Lot the Good Times Roll Motorcycle Service Manual Ninja ZX-6R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- Gific topic required. Quick Reference Guide [General Information _ 1 [Periodic Maintenance 2 [Fuel System(OF) OT [Cooling System [EngineTopEnd OT [Ciutch [Engine Removaliinstallation 8 I 00] |W} Jo] jon} |] [oo] |r] | Crankshaft/Transmission 9 I Wheels/Tires 10 Final Drive 1 [Brakes CS [Suspension 8 Steering 14 I [Frame [Electrical System 16 [Self-Diagnosis System 17 [AppendixKawasaki Let th Good Times Roll ZX636J/K 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/Kawasaki Motors, Ltd., Japan. © 2023 Kawasaki Motors, Ltd. 2nd Edition (0) : Mar. 17, 2023,LIST OF ABBREVIATIONS A ‘ampere(s) KIBS Kawasaki intelligent antilock brake system ABDC | after bottom dead center km/h kilometers per hour ABS antilock brake system KTRC | Kawasaki traction control AC alternating current kas Kawasaki quick shift Ah ampere hour L liter(s) ATDC | after top dead center Leb liquid crystal display BBDC | before bottom dead center LED light emitting diode BDC bottom dead center Ib pound(s) BTDC | before top dead center m meter(s) 6 degree(s) Celsius min minute(s) CAN controller area network mmHg | millimeters of mercury omHg | centimeters of mercury mph. miles per hour cu in. cubic inch(es) N newton(s) pc direct current oz ounce(s) DFI digital fuel injection Pa pascal(s) DOHC | double overhead camshaft PS horsepower DoT department of transportation psi pound(s) per square inch ECU electronic control unit at quart(s) F farad(s) r revolution °F degree(s) Fahrenheit tem revolution(s) per minute ft foot, feet s second(s) 9 gram(s) ToC top dead center gal gallon(s) TIR total indicator reading h hour(s) v volt(s) HP horsepower(s) w watt(s) Ic integrated circuit Q ohm(s) in, inch(es) COUNTRY AND AREA CODES AU Australia SEA-B1 [Southeast Asia B1 cA Canada SEA-B3 | Southeast Asia B3 CAL California (with Evaporative Emission |TH Thailand Control System) EUR Europe us United States 1D Indonesia WVTA _| WTA Model (Full Power) (FULL) PH Philippines.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 intake 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 in- cludes 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 bumed, or stored in a canister when the engine is stopped. 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 ex- ceeded. 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 $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 muffier(s) or any internal portion of the muffler(s) # Removal of the air box or air box cover. © Modifications to the muffier(s) or air intake system by cutting, drilling, or other means if such modifications result in increased noise levels.Foreword (About this manual) This service manual explains maintenance pro- cedures for removing, installing, disassembling, assembling, and adjusting, as necessary, in- cluding periodic inspection and maintenance of major parts of recording models. (Disclaimer) 1. This book does not describe all the matters concerning maintenance. This book is made for people who have basic skills and knowl- ‘edge on maintenance of Kawasaki product (authorized Kawasaki dealers or other re- pairers). So those who do not have these skills and knowledge do not do maintenance or inspection with this manual. Skill short- age and lack of knowledge may cause main- tenance troubles, parts breakage, etc. 2. All information contained in this publication is based on the latest product information available at the time of publication. No liabil- ity 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. 3. Illustrations and photographs in this publi- cation are intended for reference use only and may not depict actual model component parts. 4. The rightis reserved to make changes at any time without prior notice and without incur- ring an obligation to make such changes to products manufactured previously. Please accept beforehand that the description con- tent, illustration, photographs eto. may differ from actual vehicle due to vehicle specifica- tion change. 5. The content of the description may be changed without prior notice for vehicle specification change ete. 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 Ta- ble of Contents. For example, if you want ignition coil informa- tion, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chap- ter to find the Ignition Coil section. Whenever you see symbols, heed their in- structions! Always follow safe operating and maintenance practices. DANGER DANGER indicates a hazardous situa- tion which, if not avoided, will result in death or serious injury. AX WARNING WARNING indicates a hazardous situa- tion which, if not avoided, could result in death or serious injury. NOTICE NOTICE is used to address practices not related to personal injury. This manual contains four more symbols which will help you distinguish different types of information. NOTE ONOTE indicates information that may help or guide you in the operation or service of the vehicle. @ Indicates a procedural step or work to be done. Olndicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE. x Indicates a conditional step or what action to take based on the results of the test or inspec- tion in the procedural step or sub-step it fol- lows. 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 spec- ified tightening torque, oil, grease or a locking agent during assembly.GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing........ sssnsnninnnannnnninniennnnnnininennnnnnnninnnanninnenna sini 12 Model Identification 17 General Specifications. ess asm : os 18 Unit Conversion Table +114-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, 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- = rect the battery cables from the battery to prevent the en- GE gine from accidentally turning over. Disconnect the ground cable (-) first and then the positive (+). When completed G CWE LA with the service, first connect the positive (+) cable to the positive (+) terminal of the battery then the negative (-) ca- ble to the negative terminal. DISASSEIBLY ASSEABLY Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts. = Solvent Use a high flash-point solvent when cleaning parts. High flash-point solvent should be used according to directions of the solvent manufacturer. Cleaning Vehicle before Disassembly Clean the vehicle thoroughly before disassembly. Dirt or 9 other foreign materials entering into sealed areas during ve- hicle 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 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 Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled. Assembly Order In most cases assembly order is the reverse of disassem- bly, 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 se- quence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, huts, 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. All of the tightening torque values are for use with dry, solvent - cleaned threads unless otherwise indicated. If a fastener which should have dry, clean threads gets contami- nated with lubricant, etc., applying even the specified torque could damage it. 