Quick Refelrence Guide

To use, bend the manual back .and match the desi red chspter below .against

the b I fie k spot 'showing att h e eo ge of ....l1lI... th ese pages. .."..

General Infolimatlion

Scheduled Maintenance

- -

IEngine

Non ~ scheduled Maintenance

Chassis

IElectrical

Engilne

Disassembly

Chassis

Appendix

Kawasaki

750 turbo

Motorcycle Service Manual Supplement

All rights reserved. No parts of this publ ication may be reproduced, stored in a retrieval system, air transmitted in any form or by any means, electronic mechanical photocopying, recordi,rilg or ot h erwi se, wi th 0 u t the p r i or wri'Uen perm ij ss i on of the Qu a I i tv .Assu ra Ii ce De pertrn ent/M otorc yd e Group/Kawasaki Heavy I ndustries, Ltd", Japan.

No I ~abi ~ity can be accepted for any maccuractes or omissions in this publication, although every possl b I e ca re has been ts ken to make it as com pi et e and accu rate as pessl bl e.

The right is reserved to make changes at any time without prior notice end without incurri ngan obligation to make such changes to products manufactured previously. See you r Motorcycle dealer for the latest information on product irnprovernents incorporated after this publication.

All information contained in this publicatinn is based on the latest product information available st tile lime of publication. III ustrations and photographs in this publication are intended 1m reference USE! only and may not depict ac tual model component parts.

© Kawasa ki H cavy I ncu str i 0"5, 1_ td .: ~ 983

Finl Edirion (1) : July 13, 19M @

SAFETY AWARENESS

Whenever you sec the symbols shown below, heed their lnstruc tionsl Alway~ follow safe operating and rna i ntenancc pr Ole t i ces,

LWARNING)

Thi s wa m in 9 sy mhol id{!l'Itifn es specie I i nstr u etions or pr(l(;{tdun!$ which, if net correctly fOllowed, could resyH in personal injury, Of' loss of life.

U This &II III tion sy rnbo] idllnti fie~ spee ilal iln~t'ructli ons or procsdures which. if not strictly observed, could result in dOl mllge to or dastru ctiu n 01 aqu ip men L

()This note liVi'ntwl indicatllii ooiot» of parricular interest for more efficient and convenient operation.

LIST OF ABBREVIATIONS

A amperefs) Ib poundtsl
ABDC after bottom d ead c enter m rnetertsl
AC alternating current min mlnutets)
ATDC after top dead CElntHr N newton (5)
BIBIDC be 10 re bottom dead cente r P'a pescalls]
BDC bottom dead canter PS 11 orsep ower
BTDC before top dead center PSI poundts] per square inch
00(: degree (s·.1 Calcius r revolution
,DC direct current rpm revolutionls] per minute
F faradh) TOe top dead centa r
DF degr~·rs~ Fahrenheit TIA total indicator readlnu
fit foot, feet V volt{s)
9 gram ~s~ W wattts)
h hour(s) Q chrnts)
l I iteds) Read <lVVNIER'S MANUAL before operating.

~.~~~~~~§Il~

Emission Control Iinformation

To protect the environment in which WB alii live, Kawasaki has incmporarted crankcase em lsslon ~ 1) and exhaust emission (2) control systems in cornpl lance wid, appl icabl eo regulations of the United States. Environmental Protection Agency and Cal ifornla Ai r Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable: regulations of the Callfomia Air Resources Board on vehicles sold in California only.

1. Cran kcass Em ission Control System

Th is svste rn eli m i nates the re I ease of c ran kcase va po rs ~ n to the atmosphere. Instead, the vapors are routed through an oil separator to the intake side of the engine. While th e eng i n e is 0 p erat i n g,. the vapors are drawn into Com busti 0 n cha m b er, whe re they a, re burned along with the fuel and air supplied by the earburation system.

2. Exhaust Emission Control System

Tn is system reduces the amount of pol lutants discharged into the atmosphere by the exhaust of this motorcycle. The fuel and ignition systems of this motorcycle have been carefully designed and constructed to ,enSLJ re an efficient engine With low exhaust pollutant levels.

3. Evaporative Emission Control System

Vapors caused by fuel evapcration in the fuel system are not vented i nto the atrn osp h ere, I nne-ad. fu e I vap 0 rs ars ro 1I ted into th e r u nn i n 9 en 9i ne to be burned, or stored ina can ister when the engine is stopped" Liquid fuel is caught by a vapor 'separator and retu moo to the fuel tank.

The Clean Air Act, which is the Federal law covering motor vehicle pollutien, contains what is common Iy referred to as the Act's "tampering provisions."

"Sec. 203(a} The following acts and the causinq thereof are prohibited ...

'(3)(A) for any person to remove or render inoperative alny device or element of design installed on or in a motor vehicle or motor vehicle engine in ccrnpliance with requlatlons under this title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowlnqlv to remove or render i noperativs any such device or element of design after such sale' and delivery to the ultimate pu rchaser,

(3) ~ 8) for anv person engaged in the: busi ness of repairing. servicing, sell I i rig. lessl ng, or trad i ng motor vehlel es or motor vehicle engines, or who operates a fleet of motor vehicles knowingl y to remove or render inoperative any device or elernant of design installed on or in a motor vehicle or motor vehicle E!ngune in compliance with regulations under this title following its sale and delivery to the ultfrnate pu rchaser .. .'

"NOTE"

r,. The pbrsse "remove or render inop~rative any device or element of design" has been generally interpreted as tottow«.

1. Tampering does not include the temporary removal or rendering inoperative of devices or eiemen rs 0 f design in order to perform main tensnce.

2. Tampering could include:

a. Maladjustment of vehicle components such that the emission standards are exceeded.

b. Use of replacement parts or accessories which edversetv affect the performance or durability of the motorcycle ..

c. Addition of components or eccessaries that result In the vehicle exceeding the standards.

d. Permsnentiv removing. disconnecting, or rendering inoperative any component or element of design of the emission control systems.

1--

Ie ~ i:

.m:~~~m:m:m:m:~~~~m:~m:m:m:m:~m:~

WE RECOMMIEND THAT ALL DEALERS OBSERVE THESE IPROVIISIONS OF F EDE RA.L LAW. THE VIC LATION 0 F WH ICH IS IPUNISHAIBL E BY CIV I L PENALTIES NOT IEXCEEDINGI $10,000 PER VIOLATION.

I~~~~~~~~~~~~~~~~~~~~~~~~~~

I TAMPERING WII1H NOISE CONITROL SYSTEM PROHIBITED ~

IFederal hlw proh lbits the foUowing acts or the ceusl 119 thereof:

(1) The removal or rendering inoperative by any person other than for purposes of mainten ancs, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior 10 in sale or dellverv to the u ltlrnate purchaser or wn i I e it is on U5lE!, or (2} the use OT the veh iele after such device or element of design has been removed or rendered inoperative by any person.

Am on g th OSE! acts p resu 1m sd to co n st i tute tam peri ng a ra the act's listed bal ow:

• Replacement of the oriqi nal exhaust system or rnu mer with a com ponent not in GOm-

pi lance with Federall regu lations .

• Removal of the mLII'fflel'(s l or any internal portion of the m ufflarts]. -Removal of the -air box or air box cover .

• Modificarl:ions to the mufflerts] or ai r inta ke system by cutting, d ri Ilillg, or other means if su eh mod i fic at ions resu It r n i n creased noi se I eve I s.

This 75CJ tu rbo Service Manual Supplement is designed to be used in conjunction with the KZ750 Fou r Motorcycle Service Manual (PIN 99924-1 021.Q4). The maintenance and repair procedures described in this supplement are only those that are unique to the ZX7S0E motorcycle. Most service operations for th is model remain identical to those described in the base Service Manual, Complete and proper servicing of the ZX750E motorcycle therefore requires both this supplement arid the base Service Manual.

The base Service Manual and this Supplement are designed primarily for use by motorcycle rnachan les in a properly equ loped shop. However, they contain enough detail and basic information to rn <I ke t h 111m u sef u I to th e 0 pe ra to r wh (I des i res to perfo rrn his 0 wn basi c rna i ntena nce and repa i r work. A basic knowledge of mechanics, the proper use of tools, and work shop procedures must be understood I n order to carry out maintenance and repair satlstactorl lv, Whenever the operator has insufficient experience or doubts his ability to do the work, the adjustments, rnaintananca, and repai r should be carried out only by qualified mechanic'S.

In order to perform the work efficiently and to avoid costly mistakes, the mechanic should read the text, thoroughlV tarni Iliarize himself with the procedu res before startinq work, and then do the work carefu Ily ina clean area. Whenever specia~ tools and equ lprnent are specified, makeshift tools or eq u i p me n t shou I d not be used. Prec i s i on rnsasu rem ents ca n on I y be mad e if th e p rap er in S1 ru m ents are used, and the use o,f substitute tOQIIs may adversely affect safe operation of the motorcycle.

"NOTE"

c'Ihis Supplement covers all items of th« 750 turbo service data, sa it is not necesssry to refer to th~ base Service Manual tor any service data.

Kawasaki !Of i (Digital Fuel Injection) System Precautions

"NOTIE" 8Engine performance is sensitive to throttle sensor position.

o The throttle sensor does not re.quire any periodic maintenance.

':JDo not alter or adjust sensor position unless otherwise the sensor position has been obviously upset.

»Sensor position is the last cause to be suspected in troubleshooting' the DFI system.

~Whe" any fuel hose is disconnected, do not turn on the ignition switch. The fuol pump win operate and fuel will spout from the fuel hose if you turn on the '5witeh while the hose i'S d iseonneeted,

GENERAL INFORMATION 1~1

General llinformation

Table of Con'tents

Modell I denttftcatlon + + • + • , • , ••••••••••••••••••••••••••••••••• 1·:2 Specifications .. '" . , •.••••.......... " . , ...•.•.. , ... , . , . , ..... 1·3 Before Servic i ng ... . . . . . , . . . , . . , . . . . . . . . , . . . , . , . . . . . . . . . . . . . . .1 w5 High Altitude Performance

Adjustment Information (US Moden , 1-9

Setting Before Ride + •••••••••• , •••••••••••• , •• , .1-9

Special Tools " " " .. " , .. " ...• ~ ·13

T mq lJ e and Loc ki ng Agent , . , . . . . " . . . , . . . . ' . . . . . . . . . . . . , . " . " .. 1 -14

Service Datal .......•...••........ , ..........•.••.... , 1-18

ZX750E Wiring Diagram ~ US and Canada) , , . , , . , .11-23

ZX750E Wir~ng Diagram ~~Other than US and Canada)' " , .. , .1-24-

OF I System Wiring Diagram , , , ...•.. " " , ....•.•. 1-25

1-2 GENERAL INIFORMATIION

•••• i_ill tll;W;! 11"- ••••••• Ill ;I. il III_ , ,",oil Iii I II

Model Identification

I ~ , •• i. III II i!t II t!l I!!- i i ot 11!t'"'!··· ••••• , .

ZX 750-IE 1 left Side View:

ZX750-E1 Right Sid'E! View:

GENE RAI- I NIFOAMA ilON '·3,

Specificati,ons

Items

2)(750-E1

Dime nsl ons: avera II length Overall width Overa I I height Wheelbase Road clearance Seat height Dry weight

Cu rb weight: Front

Rear

2,220 rnm, © (jJ)@ 2,190 mm 740 mm, © ® (Q) 720 mm 1,260 rnrn

1,490 mm

155mm

780mm

2,285 N ~233 kgL ~ 2,290 N (233.5 kg) 1,206 N (123 kg}, COO 1,211 N (123.5 kg) 1,275 N (130 kg), cOO 1,215 N '(130 kg) 17.0 L

Fuel tank capacity

Perla rmance:

CI imbing ability

B raking distance Minimum turning radius

Engine:

Type

CQo~ing system Bore and stroke

D i sp lac erne n t Com press i on rat i 0

Ma x i mum horsepower

30"

12.5 m from 50 km/h 2.7 m

4-stroke, DO He, 4-cyl i ndar Air cooled

66.0 X 54.0 mm 738 mL

7.8

82.4 kW (112 PS) @9,OOO r/rnin (rpm),

@L@ 73.6 kW (100 PS) @9,OOO r(min [rpm}, ~ 61.0 kW ~83 PS) @6,600 rim I n (rpm)

99.l NI-m (10-' kg-m,73.1 ft·lb) @6,500 r/rnln {rpm], @@ '94.1 N·m ('9.6 kg-m, 69.4 tt-tb) @6,SOO r/rnln

'(rpm). Q 92.2 N-m (9.4 kg·m, 68.0 ft-Ib) @6,OOO rim i n (rpm)

D F I (Digital lFuel II njectionl, Turbo E I ectr ic starte r

Battery and COl I ttrensistorlzedl Electron lea II v a dven ee d

From 10" BTDC @1.050 r/min (rpm) to 300 BTDC @3.300 r/min (rpm)

(Q) From 10° BTDC @'I,200 r/rnin (rpm) to

30" BTDC @3,300 r/min (rpm) N'GK BR9EV

Left to right, 1-2-3-4 1·2·4·3

22<> BTDC

52" ABDC

254~

60° BIBDe 20° ATDC

Maximu m torque

Ca rbu ret ion system Starting 'System

I gn it i on sy stem Timing advance 19nition thming

Spark pllllg

Cy I lnder nu mberl ng method F iring order

Valve 'I:~m~rlg: I n let

Open Close Duration Open Close

Exhaust

Duration 2600

W California model ®_ : Swedish model ~ Switzerland model

CC): Can-ad ian model

©. West G~rman model @; South African model

French model US model

1-4 GENERAL INFORMATION

Items

lubrication system

Engine Oi I: Grade

Viscosity Capacity

-------

Drive Train:

Primary reduction system:

Type

Reduction ratio

Clutch tvpe Transmission: Type

'Gear ratios:

Final drive system; Type

Reduction ratio Overs II drive ra tio

5_0_-E_1 ~ __

ed lu brication (wet sump with cooled

SE class

SAE10W40, 10W50, 20W40, or 20W50 3.5 L

1st 2nd 3rd 4th 5th

Gear

1.935 (60/311 Wet multi disc

5-speed. consta n t mesh, retu rn sh ift 2.285 (32114)

1 A547 (281117)

1.272 (28/22)

1 JJ45 (23/22)

0.833 (20/2 4)

Chain drive 8.066 (46/15) 4.946 @To p ge~r

Frame:

Type

Caster (rake angle) Trail

Front tire:

Type Size Type Size Front suspension:

Type

Wheel travel

Rear tire:

Aear suspension:

Typo

Wheell travel

Brake type:

Front Rear

EleC1ricaIIEquipment:

Battery

Headlight: Type

Bulb Ta ii/braKe I j'9lht Alternator: Type

Rated output Vultaqa regulator:

Type

Tu bu lar. dou ble cradle 28°

1nmm

Tubeless

110/90 V 18

Tubeless

130/80 V 18

Telescopic 'fork (pneumatic) 130 mm

Swi no a rrn luni trak) 10Smm

Dual disc

Single disc

12V14AH Semi-Sealed beam

12 V 60/55 W (quartz-halogen}

12 V 5/21 W x 2, ©<CiD@@ 12 V 8/27 W x :2 Three-phase AC

20 A @8,OOO r/rnin [rpm), 14 V

Short-circu it

GIENERAL INFORMAT~ON '-5

Before Servicing

Before starting to service a motorcycle, carefu I reading of the applicable section is recommended to eliminate unnecessarv work. Photographs, diagrams, notes, ceutions, warnings, and detailed descriptions have been induded wherever necessary. Nevertheless, even a detail account has I lmltaticns, a certal n amount of bask knowledge is also requ ired for successful work.

E speci aUy note the fo II owi n g: (1 l' Dirt

Before removal and dlsassernblv, clean the motorcycle, Any dirt entening the engine or other parts will work as an abrasive and shorten the life of the motorcycle. For the same reason, before install ing a new part, clean off any dust or metal f II,ings.

~2) Battery Grou nd

Re move the g rou nd (-) I ead frorn th e b atts ry be to re pe rfo rm i ng an V d isass ernb I y 0 perat ions on the mota revel e. Th i s prevents:

'(1:1,) the possibility of accidental ~y turning the engine over while partlallv disassembled, (b) sparks at electrical connections which wi,li occur when they are d lsconnected,

k:) damage to el ectrical parts.

(3) ng,nten in g Sequ ence

Generally. when install.ing a part. with several bolts, nut'S, Or screws, they should all be started in their holes and tightened to a snuqtlt, Then tighten them evenl,y in a cross pattern. This is to av'Oid distortion of the part and/or causing gas or oil leakage. Conversel y wh~n loosening the bolts, nuts, or screws, first loosen al ~ of them by about iii quarter 'Of turn and then remove them.

Where there is a tlqhten lng sequence i,ndication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and method i 11.0 icated.

(4) Torque

The torque values given in this Service Manua.l should always be adhered to. Either too little: or too much torque may lead to serious damage. Use a good quality, reliable torque wrench. ~ 50) Force

Gammon sense should dictate how much force is necessary in assembly and di,sas5iembly. If a part seems especlallv difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap ~ightly usinq a wooden or plastic-faced mallet. Use an impact driver for screws [particu lar~y for the removal of 'screws held by a locking agent) in ord er to avo i d d amag i ng th e sc rew head s,

'~6} Edges

Watc h to r s harp edg es, especlatl y du r i n g m a jo r en 9 ~ ned i sassernb I 'If and assernb I v, Protect you r hands with gloves or a piece of thick doth when I i fling the enqine or turnl ng it over.

(7) Hi gh Hash-poi rrt Solvent

A high flash-poi nt solvent is recommended to reduce fire danger, A commercial solvent commonly available in North America is Stoddard solvent (generic name). Always follow manutacturer and container directions regarding the use of any solvent.

~8) Gasket, 0- Ring

Do not reuse a gasklrt or O-ri FIg once it has been if' service. The mating surfaces sround the gasket should be free of fore~gn matter and perfectly smooth to avoid ad or compression leaks. (9) Li quid Gas ket, N (I n- perrna n ent Loc k i n gAge nt

Follow manu factu rer's dl rections fnr c~eaning and preparing surfaces where these compounds wi II be used. App I Y sp ar i n 9 I y. Excessive am au n IS may bloc k eng i ne ol I passages and cause serious damage. An example of a non-permanent locking agellt commonlv available in North America is Loctite Lock'n Seal tBlue)"

(0) Press

A part installed using a press or driver, such as a wheel bearing, should f rst be coated with oi I on its outer or inner circurnference so that it wi II go into place smooth Iy.

(11) Ba~1 Bearing

Wh en i nst a! lin g a ba ~ I b sari ng, th e bea rn ng race wh lc his affected by fr i etl () n 5 h au I d be pus hed by ,;3. su ltsble driver. This prevents severe stress on the balls and races, and prevents races and balls from being, dented. Pres's a bal I bearing until it 'Stops, at the SlOP in the ho~oE! or on the shaft.

Hi GENERAL INFORMATION

(12) Oil Seal and Grease Seal

Replace anv 011 or grease seals that were removed with new ones, as removal generally damages seals.

When pressl n 9 i 1"11 1:1 sea I wh leh has rna nu f aetu fer's marks, press it in wi th th e rna rks fsci n gout.

Seals should be pressed into' place using a suitable driver, which contacts evenly with the side of seal, until the face of the sear is even with the end of the hole.

(131 Seall Guide

A seal gu ide is requ ired 'for certain ol I or grease seals du ring installation to avoid damage to the seali lips. Before a shaft passes through a sea!!, apply a little oil, preferably high temperature grease on the lips to reduce rubber to metal friction.

(14) Circlip, Retaining Ring

Replace any cirellps and retaining rings that were removed. with new ones, as removal weakens and deforms them. When installing clrllps and retaining rings. take care to compress or expand them only enouqh to install them and no more.

(15) Lubrication

Eng~ne wear is generally at its maxi mum while the engl ne is warmingl up and before all the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever ts more su itable) shou ld be applied to any rubbing !iLl rfsee which has, 105t its lubricative film. Old grease .and dilrty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles.

Don't use just any oi] or grease. Some oils and greases in particular should be used only in certain appl lcstions andlmay be harmful if used in an application for which thev are not intended. Th is manual makes rsferenee to molybdenum disulfide gr.ease (MoS2) in the assembly of certain S:l1gi ne and chassis parts. Alwavs check manufacturer recomrnendat! OI1S before usinq such special lubricants.

(16) Electrical Wires

All the electricsl wires are either single-color or two-color ami, with onl y a few exceptions, must be connected to wi res of the same color. On any of the two-color wi res there is a g,rea1l:er amount of one color and 1:1 lesser amount of a second color, so a two-color wire is identified by first the prlrnarv color and then the seeondarv collar. For example, a yellow wire with thin red stripes is referred to as a "vallow/red" wire; it would be a "re-d/yellow" wire if the colors were revarsed to make roo the main color.

1112100

Name of Wire Color

---+--

Picture in Wilring Diagnm

-------1

Red Wire Rj~m~-\-- strands

Yellow Red

Yellow

Yeillow/red

{17) Replacement Parts

When there is a replacement instruction, replace these parts With new ones every time they are removed, These replacement parts wi II be damaged or lose thei r original functi on once removed. (118) Inspection

When parts have been disassembled, visuallv inspect these pa rts for followi ng conditions or

other damaqe, If there is any doubt as to the condition of them, replace them with new ones.

Abrasion Crack Hardening Warp

Bent Dent Scratch Wear

Coior change Deterioration Seizure

~ 1 9 I, Service Data

Numbers of service data In this text have followi nq mean inqs:

"Standards": Show dimensions or performances which brand-new parts or systems have.

"Service Limits": Indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts.

GIENE RAl I N FORMATION 1·7

(20) DF I (Digital Fuell Injection) System

There are a number of important precautions that must be observed when servicing the Kawasaki DF II system, Failure to observe these preeauttons can result in serious 'SYstem damage. Learn and ob Sf! rve a i I th e ru I es listed below.

E lectnea I System:

_ Do not disco n nact the battery ~ ead s or any othe r e lee Idea I con nect i on s when the' ~ gn it ion sw itch is on, or while the' engine is running. This is to prevent control unit damage.

"NOTE"

cWhenever electrical connections are to be disconnected, first turn off the ignition swituh, disconnect the DFI positive (+) lead from the battery positive terminal, and then disconnect the required connections. There are other white/red leads wh;c;h are connected to the battery positive terminal, but 'these leads csn be! left connected .

• Conversely, make su re that all, electrical connections are firrn~y reeonneeted before sterti ng the engine, Especially, do not forget to connect the D F I negativ,ia' lead Ito the battery negatiive (-~ terminal,

-The Kawasaki electronic fuel injection system is designed to be used with a 1 2-volt battery as its power source. Do not use envth i ng other than a 12·volt battery as a power source.

"NOTE"

oDo not directlv connect iii 12-lIolt battery to iii fuel injector. Insert a resistor, whic'h has a resistance 0 f 5 - 7 Q, in series between the battery and the injector, or use a 3-iIOlt drv battery .

• Alw.ays d lsconnect the battery positive and negative leads from the terminals, and remove the batterv f rom the m nto revel e to r cha rg i n g. Th i sis to p reve n t th e D F I con trol unit from b ei ng darnaqsd bv excessive peak voltage.

-Avoid spryaing water with any great force on the electrlcal components, connectors, leads, and wiring harness of the D F I system.

-Keep the OFI system wiring harness at least 100 mm from all othersvstem leads (especially high tension leads of the ignition system). This to prevent the DFI control unit 'from malfunctioning due to exte rna I ell ectr icc,l no lses,

-If a transceiver is installed on the motorcycle, rna ke sure that the operation of the fuel injection sy stem ij S not in flu enced by e I ect ri c wave r ad n at ed fro m th ~ an ten n a. Ch ec k ope r atl 0 n 0 f t h eo system w~th the engine at idl e.

