KaYlasaki ZR-7S

Motorcycle
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki
Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your Motorcycle dealer for the latest
information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.

@ 2000 Kawasaki Heavy Industries, Ltd., Fifth Edition (1) :Jan. 25,2005 (K)

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 LIST OF ABBREVIATIONS
A ampere(s) Ib pound( s)
ABDC after bottom dead center m meter(s)
AC alternating current min minute(s)
ATOC after top dead center N newton(s)
BBOC before bottom dead center Pa pascal(s)
BOC bottom dead center PS horsepower
BTOC before top dead center psi pound(s) per square inch
°C degree(s) Celsius r revol ution
DC direct current r/min, rpm revolution(s) per minute
F farad(s) TOC top dead center
OF degree(s) Fahrenheit TIR total indicator reading
ft foot, feet V volt( s)
9 gram(s) W watt( s)
h hour(s) Q ohm(s)
L liter( s)

Read OWNER'S MANUAL before operating.

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 WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW,
THE VIOLATION OF WHICH IS PUNISHABLE BY CIVil PENALTIES NOT EXCEEDING
$10,000 PER VIOLATION.

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering
inoperative by any person other than for purposes of maintenance, repair, or replacement, of any
device or element of design incorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the
vehicle after such device or element of design has been removed or rendered inoperative by
any person.
Among those acts presumed to constitute tampering are the acts listed below:
·Replacement of the original exhaust system or muffler with a component not in compliance
with Federal regulations.
..Removal of the muffler(s) or any internal portion of the muffler(s).
Removal of the air box or air box cover.
· Modifications to the muffler(s) or air inlet system by cutting, drilling, or other means if such
modifications result in increased noise levels.

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 EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporated crankcase emis-
sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of
the United States Environmental Protection Agency and California Air Resources Board. Addi-
tionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance
with applicable regulations of the California Air Resources Board on vehicles sold in California
only.
1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors
are routed through an oil separator to the inlet side of the engine. While the engine is operating,
the vapors are drawn into combustion chamber, where they are burned along with the fuel and air
supplied by the fuel injection system.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust
of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully
designed and constructed to ensure an efficient engine with low exhaust pollutant levels.
The exhaust system of this model motorcycle manufactured primarily for sale in California in-
cludes a catalytic converter system.
3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. In-
stead, fuel vapors are routed into the running engine to be burned, or stored in a canister when
the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is
commonly referred to as the Act's "tampering provisions."
"Sec. 203 (a) The following acts and the causing thereof are prohibited.
(3)(A) for any person to remove or render inoperative any device or element of design installed
on or in a motor vehicle or motor vehicle engine in compliance with regulations under this
title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer
knowingly to remove or render inoperative any such device or element of design after such
sale and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading
motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles know-
ingly to remove or render inoperative any device or element of design installed on or in a
motor vehicle or motor vehicle engine in compliance with regulations under this title follow-
ing its sale and delivery to the ultimate purchaser..."
NOTE
o The phrase "removeor render inoperative any device or element of design" has been generally
interpreted as follows:
1. Tampering does not include the temporary removal or rendering inoperative of de-
vices or elements of design in order to perform maintenance.
2. Tampering could include:
a.Maladjustment of vehicle components such that the emission standards are ex-
ceeded.
b. Use of replacement parts or accessories which adversely affect the performance
or durability of the motorcycle.
c.Addition of components or accessories that result in the vehicle exceeding the stan-
dards.
d.Permanently removing, disconnecting, or rendering inoperative any component or
element of design of the emission control systems.

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 Foreword
This manual is designed primarily for use by
trained mechanics in a properly equipped shop. How to Use This Manual
However, it contains enough detail and basic in-
formation to make it useful to the owner who de- In preparing this manual, we divided the prod-
uct into its major systems. These systems be-
sires to perform his own basic maintenance and
came the manual's chapters. All information
repair work. A basic knowledge of mechanics,
for a particular system from adjustment through
the proper use of tools, and workshop proce-
disassembly and inspection is located in a sin-
dures must be understood in order to carry out
gle chapter.
maintenance and repair satisfactorily. When-
The Quick Reference Guide shows you all
ever the owner has insufficient experience or
of the product's system and assists in locating
doubts his ability to do the work, all adjust-
their chapters. Each chapter in turn has its own
ments, maintenance, and repair should be car-
comprehensive Table of Contents.
ried out only by qualified mechanics. The Periodic Maintenance Chart is located
In order to perform the work efficiently and
in the General Information chapter. The chart
to avoid costly mistakes, read the text, thor-
gives a time schedule for required maintenance
oughly familiarize yourself with the procedures
operations.
before starting work, and then do the work care-
If you want spark plug information, for exam-
fully in a clean area. Whenever special tools or
ple, go to the Periodic Maintenance Chart first.
equipment are specified, do not use makeshift
The chart tells you how frequently to clean and
tools or equipment. Precision measurements
gap the plug. Next, use the Quick Reference
can only be made if the proper instruments are
Guide to locate the Electrical System chapter.
used, and the use of substitute tools may ad-
Then, use the Table of Contents on the first
versely affect safe operation.
page of the chapter to find the Spark Plug sec-
For the duration of the warranty period, tion.
we recommend that all repairs and scheduled
Whenever you see these WARNING and
maintenance be performed in accordance with
CAUTION symbols, heed their instructions!
this service manual. Any owner maintenance or
Always follow safe operating and maintenance
repair procedure not performed in accordance
practices.
with this manual may void the warranty.
A. WARNING
. To get the longest life out of your vehicle:
Follow the Periodic Maintenance Chart in the
Service Manual.
This warning symbol identifies special
. Be alert for problems
maintenance.
and non-scheduled
instructions or procedures which, if not
correctly followed, could result in per-
. Use proper tools and genuine Kawasaki Mo-
torcycle parts. Special tools, gauges, and
sonal injury, or loss of life.

CAUTION
testers that are necessary when servicing
Kawasaki motorcycles are introduced by the This caution symbol identifies special
Special Tool Catalog or Manual. Genuine instructions or procedures which, if not
parts provided as spare parts are listed in the strictly observed, could result in dam-
Parts Catalog. age to or destruction of equipment.
. Follow the procedures in this manual care-
fully. Don't take shortcuts.
This manual contains four more symbols (in
. Remember to keep complete records of main-
addition to WARNING and CAUTION) which will
help you distinguish different types of informa-
tenance and repair with dates and any new tion.
parts installed.

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 NOTE
o This note symbol indicates points of par-
ticular interest for more efficient and con-
venient operation.
. Indicatesa proceduralstep or work to be
done.
Olndicates a procedural sub-step or how to do
the work of the procedural step it follows. It
also precedes the text of a NOTE.
* Indicates a conditional step or what action to
take based on the results of the test or inspec-
tion in the procedural step or sub-step it fol-
lows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you willfind the
instructions indicatingwhich parts require spec-
ified tightening torque, oil, grease or a locking
agent during assembly.

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 GENERAL INFORMATION 1-1

General Information [J
Table of Contents
Before Servicing 1-2
Model Identification 1-5
General Specifications 1-7
Periodic Maintenance Chart (U.S.A., Canada and Taiwan Model) 1-10
Periodic Maintenance Chart (Other than U.S.A., Canada, Taiwan Model) 1-12
Torque and Locking Agent 1-13
Special Tools and Sealant 1-17
Cable, Wire, and Hose Routing 1-24

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 1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly opera-
tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra-
tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.

Especially note the following:

(1) Dirt
Before removal and disassembly, clean the motorcycle. Any dirt entering the engine will shorten
the life of the motorcycle. For the same reason, before installing a new part, clean off any dust or
metal filings.
(2) Battery Leads
Disconnect the ground (-) wire from the battery before performing any disassembly operations
on the motorcycle. This prevents the engine from accidentally turning over while work is being
carried out, sparks from being generated while disconnecting the wires from electrical parts, as
well as damage to the electrical parts themselves. For reinstallation, first connect the positive
wire to the positive (+) terminal of the battery.
(3) Installation, Assembly
Generally, installation or assembly is the reverse of removal or disassembly. However, if instal-
lation or assembly sequence is given in this Service Manual, follow it. Note parts locations and
cable, wire, and hose routing during removal or disassembly so they can be installed or assem-
bled in the same way. It is preferable to mark and record the locations and routing whenever
possible.
(4) Tightening Sequence
When installing bolts, nuts, or screws for which a tightening sequence is given in this Service
Manual, make sure to follow the sequence. When installing a part with several bolts, nuts, or
screws, start them all in their holes and tighten them to a snug fit, thus ensuring that the part has
been installed in its proper location. Then, tighten them to the specified torque in the tightening
sequence and method indicated. If tightening sequence instructions are not given, tighten them
evenly in a cross pattern. Conversely, to remove a part, first loosen all the bolts, nuts, or screws
that are retaining the part a 1/4-turn before removing them.
(5) Torque
When torque values are given in this Service Manual, use them. Either too little or too much
torque may wire to serious damage. Use a good quality, reliable torque wrench.
(6) Force
Common sense should dictate how much force is necessary in assembly and disassembly. If
a part seems especially difficult to remove or install, stop and examine what may be causing the
problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use
an impact driver for loosening screws (particularly for removing screws held by non-permanent
locking agent) in order to avoid damaging the screw heads.
(7) Edges
Watch for sharp edges, as they could cause injury through careless handling, especially during
major engine disassembly and assembly. Use a clean piece of thick cloth when lifting the engine
or turning it over.
(8) High-Flash Point Solvent
A high-flash point solvent is recommended to reduce fire danger. A commercial solvent com-
monly available in North America is Stoddard solvent (generic name). Always follow manufacturer
and container directions regarding the use of any solvent.
(9) Gasket, O-ring
Replace a gasket or an O-ring with a new one when disassembling. Remove any foreign matter
from the mating surface of the gasket or O-ring to ensure a perfectly smooth surface to prevent
oil or compression leaks.
(10)Liquid Gasket, Non-Permanent Locking Agent
Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used.
Apply them sparingly. Excessive amounts may block engine oil passages and cause serious
damage.

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 GENERAL INFORMATION 1-3
Before Servicing

(11) Press
When using a press or driver to install a part such as a wheel bearing, apply a small amount of
oil to the area where the two parts come in contact to ensure a smooth fit.
(12)Ball Bearing and Needle Bearing
Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any
ball or needle bearings that were removed with new ones. Install bearings with the manufacturer
and size marks facing out, applying pressure evenly with a suitable driver. Apply force only to the
end of the race that contacts the press fit portion, and press it evenly over the base component.
(13)Oil Seal and Grease Seal
Replace any oil or grease seals that were removed with new ones, as removal generally dam-
ages seals. Oil or grease seals should be pressed into place using a suitable driver, applying a
force uniformly to the end of seal until the face of the seal is even with the end of the hole, unless
instructed otherwise. When pressing in an oil or grease seal which has manufacturer's marks,
press it in with the marks facing out.
(14)Circlip, Retaining Ring, and Cotter Pin
When installing circlips and retaining rings, take care to compress or expand them only enough
to install them and no more. Replace any circlips, retaining rings, and cotter pins that were re-
moved with new ones, as removal weakens and deforms them. If old ones are reused, they could
become detached while the motorcycle is driven, leading to a major problem.
(15)Lubrication
Engine wear is generally at its maximum while the engine is warming up and before all the sliding
surfaces have an adequate lubricative film. During assembly, make sure to apply oil to any sliding
surface or bearing that has been cleaned. Old grease or dirty oil could have lost its lubricative
quality and may contain foreign particles that act as abrasives; therefore, make sure to wipe it off
and apply fresh grease or oil. Some oils and greases in particular should be used only in certain
applications and may be harmful if used in an application for which they are not intended.
(16)Direction of Engine Rotation
To rotate the crankshaft manually, make sure to do so in the direction of positive rotation. Pos-
itive rotation is counterclockwise as viewed from the left side of the engine. To carry out proper
adjustments, it is furthermore necessary to rotate the engine in the direction of positive rotation
as well.
(17) Replacement Parts
Replacement parts will be damaged or lose their original function once they are removed. There-
fore, always replace these parts with new ones every time they are removed. Although the pre-
viously mentioned gasket, O-ring, ball bearing, needle bearing, grease seal, oil seal, circlip, and
cotter pin have not been so designated in their respective text, they are replacement parts.
(18)Electrical Wires
All the electrical wires are either one-color or two-color. A two-color wire is identified first by
the primary color and then the stripe color. For example, a yellow wire with thin red stripes is
referred to as a "yellow/red" wire; it would be a red/yellow" wire if the colors were reversed. Unless
instructed otherwise, electrical wires must be connected to wires of the same color.
Two-Color Electrical

Wi re (cross-sect i on) I Color Indicated on the Wire I Color Indicated on the "iring Diagram

Red

Wire Strands

Ve I low/Red V/R
Ye II ow

Red

GB02060 1" 1 C

(19)Replacement Parts
When there is a replacement instruction, replace these parts with new ones every time they are
removed. These replacement parts will be damaged or lose their original function once removed.

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 1-4 GENERAL INFORMATION
Before Servicing
(20) Inspection
When parts have been disassembled, visually inspect these parts for the following conditions
or other damage. If there is any doubt as to the condition of them, replace them with new ones.
Abrasion Crack Hardening Warp
Bent Dent Scratch Wear
Color change Deterioration Seizure
(21 )Specifications
Specification terms are defined as follows:
"Standards" : show dimensions or performances which brand-new parts or systems have.
"Service Limits" : indicate the usable limits. If the measurement shows excessive wear or de-
teriorated performance, replace the damaged parts.

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 GENERAL INFORMATION 1-5
Model Identification
ZR750-H1 (EU) Left Side View

ZR750-H1 (EU) Right Side View

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 1-6 GENERAL INFORMATION
Model Identification
ZR750-H1 (U.S.A. and Canada) Left Side View

ZR750-H1 (U.S.A. and Canada) Right Side View

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 GENERAL INFORMATION 1-7
General Specifications
Items ZR750-H1 I ZR750-H2 I
ZR750-H3 - H5
Dimensions
Overall Length 2 105 mm (82.87 in.)
Overall Width 785 mm (30.9 in.)
Overall Height 1 215 mm (47.83 in.)
Wheelbase 1 455 mm (57.28 in.)
Road Clearance 130 mm (5.12 in.)
Seat Height 800 mm (31.50 in.)
Dry Mass 210 kg (8.27 Ib)
Curb Mass:
Front 111 kg (245 Ib)
Rear 117 kg (258 Ib)
Fuel Tank Capacity 22.0 L (5.8 US gal)
Performance
Minimum Turning Radius 2.8 m (110.2 in.)
Engine
Type 4-stroke, DOHC, 4-cylinder
Cooling System Air-cooled
Bore And Stroke 66.0 x 54.0 mm (2.60 x 2.13 in.)
Displacement 738 mL (45.03 cu in.)
Compression Ratio 9.5
Maximum Horsepower 56.0 kW (76 PS) @9 500 r/min (rpm), (US) -
Maximum Torque 63.0 N.m (6.4 kgf.m, 46.3 ft.lb) @7 500 r/min (rpm), (US) -
Carburetion System Carburetor, Keihin, CVK32 x 4
Starting System Electric starter
Ignition System Battery and coil (transistorized)
Timing Advance Electronically advanced (digital igniter)
Ignition Timing From 12.5° BTDC @1 100 r/min (rpm)
[(CAL, TW) @1 300 r/min (rpm)] to 37.5° BTDC
@9 000 r/min (rpm)
Spark Plugs NGK DR9EA or ND X27 ESR-U
Cylinder Numbering Method Left to right 1-2-3-4
Firing Order 1-2-4-3
Valve Timing:
Inlet
Open 30° BTDC
Close 60° ABDC
Duration 270°
Exhaust
Open 60° BBDC
Close 30° ATDC
Duration 270°
Lubrication System Forced lubrication (wet sump with cooler)

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 1-8 GENERAL INFORMATION
General Specifications
Items ZR750-H1 ZR750-H2 I ZR750-H3 - H5
Engine Oil:
Type API SE, SF or SG
API SH or SJ with JASO MA
SAE10W-40,
1OW-50, SAE10W-40
Viscosity
20W-40, or
20W-50
Capacity 3.6 L (3.8 US qt)
Drive Train
Primary Reduction System:
Type Chain and gear
Reduction Ratio 2.550 (27/23 x 63/29)
Clutch Type Wet multi disc
Transmission:
5-speed, constant mesh, retu rn
Type shift

Gear Ratios:
1st 2.333 (35/15)
2nd 1.631 (31/19)
3rd 1.272 (28/22)
4th 1.040 (26/25)
5th 0.875 (21/24)
Final Drive System:
Type Chain
Reduction ratio 2.375 (38/16)
Overall drive ratio 5.299 @Top gear
Frame
Type Tubular, double cradle
Caster (Rake Angel) 25.5°
Trail 93 mm (3.66 in.)
Front Tire:
Type Tubeless
Size 120/70ZR 17 58 W I120/70ZR 17M/C 58 W
Rear Tire:
Type Tubeless
Size 160/60ZR 17 69 W I160/60ZR 17M/C 69 W
Front Suspension:
Type Telescopic fork
Wheel Travel 130 mm (5.12 in.)
Rear Suspension:
Uni-trak
Type
swingarm
Wheel Travel 130 mm (5.12 in.)

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 GENERAL INFORMATION 1-9
General Specifications

Items ZR750-H1 I ZR750-H2 I ZR750-H3 - H5

Brake Type:
Front Dual discs
Rear Single disc
Electrical Equipment
Battery 12 V 10 Ah
Headlight:
Semi-sealed
Type beam
Bulb 12 V 60/55 W (quartz-halogen)
Tail/Brake Light 12 V 5/21 W x 2
Alternator:
Type Three-phase AC
Rated Output 22 A @5 000 r/min (rpm), 14 V
Specifications are subject to change without notice, and may not apply to every country.
CAL: California Model
US: United States Model
TW: Taiwan Model

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 1-10 GENERAL INFORMATION
Periodic Maintenance Chart (U.S.A., Canada and Taiwan Model)
The scheduled maintenance must be done in accordance with thi$ chart to keep the motorcycle in
good running condition. The initial maintenance is vitally important and must not be neglected.
* ODOMETER READING
FREQUENCY Whichever .. x 1 000 km
comes first
(x 1 000 mile)
.. 0.8 5 10 15 20 25 30
INSPECTION Every (0.5) (3) (6) (9) (12) (15) (18)
Carburetorsynchronization- check t . . . . . . .
Idle speed - check t . . . . . . .
Throttle grip play - check t . . . .
Spark plug - cleanand gap t . . . . . .
Valveclearance- check t . . . .
Air suctionvalve - check t . . . . . .
Air cleaner element - clean . . . . . . .
Air cleaner element - replace 5 cleanings .
Fuel system - check . . .
Cylinder head bolt tightness - check t . . . .
Evaporative emission control system (CAL, TW)
check t
- . . . . . . .
Brake light switch - check t . . . . . . .
Brake pad wear - check # . . . . . .
Brake fluid level - check t month . . . . . . .
Brakefluid - change 2 years .
Clutch - adjust . . . . . . .
Steering - check t . . . . . . .
Drivechain wear - check t# . . . . . .
Muffler, exhaust pipe nuts and bolts
tighteness-perform t
. .
Nut, bolt, fastener tightness - check t . . . .
Tire wear - check t . . . . . .
Engineoil - change # years . . . .
Oil filter - replace . . . .
General lubrication - perform . . . . . .
Front fork oil - change .
Swingarm pivot, uni-trak linkage-lubricate . . .
Steering stem bearing - lubricate 2 years .
Master cylinder cup and dust seal - replace 2 years
Caliper piston seal and dust seal - replace 2 years
Brake hose - replace 4 years
Fuel hose - replace 4 years
Drive chain - lubricate # Every 600 km (400 mi)
Drive chain slack - check # Every 1 000 km (600 mi)

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 GENERAL INFORMATION 1-11
Periodic Maintenance Chart (U.S.A., Canada and Taiwan Model)
#: 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.
t: Replace, add, adjust, clean, or torque if necessary.
Throttle control system-check: Check the throttle grip play and the throttle body bores.
CAL: California model
TW: Taiwan model

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 1-12 GENERAL INFORMATION
Periodic Maintenance Chart (Other than U.S.A., Canada, Taiwan Model)
* ODOMETER READING
FREQUENCY Whichever
comes first
.. x 1 000 km
(x 1 000 mile)
.. 1 6 12 18 24 30 36
INSPECTION Every (0.6) (4) (7.5' (12) (15) (20) (24)
Carburetor synchronization - check t . . .
Idle speed - check t . . . .
Throttle grip play - check t . . . .
Spark plug - cleanand gap t . . . . . .
Valve clearance - check t . . .
Air suction valve - check t . . . . . .
Air cleaner element - clean t # . . . .
Cylinder head bolts tightness - check t .
Brake light switch - check t . . . . . . .
Brake hose,connections- check t . . . . . .
Fuel hose, connections - check t . . . . . .
Brake pad wear - check t # . . . . . .
Brakefluid level - check t month . . . . . . .
Brake fluid - change 2 years .
Clutch - adjust . . . . . . .
Steering - check t . . . . . . .
Drivechain wear - check t# . . . . . .
Nut, bolt, and fastener tightness - check t . . . .
Muffler, exhaustpipe nuts and bolts
tighteness-perform t
. .
Tire wear - check t . . . . . .
Engineoil - change # 6 month . . . . . . .
Oil filter - replace . . . .
General lubrication - perform . . .
Frontfork oil - change 2 years .
Frontfork oil leak - check t . . .
Rear shock absorber oil leak - check t . . .
Swingarmpivot,uni-traklinkage- lubricate . . .
Steering stem bearing - lubricate 2 years . . .
Master cylinder cup and dust seal - replace 4 years
Caliper piston seal and dust seal - replace 4 years
Drive chain - lubricate # Every 600 km (400 mi)
Drive chain slack - check t # Every 1,000 km (600 mi)
#: 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.
t: Replace, add, adjust, clean, or torque if necessary.

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 GENERAL INFORMATION 1-13
Torque and Locking Agent
Tighten all bolts and nuts to the proper torque using an accurate torque wrench. An insufficiently
tightened bolt or nut may become damaged or fall off, possibly resulting in damage to the motorcycle
and injury to the rider. A bolt or nut which is overtightened may become damaged, strip an internal
thread, or break and then fall out. The following table lists the tightening torque for the major bolts
and nuts, and the parts requiring use of a non-permanent locking agent or liquid gasket.
When checking the tightening torque of the bolts and nuts, first loosen the bolt or nut by half a turn
end then tighten it to the specified torque

Letters used in the "Remarks" column mean:

C: Caulk the head of the fasteners after tightening.
G: Apply high temperature grease to the threads.
L: Apply a non-permanent locking agent to the threads.
LG: Apply liquid gasket to the threads.
0: Apply engine oil to the threads and shaft portion.
MO: Apply molybdenum disulfide oil.
The molybdenum disulfide oil is a mixture of engine oil and molybdenum disulfide grease
with a weight ratio (10:1).
R: Replacement parts
S: Tighten the fasteners following the specified sequence.
SS: Apply silicone sealant (Kawasaki Bond: 56019-120) to the threads.

Torque
Fastener Remarks
N.m kgf.m ft.lb
Fuel System
Carburetor Holder Bolts 12 1.2 104 in.lb L
Fuel Level Sensor Bolts 3.9 0.4 35 in.lb
Fuel Tap Diaphragm Cover Screws 1.0 0.1 9 in.lb
Fuel Tap Mounting Bolts 2.5 0.25 22 in.lb
Engine Top End
Air Suction Cover Bolts 12 1.2 104 in.lb
Cylinder Head Cover Bolts 12 1.2 104 in.lb L
Spark Plugs 14 1.4 10
Cylinder Head Bolts 29 3.0 22 S
Cylinder Head Nuts 39 4.0 29 S
Camshaft Cap Bolts 12 1.2 104 in.lb S
Camshaft Sprocket Bolts 15 1.5 11 L
Carburetor Holder Bolts 12 1.2 104 in.lb L
Camshaft Chain Guide Bolts 11 1.1 97 in.lb
Camshaft Chain Tensioner Mounting Bolts 11 1.1 97 in.lb
Camshaft Chain Tensioner Cap Bolt 5.2 0.5 46 in.lb
Muffler Connecting Nuts 34 3.5 25
Muffler Mounting Bolt 25 2.5 18
CI utch
Clutch Hub Nut 132 13.5 98 R
Clutch Spring Bolts 8.8 0.9 78 in.lb
Clutch Cover Damper Plate Bolts 9.8 1.0 87 in.lb L
Clutch Cover Bolts 12 1.2 104 in.lb
Clutch Release Lever Clamp Bolt 5.9 0.6 52 in.lb
Engine Lubrication System
Oil Cooler Pipe Joint Nuts 22 2.2 16

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 1-14 GENERAL INFORMATION
Torque and Locking Agent

Fastener Torque
Remarks
N.m kgf.m ft.lb
Oil Pipe Lower End Mounting Bolts 8.8 0.9 78 in.lb
Oil Passage Plugs 15 1.5 11
Oil Pressure Switch 15 1.5 11 SS
Oil Pump Mounting Screws 5.1 0.52 45 in.lb C
Oil Pump Mounting Bolts 5.1 0.52 45 in.lb
Oil Pressure Relief Valve 15 1.5 11 L
Oil Filler Cap 1.5 0.15 13 in.lb (Finger tighten)
Engine Oil Drain Plug 29 3.0 22
Oil Pan Bolts 12 1.2 104 in.lb
Oil Filter Mounting Bolt 20 2.0 14 in.lb 0
Engine Removal/Installation
Engine Bracket Bolts 25 2.5 18
Engine Mounting Bolts, Nuts 44 4.5 33
CrankshaftlTransmission
Upper Crankcase Studs - - - L (Planted side)
Upper Crankcase M6 Bolts 12 1.2 104 in.lb
Upper Crankcase M8 Bolts 25 2.5 18 S
Lower Crankcase M6 Bolts 12 1.2 104 in.lb S
Connecting Rod Big End Cap Nuts 36 3.7 27
Return Spring Pin 20 2.0 14
External Shift Mechanism Cover Bolts:
(35 mm Length) 9.8 1.0 87 in.lb L
(20 mm Length) 9.8 1.0 87 in.lb
Neutral Switch 15 1.5 1.1
Shift Pedal Pivot Bolt 23 2.3 17 G
Oil Passage Plug 15 1.5 11 L
Oil Nozzles 6.9 0.7 61 in.lb L
Primary Chain Tensioner Holder Bolts 26 2.7 19
Primary Chain Guide Bolts 12 1.2 104 in.lb L
Starter Clutch Mounting Bolts 12 1.2 20 L
Secondary Shaft Bearing Holder Screws 5.1 0.52 45 in.lb C
Secondary Shaft Nut 59 6.0 43
Secondary Shaft Bearing Cap Screws 9.8 1.0 87 in.lb
Shift Drum Pin Plate Screw - - - L
Shift Drum Guide Bolt 26 2.7 19 L
Shift Drum Positioning Bolt 26 2.7 19
WheelsfTires
Front Axle Clamp Bolt 20 2.0 14
Front Axle 98 10 72
Front Caliper Mounting Bolts 34 3.5 25
Rear Axle Nut 110 11 81
Final Drive
Engine Sprocket Nuts 128 13 94 MO

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 GENERAL INFORMATION 1-15
Torque and Locking Agent
Torque
Fastener Remarks
N.m kgf.m ft.lb
EngineSprocketCoverBolts 12 1.2 104 in.lb
Rear Coupling Studs
- - - L (Planted side)
Rear Sprocket Nuts 59 6.0 43
Brakes
Brake Lever Pivot Bolt 1.0 0.1 9 in.lb
Brake Lever Pivot Bolt Locknut 5.9 0.6 52 in.lb
Front Brake Reservoir Cap Screws 1.5 0.15 13 in.lb
Front Master Cylinder Clamp Bolts 8.8 0.9 78 in.lb S
Brake Hose Banjo Bolts 34 3.5 25
Caliper Mounting Bolts 34 3.5 25
Caliper Bleed Valves 7.8 0.8 69 in.lb
Brake Disc Mounting Bolts 27 2.8 20 L
Brake Pedal Mounting Bolt 8.8 0.9 78 in.lb
Brake Pedal Adjuster Locknut 18 1.8 13
Rear Master Cylinder Mounting Bolts 25 2.5 18
Rear Brake Reservoir Mounting Bolts 6.9 0.7 61 in.lb
Suspension
Front Fork Top Plugs 23 2.3 17
Front Fork Clamp Bolts 20 2.0 14
Front Fork Bottom Allen Bolts 30 3.0 22 L
Front Axle Clamp Bolts 20 2.0 14
Swingarm Pivot Nut 110 11 80 G
Tie Rod Nuts 59 6.0 43
Rocker Arm Nut 59 6.0 43
Rear Shock Absorber Mounting Nuts 59 6.0 43
Steering
Handlebar Clamp Bolts 25 2.5 18 S
Steering Stem Head Nut 49 5.0 36
Front Fork Clamp Bolts 20 2.0 14
Steering Stem Nut 4.9 0.5 43 in.lb
Frame
Side Stand Bolt, Nut 44 4.5 33
Grab Rail Bolts 25 2.5 18
Wind Shield Screws 0.4 0.04 4 in.lb
Footpeg Bracket Mounting Bolts 25 2.5 18
Center Stand Nuts 29 3.0 22
Electrical System
Front Brake Light Switch Mounting Screws 1.2 0.12 10 in.lb
Spark Plugs 14 1.4 10
Starter Motor Cover Bolts 5.1 0.52 45 in.lb
Starter Motor Mounting Bolts 9.8 1.0 87 in.lb
Starter Motor Terminal Locknut 6.9 0.7 61 in.lb
Starter Motor Cable Nut 4.9 0.5 43 in.lb

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 1-16 GENERAL INFORMATION
Torque and Locking Agent

Torque
Fastener Remarks
N.m kgf.m ft.lb
Starter Motor through Bolt 6.9 0.7 61 in.lb
Alternator Cover Bolts 12 1.2 104 in.lb L
Alternator Stator Mounting Bolts 7.8 0.8 71 in.lb
Alternator Stator Wire Clamp Bolts 2.9 0.3 26 in.lb
Alternator Rotor Bolt 128 13 94
Oil Pressure Switch 15 1.5 11 SS
Oil Pressure Switch Terminal Bolt 1.6 0.16 14 in.lb
Timing Rotor Bolt 40 4.1 30
Crankshaft Sensor Mounting Bolts 6.0 0.6 53 in.lb
Crankshaft Sensor Cover Bolts 12 1.2 104 in.lb
Wire Clamp Bolt 6.0 0.6 53 in.lb
Neutral Switch 15 1.5 11
Side Stand Switch Mounting Bolts 8.8 0.9 78 in.lb L
Battery Ground Wire Terminal Bolt 5.1 0.52 45 in.lb
Taillight Mounting Nuts 5.9 0.60 52 in.lb
The table below, relating tightening torque to thread diameter, lists the basic torque for The bolts
and nuts, Use this table for only the bolts and nuts which do not require a specific torque value, Allof
the values are for use with dry solvent-cleaned threads. Basic Torque for General Fasteners
Basic Torque for General Fasteners
Threads Torque
dia. (mm) N.m kgf.m ft.lb
5 3.4 - 4.9 0.35 - 0.50 30 - 43 in.lb
6 5.9 - 7.8 0.60 - 0.80 52 - 69 in.lb
8 14 -19 1.4 -1.9 10.0 - 13.5
10 25 - 34 2.6 - 3.5 19.0 - 25
12 44 - 61 4.5 - 6.2 33 - 45
14 73 - 98 7.4 - 10.0 54 - 72
16 115 - 155 11.5-16.0 83 - 115
18 165 - 225 17.0 - 23.0 125 - 165
20 225 - 325 23 - 33 165 - 240

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 GENERAL INFORMATION 1-17
Special Tools and Sealant
Bearing Puller: Valve Guide Reamer, </>7:
57001-135 57001-162

5T5701355T C 5T5701625T C

Steering Stem Bearing Driver: Valve Guide Arbor, </>7:

57001-137 57001-163

5T5701375T C 5T5701635T C

Inside Circlip Pliers: Oil Pressure Gauge, 10 kgf/cm2:

57001-143 57001-164

5T5701435T C 5T5701645T C

Outside Circlip Pliers: Fork Cylinder Holder Handle:

57001-144 57001-183

5T5701445T C 5T5701835T C

Bearing Puller: Compression Gauge, 20 kgf/cm2:

57001-158 57001-221

5T5701585T C 5T5702215T C

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 1-18 GENERAL INFORMATION
Special Tools and Sealant
Valve Spring Compressor Assembly: Piston Pin Puller Assembly:
57001-241 57001-910

5T5702415T C 5T5709105T C

Valve Spring Compressor Adapter, <p28.2: Fuel level Gauge:

57001-243 57001-1017

5T5702435T C 5T5710175T C

Bearing Puller Adapter: Compression Gauge Adapter, M12 x 1.25:

57001-317 57001-1018

5T5703175T C 5T5710185T C

Gear Pusher & Puller: Spark Plug Wrench, Hex 18:

57001-319 57001-1024

5T5703195T C 5T5710245T C

Bearing Driver, <p32: Fork Cylinder Holder Adapter:

57001-382 57001-1057

5T5703825T C 5T5710575T C

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 GENERAL INFORMATION 1-19
Special Tools and Sealant
Oil Seal & Bearing Remover: Piston Ring Compressor -
Belt, cP50 cP67:
57001-1058 57001-1096

8157105881 C 8157109681 C

Steering Stem Bearing Driver Adapter, cP34.5: Steering Stem Nut Wrench:
57001-1074 57001-1100

8
Head Pipe Outer Race Press Shaft:
8157107481 C

Head Pipe Outer Race Driver, cP46.5:

81571100S1 C

57001-1075 57001-1106

8157107581 C 8157110681 C

Head Pipe Outer Race Driver, cP51.5: Head Pipe Outer Race Remover ID > 37 mm:
57001-1076 57001-1107

8157107681 C 8157110781 C

Piston Ring Compressor Grip: Valve Seat Cutter, 45° -cP32:

57001-1095 57001-1115

8157109581 C 8157111581 C

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 1-20 GENERAL INFORMATION
Special Tools and Sealant
Valve Seat Cutter, 45° 4>35: - Valve Seat Cutter Holder Bar:
57001-1116 57001-1128

ST571116ST C ST571128ST C

Valve Seat Cutter, 32° - 4>35: Bearing Driver Set:

57001-1121 57001-1129

ST571121ST C ST571129ST C

Valve Seat Cutter, 60° - 4>30: Rotor Puller Adapter, 4>9.5:

57001-1123 57001-1151

@ .'.
..q....

.
". .
.
. .

ST571123ST C ST571151ST C

Valve Seat Cutter, 60° - 4>41: Fork Outer Tube Weight:

57001-1124 57001-1218

~ .
.".. ..
...
".'
. ." '..
. .
. '.
..
. .
..." .
.

ST571124ST C ST571218ST C

Valve Seat Cutter Holder, 4>7: Front Fork Oil Seal Driver:
57001-1126 57001-1219

ST571126ST C ST571219ST C

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 GENERAL INFORMATION 1-21
Special Tools and Sealant
Jack: Fork Oil Level Gauge:
57001-1238 57001-1290

8T5712388T C

Clutch Holder: Pilot Screw Adjuster, C:

57001-1243 57001-1292

8T5712928T C

Bearing Remover Head, </>15x </>17: Bearing Remover Head, </>20x </>22:
57001-1267 57001-1293

8T5712678T C 8T5712938T C

Carburetor Drain Plug Wrench, Hex 3: Flywheel Holder:

57001-1269 57001-1313

8T5712698T C

Oil Pressure Gauge Adapter, M18 x 1.5: Piston Base, </>2.3:

57001-1278 57001-1336

8T5712788T C 8T5713368T C

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 1-22 GENERAL INFORMATION
Special Tools and Sealant
Pilot Screw Adjuster Adapter, cP5: Hand Tester:
57001-1372 57001-1394

ST571372ST C

Pilot Screw Adjuster Driver: Throttle Sensor Setting Adapter #1 :

57001-1373 57001-1400

ST571373ST C ST571400ST C

Bearing Remover Shaft, <jJ13: Peak Voltage Adapter:

57001-1377 57001-1415

ST571377ST C

Igniter Checker Assembly: Flywheel Puller Assembly, M30 x 1.5, M33 x 1.5:
57001-1378 57001-1426

ST571426ST C

Harness Adapter #2: Harness Adapter #14:

57001-1382 57001-1427

ST571382ST C ST571427ST C

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 GENERAL INFORMATION 1-23
Special Tools and Sealant
Kawasaki Bond (Silicone Sealant): Kawasaki Bond (Liquid Gasket -Silver):
56019-120 92104-002

5156012051 C 5192000251 C

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 1-24 GENERAL INFORMATION
Cable, Wire, and Hose Routing

GB090461WS C

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 GENERAL INFORMATION 1-25
Cable, Wire, and Hose Routing
1. Throttle Cables
2. Front Upper Brake Hose
3. Right Handlebar Switch Lead
4. Accelerator Throttle Cable
5. Clamp
6. Viewed F
7. Meter Unit Connector
8. Oeaccelerator Throttle Cable
9. Headlight & Turn Signal Light Lead
10. Clamp
11. Left Handlebar Switch Lead
12. Bolt
13. Open Type Clamp
14. Ignition Switch
15. Run the ignition switch Lead over the cross pipe.
16. Main Harness
17. Clamp (Speedometer Cable)
18. Speedometer Cable
19. Clutch Cable
20. Run the main harness, left handlebar switch lead and ignition switch lead between the top tube
and clamp.
21. Clamp
22. Viewed G
23. Clamp
24. To Ignition Switch
25. To Main Harness
26. Screw

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 1-26 GENERAL INFORMATION
Cable, Wire, and Hose Routing

68090457115 C

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 GENERAL INFORMATION 1-27
Cable, Wire, and Hose Routing
1. Choke Cable
2. Clutch Cable
3. Throttle Cable (deceleration) adjustment position
4. Throttle Cable (acceleration) adjustment position
5. Route clutch cable and starter cable along the left side of ignition coil.
6. Route between carburetor and air cleaner (Between #2 and #3 carburetors)
7. Throttle Cable (deceleration)
8. Throttle Cable (acceleration)
9. Viewed C
10. Route wiring harness above clamp and clutch and choke cable is under the clamp.
11. Welded Clamp
12. Clamp it to the center of the depression.
13. Cables are divided right and left under the hose (between Vacuum valve switch and air cleaner)
14. Vacuum Valve Switch Hose
15. Vertical relationship between throttle cables, ignition coils and vacuum valve switch.
16. Frame
17. Install clamp so that its opening faces outward to the left of vehicle.
18. Cross-Section DD (indicating clamp installation direction)
19. Ignition Coil
20. Rear Shock Absorber
21. Speedometer Cable

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 1-28 GENERAL INFORMATION
Cable, Wire, and Hose Routing

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 GENERAL INFORMATION 1-29
Cable, Wire, and Hose Routing
1. Horn Lead
2. Ignition Coil (#1, #4) Lead
3. Regulator/rectifier Connector
4. Carburetor Heater Controller Unit
5. Strap
6. Run the alternator lead inside the engine bracket.
7. Starter Relay Lead
8. Clamp
9. Cables (Seat lock)
10. Rear Turn Signal Light
11 . Junction Box Connector
12. Battery Positive [+] Lead
13. Route to the right of the switch
14. Attach a cushion under the battery.
15. Normally Open Type Relay Connection
16. Alternator Lead
17. Frame Cross Pipe
18. Route in front of the frame cross pipe.
19. Clamp all 3 lead together.
COT Wire (Side Stand Switch + Neutral Switch)
Alternator Lead
Choke cable
20. Upper hook must be installed in this direction. (Spring can be moved telescopically in the vertical
direction.)
21 . Center Stand
22. Strap hold the sidestand lead to the down tube, and no slack permissible.
23. Neutral Switch
24. Clamp it securely.
25. Side Stand Switch Connector
26. There is no problem even if the left and right leads are connected by turns.
27. To canister.
28. Coupler [A]
29. To Starter
30. Starter Relay
31. To main harness
(Face lock (shaded area) of coupler [A] outward of vehicle.)
32. To battery positive [+]
33. Canister Hose (Run the hose inside the coupler.)
34. To Breather Tank.
35. Rear Fender Battery Storage
36. Front View of starter

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 GENERAL INFORMATION 1-31
Cable, Wire, and Hose Routing
1. Tail/Brake Light Lead
2. Turn Signal Light (left) Lead
3. Install the clamp in the clamp mounting bracket and route the cable.
4. Cable (Seat lock)
5. Clamp
6. Clamp Mounting Bracket
7. Junction Box Lead
8. Strap (Velcro tape)
9. Tool Space
10. Route the junction box leads through the rear of the vertical wall behind the tool space.
11. Junction Box
12. Starter Switch Lead
13. Battery Positive [+] Lead
14. Normally Open Type Relay Connector
15. Alternator Connector
16. Strap
17. Carburetor Heater Controller Lead
18. Main Harness
19. Ignition Coil (#1, #4) Lead
20. Insert the locating clamp for the main wiring harness into this hole.
21. To Horn
22. Left Grip Switch Lead (Run the lead inside the throttle cables).
23. Turn Signal Light (right) Lead
24. Strap: secure with U-Iock (Velcro tape)
[-Route the strap through fender before installing the fender.]
25. Igniter Connector
26. Battery Ground Lead
27. Turn Signal Light Relay
28. Rear Brake Light Switch Connector
29. Crankshaft Sensor & Oil Pressure Switch Connector
30. Carburetor Heater Connector
31. Strap (Tie it immediately behind the bracket.)
32. Throttle Position Sensor Connector
33. Atmospheric Temperature Sensor Connector
34. Ignition Coil (#2, #3) Lead
35. Regulator/rectifier Connector
36. Fuel Gauge Connector
37. Frame Ground
38. Detail of area [A]
39. Run the left and right handlebar switch Leads over the crosspipe.
40. Right Handlebar Switch Lead
41. Strap tying and cutting method.
42. Direction for tying strap.
43. Tie strap under the pipe, and face it inward (viewed right side of the frame)
44. Bracket
45. Ground Lead
46. Detail of area [A] (installing ground lead).
47. Install straps in the area indicated in this manual.
(Precautions concerning he cutting of straps: Mark sure to leave 10 - 15 mm (0.4 - 0.6 in.)
when cutting a strap, or cut tip in round shape.

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 1-32 GENERAL INFORMATION
Cable, Wire, and Hose Routing

GB090458W5 C

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 GENERAL INFORMATION 1-33
Cable, Wire, and Hose Routing
1. Tail/Brake Light Connector
2. Rear Turn Signal Light Connector
3. I.C. Igniter
4. Coupler Negative [-] Lead (Connect it to the left of the turn signal light relay.)
5. Turn Signal Light Relay Connector
6. Rear Brake Light Switch Connector
7. Boss
8. Clamp
9. White Tape
10. Strap
11. In this area, route the fuel gauge drain hose along the inside of the frame, between the frame
and the air cleaner housing.
12. Route the carburetor heater connector between carburetors #3 and #4.
13. Regulator/rectifier Connector
14. Clamp
15. Route the throttle cable to the right side of horn lead.
16. Ignition Coil Connector
17. Clamp (welded to tank): Clamp only the wiring harness for the fuel gauge.
18. Fuel Gauge Connector
19. Throttle Sensor Connector
20. Atmospheric Air Temperature Sensor Connector
21. Route above frame cross pipe (for engine mount).
22. Crankshaft Sensor & Oil Pressure Switch Connector
23. Clamp (Bolted to swingarm.)
24. Fuel Tank Drain Hose (Route through the clamp below the swingarm.)*
25. Fuel Gauge Drain Hose (Route through the clamp below the swingarm.)*
26. Run the fuel tank drain hose of the California model front side the separator.
27. In this area, route the fuel tank drain hose between the frame and the air cleaner housing, and
under the boss [7] of the air cleaner housing.
28. Grab Rail Mounting Bracket
29. Route the light leads under the grab rail mounting bracket, and secure it with a strap to prevent
it from slacking.
30. Drain Hose (Route through clamp.)
31. Clamp
32. Fuel Gauge Wiring Harness (Route through the clamp.)

* 1. Do not kink the tube along its routing.

2 Do not apply lubricant to the hose in order to insert it into the drain pipes of the fuel tank
. and the fuel gauge.

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 1-34 GENERAL INFORMATION
Cable, Wire, and Hose Routing

GB09238BII5 C

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 GENERAL INFORMATION 1-35
Cable, Wire, and Hose Routing

1. Upper Side
2. Clamp
3. Starter Cable
4. Alternator Lead
5. Clamp
6. To Sidestand Switch
7. Sidestand Switch Lead
8. Neutral Switch Lead
9. Neutral Switch
10. Run the engine ground lead between this bolt and engine mount.
11. Drain Tank
12. Install the clamp as figure.
13. Hold the lead with clamp.
14. Clamp
15. Crankshaft Sensor & Oil Pressure Switch Lead
16. Run the drain hose under the engine ground lead and between the clamp and crankshaft sensor
& oil pressure switch lead.
17. ZR750-H3 - H5 Model

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 1-36 GENERAL INFORMATION
Cable, Wire, and Hose Routing

(}) o

GB090463W4 C

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 GENERAL INFORMATION 1-37
Cable, Wire, and Hose Routing
1. To Main Harness
2. Headlight & Turn Signal Light Lead
3. Headlight
4. Clamp (with Headlight Mounting Bolt)
5. Clamp (with Headlight Mounting Bolt)
6. Clamp (City light Lead Only)
7. To Front Right Turn Signal Light
8. City light (other than U.S.A. Canada and Australia)
9. To Front Left Turn Signal Light
10. Main Harness
11. Tail & Brake Light Lead
12. Clamp
13. Clamp
14. Rear Right Turn Signal Light Lead (Loop the lead as shown.)
15. Groove (Put the right turn signal light lead.)
16. Groove (Put the left turn signal light lead.)
17. Rear Left Turn Signal Light Lead (Loop the lead as shown.)

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 1-38 GENERAL INFORMATION
Cable, Wire, and Hose Routing

G8090466114 C

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 GENERAL INFORMATION 1-39
Cable, Wire, and Hose Routing
1. Clutch Cable
2. Choke Cable
3. Throttle Cable (deceleration)
4. Throttle Cable (acceleration)
5. Vacuum Valve Switch
6. Run the high-tension cable upside the vacuum valve switch.
7. Spark Plug Caps (#1, 2)
8. Ignition Coil (#1, 4)
9. To Air Cleaner Housing
10. Tube
11. Spark Plug Caps (#3, 4)
12. To #4 Carburetor
13. Ignition Coil (#2, 3)
14. Fuel Hose
15. Breather Pipe
16. Return Pipe
17. Blue label
18. Red label
19. Cylinder Head Side
20. Vacuum Hose
21. To Fuel Tap (vacuum)
22. Air Vent Hose (to right side)
23. Air Vent Hose (to left side)

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 1-40 GENERAL INFORMATION
Cable, Wire, and Hose Routing

68090460W5 C

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 GENERAL INFORMATION 1-41
Cable, Wire, and Hose Routing
1. Choke Cable
2. Clutch Cable
3. Front Brake Master Cylinder
4. Washers
5. Brake Hose Banjo Bolts
6. Front Upper Brake Hose
7. Stopper position
8. Brake Hose Banjo Bolt (longer)
9. Painted (white)
10. Brake Hose Joint
11. Front Lower Brake Hose (left)
12. Clamp
13. Steering stem
14. Front Lower Brake Hose (Right)
15. Painted (Blue)
16. Clamps
17. Bolts
18. Bleed Valve
19. Speedometer Cable
20. Grommets
21. Front Caliper
22. Caliper Mounting Bolts
23. Front Discs
24. Front Disc Bolts
25. Section A-A
26. Rear Brake Caliper
27. Rear Brake Caliper Mounting Bolts
28. Bleed Valve
29. Clamp
30. Clamp Bolt
31 . Caliper Bracket
32. Rear Brake Hose
33. Reservoir Hose
34. Upper Level (Fill the resetvoir to the upper level line.)
35. Bolts
36. Rear Brake Switch
37. Rear Brake Master Cylinder Bolts
38. Rear Brake Switch Spring
39. Rear Brake pedal
40. Pivot Bolt
41 . Washer
42. Cotter Pin
43. Return Spring
44. Return Spring Bolt
45. Gasket (Between the wheel and disc)
46. Rear Brake Disc

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 1-42 GENERAL INFORMATION
Cable, Wire, and Hose Routing
California Model

r----__
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------

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 GENERAL INFORMATION 1-43
Cable, Wire, and Hose Routing

GB090464W3 C

1. Clamps 18. Canister

2. Hose (Yellow) 19. Hose (Blue)
3. Clamps 20. Hose (Red)
4. Fitting 21. Main Harness
5. Reservoir 22. Clamp (The frame pipe and hose are fixed
6. Hose at this position)
7. Plug 23. Bands
8. Hose (Yellow) 24. Carburetor #3
9. Through the hole 25. Damper
10. Vacuum Valve Switch 26. Screw
11. To Fuel Tap 27. Cover (Hold the canister Hoses)
12. Hose (White) 28. Clamp (Yellow Hose)
13. Separator 29. Clamp (Seat lock Cable)
14. Hose (Blue) 30. Clamp Bracket
15. Hose (Green) 31 . Seat lock Cable
16. Bands 32. Bands (U-Shaped Lock)
17. Cover 33. U-Shaped Lock

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 FUEL SYSTEM 2-1

IFuel System
Table of Contents
ExplodedView ~........ 2-2 Carburetor Disassembly.............. 2-15
Specifications . 2-6 Carburetor Assembly................... 2-17
Throttle Grip and Cables ................... 2-7 Carburetor Separation................. 2-18
Throttle Grip Free Play Inspection 2-7 Carburetor Joining ....................... 2-18
Throttle Grip Free Play Carburetor Cleaning. ........... 2-19
Adjustment . 2-7 Carburetor Inspection .................. 2-20
Throttle Cable Installation ............ 2-8 Air Cleaner... ............. 2-22
Throttle Cable Lubrication and Air Cleaner Element RemovaL.... 2-22
Inspection , . 2-8 Air Cleaner Element Installation... 2-22
Choke Cable...................................... 2-9 Air Cleaner Element Cleaning and
Choke Cable Free Play Inspection . 2-23
Inspection.. ..... 2-9 Breather Oil Draining ................... 2-23
Choke Cable Free Play Air Cleaner Housing RemovaL.... 2-23
Adjustment . 2-9 Air Cleaner Housing Installation... 2-24
Choke Cable Installation .............. 2-9 Fuel Tank........................................... 2-25
Choke Cable Lubrication anti Fuel Tank Removal...................... 2-25
Inspection .. .. .... ... ... 2-9 Fuel Tank Installation ................... 2-25
Carburetors .......... 2-10 Fuel Tank Inspection .................... 2-26
Idling Speed Inspection................ 2-10 Fuel Tank Cleaning ...................... 2-26
Idle Speed Adjustment................. 2-10 Fuel Tap Removal........................ 2-26
Carburetor Synchronization Fuel Tap Installation..................... 2-27
Inspection .......... 2-10 Fuel Tap Inspection...................... 2-27
Carburetor Synchronization Evaporative Emission Control System
Adjustment . 2-11 (California and Taiwan Model) ........ 2~8
Service Fuel Level Inspection ...... 2-11 Parts Removal/Installation ........... 2-28
Service Fuel Level Adjustment .... 2-12 Hose Inspection........................... 2~8
Fuel System Cleaning and Separator Inspection.................... 2~8
Inspection .......... 2-13 Separator Operation Test............. 2~9
Carbu retor RemovaL ,........ 2-13 Canister Inspection...................... 2~9
Carburetor Installation ..,........ 2-14

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 2-2 FUEL SYSTEM
Exploded View

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 FUEL SYSTEM 2-3
Exploded View
1. California and Taiwan Model
2. Other than California and Taiwan Model
3. Other than U.S.A., Canada and Taiwan Model
T1: 0.8 N.m (0.08 kgf.m, 7 in.lb)
T2: 1.0 N.m (0.1 kgf.m, 9 in.lb)
T3: 12 N.m (1.2 kgf.m, 104 in.lb)
T4: 2.5 N.m (0.25 kgf.m, 22 in.lb)
T5: 3.9 N.m (0.4 kgf.m, 35 in.lb)
DG: Apply heat transfer grease.
L: Apply non-permanent locking agent to the threads.
R: Replacement Parts

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 2-4 FUEL SYSTEM
Exploded View

GC02098BII5 C

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 FUEL SYSTEM 2-5
Exploded View
1 . Jet Needle
2. Pilot Screw
3. Pilot Jet
4. Needle Jet
5. Needle Jet Holder
6. Main Jet
8. Other than U.S.A., Canada and Taiwan Model
9. California and Taiwan Model
10. U.S.A., Canada and Taiwan Model
G: Apply grease.
0: Apply oil.

