Kawasaki Ninja 650R, ER-6f, ER-6f ABS Motorcycle. Service Manual (2009-2011 year)

1-10 GENERAL INFORMATION

General Specifications

Items

EX650C9F, EX650D9F

Dimensions

Overall Length

2 100 mm (82.68 in.)

Overall Width

760 mm (29.9 in.)

Overall Height

1 200 mm (47.24 in.)

Wheelbase

1 410 mm (55.51 in.)

Road Clearance

145 mm (5.71 in.)

Seat Height

790 mm (31.1 in.)

Curb Mass:

EX650C Models:

204 kg (450 lb)

Front

104 kg (229 lb)

Rear

100 kg (221 lb)

EX650D Models:

208 kg (459 lb)

Front

105 kg (232 lb)

Rear

103 kg (227 lb)

Fuel Tank Capacity

15.5 L (4.10 US gal.)

Performance

Minimum Turning Radius

2.7 m (8.9 ft)

Engine

Type

4-stroke, DOHC, 2-cylinder

Cooling System

Liquid-cooled

Bore and Stroke

83.0 × 60.0 mm (3.27 × 2.36 in.)

Displacement

649 cm³ (39.6 cu in.)

Compression Ratio

11.3 : 1

Maximum Horsepower

53 kW (72 PS) @8 500 r/min (rpm)
(MY) 52 kW (71 PS) @8 000 r/min (rpm)
(US, CA, CAL) – – –

Maximum Torque

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

Carburetion System

FI (Fuel Injection), KEIHIN TTK38 × 2

Starting System

Electric starter

Ignition System

Battery and coil (transistorized)

Timing Advance

Electronically advanced (IC igniter in ECU)

Ignition Timing

From 10° BTDC @1 300 r/min (rpm)
To 34° BTDC @5 000 r/min (rpm)

Spark Plug

NGK CR9EIA-9

Cylinder Numbering Method

Left to right, 1-2

Firing Order

1-2

Valve Timing:

Inlet:

Open

31° BTDC

61° ABDC

Duration

272°

GENERAL INFORMATION 1-11

General Specifications

Items

EX650C9F, EX650D9F

Exhaust:

Open

50° BBDC

30° ATDC

Duration

260°

Lubrication System

Forced lubrication (semi-dry sump)

Engine Oil:

Grade

API SE, SF or SG

API SH, SJ, SL or SM with JASO MA, MA1 or MA2

Viscosity

SAE 10W-40

Capacity

2.4 L (2.5 US qt)

Drive Train

Primary Reduction System:

Type

Gear

Reduction Ratio

2.095 (88/42)

Clutch Type

Wet multi disc

Transmission:

Type

6-speed, constant mesh, return shift

Gear Ratios:

1st

2.438 (39/16)

2nd

1.714 (36/21)

3rd

1.333 (32/24)

4th

1.111 (30/27)

5th

0.966 (28/29)

6th

0.852 (23/27)

Final Drive System:

Type

Chain drive

Reduction Ratio

3.067 (46/15)

Overall Drive Ratio

5.473 @Top gear

Frame

Type

Tubular, diamond

Caster (Rake Angle)

25°

Trail

106 mm (4.17 in.)

Front Tire:

Type

Tubeless

Size

120/70 ZR17 M/C (58W)

Rim Size

17 × 3.50

Rear Tire:

Type

Tubeless

Size

160/60 ZR17 M/C (69W)

Rim Size

17 × 4.50

Front Suspension:

Type

Telescopic fork

Wheel Travel

120 mm (4.72 in.)

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

Periodic Maintenance Chart ..............

2-2

Torque and Locking Agent.................

2-5

Specifications ....................................

2-11

Special Tools .....................................

2-13

Periodic Maintenance Procedures.....

2-14

Fuel System (DFI)...........................

2-14

Air Cleaner Element Cleaning......

2-14

Throttle Control System

Inspection..................................

2-15

Engine Vacuum Synchronization

Inspection..................................

2-15

Idle Speed Inspection ..................

2-17

Idle Speed Adjustment.................

2-18

Fuel Hose Inspection (fuel leak,

damage, installation condition)..

2-18

Evaporative Emission Control

System Inspection (CAL and
SEA Models) .............................

2-18

Cooling System...............................

2-19

Coolant Level Inspection..............

2-19

Water Hose Damage and

Installation Condition
Inspection..................................

2-20

Engine Top End ..............................

2-20

Valve Clearance Inspection .........

2-20

Valve Clearance Adjustment........

2-21

Air Suction System Damage

Inspection..................................

2-24

Clutch..............................................

2-24

Clutch Operation Inspection.........

2-24

Wheels/Tires ...................................

2-25

Air Pressure Inspection................

2-25

Wheel/Tire Damage Inspection....

2-25

Tire Tread Wear, Abnormal Wear

Inspection..................................

2-26

Wheel Bearing Damage

Inspection..................................

2-26

Final Drive.......................................

2-27

Drive Chain Lubrication Condition

Inspection..................................

2-27

Drive Chain Slack Inspection .......

2-28

Drive Chain Slack Adjustment .....

2-28

Wheel Alignment Inspection ........

2-29

Drive Chain Wear Inspection .......

2-30

Chain Guide Inspection................

2-30

Brake System .................................

2-31

Brake Fluid Leak (Brake Hose

and Pipe) Inspection .................

2-31

Brake Hose and Pipe Damage

and Installation Condition
Inspection..................................

2-31

Brake Fluid Level Inspection........

2-32

Brake Pad Wear Inspection .........

2-33

Brake Operation Inspection .........

2-33

Brake Light Switch Operation

Inspection..................................

2-33

Suspensions ...................................

2-34

Front Forks/Rear Shock Absorber

Operation Inspection .................

2-34

Front Fork Oil Leak Inspection.....

2-34

Rear Shock Absorber Oil Leak

Inspection..................................

2-35

Steering System .............................

2-35

Steering Play Inspection ..............

2-35

Steering Play Adjustment.............

2-35

Steering Stem Bearing

Lubrication.................................

2-36

Electrical System ............................

2-37

Lights and Switches Operation

Inspection..................................

2-37

Headlight Aiming Inspection ........

2-39

Sidestand Switch Operation

Inspection..................................