"NOTE"

C Locate the antenna as far as possible from the control unit. The interierenc« from radio waves can be reduced b V grounding the unit control box to the motorcycle.

_I rnportant throttle 'sensor information for Kawasaki D F I system.

"INIOTE" of!ngfne performance is sensitive to throttle} sensor position.

(_. The throttle sensor does not require an V periodic msintenence.

oDo not alter or adjust sensor position unless otherwise the sensor position has been obviouslV upset.

<Sensor position is the last cause to be suspected in 'troubleshooting the DFf system.

Fuel System:

-Do not operate the fuel pump if the inside of the pump is. cnmpletelv dry. This us to prevent the pump from running without lubricant at the friction su rfaces,

-Slow the fuel system dean with compressed air before removing the parts.

-Any hose damps on the high-pressure fuel line must be replaced with new ones once they are

loosened.

1eB GEN E RAl INFO RMATION

"NOTE"

o Install the hose clamps in the position shown in the Disassembly Chapter and securely tLghten the clamp screws. Check the fuel system for leaks.

-To prevent corrosion and deposits in the fuel system, do not add any anti freeze chemicals in fuel.

l WARNIING •

oWhen any fuel hose is disconnected, do not turn ontha ignitlion switch. The fuel pump will operate and fuel will spout from the fuel hose if you turn onlli e swi teh while the hose b d lseonneeeed.

Ai r System:

-In order to maintain the correct fuel/air mix u re, there must be no air leaks in the ai r system.

Be sure 11:0 install the ol ~ filler cap securely after addi ng engine oi I.

iHigh A'titude Performance

Adjustment Information (US Model)

Tu improve the lM'ISSION CONlI ROL PERI ORM· M.JCE of vehicles operated above 4,000 feel an Lnvironmental Protection Agency (HA) approved rnodlfl caucn m<ly be required for scrne models. f lowever, anv kind of rnodlfleauen ls rrot necessarv for the '1984 modilllX750t:.

Sou in 9 Befor;e R id e

Before using thi~ motorcycle check and/or ddjus.t the fulluwing La ensure safe and cumfortablc riding (on dltlons,

Fu el Requ i rament:

Octence Rating

The octane rating of a gasoline is 11 measure of its reslstance to detonation or "knocking", Use prcmlum gasoline with an octane rati ng ctjual to or higher than that shown in the table below.

Octan e Rat i n g M,eth od Minimum
Rating
Antiknock lndex (RON -+ MON) 90
2
Research Octane No. (RON) 95 The Antiknock I ndex i~ an average of the Research Octane No. (RON) and the Motor Octane No. (MON). Tho Antiknock I ndcx is posted on service station pumps in the USA. Research Octane No, is a comrncnlv used term d escri bing a gasol i ne I s nc tan e rat i ng.

"NOTE"

O/f '~knocking" or ~pinfJing~ occurs, try:J difffJrflM brand Df !J:1SD/ine or a highfJr octsne grade.

Brak,e liP edal :

Bra.ke pedal positlon ls an important factor fur sate and confortab le rldlng,

GENERAL aNFORMATION 1-9

Inspection of Brak.e Pedul Position

-Mea5ure the height difference between the tops of the footpcg and the pedal.

*1 f the pedal position i~ nut with in the limit, adjust ~t.

A. I ootpeg

B. Brake Peddl

c. Pedal Posltion

50.5 54.5 mm below top Dr rOeHpet:

Adjustment of Brake Pedal Position

-Loosen the locknut, and tum the push rod or the rear brake master cylinder to adjust the pedal posltlon. -Be sure to ti1lhlcn the locknu t after adjustment. e<::heck operation or the rear brake dna the brake li~ht switch.

A. Push RoJ

MINOTEn

"'If the brske pedal position C.afU10t be arJiuitfJd by rumiflg the push rod, the brake pedal rna.v be deforme,rJ or incorr&ctly innaNM.

'-10 GENERAIL INFORMATiON

Tires:

Fallur to maintain proper inflation pressures or observe payload limits Ior your tlres may adversely affect han dl illl: an d performan ce of you r m 0 torcvc I e and can result in loss of control,

Inspection of Tire Air Pressure

.M oasu rc the ti Fe pressu re when th e tires are col d (th <It 1~. when the motorcycle has not been ridden more than a mille dmil"Dg the past J hours) •

• Tilre pressure is affected by changes in ambient temperature and altitude, and so the tire pressure should be checked and adjusted when your riding involves wide variations in temperature or altitude.

Tiro Air Pressure (US al1d c.a nada)

From 196 kPlI (2.0 kg/cm2, 28 psi)
LIp to 956 N 221 kPa (2,25
{97.S kg, 215 Ib) kg/em2, 32 psi)
load
Rear 956 - 1,170 N
(975 - 180 kg, 245 kPa (2.5
215 - 39710) kgicm~ , 36 psi]
I IOOld Tiro Air Prtl:llSUIUI (Other 'dl.an US and call1adal

Tire Air Pressure
Load Under 21 0 km/h Over 210 km/h
(130 mph) (130 mph)
Front 196 kPa (2.00 221 kPa {2_25
kg/cml, 28 psi} kglcm2, 32 psi)
Up to 956 N 221 kf'.a {2.25
(97,5 kg, 215
Ib) kg/cml, 32 pSI) 284 kPa ('2.90
Rear 956 - ~ ,770 N kg/em:!: j 41 psO
(97,5 180 245 kPa (2.50
kg. 215 - 397 kg/cml, 36 psi)
10) Front Fork:

The air in the from fork must be pressurized correctlv for safe and comfortable ri,ding,

tnspection of Front Fork Air Pressure

.Put the motorcycle on its center stand, and raise the front wheel off the ~ruuml using a jack under the engine.

.lJ~(l the air pressu re gauge (special tool; PIN 52005- 1 003} spaclallv made for air suspcnslons.

-Ch(lt;k and adjust the air pressure when the front fork is cold (room temperature),

aDo nor use a tirB gauge for checking air suspensjon's air pr!'!1iSUrf}. They do not indicate the correct pressur« because 0 f air leaks that occure when the [llJugft is apptied to the vslv».

oLower air pressure is for comttJrtabfe riding, but it should he increased for high speed r;cling. or rldiny on bsa rosat.

olnjoct air httle by little so that air pressure' does not rise Irapidlv. Air pressure exceeding 246 kPa (2.50 kg/cm~. 36 ps] I may dam.aJ;Je- the 0 il seal.

I: WARN~NG •

aBe su rll! to ad~ ~ n the air pressure with in tn e usable range. Pressiire too high or too low CIII1I produce a hazardous ridilllQ condition.

":>Only ailr or nitrogen ga5 can be used. Never inject oxyg:{lll or any kind of explosive gas.

000 not incifl!lfaJte, the front fork,

000 nm: remove, the springs and rely on compressed air only. Corf\E!ct s pr ings must be used in this suspe nl'I: ion system. Use without sprl ngs can I ead to 8 con dition cau~5~ng accident OlJnd injury.

A_ Air Valve

Front Fork Ai r Press!.! re

Standard: 49 kPa. {O.50 kg/crnl, 7.1 psi)

US<lblc range: 3~ - 59 kPa (0.4 0,6 kg,lcm2 I

5.7 8,5 psi)

Anti-Dive Adjustment

-I he anti-dive adjuster 011 each front fork leg has 3 positions ~o that the anti-dive system can be adjustud for different road and loading conditions, The numbers on the adjuster show the setting pcsltlon of the antl-dlve svstem.

.rurn the ami-dive adjuster !.Intil vou fccl a dick so that the desired position number aligns with the unan~ular mark.

-Check to sec t.hat both adjusters arc turned to the 5<I.nlC re I 11. ti ve positi on,

I WARNING'

Olf both antil-din adj,usters are not adjill~ted equally. handling may be impaired and a hazardous conditiol1l may result.

A. Anti-Dive Adjuster 13. Posltlon Nu rnber

C. Triangular Mark

GENERAL INFORMATION 1-11

Anli ·Di\lD Adju stment

Position I 2 :3
Anti-Dive Weak Moderate Strong Rear Shock Absorbers:

The rear shock absorber can he adjusted by changing the air pressure and damplng I orcc 1.0 SULt various riding and loading conditions.

Inspection of Air Pressure

-Put the motorcycle LIP on its center stand to raise the rear whee I off ih e grou n J_

• Rem ove the sld e cover,

-Usc the air pressure gauge (Special tool: PiN 52.005- 1003) specially made for air suspensions,

-Chec k an d ad jm t th e 11 i r p ressu rc wile n the rear sh oc k ab sorb ers ~ re col d (room rem pera ttl re).

ODo not use i:J tire g,{lug@ for chf'!cking air pressure.. They may not indicate the correct air preSS(JrtJ because of air leaks that occur when the gauge is applied to the vatve.

OLo LoVer air pressure is for com farrahls riding for ,m Iil vf'!f!'J{Je·bu ift rider of 68 kg with no secessoriee. Ordinarily, tnfj hf'!:ntier the total load becomes, the higher me air P(f1S$IJI",{}! should be Sf'! r,

otnject air little by !HUle '50 ttlat !lir pnmure does not rise rapidly. Air Ipressu re exc.eedil'l g 4'90 k P,!I (5.0 Iko/em l • 71 psil) may damage the el I 'seal.

I W.AIRNING)

aBe sure to, djutt~lile air preSJuro witJhin tihe ulliBlble range. Pressure too, liIiglil or too low calli psoduee hazardous ridinQI coildit!i,oll.

OOn!y air or nitrog~1I1 gal ean be used. NerW'er inject oxygen or any kind of e)l!piloshre g!&J.

ODD not i nci m~ra,te the rear shock absolrbe r5.

A_ Air Valve

"NOTEft

uTnf'! recommended air pressure i~ '96 kPa (2.00 kg/em ~ , 28 psi] for one rider with no accessories.

A ear Shock A_bl5o~b8r Ai r Pr1'luure

Air Pressu re Setting Lead Road
kPa (kg/cm~ • p~1)
-....;.._ I-
49 (0.5, 7.1) Soft Light Good
$ ~ t t
:294 (3.0, 43) Hard Irlleavy Bad Adjustment of Damping FQfCe

.PuU out or push in, the adjusting stick to (he desired setting position until you feel a click. The numbers on the adjusting stick show the setting position of the damper.

Position 1 Position 2

Position 3

the fullv-pushcd-la positlan.

the flrst cl ick pesiticn on the adjusting stick return way_

t.h c second die k pas lti om on the adiustlng stick return Wily.

th e fu n v-pu ~ I ed-ou t positic Ill.

Position 4

'1·12 GENERAL INFORMATION

It!. Pes i tton N urn bcr

~NOTE'"

o The damping force csn be left 'So fr for aVfHlf1fjf1 riding.

But it should be adjusted harder for high speed riding, or riding with 8 pa$Silnger. If tbe damper Sl1tting feels too soft Or foa stif" adjust it in accordance with the following table:

Damping Iforce

Setting Damping Setting load Read Speed
Position force I
1 Stronger Soft Lr Good Low
'2 1 ! ! ~
3
4 f-'I.ilrd Flellvy Bad High Headlight:

The helldl lght beam b <ldil..l~tablc both hori1omaHy an d vertical ~ y . Head Ii gh t aim i ng mu s t be corrcc tl y adjusted for your safe ricling <1,5 well as encornlng drivers. 111 most areas it is illegal to ride with improperly adjusted headl igh ts.

Horizontal Adjustment

A. AdlusUng Screw for Horizontal Adjustment

Vert.ical Adjustment -Remove th ecowl ing,

-Looserl the lowe r h ead ~ igh 'U b ol L

.open the headllght unit .

• Loosenthe headljght bouslng mounting nuts, and adjust the headl lght ver1!ic:,dly.

"NOTE"

OOn high beam, the brightest point snouta b& 5IigMly beta w horizontal wi rh the motorcyct« on its wheels and the rider seared" Adjust tire headlight to the proper angle accQrding to loco'l regulations.

A. HeadHght Bolt

Vertical Adj!utment

182101

GENERAL INfORMATION 1-13,

Speci 01 Too Is

Hafer to p, 383 of the Base Manual noting the following exception"

Ref. INlo. Part No. D isori pt io n Quantity
1 57001-1003 Throttle Sensor Position~f'1Ig Checker 1
2 5]001·1089 AdBpter 1 CD

1-14 GENIEIRAl INFORMATION

Torque and Locking Agent

The fo ~ low in 9 tsbl ss list t hi e ti ghten i n 9 torque for the m ajor fastern ers req u i r ~ ng use of 11 n onperm an ent ~ a ek ii n 9 a,gen t or I i qui d gasket.

Letters used in the" IRe marks" column mean:

A Apply.a non-permanent locking agent to the threads,

,0,; Apply a liquled gasket to the threads or washers.

S : Tilghten the fas1lenersfoUawing the specified sequence. St: Sta ke th e fast€! n ers to prevent I oosen i ng.

E "gli!'lle IPalrts Threads Quantity Torque Remarks
Dia. [mrn] N-m Ikg-m ft-lb
OF I Sysmm Parts:
En gi ne te m peratu Ire sense r 10 1 13 1.3 9.5 -
Fuel injector mounting bolts 5 8 4.9 0.50 43 in-Ib -
A,cces50ries:
Oi II cool er he se 1f itti",g ~
Bolts 6 4 9.B 1.0 87 in-Ib -
Nuts 6 2 7.8 2.2 69 in-Ib -
lEn Oi ne Mounti I1g=
Engline mounting bolts: 10 4 39 4.0 29 -
Engine rnourrti ng bracket bolts B 8 24 2.4 17.5 -
T,op End:
Breather cover bolt 8 1 5.9 0,.60 52 in-Ib -
Ca mshaft bea r 1 n 9 cap bol IS 6 16 112 1.2 104 in-Ib S
Ca mshaft eha i n tens i one r (;8 p 18 1 25 2.5 18 -
Ca rns haft spree ket b 0 I ts 6 4 15 1,5 11.0 A
Cy llnder head: Bolts a 2 29 3.0 22 S
Nuts 10 12 39 4.0 29 S
Cylinder head cover bolts 6 24 7.8 0.80 69 In-lb -
Sparik plugs 14 4 27 2.8 20 -
Studs.:
Cy~in1der head 6 8 - - - A
Crankcase 10 12 - - - A
Throttle valve holder bolts 6 8 14 1..4- 10.0 A
Left Side:
Engine sprocket nut 20 1 98 10.0 72 -
Alternator cover bolts 6 4 - - - A
Alternator rotor bolt 12 1 125 13.0 94 -
A Iter n a tor stator bo I ts 6 r 3 9.B 1,0 87 in-Ib A
Neutral switch 12 1 15 1.6 11 - ~ContinlJed on next paqe.)

dENERAl IINFORMA.TION 1-15

Englilile Parts Threads, Quantity Torque Hemarks
Dis. (mm) N-m kg-m ft-Ib
Shift pedal retu rn spring pin 8 1 25 2.5 18.0 A
Sta rter d u tch bol ts 8 3 34 3.5 25 -
Secondary shaft nut 18 1 5'9 6JJ 43 -
Rilght Si de;
CI utch hub nut 20 1 130 13.5 98 -
Clutch spring bolts 6 5 8.8 0.90 78 ln-lb -
Oil pressure switch - 1 15 1.5 11.0 -
I Tl rningl rotor mou nting bolt 8 I 1 25 2.5 18.0 -
Bottom Side:
Engine drain plug 12 1 37 3.B 27 -
Oi I filter rnou fIIting bolt 20 1 20 2.0 14.5 -
I Oi I pan bolts 6 17 9.8 1.0 87 in-Ib -
Sub oil pan bolts 6 2 91.8 1.0 87 in-Ib -
Oil pressure relief valve 12 1 115 1.5 11.0 A
T u rboc h arger rnou n ti n 9 be I ts 6 2 - - - -
Oi I pipe banjo bolts 10 2 2fJ 2.0 14.5 -
Oil hose elbow mountinq bolts 2 - - - - -
Shift drum pin plate screw 6 1 - - - A~
~ nterna I Pa rts ~
Crankcase bolts:
6 mm dla. 6 20 9.8 1.0 87 in-lb A
8 mm dia. 8 10 25 2.5 18.0 A, S
Connecting rod big end cap nuts. B 8 36 3.7 27 - Chassis IParts Threads Quantity Torque R.emarks
Dia. (mm) N-m kg-m ft-Ib
t--
Wheels:
F rant axle nut 14 1 59 6.0 43 -
Front axle damp nut 8 1 20 2'.0 14.5 -
Fro nt fend er rnou n ti ng bo Its 8 4 - - - -
Rear ax le nut 16 1 93 9.5 69 -
Tire air valve nuts 8 4 1.5 0 .. 15 13 in-Ib -
Muffler:
Exnaust pipe holder nuts 8 B - - - -
Exhaust manifold moutinq nuts 8 3 20 2.0 14.5 -
Connecting pipe rnountinq bolts 8 2 2fJ 2.0 14.5 -
Muffler body clamp bolts r 8 2 - - - -
R,ear rn QU nti ng bo Its 8 4 - - - - ~Continued on next page. ~

1~16 GENERAL INIFOIRMATIONI

I Chassis Pans Threads, Quantity Torque Remarks
Dis. [mml N-m Ikg·m ft-Ih
Brakes:
Air bleed valves 7 5 7.8 0.80 69' ln-lb -
Brake hose banjo bolts 10 9, 29 3.0 22 -
8 ra ke lever pivot bo I t 6 1 2.9 0.30 26 i n-l b -
Brake lever pivot bolt locknut 6 1 5.9 0.,60 52 in-Ib -
Brake pipe nipples 10 4 23, 2.3 16.5 -
Bri1lJke pedsl holt B 1 - - - I -
Caliper mountlnn bolt I W 6 32 3.3 24
(front1l rid rear) -
Disc mounting bolts 8 18 23 2.3 16 .. 5 -
F rant brake light switch 4 1 - A
- -
mounting screw
Front master cylinder damp bolts 6 2 8.8 0.90 78 ln-lb -
Torque Ilink nuts 10 2 29 3.0 22 -
~
Steering:
Handlebar damp bolts, e. 4 9.8 1.0 87 in-Ib -
Handlebar holder mounting bolts 32 2 74 7.5 54 -
Ha n d le bar wei ght m au nti ng bol ts 8 2 .- - - A
Steering stem head bolt 14 1 42 4.,3 31 -
Clutch lever holder bolt 6 1 - - - -
Suspension and Dlrive Train:
Anti-Dive brake plunger 5 4 4.4 0.45 39 ln-lb -
assembly rnnurrti ng bolts
Anti - Dive va I ve assemb I y 6 4 6.9 0.70. 61 ln-lb
-
mou FI ti ng bo Its
Eccentrnc chain adjuster clamp bolts 1.0 2 32 3.3 24 -
Front fork air valve 8 11 7.8 0.80 ,69 in-lb A
Front fork bottom bolts 8 2 23 2.3 16.5 A,G
Front fork clamp bolts: Upper 8 2 20 2.0 14.5 -
Lower 12 2 39 4.0 29 -
Front fork drain screws 4 2 - - - G
Front fork top pl u gs 32 2' 23 2.3, 16.5 -
Rear sh nck absorber n LJ ts :
Upper 10 1 37 3.8 27 -
Lower 12 1 69 7.0 51 -
Rear shock absorber aij r valve B 1 7.8 0.80 69 ln-Ib A
Rear shock absorber air hose B 1 12 1.2 104 ln-lb A
male pipe
Rear sp rocket nun W 6 39 4.0 29 - ~Continued on next page.)

GENERAL INFORMATION 1·17

Chassis Pa rts Threads Ouan1ilty Torque Remarks
f--- -
Dia. (mm) N-m kg-m fHb
0- f- -
Swi ng arm pivot shaft nut 16 1 '98 10.0 rz -
Un i-trak 11 nks:
Rocker arm pivot shaft nut 12 1 69 7.0 51 -
Tie-rod nuts: Upper 10 2 37 3.B 2.7 -
Lower 12 11 69 7.0 511 -
E~ectri oall Eq u i pmenu.:
Front brake Ilight switch 4 1 - - - A
mounting screw I
Starts r m oto rend cove r screws 6 2' 5.4 0.55 48 ln-lb -
Starter motor terrnl nail nut 6 1 11 1.1 95 in-lb -
Tum signal mounting nuts 10 4 13 1.3 1113 in-Ib -
Side stand switch rnounti ng screws. 5 2. - - - A The table below, relatlnq tightening torque to thread d iameter, II uSItS the basic torque for the bolts and nuts used on K~wasaki Motorcycles, However r the actual torque that is necessa ry may vary among bolts and nuts with the same thread dlarneter, TIghtening torque listed in the preceding tables varies to a greater or lesser extent from what IS given in the table below. Refer to this table for only the bolts and nuts not included in the tables on the previous pages. All of the values are for usa with dry 1 solvent cleaned threads.

Generall Fasteners:

Threads dla, ~mm) Torque
rN-m kg-m ft-lb
5 3.4 - 4.'9 0.35 - 0.50 30 - 43 in-lb
6 5.'9 -7.8 0.60 - 0.80 52 - 69 in-Ib
8 ~4 - 19 1.4 - 1.9 10.0 - 13.5
10 25 - 39 2.6, -3.5 19.0 - 2'5
12. 44 - 61 4.5 - 6,.2 33 -- 45
14 73 -98 7,.4 -10.0 54 -72
16 115 - 155 11.5 - 116.0 83- 115
18 165 - 225 11.0 - 23 125 - 165
20 225 - 325 23 -33 1165- - 240 1-18 GENEIRAL INIFORMATmN

Servi ce Data

The following tables, I ist the service data which show criteria for servicing 1984· model. Although rei i ab Ie rneasu ~e rn en 15 can on Iy be obta i ned by us i n 9 t hi e p roper i nstru rnents and fo II OWl n 9 the procedures explained in this manual, detail has not been explainec in th is section. See each section for a delaij led accou 1"11 t.

NNOTE"

o "'StandardsH : Show dimensions or performances which brand-new parts or systems have.

o "Service Limits" : Indicate Ute usable limits. If the messuremen t show: excessive wear or deterioreted oertormsce. replace the d8maged parts.

Engine!

Vl:!I'IIf!' stern bond Val'll!'! stem diameter

Valve !lU id(i ins i de eli ame te r Va'ye/val~e guide clearance

(wobble method)

Valve ~eating area outside diameter:

Inlet Exhaust

Item

Standard

SerYice Limit

Throttle grip plav Idle sp~ed

Engine vacuum svnehronizetlon

Call1'lshafts. Chai~:

Cam height

Camsh att bl1ar i IlIg 011 ole aJr <l nee Ca mshaft j ou rna I d is me tP-w Camshaft bearing inside diameter Csmshollft ru nout

Cam chain 20-link lenqth

2-Jmm

1,050 ±50 r/rnln (rpm), <W 1,200 50 r/min (rpm I Less than ',L7 kPa (2 cmFlg)

difference between any two cylinders

35_145 - 35.854 mrn 0.100 - 0.141 mm 21.94 - 2~ .95 rnrn 22.06'0 - 22.081 mm

127_00 - 127,36 mm

Cylinder Head, Vahras:

Valvc clearance:

Inlet Exhaust

Cylinder head warp Combustion chamber volume

V B I 'II'!l h ead th lckness: ~ IIlI et Exhaust

7B5 - 980 kPa (8.0 - 100.0 k9(cm~, 114 - 142 psi), and less than 98 kPl:! (1 kg/cm~, 14 psi) eli ffe renee IJ.e Meen any two cvli nders

0.13 - 00,23 mrn 0.08 - 00.18 mill

2'4_6 ±OA mL o,a - 1,2 mm (l,S - 1,2 rnm

18.95 -16.97 mm 7,000 - 7.015 m m

0.08 - 0.16 rnrn

33 mm 29mm

35,65 mm 0_23 mm ·:g1,91 rnrn 22.14 mm 0_1 mm TIIR 12'8.9 nun

6:l0 - 980 kPa (6,3 10.0 kg/cm2• 90 - 142 psi], or 98 k.PB f1 kg~cm2. ~ 4 ps.i) difference hetween .my two cylinoars

0_05 mm

0_5 mm 0.7 mm

0,05 mrn TI R 6_94 mm 7_08 mm

0.33 mm

157 158 158 158 158 1509

SOB Page 291 2-7 2·7

169

2·4 2-4 160 150 161 161 162' 162 Hl3

Hl3

279 279

~Con'tinued 011 next !page_)

GENIERA,l INFORMATION 1-19

Enrgine: (Cont.)