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 2-6 FUEL SYSTEM
Specifications
Item Standard
Throttle Grip and Cable
Throttle Grip Free Play 2 - 3 mm (0.08 - 0.12 in.)
Choke Cable
Choke Cable Free Play 2 - 3 mm (0.08 - 0.12 in.)
Carburetors
Make Type Keihin, CVK 32
Main Jet #108
Main Air Jet #100
Jet Needle #1 and #4 N6NC, #2 and #3 N4MD
Pilot Jet #35
Needle Jet Holder #1 and #4 (N413-16 YOO) has 0.7 mm x 14 holes
#2 and #3 (N413-16 AOO) has 0.6 mm x 18 holes
Pilot Screw 1 3/4 turns out, (CAL) (US) -
Idle Speed 1 100 :t50 r/min (rpm),
(CAL) (TW) 1 300 :t50 r/min (rpm)
Carburetor Synchronization Vacuum Less than 2.7 kPa (2 cmHg, 0.39 psi) difference
between any two carburetors
Service Fuel Level (Below The Bottom
1.5 mm (0.06 in.) below - 0.5 mm (0.02 in.) above
Edge Of The Carburetor Body)
Float Height 17 :t2 mm (0.67 :to.08 in.)
CAL: California Model
TW: Taiwan Model
US: U.S.A. Model

Special Tools - Fuel Level Gauge: 57001-1017

Carburetor Drain Plug Wrench, Hex 3: 57001-1269
Pilot Screw Adjuster, C: 57001-1292
Pilot Screw Adjuster Adapter, 4>5:57001-1372
Pilot Screw Adjuster Driver: 57001-1373

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 FUEL SYSTEM 2-7
Throttle Grip and Cables
Throttle Grip Free Play Inspection
. Check that the throttle grip moves smoothly from fullopen
to close, and the throttle closes quickly and completely in
all steering positions by the return spring.
*If the throttle grip does not return properly, check the throt-
tle cable routing, grip free play, and cable damage. Then
lubricate the throttle cable.
. Run the engine at the idle speed, and turn the handlebar
all the way to the right and left to ensure that the idle speed GC040112S1 C
does not change.
*If the idle speed increase, check the throttle cable free
play and the cable routing.
.Inspect the free play [A] of the throttle grip.
Throttle Grip Free Play
Standard: 2 - 3 mm (0.08- 0.12 in.)
*If the free play is incorrect, adjust the throttle cable.
Throttle Grip Free Play Adjustment
. Loosen the locknut [A].
. Turn the adjuster [8] until the proper amount of throttle
grip free play is obtained.
. Tighten the locknut securely against the adjuster.
* If the free play cannot be adjusted with the upper adjuster,
use the adjusters at the center of the cables.
. Loosen the locknut, and screw the adjuster near the upper
end of the accelerator cable all the way in.
. Tighten the locknut securely.
.. Remove the fuel tank (see Fuel Tank Removal).
Loosen the locknuts at the center of the acceleration ca-
ble.
. Screw both throttle cable adjuster to give the throttle grip
plenty of play.
. With the throttle grip completely closed, turn out the de-
celerator cable adjuster [A] until the inner cable just be-
comes tight.
. Tighten the decelerator cable locknut [8] securely.

. Turn the accelerator cable adjuster [A] until the correct

throttle grip free play is obtained.
. Tighten the accelerator cable locknut [8] securely.
* If the proper amount of free play can not be obtained in
the adjustable range of the adjuster, use the adjuster at
the upper end of the accelerator cable again.

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 2-8 FUEL SYSTEM
Throttle Grip and Cables
Throttle Cable Installation
.Install the throttle cables in accordance with the Cable,
Wire, and Hose Routing section in the Generallnforma-
tion chapter.
. Install the lower ends of the throttle cables in the bracket
on the carburetor after installing the upper ends of the
throttle cable in the grip.
. After installation, adjust each cable properly.
A WARNING
Operation with incorrectly routed or improperly ad-
justed cables could result in an unsafe riding con-
dition.

Throttle Cable Lubrication and Inspection

. Whenever
the cables are removed, or in accordance with
the Periodic Maintenance Chart, lubricate the throttle ca-
bles (see General Lubrication in the Appendix chapter).
. Apply a thin coating of grease to the cable upper ends.
. Use a commercially available pressure cable lubricator to
lubricate the cables.
. With the cable disconnected at both ends, the cable
should move freely in the cable housing. GC040114S1 C

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 FUEL SYSTEM 2-9
Choke Cable

.Choke Cable Free Play Inspection

Push the choke lever [A] all the way to the front.
. Check choke cable free play [8].
ODetermine the amount of choke cable play at the choke
lever. Pull the choke lever until the starter plunger lever at
the carburetor touches the starter plunger; the amount of
choke lever lower end travel is the amount of choke cable
play.
* If the free play is incorrect, adjust the choke cable.
Choke Cable Free Play
Standard: 2 - 3 mm (0.08 - 0.12in.)

Cable Free Play Adjustment

.Choke
Remove the fuel tank (see Fuel Tank Removal).
. Loosen the locknut [A] in the center of the cable, and turn
the adjuster [8] until the cable has the proper amount of
free play.
. Tighten the locknut securely.

Choke Cable Installation

.Install the choke cable in accordance with the Cable,
Wire, and Hose Routing section in General Information
chapter.
. After installation, adjust the cable properly.
A WARNING
Operation with an incorrectly routed or improperly
adjusted cable could result in an unsafe riding con-
dition.

.Choke Cable Lubrication and Inspection

Whenever the cable is removed, or in accordance with
the Periodic Maintenance Chart, lubricate the choke cable
(see General Lubrication in the Appendix chapter).
OApply a thin coating of grease to the cable upper end.
OUse a commercially available pressure cable lubricator to
lubricate the cable.
OWith the cable disconnected at both ends, the cable
should move freely in the cable housing. GC040114S1 C

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 2-10 FUEL SYSTEM
Carburetors
Idling Speed Inspection
. Start the engine and warm it up thoroughly.
. With the engine idling, turn the handlebar to both sides to
check for any changes in the idle speed.
*If handlebar movement changes the idle speed, the
throttle cables may be improperly adjusted or incorrectly
routed, or damaged. Be sure to correct any of these
conditions before riding (see Cable, Wire, and Hose
Routing section in General Information chapter).
A WARNING
Operation with an incorrectly routed, improperly
adjusted, or damaged cables could result in an
unsafe riding condition.

.*IfCheck idle speed.

the idle speed is out of standard, adjust it.
Idle Speed
Standard: 1 100 :1:50r/min (rpm)
California and
Taiwan Model 1 300 :1:50r/min (rpm)

Idle Speed Adjustment

. Start the engine and warm it up thoroughly.
. Turn the adjusting screw [A] until the idle speed is correct.
. Open and close the throttle a few times to make sure that
the idle speed is within the specified range. Readjust if
necessary.

Carburetor Synchronization Inspection

. Start the engine and warm it up thoroughly.
. Check idle speed (see Idle Speed Inspection).
..Remove the fuel tank (see Fuel Tank Removal).
Prepare an auxiliary fuel tank to supply fuel to the carbu-
retors.
. For the California model, remove the vacuum hoses [A]
and inlet pipe plug [B] from the carburetor.

. For the models other than the California model, remove

the #1,3 inlet pipe lugs and #2,3 vacuum hoses.
. Connect a vacuum gauge hoses [A] to the fitting of the
carburetor.
Vacuum Gauge [B]
. Start the engine and read the intake vacuum of each car-
buretor at idle.
*If the vacuum is incorrect, adjust the synchronization.
Carburetor Synchronization Vacuum
Standard: Less than 2.7 kPa (2 cmHg, 0.39 psi)
difference between any two carburetors.

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 FUEL SYSTEM 2-11
Carburetors
Carburetor Synchronization Adjustment
. Turn the adjusting screw to synchronize the carburetors.
OFirst synchronize the left two and then the right two car-
buretors by means of the left and right adjusting screws
[A,C]. Then synchronize the left two carburetors and the
righttwo carburetors using the center adjusting screw [8].
*If the carburetor synchronization cannot be obtained by
using the adjusting screws, check for dirtor blockage, and
then check the pilot screw settings. GC060154S1 C

Special Tools- Pilot Screw Adjuster, C: 57001-1292

Pilot Screw Adjuster Adapter, cp5: 57001
-1372
Pilot Screw Adjuster Driver: 57001-1373
. Check the carburetor synchronization again
NOTE
o Do not turn the pilot screws carelessly during carburetor
synchronization. You may cause poor running at low
enginespeed.
. Check idle speed.
Service Fuel Level Inspection
A WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
. Remove the carburetors and use an appropriate method
to secure the carburetors upright.
. Use an appropriate hose to connect the fuel tank and the
carburetors.
. Connect a hose that is 6 mm (0.24 in.) in diameter and
about 300 mm (11.8 in.) long to the fuel level gauge and
the float bowl of the carburetors.

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 2-12 FUEL SYSTEM
Carburetors
Special Tool- Fuel level Gauge: 57001-1017[A]
. Hold the gauge so that the "middle" line [B] is placed
slightly higher than the flange at the bottom of the car- A
buretor body.
. Turn the fuel tap to the PRI position and loosen the car-
buretor drain screw [C].
.. Wait untilthe fuel level in the gauge settles.
Hold the gauge vertically and lower it slowly so that the
"middle"line aligns with the mating surface [0] between
the carburetor body and the float bowl.
NOTE
000 not align the "middle"line on the gauge lower than
the mating surface between the carburetorbody and the
float bowl. If it is lowered and then raised, the gauge
willshow a fuel level that is higher than the actual level,
which will require a remeasurement.
.*IfRead the fuel level [E].
it is out of standard, adjust the fuel level (see Service
Fuel Level adjustment). GC06015852 C

Service Fuel Level - (from mating surface)

Standard: 1.5 mm (0.06 in.) below - 0.5 mm (0.02in.)
above
. Tighten the drain screw.
..Turn the fuel tap ON and remove the gauge.
Repeat the same procedure for the other carburetors.
Service Fuel Level Adjustment
.A WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is
well-ventilated and free form any source of flame
or sparks; this includes any appliance with a pilot
light.
.. Drain the fuel into a suitable container.
Remove the float bowl.
. Remove the pin [A]and take out the float [B] with float
valve needle [C].
. the
Bend the tang [A]on the float arm very slightlyto change
float height.
Olncreasing the float height lowers the fuel level and de-
creasingthe floatheight raises the fuel level.
Float Height
Standard: 17 :t2 mm (0.67 :1:0.08in.)

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 FUEL SYSTEM 2-13
Carburetors
NOTE
000 not press on the needle rod [A} when measuring the
float height [B}.
. Assemble the carburetor and recheck the fuel level.
*If the fuel level cannot be adjusted by this method, the
float or the float valve [C] is damaged.

GC060167S1 C

Fuel System Cleaning and Inspection

A WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is
well-ventilated and free form any source of flame
or sparks; this includes any appliance with a pilot
light.
. Connect a suitable hose to the fitting at the bottom of each
carburetor float bowl and run their lower ends into a suit-
able container.
. Turn the fuel tap to the PRI position.
. Turn out the carburetor drain bolt [A] and check to see if
water or dirt comes out.
Special Tool - Carburetor Drain Plug Wrench, Hex 3:
57001-1269
*If any water or dirt appears during the above inspection,
clean the carburetors and the fuel tank.

Carburetor Removal
A WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is
well-ventilated and free form any source of flame
or sparks; this includes any appliance with a pilot
light.
. Remove:
Seats (see Frame chapter)
Fuel Tank (see Fuel Tank Removal)
Vent Hose [A] (Clear the Vacuum Valve Switch Hose)
Vacuum Hose (For the California and Taiwan Model) [8]
Vacuum Hose [C]
Throttle Sensor Connector [D]
Carburetor Heater Connectors (For the other than
U.S.A., Canada and Taiwan Model)
Carburetor Clamp Screws [E]
Holder Spring [F]
Choke Cable End [G]

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 2-14 FUEL SYSTEM
Carburetors
. Remove
frame.
the carburetors assembly to the light side of the

. Remove the throttle cable ends [A].

. Stuff pieces of lint-free, clean cloth into the carburetor
holders to keep dirt out of the engine.
A WARNING
If dirt or dust is allowed to pass through into the
carburetor, the throttle may become stuck, possibly
causing an accident.
CAUTION
If dirt gets through into the engine, excessive en-
gine wear and possibly engine damage will occur.
Carburetor Installation
. Be sure to install the throttle cable ends before install the
carburetors
. erallnformation
Route the cables, harness, and hoses correctly (see Gen-
chapter).
. Tighten the clamps for the carburetor holders at the posi-
tion in the figure.
Upper Side [A]
.A.WARNING
Be sure to install the holder clamp screws in the di-
rection shown. Or, the screws could come in con-
tact with the throttle linkage resulting in unsafe rid-
ing condition.
. Check fuel leakagefrom the carburetors.
~
!
Fuel spilled from the carburetors is hazardous.
. Adjust the following items if necessary.
Idle Speed
Carburetor Synchronization
Throttle Cables
Choke Cable

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 FUEL SYSTEM 2-15
Carburetors

.Carburetor Disassembly
Remove the carburetors assembly.
A WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
NOTE
o Carburetorcan be disassembledin thejoined state.
. For the U.S.A., Canada and Taiwan model, remove the
pilot screw plug as follows: punch a hole in the plug and
pry there with an awl or other suitable tool.
. Turn in the pilot screw and count the number of turns until
it seats fully but not tightly, and then remove the screw.
This is to set the screw to its original position when as-
sembling.

. Remove the screws [A] and remove the choke lever plate
[8].
. Remove the springs [C] and the choke plunger assembly
[0].

. Remove:
Upper Chamber Cover [A]
Spring
Vacuum Piston and Diaphragm
CAUTION

During carburetor disassembly, be careful not to

damage the diaphragm. Never use a sharp edge to
remove the diaphragm.

. These
Remove the jet needle [A] from the vacuum piston [8].
are detached together with the spring seat [C].

GC060404S 1 C

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 2-16 FUEL SYSTEM
Carburetors

. For the other than U.S.A., Canada and Taiwan model:

remove the screws [A], disconnect the carburetor tem-
perature sensor connector [8] and take off the carburetor
heater lead [C] together with the clamps [D], heater hold-
ers [E] and heaters.
ORemove the temperature sensor, if necessary.

OPinch the stopper [A] and then pull the clamp [8].
ODisconnect the connector [C] of the carburetor heater [D].
Carburetor Heater Holder [E]

. Do not remove the pilot screw [A] if possible (see Pilot

Screw Adjustment).
. Remove the float bowl screws [8], the float bowl [C], and
the O-ring.

. Remove the float pivot pin [A], and remove the float [8].
The float needle valve comes out together (see Service
Fuel Level Adjustment).
. Remove the pilot jet [C].
. Remove the main jet [D].
. Remove the needle jet holder [E].

. Push the needle jet [A] down from the carburetor bore.

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 FUEL SYSTEM 2-17
Carburetors
CarburetorAssembly
CAUTION
Do not apply force to the jets and needle jet holder
or overtighten them, as this could damage the jets
or the carburetor body, requiring replacement.
. First insert the smaller end [8] of the needle jet [A]to the
carburetor body.
. Then, screw in the needle jet holder [C].
Olnstall the needle jet holder, noting the following.
The #1 and #4 carburetor has 0.7 mm x 14 holes [A]
The #2 and #3 carburetor has 0.6 mm x 18 holes [8]

.Install the float valve needle [A]in the valve seat [8] and
hook the needle hanger onto the float tang [C].
.Insert the float pivot pin into the pivot and the float holes
(see Service Fuel Level Adjustment).
. Set the float to the standard height (see Service Fuel
Level Adjustment).

.Insert the needle intothe hole in the center of the vacuum

piston [A],and place the spring seat [8] over the needle.
OThe spring seat must be installed without blocking the
hole [C].
. After installing the upper chamber cover, check to make
sure that the vacuum piston moves smoothly in the car-
buretor body.

. Turn in the pilot screw [A]fully but not tightly, and then
back it out the same number of turns counted during dis-

. assembly.
For the U.S.A., Canada and Taiwanmodel, installthe pilot
screw plug as follows: install a new plug [8] in the pilot
screw hole of the carburetor body [C], and apply a small
amount of a bonding agent [D]to the circumference of the
plug to fix the plug.
CAUTION
Do not apply too much bonding agent to the plug or
the pilot screw itself may be fixed.

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 2-18 FUEL SYSTEM
Carburetors

. For the other than U.S.A., Canada and Taiwan .model:

apply heat transfer grease, and install the sensor [A] and
the heater [8] into the carburetor.
.Install the sensor lead, and tighten the plate [C] and the
clamp [0] with screw [E].

Carburetor Separation
. Remove the carburetor (see Carburetor Removal).
..Read the WARNING in the carburetor disassembly.
Mark carburetor locations so that the carburetors can be
installed in their original positions.

. Disconnect the pipe and lead, leaving them connected to

either side.
. Remove:
Choke lever Plate [A]
Cylinder Side Connecting Plate [8]

. Remove:
Air Cleaner Side Connecting Plate [A]
. Separate the carburetor.

Carburetor Joining
. The center lines of the carburetor bores must be parallel
both horizontally and vertically. If they are not, loosen
the mounting screws and align the carburetors on a flat
surface.
.. Retighten the mounting screws.
After installing the choke mechanism, check to see that
the starter plunger lever [A] slides right to left [8] smoothly
without abnormal friction.
CAUTION
Fuel mixture trouble could result if the starter
plunger does not seat properly in its rest position
after the choke lever is returned.

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 FUEL SYSTEM 2-19
Carburetors
.OCheck
Visually synchronize the throttle (butterfly) valves.
to see that all throttle valves open and close [A]
smoothly without binding when turning the pulley.
OVisually check the clearance [B] between the throttle
valve and the carburetor bore in each carburetor.
*If there is a difference between any two carburetors, turn
the synchronization adjusting screws [C] to obtain the
same clearance.
. Install the carburetors (see Carburetor Installation).
. Adjust the synchronization (see Synchronization Adjust-
ment) .

Carburetor Cleaning
A WARNING
Clean the carburetors in a well-ventilated area, and
take care that there is no spark or flame anywhere
near the working area; this includes any appliance
with a pilot light. Because of the danger of highly
flammable liquids, do not use gasoline or low flash
-point solvents to clean the carburetors.

CAUTION
Do not use compressed air on an assembled carbu-
retor, or the floats may be crushed by the pressure,
and the vacuum piston diaphragms may be dam-
aged.
Remove as many rubber or plastic parts from the
carburetor as possible before cleaning the carbu-
retor with a cleaning solution.
This will prevent damage to or deterioration of the
parts.
The carburetor body has plastic parts that can-
not be removed. Do not use a strong carburetor
cleaning solution which could attack these parts;
instead, use a mild, high flash-point cleaning solu-
tion safe for plastic parts.
Do not use wire or any other hard instrument to
clean carburetor parts, especially jets, as they may
be damaged.

.. Remove the carburetors and drain the fuel.

Disassemble the carburetors.
. Clean all the metal parts in a carburetor cleaning solution.
.Rinse the parts in water and dry them with compressed
air.
.Blow through the air and fuel passages with compressed
air.
.Assemble the carburetors and install them on the engine.

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 2-20 FUEL SYSTEM
Carburetors

Carburetor Inspection
A WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
. Remove the carburetors.
. Before disassembling the carburetors, check the fuel level
(see Fuel level Inspection).
* Ifthe fuel level is incorrect, inspect the rest of the carbu-
retor before correcting it.
. Slide the starter plunger.lever [A]to the left and release
it to check that the starter plungers move smoothly and
return by spring tension.
* Ifthe starter plungers do not work properly, replace the
carburetors.
. Turn the throttle cable pulley [B]to check that the throttle
butterfly valves move smoothly and return by spring ten-
sion.
*If the throttle valves do not move smoothly, replace the
carburetors.
.. Clean
Disassemble the carburetors.
the carburetors.
. Check that the O-rings on the float bowl and pilot screw
and the diaphragmon the vacuumpistonare ingood con- B
dition.
*If any of the O-rings or diaphragms are not in good con-
dition, replace them.
. Check the plastic tip [A]of the float valve needle [B]. It
should be smooth, without any grooves, scratches, or
@
GC060405S 1 C
tears.
*If the plastic tip is damaged [C], replace the needle.
. Push the rod [0] in the other end of the float valve needle,
and then release it [E].
*If the rod does not spring out, replace the needle.
. Check the tapered portion [A] of the pilot screw [B] for
wear or damage.
* Ifthe pilot screw is worn or damaged on the tapered por-
tion, it willprevent the engine from idling smoothly. Re-
place it.

GC060406S 1 C

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 FUEL SYSTEM 2-21
Carburetors

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

carburetor body. The surface of the piston must not be
excessively worn.
*If the vacuum piston does not move smoothly, or if it is
very loose in carburetor body, replace the carburetor.

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 2-22 FUEL SYSTEM
Air Cleaner
Air Cleaner Element Removal
. Remove:
Seat (see Frame chapter)
Fuel Tank Mounting Bolts (see Fuel Tank Removal).
. Using the pad [A] lift the back of the fuel tank and remove
the fuel tank bracket bolts [B] and bracket [C].

. Remove the air cleaner intake duct mounting screws [A].

. Remove the intake duct [B].

. Take out the element [A].

Air Cleaner Element Installation

.Install the element with its opening [A] facing forward.

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 FUEL SYSTEM 2-23
Air Cleaner
Air Cleaner Element Cleaning and Inspection
A WARNING
Clean the element in a well-ventilated area, and take
care that there are no sparks or flame anywhere
near the working area; this includes any appliance
with a pilot light.
Because of the danger of highly flammable liquids,
do not use gasoline or a low flash-point solvent to
clean the element.
. Remove the element.
. Clean the element in cleaning solvent, and then dry itwith
compressed air or by shaking it.
. After cleaning, saturate a clean, lint-free towel with SE,
SF or SG class SAE30 oil and apply the oil to the element
by tapping the element outside with the towel.
. frame,
Visually inspect the element [A], sponge gasket [B],
etc.
*If any parts are damaged, replace them.
*If the gasket has peeled, secure it with adhesive.

Breather Oil Draining

. Visually inspect the reservoir [B] at the lower end of the
air cleaner drain hose [A] for any accumulation of oil.
*If there is any accumulation of oil, remove the plug [C] to
drain the oil.
A
WARNING
After draining the oil, be sure to reinstall the plug
on the end of the hose. Oil on tires will make them
slippery and can cause an accident and injury.
Air Cleaner Housing Removal
. Remove:
Seat (see Frame chapter)
Fuel Tank (see Fuel Tank Removal)
Carburetor (see Carburetor Removal)
Engine Breather Hose [A]
Atmospheric Temperature Sensor Connector [B]
Drain Hose (For California Model)

. Unscrew the screw [A] and pull the rear housing [B] to the
upper.
. Pull the front housing [C] to the front.

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 2-24 FUEL SYSTEM
Air Cleaner

Air Cleaner Housing Installation

. Put the stoppers [A] of the rear hosing onto the groove [8]
of the front housing.

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 FUEL SYSTEM 2-25
Fuel Tank
Fuel Tank Removal
A WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
key to OFF. Do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
. Remove:
Seat (see Frame chapter)
. Remove
screw [B]
the Side Cover Screws [A]and the seat cover

Olnset the thick cloths [C]between the frame and side cov-
ers.
. Remove the Fuel Tank Mounting Bolts [0]
. Turn the fuel tap [A]to the ON or RES position, and dis-
connect the fuel hose [B]and the vacuum hose [C].

.. Disconnect the fuel level sensor wire connector [A].

Disconnect the overflow drain hose [B],air vent hose [0]
and remove the tank [C].

Fuel Tank Installation

. Read the WARNINGmentioned in Fuel Tank Removal.
. Route the hoses and wires properly (see General Infor-
mation chapter).
..Be sure the hoses are clamped securely to prevent leaks.
Check the rubber dampers [A].
* Ifany damper is damaged or deteriorated, replaceit.

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 2-26 FUEL SYSTEM
Fuel Tank
Fuel Tank Inspection
. Remove the hose(s) from the fuel tank, and open the tank
cap.
. Check to see if the water drain pipe [B] (also the breather
pipe [C] for the California model) in the tank is not clogged.
Check the tank cap breather also.
*If they are clogged, remove the tank and drain it, and then
blow the pipes free with compressed air.
CAUTION
Do not apply compressed air to the air vent holes
[A] in the tank cap. This could cause damage and
clogging of the labyrinth in the cap.
Fuel Tank Cleaning
A. WARNING
Clean the tank in a well-ventilated area, and take
care that there are no sparks or flame anywhere
near the working area; this includes any appliance
with a pilot light. Because of the danger of highly
flammable liquids, do not use gasoline or low flash
-point solvents to the clean the tank.
. Remove the fuel tank and drain the gasoline into an ap-
. propriate container.
Pour some cleaning solvent into the fuel tank and shake
the tank to remove dirt and fuel deposits together with the
solvent.
. Remove the fuel tap and clean the filter screen in cleaning
solvent.
.. Pour cleaning solvent through the tap in all lever positions.
Dry the tank and the fuel tap with compressed air.
.Install the tap on the tank and install the tank in the frame.

.Fuel Tap Removal

Remove the fuel tank and drain the fuel into an appropri-
ate container.
. Remove:
Bolts [A]
Nylon Flat Washers [B]
Fuel Tap [C]

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 FUEL SYSTEM 2-27
Fuel Tank

.Fuel Tap Installation

Be sure the a-ring [A] is in good condition to prevent
leaks.
. Beto prevent
sure the nylon flat washers [B] are in good condition
leaks.
000 not use steel washers in place of the nylon flat wash-
ers, because they will not seal the bolts properly and fuel
will leak.
. Be sure to clamp the fuel and vacuum hoses to the tap to
prevent leaks.
i "'"'' " , ,
-
Torque Fuel Tap Mounting Bolts: 2.5 N.m (0.25 kgf.m, 22
in.lb)

..Fuel Tap Inspection

Remove the fuel tap.
Visually inspect the filter screen [A].
* If the filter has any breaks or is deteriorated, replace the
fuel tap.
*If fuel leaks from the fuel tap, or if fuel leaks from the ON
or RES position of the tap when the engine is stopped,
replace the gasket [B] or the a-ring [C] inside the tap that
could be damaged. GC070402S1C
Torque- FuelTap Plate Screws: 0.8 N.m (0.08 kgf.m, 7 in.lb)
Fuel Tap Mounting Bolts: 2.5 N.m (0.25 kgf.m, 22
in.lb)

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 2-28 FUEL SYSTEM
Evaporative Emission Control System (California and Taiwan Model)
The Evaporative Emission Control System routes fuel va-
pors from the fuel system into the running engine or stores
the vapors in a canister when the engine is stopped. Al-
though no adjustments are required, a thorough visual in-
spection must be made at the intervals specified by the Pe-
riodic Maintenance Chart.

Parts Removal/Installation
A WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
key to OFF. Do not smoke. Make sure the area is
well ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.

CAUTION
If gasoline, solvent, water or any other liquid enters
the canister, the canister's vapor absorbing capac-
ity is greatly reduced. If the canister does become
contaminated replace it with a new one.
. Tocanister,
prevent the gasoline from flowing into or out of the
hold the separator perpendicular to the ground.
. Connect the hoses according to the diagram of the sys-
tem. Make sure they do not get pinched or kinked.
. Route hoses with a minimum of bending so that the air or
vapor will not be obstructed.
. Be sure to plug the return hose to prevent fuel spilling
before fuel tank removal.
A WARNING
When removing the fuel tank, be careful not to spill
the gasoline through the return hose. Spilled fuel is
hazardous.
* If liquidgasolineflows intothe breatherhose, removethe
hose and blow it cleanwith compressedair.
Inspection
..Hose
Check that the hoses are securely connected.
Replace any kinked, deteriorated or damaged hoses.
Separator Inspection
. Remove the right side cover (see Frame chapter)
. Disconnect the hoses from the liquid/vapor separator, and
remove the separator from the motorcycle.
. Visually inspect the separator [A] for cracks and other
damage.
* If the separator has any cracks or is badly damaged, re-
place it with a new one.

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 FUEL SYSTEM 2-29
Evaporative Emission Control System (California and Taiwan Model)
Separator Operation Test
A WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is
well ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
. Connect the hoses to the separator, and install the sepa-
rator on the motorcycle.
. ject
Disconnect the breather hose from the separator, and in-
about 20 mL of gasoline [A] into the separator [8]
through the hose fitting.
.. Disconnect the fuel return hose [C]from the fuel tank [0].
Place the open end of the return hose into the container

.* and hold it with the same level of the tank top [E].
Start the engine, and let it idle.
If the gasoline in the separator comes of the hose, the
separator works well. Ifitdoes not, replace the separator GC130101S2 C

with a new one.

Canister Inspection
. Remove the seat (see Frame chapter).
. Remove the canister [A],and disconnect the hoses from
the canister.
. Visuallyinspect the canister for cracks and other damage.
* Ifthe canister has any cracks or bad damage, replace it
with a new one.
NOTE
o The canister is deigned to work well through the motor-
cycle's life without any maintenance if it is used under
normal conditions.

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 2-30 FUEL SYSTEM
EvaporativeEmission Control System (California and Taiwan Model)

GC130401W3 C

1. Clamp 11. Purge Hose (Green)

2. Clamps 12. Fitting
3. Breather Hose (Yellow) 13. Drain Hose
4. Clamps 14. Drain Tank
5. Breather Hose (Blue) 15. Plug
6. Fuel Return Hose (Red) 16. Canister
7. Breather Hose (Blue)
17. Breather Hose (Yellow)
8. LiquidNapor Separator 18. Band
9. Vacuum Hose (White) 19. To Air Cleaner Housing
10. Band

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 ENGINE TOP END 3-1

Engine Top End

Table of Contents
Exploded View................................... 3-2 Valves . 3-22
Specifications . 3-6 Valve Clearance Inspection : 3-22
Clean AirSystem ....... 3-9 Valve Clearance Adjustment........ 3-23
AirSuction Valve Removal........... 3-9 Valve Removal............................. 3-24
AirSuction Valve Installation........ 3-9 Valve Installation.......................... 3-25
AirSuction Valve Inspection ........ 3-9 Valve Guide Removal.................. 3-25
Vacuum Switch Valve Removal... 3-10 Valve Guide Installation ............... 3-25
Vacuum Switch Valve Installation 3-10 Valve-to-Guide Clearance
Vacuum Switch ValveTest ........... 3-10 Measurement (Wobble
Clean AirSystem Hose Inspection Method)..................................... 3-26
.................................................. 3-11 Valve Seat Inspection .................. 3-27
Cylinder Head Cover ......................... 3-12 Valve Seat Repair ........................ 3-27
Cylinder Head Cover Removal.... 3-12 Cylinders and Pistons........................ 3-32
Cylinder Head Cover Installation. 3-12 Cylinder RemovaL....................... 3-32
Camshaft Chain Tensioner ................ 3-13 Piston Removal............................ 3-32
Camshaft Chain Tensioner Cylinder and Piston Installation.... 3-32
Removal .................. 3-13 Cylinder Wear.............................. 3-34
Camshaft Chain Tensioner Piston Wear................................. 3-35
Installation... .......... 3-13 Piston/Cylinder Clearance ........... 3-35
Camshaft, Camshaft Chain ............... 3-14 Piston Ring/Ring Groove
Camshaft Removal...................... 3-14 Clearance . 3-35
Camshaft Installation................... 3-14 Piston Ring Groove Wear ............ 3-36
Camshaft Assembly..................... 3-16 Piston Ring Thickness ................. 3-36
Camshaft, Camshaft Cap Wear... 3-17 Piston Ring End Gap
Camshaft Runout ......................... 3-17 Measurement . 3-37
Cam Wear.................................... 3-17 Carburetor Holder.............................. 3-38
Camshaft Chain Removal............ 3-18 Carburetor Holder Installation...... 3-38
Camshaft Chain WeaL................. 3-18 Muffler.... .. ...... ... ..... .... ...... ..... 3-39
Cylinder Head.................................... 3-19 Muffler Removal........................... 3-39
Cylinder Head Compression Muffler Installation........................ 3-39
Measurement . 3-19 Muffler Body Removal.................. 3-39
Cylinder Head Removal............... 3-20 Muffler Body Installation............... 3-40
Cylinder Head Installation............ 3-20 Exhaust Pipe RemovaL............... 3-40
Cylinder Head Warp..................... 3-21 Exhaust Pipe Installation.............. 3-40

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 3-2 ENGINE TOP END
Exploded View

GE02040SWS C

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 ENGINE TOP END 3-3
Exploded View
1. Arrow faces forward.
2. "HEAD" mark faces up.
3. Muffler Connecting Nuts
4. Exhaust Holder Nuts
T1: 12 N.m (1.2 kgf.m, 104 in.lb)
T2: 14 N.m (1.4 kgf.m, 10 ft.lb)
T3: 29 N.m (3.0 kgf.m, 22 ft.lb)
T4: 39 N.m (4.0 kgf.m, 29 ft.lb)
T5: 34 N.m (3.5 kgf.m, 25 ft.lb)
L: Apply non-permanent locking agent to the threads.
MO: Apply molybdenum disulfide oil.
The molybdenum disulfide oil is a mixture of engine oil and molybdenum disulfide grease with
a weight ratio (10:1).
0: Apply engine oil.
S: Follow the specific tightening sequence.
SS: Apply silicon sealant (Kawasaki Bond: 56019-120) along the entire circumference of the seal.

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 3-4 ENGINE TOP END
Exploded View

~o

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 ENGINE TOP END 3-5
Exploded View
1. Arrow faces forward.
2. Closed coil end faces down.
3. "R" mark faces up.
4. "RN" mark faces up.
5. "UP" mark faces up.
6. Arrow faces left side.
7. Muffler Mounting Bolt
T1: 11 N.m (1.1 kgf.m, 97 in.lb)
T2: 5.2 N.m (0.5 kgf.m, 46 in.lb)
T3: 15 N.m (1.5 kgf.m, 11 ft.lb)
T4: 25 N.m (2.5 kgf.m, 18 ft.lb)
AD: Apply adhesive.
L: Apply non-permanent locking agent.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil.
The molybdenum disulfide oil is a mixture of engine oil and molybdenum disulfide grease with
a weight ratio (10:1).
0: Apply engine oil.
R: Replacement Parts.

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 3-6 ENGINE TOP END
Specifications
Item Standard Service Limit
Clean Air System
Vacuum Switch Valve Closing 57 - 65 kPa (430 - 490 mmHg, -
Pressure (Open Close) 8.3 - 9.4 psi)
Camshaft, Camshaft Chain
Cam Height 36.245 - 36.353 mm 36.15 mm
(1.4270 - 1.4312 in.) (1.423 in.)
Camshaft/Cap Oil Clearance 0.100 - 0.141 mm 0.23 mm
(0.0039 - 0.0056 in.) (0.009 in.)
Camshaft Journal Diameter 21.94 - 21.96 mm 21.91 mm
(0.8638 - 0.8646 in.) (0.8626 in.)
Camshaft Bearing Inside Diameter 22.060 - 22.081 mm 22.14 mm
(0.8685 - 0.8693 in.) (0.872 in.)
Camshaft Runout - 0.1 mm
(0.004 in.)
Camshaft Chain 20-link Length 127.00 - 127.36 mm 128.9 mm
(5.000 - 5.014 in.) (5.07 in.)
Cylinder Head (Usable range)
Cylinder Compression 755 - 1177 kPa ,
(7.7 - 12.0 kgf/cm2109 - 170 psi) -
@385r/min(rpm)
Cylinder Head Warp - 0.05 mm
(0.002 in.)
Valves
Valve Clearance (When Cold) 0.08 - 0.18 mm -
(0.0031 - 0.0071 in.)
Valve Head Thickness:
Inlet 0.8 - 1.2 mm 0.5 mm
(0.031 - 0.047 in.) (0.020 in.)
Exhaust 0.8 - 1.2 mm 0.7 mm
(0.031 - 0.047 in.) (0.028 in.)
Valve Stem Bend Not more than 0.01 mm TIR 0.05 mm
(0.0004 in.) (0.0020 in.) TIR

Valve Stem Diameter

6.965 - 6.980 mm (0.2742 - 6.95 mm
Inlet
0.2748 in.) (0.2732 in.)
Exhaust 6.955 - 6.970 mm (0.2738 - 6.94 mm
0.2744 in.) (0.2732 in.)
Valve Guide Inside Diameter 7.000 - 7.015 mm 7.08 mm
(0.2756 - 0.2762 in.) (0.2787 in.)
ValveNalve Guide Clearance
(Wobble Method):
Inlet 0.07 - 0.15 mm 0.30 mm
(0.0028 - 0.0059 in.) (0.0118 in.)

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 ENGINE TOP END 3-7
Specifications

Item Standard Service Limit

Exhaust 0.06 - 0.14 mm 0.28 mm
(0.0024 - 0.0055 in.) (0.0110 in.)
Valve Seating Surface Outside
Diameter:
Inlet 32.9 - 33.1 mm -
(1.295 - 1.303 in.)
Exhaust 28.9 - 29.1 mm -
(1.138 - 1.146 in.)
0.5 - 1.0 mm -
Valve Seating Surface Width
(0.020 - 0.039 in.)
Valve Seat Cutting Angle 45°, 32°, 60° -
Valve Spring Free Length:
Inner 37.25 mm (1.467 in.) 35.9 mm
(1.413 in.)
Outer 41.85 mm (1.648 in.) 40.3 mm
(1.587 in.)
Cylinder, Piston
Cylinder Inside Diameter 66.005 - 66.017 mm 66.10 mm
(2.5986 - 2.5991 in.) (2.602 in.)
Piston Diameter 65.951 - 65.966 mm 65.81 mm
(2.5965 - 2.5971 in.) (2.591 in.)
Piston/Cylinder Clearance 0.040 - 0.067 mm -
(0.0016 - 0.0026 in.)
Oversize Pistons And Rings + 0.5 mm (0.020 in.) and -
+ 1.0 mm (0.039 in.)
Piston Ring/Groove Clearance:
Top 0.050 - 0.080 mm 0.18 mm
(0.0020 - 0.0031 in.) (0.0071 in.)
Second 0.030 - 0.070 mm 0.17 mm
(0.0012 - 0.0028 in.) (0.0067 in.)
Piston Ring Groove Width:
Top 1.03 - 1.05 mm 1.13 mm
(0.0406 - 0.0413 in.) (0.0445 in.)
Second 1.22 - 1.24 mm 1.32 mm
(0.0480 - 0.0488 in.) (0.0520 in.)
Oil 2.01 - 2.03 mm 2.11 mm
(0.0791 - 0.0799 in.) (0.0831 in.)
Piston Ring Thickness:
Top 0.970 - 0.985 mm 0.90 mm
(0.0382 - 0.0390 in.) (0.0354 in.)
Second 1.17 - 1.19 mm 1.10 mm
(0.0461 - 0.0469 in.) (0.0433 in.)

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 3-8 ENGINE TOP END
Specifications
Item Standard Service Limit
Piston Ring End Gap:
Top 0.15 - 0.30 mm 0.6 mm
(0.0059 - 0.018 in.) (0.0236 in.)
Second 0.30 - 0.45 mm 0.75 mm
(0.0118 - 0.0177 in.) (0.0295 in.)
Oil 0.20 -0.70 mm 1.0 mm
(0.0079 - 0.0276 in.) (0.0394 in.)
-
Special Tools Valve Guide Reamer, </17:57001-162
Valve Guide Arbor, </17:57001-163
Compression Gauge, 20 kgf/cm2: 57001-221
Valve Spring Compressor Set: 57001-241
Valve Spring Compressor Adapter: 57001-243
Piston Pin Puller Set: 57001-910
Compression Gauge Adapter: 57001-1018
Spark Plug Wrench: 57001-1024
Piston Ring Compressor Grip: 57001-1095
-
Piston Ring Compressor Belt, </150 </167:57001-1096
-
Valve Seat Cutter, 450 </132:57001-1115
-
Valve Seat Cutter, 450 </135:57001-1116
-
Valve Seat Cutter, 320 </135:57001-1121
-
Valve Seat Cutter, 600 </130:57001-1123
-
Valve Seat Cutter, 600 </141:57001-1124
Valve Seat Cutter Holder, </17:57001-1126
Valve Seat Cutter Holder Bar: 57001-1128
Piston Base, </12.3:57001-1336
Sealant - Kawasaki Bond (Silicon Sealant): 56019-120

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 ENGINE TOP END 3-9
Clean Air System
Air Suction Valve Removal
. Remove:
Seat (see Frame chapter)
Fuel Tank (see Fuel System chapter)
..Unscrew the valve cover bolts [A].
Open the cover [8] with the hose.

. Take out the air suction valve [A].

OPull the projection [8] straight out with the pliers.

Air Suction Valve Installation

.Install the air suction valve so that the projection [A] faces
upwards.
. Tighten:
Torque - Air Suction ValveCover Bolts: 12 N.m(1.2 kgf.m,
104 in.lb)

Air Suction Valve Inspection

The air suction valve is essentially a check valve which
allows fresh air to flow from the air cleaner into the exhaust
port. Any air that has passed the air suction valve is pre-

.
vented from returning to the air cleaner.
Remove the air suction valves.
. Visually inspect the reeds [A] for cracks, folds, warps,
head damage, or other damage.
* If there is any doubt as to the condition of the reed, replace
the air suction valve as an assembly.
. Check the reed contact areas [8] of the valve holder for
grooves, scratches, any signs of separation from the
holder, or head damage.
* If there is any doubt as to the condition of the reed contact
areas, replace the air suction valve as an assembly.
* If any carbon or other foreign particles have accumulated
between the reed and the reed contact area, wash the
valve assembly clean with a high flash-point solvent.
CAUTION
Do not scrape off the deposits with a scraper as this
could damage the rubber, requiring replacement of
the suction valve assembly.

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 3-10 ENGINE TOP END
Clean Air System
VacuumSwitch ValveRemoval
. Remove:
Seat (see Frame chapter)
Fuel Tank (see Fuel System chapter)
. Pull off the hoses [A] from the air suction valve cover, air
cleaner, and carburetor vacuum hose joint.
. Take off the vacuum switch valve [B] with the hoses.

Vacuum Switch Valve Installation

.Install the vacuum switch valve so that the air hole [A]
faces downwards.
. Route the hoses correctly (see the General Information
chapter) .

GE040704S1

Vacuum Switch Valve Test

. Remove the vacuum switch valve.
. Connect the vacuum gauge [A] and syringe [B] to the vac-
uum hoses as shown.
Air Flow [C]
~o

. Gradually raise the vacuum (lower the pressure) applied

to the vacuum switch valve, and check the valve opera-
tion. When the vacuum is low, the vacuum switch valve
should permit air to flow. When the vacuum rises to 57
- 65 kPa (430 - 490 mmHg, 8.3 - 9.4 psi), it should stop
air flow. When the vacuum is high enough, the air cannot
flow th rough the valve.
Spring [A]
Diaphragm [B]
Valve [C]
Low Vacuum [0]
Secondary Air Flow [E]
* If the vacuum switch valve does not operate as described,
replace it with a new one.
NOTE
o To check air flow through the vacuum switch valve, just
blow through the air cleaner hose.
Vacuum Switch Valve Closing Pressure (Open ---+Close)
Standard: - -
57 65 kPa (430 490 mmHg,8.3- 9.4 psi)
GE040 1065 1 C

High Vacuum [A]

Secondary air cannot flow [B]

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 ENGINE TOP END 3-11
Clean Air System

.Clean Air System Hose Inspection

Be certainthat all the hoses are routed without being flat-
tened or kinked, and are connected correctly to the air
cleaner housing, vacuum switch valve, carburetors, and
air suction valve covers.
Olf they are not, correct them. Replace them if they are
damaged:

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 3-12 ENGINE TOP END
Cylinder Head Cover

.CylinderHead CoverRemoval
Remove:
Seat (see Frame chapter)
Fuel Tank (see Fuel System chapter)
Ignition Coil (see Electrical System chapter)
. Remove the cover bolts [A] and remove the cover [8].

.Cylinder Head Cover Installation

Replace the rubber plug [A] with a new one.
. Apply sealant to the entire sealing surface [8] of the rub-
ber plug.
Upper Side [C]
Sealant - Kawasaki Bond (Silicon Sealant): 56019-120

GE090401S1 C

. Replace the cylinder head cover gasket with a new one.

.Install the cylinder head cover with the arrow [A] pointing
forward.
. Tighten:
Torque - Cylinder Head Cover Bolts: 12 N.m (1.2 kgf.m, 104
in.lb)
. Start the engine and warm it up thoroughly. Allow the
engine to cool down and tighten the head cover bolts.

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 ENGINE TOP END 3-13
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal
CAUTION
This is a non-return type camshaft chain tensioner.
The push rod does not return to its original position
once it moves out to take up camshaft chain slack.
Observe all the rules listed below:
When removing the tensioner, do not take out the
mounting bolts only halfway. Retightening the
mounting bolts from this position could damage
the camshaft chain and the tensioner.
Once the bolts are loosened, the tensioner must
be removed and reset as described in "Camshaft
Chain Tensioner Installation".
Do not turn over the crankshaft while the tensioner
is removed. This could upset the cam chain timing
and damage the valves.
.. Loosen the Cap bolt [A].
Remove the mounting bolts [8] and pullout the chain ten-
sioner.
Camshaft Chain Tensioner Installation
. Remove the cap bolt and the O-ring.
. Turn the push rod [A]clockwise [C] (toward the direction
indicated with an arrow mark) with a screwdriver [8] tillit
stops, pushing it.
CAUTION
The tensioner will not be available because of dis-
engagement if turning counter clockwise. GE100102S1 C

. While holding the rod in position with a holder plate [A],

install the tensioner on the cylinder block.
Unit:mm
4
NOTE
co
o Tomake the procedure easjl, use a holder plate to keep
Lt)
the rod from pushing out. A replacement chain ten-
sioner (spare parts) has a holder plate.
. The holder plate can be made of 1 mm thick aluminum
plate as shown.
9.5
GE100103S1 C

.Install the O-ring in the tensioner body and cap bolt.

.Install the tensioner so that the arrow mark [A]faces left
side of the engine tighten the mounting bolts [8].
Torque - Chain Tensioner Mounting Bolts: 11 N.m (1.1
kgf.m, 97 in.lb)
. Remove the screwdriver (or the holder plate) and tighten
the cap [C].
Torque - Chain Tensioner Cap: 5.2 N.m (0.50 kgf.m, 46
in.lb)

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 3-14 ENGINE TOP END
Camshaft, Camshaft Chain

Camshaft Removal
. Remove:
Seat (see Frame chapter)
Fuel Tank (see Fuel System chapter)
Cylinder Head Cover (see Cylinder Head Cover Re-
moval)
Crankshaft Sensor Cover (see Electrical System chap-
ter)

. Position the crankshaft at #1,4 piston TOC.

TOC mark for #1,4 Pistons [A]
Timing Mark [B]

. Remove:
Camshaft Chain Tensioner (see Camshaft Chain Ten-
sioner Removal)
Chain Guide Bolts [A]
Chain Guide [B]
. Fist loosen all camshaft cap bolts [C] evenly halfway, then
remove all camshaft cap bolts.
. Remove the camshafts [0] from the camshaft chain [E].
. Stuff a clean cloth into the chain tunnel to keep any parts
from dropping into the crankcase.
CAUTION

The crankshaft may be turned while the camshafts

are removed.
Always pull the chain taut while turning the crank-
shaft. This avoids kinking the chain on the lower
(crankshaft) sprocket.
A kinked chain could damage both the chain and
the sprocket.

Camshaft Installation
.Identify the exhaust camshaft [A] and the intake camshaft
[B].
OCheck the right side of the seat to which the camshaft
sprocket mounts, and the one with the protrusion [C] is
the exhaust camshaft.
.Apply molybdenum disulfide oil to the cam and journal
surfaces of the camshaft.

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 ENGINE TOP END 3-15
Camshaft, Camshaft Chain
.Install the camshafts so that the cutout [A] of each
camshaft faces the right [8].

. Turn the timing rotor [A] in the positive direction, and align
the TDC mark [8] of the #1 and #4 pistons with the timing
mark [C] on the crankcase.
CAUTION
Always pull up the chain taut while turning the
crankshaft.

. Place the chain on the sprockets.

NOTE
OAlways pull up the chain taut on the tension (exhaust)
side.
OPlace the chain [0] by aligning the timing mark "Z7EX"
[B] of the exhaust sprocket [A] with the top [C] of the
cylinder head.
OPlace the chain by aligning the timing mark "IN"[F]of
the intake sprocket [E] with the top [C] of the cylinder GEI1040751 C

head, which accommodates 45 pins between the ex-

haust and intake timing marks.
.Install the camshaft caps.
I CAUTION
The camshaft caps are machined with the cylinder
head, and the camshaft may seize if the caps are
installed in a wrong position.
OMatch the position numbers on the caps with the numbers
on the cylinder head, and install the caps with their arrows
facing forward.

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 3-16 ENGINE TOP END
Camshaft, Camshaft Chain
.Tighten the camshaft cap bolts following the sequence
number.
OFor both the intake and exhaust camshafts, uniformly
tighten the bolts a little at a time.
Exhaust Side [A]
Inlet Side [8]

OAfter the camshaft has settled, tighten all the bolts in the
specified sequence.
Exhaust Side [A]
Inlet Side [8]
Torque -Camshaft Cap Bolts: 12 N.m(1.2 kgf.m, 104 in.lb)
.Install the chain guide
Torque - Camshaft Chain Guide Bolts: 11 N.m (1.1 kgf.m,
95 in.lb)
. Install:
Camshaft Chain Tensioner (see Camshaft Chain Ten-
sioner Installation)
Cylinder Head Cover (see Cylinder Head Cover Instal-
lation)

Camshaft Assembly
. Install the sprockets on the camshafts.
NOTE
Olnstall the sprockets by using the mounting holes fA]
provided for the intake camshaft, and the mounting
holes fB] provided for the exhaust camshaft, respec-
tively. There is a protrusion on the rightside of the seat
of the exhaust camshaft to which the sprocket mounts.

. Apply non-permanent locking agent to the camshaft

sprocket bolts and tighten them.
-
Torque Camshaft Sprocket Bolts: 15 N.m (1.5 kgf.m, 11
in.lb)

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 ENGINE TOP END 3-17
Camshaft, Camshaft Chain
Camshaft, Camshaft Cap Wear
. Cut strips of plastigage to journal width. Place a strip
on each journal parallel to the camshaft installed in the
correct position.
. Measure each clearance between the camshaft journal
and the camshaft cap using plastigage (press gauge) [A].
. Tighten:
-
Torque Camshaft Cap Bolts: 12 N.m (1.2 kgf.m, 104 in.lb)
Camshaft Chain Guide Bolts: 11 N.m (1.1 kgf.m,
95 in.lb)
NOTE
o Do not turn the camshaft when the plastigage is be-
tween the journal and camshaft cap.

Camshaft Journal, Camshaft Cap Clearance

Standard: 0.100 - 0.141 mm (0.0039 - 0.0056 in.)
Service Limit: 0.23 mm (0.009 in.)

*If any clearance exceeds the service limit, measure the

diameter of each camshaft journal with a micrometer.
Camshaft Journal Diameter
Standard: 21.94 - 21.96 mm (0.8638 - 0.8646 in.)
Service Limit: 21.91 mm (0.8626 in.)
*If the camshaft journal diameter is less than the service
limit, replace the camshaft with a new one and measure
the clearance again.
* If the clearance still remains out of the limit, replace the
cylinder head unit.

Camshaft Runout
. Remove the camshaft.
. Set the camshaft in a camshaft alignment jig or on V
blocks.
. Measure
as shown.
runout with a dial gauge at the specified place

*If the runout exceeds the service limit, replace the shaft.
Camshaft Runout
Service Limit: TIR 0.1 mm (0.004 in.) GE030402S 1 C

.Cam Wear
Remove the camshaft.
. Measure the height [A] of each cam with a micrometer.
* If the cams are worn down past the service limit, replace
the camshaft.