2-40

Engine Stop Switch Operation

Inspection..................................

2-41

Others .............................................

2-42

Chassis Parts Lubrication ............

2-42

Bolts, Nuts and Fasteners

Tightness Inspection .................

2-43

Replacement Parts .........................

2-44

Air Cleaner Element

Replacement .............................

2-44

Fuel Hose Replacement ..............

2-44

Coolant Change ...........................

2-45

Radiator Hose and O-ring

Replacement .............................

2-47

Engine Oil Change.......................

2-47

Oil Filter Replacement .................

2-48

Brake Hose and Pipe

Replacement .............................

2-49

Brake Fluid Change .....................

2-50

Master Cylinder Rubber Parts

Replacement .............................

2-51

Caliper Rubber Parts

Replacement .............................

2-52

Spark Plug Replacement .............

2-55

2-2 PERIODIC MAINTENANCE

Periodic Maintenance Chart

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

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

Periodic Inspection

FREQUENCY

Whichever

comes first

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

ITEM

Every

(0.6)

(3.75)

(7.5)

(11.25)

(15)

(18.75)

(22.5)

See

Page

Fuel System

Air cleaner element - clean

•

2-14

Throttle control system (play,
smooth return, no drag) - inspect

year

•

2-15

Engine vacuum synchronization
- inspect

•

2-15

Idle speed - inspect

•

2-17

Fuel leak (fuel hose and pipe) -
inspect

year

•

2-18

Fuel hose and pipe damage -
inspect

year

•

2-18

Fuel hose and pipe installation
condition - inspect

year

•

2-18

Evaporative emission control
system function (CAL, SEA
Models) - inspection

•

2-18

Cooling System

Coolant level - inspect

•

2-19

Coolant leak (water hose and
pipe) - inspect

year

•

2-20

Water hose damage - inspect

year

•

2-20

Water hose installation condition
- inspect

year

•

2-20

Engine Top End

US, CA, CAL
Models

•

Valve
clearance -
inspect

Other than US,
CA, CAL Models

Every 42 000 km (26 250 mile)

2-20

Air suction system damage -
inspect

•

2-24

Clutch

Clutch operation (play,
disengagement, engagement) -
inspect

•

2-24

Wheels and Tires

Tire air pressure - inspect

year

•

2-25

Wheel/tire damage - inspect

•

2-25

Tire tread wear, abnormal wear
- inspect

•

2-26

Wheel bearing damage - inspect

year

•

2-26

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

FREQUENCY

Whichever

comes first

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

ITEM

Every

(0.6)

(3.75)

(7.5)

(11.25)

(15)

(18.75)

(22.5)

See

Page

Final Drive

Drive chain lubrication condition
- inspect #

Every 600 km (400 mile)

2-27

Drive chain slack - inspect #

Every 1 000 km (600 mile)

2-28

Drive chain wear - inspect #

•

2-30

Chain guide wear - inspect

•

2-30

Brakes

Brake fluid leak (brake hose and
pipe) - inspect

year

•

2-31

Brake hose and pipe damage -
inspect

year

•

2-31

Brake hose and pipe installation
condition - inspect

year

•

2-31

Brake fluid level - inspect

6 months

•

2-32

Brake pad wear - inspect #

•

2-33

Brake operation (effectiveness,
play, no drag) - inspect

year

•

2-33

Brake light switch operation -
inspect

•

2-33

Suspension

Front forks/rear shock absorber
operation (damping and smooth
stroke) - inspect

•

2-34

Front forks/rear shock absorber
oil leak - inspect

year

•

2-34

Steering

Steering play - inspect

year

•

2-35

Steering stem bearings -
lubricate

2 years

•

2-36

Electrical System

Lights and switches operation -
inspect

year

•

2-37

Headlight aiming - inspect

year

•

2-39

Sidestand switch operation -
inspect

year

•

2-40

Engine stop switch operation -
inspect

year

•

2-41

Others

Chassis parts - lubricate

year

•

2-42

Bolts and nuts tightness - inspect

•

2-43

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

frequent starting/stopping.

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

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

Periodic Replacement Parts

FREQUENCY

Whichever

comes

first

* ODOMETER

READING

× 1 000 km

(× 1 000 mile)

ITEM

Every

(0.6)

(7.5)

(15)

(22.5)

(30)

See

Page

Air cleaner element # - replace

2 years

2-44

Fuel hose - replace

4 years

•

2-44

Coolant - change

3 years

•

2-45

Radiator hose and O-ring - replace

3 years

•

2-47

Engine oil # - change

year

•

2-47

Oil filter - replace

year

•

2-48

Brake hose and pipe - replace

4 years

•

2-49

Brake fluid - change

2 years

•

2-50

Rubber parts of master cylinder and caliper - replace 4 years

•

2-51

Spark plug - replace

•

2-55

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

frequent starting/stopping.

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

PERIODIC MAINTENANCE 2-5

Torque and Locking Agent

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

non-permanent locking agent or silicone sealant etc.

Letters used in the “Remarks” column mean:

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

EO: Apply engine oil.

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

Lh: Left-hand Threads

MO: Apply molybdenum disulfide oil solution.

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

R: Replacement Parts

S: Follow the specified tightening sequence.

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

SS: Apply silicone sealant.

Torque

Fastener

N·m

kgf·m

ft·lb

Remarks

Fuel System (DFI)

Crankshaft Sensor Bolts

6.0

0.61

53 in·lb

Fuel Level Sensor Bolts

6.9

0.70

61 in·lb

Fuel Pump Bolts

9.8

1.0

87 in·lb

L, S

Oxygen Sensor (Equipped Models)

