MAINTENANCE AND ADJUSTMENT 25

MAINTENANCE AND ADJUSTMENT

j
Periodic Maintenance Chart
The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accor-
dance with the Periodic Maintenance Chart to keep the motorcycle in good running condition.
1. Periodic Inspection (Engine Related Item)
FREQUENCY After each Every 3 Every 6 Every 12
As See
race (or races (or races (or races (or
OPERATION required Page
2.5 hour) 7.5 hour) 15 hour) 30 hour)
Throttle cable - inspect and adjust • 47
Valve clearance - inspect • 65
Clutch friction/steel plates - inspect † • 60
Spark plug - clean and regap † • 38
Clutch lever free play - adjust • 56
Air cleaner element - clean † • 45
*Cylinder, cylinder head - inspect • –
*Crankshaft - inspect • –
Silencer - inspect † • 71
Kick pedal and shift pedal - clean • –
Engine sprocket - inspect † • 81
Coolant - inspect † • 35
 26 MAINTENANCE AND ADJUSTMENT

FREQUENCY After each Every 3 Every 6 Every 12

As See
race (or races (or races (or races (or
OPERATION required Page
j 2.5 hour) 7.5 hour) 15 hour) 30 hour)
Throttle Body - inspect and clean • 48
Idling speed - inspect and adjust • 48
Breather hose - inspect • 126
Radiator hoses and connection -
inspect † • 34
 MAINTENANCE AND ADJUSTMENT 27

2. Periodic Inspection (Chassis Related Item)

FREQUENCY After each Every 3 Every 6 Every 12
As See
race (or races (or races (or races (or j
OPERATION required Page
2.5 hour) 7.5 hour) 15 hour) 30 hour)
Brake adjustment - inspect † • 84
Brake pad wear - inspect † • 87
Brake fluid level - inspect † • 85
Spoke tightness and rim runout - 123 a
inspect † • 125
Drive chain - inspect and adjust † • 75
81,
Drive chain - lubricate † • 136
Drive chain wear - inspect † • 78
Front fork - inspect • 89
Nuts, bolts, fasteners - inspect † • 127
*Fuel system - clean • –
Fuel hoses, connections - inspect † • 126
Brake hoses, connections - inspect † • 126
Steering free play - inspect † • 87
*Steering stem bearing - grease • –
Rear sprocket - inspect † • 81
General lubrication - perform • 134
*Wheel bearing - inspect † • –
 28 MAINTENANCE AND ADJUSTMENT

FREQUENCY After each Every 3 Every 6 Every 12

As See
race (or races (or races (or races (or
OPERATION required Page
j 2.5 hour) 7.5 hour) 15 hour) 30 hour)
*Swingarm and UNI-TRAK linkage
pivots - inspect • –

*Swingarm and UNI-TRAK linkage

pivots - grease • –

Frame - clean and check • –

Wheel/tire (air pressure, excessive
wear or damage) - inspect • 123

Rear shock absorber - inspect • 117

Cable - inspect • –
 MAINTENANCE AND ADJUSTMENT 29

3. Periodic Replacement (Engine and Chassis Related Item)

FREQUENCY After each Every 3 Every 6 Every 12
See
race (or 2.5 races (or races (or 15 races (or j
OPERATION Page
hour) 7.5 hour) hour) 30 hour)
Engine oil - replace R 31
Oil filter - replace R 31
*Piston and piston ring - replace † Every 6 races –
*Piston pin - replace R –
Silencer packing - replace R 71
*Brake fluid - replace † Every 2 years –
*Brake master cylinder cup and dust seal - –
Every 2 years
replace †
*Brake caliper piston seal and dust seal - –
Every 2 years
replace †
*Brake hoses and pipe - replace † Every 4 years –
Front fork oil - replace R 93
*Fuel hose - replace † Every 4 years –
*Rear shock absorber oil - replace R –

†: Replace, add, adjust, clean or torque if necessary.

* : Should be serviced by referring to the Service Manual or an authorized Kawasaki dealer.
R: Replace
 30 MAINTENANCE AND ADJUSTMENT
Oil Level Inspection
Engine Oil • Ifsitthea few
oil has just been changed, let the motorcycle
minutes allowing the oil to settle.
j In order for the engine, transmission and clutch
to function properly, maintain the engine oil at the
• Start the engine and run it for several minutes at
idle speed. Do not run the engine at high en-
proper level, and change the oil and oil filter period- gine speed.
ically.
Not only do dirt and metal particles collect in the
• Stop the engine and wait several minutes for the
oil to settle.
oil, but the oil itself loses its lubricative quality if used
too long.
• Check the engine oil level with the motorcycle ver-
tical through the oil level inspection window on the
lower right side of the engine. The oil level should
WARNING come up between the high and low level lines next
Motorcycle operation with insufficient, de- to the window.
teriorated, or contaminated engine oil will • If the oil level is too high, remove the excess oil
using a syringe or other suitable device.
cause accelerated wear and may result in en-
gine or transmission seizure, accident, and • If the oil level is too low, add the correct amount
of oil through the oil filler opening. Use oil of the
injury. Check the oil level before each ride
and change the oil according to the periodic same type and brand as those of the one that is
maintenance chart in the owner’s manual. already in the engine.
NOTE
Because of the semi-dry sump lubrication system,
the engine oil level indicated on the oil level inspec- żIf no oil appears in the oil level inspection window,
tion window will fluctuate depending on the motorcy- tip the motorcycle slightly to the right until oil is
cle’s position and engine speed when the engine’s visible then return to an upright position. If no oil
shut off. To ensure a proper reading of the engine appears even when tipped at an extreme angle,
oil level, follow the Oil Level Inspection procedures remove drain plugs to empty any oil that may be in
closely. the transmission and crankcase, reinstall the drain
plugs and refill with the specified amount of oil.
NOTICE
Racing the engine before the oil reaches ev-
ery part can cause engine seizure.
 MAINTENANCE AND ADJUSTMENT 31

Oil and/or Oil Filter Change

The engine oil and/or oil filter should be changed
periodically to ensure long engine life.
j
• Warm up the engine thoroughly so that the oil will
pick up any sediment and drain easily.
• Stop the engine, and place a container beneath it.
• Remove the oil filler cap.
• Remove the oil drain plugs and position the vehi-
cle perpendicular to the ground to allow all the oil
to drain.

A. Oil Level Inspection Window

B. High Level Line
C. Low Level Line
D. Oil Filler Cap

A. Drain Plug (M6)

B. Drain Plug (M10)
 32 MAINTENANCE AND ADJUSTMENT

WARNING • Replace the oil filter element with a new one.

Motor oil is a toxic substance. Dispose of
j used oil properly. Contact your local author-
ities for approved disposal methods or pos-
sible recycling.

• When the oil filter is replaced, remove the oil filter

cover and take off the cover with O-ring.

A. Oil Filter Element

B. Grommet

• Apply the grease oil to the grommet.

• Install the oil filter element with the grommet to-
ward the oil filter cover.
NOTICE
A. Oil Filter Cover Inside-Out installation stop oil flow, causing
B. Bolts engine seizure.

• Install the oil filter cover with the grease applied to

a new O-ring and tighten its bolts to the specified
torque.
Oil Filter Cover Bolts Tightening Torque
9.8 N·m (1.0 kgf·m, 87 in·lb)
 MAINTENANCE AND ADJUSTMENT 33

• After the oil has completely drained out, install the

drain plugs with their new gaskets. Proper torque
Type: API SG
API SH, SJ or SL with JASO MA, MA1
for them is shown in the table.
or MA2 j
Engine Oil Drain Plugs Tightening Torque
Viscosity: SAE 10W-30, 10W-40, 10W-50
Drain Plug (M6) 7.0 N·m (0.7 kgf·m, 62 in·lb)
Drain Plug (M10) 20 N·m (2.0 kgf·m, 15 ft·lb) NOTE
żDo not add any chemical additive to the oil. Oils
NOTE fulfilling the above requirements are fully formu-
żReplace any gaskets or O-ring with their new lated and provide adequate lubrication for both the
ones. engine and the clutch.

• Fill the engine up to the high level line with good

quality engine oil specified in the table.
The oil viscosity may need to be changed to ac-
commodate atmospheric conditions in your riding
• Install the oil filler cap. area.
• Start the engine.
• Check the oil level and oil leakage.
Recommended Engine Oil
Castrol “Power 1 R4 Racing” SAE5W-40

Engine Oil Capacity

0.96 L (1.01 US qt) [When filter is not removed]
0.98 L (1.04 US qt) [When filter is removed]
1.20 L (1.27 US qt) [When engine is completely
dry]

NOTE
żIf unavailable, use equivalent engine oil in accor-
dance with the following table.
 34 MAINTENANCE AND ADJUSTMENT
Coolant
Cooling System Coolant absorbs excessive heat from the engine
and transfers it to the air through the radiator. If
j the coolant level becomes low, the engine overheats
Cooling Hoses and may suffer severe damage. Check the coolant
Check the cooling hoses for cracks or deteriora-
level each day before riding the motorcycle, and re-
tion, and the connections for looseness in accor-
plenish coolant if the level is low.
dance with the Periodic Maintenance Chart.
Radiator WARNING
Check the radiator fins for obstruction by insects or Coolant can be extremely hot and cause se-
mud. Clean off any obstructions with a low-pressure vere burns, is toxic and very slippery. Do
stream of water. not remove the radiator cap or attempt to
NOTICE change the coolant when the engine is hot;
allow it cool completely. Immediately wipe
Using high-pressure water, as from a car any spilled coolant from tires, frame, engine
wash facility, could damage the radiator fins or other painted parts. Do not ingest coolant.
and impair the radiator’s effectiveness.
Do not obstruct or deflect airflow by in-
stalling unauthorized accessories in front of
NOTE
the radiator. żThe coolant originally filled into the cooling sys-
Interference with the cooling airflow can lead tem contains 50% of a permanent, ethylene-glycol
to overheating and consequent engine dam- -based antifreeze, has a freezing point of –35°C
age. (–31°F) and a green appearance.
 MAINTENANCE AND ADJUSTMENT 35

Coolant Level Inspection • Check the coolant level in the radiator. The
• Remove the right shroud. coolant should come up to the bottom of the
• Situate the motorcycle perpendicular to the
ground until the radiator cap is level to the ground,
radiator filler neck.
j
so that the radiator cap is located uppermost
NOTE
in order to exhaust the air accumulated in the żCheck the coolant level when the engine is cold
radiator. (room or ambient temperature).
• Remove the radiator cap in two steps.
• First, turn the cap counterclockwise to the first stop
and wait there for a few seconds.
• Then, push and turn the cap further in the same
direction and remove it.

A. Coolant Level
B. Filler Neck

• Ifradiator
the coolant level is low, add coolant through the
filler opening to the bottom of the filler
A. Radiator Cap neck.
Water and Antifreeze Mixing Ratio
1 : 1 (water : antifreeze)
 36 MAINTENANCE AND ADJUSTMENT
Recommended Antifreeze • Situate the motorcycle perpendicular to the
ground until the radiator cap is level to the ground.
Permanent type of antifreeze (ethylene glycol
j base plus corrosion and rust inhibitors for • Remove the radiator cap in two steps (see the
“Coolant level inspection”).
aluminum engines and radiators)
• Drain the coolant from the engine and radiator in
the following way.
Coolant Total Amount
1.05 L (1.1 US qt)
• Place a container under the coolant drain plug on
the water pump cover and remove the drain plug.

• Install the radiator cap.

Coolant Change
The coolant should be changed to ensure long en-
gine life, if necessary.
• Wait for the engine to cool completely.
• Remove the guard.

A. Coolant Drain Plug

B. Water Pump Cover

NOTICE
Immediately wash away any coolant that
spills on the frame, engine, or wheel.
A. Guard
B. Bolt
 MAINTENANCE AND ADJUSTMENT 37

WARNING NOTICE
Immediately wipe any spilled coolant from Use coolant containing corrosion inhibitors
tires, frame, engine or other painted parts. made specifically for aluminum engines and j
Do not ingest coolant. radiators in accordance with the instruction
of the manufacture. Soft or distilled water
• Visually inspect the old coolant. must be used with the antifreeze in the cool-
• parts in the
If whitish cotton-like wafts are observed, aluminum
cooling system are corroded and the
ing system. If hard water is used in the sys-
tem, it causes scale accumulation in the wa-
system must be flushed. ter passages, and considerably reduces the
• Ifingtheandcoolant is brown , iron or steel parts are rust-
the system must be flushed.
efficiency of the cooling system.

