User manual KAWASAKI Z750 ABS

Z750 Z750 ABS 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 Appendix 17 j Z750 Z750 ABS Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2007 Kawasaki Heavy Industries, Ltd. First Edition (1) : Feb. 28, 2007 (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 CH DE Austria Australia Switzerland Germany GB MY WVTA United Kingdom Malaysia Whole Vehicle Type Approval 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. · · · This note symbol indicates points of par- NOTE 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 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 ZR750L7F (Europe) Left Side View ZR750L7F (Europe) Right Side View 1-8 GENERAL INFORMATION Model Identification ZR750M7F Left Side View ZR750M7F 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: ZR750L7F ZR750M7F Curb Mass: Front: ZR750L7F ZR750M7F Rear: ZR750L7F ZR750M7F Fuel Tank Capacity Performance Minimum Turning Radius Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Cylinder Numbering Method Firing Order Valve Timing: Inlet: Open Close Duration ZR750L7F, ZR750M7F 2 085 mm (82.09 in.) 805 mm (31.69 in.) 1 100 mm (43.31 in.) 1 440 mm (56.69 in.) 155 mm (6.10 in.) 815 mm (32.09 in.) 203 kg (447.6 lb) 207 kg (456.4 lb) 113 kg (249.2 lb) 115 kg (253.6 lb) 113 kg (249.2 lb) 115 kg (253.6 lb) 18.5 L (4.9 US gal.) 3.0 m (9.8 ft) 4-stroke, DOHC, 4-cylinder Liquid-cooled 68.4 × 50.9 mm (2.69 × 2.00 in.) 748 cm³ (45.64 cu in.) 11.3 : 1 77.7 kW (106 PS) @10 500 r/min (rpm) (MY) 73.2 kW (100 PS) @9 000 r/min (rpm) 78.0 N·m (8.0 kgf·m, 57.5 ft·lb) @8 300 r/min (rpm) FI (Fuel Injection) KEIHIN TTK32 × 4 Electric starter Battery and coil (transistorized) Electronically advanced (digital igniter) From 10° BTDC @1 100 r/min (rpm) to 37.0° BTDC @5 000 r/min (rpm) NGK CR9EK Left to right, 1-2-3-4 1-2-4-3 38° BTDC 66° ABDC 284° 1-10 GENERAL INFORMATION General Specifications Items Exhaust: Open Close Duration Lubrication System Engine Oil: Type Viscosity Capacity Drive Train Primary Reduction System: Type Reduction Ratio Clutch Type Transmission: Type Gear Ratios: 1st 2nd 3rd 4th 5th 6th Final Drive System: Type Reduction Ratio Overall Drive Ratio Frame Type Caster (Rake Angle) Trail Front Tire: Type Size Rim Size Rear Tire: Type Size Rim Size Front Suspension: Type Wheel Travel ZR750L7F, ZR750M7F 51° BBDC 25° ATDC 256° Forced lubrication (wet sump) API SE, SF or SG API SH, SJ or SL with JASO MA SAE 10W-40 3.8 L (4.0 US qt) Gear 1.714 (84/49) Wet multi disc 6-speed, constant mesh, return shift 2.571 1.941 1.556 1.333 1.200 1.095 (36/14) (33/17) (28/18) (28/21) (24/20) (23/21) Chain drive 2.867 (43/15) 5.382 @Top gear Tubular, diamond 24.5° 103 mm (4.06 in.) Tubeless 120/70 ZR17 M/C (58W) 17 × 3.50 Tubeless 180/55 ZR17 M/C (73W) 17 × 5.50 Telescopic fork 120 mm (4.72 in.) GENERAL INFORMATION 1-11 General Specifications Items Rear Suspension: Type Wheel Travel Brake Type: Front Rear Electrical Equipment Battery Headlight: Type Bulb Tail/Brake Light Alternator: Type Rated Output ZR750L7F, ZR750M7F Swingarm (uni-trak) 125 mm (4.92 in.) Dual discs Single disc 12 V 8 Ah Semi-sealed beam 12 V 55 W × 2/55 W (Hi/Lo) 12 V 0.5/4.1 W (LED) Three-phase AC 24 A/14 V @5 000 r/min (rpm) Specifications are subject to change without notice, and may not apply to every country. 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 .......................................................................................................................... Periodic Maintenance Procedures.......................................................................................... Fuel System (DFI)................................................................................................................ Air Cleaner Element Cleaning........................................................................................... Throttle Control System Inspection................................................................................... Engine Vacuum Synchronization Inspection..................................................................... Idle Speed Inspection ....................................................................................................... Idle Speed Adjustment...................................................................................................... Fuel Hose Inspection (fuel leak, damage, installation condition) ...................................... Cooling System.................................................................................................................... Coolant Level Inspection................................................................................................... Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition) .......... Engine Top End ................................................................................................................... Valve Clearance Inspection .............................................................................................. Valve Clearance Adjustment............................................................................................. Exhaust Butterfly Valve Cable Inspection ......................................................................... Exhaust Butterfly Valve Cable Adjustment........................................................................ Air Suction System .............................................................................................................. 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 and Pipe 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 .................................................................................................................. 2-3 2-6 2-12 2-14 2-15 2-15 2-15 2-15 2-16 2-19 2-20 2-20 2-22 2-22 2-22 2-23 2-23 2-24 2-27 2-28 2-31 2-31 2-31 2-31 2-32 2-32 2-33 2-33 2-34 2-34 2-34 2-35 2-35 2-36 2-37 2-37 2-38 2-38 2-39 2-39 2-39 2-40 2-41 2-41 2-41 2-42 2-42 2-42 2-42 2-43 2 2-2 PERIODIC MAINTENANCE Steering Play Inspection ................................................................................................... Steering Play Adjustment.................................................................................................. Steering Stem Bearing Lubrication ................................................................................... Electrical System ................................................................................................................. Spark Plug Condition Inspection....................................................................................... Lights and Switches Operation Inspection........................................................................ Headlight Aiming Inspection ............................................................................................. Sidestand Switch Operation Inspection ............................................................................ Engine Stop Switch Operation Inspection......................................................................... Others .................................................................................................................................. Chassis Parts Lubrication ................................................................................................. Bolts, Nuts and Fasteners Tightness Inspection............................................................... Replacement Parts .............................................................................................................. Air Cleaner Element Replacement.................................................................................... Fuel Hose Replacement ................................................................................................... Coolant Change ................................................................................................................ Radiator Hose and O-ring Replacement........................................................................... Engine Oil Change............................................................................................................ Oil Filter Replacement ...................................................................................................... Brake Hose and Pipe Replacement.................................................................................. Brake Fluid Change .......................................................................................................... Master Cylinder Rubber Parts Replacement .................................................................... Caliper Rubber Parts Replacement .................................................................................. Spark Plug Replacement .................................................................................................. 