4.5

Speed Sensor Bolt

7.8

0.80

69 in·lb

Speed Sensor Bracket Bolts

9.8

1.0

87 in·lb

Switch Housing Screws

3.5

0.36

31 in·lb

Timing Rotor Bolt

4.1

Water Temperature Sensor

1.2

106 in·lb

Cooling System

Baffle Plate Bolts

5.9

0.60

52 in·lb

Radiator Bolt

1.5

Water Hose Clamp Screws

2.0

0.20

18 in·lb

Thermostat Housing Bolts

9.8

1.0

87 in·lb

Water Pump Cover Bolts

9.8

1.0

87 in·lb

Water Pump Drain Bolt

9.8

1.0

87 in·lb

Water Pump Impeller Bolt

9.8

1.0

87 in·lb

Water Temperature Sensor

1.2

106 in·lb

Engine Top End

Air Suction Valve Cover Bolts

9.8

1.0

87 in·lb

Baffle Plate Bolts

5.9

0.60

52 in·lb

Camshaft Cap Bolts

1.2

106 in·lb

Camshaft Chain Tensioner Cap Bolt

2.0

Camshaft Chain Tensioner Mounting Bolts

9.8

1.0

87 in·lb

Camshaft Sprocket Bolts

1.5

Cylinder Head Bolts (M10)

5.7

MO, S

Cylinder Head Bolts (M6)

1.2

106 in·lb

Cylinder Head Cover Bolts

9.8

1.0

87 in·lb

Rear Camshaft Chain Guide Bolts

2.0

Spark Plugs

1.5

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

Torque

Fastener

N·m

kgf·m

ft·lb

Remarks

Throttle Body Assy Holder Bolts

1.2

106 in·lb

Cylinder Bolt (M8)

27.5

2.8

MO, S

Cylinder Nut

5.0

MO, S

Cylinder Bolts (M6)

1.2

106 in·lb

Exhaust Pipe Manifold Holder Nuts

1.7

Muffler Body Mounting Bolt (Front)

2.0

Muffler Body Mounting Bolt (Rear)

2.0

Clutch

Clutch Cable Clamp Bracket Bolt

9.8

1.0

87 in·lb

Clutch Cable Holder Bolts

9.8

1.0

87 in·lb

Clutch Cover Bolts

9.8

1.0

87 in·lb

Clutch Hub Nut

130

13.3

Clutch Lever Clamp Bolts

7.8

0.80

69 in·lb

Clutch Spring Bolts

9.8

1.0

87 in·lb

Timing Rotor Bolt Cap

4.9

0.50

43 in·lb

Oil Filler Plug

–

Hand-tighten

Oil Pump Chain Guide Bolts

1.2

106 in·lb

L (1)

Oil Pump Sprocket Bolt

1.2

106 in·lb

L, Lh

Timing Inspection Cap

3.9

0.40

35 in·lb

Engine Lubrication System

Engine Oil Drain Plug

3.1

Filter Plate Bolts

9.8

1.0

87 in·lb

Holder Mounting Bolt

2.5

Lower Fairing Bracket Bolts

1.2

106 in·lb

Oil Filter

17.5

1.8

EO, R

Oil Pan Bolts

1.2

106 in·lb

Oil Passage Plug

2.0

Oil Passage Plug (M6)

3.9

0.40

35 in·lb

Oil Pipe Plate Bolt

9.8

1.0

87 in·lb

Oil Plate Bolts

9.8

1.0

87 in·lb

Oil Pressure Relief Valve

1.5

Oil Pressure Switch

1.5

Oil Pump Chain Guide Bolts

1.2

106 in·lb

L (1)

Oil Pump Cover Bolts

9.8

1.0

87 in·lb

Oil Pump Sprocket Bolt

1.2

106 in·lb

L, Lh

Engine Removal/Installation

Engine Bracket Bolts (Left)

2.5

Engine Bracket Bolts (Right)

2.5

Engine Mounting Nut (Lower)

4.5

Engine Mounting Nut (Rear)

4.5

Engine Mounting Bolt (Left)

4.5

Engine Mounting Bolt (Right)

4.5

PERIODIC MAINTENANCE 2-7

Torque and Locking Agent

Torque

Fastener

N·m

kgf·m

ft·lb

Remarks

Crankshaft/Transmission

Breather Plate Bolts

9.8

1.0

87 in·lb

Race Holder Screw

4.9

0.50

43 in·lb

Connecting Rod Big End Nuts

see Text

←

Crankcase Bolt (M8, L = 110 mm)

27.5

2.8

Crankcase Bolt (M6, L = 32 mm)

19.6

2.0

Crankcase Bolts (M6, L = 38 mm)

19.6

2.0

Crankcase Bolts (M6, L = 45 mm)

19.6

2.0

Crankcase Bolt (M8, L = 50 mm)

27.5

2.8

Crankcase Bolts (M8, L = 60 mm)

3.6

MO, S

Crankcase Bolt (M8, L = 60 mm)

27.5

2.8

Crankcase Bolts (M8, L = 73 mm)

3.6

MO, S

Crankcase Bolts (M9, L = 113 mm)

4.5

MO, S

Crankcase Bolts (M9, L = 83 mm)

4.5

MO, S

Upper Crankcase Bolt (M8, L = 120 mm)

27.5

2.8

Upper Crankcase Bolts (M8, L = 110 mm)

27.5

2.8

Oil Pipe Bolts

9.8

1.0

87 in·lb

Oil Plate Bolts

9.8

1.0

87 in·lb

Shift Shaft Return Spring Pin

3.0

Timing Rotor Bolt

4.1

Drive Shaft Bearing Holder Screw

4.9

0.50

43 in·lb

Gear Positioning Lever Bolt

1.2

106 in·lb

Neutral Switch

1.5

Neutral Switch Holder Screw

4.9

0.50

43 in·lb

Transmission Case Oil Nozzle

2.9

0.30

26 in·lb

Shift Drum Bearing Holder Screws

4.9

0.50

43 in·lb

Shift Drum Cam Bolt

1.2

106 in·lb

Shift Pedal Bolt

1.2

106 in·lb

Shift Rod Plate Bolt

9.8

1.0

87 in·lb

Shift Shaft Cover Bolts

9.8

1.0

87 in·lb

L (3)