See Page 279 164 164

Servioe Liniit

Standard

Item

f--

V ahJe seatl n g a rea wi dt h

Valve installed height:

0,5 - 1,0 mm 36.58 - 37.4B mm 37.11 38,03 rnm 37.25 mm

41,86 mm

lnlat Exhaust tnlet Exh~mt

35,3 mm 40,3 mm

Cyli n.der Block, P i$'tons:

Cylinder inside rliarneter

66.1 0 mm, or 0.05 mm difference between any two measurements

169

86,005 - 66.017 rnm, and less than 0.01 mm ditterenc@ between any two measurements

65 .. 951 - 65.966 mm 0.040 - 0.087 mm

1 .02 - 1 _04 rn rn

121 - 1.23 mm

2.50 - 2.52 mm 0.970 - 0_990 mm 1.170 - 1.190 mrn 0.03 - 0,07 mm

0_02 - 0,06 rnrn

'0.20 - 0.40 mm (installed in sta nd ard cv I i nde r bore)

65J!1 rnm 170
--- no
1.12 mm 171
1_3~ '01m 171
2.60mm 1171
O.90mm 171
~_10 mm 171
0.17 mm 171
O,Ui mm 171
O.7mm 171
O,2/1Cm mm 172
0.2/100 mm 173
0.10 mm 173
34_97 rnm 173 Piston dtarncter PiS'ton/~ylimjer clearance Piston ring groO'~~ widtl1:

Top Second Oil Top Second Piston ring/groove clearance: Top SCl'cond Piston ring end gap (top and secondl

Piston ri ngthickness:

~-

era nks haft, Co Ilrn!lcti I'Ig Rods:

Co nnecti n [) rod ber){j C onnecti n 9 rod tw i st

Connect i ny rod beari n 9 insert! c ran k pin c I narance Crankpi.n diameter:

0.036 - 0.066 mm 34,984 - 35.D()0 mm 34.984 - 34.994 mm 34_9915 - 35.000 mm

32,000 - 38.016 mrn

None 3.8.000 - 38.00B mm

o 38.009 38,018 mm

None

o

Connecti i"1g1 rod big nnd imide diameter:

174

Connecting rod big and baar inq

insert thickness: Brown

Slack

174 174 114

174,351

1.475 -1.400 mm 1 .480 - 1_485 mill

I Green 1.485 - 1.490 mm

~ L_ I

Connect) 119 rod bearing insert selection:

Marking for cOli-me! big (lnd bore

---I.

o

None

BIBCk I

PIN; 92028-1204

Brown

PIN:. 92028-1205

Marking for crankpin diameter

o

Green

PIN: 92028-1203

Black

PiN: 92028" 1204

None

1·20 GENERAL INFORMATION

Engine: (Cant.)

lte'm Standard Service Limit See Pago
GonnectinQ rod big '~Ild side clearance 0.13 - 0,33 mm 0,50 mm 174
C rain ks h adi't runou t --- 0.05 mm TIA 174
Or/llnkdmh rnaln bearinglnr.ert} OJl20- 0.044 mm 0.08 mrn
jou m ai dij~,ra n CEI 'r75
Crankshaft main [ournal diameter: 35.984 - 36.000 m m 35.96 mm 175
None 35.984 - 35:992 rnrn
0 35.993 - 36,000 mm
Crankshaft main bearing bore 39JlOO - 39,016 mill 175
inside diameter: ---
0 39.000 - 39.008 m m
None 39,008 - 39.016 mm
Crankshaft main bearing
i nsart tihick:nes~: Brown 1.490 - 1.494 mm --- 176
Black: 1_494 - 1,498 mm -- - 176
Blue '_498 ~ 1,502 mm --- 176
Crankshaft main bearing insert selection: 176
I
Marking for COon-rod big end bore
0 None
1 Brown Blsck.
Mark.ing for P/N: 92028-11.02 PIN,: 92028·1101
crankshaft
journal dla. None Black ISlue
PIN: 92028,·1101 PIN: 92028-1100

Crankshaft side clearance [),05 - 0.15 rnrn O.35mm n6
Pri mary R oduction SV3tem:
Si£ccmdary gear/clutCh hous.ing O-0,10mm 0,.14 mrn 180
glila r b OIC k lash
Clutch:
Clutch lever play 2-Jmm --- 17,346
Flrictioi'l plate thickness :2.80 - 3.10 rnrn 2,8mm 1713
Friction and steel plate warp --- 0,3mm 179
Clutth spring Free length :35.0mm 33,9 mm
Transmiu.ion:
Gear b ock.las h o ~ 0.1 7 mm 0.25 mm HM
Shift 'fork: ear thickness 4.9 - 5_0 mm 4.8 mm 184
Go ar sh i ft fork groove wid th 5,05 - 5.15 rnrn 5.25mm 184
Shift fork guide pin diameter:
1 st, 2nd -:3 rd gear sh i h fork ],g - 8 .. 0 mm 7.8 mm '1!J5
4th - 5th gear shiH fork: ',985 - 8.000 mm 7_9 mm 185
Shift drum QH)()Ve width 8_05 - 8.20 mm 8.3 rnrn 185
Engine LubrieatiDn Systom:
R liC!f valve openin~ pressure 4.4 - 6.0 kg/cm2 lBB
nn pressure @4,OOO r/rnln ~ rprn], 196 - 245 kPa ~2.0 - 2.5 kg/t:ml ,28 - 36 psi) 186
gOlle (1940 F) oil temp. {Continued on next p~e_)

GEt.JERAL INFORMATION 1·21

'engine: (CoOnt.)

I

Item

Standard

Service U m it

Engine oil:

Grarle Viscosity Amount LI}VAI

51;; class SAE lOW40, 10W50, 20W40, Of 20W5(1 3.5 L Be tween u ppe rand i owe r Ie vels

..... -------------------------~--~~

18 18 18 18

Tu rboch arge r:

AI::1:uaw r valve ClIP eni n g prsssurn @O.5 mm Actuator rod stroke

49 - SB kPIl {O.50 - 0,70 kg/ern ~ , 7.1 ~ 10.00 psi}

3·7

Chassis:

Item

StEindard

Sewvictl, Limi t

Sell P.agB

Whools:

While I b a~llnCi! T] re pay I cad

I rnhslence of less than 0:1 N {lOg) 1,770 N (180 kg)

'-

27,348 2'-9

2-9

Standard tires:

Front Rl}(Ir

'_ ---1----------1

11OJ90 V 18 1300/80 V 18

Michel in A48 Michi,91 in M48

TubC!iess Tubeless

Aiw pressure:

2-9

US a I'Id Canada

196 kPa (2_0 kg/cm~ , 28 psi ~

~---+---------------

Up to 956 N f97,5 kg, 215 [b] I'lad 221 kPa t2.25 kg/cm2 ,3:2 psi ~

Front

956 -11,770 N (97,5 - 180 kgl, 2~ 5 - 397' I b) load

245 kPlI {2.'5 kg!cfl'l~ , 36 psi ~

Oth.!lf tha n US and Ca 1'I.8Jda

Tire Air Pressure

------

Load

U nds r 2 io krn/h ~130 mph)

Over 210 krn/h (130 mph)

221 kPa

(2,25 kg/()m~ r 32 p~i)

100 kPa

(2_00 k.'i!!cm~ • ~B psi I

22l kP ..

(2.2'5 kgl/Cm2 , 32 psl ~

245 kPa

~2.50 kg/em1 , 36 psl ~

Up to 966 N t97.5 kq, 215 Ib} 9'56 - 1,770 N

(97.5- 180 kg, 215 - 397 Ib)

284 kPa

~2,90 kg/cml ,41 p~i)

Rear

Ti m tread de pt h :

Front Rear

4.5 mm 7.0mm

1 mm

2 mm, UnrJijr 130 km/h 3 rnrn, Over 130 krn/h 0.5 frwn T~ ft

O.Smm T~R

2-9 HJ3 193 193 193

Rim runout:

Axial R<lclja~

tCOrltinmld on next pagB_)

'·22 GENERAL INIFORMATiON

Chassis: (Cont.)

ltam Standard Service Ln m it 80e Page
Drive T ta in:
Ddv(! chain slack 35 -40mm 35 -45mm 347
D rl v~ cha i r'I 20-1 ink 11m gth 381.0 - 382.0 mm 389 mm 198
Front sprocket diameter 79.01 - 79.21 mm 78.3 mm 199
Rear sprocket diameter 213,1,29 - 267.79 mm 267,,0 rnm 199
Rea F' ~ prockat wa rp --- O.5mm TiFt 199
Di se B'rii k.e:
Bralkij flu id grade DOTI --- 205
Pad linin!;! thickness: Front 4,85 mm 1 mm 203
Rear 5.00mm , mm 203
Disc warp --- 0.3 mm TIR 205
Dis,c thickness: Front 4.8 - 5.1 mm 4,5 mm 205
Rear 6.8 - 7.1 mm e.Omm 205
Bralke pedal position 50.15 - 54.5 mm 293
6rak~ I igM switch operation: Front Non-a d] u st a III e 2'5
Rear On after 01 bout 15 m m pea <II travel 25
Front Fork:
Ai r Pr€SSU re 39 - 59 kPa (0.4 - (1,6 ky/cml ,5,7 - 8.6 psi) 292
011 vijs()osity SAlE10W
Oil amount 271 ±4 mL 212
Oil h~".,el 11 78, ± 2' mm {Camp ressed) 212
R !lor Shock Abklrbllr:
Ai r pressure 49 - 294 kPa {O.5 - 3.0 k[J/cml • 7,1 - 43 psi) 346 E lactr i cal cqu ip ment:

hem Standard fie tvi ce li mit SEl9 Pagij
Charg in~ System: !
Regl..ll;.ltor/rectifier output voltagll Battery voltage - 15 V 223
Alte rn ator outp u t About 50 V 223
@4,OOO r/milll (rpm), no load
Stator coil resistance 0.45 - 0.55 n 223
Igniti on System:
Spark P~u9: E I ectmd€l gap 0.5 - 0.6 mm 12
Type NGK BR9EV 1:2
Ignition Coil:
Ardnlll dis tanca (3 -ne ed II e m etho d) 7 rnrn or more 230
Primary wi nding resistance 1.8 - HI n 2'30
Secondary winding resistance 10 - '16, k.Q 230
Pick up co i I resists nee 380 - 560 [,l 373
Electrlic Starte r Syztllm:
Starter motor carbon bru~1h length 12,0 - 12.5 mm Bmm 234
F'uel Gauge:
f u e I I eve! sensn r res i stance: Full 1-5.0. 327
Empty 103, - 117 n 327
I Bllttllry:
E I ectrolvta I !)\I'e~ sense r res r stance 600 - 750 n 381 @: U.S. Mode~

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A,'~~ L.. n / SCHEDULED IMAIINTENANCE 2-'

Schedu ed Maintenance

Table of Contents

Periodic Maintenance Ch1l'lrt ......••.••••••...................... 2-2 IlESCRUJTIO:.'1 01-' EACH O["tERATION

Engine Oi I r Ol I Filter •......................................• 2-3

Spark !PIL.lgs ••••••••• , •.........................•..••••••• 2-3

Valve C~earance , .......•...... 2-4

Air Cleaner + •••••• , • + •••••••••••••• 2-6

Th rattle Grip ..........•................ ,.. Base Manual 291

Id Ie Speed ...•.•.•.•..•.•..•............................. 2-1

Engine Vacu urn SYf1chron izatlon .................•.••.•.•.••• 2·7 Clutch ...................................• Base Manual 346

Drive Chaln 2-9

Brakes , .. ,. Base Manual 366

Bra k e Li ght Swij tches . . • . . . . . . • . . . • . .. . . . . . . .. Sa se Manu ilIl :2 5

Steeri n g .....•.....••.••..••••............. Base Manu al 293

Front Fork 2-9

Wheels 2-9

Swin g Arm + •• + ••••• , • • • • • • • • • • • • • • • •• Base Manual 3,56

Unl-Trak .•............ + Base Manual 356

Fu,ell System , . + ••••••••• 2·10

Gen e ra I lu brlcstl 0 11 ••• • • • •• , • • • • • • • • • • • • • • • • • Base Man u a I, 381

Bolt and Nut Tigiltening 2·10

Evaporative Emission Control System (Californi,1j Vehicle) , 2-11

2-2 SCHEDULED MlAINITENANCE

IPer iod le M a i nten ance C hart

Th esched u 1'00 rna i n tena nee must be don e ina ceo rd snce wi th t his c ha rt to keep th e mota revel e in good running cond ition, The initial rnaintenenee is vitally important and must not bo neglected.

~ whichever.t *ODQMETER READiNG

FREQUENCY comes first ... If; . e (; e i
---~ *$,* *.* *" *
OPERATION ---......___-----~ ~S & § ~ § ~ §.
----- ............ Everv Page
Spark plug - clean • _ _ • • • • 2-3
Spark plug - check t • • _'. • • • • 2~
Vallve cles ranee =check t • _ ._ • • • • 2-4
Ai r cleaner element - clean • • • 2-6
Ai r cleaner element - replace 5 cleaning'S .- r-
• • -
Th rattle grip play - check t _ ._ . _ • • • _ 291
Idlle speed - check t • • • • • _ • 2-7
Engine vacuum svnchronization - check t _ • • • • • • 2~7
--CYlinder head bolt tightness - check t - 35
• • • _
Cylinder head nut tightness - check + - 35
_ • _ _
IEvaporative emission control svstem • • • •• • • • 2-11
- check t (for@> rn od el) -
Engine oil - change vear • • • • • • ._ 2-3
Oil filter - replace ._ • • • 2-3
Oi I screen - clean • • • • 2-3
Fuel 'filter - replace • _ • 2-110
Low'pressure fuel nose - replace 4 years 2-'0
Hlqh-pressurs fuel hose - replace 2 years 2A10
Clutch - adjust .. • _ • • • _. 346
Drive chai 11 wear - check + ~ - 198
• _ • • • _
~ve chal n - lubricate 300 krn ~98
Drive chal n slack - check t 800km 347
Brake I ini lily wear - check t _ _ • • _ _ 203
8 rake fluid level - check t month _ _ _ • • i • • 207
Brake fluid - change year • • _ 206
Brake hose and pipe - replace 4 years 208
Anti-dive brake plunger assembly - replace 2 years 3167
Master cvl inder c_!:!p and dust seal - replace 2 years 201
Caliper piston seal and dust seal - replace 2 years 204
Brake light 'Switch - check t _ _ • • • • .. 25
Steering - check t _ • • • • • • 293
Steering stem bearing - lubricate ----:- 318
2yea~_ •
Front fork: oil - change • • • 2·9
Tire wear - check t • - 2-9 I
• • • • .. •
Wheel bearing - lu bricate 2 years • Hn
Speedometer gear - lubricate 2 years • 11 ~l'7 I
I SWing arm pivot, unl-trak linkage - lubricate • • • 368
General lu brication - perform • • • • .. • 381
Nut, bolt, and fastener lightness - check t • • ,_ • 2·10 * : For hbgher odometer raadi nqs, repeat atthe frequency interval establ ished here. t : Rep~ace, add, adjust, clean, or torque if necessarv.

~: Californ~a Vehicle

••••••• r •• i •• i rii;5111 II! 1111".11 •••••••••• ., j i j iI. j II ' _ ••• .,rii 111i1i.111!I.~··

Engine Oil QillFUtor

1" •••••••••••• i iii i II Ii .. II!II •• ~ •••••••••• , •• j II. III 1" I!!!'-.! Ill •••• Ill .... Iii Ii II. II" II 1'''

Oil Vii vf;il tnspecti on

Refer to p, 18 of th e Base Manual.

Oil and/or Oil Filter Change, Oil Screen Cleaning -Warm up the engine thoroughly, and then stop the engine,

.Place an oil pan beneath the engine. .Remove the engine drain plug,

A. Drain I?lu~

e, Oil Filter Mounting Bolt

c. B.anjo Bo'lt

-With the motorcycle perpendicular to the ground, let the oil completelv drain,

.U" the oil fHter is to be changed and the oil screen cleaned, remove the oil I1lter mounitng bolt and drop out the oH filter, and remove the banjo bolt and the oil screen.

.ReplaGe the oLI filter dement with a new one.

A, O-Ring~

S, Element Fence

C. Spring

D. Flat W<lsher

E. Grommet

F. Mounting Bolt G, Filter Cover

H, Element

I,. OLI Screen

SCHEDULED MAINTENANCE 2~

UNOTE'"

oCheck for O·ring d8rrMge. If necessary, f11place .',em with new ones.

OWhen inSfalling rhe oil filfer, mek» sure me O-rings <Ire in place.

.App'ly a little engine oil to the O-fing on thtl filter mounting bolt, fit the filter cover and clement fence on the bolt, and install the spring and flat washer,

-Apply a little engine oil to the grommets on both sides of the element, and turn the filter to work (he clement into place, Be careful that the dement grommets do not ~Iip out of place,

_I tl~tall the oil fil ter, tijghtelling i'ts mounting hoH to the specified torque.

-Clean th e oil screen ina ba th of a high nash -poi n t selvent,

.~ rrstall the oil screen and tigiltenthe banjo bolt with gaskets to the sp eclfled torque,

-After the oil has completely drained. OiLIt,. install the engine drain plug with its gasket, Proper torque for it is sh own i,n th e table.

oReplace the d8fTl8ged g~Sk8t wirh new OflOS,

.F 111 the engi fie up 'W th c upper leve I with a good quality motor oll specified in the table.

-The oil cooler is equipped in U1C cngi ne lu brication

system, Su the i1ddi tional 0.2 lill!r~ [)f oit will be

rEqu ired r or oil cooler and hoses.

.check the ol] level,

Tigh1ieninll Torque

ElI1gine Drail'll Plug: 29 N-m (3.0 kg-m, 22 ft-Ih]

Oil Filter Moulltirng Bolt and Banjo Bolt:

20 N-m (2.0 kg-rn, 14_5 ft-lb)

EnllillrH! Oim

Grade: S E class

Vi~co~ity: SAE 1 OW4,O, "I OWSO, 20W40, or 20WSCI Capacltv: 3.0 L (3.2 US qt]

[when filter is not removed] 3.5 L (3.7 US qt]

[ wh en fi I tcr ls removed I

Oil Cooler and Hose: 0.2 l (0.21 US qt)

...... , ••••••••• iii i lillII'll! I !Ii jillill .. 111'- I.-III,III! I~.'" •• ' ••••••• ,11

Spark Plugs

i it iI- IIII I'II!!! i II ~III. I! •••••••••••• Illfllll 1'1 I!! •••• , •• i iIIl III ill I" e e ••••• i

Refer to p _ 12 of the Base Manu ill no In rng the following exception,

2-4 SCHEOU LIED MAINTENANCE

Cleaning and Gapping

Spark Plugs

I NGK BR9EV

Plug Gap

[ 0.5 - 0.6 !lim J

TigMel'lillig Torque

[ 27 N-m (2.8 kg-m, 20 ft-Ib)

" 111 i II!I'I' III iI!Ii iil ~."II!l1 loli II iii "' .

Valve CI!earance

11.li.ii1····.···'· .. ·'I"IlIIllllliii1li • .,.i '1"'''1111 li.i .

Inspection

-Ilf the engine is hot, wait until the engine cools. Valve clearance must be checked when the engine is cold (room temperature),

-Rem Ove th e ~y I i ndc r head cover and pic ku p coi I GOVer.

-Check the valve clearance when pistons ,ue at TDe.

C{hin~ oj If mm wrench on the tlming rotor, turn the crankshaft until d TDe mdl'" on the liming rotor is al igr1l:d with the lim ing mar k en the crankcase.

Moan.! ringl P(Hi1;ion"

TDe of the *1 and #4 pistons

Ex h aust #1 and Jt1 val ve c I ea ranee s or Ex h au st #3'arll(:i #4 va I ~ eel earances TDe of the #2 and #3 piston ~

Inlet #"1 and #2 valve clearances or Inlet #3 and #4 valve clearances

It: Measure the .... alve clearance of the valves of which Cam lobe is pointing away rom the valve lifter.

UNOTE'"

aChed the lIB'l"e cteerenc« with the proper me rhad in the text. Checking the clearance af any other Cam (JoliitlGn may result in improper varve cleal'am::e.

A. IlJC M..rk for ::¢"1 and #4 Prstons B. Crankcase Timing Mdrk

*If the valve clearance is incorrect, adiust it

Valve NIUmberi1lflg Method Iviewed from top)

YLe1ft

Ri~ht ¢

Valve Cleilranc@

1. Cam

2.. Valve lifter 3. Shim

SCH EDULED MAINTENANCE 2·5

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2-6 SCHIEDULED MAI,NT'ENANCE

Valve Olearance

Standard: Inlet

Exhaust

0.13 - 0.23 mm 0.08 - 0.18 mm

Adiustment

.To change the valve clearance, remove the camshafts and the val ... c spring retainer with a. shim of different thicknc5~ .

• To select a new snlm which brings valve clearance the specifled limit; refer to the Valve Clearance Ad[ustrnent Chart.

e5h im th lc kness IS p ri n ted on th e sh i m su rface, When 1 n sta II i n g, face the m illr kc d sl d (i toward the sprl rig retainer. Thls avoids rue marking from being polished off by the action o·f the valve ~~fter_

• 1 n stall th e cam sh a fts. B e ~'I..U re to Ume the cam si1aft~ properly.

.R,cmeasure the valve clearance that was adjusted. Readjust if necessary.

oDo not put ·shi m stock IIInde'r ·the :Ihim. Tbts may ~use thew 1m to pop Olilt 111 hlligh Irp m, causi no extensi'le 11II1gine damage.

000, not grind t'he shim. Thiil may cause it to firactulre, causingl extiinll\06 engine damage.

ODD not grind thll valvlI Item end to repair it or to pOllmiltBdditliollilal valve clearance. If the .. alve end ~s 'ground, tho lhiim may contact the Ipring retainer 8IlId/or split ~pllr~ duringl operation, allowlilngl tbe keepor to 10OMIIl. Consequ,ently. the .. :allle may d rn p into tlI1e ongilne, ca1l! sin iii se~iou5 darna ge.

Air Cleaner

A clogged air cleaner restricts the engine's air intake, in,creaslng fuel consumption, reducing engine power, and caLIs.! ng spark IP ~ug foull i ng.

The air cleaner element. must be cleaned and replaced in accordance with the Periodic. Maintcnarlcc Chart. In dusty areas, the element should be cleaned more Irequendy than the recommended Interval. After riding through rain or on muddy reads, the clement should be cleaned lrrtmedlatcly .. The element ~hould be replaced If it 1~ damaged.

tnsoection and Cleaning E le mel'lit R ilml)'val

• Remove th e A~ I en bol t on th e a i r dean or cap 0 n the

left side of th e eng'l ne, a 11 d remove the air c I caner cap. .Remove the bolt and pull ou t [he element

.Pull the clement out of tile wire frame .

.Push 11 clean, lint-free towel into the air cleaner hou~~ng 1.0 keep dirt or other foreign rnaterial from entering .

• 1 nspect 'the element material and sponge gasket for damage. If any part of the: clement is damaged, the dement must be replaced,

WARNING.

