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

8-6 ENGINE REMOVAL/INSTALLATION

Engine Removal/Installation

• Remove the engine sprocket [A] (see Engine Sprocket

Removal in the Final Drive chapter).

• Support the engine with a suitable stand [B].

○Put a plank [C] onto the suitable stand for engine balance.

• Remove:

Engine Bracket Bolts [A]

Front Engine Mounting Bolts [B]

Engine Bracket [C]

• Remove:

Engine Mounting Nuts [A]

• Disconnect the engine ground terminal [A].

• Using a hexagon wrench, turn the engine mounting bolts

[B] clockwise to make the gap between the engine and

frame.

• Remove the drive chain from the output shaft.

• Remove the starter motor cable terminal nut [A].

• Using the stand, take out the engine.

Engine Installation

• Support the engine with a suitable stand.

○Put a plank onto the suitable stand for engine balance.

• Install the heat insulation rubber plate.

8-8 ENGINE REMOVAL/INSTALLATION

Engine Removal/Installation

• Before installing the engine. Confirm the routing of the

water temperature sensor lead [A].

○Run [B] the water temperature sensor lead between the

#3 and #4 cylinder and connect the water temperature

sensor body.

• Install the engine mounting bolts and nuts, following the

specified installing sequence.

○Apply molybdenum disulfide grease [A] to the thread of

adjusting collars.

○First, tighten the adjusting collars fully by hand.

Upper Adjusting Collar [B]

Upper Crankcase [C]

Lower Adjusting Collar [D]

Lower Crankcase [E]

ENGINE REMOVAL/INSTALLATION 8-9

Engine Removal/Installation

○Secondly, insert the mounting bolts [A] until they fit [B] in

the adjusting collars [C].

○Be sure that the collar [D] is in position.

NOTE

○Replace the following bolts with new bolts pre-coated

with locking agent.

Engine Bracket Bolts (P/No. 92153-1724)

Front Engine Mounting Bolts (P/No. 92153-1723)

Subframe Bolts (P/No. 92153-1722)

○Thirdly, install the left engine bracket [A] and temporally

tighten the left engine bracket bolts [B].

○Fourthly, tighten the left front engine mounting bolt [C].

○Fourthly, turn the mounting bolts [A] counterclockwise

with specified torque until the clearance [B] between the

crankcase [C] and swingarm [D] comes to zero mm [E].

Adjusting Collars [F]

Torque - Adjusting Collars: 25 N·m (2.5 kgf·m, 18 ft·lb)

○Do not exceed the specified torque of adjusting collars.

8-10 ENGINE REMOVAL/INSTALLATION

Engine Removal/Installation

○Fifthly, tighten the left engine bracket bolts [A].

○Sixthly, tighten the upper engine mounting nut [B] and

then the lower engine mounting nut [C].

○Seventhly, install the right engine bracket and tighten the

right engine bracket bolts [D] and the right front engine

mounting bolt [E].

○Torque:

Torque - Engine Mounting Nut (M12): 59 N·m (6.0 kgf·m, 44

ft·lb)

NOTE

○Hold the upper and lower engine mounting bolts with an

Allen wrench, and torque them.

○Torque:

Torque - Engine Bracket Bolts (M8): 25 N·m (2.5 kgf·m, 18

ft·lb)

Front Engine Mounting Bolts (M10): 59 N·m (6.0

kgf·m, 44 ft·lb)

ENGINE REMOVAL/INSTALLATION 8-11

Engine Removal/Installation

• Run the leads, cable and hoses correctly (see Cable,

Wire, and Hose Routing section in the Appendix chap-

ter).

• Install the removed parts (see appropriate chapters).

• Adjust:

Throttle Cables (see Throttle Control System Inspection

in the Periodic Maintenance chapter)

Drive Chain (see Drive Chain Slack Inspection in the

Periodic Maintenance chapter)

• Fill the engine with engine oil (see Engine Oil Change in

the Periodic Maintenance chapter).

• Fill the engine with coolant and bleed the air from the cool-

ing system (see Coolant Change in the Periodic Mainte-

nance chapter).

CRANKSHAFT/TRANSMISSION 9-1

Crankshaft/Transmission

Table of Contents

Exploded View

9-2

Rear Balancer Removal

9-31

Specifications

9-6

Rear Balancer Installation

9-32

Special Tools and Sealants

9-9

Balancer Adjustment

9-34

Crankcase Splitting

9-10

Balancer Damper Inspection

9-34

Crankcase Splitting

9-10

Starter Motor Clutch and Torque

Crankcase Assembly

9-11

Limiter

9-35

Crankshaft and Connecting Rods

9-15

Starter Motor Clutch Removal

9-35

Crankshaft Removal

9-15

Starter Motor Clutch Installation...

9-35

Crankshaft Installation

9-15

Starter Motor Clutch Disassembly

9-35

Connecting Rod Removal

9-16

Starter Motor Clutch Assembly

9-36

Connecting Rod Installation

9-16

Starter Clutch Inspection

9-36

Crankshaft/Connecting Rod

Torque Limiter Removal

9-36

Cleaning

9-19

Torque Limiter Installation

9-37

Connecting Rod Bend

9-19

Transmission

9-38

Connecting Rod Twist

9-20

Shift Pedal Removal

9-38

Connecting Rod Big End Side

Shift Pedal Installation

9-38

Clearance

9-20

External Shift Mechanism

Connecting Rod Big End Bearing

Removal

9-38

Insert/Crankpin Wear

9-20

External Shift Mechanism

Crankshaft Side Clearance

9-22

Installation

9-39

Crankshaft Runout

9-23

External Shift Mechanism

Crankshaft Main Bearing

Inspection

9-39

Insert/Journal Wear

9-23

Transmission Shaft Removal

9-39

Pistons

9-26

Transmission Shaft Installation

9-40

Piston Removal

9-26

Transmission Shaft Disassembly.

9-40

Piston Installation

9-27

Transmission Shaft Assembly

9-41

Cylinder Wear (Upper

Shift Drum and Fork Removal

9-44

Crankcase)

9-28

Shift Drum and Fork Installation...

9-44

Piston Wear

9-28

Shift Drum Disassembly

9-44

Piston Ring, Piston Ring Groove

Shift Drum Assembly

9-44

Wear

9-28

Shift Fork Bending

9-45

Piston Ring Groove Width

9-29

Shift Fork/Gear Groove Wear

9-45

Piston Ring Thickness

9-29

Shift Fork Guide Pin/Drum

Piston Ring End Gap

9-29

Groove Wear

9-45

Balancer

9-30

Gear Dog and Gear Dog Hole

Front Balancer Removal

9-30

Damage

9-45

Front Balancer Installation

9-30

CRANKSHAFT/TRANSMISSION 9-3

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

Breather Cover Bolts

9.8

1.0

87 in·lb

Breather Plate Screws

9.8

1.0

87 in·lb

Crankcase Bolts (M10, L = 90 mm)

4.8

MO, S

Crankcase Bolts (M10, L = 120 mm)

4.8

MO, S

Crankcase Bolt (M7, L = 110 mm)

2.0

Crankcase Bolt (M7, L = 85 mm)

2.0

Crankcase Bolts (M7, L = 60 mm)

2.0

Crankcase Bolt (M7, L = 50 mm)

2.0

Crankcase Bolts (M7, L = 45 mm)

2.0

Crankcase Bolts (M8, L = 80 mm)

2.8

Crankcase Bolts (M8, L = 70 mm)

2.8

Crankcase Bolts (M7, L = 65 mm)

2.0

Crankcase Bolt (M6, L = 65 mm)

1.2

106 in·lb

Crankcase Bolt (M6, L = 50 mm)

1.2

106 in·lb

Crankcase Bolts (M6, L = 40 mm)

1.2

106 in·lb

Crankcase Bolts (M6, L = 25 mm)

1.2

106 in·lb

Shift Drum Bearing Holder Screws

4.9

0.50

43 in·lb

Bearing Position Plate Screws

4.9

0.50

43 in·lb

Oil Passage Plug

2.0

Connecting Rod Big End Nuts

see the text

←

Timing Rotor Bolt

4.0

Gear Position Switch Lead Clamp Bolt

9.8

1.0

87 in·lb

Drive Shaft Cover Bolts

2.5

24. "R" marked side faces up.

25. "RN" marked side faces up.

26. Hollow mark faces forward.

27. Do not apply any grease or oil.

G: Apply grease.

L: Apply a non-permanent locking agent.

LG: Apply liquid gasket (Kawasaki Bond: 92104-1064).

M: Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil.

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

R: Replacement Parts

S: Follow the specified tightening sequence.

CRANKSHAFT/TRANSMISSION 9-5

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

Balancer Shaft Clamp Bolts

9.8

1.0

87 in·lb

Balancer Shaft Clamp Lever Bolts

2.5

Starter Clutch Shaft Bolt

9.8

1.0

87 in·lb

Starter Clutch Shaft Plate Bolt

9.8

1.0

87 in·lb

Torque Limiter Bolt

2.5

Shift Drum Cam Holder Bolt

1.2

106 in·lb

Gear Position Switch Screws

2.9

0.30

26 in·lb

Gear Positioning Lever Bolt

1.2

106 in·lb

Shift Shaft Return Spring Pin

3.0

10. Front Balancer

11. Rear Balancer

12. Install the bearing into the drive shaft cover so that the shield side faces in.

EO: Apply engine oil.

M: Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil.

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

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

9-6 CRANKSHAFT/TRANSMISSION

Specifications

Item

Standard

Service Limit

Crankcase, Crankshaft, Connecting

Rods

Connecting Rod Bend

- - -

TIR 0.2/100 mm

(0.008/3.94 in.)

Connecting Rod Twist

- - -

TIR 0.2/100 mm

(0.008/3.94 in.)

Connecting Rod Big End Side

0.13 ∼ 0.38 mm

0.58 mm

Clearance

(0.0051 ∼ 0.0150 in.)

(0.023 in.)

Connecting Rod Big End Bearing

0.048 ∼ 0.086 mm

0.12 mm

Insert/crankpin Clearance

(0.0019 ∼ 0.0034 in.)

(0.0047 in.)

Crankpin Diameter:

37.984 ∼ 38.000 mm

37.97 mm

(1.4954 ∼ 1.4961 in.)

(1.4949 in.)

Marking

None

37.984 ∼ 37.992 mm

- - -

(1.4954 ∼ 1.4957 in.)

○

37.993 ∼ 38.000 mm

- - -

(1.4958 ∼ 1.4961 in.)

Connecting Rod Big End Inside

41.000 ∼ 41.016 mm

- - -

Diameter:

(1.6142 ∼ 1.6148 in.)

Marking

41.000 ∼ 41.008 mm

- - -

None

(1.6142 ∼ 1.6145 in.)

41.009 ∼ 41.016 mm

- - -

○

(1.6145 ∼ 1.6148 in.)

Connecting Rod Big End Bearing

Insert Thickness:

Brown

1.475 ∼ 1.480 mm

- - -

(0.05807 ∼ 0.05827 in.)

Black

1.480 ∼ 1.485 mm

- - -

(0.05827 ∼ 0.05846 in.)

Blue

1.485 ∼ 1.490 mm

- - -

(0.05846 ∼ 0.05866 in.)

Connecting Rod Bolt Stretch:

(Usable Range)

New Connecting Rod

0.25 ∼ 0.34 mm

- - -

(0.0098 ∼ 0.0134 in.)

Used Connecting Rod

0.25 ∼ 0.34 mm

- - -

(0.0098 ∼ 0.0134 in.)

Crankshaft Side Clearance

0.05 ∼ 0.24 mm

0.30 mm

(0.0020 ∼ 0.0094 in.)

(0.0118 in.)

Crankshaft Runout

TIR 0.03 mm (0.0012 in.) or less

TIR 0.08 mm

(0.0031 in.)

Crankshaft Main Bearing Insert/journal

0.031 ∼ 0.063 mm

0.09 mm

Clearance

(0.0012 ∼ 0.0025 in.)

(0.0035 in.)

Crankshaft Main Journal Diameter:

37.984 ∼ 38.000 mm

37.96 mm

(1.4954 ∼ 1.4961 in.)

(1.4945 in.)

Marking

None

37.984 ∼ 37.992 mm

- - -

(1.4954 ∼ 1.4957 in.)

37.993 ∼ 38.000 mm

- - -

(1.4958 ∼ 1.4961 in.)

Crankcase Main Bearing Inside

41.000 ∼ 41.016 mm

- - -

Diameter:

(1.6142 ∼ 1.6148 in.)

CRANKSHAFT/TRANSMISSION 9-7

Specifications

Item

Standard

Service Limit

Marking

○

41.000 ∼ 41.008 mm

- - -

(1.6142 ∼ 1.6145 in.)

None

41.009 ∼ 41.016 mm

- - -

(1.6145 ∼ 1.6148 in.)

Crankshaft Main Bearing Insert

Thickness:

Brown

1.490 ∼ 1.494 mm

- - -

(0.0587 ∼ 0.0588 in.)

