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Kawasaki ZZR 1400, ZZR1400 ABS, Ninja ZX-14 Motorcycle. Service Manual (2006-2007 year) - page 3

3-126 FUEL SYSTEM (DFI)

Fuel Tank

• Disconnect:

Fuel Pump Lead Connector [A]

Fuel Level Sensor Lead Connector [B]

• Open the fuel tank cap [A] to lower the pressure in the

tank.

○During tank removal, keep the tank cap open to release

pressure in the tank. This makes fuel spillage less.

• Draw the fuel out from the fuel tank with a commercially

available pump [A].

○Use a soft plastic hose [B] as a pump inlet hose in order

to insert the hose smoothly.

○Put the hose through the fill opening [C] into the tank and

draw the fuel out.

Front [D]

WARNING

The fuel could not be removed completely from the

fuel tank. Be careful for remained fuel spillage.

• Be sure to place a piece of cloth [A] around the fuel hose

joint [B].

• Push the joint lock claws [C].

• Pull the joint lock [A] as shown.

• Pull [B] the fuel hose joint [C] out of the delivery pipe.

WARNING

Be prepared for fuel spillage; any spilled fuel must

be completely wiped up immediately.

When the fuel hose is disconnected, fuel spills out

from the hose and the pipe because of residual

pressure. Cover the hose connection with a piece

of clean cloth to prevent fuel spillage.

• Close the fuel tank cap.

• Remove the fuel tank, and place a it on a flat surface.

○Do not apply the load to the delivery pipe of the fuel pump.

FUEL SYSTEM (DFI) 3-127

Fuel Tank

• For the California Model, note the following.

CAUTION

For the California model, if gasoline, solvent, water

or any other liquid enters the canister, the canister’s

vapor absorbing capacity is greatly reduced. If the

canister does become contaminated, replace it with

a new one.

○Be sure to plug the evaporative fuel return hose to prevent

fuel spilling before fuel tank removal.

WARNING

For the California model, be careful not to spill the

gasoline through the return hose. Spilled fuel is

hazardous.

If liquid or gasoline flows into the breather hose, remove

the hose and blow it clean with compressed air (California

model).

○Be careful of fuel spillage from the fuel tank since fuel still

remains in the fuel tank and fuel pump.

WARNING

Store the fuel tank in an area which is well

-ventilated and free from any source of flame

or sparks. Do not smoke in this area. Place the

fuel tank on a flat surface and plug the fuel pipes

to prevent fuel leakage.

Fuel Tank Installation

• Note the above WARNING (see Fuel Tank Removal).

• Route the hoses correctly (see Cable, Wire, and Hose

Routing section in the Appendix chapter).

• Check that the dampers [A] and pad [B] are in place on

the fuel tank as well.

If the dampers are damaged or deteriorated, replace

them.

• For the California Model, note the following.

○To prevent the gasoline from flowing into or out of the

canister, hold the separator perpendicular to the ground.

○Connect the hoses according to the diagram of the sys-

tem (see Cable, Wire, and Hose Routing section in the

Appendix chapter). Make sure they do not get pinched or

kinked.

○Route hoses with a minimum of bending so that the air or

vapor will not be obstructed.

3-128 FUEL SYSTEM (DFI)

Fuel Tank

• Pull the joint lock [A] as shown.

• Insert the fuel hose joint [A] straight onto the delivery pipe

until the hose joint clicks.

• Push the joint lock [B] until the hose joint clicks.

• Push and pull [A] the hose joint [B] back and forth more

than two times and make sure it is locked and doesn’t

come off. When the hose joint is correctly installed, it

should slide on the delivery pipe about 5 mm (0.2 in.).

WARNING

Make sure the hose joint is installed correctly on the

delivery pipe by sliding the joint, or the fuel could

leak.

If it does not slide, reinstall the hose joint.

• Connect the fuel pump, fuel level sensor lead connectors

and the battery (-) terminal (see Battery Installation in the

Electrical System chapter).

• For models equipped with an ABS, fit the grooves of the

damper [A] on the brake pipes [B].

FUEL SYSTEM (DFI) 3-129

Fuel Tank

• Fit the dampers [A] of the fuel tank into the slots [B] of the

fuel tank cover [C].

Fuel Tank and Cap Inspection

• Visually inspect the gasket [A] on the tank cap for any

damage.

Replace the gasket if it is damaged.

• Check to see if the water drain pipe [B] and fuel breather

pipe [C] (California Model) in the tank are not clogged.

Check the tank cap breather also.

If they are clogged, remove the tank and drain it, and then

blow the breather free with compressed air.

CAUTION

Do not apply compressed air to the air vent holes

[D] in the tank cap. This could cause damage and

clogging of the labyrinth in the cap.

Fuel Tank Cleaning

WARNING

Clean the tank in a well-ventilated area, and take

care that there are no sparks or flame anywhere

near the working area. Because of the danger or

highly flammable liquids, do not use gasoline or

low-flash point solvents to clean the tank.

• Remove:

Fuel Tank (see Fuel Tank Removal)

Fuel Pump (see Fuel Pump Removal)

• Pour some high-flash point solvent into the fuel tank and

shake the tank to remove dirt and fuel deposits.

• Draw the solvent out of the fuel tank.

• Dry the tank with compressed air.

• Install:

Fuel Pump (see Fuel Pump Installation)

Fuel Tank (see Fuel Tank Installation)

3-130 FUEL SYSTEM (DFI)

Evaporative Emission Control System

The Evaporative Emission Control System routes fuel va-

pors from the fuel system into the running engine or stores

the vapors in a canister when the engine is stopped. Al-

though no adjustments are required, a thorough visual in-

spection must be made at the intervals specified by the Pe-

riodic Maintenance Chart.

Parts Removal/Installation

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Turn the ignition

switch OFF. Do not smoke. Make sure the area is

well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

CAUTION

If gasoline, solvent, water or any other liquid enters

the canister, the canister’s vapor absorbing capac-

ity is greatly reduced. If the canister does become

contaminated, 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.

• Connect the hoses according to the diagram of the sys-

tem. Make sure they do not get pinched or kinked.

Hose Inspection

• Refer to the Evaporative Emission Control System In-

spection in the Periodic Maintenance chapter (see Evapo-

rative Emission Control System Inspection in the Periodic

Maintenance chapter).

Separator Inspection

• Refer to the Evaporative Emission Control System In-

spection in the Periodic Maintenance chapter (see Evapo-

rative Emission Control System Inspection in the Periodic

Maintenance chapter).

Separator [A]

FUEL SYSTEM (DFI) 3-131

Evaporative Emission Control System

Separator Operation Test

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Turn the ignition

switch OFF. Do not smoke. Make sure the area is

well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

• Connect the hoses to the separator, and install the sepa-

rator on the motorcycle.

• Disconnect the breather hose from the separator, and in-

ject about 20 mL (0.68 US oz.) of gasoline [A] into the

separator [B] through the hose fitting.

• Disconnect the fuel return hose [C] from the fuel tank [D].

• Run the open end of the return hose into the container

and hold it level with the tank top [E].

• Start the engine, and let it idle.

If the gasoline in the separator comes out of the hose, the

separator works well. If it does not, replace the separator

with a new one.

Canister Inspection

• Refer to the Evaporative Emission Control System In-

spection in the Periodic Maintenance chapter (see Evapo-

rative Emission Control System Inspection in the Periodic

Maintenance chapter).

NOTE

○The canister [A] is designed to work well through the

motorcycle’s life without any maintenance if it is used

under normal conditions.

3-132 FUEL SYSTEM (DFI)

Evaporative Emission Control System

1. Fuel Tank

2. White Hose (Vacuum)

3. Throttle Body Assy

4. Green Hose (Purge)

5. Canister

6. Band (for Canister)

7. Red Hose (Right, Return)

8. Fitting

9. Bracket (for Separator)

10. Separator

11. Blue Hose (Breather)

12. Blue Hose (Left, Breather)

4-2 COOLING SYSTEM

Exploded View

COOLING SYSTEM 4-3

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Radiator Hose Clamp Screws

2.0

0.20

18 in·lb

2

Coolant Drain Plug

12

1.2

106 in·lb

3

Water Pump Cover Bolts

9.8

1.0

87 in·lb

4

Oil Cooler Mounting Bolts

12

1.2

106 in·lb

S

5

Thermostat Housing Cover Bolts

5.9

0.60

52 in·lb

6

Thermostat Housing Mounting Bolts

9.8

1.0

87 in·lb

7

Coolant Fitting Bolt

8.8

0.90

78 in·lb

L

8

Water Temperature Sensor

25

2.5

18

9. Thermostat

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

S: Follow the specified tightening sequence.

4-4 COOLING SYSTEM

Coolant Flow Chart

COOLING SYSTEM 4-7

Coolant

Coolant Deterioration Inspection

• Visually inspect the coolant in the reserve tank.

If whitish cotton-like wafts are observed, aluminum parts

in the cooling system are corroded. If the coolant is

brown, iron or steel parts are rusting. In either case, flush

the cooling system.

If the coolant gives off an abnormal smell, check for a

cooling system leak. It may be caused by exhaust gas

leaking into the cooling system.

Coolant Level Inspection

• Refer to the Coolant Level Inspection in the Periodic Main-

tenance chapter.

Coolant Draining

• Refer to the Coolant Change in the Periodic Maintenance

chapter.

Coolant Filling

• Refer to the Coolant Change in the Periodic Maintenance

chapter.

Pressure Testing

• Remove the right middle fairing (see Middle Fairing Re-

moval in the Frame chapter).

• Remove the radiator cap, and install the cooling system

pressure tester [A] on the filler neck.

NOTE

○Wet the cap sealing surfaces with water or coolant to

prevent pressure leaks.

• Build up pressure in the system carefully until the pres-

sure reaches 142 kPa (1.45 kgf/cm², 21 psi).

CAUTION

During pressure testing, do not exceed the pres-

sure for which the system is designed. The maxi-

mum pressure is 142 kPa (1.45 kgf/cm², 21 psi).

