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Kawasaki Ninja 650R, ER-6f ABS, ER-6f Motorcycle. Service Manual (2006-2008 year) - page 4

BRAKES 12-9

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Bleed Valve

7.8

0.80

69 in·lb

2

Brake Hose Banjo Bolts

25

2.5

18

3

Brake Lever Pivot Bolt

1.0

0.10

9 in·lb

Si

4

Brake Lever Pivot Bolt Locknut

5.9

0.60

52 in·lb

L

5

Brake Pipe Joint Nuts

18

1.8

13

6

Front Brake Disc Mounting Bolts

27

2.8

20

7

Front Brake Light Switch Screw

1.0

0.10

9 in·lb

8

Front Brake Reservoir Cap Screws

1.0

0.10

9 in·lb

9

Front Caliper Mounting Bolts

34

3.5

25

10

Front Master Cylinder Clamp Bolts

8.8

0.90

78 in·lb

S

B: Apply brake fluid.

L: Apply a non-permanent locking agent.

R: Replacement Parts

S: Follow the specified tightening sequence.

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

12-10 BRAKES

Exploded View

BRAKES 12-11

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Bleed Valve

7.8

0.80

69 in·lb

2

Brake Hose Banjo Bolts

25

2.5

18

3

Brake Pedal Bolt

8.8

0.90

78 in·lb

4

Brake Pipe Joint Nuts

18

1.8

13

5

Rear Brake Disc Mounting Bolts

27

2.8

20

L

6

Rear Caliper Mounting Bolts

25

2.5

18

7

Rear Master Cylinder Mounting Bolts

25

2.5

18

8

Rear Master Cylinder Push Rod Locknut

18

1.8

13

B: Apply brake fluid.

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

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

BRAKES 12-13

Special Tools

Inside Circlip Pliers:

Hand Tester:

57001-143

57001-1394

Jack:

Jack Attachment:

57001-1238

57001-1608

12-14 BRAKES

Brake Lever, Brake Pedal

Brake Lever Position Adjustment

The brake lever adjuster has 5 positions so that the brake

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

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

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

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

ber 5 and maximum at number 1.

Brake Pedal Position Inspection

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

Footpeg [B]

Pedal Position

Standard: About 40 mm (1.6 in.) [C] below top of

footpeg

If it is incorrect, adjust the brake pedal position.

Brake Pedal Position Adjustment

NOTE

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

but always adjust it when the push rod locknut has been

loosened.

• Remove:

Frame Cover (see Frame Cover Removal in the Frame

chapter)

Bolts [A]

Right Footpeg Stay [B]

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

head [B] to achieve the correct pedal position.

If the length [C] shown is 70 ±1 mm (2.76 ±0.04 in.), the

pedal position will be within the standard range.

• Tighten:

Torque - Rear Master Cylinder Push Rod Locknut: 18 N·m

(1.8 kgf·m, 13 ft·lb)

• Install the footpeg stay, and tighten the bolts.

Torque - Footpeg Stay Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)

• Check the brake light switch operation (see Brake Light

Switch Operation Inspection in the Periodic Maintenance

chapter).

BRAKES 12-15

Brake Lever, Brake Pedal

Brake Pedal Removal

• Remove:

Frame Cover (see Frame Cover Removal in the Frame

chapter)

Bolts [A]

Right Footpeg Stay [B]

• Remove:

Cotter Pin [A]

Joint Pin [B]

Rear Brake Light Switch Spring [C]

Return Spring [D]

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

pedal.

Brake Pedal Installation

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

[B].

• Install:

Brake Pedal [C]

Washer [D]

Brake Pedal Bolt [E]

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

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

[A] on the pedal hook.

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

hook.

• Replace the cotter pin with a new one.

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

BRAKES 12-17

Calipers

Front Caliper Removal

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

and tighten it loosely.

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

caliper [C] from the disc.

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

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

CAUTION

Immediately wash away any brake fluid that spills.

NOTE

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

compressed air is not available, disassemble the caliper

before the brake hose is removed (see Front Caliper

Disassembly).

Rear Caliper Removal

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

and tighten it loosely.

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

caliper [C] from the disc.

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

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

CAUTION

Immediately wash away any brake fluid that spills.

NOTE

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

compressed air is not available, disassemble the caliper

before the brake hose is removed (see Rear Caliper

Disassembly).

Caliper Installation

• Install the caliper and brake hose lower end.

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

ones.

• Tighten:

Torque - Caliper Mounting Bolts

Front: 34 N·m (3.5 kgf·m, 25 ft·lb)

Rear: 25 N·m (2.5 kgf·m, 18 ft·lb)

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

ft·lb)

• Check the fluid level in the brake reservoirs.

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

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

and no fluid leakage.

WARNING

Do not attempt to drive the motorcycle until a full

brake lever or pedal is obtained by pumping the

brake lever or pedal until the pads are against the

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

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

12-18 BRAKES

Calipers

Front Caliper Disassembly

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

riodic Maintenance chapter.

Front Caliper Assembly

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

riodic Maintenance chapter.

Rear Caliper Disassembly

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

riodic Maintenance chapter.

Rear Caliper Assembly

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

riodic Maintenance chapter.

Caliper Fluid Seal Damage

The fluid seal (piston seal) [A] is placed around the pis-

ton to maintain clearance between the pad and the disc. If

the seal is in a poor condition, it could lead the pad to wear

excessively or the brake to drag, which may cause the tem-

perature of the discs or the brake fluid to increase.

• Replace the fluid seal if it exhibits any of the conditions

listed below.

○Brake fluid leakage around the pad.

○Brakes overheat.

○Considerable difference in inner and outer pad wear.

○Seal and piston are stuck together.

If the fluid seal is replaced, replace the dust seal [B] as

well. Also, replace all seals every other time the pads are

changed.

Rear Caliper Dust Boot and Friction Boot Damage

• Check that the dust boot [A] and friction boot [B] are not

cracked, worn, swollen, or otherwise damaged.

If they show any damage, replace it.

BRAKES 12-19

Calipers

Caliper Piston and Cylinder Damage

• Visually inspect the pistons [A] and cylinder surfaces [B].

Replace the caliper if the cylinder and piston are badly

scores or rusty.

Rear Caliper Holder Shaft Wear

The caliper body must slide smoothly on the caliper holder

shafts [A]. If the body does not slide smoothly, one pad will

wear more than the other, pad wear will increase, and con-

stant drag on the disc will raise brake and brake fluid tem-

perature.

• Check to see that the caliper holder shafts are not badly

worn or stepped, and that the rubber friction boots are not

damaged.

If the rubber friction boot is damaged, replace the rubber

friction boot. To replace the friction boot, remove the pads

and the caliper bracket.

If the caliper holder shaft is damage, replace the caliper

bracket.

12-20 BRAKES

Brake Pads

Front Brake Pad Removal

• Remove the front caliper with the hose installed (see Front

Caliper Removal).

• Draw out the holder shaft pin [A], and take off the holder

shaft [B].

• Remove the pad [C] on the piston side.

• Push the holder [D] towards the piston, and remove the

pad of the other side [E] from the holder shaft [F].

Front Brake Pad Installation

• Push the caliper pistons in by hand as far as they will go.

• Install the anti-rattle spring in its correct position.

• Install the pad on the piston side first, then install the other

pad on the holder.

• Install the front caliper (see Caliper Installation).

WARNING

Do not attempt to drive the motorcycle until a full

brake lever is obtained by pumping the brake lever

until the pads are against the disc. The brake will

not function on the first application of the lever if

this is not done.

Rear Brake Pad Removal

• Remove the rear caliper with the hose installed (see Rear

Caliper Removal).

• Draw out the holder shaft pin [A], and take off the holder

shaft [B].

• Remove the pad [C] on the piston side.

• Push the holder [D] towards the piston, and remove the

pad of the other side [E] from the holder shaft [F].

Rear Brake Pad Installation

• Push the caliper piston in by hand as far as it will go.

• Install the anti-rattle spring in its correct position.

• Install the pad on the piston side first, then install the other

pad on the holder.

• Install the rear caliper (see Caliper Installation).

WARNING

Do not attempt to drive the motorcycle until a full

brake pedal is obtained by pumping the brake pedal

until the pads are against the disc. The brake will

not function on the first application of the pedal if

this is not done.

Brake Pad Wear Inspection

• Refer to the Brake Pad Wear Inspection in the Periodic

Maintenance chapter.

BRAKES 12-21

Master Cylinder

Front Master Cylinder Removal

• Remove the banjo bolt [A] to disconnect the brake hose

from the master cylinder [B] (see Brake Hose Removal/In-

stallation).

• Disconnect the front brake light switch connectors [A].

• Unscrew the clamp bolts [B], and take off the master cylin-

der as an assembly with the reservoir, brake lever and

brake switch installed.

CAUTION

Immediately wash away any brake fluid that spills.

• Remove:

Brake Lever Pivot Bolt [A] and Locknut

Brake Lever [B]

Front Brake Light Switch [C]

Front Master Cylinder Installation

• Install the front master cylinder so that the punch mark [A]

of the handlebar is aligned with the mating surface [B] of

the master cylinder clamp to level the reservoir.

• The master cylinder clamp must be installed with the ar-

row mark [A] upward.

• Tighten the upper clamp bolt [B] first, and then the lower

clamp bolt [C]. There will be a gap at the lower part of the

clamp after tightening.

Torque - Front Master Cylinder Clamp Bolts: 8.8 N·m (0.90

kgf·m, 78 in·lb)

• Replace the washers on each side of the hose fitting with

new ones.

• Tighten the brake hose banjo bolt.

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

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

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

and no fluid leakage.

12-22 BRAKES

Master Cylinder

Rear Master Cylinder Removal

• Unscrew the brake hose banjo bolt [A] on the master cylin-

der (see Brake Hose Removal/Installation).

• Unscrew the master cylinder mounting bolts [A].

• Remove the cotter pin [B].

NOTE

○Pull off the joint pin while pressing down the brake

pedal.

• Pull off the reservoir hose lower end [C], and drain the

brake fluid into a container.

• Remove the master cylinder.

Rear Master Cylinder Installation

• Replace the cotter pin [A] with a new one.

