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Kawasaki Ninja 650R, ER-6f ABS, ER-6f Motorcycle. Service Manual (2006-2008 year) - page 2

FUEL SYSTEM (DFI) 3-49

Inlet Air Pressure Sensor (Service Code 12)

then

Pv = Pl - Pg

For example, suppose the following data is obtained:

Pg = 8 cmHg (Vacuum gauge reading)

Pl = 70 cmHg (Varometer reading)

Vv = 3.2 V (Digital volt meter reading)

then

Pv = 70 - 8 = 62 cmHg (Abs.)

Plot this Pv (62 cmHg) at a point [1] on the chart and draw a vertical line through the point. Then, you

can get the usable range [2] of the sensor output voltage.

Usable range = 3.04 ∼ 3.49 V

Plot Vv (3.2 V) on the vertical line. → Point [3].

Results: In the chart, Vv is within the usable range and the sensor is normal.

Pv = 24 ∼ 55 cmHg

3-50 FUEL SYSTEM (DFI)

Inlet Air Pressure Sensor (Service Code 12)

Pv = 55 ∼ 86 cmHg

ID: Idling

Ps: Standard Atmospheric Pressure (Absolute)

Pv: Throttle Vacuum Pressure (Absolute)

ST: Standard of Sensor Output Voltage (V)

TO: Throttle Full Open

UR: Usable Range of Sensor Output Voltage (V)

Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading)

FUEL SYSTEM (DFI) 3-51

Inlet Air Pressure Sensor (Service Code 12)

Inlet Air Pressure Sensor Circuit

1. ECU

2. Water-proof Joint E

3. Water-proof Joint D

4. Inlet Air Pressure Sensor

3-52 FUEL SYSTEM (DFI)

Inlet Air Temperature Sensor (Service Code 13)

Inlet Air Temperature Sensor Removal/Installation

CAUTION

Never drop the sensor, especially on a hard surface.

Such a shock to the sensor can damage it.

• Remove the fuel tank (see Fuel Tank Removal).

• Disconnect the connector [A] from the inlet air tempera-

ture sensor.

• Remove the screw [B].

• Pull out the inlet air temperature sensor [C].

• Put the inlet air temperature sensor into the air cleaner

housing.

• Tighten the screw securely.

Inlet Air Temperature Sensor Output Voltage

Inspection

NOTE

○Be sure the battery is fully charged.

○The output voltage changes according to the inlet air

temperature.

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

the ECU connectors.

• Connect a digital voltmeter to the ECU connector, using

needle adapter set.

Special Tool - Needle Adapter Set: 57001-1457

• Measure the sensor output voltage with the engine

stopped and the connector joined.

• Turn the ignition switch ON.

Inlet Air Temperature Sensor Output Voltage

Connections to ECU Connector

Meter (+) → Y lead (terminal 26)

Meter (-) → BR/BK lead (terminal 28)

Standard: About 2.25 ∼ 2.50 V at inlet air temperature

20°C (68°F)

• Turn the ignition switch OFF.

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

fuel tank and check the wiring. And if the output voltage

is 4.8 V, the ECU is normal.

If the output voltage is within the standard, check the ECU

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

Inspection).

If the wiring is good, check the sensor resistance.

• Remove the needle adapter set, and apply silicone

sealant to the seals of the connector for waterproofing.

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

FUEL SYSTEM (DFI) 3-53

Inlet Air Temperature Sensor (Service Code 13)

Inlet Air Temperature Sensor Resistance

Inspection

• Remove the inlet air temperature sensor (see Inlet Air

Temperature Sensor Removal/Installation).

• Suspend the sensor [A] in a container of machine oil so

that the heat-sensitive portion is submerged.

• Suspend a thermometer [B] with the heat-sensitive por-

tion [C] located in almost the same depth with the sensor.

NOTE

○The sensor and thermometer must not touch the con-

tainer side or bottom.

• Place the container over a source of heat and gradually

raise the temperature of the oil while stirring the oil gently

for even temperature.

• Using a digital meter, measure the internal resistance

of the sensor across the terminals at the temperatures

shown in the table.

Inlet Air Temperature Sensor Resistance

Standard:

5.4 ∼ 6.6 kΩ at 0°C (68°F)

0.29 ∼ 0.39 kΩ at 80°C (176°F)

If the measurement is out of the range, replace the sensor.

If the measurement is within the specified, replace the

ECU.

Inlet Air Temperature Sensor Circuit

1. ECU

2. Inlet Air Temperature Sensor

3. Water-proof Joint E

3-54 FUEL SYSTEM (DFI)

Water Temperature Sensor (Service Code 14)

Water Temperature Sensor Removal/Installation

CAUTION

Never drop the sensor, especially on a hard surface.

Such a shock to the sensor can damage it.

• Drain the coolant (see Coolant Change in the Periodic

Maintenance chapter).

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

moval in the Frame chapter).

• Disconnect the sensor connector [A], and unscrew the

water temperature sensor [B].

Torque - Water Temperature Sensor: 12 N·m (1.2 kgf·m, 106

in·lb)

• Apply grease to new O-ring on the water temperature sen-

sor.

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

ing system (see Coolant Change in the Periodic Mainte-

nance chapter).

Water Temperature Sensor Output Voltage

Inspection

NOTE

○Be sure the battery is fully charged.

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

the connectors.

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

with the needle adapter set.

Special Tool - Needle Adapter Set: 57001-1457

• Measure the sensor output voltage with the engine

stopped and the connector joined.

• Turn the ignition switch ON.

Water Temperature Sensor Output Voltage

Connections to ECU

Meter (+) → O lead (terminal 20)

Meter (-) → BR/BK lead (terminal 28)

Standard:

About 2.80 ∼ 2.97 V at 20°C (68°F)

NOTE

○The output voltage changes according to the coolant

temperature in the engine.

• Turn the ignition switch OFF.

If the output voltage is within the standard, check the ECU

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

Inspection).

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

wiring. And if the output voltage is 4.8 V, the ECU is nor-

mal.

If the wiring is good, check the water temperature sensor

resistance.

• Remove the needle adapter set, and apply silicone

sealant to the seals of the connector for waterproofing.

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

FUEL SYSTEM (DFI) 3-55

Water Temperature Sensor (Service Code 14)

Water Temperature Sensor Circuit

1. ECU

2. Water Temperature Sensor

3. Water-proof Joint E

4. Meter Unit

Water Temperature Sensor Resistance Inspection

• Remove the water temperature sensor (see Water Tem-

perature Sensor Removal/Installation).

• Refer to the Water Temperature Sensor Inspection in the

Electrical System chapter.

3-56 FUEL SYSTEM (DFI)

Crankshaft Sensor (Service Code 21)

Start the engine and switch the diagnosis mode to Dealer

1 mode to know all the problem that the DFI system has at

the time of self-diagnosis. If the engine cannot be started,

the self-diagnosis system does not detect dynamic condi-

tion of the crankshaft sensor. In this case, turn off the igni-

tion switch and turn it on again to enter the Dealer 2 mode.

In this mode, the system tells all the troubles which the DFI

system had in both static and dynamic conditions.

Crankshaft Sensor Removal/Installation

• Refer to the Crankshaft Sensor Removal/Installation in

the Electrical System chapter.

Crankshaft Sensor Inspection

○The crankshaft sensor has no power source, and when

the engine stops, the crankshaft sensor generates no sig-

nals.

• Crank the engine and measure the peak voltage of the

crankshaft sensor (see Crankshaft Sensor Inspection in

the Electrical System) in order to check the sensor.

• Check the wiring for continuity, using the following dia-

gram.

Crankshaft Sensor Circuit

1. ECU

2. Crankshaft Sensor

FUEL SYSTEM (DFI) 3-57

Speed Sensor (Service Code 24, 25)

Speed Sensor Removal/Installation

• Refer to the Speed Sensor Removal/Installation in the

Electrical System chapter.

Speed Sensor Inspection

• Refer to the Speed Sensor Inspection in the Electrical

System chapter.

Speed Sensor Input Voltage Inspection

NOTE

○Be sure the battery is fully charged.

• Turn the ignition switch OFF.

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

moval in the Frame chapter).

• Disconnect the speed sensor connector and connect the

harness adapter [A] between the harness connector and

speed sensor connector.

• Connect a digital meter to the harness adapter leads.

Special Tool - Throttle Sensor Setting Adapter #1: 57001

-1400

• Measure the sensor input voltage with the engine

stopped, and with the connector joined.

• Turn the ignition switch ON.

Speed Sensor Input Voltage

Connection to Adapter

Meter (+) → BL (sensor P) lead [C]

Meter (-) → BK (sensor BK/Y) lead [D]

Standard:

About 9 ∼ 11 V DC at Ignition Switch ON

If the reading is out of the range, check the wiring (see

wiring diagram in this section), and meter (see Electronic

Combination Meter Unit Inspection in the Electrical Sys-

tem chapter).

If the reading is good, check the output voltage.

• Turn the ignition switch OFF.

Speed Sensor Output Voltage Inspection

• Before this inspection, inspect the input voltage (see

Speed Sensor Input Voltage Inspection).

NOTE

○Be sure the battery is fully charged.

• Turn the ignition switch OFF.

3-58 FUEL SYSTEM (DFI)

Speed Sensor (Service Code 24, 25)

• Disconnect the speed sensor connector and connect the

harness adapter [A] between the harness connector and

speed sensor connector.

• Connect a digital meter to the harness adapter leads.

Special Tool - Throttle Sensor Setting Adapter #1: 57001

-1400

• Measure the sensor output voltage with the engine

stopped, and with the connector joined.

• Turn the ignition switch ON.

Speed Sensor Output Voltage at Sensor

Connections to Adapter

Meter (+) → Y/W (sensor LG/R) lead [C]

Meter (-) → BK (sensor BK/Y) lead [D]

Standard:

About 0.05 ∼ 0.07 V DC

NOTE

○If you rotate the engine sprocket, the output voltage will

be increased.

If the reading is out of the range, check the speed sensor

operation (see Speed Sensor Inspection in the Electrical

System chapter) and the wiring to ECU (see wiring dia-

gram in this section).

If the reading, speed sensor operation and wiring are

good, check the ECU for its ground, and power supply

(see ECU Power Supply Inspection).

Speed Sensor Circuit

1. ECU

2. Speed Sensor

3. Meter Unit

4. Water-proof Joint B

5. Frame Ground

6. Joint Connector

FUEL SYSTEM (DFI) 3-59

Vehicle-down Sensor (Service Code 31)

Vehicle-down Sensor Removal

CAUTION

Never drop the down-sensor, especially on a hard

surface. Such a shock to the sensor can damage it.

• Remove:

Bolts [A]

Connector and Vehicle-down Sensor [B]

Vehicle-down Sensor Installation

• The UP mark [A] of the sensor should face upward.

WARNING

Incorrect installation of the vehicle-down sensor

could cause sudden loss of engine power. The

rider could lose balance during certain riding situ-

ations like leaning over in a turn with the potential

for an accident resulting in injury or death. Ensure

that the down sensor is held in place by the sensor

brackets.

Vehicle-down Sensor Inspection

NOTE

○Be sure the battery is fully charged.

• Connect a digital volt meter [A] to the connector [B] of the

vehicle-down sensor [C] with the needle adapter set [D].

Vehicle-down Sensor Power Source Voltage

Connections to Sensor

Meter (+) → BL lead [E]

Meter (-) → BR/BK lead [F]

• Turn the ignition switch ON, and measure the power

source voltage with the connector joined.

Vehicle-down Sensor Input Voltage

Standard:

4.75 ∼ 5.25 V DC

• Turn the ignition switch OFF.

If the reading of input voltage is less than the standard,

check the ECU for its ground, power supply and wiring

shorted.

If the power source is normal, check the output voltage.

3-60 FUEL SYSTEM (DFI)

Vehicle-down Sensor (Service Code 31)

• Remove the sensor (see Vehicle-down Sensor Removal).

• Connect a digital volt meter [A] to the connector with nee-

dle adapter set [B].