• Check the cooling system for damage, loose con-

nections, and leaks.
NOTE
• Install the coolant drain plug with its new gasket żPour in the coolant slowly so that it can expel the
at the water pump cover and apply the specified air from the engine and radiator.
torques.
• Install the radiator cap.
NOTE • Check the cooling system for leaks.
żAlways replace any gasket with a new one. • stop it. engine and warm up thoroughly, then
Start the

Coolant Drain Plug Tightening Torque • Check the coolant level after the engine has
cooled down. The coolant should come up to the
7.0 N·m (0.7 kgf·m, 62 in·lb) bottom of the radiator filler neck.

• Fill the radiator up to the bottom of the radiator filler • If the coolant level is low, add coolant up to the
bottom of the radiator filler neck.
neck with coolant.
• Situate the motorcycle perpendicular to the • Install the radiator cap.
ground until the radiator filler neck is level to the • Check the cooling system for leaks.
ground so that the filler neck is located uppermost
in order to exhaust the air accumulated in the
radiator.
 38 MAINTENANCE AND ADJUSTMENT
If the plug is oily or has carbon built up on it, clean
Spark Plug it (preferably with a sandblaster) and then clean
off any abrasive particles. The plug may also be
j The spark plug should be taken out periodically for cleaned using a high-flash-point solvent and a wire
inspection and regapping. Measure the gap with a brush or other suitable tool. If the spark plug elec-
wire-type thickness gauge. If incorrect, adjust the trodes are corroded, or damaged, or if the insulator
gap to the specified value by bending the outer elec- is cracked, replace the plug. The standard spark
trode. plug is shown in the table below.
Spark Plug Gap Standard Spark Plug
CPR8EB-9 0.8 a 0.9 mm CPR8EB-9
CPR9EB-9 (0.031 a 0.035 in.)
To find out whether the plug’s heat range is correct,
remove the plug and examine the ceramic insulator
around the center electrode. If the ceramic is light
brown, the spark plug correctly matches the engine
temperature.
If the ceramic is burned white, the plug should be
replaced with a colder plug.
Optional Spark Plug
Colder CPR9EB-9

NOTE
żIf the engine performance drops, try replacing the
spark plug to regain performance.
żIf the spark plug is replaced, use the genuine
A. Gap Kawasaki spark plug.
B. Outer Electrode
 MAINTENANCE AND ADJUSTMENT 39

Spark Plug Removal and Installation • To remove the fuel hose joint, pull the joint lock
• Remove the fuel tank mounting bolt and the left
and right side shroud bolts.
outward while opening it.
j
• Unhook the rubber band on the fuel tank and re-
move the fuel tank with the left and right shrouds.

A. Joint Lock
B. Pull outward

A. Fuel Tank
B. Shrouds
C. Fuel Tank Mounting Bolt
D. Shroud Bolts
E. Rubber Band
 40 MAINTENANCE AND ADJUSTMENT

• Put a rag around the fuel hose joint. • Pull the spark plug cap off the plug before remov-
• tor. the fuel hose joint and fuel pump connec-
Remove ing the spark plug.
j • Apply a suitable wrench to the spark plug.
• Loosen and remove the spark plug.
• ification.
When reinstalling the spark plug, torque it to spec-

Spark Plug Tightening Torque

13 N·m (1.3 kgf·m, 115 in·lb)

• Install the spark plug cap so that align it to the line

on the head cover.
• Pull up the plug cap lightly to make sure of the
installation of the spark plug cap.

A. Fuel Hose Joint

B. Fuel Pump Connector

WARNING
Gasoline is extremely flammable and can be
explosive under certain conditions.
Always stop the engine and do not smoke.
Make sure the area is well-ventilated and free
from any source of flame or sparks; this in-
cludes any appliance with a pilot light.
A. Spark Plug Cap
• Clean the cylinder head cover around the spark
plug cap hole before removing the spark plug.
B. Line on the cylinder head cover
 MAINTENANCE AND ADJUSTMENT 41

Fuel Tank Installation • Push and pull the hose joint back and forth more
• Insert the fuel hose joint straight onto the fuel out-
let pipe until the hose joint clicks.
than two times, and make sure it is locked and
does not come off.
j
• Push the joint lock until the hose joint clicks.

A. Hose Joint
A. Fuel Hose Joint B. Push and Pull
B. Joint Lock
WARNING
Leaking fuel can cause a fire or explosion
resulting in serious burns. Make sure the
hose joint is installed correctly on the deliv-
ery pipe by sliding the joint.
 42 MAINTENANCE AND ADJUSTMENT
NOTICE
When installing the fuel hose joint, do not
Air Cleaner
j apply strong force to the out let pipe on the
A clogged air cleaner restricts the air intake, in-
fuel pump. The pipe made from resin could
creases fuel consumption, reduces engine power,
be damaged.
and can cause spark plug fouling. Inspect the air in-
take system, which includes the air filter and air duct
NOTE to the throttle body, and the duct clamps and throttle
żIf it comes off, reinstall the hose joint. body, before each race or practice session.

• Hook the rubber band to the fuel tank. WARNING

• right shroud
Install the fuel tank mounting bolt and the left and
bolts. If dirt or dust is allowed to pass through into
the throttle body, the throttle may become
stuck, possibly causing accident.
Be sure to keep the dust from entering during
cleaning.

NOTICE
A clogged air cleaner will affect fuel mixture
to the engine and reduce engine power and
cause spark plug fouling.

NOTE
żIn dusty areas, the element should be cleaned
more frequently than recommended interval.
żAfter riding through rain or on muddy roads, the
element should be cleaned immediately.
 MAINTENANCE AND ADJUSTMENT 43

Element Removal and Inspection • Open the both side covers slightly outward and
• Remove the seat mounting bolts on the right and
left sides.
slide the seat rearward.
j

A. Side Cover
A. Seat Mounting Bolt B. Seat
 44 MAINTENANCE AND ADJUSTMENT

• Remove
element.
the wing bolt, and take out the air cleaner • Take the element off its frame.
NOTICE
j
Do not twist or wring the element, as it gets
easily torn or damaged.

• Inspect the element. If it is dirty, clean it. Also

check if the element is in good condition (no tears,
hardening or shrinkage). If damaged, replace the
element or it will allow dirt into the throttle body.

WARNING
A clogged air cleaner may allow dirt and dust
to enter the throttle body and the throttle may
stick resulting in a hazardous operating con-
dition. Clean the air cleaner according to the
A. Air Cleaner Element periodic maintenance chart; more often if the
B. Wing Bolt
motorcycle is used in extremely dusty condi-
• Check inside of the intake tract and throttle body
for dirt. If dirty, clean the intake tract and throttle
tions.

body thoroughly. NOTICE

• Stuff a clean, lint-free towel into the throttle body
to keep dirt from entering the throttle body. A clogged air cleaner may allow dirt and dust
• Wipe out the inside of the air cleaner housing with
a clean, damp towel.
to enter the engine, causing it to wear exces-
sively or to become damaged.
 MAINTENANCE AND ADJUSTMENT 45

Element Cleaning and Installation

• Clean the element in a bath of a high flash point
solvent or hot soapy water. Rinse the element with
clear water to remove all traces of the cleaning
j
solution.
• Squeeze the element dry in a clean towel.

NOTICE
Do not twist, wring or blow the element dry
to avoid damaging it.

A. Air Cleaner Element

B. Element Frame
 46 MAINTENANCE AND ADJUSTMENT
than too little. Finally pat the inside of the element
with a paper towel to remove any excess oil.
j • Before installation, check the element for damage
such as tears, hardening, or shrinkage. If dam-
aged, replace the element.
• Apply grease to all mating surfaces and to the
screw hole in the air cleaner housing and intake
tract.
• Remove the towel from the throttle body.
• Install the element onto its frame, and coat the
element lip and lip seat with a thick layer of all
-purpose grease to assure a complete seal.

WARNING
Gasoline and low-flash point solvents can be
flammable and/or explosive and cause se-
vere burns. Clean the element in a well ven-
tilated area, and take care that there is no
spark or flame anywhere near the working ar-
eas. Do not use gasoline or low-flash point
solvents to clean the element.

• After cleaning, let the filter dry completely. Satu-

rate the element with a high-quality foam air fil-
ter oil and make sure that the oil is evenly ap-
A. Apply Grease.
plied throughout the element. Squeeze out the ex-
cess oil, but do not wring the element as this could
cause tearing. In this case, too much oil is better
 MAINTENANCE AND ADJUSTMENT 47

• Install the air cleaner element so that its tab faces

upward and its projections align with the holes in Throttle Cable
the housing.
j
Throttle Cable Adjustment
Inspect the throttle grip for smooth operation in
all steering positions. Check and adjust the throttle
cable in accordance with the Periodic Maintenance
Chart.
• Check that the throttle grip has 2 a 3 mm (0.08 a
0.12 in.) of play and turns smoothly.

A. Tab
B. Projection
C. Hole

• Install the seat.

A. Throttle Grip
B. 2 a 3 mm (0.08 a 0.12 in.)

• Ifupper
the play is incorrect, loosen the locknut on the
end of the throttle cable and turn the ad-
juster to obtain the specified play. Then, tighten
the locknut toward the adjuster.
 48 MAINTENANCE AND ADJUSTMENT

Throttle Body
j
Idle Speed
• Thoroughly warm up the engine.
• Turn the idle adjusting/choke knob to adjust the
idle speed 2 000 r/min (rpm) by using the engine
revolution tester (The tester should be followed by
the method described by the manufacture).

A. Adjusters
B. Locknuts

• With the engine idling, turn the handlebar both

ways and check if handlebar movement changes
the idling speed. If so, the throttle cable may be
improperly adjusted or incorrectly routed, or dam-
aged. Be sure to correct any of these conditions
before riding.

WARNING
A. Idle Adjusting Screw/Choke Knob
Operation with an improperly adjusted, in- B. Tester
correctly routed, or damaged cables could
result in an unsafe riding condition. Be sure • Open and close the throttle a few times to make
sure the idling speed does not change, and read-
the control cables are adjusted and routed
correctly, and are free from damage. just if necessary.
• With the engine idling, turn the handlebar both
ways and check if handlebar movement changes
the idling speed. If so, the throttle cable may be
 MAINTENANCE AND ADJUSTMENT 49

improperly adjusted, incorrectly routed, or dam- Cleaning the Throttle Body

aged. Be sure to correct any of these conditions • Remove the seat (see the “Air Cleaner” section).
before riding. • Remove the
Remove tank (see the “Spark Plug” section).
j
WARNING • section). the silencer (see the “Exhaust System”
Operation with damaged cables could result • Disconnect
nector.
the inlet air temperature sensor con-
in an unsafe riding condition. Replace dam-
aged control cables before operation.

NOTICE
This motorcycle is designed for competition
use only. Therefore, the radiator does not
incorporate a coolant reserve tank or cool-
ing fan. Prolonged idling of the engine with
no airflow through the radiator can cause
coolant loss and engine overheating result-
ing in possible engine damage. Any riding
conditions that increase engine temperature
will further reduce idling time before coolant
loss occurs. These conditions include high
ambient temperature, sandy or muddy ter- A. Inlet Air Temperature Sensor Connector
rain, or other conditions causing high engine
loads at low speeds. Furthermore, warming
the engine up excessively before operation,
or leaving idling with the hot engine temper-
ature after operation results in the engine
overheating, too.
 50 MAINTENANCE AND ADJUSTMENT

• Loosen the air cleaner duct clamp screw. • Remove

sides.
the rear frame bolts on the left and right

j • Pull the rear frame backward and remove the air

cleaner box with it.

A. Air Cleaner Duct Clamp Screw

A. Rear Frame Bolts

B. Air Cleaner Box
 MAINTENANCE AND ADJUSTMENT 51

• Disconnect the throttle sensor connector. • Disconnect

tor.
the inlet air pressure sensor connec-

• Disconnect the fuel injector connector. j

A. Throttle Sensor Connector

A. Inlet Air Pressure Sensor Connector

B. Fuel Injector Connector
 52 MAINTENANCE AND ADJUSTMENT

• Remove the throttle

mounting bolt.
cable holder cover and

A. Throttle Cable Holder Cover Mounting Bolt

B. Throttle Cable Holder Cover
A. Mounting Bolt
B. Throttle Cable Holder Cover
 MAINTENANCE AND ADJUSTMENT 53

• Remove the lower ends of the throttle cables from

the throttle body pulley by loosing the throttle cable
• Loosen the throttle body clamp screw and pull the
throttle body backward.
adjusters.
j

A. Throttle Body Clamp Screw

A. Throttle Cable Lower Ends B. Throttle Body
B. Throttle Body Pulley
C. Decelerator Cable • After removing the throttle body, cover the throttle
body holder and air cleaner duct with a clean cloth
D. Accelerator Cable
E. Adjusters to protect them form dirt.
• Clean the throttle body (Refer to “Cleaning Your
Motorcycle”).