01 f dirt or dust is allowed to pass tIh rough into tho throtth;1 nlv(IS. they may become stUCk, possibly CIlilcSlnQI an accidelilt.

Olf dirt gEnS I1:tlrough into the engine, e'!(cessive engilrne wear ai1ld paul Diy e I\\QIlII.e damag:e will OOCIIlf.

"NOTE"

oEl€!mtJM installation is perforrned in the reverse oreler of removal.

Olf the gasket is d8maged, rep/aCt} it with a new one,

A. Air C lea.ner Cap

B. Allen Bolt

A. Bolt

B. Element

IEle ment CI eanlilng

ICle.anlhe element in a bath of a high flash-point solvent.

-Dry th eel em en l with com pressed air or sq u eezc it, .After cleaning, saturate the element with SE class SAE 30 motor oil, SqUCC7(l out the excess, than wrap it In d clean rag and SqUCC7C it as dryas possible. Be careful not to tear the element,

OClean the ele mont in a wall lIemil1l1ed area. and take c:arll that tho~e ure no ~ parks, or 'flame anywlhe-re nea f the wo rk~ng area; th is i nellA des any ,appi iane!! wIth a pil at Ii ght. Do not use QiIIso'ii ne or a low fla!Sh -polnt solvent to clean tlh II olemllnt. A fi 1"(1 or e)llPlosi on eeu Id result.

A. Wire Frame

'8. Air Cleaner Element

IdEe Speed

iospection

-01 horou gh I Y warm LA p the engi ne.

-With the engine idling, tu rn the handlebar to both sides,

SCH EDU LIED MAINTENANCE 2,·7

*If handlebar movement changes the idle speed; the throttle cable may be improperly adjusted or incorrectly routed, or it may be damaged, Be sure to correct any of these conditions before riding,

COpe ration with improperly adjul'ted! inco rreC1ly trCl'uted, Of .a damaged eabl e COY Id result in iU] IU nsafe rid ingl condition.

-Check that the idle speed is within the specified rang . *If the idle speed is ou t 0 the specified range, adju~t it.

US:

Other th an US:

1,150 - 11 ~250 r/mifl lrprn) 1,000 - ]',100 rJr:nun (rpm)

Adjustment

-Turn the. idle adjusting screw to adiust the idle speed.

A_ Idle Adjusting Screw

.Opr-I} cll1d ~I()~[' (he thrut tlc J lew times to make vurc that Llll' idle speed i~ within the specified range. Ruadiust ii neccssarv,

............................ " ,. I! •••••••••••••••••• , !!!!.

Engine Vacuum Syndlroniz.ati'on

Throttle Valve Link Mochanism I nspactiom

.ch ec k the til FOUl e valve an d the fa~ t ld I e I in k mechanism for smooth operation,

-Irlf there is amy binding or other unusual operation in the llnk mectranlsrn, repair it or replace the throttle valve,

OJf anyone ot thetnrottie valves is replacBd, synchronize the valve as {JxpfainM below. If the wholfJ rlmm:le ltalvB ,iijliSBmbly is replaced. syn.chronj~8'ti()'n is riot required,

2-8 SCH'EDULED MAIINTIENANCE

Synchronization:

11 one ot the throttle valves i~ replaced, or i I combustiun varies lr orn cylinder La cylinder, svnchronizc the 1 hrn ule valves.

"NOTE"

OTheS(l procedUre!1lfffi explained on the assumption thar the intake and exhausr .rv.rrems of the engin~ a~ in good condition,

Cheekiling engine v,a~lium:

.Warm up the engine thoroughly .

• Remove the fuel tank, and put lt on the work bench near the rnotorcvcle on the same level as the original position,

.Pu ll off the two vacuum hoses from the #1 and #4 throttle valves, and two rubber caps from the #2 and #3 valves,· and connect <l vacuum gaug,c to the fittings on th e ;,0301 VeS.

A. Vacuum Hoses

B. Caps

- Usc thc balan cc ad lu ncr hp ecla I tool) to tu rn the locknut and balance adiustltlg screw.

Ad~ustilllg Screw for SYl1lch~onizlltion

A. Balance AditJ~ter: 57001-351

.Using suitable hoses .• connect U1C Fuel tap to the fuel

11i I fer, and th e chec k vaive to th e p ressu re regu: I a tor. -Start the englne, and let it idle,

-Adjust the idle speed .

• Note the gauge readings,

Engine Vacuum

Difference between any two cylinders

l.ess than 2 en} Hg

.. I f th e gau ges sh ow more vacu u m d i IT erence thans p ecified in the table, synchronize the valves,

OAfter checking or synchronizing thl} valves, and installing the fuel tank, adjust the idle speed.

Synch ron,izlilnglhe til rattle val Ve5: .Stop the engine.

.To. Change the vacuum, lumen the locknut, and turn th e b alan ce ad iu st i ng screw,

1. Left A.dju~ting Screw:

Turn this screw clockwlso to lowe r #1 cvlinder vac u 1I rn,

3_ Center Adju~ling Screw:

Tum ih i~ screw clockwise to lower #'1 and #2 cyHnder vacu urn ~i m u I taneeus I v,

2. Right Ad,jmling Screw:

"fum ih is screw clockwise to lower #4 cylinder vacuum,

oLoosen the locknut with tIle throttle valves openea: oFim synchronize the left two or right tWO cylinders by means of the adjusting screw \' or "2 between #, find #2 cylinders, or #J and #4 cylinders_ Then synchronize the left two c'Ilin (leers and the righ r t LoVQ cYlinders uslag the €."enter 8djusting screw·3. Adjust the idle speed 85 nec&:ls8ry.

-Tighten the locknuts,

.Open and close the throttle a few limes [0 make sure that the throttle ... alves are synchronized, Readjust jf necessary,

.Install all parts previously removed, and adjust the idle spe-ed.

Drive Chain

Wheel Alignment Adjustment!

Refer to p, 347 of the RilSC Manual noting the fo I ~owill& excep t i o n.

Tighwnil1l.9 Torque

Adjuster Clamp Bolls: 32 N-m {33 kg-rn, 24 rHo} Axle Nut: 93 N-m {9.5 kg-m, 69 ft-lb]

Wear Inspection:

Refer to pr, 197 and 198 or the Base Manual.

Lu brl cation!

Refer to p, '199 of the Base Manual.

Flront Fork

Oil Changlt

Refer to p. 366 of the Base Manual noting ti'le following exception.

Fork Oil

Capacity
Oil Type AtOil After Dlsas- Level
Change semblv (Dry)
SAE Approx, 271 ±4 mL 176 ±2 rnL I
10W20 230mL '" Distance from the top of the inner tube, measured with the fork tube fLllly compressed and with! the spr I rig removed,

SCHIEDUlED M"MNTENIANCE 2-9

Wheels

Tires~

Tire Wear, Damage

!Refer to p, 193 of the Base Miilnual noting the following exception.

Ti re IPayload

II 1,770 N (180 kR)

Sta III-dilrd n roe

I ront

Rear

110/90 V 18 Michelin A48 I ubcless

130/80 V 18 Michelin M48 Tubeless

Ti re Ai r Pressure (US and Canada,)

245 kPa (2.5 k&fcm2, 36 ~si)

1% kPa (2.0 kg/cm:l: • 28 p~i) 11----+---;-;--

Up to 956 N

(97.5 kg, 215 Ib} IOdJd

ronr

221 IkPa (2.25 kg/cm2• 32 p$i)

956 - 1,770 N (97.5 - '180 kg" 2'15 397 Ib) load

Tire Air Pl'eSWf,e (Other 1ilnan liS IUU.:I Canada)

l.cad

Tire Air Pressure

I-----~.----------

Under 210 kmJh Over 21 [) kmfh,

(130 mph) (130 mph)

196 IkPa (2.00 221 kPot (:,1:.25

kg/cm1, 28 p~i) kgjcm2, 32 psi)

Front

Up to 956 N 221 kPa (2,25

(97.5 kg, 2-15 k"'cm2, 32 p~'I)

lb] ~ , 284 kP" (2.90

1-.-----f-------1 kgfcm~ , 41 psi) 956 -1.770N

{97.5 180 245 kPa (2.50

kg, 215 - 397 kgJcm2, 36 p~il Ib}

Tire Tread Dep;t!h

front:

Standard Service Limit

Rear:

Standard Service Limit

4,5 rom 1 mm

7.0mm

:2 mm (Up to ~ 30 kmJh) 3 mm (Over 130 km/h)

2·10 SCHEDULED MAINTIENANCE

Wheel Baarings:

Lubrication

Refer to 197 of the BaSIc Manual.

Fuel System

., 1Il ' i ••• i. i _Ii! II i!til! iii,., I

Fue. Hose Replaoement:

-Replace the fuel hoses in accordance with the Periodic MainWIl'llanG9 Chart. Refer to p, 2·2 for instructions.

I Ii g h-p I (:~~ U rc 11 ()~ ~ ~ ;

(_)Hu~~ between i ucl pu rup and fuel distr] butlng p lpe. uHo .. c between fuel drstribu Li nJi: pipe dud pressure • e!!llldtur.

La w-p ressu rc h05~~;

OHos.c between fuel tap and fuel filter oHoSIC between fu el fliter and fu el plLU m p

ohose between pressure regulator and check valve

.~

Q~' @ (8) @~

Ij§)

®

I

I

~ ®

Fuel Fillter Replaoement:

.Replace the fuel filter in accordance with the Periodic Mdil'ltt:n'HKC: Chart, Rcter to p. 2-2 for the procedure.

So 11 and Nut Tighte nin 9

In accordance with the Periodic Maintenance Chart, it is very important to check the tighleness 01 the bolts and nuts listed here. A~so, check to see that each cotter pin 1~ in place and in good condition.

"NOTE"

oFor the Mglne f8S'tl'mers, check thf1 tighteness of them when the engifUJ is cold far room temp.er-ature).

oWhen retorquing the cylinder head nufS and 1)O/rs, follow the tigntening sequence specified in the uDis· assembly § chapter.

"I. front Axle NUl
2. I • ont ~cndcr Mou ntitl!,l
Bulb
3. Front fork Clamp
Bolb
4. Handlebar Holder
f\·\ou ntlng Boll
5. Clutch Lever Holder
sou
6. Handlebar Clamp BO~L
7. Stem Head Bolt
8. M uttler Moun ling Bolt~
an d·l\l u L~
9. Caliper Mounting Bolts
10. t I~gi ne I\.t ()U n ti ng Bolts
<Inti NU(~
1·1. Side Stand Boll
12. Shift Pedal Belt
rs. PiVOl Shaft Nut
H. I ootpcg MuuntLng Nu t
~5. Torque Link. Nuts
~ 6. Rear Shoe k Absorber
Mou minj, Bull~
17. C'Ili rrder HC<I.J lE!ulb
and Nub
18. M a ster Cyllndar Clamp
Bolts
19. B. ake Lever Pivot Bolt
20. Chain Adjuster Clamp
~olt
2l. Rear Axle Nut
22. Brake Pcd ill 130 I t
23. Muffler Connecti ng
Pipe (lamp Bolts
24. F run L Axle Clamp Nut SCHEDULED MAINTENANCE 2-11

Evaporative Emission Control System (California Vehicle)

The [ .... apor ative Ernissiun Control System routes fuel 'Vapor~ from the fuel ,>yslcm into the ru nning engine or stores the vapors in d canister when the engine is stopped. Although no adjustments are requ ired, a thorough Vi5lJ~1 inspection must he made at the i nterva Is specified by the Periodic Mai ntenarn.e U1(11 t.

Scheduled Maintenance:

Inspection

ICticck that the hoses ar e securely connected .

• Replace any kinked, deteriorated Of damaged hoses.

NON~CHEDUlED MAINTENI~NCE - EINGINE 3-1

Non-sCheduled Maintenance ~ Elngine Table o·f Contents

Camsha fts . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . .. . .. Base Manu I'll 157

Camshaft Chain .,., ,............ IBase Manual 159

Chain Guides Base Malflual 159

Chain Tensioner . . . . . . . . .. . . . . . . . . . . . . . . . . .• Base Manual 15'9

Cvl inder Head 3·2

Valves .•.•................................ , . • . . . . . . • . . . . . . :3~2

Cylinder Block, Pistons ........•................•............. 3.·2

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Base Manual 1172

Connecting Rods ,.. Base Manual 351

Clutch ,.. 3·3

Transmission , .. , Base Manua~ 18'

Shift Meehan ism. . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. Base Manua1 181

Engine Lubrlcation System ...........•••• , ..••......... ,...... 3-3

TurbclI::::h~lIr.ger .. . . . . . . . . . . • • • • . . . . . . . . . . • . • • • . . . . . . . .. . . . . • .• 3·7

D F I .~ Digital Fuel I njectlon] System , , . 3·'7

Evaporative Emission Control System .•......................... 3-32

3·2 N,ON-SCIHEDUL ED MAINITENANC E - ENGI NE

Cy I.nder Head Valves,

Cylinder Head:

Cylinder Head Warp

Refer tv p_ ] 60 of the Base Mal'lulll.

Combustion Chamber Volume Measurement R for to pp. H,)O and 161 of the Base Manual.

Vali'i8 GUide, Valve. Valve Sea,t:

Valve imcectio«

RefElr to p, 161 of the Base Mal1lual noting the following ex cep ti on.

ctlo not grind the vall1l8 stam end to repllir it or to pe1rmit additional valve elaaraaee.

OU'til1 _ vilive' '00 Is grou nd, the Ihi m may contact tihe' spring reoinii1' 8JIId/or split keepers during opeflltioi'l, ullowjfl II rl1 II kellperw I!OG58n. ConseqlJ enlly, the \ialve mllV drop into ttl 9 en gine, eau sin II Sie fli nus d !lma!)e.

Valve Guide Insf de D/arne tfJr Refer to p. 163 of the Base Manual.

Valve Seat Repair

Ref r to p, 279 of the Base Manual.

Valve Installed Heigh t

Refer to p. 164 of th e Base M anu al no ti n g the following cxccptlcn.

GOo not grind the valvii stem end to repair it or to p rmlt addltlenal valve elearanca.

~If the valve end i! grOlilnd, the shiilm may eentaet the splrillg fI!ltalirmr and/or sp~it Ikeepen durilllg eperatlen, allowi no ,tho kllilpe r to loole n, COII'I seqlil end y, the valYo8 may d fOp I~kl the en gine. CSIIII sing serioru s darna9~.

VaIli'll In'tall8d Height

Valve Spring:

Spring Tension

Refer to p_ 165 of the Base Manual,

Sprin 9 SQulfJroness

Refer to p, 166 of the Base Manual.

• •••• i 1Il ! I.,!I II< II' III'" III' IIII oi .. 11;11 II i" III •• iii !II

Cylinder Block Pistons

Compression Measuremen t

Refer to p. 168.of the Base Manual noting the followin g ex ccption .

• To stop fuel injector operation during cvllndcr compression measurement, disconnect the white/red lead which connects the battery posltive terminal to the fuel injection system harness.

A. DF ~ Sy~tem White/Red lead

Height (mm) Probable Cause Rccornm endaa i on
Inlet: 36.56 -37.48 Norrnatraeec p ta b I e -After assembling check and adjust valve
Exhaust: 37.11 - 38,03 clearance,
-M nve ... ~1 ve to shall ower cut seat,
More than Valve face or scat worn out, Rerneasure.
38.04 or gWQJ nd excessive] y , -Replace valve, Rem sasu reo
-Rep I ace c yl i nder 'he ad. Rerneasure, Cvlinder Comprouioll

Usable Range: 620 980 kPa (6.3 - 10.0 k.g/cm2 , 90 - 142 psn), and less than 98 kf'a (1 kgicn1~. 14 psi} difference between any two cvllnders

Cy lin der Diameter

Refer to pp. 169 and 170 of the Base MO'inual.

Piston Di<N'neter

Refer to p. 170 of the Base Manual,

Piston Cylinder Clearance

Refer to p. 170 of the Base Manu,aL

Boringl/=loning

Refer to. p. 170 of the Base Manual.

Piston /cvtinde« Seizure

Refer to p, 170 of the Base f'ytanual.

Piston Ring, Pisron Ring Groove Wear Refer to p, 171 of the Base Manual

Piston Ring End Gap

Refer to p, 171 of the Base Manual.

ill!. "' .. ! , ••• '" .' •••••• iI iii •• iI iI Ii. I! iI • I OR I ••••••• , i _' •• Ii iI •• 1Ij. iI. I M M ~ I·

Clutch

•••• i I • .t; II!"! ••• ' '" I j i ii II "'! II. '"'! •• !,. i. Ii

Spring Tension

Refer to p, 178 of the Base Manual.

Friction Plate Thick.ness, Damage

Refer to p. 179 of the Base Manual noting the following exception.

NON-SCH EDUlED MA~NTENA.NCE - ENGINE 3·3,

Friction Plate Thickness

2,90 - 3.10 mm 2.8 mm

Standard:

Service Limit:

Fricti on and Stee! Pia te Warp Refer to p. 179 of th e Base Ma.n u 111.

Friction Plate/Clutch Housing Clearance Refer to p, H9 of the Base Mlinuai.

Clutch Housing/Primary Gear ,Backlash Refer to p, 180 of the Base Manual.

Clutch Housing Bea'ring Sleeve Diameter Refer to p. 180 of the Ba~e Manual.

Clutch He/ease laspecti on

.Vi~ually in~pect the cllJtctl release lever, needle bearing and Ute teeth of pusher for damage or excessive wear. *If there is any damage or excessive wear, replace them.

.lllIiIlillilllli'l'lll •••• ~ ••••••••• IIIIiiIIIllIIIIllIII! 11!!.!I'., ioliil-l 1111 11111

IEngine Lubrication System

.................. .,1111<.1.11111 ".,.iili.lIiiIIiIIJlIIt.IIII'I'IIII.II •••••••• i i.,iI

General Infonnation:

The lubrication system of ZX750·El is b<l.'5iKI on that of lX750-A 1. The dltferences between the two arc that <l. new oi I fI oW P assage is ad ded J w h teh is rou ted 'fro m the oi I cool er til rough the tu rb ocharger., the su b .. oil ea n and the sea ... enging oil pump to the oil pan.

Oil Pressure:

Oil Pressure Measurement

Refer to n. 1186 of the Base Manual,

Oil Presswe Switch Inspection Refer to p. 'I 88 of th c B ase Manu <lit

Jt.4 NON·SCH EDUlEID MAl NTENAINCE - ENGINE

Engine Oil Flow Ohart

Connectmg R ad Journal s

1

1 __ - _

NOTE: 1"1'1 e 0 11 flow ~:l<Issa'ge is add ed, wh i eh is enc i rc led bV 'the ~ i f"II e: of "---

~---".

Turlbocharger Lubricartion System

NON-SCH E DULED MAINTENANCE - ENm NIE 3-5

,
_J
p
"'
Q
0 ~
:._J 0 ~
B u:: ..
~
:5 ~.., i.i ~
._ c S .. :5
~ 'r: ..
JJ - ~ .E CL €
L.~ ;:;: ~
OJ " t-
fit " 3-6 NON-SCHIEDUlED MAIINTENANCE - FNm NE

TllIrbocharger LulKication Sys1Bm

/

/

I

/

/

~ ~
~ ~
.= ~
I "' ~ U-
~ tt'
co (5
L_ :d
.... J::.
0<:1 '''';
0 0 D
I.J... _o
'-
:l
- Engine Oil Pump and Scave-no·ng Oil Pump:

Visual Inspection

.Dis,memble the' engine oil pumpand scavenging oil pump.

-Ch ec k th at th ere are no scratches, ru st 0 r pitting 0 n the lnsidc of the oil pump housings and on the outside of the pump, rotors.

• If the oil pump houslngs or pump rotors show any darnage, replace the 011 pump assembly or pump rotors,

Oil Scre-en Inspection

I he oil screen ,H the oil pump inlet removes any m tal particles and other foreign matter which COLJld u..tmag~ the oil pump ..

-When the oll pan and/or pump arc removed, remove the oil screen, and clean any metal particles alld other dirt ou:t of the suee;f"I. I of th e 0 [I '>C roc n is damaged, replace it wlth a new one.

Oil Pressure Renef Valve:

Refer to p, 186 of the Base Manual.

Tu rbochiilrg,er

Turbine Wheel

.Ensl'.l re th at the tu rb inc whee I turns smooth I y W L th your finger.

*11 the wheel docs not turn, or if i t should blnd a L any point, r~p lace the turbocharger

Actuator

ep~l! off the pressure hose from the compressor housing of turbocharger.

-Imtall the pressure gauge, compression pump, anti dial g;lUge as shown below.

Dial gauge read Pressu re gau g,e read
0,5 rnrn (0.02 in) 49 - 69 kPa (O_50 - O. 70 kgJcm~ ,
7.1. - 10.0 psij) l

NON-SCH EDULED MAINTENANCE - EN'GI NE 3-7

000 not Cilrry the turbochargor bv hold~nll':lle actuator rod to prevent it fro m bend in II.

ODu ri ng the air tilling procildlll rll, do not applv mo~e W<l!n 98 kPa l1.0 kg/.l:m l • 14 psn air p~llsrlll re, ethe rwile the actuator m IV be damaged .

000 not attem pt to dis assem bl e the actuate r rm:t wh i eln il staked.

D. Actuator Rod

E. Actuator

A. Pressu rc Gauge

B_ Compressicn Pump c. Dial Gauge

DIFII (Dligital Fuel Injection) Systeml

Gene r,!;111 I "fo rmabon:

Self·Diilgnm;iil lind Fail-Safe Function:

The 1984 DF~ control ~.lInlil diagnoses the 1)11 ~ system while the engine is running. If trouble occurs in the DF1 sy stern w h i I o rid in!ilj th e [) F I control u nit ta kes th e foil owl ng m easu res;

elf it turns on the sends a signal tv the warning unit to notify the rider of the DF I system trouble.

-If it turns on the fail-safe system. By ignoring abnormal signals which are sent from damaged se.nsor{s} or tfimug.n damaged wires and by using the fail-safe dab. the DF I control urut computes the fuel amount to be injected. The faU-silfe data arc Ch05Cf"I '~O mlnlmlze the influence of svstern damage.

3-8 N'ON~CH EDUI.EO MAIINTENANCE - ENGINE

Until the ignition switch is turned off, the D F I control unit keeps the faults in its memory and continues to tum the green L D (Light Emitting Diode] on and off repeatedly to notify the mechanics of faulb. Thls greatly helps them to troubleshoot the DF I system. Pu lses of green light can be seen through the i nspect ion hole hi the control unit. Arrangement of long and short pulses ex press the tro ubi c codes wh i ch co rrespc nd to the faults.

~NOTE"

OThe DFl camrot unit keeps system troubles in Its memory. e V&fJ ;f they occur for rime wh ile the Ignition swltr:h is on. However, the centro! unit reset« and dears the mermJry whon the itlM/D'n !lwitch is turned ,off.

Pin Numbers and Wire 'Colon in Control Unit Connector (viewed from wire s·jde)

c· ~ ~
"' ee .;;:
~ c: .c
e u ~
o 0 ~ e --
~ .::.: CIJi ~ e
- .._ Q,)
.:.l i,.l GJ '-> "'" E: ~
C :d .2 i';l 'I.'
~ QJ Q;I iS3 ~ a:l (:! ~ "0 "'0 dJ ~ C "'C ~
"' '" ::l 0 '" ~ ,t;;:
.s IY 0:: as ~ ~ .s:
W --.. --- II.l I..;J ...__ 3
}~ II.l >-
>- ::J !i -e-c,
-- ~ II.l
-- .c: II.l ::J
~ :c ...
A.. Trouble Co-de inspection Hole ..:I ~ :;l '-' ii
~ rn
S, DFI Control Unit ca S If Diaglnolil and Trouble Code

EI .
I terns Criteria I rouble I Arrangement of Pulses* Action
Codes
I-
Throttle [j [J Perform "Throtlk Open] n~
Open Or Short I 1 Angl c Signal Test ".
Sen~or

Air 0 Perform '·Air Tern pcra ill re
T em pcra tu re Open or Short 12 rg 0 Signal Test".
S~nsof -
Engine I Perform "Engine Temperature
I c rnpera tu re Open or Short 13 D D D Signal Test",
Sen~or
Roo,l Open or Short 21 I I j l 0 Replace control, u ni t.
Sensor
Perform "Starter Signal '1 est",
Starter Continues on after en" 22 L_j I l 0 0 and inspect starter switch for
Switch ginc Harts, damage,
No ignition pulses are Perform "Lngino Speed Si~ndl
lgni lion transmitted to control 23 l I L:J D D 0 Teq", ~nd inspect Ignition
PU~5C u nit when cranking en- svsrem dJrnd~l:.
gine. -
.

