Content      ..     4      5      6      7     ..

Kawasaki ZZR 1400, ZZR1400 ABS, Ninja ZX-14 Motorcycle. Service Manual (2006-2007 year) - page 6

15-10 FRAME

Seat

Seat Removal

• Insert the ignition switch key [A] into the seat lock, turning

the key counterclockwise, pulling up on the rear of the

seat [B], and pulling the seat backward.

• For seat cover equipped models; note the following.

• Remove:

Bolts [A]

Seat Cover [B]

Seat Installation

• Insert the brackets [A] of the fuel tank into the slots [B] of

the seat.

• Insert the projections [A] of the seat into the slots [B] of

the frame, and insert the seat hook [C] into the slot [D] of

the frame.

• Push down the rear part of the seat until the lock clicks.

FRAME 15-11

Fairings

Lower Fairing Removal

• Pull up the core by the thin blade driver.

• Remove the quick rivet [A].

• Remove the bolts [B] with washers.

• Clear the hook portions from the slots.

• Separate the left lower fairing from the right lower fairing.

Lower Fairing Installation

• Insert the hook portions [A] into the slots [B].

• Tighten the bolts with washers.

• Set the quick rivet and push the core.

Fairing Cover Removal

• Remove the bolts [A].

• Pull out the fairing cover [B], and clear the stoppers.

• Insert the projections [A] into the holes [B].

• Tighten the bolts.

Middle Fairing Removal

• Remove:

Lower Fairings (see Lower Fairing Removal)

Fairing Covers (see Fairing Cover Removal)

Inner Covers (see Inner Cover Removal)

Fuel Tank Cover (see Fuel Tank Removal in the Fuel

System (DFI) chapter)

• Push the central pin, and then remove the quick rivets [A].

15-12 FRAME

Fairings

• Remove:

Bolts [A] with Washers

Turn Signal Lead Connector

• Remove each middle fairing.

○Clear the hook [B] from the bracket.

• Remove:

Inner Fairing (see Inner Fairing Removal)

Screws

Bracket

Turn Signal Light

Middle Fairing Installation

• Install the turn signal light to the middle fairing, and tighten

the screws.

• Install the inner fairing (see Inner Fairing Installation).

• Connect the turn signal lead connector.

• Hang the hook of the middle fairing to the bracket.

• Install the washers and bolts.

• Install the quick rivets.

• Install the removed parts (see appropriate chapters).

Windshield Removal

• Remove:

Bolts [A] with Washers

Windshield [B]

FRAME 15-13

Fairings

Windshield Installation

• Put the front tongue [A] into the hollow [B].

• Tighten:

Torque - Windshield Mounting Bolts:

0.42

N·m (0.043

kgf·m, 3.7 in·lb)

Upper Fairing Removal

• Remove:

Lower Fairings (see Lower Fairing Removal)

Fairing Covers (see Fairing Cover Removal)

Inner Covers (see Inner Cover Removal)

Middle Fairings (see Middle Fairing Removal)

Windshield (see Windshield Removal)

Vehicle-down Sensor Lead Connector

Immobilizer Amplifier Lead Connector (Equipped Mod-

els)

• Unscrew the bracket screws [A].

• Disconnect:

Headlight Lead Connectors [A] (Both Sides)

City Light Lead Connectors [B] (Both Sides)

• Remove the bolts [A].

• Pull out the upper fairing forward.

Upper Fairing Disassembly

• Remove:

Upper Fairing (see Upper Fairing Removal)

Upper Inner Fairing (see Upper Inner Fairing Removal)

Headlights [A] (see Headlight Removal in the Electrical

System chapter)

Nuts [B] and Rear View Mirrors (Both Sides)

Upper Fairing Assembly

• Installation is the reverse of removal.

15-14 FRAME

Fairings

Upper Fairing Installation

• Installation is the reverse of removal.

Inner Cover Removal

• Remove the bolts [A].

• Remove the inner cover [B].

○Pull the inner cover backward, and clear the hooks.

Inner Cover Installation

• Insert the hooks [A] into the slots [B].

• Tighten the bolts.

Upper Inner Fairing Removal

• Remove:

Upper Fairing (see Upper Fairing Removal)

Bolt [A]

Upper Inner Fairing [B]

○Slide out the upper inner fairing backward.

FRAME 15-15

Fairings

Upper Inner Fairing Installation

• Insert the slots [A] of the upper inner fairing into the hooks

[B] of the upper fairing.

• Tighten the bolt.

Upper Fairing Bracket Removal

• Remove:

Upper Fairing (see Upper Fairing Removal)

Front and Middle Inlet Ducts (see Front and Middle Inlet

Duct Removal in the Fuel System (DFI) chapter)

Rear Inlet Ducts (see Rear Inlet Duct Removal in the

Fuel System (DFI) chapter)

Meter Unit (see Meter Unit Removal in the Electrical Sys-

tem chapter)

Headlight Relays [A]

Bolts [B]

Upper Fairing Bracket [C]

Upper Fairing Bracket Installation

• Installation is the reverse of removal.

Inner Fairing Removal

• Remove:

Middle Fairings (see Middle Fairing Removal)

Quick Rivet [A]

Bolts [B]

Inner Fairing [C]

Inner Fairing Installation

• Installation is the reverse of removal.

Rear Fairing Removal

• Remove:

Bolts [A]

Rear Fairing [B]

Rear Fairing Installation

• Installation is the reverse of removal.

15-16 FRAME

Seat Cover

Seat Cover Removal

• Remove:

Seat (see Seat Removal)

Bolts [A]

Screws [B]

Grab Rail [C] (Equipped Models)

Center Seat Cover [D]

• Remove the quick rivets [A].

• Remove the bolts [A].

• Clear the side seat covers [B] from the rear fender.

• Disconnect the turn signal lead connectors, and remove

each side seat cover.

• Remove:

Screws [A]

Turn Signal Light [B]

Seat Cover Installation

• Connect the turn signal lead connector.

• Insert the hole [A] to the projection [B].

• Install the bolts and quick rivets.

FRAME 15-17

Seat Cover

• Insert the projection [A] into the hole [B].

• Tighten the screws.

• Install the grab rail (equipped models).

• Tighten:

Torque - Grab Rail Mounting Bolts: 25 N·m (2.5 kgf·m, 18

ft·lb)

15-18 FRAME

Fenders

Front Fender Removal

• Remove:

Brake Hose Clamps [A] (Both Sides)

Bolts [B] with Washer (Both Sides)

Bracket [C] (ZX1400B Models)

• Remove the front fender assy [D].

• Remove the screws [A].

• Separate the front fender covers [B] and front fender [C].

Front Fender Installation

• Install the front fender covers to the front fender.

○Insert the hooks [A] of the front fender cover into the slots

[B] of the front fender.

• Install the front fender assy to the front fork.

• Install the brake hose clamps to the front fender holes.

Flap and Rear Fender Removal

• Remove:

Seat (see Seat Removal)

Seat Covers (see Seat Cover Removal)

Fuel Tank (see Fuel Tank Removal in the Fuel System

(DFI) chapter)

Tool Kit Case [A] (see ECU Removal in the Fuel System

(DFI) chapter)

Relay Box [B] (see Relay Box Removal in the Electrical

System chapter)

ECU (see ECU Removal in the Fuel System (DFI) chap-

ter)

Rear Wheel (see Rear Wheel Removal in the

Wheels/Tires chapter)

Fuse Box [C]

Bolts [D] and Cover [E]

Seat Lock

Bolts [F]

Screws [G]

FRAME 15-19

Fenders

• Remove:

Nuts [A]

License Light Connector (Disconnect)

Flap (with License Light)

Tail/Brake Light (LED) (see Tail/Brake Light (LED) Re-

moval in the Electrical System chapter)

• Pull out the rear fender [B] backward and downward.

Flap and Rear Fender Installation

• Hang the hook [A] of the rear fender to the slot [B] of the

rear frame.

• Tighten:

Torque - Rear Fender Mounting Screws:

1.2

N·m (0.12

kgf·m, 11 in·lb)

• Install the removed parts (see appropriate chapters).

• Run the harness correctly (see Cable, Wire, and Hose

Routing section in the Appendix chapter).

15-20 FRAME

Frame

Rear Frame Removal

• Remove:

Rear Fender (see Rear Fender Removal)

Regulator/Rectifier [A] (see Regulator/Rectifier Inspec-

tion in the Electrical System chapter)

Tail/Brake Light (see Tail/Brake Light Removal in the

Electrical System chapter)

Bolts [B] (Both Sides)

Rear Footpeg Bracket Bolts [C] and Brackets (Both

Sides)

Frame Bolts [D]

Rear Frame Installation

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

rear frame bolt, and tighten them.

Torque - Rear Frame Bolts: 44 N·m (4.5 kgf·m, 32 ft·lb)

Rear Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m, 18

ft·lb)

• Install the removed parts (see appropriate chapters).

Frame Inspection

• Visually inspect the frame [A] for cracks, dents, bending,

or warp.

If there is any damage to the frame, replace it.

WARNING

A repaired frame may fail in use, possibly causing

an accident. If the frame is bent, dented, cracked,

or warped, replace it.

FRAME 15-21

Center Stand, Sidestand

Center Stand Removal (Equipped Models)

• Remove:

Muffler Bodies (see Muffler Body Removal in the Engine

Top End chapter)

Spring [A]

Bolts [B]

Bolts [C] and Nuts

Center Stand [D]

Center Stand Installation (Equipped Models)

• Apply grease to the sliding area [A] of the center stand

[B].

• Tighten the bolts [C] and lock them with the nuts.

Torque - Center Stand Bolts: 44 N·m (4.5 kgf·m, 32 ft·lb)

• Hook the spring [D] so that face the long spring end up-

ward.

○Install the spring hook direction as shown in the figure.

Sidestand Removal

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

• Remove:

Sidestand Switch Bolt [A]

Spring [B]

Sidestand Bolt [C]

Sidestand [D]

Sidestand Bracket Bolts [E]

Sidestand Installation

• Apply grease to the sliding area [A] of the sidestand [B].

• Tighten the bolt and lock them with the nut.

Torque - Sidestand Bracket Bolts [C]: 49 N·m (5.0 kgf·m, 36

ft·lb)

Sidestand Bolt [D]: 44 N·m (4.5 kgf·m, 32 ft·lb)

• Hook the spring [E] so that face the long spring end up-

ward.

○Install the spring hook direction as shown in the figure.

• Install the sidestand switch.

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

switch bolt, and tighten it.