Black

1.494 ∼ 1.498 mm

- - -

(0.0588 ∼ 0.0590 in.)

Blue

1.498 ∼ 1.502 mm

- - -

(0.0590 ∼ 0.0591 in.)

Pistons

Cylinder (Upper Crankcase) Inside

83.994 ∼ 84.006 mm

84.10 mm

Diameter

(3.3068 ∼ 3.3073 in.)

(3.3110 in.)

Piston Diameter

83.959 ∼ 83.974 mm

83.81 mm

(3.3055 ∼ 3.3061 in.)

(3.2996 in.)

Piston/Cylinder Clearance

0.020 ∼ 0.047 mm

- - -

(0.0008 ∼ 0.0019 in.)

Piston Ring/Groove Clearance:

Top

0.03 ∼ 0.07 mm

0.17 mm

(0.0012 ∼ 0.0028 in.)

(0.0067 in.)

Second

0.02 ∼ 0.06 mm

0.16 mm

(0.0008 ∼ 0.0024 in.)

(0.0063 in.)

Piston Ring Groove Width:

Top

0.92 ∼ 0.94 mm

1.02 mm

(0.0362 ∼ 0.0370 in.)

(0.040 in.)

Second

1.01 ∼ 1.03 mm

1.11 mm

(0.0398 ∼ 0.0406 in.)

(0.044 in.)

Piston Ring Thickness:

Top

0.87 ∼ 0.89 mm

0.80 mm

(0.0343 ∼ 0.0350 in.)

(0.032 in.)

Second

0.97 ∼ 0.99 mm

0.90 mm

(0.0382 ∼ 0.0390 in.)

(0.035 in.)

Piston Ring End Gap:

Top

0.20 ∼ 0.30 mm

0.6 mm

(0.0079 ∼ 0.0118 in.)

(0.024 in.)

Second

0.40 ∼ 0.55 mm

0.8 mm

(0.0157 ∼ 0.0217 in.)

(0.031 in.)

Transmission

Shift Fork Ear Thickness

5.74 ∼ 6.00 mm

5.6 mm

(0.2260 ∼ 0.2362 in.)

(0.220 in.)

Gear Groove Width

6.05 ∼ 6.15 mm

6.25 mm

(0.238 ∼ 0.242 in.)

(0.246 in.)

Shift Fork Guide Pin Diameter

6.9 ∼ 7.0 mm

6.8 mm

(0.272 ∼ 0.276 in.)

(0.268 in.)

Shift Drum Groove Width

7.05 ∼ 7.20 mm

7.3 mm

(0.278 ∼ 0.283 in.)

(0.287 in.)

9-8 CRANKSHAFT/TRANSMISSION

Specifications

Connecting Rod Big End Bearing Insert Selection

Con-rod Big End Bore

Crankpin Diameter

Bearing Insert

Diameter Marking

Marking

Size Color

Part Number

None

○

Brown

92139-0131

None

Black

92139-0130

○

None

Blue

92139-0129

Crankshaft Main Bearing Insert Selection

Crankcase Main

Crankshaft Main

Bearing Insert

Bearing Inside

Journal Diameter

Size Color

Part Number

Journal Nos.

Diameter Marking

Marking

92139-0134

1, 3, 5

○

Brown

92139-0137

2, 4

None

92139-0133

1, 3, 5

Black

○

None

92139-0136

2, 4

92139-0132

1, 3, 5

None

Blue

92139-0135

2, 4

9-10 CRANKSHAFT/TRANSMISSION

Crankcase Splitting

• Remove the engine (see Engine Removal/Installation in

the Engine Removal/Installation chapter).

• Set the engine on a clean surface and hold the engine

steady while parts are being removed.

• Remove:

Clutch (see Clutch Removal in the Clutch chapter)

Starter Motor (see Starter Motor Removal in the Electri-

cal System chapter)

Oil Pump (see Oil Pump Removal in the Engine Lubri-

cation System chapter)

Alternator Rotor (see Alternator Rotor Removal in the

Electrical System chapter)

Oil Cooler (see Oil Cooler Removal in the Engine Lubri-

cation System chapter)

Oil Pan (see Oil Pan Removal in the Engine Lubrication

System chapter)

External Shift Mechanism (see External Shift Mecha-

nism Removal)

• Remove the upper crankcase bolts.

○First loosen the M6 bolts.

M6 Bolts [A]

M7 Bolt [B]

M7 Bolt with Clamp [C]

M8 Bolts with Washers [D]

• Remove the lower crankcase bolts.

○First loosen the M7 bolts [A].

CRANKSHAFT/TRANSMISSION 9-11

Crankcase Splitting

○Next, loosen the M10 Bolts [1∼10] (sequence numbers).

If the crankshaft is to be removed, remove the pistons

(see Piston Removal).

• Tap lightly around the crankcase mating surface with a

plastic mallet, and split the crankcase. Take care not to

damage the crankcase.

• Remove the front balancer [A] on the lower crankcase half

[B] (see Front Balancer Removal).

Crankcase Assembly

CAUTION

The upper and lower crankcase halves are ma-

chined at the factory in the assembled state, so the

crankcase halves must be replaced as a set.

NOTE

○When replacing the crankcase halves, install the

thrust washers (t = 2.5 mm, 0.0984 in.) on the upper

crankcase half.

• With a high-flash point solvent, clean off the mating sur-

faces of the crankcase halves and wipe dry.

• Using compressed air, blow out the oil passages in the

crankcase halves.

• Install the new drive shaft bearing [A] so that its stepped

side [B] faces as shown using a press.

• Install the bearing plate [C] with the screws [D].

○Apply a non-permanent locking agent to the bearing plate

screw and tighten them.

Torque - Bearing Position Plate Screws:

4.9

N·m (0.50

kgf·m, 43 in·lb)

9-12 CRANKSHAFT/TRANSMISSION

Crankcase Splitting

• Install the new needle bearing [A] for the shift shaft so that

its marked side [B] faces as shown, using a press.

• Install the new oil seal [C] so that its surface [D] is flush

with the surface of the crankcase [E].

• Install:

Crankshaft, Pistons and Connecting Rods

Transmission Shaft and Gears

Dowel Pins [A]

• Install the front balancer [A] on the upper crankcase half

[B] (see Balancer Installation).

• Before fitting the lower case on the upper case, check the

following.

○Check to see that the shift drum and transmission gears

are in the neutral position.

• Apply liquid gasket [A] to the mating surface of the lower

crankcase half.

Sealant - Kawasaki Bond: 92104-1064

NOTE

○Aster tightening the crankcase bolts, wipe up the liquid

gasket seeping out the output shaft bearing hole [D].

○Make the application finish within 20 minutes when

the liquid gasket to the mating surface of the lower

crankcase half is applied.

CAUTION

Do not apply liquid gasket to the grooves [B] inside

from the crankshaft main bearing inserts, and bal-

ancer bearing.

CAUTION

Do not plug the inside of breather hole [C] with liq-

uid gasket.

CRANKSHAFT/TRANSMISSION 9-13

Crankcase Splitting

• Fit the lower crankcase half to the upper crankcase half.

• Be sure that the breather hole [A] on the upper crankcase

[B] is not plugged with liquid gasket.

• The M10 bolts have washers, replace them with new

ones.

• Apply molybdenum disulfide oil solution to the seating sur-

faces [A] of the washers and the threads [B] of the M10

bolts.

• Tighten the lower crankcase bolts using the following

steps.

○Following the sequence numbers on the lower crankcase

half, tighten the M10 bolts [1 ∼ 10] with washers.

Torque - Crankcase Bolts (M10): 47 N·m (4.8 kgf·m, 35 ft·lb)

○Tighten the M7 bolts [A].

Torque - Crankcase Bolts (M7): 20 N·m (2.0 kgf·m, 15 ft·lb)

9-14 CRANKSHAFT/TRANSMISSION

Crankcase Splitting

• Tighten the upper crankcase bolts in the order listed.

○The M8 bolts have washers, replace them with new ones.

○Tighten:

M8 Bolts with Washers [A]

M7 Bolt with the clamp [B]

M7 Bolt [C]

M6 Bolts [D]

Torque - Crankcase Bolts (M8): 27 N·m (2.8 kgf·m, 20 ft·lb)

Crankcase Bolts (M7): 20 N·m (2.0 kgf·m, 15 ft·lb)

Crankcase Bolts (M6): 12 N·m (1.2 kgf·m, 106 in·lb)

• After tightening all crankcase bolts, check the following

items.

○Crankshaft and transmission shafts turn freely.

○While spinning the output shaft, gears shift smoothly from

the 1st to neutral, and neutral to 1st.

CRANKSHAFT/TRANSMISSION 9-15

Crankshaft and Connecting Rods

Crankshaft Removal

• Split the crankcase (see Crankcase Splitting).

• Remove the crankshaft (see Connecting Rod Removal).

Crankshaft Installation

CAUTION

If the crankshaft, bearing inserts, or crankcase

halves are replaced with new ones, select the bear-

ing inserts and check clearance with a plastigage

(press gauge) before assembling engine to be sure

the correct bearing inserts are installed.

NOTE

○When replacing the crankcase halves, install the

thrust washers (t = 2.5 mm, 0.0984 in.) on the upper

crankcase half.

• Apply molybdenum disulfide oil solution to the crankshaft

main bearing inserts.

• Follow the next procedure to insert the thrust washers on

the upper crankcase half, after installing connecting rod

on the crankshaft (see Connecting Rod Installation).

• Apply molybdenum disulfide grease to the outside sur-

faces [A] of both thrust washers [B].

• Slide [C] one thrust washer into the upper crankcase half.

• Move the crankshaft to the left or right and then slide the

other washer into the upper crankcase half.

NOTE

○Slide the thrust washers so that the oil grooves [D] face

outward. Make sure that the blue-painted edges [E] are

positioned as shown in figure.

Front [F]

9-16 CRANKSHAFT/TRANSMISSION

Crankshaft and Connecting Rods

Connecting Rod Removal

• Split the crankcase (see Crankcase Splitting).

• Remove the connecting rod nuts [A].

• Remove the crankshaft.

NOTE

○Mark and record the locations of the connecting rods

and their big end caps so that they can be reassembled

in their original positions.

• Remove the piston (see Piston Removal).

CAUTION

Discard the connecting rod bolts. To prevent dam-

age to the crankpin surfaces, do not allow the con-

necting rod bolts to bump against the crankpins.

Connecting Rod Installation

CAUTION

To minimize vibration, the connecting rods should

have the same weight mark.

Big End Cap [A]

Connecting Rod [B]

Weight Mark, Alphabet [C]

Diameter Mark [D]: “○” or no mark

CAUTION

If the connecting rods, big end bearing inserts, or

crankshaft are replaced with new ones, select the

bearing insert and check clearance with a plasti-

gage (press gauge) before assembling engine to be

sure the correct bearing inserts are installed.

• Apply molybdenum disulfide oil to the inner surface of the

upper and lower bearing inserts [A].

• Apply molybdenum disulfide oil to the threads [B] and

seating surface [C] of the connecting rod nuts.

• Install the inserts so that their nails [D] are on the same

side and fit them into the recess of the connecting rod and

cap.

CAUTION

Wrong application of oil and grease could cause

bearing damage.

○When installing the inserts [A], be careful not to damage

the insert surface with the edge of the connecting rod [B]

or the cap [C]. One way to install inserts is as follows.

Installation [D] to Cap

Installation [E] to Connecting Rod

Push [F]

Spare Dowel Pin [G]

Connecting Rod Bolts [H]

• Remove debris and clean the surface of inserts.

• Install the cap on the connecting rod, aligning the weight

and diameter marks.

CRANKSHAFT/TRANSMISSION 9-17

Crankshaft and Connecting Rods

• Install the crankshaft (see Crankshaft Installation).

• Install each connecting rod on its original crankpin.

○The connecting rod big end is bolted using the “plastic

region fastening method”.

○This method precisely achieves the needed clamping

force without exceeding it unnecessarily, allowing the

use of thinner, lighter bolts further decreasing connecting

rod weight.

○There are two types of the plastic region fastening. One is

a bolt length measurement method and other is a rotation

angle method. Observe one of the following two, but the

bolt length measurement method is preferable because

this is a more reliable way to tighten the big end nuts.

CAUTION

The connecting rod bolts are designed to stretch

when tightened. Never reuse the connecting rod

bolts. See the table below for correct bolt and nut

usage.

CAUTION

Be careful not to overtighten the nuts.

The bolts must be positioned on the seating surface

correctly to prevent the bolt heads from hitting the

crankcase.

(1) Bolt Length Measurement Method

• Be sure to clean the bolts, nuts, and connecting rods

thoroughly with a high-flash point solvent, because the

new connecting rods, bolts, and nuts are treated with an

anti-rust solution.

WARNING

Clean the bolts, nuts, and connecting rods in a well

-ventilated area, and take care that there is no spark

or flame anywhere near the working area. This in-

cludes any appliance with a pilot light. Because of

the danger of highly flammable liquids, do not use

gasoline or low-flash point solvents to clean them.