Shift Shaft Cover Screw

4.9

0.50

43 in·lb

L, S

Transmission Case Bolts

2.0

Wheels/Tires

Front Axle

108

11.0

Front Axle Clamp Bolt

3.5

Rear Axle Nut

108

11.0

Final Drive

Engine Sprocket Nut

125

12.7

Rear Axle Nut

108

11.0

Rear Sprocket Nuts

6.0

Speed Sensor Bolt

7.8

0.80

69 in·lb

Speed Sensor Bracket Bolts

9.8

1.0

87 in·lb

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

Torque

Fastener

N·m

kgf·m

ft·lb

Remarks

Brakes

Caliper Bleed Valve

7.8

0.80

69 in·lb

Brake Hose Banjo Bolts

2.5

Brake Lever Pivot Bolt

1.0

0.10

9 in·lb

Brake Lever Pivot Bolt Locknut

5.9

0.60

52 in·lb

Brake Disc Mounting Bolts

2.8

Front Brake Light Switch Screw

1.2

0.12

11 in·lb

Front Brake Reservoir Cap Screws

1.5

0.15

13 in·lb

Front Caliper Mounting Bolts

3.5

Front Master Cylinder Clamp Bolts

1.1

97 in·lb

Brake Pedal Bolt

8.8

0.90

78 in·lb

Rear Caliper Mounting Bolts

2.5

Rear Master Cylinder Mounting Bolts

2.5

Rear Master Cylinder Push Rod Locknut

1.7

Brake Pipe Joint Nuts (EX650D Models)

1.8

Wheel Rotation Sensor Bolts (EX650D Models)

2.0

Suspension

Front Axle Clamp Bolt

3.5

Front Fork Bottom Allen Bolts

3.1

Front Fork Clamp Bolts (Lower)

2.1

Front Fork Clamp Bolts (Upper)

2.0

Front Fork Top Plugs

2.5

Rear Shock Absorber Bolts

6.0

Swingarm Pivot Shaft Nut

108

11.0

Steering

Front Fork Clamp Bolts (Lower)

2.1

Front Fork Clamp Bolts (Upper)

2.0

Handlebar Holder Bolts

2.5

Handlebar Holder Mounting Nuts

3.5

Switch Housing Screws

3.5

0.36

31 in·lb

Steering Stem Head Bolt

108

11.0

Steering Stem Nut

2.0

Frame

Footpeg Stay Bolts

2.5

Front Fender Mounting Bolts

8.8

0.90

78 in·lb

Front Turn Signal Light Mounting Screws

1.2

0.12

11 in·lb

Grab Rail Mounting Bolts

2.5

Lower Fairing Bracket Bolts

1.2

106 in·lb

Lower Fairing Mounting Bolts

8.8

0.90

78 in·lb

Seat Lock Mounting Screws

1.2

0.12

11 in·lb

Sidestand Bolt

4.5

Sidestand Switch Bolt

8.8

0.90

78 in·lb

PERIODIC MAINTENANCE 2-9

Torque and Locking Agent

Torque

Fastener

N·m

kgf·m

ft·lb

Remarks

Electrical System

Tail/Brake Light Mounting Bolts

8.8

0.90

78 in·lb

License Plate Light Mounting Screws

1.2

0.12

11 in·lb

Alternator Cover Bolts

9.8

1.0

87 in·lb

Alternator Lead Holding Plate Bolt

9.8

1.0

87 in·lb

Alternator Rotor Bolt

155

15.8

114

Engine Ground Lead Terminal Bolt

9.8

1.0

87 in·lb

Front Brake Light Switch Screw

1.2

0.12

11 in·lb

Front Turn Signal Light Mounting Screws

1.2

0.12

11 in·lb

Fuel Pump Bolts

9.8

1.0

87 in·lb

L, S

Meter Cover Screws

1.2

0.12

11 in·lb

Regulator/Rectifier Bolts

8.8

0.90

78 in·lb

Switch Housing Screws

3.5

0.36

31 in·lb

Sidestand Switch Bolt

8.8

0.90

78 in·lb

Starter Motor Terminal Nut

6.0

0.61

53 in·lb

Starter Motor Clutch Bolts

3.5

Starter Motor Mounting Bolts

9.8

1.0

87 in·lb

Starter Motor Terminal Locknut

1.1

97 in·lb

Starter Motor Through Bolts

5.0

0.51

44 in·lb

Stator Coil Bolts

1.2

106 in·lb

Crankshaft Sensor Bolts

6.0

0.61

53 in·lb

Neutral Switch

1.5

Oil Pressure Switch

1.5

Oxygen Sensor (Equipped Models)

4.5

Spark Plugs

1.5

Speed Sensor Bolt

7.8

0.80

69 in·lb

Timing Rotor Bolt

4.1

Water Temperature Sensor

1.2

106 in·lb

Fuel Level Sensor Bolts

6.9

0.70

61 in·lb

2-10 PERIODIC MAINTENANCE

Torque and Locking Agent

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

nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the
values are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners

Torque

Threads Diameter

(mm)

N·m

kgf·m

ft·lb

3.4

∼

4.9

0.35

∼

0.50

∼

43 in·lb

5.9

∼

7.8

0.60

∼

0.80

∼

69 in·lb

∼

1.4

∼

1.9

10.0

∼

13.5

∼

2.6

∼

3.5

19.0

∼

4.5

∼

6.2

∼

7.4

∼

10.0

∼

115

∼

155

11.5

∼

16.0

∼

115

165

∼

225

17.0

∼

23.0

125

∼

165

225

∼

325

23.0

∼

33.0

165

∼

240

PERIODIC MAINTENANCE 2-11

Specifications

Item

Standard

Service Limit

Fuel System (DFI)

Throttle Grip Free Play

∼

3 mm (0.08

∼

0.12 in.)

– – –

Idle Speed

1 300 ±50 r/min (rpm)

– – –

Bypass Screws (Turn out)

∼

2 1/2 (for reference)

– – –

Engine Vacuum

35.3 ±1.3 kPa (265 ±10 mmHg)

– – –

Air Cleaner Element

Polyurethane Foam

– – –

Cooling System

Coolant:

Type (recommended)

Permanent type of antifreeze

– – –

Color

Green

– – –

Mixed Ratio

Soft water 50%, Coolant 50%

– – –

Freezing Point

–35°C (–31°F)

– – –

Total Amount

1.2 L (1.3 US qt)

– – –

Engine Top End

Valve Clearance:

Exhaust

0.22

∼

0.31 mm (0.0087

∼

0.0122 in.)

– – –

Inlet

0.15

∼

0.21 mm (0.0059

∼

0.0083 in.)

– – –

Clutch

Clutch Lever Free Play

∼

3 mm (0.08

∼

0.12 in.)