Torque - Sidestand Switch Bolt [F]: 8.8 N·m (0.90 kgf·m, 78

in·lb)

16-4 ELECTRICAL SYSTEM

Exploded View

ELECTRICAL SYSTEM 16-5

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Headlight Mounting Screws

1.2

0.12

11 in·lb

2

Front Turn Signal Light Mounting Screws

1.2

0.12

11 in·lb

3

Rear Turn Signal Light Mounting Screws

1.2

0.12

11 in·lb

4

License Plate Light Mounting Screws

1.2

0.12

11 in·lb

5

Tail/Brake Light Mounting Screws

1.2

0.12

11 in·lb

6

License Plate Light Cover Mounting Screws

0.9

0.09

8 in·lb

16-6 ELECTRICAL SYSTEM

Exploded View

ELECTRICAL SYSTEM 16-7

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Camshaft Position Sensor Bolt

9.8

1.0

87 in·lb

2

Water Temperature Sensor

25

2.5

18

3

Gear Position Switch Screws

2.9

0.30

26 in·lb

L

4

Gear Position Switch Lead Clamp Bolts

9.8

1.0

87 in·lb

5

Spark Plugs

13

1.3

115 in·lb

6

Stator Coil Bolts

12

1.2

106 in·lb

Alternator Rotor Bolt (First)

69

7.0

51

S

7

Alternator Rotor Bolt (Final)

110

11.2

81

S

8

Crankshaft Sensor Bolts

5.9

0.60

52

in·lb

L

9

Regulator/Rectifier Bolts

9.8

1.0

87

in·lb

10

Engine Ground Terminal Bolt

9.8

1.0

87

in·lb

11

Speed Sensor Bolt

3.9

0.40

35

in·lb

L

12

Alternator Cover Bolts

9.8

1.0

87

in·lb

13

Alternator Lead Holding Plate Bolts

8.3

0.85

73

in·lb

L

14

Crankshaft Sensor Cover Bolts

9.8

1.0

87

in·lb

L (1)

15

Fuel Level Sensor Bolts

6.9

0.70

61

in·lb

L

16. Battery

17. ECU

18. Relay Box

19. Headlight Relay (Low)

20. Headlight Relay (Hi)

21. Turn Signal Relay

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

S: Follow the specified tighten sequence.

SS: Apply silicone sealant.

16-8 ELECTRICAL SYSTEM

Exploded View

ELECTRICAL SYSTEM 16-9

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Front Brake Light Switch Screw

1.2

0.12

11 in·lb

2

Right Switch Housing Screws

3.5

0.36

31 in·lb

3

Left Switch Housing Screws

3.5

0.36

31 in·lb

4

Starter Motor Mounting Bolts

9.8

1.0

87 in·lb

5

Sidestand Switch Bolt

8.8

0.90

78 in·lb

L

6

Starter Motor Cable Mounting Bolt

3.9

0.40

35 in·lb

7

Starter Motor Cable Terminal Nut

5.9

0.60

52 in·lb

8

Starter Lockout Switch Screw

0.7

0.07

6 in·lb

9

Starter Motor Terminal Locknut

6.9

0.70

61 in·lb

10

Starter Motor Through Bolts

3.4

0.35

30 in·lb

11. Immobilizer Models

12. ZX1400B Models

13. Other than France and Malaysia Models

14. France and Malaysia Models

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

16-10 ELECTRICAL SYSTEM

Parts Location

16-12 ELECTRICAL SYSTEM

Wiring Diagram (United States, Canada, New Zealand and Colombia)

ELECTRICAL SYSTEM 16-13

Wiring Diagram (United States, Canada, New Zealand and Colombia)

16-14 ELECTRICAL SYSTEM

Wiring Diagram (Other than United States, Canada, New Zealand and Colombia)

ELECTRICAL SYSTEM 16-15

Wiring Diagram (Other than United States, Canada, New Zealand and Colombia)

16-16 ELECTRICAL SYSTEM

Wiring Diagram (ZX1400B Models)

ELECTRICAL SYSTEM 16-17

Wiring Diagram (ZX1400B Models)

ELECTRICAL SYSTEM 16-19

Special Tools and Sealant

Hand Tester:

Harness Adapter:

57001-1394

57001-1562

Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5:

Key Registration Unit:

57001-1405

57001-1582

Peak Voltage Adapter:

Grip:

57001-1415

57001-1591

Lead Wire - Peak Voltage Adapter:

Rotor Holder:

57001-1449

57001-1672

Needle Adapter Set:

Stopper:

57001-1457

57001-1679

16-22 ELECTRICAL SYSTEM

Electrical Wiring

Wiring Inspection

• Visually inspect the wiring for signs of burning, fraying,

etc.

If any wiring is poor, replace the damaged wiring.

• Pull each connector [A] apart and inspect it for corrosion,

dirt, and damage.

If the connector is corroded or dirty, clean it carefully. If it

is damaged, replace it.

• Check the wiring for continuity.

○Use the wiring diagram to find the ends of the lead which

is suspected of being a problem.

○Connect the hand tester between the ends of the leads.

Special Tool - Hand Tester: 57001-1394

○Set the tester to the × 1 Ω range, and read the tester.

If the tester does not read 0 Ω, the lead is defective. Re-

place the lead or the wiring harness [B] if necessary.

ELECTRICAL SYSTEM 16-23

Battery

Battery Removal

• Turn off the ignition switch.

• Remove:

Right Fairing Cover (see Fairing Cover Removal in the

Frame chapter)

Bolt [A]

Battery Compartment Cover [B]

○Clear the stoppers from the frame.

• Remove:

Bolt [A]

Bracket Bolts [B]

Bracket [C]

Connector [D] (Disconnect)

CAUTION

Be sure to disconnect the negative (-) cable first.

• Slightly pull out the battery tray [A].

• Unhook the band [B].

• Remove the battery cover [C].

• Slide the red cap [A] out.

• Disconnect the positive (+) cable [B].

• Remove the battery tray with battery [C].

• Disconnect the negative (-) cable [A].

• Remove the battery [B] from the battery tray.

16-24 ELECTRICAL SYSTEM

Battery

Battery Installation

• Place the battery in the tray.

• Connect the negative (-) cable to the battery.

• Apply a light coat of grease on the terminals to prevent

corrosion.

• Insert the battery tray along with the battery into the bat-

tery compartment.

• Connect the positive (+) cable to the battery.

• Cover the (+) terminal with its red cap [A].

• Install the battery cover on the battery, and hook the band.

• Be sure insert the battery tray along with the battery into

the battery compartment.

• Put the holes [A] of the bracket to the projections [B] of

the battery tray.

• Tighten the bracket bolts.

• Connect the connector.

• Connect the negative (-) cable to the frame.

• Put the projections of the battery compartment cover into

the holes of the frame.

• Install:

Bolt

Right Fairing Cover (see Fairing Cover Installation in the

Frame chapter)

Battery Activation

Electrolyte Filling

• Make sure that the model name [A] of the electrolyte con-

tainer matches the model name [B] of the battery. These

names must be the same.

Battery Model Name for ZX1400A/B: FTZ14-BS

CAUTION

Be sure to use the electrolyte container with the

same model name as the battery since the elec-

trolyte volume and specific gravity vary with the

battery type. This is to prevent overfilling of the

electrolyte, shorting the battery life, and deteriora-

tion of the battery performance.

CAUTION

Do not remove the aluminum sealing sheet [A] from

the filler ports [B] until just prior to use. Be sure to

use the dedicated electrolyte container for correct

electrolyte volume.

• Place the battery on a level surface.

• Check to see that the sealing sheet has no peeling, tears,

or holes in it.

• Remove the sealing sheet.

NOTE

○The battery is vacuum sealed. If the sealing sheet has

leaked air into the battery, it may require a longer initial

charge.

ELECTRICAL SYSTEM 16-25

Battery

• Remove the electrolyte container from the vinyl bag.

• Detach the strip of caps [A] from the container and set

aside, these will be used later to seal the battery.

NOTE

○Do not pierce or otherwise open the sealed cells [B] of

the electrolyte container. Do not attempt to separate

individual cells.

• Place the electrolyte container upside down with the six

sealed cells into the filler ports of the battery. Hold the

container level, push down to break the seals of all six

cells. You will see air bubbles rising into each cell as the

ports fill.

NOTE

○Do not tilt the electrolyte container

• Check the electrolyte flow.

If no air bubbles [A] are coming up from the filler ports, or

if the container cells have not emptied completely, tap the

container [B] a few times.

• Keep the container in place for 20 minutes or more. Don’t

remove the container from the battery until it’s empty, the

battery requires all the electrolyte from the container for

proper operation.

CAUTION

Removal of the container before it is completely

empty can shorten the service life of the battery. Do

not remove the electrolyte container until it is com-

pletely empty and 20 minutes have elapsed.

• Gently remove the container from the battery.

• Let the battery sit for 60 minutes prior to charging to allow

the electrolyte to permeate into the plates for optimum

performance.

NOTE

○Charging the battery immediately after filling can

shorten service life. Let the battery sit for at least 60

minutes after filling.

16-26 ELECTRICAL SYSTEM

Battery

Initial Charge

• Place the strip [A] of caps loosely over the filler ports.

• Newly activated sealed batteries require an initial charge.

Standard Charge:

1.4 A × 5 ∼ 10 hours

If using a recommended battery charger, follow the

charger’s instructions for newly activated sealed battery.

Kawasaki-recommended chargers:

Optimate III

Yuasa 1.5 Amp Automatic Charger

Battery Mate 150-9

If the above chargers are not available, use equivalent

one.

NOTE

○Charging rates will vary depending on how long the

battery has been stored, temperature, and the type of

charger used. Let battery sit 30 minutes after initial

charge, then check voltage using a voltmeter. If it is

not at least 12.6 volts, repeat charging cycle.

• After charging is completed, press down firmly with both

hands to seat the strip of caps [A] into the battery (don’t

pound or hammer). When properly installed, the strip of

the caps will be level with the top of the battery.

CAUTION

Once the strip of the caps is installed onto the bat-

tery, never remove the caps, nor add water or elec-

trolyte to the battery.

NOTE

○To ensure maximum battery life and customer satisfac-

tion, it is recommended the battery be load tested at

three times its amp-hour rating for 15 seconds.

Re-check voltage and if less than 12.6 volts repeat the

charging cycle and load test. If still below 12.6 volts the

battery is defective.

ELECTRICAL SYSTEM 16-27

Battery

Precautions

1) No need of topping-up

No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the

seal cap to add water is very dangerous. Never do that.

2) Refreshing charge

If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been

discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification

(see this chapter).

When a fast charge is inevitably required, do it following precisely the maximum charge current

and time conditions indicated on the battery.

CAUTION

This battery is designed to sustain no unusual deterioration if refresh-charged according

to the method specified above. However, the battery’s performance may be reduced no-

ticeably if charged under conditions other than given above. Never remove the seal cap

during refresh charge.

If by chance an excessive amount of gas is generated due to overcharging, the relief valve

releases the gas to keep the battery normal.

3) When you do not use the motorcycle for months:

Give a refresh charge before you store the motorcycle and store it with the negative cable re-

moved. Give a refresh charge once a month during storage.

4) Battery life:

If the battery will not start the engine even after several refresh charges, the battery has ex-

ceeded its useful life. Replace it (Provided, however, the vehicle’s starting system has no prob-

lem).

WARNING

Keep the battery away from sparks and open flames during charging, since the battery

gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger,

connect the battery to the charger before turning on the charger.

This procedure prevents sparks at the battery terminals which could ignite any battery

gases.

No fire should be drawn near the battery, or no terminals should have the tightening loos-

ened.

The electrolyte contains sulfuric acid. Be careful not to have it touch your skin or eyes. If

touched, wash it off with liberal amount of water. Get medial attention if severe.

Interchange

A sealed battery can fully display its performance only when combined with a proper vehicle electric

system. Therefore, replace a sealed battery only on a motorcycle which was originally equipped with

a sealed battery.

Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original

equipment, the sealed battery’s life will be shortened.

Charging Condition Inspection

○Battery charging condition can be checked by measuring

battery terminal voltage with a digital voltmeter [A].

• Remove:

Battery (see Battery Removal)

• Measure the battery terminal voltage.

NOTE

○Measure with a digital voltmeter which can be read one

decimal place voltage.

16-28 ELECTRICAL SYSTEM

Battery

If the reading is 12.6 V or more, no refresh charge is re-

quired, however, if the read is below the specified, refresh

charge is required.

Battery Terminal Voltage

Standard:

12.6 V or more

Refreshing Charge

• Remove the battery [A] (see Battery Removal).

• Do refresh charge by following method according to the

battery terminal voltage.

WARNING

This battery is sealed type. Never remove sealing

cap [B] even at charging. Never add water. Charge

with current and time as stated below.

Terminal Voltage: 11.5 ∼ less than 12.6 V

Standard Charge

1.4 A × 5 ∼ 10 h (see following chart)

Quick Charge

7A ×1 h

CAUTION

If possible, do not quick charge. If quick charge is

done unavoidably, do standard charge later on.

Terminal Voltage: less than 11.5 V

Charging Method:

1.4 A × 20 h

NOTE

○Increase the charging voltage to a maximum voltage of

25 V if the battery will not accept current initially. Charge

for no more than 5 minutes at the increased voltage then

check if the battery is drawing current. If the battery

will accept current decrease the voltage and charge by

the standard charging method described on the battery

case. If the battery will not accept current after 5 min-

utes, replace the battery.

Battery [A]

Battery Charger [B]

Standard Value [C]

Current starts to flow [D]

• Determine the battery condition after refresh charge.

○Determine the condition of the battery left for 30 minutes

after completion of the charge by measuring the terminal

voltage according to the table below.

Criteria

Judgement

12.6 V or higher

Good

12.0 ∼ lower than 12.6 V

Charge insufficient → Recharge

lower than 12.0 V

Unserviceable → Replace

ELECTRICAL SYSTEM 16-29

Charging System

Alternator Cover Removal

• Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System

(DFI) chapter)

Alternator Lead Connector [A]

Fuel Tank Bracket [B]

• Remove:

Bolts [A]

Cover [B]

• Pull the alternator lead out of between the engine and

frame.

Alternator Cover Installation

• Apply silicone sealant to the alternator lead grommet and

crankcase halves mating surface [A] on the front and rear

sides of the cover mount.

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

• Check that dowel pins [B] are in place on the crankcase.

• Install a new gasket and the alternator cover.

• Tighten:

Torque - Alternator Cover Bolts:

9.8 N·m (1.0 kgf·m, 87

in·lb)

Stator Coil Removal

• Remove:

Alternator Cover (see Alternator Cover Removal)

Holding Plate Bolts [A] and Plate

Alternator Lead Grommet [B]

Stator Coil Bolts [C]

• Remove the stator coil [D] from the alternator cover.

16-30 ELECTRICAL SYSTEM

Charging System

Stator Coil Installation

• Tighten the stator coil bolts to the specified torque.

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

• Apply silicone sealant to the circumference of the alter-

nator lead grommet, and fit the grommet into the notch of

the cover securely.

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

• Secure the alternator lead with a holding plate [A], and

apply a non-permanent locking agent to the thread of the

plate bolts and tighten them.

Torque - Alternator Lead Holding Plate Bolts: 8.3 N·m (0.85

kgf·m, 73 in·lb)

• Install the alternator cover (see Alternator Cover Installa-

tion).

Alternator Rotor Removal

• Remove the alternator cover (see Alternator Cover Re-

moval).

• Clean off the oil from the outer circumference of the rotor.

• Hold the alternator rotor steady with the rotor holder [A],

and remove the rotor bolt [B] and washer.

Special Tools - Grip [C]: 57001-1591

Rotor Holder: 57001-1672

Stopper [D]: 57001-1679

• Using the flywheel puller [A], remove the alternator rotor

from the crankshaft.

Special Tool - Flywheel Puller, M38 × 1.5: 57001-1405

CAUTION

Do not attempt to strike the alternator rotor itself.

Striking the rotor can cause the magnets to lose

their magnetism.

Alternator Rotor Installation

• Using a cleaning fluid, clean off any oil or dirt on the fol-

lowing portions and dry them with a clean cloth.

Crankshaft Tapered Portion [A]

Alternator Rotor Tapered Portion [B]

• Install the alternator rotor.

ELECTRICAL SYSTEM 16-31

Charging System

• Using a cleaning fluid, clean off any oil or dirt on the

washer [A] and dry if with a clean cloth.

• Install the washer so that its chamfer side [B] faces the

rotor bolt [C].

NOTE

○Confirm the alternator rotor fit or not to the crankshaft

before tightening it with specified torque.

• Install the rotor bolt [B] and tighten it with 69 N·m (7.0

kgf·m, 51 ft·lb) of torque.

• Remove the rotor bolt and washer.

• Check the tightening torque with flywheel puller [A].

If the rotor is not pulled out with 20 N·m (2.0 kgf·m, 15

ft·lb) of drawing torque, it is installed correctly.

If the rotor is pulled out with under 20 N·m (2.0 kgf·m, 15

ft·lb) of drawing torque, clean off any oil dirt or flaw of the

crankshaft and rotor tapered portion, and dry them with

a clean cloth. Then, confirm that it is not pulled out with

above torque.

• Install the rotor bolt and washer.

• Tighten the alternator rotor bolt [A] while holding the alter-

nator rotor steadily with the holder [B].

Special Tools - Grip [C]: 57001-1591

Rotor Holder: 57001-1672

Stopper [D]: 57001-1679

Torque - Alternator Rotor Bolt: 110 N·m (11.2 kgf·m, 81 ft·lb)

• Install the alternator cover (see Alternator Cover Installa-

tion).

Alternator Inspection

There are three types of alternator failures: short, open

(wire burned out), or loss in rotor magnetism. A short or

open in one of the coil wires will result in either a low output,

or no output at all. A loss in rotor magnetism, which may be

caused by dropping or hitting the alternator, by leaving it

near an electromagnetic field, or just by aging, will result in

low output.

16-32 ELECTRICAL SYSTEM

Charging System

• To check the alternator output voltage, do the following

procedures.

○Turn off the ignition switch.

○Remove the right seat cover (see Seat Cover Removal in

the Frame chapter).

○Disconnect the alternator lead connector [A].

○Connect the hand tester as shown in the table 1.

Special Tool - Hand Tester: 57001-1394

○Start the engine.

○Run it at the rpm given in the table 1.

○Note the voltage readings (total 3 measurements).

Table 1 Alternator Output Voltage

Tester

Connections

Reading

Range

Tester (+) to

Tester (-) to

@4 000 rpm

250 V AC

One Black Lead

Another Black Lead

51 V or more

If the output voltage shows the value in the table, the al-

ternator operates properly.

If the output voltage shows a much higher than the value

in the table, the regulator/rectifier is damaged. A much

lower reading than that given in the table indicates that

the alternator is defective.

• Check the stator coil resistance as follows.

○Stop the engine.

○Connect the commercially available tester as shown in the

table 2.

○Note the readings (total 3 measurement).

Table 2 Stator Coil Resistance

at 20°C (68°F)

Tester

Connections

Reading

Range

Tester (+) to

Tester (-) to

× 1 Ω

One Black Lead

Another Black Lead

0.05 ∼ 0.5 Ω

If there is more resistance than shown in the table, or

no tester reading (infinity) for any two leads, the stator

has an open lead and must be replaced. Much less than

this resistance means the stator is shorted, and must be

replaced.

• Using the highest resistance range of the hand tester,

measure the resistance between each of the black leads

and chassis ground.

Any hand tester reading less than infinity (∞) indicates a

short, necessitating stator replacement.

If the stator coils have normal resistance, but the voltage

check showed the alternator to be defective; then the rotor

magnets have probably weakened, and the rotor must be

replaced.

ELECTRICAL SYSTEM 16-33

Charging System

Regulator/Rectifier Inspection

• Remove:

Right Seat Cover (see Seat Cover Removal in the Frame

chapter)

Connectors [A]

Regulator/Rectifier Bolts [B]

Regulator/Rectifier [C]

• Set the hand tester to the × 1 kΩ range and make the

measurements shown in the table.

Special Tool - Hand Tester: 57001-1394

• Connect the hand tester to the regulator rectifier.

If the tester readings are not as specified, replace the

regulator/rectifier.

CAUTION

Use only Kawasaki Hand Tester 57001-1394 for this

test. A tester other than the Kawasaki Hand Tester

may show different readings.

If a megger or a meter with a large capacity battery

is used, the regulator/rectifier will be damaged.

Regulator/Rectifier Resistance

(Unit: kΩ)

Tester (+) Lead Connection

Terminal

W

BK1

BK2

BK3

BK/Y

W

-

20 ∼ 300

20 ∼ 300

20 ∼ 200

20 ∼ 750

BK1

0∼5

-

20 ∼ 300

20 ∼ 200

20 ∼ 750

BK2

0∼5

20 ∼ 300

-

20 ∼ 200

20 ∼ 750

(-)*

BK3

0∼5

20 ∼ 300

20 ∼ 300

-

20 ∼ 750

BK/Y

5 ∼ 20

5 ∼ 20

5 ∼ 20

5 ∼ 20

-

(-)*: Tester (-) Lead Connection

• Install the regulator/rectifier.

Torque - Regulator/Rectifier Bolts: 9.8 N·m (1.0 kgf·m, 87

in·lb)

16-34 ELECTRICAL SYSTEM

Charging System

Charging Voltage Inspection

• Check the battery condition (see Charging Condition In-

spection).

• Warm up the engine to obtain actual alternator operating

conditions.

• Remove the right fairing cover (see Fairing Cover Re-

moval in the Frame chapter).

• Check that the ignition switch is turned off, and connect

the hand tester [A] to the battery (+) terminal and ground.

Special Tool - Hand Tester: 57001-1394

• Start the engine, and note the voltage readings at var-

ious engine speeds with the headlight turned on and

then turned off (To turn off the headlight, disconnect

the headlight connector on the headlight unit.). The

readings should show nearly battery voltage when the

engine speed is low, and, as the engine speed rises, the

readings should also rise. But they must be kept under

the specified voltage.

Charging Voltage

Connections

Tester Range

Reading

Tester (+) to

Tester (-) to

25 V DC

Battery (+)

Ground

14.2 ∼ 15.2 V

• Turn off the ignition switch to stop the engine, and discon-

nect the hand tester.

If the charging voltage is kept between the values given in

the table, the charging system is considered to be working

normally.

If the charging voltage is much higher than the values

specified in the table, the regulator/rectifier is defective

or the regulator/rectifier leads are loose or open.

If the charging voltage does not rise as the engine speed

increases, then the regulator/rectifier is defective or the

alternator output is insufficient for the loads. Check the

alternator and regulator/rectifier to determine which part

is defective.