• Watch the gauge for at least 6 seconds.

If the pressure holds steady, the system is all right.

If the pressure drops and no external source is found,

check for internal leaks. Droplets in the engine oil indicate

internal leakage. Check the cylinder head gasket and the

water pump.

• Remove the pressure tester, replenish the coolant, and

install the radiator cap.

COOLING SYSTEM 4-9

Water Pump

Water Pump Removal

• Drain:

Coolant (see Coolant Change in the Periodic Mainte-

nance chapter)

Engine Oil (see Engine Oil Change in the Periodic Main-

tenance chapter)

• Remove:

Clutch Slave Cylinder (see Clutch Slave Cylinder Re-

moval in the Clutch chapter)

Engine Sprocket Cover (see Engine Sprocket Removal

in the Final Drive chapter)

• Remove:

Radiator Hose [A]

Water Pump Cover Bolts [B]

Water Pump Cover [C]

• Remove the radiator hose [A] and the air bleeder hose [B]

for the water pump body.

• Remove the water pump body [C] with impeller [D].

Water Pump Installation

• Turn the pump drive gear shaft so that the slot [A] in its

shaft fits onto the projection [B] of the impeller shaft.

• Install the radiator hose [A] and the air bleeder hose [B]

for the water pump body as shown.

4-10 COOLING SYSTEM

Water Pump

• Install the water pump cover [A].

• Tighten:

Torque - Water Pump Cover Bolts: 9.8 N·m (1.0 kgf·m, 87

in·lb)

• Install the water hose [B] as shown.

Water Pump Impeller Inspection

• Visually inspect the water pump impeller [A].

If the surface is corroded or if the blades are damaged,

replace the water pump assy.

COOLING SYSTEM 4-11

Radiator

Radiator and Radiator Fan Removal

• Remove:

Middle Fairings (see Middle Fairing Removal in the

Frame chapter)

Coolant (Drain, see Coolant Change in the Periodic

Maintenance chapter)

Reservoir Tank Hose [A]

Air Bleeder Hose [B] for Thermostat Housing

Radiator Hose [C]

Oil Cooler Outlet Hose [D]

Radiator Upper Bolt [E]

• Remove:

Radiator Fan Lead Connector [A]

Radiator Hose [B]

Radiator Lower Bolt [C]

Radiator Upper Bolt [D]

• Remove the radiator [E].

CAUTION

Do not touch the radiator core. This could damage

the radiator fins, resulting in loss of cooling effi-

ciency.

• Remove:

Radiator Fan Mounting Bolts [A]

Radiator Fan [B]

4-12 COOLING SYSTEM

Radiator

Radiator and Radiator Fan Installation

• Be sure that the trim seals [A] are in position on the radi-

ator as shown.

• Install the dampers [B], radiator bracket collars [C] and

bolts as shown.

Radiator Inspection

• Check the radiator core.

If there are obstructions to air flow, remove them.

If the corrugated fins [A] are deformed, carefully

straighten them.

If the air passages of the radiator core are blocked more

than 20% by unremovable obstructions or irreparably de-

formed fins, replace the radiator with a new one.

CAUTION

When cleaning the radiator with steam cleaner, be

careful of the following to prevent radiator damage:

Keep the steam gun [A] away more than 0.5 m (1.6

ft) [B] from the radiator core.

Hold the steam gun perpendicular [C] (not oblique

[D]) to the core surface.

Run the steam gun, following the core fin direction.

COOLING SYSTEM 4-13

Radiator

Radiator Cap Inspection

• Remove:

Right Middle Fairing (see Middle Fairing Removal in the

Frame chapter)

Radiator Cap

• Check the condition of the bottom [A] and top [B] valve

seals and valve spring [C].

If any one of them shows visible damage, replace the cap

with a new one.

• Install the cap [A] on a cooling system pressure tester [B].

NOTE

○Wet the cap sealing surfaces with water or coolant to

prevent pressure leaks.

• Watching the pressure gauge, pump the pressure tester

to build up the pressure until the relief valve opens: the

gauge needle flicks downward. Stop pumping and mea-

sure leak time at once. The relief valve must open within

the specified range in the table below and the gauge hand

must remain within the same range at least 6 seconds.

Radiator Cap Relief Pressure

Standard:

93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18

psi)

If the cap can not hold the specified pressure or if it holds

too much pressure, replace it with a new one.

Radiator Filler Neck Inspection

• Remove the right middle fairing (see Middle Fairing Re-

moval in the Frame chapter).

• Remove the radiator cap.

• Check the radiator filler neck for signs of damage.

• Check the condition of the top and bottom sealing seats

[A] in the filler neck. They must be smooth and clean for

the radiator cap to function properly.

4-14 COOLING SYSTEM

Thermostat

Thermostat Removal

• Drain the coolant (see Coolant Change in the Periodic

Maintenance chapter).

• Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System

(DFI) chapter)

Throttle Body Assy (see Throttle Body Assy Removal in

the Fuel System (DFI) chapter)

Thermostat Housing Mounting Bolts [A]

Radiator Hose [B]

Air Bleeder Hoses [C]

Thermostat Housing [D]

• Remove:

Thermostat Housing Cover Bolts [A]

Thermostat Housing Cover [B]

Thermostat

Thermostat Installation

• Install the thermostat [A] in the housing so that the air

bleeder hole [B] is on top.

• Install a new O-ring into the housing.

• Tighten the thermostat housing cover bolts and the ther-

mostat housing mounting bolts.

Torque - Thermostat Housing Cover Bolts: 5.9 N·m (0.60

kgf·m, 52 in·lb)

Thermostat Housing Mounting Bolts: 9.8 N·m (1.0

kgf·m, 87 in·lb)

• Fill the radiator with coolant (see Coolant Change in the

Periodic Maintenance chapter).

Thermostat Inspection

• Remove the thermostat, and inspect the thermostat valve

[A] at room temperature.

If the valve is open, replace the thermostat with a new

one.

COOLING SYSTEM 4-15

Thermostat

• To check valve opening temperature, suspend the ther-

mostat [A] in a container of water and raise the tempera-

ture of the water.

○The thermostat must be completely submerged and must

not touch the container sides or bottom. Suspend an ac-

curate thermometer [B] in the water so that the heat sen-

sitive portions [C] are located in almost the same depth.

It must not touch the container, either.

If the measurement is out of the specified range, replace

the thermostat with a new one.

Thermostat Valve Opening Temperature

58 ∼ 62°C (136 ∼ 144°F)

4-16 COOLING SYSTEM

Hoses and Pipes

Hose Installation

• Install the hoses and pipes, being careful to follow bend-

ing direction. Avoid sharp bending, kinking, flattening or

twisting.

• Run the hoses (see Cable, Wire, and Hose Routing sec-

tion in the Appendix chapter).

• Install the clamp [A] as near as possible to the hose end

to clear the raised rib of the fitting. This will prevent the

hoses from working loose.

○The clamp screws should be positioned correctly to pre-

vent the clamps from contacting the other parts.

Torque - Radiator Hose Clamp Screws: 2.0 N·m (0.20 kgf·m,

18 in·lb)

Hose Inspection

• Refer to the Radiator Hose and Connection Inspection in

the Periodic Maintenance chapter.

COOLING SYSTEM 4-17

Water Temperature Sensor

CAUTION

The water temperature sensor should never be al-

lowed to fall on a hard surface. Such a shock to

their parts can damage them.

Water Temperature Sensor Removal

• Refer to the Water Temperature Sensor Removal in the

Fuel System (DFI) chapter.

Water Temperature Sensor [A]

Water Temperature Sensor Inspection

• Refer to the Water Temperature Sensor Inspection in the

Electrical System chapter.

5-2 ENGINE TOP END

Exploded View

ENGINE TOP END 5-3

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Air Suction Valve Cover Bolts

9.8

1.0

87 in·lb

L

2

Cylinder Head Cover Bolts

9.8

1.0

87 in·lb

S

3

Camshaft Cap Bolts

12

1.2

106 in·lb

S

4

Camshaft Chain Guide Bolts

12

1.2

106 in·lb

S

Cylinder Head Bolts (M11, First)

39

4.0

29

MO, S

5

Cylinder Head Bolts (M11, Final)

71

7.2

52

MO, S

6

Cylinder Head Bolts (M6)

12

1.2

106 in·lb

S

7

Water Passage Plugs

20

2.0

15

L

8

Throttle Body Holder Bolts

9.8

1.0

87 in·lb

S

9

Throttle Body Assy Holder Clamp Bolts

2.0

0.20

18 in·lb

10

Camshaft Position Sensor Bolt

9.8

1.0

87 in·lb

11

Front Camshaft Chain Guide Bolt (Upper)

25

2.5

18

12

Front Camshaft Chain Guide Bolt (Lower)

12

1.2

106 in·lb

13

Camshaft Chain Tensioner Mounting Bolts

9.8

1.0

87 in·lb

14

Spark Plugs

13

1.3

115 in·lb

15

Cam Sprocket Mounting Bolts

15

1.5

11

L

16

Engine Bracket Bolts

25

2.5

18

R, S

17

Front Engine Mounting Bolts

59

6.0

44

R, S

18

Plug

-

-

-

Hand-tighten

19

Water Temperature Sensor

25

2.5

18

G: Apply grease.

L: Apply a non-permanent locking agent.

M: Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil.

(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10

:

1)

R: Replacement Parts

S: Follow the specific tightening sequence.

SS: Apply silicone sealant (Kawasaki Bond: 92104-0004).

5-4 ENGINE TOP END

Exploded View

ENGINE TOP END 5-5

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Muffler Body Mounting Bolts

34

3.5

25

2

Crankshaft Sensor Cover Bolts

9.8

1.0

87 in·lb

L (1)

3. Muffler Body Clamp Bolts

4. Exhaust Pipe Manifold Holder Nuts

L: Apply a non-permanent locking agent.

