Kawasaki Ninja ZX-6R Motorcycle. Service Manual (2001-2002 year)

1-6 GENERAL INFORMATION

General Specifications

Items

ZX600-J1, J2

ZX600-J3 ∼

Dimensions

Overall Length

2 030 mm (79.9 in.), (PN) 2 060 mm (81.1 in.)

←

Overall Width

730 mm (28.7 in.)

←

Overall Height

1 175 mm (46.3 in.)

←

Wheelbase

1 400 mm (55.1 in.)

←

Road Clearance

145 mm (5.70 in.)

←

Seat Height

820 mm (32.3 in.)

←

Dry Mass

171 kg (377 lb), (CAL) 173 kg (382 lb), (H) 172

←

kg (379 lb)

Curb Mass:

Front

100 kg (221 lb)

←

Rear

96 kg (212 lb), (CAL) 98 kg (216 lb), (H) 97 kg

←

(214 lb)

Fuel Tank Capacity

18 L (4.76 US gal)

←

Performance

Minimum Turning Radius

3.2 m (10.5 ft)

←

Engine

Type

4-stroke, DOHC, 4-cylinder

←

Cooling System

Liquid-cooled

←

Bore And Stroke

66 × 43.8 mm (2.60 × 1.72 in.)

←

Displacement

599 cm³ (36.6 cu in.)

←

Compression Ratio

12.8

←

Maximum Horsepower

81.6 kW (111 PS) @12 500 r/min (rpm),

←

(AU) 80.6 kW (109.6 PS) @12 500 r/min (rpm),

(PR) 78.2 kW (106.3 PS) @12 500 r/min (rpm),

(US) - - -

Maximum Torque

65.6 N·m (6.7 kgf·m, 48 ft·lb) @10 000 r/min

←

(rpm),

(AU) 64.6 N·m (6.6 kgf·m, 48 ft·lb) @10 000

r/min (rpm)

(US) - - -

Carburetion System

Carburetors, Mikuni BDSR 36R × 4

←

Starting System

Electric starter

←

Ignition System

Battery and coil (transistorized)

←

Timing Advance

Electronically advanced(digital igniter)

←

Ignition Timing

From 12.5° BTDC @1 300 r/min (rpm) to 42.5°

←

BTDC @5 000 r/min (rpm)

Spark Plug

NGK CR9E

←

Cylinder Numbering Method

Left to right, 1-2-3-4

←

Firing Order

1-2-4-3

←

Valve Timing:

Inlet:

Open

56° BTDC

←

80° ABDC

←

Duration

316°

←

GENERAL INFORMATION 1-7

General Specifications

Items

ZX600-J1, J2

ZX600-J3 ∼

Exhaust:

Open

61° BBDC

←

33° ATDC

←

Duration

274°

←

Lubrication System

Forced lubrication (wet sump with cooler)

←

Engine Oil:

Grade

API SE, SF or SG

←

API SH, SJ with JASO MA (ZX600J1 ∼ J4, J6F)

←

API SH, SJ or SL with JASO MA (ZX600J7F ∼)

Viscosity

SAE10W-40, 10W-50, 20W-40, or 20W-50

SAE10W-40

Capacity

4.0 L (4.23 US qt)

←

Drive Train

Primary Reduction System:

Type

Gear

←

Reduction Ratio

2.022 (89/44)

←

Clutch Type

Wet multi disc

←

Transmission:

Type

6-speed, constant mesh, return shift

←

Gear Ratios:

1st

2.923 (38/13)

←

2nd

2.062 (33/16)

←

3rd

1.631 (31/19)

←

4th

1.380 (29/21)

←

5th

1.217 (28/23)

←

6th

1.083 (26/24)

←

Final Drive System:

Type

Chain drive

←

Reduction Ratio

2.666 (40/15)

←

Overall Drive Ratio

5.843 @Top gear

←

Frame

Type

Tubular, diamond

←

Caster (Rake Angle)

23.5°

←

Trail

95 mm (3.7 in.)

←

Front Wheel:

Tire Type

Tubeless

←

Tire Size

120/65 ZR17 (56 W)

120/65 ZR17 M/C

(56 W)

Rim Size

J 17M/C × MT3.50

←

Rear Wheel:

Tire Type

Tubeless

←

Tire Size

180/55 ZR17 (73 W)

180/55 ZR17

M/C (73 W)

Rim Size

J 17M/C × MT5.50

←

1-8 GENERAL INFORMATION

General Specifications

Items

ZX600-J1, J2

ZX600-J3 ∼

Front Suspension:

Type

Telescopic fork

←

Wheel Travel

120 mm (4.7 in.)

←

Rear Suspension:

Type

Swingarm (uni-trak)

←

Wheel Travel

135 mm (5.3 in.)

←

Brake Type:

Front

Dual discs

←

Rear

Single disc

←

Electrical Equipment

Battery

12 V 8 Ah

←

Headlight:

Type

Semi-sealed beam

←

Bulb

12 V 60/55 W (quartz-halogen) × 2

←

Tail/Brake Light

12 V 5/21 W × 2

←

Alternator:

Type

Three-phase AC

←

Rated Output

22 A/14 V @5 000 r/min (rpm)

←

Specifications are subject to change without notice, and may not apply to every country.

H: WVTA Approval Model with Honeycomb Catalytic Converter

PN: WVTA Approval Model with Pipe Catalytic Converter (Norway Model)

PR: WVTA Approval Model with Pipe Catalytic Converter (Restricted Power Model)

AU: Australia

CAL: California

US: United States

GENERAL INFORMATION 1-9

Periodic Maintenance Chart (United States and Canada Models)

The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in

good running condition. The initial maintenance is vitally important and must not be neglected.

FREQUENCY

Whichever

* ODOMETER READING

comes

1 000 km

Re-

first

(× 1

000

mile)

marks

OPERATION

Every

(0.6)

(4)

(7.5)

(12)

(15)

(20)

(24)

Spark plug - clean and gap †

•

Valve clearance - Inspect †

•

Air suction valve - Inspect †

•

Air cleaner element and air vent filter -

clean †#

•

Throttle grip play - Inspect †

•

Idle speed - Inspect †

•

Carburetor synchronization - Inspect †

•

Fuel hoses, Connections - Inspect †

•

Engine oil - change #

6 months

•

Oil filter - replace

•

Evaporative emission control system

(CAL) - Inspect †

•

Drive chain wear - Inspect †#

•

Brake pad wear - Inspect †#

•

Brake light switch - Inspect †

•

Steering - Inspect †

•

Rear shock absorber oil leak - Inspect †

•

Front fork oil leak - Inspect †

•

Tire wear - Inspect †

•

Swingarm pivot, Unit-trak linkage -

lubricate

•

General lubrication - perform

•

Nut, bolts, and fasteners tightness -

Inspect †

•

Drive chain - lubricate #

600 km

•

Drive chain slack - Inspect †#

1000 km

•

Brake hoses, connections - Inspect †

•

Brake fluid level - Inspect †

month

•

Clutch adjust - Inspect †

month

•

Radiator hoses, connections - Inspect †

•

Brake fluid - change

2 years

•

Brake master cylinder cup and dust

4 years

cover - replace

Coolant - change

2 years

•

Caliper fluid seal and dust seal - replace

4 years

Steering stem bearing - lubricate

2 years

•

GENERAL INFORMATION 1-11

Periodic Maintenance Chart (Other than United States and Canada Models)

The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in

good running condition. The initial maintenance is vitally important and must not be neglected.

FREQUENCY

Whichever

* ODOMETER READING

comes

1 000 km

Re-

first

(× 1

000

mile)

marks

OPERATION

Every

(0.6)

(4)

(7.5)

(12)

(15)

(20)

(24)

Spark plug - clean and gap †

•

Valve clearance - Inspect †

•

Air suction valve - Inspect †

•

Air cleaner element and air vent filter -

clean †#

•

Throttle grip play - Inspect †

•

Idle speed - Inspect †

•

Carburetor synchronization - Inspect †

•

Fuel hoses, Connections - Inspect †

•

Engine oil - change #

6 months

•

Oil filter - replace

•

Drive chain wear - Inspect †#

•

Brake pad wear - Inspect †#

•

Brake light switch - Inspect †

•

Steering - Inspect †

•

Rear shock absorber oil leak - Inspect †

•

Front fork oil leak - Inspect †

•

Tire wear - Inspect †

•

Swingarm pivot, Unit-trak linkage -

lubricate

•

General lubrication - perform

•

Nut, bolts, and fasteners tightness -

Inspect †

•

Drive chain - lubricate #

600 km

•

Drive chain slack - Inspect †#

1000 km

•

Brake hoses, connections - Inspect †

•

Brake fluid level - Inspect †

month

•

Clutch adjust - Inspect †

month

•

Radiator hoses, connections - Inspect †

•

Brake fluid - change

2 years

•

Brake master cylinder cup and dust

4 years

cover - replace

Coolant - change

2 years

•

Caliper fluid seal and dust seal - replace

4 years

Steering stem bearing - lubricate

2 years

•

Coolant filter - clean

year

GENERAL INFORMATION 1-13

Technical Information-KLEEN (KAWASAKI LOW EXHAUST EMISSION)

The ZX600J have catalytic converters.

The secondary air injection system [A] helps Kawasaki keep motorcycle exhaust gases below the

established emission regulation limits. This system draws air into the exhaust ports, dilutes and burns

harmful ingredients in the exhaust gas in order to reduce them. This allows the carburetor to be set

at a reasonable setting position without adjusting it much leaner, so engine performance and actual

riding performance are not spoiled.

But, under the trend that the emission regulation becomes more severe, Kawasaki has adopted

two catalytic converters [B] in addition to the secondary air injection system. Moreover, a BDSR 36

-type carburetor has been adopted because of its good balance between cost and performance. As

a result, we can reduce the exhaust gas emission below the current standards without hurting the

output performance and the actual riding feeling at all. The harmful ingredients in the exhaust gas

are reduced considerably under running performance of emission regulation like LA4 or EC mode.

As actual examples, carbon monoxide (CO) is reduced about 70%, hydrocarbons (HC) about 60%,

nitrogen oxides (NOx) about 10%.

Moreover, in order to improve the reliability of the system, we install fuel cut valves [C] as a catalyst

protection system.

Exhaust Gas after Purification

Kawasaki Low Exhaust Emission System

1-14 GENERAL INFORMATION

Technical Information-KLEEN (KAWASAKI LOW EXHAUST EMISSION)

1. Exhaust Purification System

The burned gas, which goes out from the combustion chamber, is injected with secondary air (adding

necessary oxygen), and is cleaned up while passing through the small precatalytic converters in the

joint pipe and the main catalytic converter in the silencer, and then goes out to the atmosphere.

Secondary Air Injection System

1) In order to oxidize CO, and HC by the catalysts, the proper amount of oxygen is necessary. As

original combustion gas has little remaining oxygen, air is injected in the exhaust ports by the sec-

ondary air injection system in order to supply enough oxygen to the combustion gas to purify CO,

and HC to a certain extent as well as prepare for activation of the catalysts. Since the carburetor

is set at richer level [A], and air/fuel mixture (A/F) is about 11 ∼ 14, NOx is at lower level from the

beginning as shown in the figure. And, A/F becomes lean (about 13.5 ∼ 15) after the combustion

chambers owing to secondary air injection and combustion.

Exhaust Gas before Purification

2) Precatalytic Converters [A]

A small-size three-way catalytic converter (precatalytic converter) is installed in the pipe ahead at

the joint [B] of the silencer. A precatalytic converter is made of a punched metal pipe [C] of stain-

less steel, and its surface is covered with alumina upon which platinum and rhodium as catalysts

are applied. Generally, the temperature of the exhaust gas must be higher than the activation tem-

perature, so we set this precatalytic converter at the upper portion of the main catalytic converter

where the temperature of exhaust gas is high. Accordingly, the precatalytic converter will be acti-

vated even under low load conditions. Activation of the precatalytic converter raises the exhaust

gas temperature by the catalyst reaction, which helps the main catalytic converter operate more

efficiently. The precatalytic converter purifies CO, HC, and NOx to a certain extent.

3) Main Catalytic Converters [D]

The converter is a three-way catalytic converter upon which platinum and rhodium are applied,

and has a cylindrical metallic honeycomb structure [E] made by bending a corrugated sheet and

a flat sheet of stainless steel into a spiral of increasing diameter. The main catalytic converter is

installed in the first expansion chamber of the silencer. When the exhaust gas passes through the

upper portion of the secondary air injection system, the precatalytic converter, and the inside of

the honeycomb, the main catalytic converter works efficiently to reduce CO, HC, and NOx. So,

we can keep it within regulation.

The honeycomb structure is convenient for the catalytic converter because it has a large surface

area but small size to react effectively and has low exhaust resistance. In addition, its inherent

strength helps resist vibration, and has simple structure welded directly on the silencer.

GENERAL INFORMATION 1-15

Technical Information-KLEEN (KAWASAKI LOW EXHAUST EMISSION)

Catalytic Converters

2. Catalyst Protection System

When excessive unburned gasoline flows more than the allowable amount into the exhaust gas dur-

ing running, the temperature of the catalysts rises abnormally because the unburned gasoline reacts

with heated catalysts (at the activation temperature or higher). In an excessive case, the problem

such as melting-down occurs. Moreover, there is a possibility that the purification performance be-

comes poorer when it is cool (below the activation temperature). So, the fuel cut valve [A] as a catalyst

protection system is installed on each carburetor float bowl [B]. It runs by the IC Igniter and opens

and closes the fuel passage toward a main jet [C]. A catalyst protection system works in the following

cases.