Special Tool - Needle Adapter Set: 57001-1457

Vehicle-down Sensor Output Voltage

Connections to Sensor

Meter (+) → Y/G lead [E]

Meter (-) → BR/BK lead [F]

• Hold the sensor vertically.

• Turn the ignition switch ON, and measure the output volt-

age with the connector joined.

○Tilt the sensor 60 ∼ 70° or more [C] right or left, then hold

the sensor almost vertical with the arrow mark pointed up

[D], and measure the output voltage.

Output Voltage at Sensor

Standard:

with sensor tilted 60 ∼ 70° or more right

or left: 0.65 ∼ 1.35 V

with sensor arrow mark pointed up:

3.55 ∼ 4.45 V

NOTE

○If you need to test again, turn the ignition switch OFF,

and then ON.

• Turn the ignition switch OFF.

• Remove the needle adapter set, and apply silicone

sealant to the seals of the connector for waterproofing.

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

If the output voltage is normal, the wiring is suspect.

Check the wiring.

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

power supply (see ECU Power Supply Inspection).

If the output voltage is out of the specified, replace the

vehicle-down sensor.

FUEL SYSTEM (DFI) 3-61

Vehicle-down Sensor (Service Code 31)

Vehicle-down Sensor Circuit

1. ECU

2. Water-proof Joint E

3. Vehicle-down Sensor

4. Water-proof Joint D

3-62 FUEL SYSTEM (DFI)

Subthrottle Sensor (Service Code 32)

Subthrottle Sensor Removal/Adjustment

CAUTION

Do not remove or adjust the subthrottle 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.

Subthrottle Sensor Input Voltage Inspection

NOTE

○Be sure the battery is fully charged.

• Remove the air cleaner housing (see Air Cleaner Housing

Removal).

• Turn the ignition switch OFF.

• Disconnect the subthrottle sensor connector and connect

the harness adapter [A] between these connectors.

• Connect a digital meter to the harness adapter lead.

Special Tool - Throttle Sensor Harness Adapter:

57001

-1400

• Measure the sensor input voltage with the engine stopped

and with the connector joined.

• Turn the ignition switch ON.

Subthrottle Sensor Input Voltage

Connections to Adapter

Meter (+) → BL (sensor BL) lead

Meter (-) → BK (sensor BR/BK) lead

Standard: 4.75 ∼ 5.25 V DC

FUEL SYSTEM (DFI) 3-63

Subthrottle Sensor (Service Code 32)

• 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] ←→

Subthrottle Sensor Connector [B]

BL lead (terminal 10)

BR/BK lead (terminal 28)

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

power supply (see ECU Power Supply Inspection).

Subthrottle Sensor Output Voltage Inspection

• Remove the air cleaner housing (see Air Cleaner Housing

Removal).

• Measure the output voltage at the subthrottle sensor in

the same way as input voltage inspection. Note the fol-

lowing.

• Disconnect the subthrottle sensor connector and (black)

connect the harness adapter [A] between these connec-

tors.

Special Tool - Throttle Sensor Harness Adapter:

57001

-1400

• Measure the output voltage of the sensor with the engine

stopped, and with the connector joined.

• Turn the ignition switch ON.

• Measure the output voltage when the subthrottle valve is

fully opened or completely closed by hand.

Subthrottle Sensor Output Voltage

Connections to Adapter

Meter (+) → Y (sensor BL/W) lead

Meter (-) → BK (sensor BR/BK) lead

Standard:

0.4 ∼ 0.6 V DC (at idle throttle opening)

3.625 ∼ 3.775 V DC (at full throttle opening)

3-64 FUEL SYSTEM (DFI)

Subthrottle Sensor (Service Code 32)

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

subthrottle sensor resistance.

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

nuity.

Wiring Connection

ECU Connector [A] ←→

Subthrottle Sensor Connector [B]

BL/W lead (terminal 24)

BR/BK lead (terminal 28)

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

power supply (see ECU Power Supply Inspection).

Subthrottle Sensor Resistance Inspection

• Turn the ignition switch OFF.

• Disconnect the subthrottle sensor connector.

• Connect a digital meter [A] to the subthrottle sensor con-

nector [B].

• Measure the subthrottle sensor resistance.

Throttle Sensor Resistance

Connections: BL lead [C] ←→ 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).

FUEL SYSTEM (DFI) 3-65

Subthrottle Sensor (Service Code 32)

Subthrottle Sensor Circuit

1. ECU

2. Water-proof Joint E

3. Water-proof Joint D

4. Subthrottle Sensor

3-66 FUEL SYSTEM (DFI)

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

Oxygen Sensor Removal/Installation

• Refer to the Oxygen Sensor Removal/Installation in the

Electrical System chapter.

Oxygen Sensor Inspection

• Warm up the engine thoroughly until the radiator fan

starts.

• Turn the ignition switch OFF.

• Remove:

Left Lower Fairing (see Lower Fairing Removal in the

Frame chapter)

Engine Sprocket Cover (see Engine Sprocket Removal

in the Final Drive chapter)

• Connect a digital voltmeter [A] to the oxygen sensor con-

nector [B] (main harness side), using the needle adapter

set [C].

Special Tool - Needle Adapter Set: 57001-1457

Oxygen Sensor Output Voltage

Connections to Oxygen Sensor Connector

Meter (+) → BL/Y lead

Meter (-) → BR/BK lead

• Remove the air switching valve hose from the fitting.

• Install the suitable plugs [A] on the fitting [B] and shut off

the secondary air.

• Turn the ignition switch ON.

• Start the engine, and let it idle.

• Measure the output voltage of the sensor with the con-

nector joined.

Oxygen Sensor Output Voltage (with Plugs)

Standard:

0.7 V or more

• Next, remove the plugs from the fitting [A] with idling.

FUEL SYSTEM (DFI) 3-67

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

• Measure the output voltage of the sensor with the con-

nector joined.

Oxygen Sensor Output Voltage (without Plugs)

Standard:

0.2 V or less

If the reading is within range (with plugs: 0.7 V or more,

without plugs: 0.2 V or less), the oxygen sensor is good.

If the reading is without range, replace the oxygen sensor

(see Oxygen Sensor Removal/Installation in the Electrical

System chapter).

Oxygen Sensor Circuit

1. ECU

2. Oxygen Sensor

3. Water-proof Joint E

4. Water-proof Joint D

5. Oxygen Sensor Heater Fuse 10 A

6. Main Fuse 30 A

7. Battery

8. Frame Ground

9. Joint Connector

3-68 FUEL SYSTEM (DFI)

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

Stick Coil #1: Service Code 51

Stick Coil #2: Service Code 52

Stick Coil Removal/Installation

CAUTION

Never drop the stick coils, especially on a hard sur-

face. Such a shock to the stick coil can damage it.

• Refer to the Stick Coil (Ignition Coil together with Spark

Plug Cap) Removal/Installation in the Electrical System

chapter.

Stick Coil Input Voltage Inspection

NOTE

○Be sure the battery is fully charged.

• Turn the ignition switch OFF.

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

the ECU connector.

• Connect a digital voltmeter [A] as shown, with the needle

adapter set [B].

○Measure the input voltage to each primary winding of the

ignition coils with the engine stopped, and with the con-

nectors joined.

• Turn the ignition switch ON.

Stick Coil Input Voltage at ECU

Connections for Stick Coil #1

Meter (+) → BK lead (terminal 43)

Meter (-) → BK/Y lead (terminal 51)

Connections for Stick Coil #2

Meter (+) → BK/G lead (terminal 52)

Meter (-) → BK/Y lead (terminal 51)

Input Voltage at ECU

Standard:

Battery Voltage (12.8 V or more)

If the reading is out of the standard, check the wiring (see

next wiring diagram).

If the reading is good, the input voltage is normal. Crank

the engine, and check the peak voltage of the stick coils

(see Stick Coil Primary Peak Voltage in the Electrical Sys-

tem chapter) in order to check the primary coils.

FUEL SYSTEM (DFI) 3-69

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

Stick Coil Circuit

1. ECU

2. Water-proof Joint C

3. Stick Coils

4. Engine Stop Switch

5. Ignition Switch

6. Ignition Fuse 10 A

7. Main Fuse 30 A

8. Battery

9. Frame Ground

10. Joint Connector

3-70 FUEL SYSTEM (DFI)

Radiator Fan Relay (Service Code 56)

Radiator Fan Relay Removal/Installation

• Radiator fan relay is built in the relay box.

• Remove the relay box (see Relay Box Removal in the

Electrical System chapter).

Radiator Fan Relay Inspection

• Refer to the Relay Circuit Inspection in the Electrical Sys-

tem chapter.

• Remove the relay box and ECU (see ECU Removal). Do

not disconnect the relay box and ECU connectors. Check

the wiring for continuity, using the following diagram.

If wiring and radiator fan relay are good, check the ECU

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

Inspection). If the ground and power supply are good,

replace the ECU (see ECU Removal/Installation).

Radiator Fan Relay Circuit

1. ECU

2. Water-proof Joint C

3. Water-proof Joint B

4. Radiator Fan Fuse 15 A

5. Relay Box

6. Radiator Fan Relay

7. Main Fuse 30 A

8. Battery

9. Frame Ground

10. Joint Connector

FUEL SYSTEM (DFI) 3-71

Subthrottle Valve Actuator (Service Code 62)

Subthrottle Valve Actuator Removal

CAUTION

Do not remove the subthrottle valve actuator [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 actuator can

damage it.

Subthrottle Valve Actuator Audible Inspection

NOTE

○Be sure the battery is fully charged.

• Turn the ignition switch ON and ensure that the actuator

valves open and close (make light sounds) several times

within seconds, and then close at the idle throttle opening

position.

• Turn the ignition switch OFF.

If the actuator does not work as described above, do the

visual inspection.

Subthrottle Valve Actuator Inspection

• Remove the air cleaner housing (see Air Cleaner Housing

Removal).

• Turn the ignition switch ON.

• Check to see that all the subthrottle valves [A] open and

close smoothly.

If the subthrottle valves do not operate, check the actuator

internal resistance (see Subthrottle Valve Actuator Resis-

tance Inspection).

Subthrottle Valve Actuator Resistance Inspection

• Turn the ignition switch OFF.

• Remove the air cleaner housing (see Air Cleaner Housing

Removal).

• Disconnect the subthrottle valve actuator connector [A].

• Connect a digital meter to the subthrottle valve actuator

connector [A].

• Measure the subthrottle valve actuator resistance.

Subthrottle Valve Actuator Resistance

Connections: BK lead [1] ←→ P lead [2]

G lead [3] ←→ W/BL lead [4]

Standard:

About 5.5 ∼ 7.5 kΩ

Special Tool - Hand Tester: 57001-1394

If the reading is out of the range, replace the actuator

along with the throttle body assy.

If the reading is within the range, check the input voltage

(see Subthrottle Valve Actuator Input Voltage Inspection).

3-72 FUEL SYSTEM (DFI)

Subthrottle Valve Actuator (Service Code 62)

Subthrottle Valve Actuator Input Voltage

Inspection

NOTE

○Be sure the battery is fully charged.

• Turn the ignition switch OFF.

• Connect the peak voltage adapter [A] and a digital meter

[B] to the connector [C], using the needle adapter set [D].

Special Tools - Peak Voltage Adapter: 57001-1415

Type: KEK-54-9-B

Brand: KOWA SEIKI

Needle Adapter Set: 57001-1457

Subthrottle Valve Actuator Input Voltage

Connections to Harness Connector

(I)

Meter (+) → BK/BL lead [1]

Meter (-) → P lead [2]

(II)

Meter (+) → W/BL lead [3]

Meter (-) → G/Y lead [4]

• Measure the actuator input voltage with the engine

stopped, and with the connector joined.

• Turn the ignition switch ON.

Input Voltage at Actuator

Standard:

About 8.5 ∼ 10.5 V DC

If the reading is within the standard but the actuator

doesn’t operate, replace it.

If the reading is out of the range, check the wiring to ECU

(see wiring diagram in this section).

