2009 Kawasaki ZX1000E Ninja ZX-10R Service Repair Manual

MODEL APPLICATION Year

Model

2008

ZX1000E8F

2009

ZX1000E9F

Beginning Frame No. JKAZXCE1□8A000001 or JKAZXT00EEA000001 or ZXT00E-000001 JKAZXCE1□9A02002 or JKAZXT00EEA021002 or ZXT00E-021001

□:This digit in the frame number changes from one machine to another.

Part No.99924-1388-02

Printed in Japan

Ninja ZX-10R

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 the black tab of the desired chapter number with the black tab on the edge at each 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 j

Fuel System (DFI)

3 j

Cooling System

4 j

Engine Top End

5 j

Clutch

6 j

Engine Lubrication System

7 j

Engine Removal/Installation

8 j

Crankshaft/Transmission

9 j

Wheels/Tires

10 j

Final Drive

11 j

Brakes

12 j

Suspension

13 j

Steering

14 j

Frame

15 j

Electrical System

16 j

Appendix

17 j

Ninja ZX-10R

Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance 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 time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.

Š 2008 Kawasaki Heavy Industries, Ltd.

Second Edition (1) : Jul. 28, 2008 (K)

LIST OF ABBREVIATIONS A ABDC AC ATDC BBDC BDC BTDC °C DC F °F ft g h L

ampere(s) after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celsius direct current farad(s) degree(s) Fahrenheit foot, feet gram(s) 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 minute top dead center total indicator reading volt(s) watt(s) ohm(s)

COUNTRY AND AREA CODES AT AU BR CA CAL CH

Austria Australia Brazil Canada California Switzerland

DE

Germany

EUR

Europe

GB MY SEA TH US WVTA (FULL H) GB WVTA (FULL H) WVTA (78.2 H)

United Kingdom Malaysia Southeast Asia Thailand United States WVTA Model with Honeycomb Catalytic Converter (Full Power) WVTA Model with Honeycomb Catalytic Converter (Left Side Traffic Full Power) WVTA Model with Honeycomb Catalytic Converter (Restricted Power)

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 compliance with 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 exhaust of 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 when the 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 is commonly 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 this title 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 “remove or render inoperative any device or element of design” has been generally ○ interpreted as follows.

1. Tampering does not include the temporary removal or rendering inoperative of 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 performance or 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 or element 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 $10 000 PER VIOLATION.

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop.

However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper 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 and to 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 are used, 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 with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty.

To get the longest life out of your vehicle.

Follow the Periodic Maintenance Chart in the Service Manual.

Be alert for problems and non-scheduled maintenance.

Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual. Genuine parts provided as spare 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 new parts 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. Each chapter 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 the Table 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 maintenance practices.

WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.

CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment.

This manual contains four more symbols (in addition 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 • Indicates done.

○Indicates a procedural sub-step or how to do

the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows.

In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.

GENERAL INFORMATION 1-1

General Information Table of Contents Before Servicing .....................................................................................................................

Model Identification.................................................................................................................

General Specifications............................................................................................................

Technical Information-KIMS (Kawasaki Ignition Management System) .................................

Unit Conversion Table ............................................................................................................

1-2 1-7 1-9 1-12 1-13

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 wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.

Especially note the following.

Battery Ground

Before completing any service on the motorcycle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the ground cable (–) first and then the positive (+). When completed with the service, first connect the positive (+) cable to the positive (+) terminal of the battery then the negative (–) 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 directions of the solvent manufacturer.

Cleaning Vehicle before Disassembly Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during 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 the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.

Storage of Removed Parts After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials 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 sections of 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 or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.

Assembly Order In 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 to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead 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.

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-ring Hardening, 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 other material remains.

Install the new gaskets and replace the 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 so that no oil residue remains before applying liquid gasket or non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.

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

Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure 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 facing out. Make sure the seal is aligned properly when installing.

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

Circlips, Cotter Pins Replace the 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 during assembly 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 play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side).

Electrical Wires A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires 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 lead to improper adjustments.