NOTICE
If dirt gets through into the engine, exces-
sive engine wear and possibly engine dam-
age will occur.
 54 MAINTENANCE AND ADJUSTMENT
Throttle Body Installation • Install the air cleaner duct clamp to the air cleaner
• Apply oil to the throttle cable and reinstall it in re-
verse order of removal
duct while bringing down the rear frame a little.
Make sure the tab of the air cleaner duct clamp
j
• Check if the connectors are installed properly. is aligned with the groove in the air intake duct.
Throttle Cable Holder Cover Mounting Bolt
Tightening Torque
NOTICE
7.0 N·m (0.7 kgf·m, 62 in·lb) Be sure not to damage the rear shock ab-
sorber spring by the air cleaner duct clamp
when bringing down the rear frame.
WARNING
Operation with an improperly adjusted, in-
correctly routed, or damaged cables could
result in an unsafe riding condition. Be sure
the control cables are adjusted and routed
correctly, and are free from damage.

A. Tab
B. Groove
C. Air Cleaner Duct (View from Rear Side)
D. Frame
E. Air Cleaner Housing
 MAINTENANCE AND ADJUSTMENT 55

• Install the throttle body to the air cleaner duct and

the cylinder intake duct while bringing down the
• Install the fuel tank (see the ”Spark Plug” section).
rear frame firmly. WARNING j
• Check the each duct is installed securely, and the
projection of the throttle body is aligned with the
Gasoline is extremely flammable and can be
explosive under certain conditions.
groove in the cylinder intake duct. Always stop the engine and do not smoke.
Make sure the area is well-ventilated and free
from any source of flame or sparks; this in-
cludes any appliance with a pilot light.

• Open and close the throttle a few times to make

sure the grip operates correctly.
• Check the throttle cable play and idle speed ad-
justment.

A. Duct Groove
B. Projection

• Tighten the clamp screws securely.

• to the specified
Tighten the rear frame bolt (upper and lower sides)
torque.
Rear Frame Bolt Tightening Torque
34 N·m (3.5 kgf·m, 25 ft·lb)
 56 MAINTENANCE AND ADJUSTMENT
If the clutch lever play cannot be adjusted at the
Clutch clutch lever, make the adjustment further down the
cable as follows.
j
Clutch Lever Adjustment • Turn the adjuster in all the way.
Proper clutch lever free play is 8 a 13 mm (0.3 a • Loosen the locknut in the middle of the clutch ca-
ble, and turn the adjusting nut so that the clutch
0.5 in.). Lever play increases with cable stretch and
lever play is 8 a 13 mm (0.3 a 0.5 in.).
friction plate wear, requiring periodic adjustment.
When the clutch lever play is out of specification,
first try adjusting it at the clutch lever as follows.
• Turn the adjuster to obtain the proper amount of
clutch lever free play.

A. Adjusting Nut
B. Locknut

• Tighten the locknut.

A. Clutch Lever
B. Adjuster
C. 8 a 13 mm (0.3 a 0.5 in.)
 MAINTENANCE AND ADJUSTMENT 57

WARNING Steel and Friction Plates Inspection

Too much cable play can prevent clutch dis- NOTE
engagement and cause an accident resulting żTo inspect the steel and friction plates, remove the j
in serious injury or death. When adjusting clutch plate.
the clutch or replacing the cable, be sure the
upper end of the clutch outer cable is fully • Drain the engine oil. (see the “Engine Oil” section).
seated in its fitting, or it could slip into place • Remove the brake pedal pivot bolt and the rear
brake master cylinder mounting bolts.
later, creating enough cable play to prevent
clutch disengagement. • Remove the rear brake pedal return spring.
NOTE
żAfter the adjustment is made, start the engine and
check that the clutch does not slip and that it re-
leases properly.

A. Brake Pedal Pivot Bolt

B. Mounting Bolts
C. Rear Brake Master Cylinder
D. Brake Pedal
E. Return Spring
 58 MAINTENANCE AND ADJUSTMENT

• Remove the clutch cover mounting bolts. • Remove the clutch cover and gasket.
• plate andthesprings
Remove clutch spring bolts, clutch pressure
while pressing the push rod
j holder.

A. Mounting Bolts
B. Clutch Cover

A. Clutch Spring Bolts

B. Clutch Pressure Plate
C. Push Rod Holder
 MAINTENANCE AND ADJUSTMENT 59

• Remove the push rod holder, washer and push • Remove the friction and steel plates.
rod. • holder (special
Remove the clutch hub nut with using the clutch
tool: 57001-1243) to prevent the
clutch hub from rotating.
j
• Remove the clutch hub.

A. Push Rod Holder

B. Washer
C. Push Rod
A. Clutch Hub
B. Clutch Hub Nut
C. Clutch Holder (P.N. 57001-1243)
D. Clutch Housing
 60 MAINTENANCE AND ADJUSTMENT
Friction and Steel Plates Wear/Damage
Inspection
j • Visually inspect the friction and steel plates to see
if they show any signs of seizure, or uneven wear.
If any plates show signs of damage, replace all
friction plates and steel plates as a set.
• Measure the thickness of the friction plates with
vernier calipers.
If they have worn past the service limit, replace
them with new ones.
Friction Plate Thickness Measurement
2.92 a 3.08 mm
Standard
(0.115 a 0.121 in.)
Service Limit 2.6 mm (0.102 in.) A. Clutch Hub
B. Friction Plates
If the steel plates are replaced, measure the clutch C. Steel Plates
plate assembly length, and use the steel plates in D. Clutch Pressure Plate
the following table so that the clutch plate assembly E. Clutch Spring Bolt
F. Spring
length is standard. When measuring the clutch plate
G. Standard Length
assembly length, assemble the clutch plate assem-
bly (clutch hub, friction plates, steel plates, clutch Standard Clutch Plate Assembly Measurement
pressure plate, clutch spring bolts, springs). Standard Length:
Clutch Spring Bolts Tightening Torque
34.9 a 35.5 mm (1.37 a 1.40 in.)
8.8 N·m (0.9 kgf·m, 78 in·lb)
 MAINTENANCE AND ADJUSTMENT 61

Steel Plate (P.N.) Thickness plate and steel plate warp with a thickness gauge
(i.e., the gap between the surface plate and each
13089-1095
1.6 mm (0.062 in.) friction plate or steel plate).
(Standard) j
13089-1005 2.0 mm (0.079 in.)
• If any plate is warped over the service limit, re-
place it with a new one.
13089-1010 1.2 mm (0.047 in.) Friction and Steel Plate Warp
Maximum 0.15 mm
Friction Standard
NOTE (0.006 in.) or less
Plate
żDo not use the steel plate of 2.0 mm (0.079 in.) Service Limit 0.3 mm (0.012 in.)
and 1.2 mm (0.047 in.) thickness at the same time. Maximum 0.2 mm
Standard
Steel Plate (0.008 in.) or less
Service Limit 0.3 mm (0.012 in.)

A. Thickness
B. Friction Plate

Friction and Steel Plates Warp Inspection A. Surface Plate

• Place each friction plate and steel plate on a sur-
face plate, and measure the amount of friction
B. Friction or Steel Plate
C. Thickness Gauge
 62 MAINTENANCE AND ADJUSTMENT
Clutch Hub Installation Clutch Hub Nut Tightening Torque
• Install all parts in the reverse order of removal. 98 N·m (10 kgf·m, 72 ft·lb)
j • Install the clutch hub.
• Install the spacer while “OUT SIDE” is faced to the
nut. Friction and Steel Plates Installation
• Install all parts in the reverse order of removal.
• ing between
Install the friction plates and steel plates, alternat-
the two; be sure to start and finish
with a friction plate.

A. Spacer
B. “OUT SIDE”

• Tighten the clutch hub nut with using the clutch

holder (special tool: 57001-1243) to the specified
A. Friction and Steel Plates
torque.
 MAINTENANCE AND ADJUSTMENT 63

NOTE • Apply molybdenum disulfide grease to the contact

żThe friction lining intervals on the first and last fric- area of the push rod holder.
tion plate surfaces is different from one of the other • Install the push rod holder. j
friction plate surfaces as shown in the figure.

A. Apply Molybdenum Disulfide Grease.

B. Push Rod Holder
A. First and Last Friction Plates C. Push Rod
B. Other Friction Plates
C. Friction Lining • Install the clutch pressure plate and springs.
• Tighten
torque.
the clutch spring bolts to the specified
NOTICE
Clutch Spring Bolts Tightening Torque
If dry steel plates and friction plates are in-
stalled, apply engine oil to the surfaces of 8.8 N·m (0.9 kgf·m, 78 in·lb)
each plate to avoid clutch plate seizure.
 64 MAINTENANCE AND ADJUSTMENT

• Check the release shaft lever position by measur-

ing the position distance between the lever and the
• Iflectthethelever position is not within the standard, se-
correct thickness of adjusting washer ac-
cable bracket while pushing the release shaft lever cording to the following table.
j lightly forward. • Remove the push rod holder as necessary and
reinstall the clutch.

A. Release Shaft Lever

B. Push forward A. Adjusting Washer
C. Position Distance B. Push Rod Holder
D. Cable Bracket C. Needle Bearing
E. Generator Cover
Adjusting Washer
Thickness Part Number
1.5 mm (0.06 in.) 92200-1548
1.0 mm (0.04 in.) 92200-0045
 MAINTENANCE AND ADJUSTMENT 65

Release Shaft Lever Position and Adjusting

Washer Selection Valve Clearance
Position Judg- Washers Quan- j
Distance ment Thickness tity Valve and valve seat wear decreases valve clear-
ance, upsetting valve timing.
68.6 a 76.4 mm 1.5 mm
Standard 1
(2.70 a 3.01 in.) (0.06 in.) NOTICE
More than 76.4 1.0 mm If valve clearance is left unadjusted, wear will
Too big 1
mm (3.01 in.) (0.04 in.) eventually cause the valves to remain partly
Less than 68.6 1.0 mm open, which lowers performances, burns the
Too small 2 valves and valve seats, and may cause seri-
mm (2.70 in.) (0.04 in.)
ous engine damage.
• Place a new clutch cover gasket in position with a
thin layer of grease and tighten the bolts. Valve clearance for each valve should be checked
• When installing the brake pedal, apply the grease
to the contact area of the brake pedal pivot.
and adjusted in accordance with the Periodic Main-
tenance Chart.
• Install the parts removed. NOTE
• Check the engine oil level.
żIf the engine is hot, wait until the engine cools.
Valve clearance must be checked when the en-
gine is cold (room temperature).

Valve Clearance Inspection

• Remove the seat and left and right side covers.
• tion). the fuel tank (see the “Spark Plug” sec-
Remove
 66 MAINTENANCE AND ADJUSTMENT

• Remove the spark plug cap, cylinder head cover

bolts, and cylinder head cover.
• Remove the head cover gasket.
j

A. Head Cover Gasket

A. Spark Plug Cap B. Gasket
B. Cylinder Head Cover Bolts
C. Cylinder Head Cover
 MAINTENANCE AND ADJUSTMENT 67

• Remove the two caps from the generator cover. • Bring the piston to the Top Dead Center (TDC) of
its compression stroke to inspect the valve clear-
ance (the position at the end of the compression
stroke) by aligning the top mark with the groove on
j
the generator cover while turning the crankshaft
counter clockwise.

A. Caps

A. Top Mark
B. Groove on Generator Cover
C. Crankshaft
D. Crankshaft Rotation Direction
 68 MAINTENANCE AND ADJUSTMENT

• Atsprockets
this point, the timing marks on the camshaft
must be almost aligned with the cylinder
• Using the thickness gauge, measuring the clear-
ance between each cam lobe and valve lifter, for
head upper surface as shown in the figure. all four valves.
j
NOTE
żRecord the measured valves clearance.

A. Timing Mark
B. Camshaft Sprockets
C. Cylinder Head Upper Surface
A. Thickness Gauge

Standard Valve Clearance (Between cam and

valve lifter)
Exhaust 0.17 a 0.22 mm (0.0067 a 0.0087 in.)
Inlet 0.10 a 0.15 mm (0.0039 a 0.0059 in.)

• Ifrange,
the valve clearance is not within the specified
adjust by an authorized Kawasaki dealer or
a competent mechanic following the instructions in
the Service Manual.
 MAINTENANCE AND ADJUSTMENT 69

Cylinder Head Cover Installation • Replace the head cover gasket with a new one.
• Apply silicon sealant to the cylinder head as • Replace the
Install the head cover gasket on the cylinder head.
shown. • one, and installspark
it.
plug hole gasket with a new
j

A. Silicone Sealant
A. Head Cover Gasket
B. Spark Plug Hole Gasket
 70 MAINTENANCE AND ADJUSTMENT

• Make sure that the upper chain guide is bottomed

to the cylinder head cover.
Cylinder Head Cover Bolts Tightening Torque
9.8 N·m (1.0 kgf·m, 87 in·lb)
j
• Install the two caps to the generator cover.
• Install the spark plug cap and the parts removed.