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-tings 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. comin s D> RX, \ Ves YQ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 con- tact 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 oll 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 citclips 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. Lubri- cation 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. Ro- tate 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 thor- oughly before using the meter. Incorrect values may lead to improper adjustments. Handling Electronic Parts Severe impacts to electronic parts such as the ECU, sen- sor, and relay can damage them. If dropped on a hard sur- face, replace such parts with new ones. Ifa high voltage that is created by static electricity is ap- plied to the electric parts, it could cause them to fail. To avoid this, touch a non-painted metal surface to discharge any static electricity that is accumulated on your body be- fore inspecting or replacing electric parts. Be careful not to touch the electrical terminals of the elec- tronic parts. The static electricity discharged from your body could damage them or deform the electrical terminals. aonmGENERAL INFORMATION 1-7 Model Identification ZXB36JRIKR Left Side View ZXG36JRIKR Right Side View1-8 GENERAL INFORMATION General Specifications Items ZX636JRFIKRF Dimensions Overall Length 2.025 mm (79.72 in.) Overall Width 710 mm (27.95 in.) Overall Height 4105 mm (43.50 in.) Wheel Base 1400 mm (55.12 in.) Ground Clearance 130 mm (5.12 in.) Seat Height 830 mm (32.7 in.) Curb Mass: ZX636J: 198 kg (437 Ib) (US, CA) 197 kg (434 Ib) Front 102 kg (225 Ib) (US, CA) 101 kg (223 Ib) Rear 96 kg (212 Ib) 2X636K: 195 kg (430 Ib) (CAL) 196 kg (432 Ib) Front 100 kg (221 Ib) (CAL) 101 kg (223 Ib) Rear 95 kg (209 Ib) Fuel Tank Capacity 17 L (4.5 US gal) Performance imum Turning Radius 3.4 m (11.2 ft) Engine Type /4-stroke, DOHC, 4-cylinder Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Fuel System Fuel Type: Minimum Octane Rating: Research Octane number (RON) Starting System Ignition System Timing Advance Ignition Timing Liquid-cooled 67.0 * 45.1 mm (2.64 * 1.78 in.) 636 cm? (38.8 cu in.) 12.9:1 91.0 kW (124 PS) @13 000 r/min (rpm) (SEA-B1) 84.0 kw (114 PS) @12 000 r/min (rpm) (US, CA, CAL) ~~~ 69.0 N-m (7.0 kgfm, 51 ft1b) @11 000 r/min (rpm) (SEA-B3, WVTA (FULL)) 69.0 N-m (7.0 kgf-m, 51 ftb) @10 800 r/min (rpm) (US, CA, CAL) ~~~ FI (Fuel injection), HITACHI Astemo TTK 38 x 4 Unleaded gasoline 95 Electric starter Battery and coil (ransistorized) Electronically advanced (digital igniter in ECU) 13.5" BTDC @1 300 rimin (rpm) ~ 43.7° BTDC @6 750 imin (rpm) (SEA-B3, SEA-B1, WVTA (FULL)) 13.5° BTDC @1 300 timin (tpm) = 41.6" BTDC @7 000 r/min (rom)GENERAL INFORMATION 1-9 General Specifications Rim Size Items ZX636JRF/KRF ‘Spark Plug NGK CR9E Cylinder Numbering Method Left to right, 1-2-3-4 Firing Order 1-2-4-3 Valve Timing: Intake’ Open 41° (BTDC) Close 67° (ABDC) Duration 288° Exhaust: Open 50° (BBDC) Close 22° (ATDC) Duration 253° Lubrication System Forced lubrication (wet sump) Engine Oi Grade API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity ‘SAE 10W-40 Capacity 3.6 L (3.8 US at) Drive Train Primary Reduction System: Type Gear Reduction Ratio 1.900 (76/40) Clutch Type ‘Wet multi disc Transmission: Type 6-speed, constant mesh, return shift Gear Ratios: Ast 2.846 (37/13) 2nd 2.200 (33/15) 3rd 1.850 (37/20) 4th 4.600 (32/20) sth 4.421 (27/19) 6th 4.300 (26/20) Final Drive System: Type ‘Chain drive Reduction R 2.867 (43/15) Overall Drive Ratio 7.081 @Top gear Frame Type Tubular, diamond Caster (Rake Angle) 23.5" Trail 101 mm (3.98 in.) Front Tire: Type Tubeless Size 120/70 ZR17 MIC (58W) ATMIC x MT3.501-10 GENERAL INFORMATION General Specifications Maximum Output Items ZX636JRFIKRF Rear Tire: Type Tubeless Size 180/55 ZR17 MIC (73W) Rim Size 17MIC x MT5.50 Front Suspension: Type Telescopic fork (upside-down) Wheel Travel 120 mm (4.72 in.) Rear Suspension: Type ‘Swingarm (uni-trak) Wheel Travel 151 mm (5.94 in.) Brake Type: Front Dual discs Rear Single disc Electrical Equipment Battery 12. V 8 Ah (10 HR) Headlight: High Beam LED Low Beam LED City Light LED Tail/Brake Light LED Turn Signal Light LED License Plate Light LED Alternator: Type Three-phase AC 14.0 V - 26.0 A @5 000 r/min (rpm) Specifications are subject to change without notice, and may not apply to every country.GENERAL INFORMATION 1-11 Unit Conversion Table Prefixes for Units: Units of Length: Prefix | Symbol Power km . coer . me mega M = 1000 000 m i : kilo k x 1.000 mm ™ centi c x 0.01 a m * 0.001 Units of Torque: micro u x 0.000001 Ne «04020 = ket Nm x 0.7376 = ftlb Nm x 8.851 int Units of Mass: kgim x 9.807 Nm kg x 2.208 Ib kgim x 7.233 ftlb 9 x 0.03527 oz kgfm = «= 86.80 = —intb Units of Volume: Units of Pressure: L x 0.2642 = gal (US) kPa x (0.01020 = _—kgflem® L x 0.2200 = — gal(IMP) kPa x (0.1450 psi L x 1.057 = — qt (US) kPa x _(0.7501 cmHg L x 0.8799 = — qt (IMP) kgtlem® x 98.07 kPa L x 2113 = pint (US) kgilom® x 14.22 psi c x 1816 = pint (IMP) cmHg «= 1.333 = kPa mL x 0.03381 = — oz (US) mL = * 0.02816 = oz (IMP) Units of Speed: im = oosio2 = culn. km/h = * =~ 0.6214. =~ mph Units of Force: Units of Power: N x 0.4020 kg kW x 1360 = PS N x 0.2248 tb wa «1344 HP kg x 9.807 N PS x 0.7355 KW. ko x 2.205 o Ps x 0.9863 = HP Units of Temperature: SCC+4) yg. og SUED yy ig 4 9 °F F 2 68104 176 92,42 40 “4% 6) 8 100/120 149 160 180 200 {220 240 | 260 209) 300 300 L tape eee k Hoe ot * 4 44 a7 9 71 oa 138 °C FPERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart seen 23 Daily Checks... 25 Torque and Locking Agent... . 2-6 Specifications 242 Special TOONS «ener a 244 Periodic Maintenance Procedures... 2-16 Fuel System (DF)... 246 Air Cleaner Element Replacement......cssssnnsnnnsnnnnnnnniannennnn 2-16 Idle Speed Inspection ’ 247 Idle Speed Adjustment... - ccemmmmameccnn 47 Throttle Control System Inspection. 247 Engine Vacuum Synchronization Inspe 2418 Fuel System ee . events 2.21 Fuel Filter Replacement. seve 2:22 Fuel Hose Replacement ... 2.24 Evaporative Emission Control System Inspection (Other than US and CA Models) . 2:26 Cooling System. 2.27 Coolant Level Inspection. 2.27 Cooling System... 2.27 Coolant Change. 2.27 Water Hose and O-ring Replacement. 2:30 Engine Top End : 2-31 Valve Clearance Inspection 231 Valve Clearance Adjustment... 2.32 Air Suction System Damage Inspection... 2:34 Clutch. 2 ‘ : miammenieteremmen DOS Clutch Operation Inspection. ° 2.35 Engine Lubrication System... si ve 2236 Engine Oil Change. 2:36 Oil Filter Replacement... esenen see 237 Wheels/Tires. evennee 2:38 Air Pressure Inspection... eee 2:38 Wheels and Tires ... 2.38 Wheel Bearing Damage Inspection seo . ven 2.39 Final Drive. . 239 Drive Chain Lubrication Condition Inspection ...c.unenn ve 239 Drive Chain Slack Inspection 2-40 Drive Chain Slack Adjustment....... oe evenness 2-40 Wheel Alignment Inspection .... 2-41 Drive Chain Wear Inspection 2.42 Chain Guide Wear Inspection... 2-42 Brakes, 2-43 Brake System Inspection . 2-43 Brake Operation Inspection .....c:ss 2.44 Brake Fluid Level Inspection......... 2.44 Brake Fluid Change... seen seen 245 Brake Hose and Pipe Replacement. 2.47 Master Cylinder Rubber Parts Replacement .....snn.enene seventeen 2.49 Caliper Rubber Parts Replacement ese 251 Brake Pad Wear Inspection....... 2.542-2 PERIODIC MAINTENANCE Brake Light Switch Operation Inspection... 2-55 Suspension . ese - : 2.56 Suspension System 2.56 Steering ..... rare siammnanmonnaaminaccscmmamecratame (OT Steering Play Inspection... 2.57 Steering Play Adjustment... 2-58 Steering Stem Bearing Lubrication 2-59 Electrical System... eonnieinnsnnnnsennnninisennnimanen — 2°59 Lights and Switches Operation Inspection... 2.59 Headlight Aiming Inspection .... sesennnnnninesenin sevnninnenen 261 Side Stand Switch Operation Inspection 2-62 Engine Stop Switch Operation Inspection 263 Spark Plug Replacement 2-63 Others. 2-64 Chassis Parts Lubrication .... 