– – –

Engine Lubrication System

Engine Oil:

Type

API SE, SF or SG

– – –

API SH, SJ, SL or SM with JASO MA,
MA1 or MA2

Viscosity

SAE 10W-40

– – –

Capacity

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

– – –

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

– – –

2.4 L (2.5 US qt) (when engine is
completely dry)

– – –

Level

Between upper and lower level lines
(after idling or running)

– – –

Wheels/Tires

Tread Depth:

Front

4.8 mm (0.19 in.)

1 mm (0.04 in.),

(AT, CH, DE)

1.6 mm (0.06 in.)

Rear

6.2 mm (0.24 in.)

Up to 130 km/h (80 mph):

2 mm (0.08 in.),

Over 130 km/h (80 mph):

3 mm (0.12 in.)

Air Pressure (when Cold):

Front

Up to 180 kg (397 lb) load:

225 kPa (2.25 kgf/cm², 32 psi)

– – –

2-12 PERIODIC MAINTENANCE

Specifications

Item

Standard

Service Limit

Rear

Up to 180 kg (397 lb) load:

250 kPa (2.50 kgf/cm², 36 psi)

– – –

Final Drive

Drive Chain Slack

∼

35 mm (1.0

∼

1.4 in.)

– – –

Chain 20-link Length

317.5

∼

318.2 mm (12.50

∼

12.53 in.)

323 mm (12.7 in.)

Standard Chain:

Make

DAIDO

– – –

Type

DID 520VP2-T

– – –

Link

114 links

– – –

Brakes

Brake Fluid:

Grade

DOT4

– – –

Brake Pad Lining
Thickness:

Front

4.5 mm (0.18 in.)

1 mm (0.04 in.)

Rear

5.0 mm (0.20 in.)

1 mm (0.04 in.)

Brake Light Timing:

Front

Pulled ON

– – –

Rear

ON after about 10 mm (0.39 in.) of
pedal travel

– – –

Electrical System

Spark Plug:

Type

NGK CR9EIA-9

– – –

Gap

0.8

∼

0.9 mm (0.031

∼

0.035 in.)

– – –

2-14 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Fuel System (DFI)

Air Cleaner Element Cleaning

NOTE

○

In dusty areas, the element should be cleaned more
frequently than the recommended interval.

○

After riding through rain or on muddily roads, the ele-
ment should be cleaned immediately.

WARNING

If dirt or dust is allowed to pass through into the
throttle body assy, the throttle may become stuck,
possibly causing accident.

CAUTION

If dirt gets through into the engine, excessive en-
gine wear and possibly engine damage will occur.

•

Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Air Switching Valve Hose [A]
Air Cleaner Element Screw [B]
Air Cleaner Element [C]

•

Remove:

Plastic Holder [A]
Element [B]

WARNING

Clean the element in a well-ventilated area, and
make sure that there are no sparks or flame any-
where near the working area.
Because of the danger of highly flammable liquids,
do not use gasoline or a low-flash point solvent to
clean the element.

•

Clean the element [A] in a bath of high-flash point solvent,
and then dry it with compressed air or by shaking it.

•

After cleaning, saturate a clean, lint-free towel with SE,
SF, or SG class SAE 30 oil and apply the oil to the element
by tapping the element outside with the towel.

•

Visually inspect the element for tears or breaks.

•

If the element has any tears or breaks, replace the ele-
ment with a new one.

•

Install the element.

PERIODIC MAINTENANCE 2-15

Periodic Maintenance Procedures

Throttle Control System Inspection

•

Check that the throttle grip [A] moves smoothly from full
open to close, and the throttle closes quickly and com-
pletely by the return spring in all steering positions.
If the throttle grip does not return properly, check the throt-
tle cable routing, grip free play, and cable damage. Then
lubricate the throttle cable.

•

Check the throttle grip free play [B].

Throttle Grip Free Play

Standard:

∼

3 mm (0.08

∼

0.12 in.)

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

•

Loosen the locknut [A] at the upper end of the accelerator
cable.

•

Turn the adjuster [B] in completely so as to give the throttle
grip plenty of play.

•

Remove the right upper fairing cover (see Upper Fairing
Cover Removal in the Frame chapter).

•

Loosen the locknut [A] at the middle of the decelerator
cable.

•

Turn the adjuster [B] until there is no play when the throttle
grip is completely closed.

•

Tighten the locknut.

•

Turn the accelerator cable adjuster until the proper
amount of throttle grip free play is obtained.

•

Tighten the locknut.

Engine Vacuum Synchronization Inspection

NOTE

○

These procedures are explained on the assumption that
the inlet and exhaust systems of the engine are in good
condition.

•

Situate the motorcycle so that it is vertical.

•

Remove the left upper fairing cover (see Upper Fairing
Cover Removal in the Frame chapter).

•

Disconnect the inlet air pressure sensor hose temporary.

•

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

•

Connect the inlet air pressure sensor hose on the left fit-
ting of the throttle body.

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•

Connect a vacuum gauge (special tool) and hoses [A] to
the fittings of the throttle body as shown in the figure.

Special Tool - Vacuum Gauge: 57001-1369

•

Connect a highly accurate tachometer to one of the stick
coil primary leads.

•

Start the engine and warm it up thoroughly.

•

Check the idle speed, using a highly accurate tachometer.

•

Open and close the throttle.
If the idle speed is out of the specified range, adjust it.

CAUTION

Do not measure the idle speed by the tachometer of
the meter unit.

•

While idling the engine, inspect the engine vacuum, using
the vacuum gauge.

Special Tool - Vacuum Gauge: 57001-1369

Engine Vacuum

Standard:

35.3 ±1.3 kPa (265 ±10 mmHg) at Idle Speed
1 300 ±50 r/min (rpm)

If any one vacuum is not within the specification, turn in
the bypass screws until it seats fully but not tightly.

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

CAUTION

Do not over tighten them. They could be damaged,
requiring replacement.

•

Turn out the bypass screw of the higher vacuum between
#1 [A] and #2 [B] to the lower vacuum.

•

Open and close the throttle valves after each measure-
ment and adjust the idle speed as necessary.