CAUTION

Immediately dry the bolts and nuts with com-

pressed air after cleaning.

Clean and dry the bolts and nuts completely.

9-18 CRANKSHAFT/TRANSMISSION

Crankshaft and Connecting Rods

• Install new bolts in reused connecting rods.

• Dent both bolt head and bolt tip with a punch as shown.

• Before tightening, use a point micrometer to measure the

length of new connecting rod bolts and record the values

to find the bolt stretch.

Connecting Rod [A]

Dent here with a punch [B].

Nuts [C]

Fit micrometer pins into dents [D].

• Apply a small amount of molybdenum disulfide oil to the

following.

Threads of Nuts and Bolts

Seating Surfaces of Nuts and Connecting rods

• Tighten the big end nuts until the bolt elongation reaches

the length specified in the table.

• Check the length of the connecting rod bolts.

If the stretch is more than the usable range, the bolt has

stretched too much. An overelongated bolt may break in

use.

Bolt Length after

Bolt Length before

= Bolt Stretch

tightening

Connect-

Usable Range of

ing Rod

Bolt

Nut

Connecting Rod

Assy

Bolt Stretch

Use the bolts

Attached to

0.25 ∼ 0.34 mm

New

attached to

new con-rod

(0.0098 ∼ 0.0134

new con-rod.

in.)

New

Used

Replace the

0.25 ∼ 0.34 mm

Used

bolts with new

(0.0098 ∼ 0.0134

New

ones.

in.)

(2) Rotation Angle Method

If you don’t have a point micrometer, you may tighten the

nuts using the “Rotation Angle Method”.

• Be sure to clean the bolts, nuts and connecting rods thor-

oughly with a high-flash point solvent, because the new

connecting rods, bolts and nuts are treated with an anti

-rust solution.

WARNING

Clean the bolts, nuts and connecting rods in a well

-ventilated area, and take care that there is no spark

or flame anywhere near the working area. This in-

cludes any appliance with a pilot light. Because of

the danger or highly flammable liquids, do not use

gasoline or low-flash point solvents to clean them.

CAUTION

Immediately dry the bolts and nuts with com-

pressed air after cleaning.

Clean and dry the bolts and nuts completely.

CRANKSHAFT/TRANSMISSION 9-19

Crankshaft and Connecting Rods

• Install new bolts in reused connecting rods.

• Apply a small amount of molybdenum disulfide oil to the

following.

Threads [A] of Nuts and Bolts

Seating Surfaces [B] of Nuts and Connecting Rods

• First, tighten the nuts to the specified torque. See the

table below.

• Next, tighten the nuts 120° ± 5°.

○Mark [A] the connecting rod big end caps and nuts so that

nuts can be turned 120° [B] properly.

Connecting

Torque + Angle

Bolt

Nut

Rod Assy

N·m (kgf·m, ft·lb)

Attached to

21.6 (2.2, 16) +

Use the boltsnewcon-rod

120°

New

attached to

21.6 (2.2, 16) +

new con-rod.

New

120°

21.6 (2.2, 16) +

Replace the

Used

120°

Used

bolts with

21.6 (2.2, 16) +

new ones

New

120°

Crankshaft/Connecting Rod Cleaning

• After removing the connecting rods from the crankshaft,

clean them with a high-flash point solvent.

• Blow the crankshaft oil passages with compressed air to

remove any foreign particles or residue that may have

accumulated in the passages.

Connecting Rod Bend

• Remove the connecting rod big end bearing inserts, and

reinstall the connecting rod big end cap.

• Select an arbor [A] of the same diameter as the connect-

ing rod big end, and insert the arbor through the connect-

ing rod big end.

• Select an arbor of the same diameter as the piston pin

and at least 100 mm (3.94 in.) long, and insert the arbor

[B] through the connecting rod small end.

• On a surface plate, set the big-end arbor on V block [C].

• With the connecting rod held vertically, use a height

gauge to measure the difference in the height of the

arbor above the surface plate over a 100 mm (3.94 in.)

length to determine the amount of connecting rod bend.

If connecting rod bend exceeds the service limit, the con-

necting rod must be replaced.

Connecting Rod Bend

Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)

9-20 CRANKSHAFT/TRANSMISSION

Crankshaft and Connecting Rods

Connecting Rod Twist

• With the big-end arbor [A] still on V block [C], hold the

connecting rod horizontally and measure the amount that

the arbor [B] varies from being paralleled with the surface

plate over a 100 mm (3.94 in.) length of the arbor to de-

termine the amount of connecting rod twist.

If connecting rod twist exceeds the service limit, the con-

necting rod must be replaced.

Connecting Rod Twist

Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)

Connecting Rod Big End Side Clearance

• Measure connecting rod big end side clearance.

○Insert a thickness gauge [A] between the big end and ei-

ther crank web to determine clearance.

Connecting Rod Big End Side Clearance

Standard:

0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.)

Service Limit:

0.58 mm (0.023 in.)

If the clearance exceeds the service limit, replace the con-

necting rod with new one and then check clearance again.

If clearance is too large after connecting rod replacement,

the crankshaft also must be replaced.

Connecting Rod Big End Bearing Insert/Crankpin

Wear

• Measure the bearing insert/crankpin [B] clearance with

plastigage [A].

• Tighten the big end nuts to the specified torque (see Con-

necting Rod Installation).

NOTE

○Do not move the connecting rod and crankshaft during

clearance measurement.

CAUTION

After measurement, replace the connecting rod

bolts.

Connecting Rod Big End Bearing Insert/Crankpin

Clearance

Standard:

0.048 ∼ 0.086 mm (0.0019 ∼ 0.0034 in.)

Service Limit:

0.12 mm (0.0047 in.)

CRANKSHAFT/TRANSMISSION 9-21

Crankshaft and Connecting Rods

If the clearance is within the standard, no bearing replace-

ment is required.

If the clearance is between 0.087 mm (0.0034 in.) and

the service limit (0.12 mm, 0.0047 in.), replace the bear-

ing inserts [A] with inserts painted blue [B]. Check in-

sert/crankpin clearance with the plastigage. The clear-

ance may exceed the standard slightly, but it must not be

less than the minimum in order to avoid bearing seizure.

If the clearance exceeds the service limit, measure the

diameter of the crankpins.

Crankpin Diameter

Standard:

37.984 ∼ 38.000 mm (1.4954 ∼ 1.4961 in.)

Service Limit:

37.97 mm (1.4949 in.)

If any crankpin has worn past the service limit, replace the

crankshaft with a new one.

If the measured crankpin diameters are not less than the

service limit, but do not coincide with the original diameter

markings on the crankshaft, make new marks on it.

Crankpin Diameter Marks

None

37.984 ∼ 37.992 mm (1.4954 ∼ 1.4957 in.)

○

37.993 ∼ 38.000 mm (1.4958 ∼ 1.4961 in.)

: Crankpin Diameter Marks, "○" or no mark.

• Measure the connecting rod big end inside diameter, and

mark each connecting rod big end in accordance with the

inside diameter.

• Tighten the connecting rod big end nuts to the specified

torque (see Connecting Rod Installation).

NOTE

○The mark already on the big end should almost coincide

with the measurement.

Connecting Rod Big End Inside Diameter Marks

None

41.000 ∼ 41.008 mm (1.6142 ∼ 1.6145 in.)

○

41.009 ∼ 41.016 mm (1.6145 ∼ 1.6148 in.)

Big End Cap [A]

Connecting Rod [B]

Weight Mark, Alphabet [C]

Diameter Mark (Around Weight Mark) [D]: “○” or no

mark

9-22 CRANKSHAFT/TRANSMISSION

Crankshaft and Connecting Rods

• Select the proper bearing insert [A] in accordance with the

combination of the connecting rod and crankshaft coding.

Size Color [B]

Con-rod Big

Crankpin

Bearing Insert

End Inside

Diameter

Marking

Size Color

Part Number

Marking

None

○

Brown

92139-0131

None

Black

92139-0130

○

None

Blue

92139-0129

• Install the new inserts in the connecting rod and check

insert/crankpin clearance with the plastigage.

Crankshaft Side Clearance

• Move [A] the crankshaft to the side of the camshaft chain.

• Insert a thickness gauge [B] between the thrust washer

[C] and the crank web [D] at the No. 3 main journal to

determine clearance.

Crankshaft Side Clearance

Standard:

0.05 ~ 0.24 mm (0.0020 ~ 0.0094 in.)

Service Limit:

0.30 mm (0.0118 in.)

If the clearance exceeds the service limit, replace the

thrust washer as a set.

• Measure the width [A] of the both thrust washers.

If the thrust washers (t = 2.5 mm, 0.0984 in.) are installed

on the upper crankcase half, replace them with new thrust

washer (t = 2.5 mm, 0.0984 in.) as a set.

CRANKSHAFT/TRANSMISSION 9-23

Crankshaft and Connecting Rods

If the thrust washers (t = 4.0 mm, 0.1575 in.) are installed

on the upper crankcase half, replace them with new thrust

washer (t = 4.0 mm, 0.1575 in.) as a set.

Thrust Washer

Thickness

Edge Colar

P/No.

2.45 ∼ 2.50 mm

92200-0331

Blue

(0.0965 ∼ 0.0984 in.)

3.95 ∼ 4.00 mm

92200-0332

Blue

(0.1555 ∼ 0.1575 in.)

NOTE

○For the crankcase, only crankcase set (P/No.

14001

-0089) be available as spare parts.

• Check the width of the crankshaft #3 main journal.

• Measure the crankshaft #3 main journal width [A].

If the measurement exceeds the standard, replace the

crankshaft [B].

Crankshaft #3 Main Journal Width

Standard:

27.45 ∼ 27.50 mm (1.0807 ∼ 1.0827 in.)

Crankshaft Runout

• Measure the crankshaft runout.

If the measurement exceeds the service limit, replace the

crankshaft.

Crankshaft Runout

Standard:

TIR 0.03 mm (0.0012 in.) or less

Service Limit: TIR 0.08 mm (0.0031 in.)

Crankshaft Main Bearing Insert/Journal Wear

• Using a plastigage (press gauge) [A], measure the bear-

ing insert/journal [B] clearance.

NOTE

○Tighten the crankcase bolts to the specified torque (see

Crankcase Assembly).

○Do not turn the crankshaft during clearance measure-

ment.

○Journal clearance less than 0.025 mm (0.00098 in.) can

not be measured by plastigage, however, using genuine

parts maintains the minimum standard clearance.

9-24 CRANKSHAFT/TRANSMISSION

Crankshaft and Connecting Rods

Crankshaft Main Bearing Insert/Journal Clearance

Standard:

0.031 ∼ 0.063 mm (0.0012 ∼ 0.0025 in.)

Service Limit:

0.09 mm (0.0035 in.)

If the clearance is within the standard, no bearing replace-

ment is required.

If the clearance is between 0.064 mm (0.0025 in.) and the

service limit (0.09 mm, 0.0035 in.), replace the bearing in-

serts [A] with inserts painted blue [B]. Check insert/journal

clearance with the plastigage. The clearance may exceed

the standard slightly, but it must not be less than the min-

imum in order to avoid bearing seizure.

If the clearance exceeds the service limit, measure the

diameter of the crankshaft main journal.

Crankshaft Main Journal Diameter

Standard:

37.984 ∼ 38.000 mm (1.4954 ∼ 1.4961 in.)

Service Limit:

37.96 mm (1.4945 in.)

If any journal has worn past the service limit, replace the

crankshaft with a new one.

If the measured journal diameters are not less than the

service limit, but do not coincide with the original diameter

markings on the crankshaft, make new marks on it.

Crankshaft Main Journal Diameter Marks

None

37.984 ∼ 37.992 mm (1.4954 ∼ 1.4957 in.)

37.993 ∼ 38.000 mm (1.4958 ∼ 1.4961 in.)

□: Crankshaft Main Journal Diameter Marks, "1" or no

mark.

• Measure the main bearing inside diameter, and mark the

upper crankcase half in accordance with the inside diam-

eter.

A: Crankcase Main Bearing Inside Diameter Marks, "○"

mark or no mark.

• Tighten the crankcase bolts to the specified torque (see

Crankcase Assembly).

NOTE

○The mark already on the upper crankcase half should

almost coincide with the measurement.

Crankcase Main Bearing Inside Diameter Marks

○

41.000 ∼ 41.008 mm (1.6142 ∼ 1.6145 in.)

None

41.009 ∼ 41.016 mm (1.6145 ∼ 1.6148 in.)

• Select the proper bearing insert [A] in accordance with the

combination of the crankcase and crankshaft coding.

Size Color [B]

CRANKSHAFT/TRANSMISSION 9-25

Crankshaft and Connecting Rods

Crankcase Main Bearing

Crankshaft Main Journal

Bearing Insert

Inside Diameter Marking

Diameter Marking

Size Color

Part Number

Journal Nos.