2-64 Condition of Bolts, Nuts and Fasteners Tightness Inspection 2-65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 *A: Service at number of years shown or indicated odometer reading intervals, whichever comes first. *B: For higher odometer readings, repeat at the frequency interval established here. *C: Service more frequently when operating in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping. *D: Other than US Model ©: Emission Related Item Q: Inspection ©: Change or Replace “e: Lubrication Odometer Reading (*B) year x 1.000 km (x 1 000 mile)| See (A) | 4 | 12 | 24 | 36 | 48 | Page Items (0.6) | (7.6) | (15.2)| (22.8) | (30.4) Fuel System | Air cleaner element (*C) o Oo | 216 | Idle speed Q}Q}iQq\Q Q | 217 ° Totton system (play, smooth ew, 1 Q [Ql alalala | az ©] Engine vacuum synchronization Qi Qi Ql Q | 218 Fuel system Q1} QQ} al} Qala] Q | 22 Fuel filter © o Fuel hose Os Q | Evaporative emission control system (*D) Q Q Cooling System Cooling system aifalala Q Coolant, water hose and O-ring Os ° Engine Top End © | Valve clearance Q} Ql} al] aQ {2s © | Air suction system alalal ea | ass Clutch Cuich perain (play, engagement, aileleleleal a | 2s Engine Lubrication System Engine oil (*C) and oil filter Oy O|/ oO] oO Wheels and Tires Wheel bearing damage Q1 Ql Ql Ql Q | 239 Final Drive Drive chain wear (*C) Q}Q}Q{Q | 242 Drive chain guide wear Qalal ala | 242-4 PERIODIC MAINTENANCE Periodic Maintenance Chart ‘Odometer Reading ("B) year % 1.000 km (x 1.000 mile)! See ta) [1 | 42 | 24 | 36 | 48 | Page Items (0.6)] (7.6) |(15.2)| (22.8) | (30.4) Brakes Brake system Q1}Q} Qi Q} Qi Q | 243 Brake operation (effectiveness, play, no ailalelealal a | 2s Brake fluid (front and rear) O2 ° ° Brake hose Oa esbber parts of brake master cylinder and | (5, oO Suspension ‘Suspension system Qn Q}Qq\Q Q | 256 Steering ‘Steering play Q1 1A} Qa}; Qa} Qi Q | 257 Steering stem bearing ‘2 ‘ ~ | 259 Electrical System Electrical system Qa ala}la}ea © | Spark plug ololeole Others ‘Chassis parts Ne ‘vie |S | 264 Condition of bolts, nuts and fasteners Q}Qa}i Qa} Qi Q | 265PERIODIC MAINTENANCE 2-5 Daily Checks NOTE Daily maintenance items should also be checked at every scheduled dealer service. Daily Maintenance Items fags Fuel ‘Adequate supply in tank, no leaks = Engine oll Gil level between level lines = Tires Air pressure (when cold), install the air valve cap Tire wear ‘Slack: every 1 000 km (600 mile) Lubricate: every 600 km (400 mile) Bolts, nuts and fasteners | Check for loose and/or missing bolts, nuts and fasteners Action smooth but not loose from lock to lock = Drive chain Steering No binding of control cables = Brake pad wear 2-54 Brakes Brake fluid level 2-44 No brake fluid leakage 2-83 Throttle Throttle grip free play 247 a Clutch lever free play 2.35 Clutch lever operates smoothly 2:35 Godard No coolant leakage 2.27 ‘Coolant level between level lines (when engine is cold) 2-27 All lights (head, city, brake/tail, turn signal, license plate, warninglindicator) meter and horn work Engine stop switch ‘Stops engine 2:63 Return to its fully up position by spring tension = Return spring not weak or not damaged = Rear view mirrors Rear view sight = Electrical equipment 2-59 Side stand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. All of the values are for use with dry solvent - cleaned threads unless otherwise indicated. 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 (Middle strength: Loctite 243 or equivalent). *L: Apply a non-permanent locking agent (Three Bond: TB1360G or equivalent). LG: Apply liquid gasket Lh: Left-hand Threads LN: Apply a non-permanent locking agent (High Strength: Loctite 648 or equivalent) M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil solution, (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1) R: Replacement Parts S: Follow the specified tightening sequence. Si: Apply silicone grease. Torque Fastener Nm kot fu | Remarks Fuel System (DFI) Throttle Case Bolts 24 0.24 | 21 intb Throttle Cable Hol Plate Bolt 4.0 041 35 in-lb R Throttle Body Assy Holder Clamp Bolts 3.0 0.31 27 in-lb Delivery Pipe Screws 34 0.35 30 inIb Throttle Body Assy Holder Bolts 12 1.2 106 in-Ib R Air Intake Duct Assembly Screws 3.0 0.31 27 intb Air Intake Duct Bolts, 10 1.0 | 89inib R Air Cleaner Housing Clamp Bolts 15 015 | 13intb Fuel Pump Assembly Screws 0.98 0.10 8.7 inlb R Fuel Pump Bolts 10 1.0 89 in-lb RS Vehicle-down Sensor Bolts 6.0 0.61 53 inlb Cooling System Radiator Bolts (Upper) 10 1.0 | 89inib Water Hose Fitting 9.0 0.92 | 80intb R Water Temperature Sensor 12 1.2 106 in-Ib Thermostat Cover Bolts 6.0 0.61 53 in-lb Oil Cooler Bolts 20 2.0 15 Coolant Drain Bolt (Cylinder) 10 1.0 89 in-lb Water Hose Fitting Bolts 10 1.0 | 89intb Water Pump Impeller Bolt 10 1.0 | 89intb Water Pump Cover Bolts 12 1.2 | 106 intb R Coolant Drain Bolt (Water Pump) 9.0 0.92_| 80intb Engine Top End Air Suction Valve Cover Bolts 10 1.0 89 in-Ib R Spark Plugs 13, 1.3 115 in-lb Cylinder Head Cover Bolts 10 1.0 89 inlb Ss Breather Hose Fitting 15 15 4 RPERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener nn katm [fe | Remarks ‘Camshaft Sprocket Bolts 15 15 1 UN Camshaft Cap Bolts, First 60 0.61 | 53 inib s Camshaft Cap Bolts, Final 12 1.2 | 106 in‘ s Cylinder Head Bolts (M9) see the text] — - Mo, S Cylinder Head Water Jacket Plugs 196 2.0 14.5 R Cylinder Head Bolts (M6) 12 1.2 | 106 in-b s Front Camshaft Chain Guide Bolt (Upper) 25 25 18 Front Camshaft Chain Guide Bolt (Lower) 12 1.2 | 106 intb Camshaft Chain Tensioner Bolts 1" 14 97 int Camshaft Chain Tensioner Cap Bolt 20 2.0 15 Starter Motor Clutch Bolt Cap 3.0 031 | 27 intb Timing Inspection Cap 3.0 0.31 | 27 intb Exhaust Butterfly Valve Actuator Pulley Bolt 5.0 0.51 | 44 intb Exhaust Butterfly Valve Cable Locknuts 5.0 0st | 44 intb Muffler Body Bolt 25 25 18 Muffler Body End Cover Bolts 70 0.71 | 62 inib L Muffler Cover Bolts 70 0.71 | 62 inib Exhaust Pipe Holder Nuts 20 2.0 15 s ‘Oxygen Sensor 25 25 18 Exhaust Pipe Clamp Bolt 20 2.0 15 Premuffler Chamber Bolt 40 44 30 Premuffler Chamber Bracket Bolt 40 44 30 Muffler Body Clamp Bolt 20 2.0 15 Clutch Clutch Hub Nut 135 13.8 100 R Clutch Cover Bolts (L = 40 mm) 10 1.0 | 89 inib Clutch Stopper Bolts 90 0.92 | 80 inib Clutch Cover Bolts (L_= 25 mm) 10 1.0 | 89 intb Engine Lubrication System Oil Filter 7 17 13 R Oil Filter Pipe 25 25 18 L Oil Filter Guard Bolts 40 0.41 | 35 inib R Oil Cooler/Oil Filter Case Bolts 20 2.0 15 R Air Bleed Bolt 10 1.0 | 89 intb Oil Cooler Bolts 20 2.0 16 Oil Pump Driven Gear Bolt 10 1.0 | 89 intb R Oil Pressure Switch Terminal Bolt 20 0.20 | 18 inlb Oil Pressure Switch 15 15 " Le Oil Pressure Relief Valve 15 15 " L Engine Oil Drain Bolt 29 3.0 24 Oil Pan Bolts 10 1.0 | 89 inib s Engine Removal/installation Front Engine Mounting Bolts 45 46 33 s2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener a katm [fib | Remarks ‘Adjusting Collar (Middle) 10 1.0 | 89 inib s Adjusting Collar Locknuts 50 54 37 s Engine Mounting Nut (Middle) 45 46 33 RS Engine Mounting Nut (Lower) 45 46 33 RS Adjusting Collar (Lower) 10 1.0 | 89inb | MS Crankshaft/Transmission Breather Hose Fitting 15 15 " R Oil Jet Nozzles 3.0 0.31 | 27 intb Race Holder Screws 5.0 051 | 44 inib R n Case Bolts (M8) 20 20 16 n Case Bolt (M6) 10 1.0 | 89 indb Bearing Holder Screws 5.0 051 | 44 intb R Conneeting Rod Big End Nuts see the text} — - Breather Plate Bolts 10 1.0 | 89 inib R Oil Passage Plugs 20 2.0 15 R Oil Passage Nozzle 5.0 051 | 44 intb Oil Passage Plug (M25) 7 17 8 Crankcase Bolts (M6, L = 68 mm) 12 1.2 | 106 inb Crankcase Bolt (M8, L = 90 mm) 27 28 20 Crankcase Bolts (M8, L = 75 mm) a7 28 20 Crankcase Bolts (M6, L = 50 mm) 12 1.2 | 106 intb Crankcase Bolts (M8, L = 97 mm), First 15 15 " Mo, S Crankcase Bolts (M8, L = 97 mm), Final 34 32 23 Mo, S Shift Drum Cam Holder Bolt 12 1.2 | 106 intb R Shift Shaft Return Spring Pin 29 3.0 24 R Gear Positioning Lever Bolt 12 1.2 | 108 inb Starter Motor Clutch Cover Bolts (L = 30 mm) 10 1.0 | 89 indb Starter Motor Clutch Cover Bolt (L = 20 mm) 10 1.0 | 89 indb Idle Gear Cover Bolts 10 1.0 | 89 intb Quick Shifter Tie-Rod Locknuts 7.0 071 | 62intb | Lh (1) Shift Pedal Bolt 25 25 18 GR Starter Motor Clutch Bolt 49 5.0 36 Wheels/Tires Front Axle Clamp Bolts 20 2.0 15 s Front Axle 130 13.3 95.9 Rear Axle Nut 130 13.3 95.9 Final Drive Engine Sprocket Cover Bolts 10 1.0 | 89 indb Engine Sprocket Cover Damper Screws 35 0.36 | 31 intb Chain Guide Bolts 12 1.2 | 106 inb R Engine Sprocket Nut 147 15.0 108 Mo Rear Sprocket Nuts 60 61 44 RS Rear Axle Nut 130 13.3 95.9PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener nn katm [fe | Remarks Brakes Front Brake Reservoir Bracket Bolt 90 0.92 | 80 inib Front Brake Reservoir Cap Stopper Screw 12 012 | 11 intb Brake Lever Pivot Bolt 1.0 0.10 | 89 intb si Brake Lever Pivot Bolt Locknut 59 0.60 | 52 inib Front Brake Light Switch Screw 12 012 | 11 intb Bleed Valves 8.0 0.82 | 71 intb Front Master Cylinder Clamp Bolts 1 14 97 in-lb s Brake Hose Banjo Bolts 25 25 8 Brake Pipe Joint Nuts 145 1.48 10.7 Brake Pipe Banjo Bolts 23 23 7 Front Caliper Bolts 35 36 26 Front Brake Pad Pins 17.2 1.75 127 Wheel Rotation Sensor Bolt 8.0 0.82 | 74 inib Brake Disc Bolts 28 29 24 RS Brake Pipe Banjo Bolts 23 23 7 Brake Pipe Joint Nut 145 1.48 10.7 Brake Hose Banjo Bolts 25 25 18 Rear Master Cylinder