Kawasaki Ninja 650R, ER-6f ABS, ER-6f Motorcycle. Service Manual (2006-2008 year)

1-10 GENERAL INFORMATION

General Specifications

Items

EX650A6F, EX650B6F

Dimensions

Overall Length

2 105 mm (82.9 in.)

Overall Width

760 mm (29.9 in.)

Overall Height

1 210 mm (47.6 in.)

Wheelbase

1 410 mm (55.5 in.)

Road Clearance

145 mm (5.7 in.)

Seat Height

790 mm (31.1 in.)

Dry Mass:

EX650A6F

178 kg (392.5 lb)

(CAL) 178.5 kg (393.6 lb)

EX650B6F

182 kg (401.3 lb)

Curb Mass:

Front:

EX650A6F

101 kg (222.7 lb)

EX650B6F

103 kg (227.1 lb)

Rear:

EX650A6F

99 kg (216.1 lb)

(CAL) 99.5 kg (219.4 lb)

EX650B6F

101 kg (222.7 lb)

Fuel Tank Capacity

15.5 L (4.1 US gal.)

Performance

Minimum Turning Radius

2.7 m (8.9 ft)

Engine

Type

4-stroke, DOHC, 2-cylinder

Cooling System

Liquid-cooled

Bore and Stroke

83 × 60 mm (3.3 × 2.4 in.)

Displacement

649 cm³ (39.60 cu in.)

Compression Ratio

11.3 : 1

Maximum Horsepower

53 kW (72 PS) @8 500 r/min (rpm),

Maximum Torque

66 N·m (6.7 kgf·m, 49 ft·lb) @7 000 r/min (rpm),

Carburetion System

FI (Fuel Injection) KEIHIN TTK38 × 2

Starting System

Electric starter

Ignition System

Battery and coil (transistorized)

Timing Advance

Electronically advanced (digital igniter)

Ignition Timing

From 10° BTDC @1 300 r/min (rpm) to 35° BTDC @4 800

r/min (rpm)

Spark Plug

NGK CR9EIA-9

Cylinder Numbering Method

Left to right, 1-2

Firing Order

1-2

Valve Timing:

Inlet:

Open

31° BTDC

61° ABDC

Duration

272°

GENERAL INFORMATION 1-11

General Specifications

Items

EX650A6F, EX650B6F

Exhaust:

Open

50° BBDC

30° ATDC

Duration

260°

Lubrication System

Forced lubrication (semi-dry sump)

Engine Oil:

Type

API SE, SF or SG

API SH, SJ or SL with JASO MA

Viscosity

SAE 10W-40

Capacity

2.4 L (2.5 US qt)

Drive Train

Primary Reduction System:

Type

Gear

Reduction Ratio

2.095 (88/42)

Clutch Type

Wet multi disc

Transmission:

Type

6-speed, constant mesh, return shift

Gear Ratios:

1st

2.438 (39/16)

2nd

1.714 (36/21)

3rd

1.333 (32/24)

4th

1.111 (30/27)

5th

0.966 (28/29)

6th

0.852 (23/27)

Final Drive System:

Type

Chain drive

Reduction Ratio

3.067 (46/15)

Overall Drive Ratio

5.473 @Top gear

Frame

Type

Tubular, diamond

Caster (Rake Angle)

25°

Trail

106 mm (4.2 in.)

Front Tire:

Type

Tubeless

Size

120/70 ZR17 M/C (58W)

Rim Size

17 × 3.50

Rear Tire:

Type

Tubeless

Size

160/60 ZR17 M/C (69W)

Rim Size

17 × 4.50

Front Suspension:

Type

Telescopic fork

Wheel Travel

120 mm (4.7 in.)

Rear Suspension:

1-14 GENERAL INFORMATION

Technical Information - Inlet Air Pressure Sensor

Atmospheric pressure sensor and camshaft position sensor are not equipped with the EX650A/B.

As a substitute of these sensors above, the EX650A/B recognizes atmospheric pressure and intake

stroke of #1 by the signal of inlet air pressure sensor.

The ECU detects atmospheric pressure when the ignition is switched ON. While the engine is run-

ning, the ECU also presumes atmospheric pressure by analyzing the waveform of boost pressure over

fixed period. The intake stroke is recognized by waveform of boost pressure, therefore the system

can recognize the difference of each stroke.

GENERAL INFORMATION 1-15

Technical Information - ABS (Anti - Lock Brake System)

Outline

ABS controls the brake caliper fluid pressure by means of mechatronics - a combination of electronic

and hydraulic control technology in order to keep the friction force between the tires and the road

surfaces close to the maximum value and prevent wheel lock. But it does not operate during cruising.

ABS Total System

1. ECU

13. Front Brake Caliper

2. ABS Indicator Light (LED)

14. Front Wheel Rotation Sensor

3. Pump Motor

15. Front Wheel Rotation Sensor Rotor

4. Pump

16. Rear Brake Caliper

5. Front Reservoir

17. Rear Wheel Rotation Sensor

6. Front Inlet Solenoid Valve

18. Rear Wheel Rotation Sensor Rotor

7. Front Outlet Solenoid Valve

19. ABS Kawasaki Self-diagnosis System Con-

8. Rear Inlet Solenoid Valve

nector

9. Rear Outlet Solenoid Valve

20. ABS Solenoid Valve Relay

10. Brake Lever

21. ABS Motor Relay

11. Brake Pedal

22. Rear Reservoir

12. ABS Hydraulic Unit

1-16 GENERAL INFORMATION

Technical Information - ABS (Anti - Lock Brake System)

ABS System Block Diagram

1. Power Source

12. Inlet Solenoid Valve

2. Ignition Power Source

13. ABS Motor Relay

3. Battery Power Source

14. Pump Motor

4. Indicator Light Output

15. Hydraulic Unit

5. ABS Indicator Light (LED)

16. ABS Controller

6. ECU

17. ABS Hydraulic Unit

7. ABS Solenoid Valve Relay

18. ABS Kawasaki Self-diagnosis System Con-

8. Output

nector

9. Monitor Input

19. Wheel Rotation Input

10. Valve Output

20. Wheel Rotation Sensor

11. Outlet Solenoid Valve

GENERAL INFORMATION 1-17

Technical Information - ABS (Anti - Lock Brake System)

Related Parts and Function

1. Front Wheel Rotation Sensor

2. Front Wheel Rotation Sensor Rotor

3. Rear Wheel Rotation Sensor

4. Rear Wheel Rotation Sensor Rotor

5. ABS Indicator Light (LED)

6. ABS Hydraulic Unit

7. ABS Fuse Box

8. ABS Kawasaki Self-diagnosis System Connector

Wheel Rotation Sensor

The wheel rotation sensors output the rotation speed of each wheel to the ECU in the ABS hydraulic

unit. The wheel rotation sensor is installed to the front fork and rear caliper bracket, and the sensor

rotor is pressed into the brake disc. The number of teeth on the front and rear sensor rotor is 50.

ABS Indicator Light (LED)

The condition or the failure of the ABS system is indicated by various patterns of the ABS indicator

light (LED) blinking.

GENERAL INFORMATION 1-19

Technical Information - ABS (Anti - Lock Brake System)

Inlet Solenoid Valve

Inlet solenoid valves control the brake pressure of each wheel by combining the operation of the

outlet solenoid valve. The ECU changes the electric current in the solenoids of the inlet solenoid

valve (2 way, 2 position electromagnetic valve) to move the tappet and change the fluid pressure to

“Increase Mode”, “Hold Mode”, or “Decrease Mode”.

1. Increase Mode

2. Hold and Decrease Mode

3. Tappet

4. Valve Body

5. From Master Cylinder

Outlet Solenoid Valve

Outlet solenoid valves control the brake pressure of each wheel by combining the operation of the

inlet solenoid valve. The ECU changes the electric current in the solenoids of the outlet solenoid

valve (2 way, 2 position electromagnetic valve) to move the armature and change the fluid pressure

to “Increase Mode”, “Hold Mode”, or “Decrease Mode”.

1. Decrease Mode

2. Increase and Hold Mode

3. Armature

4. Valve

5. To Reservoir

1-20 GENERAL INFORMATION

Technical Information - ABS (Anti - Lock Brake System)

Reservoir

When the passage opens between the caliper and the reservoir with the outlet solenoid valve in

“Decrease Mode”, the brake fluid flows into the reservoir by pushing the piston, stays there temporar-

ily, and then returns to the master cylinder. With the outlet solenoid valve “Increase or Hold Mode”,

the pump returns the remaining brake fluid in the reservoir to the master cylinder.

1. From Outlet Solenoid Valve

2. To Pump

Pump Motor

The pump motor operates the pump, supply or return the brake fluid from the pump.

Pump

The pump operates continuously when the ABS is activated. The pump is driven by the motor and

supply the brake fluid to the caliper or return the brake fluid in the reservoir to the master cylinder.

The piston is reciprocated by the eccentric cam [A] on the end of the motor shaft and the pump sucks

in or discharge the brake fluid.

When the pump pulls fluid in, the piston [B] is moved right by the force of the spring [C]. At this time,

the spring [D] is compressed by the pressure of the brake fluid in the reservoir to open the inlet valve

[E] and the brake fluid flows into the cylinder [F]. The outlet valve [G] is held closed by the force of the

spring [H].

When the pump discharges the brake fluid, the inlet valve [E] is closed by the spring [D], and the

piston [B] is moved left by the cam [A], producing pressure in the cylinder [F]. The pressure pushes

the spring [H], opens the outlet valve [G], and the brake fluid returns to the master cylinder.

Spring [C]

1-22 GENERAL INFORMATION

Technical Information - ABS (Anti - Lock Brake System)

ABS Operation

The ABS has two independent hydraulic lines, one for the front wheel and the other for the rear

wheel. The front wheel system is explained here and is identical to the rear wheel system.

ABS in Action

(Increase Mode)

When the caliper fluid pressure is to be increased, first the tappet of inlet solenoid valve opens

(normally open). The brake fluid flows through the valve body as shown in the diagram below to

increase the brake fluid pressure in the caliper. The master cylinder pressurizes to the brake caliper

directly, increasing the braking force.

1. Brake Lever

2. Front Inlet Solenoid Valve

3. Pump Motor

4. Pump

5. Front Reservoir

6. Front Outlet Solenoid Valve

7. Front Caliper

1-24 GENERAL INFORMATION

Technical Information - ABS (Anti - Lock Brake System)

(Decrease Mode)

When the caliper fluid pressure is to be decreased, the tappet of inlet solenoid valve closes, and the

passage to the valve body is intercepted. The valve of outlet solenoid valve is opened by the operation

of the armature, and the brake fluid flows to the reservoir. ECU operates pump, and the pump returns

the brake fluid in the reservoir to the master cylinder. The brake fluid pressure is decreased, and the

wheel is prevented from locking.

1. Brake Lever

2. Front Inlet Solenoid Valve

3. Pump Motor

4. Pump

5. Front Reservoir

6. Front Outlet Solenoid Valve

7. Front Caliper

GENERAL INFORMATION 1-25

Technical Information - ABS (Anti - Lock Brake System)

ABS Disabled (Conventional Mode)

During cruising (without braking) or in case of a malfunction with the ABS, the ECU stops operating.

This is “Conventional Mode”.

When the caliper fluid pressure is to be increased, first the tappet of inlet solenoid valve opens

(normally open). The brake fluid flows through the valve body as shown in the diagram below to

increase the brake fluid pressure in the caliper. The master cylinder pressurizes to the brake caliper

directly, increasing the braking force.

1. Brake Lever

2. Front Inlet Solenoid Valve

3. Pump Motor

4. Pump

5. Front Reservoir

6. Front Outlet Solenoid Valve

7. Front Caliper

1-26 GENERAL INFORMATION

Technical Information - ABS (Anti - Lock Brake System)

Riding Characteristics of ABS

ABS is designed to help prevent the wheels from locking up when hard brakes are applied while

running straight. The ABS automatically regulates brake force. Intermittently gaining gripping force

and braking force helps prevent wheel lock-up and allows stable steering control while stopping.

Brake control function is identical to that of a conventional motorcycle. The brake lever is used for

the front brake and the brake pedal for the rear brake.

Although the ABS provides stability while stopping by preventing wheel lock-up, remember the fol-

lowing characteristics:

○ABS cannot compensate for adverse road conditions, misjudgement or improper application of

brakes. You must take the same care as with motorcycles not equipped with ABS.

○ABS is not designed to shorten the braking distance. On loose, uneven or downhill surfaces, the

stopping distance of a motorcycle with ABS may be longer than that of an equivalent motorcycle

without ABS. Use special caution in such areas.

○ABS will help prevent wheel lock-up during straight-up braking, but it cannot control wheel slip which

may be caused by braking during cornering. When turning a corner, it is better to limit braking to

the light application of both brakes or not to brake at all. Reduce your speed before you get into the

corner.

○The ECU integrated in the ABS compare vehicle speed with wheel speed. Since non-recommended

tires can affect wheel speed, they may confuse the ECU, which can extend braking distance.

WARNING

Use of non-recommended tires may cause malfunctioning of ABS and can lead to extended

braking distance. The rider could have an accident as a result. Always use recommended

standard tires for this motorcycle.

NOTE

○When the ABS is functioning, you may feel a pulsing in the brake lever or pedal. This is normal.

You need not suspend applying brakes.

○Immediately after turning the ignition switch on, you may hear a click of the relay operating. This

is the sound of self-checking and is quite normal.

○ABS does not function at the speed of approx. 6 km/h or below.

○ABS does not function if the battery is discharged.

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

Periodic Maintenance Chart

2-3

Torque and Locking Agent

2-6

Specifications

2-11

Special Tools

2-13

Periodic Maintenance Procedures

2-14

Fuel System (DFI)

2-14

Air Cleaner Element Cleaning

2-14

Throttle Control System Inspection

2-15

Engine Vacuum Synchronization Inspection

2-16

Idle Speed Inspection

2-18

Idle Speed Adjustment

2-18

Fuel Hose Inspection (fuel leak, damage, installation condition)

2-19

Evaporative Emission Control System (California Model)

2-19

Evaporative Emission Control System Inspection

2-19

Cooling System

2-20

Coolant Level Inspection

2-20

Radiator Hose Damage and Installation Condition Inspection

2-21

Air Suction System

2-21

Air Suction System Damage Inspection

2-21

Engine Top End

2-21

Valve Clearance Inspection

2-21

Valve Clearance Adjustment

2-23

Clutch

2-26

Clutch Operation Inspection

2-26

Wheels/Tires

2-26

Air Pressure Inspection

2-26

Wheel/Tire Damage Inspection

2-27

Tire Tread Wear, Abnormal Wear Inspection

2-27

Wheel Bearing Damage Inspection

2-28

Drive Train

2-28

Drive Chain Lubrication Condition Inspection

2-28

Drive Chain Slack Inspection

2-29

Drive Chain Slack Adjustment

2-29

Wheel Alignment Inspection

2-30

Drive Chain Wear Inspection

2-31

Chain Guide Inspection

2-31

Brake System

2-32

Brake Fluid Leak (Brake Hose and Pipe) Inspection

2-32

Brake Hose and Pipe Damage and Installation Condition Inspection

2-32

Brake Operation Inspection

2-33

Brake Fluid Level Inspection

2-33

Brake Pad Wear Inspection

2-34

Brake Light Switch Operation Inspection

2-34

Suspensions

2-35

Front Forks/Rear Shock Absorber Operation Inspection

2-35

Front Fork Oil Leak Inspection

2-35

Rear Shock Absorber Oil Leak Inspection

2-35

Steering System

2-36

Steering Play Inspection

2-36

Steering Play Adjustment

2-36

2-2 PERIODIC MAINTENANCE

Steering Stem Bearing Lubrication

2-37

Electrical System

2-37

Spark Plug Condition Inspection

2-37

Lights and Switches Operation Inspection

2-38

Headlight Aiming Inspection

2-40

Sidestand Switch Operation Inspection

2-41

Engine Stop Switch Operation Inspection

2-42

Others

2-43

Chassis Parts Lubrication

2-43

Bolts, Nuts and Fasteners Tightness Inspection

2-44

Replacement Parts

2-45

Air Cleaner Element Replacement

2-45

Fuel Hose Replacement

2-45

Coolant Change

2-46

Radiator Hose and O-ring Replacement

2-48

Engine Oil Change

2-49

Oil Filter Replacement

2-49

Brake Hose and Pipe Replacement

2-50

Brake Fluid Change

2-51

Master Cylinder Rubber Parts Replacement

2-52

Caliper Rubber Parts Replacement

2-54

Spark Plug Replacement

2-56

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

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

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

Periodic Inspection

FREQUENCY

Whichever

* ODOMETER READING

comes

× 1 000 km

first

(× 1

000 mile)

See

Page

INSPECTION

Every

(0.6)

(4)

(7.5)

(12)

(15)

(20)

(24)

Fuel System

Air cleaner element - clean

2-14

•

Throttle control system (play, smooth

year

2-15

return, no drag) - inspect

•

Engine vacuum synchronization - inspect

2-16

•

Idle speed - inspect

2-18

•

Fuel leak (fuel hose and pipe) - inspect

year

2-19

•

Fuel hose and pipe damage - inspect

year

2-19

•

Fuel hose and pipe installation condition -

year

2-19

inspect

•

Evaporative Emission Control System

(CAL)

Evaporative emission control system

2-19

function - inspect

•

Cooling System

Coolant level - inspect

2-20

•

Coolant leak (radiator hose and pipe) -

year

2-21

inspect

•

Radiator hose damage - inspect

year

2-21

•

Radiator hose installation condition -

year

2-21

inspect

•

Air Suction System

Air suction system damage - inspect

2-21

•

Engine Top End

Valve clearance - inspect

Every 42

000

km (26 000 mile)

2-21

Clutch

Clutch operation (play, disengagement,

2-26

engagement) - inspect

•

Wheels and Tires

Tire air pressure - inspect

year

2-26

•

Wheel/tire damage - inspect

2-27

•

Tire tread wear, abnormal wear - inspect

2-27

•

Wheel bearing damage - inspect

year

2-28

•

Drive Train

Drive chain lubrication condition - inspect #

Every

600

km (400 mile)

2-28

Drive chain slack - inspect #

Every 1 000 km (600 mile)

2-29

Drive chain wear - inspect #

2-31

•

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

FREQUENCY

Whichever

* ODOMETER READING

comes

× 1 000 km

first

(× 1 000 mile)

See

Page

INSPECTION

Every

(0.6)

(4)

(7.5)

(12)

(15)

(20)

(24)

Drive chain guide wear - inspect

2-31

•

Brake System

Brake fluid leak (brake hose and pipe) -

year

2-32

inspect

•

Brake hose and pipe damage - inspect

year

2-32

•

Brake hose and pipe installation condition

year

2-32

- inspect

•

Brake operation (effectiveness, play, no

year

2-33

drag) - inspect

•

Brake fluid level - inspect

6 months

2-33

•

Brake pad wear - inspect #

2-34

•

Brake light switch operation - inspect

2-34

•

Suspensions

Front forks/rear shock absorber operation

2-35

(damping and smooth stroke) - inspect

•

Front forks/rear shock absorber oil leak -

year

2-35

inspect

•

Steering System

Steering play - inspect

year

2-36

•

Steering stem bearings - lubricate

2 years

2-37

•

Electrical System

Spark plug condition - inspect

2-37

•

Lights and switches operation - inspect

year

2-38

•

Headlight aiming - inspect

year

2-40

•

Sidestand switch operation - inspect

year

2-41

•

Engine stop switch operation - inspect

year

2-42

•

Others

Chassis parts - lubricate

year

2-43

•

Bolts and nuts tightness - inspect

2-44

•

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or

frequent starting/stopping.