Cam Height
Standard: Service Limit
Exhaust, 36.245 - 36.353 mm 36.15 mm
GE110122S1 C
Inlet (1.4270 - 1.4312 in.) (1.423 in.)

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 3-18 ENGINE TOP END
Camshaft, Camshaft Chain
Camshaft Chain Removal
. Split the crankcase(see CrankshaftfTransmission
chap-
ter).
.. Remove the crankshaft [A] from upper crankcase.
Remove the camshaft chain [8] from the crankshaft
sprocket.

Camshaft Chain Wear

. Hold the chain taut with a force [A] of about 49 N (5 kg, 20-1 ink Length
(21 Pins)
11 Ib) in some manner, and measure a 20-link length.
Since the chain may wear unevenly, take measurement
at several places.
*If any measurement exceeds the service limit, replace the
chain. Also, replace the camshafts and the crankshaft
when the chain is replaced.
1st Pin
Camshaft Chain 20-link Length GE11012551 C

Standard: 127.00 -127.36 mm (5.000 - 5.014 in.)

Service Limit: 128.9 mm (5.07 in.)

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 ENGINE TOP END 3-19
Cylinder Head
Cylinder Head Compression Measurement
. Start the engine and warm it up thoroughly.
. Stop the engine and remove all the spark plugs.
Special Tool - Spark Plug Wrench: 57001-1024
. Measure the compression of a cylinder.
OWith the throttle fully open, use the starter motor to turn
the engine over, and read the highest reading on the com-
pression gauge.
-
Special Tools Compression Gauge, 20 kgf/cm2: 57001-221
[A]
Compression Gauge Adapter: 57001-1018
[B]
NOTE
o Use a battery that is fully charged.
o Make sure that there are no compression leaks from the
cylinder head gasket.

Cylinder Compression
Usable Range:
755 - 1 177 kPa (7.7 - 12.0 kgf/cm2,
109 - 170 psi) @385 r/min (rpm)
. the
Measure the compression of the remaining cylinders in
same manner.

The following table should be consulted if the obtainable compression reading is not within the us-
able range.
Problem Diagnosis Remedy (Action)
Carbon accumulation on piston and in Remove the carbon deposits
combustion chamber possibly due to and replace damaged parts if
damaged valve stem oil seal and/or necessary.
Cylinder damaged piston oil rings (This may be
compression is indicated by white exhaust smoke).
higher than usable
range
Incorrect cylinder head gasket thickness. Replace the gasket with a
standard part.

Gas leakage around cylinder head Replace damaged gasket and

check cylinder head warp.

Bad condition of valve seating Repair if necessary.

Cylinder Incorrect valve clearance. Adjust the valve clearance.
compression is Incorrect piston/cylinder clearance
lower than usable Replace the piston and/or cylinder
range Piston seizure. Inspect the cylinder and
replace/repair the cylinder
and/or piston as necessary.

Bad condition of piston ring and/or piston Replace the piston and/or the
ring grooves piston rings.

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 3-20 ENGINE TOP END
Cylinder Head

Cylinder Head Removal

. Remove:
Seat (see Frame chapter)
Side Covers (see Frame chapter)
Fuel Tank (see Fuel System chapter)
Carburetors (see Fuel System chapter)
Camshaft Chain Tensioner (see Camshaft Chain Ten-
sioner Removal)
Cylinder Head Cover (see Cylinder Head Cover Re-
moval)
Camshaft (see Camshaft Removal)
Exhaust Pipe and Muffler (see this chapter)
. Remove the cylinder head bolts [1 - 2] in the numbered
sequence.
. Remove the cylinder head nuts [3 - 14]in the numbered
sequence.
Exhaust Side [A]
Inlet Side [8]
. Remove the cylinder head [A].
NOTE
o Tap lightly
with a rubber mallet fB] if the cylinder head
does not separate easily.

Cylinder Head Installation

.Install the front camshaft chain guide [A].
OAlign the upper shoulder of the chain guide with the top
[8] of the cylinder.

.Install the O-rings [8] on the cylinder [A], and install the
orifices [C].

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 ENGINE TOP END 3-21
Cylinder Head
8 Install the gasket with its "HEAD" mark [A] facing up.

8 Tighten the cylinder head nuts following the tightening se-

quence [1 - 12].
Exhaust Side [A]
Inlet Side [B]
Torque -Cylinder Head Nuts: 39 N.m (4.0 kgf.m, 29 ft.lb)
First: 23 N.m (2.3 kgf.m, 16.5 ft.lb)
Final: 39 N.m (4.0 kgf.m, 29 ft.lb)
OAfter tightening all head nut, retighten them.
OTighten the cylinder head bolts [13 -14].
Torque- Cylinder Head Bolts: 29 N.m (3.0 kgf.m, 22 ft.lb)

Cylinder Head Warp

8 Clean the cylinder head (see Cylinder Head Cleaning).
8 Lay a straightedge across the lower surface of the cylinder
head at several positions.
8 Use a thickness gauge [A] to measure the space between
the straightedge [B] and the head.
Cylinder Head Warp
Standard:
Service Limit: 0.05 mm (0.002 in.)
*If the cylinder head is warped more than the service limit,
replace it.
*If the cylinder head is warped less than the service limit,
repair the head by rubbing the lower surface on emery
paper secured to a surface plate (first No. 200, then No.
400).

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 3-22 ENGINE TOP END
Valves

Valve Clearance Inspection

NOTE
o valve clearance must be checked and adjusted when
the engine is cold.
. Remove:
Cylinder Head Cover (see Electrical System chapter)
Crankshaft Sensor Cover (see Cylinder Head Cover Re-
moval)
. Using a thickness gauge, measure the clearances be-
tween each cam and valve lifter.
Valve Clearance
Standard: 0.08 - 0.18 mm (0.0031 - 0.0071 in.)

OTurn the timing rotor in the positive direction, and align

the TOC mark [A] of the #1 and #4 pistons with the timing
mark [8] on the crankcase.

NOTE
o Bring the #4 piston to the TOGof its compression stroke
to inspect the clearance of the intake valves of the #2
[A]and #4 [B]cylinders, and the exhaust valves of the
#3 [G]and #4 [0] cylinders. Forthe purpose of adjusting
the valve clearances, record the measured values.

GE150434S1 C

NOTE
OBring the #1 piston to the TOGof its compression stroke
to inspect the clearance of the intake valves of the #1
[A]and #3 [B]cylinders, and the exhaust valves of the
#1 [G]and #2 [0] cylinders. Forthe purpose of adjusting
the valve clearances,recordthe measured values.
*clearance.
If any measurement is out of standard, adjust the valve

GE150435S1 C

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 ENGINE TOP END 3-23
Valves

.Valve Clearance Adjustment

Remove the camshaft [A].
.. Remove the valve lifter [B] of the applicable valve.
Remove the shim [C] from the top of the spring retainer.
NOTE
OMark and record the valve lifter and shim locations so
they can be reinstalled in their original positions.
. Measure the thickness of the removed shim.
. Select an appropriate shim from the Valve Clearance Ad- GE15051BS1 C

justment Chart and replace it with the removed shim.

NOTE
o If there is no valve clearance, use a shim that is a few
sizes smaller, and remeasure the valve clearance.
o The shim must be installed with its thickness indication
[A] facing the retainer. At this time, apply grease to the
shim or to the retainer to prevent the shim from falling
off during the operation.
.Install the camshafts. Be sure to time the camshafts prop-
erly (see Camshaft Installation)
. 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 high rpm, causing exten-
sive engine damage.
Do not grind the shim. This may cause it to fracture,
causing extensive engine damage.

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 3-24 ENGINE TOP END
Valves
VALVECLEARANCEADJUSTMENTCHART

0.00 - 0.03 - - 2.00 2.00 I 2.35 I 2.40 I 2.45 I 2.50

--
2.05 2.10 2.15 2.20 2.25 2.30 2.55 2.60 2.65 2.70 2.75 2.80 2.85 290 I 2.95 I 3.00 I 305
0.04 007 - 200 200 205 210 2.15 2.20 2.25 2.30 2.35 I2 40 I 2.45 I 2.50 I 2.55 260 265 270 275 2.80 285 2.90 295 I 300 I 305 I 3 10
0.08 0.18
0.19 - 0.22 2.05 2.10 2.15 2.20 2.25
SPECIFIED VALVE CLEARANCE / NO CHANGE REQUIRED

0.23 - 0.27 2.10 2.15 2.20 2.25 2.30

2.30
2.35
2.35
2.40
2.40
2.45
2.45
2.50
2.50 255
2.55
2.60
2.60
2.65 2.70 2.75
2.65
2.80
2.70
2.85 2.90
2.75 2.80 2.85 2.90 2.95
2.95
3.00
3.00
3.05
305
310
3.10
3.15
I 3.15 I 3.20 I
I 3.20 I
.--. 0.28- 0.32 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 295 3.00 3.05 3.10 315 3.20 I
0.33- 0.37 2.20 2.25 230 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 275 2.80 2.85 2.90 295 3.00 3.05 3.10 3.15 3.20
'-"
I- 0.38- 042 225 230 235 2.40 245 250 255 2.60 265 270 275 2.80 285 2.90 2.95 300 305 3.10 3.15 320
Z 0.43- 0.47
UJ
UJ 0.48
a:: 0.53
-- 0.52
0.52
2.30
2.35
2.40
2.35
2.40
2.40
2.45
2.45
2.50
2.50
2.55
2.55
2.60
2.60
2.65
2.65
2.70
2.70
2.75
2.75
2.80
2.80
2.85
2.85
2.90
2.90
2.95
2.95
3.00
3.00
3.05
305
3.10
310
315
3.15
3.20
3.20

:::> 0.58 - 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 285 2.90 2.95 3.00 305 3.10 3.15 3.20
(j)
UJ 0.63 -- 0.62
0.72
2.45
2.50
2.50
2.55
2.55
2.60
2.60
2.65
2.65
2.70
2.70
2.75
2.75
2.80
2.80
2.85
2.85
2.90
2.90
2.95
2.95
3.00
3.00
3.05
3.05
3.10
3.10
3.15
3.15
3.20
3.20

<.)
Z
0.68
UJ 0.73 -
o78- 082
0.72
0.77
2.55
2.60
2.65
2.60
2.65
2.70
2.65
270
275
2.70
2.75
2.80
2.75
2.80
2.85
2.80
2.85
2.90
2.85
2.90
2.95
2.90
2.95
300
2.95
3.00
305
3.00
305
310
3.05
3.10
3.15
3.10
3.15
3.20
3.15
3.20
3.20

a:: 0.83- 0.87 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20
<(
UJ 0.88- 0.92 2.75 2.80 285 2.90 2.95 3.00 3.05 3.10 3.15 3.20
...J 0.93- 0.97 INSTALL THE SHIM OF THIS THICKNESS.

--
<.) 2.80 2.85 2.90 2.95 3.00 305 3.10 3.15 3.20
UJ 0.98 1.02 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20
>
...J 1.03 1.07 2.90 2.95 300 3.05 3.10 3.15 3.20
<{ 1.08
> - 112 2.95 3.00 3.05 3.10 3.15 3.20
113-117 3.00 305 310 3.15 320
118- 1.22 305 310 315 3.20
1.23- 1.27 3.10 3.15 3.20
1.28- 1.32 3.15 3.20
1.32- 1.38 3.20

1. Measure the valve clearance (with engine cold).

2. Check present shim size.
3. Match clearance in vertical column with present shim
size in horizontal column.
4. Install the shim specified where the lines that intersect.
This shim will give the proper clearance.
Example: Present Shim is 2.50 mm Measured
clearance is 0.41 mm Replace 2.50 shim
with 2.75 mm shim.
5. Apply molybdenum disulfide oil to the valve lifter surface
and install the lifter.
6. Install the camshaft.
7. Recheck the valve clearance and adjust it if it is neces-
sary.
Valve Removal
. Remove the cylinder head (see Cylinder Head Removal).
. Remove the valve lifter and shim from the valve.
OMark and record the valve lifter and shim locations so they
can be installed in their original positions.
.Using the valve spring compressor assembly, remove the
valve.
Special Tools - Valve Spring Compressor Set: 57001-241
[A]
Valve Spring Compressor Adapter: 57001
-243 [B]

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 ENGINE TOP END 3-25
Valves
Valve Installation
..Replace the oil seal [C] with a new one.
Apply a thin coat of molybdenum disulfide grease to the
valve stem [A] before installing the valve.
. Check to make sure that the valve moves up and down
smoothly.
. Check to make sure that the valve and the valve seat are
making proper contact.
. Install the inner valve spring [E] and the outer valve spring
[0] so that their closed coil end faces the spring seat [8].
. Compress the valve springs to install the split keepers [G]
in order to secure the spring retainer [F] in place.
Special Tools - Valve Spring Compressor Set: 57001-241
Valve Spring Compressor Adapter: 57001
-243
. The shim [H] must be installed with its thickness indication
facing the retainer.
NOTE
OApply grease to the shim or to the retainer to prevent GE15043652 C
the shim from fallingoff while the camshaft is being in-
stalled.
. face;
Apply molybdenumdisulfideoil to the valve lifter [I] sur-
then install the lifter.
Valve Guide Removal
. Remove the valve.
. Remove the oil seal.
. Remove the spring seat.
. Heat the area around the valve guide to 120 - 1500 C (248
- 3020 F) and hammer lightly on the valve guide arbor to
remove the valve guide towards the top of the cylinder
head.
Special Tool- Valve Guide Arbor, </17:57001-163 [A]
CAUTION

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

warp the cylinder head. Soak the cylinder head in
oil and heat the oil.
Valve Guide Installation
.Install the valve guides, making sure to install the intake
valve guide the exhaust valve guide in their respective
positions.
Intake Valve Guide: Short [A] @

Exhaust Valve Guide: Long [8]

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 3-26 ENGINE TOP END
Valves

. Usingthe valve guidearbor,drive the valve guide in until

its snap ring comes in contact with the head surface.
NOTE
o Apply a thin coat of oil to the outer surface of the valve
guide.
OHeat the area around the valve guide to 120 - 1500 C
(248 - 3020 F).
Special Tool- Valve Guide Arbor, cp7: 57001-163

. Ream the valve guide with the valve guide reamer.

Special Tool- Valve Guide Reamer, cp7: 57001-162 [A]

Valve-to-Guide Clearance Measurement (Wobble

Method)
If a small bore gauge is not available, inspect the valve
guide wear by measuring the valve to valve guide clearance
with the wobble method as indicated below.
.Insert a new valve [A] into the guide [8] and set a dial
gauge against the stem perpendicular to it as close as
possible to the cylinder head mating surface.
Move the stem back and forth [C] to measure valve/valve
guide clearance.
ORepeat the measurement in a direction at a right angle to
the first.
*If the reading exceeds the service limit, replace the guide.
NOTE
o The reading is not actual valve/valve guide clearance
because the measuring point is above the guide.
ValveNalve Guide Clearance (Wobble Method)
Standard:
Inlet 0.07 - 0.15 mm (0.0028 - 0.0059 in.)
Exhaust 0.06 - 0.14 mm (0.0024 - 0.0055 in.)
Service Limit:
Inlet 0.30 mm (0.0118 in.)
Exhaust 0.28 mm (0.0110 in.)

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 ENGINE TOP END 3-27
Valves

Valve Seat Inspection

. Remove the valve (see Valve Removal).
. Check the valve seating surtace [A between the valve [8]
and valve seat [C].
OMeasure the diameter [D] of the seating pattern on the
valve seat.
*If the outside diameter is too large or too small, repair the
seat (see this chapter).
Valve Seating Surface Diameter
Standard: I
Intake 32.9 - 33.1 mm (1.295 - 1.303 in.)
Exhaust 28.9 - 29.1 mm (1.138 -1.146 in.)
OMeasure the seat width [E] of the portion where there is
no build-up carbon (white portion) of the valve seat with a 80
vernier caliper.
Good [E]
*If the width is too wide [G], too narrow [H] or uneven [J],
repair the seat.
08 GE150117S2 C
Valve Seat Seating Surface Width
Standard: 0.5 - 1.0 mm (0.020 - 0.039 in.)

Valve Seat Repair

. Repair the valve seat with the valve seat cutters [A].
-
Special Tools Valve Seat Cutter Holder, cjJ7: 57001-1126
[B]
Valve Seat Cutter Holder Bar: 57001-1128
[C]
Inlet Valve:
-
Valve Seat Cutter, 45° cjJ35:57001-1116
Valve Seat Cutter, 32° -cjJ35:57001-1121
Valve Seat Cutter, 60° -cjJ41: 57001-1124
Exhaust Valve:
Valve Seat Cutter, 45° -cjJ32:57001-1115
Valve Seat Cutter, 32° - cjJ35: 57001-1121
Valve Seat Cutter, 60° - cjJ30:57001-1123
*If the manufacturer's instructions are not available, use
the following procedure.

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 3-28 ENGINE TOP END
Valves

Seat Cutter Operation Care

1. This valve seat cutter is developed to grind the valve for
repair. Therefore the cutter must not be used for other
purposes than seat repair.
2. Do not drop or shock the valve seat cutter, or the dia-
mond particles may fall off.
3. Do not fail to apply engine oil to the valve seat cutter
before grinding the seat surface. Also wash off ground
particles sticking to the cutter with washing oil.
NOTE
o Do not use a wire brush to remove the metal particles
from the cutter. It will take off the diamond particles.
4. Setting the valve seat cutter holder in position, operate
the cutter in one hand. Do not apply too much force to
the diamond portion.
NOTE
o Prior to grinding, apply engine oil to the cutter and dur-
ing the operation, wash off any ground particles sticking
to the cutter with washing oil.
5. After use, wash it with washing oil and apply thin layer
of engine oil before storing.
Marks Stamped on the Cutter
The marks stamped on the back of the cutter [A] represent
the following.
600 Cutter angle [8]
37.5cp Outer diameter of cutter [C]

GE150118S1 C

Operating Procedures
. Clean the seat area carefully.
.. Fit a 450 cutter into the holder and slide it into the valve
Coat the seat with machinist's dye.

guide.
. Press down lightly on the handle and turn it right or left.
Grind the seating surface only until it is smooth.
CAUTION
Do not grind the seat too much. Overgrinding will
reduce valve clearance by sinking the valve into the
head. Ifthe valve sinks too far into the head, it will
be impossible to adjust the clearance, and the cylin-
der head must be replaced.

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 ENGINE TOP END 3-29
Valves
. Measure the outside diameter of the seating surface with
a vernier caliper. @)
*If the outside diameter of the seating surtace is too small,
repeat the 45° grind until the diameter is within the spec-
ified range.
Widened Width [A] of engagement by machining with
45° cutter
Ground Volume [8] by 32° cutter
32° [C] GE150119S1 C
Correct Width [0]
Ground Volume [E] by 60° cutter
60° [F]
. Measure the outside diameter of the seating surface with
a vernier caliper.
*If the outside diameter of the seating surtace is too small,
repeat the 45° grind [A] until the diameter is within the
specified range.
Original Seating Surface [8]
NOTE
o Remove all pittings of flaws from 45° ground surface.
OAffer grinding with 45° cutter, apply thin coat of machin- GE150121S1 C

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

distinct and 32° and 60° grinding operation easier.
o When the valve guide is replaced, be sure to grind with
45° cutter for centering and good contact.
*If the outside diameter [A] of the seating surface is too
large, make the 32° grind described below.
*If the outside diameter of the seating surface is within the
specified range, measure the seat width as described be-
low.
.Grind the seat at a 32° angle [8] until the seat 0.0. is
within the specified range.
OTo make the 32° grind, fit a 32° cutter into the holder, and
slide it into the valve guide. GE150122S1 C
OTurn the holder one turn at a time while pressing down
very lightly. Check the seat after each turn.
CAUTION
The 32° cutter removes material very quickly.
Check the seat outside diameter frequently to pre-
vent overgrinding.
OAfter making the 32° grind, return to the seat 0.0. mea-
surement step above.
. To measure the seat width, use a vernier caliper to mea-
sure the width of the 45° angle portion of the seat at sev-
eral places around the seat.
*If the seat width is too narrow, repeat the 45° grind until
the seat is slightly too wide, and then return to the seat
0.0. measurement step above.

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 3-30 ENGINE TOP END
Valves

*If the seat width is too wide, makethe 60° [A] grind de-
scribed below.
* If the seat width is within the specified range, lap the valve
to the seat as described below.
. Grind the seat at a 60° angle until the seat width is within
the specified range.
OTo make the 60° grind, fit 60° cutter into the holder, and
slide it into the valve guide.
OTurn the holder, while pressing down lightly.
GE150123S1 C
OAfter making the 60° grind, return to the seat width mea-
surement step above.
Correct Width [B]

. Lap the valve to the seat, once the seat width and 0.0.
are within the ranges specified above.
OPut a little coarse grinding compound on the face of the
valve in a number of places around the valve head.
OSpin the valve against the seat until the grinding com-
pound produces a smooth, matched surface on both the
seat and the valve.
ORepeat the process with a fine grinding compound.
Lapper [A] GE150120S1 C
Valve Seat [B]
Valve [C]
.The seating area should be marked about in the middle
of the valve face.
*If the seat area is not in the right place on the valve, check
to be sure the valve is the correct part. If it is, it may have
been refaced too much; replace it.
. Be sure to remove all grinding compound before assem-
bly.
. When the engine is assembled, be sure to adjust the valve
clearance (see Valve Clearance Adjustment).

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 ENGINE TOP END 3-31
Valves

Valve Seat Repair

45° Grind
Tool: 45°Cutter
Purpose: make seating area
smooth and round.

Measure Seating Area 0.0.

Tool: Vernier Caliper
Purpose: check seat 0.0.
against spec.

Results

45° Grind
Tool: 45°Cutter
Purpose: increase 0.0. of
seat area to spec.
32° Grind
Tool: 32° Cutter
Purpose: reduce 0.0. of
seat area to spec.

Measure Seat Width

Tool: Vernier Caliper
Purpose: check seat width
against spec.

Results

45° Grind
Tool: 45° Cutter
Purpose: increase width of seat
area beyond spec.
to increase 0.0. 60° Grind
Tool: 60° Cutter
Purpose: reduce seat width
to specification.

Lap Valve
Tools: Valve Lapper,
Grinding Compound
Purpose: perfectly match valve FINISHED
and seat area; check
valve head for damage.

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 3-32 ENGINE TOP END
Cylinders and Pistons

Cylinder Removal
. Remove:
Carburetors (see Fuel System)
Cylinder Head (see Cylinder Removal)
. Using a screwdriver, pry the pry points [A] to remove the
cylinder.
CAUTION
Do not hammer on the screwdriver while it is in the
pry point as engine damage could result.
Piston Removal
. Remove the cylinder (see Cylinder Removal).
. Remove the piston pin snap ring [A] from the outside of
each piston.
NOTE
o Place a clean cloth over the crankcase opening to pre-
vent debris or parts from fallinginto the crankcase.
GE16020351 C

. Remove the piston pins.

Special Tool - Piston Pin Puller Set: 57001-910[A]

GE16112851 C

. Carefully spread the ring opening with your thumbs and

then push up on the opposite side of the ring [A] to remove
it.
. manner.
Remove the 3-piece oil ring with your thumbs in the same

Cylinder and Piston Installation

NOTE
o If a new cylinder is used, use new piston rings.
.Install the oil ring expander [A] in the piston ring groove
so the ends [8] butt together.
. one below it.
Install the oil ring steel rails, one above the expander and

OSpread the rail with your thumbs, but only enough to fit
GE16040451 C
the rail over the piston.
ORelease the rail into the bottom piston ring groove.
NOTE
o The oil ring rails have no "top" or "bottom".

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 ENGINE TOP END 3-33
Cylinders and Pistons
. Do not mix up the top and second ring.
.Install the top ring [A]so that the nRnmark [8] faces up.
Olnstall the second ring [C]so that the nRNnmark [0] faces
up.

NOTE
o If a new piston is used, use new piston ring.
.Install the piston with its marking hollowfacing forward.
. Fit a new piston pin snap ring into the side of the piston
so that the ring opening [A]does not coincide with the slit
[8] of the piston pin hole.
OWhen installing the piston pin snap ring, compress itonly
enough to install it and no more.
OPlace a clean cloth under pistons and installthe piston pin
snap ring from the outside of each piston.
CAUTION
Do not reuse snap rings, as removal weakens and
deforms them.
They could fall out and score the cylinder wall.
. Apply molybdenum disulfide oil to the inside wall of the
small end of the connecting rod. Opening Position ~
.Install the piston by facing the hollow on the top of the @-C)
piston forward.
. The piston ring openings must be positioned as shown in
the figure. The openings of the oil ring steel rails must be
~
about 30 - 40° of angle from the opening of the top ring.
Top Ring [A]
Second Ring [8]
~~
~
~ GE160409S1 C

Oil Ring Steel Rails [C]

Oil Ring Expander [0]
Allow [E]
. ber damper [A]on the shaft with adhesive.
Install the rear camshaft chain guide by securing the rub-

Olnstall the rubber damper with its nupn mark [8] facing up.

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 3-34 ENGINE TOP END
Cylinders and Pistons
.Install both the right and left orifices [8] on the crankcase
[A].

. Replace the cylinder base gasket with a new one.

Olnstall the gasket with its "UP" mark [A] facing up.

. Apply molybdenum disulfide oil to the front and back sur-

faces of the piston skirt and the inner wall of the cylinder.
. Slip the piston base [A] under the pistons to hold them
level.
Special Tool- Piston Base, ljJ2.3:57001-1336

. Compress the piston rings using the piston ring compres-

sor grips [A] and piston ring compressor belt, and install
the cylinders.
Special Tools -Piston Ring Compressor Grip: 57001-1095
-
Piston Ring Compressor Belt, ljJ50 ljJ67:
57001-1096
. Insert the piston rings in the cylinder, and remove the pis-
ton ring compressor belts and the piston bases. .
.Install the cylinder so that its angles the piston angle.

Cylinder Wear
. Since there is a difference in cylinder wear in different di-
rections take a side-to-side and a front-to-back measure-
ment at each of the three locations (total of six measure- c
ments) shown in the figure.
10 mm [A]
40 mm [8]
20 mm [C]
*If any of the cylinder inside diameter measurements ex- GE160434S1 C
ceeds the service limit, replace the cylinder.
Cylinder Inside Diameter
Standard: 66.005- 66.017 mm (2.5986- 2.5991 in.)
Service Limit: 66.10 mm (2.602 in.)

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 ENGINE TOP END 3-35
Cylinders and Pistons
Piston Wear
. Measure the diameter [8] (front-to-back) of each piston 6
mm [A] up from the bottom of the piston.
*If the piston's diameter is smaller than the service limit,
replace the piston.
Piston Diameter
Standard: 65.951 - 65.966 mm (2.5965- 2.5971in.)
Service Limit: 65.81 mm (2.591 in.)

Piston/Cylinder Clearance
. Subtract the piston diameter from the cylinder bore to ob-
tain the piston/cylinder clearance.
Piston/Cylinder Clearance
Standard: 0.040 - 0.067mm (0.0016- 0.0026 in.)
* If the piston/cylinder clearance is less than the specified
range, use a smaller piston or increase the cylinder bore
by honing.
* If the piston/cylinder clearance is greater than the speci-
fied range use a larger piston.
*If only a piston is replaced, the clearance may exceed the
standard slightly, but it must not be less than the minimum
limit in order to avoid piston seizure.
Piston Ring/Ring Groove Clearance
.*Visually inspect the piston rings and ring grooves.
If the piston rings or ring grooves are deformed or dam-
aged, replace the piston and the piston rings.
. Place a piston ring in its groove, and using a thickness
gauge [A], measure the piston ring/ring groove clearance
at several locations.
Piston Ring/Ring Groove Clearance
Standard:
Top 0.050 - 0.080 mm (0.0020 - 0.0031 in.)
Second 0.030 - 0.070 mm (0.0012 - 0.0028 in.)
Service Limit:
Top 0.18 mm (0.0071 in.)
Second 0.17 mm (0.0067 in.)
*If the clearance exceeds the service limit, measure the
piston ring thickness and the piston ring groove width to
determine whether to replace the ring and the piston as a
set.

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 3-36 ENGINE TOP END
Cylinders and Pistons
Piston Ring Groove Wear
. Using a vernier caliper, measure the groove width at sev-
erallocations around the piston.
Piston Ring Groove Width
Standard:
Top 1.03 -1.05 mm (0.0406 - 0.0413 in.)
Second 1.22 - 1.24 mm (0.0480 - 0.0488 in.)
Oil 2.01 - 2.03 mm (0.0791 - 0.0799 in.)
Service Limit:
Top 1.13 mm (0.0455 in.)
Second 1.32 mm (0.0520 in.)
Oil 2.11 mm (0.0831 in.)
* If any of the groove widths is wider than the service limit,
replace the piston.

Piston Ring Thickness

. Using a micrometer, measure the thickness at several 10-
cations around the ring.
Piston Ring Thickness
Standard:
Top 0.970 - 0.985 mm (0.0382 - 0.0390 in.)
Second 1.17 - 1.19 mm (0.0461 - 0.0469 in.)
Oil 0.20 - 0.70 mm (0.0079 - 0.0276 in.)
Service Limit:
Top 0.90 mm (0.0354 in.)
Second 1.10 mm (0.0433 in.)
Oil 1.0 mm (0.0394 in.)
*If any of the measurements is less than the service limit
on either of the rings, replace the rings as a set.

NOTE
o When using new rings on a used piston, check for un-
even groove wear. The rings should fit perfectly parallel
to the groove sides. If not, replace the piston.

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 ENGINE TOP END 3-37
Cylinders and Pistons

.Piston Ring End Gap Measurement

Place the piston ring [A] inside the cylinder, using the pis-
ton to locate the ring squarely in place. Place the piston
ring close to the bottom of the cylinder, where cylinder
wear is minimal.
. Using a thickness gauge, measure the gap [8] between
the ends of the ring.
* If the ring end gap exceeds the service limit, replace the
ring.
GE1604355 1 C

Piston Ring Thickness

Standard:
Top 0.15 - 0.30 mm (0.0059 - 0.0118 in.)
Second 0.30 - 0.45 mm (0.0118 - 0.0177 in.)
Oil 0.20 - 0.70 mm (0.0079 - 0.0276 in.)
Service Limit:
Top 0.60 mm (0.0236 in.)
Second 0.75 mm (0.0295 in.)
Oil 1.0 mm (0.0394 in.)

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 3-38 ENGINE TOP END
Carburetor Holder
Carburetor Holder Installation
.Match the position numbers [8] on the carburetor hold-
ers with the cylinder numbers, and install the holders with
their emboss number marks facing upward.
OCheck to make sure that the O-rings [A] is not damage.
.. Apply a non-permanent locking agent to the holder bolts.
Tighten the carburetor holder bolts.
-
Torque Carburetor Holder Bolts: 12 N.m (1.2 kgf.m, 104
in.lb) GE170401S1 C

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 ENGINE TOP END 3-39
Muffler

Muffler Removal
8 Loosen the muffler mounting bolt [A].

8 Remove the exhaust pipe holder nuts [A].

8 Remove the muffler mounting bolt and muffler.

Muffler Installation
8 Inspect the gaskets and replace them if they are dam-
aged.
8 Install the exhaust pipe holder with its notch [A] facing
down.
8 Temporarily tighten the bolt and nuts.
8 Uniformly tighten the exhaust pipe holder nuts.
8 Tighten the muffler mounting bolt.
-
Torque Muffler Mounting Bolt: 25 N.m (2.5 kgf.m, 18 ft.lb)
8 Start the engine and warm it up thoroughly. Allow the
engine to cool down and additionally tighten the clamp
bolts and holder nuts.

Muffler Body Removal

8 Remove the muffler connecting cover bolts [A].
8 Remove the muffler connecting cover [8].

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 3-40 ENGINE TOP END
Muffler
. Remove the muffler connecting nuts [A].
. Remove the muffler mounting bolt [8] and remove the si-
lencer [C].

Muffler Body Installation

.Inspect the gasket and replace it if it is damaged.
-
Torque Muffler Mounting Bolt: 25 N.m(2.5 kgf.m, 18 ft.lb)
Muffler Connecting Nuts: 34 N.m (3.5 kgf.m, 25
ft.lb)

Exhaust Pipe Removal

. Remove the muffler body (see muffler body Removal)
. Remove the exhaust pipe holder nuts, and remove the
exhaust pipe.

.Exhaust Pipe Installation

See Muffler Installation.

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 CLUTCH 4-1

Clutch
Table of Contents
Exploded View........................................................................................................................ 4-2
Specifications ......... 4-4
Clutch Lever and Cable ...... 4-5
Clutch Lever Free Play Inspection ................................................. 4-5
Clutch Lever Free Play Adjustment.................................................................................. 4-5
Cable Removal................................................................................................................. 4-6
Cable Installation.............................................................................................................. 4-6
Cable Lubrication.............................................................................................................. 4-6
Clutch Lever Installation.................................................................................................... 4-6
Clutch Cover........................................................................................................................... 4-7
Clutch Cover Removal... ........ 4-7
Clutch Cover Installation................................................................................................... 4-7
Clutch Release Shaft Removal. ... ... 4-8
Clutch Release Shaft Installation...................................................................................... 4-8
Clutch . 4-9
Clutch Removal................................................................................................................. 4-9
CI utch Installation.............................................................................................................. 4-10
Clutch Plate Wear and Damage ....................................................................................... 4-11
Clutch Plate Warp .. ... ... ........ 4-11
Clutch Spring Free Length Inspection............................................................................... 4-12
Clutch Housing Finger Damage.. ... ... ... 4-12
Clutch Hub Spline Damage............................................................................................... 4-12

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 4-2 CLUTCH
Exploded View

GF02021BW5 C

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 CLUTCH 4-3
Exploded View

GF020303W4 C

1. Starter Lockout Switch L: Apply non-permanent locking agent to the

2. Align the marks. threads.
3. Clutch Lever Pivot Nut M: Apply molybdenum disulfide grease.
T1: 132 N.m (13.5 kgf.m, 98 ft.lb) 0: Apply engine oil.
T2: 8.8 N.m (0.9 kgf.m, 78 in.lb) R: Replacement Part
T3: 9.8 N.m (1.0 kgf.m, 87 in.lb) Si: Apply silicon grease or PBC greace.
T4: 5.9 N.m (0.6 kgf.m, 52 in.lb) SS: Apply silicon sealant (Kawasaki Bond:
T5: 12 N.m (1.2 kgf.m, 104 in.lb) 56019-120).
G: Apply high-temperature grease.

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 4-4 CLUTCH
Specifications
Item Standard Service limit
Clutch Lever and Cable (Adjustable Range)
Lever Position - 1 - 5
Lever Free Play 2 - 3 mm (0.08 - 0.12 in.) -
Clutch
Friction Plate Thickness:
Cork-Base 2.9 - 3.1 mm (0.114 - 0.122 in.) 2.7 mm (0.106 in.)
Paper-Base 2.92 - 3.08 mm (0.115 - 0.121 in.) 2.6 mm (0.102 in.)
Friction Plates Warp Not more than 0.15 mm (0.006 in.) 0.3 mm (0.012 in.)
Steel Plates Warp Not more than 0.2 mm (0.008 in.) 0.3 mm (0.012 in.)
Spring Free Length 41.9 mm (1.650 in.) 39.4 mm (1.551 in.)
Special Tool - Clutch Holder: 57001-1243
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

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 CLUTCH 4-5
Clutch Lever and Cable
Clutch Lever Free Play Inspection
. Pull
[C].
the clutch lever just enough to take up the free play

. Measure the gap between the lever and lever holder.

Clutch Lever Free Play
Standard: 2 - 3 mm (0.08 - 0.12in.)
*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 Adjustment

A WARNING
To avoid a serious burn, never touch the engine or
exhaust pipe during clutch adjustment.
. Loosen the adjusting nuts [A].

. Loosen the adjuster locknut [A].

. Turn the adjuster [8] to create a clearance of 5 - 6 mm
(0.020 - 0.024 in.) [C] between the adjuster and the lock-
nut.

. Firmly pull on the cable [A] and tighten the adjusting nuts
[8].

. Turn the adjuster to adjust the free play to 2 - 3 mm (0.08

- 0.12 in.).
. Tighten the locknut.
. Check that the upper end of the cable is fitted correctly in
the adjuster.
A WARNING
Be sure that the outer cable end 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.
. Start the engine to check for any clutch slippage or if the
clutch disengages properly.

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 4-6 CLUTCH
Clutch Lever and Cable

.Cable Removal
Loosen the nuts, and slide the lower end of the clutch

.. cable to give the cable plenty of play.

Screw in the adjuster.
Line up the slots [A]in the clutch lever, lock nut and ad-
juster, and then free the cable from the lever.
. Free the clutch inner cable tip from the clutch release
lever.
. Push the release lever toward the front of the motorcycle
and tape the release lever to the clutch cover to prevent
the release shaft from falling out.
. Pull the clutch cable out of the frame.
Cable Installation
. Run the clutch cable correctly (see General Information
chapter) .
. Adjustthe clutch cable (see Lever Free Play Adjustment).
Cable Lubrication
Whenever the clutch cable is removed, lubricate the
clutch cable as follows.
. Apply a thin coating of grease
lower ends.
to the cable upper and

. Lubricate the cable with a penetrating rust inhibitor.

Clutch Lever Installation

.Install the clutch lever assembly so that the punch mark
[A] of the switch housing is aligned with the mating surface
[8] of the clutch lever clamp [C].

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 CLUTCH 4-7
Clutch Cover
Clutch Cover Removal
.. Drain engine oil.
Detach the clutch cable at its lower end.
OLoosen the adjusting nuts at the lower end of the cable.
OLoosen the adjuster locknut at the upper end of the cable
and screw in the adjuster.
OAlign the grooves [A] of the lever, locknut, and adjuster.
OSet the lever adjuster to "5".
ODetach the clutch cable at its upper end.
ODetach the lower end of the cable from the release lever.

. Remove the clutch cover bolts [A].

. Turn the release lever counterclockwise

the clutch cover.
[A] and remove

CAUTION
Do not pull out the clutch release shaft for clutch
cover removal. Clutch release shaft removal dam-
ages the oil seal in the clutch cover, necessitating
oil seal replacement.

Clutch Cover Installation

. Replace the gasket with a new one.
. Apply silicon sealant around [A] the crankcase mating sur-
face for the clutch cover gasket.
Sealant - Kawasaki Bond (Silicon Sealant): 56019-120

.Install the clutch cover while keeping the release lever

tu rned counterclockwise.
. Turn the release lever clockwise [A] and engage the re-
lease shaft and the clutch pusher.
NOTE
o Slightlypull the release shaft out of the cover to engage
it. When it is engaged, a clearance of approximately 4
mm fB] willbe created between the lever and thecover.

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 4-8 CLUTCH
Clutch Cover
. oilProperly route and clamp the crankshaft sensor and the
pressure warning light switch wire, and tighten the
clutch cover bolts (see Chapter 1, General Information).
-
Torque Clutch Cover Bolt: 12 N.m (1.2 kgf.m, 104 in.lb)
. Attach the lower end and upper end of the clutch cable,
and adjust the clutch lever free play.
. Pour in the specified amount of engine oil (see Engine
Lubrication System)
Clutch Release Shaft Removal
CAUTION
Do not remove the clutch release lever and shaft
assembly unless it is absolutely necessary. If re-
moved, oil seal replacement may be required.
. Cover
Detach the lower end of the clutch cable (see Clutch
Removal).
. Turn the clutch release lever rearward to free the release
shaft from the clutch pusher, and pull out the shaft.
Clutch Release Shaft Installation
. Replace the oil seal with a new one.
. Apply high-temperature grease to the lip of the oil seal in
the release hole, and engine oil to the bearing.
. Apply engine oil to the release shaft.
.Insert the shaft into the hole, with the cutout facing the
clutch.
CAUTION
Be sure that the spring does not pop out of the oil
seal while inserting the shaft.

. Turn the release lever forward and engage the release

shaft and the clutch pusher (see Clutch Cover Installa-
tion).
Olf the release lever has been removed, install it by aligning
the mark [A] of the lever and the mark [8] of the shaft.
-
Torque Clutch Release Lever Clamp Bolt: 5.9 N.m (0.6
kgf.m, 52 in.lb)

. Install the lower end of the clutch cable and adjust the
lever free play.

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 CLUTCH 4-9
Clutch
Clutch Removal
. Remove:
Engine Oil (drain, see Engine Lubrication System chap-
ter)
Clutch Cable Lower End (see Clutch Cable Removal)
Clutch Cover (see Clutch Cover Removal)
Clutch Spring Bolts [A]
Washer
Springs
Clutch Spring Plate [B)
Shim
Thrust Bearing
Pusher [C)

Friction Plates, Steel Plates

Clutch Hub Nut, Washer
OHolding the clutch hub, remove the nut.
Special Tool - Clutch Holder: 57001-1243 [A]

Clutch Hub [A]

Spacer
Clutch Housing [B)
Needle Bearing
Sleeve
Spacer

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 4-10 CLUTCH
CIutch
Clutch Installation
. Install the following parts on the drive shaft.
Spacer [A]
Sleeve [B]
Needle Bearing [C]
Clutch Housing [0]
Spacer [E]
Clutch Hub [F]
Washer [G]
Nut [I]

GF060409S2 C

Olnstall the spacer [A] with its chamfered side facing the
crankcase.

OReplace the clutch hub nut with a new one.

OHolding the clutch hub, tighten the clutch hub nut.
Special Tool- Clutch Holder: 57001-1243
-
Torque Clutch Hub Nut: 132 N.m (13.5 kgf.m, 98 ft.lb)
.Install the plates alternately in the following order: first
the cork-base friction plate [A], then the steel plate, and
paper-base friction plates [B] and steel plates at five time.
.Install the last cork-base friction plate [C] by aligning its
protrusions with the shallow grooves.
CAUTION
If new plates are installed, apply engine oil to the
surfaces of each plate to avoid clutch plate seizure.

GF06013BS2 C

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 CLUTCH 4-11
CIutch

. Apply engine oil to the thrust bearing [C].

. Apply molybdenum disulfide grease to the clutch spring
plate pusher ends [A] before installing.
. Install the clutch spring plate [E] together with the shim
[D], thrust bearing, and pusher [8].
Torque -Clutch Spring Bolts: 8.8 N.m (0.9 kgf.m, 78 in.lb)

GF060106S1 C

.Install the clutch cover (see Clutch Cover Installation).

. Push the release lever [A] towards the crankcase so that
when it stops moving the angle of the release lever is as
shown.
Less than 20° [C]
* If the angle is exceed the 20°, replace the shim to the 1.2
mm thick shim.

Clutch Plate Wear and Damage

. Visually inspect the friction and steel plates for signs of
wear, discoloration, peeled friction material, or other types
of damage.
* If any friction plates show signs of damage, replace the
friction plates and steel plates as a set.
. Measure the thickness of the friction plates [A] at several
places.
Friction Plate Thickness GF060602S 1 C

Standard:
Cork-base 2.9 - 3.1 mm (0.114 - 0.122 in.)
Paper-base 2.92 - 3.08 mm (0.115 - 0.121 in.)
Service Limit:
Cork-base 2.7 mm (0.106 in.)
Paper-base 2.6 mm (0.102 in.)
*If the thickness of any plate is smaller than the service
limit, replace it with a new one.
Clutch Plate Warp
. Place each friction plate or steel plate [8] on a surface
plate [A].
. Holding the plate, measure the gap between the surface
plate and each friction plate or steel plate with a thickness
gauge[C].
*If any plate is warped over the service limit, replace it with
a new one.
Friction Plate Warp GF060404S 1 C

Standard: 0.15 mm (0.008 in.) or less

Service Limit: 0.3 mm (0.012 in.)

Steel Plate Warp

Standard: 0.2 mm (0.008 in.) or less
Service Limit: 0.3 mm (0.012 in.)

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 4-12 CLUTCH
Clutch

.Clutch Spring Free Length Inspection

Measure the free length [A] of the clutch springs.
* If any clutch spring is shorter than the service limit, it must
be replaced.
Clutch Spring Free Length
Standard: 41.9 mm (1.650 in.)
Service Limit: 39.4 mm (1.551 in.)

Clutch Housing Finger Damage

. Visually inspect the clutch housing fingers [A] that come
in contact with the friction plate tangs.
* Ifthey are damaged or if there are groove cuts in the areas
that come in contact with the tangs, replace the housing.
Also, replace the friction plates if their tangs are damaged.

XXOOOOOOS
1 C

.Clutch Hub Spline Damage

Visually inspect the areas of the clutch hub splines that
come in contact with the teeth of the steel plates.
*If there are notches worn into the clutch hub splines [A],
replace the clutch hub. Also, replace the steel plates if
their teeth are damaged.

GE060411S1 C

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 ENGINE LUBRICATION SYSTEM 5-1

Engine Lubrication System

Table of Contents
Exploded View........................................................................................................................ 5-2
Specifications ......... 5-4
Engine Oil and Oil Filter.......................................................................................................... 5-5
Engine Oil level Inspection.............................................................................................. 5-5
Engine Oil Change............................................................................................................ 5-5
Oil Filter Change............................................................................................................... 5-6
Oil Pan ......... 5-8
Oil Pan Removal............................................................................................................... 5-8
Oil Pan Installation............................................................................................................ 5-8
Oil Pump................................................................................................................................. 5-9
Oil Pump Removal............................................................................................................ 5-9
Oil Pump Installation ... ...... ........ 5-9
Oil Screen Cleaning. ... ........ 5-9
Oil Pressure Measurement ......... 5-10
Oil Pressure Measurement ........ 5-10
Oil Pressure Relief Valve... ........ 5-11
Relief Valve Inspection...................................................................................................... 5-11
Oil Pressure Switch................................................................................................................ 5-12
Oil Pressure Switch Removal .......... 5-12
Oil Pressure Switch Installation ........................................................................................ 5-12
Oil Cooler ......... 5-13
Oil Cooler Removal........................................................................................................... 5-13

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 5-2 ENGINE LUBRICATION SYSTEM
Exploded View

GG020405W3 C

1. Oil Cooler
2. Oil Passage Plug
3. Oil Pressure Warning Light Switch
4. Oil Filler Cap
5. Oil Level Gauge
6. Oil Pump
7. Oil Pressure Relief Valve
8. Engine Oil Drain Plug
9. Oil Filter
T1: 22 N.m (2.2 kgf.m, 16 ft.lb)
T2: 8.8 N.m (0.9 kgf.m, 78 in.lb)
T3: 5.9 N.m (0.6 kgf.m, 52 in.lb)
T4: 15 N.m (1.5 kgf.m, 11 ft.lb)
T5: 5.1 N.m (0.52 kgf.m, 45 in.lb)
T6: 1.5 N.m (0.15 kgf.m, 13 in.lb) (finger-tighten)
T7: 29 N.m (3.0 kgf.m, 22 ft.lb)
T8: 12 N.m (1.2 kgf.m, 104 in.lb)
T9: 20 N.m (2.0 kgf.m, 14 ft.lb)
C: After tightening, stake it with a punch.
G: Apply high-temperature grease.
L: Apply non-permanent locking agent to the threads.
0: Apply engine oil.
SS: Apply silicon sealant (Kawasaki Bond: 56019-120).

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 ENGINE LUBRICATION SYSTEM 5-3
Exploded View

GG02062BW5 C

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 5-4 ENGINE LUBRICATION SYSTEM
Specifications
Standard
Item
ZR750-H 1 I
ZR750-H2 - H4
Engine Oil and Oil Filter
Recommended Engine Oil:
Type API SE, SF, or SG class or API SH or SJ with JASO MA
Viscosity SAE 10W-40, 1OW-50, 20W-40, or 20W-50 ISAE 10W-40
Capacity 3.0 L (3.2 US qt) [when filter is not removed]
3.5 L (3.7 US qt) [when filter is removed]
3.6 L (3.8 US qt) [when engine is completely dry]
Oil Pressure Measurement 100 kPa (1.02 kgf/cm2, 14.5 psi)
@3 000 r/min (rpm), oil temp 80° C (176° F)
-
Special Tools Oil Pressure Gauge, 10 kgflcm2: 57001-164
Oil Pressure Gauge Adapter, M18 x 1.5: 57001-1278

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 ENGINE LUBRICATION SYSTEM 5-5
En.gine Oil and Oil Filter
A WARNING
Motorcycle operation with insufficient, deteri-
orated, or contaminated engine oil will cause
accelerated wear and may result in engine or trans-
mission seizure, accident, and injury.

Engine Oil Level Inspection

. Use the center stand to support the motorcycle upright.
. Check that the engine oil level is between the upper [A]
and lower [8] levels on the gauge.
NOTE
OSituate the motorcycle so that it is perpendicular to the
ground.
o If the motorcycle has just been used, wait several min-
utes to allow the oil level to stabilize. GG050 108S 1 C

o If the oil has been changed, start and warm up the en-
gine for several minutes. Stop the engine, then wait
several minutes untilthe oil level stabilizes.
CAUTION
Racing the engine before the oil reaches every part
can cause engine seizure.
Ifthe engine oil gets extremely low or ifthe oil pump
or oil passages clog up or otherwise do not function
properly, the oil pressure warning light will light. If
this light stays on when the engine is running above
idle speed, stop the engine immediately and find the
cause.
*If the oil level is too high, drain the oil from the filler neck.
* If the oil level is too low, fill to the upper level with the
specified type of oil.
Engine Oil Change
A WARNING
To avoid a serious burn, never touch the exhaust
pipe during oil change.
. after it has been warmed up thoroughly.
Set the motorcycle on its center stand and stop the engine

. Remove the oil filler cap.

. Place a drain pan under the engine, remove the drain plug
[A] and drain the oil.
OThe oil in the filter can be drained by removing the oil filter
(see Oil Filter Change).
. Replace the drain plug gasket with new one if it is dam-
aged.

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 5-6 ENGINE LUBRICATION SYSTEM
Engine Oil and Oil Filter
. After draining the oil, reinstall the drain plug.
Torque - Engine Oil Drain Plug: 29 N.m (3.0 kgf.m, 22 tt.lb)
. Pour in the specified amount of engine oil.
Recommended Engine Oil
ZR750-H1 ZR750-H2 - H4
API SE, SF or SG
Type:
API SH or SJ with JASO MA
SAE 10W-40, 1OW-50, SAE 10W-40
Viscosity: 20W-40, or 20W-50
3.0 L (3.2 US qt) [Oil change - without
replacing filter]
Capacity:
3.5 L (3.7 US qt) [Oil change - replacing filter]
3.6 L (3.8 US qt) [Engine is completely dry]

NOTE
OAlthough 10W-40 engine oil is the recommended oil
for most conditions, the oil viscosity may need to be
changed to accommodate atmospheric conditions in
your riding area.

-20 -10 30 40 (OC)

L J......
-4 14 32 ~4("F)
I I I
L J GS09000BS1 C

.Install the oil filler cap.

Torque - Oil Filler Cap: 1.5 N.m (0.15 kgf.m, 13 in.lb) (Finger
tighten)
. Check the oil level.

Oil Filter Change

. Drain
the engine oil (see Engine Oil Change).
. Remove the mounting bolt [A], and take out the filter as-
sembly.
. Remove the filter from the mounting bolt.

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 ENGINE LUBRICATION SYSTEM 5-7
Engine Oil and Oil Filter
Olnstall a new filter on the mounting bolt.
NOTE
o The oil filter bypass valve is assembled in the filter bolt.
Filter Bolt [A]
Spring Pin [B]
Steel Ball [C]
Spring [0]
a-ring [E]
GG050403S 1 C
Filter Cover [F]
Oil Fence [G]
Washer [H]
Oil Filter [I]

NOTE
OApply engine oil to the threads of the mounting bolt [A]
and the bypass shaft. Turn[B] the filter to install it, while
making sure that the grommet [e] does not become de-
tached.
Olnstall the filter ass~mbly.
Torque - Oil Filter Mounting Bolt: 20 N.m (2.0 kgf.m, 14tt.lb)
. Pour in the specified type and amount of oil (see Oil Filter
Change).

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 5-8 ENGINE LUBRICATION SYSTEM
Oil Pan
Oil Pan Removal
. Remove:
Engine Oil (drain, see Engine Oil Change)
Exhaust Pipe (see Engine Top End Chapter)
.. Remove the lower end [A] of the oil pipes.
Remove the oil pan bolts and remove the oil pan [8].

. Remove the relief valve [A] if necessary.