ELECTRICAL SYSTEM 16-35

Charging System

Charging System Circuit

1. Ignition Switch

2. Regulator/Rectifier

3. Alternator

4. Load

5. Main Fuse 30 A

6. Frame Ground 1

7. Battery 12 V 14 Ah

8. Joint Connector 1

9. Frame Ground 2

10. Engine Ground

16-36 ELECTRICAL SYSTEM

Ignition System

ELECTRICAL SYSTEM 16-37

Ignition System

WARNING

The ignition system produces extremely high volt-

age. Do not touch the spark plugs or stick coils

while the engine is running, or you could receive

a severe electrical shock.

CAUTION

Do not disconnect the battery cables or any other

electrical connections when the ignition switch is

on, or while the engine is running. This is to prevent

ECU damage.

Do not install the battery backwards. The negative

side is grounded. This is to prevent damage to the

ECU.

Crankshaft Sensor Removal

• Remove:

Right Lower Fairing (see Lower Fairing Removal in the

Frame chapter)

Right Middle Fairing (see Middle Fairing Removal in the

Frame chapter)

Crankshaft Sensor Lead Connector [A]

• Remove:

Crankshaft Sensor Cover Bolts

Crankshaft Sensor Cover

Crankshaft Sensor Bolts [A]

Crankshaft Sensor [B]

16-38 ELECTRICAL SYSTEM

Ignition System

Crankshaft Sensor Installation

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

the crankshaft sensor bolts [A], and tighten it.

Torque - Crankshaft Sensor Bolts: 5.9 N·m (0.60 kgf·m, 52

in·lb)

• Apply silicone sealant to the circumference of the crank-

shaft sensor lead grommet [B], and fit the grommet into

the notch of the crankcase securely.

• Apply silicone sealant to the mating surface [C] of

crankcase halves.

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

• Replace the O-ring [D] with a new one.

• Install the crankshaft sensor cover.

• Apply a non-permanent locking agent to only one crank-

shaft sensor cover bolt [E] shown in figure.

• Tighten the crankshaft sensor cover bolts.

Torque - Crankshaft Sensor Cover Bolts:

9.8

N·m (1.0

kgf·m, 87 in·lb)

• Route the crankshaft sensor lead correctly (see Cable,

Wire, and Hose Routing section in the Appendix chapter).

• Install the removed parts (see appropriate chapters).

Crankshaft Sensor Inspection

• Remove the right fairing cover (see Fairing Cover Re-

moval in the Frame chapter).

• Disconnect the crankshaft sensor lead connector (see

Crankshaft Sensor Removal).

• Set the hand tester [A] to the × 100 Ω range and connect

it to the crankshaft sensor lead connector [B].

Special Tool - Hand Tester: 57001-1394

Crankshaft Sensor Resistance: 376 ∼ 564 Ω

If there is more resistance than the specified value, the

coil has an open lead and must be replaced. Much less

than this resistance means the coil is shorted, and must

be replaced.

• Using the highest resistance range of the tester, measure

the resistance between the crankshaft sensor leads and

chassis ground.

Any tester reading less than infinity (∞) indicates a short,

necessitating replacement of the crankshaft sensor.

Crankshaft Sensor Peak Voltage Inspection

NOTE

○Be sure the battery is fully charged.

○Using the peak voltage adapter is a more reliable way

to determine the condition of the crankshaft sensor than

crankshaft sensor internal resistance measurements.

• Disconnect the crankshaft sensor lead connector (see

Crankshaft Sensor Removal).

ELECTRICAL SYSTEM 16-39

Ignition System

• Set the hand tester [A] to the × 25 V DC range, and con-

nect the peak voltage adapter [B].

Special Tools - Hand Tester: 57001-1394

Peak Voltage Adapter: 57001-1415

Type: KEK-54-9-B

Connections:

Crankshaft Sensor

Adapter

Hand Tester

Connector [C]

Black

←

Black

→

(-)

Yellow

←

Red

→

(+)

• Turn the ignition switch and engine stop switch ON.

• Pushing the starter button, turn the engine 4 ∼ 5 sec-

onds with the transmission gear in neutral to measure the

crankshaft sensor peak voltage.

• Repeat the measurement 5 or more times.

Crankshaft Sensor Peak Voltage

Standard:

2.4 V or more

If the tester reading is not specified one, check the crank-

shaft sensor.

Stick Coil (Ignition Coil together with Spark Plug

Cap) Removal

• Remove:

Middle Fairings (see Middle Fairing Removal in the

Frame chapter)

• Disconnect the stick coil connectors [A].

• Pull the stick coils [B] off the spark plugs.

CAUTION

Do not pry the connector part of the coil while re-

moving the coil.

Stick Coil (Ignition Coil together with Spark Plug

Cap) Installation

• Apply grease to the stick coils.

• Insert the stick coils [A] as shown being careful of the coil

heads directions.

○Align the lines [B] of the cylinder head cover and coil

heads.

CAUTION

Do not tap the coil head while installing the coil.

• Connect the stick coil connectors.

• Run the hoses and harness correctly (see Cable, Wire,

and Hose Routing section in Appendix chapter).

• Install the removed parts (see appropriate chapters).

16-40 ELECTRICAL SYSTEM

Ignition System

Stick Coil (Ignition Coil together with Spark Plug

Cap) Inspection

• Remove the stick coils (see Stick Coil (Ignition Coil to-

gether with Spark Plug Cap) Removal).

• Measure the primary winding resistance [A] as follows.

○Connect the hand tester between the coil terminals.

○Set the tester to the × 1 Ω range, and read the tester.

• Measure the secondary winding resistance [B] as follows.

○Connect the tester between the plug terminal and (-) coil

terminal.

○Set the tester to the × 1 kΩ range and read the tester.

Stick Coil Winding Resistance

Primary Windings:

1.2 ∼ 1.6 Ω

Secondary Windings:

8.5 ∼ 11.5 kΩ

If the tester does not read as specified, replace the coil.

Stick Coil Primary Peak Voltage

NOTE

○Be sure the battery is fully charged.

• Remove the stick coils (see Stick Coil (Ignition Coil to-

gether with Spark Plug Cap) Removal).

○Do not remove the spark plug.

• Measure the primary peak voltage as follows.

○Install the new spark plug [A] into each stick coil [B], and

ground them onto the engine.

○Connect the peak voltage adapter [C] to the hand tester

[D] which is set to the × 250 V DC range.

○Connect the adapter to the lead wire-peak voltage

adapter [E] which is connected between the stick coil

connector and stick coil.

ECU [F]

Battery [G]

Special Tools - Hand Tester: 57001-1394

Peak Voltage Adapter: 57001-1415

Type: KEK-54-9-B

Lead Wire-Peak Voltage Adapter:

57001

-1449

Primary Lead Connection

Adapter (R, +) to lead wire-peak voltage adapter (W)

Adapter (BK, -) to lead wire-peak voltage adapter (R)

ELECTRICAL SYSTEM 16-41

Ignition System

WARNING

To avoid extremely high voltage shocks, do not

touch the spark plugs or tester connections.

• Turn the ignition switch and engine stop switch ON.

• Pushing the starter button, turn the engine 4 ∼ 5 seconds

with the transmission in neutral to measure the primary

peak voltage.

• Repeat the measurements 5 times for one stick coil.

Stick Coil Primary Peak Voltage

Standard:

72 V or more

• Repeat the test for the other stick coils.

If the reading is less than the specified value, check the

following.

Stick Coils (see Stick Coil (Ignition Coil together with

Spark Plug Cap) Inspection)

Crankshaft Sensor (see Crankshaft Sensor Inspection)

ECU (see ECU Power Supply Inspection in the Fuel Sys-

tem (DFI) chapter)

Spark Plug Removal

• Refer to the Spark Plug Replacement in the Periodic

Maintenance chapter (see Spark Plug Replacement in

the Periodic Maintenance chapter).

Spark Plug Installation

• Refer to the Spark Plug Replacement in the Periodic

Maintenance chapter (see Spark Plug Replacement in

the Periodic Maintenance chapter).

Spark Plug Condition Inspection

• Visually inspect the spark plugs.

If the spark plug center electrode [A] and/or side elec-

trode [B] are corroded or damaged, or if the insulator [C]

is cracked, replace the plug.

If the spark plug is dirtied or the carbon is accumulated,

replace the spark plug.

• Measure the gap [D] with a wire-type thickness gauge.

If the gap is incorrect, replace the spark plug.

Spark Plug Gap: 0.8 ∼ 0.9 mm (0.031 ∼ 0.035 in.)

• Use the standard spark plug or its equivalent.

Spark Plug: CR9EIA-9

16-42 ELECTRICAL SYSTEM

Ignition System

Camshaft Position Sensor Removal

• Remove:

Fuel Tank Cover (see Fuel Tank Removal in the Fuel

System (DFI) chapter)

Right Middle Fairing (see Middle Fairing Removal in the

Frame chapter)

• Disconnect the camshaft position sensor lead connector

[A].

• Remove:

Camshaft Position Sensor Bolt [A]

Camshaft Position Sensor [B]

Camshaft Position Sensor Installation

• Replace the O-ring of the camshaft position sensor.

• Apply grease to the new O-ring.

• Tighten:

Torque - Camshaft Position Sensor Bolt:

9.8

N·m (1.0

kgf·m, 87 in·lb)

• Route the camshaft position sensor lead correctly (see

Cable, Wire, and Hose Routing section in the Appendix

chapter).

Camshaft Position Sensor Inspection

• Disconnect the camshaft position sensor lead connector

(see Camshaft Position Sensor Removal).

• Set the hand tester to the × 10 Ω range and connect it to

the terminals.

Special Tool - Hand Tester: 57001-1394

Camshaft Position Sensor Resistance: 400 ∼ 460 Ω

If there is more resistance than the specified value, the

sensor coil has an open lead and must be replaced. Much

less than this resistance means the sensor coil is shorted,

and must be replaced.

• Using the highest resistance range of the tester, mea-

sure the resistance between the camshaft position sensor

leads and chassis ground.

Any tester reading less than infinity (∞) indicates a short,

necessitating replacement of the camshaft position sen-

sor.

ELECTRICAL SYSTEM 16-43

Ignition System

Camshaft Position Sensor Peak Voltage

Inspection

• Disconnect the camshaft position sensor lead connector

[A] (see Camshaft Position Sensor Removal).

• Connect the harness adapter [B] between the camshaft

position sensor lead connector and harness connector

[C].

• Connect the peak voltage adapter [D] to the hand tester

[E] which is set to the × 10 V range.

• Connect the adapter to the harness adapter.

[F] Camshaft Position Sensor

Special Tools - Hand Tester: 57001-1394

Peak Voltage Adapter: 57001-1415

Type: KEK-54-9-B

Harness Adapter: 57001-1562

Connections:

Peak Voltage

Harness Adapter

Hand Tester

Adapter

Black/White

←

Black

→

(-)

Red

←

Red

→

(+)

• Turn the ignition switch and engine stop switch ON.

• Pushing the starter button, run the engine with the trans-

mission gear in neutral to measure the camshaft position

sensor peak voltage.

• Repeat the measurement 5 or more times.

Camshaft Position Sensor Peak Voltage

Standard:

2.8 V or more

If the peak voltage is lower than the standard, inspect the

camshaft position sensor.

Interlock Operation Inspection

• Using the stand [A], raise the rear wheel off the ground.

