Kawasaki ZZ-R1100 Motorcycle Service ManualQuick Reference Guide General Information 1 Fuel System 2 Cooling System 3 Engine Top End [4 Clutch 5 Engine Lubrication System 6 Engine Removal/installation 7 Crankshaft/Transmission 8 Wheels/Tires 9 Final Drive 10 Brakes 11 Suspension 12 Steering 13 Frame [14 Electrical System 15 Thia quick reference guido wil ssiet you in Appendix 16 tere he pages back oath he Back tab Supplement — 1999 - 2001 Models | 17 of the desired chapter number with the black tab on the edge at each table of contents page. ‘eRefer to the sectional table of contents for Ine exact pages to locate the specific topic. required.LIST OF ABBREVIATIONS. A ‘ampere(s) Ib pound(s) ABDC _ | after bottom dead center m meter(s) AC alternating current min minute(s) ATDC | after top dead center N newton(s) BBDC — | bofore bottom dead center Pa pascal(s) BDC bottom dead cenier PS. horsepower BTDC | before top dead center psi pound(s) per square inch 6. degroo(s) Colsius ' revolution pc direct current rpm revolution(s) por minute F farad(s) TDC top dead center Fs degree(a) Fahrenheit TR total indicator reading ft oot, feet v volt(s) ‘orar(s) w watt(s) h hour(s) o ohms) liter(s) This warning may apply to any of the following components or any aseombly containing one oF more of these components: Brake Shoes or Pads CCluten Friction Material Gaskets Insulators WARNING. ‘CONTAINS SAFETY INSTRUCTIONS ASBESTOS ecg Raa eOperate if possible out of doors or in a well ‘Sensor ventilated place ve heath ePreferably use hand tools or low speed tools ‘equipped, if necessary. with an appropriate dust extraction facility. If high speed tools are used, they should slays be so equipped if possible, dampen before cutting or driling. @Dampen dust and place it in properly closed receptacte and dispose of it sately. Fotow stew Read OWNER’S MANUAL before operating.EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable reaulations of the United Statos Environmental Protection Agency and California Air Rosourcos Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only. 1. Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vopors are routed through an oil separator to the intake side of the engine. While the engine Js operating, the vapors are drawn into combustion chamber, where they are burned along with the fuel and air supplied by the carburetion system. 2. Exhaust Emission Control System This system reduces the amount of pollutants discharaed into the atmosphere by the exhaust of this motorcycle, The fual and ignition systems of this motorcycle have beon carsfully designed and constructed to ensure an efficient engine with low exhaust pollutant levels. 3. Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere Instead, fuel vapors ate routed into the running engine to be burned, or stored in a canister when the engine is stopped. Liquid fuel is cought by a vapor separator and returned to tho fuel tank. The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is, commonly referred to as the Act's "tampering provisions.” "Sec. 203(a) The following acts and the causing thereof are prohibited... (3)(A)_ for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this tile prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchasor. (3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with reulations under this, title following its sale and delivery to the ultimate purchaser..." (Continued on next page.)NOTE © The phrase "remove or render inoperative any device or element of design” has been generally interpreted as follows: 7. Tampering does net inclide the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance. 2. Tampering could include: a. Meladjustment of vehicle components such that the emission standards are exceeded b. Use of replacement parts or accessories which adversely affect the performance : or durability of the motorcycle. c. Addition of components or accessories that result in the vehicle exceeding the standards. d Permanently removing, disconnecting, or rendering inoperative any component 5 or element of design of the emission control systems. == WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE 8Y CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION. TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law probibits the following acts or tho causing thereof; (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repeit, or replacement, of any device or oloment of design incorporated into any new vehicle for the purpose of noise control prior {0 its sale or delivery to the ultimate purchaser of whila itis in use, or (2) the use of the vehicle after such device or element of design hes been removed or rendered inoperative by any person. Among those acts presumed to constitute tampering are the acts listed below: ‘e Replacement of the original exhaust system of muffler with a component not in compliance with Federal regulations. ‘Removal of the muffler(s) or any internal portion of the mufiler(s). ‘@ Removal of the air Dox or air box cover. @ Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such ‘modifications result in increased noise levels,Foreword This manual is designed primarily for use by trained mechanics in 8 properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires 10 perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must bbe understood in order to cary out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, ell adjustments, maintenence, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do tho work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substi- tute tools may adversely afiect safe operation, For the duration of the warranty period, we recommend that all repaits and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repait Procedure not performed in accordance with this manual may void the warranty. To get the longest lite out of your motorcycle. Follow the Periodic Maintenance Chart in the Service Manual ‘@8e alert for problems and non-scheduled mainte- nance. @Uso propor tools and genuine Kawasaki Motorcy: cle parts, Special too’s, gauges, and testers that ‘are necessary when servicing Kawasaki motorcy- cles are introduced by the Special Too! Manual, Genuine parts provided as spare parts are listed in the Parts Catalog. @Follow the procedures in this manual carefully. Don't take shortcuts. @Remember to keop complete records of mainte ance and repair with dates and any new pars installed. How to Use This Manual In prepering this manual, we divided the product imto its major systems. These systems became the manual's chapters. All information for a particular system from edjustment through disassembly and inspection is located in a single chapter. The Quick Reference Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own compre- hensive Table of Contents. The Periodic Maintenance Chart is located in the General Information chapter. The