Oil Pan Installation

.If the oil pressure relief valve was removed, install it.
OApply a non-permanent locking agent to the threads of
the oil pressure relief valve, and tighten it.
CAUTION
Do not apply too much non-permanent locking
agent to the threads. This may block the oil pas-
sage.
Torque - Oil Pressure Relief Valve: 15 N.m (1.5 kgf.m, 11.0
ft.lb)

. Check the O-rings [A] for any damage.

.*Apply
Replace it if it is damaged.
engine oil to the O-ring
. Install the O-ring in the passage between the crankcase
and the oil pan with the flat side of the O-ring facing the
crankcase

. Replace the oil pan gasket with a new one.

.Install the oil pan.
-
Torque Oil Pan Bolts: 12 N.m (1.2 kgf.m, 104 in.lb)
.Install the lower end [A] of the oil pipe.
-
Torque Oil Pipe Lower End Mounting Bolts [B]: 8.8 N.m
(0.9 kgf.m, 78 in.lb)

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 ENGINE LUBRICATION SYSTEM 5-9
Oil Pump
Oil Pump Removal
. Remove:
Clutch (see Clutch chapter)
Oil Pan (see Oil Pan Removal)
. Remove the mounting bolt [A] and the mounting screws
[8].

. Removethe oil pump[A].

Oil Pump Installation

. Tightenthe mountingscrewsandstakethem [A].
Torque-Oil Pump Mounting Screw: 5.1 N.m (0.52 kgf.m, 45
in.lb)
Oil Pump Mounting Bolt: 5.1 N.m (0.52 kgf.m, 45
in.lb)

Oil Screen Cleaning

.Clean the oil screen [A] with high-flash point solvent and
remove any particles stuck to it.
A
WARNING
Clean the screen in a well-ventilated area, and take
care that there is no spark or flame anywhere near
the working area. Because of the danger of highly
flammable liquids, do not use gasoline or low-flash
point solvents.
. Check the screen carefully for any damage:
broken wires.
holes and

* If the screen is damaged, replace it.

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 5-10 ENGINE LUBRICATION SYSTEM
Oil Pressure Measurement
Oil Pressure Measurement
. Remove the oil passage plug and install the oil pressure
gauge [A] and adapter [8].
Special Tool- Oil Pressure Gauge, 10 kgf/cm2: 57001-164
[A]
Oil Pressure Gauge Adapter, M18 x 1.5:
57001-1278 [B]
. Start the engine and warm up the engine.
. Run the engine and read the pressure at an engine speed
of 3,000 r/min (rpm).
* If the measurement is much lower than the standard, in-
spect the oil pump, relief valve and/or crankshaft bearing
insert wear immediately.
* If the reading is much higher than the standard, check the
oil passage for clogging.
Oil Pressure
Standard: 100 kPa (1.02 kgf/cm2, 14.5 psi)
@3 000 r/min (rpm),
Oil temperature 80°C (176°F)
. Stop the engine, remove the gauge, and reinstall the plug.
-
Torque Oil Passage Plug: 15 N.m (1.5 kgf.m, 11 ft.lb)
A. WARNING
Take care against burns from hot engine oil that will
drain through the oil passage.

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 ENGINE LUBRICATION SYSTEM 5-11
Oil Pressure Relief Valve

.Relief Valve Inspection

Remove:
Oil Pan (see Oil Pan Removal)
Relief Valve [A]
. Using a wooden stick, push the inner valve to make sure
that the valve [A] moves smoothly and that it returns to its
original position by the force of the spring [8].
NOTE
o The relief valve cannot be disassembled and it must be GG08040 1 P

inspected in the assembled state.

*If the valve movement is not smooth, wash the relief valve
with high flash-point solvent, and use compressed air to
remove any foreign particles from it.
* If the valve does not move smoothly even after washing
it, replace the relief valve. The oil pressure relief valve is
position made with no allowance for replacement of indi-
vidual parts.
-
Torque Oil Pressure Relief Valve: 1.5 N.m (1.5 kgf.m, 11
ft.lb)
A WARNING
Clean the oil pressure relief valve in a well
-ventilated area, and take care that there is no
spark or flame anywhere near the working area.
Because of the danger of highly flammable liquids,
do not use gasoline or low-flash point solvent.

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 5-12 ENGINE LUBRICATION SYSTEM
Oil Pressure Switch

.Oil Pressure
Remove:
Switch Removal

Engine Oil (drain, see Engine Oil Change)

Crankshaft Sensor Cover
Screw [A]
Switch Terminal [8]
Oil Pressure Switch [C]

Oil Pressure Switch Installation

. Apply silicone sealant to the threads of the oil pressure
switch and tighten it.
Sealant -
Kawasaki Bond (Silicone Sealant): 56019-120
Torque - Oil Pressure Switch: 15 N.m (1.5 kgf.m, 11.0 tt.lb)
. Tighten the terminal bolt.
-
Torque Oil Pressure Switch Terminal Bolt: 1.5 N.m (0.15
kgf.m, 13 in.lb)
. Apply
grease to the terminal.

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 ENGINE LUBRICATION SYSTEM 5-13
Oil Cooler
Oil Cooler Removal
. Remove:
Bolts [A]
Supply Side Hose [B]
Return Side Hose [C]

. Remove:
Bolts [A]
Oil Cooler [B]

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 ENGINE REMOVAUINSTALLATION6-1

Engine Removal/Installation
Table of Contents
Exploded View 6-2
Engine Removal/Installation 6-3
Engine Removal 6-3
Engine Installation 6-4

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 6-2 ENGINE REMOVAUINSTALLATION
Exploded View

GH020404W4 C

1. Engine Mounting Bolts

2. Engine Mounting Nuts
T1: 25 N.m (2.5 kgt.m, 18 tt.lb)
T2: 44 N.m (4.5 kgt.m, 33 ft.lb)

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 ENGINE REMOVAUINSTALLATION 6-3
Engine Removal/Installation

.Engine Removal
Set the motorcycle on its center stand, squeeze the front
brake lever, and hold it with a band [A] to prevent the
motorcycle from lunging forward.
A
WARNING
Be sure to hold the front brake when removing the
engine, or the motorcycle may fall over. It could
cause an accident and injury.
GH040110S1 C

CAUTION
Be sure to hold the front brake when removing the
engine, or the motorcycle may fall over. The engine
or the motorcycle could be damaged.
. Remove (see the respective chapters):
Engine Oil (drain)
Fairing (see Frame chapter)
Seat (see Frame chapter)
Side Cover (see Frame chapter)
Fuel Tank (see Fuel System chapter)
Right Side Step Bracket Bolts [A]
Frame Ground Terminal [B]
Crankshaft Sensor, Oil Pressure Switch Wire Connector
[C]
Clutch Cable Lower End [D]
Shift Lever (see Crankshaft/Transmission chapter)
Engine Sprocket Cover (see Final Drive chapter)
Engine Sprocket [E]
Side Stand Switch Lead Connector [F]
Side Stand Switch [G]
Neutral Switch Lead Connector [H]
Alternator Lead Connector [I]
Starter Motor Lead Terminal [J]
Air Cleaner Housing, Rear (see Fuel System chapter)
Carburetor (see Fuel System chapter)
Air Cleaner Housing, Front (see Fuel System chapter)
Horn
Ignition Coil (see Electrical System chapter)
Vacuum Switch Valve and Hoses (see Fuel System
chapter)
Exhaust Pipe and Muffler (see Engine Top End chapter)
Oil Cooler and Oil Pipe (see Engine Lubrication System
chapter)

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 6-4 ENGINE REMOVAUINSTALLATION
Engine Removal/Installation
. Using a jack [A], support the bottom of the engine.
. Remove the engine mounting bolts [8] and bracket bolts
[C].
. Raise the jack and take out the engine [0] from the right
side.

.Engine Installation
Apply soap and water solution around the rubber damper
and install it in the bracket.
CAUTION

Do not apply engine oil or petroleum distillates on

the rubber damper.
. Support the bottom of the engine with a jack and install
the engine.
Torque - Engine Mounting Bolts, Nuts: 44 N.m (4.5 kgf.m,
33 ft.lb)
Engine Bracket Bolts: 25 N.m (2.5 kgf.m, 18 ft.lb)
. Run the wires, cables, and hoses properly (see General
Information chapter).
.Install the removed parts (see the appropriate chapters).
. Adjust:
Throttle Cable (see Fuel System chapter)
Clutch Cable (see Clutch chapter)
Choke Cable (see Fuel System chapter)
Drive Chain (see Final Drive chapter)
. Fill the engine with engine oil (see Engine Lubrication
chapter)

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 CRANKSHAFT/TRANSMISSION 7-1

Cran kshaftlTransm ission

Table of Contents
Exploded View................................... 7-2 Shift Pedal Removal.................... 7-24
Specifications................................... . 7-5 Shift Pedal Installation ................. 7-24
Crankcase Splitting............................ 7-8 External Shift Mechanism
Crankcase Splitting...................... 7-8 Removal................................... . 7-24
Crankcase Assembly................... 7-9 External Shift Mechanism
Crankshaft/Connecting Rod .............. 7-12 Installation... ....... ........ .... ........... 7-25
Crankshaft Removal.................... 7-12 External Shift Mechanism
Crankshaft Installation ................. 7-12 Inspection. .................. .......... ..... 7-26
Connecting Rod Removal............
Connecting Rod Installation .........
7-12
7-12
Transmission Shaft Removal.......
Transmission Shaft Installation....
7-26
7-27
[II
Crankshaft/Connecting Rod Transmission Shaft Disassembly. 7-27
Cleaning................................... . 7-13 Transmission Assembly............... 7-27
Connecting Rod Bend.................. 7-14 Drive shaft Gear Adjustment........ 7-29
Connecting Rod Twist .................. 7-14 Output Shaft Gear Adjustment..... 7-30
Connecting Rod Big End Side Shift Fork and Shift Drum
Clearance................................. . 7-14 Removal.... .. ... .. .... .. .... .. .. .... .. .... . 7-30
Connecting Rod Big End Bearing Shift Fork/Shift Drum Installation. 7-31
InsertiCrankpin Wear ................ 7-15 Shift Fork Bending ....................... 7-32
Crankshaft Main Journal/Bearing Shift Fork Ear/Gear Shift Fork
Insert Wear.. ...... .... ...... ....... ....... 7-16 Groove Wear ............................. 7-32
Crankshaft Runout ....................... 7-18 Shift Fork Guide Pin/Shift Drum
Crankshaft Side Clearance .......... 7-18 Groove Wear............................. 7-32
Secondary Shaft and Starter Clutch.. 7-19 Gear Dog/Gear Dog Hole
Secondary Shaft Removal........... 7-19 Damage.................................... . 7-33
Secondary Shaft Installation ........ 7-20 Ball Bearing, Needle Bearing, and Oil
Starter Clutch Disassembly.......... 7-22 Seal... .. .... .. .... .. .. ... .... .... .... .... .... .... ... 7-34
Starter Clutch Assembly.............. 7-22 Ball and Needle Bearing Wear..... 7-34
Transmission.................................... . 7-24 Oil Seal Inspection ....................... 7-34

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 7-2 CRANKSHAFTrrRANSMISSION
Exploded View

GI 02040815 C

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 CRANKSHAFTITRANSMISSION 7-3
Exploded View
1. M6 bolt (50 mm length)
2. M6 bolt (40 mm length)
3. M6 bolt (100 mm length)
4. M6 bolt (115 mm length)
7. Neutral Switch
T1: 12 N.m (1.2 kgf.m, 104 in.lb)
T2: 36 N.m (3.7 kgf.m, 27 ft.lb)
T3: 20 N.m (2.0 kgf.m, 14 ft.lb)
T4: 9.8 N.m (1.0 kgf.m, 87 in.lb)
T5: 15 N.m (1.5 kgf.m, 11 ft.lb)
T6: 23 N.m (2.3 kgf.m, 17 ft.lb)
T11: 26 N.m (2.7 kgf.m, 19 ft.lb)
G: Apply high-temperature grease.
L: Apply non-permanent locking agent to the threads.
MO: Apply molybdenum disulfide oil.
The molybdenum disulfide oil is a mixture of engine oil and molybdenum disulfide grease with
a weight ratio (10:1).
0: Apply engine oil.
SS: Apply silicon sealant (Kawasaki Bond: 56019-120).

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 7-4 CRANKSHAFTITRANSMISSION
ExplodedView

EI
I
~ ~
i @ GI 020407113 C

2. M6 bolt (40 mm length)'

5. M8 bolt (95 mm length)
6. M6 bolt (105 mm length)
T1: 12 N.m (1.2 kgf.m, 104 in.lb)
T4: 9.8 N.m (1.0 kgf.m, 87 in.lb)
T5: 15 N.m (1.5 kgf.m, 11 ft.lb)
T7: 59 N.m (6.0 kgf.m, 43 ft.lb)
T8: 6.9 N.m (0.7 kgf.m, 61 in.lb)
T9: 5.1 N.m (0.52 kgf.m, 45 in.lb)
T10: 25 N.m (2.5 kgf.m, 18 ft.lb)
T11: 26 N.m (2.7 kgf.m, 19 ft.lb)
C: After tightening, stake it with a punch.
L: Apply non-permanent locking agent to the threads.
LG: Apply silver liquid gasket (Kawasaki Bond: 92104-002).
MO: Apply molybdenum disulfide oil.
The molybdenum disulfide oil is a mixture of engine oil and molybdenum disulfide grease with
a weight ratio (10:1).
0: Apply engine oil.
S: Follow the specific tightening sequence.
SS: Apply silicon sealant (Kawasaki Bond: 56019-120).

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 CRANKSHAFT/TRANSMISSION 7-5
Specifications
Item Standard Service Limit
Crankshaft,ConnectingRods
ConnectingRod Bend - 0.2/100 mm
(0.0079/4 in.)
Connecting Rod Twist - 0.2/100 mm
(0.0079/4 in.)
Connecting Rod Big End Side Clearance 0.15 - 0.30 mm 0.48 mm
(0.0059 - 0.0118 in.) (0.0157 in.)
Connecting Rod Big End Bearing,
Insert/Crankpin Clearance 0.036 - 0.066 mm 0.10 mm
(0.0014 - 0.0026 in.) (0.0039 in.)
Crankpin Diameter: 34.984 - 35.000 mm 34.97 mm
(1.3773 - 1.3780 in.) (1.3768 in.)
Marking None 34.984 - 34.994 mm - --
(1.3773 - 1.3777 in.)
o 34.995 - 35.000 mm - --
(1.3778 - 1.3780 in.)
Connecting Rod Big End Bore Diameter: 38.000 - 38.016 mm - --
(1.3778 - 1.3780 in.)
Marking None 38.000 - 38.008 mm - --
(1.4961 - 1.4964 in.)
o 38.009 - 38.016 mm - --

(1.4964 - 1.4967 in.)

Connecting Rod Big End Bearing Insert

Thickness:
Brown 11.475 - 1.480 mm - --
(0.0581 - 0.0583 in.)
Black 11.480 - 1.485 mm - --
(0.0583 - 0.0585 in.)
Blue 11.485 - 1.490 mm - --
(0.0585- 0.0587 in.)
Connecting rod big end bearing insert selection:

Con-rodBig End
Bore Diameter
Crankpin
Diameter
I Bearing Insert

Marking Marking Size Color Part Number

0 None Blue 92028-1920
0 0 Black 92028-1921
None None
None 0 I Brown I 92028-1922

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 7-6 CRANKSHAFTrrRANSMISSION
Specifications
Item Standard Service Limit
Crankshaft Main Bearing Insert!
Journal Clearance 0.020 - 0.044 mm 0.08 mm
(0.0008 - 0.0017 in.) (0.0032 in.)
Crankshaft Main Journal Diameter: 35.984 - 36.000 mm 35.96 mm
(1.4167 - 1.4173 in.) (1.4157 in.)
Marking None 35.984 - 35.992 mm - --
(1.4167 - 1.4170 in.)
1 35.993 - 36.000 mm - --
(1.4170 - 1.4173 in.)
Crankcase Main Bearing Inside Diameter: 39.000 - 39.016 mm - --
(1.5354 - 1.5361 in.)
Marking 0 39.000 - 39.008 mm - --
(1.5354- 1.5357in.)
None 39.009- 39.016mm - --
(1.5358 - 1.5361 in.)
Crankshaft Main Bearing Insert Thickness:
Brown 1.490 - 1.494 mm - --
(0.0587 - 0.0588 in.)
Black 1.494 - 1.498 mm - --
(0.0588 - 0.0590 in.)
Blue 1.498 - 1.502 mm - --
(0.0590 - 0.0591 in.)
Crankshaft main bearing insert selection:

Crankcase Main Crankshaft Main Bearing Insert

Bearing Inside Jornal Diameter
Diameter Marking Marking Size Color Part Number
0 1 Brown 92028-1919
None None Blue 92028-1917
0 None Black 92028-1918
None 0

Crankshaft Side Clearance 0.05 - 0.15 mm 0.35 mm

(0.0020 - 0.0059 in.) (0.0138 in.)
Crankshaft Runout Less than 0.02 0.05 mm
(0.0008 in.) mm TIR (0.0020 in.) TIR

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 CRANKSHAFTrrRANSMISSION 7-7
Specifications
Item Standard Service Limit
Transmission
Shift Fork Ear Thickness 4.9 - 5.0 mm (0.193 - 0.197 in.) 4.8 mm (0.189 in.)
Gear Shift Fork Groove Width 5.05 - 5.15 mm (0.1988 - 0.2028 in.) 5.25 mm (0.2067 in.)
Shift Fork Guide Pin Diameter:
Drive Shaft 7.985 - 8.000 mm (0.3144 - 0.3150 in.) 7.9 mm (0.311 in.)
Output Shaft 7.900 - 8.000 mm (0.3110 - 0.3150 in.) 7.8 mm (0.307 in.)
Shift Drum Groove Width 8.05 - 8.20 mm (0.3169 - 0.3228 in.) 8.3 mm (0.327 in.)
-
Special Tools Bearing Puller: 57001-135
Outside Circlip Pliers: 57001-144
Bearing Puller Adapter: 57001-317
Gear Pusher & Puller: 57001-319
Bearing Driver, cjJ32: 57001-382
Bearing Driver Set: 57001-1129
Flywheel Holder: 57001-1313
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120
-
Kawasaki Bond (Liquid Gasket Silver): 92104-002

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 7-8 CRANKSHAFTITRANSMISSION
Crankcase Splitting

.CrankcaseSplitting
Remove:
Engine Oil (drain, see Engine LubricationSystem chap-
ter)
Clutch (see Clutch chapter)
Engine Sprocket Cover (see Final Drive chapter)
Alternator Cover (see Electrical System chapter)
Secondary Shaft Nut (see Secondary Shaft and Starter
Clutch chapter)
Alternator Rotor (see Electrical System chapter)
Starter Motor (see Electrical System chapter)
External Shift Mechanism (see External Shift Mecha-
nism Removal)
Crankshaft Sensor, Oil Pressure Switch Wire (see Elec-
trical System chapter)
Timing Rotor (see Electrical System chapter)
Engine (see Engine Removal/Installation chapter)

NOTE
o If the purpose of disassembling the crankcase is to re-
move the crankshaft, all the parts down to the pistons
must be removed before removing the engine (see En-
gine Top End chapter).
. Remove the upper crankcase bolts [A].

. Turn the engine upside down to remove the following:

Oil Filter (see Engine Lubrication System chapter)
Oil Pan (see Engine Lubrication System chapter)
Oil Pump (see Engine Lubrication System chapter)
Starter Clutch Assembly (See Secondary Shaft and
Starter Clutch Removal)
. Remove the 6 mm bolts [A] and 8 mm bolts (10 -+ 1) [8]
from the lower crankcase half.

. Pry the points [A] to separate the mating

remove the lower crankcase half.
surfaces and

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 CRANKSHAFTITRANSMISSION 7-9
Crankcase Splitting
Crankcase Assembly
CAUTION
The upper and lower crankcase halves are ma-
chined at the factory in the assembled state, so
they must be replaced as a set.
Ifthe crankcase halves are replaced with a new one,
measure the diameter of the crankshaft main jour-
nal, and install the proper bearing inserts in accor-
dance with the combination of the new crankcase
and the crankshaft marks.
Replace the lower crankcase 8 mm bolts with new
ones if they have already been removed 5 times.

8 Clean the crankcase mating surfaces with cleaning sol-

vent and wipe them dry.
8 Using Compressed air, blowout the oil passages in the
crankcase halves.
81f the upper primary chain guide [A] is removed, install it.
OApply a non-permanent locking agent to the threads of
the chain guide bolts [B] and tighten them.
Torque - Primary Chain Guide Bolts: 12 N.m (1.2 kgf.m, 104
in.lb) GI040413S1 C

8 Check to make sure that the following parts are in their

correct positions:
8 Upper Crankcase Half:
Knock Pins [A]
Set Rings [B]
Set Pins [C]
Rubber Plug [D] (into the Oil hole of the drive shaft bear-
ing)
Bearing Inserts [E]

81f the lower primary chain guide [A] is removed, install it.
OApply a non-permanent locking agent to the threads of
the chain guide bolts [B] and tighten them.
Torque -Lower Primary Chain Guide Bolts: 12 N.m (1.2
kgf.m, in.lb)

GI040414S1 C

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 7-10 CRANKSHAFTITRANSMISSION
Crankcase Splitting
Lower Crankcase Half: :0.
Bearing Inserts [A]
Shift Mechanism [B]
, " @

. Apply engine oil:

Transmission Gears
Ball Bearings
Shift Drum
. Apply high-temperature grease to the oil seal lip.
. Apply molybdenum disulfide oil to the crankshaft main
bearing inserts inner surfaces.
.Install the transmission shafts in the upper crankcase half.
OAdjust the transmission gears (see Drive Shaft Gear and
Output Shaft Gear Adjustment).

.Install the crankshaft in the upper crankcase half.

OReplace the oil seals [A] with new ones.
OApply high-temperature grease to the oil seal lip.
OPlace the oil seals on the locating portions of the
crankcase (see Crankshaft Installation).
OApply silicone sealant [B] to the circumference of the oil
seal at both ends of the crankshaft.
OBe sure to hang the camshaft and primary chain on the
crankshaft.

. Apply silicon sealant [A] to the mating surface of the lower

crankcase half.
Sealant - Kawasaki Bond: 56019-120
CAUTION

Do no apply liquid gasket and silicone sealant to

any areas not indicated. Take care not to block or
obstruct the oil passage and apply to the crankshaft
main bearing inserts by over-applying. These could
cause engine seizure.
. Place the shift drum in the neutral position [A].

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 CRANKSHAFTfTRANSMISSION 7-11
Crankcase Splitting
. Fit the shift fork ears into the grooves
of the respective
gears, and install the lower crankcase half on the upper
crankcase half.
. Apply molybdenum disulfide oil to the threads and seating
surface of the lower Crankcase 8 mm bolts.
. Tighten the lower crankcase bolts using the following
steps:
OTemporarily tighten all bolts.
OTighten the 8 mm bolts [A] in the sequence (1-10) shown
on the crankcase, in two separate passes. Tighten them
to one-half the specified torque in the first pass, and to
the specified torque in the second pass.
OTighten the 6 mm [B] bolts.
Torque - Lower Crankcase 8 mm Bolts: 25 N.m (2.5 kgf.m,
18 ft.lb)
Lower Crankcase 6 mm Bolts: 12 N.m (1.2 kgf.m,
104 in.lb)

. Tightenthe upper crankcase bolts.

50 mm Length Bolt [A]
40 mm Length Bolt [B]
100 mm Length Bolt [C]
115 mm Length Bolt [D]
Torque -Upper Crankcase 6 mm Bolt: 12 N.m (1.2 kgf.m,
104 in.lb)

GI040416S1 C

. After tightening all the crankcase bolts, check the follow-

ing:
OThe drive shaft and the output shaft rotate smoothly.
OThe gears shift smoothly from 1st to 5th, and from 5th to
1st, while the output shaft is being rotated.
OWhen the output shaft is stationary, the gears can be
shifted to 1st and neutral, but not to 2nd and higher gears.

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 7-12 CRANKSHAFTITRANSMISSION
Crankshaft/Connecting Rod
Crankshaft Removal
. Splitthe crankcase (see Crankcase Splitting).
. Remove the crankshaft, and remove the oil seals [C],
camshaft chain [D],and primarychain [E].

Crankshaft Installation
CAUTION
If the crankshaft, bearing inserts, or crankcase
halves are replaced with new ones, select the bear-
ing inserts and check clearance with a plastigage
(Press Gauge) before assembling engine to be sure
the correct bearing inserts are installed.

. crankshaft.
Place the primary chain and the camshaft chain on the

.. Apply
Replace the crankshaft oil seal with a new one.
high-temperature grease on the seal lip.
NOTE
o Install the oilseal so that the arrow fA] of the outer sur-
face coincides with the positive rotation direction fB] of
the crankshaft.
.. Apply silicon sealant to the left and right sides.
Apply a molybdenum disulfide oil to the crankcase main

. bearing inserts and crankshaft main journals.

Assemble the crankcase (see Crankcase Assembly).
Connecting Rod Removal
. Split the crankcase (see Crankcase Splitting).
. Remove the connecting rod nuts [A].
. Remove the big end cap [B],and remove the connecting
rod.
NOTE
OMark and record the locations of the connecting rods
and their caps so that they can be reassembled in their
originalpositions.

Connecting Rod Installation

CAUTION
To minimize vibration, a pair of connecting rods (left
two rods or right two) should have the same weight
mark (a capital letter of the alphabet).
Big End Cap [A]
Connecting Rod [B]
Weight Mark, Alphabet [C] GI05060151 C

Diameter Mark (AroundWeight Mark) [D]"0" or no mark

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 CRANKSHAFTfTRANSMISSION 7-13
Crankshaft/Connecting Rod
CAUTION
If the connecting rods, bearing inserts, or crank-
shaft are replaced with new ones, select the bearing
insert and check clearance with a plastigage before
assembling engine to be sure the correct bearing
inserts are installed.

. Apply molybdenum disulfide oil to the inside [A] of the big

end bearing inserts.
OThe molybdenum disulfide oil is a mixture of engine oil
and molybdenum disulfide grease with a weight ratio (10
: 1).
*If bearing inserts are replaced, install them as follows.
ODo not apply molybdenum disulfide oil to the outside [B]
of the inserts or the inside [C] of the connecting rod and
cap. GI05042251 C

Olnstall the inserts so that their nails [D] are on the same
side and fit into the recess of the connecting rod and cap.

OWhen installing the inserts [A], be careful not to damage

the insert surface with the edge of the connecting rod [B]
or the cap [C]. One way to install inserts is as follows:
Installation [D] to Cap
Installation [E] to Connecting Rod
Push [F]
Dowel Pin [G]
Connecting Rod Bolts [H]
.Install the cap on the connecting rod, aligning the weight
and diameter marks.
. Remove debris and clean the surface of inserts.
. Apply molybdenum disulfide oil [MO] to the threads and
seating surface of the big end nuts.
. Tighten the big end nuts to the specified torque.
Torque - Connecting Rod Big End Cap Nuts: 36 N.m (3.7
kgf.m, 27 tt.lb)

.Crankshaft/Connecting Rod Cleaning

After removing the connecting rods from the crankshaft
clean them with a high flash-point solvent.
. Blow the crankshaft oil passages with compressed air to
remove any foreign particles or residue that may have
accumulated in the passages.

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 7-14 CRANKSHAFTITRANSMISSION
Crankshaft/Connecting Rod
ConnectingRod Bend
. Remove the connecting rod big end bearing inserts, and
reinstall the connecting rod big end cap.
. Select an arbor [A] of the same diameter as the connect-
ing rod big end, and insert the arbor through the connect-
ing rod big end.
. Select an arbor [8] of the same diameter as the piston
pin and at least 100 mm (4 in.) long, and insert the arbor
through the connecting rod small end.
. On a surface plate, set the big-end arbor on V block [C].
GI 05040651 C

. With the connecting rod held vertically, use a height

gauge to measure the difference in the height of the
arbor above the surface plate over a 100 mm (4 in.)
length to determine the amount of connecting rod bend.
Connecting Rod Bend
Standard: 0.21100 mm (0.0079/4 in.)
*If connecting rod bend exceeds the service limit, the con-
necting rod must be replaced.

Connecting Rod Twist

. With the big-end arbor [A] still on V block [C], hold the
connecting rod horizontally and measure the amount that
the small end arbor [8] varies from being parallel with the
surface plate over a 100 mm (4 in.) length of the arbor to
determine the amount of connecting rod twist.
Connecting Rod Twist
Standard: 0.21100mm (0.0079/4in.)
* If connecting rod twist exceeds the service limit, the con- GI05040751 C

necting rod must be replaced.

Connecting Rod Big End Side Clearance

.Insert a thickness gauge [A] between the big end [8] and
either crank web to determine clearance.

Connecting Rod Big End Side Clearance

Standard: 0.15 - 0.30 mm (0.0059- 0.0118in.)
Service Limit: 0.48 mm (0.0157 in.)
*If clearance exceeds the service limit, replace the con-
necting rod with a new one and then check clearance
again. If clearance is too large after connecting rod re-
placement, the crankshaft must be replaced also.

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 CRANKSHAFTITRANSMISSION 7-15
Crankshaft/Connecting Rod
Connecting Rod Big End Bearing Insert/Crankpin
Wear
.Insert a strip of Plastigage [A]to measure the clearance
between the bearing and the crankpin [8].
NOTE
o Tighten the connecting rodbig end cap nuts to the spec-
ified torque [36 N.m (3.7 kgf.m, 27 ft.lb)].
o Do not move the connecting rod while measuring the
clearance.

Connecting Rod Big End Bearing InsertlCrankpin

Clearance
Standard: 0.036 - 0.066 mm (0.0014 - 0.0026 in.)
Service Limit: 0.10 mm ( 0.0039 in.)
*If the clearance is withinthe standard, no bearing replace-
ment is required.
*If the clearance is between 0.067 mm and the service
limit, replace the bearing with bearing painted blue [A],
and remeasure the clearance. The clearance may ex-
ceed the upper limitslightly, but it must not be less than
the minimum in order to avoid bearing seizure.
*If the clearance exceeds the service limit, measure the
diameter of the crankpins.
Crankpin Diameter
Standard: 34.984- 35.000mm (1.3773- 1.3780in.) G1050417S1 C

Service Limit: 34.97 mm (1.3768in.)

* Ifany crankpin has worn past the service limit,replace the

crankshaft with a new one.
* If the measured crankpin diameters are within the ser-
vice limit, but have worn to the extent that they do not
coincide withthe original diameter markings on the crank-
shaft, make new marks.
Crankpin Diameter Marks
None: 34.984 - 34.994mm (1.3773- 1.3777in.)
0: 34.995- 35.000mm(1.3778- 1.3780in.)

#1 #2 #3 #4

GI 05042211 1 C

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 7-16 CRANKSHAFTfTRANSMISSION
Crankshaft/Connecting Rod
. Measure the inside diameter of the connecting rod big
ends, and mark them in accordance with the inside di-
ameter.
0: Crank pin Diameter mark (around weight classifica-
tion mark) [A]:11011 or no mark
NOTE
o Tighten the connecting rod big end cap nuts to the spec-
ified torque [36 N.m (3.7 kgf.m, 27 ft.lb)).
o The mark indicated on the connecting rod should be
practically no different from the measurement.

Connecting Rod Big End Inside Diameter Marks

None: 38.000- 38.008mm (1.4961- 1.4964in.)
0: 38.009- 38.016mm (1.4964- 1.4967in.)

. Select the proper bearing insert [A]in accordance with the

combination of the connecting rod and crankshaft mark-
ings.
Size Color [8]
Connecting Bearing Insert
Crankpin
Rod Big End Diameter Thickness
Inside Diameter Mark
Marking Part Number
Marking (Size Color)
GI050417S1 C
0 None Blue 92028-1920
0 0
Black 92028-1921
None None
None 0 Brown 92028-1922
.Install a new inserts in the connecting rod and measure
the clearance between the inserts and the crankpin.
Crankshaft Main Journal/Bearing Insert Wear
. Using a strip of Plastigage (press gauge) [A],measure the
clearance between the journal [8] and the bearing insert.
NOTE
o Tighten the crankcase bolts to the specified torque [M8:
25 N.m (2.5 kgf.m, 18 ft.lb), M6: 12 N.m (1.2 kgf.m, 104
in.lb)).
o Do not move the crankshaft during clearance measure-
ment.
OJournal clearance less than 0.025 mm can not be mea-
sured by plastigauge, however, using genuine parts
maintains the minimum standard clearance.

Crankshaft Main Journal/Bearing Insert Clearance

Standard: 0.020 mm - 0.044mm
(0.0008 - 0.0017 in.)
Service Limit: 0.08 mm (0.0032 in.)
* If clearance is within the standard, no bearing replace-
ment is required.

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 CRANKSHAFTrrRANSMISSION 7-17
Crankshaft/Connecting Rod
*If the clearance is between 0.045 mm and the service
limit, replace the bearing inserts [A] with bearing inserts
painted blue [B], and remeasure the clearance. The clear-
ance may exceed the standard slightly, but it must not be
less than the minimum in order to avoid bearing seizure.
*If the clearance exceeds the service limit, measure the
diameter of the crankshaft main journal.
Crankshaft Main Journal Diameter
Standard: 35.984- 36.000 mm GI05041151 C

(1.4167 -1.4173 in.)

Service Limit: 35.96 mm (1.4157 in.)

81f the main journal is worn beyond the service limit, re-
place the crankshaft with a new one.
8 If the measured main journal diameters are within the ser-
vice limit, but have worn to the extent that they do not
coincide with the original diameter markings [A] on the
crankshaft, make new marks.
0: Crankshaft Main Journal Diameter Marks, "1" or no
mark.
Crankshaft Main Journal Diameter Marks
None: 35.984 - 35.992 mm (1.4167 -1.4170 in.)
1: 35.993 - 36.000 mm (1.4170 -1.4173 in.)

#2 #3 #4

GI 05042311 C

8 Measure the crankcase main bearing inside diameter,

and mark [A] the upper crankcase half in accordance
with the measured inside diameter.
Crankcase Main Bearing Inside Diameter Marks [A]: 0 II II

or none
NOTE
o Tighten the crankcase bolts to the specified torque [M8:
25 N.m (2.5 kgf.m, 18 ft.lb), M6: 12 N.m (1.2 kgf.m, 104
in.lb)).
o The mark indicated on the upper crankcase half should
be practically no different from the measurement.

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 7-18 CRANKSHAFTfTRANSMISSION
Crankshaft/Connecting Rod
Crankcase Main Bearing Inside Diameter Marks
0: 39.000 - 39.008 mm(1.5354- 1.5357in.)
None: 39.009- 39.016 mm (1.5358- 1.5361 in.)
. Select the proper bearing insert [A] in accordance with the
combination of the crankcase and crankshaft markings.
Size Color [8]
Crankcase Crankshaft Bearing Insert
Main Bearing Main Journal Thickness 6105041751 C
Inside Diameter Diameter Mark
Part Number
Marking Marking (Size Color)
0 1 Brown 92028-1919
None None Blue 92028-1917
0 None
Black 92028-1918
None 1
.Install new inserts in the crankcase and measure the
clearance between the journal and the inside diameter.
Crankshaft Runout
. Set the crankshaft with a flywheel alignment jig or on V
blocks.
.. Set a dial gauge against the points indicated.
Turn the crankshaft slowly to measure the runout. The dif-
ference between the highest and lowest dial gauge read-
ing (TIR) is the amount of runout.
Crankshaft Runout
Standard: TIR Less than 0.02 mm (0.0008 in.) 6105042451 C

Service Limit: TIR 0.05 mm (0.0020 in.)

* If the measurement exceeds the service limit, replace the
crankshaft.

Crankshaft Side Clearance

.Insert a thickness gauge [A] between the crankcase main
bearing and the crank web [8] at the No.2 journal to de-
termine clearance.
Crankshaft Side Clearance
Standard: -
0.05 0.15 mm (0.0020 - 0.0059 in.)
Service Limit: 0.35 mm (0.0138 in.)
* If the clearance exceeds the service limit, replace the
crankcase assembly as a set.
NOTE
o The upper crankcase half, lower crankcase half, and
main bearing are machined at the factory in the assem-
bled state, so they must be replaced as a set.

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 CRANKSHAFTfTRANSMISSION 7-19
Secondary Shaft and Starter Clutch
Secondary Shaft Removal
. Remove:
EngineOil (drain, see Engine Lubrication System chap-
ter)
Exhaust Pipe (see Engine Top End chapter)
Engine Sprocket Cover (see Final Drive chapter)
Clutch (see Clutch chapter)
Oil Pump (see Engine Lubrication System chapter)
Alternator Cover (see Electrical System chapter)
. Remove the secondary shaft bearing cap [A].

. Remove the secondary shaft nut [A].

NOTE
o Hold the alternator rotor to prevent the secondary shaft
from turning.

Special Tool - Flywheel Holder: 57001-1313 [B)

. Remove the secondary shaft bearing holder screws [A].

The two out of the three screws are used in common with
the oil pump mounting screws.

. Remove the tensioner holder [A].

. Replace the tensioner holder with a new one.

. Tap on the secondary shaft [A] from the left of the

crankcase to remove the left bearing of the shaft from
the case. The left bearing of the shaft has the collar [8].

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 7-20 CRANKSHAFTITRANSMISSION
Secondary Shaft and Starter Clutch
. Support the secondary sprocket [A] and the starter clutch
assembly [8], and pull out the secondary shaft [C]. There
is a washer [D] between the starter clutch assembly and
the shaft.
. Remove the secondary sprocket and the starter clutch
assembly from the primary chain [E].

. Remove the circlip from the secondary shaft.

Special Tool - Outside Circlip Pliers: 57001-144
. Remove the secondary shaft gear [A], and remove the
washer.
OHave three 8 mm bolts [8] ready.
Special Tools -Gear Pusher & Puller: 57001-319 [C]
Bearing Puller Adapter: 57001-317 [0]

. Remove the ball bearing from the right side of the sec-
ondary shaft.
Special Tools -Bearing Puller: 57001-135 [A]
Bearing Puller Adapter: 57001-317 [B]

.Secondary Shaft Installation

Replace the left ball bearing of the secondary shaft with a
new one, and drive it in 10.7 - 11.3 mm (0.42 - 0.44 in.)
[A] from the outside of the crankcase.
Special Tool- Bearing Driver Set: 57001-1129

. Replace the right ball bearing of the secondary shaft with

a new one, and drive it onto the shaft.
Special Tool - Bearing Driver, cjJ32:57001-382 [A]

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 CRANKSHAFTfTRANSMISSION 7-21
Secondary Shaft and Starter Clutch
. Place the primary chain on the secondary sprocket and
the starter clutch assembly. Through the chain, insert the
secondary shaft with a washer from the right side of the
crankcase.
.Insert a collar in the left bearing of the shaft.
. Drive the right bearing [A] of the shaft into the crankcase
until it bottoms out.
Special Tool - Bearing Driver, 4J32: 57001-382 [B]

.Install the bearing holder and stake the heads of the

screws.
Olnstall the oil pump.
. Place the washer [A] over the secondary shaft and install
the gear [8].
Special Tool - Gear Pusher & Puller: 57001-319 [C]

NOTE
OApply engine oil to the secondary shaft and to the
area between the secondary shaft gear and the gear
pusher/puller. Use the flywheel holder (special tool:
57001-1313) on the alternator rotor to prevent the
secondary shaft from turning.
.Install a new circlip.
SpecialTool- OutsideCirclip Pliers: 57001-144
. Check that the collar [A] is placed on the left of the sec-
ondary shaft, and tighten the secondary shaft nut.
Torque - Secondary Shaft Nut: 59 N.m (6.0 kgf.m, 43 ft.lb)
NOTE
OHold the alternator rotor to prevent the secondary shaft
. from turning.
Special Tool - Flywheel Holder: 57001-1313

.Install the secondary shaft bearing cap and run the wires
properly (see General Information chapter).
Torque -Cap Screws: 9.8 N.m (1.0 kgf.m, 87 in.lb)
.Install the spring and pin into the tensioner holder.
. Tighten the holder.
Torque - Tensioner Holder: 26 N.m (2.7 kgf.m, 20 ft.lb)
.Install the removed parts.

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 7-22 CRANKSHAFTfTRANSMISSION
Secondary Shaft and Starter Clutch
Starter Clutch Disassembly
. Remove:
Starter Clutch Gear [A]
Needle Bearing [B]
Washer [C]

. To prevent the gears from damage, use a suitable com-

mercially available tool [A] to hold the gear securely, and
remove the bolt [B].
One-Way Clutch Race [0]
One-Way Clutch [C]

. Remove the circlip [A], and take out the secondary

sprocket [B] from the inner coupling [C]. There are eight
rubber dampers between the secondary sprocket and
the inner coupling.
Special Tool - Outside Circlip Pliers: 57001-144

Starter Clutch Assembly

.Install the starter clutch on the inner coupling.
OApply non-permanent locking agent to the threads of the
mounting bolts.
-
Torque Starter Clutch Mounting Bolts: 12 N.m (1.2 kgf.m,
104 ft.lb)
.Inspect the rubber dampers [B], and replace it if it is dam-
aged.
. Apply a small amount of engine oil on the rubber dampers,
and assemble the inner coupling [A] and the secondary
sprocket [C].
Olnstall a new circlip.
Special Tool - Outside Circlip Pliers: 57001-144

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 CRANKSHAFTrrRANSMISSION 7-23
Secondary Shaft and Starter Clutch
.Install the spring, spring cap, and roller on the starter
clutch.
. After installing the washer, install the starter clutch gear
on the clutch while turning the starter clutch gear counter-
clockwise [A].
OApply engine oil on the needle bearings and install them
in the starter clutch gear.

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 7-24 CRANKSHAFTfTRANSMISSION
Transmission
Shift Pedal Removal
. Remove the mounting bolt [8] and take out the shift lever
[A] from the shift shaft [C].
NOTE
OMark the shift shaft so that the shift lever can be rein-
stalled in its original position.
. Remove the pivot bolt [D] and take out the shift pedal
assembly.

Shift Pedal Installation

.Install the oil seals [A] direction as shown.
. Apply grease [8] to the pivot portion of the pivot bolt [C]
and tighten it.
Washer [D]
Sift Pedal [E]
Torque - Shift Pedal Pivot Bolt: 23 N.m (2.3 kgf.m, 17 ft.lb)

GI130419S2 C

.Install the shift pedal assembly so that the shift link rod
and the pedal are parallel and the shift lever and the shift
pedal arm form an angle of approximately 90° [A].
NOTE
o The locknut next to the knurled portion of the rod has
left-hand threads.
* Ifnecessary, adjust the pedal position from the standard
positionto suit your as follows.
. Loosen the locknuts [8] and turn the rod to adjust the
angle.
. Tighten the locknuts securely.
External Shift Mechanism Removal
. Remove:
Shift Lever (see Shift Pedal Removal)
Engine Sprocket Cover (see Final Drive chapter)
Engine Sprocket (see Final Drive chapter)
Neutral Switch Wire Connector [A]
Side Stand Switch [8]
External Shift Mechanism Cover [C]
NOTE
o Place an oil drain pan under the cover.

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 CRANKSHAFTrrRANSMISSION 7-25
Transmission
. Remove the shift arm [A] and the overshift limiter [8] from
the shift drum pin, pull out the shift shaft [C], and remove
the external shift mechanism.
CAUTION
Do not pull the shift rod [D] out of crankcase, or
the shift forks inside the crankcase will fall to the
bottom of the oil pan, requiring removal of the
crankcase to install them.

External Shift Mechanism Installation

.If the shift drum pin has been removed, install it so that
the long pin [A] is positioned in the third hole clockwise
from the hole [8].
Olnstall the pin plate by inserting the long pin into the hole
[C] without the round edge.
OApply non-permanent locking agent to the threads of the
pin plate screw.

.Inspect the tightening condition of the return spring pin

[A].
*Remove it if it is loose, apply non-permanent locking
agent to the threads, and tighten it.
Torque - Return Spring Pin: 20 N.m (2.0 kgf.m, 14 tt.lb)

. Make sure that the return spring [A] and the ball spring [8]
are properly installed, and install the external shift mech-
anism.
OEngage the shift arm and the overshift limiter with the shift
drum pin.

. Apply silicon sealant [A] to the mating surfaces of the

crankcase and the external shift mechanism cover gas-
ket.
Sealant- KawasakiBond(Silicon Sealant): 56019-120

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 7-26 CRANKSHAFTITRANSMISSION
Transmission
. Install the external shift mechanism
cover.
OReplace the cover gasket with a new one.
OApply non-permanent locking agent to the cover bolt (35
mm length bolts only).
NOTE
OApp/y high-temperature grease to the oil sea/lip.
Torque - External
Shift Mechanism Cover Bolts: 9.8 N.m
(1.0 kgf.m, 87 in.lb)
.Install the side stand switch.
OApply non-permanent locking agent to the mounting bolts.
-
Torque Side Stand Switch Mounting Bolts: 3.9 N.m (0.4
kgf.m, 35 in.lb)
. Check:
Drive chain slack (see Final Drive chapter)
Engine oil level (see Engine Lubrication System chapter)

.*External Shift Mechanism Inspection

Examine the shift shaft for any damage.
If the shaft is bent, straighten or replace it.
*If the serration are damaged, replace the shaft.
* If the springs [A] [8] are damaged in any way, replace
them.
* If the shift mechanism arms are damaged in any way,
replace the arm.

. Check the return spring pin [A] is not loose.

*If it is loose, unscrew it, apply a non-permanent locking
agent to the threads, and tighten it.
Torque - Return Spring Pin: 20 N.m (2.0 kgf.m, 14 ft.lb)
. Visually inspect the shift drum pin and pin plate.
* If they are badly worn or if they show any damage, replace
them.

Transmission Shaft Removal

. Split the crankcase halves (see Crankcase Splitting).
. Take out the drive shaft [A] and the output shaft [8].

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 CRANKSHAFTrrRANSMISSION 7-27
Transmission
Transmission Shaft Installation
. Adjust the transmission gears (see Drive and Output
Shaft Adjustment).
. Engage the hole in the needle bearing of the transmission
shaft with the set pin [A], and engage the groove in the
outer race of the ball bearing with the set ring [B].
. Apply engine oil:
Transmission Gears
Ball Bearings
. Assemble the crankcase (see Crankcase Assembly).

.Transmission Shaft Disassembly

Remove the transmission shafts.
. Remove the circlip and take out the gears.
Special Tool - Outside Circlip Pliers: 57001-144
.The 4th gear on the output shaft has three balls assem-
bled into it for the positive neutral finder mechanism.
.Remove the output shaft 4th gear as follows:
OHoid the 3rd gear [A] with one hand, and place the output
shaft upright.
OQuickly spin the 4th gear [B] and pull it upward while the
internal steel balls move outward by the centrifugal force.

. Remove the ball bearing [A].

-
Special Tools Bearing Puller: 57001-135 [B]
Bearing Puller Adapter: 57001-317 [C]
(Adapter to be used only for the drive shaft
bearing.)
. Discard the bearing.

..Transmission Assembly
Replace the ball bearing with a new one.
Apply engine oil to the ball bearing and shaft.
NOTE
Olnstal the bearings so that the marked side faces out.
Special Tool - Bearing Driver, 4>32: 57001-382 [A]

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 7-28 CRANKSHAFTITRANSMISSION
Transmission
. Make
one.
sure to replace the removed circlip [A] with a new B
OAlign the gap [B] of the circlip with the groove [C] of the
spline.
Special Tool - Outside Circlip Pliers: 57001-144

GI13042351 C

. To install the gear bushings on the shafts align the bush-

ing's oil hole [A] with the shaft's oil hole [B].

G113040851 C

. The drive shaft gears are from the 1st to the 5th gears,
from the smallest to the largest diameter. Install them in
the following sequence, while ensuring their correct ori-
entation:
Be sure that all parts and put back in the correct sequence
and all circlips and washers are properly in place.
. The output shaft gears are from the 1st to the 5th gears,
from the largest to the smallest diameter.
Be sure that all parts are put back in the correct sequence
and all circlips and washers are properly in place.

. Fit the steel balls into the 4th gear holes of the output shaft
as shown.
Gear (4th) [A]
Shaft [B]
Steel Balls [C]
CAUTION
When installing the 4th gear and steel balls on the
output shaft, do not apply grease to the balls to hold G113060851 C

them in place. This will cause the positive neutral

finder mechanism to malfunction.
OAfter assembling the 4th gear, move the gear in the direc-
tion of the shaft to check the ball-locking effect (so that
the gear does not come out of the shaft).
.After assembly, make sure that the gears spin and slide
properly.

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 CRANKSHAFTrrRANSMISSION 7-29
Transmission

G 1130424W3 C

1. Ball Bearing
14. Bushing
2. Circlip 15. 1st Gear
3. Bearing Outer Race
16. Busing
4. Needle Bearing 17. Toothed Washer
5. 2nd Gear
18. 2nd Gear
6. Thrust Washer (Spacer)
19. Circlip
7. 5th (Top) Gear
20. 5th (Top) Gear
8. Bushing 21. 3rd Gear
9. Toothed Washer
22. Steel Ball
10. Circlip 23. 4th Gear
11. 3rd Gear
24. 1st Gear
12. 4th Gear
25. Bearing Outer Race
13. Toothed Washer
Drive shaft Gear Adjustment
.Initially, install the standard 1 mm (0.04 in.) thick washer
[B] on the left of the 2nd gear [A].
.Install the drive shaft in the upper crankcase half.
OMake sure that the ball bearing and the needle bearing
are properly engaged in the set ring and the set pin.
. Turn the drive shaft by hand [C] to check that it turns
smoothly.
* If it still does not turn smoothly, replace the washer with
one that is 0.5 mm (0.02 in.) thick.

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 7-30 CRANKSHAFTrrRANSMISSION
Transmission

Output Shaft Gear Adjustment

. Initially, install the standard 1 mm (0.04 in.) thick washer
[8] on the right of the 1st gear [A].
.Install the output shaft in the upper crankcase half.
OMake sure that the ball bearing and the needle bearing
are properly engaged in the set ring and the set pin.
. Turn [C] the 1st gear by hand to check that it turns
smoothly.
* If it does not turn smoothly, replace the washer with one
that is 0.5 mm (0.02 in.) thick.
NOTE
o The adjustment washers are applicable for both shafts.
Shift Fork and Shift Drum Removal
. Disassemble the crankcase (see Crankcase Splitting).
. Pull out the shift rod [A] from the lower crankcase half and
remove the two shift forks [8].

. the
Remove the shift drum positioning bolt [A] and take out
spring and the pin.
. bolt
Flatten the lock washer and take out the shift drum guide
[8].
. Remove the cotter pin [C] and pull out the guide pin [0].

. Remove the circlip and take out the shift drum cam [A].
Special Tool - Outside Circlip Pliers: 57001-144
. Pull out the shift drum [8] and take out the 4th/5th shift
fork [C].

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 CRANKSHAFTITRANSMISSION 7-31
Transmission
Shift Fork/Shift Drum Installation
.Install the drive shaft 4th/5th shift fork with the shorter
flange [A]facing the pin plate [8].

.Install the shift drum cam [A]by aligning it with the drive
pin [8].
OSecure it with a new circlip.
Special Tool- Outside Circlip Pliers: 57001-144

.Install the guide pin in the 4th/5th shift fork.

OFit the guide pin [A] into the center groove of the shift
drum.
OPush the new cotter pin [8] from the opposite side of the
shift drum cam, and bend the longer end of the pin inward.

. Aftertightening
washer [8].
the shift drum guide bolt [A],bend the lock

-
Torque Shift Drum Guide Bolt: 26 N.m (2.7 kgf.m, 19 ft.lb)

.Install the shift drum positioning pin, spring, and bolt.

-
Torque Shift Drum Positioning Bolt: 26 N.m (2.7 kgf.m, 19
ft.lb)
. Set the shift drum in the neutral position [A].