1st Check

• Start the engine to the following conditions.

Condition:

Transmission Gear → 1st Position

Clutch Lever → Release

Sidestand → Down or Up

○Turn the ignition switch ON and push the starter button.

○Then the starter motor should not turn when the starter

system circuit is normality.

If the engine is start, inspect the starter lockout switch,

gear position switch, and relay box.

If their parts are normality replace the ECU.

ELECTRICAL SYSTEM 16-45

Ignition System

Ignition System Circuit

1. Sidestand Switch

14. Ignition Fuse 10 A

2. Camshaft Position Sensor

15. ECU Fuse 15 A

3. Joint Connector 1

16. Ignition Switch

4. Joint Connector 2

17. Main Fuse 30 A

5. Gear Position Switch

18. Battery 12 V 14 Ah

6. Water-proof Joint 1

19. Frame Ground 2

7. Vehicle-down Sensor

20. Engine Ground

8. Water-proof Joint 2

21. Starter Lockout Switch

9. Sub-throttle Sensor

22. Relay Box

10. Main Throttle Sensor

23. Joint Connector 3

11. Crankshaft Sensor

24. Engine Stop Switch

12. ECU

25. Stick Coils

13. Fuse Box 2

26. Spark Plugs

16-46 ELECTRICAL SYSTEM

Electric Starter System

Starter Motor Removal

• Remove:

Engine Sprocket Cover (see Engine Sprocket Removal

in the Final Drive chapter)

• Take off the heat insulation rubber plate [A].

• Slide out the rubber cap [B].

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

• Remove the starter motor mounting bolts [A].

• Pull out the starter motor [B] from the left side.

Starter Motor Installation

CAUTION

Do not tap the starter motor shaft or body. Tapping

the shaft or body could damage the motor.

• Clean the starter motor legs [A] and crankcase [B] where

the starter motor is ground.

• Replace the O-ring [C] with a new one.

• Apply grease to the new O-ring.

• Tighten:

Torque - Starter Motor Mounting Bolts: 9.8 N·m (1.0 kgf·m,

87 in·lb)

• Install the starter motor cable [A] side by side with starter

motor [B].

• Tighten:

Torque - Starter Motor Cable Terminal Nut: 5.9 N·m (0.60

kgf·m, 52 in·lb)

• Slide back the rubber cap [C] to the original position.

ELECTRICAL SYSTEM 16-47

Electric Starter System

Starter Motor Disassembly

• Remove the starter motor (see Starter Motor Removal).

• Take off the starter motor through bolts [A] and remove

both end covers [B].

• Pull the armature [A] out of the yoke [B].

• Remove:

Brush Plate Terminal Nut, Washer and Insulators [A]

Brush Plate Assembly [B]

Starter Motor Assembly

• Pry the spring end [A] and insert the brush [B].

• Install the brush plate assembly [A] into the right-hand end

cover [B].

• Replace the O-ring [C] with a new one.

• Install:

Insulators [D]

Washer [E]

• Tighten:

Torque - Starter Motor Terminal Locknut [F]: 6.9 N·m (0.70

kgf·m, 61 in·lb)

16-48 ELECTRICAL SYSTEM

Electric Starter System

• Install the armature [A] into the yoke [B].

• Install thrust washer [C].

• Replace the O-rings [D] with new ones.

• Put the armature [E] among the brushes [F].

• Align the marks [A] to assembly the yoke and the end

covers.

• Replace the O-rings [A] with new ones.

• Tighten:

Torque - Starter Motor Through Bolts [B]: 3.4 N·m (0.35

kgf·m, 30 in·lb)

• Replace the O-ring [A] with new ones.

• Apply grease to the new O-ring.

Brush Inspection

• Measure the length [A] of each brush [B].

If any is worn down to the service limit, replace the brush

holder assembly.

Starter Motor Brush Length

Standard:

10 mm (0.39 in.)

Service Limit:

5.0 mm (0.20 in.)

ELECTRICAL SYSTEM 16-49

Electric Starter System

Commutator Cleaning and Inspection

• Smooth the commutator surface [A] if necessary with fine

emery cloth [B], and clean out the grooves.

• Measure the diameter [A] of the commutator [B].

If the commutator diameter is less than the service limit,

replace the starter motor with a new one.

Commutator Diameter

Standard:

28 mm (1.10 in.)

Service Limit:

27 mm (1.06 in.)

Armature Inspection

• Using the × 1 Ω hand tester range, measure the resis-

tance between any two commutator segments [A].

Special Tool - Hand Tester: 57001-1394

If there is a high resistance or no reading (∞) between any

two segments, a winding is open and the starter motor

must be replaced.

• Using the highest hand tester range, measure the resis-

tance between the segments and the shaft [B].

If there is any reading at all, the armature has a short and

the starter motor must be replaced.

NOTE

○Even if the foregoing checks show the armature to be

good, it may be defective in some manner not readily

detectable with the hand tester. If all other starter motor

and starter motor circuit components check good, but

the starter motor still does not turn over or only turns

over weakly, replace the starter motor with a new one.

Brush Lead Inspection

• Using the × 1 Ω hand tester range, measure the resis-

tance as shown.

Terminal Bolt and Positive Brush [A]

Right-hand End Cover and Negative Brush [B]

Special Tool - Hand Tester: 57001-1394

If there is not close to zero ohms, the brush lead has an

open. Replace the brush holder assembly.

16-50 ELECTRICAL SYSTEM

Electric Starter System

Right-hand End Cover Assembly Inspection

• Using the highest hand tester range, measure the resis-

tance as shown.

Terminal and Right-hand End Cover [A]

Special Tool - Hand Tester: 57001-1394

If there is any reading, the right-hand end cover assembly

have a short. Replace the right-hand end cover assembly.

Starter Relay Inspection

• Remove the battery (see Battery Removal).

• Disconnect the starter motor cable [A] and battery positive

(+) cable [B] from the starter relay.

• Disconnect the connector [C].

• Pull out the starter relay from the damper.

• Connect the hand tester [A] and 12 V battery [B] to the

starter relay [C] as shown.

Special Tool - Hand Tester: 57001-1394

If the relay does not work as specified, the relay is defec-

tive. Replace the relay.

Testing Relay

Tester Range:

× 1 Ω range

Criteria:

When battery is connected → 0 Ω

When battery is disconnected → ∞ Ω

• Tighten:

Torque - Starter Motor Cable Mounting Bolt: 3.9 N·m (0.40

kgf·m, 35 in·lb)

ELECTRICAL SYSTEM 16-51

Electric Starter System

Electric Starter Circuit

1. Sidestand Switch

2. Engine Stop Switch

3. Starter Button

4. Fuse Box 2

5. Ignition Fuse 10 A

6. Ignition Switch

7. Joint Connector 1

8. Joint Connector 2

9. Gear Position Switch

10. Starter Lockout Switch

11. Starter Circuit Relay

12. Relay Box

13. Starter Motor

14. Main Fuse 30 A

15. Starter Relay

16. Battery 12 V 14 Ah

17. Frame Ground 2

18. Engine Ground

16-52 ELECTRICAL SYSTEM

Lighting System

This motorcycle adopt the daylight system and have a

headlight relay in the relay box. The headlight does not

go on when the ignition switch and the engine stop switch

are first turned on. The headlight comes on after the starter

button is released and stays on until the ignition switch is

turned off. The headlight will go out momentarily whenever

the starter button is pressed and come back on when the

button is released.

Headlight Beam Horizontal Vertical Adjustment

• Refer to the Headlight Aiming Inspection in the Periodic

Maintenance chapter.

Headlight Beam Vertical Adjustment

• Refer to the Headlight Aiming Inspection in the Periodic

Maintenance chapter.

Headlight Bulb Replacement

• Remove the inner covers (see Inner Cover Removal in

the Frame chapter).

• Disconnect the headlight connector [A].

• Turn the headlight bulb [A] counterclockwise and pull out

the bulb from the headlight.

CAUTION

When handling the quartz-halogen bulb, never

touch the glass portion with bare hands. Always

use a clean cloth. Oil contamination from hands or

dirty rags can reduce bulb life or cause the bulb to

explode.

NOTE

○Clean off any contamination that inadvertently gets on

the bulb with alcohol or soap and water solution.

• Replace the headlight bulb.

• Fit the projections [A] of the bulb in the hollows [B] of the

headlight.

• Turn the headlight bulb clockwise.

• Connect the headlight connector.

• After installation, adjust the headlight aim (see Headlight

Aiming Inspection in the Periodic Maintenance chapter).

○Other Bulbs: Repeat the above steps.

ELECTRICAL SYSTEM 16-53

Lighting System

City Light Bulb Replacement

• Remove the inner covers (see Inner Cover Removal in

the Frame chapter).

• Unscrew the screw [A].

• Disconnect the city light connector [B].

• Turn the city light bulb counterclockwise and pull out the

socket [A] together with the bulb.

• Pull the bulb [A] out of the socket [B].

CAUTION

Do not turn the bulb. Pull the bulb out to prevent

damage to the bulb. Do not use bulb rated for

greater wattage than the specified value.

• Replace the bulb with a new one.

• Insert the socket and to the headlight.

○Align the projections [A] of the socket and the grooves [B]

of the headlight.

• Turn the city light bulb clockwise.

• Connect the city light connector.

Headlight Removal/Installation

• Remove:

Upper Fairing (see Upper Fairing Removal in the Frame

chapter)

Upper Inner Fairing (see Upper Inner Fairing Removal

in the Frame chapter)

Headlight Mounting Screws [A]

Headlights [B]

• Tighten:

Torque - Headlight Mounting Screws: 1.2 N·m (0.12 kgf·m,

11 in·lb)

16-54 ELECTRICAL SYSTEM

Lighting System

Headlight Relay Inspection

• Remove the inner covers (see Inner Cover Removal in

the Frame chapter).

• Take off the headlight relay [A] (both sides).

• Set the hand tester to the × 1 Ω range and make the

measurements shown in the figure.

Headlight Relay [A]

12 V Battery [B]

Special Tool - Hand Tester [C]: 57001-1394

If the tester readings are not as specified, replace the

headlight relay.

CAUTION

Use only Hand Tester 57001-1394 for this test. An

ohmmeter other than the Kawasaki Hand Tester

may show different readings. If a megger or a meter

with a large-capacity battery is used, the headlight

relay will be damaged.

Testing Relay

Criteria

When battery is connected → 0 Ω

When battery is disconnected → ∞ Ω

Tail/Brake Light (LED) Removal

• Remove:

Tool Kit Case [A] (see ECU Removal in the Fuel System

(DFI) chapter)

Relay Box [B] (see Relay Box Removal in the Electrical

System chapter)

Fuse Box [C]

Screws [D]

• Disconnect the connector [A].

• Remove the tail/brake light [B].

ELECTRICAL SYSTEM 16-55

Lighting System

Tail/Brake Light (LED) Installation

• Connect the connector.

• Insert the projections [A] of the tail/brake light into the

holes [B] of the rear fender.

Torque - Tail/Brake Light Mounting Screws: 1.2 N·m (0.12

kgf·m, 11 in·lb)

• Install the removed parts (see appropriate chapters).