chart gives a time schedule for roquired maintonance operations. If you want spark plug information, for example, 90 to the Periodic Maintenance Chart first. The chart tolls you how frequently to cloan and gap the plug. Next, use the Quick Reference Guide to locate the Electrical System chapter. Then. use the Table of Contents on the first page of the chapter to find the ‘Spark Plug section, Whenever you seo these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices. AAWARNING This warning symbol identifies special instructions or procedures which. if not correctly followed, could result in personal injury, or loss of life. ‘CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment.This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information. NOTE © This note symbol indicates points of partic ular interest for more efficient and convenient operation. ‘@lndicates a procacural step or work to be cone. COlndicates a procedural sub-step or how ta do the work of the procedural step it follows. It also precedes the text of a NOTE. 4tIndicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows. In most chapters an exploded view illustration of, the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent uring assembly.GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing. Modol Identification General Specifications Periodic Maintenance Chart Torque and Locking Agent Special Tools and Sealart .... Cable, Wire, and Hose Routing1-2_GENERAL INFORMATION Before Servicing Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate unnecessary work, Photographs, diagrams, notes, cautions. warnings. and detailed descriotions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also required for successful work. Especially note the following: (1) Din Bofore removal and disassembly, clean the motorcycle. Any dirt entering the engine or other parts will work 25 an abrasive and shorten the life of the motorcycle. For the same reason, before installing a new part, ciean off any dust or metal flings. (2) Battory Ground Remove the ground (-) lead from the bettery before performing any disassembly operations on the motorcycle. This prevents: (a) the possibilty of accidentally turning the engine aver while partially disassembled. (b) sparks at electrical connections which will occur when they are disconnected. (c) damage to electrical parts. (3) Tightening Sequence Generally, when installing @ part with several bolts, nuts, or screws, start thom all in their holes and tighten them to a snug fit. Then tighten them evenly in a cross pattern. This is to avold distortion of the pert and/or causing gas or oil leakage. Conversely when loosening the bolts. nuts, or sorews, fist loosen all of them by about a quarter turn and then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and methad indicated. (4) Torque ‘When torque values are given in this Service Manual, use them. Either ta0 litle or too much torque may lead to serious damage. Use a good quailty, reliable torque wrench, (5) Force Common sense should dictate how much force is necessary in assembly and disessembly. If « part seems especially difficult to remove or install, siop and examine what may be causing the probiem. Whenever topping is necessary, tap lightly using a woaden or plestic-faced mallet. Use an impact driver for screws (particularly for the removal of screws held by a locking agent) in order to avoid damaging the screw heads. (6) Edges Wotch for sharp edges, especially during major engine disassembly and assembly. Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over. (7) High-Flash Point Solvent 'A hiigh-flash point solvent ie recommended to reduce fire danger. A commercial solvent commonly available in North America is Stoddard solvent (generic name). Always follow manufscturer and container directions regarding the use of any solvent. (8) Gasket, O-Ring ‘Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smocth to avoid oil or compression leaks. (8) Liquid Gasket, Non-Permanent Locking Agent Follow manufacturer's directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may block engine oil pessages and cause serious damage. An example of a non-permanent locking agont commonly available in North America is Loctite Lock'n Seal (Blue) (10) Press: ‘A patt installed using @ press or driver, such as a wheel bearing, should first be coated with oil on its outer ‘inner circumference so that it will go into place smoothly. (11) Ball Bearing and Neadle Beating Do not remove any ball ot needle bearings that ore pressed in unless it is necessary. Ifthey are removed. replace them with new ones. ‘When installing a bearing. press it in with the marked side facing out using a suitable driver until it is botiomed. Bearings should be pressed into place by pushing evenly the bearing race which is affected by friction.GENERAL INFORMATION 1-3 (12) Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. When pressing in a seal which has manufacturer's marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole (13) Seal Guide A seal guide is required for certain oll or grease seals during installation to evoid damage to the see! lips. Before a shaft passes through @ seal, apply a litte high temperature grease on the lips to reduce rubber 10 metal friction. (14) Circlip, Retaining Ring Replace any circlips and retaining rings that were removed with new ones, es removal weakens and deforms them. When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. (18) Cotter Pin Roplace any cotter pins that were removed with new ones, as removal deforms and breaks them. (10) Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricate film. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface which has lost its ubricatve fim. Old grease and dicy oii should be cleaned off. Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles. Don't use just any oil or grease. Some oils and greases in particular should be used only in carain applications and may be harmful if used in an epplication for which they are not intended. This manual makes reference to molybdenum disulfide grease (MoS: ) in the assembly of certain engine and chassis parts, Always check manufacturer recommendations before using such special lubricants (17) Electrical Wires Al the elecvical wires are either single-color or two-color and, with only 2 few exceptions, must be connected to wires of the samo color. On any of the two-color wires thare is a greator amount of one color and a lesser amount of a second color, so a two-color wire is identified by first the primary color an then the secondary color. For example, a yellow wire with thin red stripes is referred to as.a "yellow/red” wit it would be a “red/yellow" wiea if the colors wore reversed to make red the main color. ‘Wire (cross-section) Name of Wire Color Red Wire Strands Yellow/ Red Yellow Red (18) Replacement Fans When there is a