A. Upper Chain Guide

B. Cylinder Head Cover

NOTICE
Unless the upper chain guide is bottomed,
the camshaft chain could push the cylinder
head cover upward, leading to an oil leak.

• Install the cylinder head cover.

• Install the washer with the metal side upwards to
the cylinder head cover, and tighten the bolts to
the specified torque.
 MAINTENANCE AND ADJUSTMENT 71

Silencer Wool Replacement

Exhaust System • Remove the silencer cover bolts.

The exhaust system, in particular the silencer, is

• damper. the silencer mounting bolt, collars, and
Remove
j
designed to reduce exhaust noise and conduct the
exhaust gases away from the rider while minimizing
power loss. If carbon has built up inside the silencer,
exhaust efficiency is reduced, causing engine per-
formance to drop.
If the silencer is badly damaged, dented, cracked
or rusted, replace it. Replace the silencer wool if the
exhaust noise becomes too loud or engine perfor-
mance drops.

A. Silencer Cover Bolts

B. Silencer Mounting Bolt
 72 MAINTENANCE AND ADJUSTMENT

• Remove the silencer cover with the plastic mallet. • Replace the silencer wool with new one.
j

A. Plastic Mallet A. Silencer Wool

B. Silencer Cover
 MAINTENANCE AND ADJUSTMENT 73

• Remove the silicone sealant attaching on the si-

lencer cover and silencer pipe.
• Check that the exhaust port of the silencer cover
align with the silencer pipe.
• Arrange the shape of the silencer wool and install
the silencer cover to the silencer pipe.
j

A. Silencer Pipe Top End

B. Silencer End Cover
A. Silencer Cover
B. Silencer Pipe
C. Silencer Wool
 74 MAINTENANCE AND ADJUSTMENT

• Tighten the silencer cover bolt and apply the sil-

icone sealant (Part No: J5016-0001) to the joint
part of the silencer cover and silencer pipe.
j

A. Clamp Bolt
B. Silencer Pipe Mounting Bolt
C. Silencer Pipe

A.
B.
Silencer Cover
Silencer Pipe
• Reinstall the removed parts.
Silencer Pipe Mounting Bolt Tightening Torque
C. Silencer Cover Bolt
D. Silicone Sealant 20 N·m (2.0 kgf·m, 15 ft·lb)

NOTE Silencer Mounting Bolt Tightening Torque

żIf the threaded holes of the silencer cover and si- 20 N·m (2.0 kgf·m, 15 ft·lb)
lencer pipe do not align, remove the clamp bolts
and silencer pipe mounting bolt. Silencer Clamp Bolt Tightening Torque
żRemove the silencer pipe from the body and install 16.5 N·m (1.7 kgf·m, 12 ft·lb)
the silencer cover to the silencer pipe.

Silencer Cover Bolts Tightening Torque

12 N·m (1.2 kgf·m, 106 in·lb)
 MAINTENANCE AND ADJUSTMENT 75

Chain Slack Inspection

Drive Chain • Raise the rear wheel off the ground, then rotate
the rear wheel to find the place where the chain is
For safety and to prevent excessive wear, the drive tightest (because it wears unevenly).
j
chain must be checked, adjusted, and lubricated be-
fore riding. If the chain becomes badly worn or mal-
• Push up the drive chain in the middle of the up-
per chain run to measure the chain slack. The
adjusted - either too loose or too tight - it could jump distance between the bottom of the chain and the
off the sprockets or break. swingarm (at the end of the chain slipper) should
be within the standard value.
WARNING Drive Chain Slack
A chain that breaks or jumps off the sprock- Standard 52 a 58 mm (2.0 a 2.3 in.)
ets could snag on the engine sprocket or lock
the rear wheel, severely damaging the motor-
cycle and causing it to go out of control. In-
• Adjust
cation.
the drive chain if its slack is out of specifi-
spect the chain for damage and proper ad-
justment before each ride.

A. Chain Slack

• Inwheel
addition to checking the slack, rotate the rear
to inspect the drive chain for damaged
 76 MAINTENANCE AND ADJUSTMENT
rollers, loose pins and links and the sprockets Chain Slack Adjustment
for unevenly or excessively worn and damaged • Remove the cotter pin from the rear axle nut.
j teeth. • locknuts. rear axle nut and both chain adjuster
Loosen the
• If there are any such defects, replace the drive
chain and/or the sprockets. • Turn both chain adjusting bolts evenly until the
drive chain slack (measured between the chain
and the swingarm) is within the standard value.
For the rear wheel to be properly aligned, the
notch of the left chain adjuster should align with
the same swingarm mark that the notch of the
right chain adjuster aligns with.
Drive Chain Slack
52 a 58 mm (2.0 a 2.3 in.)
 MAINTENANCE AND ADJUSTMENT 77

• Tighten both chain adjuster locknuts.

• Torque the axle nut to the specified torque.
Rear Axle Nut Tightening Torque j
108 N·m (11.0 kgf·m, 80 ft·lb)

• Rotate the wheel, measure the chain slack again

at the tightest position, and readjust it if necessary.
• Install a new cotter pin through the axle nut and
axle, and spread its ends.

A. Axle Nut
B. Adjusting Bolt
C. Locknut
D. Marks
E. Notch
F. Cotter Pin

NOTE
żWheel alignment can also be checked using the
straightedge or string method.
A. Cotter Pin
WARNING
Misalignment of the wheel will result in ab-
normal wear, and may result in an unsafe
riding condition. Align the rear wheel using
the marks on the swingarm or measuring the
distance between the center of the axle and
swingarm pivot.
 78 MAINTENANCE AND ADJUSTMENT
NOTE WARNING
żWhen inserting the cotter pin, if the slots in the A loose axle nut can lead to an accident re-
j nut do not align with the cotter pin hole in the sulting in serious injury or death. Tighten
axle shaft, tighten the nut clockwise up to the next the axle nut to the proper torque and install
alignment. a new cotter pin.
żIt should be within 30 degree.
żLoosen once and tighten again when the slot goes • Check the rear brake effect.
past the nearest hole.
NOTE
żWhen riding in wet and muddy conditions, mud
sticks to the chain and sprockets, resulting in an
overly tight chain, which can cause it to break.
To prevent this, adjust the chain slack (measured
between the chain and the swingarm) to 62 a 68
mm (2.4 a 2.7 in.).

Chain Wear Inspection

When the chain has reached its wear limit (i.e.,
when it has stretched by 2% of its original length),
it is no longer safe for use and should be replaced.
Since it is impractical to measure the entire length of
the chain, determine the degree of wear by measur-
ing a 20-link section of the chain.
A. Turning Clockwise • Tighten the chain either by using the chain ad-
justers or by hanging a 10 kg (20 lb) weight on the
chain.
 MAINTENANCE AND ADJUSTMENT 79

• Measure the 20-link section on a straight part of NOTE

the chain from the center of the 1st pin to the cen-
ter of the 21st pin. If the length exceeds the ser-
żThe drive system was designed for use with a
DAIDO D.I.D 520DMA4 114-link chain. For maxi- j
vice limit, the chain should be replaced. Since mum stretch resistance and safety, a genuine part
overworn sprockets will cause a new chain to wear must be used for replacement.
faster, inspect both the engine and rear sprockets
whenever the chain is replaced, and replace them
żTo minimize any chance of the Master Link coming
apart, the master link clip must be installed with
if necessary. the closed end of the “U” pointing in the direction
of chain rotation.

A. Weight
B. Tape Measure
A. Master Link Clip
Drive Chain 20-Link Section B. Direction of Rotation
317.5 a 318.2 mm (12.50
Standard length
a 12.53 in.)
Wear limit 323 mm (12.7 in.)
 80 MAINTENANCE AND ADJUSTMENT
Chain Guide Wear Inspection Chain Slipper Wear Inspection
• Visually inspect the drive chain guide and replace
it if excessively worn or damaged.
• Visually inspect the front end of the chain slippers
on the swingarm and replace them if worn or dam-
j aged.

A. Chain Guide
A. Chain Slippers
B. Swingarm
 MAINTENANCE AND ADJUSTMENT 81

Sprocket Wear Inspection Chain Lubrication

• Visually inspect the sprocket teeth and replace the
sprocket if its teeth are worn or damaged.
Lubrication of the drive chain is necessary after rid-
ing in the rain or mud, or any time the chain appears
dry. A heavy oil such as SAE90 is preferred to a
j
Sprocket Tooth Wear lighter oil because it will stay on the chain longer and
provide better lubrication.
• Apply oil to the side of the rollers so that it will
penetrate to the rollers and bushings.
• Wipe off any excess oil.

A. Good Teeth
B. Worn Teeth
C. Damaged Teeth

NOTE
żSprocket wear is exaggerated in the illustration.
 82 MAINTENANCE AND ADJUSTMENT

Handlebar
• Loosen the handlebar holder nuts, turn the han-
dlebar holders 180°, and securely tighten the han-
dlebar holder nuts.
j To suit various riding positions, the handlebar
can be adjusted by turning the handlebar holders
around.
• Remove the handlebar pad.
• Check the handlebar for bent or crack.
• Remove the handlebar clamp bolts, the clamps
and the handlebar.

A. Handlebar Holders
B. Handlebar Holder Nuts

A. Handlebar Clamps
B. Clamp Bolts
C. Handlebar
 MAINTENANCE AND ADJUSTMENT 83

• Put the handlebar on the handlebar holders. Handlebar Clamp Bolts Tightening Torque
• Check the
Mount handlebar clamps. 25 N·m (2.5 kgf·m, 18 ft·lb)
• the left and the
that gauge on the handlebar is out of
j
right handlebar clamps equally.
• Check the front brake for the proper brake effect,
or no brake drag.
NOTE
żTighten the two clamp bolts alternately two times
to ensure even tightening torque.

A. Handlebar Clamps
B. Clamp Bolts
C. Gap
D. Supporting Bar

• Tighten the front and rear bolts of the handlebar

clamps equally. If the handlebar clamps are cor-
rectly installed, there will be even gap on the front
and rear side of the clamp after the bolts torqued.
• Do not disassemble the supporting bar on the han-
dlebar.
 84 MAINTENANCE AND ADJUSTMENT

Brakes
• Test the braking power and check that there is no
brake drag.
j Disc and disc pad wear is automatically compen- WARNING
sated for and has no effect on the brake lever or Air in the brake lines diminish braking perfor-
pedal action. There are no parts on the brakes that mance and can cause an accident resulting
require adjustment except brake lever position. in injury or death. If the brake lever or pedal
Brake Lever Position feels mushy when it is applied, there might
The brake lever position can be adjusted to suit be air in the brake lines or the brake may be
the rider’s preference. defective. Have the brake checked immedi-
• To adjust the brake lever position, loosen the lock-
nut, and turn the adjuster to either side with a
ately by an authorized Kawasaki dealer.

wrench. Disc Brake Fluid

• After adjustment, tighten the locknut securely. Inspect the brake fluid level in the front and rear
reservoirs and change the brake fluid in accordance
with the Periodic Maintenance Chart. The brake fluid
should also be changed when contaminated with dirt
or water.

Use only heavy-duty brake fluid as follows.

Front brake fluid : DOT 3 or DOT 4

Rear brake fluid : DOT 4

NOTE
żThe motorcycle is shipped with brake fluid DOT4
in the brake system.
A. Brake Lever
B. Adjuster
C. Locknut
 MAINTENANCE AND ADJUSTMENT 85

NOTICE
Do not spill brake fluid onto any painted sur-
face. j
Do not use fluid from a container that has
been left open or that has been unsealed for
a long time.
Check for fluid leakage around the brake sys-
tem fittings.
Check for brake hose damage.

Brake Fluid Level Inspection (Front and Rear

Reservoirs)
With the front or rear reservoir positioned horizon-
tally, the brake fluid must always be above the mini- A. Rear Reservoir
mum level line. B. Minimum Level Line

A. Front Reservoir
B. Minimum Level Line
 86 MAINTENANCE AND ADJUSTMENT

• Iflowthethebrake fluid in the front or rear reservoir is be-

minimum level line, check for fluid leaks
in the brake line and fill the reservoir to the maxi-
j mum level line. (The step inside the front and rear
reservoirs indicate the maximum level.)

