3. Quick Reference Guide
General Information 1
j
Periodic Maintenance 2
j
Fuel System (DFI) 3
j
Cooling System 4
j
Engine Top End 5
j
Clutch 6
j
Engine Lubrication System 7
j
Engine Removal/Installation 8
j
Crankshaft/Transmission 9
j
Wheels/Tires 10
j
Final Drive 11
j
Brakes 12
j
Suspension 13
j
Steering 14
j
Frame 15
4. j
Electrical System 16
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Appendix 17
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This quick reference guide will assist
you in locating a desired topic or pro-
cedure.
•Bend the pages back to match the
black tab of the desired chapter num-
ber 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 spe-
cific topic required.
7. LIST OF ABBREVIATIONS
A ampere(s) lb pound(s)
ABDC after bottom dead center m meter(s)
AC alternating current min minute(s)
ATDC after top dead center N newton(s)
BBDC before bottom dead center Pa pascal(s)
BDC bottom dead center PS horsepower
BTDC before top dead center psi pound(s) per square inch
°C degree(s) Celsius r revolution
DC direct current rpm revolution(s) per minute
F farad(s) TDC top dead center
°F degree(s) Fahrenheit TIR total indicator reading
ft foot, feet V volt(s)
g gram(s) W watt(s)
h hour(s) Ω ohm(s)
L liter(s)
COUNTRY AND AREA CODES
AT Austria GB United Kingdom
AU Australia MY Malaysia
CA Canada SEA Southeast Asia
CAL California US United States
CH Switzerland WVTA WVTA Model with Honeycomb
(FULL H) Catalytic Converter (Full Power)
DE Germany GB WVTA WVTA Model with Honeycomb Catalytic
(FULL H) Converter (Left Side Traffic Full
Power)
EUR Europe WVTA WVTA Model with Honeycomb Catalytic
(78.2 H) Converter (Restricted Power)
8. EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporated crankcase emis-
sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of
the United States Environmental Protection Agency and California Air Resources Board. Addi-
tionally, 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. In-
stead, 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 know-
ingly 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 follow-
ing 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 de-
vices or elements of design in order to perform maintenance.
2. Tampering could include.
a.Maladjustment of vehicle components such that the emission standards are 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 stan-
dards.
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
$10000 PER VIOLATION.
9. 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.
10. Foreword
This manual is designed primarily for use by Guide shows you all of the product’s system
trained mechanics in a properly equipped shop. and assists in locating their chapters. Each
However, it contains enough detail and basic in- chapter in turn has its own comprehensive Ta-
formation to make it useful to the owner who de- ble of Contents.
sires to perform his own basic maintenance and For example, if you want ignition coil informa-
repair work. A basic knowledge of mechanics, tion, use the Quick Reference Guide to locate
the proper use of tools, and workshop proce- the Electrical System chapter. Then, use the
dures must be understood in order to carry out Table of Contents on the first page of the chap-
maintenance and repair satisfactorily. When- ter to find the Ignition Coil section.
ever the owner has insufficient experience or Whenever you see these WARNING and
doubts his ability to do the work, all adjust- CAUTION symbols, heed their instructions!
ments, maintenance, and repair should be car- Always follow safe operating and maintenance
ried out only by qualified mechanics. practices.
In order to perform the work efficiently and WARNING
to avoid costly mistakes, read the text, thor-
oughly familiarize yourself with the procedures This warning symbol identifies special
before starting work, and then do the work care- instructions or procedures which, if not
fully in a clean area. Whenever special tools or correctly followed, could result in per-
equipment are specified, do not use makeshift sonal injury, or loss of life.
tools or equipment. Precision measurements
can only be made if the proper instruments are CAUTION
used, and the use of substitute tools may ad-
This caution symbol identifies special
versely affect safe operation.
instructions or procedures which, if not
For the duration of the warranty period,
strictly observed, could result in dam-
we recommend that all repairs and scheduled
age to or destruction of equipment.
maintenance be performed in accordance with
this service manual. Any owner maintenance or This manual contains four more symbols (in
repair procedure not performed in accordance addition to WARNING and CAUTION) which will
with this manual may void the warranty. help you distinguish different types of informa-
To get the longest life out of your vehicle. tion.
• Servicethe Periodic Maintenance Chart in the
Follow
Manual. NOTE
• maintenance. problems and non-scheduled
Be alert for
○This note symbol indicates points of par-
ticular interest for more efficient and con-
• Use proper tools and genuine Kawasaki Mo- venient operation.
torcycle parts. Special tools, gauges, and
testers that are necessary when servicing • done. a procedural step or work to be
Indicates
Kawasaki motorcycles are introduced by the
Service Manual. Genuine parts provided as
○Indicates a procedural sub-step or how to do
the work of the procedural step it follows. It
spare parts are listed in the Parts Catalog. also precedes the text of a NOTE.
• fully. Don’t take shortcuts. this manual care-
Follow the procedures in Indicates a conditional step or what action to
take based on the results of the test or inspec-
• Remember to keep complete records of main- tion in the procedural step or sub-step it fol-
tenance and repair with dates and any new lows.
parts installed. In most chapters an exploded view illustration of
the system components follows the Table of
How to Use This Manual Contents. In these illustrations you will find the
In this manual, the product is divided into instructions indicating which parts require spec-
its major systems and these systems make up ified tightening torque, oil, grease or a locking
the manual’s chapters. The Quick Reference agent during assembly.
11.
12. GENERAL INFORMATION 1-1
General Information
Table of Contents
1
Before Servicing ............................................................................................................................1-2
Model Identification.........................................................................................................................1-7
General Specifications....................................................................................................................1-9
Technical Information-KIMS (Kawasaki Ignition Management System) ..........................................1-12
Unit Conversion Table ..................................................................................................................1-13
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, discon-
nect the battery cables from the battery to prevent the en-
gine 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 (-) ca-
ble 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.
14. 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 ac-
cident. Visually inspect removed parts for corrosion, discol-
oration, 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 be-
yond 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.
15. 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 se-
quence 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 quar-
ter 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 dam-
age. 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 thor-
oughly 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 exces-
sively. Excessive application can clog oil passages and
cause serious damage.
16. 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.
17. 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.
18. GENERAL INFORMATION 1-7
Model Identification
ZX1000E8F (US and CA Models) Left Side View
ZX1000E8F (US and CA Models) Right Side View
19. 1-8 GENERAL INFORMATION
Model Identification
ZX1000E8F (EUR Models) Left Side View
ZX1000E8F (EUR Models) Right Side View
Frame Number Engine Number
20. GENERAL INFORMATION 1-9
General Specifications
Items ZX1000E8F
Dimensions
Overall Length 2 110 mm (83.1 in.)
Overall Width 710 mm (28.0 in.)
Overall Height 1 135 mm (44.7 in.)
Wheelbase 1 415 mm (55.7 in.)
Road Clearance 125 mm (4.9 in.)
Seat Height 830 mm (32.7 in.)
Dry Mass 179 kg (395 lb)
Curb Mass:
Front 106 kg (234 lb)
Rear 102 kg (225 lb)
Fuel Tank Capacity 17 L (4.5 US gal)
Performance
Minimum Turning Radius 3.4 m (11.2 ft)
Engine
Type 4-stroke, DOHC, 4-cylinder
Cooling System Liquid-cooled
Bore and Stroke 76.0 × 55.0 mm (3.0 × 2.2 in.)