replacement instruction, replace these parts with new ones every time they are removed, These replacement parts will be damaged or lose thoir original function once removed. (18) Inspection When paris have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt es to the condition of thom, replace them with new ones. Abrasion rack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizuro (20) Specifications Specification terms are defined as follows: "Standards": Show dimensions or porformancos which brand-naw parts or systems have. “Service Limits”: Indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, repiace the damaged parts1-4 GENERAL INFORMATION Model Identification 2X1100-D1 (US and Canadian Models) Left Side View: 2X1100-D1 (US and Canadian Models) Riaht Side View:GENERAL INFORMATION 1-5 2X1100-D1 (European Model) Right Side View: 2X1100-D1 (European Model) Right Side View:1-6 GENERAL INFORMATION Item 2x1100-D1- Dimensions: Overall length 2165 mm, (Gi (N) (S) (SW) (GR) 2180 mm Overall wth 730 mm Overallheignt 4205 mm Wheelbase 1495 mm, D3 ~: (G)[EU)'SP)INLY 1 )(FUK)IN)(GR) 1500 mm Road elearance 110mm ‘Seat heignt 780 mm Dry mass: 233 kg. (Cal) 233.5 ko Curbmass: Front 190 kg Rear 139 kg, (Cal) 139.5ko Fuol tank capacity 240 Performance: Minimurn turning radius 20m Engine: Type ‘Coating system Bore and stioke Displacoment ‘Compression ratio ‘Maximum horsepower Maximum torque Carburetion system Starting sysiom Ignition system Timing advance Ignition timing 4-stroke, DOHC, +-cylinger Liquid-cooled 76.0 x58.0 mm 4052 mL. VOE1 (F)IO.N 4108 kW (147 PS) @ 10500 ¢/min (rpm), JAR) (K) 74 KW (190 PS) @9000 ¢/min (1pm), (F) 75.1 kW (-) @8509 din (rom) (UTAC'S norm), 03~:75.1 KW (-) @8400 rimin (rpm) {UTAGS norm), (S) $5 kW (75 PS) @6000 r/min (rom), (SW) 68 KW (@2 PS) @8500 r/min (rpm), (u)-. (UK) 92 KW (-~) @9500 r/min (rom) (ISO4106), DB: 108 KW (147 PS) @ 10500 renin (rpm) (G) 74 KW (100 PS) @9000 rmin (rpm) (DIN) Ds: (G) 74 kW (100 PS) @9500 rimin (rpm) (DIN) Dé ~: (G) 72 kW (98 PS) @9300 r/min (1pm) (DIN) 440. Nem (11.2 kgm, 81 ft1B) @ 8500 e/min (pm). (AR) (&) 90 Nem (9.2 kgm, 67 feb) @ 7000 rimin (Pm), (FU) (UK) ~, (5) 90 Nem (9.2 kg-m, 67 fulb) @5500 rimin (rpm), (SW) 86 Nom (8.8 kgm, 64 f-lb) @4500 rimin (rpm), (G) 30NN-m (9.2 kgm, 67 t-bo) ©7000 s/min (pr) (DIN) Ds ~: (G) 93 N-m (9.5 ko-m, 69 ft-lb) {©5000 r/min (pm) (DIN) Carburetors, Keihin CVK:D 40 x 4 Electric starter Battery and coll (vansistorized) Electronically advanced From 10° BTDC @1000 r/min (rpm) to 40” BTDC @6000 r/min (rpm) (Cal) From 75° BTDG @ 1200 rimin (rpm) to 40° BTDC @6000 vin (rom) (S),D8 ~ () From 7.5" BTOC 6 1300 ¢/min (1pm) to 40° BTDC @6000 ymin (rpm) (U) (C) From 75" BTDG @ 1000 r/min (rpm) to 40" BTDC 6900 r/min (rpm)GENERAL INFORMATION 1-7 tem zx1100-01 ~ ‘Spark plug NGK CAGE 07 ND U27ESR-N Cylinder numbering method Lett to right, 1-2-3-4 Firing ordor 1.243 Vaive timing: Inlet Open 40° BTDC. (F) 20° Close 70) ABDG, (F) 50° Duration 290" (F) 260" Exhaust Open 63° BBDC. (F) 45° Close 43° ATDC, (F) 25° Duration 286° (F) 250° Lubrication system Forced lubrication (wet sump with elor) Engine Grade SE,SF, oF SG class Viscosity SAE1OW.40, 10W-50, 20W.-£0, or 20W-50 Capacity 35L Drive Train: Primary reduction system Type Gear Reduction ratio 1.637 (98/58) Clutch type Wet muti disc Transmission: Type 6-speed, constant mesh, retum shit Geerratos: 1st 2,800 (42/15) 2nd 2.055 (37/10) ard 1.890 (35/22) ath 1.238 (32/24) ‘th 1.183 (8028) ath 1.035 (29/28) Final drive system: Type Chain drive Reduction ratio 2.647 (45/17), DS ~: (GFUK)(GF)(N\EU)SPHINL) 1) 2588 (44/17) Qveral crive ratio Frame: Type Caster (rake angie) Trail Fronttire: Type Size Rear tio: Type size Front suspension: Type Wheel travel ear suspension: Type Wheel travel Brake type Front Fear 4.490 @ Top gear D3~: ()(FYUK)(GA)N)IEUYEPHNLY |) 4.990 @Top gear Tupuiar, double cradle 255° 107 mm Tupeiess 320/70 ZR17 Tuboless 180155 ZR17 ‘Telesconic fork 420 mm ‘Swing arm (uni-trak) 112mm Dual dice Single disc1-8 GENERAL INFORMATION tem 2x4100-01 - Electrical Equipme Battery r2V12 An Headlight: Type ‘Semisealed beam Bulb 2V60/55W (quartz-halogen) Tailorake light 42.V/5/21 W x2 (C) (Cal) (U) 12V8/27W x2 Aternator: Type Three-phase AC Rated output 28.6 A 6000 r/min (rem), 14 Spectications subiect to change without notics, and may not apply to every country. (AS) + Australia Modal (8) = Switzerlana (AR) = Austria Mode! (GA): South Africa Modo! (©) = Canada Model (SW): Sweden Model (Cal) + California Model (WU) » USA. Modo! ©): France Model (UK): UK Mode! (@) + Germany Model (EU): Europe Model (GR) : Greece Mode! (SP): Span Model (1) = Maly Model (NL): Netherlands Model (N)_ = Norway Model (6): Korea Mode!Periodic Maintenance Chart GENERAL INFORMATION 1-9 Tho scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenanes is vitally important and must not be neglected. iahever IN PELUEY wri ay TODOMETER READING Efs [s/s /§ 4 Ss [S/S] 8 (S/S) 5 OPERATION S /E/E/S /E/E/S trey [/s /e/e/e (efe/e Spark plug -clean and gap" elelefelele Valve cloaranes - check” e e ° e ‘Ar suction valve - check" elelelelele Ar leaney element and air vent filer- clear ° ° ° Air cleaner element and air vent fiter- replace |S cleaning ° Throtle op play - check * . e . . Tele spoad- chock * elelelelelele Engine vacuum Synchronization - check e@lelejelelele Fuel system - check * e . ° Fuel hoses, connections ~ check = elelelelele Coolant change 2years ° Evaporative omiasion contol syaien (Cal) -check” SASS ETS sR. Engine ol change years | © ° . = ‘Oi tier = repiace [le ° e ° Radiator hoses. connections - chack * _years | © e e ° Fuel fiter-replace . . . Fuel hose replace ayears ‘Clutch fuid level - check ™ month |e [elelelelel|e ‘Guutch tid charge 2years ° (Cluteh hose and pipe - replace a years ‘Clutch master cylinder cup and dust seal replace | 2 years ‘Ciutch slave cylinder piston seal - replace. 