*: For higher odometer readings, repeat at the frequency interval established here.

PERIODIC MAINTENANCE 2-5

Periodic Maintenance Chart

Periodic Replacement Parts

FREQUENCY

Whichever

* ODOMETER READING

comes

× 1 000 km

first

(×

1 000

mile)

See

Page

CHANGE/REPLACE ITEM

Every

(0.6)

(7.5)

(15)

(24)

(30)

Air cleaner element #

2 years

2-45

Fuel hose

4 years

2-45

•

Coolant

3 years

2-46

•

Radiator hose and O-ring

3 years

2-48

•

Engine oil #

year

2-49

•

Oil filter

year

2-49

•

Brake hose and pipe

4 years

2-50

•

Brake fluid

2 years

2-51

•

2-52,

Rubber parts of master cylinder and caliper

4 years

•

2-54

Spark plug

2-56

•

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or

frequent starting/stopping.

*: For higher odometer readings, repeat at the frequency interval established here.

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

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

non-permanent locking agent or silicone sealant etc.

Letters used in the “Remarks” column mean:

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

EO: Apply engine oil.

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

Lh: Left-hand threads

MO: Apply molybdenum disulfide oil solution.

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

R: Replacement Parts

S: Follow the specified tightening sequence.

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

SS: Apply silicone sealant.

Torque

Fastener

Remarks

N·m

kgf·m

ft·lb

Fuel System (DFI)

Water Temperature Sensor

1.2

106 in·lb

Speed Sensor Bolt

7.8

0.80

69 in·lb

Fuel Pump Bolts

9.8

1.0

87 in·lb

L, S

Oxygen Sensor (Europe Models)

44.1

4.50

32.5

Cooling System

Radiator Hose Clamp Screws

2.0

0.20

17 in·lb

Water Pump Impeller Bolt

9.8

1.0

87 in·lb

Water Pump Cover Bolts

9.8

1.0

87 in·lb

Water Pump Drain Bolt

7.0

0.70

62 in·lb

Thermostat Housing Bolts

9.8

1.0

87 in·lb

Water Temperature Sensor

1.2

106 in·lb

Baffle Plate Bolts

5.9

0.60

52 in·lb

Engine Top End

Air Suction Valve Cover Bolts

9.8

1.0

87 in·lb

Cylinder Head Cover Bolts

9.8

1.0

87 in·lb

Camshaft Cap Bolts

1.2

106 in·lb

Cylinder Head Bolts (M10 New Bolts)

5.5

MO, S

Cylinder Head Bolts (M10 Used Bolts)

5.0

MO, S

Cylinder Bolt (M8)

27.5

2.8

MO, S

Cylinder Nut (M10)

5.0

MO, S

Cylinder Head Bolts (M6)

1.2

106 in·lb

Cylinder Bolts (M6)

1.2

106 in·lb

Throttle Body Holder Bolts

1.2

106 in·lb

Rear Camshaft Chain Guide Bolt

2.0

Camshaft Chain Tensioner Mounting Bolts

9.8

1.0

87 in·lb

Camshaft Chain Tensioner Cap Bolt

2.0

Camshaft Sprocket Bolts

1.5

Spark Plugs

1.5

Exhaust Pipe Manifold Holder Nuts

1.7

Muffler Body Mounting Bolt (Front)

2.0

PERIODIC MAINTENANCE 2-7

Torque and Locking Agent

Torque

Fastener

Remarks

N·m

kgf·m

ft·lb

Muffler Body Mounting Bolt (Rear)

2.0

Baffle Plate Bolts

5.9

0.60

52 in·lb

Clutch

Upper Cap on Clutch Cover

3.9

0.40

35 in·lb

Lower Cap on Clutch Cover

Hand-tighten

Oil Filler Plug

Hand-tighten

Clutch Cover Mounting Bolts

9.8

1.0

87 in·lb

Clutch Spring Bolts

9.8

1.0

87 in·lb

Clutch Hub Nut

132

13.5

Clutch Lever Clamp Bolts

7.8

0.80

69 in·lb

Oil Pump Chain Guide Bolts

1.2

106 in·lb

Clutch Cable Holder Bolts

9.8

1.0

87 in·lb

Clutch Cable Clamp Bolt

9.8

1.0

87 in·lb

Engine Lubrication

Engine Oil Drain Bolt

3.0

Filter Plate Bolts

9.8

1.0

87 in·lb

Oil Filter

17.2

1.75

EO, R

Holder Mounting Bolt

2.5

Oil Pan Bolts

1.2

106 in·lb

Oil Pump Chain Guide Bolts

1.2

106 in·lb

Oil Pipe Plate Bolt

9.8

1.0

87 in·lb

Oil Pressure Relief Valve

1.5

Oil Pressure Switch

1.5

Oil Pump Cover Bolts

9.8

1.0

87 in·lb

Lower Fairing Bracket Bolts

1.2

106 in·lb

Oil Pump Sprocket Bolt

1.2

106 in·lb

L, Lh

Oil Passage Plug

2.0

Oil Plate Bolts

9.8

1.0

89 in·lb

Engine Removal/Installation

Rear Engine Mounting Nuts

4.5

Engine Mounting Bracket Bolts

2.5

Front Engine Mounting Bolts

4.5

Crankshaft/Transmission

Oil Plate Bolts

9.8

1.0

87 in·lb

Breather Plate Bolts

9.8

1.0

87 in·lb

Crankcase Bolts (M9, L = 113 mm)

4.5

MO, S

Crankcase Bolts (M9, L = 83 mm)

4.5

MO, S

Crankcase Bolts (M8, L = 73 mm)

3.6

MO, S

Crankcase Bolts (M8, L = 60 mm)

3.6

MO, S

Crankcase Bolts (M8, L = 110 mm)

27.5

2.8

Crankcase Bolts (M8, L = 50 mm)

27.5

2.8

Crankcase Bolts (M6)

19.6

2.0

Upper Crankcase Bolts

27.5

2.8

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

Torque

Fastener

Remarks

N·m

kgf·m

ft·lb

Shift Drum Bearing Holder Screw

4.9

0.50

43 in·lb

Connecting Rod Big End Nuts

see Text

←

Timing Rotor Bolt

4.1

Oil Pressure Switch

1.5

Oil Passage Plug

2.0

Gear Positioning Lever Bolt

1.2

106 in·lb

Shift Shaft Return Spring pin

2.9

Shift Drum Cam Bolt

1.2

106 in·lb

Neutral Switch

1.5

Transmission Case Bolts

2.0

Shift Rod Plate Bolt

9.8

1.0

87 in·lb

Neutral Switch Holder Screw

4.9

0.50

43 in·lb

Shift Shaft Cover Bolts

9.8

1.0

87 in·lb

L (2)

Shift Shaft Cover Screw

4.9

0.50

43 in·lb

Wheels/Tires

Front Axle

108

11.0

Front Axle Clamp Bolt

3.5

Rear Axle Nut

108

11.0

Final Drive

Engine Sprocket Nut

125

12.7

Rear Axle Nut

108

11.0

Rear Sprocket Nuts

6.0

Speed Sensor Bolt

7.8

0.80

69 in·lb

Speed Sensor Bracket Bolts

9.8

1.0

87 in·lb

Brakes

Bleed Valve

7.8

0.80

69 in·lb

Brake Hose Banjo Bolts

2.5

Brake Lever Pivot Bolt

1.0

0.10

9 in·lb

Brake Lever Pivot Bolt Locknut

5.9

0.60

52 in·lb

Brake Pedal Bolt

8.8

0.90

78 in·lb

Brake Pipe Joint Nuts (EX650B Models)

1.8

Front Brake Disc Mounting Bolts

2.8

Front Brake Light Switch Screw

1.0

0.10

9 in·lb

Front Brake Reservoir Cap Screws

1.0

0.10

9 in·lb

Front Caliper Mounting Bolts

3.5

Front Master Cylinder Clamp Bolts

8.8

0.90

78 in·lb

Rear 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 Axle Clamp Bolt

3.5

Front Fork Bottom Allen Bolts

3.1

PERIODIC MAINTENANCE 2-9

Torque and Locking Agent

Torque

Fastener

Remarks

N·m

kgf·m

ft·lb

Front Fork Clamp Bolts (Lower)

2.0

Front Fork Clamp Bolts (Upper)

2.0

Front Fork Top Plugs

2.5

Rear Shock Absorber Bolt

6.0

Rear Shock Absorber Nut

6.0

Swingarm Pivot Shaft Nut

108

11.0

Steering

Front Fork Clamp Bolts (Lower)

2.0

Front Fork Clamp Bolts (Upper)

2.0

Handlebar Holder Bolts

2.5

Left Switch Housing Screws

3.5

0.36

31 in·lb

Right Switch Housing Screws

3.5

0.36

31 in·lb

Steering Stem Head Bolt

108

11.0

Steering Stem Nut

2.0

Frame

Footpeg Stay Bolts

3.5

Front Fender Bolts

3.9

0.40

35 in·lb

Front Fender Bracket Bolts

8.8

0.90

78 in·lb

Front Turn Signal Light Mounting Screws

1.2

0.12

11 in·lb

Grab Rail Mounting Bolts

2.5

Seat Lock Mounting Screws

1.2

0.12

11 in·lb

Sidestand Bolt

4.5

Sidestand Switch Bolt

8.8

0.90

78 in·lb

Electrical System

Alternator Cover Bolts

9.8

1.0

87 in·lb

Alternator Lead Holding Plate Bolt

9.8

1.0

87 in·lb

Alternator Rotor Bolt

155

15.8

114

Crankshaft Sensor Bolts

6.0

0.60

53 in·lb

Engine Ground Cable Terminal Bolt

9.8

1.0

87 in·lb

Front Brake Light Switch Screw

1.2

0.12

11 in·lb

Front Turn Signal Light Mounting Screws

1.2

0.12

11 in·lb

Left Switch Housing Screws

3.5

0.36

31 in·lb

License Plate Light Cover Screws

0.90

0.090

8 in·lb

License Plate Light Mounting Screws

1.2

0.12

11 in·lb

Meter Screws

1.2

0.12

11 in·lb

Neutral Switch

1.5

Oil Pressure Switch

1.5

Oxygen Sensor

44.1

4.50

32.5

Regulator/Rectifier Bolts

8.8

0.90

78 in·lb

Right Switch Housing Screws

3.5

0.36

31 in·lb

Sidestand Switch Bolt

8.8

0.90

78 in·lb

Spark Plugs

1.5

Speed Sensor Bolt

7.8

0.80

69 in·lb

2-10 PERIODIC MAINTENANCE

Torque and Locking Agent

Torque

Fastener

Remarks

N·m

kgf·m

ft·lb

Starter Motor Cable Terminal Nut

6.0

0.60

53 in·lb

Starter Motor Clutch Bolts

3.5

Starter Motor Mounting Bolts

9.8

1.0

87 in·lb

Starter Motor Terminal Locknut

1.1

97 in·lb

Starter Motor Through Bolts

4.9

0.50

43 in·lb

Stator Coil Bolts

1.2

106 in·lb

Timing Rotor Bolt

4.1

Water Temperature Sensor

1.2

106 in·lb

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

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

values are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners

Threads Diameter

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

23.0 ∼ 33.0

165 ∼ 240

PERIODIC MAINTENANCE 2-11

Specifications

Item

Standard

Service Limit

Fuel System (DFI)

Throttle Grip Free Play

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

- - -

Idle Speed

1 300 ±50 r/min (rpm)

- - -

Bypass Screws (Turn Out)

0 ∼ 2 1/2 (for reference)

- - -

Engine Vacuum

35.3 ±1.3 kPa (265 ±10 mmHg)

- - -

Air Cleaner Element

Polyurethane Foam

- - -

Cooling System

Coolant:

Type (recommended)

Permanent type of antifreeze

- - -

Color

Green

- - -

Mixed Ratio

Soft water 50%, Coolant 50%

- - -

Freezing Point

-35°C (-31°F)

- - -

Total Amount

1.2 L (1.3 US qt)

- - -

Engine Top End

Valve Clearance:

Exhaust

0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.)

- - -

Inlet

0.15 ∼ 0.21 mm (0.0059 ∼ 0.0083 in.)

- - -

Clutch

Clutch Lever Free Play

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

- - -

Engine Lubrication System

Engine Oil:

Type

API SE, SF or SG

- - -

API SH, SJ or SL with JASO MA

Viscosity

SAE 10W-40

- - -

Capacity

1.7 L (1.8 US qt) (when filter is not

- - -

removed)

1.9 L (2.0 US qt) (when filter is removed)

- - -

2.4 L (2.5 US qt) (when engine is

- - -

completely dry)

Level

Between upper and lower level lines

- - -

(after idling or running)

Wheels/Tires

Tread Depth:

Front

4.3 mm (0.17 in.)

1 mm (0.04 in.),

(AT, CH, DE)

1.6 mm (0.06 in.)

Rear

7.0 mm (0.28 in.)

Up to 130 km/h (80 mph):

2 mm (0.08 in.),

Over 130 km/h (80 mph):

3 mm (0.12 in.)

Air Pressure (when Cold):

Front

Up to 180 kg (397 lb) load:

- - -

225 kPa (2.25 kgf/cm², 32 psi)

Rear

Up to 180 kg (397 lb) load:

- - -

250 kPa (2.50 kgf/cm², 36 psi)

2-12 PERIODIC MAINTENANCE

Specifications

Item

Standard

Service Limit

Final Drive

Drive Chain Slack

30 ∼ 40 mm (1.2 ∼ 1.6 in.)

- - -

Drive Chain Wear (20-link

317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)

323 mm (12.7 in.)

Length)

Standard Chain:

Make

ENUMA

- - -

Type

EK520MVXL1

- - -

Link

114 links

- - -

Brakes

Brake Fluid:

Grade

DOT4

- - -

Brake Pad Lining

Thickness:

Front

4.5 mm (0.18 in.)

1 mm (0.04 in.)

Rear

5.0 mm (0.20 in.)

1 mm (0.04 in.)

Brake Light Timing:

Front

Pulled ON

- - -

Rear

ON after about 10 mm (0.39 in.) of

- - -

pedal travel

Electrical System

Spark Plug Gap

0.8 ∼ 0.9 mm (0.03 ∼ 0.04 in.)

- - -

2-14 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Fuel System (DFI)

Air Cleaner Element Cleaning

NOTE

○In dusty areas, the element should be cleaned more

frequently than the recommended interval.

○After riding through rain or on muddily roads, the ele-

ment should be cleaned immediately.

WARNING

If dirt or dust is allowed to pass through into the

throttle assy, the throttle may become stuck, possi-

bly causing accident.

CAUTION

If dirt gets through into the engine, excessive en-

gine wear and possibly engine damage will occur.

• Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System

(DFI) chapter)

Air Switching Valve Hose [A] (Disconnect)

Air Cleaner Element Screw [B]

Air Cleaner Element [C]

• Remove:

Upper Plastic Holder [A]

Element [B]

NOTE

○The wire screen [A] is fastened with an adhesive for the

shaded portion [B]. Do not remove the wire screen.

PERIODIC MAINTENANCE 2-15

Periodic Maintenance Procedures

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.

• Clean the element [A] 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.

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

(gray) [B] facing down.

Throttle Control System Inspection

• Check that the throttle grip moves smoothly from full open

to close [A], and the throttle closes quickly and completely

by the return spring in all steering positions.

If the throttle grip doesn’t return properly, check the throt-

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

lubricate the throttle cable.

• Check the throttle grip free play [A].

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

Throttle Grip Free Play

Standard:

2∼3mm(0.08∼0.12in.)

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

If necessary, adjust the throttle cable as follows.

• Loosen the locknut [A] at the upper end of the accelerator

cable.

• Turn the adjuster [B] in completely so as to give the throttle

grip plenty of play.

• Remove the right center fairing (see Center Fairing Re-

moval in the Frame chapter).

• Loosen the locknut [A] at the middle of the decelerator

cable.

• Turn the adjuster [B] until there is no play when the throttle

grip is completely closed.

• Tighten the locknut.

• Turn the accelerator cable adjuster until the proper

amount of throttle grip free play is obtained.

• Tighten the locknut.

Engine Vacuum Synchronization Inspection

NOTE

○These procedures are explained on the assumption that

the inlet and exhaust systems of the engine are in good

condition.

• Situate the motorcycle so that it is vertical.

• Remove the center fairings (see Center Fairing Removal

in the Frame chapter).

• Pull off the rubber caps [A] from the fitting of each throttle

body (In the photo, the throttle body has been removed

for clarity.).

CAUTION

Do not remove the inlet air pressure sensor hose

[B] on the left fitting of the throttle body.

• Connect a commercially available vacuum gauge and

hoses [A] to the fittings of the throttle body as shown.

• Connect a highly accurate tachometer to one of the stick

coil primary leads.

PERIODIC MAINTENANCE 2-17

Periodic Maintenance Procedures

• Start the engine and warm it up thoroughly.

• Check the idle speed.

Tachometer [A]

• Open and close the throttle.

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

CAUTION

Do not measure the idle speed by the tachometer of

the meter unit.

• While idling the engine, inspect the engine vacuum, using

the vacuum gauge [B].

Engine Vacuum

Standard:

35.3 ±1.3 kPa (265 ±10 mmHg) at Idle

Speed 1 300 ±50 r/min (rpm)

If any one vacuum is not within the specification, turn in

the bypass screws until it seats fully but not tightly.

Special Tool - Pilot Screw Adjuster, E [A]: 57001-1603

CAUTION

Do not over tighten them. They could be damaged,

requiring replacement.

• Turn out the bypass screw of the higher vacuum between

#1 [A] and #2 [B] to the lower vacuum.

• Open and close the throttle valves after each measure-

ment and adjust the idle speed as necessary.

• Inspect the vacuums as before.

If both vacuums are within the specification, finish the en-

gine vacuum synchronization.

If any vacuum can not be adjusted within the specification,

remove the bypass screws #1, #2 and clean them.

• Remove the bypass screw [A], spring [B], washer [C] and

O-ring [D].

○Check the bypass screw and its hole for carbon deposits.

If any carbon accumulates, wipe the carbon off the bypass

screw and the hole, using a cotton pad penetrated with a

high-flash point solvent.

○Replace the O-ring with a new one.

○Check the tapered portion [E] of the bypass screw for

wear or damage.

If the bypass screw is worn or damaged, replace it.

• Turn in the bypass screw until it seats fully but not tightly.

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

• Repeat the same procedure for other bypass screws.

• Repeat the synchronization.

If the vacuums are correct, check the output voltage of

the main throttle sensor (see Main Throttle Sensor Output

Voltage Inspection in the Fuel System (DFI) chapter).

Main Throttle Sensor Output Voltage

Connections to ECU

Meter (+) → Y/W lead (terminal 7)

Meter (-) → BR/BK lead (terminal 28)

Standard:

1.055 ∼ 1.095 V DC (at idle throttle opening)

If the output voltage is out of the range, check the throt-

tle input voltage (see Main Throttle Sensor Input Voltage

Inspection in the Fuel System (DFI) chapter).