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

power supply (see ECU Power Supply Inspection).

Subthrottle Valve Actuator Circuit

1. ECU

2. Subthrottle Valve Actuator

FUEL SYSTEM (DFI) 3-73

Air Switching Valve (Service Code 64)

Air Switching Valve Removal/Installation

• Refer to the Air Switching Valve Removal/Installation in

the Engine Top End chapter.

Air Switching Valve Inspection

• Refer to the Air Switching Valve Operation Test/Unit Test

in the Electrical System chapter.

• Remove the fuel tank (see Fuel Tank Removal) and check

the wiring continuity, using the following diagram.

Air Switching Valve Circuit

1. ECU

2. Air Switching Valve

3. Water-proof Joint C

4. Ignition Switch

5. Water-proof Joint A

6. ECU Fuse 15 A

7. ECU Main Relay

8. Relay Box

9. Main Fuse 30 A

10. Battery

11. Frame Ground

12. Joint Connector

3-74 FUEL SYSTEM (DFI)

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

Oxygen Sensor Heater Removal/Installation

The oxygen sensor heater is built in the oxygen sensor.

So, the heater itself can not be removed. Remove the oxy-

gen sensor (see Oxygen Sensor Removal in the Electrical

System chapter).

Oxygen Sensor Heater Inspection

• Remove the engine sprocket cover (see Engine Sprocket

Removal in the Final Drive chapter).

• Disconnect the oxygen sensor lead connector [A].

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

to the terminals in the oxygen sensor lead connector [B].

Black [C]

Black [D]

Special Tool - Hand Tester: 57001-1394

Oxygen Sensor Resistance

Standard:

11.7 ∼ 14.5 Ω at 20°C (68°F)

If the tester reading is not as specified, replace the oxygen

sensor with a new one.

If the tester reading is specified, check the power source

voltage Inspection.

NOTE

○Be sure the battery is fully charged.

• Connect a digital voltmeter [A] to the oxygen sensor con-

nector [B], using the needle adapter [C].

Special Tool - Needle Adapter Set: 57001-1457

• Measure the power source voltage with the engine

stopped, and with the oxygen sensor connector joined.

Oxygen Sensor Power Source Voltage

Connections to Oxygen Sensor Connector

Tester (+) → W/Y lead [D]

Tester (-) → Battery (-) Terminal [E]

Standard:

Battery Voltage (12.8 V or more)

Oxygen Sensor [F]

If the reading is incorrect, check the following.

Battery

Main Fuse 30 A

Oxygen Sensor Heater Fuse 10 A

If the reading is good, the power source voltage is normal,

Inspect the Red/Black lead between the oxygen sensor

connector and the ECU for continuity, using the following

diagram.

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

power supply (see ECU Power Supply Inspection). If the

ground and power supply are good, replace the ECU (see

ECU Removal/Installation).

FUEL SYSTEM (DFI) 3-75

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

Oxygen Sensor Circuit

1. ECU

2. Oxygen Sensor

3. Water-proof Joint E

4. Water-proof Joint D

5. Oxygen Sensor Heater Fuse 10 A

6. Main Fuse 30 A

7. Battery

8. Frame Ground

9. Joint Connector

3-76 FUEL SYSTEM (DFI)

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

Oxygen Sensor Removal/Installation

• Refer to the Oxygen Sensor Removal/Installation in the

Electrical System chapter.

Oxygen Sensor Inspection

• Warm up the engine thoroughly until the radiator fan

starts.

• Turn the ignition switch OFF.

• Remove:

Left Lower Fairing (see Lower Fairing Removal in the

Frame chapter)

Engine Sprocket Cover (see Engine Sprocket Removal

in the Final Drive chapter)

• Connect a digital voltmeter [A] to the oxygen sensor con-

nector [B] (main harness side), using the needle adapter

set [C].

Special Tool - Needle Adapter Set: 57001-1457

Oxygen Sensor Output Voltage

Connections to Oxygen Sensor Connector

Meter (+) → BL/Y lead

Meter (-) → BR/BK lead

• Remove the air switching valve hose from the fitting.

• Install the suitable plugs [A] on the fitting [B] and shut off

the secondary air.

• Turn the ignition switch ON.

• Start the engine, and let it idle.

• Measure the output voltage of the sensor with the con-

nector joined.

Oxygen Sensor Output Voltage (with Plugs)

Standard:

0.7 V or more

• Next, remove the plugs from the fitting [A] with idling.

FUEL SYSTEM (DFI) 3-77

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

• Measure the output voltage of the sensor with the con-

nector joined.

Oxygen Sensor Output Voltage (without Plugs)

Standard:

0.2 V or less

If the reading is within range (with plugs: 0.7 V or more,

without plugs: 0.2 V or less), the oxygen sensor is good.

If the reading is without range, inspect the engine and fuel

supply system.

If the engine and fuel supply system good, replace the

oxygen sensor (see Oxygen Sensor Removal/Installation

in the Electrical System chapter).

Oxygen Sensor Circuit

1. ECU

2. Oxygen Sensor

3. Water-proof Joint E

4. Water-proof Joint D

5. Oxygen Sensor Heater Fuse 10 A

6. Main Fuse 30 A

7. Battery

8. Frame Ground

9. Joint Connector

3-78 FUEL SYSTEM (DFI)

FI Indicator Light (LED)

Inspection Flow Chart

FUEL SYSTEM (DFI) 3-79

FI Indicator Light (LED)

FI Indicator Light (LED) Inspection

• Remove the meter unit (see Meter Unit Removal in the

Electrical System chapter).

• Using two auxiliary leads, supply battery power to the FI

indicator light (LED) [A].

12 V Battery [B]

FI Indicator Light (LED) Check

Connector:

Meter Connector [C] (disconnected)

Connection:

W/BK Lead Terminal [10] of the Meter

→ Battery (+) Terminal

BR/R Lead Terminal [6] of the Meter →

Battery (-) Terminal

Criterion:

The light (LED) should light.

If the light (LED) does not go on, replace the meter unit

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

tem chapter).

FI Indicator Light (LED) Circuit

1. ECU

2. Water-proof Joint C

3. Ignition Switch

4. Meter Unit

5. Ignition Fuse 10 A

6. Main Fuse 30 A

7. Battery

8. Frame Ground

9. Joint Connector

3-80 FUEL SYSTEM (DFI)

ECU

CAUTION

Never drop the ECU, especially on a hard surface.

Such a shock to the ECU can damage it.

ECU Removal

• Remove:

Seat (see Seat Removal in the Frame chapter)

Grab Rails [A] (see Seat Cover Removal in the Frame

chapter)

Center Seat Cover [B] (see Seat Cover Removal in the

Frame chapter)

Seat Covers [C] (see Seat Cover Removal in the Frame

chapter)

Rear Fender Rear Bolts [D]

• Pull down the rear fender rear [A].

• Remove the ECU bracket bolts [A].

• Take the ECU [B] out along with the harness.

• Disconnect the ECU lead connectors.

ECU Installation

• Fit [A] the bracket on the ECU as shown.

FUEL SYSTEM (DFI) 3-81

ECU

ECU Power Supply Inspection

• Visually inspect the terminals [A] of the ECU connectors.

If the connector is clogged with mud or dust, blow it off

with compressed air.

Replace the main harness if the terminals of the main

harness connectors are cracked, bent, or otherwise dam-

aged.

Replace the ECU if the terminals of the ECU connectors

are cracked, bent, or otherwise damaged.

• With the ECU connectors [A] connected, check the fol-

lowing ground lead for continuity with the ignition switch

OFF, using a tester and needle adapter set.

Battery [B]

Tester [C]

Special Tool - Needle Adapter Set: 57001-1457

ECU Grounding Inspection

34, 50, or 51 (BK/Y)

←→ Battery (-) Terminal: 0 Ω

Terminal

Engine Ground

←→ Battery (-) Terminal: 0 Ω

If no continuity, check the connector, the engine ground

lead, or main harness, and repair or replace them if nec-

essary.

• Check the ECU power source voltage with a digital meter

[A].

○Position the terminal in accordance with terminal numbers

of ECU connectors [B] in this chapter figure.

Battery [C]

ECU Power Source Inspection

Meter Connections:

Between Terminal 16 (BR/W) and Battery (-) Terminal

Between Terminal 17 (W/BK) and Battery (-) Terminal

Ignition Switch OFF:

Terminal 16 (BR/W): 0 V

Terminal 17 (W/BK): Battery Voltage (12.8 V or more)

Ignition Switch ON:

Both: Battery Voltage (12.8 V or more)

If the meter does not read as specified, check the follow-

ing:

Main Fuse 30 A (see Fuse Inspection in the Electrical

System chapter)

ECU Fuse 15 A (see Fuse Inspection in the Electrical

System chapter)

ECU Main Relay (see Relay Circuit Inspection in the

Electrical System chapter)

Power Source Wiring (see wiring diagram below)

If the inspection checks good, the ECU is damaged. Re-

place the ECU (see ECU Removal/Installation). The ECU

itself cannot be checked or serviced.

3-82 FUEL SYSTEM (DFI)

ECU

ECU Power Source Circuit

1. ECU

2. Water-proof Joint C

3. Ignition Switch

4. Water-proof Joint A

5. ECU Main Fuse 15 A

6. ECU Main Relay

7. Relay Box

8. Main Fuse 30 A

9. Battery

10. Frame Ground

11. Joint Connector

FUEL SYSTEM (DFI) 3-83

Fuel Line

Fuel Pressure Inspection

NOTE

○This inspection can determine which trouble the DFI

system has, mechanical or electrical trouble.

○It is preferable to measure the fuel pressure while run-

ning the motorcycle just when trouble occurred in order

to know symptom well.

○Be sure the battery is fully charged.

• Remove the fuel tank (see Fuel Tank Removal).

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

moval in the Frame chapter).

• Be sure to place a piece of cloth around the fuel hose joint

and the delivery pipe.

• Insert a minus screw driver [A] into the slit on the joint lock

[B].

• Turn the driver to disconnect the joint lock.

• Remove the fuel hose [C].

WARNING

Be prepared for fuel spillage; any spilled fuel must

be completely wiped up immediately.

When the fuel hose is disconnected, fuel spills out

from the hose and the pipe because of residual

pressure. Cover the hose connection with a piece

of clean cloth to prevent fuel spillage.

• Install the fuel pressure gauge adapter [A] and fuel hoses

between the fuel pump outlet pipe [B] and the delivery

pipe [C].

• Connect the pressure gauge [D] to the fuel pressure

gauge adapter.

Special Tools - Oil Pressure Gauge, 5 kgf/cm²: 57001-125

Fuel Pressure Gauge Adapter: 57001-1593

Fuel Hose: 57001-1607

WARNING

Do not try to start the engine with the fuel hoses

disconnected.

• Temporarily, install the fuel tank [E].

Clamps [F]

FUEL SYSTEM (DFI) 3-85

Fuel Line

Fuel Flow Rate Inspection

NOTE

○Be sure the battery is fully charged.

WARNING

Gasoline is extremely flammable and can be explo-

sive under certain conditions. Make sure the area

is well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light. Do not smoke. Turn the ignition switch OFF.

Be prepared for fuel spillage; any spilled fuel must

be completely wiped up immediately.

• Turn the ignition switch, and engine stop switch OFF.

• Wait until the engine cools down.

• Prepare a plastic hose of the inside diameter 7.5 mm

(0.30 in.) and a measuring cylinder.

• Remove the fuel tank bolt (see Fuel Tank Removal).

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

tank.

WARNING

Be prepared for fuel spillage; any spilled fuel must

be completely wiped up immediately.

When the fuel hose is disconnected, fuel spills out

from the hose and the pipe because of residual

pressure. Cover the hose connection with a piece

of clean cloth to prevent fuel spillage.

• Connect the plastic hose [A] to the fuel pump outlet pipe.

• Secure the plastic hose with a clamp [B].

• Run the other side of the plastic hose into the measuring

cylinder [C].

WARNING

Wipe off spilled out fuel immediately.