Displacement 998 cm³ (60.9 cu in.)
Compression Ratio 12.9 : 1
Maximum Horsepower 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), (SEA) 119.2 kW (162.1 PS) @10 000 r/min (rpm),
(CA), (CAL), (US) - - -
Maximum Torque 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) - - -
Carburetion System FI (Fuel injection), KEIHIN TTK43 × 4
Starting System Electric starter
Ignition System Battery and coil (transistorized)
KIMS (Kawasaki Ignition Management System)
Timing Advance Electronically advanced (IC igniter in ECU)
Ignition Timing From 10° BTDC @1 100 r/min (rpm)
Spark Plug NGK CR9EIA-9
Cylinder Numbering Method Left to right, 1-2-3-4
Firing Order 1-2-4-3
Valve Timing:
Inlet:
Open 35° BTDC
Close 77° ABDC
Duration 292°
Exhaust:
Open 62° BBDC
Close 38° ATDC
Duration 280°
21. 1-10 GENERAL INFORMATION
General Specifications
Items ZX1000E8F
Lubrication System Forced lubrication (wet sump with oil cooler)
Engine Oil:
Grade API SE, SF or SG
API SH, SJ or SL with JASO MA
Viscosity SAE10W-40
Capacity 4.0 L (4.2 US qt)
Drive Train
Primary Reduction System:
Type Gear
Reduction Ratio 1.611 (87/54)
Clutch Type Wet multi disc
Transmission:
Type 6-speed, constant mesh, return shift
Gear Ratios:
1st 2.600 (39/15)
2nd 2.053 (39/19)
3rd 1.737 (33/19)
4th 1.550 (31/20)
5th 1.400 (28/20)
6th 1.304 (30/23)
Final Drive System:
Type Chain drive
Reduction Ratio 2.412 (41/17)
Overall Drive Ratio 5.068 @Top gear
Frame
Type Tubular, diamond
Caster (Rake Angle) 25.5°
Trail 110 mm (4.3 in.)
Front Tire:
Type Tubeless
Size 120/70 ZR17 M/C (58 W)
Rim Size 17 × 3.50
Rear Tire:
Type Tubeless
Size 190/55 ZR17 M/C (75 W)
Rim Size 17 × 6.00
Front Suspension:
Type Telescopic fork (upside-down)
Wheel Travel 120 mm (4.7 in.)
Rear Suspension:
Type Swingarm (uni-trak)
Wheel Travel 125 mm (4.9 in.)
22. GENERAL INFORMATION 1-11
General Specifications
Items ZX1000E8F
Brake Type:
Front Dual discs
Rear Single disc
Electrical Equipment
Battery 12 V 10 Ah
Headlight:
Type Semi-sealed beam
Bulb:
High 12 V 55 W + 65 W (quartz-halogen)
Low 12 V 55 W (quartz-halogen)
Tail/Brake Light 12 V 0.5/4.1 W (LED)
Alternator:
Type Three-phase AC
Rated Output 30 A/14 V @5 000 r/min (rpm)
Specifications are subject to change without notice, and may not apply to every country.
23. 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. How-
ever, 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 ex-
perience.
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 calcu-
lated 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 continu-
ous sampling, with the aim being to optimize
the relationship between throttle opening, en-
gine/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 ac-
count.
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.
24. GENERAL INFORMATION 1-13
Unit Conversion Table
Prefixes for Units:
Units of Length:
Prefix Symbol Power km × 0.6214 = mile
mega M × 1 000000 m × 3.281 = ft
kilo k × 1 000 mm × 0.03937 = in
centi c × 0.01
milli m × 0.001
Units of Torque:
micro µ × 0.000001
N·m × 0.1020 = kgf·m
N·m × 0.7376 = ft·lb
Units of Mass: N·m × 8.851 = in·lb
kg × 2.205 = lb kgf·m × 9.807 = N·m
g × 0.03527 = oz kgf·m × 7.233 = ft·lb
kgf·m × 86.80 = in·lb
Units of Volume:
L × 0.2642 = gal (US) Units of Pressure:
L × 0.2200 = gal (imp) kPa × 0.01020 = kgf/cm²
L × 1.057 = qt (US) kPa × 0.1450 = psi
L × 0.8799 = qt (imp) kPa × 0.7501 = cmHg
L × 2.113 = pint (US) kgf/cm² × 98.07 = kPa
L × 1.816 = pint (imp) kgf/cm² × 14.22 = psi
mL × 0.03381 = oz (US) cmHg × 1.333 = kPa
mL × 0.02816 = oz (imp)
mL × 0.06102 = cu in Units of Speed:
km/h × 0.6214 = mph
Units of Force:
N × 0.1020 = kg Units of Power:
N × 0.2248 = lb kW × 1.360 = PS
kg × 9.807 = N kW × 1.341 = HP
kg × 2.205 = lb PS × 0.7355 = kW
PS × 0.9863 = HP
Units of Temperature:
25.
26. PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart ...........................................................................................................2-3
Torque and Locking Agent..............................................................................................................2-6 2
Specifications ..............................................................................................................................2-13
Special Tools ...............................................................................................................................2-15
Maintenance Procedure ...............................................................................................................2-16
Fuel System (DFI)......................................................................................................................2-16
Throttle Control System Inspection..........................................................................................2-16
Engine Vacuum Synchronization Inspection.............................................................................2-16
Idle Speed Inspection .............................................................................................................2-20
Idle Speed Adjustment............................................................................................................2-21
Fuel Hose Inspection (fuel leak, damage, installation condition)................................................2-21
Evaporative Emission Control System Inspection (CAL and SEA Models) ..............................2-22
Cooling System..........................................................................................................................2-23
Coolant Level Inspection.........................................................................................................2-23
Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition) ...................2-23
Engine Top End ........................................................................................................................2-24
Valve Clearance Inspection ....................................................................................................2-24
Valve Clearance Adjustment....................................................................................................2-25
Air Suction System Damage Inspection...................................................................................2-27
Clutch........................................................................................................................................2-28
Clutch Operation Inspection ....................................................................................................2-28
Wheels/Tires..............................................................................................................................2-29
Tire Air Pressure Inspection.....................................................................................................2-29
Wheel/Tire Damage Inspection................................................................................................2-30
Tire Tread Wear Inspection ....................................................................................................2-30
Wheel Bearing Damage Inspection .........................................................................................2-31
Final Drive.................................................................................................................................2-31
Drive Chain Lubrication Condition Inspection...........................................................................2-31
Drive Chain Slack Inspection...................................................................................................2-32
Drive Chain Slack Adjustment .................................................................................................2-32
Wheel Alignment Inspection ...................................................................................................2-33
Drive Chain Wear Inspection ..................................................................................................2-33
Chain Guide Wear Inspection..................................................................................................2-34
Brake ........................................................................................................................................2-34
Brake Fluid Leak (Brake Hose and Pipe) Inspection ................................................................2-34
Brake Hose Damage and Installation Condition Inspection.......................................................2-35
Brake Operation Inspection ....................................................................................................2-35
Brake Fluid Level Inspection....................................................................................................2-35
Brake Pad Wear Inspection ....................................................................................................2-36
Brake Light Switch Operation Inspection..................................................................................2-36
Suspensions .............................................................................................................................2-37
Front Forks/Rear Shock Absorber Operation Inspection...........................................................2-37
Front Fork Oil Leak Inspection.................................................................................................2-37
Rear Shock Absorber Oil Leak Inspection................................................................................2-38
Rocker Arm Operation Inspection............................................................................................2-38
Tie-Rod Operation Inspection..................................................................................................2-38
Steering ....................................................................................................................................2-38
Steering Play Inspection .........................................................................................................2-38
Steering Play Adjustment........................................................................................................2-39
Steering Stem Bearing Lubrication ..........................................................................................2-40
27. 2-2 PERIODIC MAINTENANCE
Steering Damper Oil Leak Inspection ......................................................................................2-40
Electrical System .......................................................................................................................2-41
Lights and Switches Operation Inspection................................................................................2-41
Headlight Aiming Inspection ....................................................................................................2-43
Sidestand Switch Operation Inspection ...................................................................................2-44
Engine Stop Switch Operation Inspection.................................................................................2-45
Others.......................................................................................................................................2-45
Chassis Parts Lubrication .......................................................................................................2-45
Bolts, Nuts and Fasteners Tightness Inspection.......................................................................2-46
Replacement Parts ....................................................................................................................2-48
Air Cleaner Element Replacement...........................................................................................2-48
Fuel Hose Replacement .........................................................................................................2-48
Coolant Change......................................................................................................................2-52
Radiator Hose and O-ring Replacement...................................................................................2-54
Engine Oil Change..................................................................................................................2-55
Oil Filter Replacement ............................................................................................................2-56
Brake Hose and Pipe Replacement.........................................................................................2-56
Brake Fluid Change ................................................................................................................2-57
Master Cylinder Rubber Parts Replacement ...........................................................................2-59
Caliper Rubber Parts Replacement .........................................................................................2-60
Spark Plug Replacement ........................................................................................................2-64
28. 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 * ODOMETER READING
comes × 1 000 km
first (× 1 000 mile) See
Page
1 6 12 18 24 30 36
ITEM Every (0.6) (4) (7.5) (12) (15) (20) (24)
Fuel System
Throttle control system (play, smooth
return, no drag)-inspect year • • • • 2-16
Engine vacuum synchronization-inspect
• • • 2-16
Idle speed-inspect • • • 2-20
•
Fuel leak (fuel hose and pipe)-inspect
Fuel hose and pipe damage-inspect
year
year
•
• •
• •
• •
•
2-21
2-21
Fuel hose and pipe installation
condition-inspect year • • • 2-21
•
Evaporative emission control system
function-inspect (CAL and SEA Models) • • • • • • • 2-22
Cooling System
Coolant level-inspect • • • • 2-23
Coolant leak (radiator hose and year • • • • 2-23
pipe)-inspect
Radiator hose damage-inspect year • • • •
2-23
Radiator hose installation condition -
inspect
year • • • •
2-23
Engine Top End
Valve clearance-inspect • 2-24
Air suction system damage-inspect • • • 2-27
Clutch
Clutch operation (play, disengagement,
engagement)-inspect • • • 2-28
•
Wheels and Tires
Tire air pressure-inspect year • • • 2-29
Wheel/tire damage-inspect • • • 2-30
Tire tread wear, abnormal wear-inspect • •
29. • 2-30
Wheel bearing damage-inspect year • • • 2-31
Final Drive
Drive chain lubrication condition-inspect # Every 600 km (400 mile) 2-31
Drive chain slack-inspect # Every 1 000 km (600 mile) 2-32
Drive chain wear-inspect # • • • 2-33
Drive chain guide wear-inspect • • • 2-34
Brakes
Brake fluid leak (brake hose and
pipe)-inspect year • • • • • 2-34
• •
30. 2-4 PERIODIC MAINTENANCE
Periodic Maintenance Chart
FREQUENCY Whichever * ODOMETER READING
comes × 1 000 km
first (× 1 000 mile) See
Page
1 6 12 18 24 30 36
ITEM Every (0.6) (4) (7.5) (12) (15) (20) (24)
Brake hose and pipe damage-inspect year • • • • • • • 2-35
Brake hose installation condition-inspect year • • • • • • • 2-35
Brake operation (effectiveness, play, no
drag)-inspect year • • • • • • • 2-35
Brake fluid level-inspect 6 months • • • • • 2-35
• •
Brake pad wear-inspect # • • • • • • 2-36
Brake light switch operation-inspect
Suspension
• • • • • • • 2-36
Front forks/rear shock absorber operation
(damping and smooth stroke)-inspect • • • 2-37
Front forks/rear shock absorber oil 2-37,
leak-inspect year
• • • 2-38
Rocker arm operation-inspect • • • 2-38
Tie-rods operation-inspect
Steering
• • • 2-38
Steering play-inspect year • • • 2-38
•
Steering stem bearings-lubricate 2 years • 2-40
Steering damper oil leak-inspect
Electrical System
• • • • • • 2-40
Lights and switches operation-inspect year • • • 2-41
Headlight aiming-inspect year • • • 2-43
Sidestand switch operation-inspect year • • • 2-44
Engine stop switch operation-inspect year • • • 2-45
Others
Chassis parts-lubricate year • • • 2-45
Bolts and nuts tightness-inspect • • • 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.
31. PERIODIC MAINTENANCE 2-5
Periodic Maintenance Chart
Periodic Replacement Parts
FREQUENCY Whichever * ODOMETER READING
come × 1 000 km
first (× 1 000 mile) See
Page
1 12 24 36 48
ITEM Every (0.6) (7.5) (15) (24) (30)
Air cleaner element # - replace Every 18 000 km (12 000 mile) 2-48
Fuel hose - replace 4 years • 2-48
Coolant - change 3 years • 2-52
Radiator hose and O-ring - replace 3 years • 2-54
Engine oil # - change year • • • • • 2-55
Oil filter - replace year • • • • • 2-56
Brake hose and pipe - replace 4 years • 2-56
Brake fluid - change 2 years • • 2-57
Rubber parts of master cylinder and caliper -
replace
4 years • 2-59,
2-60
Spark plug - replace • • •
*: For higher odometer readings, repeat at the frequency interval established here.
• 2-64
#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or
frequent starting/stopping.
32. 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.