2-43 2-43 2-44 2-45 2-45 2-46 2-48 2-49 2-50 2-50 2-50 2-52 2-53 2-53 2-54 2-56 2-58 2-58 2-59 2-60 2-62 2-63 2-64 2-67 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 1 INSPECTION Fuel System Air cleaner element - clean 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 Cooling System Coolant level - inspect Coolant leak (radiator hose and pipe) inspect Radiator hose damage - inspect Radiator hose installation condition - inspect Engine Top End AU Model Valve clearance - inspect Other than AU Model Exhaust butterfly valve cable - 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 year Every 6 * ODOMETER READING × 1 000 km (× 1 000 mile) 12 18 24 30 36 See Page (0.6) (4) (7.5) (12) (15) (20) (24) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-15 2-15 2-16 2-19 2-20 2-20 2-20 2-22 2-22 2-22 2-22 2-23 2-23 2-27 2-31 Every 42 000 km (26 000 mile) ······· · · · · · · · · · · · · · · · · · · · · · · · · · 2-31 2-32 2-33 2-33 2-34 2-34 2-35 2-37 2-37 Every 600 km (400 mile) Every 1 000 km (600 mile) 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever comes first 1 INSPECTION Brake System Brake fluid leak (brake hose and pipe) inspect Brake hose and pipe damage - inspect Brake hose and pipe installation condition inspect Brake operation (effectiveness, play, no drag) - inspect Brake fluid level - inspect Brake pad wear - 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 Electrical System Spark plug condition - inspect 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 Every year year year year 6 months 6 * ODOMETER READING × 1 000 km (× 1 000 mile) 12 18 24 30 36 See Page (0.6) (4) (7.5) (12) (15) (20) (24) · · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-38 2-39 2-39 2-39 2-39 2-40 2-41 2-41 2-42 2-42 2-42 2-43 2-44 2-45 2-46 2-48 2-49 2-50 2-50 2-52 year · · · · · · · #: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping. *: For higher odometer readings, repeat at the frequency interval established here. · · · PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever comes first 1 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 4 years 3 years 3 years year year 4 years 2 years 4 years Every * ODOMETER READING × 1 000 km (× 1 000 mile) 12 24 36 (24) 48 (30) 2-53 (0.6) (7.5) (15) See Page · · · · · · · · · · · · · · · · · · · · · · 2-54 2-56 2-58 2-58 2-59 2-60 2-62 2-63, 2-64 2-67 #: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping. *: For higher odometer readings, repeat at the frequency interval established here. 2-6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the "Remarks" column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. EO: Apply engine oil. G: Apply grease. HG: Apply high-temperature grease. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide grease 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. Torque kgf·m 0.39 1.0 0.12 0.20 0.02 1.2 0.60 0.35 0.70 0.70 0.51 1.0 0.35 4.50 1.2 1.3 0.20 0.60 0.20 0.61 2.5 1.0 1.1 0.70 0.70 0.70 0.31 1.0 Fastener Fuel System (DFI) Air Cleaner Duct Screws Air Cleaner Housing Mounting Bolts Air Cleaner Housing Tapping Screws Air Duct Clamp Bolts Bypass Screws Camshaft Position Sensor Bolt Crankshaft Sensor Bolts Delivery Pipe Assy Mounting Screws Exhaust Butterfly Valve Actuator Bracket Bolt Exhaust Butterfly Valve Actuator Mounting Bolts Exhaust Butterfly Valve Actuator Pulley Bolt Fuel Pump Bolts Idle Adjusting Cable Clamp Screw Oxygen Sensor (Equipped Models) Speed Sensor Bolt Throttle Body Assy Holder Bolts Throttle Body Assy Holder Clamp Bolts Throttle Cable Plate Bolt Throttle Link Holder Screws Vehicle-down Sensor Bolts Water Temperature Sensor Cooling System Coolant Drain Bolt (Cylinder) Coolant Drain Bolt (Water Pump) Radiator Bracket Mounting Bolt Radiator Lower Bolt Radiator Upper Bolts Radiator (Water) Hose Clamp Screws Reserve Tank Bolts N·m 3.8 9.8 1.2 2.0 0.2 12 5.9 3.4 6.9 6.9 5.0 9.8 3.4 44.1 12 13 2.0 5.9 2.0 6.0 25 9.8 11 6.9 6.9 6.9 3.0 9.8 ft·lb 34 in·lb 87 in·lb 11 in·lb 18 in·lb 1.8 in·lb 106 in·lb 52 in·lb 30 in·lb 61 in·lb 61 in·lb 44 in·lb 87 in·lb 30 in·lb 32.5 106 in·lb 115 in·lb 18 in·lb 52 in·lb 18 in·lb 53 in·lb 18 87 97 61 61 61 27 87 in·lb in·lb in·lb in·lb in·lb in·lb in·lb Remarks L, S PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Fastener Thermostat Bracket Bolt Thermostat Housing Ground Bolt Thermostat Housing Screws Water Pipe Bolts Water Pump Cover Bolts Water Pump Impeller Bolt Water Temperature Sensor Engine Top End Air Suction Valve Cover Bolts Camshaft Cap Bolts (L = 45 mm) Camshaft Cap Bolts (L = 40 mm) Camshaft Chain Tensioner Cap Bolt Camshaft Chain Tensioner Mounting Bolts Coolant