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

ones.

• Tighten the following bolts.

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

kgf·m, 18 ft·lb)

Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

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

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

and no fluid leakage.

Front Master Cylinder Disassembly

• Refer to the Master Cylinder Rubber Parts Replacement

in the Periodic Maintenance chapter.

Rear Master Cylinder Disassembly

• Refer to the Master Cylinder Rubber Parts Replacement

in the Periodic Maintenance chapter.

Master Cylinder Assembly

• Refer to the Master Cylinder Rubber Parts Replacement

in the Periodic Maintenance chapter.

BRAKES 12-23

Master Cylinder

Master Cylinder Inspection

• Remove the master cylinders (see Front/Rear Master

Cylinder Removal).

• Disassemble the front and rear master cylinders.

• Check that there are no scratches, rust or pitting on the

inner wall [A] of each master cylinder and on the outside

of each piston [B].

If a master cylinder or piston shows any damage, replace

them.

• Inspect the primary cup [C] and secondary cup [D].

If a cup is worn, damaged softened (rotted), or swollen,

the piston assembly should be replaced to renew the

cups.

If fluid leakage is noted at the brake lever, the piston as-

sembly should be replaced to renew the cups.

Front Master Cylinder [J]

• Check the dust covers [E] for damage.

If they are damaged, replace them.

• Check the piston return springs [F] for any damage.

If the springs are damaged, replace them.

• Check that relief port [G] and supply port [H] are not

plugged.

If the relief port becomes plugged, the brake pads will

drag on the disc. Blow the ports clean with compressed

air.

Rear Master Cylinder [K]

12-24 BRAKES

Brake Disc

Brake Disc Removal

• Remove the wheel (see Front/Rear Wheel Removal in the

Wheels/Tires chapter).

• Unscrew the mounting bolts, and take off the disc.

• Remove the gaskets.

Brake Disc Installation

• Replace the gaskets with new ones.

• Install the brake disc on the wheel so that the marked side

[A] faces out.

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

the front and rear brake disc mounting bolts [B].

• Tighten:

Torque - Brake Disc Mounting Bolts: 27 N·m (2.8 kgf·m, 20

ft·lb)

Brake Disc Wear

• Measure the thickness of each disc [A] at the point where

it has worn the most.

If the disc has worn past the service limit, replace it.

Measuring Area [B]

Brake Discs Thickness

Standard:

Front:

EX650A Models

4.3 ∼ 4.7 mm (0.17 ∼ 0.19 in.)

EX650B Models

4.8 ∼ 5.2 mm (0.19 ∼ 0.20 in.)

Rear

4.8 ∼ 5.2 mm (0.19 ∼ 0.20 in.)

Service Limit:

Front

4.0 mm (0.16 in.)

Rear

4.5 mm (0.18 in.)

Brake Disc Warp

• Raise the wheel off the ground with jack (see Front/Rear

Wheel Removal in the Wheels/Tires chapter).

Special Tools - Jack: 57001-1238

Jack Attachment: 57001-1608

○For front disc inspection, turn the handlebar fully to one

side.

• Set up a dial gauge against the disc [A] as shown and

measure disc runout, while turning [B] the wheel by hand.

If runout exceeds the service limit, replace the disc.

Disc Runout

Standard:

0.15 mm (0.006 in.) or less

Service Limit:

0.3 mm (0.01 in.)

BRAKES 12-25

Brake Fluid

Brake Fluid Level Inspection

• Refer to the Brake Fluid Level Inspection in the Periodic

Maintenance chapter.

Brake Fluid Change

• Refer to the Brake Fluid Change in the Periodic Mainte-

nance chapter.

Brake Line Bleeding

The brake fluid has a very low compression coefficient so

that almost all the movement of the brake lever or pedal

is transmitted directly to the caliper for braking action. Air,

however, is easily compressed. When air enters the brake

lines, brake lever or pedal movement will be partially used

in compressing the air. This will make the lever or pedal feel

spongy, and there will be a loss in braking power.

WARNING

Be sure to bleed the air from the brake line when-

ever brake lever or pedal action feels soft or

spongy after the brake fluid is changed, or when-

ever a brake line fitting has been loosened for any

reason.

NOTE

○The procedure to bleed the front brake line is as follows.

Bleeding the rear brake line is the same as for the front

brake.

• Remove the reservoir cap [A] and diaphragm.

• Fill the reservoir with fresh brake fluid to the upper level

line in the reservoir.

• Slowly pump the brake lever several times until no air

bubbles can be seen rising up through the fluid from the

holes at the bottom of the reservoir.

○Bleed the air completely from the master cylinder by this

operation.

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

caliper.

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

the other end of the hose into a container.

12-26 BRAKES

Brake Fluid

• Bleed the brake line and the caliper.

○Repeat this operation until no more air can be seen com-

ing out into the plastic hose.

1. Pump the brake lever until it becomes hard, and apply

the brake and hold it [A].

2. Quickly open and close [B] the bleed valve while hold-

ing the brake applied.

3. Release the brake [C].

NOTE

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

ing operation and replenished with fresh brake fluid as

necessary. If the fluid in the reservoir runs completely

out any time during bleeding, the bleeding operation

must be done over again from the beginning since air

will have entered the line.

○Tap the brake hose lightly from the caliper to the reser-

voir for more complete bleeding.

○Front Brake: First bleeding the right caliper then repeat

the above steps for the left caliper.

• Remove the clear plastic hose.

• Install the diaphragm and reservoir cap.

• Tighten:

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

kgf·m, 9 in·lb)

• Follow the procedure below to install the rear brake fluid

reservoir cap correctly.

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

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

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

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

fluid reservoir body [A].

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

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

• Check the fluid level (see Brake Fluid Level Inspection in

the Periodic Maintenance chapter).

• After bleeding is done, check the brake for good braking

power, no brake drag, and no fluid leakage.

BRAKES 12-29

Anti-Lock Brake System

Parts Location

1. Front Wheel Rotation Sensor

2. Front Wheel Rotation Sensor Rotor

3. Rear Wheel Rotation Sensor

4. Rear Wheel Rotation Sensor Rotor

5. ABS Indicator Light (LED)

6. ABS Hydraulic Unit

7. ABS Fuse Box

8. ABS Kawasaki Self-diagnosis System Connector

12-30 BRAKES

Anti-Lock Brake System

ABS System Wiring Diagram

1. Ignition Switch

2. ABS Hydraulic Unit

3. ABS Self-diagnosis Terminal

4. ABS Kawasaki Self-diagnosis System Connector

5. Front Wheel Rotation Sensor

6. Rear Wheel Rotation Sensor

7. ABS Solenoid Valve Relay

8. ABS Motor Relay

9. Frame Ground

10. Meter Unit

11. Front Brake Switch

12. Water-proof Joint C

13. Ignition Fuse 10 A

14. Main Fuse 30 A

15. Battery 12 V 10 Ah

16. Frame Ground

17. Rear Brake Switch

18. Joint Connector

BRAKES 12-31

Anti-Lock Brake System

Terminal Names

1. Ground to Motor

2. Power Supply to ABS Motor Relay

3. Power Supply to ABS Solenoid Valve Relay

4. Ground

5. Front Wheel Rotation Sensor Signal

6. Unused

7. Power Supply to Rear Wheel Rotation Sensor

8. Unused

9. Unused

10. Unused

11. ABS Kawasaki Self-diagnosis System Terminal

12. ABS Indicator Light (LED)

13. Unused

14. Unused

15. Unused

16. Power Supply to Front Wheel Rotation Sensor

17. Unused

18. Power Supply

19. Rear Wheel Rotation Sensor Signal

20. Front Brake Light Switch

21. Rear Brake Light Switch

22. Unused

23. Unused

24. Unused

25. ABS Self-diagnosis Terminal

26. Unused

12-34 BRAKES

Anti-Lock Brake System

ABS Troubleshooting Outline

When an abnormality in the system occurs, the ABS in-

dicator light (LED) lights up to alert the rider. In addition,

the nature of the fault is stored in the memory of the ABS

hydraulic unit and when in the self-diagnosis mode, the ser-

vice code [A] is indicated by the number of times the ABS

indicator light (LED) blinks. The service codes stored in

memory are not erased until the mode has been changed

to the fault erase mode after the fault has been corrected.

Therefore, after correcting the problem, always erase the

service codes and then run the self-diagnosis program to

confirm normal signal output. When, due to a malfunction,

the ABS indicator light (LED) remains lit, get a thorough

understanding of the background before starting the repair

work. Ask the rider about the conditions [B] under which

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

Do not rely solely on the ABS self-diagnosis function, use

common sense; check the brakes for proper braking power,

and brake fluid level, search for leaks, etc.

Even when the ABS is operating normally, the ABS indi-

cator light (LED) may light up under the conditions listed be-

low. Turn the ignition switch OFF to stop blinking or lighting

of the indicator light. If the motorcycle runs without erasing

the service code, the light may light up again.

○After continuous riding on a rough road.

○When the engine is started with the stand raised and the

transmission engaged, and the rear wheel turns.

○When accelerating so abruptly that the front wheel leaves

the ground.

○When the ABS has been subjected to strong electrical

interference.

○When tire pressure is abnormal. Adjust tire pressure.

○When a tire different in size from the standard size is being

used. Replace with standard size.

○When the wheel is deformed. Replace the wheel.

Much of the ABS troubleshooting work consists of con-

firming continuity of the wiring. The ABS parts are assem-

bled and adjusted by the manufacturer, so there is no need

to disassemble or repair them. Replace the ABS hydraulic

unit.

The basic troubleshooting procedures are listed below.

• Carry out pre-diagnosis inspections as a preliminary in-

spection.

• Determine the fault using the self-diagnosis function.

• Check wiring and connections from the ABS hydraulic

unit connector to the suspected faulty ABS part, using the

hand tester.

Special Tool - Hand Tester: 57001-1394

BRAKES 12-35

Anti-Lock Brake System

• Visually inspect the wiring for signs of burning or fraying.

If any wiring is poor, replace the damaged wiring.

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

dirt and damage.

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

is damaged, replace it.

• Check the wiring for continuity.