Torque
Fastener Remarks
N·m kgf·m ft·lb
Fuel System (DFI)
Inlet Air Temperature Sensor Screw 1.2 0.12 11 in·lb
Air Inlet Duct Mounting Bolts 7.0 0.71 62 in·lb L
Air Cleaner Housing Bracket Bolt 7.0 0.71 62 in·lb
Air Cleaner Housing Mounting Bolt (Upper) 7.0 0.71 62 in·lb
Air Cleaner Housing Mounting Bolts (Lower) 4.2 0.43 37 in·lb L
Air Cleaner Housing Assembly Screws 1.1 0.11 9.7 in·lb
Rubber Plate Holder Screws 1.1 0.11 9.7 in·lb
Delivery Pipe Assy Mounting Screws (Nozzle Assy) 3.4 0.35 30 in·lb
Nozzle Assy Mounting Bolts 7.0 0.71 62 in·lb
Delivery Pipe Assy Mounting Screws (Throttle Body
Assy) 3.4 0.35 30 in·lb
Throttle Body Assy Holder Clamp Bolts 2.0 0.20 18 in·lb
Throttle Body Assy Holder Bolts 10 1.0 89 in·lb S
Vehicle-down Sensor Bolts 6.0 0.61 53 in·lb
Camshaft Position Sensor Bolt 10 1.0 89 in·lb
Water Temperature Sensor 25 2.5 18
Crankshaft Sensor Bolts 6.0 0.61 53 in·lb L
Fuel Pump Bolts 10 1.0 89 in·lb L, S
Gear Position Switch Screws 3.0 0.31 27 in·lb L
Speed Sensor Bolt 10 1.0 89 in·lb
Inlet Air Pressure Sensor Bracket Screws 3.4 0.35 30 in·lb
Exhaust Butterfly Valve Actuator Mounting Screws 4.3 0.44 38 in·lb
Exhaust Butterfly Valve Actuator Pulley Bolt 5.0 0.51 44 in·lb
Separator Bracket Bolts 7.0 0.71 62 in·lb
Canister Bracket Bolts 4.3 0.44 38 in·lb
Cooling System
Water Hose Clamp Screws 2.0 0.20 18 in·lb
Coolant Drain Bolt (Cylinder) 10 1.0 89 in·lb
Water Pump Cover Bolts 10 1.0 89 in·lb
Water Temperature Sensor 25 2.5 18
Coolant Reserve Tank Mounting Bolts 7.0 0.71 62 in·lb
33. PERIODIC MAINTENANCE 2-7
Torque and Locking Agent
Torque
Fastener Remarks
N·m kgf·m ft·lb
Coolant By-pass Fitting Bolt 9.0 0.92 80 in·lb L
Thermostat Housing Cover Bolts 6.0 0.61 53 in·lb
Thermostat Housing Mounting Bolts 10 1.0 89 in·lb
Oil Cooler Mounting Bolts 20 2.0 15
Water Hose Fitting Bolts 10 1.0 89 in·lb
Water Passage Plugs 20 2.0 15 L
Radiator Bracket Mounting Bolt 7.0 0.71 62 in·lb
Radiator Upper Bolt 7.0 0.71 62 in·lb
Radiator Lower Bolt 7.0 0.71 62 in·lb
Coolant Drain Bolt (Water Pump) 10 1.0 89 in·lb
Radiator Overflow Hose Clamp Bolt 10 1.0 89 in·lb
Engine Top End
Air Suction Valve Cover Bolts 10 1.0 89 in·lb L
Cylinder Head Cover Bolts 10 1.0 89 in·lb
Camshaft Cap Bolts 12 1.2 106 in·lb S
Upper Camshaft Chain Guide Bolts 12 1.2 106 in·lb S
Cylinder Head Bolts (M10 New Bolts) 59 6.0 44 MO, S
Cylinder Head Bolts (M10 Used Bolts) 57 5.8 42 MO, S
Cylinder Head Bolts (M6) 12 1.2 106 in·lb S
Water Passage Plugs 19.6 2.0 14.5 L
Throttle Body Assy Holder Bolts 10 1.0 89 in·lb S
Throttle Body Assy Holder Clamp Bolts 2.0 0.20 18 in·lb
Camshaft Position Sensor Bolt 10 1.0 89 in·lb
Front Camshaft Chain Guide Bolt (Upper) 25 2.5 18
Front Camshaft Chain Guide Bolt (Lower) 12 1.2 106 in·lb
Camshaft Chain Tensioner Mounting Bolts 10 1.0 89 in·lb
Camshaft Chain Tensioner Cap Bolt 20 2.0 15
Spark Plugs 13 1.3 115 in·lb
Cam Sprocket Mounting Bolts 15 1.5 11 L
Starter Clutch Cover Bolts (M6, L = 30) 10 1.0 89 in·lb
Starter Clutch Cover Bolts (M6, L = 20) 10 1.0 89 in·lb
Torque Limiter Cover Bolts 10 1.0 89 in·lb L (1), S
Coolant Drain Plug (Cylinder) 10 1.0 89 in·lb
Starter Clutch Bolt Cap - - - Hand-tighten
Timing Inspection Cap - - - Hand-tighten
Right Engine Bracket Bolts (Cylinder Head) 9.8 1.0 87 in·lb L
Exhaust Pipe Holder Nuts 17 1.7 13
Exhaust Manifold Clamp Bolt 25 2.5 18
Premuffler Chamber Mounting Bolt 25 2.5 18
Premuffler Chamber Outer Cover Bolts 7.0 0.71 62 in·lb
Premuffler Chamber Inner Cover Bolts 7.0 0.71 62 in·lb
Exhaust Butterfly Valve Cable Clamp Bolt 10 1.0 89 in·lb
Exhaust Butterfly Valve Pulley Cover Bolts 7.0 0.71 62 in·lb
34. 2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
Torque
Fastener Remarks
N·m kgf·m ft·lb
Muffler Body Clamp Bolt 25 2.5 18
Muffler Body Mounting Bolt 25 2.5 18
Muffler Body Front Cover Bolts 7.0 0.71 62 in·lb
Muffler Body Rear Cover Bolts 7.0 0.71 62 in·lb
Clutch
Clutch Lever Clamp Bolts 7.8 0.80 69 in·lb S
Clutch Cover Bolts (M6, L = 25) 10 1.0 89 in·lb S
Clutch Cover Bolts (M6, L = 35) 10 1.0 89 in·lb S
Oil Filler Plug - - - Hand-tighten
Clutch Spring Bolts 11 1.1 97 in·lb
Clutch Hub Nut 130 13.3 96 R
Sub Clutch Hub Bolts 25 2.5 18 L
Engine Lubrication System
Engine Oil Drain Bolt 30 3.1 22
Oil Filter 17 1.7 13 G, R
Oil Filter Pipe 35 3.6 26 L
Oil Pan Bolts 10 1.0 89 in·lb
Oil Pressure Relief Valve 15 1.5 11 L
Oil Pressure Switch 15 1.5 11 SS
Oil Pressure Switch Terminal Bolt - - - Hand-tighten
Oil Pump Gear Bolts 10 1.0 89 in·lb L
Oil Passage Plugs 20 2.0 15 L
Oil Pump Cover Bolts 10 1.0 89 in·lb
Oil Cooler/Oil Filter Case Mounting Bolts 20 2.0 15 L
Oil Cooler Mounting Bolts 20 2.0 15
Engine Removal/Installation
Adjusting Collar Locknut 49 5.0 36 S
Left Front Engine Mounting Bolt (M10, L = 42) 44 4.5 32 S
Right Front Engine Mounting Bolt (M10, L = 67) 44 4.5 32 S
Middle Engine Mounting Bolt 9.8 1.0 87 in·lb S