•

Inspect the vacuums as before.
If both vacuums are within the specification, finish the en-
gine vacuum synchronization.
If any vacuum can not be adjusted within the specification,
remove the bypass screws #1, #2 and clean them.

PERIODIC MAINTENANCE 2-17

Periodic Maintenance Procedures

•

Remove the bypass screw [A], spring [B], washer [C] and
O-ring [D].

•

Check the bypass screw and its hole for carbon deposits.
If any carbon accumulates, wipe the carbon off from the
bypass screw and the hole, using a cotton pad penetrated
with a high-flash point solvent.

•

Replace the O-ring with a new one.

•

Check the tapered portion [E] of the bypass screw for
wear or damage.
If the bypass screw is worn or damaged, replace it.

•

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

•

Repeat the same procedure for other bypass screws.

•

Repeat the synchronization.
If the vacuums are correct, check the output voltage of
the main throttle sensor (see Main Throttle Sensor Output
Voltage Inspection in the Fuel System (DFI) chapter).

Special Tool - Throttle Sensor Setting Adapter:

57001

-1538

Main Throttle Sensor Output Voltage

Connections to Adapter:

Meter (+)

→

R (Sensor Y/W) lead

Meter (–)

→

W (Sensor BR/BK) lead

Standard:

DC 1.005

∼

1.035 V at idle throttle opening

If the output voltage is out of the range, check the main
throttle sensor input voltage (see Main Throttle Sensor In-
put Voltage Inspection in the Fuel System (DFI) chapter).

•

Remove the vacuum gauge hoses and install the rubber
caps onto the original positions.

Idle Speed Inspection

•

Start the engine and warm it up thoroughly.

•

With the engine idling, turn [A] the handlebar to both
sides.
If handlebar movement changes the idle speed, the
throttle cables may be improperly adjusted or incorrectly
routed or damaged.

Be sure to correct any of these

conditions before riding (see Throttle Control System
Inspection and Cable, Wire, and Hose Routing section in
the Appendix chapter).

WARNING

Operation with improperly adjusted, incorrectly
routed or damaged cables could result in an unsafe
riding condition.

•

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

Idle Speed

Standard:

1 300 ±50 r/min (rpm)

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Idle Speed Adjustment

•

Start the engine and warm it up thoroughly.

•

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

○

Open and close the throttle a few times to make sure that
the idle speed is within the specified range. Readjust if
necessary.

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

○

If the motorcycle is not properly handled, the high pres-
sure inside the fuel line can cause fuel to leak [A] or the
hose to burst. Remove the fuel tank (see Fuel Tank Re-
moval in the Fuel System (DFI) chapter) and check the
fuel hose.
Replace the fuel hose if any fraying, cracks [B] or bulges
[C] are noticed.

•

Check that the hoses are routed according to Cable, Wire,
and Hose Routing section in the Appendix chapter.
Replace the hose if it has been sharply bent or kinked
(see Fuel Hose Replacement).

Hose Joints [A]
Fuel Hose [B]

•

Check that the hose joints are securely connected.

○

Push and pull [A] the hose joints [B] back and forth more
than two times, and make sure it is locked.
If it does not locked, reinstall the hose joint.

WARNING

Make sure the hose joint is installed correctly on the
delivery pipe by sliding the joint, or the fuel could
leak.

Evaporative Emission Control System Inspection
(CAL and SEA Models)

•

Inspect the canister as follows.

○

Remove the upper fairing (see Upper Fairing Removal in
the Frame chapter).

○

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

○

Visually inspect the canister for cracks or other damage.
If the canister has any cracks or bad damage, replace it
with a new one.

NOTE

○

The canister is designed to work well through the motor-
cycle’s life without any maintenance if it is used under
normal conditions.

PERIODIC MAINTENANCE 2-19

Periodic Maintenance Procedures

•

Check the liquid/vapor separator as follows.

○

Remove the canister cover on the left side of the frame.

○

Disconnect the hoses from the separator, and remove the
separator [A].

○

Visually inspect the separator for cracks and other dam-
age.
If the separator has any cracks or damage, replace it with
a new one.

○

To prevent the gasoline from flowing into or out of the
canister, hold the separator perpendicular to the ground.

•

Check the hoses of the evaporative emission control sys-
tem as follows.

○

Check that the hoses are securely connected and clips
are in position.

○

Replace any kinked, deteriorated or damaged hoses.

○

Route the hoses according to Cable, Wire, and Hose
Routing section in the Appendix chapter.

○

When installing the hoses, avoid sharp bending, kinking,
flattening or twisting, and route the hoses with a minimum
of bending so that the emission flow will not be obstructed.

Cooling System

Coolant Level Inspection

NOTE

○

Check the level when the engine is cold (room or ambi-
ent temperature).

•

Check the coolant level in the reserve tank [A] with the
motorcycle held perpendicular (do not use the sidestand).
If the coolant level is lower than the “L” level line [B], re-
move the upper fairing (see Upper Fairing Removal in the
Frame chapter) and unscrew the reserve tank cap, and
add coolant to the “F” level line [C].

“L”: Low
“F”: Full

CAUTION

For refilling, add the specified mixture of coolant
and soft water.

Adding water alone dilutes the

coolant and degrades its anticorrosion properties.
The diluted coolant can attack the aluminum en-
gine parts. In an emergency, soft water alone can
be added. But the diluted coolant must be returned
to the correct mixture ratio within a few days.
If coolant must be added often or the reservoir tank
has run completely dry, there is probably leakage in
the cooling system. Check the system for leaks.
Coolant ruins painted surfaces. Immediately wash
away any coolant that spills on the frame, engine,
wheels or other painted parts.

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Water Hose Damage and Installation Condition
Inspection

○

The high pressure inside the water hose can cause
coolant to leak [A] or the hose to burst if the line is not
properly maintained.

•

Visually inspect the hoses for signs of deterioration.
Squeeze the hoses.

A hose should not be hard and

brittle, nor should it be soft or swollen.
Replace the hose if any fraying, cracks [B] or bulges [C]
are noticed.

•

Check that the hoses are securely connected and clamps
are tightened correctly.

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

18 in·lb)

Engine Top End

Valve Clearance Inspection

NOTE

○

Valve clearance must be checked and adjusted when
the engine is cold (room temperature).