CPU** Memoric~ ill CPU do 31 I ,I [I I ] °1 Replace control unit.
Memory 1 not upurate properly. L-_---.JI long pulse, 0 Short pu lsc **. Ccntral Proce~sjng Unit

NON.SCIHEDlILED MAIINTENAN,CE - ENGIINE 3·9

'l. Throttle Sensor

2. Air Temperature Sensor

3. Fuel Pump

4. Surge I ank

5. Fuel lnjectors

6. Fuel Filter

7 . Pressu re Rcgu ~a to r

1. Main/Pllmp Relav

2. 0 FI Neg.ative (-) Lead Connector

3. D FI Posltive (+) Lead Connector

4. Throttle Valve

5. Control Unit

6. B Clost Sensa r

7. Engine Temperature Sensor (between #1 and #2 in let) B. Air Cleaner (chain cover)

9. Battery

10. Starter Relay

11. ~ U nction Bo)(. Connector

,3~1'0 NON..sCHEDUILED MAINTENANCE ~ ENGINE

OF I System Irupectiion:

The section ej(pla~ns the diagnostic procedures for the Kawasak i [) F I system. Before d lagn osi n g the 0 F I svstern, check the items I lsted below, and replace, add, adjust, or repair if necessary.

.c:h ec k the mote rev de for e vide n ce 0 f P h ysica~ d ann age, eTh ere ~~ su ff c:i ell! fu el in the tan k,

eA11 e I ec trical co n n actors are clean, Ught, and co rretlv connected. Fuses are not blown out.

eThe engine is in gooc condhlon, he pcriodk maintenance should be properly performed.

-The engine is cranked over normally w~th the starter motor.

-I he ignition system operates normally.

Tests in this section include the following:

1. QUick In.itidl Check

2. Electronic Control System Tests: 01 nlcctor Signal

("Jfu~1 Pump Power Supply oru mp Relay Wire~

01 niector Wire~ (I ncluding Balt~ry Vol rage Signal) oTl1rotlh: Opcnin~ Angle Signal

("J[nginc Speed Signal

nAir Temperature Signal

OEnginc Tern pcratui e Signal

t ·St.HLt!1 Si~t1d1

G I hrottl u Sensor

roTh rottlc Sensor Pmi tion oAir Temperature Sensor DEngincl ernpcrature Sensor C::M.airn/Pump Rel<l!Y

cWires and Connectors

oo I-I Warning Function

3. Fuel Sy~tcm Tests: nFucl r'u mp

t: 'I nice tor

"Pr~~~Llrl" Rcguldtor . "1 ucl l.cak

r)i lJCI Svstcrn Cleaning "I' ue] ~ u icr

4. Air Svstern Tests: oTh I ol tlc Vul v I.:~ "Air l.cak

"~lSurge Tank Drainlng

"NOTE"

Llf 811 eoov» inspections prove good but tile f!rJgifle :;filt OPOI'l}tlJS poorly, the trouble may be caused by thf!.' ongine itself. It mav be necessary to Qllfjmau! the engine. t=r;peclafly inSiJect the pistons and cylinders for wesr end s-eizul'e, piston rlngs for ,Hicking, and varve' seatS for any irregularity. Remove the carbon from ffle piswn heads, piston ring grooves, cylinder head and vr.JIVlJS.

Test No.1 Quick lmtial Check:

Glve the system d qu ick initial check before star tl ng d scr lcs ul time consuming tests, or worse vet, ICIl'HJVing pdrh for repair or replacement, Such d check will ol Len turn up the ~(lurcc of the trouble.

Quick Initial Check

-Confirm the DF I system trouble by redding the trou blc code emitted through the inspection hole in. the conu ol unit.

-I urn on the ignition switchand I isten to the fuel pump .

The pump shou ld start ru nni ng when the switch is turned on and stop after about 5 seconds,

,.Turn off the swltcn.

*11' the pump doe, not operate as above, perform the lullowil1g tests first which are explained ill the "Test No.2 Electronic Control System Tests" and "Test No.3 Fuel System tests."

Ofucl Pump Power Supply oPump Relay Wire~

OM<lLn Relay Wire~

O[onlrol Unit Power Supply (including Ignition ON Signal}

oFucl Pump

*1 f the pump operates normallv I proceed to lh,~ next check.

-Di~onnc't the 2·pin connector from the starter relav under the Idl side [Oller. This is ro prevent the starter motor from working during this inspection.

-Tum on the ignition switch and wail until the pump stops.

-Turn on the starter switch {with the clutch lever pulled in), and listen to the fuel pump,

*H the above check shows goocl pump operation, proceed to the nex l check.

*1 f [he pump doc, not run when the 5t,[[ tcr swi tch LS on, perlorrn the following rest in the "Test No.2 electronic Control SY5(em TCSh. ")

Grump Rcld~" Wir~~

'*1 f the above check ,how5 good pump operation,

proceed to the next chock.

-Reconnect the sUu tcr motor relay connector, .Try ~(dftin~ th~ engine.

-I Urn o] l the ignition swl tch,

*If the engine won 't start, perform the following rests in (he "Test No.2 Electronic Control System Tests."

GEngine Speed Signal CStarter Signal

*If [he engine stan.s but runs poorly, fuel/alr mixture [I ouble is suspec ted. Perform the following tests in the "Test No.2 Electronic Control Svstern Tests!'

cAir Temperature Signal

cAir Temperature Sensor

c[ngine Temperature Signal

OEngone Temperature Sensor

OThrottle Sensor

oThroule Sensor Po~ilio'n

11 est No. 2 Electro n ic Contra I System Tests:

When. perform] ng each test, observe the followl ng rules u nless otherwise inJic.iwd;

,.Set the Kdwa~aki mu ltimeter to the 25 V DC range, and connect the meter negative (-) lead to {he battery negati ... c ( ) terminal.

'-Set the engi 11C stop ~witch in the RUN POSilI011.

-Set me motorcvcle upon its center stand and the gear in neutral. KLck up the side stand. This is to crank over the engi ne only bv push itl~ lhlJ starter swl tch. eMea~ure the vol rages wuh all connectors left connected.

NON·SCHEDULED MAINTENANCIE - E.NGINE 3·11

Injector Signal Test

~.oI.!j1 ~ I i-I~------.....,

JIo:~~~" ~ c~,",'''"'--''--------." ~,~~- I •• ;]0- ~.'~.~----h

... _'111 ~ ---_ .... '1:.1

_:_ 1+=

L

I ....... '1 ......

........... -. ·'IIIiI ... .-.rII .... r ..... """ .. .t'I

"=a-.. tioIiN- ...

'0hre Connecrions Criteria TC~l I terns when out
l.ocat ion of Critcrid
, Control unit power
) I urn ul1 i~rl ition switch. ~upply
( M'lin relay wires
, ;lnj~ctOf ' 'R~mOVL~ tuct tdnk. Sev (he WA RN I NC bcfow. :JTl:, l I i ~h l~ 11 i cker a t rcgu I ar ' I njector wijres
connecrors , )Di~conn~ct <III injector connectors, anti COM- intervals while cranking en- , E n ~i n ~ ~ peed ~igt1cL1
;>;:4 ncct injector ~ilolnal lest lights La connectors. glne with starter motor, ( Starter <lgnal
')1 nstall luel rank and connect luel hoses, ('Main/pump relay
iTurn I~n ignition swncn. , Replace control
unit, " WAR N I N G l'· While the fuel hoses ar:~ ~i~COI'il1le-:ted,

,_,. i11 do not tu rI1 on tim 191n1t I on SWI ten.

The fuell pu rn p willi ope HI'tt! and fuel willi $fl Old t from

th e fu el hose if YOLI ttl rn on the i gnh i on switch with th EI fu Ell hoses d i scannse tad.

A, Injector Signal Test liWlt

·~,-r~. VII'I7I'IJI!lili' C n-'"
~~,.;:~ ... ~ ~. Pil~

m.n~F"1' u ~ .'.
~I r.r..-.
.. - _ill I.L'I
,
I , .-----
I ~
,
,
, ,
,
t
I ~ , .
'- -
-r'," ,-
~d
~ ~ .
,
~ > . : > ~ . • ~ , . ~ - ~ .. ; •• • . "
.. - '. • . ., ••• ~ . . ,
l_j , 't ... t~""!... -"t,.~r~
L k ~ I - -
''':'!l .~ ~,~ ( ( ., '11fH1i ~ lp i I'~ ill '
f( ~. \ ~~~I~~.!'~. ~ .~!' 3·12 NON-SCHEDULED MAINTENANCE - ENGIINE

Control Un;t: Power SupOly Test (including Ignition .oN Signal Test)

1"

~-

!

........ ',... ....

~_ ......... ·1." .... ," ~-

I I Meter RCdei ing Test hem~ when out
Wire Location Connections (Criteri@) of Criteria
uMeler (+) ~ No.'16 pin cO V regard less of ign ilion ;l3ldck/Gr cen wire
(hlack!green wire) switch positions.
u(ontrol unit uBattery voltage when ignition GBlue/velluw wire
connector OMeter (+) ~ No.7 pin ~W.LC~~ i~ on.
(blue/yellow wire) <...'0 V when. ignition swtich is 18M~in relay wires
off. ;)M ai n l pu rnp rota y Main Relay Wire Test

NON-&CHEDULED !MAINTENANCE - ENGIINE 3·13

""" ..... -

. "

Wire Location Connections. ,\1etcr Reading Test lterns when out
(Criteria) of Criteria
r- -
oMcter (+) _,. 00 V regardless uf i~njtion ()Black/yellow wire
BIClckjyellow wire switch posl ti()n~.
o!3aucry voltage when igo
DRelay.while G[\>kter (+)- nition switch is on, uRed wire
connector Red wire o{JV when ignition swi tch is
off.
l Merer (I} • '.: B~ tte rv voila ge regardle-ss of
W'hileJred wire Ignition SiWICh positions, ")White/r~(J wire LI".~-:"_ •• '.

I l=

I . ,3' .

CI I~ J!!.

/.....u... _ _,

I

II r--
, II
" ~.
I' ~ J
'.
n
PI
~ , ( c

.. .. ~ Q-r~ -

I Ii

="::...;".1 ..... ,

Fuel Pump Power SupplV Test

3-14 NON·SCHEDULED !MAINTENANCE - ENGINE

......... I~~ ".-t .. II!III~ .... II It:
............... !]I ':::;; '"It
~'~ ~:'" -u 1'1'" I
dl,....._j)<"~
~_ .... t' _jIjj .... n
,.
, ,
, I -
,
-
, I
,
~ . ,
i!::::: a "
\
~ ! 1
~ ~ I
~ i
~ f • I· ~ I
~ , : . .. _. . ~ ~ ~ ~ .
. - I·, .. -
-] L__ ,'~) rr J Ii-' · ,,-, , , ~ ~ e • , • - • 0 l
Tt tFll p,'? Tel l J l-lt~"Pl}" U '
- \_r/ l~ ir u: J. 'i r
~ ~ ~ q r.}J L
I J J.. .
I ........ !I~~~ 1 .. ...-.-.., •• .... - j ........ -

""' .... .....

_I

",1".:... I .... ~

T \1eter Reading Test Items when
Wire location Connections (Criteria) out of Criteria
- oMeler (+) 00 V regardless of ignition
~Ck/YCIIOW w~ switch positions, uBlack/yell()w wire
-
o B,mery v 0 I tage fo r a bout OOr<lngc/ b I ac k wire
5 sec immediately after ignlton
switch i~ turned on, thun [) V_ oPump relav wire~
c'Fud pump OBaUery voltage when starter cJMai n/pump relay
2-pin con- cMeter (+) -> uBlack wire
ncctor Orange/black wire switch is on,
"0 V when starter )witch is off, OGrecn wire
<lIs:BaHery voltage when engine oRcplace control
speed signal is sent to control unit,
1 unit, and 0 V in abou t 1 sec
I after ~ign<il steps, "I~ow to send the engine speed signal to the control unit:" .Prepare <In auxiliarv wire which can reach to the hatterv from the controi unit.

•• round the one end 01 the wire to the battery negative ( )lerminaL

-C01111Cct 1 he other end ol the wire repeatedly to 1 he #18 pin [black wire) or ,.;8 pin (J<:,recn wire) in the control unit connecter. This motion sends the engine speed signal to the controlunit.

.Rerno'll'L: the auxil larv wire after thi~ test is over.

Pump Relay Wire Test

NON-SCH EDULED M,AINTENANCIE - ENG I NE 3-15

~~I!I~ "_'_pw .. m ..

k:~~ 1) L. .....
1iI~==:t ........
..... r .. _"""
I
-
, ,
, .-
,
,
"
•
• ~
='
I
• l I
~(
~ I
. . ~ a . Ij ~ P ~ • -
~ . .. . , . " ~
U (_-:J.\ ",; ____l, r .I r .. , , ~ ,~ r 'I t L,
n , ~5 ,)::h e9"tt:.~ I n" I '
II I " I ~ 1]1 Jfft f1 ~ Ii' r r
<t,"- ~ <:» i jl-J iJ 'J JOM
- L . ...-, ......

.:.a.i~ '.w"'r.mil;!,~ n_

5fio..::i" .. ..:..

Wire Connections ,\1ctcr Reading Test Items when om
Location (Criteria) of Criteria
oRelay wh ite oMctcr (+} Black/ 00 V regardless or igniLiun switch )Blllck/yellow wire
connector 'fellow wire positions.
oB~ttery vfllt<lge for about 5 sec lrnrne-
dlatelv after ignition switch is turned uGreenlwhite wire
()Cuntroi uni t oMeter (+} _,. No. 21 .011, then 0 V, <Con trol unit power
connector pin (green/white *OlBatt!.::ry voltage when englD1€ speed supplv
wire] signal is sent to control unit, and 0 V oReplacl.! control unit I
in about 1 sec after signal stops.
oM eter ( I ) .... Black. OBattery vol rage when starter switch is
()Rel.!l.\' wh itc wire on, OBlack ...... i"· I
connector 00 V when starter switch is off,
()Mcter ( I ) • White/ oBa.tterv voltage 1 cg,u d I ('S~ 01 ignition "White/red wire
red wire switch position, !lO Refer to p, 3-14 for how to send the engine speed signal to the control unit.

J

3~ 16 NON-SCH EDULEIJ MAINTENANCE - E.NGIINE

Injector Wire Test

(including Battery Voltage Signal Test)

-
...... ~I~ ~ ............. ...
t..::~:::: I.D -"-
.... I'.;ii~ """" • ..- _ M. I
ttt.,___.... .1- -" IC~
...... L ~
, ,
-
-
; I
~
.:::: -
I In
p~
l.l
~ . ~
I ~
I
j .. .~ j ~ ~ , L ' ~ - I
>. 1_ L ,; - •
~ - ~ = ;; ; jj ij:; .. r. r I ~ I '. T
'- 9 ~ lfjlP Ii UOiliL I
-"" /
I ~·i· i -I ~1· ~.~
~ 1 ~. of: - _-.
",r ... Ilf"1'1;''' ....... ""'1'. ~ ..... 1 .. _ .. l ~
_, - ........... I,!rr ..... _ ... .t'!II ........ - -

-

Wire Connection> Meter Rc.ttlin:.; Te<,1 Item" when out
Location (lritcria.) of Cri icria
-
OMeter (+) _,.. No, 12 r: Ildttci ~' voltage regardless of i~ni tion "Yl'llow wlr e
In jcctol ~
(yellow wlre] switch pcsi tlons, .lnjcctor connectors
I---
UCon~rol oMclcr (+) -> No, 4 (, B~ t te ry val ta~e r ~ gar die ~~ 0 f ign i t i 011 ~;Whit~/red wire
unit pin (whitelred wire) switch po~i(iun~, I
I
connccro: olvtctcr (~) ~ Nn. 1
pin (black/ydluw (;Q V regardless 01 i~ni Lion switch r Black/yellow wire
wire) posltlons, Throttle Opening Angle Signal Test

".

>

~"","Iii ... ,..,_... I._.",.~

"'M

I

NON-SCH EDULEID MA~NTENANCE - ENG. NE 3-17

__ c: rJ.[j-I .. Ii.- ........,

iI~= ~ ~-"f-=""":iII...~---...,

.. :~ :II q..::;"':.::.'. -----h t..'M.."i:ltl; ~D:."l

I') I

- " r--
, ,
, -
,
I I
I 6
I
\
I P1
dl, -

"'-

Connections

MCLcr Reading" (Criteria)

--------~-----------

rMCler {i } _,. No.5 pill (bl ul!/rcd wire)

*Set the rnul timctcr 10 the IOV Dr. range for th i~ test

--- -

Wire Location

! Test Items when out of Criteria

uControl unit connector

00 V regardless of ignition swltch oBll.lc/red wire

positions, OReplace control unit.

ClOV whim ignition switch is off. oBlue/white wire

80.5 5.2 V when ignillon switch is onnroU~c scnser

on, decreasi ng srncothlv as throttle o'Throttlc ~Cn5()F

opens. pos i tio n

~--------4- -----------~-~----~--~

oB~llIe/orangc wire

oThrottle sensor cControl unit power supply

oRcplace control unit.

()Mctcr (+) ~\lo. 1"1

pin (blue/white wire)

I'. I \ N l' 00 V when igni.tlon >.wit<:h is, off.

O'¥'ICLC-r ~ + I O. { 7 2 8 8 \' h . ,. . h '.

. (bl . I ' )1"0.. \It en I~nltlon swrrc IS

pi n uue, orange Wire, Ion.

3-118 NONI-SCH EDULED MAINTENANCE - ENGINE

Engine Speed Signal Test

Wire Connectkms Meter Redding Test Ilem~ when
Location (Criteria) out of Crh eri~
OMcter (+) ...., No.8 -
oCunlrol pin (green wire} or r() V when ignition switch is off. . ·Green wire
unit No. 28 pin [black I rBatrerv voltage when igniLiun swi tch ~;BI<lck wire
connector wire] is on .. ,

, ,

NON.SCHEDU L EO MIA INTEN.ANCE - ENGI,N,E 3-19

Air Temperature Signal Test

~-- .. ~~ ......... 1IJi!. .... ~

~:"1~.: .D ~~Jf.'Pi
.. ~ml... ~1'1
I~ T.......... J: ;0:; II
11n;w .... 1" .... ·~L 1
I "
" ,
, , .------
, l-
I
I ,
1
~
I nr
J ~ 1
dl
t . > • > .- • ; . ~ ~ ! ~ ..
•
~ F rl;7' J- .__ L.: L L.rtL~ • I,i .
" 9 'V r li~iPjdH ~i~l, 1
-- '--------.l
~ ]1 J l} ~I t· Wire Connections I Merer Reading" Test ltems when
I t.ocauon (Criteria) out of Crlterla
f-- - -
r.{)V when lgnulon swi tch i~ off. uBlul! wire
**02.3 - 3.4 V wncn ignition switch OAir temperature
~~Contml OMdt'f {~} No.6 is Or! .. 5ensor
unit pin (blule wire) 03.4 - 4.6 V wilen temperature -J[ontro~ unit power
sensor 2 -pi n co n nector is di ~.- ~lIppl.y
[011 ncctor connected and 11<:t1ition switch is on. cRepl~clt. control unit.
! 'Meter ( I} _,. No_5 ) I C{) V regardless of ignition switch oBlucired wire
pi n (hILiI!/r~d wire) p osi t i ons. cReplacc control unit. * Set the multlrneter to the 10 V DC nUlIge for this test.

:+0* This is true when sensor temperature is 20°C {6S0F), 2_8 - 4.0 V when O°C (32°F). and 2.1 2..9 V

when 30°C (860 ).

3~20 NON-SCHEDULED MAINTENANCE - ENGaNIE

Engine Temperature Signal Test

... ~~ . .-.

,r r

II r=nRmnr-1~

Wir Connections Meter Reauin~* Test Items when
Location (Criteria) out of Criteria
00 V when ignition siwtch is off, ~Gray wire
OControl **02.0 - 3.1 V when ignition switch o E ngi n ~ tempe ra tu re
unh OMet.er (+) Nu,lO i~ on. ~en~or
connecter pi n (~ra y wire] 03.4 4.6 V wh en gray sensor I ead i ~ (_)Contro~ unit power
disconnected trom the sensor and ig· supplv
nition switch i~ nn, r)Rep~d~c control unit. *Set the rnulrlmetcr to the lOV DC scale for this test.

This is true when sensor temperature is 20"C (68(>1 ), 2.6 3,8 V when OC C (32"F}. and 0.52 - 0,96

V when so'c ("1 76"F).

N,QIN-SCHEDULED MAINTENANCE - ENGINE 3·21

Starter Signal Test

OL
-:.~l R=== ............... (:0 ....
~:= D.....,~ ...
... ...,. ........ c."I!l
1~lr_ ..... iI.
iJ."<!!.-o:i i[ ,_I!I~._f1! !
~ ..
.- ' ,
, ....--
,
'F-
f
1 s -
\[
I Pl
I ill
I
~ . j > .. . ~ : • ~ I ~ -
•
II ~ F~ k.. n " ~ q II ~' M • I • '
. p~p~ r fl\fH j:p~ 11 '!h I
. , I - ' L
~.Jj V ............ ~ I

Wire I M etcr Read i ng I T est ltems when I
Connections
Location (Criteria) out of Criteria
I--
cC:ontrol oMctcr (+) -+ No. '19 oBallcry vo~tagc when starter ~wilCh n~ oRed/black wire
unit
pin (red/black. wire} on. oMilLnjpump relay
connector
1-
<..lRe~ay ':jMelcr t·~) _,_ Black oS<lttery voltage when starter switch is I oBlack wire
white wire on.
connector 3-22 NON~CH EDUILED MAINTENANCE - ENGINE

Boost S;gnal Test

'"

-. ~[~ ......!.oiIo .. C ~

.1"!!"Il'iRlPii G t...,: ";1"1
~n;::, ~"
j.,,_ ......
_ ([ --.JI5&
I
F"""-
-'l-
I ~
[
',' i
III
Hi
1il , L _ I I $
s- . , I- f
, - ~ - ~- -
~ I- pp (J r \.- ~~ . ~. Iii III "il' • Q
I i~Hij iIPHi~~l
'--~ .,__) _J
"::~IU" ........... 1 _,_ ".iIljl!,.!iop "'T"~ __ ,. .._ .. . i _.