GENERAL INFORMATION 1-7 Model Identification ZX1000E8F (US and CA Models) Left Side View

ZX1000E8F (US and CA Models) Right Side View

1-8 GENERAL INFORMATION Model Identification ZX1000E8F (EUR Models) Left Side View

ZX1000E8F (EUR Models) Right Side View

Frame Number

Engine Number

GENERAL INFORMATION 1-9 General Specifications ZX1000E8F ∼ E9F

Items Dimensions Overall Length Overall Width Overall Height Wheelbase Road Clearance Seat Height Dry Mass ZX1000E8F Curb Mass: ZX1000E9F Front Rear Fuel Tank Capacity Performance Minimum Turning Radius Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower

Maximum Torque

Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Cylinder Numbering Method Firing Order Valve Timing: Inlet: Open Close Duration

2 110 mm (83.1 in.)

710 mm (28.0 in.)

1 135 mm (44.7 in.)

1 415 mm (55.7 in.)

125 mm (4.9 in.)

830 mm (32.7 in.)

179 kg (395 lb) 208 kg (459 lb) 106 kg (234 lb) 102 kg (225 lb) 17 L (4.5 US gal) 3.4 m (11.2 ft) 4-stroke, DOHC, 4-cylinder Liquid-cooled 76.0 × 55.0 mm (3.0 × 2.2 in.)

998 cm³ (60.9 cu in.)

12.9 : 1 138.3 kW (188.1 PS) @12 500 r/min (rpm), WVTA (78.2 H) 78.2 kW (106 PS) @11 000 r/min (rpm), (MY), (TH) 119.2 kW (162.1 PS) @10 000 r/min (rpm), (SEA) 133 kW (181 PS) @12 500 r/min (rpm), (CA), (CAL), (US) – – – 113 N·m (11.5 kgf·m, 83.3 ft·lb) @8 700 r/min (rpm), WVTA (78.2 H) 83 N·m (8.5 kgf·m, 61.2 ft·lb) @5 100 r/min (rpm), (CA), (CAL), (US) – – – FI (Fuel injection), KEIHIN TTK43 × 4 Electric starter Battery and coil (transistorized) KIMS (Kawasaki Ignition Management System) Electronically advanced (IC igniter in ECU) From 10° BTDC @1 100 r/min (rpm) NGK CR9EIA-9 Left to right, 1-2-3-4 1-2-4-3

35° BTDC 77° ABDC 292°

1-10 GENERAL INFORMATION General Specifications ZX1000E8F ∼ E9F

Items Exhaust: Open Close Duration Lubrication System Engine Oil: Grade Viscosity Capacity Drive Train Primary Reduction System: Type Reduction Ratio Clutch Type Transmission: Type Gear Ratios: 1st 2nd 3rd 4th 5th 6th Final Drive System: Type Reduction Ratio Overall 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

62° BBDC 38° ATDC 280° Forced lubrication (wet sump with oil cooler) API SE, SF or SG API SH, SJ or SL with JASO MA, MA1 or MA2 SAE10W-40 4.0 L (4.2 US qt)

Gear 1.611 (87/54) Wet multi disc 6-speed, constant mesh, return shift 2.600 2.053 1.737 1.550 1.400 1.304

(39/15) (39/19) (33/19) (31/20) (28/20) (30/23)

Chain drive 2.412 (41/17) 5.068 @Top gear Tubular, diamond 25.5° 110 mm (4.3 in.)

Tubeless 120/70 ZR17 M/C (58 W) 17 × 3.50 Tubeless 190/55 ZR17 M/C (75 W) 17 × 6.00 Telescopic fork (upside-down) 120 mm (4.7 in.)

GENERAL INFORMATION 1-11 General Specifications Items Rear Suspension: Type Wheel Travel Brake Type: Front Rear Electrical Equipment Battery Headlight: Type Bulb: High Low Tail/Brake Light Alternator: Type Rated Output

ZX1000E8F ∼ E9F Swingarm (uni-trak) 125 mm (4.9 in.)

Dual discs Single disc 12 V 10 Ah Semi-sealed beam 12 V 55 W + 65 W (quartz-halogen) 12 V 55 W (quartz-halogen) 12 V 0.5/4.1 W (LED) Three-phase AC 30 A/14 V @5 000 r/min (rpm)

Specifications are subject to change without notice, and may not apply to every country.