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 7-32 CRANKSHAFTITRANSMISSION
Transmission
. Install the output shaft 2nd/3rd shift fork [A] and the 1st
shift fork [B]. These shift forks are identical parts.
OApply engine oil to the shift rod [C] and the ear of the fork.
Olnstall a new circlip on the shift rod and insert it from the
left of the case.
-
Special Tool Outside Circlip Pliers: 57001-144
Olnstall the shift fork on the rod, starting with the shift fork
with the longer flange [D].
OPush the rod while engaging the guide pin [E] into the
groove of the shift drum.
Shift Fork Bending
. Visually inspect the shift forks, and replace any fork that is
bent. A bent fork could cause difficulty in shifting, or allow
the transmission to jump out of gear when under power.
[A] 90°

GI13014551 C

Shift Fork Ear/Gear Shift Fork Groove Wear

. Measure the thickness [A] of the shift fork ears, and mea-
sure the width [B] of the shift fork grooves on the trans-
mission gears.
* If the thickness of a shift fork ear is less than the service
limit, the shift fork must be replaced.
Shift Fork Ear Thickness
Standard: 4.9 - 5.0 mm (0.193 - 0.197 in.)
Service Limit: 4.8 mm (0.189 in.)
* If a gear forkgroove is worn over the service limit, the
gear must be replaced.
Gear Shift Fork Groove Width
Standard: 5.05- 5.15 mm (0.1988- 0.2028 in.)
Service Limit: 5.3 mm (0.2067 in.)

Shift Fork Guide Pin/Shift Drum Groove Wear

. Measure the diameter [A] of each shift fork guide pin, and
measure the width [B] of each shift drum groove.
* If the guide pin on any shift fork is less than the service
limit, the fork must be replaced.
Shift Fork Guide Pin Diameter
Standard: Drive shaft - 7.985- 8.000mm
(0.3144 - 0.3150 in.)
-
Output shaft 7.900- 8.000 mm
(0.3110 - 0.3150 in.)
Service Limit: Drive shaft -7.9mm (0.311 in.)
Output shaft - 7.8 mm (0.307 in.)

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 CRANKSHAFTrrRANSMISSION 7-33
Transmission
*If any shift drum groove is worn over the service limit, the
drum must be replaced.
Shift Drum Groove Width
Standard: 8.05- 8.20 mm (0.3169- 0.3228in.)
Service Limit: 8.3 mm (0.327in.)

Gear Dog/Gear Dog Hole Damage

.*Visually inspect the gear dogs [A] and gear dog holes [8].
Replace any damaged gears or gears with excessively
worn dogs or dog holes.

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 7-34 CRANKSHAFTITRANSMISSION
Ball Bearing, Needle Bearing, and Oil Seal
Ball and Needle Bearing Wear
CAUTION
Do not remove the ball bearings for inspection. Re-
moval may damage them.
.OSince
Check the ball bearings.
the ball bearings are made to extremely close toler-
ances, the wear must be judged by feel rather than mea-
surement. Clean each bearing in a high-flash point sol- GI130149S1 C

vent, dry it (do not spin the bearing while it is dry), and oil
it with engine oil.
OSpin [A]the bearing by hand to check its condition.
* Ifthe bearing is noisy, does not spin smoothly, or has any
rough spots, replace it.
. Check the needle bearings.
OThe rollers in a needle bearing normally wear very little,
and wear is difficultto measure. Instead of measuring,
inspect the bearing for abrasion, color change, or other
damage.
* Ifthere is any doubt as to the condition of a needle bear-
ing, replace it.
Oil Seal Inspection
. Inspect the oil seal.
OReplace itifthe lips are misshapen, discolored (indicating
that the rubber has deteriorated), hardened or otherwise
damaged.

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 WHEELSITIRES 8-1

WheelslTires
Table of Contents
Exploded View........................................................................................................................ 8-2
Specifications ......... 8-3
Wheels ............ 8-4
Front Wheel Removal....................................................................................................... 8-4
Front Wheel Installation.................................................................................................... 8-4
Rear Wheel Removal........................................................................................................ 8-5
Rear Wheel Installation ... ........ 8-6
Wheel Inspection .............................................................................................................. 8-7
Axle Inspection ~ .... ................... ......... ..... .......... .... ...... 8-7
Balance Inspection............................................................................................................ 8-7
Balance Adjustment.......................................................................................................... 8-8
Balance Weight Removal.................................................................................................. 8-8
Balance Weight Installation............................................................................................... 8-8
Tires.. .. .... .... .. ....................... ........... .... ............ ...... ......... ....... ..... ... 8-10
Air Pressure Inspection and Adjustment........................................................................... 8-10
Tire Inspection .................................................................................................................. 8-10
Tire Removal.. ...... 8-11
Tire Installation.................................................................................................................. 8-11
TireRepair ...... 8-13
Hub Bearing (Wheel Bearing)................................................................................................. 8-14
Hub Bearing Removal ............................................................................................... 8-14
Bearing Installation ........................................................................................................... 8-14
Hub Bearing Inspection..................................................................................................... 8-15
Bearing Lubrication........................................................................................................... 8-15
Speedometer Gear Housing................................................................................................... 8-16
Disassembly/Assembly . 8-16
Lubrication ........................................................................................................................ 8-16

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 8-2 WHEELSrrlRES
Exploded View

GJ020403W4 C

1. Front Axle Clamp Bolts

2. Front Axle
3. Rear Axle Nut
4. Rear Axle Nut Cotter Pin
T1: 20 N.m (2.0 kgt.m, 14 tt.lb)
T2: 98 N.m (10 kgt.m, 72 ft.lb)
T3: 110 N.m (11 kgt.m, 81 tt.lb)
G: Apply grease
R: Replacement Parts.
WL: Apply soap and water solution or rubber lubricant.

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 WHEELsrrlRES 8-3
Specifications
Item Standard Service Limit
Wheels (Rims)
Rim Runout:
Axial --- 0.5 mm (0.020 in.)
Radial 0.8 mm (0.031 in.)
Axle Runout/100
mm Under 0.05 mm (0.0020 in.) 0.2 mm (0.008 in.)

(4 in.)
ZR750-H1 - H2 ZR750-H3 - H5
Tires
Air Pressure
(when cold):
Front Up to 182 kg (401 Ib) load: - --
250 kPa (2.5kgf/cm2, 36 psi)
Rear - --
Up to 182 kg (401 Ib) load:
250 kPa (2.5kgf/cm2, 36 psi)
Tread Depth:
Front 4.3 mm (0.17 in.) 1 mm (0.04 in.)
AR, FG, ST 1.6 mm (0.062 in.)
Rear 7 mm (0.28 in.) Up to 130 km/h (80 mph):
2 mm (0.08 in.)
Over 130 km/h (80 mph):
3 mm (0.12 in.)
Standard Tires:
Front 120/70 ZR17 120/70 ZR 17 M/C - --
(58W) (58W)
BRIDGESTONE BT020 F RADIAL J
DUNLOP D220F ST
MICHELIN MACADAM 100X
Rear 160/60 ZR17 160/60 ZR 17 M/C - --
(69W) (69W)
BRIDGESTONE BT020 R RADIAL
DUNLOP D220F ST
MICHELIN MACADAM 100X
AR: Austria
FG: Germany
ST: Switzerland

Use the same manufacturer's tires on both front and rear wheels.
Special Tools -Inside Circlip Pliers: 57001-143
Bearing Driver Set: 57001-1129
Jack: 57001-1238
Bearing Remover Shaft: 57001-1377
Bearing Remover Head, cp 15 x cp 17: 57001-1267
Bearing Remover Head, cp20 x cp22: 57001-1293

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 8-4 WHEELSITIRES
Wheels

.Front Wheel Removal

Remove:
Speedometer Cable, lower end [A]
LeftFront Brake Caliper (remove the mounting bolts and
take the caliper out of the disc) [B]

Right Front AxleClamp Bolts (loosen) [A]

Front Axle (loosen) [B]

. Raise the front wheel off the ground.

Special Tool- Jack: 57001-1238[A]

., Pull out the front axle and remove the front wheel.
CAUTION
Do not lay the wheel down on one of the discs. This
can damage or warp the disc. Place blocks un-
der the wheel so that the disc does not touch the
ground.

Front Wheel Installation

.If the speedometer gear housing is removed, engage the
protrusion [A] inside the speedometer gear housing with
the cutout [B] in the gear drive of the wheel.

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 WHEELSITIRES 8-5
Wheels

8 Place the stop [A] of the speedometer gear housing be-

tween the stops [8] of the fork.
8 Install the collar on the right side of the hub.
8 Install the axle from the right side.
Torque - FrontAxle: 98 N.m (10 kgf.m, 72 ft.lb)
Front Axle Clamp Bolts: 20 N.m (2.0 kgf.m, 14 ft.lb)
Front Caliper Mounting Bolts: 34 N.m (3.5 kgf.m,
25 ft.lb)
NOTE
o Tighten the two clamp bolts alternately two times toen-
sure even tightening torque.
o Tighten the top plug before tightening the upper fork
clamp bolt.
8 Check the effectiveness of the brake.
A 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 Wheel Removal

8 Set the motorcycle on its center stand and raise the rear
wheel off the ground.
8 Loosen the drive chain (see Final Drive chapter).
8 Remove the cotter pin [A] and the rear axle nut [8].

8 Take out the chain [A] to the left side of the rear sprocket.
8 Remove the rear axle.
8 Pull the rear wheel [8] to the back to take it out of the rear
caliper.
CAUTION
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.

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 8-6 WHEELSrrlRES
Wheels
Rear Wheel Installation
8 Fitthe caliper bracket [A]over the swingarm stop [B].
OApplygrease to the lipof the grease seal.
8 Place the drive chain on the sprocket and install the
wheel.
Olnsert both collars.
Olnsert the axle from the right side.
OAdjust the drive chain slack (see Final Drive chapter).
Torque - Rear Axle Nut: 108 N.m(11 kgf.m,80 ft.lb)

8 Insert a new cotter pin [A].

NOTE
o 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 fB] up to next alignment.
Olt should be within30 degree.
o Loosen once and tighten again when the slot goes past
the nearest hole.
GJ04071851 C

8 Bend the cotter pin [A]over the nut.

c:>

G512012851 C

8 Check the effectiveness of the rear brake.

A 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.

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 WHEELsrrlRES 8-7
Wheels

.Wheel Inspection
Raise the front or rear wheel.
Special Tool - Jack: 57001-1238
. Turn the wheel by hand to check that it turns smoothly
without making a noise.
*If any abnormal condition is found, replace the hub bear-
ings.

. Check the rim for cracks, dents, bend, or warpage.

*If there is any damage to the wheel, replace the wheel.
.. Remove the wheel, and replace the tire.
Using a dial gauge, measure the radial [A] and axial [8]
rim runout.
OThe difference (TIR) between the maximum and minimum
values read on the dial gauge is the amount of runout.
* If rim runout exceeds the service limit, inspect the bear-
ings. If the problem is not due to the bearings, replace
the wheel.
GJ040612S2 C
Rim Runout
Item Service Limit
Axial Runout TIR 0.5 mm (0.020 in.)
Radial Runout TIR 0.8 mm (0.031 in.)

A
WARNING
Never attempt to repair a damaged wheel. If there
is any damage besides wheel bearings, the wheel
must be replaced to insure safe operational condi-
tion.
Axle Inspection
. Visually inspect the front and rear axles.
*If the axle is cracked, damaged, or bent, replace it.
. Place the axle in two V blocks that are placed 100 mm (4
in.) [A] apart, and set a dial gauge on the axle at a point
halfway between the blocks. Turn the axle to measure
the runout.
*Ifaxle runout exceeds the service limit, replace the axle.
Axle Runout/100 mm (4 in.) GJ040102S1 C

Standard: TIR 0.05 (0.0020 in.)

Service Limit: TIR 0.2 mm (0.008 in.)

Balance Inspection
Olf the wheel balance has been altered, such as due to the
replacement of the tire, inspect the wheel balance.
. Remove the wheel and place it on a wheel balancer.
. Spin the wheel lightly, and mark [A] the wheel at the top
when the wheel stops.
ORepeat this procedure several times. If the wheel stops
of its own accord in various positions, it is well balanced.
*If the wheel always stops in one particular position, adjust GJ040413S1 C
the wheel balance.

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 8-8 WHEELSITIRES
Wheels
Balance Adjustment
.If the wheel always stops in one position, tentatively at-
tach a balance weight [A] on the rim near the marking.
. Rotate the wheel a 1/4 turn [8], and see whether or not
the wheel stops in this position. If it does, the tentatively
attached weight is of the proper size.
* If the wheel does not stop in this position and the weight
goes up, replace the weight with the next heavier size.
. Repeat these steps until the wheel remains at rest after
being rotated a 1/4 turn.
GJ040414S1 C

. Rotate the wheel another 1/2 turn and then another 3/4
. turn to see if the wheel is correctly balanced.
Repeat the entire procedure described above as many
times as necessary to achieve correct wheel balance.
Once proper balance has been achieved, permanently
secure the balance weight.

Balance Weight Removal

Without tire
.Push [A] the blade portion toward the outside with a reg-
ular tip screwdriver, and slip the balance weight off, as
shown.
ODiscard the used balance weight.

GJ040 1 05S 1 C

With tire
. Remove the balance weight by using a screwdriver to pry
[A] on the blade.
. Take out the balance weight by inserting the screwdriver
between the bead [8] and the blade [C], as shown.
ODiscard the used balance weight.

GJ040106S1 C

Balance Weight Installation

. Check if weight portion has any play on the blade and clip.
. If there is any play, discard it.
A WARNING
If the balance weight has any play on the rim
flange, the blade and/or of the weight clip have
been stretched. Replace the loose balance weight.
Do not reuse used balance weight Unbalanced
wheels can create an unsafe riding condition.

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 WHEELSITIRES 8-9
Wheels

Olf 20 g (0.71 oz.) or more balance weight must be at-

tached to the wheel, they must be attached to both sides
of the wheel in the combination shown below, in order to
ensure driving stability.
Balance Weight Installation
Necessary Weight Combination
Weight (mass) Side [A] Side [B]
10 9 (0.35 oz.) 10 9 (0.35 oz.) -
GJ04061551 C

20 9 (0.71 oz.) 10 9 (0.35 oz.) 10 9 (0.35 oz.)

30 9 (1.06 oz.) 20 9 (0.71 oz.) 10 9 (0.35 oz.)
40 9 (1.41 oz.) 20 9 (0.71 oz.) 20 9 (0.71 oz.)
50 9 (1.76 oz.) 30 9 (1.06 oz.) 20 9 (0.71 oz.)
60 9 (2.12 oz.) 30 9 (1.06 oz.) 30 9 (1.06 oz.)
70 9 (2.47 oz.) 20 9 (0.71 oz.) + 30 9 (1.06 oz.)
20 9 (0.71 oz.)
80 9 (2.82 oz.) 20 9 (0.71 oz.) + 20 9 (0.71 oz.) +
20 9 (0.71 oz.) 20 9 (0.71 oz.)
90 9 (3.17 oz.) 20 9 (0.71 oz.) + 20 9 (0.71 oz.) +
30 9 (1.06 oz.) 20 9 (0.71 oz.)

NOTE
Off the imbalance is less than 10 g (0.35 oz.), it willnot
affect the motorcycle's stability during driving. Do not
use more than four balance weights or exceed 90 g
(3.17 oz.). In such a case, inspect the wheel.
. Apply a soap and water solution to the tire bead [C], rim
flange [8], and weight blade [D]. This helps the balance
weight slip onto the rim flange.
CAUTION

Do not lubricate the tire bead with engine oil or pe-

troleum distillates because they will deteriorate the
tire.
. Lightly
it.
hammer (or push) [A] the balance weight to install GJ040 1 075 1 C

. After installing, make sure that the blade [A] and weight
[8] are fully seated on the rim flange [C], and that the clip
[D] is hooked over the rim ridge [E] and reaches the rim
flat portion.

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 8-10 WHEELSITIRES
Tires
Air PressureInspectionand Adjustment
. 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).
* Adjust the tire air pressure according to the specifications
if necessary.
.Install the air valve cap.
-
Air Pressure when cold
250 kPa
Front Up to 182 kg (401 Ib) load
(2.5 kg/cm2,36 psi)
250 kPa
Rear Up to 182 kg (401 Ib) load
(2.5 kg/cm2,36 psi)

.Tire Inspection
Visually inspect the sidewalls and tread for cracks and
cuts.
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 up safe to use
the tires until they are hold.
*Replace the tire with a new one in case of damage. GJ050107S1 C

. Check for any nails, metal pieces, stones, or other foreign

particles that may be embedded or stuck in the tires.
* Repair or replace the tire with a new one if necessary.
. Using a depth gauge [A], measure the tread depth at sev-
eral places.
*If any measurement is less than the service limit, replace
the tire.

Tread Depth
Standard Service Limit

Front 1 mm (0.04 in.)

4.3 mm (0.17 in.)
AR, FG, ST 1.6 mm (0.062 in.)
Rear 2 mm (0.08 in.)
7 mm (0.28 in.)
[Up to 130 km/h (80 mph)]
3 mm (0.12 in.)
[Over 130 km/h (80 mph)]

A WARNING
To ensure safe handling and stability, use only the
recommended standard tires for replacement, in-
flated to the standard pressure. The front and rear
tires must be made by the same manufacturer.

NOTE
OMost countries may have their own regulations a mini-
mum tire tired depth: be sure to follow them.
o Check and balance the wheel when a tire is replaced
with a new one.

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 WHEELSITIRES 8-11
Tires
Tire Removal
. Remove:
Wheel (see this chapter)
Brake Disc (see Brakes chapter)
Valve Core (let out the air)
. To maintain wheel balance, mark the valve stem position
on the tire with chalk so that the tire can be reinstalled in
the same position.
Chalk Mark or Yellow Mark [A]
Air valve [B]
Align [C]
. Lubricate the tire beads and rim flanges on both sides with
a soap and water solution or rubber lubricant. This helps
the tire beads slip off the rim flanges.
CAUTION
Never lubricate with engine oil or petroleum distil-
lates because they will deteriorate the tire.

. cially
Remove the tire from the rim using a suitable commer-
available tire changer.
NOTE
o The tires cannot be removed with hand tools because
they fit the rims too tightly.

Tire Installation
A WARNING
Use the same manufacturer's tires on both front and
rear wheels.

..Inspect the rim and tire, and replace them if necessary.

Clean the sealing surfaces of the rim and tire, and smooth
the sealing surfaces of the rim with a fine emery cloth if
necessary.
. Remove the air valve and discard it.
CAUTION

Replace the air valve whenever the tire is replaced.

Do not reuse the air valve.

.Install
a new valve in the rim.
ORemove the valve cap, lubricate the stem seal with a soap
and water solution or rubber lubricant, and pull the valve
stem [A] through the rim from the inside out [B] until it
snaps into place.
CAUTION
Do not use engine oil or petroleum distillates to lu-
bricate the stem because they will deteriorate the GJ050606S 1 C
rubber.
. Applya soapandwatersolution,or rubberlubricantto the
rim flange and tire beads.

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 8-12 WHEELSITIRES
Tires
OTheair valve is shown in the figure.
Valve Cap [A]
Valve Core [8]
Stem Seal [C]
Valve Stem [0]
Valve Seat [E]
Valve Opened [F]

GJ050108S1 C

. Check the tire rotation mark on the front and rear tires and
install them on the rim accordingly.
Rotation Direction [A]
Tire Rotation Mark [8]

. Position the tire on the rim so that the valve [A] is at the tire
balance mark [8] (the chalk mark made during removal,
or the yellow paint mark on a new tire).
.Install the tire on the rim using a suitable commercially
available tire changer.
. Lubricate the tire beads and rim flanges with a soap and
water solution or rubber lubricant to help seat the tire
beads in the sealing surfaces of the rim while inflating the
tire.
. Center the rim in the tire beads, and inflate the tire with
compressed air until the tire beads seat in the sealing
surfaces.
A WARNING
Be sure to install the valve core whenever inflating
the tire, and do not inflate the tire to more than 400
kPa (4.0 kgf/cm2, 57 psi). Overinflating can explode
the tire with possibility of injury and loss of life.

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 WHEELSfTlRES 8-13
Tires

. Check to see that the rim lines [A] on both sides of the tire
sidewalls are parallel with the rim flanges.
*Ifthe rim flanges and tire sidewall rim lines are not parallel,
remove the valve core.
. Lubricate the rim flanges and tire beads.
.Install the valve core and inflate the tire again.
. After the tire beads seat in the rim flanges, check for air
leakage.
Olnflate the tire slightly above standard inflation.
OUse a soap and water solution or submerge the tire, and
check for bubbles that would indicate leakage.
. Adjust the air pressure to the specified pressure (see Tire
Inspection).
.Install the air valve cap.
.Install the brake disc(s) so that the marked side faces out
(see Brakes chapter).
. Adjust the wheel balance.

Tire Repair
Currently two types of repair for tubeless tires have come
into wide use. One type is called a temporary (external) re-
pair which can be carried out without removing the tire from
the rim, and the other type is called permanent (internal)
repair which requires tire removal. It is generally under-
stood that higher running durability is obtained by perma-
nent (internal) repairs than by temporary (external) ones.
Also, permanent (internal) repairs have the advantage of
permitting a thorough examination for secondary damage
not visible from external inspection of the tire. For these
reasons, Kawasaki does not recommend temporary (exter-
nal) repair. Only appropriate permanent (internal) repairs
are recommended. Repair methods may vary slightly from
make to make. Follow the repair methods indicated by the
manufacturer of the repair tools and materials so that safe
results can be obtained.

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 8-14 WHEELSITIRES
Hub Bearing (Wheel Bearing)
Hub Bearing Removal
. Remove the wheel and take out the following parts:
Collar
Coupling (out of rear hub)
Grease Seals
Circlips
Special Tool - Inside Circlip Pliers: 57001-143 [A]
Speedometer Gear Drive (front hub) [B]

. Use the bearing remover to remove the hub bearings [A].

I CAUTION I

Do not lay the wheel on the ground with the disc

facing down. This can damage or warp the disc.
Place wooden blocks under the wheel so that the
disc does not touch the ground.
OSelect a remover head that matches the bearing bore and
insert it. GJ060606S 1 C

OPass the remover shaft from the opposite end and engage
its tip into the groove of the head.
OTap the shaft with a hammer and remove the bearing.
Special Tools - Bearing Remover Shaft: 57001-1377 [B]
Bearing Remover Head, cP15 x cP17: 57001
-1267 [C]
Bearing Remover Head, cP20 x cP22: 57001
-1293 [C]

.Bearing Installation
Before installing the wheel bearings, blow any dirt or for-
eign particles out of the hub with compressed air to pre-
vent contamination of the bearings.
. Replace the bearings with new ones.
NOTE
o Install the bearings so that the marked side faces out.
. does
Install the bearings by using the bearing driver set which GJ050004S 1 C

. not contact the bearing inner race.

Press in each bearing [A] right until they are it bottomed.
Special Tool- Bearing Driver Set: 57001-1129 [B]
. Replace the circlips with a new one.
Special Tool - Inside Circlip Pliers: 57001-143
. Replace the grease seal [A] with a new one and press it
in so that seal surface is flush [B] with the end of the hub
hole.
OApply high-temperature grease to the grease seal lips.
Special Tool- Bearing Driver Set: 57001-1129 [C]
GJ050005S 1 C

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 WHEELSITIRES 8-15
Hub Bearing (Wheel Bearing)
. Engage the speedometer gear drive [A] into the notch [8]
of the front wheel hub and install the circlip [C].
Special Tool - Inside Circlip Pliers: 57001-143

Hub Bearing Inspection

Since the ball bearings are made to extremely close tol-
erances, the wear must be judged by feel rather than mea-
surement.
NOTE
o Do not remove any bearings for inspection. If any bear-
ing are removed, they will need to be replaced with new
ones.
. Turn each bearing in the hub back and forth [A] while
checking for plays, roughness, or binding.
GJ06002BS 1 C

* If the bearing is noisy, does not spin smoothly, or has any

rough spots, replace it.
.Inspect the bearing seal [8] for tears or leakage.
*If the seal is torn or is leaking, replace the bearing.

Bearing Lubrication
NOTE
o Since the bearings are packed with grease and sealed
on both sides, lubricationis not required.

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 8-16 WHEELSITIRES
Speedometer Gear Housing

.Disassembly/Assembly
Pull out the grease seal [A] using a thin-bladed screw-
driver.
. Pull out the speedometer gear [8].
NOTE
o It is recommended that the speedometer unit be re-
placed rather than attempting to replace the bushing
[C}, pinion [OJ, and washers [E}. However, if you wish,
replace them as follows. GJ070204S 1 C

. First, drill the inner hole of the spring pin [8] in the housing
[A] using a 1.0 to 1.5 mm drill bit [C].

GJ070101S1 C

. Drill the housing from the opposite side to the pin end [8],
using a 3.0 to 3.5 mm drill bit [A].

GJ070 1 02S 1 C

. the speedometer cable bushing, pinion, and washers.

Using a 3 mm rod [A], tap the pin [8] out, and then pull out

. Apply grease to the gear, pinion, grease seal, and wash-

ers (see Exploded View).
. After inserting a new spring pin, stake the housing hole to
secure the pin in place.
. Replace the grease seal.
. Press in the grease seal so that the seal end is flush with
the end of the hole.
. Apply high temperature grease to the seal lips.
GJ070103S1 C

Lubrication
. Clean the speedometer gear housing [A] and grease the
grease seal lips [8].

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 FINAL DRIVE 9-1

Final Drive
Table of Contents
Exploded View........................................................................................................................ 9-2
Specifications ......... 9-3
Drive Chain .... 9-4
Drive Chain Slack Inspection............................................................................................ 9-4
Drive Chain Slack Adjustment.......................................................................................... 9-4
Wheel Alignment Inspection Adjustment.......................................................................... 9-5
Drive Chain Wear Inspection............................................................................................ 9-5
Drive Chain Lubrication..................................................................................................... 9-6
Drive Chain Removal........................................................................................................ 9-7
Drive Chain Installation..................................................................................................... 9-7
Drive Chain Replacement ..................................................... 9-7
Sprocket/Sprocket Coupling................................................................................................... 9-11
Engine Sprocket Removal ................................................................................................ 9-11
Engine Sprocket Installation ............................................................................................. 9-11
Rear Sprocket/Coupling RemovaL.................................................................................... 9-12
Rear Sprocket/Coupling Installation.................................................................................. 9-12
Sprocket Wear Inspection................................................................................................. 9-12
Rear Sprocket Warp Inspection.. ... ... ...... 9-13
Coupling Damper Inspection............................................................................................. 9-13
Coupling Bearing Removal ..................................... 9-13
Coupling Bearing Installation............................................................................................ 9-14
Coupling Bearing Inspection and Lubrication................................................................... 9-14

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 9-2 FINAL DRIVE
Exploded View

GK020403W4 C

1. Lettering side faces out.

T1: 127 N.m (13 kgf.m, 94 ft.lb)
T2: 59 N.m (6.0 kgf.m, 43 ft.lb)
T3: 12 N.m (1.2 kgf.m, 104 in.lb)
CO: Apply chain oil.
G: Apply high-temperature grease.
L: Apply a non-permanent locking agent to the threads (of stud bolt).
MO: Apply molybdenum disulfide oil to the thread and seating surface.
The molybdenum disulfide oil is mixture of engine oil and molybdenum disulfide grease with a
weight ratio (10:1).

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 FINAL DRIVE 9-3
Specifications
Item Standard Service Limit
Drive Chain
Chain Slack 30 - 45 mm (1.2 -1.8 in.)
Chain 20-link Length 317.5 - 318.2 mm (12.50 - 12.53 in.) 323 mm (12.7 in.)
Standard Chain
Make ENUMA - --
Type EK525 MV-X,Endless - --
Link 108 Links - --
Sprockets, Coupling
Engine Sprocket 71.01 - 71.21 mm (2.796 - 2.804 in.) 70.3 mm (2.77 in.)
Diameter
Rear Sprocket Diameter 182.13 - 182.63 mm (7.170 -7.190 in.) 181.8 mm (7.16 in.)
Rear Sprocket Warp Under 0.4 mm (0.016 in.) 0.5 mm (0.020 in.)
-
Special Tools Inside Circlip Pliers: 57001-143
Bearing Driver Set: 57001-1129

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 9-4 FINAL DRIVE
Drive Chain
Drive Chain Slack Inspection
NOTE
OSet the motorcycle up on its center stand for drive chain
inspection.
o Clean the drive chain if it is dirty and lubricate it if it
appears dry.
.Inspect the wheel alignment (see Wheel Alignment In-
spection) .
. Rotate the rear wheel to find the position where the chain
is tightest.
GS12020BS1 C

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

between the front and rear sprockets.
* Ifthe chain slack exceeds the standard, adjust it.
DriveChain Slack
Standard: 30 - 45 mm (1.2- 1.8 in.)

Drive Chain Slack Adjustment

. Pull out the cotter pin [A].
.. Loosen the axle nut [8].
Turnboth chain adjuster locknuts[C].
*If the chain is too loose, turn out the left and right chain
adjuster [D]evenly.
* If the chain is too tight, turn in the left and right chain
adjusters evenly, and kick the wheel forward.
. Turn both chain adjusters evenly untilthe drive chain has
the correct amount of slack. To keep the chain and wheel
properly aligned, the notch [E]on the leftwheel alignment
indicator [F]should align with the same swingarm mark or
position [G]that the right indicator notch aligns with.
A 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 kgf.m, 80 ft.lb)
. Turnthe wheel, measure the chain slack again at the tight-
est position, and readjust if necessary.
. Insert a new cotter pin [A].
NOTE
o When inserting the cotter pin, if the slots in the nut do
not align with the cotter pin hoke in the axle, tighten the
nut clockwise fB] up to next alignment.
o If should be within 30 degree.
o Loosen once and tighten again when the slot goes past
the nearest hole.
GJ04071 BS 1 C

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 FINAL DRIVE 9-5
Drive Chain
. Bend the cotter pin [A]over the nut.

GS12012BS1 C

Wheel Alignment Inspection Adjustment

. Check to see that the graduation of the chain adjuster [B]
and the swingarm notch [A]of both sides are in the same
relative position.
* If they are do not, adjust the chain slack and align the
wheel alignment (see chain slack Adjustment).
NOTE
o Wheel alignment can be also checked using the
. straightedge to string method.

A WARNING
Misalignment of both alignment indicators will re-
sult in abnormal wear of the drive chain and the
sprocket, which may result in an unsafe riding con-
dition.
Drive Chain Wear Inspection
. Remove:
Mounting Screw [A]
Chain Cover [B]

. Rotate the rear wheel to inspect the drive chain for dam-
aged rollers or links, or loose pins.
*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, 201 Ib)
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 21 st pin. Since the chain may wear unevenly, take 1st 21st
GK040606S 1 C
measurement at several place.
* If any measurements exceed the service limit, replace the
chain. Also, replace the front and rear sprockets when the
drive chain is replaced.

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 9-6 FINAL DRIVE
Drive Chain
Drive Chain Length -20 Links
Standard: -
317.5 318.2 mm (12.50 -12.53 in.)
Service Limit: 323 mm (12.7 in.)
.A. WARNING
Ifthe 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 safety, use only the standard chain. It is an end-
less type and should not be cut for installation

Standard Chain
Make: Enuma Chain
Type: EK525 MV-X
Links: 108

Drive Chain Lubrication

81f a special lubricant is not available, a heavy oil such as
SAE 90 is preferred to a lighter oil because it willstay on
the chain longer and provide better lubrication.
81f 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 0
-ring drive chain.
Any other cleaning solution such as gasoline
or trichloroethylene 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.

8 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.
8 Wipe off any excess oil.
Oil Applied Areas [A]
O-ring [8]

GK040607S 1 C

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 FINAL DRIVE 9-7
Drive Chain
Drive Chain Removal
. Remove:
Rear Wheel (see WheelsfTires chapter)
Chain Cover (see Drive Chain Wear Inspection)
Swingarm (see Suspension chapter)
Engine Sprocket Cover (see Engine Sprocket Removal)
. Disengage the drive chain [A] from the engine sprocket
[B], and take it off the chassis.

Drive Chain Installation

. Engage
the drive chain to the engine sprocket.
.Install:
Swingarm (see Suspension chapter)
Rear Wheel (see WheelsfTires chapter)
Engine Sprocket Cover
Chain Cover
. Adjust the chain slack after installing the chain (see Drive
Chain Slack Adjustment).

Chain Replacement
.Drive
Remove:
Chain Cover
Engine Sprocket (see Engine Sprocket Removal)
. Using a suitable tool, cut the drive chain by removing the
link pins.
Recommended Tool: EK JOINT TOOL #50

CAUTION
Read the Tool Manual before removing.

Body [A]
Handlebar [B]
Cutting & Riveting Pin [C]
For Cutting [0]
For Riveting [E]
Plate Holder (A) [F]
Plate Holder (B) [G]
Gauge [H]
GK04016BS1 C

.. Grind [A] the pin head to make it flat.

Set the cutting & riveting pin [B] as shown.

GK04017BS1 C

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 9-8 FINAL DRIVE
Drive Chain

. Screw the pin holder until it touches the chain pin.

. Be sure that the cutting pin hits center of the chain pin.

GK040188S1 C

.. Screw the handlebar [A] into body.

Turn the pin holder with the wrench [B] clockwise to the
extract chain pin.

GK04019BS1 C

. Engage the new drive chain to the old drive chain and pull
the end of the old drive chain until they are changing the
position.
. Remove the old drive chain from the new drive chain.
. Apply grease to the new link pins [A] and new a-rings [B]
[C].
. Engage the drive chain on the engine and rear sprockets.
. Insert the link pins in the drive chain ends.
.
.. Install the a-rings [C].
Install the link plate so that the mark [0] faces out.
Push the link plate by hand or plier to fix it.
.In case of the a-ring chain, be sure to set the a-rings
correctly.
. body.
Set the plate holder (A) [A] and plate holder (B) [B] on the

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 FINAL DRIVE 9-9
Drive Chain

.. Turn the pin holder by hand until the plate holder (8)
Fit the plate holder (A) to the link plate.

touches the other linkplate.

.Turn the pin holder by wrench clockwise untiltwo pins of

the linkcome into the groove of the plate holder (A).
. Take off the plate holder.

GK04023BS1 C

. Set the plate holder (8) [A]and cutting & riveting pin [8]
as shown.

. Turn
pin.
the pin holder until the riveting pin touches the link

. Turn the wrench clockwise untilthe tip of the riveting pin

hits of the link pin.
. Rivet it.
. Some workforthe other linkpin.

GK04026BS1 C

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 9-10 FINAL DRIVE
Drive Chain
. After staking, check the staked area of the link pin for
cracks. A
. Measure the outside diameter [A] of the link pin and link
plates width [8].
Link Pin Outside Diameter
Standard: 5.60- 6.00 mm (0.220- 0.236 in.) @
Link Plates Outside Width
Standard: 19.85- 20.00 mm (0.703- 0.787 in.) GK04028BS 1 C

* If the reading exceeds the specified length, cut and rejoin

. the chain again.
Check:
Movement of the Rollers
. Adjust the drive chain slack after installing the chain (see
Drive Chain Slack Adjustment).

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 FINAL DRIVE 9-11
Sprocket/Sprocket Coupling

..Engine Sprocket Removal

Set the motorcycle up on its center stand.
Remove:
Shift Lever [A]
Engine Sprocket Cover [8]

. Flatten out the bended washer [A].

. washer.
Remove the engine sprocket nut [8], and take out the

NOTE
o Apply the rear brake to loosen the sprocket nut.

. Slacken the drive chain all the way (see Drive Chain Slack
Adjustment).
. from
Take out the drive chain together with the engine sprocket
the output shaft [8], and remove the sprocket [A].

Engine Sprocket Installation

. Replace the sprocket washer and axle cotter pin.
.. Apply
Install the engine sprocket.
a molybdenum disulfide oil to the thread and seat-
ing surface of the engine sprocket nut.
. Tighten the engine sprocket nut [A] and bend the one side
[8] of the washer over the nut.
NOTE
OApply the rear brake to tighten the nut.
Torque - Engine Sprocket Nut: 128 N.m (13 kgf.m, 94 ft.lb)
. Check to see that the rubber dampers in place to the
sprocket cover.
.Install the pin and fit the sprocket cover.
. Tighten the sprocket cover bolts.
Torque -Engine Sprocket Cover Bolts: 12 N.m (1.2 kgf.m,
104 in.lb)

. Adjustthe drive chain slack (see Drive Chain Slack Ad-

justment).

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 9-12 FINAL DRIVE
Sprocket/Sprocket Coupling
Rear Sprocket/Coupling Removal
. Remove the rear wheel (see Wheel/Tires chapter).
I CAUTION
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Please blocks under the wheel so that the disc does
not touch the ground.
. Remove the coupling from the wheel.
. Remove the collar [A] and grease seal [B] from the left of
the coupling and the sleeve [C] from the right.
. Remove the nut [0] and take out the sprocket [E].
NOTE
OAttach the coupling temporarily to the hub.
Rear Sprocket/Coupling Installation
. Replace the grease seal with a new one and press it in so
that seal surface is flush with the end of the hole.
Special Tool - Bearing Driver Set: 57001-1129
. Install the rear sprocket, facing the touth number marking
[A] outward.
Torque -Rear Sprocket Nut: 59 N.m (6.0 kgf.m, 43 tt.lb)

. Grease the following and install the coupling.

Ball Bearing [A]
Coupling Grease Seal [B]

. Coupling Internal Surface [C]

Install the collars.
.Install the rear wheel (see Wheel/Tires chapter)

.Sprocket Wear Inspection

Visually inspect the sprockets for uneven wear, abnormal
wear, or damaged teeth.
*If the teeth are worn or damaged, replace the sprockets
and inspect the drive chain.
Worn Teeth (engine sprocket) [A]
Worn Teeth (rear sprocket) [B]
Rotation Direction [C]
GK050304S

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 FINAL DRIVE 9-13
Sprocket/Sprocket Coupling

.Rear Sprocket Warp Inspection

Raise the rear wheel off the ground (see Wheelsmres
chapter) so that it will turn freely.
. Set a dial gauge [A] against the rear sprocket [8] near the
teeth as shown, and rotate [C] the rear wheel to measure
the sprocket runout (warp). The difference between the
highest and lowest dial gauge readings is the amount of
runout (warp).
*If the runout exceeds the service limit, replace the rear
GK050 111 SIC
sprocket.
Rear Sprocket Warp
Standard: TIR 0.4 mm (0.016 in.) or less
Service Limit: TIR 0.5 mm (0.020 in.)

Coupling Damper Inspection

. Remove the rear wheel coupling, and inspect the rubber
dampers [A].
. Replace the damper if it appears damaged or deterio-
rated.

Bearing Removal
.Coupling
Remove:
Coupling
Grease Seal
Circlip [A]
-
Special Tool Inside Circlip Pliers: 57001-143 [B]

. Remove the bearing by tapping from the wheel side.

SpecialTool- BearingDriverSet: 57001-1129 [A]

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 9-14 FINAL DRIVE
Sprocket/Sprocket Coupling
Coupling Bearing Installation
. Replace the bearing with a new one.
. Press in the bearing until it is bottomed.
Special Tool- Bearing Driver Set: 57001-1129 [A]
. Packthe bearing with high temperature grease.
. Replace the circlip with a new one.
Special Tool - Inside Circlip Pliers: 57001-143

. Replace the grease seal with a new one.

. with
Press in the grease seal so that the seal surface
the end of the hole.
is flush

OApply high temperature grease to the grease seal lips.

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

Coupling Bearing Inspection and Lubrication

Since the coupling bearing is made to extremely close
tolerances, the clearance can not normally be measured.
NOTE
o It is not necessary to remove the coupling bearing for
inspection and lubrication. If the bearing is removed, it
will need to be replaced with a new one.
. Spin [A] it by hand to check its condition.
* If it is noisy, does not spin smoothly, or has any rough
GI14010151 C

spots, it must be replaced.

. the bearing around by hand a few times to make sure the
Pack the bearing with good quality bearing grease. Turn

grease is distributed uniformly inside the bearing.

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 BRAKES 10-1

Brakes
Table of Contents
Exploded View........................................................................................................................ 10-2
Specifications ......... 10-4
Brake Lever, Brake Pedal....................................................................................................... 10-5
Brake Lever Position Adjustment.. ... 10-5
Brake Pedal Position Inspection ... 10-5
Brake Pedal Position Adjustment...................................................................................... 10-5
Brake Pedal Removal....................................................................................................... 10-5
Brake Pedal Installation.................................................................................................... 10-6
Calipers ........... 10-7
Caliper Removal............................................................................................................... 10-7
Caliper Installation............................................................................................................ 10-7
Caliper Disassembly......................................................................................................... 10-7
Caliper Assembly.............................................................................................................. 10-8
Caliper Fluid Seal Damage............................................................................................... 10-9
Caliper Dust Seal/Friction Boot Damage.......................................................................... 10-9
Caliper Piston and Cylinder Damage................................................................................ 10-9
Caliper Holder Shaft Wear................................................................................................ 10-9
Brake Pads ... 10-1 0
Brake Pad Removal.......................................................................................................... 10-1 0
Brake Pad Installation ........ 10-1 0
Brake Pad Inspection........................................................................................................ 10-1 0
Master Cylinder...................................................................................................................... 10-11
Front Master Cylinder Removal........................................................................................ 10-11
Front Master Cylinder Installation..................................................................................... 10-11
Rear Master Cylinder Removal .............. 10-12
Rear Master Cylinder Installation...................................................................................... 10-12
Front Master Cylinder Disassembly.................................................................................. 10-12
Rear Master Cylinder Disassembly................................................................................... 10-13
Master Cylinder Assembly................................................................................................ 10-13
Master Cylinder Inspection (Visual Inspection) ................................................................ 10-14
Brake Discs ... 10-1 5
Brake Disc Removal......................................................................................................... 10-1 5
Brake Disk Installation...................................................................................................... 10-15
Brake Disc Wear............................................................................................................... 10-1 5
Brake Disc Warp............................................................................................................... 10-16
Brake Fluid .... 10-17
Brake Fluid Level Inspection............................................................................................. 10-17
Brake Fluid Change.......................................................................................................... 10-17
Brake Bleeding.................................................................................................................. 10-18
Brake Hose ... 10-21
Brake Hose Removal/Installation...................................................................................... 10-21
Brake Hose Inspection...................................................................................................... 10-21

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 10-2 BRAKES
Exploded View

GL021388W4 C

1. Front Brake Light Switch T3: 1.5 N.m (0.15 kgt.m, 13 in.lb)
2. Front Master Cylinder Clamp Bolts T4: 8.8 N.m (0.9 kgt.m, 78 in.lb)
3. Caliper Mounting Bolts T5: 1.2 N.m (0.12 kgt.m, 10 in.lb)
4. Rear Master Cylinder Mounting Bolts T6: 34 N.m (3.5 kgt.m, 25 tt.lb)
5. Brake Lever Pivot Bolt Locknut T7: 25 N.m (2.5 kgt.m, 18 tt.lb)
6. Brake Pedal Mounting Bolt T8: 7.8 N.m (0.8 kgt.m, 69 in.lb)
7. Brake Rod Joint Cotter Pin T9: 18 N.m (1.8 kgt.m, 13 ft.lb)
T1: 1.0 N.m (0.1 kgt.m, 9 in.lb) T10: 6.9 N.m (0.7 kgf.m, 61 in.lb)
T2: 5.9 N.m (0.6 kgt.m, 52 in.lb) T11: 27 N.m (2.8 kgt.m, 20 tt.lb)

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 BRAKES 10-3
Exploded View

GL02139BW4 C

B: Apply brake fluid.

G: Apply high-temperature grease.
L: Apply a non-permanent locking agent.
0: Apply engine oil
R: Replacement parts
S: Follow the specific tightening sequence.
Si: Apply silicon grease or PBC grease.

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 10-4 BRAKES
Specifications
Item Standard Service Limit
Brake Lever, Brake Pedal (Adjustable Range)
Lever Position --- 1 4
(ZR750-H4 ) --- 1 5
Pedal Position About 40 mm (1.6 in.) below top - --
of footpeg
Brake Fluid
Recommended Disc Brake
Fluid:
Type DOT4 - --
Brake Pads
Lining Thickness 4.7 mm (0.185 in.): Outer Pad 1 mm (0.04 in.)
4.5 mm (0.177 in.): Inner Pad 1 mm (0.04 in.)
Brake Disc
Thickness:
Front: 4.0 mm (0.16 in.)
(ZR750-H1 H2) 4.3 mm 4.5 mm (0.169 0.177 in.)
(ZR750-H3 ) 4.4 mm 4.6 mm (0.173 0.181 in.)
Rear: 5.0 mm (0.20 in.)
(ZR750-H1 H2) 5.8 mm 6.0 mm (0.228 0.236 in.)
(ZR750-H3 ) 5.9 mm 6.1 mm (0.232 0.240 in.)
Runout Not more than 0.2 mm (0.008 in.) 0.3 mm (0.0012 in.)
Special Tools -Inside Circlip Pliers: 57001-143
Jack: 57001-1238

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 BRAKES 10-5
Brake Lever, Brake Pedal
Brake Lever Position Adjustment
The brake lever is adjustable to four positions to suit the
rider.
. Push the lever forward and turn the adjuster [A] to align
the number with the arrow mark [B].
OThe distance from the grip to the lever is maximum at
Number 1 and minimum at Number 4, or Number 5
(ZR750-H4 - ).

Brake Pedal Position Inspection

.Inspect the position [A] of the brake pedal.
* Adjust the position if it is out of standard.
Brake Pedal Position
Standard: 40 mm (1.6 in.)

Brake Pedal Position Adjustment

NOTE
o Visuallyit is not necessary to adjust the pedal position,
but always adjust it when the push rod locknut has been
loosened.
. Loosen the adjuster locknut [A] at the bottom of the mas-
ter cylinder, which is behind the right step bracket.
. Turn the push rod with the hex head [B] to achieve the
correct pedal position (see Brake Pedal Position Inspec-
tion).

. Tighten the adjuster locknut.

-
Torque Brake Pedal Adjuster Locknut: 18 N.m (1.8 kgf.m,
13 ft.lb)
.Inspect the engagement timing of the brake light switch
(see Electrical System chapter).
Brake Pedal Removal
. Remove:
Rear Master Cylinder Mounting Bolts [B]
Right Step Bracket Bolts [A]

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 10-6 BRAKES
Brake Lever, Brake Pedal
. Remove:
Cotter Pin
Joint Pin [A](see Rear Master Cylinder Removal)
Rear Brake LightSwitch connector [B]
Right Step Bracket Assembly

.. Remove
Remove the Rear Brake LightSwitch Spring [A].
the return spring [B].
. Remove the mounting bolt [C] and take out the brake
pedal [D].

Brake Pedal Installation

. Apply high-temperature grease to the pivot shaft [A]and
install the pedal.
Torque - Brake Pedal MountingBolt: 8.8 N.m(0.9 kgf.m,78
in.lb)
. Hookthe return spring on the bracket hook bolt [B]and
the pedal hook shaft [C].

.. Connect the rear brake lightswitch connector.

Install the step bracket assembly.
. Hookthe lower end [A]ofthe rear brake lightswitch spring
on the pedal hook bolt [B].

..Install
Replace the cotter pin with a new one.
the rear master cylinder (see Rear Master Cylinder
Installation).
Olnsert the cotter pin and bend its ends surely.
-
Torque Rear Master Cylinder Mounting Bolts: 25 N.m (2.5
kgf.m, 18 ft.lb)
. Check the brake pedal position (see Brake Pedal Position
Inspection).

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 BRAKES 10-7
Calipers
Caliper Removal
.. Slightly loosen the banjo bolt [A].
Remove the mounting bolts [B] and remove the caliper [C]
from the disc.
. Remove the banjo bolt and detach the brake hose [D] (see
Brake Hose Removal/Installation).
NOTE
OAffer the caliper removal, if compressed air will not be
available for disassembling the caliper, remove the pis-
ton before detaching the brake hose (see Caliper Dis-
assembly).

CAUTION
Immediately wash away any brake fluid that spills.

Caliper Installation
.Install the caliper and the hose.
OReplace the flat washers on each side of the hose fitting
with new ones.
Torque - Caliper Mounting Bolts: 34 N.m (3.5 kgf.m, 25 ft.lb)
Brake Hose Banjo Bolt: 34 N.m (3.5 kgf.m, 25 ft.lb)
. Check the fluid level in the brake reservoirs.
.. Bleed the brake line (see Brake Bleeding).
Check the brake for good braking power, no brake drag,
and no fluid leakage.
A 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.

.Caliper Disassembly
Remove the caliper.
.Remove the pads and anti-rattle springs (see Pad Re-
moval).
.Take out the piston.
OCover the piston area with a clean, thick cloth [A].
OLightly blow compressed air [B] into the hole for the banjo
bolt to remove the piston.
A WARNING
To avoid serious injury,never place your fingers or
palm inside the caliper opening. If you apply com-
pressed air into the caliper, the piston(s) may crush
your hand or fingers.

NOTE
o If compressed airis not available,withthe brake hose
still attached, apply the brake lever to remove the pis-
ton. Theremainingprocessis as describedabove.

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 10-8 BRAKES
Calipers
. Remove the dust seal and the fluid seal.
. Remove the caliper holder, shaft rubber friction boot and
dust cover.
. Remove the bleed valve [A] and the rubber cap [B].

!1
Gl050401S1 C

Caliper Assembly
. Wash all parts other than the pads.
I CAUTION
For cleaning the parts, use only disc brake fluid,
isopropyl alcohol, or ethyl alcohol.
.Install the bleedvalve and rubbercap.
Torque - Caliper Bleed Valve: 7.8 N.m(0.8 kgf.m,69 in.lb)

.OApply
Replace the fluid seals [A] with new ones.
brake fluid to them, and install them in to the cylin-
der by hand.
. Replace the dust seals [B] whenever the fluid seals are
replaced with new ones.
OApply brake fluid to them, and install them in to the cylin-
der by hand.

Gl050402S 1 C

. Apply brake fluid to the outside of the pistons and push

them into each cylinder by hand.
. Check the shaft rubber friction boot [A] and the dust cover
[B] replace them with new ones if they are damaged.
. Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to
the holder shafts [C] and the holder holes [0] (PBC is a
special high temperature, water-resistant grease).

.Install the anti-rattle pad spring [A] in the caliper body as

shown.

.Install the pads (see Pad Installation).

. Wash the caliper with water to remove brake fluid and
wipe it off.

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 BRAKES 10-9
Calipers
CaliperFluid Seal Damage
The fluid seals [A] around the piston maintain the proper
pad/disc clearance. If the seals are not satisfactory, pad
wear will increase, and constant pad drag on the disc will
raise brake and brake fluid temperature.
. Replace the fluid seals under any of the following condi-
tions; (a) fluid leakage around the pad; (b) brakes over-
heat (c) there is a large difference in inner and outer pad
wear; (d) the seal is stuck to the piston.
GL050402S 1 C
* If the fluid seal is replaced, replace the dust seal [8] as
well. Also, replace all seals every other time the pads are
changed.

Caliper Dust Seal/Friction Boot Damage

. Check that the dust seals [8] and friction boot [0] are not
cracked, worn, swollen, or otherwise damaged.
*If they show any damage, remove the caliper bracket and
replace them.
Fluid Seal [A]
Dust Cover [C]

GL050404S1 C

Caliper Piston and Cylinder Damage

. Visuallyinspect the piston [E] and cylinder surfaces.
*Replace the caliper if the cylinder and piston are badly
scores or rusty.

Caliper Holder Shaft Wear

The caliper body must slide smoothly on the caliperholder
shaft [F]. 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 shaft 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
frictionboot. Toreplacethefrictionboot, remove the pads
and the caliper bracket.
* If the caliper holder shaft is damage, replace the caliper
bracket.

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 10-10 BRAKES
Brake Pads
Brake Pad Removal
. Detach the caliper from the disc (see Caliper Removal).
. Draw out the holder shaft pin [A],and take off the holder
shaft [8].
..Remove the pad [C] on the piston side.
Push the holder [0] towards the piston, and remove the
pad of the other side [E]from the holder shaft [F].

Brake Pad Installation

. Push the pistons in by hand as far as they willgo.
.. Installthe anti-rattle spring in its correct position.
Installthe pad on the piston side first, then install the other
pad on the holder.
.Install the caliper (see Caliper Installation).
A 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 brake will not function on the first appli-
cation of the lever or pedal if this not done.

.Brake Pad Inspection

Check the pads for damage and liningthickness.
* Ifany pad is damaged, replace the pads as a set.
* If the lining thickness [A] of either pad is less than the
service limit[8], replace both pads in the caliper as a set.
Brake Pad Thickness
Standard: 4.7 mm (0.185in.): Outer Pad
4.5 mm (0.177 in.): Inner Pad
GL060 1 025 1 C
Service Limit: 1 mm (0.04 in.)

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 BRAKES 10-11
Master Cylinder
CAUTION
Brake fluid damages a paint surface or a plastic part
upon contact by peeling, discoloring, or cracking.
Therefore, immediately wash the affected area with
water and wipe it off if it comes in contact with brake
fluid.

