User manual KAWASAKI NINJA ZX-10R

Ninja ZX-10R Motorcycle Service Manual Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires Final Drive Brakes Suspension Steering Frame Electrical System This quick reference guide will assist you in locating a desired topic or procedure. ·Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. ·Refer to the sectional table of contents for the exact pages to locate the specific topic required. 1j 2j 3j 4j 5j 6j 7j 8j 9j 10 j 11 j 12 j 13 j 14 j 15 j 16 j 17 j Appendix Ninja ZX-10R Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2005 Kawasaki Heavy Industries, Ltd. Second Edition (1): Jan. 19, 2006 (K) LIST OF ABBREVIATIONS A ABDC AC ATDC BBDC BDC BTDC °C DC F °F ft g h L ampere(s) after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celsius direct current farad(s) degree(s) Fahrenheit foot, feet gram(s) hour(s) liter(s) lb m min N Pa PS psi r rpm TDC TIR V W pound(s) meter(s) minute(s) newton(s) pascal(s) horsepower pound(s) per square inch revolution revolution(s) per minute top dead center total indicator reading volt(s) watt(s) ohm(s) COUNTRY AND AREA CODES AT AU CA CAL CH DE Austria Australia Canada California Switzerland Germany FR GB MY US WVTA France United Kingdom Malaysia United States Whole Vehicle Type Approval EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only. 1. Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors are routed through an oil separator to the inlet side of the engine. While the engine is operating, the vapors are drawn into combustion chamber, where they are burned along with the fuel and air supplied by the fuel injection system. 2. Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels. The exhaust system of this model motorcycle manufactured primarily for sale in California includes a catalytic converter system. 3. Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister when the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank. The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly referred to as the Act's "tampering provisions". "Sec. 203(a) The following acts and the causing thereof are prohibited... (3)(A) for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser. (3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser..." The phrase "remove or render inoperative any device or element of design" has been generally interpreted as follows. 1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance. 2. Tampering could include. a.Maladjustment of vehicle components such that the emission standards are exceeded. b.Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle. c.Addition of components or accessories that result in the vehicle exceeding the standards. d.Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems. NOTE WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10 000 PER VIOLATION. TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. Among those acts presumed to constitute tampering are the acts listed below. Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations. Removal of the muffler(s) or any internal portion of the muffler(s). Removal of the air box or air box cover. Modifications to the muffler(s) or air inlet system by cutting, drilling, or other means if such modifications result in increased noise levels. · · · · Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your vehicle. Follow the Periodic Maintenance Chart in the Service Manual. Be alert for problems and non-scheduled maintenance. Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual. Genuine parts provided as spare parts are listed in the Parts Catalog. Follow the procedures in this manual carefully. Don't take shortcuts. Remember to keep complete records of maintenance and repair with dates and any new parts installed. Guide shows you all of the product's system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. For example, if you want ignition coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Ignition Coil section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices. WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information. · · · NOTE This note symbol indicates points of par ticular interest for more efficient and convenient operation. · Indicates a procedural step or work to be done. · · 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 the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly. Indicates a procedural sub-step or how to do GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ..................................................................................................................... Model Identification................................................................................................................. General Specifications............................................................................................................ Unit Conversion Table ............................................................................................................ 1-2 1-7 1-9 1-12 1 1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts. Especially note the following. Battery Ground Before completing any service on the motorcycle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the ground cable (­) first and then the positive (+). When completed with the service, first connect the positive (+) cable to the positive (+) terminal of the battery then the negative (­) cable to the negative terminal. Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts. Solvent Use a high-flush point solvent when cleaning parts. High -flush point solvent should be used according to directions of the solvent manufacturer. Cleaning vehicle before disassembly Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle. GENERAL INFORMATION 1-3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly. Storage of Removed Parts After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly. Inspection Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit. Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled. Assembly Order In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given. 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally. Tightening Torque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench. Force Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non -permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary. Gasket, O-ring Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove the old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install the new gaskets and replace the used O-rings when re-assembling Liquid Gasket, Non-permanent Locking Agent For applications that require Liquid Gasket or a Non-permanent Locking Agent, clean the surfaces so that no oil residue remains before applying liquid gasket or non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage. GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown. Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage. Oil Seal, Grease Seal Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed. Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing. Apply specified grease to the lip of seal before installing the seal. Circlips, Cotter Pins Replace the circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation. 1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side). Electrical Wires A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color. Instrument Use a meter that has enough accuracy for an accurate measurement. Read the manufacture's instructions thoroughly before using the meter. Incorrect values may lead to improper adjustments. GENERAL INFORMATION 1-7 Model Identification ZX1000D6F (Europe) Left Side View ZX1000D6F (Europe) Right Side View 1-8 GENERAL INFORMATION Model Identification ZX1000D6F (United States and Canada) Left Side View ZX1000D6F (United States and Canada) Right Side View Frame Number Engine Number GENERAL INFORMATION 1-9 General Specifications Items Dimensions Overall Length Overall Width Overall Height Wheelbase Road Clearance Seat Height Dry Mass Curb Mass: Front Rear Fuel Tank Capacity Performance Minimum Turning Radius Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower ZX1000D6F (Ninja ZX-10R) 2 065 mm (81.3 in.) (CA), (CAL), (US) 730 mm (28.7 in.) 705 mm (27.8 in.) 1 130 mm (44.5 in.) 1 390 mm (54.7 in.) 120 mm (4.7 in.) 825 mm (32.5 in.) 175 kg (386 lb) 102 kg (225 lb) 100 kg (221 lb) 17 L (4.5 US gal) 3.3 m (10.8 ft) 4-stroke, DOHC, 4-cylinder Liquid-cooled 76.0 × 55.0 mm (3.0 × 2.2 in.) 998 mL (60.9 cu in.) 12.7 : 1 128.7 kW (175 PS) @11 700 r/min (rpm), (FR) 78.2 kW (106 PS) @10 500 r/min (rpm), (AU) 128.7 kW (175 PS) @11 500 r/min (rpm), (MY) 120.5 kW (164 PS) @10 000 r/min (rpm), (CA), (CAL), (US) ­ ­ ­ 115 N·m (11.7 kgf·m, 85 ft·lb) @9 500 r/min (rpm), (FR) 86 N·m (8.8 kgf·m, 63 ft·lb) @5 200 r/min (rpm), (CA), (CAL), (US) ­ ­ ­ FI (Fuel injection), MIKUNI 43EIDW × 4 Electric starter Battery and coil (transistorized) Electronically advanced (digital igniter in ECU) From 10° BTDC @1 100 r/min (rpm) NGK CR9EIA-9 Left to right, 1-2-3-4 1-2-4-3 Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Cylinder Numbering Method Firing Order Valve Timing: Inlet: Open Close Duration Exhaust: Open Close 46° BTDC 74° ABDC 300° 66° BBDC 46° ATDC 1-10 GENERAL INFORMATION General Specifications Items Duration Lubrication System Engine Oil: Type Viscosity Capacity Drive Train Primary Reduction System: Type Reduction Ratio Clutch Type Transmission: Type Gear Ratios: 1st 2nd 3rd 4th 5th 6th Final Drive System: Type Reduction Ratio Overall Drive Ratio Frame Type Caster (Rake Angle) Trail Front Tire: Type Size Rear Tire: Type Size Rim Size: Front Rear Front Suspension: Type Wheel Travel Rear Suspension: Type Wheel Travel ZX1000D6F (Ninja ZX-10R) 292° Forced lubrication (wet sump with cooler) API SE, SF or SG API SH, SJ or SL with JASO MA SAE10W-40 4.0 L (4.2 US qt) Gear 1.611 (87/54) Wet multi disc 6-speed, constant mesh, return shift 2.533 2.053 1.737 1.524 1.381 1.304 (38/15) (39/19) (33/19) (32/21) (29/21) (30/23) Chain drive 2.353 (40/17) 4.945 @Top gear Tubular, diamond 24.5° 102 mm (4.0 in.) Tubeless 120/70 ZR17 M/C (58 W) Tubeless 190/55 ZR17 M/C (75 W) 17 × 3.50 17 × 6.00 Telescopic fork (upside-down) 120 mm (4.7 in.) Swingarm (uni-trak) 125 mm (4.9 in.) GENERAL INFORMATION 1-11 General Specifications Items Brake Type: Front Rear Electrical Equipment Battery Headlight: Type Bulb: High Low Tail/Brake Light Alternator: Type Rated Output Dual discs Single disc 12 V 10 Ah Semi-sealed beam 12 V 55 W + 65 W (quartz-halogen) 12 V 55 W (quartz-halogen) 12 V 0.5/4.1 W (LED) Three-phase AC 31 A/14 V @5 000 r/min (rpm) ZX1000D6F (Ninja ZX-10R) Specifications subject to change without notice, and may not apply to every country. 1-12 GENERAL INFORMATION Unit Conversion Table Prefixes for Units Prefix mega kilo centi milli micro Symbol M k c m µ × × × × × Power 1 000 000 1 000 0.01 0.001 0.000001 Units of Length km m mm × × × 0.6214 3.281 0.03937 = = = mile ft in Units of Torque N·m N·m N·m kgf·m kgf·m kgf·m × × × × × × 0.1020 0.7376 8.851 9.807 7.233 86.80 = = = = = = kgf·m ft·lb in·lb N·m ft·lb in·lb Units of Mass kg g × × 2.205 0.03527 = = lb oz Units of Volume L L L L L L mL mL mL × × × × × × × × × 0.2642 0.2200 1.057 0.8799 2.113 1.816 0.03381 0.02816 0.06102 = = = = = = = = = gal (US) gal (imp) qt (US) qt (imp) pint (US) pint (imp) oz (US) oz (imp) cu in Units of Pressure kPa kPa kPa kgf/cm² kgf/cm² cmHg × × × × × × 0.01020 0.1450 0.7501 98.07 14.22 1.333 = = = = = = kgf/cm² psi cmHg kPa psi kPa Units of Speed km/h × 0.6214 = mph Units of Force N N kg kg × × × × 0.1020 0.2248 9.807 2.205 = = = = kg lb N lb Units of Power kW kW PS PS × × × × 1.360 1.341 0.7355 0.9863 = = = = PS HP kW HP Units of Temperature PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ................................................................................................... Torque and Locking Agent...................................................................................................... Specifications ......................................................................................................................... Special Tools .......................................................................................................................... Maintenance Procedure ......................................................................................................... Fuel System (DFI)................................................................................................................ Throttle Control System Inspection................................................................................... Engine Vacuum Synchronization Inspection..................................................................... Idle Speed Inspection ....................................................................................................... Idle Speed Adjustment...................................................................................................... Fuel Hose Inspection (fuel leak, damage, installation condition) ...................................... Evaporative Emission Control System (California Model) ................................................... Evaporative Emission Control System Inspection ............................................................ Cooling System.................................................................................................................... Coolant Level Inspection................................................................................................... Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition) .......... Engine Top End ................................................................................................................... Valve Clearance Inspection .............................................................................................. Valve Clearance Adjustment............................................................................................. Air Suction System .............................................................................................................. Air Suction System Damage Inspection............................................................................ Clutch................................................................................................................................... Clutch Operation Inspection ............................................................................................. Wheels/Tires ........................................................................................................................ Air Pressure Inspection..................................................................................................... Wheel/Tire Damage Inspection......................................................................................... Tire Tread Wear Inspection .............................................................................................. Wheel Bearing Damage Inspection .................................................................................. Drive Train ........................................................................................................................... Drive Chain Lubrication Condition Inspection ................................................................... Drive Chain Slack Inspection ............................................................................................ Drive Chain Slack Adjustment .......................................................................................... Wheel Alignment Inspection ............................................................................................. Drive Chain Wear Inspection ............................................................................................ Chain Guide Wear Inspection ........................................................................................... Brake System ...................................................................................................................... Brake Fluid Leak (Brake Hose and Pipe) Inspection ........................................................ Brake Hose Damage and Installation Condition Inspection.............................................. Brake Operation Inspection .............................................................................................. Brake Fluid Level Inspection............................................................................................. Brake Pad Wear Inspection .............................................................................................. Brake Light Switch Operation Inspection .......................................................................... Suspensions ........................................................................................................................ Front Forks/Rear Shock Absorber Operation Inspection .................................................. Front Fork Oil Leak Inspection.......................................................................................... Rear Shock Absorber Oil Leak Inspection ........................................................................ Rocker Arm Operation Inspection..................................................................................... Tie-Rod Operation Inspection ........................................................................................... Steering System .................................................................................................................. Steering Play Inspection ................................................................................................... 2-3 2-6 2-13 2-15 2-16 2-16 2-16 2-16 2-19 2-20 2-20 2-21 2-21 2-22 2-22 2-22 2-22 2-22 2-24 2-26 2-26 2-27 2-27 2-28 2-28 2-28 2-28 2-29 2-30 2-30 2-30 2-31 2-32 2-32 2-33 2-33 2-33 2-33 2-33 2-34 2-34 2-34 2-35 2-35 2-36 2-36 2-36 2-36 2-37 2-37 2 2-2 PERIODIC MAINTENANCE Steering Play Adjustment.................................................................................................. Steering Stem Bearing Lubrication ................................................................................... Steering Damper Oil Leak Inspection ............................................................................... Electrical System ................................................................................................................. Lights and Switches Operation Inspection........................................................................ Headlight Aiming Inspection ............................................................................................. Sidestand Switch Operation Inspection ............................................................................ Engine Stop Switch Operation Inspection......................................................................... Others .................................................................................................................................. Chassis Parts Lubrication ................................................................................................ Bolts, Nuts and Fasteners Tightness Inspection............................................................... Replacement Parts .............................................................................................................. Air Cleaner Element Replacement.................................................................................... Fuel Hose Replacement ................................................................................................... Coolant Change ................................................................................................................ Radiator Hose and O-ring Replacement........................................................................... Engine Oil Change............................................................................................................ Oil Filter Replacement ...................................................................................................... Brake Hose and Pipe Replacement.................................................................................. Brake Fluid Change .......................................................................................................... Master Cylinder Rubber Parts Replacement .................................................................... Caliper Rubber Parts Replacement .................................................................................. Spark Plug Replacement .................................................................................................. 