-

-

Wire Connections Meter Reading* T es t ltems wh en
Location (Criteria) out of Criteria
f-
"Meter (~) -+ No.1 5 00 V when ignition switch is off, cPink wire
Pill {pink wire} 11'-"01.9 2.8 V when ignition switch :J R. cplace boost
is on. sensor
,jMeter (+) No.5 00 V regardless of i~nrtiCin switch uBllw/red wlre
pin (blue/red wire) p osltl ons. <Replace control u nil
r 'Control uBlue/owaUlgc wire
lmit OBo05t sensor
connector oMieter (+} -+ No.1 7 ' 10 V when ignition switch is oft. cOm'tml unit
pin (blue/orange w~re) <l7.2 8.8 V when ignition switch power supply'
is On, '!Replace control
unit '" Set tile multirneter to the '10 V DC range for this test,

-.. .. This IS, true when atmospheric pressure is 1 ,DB mb (760 mm hlg), 1.7 2.5 V when R98 mb (674

mmHg), 1.5 - 2.2 V when 795 mb {596 tWflHg),

NON~CH EIDUlED MAINTEINANCE - ENmNE 3~23

Throttle Sensor Test -Turn uff the ignitiun switch,

.I)i~conncct the connector from the throttle sensor. -Connect an ohmmeter to the sensor according to the

fo II ow i ng La ble, an d me asu rc th e i "Hemal resis ranee. *~ f th e m erersh OW& the rc ~LS ra Ilees spe cifl ed in the table, the ttl ro it I e sensor h guu d. l f it does not, re piace the throttle sensor.

Throttle Senior Flesis:t:al'lce

Meter Connections Throllie position Reading
Range
--
')One meter lead -
x '~ kU Ground terminal oAny position from idle 03.3 6_81d1
oOth er me te r I ead --,-. to full open,
Volt,1.ge source
terminal I
oOne meter lead
Ground terminal oldIe position 02.1 - 4.2 kf1
cOther meter lead ~ .,
Output terminal -
oFullyopened 00.35 0_71 k!l II< R.ead ing sho u Ide h arl~c srn ooth I y as th e thro ttl fl i s turned,

Throttle ~IUor

T:

T

1. Brushes

2. Carbon. Film Resistors

3. Ground Terminal 4, Output Terminal

5. Voltage Sou rce Terminal

3·24 INON·SCHIEDUlE.D MAINTIENANCE -IEN'GINE

Throttle SenSQr Position Inspection

ngine performance i~ sensitive W the throttle sensor position. To obtain the best sensor position, you must use the throttle sensor posl Lion cheder [speclal tool:

P/No, 57001·1003) and the vacuum gauge following tile i nspcc lion and ad j u strn en ~ chart on ttl C n ex. t page. Belore and After Til rcttle Sensor Inspection:

-Check that the engine is maintained corrcctl Y according

to the Periodic Maintenance ChML Replace, add,

adjml, cle,Ul, or torque if necessary.

.W rm up the engine thoroughly, and then stop it.

• Remove the fuel tank, ami put it on a work bench somewhere ncar the motorcycle.

-ConnecL the fuel tan k to the fuel hoses l.I~Lng suitable hoses,

-Set the engine idle speed to the v aim specified below duri n~ throttle sensor position inspectionand adjustment,

Enlliml Speed Outing Throttia Sensor Positio!! Inspeotion ilnd Adjll.stment

1,000 r/min [rpm]

"A .ft;e,. im;plJCtion and edjustmer: r of the thro ttte SMS()'F posirir:m, adjust the engine idte speed· to the stand~rd, rlmin (rpm),

How to U!II Position Checker: .TtJrn uff the ignition switch,

-Di~wnnecl the connector from the throttle sensor.

-COnnect 1 he checker to the sensor and the disconnected

connector,

A. Throttle Sensor Position Checker: 57001'-1003

eTurn on the ignition <witch to supply elect: icit')' to the sensor. Engine starting is not neccssar ",.

.Both lndicator, on the cheder shoul d go on when the throttle i~, at the idle position. If th ~'r' do not, adjust the sensor position.

How to Adjun SClisor Pcsitlon:

'.Remove the throttle sensor cover. Refer to "Engine Disassernbly Chapter" for covel removal of the LIS model.

-Loosen the sensor mounting screws (2) [ust enough In move it.

eTurn the sensor so that both indicators go on,

"JThe poeition where ontv on lndiceto« goes on is not fa,. wide of the· mark. but is not the eX8Ct position .

A. Throttle Sensor

B. Mounti ng SCFew~

.Tighten the rnou ntlng screws,

-Open and close the throttle a few times to make sure

b oth i nd lcators go 0 n. Read just if n cc cssarv . -Turn off the igniuon switch.

After the sensor is fixed at the bast position

-Install the sensor cover, Refer to" rJ1line Disawernblv Chapter' tor COver invtallatlon (.1 I the US rnndel. -Removc the checker and reconnect the sensor connector to the sensor,

Air Temperature Sensor Inspection -Turn off the ignition switch.

-Dis.conne.cl ehe air temperature sense: 2·pin connector,

-Connect an ohmmeter ro the S nsor connector {mall.',

2·pin) to measure the resistance of the air tern perature ~en~or .

• rf rnc meter shows the resistance shown in the table <it the specified tempe. ature, the ~en~or is ~(.1l1J. r I i L does not, replace the sensor

Air T e ml~ ratu re Senmr R !!sistance

rvletcr I Co n n ection s Reading
Range
cOne meter lead -+
Om: sensor lead *3.0 4.0 kU
x 1 Ul @20"C (6S0F)
80ther meter lead ..... I
Othe sensor lead *Thi~ reading i, true Wh,'11 ~{'Ih~ II temperature i~ 20~( (6SDF), s.o - 9.0 kr.l when O°C (32"F), and 2.0 - 3.0 k:Q when 30°C (B6DF).

Throttle, Sensor Position

lnspectlon and AdiLlstmernt Chart

NON-SCH EDULED MAmNTENAJNC E - ENGI NE 3;25

No

Warnl up engine,

=Chcck whether idle speed is between 950 1,050 rpm.

Svnchronize engine "',~CUlJm,

Adjust sensor positlorr,

No Sec "Huw 10 Adju~t Sensor Position' (IPg.3-24),.

~When checking idle speed following engine vacuum ~yn'hrol1iz~tjon inspection, disconnect the vacuum gauge hoses from the throttle valves, o:Inu connect the hoses, which lead to the pressu Fe regulator, to the fittings on the throttle valves.

No

Chuck l!rL~ir:lc vacuum s vnc h r on 1 za tl o n. Difference between any two cylinders, should be less than 2 em ~Ig.

throttle sensor posi [ion using specia] tool. Sec "l low to Usc Po~ition Checker" (Pg.3-24).

Adjust idle speed

3·26 INON~CHIEOULE D MAINTENANCE - ENGINE

A. Air 1 crnperaturc Sensor

I: ngine Temoeren: re Sensor I nspec r ion

.Turn off the ignition switch, and disconnect the lead lr orn the engine temperature sensor,

..... h:d~ure tin: resistance ul the sensor with an ohmmeter. *11 the meter shews the re!>i~l.inCI.: shown in the table at the specified temperature, the sensor is good.

A. Engine Tempcr arurc Sensor

Engine Temperature SernOf Resistance

f'."eter Connect Lon .. RcadinJ.:
Range
I-
lOne meier lead
Sensor terminal 2.0 3_0 kU
x 1 kll @2:0QC {68D F)
<Other meter lead _,.,
Ch assi ... ~r ou n d "Thi~ reading is trw: when sensor tcmpcrann e i~ 2UoC ~68° F}, 4_7 - - 7.6 kn. when O°C (32°f), and 1.4 - 2,2 kn when 30°C (8G" f )_

Main/Pump R~/av Inspection

The r lay is dlvtded into two pam: the main and fuel pump relays. The two pam can be tested scparatclv. Before starting the relay inspection, prepare Of 12-vol~

batterv, a test Hght (12 V 3 3.4 W), Jnd two auxlllarv

leads, and remove the relay. •

Malin He'ay lnspectiore .Remove the relay.

-Connect the battery to the relay terminals, two at a. time, and chock the conducuvlt y between the other two terminals as specified in tile following table.

*1 f th e te rm i nals ~pec i fled in th e tab le co ndu ct, the rnai n relay us good.

Main Relav lnspeetlnn

No. Connections Conductivity between
+ Lead! Lead #8Sl and ~Sa
1 #85c #85 on
2 #85 #86c oeD. 860 =

86a

D

~ 88, I 8"~ -88e

085 86bO ~

Mounting Brdckl!t

Internal Circuit of Relay

'I. Fuel Pump Re.~,O!y

Fuel Pump Relay Inspection:

Pump rela y test iI:

Using the 12-volt. battery and ohmmeter, check the pump relay as follows:

-Connect the battery to the mlay terminals, two at a time, and check the conductlvltv between the other two terminals as specified in the fol'owpng table. -If the terminalsconduct as shown tn the table, the fuel

pump relay is good.

Fuel Pump IRelay I nsp ction

Connec Li on s Conductivltv between
No,
~ l~,Hj , lead #88 y JJ nd #B8d term ina I ~
~ #86 :lffi5 OQ
1-
2 :#:85 #So oog
3 #86<1. #85 on
~- -
4 #85 #B6a ooU
5 #8611 #85 Or.! Pump, relay test 2:

U~ing the test light, 12-voll battery J and ohmmeter. check the pump relav <15 follows;

.(0 n nect the !J a iter y + term i n al to the rei ilY #85 terminal .

• ConnCG1 the test light between the battery terminal

and the relay ~86b terminal.

OTh4:l 1iEt!t light works a5 an illlldiCIIJfor and also as II CU rrent Ii m iter to protect lin e re sinor in tn e re lavfrom ex celSive current. Do not eonnaet the battery d ireC1ly to the relavter mi nals in the upl*mp relay test 2:,~ or'lihe reS'i ster wW be bu rnt out.

*If the light goes on and the relay does not work (the terminals #BBy and #88d do not show conductlvltv), the tucl pump relay is good.

A. Test Ught (12 V:3 - 3.4 W)

B. Relay

C. 12 V Battery

NON-SCH EDULED MAIINTENANICE - ENGIINE 3-27

.",1ake sure 'III connectors are clean and tight, and none of the male pim in th connector have been displaced during the connection of the connector. Tug on the wires to see of any pins are loose, Push any loose pins all the way into the connector unti I you feci rile small locking tang catch in place,

• bam i riC wi res for sign 5 u f bu rn i n:g, f fayi ng, etc. .che,1<;. conductivity of the wires in the harness. Both ends of the same color wire should conduct .

• Check the Q.dng in the mu Itf.pirl connectors for darnage, and check the retain ing dip of the connector for deformation.

*If there are poor wires. or bad connections, replace the harness, ,

*If there are open wires, replace (he harness.

*1 f the O-ring!> or clip~ arc damaged, replace them,

Wires and Connectors Inspection

If each component checks out good upon individual inspection, but the ~y~lem does not work well when they are connected together, inspect the harness for the electronic fuel injection svsrern <IS follows-

• R em ove the h arness,

DF I Warningl FUll'lction Test

Whell the DF I ~'l~telTI trouble occurs while riding, the Df I control u ni t sends d ~igt1d1 to HH: warner uni] to warn the rider.

Warning Signal Test

-Remove the fuel tank, dud disconnect H1{; warner unit 8-pin connector.

-Conl1~ct the open ends of the fuel huses LJ)il1g the ~'~CULJm gilLJge adapter (special tool).

Olf the ends oftllle fuel hoSIl5 III'B not conn CLd 10gMI'l:her using" suitable pipe, fuel will spout from the fUlel hoses when tlhe ig",irtio~ ~witclll is turned on. Flilel spilled from the hoses is hazard OUI.

A_ Outlet Hose S, Return Hose

C. Adapter: 57001-401

.OLsconnect the igniter connecter to stop ignition ~y~tem operation.

3·28 NON~SCH EDULEID MAINTIENANCE - ENGINIE

A. lgnlter

8. Con nee tor

-Connect the ohmmeter to the wire shown in thetable, and lnspect the warning signa],

"N01iEn

oThe eats to kill rh~ ignitiori system and to pu:sh the starter switch with the ignition switch turned on if ,ro let the DFI control unit roccmgnizf1 no ignition ptl1~s reach.

*I'f the meter does not read as specified in the table, check the green/red wire and its connectors for damage. *U green/red wire and its connectors check (Jut good, replace the DF I control unit,

A, Warn,er Unit Connector ,(Mann Harness Std~) B, Black Probe

Warni no Siglllal I nspecti on

Test No.3 Fu'el System Tests; Fuel Pump Inspection

.Di~col1n1ecl the pump 2-pin connector.

.Col1necl ~ I 2·voll bauurv to 1t1(: 2-pin connector (pump sldc), and check whether the pump operates.

Con 111 ecti ngl Ba,ttery to F ue I Pu mp

I ..... ---.:......--..:;_---~....:;..-._,

Bauurv (+} .... Orange.black lead

Baucrv ( ) ~ B lei' k:'yellllw lead

*1 f the pump dlle~ not oper dLC, l'L' trouble i~ wi th the plJIl1P or pump kelu~. Check 1 he pu rup .lnd leads, and replace them if ncccssarv.

In/ector Inspection

'.1 urn off the 19n1 tlon switch.

-Remove tna 1 uel tank, arul db~prl11ccl [nc con nector rrom the injector,

-Set the rnu I umercr 1<) the oh rnrneter range, und measure the i njcctot r(;~i~telrlcc,

Injector Hesistance

for'Ieter Connccrion, Readi ng
Range
1- .
c.)One meter lead _,.
x 1 ~l One in jl'c1or terminal *"Ul 3_0 ~ ~
)O~·her meter lead - &20DC (680 F)
Orh er injector terminal *MCilSlncd when the injecto: is cold (room or ambient temperature].

*1 f the meter shows conduutivuv ,l~ ~hllwn int he table, perform th e 1 evt below.

*ll the meter d()c~ !1L)[ read ,]~ vpecilicd, replace the injector .

• Prepare an au xi liarv lead, <I 12 V 2 l 23 \\' r.lling bu Ib

with leads, and J 2·,,'oll bauer y.

'.Cun ncct rhc bul b between 1 he battery positive I:"') i errni 11,;1 and one injector term in.n.

':;Tl1e bioi I b works as a CiU rront I imri ter to p rotect the ~Q lenold n iI'I tin e Ii n~ seter 'from IlXCo(lSS i ~ e 'DU rre nt.

Meter Co n n ec ti o n s * Meter Reading (Critcrla)
Rango
OMeter B~ack (-) Probe cmQ wLth i10lnitiun switch turned on,
-+ Grccnired and before starter ~witi;:,h is pushed
(Main harness ~idL') on,
.j( won coShow~ contlnultv (less. than 100 i!)
uMcLcr R~d (+) Probe with ign L t i on sw i tch turned on, and
--.. Cha~~i~ ground after starter switch is pushed on for
more than 0.5 second. ... : Du not reverse the ohmmeter conncctlcns asthis gi",e~ dirfcn.;nt readings,

.Cnnne'ct line l'rlO III the .lUX 11,11"" le.Hi I() rhe othur inje'-IL)f tcr minul, .I d connect the .uhcr cnu (It the lead rvpcatculv to the bau crv nq~.I1I~·\~ .:, :1 ter mirul.

.·r he injruun ~h'l\..lld c lic k f'~'l!I'r rime the lead contacts to I he o,!11 cry u-rm] IHI. II the in] ector doe~ not click, replace ~ 11c in il'l tor ,

I nj ector ~ ns pection

23W

Open

• and

: Close,

NON-SCH EDULED MAINTENANCE - ENGII NE 3-291

Flilel Pressure

Condition, Rcading*
- ahou ~ 226 k Pa
Engine idling (2.3 kgit.1ll2, ::13 p~~)
-
The moment thr ut tic about 245 kPil.
i~ ! ully opened (2.5 kg.h .. ml, 36 psi] *The gauge needle will oscillate. Read d1C pressure ilt the average of the maximum and the minimum ind ications.

*1' the ~du~e shows the pr cvsur e specified in the table, the fuel prewure i~ good.

*I( the Ilh'l p cssur e i~ abuor mal, check the prussure I q~u later

+'2V Battery

ld,C 2; If the engine will not start

,.1 fhl oJtl the pressure g.:lLJ~C (~pecid! tool) in the fuel pre~~w c line ..i~ explained in the "I r I he eng1l1C w,11 srart" paragraph,

Pressure R~gulator Inspection

hi ~l mcasur l' L IC I uel pre--ure as fnlluw~; Ll~C I: If the engine' will .. tun

• Dlsconncct the hIgh pressure fuel hose from the" pres-ure rcgul.uor ,

'_;Whlln the fUll I hose is pulled off, II sma n II mnu nt of 'fl,q el may spout aut because of r{lsidual pre~S1i.1re in the hel lme. Cover thE! hose connection with .. clean cloth to prl!lIent the fuel from flying about.

-I mull 1 he prCl,surC;!iJllge I:~pecia! tool) between the pre~,urc regulator und the hose disconncctcc usi n~ the .ulupter (~pCl'ial tnol) {1 nd h lgh-pr essure luel hove,

• i ightun the hose clampv 111 the correct posi lion.

A. Pressure Gauge: 57001·125 11. A~tlr)lel: 57001-1089

C. PI cssur c Regula tor

D. High Pressure HCI:)e F iHin~

'.1 LIf n on the ignition swi Leh to run I he fuel pump .

Rc.id the pre~,UI'e &dUgC while the pump is running I he pump Cllfit inucs to run lor 5 seconds ,jflerl heIgnn ion swi Ld1 i~ tur ned on,

*11 the ~dUg~ reJJ(j, about 241 k p", {2. 5 kg/~nll • 36 psi], the fuel prC'\,ure i~ good.

*1 r the fuel pr essurc j~ abnormal, check the pr ev-urc regulator.

Check the pressure regu l.n or a, fl.llnw~:

*1 f the fuel prewure ., hl!;hN ! an the spccifled v,II UIJ~, check. 1 he fuel rc: urn I Inc (fl ('1m the pr l'~>ure rugulutor to the check valve in the l<ink) I or obstructions, and the- vacuum hose 01 the prussure r cgulator for .nr le,lk, If they prove ~U()U, r l'p1Jt~ the prcssur e regulator,

*If the fuel prcssur e i~ lower than the specified v.rlues, check .. the 'I uvl line [or obvtrucuonv [frurn the fuel 'I JP to the pump inlet] and flJCI leaks (in lhe nigh-pressure luel line). I F the line rs good, f cplace the PI ~~~u re regulator nr fuel pump.

13. V acuurn Hose

'9' (9)
I,,)
)
1. f-ucl Tank 5. fuel Hose 8. l-uel Distri buting 11 . Prc~sure Regulator
2. Fuel Tdp [low pressure) Pbpe 12. Fuel Hose
3. Fuel f lose 6, Fuel Pump 9. Fuel I njector s (low pressure)
( low 'P rC~5U re] 7. Fuel Hose 10. Fuel Hose 13, Check Valve
4, I uel Filter (hi1,lh pressure] (high pressure] 3·30 NON·SCH EDUlED MAINTENANCE - E NGIINE

Fuel Leak Inspection

I n .. pect the ccnnectionv bet ween the PelOt, vhown in the figure for ICdk~,

Fuel System Cleaning

OClean the fuel system in II well ventilated araa, IIlIld ta'k.'11 IImplll Glue there are no sparks or fl!amll anywhllra lIIaar tha working ar08, Navar chum out the fuel system when the engine is still warm. Wipe any fuel off the engine before !tufting it.

-Remove the fuel tilnk, and drain it.

.Rcmo~~ th~ fuel t.rp from l11~ tank, .:H1U clean the I uel

tap filler with d Iligh flash-point solvent,

• r lush out the 'I uel l.mk with J. hi~h l lash-potnt. solvent. .CI~;m the ilLr vent in the tank CdP with compressed ail'.

• Rcmt)~'~ the fuel pump, fuel injectors, fuel distribu Lin~ pipe, and pressure rcgulator : .irrd clean them using a high flash pomt .. olvent.

FUIl,1 L.eak Ilmpection

(1 )
(13,
tj 2: (~:
Ill'
(10\ 13.

4 _Replace Lhe I uel I iher and hove-, wl Lh ne ..... ones,

-lnSLilll the parts OF\ the mellor cycle. Usc new hose clamps,

Ftrftl Filter Inspection

Rcgu lar replacement of the fuel filter is required, but replacement ls not otherwise ncccssarv unless the filter has been damaged.

If water accumulates in the filter, clean the fuel system. See above.

T est No.4 Air System Inspect lon :

Throttle Valv€' Inspection

,-Chock. (he: Mgbl'i£ vacuum svnchronlaetlon.

.chock the throttle valve and the fast idle link mechani srn 'for smooth opera tlon .

*l f mere is any bind ing or other unusual operation ln the link mechanism, repair it or replace the throttle valve,

.s I

"NOTIE·

elf anyone of tne tnrottte va/Yes Is replaced, syncbmnize tile vstve« as explained on the p, 2·7. If the whole thra ttle valve assembly is roplaCfld .• synchronization is no t required,

Air Leak Inspection

-Inspect the connectinns between the carts shown in the figure for air lea ks,

Surge Tank Draining

Usually water, oil, etc, do not collect at the bottom 0'1' the tank. ln the event that rain water is drawn in through the air cleaner, or if engine oil is blown had .. ; pull off the drain plugs from the ends of the J rain hoses.

Ber ore in~tall1n~ the d min plugs, check. the plugs and drain hoses lor damage. I f they are damaged, replace them with new ones.

Air Leak Inspection

1··

\

\.

2

NON-SCH E DULED MAIINTENAN,CE - ENG~NE, 3·31

A. Drain Bolt

S, Surge Tank

._H ai r i ~ drawn iln throu gh ,a damaged or loosil d rai n bolt. the fuel injection system will not operitte properly.

11

11

.......

, "

9

7

'7
L Cvl lnder Head 9, Air Cleaner Housing 16. Surge lank
2. Iruakc Pipe Se.31 [Chain Cover] 17. .AI! I ernper: I ur e
3, Intake Pipe 10. Ai! Cleaner Element Scnsur
4. I urbocharger Seal (outlet] II. Oi I Filler Cap 18_ Vacuum H II~C~
5. Tu! bocharger 12, Brea th er I u bcs 19. Pressure Rc~ul..LLo!
6_ Turbcchur ger Seal (inlet) "13, Drain Boll 20. Vacuum 11-1 oxu [oin;
7, I ntake Pi pc 14_ Boo ~ l 5 ensor 21, fuel I n [cctorv
8, r:;::J,~ket 15_ DUel 3·32 INON·SCHEDULED MlA~NTENANCE ~ IENGIINE

••• ! !,,! ! III ••••..... ,. ••••••• ,.,,., ••••....... i. i i ~ II + III i '" II! II ••• II .

Evaporative Emission Control System (Californial Vehiclle)

'II if! J!! I ! "' ,., i. i j iI. oil Iii. i iI ot. Ii I i ~ Ii III Ii! II! If' II ~ LII •••

NOln-'5C hedu I ed M a i ntenan ce: liq Ll!id Napor' Separator:

Separator Inspection

.Disc·ornn~ct the hoses from the llqu id/vapor separator, and remove the separator from the motorcycle. -Visually inspect the scpMatOi for cracks and other damage.

*If the separator has any cracks or severe damage, replace it wuth a nl!w one,

Separator Test:

-C:onnect the hoses to Ole separator, and rnst .. 11 the separator on the rnctorcvcle .

• Disconnect om: u f the breather hoses from the separator: and inject about 20mL of gasoline into the separator through the hose filLin~.

_Oi~(;UrlrlCC( th fuel return hose from the fuel tank. -Run the open end of the return hose into the container level with the tank top,

-St~n 1 he engine, and let it idle.

*1[ the gd~~lli nc in. the separator CClme~ ou t or the hosv, the separator wor ks well. ~f H does not, replace the separ aror wi tn d. new one.

CaniS'ter:

Caniner Inspection

.Remm'c the canistcr , and di>I,Urir1Cl.t the noses from the can ivter .

• Vlsuallv lnspect the canister for cracks and other damage,

__ I f the canister has any cracks or severe damage, replace it with a neW one.

"NOTr

oThe (..'tmistaf is desfgnfld to work well rhrough out the motorcycle's life without dny m~intf1nfjnC8. if if ;$ used under normal conditions.