1) Prevention of unburned gasoline from flowing when overspeed limiter works.

The limiter has fuel cut-off and ignition cut-off operations.

2) Prevention of unburned gasoline from flowing when the engine stop switch is turned off during

running.

When the engine stop switch is turned off while coasting the motorcycle, fuel is cut off. For ex-

ample, fuel is cut off under the abnormal running condition that you go down the slope with the

engine stop switch OFF.

3) Prevention of unburned gasoline from flowing when misfire occurs by a cutoff of a primary coil in

a stick coil.

Fuel is cut off when an electric current of a primary coil becomes abnormal because of a cutoff of

the primary coil when the engine is running.

4) Prevention of solenoid valve lock

If a driver always runs the engine under the red zone in the tachometer, the IC igniter doesn’t

operate overspeed limiter and the catalyst protection system doesn’t have a chance to work. The

1-16 GENERAL INFORMATION

Technical Information-KLEEN (KAWASAKI LOW EXHAUST EMISSION)

old fuel may gum up the fuel cut valves which remain seated in the float bowls. To cope with, the IC

igniter test-operates the fuel cut valves when starting the engine and prevents lock of the valves.

5) Usage of leaded gasoline is prohibited completely.

Leaded gasoline harms the purification efficiency of the catalysts.

The performance of the catalyst protection system is summed up as follows.

Fuel Cut Valve

Performance of Catalyst Protection System

Engine

Ignition

Protection

Fuel

Running Condition

Stop

Remedy (Action)

Switch

System

Cutvalve

Switch

Not necessary

Normal

OFF

OPEN

•

(Normal condition)

Overspeed performance

Not necessary

CLOSE •

Abnormal (misfire)

Defects at the stick coil

Inspect the

•

primary-side

connection at the

primary-side of the

stick coil.

Abnormal (misfire)

OFF

OPEN

Defects at the stick coil

Inspect the stick coil.

•

secondary-side

Battery is dead.

Charge the battery.

•

Spark plug fouling

Clean the spark plug

•

and adjust the gap.

Defects of the pickup coil

Inspect and replace

•

the pickup coil.

Defects of the IC igniter

Inspect and replace

•

the IC igniter.

Defects of the carburetor

Inspect and adjust

•

the carburetor.

Abnormal (no spark)

OFF

Short of the engine stop

Inspect and repair

•

switch

the engine stop

switch.

While coasting the

Turn the engine stop

•

motorcycle, do not turn

switch ON, and run.

the engine stop switch

OFF.

GENERAL INFORMATION 1-17

Technical Information-KLEEN (KAWASAKI LOW EXHAUST EMISSION)

Engine

Ignition

Protection

Fuel

Running Condition

Stop

Remedy (Action)

Switch

System

Cutvalve

Switch

Abnormal (no spark)

OFF

OPEN

Short of the ignition

Inspect and replace

•

switch

OFF

the ignition switch.

While coasting the

Turn the ignition

•

motorcycle, do not turn

switch and the

the ignition switch OFF.

engine stop switch

ON, and run.

3. Maintenance

Special maintenance is not necessary except for the inspection of the air suction valve (which has

been described in this manual).

1) Replacement of Muffler Assy

It is impossible to replace only catalytic converters because they are welded in the muffler. So, in

the following case, the replacement of the muffler assy is also necessary.

In case of using not-appointed fuel (leaded gasoline, etc.):

•

Purification efficiency decreases in a very short period because lead poisons the catalytic con-

verters. Although the appearance of the converter and engine performance are not effected, the

replacement of a muffler assy is necessary to secure the purification efficiency of exhaust gas.

In case catalytic converters melt down by overheating:

•

Especially in the case that a lot of unburned gasoline flows into the catalytic converters under

the extreme running condition far beyond common sense, there is a possibility that the catalysts

overreact and that catalytic converters overheat severely. If they melt down, it causes poor engine

performance, deterioration of emission noise level, and purification efficiency. So, the muffler assy

must be replaced

2) Durability

It has the same durability as a conventional muffler.

3) Disposal to Waste

As any harmful toxic substance is not used especially, it can be disposed as usual industrial wastes.

The body of the muffler is made of aluminum steel. The catalytic converter is also made of stain-

less steel which has alumina on its surface, and the main ingredients of catalysts are platinum and

rhodium.

4. Handling Precautions

Catalyst protection system against mishandling is applied to a vehicle with catalysts. But, we prohibit

depending on the system too much when running.

1) Use only unleaded gasoline:

Usage of leaded gasoline is prohibited completely. Only fuel and additives which are specified in

the Owner’s Manual can be used.

2) Use specified engine oil which is described in the Owner’s Manual:

In case of some ingredients which give bad effects to the catalysts (such as phosphorus “P”, lead

“Pb”, sulfur “S”) are included, the purification efficiency decreases.

3) Coasting (such as cranking while going down a slope) is prohibited with the ignition system OFF:

The engine running without igniting causes a great flow of unburned gasoline and the decreasing

of purification efficiency, and melting down of catalysts at the activation temperature or higher.

1-18 GENERAL INFORMATION

Technical Information-KLEEN (KAWASAKI LOW EXHAUST EMISSION)

When the ignition switch [A] is turned off, the fuel cut valves [B] do not work. So, avoid coasting

•

with the ignition switch OFF.

Do not run the engine nor coast the motorcycle under the misfire which occurs by defects such as

•

a bad connection with the spark plug at the secondary wiring of the stick coil [C].

Do not coast too much with the engine stop switch [D] OFF. Under the condition that the engine stop

•

switch is turned off during running, the IC igniter [E] closes the fuel cut valves to shut off fuel.

Do not run the engine nor coast the motorcycle too much under the condition that the primary wiring

•

of the stick coil does not connect completely (misfire). Incomplete connection or cut-off of the pri-

mary coil makes the fuel cut valves start to cut fuel. In this case, from the standpoint to protect the

catalysts, the fuel for all cylinders is cut off even if one cylinder has been affected.

Kawasaki Low Exhaust Emission System

GENERAL INFORMATION 1-19

Technical Information-KLEEN (KAWASAKI LOW EXHAUST EMISSION)

Do not run overspeed limiter too much from the standpoint to protect the engine. (Overspeed limiter

•

has a protection system that applies ignition cut method and fuel cut method together. Conventional

system applies fuel-on method.)

Do not run the engine even if only one cylinder has a misfire or has unstable running. In this case,

•

request the nearest service facility to correct it. If you have no choice but running by yourself, keep

engine rpm as low as possible and try to finish running at the shortest period.

When the battery is dead, do not push-start. Connect another full-charged battery with jumper ca-

•

bles, and start the engine.

5. Additional Information

1) Secondary Air Injection System

The mechanism is simple and power loss is minimum because the system uses the vacuum pres-

sure created by exhaust pulses.

The secondary injection air helps the fuel/air mixture burn more completely (Primary air means air

which flows through the inlet pipe). As the exhaust valve opens, and the burned fuel passes the

exhaust valve, a stream of fresh air is introduced through the air suction valve. This fresh air burns

the unburned gas and converts the carbon monoxide (CO) and hydrocarbons (HC) into harmless

carbon dioxide (CO₂) and water (H₂O).

CO + 1/2 O₂ → CO₂

HC + O₂ → CO₂ + H₂O

The secondary air injection system consists of a vacuum switch valve, and two air suction valves.

Without using an air pump, the air suction valve can draw fresh air into the exhaust passage near the

exhaust valves by vacuum that exhaust pulses generate.

Air Suction Valves

The air suction valves is a check valve which allows fresh air to flow only from the air cleaner via

air hoses into the exhaust port and prevents return flow. Remove and inspect the air suction valves

periodically (see Engine Top End chapter in this Service Manual). Also, remove and inspect the air

suction valves whenever the idle speed is unstable, engine power is greatly reduced, or there are

abnormal engine noises.

Vacuum Switch Valve

Although the vacuum switch valve usually permits secondary air flow, it closes when a high vacuum

(low pressure) is developed at the inlet pipe during engine braking. This is to shut off secondary air

flow and prevent explosions in the exhaust ports which might be caused by extra unburned fuel in the

exhaust during deceleration. These explosions, or backfiring in the exhaust system could damage

the air suction valves.

Regular inspection of the vacuum switch valve is not needed. If backfiring occurs frequently in the

exhaust system during engine braking or if there are abnormal engine noises, check the vacuum

switch valve as described in the text (see Engine Top End chapter in this Service Manual).

1-20 GENERAL INFORMATION

Technical Information-KLEEN (KAWASAKI LOW EXHAUST EMISSION)

Secondary Air Injection System

1. Air Cleaner Housing

6. Exhaust Valve

2. Air Hose

7. Carburetors

3. Inlet Silencer

8. Inlet Pipe

4. Vacuum Switch Valve

9. Inlet Valve

5. Air Suction Valve

2) Operation of Three-way Catalytic Converter

The three-way catalysts are used for the catalytic converters and the main catalytic converter. These

converters can clean up carbon monoxide (CO), hydrocarbons (HC), and nitrogen oxides (NOx) at

the same time.

CO and HC are oxidized (O is added) by platinum (Pt) and converted to harmless carbon dioxide

gas (CO₂) and water (H₂O), and then the exhaust gas is cleaned up:

CO + 1/2 O₂ → CO₂

HC + O₂ → CO₂ + H₂O

NOx is reduced (O is removed) by rhodium (Rh) and converted to harmless nitrogen (N₂) and oxygen

(O₂), and the exhaust gas is cleaned up.

NOx → N₂ + O₂

Main Catalytic Converter

GENERAL INFORMATION 1-21

Technical Information-KLEEN (KAWASAKI LOW EXHAUST EMISSION)

3) Property of Catalyst

Most catalysts are powders of metal or of metallic compounds, and they increase the rate of a

chemical reaction.

Catalysts are supposed to act in some way to loosen the bonds of the reacting substances. In other

words, they lower the energy of activation, thus allowing the reaction to proceed more rapidly. To

activate catalysts, the temperature of the exhaust gas must be higher than the activation temperature

that is 220° ∼ 230°C for new catalysts, and 270° ∼ 280 °C for used catalysts (after 10 000 ∼ 20 000

km ride).

The catalyst itself undergoes no permanent chemical change, or can be recovered when the chem-

ical reaction is completed. So, the muffler with built-in catalyst has the same durability as the conven-

tional muffler.

The mechanism of catalytic action is supposed to be a surface phenomenon in which reactants

are absorbed onto a small portion of the surface of the catalyst. The catalytic converter is made of

stainless steel and the surface is applied by alumina (aluminum oxide Al₂O₃). The alumina adheres

to the stainless steel wall and the catalyst adheres to the alumina very well. The alumina surface is

not uniform and there are corners, edges, dislocations, and grain boundaries. Catalyst is applied on

the alumina and this makes the catalyst surface rough. The rougher the surface is, the more actively

the catalyst absorbs the reactants.

If various impurities like lead are absorbed, they block the small portion of the catalyst surface,

preventing absorption of CO, HC, and NOx. This is the reason why leaded fuel poisons the catalyst

without any break on the surface or generation of heat.

Catalysts are generally efficient in small quantities. A catalyst can catalyze the reaction of several

thousand to a million times its weight in reactants. The three-way catalyst is a blend of platinum (Pt)

and rhodium (Rh) which are expensive. But a converter uses only about 0.05 gram of Pt and 0.01

gram of Rh and a main catalytic converter uses only about 0.4 gram of Pt and 0.1 gram of Rh.

1-22 GENERAL INFORMATION

Technical Information - Non-Contact Hall IC-Type Speed Sensor

Details

The electronic combination meter unit, superior to the

conventional type in weight and durability is installed on

the ZX600-J. The hall IC-type speed sensor is installed on

the ZX600-J together with it, which needs no cable and

speedometer gears. Its construction and operation are de-

scribed as follows;

Construction and Operation

The speed sensor [A] consists of a magnet [B] and the

•

Hall IC [C].

The Hall IC consists of Hall element [A], the differential

•

amplifier [B], the high pass filter [C], the comparator [D]

and the output transistor [E].

Hall Element

The semi-conductors (e.g. CaAs, InAs, InSb) are called

as mentioned above. The magnetic induction applied on

the two (2) Hall elements will be converted into the voltage,

and outputted.

Differential Amplifier

This can output the difference between output powers of

the two (2) Hall elements.

High Pass Filter

Sensitivity of the two (2) Hall elements.

Surface magnetic induction of a magnet.

Relative positions of the Hall element, magnet, and de-

tector gear.

↓↓

Able to cancel the DC off-set because of scattering of

differential output.

Comparator & Output Transistor

Able to output the square wave in accordance with the

magnetic induction alternation with the transistor turning on

or off.

The magnetic induction passing through the Hall element

•

will be changed in accordance with the relative position

of the sensor and the rotor nut [A] installed on the engine

sprocket will be rotated.

amount of magnetic induction

when large [B]

when small [C]

GENERAL INFORMATION 1-23

Technical Information - Non-Contact Hall IC-Type Speed Sensor

In the internal system of the Hall IC, the switch is operated

•

in accordance with the magnetic induction alternator. This

makes the square wave equal to the pulse of the rotor nut

output.