2-37 2-38 2-38 2-39 2-39 2-41 2-42 2-43 2-44 2-44 2-45 2-47 2-47 2-48 2-49 2-52 2-53 2-53 2-54 2-54 2-56 2-57 2-60 PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic Inspection FREQUENCY Whichever comes first INSPECTION Fuel System Throttle control system (play, smooth return, no drag)-inspect Engine vacuum synchronization-inspect Idle speed-inspect Fuel leak (fuel hose and pipe)-inspect Fuel hose and pipe damage-inspect Fuel hose and pipe installation condition-inspect Evaporative Emission Control System (CAL) Evaporative emission control system function-inspect Cooling System Coolant level-inspect Coolant leak (radiator hose and pipe)-inspect Radiator hose damage-inspect Radiator hose installation condition -inspect Engine Top End Valve clearance-inspect Air Suction System Air suction system damage-inspect Clutch Clutch operation (play, disengagement, engagement)-inspect Wheels and Tires Tire air pressure-inspect Wheel/tire damage-inspect Tire tread wear, abnormal wear-inspect Wheel bearing damage-inspect Drive Train Drive chain lubrication condition-inspect # Drive chain slack-inspect # Drive chain wear-inspect # Drive chain guide wear-inspect year year year year year year year year Every year 1 6 (0.6) (4) * ODOMETER READING × 1 000 km (× 1 000 mile) 12 18 24 30 36 (7.5) (12) (15) (20) (24) See Page · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · 2-16 2-16 2-19 2-20 2-20 2-20 ····· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-21 2-22 2-22 2-22 2-22 2-22 2-26 · · · · · · · · 2-27 2-28 2-28 2-28 2-29 2-30 2-30 2-32 2-33 Every 600 km (400 mile) Every 1 000 km (600 mile) 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever comes first INSPECTION Brake System Brake fluid leak (brake hose and pipe)-inspect Brake hose and pipe damage-inspect Brake pad wear-inspect # Brake hose installation condition-inspect Brake fluid level-inspect Brake operation (effectiveness, play, no drag)-inspect Brake light switch operation-inspect Suspensions Front forks/rear shock absorber operation (damping and smooth stroke)-inspect Front forks/rear shock absorber oil leak-inspect Rocker arm operation-inspect Tie-Rods operation-inspect Steering System Steering play-inspect Steering stem bearings-lubricate Steering damper oil leak-inspect Electrical System Lights and switches operation-inspect Headlight aiming-inspect Sidestand switch operation-inspect Engine stop switch operation-inspect Others Chassis parts-lubricate Bolts and nuts tightness-inspect year year year year year year 2 years year 6 months year Every year year 1 6 (0.6) (4) * ODOMETER READING × 1 000 km (× 1 000 mile) 12 18 24 30 36 (7.5) (12) (15) (20) (24) See Page ·· ·· · ·· ·· ·· ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-33 2-33 2-34 2-33 2-34 2-33 2-34 2-35 2-36 2-36 2-36 2-37 2-38 2-38 2-39 2-41 2-42 2-43 2-44 2-45 year · · · · · ····· · · · · · · · · · · · · · · · · · *: For higher odometer readings, repeat at the frequency interval established here. #: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping. · · · PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever come first CHANGE/REPLACE ITEM Air cleaner element # Fuel hose Coolant Radiator hose and O-ring Engine oil # Oil filter Brake hose and pipe Brake fluid Rubber parts of master cylinder and caliper Spark plug Every 4 years 3 years 3 years year year 4 years 2 years 4 years 1 (0.6) * ODOMETER READING × 1 000 km (× 1 000 mile) 12 (7.5) 24 (15) 36 (24) 48 (30) See Page 2-47 2-48 2-49 2-52 2-53 2-53 2-54 2-54 2-56 2-60 Every 18 000 km (12 000 mile) · · · · · · · · · · · · · · · · · · · · · *: For higher odometer readings, repeat at the frequency interval established here. #: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping. 2-6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the "Remarks" column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil solution. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1.) R: Replacement Parts S: Follow the specified tightening sequence. Si: Apply silicone grease (ex. PBC grease). SS: Apply silicone sealant. Fastener Fuel System Air Cleaner Element Cover Screws Air Cleaner Housing Holder Clamp Screws Air Cleaner Housing Mounting Bolts Air Inlet Duct Mounting Bolts Bypass Screws Camshaft Position Sensor Bolt Canister Bracket Mounting Bolt (M5) Canister Bracket Mounting Screws (M5) Crankshaft Sensor Bolts Delivery Pipe Mounting Screws Exhaust Butterfly Valve Actuator Mounting Bolts Exhaust Butterfly Valve Actuator Pulley Bolts Fuel Pump Bolts Gear Position Switch Screws Inlet Air Pressure Sensor Bracket Screws Separator Bracket Mounting Bolts Separator/Canister Hose Clamp Bolt Speed Sensor Bolt Throttle Body Assy Holder Bolts Throttle Body Assy Holder Clamp Bolts Vehicle-down Sensor Bolts Water Temperature Sensor Cooling System Coolant By-pass Fitting Bolt Coolant Drain Bolt (Cylinder) Coolant Drain Bolt (Water Pump) Coolant Reserve Tank Mounting Bolts Oil Cooler Mounting Bolts Thermostat Housing Cover Bolts Thermostat Housing Mounting Bolts Radiator Bracket Mounting Bolt N·m 1.1 2.0 7.0 7.0 0.2 10 4.3 4.3 6.0 5.0 0.8 5.0 10 3.0 3.5 7.0 7.0 10 10 2.0 6.0 25 9.0 10 10 7.0 20 6.0 10 7.0 Torque kgf·m 0.11 0.20 0.71 0.71 0.02 1.0 0.44 0.44 0.61 0.51 0.08 0.51 1.0 0.31 0.36 0.71 0.71 1.0 1.0 0.20 0.61 2.5 0.92 1.0 1.0 0.71 2.0 0.61 1.0 0.71 ft·lb 9.7 in·lb 18 in·lb 62 in·lb 62 in·lb 17 in·lb 89 in·lb 38 in·lb 38 in·lb 53 in·lb 44 in·lb 7 in·lb 44 in·lb 89 in·lb 27 in·lb 31 in·lb 62 in·lb 62 in·lb 89 in·lb 89 in·lb 18 in·lb 53 in·lb 18 80 in·lb 89 in·lb 89 in·lb 62 in·lb 15 53 in·lb 89 in·lb 62 in·lb Remarks L L L, S L SS L PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Fastener Radiator Lower Bolt Radiator Upper Bolt Water Hose Clamp Screws Water Hose Fitting Bolts Water Passage Plugs Water Pump Cover Bolts Water Temperature Sensor Engine Top End Air Suction Valve Cover Bolts Camshaft Cap Bolts Camshaft Chain Tensioner Cap Bolt Camshaft Chain Tensioner Mounting Bolts Camshaft Position Sensor Bolt Cam Sprocket Mounting Bolts Coolant Drain Plug (Cylinder) Cylinder Head Bolts (M6) Cylinder Head Bolts (M10 New Bolts) Cylinder Head Bolts (M10 Used Bolts) Cylinder Head Cover Bolts Exhaust Butterfly Valve Cable Adjuster Locknuts Exhaust