92139-0134

1, 3, 5

○

Brown

92139-0137

2, 4

None

92139-0133

1, 3, 5

Black

○

None

92139-0136

2, 4

92139-0132

1, 3, 5

None

Blue

92139-0135

2, 4

• Install the new inserts in the crankcase halves and check

insert/journal clearance with the plastigage.

9-26 CRANKSHAFT/TRANSMISSION

Pistons

Piston Removal

• Split the crankcase (see Crankcase Splitting).

• Remove the connecting rod nuts [A].

• Remove the connecting rod big end caps.

• Remove the crankshaft.

• Remove the piston to the cylinder head side.

• Remove the piston pin snap ring [A].

• Remove the piston pins.

Special Tool - Piston Pin Puller Assembly [A]: 57001-910

• Remove the pistons.

• Carefully spread the ring opening with your thumbs and

then push up on the opposite side of the ring [A] to remove

it.

• Remove the 3-piece oil ring with your thumbs in the same

manner.

CRANKSHAFT/TRANSMISSION 9-27

Pistons

Piston Installation

• Apply molybdenum disulfide oil solution to the oil ring ex-

pander, and install the oil ring expander [A] in the bottom

piston ring groove so the ends [B] butt together.

• Apply molybdenum disulfide oil solution to the oil ring steel

rails, and install the oil ring steel rails, one above the ex-

pander and one below it.

○Spread the rail with your thumbs, but only enough to fit

the rail over the piston.

○Release the rail into the bottom piston ring groove.

NOTE

○The oil ring rails have no “top” or “bottom”.

• Do not mix up the top and second ring.

• Install the top ring [A] so that the "R" mark [B] faces up.

• Install the second ring [C] so that the "RN" mark [D] faces

up.

○Apply molybdenum disulfide oil solution to the piston

rings.

NOTE

○If a new piston is used, use new piston ring.

• Fit a new piston pin snap ring into the side of the piston

so that the ring opening [A] does not coincide with the slit

[B] of the piston pin hole.

○Apply molybdenum disulfide oil solution to the piston pins

and piston journals.

○When installing the piston pin snap ring, compress it only

enough to install it and no more.

CAUTION

Do not reuse snap rings, as removal weakens and

deforms them. They could fall out and score the

cylinder wall.

• The piston ring openings must be positioned as shown in

the figure. The openings of the oil ring steel rails must be

about 30-40° of angle from the opening of the top ring.

Top Ring [A]

Second Ring [B]

Oil Ring Steel Rails [C]

Oil Ring Expander [D]

Hollow [E]

30 ∼ 40° [F]

9-28 CRANKSHAFT/TRANSMISSION

Pistons

• Install the piston with its marking hollow facing exhaust

side.

• Using the piston ring compressor assy [A] to install the

piston from the cylinder head side.

Special Tools - Piston Ring Compressor Grip: 57001-1095

Piston Ring Compressor Belt,

80 ∼

91:

57001-1320

• Install the crankshaft.

• Install the connecting rod to the crankshaft (see Connect-

ing Rod Installation).

Cylinder Wear (Upper Crankcase)

• Since there is a difference in cylinder wear (upper

crankcase) in different directions, take a side-to-side and

a front-to-back measurement at each of the two locations

(total of four measurements) shown in the figure.

If any of the cylinder inside diameter measurements ex-

ceeds the service limit, replace the crankcase.

10 mm (0.39 in.) [A]

60 mm (2.36 in.) [B]

Cylinder Inside Diameter

Standard:

83.994 ∼ 84.006 mm (3.3068 ∼ 3.3073 in.)

Service Limit:

84.10 mm (3.3110 in.)

Piston Wear

• Measure the outside diameter [A] of each piston 10 mm

(0.39 in.) [B] up from the bottom of the piston at a right

angle to the direction of the piston pin.

If the measurement is under service limit, replace the pis-

ton.

Piston Diameter

Standard:

83.959 ∼ 83.974 mm (3.3055 ∼ 3.3061 in.)

Service Limit:

83.81 mm (3.2996 in.)

Piston Ring, Piston Ring Groove Wear

• Check for uneven groove wear by inspecting the ring seat-

ing.

The rings should fit perfectly parallel to groove surfaces.

If not, replace the piston and all the piston rings.

• With the piston rings in their grooves, make several mea-

surements with a thickness gauge [A] to determine piston

ring/groove clearance.

Piston Ring/Groove Clearance

Standard:

Top

0.03 ∼ 0.07 mm (0.0012 ∼ 0.0028 in.)

Second

0.02 ∼ 0.06 mm (0.0008 ∼ 0.0024 in.)

Service Limit:

Top

0.17 mm (0.0067 in.)

Second

0.16 mm (0.0063 in.)

CRANKSHAFT/TRANSMISSION 9-29

Pistons

Piston Ring Groove Width

• Measure the piston ring groove width.

○Use a vernier caliper at several points around the piston.

Piston Ring Groove Width

Standard:

Top [A]

0.92 ∼ 0.94 mm (0.0362 ∼ 0.0370 in.)

Second [B]

1.01 ∼ 1.03 mm (0.0398 ∼ 0.0406 in.)

Service Limit:

Top [A]

1.02 mm (0.040 in.)

Second [B]

1.11 mm (0.044 in.)

If the width of any of the two grooves is wider than the

service limit at any point, replace the piston.

Piston Ring Thickness

• Measure the piston ring thickness.

○Use the micrometer to measure at several points around

the ring.

Piston Ring Thickness

Standard:

Top [A]

0.87 ∼ 0.89 mm (0.0343 ∼ 0.0350 in.)

Second [B]

0.97 ∼ 0.99 mm (0.0382 ∼ 0.0390 in.)

Service Limit:

Top [A]

0.80 mm (0.032 in.)

Second [B]

0.90 mm (0.035 in.)

If any of the measurements is less than the service limit

on either of the rings, replace all the rings.

NOTE

○When using new rings in a used piston, check for un-

even groove wear. The rings should fit perfectly parallel

to the groove sides. If not, replace the piston.

Piston Ring End Gap

• Place the piston ring [A] inside the cylinder (upper

crankcase), using the piston to locate the ring squarely

in place. Set it close to the bottom of the cylinder, where

cylinder wear is low.

• Measure the gap [B] between the ends of the ring with a

thickness gauge.

Piston Ring End Gap

Standard:

Top

0.20 ∼ 0.30 mm (0.0079 ∼ 0.0118 in.)

Second

0.40 ∼ 0.55 mm (0.0157 ∼ 0.0217 in.)

Service Limit:

Top

0.6 mm (0.024 in.)

Second

0.8 mm (0.031 in.)

If the end gap of either ring is greater than the service

limit, replace all the rings.

9-30 CRANKSHAFT/TRANSMISSION

Balancer

Front Balancer Removal

• Split the crankcase (see Crankcase Splitting).

• Unscrew:

Balancer Shaft Clamp Bolt [A]

Balancer Shaft Clamp Lever Bolt [B]

• Remove the front balancer [C] from the lower crankcase

half [D]

Front Balancer Installation

• Check that the rubber dampers [A] are in place as shown.

• Apply molybdenum disulfide oil solution to the damper

contact portions of the balancer weight.

• Install the balancer weight [A] into the gear [B].

○Align the mark [C] of the balancer weight to the groove

[D] of the gear.

• Apply molybdenum disulfide oil solution to the needle

bearings. Insert the needle bearings.

• Fit the copper washers [A] on both ends of the weight and

gear assembly. The projected sides [B] face inward.

CRANKSHAFT/TRANSMISSION 9-31

Balancer

• Position the crankshaft at 2, 3 position TDC.

• Insert the pin [A] as shown.

• Set the front balancer on the upper crankcase half.

○Align the punch mark [B] on the balancer gear [C] with the

mark [D] on the balancer drive gear [E] of crankshaft.

• Assemble the crankcase (see Crankcase Assembly).

• Install the new oil seal [A] so that its surface [B] is flush

with the surface of the crankcase [C].

○Fill the oil seal lips with grease.

• Tighten the balancer shaft clamp lever bolt [D]

Torque - Balancer Shaft Clamp Lever Bolt:

25 N·m (2.5

kgf·m, 18 ft·lb)

• Turn the balancer shaft so that its mark [E] is aligned with

the crankcase mating line [F].

• Tighten the balancer shaft clamp bolt [G]

Torque - Balancer Shaft Clamp Bolt: 9.8 N·m (1.0 kgf·m, 87

in·lb)

Rear Balancer Removal

• Remove the engine (see Engine Removal in the Engine

Removal/Installation chapter).

• Remove:

Breather Cover Bolts [A]

Breather Cover [B]

9-32 CRANKSHAFT/TRANSMISSION

Balancer

• Unscrew the balancer shaft clamp bolt [A], and balancer

shaft clamp lever bolt [B], and pull off the clamp lever [C].

• Pull the balancer shaft [D] out of the crankcase. The bal-

ancer weight and gear assembly [E] come off with needle

bearings and copper washers.

Rear Balancer Installation

• Check that the rubber dampers [A] are in place as shown.

• Apply molybdenum disulfide oil solution to the damper

contact portions of the balancer weight.

• Install the balancer weight [A] into the gear [B].

○Align the mark [C] of the balancer weight to the groove

[D] of the gear.

• Apply molybdenum disulfide oil solution to the needle

bearings. Insert the needle bearings.

• Fit the copper washers [A] on both ends of the weight and

gear assembly. The projected sides [B] face inward.

CRANKSHAFT/TRANSMISSION 9-33

Balancer

• Position the crankshaft at # 2, 3 position TDC or at # 1, 4

position TDC.

• Aligin the mark [A] on the balancer gear [B] with the mat-

ing surface [C] of the upper crankcase half.

• Install the balancer shaft [D] and then align the balancer

gear with the starter motor clutch gear.

• Install the new oil seal [A] so that its surface [B] is flush

with the surface of crankcase [C].

○Fill the oil seal lips with grease.

• Tighten the balancer shaft clamp lever bolt [D].

Torque - Balancer Shaft Clamp Lever Bolt:

25 N·m (2.5

kgf·m, 18 ft·lb)

• Turn the balancer shaft so that its mark [E] is in position

as shown.

• Tighten the balancer shaft clamp bolt [F].

Torque - Balancer Shaft Clamp Bolt: 9.8 N·m (1.0 kgf·m, 87

in·lb)

9-34 CRANKSHAFT/TRANSMISSION

Balancer

Balancer Adjustment

• First, adjust the front balancer [A], next the rear balancer

[B].

○For the front balancer adjustment, remove the lower fair-

ing (see Lower Fairing Removal in the Frame chapter).

• Start the engine and warm it up thoroughly.

• Adjust the balancer gear backlash with the engine idling.

The amount of backlash can be changed by turning the

balancer shaft which has eccentric journals.

○Start the engine and let it idle.

○Loosen the clamp bolt [C] and turn the balancer shaft

[D] clockwise [E] until the balancer gear makes a whin-

ing sound.

○Turn the shaft counter-clockwise [F] until the balancer

gear whining sound disappears and tighten the clamp

bolt.

Torque - Balancer Shaft Clamp Bolt: 9.8 N·m (1.0 kgf·m, 98

in·lb)

Balancer Damper Inspection

• Remove the balancer and disassemble the weight and

gear assembly.

• Visually inspect the rubber dampers [A].

If they appear damaged or deteriorated, replace them.

CRANKSHAFT/TRANSMISSION 9-35

Starter Motor Clutch and Torque Limiter

Starter Motor Clutch Removal

• Remove the engine (see Engine Removal in the Engine

Removal/Installation chapter).

• Remove the rear balancer (see Rear Balancer Removal).

• Unscrew the starter clutch shaft plate bolt [A].

• Pull the starter clutch shaft bolt [A] with the shaft plate [B]

and starter clutch shaft holding the starter clutch [C].

• Remove the starter clutch.

Starter Motor Clutch Installation

• Install:

Coller (Long) [A]

Starter Motor Clutch [B]

Coller (Short) [C]

Starter Motor Clutch Shaft [D]

○Apply molybdenum disulfide grease [E] to the starter mo-

tor clutch shaft.

• Align [F] the starter motor clutch gear with the torque lim-

iter gear.

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

the starter clutch shaft plate bolt, and tighten it.

Torque - Starter Clutch Shaft Plate Bolt [G]: 9.8 N·m (1.0

kgf·m, 87 in·lb)

If the shaft bolt removed, tighten it.

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

the shaft bolt.

Torque - Starter Clutch Shaft Bolt [H]: 9.8 N·m (1.0 kgf·m,

87 in·lb)

Starter Motor Clutch Disassembly

• Remove the starter motor clutch.

• Pull the driven gear out off from the drive gear.

• Remove:

Flat Washer [A]

9-36 CRANKSHAFT/TRANSMISSION

Starter Motor Clutch and Torque Limiter

• Holding the drive gear [A] with a hand, take off the one

-way clutch [B] from the gear by using the screw driver

[C].

Starter Motor Clutch Assembly

• Be sure to install the one-way clutch [A] so that its arrow

[B] faces the side of the flat washer.