Amount of magnetic induction when large [A]

Amount of magnetic induction when small [B]

Operating point [C]

Returning point [D]

When high voltage [E]

When low voltage [F]

The vehicle speed is indicated in the speedometer, alter-

•

ing the pulse of this square wave.

Speed Sensor Inspection

Refer to the Electrical System chapter 15.

•

GENERAL INFORMATION 1-25

Torque and Locking Agent

The following tables list the tightening torque for the major fasteners requiring use of a

non-permanent locking agent or liquid gasket.

Letters used in the “Remarks” column mean:

L: Apply a non-permanent locking agent to the threads.

LG: Apply grease to the threads.

Lh: Left-hand threads.

M: Apply molybdenum disulfide grease.

O: Apply oil to the threads and seating surface.

R: Replacement parts

S: Tighten the fasteners following the specified sequence.

SS: Apply silicone sealant.

St: Stake the fasteners to prevent loosening.

Torque

Fastener

Remarks

N·m

kgf·m

ft·lb

Fuel System

Vacuum Valve Drain Screw

1.0

0.10

9 in·lb

Fuel Tap Bolts

4.9

0.50

43 in·lb

with black

washer

Fuel Tap Bolts

2.5

0.25

22 in·lb

with white

washer

Cooling System

Water Hose Clamp Screws

2.0

0.20

17 in·lb

Coolant By-pass Fitting

9.8

1.0

87 in·lb

Coolant Drain Plug (Water Pump)

9.8

1.0

87 in·lb

Coolant Drain Plugs (Cylinder)

9.8

1.0

87 in·lb

Radiator Fan Switch

1.8

Water Temperature Sensor

7.8

0.80

69 in·lb

Impeller Bolt

9.8

1.0

87 in·lb

Water Pump Cover Bolts

1.2

104 in·lb

Thermostat Housing Cover Bolts

5.9

0.60

52 in·lb

Water Hose Fitting Bolts

1.1

95 in·lb

Engine Top End

Spark Plugs

1.3

113 in·lb

Air Suction Valve Cover Bolts

1.2

104 in·lb

Cylinder Head Cover Bolts

9.8

1.0

87 in·lb

Camshaft Chain Tensioner Mounting Bolts

1.2

104 in·lb

Camshaft Cap Bolts

1.2

104 in·lb

Camshaft Chain Guide Bolts (Upper)

1.2

104 in·lb

Cylinder Head Bolts:

5.0

S, O

(Washer)

1.2

104 in·lb

Cylinder Head Jacket Plugs (Right)

1.5

Cylinder Head Jacket Plugs (Upper, Left)

2.0

14.5

Engine Side Cover Bolts

1.2

104 in·lb

Camshaft Chain Guide Bolt (Crankcase)

2.5

Carburetor Holder Bolts

1.2

104 in·lb

1-26 GENERAL INFORMATION

Torque and Locking Agent

Torque

Fastener

Remarks

N·m

kgf·m

ft·lb

Baffle Plate Bolts

9.8

1.0

87 in·lb

Muffler Body and Exhaust Pipe Connecting

4.5

Nuts

Exhaust Pipe Mounting Bolt

3.5

Clutch

Clutch Cover Bolts

1.2

104 in·lb

L (2, Front)

Clutch Cover Damper Bolts

5.9

0.60

52 in·lb

Clutch Spring Bolts

8.8

0.90

78 in·lb

Clutch Hub Nut

137

101

Engine Lubrication System

Oil Filler Plug

1.5 or

0.15 or

13 in·lb or

Hand-Tight

Engine Drain Plug

2.0

14.5

Oil Filter (Cartridge type)

3.2

R, O

Oil Cooler Mounting Bolt

8.0

Oil Pan Bolts

9.8

1.0

87 in·lb

Oil Pipe Holder Bolts

1.2

104 in·lb

Oil Pressure Relief Valve

1.5

Oil Pressure Switch

1.5

Oil Pressure Switch Terminal Bolt

1.5

0.15

13 in·lb

Impeller Bolt

9.8

1.0

87 in·lb

Oil Passage Plug (Right)

1.5

Oil Hose Banjo Bolts

2.5

Engine Removal/Installation

Engine Mounting Bolts and Nuts

4.5

Engine Mounting Locknuts

5.0

Engine Mounting Bracket Bolts

2.5

Crankshaft/Transmission

Breather Plate Bolts

9.8

1.0

87 in·lb

Breather Tube Bracket Bolts

1.2

104 in·lb

Crankcase Bolts:

3.0

2.0

14.5

6, L38 (Front, 6)

1.8

1.2

104 in·lb

Oil Passage Plug (Left)

2.0

14.5

Oil Passage Plug (Right)

1.5

Connecting Rod Big End Nuts

in the text

←

Engine Ground Lead Terminal Bolt

9.8

1.0

87 in·lb

Timing Rotor Bolt

4.5

Oil Pressure Switch

1.5

Gear Positioning Lever Bolt

1.2

104 in·lb

Shift Shaft Return Spring Pin (Bolt)

2.9

GENERAL INFORMATION 1-27

Torque and Locking Agent

Torque

Fastener

Remarks

N·m

kgf·m

ft·lb

Neutral Switch

1.5

Shift Drum Bearing Holder Bolt

1.2

104 in·lb

Shift Drum Bearing Holder Screw

4.9

0.5

43 in·lb

Shift Drum Cam Bolt

1.2

104 in·lb

Oil Pipe Holder Bolts

1.2

104 in·lb

Crankshaft Sensor Cover Bolts

1.2

104 in·lb

L (1)

Oil Nozzles

6.9

0.70

61 in·lb

Starter Motor Clutch Bolt

3.5

Wheels/Tires

Front Axle Clamp Bolts

2.0

14.5

Front Axle Nut

127

Rear Axle Nut

127

Final Drive

Engine Sprocket Nut

127

Engine Sprocket Cover Bolts

1.2

104 in·lb

Speed Sensor Mounting Bolt

6.9

0.70

61 in·lb

Rear Sprocket Nuts

6.0

Rear Sprocket Studs

Brakes

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 Reservoir Cap Stopper Screw

1.5

0.15

13 in·lb

Front Brake Reservoir Bracket Bolt

6.9

0.70

61 in·lb

Front Brake Light Switch Screws

1.0

0.10

9 in·lb

Front Master Cylinder Clamp Bolts

ZX600J1 ∼ J4, J6F

8.8

0.90

78 in·lb

ZX600J7F

1.1

97 in·lb

Front Brake Pad Spring Bolts

2.9

0.30

26 in·lb

Front Caliper Mounting Bolts

3.5

Front Caliper Assembly Bolts

2.1

Brake Disc Mounting Bolts

2.8

Rear Caliper Mounting Bolts

2.5

Rear Master Cylinder Mounting Bolts

2.5

Rear Master Cylinder Push Rod Locknut

1.8

Suspension

Front Fork Clamp Bolts (Upper)

2.0

14.5

Front Fork Clamp Bolts (Lower)

2.0

14.5

Front Fork Top Plugs

2.3

16.5

Piston Rod Nut

2.9

Front Fork Bottom Allen Bolt

4.0

Front Axle Clamp Bolts

2.0

14.5

1-28 GENERAL INFORMATION

Torque and Locking Agent

Torque

Fastener

Remarks

N·m

kgf·m

ft·lb

Rear Shock Absorber Nuts (Upper and Lower)

3.5

Rear Shock Absorber Upper Bracket Nut

6.0

Swingarm Pivot Shaft Nut

108

Uni-Trak:

Rocker Arm Nut

3.5

Tie-Rod Nuts

6.0

Steering

Steering Stem Head Nut

5.0

Steering Stem Locknut

4.9

0.5

43 in·lb

Steering Stem Nut

1.5

Handlebar Bolts

3.5

Handlebar Holder Bolts

2.5

Handlebar Holder Position Bolts

9.8

1.0

87 in·lb

Handlebar Weight Screws

Handlebar Switch Housing Screws

3.5

0.35

30 in-lb

Frame

Footpeg Mounting Bolts

3.5

Side Stand Mounting Bolt

4.5

Grab Rail Bolts

2.5

Footpeg Bracket Mounting Bolts

2.5

Side Stand Bracket Bolts

5.0

Rear Frame Bolts and Nuts

4.5

Rear Shock Absorber Upper Bracket Nut

6.0

Electrical System

Spark Plugs

1.3

113 in·lb

Alternator Rotor Bolt

120

Stator Coil Bolts

1.2

104 in·lb

Alternator Lead Holding Plate Bolts

6.9

0.70

61 in·lb

Engine Ground Lead Terminal Bolt

9.8

1.0

87 in·lb

Alternator Cover Bolts

1.2

104 in·lb

Crankshaft Sensor Coil Cover Bolts

1.2

104 in·lb

L (1)

Crankshaft Sensor Coil Bolts

5.9

0.60

52 in·lb

Timing Rotor Bolt

4.5

Starter Motor Mounting Bolts

1.2

104 in·lb

Handlebar Switch Housing Screws

3.4

0.35

30 in·lb

Radiator Fan Switch

1.8

Water Temperature Sensor

7.8

0.80

69 in·lb

Oil Pressure Switch

1.5

Oil Pressure Switch Terminal Bolt

1.5

0.15

13 in·lb

Neutral Switch

1.5

Starter Lockout Switch Screws

1.0

0.10

9 in·lb

Front Brake Light Switch Screws

1.0

0.10

9 in·lb

1-30 GENERAL INFORMATION

Torque and Locking Agent

The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and

nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the

values are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners

Threads dia.

Torque

(mm)

N·m

kgf·m

ft·lb

3.4 ∼ 4.9

0.35 ∼ 0.50

30 ∼ 43 in·lb

5.9 ∼ 7.8

0.60 ∼ 0.80

52 ∼ 69 in·lb

14 ∼19

1.4 ∼1.9

10.0 ∼ 13.5

25 ∼ 34

2.6 ∼ 3.5

19.0 ∼ 25

44 ∼ 61

4.5 ∼ 6.2

33 ∼ 45

73 ∼ 98

7.4 ∼ 10.0

54 ∼ 72

115 ∼ 155

11.5 ∼ 16.0

83 ∼ 115

165 ∼ 225

17.0 ∼ 23.0

125 ∼ 165

225 ∼ 325

23 ∼ 33

165 ∼ 240

1-40 GENERAL INFORMATION

Cable, Wire, and Hose Routing

1. Headlight/Turn Signal

12. Fuel Pump Relay

19. Engine (Battery) Ground

Light Lead

13. Regulator/Rectifier

Cable

2. Headlight Relay Lead

14. Rear Brake Light Switch

20. Clamp

3. Horn

15. Starter Relay

21. Oil Pressure Switch Lead

4. Radiator Fan Switch

16. Run the speed sensor lead

22. Main Harness

5. Alternator

under the clamp.

23. Regulator/Rectifier Lead

6. Neutral Switch

17. Clamp (Speed Sensor Lead,

24. Speed Sensor Lead

7. Speed Sensor

Side Stand Switch Lead,

25. Side Stand Switch Lead

8. Side Stand Switch Lead

Neutral Switch Lead, Alter-

26. Neutral Switch Lead

9. Speed Sensor Lead

nator Lead)

27. Alternator Lead

10. Junction Box

18. Clamp (Main Harness, Reg-

11. IC Igniter

ulator Lead, Oil Pressure

Switch Lead)

GENERAL INFORMATION 1-43

Cable, Wire, and Hose Routing

1. Air Vent Filter

11. To Radiator

2. Align the mark on the hose with the mark

12. Install the clamps with the baffle plate.

on the filter.

13. Baffle Plate

3. To Carburetors

14. Vacuum Hose

4. Air Cleaner Housing

15. Vacuum Hose Fitting

5. Fit the projection of the housing in the re-

16. Plug

cess of the air duct.

17. Fuel Tank Drain Hose

6. Vacuum Switch Valve

18. Clamp (Air Vent Filter Hose)

7. Through the stick coil lead

19. Cylinder Head Cover Ground Lead

8. Stick Coil Lead

20. Run the hose through the hole of the

9. Coolant Reserve Tank Hose

fender.

10. To Coolant Reserve Tank

GENERAL INFORMATION 1-45

Cable, Wire, and Hose Routing

1. Vacuum Valve

12. Vacuum Hoses (To #2, #3

20. Breather Hose (To Canis-

2. To Air Vent Filter

Carburetor Holder)

ter, Blue)

3. Carburetor Vent Hose

13. Fitting (4 Way)

21. Breather Hose (To Fuel

4. Carburetor Vent Hoses

14. Vacuum Hose (To #1 Car-

Tank)

5. Fitting (3 Way)

buretor Holder)

22. Drain Hose

6. Carburetor Vent Hose (To

15. Separator

23. Clamp

3 Way Fitting)

16. Band

24. Air Cleaner

7. Fitting

17. Purge Hose (3 Way Fit-

25. Clamp

8. Carburetor Vent Hose (To

ting to Canister, Green)

26. Pickup Coil Cover

Canister, Yellow)

18. Fitting (3 Way)

27. Clamp

9. Vacuum Switch Valve

19. Return Hose (To Fuel

28. Plug

10. Vacuum Hose

Tank)

29. Clamp

11. Vacuum Hose

GENERAL INFORMATION 1-47

Cable, Wire and Hose Routing (ZX600-J4)

Evaporative Emission Control System (California Model)

1. Main Harness

10. Fuel Hose

2. Regulator/Rectifier Lead

11. Carburetor Vent Hose (Yellow)

3. Purge Hose (green)

12. Breather Hose (Blue) (To Fuel Tank)

4. Vacuum Hose (To #1 Carburetor Holder)

13. Return Hose (Red) (To Fuel Tank)

5. To Drain Plug

14. Run the red return hose under the regu-

6. Run all the evaporative hoses over the

lator lead, and other hoses over the reg-

main harness.

ulator lead.