Butterfly Valve Cable Locknuts Exhaust Pipe Manifold Mounting Bolts Front Camshaft Chain Guide Bolt (Upper) Front Camshaft Chain Guide Bolt (Lower) Front Exhaust Pipe Manifold Holder Nuts Idle Gear Cover Bolts Middle Exhaust Pipe Clamp Bolt Middle Exhaust Pipe Stay Bolt Muffler Body Assembly Nuts Muffler Body Cover Bolts Muffler Body Mounting Bolts Oxygen Sensors (Europe Models) Rear Exhaust Pipe Clamp Bolt Right Engine Bracket Bolts (Cylinder Head Side) Spark Plugs Starter Clutch Bolt Cap Starter Clutch Cover Bolts (M6, L = 30 mm) Starter Clutch Cover Bolts (M6, L = 20 mm) Throttle Body Assy Holder Bolts Throttle Body Assy Holder Clamp Bolts Timing Inspection Cap Upper Camshaft Chain Guide Bolts Water Passage Plugs N·m 7.0 7.0 2.0 10 19.6 10 25 10 12 20 10 10 15 10 12 59 57 10 7.0 7.0 14 25 12 17 10 17 25 22 7.0 25 25 17 10 13 ­ 10 10 10 2.0 ­ 12 19.6 Torque kgf·m 0.71 0.71 0.20 1.0 2.0 1.0 2.5 1.0 1.2 2.0 1.0 1.0 1.5 1.0 1.2 6.0 5.8 1.0 0.71 0.71 1.4 2.5 1.2 1.7 1.0 1.7 2.5 2.2 0.71 2.5 2.5 1.7 1.0 1.3 ­ 1.0 1.0 1.0 0.20 ­ 1.2 2.0 ft·lb 62 in·lb 62 in·lb 18 in·lb 89 in·lb 14 89 in·lb 18 Remarks L SS 89 in·lb L 106 in·lb S 15 89 in·lb 89 in·lb 11 L 89 in·lb 106 in·lb 44 MO, S 42 MO, S 89 in·lb 62 in·lb 62 in·lb 10 18 106 in·lb 13 89 in·lb 13 18 16 62 in·lb 18 18 13 89 in·lb L 115 in·lb ­ Hand-tighten 89 in·lb 89 in·lb 89 in·lb S 18 in·lb S ­ Hand-tighten 106 in·lb S 14 L 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Clutch Clutch Cover Mounting Bolts Clutch Hub Nut Clutch Lever Clamp Bolts Clutch Spring Bolts Oil Filler Plug Sub Clutch Hub Bolts Engine Lubrication System Engine Oil Drain Bolt Oil Cooler Mounting Bolts Oil Filter Oil Cooler/Oil Filter Case Mounting Bolts Oil Filter Pipe Oil Pan Bolts Oil Passage Plugs Oil Pressure Relief Valve Oil Pressure Switch Oil Pressure Switch Terminal Bolt Oil Pump Cover Bolts Oil Pump Gear Bolts Engine Removal/Installation Adjusting Collar Locknut Left Engine Bracket Bolts (M10, L = 30 mm) Left Front Engine Mounting Bolt (M10, L = 42 mm) Lower Engine Mounting Bolt Lower Engine Mounting Nut Middle Engine Mounting Bolt Middle Engine Mounting Nut Right Engine Bracket Bolt (M10, L = 35 mm) Right Engine Bracket Bolts (M10, L = 30 mm) Right Engine Bracket Bolts (Cylinder Head Side) Right Front Engine Mounting Bolt (M10, L = 67 mm) Crankshaft/Transmission Bearing Position Plate Screws Breather Plate Bolts Connecting Rod Bid End Bolts Coolant Drain Plug (Cylinder) Crankcase Bolts (M9) Crankcase Bolts (M8) Crankcase Bolts (M7, L = 85 mm) Crankcase Bolts (M7, L = 50 mm) Crankcase Bolts (M7, L = 32 mm) Crankcase Bolts (M6, L = 45 mm) N·m 10 130 7.8 9.8 ­ 25 20 20 31 20 35 10 20 15 15 1.5 10 10 49 44 44 9.8 44 9.8 44 44 44 10 44 5.0 10 see Text 10 39 27 20 20 20 12 Torque kgf·m 1.0 13.3 0.80 1.0 ­ 2.5 2.0 2.0 3.2 2.0 3.6 1.0 2.0 1.5 1.5 0.15 1.0 1.0 5.0 4.5 4.5 1.0 4.5 1.0 4.5 4.5 4.5 1.0 4.5 0.51 1.0 1.0 4.0 2.8 2.0 2.0 2.0 1.2 ft·lb Remarks 89 in·lb S 96 R 69 in·lb S 87 in·lb ­ Hand-tighten 18 L 15 15 23 15 26 89 in·lb 15 11 11 13 in·lb 89 in·lb 89 in·lb 36 32 32 87 in·lb 32 87 in·lb 32 32 32 89 in·lb 32 44 in·lb 89 in·lb 89 in·lb 29 20 15 15 15 106 in·lb L EO, R L L L L SS G L S S S S S S S S S L S L L MO MO, S S S S S S PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Fastener Crankcase Bolts (M6, L = 40 mm) Drive Shaft Cover Bolts Gear Position Lever Bolt Oil Passage Plugs Piston Oil Jet Plate Screw Plug Shift Drum Bearing Holder Screws Shift Drum Cam Holder Bolt Shift Fork Hold Bolt Shift Lever Bolt Shift Pedal Mounting Bolt Shift Shaft Return Spring Pin Tie-Rod Locknuts Wheels/Tires Front Axle Clamp Bolts Front Axle Nut Rear Axle Nut Final Drive Engine Sprocket Cover Bolts Engine Sprocket Nut Rear Axle Nut Rear Sprocket Nuts Brakes Brake Hose Banjo Bolts Brake Lever Pivot Bolt Brake Lever Pivot Bolt Nut Brake Pedal Bolt Bleed Valves Front Brake Disc Mounting Bolts Front Brake Light Switch Screw Front Brake Master Cylinder Bleed Valve Front Brake Pad Pins Front Brake Reservoir Cap Stopper Screw Front Caliper Assembly Bolts Front Caliper Mounting Bolts Front Master Cylinder Clamp Bolts Rear Brake Disc Mounting Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut Suspension Front Axle Clamp Bolts N·m 12 25 12 20 3.0 5.0 20 5.0 12 12 7.0 25 29 7.0 20 127 108 10 125 108 59 25 1.0 5.9 8.8 7.8 27 1.2 5.4 15 1.2 22 34 8.8 27 25 25 17 20 Torque kgf·m 1.2 2.5 1.2 2.0 0.31 0.51 2.0 0.51 1.2 1.2 0.71 2.5 3.0 0.71 2.0 13.0 11.0 1.0 12.7 11.0 6.0 2.5 0.10 0.60 0.90 0.80 2.8 0.12 0.55 1.5 0.12 2.2 3.5 0.90 2.8 2.5 2.5 1.7 2.0 ft·lb 106 in·lb 18 106 in·lb 15 27 in·lb 44 15 44 in·lb 106 in·lb 106 in·lb 62 in·lb 18 21 62 in·lb 15 94 80 89 in·lb 92 80 44 18 9 in·lb 52 in·lb 78 in·lb 69 in·lb 20 11 in·lb 48 in·lb 11 11 in·lb 16 25 78 in·lb 20 18 18 13 15 Remarks S L L L L L L AL MO Si L S L AL 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Front Fork Bottom Allen Bolts Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Front Fork Top Plugs Piston Rod Nuts Rear Shock Absorber Bracket Nut Rear Shock Absorber Nut (Lower) Rear Shock Absorber Nut (Upper) Swingarm Pivot Adjusting Shaft Swingarm Pivot Shaft Nut Swingarm Pivot Adjusting Collar Locknut Tie-Rod Nuts Uni-Trak Rocker Arm Nut Steering Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Handlebar Bolts Handlebar Position Bolts Steering Stem Nut Steering Stem Head Nut Steering Stem Locknut Switch Housing Screws Frame Front Fender Mounting Bolts Front Footpeg Bracket Bolts Rear Master Cylinder Mounting Bolts Rear Frame Bolts Sidestand Bolt Sidestand Bracket Bolts Sidestand Switch Bolt Rear Footpeg Bracket Bolts Windshield Mounting Bolts Electrical System Alternator Cover Bolts Alternator Lead Holding Plate Bolt Alternator Rotor Bolt Battery Cable Mounting Bolt Camshaft Position Sensor Bolt Crankshaft Sensor Bolts Frame Earth Mounting Bolt Front Turn Signal Light Mounting Screws Front Brake Light Switch Screw Fuel Pump Bolts N·m 23 30 20 23 15 59 34 34 20 108 98 59 34 30 20 25 9.8 20 78 ­ 3.5 3.9 25 25 44 44 49 8.8 25 0.4 10 10 155 4.0 10 6.0 10 1.2 1.2 10 Torque kgf·m 2.3 3.1 2.0 2.3 1.5 6.0 3.5 3.5 2.0 11.0 10.0 6.0 3.5 3.1 2.0 2.5 1.0 2.0 8.0 ­ 0.36 0.40 2.5 2.5 4.5 4.5 5.0 0.90 2.5 0.04 1.0 1.0 15.8 0.41 1.0 0.61 1.0 0.12 0.12 1.0 ft·lb 17 22 15 17 11 44 25 25 15 80 72 44 25 Remarks L AL 22 AL 15 18 87 in·lb L 15 58 ­ Hand-tighten 31 in·lb 35 in·lb 18 18 32 32 36 78 in·lb 18 4 in·lb 89 in·lb 89 in·lb 114 35 in·lb 89 in·lb 53 in·lb 89 in·lb 10 in·lb 10 in·lb 89 in·lb G L L L L L, S PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Fastener Gear Position Switch Screws Headlight Mounting Screws Idle Gear Cover Bolts Left Handlebar Switch Housing Screws (M5, L = 25) License Plate Light Cover Screws License Plate Light Mounting Screws Meter Unit Mounting Screws Oil