• Turn in the driven gear [A] to the drive gear [B].

Counterclockwise [C]

Starter Clutch Inspection

• Remove the rear balancer (see Rear Balancer Removal).

• Turn the starter idle gear [A] by hand. When viewed from

the rear side of the engine, the starter idle gear should

turn forward [B] freely, but should not turn backward [C].

If the clutch does not operate as it should or if it makes

noise, disassemble the starter clutch, examine each part

visually, and replace any worn or damaged parts.

Torque Limiter Removal

• Remove:

Rear Balancer (see Rear Balancer Removal)

Starter Motor Clutch (see Starter Motor Clutch Re-

moval).

• Remove the torque limiter bolt [A].

CRANKSHAFT/TRANSMISSION 9-37

Starter Motor Clutch and Torque Limiter

• Holding the torque limiter [A], remove the torque limiter

shaft [B] and the torque limiter.

Torque Limiter Installation

• Replace the O-ring with a new one.

• Apply engine oil to the new O-ring.

• Apply molybdenum disulfide grease to the torque limiter

shaft.

• Install the torque limiter bolt.

○Apply a non-permanent locking agent to the bolt.

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

9-38 CRANKSHAFT/TRANSMISSION

Transmission

Shift Pedal Removal

• Remove:

Shift Lever Bolt [A]

Shift Lever [B]

Shift Pedal Installation

• Install the shift pedal.

○Align [A] the punch mark [B] on the shift shaft with the

upper surface [C] of shift lever slit.

○Tighten the shift pedal bolt securely.

External Shift Mechanism Removal

• Remove:

Shift Pedal (see Shift Pedal Removal)

Snap Ring [A] and Washer [B]

Clutch (see Clutch Removal in the Clutch chapter)

• Remove the shift shaft assembly [A] while pulling the shift

mechanism arm.

• Remove:

Gear Positioning Lever Bolt [A]

Gear Positioning Lever [B], Collar and Spring

CRANKSHAFT/TRANSMISSION 9-39

Transmission

External Shift Mechanism Installation

• Install the gear positioning lever [A] as shown.

Spring [B]

Collar [C]

Bolt [D]

• Tighten:

Torque - Gear Positioning Lever Bolt: 12 N·m (1.2 kgf·m,

106 in·lb)

External Shift Mechanism Inspection

• Examine the shift shaft [A] for any damage.

If the shaft is bent, straighten or replace it.

If the serration [B] are damaged, replace the shaft.

If the springs [C] are damaged in any way, replace them.

If the shift mechanism arm [D] is damaged in any way,

replace the arm.

• Check the return spring pin [A] is not loose.

If it is loose, unscrew it, apply a non-permanent locking

agent to the threads, and tighten it.

Torque - Shift Shaft Return Spring Pin: 29 N·m (3.0 kgf·m,

21 ft·lb)

• Check the gear positioning lever [B] and its spring for

breaks or distortion.

If the lever or spring are damaged in any way, replace

them.

• Visually inspect the shift drum cam [C].

If they are badly worn or if they show any damage, replace

it.

Transmission Shaft Removal

• Split the crankcase (see Crankcase Splitting).

• Remove the output shaft [A].

9-40 CRANKSHAFT/TRANSMISSION

Transmission

• Remove the cover bolts [A] and cover [B].

• Remove the shift forks (see Shift Drum and Fork Re-

moval).

• Pull out the drive shaft.

Transmission Shaft Installation

• Check to see that the set pin [A] and set ring [B] are in

place.

• Install the output shaft into the upper crankcase half.

• Apply engine oil to the bearing.

○The bearing set pin and ring must match properly with

the hole or groove in the bearing outer races. When they

are properly matched, there is no clearance between the

crankcase and the bearing outer races.

• Install the drive shaft into the lower crankcase half.

• Apply grease to the O-ring.

• Install the cover.

• Apply a non-permanent locking agent to the drive shaft

cover bolts and tighten them.

Torque - Drive Shaft Cover Bolts [A]: 25 N·m (2.5 kgf·m, 18

ft·lb)

• Assemble the crankcase.

• Press in the oil seal [A] onto collar [B] so that the surface

of the oil seal is flush with the counterbore bottom surface

[C] of the crankcase.

Transmission Shaft Disassembly

• Remove the transmission shafts (see Transmission Shaft

Removal).

• Remove the circlips, disassemble the transmission

shafts.

• The 5th gear [A] on the output shaft has three steel balls

assembled into it for the positive neutral finder mecha-

nism. Remove the 5th gear.

○Set the output shaft in a vertical position holding the 3rd

gear [B].

○Spin the 5th gear quickly [C] and pull it off upward.

CRANKSHAFT/TRANSMISSION 9-41

Transmission

• Remove the ball bearing [A] from each shafts.

Special Tools - Bearing Puller [B]: 57001-135

Bearing Puller Adapter [C]: 57001-317

• Discard the bearing.

Transmission Shaft Assembly

• Apply engine oil to the bushings, ball bearings and shafts.

• Install the gear bushings [A] on the shaft with their holes

[B] aligned.

• Replace any circlips removed with new ones.

• Install the circlips [A] so that the opening [B] of it is aligned

with spline grooves [C].

• Install the circlips so that the mark [D] on them faces to

each gear side.

• The drive shaft gears can be recognized by size: the gear

with the smallest diameter is 1st gear, and the largest one

is 6th gear. Be sure that all parts are put back in the cor-

rect sequence and all circlips and washers are properly in

place.

• Install the 3rd/4th gear onto the drive shaft with their oil

holes aligned.

• Install the 6th gear bushing onto the drive shaft with their

oil holes aligned.

• The output shaft gears can be recognized by size: the

gear with the largest diameter is 1st gear, and the small-

est one is 6th gear. Be sure that all parts are put back

in the correct sequence and all circlips and washers are

properly in place.

• Install the 5th and 6th gears onto the output shaft with

their oil holes aligned.

• Install the 3rd/4th gear bushings onto the output shaft with

their oil holes aligned.

9-42 CRANKSHAFT/TRANSMISSION

Transmission

• Fit the steel balls into the 5th gear holes in the output

shaft, aligning three oil holes [D].

5th Gear [A]

Output Shaft [B]

Steel Balls [C]

CAUTION

Do not apply grease to the balls to hold them in

place. This will cause the positive neutral finder

mechanism to malfunction.

○After assembling the 5th gear with steel balls in place on

the output shaft, check the ball-locking effect that the 5th

gear doesn’t come out of the output shaft when moving it

up and down by hand.

• Check that each gear spins or slides freely on the trans-

mission shafts without binding after assembly.

CRANKSHAFT/TRANSMISSION 9-43

Transmission

1. Output Shaft

13. 5th Gear

2. Collar

14. Thrust Washer,

35 mm (1.38 in.)

3. Ball Bearing

15. 1st Gear

4. Bushing

16. Needle Bearing

5. 2nd Gear

17. Bearing Outer Race

6. Toothed Washer,

30 mm (1.18 in.)

18. Needle Bearing

7. Circlip

19. Snap Ring,

25.5 mm (1.00 in.)

8. 6th (Top) Gear

20. Toothed Washer, 35.5 mm (1.40 in.)

9. 4th Gear

21. Snap Ring, 33 mm (1.30 in.)

10. Toothed Washer,

43 mm (1.69 in.)

22. Toothed Washer, 40.5 mm (1.59 in.)

11. Toothed Washer, 39.7 mm (1.56 in.)

23. Toothed Washer, 37 mm (1.46 in.)

12. 3rd Gear

24. Drive Shaft

○When the tangs [A] of the toothed washer [11] shall be assembled, they shall be installed into the

notches [B] of the toothed washer [10].

○When the tangs [C] of the toothed washer [23] shall be assembled, they shall be installed into the

notches [D] of the toothed washer [22].

9-44 CRANKSHAFT/TRANSMISSION

Transmission

Shift Drum and Fork Removal

• Remove:

Lower Crankcase Half (see Crankcase Splitting)

External Shift Mechanism (see External Shift Mecha-

nism Removal)

Screws [A]

Shift Drum Bearing Holder [B]

• Pull out the shift rods [C], and take off the shift forks.

• Pull out the shift drum [D].

Shift Drum and Fork Installation

• Apply engine oil to the shift drum, forks and rods.

• Install the shift rods [A], noting the groove position.

○Position the one with shortest ears [B] on the drive shaft

and place the pin in the center groove in the shift drum.

○The two forks [C] on the output shaft are identical.

NOTE

○The forks have marks (029 [D], 030 [E]), and position

them so that so that their marks face the engine left side.

• Install the forks as shown.

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

the shift drum bearing holder screws and tighten them.

Torque - Shift Drum Bearing Holder Screws: 4.9 N·m (0.50

kgf·m, 43 in·lb)

Shift Drum Disassembly

• Remove the shift drum (see Shift Drum and Fork Re-

moval).

• While holding the shift drum with a vise, remove the shift

drum cam holder bolt.

Shift Drum Cam Holder Bolt [A]

Dowel Pin [B]

Shift Drum Assembly

• Be sure to install the dowel pin.

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

the shift drum cam holder bolt, and tighten it.

Torque - Shift Drum Cam Holder Bolt: 12 N·m (1.2 kgf·m,

106 in·lb)

CRANKSHAFT/TRANSMISSION 9-45

Transmission

Shift Fork Bending

• Visually inspect the shift forks, and replace any fork that is

bent. A bent fork could cause difficulty in shifting, or allow

the transmission to jump out of gear when under power.

90° [A]

Shift Fork/Gear Groove Wear

• Measure the thickness of the shift fork ears [A], and mea-

sure the width [B] of the gear grooves.

If the thickness of a shift fork ear is less than the service

limit, the shift fork must be replaced.

Shift Fork Ear Thickness

Standard:

5.74 ∼ 6.000 mm (0.2260 ∼ 0.2362 in.)

Service Limit:

5.6 mm (0.220 in.)

If the gear groove is worn over the service limit, the gear

must be replaced.

Gear Groove Width

Standard:

6.05 ∼ 6.15 mm (0.238 ∼ 0.242 in.)

Service Limit:

6.25 mm (0.246 in.)

Shift Fork Guide Pin/Drum Groove Wear

• Measure the diameter of each shift fork guide pin [A], and

measure the width [B] of each shift drum groove.

If the guide pin on any shift fork is less than the service

limit, the fork must be replaced.

Shift Fork Guide Pin Diameter

Standard:

6.9 ∼ 7.0 mm (0.272 ∼ 0.276 in.)

Service Limit:

6.8 mm (0.268 in.)

If any shift drum groove is worn over the service limit, the

drum must be replaced.

Shift Drum Groove Width

Standard:

7.05 ∼ 7.20 mm (0.278 ∼ 0.283 in.)

Service Limit:

7.3 mm (0.287 in.)

Gear Dog and Gear Dog Hole Damage

• Visually inspect the gear dogs [A] and gear dog holes [B].

Replace any damaged gears or gears with excessively

worn dogs or dog holes.

WHEELS/TIRES 10-1

Wheels/Tires

Table of Contents

Exploded View

10-2

Specifications

10-4

Special Tools

10-5

Wheels (Rims)

10-6

Front Wheel Removal

10-6

Front Wheel Installation

10-6

Rear Wheel Removal

10-7

Rear Wheel Installation

10-8

Wheel Inspection

10-10

Axle Inspection

10-10

Balance Inspection

10-11

Balance Adjustment

10-11

Balance Weight Removal

10-11

Balance Weight Installation

10-12

Tires

10-14

Air Pressure Inspection/Adjustment

10-14

Tire Inspection

10-14

Tire Removal

10-14

Tire Installation

10-14

Tire Repair

10-16

Hub Bearing

10-17

Hub Bearing Removal

10-17

Hub Bearing Installation

10-17

Hub Bearing Inspection

10-17

Hub Bearing Lubrication

10-18

WHEELS/TIRES 10-3

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

Front Axle Clamp Bolts

2.0

Front Axle Nut

127

13.0

Rear Axle Nut

127

13.0

4. Caliper Bracket (ZX1400B Models)

AL: Tighten the two clamp bolts alternately two time to ensure even tightening.

G: Apply grease.

HG: Apply high-temperature grease.

R: Replacement Parts

WL: Apply soap and water solution or rubber lubricant.

10-4 WHEELS/TIRES

Specifications

Item

Standard

Service Limit

Wheels (Rims)

Rim Runout:

Axial

TIR 0.5 mm (0.02 in.) or less

TIR 1.0

mm (0.04 in.)

Radial

TIR 0.8 mm (0.03 in.) or less

TIR 1.0

mm (0.04 in.)

Axle Runout/100 mm (3.94 in.)

TIR 0.03 mm (0.0012 in.) or less

TIR 0.2

mm (0.01 in.)

Wheel Balance

10 g (0.35 oz.) or less

- - -

Balance Weights

10 g (0.35 oz.), 20 g (0.71 oz.),

- - -

30 g (1.06 oz.)