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

is suspected of being a problem.

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

Special Tool - Hand Tester: 57001-1394

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

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

place the main harness [B] if necessary.

• Narrow down suspicious parts and close in on the faulty

ABS part by repeating the continuity tests.

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

ABS parts are the next likely suspects. Check each part

one by one.

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

12-36 BRAKES

Anti-Lock Brake System

ABS Diagnosis Flow Chart

BRAKES 12-37

Anti-Lock Brake System

Inquiries to Rider

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

the rider is dissatisfied with.

○Try to find out exactly what problem occurs under exactly what conditions by asking the rider; know-

ing this information may help you reproduce the problem in the shop.

○The diagnosis sheet will help prevent you from overlooking any keys, so always use it.

Sample Diagnosis Sheet

Rider name:

Registration No. (license plate No.):

Year of initial registration:

Model:

Engine No.:

Frame No.:

Date problem occurred:

Frequency:

Weather:

Mileage:

□ Brake

□ Indicator

□

Braking

□ Abnor-

□

ABS not

□

ABS

□

ABS op-

lever

light

distance

mal

working

works

erating

vibration

blinks

too long

brake

but

too fre-

or noise

lever

indicator

quently

move-

light

Phenome-

ment

doesn’t

non

light up

□ Pedal

□ Indicator

□ Abnor-

vibration

light

mal

or noise

remains

pedal

lit up

move-

ment

Engine conditions at

□ At start-up

□ After starting

□ At 5 000

r/min (rpm)

problem

or more

Road conditions

□ Slippery road

(□ snow,

□ gravel,

□ other

)

□ Rough surface

□ Other

Driving conditions

□ High-speed cornering

□ Driving 10 km/h (6 mph) or above

□ Driving below 10 km/h (6 mph)

□ When stopping

□ When turning

Brake application

□ Gradual

□ Abrupt

Other conditions

□ Large brake lever stroke

□ Large pedal stroke

12-38 BRAKES

Anti-Lock Brake System

Pre-Diagnosis Inspection 1

BRAKES 12-39

Anti-Lock Brake System

Pre-Diagnosis Inspection 2

Self-diagnosis Outline

When the indicator light has blinked or come on, the ABS hydraulic unit memorizes and stores the

service code (15 codes including “Normal Code”) for the service person to troubleshoot easily. The

service code memory is powered directly by the battery and cannot be canceled by the ignition switch.

The ABS hydraulic unit can memorize up to six service codes. Further service codes are memorized

after erasing the preceding six service codes. If there is no fault, only the start code 12 is shown,

indicating that “The ABS is normal”

Self-diagnosis Procedures

○When a problem occurs with the ABS system, the ABS

indicator light (LED) [A] is blinks and lights.

NOTE

○Use a fully charged battery when conducting

self-diagnosis. Otherwise, the light blinks very slowly

or doesn’t blink.

○The motorcycle is stopped.

○Keep the self-diagnosis terminal grounded during self

-diagnosis, with an auxiliary lead.

12-40 BRAKES

Anti-Lock Brake System

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

ter).

• Ground the self-diagnosis terminal [A] (Gray) to the bat-

tery (-) terminal or battery (-) lead connector, using a

lead.

• Turn on the ignition switch.

○Count the blinks of the light to read the service code.

Keep the auxiliary lead ground until you finish reading the

service code.

Service Code Clearing Procedures

• Start the service code erase mode with the following pro-

cedure.

○The erase mode starts when the ABS self-diagnosis ter-

minal is disconnected from the ground terminal after start-

ing the self-diagnosis mode.

○The service code can be erased by grounding and un-

grounding (each time for at least one second) the ABS

self-diagnosis terminal three times or more within about

12.5 seconds after starting the erase mode.

○The ABS indicator light (LED) remains lit during the erase

mode and after erasing.

○Once erasing is finished, enter the self-diagnosis mode

again to confirm that the service codes have been

erased. If the ABS has been reset and all codes have

been erased, only start code 12 will be shown.

BRAKES 12-41

Anti-Lock Brake System

Self-diagnosis Flow Chart

12-42 BRAKES

Anti-Lock Brake System

How to Read Service Codes

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

shown below.

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

○When there are a number of faults, a maximum of six service codes can be stored and the display

will begin starting from the last service code entered.

○For the display pattern, first, start code 12 is shown, next up to six service codes starting with the

last one stored, then the display is repeated from the start code once again.

○If there is no fault, only the start code is shown.

How to Erase Service Codes

○Even if the ignition switch is turned OFF, the battery or the ABS hydraulic unit are disconnected, all

service codes remain in the ABS hydraulic unit.

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

BRAKES 12-43

Anti-Lock Brake System

Service Code Table

Service

ABS Indicator Light (LED)

Problems

Light State

Code

After starts,

12

Start code (not fault)

turn off

Rear inlet solenoid valve trouble (open,

13

ON

temperature abnormal)

Rear outlet solenoid valve trouble (open,

14

ON

temperature abnormal)

Front inlet solenoid valve trouble (open,

17

ON

temperature abnormal)

Front outlet solenoid valve trouble (open,

18

ON

temperature abnormal)

ABS solenoid valve relay trouble (wiring

19

shorted or open, stuck relay (ON or OFF)

ON

or dropout)

Front, rear wheel rotation difference

25

abnormal (substandard tire, sensor rotor

ON

teeth number wrong)

ABS motor relay trouble (wiring shorted or

35

ON

open, stuck relay (ON or OFF)

Front wheel rotation sensor signal abnormal

42

(sensor or rotor missing, too large

ON

clearance, rotor tooth worn or missing)

Front wheel rotation sensor wiring (wiring

43

ON

shorted or open, connector bad connection)

Rear wheel rotation sensor signal abnormal

44

(sensor or rotor missing, too large

ON

clearance, rotor tooth worn or missing)

Rear wheel rotation sensor wiring (wiring

45

ON

shorted or open, connector bad connection)

Power supply voltage abnormal

52

ON

(under-voltage)

Power supply voltage abnormal

53

ON

(over-voltage)

55

ECU trouble (ECU operation abnormal)

ON

12-44 BRAKES

Anti-Lock Brake System

ABS Indicator Light (LED) Inspection

• Turn the ignition switch ON.

If the ABS indicator light (LED) [A] lights, it is normal.

If the ABS indicator light (LED) does not light, go to step

“ABS Indicator Light (LED) is Unlit (When the Ignition

Switch turned to ON)”.

• Turn the ignition switch OFF.

If the ABS indicator light (LED) [A] does not light, it is

normal.

If the ABS indicator light (LED) lights, go to step “ABS In-

dicator Light (LED) Lights (When the Motorcycle is Run-

ning, - No Service Code)”.

ABS Indicator Light (LED) is Unlit (When the

Ignition Switch turned to ON)

• Do the 1st step test.

○Check the terminal voltage between the orange/black and

black/yellow lead terminals of the meter connector [A].

Special Tool - Hand Tester: 57001-1394

Terminal Voltage

Standard:

About 9 V

If the terminal voltage is not within the specification, 2nd

step.

If the terminal voltage correct, replace the meter assem-

bly.

• Do the 2nd step test.

○Disconnect the ABS hydraulic unit connector and meter

connector.

○Check for continuity between the orange/black lead

terminal of the main harness side connector [A] and

orange/black lead terminal of the main harness side

connector [B].

If there is the continuity in the lead, 3rd step.

If there is not the continuity in the lead, replace or repair

the main harness.

• Do the 3rd step test.

○Check the battery terminal voltage (see 2nd Step in the

Power Supply Voltage Abnormal (Under-Voltage) (Ser-

vice Code 52)).

If the battery terminal voltage correct, replace the ABS

hydraulic unit.

BRAKES 12-45

Anti-Lock Brake System

ABS Indicator Light (LED) Lights (When the Motorcycle

is Running, - No Service Code)

• Do the 1st step test.

○Check the terminal voltage between the orange/black and

black/yellow lead terminals of the meter connector [A].

Special Tool - Hand Tester: 57001-1394

Terminal Voltage

Standard:

About 9 ~ 12 V

If the terminal voltage is not within the specification, re-

place the meter assembly.

If the terminal voltage correct, 2nd step.

• Do the 2nd step test.

○Disconnect the ABS hydraulic unit connector.

○Check the terminal voltage between the orange/black and

black/yellow lead terminals of the main harness side con-

nector [A].

Special Tool - Hand Tester: 57001-1394

If the terminal voltage is about 9 ∼ 12 V, replace the main

harness.

If the terminal voltage is 0 V, replace the ABS hydraulic

unit.

Solenoid Valve Inspection (Service Code

13,14,17,18)

• Do the 1st step test.

○Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, and

retrieve the service code.

If the ABS indicator light (LED) [A] lit, faulty solenoid valve

in the ABS hydraulic unit. Replace the ABS hydraulic unit.

If the ABS indicator light (LED) [A] unlit, ABS system is

normal (service code is not stored; temporary failure.).

ABS Solenoid Valve Relay Inspection (Service

Code 19)

• Do the 1st step test.

○Check the ABS solenoid valve relay fuse [A].

If the fuse blown, 2nd step.

If the fuse correct, 4th step.

12-46 BRAKES

Anti-Lock Brake System

• Do the 2nd step test.

○Disconnect the ABS hydraulic unit connector [A].

○Check for continuity between the white/red and black/yel-

low lead terminals of the ABS hydraulic unit connector.

If there is the continuity in the lead, replace the ABS hy-

draulic unit.

If there is not the continuity in the lead, 3rd step.

• Do the 3rd step test.

○Check for continuity between the white/red lead terminal

of the main harness side connector [A] and white/red lead

terminal of the fuse box [B] .

If there is the continuity in the lead, replace the fuse.

If there is not the continuity in the lead, replace or repair

the main harness.

• Do the 4th step test.

○Check the battery terminal voltage between the white/red

lead terminal of the fuse box [A] and ground.

Special Tool - Hand Tester 57001-1394

Battery Terminal Voltage

Standard:

Battery Voltage

If the battery terminal voltage is not within the specifica-

tion, 5th step.

If the battery terminal voltage correct, 6th step.

• Do the 5th step test.