• Remove the vacuum gauge hoses and install the vacuum

hoses and rubber caps.

Idle Speed Inspection

• Start the engine and warm it up thoroughly.

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

[A].

If handlebar movement changes the idle speed, the

throttle cables may be improperly adjusted or incorrectly

routed or damaged. Be sure to correct any of these

conditions before riding (see Throttle Control System

Inspection or Cable, Wire, and Hose Routing section in

the Appendix chapter).

WARNING

Operation with improperly adjusted, incorrectly

routed or damaged cables could result in an unsafe

riding condition.

• Check 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.

PERIODIC MAINTENANCE 2-19

Periodic Maintenance Procedures

Fuel Hose Inspection (fuel leak, damage,

installation condition)

○The fuel hose is designed to be used throughout the mo-

torcycle’s life without any maintenance. However, if the

motorcycle is not properly handled, the high pressure in-

side the fuel line can cause fuel to leak [A] or the hose to

burst. Remove the fuel tank (see Fuel Tank Removal in

the Fuel System (DFI) chapter) and check the fuel hose.

Replace the fuel hose if any fraying, cracks [B] or bulges

[C] are noticed.

• Check that the hoses are routed according to Cable, Wire,

and Hose Routing section in the Appendix chapter.

Replace the hose if it has been sharply bent or kinked.

Hose Joints [A]

Fuel Hose [B]

• Check that the hose joints are securely connected.

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

than two times, and make sure it is locked.

If it does not locked, reinstall the hose joint.

WARNING

Make sure the hose joint is installed correctly on the

delivery pipe by sliding the joint, or the fuel could

leak.

Evaporative Emission Control System (California Model)

Evaporative Emission Control System Inspection

• Inspect the canister as follows.

○Remove:

Left Center Fairing (see Center Fairing Removal in the

Frame chapter)

○Remove the canister [A], and disconnect the hoses from

the canister.

○Visually inspect the canister for cracks or 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.

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

• Check the liquid/vapor separator as follows.

○Remove:

Left Center Fairing (see Center Fairing Removal in the

Frame chapter)

○Disconnect the hoses from the separator, and remove the

separator [A] from the motorcycle left side.

○Visually inspect the separator for cracks and other dam-

age.

If the separator has any cracks or damage, 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.

• Check the hoses of the evaporative emission control sys-

tem as follows.

○Check that the hoses are securely connected and clips

are in position.

○Replace any kinked, deteriorated or damaged hoses.

○Route the hoses according to Cable, Wire, and Hose

Routing section in the Appendix chapter.

○When installing the hoses, avoid sharp bending, kinking,

flattening or twisting, and route the hoses with a minimum

of bending so that the emission flow will not be obstructed.

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 [A] with the

motorcycle held perpendicular (Do not use the sidestand).

If the coolant level is lower than the “L” level line [B], re-

move the right center fairing (see Center Fairing Removal

in the Frame chapter) and unscrew the reserve tank cap,

and add coolant to the “F” level line [C].

“L”: low

“F”: full

CAUTION

For refilling, add the specified mixture of coolant

and soft water. Adding water alone dilutes the

coolant and degrades its anticorrosion properties.

The diluted coolant can attack the aluminum 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 ruins painted surfaces. Immediately wash

away any coolant that spills on the frame, engine,

wheels or other painted parts.

PERIODIC MAINTENANCE 2-21

Periodic Maintenance Procedures

Radiator Hose Damage and Installation Condition

Inspection

○The high pressure inside the radiator hose and pipe can

cause coolant to leak [A] or the hose to burst if the line is

not properly maintained.

• Visually inspect the hoses for signs of deterioration.

Squeeze the hoses. A hose should not be hard and

brittle, nor should it be soft or swollen.

Replace the hose if any fraying, cracks [B] or bulges [C]

are noticed.

• Check that the hoses are securely connected and clamps

are tightened correctly.

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

17 in·lb)

Air Suction System

Air Suction System Damage Inspection

• Remove the fuel tank (see Fuel Tank Removal in the Fuel

System (DFI) chapter).

• Remove the fuel hose (see Fuel Hose Replacement).

• Connect:

Fuel Pump Lead Connector [A]

Extension Tube [B]

Special Tool - Extension Tube: 57001-1578

• Pull the air switching valve hose [C] out of the air cleaner

housing.

• Start the engine and run it at idle speed.

• Plug [A] the air switching valve hose end with your finger

and feel vacuum pulsing in the hose.

If there is no vacuum pulsation, check the hose line for

leak. If there is no leak, check the air switching valve

(see Air Switching Valve Unit Test in the Electrical Sys-

tem chapter) or air suction valve (see Air Suction Valve

Inspection in the Engine Top End chapter).

Engine Top End

Valve Clearance Inspection

NOTE

○Valve clearance must be checked and adjusted when

the engine is cold (room temperature).

• Remove:

Cylinder Head Cover (see Cylinder Head Cover Re-

moval in the Engine Top End chapter)

Right Lower Fairing (see Lower Fairing Removal in the

Frame chapter)

• Unscrew the upper [A] and lower [B] caps on the clutch

cover.

2-22 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

• Check the valve clearance when the pistons are at TDC.

○The pistons are numbered beginning with the engine left

side.

• Using a wrench [A] on the crankshaft rotation bolt, turn

the crankshaft clockwise until the "1/T" mark on the timing

rotor is aligned with the notch [B] in the edge of the upper

hole in the clutch cover for #1 piston and "2/T" mark for

#2 piston.

1/T Mark [A]

2/T Mark [B]

Hole [C] of Upper Cap

Notch [D] in Edge of Upper Hole

○Measure the valve clearance of the valves for which the

cam [A] are turned away from each other.

• Using the thickness gauge [A], measure the valve clear-

ance between cam and valve lifter.

Valve Clearance

Standard:

Exhaust

0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.)

Inlet

0.15 ∼ 0.21 mm (0.0059 ∼ 0.0083 in.)

○Each piston has two inlet and two exhaust valves. Mea-

sure these two inlet or exhaust valves at the same crank-

shaft position.

Valve Clearance Measuring Position

#1 Piston TDC at End of Compression Stroke →

Inlet valve clearances of #1 piston, and

Exhaust valve clearances of #1 piston

NOTE

○Check the valve clearance using this method only.

Checking the clearance at any other cam position may

result in improper valve clearance.

PERIODIC MAINTENANCE 2-23

Periodic Maintenance Procedures

Valve Clearance Measuring Position

#2 Piston TDC at End of Compression Stroke →

Inlet valve clearances of #2 piston, and

Exhaust valve clearances of #2 piston

If the valve clearance is not with in the specified range,

first record the clearance, and adjust it.

Valve Clearance Adjustment

• To change the valve clearance, remove the camshaft

chain tensioner, camshafts and valve lifters. Replace the

shim with one of a different thickness.

NOTE

○Mark and record the valve lifter and shim locations so

they can be reinstalled in their original positions.

○If there is no clearance, select a shim which is several

sizes smaller and then measure the clearance.

• To select a new shim which brings the valve clearance

within the specified range, refer to the Valve Clearance

Adjustment Charts.

• Apply a thin coat of molybdenum disulfide grease to the

valve lifters.

• Install the camshafts. Be sure to time the camshafts prop-

erly (see Camshaft Installation in the Engine Top End

chapter).

• Remeasure any valve clearance that was adjusted.

Readjust if necessary.

CAUTION

Do not put shim stock under the shim. This may

cause the shim to pop out at high rpm, causing ex-

tensive engine damage.

Do not grind the shim. This may cause it to fracture,

causing extensive engine damage.

2-26 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Clutch

Clutch Operation Inspection

• Pull the clutch lever just enough to take up the free play

[A].

• Measure the gap between the lever and the lever holder.

If the gap is too wide, the clutch may not release fully. If

the gap is too narrow, the clutch may not engage fully. In

either case, adjust it.

Clutch Lever Free Play

Standard:

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

WARNING

To avoid a serious burn, never touch the engine or

exhaust pipe during clutch adjustment.

• Turn the adjuster [A] so that 5 ∼ 6 mm (0.20 ∼ 0.24 in.) [B]

of threads are visible.

• Remove the right center fairing (see Center Fairing Re-

moval in the Frame chapter).

• Slide the dust cover [A] at the middle of the clutch cable

out of place.

• Loosen the locknut [B] at the middle of clutch cable.

• Turn the adjusting nut [C] until the free play is correct.

WARNING

Be sure that the outer cable end at the clutch lever

is fully seated in the adjuster at the clutch lever, or

it could slip into place later, creating enough cable

play to prevent clutch disengagement.

• After the adjustment, tighten the locknut and start the en-

gine and check that the clutch does not slip and that it

releases properly.

Wheels/Tires

Air Pressure Inspection

• Remove the air valve cap.

• Measure the tire air pressure with an air pressure gauge

[A] when the tires are cold (that is, when the motorcycle

has not been ridden more than a mile during the past 3

hours).

• Install the air valve cap.

Adjust the tire air pressure according to the specifications

if necessary.

Air Pressure (when Cold)

Front:

Up to 180 kg (397 lb)

225 kPa (2.25 kgf/cm², 32 psi)

Rear:

Up to 180 kg (397 lb)

250 kPa (2.50 kgf/cm², 36 psi)

PERIODIC MAINTENANCE 2-27

Periodic Maintenance Procedures

Wheel/Tire Damage Inspection

• Remove any imbedded stones [A] or other foreign parti-

cles [B] from tread.

• Visually inspect the tire for cracks and cuts, and replace

the tire if necessary. Swelling or high spots indicate inter-

nal damage, requiring tire replacement.

• Visually inspect the wheel for cracks, cuts and dents dam-

age.

If any damage is found, replace the wheel if necessary.

Tire Tread Wear, Abnormal Wear Inspection

As the tire tread wears down, the tire becomes more sus-

ceptible to puncture and failure. An accepted estimate is

that 90% of all tire failures occur during the last 10% of tread

life (90% worn). So it is false economy and unsafe to use

the tires until they are bald.

• Measure the tread depth at the center of the tread with a

depth gauge [A]. Since the tire may wear unevenly, take

measurement at several places.

If any measurement is less than the service limit, replace

the tire (see Tire Removal/Installation in the Wheels/Tires

chapter).

Tread Depth

Standard:

Front

4.3 mm (0.17 in.)

Rear

7.0 mm (0.28 in.)

Service Limit:

Front

1 mm (0.04 in.)

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

Rear

2 mm (0.08 in.)

(Up to 130 km/h (80 mph))

3 mm (0.12 in.)

(Over 130 km/h (80 mph))

WARNING

To ensure safe handling and stability, use only the

recommended standard tires for replacement, in-

flated to the standard pressure.

NOTE

○Most countries may have their own regulations a mini-

mum tire tread depth: be sure to follow them.

○Check and balance the wheel when a tire is replaced

with a new one.

2-28 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Wheel Bearing Damage Inspection

• Raise the front wheel off the ground with jack (see Front

Wheel Removal in the Wheels/Tires chapter).

• Turn the handlebar all the way to the right or left.

• Inspect the roughness of the front wheel bearing by push-

ing and pulling [A] the wheel.

• Spin [B] the front wheel lightly, and check for smoothly

turn, roughness, binding or noise.

If roughness, binding or noise is found, remove the front

wheel and inspect the wheel bearing (see Front Wheel

Removal, Hub Bearing Inspection in the Wheels/Tires

chapter).

• Raise the rear wheel off the ground with stand (see Rear

Wheel Removal in the Wheels/Tires chapter).

• Inspect the roughness of the rear wheel bearing by push-

ing and pulling [A] the wheel.

• Spin [B] the rear wheel lightly, and check for smoothly

turn, roughness, binding or noise.

If roughness, binding or noise is found, remove the rear

wheel and inspect the wheel bearing (see Rear Wheel Re-

moval, Hub Bearing Inspection in the Wheels/Tires chap-

ter) and coupling (see Coupling Bearing Inspection in the

Final Drive chapter).

Drive Train

Drive Chain Lubrication Condition Inspection

• If a special lubricant is not available, a heavy oil such as

SAE 90 is preferred to a lighter oil because it will stay on

the chain longer and provide better lubrication.

• If the chain appears especially dirty, clean it before lubri-

cation.

CAUTION

The O-rings between the side plates seal in the lu-

bricant between the pin and the bushing. To avoid

damaging the O-rings and resultant loss of lubri-

cant, observe the following rules.

Use only kerosene or diesel oil for cleaning an O

-ring drive chain. Any other cleaning solution such

as gasoline or trichloroethylene will cause deterio-

ration and swelling of the O-ring. Immediately blow

the chain dry with compressed air after cleaning.

Complete cleaning and drying the chain within 10

minutes.

PERIODIC MAINTENANCE 2-29

Periodic Maintenance Procedures

• Apply oil to the sides of the rollers so that oil will penetrate

to the rollers and bushings. Apply the oil to the O-rings so

that the O-rings will be coated with oil.

• Wipe off any excess oil.

Oil Applied Areas [A]

O-rings [B]

Drive Chain Slack Inspection

NOTE

○Check the slack with the motorcycle setting on its side-

stand.

○Clean the chain if it is dirty, and lubricate it if it appears

dry.

• Check the wheel alignment (see Wheel Alignment Inspec-

tion).

• Rotate the rear wheel to find the position where the chain

is tightest.

• Measure the vertical movement (chain slack) [A] midway

between the sprockets.

If the chain slack exceeds the standard, adjust it.

Chain Slack

Standard:

30 ∼ 40 mm (1.2 ∼ 1.6 in.)

Drive Chain Slack Adjustment

• Remove the cotter pin [A], and loosen the axle nut [B].

• Loosen the both chain adjuster locknuts [C].

If the chain is too loose, turn in the left and right chain

adjuster nuts [D] evenly.

If the chain is too tight, turn out the left and right chain

adjuster nuts evenly, and kick the wheel forward.

• Turn both chain adjuster nuts evenly until the drive chain

has the correct amount of slack. To keep the chain and

wheel properly aligned, the value [E] on the left wheel

alignment adjuster [F] should align with the same (left or

right) edge [G] of inspection window on the swingarm that

the right wheel alignment adjuster value aligns with.

WARNING

Misalignment of the wheel will result in abnormal

wear and may result in an unsafe riding condition.

• Tighten both chain adjuster locknuts securely.

• Tighten the axle nut.

Torque - Rear Axle Nut: 108 N·m (11.0 kgf·m, 80 ft·lb)

• Turn the wheel, measure the chain slack again at the tight-

est position, and readjust if necessary.

2-30 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

• Insert a new cotter pin [A].

NOTE

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

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

nut clockwise [B] up to next alignment.

○It should be within 30°.

○Loosen once and tighten again when the slot goes past

the nearest hole.

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

WARNING

If the rear axle nut is not securely tightened or the

cotter pin is not installed, an unsafe riding condi-

tion may result.

Wheel Alignment Inspection

• Check that the value [A] on the left wheel alignment ad-

juster [B] aligns with the same (left or right) edge [C] of

inspection window on the swingarm that the right wheel

alignment adjuster value aligns with.

If they do not, adjust the chain slack and align the wheel

alignment (see Drive Chain Slack Adjustment).

NOTE

○Wheel alignment can be also checked using the

straightedge or string method.

WARNING

Misalignment of the wheel will result in abnormal

wear, and may result in an unsafe riding condition.

PERIODIC MAINTENANCE 2-31

Periodic Maintenance Procedures

Drive Chain Wear Inspection

• Remove:

Chain Cover (see Swingarm Removal in the Suspension

chapter)

• Rotate the rear wheel to inspect the drive chain for dam-

aged rollers, and loose pins and links.

If there is any irregularity, replace the drive chain.

Lubricate the drive chain if it appears dry.

• Stretch the chain taut by hanging a 98 N (10 kg, 20 lb)

weight [A] on the chain.

• Measure the length of 20 links [B] on the straight part [C] of

the chain from the pin center of the 1st pin to the pin center

of the 21st pin. Since the chain may wear unevenly, take

measurements at several places.

If any measurements exceed the service limit, replace the

chain. Also, replace the front and rear sprockets when the

drive chain is replaced.

Drive Chain 20-link Length

Standard:

317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)

Service Limit:

323 mm (12.7 in.)

WARNING

If the drive chain wear exceeds the service limit, re-

place the chain or an unsafe riding condition may

result. A chain that breaks or jumps off the sprock-

ets could snag on the engine sprocket or lock the

rear wheel, severely damaging the motorcycle and

causing it to go out of control.

For safely, use only the standard chain. It is an end-

less type and should not be cut for installation.

Standard Chain

Make:

ENUMA

Type:

EK520MVXL1

Link:

114 links

Chain Guide Inspection

• Remove:

Swingarm (see Swingarm Removal in the Suspension

chapter)

• Visually inspect the chain guide [A].

Replace the chain guide if it shows any signs of abnormal

wear or damage.

2-32 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Brake System

Brake Fluid Leak (Brake Hose and Pipe) Inspection

• Apply the brake lever or pedal and inspect the brake fluid

leak from the brake hoses [A], fittings [B] and pipes [C].

If the brake fluid leaked from any position, inspect or re-

place the problem part.

Brake Hose and Pipe Damage and Installation

Condition Inspection

• Inspect the brake hoses, fittings and pipes for deteriora-

tion, cracks and signs of leakage.

○The high pressure inside the brake line can cause fluid to

leak [A] or the hose to burst if the line is not properly main-

tained. Bend and twist the rubber hose while examining

it.

Replace the hose and pipe if any crack [B], bulge [C] or

leakage is noticed.

Tighten any brake hose banjo bolts and brake pipe joint

nuts.

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

ft·lb)

Brake Pipe Joint Nuts: 18 N·m (1.8 kgf·m, 13 ft·lb)

(EX650B Models)

• Inspect the brake hose routing.

If any brake hose routing is incorrect, route the brake hose

according to Cable, Wire, and Hose Routing section in the

Appendix chapter.

PERIODIC MAINTENANCE 2-33

Periodic Maintenance Procedures

Brake Operation Inspection

• Inspect the operation of the front and rear brake by run-

ning the vehicle on the dry road.

If the brake operation is insufficiency, inspect the brake

system.

WARNING

When inspecting by running the vehicle, note a

surrounding traffic situation enough in the place of

safety.

Brake Fluid Level Inspection

• Check that the brake fluid level in the front brake reservoir

[A] is above the lower level line [B].

NOTE

○Hold the reservoir horizontal by turning the handlebar

when checking brake fluid level.

If the fluid level is lower than the lower level line, fill the

reservoir to the upper level line [C] in the reservoir.

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

ter).

• Check that the brake fluid level in the rear brake reservoir

[A] is above the lower level line [B].

If the fluid level is lower than the lower level line, fill the

reservoir to the upper level line [C].

WARNING

Change the brake fluid in the brake line completely

if the brake fluid must be refilled but the type and

brand of the brake fluid that is already in the reser-

voir are unidentified. After changing the fluid, use

only the same type and brand of fluid thereafter.

Recommended Disc Brake Fluid

Grade:

DOT4

2-34 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

• Follow the procedure below to install the rear brake fluid

reservoir cap correctly.

○First, tighten the rear brake fluid reservoir cap [B] clock-

wise [C] by hand until slight resistance is felt indicating

that the cap is seated on the reservoir body, then tighten

the cap an additional 1/6 turn [D] while holding the brake

fluid reservoir body [A].

Brake Pad Wear Inspection

• Check the lining thickness [A] of the pads in each caliper.