Be sure to hold the measuring cylinder vertical.

• Temporarily install the fuel tank and close the fuel tank

cap.

• With the engine stopped, turn the ignition switch ON. The

fuel pump should operate for 3 seconds, and then should

stop. Repeat this several times until the plastic hose is

filled with fuel.

FUEL SYSTEM (DFI) 3-87

Fuel Pump

Fuel Pump Removal

CAUTION

Never drop the fuel pump, especially on a hard sur-

face. Such a shock to the pump can damage it.

WARNING

Gasoline is extremely flammable and can be explo-

sive under certain conditions. Make sure the area

is well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light. Do not smoke. Turn the ignition switch OFF.

Disconnect the battery (-) terminal.

To make fuel spillage minimum, draw the fuel out

from the fuel tank when the engine is cold. Be

prepared for fuel spillage; any spilled fuel must be

completely wiped up immediately.

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

available electric pump.

• Remove the fuel tank (see Fuel Tank Removal).

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

remains in the fuel tank and fuel pump. Plug the fuel pipe

of the fuel tank.

• Turn the fuel tank upside down.

• Remove:

Fuel Pump Bolts [A]

Fuel Pump [B] and gasket

• Discard the fuel pump gasket.

CAUTION

Do not pull the lead of the fuel pump. If they are

pulled, the lead terminals may be damaged.

Fuel Pump Installation

• Remove dirt or dust from the fuel pump [A] by lightly ap-

plying compressed air.

FUEL SYSTEM (DFI) 3-89

Fuel Pump

• Connect the hand tester (25 V DC) to the fuel pump con-

nector [A] with needle adapter set.

Special Tools - Hand Tester: 57001-1394

Needle Adapter Set: 57001-1457

○Measure the operating voltage with the engine stopped,

and with the connector joined.

• Turn the ignition switch ON.

○The tester needle should indicate battery voltage for 3

seconds, and then 0 V.

Pump Operating Voltage at Pump

Connections to Pump Connectors

Tester (+) → W/R Lead

Tester (-) → BK/Y Lead

Operating Voltage at Pump Connector

Standard:

Battery Voltage (12.8 V or more) for 3

seconds, and then 0 V.

If the reading stays on battery voltage, and never shows

0 V. Check the ECU and fuel pump relay.

If the voltage is in specification, but the pump doesn’t

work, replace the pump (see Fuel Pump Removal/Instal-

lation).

If there is still no battery voltage, check the pump relay

(see Relay Box section in the Electrical System chapter).

Pressure Regulator Removal

○The pressure regulator [A] is built into the fuel pump [B]

and cannot be removed.

Pump Screen, Fuel Filter Cleaning

○The fuel filter [A] is built into the pump and cannot be

cleaned or checked.

If the fuel filter is suspected of clogging or being damaged,

replace it with the fuel pump as a set.

3-90 FUEL SYSTEM (DFI)

Fuel Pump

Fuel Pump Circuit

1. ECU

2. Water-proof Joint C

3. Engine Stop Switch

4. Ignition Switch

5. Ignition Fuse 10 A

6. Fuel Pump Relay

7. Relay Box

8. Main Fuse 30 A

9. Battery

10. Frame Ground

11. Fuel Pump

FUEL SYSTEM (DFI) 3-91

Fuel Injectors

Removal/Installation

• Refer to the Throttle Body Assy Disassembly/Assembly.

Audible Inspection

• Start the engine.

• Apply the tip of a screwdriver [A] to the injector [B]. Put

the grip end onto your ear, and listen whether the injector

is clicking or not.

○A sound scope [C] can also be used.

• Do the same for the other injectors.

If all the injectors click at a regular intervals, the injec-

tors are good. The trouble may be related to the fuel line,

requiring fuel pressure inspection (see Fuel Pressure In-

spection).

○The click interval becomes shorter as the engine speed

rises.

If any injector(s) doesn’t click, the DFI circuit or the injector

is suspect. Perform “Fuel Injector Power Source Voltage

Inspection”, first.

Fuel Injector Power Source Voltage Inspection

• Remove the ECU (see ECU Removal).

○Do not disconnect the ECU connector.

• Connect a digital meter [A] to the ECU connector [B], us-

ing the needle adapter [C].

Special Tool - Needle Adapter Set: 57001-1457

○Measure the power source voltage with the engine

stopped, and with the connector joined.

• Turn the ignition switch ON.

Injector Power Source Voltage at ECU

Connections: Meter (+) → W/Y (terminal 16)

Meter (-) → Battery (-) Terminal

Service Limit: Battery Voltage (12.8 V or more)

If the meter doesn’t read as specified, check the following.

Main Fuse 30 A (see Fuse Inspection in the Electrical

System chapter)

Fuel Pump Relay (see Relay Circuit Inspection in the

Electrical System chapter)

Power Source Wiring (see wiring diagram below)

○To check the W/R leads between the injector connector

and the fuel pump relay, remove the fuel tank (see Fuel

Tank Removal) and the left side cover (see Side Cover

Removal in the Frame chapter).

If the power source voltage is normal, check the output

voltage of the injectors.

3-92 FUEL SYSTEM (DFI)

Fuel Injectors

Fuel Injector Output Voltage Inspection

• Turn the ignition switch OFF.

• Remove the ECU (see ECU Removal).

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

with the needle adapter set [C].

Special Tool - Needle Adapter Set: 57001-1457

Injector Output Voltage

Connections to Injector #1

Meter (+) → BL/R lead (terminal 42)

Meter (-) → Battery (-) Terminal

Connections to Injector #2

Meter (+) → BL/G lead (terminal 41)

Meter (-) → Battery (-) Terminal

• Turn the ignition switch ON.

Output Voltage at Injector Connector

Standard:

Battery Voltage (12.8 V or more)

If the output voltage is normal, perform “Injector Signal

Test”.

If the output voltage is out of the standard, turn the ignition

switch OFF, remove the fuel tank, and check the injector

wiring for continuity.

Injector Wiring Inspection

ECU Connector

Injector Connectors

Terminal 42

→ Injector #1 Terminal (BL/R)

Terminal 41

→ Injector #2 Terminal (BL/G)

If the wiring is good, inspect the resistance of the injectors

(see Injector Resistance Inspection).

• Remove the needle adapter.

• Apply silicone sealant to the seals of the ECU connector

for waterproofing.

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

Injector Signal Test

• Prepare two test light sets with male terminals as shown.

Rating of Bulb [A]: 12 V × 3 ∼ 3.4 W

Terminal Width [B]: 1.8 mm (0.071 in.)

Terminal Thickness [C]: 0.8 mm (0.031 in.)

CAUTION

Do not use larger terminals than specified above. A

larger terminal could damage the injector main har-

ness connector (female), leading to harness repair

or replacement.

Be sure to connect bulbs in series. The bulb works

as a current limiter to protect the solenoid in the

injector from excessive current.

FUEL SYSTEM (DFI) 3-93

Fuel Injectors

• Remove the fuel tank (see Fuel Tank Removal).

• Remove the air cleaner housing (see Air Cleaner Housing

Removal)

• Remove connectors for injector [A].

• Connect each test light set [B] to the injector sub harness

connector [C].

• Turn the ignition switch ON.

• While cranking the engine with the starter motor, watch

the test lights.

If the test lights flicker at regular intervals, the injector

circuit in the ECU, and the wiring are good. Perform the

“Injector Resistance Inspection”.

○Injector signals can be also confirmed by connecting the

hand tester (× 10 V AC) instead of the test light set to

the injector main harness (female) connector. Crank the

engine with the starter motor, and check to see if the hand

oscillates at regular intervals.

Special Tool - Hand Tester: 57001-1394

If the test light doesn’t flicker (or the tester needle doesn’t

oscillates), check the wiring and connectors again. If the

wiring is good, check the injector voltage. If the wiring is

good, inspect the ECU for its ground and power supply

(see ECU Power Supply Inspection).

Injector Resistance Inspection

• Remove the fuel tank (see Fuel Tank Removal).

• Remove the air cleaner housing (see Air Cleaner Housing

Removal).

• Disconnect the connector from the injector [A].

• Measure the injector resistance with the hand tester [B].

Special Tool - Hand Tester: 57001-1394

Injector Resistance

Connections to Injector

Meter (+)

Meter (-)

#1: W/R ←→ BL/R Terminal

#2: W/R ←→ BL/G Terminal

Standard:

About 11.7 ∼ 12.3 Ω at 20°C (68°F)

If the reading is out of the range, perform the “Injector Unit

Test”.

If the reading is normal, perform the “Injector Unit Test”

for confirmation.

3-94 FUEL SYSTEM (DFI)

Fuel Injectors

Injector Unit Test

• Use two leads [A] and the same test light set [B] as in

“Injector Signal Test”.

Rating of Bulb [C]: 12 V × (3 ∼ 3.4) W

12 V Battery [D]

CAUTION

Be sure to connect the bulb in series. The bulb

works as a current limiter to protect the solenoid

in the injector from excessive current.

• Connect the test light set to the injector [E] as shown.

• Open and connect [F] the end of the lead to the battery

(-) terminal repeatedly. The injector should click.

If the injector does not click, replace the injector.

If the injector clicks, check the wiring again. If the wiring

is good, replace the injector (may be clogged) or ECU.

Injector Fuel Line Inspection

• Remove:

Fuel Tank (see Fuel Tank Removal)

Left Center Fairing (see Center Fairing Removal in the

Frame chapter)

• Be sure to place a piece of cloth around the fuel hose joint

and the delivery pipe.

• Insert a minus screw driver [A] into the slit on the joint lock

[B].

• Turn the driver to disconnect the joint lock.

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

• Check the injector fuel line for leakage as follows.

○Connect a commercially available vacuum/pressure

pump [A] to the nipple of the delivery pipe [B] with a

high-pressure fuel hose [C] (both ends connected with

the clamps [D]) as shown.

Torque - Fuel Hose Clamp Screws: 1.5 N·m (0.15 kgf·m, 13

in·lb)

○Apply soap and water solution to the areas [E] as shown.

○Watching the pressure gauge, squeeze the pump lever

[F], and build up the pressure until the pressure reaches

the maximum pressure.

Injector Fuel Line Maximum Pressure

Standard:

333 kPa (3.4 kgf/cm², 48 psi)

CAUTION

During pressure testing, do not exceed the maxi-

mum pressure for which the system is designed.

FUEL SYSTEM (DFI) 3-95

Fuel Injectors

• Watch the gauge for at least 6 seconds.

If the pressure holds steady, the system is good.

If the pressure drops at once or if bubbles are found in

the area, the line is leaking. Replace the delivery pipe,

injectors and related parts.

○Repeat the leak test, and check the fuel line for no leak-

age.

• Install the pump outlet hose (see Fuel Tank Installation).

• Run the hoses correctly (see Cable, Wire, and Hose Rout-

ing section in the Appendix chapter).

Fuel Injector Circuit

1. ECU

2. Fuel Injectors

3. Water-proof Joint C

4. Engine Stop Switch

5. Ignition Switch

6. Ignition Fuse 10 A

7. Fuel Pump Relay (for fuel pump and injectors)

8. Relay Box

9. Main Fuse 30 A

10. Battery

11. Frame Ground

12. Joint Connector

FUEL SYSTEM (DFI) 3-97

Throttle Body Assy

Idle Speed Inspection

• Refer to the Idle Speed Inspection in the Periodic Main-

tenance chapter.

Engine Vacuum Synchronization Inspection/Ad-

justment

• Refer to the Engine Vacuum Synchronization Inspection

in the Periodic Maintenance chapter.

High Altitude Performance Adjustment

• Any modification is not necessary in this model since

the inlet air pressure sensor senses inlet air pressure

change due to high altitude and the ECU compensates

the change.

Throttle Body Assy Removal

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Turn the ignition

switch OFF. Disconnect the battery (-) cable ter-

minal. Do not smoke. Make sure the area is

well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

Be prepared for fuel spillage: any spilled fuel must

be completely wiped up immediately.