Bolts 25 25 18 Brake Pedal Bolt 35 36 26 R Rear Master Cylinder Push Rod Locknut 17.2 1.75 127 Rear Caliper Pin Bolt 27 28 20 si Rear Brake Pad Pin 17.2 1.78 127 Rear Brake Pad Pin Plug 25 0.25 | 22 inib Brake Disc Bolts 28 29 24 RS Suspension Front Fork Clamp Bolts (Upper) 20 2.0 15 s Front Fork Clamp Bolts (Lower) 25 25 18 AL Front Fork Top Plugs 35 36 26 Piston Rod Guide Case 90 9.2 66 Rear Shock Absorber Bracket Nut 60 61 44 ‘Swingarm Pivot Shaft Nut 110 12 814 s ‘Swingarm Pivot Adjusting Collar 20 2.0 15 s ‘Swingarm Pivot Adjusting Collar Locknut 100 10.2 738 s Rear Shock Absorber Nuts 35 36 26 R Tie-Rod Nuts 60 64 44 R Rocker Arm Bolt 35 36 26 ‘Steering Handlebar Clamp Bolts 25 25 18 Handlebar Positioning Bolts 10 1.0 | 89 inib R Throttle Case Bolts 24 0.24 | 24 inib Handlebar End Bolts 25 25 18 R ‘Switch Housing Screws 24 0.24 | 24 intb s2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener a tam fe | Remarks Steering Stem Head Bolt 80 82 59 s Front Fork Clamp Bolts (Upper) 20 2.0 15 s Steering Stem Nut 28 29 24 Front Fork Clamp Bolts (Lower) 25 25 18 AL Frame Rear Frame Bolts (M10) 45 46 33 R Front Footpeg Bracket Bolts 25 25 18 Rear Master Cylinder Bolts 25 25 18 Front Footpeg Bolts 35 36 26 R Side Stand Switch Bolt 9.0 0.92 | 80 intb R Side Stand Bracket Bolts 50 5A 37 R Side Stand Nut 45 46 33 RS Side Stand Bolt 30 34 22 s Rear Footpeg Bracket Bolts 25 25 18 Rear Frame Bolts (M8) 25 25 18 R Front Side Reflector Nuts 34 0.35 | 30 intb Electrical System Switch Housing Screws 24 0.24 | 21 intb s Front Brake Light Switch Screw 12 012 | 11 int Crankshaft Sensor Bolts 6.0 0.61 | 53 intb Starter Motor Clutch Cover Bolt (L = 30 mm) 10 1.0 | 89 ind Starter Motor Clutch Cover Bolt (L = 20 mm) 10 1.0 | 89 inib Idle Gear Cover Bolts 10 1.0 | 89 inib Starter Motor Clutch Bolt 49 50 36 Oil Pressure Switch 15 15 " Ls Oil Pressure Switch Terminal Bolt 2.0 0.20 | 18 intb SG Starter Motor Mounting Bolts 10 1.0 | 89 indb Alternator Rotor Bolt 155 15.8 114 Stator Coil Bolts 12 1.2 | 106 intb R Alternator Lead Holding Plate Bolt 10 1.0 | 89 indb R Altemator Cover Bolts 10 1.0 | 89 indb Radiator Bolts (Upper) 10 1.0 | 89 indb Spark Plugs 13 1.3 | 115 intb Fuel Pump Assembly Screws 0.98 0.10 | 8&7 intb R Fuel Pump Bolts 10 10 | 89inb | RS Water Temperature Sensor 12 1.2 | 106 intb Starter Motor Cable Terminal Bolt 3.0 0.31 | 27 intb Engine Ground Terminal Bolt 10 1.0 | 89 indb Side Stand Switch Bolt 9.0 0.92 | 80 intb R The tables below, relating tightening torque to thread diameter, lists the basic torque for the bolts, nuts and screws. Use these tables for the bolts, nuts and screws wt are not specified the tighten- ing torque particularly on the previous pages. Alll of the values are for use with dry solvent-cleaned threads.PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Basic Torque for General Fasteners For Bolts and Nuts Threads Diameter Torque (mm) Nm kgf-m feb 5 45 0.46 40 in 6 8.0 0.82 71 int 8 20 20 15 10 35 36 26 12 60 64 44 For Screws, Plastic Part Tightening Portions and Plastic Washer Tightening Portions Threads Diameter Torque (mm) Nm kgf-m feb 4 12 0.12 11 intb 5 3.0 0.31 27 int 6 4.0 0.41 For Self-Tapping Screws Threads Diameter Torque (mm) Nem kgf-m feb All 1.2 0.12 11 in For Wellnuts Threads Diameter Torque (mm) Nm kgf-m feb 4 02 0.02 1.8 inib 5 05 0.05 4.4 init 6 1.0 0.10 89 inb2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System Throttle Grip Free Play Idle Speed Throttle Body Vacuum Bypass Screws (Turn Out) Air Cleaner Element 2-3 mm (0.08 - 0.12 in.) 1300 450 r/min (rpm) 31.3 41.33 kPa (235 £10 mmHg) at idle speed 0-2 1/2 (for reference) Viscous paper element Cooling System Coolant: ‘Type (Recommended) Color Mixed Ratio Freezing Point Total Amount Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals or aluminum engines and radiators) Green Soft water 50%, coolant 50% 35°C (-31°F) 2.4L (2.5 US qt) (Reserve tank full level, including radiator and engine) Engine Top End Valve Clearance: Exhaust 0.24 - 0.31 mm (0.0094 — 0.0122 in.) - Intake 0.13 - 0.19 mm (0.0051 — 0.0075 in.) --- Clutch Clutch Lever Free Play 2-3 mm (0.08 - 0.12 in.) Engine Lubrication System Engine Oi Type API SG, SH, SJ, SL or SM with JASO a MA, MA1 or MA2 Viscosity SAE 10W-40 --- Capacity 2.8 L (3.0 US qt) (When filter is not a removed.) 3.1 L (3.3 US qt) (When filter is a removed.) 3.6 L (3.8 US qt) (When engine is oe completely dry.) Oil Level Between upper and lower level lines (Wait several minutes after idling or --- running) Wheels/Tires Tire Tread Depth: Front 4.4 mm (0.16 in.) 1mm (0.04 in.) Rear 5.8 mm (0.23 in.) Up to 130 km/h (80 mph): 2 mm (0.08 in.) Over 130 kg (80 mph): 3 mm (0.12 in.)PERIODIC MAINTENANCE 2-13 Specifications Item Standard Service Limit Tire Air Pressure (when cold): Front Up to 180 kg (397 Ib) load: 250 kPa a (2.50 kaffcm?, 36 psi) Rear Up to 180 kg (397 Ib) load: 290 kPa a (2.90 kaf/cm?, 42 psi) Final Drive Drive Chain Stack 30 — 40 mm (1.2 - 1.6 in.) --- Drive Chain 20-ink Length |317.5 - 318.2 mm (12.50 ~ 12.53 in.) | __ 319 mm (12.6 in.) Standard Chain: Make DAIDO --- Type DID 520HV2 --- Link 112 links --- Brakes Brake Fluid Grade Dora --- Brake Pad Lining Thickness: Front 4 mm (0.16 in.) 41mm (0.04 in.) Rear 5mm (0.20 in.) 1mm (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 Gap NGK CROE 0.7 — 0.8 mm (0.028 - 0.031 in.)2-14 PERIODIC MAINTENANCE Special Tools Inside Circlip Pliers: Pilot Screw Adjuster, C: 57001-1292 s7oot-143 Z fe a \ Steering Stem Nut Wrench: 57001-1100 Vacuum Gauge: 57001-1369 dp, ti 57001-1238 Throttle Sensor Setting Adapter: 57001-1538 y Oil Filter Wrench: 57001-1249, Extension Tube: 57001-1578 fT Spark Plug Wrench, Hex 57001-1262 Jack Attachment: 57001-1608 —2 ay ¢ 0PERIODIC MAINTENANCE 2-15 Special Tools Brake Caliper Piston Pliers (#16 ~ 426): Adjustable Hook Wrench: 57001-1861 57001-18632-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DF) Air Cleaner Element Replacement NOTE Oln dusty areas, the element should be replaced more frequently than the recommended interval. ANWARNING If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident. Replace the air cleaner element according to the maintenance chart. NOTICE If dirt gets through into the engine, excessive en- gine wear and possibly engine damage will occur. ¢ Remove the fuel tank (see Fuel Tank Removal(3-38) @ Disconnect the intake air temperature sensor connector {Al ¢ Remove’ Screws [B] Upper Air Cleaner Housing [C] Discard the air cleaner element [A]. ¢ Install a new element [A] so that the screen side [B] faces upward, NOTICE Use only the recommended air cleaner element (Kawasaki part number 11013-0036). Using another air cleaner element will wear the engine prema- turely or lower the engine performance. Install the upper air cleaner housing (see Air Cleaner Housing Assembly(3-35)). ¢ Install the removed parts.PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Idle Speed Inspection @ Start the engine and warm it up thoroughly. With the engine idling, turn the handlebar to both sides Al xIf 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 Throttle Control System Inspection(2-17)) (see Cable, Wire, and Hose Routing section (18-2) 4. WARNING Operation with improperly adjusted, incorrectly routed or damaged cable could result in an unsafe riding condition. Follow the service manual to make sure to correct any of these conditions. © Check the idle speed. If the idle speed is out of specified range, adjust it Idle Speed Standard: 1 300 +50 rimin (rpm) 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. Throttle Control System Inspection © Keep the handlebars straight ahead. © Check the throttle grip free play [A]. +f the free play is incorrect, adjust the throttle cables. Throttle Grip Free Play Standard: 2-3 mm (0.08 - 0.12 in.) © Check that the throttle grip [B] moves smoothly from full open to close, and the throttle closes quickly and com- pletely by the return spring in all steering positions. x If the throttle grip does not return properly, check the throt- tle cables routing, grip free play, and cable damage. Then lubricate the throttle cable. Run the engine at the idle speed, and turn the handlebar allthe 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,2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures +f 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 it has no play when the throttle grip is completely closed. 