Drain Bolt (Cylinder) Cylinder Head Bolts (M10 New Bolts) Cylinder Head Bolts (M10 Used Bolts) Cylinder Head Bolts (M6) Cylinder Head Cover Bolts Cylinder Head Jacket Plugs Exhaust Butterfly Valve Actuator Bracket Bolt Exhaust Butterfly Valve Actuator Mounting Bolts Exhaust Butterfly Valve Actuator Pulley Bolt Exhaust Butterfly Valve Cable Adjuster Locknuts Exhaust Butterfly Valve Cable Locknuts Exhaust Butterfly Valve Cover Bolts Exhaust Pipe Manifold Holder Nuts Front Camshaft Chain Guide Bolt (Lower) Front Camshaft Chain Guide Bolt (Upper) Muffler Body Clamp Bolt Muffler Body Mounting Bolt Muffler Body Mounting Nut Muffler Body Side Cover Bolts Rear Camshaft Chain Guide Bolt Spark Plugs Throttle Body Assy Holder Bolts Throttle Body Assy Holder Clamp Bolts Clutch Clutch Cover Mounting Bolts Clutch Hub Nut Clutch Lever Clamp Bolts Clutch Spring Bolts Oil Filler Plug N·m 6.9 6.9 5.9 11 11 9.8 25 9.8 12 12 20 11 9.8 54 49 12 9.8 22 6.9 6.9 5.0 6.9 6.9 6.9 17 12 25 15 4.9 34 6.9 25 13 13 2.0 11 135 7.8 8.8 2.0 Torque kgf·m 0.70 0.70 0.60 1.1 1.1 1.0 2.5 1.0 1.2 1.2 2.0 1.1 1.0 5.5 5.0 1.2 1.0 2.2 0.70 0.70 0.51 0.70 0.70 0.70 1.7 1.2 2.5 1.5 0.50 3.5 0.70 2.5 1.3 1.3 0.20 1.1 13.8 0.80 0.90 0.20 ft·lb 61 in·lb 61 in·lb 52 in·lb 97 in·lb 97 in·lb 87 in·lb 18 87 in·lb 106 in·lb 106 in·lb 15 97 in·lb 87 in·lb 40 36 106 in·lb 87 in·lb 16 61 in·lb 61 in·lb 44 in·lb 61 in·lb 61 in·lb 61 in·lb 13 106 in·lb 18 11 43 in·lb 25 61 in·lb 18 115 in·lb 115 in·lb 18 in·lb 97 in·lb 99.6 69 in·lb 78 in·lb 18 in·lb Remarks L S S S S S S L S S S S R S 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Engine Lubrication System Coolant Drain Bolt (Water Pump) Engine Oil Drain Bolt Oil Filter Oil Filter Holder Oil Filler Plug Oil Jet Nozzle Bolts Oil Pan Bolts Oil Pan Side Dummy Bolts Oil Passage Plugs Oil Pipe Holder Bolts Oil Pressure Relief Valve Oil Pressure Switch Oil Pressure Switch Terminal Bolt Water Pump Cover Bolts Water Pump Impeller Bolt Engine Removal/Installation Adjusting Collar Lock Bolt Adjusting Collar Locknut Engine Ground Cable Terminal Bolt Front Engine Mounting Bolts Lower Engine Mounting Nut Middle Engine Mounting Nut Rear Engine Bracket Bolts Subframe Bolts Upper Engine Bracket Bolts Crankshaft/Transmission Breather Plate Bolts (M6) Breather Plate Bolts (M5) Connecting Rod Big End Nuts Crankcase Bolts (M9) Crankcase Bolts (M8) Crankcase Bolts (M7) Crankcase Bolts (M6) Front Footpeg Bracket Bolts Gear Positioning Lever Bolt Neutral Switch Oil Jet Nozzle Bolts Oil Passage Plugs Oil Pipe Holder Bolts Shift Drum Bearing Holder Bolt Shift Drum Bearing Holder Screw Shift Drum Cam Holder Bolt N·m 11 29 17 78 2.0 6.9 11 6.9 20 13 15 15 2.0 11 9.8 34 49 9.8 44 44 44 25 25 44 9.8 5.9 see the text 42 27 20 12 25 12 15 6.9 20 13 13 5.9 12 Torque kgf·m 1.1 3.0 1.7 8.0 0.20 0.70 1.1 0.70 2.0 1.3 1.5 1.5 0.20 1.1 1.0 3.5 5.0 1.0 4.5 4.5 4.5 2.5 2.5 4.5 1.0 0.60 4.3 2.8 2.0 1.2 2.5 1.2 1.5 0.70 2.0 1.3 1.3 0.60 1.2 ft·lb 97 in·lb 21 13 58 18 in·lb 61 in·lb 97 in·lb 61 in·lb 15 115 in·lb 11 11 18 in·lb 97 in·lb 87 in·lb 25 36 87 in·lb 32 32 32 18 18 32 87 in·lb 52 in·lb 31 20 15 106 in·lb 18 106 in·lb 11 61 in·lb 15 115 in·lb 115 in·lb 52 in·lb 106 in·lb Remarks G, R EO L L L L SS HG S S S S S S S S L L MO MO, S S S S L L L L L L PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Fastener Shift Lever Bolt Shift Pedal Mounting Bolt Shift Shaft Return Spring Pin Starter Motor Clutch Bolts Tie-Rod Locknuts Wheels/Tires Front Axle Front Axle Clamp Bolt Rear Axle Nut Final Drive Engine Sprocket Cover Bolts Engine Sprocket Cover Plate Bolts Engine Sprocket Nut Rear Axle Nut Rear Sprocket Nuts Brakes Bleed Valves Brake Hose Banjo Bolts Brake Lever Pivot Bolt Brake Lever Pivot Bolt Locknut Brake Pedal Bolt Brake Pipe Joint Nuts (ABS Equipped Models) Front Brake Disc Mounting Bolts Front Brake Light Switch Screw Front Brake Pad Pin Plugs Front Brake Pad Pins Front Brake Reservoir Cap Stopper Screw Front Caliper Holder Pin Bolt Front Caliper Mounting Bolts Front Master Cylinder Clamp Bolts Rear Brake Disc Mounting Bolts Rear Brake Pad Pin Rear Brake Pad Pin Plug Rear Caliper Mounting Bolt Rear Caliper Pin Bolt Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut Suspension Front Axle Clamp Bolt Front Fork Bottom Allen Bolts Front Fork Top Plugs Lower Front Fork Clamp Bolts Piston Rod Nuts N·m 6.9 34 29 12 6.9 108 20 108 9.8 9.8 125 108 59 7.8 25 1.0 5.9 34 18 27 1.2 2.5 17.2 1.2 22 25 8.8 27 17.2 2.5 22 27 25 17.2 20 40 23 21 15 Torque kgf·m 0.70 3.5 