1-12 GENERAL INFORMATION Technical Information-KIMS (Kawasaki Ignition Management System) Overview This motorcycle is equipped with the Kawasaki ignition management system which was developed as a rider aid for track riding using technology borrowed from racing machines. Experienced racers or track riders can deliberately cause wheel spin to occur when exiting mid/high speed corners. However, they rely on precise throttle control to maintain the optimum acceleration level without sacrificing too much wheel spin. KIMS was designed to aid such riding where precise throttle control is required.

This system has not been developed to eliminate all wheel spin, as there are times when this can be advantageous for experienced riders, and too much control would lead to a very sterile riding experience.

Operation In addition to normal DFI activity the ECU’s complex programme monitors throttle opening, vehicle speed, gear position, and the rate of change of engine speed.

When the ECU detects the rear wheel is slipping by a sudden change in engine speed, the previously mentioned factors are calculated and within certain parameters the ignition timing is retarded to reduce excessive engine speed. The number of degrees that the ECU retards the ignition is determined by continuous sampling, with the aim being to optimize the relationship between throttle opening, engine/vehicle speed and ultimately ensuring the optimum combination of grip/acceleration.

To ensure that this system does not act unnecessarily, the following situations are taken into account.

1. This system does not act at idle speed, small throttle openings, or at full throttle.

2.

In cases of snapping open the throttle with the clutch half-engaged (example [A]), the system compares the gear position, engine speed and the vehicle speed to determine whether or not to engage. This system does not act when the clutch is at the partially disengaged or slipping.

3. This system does not act on sudden throttle openings.

GENERAL INFORMATION 1-13 Unit Conversion Table Prefixes for Units: Prefix mega kilo centi milli micro

Units of Length:

Symbol M k c m μ

× × × × ×

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

× × × × × × × × ×

0.2642 0.2200 1.057 0.8799 2.113 1.816 0.03381 0.02816 0.06102

× × × ×

× × ×

0.6214 3.281 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

× × × × × ×

0.1020 0.7376 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

0.1020 0.2248 9.807 2.205

Units of Temperature:

kPa kPa kPa kgf/cm² kgf/cm² cmHg

× × × × × ×

0.01020 0.1450 0.7501 98.07 14.22 1.333

Units of Speed: km/h

×

0.6214

Units of Power: kW kW PS PS

× × × ×

1.360 1.341 0.7355 0.9863

PERIODIC MAINTENANCE 2-1

Periodic Maintenance Table of Contents Periodic Maintenance Chart ...................................................................................................

Torque and Locking Agent......................................................................................................

Specifications .........................................................................................................................

Special Tools ..........................................................................................................................

Maintenance Procedure .........................................................................................................

Fuel System (DFI)................................................................................................................

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 Inspection (CAL, SEA and TH Models) ...............

Cooling System....................................................................................................................

Coolant Level Inspection...................................................................................................

Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition) ..........

Engine Top End ...................................................................................................................

Valve Clearance Inspection ..............................................................................................

Valve Clearance Adjustment.............................................................................................

Air Suction System Damage Inspection............................................................................

Clutch...................................................................................................................................

Clutch Operation Inspection .............................................................................................

Wheels/Tires ........................................................................................................................

Tire Air Pressure Inspection..............................................................................................

Wheel/Tire Damage Inspection.........................................................................................

Tire Tread Wear Inspection ..............................................................................................

Wheel Bearing Damage Inspection ..................................................................................

Final Drive............................................................................................................................

Drive Chain Lubrication Condition Inspection ...................................................................

Drive Chain Slack Inspection ............................................................................................

Drive Chain Slack Adjustment ..........................................................................................

Wheel Alignment Inspection .............................................................................................

Drive Chain Wear Inspection ............................................................................................

Chain Guide Wear Inspection ...........................................................................................

Brake ...................................................................................................................................

Brake Fluid Leak (Brake Hose and Pipe) Inspection ........................................................

Brake Hose 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 ........................................................................

Rocker Arm Operation Inspection.....................................................................................

Tie-Rod Operation Inspection ...........................................................................................

Steering ...............................................................................................................................

Steering Play Inspection ...................................................................................................

Steering Play Adjustment..................................................................................................

Steering Stem Bearing Lubrication ...................................................................................