Rim Size:

Front

17 × 3.50

- - -

Rear

17 × 6.00

- - -

Tires

Air Pressure (when Cold):

Front

Up to 180 kg (397 lb) load:

- - -

290 kPa (2.9 kgf/cm², 42 psi)

Rear

Up to 180 kg (397 lb) load:

- - -

290 kPa (2.9 kgf/cm², 42 psi)

Tread Depth:

Front

3.8 mm (0.15 in.)

1 mm (0.04 in.)

(AT, CH, DE) 1.6 mm (0.06 in.)

Rear

4.8 mm (0.19 in.)

Up to 130 km/h (80 mph):

2 mm (0.08 in.)

Over 130 km/h (80 mph):

3 mm (0.12 in.)

Standard Tires:

Make, Type

Size

Front

BRIDGESTONE,

120/70 ZR17 M/C (58 W)

BATTLAX BT014 F RADIAL SL

Rear

BRIDGESTONE,

190/50 ZR17 M/C (73 W)

BATTLAX BT014 R RADIAL L

WARNING

Use the same manufacturer’s tires on both front and rear wheels.

10-6 WHEELS/TIRES

Wheels (Rims)

Front Wheel Removal

• Remove:

Front Caliper Mounting Bolts [A]

Front Calipers [B]

• Loosen:

Axle Clamp Bolts [A] (Left Side)

Axle Nut [B]

Axle Clamp Bolts (Right Side)

• Remove the lower fairings (see Lower Fairing Removal in

the Frame chapter).

• Raise the front wheel off the ground with the jack.

Special Tools - Jack: 57001-1238

Jack Attachment: 57001-1608

• Remove the axle nut and pull out the axle to the right and

drop the front wheel out of the forks.

CAUTION

Do not lay the wheel down on one of the discs. This

can damage or warp the disc. Place blocks un-

der the wheel so that the disc does not touch the

ground.

Front Wheel Installation

NOTE

○The direction of the wheel rotation [A] is shown by an

arrow [B] on the wheel spoke.

• Check the wheel rotation mark on the front wheel and

install it.

WHEELS/TIRES 10-7

Wheels (Rims)

• Apply high-temperature grease to the grease seal lip.

• Fit the collars [A] on the both sides of the hub.

○The collars are identical.

• Insert the axle from the right side.

• Tighten the axle nut [B].

Right Axle Clamp Bolts [C]

Left Axle Clamp Bolts [D]

Viewed from Rear [E]

Torque - Front Axle Nut: 127 N·m (13.0 kgf·m, 94 ft·lb)

• Before tightening the axle clamp bolts on the right front

fork leg, pump the front fork up and down 4 or 5 times to

all on the right front fork leg to seat on the front axle.

NOTE

○Put a block in front of the front wheel to stop moving.

• Tighten the axle clamp bolts on the right fork leg first.

Next, tighten the left axle clamp bolts.

Torque - Front Axle Clamp Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb)

NOTE

○Tighten the two clamp bolts alternately two times to en-

sure even tightening torque.

• Install the lower fairings (see Lower Fairing Installation in

the Frame chapter).

• Install the front calipers (see Caliper Installation in the

Brakes chapter).

• Check the front brake effectiveness (see Brake Operation

Inspection in the Periodic Maintenance chapter).

WARNING

Do not attempt to drive the motorcycle until a full

brake lever is obtained by pumping the brake lever

until the pads are against the disc. The brake will

not function on the first application of the lever if

this is not done.

Rear Wheel Removal

• Raise the rear wheel off the ground with the stand [A].

10-8 WHEELS/TIRES

Wheels (Rims)

• Remove:

Rear Caliper Mounting Bolts [A]

Rear Caliper [B]

• Remove the rear wheel rotation sensor from the caliper

bracket (see Rear Wheel Rotation Sensor Removal in the

Brakes chapter) (ZX1400B Models).

• Remove:

Cotter Pin [A]

Axle Nut [B]

Washer [C]

Axle [D] (from Left Side)

• Remove the drive chain [A] from the rear sprocket toward

the left.

• Move the rear wheel back and remove it.

CAUTION

Do not lay the wheel on the ground with the disc

facing down. This can damage or warp the disc.

Place blocks under the wheel so that the disc does

not touch the ground.

Rear Wheel Installation

• Apply high-temperature grease to the grease seal lips.

• Fit the collars on the both sides of the hub.

Right Side Collar [A]

Left Side Collar [B]

• Engage the drive chain with the rear sprocket.

• Install the caliper bracket [A] onto the swingarm stop [B].

• Insert the axle from the left side of the wheel, and tighten

the axle nut.

Torque - Rear Axle Nut: 127 N·m (13.0 kgf·m, 94 ft·lb)

WHEELS/TIRES 10-9

Wheels (Rims)

• Insert a new cotter pin [A].

NOTE

○When inserting the cotter pin, if the slots in the nut do

not align with the cotter pin hole in the axle, tighten the

nut clockwise [B] up to next alignment.

○It should be within 30°.

○Loosen once and tighten again when the slot goes past

the nearest hole.

• Bend the cotter pin [A] over the nut.

WARNING

If the rear axle nut is not securely tightened or the

cotter pin is not installed, an unsafe riding condi-

tion may result.

• Adjust the drive chain slack after installation (see Drive

Chain Slack Inspection in the Periodic Maintenance chap-

ter).

• Install the rear caliper (see Caliper Installation in the

Brakes chapter).

• Install the rear wheel rotation sensor (see Rear Wheel

Rotation Sensor Installation in the Brakes chapter)

(ZX1400B Models).

• Check the rear brake effectiveness (see Brake Operation

Inspection in the Periodic Maintenance chapter).

WARNING

Do not attempt to drive the motorcycle until a full

brake pedal is obtained by pumping the brake pedal

until the pads are against the disc. The brake will

not function on the first application of the pedal if

this is not done.

10-10 WHEELS/TIRES

Wheels (Rims)

Wheel Inspection

• Raise the front/rear wheel off the ground.

Special Tools - Jack: 57001-1238

Jack Attachment: 57001-1608

• Spin the wheel lightly, and check for roughness or binding.

If roughness or binding is found, replace the hub bearings

(see Hub Bearing Removal/Installation).

• Inspect the wheel for small cracks, dents, bending, or

warp.

If there is any damage to the wheel, replace the wheel.

• Remove the wheel, and support it with the tire by the axle.

• Measure the rim runout, axial [A] and radial [B], with a dial

gauge.

If rim runout exceeds the service limit, check the hub bear-

ings (see Hub Bearing Inspection).

If the problem is not due to the bearings, replace the

wheel.

Rim Runout (with tire installed)

Standard:

Axial

TIR 0.5 mm (0.02 in.) or less

Radial

TIR 0.8 mm (0.03 in.) or less

Service Limit:

Axial

TIR 1.0 mm (0.04 in.)

Radial

TIR 1.0 mm (0.04 in.)

WARNING

Never attempt to repair a damaged wheel. If there

is any damage besides wheel bearings, the wheel

must be replaced to insure safe operational condi-

tion.

Axle Inspection

• Remove the front and rear axles (see Front/Rear Wheel

Removal).

• Visually inspect the front and rear axle for damages.

If the axle is damaged or bent, replace it.

• Place the axle in V blocks that are 100 mm (3.94 in.) [A]

apart, and set a dial gauge [B] on the axle at a point

halfway between the blocks. Turn [C] the axle to mea-

sure the runout. The difference between the highest and

lowest dial readings is the amount of runout.

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

Axle Runout/100 mm (3.94 in.)

Standard:

TIR 0.03 mm (0.0012 in.) or less

Service Limit: TIR 0.2 mm (0.01 in.)

WHEELS/TIRES 10-11

Wheels (Rims)

Balance Inspection

• Remove the front and rear wheels (see Front/Rear Wheel

Removal).

• Support the wheel so that it can be spun freely.

• Spin the wheel lightly, and mark [A] the wheel at the top

when the wheel stops.

○Repeat this procedure several times. If the wheel stops

of its own accord in various positions, it is well balanced.

If the wheel always stops in one position, adjust the wheel

balance (see Balance Adjustment).

Balance Adjustment

• If the wheel always stops in one position, provisionally

attach a balance weight [A] on the rim at the marking using

adhesive tape.

• Rotate the wheel 1/4 turn [B], and see whether or not the

wheel stops in this position. If it does, the correct balance

weight is being used.

If the wheel rotates and the weight goes up, replace the

weight with the next heavier size. If the wheel rotates and

the weight goes down, replace the weight with the next

lighter size. Repeat these steps until the wheel remains

at rest after being rotated 1/4 turn.

• Rotate the wheel another 1/4 turn and then another 1/4

turn to see if the wheel is correctly balanced.

• Repeat the entire procedure as many times as necessary

to achieve correct wheel balance.

• Permanently install the balance weight.

Balance Weight Removal

• Insert a regular tip screwdrivers [A] [B] between the rib [C]

and weight [D] as shown.

• Pry the balance weight with two screwdrivers and remove

the balance weight.

• Discard the used balance weight.

CAUTION

Do not tap the screwdrivers. The rim could be dam-

aged.

10-12 WHEELS/TIRES

Wheels (Rims)

Balance Weight Installation

• Check if the weight portion has any play on the blade [A]

and clip [B].

If it does, discard it.

WARNING

If the balance weight has any play on the rib of the

rim, the blade and/or clip have been stretched. Re-

place the loose balance weight.

Do not reuse used balance weight.

Unbalanced wheels can create an unsafe riding

condition.

Balance Weight

Part Number

Weight

41075-0007

10 g (0.35 oz.)

41075-0008

20 g (0.71 oz.)

41075-0017

30 g (1.06 oz.)

NOTE

○Balance weights are available from Kawasaki dealers

in 10, 20, and 30 grams (0.35 oz., 0.71 oz., and 1.06

oz.) sizes. An imbalance of less than 10 grams (0.35

oz.) will not usually affect running stability.

○Do not use four or more balance weight (more than 90

gram, 3.2 oz.). If the wheel requires an excess balance

weight, disassemble the wheel to find the cause.

10-14 WHEELS/TIRES

Tires

Air Pressure Inspection/Adjustment

• Refer to the Air Pressure Inspection in the Periodic Main-

tenance chapter.

Tire Inspection

• Refer to the Wheel/Tire Damage Inspection in the Peri-

odic Maintenance chapter.

Tire Removal

• Remove:

Wheel (see Front/Rear Wheel Removal)

Valve Core (Let out the air)

• To maintain wheel balance, mark the valve stem position

on the tire with chalk so that the tire can be reinstalled in

the same position.

Chalk Mark or Yellow Mark [A]

Air Valve [B]

Align [C]

• Lubricate the tire beads and rim flanges on both sides with

a soap and water solution or rubber lubricant. This helps

the tire beads slip off the rim flanges.

CAUTION

Never lubricate with engine oil or petroleum distil-

lates because they will deteriorate the tire.

• Remove the tire from the rim using a suitable commer-

cially available tire changer.

NOTE

○The tires cannot be removed with hand tools because

they fit the rims too tightly.

Tire Installation

WARNING

Use the same manufacture’s on both front and rear

wheels.

• Inspect the rim and tire, and replace them if necessary.

• Clean the sealing surfaces of the rim and tire, and smooth

the sealing surfaces of the rim with a fine emery cloth if

necessary.

• Remove the air valve and discard it.

CAUTION

Replace the air valve whenever the tire is replaced.

Do not reuse the air valve.

WHEELS/TIRES 10-15

Tires

• Install a new valve in the rim.

○Remove the valve cap, lubricate the stem seal [A] with a

soap and water solution or rubber lubricant, and pull [B]

the valve stem through the rim from the inside out until it

snaps into place.

CAUTION

Do not use engine oil or petroleum distillates to lu-

bricate the stem because they will deteriorate the

rubber.

○The air valve is shown in the figure.

Valve Cap [A]

Valve Core [B]

Stem Seal [C]

Valve Stem [D]

Valve Seat [E]

Valve Opened [F]

• Check the tire rotation mark on the front and rear tires and

install them on the rim accordingly.

Tire Rotation Mark [A]

Rotating Direction [B]

• Position the tire on the rim so that the valve [A] align with

the tire balance mark [B] (the chalk mark made during

removal, or the yellow paint mark on a new tire).

• Install the tire bead over the rim flange using a suitable

commercially available tire changer.

• Lubricate the tire beads and rim flanges with a soap and

water solution or rubber lubricant to help seat the tire

beads in the sealing surfaces of the rim while inflating the

tire.

• Center the rim in the tire beads, and inflate the tire with

compressed air until the tire beads seat in the sealing

surfaces.

WARNING

Be sure to install the valve core whenever inflating

the tire, and do not inflate the tire to more than 400

kPa (4.0 kgf/cm², 57 psi). Overinflation can explode

the tire with possibility of injury and loss of life.

10-16 WHEELS/TIRES

Tires

• Check to see that the rim lines [A] on both sides of the tire

sidewalls are parallel with the rim flanges.

If the rim flanges and tire sidewall rim lines are not parallel,

remove the valve core.