3.0 1.2 0.70 11.0 2.0 11.0 1.0 1.0 12.7 11.0 6.0 0.80 2.5 0.10 0.60 3.5 1.8 2.8 0.12 0.25 1.8 0.12 2.2 2.5 0.90 2.8 1.8 0.25 2.2 2.8 2.5 1.8 2.0 4.1 2.3 2.1 1.5 ft·lb 61 in·lb 25 21 106 in·lb 61 in·lb 79.7 15 79.7 87 in·lb 87 in·lb 92.2 79.7 44 69 in·lb 18 9 in·lb 52 in·lb 25 13 20 11 in·lb 25 in·lb 13 11 in·lb 16 18 78 in·lb 20 13 25 in·lb 16 20 18 13 15 30 17 15 11 Remarks L L L MO Si L L L, Si S L Si L AL 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Rear Shock Absorber Nut (Lower) Rear Shock Absorber Nut (Upper) Swingarm Pivot Shaft Swingarm Pivot Shaft Locknut Swingarm Pivot Shaft Nut Tie-Rod Nuts Uni-Trak Rocker Arm Nut Upper Front Fork Clamp Bolts Steering Handlebar Holder Bolts Handlebar Lower Clamp Nuts Lower Front Fork Clamp Bolts Steering Stem Head Bolt Steering Stem Nut Switch Housing Screws Upper Front Fork Clamp Bolts Frame Front Fender Bolts Front Footpeg Bracket Bolts Rear Footpeg Bracket Bolts Sidestand Bolt Sidestand Switch Bolt Electrical System Alternator Cover Bolts Alternator Lead Holding Plate Bolt Alternator Rotor Bolt Camshaft Position Sensor Bolt Crankshaft Sensor Bolts Crankshaft Sensor Cover Bolts Engine Ground Cable Terminal Bolt Front Brake Light Switch Screw Fuel Level Sensor Bolts License Plate Light Cover Mounting Screws License Plate Light Mounting Screws Meter Mounting Screws Neutral Switch Oil Pressure Switch Oil Pressure Switch Terminal Bolt Oxygen Sensor (Equipped Models) Regulator/Rectifier Bolts Regulator/Rectifier Bracket Bolts Sidestand Switch Bolt Spark Plugs N·m 34 34 9.8 98 108 59 34 20 25 34 21 108 27 3.5 20 3.9 25 25 44 8.8 11 12 155 12 5.9 11 9.8 1.2 6.9 0.9 1.2 1.2 15 15 2.0 44.1 6.9 6.9 8.8 13 Torque kgf·m 3.5 3.5 1.0 10.0 11.0 6.0 3.5 2.0 2.5 3.5 2.1 11.0 2.8 0.36 2.0 0.40 2.5 2.5 4.5 0.90 1.1 1.2 15.8 1.2 0.60 1.1 1.0 0.12 0.70 0.09 0.12 0.12 1.5 1.5 0.20 4.50 0.70 0.70 0.90 1.3 ft·lb 25 25 87 in·lb 72.3 79.7 44 25 15 18 25 15 79.7 20 31 in·lb 15 35 in·lb 18 18 32 78 in·lb 97 in·lb 106 in·lb 114 106 in·lb 52 in·lb 97 in·lb 87 in·lb 11 in·lb 61 in·lb 8 in·lb 11 in·lb 11 in·lb 11 11 18 in·lb 32.5 61 in·lb 61 in·lb 78 in·lb 115 in·lb Remarks S AL L L S L SS HG L L PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Fastener Speed Sensor Bolt Starter Motor Mounting Bolts Starter Relay Cable Terminal Bolts Stator Coil Bolts Switch Housing Screws Tail/Brake Light Mounting Screws Timing Rotor Bolt Vehicle-down Sensor Bolts Water Temperature Sensor N·m 12 11 3.9 12 3.5 1.2 39 6.0 25 Torque kgf·m 1.2 1.1 0.40 1.2 0.36 0.12 4.0 0.61 2.5 ft·lb 106 in·lb 97 in·lb 35 in·lb 106 in·lb 31 in·lb 11 in·lb 29 53 in·lb 18 Remarks L The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads. Basic Torque for General Fasteners Threads Diameter (mm) 5 6 8 10 12 14 16 18 20 N·m 3.4 4.9 5.9 7.8 14 19 25 34 44 61 73 98 115 155 165 225 225 325 Torque kgf·m 0.35 0.50 0.60 0.80 1.4 1.9 2.6 3.5 4.5 6.2 7.4 10.0 11.5 16.0 17.0 23.0 23.0 33.0 ft·lb 30 43 in·lb 52 69 in·lb 10.0 13.5 19.0 25 33 45 54 72 83 115 125 165 165 240 2-12 PERIODIC MAINTENANCE Specifications Item Fuel System (DFI) Throttle Grip Free Play Idle Speed Bypass Screws (Turn Out) Throttle Body Vacuum Air Cleaner Element Cooling System Coolant: Type (Recommended) Color Mixed Ratio Freezing Point Total Amount Engine Top End Valve Clearance: Exhaust Inlet Clutch Clutch Lever Free Play Engine Lubrication System Engine Oil: Type Viscosity Capacity Standard 2 3 mm (0.08 0.12 in.) 1 100 ±50 r/min (rpm) 2 1/2 (for reference) 35.3 ±1.3 kPa (265 ±10 mmHg) at idle speed Paper filter Service Limit ­­­ ­­­ ­­­ ­­­ ­­­ Permanent type of antifreeze Green Soft water 50%, Coolant 50% ­35°C (­31°F) 2.9 L (3.1 US qt) ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ 0.22 0.31 mm (0.0087 0.0122 in.) 0.15 0.24 mm (0.0059 0.0094 in.) 2 3 mm (0.08 0.12 in.) ­­­ ­­­ ­­­ Level Wheels/Tires Tread Depth: Front API SE, SF or SG API SH, SJ or SL with JASO MA SAE 10W-40 3.1 L (3.3 US qt) (when filter is not removed) 3.3 L (3.5 US qt) (when filter is removed) 3.8 L (4.0 US qt) (when engine is completely dry) Between upper and lower level lines (Wait 2 3 minutes after idling or running) ­­­ ­­­ ­­­ ­­­ ­­­ ­­­ 4.0 mm (0.16 in.) Rear 5.0 mm (0.20 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 Up to 180 kg (397 lb) load: 250 kPa (2.5 kgf/cm², 36 psi) Up to 180 kg (397 lb) load: 290 kPa (2.9 kgf/cm², 42 psi) Rear ­­­ PERIODIC MAINTENANCE 2-13 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 Gap Standard 30 40 mm (1.2 1.6 in.) 317.5 318.2 mm (12.50 12.53 in.) Service