If the lining thickness of either pad is less than the service

limit [B], replace both pads in the caliper as a set.

Pad Lining Thickness

Standard:

Front

4.5 mm (0.18 in.)

Rear

5.0 mm (0.20 in.)

Service Limit:

1 mm (0.04 in.)

Brake Light Switch Operation Inspection

• Turn on the ignition switch.

• The brake light [A] should go on when the brake lever is

applied or after the brake pedal is depressed about 10

mm (0.39 in.).

If it does not, adjust the brake light switch.

• Disconnect the connector [A].

• Turn the brake light switch to adjust the switch.

• Connect the connector.

If it does not go on, inspect or replace the following items.

Battery (see Charging Condition Inspection in the Elec-

trical System chapter)

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

cal System chapter)

Main Fuse 30 A and Taillight Fuse 10 A (see Fuse In-

spection in the Electrical System chapter)

Front Brake Light Switch [A] (see Switch Inspection in

the Electrical System chapter)

Rear Brake Light Switch (see Switch Inspection in the

Electrical System chapter)

Harness (see Wiring Inspection in the Electrical System

chapter)

PERIODIC MAINTENANCE 2-35

Periodic Maintenance Procedures

Suspensions

Front Forks/Rear Shock Absorber Operation

Inspection

• Pump the forks down and up [A] 4 or 5 times, and inspect

the smooth stroke.

If the forks do not smoothly or noise is found, inspect the

fork oil level or fork clamps (see Front Fork Oil Change in

the Suspension chapter).

• Pump the seat down and up [A] 4 or 5 times, and inspect

the smooth stroke.

If the shock absorber does not smoothly stroke or noise

is found, inspect the oil leak (see Rear Shock Absorber

Oil Leak Inspection).

Front Fork Oil Leak Inspection

• Visually inspect the front forks [A] for oil leakage.

Replace or repair any defective parts, if necessary.

Rear Shock Absorber Oil Leak Inspection

• Visually inspect the shock absorber [A] for oil leakage.

If the oil leakage is found on it, replace the shock absorber

with a new one.

2-36 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Steering System

Steering Play Inspection

• Raise the front wheel off the ground with jack (see Front

Wheel Removal in the Wheels/Tires chapter).

• With the front wheel pointing straight ahead, alternately

tap each end of the handlebar. The front wheel should

swing fully left and right from the force of gravity until the

fork hits the stop.

If the wheel binds or catches before the stop, the steering

is too tight.

• Feel for steering looseness by pushing and pulling the

forks.

If you feel looseness, the steering is too loose.

NOTE

○The cables and wiring will have some effect on the mo-

tion of the fork which must be taken into account.

○Be sure the wires and cables are properly routed.

○The bearings must be in good condition and properly

lubricated in order for any test to be valid.

Steering Play Adjustment

• Remove:

Upper Inner Fairings (see Upper Inner Fairing Removal

in the Frame chapter)

Handlebar (see Handlebar Removal in the Steering

chapter)

Upper Fork Clamp Bolts [A]

Steering Stem Head Bolt Plug [B]

Stem Head Bolt [C]

• Remove the steering stem head [D].

• Bend the claws [A] of the claw washer straighten.

• Remove the steering stem locknut [B] and claw washer

[C].

• Adjust the steering.

Special Tool - Steering Stem Nut Wrench [A]: 57001-1100

If the steering is too tight, loosen the stem nut [B] a fraction

of a turn.

If the steering is too loose, tighten the stem nut a fraction

of a turn.

NOTE

○Turn the stem nut 1/8 turn at time maximum.

PERIODIC MAINTENANCE 2-37

Periodic Maintenance Procedures

• Install the claw washer [A] so that its bent side [B] faces

upward, and engage the bent claws with the grooves of

stem locknut [C].

• Hand tighten the stem locknut until it touches the claw

washer.

• Tighten the stem locknut clockwise until the claws are

aligned with the grooves (ranging from 2nd to 4th) of stem

nut [D], and bend the 2 claws downward [E].

• Install the steering stem head.

• Install the washer, and tighten the stem head bolt.

• Tighten:

Torque - Steering Stem Head Bolt: 108 N·m (11.0 kgf·m, 80

ft·lb)

Front Fork Clamp Bolts (Upper):

20 N·m (2.0

kgf·m, 15 ft·lb)

• Check the steering again.

If the steering is still too tight or too loose, repeat the ad-

justment.

• Install the removed parts (see appropriate chapters).

Steering Stem Bearing Lubrication

• Remove the steering stem (see Stem, Stem Bearing Re-

moval in the Steering chapter).

• Using a high-flash point solvent, wash the upper and

lower ball bearings in the cages, and wipe the upper and

lower outer races, which are press-fitted into the frame

head pipe, clean off grease and dirt.

• Visually check the outer races and the ball bearings.

Replace the bearing assemblies if they show wear or

damage.

• Pack the upper and lower ball bearings [A] in the cages

with grease, and apply a light coat of grease to the upper

and lower outer races.

• Install the steering stem (see Stem, Stem Bearing Instal-

lation in the Steering chapter).

• Adjust the steering (see Steering Play Adjustment).

Electrical System

Spark Plug Condition Inspection

• Remove the spark plugs (see Spark Plug Replacement).

• Visually inspect the spark plugs.

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

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

is cracked, replace the plug.

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

replace the spark plug.

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

If the gap is incorrect, replace the spark plug.

Spark Plug Gap:

0.8 ∼ 0.9 mm (0.03 ∼ 0.04 in.)

• Use the standard spark plug or its equivalent.

Spark Plug:

CR9EIA-9

2-38 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Lights and Switches Operation Inspection

First Step

• Turn on the ignition switch.

• The following lights should go on according to below table.

City Light [A]

goes on

Taillight [B]

goes on

License Plate Light [C]

goes on

Meter Panel LCD [D]

goes on

Neutral Indicator Light (LED) [E]

goes on

Oil Pressure Warning Indicator Light (LED)

goes on

[F]

Water Temperature Warning Indicator

goes on

Light (LED) [G]

FI Indicator Light (LED) [H]

goes on

(about 2 seconds)

EX650B Models

ABS Indicator Light (LED) [I]

goes on

If the light does not go on, inspect or replace the following

item.

Battery (see Charging Condition Inspection in the Elec-

trical System chapter)

Applicable Bulb (see Wiring Diagram in the Electrical

System chapter)

Meter Unit for Meter Panel LCD (see Electronic Com-

bination Meter Unit Inspection in the Electrical System

chapter)

Meter Unit for Neutral Indicator Light (LED) (see Elec-

tronic Combination Meter Unit Inspection in the Electri-

cal System chapter)

Meter Unit for Oil Pressure Warning Indicator Light

(LED) (see Electronic Combination Meter Unit Inspec-

tion in the Electrical System chapter)

Meter Unit for FI Indicator Light (LED) (see Electronic

Combination Meter Unit Inspection in the Electrical Sys-

tem chapter)

Meter Unit for Water Temperature Warning Indicator

Light (LED) (see Electronic Combination Meter Unit

Inspection in the Electrical System chapter)

Meter Unit for ABS Indicator Light (LED) (see ABS In-

dicator Light (LED) Inspection in the Brakes chapter)

(EX650B Models)

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

tem (DFI) chapter)

Main Fuse 30 A and Taillight Fuse 10 A (see Fuse In-

spection in the Electrical System chapter)

Ignition Switch (see Switch Inspection in the Electrical

System chapter)

Neutral Switch (see Switch Inspection in the Electrical

System chapter)

Harness (see Wiring Inspection in the Electrical System

chapter)

PERIODIC MAINTENANCE 2-39

Periodic Maintenance Procedures

• Turn off the ignition switch.

• The all lights should go off.

If the light does not go off, replace the ignition switch.

Second Step

• Turn the ignition switch to P (Park) position.

• The city light, taillight and license plate light should go on.

If the light does not go on, inspect or replace the following

item.

Ignition Switch (see Switch Inspection in the Electrical

System chapter)

Third Step

• Turn on the turn signal switch [A] (left or right position).

• The left or right turn signal lights [B] (front and rear) ac-

cording to the switch position should flash.

• The turn signal indicator light (LED) [C] in the meter unit

should flash.

If the each light does not flash, inspect or replace the

following item.

Turn Signal Light Bulb (see Turn Signal Light Bulb Re-

placement in the Electrical System chapter)

Meter Unit for Turn Signal Light Indicator Light (LED)

(see Electronic Combination Meter Unit Inspection in the

Electrical System chapter)

Turn Signal Relay Fuse 10 A (see Fuse Inspection in the

Electrical System chapter)

Turn Signal Switch (see Switch Inspection in the Electri-

cal System chapter)

Turn Signal Relay (see Turn Signal Relay Inspection in

the Electrical System chapter)

Harness (see Wiring Inspection in the Electrical System

chapter)

• Push the turn signal switch.

• The turn signal lights and indicator light (LED) should go

off.

If the light does not go off, inspect or replace the following

item.

Turn Signal Switch (see Switch Inspection in the Electri-

cal System chapter)

Turn Signal Relay (see Turn Signal Relay Inspection in

the Electrical System chapter)

2-40 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Fourth Step

• Set the dimmer switch [A] to low beam position.

• Start the engine.

• The low beam headlight should go on.

If the low beam headlight does not go on, inspect or re-

place the following item.

Headlight Low Beam Bulb (see Headlight Bulb Replace-

ment in the Electrical System chapter)

Headlight Fuse 10 A (see Fuse Inspection in the Electri-

cal System chapter)

Dimmer Switch (see Switch Inspection in the Electrical

System chapter)

Headlight Relay in Relay Box (see Relay Circuit Inspec-

tion in the Electrical System chapter)

Harness (see Wiring Inspection in the Electrical System

chapter)

• Set the dimmer switch to high beam position.

• The low beam [A] and high beam [B] headlights should

go on.

• The high beam indicator light (LED) [C] should go on.

If the high beam headlight and/or high beam indicator light

(LED) does not go on, inspect or replace the following

item.

Headlight High Beam Bulb (see Headlight Bulb Replace-

ment in the Electrical System chapter)

Dimmer Switch (see Switch Inspection in the Electrical

System chapter)

• Turn off the engine stop switch.

• The low beam and high beam headlights should stay go-

ing on.

If the headlights and high beam indicator light (LED) does

go off, inspect or replace the following item.

Headlight Relay in Relay Box (see Relay Circuit Inspec-

tion in the Electrical System chapter)

• Turn off the ignition switch.

• The headlights and high beam indicator light (LED) should

go off.

Headlight Aiming Inspection

• Inspect the headlight beam for aiming.

If the headlight beam points to one side rather than

straight ahead, adjust the horizontal beam.

Headlight Beam Horizontal Adjustment

• Turn the horizontal adjuster [A] on the headlight with the

screwdriver in or out until the beam points straight ahead.

If the headlight beam points too low or high, adjust the

vertical beam.

PERIODIC MAINTENANCE 2-41

Periodic Maintenance Procedures

Headlight Beam Vertical Adjustment

• Turn the vertical adjuster [A] on the headlight with the

screwdriver in or out to adjust the headlight vertically.

NOTE

○ON high beam, the brightest points should be slightly

below horizontal with the motorcycle on its wheels and

the rider seated. Adjust the headlight to the proper an-

gle according to local regulations.

○For US model, the proper angle is 0.4 degrees below

horizontal. This is 50 mm (2 in.) drop at 7.6 m (25

ft) measured from the center of the headlight with the

motorcycle on its wheels and the rider seated.

50 mm (2 in.) [A]

Center of Brightest Spot [B]

7.6 m (25 ft) [C]

Low Beam [D]

Height of Headlight Center [E]

High Beam [F]

Sidestand Switch Operation Inspection

• Inspect the sidestand switch [A] operation accordance to

below table.

Sidestand Switch Operation

Gear

Clutch

Engine

Sidestand

Position

Lever

Start

Run

Continue

Neutral

Released

Starts

running

Continue

Neutral

Pulled in

Starts

running

Doesn’t

In Gear

Released

Stops

start

Continue

In Gear

Pulled in

Starts

running

Continue

Down

Neutral

Released

Starts

running

Continue

Down

Neutral

Pulled in

Starts

running

Doesn’t

Down

In Gear

Released

Stops

start

Doesn’t

Down

In Gear

Pulled in

Stops

start

2-42 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

If the sidestand switch operation does not work, inspect

or replace the following item.

Battery (see Charging Condition Inspection in the Elec-

trical System chapter)

Main Fuse 30 A (see Fuse Inspection in the Electrical

System chapter)

Ignition Fuse 10 A (see Fuse Inspection in the Electrical

System chapter)

Ignition Switch (see Switch Inspection in the Electrical

System chapter)

Sidestand Switch (see Switch Inspection in the Electrical

System chapter)

Engine Stop Switch (see Switch Inspection in the Elec-

trical System chapter)

Starter Button (see Switch Inspection in the Electrical

System chapter)

Neutral Switch (see Switch Inspection in the Electrical

System chapter)

Starter Relay (see Starter Relay Inspection in the Elec-

trical System chapter)

Relay Box (see Relay Circuit Inspection in the Electrical

System chapter)

Starter Circuit Relay (see Relay Circuit Inspection in the

Electrical System chapter)

Harness (see Wiring Inspection in the Electrical System

chapter)

If the all parts are good condition, replace the ECU (see

ECU Removal/Installation in the Fuel System (DFI) chap-

ter).

Engine Stop Switch Operation Inspection

First Step

• Turn on the ignition switch.

• Set the neutral position.

• Turn the engine stop switch to stop position [A].

• Push the starter button.

• The engine does not start.

If the engine starts, inspect or replace the following item.

Engine Stop Switch (see Switch Inspection in the Elec-

trical System chapter)

Second Step

• Turn on the ignition switch.

• Set the neutral position.

• Turn the engine stop switch to run position [A].

• Push the starter button and run the engine.

• Turn the engine stop switch to stop position.

• Immediately the engine should be stop.

If the engine does not stop, inspect or replace the follow-

ing item.

Engine Stop Switch (see Switch Inspection in the Elec-

trical System chapter)

If the engine stop switch is good condition, replace the

ECU (see ECU Removal/Installation in the Fuel System

(DFI) chapter).

PERIODIC MAINTENANCE 2-43

Periodic Maintenance Procedures

Others

Chassis Parts Lubrication

• Before lubricating each part, clean off any rusty spots with

rust remover and wipe off any grease, oil, dirt, or grime.

• Lubricate the points listed below with indicated lubricant.

NOTE

○Whenever the vehicle has been operated under

wet or rainy conditions, or especially after using a

high-pressure water spray, perform the general lubri-

cation.

Pivots: Lubricate with Grease.

Brake Lever

Brake Pedal

Clutch Lever

Rear Brake Joint Pin

Sidestand

Points: Lubricate with Grease.

Clutch Inner Cable Upper and Lower Ends [A]

Throttle Inner Cable Upper and Lower Ends

Cables: Lubricate with Rust Inhibitor.

Clutch Cable

Throttle Cables

• Lubricate the cables by seeping the oil between the cable

and housing.

○The cable may be lubricated by using a commercially

available pressure cable lubricator with an aerosol cable

lubricant.

• With the cable disconnected at both ends, the inner cable

should move freely [A] within the cable housing.

If cable movement is not free after lubricating, if the cable

is frayed [B], or if the cable housing is kinked [C], replace

the cable.

2-44 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Bolts, Nuts and Fasteners Tightness Inspection

• Check the tightness of the bolts and nuts listed here. Also,

check to see that each cotter pin is in place and in good

condition.

NOTE

○For the engine fasteners, check the tightness of them

when the engine is cold (at room temperature).

If there are loose fasteners, retighten them to the spec-

ified torque following the specified tightening sequence.

Refer to the appropriate chapter for torque specifications.

If torque specifications are not in the appropriate chapter,

see the Standard Torque Table. For each fastener, first

loosen it by 1/2 turn, then tighten it.

If cotter pins are damaged, replace them with new ones.

Bolt, Nut and Fastener to be checked

Engine:

Clutch Lever Pivot Nut

Engine Mounting Bolts and Nuts

Exhaust Pipe Manifold Holder Nuts

Muffler Body Mounting Bolts

Wheels:

Front Axle

Front Axle Clamp Bolt

Rear Axle Nut

Rear Axle Nut Cotter Pin

Brakes:

Brake Lever Pivot Nut

Brake Pedal Bolt

Brake Rod Joint Cotter Pin

Caliper Mounting Bolts

Front Master Cylinder Clamp Bolts

Rear Master Cylinder Mounting Bolts

Suspension:

Front Fork Clamp Bolts

Rear Shock Absorber Bolt and Nut

Swingarm Pivot Shaft Nut

Steering:

Steering Stem Head Bolt

Handlebar Holder Bolts

Others:

Footpeg Stay Bolts

Front Fender Bolts

Sidestand Bolt

PERIODIC MAINTENANCE 2-45

Periodic Maintenance Procedures

Replacement Parts

Air Cleaner Element Replacement

• Refer to the Air Cleaner Element Cleaning.

Fuel Hose Replacement

CAUTION

When removing and installing the fuel hose joint, do

not apply strong force to the outlet pipe on the fuel

pump and delivery pipe on the throttle body assy.

The pipes made from resin could be damaged.

• Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System

(DFI) chapter)

Left Center Fairing (see Center Fairing Removal in the

Frame chapter)

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

joint.

• Insert a minus screw driver [B] into the slit [C] on the joint

lock.

• Turn [A] the driver to disconnect the joint lock [B].

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

WARNING

Be prepared for fuel spillage; any spilled fuel must

be completely wiped up immediately.

When the fuel hose is disconnected, fuel spills out

from the hose and the pipe. Cover the hose connec-

tion with a clean shop towel to prevent fuel spillage.

• Install the new fuel hose.

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

pipe until the hose joint clicks.

• Push [C] the joint lock [D].

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

more than two times and make sure it is locked and

doesn’t come off.

WARNING

Make sure the fuel hose joint is installed correctly

on the delivery pipe or the fuel could leak.

If it comes off, reinstall the hose joint.

• Run the fuel hose correctly (see Cable, Wire, and Hose

Routing section in the Appendix chapter).

• Install the removed parts (see appropriate chapters).

• Start the engine and check the fuel hose for leaks.

2-46 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Coolant Change

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.

• Remove:

Right Center Fairing (see Center Fairing Removal in the

Frame chapter)

Reserve Tank Bolts [A]

Reserve Tank [B]

• Put [A] the projection [B] on the reserve tank into the hole

[C] on the frame bracket, and place the reserve tank on

the right side of frame.

• Place a container under the water pump drain bolt [A],

then remove the drain bolt.

PERIODIC MAINTENANCE 2-47

Periodic Maintenance Procedures

• Remove the radiator cap [A] in two steps. First turn the

cap counterclockwise to the first stop. Then push and turn

it further in the same direction and remove the cap.

○The coolant will drain from the radiator and engine.

• Turn over [A] the reserve tank, remove the cap, and pour

the coolant into a suitable container.

• Place the reserve tank on the right side of frame.

• Tighten the drain bolt with the gasket.

○Replace the drain bolt gasket with a new one.

Torque - Water Pump Drain Bolt: 7.0 N·m (0.70 kgf·m, 62

in·lb)

• When filling the coolant, choose a suitable mixture ratio

by referring to the coolant manufacturer’s directions.

CAUTION

Soft or distilled water must be used with the an-

tifreeze in the cooling system.