• Lubricate the rim flanges and tire beads.

• Install the valve core and inflate the tire again.

• After the tire beads seat in the rim flanges, check for air

leakage.

○Inflate the tire slightly above standard inflation.

○Use a soap and water solution or submerge the tire, and

check for bubbles that would indicate leakage.

• Adjust the air pressure to the specified pressure (see Air

Pressure Inspection in the Periodic Maintenance chap-

ter).

• Install the air valve cap.

• Adjust the wheel balance (see Balance Adjustment).

Tire Repair

Currently two types of repair for tubeless tires have come

into wide use. One type is called a temporary (external) re-

pair which can be carried out without removing the tire from

the rim, and the other type is called permanent (internal)

repair which requires tire removal. It is generally under-

stood that higher running durability is obtained by perma-

nent (internal) repairs than by temporary (external) ones.

Also, permanent (internal) repairs have the advantage of

permitting a thorough examination for secondary damage

not visible from external inspection of the tire. For these

reasons, Kawasaki does not recommend temporary (exter-

nal) repair. Only appropriate permanent (internal) repairs

are recommended. Repair methods may vary slightly from

make to make. Follow the repair methods indicated by the

manufacturer of the repair tools and materials so that safe

results can be obtained.

WHEELS/TIRES 10-17

Hub Bearing

Hub Bearing Removal

• Remove the wheel (see Front/Rear Wheel Removal), and

take out the following.

Collars

Coupling (Out of rear hub)

Grease Seals

• Use the bearing remover to remove the hub bearing [A].

CAUTION

Do not lay the wheel on the ground with the disc

facing down. This can damage or warp the disc.

Place blocks under the wheel so that the disc does

not touch the ground.

Special Tools - Bearing Remover Head,

25 ×

28 [B]:

57001-1346

Bearing Remover Shaft,

13 [C]:

57001

-1377

Hub Bearing Installation

• Before installing the hub bearings, blow any dirt or foreign

particles out of the hub with compressed air to prevent

contamination of the bearings.

• Replace the bearings with new ones.

• Install the bearings by using the bearing driver set which

does not contact the bearing inner race.

• Press in each right the bearing [A] until they are bottomed.

Special Tool - Bearing Driver Set [B]: 57001-1129

• Replace the grease seals with new ones.

• Press in the grease seals [A] so that the seal surface is

flush [B] with the end of the hole.

○Apply high-temperature grease to the grease seal lips.

Special Tool - Bearing Driver Set [C]: 57001-1129

Hub Bearing Inspection

Since the hub bearings are made to extremely close tol-

erances, the clearance can not normally be measured.

NOTE

○Do not remove any bearings for inspection. If any bear-

ings are removed, they will need to be replaced with

new ones.

• Turn each bearing in the hub back and forth [A] while

checking for plays, roughness, or binding.

If bearing play, roughness or binding is found, replace the

bearing.

• Examine the bearing seal [B] for tears or leakage.

If the seal is torn or is leaking, replace the bearing.

FINAL DRIVE 11-1

Final Drive

Table of Contents

Exploded View

11-2

Specifications

11-4

Special Tools

11-5

Drive Chain

11-6

Drive Chain Slack Inspection

11-6

Drive Chain Slack Adjustment

11-6

Wheel Alignment Inspection/Adjustment

11-6

Drive Chain Wear Inspection

11-6

Drive Chain Lubrication

11-6

Drive Chain Removal

11-6

Drive Chain Installation

11-6

Sprocket, Coupling

11-7

Engine Sprocket Removal

11-7

Engine Sprocket Installation

11-7

Rear Sprocket Removal

11-8

Rear Sprocket Installation

11-8

Coupling Installation

11-8

Coupling Bearing Removal

11-9

Coupling Bearing Installation

11-9

Coupling Bearing Inspection

11-10

Coupling Bearing Lubrication

11-10

Coupling Damper Inspection

11-10

Sprocket Wear Inspection

11-10

Rear Sprocket Warp Inspection

11-11

FINAL DRIVE 11-3

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

Chain Guide Bolt

1.2

106 in·lb

Chain Guide Bolts

9.8

1.0

87 in·lb

Engine Sprocket Cover Bolts

9.8

1.0

87 in·lb

Engine Sprocket Nut

125

13.0

Rear Axle Nut

127

13.0

Rear Sprocket Nuts

7.0

Speed Sensor Bolt

3.9

0.40

35 in·lb

Stud Bolts

14.7

1.5

G: Apply grease.

HG: Apply high-temperature grease.

HO: Apply heavy oil.

L: Apply a non-permanent locking agent.

MO: Apply molybdenum disulfide oil solution.

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

R: Replacement Parts

11-6 FINAL DRIVE

Drive Chain

Drive Chain Slack Inspection

• Refer to the Drive Chain Slack Inspection in the Periodic

Maintenance chapter.

Drive Chain Slack Adjustment

• Refer to the Drive Chain Slack Adjustment in the Periodic

Maintenance chapter.

Wheel Alignment Inspection/Adjustment

• Refer to the Wheel Alignment Inspection in the Periodic

Maintenance chapter.

Drive Chain Wear Inspection

• Refer to the Drive Chain Wear Inspection in the Periodic

Maintenance chapter.

Drive Chain Lubrication

• Refer to the Drive Chain Lubrication Condition Inspection

in the Periodic Maintenance chapter.

Drive Chain Removal

• Remove the chain cover screws [A] and chain cover [B].

○Clear the chain cover from the swingarm.

• Remove:

Rear Wheel (see Rear Wheel Removal in the

Wheels/Tires chapter)

Engine Sprocket (see Engine Sprocket Removal)

Swingarm (see Swingarm Removal in the Suspension

chapter)

• Remove the drive chain [A] from the output shaft [B], and

take it off the chassis.

Drive Chain Installation

• Install the drive chain to the output shaft.

• Install:

Swingarm (see Swingarm Installation in the Suspension

chapter)

Engine Sprocket (see Engine Sprocket Installation)

Rear Wheel (see Rear Wheel Installation in the

Wheels/Tires chapter)

Chain Cover

• Adjust the drive chain slack after installing the chain (see

Drive Chain Slack Adjustment in the Periodic Mainte-

nance chapter).

FINAL DRIVE 11-7

Sprocket, Coupling

Engine Sprocket Removal

• Remove:

Left Lower Fairing (see Lower Fairing Removal in the

Frame chapter)

Speed Sensor [A] (see Speed Sensor Removal in the

Electrical System chapter)

Clutch Slave Cylinder [B] (see Clutch Slave Cylinder in

the Clutch chapter)

Engine Sprocket Cover Bolts [C]

Engine Sprocket Cover [D]

• Flatten out the bended washer [A].

• Remove the engine sprocket nut [B].

NOTE

○When loosening the engine sprocket nut, hold the rear

brake on.

• Remove:

Washer [A]

Chain Guide Bolts [B]

Chain Guide [C]

• Raise the rear wheel off the ground with the stand.

• Remove the axle cotter pin, and loosen the rear axle nut.

• Loosen the both chain adjuster locknut to loosen the drive

chain.

• Remove the drive chain from the rear sprocket toward the

right.

• Pull the engine sprocket [D] with drive chain [E] off the

output shaft [F].

• Disengage the drive chain from the engine sprocket.

Engine Sprocket Installation

• Replace the sprocket washer and axle cotter pin.

• Install the engine sprocket onto the output shaft.

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

the chain guide bolts.

• Install the chain guide, and tighten the bolts.

Torque - Chain Guide Bolt: 12 N·m (1.2 kgf·m, 106 in·lb)

Chain Guide Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

• Apply molybdenum disulfide oil solution to the threads of

the output shaft and the seating surface of the engine

sprocket nut.

• After torquing the engine sprocket nut, bend the one side

of the washer [A] over the nut.

NOTE

○Tighten the nut while applying the rear brake.

Torque - Engine Sprocket Nut: 125 N·m (13.0 kgf·m, 92 ft·lb)

• Adjust the drive chain slack after installing the engine

sprocket (see Drive Chain Slack Adjustment in the Pe-

riodic Maintenance chapter).

11-8 FINAL DRIVE

Sprocket, Coupling

• Install the engine sprocket cover.

• Install the clamp [A] as shown in the figure, and tighten

the cover bolts.

Torque - Engine Sprocket Cover Bolts: 9.8 N·m (1.0 kgf·m,

87 in·lb)

• Bend the end of axle cotter pin surely after tightening the

axle nut (see Rear Wheel Installation in the Wheels/Tires

chapter).

• Install the removed parts (see appropriate chapters).

Rear Sprocket Removal

• Remove the rear wheel (see Rear Wheel Removal in the

Wheels/Tires chapter).

CAUTION

Do not lay the wheel on the ground with the disc

facing down. This can damage or warp the disc.

Place blocks under the wheel so that the disc does

not touch the ground.

• Remove the rear sprocket nuts [A].

• Remove the rear sprocket [B].

Rear Sprocket Installation

• Install the sprocket facing the tooth number marking [A]

outward.

• Tighten the rear sprocket nuts.

Torque - Rear Sprocket Nuts: 69 N·m (7.0 kgf·m, 51 ft·lb)

• Install the rear wheel (see Rear Wheel Installation in the

Wheels/Tires chapter).

Coupling Installation

• High-temperature grease the following.

Coupling Grease Seal Lips [A]

Coupling Internal Surface [B]

FINAL DRIVE 11-9

Sprocket, Coupling

• Install the collar [A].

• Install the coupling.

Coupling Bearing Removal

• Remove:

Coupling

Grease Seal

Circlip [A]

Special Tool - Inside Circlip Pliers: 57001-143

• Remove the bearing [A] by tapping from the wheel side.

Special Tool - Bearing Driver Set [B]: 57001-1129

Coupling Bearing Installation

• Replace the bearing with a new one.

NOTE

○Install the bearing so that the marked side faces out.

• Press in the bearing [A] until it is bottomed.

Special Tool - Bearing Driver Set [B]: 57001-1129

• Replace the circlip with a new one.

Special Tool - Inside Circlip Pliers: 57001-143

• Replace the grease seal with a new one.

• Press in the grease seal so that the seal surface is flush

with the end of the hole.

○Apply high-temperature grease to the grease seal lips.

Special Tool - Bearing Driver Set: 57001-1129

11-10 FINAL DRIVE

Sprocket, Coupling

Coupling Bearing Inspection

Since the coupling bearing is made to extremely close

tolerances, the clearance can not normally be measured.

NOTE

○It is not necessary to remove the coupling bearing for

inspection. If the bearing is removed, it will need to be

replaced with a new one.

• Turn the bearing in the coupling back and forth [A] while

checking for plays, roughness or binding.

If the bearing play, roughness or binding is found, replace

the bearing.

• Examine the bearing seal [B] for tears or leakage.

If the seal is torn or is leaking, replace the bearing.

Coupling Bearing Lubrication

NOTE

○Since the coupling bearing is packed with grease and

sealed, lubrication is not required.

Coupling Damper Inspection

• Remove the rear wheel coupling, and inspect the rubber

dampers [A].

• Replace the damper if it appears damaged or deterio-

rated.

Sprocket Wear Inspection

• Visually inspect the engine and rear sprocket teeth for

wear and damage.

If the teeth are worn as illustrated, replace the sprocket,

and inspect the drive chain wear (see Drive Chain Wear

Inspection in the Periodic Maintenance chapter).

Worn Tooth (Engine Sprocket) [A]

Worn Tooth (Rear Sprocket) [B]

Direction of Rotation [C]

NOTE

○If a sprocket requires replacement, the chain is proba-

bly worn also. When replacing a sprocket, inspect the

chain.

FINAL DRIVE 11-11

Sprocket, Coupling

Rear Sprocket Warp Inspection

• Raise the rear wheel off the ground with the stand so that

it will turn freely.

• Set a dial gauge [A] against the rear sprocket [B] near the

teeth as shown in the figure, and rotate [C] the rear wheel

to measure the sprocket runout (warp). The difference

between the highest and lowest dial gauge readings is

the amount of runout (warp).

If the runout exceeds the service limit, replace the rear

sprocket.

Rear Sprocket Warp

Standard:

0.4 mm (0.016 in.) or less

Service Limit:

0.5 mm (0.020 in.)