7. To Carburetor

15. Run the red return hose under the fuel

8. To Vacuum Switch Valve

hose, and other hoses over the fuel

9. To #1 Carburetor Holder

hoses.

FUEL SYSTEM 2-1

Fuel System

Table of Contents

Exploded View

2-2

Coolant Valve Inspection (Other

Specifications

2-5

than United States and Canada

Throttle Grip and Cables

2-6

Models)

2-17

Throttle Grip Play Inspection

2-6

Air Cleaner

2-18

Throttle Cable Installation

2-6

Element Removal

2-18

Throttle Cable Lubrication and

Element Installation

2-18

Inspection

2-6

Element Cleaning and Inspection

2-18

Choke Cable

2-7

Air Cleaner Housing Removal

2-19

Choke Cable Free Play

Air Cleaner Housing Installation...

2-19

Inspection

2-7

Air Vent Filter Cleaning

2-19

Choke Cable Free Play

Fuel Tank

2-20

Adjustment

2-7

Fuel Tank Removal

2-20

Choke Cable Installation

2-7

Fuel Tank Installation

2-20

Choke Cable Lubrication and

Fuel Tank Inspection

2-21

Inspection

2-7

Fuel Tank Cleaning

2-21

Carburetors

2-8

Fuel Tap Removal

2-21

Idle Speed Inspection

2-8

Fuel Tap Installation

2-22

Idle Speed Adjustment

2-8

Fuel Tap Inspection

2-22

Synchronization Inspection

2-8

Fuel Pump, Fuel Filter

2-23

Synchronization Adjustment

2-9

Fuel Pump, Fuel Filter Removal ..

2-23

Service Fuel Level Inspection

2-9

Fuel Pump, Fuel Filter Installation

2-23

Service Fuel Level Adjustment

2-10

Fuel Pump Inspection

2-23

Fuel System Cleanliness

Fuel Filter Inspection

2-23

Inspection

2-11

Evaporative Emission Control System

Carburetor Removal

2-11

(California Model Only)

2-24

Carburetor Installation

2-12

Parts Removal/Installation

2-24

Carburetor Disassembly

2-13

Hose Inspection

2-24

Carburetor Assembly

2-14

Separator Inspection

2-24

Carburetor Separation

2-14

Separator Operation Test

2-25

Carburetor Joining

2-14

Canister Inspection

2-25

Carburetor Cleaning

2-15

Vacuum Valve Inspection

2-26

Carburetor Inspection

2-15

Coolant Filter Cleaning (Other

than United States and Canada

Models)

2-17

FUEL SYSTEM 2-5

Specifications

Item

Standard

Throttle Grip And Cables

Throttle Grip Free Play

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

Choke Cable

Free Play

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

Carburetors

Make, Type

MIKUNI, BDSR-36 × 4

Main Jet

#1, 4: #155, #2, 3: #157.5

Main Air Jet

#45

Jet Needle

5E110-54-1,

(Other than US, CA) #1,4; 5E18-3, #2,3: 5E19-3

Pilot Jet (Slow Jet)

#12.5

Pilot Air Jet (Slow Air Jet)

#125

Pilot Screw (Turns Out)

3 turns out

Starter Jet

#35

Idle Speed

1300 ±50 r/min (rpm)

Carburetor Synchronization Vacuum

Less than 2.7 kPa (2 cmHg) difference between any two

carburetors

Service Fuel Level

20.2 ±1 mm (0.80 ±0.04 in.) below the mark on the

carburetor body

Float Height

7 ±2 mm (0.28 ±0.08 in.)

CA: Canada

US: United States

Special Tools - Carburetor Drain Plug Wrench, Hex 3: 57001-1269

Fuel Level Gauge: 57001-1017

Fork Oil Level Gauge: 57001-1290

(as required)

Pilot Screw Adjuster, A: 57001-1239

2-6 FUEL SYSTEM

Throttle Grip and Cables

Throttle Grip Play Inspection

Throttle Grip Free Play Inspection

Check the throttle grip free play [A].

•

If the free play is incorrect, adjust the throttle cable.

Throttle Grip Free Play

Standard:

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

Check that the throttle grip moves smoothly from full open

•

to close, and the throttle closes quickly and completely in

all steering positions by the return spring.

If the throttle grip does not return properly, check the throt-

tle cable routing, grip free play, and cable damage. Then

lubricate the throttle cable.

Run the engine at the idle speed, and turn the handlebar

•

all the way to the right and left to ensure that the idle speed

does not change.

If the idle speed increase, check the throttle cable free

play and the cable routing.

Throttle Grip Free Play Adjustment

Loosen the locknuts [A], and screw both throttle cable ad-

•

justers in completely so as to give the throttle grip plenty

of play.

Turn out the decelerator cable adjuster [B] until there is

•

no play when the throttle grip is completely closed.

Tighten the locknut.

•

Turn the accelerator cable adjuster [C] until 2 ∼ 3 mm

(0.08 ∼ 0.12 in.) of throttle grip play is obtained.

Tighten the locknut.

•

Throttle Cable Installation

Install the throttle cables in accordance with Cable, Wire,

•

and Hose Routing section in the General Information

chapter.

Install the lower ends of the throttle cables in the cable

•

bracket on the carburetor after installing the upper ends

of the throttle cables in the grip.

After installation, adjust each cable properly.

•

WARNING

Operation with incorrectly routed or improperly ad-

justed cables could result in an unsafe riding con-

dition.

Throttle Cable Lubrication and Inspection

Whenever the cables are removed, or in accordance with

•

the Periodic Maintenance Chart, lubricate the throttle ca-

bles (see General Lubrication in the Appedix chapter).

○Apply a thin coating of grease to the cable upper ends.

○Use a commercially available pressure cable lubricator to

lubricate the cables.

○With the cable disconnected at both ends, the cable

should move freely in the cable housing.

FUEL SYSTEM 2-7

Choke Cable

Choke Cable Free Play Inspection

Push the choke lever [A] all the way to the front.

•

Check choke cable free play [B].

•

○Determine the amount of choke cable play at the choke

lever. Pull the choke lever until the starter plunger lever

[C] at the carburetor touches the starter plunger [D]; the

amount of choke lever lower end travel is the amount of

choke cable play.

If the free play is incorrect, adjust the choke cable.

Choke Cable Free Play

Standard:

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

Choke Cable Free Play Adjustment

Loosen the locknut [A], and turn the adjuster [B] until the

•

cable has the proper amount of free play.

Tighten the locknut securely.

•

Choke Cable Installation

Install the choke cable in accordance with the Cable,

•

Wire, and Hose Routing section in the General Informa-

tion chapter.

After installation, adjust the cable properly.

•

WARNING

Operation with an incorrectly routed or improperly

adjusted cable could result in an unsafe riding con-

dition.

Choke Cable Lubrication and Inspection

Whenever the cable is removed, or in accordance with

•

the Periodic Maintenance Chart, lubricate the choke cable

(see General Lubrication in the Appendix chapter).

○Apply a thin coating of grease to the cable upper end.

○Use a commercially available pressure cable lubricator to

lubricate the cable.

○With the cable disconnected at both ends, the cable

should move freely in the cable housing.

2-8 FUEL SYSTEM

Carburetors

Idle Speed Inspection

Start the engine and warm it up thoroughly.

•

With the engine idling, turn the handlebar to both sides.

•

If handlebar movement changes the idle speed, the

throttle cables may be improperly adjusted or incorrectly

routed, or damaged. Be sure to correct any of these

conditions before riding (see Cable, Wire, and Hose

Routing section in the General Information chapter).

WARNING

Operation with improperly adjusted, incorrectly

routed, or damaged cables could result in an un-

safe riding condition.

Check idle speed.

•

If the idle speed is out of the specified range, adjust it.

Idle Speed

Standard:

1 300 ±50 r/min (rpm)

Idle Speed Adjustment

Start the engine and warm it up thoroughly.

•

Turn the adjusting screw [A] until the idle speed is correct.

•

○Open and close the throttle a few times to make sure that

the idle speed is within the specified range. Readjust if

necessary.

Synchronization Inspection

Start the engine and warm it up thoroughly.

•

Check the idle speed (see Idle Speed Inspection).

•

Remove the fuel tank and air cleaner housing (see Fuel

•

Tank Removal and Air Cleaner Housing Removal).

Supply fuel to the carburetors with an auxiliary fuel tank.

•

For the models other than the California model, remove

•

the #1, 4 carburetor vacuum hose plugs and #2, 3 carbu-

retor vacuum hose fitting.

Connect the suitable pipe joints [A] to the carburetor vac-

•

uum hoses [B] and vacuum gauge hoses [C].

Install the air cleaner housing.

•

Connect the vacuum gauge hoses to a vacuum gauge [A].

•

Start the engine and let it idle to measure the carburetor

•

intake vacuum.

If the vacuum is incorrect, adjust the synchronization.

Carburetor Synchronization Vacuum

Standard: Less than 2.7 kPa (2 cmHg) difference

between any two carburetors.

FUEL SYSTEM 2-9

Carburetors

Synchronization Adjustment

Turn the adjusting screw to synchronize the carburetors.

•

○Apply grease to the tip of the adjusting screw threads.

○First synchronize the left two and then the right two car-

buretors by means of the left and right adjusting screws

[A, C]. Then synchronize the left two carburetors and the

right two carburetors using the center adjusting screw [B].

If the carburetor synchronization cannot be obtained by

using the adjusting screws, check for dirt or blockage, and

then check the pilot screw settings.

Special Tool - Pilot Screw Adjuster, A: 57001-1239

Check the carburetor synchronization again.

•

NOTE

○Do not turn the pilot screws carelessly during carburetor

synchronization. You may cause poor running at low

engine speed.

For the other than the California model, remove the car-

•

buretor vacuum hose plugs and carburetor vacuum hose

fitting.

Check the idle speed.

•

Service Fuel Level Inspection

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Turn the ignition

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

well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

Situate the motorcycle so that it is perpendicular to the

•

ground.

Remove the fuel tank (see Fuel Tank Removal).

•

Prepare an auxiliary fuel tank and connect the fuel hose

•

to the carburetors.

Prepare a fuel hose.

•

Connect the fuel level gauge [A] to the carburetor float

•

bowl with the fuel hose.

Special Tool - Fuel Level Gauge: 57001-1017

Hold the gauge vertically against the side of the carburetor

•

body so that the "middle" line [B] is several millimeters

higher than the mark [C] on the carburetor body.

Feed fuel to the carburetor, then turn the carburetor drain

•

plug [D] out a few turns.

2-10 FUEL SYSTEM

Carburetors

Wait until the fuel level in the gauge settles.

•

Keeping the gauge vertical, align the "middle" line with the

•

mark.

NOTE

○Do not lower the "middle" line below the mark of the

carburetor body. If the gauge is lowered and then raised

again, the fuel level measured shows somewhat higher

than the actual fuel level. If the gauge is lowered too

far, dump the fuel into a suitable container and start the

procedure over again.

Read the fuel level [E] in the gauge and compare to the

•

specification.

Screw in the carburetor drain plug.

•

Stop feeding and remove the fuel level gauge.

•

If the fuel level is incorrect, adjust it (see Service Fuel

Level Adjustment).

Service Fuel Level (below the mark on the carburetor

body)

Standard:

20.2 ±1 mm (0.80 ±0.04 in.)

Service Fuel Level Adjustment

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Turn the ignition

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

well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

Remove the carburetor, and drain the fuel into a suitable

•

container.

Remove the float bowl.

•

Slide out the pivot pin [A] with a suitable tool [B], and

•

remove the float [C] and float valve needle [D].

Bend the tang [A] on the float arm very slightly to change

•

the float height. Increasing the float height lowers the fuel

level and decreasing the float height raises the fuel level.

Float Height

Standard:

7 ±2 mm (0.28 ±0.08 in.)

FUEL SYSTEM 2-11

Carburetors

NOTE

○Do not push the needle rod [A] in during the float height

measurement [B].

Assemble the carburetor, and recheck the fuel level.

•

If the fuel level cannot be adjusted by this method, the

float or the float valve [C] is damaged.

Fuel System Cleanliness Inspection

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Turn the ignition

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

well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

Remove the fuel tank (see Fuel Tank Removal)

•

Connect a suitable hose [A] to the fitting at the bottom of

•

each carburetor float bowl.

Run the lower ends of the hoses into a suitable container.

•

Turn out each drain plug [B] a few turns and drain the float

•

bowls.

Special Tool - Carburetor Drain Plug Wrench, Hex

57001-1269

Check to see if water or dirt comes out.

•

Tighten the drain plugs.

•

If any water or dirt appears during the above inspection,

clean the fuel system (see Carburetor Cleaning and Fuel

Tank Cleaning).