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.

Water and Coolant Mixture Ratio (Recommended)

Soft Water:

50%

Coolant:

50%

Freezing Point:

-35°C (-31°F)

Total Amount:

1.2 L (1.3 US qt)

• Fill the radiator up to the filler neck [A] with coolant.

NOTE

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

from the engine and radiator.

• Check the cooling system for leaks.

• Tap the radiator hoses to force any air bubbles caught

inside.

• Fill the radiator up to the filler neck with coolant.

2-48 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

• Temporarily install the reserve tank to the frame with two

bolts.

• Fill the reserve tank up to the “F” (full) level line [A] with

coolant and install the cap [B].

• 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 “L” level line, add

coolant to the “F” level line.

CAUTION

Do not add more coolant above the “F” level line.

Radiator Hose and O-ring Replacement

• Drain the coolant (see Coolant Change).

• Remove:

Thermostat Housing [A] (see Water Pump Removal in

the Cooling System chapter)

Water Pump Cover [B] (see Water Pump Removal in the

Cooling System chapter)

Hoses [C]

O-rings [D]

• Apply grease to the new O-rings and install them.

• Install the new hoses and tighten the clamps securely.

• Fill the coolant (see Coolant Change).

• Check the cooling system for leaks.

PERIODIC MAINTENANCE 2-49

Periodic Maintenance Procedures

Engine Oil Change

• Situate the motorcycle so that it is vertical after warming

up the engine.

• Unscrew the oil filler plug [A].

• Place on oil pan beneath the engine.

• Remove the engine oil drain bolt [A] to drain the oil.

○The oil in the oil filter can be drained by removing the filter

(see Oil Filter Replacement).

Replace the drain bolt gasket [B] with a new one.

• Tighten the drain bolt.

Torque - Engine Oil Drain Bolt: 30 N·m (3.0 kgf·m, 22 ft·lb)

• Pour in the specified type and amount of oil.

Recommended Engine Oil

Type:

API SE, SF or SG

API SH, SJ or SL with JASO MA

Viscosity:

SAE 10W-40

Capacity:

1.7 L (1.8 US qt) (when filter is not

removed)

1.9 L (2.0 US qt) (when filter is removed)

2.4 L (2.5 US qt) (when engine is

completely dry)

NOTE

○Although 10W-40 engine oil is the recommended oil

for most conditions, the oil viscosity may need to be

changed to accommodate atmospheric conditions in

your riding area.

• Check the oil level (see Oil Level Inspection in the Engine

Lubrication System chapter).

Oil Filter Replacement

• Drain the engine oil (see Engine Oil Change).

• Remove the oil filter [A] with the oil filter wrench [B].

Special Tool - Oil Filter Wrench: 57001-1249

2-50 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

• Replace the filter with a new one.

• Apply engine oil to the gasket [A] before installation.

• Tighten the filter with the oil filter wrench.

Torque - Oil Filter: 17.2 N·m (1.75 kgf·m, 13 ft·lb)

NOTE

○Hand tightening of the oil filter can not be allowed since

it does not reach to this tightening torque.

• Pour in the specified type and amount of oil (see Engine

Oil Change).

Brake Hose and Pipe Replacement

CAUTION

Brake fluid quickly ruins painted plastic surfaces;

any spilled fluid should be completely washed away

immediately.

• Remove the banjo bolts [A].

• When removing the brake hose, take care not to spill the

brake fluid on the painted or plastic parts.

• When removing the brake hoses [B], temporarily secure

the end of the brake hose to some high place to keep fluid

loss to a minimum.

• Immediately wash away any brake fluid that spills.

PERIODIC MAINTENANCE 2-51

Periodic Maintenance Procedures

• Remove:

Rear Fender Front (see Rear Fender Front Removal in

the Frame chapter) (EX650B Models)

Right Center Fairing (see Center Fairing Removal in the

Frame chapter) (EX650B Models)

Air Cleaner Housing (see Air Cleaner Housing Removal

in the Fuel System (DFI) chapter) (EX650B Models)

• Remove the brake pipe joint nuts [C] (EX650B Models).

• Remove the bracket bolt [D] and bracket [E] (EX650B

Models).

• There are washers on each side of the brake hose fitting.

Replace them with new ones when installing.

• Tighten:

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

ft·lb)

Brake Pipe Joint Nuts: 18 N·m (1.8 kgf·m, 13 ft·lb)

(EX650B Models)

• When installing the hoses, avoid sharp bending, kink-

ing, flatting or twisting, and route the hoses according to

Cable, Wire, and Hose Routing section in the Appendix

chapter.

• Fill the brake line after installing the brake hose (see

Brake Fluid Change).

Brake Fluid Change

NOTE

○The procedure to change the front brake fluid is as fol-

lows. Changing the rear brake fluid is the same as for

the front brake.

• Level the brake fluid reservoir.

• Remove the reservoir cap and diaphragm.

• Remove the rubber cap from the bleed valve [A] on the

caliper.

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

the other end of the hose into a container.

• Fill the reservoir with fresh specified brake fluid.

2-52 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

• Change the brake fluid.

○Repeat this operation until fresh brake fluid comes out

from the plastic hose or the color of the fluid changes.

1. Open the bleed valve [A].

2. Apply the brake and hold it [B].

3. Close the bleed valve [C].

4. Release the brake [D].

NOTE

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

ing operation and replenished with fresh brake fluid. If

the fluid in the reservoir runs out any time during the

changing operation, the brakes will need to be bled

since air will have entered the brake line.

○Front Brake: Repeat the above steps for the other

caliper.

• Remove the clear plastic hose.

• Install the diaphragm and reservoir cap.

• Tighten:

Torque - Front Brake Reservoir Cap Screws: 1.0 N·m (0.10

kgf·m, 9 in·lb)

• Follow the procedure below to install the rear brake fluid

reservoir cap correctly.

○First, tighten the rear brake fluid reservoir cap [B] clock-

wise [C] by hand until slight resistance is felt indicating

that the cap is seated on the reservoir body, then tighten

the cap an additional 1/6 turn [D] while holding the brake

fluid reservoir body [A].

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

Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

• After changing the fluid, check the brake for good braking

power, no brake drag, and no fluid leakage.

If necessary, bleed the air from the lines.

Master Cylinder Rubber Parts Replacement

Front Master Cylinder Disassembly

• Remove the front master cylinder (see Front Master Cylin-

der Removal in the Brakes chapter).

• Remove the reservoir cap and diaphragm, and pour the

brake fluid into a container.

• Unscrew the locknut and pivot bolt, and remove the brake

lever.

• Pull the dust cover [A] out of place, and remove the circlip

[B].

Special Tool - Inside Circlip Pliers: 57001-143

• Pull out the piston [C], secondary cup [D], primary cup [E],

and return spring [F].

CAUTION

Do not remove the secondary cup from the piston

since removal will damage it.

PERIODIC MAINTENANCE 2-53

Periodic Maintenance Procedures

Rear Master Cylinder Disassembly

NOTE

○Do not remove the push rod clevis for master cylinder

disassembly since removal reguires brake position ad-

justment.

• Remove the rear master cylinder (see Rear Master Cylin-

der Removal in the Brakes chapter).

• Slide the dust cover on the push rod out of place, and

remove the circlip.

Special Tool - Inside Circlip Pliers: 57001-143

• Pull out the push rod with the piston stop.

• Take off the piston [A], secondary cup [B], primary cup [C]

and return spring [D].

CAUTION

Do not remove the secondary cup from the piston

since removal will damage it.

Master Cylinder Assembly

• Before assembly, clean all parts including the master

cylinder with brake fluid or alcohol.

CAUTION

Except for the disc pads and disc, use only disc

brake fluid, isopropyl alcohol, or ethyl alcohol for

cleaning brake parts. Do not use any other fluid for

cleaning these parts. Gasoline, engine oil, or any

other petroleum distillate will cause deterioration of

the rubber parts. Oil spilled on any part will be diffi-

cult to wash off completely, and will eventually de-

teriorate the rubber used in the disc brake.

• Apply brake fluid to the new parts and to the inner wall of

the cylinder.

• Take care not to scratch the piston or the inner wall of the

cylinder.

• Tighten the brake lever pivot bolt and locknut.

• Apply silicone grease.

Brake Lever Pivot Bolt

• Tighten:

Torque - Brake Lever Pivot Bolt:

1.0 N·m (0.10 kgf·m, 9

in·lb)

Brake Lever Pivot Bolt Locknut:

5.9 N·m (0.60

kgf·m, 52 in·lb)

2-54 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Caliper Rubber Parts Replacement

Front Caliper Disassembly

• Remove:

Front Caliper (see Front Caliper Removal in the Brakes

chapter)

Brake Pads (see Front Brake Pad Removal in the Brakes

chapter)

• Using compressed air, remove the pistons.

○Cover the piston area with a clean, thick cloth [A].

○Blow compressed air [B] into the hole for the banjo bolt to

remove the piston.

WARNING

To avoid serious injury, never place your fingers or

palm in front of the piston. If you apply compressed

air into the caliper, the piston may crush your hand

or fingers.

○Pull out the pistons by hand.

• Remove the dust seals [A] and fluid seals [B].

• Remove the bleed valve [C] and rubber cap [D].

NOTE

○If compressed air is not available, with the brake hose

still attached, apply the brake lever to remove the pis-

ton. The remaining process is as described above.

Front Caliper Assembly

• Clean the caliper parts except for the pads.

CAUTION

For cleaning the parts, use only disc brake fluid,

isopropyl alcohol, or ethyl alcohol.

• Install the bleed valve and rubber cap.

Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

• Replace the fluid seals [A] with new ones.

○Apply brake fluid to the fluid seals, and install them into

the cylinders by hand.

• Replace the dust seals [B] with new ones if they are dam-

aged.

○Apply brake fluid to the dust seals, and install them into

the cylinders by hand.

PERIODIC MAINTENANCE 2-55

Periodic Maintenance Procedures

• Apply brake fluid to the outside of the pistons, and push

them into each cylinder by hand.

• Check the shaft rubber friction boot [A] and the dust cover

[B] replace them with new ones if they are damaged.

• Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to

the caliper holder shafts [C] and holder holes [D] (PBC is

a special high-temperature, water-resistance grease).

• Install the anti-rattle spring [A].

• Install the pads (see Front Brake Pad Installation in the

Brakes chapter).

• Wipe up any spilled brake fluid on the caliper with wet

cloth.

Rear Caliper Disassembly

• Remove the rear caliper (see Rear Caliper Removal in

the Brakes chapter).

• Remove the pads and anti-rattle spring (see Rear Brake

Pad Removal in the Brakes chapter).

• Using compressed air, remove the piston.

○Cover the piston area with a clean, thick cloth [B].

○Blow compressed air [A] into the hole for the banjo bolt to

remove the piston.

WARNING

To avoid serious injury, never place your fingers or

palm inside the caliper opening. If you apply com-

pressed air into the caliper, the piston may crush

your hand or fingers.

• Remove the dust seal and fluid seal.

• Remove the bleed valve and rubber cap.

NOTE

○If compressed air is not available, with the brake hose

still attached, apply the brake pedal to remove the pis-

ton. The remaining process is as described above.

Rear Caliper Assembly

• Clean the caliper parts except for the pads.

CAUTION

For cleaning of the parts, use only disc brake fluid,

isopropyl alcohol, or ethyl alcohol.

• Install the bleed valve and rubber cap.

Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

2-56 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

• Replace the fluid seal [A] with a new one.

○Apply brake fluid to the fluid seal, and install it into the

cylinder by hand.

• Replace the dust seal [B] with a new one if it is damaged.

○Apply brake fluid to the dust seal, and install it into the

cylinder by hand.

• Apply brake fluid to the outside of the piston, and push it

into the cylinder by hand.

• Replace the shaft rubber friction boot [A] and dust cover

[B] if they are damaged.

• Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to

the caliper holder shafts [C] and holder holes [D] (PBC is

a special high-temperature, water-resistance grease).

• Install the anti-rattle spring [A] in the caliper as shown.

• Install the pads (see Rear Brake Pad Installation in the

Brakes chapter).

• Wipe up any spilled brake fluid on the caliper with wet

cloth.

Spark Plug Replacement

• Remove:

Stick Coils (see Stick Coil (Ignition Coil together with

Spark Plug Cap) Removal in the Electrical System chap-

ter)

• Remove the spark plugs using the 16 mm plug wrench

[A].

Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-1132

• Insert the spark plug vertically into the plug hole with the

spark plug installed in the plug wrench [A].

Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-1132

• Tighten:

Torque - Spark Plugs: 15 N·m (1.5 kgf·m, 11 ft·lb)

• Install:

Stick Coils (see Stick Coil (Ignition Coil together with

Spark Plug Cap) Installation in the Electrical System

chapter)

FUEL SYSTEM (DFI) 3-1

Fuel System (DFI)

Table of Contents

Exploded View

3-4

DFI System

3-10

DFI System

3-12

DFI Parts Location

3-15

Specifications

3-16

Special Tools and Sealant

3-18

DFI Servicing Precautions

3-20

DFI Servicing Precautions

3-20

Troubleshooting the DFI System

3-22

Outline

3-22

Outline

3-22

Inquiries to Rider

3-26

Inquiries to Rider

3-26

DFI System Troubleshooting Guide

3-29

Self-Diagnosis

3-37

Self-diagnosis Outline

3-37

Self-diagnosis Outline

3-37

Self-diagnosis Procedures

3-37

Self-diagnosis Procedures

3-37

Service Code Clearing Procedures

3-38

Service Code Clearing Procedures

3-38

How to Read Service Codes

3-40

How to Read Service Codes

3-40

How to Erase Service Codes

3-40

How to Erase Service Codes

3-40

Service Code Table

3-41

Service Code Table

3-41

Backups

3-42

Backups

3-42

Main Throttle Sensor (Service Code 11)

3-44

Main Throttle Sensor Removal/Adjustment

3-44

Main Throttle Sensor Input Voltage Inspection

3-44

Main Throttle Sensor Output Voltage Inspection

3-45

Main Throttle Sensor Resistance Inspection

3-46

Inlet Air Pressure Sensor (Service Code 12)

3-47

Inlet Air Pressure Sensor Removal

3-47

Inlet Air Pressure Sensor Installation

3-47

Inlet Air Pressure Sensor Input Voltage Inspection

3-47

Inlet Air Pressure Sensor Output Voltage Inspection

3-48

Inlet Air Temperature Sensor (Service Code 13)

3-52

Inlet Air Temperature Sensor Removal/Installation

3-52

Inlet Air Temperature Sensor Output Voltage Inspection

3-52

Inlet Air Temperature Sensor Resistance Inspection

3-53

Water Temperature Sensor (Service Code 14)

3-54

Water Temperature Sensor Removal/Installation

3-54

Water Temperature Sensor Output Voltage Inspection

3-54

Water Temperature Sensor Resistance Inspection

3-55

Crankshaft Sensor (Service Code 21)

3-56

Crankshaft Sensor Removal/Installation

3-56

Crankshaft Sensor Inspection

3-56

3-2 FUEL SYSTEM (DFI)

Speed Sensor (Service Code 24, 25)

3-57

Speed Sensor Removal/Installation

3-57

Speed Sensor Inspection

3-57

Speed Sensor Input Voltage Inspection

3-57

Speed Sensor Output Voltage Inspection

3-57

Vehicle-down Sensor (Service Code 31)

3-59

Vehicle-down Sensor Removal

3-59

Vehicle-down Sensor Installation

3-59

Vehicle-down Sensor Inspection

3-59

Subthrottle Sensor (Service Code 32)

3-62

Subthrottle Sensor Removal/Adjustment

3-62

Subthrottle Sensor Input Voltage Inspection

3-62

Subthrottle Sensor Output Voltage Inspection

3-63

Subthrottle Sensor Resistance Inspection

3-64

Oxygen Sensor-not activated (Service Code 33) (Europe Models)

3-66

Oxygen Sensor Removal/Installation

3-66

Oxygen Sensor Inspection

3-66

Stick Coils #1, #2: (Service Code 51, 52)

3-68

Stick Coil Removal/Installation

3-68

Stick Coil Input Voltage Inspection

3-68

Radiator Fan Relay (Service Code 56)

3-70

Radiator Fan Relay Removal/Installation

3-70

Radiator Fan Relay Inspection

3-70

Subthrottle Valve Actuator (Service Code 62)

3-71

Subthrottle Valve Actuator Removal

3-71

Subthrottle Valve Actuator Audible Inspection

3-71

Subthrottle Valve Actuator Inspection

3-71

Subthrottle Valve Actuator Resistance Inspection

3-71

Subthrottle Valve Actuator Input Voltage Inspection

3-72

Air Switching Valve (Service Code 64)

3-73

Air Switching Valve Removal/Installation

3-73

Air Switching Valve Inspection

3-73

Oxygen Sensor Heater (Service Code 67) (Europe Models)

3-74

Oxygen Sensor Heater Removal/Installation

3-74

Oxygen Sensor Heater Inspection

3-74

Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Europe Models)

3-76

Oxygen Sensor Removal/Installation

3-76

Oxygen Sensor Inspection

3-76

FI Indicator Light (LED)

3-78

FI Indicator Light (LED) Inspection

3-79

ECU

3-80

ECU Removal

3-80

ECU Installation

3-80

ECU Power Supply Inspection

3-81

Fuel Line

3-83

Fuel Pressure Inspection

3-83

Fuel Flow Rate Inspection

3-85

Fuel Pump

3-87

Fuel Pump Removal

3-87

Fuel Pump Installation

3-87

Fuel Pump Operation Inspection

3-88

Fuel Pump Operating Voltage Inspection

3-88

Pressure Regulator Removal

3-89

Pump Screen, Fuel Filter Cleaning

3-89

Fuel Injectors

3-91

Removal/Installation

3-91

Audible Inspection

3-91

FUEL SYSTEM (DFI) 3-3

Fuel Injector Power Source Voltage Inspection

3-91

Fuel Injector Output Voltage Inspection

3-92

Injector Signal Test

3-92

Injector Resistance Inspection

3-93

Injector Unit Test

3-94

Injector Fuel Line Inspection

3-94

Throttle Grip and Cables

3-96

Throttle Grip Free Play Inspection

3-96

Throttle Grip Free Play Adjustment

3-96

Throttle Cable Installation

3-96

Throttle Cable Lubrication

3-96

Throttle Body Assy

3-97

Idle Speed Inspection

3-97

Engine Vacuum Synchronization Inspection/Adjustment

3-97

High Altitude Performance Adjustment

3-97

Throttle Body Assy Removal

3-97

Throttle Body Assy Installation

3-98

Throttle Body Assy Disassembly

3-99

Throttle Body Assy Assembly

3-100

Air Cleaner

3-101

Air Cleaner Element Removal/Installation

3-101

Air Cleaner Element Inspection

3-101

Air Cleaner Oil Draining

3-101

Air Cleaner Housing Removal

3-101

Air Cleaner Housing Installation

3-102

Fuel Tank

3-103

Fuel Tank Removal

3-103

Fuel Tank Installation

3-105

Fuel Tank and Cap Inspection

3-106

Fuel Tank Cleaning

3-107

Evaporative Emission Control System (California Model)

3-108

Parts Removal/Installation

3-108

Hose Inspection

3-108

Separator Inspection

3-108

Separator Operation Test

3-109

Canister Inspection

3-109

FUEL SYSTEM (DFI) 3-7

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

Water Temperature Sensor

1.2

106 in·lb

Speed Sensor Bolt

7.8

0.80

69 in·lb

Oxygen Sensor (Europe Models)

44.1

4.50

32.5

4. Inlet Air Pressure Sensor

5. Air Switching Valve

6. Inlet Air Temperature Sensor

7. Crankshaft Sensor

8. Battery

9. Relay Box

10. Stick Coil

11. Vehicle-down Sensor

12. ECU (Electronic Control Unit)

13. California Model

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

SS: Apply silicone sealant.