BRAKES 12-1

Brakes

Table of Contents

Exploded View

12-3

Specifications

12-12

Special Tools

12-13

Brake Lever, Brake Pedal

12-14

Brake Lever Position Adjustment

12-14

Brake Pedal Position Inspection

12-14

Brake Pedal Position Adjustment

12-14

Brake Pedal Removal

12-14

Brake Pedal Installation

12-15

Calipers

12-16

Front Caliper Removal

12-16

Rear Caliper Removal

12-16

Caliper Installation

12-17

Front Caliper Disassembly

12-17

Front Caliper Assembly

12-17

Rear Caliper Disassembly

12-17

Rear Caliper Assembly

12-17

Caliper Fluid Seal Damage

12-18

Caliper Dust Seal Damage

12-18

Caliper Piston and Cylinder Damage

12-19

Brake Pads

12-20

Front Brake Pad Removal

12-20

Front Brake Pad Installation

12-20

Rear Brake Pad Removal

12-21

Rear Brake Pad Installation

12-21

Brake Pad Wear Inspection

12-21

Master Cylinder

12-22

Front Master Cylinder Removal

12-22

Front Master Cylinder Installation

12-22

Rear Master Cylinder Removal

12-22

Rear Master Cylinder Installation

12-23

Front Master Cylinder Disassembly

12-23

Rear Master Cylinder Disassembly

12-23

Master Cylinder Assembly

12-23

Master Cylinder Inspection (Visual Inspection)

12-23

Brake Disc

12-25

Brake Disc Removal

12-25

Brake Disc Installation

12-25

Brake Disc Wear

12-25

Brake Disc Warp

12-25

Brake Fluid

12-26

Brake Fluid Level Inspection

12-26

Brake Fluid Change

12-26

Brake Line Bleeding

12-26

Brake Hose

12-30

Brake Hose and Pipe Removal/Installation

12-30

Brake Hose and Pipe Inspection

12-30

Anti-Lock Brake System (Equipped Models)

12-31

ABS Servicing Precautions

12-34

ABS Troubleshooting Outline

12-36

12-2 BRAKES

Inquiries to Rider

12-39

Self-diagnosis Outline

12-41

Self-diagnosis Procedures

12-41

Service Code Clearing Procedures

12-42

How to Read Service Codes

12-45

How to Erase Service Codes

12-45

ABS Indicator Light (LED) Inspection

12-47

ABS Indicator Light (LED) is Unlit (When the Ignition Switch turned to ON)

12-47

ABS Indicator Light (LED) Lights (When the Motorcycle is Running, - No Service Code)

12-48

Solenoid Valve Inspection (Service Code 13,14,17,18)

12-48

ABS Solenoid Valve Relay Inspection (Service Code 19)

12-48

Front, Rear Wheel Rotation Difference Abnormal (Service Code 25)

12-50

ABS Pump Motor Relay Inspection (Service Code 35)

12-50

Front Wheel Rotation Sensor Signal Abnormal (Service Code 42)

12-51

Front Wheel Rotation Sensor Wiring Inspection (Service Code 43)

12-52

Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44)

12-53

Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45)

12-54

Power Supply Voltage Abnormal (Under-Voltage) (Service Code 52)

12-54

Power Supply Voltage Abnormal (Over-Voltage) (Service Code 53)

12-55

ECU Inspection (Service Code 55)

12-56

ABS Hydraulic Unit Removal

12-56

ABS Hydraulic Unit Installation

12-58

ABS Hydraulic Unit Inspection

12-59

Front Wheel Rotation Sensor Removal

12-59

Front Wheel Rotation Sensor Installation

12-59

Rear Wheel Rotation Sensor Removal

12-60

Rear Wheel Rotation Sensor Installation

12-60

Wheel Rotation Sensor Inspection

12-61

Wheel Rotation Sensor Air Gap Inspection

12-61

Wheel Rotation Sensor Rotor Inspection

12-62

ABS Solenoid Valve Relay Fuse (20 A) Removal

12-62

ABS Motor Relay Fuse (30 A) Removal

12-62

ABS ECU Fuse (10 A) Removal

12-62

Fuse Installation

12-63

Fuse Inspection

12-63

BRAKES 12-5

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

Bleed Valves

7.8

0.80

69 in·lb

Brake Hose Banjo Bolts

2.5

Brake Lever Pivot Bolt

1.0

0.10

9 in·lb

Brake Lever Pivot Bolt Locknut

5.9

0.60

52 in·lb

Front Brake Disc Mounting Bolts

2.8

Front Brake Light Switch Screw

1.2

0.12

11 in·lb

Front Brake Pad Pins

17.2

1.8

Front Brake Reservoir Cap Stopper Screw

1.2

0.12

11 in·lb

Front Caliper Assembly Bolts

2.8

Front Caliper Mounting Bolts

3.5

Front Master Cylinder Bleed Valve

7.8

0.80

69 in·lb

Front Master Cylinder Clamp Bolts

8.8

0.90

78 in·lb

B: Apply brake fluid.

L: Apply a non-permanent locking agent.

R: Replacement Parts

S: Follow the specified tightening sequence.

Si: Apply silicone grease (ex. PBC grease).

BRAKES 12-7

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

Bleed Valves

7.8

0.80

69 in·lb

Brake Hose Banjo Bolts

2.5

Brake Pedal Bolt

8.8

0.90

78 in·lb

Rear Brake Disc Mounting Bolts

2.5

Rear Brake Pad Pin

17.2

1.8

Rear Caliper Assembly Bolts

3.8

Rear Caliper Mounting Bolts

2.5

Rear Master Cylinder Mounting Bolts

2.5

Rear Master Cylinder Push Rod Locknut

17.2

1.8

B: Apply brake fluid.

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

Si: Apply silicone grease (ex. PBC grease).

BRAKES 12-9

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

Bleed Valves

7.8

0.80

69 in·lb

Brake Hose Banjo Bolts

2.5

Brake Lever Pivot Bolt

1.0

0.10

9 in·lb

Brake Lever Pivot Bolt Locknut

5.9

0.60

52 in·lb

Brake Pipe Joint Nuts

1.8

Front Brake Disc Mounting Bolts

2.8

Front Brake Light Switch Screw

1.2

0.12

11 in·lb

Front Brake Pad Pins

17.2

1.8

Front Brake Reservoir Cap Stopper Screw

1.2

0.12

11 in·lb

Front Caliper Assembly Bolts

2.8

Front Caliper Mounting Bolts

3.5

Front Master Cylinder Bleed Valve

7.8

0.80

69 in·lb

Front Master Cylinder Clamp Bolts

8.8

0.90

78 in·lb

B: Apply brake fluid.

L: Apply a non-permanent locking agent.

R: Replacement Parts

S: Follow the specified tightening sequence.

Si: Apply silicone grease (ex. PBC grease).

BRAKES 12-11

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

Bleed Valves

7.8

0.80

69 in·lb

Brake Hose Banjo Bolts

2.5

Brake Pedal Bolt

8.8

0.90

78 in·lb

Brake Pipe Joint Nuts

1.8

Rear Brake Disc Mounting Bolts

2.8

Rear Brake Pad Pin

17.2

1.8

Rear Caliper Assembly Bolts

3.8

Rear Caliper Mounting Bolts

2.5

Rear Master Cylinder Mounting Bolts

2.5

Rear Master Cylinder Push Rod Locknut

17.2

1.8

B: Apply brake fluid.

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

Si: Apply silicone grease (ex. PBC grease).

12-12 BRAKES

Specifications

Item

Standard

Service Limit

Brake Lever, Brake Pedal

Brake Lever Position

6-way adjustable (to suit rider)

- - -

Brake Lever Free Play

Non-adjustable

- - -

Pedal Free Play

Non-adjustable

- - -

Pedal Position

About 45 mm (1.8 in.) below footpeg top

- - -

Brake Pads

Lining Thickness:

Front

4.0 mm (0.16 in.)

1 mm (0.04 in.)

Rear

5.0 mm (0.20 in.)

1 mm (0.04 in.)

Brake Discs

Thickness:

Front

4.8 ∼ 5.2 mm (0.19 ∼ 0.20 in.)

4.5 mm (0.18 in.)

Rear

5.8 ∼ 6.2 mm (0.23 ∼ 0.24 in.)

5.5 mm (0.22 in.)

Runout

TIR 0.15 mm (0.006 in.) or less

TIR 0.3 mm (0.01 in.)

Brake Fluid

Grade

DOT4

- - -

12-14 BRAKES

Brake Lever, Brake Pedal

Brake Lever Position Adjustment

The brake lever adjuster has 6 positions so that the brake

lever position can be adjusted to suit the operator’s hand.

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

the number with the arrow mark [B] on the lever holder.

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

ber 6 and maximum at number 1.

Brake Pedal Position Inspection

• Check that the brake pedal [A] is in the correct position.

Footpeg [B]

Pedal Position

Standard:

About 45 mm (1.8 in.) [C] below top of

footpeg

If it is incorrect, adjust the brake pedal position.

Brake Pedal Position Adjustment

NOTE

○Usually it is not necessary to adjust the pedal position,

but always adjust it when push rod locknut has been

loosened.

• Loosen the locknut [A] and turn the push rod with the hex

head [B] to achieve the correct pedal position.

If the length [C] shown is 80 ±1 mm (3.1 ±0.04 in.), the

pedal position will be within the standard range.

• Tighten:

Torque - Rear Master Cylinder Push Rod Locknut: 17.2 N·m

(1.8 kgf·m, 13 ft·lb)

• Check the brake light switch operation (see Brake Light

Switch Operation Inspection in the Periodic Maintenance

chapter).

Brake Pedal Removal

• Remove:

Rear Master Cylinder Mounting Bolts [A]

Right Footpeg Bracket Bolts [B]

BRAKES 12-15

Brake Lever, Brake Pedal

• Remove:

Cotter Pin [A]

Joint Pin [B]

Rear Brake Light Switch Spring [C]

Return Spring [D]

• Remove the mounting bolt [E] and take out the brake

pedal.

Brake Pedal Installation

• Apply grease to the pivot shaft [A] and install the washer

[B].

• Install:

Brake Pedal [C]

Washer [D]

Brake Pedal Bolt [E]

Torque - Brake Pedal Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)

• Hook the lower end of the rear brake light switch spring

[A] on the pedal hook.

• Hook the upper end of the return spring [B] on the pedal

hook.

• Replace the cotter pin with a new one.

• Insert the cotter pin [A] and bend the pin ends [B].

• Install the right footpeg bracket.

Torque - Front Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m,

18 ft·lb)

○Depress the brake pedal [A] and then align the bolts holes

of the master cylinder [B].

Torque - Rear Master Cylinder Mounting Bolts: 25 N·m (2.5

kgf·m, 18 ft·lb)

• Check the brake pedal position (see Brake Pedal Position

Inspection).

12-16 BRAKES

Calipers

Front Caliper Removal

• Loosen the banjo bolt [A] at the brake hose lower end,

and tighten it loosely.

• Unscrew the caliper mounting bolts [B], and detach the

caliper [C] from the disc.

CAUTION

Do not loosen the caliper assembly bolts. Take out

only the caliper mounting bolts for caliper removal.

Loosening the caliper assembly bolts will cause

brake fluid leakage.

• Unscrew the banjo bolt and remove the brake hoses [D]

from the caliper (see Brake Hose Removal/Installation).

CAUTION

Immediately wash away any brake fluid that spills.

NOTE

○If the caliper is to be disassembled after removal and if

compressed air is not available, disassemble the caliper

before the brake hose is removed (see Front Caliper

Disassembly).

Rear Caliper Removal

• Loosen the banjo bolt [A] at the brake hose lower end,

and tighten it loosely.

• Unscrew the caliper mounting bolts [B], and detach the

caliper [C] from the disc.

CAUTION

Do not loosen the caliper assembly bolts. Take out

only the caliper mounting bolts for caliper removal.

Loosening the caliper assembly bolts will cause

brake fluid leakage.

• Unscrew the banjo bolt and remove the brake hose [D]

from the caliper (see Brake Hose Removal/Installation).

CAUTION

Immediately wash away any brake fluid that spills.

NOTE

○If the caliper is to be disassembled after removal and if

compressed air is not available, disassemble the caliper

before the brake hose is removed (see Rear Caliper

Disassembly).

BRAKES 12-17

Calipers

Caliper Installation

• Install the caliper and brake hose lower end.

○Replace the washers on each side of hose fitting with new

ones.

• Tighten:

Torque - Caliper Mounting Bolts

Front: 34 N·m (3.5 kgf·m, 25 ft·lb)

Rear: 25 N·m (2.5 kgf·m, 18 ft·lb)

Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18

ft·lb)

• Check the fluid level in the brake reservoirs.

• Bleed the brake line (see Brake Line Bleeding).

• Check the brake for good braking power, no brake drag,

and no fluid leakage.

WARNING

Do not attempt to drive the motorcycle until a full

brake lever or pedal is obtained by pumping the

brake lever or pedal until the pads are against the

disc. The brakes will not function on the first appli-

cation of the lever or pedal if this is not done.

Front Caliper Disassembly

• Refer to the Caliper Rubber Parts Replacement in the Pe-

riodic Maintenance chapter.

Front Caliper Assembly

• Refer to the Caliper Rubber Parts Replacement in the Pe-

riodic Maintenance chapter.

Rear Caliper Disassembly

• Refer to the Caliper Rubber Parts Replacement in the Pe-

riodic Maintenance chapter.

Rear Caliper Assembly

• Refer to the Caliper Rubber Parts Replacement in the Pe-

riodic Maintenance chapter.

Kawasaki ZZR 1400, ZZR1400 ABS, Ninja ZX-14 Motorcycle. Service Manual (2006-2007 year) - page 4