Carburetor Removal

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Turn the ignition

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

well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

Drain the coolant (For the other than US & CA models,

•

see Cooling System chapter)

Remove:

•

Seats (see Frame chapter)

Fuel Tank (see Fuel Tank Removal)

Air Cleaner Housing (see Air Cleaner Housing Removal)

Vent Hose

Fuel Hose

Coolant Hoses (For the other than US & CA Models)

Throttle Sensor Connector

Fuel Cut Valve Connectors (CAL and H Model)

2-12 FUEL SYSTEM

Carburetors

Loosen the carburetor clamp screws [A], and remove the

•

carburetors.

Remove the throttle cable ends and choke cable.

•

Stuff pieces of lint-free, clean cloth into the carburetor

•

holders to keep dirt out of the engine.

WARNING

If dirt or dust is allowed to pass through into the

carburetor, the throttle may become stuck, possibly

causing an accident.

CAUTION

If dirt gets through into the engine, excessive en-

gine wear and possibly engine damage will occur.

Carburetor Installation

Route the cables, harness, and hoses correctly (see Gen-

•

eral Information chapter).

Tighten the clamps for the carburetor holders at the posi-

•

tion in the figure.

WARNING

Be sure to install the holder clamp screws in the di-

rection shown. Or, the screws could come in con-

tact with the throttle linkage resulting in unsafe rid-

ing condition.

Check fuel leakage from the carburetors.

•

WARNING

Fuel spilled from the carburetors is hazardous.

Adjust the following items if necessary.

•

Idle Speed

Carburetor Synchronization

Throttle Cables

Choke Cable

FUEL SYSTEM 2-13

Carburetors

Carburetor Disassembly

Remove the carburetors.

•

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Turn the ignition

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

well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

NOTE

○Carburetor can be disassembled in the joined state.

For the US model, remove the pilot screw plug as follows:

•

punch a hole in the plug and pry there with an awl or other

suitable tool.

Turn in the pilot screw and count the number of turns until

•

it seats fully but not tightly, and then remove the screw.

This is to set the screw to its original position when as-

sembling.

CAUTION

During carburetor disassembly, be careful not to

damage the diaphragm. Never use a sharp edge to

remove the diaphragm.

When removing the jet needle, pull straight out the holder

•

[A] from the vacuum piston [B].

○Remove:

Holder [A]

Spring [B]

Washer [C]

Jet Needle [D]

2-14 FUEL SYSTEM

Carburetors

Carburetor Assembly

Turn in the pilot screw [A] fully but not tightly, and then

•

back it out the same number of turns counted during dis-

assembly.

For the US model, install the pilot screw plug as follows:

•

install a new plug [B] in the pilot screw hole of the car-

buretor body [C], and apply a small amount of a bonding

agent [D] to the circumference of the plug to fix the plug.

CAUTION

Do not apply too much bonding agent to the plug or

the pilot screw itself may be fixed.

○Set the float height as specified (see Service Fuel Level

Adjustment).

After installing the upper chamber cover, check that the

•

vacuum piston slides up and down smoothly without bind-

ing in the carburetor bore.

Carburetor Separation

Remove the carburetor (see Carburetor Removal).

•

Read the WARNING in the carburetor disassembly.

•

Mark carburetor locations so that the carburetors can be

•

installed in their original positions.

Carburetor Joining

The center lines of the carburetor bores must be parallel

•

both horizontally and vertically. If they are not, loosen

the mounting screws and align the carburetors on a flat

surface.

Retighten the mounting screws.

•

After installing the choke mechanism, check to see that

•

the starter plunger lever slides right to left smoothly with-

out abnormal friction.

CAUTION

Fuel mixture trouble could result if the starter

plunger does not seat properly in its rest position

after the choke lever is returned.

Visually synchronize the throttle (butterfly) valves.

•

○Check to see that all throttle valves open and close

smoothly without binding when turning the pulley.

○Visually check the clearance [A] between the throttle

valve and the carburetor bore in each carburetor.

If there is a difference between any two carburetors, turn

the balance adjusting screw [B] to obtain the same clear-

ance.

Install the carburetors (see Carburetor Installation).

•

Adjust the synchronization (see Synchronization Adjust-

•

ment).

FUEL SYSTEM 2-15

Carburetors

Carburetor Cleaning

WARNING

Clean the carburetors in a well-ventilated area, and

take care that there is no sparks or flame anywhere

near the working area; this includes 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 the carburetors.

CAUTION

Do not use compressed air on an assembled carbu-

retor, or the floats may be crushed by the pressure,

and the vacuum piston diaphragms may be dam-

aged.

Remove as many rubber or plastic parts from the

carburetor as possible before cleaning the carbure-

tor with a cleaning solution. This will prevent dam-

age to or deterioration of the parts.

The carburetor body has plastic parts that can-

not be removed. Do not use a strong carburetor

cleaning solution which could attack these parts;

instead, use a mild high flash-point cleaning solu-

tion safe for plastic parts.

Do not use wire or any other hard instrument to

clean carburetor parts, especially jets, as they may

be damaged.

Disassemble the carburetor.

•

Immerse all the metal parts in a carburetor cleaning solu-

•

tion.

Rinse the parts in water.

•

When the parts are clean, dry them with compressed air.

•

Blow through the air and fuel passages with compressed

•

air.

Assemble the carburetor.

•

Carburetor Inspection

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Turn the ignition

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

well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

Remove the carburetors.

•

Before disassembling the carburetors, check the fuel level

•

(see Fuel Level Inspection).

If the fuel level is incorrect, inspect the rest of the carbu-

retor before correcting it.

2-16 FUEL SYSTEM

Carburetors

Slide the starter plunger lever to the left and release it to

•

check that the starter plungers move smoothly and return

by spring tension.

If the starter plungers do not work properly, replace the

carburetors.

Turn the throttle cable pulley to check that the throttle but-

•

terfly valves [A] move smoothly and return by spring ten-

sion.

If the throttle valves do not move smoothly, replace the

carburetors.

Disassemble the carburetors.

•

Clean the carburetors.

•

Check that the O-rings on the float bowl and pilot screw

•

and the diaphragm on the vacuum piston are in good con-

dition.

If any of the O-rings or diaphragms are not in good con-

dition, replace them.

Check the plastic tip [A] of the float valve needle [B]. It

•

should be smooth, without any grooves, scratches, or

tears.

If the plastic tip is damaged [C], replace the needle.

Push the rod [D] in the other end of the float valve needle,

•

and then release it [E].

If the rod does not spring out, replace the needle.

Check the tapered portion [A] of the pilot screw [B] for

•

wear or damage.

If the pilot screw is worn or damaged on the tapered por-

tion, it will prevent the engine from idling smoothly. Re-

place it.

Check that the vacuum piston [A] moves smoothly in the

•

carburetor body. The surface of the piston must not be

excessively worn.

If the vacuum piston does not move smoothly, or if it is

very loose in carburetor body, replace the carburetor.

FUEL SYSTEM 2-17

Carburetors

Coolant Filter Cleaning (Other than United States and

Canada Models)

Before winter season starts, clean the filter of carburetor

system.

Remove the fuel tank (see Fuel Tank Removal).

•

Drain the coolant (see Cooling System chapter).

•

Remove the filter [A] from the cooling hoses [B] of carbu-

•

retor system.

Blow off dirt and sediment on the filter with compressed

•

air.

Coolant Valve Inspection (Other than United States

and Canada Models)

Drain the coolant (see Cooling System chapter).

•

Remove the coolant valve on the engine left side.

•

Inspect the coolant valve [A] at room temperature.

•

If the valve is closed, replace the valve with a new one.

○To check valve opening just blow through the valve.

Valve Closing Temperature (for reference)

Standard:

70°C (158°F) or more at 25 kPa (0.25 kg/cm²,

3.6 psi)

2-18 FUEL SYSTEM

Air Cleaner

Element Removal

Remove:

•

Seats (see Frame chapter)

Fuel Tank (see Fuel Tank Removal)

Upper Housing Mounting Bolts [A]

Upper Housing [B]

Remove the following parts as a unit.

•

Upper Plastic Holder [A]

Element [B]

Lower Plastic Holder [C]

Put a clean, lint-free towel on the air cleaner housing to

•

keep dirt or other foreign material from entering.

WARNING

If dirt or dust is allowed to pass through into the car-

buretors, the butterfly valves may become stuck,

possibly causing an accident.

CAUTION

If dirt gets through into the engine, excessive en-

gine wear and possibly engine damage will occur.

Element Installation

Install the element unit [A] with the foam element side

•

(gray) facing up.

Element Cleaning and Inspection

WARNING

Clean the element in a well-ventilated area, and

make sure that there are no sparks or flame any-

where near the working area.

Because of the danger of highly flammable liquids,

do not use gasoline or a low flash-point solvent to

clean the element.

Remove the air cleaner element [A] (see this chapter).

•

Clean the element in a bath of high flash-point solvent,

•

and then dry it with compressed air or by shaking it.

After cleaning, saturate a clean, lint-free towel with SE,

•

SF, or SG class SAE 30 oil and apply the oil to the element

by tapping the element outside with the towel.

Visually check the element for tears or breaks.

•

If the element has any tears or breaks, replace the ele-

ment.

FUEL SYSTEM 2-19

Air Cleaner

Air Cleaner Housing Removal

Remove:

•

Seats (see Frame chapter)

Fuel Tank (see Fuel Tank Removal)

Engine Breather Hose [A]

Rubber Plugs [B]

Fuel Cut Valve Connectors [C] (California and H Models)

Remove:

•

Air Cleaner Housing Mounting Bolts [A]

Free the main harness from the clamp [B].

•

○Pull up the rear of the housing, and then remove it from

the air ducts.

Air Cleaner Housing Installation

Insert the housing into the air ducts [A] securely, and fit

•

the projection [B] of the housing in the recess of the air

ducts.

Tighten:

•

Housing Mounting Bolts

Be sure to fit the engine breather hose.

•

Install the rubber plugs in place.

•

Air Vent Filter Cleaning

Slide the clamps of air vent filter and remove the filter.

•

Clean the filter by directing a stream of compressed air

•

from clean side [A] to dirty side [B].

2-20 FUEL SYSTEM

Fuel Tank

Fuel Tank Removal

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Turn the ignition

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

well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

CAUTION

For California model, if gasoline, solvent, water or

any other liquid enters the canister, the canister’s

vapor absorbing capacity is greatly reduced. If the

canister does become contaminated, replace it with

a new one.

Turn the fuel tap position lever [A] to the OFF position.

•

Remove:

•

Seats (see Frame chapter)

Evaporative Emission Hoses (California model)

Fuel Filter Hose [B]

Fuel Tap Position Lever Screws [C]

Remove:

•

Mounting Bolts [A]

Bracket [B]

Pull the rear part of the fuel tank right side to clear the fuel

•

tap, and then remove the fuel tank.

Fuel Tank Installation

Read the WARNING mentioned in Fuel Tank removal.

•

Route the hoses correctly (see General Information chap-

•

ter).

Be sure the hoses are clamped securely to prevent leaks.

•

Check the rubber dampers.

If any damper is damaged or deteriorated, replace it.

FUEL SYSTEM 2-21

Fuel Tank

Fuel Tank Inspection

Remove the hose(s) from the fuel tank, and open the tank

•

cap.

Check to see if the water drain pipe [B] (also the breather

•

pipe [C] for the California model) in the tank is not clogged.

Check the tank cap breather also.

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

blow the pipes free with compressed air.

CAUTION

Do not apply compressed air to the air vent holes

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

clogging of the labyrinth in the cap.

Fuel Tank Cleaning

WARNING

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

care that there are no sparks or flame anywhere

near the working area. Because of the danger of

highly flammable liquids, do not use gasoline or low

flash- point solvents to clean the tank.

Remove the fuel tank and drain it.

•

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

•

shake the tank to remove dirt and fuel deposits.

Pour high flash-point solvent through the tap in all lever

•

positions.

Pour the solvent out of the tank.

•

Remove the fuel tap from the tank (see Fuel Tap Re-

•

moval).

Clean the fuel tap filter screens in a high flash-point sol-

•

vent.

Dry the tank and screens with compressed air.

•

Install the tank filters in the tank.

•

Install the fuel tank (see Fuel Tank Installation).

•

Fuel Tap Removal

Remove the Fuel Tap Position Lever (see Fuel Tank Re-

•

moval).

Remove the fuel tank and drain it.

•

Remove:

•

Bolts [A]

Flat Washers [B]

Fuel Tap [C]

2-22 FUEL SYSTEM

Fuel Tank

Fuel Tap Installation

Be sure the O-rings [A] is in good condition to prevent

•

leaks.

Be sure the flat washers [B] are in good condition to pre-

•

vent leaks.

○Do not use steel washers in place of the flat washers,

because they will not seal the bolts properly and fuel will

leak.

Be sure to clamp the fuel hoses to the tap to prevent leaks.

•

Torque - Fuel Tap Bolts (with white washer): 2.5 N·m (0.25

kg·m, 22 in·lb)

Fuel Tap Bolts (with black washer): 4.9 N·m (0.50

kg·m, 43 in·lb)

Fuel Tap Inspection

Remove the fuel tap.

•

Check the fuel tap filter screens [A] for any breaks or de-

•

terioration.

If the fuel tap screens have any breaks or are deterio-

rated, they may allow dirt to reach the carburetor, causing

poor running. Replace the fuel tap.