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]. xf 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 intake and exhaust systems of the engine are in good condition. # Situate the motorcycle so that it is vertical. © Remove’ Air Cleaner Housing (see Air Cleaner Housing Re- moval(3-33} Fuel Hose (see Fuel Hose Replacement(2-24) © For the US and CA models, pull off the rubber caps [A] and vacuum hose [B] from the fittings of each throttle body. © For other than US and CA models, pull off the vacuum hoses [AlPERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Connect a vacuum gauge and hoses [A] (Special Tool: 57001-1369) to the fittings on the throttle body. Special Tool - Vacuum Gauge: 57001-1369 © Connect a highly accurate tachometer lead [B] to one of the stick coil primary leads. Plug the air switching valve hose end [A] and air cleaner housing fitting [B]. install the air cleaner housing (see Air Cleaner Housing Installation| Connect the following parts temporarily. Fuel Pump Connector [A] Extension Tube [8] Special Tool - Extension Tube: 57001-1578 Start the engine and warm it up thoroughly. Check the idle speed, using a highly accurate tachometer (Al. Idle Speed Standard: 1.300 £50 r/min (rpm) IF the idle speed is out of the specified range, adjust it with the adjusting screw (see Idle Speed Adjustment(2-17)). NOTICE Do not measure the idle speed by the tachometer of the meter unit. While idling the engine, inspect the throttle body vacuum, using the vacuum gauge [8]. Throttle Body Vacuum Standard: 31.341.33 kPa (235 £10 mmHg) at idle speed2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures If any vacuum is not within specifications, adjust the by- pass screws [A]. View from Rear (B] Special Tool - Pilot Screw Adjuster, C [C]: 57001-1292 « Adjust the each vacuum (#1 — #4) to the standard value. © Open and close the throttle valves after each measure- ment NOTE Do not turn the center adjusting screw [D]. © Check the vacuums as before. + Ifall vacuums are within the specification range, finish the engine vacuum synchronization. x Ifany vacuum can not be adjusted within the specification, replace the bypass screws #1 — #4 with new ones, refer to the following procedure. Remove the throttle body assy (see Throttle Body Assy Removal(3-28} © Turn in the bypass screw [A] with counting the number of turns unti it seats fully but not tightly. Record the number of turns. # Remove! Bypass Screw Spring [B] Washer [C] O-ting [0] # Check the bypass screw hole in the throttle body for car- bon deposits. x 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 aset Turn in the bypass screw until it seats fully but not tightly. NOTICE Do not over-tighten the bypass screw. The tapered portion [E] of the bypass screw could be damaged.PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Back out the same number of turns counted when first tured in. This is to set the screw to its original position. NOTE OA 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. xIf the vacuums are correct, check the output voltage of the main throttle sensor. 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 G) lead Standard: DC 1.02 - 1.05 V at idle throttle opening If the output voltage is out of the standard, check the input voltage of the main throttle sensor (see DTC P0123(17 Remove the vacuum gauge hoses. © For the US and CA models, install the rubber caps and vacuum hose on the original position. For other than US and CA models, install the vacuum hoses. Run the vacuum hose correctly (see Cable, Wire, and Hose Routing section (18. « Install the removed parts. Fuel System Fuel Hose Inspection (fuel leak, damage, installation condition) Oif 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(3-38)) and check the fuel hoses Replace the fuel hose if any fraying, cracks [B] or bulges [C] are noticed.2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures @ Check that the fuel hose is routed correctly (see Cable, Wire, and Hose Routing section (18-2)). Replace the hose if it has been sharply bent or kinked. Hose Joints [A] Fuel Hose [B] @ Check that the fuel hose joints are securely connected. Push and pull [A] the fuel hose joint (B] back and forth more than two times, and make sure it is locked. AY WARNING Leaking fuel can cause a fire or explosion resulting in serious burns. Make sure the hose joint is in- stalled correctly on the delivery pipe by g the joint. + If it does not locked, reinstall the hose joint. Fuel Filter Replacement AS WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions, creating the potential for serious burns, Make sure the area is well venti- lated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke, Turn the ignition switch off. Disconnect the battery (-) terminal. To avoid fuel spills, draw it from the tank when the engine is cold. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. NOTICE Never drop the fuel pump especially on a hard sur- face. Such a shock to the pump can damage it. © Remove: Fuel Pump (see Fuel Pump Removal(3-22) Fuel Pump Assembly Screws [A] Lead Terminals [B]PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures '* Disconnect: Lead Terminal (Red) [A] Lead Terminal (Light Blue) [B) '* Using the flat tip screwdriver [A], remove the fuel pump ‘case [B] from the fuel pump body [C]. @ Remove the O-ring [A]. ‘* Remove the fuel pump body [B] from the installation plate (Cc) ‘© Remove the fuel filter [A]. ‘* Replace the fue! fitter [A] with a new one, and install it.2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures ‘* Replace the following parts with new ones. O-rings [A] Fuel Pump Assembly Screws [B] (A) ‘ Install the removed parts in the reverse procedure. ‘* Install the cap [A] so that the light blue lead terminal is covered as shown, ‘Tighten: Torque -Fuel Pump Assembly Screws: 0.98 Nem (0.10 kgf-m, 8.7 in-Ib) Fuel Hose Replacement ‘* Remove the fuel tank (see Fuel Tank Removal(3-38) ‘* Be sure to place a piece of cloth around the fuel hose joint. '® Wipe off the dirt of the surface [A] around the connection using a cloth or a soft brush.PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures When removing with flat tip screwdriver ¢ Insert the flat tip screwdriver [A] into slit on the joint lock (B). # Tum the driver to disconnect the joint lock When removing with fingers * Open and push up [C] the joint lock with your fingers. NOTICE Prying or excessively widening the joint lock ends for fuel hose removal will permanently deform the joint lock, resulting in a loose or incomplete lock that may allow fuel to leak and create the potential for a fire explosion. To prevent fire or explosion from a damaged joint lock, do not pry or excessively widen the joint lock ends when removing the fuel hose. The joint lock has a retaining edge that locks around the housing. Pull the fuel hose joint [A] out of the delivery pipe [B]. A\ WARNING Fuel is flammable and explosive under certain con- ditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is dis- connected, fuel spills out from the hose and the pipe. Cover the hose connection with a clean shop towel to prevent fuel spillage. © Clean the delivery pipe. © Cover the delivery pipe with the vinyl bag to keep it clean. Remove the vinyl bag on the pipe. © Check that there are no flaws, burrs, and adhesion of foreign materials on the delivery pipe [A]. # Replace the fuel hose [A] with a new one. Run the fuel hose correctly (see Cable, Wire, and Hose Routing section (18 insert [B] the fuel hose joint (C] straight onto the delivery pipe until the hose joint clicks. # Push [D] the joint lock (E].2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Push and pull [A] the fuel hose joint [B] back and forth more than two times and make sure itis locked and does not come off. A\WARNING Leaking fuel can cause a fire or explosion resulting in severe burns. Make sure the fuel hose joint is installed correctly