Middle Engine Mounting Nut 44 4.5 32 S
Lower Engine Mounting Bolt 9.8 1.0 87 in·lb S
Lower Engine Mounting Nut 44 4.5 32 S
Left Engine Bracket Bolts (M10, L = 30) 44 4.5 32 S
Right Engine Bracket Bolts (M10, L = 30) 44 4.5 32 S
Right Engine Bracket Bolt (M10, L = 35) 44 4.5 32 S
Right Engine Bracket Bolts (Cylinder Head) 9.8 1.0 87 in·lb L
Crankshaft/Transmission
Breather Plate Bolts 10 1.0 89 in·lb L
Crankcase Bolts (M9) 39 4.0 29 MO, S
Crankcase Bolts (M8) 27 2.8 20 S
Crankcase Bolts (M7, L = 32) 20 2.0 15 S
Crankcase Bolt (M7, L = 50) 20 2.0 15 S
35. PERIODIC MAINTENANCE 2-9
Torque and Locking Agent
Torque
Fastener Remarks
N·m kgf·m ft·lb
Crankcase Bolt (M7, L = 85) 20 2.0 15 S
Crankcase Bolts (M6, L = 45) 12 1.2 106 in·lb S
Crankcase Bolts (M6, L = 40) 12 1.2 106 in·lb S
Shift Drum Bearing Holder Screws 5.0 0.51 44 in·lb L
Plate Screw 5.0 0.51 44 in·lb L
Drive Shaft Bearing Holder Screws 5.0 0.51 44 in·lb L
Connecting Rod Big End Nuts see Text ← ← MO
Oil Passage Plugs 20 2.0 15 L
Piston Oil Jet 3.0 0.30 27 in·lb
Coolant Drain Bolt (Cylinder) 10 1.0 89 in·lb
Drive Shaft Cover Bolts 25 2.5 18
Plug 20 2.0 15 L
Shift Pedal Mounting Bolt 25 2.5 18 L
Gear Positioning Lever Bolt 12 1.2 106 in·lb
Shift Ratchet Assembly Holder Bolts 15 1.5 11 L
Shift Shaft Return Spring Pin 29 3.0 21 L
Shift Drum Cam Bolt 12 1.2 106 in·lb L
Shift Lever Bolt 7.0 0.71 62 in·lb
Tie-Rod Locknuts 7.0 0.71 62 in·lb Lh (1)
Gear Position Switch Screws 3.0 0.30 27 in·lb L
Torque Limiter Cover Bolts 10 1.0 89 in·lb L (1), S
Starter Clutch Bolt Cap - - - Hand-tighten
Timing Inspection Cap - - - Hand-tighten
Starter Clutch Cover Bolts (M6, L = 30) 10 1.0 89 in·lb
Starter Clutch Cover Bolts (M6, L = 20) 10 1.0 89 in·lb
Starter Clutch Bolt 49 5.0 36
Wheels/Tires
Front Axle Clamp Bolts 20 2.0 15 AL
Front Axle Nut 127 13.0 94
Rear Axle Nut 108 11.0 80
Final Drive
Rear Axle Nut 108 11.0 80
Rear Sprocket Nuts 59 6.0 44
Engine Sprocket Nut 125 12.7 92 MO
Engine Sprocket Cover Bolts 10 1.0 89 in·lb
Brakes
Bleed Valves 7.8 0.80 69 in·lb
Brake Hose Banjo Bolts 25 2.5 18
Brake Lever Pivot Bolt 1.0 0.10 9 in·lb Si
Brake Lever Pivot Bolt Nut 5.9 0.60 52 in·lb
Front Brake Disc Mounting Bolts 27 2.8 20 L
Front Brake Light Switch Screw 1.2 0.12 11 in·lb
Front Brake Pad Pins 15 1.5 11
36. 2-10 PERIODIC MAINTENANCE
Torque and Locking Agent
Torque
Fastener Remarks
N·m kgf·m ft·lb
Front Brake Reservoir Cap Stopper Screw 1.2 0.12 11 in·lb
Front Caliper Assembly Bolts 22 2.2 16
Front Caliper Mounting Bolts 34 3.5 25
Front Master Cylinder Bleed Valve 5.4 0.55 48 in·lb
Front Master Cylinder Clamp Bolts 11 1.1 97 in·lb S
Brake Pedal Bolt 8.8 0.90 78 in·lb
Rear Brake Disc Mounting Bolts 27 2.8 20 L
Rear Caliper Mounting Bolts 25 2.5 18
Rear Master Cylinder Mounting Bolts 25 2.5 18
Rear Master Cylinder Push Rod Locknut 17 1.7 13
Suspension
Front Axle Clamp Bolts 20 2.0 15 AL
Front Fork Bottom Allen Bolts 23 2.3 17 L
Lower Front Fork Clamp Bolts 30 3.1 22 AL
Upper Front Fork Clamp Bolts 20 2.0 15
Front Fork Top Plugs 23 2.3 17
Piston Rod Nuts 15 1.5 11
Rear Shock Absorber Bracket Nut 59 6.0 44
Lower Rear Shock Absorber Nut 34 3.5 25
Upper Rear Shock Absorber Nut 34 3.5 25
Uni-Trak Rocker Arm Nut 34 3.5 25
Swingarm Pivot Shaft 20 2.0 15
Swingarm Pivot Adjusting Collar Locknut 98 10.0 72
Swingarm Pivot Shaft Nut 108 11.0 80
Tie-Rod Nuts 59 6.0 44
Steering
Left Switch Housing Screws 3.5 0.36 31 in·lb
Right Switch Housing Screws 3.5 0.36 31 in·lb
Handlebar Clamp Bolts 25 2.5 18
Handlebar Positioning Bolts 9.8 1.0 87 in·lb L
Steering Stem Head Bolt 108 11.0 80
Upper Front Fork Clamp Bolts 20 2.0 15
Steering Stem Nut 20 2.0 15
Lower Front Fork Clamp Bolts 30 3.1 22 AL
Steering Damper Mounting Bolts 11 1.1 97 in·lb L
Frame
Front Footpeg Bracket Bolts 25 2.5 18
Rear Footpeg Bracket Bolts 25 2.5 18
Rear Frame Front Bolts 44 4.5 32 L
Rear Frame Rear Bolts 25 2.5 18 L
Sidestand Bolt 44 4.5 32
Sidestand Switch Bolt 8.8 0.90 78 in·lb L
Sidestand Bracket Bolts 49 5.0 36 L
37. PERIODIC MAINTENANCE 2-11
Torque and Locking Agent
Torque
Fastener Remarks
N·m kgf·m ft·lb
Front Fender Mounting Bolts 3.9 0.40 35 in·lb
Windshield Mounting Bolts 0.40 0.041 3.5 in·lb
Electrical System
Meter Unit Mounting Screws 1.2 0.12 11 in·lb
Front Turn Signal Light Lens Screws 1.0 0.10 9 in·lb
Rear Turn Signal Light Lens Screws 1.0 0.10 9 in·lb
License Plate Light Cover Screws 1.0 0.10 9 in·lb
Camshaft Position Sensor Bolt 10 1.0 89 in·lb
Water Temperature Sensor 25 2.5 18
Oxygen Sensors (Equipped Models) 25 2.5 18
Vehicle-down Sensor Bolts 6.0 0.61 53 in·lb
Gear Position Switch Screws 3.0 0.30 27 in·lb L
Spark Plugs 13 1.3 115 in·lb
Stator Coil Bolts 12 1.2 106 in·lb
Alternator Rotor Bolt 155 15.8 114
Crankshaft Sensor Bolts 6.0 0.61 53 in·lb L
Regulator/Rectifier Bolts 7.0 0.71 62 in·lb
Regulator/Rectifier Bracket Bolts 7.0 0.71 62 in·lb