R: Replacement Parts

5-6 ENGINE TOP END

Exhaust System

Full: Full Power

H: Honeycomb Type Catalyst

78.2: Hosepower 78.2 kW (106.3 ps)

Manifold Mark Position [A]

ENGINE TOP END 5-7

Exhaust System

Silencer Mark Position [A]

Honeycomb Type Catalyst [A]

ENGINE TOP END 5-11

Clean Air System

Air Suction Valve Removal

• Remove:

Middle Fairings (see Middle Fairing Removal in the

Frame chapter)

• Pull out the hoses [A].

• Disconnect the connector [B].

• Remove the air switching valve [C] with the hoses.

• Remove the following from the bracket [A].

Rivets [B]

Bolts [C]

• Remove:

Air Suction Valve Cover Bolts [A]

Air Suction Valve Cover [B]

Air Suction Valve [C]

Air Suction Valve Installation

• Install the air suction valve so that opening [A] of the reed

faces the rear and downward.

• Apply a non-permanent locking agent to the threads of

the air suction valve cover bolts, and tighten them with

the specified torque.

Torque - Air Suction Valve Cover Bolts: 9.8 N·m (1.0 kgf·m,

87 in·lb)

5-12 ENGINE TOP END

Clean Air System

Air Suction Valve Inspection

• Remove the air suction valve (see Air Suction Valve Re-

moval).

• Visually inspect the reeds [A] for cracks, folds, warps,

heat damage, or other damage.

If there is any doubt as to the condition of the reed, replace

the air suction valve as an assembly.

• Check the reed contact areas [B] of the valve holder for

grooves, scratches, any sings of separation from the

holder, or heat damage.

If there is any doubt as to the condition of the reed contact

areas, replace the air suction valve as an assembly.

• If any carbon or other foreign particles have accumulated

between the reed and the reed contact area, wash the

valve assembly with a high flash-point solvent.

CAUTION

Do not scrape off the deposits with a scraper as this

could damage the rubber, requiring replacement of

the suction valve assembly.

Air Switching Valve Removal

• Remove:

Middle Fairings (see Middle Fairing Removal in the

Frame chapter)

Connector [A]

Air Switching Valve [B]

CAUTION

Never drop the switch especially on a hard surface.

Such a shock to the switch can damage it.

Air Switching Valve Installation

• Install the air switching valve so that the air duct [A] faces

left side.

• Route the hoses correctly (see Cable, Wire, and Hose

Routing section in the Appendix chapter).

Air Switching Valve Operation Test

• Refer to the Air Switching Valve Operation Test in the

Electrical System chapter.

Air Switching Valve Unit Test

• Refer to the Air Switching Valve Unit Test in the Electrical

System chapter.

Clean Air System Hose Inspection

• Be certain that all the hoses are routed without being flat-

tened or kinked, and are connected correctly to the air

cleaner housing, air switching valve and air suction valve

covers.

If they are not, correct them. Replace them if they are

damaged.

ENGINE TOP END 5-13

Cylinder Head Cover

Cylinder Head Cover Removal

• Remove:

Middle Fairings (see Middle Fairing Removal in the

Frame chapter)

Throttle Body Assy (see Throttle Body Assy Removal in

the Fuel System (DFI) chapter)

Air Switching Valve (see Air Switching Valve Removal)

• Free the heat insulation rubber plate.

• Remove:

Stick Coils (see Stick Coil (Ignition Coil together with

Spark Plug Cap) Removal in the Electrical System chap-

ter)

Air Suction Valve Covers (see Air Suction Valve Re-

moval)

• Remove the cylinder head cover bolts [A].

• Remove the cylinder head cover to backward floating it a

little up.

Cylinder Head Cover Installation

• Replace the head cover gasket with a new one.

• Apply silicone sealant [A] to the cylinder head as shown.

Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004

• Install:

Dowel Pins [A]

Plug Hole Gaskets [B]

5-14 ENGINE TOP END

Cylinder Head Cover

• Install the washer [A] with the metal side faces upward.

• Tighten the cover bolts, following the sequence numbers

on the cover.

Torque - Cylinder Head Cover Bolts [B]: 9.8 N·m (1.0 kgf·m,

87 in·lb)

• Install the removed parts (see appropriate chapters).

ENGINE TOP END 5-15

Camshaft Chain Tensioner

Camshaft Chain Tensioner Removal

CAUTION

Do not turn over the crankshaft while the tensioner

is removed. This could upset the camshaft chain

timing, and damage the valves.

• Remove the right middle fairing (see Middle Fairing Re-

moval in the Frame chapter).

• Remove the mounting bolts [A] and take off the camshaft

chain tensioner [B].

Camshaft Chain Tensioner Installation

• Remove the cylinder head cover (see Cylinder Head

Cover Removal).

• Pinching [A] the stopper [B], release it and push [C] the

push rod [D] into the interior of tensioner body [E].

• Pushing [A] the push rod, slide the snap ring [B] into the

groove [C] of smaller diameter from the groove [D] of

larger diameter.

• Install the tensioner body so that the stopper [A] faces

upward.

• Tighten the tensioner mounting bolts.

Torque - Camshaft Chain Tensioner Mounting Bolts:

9.8

N·m (1.0 kgf·m, 87 in·lb)

5-16 ENGINE TOP END

Camshaft Chain Tensioner

• Lightly hit the push rod head [A] with a minus screw driver

[B] to move out the push rod.

NOTE

○You hear of the sound from which the push rod moves

out.

• Turn the crankshaft 2 turns clockwise to allow the ten-

sioner to expand and recheck the camshaft chain timing.

ENGINE TOP END 5-17

Camshaft, Camshaft Chain

Camshaft Removal

• Remove:

Cylinder Head Cover (see Cylinder Head Cover Re-

moval)

Crankshaft Sensor Cover

• Position the crankshaft at #1, 4 piston TDC.

TDC mark [A] for #1, 4 Pistons

Timing Mark (crankcase halves mating surface) [B]

• Remove:

Camshaft Chain Tensioner (see Camshaft Chain Ten-

sioner Removal)

Camshaft Cap Bolts [A]

Chain Guide

Camshaft Caps [B]

Camshafts [C]

• Stuff a clean cloth into the chain tunnel to keep any parts

from dropping into the crankcase.

• Remove the cam sprocket mounting bolts [A].

• Remove the cam sprocket.

CAUTION

The crankshaft may be turned while the camshafts

are removed. Always pull the chain taut while turn-

ing the crankshaft. This avoids kinking the chain

on the lower (crankshaft) sprocket. A kinked chain

could damage both the chain and the sprocket.

Camshaft Installation

• Be sure to install the following parts.

Plug Hole Gaskets [A]

Dowel Pins [B]

• Install the cam sprockets as shown in figure.

#4 Cam Positions [A]

Inlet Cam Sprocket [B]

Exhaust Cam Sprocket [C]

• Apply a non-permanent locking agent to the threads and

tighten the bolts.

Torque - Cam Sprocket Mounting Bolts: 15 N·m (1.5 kgf·m,

11 ft·lb)

5-18 ENGINE TOP END

Camshaft, Camshaft Chain

• Apply engine oil to all cam parts and journals.

• If a new camshaft is to be used, apply a thin coat of molyb-

denum disulfide grease to the cam surfaces.

NOTE

○The exhaust camshaft has a 1090 EX mark [A] and the

inlet camshaft has a 1090 IN mark [B]. Be careful not to

mix up these shafts.

NOTE

○The exhaust camshaft has the projection [A] for

camshaft position sensor.

• Position the crankshaft at #1, 4 piston TDC.

• Pull the tension side (exhaust side) [A] of the chain taut

to install the chain.

• Engage the camshaft chain with the camshaft sprockets

so that the timing marks on the sprockets are positioned

as shown.

○The timing marks of #1, 4T must be aligned with the lower

surface of crankcase of rear side [B].

ENGINE TOP END 5-19

Camshaft, Camshaft Chain

○The timing marks must be aligned with the cylinder head

upper surface [A].

EX mark [B]

IN mark [C]

5-20 ENGINE TOP END

Camshaft, Camshaft Chain

• Install the camshaft cap, following the identification No.

[A] and chain guide [B].

○First tighten the camshaft cap and all chain guide bolts

evenly to seat the camshaft in place, then tighten all bolts

following the specified tightening sequence.

Torque - Camshaft Cap Bolts (1 ∼ 16, 17, 18): 12 N·m (1.2

kgf·m, 106 in·lb)

Camshaft Chain Guide Bolts (19, 20): 12 N·m (1.2

kgf·m, 106 in·lb)

• Install the camshaft chain tensioner (see Camshaft Chain

Tensioner Installation).

Camshaft, Camshaft Cap Wear

• Remove:

Camshaft Chain Guide

Camshaft Cap (see Camshaft Removal)

• Cut strips of plastigage to journal width. Place a strip

on each journal parallel to the camshaft installed in the

correct position.

• Measure each clearance between the camshaft journal

and the camshaft cap using plastigage (press gauge) [A].

• Tighten:

Torque - Camshaft Cap Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)

Camshaft Chain Guide Bolts: 12 N·m (1.2 kgf·m,

106 in·lb) (see Camshaft Installation)

NOTE

○Do not turn the camshaft when the plastigage is be-

tween the journal and camshaft cap.

Camshaft Journal, Camshaft Cap Clearance

Standard:

0.038 ∼ 0.081 mm (0.0015 ∼ 0.0032 in.)

Service Limit:

0.17 mm (0.0067 in.)

ENGINE TOP END 5-21

Camshaft, Camshaft Chain

If any clearance exceeds the service limit, measure the

diameter of each camshaft journal with a micrometer.

Camshaft Journal Diameter

Standard:

23.940 ∼ 23.962 mm (0.9425 ∼ 0.9434 in.)

Service Limit: 23.91 mm (0.941 in.)

If the camshaft journal diameter is less than the service

limit, replace the camshaft with a new one and measure

the clearance again.

If the clearance still remains out of the limit, replace the

cylinder head unit.

Camshaft Runout

• Remove the camshaft (see Camshaft Removal).

• Set the camshaft in a camshaft alignment jig or on V

blocks.

