp.)
10. Drain Hose
11. Sidestand Switch Lead
12. Corrugated Tube
13. Alternator Lead Connector
14. Sidestand Switch Lead Connector
15. Speed Sensor Lead Connector
16. Main Throttle Sensor Lead Connector
17. Tube
18. Neutral Switch Lead
19. Drain Hose (Through the drain hose between main harness and air cleaner.)
20. Clamp (Insert the clamp in the cross pipe.)17-10 APPENDIX
Cable, Wire, and Hose Routing

APPENDIX 17-11
Cable, Wire, and Hose Routing
1. Clamp (Through the right switch housing lead, and insert the clamp in the frame.)
2. Clutch Cable
3. Throttle Cables
4. Clamp
5. Right Switch Housing Lead
6. Clamp (Through the clutch cable in the clamp.)
7. Frame (Through the coolant hose in the frame.)
8. Coolant Hose
9. Clamp

17-12 APPENDIX
Cable, Wire, and Hose Routing
EX650B Models

APPENDIX 17-13
Cable, Wire, and Hose Routing
1. Brake Hose
2. Clutch Cable
3. Throttle Cables
4. Clamp
5. Right Switch Housing Lead
6. Clamp (Through the clutch cable in the clamp.)
7. Frame (Through the coolant hose in the frame.)
8. Coolant Hose
9. Clamp
10. Clamp (Clamp the right switch housing lead connector.)
11. Bracket
12. Throttle Cables
13. Through the brake hose at the right side of the throttle cables.

17-14 APPENDIX
Cable, Wire, and Hose Routing
EX650B Models

APPENDIX 17-15
Cable, Wire, and Hose Routing
1. Right Switch Housing Lead
2. Throttle Cable (Decelerator)
3. Throttle Cable (Accelerator)
4. Through the brake hose at the right side of the throttle cables.

17-16 APPENDIX
Cable, Wire, and Hose Routing

APPENDIX 17-17
Cable, Wire, and Hose Routing
1. Crankshaft Sensor Lead Connector
2. Clamp (Insert the clamp in the bracket.)17-18 APPENDIX
Cable, Wire, and Hose Routing

APPENDIX 17-19
Cable, Wire, and Hose Routing
1. Tail Light Connector
2. License Plate Light Connector
3. Rear Right Turn Signal Light Connector
4. Rear Left Turn Signal Light Connector
5. Clamp (Insert the clamp in the rear fender rear.)
6. Clamp (Insert the clamp in the rear fender rear.)
7. Diagnosis Connector
8. Clamp (Insert the clamp in the rear fender front.)
9. Rear Brake Light Switch Lead
10. Band (Clamp the main harness with the frame.)
11. Band
12. ABS Kawasaki Self-diagnosis System Connector (EX650B Models)17-20 APPENDIX
Cable, Wire, and Hose Routing

APPENDIX 17-21
Cable, Wire, and Hose Routing
1. Right Switch Housing Lead
2. Throttle Cables
3. Headlight (LO) Connector (Green Tape)
4. Headlight (HI) Connector
5. Brake Hose
6. Clamp
7. Ignition Switch Lead
8. Main Harness
9. Left Switch Housing Lead
10. Clutch Cable
11. Clamp (Insert the clamp to the inner fairing.)
12. Clamp
13. Clamp
14. Clamp (Clamp the left switch housing lead and ignition switch lead.)
15. 20 mm (0.79 in.)16. 50 mm (1.97 in.)

17-22 APPENDIX
Cable, Wire, and Hose Routing
EX650B Models

APPENDIX 17-23
Cable, Wire, and Hose Routing
1. Right Switch Housing Lead
2. Throttle Cables
3. Headlight (LO) Connector (Green Tape)
4. Headlight (HI) Connector
5. Brake Hose (Through the brake hose at the right side of the throttle cables.)6. Clamp
7. Ignition Switch Lead
8. Main Harness
9. Left Switch Housing Lead
10. Clutch Cable
11. Clamp (Insert the clamp to the inner fairing.)
12. Clamp
13. Clamp
14. Front Wheel Rotation Sensor Lead
15. Front
16. Baffle Plate
17. Clamp (Insert the clamp to the baffle plate.)
18. Front Wheel Rotation Sensor Lead Connector
19. Clamp (Clamp the left switch housing lead and ignition switch lead.)
20. 20 mm (0.79 in.)21. 50 mm (1.97 in.)