•

Remove:

Cylinder Head Cover (see Cylinder Head Cover Re-
moval in the Engine Top End chapter)
Lower Fairing (see Lower Fairing Removal in the Frame
chapter)
Timing Inspection Cap [A]
Timing Rotor Bolt Cap [B]

•

Check the valve clearance when the pistons are at TDC.

○

The pistons are numbered beginning with the engine left
side.

•

Using a wrench on the timing rotor bolt, turn the crank-
shaft clockwise until the 1/T mark line [A] on the timing
rotor is aligned with the notch [B] in the edge of the timing
inspection hole [C] in the clutch cover for #1 piston and
2/T mark line [D] for #2 piston.

○

Measure the valve clearance of the valves for which the
cams [A] are turned away from each other.

PERIODIC MAINTENANCE 2-21

Periodic Maintenance Procedures

•

Using the thickness gauge [A], measure the valve clear-
ance between cam and valve lifter.

Valve Clearance

Standard:

Exhaust 0.22

∼

0.31 mm (0.0087

∼

0.0122 in.)

Inlet

0.15

∼

0.21 mm (0.0059

∼

0.0083 in.)

○

Each piston has two inlet and two exhaust valves. Mea-
sure these two inlet or exhaust valves at the same crank-
shaft position.

NOTE

○

Check the valve clearance using this method only.
Checking the clearance at any other cam position may
result in improper valve clearance.

Valve Clearance Measuring Position

#1 Piston TDC at End of Compression Stroke:

Inlet valve clearances of #1 piston, and

Exhaust valve clearances of #1 piston

#2 Piston TDC at End of Compression Stroke:

Inlet valve clearances of #2 piston, and

Exhaust valve clearances of #2 piston

If the valve clearance is not within the specified range,
first record the clearance, and then adjust it.

Valve Clearance Adjustment

•

To change the valve clearance, remove the camshaft
chain tensioner, camshafts and valve lifters. Replace the
shim with one of a different thickness.

NOTE

○

Mark and record the locations of the valve lifters and
shims so that they can be reinstalled in their original
positions.

○

If there is no valve clearance, use a shim that is a few
sizes smaller, and remeasure the valve clearance.

•

To select a new shim which brings the valve clearance
within the specified range, refer to the Valve Clearance
Adjustment Charts.

•

Apply a thin coat of molybdenum disulfide grease to the
valve lifters.

•

Install the camshafts. Be sure to time the camshafts prop-
erly (see Camshaft Installation in the Engine Top End
chapter).

•

Remeasure any valve clearance that was adjusted.
Readjust if necessary.

CAUTION

Do not put shim stock under the shim. This may
cause the shim to pop out at high rpm, causing ex-
tensive engine damage.
Do not grind the shim. This may cause it to fracture,
causing extensive engine damage.

2-24 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Air Suction System Damage Inspection

•

Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Fuel Hose (see Fuel Hose Replacement)

•

Connect the following parts temporary.

Fuel Pump Lead Connector [A]
Fuel Level Sensor Lead Connector [B]
Extension Tube [C]

Special Tool - Extension Tube: 57001-1578

•

Pull the air switching valve hose [D] out of the air cleaner
housing.

•

Start the engine and run it at idle speed.

•

Plug [A] the air switching valve hose end with your finger
and feel vacuum pulsing in the hose.
If there is no vacuum pulsation, check the hose line for
leak. If there is no leak, check the air switching valve
(see Air Switching Valve Unit Test in the Electrical Sys-
tem chapter) or air suction valve (see Air Suction Valve
Inspection in the Engine Top End chapter).

Clutch

Clutch Operation Inspection

•

Pull the clutch lever just enough to take up the free play
[A].

•

Measure the gap between the lever and the lever holder.
If the gap is too wide, the clutch may not release fully. If
the gap is too narrow, the clutch may not engage fully. In
either case, adjust it.

Clutch Lever Free Play

Standard:

∼

3 mm (0.08

∼

0.12 in.)

WARNING

To avoid a serious burn, never touch the engine or
exhaust pipe during clutch adjustment.

•

Turn the adjuster [A] so that 5

∼

6 mm (0.20

∼

0.24 in.) [B]

of threads are visible.

PERIODIC MAINTENANCE 2-25

Periodic Maintenance Procedures

•

Remove the right upper fairing cover (see Upper Fairing
Cover Removal in the Frame chapter).

•

Open the clamp [A].

•

Slide the dust cover [B] out of place.

•

Loosen the locknut [C].

•

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

WARNING

Be sure that the outer cable end at the clutch lever
is fully seated in the adjuster at the clutch lever, or
it could slip into place later, creating enough cable
play to prevent clutch disengagement.

•

Tighten the locknut, and slip the dust cover back onto
place.

•

After the adjustment, start the engine and check that the
clutch does not slip and that it releases properly.

Wheels/Tires

Air Pressure Inspection

•

Remove the air valve cap.

•

Measure the tire air pressure with an air pressure gauge
[A] when the tires are cold (that is, when the motorcycle
has not been ridden more than a mile during the past 3
hours).

•

Install the air valve cap.
Adjust the tire air pressure according to the specifications
if necessary.

Air Pressure (when Cold)

Front:

Up to 180 kg (397 lb)
225 kPa (2.25 kgf/cm², 32 psi)

Rear:

Up to 180 kg (397 lb)
250 kPa (2.50 kgf/cm², 36 psi)

Wheel/Tire Damage Inspection

•

Remove any imbedded stones [A] or other foreign parti-
cles [B] from tread.

•

Visually inspect the tire for cracks and cuts, and replace
the tire if necessary. Swelling or high spots indicate inter-
nal damage, requiring tire replacement.

•

Visually inspect the wheel for cracks, cuts and dents dam-
age.
If any damage is found, replace the wheel if necessary.

2-26 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Tire Tread Wear, Abnormal Wear Inspection

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

ceptible to puncture and failure. An accepted estimate is
that 90% of all tire failures occur during the last 10% of tread
life (90% worn). So it is false economy and unsafe to use
the tires until they are bald.

•

Measure the tread depth at the center of the tread with a
depth gauge [A]. Since the tire may wear unevenly, take
measurement at several places.
If any measurement is less than the service limit, replace
the tire (see Tire Removal/Installation in the Wheels/Tires
chapter).