License Plate Light Bulb Replacement

• Remove:

Screws [A]

License Plate Light Cover [B]

• Push and turn the bulb [A] counterclockwise wise and re-

move it.

• Replace the bulb with a new one.

• Insert the new bulb [A] by aligning its upper and lower pins

[B] with the upper and lower grooves [C] in the socket, and

turn the bulb clockwise.

○Turn the bulb about 15°.

• Tighten:

Torque - Licence Plate Light Cover Mounting Screws: 0.9

N·m (0.09 kgf·m, 8 in·lb)

16-56 ELECTRICAL SYSTEM

Lighting System

Headlight/Tail Light Circuit

1. Ignition Switch

15. Headlight Fuse (Low) 10 A

2. Joint Connector 1

16. Fuse Box 1

3. High Beam Indicator Light (LED)

17. Relay Box

4. Right City Light

18. Headlight Circuit Relay

5. Headlight (High Beam)

19. Alternator

6. Headlight (Low Beam)

20. Main Fuse 30 A

7. Left City Light

21. Starter Relay

8. Headlight Relay (Low)

22. Battery 12 V 14 Ah

9. Headlight Relay (High)

23. Frame Ground

10. Dimmer Switch

24. Tail/Brake Light (LED)

11. Passing Button (Other than US Models)

25. License Plate Light

12. Headlight Fuse 10 A

26. Joint Connector 2

13. Taillight Fuse 10 A

27. Fuse Box 2

14. Headlight Fuse (High) 10 A

28. Ignition Fuse 10 A

Turn Signal Light Bulb Replacement

Front Turn Signal Light

• Remove:

Middle Fairings (see Middle Fairing Removal in the

Frame chapter)

Inner Fairings (see Inner Fairing Removal in the Frame

chapter)

• Turn the socket [A] counterclockwise and pull out the

socket together with the bulb.

ELECTRICAL SYSTEM 16-57

Lighting System

• Push and turn the front turn signal light bulb [A] counter-

clockwise and remove it.

• Replace the bulb with new ones.

• Insert the new bulb [A] by aligning its upper and lower pins

[B] with the upper and lower grooves [C] in the socket, and

turn the bulb clockwise.

○Turn the bulb about 15°.

• Pushing the socket and turn it clockwise.

○Fit the projections [A] of the socket into the grooves [B] of

the turn signal light.

• Install the middle fairings (see Middle Fairing Installation

in the Frame chapter).

Rear Turn Signal Light

• Remove:

Screw [A]

Rear Turn Signal Light Lens [B]

• Push and turn the rear turn signal light bulb [A] counter-

clockwise and remove it.

16-58 ELECTRICAL SYSTEM

Lighting System

• Insert the new bulb [A] by aligning its upper and lower pins

[B] with the upper and lower grooves [C] in the socket, and

turn the bulb clockwise.

○Turn the bulb about 15°.

• Fit the projections [A] of the lens into the grooves [B] of

the turn signal light.

• Tighten the screw.

Turn Signal Relay Inspection

• Remove:

Left Seat Cover (see Seat Cover Removal in the Frame

chapter)

Turn Signal Relay [A]

• Disconnect the connector [B].

• Connect one 12 V battery and turn signal lights as indi-

cated in the figure, and count how may times the lights

flash for one minute.

Turn Signal Relay [A]

Turn Signal Lights [B]

12 V Battery [C]

If the lights do not flash as specified, replace the turn sig-

nal relay.

Testing Turn Signal Relay

Load

The Number of Turn

Flashing Times

Wattage (W)

Signal Lights

(c/m*)

1**

21 or 23

140 ∼ 250

2

42 or 46

75 ∼ 95

*: Cycle(s) per minute

**: Corrected to “one light burned out”.

ELECTRICAL SYSTEM 16-59

Lighting System

Turn Signal Light Circuit

1. Ignition Switch

2. Joint Connector 1

3. Turn Signal Indicator Light (LED) (Right)

4. Turn Signal Indicator Light (LED) (Left)

5. Front Right Turn Signal Light

6. Front Left Turn Signal Light

7. Other than US Models

8. Hazard Button

9. Turn Signal Switch

10. Turn Signal Fuse 10 A

11. Fuse Box 1

12. Turn Signal Relay

13. Joint Connector 2

14. Frame Ground

15. Main Fuse 30 A

16. Battery 12 V 14 Ah

17. Rear Left Turn Signal Light

18. Rear Right Turn Signal Light

19. Ignition Fuse 10 A

20. Fuse Box 2

16-60 ELECTRICAL SYSTEM

Air Switching Valve

Air Switching Valve Operation Test

• Refer to the Air Suction System Damage Inspection in the

Periodic Maintenance chapter.

Air Switching Valve Unit Test

• Remove the air switching valve (see Air Switching Valve

Removal in the Engine Top End chapter).

• Set the hand tester [A] to the × Ω range and connect it to

the air switching valve terminals as shown.

Special Tool - Hand Tester: 57001-1394

Air Switching Valve Resistance

Standard:

18 ∼ 22 Ω at 20°C (68°F)

If the resistance reading is except the specified value, re-

place it with a new one.

• Connect the 12 V battery [A] to the air switching valve

terminals as shown.

• Blow the air to the inlet air duct [A], and make sure does

not flow the blown air from the outlet air ducts [B].

• Disconnect the 12 V battery.

• Blow the air to the inlet air duct [A] again, and make sure

flow the blown air from the outlet air ducts [B].

If the air switching valve dose not operate as described,

replace it with a new one.

NOTE

○To check air flow through the air switching valve, just

blow through the air switching valve hose (inlet side)

[C].

ELECTRICAL SYSTEM 16-61

Radiator Fan System

Fan Motor Inspection

• Remove the left fairing cover (see Fairing Cover Removal

in the Frame chapter).

• Disconnect the connector [A].

• Using an auxiliary leads, supply battery power to the fan

motor.

If the fan does not rotate, the fan motor is defective and

must be replaced.

Radiator Fan Circuit

1. Ignition Switch

9. Battery 12 V 14 Ah

2. Joint Connector 1

10. Frame Ground 2

3. Fuse Box 2

11. Engine Ground

4. Fan Fuse 15 A

12. Radiator Fan

5. Relay Box

13. Water Temperature Sensor

6. Radiator Fan Relay

14. Water-proof Joint 2

7. Main Fuse 30 A

15. ECU

8. Starter Relay

16-62 ELECTRICAL SYSTEM

Meter, Gauge, Indicator Unit

Meter Unit Removal

• Remove:

Windshield (see Windshield Removal in the Frame

chapter)

Immobilizer Amplifier [A] (Equipped Models)

• Remove:

Immobilizer Amplifier Bracket and Bolt [A] (Equipped

Models)

Vehicle-down Sensor Bracket and Bolt [B]

Meter Lead Connector [C]

• Remove:

Meter Unit Mounting Nuts [A] and Washers

Meter Unit [B]

CAUTION

Place the meter unit so that the face is up. If a meter

unit is left upside down or sideways for any length

of time, it will malfunction.

Meter Unit Installation

• Install:

Meter Unit [A]

Washers [B] and Meter Unit Mounting Nuts [C]

• Install:

Meter Lead Connector

Vehicle-down Sensor Bracket (as shown) and Bolt [A]

Immobilizer Amplifier Bracket and Bolt (Equipped Mod-

els)

Immobilizer Amplifier [B] (Equipped Models)

Windshield (see Windshield Installation in the Frame

chapter)

ELECTRICAL SYSTEM 16-63

Meter, Gauge, Indicator Unit

Meter Unit Disassembly

• Remove:

Meter Unit (see Meter Unit Removal)

Screws [A]

Lower Meter Cover [B]

• Separate:

Upper Meter Cover [A]

Middle Meter Cover [B]

Meter Assembly [C]

Meter Unit Inspection

• Remove the meter unit (see Meter Unit Removal).

[1] High Beam Indicator Light (LED)

[2] Oil Pressure Warning Indicator Light (LED) (-)

[3] Right Turn Signal Indicator Light (LED) (+)

[4] Neutral Indicator Light (LED) (-)

[5] Unused

[6] ABS Indicator Light (LED) (-)

[7] Unused

[8] Unused

[9] Ignition (+)

[10] Battery (+)

[11] Speed Sensor Supply Voltage (+)

[12] Ground (-)

[13] Speed Sensor Signal

[14] Unused

[15] Fuel Reserve Switch

[16] Fuel Level Sensor

[17] CAN Communication Line (Hight)

[18] CAN Communication Line (Low)

[19] Left Turn Signal Indicator Light (LED) (+)

[20] Unused

CAUTION

Do not drop the meter unit. Place the meter unit so

that it faces upward. If the meter assembly is left up-

side down or sideways for a long time or dropped,

it will malfunction. Do not short each terminals.

16-64 ELECTRICAL SYSTEM

Meter, Gauge, Indicator Unit

Check 1: CAN Communication Line Resistance Inspec-

tion

• Set the hand tester [A] to the ×1 Ω range and connect it

to the terminal [17] and [18] in the meter unit.

Special Tool - Hand Tester: 57001-1394

CAN Communication Line Resistance (at Meter Unit)

Standard:

122 ∼ 126 Ω

If the tester reading is not specified, replace the meter

assembly.

Check 2: Meter Unit Primary Operation Check

• Using the auxiliary leads, the 12 V battery [A] to the meter

unit connector as follows.

○Connect the battery positive (+) terminal to the terminal

[10].

○Connect the battery negative (-) terminal to the terminal

[12].

• Check that the speedometer and tachometer needles [A]

momentarily point their last readings and back to the min-

imum position.

If the meter unit does not work, replace the meter assem-

bly.

• Connect terminal [9] to the battery (+) terminal.

• Check that the following items.

○The speedometer and tachometer needles momentarily

point their last readings and back to the minimum position.

○The ABS indicator light (LED) [A] (equipped models)

should go on.

○The K Kawasaki mark [B] in the LCD appears for three

seconds.

ELECTRICAL SYSTEM 16-65

Meter, Gauge, Indicator Unit

○After the K Kawasaki mark appeared, the TRIP A/B meter

[A], water temperature gauge [B], fuel level gauge [C],

odometer and clock appear in the display [D].

○The ABS indicator light (LED) [E] (equipped models)

should go on.

If the meter unit does not work, replace the meter assem-

bly.

NOTE

○The flashings of the three segments for the water tem-

perature gauge and fuel level gauge do not failure of the

meter unit.

○Currently, for the meter is disconnected from the main

harness each flashing occur.

○The flashing of water temperature gauge is communi-

cation error to the ECU.

○The flashing of the fuel level gauge is open or short of

the fuel reserve switch.

○Normally, each flashing disappears when the meter unit

is connected to main harness.

Check 3: MODE and RESET Button Operation Check

• Connect the leads in the same circuit as Check 2.

• By pushing the MODE button [A] each time, check that

the display [B] changes as follows.

○This display is ordinary indication.

If the display function does not work, replace the meter

assembly.

• Push the MODE button [A] and RESET button [B] for more

than two seconds.

• Check that the display changes to the language setting

mode [A].

○This display is system menu indication.

• By pushing the RESET button each time, check that the

display selects the ENGLISH or FRANCAIS.

If the display function does not work, replace the meter

assembly.