If the fuel tap leaks, or allows fuel to flow when it is at OFF

position, replace the damaged gasket [B] or O-ring [C].

FUEL SYSTEM 2-23

Fuel Pump, Fuel Filter

Fuel Pump, Fuel Filter Removal

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Turn the ignition

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

well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

Remove:

•

Seats (see Frame chapter)

Fuel Tank (see Fuel Tank Removal)

Fuel Hose [A]

Fuel Pump Lead Connector [B]

Remove the fuel pump [C] and fuel filter [D].

•

Fuel Pump, Fuel Filter Installation

Install the fuel filter so that the arrow [A] on it shows the

•

fuel flow from the fuel tank to the fuel pump.

Connect the fuel hose [C] from the fuel filter to the pump

•

fitting marked “INLET” [B].

Be sure to route the hoses so that they will not be kinked

•

or stretched.

Fuel Pump Inspection

Refer to the Electrical System chapter.

•

Fuel Filter Inspection

Remove:

•

Seats (see Frame chapter)

Fuel Tank (see Fuel Tank Removal)

Band

Visually inspect the fuel filter.

•

If the filter is clear with no signs of dirt or other contami-

nation, it is not necessary to replace it.

If the filter is dark or looks dirty, replace it. Also, check the

rest of the fuel system for contamination.

2-24 FUEL SYSTEM

Evaporative Emission Control System (California Model Only)

The Evaporative Emission Control System routes fuel va-

pors from the fuel system into the running engine or stores

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

though no adjustments are required, a thorough visual in-

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

riodic Maintenance Chart.

Parts Removal/Installation

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Turn the ignition

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

well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

CAUTION

If gasoline, solvent, water or any other liquid enters

the canister, the canister’s vapor absorbing capac-

ity is greatly reduced. If the canister does become

contaminated, replace it with a new one.

To prevent the gasoline from flowing into or out of the

•

canister, hold the separator perpendicular to the ground.

Connect the hoses according to the diagram of the sys-

•

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

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

•

vapor will not be obstructed.

Be sure to plug the return hose to prevent fuel spilling

•

before fuel tank removal.

WARNING

When removing the fuel tank, be careful not to spill

the gasoline through the return hose. Spilled fuel is

hazardous.

If liquid gasoline flows into the breather hose, remove the

hose and blow it clean with compressed air.

Hose Inspection

Check that the hoses are securely connected.

•

Replace any kinked, deteriorated or damaged hoses.

•

Separator Inspection

Remove the seats (see Frame chapter).

•

Disconnect the hoses from the liquid/vapor separator, and

•

remove the separator from the motorcycle.

Visually inspect the separator for cracks and other dam-

•

age.

If the separator has any cracks or is badly damaged, re-

place it with a new one.

FUEL SYSTEM 2-25

Evaporative Emission Control System (California Model Only)

Separator Operation Test

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Turn the ignition

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

well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

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

•

rator on the motorcycle.

Disconnect the breather hose from the separator, and in-

•

ject about 20 mL of gasoline [A] into the separator [B]

through the hose fitting.

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

•

Place the open end of the return hose into the container

•

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

Start the engine, and let it idle.

•

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

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

with a new one.

Canister Inspection

Remove the seats and seat cover (see Frame chapter).

•

Remove the canister, and disconnect the hoses from the

•

canister.

Visually inspect the canister for cracks and other damage.

•

If the canister has any cracks or bad damage, replace it

with a new one.

NOTE

○The canister is designed to work well through the motor-

cycle’s life without any maintenance if it is used under

normal conditions.

2-26 FUEL SYSTEM

Evaporative Emission Control System (California Model Only)

Vacuum Valve Inspection

Remove:

•

Air Cleaner Housing (see Air Cleaner Housing Removal)

Bracket [A] and Vacuum Valve [B]

Vacuum Valve Hoses [C]

Remove the drain screw [A] from the bottom of the cham-

•

ber.

If any liquid accumulates in the chamber, drain it.

WARNING

The liquid may contain gasoline.

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

•

After draining, install the drain screw with the O-ring.

•

Torque - Vacuum Valve Drain Screw: 1.0 N·m (0.10 kg·m, 9

in·lb)

Using a vacuum gauge and fork oil level gauge, inspect

•

the vacuum valve operation (see Vacuum Switch Valve

Test in Engine Top End chapter).

Special Tool - Fork Oil Level Gauge: 57001-1290

○When applying vacuum (1.5 cmHg) to the vacuum sens-

ing fitting [A], air flows from pipe [B] to pipe [C], and vice

versa.

○When stopping applying vacuum, air flows from pipe [B]

to pipe [D], and vice versa.

If the vacuum valve does not operate as described, re-

place it with a new one.

CAUTION

Do not use compressed air during the valve check,

or the vacuum valve may be damaged.

COOLING SYSTEM 3-1

Cooling System

Table of Contents

Exploded View

3-2

Specifications

3-3

Coolant Flow Chart

3-4

Coolant

3-6

Coolant Deterioration Inspection

3-6

Coolant Level Inspection

3-6

Coolant Draining

3-6

Coolant Filling

3-7

Pressure Testing

3-8

Cooling System Flushing

3-9

Coolant Filter Cleaning

3-9

Water Pump

3-10

Water Pump Removal

3-10

Water Pump Installation

3-10

Water Pump Inspection

3-10

Radiator, Radiator Fan

3-11

Radiator and Radiator Fan Removal

3-11

Radiator Inspection

3-12

Radiator Cap Inspection

3-12

Thermostat

3-13

Thermostat Removal

3-13

Thermostat Installation

3-13

Thermostat Inspection

3-13

Hose and Pipes

3-14

Hose Installation

3-14

Hose Inspection

3-14

Radiator Fan Switch, Water Temperature Sensor

3-15

Radiator Fan Switch, Water Temperature Sensor Removal

3-15

Radiator Fan Switch, Water Temperature Sensor Installation

3-15

Radiator Fan Switch, Water Temperature Sensor Inspection

3-15

3-2 COOLING SYSTEM

Exploded View

1. Radiator Fan Switch

T3: 12 N·m (1.2 kgf·m, 104 in·lb)

2. Water Temperature Sensor

T4: 7.8 N·m (0.80 kgf·m, 69 in·lb)

3. Coolant By-pass Fitting

T5: 9.8 N·m (1.0 kgf·m, 87 in·lb)

4. Drain Plug

T6: 11 N·m (1.1 kgf·m, 95 in·lb)

5. Thermostat

T7: 18 N·m (1.8 kgf·m, 13 ft·lb)

6. Cooling Hose Assy (other than US, CA

T8: 20 N·m (2.0 kgf·m, 14.5 ft·lb)

Models)

EO: Apply engine oil.

T1: 5.9 N·m (0.60 kgf·m, 52 in·lb)

L: Apply a non-permanent locking agent.

T2: 2.0 N·m (0.20 kgf·m, 17 in·lb)

SS: Apply silicone sealant.

CA: Canada

US: United States

COOLING SYSTEM 3-3

Specifications

Item

Standard

Coolant provided when shipping

Type

Permanent type of antifreeze (soft water and ethylene glycol

plus corrosion and rust inhibitor chemicals for aluminum

engines and radiators)

Color

Green

Mixed ratio

Soft water 50%, coolant 50%

Freezing point

-35°C (-31°F)

Total amount

2.3 L (2.43 US qt) (reserve tank full level including radiator

and engine)

Radiator cap

Relief pressure:

93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 14 ∼ 18 psi)

Thermostat

Valve opening temperature

58 ∼ 62°C (136 ∼ 144°F)

Valve full opening lift

8 mm (0.32 in.) or more @75°C (167°F)

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

3-4 COOLING SYSTEM

Coolant Flow Chart

Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion.

When the engine starts, the water pump turns and the coolant circulates.

The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The

thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.

When coolant temperature is below 55°C (131°F), the thermostat closes so that the coolant flow is

restricted through the air bleeder hole, causing the engine to warm up more quickly. When coolant

temperature is 58 ∼ 62°C (136 ∼ 144°F), the thermostat opens and the coolant flows.

When the coolant temperature goes up beyond 96 ∼ 100°C (205 ∼ 212°F), the radiator fan switch

conducts to operate the radiator fan. The radiator fan draws air through the radiator core when there

is not sufficient air flow such as at low speeds. This increases up the cooling action of the radiator.

When the temperature is below 91°C (196°F), the fan switch opens and the radiator fan stops.

In this way, this system controls the engine temperature within narrow limits where the engine op-

erates most efficiently even if the engine load varies.

The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles

which can cause engine overheating. As the engine warms up, the coolant in the radiator and the

water jacket expands. The excess coolant flows through the radiator cap and hose to the reserve tank

to be stored there temporarily. Conversely, as the engine cools down, the coolant in the radiator and

the water jacket contracts, and the stored coolant flows back to the radiator from the reserve tank.

The radiator cap has two valves. One is a pressure valve which holds the pressure in the system

when the engine is running. When the pressure exceeds 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/m², 14 ∼ 18

psi) the pressure valve opens and releases the pressure to the reserve tank. As soon as pressure

escapes, the valve closes, and keeps the pressure at 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/m², 14 ∼ 18 psi).

When the engine cools down, another small valve (vacuum valve) in the cap opens. As the coolant

cools, the coolant contracts to form a vacuum in the system. The vacuum valve opens and allows the

coolant from the reserve tank to enter the radiator.

COOLING SYSTEM 3-5

Coolant Flow Chart

1. Radiator

5. Drain Plug

2. Radiator Cap

6. Water Pump

3. Radiator Fan

7. Water Temperature Sensor

4. Fan Switch

8. Oil Cooler

9. Thermostat

When the engine is cold, the thermostat is closed so that the coolant flow is restricted through

the air bleeder hole, causing the engine to warm up more quickly.

10. By-pass Fitting

The fitting is installed to bleed the air.

11. Reserver Tank

When the engine is very hot, the pressure valve in the radiator cap allows air and vapor to

escape into the reserve tank. When the engine cools down, the pressure drop draws the vacuum

valve (another small valve) open, admitting coolant from the reserve tank into the radiator.

3-6 COOLING SYSTEM

Coolant

Coolant Deterioration Inspection

Visually inspect the coolant in the reserve tank.

•

If whitish cotton-like wafts are observed, aluminum parts

in the cooling system are corroded. If the coolant is

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

the cooling system.

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

cooling system leak. It may be caused by exhaust gas

leaking into the cooling system.

Coolant Level Inspection

NOTE

○Check the level when the engine is cold (room or ambi-

ent temperature).

Check the coolant level in the reserve tank with the mo-

•

torcycle held perpendicular.

If the coolant level is lower than the low level line [A], add

coolant to the full level line [B].

CAUTION

For refilling, add the specified mixture of coolant

and soft water. Adding water alone dilutes the

coolant and degrades its anticorrosion properties.

The diluted coolant can attack the aluminum en-

gine parts. In an emergency, soft water alone can

be added. But the diluted coolant must be returned

to the correct mixture ratio within a few days.

If coolant must be added often, or the reservoir tank

has run completely dry, there is probably leakage in

the cooling system. Check the system for leaks.

Coolant Draining

WARNING

To avoid burns, do not remove the radiator cap or

try to change the coolant when the engine is still

hot. Wait until it cools down. Coolant on tires will

make them slippery and can cause an accident

and injury. Immediately wipe up or wash away any

coolant that spills on the frame, engine, or other

painted parts.

Since coolant is harmful to the human body, do not

use for drinking.

COOLING SYSTEM 3-7

Coolant

Remove:

•

Lower Fairing (see Frame chapter)

Radiator Cap [A]

Place a container under the drain plug [A] at the bottom

•

of the water pump cover [B].

Drain the coolant from the radiator and engine by remov-

•

ing the drain plug.

Remove:

•

Lower Fairing (see Frame chapter)

Hose [A]

Mounting Screws [B] and Reserve Tank [C]

Collar and Idle Speed Adjusting Screw Bracket [D]

Remove the cap [E] and pour the coolant into a container.

•

Coolant Filling

Remove:

•

Lower Fairing (see Frame chapter)

Tighten the drain plug.

•

Torque - Drain Plug: 9.8 N·m (1.0 kgf·m, 87 in·lb)

Fill the radiator up to the radiator filler neck [A] with

•

coolant, and install the radiator cap.

NOTE

○Pour in the coolant slowly so that it can expel the air

from the engine and radiator.

Fill the reserve tank up to the full level line with coolant,

•

and install the cap.

CAUTION

Soft or distilled water must be used with the an-

tifreeze (see below for antifreeze) in the cooling sys-

tem.

If hard water is used in the system, it causes scales

accumulation in the water passages, and consider-

ably reduces the efficiency of the cooling system.

3-8 COOLING SYSTEM

Coolant

Water and Coolant Mixture Ratio (Recommended)

Soft Water

50%

Coolant

50%

Freezing Point

-35°C (-31°F)

Total Amount

2.3 L (2.43 US qt)

NOTE

○Choose a suitable mixture ratio by referring to the

coolant manufacturer’s directions.

Bleed the air from the cooling system as follows.

•

○Start the engine with the radiator cap removed and run it

until no more air bubbles [A] can be seen in the coolant.

○Tap the radiator hoses to force any air bubbles caught

inside.

○Stop the engine and add coolant up to the radiator filler

neck.

Install the radiator cap.

•

Start the engine, warm it up thoroughly until the radiator

•

fan turns on and then stop the engine.

