2009 Kawasaki ZR1000C9F Service Repair Manual

MODEL APPLICATION Year

Model

2007

ZR1000B7F

2007

ZR1000C7F

2008

ZR1000B8F

2008

ZR1000C8F

2009

ZR1000B9F

2009

ZR1000C9F

Beginning Frame No. JKAZRCB1□7A000001 JKAZRT00BBA000001 ZRT00B-000001 JKAZRT00BCA000001 ZRT00C-000001 JKAZRCB1□8A015001 JKAZRT00BBA015001 ZRT00B-015001 JKAZRT00BCA015001 JKAZRCB1□9A029001 JKAZRT00BBA029001 ZRT00B-029001 JKAZRT00BCA029001

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

Part No.99924-1380-03

Printed in Japan

Z1000 Z1000 ABS

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

Z1000 Z1000 ABS

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 2007 Kawasaki Heavy Industries, Ltd.

Third Edition (1) : Jun. 26, 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 CA

Austria Australia Canada

CAL

California

CH

Switzerland

DE

Germany

GB

United Kingdom

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

Malaysia Southeast Asia 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 (78.2 Kw 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.

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 the vehicle 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 compliance with 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 such modifications result in increased noise levels.

• • • •

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 particular 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............................................................................................................

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

1 1-2 1-7 1-10 1-13

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 ZR1000B7F/B8F (United States and Canada) ZR1000B8F (Southeast Asia) Left Side View

ZR1000B7F/B8F (United States and Canada) ZR1000B8F (Southeast Asia) Right Side View

1-8 GENERAL INFORMATION Model Identification ZR1000B7F/B8F (Europe) Left Side View

ZR1000B7F/B8F (Europe) Right Side View

GENERAL INFORMATION 1-9 Model Identification ZR1000C7F/C8F Left Side View

ZR1000C7F/C8F Right Side View

Frame Number

Engine Number

1-10 GENERAL INFORMATION General Specifications Items Dimensions Overall Length Overall Width Overall Height Wheelbase Road Clearance Seat Height Dry Mass: ZR1000B7F ∼ B8F ZR1000C7F ∼ B8F Curb Mass: ZR1000B9F ZR1000C9F Front: ZR1000B ZR1000C Rear: ZR1000B ZR1000C 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

ZR1000B7F ∼, ZR1000C7F ∼ 2 090 mm (82.28 in.)

780 mm (30.71 in.)

1 065 mm (41.93 in.)

1 445 mm (56.89 in.)

160 mm (6.30 in.)

820 mm (32.28 in.)

205 kg (452.0 lb) 209 kg (460.8 lb) 228 kg (502.7 lb) 232 kg (511.6 lb) 112 kg (247.0 lb) 114 kg (251.4 lb) 116 kg (255.8 lb) 118 kg (260.2 lb) 18.5 L (4.9 US gal.)

3.0 m (9.8 ft) 4-stroke, DOHC, 4-cylinder Liquid-cooled 77.2 × 50.9 mm (3.04 × 2.00 in.)

953 cm³ (58.15 cu in.)

11.2 : 1 92.0 kW (125 PS) @10 000 r/min (rpm) (WVTA (78.2 H)) 78.2 kW (106 PS) @9 000 r/min (rpm) (CA), (CAL), (US) – – – 98.7 N·m (10.1 kgf·m, 72.8 ft·lb) @8 200 r/min (rpm) (WVTA (78.2 H)) 92.4 N·m (9.4 kgf·m, 68.2 ft·lb) @7 700 r/min (rpm) (CA), (CAL), (US) – – – FI (Fuel Injection) KEIHIN TTK36 × 4 Electric starter Battery and coil (transistorized) Electronically advanced (digital igniter) From 10° BTDC @1 100 r/min (rpm) to 37.5° BTDC @5 500 r/min (rpm) NGK CR9EIA-9 Left to right, 1-2-3-4 1-2-4-3

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

ZR1000B7F ∼, ZR1000C7F ∼

38° BTDC 58° ABDC 276° 51° BBDC 25° ATDC 256° Forced lubrication (wet sump) API SE, SF or SG API SH, SJ or SL with JASO MA SAE 10W-40 3.8 L (4.0 US qt)

Gear 1.714 (84/49) Wet multi disc 6-speed, constant mesh, return shift 2.571 1.882 1.556 1.333 1.200 1.095

(36/14) (32/17) (28/18) (28/21) (24/20) (23/21)

Chain drive 2.667 (40/15) 5.007 @Top gear Tubular, diamond 24.5° 103 mm (4.06 in.)