17-24 APPENDIX
Cable, Wire, and Hose Routing

APPENDIX 17-25
Cable, Wire, and Hose Routing
1. Clamp
2. Clamp
3. Clamp
4. Clamp (Clamp the subthrottle sensor lead and subthrottle valve actuator lead to the delivery
pipe.)
5. Ground Lead
6. Clamp
7. Subthrottle Sensor Lead Connector
8. Subthrottle Valve Actuator Lead Connector
9. Clamp (Clamp the harness.)
10. Clamp
11. Clamp
12. Stick Coil Lead Connector
13. Clamp (Clamp the stick coil lead.)
14. Clamp (Push the subthrottle valve actuator lead, and clamp the subthrottle sensor lead andsubthrottle valve actuator lead to the delivery pipe.)17-26 APPENDIX
Cable, Wire, and Hose Routing

APPENDIX 17-27
Cable, Wire, and Hose Routing
1. Regulator/Rectifier Lead
2. Clamp (Insert the clamp in the frame.)
3. Rear Brake Light Switch Lead Connector
4. Through the rear brake light switch lead and vehicle-down sensor lead from the front side of therear shockabsorber installation part.
5. Through the regulator/rectifier lead to the front opening of the rear fender front.
6. Vehicle-down Sensor Lead
7. Fuel Pump Lead Connector
8. Through the fuel pump lead to the hook of the rear fender front (Routing is done so that there
is no slack.).
9. Through the fuel pump lead to the slit of the cover.

17-28 APPENDIX
Cable, Wire, and Hose Routing
EX650B Models

APPENDIX 17-29
Cable, Wire, and Hose Routing
1. ABS Hydraulic Unit Lead (ECU) (Through the lead to the forward of frame cross pipe.)
2. ABS Hydraulic Unit
3. Through the rear wheel rotation sensor lead upper the starter motor cable and engine groundcable.
4. Through the regulator/rectifier lead in the clamp.
5. Through the rear wheel rotation sensor lead upper the brake hose.
6. Rear Wheel Rotation Sensor Lead
7. Through the regulator/rectifier lead under the brake fluid reservoir hose.
8. Through the vehicle-down sensor lead under the brake hose.
9. Clamp (Clamp the brake hose and rear wheel rotation sensor lead.)
10. Through the rear wheel rotation sensor lead upper the rear brake light switch lead.
11. Through the rear wheel rotation sensor lead under the brake hose.

17-30 APPENDIX
Cable, Wire, and Hose Routing
EX650B Models

APPENDIX 17-31
Cable, Wire, and Hose Routing
1. Front Wheel Rotation Sensor Lead
2. Ignition Switch Lead
3. Left Switch Housing Lead
4. Clamp (Clamp the front wheel rotation sensor lead.)
5. Main Harness
6. Clamp (Clamp the front wheel rotation sensor lead.)17-32 APPENDIX
Cable, Wire, and Hose Routing

APPENDIX 17-33
Cable, Wire, and Hose Routing
1. To Meter Unit
2. Clamp
3. To Front Right Turn Signal Light Lead
4. Left Switch Housing Lead
5. Ignition Switch Lead
6. Main Harness
7. To Front Left Turn Signal Light Lead

17-34 APPENDIX
Cable, Wire, and Hose Routing

APPENDIX 17-35
Cable, Wire, and Hose Routing
1. Clamp
2. Clamp (Insert the clamp to the inner fairing.)
3. Clamp (Insert the clamp to the upper fairing bracket.)17-36 APPENDIX
Cable, Wire, and Hose Routing
California ModelAPPENDIX 17-37
Cable, Wire, and Hose Routing
1. Through the hose between main harness and air cleaner housing.
2. To Fuel Tank (Red)
3. To Fuel Tank (Blue)
4. Left Side View
5. Through the hose between main harness and air cleaner housing.
6. Front
7. Lower Side View

17-38 APPENDIX
Cable, Wire, and Hose Routing

APPENDIX 17-39
Cable, Wire, and Hose Routing
1. Clamp (Insert the clamp in the front fender.)2. Brake Hose
3. Clamp
4. Clamp