Limit ­­­ 323 mm (12.7 in.) ENUMA EK520MVXL1 112 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 CR9EK 0.7 0.8 mm (0.028 0.031 in.) ­­­ ­­­ 2-14 PERIODIC MAINTENANCE Special Tools Inside Circlip Pliers: 57001-143 Vacuum Gauge: 57001-1369 Steering Stem Nut Wrench: 57001-1100 Throttle Sensor Setting Adapter: 57001-1538 Jack: 57001-1238 Extension Tube: 57001-1578 Oil Filter Wrench: 57001-1249 Jack Attachment: 57001-1608 PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Fuel System (DFI) Air Cleaner Element Cleaning In dusty areas, the element should be cleaned more After riding through rain or on muddily roads, the element should be cleaned immediately. frequently than the recommended interval. NOTE WARNING If dirt or dust is allowed to pass through into the throttle assy, the throttle may become stuck, possibly causing accident. CAUTION If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur. · Remove the element (see Air Cleaner Element Replacement). the lightly to loosen dust. · Cleanawayelement by tapping it by applying compressed the remaining dust · Blow from the outside to the inside (from the clean side air [A] · to the dirty side). Visually inspect the element for no tears or no breaks and inspect the sponge gaskets [B] also. If the element or gasket has any tears or breaks, replace the element. Throttle Control System Inspection throttle from full · Checktothat the and thegrip [A] 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 cable routing, grip free play, and cable damage. Then lubricate the throttle cable. Check the throttle grip free play [B]. Throttle Grip Free Play Standard: 2 3 mm (0.08 0.12 in.) · · · · · · If the free play is incorrect, adjust the throttle cable as follows. Loosen the locknut [A]. Turn the adjuster [B] until the proper amount of free play can be obtained. Tighten the locknut against the adjuster securely. If the throttle grip free play can not be adjusted with the adjuster, use the adjusters in the middle of the throttle cables. Loosen the locknut, and screw the adjuster at the upper end of the accelerator cable all the way in. Tighten the locknut against the adjuster securely. 2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures turn the lower [B] · Loosen the locknuts [A], andthrottle grip freeadjusters obuntil the proper amount of play is · tained. Tighten the locknuts against the adjusters securely. If the throttle grip free play can not be adjusted with the lower adjusters, use the adjuster at the upper end of the cable again. 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. so is vertical. · Situate the motorcycle(see that itTank Removal in the Fuel Remove the fuel tank Fuel · System (DFI) chapter). · Pull off the rubber caps [A] from the fittings of each throttle body. Upside View [B] · Pull off the air switching valve hose [A] from the air cleaner housing. air switching valve hose end and air cleaner · Plug thefitting. housing gauge (special · Connect a vacuumthrottle body. tool) and hoses [A] to the fittings on the accurate · Connect a highly leads. tachometer [B] to one of the stick coil primary Special Tool - Vacuum Gauge: 57001-1369 PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures · Remove the fuel outlet hose (see Fuel Hose Replacement). following parts temporary. · Connect the Lead Connector [A] Fuel Pump Fuel Level Sensor Lead Connector [B] Extension Tube [C] Special Tool - Extension Tube: 57001-1578 · Start the engine and warm itaup thoroughly. tachometer · Check the idle speed, using highly accurate [A]. Idle Speed Standard: 1 100 ±50 r/min (rpm) If the idle speed is out of the specified range, adjust it with the adjusting screw (see Idle Speed Adjustment). CAUTION Do not measure the idle speed by the tachometer of the meter unit. idling the engine, inspect · While the vacuum gauge [B]. the throttle body vacuum, using Throttle Body Vacuum Standard: 35.3 ±1.3 kPa (265 ±10 mmHg) at idle speed If any vacuum is not within specifications, first synchronize the balance of the left (#1, #2 throttle valves) and right (#3, #4 throttle valves) assemblies. Example: #1: 260 mmHg #2: 290 mmHg #3: 250 mmHg #4: 270 mmHg With the engine at the correct idle speed, equalize higher vacuum of #1 or #2 (for example 290 mmHg) to higher vacuum of #3 or #4 (for example 270 mmHg) by turning the center adjusting screw [A]. Upside View [B] · After adjustment, NOTE the final vacuum measurement between the highest throttle valves may not be 290 mmHg (for example). The