Tubeless 120/70 ZR17 M/C (58W) 17 × 3.50

1-12 GENERAL INFORMATION General Specifications ZR1000B7F ∼, ZR1000C7F ∼

Items Rear Tire: Type Size Rim Size Front Suspension: Type Wheel Travel Rear Suspension: Type Wheel Travel Brake Type: Front Rear Electrical Equipment Battery Headlight: Type Bulb Tail/Brake Light Alternator: Type Rated Output

Tubeless 190/50 ZR17 M/C (73W) 17 × 6.00 Telescopic fork 120 mm (4.72 in.)

Swingarm (uni-trak) 150 mm (5.91 in.)

Dual discs Single disc 12 V 8 Ah Semi-sealed beam 12 V 55 W × 2/55 W (Hi/Lo) 12 V 0.5/4.1 W (LED) 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 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 ..........................................................................................................................

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

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

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

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

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

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

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

Exhaust Butterfly Valve Cable Inspection .........................................................................

Exhaust Butterfly Valve Cable Adjustment........................................................................

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

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

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

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

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

Brakes..................................................................................................................................

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

Suspension ..........................................................................................................................

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

2-3 2-6 2-12 2-14 2-15 2-15 2-15 2-15 2-16 2-19 2-20 2-20 2-21 2-22 2-22 2-23 2-23 2-23 2-24 2-28 2-29 2-32 2-32 2-32 2-33 2-33 2-34 2-34 2-35 2-35 2-35 2-36 2-36 2-37 2-38 2-38 2-39 2-39 2-40 2-40 2-40 2-41 2-42 2-42 2-42 2-43 2-43 2-43 2-43 2-44

2

2-2 PERIODIC MAINTENANCE Steering Play Inspection ...................................................................................................

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

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

2-44 2-44 2-45 2-46 2-46 2-47 2-49 2-50 2-51 2-52 2-52 2-54 2-55 2-55 2-56 2-58 2-60 2-60 2-61 2-62 2-64 2-65 2-66 2-69

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

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

1 ITEM Fuel System

Every

6

12

30

• year

Idle speed - inspect Fuel leak (fuel hose and pipe) - inspect

year

Fuel hose and pipe damage - inspect

year year

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

year

Water hose damage - inspect

year

Water hose installation condition - inspect

year

36

• • • • •

• • • • • • • • •

• • • • • • •

• • • • • • • • •

• • • •

• • • •

• • • •

• • • •

•

Engine vacuum synchronization - inspect

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

24

(0.6) (4) (7.5) (12) (15) (20) (24)

Air cleaner element - clean Throttle control system (play, smooth return, no drag) - inspect

18

See Page

2-15

2-22

2-15 2-16 2-19 2-20 2-20 2-20 2-21

2-23 2-23 2-23

Engine Top End

•

US, CA, AU Model Valve clearance - inspect Other than US, CA, AU Model Exhaust butterfly valve cable - 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 Final Drive Drive chain lubrication condition - inspect # Drive chain slack - inspect # Drive chain wear - inspect # Drive chain guide wear - inspect

year

2-23

Every 42 000 km (26 000 mile)

2-23

• • • • • • • • • •

2-28

•

2-32

•

•

•

2-32

• • • •

• • • •

• • • •

2-33

• •

2-34 2-35 2-35 2-36

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

• •

2-34

• •

2-38 2-38

2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever comes first 1 ITEM Brakes Brake fluid leak (brake hose and pipe) inspect Brake hose and pipe damage - inspect Brake hose and pipe installation condition inspect Brake operation (effectiveness, play, no drag) - inspect Brake fluid level - inspect