17-40 APPENDIX
Cable, Wire, and Hose Routing
EX650B Models

APPENDIX 17-41
Cable, Wire, and Hose Routing
1. Clamp (Insert the clamp in the front fender.)2. Brake Hose

17-42 APPENDIX
Cable, Wire, and Hose Routing

APPENDIX 17-43
Cable, Wire, and Hose Routing
1. Brake Hose
2. Clamp
3. Clamp

17-44 APPENDIX
Cable, Wire, and Hose Routing
EX650B Models

APPENDIX 17-45
Cable, Wire, and Hose Routing
1. Brake Hose
2. Clamp
3. Clamp
4. Clamp

17-46 APPENDIX
Troubleshooting Guide
NOTE○Refer to the Fuel System chapter for mostof 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 morecommon difficulties.

Engine Doesn’t Start, Starting
Difficulty:
Starter motor not rotating:Starter lockout switch or neutral switch trouble
Starter motor trouble
Battery voltage low
Starter relay not contacting or operating
Starter button not contacting
Wiring open or shorted
Ignition switch trouble
Engine stop switch trouble
Fuse blown
Starter motor rotating but engine doesn’tturn over:Starter clutch trouble
Vehicle-down sensor (DFI) coming off
Engine won’t turn over:
Valve seizure
Valve lifter seizure
Cylinder, piston seizure
Crankshaft seizure
Connecting rod small end seizure
Connecting rod big end seizure
Transmission gear or bearing seizure
Camshaft seizureStarter idle gear seizure
No fuel flow:
No fuel in tank
Fuel pump trouble
Fuel tank air vent obstructed
Fuel filter clogged
Fuel line clogged
Engine flooded:
Clean spark plug and adjust plug gap
Starting technique faulty(When flooded, do not crank the engine withthe throttle fully opened. This promotes
engine flood because more fuel is supplied
automatically by DFI.)No spark; spark weak:
Vehicle-down sensor (DFI) coming off
Ignition switch not ON
Engine stop switch turned OFF
Clutch lever not pulled in or gear not in neutral
Battery voltage low

Spark plug dirty, broken, or gap maladjusted
Stick coil shorted or not in good contact
Stick coil trouble
Spark plug incorrect
IC igniter in ECU trouble
Neutral, starter lockout, or side stand switch
troubleCrankshaft sensor trouble
Ignition switch or engine stop switch
shortedWiring shorted or open
Fuse blown
Fuel/air mixture incorrect:
Bypass screw and/or idle adjusting screw
maladjusted
Air passage clogged
Air cleaner clogged, poorly sealed, or missing
Compression Low:
Spark plug loose
Cylinder head not sufficiently tighteneddown
No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent,
worn, or carbon accumulation on theseating surface)

Poor Running at Low Speed:
Spark weak:
Battery voltage low
Spark plug dirty, broken, or maladjusted
Stick coil wiring trouble
Stick coil not in good contact
Spark plug incorrect
IC igniter in ECU trouble
Crankshaft sensor trouble
Stick coil trouble
Fuel/air mixture incorrect:
Bypass screw maladjusted
Air passage clogged
Air bleed pipe bleed holes clogged
Pilot passage clogged
Air cleaner clogged, poorly sealed, or missing
Fuel tank air vent obstructed
Fuel pump trouble
Throttle body assy holder loose
Air cleaner duct loose

APPENDIX 17-47
Troubleshooting Guide
Compression low:
Spark plug loose
Cylinder head not sufficiently tighteneddown
No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring/groove clearance excessive
Cylinder head warped
Cylinder head gasket damaged
Valve spring broken or weak
Valve not seating properly (valve bent,
worn, or carbon accumulation on theseating surface)
Other:
IC igniter in ECU trouble
Throttle body assy not synchronizing
Engine oil viscosity too highDrive train trouble
Brake dragging
Air suction valve trouble
Air switching valve trouble
Engine overheating
Clutch slipping