Pressure Switch Oil Pressure Switch Terminal Bolt Oxygen Sensors (Europe Models) Rear Turn Signal Light Lens Screws Rear Turn Signal Light Mounting Screws Regulator/Rectifier Bolts Right Handlebar Switch Housing Screws (M5, L = 45) Sidestand Switch Bolts Spark Plugs Speed Sensor Bolt Starter Clutch Bolt Starter Clutch Bolt Cap Starter Clutch Cover Bolts (M6, L = 30) Starter Clutch Cover Bolts (M6, L = 20) Starter Motor Cable Mounting Bolt Starter Motor Cable Terminal Nut Starter Motor Mounting Bolts Starter Motor Terminal Locknut Starter Motor Through Bolts Stator Coil Bolts Vehicle-down Sensor Bolts Water Temperature Sensor N·m 3.0 1.2 10 3.5 1.2 1.2 1.2 15 1.5 25 1.2 1.2 10 3.5 8.8 13 10 49 ­ 10 10 4.0 6.0 10 6.9 3.4 12 6.0 25 Torque kgf·m 0.31 0.12 1.0 0.36 0.12 0.12 0.12 1.5 0.15 2.5 0.12 0.12 1.0 0.36 0.90 1.3 1.0 5.0 ­ 1.0 1.0 0.41 0.61 1.0 0.70 0.35 1.2 0.61 2.5 Remarks ft·lb 27 in·lb L 11 in·lb 89 in·lb 31 in·lb 11 in·lb 11 in·lb 11 in·lb 11 SS 13 in·lb G 18 11 in·lb 11 in·lb 89 in·lb 31 in·lb 78 in·lb L 115 in·lb 89 in·lb 36 ­ Hand-tighten 89 in·lb 89 in·lb 35 in·lb 53 in·lb 89 in·lb 61 in·lb 30 in·lb 106 in·lb 53 in·lb 18 SS 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 (mm) 5 6 8 10 12 14 16 18 20 N·m 3.4 4.9 5.9 7.8 14 19 25 34 44 61 73 98 115 155 165 225 225 325 Torque kgf·m 0.35 0.50 0.60 0.80 1.4 1.9 2.6 3.5 4.5 6.2 7.4 10.0 11.5 16.0 17.0 23.0 23.0 33.0 ft·lb 30 43 in·lb 52 69 in·lb 10 13.5 19 25 33 45 54 72 83 115 125 165 165 240 PERIODIC MAINTENANCE 2-13 Specifications Item Fuel System (DFI) Throttle Grip Free Play Idle Speed Throttle Body Vacuum Air Cleaner Element Cooling System Coolant: Type (Recommended) Color Mixed Ratio Freezing Point Total Amount Engine Top End Valve Clearance: Exhaust Inlet Clutch Clutch Lever Free Play Engine Lubrication System Engine Oil: Type Viscosity Capacity Standard 2 3 mm (0.08 0.12 in.) 1 100 ±50 r/min (rpm) 31.5 ±1.3 kPa (236 ±10 mmHg) at idle speed Viscous paper element Service Limit ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ Permanent type antifreeze Green Soft water 50%, coolant 50% ­35°C (­31°F) 2.9 L (3.1 US qt) ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ 0.17 0.22 mm (0.0067 0.0087 in.) 0.15 0.24 mm (0.0059 0.0094 in.) 2 3 mm (0.08 0.12 in.) ­­­ ­­­ ­­­ Level Wheels/Tires Tread Depth: Front API SE, SF or SG API SH, SJ or SL with JASO MA SAE 10W-40 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) Between upper and lower level lines (Wait 2 3 minutes after idling or running) ­­­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ 6.0 mm (0.24 in.) Rear 6.5 mm (0.26 in.) 1 mm (0.04 in.), (AT, CH, DE) 1.6 mm (0.06 in.) Up to 130 km/h (80 mph): 2 mm (0.08 in.), Over 130 km/h (80 mph): 3 mm (0.12 in.) ­­­ ­­­ Air Pressure (when Cold): Front Rear Up to 180 kg (397 lb) load: 250 kPa (2.50 kgf/cm², 36 psi) Up to 180 kg (397 lb) load: 290 kPa (2.90 kgf/cm², 42 psi) 2-14 PERIODIC MAINTENANCE Specifications Item Final Drive Drive Chain Slack Drive Chain Wear (20-link Length) Standard Chain: Make Type Link Brakes Brake Fluid: Grade Brake Pad Lining Thickness: Front Rear Brake Light Timing: Front Rear Electrical System Spark Plug Type Standard 30 35 mm (1.2 1.4 in.) 317.5 318.2 mm (12.50 12.53 in.) Service Limit ­­­ 323 mm (12.7 in.) RK EXCEL RK 525MFO, Endless 108 links ­­­ ­­­ ­­­ DOT4 ­­­ 4.0 mm (0.16 in.) 5.0 mm (0.20 in.) Pulled ON On after about 10 mm (0.39 in.) of pedal travel 1 mm (0.04 in.) 1 mm (0.04 in.) ­­­ ­­­ NGK CR9EIA-9 ­­­ PERIODIC MAINTENANCE 2-15 Special Tools Inside Circlip Pliers: 57001-143 Vacuum Gauge: 57001-1369 Steering Stem Nut Wrench: 57001-1100 Extension Tube: 57001-1578 Jack: 57001-1238 Pilot Screw Adjuster, D: 57001-1588 Oil Filter Wrench: 57001-1249 Jack Attachment: 57001-1608 2-16 PERIODIC MAINTENANCE Maintenance Procedure Fuel System (DFI) Throttle Control System Inspection the throttle grip free play [A]. · Checkfree play is incorrect, adjust the throttle cables. If the Throttle Grip Free Play Standard: 2 3 mm (0.08 0.12 in.) throttle from full · Checktothat the and thegrip [B] moves smoothlyand comopen close, throttle closes quickly 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 3 mm (0.08 0.12 in.) of throttle grip play is obtained. Tighten the locknut [A]. Turn the accelerator cable adjuster [D] until 2 3 mm (0.08 0.12 in.) of throttle grip play is obtained. Tighten the locknut [B]. If the free play cannot be adjusted with the adjusters, replace the cable. · · · · · · · Engine Vacuum Synchronization Inspection These procedures are explained on the assumption that NOTE the inlet and exhaust systems of the engine are in good condition. is vertical. · Situate the motorcycle so that it(see Air Cleaner Housing Remove the air cleaner housing · Removal in the Fuel System (DFI) chapter). · Pull off the rubber caps [A] from the fittings of each throttle body. · For the California Model, pull off the vacuum hoses [B]. · Plug the engine breather hose end [A]. PERIODIC MAINTENANCE 2-17 Maintenance Procedure gauge (special · Connect a vacuumthrottle body. tool) and hoses [A] to the fittings on the · Connect a highly accurate tachometer to one of the stick coil primary leads. Special Tool - Vacuum Gauge: 57001-1369 · Connect: Lead Connector Fuel Pump Extension Tube [A] · Start the engine and warm itaup thoroughly. tachometer · Check the idle speed, using highly accurate [B]. If the idle speed is out of the specified range, adjust it with the adjust screw. Special Tool - Extension Tube: 57001-1578 CAUTION Do not measure the idle speed by the tachometer of the meter unit. idling the engine, inspect · While the vacuum gauge [C]. the throttle body vacuum, using Throttle Body Vacuum Standard: 31.5 ±1.3 kPa (236 ±10 mmHg) at Idle Speed 1 100 ±50 r/min (rpm) 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: 210 mmHg #2: 240 mmHg #3: 200 mmHg #4: 220 mmHg With the engine at the correct idle speed, equalize higher vacuum of #1 or #2 (for example 240 mmHg) to higher vacuum of #3 or #4 (for example 220 mmHg) by turning the center adjusting screw [A]. · After adjustment, NOTE the final vacuum measurement between the highest throttle valves may not be 240 mmHg (for example). The goal is to have the highest two vacuums between the left (#1 and #2) and right (#3 and #4) banks be the same and be within the service limits. · Open and close the throttle after each measurement, and adjust the idle speed as necessary. valves have been synchronized, · Once the throttle the main throttle sensor to ensureinspect output voltage of proper operation (procedure is explained at the end of this section). 