Speed Sensor Bolt 10 1.0 89 in·lb
Alternator Cover Bolts 10 1.0 89 in·lb
Alternator Lead Holding Plate Bolt 10 1.0 89 in·lb L
Oil Pressure Switch 15 1.5 11 SS
Oil Pressure Switch Terminal Bolt - - - Hand-tighten
Torque Limiter Cover Bolts 10 1.0 89 in·lb L (1), S
Starter Clutch Cover Bolts (M6, L = 30) 10 1.0 89 in·lb
Starter Clutch Cover Bolts (M6, L = 20) 10 1.0 89 in·lb
Starter Clutch Bolt 49 5.0 36
Front Brake Light Switch Screw 1.2 0.12 11 in·lb
Right Switch Housing Screws (M5, L = 45) 3.5 0.36 31 in·lb
Left Switch Housing Screws (M5, L = 25) 3.5 0.36 31 in·lb
Starter Motor Mounting Bolts 10 1.0 89 in·lb
Sidestand Switch Bolt 8.8 0.90 78 in·lb L
Starter Motor Cable Mounting Bolt 4.0 0.41 35 in·lb
Starter Motor Cable Terminal Nut 6.0 0.61 53 in·lb
Battery Cable Mounting Bolt 4.0 0.41 35 in·lb
Starter Motor Terminal Locknut 6.9 0.70 61 in·lb
Starter Motor Through Bolts 3.4 0.35 30 in·lb
Engine Ground Cable Terminal Bolt 10 1.0 89 in·lb
Fuel Pump Bolts 10 1.0 89 in·lb L, S
38. 2-12 PERIODIC MAINTENANCE
Torque and Locking Agent
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 Torque
(mm) N·m kgf·m ft·lb
5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb
6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb
8 14 ∼ 19 1.4 ∼ 1.9 10 ∼ 13.5
10 25 ∼ 34 2.6 ∼ 3.5 19 ∼ 25
12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45
14 73 ∼ 98 7.4 ∼ 10.0 54 ∼ 72
16 115 ∼ 155 11.5 ∼ 16.0 83 ∼ 115
18 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165
20 225 ∼ 325 23.0 ∼ 33.0 165 ∼ 240
39. PERIODIC MAINTENANCE 2-13
Specifications
Item Standard Service Limit
Fuel System (DFI)
Throttle Grip Free Play 2∼3mm(0.08∼0.12in.) ---
Idle Speed 1 100 ±50 r/min (rpm) ---
Bypass Screws (Turn Out) 2 1/2 (for reference) ---
Throttle Body Vacuum Air 32.7 ±1.33 kPa (245 ±10 mmHg) at idle speed ---
Cleaner Element Viscous paper element ---
Cooling System
Coolant:
Type (Recommended) Permanent type antifreeze ---
Color Green ---
Mixed Ratio Soft water 50%, coolant 50% ---
Freezing Point -35°C (-31°F) ---
Total Amount 2.9 L (3.1 US qt) ---
Engine Top End
Valve Clearance:
Exhaust 0.17 ∼ 0.22 mm (0.0067 ∼ 0.0087 in.) ---
Inlet 0.15 ∼ 0.22 mm (0.0059 ∼ 0.0087 in.) ---
Clutch
Clutch Lever Free Play 2∼3mm(0.08∼0.12in.) ---
Engine Lubrication System
Engine Oil:
Grade API SE, SF or SG ---
API SH, SJ or SL with JASO MA
Viscosity SAE 10W-40 ---
Capacity 3.2 L (3.4 US qt) (when filter is not removed) ---
3.7 L (3.9 US qt) (when filter is removed) ---
4.0 L (4.2 US qt) (when engine is completely dry) ---
Level Between upper and lower level lines (Wait 2 ∼ 3 ---
minutes after idling or running)
Wheels/Tires
Tread Depth:
EUR and CA Models:
Front 3.8 mm (0.15 in.) 1 mm (0.04 in.)
(AT, CH, DE) 1.6
mm (0.06 in.)
Rear 5.2 mm (0.20 in.) Up to 130 km/h
(80 mph): 2 mm
(0.08 in.)
Over 130 km/h
(80 mph): 3 mm
(0.12 in.)
40. 2-14 PERIODIC MAINTENANCE
Specifications
Item Standard Service Limit
Other than EUR and CA
Models:
Front 3.6 mm (0.14 in.) 1 mm (0.04 in.)
Rear 5.3 mm (0.21 in.) Up to 130 km/h
(80 mph): 2 mm
(0.08 in.)
Over 130 km/h
(80 mph): 3 mm
(0.12 in.)
Air Pressure (when Cold):
Front Up to 180 kg (397 lb) load: ---
250 kPa (2.5 kgf/cm², 36 psi)
Rear Up to 180 kg (397 lb) load: ---
290 kPa (2.9 kgf/cm², 42 psi)
Final Drive
Drive Chain Slack 30 ∼ 40 mm (1.2 ∼ 1.6 in.) ---
Drive Chain Wear (20-link 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.)
Length)
Standard Chain:
Make RK EXCEL ---
Type RK 525MFOZ, Endless ---
Link 110 links ---
Brakes
Brake Fluid:
Grade DOT4 ---
Brake Pad Lining
Thickness:
Front 4.0 mm (0.16 in.) 1 mm (0.04 in.)
Rear 5.0 mm (0.20 in.) 1 mm (0.04 in.)
Brake Light Timing:
Front Pulled ON ---
Rear On after about 10 mm (0.39 in.) of pedal travel ---
Electrical System
Spark Plug:
Type NGK CR9EIA-9 ---
42. 2-16 PERIODIC MAINTENANCE
Maintenance Procedure
Fuel System (DFI)
Throttle Control System Inspection
•Check the throttle grip free play [A].
If the free play is incorrect, adjust the throttle cables.
Throttle Grip Free Play
Standard: 2∼3mm(0.08∼0.12in.)
• Checkclose, the throttle grip closes quickly and com- full
open to
that
and the throttle
[B] moves smoothly from
pletely by the return spring in all steering positions.
If the throttle grip does not return properly, check the throttle
cables routing, grip free play, and cable damage. Then
lubricate the throttle cable.
• Run the engine at the idle speed, and turn the handlebar
all the way to the right and left to ensure that the idle speed
does not change.
If the idle speed increases, check the throttle cable free
play and the cable routing.
If necessary, 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
∼ 0.12 in.) of throttle grip play is obtained.
∼ 3 mm (0.08
• Tighten the locknut [A].
• Turn the accelerator cable adjuster [D] until 2
∼ 0.12 in.) of throttle grip play is obtained.
∼ 3 mm (0.08
• Tighten the locknut [B].