• Measure runout with a dial gauge at the specified place

as shown.

If the runout exceeds the service limit, replace the shaft.

Camshaft Runout

Standard:

TIR 0.02 mm (0.0008 in.) or less

Service Limit: TIR 0.1 mm (0.004 in.)

Cam Wear

• Remove the camshaft (see Camshaft Removal).

• Measure the height [A] of each cam with a micrometer.

If the cams are worn down past the service limit, replace

the camshaft.

Cam Height

Standard:

Exhaust

34.442 ∼ 34.556 mm (1.3560 ∼ 1.3605 in.)

Inlet

34.943 ∼ 35.057 mm (1.3757 ∼ 1.3802 in.)

Service Limit:

Exhaust

34.34 mm (1.352 in.)

Inlet

34.84 mm (1.372 in.)

Camshaft Chain Removal

• Remove:

Camshafts (see Camshaft Removal)

Timing Rotor [A] (see Timing Rotor Removal in the Elec-

trical System chapter)

Front Camshaft Chain Guide Bolts [B]

Front Camshaft Chain Guide [C]

Dowel Pin [D]

Rear Camshaft Chain Guide [E]

5-22 ENGINE TOP END

Camshaft, Camshaft Chain

• Remove the crankshaft sprocket [A].

• Pull out the camshaft chain [B] from downward.

Camshaft Chain Installation

• Install the camshaft chain from head side.

• Install the crankshaft sprocket [A] on the crankshaft [B]

with their teeth [C] aligned.

• Install the front camshaft chain guide, and tighten the

bolts.

Torque - Front Camshaft Chain Guide Bolt (Upper): 25 N·m

(2.5 kgf·m, 18 ft·lb)

Front Camshaft Chain Guide Bolt (Lower): 12 N·m

(1.2 kgf·m, 106 in·lb)

• Install the removed parts (see appropriate chapters).

ENGINE TOP END 5-23

Cylinder Head

Cylinder Compression Measurement

NOTE

○Use the battery which is fully charged.

• Warm up the engine thoroughly.

• Stop the engine.

• Remove:

Stick Coils (see Stick Coil (Ignition Coil together with

Spark Plug Cap) Removal in the Electrical System chap-

ter)

Spark Plugs (see Spark Plug Replacement in the Peri-

odic Maintenance chapter)

Owner’s Tool - Spark Plug Wrench: 92110-1132

• Attach the compression gauge [A] and adapter [B] firmly

into the spark plug hole.

○Using the starter motor, turn the engine over with the throt-

tle fully open until the compression gauge stops rising; the

compression is the highest reading obtainable.

Special Tools - Compression Gauge, 20 kgf/cm²: 57001-221

Compression Gauge Adapter, M10 × 1.0:

57001-1601

L-Shape Hose: 57001-1606 [C]

Cylinder Compression

Usable Range:

1 030 ∼ 1 569 kPa (10.5 ∼ 16.0 kgf/cm²,

149 ∼ 228 psi) @300 r/min (rpm)

• Repeat the measurement for the other cylinders.

• Install the spark plugs.

Torque - Spark Plugs: 13 N·m (1.3 kgf·m, 115 in·lb)

The following table should be consulted if the obtainable compression reading is not within the us-

able range.

Problem

Diagnosis

Remedy (Action)

Cylinder

Carbon accumulation on piston and in

Remove the carbon deposits and

compression

combustion chamber possibly due to

replace damaged parts if necessary.

is higher than

damaged valve stem oil seal and/or

usable range

damaged piston oil rings (This may be

indicated by white exhaust smoke).

Incorrect cylinder head gasket thickness

Replace the gasket with a standard part.

Cylinder

Gas leakage around cylinder head

Replace damaged check gasket and

compression

cylinder head warp.

is lower than Bad condition of valve seating

Repair if necessary.

usable range

Incorrect valve clearance

Adjust the valve clearance.

Incorrect piston/cylinder clearance

Replace the piston and/or cylinder.

Piston seizure

Inspect the cylinder and replace/repair

the cylinder and/or piston as necessary.

Bad condition of piston ring and/or piston

Replace the piston and/or the piston

ring grooves

rings.

5-24 ENGINE TOP END

Cylinder Head

Cylinder Head Removal

• Drain the coolant (see Coolant Change in the Periodic

Maintenance chapter).

• Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System

(DFI) chapter)

Throttle Body Assy (see Throttle Body Assy Removal in

the Fuel System (DFI) chapter)

Exhaust Pipe (see Exhaust Pipe Removal)

Cylinder Head Cover (see Cylinder Head Cover Re-

moval)

Camshafts (see Camshaft Removal)

Front Camshaft Chain Guide

Rear Camshaft Chain Guide

• Remove:

Front Engine Mounting Bolts [A]

Engine Bracket Mounting Bolts [B]

Engine Brackets [C]

• Remove the M6 cylinder head bolts [B], and then the M11

cylinder head bolts [A].

• Take off the cylinder head.

Cylinder Head Installation

NOTE

○The camshaft cap is machined with the cylinder head,

so if a new cylinder head is installed, use the cap that

is supplied with the new head.

• Install a new cylinder head gasket and dowel pins.

• Replace the cylinder head bolt washers with new ones.

• Apply molybdenum disulfide oil solution to both sides [A]

of the cylinder head bolt washers [B] and the thread of

head bolts [C].

ENGINE TOP END 5-25

Cylinder Head

• Tighten the M11 cylinder head bolts following the tighten-

ing sequence [1 ∼ 10].

Torque - Cylinder Head Bolts (M11):

First: 39 N·m (4.0 kgf·m, 29 ft·lb)

Final: 71 N·m (7.2 kgf·m, 52 ft·lb)

• Tighten the M6 cylinder head bolts [11 ∼ 12].

Torque - Cylinder Head Bolts (M6): 12 N·m (1.2 kgf·m, 106

in·lb)

• Install:

Dowel Pin [A]

Rear Camshaft Chain Guide [B]

Front Camshaft Chain Guide [C]

O-ring [D]

Collar [E]

• Tighten:

Torque - Front Camshaft Chain Guide Bolt (Upper) [F]: 25

N·m (2.5 kgf·m, 18 ft·lb)

Front Camshaft Chain Guide Bolt (Lower) [G]: 12

N·m (1.2 kgf·m, 106 in·lb)

• Replace the following bolts with new bolts pre-coated with

locking agent and torque them.

Engine Bracket Bolts

Front Engine Mounting Bolts

Subframe Bolts

Torque - Front Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

Front Engine Mounting Bolts: 59 N·m (6.0 kgf·m,

44 ft·lb)

Subframe Bolts: 23 N·m (2.3 kgf·m, 17 ft·lb)

• Install the removed parts (see appropriate chapters).

Cylinder Head Warp

• Clean the cylinder head.

• Lay a straightedge across the lower surface of the cylinder

head at several positions.

• Use a thickness gauge [A] to measure the space between

the straightedge [B] and the head.

Cylinder Head Warp

Standard:

- - -

Service Limit: 0.05 mm (0.002 in.)

If the cylinder head is warped more than the service limit,

replace it.

If the cylinder head is warped less than the service limit,

repair the head by rubbing the lower surface on emery

paper secured to a surface plate (first No. 200, then No.

400).

5-26 ENGINE TOP END

Valves

Valve Clearance Inspection

• Refer to the Valve Clearance Inspection in the Periodic

Maintenance chapter.

Valve Removal

• Remove the cylinder head (see Cylinder Head Removal).

• Remove the valve lifter and shim.

○Mark and record the valve lifter and shim locations so they

can be installed in their original positions.

• Using the valve spring compressor assembly, remove the

valve.

Special Tools - Valve Spring Compressor Assembly: 57001

-241 [A]

Adapter,

24: 57001-1586 [B]

Valve Installation

CAUTION

Do not lap the exhaust valve to the exhaust valve

seat, using the grinding compound. It will come off

oxide film treated surface of the valve.

• Replace the oil seal with a new one.

• Apply a thin coat of molybdenum disulfide grease to the

valve stem before valve installation.

• Install the springs so that the closed coil end faces down-

wards.

Valve Stem [A]

Oil Seal [B]

Spring Seat [C]

Closed Coil End [D]

Valve Spring [E]:

EX-White Paint

IN-Red Paint

Retainer [F]

Split Keepers [G]

Valve Guide Removal

• Remove:

Valve (see Valve Removal)

Oil Seal

Spring Seat

• Heat the area around the valve guide to 120 ∼ 150°C (248

∼ 302°F), and hammer lightly on the valve guide arbor [A]

to remove the guide from the top of the head.

CAUTION

Do not heat the cylinder head with a torch. This will

warp the cylinder head. Soak the cylinder head in

oil and heat the oil.

Special Tool - Valve Guide Arbor,

5: 57001-1203

ENGINE TOP END 5-27

Valves

Valve Guide Installation

• Apply oil to the valve guide outer surface before installa-

tion.

• Heat the area around the valve guide hole to about 120 ∼

150°C (248 ∼ 302°F).

CAUTION

Do not heat the cylinder head with a torch. This Will

warp the cylinder head. Soak the cylinder head and

heat the oil.

• Assembly the valve guide driver parts (Holder and attach-

ment E).

• Insert the rod of the driver into the valve guide bore and

hammer the end of the driver until it bottoms.

Valve Guide Driver Attachment E [A]

Valve Guide Driver (Holder) [B]

Valve Guide [C]

Cylinder Head [D]

Valve Guide Installed Height = 13 mm [E]

Special Tools - Valve Guide Driver: 57001-1564

Valve Guide Driver Attachment, E: 57001

-1677

• Ream the valve guide with valve guide reamer [A], even

if the old guide is reused.

Special Tool - Valve Guide Reamer,

5: 57001-1204

5-28 ENGINE TOP END

Valves

Valve-to-Guide Clearance Measurement (Wobble

Method)

If a small bore gauge is not available, inspect the valve

guide wear by measuring the valve to valve guide clearance

with the wobble method as indicated below.