Check the coolant level in the reserve tank after the en-

•

gine cools down.

If the coolant level is lower than the low level line, add

coolant to the full level line.

CAUTION

Do not add more coolant above the full level line.

Pressure Testing

Remove:

•

Lower Fairing (see Frame chapter)

Remove the radiator cap, and install a cooling system

•

pressure tester [A] on the filler neck.

NOTE

○Wet the cap sealing surfaces with water or coolant to

prevent pressure leaks.

Build up pressure in the system carefully until the pres-

•

sure reaches 123 kPa (1.25 kgf/cm², 18 psi).

CAUTION

During pressure testing, do not exceed the pres-

sure for which the system is designed. The maxi-

mum pressure is 123 kPa (1.25 kgf/cm², 18 psi).

Watch the gauge for at least 6 seconds.

•

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

If the pressure drops and no external source is found,

check for internal leaks. Droplets in the engine oil indicate

internal leakage. Check the cylinder head gasket and the

water pump.

Remove the pressure tester, replenish the coolant, and

•

install the radiator cap.

COOLING SYSTEM 3-9

Coolant

Cooling System Flushing

Over a period of time, the cooling system accumulates

rust, scale, and lime in the water jacket and radiator. When

this accumulation is suspected or observed, flush the cool-

ing system. If this accumulation is not removed, it will clog

up the water passage and considerable reduce the effi-

ciency of the cooling system.

Drain the cooling system (see Coolant Draining).

•

Fill the cooling system with fresh water mixed with a flush-

•

ing compound.

CAUTION

Do not use a flushing compound which is harmful to

the aluminum engine and radiator. Carefully follow

the instructions supplied by the manufacturer of the

cleaning product.

Warm up the engine, and run it at normal operating tem-

•

perature for about ten minutes.

Stop the engine, and drain the cooling system.

•

Fill the system with fresh water.

•

Warm up the engine and drain the system.

•

Repeat the previous two steps once more.

•

Fill the system with a permanent type coolant and bleed

•

the air from the system (see Coolant Filling).

Coolant Filter Cleaning

Refer to the chapter of carburetor in Fuel System for the

cleaning procedures.

3-10 COOLING SYSTEM

Water Pump

Water Pump Removal

Refer to Oil Pump Removal in the Engine Lubrication Sys-

•

tem chapter.

Water Pump Installation

Refer to Oil Pump Installation in the Engine Lubrication

•

System chapter.

Water Pump Inspection

Check the drainage outlet passage [A] at the bottom of

•

the water pump body for coolant leaks.

If the mechanical seal is damaged, the coolant leaks

through the seal and drains through the passage. Re-

place the water pump unit.

Visually inspect the impeller [A].

•

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

replace the water pump unit.

COOLING SYSTEM 3-11

Radiator, Radiator Fan

Radiator and Radiator Fan Removal

WARNING

The radiator fan is connected directly to the bat-

tery. The radiator fan may start even if the ignition

switch is off. NEVER TOUCH THE RADIATOR FAN

UNTIL THE RADIATOR FAN CONNECTOR IS DIS-

CONNECTED. TOUCHING THE FAN BEFORE THE

CONNECTOR IS DISCONNECTED COULD CAUSE

INJURY FROM THE FAN BLADES.

Remove:

•

Lower Fairings (see Frame chapter)

Coolant (see Coolant Draining)

Water Hoses [A]

Radiator Mounting Bolt [B]

Fan Switch Lead Connector [A]

Water Hose [B]

Radiator Mounting Bolts [C]

Radiator Fan Lead Connector [D]

Radiator

Radiator Fan Mounting Bolts [A]

Radiator Fan [B]

CAUTION

Do not touch the radiator core. This could damage

the radiator fins, resulting in loss of cooling effi-

ciency.

3-12 COOLING SYSTEM

Radiator, Radiator Fan

Radiator Inspection

Check the radiator core.

•

If there are obstructions to air flow, remove them.

If the corrugated fins [A] are deformed, carefully

straighten them.

If the air passages of the radiator core are blocked more

than 20% by unremovable obstructions or irreparably de-

formed fins, replace the radiator with a new one.

CAUTION

When cleaning the radiator with steam cleaner, be

careful of the following to prevent radiator damage.

Keep the steam gun [A] away more than 0.5 m (1.64

ft ) [B] from the radiator core.

Hold the steam gun perpendicular to the core sur-

face.

Run the steam gun following the core fin direction.

Radiator Cap Inspection

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

•

seals and valve spring [C].

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

with a new one.

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

•

NOTE

○Wet the cap sealing surfaces with water or coolant to

prevent pressure leaks.

Watching the pressure gauge, pump the pressure tester

•

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

gauge hand flicks downward. Stop pumping and measure

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

specified range in the table below and the gauge hand

must remain within the same range at least 6 seconds.

Radiator Cap Relief Pressure

93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm²,14 ∼ 18

Standard:

psi)

If the cap cannot hold the specified pressure, or if it holds

too much pressure, replace it with a new one.

COOLING SYSTEM 3-13

Thermostat

Thermostat Removal

Remove:

•

Coolant (see Coolant Draining)

Seats (see Frame chapter)

Fuel Tank (see Fuel System chapter)

Thermostat Housing Cover Bolts [A]

Thermostat Housing Cover [B]

Thermostat

Thermostat Installation

Be sure to install the O-ring [A] on the housing cover.

•

Tighten the housing cover bolts.

•

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

kgf·m, 52 in·lb)

Fill the radiator with coolant.

•

Thermostat Inspection

Remove the thermostat, and inspect the thermostat valve

•

[A] at room temperature.

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

one.

To check valve opening temperature, suspend the ther-

•

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

ture of the water.

○The thermostat must be completely submerged and must

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

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

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

It must not touch the container, either.

If the measurement is out of the specified range, replace

the thermostat with a new one.

Thermostat Valve Opening Temperature

58 ∼ 62°C (136 ∼ 144°F)

3-14 COOLING SYSTEM

Hose and Pipes

Hose Installation

Install the hoses and pipes being careful to follow bend-

•

ing direction or diameter. Avoid sharp bending, kinking,

flattening, or twisting.

Install the clamps [A] as near as possible to the hose end

•

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

hoses from working loose.

○The clamp screws should be positioned correctly to pre-

vent the clamps from contacting anything.

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

17 in·lb)

Hose Inspection

Visually inspect the hoses for signs of deterioration.

•

Squeeze the hoses. A hose should not be hard and

brittle, nor should it be soft to swollen.

Replace any damaged hoses.

•

COOLING SYSTEM 3-15

Radiator Fan Switch, Water Temperature Sensor

Removal

CAUTION

The fan switch or the water temperature sensor

should never be allowed to fall on a hard surface.

Such a shock to their parts can damage them.

Drain the coolant (see Coolant Draining).

•

Remove:

•

Radiator Fan Switch Lead Connector [A]

Radiator Fan Switch [B]

Seats (see Frame chapter)

Fuel Tank (see Fuel System chapter)

Water Temperature Sensor Lead Connector [A]

Water Temperature Sensor [B]

Radiator Fan Switch, Water Temperature Sensor

Installation

Apply silicone sealant to the threads of the water temper-

•

ature sensor.

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

Tighten the fan switch and water temperature sensor.

•

Torque - Radiator Fan Switch: 18 N·m (1.8 kgf·m, 13 ft·lb)

Water Temperature Sensor: 7.8 N·m (0.80 kgf·m,

69 in·lb)

Fill the coolant and bleed the air from cooling system (see

•

Coolant Filling in the Cooling System chapter).

Radiator Fan Switch, Water Temperature Sensor

Inspection

Refer to the Electrical System chapter for these inspec-

•

tions.

ENGINE TOP END 4-1

Engine Top End

Table of Contents

Exploded View

4-2

Valve Clearance Inspection

4-19

Specifications

4-4

Valve Clearance Adjustment

4-20

Clean Air System

4-7

Valve Removal

4-23

Air Suction Valve Removal

4-7

Valve Installation

4-23

Air Suction Valve Installation

4-7

Valve Guide Removal

4-23

Air Suction Valve Inspection

4-7

Valve Guide Installation

4-24

Vacuum Switch Valve Removal ...

4-7

Valve-to-Guide Clearance

Vacuum Switch Valve Installation

4-8

Measurement (Wobble

Vacuum Switch Valve Test

4-8

Method)

4-24

Clean Air System Hose

Valve Seat Inspection

4-25

Inspection

4-8

Valve Seat Repair

4-25

Cylinder Head Cover

4-9

Cylinder, Pistons

4-30

Cylinder Head Cover Removal

4-9

Cylinder Removal

4-30

Cylinder Head Cover Installation .

4-10

Cylinder Installation

4-30

Camshaft Chain Tensioner

4-11

Piston Removal

4-30

Camshaft Chain Tensioner

Piston Installation

4-31

Removal

4-11

Cylinder Wear Inspection

4-32

Camshaft Chain Tensioner

Piston Wear Inspection

4-32

Installation

4-11

Piston Ring, Piston Ring Groove

Camshaft, Camshaft Chain

4-12

Wear Inspection

4-32

Camshaft Removal

4-12

Piston Ring Groove Width

Camshaft Installation

4-12

Inspection

4-33

Camshaft, Camshaft Cap Wear

Piston Ring Thickness Inspection

4-33

Inspection

4-14

Piston Ring End Gap Inspection ..

4-33

Camshaft Runout Inspection

4-14

Carburetor Holder

4-34

Cam Wear Inspection

4-14

Carburetor Holder Installation

4-34

Camshaft Chain Removal

4-15

Muffler

4-35

Cylinder Head

4-16

Muffler and Exhaust Pipe

Cylinder Compression

Removal

4-35

Measurement

4-16

Muffler and Exhaust Pipe

Cylinder Head Removal

4-17

Installation

4-35

Cylinder Head Installation

4-17

Muffler Body Removal

4-36

Cylinder Head Warp Inspection ...

4-18

Muffler Body Installation

4-36

Valves

4-19

4-4 ENGINE TOP END

Specifications

Item

Standard

Service Limit

Clean Air System

Vacuum Switch Valve Closing

Open → Close

Pressure

57 ∼ 65 kPa (430 ∼ 490 mmHg)

- - -

Camshafts

Cam Height:

Exhaust

34.345 ∼ 34.453 mm

34.24 mm (1.348 in.)

(1.352 ∼ 1.356 in.)

Inlet

35.146 ∼ 35.254 mm

35.04 mm (1.380 in.)

(1.384 ∼ 1.388 in.)

Camshaft Journal, Camshaft Cap

0.038 ∼ 0.081 mm

0.17 mm (0.0067 in.)

Clearance

(0.0015 ∼ 0.0032 in.)

Camshaft Journal Diameter

23.940 ∼ 23.962 mm

23.91 mm (0.941 in.)

(0.9425 ∼ 0.9434 in.)

Camshaft Bearing Inside Diameter

24.000 ∼ 24.021 mm

24.08 mm (0.948 in.)

(0.9449 ∼ 0.9457 in.)

Camshaft Runout

TIR 0.02 mm (0.0008 in.) or less

TIR 0.1 mm (0.004 in.)

Cylinder Head

Cylinder Compression

(usable range)

950 ∼ 1 450 kPa (9.7 ∼ 14.8

kgf/cm², 138 ∼ 210 psi) @350 r/min

- - -

(rpm)

Cylinder Head Warp

- --

0.05 mm (0.002 in.)

Valves

Valve Clearance:

0.22 ∼ 0.31 mm

Exhaust

- - -

(0.0087 ∼ 0.0122 in.)

0.11 ∼ 0.19 mm

Inlet

- - -

(0.0043 ∼ 0.0075 in.)

Valve Head Thickness:

Exhaust

1.0 mm (0.04 in.)

0.6 mm (0.024 in.)

Inlet

0.5 mm (0.02 in.)

0.25 mm (0.010 in.)

Valve Stem Bend

TIR 0.01mm (0.0004 in.) or less

TIR 0.05 mm (0.002 in.)

Valve Stem Diameter:

Exhaust

3.955 ∼ 3.970 mm

3.94 mm (0.155 in.)

(0.1557 ∼ 0.1563 in.)

Inlet

3.975 ∼ 3.990 mm

3.96 mm (0.156 in.)

(0.1565 ∼ 0.1571 in.)

Valve Guide Inside Diameter

Exhaust

4.000 ∼ 4.012 mm

4.08 mm (0.161 in.)

(0.1575 ∼ 0.1580 in.)

Inlet

4.000 ∼ 4.012 mm

4.08 mm (0.161 in.)

(0.1575 ∼ 0.1580 in.)

Valve/Valve Guide Clearance

(Wobble Method):

Exhaust

0.10 ∼ 0.18 mm

0.35 mm (0.014 in.)

(0.004 ∼ 0.007 in.)

ENGINE TOP END 4-5

Specifications

Item

Standard

Service Limit

Inlet

0.03 ∼ 0.12 mm

0.29 mm (0.011 in.)

(0.0012 ∼ 0.0047 in.)

Valve Seat Cutting Angle

45°, 32°, 60°

- - -

Valve Seat Surface:

Width:

Exhaust

0.5 ∼ 1.0 mm (0.02 ∼

0.04 in.)

- - -

Inlet

0.5 ∼ 1.0 mm (0.02 ∼

0.04 in.)