Poor Running or No Power at High
Speed:
Firing incorrect:
Spark plug dirty, broken, or maladjusted
Stick coil wiring trouble
Stick coil not in good contact
Spark plug incorrect
Camshaft position trouble
IC igniter in ECU trouble
Crankshaft sensor trouble
Stick coil trouble
Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed, or missing
Air cleaner O-ring damaged
Air cleaner duct loose
Water or foreign matter in fuelThrottle body assy holder loose
Fuel to injector insufficient (DFI)
Fuel tank air vent obstructed
Fuel line clogged
Fuel pump trouble
Compression low:
Spark plug loose
Cylinder head not sufficiently tighteneddown
No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring/groove clearance excessive

Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent,
worn, or carbon accumulation on theseating surface)
Knocking:
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
IC igniter in ECU trouble
Crankshaft sensor trouble
Miscellaneous:Throttle valve won’t fully open
Brake dragging
Clutch slipping
Engine overheating
Engine oil level too highEngine oil viscosity too highDrive train trouble
Air suction valve trouble
Air switching valve trouble
Catalytic converter melt down due to muffler
overheating (KLEEN)

Overheating:Firing incorrect:
Spark plug dirty, broken, or maladjusted
Spark plug incorrect
IC igniter in ECU trouble
Muffler overheating:
For KLEEN, do not run the engine even ifwith only one cylinder misfiring or poor
running (Request the nearest service facility to correct it)
For KLEEN, do not push-start with a deadbattery (Connect another full-charged
battery with jumper cables, and start theengine using the electric starter)
For KLEEN, do not start the engine under
misfire due to spark plug fouling or poorconnection of the stick coil
For KLEEN, do not coast the motorcyclewith the ignition switch off (Turn the ignition switch ON and run the engine)
IC igniter in ECU trouble
Fuel/air mixture incorrect:
Throttle body assy holder loose
Air cleaner duct loose
Air cleaner poorly sealed, or missing
Air cleaner O-ring damaged
Air cleaner clogged
Compression high:Carbon built up in combustion chamberEngine load faulty:
Clutch slipping
Engine oil level too high

17-48 APPENDIX
Troubleshooting Guide
Engine oil viscosity too highDrive train trouble
Brake dragging
Lubrication inadequate:
Engine oil level too low
Engine oil poor quality or incorrect
Gauge incorrect:
Water temperature gauge broken
Water temperature sensor broken
Coolant incorrect:
Coolant level too low
Coolant deteriorated
Wrong coolant mixed ratio
Cooling system component incorrect:
Radiator fin damaged
Radiator clogged
Thermostat trouble
Radiator cap trouble
Radiator fan relay trouble
Fan motor broken
Fan blade damaged
Water pump not turning
Water pump impeller damaged

Over Cooling:
Gauge incorrect:
Water temperature gauge broken
Water temperature sensor broken
Cooling system component incorrect:
Radiator fan relay trouble
Thermostat trouble

Clutch Operation Faulty:
Clutch slipping:
Friction plate worn or warped
Steel plate worn or warped
Clutch spring broken or weak
Clutch hub or housing unevenly worn
No clutch lever play
Clutch inner cable trouble
Clutch release mechanism trouble
Clutch not disengaging properly:
Clutch plate warped or too roughClutch spring compression uneven
Engine oil deteriorated
Engine oil viscosity too highEngine oil level too highClutch housing frozen on drive shaft
Clutch hub nut loose
Clutch hub spline damaged
Clutch friction plate installed wrong
Clutch lever play excessive
Clutch release mechanism trouble

Gear Shifting Faulty:
Doesn’t go into gear; shift pedal doesn’t
return:Clutch not disengaging
Shift fork bent or seizedGear stuck on the shaft
Gear positioning lever binding
Shift return spring weak or broken
Shift return spring pin loose
Shift mechanism arm spring broken
Shift mechanism arm broken
Shift pawl broken
Jumps out of gear:
Shift fork ear worn, bent
Gear groove worn
Gear dogs and/or dog holes worn
Shift drum groove worn
Gear positioning lever spring weak or broken
Shift fork guide pin worn
Drive shaft, output shaft, and/or gear
splines worn
Overshifts:
Gear positioning lever spring weak or broken
Shift mechanism arm spring broken

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 pin, piston pin hole worn
Valve noise:
Valve clearance incorrect
Valve spring broken or weak
Camshaft bearing worn
Valve lifter worn
Other noise:
Connecting rod small end clearance excessive
Connecting rod big end clearance excessive
Piston ring/groove clearance excessive
Piston ring worn, broken, or stuck
Piston ring groove worn
Piston seizure, damage
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head connection
Crankshaft runout excessive