• Insert a new valve [A] into the guide [B] and set a dial

gauge against the stem perpendicular to it as close as

possible to the cylinder head mating surface.

• Move the stem back and forth [C] to measure valve/valve

guide clearance.

• Repeat the measurement in a direction at a right angle to

the first.

If the reading exceeds the service limit, replace the guide.

NOTE

○The reading is not actual valve/valve guide clearance

because the measuring point is above the guide.

Valve/Valve Guide Clearance (Wobble Method)

Standard:

Exhaust

0.10 ∼ 0.18 mm (0.0039 ∼ 0.0071 in.)

Inlet

0.03 ∼ 0.12 mm (0.0012 ∼ 0.0047 in.)

Service Limit:

Exhaust

0.39 mm (0.015 in.)

Inlet

0.33 mm (0.013 in.)

ENGINE TOP END 5-29

Valves

Valve Seat Inspection

• Remove the valve (see Valve Removal).

• Check the valve seating surface [A] between the valve [B]

and valve seat [C].

○Measure the outside diameter [D] of the seating pattern

on the valve seat.

If the outside diameter is too large or too small, repair the

seat (see Seat Repair).

Valve Seating Surface Outside Diameter

Standard:

Exhaust

27.6 ∼ 27.8 mm (1.087 ∼ 1.094 in.)

Inlet

32.6 ∼ 32.8 mm (1.283 ∼ 1.291 in.)

○Measure the seat width [E] of the portion where there is

no build-up carbon (white portion) of the valve seat with a

vernier caliper.

Good [F]

If the width is too wide [G], too narrow [H] or uneven [J],

repair the seat (see Valve Seat Repair).

Valve Seating Surface Width

Standard:

Exhaust

0.8 ∼ 1.2 mm (0.031 ∼ 0.047 in.)

Inlet

0.5 ∼ 1.0 mm (0.020 ∼ 0.039 in.)

Valve Seat Repair

• Repair the valve seat with the valve seat cutters [A].

Special Tools - Valve Seat Cutter Holder,

5:

57001-1208

[B]

Valve Seat Cutter Holder Bar: 57001-1128

[C]

For Exhaust Valve Seat

Valve Seat Cutter, 45° -

30: 57001-1187

Valve Seat Cutter, 32° -

30: 57001-1120

Valve Seat Cutter, 60° -

30: 57001-1123

For Inlet Valve Seat

Valve Seat Cutter, 45° -

35: 57001-1116

Valve Seat Cutter, 32° -

35: 57001-1121

Valve Seat Cutter, 60° -

33: 57001-1334

If the manufacturer’s instructions are not available, use

the following procedure.

5-30 ENGINE TOP END

Valves

Seat Cutter Operation Care

1. This valve seat cutter is developed to grind the valve for

repair. Therefore the cutter must not be used for other

purposes than seat repair.

2. Do not drop or shock the valve seat cutter, or the dia-

mond particles may fall off.

3. Do not fail to apply engine oil to the valve seat cutter

before grinding the seat surface. Also wash off ground

particles sticking to the cutter with washing oil.

NOTE

○Do not use a wire brush to remove the metal particles

from the cutter. It will take off the diamond particles.

4. Setting the valve seat cutter holder in position, operate

the cutter in one hand. Do not apply too much force to

the diamond portion.

NOTE

○Prior to grinding, apply engine oil to the cutter and dur-

ing the operation, wash off any ground particles sticking

to the cutter with washing oil.

5. After use, wash it with washing oil and apply thin layer

of engine oil before storing.

Marks Stamped on the Cutter

The marks stamped on the back of the cutter [A] represent

the following.

60°

Cutter angle [B]

37.5

Outer diameter of cutter [C]

Operating Procedures

• Clean the seat area carefully.

• Coat the seat with machinist’s dye.

• Fit a 45° cutter into the holder and slide it into the valve

guide.

• Press down lightly on the handle and turn it right or left.

Grind the seating surface only until it is smooth.

CAUTION

Do not grind the seat too much. Overgrinding will

reduce valve clearance by sinking the valve into the

head. If the valve sinks too far into the head, it will

be impossible to adjust the clearance, and the cylin-

der head must be replaced.

ENGINE TOP END 5-31

Valves

• Measure the outside diameter of the seating surface with

a vernier caliper.

If the outside diameter of the seating surface is too small,

repeat the 45° grind until the diameter is within the spec-

ified range.

Widened Width [A] of engagement by machining with

45° cutter

Ground Volume [B] by 32° cutter

32° [C]

Correct Width [D]

Ground Volume [E] by 60° cutter

60° [F]

• Measure the outside diameter of the seating surface with

a vernier caliper.

If the outside diameter of the seating surface is too small,

repeat the 45° grind [A] until the diameter is within the

specified range.

Original Seating Surface [B]

NOTE

○Remove all pittings of flaws from 45° ground surface.

○After grinding with 45° cutter, apply thin coat of machin-

ist’s dye to seating surface. This makes seating surface

distinct and 32° and 60° grinding operation easier.

○When the valve guide is replaced, be sure to grind with

45° cutter for centering and good contact.

If the outside diameter [A] of the seating surface is too

large, make the 32° grind described below.

If the outside diameter of the seating surface is within the

specified range, measure the seat width as described be-

low.

• Grind the seat at a 32° angle [B] until the seat O.D. is

within the specified range.

○To make the 32° grind, fit a 32° cutter into the holder, and

slide it into the valve guide.

○Turn the holder one turn at a time while pressing down

very lightly. Check the seat after each turn.

CAUTION

The 32° cutter removes material very quickly.

Check the seat outside diameter frequently to pre-

vent overgrinding.

○After making the 32° grind, return to the seat O.D. mea-

surement step above.

• To measure the seat width, use a vernier caliper to mea-

sure the width of the 45° angle portion of the seat at sev-

eral places around the seat.

If the seat width is too narrow, repeat the 45° grind until

the seat is slightly too wide, and then return to the seat

O.D. measurement step above.

5-32 ENGINE TOP END

Valves

If the seat width is too wide, make the 60° [A] grind de-

scribed below.

If the seat width is within the specified range, lap the valve

to the seat as described below.

• Grind the seat at a 60° angle until the seat width is within

the specified range.

○To make the 60° grind, fit 60° cutter into the holder, and

slide it into the valve guide.

○Turn the holder, while pressing down lightly.

○After making the 60° grind, return to the seat width mea-

surement step above.

Correct Width [B]

CAUTION

Do not lap the exhaust valve to the exhaust valve

seat, using the grinding compound. It will come off

oxide film treated surface of the valve.

• Lap the inlet valve to the inlet valve seat, once the seat

width and O.D. are within the ranges specified above.

○Put a little coarse grinding compound on the face of the

valve in a number of places around the valve head.

○Spin the valve against the seat until the grinding com-

pound produces a smooth, matched surface on both the

seat and the valve.

○Repeat the process with a fine grinding compound.

Lapper [A]

Valve Seat [B]

Valve [C]

• The seating area should be marked about in the middle

of the valve face.

If the seat area is not in the right place on the valve, check

to be sure the valve is the correct part. If it is, it may have

been refaced too much; replace it.

• Be sure to remove all grinding compound before assem-

bly.

• When the engine is assembled, be sure to adjust the valve

clearance (see Valve Clearance Inspection in the Periodic

Maintenance chapter).

ENGINE TOP END 5-33

Valves

5-34 ENGINE TOP END

Throttle Body Holder

Throttle Body Holder Installation

• Be sure to install the O-rings [A].

• Install the clamps [B] as shown.

• Tighten the holder bolts following the tightening sequence

[1 ∼ 3].

Torque - Throttle Body Holder Bolts [C]: 9.8 N·m (1.0 kgf·m,

87 in·lb)

Throttle Body Assy Holder Clamp Bolts [D]: 2.0

N·m (0.20 kgf·m, 18 in·lb)

ENGINE TOP END 5-35

Muffler

WARNING

To avoid a serious burn, do not remove the muffler

when the engine is still hot. Wait until the muffler

cool down.

Muffler Body Removal/Installation

• Remove:

Lower Fairings (see Lower Fairing Removal in the Frame

chapter)

Rear Fairing (see Rear Fairing Removal in the Frame

chapter)

Muffler Clamp Bolts [A]

Muffler Mounting Bolts and Nuts [B]

• Pull the muffler body [C] backward.

• Replace the muffler gaskets [A] with new ones.

○Install the gaskets until they are bottomed [B].

○Install the gaskets so that their chamfer sides [C] face the

front.

5-36 ENGINE TOP END

Muffler

• Align [A] the projections on the muffler bodies with the

hoses on the muffler clamps.

• Tighten:

Torque - Muffler Body Mounting Bolts: 34 N·m (3.5 kgf·m,

25 ft·lb)

Exhaust Pipe Removal

• Remove:

Radiator (see Radiator Removal in the Cooling System

chapter)

Right and Left Muffler Body (see Muffler Body Re-

moval/Installation)

• Remove the exhaust pipe manifold holder nuts [A].

• Remove the exhaust pipe manifold [B].

Exhaust Pipe Installation

• Replace the exhaust pipe gaskets [A], muffler gasket with

new ones and install them.

○Install the muffler gasket until it is bottomed so that the

chamfer side faces front (see Muffler Body Removal/In-

stallation).

• Tighten:

Torque - Muffler Body Mounting Bolts: 34 N·m (3.5 kgf·m,

25 ft·lb)

6-2 CLUTCH

Exploded View

CLUTCH 6-3

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Clutch Lever Pivot Bolt

1.0

0.10

8.9 in·lb

2

Clutch Lever Pivot Bolt Locknut

5.9

0.60

52 in·lb

3

Clutch Master Cylinder Bleed Valve

7.8

0.80

69 in·lb

4

Clutch Slave Cylinder Bleed Valve

7.8

0.80

69 in·lb

5

Clutch Slave Cylinder Bolts

-

-

-

L

6

Clutch Hose Banjo Bolt

25

2.5

18

7

Clutch Master Cylinder Clamp Bolts

8.8

0.90

78 in·lb

S

8

Clutch Cover Bolts

9.8

1.0

87 in·lb

L (1)

9

Clutch Spring Bolts

8.8

0.9

78 in·lb

10

Clutch Hub Nut

135

14

100

R

11

Oil Filler Cap

-

-

-

Hand-tighten

C: Apply clutch fluid.