Every

year year year year 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) 6

12

18

24

30

36

See Page

(0.6) (4) (7.5) (12) (15) (20) (24)

• • • • •

• • • • • • • •

year

Rocker arm operation - inspect Tie-rods operation - inspect

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • • •

2-39 2-40 2-40 2-40 2-40 2-41 2-42

• • • •

• • • •

• • • •

2-42

•

• •

•

2-44

• • • • •

• • • • •

• • • • •

2-46

• •

• •

• •

2-52

2-43 2-43 2-43

Steering Steering play - inspect Steering stem bearings - lubricate

year

•

2 years

2-45

Electrical System 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

2-47 2-49 2-50 2-51

Others Chassis parts - lubricate Bolts and nuts tightness - inspect

year

•

2-54

#: 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

ITEM

Every

12

24

(0.6) (7.5) (15)

48

(24)

(30)

•

Air cleaner element # - replace 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

36

• •

• •

• •

• • • •

• •

•

•

See Page

2-55

•

2-56 2-58 2-60

• • • • • •

2-60 2-61 2-62 2-64 2-65, 2-66 2-69

#: 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 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.

EO: Apply engine oil.

G: Apply grease.

HG: Apply high-temperature 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 (ex. PBC grease).

SS: Apply silicone sealant.

Fastener Fuel System (DFI) Air Cleaner Duct Screws Air Cleaner Housing Mounting Bolts Air Cleaner Housing Tapping Screws Air Duct Clamp Bolts Bypass Screws Camshaft Position Sensor Bolt Crankshaft Sensor Bolts Delivery Pipe Assy Mounting Screws Exhaust Butterfly Valve Actuator Bracket Bolt Exhaust Butterfly Valve Actuator Mounting Bolts Exhaust Butterfly Valve Actuator Pulley Bolt Fuel Pump Bolts Idle Adjusting Cable Clamp Screw Oxygen Sensor (Equipped Models) Speed Sensor Bolt Throttle Body Assy Holder Bolts Throttle Body Assy Holder Clamp Bolts Throttle Cable Plate Bolt Throttle Link Holder Screws Vehicle-down Sensor Bolts Water Temperature Sensor Cooling System Coolant Drain Bolt (Cylinder) Coolant Drain Bolt (Water Pump) Radiator Bracket Mounting Bolt Radiator Lower Bolt Radiator Upper Bolts Radiator (Water) Hose Clamp Screws Reserve Tank Bolts

N·m

Torque kgf·m

ft·lb

3.8 9.8 1.2 2.0 0.2 12 5.9 3.4 6.9 6.9 5.0 9.8 3.4 44.1 12 13 2.0 5.9 2.0 6.0 25

0.39 1.0 0.12 0.20 0.02 1.2 0.60 0.35 0.70 0.70 0.51 1.0 0.35 4.50 1.2 1.3 0.20 0.60 0.20 0.61 2.5

34 in·lb 87 in·lb 11 in·lb 18 in·lb 1.8 in·lb 106 in·lb 52 in·lb 30 in·lb 61 in·lb 61 in·lb 44 in·lb 87 in·lb 30 in·lb 32.5 106 in·lb 115 in·lb 18 in·lb 52 in·lb 18 in·lb 53 in·lb 18