2years Dive chain woar -cheok ™ elelelelele Dive chain ~ lubricate OOK | Drive chain slack - check * 800 km Brake ped wear - check = elelelelele Brake fuidlevel- check” month |e [ele|elelele Brake fuid- change: years ° | Brake nose - replace years Brake hoses, connections ~ check" elelelelele Brake master cylinder cup and dust seal replace | 2 years Caliper piston seal and dust seal - replace 2 years Brake light awitch - check * Lelelelelelele Steering check * elelelelelele Steering stem bearing - lubricate 2years ° Front fork cil~ change . : Tite wear - check" —— =| elelelelele ‘Swing arm pivot, unitrak inkage lubricate ° ° ° Battery electrolyte level - check ™ month | @ [elelelelele General lubrication - perform T elelelelele Nuts, boli, and fasteners tighin@ss Gheok = ° ° ° e Coolant fiter- clean “Tyee | F: For higher odometer readings, repeat at the frequency interval established here. (Cal) : California Mode! only Replace, add, adjust, clean, or torque i necessary.1-40 GENERAL INFORMATION (Other than U.S.A. and Canada Models) Whichever ODOMETER READING FREQUENCY ey a < ever Lf is Brey > Ag ‘Spark plug -clean and G20" e Vawe learance check” ° e “Airsucton valve = check = ° ‘cleaner element and ai vent fitar clean Throtle gp play - check * ° ° ide speed - check * e e ‘Carburetor synonronization - check ° Fual hoses. connections - chek” ° Coolant = change 2yeare e Engine oll- change Sronhs| © felelelelele Oilfiter -replace ° e e e adhator hoses, connections - check ° Cich fu evel - check * Tom |e [elelelelele ‘Giuteh uid chenge Byears e Cluich hose and pipe - replace a years ‘utch mastor cylinder cup and dust seal years = replace Glutch stave cylinder piston seal- replace ‘Tyears Drve chan wear = check elelelelele Drive chan -lubicate BOOK Drive chain slack - chook = 7000 «re Brake pad wear check." e[elelelele Brake fluid level - check * month | @ |e@|e|el/elele Brake uid - change 2 years ° ‘Brake hoses, connections - check elelelelele [aia otro eed seat a Caliper pston seal and dust seal replace a years Brake fight switch - check” @l[el[elelelele Steering - check” elfelelelelele ‘Soaring stem baaving -Wbicate 2 years e Front fork ol - change 2 years Oo Front fork oll leak Check” ° ° ° ear shock absorber oll eak check ° e ° Tire wear - check" elelelelele Swing arm pivot, uni tak kage — lubricate ° ° ° Battery electroyte level -check™ Srontns elelelelele ‘General lubrication - perform e| Te ° Nuts, Gots, and fasteners ighinass - cveck™ ° ° ° ° Coolant fiter= clean year T : For higher odometer readings, repeat at the frequency interval established here. * + Replace, add, adjust. clean, or torque if necessary.GENERAL INFORMATION 1-17 Torque and Locking Agent The following table list the tightening torque for the msjar fasteners, and the pats requiring use of @ non-permanent focking agent or liquid gasket Letters used in the “Remarks” column mean: L: Apply a non-permanent locking agent to the threads, 0: Appian cil to the threads, seated surface, or washer 'S = Tighten tho fasteners following the specified sequence. SS: Apply sifcone sealant to the threads. Fastener Torque Remarks Nm kgm ft-lb Cooling System: Fen switch 18 18 139 Water temperature sensor 15 15 110 ss Bleed valve 78 | 080 69 in-tb Water pump cover bolts 98 10 Water pump drain plug 98 10 Engine Top End: Camshaft cap bolts 12 12 s Rocker shaft end bolts 5 25 Oil hose fitting 22 2.2 Oil hose banjo bolt 25 25 Carburetor holder bolts qua! =A L Cylinder head bolts: 11 mm dia. 51 52 os 10 mm dia. 38 40 | as 6mmdia 98 10 87 in-tb Cylinder bolts 15 4B Sao Upper chain guide mounting bolt - - =< il) oa Rear chain guide mounting bolts 0 20 145 L Chain tensioner mounting bolts 98 10 87 in-lb Camshaft sprocket bolts 15 15 110 L Clutet Clutch hose banjo bolts 26 25 18.0 Clutch pipe nipple 18 18 130 Clutch lever pivot nut 59 0.60 52 in-lb Clutch master cylinder clamp bolts 4 14 95 in-b 8 Clutch slave cylinder bolts - - - LQ) Bleed valve 78 080 89 inl Right cover bolts = - La) Right cover damper boks - - - L Clutch spring bolts " 14 95 in-ib Clutch hub nut 130 135 98 Engine Lubrication Syster Oil hose banjo bolts (14 mm dia.): Coolor side 26 26 180 Oil pan side 34 35 25 Gil hose banjo bolti& mm ia.) 15 15 110 Gil pan bolts = - 2 Lay Drain plugs 29 30 22 il pressure switch 6 15 11.0 ss Gil pen plug 20 20 145 L Crankcase mein oil pessage plug 18 18 130 Crankcase plug 18 18 1301-12 GENERAL INFORMATION Fastener Torque Remarks Nem ko-m ft-lb Oil pipe banjo bolts(12 mm cia.) B 25 180 Oil pimp gear holder screws - - - L Oil pump mounting boks 12 12 108 in-Ib ig Oil fiter bolt 20 20 145 Engine Removal/Installati Engine mounting nuts. = 8mm 20 20 148 10mm 44 45 33 Down tube mounting bolts 4a 45 33 Crankshaft/Transmission: Crankshaft cap bolts 2 33 24 Balancer shaft guide pin plate bolt - - - L Balancer shaft clamp lever mounting bolt - - - L Alternator shaft chain tensioner bolts - - = L Crankcase botts: 9mm dia 2 33 24 s 3 mm dia ) Sey 28 20 Timea, ||| 9B 48 130 6 mm dia. 18 18 11.0 Connecting 1od big end cap nuts See p8-11 ‘Altemator shaft chain sprocket bolt 25 26 180 Altenator shaft nut 89 60 43 Alternator shaft boit 2 25 180 One-way clutch bolts 12 12 104 in-Ib L Shift drum bearing holder bolts - = - L External shift mechanism return spring pin 23 30 22 L External shift mechanism cover bolts 98 10 87 in-lb Lay Neutral switch 15 15 11.0 Wheels/Tires: Front axle nut 145; 150 110 Front axle clamp bolts 20 2.0 145 Rear axle nut 110 10 80 Final Drive: Engine sprocket nut 125 130 94 Engine sprocket cover damper bolts - - - L Rear sprocket nuts 74 78 54 Rear sprocket studs - - = L Chain adjuster clamp boks 39 40 29 Brakes: Brake lever pivot nut 88 0.90 78 in-Ib Front moster cylinder clamp boits " 1. 95 in-tb s Brake hose banjo bolts 25 25 180 Bleed valves 78 0.80 69 in-Ib Caliper mounting bolts: Front 34 35 25 Rear 25 25 18 Front caliper assembly bolts a 24 150 Brake disc mounting bolts 23 23 165 Brake pedal pivot bolt 88 0.90 78 in-ib Rear master cylinder mounting bolts 23 23 165 Push rod nut 18 18 130 Torque link bolts/nut 25 25 18.0GENERAL INFORMATION 1-13 Fastonor Torque Remarks Nm kgm ftlb ‘Suspension: Front fork top plugs 23 23 165 Front fork clamp bolts(Upper) 2B 29 2 Front fork clamp nuts(Lower) a 24 150 Front fork bottom Allen bolts a 62 45 L Front axle clamp bolts 20 20 145 Rear shock absorber mounting nuts 59 60 43 ‘Swing arm pwvot nut 8 9.0 65 Rocker arm pivot nut 59 60 43 Tie-rod bolts 59 60 43 Steering: Handlebar weight bolts - - - i Handlebar holder bolts 20 20 145 Steering stem head nut 39 40 29 Stooring stom nut 49 050 43 in-tb Frame: Downtube bolts a4 45 33 Side stand switch sorews - - - L Center stand spring hook bolts - = - L Side stand bracket mounting bolts 49 50 26 L Side Stand Bolt a“ 35 25 Electrical System: Spark plugs 14 14 400 up coil cover bolts, - - - L2) iming rotor bolt 6 25 180 Pickup coil holder bolts L Alternator mounting bolts 25 25 180 Alternator coupling bolts 98 10 87 in-lo Alternator cover nuts, 44 0.45 39 in-to Aterator cover studs 8g 090 18 in-Io The table below, relating tightening torque to Basic Torque for General Fasteners thread diameter, lists the basic torque for the bolts Frege dia, To and nuts, Use this table for only the bolts and nuts pa which do not require a specific torque value. All of fore Naw fem Fe the values are for use with dry solvent-cleaned 6 | 94-49 [035~050 | 30~ 43 in-tb threads. 6 | &9~78 |0.80 ~ 0.80) 62 ~ 69 in-ib 8 ta~19 | 14-19 | 100~135 10 | 25~34 | 26~35 | 190~250 12 «| 44-61 | 45~62 | 33 ~45 14 | 73~98 | 74~100| 54 ~72 16 [115 ~155/11.5~160| 63~115 1g |165~ 225] 17.0~ 230) 125 ~ 165 20__|225~325| 23~33 | 165 ~2404-14 GENERAL INFORMATION Special Tools and Sealant Bearing Puller Adapter: 5701-138 @ ‘Compression Gauge: §7001-221 @ ‘Steering Stem Bearing Driver. §7001-137 Valve Spring Compressor Assembly: 5701-241 =. NO Inside Circlip Pliers: §7001-143 Bearing Puller Adapter: 57001-317 Bozring Puller: 57001-1658 Piston Pin Puller Assembly: 7001-910 Hand Tester: 87001-1394GENERAL INFORMATION 1-15 il Seal & Bearing Remover: 67001-1058 Piston Ring Compressor Grip: 67001-1095, oS TS Le Steering Stem Bearing Driver Adapter: 57001-1074 Piston Ring Compressor Belt, 067 ~ 979: 57001-1097 hoa Head Pipe Outer Race Press Shatt: 57001-1075 ‘Steering Stem Nut Wrench: 57001-1100 Head Pipe Outer Race Driver. 