EO: Apply engine oil.

L: Apply a non-permanent locking agent.

M: Apply molybdenum disulfide grease.

R: Replacement Parts

S: Follow the specific tightening sequence.

Si: Apply silicone grease.

CLUTCH 6-5

Special Tools and Sealant

Inside Circlip Pliers:

Clutch Gear Setting Screw:

57001-143

57001-1671

Clutch Holder:

Kawasaki Bond (Silicone Sealant):

57001-1243

92104-0004

6-6 CLUTCH

Clutch Master Cylinder

Clutch Lever Adjustment

○The adjuster has 5 positions so that the clutch lever posi-

tion can be adjusted to suit the operator’s hand.

• Push the lever forward and turn the adjuster [A] to align

the number with the triangular mark [B] on the lever holder

(front view).

○The distance from the grip to the lever is minimum at Num-

ber 5 and maximum at Number 1.

Clutch Master Cylinder Removal

• Disconnect the starter lockout switch connector [A] (rear

view).

• Drain the clutch fluid from the reservoir (see Clutch Fluid

Change in the Periodic Maintenance chapter).

• Remove:

Bracket Bolt [A]

Clutch Reservoir Bolt [B]

• Remove the banjo bolt [C] to disconnect the clutch hose

from the master cylinder (rear view).

• Unscrew the clamp bolts [D], and take off the master cylin-

der as an assembly with the clutch reservoir, clutch lever,

and starter lockout switch installed.

CAUTION

Clutch fluid quickly ruins painted surface; any

spilled fluid should be completely washed away

immediately.

Clutch Master Cylinder Installation

• Align the punch mark [A] on the handlebar with the mating

surface [B] of the master cylinder clamp (left view).

Front [C]

CLUTCH 6-7

Clutch Master Cylinder

• Install the master cylinder clamp with the triangular mark

[A] up.

• Tighten the upper clamp bolt [B] first, and then the lower

clamp bolt [C]. There will be a gap at the lower part of the

clamp after tightening.

Torque - Clutch Master Cylinder Clamp Bolts: 8.8 N·m (0.90

kgf·m, 78 in·lb)

• Use a new flat washer on each side of the clutch hose

fitting.

Torque - Clutch Hose Banjo Bolt:

25 N·m (2.5 kgf·m, 18

ft·lb)

• Replenish the clutch fluid into the reservoir and bleed the

clutch line (See Bleeding the Clutch Line in this chapter).

• Check that the clutch line has proper fluid pressure and

no fluid leakage.

Clutch Master Cylinder Disassembly

• Refer to the Clutch Master Cylinder Cap and Dust Seal

Replacement in the Periodic Maintenance chapter.

Clutch Master Cylinder Assembly

• Refer to the Clutch Master Cylinder Cap and Dust Seal

Replacement in the Periodic Maintenance chapter.

Clutch Master Cylinder Inspection

• Disassemble the clutch master cylinder (see Clutch Mas-

ter Cylinder Cap and Dust Seal Replacement in the Peri-

odic Maintenance chapter).

Special Tool - Inside Circlip Pliers: 57001-143

• Check that there are no scratches, rust or pitting on the

inside of the master cylinder [A] and on the outside of the

piston [B].

If the master cylinder or piston shows any damage, re-

place them.

• Inspect the primary cup [C] and secondary cup [D].

If a cup is worn, damaged, softened (rotted), or swollen,

the piston assembly should be replaced to renew the cup.

• If fluid leakage is noted at the clutch lever, the piston as-

sembly should be replaced to renew the cup.

• Check the dust cover [E] for damage.

• If it is damaged, replace the piston assembly.

• Check that the relief [F] and supply [G] ports are not

plugged.

If the small relief port becomes plugged, the clutch will

drag. Blow the ports clean with compressed air.

• Check the piston return spring [H] for any damage.

If the spring is damaged, replace it.

6-8 CLUTCH

Clutch Slave Cylinder

Clutch Slave Cylinder Removal

• Remove:

Left Lower Fairing (see Lower Fairing Removal Frame

chapter)

Left Middle Fairing (see Middle Fairing Removal in the

Frame chapter)

Banjo Bolt [A]

Clutch Slave Cylinder Bolts [B]

Slave Cylinder [C]

CAUTION

Immediately wash away any clutch fluid that spills.

It may damage painted surfaces.

• Pull off the clutch pipe [A] by prying the dampers [B] out

of the grooves of the frame. This prevents the pipe from

distorting.

• Perform the following if the clutch slave cylinder is to be

removed but not disassembled.

CAUTION

If the clutch slave cylinder is removed and left

alone, the piston will be pushed out by spring force

and the clutch fluid will drain out.

○Remove the clutch slave cylinder from the engine with the

pipe installed. Push [A] the piston into the cylinder as far

as it will go.

○Apply the clutch lever [A] slowly and hold it with a band

[B].

NOTE

○Holding the clutch lever keeps the piston from coming

out.

CLUTCH 6-9

Clutch Slave Cylinder

Clutch Slave Cylinder Installation

• Apply molybdenum disulfide grease to either end [A] of

the push rod, and install the push rod so that the greased

end faces in.

• Replace the spacer [B] of the clutch slave cylinder with a

new one.

• Install the spacer so that the stepped side [C] faces out-

ward.

• Apply a non-permanent locking agent to the threads of

the slave cylinder bolts [A].

• Finger tighten all the clutch slave cylinder bolts.

• Remove the band from the clutch lever and release the

clutch lever.

• Tighten the slave cylinder bolts.

• Replace the washer on each side of the clutch hose fitting

with new one.

• Tighten the banjo bolt [B] to the specified torque.

Torque - Clutch Pipe Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

• Check the fluid level in the master cylinder reservoir, and

bleed the air in the clutch line.

• Check the clutch operation.

• Install the removed parts.

Coolant Reserve Tank

Left Lower Fairing (see Lower Fairing Installation in the

Frame chapter)

Clutch Slave Cylinder Disassembly

• Refer to Rubber Parts of Clutch Master Cylinder/Slave

Cylinder Replacement in the Periodic Maintenance chap-

ter.

Clutch Slave Cylinder Assembly

• Refer to Rubber Parts of Clutch Master Cylinder/Slave

Cylinder Replacement in the Periodic Maintenance chap-

ter.

6-10 CLUTCH

Clutch Fluid

Clutch Fluid Level Inspection

• Refer to the Clutch Fluid Level Inspection in the Periodic

Maintenance chapter.

Clutch Fluid Change

• Refer to the Clutch Fluid Change in the Periodic Mainte-

nance chapter.

Bleeding the Clutch Line

WARNING

Be sure to bleed the air from the clutch line when-

ever clutch lever action feels soft or spongy after

the clutch fluid is changed, or whenever a clutch

line fitting has been loosened for any reason.

CAUTION

Clutch fluid quickly ruins painted or plastic sur-

faces; any spilled fluid should be completely wiped

up immediately with wet cloth.

• Remove:

Screw [A]

Clamp [B]

Clutch Reservoir Cap [C]

Diaphragm Plate

Diaphragm

• Fill the reservoir with fresh clutch fluid to the upper level

line in the reservoir.

NOTE

○Tap the clutch hose lightly going from the lower end to

upper end and bleed the air off the reservoir.

• With the reservoir cap off, slowly pump the clutch lever

several times until no air bubbles can be seen rising up

through the fluid from the holes at the bottom of the reser-

voir.

○Bleed the air completely from the master cylinder by this

operation.

• Remove the rubber cap from the bleed valve on the mas-

ter cylinder.

• Attach a clear plastic hose [A] to the bleed valve, and run

the other end of the hose into a container.

CLUTCH 6-11

Clutch Fluid

• Bleed the clutch line and the master cylinder.

○Repeat this operation until no more air can be seen com-

ing out into the plastic hose.

1. Pump the clutch lever until it becomes hard, and apply

the clutch lever and hold it [C].

2. Quickly open and close [B] the bleed valve while hold-

ing the clutch lever applied.

3. Release the clutch lever [A].

NOTE

○The fluid level must be checked often during the bleed-

ing operation and replenished with fresh clutch fluid as

necessary. If the fluid in the reservoir runs completely

out any time during bleeding, the bleeding operation

must be done over again from the beginning since air

will have entered the line.

• Remove the clear plastic hose.

• Tighten the bleed valve, and install the rubber cap.

Torque - Clutch Master Cylinder Bleed Valve: 7.8 N·m (0.80

kgf·m, 69 in·lb)

• Remove the left lower fairing (see Lower Fairing Removal

in the Frame chapter).

• Remove the rubber cap from the bleed valve.

• Attach a clear plastic hose [A] to the bleed valve on the

clutch slave cylinder, and run the other end of the hose

into a container.

• Bleed the clutch line as follows:

○Repeat this operation until no more air can be seen com-

ing out into the plastic hose.

1. Pump the clutch lever a few times until it becomes hard

and then hold it applied [D].

2. Quickly open and close [C] the bleed valve.

3. Release the clutch lever [B].

NOTE

○Check the fluid level in the reservoir often, replenishing

it as necessary.

○If the fluid in the reservoir runs completely out any time

during bleeding, the bleeding operation must be done

over again from the beginning since air will have en-

tered the line.

WARNING

Do not mix different grades and brands of fluid.

• Remove the clear plastic hose.

Torque - Clutch Slave Cylinder Bleed Valve: 7.8 N·m (0.80

kgf·m, 69 in·lb)

Clutch Hose Removal/Installation

• Refer to the Clutch Hose and Pipe Replacement in the

Periodic Maintenance chapter.

Clutch Hose and Connection Inspection

• Refer to the Clutch Hose Damage and Installation Con-

nection Inspection in the Periodic Maintenance chapter.