9.8 11 6.9 6.9 6.9 3.0 9.8

1.0 1.1 0.70 0.70 0.70 0.31 1.0

87 97 61 61 61 27 87

in·lb in·lb in·lb in·lb in·lb in·lb in·lb

Remarks

L, S

PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Fastener Thermostat Bracket Bolt Thermostat Housing Ground Bolt Thermostat Housing Screws Water Pipe Bolts Water Pump Cover Bolts Water Pump Impeller Bolt Water Temperature Sensor Engine Top End Air Suction Valve Cover Bolts Camshaft Cap Bolts (L = 45 mm) Camshaft Cap Bolts (L = 40 mm) Camshaft Chain Tensioner Cap Bolt Camshaft Chain Tensioner Mounting Bolts Coolant Drain Bolt (Cylinder) Cylinder Head Bolts (M10 New Bolts) Cylinder Head Bolts (M10 Used Bolts) Cylinder Head Bolts (M6) Cylinder Head Cover Bolts Cylinder Head Jacket Plugs Exhaust Butterfly Valve Actuator Bracket Bolt Exhaust Butterfly Valve Actuator Mounting Bolts Exhaust Butterfly Valve Actuator Pulley Bolt Exhaust Butterfly Valve Cable Adjuster Locknuts Exhaust Butterfly Valve Cable Locknuts Exhaust Butterfly Valve Cover Bolts Exhaust Pipe Manifold Holder Nuts Exhaust Pipe Mounting Bolt Front Camshaft Chain Guide Bolt (Lower) Front Camshaft Chain Guide Bolt (Upper) Muffler Body Clamp Bolt (Left) Muffler Body Clamp Bolt (Right) Muffler Body Mounting Bolt Muffler Body Mounting Nuts Muffler Body Side Cover Bolts Rear Camshaft Chain Guide Bolt Spark Plugs Throttle Body Assy Holder Bolts Throttle Body Assy Holder Clamp Bolts Upper Chain Guide Bolts Clutch Clutch Cover Mounting Bolts Clutch Cover Outer Cover Bolts Clutch Hub Nut

N·m 6.9 6.9 5.9 11 11 9.8 25

Torque kgf·m 0.70 0.70 0.60 1.1 1.1 1.0 2.5

ft·lb 61 in·lb 61 in·lb 52 in·lb 97 in·lb 97 in·lb 87 in·lb 18

9.8 12 12 20 11 9.8 54 49 12 9.8 22 6.9 6.9 5.0 6.9 6.9 6.9 17 4.9 12 25 17 15 25 34 6.9 25 13 13 2.0 12

1.0 1.2 1.2 2.0 1.1 1.0 5.5 5.0 1.2 1.0 2.2 0.70 0.70 0.51 0.70 0.70 0.70 1.7 0.50 1.2 2.5 1.7 1.5 2.5 3.5 0.70 2.5 1.3 1.3 0.20 1.2

87 in·lb 106 in·lb 106 in·lb 15 97 in·lb 87 in·lb 40 36 106 in·lb 87 in·lb 16 61 in·lb 61 in·lb 44 in·lb 61 in·lb 61 in·lb 61 in·lb 13 43 in·lb 106 in·lb 18 13 11 18 25 61 in·lb 18 115 in·lb 115 in·lb 18 in·lb 106 in·lb

11 6.9 135

1.1 0.70 13.8

97 in·lb 61 in·lb 99.6

Remarks

L

S S

S S S S L

S S

S S S S

S

R

2-8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Clutch Lever Clamp Bolts Clutch Spring Bolts Oil Filler Plug Engine Lubrication System Coolant Drain Bolt (Water Pump) Engine Oil Drain Bolt Lower Fairing Bracket Bolts Oil Filter Oil Filter Holder Oil Filler Plug Oil Pan Bolts Oil Passage Plugs Oil Pipe Holder Bolts Oil Pressure Relief Valve Oil Pressure Switch Oil Pressure Switch Terminal Bolt Water Pump Cover Bolts Water Pump Impeller Bolt Engine Removal/Installation Adjusting Collar Lock Bolt Adjusting Collar Locknut Engine Ground Cable Terminal Bolt Front Engine Mounting Bolts Lower Engine Mounting Nut Middle Engine Mounting Nut Rear Engine Bracket Bolts Subframe Bolts Upper Engine Bracket Bolts Crankshaft/Transmission Breather Plate Bolts (M6) Breather Plate Bolts (M5) Connecting Rod Big End Nuts Crankcase Bolts (M9) Crankcase Bolts (M8) Crankcase Bolts (M7) Crankcase Bolts (M6) Front Footpeg Bracket Bolts Gear Positioning Lever Bolt Neutral Switch Oil Passage Plugs Oil Pipe Holder Bolts Shift Drum Bearing Holder Bolt Shift Drum Bearing Holder Screw