'-Jllf: {lasol lne, solvent, W<lte:r or any other liquid antars the coni site r, tin B' ca nider'~ ~ apo r abso rb i ng ca,pacily is groady wd uced, an d there i5 no"W ~ to, retulrl'l it to the or i gi nal 1.111' ~I, I n t hi at case. re pl<u:e the can iner wi th a new one.

Fuel Tank and Cap:

Cap tnsoection

_Visually inspect 1 he gasket on the lank cap r or dny damage,

*Rcplace the gasket if it i~ darnaged.

_Blow the air vent in the lank C.bP free wi ih cumpr l'~~cd air.

Tank Inspection

_Rem(J~'e [he hoses from the Iuel tank. and open the tank cap_

.check to see if the breather and fuel return. pipes In the tank are not clogged.

*Ir thevare dogged, blow them out with compressed air,

NON·SCHEDULED MAINITENANCE - CHASSIS 4·1

(

Non -scheduled Maintenlance - Chassis

Tab'e of Contents

Brakes .................................•.................. 4-2

Service Data 1-18

Wheels Base Manual 348

Sprockets .....•.............................. Base Manljal 318

Front Fork , Base Manual 366

Drive Chain .................................• Base Malnua~ 347

*If ill CUp or O-ring if> worn, damaged, sottcned (rolled) • or 5WO~ I en, rep lac c the pi stu n assern b I Y .

*11f fluid leakage is noted at the brake lever, the piston a~scmbly should be replaced to renew the cupls] and D-ring.

It( In ec k the dust COVers, r or d arnage, *If thcv am damaged, replace them,

-Check that the relief and ~upply ports are not plugged. *1 r the small relief port becomes plugged, especiallv with

a swollen or damdged primary cup, the brake pads will drag on the disc. Blow the ports clean with compressed air.

IICheck the piston return springs for any damage, ~H the spring is dam.:l1led. replace the piston assernblv.

4-,2 NON-SCHEDULED MAIIINTENANCE - CHASSIIS

IBrakes

•• iiI •• i ••••• .,., , •••• '1''' II' <ltI i i.,,,, i i ! II !I !I' 111111 I

iliilllliliillilillill.iii ••••••• r"'···,···· .. ··I'II!!JIl!llllliI,.,tIi ~!I I!.!II!III i

M1aS1er Cy I i nders:

Visual In spec ti on

-D I sassem b I e the front and rear master ~y ~ i n ders,

e(;h,e~k that there am no scratches, rust or plttlng Om the inside of the master cylinder and on the outside or the piston.

.If the master cylinder or piston shows any damage, replace the master cylinder ami piston.

-Inspect the primary cups, secondary cup, and O-rin~ om til c p lstuns,

Front l1li d Rea r Ma'ner Cyl i nden

1. Reservoir Cap 9. Return Spring n. Brake F luid Host
2. Relief Port "10. PrimdfY Cup 18. Hose Connector
3. Didphragm 11. Nun-return Valve 19. Retainer ;
4. Supply port 12. Piston 20. Grommet
5. Reservoir n. O-Ring 21. Push Rod
6. Liner 14. Piston Stop 22. Locknut
7. Brake Lever 15 .. DlM Cover 21. Sccondn y Cup
B. Ma~ter Cylinder Body 16. Plate' (

ca.ipers~

Fluid Seal Damage

The fluid seal arou nd the piston maintains the croper pd.d/ d isc de ar an cc, ~ f this sea I is no t sa tisfac lory, pad wear will increase, and constant pad drag on the disc will raise brake a nJ brake ~ luid temperature.

Ca.liper

CD

'I

II

I

I I I I

(i)

1. Caliper 6. Piston
2. Brake Pad 7. AMi-Rattle Spring
3. Brake Pad 8. Dust Seal
4. Caliper Holder 9. fluid SeJJ~
5. Dust Cover '10. Friction Boot Replace the fluid seals under any of the following conditions: (a) fluid leakage around tile pad; (b) brakes overheat; (c} there is large difference ilm left and r1ght pad wear; ~d) the seal i3 stuck to the piston. If the nuid seal is replaced, rep lace the Just seal as well, AI~o, reo p I ace all seal 5 ev cry oth er ti me lilt: pad s arc chan ~ed.

NON~CH EDUlED MAl NTENANC E - CHASSIS 4-3

Dust: Seal and Cover Damage

-Check that the dust seals and covers are not racked, worn, swollen, or otherwise damaged.

*If they show any tlama~e, replace them,

Piston Cylinder Damage

-Visually inspect the piston and cvl lnder surfaces, *Replace the cylinder dnd piston if they are badly

scored or rustv,

Caliper Holder Shaft Wear

Th e c<llipc r body m u ~[ ~I ide sm 00 thy' Or! th c cal i per holder shafts, If the body does notslide smoothly, one pad will wear rnor e than the other, pad weM win LrIere asc , and constant dra.g on tile disc will raise brake and brake tluid temperature .

• heck tu see tnat the caliper holder ~t1dh~ .irc not badly WOIII or stepped, 11I that the r ubbc: I r 1<.1 ion boot i .. not dumaged.

*1 f the shafts or ru hber friction boot arc damaged, replace the rubber 1 rlctlon boot, and the caliper holder.

Brake Discs:

Disc Warp

Refer to p, 205 of the Ba.~c Manual.

Disc Wear

Refer tv p, 205 of the Base Manual.

Brake Hoses;

Brake Line D.amage

Refer to p. 208 of the Base M.mual noting the following exceptlon.

-The metal pipes wh lch feed the brake fluid to the antidive units are made of plated steel, and wW rust If the plaring is damaged. Replace the pipe if it is rusted, cracked (espcciaHy check the finings·L or if the plating is h'ldly scratched.

NON-SCHEDULED MAINTENANCE - ELECTRICA~ 5·11

Non ~schedulled Maintenance - Electrical

Tab~e of Contents

Precautions ............•.................... " 5-2

Battery Base Manual 218

C h ar9li n91 System . . . . . . . . " . . . . . . . . . . . . . . . . . . . . , . Base Ma nus 13 70

Ju nction Box Base: Manual 36·9

Ign ltlon System " ...........................•........... 5-2

Electric Starter System , Base Manual 315

Head light System , Base Manual 376

Tachometer " Base Manual 378

Fuel Gauge , Base Manual 3·78·

lCD F uel Gauge and Warner Un it " .........•................ 5--3

ili'I" I' ii ••• iltli , •• "' ••• 11'111' .. 1 .. 1' 11.11 tt ••• , "." I. !tl!lilililiiil! ii •••••••

5~2 NON.SCHEIJUl ED MAINTENIANCIE - ELECTRICAL

Male Connllcton

Precautions

t •••••••••••••• ,' ~ .. 'FI,.'FIIIiliIIII .. ii I •••• ,.,. "'''.''' .. 11 .. 111 ,. .

Then~ are numbers of important precautions that are musts when servicing electrical systems. Though cautlcns that applv to the indications are I,i~t~{j below, fail ure to observe these rules can result in serious system damage. Learn a nd observe all the rules below.

(a) Do not f'eYCrSC the Ibattery lead connections. Tbis will burn out the diodes in the electrical parts,

(b) Always check battery condition before condemning other p,uts, of an electrical system. A fully Charged bdLtery f~ a must tor conducti ng accurate electrical system tests.

{c} The electrical parts should never be struck sharply, as with d hammer, or allowed to fallon a hard surface. Such a shod to U1C parts can damage them.

(d) To prevent dami:l,ge to electrical parts, unle~5 otherwise there is lnstruction during a test, do not disconnect the battery leads or allY other electrical connections when HH; ignition switch is on, or during the engine is running.

(e) Because of the large amoun t of current, never keep the starter switch pushed when the starter motor will not turn over, or the current may burn out the sta r ter m oto r wind ings,

(f) Do not use d meter illurnlnatlon bulb rated for other iha n Ow voltage or wattage spuci lied in the wir i ng di (l~r .rm, d, the rncrur ur !ldUlolC panel could be warped ev excosvivc hea l r d d iatcd I r om the lou lb.

(g) Take Care not W short the leads that arc directly connected to the battery positive (+) terminal to the chassis ground.

(h) roubles may Involve one or in some cases all items.

Never replace 11 defective part without deterrnlnlng what CAUSED the failure, If the fairure was brought on by some other item Of Hems, they too must be repaired or replaced, or the new replacement will soon fail agaln,

(I) Milke sure all connectors in the circuit are clean and tight, and examine wires for signs of burning, fraYing. etc. Poor wires and bad connectlons will affect el ectrl cal sy stern opel at ion _

(j) ElectriCilIr Connectors.

Familia Connl!CtQ rs

{k} Co~or Codes:

BK BL BR CH DG G GY LB LG o

P

R W Y

Black

Blue Brown Chocolate Dark green Green

Gray

l.ight blue Light green Orange Pink

Red

White Yctlow

(I) Measure coil and winding resistance when the part is cold (at room temperature),

i gn it ion System

.",,~~ lili ••••• ., ••• ,.,., !+~Ii.".ii ii •• , •••••••••••• ~ ~II ii."' ! !!I~

~ •••• , !""I.iI.".ii ••••••••••••••••• 1 .ii !.!iI i ••• '.' ••

Refer to p. 371 of the Base Mal1lJal noting the following exception.

I gn i t i on System I nspecti 0 n:

lf trou ble is suspected in the- ignition svstcrn, check the fo Ilu win g items, Befure i n ~p ec tl ng these i terns, make sure that all connectors and leads in the igl1itioFl svstcm are clean, tight, and in good condition.

LOt' nam it: I ~n i ti 0 n Tl III i ng I nspect ion

2. Checking Power Supply to Ie Igniter

3_ Ignition Coil lnspection

4. Pickup Coil Inspection

5. rc I gn iter Inspection

6. Switches Inspection

DescriptPOIil of lEach To~ting Procedure:

I. DynlJm ic Ignition Timing Insepction

Check the lgnltlon timing with a strobe I ight for bOU1 low and high speed operations,

NON-SCHEDU LED MA~NTENIANC E - ELECTRICAL 5·3

Ignition Timing/Engine Speed Relationship

(

lOG ± 1°

t ,000 rpm

10

o

2,000

4,000

~ ,000

Fngine SpNd (r,lmm)

.conned strobe light til the ~1 or #4 spark p~ug lead in the manner prescri bed by the manufacturer in order 1u c h ec k the ign i Liu n till! i n~ U rider oper atl on co nd i ti ons, -Stdrl the engine, and direct the strobe light. at the timing marks.

-Check. the ign ition tlrnl ng <It low and high engine speeds,

Chllcki nil En,gin e Speed

low Speed:

High Speed:

Idle speed

Above 3,600 r/rnin (rpm)

A_ Timing Mark B. "F" Mark

c. Ad .... anced Mar k

*At low speed, th . ~ f" mark on the timing rotor ~hould be aligned with the timing mark on the engine.

*At high speed, the Liming mark on the engine should be aligned with the advanced timin~ mark.

2. Chl1Ck ing Po wer Supply to Ie Igniter Refer to p .. 371 of the B<ls-e Man'U<i1.

3_ Ignition Coil Inspection

Refer to p_ 371 of the Ba~c Manu<ll.

4. Pickup Coillnspectiofi

Refer to p. 371 of the Base Manual.

5. «: Igniter In:wecrio(l

Refer to p, 371 of the Base Manual.

(J_ Switches tnspeatio«

Refer to p .. 371 of the Base Manua.1.

.' ...........• 11 iI ••• 1 II'.I.I I! ~ "' •• M ~. Ii' •• , ..................• , i i. i iii •

LCD Fuel Gaug;e and Warner Unit

Outlilne:

Refer to p_ 378 of the Base Manual noting the fullowing exception.

1. The DFI warner ls newly added to the U:EI warner [mit

ODF I (DF I W<lrning): Thi5 ted LCD warner consists of two segments, upper and lower halves, When the DFI system is troubled, this warner warns the rider by flashing.

2_ The oil pressure warner is Ilew~y added to the LCD warner unit The odl level warner mounted in the ZX750A'I LCD warner unit is not needed.

Gauge and Warnililg) System Troubteshooting:

ReFer ro p, 379 of the Base Mafllllal noting the folluwinl?, exception.

Test ND. ,·Quick Initial Check Refer to p, 379 of the Base M,muaL

Test No.2-Power Supply Test Refer to p, 379 of the Base Manual.

Test NO'. 3· Gaug8' and Warner Unit Test

.Prepo:lft.: eight auxiliary wires, two tv ~pply battery power to the unit, five to simulate the sensors, and one to connect to tile warning light.

'.Remove the gauge and warner unit frum the fuel tank.

(b) Sensor-simulating wires are disconnected,

Gallile arid IN -,ner Unit Test

54 NONI-SCH EDULED MAINTENAINCE - E L'ECTRICAL

* [he time delay circuit is provided ill the fuel gauge circuit to stabilize the gauge display. It takes 3 to 12 seconds for each segment to disappear or appear. Also it takes 3 to 7 seconds for the bottom segment to begin or stop flashing.

(a) All sensor-slrnulaung wires are connected.

1. Fuel Gauge: N lne segments appear. 2_ Warning Light: Unlits.

3, Side Stand Warner: Does not appear,

4. Oil Pressure Warner: Does not arrear.

5. B,attery lcctrclvte level W~rnef: Docs not appear.

6. DFI Warner: Does not Appear,

-Connect one wire between the gree'njydlow wires in tile male unit connector and female main harness connector.

e(onnect the five sensor slmulating wires w the terminals in·the unlr connectors.

.2

I. Warning Ugh t: Ftashes when any {me of sinlljlatirlg wires is dlseonnecteu

"'2, Fuel Warner; Flashes when wllite/yelluw wire is disconnected.

3. Side Stand Wilmer: Flashes when green/white wire is d isco n nected,

4. Oil Pressure W~rner: Flashes when blue/red wife is connected,

5. Hatterv Elcctrolvtc Level Wilmer: F lashes when pink wire is disconnected,

6, D F~ Warner: Flashes when grten/red wire is conn ected to bat terv {-) term ina I_

Sensc,r Si mulati ng Wire (:onnectimlS

- -
Circuit Connections
Side Stand W;arner OGrccniwhiw lead
...., Batterv ( )
DB Pressure Warner oBlueired lead Bdttery ( )
Battery Electrolyte 0Pink Iead __., Battery (+)
Level Warner
Fuel Gauge and oWhitc,IY 'Jluw lead
W,uner -+ B~t1:NY ( )
~
DFI Warner oG ree n/red lead -+ Open NON-5CHEDULIED MAINTENANCE- ElECTIRtCAL 5-6

.U~ing the wir es to supplv batterv power to the unit, con neet lilt: brown term lnal ill the connector with the batturv povitive (+) terminal and connect the black! yellow term inal in [IH." connector with the battery negative ( ) terminal.

oTake Cine not to sl10rt thoe wtres to the chassis 'grOlllnd.

*Whcn the unit is connected to the battery, Lhc sellcnce kin ~ procedu re sh au I d s tart. A he r t h e proccd u re is completed, the gauge and warner di~play shou ld be a~ ~hown. I f the ~I t-checking procedure did not vtart, or if there i$ dny fault on the displll~'; replace th gauge and warner unit.

-Oisconnect one uf the sensor simulating wires from the connector,

*If both UiC LCD warner and the red warning light flll~h as shown the unit works properly, Proceed to the "Test No. 4.Wiring and Connect-or TeSL" If any of thorn does not flash, or if anv of them ~lay~ on without na~hing. replace the gauge and warner unit

WirirnQ and Connector Ten

Test No.4-Wiring and Connector Test -Set ihe motcrcvcje on the center stand,

'.Connect the rnu ltimeter to wire in the disconnected female connector (main wiring harness side connecter) as indicated in the table and read] the meter, Wh'iim checking the wiring for the fuel g,auge and low Fuel warner, disconnect the fuel level sensor connector.

*If the rnultlrneter does not read <IS shown in the table, first inspect the related wire(s.) and connectcrtsl, then repair or replace the damaged partls). I f the wlrels) and connectorls] prove good, proceed tothe "Test No, 5-Sensor Te'5l"

Test No. 5,Sensor Test (a I Sid e S:t8 fll.d SWitch:

.l)i~connc"Ct the side Hand switch leads,

.Zero the ohmmeter, and connect 'the merer to the switch leads. as mdicated in the table 'to check the switch operation.

*If the meter does not read as indicated in the table, check to see that the ~ude stand switch is properly in'5lalled on the fir .. .tne. I f the switch is not eorrccnv installed, re-mount it correctly. If the swltch ls correctly mounted, replace the side stand s.witch,

Wire Meter Cormectlons ! M cter Read i ng
R,mg1..! {Critcria)
OOnc meter lead __,. 00 n when side stand is up.
Side Stand X 1 Q Gn.·cn,h",'~)ilC wire
Warner' <Other meter lead -+ OX> U when side stand is down.
Black/yellow wire
t.O ne nil: ter lead -+ 00 n whe n e I1Igi ne 0 II p ressu rc is lower t ha n the spec-
D i I Pressu re )(10Q Blue/reel wire lfled value,
Wamer I cOther meter lead Co<> U when engine oil pressure is. much higher than Ole
Black/yellow wire speci Ilcd value.
I C;\oteter (+) OM ore th <In 6 V when electrolyte level is higher than
Ballery lOV DC Pink wire "lower level line."
electrolyte OMetcr (-) 00 V when electro! yic level is lower than "lower level
level warner BI;ack/yellow wire line."
Fuel gauge oQn~ meter lead -+
WhdtetyeUow wire
and low tuel x io n cOlht!r meter lead -+ C(l5 11Sn
warner Black/yellow wire [
DFI Refer W "'Warning Function Test" in the DF II System section,
warner lb) Oil Pressure Switch:

Refer to p , 188 of the BafJe Mamlal.

5-6 N'ON-5CHIEDULED MAIINTENANCE - ELECTRICAL

Side Stand Switdl Operation

[eter
Range Cunnections Meter Readl ng (llil ria)
x I U ('...(Jne meter lead Brown sw!tch lead (.)0 Q when 1 he side ~t~nd ls up.
OOther meter lead -t. Green/whLte switch lead c- n when the side stand is down. (c) EI ectrolyte Level Sell'llilDr:

Refer to p, 327 and p. 364 or the Base Manual.

(d) Fuel Lovel ~ntor~

Refer to the nFuel ,Level Sensor TestW on p, 327 of the BaS(: M aneu I.

{ol DFI Sensor:

Refer to Warning Funcrion Test" in the DF I System section,

DISASSEM6L V - ENGINIE 6·1

Disassembly - Engine

Table of Contents

DISASSEMB L Y WHICH CAN BE CARR reo OUT WnHOUT ENGtNE REMOVAL

Precautions •.•.••.•.......... "."." •.•.•...........•••• 6-3

fUEl.. SYSTEM

Fuel Hoses " . , . , . , . , " , •.•...... 6·3

Fuel Tank, Fuel level Sensor , • , .............•.• 6-3

Fuel Filter , , " , .. 6·4

Throttle Valves, Fuel lnjectcrs,

IFue~ Distrl outing Pipe ., , , . , , , , , .. 6-5

Fuel Pu mp " . , . , . , .. , . , , , , . , 6-8

Pressu re Regu later . " " , . , . , . , , . , .. 6-8

Evaporative Emission Control System" ....•.• , , .. 6-9

AIR SYSTEl\t

Surge Tank, Air Cleaner Housing " " " .• " •..... 6-9

F.LF.CTRONIC CONTROL SYSTEM

DF I Control Unit "."., ....•........... "." .. " ,,6·11

Th rattle Sensor ." , " " "" ....• "" 6-11

Engine Ternperatu re· Sensor" .. , , .......•..•....•.•••••...•. 6- 111

Fuel Injection System Harness , ,,, .. ,, .............•. 6-~ 2

Relay "."",., " .. " .. "." ,, .6-12

01'1-11rt_.R

Tu rbocharqer "., •...............•. , • , 6- 12

IMuffler , , . , ..•... , , .. , .. " .. , " 6-12

~gllition Coils .. , , . , , Base Manual 51

ENGINE TOr END

Camshaft Chain Tensioner . , , ' Base Manual 275

Camshaft: " " ".".".,." ,,, 6-13·

ea m sh aft Sproc kets . . . . . . . . . , . . . . . . , . . . . . . . . . . .. . . . . . . 6- ~ 5

Cy Ii ndar Head " " Base Manual 51

Valves, Valve Guides .•.......... "." .. " •. " .. Base Manual 58

Camsha,ft Chain Guides " Base Manual 159

Cylinder Block Base Manual 168

Piston, Piston Rungs Sase Manual 62

6·2 DISASSEMBL V - IENIGINE

ENGI I': LEFT SIDE

En'gine Sprocket Cover Base Manual 65

Engine Sprock,e1t Base Manual 66

External Sh j,ft Mechanism .......•........ , .. Base Manua~ 67

Neutral Switch , . + ••••••••••••••••••••• Base Manual 68

StaM.er Motor + • + , •••••••••••••••••• Base Manu~1 6,9

AI tern alar State r .. . . . . . . . . . . . . . . . . . . , . . ... Base M,anua I 70

AI tern ator Roto r . . . . . . . . . . . . . . . . . . + • • • Base Manu al 71

Scavenging Oil Pump 6·15

ENGINE RIGHT SIDE

Pick-Up Coil Assembly , , , 72

O~I Pressu re Switch + •••••••• , ••••••••••• Base Manual, 74

Clutch Release Base Manual, 351

C I u tc h . I , ~ h • ~ M ~ , • ~ • u .... ~ •• ~ • ft • M • MM. • ~ ;; iI ~ iI ~ ! ~ • , • ~ • ~ • • .6 ... ' 5

ENGINE BOTTOM END

Dill Fllter, Bypass 'Valve ...........•. + •••••••••••••••••••• 6·4

OU Pam, Oil Pressure Relief Valve IBase Manual 77

IEngine Oil Pump Base Manual 77

Secondalry Shaft,. Starter Motor Clutch .. , ....•. Base Manual 78

Starter Met,or ldle Gear " ., Base Manual B,2

ENIOI NE REMOVAL

ENGINE ItEMOV At

Engline " , Base Manual 305

DISASSEMBLY WIH~CH CAN 61E

CARFU 1:.10 OUT AFTEIR IENG I NE SPLIT E '. GINE SPLIT

Crankcase split ............••.•............ Base Manual 89

Transmission , , Base Manual 351

Crankshaft, Camsheft Chain,

Primary Chain Base Manu61 103

Connecting RodS " ., ., ' ......•.. .Bass Manual 351

Precautions

.Set the motorcycle UI) on ttl; center stand so that it is stable during removal and installation operations,

-An arro .... mark i~ placed on some parts. The arrow shows ei th er the ortentatlon or the direction of rotation (if it part.

I ~ the arrow mark ~huw~ 01 ientatiorr, install Ull! PML so that the arrow points fnward the front of the motorcycle when it is installed,

If (he ::irru\~' mar k ~huw~ oirection of rocanon, in~tJII the part ~u th.H thc .n r ow rrurk coincides with the rotational direction .

• For later in~1.~II~ tion convenience, note and record how and when: cables, wiring, and hoses are routad. They shou ld not be allowed sharp bends, kjnking or twisti ng, .ln~t~11 the gaskets in the correct po-ition JJl1d direction

so that the-y perfectlv mal ch wi th the rnarmg surface-, where thcv arc tl_1 be i nsra lied,

.Before assern bl in~ parts, wear an eve protector, and blow the 0'1 passages III the parte clean with com pressed air.

oWhon any fuel hose is dlseorrneeted, do not tum on the igrnl iti on swi'tch. Tho fUll I pu m p will op erate and fu el wi II s po~ t from the fU11l11 hO$o if Y'OLl ttl rn on the igni. tion switch whi Ie the hose is dl ~con n.ecte d.