Front Masrer Cylinder Removal

. Disconnectthe connectors [A]of the front brake light
switch wires.

. Unscrew the banjo bolt [A],and detach the brake hose

(see Brake Hose Removal/Installation).
. Remove the clamp bolts [B]and remove the master cylin-
der [C]together with the reservoir, brake lever, and brake
light switch.

Front Master Cylinder Installation

. Alignthe punch mark [A]on the handlebar and the clamp
mating surface [B]so that the reservoir is parallel.

..Install the clamp with its arrow [A]facing up.

Tighten the bolts [B],top and bottom, in that order, leaving
a small clearance at the bottom of the clamp.
Torque - Front Master Cylinder Clamp Bolts: 8.8 N.m (0.9
kgf.m, 78 in.lb)

. Replace the flat washers on each side of the brake hose

fittingwith new ones.
. Tighten the banjo bolt.
Torque - Brake Hose BanjoBolt: 34 N.m(3.5kgf.m,25 tt.lb)
. Bleedthe air fromthe brake line (see Brake Bleeding).
. and no fluid leakage.
Check the brake for good brakingpower,no brake drag,

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 10-12 BRAKES
Master Cylinder
Rear Master Cylinder Removal
. the
Remove the lower end [A] of the reservoir hose, and drain
brake fluid from the reservoir into a suitable container.
. Remove the reservoir and the hose.
. Remove the brake hose banjo bolt [B] (see Brake Hose
Removal and Installation).
. Remove the master cylinder mounting bolts [C].

. Removethe cotter pin.

. Pullout the joint pin and removethe mastercylinder.
NOTE
o Push the brake pedal down, and pull out the joint pin
from the hole in the step bracket.

Rear Master Cylinder Installation

. Replace the cotter pin with a new one.
.Insert the cotter pin and spread its ends [A].
. Replace the flat washers on each side of the brake hose
fitting with new ones.
. Tighten the following:
Torque - Rear Master Cylinder Mounting Bolts: 25 N.m (2.5
kgf.m, 18 ft.lb)
Brake Hose Banjo Bolts: 34 N.m (3.5 kgf.m, 25
ft.lb)
Rear Brake Reservoir Mounting Bolt: 6.9 N.m (0.7
kgf.m, 61 in.lb)
. Bleed the air from the brake line (see Brake Bleeding).
. Check the brake for good braking power, no brake drag,
and no fluid leakage.

Front Master Cylinder Disassembly

. Remove the front master cylinder (see Front Master Cylin-
der Removal).
. Remove the reservoir cap, the diaphragm plate and di-
aphragm, and transfer the brake fluid into a suitable con-
tainer.
. Unscrew the locknut and the pivot bolt, and take out the
brake lever.
. Pull the dust cover out of place, and take out the circlip.
Special Tool - Inside Circlip Pliers: 57001-143

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 BRAKES 10-13
Master Cylinder

. Pull out the piston [A], secondary cup [B], primary cup [C],
and the return spring [D].
CAUTION

Do not remove the secondary cup from the piston

since removal will damage it.

Rear Master Cylinder Disassembly

NOTE
o Do not remove the push rod clevis for master cylinder
disassembly since removal requires brake position ad-
just ment.
. der
Remove the rear master cylinder (see Rear Master Cylin-
Removal).
. Slide the dust cover of the push rod out of place, and
remove the circlip.
Special Tool - Inside Circlip Pliers: 57001-143
.. Pull out the push rod together with the piston stop.
Pull out the piston [A], secondary cup [B], primary cup [C],
and the return spring [D].
CAUTION

Do not remove the secondary cup from the piston

since removal will damage it.
Gl07011082 C

Master Cylinder Assembly

. Before assembly, clean all parts with brake fluid or alco-
hol, and apply brake fluid to the removed parts and inner
wall of the cylinder.
CAUTION
Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol or ethyl alcohol for
cleaning brake parts. Do not use any other fluid for
cleaning these parts. Gasoline, engine oil, or any
other petroleum distillate will cause deterioration of
the rubber part. Oil spilled on any part will be diffi-
cult to wash off completely, and will eventually de-
teriorate the rubber used in the disc brake.

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 10-14 BRAKES
Master Cylinder
. Takecare
cylinder.
notto scratchthe pistonor the innerwall of the

. Applysiliconegrease(ex. PBCgrease).
Brake Lever Pivot Bolt
Brake Lever Pivot Contact
Push Rod Contact
Dust Cover
. Tighten the front brake lever pivot bolt and locknut.
-
Torque Brake Lever Pivot bolt: 1.0 Nom(0.1 kgfom,9 inolb)
Brake Lever Pivot Bolt Locknut: 5.9 N.m (0.6
kgfom, 52 in.lb)

..
Master Cylinder Inspection (Visual Inspection)
Disassemble the front and rear master cylinders.
o
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 cap [C] and secondary cap [0].
*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 spring [F] for any damage.

.
*If the spring 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]

GL070406S2 C

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 BRAKES 10-15
Brake Discs
Brake Disc Removal
.. Remove the wheel (see Wheels/Tires chapter).
Unscrew the mounting bolts [A], and take out the disc [8].
I CAUTION I

Do not lay the wheel down on one of the discs. This

can damage or warp the disc. Place blocks un-
der the wheel so that the disc does not touch the
ground.
GL080701S1

Brake Disk Installation

. Facing
the mark side [A] outward, install the brake disc,
and tighten the bolts [8].
-
Torque Brake Disc Mounting Bolts: 27 N.m (2.8 kgf.m, 20
ft.lb)

Brake Disc Wear

.* Visually inspect the disc.
Replace the disc if it shows any damage or crack.
. Measure the thickness of each disc at the point where it
has worn the most.
* Replace the disc if it has worn past the service limit.
Thickness
Standard
(ZR750-H1 - H2):
Front 4.3 - 4.5 mm (0.169 - 0.177 in.)
Rear 5.8 - 6.0 mm (0.228 - 0.236 in.)
Standard
(ZR750-H3 -):
Front 4.4 - 4.6 mm (0.173 - 0.181 in.)
Rear 5.9 - 6.1 mm (0.232 - 0.240 in.)
Service Limit:
Front 4.0 mm (0.16 in.)
Rear 5.0 mm (0.20 in.)

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 10-16 BRAKES
Brake Discs
Br:3ke Disc W:3rp
. Set the motorcycle up on its center stand for rear disc
measurement.
. Set up a dial gauge perpendicularly against the disc [A]
as shown and measure disc runout. While turning [B] the
wheel by hand.
NOTE
o In the case of the front disc, place a suitable base under
the engine to raise the front wheel, and turn the handle-
bar fully to either right or left. The measurement should
be taken approximately 10 mm (0.4 in.) inside from the
outer perimeter.
Special Tool- Jack: 57001-1238
. Slowly turn the wheel by hand and measure the disc
runout.
*Replace the disc if it has worn past the service limit.
Brake Disc Runout
Standard: 0.2 mm (0.008 in.) or less
Service Limit: 0.3 mm (0.012 in.)

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 BRAKES 10-17
Brake Fluid

.Brake Fluid Level Inspection

Check that the brake fluid level in the front brake fluid
reservoir [A]is higher than the lower [8] level line.
NOTE
OHold the reservoir horizontallyby turning the handlebar
when checking brake fluid level.
.Remove the seat, and check that the brake fluid level in
the rear brake fluid reservoir [C] is between the upper [D]
and the lower [E] level lines.
* Ifthe fluid level is lower than the lower level line, fillthe
reservoir with the specified type of brake fluid.
A WARNING
Change the brake fluid in the brake line completely
if the brake fluid must be refilled but the type and
brand of the brake fluid that already is in the reser-
voir are unidentified. After changing the fluid, use
only the same type and brand of fluid thereafter.
Mixing different types and brand of brake fluid low-
ers the brake fluid boiling point and could cause the
brake to be ineffective. It may also cause the rubber
brake parts to deteriorate.
Recommended Disc Brake Fluid
Grade: DOT4

Brake Fluid Change

NOTE
o The procedure described below for changing the fluid
in the front brake is also applicable for the rear brake.
. Level the brake fluid reservoir.
. Remove
aphragm.
the reservoir cap, diaphragm plate and di-
. Remove
caliper.
the rubber cap from the bleed valve [A]on the

. Attach a clear plastic hose [8] to the bleed valve of the

caliper, and run the other end of the hose into a suitable
container.
. Fill the reservoir with fresh specified brake fluid.

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 10-18 BRAKES
Brake Fluid
. fluid
Repeat the operation described below until fresh brake
comes out from the plastic hose or the color of the
fluid changes.
1. Open the bleed valve [A].
2. Pump the brake lever several times and hold it [8].
3. Close the bleed valve [C] while holding the brake lever.
4. Release the brake lever [D].
NOTE
a The fluid level must be checked often during the chang-
ing operation and replenished with specified brake fluid
to the upper level line. If the fluid in the reservoir runs
out any time during the changing operation, the brakes
willneed to be bled since air willhave entered the brake
line.
a Perform the same operation on the other caliper of the
front brake.
. Remove the clear plastic hose.
.Install the front reservoir cap.
Torque - Front Reservoir Cap Screws: 1.5 N.m (0.15 kgf.m,
13 in.lb)

. Follow procedure below to rear brake fluid reservoir cap

correctly.
aFirst, tighten the rear brake fluid reservoir cap [8] 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].

. After changing the fluid, check the brake for fluid level,
good braking power, and no fluid leakage.
Torque - Caliper Bleed Valve: 7.8 N.m (0.8 kgf.m, 69 in.lb)
*If necessary, bleed the air from the lines.

Brake 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.
A 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
a The procedure described below for bleeding the front
brake is also applicable for the rear brake.

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 BRAKES 10-19
Brake Fluid

. Remove the reservoir cap, diaphragm plate, and di-

aphragm, and fill the reservoir with fresh brake fluid to
the upper level line in the reservoir.
. Slowly pump the brake lever several times to completely
eliminate the air in the master cylinder, until no air bubbles
can be seen rising up through the fluid from the small
holes [A] at the bottom of the reservoir.
aThis operation is for completely eliminating any air in the
master cylinder.

. Temporarily install the reservoir cap.

. Remove the rubber cap from the bleed valve on the
caliper.
. Attach a clear plastic hose to the caliper bleed valve, and
run the other end of the hose into a suitable container.
. Repeat the operation described below until no more air
bubbles can be seen coming out into the plastic hose.
1. Pump the brake lever until it becomes hard, and apply
the brake lever and hold it [A].
2. Quickly open and close [8] the bleed valve while keep-
ing the brake lever applied.
3. Release the brake lever [C].
NOTE
a The fluid level must be checked often during the bleed-
ing operation and replenished with specified brake fluid
as necessary. If the fluid in the reservoir runs com-
pletely out any time during bleeding, the bleeding oper-
ation must be done over again from the beginning since
air will have entered the line.
a Tap the brake hose lightly from the caliper to the reser-
voir for more complete bleeding.
a Perform the same operation on the other caliper of the
front brake, and on the other bleed valve of the rear
brake.

.Install the front reservoir cap

Torque - Front Reservoir Cap Screws: 1.5 N.m (0.15 kgf.m,
13 in.lb)

. Follow procedure below to rear brake fluid reservoir cap

correctly.
aFirst, tighten the rear brake fluid reservoir cap [8] 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].

. Remove the clear plastic hose.

. Tighten the bleed valve, and install the rubber cap.
Torque ·Caliper Bleed Valve: 7.8 N.m (0.8 kgf.m, 69 in.lb)
. Check the fluid level.
. After changing the fluid, check the brake for fluid level,
good braking power, and no fluid leakage.

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 10-20 BRAKES
Brake Fluid
A WARNING
When working with the disc brake, observe the pre-
cautions listed below.
1. Never reuse old brake fluid.
2. Do not use fluid from a container that has been left
unsealed or that has been open for a long time.
3. Do not mix two types and brands of fluid for use in
the brake. This lowers the brake fluid boiling point
and could cause the brake to be ineffective. It may
also cause the rubber brake parts to deteriorate.
4. Don't leave the reservoir cap off for any length of
time to avoid moisture contamination of the fluid.
5. Don't change the fluid in the rain or when a strong
wind is blowing.
6. Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning brake parts. Do not use any other fluid for
cleaning these parts. Gasoline, engine oil, or any
other petroleum distillate willcause deterioration of
the rubber parts. Oil spilled on any part willbe diffi-
cult to wash off completely and willeventually dete-
riorate the rubber used in the disc brake.
7. When handling the disc pads or disc, be careful that
no disc brake fluidor any oil gets on them. Clean off
any fluid or oilthat inadvertently gets on the pads or
disc with a high-flash point solvent. Do not use one
which wilt leave an oily residue. Replace the pads
with new ones if they cannot be cleaned satisfacto-
rily.
8. Brake fluid quickly ruins painted surfaces; any
spilled fluid should be completely wiped up imme-
diately.
9. Ifany of the brake line fittings or the bleed valve is
opened at any time, the AIR MUSTBE BLEDFROM
THE BRAKE.

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 BRAKES 10-21
Brake Hose
Brake Hose Removal/Installation
CAUTION
Brake fluid quickly ruins painted or plastic sur-
faces; any spilled fluid should be completely wiped
up immediately with wet cloth.
. When removing the brake hose, take care not to spillthe
brake fluid on the painted or plastic parts.
. When removing the brake hose, temporarily secure the
end of the brake hose to some high place to keep fluid
loss to a minimum.
. There
.

are washers on each side of the brake hose fitting.

Replace them with new ones when installing.
. flattening
When installingthe hoses, avoid sharp bending, kinking,
or twisting, and route the hoses according to
Cable, Wire and Hose Routing section in General Infor-
mation chapter.
. Tighten:
Torque -Brake Hose Banjo Bolts: 34 N.m (3.5 kgf.m, 25
ft.lb)
. Bleed the brake line after installingthe brake hose (see
Bleedingthe Brake Line).

.Brake Hose Inspection

The high pressure inside the brake line can cause fluidto
leak or the hose to burst if the line is not properly main-
tained. Bend and twist the rubber hose while examining
it.
*Replace it if any cracks [B] or bulges [C] or fluid leak [A]
are noticed.

G1100201S1 C

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 SUSPENSION 11-1

Suspension
Table of Contents
Exploded View........................................................................................................................ 11-2
Specifications ......... 11-4
Front Fork .... . 11-5
Front Fork Removal ................................ 11-5
Front Fork Installation .......... 11-5
Front Fork Oil Change...................................................................................................... 11-5
Front Fork Disassembly.................................................................................................... 11-7
Front Fork Assembly .......... 11-8
Inner Tube/Outer Tube Inspection.................................................................................... 11-9
Dust Seal Inspection......................................................................................................... 11-10
Fork Spring Inspection .......... 11-10
Rear Shock Absorber............................................................................................................. 11-11
Rebound Damping Adjustment......................................................................................... 11-11
Spring Preload Adjustment............................................................................................... 11-11
Rear Shock Absorber Removal........................................................................................ 11-11
Rear Shock Absorber Installation..................................................................................... 11-12
Swingarm .......... 11-13
Swingarm Removal........................................................................................................... 11-13
Swingarm Installation........................................................................................................ 11-13
Swingarm Bearing Removal............................................................................................. 11-13
Swingarm Bearing Installation .......................................................................................... 11-14
Swingarm Bearing, Sleeve Inspection and Lubrication..................................................... 11-14
Chain Slider Inspection..................................................................................................... 11-14
Tie Rod/Rocker Arm............................................................................................................... 11-15
Tie Rod Removal.............................................................................................................. 11-15
Tie Rod Installation ...... 11-15
Rocker Arm Removal........................................................................................................ 11-15
Rocker Arm Installation ... ............ 11-16
Rocker Arm and Tie Rod Needle Bearing Inspection ....................................................... 11-16
Rocker Arm and Tie Rod Sleeve Inspection ..................................................................... 11-16
Tie-Rod, Rocker Arm Needle Bearing Lubrication (Periodic Maintenance) ...................... 11-16

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 11-2 SUSPENSION
Exploded View

I
I
I
I
I

GM020407.4 C

1. View trom under side T2: 20 N.m (2.0 kgt.m, 14 ft.lb)

2. Adjuster mark position T3: 59 N.m (6.0 kgt.m, 43 tt.lb)
3. Front T4: 29 N.m (3.0 kgt.m, 22 tt.lb)
4. Front Fork Clamp Bolts T5: 110 N.m (11 kgt.m, 80 tt.lb)
5. Rear Schock Absorber Mounting Nuts G: Apply high-temperature grease.
6. Rocker Arm Nut L: Apply non-permanent locking agent to the
7. Tie Rod Nuts threads.
8. Swingarm Pivot Shaft Nut R: Replacement Parts
T1: 23 N.m (2.3 kgt.m, 17 ft.lb)

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 SUSPENSION 11-3
Exploded View

~
~
,. t-}",.

U/ @" I

~ ~~ ~ ~\"'"'

t:8 15
1G

GII02021BW5 C

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 11-4 SUSPENSION
Specifications
Item Standard Service Limit
Front Fork
Fork Oil KAYABA KHL 34-G10 or
equivalent
Amount (per side):
When Changing Oil Approx. 400 mL (13.52 US oz.) - --
After Disassembly and Completely Dry 473 :t4 mL (15.99 :to.14 US oz.) - --
Oil Level (Fully Compressed, Without - --
115 :t2 mm (4.53 :to.08 in.)
Spring)
Fork Spring Free Length 309.4 mm (12.19 in.) 303 mm (11.93 in.)
Rear Shock Absorber (Adjustable Range)
Rebound Damping Force Number 2 Number 1 - 4
Spring Preload 3rd position 1st - 7th position
-
Special Tools Fork Cylinder Holder Handle: 57001-183
Fork Cylinder Holder Adapter: 57001-1057
Oil Seal & Bearing Remover: 57001-1058
Bearing Driver Set: 57001-1129
Jack: 57001-1238
Fork Oil Level Gauge: 57001-1290
Fork Oil Seal Driver: 57001-1219
Inside Circlip Pliers: 57001-143

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 SUSPENSION 11-5
Front Fork
Front Fork Removal
. Remove:
Front Wheel (see Tire/Wheels chapter)
Front Fender (see Frame chapter)
Front Brake Caliper (see Brakes chapter)
NOTE
o If the fork is to be disassembled later, loosen the top
plug before-hand. Loosen the upper clamp bolts [A]
before loosening the top plug [B].
. Loosen the fork upper clamp bolt and the fork lower clamp
bolts [C].

. With a twisting motion [A], work the fork leg down and out.

Front Fork Installation

NOTE
o If loosenthe top plug, tighten the top plug before tight-
ening the upper fork clamp bolt.
.Install the fork with the upper end of the inner tube flush
[A] against the top surface of the stem head [B].
Torque - Front Fork Clamp Bolts: 20 N.m (2.0 kgf.m, 14
ft.lb) GII040407S 1 C

A WARNING
Run the cables, wiring harnesses, and hoses
properly to prevent them from obstructing the
movement of the handlebar (see Generallnforma-
tion chapter).
.Install the front fender and the front wheel (see
Wheelsmres chapter).

Front Fork Oil Change

. Remove the front fork (see Front Fork Removal).
. Remove:
Top Plug [A]
Collar [B]
Fork Spring Seat [C]
Fork Spring [D]

GII040402S 1 C

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 11-6 SUSPENSION
Front Fork
. Compress [8] the fork [A] upside down to draw out the oil
into the contain [C].
. Pour in the specified amount of oil.
Fork Oil
KAYABA KHl34-G1 0 or equivalent
Capacity (one side):
For oil change: approx. 400 ml (13.52 US oz.)

NOTE
o 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.
. between the top of the inner tube to the oil level.
Use the fork oil level gauge [A] to measure the distance

Special Tool- Fork Oil level Gauge: 57001-1290

OSet the oil level gauge stopper [8] so that the distance [C]
from the bottom of the stopper to the lower end of the pipe
is the standard oil level distance.
OA correct measurement cannot be obtained unless the
level gauge pipe is placed in the center of the inner tube.
Oil level (Full compressed, without fork spring)
Standard: 115:t2 mm (4.53 :to.08 in.)
OPlace the stopper of the level gauge at the top [E] of the
inner tube [0] and pull the handle slowly to draw out the
excess oil from fork into the gauge, thus attaining the stan-
dard level.
Olf not oil is drawn out, there is not enough oil in the fork.
Pour in some more oil and measure again. GM040403S2 C

. Repeat the same procedure for adjusting the other fork.

.Install the fork spring [A], fork spring seat [8] and collar
[C].
. Inspect the top plug Q-ring and replace it with a new one
if it is damaged.
. Install the removed parts.
Torque - Front Fork Top Plugs: 23 N.m (2.3 kgf.m, 17 ft.lb)
Front Fork Clamp Bolts: 20 N.m (2.0 kgf.m, 14
ft.lb) GM040404S 1 C

Handlebar Clamp Bolts: 25 N.m (2.5 kgf.m, 18

ft.lb)
NOTE
o Tighten the two clamp bolts alternately two times to en-
sure even tightening torque.
o Tighten the top plug before tightening the upper fork
clamp bolt.

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 SUSPENSION 11-7
Front Fork

.Front Fork Disassembly

Remove the front fork (see Front Fork Removal).
. Remove the top plug with O-ring [A], take out the spacer
. [8], spring seat [C], and spring [0].
Drain the fork oil (see Front Fork Oil Change).
NOTE
o Turn the fork upside down and drain the oil while com-
pressing the fork.
GM040402S 1 C

. Remove the Allen bolt [C] from the bottom of the fork.
Special Tools - Fork Cylinder Holder Handle: 57001-183 [D] D E
Fork Cylinder Holder Adapter: 57001-1057
[E]
NOTE
OHold the outer tube in a vise [A], stop the cylinder unit
[B] from turning by using the special tools, and unscrew
the Allen bolt.
GM040138S1 C

. Remove the cylinder unit [A], washer, and the spring [8]
from the inner tube.

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

Dust Seal [A]
Retaining Ring [8]

. Separate the inner tube [8] from the outer tube [A].
NOTE
o From the compressed state, firmly pull down the outer
tube a few times towards the direction of elongation.

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 11-8 SUSPENSION
Front Fork

. Remove the following from the inner tube:

Guide Bushing (inner) [A]
Guide Bushing (outer) [B]
Washer [C]
Oil Seal [D]

. tube.
Remove the cylinder base [A] from the bottom of the outer

Front Fork Assembly

. Check the top plug O-ring and replace it with a new one
if it is damaged.
. Replace the following parts with new ones:
Retaining Ring [A]
Dust Seal [B]
Oil Seal [C]
Inner Guide Bushing [D]
Outer Guide Bushing [E] 61104040951 C

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 [B] onto the cylinder end [A]
that protrudes from the bottom.
Olnstall 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.

NOTE
o Place the used guide bushing [B] on the new guide
bushing [A],and tap the used guide bushing.
o The split[0] of the guide bushing should face the side
of the vehicle.
Special Tool- Fork Oil Seal Driver: 57001-1219 [C]

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 SUSPENSION 11-9
Front Fork
. After installing the washer, drive the oil seal [A] into place.
OApply high-temperature grease to the oil seal lips
Special Tool - Fork Oil Seal Driver: 57001-1219 [B]
.Install the retaining ring into the outer tube.
.Install the dust seal by hand.

6104041251 C

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

bottom Allen bolt [C].
. Hold the front fork horizontally in a vise [A].
D E
. Hold the cylinder unit [8] 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 (3.0 kgf.m,
22 ft.lb)
Special Tools -Fork Cylinder Holder Handle: 57001-183 [D]
6104013851 C
Fork Cylinder Holder Adapter: 57001-1057
[E]
. Pour in the specified amount of oil and install the removed
parts (see Front Fork Oil Change).
Fork Oil
KAYABA KHL34-G10 or equivalent
Capacity 473 :t4 mL (15.99 :to.14 US oz.)
(one side): (after fork disassembly, completely dry)
.Install the front fork (see Front Fork Installation).

Inner Tube/Outer Tube Inspection

. Visually inspect the inner tube [A] and repair any nicks or
rust by using an oil stone.
*If the damage is not repairable, replace the inner tube.
Since damage to the inner tube damages the oil seal slip,
replace the oil seal whenever the inner tube is repaired or
replaced.
CAUTION
If the inner tube is badly nicked or bent, replace
it. Excessive bending, followed by subsequent
straightening, can weaken the inner tube.
. Place the inner tube in the outer tube [8] and pump them
back and forth manually to check for smooth operation.
* If the movement is not smooth, replace both the inner tube
and the outer tube.
A WARNING
Replace the inner and outer tubes with new ones if
they are bent because it is dangerous to use them
by repairing them.
Make sure to inspect the inner and outer tubes of
the other side.

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 11-10 SUSPENSION
Front Fork

Dust Seal Inspection

.Inspect the dust seal [A]forany signs of deteriorationor
damage.
* Replace it ifnecessary.

GII040625S 1 C

Fork Spring Inspection

. Measure the free length [8] of the fork spring [A].
* Ifthe measured length is shorter than the service limit,the
spring must be replaced. Ifthe 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: 309.4 mm (12.19 in.) GII040413S1 C

Service Limit: 303 mm (11.93 in.)

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 SUSPENSION 11-11
Rear Shock Absorber

.Rebound Damping Adjustment

Turn the damper adjuster [A] to adjust the rebound damp-
ing.
OAlign the numbered mark [8] of the adjuster.
OThe standard adjuster setting for average-build rider of
68 kg (150 Ib) with no passenger and no accessories is
position "2".
* If the damper's effectiveness is not suited to the operating
conditions, adjust it to an appropriate position by referring
to the table below.
Rebound Damping Adjustment
Damp- Shock Road
Adjuster Absorber Load Condi- Driving
Position ing
Force Hardness tions Speed

1 Weak Soft Light Good Street

2 i i i i i
3 1 1 1 1 1
4 Strong Hard Heavy Bad Highway

.Spring Preload Adjustment

Turn the nut backward.
. adjust
Using the hook wrench [A], turn the adjusting nut [8] to
the spring preload.
OThe standard adjuster setting for average-build rider of 68
kg (150 Ib) with no passenger and no accessories is 3rd
position.
Spring Preload Setting
Standard Position: 3rd position
Operating 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 Road Driv-
Adjuster Damping Absorber Load Condi-
Position Force ing
Hardness tions Speed
1st Weak Soft Light Good Low
i i i i i i
1 1 1 1 1 1
7th Hard Bad High-
Strong Heavy
way

Rear Shock Absorber Removal

. Set the motorcycle on its center stand and raise the rear
wheel.
. Squeeze the brake lever slowly and hold it with a band
[A].
A WARNING
Be sure to hold the front brake when removing the
shock absorber, or the motorcycle may tall over. It GH040110S1 C
could cause an accident and injury.

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 11-12 SUSPENSION
Rear Shock Absorber
. Remove:
Seat (see Frame chapter)
Left Side Cover (see Frame chapter)
. Remove:
Rear Shock Absorber Lower Mounting Bolt [A]
Rear Shock Absorber Upper Mounting Bolt [B]
Tie Rod Bolt [C]
. Take out the rear shock absorber from the bottom.

Rear Shock Absorber Installation

. Apply grease to the needle bearing of the shock absorber.
. Tighten the rear shock absorber mounting nuts.
Torque -Rear Shock Absorber Mounting Nuts: 59 N.m (6.0
kgf.m, 43 ft.lb)

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 SUSPENSION 11-13
Swingarm

.Swingarm
Remove:
Removal
Rear Brake Hose Banjo Bolt [A]
Pass the Clamps [B] to pull it out.
Rear Wheel (see Wheelsffires chapter)
Chain Cover (see Final Drive chapter)
NOTE
o Place the tip of the brake hose at a position that is higher
than the rear brake fluid reservoir.

8 Remove:
Upper Tie Rod Bolt [A]
Pivot Shaft Caps
Lower Shock Absorber Bolt [B]
Pivot Shaft Nut [C]
8 Pull off the pivot shaft and remove the swingarm.

Swingarm Installation
. Apply plenty of grease to the following:
Ball Bearing
Needle Bearings
Grease Seals [A]
.Install right collars [B].
8 Insert the pivot shaft into the frame from the left side.
8 Tighten the following:
Torque - Swingarm Pivot Shaft Nut: 110 N.m (11 kgf.m,80
ft.lb)
Upper Tie Rod Nut: 59 N.m (6.0 kgf.m, 43 in.lb)
Lower Shock Absorber Nut: 59 N.m (6.0 kgf.m, 43
in.lb)
8 Install the removed parts (see the respective chapters).

Swingarm Bearing Removal

8 Remove:
Swingarm (see Swingarm Removal)
Collar [A]
Grease Seals [B]
Sleeve [C]
Circlip (right side) [D]
Special Tool - Inside Circlip Pliers: 57001-143
61106040751 C

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 11-14 SUSPENSION
Swingarm
. Remove:
Ball Bearing
Needle Bearings
Special Tool- Oil Seal & Bearing Remover: 57001-1058 [A]

GII060603S 1 C

Swingarm Bearing Installation

. Apply plenty of grease to the following:
Needle Bearing and Sleeve
Ball Bearings
Grease Seal Lip
.Install the needle bearings so that the manufacturer's
marks faces in.
. Install the bearings so that the manufacturer's
out. This prevents bearing damage.
marks face

-
SpecialTools Bearing Driver Set: 57001-1129 [A]
Inside Circlip Pliers: 57001-143

Swingarm Bearing, Sleeve Inspection and Lubrication

CAUTION
Do not remove the bearings for inspection. Remove
may damage them.
.Check the ball bearing.
OSince the ball bearing is made to extremely close toler-
ances, the wear must be judged by feel rather than mea-
surement.

. Turn [A] the bearing in the swingarm back and forth while
checking for plays, roughness, or binding. If bearing play,
roughness, or binding is found, replace the bearing.
. The rollers in a needle bearing normally wear very little,
and wear is difficult to measure. Instead of measuring,
inspect the bearing in the swingarm for abrasion, color
change, or other damage.
* If there is any doubt as to the condition of any of the nee-
dle bearings or sleeve, replace the sleeve, and needle
bearings as a set.

. Apply grease to the inner surfaces of the swingarm bear-

ing in accordance with the Periodic Maintenance Chart.
OFor the swingarm bearing, it is grease nipple [A] on the
swingarm for lubrication. Force grease into the nipple
until it comes out at both sides of the swingarm, and wipe
off any excess.

Chain Slider Inspection

. Visually inspect the chain slider.
* Replace the chain slider if it shows any signs of abnormal
wear or damage.

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 SUSPENSION 11-15
Tie Rod/Rocker Arm
Tie Rod Removal
. Set the motorcycle on its center stand and raise the rear
wheel.
. Squeeze the brake lever slowly and hold it with a band
[A].
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:
Upper Tie Rod Bolt [A]
Lower Tie Rod Bolt [B]
Tie Rods [C]

Tie Rod Installation

. Apply grease to the inside of the needle bearings, sleeve
and the grease seals.
.Install the tie-rods so that the chamfered side faces the
bolt and nut.
. Tighten the tie rod nuts.
Torque -Tie Rod Nuts: 59 N.m (6.0 kgf.m, 43 ft.lb)
Rocker Arm Removal
. Set the motorcycle on its center stand and raise the rear
wheel.
. 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:
Lower Rear Shock Absorber Bolt [A]
Lower Tie Rod Bolt [B]
Center Stand Spring [C]
Rocker Arm Bolt [D]
Rocker Arm [E]

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 11-16 SUSPENSION
Tie Rod/Rocker Arm
Rocker Arm Installation
. Applygrease to the inside of the needle bearings, sleeve,
and the grease seals.
. Tighten:
-
Torque Rocker Arm Nut: 59 N.m (6.0 kgf.m, 43 ft.lb)
Tie Rod Nuts: 59 N.m (6.0 kgf.m, 43 ft.lb)
Rear Shock Absorber Mounting Nut: 59 N.m (6.0
kgf.m, 43 ft.lb)

Rocker Arm and Tie Rod Needle Bearing Inspection

. Visually inspect the rocker arm/tie rod needle bearings.
OThe rollers in a needle 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 shows any signs of abnormal condi-
tions, replace the sleeve, needle bearing, and ball bearing
as a set.

Rocker Arm and Tie Rod Sleeve Inspection

. Visually inspect the rocker arm/tie rod sleeves.
* If the sleeve shows any signs of abnormal wear, discol-
oration, or damage, replace the sleeve, needle bearing,
and ball bearing as a set.
Tie-Rod, Rocker Arm Needle Bearing Lubrication
(Periodic Maintenance)
In order for the tie-rod and rocker arm to function safely
and wear slowly, it should be lubricated in accordance with
the Periodic Maintenance Chart.
. For the rocker arm and tie-rod needle bearings there are
grease nipples [A] on the rocker arm and swingarm for
lubrication. Force grease into the nipples until it comes
out at both sides of the rocker arm and tie-rod, and wipe
off any excess.

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 STEERING 12-1

Steering
Table of Contents
Exploded View........................................................................................................................ 12-2
Specifications ......... 12-3
Steering ........... 12-4
Steering Inspection........................................................................................................... 12-4
Steering Adjustment.......................................................................................................... 12-4
Steering Stem and Stem Bearing Removal...................................................................... 12-5
Steering Stem and Stem Bearing Installation................................................................... 12-6
Steering Stem Bearing Lubrication................................................................................... 12-8
Steering Stem Warp.......................................................................................................... 12-8
Handlebar ......... 12-9
Handlebar Removal.......................................................................................................... 12-9
Handlebar Installation....................................................................................................... 12-9

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 12-2 STEERING
Exploded View

1. Alignthe punch mark with the gap between the holder and the clamp.
2. Stem Head Nut
3. Handlebar Clamp Bolts
T1: 25 N.m (2.5 kgf.m, 18 ft.lb)
T2: 49 N.m (5.0 kgf.m, 36 ft.lb)
T3: 20 N.m (2.0 kgf.m, 14 ft.lb)
T4: 4.9 N.m (0.5 kgf.m, 43 in.lb)
AD: Apply adhesive.
G: Apply grease.
L: Apply a non-permanent locking agent to the threads.
S: Follow the specific tightening sequence.

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 STEERING 12-3
Specifications
-
Special Tools Steering Stem Bearing Driver: 57001-137
Bearing Puller: 57001-158
Bearing Puller Adapter: 57001-317
Steering Stem Bearing Driver Adapter, 4>34.5: 57001-1074
Head Pipe Outer Race Press Shaft: 57001-1075
Head Pipe Outer Race Driver, 4>51.5: 57001-1076
Steering Stem Nut Wrench: 57001-1100
Head Pipe Outer Race Driver, 4>46.5: 57001-1106
Head Pipe Outer Race Remover ID > 37 mm: 57001-1107
Jack: 57001-1238

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 12-4 STEERING
Steering
Steering Inspection
. Raise the front wheel off the grounds, using the jack.
Special Tool - Jack: 57001-1238
. With the front wheel pointing straight ahead, alternately
tap each end of the handlebar. The front wheel should
swing fully left and right from the force of gravity until the
fork hits the stop.
* If the wheel binds or catches before the stop, the steering
is too tight.
. Feel for steering looseness by pushing and pulling [A] the
forks.
*If you feel looseness, the steering is too loose.
NOTE
o The cables and wiring will have some effect on the mo-
tion of the fork which must be taken into account.
o Be sure the wires and cables are properly routed.
o The bearings must be in good condition and properly
lubricated in order for any test to be valid.

..Steering Adjustment
Loosen the Front Fork Lower Clamp Bolts [A].
Removethe Handlebar.
. Loosenthe SteeringStem Head Nut.

. Raise the front wheel and turn the stem locknut [A] to
adjust.
OLoosen the stem locknut if the steering is too tight, and
tighten the stem locknut if the steering is too loose.
-
Special Tools Jack: 57001-1238
Steering Stem Nut Wrench: 57001-1100 [B]
NOTE
o Do not separate the upper and lower stem locknuts.
Turnthe lowernut to loosen and turnthe upper nut to
tighten. Ineithercase, turnthe nut only 1/8of a turnat
a time.

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 STEERING 12-5
Steering
. Tighten the following:
Torque - Steering Stem Head Nut: 49 N.m (5.0 kgf.m, 36
ft.lb)
Front Fork Lower Clamp Bolts: 20 N.m (2.0 kgf.m,
14 ft.lb)
NOTE
o Tighten the two clamp bolts alternately two times to en-
sure even tightening torque.
o Tighten the top plug before tightening the upper fork
clamp bolt.
. Reinspect the steering.
*If it still feels tight or loose, inspect every part of the steer-
ing.
.Install the removed parts.
Steering Stem and Stem Bearing Removal
. Remove:
Fuel Tank (see Fuel Tank Removal)
Front Wheel (see Wheel/Tires chapter)
Front Fender (see Frame chapter)
. Disconnect:
Ignition Switch Connector [A]
. Loosen:
Front Fork Clamp Bolts [B]
. Remove:
Harness and Cable Holder Bolts [C]
Handlebar Clamps [D]
Handlebar [E]
.. Remove the front fork [G] (see Suspension chapter).
Remove the stem head nut [F] and washer.

. Remove the stem head [H].

. Remove the brake hose joint mounting bolts [A].

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 12-6 STEERING
Steering
. Remove the stem locknuts [A].
. Removethe stem cap [8].
Special Tool - Steering Stem Nut Wrench: 57001-1100 [B]

. Hold the stem base, remove the O-ring [A], and take out
the stem [8].
. Remove the upper bearing [C].

. Remove the bearing outer race.

Special Tool - Head Pipe Outer Race Remover ID > 37 mm:
57001-1107 [A]

. Remove the lower bearing [A] and grease seal.

Special Tools - Bearing Puller: 57001-158 [B]
Bearing Puller Adapter: 57001-317 [C]

Steering Stem and Stem Bearing Installation

. Replace the bearing outer races with new ones.
. Apply grease to the outer race, and drive both upper and
lower races into the head pipe at the same time.
Special Tools -Head Pipe Outer Race Press Shaft: 57001
-1075 [A]
Head Pipe Outer Race Driver, cp46.5: 57001
-1106 [B]
Head Pipe Outer Race Driver, cp51.5: 57001
-1076 [C]

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 STEERING 12-7
Steering
. Replace the lower bearing with a new one.
.Install the grease seal on the steering stem, and drive the
lower bearing [A] applied the grease onto the stem.
Special Tools -Steering Stem Bearing Driver: 57001-137
[A]
Steering Stem Bearing Driver Adapter,
<1>34.5:57001-1074 [B]

. Apply grease
head pipe.
to the upper bearing, and install it in the

.Insert the stem shaft through the head pipe and the bear-
ings. Then, while holding the stem base from the bottom,
install the Q-ring [A] on the shaft.
.Install the stem cap [8] and hand-tighten the locknuts [C].
NOTE
o To install the stem locknut, face its stepped side down.

.Install the stem head.

. Install the washer, and lightly tighten the stem head nut.
. Allow the bearings to settle.
OTorque the stem locknut to 39 N.m (4.0 kgf.m, 29 ft.lb).
Special Tool - Steering Stem Nut Wrench: 57001-1100 [A]
22.2 kg

GN050604S 1 C

OCheck whether the stem turns smoothly without free play.

If it feels tight or has free play, the bearings could be dam-
aged.
OGradually loosen the stem locknut until the stem turns
easily.
ORetighten the stem locknut and stop when the stem starts
to turn hard.
-
Torque Steering Stem Locknut: 4.9 N.m (0.5 kgf.m, 43
in.lb)

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 12-8 STEERING
Steering
.Install the front fork (see Suspension chapter).
NOTE
OA/ign the installationposition (see Front Fork Installa-
tion) of the fork and tighten the fork upper clamp bolt.
Then, tighten the stem head nuts, and finally the fork
lower clamp bolts.
Torque - Steering Stem Head Nut: 49 N.m (5.0 kgf.m, 36
ft.lb)
Front Fork Clamp Bolts: 20 N.m (2.0 kgf.m, 14
ft.lb)
NOTE
o Tighten the two clamp bolts alternately two times to en-
sure even tightening torque.
o Tighten the top plug before tightening the upper fork
clamp bolt.
.Install the removed parts (see the respective chapters).
A. WARNING
Do not impede the handlebar turning by routing the
cables, harness and hose improperly (see General
Information chapter).

Steering Stem Bearing Lubrication

. Remove the steering stem.
. Using a high-flash point solvent, wash the upper and
lower tapered roller bearings.
. Wipe
races.
off the old grease from the upper and lower outer

. Visually
bearings.
inspect the outer races and the tapered roller

* Ifeither the races or the tapered roller bearings show any

wear or damage, replace both as a set.
. Applygrease to the rollers [A],spin them a few times by
hand, and thoroughlypackthe insidewith grease. Apply
a thin coat of grease also to the outer race.
.Install the steering stem and adjust the steering.

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.

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 STEERING 12-9
Handlebar
Handlebar Removal
. Remove:
ClutchLeverAssy [A]
Left SwitchHousing[B]

Handlebar Weight [A]

Front Brake Master Cylinder [B]
Right Switch Housing [C]
Throttle Grip [D]

. Remove the handlebar clamp bolts [A].

. Remove the handlebar clamps [B] and take out the han-
dlebar [C].

Handlebar Installation
. Align the punch mark [A] on the handlebar with the gap
[B] between the left holder and the left clamp.

. First tighten the front clamp bolts [A]. Then, tighten the
rear clamp bolts [B]. After tightening the bolts, a clearance
[C] will be created behind the clamps.
Torque - Handlebar Clamp Bolts: 25 N.m (2.5 kgf.m, 18
ft.lb)

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 12-10 STEERING
Handlebar

. The front half of the right and left switch housings [A] has a
small protrusion [B]. Engage this protrusion with the hole
[C] in the handlebar.
. Install the handlebar switch housings.
Torque - Handlebar Switch Housing Screws: 3.4 N.m (0.35
kgf.m, 30 in.lb)

. Align the punch mark [A] on the handlebar with the mating
surtace [B] between the clutch lever holder [B] and the
clamp.

.Install the front master cylinder (see Brake chapter).

.Install the throttle and left grip.

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 FRAME 13-1

Frame
Table of Contents
Exploded View........................................................................................................................ 13-2
Seat .. .. . .................... ........... .. ...... . 13-4
Seat Removal................................................................................................................... 13-4
Seat Installation ................................................................................................................ 13-4
Side Cover and Seat Cover... ........ 13-5
Left Side Cover Removal.................................................................................................. 13-5
Left Side Cover Installation............................................................................................... 13-5
Right Side Cover Removal ... ...... 13-5
Right Side Cover Installation............................................................................................. 13-5
Seat Cover Removal......................................................................................................... 13-5
Seat Cover Installation...................................................................................................... 13-6
Fairing .............. 13-7
Wind Shield Removal........................................................................................................ 13-7
Wind Shield Installation..................................................................................................... 13-7
Fairing Removal................................................................................................................ 13-7
Fairing Installation ........ 13-8
Fairing Disassembly.......................................................................................................... 13-8
Fairing Assembly... ...... 13-8
Fender ........... 13-9
Front Fender Removal ............................................... 13-9
Rear Fender Rear Removal.............................................................................................. 13-9
Rear Fender Front Removal.............................................................................................
Rear Fender Front Installation..........................................................................................
13-9
13-10
f138
~
Frame... .. ..... .. .... ........... ................................. ............ 13-11
Frame Inspection.............................................................................................................. 13-11
Fairing Bracket Removal................................................................................................... 13-11

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 13-2 FRAME
Exploded View

G0020407W4 C

T3: 29 N.m (3.0 kgf.m, 22 ft.lb)

T4: 44 N.m (4.5 kgf.m, 33 ft.lb)
G: Apply grease.
L: Apply a non-permanent locking agent.
CAL: California Model
CN: Canada Model
US: U.S.A. Model

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 13-4 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 [8],
and pulling the seat backward.

Seat Installation
. Insert the seat hook [A] under [8] the frame bracket and
slip the seat hollow-cubic brackets [C] into the tabus [D]
of the fuel tank at the same time.
. Push down the middle part of the seat until the lock clicks.

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 FRAME 13-5
Side Cover and Seat Cover
Left Side Cover Removal
. Remove the seat (see seat Removal).
. Remove the screws [A].

. Pull the front parts [A] of the seat and side [B] covers to
your side, then remove the left side cover forward [C].

Left Side Cover Installation

.Insert the projection [A] of the side cover [B] into the grom-
met hole [C] of the seat cover [D]. At the same time, clear
the screw damper [E] from the front part [F] of the seat
cover.
. Push the front part of the side cover.

Right Side Cover Removal

. Remove the right side cover following the same proce-
dure of left side cover.

Right Side Cover Installation

.Install the right side cover following the same procedure
of left side cover.
Seat Cover Removal
. Remove:
Seat (see Seat Removal)
Side Covers
Grab Rail Bolts [A]
Grab Rails [B]

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 13-6 FRAME
Side Cover and Seat Cover
. Remove the seat lock wires [A].

. Remove the rivet screw [A].

. Pull out the seat cover back ward.

.. Unscrew the screws [A].

Remove the seat lock [8].

Seat Cover Installation

. Tighten the grab rail bolts.
-
Torque Grab Rail Bolts: 25 N.m (2.5 kgf.m, 18 tt.lb)

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 FRAME 13-7
Fairing

.Wind Shield Removal

Remove:
Screws [A]
Wind Shield [B]

Wind Shield Installation

. Put the each side [A] of the shield between the fairing and
inner cover [B], and then install the other side.
. Put the tabus [C] of the shield in the grooves [D] of the
fairing.
-
Torque Wind Shield Screws: 0.4 N.m (0.04 kgf.m, 4 in.lb)

Fairing Removal
CAUTION
Be careful not to scratch the painted surface during
removal or installation.
. Remove:
Bolts [A] (bothsides)

. Slide the rubber covers [A] and unscrew the bolts [B].

. Remove:
Wind Shield (see Wind Shield Removal)
Screws [A]
Inner Cover [B]

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 13-8 FRAME
Fairing
. Disconnect:
Headlight/Turn Signal Light Harness Connector [A]
. Clear the fairing from the projections [B] of the rear view
mirror bracket.
. Pull the fairing forward.

Fairing Installation
. Fairing installation is the reverse of removal.

Fairing Disassembly
. Disconnect:
Headlight Connector [A]
City Light (other than U.S.A. see Electrical System chap-
ter)
Turn Signal Light Connectors [B]
. Remove:
Headlight/Turn Signal Light harness [C]
Bolts [0]
Headlight Unit [E]
. Remove:
Screws [A]
. Separate the right fairing [B], joint cover [C], and left faring
[0].

. Remove:
Screw [A]
. holder
Remove the turn signal outer holder [B] and pull the inner
out.
. Remove the Turn Signal.

Fairing Assembly
. Fairing assembly is the reverse of assembly.

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 FRAME 13-9
Fender

Front Fender Removal

.. Remove the bolts [A] and clamp [B].
Remove the front fender forward.

Rear Fender Rear Removal

. Remove:
Seat Cover (see Seat Cover Removal)

. Remove the rivet screws [A] and bolts [B].

. Disconnect the tail/brake light and turn signal wire con-

nectors.
..Unscrew the bracket bolts [A] and nuts [E].
Remove the tail/brake light Assembly [B].
.Unscrew the mounting bolts [C], and take out the rear
fender rear [0].

.Rear Fender Front Removal

Remove:
Rear Fender Rear
Side Covers (see Left Side Cover Removal)
Battery (see Electrical System chapter)
Rear Brake Fluid Reservoir Mounting Bolt [A]
. Remove from the rear fender:
Turn Signal Relay [B]
Starter Relay [C]
IC Igniter [0]
Junction Box [E]

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 13-10 FRAME
Fender

. Removethe rearfenderfront [A].

Rear Fender Front Installation

.Install the rear fender front by pushing the stopper [A],
which is located at the front bottom of the rear fender front,
all the way to the bracket [8].

. General
Run the wiring harnesses and wires properly (see the
Information chapter).
.Install the removed parts.

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 FRAME 13-11
Frame

.Frame Inspection
Visually inspect the frame [A] for cracks, dents, bending,
or warp.
*If there is any damage to the frame, replace it.
A WARNING
A repaired frame may fail in use, possibly causing
an accident. If the frame is bent, dented, cracked,
or warped, replace it.

.FairingBracket Removal
Remove:
Fairing (see Fairing Removal)
Speedometer Cable Upper End [A]
Main Harness Clamp [8]
. Unscrew the bolts [C] and pull out the fairing bracket [D]
together with the meter unit [E], rear view mirror bracket
[F] and lower inner cover [G].

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 ELECTRICAL SYSTEM 14-1

Electrical System
Table of Contents
Exploded View................................... 14-3 Starter Motor Installation .............. 14-41
Specifications................................... . 14-7 Starter Motor Disassembly........... 14-41
Wiring Diagram (U.S.A., Canada and Starter Motor Assembly............... 14-42
Taiwan Model)................................. 14-8 Commutator Cleaning/Inspection. 14-43
Wiring Diagram (Australia Model)...... 14-10 Armature Inspection..................... 14-44
Wiring Diagram (Other than U.S.A., Starter Motor Brush Length.......... 14-44
Canada, Australia and Taiwan Brush Assembly Inspection.......... 14-44
Model) ............................................. 14-12 Brush Plate and Terminal Bolt
Parts Location.................................... 14-16 Inspection................................. . 14-45
Precautions....................................... . 14-17 Starter Relay Inspection............... 14-45
Electrical Wiring................................. 14-19 Lighting System................................. 14-47
Wiring Inspection......................... 14-19 Headlight Beam HorizontalNerti-
Battery.............................................. . 14-20 cal Adjustment........................... 14-47
Battery Removal.......................... 14-20 Headlight Bulb Replacement ....... 14-47
Battery Installation....................... 14-20 City Light Bulb Replacement........ 14-48
ElectrolYte Filling.......................... 14-20 Tail/Brake Light Bulb
Initial Charge................................ 14-22 Replacement............................ . 14-49
Precautions................................. . 14-22 Turn Signal Light Bulb
Interchange .................................. 14-23 Replacement............................ . 14-52
Charging Condition Inspection..... 14-23 Turn Signal Relay Inspection ....... 14-53
Refreshing Charge....................... 14-24 Meters, Gauges................................. 14-56
Charging System ............................... 14-25 Meter Unit Removal..................... 14-56
Alternator Rotor Removal............ 14-25 Meter Unit Disassembly............... 14-56
Alternator Rotor Installation ......... 14-25 Bulb Replacement........................ 14-57
Stator Coil Removal..................... 14-26 Meter Unit Assembly.................... 14-58
Stator Coil Installation .................. 14-26 Tachometer Inspection................. 14-58
Alternator Inspection .................... 14-27 Fuel Gauge Operation Inspection 14-59
Regulator/Rectifier Inspection...... 14-28 Switches and Sensors ....................... 14-60
Charging Voltage Rear Brake Light Timing
(regulator/rectifier's output Inspection. ................................. 14-60
voltage) Inspection .................... 14-30 Rear Brake Light Timing
Ignition System.................................. 14-32 Adjustment ................................ 14-60
Crankshaft Sensor Removal........ 14-32 Inspection..................................... 14-60
Crankshaft Sensor Installation..... 14-32 Fuel Level Sensor Inspection....... 14-61
Crankshaft Sensor Inspection...... 14-33 Throttle Sensor Removal and
Ignition Coil Removal................... 14-33 Installation................................ . 14-61
Ignition Coil Installation ................ 14-33 Throttle Sensor Inspection ........... 14-61
Ignition Coil Inspection................. 14-34 Throttle Sensor Position
Spark Plug Removal, Installation. 14-34 Adjustment............................... . 14-62
Spark Plug Cleaning, Inspection.. 14-35 Carburetor Heater.............................. 14-63
Spark Plug Gap Inspection .......... 14-35 Carburetor Heater Inspection....... 14-63
IC Igniter Removal....................... 14-35 Normal Open Type Relay
IC Igniter Inspection ..................... 14-35 Inspection................................. . 14-64
Electric Starter System ...................... 14-41 Atmospheric Temperature Sensor
Starter Motor Removal................. 14-41 Inspection................................. . 14-64

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 14-2 ELECTRICAL SYSTEM

PTC Sensor (Carburetor Fuse Installation........................... 14-67

Temperature Sensor) Fuse Inspection............................ 14-67
Inspection .. 14-65 Fuse Circuit Inspection ................ 14-67
Carburetor Heater Controller Headlight Relay, Starter Circuit
Inspection . 14-65 Relay Circuit Inspection ............ 14-70
Junction Box...................................... 14-67 Diode Circuit Inspection ............... 14-71
Fuse Removal ..... 14-67

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 ELECTRICAL SYSTEM 14-3
Exploded View

Dummy Page

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 14-4 ELECTRICAL SYSTEM
Exploded View

(Other than .
USA Cana d a a nd Austra I i a)

"'"

"'"
~ 'e
'

O'Q ~!
~
~
@
~p'~
J ~
~ GP020414W4 C

1. Starter Lockout Switch 10. Starter Motor

2. Front Brake Light Switch 11. Alternator Stator
3. IgnitionSwitch 12. Alternator Rotor
4. Fuel Level Sensor 13. Oil Pressure Warning Light Switch
5. Regulator/Rectifier 14. Timing Rotor
6. #1, #4 Ignition Coil 15. Crankshaft Sensor
7. #2, #3 Ignition Coil 16. Neutral Switch
8. Spark Plug 17. Rear Brake Light Switch
9. Horn 18. Side Stand Switch

----
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 ELECTRICAL SYSTEM 14-5
Exploded View

T1: 1.2 N.m (0.12 kgf.m, 10 in.lb) T12: 5.9 N.m (0.6 kgf.m, 53 in.lb)
T2: 14 N.m (1.4 kgf.m, 10 ft.lb) T13: 12 N.m (1.2 kgf.m, 104 in.lb)
T3: 5.1 N.m (0.52 kgf.m, 45 in.lb) T14: 3.9 N.m (0.4 kgf.m, 35 in.lb)
T4: 9.8 N.m (1.0 kgf.m, 87 in.lb) T15: 4.9 N.m (0.5 kgf.m, 43 in.lb)
T5: 7.8 N.m (0.8 kgf.m, 71 in.lb) G. Apply grease.
T6: 128 N.m (13 kgf.m, 94 ft.lb) L: Apply non-permanent locking agent to the
T7: 2.9 N.m (0.3 kgf.m, 26 in.lb) threads.
T8: 15 N.m (1.5 kgf.m, 11 ft.lb) 0: Apply oil.
T9: 1.6 N.m (0.16 kgf.m, 14 in.lb) 88: Apply silicon sealant (Kawasaki Bond:
T10: 40 N.m (4.1 kgf.m, 30 ft.lb) 56019-120) along the entire circumfer-
T11: 8.8 N.m (0.9 kgf.m, 78 in.lb) ence of the seal.