57001-1076 Head Pipe Outer Race Remover, 57001-1107 | les Head Pipe Outer Race Driver 57001-1077 Valve Seat Cutter. 45" ~ 0275: 57001-1114 ©1-16 GENERAL INFORMATION Valve Seat Cutter, 45° ~ 082; 67001-1116 Valve Seat Cutter, 32° - 933: 57001-1199 2 © Valve Seat Cutter, 32° - 30: 57001-1120 Valve Spring Compressor Adapter, 22: 57001-1202 2 & Valve Seat Cutter, 60° - 30: 57001-1123 Valve Guide Arbor, @5: 57001-1203 © a Valve Seat Cutter Holder Bar. 87001-1128 Valve Guide Reamer, 05: 57001-1204 a oe Bearing river Set §7001-1129 Valve Seat Cutter Holder, @5: 67001-1208 seGENERAL INFORMATION 1-17 Fork Outer Tube Weight: 57001-1218 Piston Base, 96: 57001-1263 Front Fork Oil Seal Driver: 67001-1219 Bearing Removor Shatt: 57001-1285 Coil Tester: 57001-1242 Bearing Remover Head, 15x O17: 57001-1267 & ‘Spark Plug Wrench, Hex 16: 57001-1262 Fork Oil Level Gauge: 97001-1290 s- Jack: 57001-1238 Bearing Remover Head, ©20 x ©22: 57001-1293 &1-18 GENERAL INFORMATION ‘Compression Gauge Adapter, M10 X 1.0: 57001-1317 Kewasaki Bond (Liquid Gasket ~ Black): 92104-1003 = foe Valve Seat Cutter, 60° — 33: 57001-1334. Kawasaki Bond (Liquid Gasket - Stver): 92104-002 8 gy \ Hexagon Wrench, Hex 29: 57001-1335 & = Vacuum Gauge: 57001-1369 Kawacaki Bond (Silicone Sealant): 58019-120 “Ba ioe eeGENERAL INFORMATION 1-19 Cable, Wire, and Hose Routing 3, Main Hames 4. Water Temp. Sensor Leads 5. Ground Load 8. Fan Motor Lead 7. #2,3 Ignition Coil Leads 8, Right Hom Lead 9. Alternator Lead 10. Pickup Coil Leod 411. Battery (-) Lead 12. Oil Pressure Switch Lead 13. Rear Brake Switch Lead. 14, Junction Box Load, 15. Fuel Level Gauge Lead 16. Tail/Brake Light Lead 17. Right Turn Signal Lead 18. Licence Light Lead 19. Left Turn Signal Lead 20. Tum Signal Relay Lead 21. Rectifier Lead 22.1C Igniter Lead 23. Starner Relay Lead 24. Fuel pump Relay lead 25, Side Stand Switch Lead 28. Noutral Switch Load 1 2. Cable passing in Right Hole 27. 28, 29. 30. 31 32 33 34. 36. Cables passing in Left Hole Throwtle Cable Choke Cable Ignition Switch Leacs Left Switch Case Leeds Main Hames Right Switch Case Leads Cooling Fan Switch Lead Loft Horn Lead Loft Hendleber Switch Lead Right Handlebar Switch Lead Ignition Switch Leads Clamp White Color Tape Wound ‘on Main Harness #1, 4 Ignition Coil Leads Fuel Pump Lead1-20 GENERAL INFORMATION eG ae 3) a) Sea CRAANY RS&s TEETER 8. Clamp Following Leads 1. Fuel Pump Lead 2. Ground Lead Pickup Coil Lead Alternator Lead 3. Oil Pressure Switch Lead 4. Battery (—) Lead Neutral Switch Lead 9. Fuel Pump Relay 10. Starter Motor Lead 11. Starter Relay 5. Rear Brake Switch Lead 6. Junction Box 7. Igniter 12. To Starter Motor 13. Main Harness 14. Battery (+) Lead 15. Rectifier 16. Turn Signal RelayGENERAL INFORMATION 1-21 Fairing Inside Harness Leads (@) 3. Guards 1. Clamp 2. Upper Fairing 3, Right Tum Signal Lead 4. Clamp 5. Headlight 6. Lett Tum Signal Lead 1. Clamp 2. Speedometer 3. Bracket 1. Cables passing in Left Hole Throtle Cable Choke Cable Ignition Switch Leads Left Handlebar Leads 2. Cable passing in Right Hole Main Harnoss Right Handlebar Leads 4. Ignition Switch Lead 5. Throttle and Choke Cables 6. Left Handlebar Switch Lead 7. Clamp 8. Ground Lead 9. Radiator 10. Fan Switch Lead 11. Band 12. Down Tube4-22 GENERAL INFORMATION 1. Front Brake Hose 2. Throttle Cables 3. Right Handlebar Switch Lead 4, Bands 5. Main Hames 6. Ignition Switch Lead 7. Choke Cable 8, Left Handlebar Switch Lead 9, Clutch Hose 10. Speedometer Cable 11. Clamp 12, Side Stand Switch 13, Band 14, Oil Pressure Switch LeadGENERAL INFORMATION 1-23 Ignition Coil Read Right Rear Tum Signal Lead Clamp Tighten to the tail Light Left Rear Tum Signal Lead 1.#1,4 Ignition Coil 2. #2, 3 Ignition Coil 3. Heat Sealed (Whito paint mark should bbe on top). 4. White paint 5. Bolt 6. Nut4-24 GENERAL INFORMATION Air Filter Vacuum Switch Valve (Other than California Model) 3, 6. 7. 8. 10. n 12 13 14, 16, 16. 17. Screen ‘White paint ID mark for R.H.screen Air Vont Filtor Clamp Air Duct . Clump Clamp Reservoir Tank Hose Pipe To #1, 4 Carburetors Pipe Tube Nut Screw Screw 18, Duct 1D Mark 20. Lor R mark should be up. it Cleanor Housing Plugs Front Drain Tube Rear Drain Tube Catch Tank Plug Vecuum Switch Valve ‘Vacuum Switch Valve Hose To Bottom of Air Cleaner Housing Vacuum Tube To #1 Carburetor Holder To #4 Carburetor HolderGENERAL INFORMATION 1-25 Fuel Pump Pipe 1. Fuel Pump Pipe: Route under cross pipe 2, Connect pipe so that while paint on| Pipe is top, Cooling System 1. Reservoir Tank 8. Thermostat Body Cap 8. Water Temp. Switch 3. Drain Hose 10. Radiator 4. Clamps. 11. Groove 5. Insert drain hose tip in breather case, 12. White Color Painted 6. Reservoir Tank Hose 13. Insert hose so that white paint meets with groove. 7. Radiator Cap4-26 GENERAL INFORMATION Brake Hose (1) Front Brake see 2. Front Caliper 3. Banjo Bolts 4. Bleed Valve 5. Brake Hose | 6. Three Way Joint 7. Front Master Cylinder 8. Boot 9. Clamp 10. Rear Reservoir Tank 11. Rear Master Cylinder 12, Banjo Bolt 13. Clamp 14. Brake Hose 19. Rear Caliper 16. Brake DiscGENERAL INFORMATION 1-27 Evaporative Emission Control System (California Model Only) 1. Vacuum Valve 11. #3 Carburetor Holder 2. Tube (Yellow) 12. To Vacuum Switch Valve Hose Connecter 43. Catch Tank 4. Plug 5. Canister 6. Tube (Blue) 7. Separator 8 Tube (Rog) 8. Tube (Green) 10 Tube (White)4-28 GENERAL INFORMATION 4. Vacuum Switch Valve 2. Vacuum Switch Valve Hose: 2, To Bottom of Air Cleaner Housing 4. Vacuum Tube 5. To#1 Carburetor Holder 6. (4 Carburetor Holder 7, Tupe (Greer) ToCanister 1. Air Gleaner Housing Front Left and Right Drain Tubes Front of air Cleaner housing ~» Under igntion col + Clamps (Lelt and Right, Air Cleaner Housing Rear Drain Tube ‘Three Way Joint Tube (Yelow) ‘This area should be lowest position inthe yellow tube line. Clamp Clamp NomeenGENERAL INFORMATION 1-29 Sereen 3. White Paint 1D mark for RH-screen ‘Air Vent Finer Vacuum Valve ‘Tube(Yetlow) Clamp ‘Ar Dust Clamp Pere mae ube ‘To # 2Carburetor Holder 10. Clamp 11, Reservoir Tank Hose 12. Pipe Tot, 4 Carburetors 13, Pipe 14, Tube 18. Nut 16. Sorew 17. Screw 18, Duct ID Mark Lor R mark should be up. 19. To##2 Carburetor Helder 20, Ait Cleaner HousingGENERAL INFORMATION 1-31 1. Tube (Yellow) Three Way Joint at (G) —+ Front of erankcase breather hose + Under ignition coll + Under frame —+ Inside of r fark hose + Front of thermostat > Vacuum Valve. 2. Vacuum Hose # 2 Carburetor Holder —+ Under ignition coil + Under frame + inside of radiator tank hose -+ Frent of thermostat —* Yacuum Valve. 