If the free play can not be adjusted with the adjusters,
replace the cable.
Engine Vacuum Synchronization Inspection
NOTE
○These procedures are explained on the assumption that
the inlet and exhaust systems of the engine are good
condition.
• Situate the motorcycle so that it is vertical.
• Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
Primary Fuel Hose (see Fuel Hose Replacement)
• Plug the breather hose end [A] and air switching valve
hose end [B].
43. PERIODIC MAINTENANCE 2-17
Maintenance Procedure
• Remove the rubber caps [A] from the fittings of each throt-
tle body
• For the California and Southeast Asia models, pull off the
vacuum hoses [B].
• Connect atovacuum gaugethe throttle body. (Special Tool:
57001-1369) the fittings on
and hoses [A]
Special Tool - Vacuum Gauge: 57001-1369
• Connect a highly accurate tachometer [B] to one of the
stick coil primary leads.
• Connect the Lead Connector [A]
Fuel Pump
following parts temporarily.
Extension Tube [B]
Special Tool - Extension Tube: 57001-1578
• Connect the following parts temporarily.
Inlet Air Temperature Sensor Connector [A]
Secondary Fuel Hose [B] (see Fuel Hose Replacement)
NOTE
○Be sure to connect the air temperature sensor connec-
tor. When the ignition switch is turned ON with inlet air
temperature sensor connector disconnected, the ECU
detects the service code 13. Then the ECU starts the
fail-safe (see Self-diagnosis Outline in the Fuel System
(DFI) chapter). In this case, the engine vacuum syn-
chronization can not be inspected correctly.
○Do not connect the secondary fuel injector connectors.
The engine vacuum synchronization is inspected with
the air cleaner housing removed and the engine started.
The secondary fuel injectors are operating with following
conditions.
1. The engine speed is more than 6 000 r/min (rpm).
2. The throttle opening is more than 30°.
WARNING
Gasoline is extremely flammable and can be explo-
sive under certain condition. Especially, the gaso-
line jetted from the secondary fuel injector is ex-
tremely flammable for atomizing the gasoline by the
injector.
44. 2-18 PERIODIC MAINTENANCE
Maintenance Procedure
• Start the engine and warm it up thoroughly.
• Check the idle speed, using a highly accurate tachometer
[A].
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.
• While idling thegauge [B].inspect the throttle body vacuum,
using the vacuum
engine,
Throttle Body Vacuum
Standard: 32.7 ±1.33 kPa (245 ± 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: 220 mmHg
#2: 250 mmHg
#3: 210 mmHg
#4: 230 mmHg
• With the engine at the correct idle speed, equalize higher
vacuum of #1 or #2 (for example 250 mmHg) to higher
vacuum of #3 or #4 (for example 230 mmHg) by turning
the center adjusting screw [A].
Rear View [B]
NOTE
○After adjustment, the final vacuum measurement be-
tween the highest throttle valves may not be 250 mmHg
(for example). The goal is to have the highest two vac-
uums between the left (#1 and #2) and right (#3 and #4)
banks be the same.
• Open and close the necessary. each measurement, and
adjust the idle speed as
throttle after
NOTE
○The engine vacuum synchronization is adjusted with
the secondary fuel injector connectors disconnected.
Therefore, the secondary fuel injectors do not operate
while adjusting the engine vacuum synchronization. If
raising the engine speed more than 6 000 r/min (rpm),
the engine may not operate smoothly.
• Once the throttle main throttle sensorsynchronized, inspect
output voltage of the
valves have been
to ensure proper
operation (procedure is explained at the end of this sec-
tion).
45. PERIODIC MAINTENANCE 2-19
Maintenance Procedure
If any one vacuum measurement is out of the specified
range after left (#1, #2) and right (#2, #3) synchroniza-
tion, adjust the bypass screws [A] Using the pilot screw
adjuster [B].
Front View [C]
Special Tool - Pilot Screw Adjuster, D: 57001-1588
• vacuumthe lower vacuum between #1 and #2 to the higher
Adjust
of #1 and #2.
• vacuumthe lower vacuum between #3 and #4 to the higher
Adjust
of #3 and #4.
• ment, and adjust the idle speed as necessary. measure-
Open and close the throttle valves after each
NOTE
○The engine vacuum synchronization is adjusted with the
secondary injector connectors disconnected. There-
fore, the secondary injectors do not operate while ad-
justing the engine vacuum synchronization. If raising
the engine speed more than 6 000 r/min (rpm), the
engine may not operate smoothly.
• 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 replace them with
new ones.
• Turn in the bypass screw [A] with counting the number of
turns until it seals fully but not tightly. Record the number of
turns.
• Remove:
Bypass Screw
Spring [B]
Washer [C]
O-ring [D]
• Check the bypass screw hole in the throttle body for car-
bon deposits.
If any carbons accumulate, wipe the carbons off from the
hole, using a cotton pad penetrated with a high-flash point
solvent.
• Replace the bypass screw, spring, washer and O-ring as
a set.
• Turn in the bypass screw until it seats fully but not tightly.
CAUTION
Do not over-tighten the bypass screw. The tapered
portion [E] of the bypass screw could be damaged.
46. 2-20 PERIODIC MAINTENANCE
Maintenance Procedure
• Backin. This is same the screwoftoturns counted when first
turned
out the
to set
number
its original position.
NOTE
○A throttle body has different “turns out” of the bypass
screw for each individual unit. On setting the bypass
screw, use the “turns out” determined during disassem-
bly.
• Repeat the same procedure for other bypass screws.
• Repeat the synchronization.
If the vacuums are correct, check the output voltage of
the main throttle sensor (see Main Throttle Sensor Output
Voltage Inspection in the Fuel System (DFI) chapter).
Special Tool - Throttle Sensor Setting Adapter: 57001
-1538
Main Throttle Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor Y/W) lead
Digital Meter (-) → BK (sensor BR/BK) lead
Standard: DC 0.645 ∼ 0.675 V at idle throttle opening
If the output voltage is out of the standard, check the in-
put voltage of the main throttle sensor (see Main Throttle
Sensor Input Voltage Inspection in the Fuel System (DFI)
chapter).
• Remove the vacuum gauge hoses and install the rubber
caps on the original position.
• For the California and Southeast Asia models, install the
vacuum hoses.
○Run the vacuum hoses according to Cable, Wire, and
Hose Routing section in the Appendix chapter. Refer to
the diagram of the evaporative emission control system
in the Fuel System (DFI) chapter too.
Idle Speed Inspection
• Start the engine and warm it up thoroughly.
• With the engine idling, turn the handlebar to both sides
[A].
If handlebar movement changes the idle speed, the
throttle cables may be improperly adjusted or incorrectly
routed, or damaged. Be sure to correct any of these
conditions before riding (see Cable, Wire, and Hose
Routing section in the Appendix chapter).
WARNING
Operation with improperly adjusted, incorrectly
routed, or damaged cables could result in an
unsafe riding condition.
• Check the idle speed.
If the idle speed is out of specified range, adjust it.
Idle Speed
Standard: 1 100 ±50 r/min (rpm)
47. PERIODIC MAINTENANCE 2-21
Maintenance Procedure
Idle Speed Adjustment
• Start the engine and warm it up thoroughly.