6-12 CLUTCH

Clutch Cover

Clutch Cover Removal

• Remove:

Engine Oil (Drain, see Engine Oil Change in the Periodic

Maintenance chapter)

Right Lower Fairing (see Lower Fairing Removal in the

Frame chapter)

Clutch Cover Bolts [A]

Clutch Cover [B]

Clutch Cover Installation

• Apply silicone sealant to the area [A] where the mating

surface of the crankcase touches the clutch cover gasket.

Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004

• Replace the clutch cover gasket with a new one.

• Tighten the clutch cover mounting bolts.

○Apply a non-permanent locking agent to only one clutch

cover mounting bolt [A] shown in figure.

Torque - Clutch Cover Mounting Bolts: 9.8 N·m (1.0 kgf·m,

87 in·lb)

• If the oil gauge [A] is removed, press the gauge so that its

projection [B] faces the inside, using lubricant.

CLUTCH 6-13

Clutch

Clutch Removal

• Remove:

Right Lower Fairing (see Lower Fairing Removal in the

Frame chapter)

Clutch Cover (see Clutch Cover Removal)

Clutch Spring Bolts [A]

Clutch Springs

Clutch Spring Plate [B] (with thrust bearing, pusher [C]

and washer)

• Remove:

Friction Plates [A]

Steel Plates

Spring

Spring Seat

○Holding the clutch hub [A], remove the nut [B] and wash-

ers [C]

Special Tool - Clutch Holder: 57001-1243 [D]

• Remove:

Clutch Hub

Washer

• Insert the clutch gear setting screw to the hole of the

clutch housing (see Clutch Installation).

○Position the hole of the clutch housing at the front side of

the engine so that the tip of the gear setting does not hit

the crankcase wall.

○Align the teeth of the clutch housing gears by the gear

setting.

Special Tool - Clutch Gear Setting Screw: 57001-1671

• Pull out the sleeve [B] from the clutch housing [D], and

remove the housing.

○If the sleeve does not pull out easily, insert M4 bolts [A]

into the threaded hole of the sleeve, and pull out the

sleeve and needle bearing [C].

• Remove the thrust washer.

6-14 CLUTCH

Clutch

Clutch Installation

• Install the thrust washer [A] by facing its chamfered side

[B] towards the crankcase.

• Align the teeth of the clutch housing gears by the gear

setting screw [A].

○Install the clutch housing so that the hole position forward

of the engine.

Special Tool - Clutch Gear Setting Screw: 57001-1671

• Install:

Clutch Housing

Needle Bearing

Sleeve

Washer [A]

○Apply engine oil to the needle bearing and the sleeve be-

fore installation.

• Install the clutch hub and two washers [A].

○The outside washer has the OUT SIDE mark [B].

• Replace the clutch hub nut with a new one.

• Holding the clutch hub, tighten the clutch hub nut with the

torque wrench.

Special Tool - Clutch Holder: 57001-1243

Torque - Clutch Hub Nut: 135 N·m (14 kgf·m, 100 ft·lb)

CLUTCH 6-15

Clutch

• Install the spring seat [A], spring [B], friction plates [C] [D]

[E] and steel plates [F] as shown.

NOTE

○The inside diameter of first friction plates are larger

than the others because the spring seat and spring are

equipped to decrease the judder noise as shown.

Clutch Hub [G]

CAUTION

If new dry friction plates and steel plates are in-

stalled, apply engine oil to the surfaces of each

plate to avoid clutch plate seizure.

○Install outer-end friction plate, that has the large lining

blocks [A] among others.

○Install the last friction plate [A] fitting the tangs in the

grooves in the housing as shown.

• Apply molybdenum disulfide grease [M] to the outside sur-

face of the pusher [A], then install the pusher into the drive

shaft.

• Install the spring, and tighten the clutch spring bolts

evenly.

Torque - Clutch Spring Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

• Install the clutch cover (see Clutch Cover Installation).

6-16 CLUTCH

Clutch

Clutch Plate Assembly Inspection

• Inspect the friction plate thickness (see Clutch Plate,

Wear, Damage Inspection).

• Measure the length [A] of the clutch plate assembly as

shown.

○Assemble:

Clutch Hub [B]

Spring Seat [C]

Spring [D]

Friction Plates [E] [F] [G]

Steel Plates [H]

Spring Plate [J]

Springs [K]

Spring Bolts [L]

Torque - Clutch Spring Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

Clutch Plate Assembly Length

Standard:

53.52 ∼ 54.52 mm (2.11 ∼ 2.15 in.)

If the length is not within the specified range, adjust the

length (see Clutch Plate Assembly Adjustment).

Clutch Plate Assembly Adjustment

• Inspect the clutch plate assembly length, and then re-

place the steel plate(s) which brings the length within the

specified range.

○Remove:

Spring Bolts

Springs

Spring Plate

Clutch Plates

○Replace the following steel plate(s).

Part No.

Thickness

13089-0019

2.3 mm (0.091 in.)

13089-0018

2.6 mm (0.102 in.) (STD)

13089-0020

2.9 mm (0.114 in.)

NOTE

○Do not use the steel plate of 2.9 mm (0.114 in.) and 2.3

mm (0.091 in.) thickness at the same time.

• Install the removed parts, and inspect the clutch plate as-

sembly length.

Torque - Clutch Spring Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

CLUTCH 6-17

Clutch

Clutch Plate, Wear, Damage Inspection

• Visually inspect the friction and steel plates for signs of

seizure, overheating (discoloration), or uneven wear.

• Measure the thickness of each friction plate [A] at several

points.

If any plates show signs of damage, or if they have worn

past the service limit, replace them with new ones.

Friction Plate Thickness (13088-0030, 13088-0031)

Standard:

2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.)

Service Limit:

2.7 mm (0.106 in.)

Friction Plate Thickness (13088-0032)

Standard:

3.72 ∼ 3.88 mm (0.146 ∼ 0.153 in.)

Service Limit:

3.5 mm (0.138 in.)

Clutch Plate Warp Inspection

• Place each friction plate or steel plate on a surface plate

and measure the gap between the surface plate [A] and

each friction plate or steel plate [B] with a thickness gauge

[C]. The gap is the amount of friction or steel plate warp.

If any plate is warped over the service limit, replace it with

a new one.

Friction and Steel Plate Warp

Standard:

0.15 mm (0.0059 in.) or less

Service Limit:

0.3 mm (0.012 in.)

Friction Plate Warp (only 13088-0030)

Standard:

0.2 mm (0.008 in.) or less

Service Limit:

0.3 mm (0.012 in.)

Clutch Spring Free Length Measurement

• Measure the free length of the clutch springs [A].

If any spring is shorter than the service limit, it must be

replaced.

Clutch Spring Free Length

Standard:

65.0 mm (2.56 in.)

Service Limit:

62.0 mm (2.44 in.)

7-2 ENGINE LUBRICATION SYSTEM

Exploded View

ENGINE LUBRICATION SYSTEM 7-3

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Engine Oil Drain Bolt

30

3.0

22

2

Oil Filter

31

3.2

23

G, R

3

Holder Mounting Bolt

35

3.6

26

L

4

Oil Pan Bolts

9.8

1.0

87 in·lb

5

Oil Pressure Relief Valve

15

1.5

11

L

6

Oil Pressure Switch

15

1.5

11

SS

7

Oil Pressure Switch Terminal Bolt

1.5

0.15

13 in·lb

G

8

Oil Passage Plug

20

2.0

15

L

9

Oil Pump Cover Bolts

9.8

1.0

87 in·lb

10

Oil Cooler Mounting Bolts

12

1.2

106 in·lb

S

11

Oil Pan Plate Bolts

9.8

1.0

87 in·lb

L

EO: Apply engine oil.

G: Apply grease.

L: Apply a non-permanent locking agent.

MO: Apply molybdenum disulfide oil.

(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)

R: Replacement Parts

SS: Apply silicone sealant (Kawasaki Bond: 56019-120).

7-4 ENGINE LUBRICATION SYSTEM

Engine Oil Flow Chart

ENGINE LUBRICATION SYSTEM 7-5

Engine Oil Flow Chart

ENGINE LUBRICATION SYSTEM 7-7

Special Tools and Sealant

Oil Pressure Gauge, 10 kgf/cm²:

Oil Filter Wrench:

57001-164

57001-1249

Oil Pressure Gauge Adapter, PT3/8 × 19/in.:

Kawasaki Bond (Silicone Sealant):

57001-1233

56019-120

7-8 ENGINE LUBRICATION SYSTEM

Engine Oil and Oil Filter

WARNING

Motorcycle operation with insufficient, deteri-

orated, or contaminated engine oil will cause

accelerated wear and may result in engine or trans-

mission seizure, accident, and injury.

Oil Level Inspection

• Check that the engine oil level is between the upper [A]

and lower [B] levels in the gauge.

NOTE

○Situate the motorcycle so that it is perpendicular to the

ground.

○If the motorcycle has just been used, wait several min-

utes for all the oil to drain down.

○If the oil has just been changed, start the engine and

run it for several minutes at idle speed. This fills the oil

filter with oil. Stop the engine, then wait several minutes

until the oil settles.

CAUTION

Racing the engine before the oil reaches every part

can cause engine seizure.

If the engine oil gets extremely low or if the oil pump

or oil passages clog up or otherwise do not function

properly, the oil pressure warning light will light. If

this light stays on when the engine is running above

idle speed, stop the engine immediately and find the

cause.

Engine Oil Change

• Refer to the Engine Oil Change in the Periodic Mainte-

nance chapter.

Oil Filter Replacement

• Refer to the Oil Filter Replacement in the Periodic Main-

tenance chapter.

ENGINE LUBRICATION SYSTEM 7-9

Oil Pan

Oil Pan Removal

• Remove:

Engine Oil (Drain, see Engine Oil Change in the Periodic

Maintenance chapter)

Muffler Bodies (see Muffler Body Removal/Installation in

the Engine Top End chapter)

Exhaust Pipe (see Exhaust Pipe Removal in the Engine

Top End chapter)

• Disconnect the oil pressure switch terminal [A].