○Check for continuity between the positive cable [A] of the

battery and white/red lead terminal of the main harness

side connector [B].

If there is the continuity in the lead, 4th step.

If there is not the continuity in the lead, replace or repair

the main harness.

• Do the 6th step test.

○Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, and

retrieve the service code.

If the ABS indicator light (LED) [A] lit, faulty ABS solenoid

valve relay in the ABS hydraulic unit. Replace the ABS

hydraulic unit.

If the ABS indicator light (LED) [A] unlit, ABS system is

normal (service code is not stored; temporary failure.).

BRAKES 12-47

Anti-Lock Brake System

Front, Rear Wheel Rotation Difference Abnormal

(Service Code 25)

• Do the 1st step test.

○Check the following and correct the faulty part.

Incorrect the tire pressure.

Tires not recommended for the motorcycle were installed

(incorrect tire size).

Deformation of the wheel or tire.

Sensor rotor for missing teeth and clogging with foreign

matter.

If the all parts correct, 2nd step.

• Do the 2nd step test.

○Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, and

retrieve the service code.

If the ABS indicator light (LED) [A] lit, faulty ECU in the

ABS hydraulic unit. Replace the ABS hydraulic unit.

If the ABS indicator light (LED) [A] unlit, ABS system is

normal (service code is not stored; temporary failure.).

ABS Pump Motor Relay Inspection (Service Code

35)

• Do the 1st step test.

○Check the ABS pump motor relay fuse [A].

If the fuse blown, 2nd step.

If the fuse correct, 4th step.

• Do the 2nd step test.

○Disconnect the ABS hydraulic unit connector.

○Check for continuity between the red/white and black/yel-

low lead terminals of the ABS hydraulic unit connector [A].

If there is the continuity in the lead, replace the ABS hy-

draulic unit.

If there is not the continuity in the lead, 3rd step.

• Do the 3rd step test.

○Check for continuity between the red/white lead terminal

of the main harness side connector [A] and red/white lead

terminal of the fuse box [B].

If there is the continuity in the lead, replace the fuse.

If there is not the continuity in the lead, replace or repair

the main harness.

12-48 BRAKES

Anti-Lock Brake System

• Do the 4th step test.

○Check the battery terminal voltage between the red/white

lead terminal of the fuse box [A] and ground.

Special Tool - Hand Tester: 57001-1394

Battery Terminal Voltage

Standard:

Battery Voltage

If the battery terminal voltage is not within the specifica-

tion, 5th step.

If the battery terminal voltage correct, 6th step.

• Do the 5th step test.

○Check for continuity between the positive cable [A] of the

battery and red/white lead terminal of the main harness

side connector [B].

If there is the continuity in the lead, 4th step.

If there is not the continuity in the lead, replace or repair

the main harness.

• Do the 6th step test.

○Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, and

retrieve the service code.

If the ABS indicator light (LED) [A] lit, faulty ABS pump

motor relay in the ABS hydraulic unit. Replace the ABS

hydraulic unit.

If the ABS indicator light (LED) [A] unlit, ABS system is

normal (service code is not stored; temporary failure.).

Front Wheel Rotation Sensor Signal Abnormal

(Service Code 42)

• Do the 1st step test.

○Measure the air gap between the front wheel rotation sen-

sor and sensor rotor.

Thickness Gauge [A]

Air Gap

Standard:

1 mm (0.04 in.)

If the measurement is over standard, check each part

for deformation and looseness and correct accordingly.

Recheck the air gap.

If the measurement is correct, 2nd step.

BRAKES 12-49

Anti-Lock Brake System

• Do the 2nd step test.

○Check that there is iron or other magnetic deposits be-

tween the sensor [A] and sensor rotor [B], and the sensor

rotor slots for obstructions.

○Check the installation condition of the sensor for loose-

ness.

○Check the sensor and sensor rotor tip for deformation or

damage (e.g., chipped sensor rotor teeth).

If the sensor and sensor rotor in bad condition, remove the

any deposits. Install the properly or replace faulty part.

If the all correct, 3rd step.

• Do the 3rd step test.

○Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, and

retrieve the service code.

If the ABS indicator light (LED) [A] lit, faulty ECU in the

ABS hydraulic unit. Replace the ABS hydraulic unit.

If the ABS indicator light (LED) [A] unlit, ABS system is

normal (service code is not stored; temporary failure.).

Front Wheel Rotation Sensor Wiring Inspection

(Service Code 43)

• Do the 1st step test.

○Disconnect the ABS hydraulic unit connector and front

wheel rotation sensor connector.

○Short the white and black lead terminals of the main har-

ness side connector [A] with a jumper lead, and check for

continuity between the white and black lead terminals of

the main harness side connector [B].

If there is the continuity in the lead, 2nd step.

If there is not the continuity in the lead, replace or repair

the main harness.

• Do the 2nd step test.

○Check for continuity between the white lead terminal of

the sensor connector [A] and ground, and black lead ter-

minal of the sensor connector and ground.

If there is the continuity in the lead, replace the front wheel

rotation sensor.

If there is not the continuity in the lead, 3rd step.

12-50 BRAKES

Anti-Lock Brake System

• Do the 3rd step test.

○Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, and

retrieve the service code.

If the ABS indicator light (LED) [A] lit, faulty ECU in the

ABS hydraulic unit. Replace the ABS hydraulic unit.

If the ABS indicator light (LED) [A] unlit, ABS system is

normal (service code is not stored; temporary failure.).

Rear Wheel Rotation Sensor Signal Abnormal

(Service Code 44)

• Do the 1st step test.

○Measure the air gap between the rear wheel rotation sen-

sor and sensor rotor.

Thickness Gauge [A]

Air Gap

Standard:

1 mm (0.04 in.)

If the measurement is over standard, check each part

for deformation and looseness and correct accordingly.

Recheck the air gap.

If the measurement is correct, 2nd step.

• Do the 2nd step test.

○Check that there is iron or other magnetic deposits be-

tween the sensor [A] and sensor rotor [B], and the sensor

rotor slots for obstructions.

○Check the installation condition of the sensor for loose-

ness.

○Check the sensor and sensor rotor tip for deformation or

damage (e.g., chipped sensor rotor teeth).

If the sensor and sensor rotor in bad condition, remove the

any deposits. Install the properly or replace faulty part.

If the all correct, 3rd step.

• Do the 3rd step test.

○Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, and

retrieve the service code.

If the ABS indicator light (LED) [A] lit, faulty ECU in the

ABS hydraulic unit. Replace the ABS hydraulic unit.

If the ABS indicator light (LED) [A] unlit, ABS system is

normal (service code is not stored; temporary failure.).

BRAKES 12-51

Anti-Lock Brake System

Rear Wheel Rotation Sensor Wiring Inspection

(Service Code 45)

• Do the 1st step test.

○Disconnect the ABS hydraulic unit connector and rear

wheel rotation sensor connector.

○Short the red and green lead terminals of the main har-

ness side connector [A] with a jumper lead, and check for

continuity between the red and green lead terminals of

the main harness side connector [B].

If there is the continuity in the lead, 2nd step.

If there is not the continuity in the lead, replace or repair

the main harness.

• Do the 2nd step test.

○Check for continuity between the white lead terminal of

the sensor connector [A] and ground, and black lead ter-

minal of the sensor connector and ground.

If there is the continuity in the lead, replace the rear wheel

rotation sensor.

If there is not the continuity in the lead, 3rd step.

• Do the 3rd step test.

○Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, and

retrieve the service code.

If the ABS indicator light (LED) [A] lit, faulty ECU in the

ABS hydraulic unit. Replace the ABS hydraulic unit.

If the ABS indicator light (LED) [A] unlit, ABS system is

normal (service code is not stored; temporary failure.).

Power Supply Voltage Abnormal (Under-Voltage)

(Service Code 52)

• Do the 1st step test.

○Disconnect the ABS Kawasaki self-diagnosis system con-

nector and ABS hydraulic unit connector.

○Check for continuity between the brown lead terminal of

the main harness side connector [A] and brown lead ter-

minal of the main harness side connector [B].

If there is the continuity in the lead, 2nd step.

If there is not the continuity in the lead, replace or repair

the main harness.

12-52 BRAKES

Anti-Lock Brake System

• Do the 2nd step test.

○Connect the ABS Kawasaki self-diagnosis system con-

nector and ABS hydraulic unit connector.

○Check the battery terminal voltage, connect the

hand tester to the brown terminal of ABS Kawasaki

self-diagnosis system connector [A] and ground.

Special Tool - Hand Tester: 57001-1394

Battery Terminal Voltage

Standard:

Battery Voltage

If the battery terminal voltage is not within the specifica-

tion, 3rd step.

If the battery terminal voltage correct, 4th step.

• Do the 3rd step test.

○Charge or replace the battery.

• Do the 4th step test.

○Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, and

retrieve the service code.

If the ABS indicator light (LED) [A] lit, faulty ECU in the

ABS hydraulic unit. Replace the ABS hydraulic unit.

If the ABS indicator light (LED) [A] unlit, ABS system is

normal (service code is not stored; temporary failure.).

Power Supply Voltage Abnormal (Over-Voltage)

(Service Code 53)

• Do the 1st step test.

○Check the battery terminal voltage, connect the

hand tester to the brown terminal of ABS Kawasaki

self-diagnosis system connector [A] and ground.

Special Tool - Hand Tester: 57001-1394

Battery Terminal Voltage

Standard:

Battery Voltage

If the battery terminal voltage is not within the specifica-

tion, 2nd step.

If the battery terminal voltage correct, 3rd step.

• Do the 2nd step test.

○Check the battery condition and regulator/rectifier (see

Charging Condition Inspection, Regulator/Rectifier In-

spection in the Electrical System chapter).

BRAKES 12-53

Anti-Lock Brake System

• Do the 3rd step test.

○Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, and

retrieve the service code.

If the ABS indicator light (LED) [A] lit, faulty ECU in the

ABS hydraulic unit. Replace the ABS hydraulic unit.

If the ABS indicator light (LED) [A] unlit, ABS system is

normal (service code is not stored; temporary failure.).

ECU Inspection (Service Code 55)

• Do the 1st step test.

○Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, and

retrieve the service code.

If the ABS indicator light (LED) [A] lit, faulty ECU in the

ABS hydraulic unit. Replace the ABS hydraulic unit.

If the ABS indicator light (LED) [A] unlit, ABS system is

normal (service code is not stored; temporary failure.).

ABS Hydraulic Unit Removal

CAUTION

The ABS hydraulic unit [A] has been adjusted

and set with precision at the factory. Therefore, it

should be handled carefully, never struck sharply,

as with a hammer, or allowed to fall on a hard

surface.

Be careful not to get water or mud on the ABS hy-

draulic unit.

• Drain the brake fluid from the front and rear brake lines.

○Drain the brake fluid through the bleed valve by pumping

the brake lever and pedal.

• Remove:

Left Frame Cover (see Frame Cover Removal in the

Frame chapter)

Rear Fender Front (see Rear Fender Front Removal in

the Frame chapter)

Regulator/Rectifier (see Regulator/Rectifier Removal in

the Electrical System chapter)

• Clean the ABS hydraulic unit.

CAUTION

Clean all fittings on the ABS hydraulic unit and the

rear master cylinder because dirt around the banjo

bolts could contaminate the brake fluid in the line

during removal/installation.

Spread out a shop towel around the ABS hydraulic

unit before removing the brake line so that brake

fluid does not leak on the parts.

12-54 BRAKES

Anti-Lock Brake System

• Remove:

Bolts [A]

• Remove:

Brake Pipe Joint Nuts [A] [B] [C] [D]

• Tape the brake line opening to prevent brake fluid leakage

or contamination by foreign matter.

CAUTION

Brake fluid quickly ruins painted plastic surfaces;

any spilled fluid should be completely washed away

immediately.

• Disconnect the connector [A].

○Pull the lever [B] as shown.

• Remove the ABS hydraulic unit with bracket.

• Remove:

Nuts [A] and Bracket [B]

CAUTION

The ABS hydraulic unit has been adjusted and set

with precision at the factory. Do not try to disas-

semble and repair the ABS hydraulic unit.

ABS Hydraulic Unit Installation

• Install the ABS hydraulic unit to the bracket.

CAUTION

Brake fluid quickly ruins painted plastic surfaces;

any spilled fluid should be completely washed away

immediately.

• Route the lead correctly, and join connector [A] securely.

○Pull the lever [B] as shown.

• Route the brake pipes correctly (see Cable, Wire, and

Hose Routing section in the Appendix chapter).

• Tighten the joint nuts.

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

• Install the removed parts (see appropriate chapters).

BRAKES 12-55

Anti-Lock Brake System

ABS Hydraulic Unit Inspection

• Remove the ABS hydraulic unit (see ABS Hydraulic Unit

Removal).

• Visually inspect the ABS hydraulic unit.

Replace the ABS hydraulic unit if any of them are cracked,

or otherwise damaged.

• Visually inspect the connector terminals [A].

Replace the ABS hydraulic unit or main harness if either

of the terminals are cracked, bent, or otherwise damaged.

If the ABS hydraulic unit connector is clogged with mud

or dust, blow it off with compressed air.

Front Wheel Rotation Sensor Removal

CAUTION

The wheel rotation sensor should be handled care-

fully, never struck sharply, as with a hammer, or al-

lowed to fall on a hard surface since the wheel rota-

tion sensor is precision made. Be careful not to get

water or mud on the wheel rotation sensor.

Do not try to disassemble or repair the wheel rota-

tion sensor.

• 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)

Left Upper Inner Fairing (see Upper Inner Fairing Re-

moval in the Frame chapter)

Bolt [A]

Clamp [B]

• Disconnect the connector [A].

12-56 BRAKES

Anti-Lock Brake System

• Remove:

Clamp [A]

Bolt [B]

Front Wheel Rotation Sensor [C]

Front Wheel Rotation Sensor Installation

• Installation is the reverse of removal.

○Route the lead correctly (see Cable, Wire, and Hose

Routing section in the Appendix chapter).

Rear Wheel Rotation Sensor Removal

CAUTION

The wheel rotation sensor should be handled care-

fully, never struck sharply, as with a hammer, or al-

lowed to fall on a hard surface since the wheel rota-

tion sensor is precision made. Be careful not to get

water or mud on the wheel rotation sensor.

Do not try to disassemble or repair the wheel rota-

tion sensor.

• 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)

• Disconnect the connector [A].

• Remove:

Bolt [A]

Rear Wheel Rotation Sensor [B]

Rear Wheel Rotation Sensor Installation

• Installation is the reverse of removal.

○Route the lead correctly (see Cable, Wire, and Hose

Routing section in the Appendix chapter).

BRAKES 12-57

Anti-Lock Brake System

Wheel Rotation Sensor Inspection

• Remove the front wheel rotation sensor [A] from the front

fork.

• Remove the rear wheel rotation sensor [B] from the

caliper bracket.

• Visually inspect the wheel rotation sensors.

Replace the wheel rotation sensor if it is cracked, bent, or

otherwise damaged.

Wheel Rotation Sensor Air Gap Inspection

• Raise the front/rear wheel off the ground (see Front/Rear

Wheel Removal in the Wheels/Tires chapter).

• Measure the air gap between the sensor and sensor rotor

at several points by turning the wheel slowly.

Thickness Gauge [A]

Air Gap

Standard:

Front

1 mm (0.04 in.)

Rear

1 mm (0.04 in.)

NOTE

○The sensor air gap cannot be adjusted.

If the air gap is not within the specification, inspect the hub

bearing (see Hub Bearing Inspection in the Wheels/Tires

chapter), sensor installation condition and sensor (see

Wheel Rotation Sensor Inspection).

Wheel Rotation Sensor Rotor Inspection

• Remove the front/rear brake discs (see Brake Disc Re-

moval).

• Visually inspect the wheel rotation sensor rotor.

If the rotor is deformed or damaged (chipped teeth [A]),

replace the sensor rotor with the brake disc.

If there is iron or other magnetic deposits [B], remove the

deposits.

Brake Hose and Pipe Removal/Installation

• Refer to the Brake Hose and Pipe Replacement in the

Periodic Maintenance chapter.

12-58 BRAKES

Anti-Lock Brake System

Brake Hose and Pipe Inspection

• Refer to the Brake Hose and Pipe Damage and Instal-

lation Condition Inspection in the Periodic Maintenance

chapter.

ABS Solenoid Valve Relay Fuse Removal

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

ter).

• Unlock the hook [A] to lift up the lid [B].

• Pull out the relay fuse [A] from the fuse box with needle

nose pliers.

ABS Motor Relay Fuse Removal

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

ter).

• Unlock the hook [A] to lift up the lid [B].

• Pull out the relay fuse [A] from the fuse box with needle

nose pliers.

Fuse Installation

• If a fuse fails during operation, inspect the electrical sys-

tem to determine the cause, and then replace it with a

new fuse of proper amperage.

BRAKES 12-59

Anti-Lock Brake System

Fuse Inspection

• Remove the fuse (see ABS Solenoid Valve Relay/ABS

Motor Relay Fuse Removal).

• Inspect the fuse element.

If it is blown out, replace the fuse. Before replacing a

blown fuse, always check the amperage in the affected

circuit. If the amperage is equal to or greater than the

fuse rating, check the wiring and related components for

a short circuit.

Housing [A]

Fuse Element [B]

Terminals [C]

Blown Element [D]

CAUTION

When replacing a fuse, be sure the new fuse

matches the specified fuse rating for that circuit.

Installation of a fuse with a higher rating may cause

damage to wiring and components.

13-2 SUSPENSION

Exploded View

SUSPENSION 13-3

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Front Axle Clamp Bolt

34

3.5

25

2

Front Fork Bottom Allen Bolts

30

3.1

22

L

3

Front Fork Clamp Bolts (Lower)

20

2.0

15

AL

4

Front Fork Clamp Bolts (Upper)

20

2.0

15

5

Front Fork Top Plugs

25

2.5

18

6. Outer Tube (EX650B Models)

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

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

13-4 SUSPENSION

Exploded View

SUSPENSION 13-5

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Rear Shock Absorber Bolt

59

6.0

44

2

Rear Shock Absorber Nut

59

6.0

44

3

Swingarm Pivot Shaft Nut

108

11.0

80

G: Apply grease.

R: Replacement Parts

SUSPENSION 13-7

Special Tools

Inside Circlip Pliers:

Jack:

57001-143

57001-1238

Fork Cylinder Holder Handle:

Fork Oil Seal Driver,

41:

57001-183

57001-1288

Fork Cylinder Holder Adapter:

Fork Oil Level Gauge:

57001-1057

57001-1290

Oil Seal & Bearing Remover:

Jack Attachment:

57001-1058

57001-1608

Bearing Driver Set:

Stem Bearing Driver,

28:

57001-1129

57001-1610

SUSPENSION 13-9

Front Fork

Front Fork Removal

• Remove:

Upper Inner Fairing (see Upper Inner Fairing Removal

in the Frame chapter)

Front Wheel (see Front Wheel Removal in the

Wheels/Tires chapter)

Front Fender (see Front Fender Removal in the Frame

chapter)

Front Wheel Rotation Sensor (see Front Wheel Rotation

Sensor Removal in the Brakes chapter) (EX650B Mod-

els)

Loosen the upper fork clamp bolt [A] and fork top plug [B]

beforehand if the fork leg is to be disassembled.

NOTE

○Loosen the top plug after loosening the upper fork

clamp bolt.

• Loosen the upper fork clamp bolt and lower fork clamp

bolts [C].

• With a twisting motion, work the fork leg down and out.

Front Fork Installation

• Install the fork so that the top end [A] of the inner tube as

shown.

10 mm (0.40 in.) [B]

• Tighten:

Torque - Front Fork Clamp Bolts (Lower):

20 N·m (2.0

kgf·m, 15 ft·lb)

Front Fork Top Plug: 25 N·m (2.5 kgf·m, 18 ft·lb)

NOTE

○Tighten the top plug before tightening the upper fork

clamp bolt.

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

sure even tightening torque.