• Remove:

Air Cleaner Housing (see Air Cleaner Housing Removal)

Center Fairings (see Center Fairing Removal in the

Frame chapter)

• Disconnect:

Main Throttle Sensor Connector [A]

Fuel Hose Lower End [B]

Vacuum Hose [C]

• Disconnect:

#1, #2 Injector Connector [A]

Subthrottle Sensor Connector [B]

Subthrottle Sensor Actuator Connector [C]

• Loosen:

Holder and Duct Clamp Bolts

3-98 FUEL SYSTEM (DFI)

Throttle Body Assy

• Loosen the locknut and screw in the throttle cable adjuster

fully to give the cables plenty of play.

• Remove the right switch housing and take out the acceler-

ator cable upper end [A] and the decelerator cable upper

end [B].

• Remove the throttle cable lower ends [A] from the throttle

pulley.

• After removing the throttle body assy, stuff pieces of lint

-free, clean cloth into the throttle body holders.

CAUTION

If dirt gets into the engine, excessive engine wear

and possible engine damage will occur.

Throttle Body Assy Installation

• Install the holder clamp bolts [A] in the direction shown

with each bolt heads [B], facing outwards.

• Install the air cleaner duct clamp screws [A] so that their

screw heads [B] face the right.

• Run the vacuum hose (see Cable, Wire, and Hose Rout-

ing section in the Appendix chapter).

FUEL SYSTEM (DFI) 3-99

Throttle Body Assy

• Fit the accelerator cable end [A] and the decelerator cable

end [B] into the throttle pulley.

• Check fuel leakage from the throttle body assy.

WARNING

Fuel spilled from the carburetors is hazardous.

• Apply a thin coating of grease to the throttle cable upper

ends.

• Install the upper ends of the throttle cables in the grip.

• Fit the projection [A] of the right switch housing into the

hole [B] of the handlebar.

• Turn the throttle grip and make sure that the throttle valves

move smoothly and return by spring force.

• Check the throttle grip free play (see Throttle Control Sys-

tem Inspection in the Periodic Maintenance chapter).

WARNING

Operation with an incorrectly routed cable could re-

sult in an unsafe riding condition.

• Adjust:

Throttle Grip Free Play (see Throttle Control System In-

spection in the Periodic Maintenance chapter)

Idle Speed (see Idle Speed Adjustment in the Periodic

Maintenance chapter)

Throttle Body Assy Disassembly

CAUTION

Do not remove, disassemble or adjust the main

throttle sensor [A], subthrottle sensor [B], sub-

throttle valve actuator [C], throttle link mechanism

[D] and throttle body assy [E], because they are

adjusted or set at the manufacturer. Adjustment

of these parts could result in poor performance,

requiring replacement of the throttle body assy.

• Remove the throttle body assy (see Throttle Body Assy

Removal).

CAUTION

Never drop the throttle body assy , especially on a

hard surface. Such a shock to the body assy can

damage it.

3-100 FUEL SYSTEM (DFI)

Throttle Body Assy

• Remove:

Screws [A]

Delivery Pipe [B]

Fuel Injectors [C]

Throttle Body Assy Assembly

○Replace the O-rings [A] and seals [B] with the new ones.

• Before assembling, blow away dirt or dust from the throttle

body and delivery pipe by applying compressed air.

• Apply engine oil to the new O-rings of each injector [C],

insert them into the delivery pipe and confirm whether the

injectors turn smoothly or not.

• Install the injectors along with the delivery pipe assy into

the throttle bodies.

• Install the throttle body assy (see Throttle Body Assy In-

stallation).

FUEL SYSTEM (DFI) 3-101

Air Cleaner

Air Cleaner Element Removal/Installation

• Refer to the Air Cleaner Element Replacement in the Pe-

riodic Maintenance chapter.

Air Cleaner Element Inspection

• Remove the air cleaner element (see Air Cleaner Element

Replacement in the Periodic Maintenance chapter).

• Visually check the element [A] for tears or breaks.

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

ment.

Air Cleaner Oil Draining

A drain hose is connected to the bottom of the air cleaner

to drain water or oil accumulated in the cleaner part.

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

moval in the Frame chapter).

• Visually check the drain hose [A] if the water or oil accu-

mulates.

If any water or oil accumulates in the hose, remove the

plug [B] from the drain hose and drain it.

WARNING

Be sure to reinstall the plug in the drain hose after

draining. Oil on tires will make them slippery and

can cause an accident and injury.

Air Cleaner Housing Removal

• Remove:

Fuel Tank (see Fuel Tank Removal)

Hose (Disconnect) [A]

Inlet Air Temperature Sensor Connector [B]

Screws [C]

Cover [D]

• Disconnect the breather hose [A] on the upper crankcase.

3-102 FUEL SYSTEM (DFI)

Air Cleaner

• Unscrew the bolts [A] and remove the air cleaner housing

[B].

Air Cleaner Housing Installation

• Install the clamp on the hose [A] so that its pinch heads

[B] face the right.

• Install the clamp on the breather hose [C] so that its pinch

heads [D] face the front.

FUEL SYSTEM (DFI) 3-103

Fuel Tank

Fuel Tank Removal

WARNING

Gasoline is extremely flammable and can be explo-

sive under certain conditions. Make sure the area

is well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light. Do not smoke. Turn the ignition switch OFF.

Be prepared for fuel spillage; any spilled fuel must

be completely wiped up immediately.

• Turn the ignition switch and engine stop switch OFF.

• Wait until the engine cools down.

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

tank.

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

pressure in the tank. This makes fuel spillage less.

• Remove:

Seat (see Seat Removal in the Frame chapter)

Side Covers (see Side Cover Removal in the Frame

chapter)

Fuel Tank Bolts [A]

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

available pump [A].

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

to insert the hose smoothly.

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

draw the fuel out.

Front [D]

WARNING

The fuel could not be removed completely from the

fuel tank. Be careful for remained fuel spillage.

3-104 FUEL SYSTEM (DFI)

Fuel Tank

• Disconnect the fuel pump lead connector [A] and the tube

[B].

• Remove:

Fuel Return Hose [C] (Red, California Model)

Fuel Tank Breather Hose [D] (Blue, California Model)

• 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 out [D] of the outlet pipe.

CAUTION

When removing the fuel hose joint, do not apply

strong force to the outlet pipe on the fuel pump. The

pipe made from resin could be damaged.

WARNING

Be prepared for fuel spillage; any spilled fuel must

be completely wiped up immediately.

When the fuel hose is disconnected, fuel spills out

from the hose and the pipe because of residual

pressure . Cover the hose connection with a piece

of clean cloth to prevent fuel spillage.

FUEL SYSTEM (DFI) 3-105

Fuel Tank

• Close the fuel tank cap.

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

○Do not apply the load to the fuel pump outlet portion [A]

especially the outlet pipe made from resin.

• For California model, note the following.

CAUTION

For California model, if gasoline, solvent, water or

any other liquid enters the canister, the canister’s

vapor absorbing capacity is greatly reduced. If the

canister does become contaminated, replace it with

a new one.

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

fuel spilling before fuel tank removal.

WARNING

For California model, be careful not to spill the

gasoline through the return hose. Spilled fuel is

hazardous.

If liquid or gasoline flows into the breather hose, remove

the hose and blow it clean with compressed air.

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

remains in the fuel tank and fuel pump.

WARNING

Store the fuel tank in an area which is well

-ventilated and free from any source of flame

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

fuel tank on a flat surface and plug the fuel pipes

to prevent fuel leakage.

Fuel Tank Installation

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

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

Routing in the Appendix chapter).

• Check that the rubber dampers [A] are on the frame and

the fuel tank.

• Check that the dampers [A] are in place on the fuel tank

as well.

If the dampers are damaged or deteriorated, replace

them.

3-106 FUEL SYSTEM (DFI)

Fuel Tank

• Be sure that the trim seal [A] is on the fuel tank.

Reverse Side of Fuel Tank [B]

Side Cover [C]

Approx. 17 mm (0.67 in.) [D]

Front [E]

• For California model, note the following.

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

canister, hold the separator perpendicular to the ground.

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

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

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

kinked.

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

vapor will not be obstructed.

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

pipe until the hose joint clicks.

CAUTION

When installing the fuel hose joint, do not apply

strong force to the outlet pipe on the fuel pump. The

pipe made from resin could be damaged.

• Push [C] the joint lock [D].

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

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

come off.

WARNING

Make sure the hose joint is installed correctly on the

delivery pipe by sliding the joint, or the fuel could

leak.

If it comes off, reinstall the hose joint.

• Connect the fuel pump and the fuel level sensor connec-

tors and the battery (-) cable terminal.

Fuel Tank and Cap Inspection

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

damage.

Replace the gasket if it is damaged.

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

pipe [C] in the tank is not clogged. check the tank cap

breather also.

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

blow the breather free with compressed air.

CAUTION

Do not apply compressed air to the air vent holes

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

clogging of the labyrinth in the cap.

3-108 FUEL SYSTEM (DFI)

Evaporative Emission Control System (California Model)

The Evaporative Emission Control System routes fuel va-

pors from the fuel system into the running engine or stores

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

though no adjustments are required, a thorough visual in-

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

riodic Maintenance Chart.

Parts Removal/Installation

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Turn the ignition

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

well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

CAUTION

If gasoline, solvent, water or any other liquid enters

the canister, the canister’s vapor absorbing capac-

ity is greatly reduced. If the canister does become

contaminated, replace it with a new one.

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

canister, hold the separator perpendicular to the ground.

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

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

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

kinked.

Hose Inspection

• Refer to the Evaporative Emission Control System In-

spection in the Periodic Maintenance chapter.

Separator Inspection

• Refer to the Evaporative Emission Control System In-

spection in the Periodic Maintenance chapter.

Separator [A]

FUEL SYSTEM (DFI) 3-109

Evaporative Emission Control System (California Model)

Separator Operation Test

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Turn the ignition

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

well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

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

rator on the motorcycle.

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

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

separator [B] through the hose fitting.

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

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

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

• Start the engine, and let it idle.

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

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

with a new one.

Canister Inspection

• Refer to the Evaporative Emission Control System In-

spection in the Periodic Maintenance chapter.

NOTE

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

motorcycle’s life without any maintenance if it is used

under normal conditions.

4-2 COOLING SYSTEM

Exploded View

COOLING SYSTEM 4-3

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Radiator Hose Clamp Screws

2.0

0.20

17 in·lb

2

Water Pump Impeller Bolt

9.8

1.0

87 in·lb

3

Water Pump Cover Bolts

9.8

1.0

87 in·lb

4

Water Pump Drain Bolt

7.0

0.70

62 in·lb

5

Thermostat Housing Bolts

9.8

1.0

87 in·lb

6

Water Temperature Sensor

12

1.2

106 in·lb

7

Baffle Plate Bolts

5.9

0.60

52 in·lb

8. Reserve Tank

9. Baffle Plate

10. Cylinder Head Cover

11. Thermostat

12. Water Pump Impeller

13. Mechanical Seal

G: Apply grease.

HG: Apply high-temperature grease.

R: Replacement Parts

4-4 COOLING SYSTEM

Coolant Flow Chart

COOLING SYSTEM 4-7

Special Tools

Bearing Driver Set:

Oil Seal Driver:

57001-1129

57001-1660

4-8 COOLING SYSTEM

Coolant

Coolant Deterioration Inspection

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

moval in the Frame chapter).

• Visually inspect the coolant [A] in the reserve tank.

If whitish cotton-like wafts are observed, aluminum parts

in the cooling system are corroded. If the coolant is

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

the cooling system.

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

cooling system leak. It may be caused by exhaust gas

leaking into the cooling system.

Coolant Level Inspection

• Refer to the Coolant Level in the Periodic Maintenance

chapter.

Coolant Draining

• Refer to the Coolant Change in the Periodic Maintenance

chapter.

Coolant Filling

• Refer to the Coolant Change in the Periodic Maintenance

chapter.

Pressure Testing

• Remove the reserve tank (see Coolant Change in the Pe-

riodic Maintenance chapter).