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 14-6 ELECTRICAL SYSTEM
Exploded View

GP020416W4 C

1. Turn Signal Relay

2. Battery
3. IC Igniter
4. Junction Box
5. Fuse
6. Starter Relay
T1: 5.1 N.m (0.52 kgf.m, 45 in.lb)
T2: 5.9 N.m (0.6 kgf.m, 52 in.lb)

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 ELECTRICAL SYSTEM 14-7
Specifications
Item Standard Service Limit
Battery
Terminal Voltage 12.8 V or more - --
Charging System
Alternator Output Voltage 35 V or more @4000 r/min (rpm) - --
Stator Coil Resistance 0.1 - 0.8 0 - --

Charging Voltage 14 - 15 V
(Regulator/Rectifier Output 14.7 :to.5 V (with headlight switch - --
Voltage) ON if applicable)
Ignition System
Crankshaft Sensor Resistance 380 - 560 0 - --
Ignition Coil:
3 Needle Arcing Distance 7 mm (0.28 in.) or more - --

Winding Resistance:
2.61-3.190 - --
Primary Windings
Secondary Windings 13.5 - 16.5 kO - --
Spark plug:
Type NGK DR9EA or ND X27ES R-U, - --
Gap 0.6 - 0.7 mm (0.024- 0.028 in.) - --
Electric Starter System
Starter motor:
Carbon brush length 12.0 - 12.5 mm (0.47 - 0.49 in.) 6 mm (0.24 in.)
Commutator diameter 28.0 mm (1.10 in.) 27.0 mm (1.06 in.)
Switch and Sensor
On after about 10 mm (0.4 in.) - --
Brake light timing
pedal travel
Fuel level sensor resistance:
Full position 4 - 10 0 - --
90 - 100 0 - --
Empty position
Special Tools -Outside Circlip Pliers: 57001-144
Hand Tester: 57001-1394
Spark Plug Wrench, Hex 18: 57001-1024
Rotor Puller Adapter, <p 9.5: 57001-1151
Flywheel Puller Assembly, M30 x 1.5, M33 x 1.5: 57001-1426
Flywheel Holder: 57001-1313
Igniter Checker Set: 57001-1378
Harness Adapter #14: 57001-1427
Harness Adapter #2: 57001-1382
Throttle Sensor Setting Adapter #1: 57001-1400
Peak Voltage Adapter: 57001-1415
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

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 14-8 ELECTRICAL SYSTEM
Wiring Diagram (U.S.A., Canada and Taiwan Model)

Fuel Level
Right Handlebar Switches
I. Front Brake Light Switch
ONIPARI 2. Engine Stop Switch
3. Starter Button
I~ BR BR
iiTITiTT 1 1
ITITT BL R/BL

ill
TAI L2 R R
Ignition BTiTI"iTI I/BK 1
Switch 'fATIT" I/G DIG s'"'~
iGiiTi'OiI GY GY
ffii1iOi1

'11"r
::::

a::-I. a::

;;D:a:::;

~ Tachometer
12VI.7W Light ~ I I ..""... I ...
U-C::
ITachometer Light
112VI.7W
BK BL/I-
Tachometer - BR mBR/1 -
ISpeedometer
12VI.7W
Light f"" ",,-
ISpeedometer Light I
112VI.7W I

0i I Pressure
1 Warning Light 12VI.7W
-;- R{L R:L=- -
INeutral Indicator
Light 12V3.4W --R/BK
G R/BK--,
G I
IHigh
Light
Right
Indicator
Beam Indicator
12V3.4W
Turn Signal
Light 12V3.4W
J''''ffi''''-+-
: :/Y IG/y

Left Turn Signa I

] Indicator Light 12V3.4W
I Fu e I Ga u g e ((,9
I

---- --~ I Frame

Ground
Meter Unit SS§S:<' I

IIIIII 22'"o§ S

',:

RIBK
BK I Y
Headl ight 12V60/55W RI Y

1 LlYbll
Front Right Turn
Signa/Running GY ~ GY Side
Position
12V23/SW
Lights
CIl BK/Y~BK/Y
BL ~ BL
CD 0
Left
0
Handlebar Switches
Stand
Switch
1. Horn Button
Front Left Turn 2. Hazard Switch
Signa/Running GY ~ G 3. Turn Signal Switch
Position
12V23/SW
Lights
em BK/Y~BK/Y
BL ~ BL
Horn
12V2.5A
4.
5.
Dimmer
Starter
Switch
Lockout Switch

CONNECTIONS
Horn Oimmer Switch Starter Lockout S.itch
Color IBK/yl BK IBK/R

Push Push OFF (Push)

OFF(Push)

WIL1984CW5 C

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 ELECTRICAL SYSTEM 14-9
Wiring Diagram (U.S.A., Canada and Taiwan Model)

Rear Junction Box

Brake Junction Box
1. Starter Circuit Relay
2. Horn Fuse lOA
3. Ignition Fuse lOA
4. Tai I I ight Fuse lOA
5. Turn Signal Relay Fuse lOA
6. Headl ight Relay
~;Wh 7.
8.
Headlight
Ma inFuse
Fuse
30A
lOA

9. Accessory Circuit Fuse lOA

~
Turn
Ignition Si gna I
Co i I s I
111::::::::::III:::I::::,1 I

I I I §> :;f -8e EI ec t r i c a I

J I
J
Accessory
BKI R
-80 Terminals

RI,Bl- J
BR
BRII
0
BLlY Rear Rig t
YI G GY ==[[t GY Turn Sig a I
lG 2111

Toil/' rake
GY f"" "" U ,h t 12
lights
IIIX2
R R R R
BKI Y
G
BK/Y
B;R BK/Y
BLIR 3IE BK/Y
Bl 12 V 5/2

G/I

Rear lef
'1L BK/Y=[[J=
G BK/Y
GY Turn
light g 2111
S i12
a I

'---- G

BK
>
J
-

n
.
- -
-
'- '-
r I >- ;;;
"'I

. '" I
II I I
-'
S $$ . >Tl.
::;>-;;::;e;::=
I / "
JiLj \_ I
i
(
I i.iililli.

IC Igniter
I Sensor
haft

Color Code
~ BI a c k
Bl ~
Oi I Neutral BR Brown
Pressure Switch CH Chaco I ate
Switch DG Dark Green
G Green
GY ~
l B light Blue
l G li~een
I GN I T ION SYf I TCH CONNECT IONS RIGHT HANDLEBAR SWITCH CONNECTIONS o O~e
I en I t I 0nl Bat to r V I To i 11 I To i I 2 IB a t t or vi T a i I 3 l~ionI1Initi.n Front Brake light Switch Starter Button P Pin k
Co I or BR BL II/BK I II/G GY ~ P U Pu..!.!..1e
OFF, LOCK R Red
ON II . hit e
P (P';'"r k ) Y Ye I low

W1RI984CWS C

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 14-10 ELECTRICAL SYSTEM
Wiring Diagram (Australia Model)

Fuel
Level
Sensor Right Handlebar Switches
1. Front Brake Lgith Switch
2. Engine Stop Switch
3. Starter Button

ION1"11 <D 00

~
IGIIIIOI BR BR
iITi1TI I I
Ignition Switch ITTTI BL R/BL
mTI R R
TffiiiOi GY GY
IGIIIIG!

§
1------
!Tachometer Light 12VI.71X2

'Tachometer
- BR mBR/I

Light 12V1.71X2
1"",0."" r:' :;:
I I
I
Oi I Pressure larning Light 12VI.71 .".""
RlBL R/BL
LG LG
Neutral Indicator Light 12V3.41 R/BK R/BK
G G
!
High Beam Indicator Light 12V3.41
- GY
I/Y
GY
I/Y

,Right Turn Signal Indicator Light 12V3.41

,Left Turn Signal Indicator Light

IFuel Level Gauge

L.______
lIeter Unit

§S§ :c .>- IOII: IOII:

cro UJ
GClCD IXCDG:CD a:: ,........

C : : ::
Headlight
12V60/551
.m
SK/Y
RIY

[:rw
Front Right
Turn Signal L i ght ~ G -f1l--- GY
12 V 2 1 I ~ BK/Y--lJ..j-- BK/Y
Left Handlebar Switches
1. Horn Button
2. Turn Signal Switch
Front Left 3. Dimmer Switch
Turn Signal Li ght Horn 4. Starter Lockout Switch
12 V21 I 12 V 2. 5" 5. Passing Button

CONNECTIONS
Horn
C-;j";;
Push
Rele8sed

W1L1985BW5 C

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 ELECTRICAL SYSTEM 14-11
Wiring Diagram (Australia Model)

Junction Box
I. Start r Circuit Relay 5. Turn Signal Relay Fuse 10A
2. Horn use lOA 6. Headlight Relay
3. Ignit on Fuse lOA 7. Headl ight Fuse lOA
4. Tai I I ght Fuse lOA 8. lIain Fuse 30A
9. Accessory Circuit Fuse 10A
Junction Box
Rear Brake
Light Switch

fJ~:;:""<o' n.".,
Spark Plugs
'rl
~~
. s: C. Atmospher
Temp~~:~~~e
ic Sensor

..
1* D. ~::::~ature Sensor

L:t:D:';" ~~~ E."

Turn
I" Co,,, 0I U,;.
S i gn a I
II Relay
I

1
n/R

R/.- I
BR
BR/.
° I
BlI Y
YIs Rear Right Turn
Signal Light
L0
ItB:;' =[O:nO/'@ 12V211

Ta i I I
oY OY - Brake Light

n/Y
R
BlIR-
R - r"""111::u
BK/Y- ~B:I,:uJ:BK~Y~
rrm 12V5/211X2

o o-
0/.

Rear Left Turn

Signal Light
12V21W
Lt=B:/Y==ITtK:~
-0
BK
I
~~~

~
~~

",~.."
,Q]
I I
n Regurator/
Rectifier I
I.C. Igniter
"',

Crankshaft
Sensor

tt
I 1

Color Code
Side
Stand Iternator
BK
BL
Black
Blue
Switch -=::I
BR Brown
CH Chocolate
/": DG Dark Green
Throttle G Green
Oil Neutral Sensor
Pressure GY Gray
Switch
Switch LB light Blue
IGNITION SWITCH CONNECTIONS RIGHT HANDLEBAR SWITCH CONNECTIONS LG light Gr..n
o Orange
Co I or P Pin k

OFF.:.!;,OCK
PU Purple
ON R Red
p '('P'AR K ) I White
Y Vellow

II R 19858115 C

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 ".

14-12 ELECTRICAL SYSTEM

Wiring Diagram (Other than U.S.A., Canada, Australia and Taiwan Model)
ZR750-H1 - H2

Right Handlebar Switches

1. Headl ight Switch
2. Front Brake Light Switch
3. Engine Stop Switch
4. Starter Button

IGNITION 2
ION IPIRI
BR BR CD 0 00
iii'iTiTT
Ignition
Switch
mLi
ITiT2'
I
BL
R
I
R/BL
R ~:::~
IGNITION 1
iGNTiTON3
GY

ijf GY

lKljr ::§

s
w
SCE
-
rs Tachometer
12V1-7W
ITachometer
Light

Light
rg, I , m "'7 m"'m"i
W-t
112 VI. 7 W II
--.
BK BLlI-
Tachometer
- BR :[[EBR/I -
I Speedometer L i g ht fBK/Y BK/Y-

1~~:1d~:eter Light I
112V1- 7W I

0; I Pressure
Warning Light 12VI. 7W
-.---
1

INeutral
Light
Indicator
12V3.411
+ LG LG - r
IHigh Beam Indicator ( RBKI--J
Light 12V3.411 GY
, II Y
Right
Indicator
Turn Signal
Light 12V3.411
Lm:;-
Left Turn Signal
I Indicator Light 12V3.411

I Fue I Gauge
I

L__ ---- --~ I Frame

Ground
Meter Unit
l
miii
I

§CJo§S

i::::::::
§CJo:;:S :
Head light 12V60!55W

R
City Light 12V5W
=ill= BK/Y -
m-
::
Front
Signal
Right
Light
Turn ~ G ~ GY

12V21W ~BK/Y-LJJ-BK/Y

*
Left Handlebar Switches
1. Horn Button
2. Turn Signal Switch
Front Left Turn 3. Dimmer Switch
Signal Light Horn 4. Starter Lockout Switch
12V21W 1 2V2. 5A 5. Passing Button

HANDLEBAR SWITCH CONNECTIONS

Horn Dimmer S.itch Starter Lockout S.itch IPass i nl Button
Co lor
Pus h

.1L1962B.S C

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 ELECTRICAL SYSTEM 14-13
Wiring Diagram (Other than U.S.A., Canada, Australia and Taiwan Model)

1. Starter Circuit Relay 5. Turn Signal Relay Fuse lOA

2. Horn Fuse 10A 6. Headl ight Fuse 10A
3. Ignition Fuse lOA 7. Main Fuse 30A
4. Tai I I ight Fuse 10A 8. Accessory Circuit Fuse lOA
Rear
Brake
Light
Switch

A. Carburetor Heater
B. Carburetor
Temperature Sensor
C. Atmospher i c
Temperature Sensor
D. Heater Control Unit
Open Type Relay

1511 I 10.I ""..

Co i I s

t
BKI,--L.W- Rear ~:~~ al
0' -rn-SK/'~LG ~Turn i ght 12V 21 W

BUR
SKI,
R ill BL
R
SKI'
~ TailiB
Lights
12V5/2
rake

IWX2

o Rear ~~:~ al
BKI' ---I !.J- 0 ~
-f11-SK/'~TUr~t L1g 12V 21 W

~ n"'n S~. ~$

m ~; \.....
IC Igniter
shaft

Color Code
~ BI ac k

Oi I Neutral
;:>101:
!U ~
BR ~
Pressure Switch Jl-J.~hrottle
Switch CH ChocoI ate
0ensor o G ~n
G G,een
GY ~
!:..! ~
IGNITION SWITCH CONNECTIONS !:..! Li~.n
Ilnob.nlhtter,1 Todl I hil2 IIlnitionlllnition Starter Button o O,ang.
Co lor BR BL GY
P ~
OFF, LOCK
PU pu'p I .
ON
II W
P (PARK)
W Ih i te
(98051-19628) Y Y. II ow

W1RI962BW5 C

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 14-14 ELECTRICAL SYSTEM
Wiring Diagram (Other than U.S.A., Canada, Australia and Taiwan Model)
ZR750-H3 -

Right Handlebar Switches

1. Front Brake Light Switch
2. Engine Stop Switch
3. Starter Button
___ION
IPARI
<D 0 CD
1611

BAITER!
TIOI

1
2 BR
. .
BR
Ignition Bl R/Bl
~:::~
~
Switch ITi1"1
ITT[""'"'1" R R
i1ii'TiOi1 GY GY
i'iiiTiOi1

~h~m~e~t - - - -I
112VI.7W
ITachometer
112VI.7W
T8chometer
Light ~ I
I
~~~'ik

I Speedometer Light
12 V 1 . 7 W
ISpeedometer Light
112VI.7W

0i I Pressure
1 Warning Light 12V1. 7W
INeutral Indicator I
Light 12V3.4W
IHigh Beam Indicator
Light 12V3.4W
Right Turn Signal
Indicator Light 12V3.4W
Left Turn Signa I
II nd i cator Light 12V3.4W

IFuel Gauge
I

---- --~ r Frame

Meter Unit Ground

mill
Headl ight 12V60/55W

R
City Light 12V5W
BK/Y-

Front
Signal
Right
Light
Turn ~ G -ril- GY

12 V21 W ~B KI Y--l.!..J-B KI Y
Left Handlebar Switches
1. Horn Button
2. Turn Signal Switch
Front Left Turn 3. Dimmer Switch
Horn 4. Starter Lockout Switch
Signal Light
12 V21 W 12V2.5A 5. Passing Button
LEFT HANDLEBAR SWITCH CONNECTIONS
Horn Dimmer S.itch Button
Color
Pus h

W2L1145AW5 C

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 ELECTRICAL SYSTEM 14-15
Wiring Diagram (Other than U.S.A., Canada, Australia and Taiwan Model)

, " •• , •• C" •• ,t •• Or 5 t ••• S I" I.,., ro •• 10.

Z I.,. r ..... ~ I1 h." .10. 1010.
_'011.10.,••• ,..
J 1•• _, O' f • • • • • •
".,.f
,
h."
I •••••••• c"
f ...
JI.
•• ,.
, ••

fo •• It I
"0'
Ir.~.
L'I __
So to"

-- .
......•.
... .
" f------- "' ----fl"l- •
.-----
L -.. ,--l.JJ- .. ,
:@h" ,. 0"
"""0• t., ..
t
urlll

. .. - .....
~
"
.....•
• ,.".'=
•
,-
to , . .
• ::1Tt.
0< .:::l.lJ=.. ,
L .10 ••
,ns f"XI

"

C.""~.,
10". 0'
.. ft

....
Color Code
....
.. .
....
, I 00

t· I ..
" 101' C" ••
• lit . . .
It ..
o'
"" l,." I

I... .
.. . .. I'" I,,,.. ,
.. . ..
CDuEetlONS •• GMT MA.DlEB.' siitel eO"EeIIOIS
,,,,, .... " .. •,
j ."' .....

...... ,...... .
10,' '., I to ,," "",' .. .......... 1, ... $0' .. , ..... St . . . . . " .
, ••
..
P,d
n' LUI ....o. ,.
h .'
,","
II Ie ~", "~I •
'u'
... .u"
'"•
'

1.... 1 ........
10

(fI.II-II'Ul
,• lI,to
", I,.

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 14-16 ELECTRICAL SYSTEM
Parts Location

A. Ignition Switch H. Starter Relay O. Battery

B. Starter Lockout Switch I. Alternator P. Front Brake Light Switch
C. Horn J. Starter Motor Q. Rear Brake Light Switch
D. Regulator/Rectifier K. Side Stand Switch R. Crankshaft Sensor
E. Ignition Coil L. Neutral Switch S. Oil Pressure Warning
F. Spark Plug M. Junction Box Light Switch
G. Turn Signal Relay N. Ie Igniter

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 ELECTRICAL SYSTEM 14-17
Precautions

There are a number of important precautions that are

musts when servicing electrical systems. Learn and ob·
serve all the rules below.
ODo not reverse the battery wire connections. This will bum
out the diodes on the electrical parts.
OAlways check battery condition before condemning other
parts of an electrical system. A fully charged battery is a
must for conducting accurate electrical system tests.
OThe electrical parts should never be struck sharply, as
with a hammer, or allowed to fall on a hard surface. Such
a shock to the parts can damage them.
eTc prevent damage to electrical parts, do not disconnect
the battery wires or any other electrical connections when
the ignition switch is on, or while the engine is running.
OBecause of the large amount of current, never keep the
starter button pushed when the starter motor will not tum
over, or the current may bum out the starter motor wind·
ings.
000 not use a meter illumination bulb rated for other than
voltage or wattage specified in the wiring diagram, as the
meter or gauge panel could be warped by excessive heat
radiated from the bulb.
OTake care not to short the wires that are directly connected
to the battery positive (+) terminal to the chassis ground.
OTroubles may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the failure. If the failure was caused by some
other item or items, they too must be repaired or replaced,
or the new replacement will soon fail again.
OMake sure all connectors in the circuit are clean and tight,
and examine wires for signs of burning, fraying, etc. Poor
wires and bad connections will affect electrical system op-
eration.
OMeasure coil and winding resistance when the part is cold
(at room temperature).
OColor Codes:
BK Black G Green P Pink
BL Blue GY Gray PU Purple
BA Brown LB Ught blue R Red
CH Chocolate LG Ught green W White
DG Dark green o Orange Y Yellow

OElectrlca.1 Connectors
Female Connectors [A]

"'0'0'0'" 0

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 14-18 ELECTRICAL SYSTEM
Precautions

Male Connectors [6)

.'0'0'0'" C

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 ELECTRICAL SYSTEM 14-19
Electrical Wiring

Wiring Inspection
• Visually inspect the wiring for signs of burning, fraying,
etc.
*11 any wiring is poor, replace the damaged wiring.
• Pull each connector [A] apart and inspect it for corrosion,
dirt, and damage.
*11 the connector is corroded or dirty, clean it carefully. If it
is damaged, replace it.
• Check the wiring for continuity.
OUse the wiring diagram to find the ends of the wire which
is suspected of being a problem.
OConnect the hand tester between the ends of the wires
Special Tool - Hand Tester: 57001-1394
OSet the tester to the x 1 0 range, and read the tester.
*11 the tester does not read 0 0, the wire is defective. Re-
place the wire or the wiring harness [8] if necessary.

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 14-20 ELECTRICAL SYSTEM
Battery

Battery Removal
eRemove:
Seat (see Frame chapter)
Air Cleaner Intake Duct (see Fuel System chapter)

• Slide the protective cap [A] disconnect the negative (-)

cable [B] first.
• Next disconnect the positive (+) cable [C].
CAUTION
Always disconnect the negative (-) cable first be-
fore disconnecting the positive (+) cable.

• Remove the battery [D).

Battery Installation
• Place the battery in the battery box.
• Connect the capped cable [A] to the (+) terminal.
• Put a light coat to grease on the (+) terminal to prevent
corrosion.
• Cover the (+) terminal with its protective cap [B].
• Connect the negative cable [C] to the (-) terminal [OJ.
• Install the removed parts.
CAUTION
To connect, always connect the positive (+) wire
first, and to disconnect, always disconnect the
negative (-) wire first. Otherwise, it could create a
spark, which could damage the electrical parts.

Electrolyte Filling
• Make sure that the model name [A] of the electrolyte con-
tainer matches the model name [B] of the battery. These
names must be the same.
Battery Model Name for ZR750-H1: XTX12-B$

CAUTION
Be sure to use the electrolyte container with the A B
same model name as the battery since the elec-
trolyte volume and specific gravity vary with the
battery type. This is to prevent overfilling of the
electrolyte, shorting the battery life, and deteriora·
tion of the battery performance.

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 ELECTRICAL SYSTEM 14-21
Battery

• Check to see that there is no peeling, tears or holes in the

seal sheet on the top of the battery.
• Place the battery on a level surface. B
• Remove the seal sheet [Al.
CAUTION o

Do not remove the seal sheet sealing the filler ports

[B] until just before use.

• . . . 0,. . . ' c
NOTE
OA battery whose seal sheet has any peeling, lears, or
holes, requires a refreshing charge (initial charge).

• Take the electrolyte container out of the plastic bag.

• Detach the seal cap [A] from the container.
NOTE
000 not discard the seal cap because it is used as the
battery plugs later.
A
a Do not peel back orpierce the seals fB] on the container.

• Place the electrolyte container upside down aligning the

six seals with the six battery filler ports.
• Push the container down strongly enough to break the
seats. Now the electrolyte should start to flow into the
battery.
NOTE
:1
01l!1JJJ
000 not tilt the container as the electrolyte flow may be
interrupted. fill ""\
"0'000'" t

• Make sure air bubbles [A] are coming up from all six filler
ports.
OLeave the container this way for 5 minutes or longer.
NOTE
Olf no air bubbles are coming up from a filler port, tap fB]
the bottom of the container two or three times. Never A
remove the container from the battery.

CAUTION .".OOOOS, C

Fill the electrolyte into the battery until the con-

tainer is completely emptied.

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 14-22 ELECTRICAL SYSTEM
Battery

• Be certain that all the electrolyte has flowed Qut.

• Tap the bottom the same way as above if there is any
electrolyte left in the container.
• Now pull the container gently out of the battery.
• Let the battery sit for 20 minutes. During this time, the
electrolyte permeates the special separators and the gas
generated by chemical reaction is released.
• Fit the seal cap [A] tightly into the filler ports until the seal
cap is at the same level as the top of the battery.
'.OloOOU' C
NOTE
000 not hammer. Press down evenly with both hands.

A WARNING
Once you installed the seal cap after filling the bat·
tery, never remove it, nor add any water or elec-
trolyte.

Initial Charge
While a maintenance free battery can be used after only filling with electrolyte, a battery may not
be able to sufficientty move a starter motor to start an engine in the cases shown in the table below,
where an initial charge is required before use. However, if a battery shows a terminal voltage of 12.6
V or more, using a digital volt meter, after 10 minutes of filling, no initial charge is necessary.
NOTE
o To measure battery terminal voltage, use a digital voltmeter which can be read one decimal place
voltage.

Condition requiring initial charge Charging method

At low temperature (lower than O°C) 1.2 A x 2 - 3 hours
Battery has been stored under high temperature and humidity.
Seal sheet has been removed, or broken· peeling, tear or hole.
Battery two or more years old from date of manufacture.
1.2 A x 15 - 20 hours
Battery manufacturing date is printed on battery top.
Example) 12 10 99 T1
Day Month Year Mfg. location
PrecautIOns
1) No need of topping-up
No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the
seal cap to add water is very dangerous. Never do that.
2) Refreshing charge
If an engine wilt not start, a horn sounds weak, or lamps are dim, it indicates the battery has been
discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification
(see this chapter).
When a fast charge is inevitably required, do it following precisely the maximum charge current
and time conditions indicated on the battery.
CAUTION
This battery is designed to sustain no unusual deterioration if refresh-charged according
to the method specified above. However, the battery's performance may be reduced no-
ticeably if charged under conditions other than given above. Never remove the seal caR
during refresh charge.
If by chance an excessive amount of gas is generated due to overcharging, the relief valve
releases the gas to keep the battery normal.
3) When you do not use the motorcycle for months:
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 ELECTRICAL SYSTEM 14-23
Battery

Give a refresh charge before you store the motorcycle and store it with the negative lead re-
moved. Give a refresh charge once a month during storage.
4) Battery life:
If the battery will not start the engine even after several refresh charges, the battery has ex-
ceeded its useful life. Replace it (Provided, however, the vehicle's starting system has no prob-
lem).
A WARNING
Keep the battery away from sparks and open flames during charging, since the battery
gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger,
connect the battery to the charger before turning on the charger.
This procedure prevents sparks at the battery terminals which could ignite any battery
gases.
No fire should be drawn near the battery, or no terminals should have the tightening loos-
ened.
The electrolyte contains sulfuric acid. Be careful not to have it touch your skin or eyes. If
touched, wash it off with liberal amount of water. Get medial attention if severe.

Interchange
A sealed battery can fully display its performance only when combined with a proper vehicle electric
system. Therefore, replace a sealed battery only on a motorcycle which was originally equipped with
a sealed battery.
Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original
equipment, the sealed battery's life will be shortened.

Charging Condition Inspection

OBattery charging condition can be checked by measuring
battery tenninal voltage with a digital voltmeter (A).
• Remove the seat (see Frame chapter).
• Disconnect the battery terminals.
CAUTION
Be sure to disconnect the negative terminal first.

• Measure the battery tenninal voltage.

NOTE
OMeasure with a digital voltmeter which can be read one
decimal place voltage.

*11 the reading is 12.6 V or more, no refresh charge is re-

quired, however, if the read is below the specified, refresh ", ./
charge is required. 012 S
/'

Battery Terminal Voltage /'

" ,
Standard: 12.6 V or more
Terminal Voltage (V) [AI
'"
.
" , "
.I·m
50 15 100( .. l _ @
Battery Charge Rate ('0) [B]
Refresh charge is required [C]
Good [DJ

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 14-24 ELECTRICAL SYSTEM
Battery
Refreshing Charge
• Remove the battery [A] (see this chapter).
• Do refresh charge by following method according to the
battery terminal voltage.
A WARNING o o
This battery is sealed type. Never remove seal cap
[8] even at charging. Never add water. Charge with
current and time as stated below.
A
D '''''H,n, I

Terminal Voltage: 11.5 -less than 12.6 V "

Standard Charge 1.2 A x 5 -10 h - ,•
L
"'-
.
~

(see following chart)

Quick Charge SAx1.0h
••
.- "'-
"
~

•• •
CAUTION -,
~

, "-'"
0
If possible, do not quick charge. If quick charge is •
done unavoidably, do standard charge later on. " "
B.ttery Ter.,n.1 Volt.,o(lI)
"01'"111 ,

Terminal Voltage: less than 11.5 V

I~~
Charging Method: 1.2 A x 20 h

NOTE
Olf the current does not flow when charging, raise the

,~©
voltage initially (25 Vas maximum), and let down the
,
voltage to charge when the current starts to flow as a
yardstick. If ammeter shows no change in current after
B -
I~ ~
5 minutes, you need a new battery. The current, if it can ~®
ffow into the battery, tends do become excessive. Ad-
' ...."11. e
just the voltage as often as possible to keep the current
at standard value (1.2 A).
Battery [AJ
Battery Charger [BI
Standard Value [C]
Current starts to flow [D].

• Determine the battery condition after refresh charge.

ODetermine the condition of the battery left for 30 minutes
after completion of the charge by measuring the terminal
voltage according to the table below.
Criteria Judgement
12.6 V or higher Good
12.0 - lower than 12.6 V Charge insufficient - Recharge
lower than 12.0 V Unserviceable - Replace

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 ELECTRICAL SYSTEM 14-25
Charging System

Alternator Rotor Removal

• Remove the alternator cover bolts (AI.
• Remove the alternator cover [B].

• Holding the rotor steady, unscrew the rotor bolt (A]

Special Tool - Flywheel Holder: 57001-1313 [8]

elnsert the rotor puller adapter into the rotor bolt hole.
Special Tool - Rotor Puller Adapter: 57001-1151 [A]

• Remove the rotor (Al, using the rotor puller.

Special Tool - Flywheel Puller Assembly, M30 )( 1.5, M33 x
1.5: 57001-1426 [B]

Alternator Rotor Installation

• Clean the following areas with cleaning solvent:
Oil seal surface of crankshaft [A]
Tapered portion of crankshaft (B) ~
Threaded portion of alternator bolt and crankshaft (C] ~
Tapered portion of alternator rotor (OJ

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 14-26 ELECTRICAL SYSTEM
Charging System
NOTE
OConfirm the alternator rotor fit or not to the crankshaft
before tightening it with specified torque.
Olnstall the rotor and tighten it with 113 N·m (11.5 kgf·m, 83
ft·lb) of torque.
ORemove the rotor bolt.
OCheck the tightening torque with rotor puller.
*11 the rotor is not pulled out with 20 N·m (2 kgf·m, 15 ft·lb)
of drawing torque, it is installed correctly.
*11 the rotor is pulled out with under 20 N·m (2 kgf·m, 15
ft·lb) of drawing torque, clean off any oil dirt or flaw of the
crankshaft and rotor tapered portion, and dry them with
a clean cloth. Then, confirm that it is not pulled out with
above torque.
• Tighten the alternator rotor bolt while holding the alterna-
tor rotor steady with the flywheel holder.
Torque - Alternator Rotor Bolt: 128 N·m (13 kgf.m, 94 ft·lb)
Special Tool - Flywheel Holder: 57001-1313
Torque - Alternator Cover Bolt: 12 N·m (1.2 kgf.m, 104 in.lb)

Stator Coil Removal

• Remove:
Alternator Cover (see Alternator Rotor Removal)
Holding Plate Botts [A] and Plate
Alternator Grommet [Bl
Stator Coil Bolts (C)
• Remove the stator coil [OJ from the alternator cover.

Stator Coil Installation

• Apply a non-permanent locking agent to the bolts and
tighten them.
Torque - Stator Coil Bolts: 7.8 N·m (0.8 kgf·m, 69 in·lb)
• Secure the alternator lead with a holding plate, and
tighten the bolts.
Torque - Alternator Lead Holding Plate Bolts: 2.9 N·m (0.3
kgf·m, 26 in.lb)
• Install the Alternator Cover (see Alternator Rotor Installa-
tion).

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 ELECTRICAL SYSTEM 14-27
Charging System

Alternator Inspection
There are three types of alternator failures: short circuit,
open circuit, and demagnetized rotor. If there is a short or
open circuit in the coil, the output decreases, or is at zero.
A rotor could become demagnetized if it is dropped, struck,
left apart from the stator, or simply through aging, leading
to reduced output.
• Measure the alternator's no-load output voltage in the fol·
lowing sequence:
OTum the ignition switch OFF.
ORemove the left side cover (see Frame chapter)
ORemove the alternator lead connector [A].
OConnect the hand tester as shown in Table 1.
Table 1. Alternator No-Load Output Voltage
Connecting terminal Standard
Tester
Tester positive Tester negative @4000
Range
(+) terminal (-) terminal r/min (rpm)
Another yellow 35 V or
AC250V One yellow lead
lead more

OStart the engine.

OMaintain the engine speed at 4 000 r/min (rpm).
OMeasure the voltage (total 3 times).
*If the measurement is considerably lower than the stan-
dard, stop the engine, and inspect the stator coil.
• Measure the stator coil resistance.
OConnect the hand tester as shown in Table 2.
Table 2. Alternator No-Load Output Voltage
Connecting terminal
Tester
Tester positive Tester negative Standard
Range
(+) terminal (-) terminal
Another yellow
x 10 One yellow lead 0.1 - 0.8 0
lead
ORead the measurement (total 3 tImes).
*11 the measurement is greater than the standard, replace
the stator.
• Set the hand tester to x 1n range and connect it between
the respective yellow wire in the female connector of the
alternator and the frame to measure the resistance.
*11 the tester reads a value other than infinity (00), replace
the stator.
*If the output voltage is out of standard even if the stator
coil and wires appear normal, replace the alternator rotor.

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 14-28 ELECTRICAL SYSTEM
Charging System

Regulator/Rectifier Inspection
Rectifier Circuit Check
• Remove the fuel tank (see Fuel System chapter).
• Disconnect the connector [A] from the regulator/rectifier.

White Lead Terminal (A]

Brown Lead Terminal [B] A C
Black/Yellow Lead Terminal [C]
Yellow 1 Lead Terminal (OJ
Yellow 2 Lead Terminal [E]
Yellow 3 Lead Terminal {F]

D E F

• Connect the hand tester to the regulator/rectifier as shown

in the table, and measure the resistance of the respective
diodes in both directions, in the sequence in the table.
* The measured resistance should be small in one direction
and 10 or more times in the other direction. If the mea-
sured resistance of any of the two wires (White or Yellow)
is small or large in both directions, the rectifier is dam-
aged; therefore, replace the regulator/rectifier.

Rectifier Circuit Inspection

Connecting terminal
Tester Tester Tester-
Standard
positive negative range
(+) terminal (-) terminal
1 Y1
2 Y2 W •
3 Y3
4 Y1
5 Y2 BKIY
6 Y3 Approximately x 10 n
~ Y1 1/2 of the entire 0'

~ W Y2 graduation x 100 n
9 Y3
Y1
~
11 BKlYW Y2 •
f,,- Y3
NOTE
OThe actual resistance measurement varies with the
tester used and the individual diodes, Generaffy speak-
ing, it is acceptable if the tester's indicator swings
approximately halfway.
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 ELECTRICAL SYSTEM 14-29
Charging System

Regulator Circuit Check

• Prepare the following:
Test Light Bulb: one 12 V 3.4 W bulb
Batteries: three 12 V batteries
Wires: five wires of appropriate lengths
CAUTION
The test light works as an indicator and also a cur·
rent limiter to protect the regulator/rectifier from ex·
cessive current. 00 not use an ammeter instead of
a test light.
• Check to be sure the rectifier circuit is nannal before con-
tinuing.
Regulator Circuit Test·1 5t Step:
• Connect the test light and the 12 V battery to the regula- @
tor/rectifier as shown.
• Check Y1, Y2, and Y3 terminal respectively_
* If the test light turns on, the regulator/rectifier is defective. ~
Replace it. 1//
* If the test light does not tum on, continue the test.

. . . . . .OUI ~

Regulator Circuit Test-2nd Step: r--.

e Connect the test light and the 12 V battery in the same
'-'
manner as specified in the "Regulator Circuit Test·1st
•b
Step'.
e Apply 12 V to the SR (voltage monitoring) terminaL
II-
e Check Y1, Y2, and Y3 terminal respectively. I. ,"
*11 the test light turns on, the regulator/rectifier is defective. I
Replace it.
elf the test light does not turn on, continue the test. I I I "'0000'" 0

Regulator Circuit Test-3rd Step: ,',\li;/

~
e Connect the test light and the 12 V battery in the same
manner as specified in the ~Regulator Circuit Test·1 st
Step'. II-"
e Momentarily apply 24 V to the SR terminal by adding a 12
V battery. I.',-,
eCheck Y1, Y2. and Y3 terminals respectively. 1
CAUTION I II I IO."_U' c
Do not apply more than 24 V to the regulator/recti.
fier and do not leave the 24 V applied for more than
a few seconds, or the unit will be damaged.

* If the test light did not light when the 24 V was applied
momentarily to the SR terminal, the regulator/rectifier is
defective. Replace it.
* If the regulator/rectifier passes all of the tests described.
it may still be defective. If the charging system still does
not work property after checking all of the components
and the battery, test the regulator/rectifier by replacing it
with a known good unit.
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 14-30 ELECTRICAL SYSTEM
Charging System

Charging Voltage (regulatorlrectifier's output voltage)

Inspection
• Inspect the charging condition of the battery (see Battery
Section).
• Warm up the engine to obtain actual alternator operating
conditions.
• Turn the ignition switch OFF.
• Connect the hand tester in accordance with the following
table:
Charging Voltage (regulator/rectifier's output voltage)
Inspection
Connecting terminal
Tester
Tester positive Tester negative Standard
Range
(+) terminal (-) terminal
Battery Position (+) Battery negative (-)
DC25 V 14 - 15 V
terminal (W/R) terminal (BKJY)

• Start the engine, and note the voltage readings at vari-

ous engine speeds with the headlight turned on and then
turned off. (To tum off the headlight of US, Australia and
Canada models, disconnect the headlight connector in
the upper fairing.) The readings should show nearly bat-
tery voltage when the engine speed is low, and as the en-
gine speed rises, the readings should also rise. But they
must be kept under the specified voltage .
• Turn off the ignition switch to stop the engine, and discon-
nect the hand tester.
* If the regulator/rectifier output voltage is kept between the
values given in the table, the charging system is consid-
ered to be working normally.
* If the output voltage is much higher than the values spec-
ified in the table, the regulator/rectifier is defective or the
regulator/rectifier lead are loose or open.
*If the battery voltage does not rise as the engine speed
increases, then the regulator/rectifier is defective or the
alternator output is insufficient for the loads. Check the
alternator and regulator/rectifier to determine which part
is defective.

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 ELECTRICAL SYSTEM 14-31
Charging System

Charging System Circuit

CD ®
¢ r1 ®
,
> .I, .,•
CD @ =a.:t=S.R 8R
1l

n
,•
• ®
illtti »> • .~
•• ~
$,
•
•
/

---
'"
••• I I I I Ii
-~
,>

®[(JJ CD o~
/
CD
+

..... n ... c

1. Ignition Switch
2. Alternator
3. Regulator/Rectifier
4. Battery
5. Main Fuse 30 A (in junction box)
6. load
7. Headlight Relay
8. Junction Box

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 14-32 ELECTRICAL SYSTEM
Ignition System
Crankshaft Sensor Removal
CAUTION
Do not disconnect the battery cables or any other
electrical connections when the ignition switch is
on, or while the engine is running. This is to prevent
Ie igniter damage.
Do not install the battery backwards. The negative
side is grounded. This is to prevent damage to the
diodes and Ie igniter.

• Remove the right side cover.

• Disconnect the crankshaft sensor lead connector (A].

• Unscrew the crankshaft sensor cover bolts [Al.

• Remove the crankshaft sensor cover (8].

• Unscrew the lead holder bolt (A] and remove the holder
[8].
• Unscrew the crankshaft sensor mounting bolts [C).
• Remove the oil pressure warning light switch lead termi-
nal [OJ and remove the crankshaft sensor [E] together with
the lead.

Crankshaft Sensor Installation

e Run the leads wires properly (see General Information
chapter).
Torque - Oil Pressure Warning Light Switch Terminal Bolt:
1.6 N·m (0.16 kgf·m, 14 in·lb)
Crankshaft Sensor Mounting Bolts: 6.0 N·m (0.6
kgf·m, 53 in·lb)
elnstall the crankshaft sensor cover.
Torque - Crankshaft Sensor Cover Bolt: 12 N·m (1.2 kgf·m.
104 in.lb)

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 ELECTRICAL SYSTEM 14-33
Ignition System

Crankshaft Sensor Inspection

• Remove the right side cover.
• Disconnect the crankshaft sensor lead connector.
eSet the hand tester to the x 100 n range, and measure
the resistance between the female connector's black lead
and the yellow lead terminal
Special Tool - Hand Tester: 57001·1394
*11 the reading is out of standard, replace the crankshaft
sensor.
Crankshaft Sensor Resistance
Standard: 380 - 560 0

• Set the hand tester to the maximum range and measure

the resistance between the frame ground and the female
connector's black wire, yellow wire terminals.
*If the reading is not infinity (00), replace the crankshaft
sensor.

Ignition Coil Removal

• Remove the fuel tank (see Fuel tank Removal).
• Disconnect the secondary lead from the spark plug.
e Disconnect the primary lead from the ignition coil.
e Remove the mounting nuts and take out the ignition coil
[A).
e Disconnect the secondary lead from the spark plug cap.

Ignition Coil Installation

eTighten the ground terminal [A] with the front mounting
nut for the #3 and #4 ignition coils.
e Connect the primary wire to the primary coil tenninal as
follows:
Black wire ignition coil for #1, #4 cylinder [B)
Green wire ignition coil for #2, #3 cylinder [C)
Red wire ignition coil for #1 - #4 cylinder

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 14-34 ELECTRICAL SYSTEM
Ignition System
Ignition Coil Inspection
• Remove the ignition coils.
• With the spark plug caps left attached, connect the igni-
tion coil [8] to the tester [A] to measure the arcing dis-
tance.
A WARNING A

To avoid extremely high voltage shocks, do not

touch the coil body or leads.

* If the distance reading is less than the specified value, the .., ..... " c

ignition coil or spark plug caps are defective.

Ignition Coil Arcing Distance
Standard: 7 mm (0.28 in.) or more
• Remove the spark plug caps to measure the arcing dis-
tance again.
*11 the arcing distance is subnormal as before, replace the
ignition coil.
* If the arcing distance is now normal, replace the spark
plug caps
NOTE
Off the coil tester is unavailable, the internal resistance
of the ignition coil can be checked with a hand tester.
However, this inspection is not sufficient to determine
whether or not the coil is defective.

• Remove the spark plug caps and measure the resistance

as shown on the right.
OSet the hand tester to the x 1 Q range and measure [A]
the resistance of the primary windings.
OSet the hand tester to the x 1 kQ range and measure [8]
the resistance of the secondary windings. Ignition Coil [C]
*If the measurement is out of standard, replace the ignition
coil.
Ignition Coil Resistance
Standard: Primary windings 2.61 - 3.19 n
Secondary windings 13.5 -16.5 kO:
• Visually inspect the secondary wire.
* If it is damaged, replace the ignition coil.
OTo install the spark plug caps, turn them in clockwise.
Spark Plug Removal, Installation
• Take out the spark plug cap and remove the spark plug.
Owner's Tool-Spark Plug Wrench: 92110-1130 [A]
Special Tool- Spark Plug Wrench: 57001-1024
• Install the spark plug and tighten it to the specified torque.
Torque - Spark Plug: 14 N·m (1.4 kgf·m, 10 ft·lb)
• Fit the plug caps securely.
• Pull up the spark plug caps lightly to make sure of the
installation of the spark plug caps.

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 ELECTRICAL SYSTEM 14-35
Ignition System

Spark Plug Cleaning, Inspection

• Remove the spark plugs and visually inspect them.
* If the spark plugs have any carbon deposits on them, use
a spark plug cleaner or a wire brush to remove them.
* If the spark plugs are contaminated with oil, wash them in
cleaning solvent.
*If the spark plug's center electrode is corroded or burned,
or if the insulator is broken, replace the spark plug.

Spark Plug Gap Inspection

• Using a wire type spark plug gap gauge, measure the
spark plug gap [Aj.
* If the gap is incorrect, carefully bend the side electrode
[B] with a suitable tool to obtain the correct gap.
Spark Plug Gap
Standard: 0.6 - 0.7 mm (0.024 -0.028 in.)

IC Igniter Removal
CAUTION
Do not disconnect the Ie igniter or other electrical
connections when the ignition switch is ON or the
engine is running, as this could damage the igniter.

• Remove the seat (see Frame chapter).

• Remove the IC igniter [A] from the bracket, and discon-
nect the connector.
• Remove the IC Igniter.
Ie Igniter Inspection
• Remove the seat (see Frame chapter).
• Disconnect the connector [8] from the igniter [A).
• Remove the igniter.

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 14-36 ELECTRICAL SYSTEM
Ignition System

• To examine the condition of the igniter, connect the igniter

checker to the igniter as shown.
Special Tools -Igniter Checker Set: 57001-1378 [A]
Wiring Harness Adapter, #14: 57001-1427
[B]
Wiring Harness Adapter, #2: 57001-1382 [C]
Ie Igniter [D]
Battery [E]
aSet the select knob to position "AM. ."0013OS, C

NOTE
OFo/Jow the instructions in the manufacturer's operation
manual for the proper procedure for operating the ig-
niter checker.
o The igniter checker can perform inspections by simu-
lating the following dynamic characteristics: the igniter
response in relation to the engine speed, interlock cir-
cuit signals, tachometer signals, and engine overspeed
limiter signals.
o The igniter checker cannot be used for inspecting the
conditions of the COl unit.
*If the igniter is defective, replace it.

IC Igniter Operating Voltage Check

• Set the range ofthe hand tester to DC25 V, and connect
its terminals to the brown/white [6] and the black/yellow
[C] terminals in the igniter connector [AJ at the main har-
ness.
Special Tool- Kawasaki Hand Tester: 57001·1394

Connect:
Tester positive (+) terminal.......... brown/white lead
terminal
Tester negative (-) terminal _ black/yellow lead
terminal

• Turn the ignition switch ON.

• Read the voltage on the tester.
Ie Igniter Operating Voltage
Standard: battery voltage
* If there is no voltage or if it is low, inspect the battery
voltage, ignition switch, and the ignition fuse.

Ignition Coil Primary Side Peak Voltage Inspection

• Remove the following parts:
Seat (see Frame chapter).
Fuel Tank (see Fuel System chapter).

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 ELECTRICAL SYSTEM 14-37
Ignition System

• Remove the spark plug cap from a spark plug.

• Attach a spark plug (A) that is known to be good to the
removed spark plug cap, and ground the spark plug to
the engine.
NOTE
o To obtain a correct measurement, the leads as wef! as
the wire connections must be correct.
OPerlorm the measurement with the cylinder compres-
sion in the normal state (with the spark plug inserted in
the cylinder head). Without the proper compression, a
correct measurement cannot be obtained.
• Set the range of the taster to 250 V. Connect the peak volt-
age adapter [C] to the tester [B], and connect the adapter
terminals to the respective terminals of the ignition coil
[D].

OKeep the terminals connected.

Special Tool- Kawasaki Hand Tester: 57001-1394
Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B

Connect:
Adapter positive (+) lead [A] -green lead terminal
Adapter negative (-) lead [8] -red lead terminal

Adapter positive (+) lead [A] _black lead terminal

Adapter negative (-) lead [8] -red lead terminal
• Tum the ignition switch ON.
• Shift the gear into neutral and push the engine stop switch
to RUN.
• Crank the starter motor for several seconds and read the
highest value on the tester.

Ignition Coil Primary Side Peak Voltage

Standard: 100 V or more

A WARNING
To avoid high-voltage electrical shocks, do not
touch adapter terminals or leads.
*If the peak voltage is lower than the standard, proceed to
the next page.

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 14-38 ELECTRICAL SYSTEM
Ignition System
Troubleshooting

Faulty Ignition (engine malfunction)

~
--. Check wires in Ignition system for open or short circuit.
Abnormal I Repair or replace
and if connectors are connected correctly I
~ Normal
Abnormal I Repair or replace
Inspect spark plugs
I
~ Normal

Inspect spark plug caps IAbnOm1a~1 Replace

I I
~ Normal
...
Abnormal
---1 Inspect ignition coil primary coil peak voltage Peak voltage is
lower than standard.
Normal
~ Normal L Abnormal

Peak voltage is normal but there The peak voltage

~
is no arcing on the spark plug. is almost nil. Whether the peak voltage has
been measured five or more times
(Whether the engine has been
cranked several seconds to read No
the maximum value on tester.)

. ~ Yes

Defective IgnitIon COil Inspect the following. Inspect and check the following
1 Adapter connection
1 and condition
2 Ignition switch and
1 Whether a tester with a low
Internal resistance is used (or
-
Replace whether a Kawasaki hand
engine stop sWitch tester is used.)
3. Battery voltage 2. Battery voltage
4. Crankshaft sensor 3. Crankshaft sensor peak
Replace the peak voltage voltage
Abnormal
defective part

All normal

Ie igniter defective
1 All normal

Abnormal

Replace the defective part or measure with Kawasaki hand tester f.-

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 ELECTRICAL SYSTEM 14-39
Ignition System

Crankshaft Sensor Peak Voltage Inspection

• Measure the crankshaft sensor's peak voltage as follows:
ORemove the right side cover.
ODisconnect the crankshaft sensor connector [A].
NOTE
o To obtain a correct measurement, the leads as well as
the lead connections must be correct. Take the volt-
age measurement with the proper cylinder compres-
sion (with the spark plugs in the cylinder head). Without
proper compression, a correct measurement cannot be
obtained.

aSet the range of the tester to DC 10 V.

OConnect the peak voltage adapter [A] to the tester, and
connect the terminals of the adapter to the terminals of
the crankshaft sensor connector [8].
Special Tool - Kawasaki Hand Tester: 57001-1394
Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B

Connect:
Adapter positive (+) terminal _ yellow lead
terminal [A] A
Adapter negative (-) terminal _ black/white lead
terminal [B)
OCrank the starter motor for several seconds and read the
highest value on the tester.
B
Crankshaft Sensor Peak Voltage
Standard: 2.4 V or more
* If the peak voltage is lower than the standard, inspect the
crankshaft sensor.