• Tighten:

Torque - Front Fork Clamp Bolt (Upper): 20 N·m (2.0 kgf·m,

15 ft·lb)

• Install the removed parts (see appropriate chapters).

Front Fork Oil Change

• Remove the front fork (see Front Fork Removal).

• Remove:

Top Plug [A] with O-ring

Collar [B]

Fork Spring Seat [C]

Fork Spring [D]

13-10 SUSPENSION

Front Fork

• Compress [A] the fork [B] upside down to draw out the oil

into the suitable container [C].

• Pour in the specified amount of oil.

Fork Oil

Viscosity:

KAYABA KHL34-G10 or

equivalent

Amount (Per Side):

When changing oil:

EX650A Models

approx. 415 mL (14.0 US oz.)

EX650B Models

approx. 420 mL (14.2 US oz.)

After disassembly and completely dry:

EX650A Models

489 ±4 mL (16.5 ±0.14 US oz.)

EX650B Models

498 ±3 mL (16.8 ±0.10 US oz.)

NOTE

○Move the outer tube up and down a few times to remove

the air that is trapped in the fork oil in order to stabilize

the oil level.

• Hold the outer tube vertically in a vise and compress the

fork completely.

• Wait until the oil level stabilizes.

• Use the fork oil level gauge [A] to measure the distance

between the top of the inner tube to the oil level.

Special Tool - Fork Oil Level Gauge: 57001-1290

○Set the oil level gauge stopper [B] so that the distance [C]

from the bottom of the stopper to the lower end of the pipe

is the standard oil level distance.

○A correct measurement can not be obtained unless the

level gauge pipe is placed in the center of the inner tube.

Oil Level (fully compressed, without spring)

Standard:

EX650A Models

98 ±2 mm (3.9 ±0.08 in.)

EX650B Models

89 ±2 mm (3.5 ±0.08 in.)

○Place the stopper of the level gauge at the top [D] of the

inner tube [E] and pull the handle slowly to draw out the

excess oil from fork into the gauge, thus attaining the stan-

dard level.

○If not oil is drawn out, there is not enough oil in the fork.

Pour in some more oil and measure again.

• Repeat the same procedure for adjusting the other fork.

• Install the fork spring [A], fork spring seat [B] and collar

[C].

• Inspect the top plug O-ring and replace it with a new one.

• Install the front fork (see Front Fork Installation).

SUSPENSION 13-11

Front Fork

Front Fork Disassembly

• Remove the front fork (see Front Fork Removal).

• Remove the top plug [A] with O-ring, take out the collar

[B], fork spring seat [C], and fork spring [D].

• Drain the fork oil (see Front Fork Oil Change).

• Remove the Allen bolt [A] from the bottom of the fork.

Special Tools - Fork Cylinder Holder Handle [B]: 57001-183

Fork Cylinder Holder Adapter [C]: 57001

-1057

NOTE

○Hold the outer tube in a vise [D], stop the cylinder unit

[E] from turning by using the special tools, and unscrew

the Allen bolt.

• Remove the cylinder unit [A], washer, and the spring [B]

from the inner tube.

• Remove the following from the top of the outer tube.

Dust Seal [A]

Retaining Ring [B]

• Separate the inner tube [A] from the outer tube [B].

NOTE

○From the compressed state, firmly pull down the outer

tube a few times towards the direction of elongation.

13-12 SUSPENSION

Front Fork

• Remove the following from the inner tube.

Inner Guide Bushing [A]

Outer Guide Bushing [B]

Washer [C]

Oil Seal [D]

• Remove the cylinder base [A] from the bottom of the outer

tube.

Front Fork Assembly

• Check the top plug O-ring and replace it with a new one.

• Replace the following parts with new ones.

Retaining Ring [A]

Dust Seal [B]

Oil Seal [C]

Inner Guide Bushing [D]

Outer Guide Bushing [E]

Fork Bottom Allen Bolt Gasket [F]

• Install the guide bushing on the end of the inner tube.

• Insert the cylinder unit and the spring into the inner tube,

and install the cylinder base [A] onto the cylinder end [B]

that protrudes from the bottom.

○Install the cylinder base starting with its stepped end.

• Insert the inner tube, cylinder unit, washer, spring, and

cylinder base as a set into the outer tube.

• Install the guide bushing into the outer tube.

• After installing the washer, install the oil seal [A] by using

the fork oil seal driver [B].

Special Tool - Fork Oil Seal Driver,

41: 57001-1288

• Install the retaining ring into the outer tube.

• Install the dust seal by hand.

SUSPENSION 13-13

Front Fork

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

bottom Allen bolt [A].

• Hold the front fork horizontally in a vise [B].

• Hold the cylinder unit [C] with the special tools and tighten

the bottom Allen bolt to secure the cylinder in place.

Torque - Front Fork Bottom Allen Bolt: 30 N·m (3.1 kgf·m,

22 ft·lb)

Special Tools - Fork Cylinder Holder Handle [D]: 57001-183

Fork Cylinder Holder Adapter [E]: 57001

-1057

• Pour in the specified type of oil (see Front Fork Oil

Change).

Inner Tube Inspection

• Visually inspect the inner tube [A], and repair any dam-

age.

• Nicks or rust damage can sometimes be repaired by using

a wet-stone to remove sharp edges or raised areas which

cause seal damage.

If the damage is not repairable, replace the inner tube.

Since damage to the inner tube damages the oil seal,

replace the oil seal whenever the inner tube is repaired

or replaced.

CAUTION

If the inner tube is badly bent or creased, replace

it.

Excessive bending, followed by subsequent

straightening, can weaken the inner tube.

• Temporarily assemble the inner and outer tubes, and

pump them back and forth manually to check for smooth

operation.

• If you feel binding or catching, the inner and outer tubes

must be replaced.

WARNING

A straightened inner or outer fork tube may fall in

use, possibly causing an accident. Replace a badly

bent or damaged inner or outer tube and inspect the

other tube carefully before reusing it.

Dust Seal Inspection

• Inspect the dust seal [A] for any signs of deterioration or

damage.

Replace it if necessary.

13-14 SUSPENSION

Front Fork

Fork Spring Inspection

• Measure the free length [A] of the fork spring [B].

If the measured length is shorter than the service limit, the

spring must be replaced. If the free length of the replace-

ment spring and that of the remaining spring vary greatly,

the remaining spring should also be replaced in order to

keep the fork legs balanced to ensure stability.

Fork Spring Free Length

Standard:

277.2 mm (10.91 in.)

Service Limit:

272 mm (10.7 in.)

SUSPENSION 13-15

Rear Shock Absorber

Spring Preload Adjustment

• Using the hook wrench [A], turn the adjusting nut [B] to

adjust the spring preload.

○The standard adjuster setting for average-build rider of 68

kg (150 Ib) with no passenger and no accessories is 2nd

position.

Spring Preload Setting

Standard Position:

2nd position

Adjustable Range:

1st to 7th position

• If the compression of the spring is not suited to the op-

erating conditions, adjust it to an appropriate position by

referring to the table below.

Spring Preload Adjustment

Shock

Adjuster

Damping

Road

Driving

Absorber

Load

Position

Force

Conditions

Speed

Hardness

1st

Weak

Soft

Light

Good

Low

↑

↑

↑

↑

↑

↑

↓

↓

↓

↓

↓

↓

7th

Strong

Hard

Heavy

Bad

Highway

Rear Shock Absorber Removal

• Remove:

Frame Covers (see Frame Cover Removal in the Frame

chapter)

Muffler Body (see Muffler Body Removal in the Engine

Top End chapter)

• Raise the rear wheel off the ground with jack.

Special Tools - Jack: 57001-1238

Jack Attachment: 57001-1608

• Squeeze the brake lever slowly and hold it with a band

[A].

WARNING

Be sure to hold the front brake when removing the

shock absorber, or the motorcycle may tall over. It

could cause an accident and injury.

• Remove:

Right Stay Cover [A]

13-16 SUSPENSION

Rear Shock Absorber

• Remove:

Upper Shock Absorber Bolt [A]

Lower Shock Absorber Nut and Washer

Lower Shock Absorber Bolt [B]

• Remove the shock absorber [C] from backward.

Rear Shock Absorber Installation

• Installation is the reverse of removal.

• Apply grease to the lip of oil seals.

○Be sure to install the oil seals to the shock absorber.

• Tighten:

Torque - Rear Shock Absorber Bolt: 59 N·m (6.0 kgf·m, 44

ft·lb)

Rear Shock Absorber Nut: 59 N·m (6.0 kgf·m, 44

ft·lb)

• Install the removed parts (see appropriate chapters).

Rear Shock Absorber Inspection

• Remove the rear shock absorber (see Rear Shock Ab-

sorber Removal).

• Visually inspect the following items.

Smooth Stroke

Oil Leakage

Crack or Dent

If there is any damage to the rear shock absorber, replace

it.

• Visually inspect the rubber bushing.

If it show any signs of damage, replace it.

SUSPENSION 13-17

Swingarm

Swingarm Removal

• Remove:

Chain Cover Bolts [A] and Cover [B]

• Remove:

Right Side Cover (see Side Cover Removal in the Frame

chapter)

Frame Covers (see Frame Cover Removal in the Frame

chapter)

• Remove the brake hose banjo bolt from the rear caliper,

free the brake hose [A] from the clamps [B], and remove

the footpeg stay with the rear master cylinder (see Rear

Caliper Removal in the Brakes chapter).

• Remove:

Muffler Body (see Muffler Body Removal in the Engine

Top End chapter)

Rear Wheel (see Rear Wheel Removal in the

Wheels/Tires chapter)

• Raise the rear wheel off the ground with jack.

Special Tools - Jack: 57001-1238

Jack Attachment: 57001-1608

• Remove the lower shock absorber nut and bolt [A].

• Remove the drive chain (see Drive Chain Removal in the

Final Drive chapter).

• Unscrew the swingarm pivot shaft nut [A].

• Pull off the pivot shaft [B], and remove the swingarm.

Swingarm Installation

• Installation is the reverse of removal.

○Apply grease to the lip of the oil seals.

○Be sure to install the oil seal and collar to the swingarm.

• Tighten the pivot shaft nut.