A. Rear Reservoir
B. Maximum Level Line

WARNING
Mixing brands and types of brake fluid can
A. Front Reservoir reduce the brake system’s effectiveness
B. Maximum Level Line and cause an accident resulting in injury
or death. Do not mix two brands of brake
fluid. Change the brake fluid in the brake line
completely if the brake fluid must be refilled
but the type and brand of the brake fluid that
is already in the reservoir are unidentified.
 MAINTENANCE AND ADJUSTMENT 87

Brake Pad Wear Inspection

Inspect the brake pads for wear in accordance with Steering
the Periodic Maintenance chart. If the thickness of
any pad in any (front or rear) brake caliper is less The steering should always be kept adjusted so
j
than 1 mm (0.04 in.), have both pads in the caliper that the handlebar will turn freely but not have ex-
replaced as a set. Pad replacement should be done cessive play.
by an authorized Kawasaki dealer.
Steering Inspection
Usable Brake Pad Range • To check the steering adjustment, raise the front
wheel off the ground using a jack (special tool).
• Push the handlebar lightly to either side. If the
handlebar continues moving under its own mo-
mentum, the steering is not too tight.
• Squatting in front of the motorcycle, grasp the
lower ends of the front fork at the axle, and push
and rock the front fork back and forth as shown.
If play is felt, the steering is too loose and needs
to be adjusted.

A. Lining Thickness
B. 1 mm (0.04 in.)
 88 MAINTENANCE AND ADJUSTMENT
Steering Adjustment • Turn the steering stem locknut with a stem nut
• Raise the front wheel off the ground using a jack
(special tool).
wrench (special tool: 57001-1100) to obtain the
proper adjustment.
j
• Remove the number plate.
• Remove the handlebar.
• Loosen the left and right front fork upper clamp
bolts.
• Remove the steering stem head nut, and raise the
front fork upper clamp.

A. Steering Stem Locknut

B. Stem Nut Wrench (P.N. 57001-1100)

• Install
position.
the front fork upper clamp to the original

• Apply the specified torques to the steering stem

head nut and front fork upper clamp bolts.
A. Front Fork Upper Clamp
B. Steering Stem Head Nut Steering Stem Head Nut Tightening Torque
C. Front Fork Upper Clamp Bolts 98 N·m (10.0 kgf·m, 72 ft·lb)

Front Fork Upper Clamp Bolts Tightening Torque

20 N·m (2.0 kgf·m, 15 ft·lb)
 MAINTENANCE AND ADJUSTMENT 89

NOTE
żTighten the two clamp bolts alternately two times Front Suspension
to ensure even tightening torque. j
Front Fork Inspection
• Install the handlebar and apply the specified
torque, check the steering again and readjust it if • Holding the brake lever, pump the front fork back
necessary. and forth manually to check for smooth operation.
Handlebar Clamp Bolts Tightening Torque • Visually inspect the front fork for oil leakage, scor-
ing or scratches on the outer surface of the inner
25 N·m (2.5 kgf·m, 18 ft·lb) tube.
• IfKawasaki
necessary, repair or replace by an authorized
dealer.
NOTE
żTighten the two clamp bolts alternately two times
to ensure even tightening torque.

• Check the front brake for the proper brake effect,

or no brake drag.

A. Inner Tube
 90 MAINTENANCE AND ADJUSTMENT
NOTICE This adjustment affects how quickly the fork com-
presses. Depending on the model, the fork com-
If the inner tube is badly bent or creased,
pression damping adjuster has at least 22 positions.
j replace it. Excessive bending, followed by
The fully seated position (adjuster turned fully clock-
subsequent straitening, can weaken the in-
wise) is the hardest setting. Turning the adjuster 11
ner tube.
clicks counterclockwise from the fully seated posi-
tion is the standard setting, turning it counterclock-
Front Fork Adjustment wise 22 or more clicks (depending on the model) is
Any of the following front fork adjustments should the softest setting.
be made to tune the front suspension to the rider’s
weight and the condition of the track.
• Fork Oil Amount Adjustment
The fork oil amount affects only the final 100 mm
Basically, there are six adjustments you can make (4 in.) of fork travel. A higher oil amount will make
to the front fork. the fork rebound more quickly. A lower oil amount
• Air Pressure will make the fork rebound more slowly.
Air pressure acts as a progressive spring over the
entire fork travel range. Since the air pressure in the
• Fork Springs
Optional springs, softer and stiffer than standard,
fork legs increases with normal use, the fork action are available.
on your KX will get stiffer as the race progresses.
Therefore, it is not recommended to increase the air
• Fork Clamp Position
Steering is greatly affected by the fork clamp posi-
pressure for additional springing. The KX forks are tion (how much the outer fork tubes protrude above
designed to function without added air. the upper fork clamp). The less the fork tube pro-
• Rebound Damping Adjustment
This adjustment affects how quickly the fork re-
trudes, the lighter the front end becomes and the
greater the tendency for understeering and washout
bounds. Depending on the model, the fork rebound due to weight biasing. Increasing the amount of fork
damping adjuster has at least 20 positions. The fully tube protrusion has opposite effects. Be sure that
seated position (adjuster turned fully clockwise) is the front tire does not touch the fender when the fork
the hardest setting. Turning the adjuster 13 clicks is fully compressed. Make this adjustment in 10 mm
counterclockwise from the fully seated position is the (0.4 in.) steps.
standard setting, turning it counterclockwise 20 or
more clicks (depending on the model) is the softest NOTICE
setting.
The right and left fork tubes must be adjusted
• Compression Damping Adjustment
evenly.
 MAINTENANCE AND ADJUSTMENT 91

Air Pressure Adjustment Rebound Damping Adjustment

The standard air pressure in the front fork legs is • Clean the bottom of the fork tubes.
atmospheric (0 kPa, 0 kgf/cm², 0 ft·lb). Air pressure • To adjustthe
Remove caps on the bottom of the fork tubes.
j
in the fork legs increase with normal use, so the fork
action stiffens during operation. Release air pres-
• on each front
the rebound damping, turn the adjuster
fork top plug with a flat-head screw-
sure from the fork legs prior to each race through the driver. Adjust the rebound damping to suit your
pressure relief screw located in each front fork cap. preference under certain conditions.
Make sure the front forks are fully extended with the
front wheel off the ground when releasing the pres- NOTICE
sure. Do not force the rebound and compression
• Raise the front wheel off the ground using a jack
(special tool).
damping force adjusters beyond the fully
seated position, or the adjusting mechanism
• Remove the screw on each front fork top plug to
let the air pressure equalize. Then, reinstall the
may be damaged.
screws.

A. Rebound Damping Adjuster

A. Screw
 92 MAINTENANCE AND ADJUSTMENT
Rebound Damping Adjuster Settings • Install the caps on the bottom of the fork tubes.
Compression Damping Adjustment
j • To adjust the compression damping, turn the ad-
juster on the each front fork cylinder valve with
a flat-head screwdriver. Adjust the compression
damping to suit your preference under certain con-
ditions.
NOTICE
Do not force the rebound and compression
damping force adjusters beyond the fully
seated position, or the adjusting mechanism
may be damaged.

A. Seated Position (Adjuster Turned Fully

Clockwise)
B. Softer (Counterclockwise)
C. Harder (Clockwise)
D. Standard Setting
*: Number of turns counterclockwise usable range
-20 clicks or more.
Standard Rebound Damping Adjuster Setting
10 clicks *

* Counterclockwise from the fully seated position

NOTICE
A. Compression Damping Adjuster
The right and left fork tubes must be adjusted
evenly.
 MAINTENANCE AND ADJUSTMENT 93

Compression Damping Adjuster Settings Front Fork Oil Change

• Thoroughly clean the fork before disassembly.
NOTICE j
Be careful not to scratch the inner tube and
not to damage the dust seal.
Avoid scratching or damaging the inner tube
or the dust seal. Use a mild detergent and
sponge out dirt with plenty of water.

• Loosen the front fork upper clamp bolts.

A. Seated Position (Adjuster Turned Fully

Clockwise)
B. Softer (Counterclockwise)
C. Harder (Clockwise)
D. Standard Setting
*: Number of turns counterclockwise usable range
-22 clicks or more.
Standard Compression Damping Adjuster
Setting
11 clicks *
A. Upper Clamp Bolt
* Counterclockwise from the fully seated position
NOTE
NOTICE żSet the rebound and compression damping set-
ting to the softest settings before disassembly to
The right and left fork tubes must be adjusted
prevent the needle of adjusters from damping.
evenly.
Record the setting before turning the adjuster.
 94 MAINTENANCE AND ADJUSTMENT

• Loosen the front fork top plug with the top plug • Support the motorcycle using a jack (special tool).
wrench, 49 mm (special tool: 57001-1653). • left front axle
Unscrew the front axle nut, and then loosen the
clamp bolts.
j NOTE
żDo not take off the top plug.

A. Front Axle Nut

B. Left Front Axle Clamp Bolt
A. Front Fork Top Plug
B. Top Plug Wrench, 49 mm (P.N. 57001-1653)
 MAINTENANCE AND ADJUSTMENT 95

• Remove the brake caliper from the fork leg to be • Using a jack to raise the front wheel off the ground.
removed, and rest the caliper on some kind of
stand so that it does not dangle.
• the collarthe
Remove axle, and pull out the wheel. Take off
and cap from each side of the front hub.
j
• Remove the brake hose holder by removing the
brake hose holder mounting bolts. NOTICE
• Remove the fork protector by removing the fork
protector mounting bolts.
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 the
disc does not touch the ground.

A. Brake Caliper
B. Brake Caliper Mounting Bolts
C. Brake Hose Holder
D. Brake Hose Holder Mounting Bolts A. Right Front Axle Clamp Bolts
E. Fork Protector B. Front Axle
F. Fork Protector Mounting Bolts C. Collar
• Remove the front fork protector by removing the
front fork protector mounting bolts.
D. Cap
E. Front Fork Protector
F. Mounting Bolts
• Loosen the right front axle clamp bolts.
 96 MAINTENANCE AND ADJUSTMENT

• Loosen the front fork lower clamp bolts. • Remove

ing it.
the front fork by pulling down while twist-

A. Front Fork Lower Clamp Bolts

A. Pull down by twisting.
B. Front Fork
 MAINTENANCE AND ADJUSTMENT 97

• Using the top plug wrench, 49 mm (special tool:

57001-1653), remove the fork top plug from the
• Place a drain pan under the front fork and drain
fork oil.
outer tube and slowly slide down the outer tube.
NOTE j
żPump the fork tube several times to discharge the
fork oil.

A. Top Plug Wrench, 49 mm (P.N. 57001-1653)

B. Front Fork Top Plug
C. Outer Tube
D. Slide down A. Fork Oil
 98 MAINTENANCE AND ADJUSTMENT

• Raise the outer tube and temporarily install the

fork top plug to the outer tube using the top plug
• Protect the axle holder with a thick rag and secure
it with a vise.
wrench, 49 mm (special tool: 57001-1653).
j

A. Axle Holder Part

A. Front Fork Top Plug B. Protect
B. Outer Tube C. Vise
C. Top Plug Wrench, 49 mm (P.N. 57001-1653)
WARNING
Clamping the axle holder too tight can dam-
age it which will affect riding stability.
Do not clamp the axle holder too tight.

NOTE
żProtect the axle holder with a rag when using a
vise.
 MAINTENANCE AND ADJUSTMENT 99

• Loosen the adjuster assembly completely. WARNING

NOTE The fork spring applies pressure to the ad-
żWhen removing the adjuster assembly, do not juster assembly and can eject the special j
force to loosen it at once using an impact wrench. tool with substantial force if the tool is not
properly and securely placed. Be sure the
tool is fully in place as shown in the photo,
and keep fingers away to avoid getting them
pinched between the tool, adjuster assembly
and axle holder.

• Hold the locknut with a wrench and remove the

adjuster assembly.

A. Adjuster Assembly

• Compress the outer tube by hands and in-

stall the top plug wrench, 49 mm (special tool:
57001-1653) between the axle holder bottom and
locknut.

A. Top Plug Wrench

B. Axle Holder Bottom
C. Locknut
D. Wrench
E. Adjuster Assembly
 100 MAINTENANCE AND ADJUSTMENT

• Remove the push rod. NOTICE

Removing the locknut and pushing the pis-
j ton rod thread into the cylinder unit will dam-
age the oil seal. Do not remove the locknut
from the piston rod.
Be careful of reaction force from the fork
spring when removing the top plug wrench.
Hold the cylinder unit tight enough so that
the locknut does not damage the fork leg.

A. Push Rod

• With the outer tube compressed by hand, remove

the top plug wrench, 49 mm (special tool: 57001
-1653).