N·m 7.8 8.8 2.0

Torque kgf·m 0.80 0.90 0.20

ft·lb 69 in·lb 78 in·lb 18 in·lb

11 29 6.9 17 78 2.0 11 20 13 15 15 2.0 11 9.8

1.1 3.0 0.70 1.7 8.0 0.20 1.1 2.0 1.3 1.5 1.5 0.20 1.1 1.0

97 in·lb 21 61 in·lb 13 58 18 in·lb 97 in·lb 15 115 in·lb 11 11 18 in·lb 97 in·lb 87 in·lb

34 49 9.8 44 44 44 25 25 44

3.5 5.0 1.0 4.5 4.5 4.5 2.5 2.5 4.5

25 36 87 in·lb 32 32 32 18 18 32

S S

9.8 5.9 see the text 42 27 20 12 25 12 15 20 13 13 5.9

1.0 0.60 ← 4.3 2.8 2.0 1.2 2.5 1.2 1.5 2.0 1.3 1.3 0.60

87 in·lb 52 in·lb ← 31 20 15 106 in·lb 18 106 in·lb 11 15 115 in·lb 115 in·lb 52 in·lb

L L MO MO, S S S S

Remarks S

G, R EO

L L L SS HG

S S S S S S

L L L L

PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Fastener Shift Drum Cam Holder Bolt Shift Lever Bolt Shift Pedal Mounting Bolt Shift Shaft Return Spring Pin Starter Motor Clutch Bolts Tie-Rod Locknuts Wheels/Tires Front Axle Front Axle Clamp Bolt Rear Axle Nut Final Drive Engine Sprocket Cover Bolts Engine Sprocket Nut Rear Axle Nut Rear Sprocket Nuts Brakes Bleed Valves Brake Hose Banjo Bolts Brake Lever Pivot Bolt Brake Lever Pivot Bolt Locknut Brake Pedal Bolt Brake Pipe Joint Nuts (ABS Equipped Models) Front Brake Disc Mounting Bolts Front Brake Light Switch Screw Front Brake Pad Pins Front Brake Reservoir Cap Stopper Screw Front Caliper Assembly Bolts Front Caliper Mounting Bolts Front Master Cylinder Bleed Valve Front Master Cylinder Clamp Bolts Rear Brake Disc Mounting Bolts Rear Brake Pad Pin Rear Brake Pad Pin Plug Rear Caliper Mounting Bolt Rear Caliper Pin Bolt Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut Suspension Front Axle Clamp Bolt Front Fork Bottom Allen Bolts Front Fork Top Plugs Lower Front Fork Clamp Bolts (Middle) Lower Front Fork Clamp Bolts (Upper, Lower)

N·m 12 6.9 34 29 12 6.9

Torque kgf·m 1.2 0.70 3.5 3.0 1.2 0.70

ft·lb 106 in·lb 61 in·lb 25 21 106 in·lb 61 in·lb

127 20 127

13.0 2.0 13.0

93.7 15 93.7

9.8 125 127 59

1.0 12.7 13.0 6.0

87 in·lb 92.2 93.7 44

7.8 25 1.0 5.9 34 18 27 1.2 17.2 1.2 27 34 5.4 11 27 17.2 2.5 22 27 25 17.2

0.80 2.5 0.10 0.60 3.5 1.8 2.8 0.12 1.8 0.12 2.8 3.5 0.55 1.1 2.8 1.8 0.25 2.2 2.8 2.5 1.8

69 in·lb 18 9 in·lb 52 in·lb 25 13 20 11 in·lb 13 11 in·lb 20 25 48 in·lb 97 in·lb 20 13 25 in·lb 16 20 18 13