- - -

Outside Diameter:

Exhaust

22.1 ∼ 22.3 mm

- - -

(0.870 ∼ 0.878 in.)

Inlet

26.4 ∼ 26.6 mm

- - -

(1.039 ∼ 1.047 in.)

Valve Spring Free Length:

Exhaust (Inner)

49.0 mm (1.93 in.)

47.6 mm (1.87 in.)

Inlet (Inner)

44.1 mm (1.44 in.)

42.6 mm (1.68 in.)

Inlet (Outer)

48.2 mm (1.90 in.)

46.6 mm (1.83 in.)

Cylinder, Piston

Cylinder Inside Diameter

65.960 ∼ 65.972 mm

66.06 mm (2.601 in.)

(2.5968 ∼ 2.5973 in.)

Piston Diameter

65.935 ∼ 65.950 mm

65.78 mm (2.590 in.)

(2.5957 ∼ 2.5965 in.)

Piston/Cylinder Clearance:

0.010 ∼ 0.037 mm

- - -

(0.0004 ∼ 0.0015 in.)

Piston Ring/Groove Clearance

Top

0.05 ∼ 0.09 mm

0.19 mm (0.0075 in.)

(0.0020 ∼ 0.0035 in.)

Second

0.03 ∼ 0.07 mm

0.17 mm (0.0067 in.)

(0.0012 ∼ 0.0028 in.)

Piston Ring Groove Width:

Top

0.84 ∼ 0.86 mm

0.94 mm (0.037 in.)

(0.0331 ∼ 0.0339 in.)

Second

0.82 ∼ 0.84 mm

0.92 mm (0.036 in.)

(0.0323 ∼ 0.0331 in.)

Piston Ring Thickness:

Top

0.77 ∼ 0.79 mm

0.70 mm (0.028 in.)

(0.0303 ∼ 0.0311 in.)

Second

0.77 ∼ 0.79 mm

0.70 mm (0.028 in.)

(0.0303 ∼ 0.0311 in.)

Piston Ring End Gap:

Top

0.15 ∼ 0.30 mm

0.6 mm (0.024 in.)

(0.0059 ∼ 0.0118 in.)

Second

0.30 ∼ 0.45 mm

0.8 mm (0.031 in.)

(0.0118 ∼ 0.0177 in.)

4-6 ENGINE TOP END

Specifications

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

Valve Spring Compressor Assembly: 57001-241

Piston Pin Puller Assembly: 57001-910

Valve Seat Cutter, 45° -

27.5: 57001-1114

Valve Seat Cutter, 45° -

32: 57001-1115

Valve Seat Cutter, 32° -

28: 57001-1119

Valve Seat Cutter, 32° -

30: 57001-1120

Valve Seat Cutter, 60° -

30: 57001-1123

Valve Seat Cutter Holder Bar: 57001-1128

Valve Spring Compressor Adapter,

20: 57001-1154

Valve Spring Compressor Adapter,

22: 57001-1202

Spark Plug Wrench, Hex 16: 57001-1262

Valve Guide Arbor,

4: 57001-1273

Valve Guide Reamer,

4: 57001-1274

Valve Seat Cutter Holder,

4: 57001-1275

Fork Oil Level Gauge: 57001-1290

Compression Gauge Adapter, M10 × 1.0: 57001-1317

Valve Seat Cutter, 60° -

33: 57001-1334

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

ENGINE TOP END 4-7

Clean Air System

Air Suction Valve Removal

Remove:

•

Seats (see Frame chapter)

Fuel Tank, Air Cleaner Housing (see Fuel System chap-

ter)

Separate the intake silencer [A] from the vacuum switch

•

valve [B].

Remove:

•

Vacuum Switch Valve with the Hoses

Air Suction Valve Cover Bolts [C]

Air Suction Valve Cover [D]

Air Suction Valve

Air Suction Valve Installation

Install the air suction valve so that its wider side [A] of the

•

reed faces the rear.

Apply a non-permanent locking agent to the threads of

•

the air suction valve cover bolts, and tighten them with

the specified torque.

Torque - Air Suction Valve Cover Bolts: 12 N·m (1.2 kgf·m,

104 in·lb)

Air Suction Valve Inspection

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

•

heat damage, or other damage.

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

the air suction valve as an assembly.

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

•

grooves, scratches, any signs of separation from the

holder, or heat damage.

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

areas, replace the air suction valve as an assembly.

If any carbon or other foreign particles have accumulated

•

between the reed and the reed contact area, wash the

valve assembly with a high flash-point solvent.

CAUTION

Do not scrape off the deposits with a scraper as this

could damage the rubber, requiring replacement of

the suction valve assembly.

Vacuum Switch Valve Removal

Remove the vacuum switch valve (see Air Suction Valve

•

Removal).

4-8 ENGINE TOP END

Clean Air System

Vacuum Switch Valve Installation

Install the vacuum switch valve so that the air hole [A]

•

faces downwards.

Route the hoses correctly (see General Information chap-

•

ter).

Vacuum Switch Valve Test

Remove:

•

Fuel Tank, Air Cleaner Housing (see Fuel System chap-

ter)

Vacuum Switch Valve

Connect a vacuum gauge [A] and syringe [B] or fork oil

•

level gauge to the vacuum hoses as shown.

Special Tool - Fork Oil Level Gauge: 57001-1290

Air Flow [C]

Gradually raise the vacuum (lower the pressure) applied

•

to the vacuum switch valve, and check the valve opera-

tion. When the vacuum is low, the vacuum switch valve

should permit air to flow. When the vacuum raises to

valve closing pressure, it should stop air flow.

Spring [A]

Diaphragm [B]

Valve [C]

Low Vacuum [D]

Secondary Air Flow [E]

If the vacuum switch valve does not operate as described,

replace it with a new one.

NOTE

○To check air flow through the vacuum switch valve, just

blow through the air cleaner hose.

Vacuum Switch Valve Closing Pressure (Open → Close)

Standard:

57 ∼ 65 kPa (430 ∼ 490 mmHg)

High Vacuum [A]

Secondary air cannot flow [B]

Clean Air System Hose Inspection

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

•

tened or kinked, and are connected correctly to the air

cleaner housing, vacuum switch valve, #1 and #4 carbu-

retor holders and air suction valve covers.

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

damaged.

ENGINE TOP END 4-9

Cylinder Head Cover

Cylinder Head Cover Removal

Remove:

•

Lower Fairing (see Frame chapter)

Coolant (drain, see Cooling System chapter) Other than

US, CAL Models

Seats (see Frame chapter)

Fuel Tank, Air Cleaner Housing and Carburetor (see

Fuel System chapter)

Vacuum Valve (California Model only)

Vacuum Switch Valve and Hoses

Stick Coil (see Electrical System)

Engine Side Cover [A] and Bolts [B]

Turn the handlebar to left side.

•

Remove:

•

Radiator Mount Bolts [A]

Radiator Bracket Bolts [B]

Radiator Bracket [C]

Move the radiator toward the down [D] and put the suit-

•

able support [E] under the radiator.

CAUTION

Do not touch the radiator core. This could damage

the radiator fins, resulting in loss of cooling effi-

ciency.

Remove:

•

Baffle Plate Bolts [A]

Baffle Plate [B]

NOTE

○If the baffle plate cannot easily be removed, remove the

air suction valve covers.

Remove the cylinder head cover bolts [A].

•

4-10 ENGINE TOP END

Cylinder Head Cover

Remove the cylinder head cover [A].

•

Cylinder Head Cover Installation

Replace the head cover gasket with a new one if dam-

•

aged.

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

•

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

Be sure to install the pins [A] and rubber gaskets [B].

•

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

•

Tighten:

•

Torque - Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87

in·lb) [B]

Baffle Plate Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

Apply a non-permanent locking agent to the threads of

•

the engine side cover bolt [A].

Tighten:

•

Torque - Engine Side Cover Bolts: 12 N·m (1.2 kgf·m, 104

in·lb) [A] [B]

ENGINE TOP END 4-11

Camshaft Chain Tensioner

Camshaft Chain Tensioner Removal

CAUTION

This is a non-return type camshaft chain tensioner.

The push rod does not return to its original position

once it moves out to take up camshaft chain slack.

Observe all the rules listed below:

When removing the tensioner, do not take out the

mounting bolts only halfway. Retightening the

mounting bolts from this position could damage

the tensioner and the camshaft chain. Once the

bolts are loosened, the tensioner must be removed

and reset as described in "Camshaft Chain Ten-

sioner Installation."

Do not turn over the crankshaft while the tensioner

is removed. This could upset the camshaft chain

timing, and damage the valves.

Remove:

•

Seats (see Frame chapter)

Fuel Tank (see Fuel System chapter)

Cap Bolt [A]

Washer [B]

Spring [C]

Rod [D]

Remove the mounting bolts [E] and take off the camshaft

•

chain tensioner.

Camshaft Chain Tensioner Installation

Release the stopper [A] and push the push rod [B] into

•

the tensioner body [C].

○Insert the push rod so that the push rod teeth are leaved

five notches.

Install the tensioner body so that the stopper faces up-

•

ward.

Tighten:

•

Torque - Camshaft Chain Tensioner Mounting Bolts [B]: 12

N·m (1.2 kgf·m, 104 in·lb)

Install the spring and washer.

•

Tighten the cap bolt [A].

•

Turn the crankshaft 2 turns clockwise to allow the ten-

•

sioner to expand and recheck the camshaft chain timing.

4-12 ENGINE TOP END

Camshaft, Camshaft Chain

Camshaft Removal

Remove:

•

Cylinder Head Cover (see Cylinder Head Cover Re-

moval)

Pickup Coil Cover

Position the crankshaft at #1, 4 piston TDC.

•

[A] TDC mark for #1, 4 Pistons

[B] Timing Mark (crankcase halves mating surface)

Remove:

•

Camshaft Chain Tensioner (see Camshaft Chain Ten-

sioner Removal)

Rubber Gaskets and Cylinder Head Cover Gasket

Camshaft Cap Bolts

Chain Guide [A]

Camshaft Cap [B]

Camshafts [C]

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

•

from dropping into the crankcase.

CAUTION

The crankshaft may be turned while the camshafts

are removed. Always pull the chain taut while turn-

ing the crankshaft. This avoids kinking the chain

on the lower (crankshaft) sprocket. A kinked chain

could damage both the chain and the sprocket.

Camshaft Installation

Be sure to install the following parts.

•

[A] O-rings

[B] Pins

Apply engine oil to all cam parts and journals.

•

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

•

denum disulfide grease to the cam surfaces.

NOTE

○The exhaust camshaft has a 117 EX mark [A] and the

inlet camshaft has a 117 IN mark [B]. Be careful not to

mix up these shafts.

ENGINE TOP END 4-13

Camshaft, Camshaft Chain

Position the crankshaft at #1, 4 piston TDC.

•

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

•

to install the chain.

Engage the camshaft chain with the camshaft sprockets

•

so that the timing marks on the sprockets are positioned

as shown.

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

surface of crankcase of rear side [E].

○The timing marks must be aligned with the cylinder head

upper surface [B].

[C] EX mark

[D] IN mark

Install the camshaft cap and chain guide.

•

○First tighten the camshaft cap and all chain guide bolts

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

following the specified tightening sequence.

Torque - Camshaft Cap Bolts: 12 N·m (1.2 kgf·m, 104 in·lb)

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

104 in·lb)

Tighten the camshaft chain tensioner (see Camshaft

•

Chain Tensioner Installation).

Install the cylinder head cover (see Cylinder Head Cover

•

Installation).

4-14 ENGINE TOP END

Camshaft, Camshaft Chain

Camshaft, Camshaft Cap Wear Inspection

Cut strips of plastigage to journal width. Place a strip

•

on each journal parallel to the camshaft installed in the

correct position.

Measure each clearance between the camshaft journal

•

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

Tighten:

•

Torque - Camshaft Cap Bolts: 12 N·m (1.2 kgf·m, 104 in·lb)

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

104 in·lb)

NOTE

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

tween the journal and camshaft cap.

Camshaft Journal, Camshaft Cap Clearance

Standard:

0.038 ∼ 0.081 mm (0.0015 ∼ 0.0032 in.)

Service Limit:

0.17 mm (0.0067in.)

If any clearance exceeds the service limit, measure the

diameter of each camshaft journal with a micrometer.

Camshaft Journal Diameter

Standard:

23.940 ∼ 23.962 mm (0.9425 ∼ 0.9434 in.)

Service Limit:

23.91 mm (0.941 in.)

If the camshaft journal diameter is less than the service

limit, replace the camshaft with a new one and measure

the clearance again.

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

cylinder head unit.

Camshaft Runout Inspection

Remove the camshaft.

•

Set the camshaft in a camshaft alignment jig or on V

•

blocks.

Measure runout with a dial gauge at the specified place

•

as shown.

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

Camshaft Runout

Standard: TIR 0.1 mm (0.004 in.)

Cam Wear Inspection

Remove the camshaft.

•

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

•

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

the camshaft.

Cam Height

Standard:

Exhaust

34.345 ∼ 34.453 mm (1.352 ∼ 1.356 in.)

Inlet

35.146 ∼ 35.254 mm (1.384 ∼ 1.388 in.)

Service Limit:

Exhaust

34.24 mm (1.348 in.)

Inlet

35.04 mm (1.380 in.)

Kawasaki Ninja ZX-6R Motorcycle. Service Manual (2001-2002 year) - page 1