Fuel Hoses

••••••••• , .................• lilii!l ... ~ •• ~~ I.! 1i.1'f- .... ~ •• I.! !.!~ .. ~! •• !.~y ••••••••• ' .....

Removal:

Fuel Hose Removal Note

~w IlIRn the til el hose-s 8 re pu lied off, a small .. meu nt of fuel m<!y ~pO'lJ tout becau SEl of res idu 81 p reSSIl rE! iln t hie fu el Ii ifII e. Cover the hose con I1Rctio!ll wi 1h 8 cI ean clot h to prevent t he fUll i from 'fly i ng ilb(U.lllt.

DISASSEMBLY - ENGINE 6·3

Install ati on :

Fuel Hoses Installation Notes

anne inner surfaces of me high-prc~~Yrc fuel hoses are coated with a special material, I r th;~ ~pc{;idl Id)it:1 i~ d a m aged, r~p lace th e hose wi th anew one, ~\hu replace the hose if ~t ls ~hi1rply oem or kinked,

ODi~ard the old hose 'L~.mp~,al'ld usc rlCW clamps when assern b ling the sys tern.

OR,oule the fuel h05C~ wi in a III inirnurn uf bending !>O that the fuel flow will 110t be obstructed.

Dlmta.1I the clamps for the high-pressure fuel hoses in the position indicated in the figure below.

1, Fuel Hose

3. Pipe Dr Filling

2, Clamp

Fuel Tank, Fuel Level Sensor

fuel Tank Installation Note

oeo n n ~c t [he fuell hose, wh lch comes fro m the press L.U re regulator to the check valve: and connect (he fLJ~1 hose, which comes from the fuel filter, 10 1 he fuel tap,

6-4 O.SASSEMBLY - EINGINIE

A, Fuel Tap (To Fuel Hose]

B. Check Valve (10 Return Hose]

C. F lJ el Sensor Lead

D. Drain H()~~

A. H ose From pressu re R egu 101 tor B, Hose to Fuell Filter

Fuel Level Sensor Removal

-Remove the fuel level sensor cover and breather hose by prying the cover flange,

.Remuve the bolts (6), and remove the sensor, Be careful not to bent! [he float arm.

A Float

S, Arm

Fuel Level Sensor lnstsltetion Notes

.Mald; the bolt holes so that the rlUott is positioned directly forward of the sensor body, Fioat movement will be hindered in any other position,

_Replace the O.r1n.g with a new one If it is swollen or otherwise damaged .

.check fur fuel leaks after in~t<LWng and fiHiDlig the tank,

•• ,. I~ ~ ••• "' ••••••• I11 ••• ,., •••• "'~ij+~! ' i!l~ ~!.~ ••• IIl ••••

Fuel Filter

..... i++'!" !.!."' ••••••• "' •••••••••••• ",,,.11 .!!."', •• '" I,.il·;O ••• .. •

Removal Note

.Rt;rnuv~ ihu fU I. ~ide cover before- fuel filler removal.

I WARNING I

aP,erform proCOOIJ res ina we II "entBlteci IIf(l8, and take Glue tih at the re n ~ 1'10 spark 0 r 'fIame a l'Iywh!lN' ne ar the work.ing area.

A. FHe~ Filter

R. Fi Iter Clamp Bdnd

Installation Not«

ctn Older 10 feed 111e fuel pump with fuel quickly al tci running out of fuel, obse ve the follnwLng:

1, I nstall the r iller SD lhotl the "I N" sidu i~ uri top.

2, Install the fuel hove to the luel pump un U1C lower fiuing lmarked "OUT"), and the hose from the 1 uel lank on the upper riltill~ (marked "IN")

F ue I F ilte r I nsta Il<lIti on

Top

From Tank ¢

To Fuel Pump

Throttle Va Ives Fuel lnjectoss

Fue~ Distributing Pipe

Removal:

Throttle vstve Remove! Notes

Fuel ktiector», and Fuel Distributing Pipe -R~mcwe the fuel tan k and surge tan k,

-Rcmcwe the throttle valves, fuel tniectors, and fuel dis-

tri butlng pjpe as an assembly! and then separate them.

000 not damagll ilnj aetnr nozzlll1l5. A dama,~d nOilzllo will advenolv affect the injector performance.

A. I ruector

B. \lua'c

DISASSEMB,L Y - ENGI N E 6-5

I ",slallation :

Throttle Valve Installation Notes

Fuel Injectors, and Fuel Distribut{ng Pipe -Chec k the seal and dam per fo r de ter i ora tion or oth er damage, and replace them i1 t1l:C(;~~.aFY •

.ab~er\lc the "Fuel H05e lnstallation Point" (p. 6·3), .Tighten the injector mounting bolt (8} lu 4_9 N-m (O.SO kg-m, 43 in-lb] of toruue.

.Tigt1tcn the hose clamps after all inj(lctor~ and tuel distribu ting pipe are correctly positioned in place.

.The Iour fuel injector 2-pin connectors differ in the length of their leads. The cvl inder number is marked on the lead sheath,

-I f the throttle sensor position i~ al tcrcd, adjust the sensor position using the po~i lion checker (special tool). See p, 3·24.

-~ f the lth rcttl e .... al ve is rep I aced' , sy nc h ron i ze the en &1 n e i nta ke vacu u rn, and ad just th e thro ltl~ se n sor position using the position cheder (special tool). See p, 3-24.

-I r a throule valve or the whole assernbly is replaced, adjust the fast idle engine speed after engine intake vacuum synchronization, and throttle sensor position adjustment, Engine speed should rise 10 about 3,000 r/min (rpm) when the fast idle lever is pulled up fully with the engine completely warmed up, I f it docs not, adjust ra~t idle speed by tumlng the adruslin~ screw,

A. Fast Idle Speed Adjl.l5ting Screw

D ilsassell1bly and Assembly:

Throttle Valve Assembly Notes

.Rem ove th e clip ,,·u from th e fas t id le le v e r Soh afU 7 : .

• Remove the screw 'II , <lind pull off the fast idle lever shaft. The positioning sprnng'll • ball 41 , and washer 19 will filii off .

• Remove the Four screws J~) and i~l, for each valve, and separate the valves ·9), 'I 0, '11,. and I~ from the moumlng frames 5and 6 .

Fuel bljeetors

6-6 DISASSEMB,L V - ENG liN E

Th~ottle VailliiS

1. Injectors 2" Seal

3, Damper

4. I nicctor Holder 5, Plate

(j. Bolt

7, Protector

." Throttle Sensor Bracket 2, Bracket

3. I ast I dle earn

4. Bracket

5, Moulnti ng Frame 6, Mounting Frame

7, Fast I eilid Lever S h art 8. Throttle Stop Screw 9, #1 Throttle Valve

10. :#!2 c~ ~lro rtle Val ve

11. #3 Throttte Valve "12, #4 Throttle Valve 13., Throttle Sensor lA, Cable Bracket

'1 5. Bal ance A dljll s ti ng Screw '16. 3·Way joint

17. Screw

1 8. Lee kriUl t

19. Nylon Washer

20. Wa~her

21. Washer

22. Collar

23. Clamp

24. Clamp

25. Pin

26. Tube 27, Tube

28. lube

29. Plug

30. Spring 31, Spring 32, Spring

33. sprtl1lg

34. Screw 35, Screw 36, Screw 37, Screw

38. Screw

39. Screw

40. Orcllp

41. Ball

Fuel Distributingl Pipe

IFuel Feild and Return Hoses Route

,.r::4'.

~._ I

OISASSIEMBl Y - ENGIINE 6·7

1, IFuel Di~tributing Pi pc 2. Clamp

3, (Feet! Hose)

4. (Return Hose)

5. Hose 6, Hose 7, Hose s. Pump 9. Filter

'I 0, Pre~~uFe Regulator 11, Check Val~'e

12. ut

13. Screw

'14, Regulator Holder 15, Clamp

16, Gasket

17, Clamp

1 B. Clamp

1 s. Fuel Return Hose Guide

1. Feed Hose 2, Return Hose

:3, I njector (No. 2: Cylil'lder} 4, Protector

6-8 DII SASS EM Bil Y - ENmNE

Fuel Pump

Removal:

Fuel Pump Remo ve!

-Remove the battery case before fuel pump removal.

-The luel pump i~ secured by the screw and holding

plate.

A. Hose (to fuel d istrlbutlng pipe) C. Fuel Pump

B. Holding 'Plate D. Hose (from filter)

Installation:

Fuel Pump Installation Notes

.ebserve the "Fuel Hose lnstallatlon Point" (p, 6-3).

-If <J. new fuel pump is lnstallcd, Meed the air in the [ue] lin o before' start i ng th e engine,

«:hcck to ~~ if the fuel tan k is fu II, If not, top u:p the tank,

oTurn on the ignition switch to operate the fuel pump, When the fuel pump stops, tum off the swi tch and nn n it on again.

ORepeat the prevlous step <I few rimes. uTurn off the switch.

Pressure Regulator

Removul:

Pressure Regulator Removal

.'The pressure regulator is installed under the th rnttlc Y<l1 VC"s,

A. ~ hrottle Valves

B. Mounting Nut

C, Pressure Regu late r 00, Return Fuel Hose

(to tank)

'L Fuel Hose

(from distributing pipe) F, VaCUlJm Hose

(from throttle valve)

In stalll,a1 ion:

Pressure Regulator Installation

-Observe tile "I uel Hose Installation Pclm " (Pg_ 6-3)

-Install the regulator holder ami rllel return hose guldu

on the pressure regulator.

.Tighten the regulator holder to the bracket with screws, set the screw closet 'it to the circle in a groove,

FtI!@J~ atur Bracket IIIIUiillllt len

l'~-

, t. A t----J§l._ I 0 L. ,:

1+- ~.,b -., :

2 : .... r====--- - :;:;"I. ,

I I ""__ ... "

i I 1-

.I II I ._L

... I \ ~----r'3

_ _jJct-=- _j

~~

I. Fuel Return HQ5e GUIU(' 3. PIC~~llrl:' Regulator 2. Regu ator Holder

-I-Iold thctucl r cturn hose with the guide,

Fuel Return Hose Guide I nstalletion

I. Guitk

2. FlI~'1 Rctur n I k)~~'

1 ii. •• II '" I! I! i. ot; •• "." iii i III ." .

Evaporative Emission Control System (CaUfornia Vehicle)

,.;to .. , I ••••• "' ., i I. + II'" ~ ., ••• '" III "'.,. "' "' •••• i .. ii' I"" ~ ••

D i sa ssem b~y and A ssembl y :

Bemo vst Note

.w h en the fu el tim k i ~ rem oved, breathe ran d retu r n hoses shou ld be disconnected from the tank,

Installation Points

-Hold UH: separator perpendicular to the ground,

-Connect ttH: hoses <If> shown in the figure. The front

hose fitting on the fuel tank is tor the fuel return hose, and the rear one i~ for the breather hose,

Evaporative Erni!s~on Cont",ol System

r+>:

I

l FUEL TA~N_K~~_

sLUE

DISASSEMBL V - ENG I NE 6·9

II '"! ••••••••••••• I~~ III'.I1 ••• , ~ 'I~"'''·········· •• ;!~ t!!.

Surge Tank

Air Cleaner Housing

I!;I II + I!! ••••• , ••• .., ••••• i 1;0 ~ ••••••• "'II •• 11.1- .. I ~. I! iii;o,!·· •••

Surge Tank Removal Notes

'.Remo~c the following parts before surge tank removal. olntake pipe (from turbocharger)

OSu~ gc tank cover

<Boos t p rC55U re ~e n sor

c-:Mail1/pump relay

oAir temperaurrc sensor

A. Surge Tank

B.. Smge Ta n k Cover

C. I ntake Pipe {from turbocharger] D_ Boost Pressure Sensor

E. Mil ~nj F ue ~ Pump Relay

A. Surge Tank

B_ Surge Tank Cover

c.. Ai,r Temperature Sensor

Air Cleaner HDusing Removal Notes

-Remove the following parts before air cleaner housing

removal,

05hifl pedal llnkage

:)1 ntakc pipe ilod gasket o Breather tu b c

cAir cleaner cover

c lement bolt arid element

-loosen th e starter rn etor cover rno u nti n El bolts '. Rem eve the air de a n er ho u sl n g m ou n ting Dol ts.

6·10 DISASSEMBL V - ENIGINE

SU~l!Ie Tanl< and Air 'Cleaner HOIlISing

l , Breather T IJ b e

2. Tube

3. Air Cleaner Housing {Chain Cover]

4. Air Cleaner Element

5. Element Bolt

6. Gasket

7. Screw

B. I ntake Pipe 9. Claenp

"10. Turbocharger Seal (inlet) 11. Turbocharger

12 .. Turbocharger Seal [ou lk1)

13. lntake Pipe

14. lntake Pipe Seal 1 S .. Intake IPipe

16. Duct

17. Bolt

18. Air Temperature Sensor

19. Bolt

20. a.RIng

21. Surge Tank (frunt)

22. Grommet

23. Wa~her

24. Belt

25. Gasket

26. Surge Tank (rear)

27. Bo~t

28. Grommet

29. Pipe

30. Surge Tank Cover

31. Screw

Apply Non·Pormanent Lockl ng Ag:e ni to :

(29)

\ ~

",,' ~~,28)

"f-rl.

\

drl

':Whllll ,aonnectingl the pipes ( GJ). @. @ I. make Sure the foliowillQ to prevent air leeks,

C"lnsert the pip~s ( @ . @" @ } inte the seals f @. 6.j), rJ] ) u ntill th e ridge 0 n it fit into tine groove of tho 5,[1 a II ~~urely.

·)Clean the inside of the soah Oind outside of the pipQ~ Yo! I tll1 an oil! ess h ugh Hash point ~oli,l'eflt.

1. Clamps

2. Seals 3, Pipes

4. Connectlon of ridge and groove

DFI Control Unit

••••••••••• 1Il ••••• Ii •• i i ti iii III '" ~. I 111.illll III·!! " •• !! .

Removal Nores

-Turnl off the ignition switch, and disconnect the whitel red fuel injection system lead from the battery positive side .

• lih:m oved th c seat,

.slide the rubber dust cover ou l of position, and pressing in the lock on the 2'I·pin connector, pull the connector ~traLght uff the cornrol unit.

A. Lock

'8. D4~t Cover

C. 21-Pil1 Connector D_ Control Unit

installation Note

-Fit the dust cover properiy on the control unit .

• Ii Ii -Ii Ii II 'II!!! "'_! •• I ••• 1Il Ii Ii. II.III.! 1Il •••••••• ., Ii i. i' Ii Ii II II ~ ~ .

Th rottle Sensor

...... ii ii 1i •• ;t;.I! II! ~ ", r. _ , iII •• Ii I .. I. 1" ,.1 iI Ii •• Iii_ !._ Ill •••

Removal and lnstettetion Notes

olf the sensor position i~ altered for any reason, adjust the sensor position u~ing the posi tlon checker [special tool). See p_ 3-24.

oUS model ontv: Each thronle-scnsor-cover screw is scaled with- Of plastic plug, Arter the throttle sensor posl tion i~ adjusted correctly, seal the screws with new plugs. Apply bonding agent ro the circumference of each plug.

IJ ISASSEMBI..Y ~ ENG INE 6·11

Seal PIUlllmltalllltion (US modell~

A: Detailed

1. Seal PI'l~&S

2. Sensor Cover

3. Mounting Bracket

•••••• ., i. nIi iii 1,,1 I! I "if!.t ihilili I i .111;,.. I •• ' I

Engine Temperature Sensor

........................ i. ii III Iii. 1'!!'11! II!!' ,_ ilili ••• II il4

tnststletio» Note

-Tighten the sensor to 13 N-m (l.3 kg-rn, 9.5 fUb) of torque.

6·12 DISASSEMBLY - ENGINE

A. E nlli ne Tempe r atu re S ensor

Fuel Injection System IHlarness

Instal/lltion Note

eBe sure to connect the two fuel injection system leads (blackfgr~en and black/yellow) to the battery negative side, and black lead In the starter relay.

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....

A. Black/Green and Blac;k/Yeliow Leads

B. Battery Negative ( ) Lead

!t ~~"IIf.", ••• " ••••• , •••••••••••••••••••• ~ ~!'I't !iii •• 1 ' '"'

Re1ay

i. i '!I •• !!!tlll II II iI- III. II , •••• ., ., ••• '"' '!I' •• I"." III!-'Ii III

Installation Note

Glnstalr the black connector on the m8rk ing side (black line).

A. Relay

A. Relay

B, Black Line

Tu rboclharger Muffler

Removal:

Turbocharger and Muffler Removal Notes .Removc the Following psrts bc'l ore turbocharger

removal.

Co ower cowling cCowlirilo: ~[ay ::;$ide cowling uShift mechanism

oAir cleaner intake pipe {See p. 6-9). oAir cleaner housing (See p, 6-9). c'lntake plpes (See p. 6-9).

C'Mu ffI.er bodY5 (R.H. & L.H.)

-Remove the barrio bul: II which connects the oil p ipe il~' to the ail pan and cl.dlfrip ~I which connect .. the oil huse 2<' to 1 he su b oil pan (5~1.) p. x-xx],

-Remove the e ..... haust pipe holder lightening nuts 4 , the turbocharger mounting holt ie and the boll 23 wh lch fixes the connecting pipe 2~ to the oil pan,

-Remove the exhaust man lfold 5 !' the turbochar gel' 9 and the exhaust pipe ~5 J.~ an assembly.

-I{cmovc from the turbocharger 9 , the exhaust manifold 5 , the connecting pipe 25 • the oil pipe I ~ and the elbow 19 with the oil hose 1;' and the turbocharger seals (inlet and outlet).

II nstall abo n :

Turbocharger and Muffler installation Notes -Install the oil pipe 1 ~. elbow:' ~! oil hose 21 and damper

'I': onto the turbocharger 9 _

(~'Take CIiFe to iostall th,g oil pilpe 1 ~ in the eorract direC1Jiof1 {See p. 3-6L

-Illstati the exhaust ma ni Iold S Uri rhe turbn .. charger 9 , .T8ITIp,-H,HLly in~t,111 the turbocharger 9 I exhaust manifold 5 and the cunnect.mg p ipc ~~ on the engine.

'-)T.akc ~"e to msert the oB scrllen '~ i 111 the ecrrset dhecticn into thebanjn bolt 'IT.

.Tighten the above components to the engine with a correct torque in the I ollowlng order.

Ca.m!h aft Ch ai n Ti m ing

l2:

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OISASSEMIBLY - ENGINE 6·13

(fl lghtcn the exhaust pipe holders

Olmldll the connecting pipe IlS on the oil pan. 01 mull the turbocharger 19 on the crankcase. 01 nstal' the banjo boH 11 on the oil I'la,n.

01ighten the connecting pipe ~~ ami the turbocharger 9,

OTi1is pH:mechllrEi i:5 oxtremelly importalilt and must be pe'rformed correcdy.

.1 rtstall other removed parts,

CWhen i n!tall i nil tn e intake, rpiPll' leals onl Elt and 0 u'i:let), rem Dye any 9 male 'from tihe' ,Iud !il:nfllal to prEil/ont the pipe from beillg d ilsengaged.

II io"; I i +t'" I '" i ~ I '!-!' II II II • II II II II II II II II ,.'" II II II '"' II" II III II! II

Camshaft

••••••• "'.IIII,.I ~ ~~ •••••••• ItI.f;i.iI-~ I~ •• IIIIIII ••• •• ••••••••• "' •••• IiIi •••• ,t;

Ramo,va.:

CamshBft Removal

Refer to p. 53 of the Base MJJnQ..UaL

I nsta Ilation:

Gamsh.a ft Installation

Refer to p, 53 of the Base Manual noting the following exception.

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I_ IN Mdrk 2. Inlet Camshaft Sprocket

3 _ Camshaft Chain

4_ Cylinder Head Upper Surface 5, Exhaust Camshaft Sprocket s. ZGEX Mdl h

6-14 DISASSEMBLY - ENGINE

Turbochiill'ger and Mufflier

"~

1. Gasket

2. Collar

3. Exhaust Pipe Holder

4. Nut

5. Exhaust Manifuld

6. Stud

7. Gasket 8, Nut

9. T erbcc h arge r

10. Mounting Bolt

11. Damper

~ 2. Banjo Bolt. 13. Gasket

"14. OUI Pipe

15. Oil Screen

16. Gasket

17. Banjo Bolt

18. Gasket

19. Elbow 20'. Bolt

21. Clamp

22. O~ I Hose

23. Gasket

24. Bolt

25. Cormec ling Pi p c

26. Washer

27. Spring Washer

28. Mounting Bolt

29. Gilftket

30. Clamp

31. Bolt

32. Muffler Body (R.H.)

33. Muffler B.ody (L. H.)

34. Damper

Tightening TorqulI:

Nut IS' Banjo Bolt 'Itl, It Mountingl Boli!: (18,

20 N·m (2.0 kg-m, 14Ji· ln-lb) 20 N·m 12.0 kg-m. 14.5 in-lib) 20 N in (2.0 kQl-(n, 14.5 in-Ib)

"' ••••••••••• ,. i",j i il.- ii '" '" .. _ '" ••••••••••••••••••• .II! •••• ~ II. III ! '" '"

Camshilift Sprockets

1"'" •• ~."' ••••••••••••••••• 11 •••• 11" .. ", •••• ~ 11.1'"

RenlOv.d:

Camshaft Sprockets Removal Refer to p_ 56 01 the Ba.~ \otM-nU~.L

l nsta I tatlo n:

Camshaft Sprockets Installation

Refer to p. 55 ul the Base M:mual noting [he fullowing exception,

Camsha,ft Sprocket I nstaUation

,

I

- I

@/

/ /

(1)

1_ BoH I ~ule for I nlet Camshaft

2. Bolt Hole for Exhdust Camshaft

.. , ~.~ ••••••••• , •••••••• ,.i •••• 1 .iito.~. 1i1."'''';1 •• 1 III! ··!!!! .! , ..

Scaveng inO 0 il Purn p

~~ , ilII ii ~ 111. liillllo.IIIII'I'II! ~!.~ ••• , .

Removal:

Scavenging Oil Pump Removal Notes .Remove the shift mechanlsrn .

• Loosen th e 5 ta rter cover mou n ti ng be I ts.

-Lomien the clamps which tighten the s.cal connecting

the air cleaner intake pipe with the turbocharger. .Unsc;rcw the air cleaner intake pipe mounting screw, • D 1 sconnec t th e b rca th or tube.

-Remove the air cleaner housing,

• Re move the sea vengl ng oil pum p rnou 11 tlng hoi ts,

DlSASSEMBLV - ENGINE 6·15

A. Seave ngi rig Oi1 Pu m p

B, Mounlin~ Screws

I nstaUa.t ion:

Scavenging Oil Pump Installation Not»

.When mounting the scavenging oil pump) note the position of the notch on the oil pump dnve secondarv shaft and then turn the oil pump shaft ~o that it 'will fit into the notch.

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A. Secoildary Shaft S, Notch

C. SClIvcngi rig 0 i I PIUi m p

D. Shaft

i i II "'II' ,,. II ••• , II II I ~. III" II ~ 111 ••••••• I j '1111 II ••• '" •••••••

Clutch

.~ ••• ili 1'111"' i' ii ""'1" I~. !!.~ i .ilill • ••••• ..

Re1 er to p. 351 of the Base Manual noting the following exception,

6~16 DISASSEMBLY - ENGINE

Removal and I nstallatton:

Clutch Installation' Notes

,.To Install the dutch plates in the clutch bub install the frlctlon plates (8) and steel plates (7), starting with a fri ctlon p late and altern atln g them,

~NOTE~

oF/rst, Inswll th~ !Ri ven friction plates flttingrne nmg.s f} f plates in the groo veti ® in the clutch bO'lJslng. A nr1 then, install the last one .fitting the tangs in the grooves @ in tht! housing.