on the delivery pipe and that it doesn't leak. x fit comes off, reinstall the hose joint. ¢ Install the fuel tank (see Fuel Tank Installation(3-40)). ¢ Start the engine and check the fuel hose for leaks. Evaporative Emission Control System Inspection (Other than US and CA Models) © Inspect the canister as follows. ¢ Remove’ Right Middle Inner Fairing (see Middle Inner Fairing Re- moval(15-12) Screws [A] Canister Bracket [B] Canister [C] ually inspect the canister for cracks or other damage. If the canister has any cracks or bad damage, replace it with a new one. NOTE OThe canister is designed to work well through the motor cycle's life without any maintenance if it is used under normal conditions. @ Inspect the purge valve (see DTC P0443(17-103)) (see DTC P0459(17-104)). Replace any kinked, deteriorated or damaged hoses. Run the hoses correctly (see Cable, Wire, and Hose Rout- ing section (18-2)). When installing the hoses, avoid sharp bending, kinking, flattening or twisting, and run the hoses with a minimum of bending so that the emission flow will not be obstructed. # Check that the hoses are securely connected and clips are in position.PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Cooling System Coolant Level Inspection NOTE Check the level when the engine is cold (room or ambi- ent temperature). Check the coolant level in the reserve tank [A] with the motorcycle held perpendicular (Do not use the side stand). If the coolant level is lower than the “L" level line [B], re- move the middle inner fairing (see Middle Inner Fairing Removal(15-12)), and then remove the reserve tank cap and add coolant to the “F” level line [C} “Ls Low “F: Full NOTICE 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. Cooling System Water Hose and Pipe Inspection (coolant leak, damage, installation condition) OThe 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 britle, 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. Coolant Change 4 WARNING Coolant can be extremely hot and cause severe burns, is toxic and very slippery. Do not remove the radiator cap or attempt to change the coolant when the engine is hot; allow it cool completely. Immediately wipe any spilled coolant from tires, frame, engine or other painted parts. Do not ingest coolant.2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures * Remove: Lower Fairings (see Lower Fairing Removal(15-9) Right Middle Inner Fairing (see Middle Inner Fairing Re- moval(15-12) Radiator Cap [A] @ Place a container under the drain bolt [A] of the water pump cover. © Drain the coolant from the radiator by removing the drain bolt © Slide the clamp [A] © Disconnect: Radiator Overflow Hose [B] # Remove! Bolts [C] Coolant Reserve Tank [D] Cap [E] # Pour the coolant into a container. ¢ Install the coolant reserve tank and tighten the bolt Tighten the drain bolt with new gasket. Torque - Coolant Drain Bolt (Water Pump): 9.0 N-m (0.92 kgf'm, 80 in-Ib) *Fill the radiator up to the radiator filler neck [A] with coolant, and install the radiator cap. NOTE Pour in the coolant slowly so that it can expel the air from the engine and radiator. NOTICE Soft or distilled water must be used with the an- tifreeze (see below for antifreeze) in the cooling sys- tem. Ifhard water is used in the system, it causes scales accumulation in the water passages, and consider- ably reduces the efficiency of the cooling system.PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Water and Coolant Mixture Ratio (Recommended) Soft Water: 50% Coolant: 50% Freezing Point: -35°C (-31°F) Total Amount: 2.4L (2.5 US at) NOTE Choose a suitable mixture ratio by referring to the coolant manufacturer's directions. © Check the cooling system for leaks. Tap the radiator hoses to force any air bubbles caught inside. Fill the coolant to the inlet agai Fill the reserve tank up to the * and install the cap. ¢ Install the radiator cap Start the engine, warm it up thoroughly until the radiator fan turns on and then stop the engine. © Check the coolant level in the reserve tank after the en- gine cools down. +f the coolant level is lower than the “L" level line, add coolant to the “F” level line. NOTICE Do not add more coolant above the “F” level line. level line with coolant,2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Water Hose and O-ring Replacement © Drain the coolant (see Coolant Change(2-27} ¢ Remove! Middle Inner Fairing (see Middle Inner Fairing Re- moval(15-12) Oil Cooler [A] (see Oil Cooler Removal(7-18)) Thermostat Housing Cover [B] (see Thermostat Re- moval(4-16 Water Pump Cover [C] (see Water Pump Removal(4 -10)) Fitting [D] Replace the hoses [E] and O-rings [F] with new ones. © Apply grease to the new O-rings. Run the new hoses correctly (see Cable, Wire, and Hose Routing section (18-2)). Install the removed parts. ¢ Fill the coolant (see Coolant Change(2-27 © Check the cooling system for leaks.PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Engine Top End Valve Clearance Inspection NOTE Valve clearance must be checked and adjusted when the engine is cold (at room temperature). Remove the cylinder head cover (see Cylinder Head Cover Removal(5-14) ‘Remove the timing inspection cap [A] and starter clutch bolt cap [B] on the starter clutch cover [C]. Using a wrench on the starter clutch bolt [A], turn the crankshaft clockwise until the line [B] (TDC mark for #14 pistons) on the starter clutch is aligned with the notches [C] in the edge of the timing inspection hole [D] in the starter clutch cover. © Using a thickness gauge [A], measure the valve clearance between the cam and the valve lifter. Valve Clearance Standard: Exhaust 0.24 0.31 mm (0.0094 — 0.0122 in.) Intake 0.13 0,19 mm (0.0051 — 0.0075 in.) NOTE Thickness gauge is horizontally inserted on the valve ifter. Appropriateness [A] Inadequacy [8] Thickness Gauge [C] Horizontally Inserts [D] Cam [E] Valve Lifter [F] Hits the Valve Lifter Ahead [G]2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures When positioning #1 piston TDC at the end of the compression stroke: Intake 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 Intake 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(5-18)) 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. atb-c [a] Present Shim Thickness [b] Measured Valve Clearance Ic] Specified Valve Clearance [Mean Value = 0.275 mm (Exhaust), 0.160 mm (Intake)} {[d] Replace Shim Thickness Example (Exhaust): 1,600 + 0.33 ~ 0.275 = 1.655 mm OExchange the shim for the 1.675 size shim. eo 183 89 09 OG ee “E3 @o) $9 $9 ca mA Ay ALLETLLLPERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures Adjustment Shims. Thickness. Part Number Mark 4.300 92180-0108 130 4.325 92180-0109 132 160 4.350 92180-0110 135 1.375 92180-0111 138 4.400 92180-0112 140 1.425 92180-0113 142 aeeernea 4.450 92180-0114 145 4.475 92180-0115 148 4.500 92180-0116 150 1.525 92180-0117 152 1.550 92180-0118 155 1.575 92180-0119 158 4.600 92180-0120 160 4.625 (92180-0121 162 1.650 92180-0122 165 1.675 92180-0123 168 4.700 92180-0124 170 4.725 92180-0125 172 4.750 92180-0126 175 4.775 92180-0127 178 4.800 92180-0128 180 1.825 92180-0129 182 1.850 92180-0130 185 4.875 92180-0131 188 4.900 92180-0132 190 1.925 92180-0133 192 1.950 92180-0134 195 1.975 92180-0135 198 2.000 92180-0136 200 2.025 92180-0137 202 2.050 92180-0138 205 2.075 92180-0139 208 2.100 92180-0140 210 2.125 92180-0741 212 2.150 92180-0142 215 2.175 92180-0143 218 2.200 92180-0144 220 2.225 92180-0145 222 2.250 92180-0146 225 2.275 92180-0147 228 2.300 92180-0148 2302-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTICE Be sure to remeasure the clearance after sele ashim. The clearance can be out of the specified range because of the shim tolerance. Olf there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance. © When installing the shim, face the marked side toward the valve lifter. At this time, apply engine oil to the shim or the valve lifter to keep the shim in place during camshaft installation. NOTICE Do not put shim stock under the shim. This may cause the shim to pop out at high rpm, causing ex- tensive engine damage. Do not grind the shim. This may cause it to fracture, causing