• Turn the adjusting screw [A] until the idle speed is correct.
○Open and close the throttle a few times to make sure that
the idle speed is within the specified range. Readjust if
necessary.
Fuel Hose Inspection (fuel leak, damage,
installation condition)
○If the motorcycle is not properly handled, the high pres-
sure inside the fuel line can cause fuel to leak [A] or the
hose to burst. Remove the fuel tank (see Fuel Tank Re-
moval in the Fuel System (DFI) chapter) and check the
fuel hoses.
Replace the fuel hose if any fraying, cracks [B] or bulges
[C] are noticed.
• Check thatand Hose Routing[A] are routed Appendix to
Cable, Wire,
the fuel hoses
section in the
according
chapter.
Replace the hose if it has been sharply bent or kinked.
• Push and pull [A]fuel fuel hose joint [B]securely connected.
○
Check that the
the
hose joints are
back and forth
more than two times, and make sure it is locked.
○Check the other hose joint in the same way.
CAUTION
When pushing and pulling the fuel hose joint, do
not apply strong force to the delivery pipe [C] on
the nozzle assy. The pipe made from resin could be
damaged.
WARNING
Make sure the hose joint is installed correctly on the
delivery pipe by sliding the joint, or the fuel could
leak.
If it does not locked, reinstall the hose joint.
48. 2-22 PERIODIC MAINTENANCE
Maintenance Procedure
Evaporative Emission Control System Inspection
(CAL and SEA Models)
• Inspect the canister as follows.
○Remove the left upper inner fairing (see Upper Inner Fairing
Removal in the Frame chapter).
○Remove the canister [A], and disconnect the hoses from
the canister.
○Visually inspect the canister for cracks or other damage. If
the canister has any cracks or bad damage, replace it with a
new one.
NOTE
○The canister is designed to work well through the
motorcycle’s life without any maintenance if it is used under
normal conditions.
• Check the liquid/vapor separator as follows.
○Remove the upper fairing assembly (see Upper Fairing
Assembly Removal in the Frame chapter).
○Disconnect the hoses from the separator, and remove the
separator [A] from the motorcycle left side.
○Visually inspect the separator for cracks and other dam-
age.
If the separator has any cracks or damage, replace it with a
new one.
○To prevent the gasoline from flowing into or out of the
canister, hold the separator perpendicular to the ground.
• Check the hoses of the evaporative emission control system
as follows.
○Check that the hoses are securely connected and clips
are in position.
○Replace any kinked, deteriorated or damaged hoses.
○Route the hoses according to Cable, Wire, and Hose
Routing section in the Appendix chapter.
○When installing the hoses, avoid sharp bending, kinking,
flattening or twisting, and route the hoses with a minimum
of bending so that the emission flow will not be obstructed.
49. PERIODIC MAINTENANCE 2-23
Maintenance Procedure
Cooling System
Coolant Level Inspection
NOTE
○Check the level when the engine is cold (room or ambient
temperature).
• Check the coolant level in the reserve tank [A] with the
motorcycle held perpendicular (Do not use the sidestand).
If the coolant level is lower than the “L” level line [B], re-
move the left upper fairing cover (see Upper Fairing Cover
Removal in the Frame chapter), and then unscrew the re-
serve tank cap and add coolant to the “F” level line [C].
“L”: Low
“F”: Full
CAUTION
For refilling, add the specified mixture of coolant
and soft water. Adding water alone dilutes the
coolant and degrades its anticorrosion properties.
The diluted coolant can attack the aluminum en-
gine parts. In an emergency, soft water alone can
be added. But the diluted coolant must be returned
to the correct mixture ratio within a few days.
If coolant must be added often or the reservoir tank
has run completely dry, there is probably leakage in
the cooling system. Check the system for leaks.
Coolant ruins painted surfaces. Immediately wash
away any coolant that spills on the frame, engine,
wheels or other painted parts.
Radiator Hose and Pipe Inspection (coolant leak,
damage, installation condition)
○The high pressure inside the radiator hose can cause
coolant to leak [A] or the hose to burst if the line is not
properly maintained. Visually inspect the hoses for signs
of deterioration. Squeeze the hoses. A hose should not
be hard and brittle, nor should it be soft or swollen.
Replace the hose if any fraying, cracks [B] or bulges [C]
are noticed.
• Check that the hoses are securely connected and clamps
are tightened correctly.
Torque - Radiator (Water) Hose Clamp Screws: 2.0 N·m
(0.20 kgf·m, 18 in·lb)
50. 2-24 PERIODIC MAINTENANCE
Maintenance Procedure
Engine Top End
Valve Clearance Inspection
NOTE
○Valve clearance must be checked and adjusted when
the engine is cold (at room temperature).
• Remove theincylinder head coverchapter).
Cover Removal the Engine Top End
(see Cylinder Head
• Remove on the starter clutch cover [C]. and starter clutch
bolt cap [B]
the timing inspection cap [A]
• Using aclockwiseon the starter clutch mark[A], #1,4 the
crankshaft
wrench
until the line [B] (TDC
bolt
for
turn
pistons) on the starter clutch is aligned with the notch [C] in
the edge of the timing inspection hole [D] in the starter
clutch cover.
• Using thethickness gauge [A],lifter.
between
a
cam and the valve
measure the valve clearance
Valve Clearance
Standard:
Exhaust 0.17 ∼ 0.22 mm (0.0067 ∼ 0.0087 in.)
Inlet 0.15 ∼ 0.22 mm (0.0059 ∼ 0.0087 in.)
NOTE
○Thickness gauge is horizontally inserted on the valve
lifter.
Appropriateness [A]
Inadequacy [B]
Thickness Gauge [C]
Horizontally Inserts [D]
Cam [E]
Valve Lifter [F]
Hits the Valve Lifter Ahead [G]
51. PERIODIC MAINTENANCE 2-25
Maintenance Procedure
○When positioning #1 piston TDC at the end of the
compression stroke:
Inlet Valve Clearance of #1 and #3 Cylinders
Exhaust Valve Clearance of #1 and #2 Cylinders
Measuring Valve [A]
○When positioning #4 piston TDC at the end of the
compression stroke:
Inlet Valve Clearance of #2 and #4 Cylinders
Exhaust Valve Clearance of #3 and #4 Cylinders
Measuring Valve [A]
If the valve clearance is not within the specified range,
first record the clearance, and then adjust it.
Valve Clearance Adjustment
• To change the valve clearance, remove the camshafts
(see Camshaft Removal in the Engine Top End chapter)
and valve lifters.
• Replace the shim with one of a different thickness.
NOTE
○Mark and record the locations of the valve lifters and
shims so that they can be reinstalled in their original
positions.
• Clean the shim to remove any dust or oil.
• Measure the thickness of the removed shim [A].
• Select a new shim thickness calculation as follows.
a+b-c=d
[a] Present Shim Thickness
[b] Measured Valve Clearance
[c] Specified Valve Clearance (Mean Value = 0.195 mm
(Exhaust), 0.185 mm (Inlet))
[d] Replace Shim Thickness
Example (Exhaust):
1.600 + 0.31 - 0.195 = 1.715 mm
○Exchange the shim for the 1.725 size shim.