• Remove the oil filter [B] (see Oil Filter Replacement in the

Periodic Maintenance chapter).

• Remove:

Oil Pan Bolts [A]

Oil Pan [B]

• Remove:

Oil Screen [A]

Oil Pipe [B]

Oil Pressure Relief Valve [C] (if necessary)

CAUTION

Do not remove the relief valve with the oil pipe in-

stalled on the lower crankcase half. The oil pipe will

be damaged.

Oil Pan Installation

• Clean the oil screen [A].

• Install the oil screen so that the crankcase rib [B] fits the

notch [C] of oil screen.

• Apply grease the oil pipe O-rings and install the oil pipe.

If the oil pressure relief valve was removed, install it.

○Apply a non-permanent locking agent to the threads of

the oil pressure relief valve, and tighten it.

CAUTION

Do not apply too much non-permanent locking

agent to the threads. This may block the oil pas-

sage.

Torque - Oil Pressure Relief Valve: 15 N·m (1.5 kgf·m, 11

ft·lb)

7-10 ENGINE LUBRICATION SYSTEM

Oil Pan

• Put new O-ring [A] on the lower crankcase [B] as shown.

Oil Pipe [C]

• Install the brackets [A] as shown.

• Replace the oil pan gasket [B] with a new one.

• Tighten:

Torque - Oil Pan Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

ENGINE LUBRICATION SYSTEM 7-11

Oil Pressure Relief Valve

Oil Pressure Relief Valve Removal

• See Oil Pan Removal.

Oil Pressure Relief Valve Installation

• See Oil Pan Installation.

Oil Pressure Relief Valve Inspection

• Check to see if the valve [A] slides smoothly when push-

ing it in with a wooden or other soft rod, and see if it comes

back to its seat by spring [B] pressure.

NOTE

○Inspect the valve in its assembled state. Disassembly

and assembly may change the valve performance.

If any rough spots are found during above inspection,

wash the valve clean with a high-flash point solvent and

blow out any foreign particles that may be in the valve with

compressed air.

WARNING

Clean the oil pressure relief valve in a well

-ventilated area, and take care that there is no

spark or flame anywhere near the working area.

Because of the danger of highly flammable liquids,

do not use gasoline or low-flash point solvent.

If cleaning does not solve the problem, replace the oil

pressure relief valve as an assembly. The oil pressure

relief valve is precision made with no allowance for re-

placement of individual parts.

7-12 ENGINE LUBRICATION SYSTEM

Oil Pump

Oil Pump Removal

• Drain:

Coolant (see Coolant Change in the Periodic Mainte-

nance chapter)

Engine Oil (see Engine Oil Change in the Periodic Main-

tenance chapter)

• Remove:

Clutch (see Clutch Removal in the Clutch chapter)

• Remove the oil pump cover bolts [A].

• Remove the oil pump cover [B] with oil pump shaft.

• Remove the outer rotor and inner rotor.

Oil Pump Installation

• Apply molybdenum disulfide oil solution to the journal por-

tions [A] on the oil pump drive gear shaft [B].

• Insert the outer rotor [A] the dowel pin [B] into the

crankcase.

• Insert the pump cover [A], washer [B], pin [C] and inner

rotor [D] to the oil pump shaft [E].

ENGINE LUBRICATION SYSTEM 7-13

Oil Pump

• Install the oil pump shaft with inner rotor.

○Turn the pump shaft [A] so that the projection [B] in its

shaft fits onto the slot [C] of the water pump shaft [D].

○Fit the pin of the oil pump cover into the hole in the

crankcase. (in the photo, the oil pan have been removed

for clarity)

• Tighten:

Torque - Oil Pump Cover Bolts [A]: 9.8 N·m (1.0 kgf·m, 87

in·lb)

7-14 ENGINE LUBRICATION SYSTEM

Oil Cooler

Oil Cooler Removal

• Remove:

Lower Fairings (see Lower Fairing Removal in the Frame

chapter)

• Drain:

Coolant (see Coolant Change in the Periodic Mainte-

nance chapter)

Engine Oil (see Engine Oil Change in the Periodic Main-

tenance chapter)

• Remove the water hoses from the oil cooler.

• Unscrew the oil cooler mounting bolts [A], and remove the

oil cooler [B].

Oil Cooler Installation

• Apply grease to new O-ring [A] before installation.

• Install the oil cooler to the oil cooler case, and tighten the

bolts, following the specified tightening sequence [1 ∼ 4].

Torque - Oil Cooler Mounting Bolts [B]: 12 N·m (1.2 kgf·m,

106 in·lb)

• Install the water hoses as shown.

White Mark [A]

• Tighten:

Torque - Water Hose Clamp Screws: 2.0 N·m (0.20 kgf·m,

18 in·lb)

• Pour:

Engine Oil (see Engine Oil Change in the Periodic Main-

tenance chapter)

Coolant (see Coolant Change in the Periodic Mainte-

nance chapter)

ENGINE LUBRICATION SYSTEM 7-15

Oil Pressure Measurement

Oil Pressure Measurement

• Remove the left lower fairing (see Lower Fairing Removal

in the Frame chapter).

• Remove the oil passage plug, and attach the adapter [A]

and gauge [B] to the plug hole.

Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164

Oil Pressure Gauge Adapter, PT3/8 × 19/in.:

57001-1233

• Start the engine and warm up the engine.

• Run the engine at the specified speed, and read the oil

pressure gauge.

If the oil pressure is much lower than the standard, check

the oil pump, relief valve, and/or crankshaft bearing insert

wear immediately.

If the reading is much higher than the standard, check the

oil passages for clogging.

Oil Pressure

Standard:

245 ∼ 343 kPa (2.5 ∼ 3.5 kgf/cm², 36 ∼ 50

psi) @ 4 000 r/min (rpm), oil temperature

90°C (194°F)

• Stop the engine.

• Remove the oil pressure gauge and adapter.

WARNING

Take care against burns form hot engine oil that

will drain through the oil passage when the gauge

adapter is removed.

• Apply a non-permanent locking agent to the oil passage

plug, and install it.

Torque - Oil Passage Plug: 20 N·m (2.0 kgf·m, 15 ft·lb)

7-16 ENGINE LUBRICATION SYSTEM

Oil Pressure Switch

Oil Pressure Switch Removal

• Remove:

Engine Oil (Drain, see Engine Oil Change in the Periodic

Maintenance chapter)

Left Lower Fairing (see Lower Fairing Removal in the

Frame chapter)

Switch Cover [A]

Switch Terminal [B]

Oil Pressure Switch [C]

Oil Pressure Switch Installation

• Apply silicone sealant to the threads of the oil pressure

switch and tighten it.

Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb)

• Install the switch lead direction [A] upward.

• Apply grease [B] to the terminal.

• Tighten the terminal bolt.

Torque - Oil Pressure Switch Terminal Bolt: 1.5 N·m (0.15

kgf·m, 13 in·lb)

NOTE

○Apply a small amount grease to the terminal so that

grease should not close two breather holes [A] for

switch diaphragm.

8-2 ENGINE REMOVAL/INSTALLATION

Exploded View

ENGINE REMOVAL/INSTALLATION 8-3

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Engine Mounting Nuts (M12)

59

6.0

44

S

2

Adjusting Collars

25

2.5

18

M

3

Front Engine Mounting Bolts (M10)

59

6.0

44

S, R

4

Engine Bracket Bolts (M8)

25

2.5

18

S, R

5

Subframe Bolts

23

2.3

17

R

M: Apply molybdenum sulfide grease.

R: Replacement Parts

S: Follow the specified tightening sequence.

8-4 ENGINE REMOVAL/INSTALLATION

Engine Removal/Installation

Engine Removal

• Support the rear part of the swingarm with a stand.

• Squeeze the brake lever slowly and hold it with a band

[A].

WARNING

Be sure to hold the front brake when removing the

engine, or the motorcycle may fall over. It could

cause an accident and injury.

CAUTION

Be sure to hold the front brake when removing the

engine, or the motorcycle may fall over. The engine

or the motorcycle could be damaged.

• Drain:

Engine Oil (see Engine Oil Change in the Periodic Main-

tenance chapter)

Coolant (see Coolant Change in the Periodic Mainte-

nance chapter)

• Remove:

Lower Fairings (see Lower Fairing Removal in the Frame

chapter)

Middle Fairings (see Middle Fairing Removal in the

Frame chapter)

Fuel Tank (see Fuel Tank Removal in the Fuel System

(DFI) chapter)

Coolant Reserve Tank

Clutch Slave Cylinder (see Clutch Slave Cylinder Re-

moval in the Clutch chapter)

Radiator (see Radiator and Radiator Fan Removal in the

Cooling System chapter)

Muffler Bodies (see Muffler Body Removal/Installation in

the Frame chapter)

Exhaust Pipe (see Exhaust Pipe Removal in the Engine

Top End chapter)

Shift Pedal (see Shift Pedal Removal in the Crank-

shaft/Transmission chapter)

• Disconnect:

Sidestand Switch Lead Connector [A]

Oil Pressure Switch/Gear Position Switch Leads Con-

nector [B]

ENGINE REMOVAL/INSTALLATION 8-5

Engine Removal/Installation

• Disconnect the alternator lead conductor [A].

• Remove:

Connector [A] of Subharness for Sensor and Valve (dis-

connect)

Subframe Bolts [B]

Subframe Bracket Bolt [C]

• Remove the subframe [D] with the clutch pipe [E].

• Disconnect:

Throttle Body Subharness Connector [A]

Breather Hose [B]

Fuel Hose [C] on the Delivery Pipe

Throttle Cable Lower Ends [D]

• Remove the bracket Bolt [A].

• Disconnect:

Air Switching Valve Connector [B]

Stick Coil Subharness Connector [C]

• Remove the air switching valve [A] with hoses.

• Remove the air suction cover (see Air Suction Valve Re-

moval in the Engine Top End chapter).

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