APPENDIX 17-49
Troubleshooting Guide
Engine mount loose
Crankshaft bearing worn
Primary gear worn or chipped
Camshaft chain tensioner trouble
Camshaft chain, sprocket, guide worn
Air suction valve damaged
Air switching valve damaged
Alternator rotor loose
Catalytic converter melt down due to muffler
overheating (KLEEN)

Abnormal Drive Train Noise:
Clutch noise:
Clutch housing/friction plate clearance excessive
Clutch housing gear worn
Wrong installation of outside friction plateTransmission noise:
Bearings worn
Transmission gear worn or chipped
Metal chips jammed in gear teeth
Engine oil insufficient
Drive line noise:
Drive chain adjusted improperly
Drive chain worn
Rear and/or engine sprocket worn
Chain lubrication insufficient
Rear wheel misaligned

Abnormal Frame Noise:
Front fork noise:
Oil insufficient or too thin
Spring weak or broken
Rear shock absorber noise:
Shock absorber damaged
Disc brake noise:
Pad installed incorrectly
Pad surface glazed
Disc warped
Caliper trouble
Other noise:
Bracket, nut, bolt, etc.
not properly
mounted or tightened

Oil Pressure Warning Light Goes On:
Engine oil pump damaged
Engine oil screen clogged
Engine oil filter clogged
Engine oil level too low
Engine oil viscosity too low
Camshaft bearing worn
Crankshaft bearing worn
Oil pressure switch damaged
Wiring faulty
Relief valve stuck open

O-ring at the oil passage in the crankcase
damagedExhaust Smokes Excessively:
White smoke:
Piston oil ring worn
Cylinder worn
Valve oil seal damaged
Valve guide worn
Engine oil level too highBlack smoke:
Air cleaner clogged
Brown smoke:
Air cleaner duct loose
Air cleaner O-ring damaged
Air cleaner poorly sealed or missing

Handling and/or Stability
Unsatisfactory:
Handlebar hard to turn:
Cable routing incorrect
Hose routing incorrect
Wiring routing incorrect
Steering stem nut too tightSteering stem bearing damaged
Steering stem bearing lubrication inadequate
Steering stem bent
Tire air pressure too low
Handlebar shakes or excessively vibrates:
Tire worn
Swingarm pivot bearing worn
Rim warped, or not balanced
Wheel bearing worn
Handlebar holder bolt loose
Steering stem nut loose
Front, rear axle runout excessive
Engine mounting bolt loose
Handlebar pulls to one side:
Frame bent
Wheel misalignment
Swingarm bent or twisted
Swingarm pivot shaft runout excessive
Steering maladjusted
Front fork bent
Right and left front fork oil level uneven
Shock absorption unsatisfactory:(Too hard)
Front fork oil excessive
Front fork oil viscosity too highRear shock absorber adjustment too hard
Tire air pressure too highFront fork bent
(Too soft)
Tire air pressure too low
Front fork oil insufficient and/or leaking
Front fork oil viscosity too low17-50 APPENDIX
Troubleshooting Guide
Rear shock adjustment too soft
Front fork, rear shock absorber spring weak
Rear shock absorber oil leaking

Brake Doesn’t Hold:
Air in the brake line
Pad or disc worn
Brake fluid leakage
Disc warped
Contaminated pad
Brake fluid deteriorated
Primary or secondary cup damaged in mastercylinderMaster cylinder scratched inside

Battery Trouble:
Battery discharged:
Charge insufficient
Battery faulty (too low terminal voltage)
Battery lead making poor contact
Load excessive (e.g., bulb of excessive
wattage)
Ignition switch trouble
Alternator trouble
Wiring faulty
Regulator/rectifier trouble
Battery overcharged:
Alternator trouble
Regulator/rectifier trouble
Battery faulty

MODEL APPLICATION
Year

Model

2006

EX650A6F

2006

EX650B6F

Beginning Frame No.
JKAEXEA1□6A000001
JKAEX650AAA000001
JKAEX650ABA000001□:This digit in the frame number changes from one machine to another.

Part No.99924-1361-01

Printed in Japan