Tread Depth

Standard:

Front

4.8 mm (0.19 in.)

Rear

6.2 mm (0.24 in.)

Service Limit:

Front

1 mm (0.04 in.)

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

Rear

2 mm (0.08 in.)

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

3 mm (0.12 in.)

(Over 130 km/h (80 mph))

WARNING

To ensure safe handling and stability, use only the
recommended standard tires for replacement, in-
flated to the standard pressure.

NOTE

○

Most countries may have their own regulations a mini-
mum tire tread depth: be sure to follow them.

○

Check and balance the wheel when a tire is replaced
with a new one.

Wheel Bearing Damage Inspection

•

Raise the front wheel off the ground with the jack (see
Front Wheel Removal in the Wheels/Tires chapter).

•

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

•

Inspect the roughness of the front wheel bearing by push-
ing and pulling [A] the wheel.

•

Spin [B] the front wheel lightly, and check for smoothly
turn, roughness, binding or noise.
If roughness, binding or noise is found, remove the front
wheel and inspect the wheel bearing (see Front Wheel
Removal, Hub Bearing Inspection in the Wheels/Tires
chapter).

PERIODIC MAINTENANCE 2-27

Periodic Maintenance Procedures

•

Raise the rear wheel off the ground with the stand (see
Rear Wheel Removal in the Wheels/Tires chapter).

•

Inspect the roughness of the rear wheel bearing by push-
ing and pulling [A] the wheel.

•

Spin [B] the rear wheel lightly, and check for smoothly
turn, roughness, binding or noise.
If roughness, binding or noise is found, remove the rear
wheel and inspect the wheel bearing (see Rear Wheel Re-
moval, Hub Bearing Inspection in the Wheels/Tires chap-
ter) and coupling (see Coupling Bearing Inspection in the
Final Drive chapter).

Final Drive

Drive Chain Lubrication Condition Inspection

•

If a special lubricant is not available, a heavy oil such as
SAE 90 is preferred to a lighter oil because it will stay on
the chain longer and provide better lubrication.

•

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

CAUTION

The O-rings between the side plates seal in the lu-
bricant between the pin and the bushing. To avoid
damaging the O-rings and resultant loss of lubri-
cant, observe the following rules.
Use only kerosene or diesel oil for cleaning an O
-ring of the drive chain. Any other cleaning solu-
tion such as gasoline will cause deterioration and
swelling of the O-ring. Immediately blow the chain
dry with compressed air after cleaning. Complete
cleaning and drying the chain within 10 minutes.

•

Apply oil to the sides of the rollers so that oil will penetrate
to the rollers and bushings. Apply the oil to the O-rings so
that the O-rings will be coated with oil.

•

Wipe off any excess oil.

Oil Applied Areas [A]
O-rings [B]

2-28 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Drive Chain Slack Inspection

NOTE

○

Check the slack with the motorcycle setting on its side-
stand.

○

Clean the chain if it is dirty, and lubricate it if it appears
dry.

•

Check the wheel alignment (see Wheel Alignment Inspec-
tion).

•

Rotate the rear wheel to find the position where the chain
is tightest.

•

Measure the vertical movement (chain slack) [A] midway
between the sprockets.
If the chain slack exceeds the standard, adjust it.

Chain Slack

Standard:

∼

35 mm (1.0

∼

1.4 in.)

Drive Chain Slack Adjustment

•

Raise the rear wheel off the ground with the stand.

•

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

•

Loosen the both chain adjuster locknuts [C].
If the chain is too loose, turn out the right and left chain
adjusters [D] evenly.
If the chain is too tight, turn in the right and left chain
adjusters evenly, and kick the wheel forward.

•

Turn both chain adjusters evenly until the drive chain has
the correct amount of slack. To keep the chain and wheel
properly aligned, the edge [E] of the left wheel alignment
indicator [F] should align with the same swingarm mark or
position [G] that the right indicator notch aligns with.

WARNING

Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.

•

Tighten both chain adjuster locknuts securely.

•

Tighten the axle nut.

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

•

Turn the wheel, measure the chain slack again at the tight-
est position, and readjust if necessary.

•

Insert a new cotter pin [A].

NOTE

○

When inserting the cotter pin, if the slots in the nut do
not align with the cotter pin hole in the axle, tighten the
nut clockwise [B] up to next alignment.

○

It should be within 30°.

○

Loosen once and tighten again when the slot goes past
the nearest hole.

2-30 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Drive Chain Wear Inspection

•

Remove the chain cover (see Swingarm Removal in the
Suspension chapter).

•

Rotate the rear wheel to inspect the drive chain for dam-
aged rollers, and loose pins and links.
If there is any irregularity, replace the drive chain.
Lubricate the drive chain if it appears dry.

•

Stretch the chain taut by hanging a 98 N (10 kg, 20 lb)
weight [A] on the chain.

•

Measure the length of 20 links [B] on the straight part [C] of
the chain from the pin center of the 1st pin to the pin center
of the 21st pin. Since the chain may wear unevenly, take
measurements at several places.
If any measurements exceed the service limit, replace the
chain. Also, replace the front and rear sprockets when the
drive chain is replaced.

Drive Chain 20-link Length

Standard:

317.5

∼

318.2 mm (12.50

∼

12.53 in.)

Service Limit: 323 mm (12.7 in.)

WARNING

If the drive chain wear exceeds the service limit, re-
place the chain or an unsafe riding condition may
result. A chain that breaks or jumps off the sprock-
ets could snag on the engine sprocket or lock the
rear wheel, severely damaging the motorcycle and
causing it to go out of control.
For safely, use only the standard chain. It is an end-
less type and should not be cut for installation.

Standard Chain

Make:

DAIDO

Type:

DID 520VP2-T

Link:

114 links

Chain Guide Inspection

•

Remove the swingarm (see Swingarm Removal in the
Suspension chapter).

•

Visually inspect the chain guide [A].
Replace the chain guide if it shows any signs of abnormal
wear or damage.

Kawasaki Ninja 650R, ER-6f, ER-6f ABS Motorcycle. Service Manual (2009-2011 year) - page 1