Torque - Swingarm Pivot Shaft Nut: 108 N·m (11.0 kgf·m,

80 ft·lb)

• Install the removed parts (see appropriate chapters).

13-18 SUSPENSION

Swingarm

Swingarm Bearing Removal

• Remove:

Swingarm (see Swingarm Removal)

Collar [A]

Oil Seals [B]

Sleeve [C]

Circlip [D]

Special Tool - Inside Circlip Pliers: 57001-143

• Remove the ball bearing and needle bearings.

Special Tool - Oil Seal & Bearing Remover [A]: 57001-1058

Swingarm Bearing Installation

• Replace the ball and needle bearings [A] with new ones.

• Install the ball and needle bearings so that the manufac-

turer’s marks face out.

Special Tools - Bearing Driver Set: 57001-1129

Stem Bearing Driver,

28 [B]: 57001-1610

Spacer,

28: 57001-1663

SUSPENSION 13-19

Swingarm

• Install the needle bearings [A], ball bearing [B] and oil

seals [C] position as shown.

Circlip [D]

25 mm (0.98 in.) [E]

17 mm (0.67 in.) [F]

1 mm (0.04 in.) [G]

0.5 mm (0.02 in.) [H]

1 mm (0.04 in.) [I]

23.5 mm (0.93 in.) [J]

6 mm (0.24 in.) [K]

Swingarm Bearing, Sleeve Inspection

CAUTION

Do not remove the bearings for inspection. Re-

moval may damage them.

• Inspect the needle bearings [A] and ball bearing installed

in the swingarm.

○The rollers and ball in a bearing normally wear very little,

and wear is difficult to measure. Instead of measuring,

visually inspect the bearing for abrasion, discoloration, or

other damage.

If the needle bearing and sleeve [B] show any sings of

abnormal wear, discoloration, or damage, replace them

as a set.

13-20 SUSPENSION

Swingarm

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

checking for plays, roughness, or binding.

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

the bearing.

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

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

Swingarm Bearing Lubrication

NOTE

○Since the bearings are packed with grease and sealed,

lubrication is not required.

Chain Guide Inspection

• Refer to the Chain Guide Wear Inspection in the Periodic

Maintenance chapter.

14-2 STEERING

Exploded View

STEERING 14-3

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Front Fork Clamp Bolts (Lower)

20

2.0

15

AL

2

Front Fork Clamp Bolts (Upper)

20

2.0

15

3

Handlebar Holder Bolts

25

2.5

18

S

4

Left Switch Housing Screws

3.5

0.36

31 in·lb

5

Right Switch Housing Screws

3.5

0.36

31 in·lb

6

Steering Stem Head Bolt

108

11.0

80

7

Steering Stem Nut

20

2.0

15

AD: Apply adhesive.

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

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

S: Follow the specified tightening sequence.

14-4 STEERING

Special Tools

Steering Stem Nut Wrench:

Steering Stem Bearing Driver,

42.5:

57001-1100

57001-1344

Bearing Driver Set:

Steering Stem Bearing Driver Adapter,

41.5:

57001-1129

57001-1345

14-6 STEERING

Steering Stem

Stem, Stem Bearing Removal

• Remove:

Upper Fairing (see Upper Fairing Removal in the Frame

chapter)

Under Bracket [A] (see Upper Fairing Bracket Removal

in the Frame chapter)

• Remove:

Upper Fairing Bracket [A] (see Upper Fairing Bracket

Removal in the Frame chapter)

• Remove:

Front Wheel (see Front Wheel Removal in the

Wheels/Tires chapter)

Front Forks (see Front Fork Removal in the Suspension

chapter)

Handlebar (see Handlebar Removal)

Steering Stem Head Bolt Plug [A]

Steering Stem Head Bolt [B] and Washer

Front Fork Clamp Bolts (Upper) [C] (Loosen)

Steering Stem Head [D]

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

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

[C].

• Pushing up the stem base, and remove the steering stem

nut [A] with stem cap [B].

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

• Remove the steering stem [D] under side.

• Remove the upper stem bearing inner race and bearing.

STEERING 14-7

Steering Stem

• To remove the bearing outer races [A] pressed into the

head pipe [B], insert a bar [C] into the recesses of head

pipe, and applying it to both recess alternately hammer it

to drive the race out.

NOTE

○If either steering stem bearing is damaged, it is recom-

mended that both the upper and lower bearings (includ-

ing outer races) should be replaced with new ones.

• Remove the lower bearing inner race [A] which is pressed

onto the steering stem with a suitable commercially avail-

able chisel [B].

Stem, Stem Bearing Installation

• Replace the bearing outer races with new ones.

• Apply grease to the outer races, and drive them into the

head pipe at the same time.

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

• Replace the bearing inner races and oil seal with new

ones.

• Apply grease to the oil seal.

• Drive the lower ball bearing inner race applied the grease

onto the stem.

Special Tools - Steering Stem Bearing Driver,

42.5 [A]:

57001-1344

Steering Stem Bearing Driver Adapter,

41.5 [B]: 57001-1345

• Apply grease to the lower ball bearing [A], and install it

onto the stem.

• Apply grease to the upper ball bearing [B] and inner race

[C].

14-8 STEERING

Steering Stem

• Install the stem [A] through the head pipe and install the

ball bearing [B] and inner race [C] on it.

• Install the stem cap [D] and steering stem nut [E].

• Settle the inner races in place as follows.

○Tighten the steering stem nut with 39 N·m (4.0 kgf·m, 29

ft·lb) of torque first, and loosen it a fraction of a turn until

it turns lightly. Afterward tighten it again with specified

torque using a stem nut wrench [A] in the direction shown.

○Check that there is no play and the steering stem turns

smoothly without rattles. If not, the steering stem bearings

may be damaged.

Special Tool - Steering Stem Nut Wrench: 57001-1100

Torque - Steering Stem Nut: 20 N·m (2.0 kgf·m, 15 ft·lb)

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

upward, and engage the bent claws with the grooves of

stem locknut [C].

• Hand tighten the stem locknut until it touches the claw

washer.

• Tighten the stem locknut clockwise until the claws are

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

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

• Install the stem head.

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

specified torque.

• Install the front forks (see Front Fork Installation in the

Suspension chapter).

NOTE

○Tighten the upper fork clamp bolts first, next the stem

head bolt, last the lower fork clamp bolts.

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

sure even tightening torque.

Torque - Front Fork Clamp Bolts (Upper):

20 N·m (2.0

kgf·m, 15 ft·lb)

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

ft·lb)

Front Fork Clamp Bolts (Lower):

20 N·m (2.0

kgf·m, 15 ft·lb)

WARNING

Do not impede the handlebar turning by routing the

cables, harnesses and hoses improperly (see Ca-

ble, Wire, and Hose Routing section in the Appen-

dix chapter).

• Install the steering stem head bolt plug.

• Install the removed parts (see appropriate chapters).

STEERING 14-9

Steering Stem

Stem Bearing Lubrication

• Refer to the Steering Stem Bearing Lubrication in the Pe-

riodic Maintenance chapter.

Steering Stem Warp

• Whenever the steering stem is removed, or if the steering

cannot be adjusted for smooth action, check the steering

stem for straightness.

If the steering stem [A] is bent, replace the steering stem.

Stem Cap Deterioration, Damage

Replace the stem cap if its oil seal [A] shows damage.

14-10 STEERING

Handlebar

Handlebar Removal

• Remove:

Clutch Lever Assembly [A]

Left Switch Housing [B]

Left Handlebar Weight [C]

• Remove:

Front Brake Master Cylinder [A] (see Front Master Cylin-

der Removal in the Brakes chapter)

Right Switch Housing [B]

Right Handlebar Weight [C]

Throttle Grip [D]

• Remove the handlebar holder bolts [A].

• Remove the handlebar holder [B] and then pull out the

handlebar.

Handlebar Installation

• Align the punch mark [A] on the handlebar and the corner

edge [B] on the stem head.

• Tighten the front holder bolts first, and then the rear holder

bolts. There will be a gap [A] at the rear part of the han-

dlebar holder after tightening.

Torque - Handlebar Holder Bolts:

25 N·m (2.5 kgf·m, 18

ft·lb)

STEERING 14-11

Handlebar

• Install the clutch lever (see Clutch Lever Installation in the

Clutch chapter).

• Apply adhesive cement to the inside of the left handlebar

grip.

• Apply a non-permanent locking agent to the left handlebar

weight bolt.

• Install the left switch housing.

○Fit the projection [A] into a small hole [B] in the handlebar.

Torque - Left Switch Housing Screws: 3.5 N·m (0.36 kgf·m,

31 in·lb)

• Install:

Throttle Grip

Throttle Cable Tips [A]

Right Switch Housing

○Fit the projection [B] into a small hole [C] in the handlebar.

Torque - Right Switch Housing Screws:

3.5

N·m (0.36

kgf·m, 31 in·lb)

• Apply a non-permanent locking agent to the right handle-

bar weight bolt.

• Install the front brake master cylinder (see Front Master

Cylinder Installation in the Brakes chapter).

15-2 FRAME

Exploded View

15-4 FRAME

Exploded View

FRAME 15-5

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Front Fender Bolts

3.9

0.40

35 in·lb

2

Front Fender Bracket Bolts

8.8

0.90

78 in·lb

L

3

Front Turn Signal Light Mounting Screws

1.2

0.12

11 in·lb

L: Apply a non-permanent locking agent.

15-6 FRAME

Exploded View

15-8 FRAME

Seat

Seat Removal

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

the key clockwise, pulling up on the rear of the seat [B],

and pulling the seat backward.

Seat Installation

• Slip the seat hook [A] under the brace [B] on the fuel tank

bracket.

• Insert the seat latch [A] into the latch hole [B].

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

FRAME 15-9

Fairings

Lower Fairing Removal

• Pull up the core by the thin blade driver.

• Remove the quick rivets [A].

• Remove the bolts [B] with collar and washers.

• Clear the hook portions from the slots.

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

Lower Fairing Installation

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

• Set the quick rivet and push the core.