• Remove the radiator cap, and install a cooling system

pressure tester [A] on the filler neck [B].

NOTE

○Wet the cap sealing surfaces with water or coolant to

prevent pressure leaks.

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

sure reaches 141.7 kPa (1.45 kgf/cm², 20.5 psi).

CAUTION

During pressure testing, do not exceed the pres-

sure for which the system is designed. The maxi-

mum pressure is 141.7 kPa (1.45 kgf/cm², 20.5 psi).

• Watch the gauge for at least 6 seconds.

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

If the pressure drops and no external source is found,

check for internal leaks. Droplets in the engine oil indicate

internal leakage. Check the cylinder head gasket and the

water pump.

• Remove the pressure tester, replenish the coolant, and

install the radiator cap.

4-10 COOLING SYSTEM

Water Pump

Water Pump Removal

• Drain the coolant (see Coolant Change in the Periodic

Maintenance chapter).

• Loosen the clamp and remove the radiator hose [A] from

the water pump cover [B].

• Remove the water pump cover bolts [C].

• Shift the transmission into 1st gear.

• While applying the rear brake, remove the water pump

impeller bolt [A].

• Remove:

Impeller [B]

Water Pump Housing [C]

Water Pump Installation

• When installing the water pump impeller bolt, shift the

transmission into 1st gear and apply the rear brake.

• Replace the O-rings [A] on the water pump housing with

new ones and apply grease them.

• Apply high-temperature grease to the lips of the water

pump housing oil seal [B].

• Be sure that the dowel pin [A] is in position.

• Install the water pump housing.

• Tighten:

Torque - Water Pump Impeller Bolt: 9.8 N·m (1.0 kgf·m, 87

in·lb)

• Replace the O-ring [A] on the water pump cover with a

new one and grease it.

COOLING SYSTEM 4-11

Water Pump

• Install the water pump cover, being careful of the two

dowel pins [A].

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

in·lb)

Mechanical Seal Inspection

• Visually inspect the mechanical seal.

If any one of the parts is damaged, replace the mechani-

cal seal as a unit.

○The sealing seat and rubber seal may be removed easily

by hand.

Impeller Sealing Seat Surface [A]

Rubber Seal [B]

Mechanical Seal Diaphragm [C]

Water Pump Housing Disassembly

CAUTION

Be careful not to damage the sealing surface of the

mechanical seal.

• Take the oil seal [A] out of the housing [B] with a hook [C].

• Press the mechanical seal [A] out of the housing with a

bearing driver [B].

Special Tool - Bearing Driver Set: 57001-1129

Water Pump Housing Assembly

• Apply high-temperature grease [A] to the new oil seal [B].

• Press the oil seal into the housing with a bearing driver so

that the seal surface is flush [C] with the end of the hole.

• Press the new mechanical seal into the housing with the

oil seal driver [D] until its flange [E] touches the surface

[F] of the housing.

Special Tool - Oil Seal Driver: 57001-1660

4-12 COOLING SYSTEM

Water Pump

Impeller Assembly

• Clean the sliding surface of the mechanical seal with a

high-flash point solvent, and apply a little coolant to the

sliding surface to give the mechanical seal initial lubrica-

tion.

• Apply coolant to the surfaces of the rubber seal [A] and

sealing seat [B], and install the rubber seal and sealing

seat into the impeller by pressing them by hand until the

seat stops at the bottom of the hole.

Pump Impeller Inspection

• Visually check the impeller [A].

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

replace the impeller (see Water Pump Removal).

COOLING SYSTEM 4-13

Radiator

Radiator and Radiator Fan Removal

• Drain the coolant (see Coolant Change in the Periodic

Maintenance chapter).

• Remove:

Center Fairings (see Center Fairing in the Frame chap-

ter)

Reserve Tank (see Coolant Change in the Periodic Main-

tenance chapter)

Radiator Fan Motor Connector [A] (Disconnect)

Radiator Hose Clamp Screw [B] (Loosen)

• Loosen:

Radiator Hose Clamp Screw [A]

• Remove:

Radiator Bolt [B]

• Pull [A] the radiator [B] toward the left, noting the baffle

plate [C] on the cylinder head cover.

CAUTION

Do not touch the radiator core. This could damage

the radiator fins, resulting in loss of cooling effi-

ciency.

• If necessary, remove:

Radiator Fan Mounting Bolts [A]

Radiator Fan [B]

4-14 COOLING SYSTEM

Radiator

Radiator and Radiator Fan Installation

• Install the radiator [A] to the frame.

○Align [B] the projection on the frame with the hole on the

radiator.

○Tighten the radiator bolt [C].

○Note the baffle plate on the cylinder head cover when

installing the radiator.

○Position the radiator hose clamp screws [D] as shown.

Radiator Inspection

• Check the radiator core.

If there are obstructions to air flow, remove them.

If the corrugated fins [A] are deformed, carefully

straighten them.

If the air passages of the radiator core are blocked more

than 20% by unremovable obstructions or irreparably de-

formed fins, replace the radiator with a new one.

CAUTION

When cleaning the radiator with steam cleaner, be

careful of the following to prevent radiator damage:

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

ft) [B] from the radiator core.

Hold the steam gun perpendicular [C] (not oblique

[D]) to the core surface.

Run the steam gun, following the core fin direction.

Radiator Cap Inspection

• Remove:

Reserve Tank (see Coolant Change in the Periodic Main-

tenance chapter)

Radiator Cap

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

seals and valve spring [C].

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

with a new one.

COOLING SYSTEM 4-15

Radiator

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

NOTE

○Wet the cap sealing surfaces with water or coolant to

prevent pressure leaks.

• Watching the pressure gauge, pump the pressure tester

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

gauge needle flicks downward. Stop pumping and mea-

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

the specified range in the table below and the gauge hand

must remain within the same range at least 6 seconds.

Radiator Cap Relief Pressure

Standard:

112.3 ∼ 141.7 kPa (1.15 ∼ 1.45 kgf/cm², 16.3

∼ 20.5 psi)

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

too much pressure, replace it with a new one.

Radiator Filler Neck Inspection

• Remove the reserve tank (see Coolant Change in the Pe-

riodic Maintenance chapter).

• Remove the radiator cap.

• Check the radiator filler neck for signs of damage.

• Check the condition of the top and bottom sealing seats

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

the radiator cap to function properly.

4-16 COOLING SYSTEM

Thermostat

Thermostat Removal

• Drain the coolant (see Coolant Change in the Periodic

Maintenance chapter).

• Remove:

Left Center Fairing (see Center Fairing Removal in the

Frame chapter)

Thermostat Hosing Bolts [A]

Thermostat Hosing [B]

• Pull the thermostat [A] out of the cylinder head.

Thermostat Installation

• Install the thermostat [A] in the cylinder head so that the

air bleeder hole [B] is on top.

• Install a new O-ring into the housing and apply grease it.

• Tighten:

Torque - Thermostat Hosing Bolts: 9.8 N·m (1.0 kgf·m, 87

in·lb)

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

Periodic Maintenance chapter).

Thermostat Inspection

• Remove the thermostat, and inspect the thermostat valve

[A] at room temperature.

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

one.

COOLING SYSTEM 4-17

Thermostat

• To check valve opening temperature, suspend the ther-

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

ture of the water.

○The thermostat must be completely submerged and must

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

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

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

It must not touch the container, either.

If the measurement is out of the specified range, replace

the thermostat with a new one.

Thermostat Valve Opening Temperature

80.5 ∼ 83.5°C (177 ∼ 182°F)

5-4 ENGINE TOP END

Exploded View

ENGINE TOP END 5-5

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Air Suction Valve Cover Bolts

9.8

1.0

87 in·lb

2

Cylinder Head Cover Bolts

9.8

1.0

87 in·lb

3

Camshaft Cap Bolts

12

1.2

106 in·lb

S

Cylinder Head Bolts (M10 New Bolts)

54

5.5

40

MO, S

4

Cylinder Head Bolts (M10 Used Bolts)

49

5.0

36

MO, S

5

Cylinder Head Bolts (M6)

12

1.2

106 in·lb

S

6

Throttle Body Holder Bolts

12

1.2

106 in·lb

7

Rear Camshaft Chain Guide Bolts

20

2.0

15

L

8

Camshaft Chain Tensioner Mounting Bolts

9.8

1.0

87 in·lb

9

Camshaft Chain Tensioner Cap Bolt

20

2.0

15

10

Spark Plugs

15

1.5

11

11

Camshaft Sprocket Bolts

15

1.5

11

L

12

Baffle Plate Bolts

5.9

0.60

52 in·lb

L: Apply a non-permanent locking agent.

M: Apply molybdenum disulfide grease.

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.

SS: Apply silicone sealant.

5-6 ENGINE TOP END

Exploded View

ENGINE TOP END 5-7

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Cylinder Bolt (M8)

27.5

2.8

20

MO,S

2

Cylinder Nut (M10)

49

5.0

36

MO,S

3

Cylinder Bolts (M6)

12

1.2

106 in·lb

S

4

Exhaust Pipe Manifold Holder Nuts

17

1.7

12

5

Muffler Body Mounting Bolt (Front)

20

2.0

15

6

Muffler Body Mounting Bolt (Rear)

20

2.0

15

7. "R" marked side faces up.

8. "RN" marked side faces up.

9. Hollow mark faces forward.

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.

5-8 ENGINE TOP END

Exhaust System

Exhaust System EX650A6F/EX650B6F

Full: Full Power

H: Honeycomb Type Catalyst

Silencer [A] with Hole [B] for Oxygen Sensor [C]

ENGINE TOP END 5-9

Exhaust System

Manifold Mark Position [A]

Silencer Mark Position [A]

ENGINE TOP END 5-11

Specifications

Item

Standard

Service Limit

Valve Spring Free Length:

Exhaust

41.91 mm (1.650 in.)

40.3 mm (1.587 in.)

Inlet

41.91 mm (1.650 in.)

40.3 mm (1.587 in.)

Cylinder, Pistons

Cylinder Inside Diameter

82.994 ∼ 83.006 mm

83.10 mm (3.2716 in.)

(3.2675 ∼ 3.2679 in.)

Piston Diameter

82.969 ∼ 82.984 mm

82.82 mm (3.2606 in.)

(3.2665 ∼ 3.2671 in.)

Piston/Cylinder Clearance

0.010 ∼ 0.037 mm (0.0004 ∼ 0.0015 in.)

- - -

Piston Ring/Groove Clearance:

Top

0.03 ∼ 0.07 mm (0.0012 ∼ 0.0028 in.)

0.17 mm (0.0067 in.)

Second

0.02 ∼ 0.06 mm (0.0008 ∼ 0.0024 in.)

0.16 mm (0.0063 in.)

Piston Ring Groove Width:

Top

0.92 ∼ 0.94 mm (0.0362 ∼ 0.0370 in.)

1.02 mm (0.040 in.)

Second

1.01 ∼ 1.03 mm (0.0398 ∼ 0.0406 in.)

1.11 mm (0.044 in.)

Piston Ring Thickness:

Top

0.87 ∼ 0.89 mm (0.0342 ∼ 0.0350 in.)

0.80 mm (0.031 in.)

Second

0.97 ∼ 0.99 mm (0.0382 ∼ 0.0390 in.)

0.90 mm (0.035 in.)

Piston Ring End Gap:

Top

0.25 ∼ 0.40 mm (0.0098 ∼ 0.0157 in.)

0.7 mm (0.028 in.)

Second

0.40 ∼ 0.55 mm (0.0157 ∼ 0.0217 in.)

0.8 mm (0.031 in.)