16-66 ELECTRICAL SYSTEM

Meter, Gauge, Indicator Unit

• By pushing the MODE button each time at the language

setting mode, check that the display [A] selects as follows.

If the display function does not work, replace the meter

assembly.

• Select the MILEAGE [A] indication.

• Push the MODE button for more than two seconds, check

that the unit setting menu [B] flashes.

• By pushing the RESET button each time, check that the

display changes as follows.

• Check that the unit setting menu is decided by the MODE

button push.

If the display function does not work, replace the meter

assembly.

• Select the ENGAGE LAMP [A] indication.

• Push the MODE button for more than two seconds, check

that the engine speed setting menu [B] flashes.

• By pushing the RESET button each time, check that the

display changes as follows.

• Check that the engine speed setting menu is decided by

the MODE button pushing.

If the display function does not work, replace the meter

assembly.

• Select the SHIFT LAMP [A] indication.

• Push the MODE button for more than two seconds, check

that the engine speed setting menu [B] flashes.

• By pushing the RESET button each time, check that the

display changes as follows.

• Check that the engine speed setting menu is decided by

the MODE button pushing.

If the display function does not work, replace the meter

assembly.

ELECTRICAL SYSTEM 16-67

Meter, Gauge, Indicator Unit

• Select the LAMP MODE [A] indication.

• Push the MODE button for more than two seconds, check

that the lighting mode setting menu [B] flashes.

• By pushing the RESET button [C] each time, check that

the display changes as follows and the indicator light

(LED) [D] goes on according to message.

• Check that the lighting mode setting menu is decided by

the MODE button pushing.

If the display function does not work, replace the meter

assembly.

• Select the CLOCK [A] indication.

• Push the MODE button for more than two seconds.

○The clock setting menu (hour and minute) [B] should flash.

• Push the RESET button.

○The hour display [A] starts flashing.

• By pushing the MODE button each time, check that the

hour display changes.

• By pushing the RESET button, check that the hour display

decide and minute display [A] starts flashing.

• By pushing the MODE button each time, check that the

minute display changes.

16-68 ELECTRICAL SYSTEM

Meter, Gauge, Indicator Unit

• By pushing the RESET button, check that the hour and

minute display [A] starts flashing.

• By pushing the MODE button, check that the hour and

minute display decide.

• When both hour and minute display flashing, by pushing

the RESET button, check that the hour display start flash-

ing. This flashing returns the hour setting mode.

If the display function does not work, replace the meter

assembly.

Check 4: Battery Voltage Inspection

• Connect the leads in the same circuit as Check 2.

• 1st, set the BATTERY display.

• Check that the display indicates the battery voltage.

• 2nd, disconnect the terminal [10].

• Check that the display changes 9.0 V within about 30 sec-

onds.

• 3rd, connect the terminal [10].

• Check that the display changes the current battery volt-

age within about 30 seconds.

○The tolerance of the voltage is ±0.4 V.

If the display function does not work, replace the meter

assembly.

ELECTRICAL SYSTEM 16-69

Meter, Gauge, Indicator Unit

Check

5:

Immobilizer Flashing Mode Inspection

(Equipped Models)

• Connect the leads in the same circuit as Check 2.

• Disconnect the terminal [9].

• Check that the warning light (LED) [A] starts flashing (Im-

mobilizer Warning Light Flashing Mode).

• Push the MODE [B] and RESET [C] buttons more than 2

second, within 20 seconds after the terminal [9] discon-

nected.

• Check that the warning light (LED) goes on one second,

and then the light goes off (Immobilizer Warning Light No

Flashing Mode).

NOTE

○For this inspection, be sure the battery is 12.4 V or

more. Immobilizer Warning Light Flashing Mode does

not work, when the battery voltage is less than 12±0.4

V.

• Connect the terminal [9] to the battery (+) terminal.

• And then, disconnect the terminal [9].

• Push the MODE and RESET buttons more than 2 second,

within 20 seconds after the terminal [9] disconnected.

• Check that the warning light (LED) goes on one second,

and then the light starts flashing (Immobilizer Warning

Light Flashing Mode).

If the meter function does not work, replace the meter

assembly.

Check 6: High Beam Indicator Light (LED) Inspection

• Connect the leads in the same circuit as Check 2.

• Connect the terminal [1] to the battery (+) terminal.

16-70 ELECTRICAL SYSTEM

Meter, Gauge, Indicator Unit

• Check that the high beam indicator light (LED) [A] goes

on.

If the indicator light does not go on, replace the meter

assembly.

Check 7: Right Turn Signal Indicator Light (LED) In-

spection

• Connect the leads in the same circuit as Check 2.

• Connect the terminal [3] to the battery (+) terminal.

• Check that the right turn signal indicator light (LED) [A]

goes on.

If the indicator light does not go on, replace the meter

assembly.

Check 8: Left Turn Signal Indicator Light (LED) Inspec-

tion

• Connect the leads in the same circuit as Check 2.

• Connect the terminal [19] to the battery (+) terminal.

• Check that the left turn signal indicator light (LED) [A]

goes on.

If the indicator light does not go on, replace the meter

assembly.

ELECTRICAL SYSTEM 16-71

Meter, Gauge, Indicator Unit

Check 9: Oil Pressure Warning Indicator Light (LED)

Inspection

• Connect the leads in the same circuit as Check 2.

• Connect the terminal [2] to the battery (-) terminal.

• Check that the oil pressure warning indicator light (LED)

goes on.

If the indicator light does not go on, replace the meter

assembly.

Check 10: Neutral Indicator Light (LED) Inspection

• Connect the leads in the same circuit as Check 2.

• Connect the terminal [4] to the battery (-) terminal.

• Check that the neutral indicator light (LED) goes on.

If the indicator light does not go on, replace the meter

assembly.

Check 11: ABS Indicator Light (LED) Inspection

(Equipped Models)

• Connect the leads in the same circuit as Check 2.

• Check that the ABS indicator light (LED) [A] goes on.

16-72 ELECTRICAL SYSTEM

Meter, Gauge, Indicator Unit

• Connect the terminal [6] to the battery (-) terminal.

• Check that the ABS indicator light (LED) goes off.

If the indicator light does not go on, replace the meter

assembly.

Check 12: Fuel Level Warning Inspection

• Connect the leads in the same circuit as Check 2.

• Connect the variable rheostat [A] (about 22 Ω) to the ter-

minal [15] and the battery (-) terminal.

• After about 5 seconds, check that one segment [A] in the

fuel gauge starts flashing.

• Check that the FUEL EMPTY [B] and fuel symbol [C] ap-

pear alternately in the display.

If the display function does not work, replace the meter

assembly.

○This display is the warning message indication.

• Push the MODE button [A] more than 2 seconds.

• Check that the warning light (LED) [B] goes on and display

changes TRIP A/B meter [C] mode.

○The one segment [D] in the fuel gauge keeps flashing.

• Push the MODE button more than 2 seconds.

• Check that the warning light (LED) goes off and display

changes the warning message indication mode.

○The one segment in the fuel gauge keeps flashing.

If the display function does not work, replace the meter

assembly.

• Disconnect the battery to disappear the warning message

indication.

ELECTRICAL SYSTEM 16-73

Meter, Gauge, Indicator Unit

Check 13: Fuel Gauge Inspection

• Connect the leads in the same circuit as Check 2.

• Connect the resistor [A] (about 1 kΩ) to the terminal [15]

and the battery (-) terminal.

• Connect the variable rheostat [B] to the terminal [16] and

the battery (-) terminal.

• Check that the number of segments matches the resis-

tance value of the variable rheostat.

○When the terminal [16] is connected, one segment in the

fuel level gauge should appear about every 15 seconds.

Variable Rheostat

Display Segments [A]

Resistance (Ω)

10

6

200

1

If the display function does not work, replace the meter

assembly.

Check 14: Speedometer Inspection

• Connect the leads in the same circuit as Check 2.

• The speed equivalent to the input frequency is indicated in

the oscillator [A], if the square wave is input into terminal

[13].

○Indicates approximately 60 mph if the input frequency is

approximately 131.2 Hz.

○Indicates approximately 60 km/h if the input frequency is

approximately 82 Hz.

If the meter function does not work, replace the meter

assembly.

Check 15: Trip A/B Meter Inspection

• Connect the leads in the same circuit as Check 14.

• Set the TRIP A/B meter mode in the display.

• Raise the input frequency of the oscillator to see the result

of this inspection.

If the value indicated by the trip meter A/B do not increase,

replace the meter assembly.

16-74 ELECTRICAL SYSTEM

Meter, Gauge, Indicator Unit

• By pushing the RESET button each time, check that the

display starts flashing as follows.

• When flushing the display, push the RESET button for

more than two seconds, check that the display changes

0.0 (TRIP A) and 0 (TRIP B).

If the display function does not change, replace the meter

assembly.

Check 16: Odometer Inspection

• Connect the leads in the same circuit as Check 14.

• Raise the input frequency of the oscillator to see the result

of odometer [A] inspection.

○Example: Indicates the increase of approximately 1 mile,

if the input frequency is approximately 131.2 Hz for one

minute.

○Example: Indicates the increase of approximately 1

km/h, if the input frequency is approximately 82 Hz for

one minute.

If the value indicated by the odometer does not increase,

replace the meter assembly.

Check 17: Speed Sensor Supply Voltage Inspection

• Connect the leads in the same circuit as Check 2.

• Set the hand tester to the 25 V range and connect it in the

meter unit as follows.

Special Tool - Hand Tester: 57001-1394

Connections:

Hand Tester (+)

→

Terminal [11]

Hand Tester (-)

→

Terminal [12]

Speed Sensor Supply Voltage

Standard:

about 12 V

If the tester reading is not specified, replace the meter

assembly.

ELECTRICAL SYSTEM 16-75

Meter, Gauge, Indicator Unit

Check 18: Water Temperature Gauge Inspection

• Connect the leads in the same circuit as Check 2.

• Connect the CAN communication lines from meter con-

nector [A] to main harness connector [B] as shown.

Connections:

Meter Terminal [17]

→ Main Harness Terminal [17]

Meter Terminal [18]

→ Main Harness Terminal [18]

• Turn the ignition switch ON.

• Check that the only symbol [A] appears in the water tem-

perature gauge.

• Turn the ignition switch OFF.

If the display function does not work, go to the Check 1

and check the following items.

Wiring (see Wiring Inspection)

CAN Communication Line Resistance (at ECU) (see

CAN Communication Line Resistance Inspection in the

Fuel System (DFI) chapter)

Water Temperature Sensor (see Water Temperature

Sensor (Service Code 14) section in the Fuel System

(DFI) chapter)

If the above items are good, replace the meter assembly

and/or ECU.

Check 19: FI/IMMOBILIZER Error Inspection

• Connect the leads in the same circuit as Check 18.

• For example, disconnect the atmospheric pressure sen-

sor [A].

• Install the key registration unit [B] (see Key Registration)

(Immobilizer equipped model).

Special Tool - Key Registration Unit: 57001-1582

16-76 ELECTRICAL SYSTEM

Meter, Gauge, Indicator Unit

• Turn the ignition switch ON by the current key.

• Check that the warning light (LED) [A] starts flashing and

the display [B] changes as follows.