FUEL SYSTEM (DFI) 3-11

DFI System

1. Ignition Switch

2. Starter Lockout Switch

3. Starter Relay

4. Tachometer

5. FI Indicator Light (LED)

6. Inlet Air Pressure Sensor

7. Spark Plug

8. Crankshaft Sensor

9. Injector

10. Main Throttle Sensor

11. Delivery Pipe

12. Subthrottle Sensor

13. Subthrottle Valve

14. Main Throttle Valve

15. Subthrottle Valve Actuator

16. Fuel Pump

17. Pressure Regulator

18. Fuel Tank

19. Air Cleaner Element

20. Air Switching Valve

21. Inlet Air Temperature Sensor

22. Air Cleaner Housing

23. Neutral Switch

24. Speed Sensor

25. Vehicle-down Sensor

26. Oxygen Sensor (Europe Models)

27. ECU (Electronic Control Unit)

28. Battery

29. Air Flow

30. Fuel Flow

31. Water Temperature Sensor

FUEL SYSTEM (DFI) 3-13

DFI System

Part Name

1. Oxygen Sensor (Europe Models)

2. Crankshaft Sensor

3. Inlet Air Temperature Sensor

4. Water Temperature Sensor

5. Water-proof Joint E

6. Injectors

7. Vehicle-down Sensor

8. Water-proof Joint D

9. Inlet Air Pressure Sensor

10. Main Throttle Sensor

11. Subthrottle Sensor

12. Subthrottle Valve Actuator

13. Speed Sensor

14. Air Switching Valve

15. Water-proof Joint C

16. Stick Coils

17. Fan Motor

18. Engine Stop Switch

19. Ignition Switch

20. FI Indicator Light (LED)

21. Water Temperature Gauge

22. Tachometer

23. Speedometer

24. Water-proof Joint A

25. Water-proof Joint B

26. Oxygen Sensor Heater Fuse 10 A

27. Radiator Fan Fuse 15 A

28. ECU Fuse 15 A

29. Ignition Fuse 10 A

30. Radiator Fan Relay

31. ECU Main Relay

32. Fuel Pump Relay

33. Relay Box

34. Main Fuse 30 A

35. Battery

36. Frame Ground

37. Fuel Pump

38. Diagnosis Connector

39. Self-diagnosis Terminal

40. Joint Connector

41. ECU

3-14 FUEL SYSTEM (DFI)

DFI System

Terminal Names

1. Subthrottle Valve Actuator Drive Signal 2

27. Unused

2. Subthrottle Valve Actuator Drive Signal 1

28. Ground to Sensors

3. Water Temperature Warning Light Signal

29. Oxygen Sensor Heater Signal (Europe

4. Unused

Models)

5. Oxygen Sensor Signal (Europe Models)

30. Crankshaft Sensor (-) Signal

6. Speed Sensor Signal

31. Unused

7. Main Throttle Sensor Signal

32. External Diagnosis System Signal

8. Inlet Air Pressure Sensor Signal

33. Unused

9. Unused

34. Ground to ECU

10. Power Supply to Sensors

35. Engine Stop Switch Signal

11. Vehicle-down Sensor Signal

36. Starter Lockout Switch Signal

12. Neutral Switch Signal

37. Starter Button Signal

13. Crankshaft Sensor (+) Signal

38. Unused

14. Unused

39. Fuel Pump Relay Signal

15. Unused

40. Air Switching Valve Signal

16. Power Supply to ECU (from ECU Main Re-

41. Fuel Injector #2 Signal

lay)

42. Fuel Injector #1 Signal

17. Power Supply to ECU (from Battery)

43. Stick Coil #1 Signal

18. Subthrottle Valve Actuator Drive Signal 4

44. Sidestand Switch Signal

19. Subthrottle Valve Actuator Drive Signal 3

45. Radiator Fan Relay Signal

20. Water Temperature Sensor Signal

46. External Communication Line (Mode

21. Unused

Switch)

22. Self-diagnosis Terminal

47. Tachometer Signal

23. Unused

48. FI Indicator Light (LED)

24. Subthrottle Sensor Signal

49. -

25. Unused

50. Ground for Fuel System

26. Inlet Air Temperature Sensor Signal

51. Ground for Ignition System

52. Stick Coil #2 Signal

FUEL SYSTEM (DFI) 3-15

DFI Parts Location

DFI: Digital Fuel Injection Parts

12. Speed Sensor

1. FI Indicator Light (LED)

13. Neutral Switch

2. Ignition Switch

14. Water Temperature Sensor

3. Throttle Body Assy

15. Subthrottle Sensor

4. Inlet Air Temperature Sensor

16. Main Throttle Sensor

5. Injectors

17. Subthrottle Valve Actuator

6. Fuel Pump

18. Stick Coils

7. Relay Box (ECU Main Relay, Fuel Pump

19. Inlet Air Pressure Sensor

Relay, Radiator Fan Relay)

20. Diagnosis Connector

8. Fuse Box (ECU Fuse 15 A, Oxygen Sen-

21. Self-diagnosis Terminal

sor Heater Fuse 10 A)

22. Air Switching Valve

9. ECU

23. Crankshaft Sensor

10. Battery

24. Vehicle-down Sensor

11. Oxygen Sensor (Europe Models)

3-16 FUEL SYSTEM (DFI)

Specifications

Item

Standard

Digital Fuel Injection System

Idle Speed

1 300 ±50 r/min (rpm)

Throttle Assy:

Type

Two barrel type

Bore

38 mm (1.50 in.)

ECU (Electronic Control Unit):

Make

Denso

Type

Digital memory type, with built in IC igniter, sealed

with resin

Usable Engine Speed

100 ∼ 11 000 r/min (rpm) (Europe Models)

100 ∼ 11 160 r/min (rpm) (Other than Europe Models)

Fuel Pressure (High Pressure Line):

Right after Ignition Switch ON

323 kPa (3.3 kgf/cm², 47 psi) with fuel pump running

After 3 Seconds from Ignition Switch ON

265 kPa (2.7 kgf/cm², 38 psi) with fuel pump stopped

With Engine Idling

333 kPa (3.4 kgf/cm², 48 psi) with fuel pump running

Fuel Pump:

Type

In-tank friction pump

Discharge

60 mL or more for 3 seconds

Fuel Injectors:

Type

INP-287

Nozzle Type

One spray type with 12 holes

Resistance

About 11.7 ∼ 12.3 Ω at 20°C (68°F)

Main Throttle Sensor:

Non-adjustable and non-removable

Input Voltage

4.75 ∼ 5.25 V DC between BL and BR/BK leads

Output Voltage at Idle Throttle Opening

1.073 ∼ 1.077 V DC between Y/W and BR/BK leads

Output Voltage at Full Throttle Opening

4.29 ∼ 4.49 V DC between Y/W and BR/BK leads

Resistance

4 ∼ 6 kΩ

Inlet Air Pressure Sensor:

Input Voltage

4.75 ∼ 5.25 V DC between BL and BR/BK leads

Output Voltage

3.80 ∼ 4.20 V DC at standard atmospheric pressure

(see this text for details)

Inlet Air Temperature Sensor:

Resistance

5.4 ∼ 6.6 kΩ at 0°C (32°F)

0.29 ∼ 0.39 kΩ at 80°C (176°F)

Output Voltage at ECU

About 2.25 ∼ 2.50 V at 20°C (68°F)

Water Temperature Sensor:

Resistance

see Electrical System chapter

Output Voltage at ECU

About 2.80 ∼ 2.97 V at 20°C (68°F)

Speed Sensor:

Input Voltage at Sensor

About 9 ∼ 11 V DC at Ignition Switch ON

Output Voltage at Sensor

About 0.05 ∼ 0.07 V DC at Ignition Switch ON and 0

km/h

Vehicle-down Sensor:

Detection Method

Magnetic flux detection method

Detection Angle

more than 60 ∼ 70° for each bank

FUEL SYSTEM (DFI) 3-17

Specifications

Item

Standard

Output Voltage

with the sensor tilted 60 ∼ 70° or more: 0.65 ∼ 1.35 V

with sensor arrow mark pointed up: 3.55 ∼ 4.45 V

Subthrottle Sensor:

Non-adjustable and non-removal

Input Voltage

4.75 ∼ 5.25 V DC between BL and BR/BK leads

Output Voltage at Idle Throttle Opening

0.4 ∼ 0.6 V DC between BL/W and BR/BK leads

Output Voltage at Full Throttle Opening

3.625 ∼ 3.775 V DC between BL/W and BR/BK leads

Resistance

4 ∼ 6 kΩ

Subthrottle Valve Actuator:

Resistance

About 5.5 ∼ 7.5 Ω

Input Voltage

About 8.5 ∼ 10.5 V DC

Oxygen Sensor (Europe Models):

Output Voltage (Rich)

0.7 V or more

Output Voltage (Lean)

0.2 V or less

Heater Resistance

11.7 ∼ 14.5 Ω at 20°C (68°F)

Throttle Grip and Cables

Throttle Grip Free Play

2∼3mm(0.08∼0.12in.)

3-20 FUEL SYSTEM (DFI)

DFI Servicing Precautions

There are a number of important precautions that should

be followed servicing the DFI system.

○This DFI system is designed to be used with a 12 V sealed

battery as its power source. Do not use any other battery

except for a 12 V sealed battery as a power source.

○Do not reverse the battery cable connections. This will

damage the ECU.

○To prevent damage to the DFI parts, do not disconnect the

battery cables or any other electrical connections when

the ignition switch is on or while the engine is running.

○Take care not to short the leads that are directly con-

nected to the battery positive (+) terminal to the chassis

ground.

○When charging, remove the battery from the motorcycle.

This is to prevent ECU damage by excessive voltage.

○Do not turn the ignition switch ON while any of the DFI

electrical connectors are disconnected. The ECU memo-

rizes service codes.

○Do not spray water on the electrical parts, DFI parts, con-

nectors, leads, and wiring.

○Whenever the DFI electrical connections are to be dis-

connected, first turn off the ignition switch, and disconnect

the battery (-) terminal. Do not pull the lead, only the con-

nector. Conversely, make sure that all the DFI electrical

connections are firmly reconnected before starting the en-

gine.

○Connect these connectors until they click [A]

○If a transceiver is installed on the motorcycle, make sure

that the operation of the DFI system is not influenced by

electric wave radiated from the antenna. Check operation

of the system with the engine at idle. Locate the antenna

as far as possible away from the ECU.

○When any fuel hose is disconnected, fuel may spout out

by residual pressure in the fuel line. Cover the hose joint

with a piece of clean cloth to prevent fuel spillage.

○When any fuel hose is disconnected, do not turn on the

ignition switch. Otherwise, the fuel pump will operate and

fuel will spout from the fuel hose.

○Do not operate the fuel pump if the pump is completely

dry. This is to prevent pump seizure.

○Before removing the fuel system parts, blow the outer sur-

faces of these parts clean with compressed air.

○To prevent corrosion and deposits in the fuel system, do

not add to fuel any fuel antifreeze chemicals.

3-22 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

Outline

When an abnormality in the system occurs, the FI indi-

cator light (LED) goes on to alert the rider on the meter

panel. In addition, the condition of the problem is stored

in the memory of the ECU (electronic control unit). With the

engine stopped and turned in the self-diagnosis mode, the

service code [A] is indicated by the number of times the FI

indicator light (LED) blinks.

When due to a malfunction, the FI indicator light (LED) re-

mains lit, ask the rider about the conditions [B] under which

the problem occurred and try to determine the cause [C].

• First, conduct a self-diagnosis inspection and then a non

-self-diagnosis inspection. The non-self-diagnosis items

are not indicated by the FI indicator light (LED). Don’t rely

solely on the DFI self-diagnosis function, use common

sense.

Even when the DFI system is operating normally, the FI

indicator light (LED) [A] may light up under strong electrical

interference. No repair needed. Turn the ignition switch

OFF to stop the indicator light.

When the FI indicator light (LED) goes on and the motor-

cycle is brought in for repair, check the service codes.

When the repair has been done, the light (LED) doesn’t go

on. But the service codes stored in memory are not erased

to preserve the problem history, and the light (LED) can

display the codes in the self-diagnosis mode. The problem

history is referred when solving unstable problems.

When the motorcycle is down, the vehicle-down sensor

is turned OFF and the ECU shuts off the fuel injectors and

ignition system. The FI indicator light (LED) blinks but the

service code cannot be displayed. The ignition switch is left

ON. If the starter button is pushed, the electric starter turns

but the engine doesn’t start. To start the engine again, raise

the motorcycle, turn the ignition switch OFF, and then ON.

The vehicle-down sensor is turned ON and the light (LED)

goes OFF.

FUEL SYSTEM (DFI) 3-23

Troubleshooting the DFI System

○The DFI part connectors [A] have seals [B], including the

ECU.

• Join the connector and insert the needle adapters [C]

inside the seals [B] from behind the connector until the

adapter reaches the terminal.

Special Tool - Needle Adapter Set: 57001-1457

CAUTION

Insert the needle adapter straight along the terminal

in the connector to prevent short-circuit between

terminals.

• Make sure that measuring points are correct in the con-

nector, noting the position of the lock [D] and the lead

color before measurement. Do not reverse connections

of the hand tester or a digital meter.

• Be careful not to short-circuit the leads of the DFI or elec-

trical system parts by contact between adapters.

• Turn the ignition switch ON and measure the voltage with

the connector joined.

CAUTION

Incorrect, reverse connection or short circuit by

needle adapters could damage the DFI or electrical

system parts.

○After measurement, remove the needle adapters and ap-

ply silicone sealant to the seals [A] of the connector [B]

for waterproofing.

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

• Always check battery condition before replacing the DFI

parts. A fully charged battery is a must for conducting

accurate tests of the DFI system.

• Trouble may involve one or in some cases all items.

Never replace a defective part without determining what

CAUSED the problem. If the problem was caused by

some other item or items, they too must be repaired or

replaced, or the new replacement part will soon fail again.

• Measure coil winding resistance when the DFI part is cold

(at room temperature).

• Make sure all connectors in the circuit are clean and tight,

and examine wires for signs of burning, fraying, short,

etc. Deteriorated wires and bad connections can cause

reappearance of problems and unstable operation of the

DFI system.

If any wiring is deteriorated, replace the wiring.

3-24 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

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

dirt, and damage.

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

is damaged, replace it. Connect the connectors securely.

• Check the wiring for continuity.

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

is suspected of being a problem.

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

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

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

place the lead or the main harness or the sub harness.

○If both ends of a harness [A] are far apart, ground [B] the

one end [C], using a jumper lead [D] and check the con-

tinuity between the end [E] and the ground [F]. This en-

ables to check a long harness for continuity. If the harness

is open, repair or replace the harness.

○When checking a harness [A] for short circuit, open one

end [B] and check the continuity between the other end

[C] and ground [D]. If there is continuity, the harness has

a short circuit to ground, and it must be repaired or re-

placed.

• Narrow down suspicious locations by repeating the con-

tinuity tests from the ECU connectors.

If no abnormality is found in the wiring or connectors, the

DFI parts are the next likely suspects. Check the part,

starting with input and output voltages. However, there is

no way to check the ECU itself.

If an abnormality is found, replace the affected DFI part.

If no abnormality is found in the wiring, connectors, and

DFI parts, replace the ECU.

○Lead Color Codes:

BK: Black

G: Green

P: Pink

BL: Blue

GY: Gray

PU: Purple

BR: Brown

LB: Light Blue

R: Red

CH: Chocolate

LG: Light Green

W: White

DG: Dark Green

O: Orange

Y: Yellow

FUEL SYSTEM (DFI) 3-25

Troubleshooting the DFI System

○There are two ways to inspect the DFI system. One is

voltage Check Method and the other is Resistance Check

Method.

(Voltage Check Method)

○This method is conducted by measuring the input voltage

[B] to a sensor [A] first, and then the output voltage [C]

from the sensor.

○Sometimes this method can detect a fault of the ECU.

• Refer to each sensor inspection section for detail in this

chapter.

• Use a fully charged battery and a digital meter [D] which

can be read two decimal places voltage or resistance.

(Resistance Check Method)

○This method is simple. No need for a fully charged battery

and the needle adapter. Just do the following especially

when a sensor [A] is suspect.

• Turn the ignition switch OFF and disconnect the connec-

tors.

• Inspect the sensor resistance, using a digital meter (see

each sensor inspection).

• Inspect the wiring and connectors [B] for continuity, using

the hand tester [C] (analog tester) rather than a digital

meter.

Special Tool - Hand Tester: 57001-1394

If the sensor, the wiring and connections are good, inspect

the ECU for its ground and power supply (see ECU Power

Supply Inspection). If the ground and power supply are

good, the ECU is suspect. Replace the ECU.

3-26 FUEL SYSTEM (DFI)

Troubleshooting the DFI System

DFI Diagnosis Flow Chart

Inquiries to Rider

○Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms

the rider has encountered.

○Try to find out exactly what problem occurred under exactly what conditions by asking the rider;

knowing this information may help you reproduce the problem.

○The following sample diagnosis sheet will help prevent you from overlooking any areas, and will

help you decide if it is a DFI system problem, or a general engine problem.

FUEL SYSTEM (DFI) 3-27

Troubleshooting the DFI System

Sample Diagnosis Sheet

Rider name:

Registration No. (license plate No.):

Year of initial registration:

Model:

Engine No.:

Frame No.:

Date problem occurred:

Mileage:

Environment when problem occurred.

Weather

□fine, □cloudy,□rain, □snow, □always, □other:

Temperature

□hot, □warm, □cold, □very cold, □always

Problem

□chronic, □often, □once

frequency

Road

□street, □highway, □mountain road (□uphill, □downhill), □bumpy, □pebble

Altitude

□normal, □high (about 1 000 m or more)

Motorcycle conditions when problem occurred.

FI indicator

□light up immediately after ignition switch ON, and goes off after 1 ∼ 2 seconds

light (LED)

(normal)

□lights blinks immediately after ignition switch ON, and stays on (DFI problem)

□lights up immediately after ignition switch ON, but goes off after about 10 seconds

(DFI problem)

□unlights (light (LED), ECU or its wiring fault)

□sometimes lights up (probably wiring fault)

Starting

□starter motor not rotating

difficulty

□starter motor rotating but engine doesn’t turn over

□starter motor and engine don’t turn over

□no fuel flow (□no fuel in tank, □no fuel pump sound)

□engine flooded (do not crank engine with throttle opened, which promotes engine

flooding)

□no spark

□other

□right after starting

Engine stops

□when opening throttle grip

□when closing throttle grip

□when moving off

□when stopping the motorcycle

□when cruising

□other

Poor running

□very low idle speed, □very high idle speed, □rough idle speed

at low speed

□battery voltage is low (charge the battery)

□spark plug loose (tighten it)

□spark plug dirty, broken, or gap maladjusted (remedy it)

□backfiring

□afterfiring

□hesitation when acceleration

□engine oil viscosity too high

□brake dragging

□engine overheating

□clutch slipping

FUEL SYSTEM (DFI) 3-29

DFI System Troubleshooting Guide

NOTE

○This is not an exhaustive list, giving every possible cause for each problem listed. It is meant

simply as a rough guide to assist the troubleshooting for some of the more common difficulties.