goal is to have the highest two vacuums between the left (#1 and #2) and right (#3 and #4) banks be the same. · 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 Periodic Maintenance Procedures If any one vacuum measurement is out of the specified range after left (#1, #2) and right (#2, #3) synchronization, adjust the bypass screws [A]. Upside View [B] Adjust the lower vacuum between #1 and #2 to the higher vacuum of #1 and #2. Adjust the lower vacuum between #3 and #4 to the higher vacuum of #3 and #4. Open and close the throttle valves after each measurement, and adjust the idle speed as necessary. Check the vacuums as before. If all vacuums are within the specification range, finish the engine vacuum synchronization. If any vacuum can not be adjusted within the specification, remove the bypass screws #1 #4 and clean them. · · · · screw number of · Turn in theitbypassfully but[A] with counting thethe number turns until seals not tightly. Record of turns. Torque - Bypass Screws: 0.2 N·m (0.02 kgf·m, 1.8 in·lb) CAUTION Do not over tighten them. They could be damaged, requiring replacement. · Remove: 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 Screws: 0.2 N·m (0.02 kgf·m, 1.8 in·lb) PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures 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 Main Throttle Sensor Output Voltage Inspection in the Fuel System (DFI) chapter). Special Tool - Throttle Sensor Setting Adapter: -1538 Main Throttle Sensor Output Voltage Connections to Adapter: Digital Meter (+) R (sensor Y/W) lead Digital Meter (­) W (sensor BR/BK) lead Standard: DC 0.985 1.015 V at idle throttle opening 57001 · If the output voltage is out of the standard, check the input voltage of the main throttle sensor (see Main Throttle Sensor Input Voltage Inspection in the Fuel System (DFI) chapter). Remove the vacuum gauge hoses and install the rubber caps on the original position. 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 Throttle Control System Inspection and Cable, Wire, and Hose Routing section in the Appendix chapter). WARNING Operation with improperly adjusted, incorrectly routed or damaged cables could result in an unsafe riding condition. · Check the idle speed. Idle Speed Standard: 1 100 ±50 r/min (rpm) If the idle speed is out of the specified range, adjust it. 2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures 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 hoses. Replace the 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 Outlet Hose [B] Fuel Inlet Hose [C] Front [D] PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures that the outlet are securely · Checkand pull [A] thehose joints [B] back andconnected. hose joint forth more Push than two times, and make sure it is locked and does not come off. Fuel Pump Side [C] Throttle Body Assy Side [D] WARNING Make sure the hose joint is installed correctly on the delivery pipe or the fuel could leak. If it comes off, reinstall the hose joint. the [A] is · Check that are inlet hosebeyondonto the pipe fully and the clamps [B] installed the raised rib [C]. 1 2 mm (0.039 0.079 in.) [D] 2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cooling System Coolant Level Inspection Check the level when the engine is cold (room or ambient temperature). NOTE · Remove the front seat (see Front Seat Removal in the Frame chapter). level in the with the · Check the coolantperpendicularreserve tank [A]the sidemotorcycle held (Do not use stand.). 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 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 (Water) Hose Clamp Screws: 3.0 N·m (0.31 kgf·m, 27 in·lb) PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Engine Top End Valve Clearance Inspection Valve clearance must be checked and adjusted when the engine is cold (room temperature). NOTE · Remove: Sensor Cover (see Crankshaft Sensor ReCrankshaft moval in the Electrical System chapter) Cylinder Head Cover (see Cylinder Head Cover Removal in the Engine Top End chapter) crankshaft 1,4 piston · Position the [A] for #1, 4atPistons TDC. TDC Mark Timing Mark [B] (Crankcase Halves Mating Surface) the thickness gauge · Usingbetween the cam and [A], measure the valve clearance the valve lifter. Valve Clearance Standard: Exhaust Inlet 0.22 0.31 mm (0.0087 0.0122 in.) 