20 20 34 17 25

2.0 2.0 3.5 1.7 2.5

15 15 25 13 18

Remarks L L L L

MO

Si L L

L

S L

Si

L

AL

2-10 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Piston Rod Nuts Rear Shock Absorber Nut (Lower) Rear Shock Absorber Nut (Upper) Swingarm Pivot Shaft Swingarm Pivot Shaft Locknut Swingarm Pivot Shaft Nut Tie-Rod Nuts Uni-Trak Rocker Arm Nut Upper Front Fork Clamp Bolts Steering Handlebar Holder Bolts Handlebar Lower Holder Nuts Lower Front Fork Clamp Bolts (Middle) Lower Front Fork Clamp Bolts (Upper, Lower) Steering Stem Head Bolt Steering Stem Nut Switch Housing Screws Upper Front Fork Clamp Bolts Frame Front Fender Bolts Front Footpeg Bracket Bolts Lower Fairing Mounting Bolts Rear Footpeg Bracket Bolts Sidestand Bolt Sidestand Switch Bolt Windshield Mounting Bolts Electrical System Alternator Cover Bolts Alternator Cover Outer Cover Bolts Alternator Lead Holding Plate Bolt Alternator Rotor Bolt Camshaft Position Sensor Bolt Crankshaft Sensor Bolts Crankshaft Sensor Cover Bolts Engine Ground Cable Terminal Bolt Front Brake Light Switch Screw Fuel Level Sensor Bolts License Plate Light Cover Mounting Screws License Plate Light Mounting Screws Meter Mounting Screws Neutral Switch Oil Pressure Switch Oil Pressure Switch Terminal Bolt

N·m 19 34 34 9.8 98 108 59 34 20

Torque kgf·m 1.9 3.5 3.5 1.0 10.0 11.0 6.0 3.5 2.0

ft·lb 14 25 25 87 in·lb 72.3 79.7 44 25 15

25 34 17 25 108 27 3.5 20

2.5 3.5 1.7 2.5 11.0 2.8 0.36 2.0

18 25 13 18 79.7 20 31 in·lb 15

3.9 25 6.9 25 44 8.8 0.42

0.40 2.5 0.70 2.5 4.5 0.90 0.043

35 in·lb 18 61 in·lb 18 32 78 in·lb 3.7 in·lb

11 6.9 12 155 12 5.9 11 9.8 1.2 6.9 0.9 1.2 1.2 15 15 2.0

1.1 0.70 1.2 15.8 1.2 0.60 1.1 1.0 0.12 0.70 0.09 0.12 0.12 1.5 1.5 0.20

97 in·lb 61 in·lb 106 in·lb 114 106 in·lb 52 in·lb 97 in·lb 87 in·lb 11 in·lb 61 in·lb 8 in·lb 11 in·lb 11 in·lb 11 11 18 in·lb

Remarks

S

AL

L

L S

L

SS HG

PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Fastener Oxygen Sensor (Equipped Models) Regulator/Rectifier Bolts Regulator/Rectifier Bracket Bolts Sidestand Switch Bolt Spark Plugs Speed Sensor Bolt Starter Motor Mounting Bolts Starter Relay Cable Terminal Bolts Stator Coil Bolts Switch Housing Screws Tail/Brake Light Mounting Screws Timing Rotor Bolt Vehicle-down Sensor Bolts Water Temperature Sensor

N·m 44.1 6.9 6.9 8.8 13 12 11 3.9 12 3.5 1.2 39 6.0 25

Torque kgf·m 4.50 0.70 0.70 0.90 1.3 1.2 1.1 0.40 1.2 0.36 0.12 4.0 0.61 2.5

ft·lb 32.5 61 in·lb 61 in·lb 78 in·lb 115 in·lb 106 in·lb 97 in·lb 35 in·lb 106 in·lb 31 in·lb 11 in·lb 29 53 in·lb 18

Remarks

L L

L

The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values 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 ∼ 19 25 ∼ 34 44 ∼ 61 73 ∼ 98 115 ∼ 155 165 ∼ 225 225 ∼ 325