A. Top Plug Wrench, 49 mm (P.N. 57001-1653)

 MAINTENANCE AND ADJUSTMENT 101

• Remove the fork leg from vise. • Remove the cylinder unit and fork spring from the
• wrench (special
Remove the front fork top plug with the top plug
tool).
outer tube.
NOTICE j
Disassembling the cylinder unit can lead to
trouble. Do not disassemble the cylinder
unit.

A. Front Fork Top Plug

B. Outer Tube
C. Top Plug Wrench, 49 mm (P.N. 57001-1653)

A. Cylinder Unit
B. Fork Spring
C. Outer Tube
D. Piston Rod
E. Spacer
 102 MAINTENANCE AND ADJUSTMENT

• Secure the top plug wrench, 49 mm (special tool:

57001-1653) with a vise and hold the fork cylinder
• Remove
der unit.
the base valve assembly from the cylin-

unit with the top plug wrench.

j
• Loosen the base valve assembly completely with NOTICE
the top plug wrench, 36 mm (special tool: 57001 Be careful not to damage the bushing of the
-1705). base valve.

A. Top Plug Wrench, 49 mm (P.N. 57001-1653)

B. Fork Cylinder Unit A. Base Valve Assembly
C. Base Valve Assembly B. Cylinder Unit
D. Top Plug Wrench, 36 mm (P.N. 57001-1705)
NOTE
żSlowly compress the piston rod until it stops so
that the base valve assembly can be removed
easily.
 MAINTENANCE AND ADJUSTMENT 103

NOTICE • Hold the front fork at the inverted position for more
than 20 minutes to allow the fork oil to fully drain.
Disassembling the base valve assembly can
lead to trouble. Do not disassemble the base j
valve assembly.

• Drain the fork oil from the cylinder unit by pumping

the piston rod several times.

A. Fork Oil
B. Cylinder Unit
 104 MAINTENANCE AND ADJUSTMENT

• Clean the threads of cylinder unit and base valve

assembly.
• Replace the O-ring on the base valve assembly
and cylinder unit with new ones.
j • Apply specified fork oil to the O-rings and bushings
on the base valve assembly.

A. Threads

A. O-ring
B. Bushing
 MAINTENANCE AND ADJUSTMENT 105

• With the piston rod fully compressed, pour the

specified amount of fork oil.
Standard Fork Oil Amount (Cylinder Unit)
198 mL (6.7 US oz.)
NOTE j
żPut a hand over the two oil holes to prevent oil • Pump
air.
the piston rod slowly several times to expel
leak.
• Hold the piston rod immovable with the fully com-
pressed position.

A. Fork Oil
B. Oil Holes A. Compressed Position
C. Cylinder Unit

Recommended Fork Oil

KAYABA 01 or equivalent
 106 MAINTENANCE AND ADJUSTMENT

• Gently install the base valve assembly to the cylin- NOTE

der unit. żWhen it is hard to screw in the base valve assem-
bly, pull down the piston rod a little.
j NOTICE
Do not damage the bushings when assem- • Hold the top plug wrench, 49 mm (special tool:
57001-1653) with a vise.
bling the base valve.
• Holding the cylinder unit with the top plug wrench,
36 mm (special tool: 57001-1705), torque the
base valve assembly to the specified torque.

A. Base Valve Assembly

B. Cylinder Unit
A. Top Plug Wrench, 49 mm (P.N. 57001-1653)
NOTE B. Cylinder Unit
C. Base Valve Assembly
żPut a hand over the two oil holes to prevent oil D. Top Plug Wrench, 36 mm (P.N. 57001-1705)
leak.
Base Valve Assembly Tightening Torque
• Screw in the base valve assembly in the cylinder
unit when the piston rod extends. 27.5 N·m (2.8 kgf·m, 20 ft·lb)
 MAINTENANCE AND ADJUSTMENT 107

NOTE NOTE
żCheck if the locknut is completely screwed on to żCheck the piston rod sliding surface for damage.
the piston rod. żApply fork oil to the piston rod sliding surface. j
• Protect the piston rod end with a rag to prevent
fork damage.
• Drain the extra oil from the cylinder unit oil hole.
• Discharge the extra oil off the cylinder unit by
pumping the piston rod to full stroke.

NOTICE
Be careful not to bend or damage the pis-
ton rod when the piston rod is stroked. Ser-
vice carefully because oil flies out from the
oil hole of the cylinder unit.

A. Oil Hole

A. Piston Rod End

B. Rag
C. Pump the Piston
 108 MAINTENANCE AND ADJUSTMENT

• With the cylinder unit in horizontal position, slide NOTICE

the piston rod by hand to inspect it if operating
Be careful not to bend or damage the piston
smoothly.
j rod when the piston rod is stroked.
• If the piston rod is not extend, remove the base
valve assembly and perform the air bleeding (pour
the specified amount fork oil and discharge an ex- • Make sure about 16 mm (0.63 in.)
thread is exposed from the locknut.
of push rod
cess of oil).

A. 16 mm (0.63 in.)
A. Slide Piston Rod. B. Locknut
B. Piston Rod
 MAINTENANCE AND ADJUSTMENT 109

• Completely wipe off the fork oil from the spring and
cylinder unit.
• Temporarily tighten the fork top plug by us-
ing the top plug wrench, 49 mm (special tool:
• Insert the spring and cylinder unit to the outer tube. 57001-1653).
j

A. Cylinder Unit A. Front Fork Top Plug

B. Fork Spring B. Outer Tube
C. Outer Tube C. Top Plug Wrench, 49 mm (P.N. 57001-1653)
D. Piston Rod
E. Spacer • Clamp the axle holder with a vise.
NOTE
żProtect the axle holder with a rag when using a
vise.

WARNING
Clamping the axle holder too tight can dam-
age it which will affect riding stability.
Do not clamp the axle holder too tight.
 110 MAINTENANCE AND ADJUSTMENT

• Compress the outer tube by hands and in-

stall the top plug wrench, 49 mm (special tool:
• Insert the push rod into the piston rod.
57001-1653) between the axle holder bottom and
NOTE
j locknut. żCheck the push rod installation by turning the push
rod right and left.
WARNING
The fork spring applies pressure to the ad-
juster assembly and can eject the special
tool with substantial force if the tool is not
properly and securely placed. Be sure the
tool is fully in place as shown in the photo,
and keep fingers away to avoid getting them
pinched between the tool, adjuster assembly
and axle holder.

A. Push Rod

• Replace the O-ring on the adjuster assembly with

new ones and apply specified fork oil to the O-ring.
• Slowly turn the adjuster assembly clockwise until
resistance is felt and check the clearance between
the locknut and adjuster assembly for more than 1
mm (0.04 in.).
• Turn the locknut counterclockwise until it contacts
with the adjuster assembly.
A. Top Plug Wrench, 49 mm (P.N. 57001-1653)
 MAINTENANCE AND ADJUSTMENT 111

• With the locknut held immovable using a wrench,

tighten the adjuster assembly to the specified
• With the outer tube compressed by hands, remove
the top plug wrench, 49 mm (special tool: 57001
torque. -1653).
j
Adjuster Assembly Locknut Tightening Torque • Apply a non-permanent locking agent to the
threads of a adjuster assembly.
28.5 N·m (2.9 kgf·m, 21 ft·lb)
• Torque
torque.
the adjuster assembly to the specified

A. Adjuster Assembly
B. Locknut A. Adjuster Assembly
C. More Than 1 mm (0.04 in.)
Adjuster Assembly Tightening Torque
55 N·m (5.6 kgf·m, 40 ft·lb)
 112 MAINTENANCE AND ADJUSTMENT

• Using the top plug wrench, 49 mm (special tool:

57001-1653), remove the fork top plug from the
Standard Fork Oil Amount
Fork spring 4.7 N·mm (0.48 kgf·mm)
outer tube and slowly slide down the outer tube.
j Fork oil amount 335 mL (11.3 US oz.)
• Pour
tube.
the specified amount of fork oil into the outer
Adjustable 320 a 380 mL (10.8 a 12.8 US
Range oz.)

• When changing the fork spring, the oil quantity is

as shown in the table.
Standard Oil 333 mL
SOFT: 4.6 Quantity (11.3 US oz.)
N·mm
(K = 0.48 320 a 380 mL
Adjustable
kgf/mm) (10.8 a 12.8 US
Range
oz.)
Standard Oil 336 mL
HARD: 4.8 Quantity (11.4 US oz.)
N·mm
(K = 0.49 320 a 380 mL
Adjustable
kgf/mm) (10.8 a 12.8 US
A. Outer Tube Range
oz.)
B. Fork Oil

NOTICE
• Raise the outer tube and temporarily install the
fork top plug to the outer tube using the top plug
wrench, 49 mm (special tool: 57001-1653).
Be sure the oil capacity is the same in both
fork legs. • Install the front forks to the motorcycle.
• Tighten the front fork lower clamp bolts to the
specified torque.
Recommended Fork Oil
Front Fork Lower Clamp Bolts Tightening Torque
KAYABA 01 or equivalent
20 N·m (2.0 kgf·m, 15 ft·lb)
 MAINTENANCE AND ADJUSTMENT 113

• Tighten the front fork top plug with using the top
plug wrench, 49 mm (special tool: 57001-1653) to
torque wrench is fitted, and that of the octagonal
hole of the wrench.
the specified torque. żThis torque value [27 N·m (2.8 kgf·m, 20 ft·lb)] is j
applicable when you use a torque wrench whose
length gives leverage of approximately 310 mm
between the grip point to the center of the coupling
square.

• Tighten the front fork upper clamp bolts to the

specified torque.
Front Fork Upper Clamp Bolts Tightening Torque
20 N·m (2.0 kgf·m, 15 ft·lb)

A. Front Fork Top Plug

B. Outer Tube
C. Top Plug Wrench, 49 mm (P.N. 57001-1653)

Front Fork Top Plug Tightening Torque

30 N·m (3.1 kgf·m, 22 ft·lb)

NOTE
żThe torque of fork top plug is specified to 30 N·m
(3.1 kgf·m, 22 ft·lb) however, when you use the top A. Top Plug Wrench
plug wrench, 49 mm (special tool: 57001-1653), B. Distance
reduce the torque to 90% of the specified value
[27 N·m (2.8 kgf·m, 20 ft·lb)] due to the distance • Install the brake caliper to the fork leg, and tighten
the brake caliper bolts to the specified torque.
between the center of the square hole, where the
 114 MAINTENANCE AND ADJUSTMENT
Brake Caliper Bolts Tightening Torque • Tighten the left front axle clamp bolt to the speci-
fied torque.
25 N·m (2.5 kgf·m, 18 ft·lb)
j Left Front Axle Clamp Bolt Tightening Torque
• Take
pads.
out wood wedge between the disc brake
20 N·m (2.0 kgf·m, 15 ft·lb)

• Apply grease to the oil seals of the wheel.

• side ofthe
Install caps and collars on the left and right
the hub.
• Put the front wheel assembly between the fork
legs, and insert the front brake disc into the front
brake pads.
• Insert the front axle from the right side of the mo-
torcycle.
• Tighten the front axle nut to the specified torque.
Front Axle Nut Tightening Torque
79 N·m (8.1 kgf·m, 58 ft·lb)

A. Collars
B. Caps
C. Axle
D. Right Front Axle Clamp Bolts
E. Axle Nut
F. Left Front Axle Clamp Bolts
G. Oil Seal

NOTE
żTighten the two clamp bolts alternately two times
to ensure even tightening torque.

• Remove
cycle.
the jack and stand supporting the motor-
 MAINTENANCE AND ADJUSTMENT 115

• Install the parts removed. NOTE

• leg, pump
Before tightening the clamp bolts on the right fork
the forks up and down 4 or 5 times to
żTighten the two clamp bolts alternately two times
to ensure even tightening torque. j
allow the right fork leg to find a neutral position on
the front axle. • Check the front brake for good braking power and
no brake drag.
NOTE
żDo not apply the front brake during this process WARNING
to stop the motorcycle from rolling forward. Put a After servicing, it takes several applications
block in front of the wheel to stop it from moving. of the brake lever before the brake pads con-
tact the disc, which could result in increased
stopping distance and cause an accident re-
sulting in injury or death. Do not attempt to
ride the motorcycle until a firm brake lever is
obtained by pumping the lever until the pads
are against the disc.