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 Periodic Maintenance Procedures When positioning #1 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] When positioning #4 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] 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 shims so that they can be reinstalled in their original positions. NOTE Bisides the standard shims in the valve clearance adjustment charts, the following additional shims maybe used. Part Number 92180-0276 92180-0277 92180-0278 Thickness 3.225 mm 3.275 mm 3.325 mm Adjustment Shims shim to remove any dust or · Clean thethe thickness of the removedoil. [A]. Measure shim · PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE 1. 2. 3. 4. Measure the clearance (when engine is cold). Check present shim size. Match clearance in vertical column with present shim size in horizontal column. Install the shim specified where the lines intersect. This shim will give the proper clearance. Present shim is 2.95 mm Measured clearance is 0.45 mm Replace 2.95 mm shim with 3.20 mm shim. Example: 5. Remeasure the valve clearance and readjust if necessary. 2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1. 2. 3. 4. Measure the clearance (when engine is cold). Check present shim size. Match clearance in vertical column with present shim size in horizontal column. Install the shim specified where the lines intersect. This shim will give the proper clearance. Present shim is 2.95 mm. Measured clearance is 0.47 mm. Replace 2.95 mm shim with 3.15 mm shim. Example: 5. Remeasure the valve clearance and readjust if necessary. PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures CAUTION Be sure to remeasure the clearance after selecting a shim according to the table. If the clearance is out of the specified range, use the additional shim. If 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. 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. camshaft (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 · Exhaust Butterfly Valve Cable Inspection · Remove the left side cover (see Side Cover Removal in the Frame chapter). whether · Confirm±7° [B] pulley [A] is an angle shown in the figure. 41.7° This position is original position of the pulley. NOTE Correct the position electrically after confirming the use is discontinued and there no damage when differing from the angle of shown in the figure. CAUTION Do not correct the pulley position with the tool, forcibly. The actuator damage will occur. Turn the ignition switch ON. Confirm the pulley turns clockwise and then counterclockThe pulley returns to the original position. Turn the ignition switch OFF. wise, and clockwise again. If the operation of the pulley is different, adjust the exhaust butterfly valve cables (see Exhaust Butterfly Valve Cable Adjustment). If the pulley does not return to the original position, adjust the pulley (see Exhaust Butterfly Valve Actuator Installation in the Fuel System (DFI) chapter). If the pulley angle is wrong, adjust the angle as follows. 2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures that · Check themthere is no play in the inner cables [A] by pulling lightly. If there is play in the inner cables, adjust them (see Exhaust Butterfly Valve Cable Adjustment). Exhaust Butterfly Valve Cable Adjustment dust covers [A]. · Slide thethe locknuts [B]. Loosen · PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures · Stretch the open cable (white) [A] first by using the adjuster [B]. Turn the adjuster counterclockwise until it becomes hard to turn. Locknut of White [C] CAUTION To keep the correct exhaust butterfly valve position, adjust the open cable first. Do not overstretch. If the adjustment of the exhaust butterfly valve cables are incorrect, the exhaust butterfly valve actuator does not operate correctly. stretch · Then, [E]. the close cable (black) [D] by using the adjuster Turn the adjuster counterclockwise until it becomes hard to turn. Locknut of Black [F] 2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures · Turn the ignition switch ON and wait until the pulley [A] turns fully clockwise [B]. switch when the pulley become fully · Turn off the ignition[C] as shown in the figure. clockwise position The target position is a position in which the upper end · [D] of the open cable and the screw [E] of the actuator become almost straight. The pulley stops at fully clockwise position. The exhaust butterfly valve is full closed position when the pulley turned fully clockwise. Therefore, the play [F] appears in the open cable when pulley is fully clockwise position. The open and close cables can be evenly stretching by adjusting this play. NOTE