3. Thermostat 4. Tubes (White, Green, Yellow) and Reservoir Tank Hose Route these tubes and hose between frame and carburetor. 5. Tube (White) #3 Carburetor + Clamp at (B) -> Separator 6. Clamp Following ones at (B) Tube (White) Racervoir Tank Hose Main Wiring Harness 7. Separator 8. Tube (Red) ‘Soparator ~ Back of battery caso -+ Fuel tank. 8. Tube (Blue) ‘Separator ~> Back of battery case -> Fuel tank. 10. Reservoir Tank Hose ‘Thermostat Cap —+ Clamp at (A) -+ Clamp at (8) —> Reservoir Tank. 11. Reservoir Tank 12. Reservoir Tank Overtiow Tube Reservoir Tank -> Clamp at (D) and (E) -» Breather at side of battery case. 1. Three Way Joint 44, To Vacuum Valve 18. To Catch Tank 16. To Canister 17. Tubes (Yellow, Green) Route these tubos at ront of erarkcace breather tube. 18 Engine Breather Tube 18, Clamp Route tube (Yellow) at outside and tube (Green) 20. Clamp 21, Tube (Bluo) Separator ~ Clamp at F) — canister. 22. Tube (Green) Joint (H) + at ront of crarkease broather tube —> Clamp at (C) > Clamp at (F) —+ Canister. 23. Tube (Yellow) ‘Three Way Joint at (G) —+ Clamp at(C) -> Clamp (F) -> Canister. 24. Canister ide.FUEL SYSTEM 2-1 Fuel System Table of Contents Exploded View 2-2 Specifications. 25 Throttle Grio and Cables... 2-6 Fioe Play Inepostion 2.6 Free Play Adjustment 26 ‘Cable Installation Notes. 2-6 Cable Lubrication ....0msnunenennse 2-6 Choke Cable es 2-7 7 27 27 2-7 28 28 28 28 Free Play Inspection. Free Play Adjustment .. Installation Notes. 3 Lubrication . mn Corburstors. Idle Speed Inspection... lle Speed Adjustment... ‘Synchronization Inspection. Synchronization Adjustment onus. Service Fuel Level Inspection. Sonic Fuol Level Adjustmont Fuel System Cleanliness Inspection Removal Installation Notes... Disassombly/Assembly Notes. ‘Soparation/Assembly Notes. Cleaning. ri Inspection High Atitude Performance Adjustment (US mode). Coolant Filter Cieanng (Ar. G. F.1,NL. UK, K Models). Air Cleaner. Housing Removal Housing installation Notes... Element Removal Element Installation. Element Cleaning and Inspection, Oil Draining. Air Cleaner Housing Installation. Fuel Tank, Removal Installation Notes. Inspection.. oa Cleaning a Fuel Tap Removal Fuel Tap Installation Notes. Fuel Tap inspection... Air Vert Filter Cleaning... Evaporative Emission Control System (Caifornia Model Only) Parts Remevalinctalation Notes. Hose Inspection... Separator Inspection. Separator Operation Test Canister Inspection.2.2 FUEL SYSTEM Exploded View 4. Jet Noodle 2. Pilot Screw 3. Pilot Jet 4. Main Jet 5. Needle Je¥Bleod Pipe 6. Fuel Filter 7. Fuel Level Sensor 8. Vacuum Valve, (©): Canada Modet : Model jermany,France,|taly, .de, Switzerland, UK ‘and Korea Models (8): Switzeriand Model (W): USA. Model (UK): UK Model G: Apply grease. 0: Apply aiFUEL SYSTEM 2-32-4 FUEL SYSTEMFUEL SYSTEM 2-5 Specifications Item Standard Throttle Grip and Cables: Throttle grip ree play 2~3mm Choke Cable: Choke cable free play 2~3mm Carburetors: ‘Make, type Keihin, CVKD40 Main jot #1, 44: 160(188) #243: 158 (155) Main airjet 70 Jet needle INQBX, (FR) #1, #4 N6OU Piot jet 38 [35] Pilot at jot 420, (UK) 130, Starner jet 98 Pilot screw 20 tums out, (Cal)(S) (U) ~ Service fuel level 45 4 11mm below the mark Float height 134.2mm fee speed 950 ~1050 r/min (rpm) (Cal)(S) 1150 ~ 1250 r/min (rpm) Synchronization vacuum Less than 2:7 kPa (26m Ha) (Cal: California Mode! (S): Switzerland Model (U): U.S. Model [1s High Attitude(US only) ‘Special Too! ~ Fuel Level Gauge: 57001-1017 Pilot Screw Adjuster, A: 57001-1299" ‘Vacuum Gauge: 57001-1359 Pilot Screw Adjuster, C: 57001-1202" (): You may use whichever too! you like. ZX1100-D3- (Refer to the above, noting the following): Hem ‘Standard Carburetors: Jet needle NOX, (E) #1.4:NIV, #23: NIVL Pilot ai et 120 Pilot sorow 2.0 turns out, (E) 13/4 tums cut, (G)(UK) 1 6/8 tums out, (Can (5) (U) - Idle speed 950 ~ 1050 r/min (rpm), (8) 1250 ~ 1950 r/min (rpm) (E): Europe Models except for Austiia, Sweden, and Switzerland Models, (G): Gormany Modo! (UK): UK Model2-6 FUEL SYSTEM Throttle Grip and Cables Free Play Inspection © Check the throtle grip free piay [A] + If the free play is ncorrect, adjust the throtle cable Throttle Grip Free Play Standard: = 2 ~ 3mm ‘© Chock that the throttle grip moves smoothly from full open to close, and. the throte closes quickly and completely in all steering Positions by the return spring. 4 If the throtle gp does not return properly, check the throttle cable routing, grip tree play, and cable damage. Then lubricate the throtte cable. ‘© lun the engine at the idle speed, and turn the handlebar all the way to the right and left io ensure thai the idle spaed does nat change. + If the idle epeed inereaso, check the throttle cabio froe play and the cable routing. Free Play Adjustment Loosen the locknut (A ‘© Tum the adjuster [8] until the proper amount of tree play can be obtained. © Tighten the locknut securely. 4 If the proper amount of free play cannot be obtained by using the adjuster only, use the adjuster in the middle part of the accelerator cable. Loosen the locknut and screw the adjuster at the upper end of the ‘accelerator cable all the way in. Tighten the locknut securely. @Remove the fuel tank and air cleaner housing (see Fuel Tank Removal) @ Loosen the locknut [A] at the middle part of the accelerator cable. @Tumn the adjuster (8) until the proper amount of throttle grip free play 's obtained. Tighten the locknut securely. 4f the proper amount of fiee play can not be obtained in the adjustable range of the adjuster, use the adjuster at the upper end of the acceler ator cable agein. Cable Installation Notes @ install the throtte cables in accordance with the Cable Routina section in the General Information chapter @install the lower ends of the throttle cable in tho cable bracket on the carburetor after instaling the upper ends of the throttle cable in the arip. ‘© After installation, adjust each cable properly. ES Operation with incorrectly routed or improperly adjusted cables ‘could reeultin an uneate riding condition. Cable Lubrication Whenever the cable ie removed, and in accordance with the Poriodio Naintenance Cher (see General Information chapter), do the folowing. ‘@Apply a thin coating of grease to the cable lower ends. ‘eLubricate the cabla with 2 penetrating rust inhibio’Choke Cable FUEL SYSTEM 2-7 Fiee Play Inspection {@Check that the choke inner cable slides smoothly by moving the choke lever [A] to the front and rear “It there is any irregularity, check the choke cable play [8] ‘@Push the choke lever all the way to the front. ‘eCheck choke cable free play. Determine the amount of choke cable play at the choke lever. Pull the ‘choke lover until the starter plunger lever [A] at the carburetor touches the starter plunger (B]; the amount of choke lover lower end travel is ‘the