2-3 2-6 2-13 2-15 2-16 2-16 2-16 2-16 2-20 2-21 2-21 2-22 2-23 2-23 2-23 2-24 2-24 2-25 2-27 2-28 2-28 2-29 2-29 2-30 2-30 2-31 2-31 2-31 2-32 2-32 2-33 2-33 2-34 2-34 2-34 2-35 2-35 2-35 2-36 2-36 2-37 2-37 2-37 2-38 2-38 2-38 2-38 2-38 2-39 2-40

2

2-2 PERIODIC MAINTENANCE Steering Damper Oil Leak Inspection ...............................................................................

Electrical System .................................................................................................................

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 ..................................................................................................

2-40 2-41 2-41 2-43 2-44 2-45 2-45 2-45 2-46 2-48 2-48 2-48 2-52 2-54 2-55 2-56 2-56 2-57 2-59 2-60 2-64

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

Periodic Inspection FREQUENCY Whichever comes first ITEM Fuel System Throttle control system (play, smooth return, no drag)-inspect

Every year

* ODOMETER READING × 1 000 km (× 1 000 mile) 1 6 (0.6) (4)

•

• • • • • •

2-16

• • • •

• • • • • •

• •

• • • • •

2-22

• • • •

• • • •

• • • •

2-23

•

• •

•

2-27

•

•

•

2-28

• • • •

• • • •

• • • •

2-29

Engine vacuum synchronization-inspect Idle speed-inspect 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 function (CAL, SEA and TH Models) -inspect Cooling System

year

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

year

Water hose damage-inspect

year

Water hose installation condition-inspect

year

Engine Top End

12 18 24 30 36 (7.5) (12) (15) (20) (24)

Valve clearance-inspect Air suction system damage-inspect Clutch Clutch operation (play, disengagement, engagement)-inspect Wheels and Tires Tire air pressure-inspect

• year

Wheel/tire damage-inspect Tire tread wear, abnormal wear-inspect Wheel bearing damage-inspect

year

Final Drive Drive chain lubrication condition-inspect # Drive chain slack-inspect #

• • • •

• •

Drive chain guide wear-inspect

year

• •

• •

2-16 2-20 2-21 2-21 2-21

2-23 2-23 2-23 2-24

2-30 2-30 2-31 2-31 2-32

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

Drive chain wear-inspect # Brakes Brake fluid leak (brake hose and pipe)-inspect

• • • • • •

See Page

• •

2-33

• • • • •

2-34

2-34

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

Every

Brake hose and pipe damage-inspect

year

Brake hose installation condition-inspect

year

Brake operation (effectiveness, play, no drag)-inspect

year

Brake fluid level-inspect

6 months

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

* ODOMETER READING × 1 000 km (× 1 000 mile) 1 6 (0.6) (4)

• • • •

• • • • • • •

year

Tie-rods operation-inspect Steering Steering stem bearings-lubricate

year 2 years

•

Electrical System year

Headlight aiming-inspect

year

Sidestand switch operation-inspect

year

Engine stop switch operation-inspect

year

Others Chassis parts-lubricate Bolts and nuts tightness-inspect

year

•

• • • • • •

• • • • • • • • • •

• • • • • •

• • • • • •

2-35

• • • •

2-37

• •

Steering damper oil leak-inspect Lights and switches operation-inspect

• • • • • • • • • •

Rocker arm operation-inspect

Steering play-inspect

12 18 24 30 36 (7.5) (12) (15) (20) (24)

See Page

2-35 2-35 2-35 2-36 2-36

2-37, 2-38 2-38 2-38

• • • • • • • •

2-38

• • • •

• • • •

• • • •

2-41

• •

• •

• •

2-45

2-40 2-40

2-43 2-44 2-45

2-46

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

PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever come first ITEM Air cleaner element # - replace

Every

1 (0.6)

12 (7.5)

24 (15)

36 (24)

48 (30)

Every 18 000 km (12 000 mile)

Fuel hose - replace

4 years

Coolant - change

3 years

Radiator hose and O-ring - replace

3 years

Engine oil # - change

year

Oil filter - replace

year

Brake hose and pipe - replace

4 years

Brake fluid - change

2 years

Rubber parts of master cylinder and caliper replace

4 years

Spark plug - replace

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

• •

• •

• •

• • • •

• •

•

•

•

See Page 2-48 2-48 2-52 2-54

• • • • • •

2-55 2-56 2-56 2-57 2-59, 2-60 2-64

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

2-6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc.

Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.

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 S: Follow the specified tightening sequence.

Si: Apply silicone grease.

SS: Apply silicone sealant.

Fastener Fuel System (DFI) Inlet Air Temperature Sensor Screw Air Inlet Duct Mounting Bolts Air Cleaner Housing Bracket Bolt Air Cleaner Housing Mounting Bolt (Upper) Air Cleaner Housing Mounting Bolts (Lower) Air Cleaner Housing Assembly Screws Rubber Plate Holder Screws Delivery Pipe Assy Mounting Screws (Nozzle Assy) Nozzle Assy Mounting Bolts Delivery Pipe Assy Mounting Screws (Throttle Body Assy) Throttle Body Assy Holder Clamp Bolts Throttle Body Assy Holder Bolts Vehicle-down Sensor Bolts Camshaft Position Sensor Bolt Water Temperature Sensor Crankshaft Sensor Bolts Fuel Pump Bolts Gear Position Switch Screws Speed Sensor Bolt Inlet Air Pressure Sensor Bracket Screws Exhaust Butterfly Valve Actuator Mounting Screws Exhaust Butterfly Valve Actuator Pulley Bolt Separator Bracket Bolts Canister Bracket Bolts Cooling System Water Hose Clamp Screws Coolant Drain Bolt (Cylinder) Water Pump Cover Bolts Water Temperature Sensor Coolant Reserve Tank Mounting Bolts

N·m

Torque kgf·m

ft·lb

1.2 7.0 7.0 7.0 4.2 1.1 1.1 3.4 7.0

0.12 0.71 0.71 0.71 0.43 0.11 0.11 0.35 0.71

11 in·lb 62 in·lb 62 in·lb 62 in·lb 37 in·lb 9.7 in·lb 9.7 in·lb 30 in·lb 62 in·lb

3.4

0.35

30 in·lb

2.0 10 6.0 10 25 6.0 10 3.0 10 3.4 4.3 5.0 7.0 4.3

0.20 1.0 0.61 1.0 2.5 0.61 1.0 0.31 1.0 0.35 0.44 0.51 0.71 0.44

18 in·lb 89 in·lb 53 in·lb 89 in·lb 18 53 in·lb 89 in·lb 27 in·lb 89 in·lb 30 in·lb 38 in·lb 44 in·lb 62 in·lb 38 in·lb

2.0 10 10 25 7.0

0.20 1.0 1.0 2.5 0.71

18 in·lb 89 in·lb 89 in·lb 18 62 in·lb

Remarks

L

L

S

L L, S L

PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Fastener Coolant By-pass Fitting Bolt Thermostat Housing Cover Bolts Thermostat Housing Mounting Bolts Oil Cooler Mounting Bolts Water Hose Fitting Bolts Water Passage Plugs Radiator Bracket Mounting Bolt Radiator Upper Bolt Radiator Lower Bolt Coolant Drain Bolt (Water Pump) Radiator Overflow Hose Clamp Bolt Engine Top End Air Suction Valve Cover Bolts Cylinder Head Cover Bolts Camshaft Cap Bolts Upper Camshaft Chain Guide Bolts Cylinder Head Bolts (M10 New Bolts) Cylinder Head Bolts (M10 Used Bolts) Cylinder Head Bolts (M6) Water Passage Plugs Throttle Body Assy Holder Bolts Throttle Body Assy Holder Clamp Bolts Camshaft Position Sensor Bolt Front Camshaft Chain Guide Bolt (Upper) Front Camshaft Chain Guide Bolt (Lower) Camshaft Chain Tensioner Mounting Bolts Camshaft Chain Tensioner Cap Bolt Spark Plugs Cam Sprocket Mounting Bolts Starter Clutch Cover Bolts (M6, L = 30) Starter Clutch Cover Bolts (M6, L = 20) Torque Limiter Cover Bolts Coolant Drain Plug (Cylinder) Starter Clutch Bolt Cap Timing Inspection Cap Right Engine Bracket Bolts (Cylinder Head) Exhaust Pipe Holder Nuts Exhaust Manifold Clamp Bolt Premuffler Chamber Mounting Bolt Premuffler Chamber Outer Cover Bolts Premuffler Chamber Inner Cover Bolts Exhaust Butterfly Valve Cable Clamp Bolt Exhaust Butterfly Valve Pulley Cover Bolts