5-12 ENGINE TOP END

Special Tools and Sealant

Compression Gauge, 20 kgf/cm²:

Valve Seat Cutter, 60° -

30:

57001-221

57001-1123

Valve Spring Compressor Assembly:

Valve Seat Cutter Holder Bar:

57001-241

57001-1128

Valve Seat Cutter, 45° -

35:

Valve Seat Cutter, 45° -

30:

57001-1116

57001-1187

Valve Seat Cutter, 32° -

30:

Valve Seat Cutter, 55° -

35:

57001-1120

57001-1247

Valve Seat Cutter, 32° -

35:

Valve Spring Compressor Adapter,

21:

57001-1121

57001-1272

ENGINE TOP END 5-13

Special Tools and Sealant

Compression Gauge Adapter, M10 × 1.0:

Piston Pin Puller:

57001-1317

57001-1568

Valve Seat Cutter Holder,

4.5:

Piston Pin Puller Adapter C:

57001-1330

57001-1657

Valve Guide Arbor,

4.5:

Kawasaki Bond (Silicone Sealant):

57001-1331

92104-0004

Valve Guide Reamer,

4.5:

57001-1333

5-14 ENGINE TOP END

Clean Air System

Air Suction Valve Removal

• Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System

(DFI) chapter)

Air Cleaner Housing (see Air Cleaner Housing Removal

in the Fuel System (DFI) chapter)

Air Switching Valve with Hoses (see Air Switching Valve

Removal)

Air Suction Valve Cover Bolts [A] and Clamp

Air Suction Valve Cover [B]

Air Suction Valve [C]

Air Suction Valve Installation

• Install the air suction valve [A] so that its side where stop-

per is fixed with the screws [B] faces the front [C] .

• Tighten:

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

87 in·lb)

Air Suction Valve Inspection

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

moval).

• Visually inspect the reeds for cracks, folds, warps, heat

damage or other damage.

If there is any doubt as to the condition of the reeds [A],

replace the air suction valve as an assembly.

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

grooves, scratches, any signs of separation from the

holder or heat damage.

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

areas, replace the air suction valve as an assembly.

• If any carbon or other foreign particles have accumulated

between the reed and the reed contact area, wash the

valve assembly clean with a high-flash point solvent.

CAUTION

Do not scrape off the deposits with a scraper as this

could damage the rubber, requiring replacement of

the suction valve assembly.

Air Switching Valve Removal

• Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System

(DFI) chapter)

Air Switching Valve Connector [A] (Disconnect)

Air Switching Valve [B]

Air Switching Valve Installation

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

Routing section in the Appendix chapter).

5-16 ENGINE TOP END

Cylinder Head Cover

Cylinder Head Cover Removal

• Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System

(DFI) chapter)

Air Cleaner Housing (see Air Cleaner Housing Removal

in the Fuel System (DFI) chapter)

Air Suction Valve Cover [A] with Hose [B]

Stick Coils [C]

Baffle Plate [D]

Throttle Cables [E]

Clutch Cable Holder [F] with Bolt [G]

Cylinder Head Cover Bolts [H]

Cylinder Head Cover [I]

EX650B Models

• Remove the radiator with radiator hoses and move it

forward (see Radiator and Radiator Fan Removal in the

Cooling System chapter).

Cylinder Head Cover Installation

• Replace the head cover gasket [A] with a new one.

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

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

• Install:

Dowel Pins [C]

Plug Hole Gaskets [D]

• Install:

Washers [A]

Cylinder Head Cover Bolts [B]

○Install the washers with metal side [C] faces upward.

• Tighten:

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

in·lb)

ENGINE TOP END 5-17

Cylinder Head Cover

• Install the baffle plate [A].

• Tighten:

Torque - Baffle Plate Bolts [B]: 5.9 N·m (0.60 kgf·m, 52 in·lb)

5-18 ENGINE TOP END

Camshaft Chain Tensioner

Camshaft Chain Tensioner Removal

CAUTION

This is a non-return type camshaft chain tensioner.

The push rod does not return to its original position

once it moves out to take up camshaft chain slack.

Observe all the rules listed below:

When removing the tensioner, do not take out the

mounting bolts only halfway. Retightening the

mounting bolts from this position could damage

the tensioner and the camshaft chain. Once the

bolts are loosened, the tensioner must be removed

and reset as described in “Camshaft Chain Ten-

sioner Installation.”

Do not turn over the crankshaft while the tensioner

is removed. This could upset the camshaft chain

timing, and damage the valves.

• Remove:

Right Center Fairing (see Center Fairing Removal in the

Frame chapter)

Cap Bolt [A]

Washer [B]

Spring [C]

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

chain tensioner.

Camshaft Chain Tensioner Installation

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

the tensioner [C].

• Install the tensioner so that the stopper faces upward.

• Tighten the tensioner mounting bolts [A].

Torque - Camshaft Chain Tensioner Mounting Bolts:

9.8

N·m (1.0 kgf·m, 87 in·lb)

• Install the spring and washer.

• Tighten the cap bolt [B].

Torque - Camshaft Chain Tensioner Cap Bolt: 20 N·m (2.0

kgf·m, 15 ft·lb)

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

sioner to expand and recheck the camshaft chain timing.

ENGINE TOP END 5-19

Camshaft, Camshaft Chain

Camshaft Removal

• Remove:

Cylinder Head Cover (see Cylinder Head Cover Re-

moval)

Right Lower Fairing (see Lower Fairing Removal in the

Frame chapter)

• Position the crankshaft as follows.

○Remove the upper [A] and lower [B] caps on the clutch

cover.

○Using a wrench on the crankshaft rotation bolt, turn the

crankshaft clockwise until the 2/T mark line [A] on the tim-

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

upper hole [C] in the clutch cover.

• Remove:

Camshaft Chain Tensioner (see Camshaft Chain Ten-

sioner Removal)

Camshaft Cap Bolts [A]

Camshaft Caps [B]

Camshafts [C]

CAUTION

The crankshaft may be turned while the camshafts

are removed. Always pull the chain taut while turn-

ing the crankshaft. This avoids kinking the chain

on the lower (crankshaft) sprocket. A kinked chain

could damage both the chain and the sprocket.

Camshaft Installation

• Be sure to install the following parts.

Plug Hole Gaskets [A]

Dowel Pins [B]

5-20 ENGINE TOP END

Camshaft, Camshaft Chain

• Apply molybdenum disulfide oil solution to all cams [A]

journals [B] and thrust blocks [C] with × marks.

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

denum disulfide grease to the cam surfaces.

NOTE

○The exhaust camshaft has a 2 412 EX mark [D] and the

inlet camshaft has a 2 412 IN mark [E]. Be careful not

to mix up these shafts.

• Position the crankshaft as follows.

• Pull the tension side (exhaust side) of the chain taut to

install the chain.

• Engage the camshaft chain with the camshaft sprockets

so that the timing marks on the sprockets are positioned

as shown.

○Using a wrench on the crankshaft rotation bolt, turn the

crankshaft clockwise until the 2/T mark line [A] on the tim-

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

upper hole [C] in the clutch cover.

• If the clutch cover is removed, perform the next proce-

dure.

○Using a wrench on the crankshaft rotation bolt, turn the

crankshaft clockwise until the 1/T mark line [A] on the

timing rotor is aligned with the wating surface [B] of the

crankcase halves.

ENGINE TOP END 5-21

Camshaft, Camshaft Chain

○The timing marks must be aligned with the cylinder head

upper surface [C].

EX Mark [D] (Between #1 Pin and #2 Pin)

IN Mark [E] (Between #31 Pin and #32 Pin)

#1 Pin [F]

#2 Pin [G]

#31 Pin [H]

#32 Pin [J]

• Install the camshaft cap, while pushing the camshaft

chain, tighten all camshaft bolts and chain guide bolts.

NOTE

○The exhaust cap has a “EX” mark [A] and the inlet cap

has a “IN” mark [B]. Be careful not to mix up these caps.

○First tighten all the camshaft cap bolts evenly to seat the

camshaft in place, then tighten all bolts following the spec-

ified tightening sequence.

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

106 in·lb)

• Install:

Camshaft Chain Tensioner (see Camshaft Chain Ten-

sioner Installation)

Cylinder Head Cover (see Cylinder Head Cover Instal-

lation)

Right Lower Fairing (see Lower Fairing Removal in the

Frame chapter)

5-22 ENGINE TOP END

Camshaft, Camshaft Chain

Camshaft and Sprocket Assembly

○The inlet and exhaust sprockets are identical.

• Install the sprockets so that the marked (“IN” and “EX”)

side faces to the right side.

CAUTION

Inlet sprocket must use “IN” marked bolts holes [A].

Exhaust sprocket must use “EX” marked bolts

holes [B].

• Apply a non-permanent locking agent to the camshaft

sprockets bolts and tighten them.

Torque - Camshaft Sprockets Bolts: 15 N·m (1.5 kgf·m, 11

ft·lb)

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

molybdenum disulfide grease to the cam surfaces.

Camshaft, Camshaft Cap Wear

• Remove:

Camshaft Caps (see Camshaft Removal)

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

on each journal parallel to the camshaft installed in the

correct position.

• Measure each clearance between the camshaft journal

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

• Tighten:

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

NOTE

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

tween the journal and camshaft cap.

Camshaft Journal, Camshaft Cap Clearance

Standard:

0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in.)

Service Limit: 0.16 mm (0.0063 in.)

If any clearance exceeds the service limit, measure the

diameter of each camshaft journal with a micrometer.

Camshaft Journal Diameter

Standard:

23.950 ∼ 23.972 mm (0.9429 ∼ 0.9438 in.)

Service Limit: 23.92 mm (0.942 in.)

If the camshaft journal diameter is less than the service

limit, replace the camshaft with a new one and measure

the clearance again.

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

cylinder head unit.

ENGINE TOP END 5-23

Camshaft, Camshaft Chain

Camshaft Runout

• Remove the camshaft (see Camshaft Removal).

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

blocks.

• Measure runout with a dial gauge at the specified place

as shown.

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

Camshaft Runout

Standard:

TIR 0.02 mm (0.0008 in.) or less

Service Limit: TIR 0.1 mm (0.004 in.)

Cam Wear

• Remove the camshaft (see Camshaft Removal).

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

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

the camshaft.

Cam Height

Standard:

Exhaust

35.843 ∼ 35.957 mm (1.4111 ∼ 1.4156 in.)

Inlet

36.543 ∼ 36.657 mm (1.4387 ∼ 1.4432 in.)

Service Limit:

Exhaust

35.74 mm (1.4071 in.)

Inlet

36.44 mm (1.4346 in.)

Camshaft Chain Removal

• Split the crankcase (see Crankcase Splitting in the Crank-

shaft/Transmission chapter).

• Remove the camshaft chain [A] from the crankshaft

sprocket.

5-24 ENGINE TOP END

Cylinder Head

Cylinder Compression Measurement

NOTE

○Use the battery which is fully charged.

• Warm up the engine thoroughly.

• Stop the engine.

• Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System

(DFI) chapter)

Air Cleaner Housing (see Air Cleaner Housing Removal

in the Fuel System (DFI) chapter)

Stick Coils (see Stick Coil (Ignition Coil together with

Spark Plug Cap) Removal in the Electrical System chap-

ter)

Spark Plugs (see Spark Plug Replacement in the Peri-

odic Maintenance chapter)

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

NOTE

○Reconnect the connectors of the air switching valve

lead and the inlet air temperature sensor lead. When

the ignition switch is turned ON with the above connec-

tors disconnected, the service codes (13, 64) are stores

in the ECU.

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

into the spark plug hole.

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

tle fully open until the compression gauge stops rising; the

compression is the highest reading obtainable.

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

Compression Gauge Adapter, M10 × 1.0:

57001-1317

Cylinder Compression

Usable Range:

961 ∼ 1 471 kPa (9.8 ∼ 15.0 kgf/cm², 139

∼ 213 psi) at 400 r/min (rpm)

• Repeat the measurement for the other cylinders.

• Install the spark plugs.

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

ENGINE TOP END 5-25

Cylinder Head

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

able range.

Problem

Diagnosis

Remedy (Action)

Cylinder compression

Carbon accumulation on piston and in

is higher than usable

combustion chamber possibly due to

Remove the carbon deposits

range

damaged valve stem oil seal and/or

and replace damaged parts if

damaged piston oil rings (This may be

necessary.

indicated by white exhaust smoke).