Center Fairing Removal

• Remove:

Lower Fairings (see Lower Fairing Removal)

Upper Inner Fairing (see Upper Inner Fairing Removal)

Screw [A]

Bolt [B] with Washers

• Remove the meter cover (see Meter Unit Removal/Instal-

lation in the Electrical System chapter).

• Disconnect the turn signal lead connector [A].

• Remove the screw [B].

• Pull the center fairing [C] evenly outward to clear the stop-

pers.

• Remove the inner fairing (see Inner Fairing Removal).

• Remove the screw [A] and turn signal light [B].

Center Fairing Installation

• Install the turn signal light to the center fairing.

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

15-10 FRAME

Fairings

• Insert the hook [A] into the slot [B].

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

• Connect the turn signal lead connector.

• Install the bolt and screws.

Windshield Removal

• Remove:

Bolts [A] with Washers

Windshield [B]

Dampers

Windshield Installation

• Install the dampers.

• Insert the hook [A] into the slot [B].

• Tighten the bolts with washers.

Upper Fairing Removal

• Remove:

Windshield (see Windshield Removal)

Upper Inner Fairings (see Upper Inner Fairing Removal)

Lower Fairings (see Lower Fairing Removal)

Center Fairings (see Center Fairing Removal)

Headlight Lead Connectors

Rear View Mirror Nuts (Both Side) [A]

• Remove the upper fairing forward.

FRAME 15-11

Fairings

Upper Fairing Disassembly

• Remove:

Headlight [A] (see Headlight Removal/Installation in the

Electrical System chapter)

Upper Fairing Assembly

• Install the headlight (see Headlight Removal/Installation

in the Electrical System chapter).

Upper Fairing Installation

• Installation is the reverse of removal.

Upper Inner Fairing Removal

• Remove the bolts [A].

• Pull the upper inner fairing [B] backward, and clear the

hooks.

Upper Inner Fairing Installation

• Insert the hook [A] into the slot [B].

• Tighten the bolts.

Upper Fairing Bracket Removal

• Remove:

Upper Fairing (see Upper Fairing Removal)

Meter Unit (see Meter Unit Removal/Installation in the

Electrical System chapter)

Clamp [A]

Bolts [B]

Horn Leads [C]

Under Bracket [D]

15-12 FRAME

Fairings

• Remove:

Bolts [A]

Clamps [B]

Upper Fairing Bracket [C]

Inner Fairing Removal

• Remove:

Center Fairings (see Center Fairing Removal)

Mounting Screws [A]

Inner Fairing [B]

Inner Fairing Installation

• Tighten the mounting screws.

Torque - Front Turn Signal Light Mounting Screws: 1.2 N·m

(0.12 kgf·m, 11 in·lb)

• Install the center fairings (see Center Fairing Installation).

FRAME 15-13

Side Covers

Side Cover Removal

• Remove the seat (see Seat Removal).

• Remove the bolt [A].

• Pull the side cover [B] evenly outward to clear the stop-

pers.

Side Cover Installation

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

• Tighten the bolt.

• Install the seat (see Seat Installation).

15-14 FRAME

Seat Covers

Seat Cover Removal

• Remove:

Seat (see Seat Removal)

Bolts [A]

Grab Rails [B] (Other than United States and Canada

Models)

Screw Rivets [C]

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

• Pull the front and rear portions of the seat cover outside,

and then remove the seat covers.

Seat Cover Installation

• Installation is the reverse of removal.

• Put the projection [A] into the grommet [B] on the rear

fender rear.

• Put the projection [A] into the hole [B] of the seat cover.

• Install:

Grab Rails (Other than United States and Canada Mod-

els) and Bolts

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

ft·lb)

• Insert the projections [A] of the center seat cover into the

holes [B] of the side seat cover.

• Install:

Screw Rivets

Seat (see Seat Installation)

FRAME 15-15

Fenders

Front Fender Removal

• Remove:

Brake Hose Clamps [A]

Bolts [B] with Collar (Both Side)

• Remove the front fender [C].

Front Fender Installation

• Tighten:

Torque - Front Fender Bolts: 3.9 N·m (0.40 kgf·m, 35 in·lb)

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

Flap and Rear Fender Rear Removal

• Remove:

Seat (see Seat Removal)

Seat Covers (see Seat Cover Removal)

Tail/Brake Light [A] (see Tail/Brake Light Removal in the

Electrical System chapter)

• Remove:

Nuts [A] and Bolts [B]

Flap (with License Plate Light)

• Remove:

Seat Lock Cable Lower End [A]

Quick Rivet [B]

• Free the clamps from the rear fender rear.

• Pull out the rear fender rear backward and downward.

Flap and Rear Fender Rear Installation

• Installation is the reverse of removal.

15-16 FRAME

Fenders

Rear Fender Front Removal

• Remove:

Rear Fender Rear (see Flap and Rear Fender Rear Re-

moval)

Battery (see Battery Removal in the Electrical System

chapter)

Relay Box (see Relay Box Removal in the Electrical Sys-

tem chapter)

Starter Relay (see Starter Relay Inspection in the Elec-

trical System chapter)

• Remove the fuse box from the rear fender front.

• Remove:

Bolt [A]

Clamp [B]

• Free the clamp from the rear fender front.

• Remove the rear fender front [A] backward and upward.

Rear Fender Front Installation

• Installation is the reverse of removal.

• Install the removed parts (see appropriate chapters).

15-18 FRAME

Sidestand

Sidestand Removal

• Raise the rear wheel off the ground with stand.

• Remove:

Frame Cover (see Frame Cover Removal)

Bolts [A]

Footpeg Stay [B]

• Remove:

Sidestand Switch Bolt [A] with Clamp

Sidestand Switch [B]

• Remove:

Spring [A]

Sidestand Nut [B]

Sidestand Bolt [C]

Sidestand [D]

Sidestand Installation

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

• Tighten the bolt and lock them with the nut.

Torque - Sidestand Bolt: 44 N·m (4.5 kgf·m, 33 ft·lb)

• Hook the spring.

• Install the sidestand switch.

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

switch bolt.

Torque - Sidestand Switch Bolt:

8.8 N·m (0.90 kgf·m, 78

in·lb)

• Install the footpeg stay.

• Tighten:

Torque - Footpeg Stay Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)

FRAME 15-19

Frame Cover

Frame Cover Removal

• Remove the bolt [A].

• Pull the frame cover [B] outward to clear the stoppers.

Frame Cover Installation

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

• Tighten the bolt.

16-4 ELECTRICAL SYSTEM

Exploded View

ELECTRICAL SYSTEM 16-5

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Front Turn Signal Light Mounting Screws

1.2

0.12

11 in·lb

2

License Plate Light Cover Screws

0.90

0.090

8 in·lb

3

License Plate Light Mounting Screws

1.2

0.12

11 in·lb

4

Meter Screws

1.2

0.12

11 in·lb

5. Meter Unit (EX650B Models)

6. City Light (Europe Models)

16-6 ELECTRICAL SYSTEM

Exploded View

ELECTRICAL SYSTEM 16-7

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Front Brake Light Switch Screw

1.2

0.12

11 in·lb

2

Left Switch Housing Screws

3.5

0.36

31 in·lb

3

Right Switch Housing Screws

3.5

0.36

31 in·lb

4

Starter Motor Cable Terminal Nut

6.0

0.60

53 in·lb

5

Starter Motor Mounting Bolts

9.8

1.0

87 in·lb

L

6

Starter Motor Terminal Locknut

11

1.1

97 in·lb

7

Starter Motor Through Bolts

4.9

0.50

43 in·lb

8

Engine Ground Cable Terminal Bolt

9.8

1.0

87 in·lb

9. Main Harness (EX650B Models)

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

16-8 ELECTRICAL SYSTEM

Exploded View

ELECTRICAL SYSTEM 16-9

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Alternator Cover Bolts

9.8

1.0

87 in·lb

2

Alternator Lead Holding Plate Bolt

9.8

1.0

87 in·lb

L

3

Alternator Rotor Bolt

155

15.8

114

MO

4

Crankshaft Sensor Bolts

6.0

0.60

53 in·lb

5

Neutral Switch

15

1.5

11

6

Oil Pressure Switch

15

1.5

11

SS

7

Oxygen Sensor

44.1

4.50

32.5

8

Regulator/Rectifier Bolts

8.8

0.90

78 in·lb

9

Sidestand Switch Bolt

8.8

0.90

78 in·lb

L

10

Spark Plugs

15

1.5

11

11

Speed Sensor Bolt

7.8

0.80

69 in·lb

L

12

Starter Motor Clutch Bolts

34

3.5

25

L

13

Stator Coil Bolts

12

1.2

106 in·lb

L

14

Timing Rotor Bolt

40

4.1

30

15

Water Temperature Sensor

12

1.2

106 in·lb

16. EX650B Models

17. EX650A Models

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

SS: Apply silicone sealant.

ELECTRICAL SYSTEM 16-11

Special Tools and Sealants

Hand Tester:

Grip:

57001-1394

57001-1591

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

Flywheel & Pulley Holder:

57001-1405

57001-1605

Peak Voltage Adapter:

Rotor Holder:

57001-1415

57001-1658

Lead Wire - Peak Voltage Adapter:

Kawasaki Bond (Silicone Sealant):

57001-1449

56019-120

Needle Adapter Set:

Kawasaki Bond (Silicone Sealant):

57001-1457

92104-0004

16-12 ELECTRICAL SYSTEM

Parts Location

1. Air Switching Valve

13. Rear Brake Light Switch

2. Alternator

14. Regulator/Rectifier

3. Battery 12 V 10 Ah

15. Relay Box

4. Crankshaft Sensor

16. Sidestand Switch

5. ECU

17. Speed Sensor

6. Fan Motor

18. Starter Lockout Switch

7. Front Brake Light Switch

19. Starter Motor

8. Fuse Box with ECU Main Fuse

20. Starter Relay with Main Fuse

9. Ignition Switch

21. Stick Coils

10. Meter Unit

22. Turn Signal Relay

11. Neutral Switch

23. Water Temperature Sensor

12. Oil Pressure Switch

24. Oxygen Sensor (Europe Models)

16-14 ELECTRICAL SYSTEM

Wiring Diagram (Europe, Korea, Hong Kong and Kuwait)