N·m 9.0 6.0 10 20 10 20 7.0 7.0 7.0 10 10

Torque kgf·m 0.92 0.61 1.0 2.0 1.0 2.0 0.71 0.71 0.71 1.0 1.0

10 10 12 12 59 57 12 19.6 10 2.0 10 25 12 10 20 13 15 10 10 10 10 – – 9.8 17 25 25 7.0 7.0 10 7.0

1.0 1.0 1.2 1.2 6.0 5.8 1.2 2.0 1.0 0.20 1.0 2.5 1.2 1.0 2.0 1.3 1.5 1.0 1.0 1.0 1.0 – – 1.0 1.7 2.5 2.5 0.71 0.71 1.0 0.71

ft·lb 80 in·lb 53 in·lb 89 in·lb 15 89 in·lb 15 62 in·lb 62 in·lb 62 in·lb 89 in·lb 89 in·lb

Remarks L

L

89 in·lb L 89 in·lb 106 in·lb S 106 in·lb S 44 MO, S 42 MO, S 106 in·lb S 14.5 L 89 in·lb S 18 in·lb 89 in·lb 18 106 in·lb 89 in·lb 15 115 in·lb 11 L 89 in·lb 89 in·lb 89 in·lb L (1), S 89 in·lb – Hand-tighten – Hand-tighten 87 in·lb L 13 18 18 62 in·lb 62 in·lb 89 in·lb 62 in·lb

2-8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Muffler Body Clamp Bolt Muffler Body Mounting Bolt Muffler Body Front Cover Bolts Muffler Body Rear Cover Bolts Clutch Clutch Lever Clamp Bolts Clutch Cover Bolts (M6, L = 25) Clutch Cover Bolts (M6, L = 35) Oil Filler Plug Clutch Spring Bolts Clutch Hub Nut Sub Clutch Hub Bolts Engine Lubrication System Engine Oil Drain Bolt Oil Filter Oil Filter Pipe Oil Pan Bolts Oil Pressure Relief Valve Oil Pressure Switch Oil Pressure Switch Terminal Bolt Oil Pump Gear Bolts Oil Passage Plugs Oil Pump Cover Bolts Oil Cooler/Oil Filter Case Mounting Bolts Oil Cooler Mounting Bolts Engine Removal/Installation Adjusting Collar Locknut Left Front Engine Mounting Bolt (M10, L = 42) Right Front Engine Mounting Bolt (M10, L = 67) Middle Engine Mounting Bolt Middle Engine Mounting Nut Lower Engine Mounting Bolt Lower Engine Mounting Nut Left Engine Bracket Bolts (M10, L = 30) Right Engine Bracket Bolts (M10, L = 30) Right Engine Bracket Bolt (M10, L = 35) Right Engine Bracket Bolts (Cylinder Head) Crankshaft/Transmission Breather Plate Bolts Crankcase Bolts (M9) Crankcase Bolts (M8) Crankcase Bolts (M7, L = 32) Crankcase Bolt (M7, L = 50)

N·m 25 25 7.0 7.0

Torque kgf·m ft·lb 2.5 18 2.5 18 0.71 62 in·lb 0.71 62 in·lb

Remarks

7.8 10 10 – 11 130 25

0.80 1.0 1.0 – 1.1 13.3 2.5

69 in·lb S 89 in·lb S 89 in·lb S – Hand-tighten 97 in·lb 96 R 18 L

30 17 35 10 15 15 – 10 20 10 20 20

3.1 1.7 3.6 1.0 1.5 1.5 – 1.0 2.0 1.0 2.0 2.0

22 13 G, R 26 L 89 in·lb 11 L 11 SS – Hand-tighten 89 in·lb L 15 L 89 in·lb 15 L 15

49 44 44 9.8 44 9.8 44 44 44 44 9.8

5.0 4.5 4.5 1.0 4.5 1.0 4.5 4.5 4.5 4.5 1.0

36 32 32 87 in·lb 32 87 in·lb 32 32 32 32 87 in·lb

S S S S S S S S S S L

10 39 27 20 20

1.0 4.0 2.8 2.0 2.0

89 in·lb 29 20 15 15

L MO, S S S S

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