• Adjust the compression

force adjusters.
and rebound damping

Optional Fork Springs

Various fork springs are available to achieve suit-
able front fork action in accordance with the rider’s
weight and track condition.
Harder springs stiffen the fork action and acceler-
A. Pump up and down ate the rebound damping.
B. Block Softer springs soften the fork action and slow down
the rebound damping.
• Tighten
torque.
the right axle clamp bolts to the specified

Right Front Axle Clamp Bolt Tightening Torque

20 N·m (2.0 kgf·m, 15 ft·lb)
 116 MAINTENANCE AND ADJUSTMENT
Fork Clamp Position Adjustment Standard Fork Clamp Position
Steering is greatly affected by the fork clamp posi- 10 mm (0.39 in.)*
tion (how much the outer fork tubes protrude above
j the upper fork clamp). The less the fork tube pro- * below the surface of the top plug
trudes, the lighter the front end becomes and the
greater the tendency for understeering and washout NOTE
due to weight biasing. Increasing the amount of fork żTighten the two clamp bolts alternately two times
tube protrusion has opposite effects. to ensure even tightening torque.
Be sure that the front tire does not touch the fender
when the fork is fully compressed. Make this adjust-
ment in 10 mm (0.39 in.) steps.

NOTICE
The right and left fork tubes must be adjusted
evenly.

A. Standard Fork Clamp Position

 MAINTENANCE AND ADJUSTMENT 117

Rebound Damping Adjustment

Rear Suspension (UNI-TRAK®) To adjust the rear shock absorber rebound damp-
ing, turn the rebound damping adjuster at the bottom
This motorcycle’s rear suspension system is called of the rear shock absorber with a flat-head screw-
j
“UNI-TRAK®” and consists of a rear shock absorber driver.
unit, a swingarm, two lever rods and a lever.
The operating characteristics of the UNI-TRAK®
suspension are similar to those of the front fork.
However, a linkage system is used to achieve pro-
gressive springing characteristics.
Rear Shock Absorber Inspection
• Pump the seat down and up by 4 or 5 times, and
inspect the smooth stroke.
• Iftheit oildoes not smoothly or noise is found, inspect
leak and rear shock absorber mounting.
• Visually
leakage.
inspect the rear shock absorber for oil

• IfKawasaki
necessary, repair or replace by an authorized
dealer.
A. Rebound Damping Adjuster
Rear Shock Absorber Adjustment
The spring preload of the shock absorber can be If the damping feels too soft or too stiff, adjust it in
adjusted or the spring can be replaced with an op- accordance with the following table.
tional one to suit various riding conditions. In addi-
tion, the damping force can be adjusted easily, mak-
ing it unnecessary to change the oil viscosity.
 118 MAINTENANCE AND ADJUSTMENT
Rebound Damping Adjuster Settings Standard Rebound Damping Adjuster Setting
10th position*
j
*Counterclockwise from the fully seated position

NOTICE
Do not force the rebound and compression
damping force adjusters beyond the fully
seated position, or the adjusting mechanism
may be damaged.

NOTE
żAdjustment of the rebound damping adjuster for
the rear suspension will slightly affect the com-
A. Seated Position (Adjuster Turned Fully pression damping force. Always make any damp-
Clockwise) ing adjustments in small steps and test their ef-
B. Softer (Counterclockwise) fects before using them in competition.
C. Harder (Clockwise)
D. Standard Setting
* Number of turns counterclockwise usable range-33
clicks or more
 MAINTENANCE AND ADJUSTMENT 119

Compression Damping Adjustment (Gas If the damper setting feels too soft or too stiff, ad-
Reservoir) just it in accordance with the following table.
There are two adjustments you can make to the Low Speed Compression Damping Adjuster
rear shock absorber gas reservoir. Settings
j
To adjust the high speed compression damping,
turn the high speed compression damping adjuster.
To adjust the low speed compression damping,
turn the low speed compression damping adjuster
with a flat head screwdriver.
If the damping feels too soft or too stiff, adjust it in
accordance with the following table.

A. Seated Position (Adjuster Turned Fully

Clockwise)
B. Softer (Counterclockwise)
C. Harder (Clockwise)
D. Standard Setting
* Number of turns counterclockwise usable range-22
clicks or more
A. Compression Damping Adjuster for High Speed
B. Compression Damping Adjuster for Low Speed Standard Compression Damping Adjuster
Setting
High Speed Compression Damping Adjuster High speed Low speed
Setting 1 1/2 turns out* 10th clicks*
0 a 2 turns out
* Counterclockwise from the fully seated position
 120 MAINTENANCE AND ADJUSTMENT
NOTICE • Raise the rear wheel off the ground using a jack
(special tool).
Do not force the rebound and compression
j damping force adjusters beyond the fully • Using the hook wrenches (special tool: 57001
-1101), loosen the locknut on the rear shock ab-
seated position, or the adjusting mechanism
sorber.
may be damaged.

NOTE
żAdjustment of the rebound damping adjuster for
the rear suspension will slightly affect the com-
pression damping force. Always make any damp-
ing adjustments in small steps and test their ef-
fects before using them in competition.

Spring Preload Adjustment

• Remove the seat and both side covers.
• section). the silencer (see the “Exhaust System”
Remove

• Remove the rear frame and air cleaner box (see

the “Throttle Body” section). A. Spring Preload Adjusting Nut
B. Locknut
NOTICE C. Hook Wrenches (P.N. 57001-1101)
If the clamp is not removed from the air
cleaner housing, the rear shock absorber
spring may be damaged.
 MAINTENANCE AND ADJUSTMENT 121

• Using the stem nut wrench (special tool: 57001

-1100), turn the spring preload adjusting nut as re-
Rear Shock
Absorber Spring
Adjustable Range
quired. Turning the adjusting nut down increases
the spring preload.
K = 52 N·mm 126.5 a 138.5 mm (4.78 a 5.45 j
(K = 5.5 kgf·mm) in.)
K = 54 N·mm* 126.5 a 138.5 mm (4.78 a 5.45
(K = 5.7 kgf·mm) in.)
K = 56 N·mm 126.5 a 138.5 mm (4.78 a 5.45
(K = 5.9 kgf·mm) in.)

* : Standard

A. Stem Nut Wrench (P.N. 57001-1100)

B. Spring Preload Adjusting Nut

• The standard adjusting nut position from the cen-

ter of the upper rear shock absorber pivot point is
129.5 mm (5.10 in.).
• The adjustable range is as shown in the table be-
low.
A. Adjusting Nut Position
B. Locknut
C. Spring Preload Adjusting Nut

• Tighten the locknut securely.

• and down to make
After making the adjustment, move the spring up
sure that it is properly seated.
 122 MAINTENANCE AND ADJUSTMENT

• After installing the rear frame bolt (upper side) • Check the air cleaner duct is installed securely.
temporarily, install the air cleaner duct clamp to • Tighten the
Tighten the clamp screws securely.
j the air cleaner duct while bringing down the rear
frame a little. Make sure the tab of the air cleaner
• to the specified
rear frame bolt (upper and lower sides)
torque.
duct clamp is aligned with the groove in the air in- Rear Frame Bolts Tightening Torque
take duct.
34 N·m (3.5 kgf·m, 25 ft·lb)
NOTICE
Be sure not to damage the rear shock ab- • Install the parts removed.
sorber spring by the air cleaner duct clamp Optional Rear Shock Absorber Springs
when bringing down the rear frame. Various rear shock absorber springs are available
to achieve suitable rear shock absorber action in ac-
cordance with the rider’s weight and track condition.
A harder spring stiffens the shock absorber action
and accelerates the rebound damping.
A softer spring softens the shock absorber action
and slows down the rebound damping.

WARNING
Improper removal or installation of the rear
shock absorber spring may cause the spring
and/or related parts to be ejected at high ve-
locity. Always wear eye and face protection
when working on the rear shock absorber.
Removal and installation of the rear shock
absorber spring should be performed by an
A. Tab authorized Kawasaki dealer.
B. Groove
C. Air Cleaner Duct (View from Rear Side)
D. Frame
E. Air Cleaner Case
 MAINTENANCE AND ADJUSTMENT 123

Spokes and Rims

Wheels The spokes on both wheels must all be securely
and evenly tightened and not be allowed to loosen.
Unevenly tightened or loose spokes will cause the
j
Tire Air Pressure rim to warp, the nipples and spokes to fatigue more
Tire air pressure affects traction, handling, and tire
quickly, and the spokes to break.
life. Adjust the tire air pressure to suit track condi-
tions and rider preference, but keep it close within
the recommended range.
• To check the tire air pressure, remove the air valve
cap, and make sure to tighten the cap securely
after checking the tire pressure.
• Reduce the tire air pressure to increase the tire
tread surface on the ground when riding on a wet,
muddy, sandy or slippery track.
• Increase the tire air pressure to prevent damage
or punctures (though the tires will skid more easily)
when riding on a pebbly or hard track.
Tire Air Pressure Adjustable Range
80 kPa (0.8 kgf/cm², 11 psi) a
100 kPa (1.0 kgf/cm², 14 psi) A. Spoke and Spark Plug Wrench

NOTE
żTire air pressure should be checked when the tires
are cold, before you ride the motorcycle.
 124 MAINTENANCE AND ADJUSTMENT
Bead Protector
There is a bead protector on the both wheels. The
• Set up the dial gauge on the inner circumference
of the rim and rotate the wheel to measure its ra-
bead protector prevents the tire and tube from slip- dial runout. The difference between the highest
j ping on the rim and damaging the valve stem. Valve and lowest readings is the amount of runout.
stem damage may cause the tube to leak, necessi-
tating tube replacement. In order to keep the tire and
• A certain amount of rim warpage (runout) can be
corrected by recentering the rim, that is, by loos-
tube in position on the rim, inspect the bead protec- ening some spokes and tightening other to change
tor before riding and tighten it if necessary. Tighten the position of certain portions of the rim. If the rim
the valve stem nut finger tight only. is badly bent, however, it should be replaced.
NOTE
żThe welding spot of the rim may show exces-
sive runout. Disregard this when measuring rim
runout.
Rim Runout

A. Bead Protector

Rim Runout
Set up a dial gauge on the side of the rim and
rotate the wheel to measure its axial runout. The
difference between the highest and lowest readings
is the amount of runout. A. Rim
B. Radial Runout
C. Axial Runout
 MAINTENANCE AND ADJUSTMENT 125

Rim Runout Maximum Limit

Axial
2.0 mm (0.08 in.)
Radial j

A. Radial Rim Runout Measurement

A. Axial Rim Runout Measurement

 126 MAINTENANCE AND ADJUSTMENT

Hoses Inspection
j Check the brake and fuel hoses for cracks or de-
terioration, and the connections for looseness in ac-
cordance with the Periodic Maintenance Chart.
• Inspect the brake hose and fittings for deteriora-
tion, cracks and signs of leakage by bending or
twisting the hoses.
• If damaged, replace the hoses.

A. Leakage
B. Cracks
C. Bulges

• Check the hose are securely

clamps are tightened correctly.
connected and
 MAINTENANCE AND ADJUSTMENT 127

Tightening Torques of Nuts and Bolts

j
Location of nuts and bolts
Before the first ride of each day of operation, check the tightness of the nuts and bolts shown below. Check
also that all cotter pins are in place and in good condition.

1. Front Fork Clamp Bolts 8. Rear Frame Bolts 15. Camshaft Chain Tensioner
2. Handlebar Clamp Bolts 9. Spokes Bolts
3. Clutch Lever Holder Bolt 10. Brake Disc Mounting Bolts 16. Shift Pedal Bolts
4. Spark Plug 11. Front Axle Nut 17. Swingarm Pivot Shaft Nut
5. Cylinder Head Cover Bolts 12. Front Axle Clamp Bolts 18. Rear Sprocket Nut
6. Cylinder Head Bolts 13. Brake Caliper Bolts
7. Cylinder Bolts 14. Rotor Nut
 128 MAINTENANCE AND ADJUSTMENT

19. Silencer Pipe Mounting 23. Steering Head Nut 29. Kick Pedal Pivot Bolt
Bolts 24. Front Master Cylinder 30. Engine Oil Drain Plugs
20. Silencer Cover Mounting Mounting Bolts 31. Clutch Cover Bolts
Bolts 25. Rear Axle Nut 32. Water Pump Cover Bolts
21. Rear Master Cylinder 26. UNI-TRAK® Rod Nuts
Mounting Bolts 27. Rear Brake Pedal Pivot Bolt
22. Rear Shock Absorber Bolt 28. UNI-TRAK Arm Nut
 MAINTENANCE AND ADJUSTMENT 129