2-18 PERIODIC MAINTENANCE Maintenance Procedure If a value of measured vacuum pressure is out of the specified range after synchronization, adjust the bypass screws [A]. · Adjust lower vacuum between #1 and #2 to higher vacuum of #1 and #2. lower · Adjust the #3 andvacuum between #3 and #4 to higher vacuum of #4. Open and close the throttle valves after each measure· ment, and adjust the idle speed as necessary. · Check the vacuums as before. If all vacuums are within the specification range, finish the engine vacuum synchronization. If any vacuum cannot be adjusted within the specification, remove the bypass screws #1 #4 and clean them. screw number of · Turn in theitbypassfully but[A] with counting thethe number turns until seals not tightly. Record of turns. Torque - Bypass Screw: 0.2 N·m (0.02 kgf·m, 1.7 in·lb) Special Tool - Pilot Screw Adjuster, D: 57001-1588 CAUTION Do not over tighten them. They could be damaged, requiring replacement. · Remove: Screw Bypass · · · · Spring [B] Washer [C] O-ring [D] Check the bypass screw and its hole for carbon deposits. If any carbons accumulate, wipe the carbons off from the bypass screw and the hole, using a cotton pad penetrated with a high-flash point solvent. Replace the O-ring with a new one. Check the tapered portion [E] of the bypass screw for wear or damage. If the bypass screw is worn or damaged, replace it. Turn in the bypass screw until it seats fully but not tightly. Torque - Bypass Screw: 0.2 N·m (0.02 kgf·m, 1.7 in·lb) PERIODIC MAINTENANCE 2-19 Maintenance Procedure number of turns counted · Back out the same set the screw to its originalwhen first turned in. This is to position. A throttle body has different "turns out" of the bypass NOTE screw for each individual unit. On setting the bypass screw, use the "turns out" determined during disassembly. · Repeat the same procedure for other bypass screws. · Repeat the synchronization. check the output voltage of If the vacuums are correct, the main throttle sensor (see Output Voltage Inspection of Main Throttle Sensor in the Fuel System (DFI) chapter). Main Throttle Sensor Output Voltage Connections to ECU Meter (+) Y/W lead (terminal 26) Meter (­) BR/BK lead (terminal 34) Standard: DC 0.65 0.67 V (at idle throttle opening) If the output voltage is out of the range, check the input voltage of the main throttle sensor (see Input Voltage Inspection in the Main Throttle Sensor section in the Fuel System (DFI) chapter). the vacuum gauge · Remove the original position.hoses and install the rubber caps on California · For thethe vacuumModel, install the vacuum hoses. and hoses according to Cable, Wire, Route Hose Routing section in the Appendix chapter. Idle Speed Inspection the up · Start the engine and warm itthe thoroughly.to both sides With engine idling, turn handlebar · [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. the idle · Checkidle speedspeed. of specified range, adjust it. If the is out Idle Speed Standard: 1 100 ±50 r/min (rpm) 2-20 PERIODIC MAINTENANCE Maintenance Procedure Idle Speed Adjustment the engine and warm up · Start the adjusting screw [A]ituntil thoroughly. is correct. Turn speed · Open and close the throttle a fewthe idleto make sure that times 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 Removal in the Fuel System (DFI) chapter) and check the fuel hose. Replace the fuel hose if any fraying, cracks [B] or bulges [C] are noticed. the hoses are routed · Check thatRouting section in theaccording to Cable, Wire, and Hose Appendix chapter. Replace the hose if it has been sharply bent or kinked. Hose Joints [A] Fuel Hose [B] that the hose · Checkand pull [A] thejoints are securely connected. more hose joint [B] back and forth Push than two times, and make sure it is locked. If it does not locked, reinstall the hose joint. WARNING Make sure the hose joint is installed correctly on the delivery pipe by sliding the joint, or the fuel could leak. PERIODIC MAINTENANCE 2-21 Maintenance Procedure Evaporative Emission Control System (California Model) Evaporative Emission Control System Inspection as follows. · Inspect the canisterupper inner fairing (see Upper Inner Remove the right 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. The canister is designed to work well through the motoras · Check the liquid/vapor separator(seefollows. Fairing ReRemove the right middle fairing Middle NOTE cycle's life without any maintenance if it is used under normal conditions. Disconnect the hoses from the separator, and remove the moval in the Frame chapter). separator [A] from the motorcycle right side. Visually inspect the separator for cracks and other damage. 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. · 2-22 PERIODIC MAINTENANCE Maintenance Procedure Cooling System Coolant Level Inspection Check the level when the engine is cold (room or ambient temperature). reserve tank · Check the coolant level in the(Do not use the[A] with the motorcycle held perpendicular sidestand). If the coolant level is lower than the "L" level line [B], unscrew the reserve tank cap and add coolant to the "F" level line [C]. "L": low "F": full NOTE 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 engine 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 Hose Clamp Screws: 2.0 N·m (0.20 kgf·m, 18 in·lb) Engine Top End Valve Clearance Inspection Valve clearance must be checked and adjusted when the engine is cold (at room temperature). NOTE PERIODIC MAINTENANCE 2-23 Maintenance Procedure head (see Cylinder · Remove the cylinder EnginecoverEnd chapter). Head Cover Removal in the Top Remove the timing inspection cap [A] and starter clutch · bolt cap [B] on the starter clutch cover [C]. [A], the · Using a wrench on the starter clutch bolt mark turn#1,4 crankshaft clockwise until the line [B] (TDC for pistons) on the starter clutch is aligned with the notch [C] in the edge of the timing inspection hole [D] in the crankshaft sensor cover. · Using a thickness gauge [A], measure the valve clearance between the cam and the valve lifter. Valve Clearance Standard: Exhaust 0.17 0.22 mm (0.0067 0.0087 in.) Inlet 0.15 0.24 mm (0.0059 0.0094 in.) 