extensive engine damage. © Apply molybdenum disulfide oil solution to the valve lifter surface and install the lifter. ¢ Install the camshafts (see Camshaft Installation(5-19)) # Recheck the valve clearance and readjust if necessary, Install the removed parts. Air Suction System Damage Inspection # Remove the Fuel Tank (see Fuel Tank Removal(3-38)), © Disconnect the air switching valve hose [A] from the lower air cleaner housing [B] (see Air Cleaner Housing Removal(3-33 © Connect the following parts temporarily. Fuel Pump Connector [A] Extension Tube [8] Air Cleaner Housing (see Air Cleaner Housing Installa- tion(3-34)) Special Tool - Extension Tube: 57001-1578PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Start the engine and run it at idle speed. Plug the air switching valve hose end [A] with your finger and feel vacuum pulsing in the hose. If there is no vacuum pulsation, check the hose line for leak. If there is no leak, check the air switching valve (see Air Switching Valve Unit Test(16-58)) or air suction valve (see Air Suction Valve Inspection(5-12)). Clutch Clutch Operation Inspection '* Keep the handlebars straight ahead. ‘© Pull the clutch lever just enough to take up the free play (Al. * Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully. In either case, adjust it Clutch Lever Free Play Standard: 2-3 mm (0.08 — 0.12 in.) 4. WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns. Never touch the engine or exhaust pipe during clutch adjustment. @ Loosen the locknut [A]. © Turn the adjuster [B] so that 5 - 6 mm (0.20 - 0.24 in.) [C] of threads is visible. * Slide the dust cover [A] at the clutch cable lower end out of place. * Loosen both adjusting nuts [B] at the bracket [C] on the clutch cover as far as they will go. # Pull the clutch outer cable [0] tight and tighten the adjust- ing nuts against the bracket. Slip the dust cover back onto place. Tum the adjuster at the clutch lever until the free play is correct.2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures © Push the release lever [A] toward the front of the motor- cycle until it becomes hard to turn. CAL this time, the release lever should have the proper an- gle shown, 60° [B] If the angle is wrong, check the clutch and release parts for wear. AY WARNING Too much cable play can prevent clutch disengage- ment and cause an accident resulting in serious in- jury or death. When adjusting the clutch or replac- ing the cable, be sure the upper end of the clutch outer cable is fully seated in its fitting, or it could slip into place later, creating enough cable play to prevent clutch disengagement. © After the adjustment, start the engine and check that the clutch does not slip and that it releases properly. Engine Lubrication System Engine Oil Change ¢ Situate the motorcycle so that itis vertical after warming up the engine. Remove the engine oil drain bolt [A] to drain the oil The olin the oll filter can be drained by removing the filter (see Oil Filter Replacement(2-37)). # Replace the drain bolt gasket [B] with a new one. © Tighten the drain bolt. Torque - Engine Oil Drain Bolt: 29 N-m (3.0 kgfm, 21 ft1b) Remove the oil filler plug [A].PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures © Pour in the specified type and amount of oil. SAE 208-50 Recommended Engine Oil ‘API SG, SH, SJ, SL or SM with JASO MA, [sie aenmas > MA‘ or MA2 SAE 100-50 a ee SAE 106-40 SKE_108=40 2.8 L (3.0 US qt) (when filter is not enaEeae removed.) ot ee ew 3.1L (8.3 US qt) (when filter is removed.) a 3.6L (3.8 US qt) (when engine is completely ‘eens 8 ary) NOTE (Do not add any chemical additive to the oil. Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for both the engine and the clutch. Although 10W-40 engine oil is the recommended oil for most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area. * Replace the O-ring of the oil filler plug with a new one. © Apply grease to the new O-ring. « Install the oi! filler plug. Check the oil level (see Oil Level Inspection(7-9) Oil Filter Replacement © Drain the engine oil (see Engine Oil Change(2-36) Remove the oil fitter [A] with the oil filter wrench [B] Special Tool - Oil Filter Wrench: 57001-1249 © Replace the filter with a new one. © Apply grease to the gasket [A] before installation. @ Tighten the filter with the oil filter wrench. Special Tool - Oil Filter Wrench: 57001-1249 17 Nem (1.7 kgf-m, 13 fttb) NOTE Hand tightening of the oil filter can not be allowed since it does not reach to this tightening torque. Pour in the specified type and amount of oil (see Engine Oil Change(2-36 Torque - Oil Fi2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheels/Tires Air Pressure Inspection ¢ Remove the air valve cap. © Measure the tite air pressure with an air pressure gauge IA] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours). ¢ Install the air valve cap. Adjust the tire air pressure according to the specifications if necessary. Air Pressure (when Cold) Front: Up to 180 kg (397 Ib) load: 250 kPa (2.50 kgficm*, 36 psi) Rear: Up to 180 kg (397 Ib) load: 290 kPa (2.90 kaf/cm*, 42 psi) Wheels and Tires Wheel/Tire Damage Inspection # Remove any imbedded stones [A] or other foreign parti- cles [B] from tread. Visually inspect the tire for cracks and cuts, and replace the tire if necessary. Swelling or high spots indicate inter- nal damage, requiring tire replacement. Visually inspect the wheel for cracks, cuts and dents dam- age. ¥Ifany damage is found, replace the wheel if necessary. Tire Tread Wear Inspection As the tire tread wears down, the tire becomes more sus- ceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (20% worn). So it is false economy and unsafe to use the tires until they are bald. © Measure the tread depth at the center of the tread with a depth gauge [A]. Since the tire may wear unevenly, take measurement at several places. x If any measurement is less than the service limit, replace the tire (see Tire Removal(10-13)) (see Tire Installa- 13) tion(1 Tread Depth Standard: Front 4.1 mm (0.16 in.) Rear 5.8 mm (0.23 in.) Service Limit: Front 4 mm (0.04 in.) Rear 2 mm (0.08 in.) (Up to 130 km/h (80 mph)) 3. mm (0.12 in.) (Over 130 km/h (80 mph))PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures 4 WARNING ‘Some replacement tires may adversely affect han- dling and cause an accident resulting in serious in- jury or death. To ensure proper handling and sta- bility, use only the recommended standard tires for replacement, inflated to the standard pressure. NOTE (Most countries may have their own regulations a mini- mum tire tread depth: be sure to follow them. Check and balance the wheel when a tire is replaced with a new one. Wheel Bearing Damage Inspection # Raise the front wheel off the ground ‘Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 © Tum the handlebars all the way to the right or left, * Inspect the roughness of the front wheel bearing by push- ing and pulling [A] the wheel. © Spin [B] the front wheel lightly, and check for smoothly tum, roughness, binding or noise. If roughness, binding or noise is found, remove the front wheel and inspect the wheel bearing (see Front Wheel Removal(10-6)) (see Hub B © Raise the rear wheel off the ground with the stand (see Rear Wheel Removal( 10-7 « Inspect the roughness of the rear wheel bearing by push- ing and pulling [A] the wheel. © Spin [B] the rear wheel lightly, and check for smoothly turn, roughness, binding or noise. If roughness, binding or noise is found, remove the rear Wheel and inspect the wheel bearing (see Rear Wheel Removal(10-7)) (see Hub Bearing Inspection(10-17)) and coupling (see Coupling Bearing Installation(11-14)). Final Drive Drive Chain Lubrication Condition Inspection @ If a special lubricant is not available, a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. If the chain appears especially dirty, clean it before lubri- cation. NOTICE The O-rings between the side plates seal in the lu- bricant between the pin and the bushing. To avoid damaging the O-rings and resultant loss of lubri- cant, observe the following rules. Use only kerosene or diesel oil for cleaning of the O-ring of the drive chain. Any other