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 14-40 ELECTRICAL SYSTEM
Ignition System
Ignition System Circuit

~! ~@ .•- - - - , 18
f
~

Ir 18 18

~
....
;;; ;;; .
0-
I I I
.- ,•. .- --
I I

-
I 0
I I I ."- ,
; 7
,
0

..•
"'

.I.,o

-
,
•
--
,
•
11
",~,
0

"'~;;:
o

·•· -0
~ ~·- JM .
,

, ... .. ....
~"
~. ,
,• ,
. •
•

~ , V-
• I I I I I I I I I

- 18
0J
,%

1. Ignition Switch
2. Engine Stop Switch
3. Starter Button
4. Spark Plugs
5. #1, #4 Ignition Coil
6. #2, #3 Ignition Coil
7. Starter Lockout Switch
8. Side Stand Switch
9. Neutral Switch
10. Battery
11. Diodes
12. Main Fuse 30 A
13. Ie Igniter
14. Crankshaft Sensor
15. Ignition Fuse lOA
16. Throttle Sensor
17. Junction Box

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 ELECTRICAL SYSTEM 14-41
Electric Starter System
Starter Motor Removal
eRemove:
Engine Sprocket Cover (see Final Drive chapter)
Starter Motor Cover
Starter Motor Wire [A]
Starter Motor Mounting Bolts [B]
Starter Motor [C]
CAUTION
Do not tap the end of the starter motor shaft or the
motor may be damaged.

Slarter Motor Installation

• When installing the starter motor, clean the starter mo-
tor lugs (A] and crankcase {B] where the starter motor is
grounded.

elf the O-ring [A] shows any damage or if it is hardened,

replace it with a new one.
• Apply a small amount of engine oil to the D-ring.

• Push the starter motor into the crankcase, guiding the

sprocket (torque limiter) onto the shaft at the same time.
• Tighten:
Torque - Starter Motor Mounting Bolts: 9.8 N·m (1.0 kgf·m,
87 in·lb)

Starter Motor Disassembly

eRemove:
Starter Motor Through Bolts [A]
Right End Cover [B}
Left End Cover IC]

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 14-42 ELECTRICAL SYSTEM
Electric Starter System
• Do not disassemble the right end cover [Al.
• Do not remove the planet gears [B] and internal gear {C].
• Push the armature [D] out of the yoke.
• Remove the plate [E].

eTo remove the brush plate assembly (Al, remove the ter-
minal nut [B].

• Hold the brush spring [AJ with needle nose pliers, and pull
the brush [B] off the holder.

Starter Motor Assembly

• Replace the O-rings with new ones.
elnstall the brush plate assembly to the left end cover
so that the projection (A] on the brush plate fits into the
groove [B) on the left end cover.

• Install the a-ring [A], insulators [B), and washer [C] in that
order to the terminal bolt.
• Tighten:
Torque - Starter Motor Terminal Locknut: 6.9 N·m (0.70
kgf·m, 61 in.lb)

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 ELECTRICAL SYSTEM 14-43
Electric Starter System
elnstall the washers [AJ,
• Install the armature [B] between the brushes.

elnstall the yoke [A] onto the left end cover (B] aligning the
marKs [CJ on the yoke and left end cover. A

• Install the washers (A).

elnstall the plate [B) into the yoke until it is stopped.

elnstall the right end cover so that the projection [A] fits into
the notch [B] on the internal gear.
• Tighten:
Torque· Starter Motor Through Bolts: 6.9 N·m (0.70 kgf·m,
61 in-Ib)

Commutator Cleaning/Inspection
• Smooth the commutator surface [A) if necessary with fine
emery cloth (B], and clean out the grooves.

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 14-44 ELECTRICAL SYSTEM
Electric Starter System

• Measure the diameter [AJ of the commutator [8].

*Replace the starter motor with a new one if the commu-
tator diameter is less than the selViee limit.
Commutator Diameter
Standard: 28 mm (1.10 in.)
Service Limit: 27 mm (1.06 in.)

Armature Inspection
• Using the x 1 n range of the hand tester, measure the
resistance between any two commutator segments {A].
Special Tool- Hand Tester: 57001-1394
*11 there is a high resistance or no reading (<>:» between
any two segments, a winding is open. Replace the starter
motor.
• Using the highest range of the hand tester, measure the
resistance between the segments and the shaft [8].
* If there is any reading at all, the armature has short. Re-
place the starter motor.
NOTE
OEven is the foregoing checks show the armature to be
good, it may be defective in some manner not readily
detected with the hand tester. If a/l other starter motor
and starter motor circuit components check good, but
the starter motor still does not tum over or only turns
over weakly, replace the starter motor with a new one.

Starter Motor Brush Length A

• Measure the overall length (A] of each brush.
Starter Motor Brush Length
Standard: 8 rnm (0.31 in.)
Service Limit: 5 mm (0.20 in.)
*If any is worn down to the service limit, replace the brush
plate assembly.

Brush Assembly Inspection

• Using the x 1 n range of the hand tester, measure the
resistance as shown
Terminal Bolt and Positive Brush [A]
Brush Plate and Negative Brush [B]
*If there is not close to zero ohms, the brush lead has an
open. Replace the brush plate assembly.

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 ELECTRICAL SYSTEM 14-45
Electric Starter System

Brush Plate and Terminal Bolt Inspection

• Using the highest range of the hand tester, measure the
resistance as follows:
Terminal Bolt and Left End Cover [A]
Terminal Bolt and Brush Plate [BI
*11 there is any reading, the brush holder assembly has a
short. Replace the brush plate assembly.

Starter Relay Inspection

• Remove:
Seat (see Frame chapter)
Starter Relay [AJ

• Connect the hand tester [A] and 12 V battery [B] to the

starter relay as shown.
elf the relay does not work as specified, the relay is detec-
tive. Replace the relay.
Testing Relay
Hand Tester Range: )( 1 a range
Criteria: When battery is connected _ 0 0
When battery is disconnected _ .., 0
'."0011" •

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 14-46 ELECTRICAL SYSTEM
Electric Starter System

Starter System Circuit

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1. Ignition Switch
2. Engine Stop Switch
3. Starter Button
4. Starter Lockout Switch
5. Neutral Switch
6. Starter Circuit Relay
7. Ignition Fuse 10 A
8. Main Fuse 30 A
9. Starter Relay
10. Starter Motor
11. Battery
12. Junction Box

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 ELECTRICAL SYSTEM 14-47
Lighting System

The US, Canada, Australia, and Taiwan models adopt the

daylight system and have a headlight relay in the junction
box. In these models, the headlight does not go on when
the ignition switch and the engine stop switch are first turned
on. The headlight comes on after the starter button is re-
leased and stays on until the ignition switch is turned off.
The headlight will go out momentarily whenever the starter
button is pressed and come back on when the button is re·
leased.

Headlight Beam HorizontallVertical Adjustment

• Tum the horizontal adjusters [A] on the headlight in or out
until the beam points straight ahead.
• Tum the vertical adjusters [B) on the headlight in or out to
adjust the headlight vertically.
NOTE
OOn high beam, the brightest points should be slightly
below horizontal with the motorcycle on its wheels and
the rider seated. Adjust the headlight(s) to the proper
angle according to local regulations.
OFor US model, the proper angle is 0.4 degrees below
horizontal. This is 50 mm (2 in.) drop at 7.6 m (25
ft) measured from the center of the headlights with the
motorcycle on its wheels and the rider seated.

50 mm (2 in.) [AI
Center of Brightest Spot [B]
7.6 m (25 it) [C]
Height of Headlight Center [D]

Headlight Bulb Replacement

• Remove the headlight connector [A].
• Remove the dust cover [B}.

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 14-48 ELECTRICAL SYSTEM
Lighting System

• Detach the retainer [A] and replace the bulb [8].

CAUTION
When handling the quartz·halogen bulb, never
touch the glass portion with bare hands. Always
use a clean cloth. Oil contamination from hands or
dirty rags can reduce bulb life or cause the bulb to
explode.

NOTE
OC/ean off any contamination that inadvertently gets on
the bulb with alcohol or soap and water solution.
• Replace the headlight bulb. o
• Fit the dust cover [Aj with the TOP mark [B} upward, onto
the [C] bulb firmly as shown.
Good [D]
Bad [E]
• After installation, adjust the headlight aim (see Headlight ® ®
Beam Adjustment).

City Light Bulb Replacement

• Remove:
Screws [AI
Joint Cover [B]

• Pull out the socket [AI together with the bulb.

• Pull the bulb out of the socket
CAUTION
Do not turn the bulb. Pull the bulb out to prevent
damage to the bulb. Do not use bulb rated for
greater wattage than the specified value.

• Fit the tabus [A] of the joint cover into the grooves [B] of
the fairings.

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 ELECTRICAL SYSTEM 14-49
Lighting System

Tail/Brake Light Bulb Replacement

• Remove:
Seat (see Frame chapter)
.Tum the socket [A] counter clockwise, and remove the
socket and bulb .

• Push and tum the bulb [A] counter clockwise and remove
it.

• Insert a new bulb [A) by aligning its upper pin [B) with the
upper groove [el in the socket, and tum the bulb clock-
wise.

elnsert the socket by aligning its wide projection [A] wide

notch, and turn it clockwise.

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 14-50 ELECTRICAL SYSTEM
Lighting System

Headlight Circuit (U.S.A., Canada, Australia and Taiwan Models)

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1. Ignition Switch
2. High Beam Indicator Light
3. Headlight
4. Dimmer Switch
6. Alternator
7. Starter Relay
8. Headlight Relay
9. Headlight Fuse 10 A
10. Main Fuse 30 A
11. Battery
12. Junction Box
13. Tachometer Lights
14. Speedometer Lights
18. Passing Button
19. TaiVBrake Light
20. Front Right Tum Signal Position Light
21. Front left Tum Signal Position Light

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 ELECTRICAL SYSTEM 14-51
Lighting System

Headlight Circuit (Other than U.S.A., Canada, Australia and Taiwan Models)

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1. Ignition Switch
2. High Beam Indicator Light
3. Headlight
4. Dimmer Switch
5. Passing Button
6. Alternator
7. Starter Relay
8. Headlight Relay
9. Headlight Fuse lOA
10. Main Fuse 30 A
11. Battery
12. Junction Box
13. Tachometer Lights
14. Speedometer Lights
, 5. City Light
16. Headlight Switch
17. Taillight Fuse 10 A
18. Passing Button
19. Tail/Brake Light
20. Front Right Tum Signal Position Light
21. Front Left Tum Signal Position Light

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 14-52 ELECTRICAL SYSTEM
Lighting System

ZR750·H3 - H4 (Other than U.S.A., Canada, Australia and Taiwan Models)

CD

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1. Ignition Switch
2. High Beam Indicator Light
3. Tachometer Light
4. Speedometer Light
5. Headlight
6. City Light
7. Junction Box
8. Headlight Relay
9. Headlight Fuse lOA
10. Tail Light Fuse lOA
11. Main Fuse 30 A
12. Dimmer Switch
13. Passing Button
14. Alternator
15. Starter Relay
16. Battery
17. TaiVBrake Light
Turn Signal Light Bulb Replacement
• Unscrew the screw [AJ

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 ELECTRICAL SYSTEM 14-53
Lighting System

• Unscrew the screws [A]

• Push and turn the bulb [AJ counter clockwise and remove
it.

_Insert the new bulb [A] by aligning its upper pin [B] with
the upper groove [C] in the socket, and turn the bulb clock-
wise.

Turn Signal Relay Inspection

• Remove the left side cover.
• Inspect the condition of the relay [A] in reference to the
abnormal conditions listed below.
(1) The turn signal light does not illuminate.
• Inspect the charging condition of the battery.
• Disconnect the wires from the relay and check the relay
terminals for continuity.
*11 there is no continuity or there is slight resistance, re·
place the relay.
* If the relay does not show any abnormal condition, inspect
the wiring of the turn signal circuit.
Special Tool - Hand Tester: 57001-1394
e Set the tester to the DC 10 V range, and connect the
following: tester's positive (+) wire to the brown wire that
was disconnected from the relay; and tester's negative
(-) wire to the orange wire.
eTum the ignition switch ON, and tum the tum signal switch
from L to R. Measure the voltage between both terminals
at this time.
*If there is no battery voltage, the fuse, ignition switch, or
the wiring is faulty.
*Even if there is battery voltage, but the tum signal light
still does not illuminate, reinspect the wiring connections.
Downloaded from www.Manualslib.com manuals search engine
SDecial Tool - Hand Tester: 57001-1394
 14-54 ELECTRICAL SYSTEM
Lighting System

(2) The turn signal light does not flash or the flashing
cycle is slow.
• Inspect the following:
Battery's charging condition
Wiring connections
Turn signal light and indicator light wattage
* If the foregoing checks do not show any abnormal condi·
lions, replace the relay.

(3) One of the turn signal lights in the front or rear re-
mains lit.
• Inspect the following and repair or replace the parts as
necessary: Check the unlit light for blown bulb, wrong
wattage, open circuit in wiring, or poor contact.

(4) The turn signal light of either side does not illumi-
nate both in the front and rear.
elnspect the following and repair or replace the parts as
necessary: Check the unlit light for blown bulb, or faulty
turn signal switch.

(5) The flashing cycle is too fast.

elf both right and left tum signal lights flash too fast, inspect
the battery's charging condition.
*If the charging condition is normal, replace the relay.
elf one flashes faster than the other, either one of the bulbs
has a higher wattage rating, and it must be replaced with
one with the correct wattage.

Turn Signal Light Circuit (U.S.A., Canada and Taiwan Models)

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 ELECTRICAL SYSTEM 14-55
Lighting System

Turn Signal Light Circuit (Other than U.S.A., Canada and Taiwan Models)

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1. Ignition Switch
2. Right Turn Signal Indicator Light
3. Left Turn Signal Indicator Light
4. Front Right Tum Signal/Running Position Light
5. Front Left Turn SignaL/Running Position Light
6. Junction Box
7. Main Fuse 30 A
8. Turn Signal Relay Fuse lOA
9. Turn Signal Relay
10. Hazard Switch
11. Turn Signal Switch
12. Battery
13. Rear Right Turn Signal Light
14. Rear Left Turn Signal Light
15. Front Right Turn Signal Light
16. Front Left Turn Signal Light

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 14-56 ELECTRICAL SYSTEM
Meters, Gauges

Meter Unit Removal

eRemove:
Wind Shield (see Frame chapter)
Upper Inner Cover (see Frame chapter)
• Disconnect the upper end (A] of the speedometer cable.

• Disconnect the meter unit wire connectors [A].

• Remove the mounting nut [8], and take out the meter unit
[C].
CAUTION
Place the meter or gauge so that the face is up. If a
meter or gauge is left upside down or sideways for
any length of time, it will malfunction.

Meter Unit Disassembly

eRemove:
Meter Unit (see Meter Unit Removal)
Nuts [A]
Bracket IB)

• Unscrew the screw and remove the trip meter knob [A].

• Unscrew the screws [A] and separate the meter assembly

[8] and upper meter cover [C].

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 ELECTRICAL SYSTEM 14-57
Meters, Gauges

• Unscrew the screws [A] and remove the fuel gauge.

CAUTION
Do not fail to remove the screws while the meter
faced up [A] when removing each meters. If the
screws are removed while the meter faced down,
the meter may come down, and the meter may be
damage.

• Pull the sockets out from the lower meter cover.

• Unscrew the screws [Aj.
• Remove the meter harness [8] and tachometer.

• Unscrew the screws [AJ and remove the speedometer up-

per gear Assembly (B].
• Unscrew the screws [C] and remove the speedometer.

Bulb Replacement
eRemove:
Meter Unit (see Meter Unit Removal)
Socket
• Remove the wedge-base type bulb [A], pull the bulb out
of the socket [B].
CAUTION
Do not turn the bulb. Pull the bulb out to prevent
damage to the bulb. Do not use bulb rated for other
than voltage or wattage specified in the wiring dia-
gram.

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 14-58 ELECTRICAL SYSTEM
Meiers, Gauges
Meter Unit Assembly
• Install the bulbs and wire terminals in the original posi·
lions.
BR [A] BK [F] R/BK and BKIY [M]
BKIY [B] BR [G] LG and BKIY [N]
WIY Ie] BKIY [H] GY and BKIY [0]
R/BL and BKIY [D] R/BL and BKIY [I] [J] [K]
BUR and BKIY [E] G and BKIY [L]

® ®®®® CD
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Tachometer Inspection
• Remove the fuel tank (see Fuel System chapter).
• Disconnect the black wire from the ignition coil.
• Turn the ignition switch ON.
• Connect a suitable wire to the black wire, and momentar-
ily connect and disconnect it to the battery positive (+)
terminal. At this time. check the movement [B] of the
tachometer [A] needle.
* If connecting the terminal does not cause the tachometer
needle to swing, replace the tachometer.

Tachometer Circuit

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1. Ignition Switch 4. Ignition Coil 7. Main Fuse 30 A
2. Tachometer 5. Ie Igniter 8. Ignition Fuse 10 A
3. Engine Stop Switch 6. Junction Box 9. Battery

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 ELECTRICAL SYSTEM 14-59
MeIers, Gauges

Fuel Gauge Operation Inspection

• Remove the fuel tank and disconnect the fuel level sensor
lead connector.
• Tum the ignition switch ON.
• Using a suitable wire, short the terminals of the connector
on the main wiring harness. At this time, check the move-
ment of the fuel gauge needle.
* The fuel gauge needle should point to E [A] when the
terminals are not shorted, and to F [B] when they are
shorted. Otherwise, the fuel gauge or the wiring is fautty.

elnspect the wiring of the fuel gauge circuit.

*If no abnormal condition is found in the circuit, replace the
fuel gauge.

Fuel Gauge Circuit

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1. Ignition Switch
5. Ignition Fuse 10 A
2. Fuel Gauge
6. Main Fuse 30 A
3. Fuel Level Sensor
7. Battery
4. Junction Box

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 14-60 ELECTRICAL SYSTEM
Switches and Sensors

Rear Brake Light Timing Inspection

• Turn the ignition switch ON.
• Depress the brake pedal to check the timing of the rear
brake light operation.
*If the brake light does not turn ON as specified, adjust the
rear brake tight switch.
Rear Brake Light Timing
Standard: Turns ON when the brake pedal is
depressed approximately 10 mm
(0.4 ;n.) [AI

Rear Brake Light Timing Adjustment

• Turn the adjusting nut [A] to adjust the switch.
CAUTION
To avoid damaging the electrical connections in-
side the switch, be sure that the switch body does
not turn during adjustment.

NOTE
ORaising the switch operates the brake light sooner, and
lowering the switch operates the brake light later.

Inspection
• Check the switches for continuity (they should read al-
most a 0).
• Refer to the wiring diagram for details concerning the
switches on the handlebar and the ignition switch.
* If anyone of the switches has an open or short circuit,
repair or replace it.
Special Tool- Kawasaki Hand Tester: 57001·1394
Rear Brake Light Switch Connection Table

I
Br~e
I Brake pedal depressed
Side Stand Switch Connection Table
~

Green I White Black I Yellow

Side stand kicked up
Side stand lowered
Neutral Switch Connection Table
Switch terminal
Gear in neutraled up ""
Gear other than neutral
Oil Pressure Warning Light Switch Connection Table

Switch terminal
Eng;ne stopped ""
Engine running
* ProvIded there IS no problem with the engine lubrication
system.

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 ELECTRICAL SYSTEM 14-61
Switches and Sensors

Fuel Level Sensor Inspection

• Remove the fuel tank and take out the fuel level sensor
[A].
• Measure the resistance between the leoninaIs of the wire
connector [B].
*If the measurement is out of standard, or if the resistance
does not change smoothly in accordance with the up and
down movement of the float, replace the sensor.
Fuel level Sensor Resistance
Standard: Maximum Position (full): 4 - 10 (}
Minimum Position (empty): 90 - 100 n

Special Tool - Hand Tester: 57001~1394 -.~---~

• Check whether the float moves up and down without bind-
ing.
*11 it does not move smoothly, replace the sensor. c
Float in Full Position (A]
Float in Empty Position [B]
Float Arm Stoppers [C]

Throttle Sensor Removal and Installation

eRemove:
Seat (see Frame chapter)
Right Side Cover (see Frame chapter)
• Disconnect the throttle sensor connector [A).

• Remove the mounting screw [8] and remove the throttle

sensor [A).
Inlet side [C]
• When installing the throttle sensor, make sure to pertonn
an adjustment (see Throttle Sensor Adjustment).

Throttle Sensor Inspection

NOTE
OMake sure that the battery is fully charged.
• Start the engine and warm it up thoroughly.
• Check the idle speed and stop the engine.
*11 the idle speed is out of standard, adjust it (see Fuel
System chapter).
Idle Speed
Standard: 1 100 :t50 r/min (rpm)

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 14-62 ELECTRICAL SYSTEM
Switches and Sensors

• Remove the throttle sensor connector [A].

• Connect the throttle sensor setting adapter [C] (special
tool) between the carburetor [A] and the main hamess [8].
• Measure the throttle sensor's input voltage.
B
OConnect the hand tester [0] to the setting adapter.
Hand Tester (+) ~ blue lead (G]
Hand Tester H . blacklblue lead IF]
c
Throttle Sensor Input Voltage
Standard: Approx. 5 V
*If the input voltage is cut of standard, inspect the igniter.
• Connect the hand tester to the setting adapter.
Hand Tester (+) - YIW Wire IE] E
Hand Tester H - BKlBL Wire IF]
Special Tools - Throttle Sensor Setting Adapter #1: 57001
-1400 G
Hand Tester: 57001-1394 F
• Tum on the ignition switch.
• Measure the sensor output voltage with the engine
stopped and with the idle throttle opening.
Throttle Sensor Output Voltage
Standard: 0.9 -1.1 V (at idle throttle opening)
* If the reading is not within the specified range, adjust the
throttle sensor position (see Throttle Sensor Position Ad-
justment).
*If the reading is within the specified range, check the sen-
sor output voltage at full throttle opening.
Throttle Sensor Output Voltage
Standard: 4.06 - 4.26 V (at full throttle opening)
*If the reading is not within the specified range, readjust
the sensor.
*If the throttle sensor cannot be adjusted, replace the sen-
sor.

Throttle Sensor Position Adjustment

• Check the throttle sensor output voltage (see Throttle
Sensor Inspection).
• If the output voltage is out of the range. adjust it as follows.
• Loosen the throttle sensor mounting screws.
• Adjust the position of the sensor until the output voltage
is within the specified range (see Throttle Sensor Inspec-
tion).

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 ELECTRICAL SYSTEM 14-63
Carburetor Heater

At times, the temperature of the carburetors could be too low for efficient atomization of fuel, such as
immediately after the engine has been started or when the ambient temperature is low. Under these
conditions, the electric carburetor heaters electrically heat the carburetors to prevent the engine from
stalling.

Outline
To activate the carburetor heaters, the (stopped) engine must first be started. Then, the PTe [Pos-
itive Temperature Coefficient (Carburetor Temperature)) sensor detects the temperature of one car-
buretor body, and this signal is sent to the control unit. When the atmospheric temperature sensor is
ON, the control unit turns the carburetor heater relay ON or OFF in accordance with the signals sent
by the Ie igniter and the PTC sensor. As a result, the carburetor heater operates or stops operating
depending on whether the relay is turned ON or OFF.

Carburetor Heater Circuit

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1. Ignition Switch 7. Carburetor Heater Control Unit

2. Hom Fuse 10 A 8. Normal Open Type Relay
3. Accessory Fuse 10 A 9. Main Fuse 30 A
4. Atmospheric Temperature Sensor 10. Battery
5. PTC Sensor (Carburetor Temperature Sensor) 11. Ie Igniter
6. Carburetor Heaters
Carburetor Heater Inspection
• Disconnect the connector [A] from the carburetor heater
lead.
• Set the hand tester to the x 1 0 range. and measure the
resistance between the carburetor heater tenninal and
the carburetor body.
Carburetor Heater Resistance
Standard: 7 - 12 0

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 14-64 ELECTRICAL SYSTEM
Carburetor Heater

Normal Open Type Relay Inspection

eRemove:
Seat (see Frame chapter)
left Side Cover (see Frame chapter)
• Remove the relay [A] from the frame.

• Connect the 12 V battery as indicated in the table, and

check the continuity between the terminals.
Relay Circuit Inspection
Battery
Tester Connection Measurement (0)
Connection
2
1-2 3-4 o
3-4

GP~30c401 S

Atmospheric Temperature Sensor Inspection

• Remove:
Right Side Cover (see Frame chapter)
• Disconnect the atmospheric temperature sensor connec-
tor.
• Remove the atmospheric temperature sensor [A].

• Set the hand tester to the x 1 0 range, and check the

continuity between the terminals.
Special Tool- Kawasaki Hand Tester: 57001-1394
elmmerse the atmospheric temperature sensor [A] and the
thermometer [8] in a container filled with coolant, and
gradually increase the temperature of the coolant.
NOTE
A
o Do not allow the atmospheric temperature sensor or the
thermometer to come in contact with the container.

Atmospheric Temperature Sensor Activation

Increasing temperature: ON __ OFF between
7 - 13'C (45' - 55'F)
Decreasing temperature: OFF __ ON before
3'C (37'F)
* If the sensor does not operate properly, replace it.

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 ELECTRICAL SYSTEM 14-65
Carburetor Heater

PTC Sensor (Carburetor Temperature Sensor)

Inspection
• Remove the PTe sensor [A].

• Set the hand tester to the x 1 kO and measure the resis-

tance between the lenninals.
Special Tool - Kawasaki Hand Tester: 57001-1394
• Immerse the PTe sensor [A] and the thermometer [B} in
a container filled with water, and gradually increase the
water temperature.
NOTE
000 not allow the PTe sensor or the thermometer to A
come in contact with the container.

Sensor Sensor
Temperature Temperature
Resistance Resistance
°C (OF) °C (OF)
(kQ) (kQ)

8 (46) 2.5 12 (54) 4.6

9 (48) 2.9 13 (55) 5.4
10 (50) 3.4 14 (57) 6.5
11 (52) 4.0 15 (59) 7.7
* If the measurements are out of standard, replace the PTe .,no,o,", <
sensor.

Carburetor Heater Controller Inspection

eRemove:
Fuel Tank (see Fuel System chapter)
Carburetor Heater Controller Connector [A]
• Set the hand tester to the x 1 kO range, and measure the
internal resistance of the controller [8].
Special Tool- Kawasaki Hand Tester: 57001-1394
*If the measurement is out of standard, replace the con-
troller.
CAUTION
Using a tester other than the Kawasaki Hand Tester
may show different readings. The use of a measure
or a tester with high-voltage battery could damage
the unit.

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 14-66 ELECTRICAL SYSTEM
Carburetor Heater

Heater Controller internal Resistance (Kn)

Tester Positive (+) Terminal
2 5
1 2 3 4 5
(white (green (black
(green) (black)
Igreen) /yellow) Iyellow)
1
(whitel - 7 - 28 ~
6.5 - 28 17 - 80 3
green)
2
~
- ~ ~ ~

(green)
3
(green! ~ - 26 9.5 - 40 - 9.5 - 40 24-150
low)
4
(black 4.4-19 1.4 - 6 ~ - 6.5 - 28
/yellow)
5
13 - 60 10 - 45 ~
6.5 - 28 -
(black)
• Due to the effect of the internal condenser, the tester
indicator will make a large swing the moment the
tester probe contacts the tenninal, and moves slowly
to an area where it stabilizes. Take the reading at the
area where the indicator stabilizes.

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 ELECTRICAL SYSTEM 14-67
Junction Box

Fuse Removal
• Remove the seat.
• Remove the fuse cover [A], and pull the fuse out with nee·
die nose pliers.

Fuse Installation
elnstall the fuses [B} in the original position as specified in
the layout diagram [A] on the inside of the fuse cover.

Fuse Inspection
• Remove the fuse and inspect the element.
*11 the element is blown out, replace the fuse.
Housing [A]
Fuse Element [B]
Terminals [C]
Blown Element [OJ
NOTE
OBetore rep/acing a blown fuse. always check the am-
perage 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.

CAUTION
When replacing a fuse, be sure the new fuse
matches the specified fuse rating 10r that circuit.
Installation of a fuse with a higher rating may cause
damage to wiring and components, and installation
of a fuse with a lower rating may cause the fuse to
be blown quickly.

Fuse Circuit Inspection

elnspect the fuses and replace those that are blown.
e Remove the junction box.
e Check the continuity between the terminals.
*If any of the measurements differ from those in the table,
replace the junction box.
Special Tool - Hand Tester: 57001-1394

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 14-68 ELECTRICAL SYSTEM
Junction Box
Junction Box Internal Circuit (U.S.A., Canada, Australia and Taiwan Models)
(ZR750-H3 -- H4: N, NU Models)

~
-
<9 ® C D ® ® ®
® Q)

® ®
1/ $ ~ ~~ • I. \ ~ ~~

- <D

1 .e!' 2 )~ <iJ®Q D 6)( 7 8 9)Qj -!3lQ3l "

15){16)(17

~~
I~~@@"
9)(f;)@®®
<D®®<D
I~®@@
"1I".1I~ c

Junction Box Internal Circuit (other than U.S.A., Canada, Australia and Taiwan
Models)

® (j) <D' ® ®

fll <1l

§ ,\
®
<D

~
r L_+_
(j)

0 .. 1 1 • , " ., <D (.)B @<" 2> '" . "

~JC~~ J "'"
@@@ 6)(!~ 0 <D<D <D
08@00 @ CD@ @
.........r c

N: No Catalytic Converter C. Tum Signal Relay Fuse 10 H. Headlight Diodes

NU: No Catalytic Converter A I. Starter Diode
(UK model) D. Hom Fuse 10 A J. Starter Circuit Relay
A. Accessory Fuse 15 A E. Ignition Fuse lOA K. Interlock Diodes
B. Main Fuse 30 A F. Headlight Fuse 10 A l. Taillight Fuse lOA
G. Headlight Relay

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 ELECTRICAL SYSTEM 14-69
Junction Box

Fuse Circuit Inspection

Tester Connection Measurement (0)
1 - 1A 0
1 - 2 0
3A • 4 0
6 - 5 0
6 - 10 0
6 - 7 0
6 - 17 0
1A -8 ~

2 - 8 ~

3A • 8 ~

6 - 2 ~

6 - 3A ~

17 - 3A ~

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 14-70 ELECTRICAL SYSTEM
Junction Box
Headlight Relay, Starter Circuit Relay Circuit
Inspection
• Remove the junction box.
• Check the continuity between the terminals in accordance
with Table 1.
Table 1. Relay Circuit Inspection (without battery)
Tester Connection Measurement (0)
7 - 8 ~

Headlight Relay· 7 - 13 ~

(+) 13-9(-) other than .....

9 • 11 ~

Starter Circuit
12 - 13 ~

Relay
~
(+) '3 - " (-)
(+) '2 - " (-) other than MO'

(0): U.S.A., Canada Australia and Taiwan Models

CO): The actual reading varies with the hand tester used.
(+): Apply tester positive wire.
(-): Apply tester negative wire.
• Connect a 12 V battery in accordance with Table 2 and
check the continuity between the terminals.
*11 any of the measurements differ from those in the table,
replace the junction box.
Special Tool - Hand Tester: 57001-983

Table 2. Relay Circuit Inspection (battery connected)

Battery
Tesler Measurement
Connection
Connection (W)
(+) (-)
Headlight Relay· 7 -8 • 9 - 13 • 0
Starter Circuit (+)13-11
11 • 1 other than .....
Relay (-)
('): U.S.A., Canada. Australia and Models
C·): The actual reading varies with the hand tester used.
(+): Apply tester positive wire.
(-): Apply tester negative wire.
,

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 ELECTRICAL SYSTEM 14-71
Junction Box

Diode Circuit Inspection

• Remove the junction box .
• Check the continuity between the following terminals, in
both directions:
Diode Circuit Inspection
13 - 8,13 - 9,12·11,12·14,
Tester Connection
15-14,16-14
If the measurement is low in one direction (forward direc-
tion), but 10 or more times higher in the reverse direction
(with practically no movement of the needle), the diode is
normal. The diode is defective if there is continuity after
changing the direction, or if it remains with no continuity. In
this case, replace the junction box.
NOTE
o The actual meter reading varies with the meter used
and the individual diodes, but generally speaking, the
diode is good if the tester's needle sings about 1/2 the
scale.

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 APPENDIX 15-1

Appendix
Table of Contents
Additional Considerations for Racing . 15-2
Carburetor: . 15-2
Spark Plug: . 15-3
Spark Plug Inspection . 15-4
Troubleshooting Guide . 15-6
General Lubrication . 15-11
Lubrication (Periodic Maintenance) . 15-11
Nut, Bolt, and Fastener Tightness . 15-12
Tightness Inspection . 15-12
Unit Conversio able . 15-13

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 15·2 APPENDIX
Additional Considerations for Racing

This motorcycle has been manufactured for use in a rea-

sonable and prudent manner and as a vehicle only. How-
ever, some may wish to subject this motorcycle to abnor-
mal operation, such as would be experienced under rae·
ing cond~ions. KAWASAKI STRONGLY RECOMMENDS
THAT ALL RIDERS RIDE SAFELY AND OBEY ALL LAWS
AND REGULATIONS CONCERNING THEIR MOTORCY-
CLE AND ITS OPERATION.
Racing should be done under supervised conditions, and
recognized sanctioning bodies should be contacted for fur-
ther details. For those who desire to participate in competi-
tive racing or related use, the following technical information
may prove useful. However, please note the following im-
portant notes.
• You are entirely responsible for the use of your motorcycle
under abnormal conditions such as racing, and Kawasaki
shall not be liable for any damages which might arise from
such use.
• Kawasaki's Limited Motorcycle Warranty and Limited
Emission Control Systems Warranty specifically exclude
motorcycles which are used in competition or related
uses. Please read the warranty carefully.
• Motorcycle racing is a very sophisticated sport, subject to
many variables. The following information is theoretical
onty, and Kawasaki shall not be liable for any damages
which might arise from alterations utilizing this informa-
tion.
• When the motorcycle is operated on public roads, it must
be in its original state in order to ensure safety and com-
pliance with applicable regulations.

Carburetor:
Sometimes an alteration may be desirable for improved
performance under special conditions when proper mixture
is not obtained after the carburetor has been property ad-
justed, and all parts cleaned and found to be functioning
properly.
If the engine still exhibits symptoms of overly rich or lean
carburetion after all maintenance and adjustments are cor-
rectly performed, the main jet can be replaced with a smaller
or larger one. A smaller numbered jet gives a leaner mix-
ture and a larger numbered jet a richer mixture.

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 APPENDIX 15-3
Additional Considerations for Racing

Spark Plug:
The spark plug ignites the fuel and air mixture in the com-
bustion chamber. To do this effectively and at the proper
time, the correct spark plug must be used, and the spark
plug must be kept clean and the gap adjusted.
Tests have shown the plug listed in the "General Informa-
tion" chapter to be the best plug for general use.
Since spark plug requirements change with the ignition
and carburetion adjustments and with riding conditions,
whether or not a spark plug of the correct heat range is
used should be determined by removing and inspecting
the plug.
Terminal [Aj
Insulator [SI
Cement IC]
Gasket [D]
Center Electrode [E] ®
Gap [F)
Reach [G]
Side Electrode [H]

When a plug of the correct heat range is being used,

the electrodes will stay hot enough to keep all the carbon
burned off, but cool enough to keep from damaging the en-
gine and the plug itself. This temperature is about 400 -
800"C (750 -1450°F) and can be judged by noting the con-
dition and color of the ceramic insulator around the center
electrode. If the ceramic is clean and of a light brown color,
the plug is operating at the right temperature.
A spark plug for higher operating temperatures is used for
racing. Such a plug is designed for better cooling efficiency
so that it will not overheat and thus is often called a "colder"
plug. If a spark plug with too high a heat range is used - that
is, a "cold" plug that cools itself too well - the plug will stay
too cool to bum off the carbon, and the carbon will collect
on the electrodes and the ceramic insulator.
The carbon on the electrodes conducts electricity, and
can short the center electrode to ground by either coating
the ceramic insulator or bridging across the gap. Such a
short will prevent an effective spark. Carbon build-up on the
plug can also cause other troubles. It can heat up red-hot
and cause preignition and knocking, which may eventually
burn a hole in the top of the piston.

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 15-4 APPENDIX
Additional Considerations for Racing

Spark Plug Inspection

• Remove the spark plug and inspect the ceramic insulator.
*Whether or not the right temperature plug is being used
®
can be ascertained by noting the condition of the ceramic
insulator around the electrode. A light brown color indi-
cates the correct plug is being used. If the ceramic is
black, it indicates that the plug is firing at too Iowa tern·
perature, so the next hotter type should be used instead.
If the ceramic is white. the plug is operating at too high a
temperature and it should be replaced with the next colder gq010005tlf
type.
Carbon Fouling [A]
Oil Fouling [S] ®
Normal Operation [C]
Overheating [0]
CAUTION
If the spark plug is replaced with a type other than
the standard plug, make certain the replacement
plug has the same thread pitch and reach (length of
q010006llf
threaded portion) and the same insulator type (reg-
ular type or projected type) as the standard plug.
If the plug reach is too short, carbon will build up on
the plug hole threads in the cylinder head, causing ©
overheating and making it very difficult to insert the
correct spark plug later.
If the reach is too long, carbon will build up on the
exposed spark plug threads causing overheating,
preignition, and possibly burning a hole in the pIs-
ton top. In addition, it may be impossible to remove
the plug without damaging the cylinder head. gq010007tlf

Standard Spark Plug Threads

Diameter: 12 mm (0.47 in.)
Pitch: 1.25 mm (0.049 in.)
Reach: 19 mm (0.75 in.)

NOTE
OThe heat range of the spark plug functions like ather- @
mostat for the engine. Using the wrong type of spark
plug can make the engine run too hot (resulting in en-
gine damage) or too cold (with poor performance, mis-
firing, and stalling).

gqOl0008llf

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 APPENDIX 15-5
Additional Considerations for Racing

Tool short IE]

Carbon builds up here [F] ® ©
Correct reach [G]

gq01D014.1If

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 15·6 APPENDIX
Troubleshooting Guide

NOTE Neutral, starter lockout, or sidestand switch

OThis is not an exhaustive list, giving every trouble
possible cause for each problem listed. It Crankshaft sensor trouble
is meant simply as a rough guide to assist Ignition coil trouble
the troubleshooting for some of the more Ignition or engine stop switch shorted
common difficulties. Wiring shorted or open
Fuse blown
Engine Doesn't Start, Starting
Fuel/air mixture incorrect:
Difficulty:
Pilot screw and/or idle adjusting screw mal·
Starter motor not rotating:
adjusted
Starter lockout switch or neutral switch trou·
Pilot jet, or air passage clogged
ble
Air cleaner clogged, poorly sealed, or miss-
Starter motor trouble
ing
Battery voltage low
Starter jet clogged
Starter relays not contacting or operating
Compression Low:
Starter button not contacting
Wiring open or shorted
Spall< plug loose
Cylinder head not sufficiently tightened
Ignition switch trouble
down
Engine stop switch trouble
No valve clearance
Fuse blown
Cylinder, piston worn
Starter motor rotating but engine doesn't
Piston ring bad (worn, weak, broken, or
turn over:
sticking)
Starter clutch trouble
Piston ring/groove clearance excessive
Engine won't turn over:
Cylinder head gasket damaged
Valve seizure
Cylinder head warped
Valve lifter seizure
Valve spring broken or weak
Cylinder, piston seizure
Valve not seating properly (valve bent,
Crankshaft seizure
worn, or carbon accumulation on the
Connecting rod small end seizure
seating surface)
Connecting rod big end seizure
Transmission gear or bearing seizure
Camshaft seizure Poor Running at Low Speed:
Starter idle gear seizure Spark weak:
No fuel flow: Battery voltage low
No fuel in tank Spark plug dirty, broken, or maladjusted
Fuel tank air vent obstructed Spark plug cap or high tension wiring trou-
Fuel tap clogged ble
Fuel line clogged Spark plug cap shorted or not in good con-
Float valve clogged tact
Engine flooded: Spark plug incorrect
Fuel level in carburetor float bowl too high IC igniter trouble
Float valve worn or stuck open Crankshaft sensor trouble
Starting technique faulty Ignition coil trouble
(When flooded, crank the engine with the Fuel/air mixture incorrect:
throttle Pilot screw maladjusted
fully opened to allow more air to reach the Pilot jet, or air passage clogged
engine.) Air bleed pipe bleed holes clogged
No spark; spark weak: Pilot passage clogged
Battery voltage low Air cleaner element clogged, poorly sealed,
Spark plug dirty, broken, or maladjusted or missing
Spark plug cap or high tension wiring trou- Starter plunger stuck open
ble Fuel level in carburetor 1Ioat bowl too high
Spark plug cap shorted or not in good con- or too low
tact Fuel tank air vent obstructed
Spark plug incorrect Carburetor holder loose
IC igniter trouble Air cleaner duct loose
Air cleaner a-ring damaged

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 APPENDIX 15-7
Troubleshooting Guide

Compression low: Fuel tank air vent obstructed

Spark plug loose Fuel tap clogged
Cylinder head not sufficiently tightened Fuel line clogged
down Compression low:
No valve clearance Spark plug loose
Cylinder, piston worn Cylinder head not sufficiently tightened
Piston ring bad (worn, weak, broken, or down
sticking) No valve clearance
Piston ring/groove clearance excessive Cylinder, piston worn
Cylinder head warped Piston ring bad (worn, weak, broken, or
Cylinder head gasket damaged sticking)
Valve spring broken or weak Piston ring/groove clearance excessive
Valve not seating properly (valve bent, Cylinder head gasket damaged
worn, or carbon accumulation on the Cylinder head warped
seating surface) Valve spring broken or weak
Other: Valve not seating property (valve bent,
Ie igniter trouble worn, or carbon accumulation on the
Carburetor not synchronizing seating surface.)
Carburetor vacuum piston doesn't slide Knocking:
smoothly Carbon built up in combustion chamber
Carburetor vacuum piston diaphragm dam· Fuel poor quality or incorrect
age Spark plug incorrect
Engine oil viscosity too high IC igniter trouble
Drive train trouble Miscellaneous:
Brake dragging Throttle valve won't fully open
Air suction valve trouble Carburetor vacuum piston doesn't slide
Vacuum switch valve trouble smoothly
Engine overheating Carburetor vacuum piston diaphragm dam-
Clutch slipping aged
Brake dragging
Poor Running or No Power at High Clutch slipping
Speed: Overheating
Firing incorrect: Engine oil level too high
Spark plug dirty, broken, or maladjusted Engine oil viscosity too high
Spark plug cap shorted or coil wiring trouble Drive train trouble
Spark plug cap or high tension coil not in Air suction valve trouble
good contact Vacuum switch valve trouble
Spark plug incorrect
Ie igniter trouble Overheating:
Crankshaft sensor trouble Firing incorrect:
Ignition coil trouble Spark plug dirty, broken, or maladjusted
Fuel/air mixture incorrect: Spark plug incorrect
Starter plunger stuck open IC igniter trouble
Main jet clogged or wrong size Fuel/air mixture incorrect:
Jet needle or needle jet worn Main jet clogged or wrong size
Air jet clogged Fuel level in carburetor float bowl too low
Fuel level in carburetor float bowl too high Carburetor holder loose
or too low Air cleaner duct loose
Bleed holes of needle jet holder or needle Air cleaner element poorly sealed, or miss·
jet clogged ing
Air cleaner element clogged, poorly sealed, Air cleaner O-ring damaged
or missing Air cleaner clogged
Air cleaner duct loose Compression high:
Air cleaner O-ring damaged Carbon built up in combustion chamber
Water or foreign matter in fuel Engine load faulty:
Carburetor holder loose Clutch slipping
Fuel to carburetor
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manuals search engine Engine oil level too high
 15-8 APPENDIX
Troubleshooting Guide

Engine oil viscosity too high Abnormal Engine Noise:

Drive train trouble Knocking:
Brake dragging IC igniter trouble
Lubrication inadequate: Carbon built up in combustion chamber
Engine oil level too low Fuel poor quality or incorrect
Engine oil poor quality or incorrect Spark plug incorrect
Overheating
Clutch Operation Faulty: Piston slap:
Clutch slipping: Cylinder/piston clearance excessrve
Friction plate wom or warped Cylinder, piston worn
Steel plate worn or warped Connecting rod bent
Clutch spring broken or weak Piston pin, piston pin hole worn
Clutch hub or housing unevenly wom Valve noise:
No clutch lever play Valve clearance incorrect
Clutch inner cable trouble Valve spring broken or weak
Clutch release mechanism trouble Camshaft bearing wom
Clutch not disengaging properly: Valve lifter worn
Clutch plate warped or too rough Other noise:
Clutch spring compression uneven Connecting rod small end clearance exces-
Engine oil deteriorated sive
Engine oil viscosity too high Connecting rod big end clearance exces-
Engine oil level too high sive
Clutch housing frozen on drive shaft Piston ring/groove clearance excessrve
Clutch hub nut loose Piston ring worn, broken, or stuck
Clutch hub spline damaged Piston ring groove wom
Clutch friction plate installed wrong Piston seizure, damage
Clutch lever play excessive Cylinder head gasket leaking
Clutch release mechanism trouble Exhaust pipe leaking at cylinder head con-
nection
Gear Shifting Faulty: Crankshaft runout excessive
Doesn't go into gear; shift pedal doesn't Engine mounts loose
return: Crankshaft bearing worn
Clutch not disengaging Primary gear worn or chipped
Shift fork bent, worn, or seized Camshaft chain tensioner trouble
Gear stuck on the shaft Camshaft chain, sprocket, guide worn
Shift drum positioning pin spring broken Air suction valve damaged
Shift return spring weak or broken Vacuum switch valve damaged
Shift return spring pin loose Alternator rotor loose
Shift mechanism ann spring broken Primary chain wom
Shift mechanism ann broken
Shift pawl broken Abnormal Drive Train Noise:
Pawl spring broken Clutch noise:
Jumps out of gear: Clutch rubber damper weak or damaged
Shift fork ear worn, bent Clutch housinglfriction plate clearance ex-
Gear groove wom cessive
Gear dogs andlor dog holes worn Clutch housing gear worn
Shift drum groove wom Transmission noise:
Shift drum positioning pin spring weak or Bearings wom
broken Transmission gears wom or chipped
Shift fork guide pin worn Metal chips jammed in gear teeth
Drive shaft, output shaft, and/or gear Engine oil insufficient
splines wom Drive line noise:
Overshilts: Drive chain adjusted improperly
Shift positioning pin spring weak or broken Drive chain worn
Overshift limiter broken Rear and/or engine sprocket worn
Chain lubrication insufficient
Rear wheel misaligned
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 APPENDIX 15·9
Troubleshooting Guide

Abnormal Frame Noise: Steering stem bearing lubrication inade-

Front fork noise: quate
Oil insufficient or too thin Steering stem bent
Spring weak or broken Tire air pressure too low
Rear shock absorber noise: Handlebar shakes or excessively vibrates:
Shock absorber damaged Tire worn
Disc brake noise: Swingarm pivot bearings worn
Pad installed incorrectly Rim warped, or not balanced
Pad surtace glazed Wheel bearing worn
Disc warped Handlebar clamp bolts loose
Caliper trouble Steering stem head nut loose
Other noise: Front/rear axle runout excessive
Bracket, nut, bolt, etc. not properly Handlebar pulls to one side:
mounted or tightened Frame bent
Wheel misalignment
Oil Pressure Warning Light Goes On: Swingarm bent or twisted
Engine oil pump damaged Steering maladjusted
Engine oil screen clogged Front fork bent
Engine oil filter clogged Right and left front fork oil level uneven
Engine oil level too low Shock absorption unsatisfactory:
Engine oil viscosity too low (Too hard)
Camshaft bearing worn Front fork oil excessive
Crankshaft bearings worn Front fork oil viscosity too high
Oil pressure warning light switch damaged Rear shock absorber adjustment too hard
Oil pressure warning light switch Wiring faulty Tire air pressure too high
Relief valve stuck open Front fork bent
O-ring at the oil passage in the crankcase (Too soft)
damaged Tire air pressure too low
Front fork oil insufficient and/or leaking
Exhaust Smokes Excessively: Front fork oil viscosity too low
White smoke: Rear shock adjustment too soft
Piston oil ring worn Front fork, rear shock absorber spring weak
Cylinder worn Rear shock absorber oil leaking
Valve oil seal damaged
Valve guide worn Brake Doesn't Hold:
Engine oil level too high Air in the brake line
Black smoke: Pad or disc worn
Air cleaner element clogged Brake fluid leakage
Main jet too large or fallen off Disc warped
Starter plunger stuck open Contaminated pad
Fuel level in carburetor float bowl too high Brake fluid deteriorated
Brown smoke: Primary or secondary cup damaged in master
Main jet too small cylinder
Fuel level in carburetor float bowl too low Master cylinder scratched inside
Air cleaner duct loose
Air cleaner O-ring damaged Battery Trouble:
Air cleaner poorly sealed or missing Battery discharged:
Battery faulty
Handling and/or Stability Battery leads making poor contact
Unsatisfactory: Load excessive (e.g., bulb of excessive
Handlebar hard to turn: wattage)
Cable routing incorrect Ignition switch trouble
Hose routing incorrect Alternator trouble
Wiring routing incorrect Wiring faulty
Steering stem locknut too tight Regulator/rectifier trouble
Steering stem bearing damaged Battery overcharged:
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 15-10 APPENDIX
Troubleshooting Guide

Battery faulty

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 APPENDIX 15·11
General Lubrication

Lubrication (Periodic Maintenance)

• Before lubricating each part, clean off any rusty spots with
rust remover and wipe off any grease, oil, dirt, or grime.
• Lubricate the points listed below with indicated lubricant.
NOTE
OWhenever the vehicle has been operated under
wet or rainy conditions. or especially after using a
high-pressure water spray, perfonn the general lubri-
cation
Pivots: Lubricate with Motor Oil.
Rear Brake Rod Joint

Points: Lubricate with Grease.

Clutch Inner Cable Upper and Lower Ends (A]
Throttle Inner Cable Upper and Lower Ends
Choke Inner Cable Upper and Lower End
Speedometor Inner Cable Lower End
Clutch Lever (Silicon Grease)
Brake Lever (Smcon Grease)
Brake Pedal
Side Stand
Front and Rear Footpegs
Swingarm Bearings
Rocker Arm Bearings
Tie·Rod Bearing

Cables: lubricate with Rust Inhibiter

Choke Cable
Throttle Cables
Clutch Cable
elubricate the cables by seeping the oil between the cable
and housing.
OThe cable may be lubricated by using a commercially
available pressure cable lubricator with an aerosol cable
lubricant.

e With the cable disconnected at both ends, the cable

should move freely [A] within the cable housing.
*If cable movement is not free after lubricating, if the cable
is frayed (B] or if the cable housing is kinked (C), replace
the cable.

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 15-12 APPENDIX
Nut, Bolt, and Fastener Tightness

Tightness Inspection
• Check the tightness of the bolts and nuts listed here. Also,
check to see that each cotter pin is in place and in good
condition.
NOTE
OFar the engine fasteners, check the tightness of them
when the engine is cold (at room temperature).
*If there are loose fasteners, retorque them to the spec·
ified torque following the specified tightening sequence.
Refer to the appropriate chapter for torque specifications.
If torque specifications are not in the appropriate chapter,
see the Standard Torque Table. For each fastener, first
loosen it by 1/2 tum, then tighten it.
* If cotter pins are damaged, replace them with new ones.
Nut, Bolt and Fastener to be checked
Wheels:
Front Axle
Front Axle Clamp Bolts
Rear Axle Nut
Rear Axle Nut Cotter Pin
Brakes:
Front Master Cylinder Clamp Bolts
Caliper Mounting Bolts
Rear Master Cylinder Mounting Bolts
Brake Lever Pivot Bolt Locknut
Brake Pedal Mounting Bolt
Brake Rod Joint Cotter Pin
Suspension:
Front Fork. Clamp Bolts
Front Fender Mounting Bolts
Rear Shock Absorber Mounting Nuts
SWingarm Pivot Shaft Nut
Tie Rod Nuts
Rocker Arm Nut
Steering:
Stem Head Nut
Handlebar Clamp Bolts
Engine:
Engine Mounting Bolts, Nuts
Cylinder Head Bolts
Muffler Mounting Bolt
Exhaust Pipe Holder Nuts
Muffler Connecting Nuts
Clutch Lever Pivot Nut
Others:
Sidestand Bolt, Nut
Center Stand Nuts
Footpeg Mounting Pin Circlips
Footpeg Bracket Mounting Bolts

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