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] NOTE 2-24 PERIODIC MAINTENANCE 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 camshaft chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness. Mark and record the locations of the valve lifters and NOTE shims so that they can be reinstalled in their original positions. shim to remove any dust or · Clean thethe thickness of the removedoil. [A]. Measure · Select a new shim thickness calculationshimfollows. as · a+b­c=d [a] Present Shim Thickness [b] Measured Valve Clearance [c] Specified Valve Clearance (Mean Value = 0.195) [d] Replace Shim Thickness Example: 1.600 + 0.31 ­ 0.195 = 1.715 mm Exchange the shim for the 1.725 size shim. CAUTION Don't use the shims for another models. This could cause wear of the valve stem end, and valve stem damage. PERIODIC MAINTENANCE 2-25 Maintenance Procedure Adjustment Shims Thickness 1.300 1.325 1.350 1.375 1.400 1.425 1.450 1.475 1.500 1.525 1.550 1.575 1.600 1.625 1.650 1.675 1.700 1.725 1.750 1.775 1.800 1.825 1.850 1.875 1.900 1.925 1.950 1.975 2.000 2.025 2.050 2.075 2.100 2.125 2.150 2.175 2.200 2.225 2.250 2.275 2.300 Part Number 92180-0108 92180-0109 92180-0110 92180-0111 92180-0112 92180-0113 92180-0114 92180-0115 92180-0116 92180-0117 92180-0118 92180-0119 92180-0120 92180-0121 92180-0122 92180-0123 92180-0124 92180-0125 92180-0126 92180-0127 92180-0128 92180-0129 92180-0130 92180-0131 92180-0132 92180-0133 92180-0134 92180-0135 92180-0136 92180-0137 92180-0138 92180-0139 92180-0140 92180-0141 92180-0142 92180-0143 92180-0144 92180-0145 92180-0146 92180-0147 92180-0148 Mark 130 132 135 138 140 142 145 148 150 152 155 158 160 162 165 168 170 172 175 178 180 182 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 2-26 PERIODIC MAINTENANCE Maintenance Procedure CAUTION Be sure to remeasure the clearance after selecting a shim. The clearance can be out of the specified range because of the shim tolerance. If there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance. installing the toward · When lifter. At this shim, face the marked sidethe shimthe valve time, apply engine oil to or the valve lifter to keep the shim in place during camshaft installation. CAUTION Do not put shim stock under the shim. This may cause the shim to pop out at high rpm, causing extensive engine damage. Do not grind the shim. This may cause it to fracture, causing extensive engine damage. · Apply engine oil to the valve lifter surface and install the lifter. camshafts (see · Install theEnd chapter). Camshaft Installation in the Engine Top if necessary. · Recheck the valve clearance and readjust chapters). Install the removed parts (see appropriate · Air Suction System Air Suction System Damage Inspection · Remove: (see Fuel Tank Removal in the Fuel System Fuel Tank · (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Pull the air switching valve hose [A] out of the air cleaner housing holder. following parts temporary. · Connect the Lead Connector [A] Fuel Pump Extension Tube [B] Special Tool - Extension Tube: 57001-1578 PERIODIC MAINTENANCE 2-27 Maintenance Procedure the engine and run at idle speed. · Start [A] the air switchingit valve hose [B] end with your · Plug and feel vacuum pulsing in the hose. finger 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 in the Electrical System chapter) or air suction valve (see Air Suction Valve Inspection in the Engine Top End chapter). Apply a soap and water solution or rubber lubricant to the end of the air switching hose and install the hose on the fitting. · Clutch Clutch Operation Inspection · Pull the clutch lever just enough to take up the free play [A]. gap between the lever and holder. · Measure thetoo wide, the clutch may notthe lever fully. If If the gap is release 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.) WARNING To avoid a serious burn, never touch the engine or exhaust pipe during clutch adjustment. Turn the adjuster [A] · of threads is visible. so that 4 6 mm (0.16 0.24 in.) [B] right middle fairing · Remove thethe Frame chapter). [A] (see Middle Fairing Removal in · Slide the dust cover [B] at the clutch cable lower end out of place. adjusting nuts [C] at the clutch cover as far · Loosen bothgo. as they will the tight · Pullnutsclutch outer cable [D][E]. and tighten the adjusting against the bracket onto place. · Slip the rubber dust cover backlever until the free play is · Turn the adjuster at the clutch correct. 2-28 PERIODIC MAINTENANCE Maintenance Procedure the [A] · Push untilrelease leverhardtoward the front of the motorcycle it becomes to turn. At 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. WARNING Be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever, 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. Wheels/Tires Air Pressure Inspection · Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle · has not been ridden more than a mile during the past 3 hours). Install the air valve cap. Adjust the tire air pressure according to the specifications if necessary. Air Pressure (when Cold) Front: Up to 180 kg (397 lb) 250 kPa (2.50 kgf/cm², 36 psi) Rear: Up to 180 kg (397 lb) 290 kPa (2.90 kgf/cm², 42 psi) Wheel/Tire Damage Inspection any imbedded · Removefrom tread. stones [A] or other foreign particles [B] · Visuallyifinspect the tire for cracks and cuts, and replace the tire necessary. Swelling or high spots indicate inter- · nal damage, requiring tire replacement. Visually inspect the wheel for cracks, cuts and dents damage. If any damage is found, replace the wheel if necessary. Tire Tread Wear Inspection As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn). So it is false economy and unsafe to use the tires until they are bald. Measure the tread depth at the center of the tread with a depth gauge [A]. Since the tire may wear unevenly, take measurement at several places. If any measurement is less than the service limit, replace the tire (see Tire Removal/Installation in the Wheels/Tires chapter). · PERIODIC MAINTENANCE 2-29 Maintenance Procedure Tread Depth Standard: Front Rear Service Limit: Front Rear 1 mm (0.04 in.) (AT, CH, DE) 1.6 mm (0.06 in.) 2 mm (0.08 in.) (Up to 130 km/h) 3 mm (0.12 in.) (Over 130 km/h) 6.0 mm (0.24 in.) 6.5 mm (0.26 in.) WARNING To ensure safe handling and stability, use only the recommended standard tires for replacement, inflated to the standard pressure. Most countries may have their own regulations a mini- NOTE 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 jack wheel off the · Using a (see and attachment, raise the front Wheels/Tires ground Front Wheel Removal in the · · · chapter). Turn the handlebar all the way to the right or left. Inspect the roughness of the front wheel bearing by pushing and pulling [A] the wheel. Spin [B] the front wheel lightly, and check for smoothly turn, roughness, binding or noise. If roughness, binding or noise is found, remove the front wheel and inspect the wheel bearing (see Front Wheel Removal, Hub Bearing Inspection in the Wheels/Tires chapter). a stand, raise rear wheel off the ground · UsingWheel Removalthethe Wheels/Tires chapter). (see Rear in · Inspect the roughness of the rear wheel bearing by pushing and pulling [A] the wheel. [B] the rear wheel · Spin roughness, binding lightly, and check for smoothly turn, or noise. If roughness, binding or noise is found, remove the rear wheel and inspect the wheel bearing (see Rear Wheel Removal, Hub Bearing Inspection in the Wheels/Tires chapter) and coupling (see Coupling Bearing Inspection in the Final Drive chapter).