cleaning solu- tion such as gasoline will cause deterioration and swelling of the O-ring. Immediately blow the chain dry with compressed air after cleaning. Complete cleaning and drying the chain within 10 minutes.2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures @ Apply oil to the sides of the rollers so that oil will penetrate tothe rollers and bushings. Apply the oil to the O-rings so that the O-rings will be coated with oil. © Wipe off any excess oil Oil Applied Areas [A] O-rings [B] Drive Chain Slack Inspection NOTE Check the slack with the motorcycle setting on its side- stand, Clean the chain if tis dirty, and lubricate it fit appears ary. © Check the wheel alignment (see Wheel Alignment Inspec- tion(2-41)) Rotate the rear wheel to find the position where the chain is tightest * Measure the vertical movement (chain slack) [A] midway between the sprockets. xf the chain slack exceeds the standard, adjust it Chain Slack Standard: 30-40 mm (1.2 ~ 1.6 in) Drive Chain Slack Adjustment # Remove the cotter pin [A], and loosen the rear axle nut Bl # Loosen the both chain adjuster locknuts [C]. If the chain is too loose, tun out the left and right chain adjusters [A] evenly. If the chain is too tight, turn in the left and right chain adjusters evenly, and push the wheel forward. © Turn both chain adjusters evenly until the drive chain has the correct amount of slack. To keep the chain and wheel properly aligned, the notch [B] on the right wheel align- ment indicator should align with the same swingarm mark or position {C] that the left indicator notch aligns with B she obawyl EEE aePERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures 4 WARNING Misalignment of the wheel result in abnormal wear and may result in an unsafe riding condition. Be sure the wheel is properly aligned. ® Tighten the both chain adjuster locknuts securely. © Tighten: Torque - Rear Axle Nut: 130 N-m (13.3 kgf-m, 95.9 ft'lb) © Tum the wheel, measure the chain slack again at the tight- est position, and readjust if necessary. © Insert a new cotter pin [A] NOTE When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [8] up to next alignment. Olt should be within 30 degrees. Loosen once and tighten again when the slot goes past the nearest hole. © Bend the cotter pin [A] over the nut [B]. AX WARNING A loose axle nut can lead to an accident resulting in serious injury or death. Tighten the axle nut to the proper torque and install a new cotter pin. Wheel Alignment Inspection # Check that the notch [A] on the left alignment i aligns with the same swingarm mark or posit the right alignment indicator notch aligns with. If they do not, adjust the chain slack and align the wheel alignment (see Drive Chain Slack Adjustment(2-40)).. NOTE Wheel alignment can be also checked using the straightedge or string method. AX WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition. Be sure the wheel is properly aligned. icator [B] n [C] that2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Wear Inspection Remove the chain cover (see Drive Chain Replace- ment(11-6)). © Rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry. The drive chain may wear unevenly, so check the chain slack by changing the position, and position the loosest part of the drive chain lower side. @ Loosen the rear axle shaft, and pull [A] the rear wheel rearward to stretch the drive chain steady. Measure the length of 20 links [B] on the straight part [C] of the lower side of chain from the pin center of the 1st pin to the pin center of the 21st pin. x Ifany measurements exceed the service limit, replace the chain. Also, replace the front and rear sprockets when the drive chain is replaced. 20-1ink Length 317.5 ~ 318.2 mm (12.50 ~ 12.53 in.) Service Limit: 319 mm (12.6 in.) ANWARNING A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control. Inspect the chain for damage and proper adjustment before each ride. If chain wear exceeds the service limit, replace it with the standard chain. It is an endless type and should not be cut for installation. Standard Chain Make: DAIDO DID s20HV2 112 links Chain Guide Wear Inspection # Remove the engine sprocket cover (see Engine Sprocket Cover Removal(11-11 « Visually inspect the chain guide [A], Replace the chain guide if it shows any signs of abnormal wear or damage.PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Brakes Brake System Inspection Brake Fluid Leak (Brake Hose and Pipe) Inspection © For ABS equipped models, remove the air cleaner hous- ing (see Air Cleaner Housing Removal(3-33)). © Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A], pipes [B] (ABS equipped models) and fittings [C} If the brake fluid leaked from any position, inspect or re- place the problem parts. Brake Hose and Pipe Damage and Installation Condi- tion Inspection * For ABS equipped models, remove the air cleaner hous- ing (see Air Cleaner Housing Removal(3-33)). Inspect the brake hoses, pipe and fittings for deteriora- tion, cracks and signs of leakage. The high pressure inside the brake line can cause fluid to leak [A] or the hose, pipes (ABS equipped models) to burst ifthe line is not properly maintained. Bend and twist the rubber hose while examining it. Replace the hose and pipe (ABS equipped models) if any crack [B], bulge (C] or leakage is noticed (see Brake Hose and Pipe Replacement(2-47)).2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures x Tighten any brake hose banjo bolts and brake pipe banjo bolts to check tightness condition Torque - Brake Hose Banjo Bolts [A]: 25 N-m (2.5 kgf'm, 18 ftlb) Brake Pipe Banjo Bolts [B] (ABS Equipped Mod- (els): 23 Nem (2.3 kaf'm, 17 ftlb) Brake Pipe Joint Nuts [C] (ABS Equipped Models): 14.5 Nem (1.48 kgf'm, 10.7 ftb) Inspect the brake hose and pipe routing, x If any brake hose and pipe routing is incorrect, run the brake hose and pipe correctly (see Cable, Wire, and Hose Routing section (18-2)). Brake Operation Inspection © Inspect the operation of the front and rear brake by run- ning the vehicle on the dry road. If the brake operation is insufficiency, inspect the brake system. A\WARNING When test riding the vehicle, be aware of surround- ing traffic for your safety. Brake Fluid Level Inspection # Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. NOTE OHold the reservoir horizontal by turning the handlebar when checking brake fluid level. NOTICE Brake fluid quickly damages painted plastic sur- faces; any spilled fluid should be completely washed away immediately. +f the fluid level is lower than the lower level line, remove the screw [C], stopper [D] and cap [E] then fillthe reservoir to the upper level line [F].PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures # Check that the brake fluid level in the rear brake reservoir [A] is above the lower level line [B]. NOTICE Brake fluid quickly damages painted plastic sur- faces; any spilled fluid should be completely washed away immediately. If the fluid level is lower than the lower level line, remove the bolt (C] and cap [0] then fill the reservoir to the upper level line [E] 4. WARNING ing brands and types of brake fluid can reduce s effectiveness and cause an ac- cident resulting in injury or death. Do not two brands of brake fluid. Change the brake fluid in the brake line completely if the brake fluid must be re- filled but the type and brand of the brake fluid that is already in the reservoir are unidentified. Recommended Disc Brake Fluid Grade: DOT4 * Follow the procedure below to install the front/rear brake fluid reservoir cap correctly. First, tighten the brake fluid reservoir cap [A] clockwise [8] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body [C], then tighten the cap an additional 1/6 tur [D] while holding the brake fluid reservoir body. ¢ Install the stopper to the reservoir. Tighten: Torque -Front Brake Reservoir Cap Stopper Screw: 1.2 Nem (0.12 kgf'm, 11 in-tb) Brake Fluid Change NOTE ©The procedure to change the front brake fluid is as fol- lows. Changing the rear brake fluid is the same as for the front brake. Level the brake fluid reservoir. ¢ Remove: Screw [A] Stopper [B] Front Brake Reservoir Cap [C] Diaphragm Plate Diaphragm