Torque kgf·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 ∼ 45 54 ∼ 72 83 ∼ 115 125 ∼ 165 165 ∼ 240

2-12 PERIODIC MAINTENANCE Specifications Item Fuel System (DFI) Throttle Grip Free Play Idle Speed Bypass Screws (Turn Out) Throttle Body Vacuum Air Cleaner Element Cooling System Coolant: Type (Recommended) Color Mixed Ratio Freezing Point Total Amount Engine Top End Valve Clearance: Exhaust Inlet Clutch Clutch Lever Free Play

Standard 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

1 100 ±50 r/min (rpm) 2 1/2 (for reference) 38.0 ±1.3 kPa (285 ±10 mmHg) at idle speed Paper filter

– – – – – – – – –

Permanent type of antifreeze Green Soft water 50%, Coolant 50% –35°C (–31°F) 2.9 L (3.1 US qt)

– – – – –

0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.)

0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.)

– – – – – –

2 ∼ 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, MA1 or MA2 Viscosity SAE 10W-40 Capacity

Level Wheels/Tires Tread Depth: Front

Rear

Service Limit

3.1 L (3.3 US qt) (when filter is not removed) 3.3 L (3.5 US qt) (when filter is removed) 3.8 L (4.0 US qt) (when engine is completely dry) Between upper and lower level lines (after idling or running)

4.0 mm (0.16 in.)

5.5 mm (0.22 in.)

– – – – – –

– – – – –

– – – – –

– – –

– – – – – – – – – – – – – – –

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.)

PERIODIC MAINTENANCE 2-13 Specifications Item Air Pressure (when Cold): Front

Rear

Standard

Up to 180 kg (397 lb) load: 250 kPa (2.5 kgf/cm², 36 psi)

Service Limit – – –

Up to 180 kg (397 lb) load: 290 kPa (2.9 kgf/cm², 42 psi)

– – –

25 ∼ 30 mm (1.0 ∼ 1.2 in.)

317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)

– – –

Final Drive Drive Chain Slack Drive Chain Wear (20-link Length) Standard Chain: Make Type Link Brakes Brake Fluid: Grade Brake Pad Lining Thickness: Front Rear Brake Light Timing: Front Rear Electrical System Spark Plug: Type Gap

323 mm (12.7 in.)

ENUMA EK525UVXL3 110 Links

– – – – – – – – –

DOT4

– – –

4.0 mm (0.16 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

– – –

NGK CR9EIA-9 0.8 ∼ 0.9 mm (0.031 ∼ 0.035 in.)

– – – – – –

– – –

2-14 PERIODIC MAINTENANCE Special Tools Inside Circlip Pliers: 57001-143

Vacuum Gauge: 57001-1369

Steering Stem Nut Wrench: 57001-1100

Throttle Sensor Setting Adapter: 57001-1538

Jack: 57001-1238

Extension Tube: 57001-1578

Oil Filter Wrench: 57001-1249

Jack Attachment: 57001-1608

PERIODIC MAINTENANCE 2-15 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 the throttle 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. the element (see Air Cleaner Element Replace• Remove ment). the element by tapping it lightly to loosen dust.

• Clean away the remaining dust by applying compressed • Blow air [A] from the outside to the inside (from the clean side

•

to the dirty side).

Visually inspect the element for no tears or no breaks and inspect the sponge gaskets [B] also.

If the element or gasket has any tears or breaks, replace the element.

Throttle Control System Inspection

that the throttle grip [A] moves smoothly from full • Check open to close, and the throttle closes quickly and com-

•

pletely by the return spring in all steering positions.

If the throttle grip does not return properly, check the throttle cable routing, grip free play, and cable damage. Then lubricate the throttle cable.

Check the throttle grip free play [B].

Throttle Grip Free Play Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

• • • • • •

If the free play is incorrect, adjust the throttle cable as follows.

Loosen the locknuts [A] [B].

Screw both throttle cable adjusters [C] [D] to give the throttle grip plenty of play.

Turn the decelerator cable adjuster [C] until 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of throttle grip play is obtained.