○The ECU may be involved in the DFI electrical and ignition system troubles. If these parts and

circuits are checked out good, be sure to check the ECU for ground and power supply. If the

ground and power supply are checked good, replace the ECU.

Engine Doesn’t Start, Starting Difficulty

Symptoms or possible Causes

Actions (chapter)

Starter motor not rotating:

Ignition and engine stop switches not ON

Turn both switches ON.

Starter lockout switch or neutral switch trouble

Inspect (see chapter 16).

Starter motor trouble

Inspect (see chapter 16).

Battery voltage low

Inspect and charge (see chapter 16).

Starter relays not contacting or operating

Inspect the starter relay (see chapter 16).

Starter button not contacting

Inspect and replace (see chapter 16).

Starter system wiring open or shorted

Inspect the wiring (see chapter 16).

Ignition switch trouble

Inspect and replace (see chapter 16).

Engine stop switch trouble

Inspect and repair or replace (see chapter 16).

Main 30A or ignition fuse blown

Inspect and replace (see chapter 16).

Starter motor rotating but engine doesn’t

turn over:

Starter clutch trouble

Inspect (see chapter 16).

Starter idle gear trouble

Inspect (see chapter 16).

Engine won’t turn over:

Valve seizure

Inspect and replace (see chapter 5).

Cylinder, piston seizure

Inspect and replace (see chapter 5).

Camshaft seizure

Inspect and replace (see chapter 5).

Connecting rod small end seizure

Inspect and replace (see chapter 9).

Connecting rod big end seizure

Inspect and replace (see chapter 9).

Crankshaft seizure

Inspect and replace (see chapter 9).

Transmission gear or bearing seizure

Inspect and replace (see chapter 9).

Balancer bearing seizure

Inspect and replace (see chapter 9).

No fuel flow:

No or little fuel in tank

Supply fuel (see Owner’s Manual).

Fuel pump not rotating

Inspect (see chapter 3).

Fuel injector trouble

Inspect and replace (see chapter 3).

Fuel tank air vent obstructed

Inspect and repair (see chapter 3).

Fuel filter or pump screen clogged

Inspect and replace fuel pump (see chapter 3).

Fuel pressure regulator clogged

Inspect and replace fuel pump (see chapter 3).

Fuel line clogged

Inspect and repair (see chapter 3).

Engine flooded:

Spark plug dirty, broken or gap maladjusted

Replace (see chapter 2).

Starting technique faulty

When flooded, don’t crank engine with throttle

fully opened.

No spark or spark weak:

Ignition and engine stop switches not ON

Turn both switches ON .

3-30 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide

Symptoms or possible Causes

Actions (chapter)

Clutch lever not pulled in and gear not in neutral

Pull the lever in and shift the gear in neutral.

whether sidestand up or not

Though clutch lever pulled in, sidestand up and

Sidestand down and clutch lever pulled in

gear not in neutral

whether gear in neutral or not

Vehicle-down-sensor coming off

Reinstall (see chapter 3).

Vehicle-down-sensor trouble

Inspect (see chapter 3).

ECU ground or power supply trouble

Inspect (see chapter 3).

Battery voltage low

Inspect and charge (see chapter 16).

Spark plug dirty, broken or gap maladjusted

Replace (see chapter 2).

Stick coil trouble

Inspect stick coil (see chapter 16).

Stick coil shorted or not in good contact

Reinstall or inspect stick coil (see chapter 16).

Spark plug incorrect

Replace it with the correct plug (see chapter 16).

IC igniter in ECU trouble

Inspect (see chapter 16).

Neutral, starter lockout or sidestand switch

Inspect each switch (see chapter 16).

trouble

Crankshaft sensor trouble

Inspect (see chapter 16).

Stick coil trouble

Inspect (see chapter 16).

Ignition switch shorted

Inspect and replace (see chapter 16).

Engine stop switch shorted

Inspect and repair or replace (see chapter 2).

Starter system wiring shorted or open

Inspect and repair or replace (see chapter 16).

Main 30A or ignition fuse blown

Inspect and replace (see chapter 16).

Fuel/air mixture incorrect:

Air cleaner clogged, poorly sealed or missing

Clean or reinstall (see chapter 3).

Leak from oil filler cap, crankcase breather hose

Inspect and repair or replace (see chapter 3).

or air cleaner drain hose

Water or foreign matter in fuel

Change fuel. Inspect and clean fuel system (see

chapter 3).

Fuel pressure regulator trouble

Inspect fuel pressure and replace fuel pump (see

chapter 3).

Main throttle sensor trouble

Inspect (see chapter 3).

Fuel pressure may be low

Inspect (see chapter 3).

Fuel pump trouble

Inspect (see chapter 3).

Fuel injector trouble

Inspect (see chapter 3).

Inlet air pressure sensor trouble

Inspect (see chapter 3).

Inlet air temperature sensor trouble

Inspect (see chapter 3).

Water temperature sensor trouble

Inspect (see chapter 3).

Crankshaft sensor trouble

Inspect (see chapter 3).

Compression low:

Spark plug loose

Reinstall (see chapter 16).

Cylinder head not sufficiently tightened down

Tighten (see chapter 5).

Cylinder, piston worn

Inspect and replace (see chapter 5).

Piston ring bad (worn, weak, broken or sticking)

Inspect and replace (see chapter 5).

Piston ring/groove clearance excessive

Inspect and replace (see chapter 5).

Cylinder head gasket damaged

Replace (see chapter 5).

Cylinder head warped

Inspect and replace (see chapter 5).

FUEL SYSTEM (DFI) 3-31

DFI System Troubleshooting Guide

Symptoms or possible Causes

Actions (chapter)

No valve clearance

Adjust (see chapter 2).

Valve guide worn

Inspect and replace (see chapter 5).

Valve spring broken or weak

Inspect and replace (see chapter 5).

Valve not seating properly (valve bent, worn or

Inspect and repair or replace (see chapter 5).

carbon accumulating on seating surface)

Poor Running at Low Speed

Symptoms or Possible Causes

Actions (chapter)

Spark weak:

Battery voltage low

Inspect and charge (see chapter 16).

Spark plug dirty, broken or gap maladjusted

Replace (see chapter 2).

Stick coil trouble

Inspect the stick coil (see chapter 16).

Stick coil shorted or not in good contact

Reinstall or inspect stick coil (see chapter 16).

Spark plug incorrect

Replace it with the correct plug (see chapter 16).

IC igniter in ECU trouble

Inspect (see chapter 16).

Crankshaft sensor trouble

Inspect (see chapter 16).

Stick coil trouble

Inspect (see chapter 16).

Fuel/air mixture incorrect:

Little fuel in tank

Supply fuel (see Owner’s Manual).

Air cleaner clogged, poorly sealed, or missing

Clean element or inspect sealing (see chapter

2, 3).

Air cleaner duct loose

Reinstall (see chapter 3).

Air cleaner O-ring damaged

Replace (see chapter 3).

Fuel tank air vent obstructed

Inspect and repair (see chapter 3).

Throttle body assy loose

Reinstall (see chapter 3).

Throttle body assy O-ring damage

Replace (see chapter 3).

Fuel filter or pump screen clogged

Inspect and replace fuel pump (see chapter 3).

Inspect fuel pressure and replace fuel pump (see

Fuel pressure regulator clogged

chapter 3).

Fuel line clogged

Inspect and repair (see chapter 3).

Inlet air pressure sensor trouble

Inspect (see chapter 3).

Inlet air temperature sensor trouble

Inspect (see chapter 3).

Thermostat trouble

Inspect and replace (see chapter 4).

Unstable (rough) idling:

Fuel injector trouble

Inspect (see chapter 3).

Main throttle sensor trouble

Inspect (see chapter 3).

Crankshaft sensor trouble

Inspect (see chapter 3).

Throttle valves not synchronizing

Inspect (see chapter 2).

Inlet air temperature sensor trouble

Inspect (see chapter 3).

Water temperature sensor trouble

Inspect (see chapter 3).

Fuel pressure too low or too high

Inspect (see chapter 3).

Battery voltage low

Inspect and charge (see chapter 16).

Incorrect idle speed:

Water temperature sensor trouble

Inspect (see chapter 3).

Main throttle sensor trouble

Inspect (see chapter 3).

3-32 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide

Symptoms or Possible Causes

Actions (chapter)

Engine stalls easily:

Fuel pump trouble

Inspect (see chapter 3).

Fuel injector trouble

Inspect (see chapter 3).

Main throttle sensor trouble

Inspect (see chapter 3).

Fuel pressure too low or too high

Inspect (see chapter 3).

Inlet air pressure sensor trouble

Inspect (see chapter 3).

Water temperature sensor trouble

Inspect (see chapter 3).

Inlet air temperature sensor trouble

Inspect (see chapter 3).

Fuel line clogged

Inspect and repair (see chapter 3).

Fuel pressure too low or too high

Inspect (see chapter 3).

Fuel pressure regulator trouble

Inspect fuel pressure and replace fuel pump (see

chapter 3).

Crankshaft sensor trouble

Inspect (see chapter 16).

Stick coil trouble

Inspect (see chapter 16).

Compression Low:

Spark plug loose

Reinstall (see chapter 16).

Cylinder head not sufficiently tightened down

Tighten (see chapter 5).

No valve clearance

Adjust (see chapter 2).

Cylinder, piston worn

Inspect and replace (see chapter 5).

Piston ring bad (worn, weak, broken or sticking )

Inspect and replace (see chapter 5).

Piston ring/groove clearance excessive

Inspect and replace (see chapter 5).

Cylinder head gasket damaged

Replace (see chapter 5).

Cylinder head warped

Inspect and replace (see chapter 5).

Valve guide worn or stem seal damaged

Inspect and replace (see chapter 5).

Valve spring broken or weak

Inspect and replace (see chapter 5).

Valve not seating properly (valve bent, worn or

Inspect and repair or replace (see chapter 5).

carbon accumulating on seating surface)

Camshaft cam worn

Inspect and replace (see chapter 5).

Hesitation:

Too low fuel pressure

Inspect (see chapter 3).

Clogged fuel line

Inspect and repair (see chapter 3).

Cracked or obstructed inlet air pressure sensor

Inspect and repair or replace (see chapter 3).

hose

Fuel pump trouble

Inspect (see chapter 3).

Fuel injector trouble

Inspect (see chapter 3).

Inlet air temperature sensor trouble

Inspect (see chapter 3).

Main throttle sensor trouble

Inspect (see chapter 3).

Subthrottle sensor trouble

Inspect (see chapter 3).

Subthrottle valve actuator trouble

Inspect (see chapter 3).

Water temperature sensor trouble

Inspect (see chapter 3).

Inlet air pressure sensor trouble

Inspect (see chapter 3).

Loose injector connectors

Remedy (see chapter 3).

Crankshaft sensor trouble

Inspect and repair or replace (see chapter 16).

Stick coil trouble

Inspect and repair or replace (see chapter 16).

FUEL SYSTEM (DFI) 3-33

DFI System Troubleshooting Guide

Symptoms or Possible Causes

Actions (chapter)

Loose terminal of battery (-) cable or engine

Inspect and repair (see chapter 16).

ground lead

Delay of ignition timing

Inspect crankshaft sensor and IC igniter in ECU

(see chapter 16).

Poor acceleration:

Too low fuel pressure

Inspect (see chapter 3).

Water or foreign matter in fuel

Change fuel. Inspect and clean fuel system (see

chapter 3).

Clogged fuel filter or pump screen

Inspect and replace fuel pump (see chapter 3).

Fuel pump trouble

Inspect (see chapter 3).

Fuel injector trouble

Inspect (see chapter 3).

Inlet air temperature sensor trouble

Inspect (see chapter 3).

Water temperature sensor trouble

Inspect (see chapter 3).

Subthrottle sensor trouble

Inspect (see chapter 3).

Subthrottle valve actuator trouble

Inspect (see chapter 3).

Stick coil trouble

Inspect and replace (see chapter 16).

Engine oil level to high

Repair (see chapter 7).

Spark plug dirty, broken or gap maladjusted

Replace (see chapter 2).

Stumble:

Too low fuel pressure

Inspect (see chapter 3).

Fuel injector trouble

Inspect (see chapter 3).

Main throttle sensor malfunction

Inspect (see chapter 3).

Subthrottle sensor trouble

Inspect (see chapter 3).

Subthrottle valve actuator trouble

Inspect (see chapter 3).

Water temperature sensor trouble

Inspect (see chapter 3).

Inlet air pressure sensor trouble

Inspect (see chapter 3).

Surge:

Unstable fuel pressure

Fuel pressure regulator trouble (Inspect and

replace fuel pump) or kinked fuel line (Inspect

and repair fuel line) (see chapter 3).

Fuel injector trouble

Inspect (see chapter 3).

Water temperature sensor trouble

Inspect (see chapter 3).

Backfiring when deceleration:

Spark plug dirty, broken or gap maladjusted

Replace (see chapter 2).

Too low fuel pressure

Inspect (see chapter 3).

Fuel pump trouble

Inspect (see chapter 3).

Main throttle sensor trouble

Inspect (see chapter 3).

Inlet air temperature sensor trouble

Inspect (see chapter 3).

Water temperature sensor trouble

Inspect (see chapter 3).

Inlet air pressure sensor trouble

Inspect (see chapter 3).

Air switching valve broken

Inspect and replace (see chapter 5).

Air suction valve trouble

Inspect and replace (see chapter 5).

After fire:

Crankshaft sensor trouble

Inspect (see chapter 16).

Spark plug burned or gap maladjusted

Replace (see chapter 2).

3-34 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide

Symptoms or Possible Causes

Actions (chapter)

Inlet air temperature sensor trouble

Inspect (see chapter 3).

Water temperature sensor trouble

Inspect (see chapter 3).

Inlet air pressure sensor trouble

Inspect (see chapter 3).

Fuel injector trouble

Inspect (see chapter 3).

Run-on (dieseling):

Ignition switch trouble

Inspect and replace (see chapter 16).

Engine stop switch trouble

Inspect and repair or replace (see chapter 2).

Fuel injector trouble

Inspect (see chapter 3).

Loose terminal of battery (-) cable or ECU

Inspect and repair (see chapter 16).

ground lead

Carbon accumulating on valve seating surface

Repair (see chapter 5).

Engine overheating

(see Overheating of Troubleshooting Guide, see

chapter 17)

Other:

Engine oil viscosity too high

Change (see chapter 2).

Inspect drive chain (see chapter 2) and sprocket

Drive train trouble

(see chapter 11).

Inspect caliper fluid seal damage or clogging

Brake dragging

of master cylinder relief and supply ports (see

chapter 12).

Clutch slipping

Inspect friction plates for wear (see chapter 6).

(see Overheating of Troubleshooting Guide, see

Engine overheating

chapter 17)

Air switching valve trouble

Inspect and replace (see chapter 5).

Air suction valve trouble

Inspect and replace (see chapter 5).

Intermittent any DFI fault and its recovery

Check that DFI connectors are clean and tight,

and examine wires for signs of burning or fraying

(see chapter 3).

Poor Running or No Power at High Speed:

Symptoms or Possible Causes

Actions (chapter)

Firing incorrect:

Spark plug dirty, broken or maladjusted

Replace (see chapter 2).

Stick coil trouble

Inspect stick coil (see chapter 16).

Stick coil shorted or not in good contact

Reinstall or inspect stick coil (see chapter 16).

Spark plug incorrect

Replace it with the correct plug (see chapter 16).

IC igniter in ECU trouble

Inspect (see chapter 16).

Crankshaft sensor trouble

Inspect (see chapter 16).

Stick coil trouble

Inspect (see chapter 16).

Fuel/air mixture incorrect:

Air cleaner clogged, poorly sealed, or missing

Clean element or inspect sealing (see chapter 3).

Air cleaner duct loose

Reinstall (see chapter 3).

Air cleaner O-ring damaged

Replace (see chapter 3).

Water or foreign matter in fuel

Change fuel. Inspect and clean fuel system (see

chapter 3).

Throttle body assy loose

Reinstall (see chapter 3).

FUEL SYSTEM (DFI) 3-35

DFI System Troubleshooting Guide

Symptoms or Possible Causes

Actions (chapter)

Throttle body assy O-ring damaged

Replace (see chapter 3).

Fuel tank air vent obstructed

Inspect and repair (see chapter 3).

Fuel line clogged

Inspect and repair (see chapter 3).

Fuel pump operates intermittently and often DFI

Pump bearings may wear. Replace the pump

fuse blows.

(see chapter 3).

Fuel pump trouble

Inspect (see chapter 3).

Inlet air temperature sensor trouble

Inspect (see chapter 3).

Main throttle sensor trouble

Inspect (see chapter 3).

Inlet air pressure sensor trouble

Inspect (see chapter 3).

Cracked or obstructed inlet air pressure sensor

Inspect and repair or replace (see chapter 3).

hose

Injector clogged

Visually inspect and replace (see chapter 3).

Compression low:

Spark plug loose

Reinstall (see chapter 16).

Cylinder head not sufficiently tightened down

Tighten (see chapter 5).

No valve clearance

Adjust (see chapter 2).

Cylinder, piston worn

Inspect and replace (see chapter 5).

Piston ring bad (worn, weak, broken or sticking)

Inspect and replace (see chapter 5).

Piston ring/groove clearance excessive

Inspect and replace (see chapter 5).

Cylinder head gasket damaged

Replace (see chapter 5).

Cylinder head warped

Inspect and replace (see chapter 5).

Valve spring broken or weak

Inspect and replace (see chapter 5).

Valve not seating properly (valve bent , worn or

Inspect and repair or replace (see chapter 5).

carbon accumulating on the seating surface)

Knocking:

Carbon built up in combustion chamber

Repair (see chapter 5).

Fuel poor quality or incorrect (Use the gasoline

Change fuel (see chapter 3).

recommended in the Owner’s Manual)

Spark plug incorrect

Replace it with the correct plug (see chapter 16).

Stick coil trouble

Inspect (see chapter 16).

IC igniter in ECU trouble

Inspect (see chapter 16).

Inlet air temperature sensor trouble

Inspect (see chapter 3).

Miscellaneous:

Subthrottle sensor trouble

Inspect (see chapter 3).

Subthrottle valve actuator trouble

Inspect (see chapter 3).

Speed sensor trouble

Inspect (see chapter 3).

Throttle valves won’t fully open

Inspect throttle cable and lever linkage (see

chapter 3).

Brake dragging

Inspect caliper fluid seal damage or clogging

of master cylinder relief and supply ports (see

chapter 12).

Clutch slipping

Inspect friction plates for wear (see chapter 6).

Engine overheating - Water temperature sensor,

(see Overheating of Troubleshooting Guide in

crankshaft sensor or speed sensor trouble

chapter 17).

Engine oil level too high

Repair (see chapter 7).

Engine oil viscosity too high

Change (see chapter 2).

3-36 FUEL SYSTEM (DFI)

DFI System Troubleshooting Guide

Symptoms or Possible Causes

Actions (chapter)

Drive train trouble

Inspect drive chain (see chapter 2) and sprockets

(see chapter 11).