amount of choke cable play. ef the fee piay is incorrect, adjust the choke cable. Choke Cable Free Play [C] Standard: 2 ~ 3mm Free Play Adjustment ‘@Remove the fuel tank (see Fuel Tank Removal). ‘@Lcosen the locknut [A], and turn the adjuster [8] until the cable has the proper emount of free play. ‘@TTighten the locknut securely Installation Notes ‘@install the choko eable in sccordance with the Cable Routing section in the General Information chapter. ‘@Atter installation, adjust the cable properly. Win Incorrectly routed or improperty adjusted cable could result in an unsafe riding condition. Lubrication Whenever the choke cable is removed, lubricate the choke cable as follows: ‘eApply a thin coating of grease to the cable upper end, ‘eLubrcate the cabo with a ponoirating rust inhibitor.2-8 FUEL SYSTEM Carburetors Idle Speed Inspection ‘eStart the engine and warm it up thoroughly. ‘eWith the engine idling, turn the handlebar to both sides. +Ithandlebar movement changes the idle speed, the throttle cables may be improperly adjusted or ncorrectly routed, or damaged. Be sure 10 correct any of these conditions before riding (see Cable Routing section in tie General Infomation chapter) ‘Operation with an improperly adjusted, incorrectly routed, or damaged cable could result in an unsafe ‘eCheck idle spead xf the idle speed is out of the specified range, edjust it Idle Speed Standard: 1,000 = 60 r/min (rpm) (Catitomia, Swiss Models) 1,200 + £0 rimin pm) ZX1100-3- : (Swiss Model) 1.300 = 50 r/min (rpm) Jdlle Speed Adjustment (@Start the engine and warm it up thoroughy. @Tum the adjusting screw [A until the idle speed is correct. (©Open and ciose the throttle few times to make sure that the idle speed is within the specified range. Readjust if necessary. ‘Synchronization Inspection ‘@Set the motorcycle on its center stand, ‘@Statt the engine and warm it up theroughy. ‘© Check idle speed, ‘@ Remove the fuel tank. (see Fuel Tank Removal) ‘@Supply fuel to the carburetors with an auxiliary fuel tank. ‘@ Remove the inner rear faring, ‘@ Remove the air cleaner housing. ‘@Pull the vacuum noses off, and attach the vacuum gauge [A] to the fittings [B] on the carburetors. ‘Special Tool ~ Vacuum Gauge: 57001-1369 ‘@Start the engine and let it idle to moacure the carburetor intake vacuum, >If the vacuum is incorect, adjust the synchronization Carburetor Synchronization Vacuum ‘Standard: Less than 27 kPa (2 emHg) diference between any two carburetors.FUEL SYSTEM 2-9 Synchronization Adjustment {@Turn the adjusting serew to syncheonize tho carburetor. (OFFist synctronize the left two and then the right two carbureiors by ci ‘reans othe let nd rat adusting screws (A, CI. Then sehen fn Vea ais. the let two carburetors and the right two carburetors using the center 6 adjusting screw [8] XI the carburetor synchronization cannot be obiained by using the agjusting screws, check for dirt or blockage, and then check the pilot ) a screw settings. a ‘Special Tool ~ Pilot Screw Acjuster, A: 57001-1299 or Pilot Screw Acjuster, C: 57001-1292 @ Check the carburetor synchrenization again. NOTE (©Do not turn the pilot screves carelessly during carburetor synehroni- zation. You may cause poor running at law engine speed. ‘eCneck idle speed. Service Fuel Level Inspection Gasoline is extremely flammable and can be explosive under certain ‘conditions. Turn the ignition switch OFF. Do notsmoke. Make sure the area ie well-ventilated and free from any source ol flame or sparks; this includes any appliance with a pilot ight. @Romove the carburetors, and hold them upright on a stand (see ‘Carburetor Removal) ‘ePrepare an auxiliary fuel tank and connect the fuel ose to the ‘carburetors. ‘@ Prepare a fuel hose (6 mm in diameter and about 300 mm long). ‘@Conneet the fus! lavel gauge [A] to the earburetor float bow! with the fuel hose. ‘Special Tool ~ Fuel Level Gauge: 57001-1017 ‘@Hold the gauge [/] vertically against the side of the carburetor body 's0 that the “zero” ine (B] is several milimeters higher than the bottom ‘edge of the carburetor body. ‘@ Feed fuel to the carburetor, then turn the carburetor drain plug [C] out a few tums. @Wait until the fuel level in the gauge settes. NOTE Do not lower the "20:0" line below the bottom edge of the carburetor body. If the gauge is lowered and then raised again, the fuel level measured shows somewhat higher than the actual fuel level. If the gauge is lowered 100 far, dump the fuel ino a surtaole ‘eantaines and start the procedure over again.2-10 FUEL SYSTEM ‘@Read the fue! level (D] in the gauge and compare to the specification ‘Serew in the carburetor drain plug, ‘@Siop feeding and remove the fuel level gauge. >If the fuel level is incorect, adjust it (see Service Fuel Level Adjust mort) Service Fuel Level Standard: 4.5 41 mm below the mark Service Fuel Level Adjustment “AWARNING Gasoline is extremely flammable and canbe explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. @Remove the carburetor, and drain the fuel into a suitable container @Remove the float bowl @Remove the screw {A} and take out the float (81, @Bend the tang [A] on the flost arm very slightly to change the float height. Increasing the float hoight lowers the fuel level and decreasing the float height rises the fue! level. Float Height Standard: 13+ 2mm NOTE (Do nor push the needle rod (A) in during the float height measure ‘ment (6) (@ Assemble the carburetor, and recheck the fuel level Ifthe fuel level cannot be adjusted by this method, the float or the float valve is damaged.FUEL SYSTEM 2-11 Fuel System Cleanliness Inspection ENNIS Gasoline is extremely flammable and can be explosive under certain ‘conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area ie well-ventilated and tree from any source of flame or Sparks; this includes any appliance with a pilot ight (© Remove the following. Seat Fuel Tank ‘@ Connect a suitable hose to the fitting et the bottom of ach carburetor ‘oat bowl ‘@ Run the lower ends of the hoses into a suitable container Tun the fuel tap to the PRI postion ‘@Turn out each drain plug a few tums and drain the flost bowls Special Tool ~ Pilot Screw Adjuster, A: 57001-1239 or Pilot Screw Adjuster, C: 57001-1292 [A] © Check to see it water oF dirt comes out ‘@Tighten the drain plugs and turn the fuel tap to the ON position. ‘If any water 0 dirt appears during the above inspection, clean the fuel ayatem (¢oe Carburetor Cleaning and Fuel Tank Cieaning), Removal Ea Gasoline is extremely flammable and can be explosive under certain ‘conditions. Turn the ignition ewitch OFF. De notsmoke. Make cure the area ‘s wellventilated and free from any source of flame or sparks; ths includes any appliance with a plot ight. @Remove: Seat Rea Inner Tank Fuel Tank Air Cleaner Rear Housing ‘@Loosen the clamps, and pull the carburetors off the hovers. ‘@Take out the carburetor essembiy. ‘@Remave the throttie cable