Incorrect cylinder head gasket

Replace the gasket with a standard

thickness

part.

Cylinder compression

Replace damaged gasket and

Gas leakage around cylinder head

is lower than usable

check cylinder head warp.

range

Bad condition of valve seating

Repair if necessary.

Incorrect valve clearance

Adjust the valve clearance.

Incorrect piston/cylinder clearance

Replace the piston and/or cylinder.

Inspect the cylinder and

Piston seizure

replace/repair the cylinder and/or

piston as necessary.

Bad condition of piston ring and/or

Replace the piston and/or the

piston ring grooves

piston rings.

Cylinder Head Removal

• Remove:

Exhaust Pipes (see Exhaust Pipe Removal)

Cylinder Head Cover (see Cylinder Head Cover Re-

moval)

Camshafts (see Camshaft Removal)

Throttle Body Assy (see Throttle Body Assy Removal in

the Fuel System (DFI) chapter)

Throttle Body Holder

Water Hose

Water Temperature Sensor Connector

Front Camshaft Chain Guide

5-26 ENGINE TOP END

Cylinder Head

• Firstly remove the M6 cylinder head bolts and M6 cylinder

bolts [A].

• Secondly, remove the M8 bolts [B].

• Thirdly, remove the M10 nut [C].

• Fourthly, remove the M10 bolts [D].

Cylinder Head Installation

NOTE

○The camshaft cap is machined with the cylinder head,

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

is supplied with the new head.

• Install a new cylinder head gasket [A] and dowel pins [B].

ENGINE TOP END 5-27

Cylinder Head

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

of washers and the threads of bolts and nut.

M10 Cylinder Head Bolts [B]

M10 Cylinder Nut [C]

M8 Cylinder Bolt [D]

• Tighten the all the bolts and nut following the tightening

sequence [1 ∼ 8].

Torque - Cylinder Head Bolts (M10):

First: 25 N·m (2.5 kgf·m, 18 ft·lb)

Final:

Used Bolts 49 N·m (5.0 kgf·m, 36 ft·lb)

New Bolts 54 N·m (5.5 kgf·m, 40 ft·lb)

Cylinder Nut (M10): 49 N·m (5.0 kgf·m, 36 ft·lb)

Cylinder Bolt (M8): 27.5 N·m (2.8 kgf·m, 20 ft·lb)

NOTE

○The tightening sequence No.1 ∼ No.5 are the cylinder

head bolts that are tightened between the cylinder head

with the crankcase.

○The No.6 is the cylinder head bolt that is tightened be-

tween the cylinder head with the cylinder.

○The No.7 and No.8 are the cylinder nut and cylinder

bolt that are tightened between the cylinder and the

crankcase.

5-28 ENGINE TOP END

Cylinder Head

• Tighten the M6 cylinder head bolts and M6 cylinder bolts

[A].

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

in·lb)

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

• Install the front camshaft chain guide [A].

○Insert the end [B] of front camshaft chain guide into the

hollow on the lower crankcase half.

• Install the removed parts (see appropriate chapters).

Cylinder Head Warp

• Clean the cylinder head.

• Lay a straightedge across the lower surface of the cylinder

head at several positions.

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

the straightedge [B] and the head.

Cylinder Head Warp

Standard:

- - -

Service Limit: 0.05 mm (0.002 in.)

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

replace it.

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

repair the head by rubbing the lower surface on emery

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

400).

ENGINE TOP END 5-29

Valves

Valve Clearance Inspection

• Refer to the Valve Clearance Inspection in the Periodic

Maintenance chapter.

Valve Clearance Adjustment

• Refer to the Valve Clearance Adjustment in the Periodic

Maintenance chapter.

Valve Removal

• Remove cylinder head (see Cylinder Head Removal).

• Remove the valve lifter and shim.

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

can be installed in their original positions.

• Using the valve spring compressor assembly, remove the

valve.

Special Tools - Valve Spring Compressor Assembly [A]:

57001-241

Valve Spring Compressor Adapter,

21 [B]:

57001-1272

Valve Installation

• Replace the oil seal with a new one.

○Apply engine oil to the oil seal lip.

• Apply a thin coat of molybdenum disulfide grease to the

valve stem before valve installation.

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

wards (the side painted in green faces upwards).

Valve Stem [A]

Oil Seal [B]

Spring Seat [C]

Closed Coil End [D]

Valve Spring [E]

Side Painted in Green [F]

Retainer [G]

Split Keepers [H]

Valve Guide Removal

• Remove:

Valve (see Valve Removal)

Oil Seal

Spring Seat

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

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

to remove the guide from the top of the head.

CAUTION

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

warp the cylinder head. Soak the cylinder head in

oil and heat the oil.

Special Tool - Valve Guide Arbor,

4.5: 57001-1331

5-30 ENGINE TOP END

Valves

Valve Guide Installation

• Apply engine oil to the valve guide outer surface before

installation.

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

150°C (248 ∼ 302°F).

• Drive the valve guide in from the top of the head using the

valve guide arbor. The flange stops the guide from going

in too far.

Special Tool - Valve Guide Arbor,

4.5: 57001-1331

• Wait until the cylinder head cools down and then ream the

valve guide with the valve guide reamer [A] even if the old

guide is reused.

○Turn the reamer in a clockwise direction until the reamer

turns freely in the guide. Never turn the reamer counter-

clockwise or it will be dulled.

○Once the guides are reamed they must be cleaned thor-

oughly.

Special Tool - Valve Guide Reamer,

4.5: 57001-1333

Valve-to-Guide Clearance Measurement (Wobble

Method)

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

guide wear by measuring the valve to valve guide clearance

with the wobble method as indicated below.

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

gauge against the stem perpendicular to it as close as

possible to the cylinder head mating surface.

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

guide clearance.

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

the first.

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

NOTE

○The reading is not actual valve/valve guide clearance

because the measuring point is above the guide.

Valve/Valve Guide Clearance (Wobble Method)

Standard:

Exhaust

0.07 ∼ 0.14 mm (0.0028 ∼ 0.0055 in.)

Inlet

0.02 ∼ 0.08 mm (0.0008 ∼ 0.0032 in.)

Service Limit:

Exhaust

0.27 mm (0.0106 in.)

Inlet

0.22 mm (0.0087 in.)

ENGINE TOP END 5-31

Valves

Valve Seat Inspection

• Remove the valve (see Valve Removal).

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

and valve seat [C].

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

on the valve seat.

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

seat (see Valve Seat Repair).

Valve Seating Surface Outside Diameter

Standard:

Exhaust

27.6 ∼ 27.8 mm (1.087 ∼ 1.094 in.)

Inlet

32.6 ∼ 32.8 mm (1.283 ∼ 1.291 in.)

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

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

vernier caliper.

Good [F]

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

repair the seat (see Valve Seat Repair).

Valve Seating Surface Width

Standard:

Exhaust

0.5 ∼ 1.0 mm (0.020 ∼ 0.039 in.)

Inlet

0.5 ∼ 1.0 mm (0.020 ∼ 0.039 in.)

Valve Seat Repair

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

Special Tools - Valve Seat Cutter Holder Bar [C]: 57001-1128

Valve Seat Cutter Holder,

4.5 [B]: 57001-1330

For Exhaust Valve Seat

Valve Seat Cutter, 45° -

30: 57001-1187

Valve Seat Cutter, 32° -

30: 57001-1120

Valve Seat Cutter, 60° -

30: 57001-1123

For Inlet Valve Seat

Valve Seat Cutter, 45° -

35: 57001-1116

Valve Seat Cutter, 32° -

35: 57001-1121

Valve Seat Cutter, 55° -

35: 57001-1247

If the manufacturer’s instructions are not available, use

the following procedure.

5-32 ENGINE TOP END

Valves

Seat Cutter Operation Care

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

repair. Therefore the cutter must not be used for other

purposes than seat repair.

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

mond particles may fall off.

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

before grinding the seat surface. Also wash off ground

particles sticking to the cutter with washing oil.

NOTE

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

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

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

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

the diamond portion.

NOTE

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

ing the operation, wash off any ground particles sticking

to the cutter with washing oil.

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

of engine oil before storing.

Marks Stamped on the Cutter

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

the following.

60°

Cutter angle [B]

37.5

Outer diameter of cutter [C]

Operating Procedures

• Clean the seat area carefully.

• Coat the seat with machinist’s dye.

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

guide.

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

Grind the seating surface only until it is smooth.

CAUTION

Do not grind the seat too much. Overgrinding will

reduce valve clearance by sinking the valve into the

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

be impossible to adjust the clearance, and the cylin-

der head must be replaced.

ENGINE TOP END 5-33

Valves

• Measure the outside diameter of the seating surface with

a vernier caliper.

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

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

ified range.

Widened Width [A] of engagement by machining with

45° cutter

Ground Volume [B] by 32° cutter

32° [C]

Correct Width [D]

Ground Volume [E] by 60° or 55° cutter

60° or 55° [F]

• Measure the outside diameter of the seating surface with

a vernier caliper.

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

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

specified range.

Original Seating Surface [B]

NOTE

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

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

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

distinct and 32° and 60° (or 55°) grinding operation eas-

ier.

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

45° cutter for centering and good contact.

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

large, make the 32° grind described below.

If the outside diameter of the seating surface is within the

specified range, measure the seat width as described be-

low.

• Grind the seat at a 32° angle [B] until the seat outside

diameter is within the specified range.

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

slide it into the valve guide.

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

very lightly. Check the seat after each turn.

CAUTION

The 32° cutter removes material very quickly.

Check the seat outside diameter frequently to pre-

vent overgrinding.

○After making the 32° grind, return to the seat outside di-

ameter measurement step above.

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

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

eral places around the seat.

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

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

outside diameter measurement step above.

5-34 ENGINE TOP END

Valves

If the seat width is too wide, make the 60° or 55° [A] grind

described below.

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

to the seat as described below.

• Grind the seat at a 60° or 55° angle until the seat width is

within the specified range.

○To make the 60° or 55° grind, fit 60° or 55° cutter into the

holder, and slide it into the valve guide.

○Turn the holder, while pressing down lightly.

○After making the 60° or 55° grind, return to the seat width

measurement step above.

Correct Width [B]

• Lap the valve to the seat, once the seat width and outside

diameter are within the ranges specified above.

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

valve in a number of places around the valve head.

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

pound produces a smooth, matched surface on both the

seat and the valve.

○Repeat the process with a fine grinding compound.

Lapper [A]

Valve Seat [B]

Valve [C]

• The seating area should be marked about in the middle

of the valve face.

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

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

been refaced too much; replace it.

• Be sure to remove all grinding compound before assem-

bly.

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

clearance (see Valve Clearance Adjustment in the Peri-

odic Maintenance chapter).

ENGINE TOP END 5-35

Valves

5-36 ENGINE TOP END

Cylinder, Pistons

Cylinder Removal

• Remove:

Cylinder Head (see Cylinder Head Removal)

Front Engine Mounting Bolts (Both Side) [A] (see Engine

Removal in the Engine Removal/Installation chapter)

Front Engine Brackets (Both Side) [B] (see Engine Re-

moval in the Engine Removal/Installation chapter)

Cylinder [C]

Cylinder Installation

NOTE

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

• Install the dowel pins [A] and new cylinder gasket [B].

• The piston ring openings must be positioned as shown in

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

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

Top Ring [A]

Second Ring [B]

Oil Ring Steel Rails [C]

Oil Ring Expander [D]

Hollow [E]

30 ∼ 40° [F]

• Apply molybdenum disulfide oil solution to the cylinder

bore, piston rings and piston.

• Prepare two auxiliary head bolts with their head cut.

○Install the two bolts [A] diagonally in the crankcase.

• Position the crankshaft so that all the piston heads are

almost level.

• Install the cylinder block.

○Insert the piston rings with your thumbs.

Piston Removal

• Remove the cylinder (see Cylinder Removal).

• Place a clean cloth under the pistons and remove the pis-

ton pin snap ring [A] from the outside of each piston.