Camshaft cam worn

Inspect and replace (see chapter 5).

Air switching valve trouble

Inspect and replace (see chapter 5).

Air suction valve trouble

Inspect and replace (see chapter 5).

Catalytic converters melt down due to muffler

Replace muffler (see chapter 5).

overheating

Exhaust Smokes Excessively:

(White smokes)

Piston oil ring worn

Inspect and replace (see chapter 5).

Cylinder worn

Inspect and replace (see chapter 5).

Valve oil seal damaged

Replace (see chapter 5).

Valve guide worn

Replace the guide (see chapter 5).

Engine oil level too high

Repair (see chapter 7).

(Black smoke)

Air cleaner clogged

Clean (see chapter 3).

Too high fuel pressure

Inspect (see chapter 3).

Injector stuck open

Inspect (see chapter 3).

Water temperature sensor trouble

Inspect and replace (see chapter 3).

Inlet air temperature sensor trouble

Inspect and replace (see chapter 3).

(Brown smoke)

Air cleaner duct loose

Reinstall (see chapter 3).

Air cleaner O-ring damaged

Replace (see chapter 3).

Too low fuel pressure

Inspect fuel line and fuel pump (see chapter 3).

Water temperature sensor trouble

Inspect and replace (see chapter 3).

Inlet air temperature sensor trouble

Inspect and replace (see chapter 3).

FUEL SYSTEM (DFI) 3-37

Self-Diagnosis

Self-diagnosis Outline

The self-diagnosis system has three modes and can be

switched to another mode by grounding the self-diagnosis

terminal.

User Mode

The ECU notifies the rider of troubles in DFI system and

ignition system by lighting the FI indicator when DFI system

and ignition system parts are faulty, and initiates fail-safe

function. In case of serious troubles, the ECU stops the

injection/ignition/starter motor operation.

Dealer Mode 1

The FI indicator light (LED) emits service code(s) to show

the problem(s) which the DFI system, and ignition system

has at the moment of diagnosis.

Dealer Mode 2

The FI indicator light (LED) emits service code(s) to show

the problem(s) which the DFI system, and ignition system

had in the past.

Self-diagnosis Procedures

○When a problem occurs with the DFI system and ignition

system, the FI indicator light (LED) [A] goes on.

NOTE

○Use a fully charged battery when conducting

self-diagnosis.

Otherwise, the light (LED) blinks

very slowly or doesn’t blink.

○Keep the self-diagnosis terminal grounded during self

-diagnosis, with an auxiliary lead.

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

ter).

• Ground [A] the self-diagnosis terminal [B] (Orange/Black

lead) to the battery (-) terminal [C] or battery (-) lead con-

nector, using a wire.

• Turn on the ignition switch.

• Connect an auxiliary lead [E] to the self-diagnosis terminal

[G] for grounding.

• To enter the self-diagnosis dealer mode 1, ground [A] the

self-diagnosis indicator terminal to the battery (-) terminal

for more than 2 seconds [C], and then keep it grounded

continuously [D].

○Count the blinks of the light (LED) to read the service

code. Keep the auxiliary lead ground until you finish read-

ing the service code.

3-38 FUEL SYSTEM (DFI)

Self-Diagnosis

• To enter the self-diagnosis dealer mode 2, open [B] and

ground [A] the lead more than five times [F] within 2 sec-

onds [C] after the lead is first grounded, and then keep it

grounded continuously [D] for more than 2 seconds.

○Count the blinks of the light (LED) to read the service

code. Keep the auxiliary lead ground until you finish read-

ing the service code.

Auxiliary Lead [E]

Self-diagnosis Terminal [G]

NOTE

○To enter the dealer mode 2 from the dealer mode 1, turn

off the ignition switch once.

Service Code Clearing Procedures

(see Self

• Enter the self-diagnosis dealer mode

-diagnosis Procedures).

NOTE

○Make sure to keep the grounding until the following

opening and grounding starts.

• Pull the clutch lever in more than 5 seconds, and then

release it.

• Repeat opening [B] and grounding [A] the lead

(self-diagnosis terminal) more than five times [F] within 2

seconds [C] after the lead is grounded, and then keep it

grounded continuously [D] for more than 2 seconds.

Auxiliary Lead [E]

Self-diagnosis Terminal [G]

3-40 FUEL SYSTEM (DFI)

Self-Diagnosis

How to Read Service Codes

○Service codes are shown by a series of long and short blinks of the FI indicator light (LED) as shown

below.

○Read 10th digit and unit digit as the FI indicator light (LED) blinks.

○When there are a number of problems, all the service codes can be stored and the display will

begin starting from the lowest number service code in the numerical order. Then after completing

all codes, the display is repeated until the self-diagnosis indicator terminal is open.

○If there is no problem, no code and unlight.

○For example, if two problems occurred in the order of 21, 12, the service codes are displayed from

the lowest number in the order listed.

(12 → 21) → (12 → 21) → · · · (repeated)

○If the problem is with the following parts, the ECU cannot memorize these problems, the FI indicator

light (LED) doesn’t go on, and no service codes can be displayed.

FI Indicator Light (LED)

Fuel Pump

Fuel Pump Relay

DFI Main Relay

ECU Power Source Wiring and Ground Wiring (see ECU Inspection)

Fuel Injectors

How to Erase Service Codes

○Even if the ignition switch is turned OFF, the battery or the ECU are disconnected or the problem is

solved, all service codes remain in the ECU.

○Refer to the Service Code Clearing Procedure for the service code erasure.

FUEL SYSTEM (DFI) 3-41

Self-Diagnosis

Service Code Table

Service

FI Indicator Light (LED)

Problems

Code

Main throttle sensor malfunction,

wiring open or short

Inlet air pressure sensor malfunction,

wiring open or short

Inlet air temperature sensor

malfunction, wiring open or short

Water temperature sensor

malfunction, wiring open or short

Crankshaft sensor malfunction, wiring

open or short

Speed sensor malfunction, wiring

open or short

and

First 24 is displayed and then 25,

repeatedly

Vehicle-down sensor, malfunction,

wiring open or short

Subthrottle sensor malfunction, wiring

open or short

Oxygen sensor inactivation, wiring

open or short (Europe Models)

Stick (Ignition) coil #1 malfunction,

wiring open or short

Stick (Ignition) coil #2 malfunction,

wiring open or short

Radiator fan relay malfunction, wiring

open or short

Subthrottle valve actuator

malfunction, wiring open or short

Air switching valve malfunction, wiring

open or short

Oxygen sensor heater malfunction,

wiring open or short (Europe Models)

Oxygen sensor malfunction, wiring

open or short (Europe Models)

Notes:

○The ECU may be involved in these problems. If all the parts and circuits checked out good, be sure

to check the ECU for ground and power supply. If the ground and power supply are checked good,

replace the ECU.

○When no service code is displayed, the electrical parts of the DFI system has no fault, and the

mechanical parts of the DFI system and the engine are suspect.

3-42 FUEL SYSTEM (DFI)

Self-Diagnosis

Backups

○The ECU takes the following measures to prevent engine damage when the DFI or the ignition

system parts have troubles.

Service

Output Signal Usable

Parts

Backups by ECU

Codes

Range or Criteria

If the main throttle sensor system fails (the

signal is out of the usable range, wiring short

or open), the ECU locks ignition timing into the

Main Throttle Sensor

ignition timing at closed throttle position and

Main Throttle

Output Voltage

sets the DFI in the D-J method.

Sensor

0.20 ∼ 4.8 V

Also, the main throttle sensor system and

inlet air pressure fails, the ECU locks ignition

timing into the ignition timing at closed throttle

position and sets the DFI in the α-N method.

Inlet Air Pressure

If the inlet air pressure sensor system fails (the

Inlet Air

(absolute)

signal Pv is out of the usable range, wiring

Pressure

Pv = 150 mmHg ∼ 800

short or open), the ECU sets the DFI in the α

Sensor

mmHg

- N method.

Inlet Air

If the inlet air temperature sensor fails (the

Inlet Air Temperature

Temperature

signal is out of the usable range, wiring short

Ta = -30°C ∼ +120°C

Sensor

or open), the ECU sets Ta at 40°C.

Water

If the water temperature sensor system fails

Water Temperature

Temperature

(the signal is out of the usable range, wiring

Tw = -30°C ∼ +120°C

Sensor

short or open), the ECU sets Tw at 80°C.

Crankshaft sensor must

Crankshaft

send 22 signals (output

If crankshaft sensor generates other than 22

Sensor

signal) to the ECU at

signals, the engine stops by itself.

the one cranking.

Speed sensor must

send 4 signals (output

signal) to the ECU at

If the speed sensor system fails (no signal,

the one rotation of the

and

Speed Sensor

wiring short or open), the speedometer shows

engine sprocket.

0, and the ECU sets the top (6) gear position.

The gear position is

decided by the signal of

the speed sensor.

If the vehicle-down sensor system has failures

Vehicle-down Sensor

(the output voltage Vd is more than usable

Vehicle-down

Output Voltage (signal)

range, wiring open), the ECU shuts off the

Sensor

Vd = 0.65 V ∼ 4.45 V

fuel pump, the fuel injectors and the ignition

system.

If the subthrottle sensor system fails (the

Subthrottle Sensor

Subthrottle

signal is out of the usable range, wiring short

Output Voltage

Sensor

or open), the actuator locks sub throttle valve

0.15 ∼ 4.85 V

at full open position.

The oxygen sensor is

Oxygen Sensor

active and sensor must

If the oxygen sensor is not activated, the ECU

(Europe

send signals (output

stops oxygen sensor feedback mode.

Models)

voltage) continuously to

the ECU.

FUEL SYSTEM (DFI) 3-43

Self-Diagnosis

Service

Output Signal Usable

Parts

Backups by ECU

Codes

Range or Criteria

The stick coil primary

If the ignition primary winding #1 has failures

winding must send

Stick Coil #1

(no signal, wiring short or open), the ECU

signals (output voltage)

(Ignition Coil)*

shuts off the injector #1 to stop fuel to the

continuously to the

cylinder #1, though the engine keeps running.

ECU.

The stick coil primary

If the ignition primary winding #2 has failures

winding must send

Stick Coil #2

(no signal, wiring short or open), the ECU

signals (output voltage)

(Ignition Coil)*

shuts off the injector #2 to stop fuel to the

continuously to the

cylinder #2, though the engine keeps running.

ECU.

The actuator operates

If the subthrottle valve actuator fails (the

open and close of the

Subthrottle

signal is out of the usable range, wiring short

subthrottle valve by the

Valve Actuator

or open), the ECU stops the current to the

pulse signal from the

actuator.

ECU.

The oxygen sensor

heater raise

Oxygen Sensor

If the oxygen sensor heater fails (wiring short

temperature of the

(Europe

or open), the ECU stops the current to the

sensor for its earlier

Models)

heater.

activation. 12V-6.6W,

0.55A

The oxygen sensor

Oxygen Sensor

must send signals

If the oxygen sensor output voltage is incorrect,

(Europe

(output voltage)

the ECU stops oxygen sensor feed back mode.

Models)

continuously to the

ECU

Note:

(1) D-J Method and α - N Method: When the engine load is light like at idling or low speed, the ECU

determines the injection quantity by calculating from the throttle vacuum (inlet air pressure sensor

output voltage) and engine speed (crankshaft sensor output voltage). This method is called D-J

method (low-speed mode). As the engine speed increases, and the engine load turns middle to

heavy, the ECU determines the injection quantity by calculating from the throttle opening (throttle

sensor output voltage) and the engine speed. This method is called α - N method (high-speed

mode).

(*) This depends on the number of stopped cylinders.

3-44 FUEL SYSTEM (DFI)

Main Throttle Sensor (Service Code 11)

Main Throttle Sensor Removal/Adjustment

CAUTION

Do not remove or adjust the main throttle sensor [A]

since it has been adjusted and set with precision at

the factory.

Never drop the throttle body assy, especially on a

hard surface. Such a shock to the sensor can dam-

age it.

Main Throttle Sensor Input Voltage Inspection

NOTE

○Be sure the battery is fully charged.

• Turn the ignition switch OFF.

• Remove the left center fairings (see Center Fairing Re-

moval in the Frame chapter).

• Disconnect the main throttle sensor connector and con-

nect the harness adapter [A] between these connectors.

• Connect a digital meter to the harness adapter lead.

Special Tool - Throttle Sensor Harness Adapter:

57001

-1538

• Measure the sensor input voltage with the engine stopped

and with the connector joined.

• Turn the ignition switch ON.

Main Throttle Sensor Input Voltage

Connections to Adapter

Meter (+) → R (sensor BL) lead

Meter (-) → BK (sensor BR/BK) lead

Standard: 4.75 ∼ 5.25 V DC

• Turn the ignition switch OFF.

If the input voltage is normal, check the sensor output

voltage.

If the input voltage is less than the standard, remove the

ECU and check the wiring between these connectors.

○Disconnect the ECU and sensor connectors.

Wiring Connection

ECU Connector [A] ←→ Throttle Sensor Connector [B]

BL lead (ECU terminal 10)

BR/BK lead (ECU terminal 28)

If the wiring is good, check the ECU for its ground and

power supply (see ECU Power Supply Inspection).

FUEL SYSTEM (DFI) 3-45

Main Throttle Sensor (Service Code 11)

Main Throttle Sensor Output Voltage Inspection

• Measure the output voltage at the main throttle sensor

in the same way as input voltage inspection, Note the

following.

• Disconnect the main throttle sensor connector and con-

nect the harness adapter [A] between these connectors.

Special Tool - Throttle Sensor Harness Adapter:

57001

-1538

• Start the engine and warm it up thoroughly.

• Check idle speed to ensure the throttle opening is correct.

Idle Speed

Standard:

1 300 ±50 r/min (rpm)

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

(see Idle Speed Inspection in the Periodic Maintenance

chapter).

• Turn off the ignition switch.

• Measure the output voltage of the sensor with the engine

stopped, and with the connector joined.

• Turn the ignition switch ON.

Main Throttle Sensor Output Voltage

Connections to Adapter

Meter (+) → R (sensor Y/W) lead

Meter (-) → W (sensor BR/BK) lead

Standard:

1.073 ∼ 1.077 V DC (at idle throttle opening)

4.29 ∼ 4.49 V DC (at full throttle opening)

If the output voltage is out of the standard, inspect the

main throttle sensor resistance.

If the output voltage is normal, check the wiring for conti-

nuity.

Wiring Connection

ECU Connector [A] ←→ Throttle Sensor Connector [B]

Y/W lead (ECU terminal 7)

BR/BK lead (ECU terminal 28)

If the wiring is good, check the ECU for its ground and

power supply (see ECU Power Supply Inspection).

3-46 FUEL SYSTEM (DFI)

Main Throttle Sensor (Service Code 11)

Main Throttle Sensor Resistance Inspection

• Turn the ignition switch OFF.

• Disconnect the main throttle sensor connector.

• Connect a digital meter [A] to the main throttle sensor

connector [B].

• Measure the main throttle sensor resistance.

Main Throttle Sensor Resistance

Connections:

BL lead [C] ←→ BR/BK lead [D]

Standard:

4 ∼ 6 kΩ

If the reading is out of the range, replace the throttle body

assy.

If the reading is within the range, but the problem still

exists, replace the ECU (see ECU Removal/Installation).

Main Throttle Sensor Circuit

1. ECU

2. Water-proof Joint E

3. Water-proof Joint D

4. Main Throttle Sensor

FUEL SYSTEM (DFI) 3-47

Inlet Air Pressure Sensor (Service Code 12)

CAUTION

Never drop the sensor, especially on a hard surface.

Such a shock to the part can damage it.

Inlet Air Pressure Sensor Removal

• Remove:

Left Upper Inner Fairing (see Upper Inner Fairing Re-

moval in the Frame chapter)

• Disconnect the inlet air pressure sensor connector [A] and

the vacuum hose.

• Pull up the inlet air pressure sensor [B].

Inlet Air Pressure Sensor Installation

• Install:

Vacuum Hose

Inlet Air Pressure Sensor

Inlet Air Pressure Sensor Input Voltage Inspection

NOTE

○Be sure the battery is fully charged.

○The inspection is the same as “Input Voltage Inspection”

of the main throttle sensor.

• Turn the ignition switch OFF.

• Remove the ECU (see ECU Removal). Do not disconnect

the ECU connectors.

• Connect a digital voltmeter [A] to the connector [B] with

the needle adapter set.

Special Tool - Needle Adapter Set: 57001-1457

• Measure the input voltage with the engine stopped, and

with the connectors joined.

• Turn the ignition switch ON.

Inlet Air Pressure Sensor Input Voltage

Connections to ECU

Meter (+) → BL lead (terminal 10)

Meter (-) → BR/BK lead (terminal 28)

Standard:

4.75 ∼ 5.25 V DC

If the reading is within the standard range, check the sen-

sor output voltage.

If the reading is less than the standard range, remove the

ECU and check the wiring between these connectors.

If the wiring is good, check the ECU for its ground and

power supply (see ECU Power Supply Inspection).

3-48 FUEL SYSTEM (DFI)

Inlet Air Pressure Sensor (Service Code 12)

Inlet Air Pressure Sensor Output Voltage

Inspection

NOTE

○The output voltage changes according to the local at-

mospheric pressure.

• Measure the output voltage at the ECU in the same way

as input voltage inspection. Note the following.

Inlet Air Pressure Sensor Output Voltage

Connections to ECU

Meter (+) → Y/BL lead (terminal 8)

Meter (-) → BR/BK lead (terminal 28)

Usable Range:

3.74 ∼ 4.26 V DC at the standard

atmospheric pressure (101.32 kPa,

76 cmHg abs.)

• Turn the ignition switch OFF.

If the output voltage is within the usable range, check the

ECU for its ground, and power supply (see ECU Power

Supply Inspection).

If the output voltage is out of the usable range, remove

the fuel tank and check the wiring. If the output voltage is

4.8 V, the ECU is normal.

If the wiring is good, check the sensor for various vacuum.

If the output voltage for various vacuum is normal, check

the ECU for its ground, and power supply (see ECU

Power Supply Inspection).

• Remove the inlet air pressure sensor [A] and disconnect

the vacuum hose from the sensor.

○Do not disconnect the sensor connector.

• Connect an auxiliary hose [B] to the inlet air pressure sen-

sor.

• Temporarily install the inlet air pressure sensor.

○Connect a commercially available digital meter [C], vac-

uum gauge [D], the fork oil level gauge [E] and the har-

ness adapter to the inlet air pressure sensor.

Special Tools - Fork Oil Level Gauge: 57001-1290

Sensor Harness Adapter: 57001-1561

Inlet Air Pressure Sensor Output Voltage

Connection to Adapter

Meter (+) → G (sensor Y/BL) lead

Meter (-) → BK (sensor BR/BK) lead

○Turn the ignition switch ON.

○Measure the inlet air pressure sensor output voltage from various vacuum readings, while pulling

the handle of the fork oil level gauge.

○Check the inlet air pressure sensor output voltage, using the following formula and chart.

Suppose:

Pg: Vacuum Pressure (gauge) to Sensor

Pl: Local Atmospheric Pressure (absolute) measured by a barometer

Pv: Vacuum Pressure (absolute) to Sensor

Vv: Sensor Output Voltage (V)

Kawasaki Ninja 650R, ER-6f ABS, ER-6f Motorcycle. Service Manual (2006-2008 year) - page 1