Torque table
Tighten all nuts and bolts to the proper torque using an accurate torque wrench. An insufficiently tightened
nut or bolt may become damaged or fall out, possibly resulting in damage to the motorcycle and injury to the
rider. An overtightened nut or bolt may become damaged, broken, or fall out.
j
Part Name N·m kgf·m ft·lb
Cylinder Head Cover Bolts 9.8 1.0 (87 in·lb)
Cylinder Head Bolts (M10) 59 6.0 44
(M6) 12 1.2 (106 in·lb)
Camshaft Chain Tensioner Bolts 9.8 1.0 (87 in·lb)
Cylinder Bolts (M6) 12 1.2 (106 in·lb)
Camshaft Cap Bolts 9.8 1.0 (87 in·lb)
Engine Oil Drain Plug (M6) 7.0 0.7 (62 in·lb)
Engine Oil Drain Plug (M10) 20 2.0 15
Oil Filter Cover Bolts 9.8 1.0 (87 in·lb)
Kick Pedal Pivot Bolt 25 2.5 18
Shift Pedal Bolt 9.8 1.0 (87 in·lb)
Spark Plug 13 1.3 (115 in·lb)
Coolant Drain Plug 7.0 0.7 (62 in·lb)
Clutch Cover Bolts 9.8 1.0 (87 in·lb)
Clutch Spring Bolts 8.8 0.9 (78 in·lb)
Generator Cover Bolts 9.8 1.0 (87 in·lb)
 130 MAINTENANCE AND ADJUSTMENT

Part Name N·m kgf·m ft·lb

Brake Caliper Bolts (Front) 25 2.5 18
j Brake Disc Mounting Bolts (Front) 9.8 1.0 (87 in·lb)
(Rear) 23 2.3 17
Engine Bracket Nut/Bolt M8 29 3.0 21
M10 49 5.0 36
Engine Mounting Bolts 49 5.0 36
Front Axle Nut 79 8.1 58
Front Axle Clamp Bolts 20 2.0 15
Front Fork Clamp Bolts 20 2.0 15
Silencer Bolts 20 2.0 15
Silencer Cover Bolts 12 1.2 (106 in·lb)
Front Fork Top Plug 30 3.1 22
Handlebar Clamp Bolts 25 2.5 18
Swingarm Pivot Shaft Nut 98 10.0 72
Rear Axle Nut 108 11.0 80
Rear Brake Pedal Pivot Bolt 25 2.5 18
Rear Frame Bolts 34 3.5 25
Rear Shock Absorber Upper Nut 39 4.0 29
 MAINTENANCE AND ADJUSTMENT 131

Part Name N·m kgf·m ft·lb

Rear Shock Absorber Lower Nut 34 3.5 25
Spokes 2.2 0.22 (19 in·lb) j
Steering Stem Head Nut 98 10.0 72
Steering Stem Locknut 4.9 0.5 (43 in·lb)
UNI-TRAK® Arm Nut* 59 6.0 44
UNI-TRAK® Rod Nuts* 59 6.0 44
Rear Sprocket Nuts 34 3.5 25
Front Brake Master Cylinder Clamp Bolts 8.8 0.9 (78 in·lb)
Rear Brake Master Cylinder Mounting Bolts 9.8 1.0 (87 in·lb)
Air Cleaner Duct Clamp Screw 2.0 0.2 (18 in·lb)
Cylinder Intake Duct Clamp Screw 2.0 0.2 (18 in·lb)

*: Apply the oil to blot threads or nut seat side.

 132 MAINTENANCE AND ADJUSTMENT
electrical components, muffler outlets, and fuel tank
Cleaning Your Motorcycle openings.
j Washing Your Motorcycle
General Precautions
Frequent and proper care of your Kawasaki mo-
• Rinse your bike with cold water from a garden
hose to remove any loose dirt.
torcycle will enhance its appearance, optimize over-
all performance, and extend its useful life. Covering
• Mix a mild neutral detergent (designed for motor-
cycles or automobiles) and water in bucket. Use
your motorcycle with a high quality, breathable mo- a soft cloth or sponge to wash your motorcycle. If
torcycle cover will help protect its finish from harmful needed, use a mild degreaser to remove any oil or
UV rays, pollutants, and reduce the amount of dust grease build up.
reaching its surfaces. • After washing, rinse your motorcycle thoroughly
• Be sure the engine and exhaust are cool before
washing.
with clean water to remove any residue (residue
from the detergent can damage parts of your mo-
• Avoid applying degreaser to seals, brake pads, torcycle).
and tires. • Use a soft cloth to dry your motorcycle. As you dry,
• Always use non-abrasive wax and cleaner/pol-
isher.
inspect your motorcycle for chips and scratches.
Do not let the water air dry as this can damage
• Avoid all harsh chemicals, solvents, detergents, the painted surfaces.
and household cleaning products such as ammo-
nia-based window cleaners.
• Start the engine and let it idle for several minutes.
The heat from the engine will help dry moist areas.
• Gasoline, brake fluid, and coolant will damage the
finish of painted and plastic surfaces: wash them
• Carefully ride your motorcycle at a slow speed and
apply the brakes several times. This helps dry
off immediately. the brakes and restores them to normal operating
• Avoid wire brushes, steel wool, and all other abra- performance.
sive pads or brushes. • Lubricate the drive chain to prevent rusting.
• Use care when washing the plastic parts as they
can easily be scratched.
NOTE
• Avoid using pressure washers; water can pene- żThe front fork may have a scrach by the spattered
trate seals and electrical components and damage stones, etc. but it is no effect for the performance
your motorcycle. of the front fork. After riding in an area where the
• Avoid spraying water in delicate areas such as in
air intakes, throttle body, brake components,
roads are salted or near the ocean, immediately
wash your motorcycle with cold water. Do not use
 MAINTENANCE AND ADJUSTMENT 133

warm water as it accelerates the chemical reaction Chrome and Aluminum

of the salt. After drying, apply a corrosion protec- Chrome and uncoated aluminum parts can be
tion spray on all metal and chrome surfaces to pre- treated with a chrome/aluminum polish. Coated
vent corrosion. aluminum should be washed with a mild neutral de-
j
tergent and finished with a spray polish. Aluminum
Painted Surfaces wheels, both painted and unpainted can be cleaned
After washing your motorcycle, coat painted sur- with special non-acid based wheel spray cleaners.
faces, both metal and plastic, with a commercially
Leather, Vinyl, and Rubber
available motorcycle/automotive wax. Wax should
If your motorcycle has leather accessories, special
be applied once every three months or as conditions
care must be taken. Use a leather cleaner/treatment
require. Avoid surfaces with “satin” or “flat” finishes.
to clean and care for leather accessories. Washing
Always use nonabrasive products and apply them
leather parts with detergent and water will damage
according to the instructions on the container.
them, shortening their life.
Plastic Parts
After washing use a soft cloth to gently dry plastic Vinyl parts should be washed with the rest of the
parts. When dry, treat the non-painted plastic parts motorcycle, then treated with a vinyl treatment.
with an approved plastic cleaner/polisher product.
The sidewalls of tires and other rubber compo-
NOTICE nents should be treated with a rubber protectant to
Plastic parts may deteriorate and break if help prolong their useful life.
they come in contact with chemical sub-
stances or household cleaning products WARNING
such as gasoline, brake fluid, window clean- Rubber protectants can be slippery and, if
ers, thread-locking agents, or other harsh used on the tread area, cause loss of traction
chemicals. If a plastic part comes in contact resulting in accident causing injury or death.
with any harsh chemical substance, wash it Do not apply rubber protectant to any tread
off immediately with water and a mild neutral area.
detergent, and then inspect for damage.
 134 MAINTENANCE AND ADJUSTMENT

• Rear brake pedal

Lubrication • Kick pedal rod joints
Rear brake
j • Foot peg
Lubricate the areas shown in the illustrations of
this section with either motor oil or regular grease,
•
after each race and whenever the vehicle has been
operated under wet or rainy conditions, especially
after using a high-pressure spray washer. Before
lubricating a part, clean off any rust with rust remover
and wipe off any grease, oil, dirt, or grime.
General Lubrication
Apply motor oil to the following pivots:
• Clutch lever
• Front brake lever
 MAINTENANCE AND ADJUSTMENT 135

• Shift pedal Apply an aerosol cable lubricant with a pressure

lubricator on all cables:
• Clutch cable
j
• Throttle cable
Cable Lubrication
 136 MAINTENANCE AND ADJUSTMENT
Apply grease to the following points: Drive Chain Lubrication
• Upper end of clutch cable Lubricate the drive chain after riding through rain
j • Upper end of throttle cable or on wet track, or any time that the chain appears
• Upper end of hot starter cable dry. A heavy oil such as SAE90 is preferred to a
lighter oil because it will stay on the chain longer and
provide better lubrication.
• Apply oil to the sides of the rollers so that it will
penetrate to the rollers and bushings.
• Wipe off any excess oil.

A. Grease.
 MAINTENANCE AND ADJUSTMENT 137

Self-diagnosis Procedures
DFI Self-Diagnosis •Remove the FI indicator light assy cap, and con-
nect the FI indicator light assy (Optional part:
This motorcycle equips the DFI trouble self 23016-0034).
j
-diagnosis system. Trouble diagnosis can be con-
ducted with the optional parts sold separately as the
following procedures.
Self-diagnosis Outline
The self-diagnosis has two modes and can
be switched to another mode by grounding the
self-diagnosis terminal.
User Mode -
The ECU connected FI indicator light goes on
when DFI system and ignition system and ignition
system parts are faulty. In case of serious troubles,
the ECU stops the injection/ignition operation.
Dealer Mode -
The FI indicator light emits service code(s) to show A. FI Indicator Light Assy Cap
the problem(s) which the DFI system, and ignition
system has at the moment of diagnosis.
 138 MAINTENANCE AND ADJUSTMENT

• Remove the bolts and then, remove the left radia-

tor shroud.
• Disconnect the capacitor lead connector.
j

A. Capacitor Lead Connector

A. Bolts
B. Left Radiator Shroud
 MAINTENANCE AND ADJUSTMENT 139

• Connect the power supply harness (Optional part:

26011-0246) to the capacitor lead connector of the
• Keep the FI indicator light assy (Optional part:
23016-0034) Y lead ground.
main harness. • Count the blinks of the light to read the service
j
• Connect the power supply harness (Optional part:
26011-0246) to the 12V battery as shown.
code. Keep the lead ground until you finish read-
ing the service code.
• To enter the self-diagnosis dealer mode, ground
the self-diagnosis indicator terminal for more than
2 seconds, and them keep it grounded continu-
ously.

A. Power Supply Harness (P.N. 26011-0246)

B. Capacitor Lead Connector
C. 12 V Battery

NOTE A. Y Lead
żUse a fully charged battery when conduct- B. 2 seconds
C. Keep it grounded continuously
ing self-diagnosis terminal grounded during
self-diagnosis. Otherwise, the light blinks very
slowly or doesn’t blink.
żKeep the self-diagnosis terminal grounded during
self-diagnosis.
 140 MAINTENANCE AND ADJUSTMENT
How to Read Service Codes

j • Service codes are shown by a series of long and short blinks of the FI indicator light as shown below.
• When theredigit
Read 10th and unit digit as the FI indicator light blinks.
• starting from thealowest
are number of problems, all the service codes can be stored and the display will begin
number service codes in the numerical order. Then after completing all codes, the
display is repeated until the self-diagnosis indicator terminal is open.
• If there is no problem, no code and unlighted.
• For example, if two problems occurred in the order of 21, 12, the service codes are displayed from the
lowest number in the order listed. (12 ĺ 21) ĺ (12 ĺ 21) ĺ (repeated)

• Ifdoesn’t
the problem is with the following parts, the ECU cannot memorize these problems, the FI indicator light
go on, and no service codes can be displayed.

NOTE
żECU power source wiring and ground wiring (see Service Manual)
żEven if the battery of the ECU is disconnected, or the problem is solved, all service codes remain in the ECU.
 MAINTENANCE AND ADJUSTMENT 141

Service Code Table

Service
FI Indicator Light (LED) Problems
Code j
11 Throttle sensor malfunction, wiring open or short

12 Inlet air pressure sensor malfunction, wiring open or short

Inlet air temperature sensor malfunction, wiring open or

13
short
Water temperature sensor malfunction, wiring open or
14
short

21 Crankshaft sensor malfunction, wiring open or short

25 Gear position switch malfunction, wiring open or short

31 Vehicle-down sensor, malfunction, wiring open or short

41 Injector malfunction, wiring open or short

 142 MAINTENANCE AND ADJUSTMENT

Service
FI Indicator Light (LED) Problems
Code
j
46 Fuel pump malfunction, wiring open or short

51 Ignition coil malfunction, wiring open or short

NOTE
żThe ECU may be involved in these problems. If all the parts and circuits checked out good, be sure to check
the ECU for ground and power supply. If the ground and power supply are checked good, replace the ECU
(see Service Manual).
żWhen no service code is displayed, the electrical parts of the DFI system has no fault, and the mechanical
parts of the DFI system and the engine are suspect.
A bracket to fix the FI indicator light on the handlebar is sold separately as an optional part.

Bracket (optional part):

P.N. 11055-1673

While the vehicle equipped with the FI indicator light is moving, if there is any problem in the DFI system, the
FI indicator light blinks.