Tighten the locknut [A].

Turn the accelerator cable adjuster [D] until 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of throttle grip play is obtained.

Tighten the locknut [B].

If the free play can not be adjusted with the adjusters, replace the cable.

2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Vacuum Synchronization Inspection NOTE

○These procedures are explained on the assumption that the inlet and exhaust systems of the engine are in good condition. the motorcycle so that it is vertical.

• Situate Remove the fuel tank (see Fuel Tank Removal in the Fuel • System (DFI) chapter). off the rubber caps [A] from the fittings of each throttle • Pull body.

Upside View [B]

the California and Southeast Asia Models, pull off the • For vacuum hoses [A].

off the air switching valve hose [A] from the air cleaner • Pull housing. the air switching valve hose end and air cleaner • Plug housing fitting.

a vacuum gauge (special tool) and hoses [A] to • Connect the fittings on the throttle body.

Special Tool - Vacuum Gauge: 57001-1369

a highly accurate tachometer [B] to one of the • Connect stick coil primary leads.

PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures the fuel outlet hose (see Fuel Hose Replace• Remove ment). the following parts temporary.

• Connect Fuel Pump Lead Connector [A] Fuel Level Sensor Lead Connector [B] Extension Tube [C] Special Tool - Extension Tube: 57001-1578

the engine and warm it up thoroughly.

• Start Check • [A]. the idle speed, using a highly accurate tachometer Idle Speed Standard:

1 100 ±50 r/min (rpm)

If the idle speed is out of the specified range, adjust it with the adjusting screw (see Idle Speed Adjustment).

CAUTION Do not measure the idle speed by the tachometer of the meter unit. idling the engine, inspect the throttle body vacuum, • While using the vacuum gauge [B].

Throttle Body Vacuum Standard: 38.0 ±1.3 kPa (285 ±10 mmHg) at idle speed

If any vacuum is not within specifications, first synchronize the balance of the left (#1, #2 throttle valves) and right (#3, #4 throttle valves) assemblies.

Example: #1: 260 mmHg #2: 290 mmHg #3: 250 mmHg #4: 270 mmHg With the engine at the correct idle speed, equalize higher vacuum of #1 or #2 (for example 290 mmHg) to higher vacuum of #3 or #4 (for example 270 mmHg) by turning the center adjusting screw [A].

Upside View [B]

•

NOTE

○After adjustment, the final vacuum measurement between the highest throttle valves may not be 290 mmHg (for example). The goal is to have the highest two vacuums between the left (#1 and #2) and right (#3 and #4) banks be the same. and close the throttle after each measurement, and • Open adjust the idle speed as necessary. the throttle valves have been synchronized, inspect • Once output voltage of the main throttle sensor to ensure proper operation (procedure is explained at the end of this section).

2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures

• • • •

If any one vacuum measurement is out of the specified range after left (#1, #2) and right (#2, #3) synchronization, adjust the bypass screws [A].

Upside View [B] Adjust the lower vacuum between #1 and #2 to the higher vacuum of #1 and #2.

Adjust the lower vacuum between #3 and #4 to the higher vacuum of #3 and #4.

Open and close the throttle valves after each measurement, and adjust the idle speed as necessary.

Check the vacuums as before.

If all vacuums are within the specification range, finish the engine vacuum synchronization.

If any vacuum can not be adjusted within the specification, remove the bypass screws #1 ∼ #4 and clean them.

in the bypass screw [A] with counting the number of • Turn turns until it seals fully but not tightly. Record the number of turns.

Torque - Bypass Screw: 0.2 N·m (0.02 kgf·m, 1.8 in·lb)

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

• Remove: Bypass Screw • • • •

Spring [B] Washer [C] O-ring [D] Check the bypass screw and its hole for carbon deposits.

If any carbons accumulate, wipe the carbons off from the bypass screw and the hole, using a cotton pad penetrated with a high-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.

Torque - Bypass Screw: 0.2 N·m (0.02 kgf·m, 1.8 in·lb)

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