[C] Warning Message

[D] Symbol

○This display is the warning message indication.

If the display function does not work, go to the Check 1

and check the following items.

Wiring (see Wiring Inspection)

CAN Communication Line Resistance (at ECU) (see

CAN Communication Line Resistance Inspection in the

Fuel System (DFI) chapter)

Example:

Immobilizer System (see Immobilizer Amplifier and

Blank Key Detection section in the Fuel System (DFI)

chapter)

Atmospheric Pressure Sensor (see Atmospheric Pres-

sure Sensor (Service Code 15) section in the Fuel Sys-

tem (DFI) chapter)

○Refer to Troubleshooting the DFI System section in the

Fuel System (DFI) chapter for other DFI parts

If the above items are good, replace the meter assembly

and/or ECU.

• By pushing the MODE button [A] each time, check that

the display changes the error messages [B] only.

○During this operating, the symbols do not appear.

○The warning indicator light (LED) keeps flashing.

• Push the MODE and RESET buttons for more than two

seconds, check that each ERROR CODE [A] and num-

bers appears in the display.

○The warning indicator light (LED) keeps flashing.

• Again, push the MODE and RESET buttons for more than

two seconds, check that the display returns the warning

message indication.

○The warning indicator light (LED) keeps flashing.

If the display function does not work, replace the meter

assembly.

ELECTRICAL SYSTEM 16-77

Meter, Gauge, Indicator Unit

Check 20: Tachometer Inspection

• Connect the leads in the same circuit as Check 18.

• Confirm the vehicle down sensor is correct position.

• Start the engine.

• Check that the needle [A] in the tachometer moves.

If the needle does not move, go to the Check 1 and in-

spect the following items.

Wiring (see Wiring Inspection)

CAN Communication Line Resistance (at ECU) (see

CAN Communication Line Resistance Inspection in the

Fuel System (DFI) chapter)

Crankshaft Sensor (see Crankshaft Sensor Inspection)

If the above items are good, replace the meter assembly

and/or ECU.

Check 21: Gear Position Indication Inspection

• Install the meter unit (see Meter Unit Installation).

• Turn the ignition switch ON.

• Check that the N mark [A] appears in the display and neu-

tral indicator light (LED) [B] goes on.

• Set the low gear position, check that the display changes

to 1 mark.

• For the other gear position indication;

• Using the stand, raise the rear wheel off the ground (see

Interlock Operation Inspection).

• Start the engine, change the gear position.

• Check that the display corresponding to each gear posi-

tion appears.

• Turn the ignition switch OFF.

If the display function does not work, go to the Check 1

and check the following items.

Wiring (see Wiring Inspection)

CAN Communication Line Resistance (at ECU) (see

CAN Communication Line Resistance Inspection in the

Fuel System (DFI) chapter)

Gear Position Switch (see Gear Position Switch (Service

Code 25) section in the Fuel System (DFI) chapter)

Speed Sensor (see Speed Sensor (Service Code 24)

section in the Fuel System (DFI) chapter)

If the above items are good, replace the meter assembly

and/or ECU.

ELECTRICAL SYSTEM 16-79

Meter, Gauge, Indicator Unit

Meter Unit Circuit

1. Meter Unit

14. Water Temperature Sensor

2. Dimmer Switch (High Beam)

15. Crankshaft Sensor

3. Turn Signal Switch (Right)

16. ECU

4. Turn Signal Switch (Left)

17. Frame Ground 1

5. ABS Hydraulic Unit (Equipped Models)

18. Water-proof Joint 1

6. Oil Pressure Switch

19. Ignition Fuse 10 A (in Fuse Box 2)

7. Gear Position Switch

20. ECU Fuse 15 A (in Fuse Box 2)

8. Speed Sensor

21. Ignition Switch

9. Fuel Level Sensor

22. Main Fuse 30 A

10. Joint Connector 1

23. Battery 12 V 14 Ah

11. Joint Connector 2

24. Frame Ground 2

12. Fuel Reserve Switch

25. Engine Ground

13. Water-proof Joint 2

26. Immobilizer Amplifier (Equipped Models)

16-80 ELECTRICAL SYSTEM

Immobilizer System (Equipped Models)

This motorcycle is equipped with an immobilizer system to protect the motorcycle from theft. This

system provides a theft proof device by means of matching a code between the inbuilt key transponder

and ECU (Electronic Control Unit). If the code does not match, ignition system, injectors, and sub

-throttle valve actuator will not operate and the engine will not start.

Abstract

• Do not keep more than one immobilizer key of any system on a key ring. Jamming of the key code

signal may occur and the operation of the system may be affected.

• The warning indicator light (LED) will flash for a period of 24 hours once the ignition switch has been

switched off and the key removed. This flashing can be set to on or off as desired by holding the

Mode and Reset buttons down for two seconds within twenty seconds of switching the ignition off.

• If all coded keys (master key and user keys) are lost the ECU and ignition switch will have to be

replaced.

• The immobilizer system can not function until the master key code is registered in the ECU.

•A total of six keys can be registered in the ECU at any one time (one master key and five user keys).

• If the master key is lost it is not possible to register new user keys.

Operational Cautions

1. Do not put two keys of any immobilizer system on the same key ring.

2. Do not submerge any key in water.

3. Do not expose any key to excessively high temperature.

4. Do not place any key close to magnet.

5. Do not place a heavy item on any key.

6. Do not grind any key or alter its shape.

7. Do not disassemble the plastic part of any key.

8. Do not drop the key and/or apply any shocks to the key.

9. When a user key is lost, the user should go to his dealer to invalidate the lost key registration in

the ECU.

10.When the master key is lost, the user should go to his dealer and have a new ECU installed and

register a new master key and user keys.

NOTE

○No.9 and 10 are strongly recommended to the customer to ensure security of the motorcycle.

Key Registration

Case 1: When the user key has been lost or additional

spare user key is required.

• Prepare a new spare user key.

• Cut the key in accordance with the shape of the current

user key.

• Remove the seat (see Seat Removal in the Frame chap-

ter).

• Disconnect the immobilizer/Kawasaki diagnostic system

connector [A].

• Connect the key registration unit [A].

Special Tool - Key Registration Unit: 57001-1582

ELECTRICAL SYSTEM 16-81

Immobilizer System (Equipped Models)

• Insert the master key to the ignition switch and turn it ON.

Verified

○The warning indicator light (LED) [A] blinks to display the

registration mode (go to the next step).

Not Verified

○The warning indicator light (LED) [A] blinks to display the

collation error (refer to the following failure illustrations).

Immobilizer Amplifier Failure

Master Key Collation Error

• Turn the master key OFF and remove the master key.

○The warning indicator light (LED) [A] blinks continuously

to display that the ECU is in the registration mode for 15

seconds.

NOTE

○Insert next key and turn ON within 15 seconds after pre-

vious key is turned off and removed otherwise registra-

tion mode will be ended and the warning indicator light

(LED) stops flashing.

○To return to the registration mode start the master key

verification procedure. This applies to all user key reg-

istration.

• Insert the user key 1 to the ignition switch and turn it ON.

NOTE

○Keep the other user key away from the immobilizer an-

tenna.

16-82 ELECTRICAL SYSTEM

Immobilizer System (Equipped Models)

○If there is any problem in the registration, the warning

indicator light (LED) [A] blinks to display the collation error.

Immobilizer Amplifier Failure

When Registered User Key is Inserted.

User Key Collation Error

• The user key 1 is successfully registered in the ECU.

○The warning indicator light (LED) [A] blinks 2 times and

stops for 1 second and then repeats this cycle.

• Turn the user key 1 OFF and remove the user key 1.

○The warning indicator light (LED) [A] blinks to display the

registration mode.

NOTE

○Turn off the ignition switch and wait for the period of 15

seconds or more. The registration mode automatically

finishes and the warning indicator light (LED) will switch

off.

○This procedure registered the master key and one user

key.

○Continue with the procedure to register the second and

later keys before the 15 seconds period has elapsed.

• Insert the user key 2 to the ignition switch and turn it ON.

ELECTRICAL SYSTEM 16-83

Immobilizer System (Equipped Models)

○If there is any problem in the registration, the warning

indicator light [A] blinks to display the collation error.

Immobilizer Amplifier Failure

When Registered User Key is Inserted.

User Key Collation Error

• The user key 2 is registered in the ECU.

○The warning indicator light (LED) [A] blinks 3 times and

stops for 1 second and then repeats this cycle.

○This procedure has registered the master key and 2 user

keys.

• Continue with the procedure to register an additional 3

user keys.

NOTE

○The ECU can store up the six key codes (master key ×

1 and user key × 5).

User Key Indicator Light Flashes

Indicator

Indicator

Remarks

Light Blinks

Light Stop

User Key 3

4 times

1 seconds

Repeat

User Key 4

5 times

1 seconds

Repeat

User Key 5

6 times

1 seconds

Repeat

• Turn OFF the ignition switch and wait for period of more

than 15 seconds.

• The registration mode automatically ends.

16-84 ELECTRICAL SYSTEM

Immobilizer System (Equipped Models)

• Warning indicator light (LED) goes off [A].

• Remove the key registration unit and connect the immo-

bilizer/Kawasaki diagnostic system connector.

NOTE

○Turn the ignition switch ON with the registered user key.

○Check that the engine can be started using all regis-

tered user keys.

16-86 ELECTRICAL SYSTEM

Immobilizer System (Equipped Models)

Case 2: When the ignition switch is faulty and to be

replaced.

• Prepare a new ignition switch [A] and two new user keys

[B].

○These parts are available as a set. Prepare the current

master key [C].

• Remove:

Ignition Switch and Immobilizer Antenna (see Immobi-

lizer System Parts Replacement)

Seat (see Seat Removal in the Frame chapter)

• Disconnect the immobilizer/Kawasaki diagnostic system

connector.

• Connect the key registration unit [A].

Special Tool - Key Registration Unit: 57001-1582

• Connect:

New Ignition Switch Lead Connector [A]

Immobilizer Antenna Lead Connector [B]

NOTE

○Keep the antenna more than 15 cm from the ignition

switch.

• Put the current master key [C] at the antenna [D].

• Insert the new user key 1 [E] to the new ignition switch [F]

and turn it ON.

Verified

○The warning indicator light (LED) [A] blinks to display the

ECU is in the registration mode (go to the next step).

Not Verified

○The warning indicator light (LED) [A] blinks to display the

collation error.

Immobilizer Amplifier Failure

ELECTRICAL SYSTEM 16-87

Immobilizer System (Equipped Models)

Master Key Collation Error

• Turn OFF and remove the new user key 1.

• Temporarily place the antenna [A] on the new ignition

switch [B].

• Insert the user key 1 [C] again into the new ignition switch

and turn it ON.

NOTE

○Place the antenna on the ignition switch, insert the next

key and turn ON within 15 seconds after previous key

is turned off and removed otherwise registration mode

will be ended and the warning indicator light (LED) stops

flashing.

○To return to the registration mode start the master key

verification procedure. This applies to all user key reg-

istration.

○Keep other user keys away from the immobilizer an-

tenna.

○If there is any problem in the registration, the warning

indicator light (LED) [A] blinks to display the collation error.

Immobilizer Amplifier Failure

Content      ..     4      5      6      7     ..