and choke cable lower ends. ‘@Stut piace of lint-free, cloan cloth into the carburetor holders and the intake ducts to keep din out of the engine and air cleaner2-12 FUEL SYSTEM Installation Notes ‘@ Route the cables, hemness, and hoses correcty (see General Infooma- tion chapter). Tighten the clamps[A] for the carburetor holders. {© Chock fual leakage from the carburetor. En Fuel spilled trom the carburetors is hazardous. (@ Agiust the following items if necessary. Idle Speed Carburetor Synctronization Throttle Cable Choke Cable Disassembly/Assembly Notes GN ‘Gasoline Is extremely flammable and can be explosive under certain conditions, Tum the ignition switch OFF. Donot smoke. Make sure the area ts well-ventilated and free trom any source of flame ot ‘sparks; this includes any appliance with a plot light. @ For the US and Swiss madels. remove the pilot screw plug as follows: (© Punch a hole in the plug and pry there with an aw! or other suitable tool ‘@ Tum in the pilot screw and count the number of turns unt it sats fully ‘but not tightly, and then remove the screw. This is to set the sorew to its original position when assembling. ‘© After installing the upper chamber cover, check thet the vacuum piston, slides up and down smoothly without binding in the carburetor bore. ‘CAUTION During carburetor disassembly, be careful not to damage the diaphragm. Never use 2 sharp edge to remove the diaphragm. @ Turn in the pilot screw [A] fully but not tightly, and then back it out the same number of tuins counted during cisessembly. @For the US and Swiss made install the pilot serew plug as follows: ‘Olnstall a new plug [B] in the pilot screw tole, and apply a small ‘amount of a bonding agent [C] to the citcumierence of the plug to fix the plug, CAUTION ‘Do not apply too much bonding agent tothe plug or the pilot screw itself may be fixed.FUEL SYSTEM 2-13 (@Turn the carburetor body upside-down, and drop the noodle jot [A] into place s0 that the smaller diameter end [8] of the jet goes in frst. ‘© Carefully screw in the needle jet holder. It will seat against the needle Je, pushing the end of the et into the carburetor bore. CAUTION Donot lorce the needle jetholder [A] and main jet [8] or overtighten them, They could be damaged requiring replacement. {@Sip the needle through the hole in the center of the vacuum piston, ‘and put the spring seat [A] on the top of theneedle. Turn the seat 50 thatit does not block the hole (8 at the bottom of the vacuum piston. Separation/Assembly Notes ‘@Read the WARNING in the Carburetor Disassembly/ Assembly Notes. {@The centor lines of the oarburetor bores must be parallel both horizon tally and vertically. If they ae not, loosen the mounting screws and align the carburetors on a flat surface. Retighten the mounting screws. ‘@Aiter assembling the choke mechanism, check to see that the starter plunger laver slides right to left smoothly without abnormal fiction, ‘CAUTION Fuel mixture trouble could result the starter does net seat properly in te rest position after the choke lover ia returned. ‘@ Visually synchronize the throne (buttery) valves. (OCheck to see that all throttle valves open and close smoothly without ‘binding when turing the pulley. (Visually check the clearance [A] between the throttle valve and the ccerburetor bore in each carburetor. It there is a difference between any two carburetors, turn the balance adjusting screw(s) [B] to obtain the same clearance.2-14 FUEL SYSTEM Cleaning “AWARNING Clean the carburetors in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area; this inckides any appliance with a pilot light Because of the danger of highly flammable liquids, do not use gasoline or low flach-peint solvents to clean the carburetors. - ‘CAUTION ‘Do not use compressed alr on an assembled carburetor, or the floats ‘may be crushed by the pressure, and the vacuum piston diaphragms may be damaged. Remove se many rubber or plastic parts rom the carburetor as possible betore cleaning the carburetor with a cleaning solution. This will prevent damage to or deterioration ofthe parts. ‘The carburetor body has plastic parts that cannot be removed. Do rot use a strang carburetor cleaning solution which could attack these parte; instead, use a mild high flash-point cleaning solution sale for plastic parts. Do net use wire or any other hard instrument to clean carburetor parts, especially jets, as they may be damaged. © Disassemble the carburetor. @lmmerse all the metal pans in a carburetor cleaning solution. @Rinse the parts in water. @When the parts are clean. dry them with compressed air. @Blow through the ait and fuel passages with compressed ar ‘@ Assemble the carburstor. Inspection Pan ‘Gasoline is extremely flammable andcen be explosive under certain conditions. Turn the ignition switch OFF. Donot smoke. Make sure the area Is well-ventilated and free from any source of flame or sparks: this includes any appliance with a plot light. ‘@Remrove the carburetors. {@8etore d'sassembiing the carburetors, check the fuel level (see Fuel Level Inspection). IF the fuel level is incorrect, inspect the rest of the carburetor before correcting it ‘@Move the choke shaft left and release it 10 check that the starter plungers move smoothly and return by spring tension, “IF the starter plungers do not work properly, replace the carburetors. ‘eTumn the throttle cable pulley to check that the throttle butterily valves [A] move smootniy and retum by spring tension kIF the throttle valves do not move smoothly, replace the carburetors.FUEL SYSTEM 2-15 ‘eDissssomble the carburetors. (@Clean the carburetors. ‘eCheck that the O-rings on the float bow! and drain plug and tne diaphragm on the vacuum piston are in good condition If any of the O-rings or diaphragms aro not in goed condition, replace them. ‘eCheck the plastic tip (A) of the tlost valve needle |B]. It should be smooth, without any grooves, scratches, or teas, | “If th plastic tip is damaged [C}, replace the noodle. ‘@Push in the rod [0] in the other end of the float valve nesdie and then epmcait Pus nd release deIf it does not spring out, replace the needle. @Check the tapered portion [A] of the pilot screw (B] for wear or damage, “IF the pilot screw is worn or damaged on the tapered portion, it will prevent the engine from iding smoothly. Replace it ® |@Check that the vacuum piston [A] moves smoothly in the carburetor body. The surface of the piston must not be excessively worn, >If the vacuum piston does not move smoothly, or if it is very loose in ‘carburetor body, replace the carburetor High Atitude Performance Adjustment (US model) To improve the EMISSION CONTROL PERFORMANCE of vehicle ‘operated above 4000 feet, Kewasaki recommends the following Enviromental Protection Agency (EPA) approved modification {© Change the main jot and plot ot for high akitudo usa High Altitude Carburetor Specifications, Pilot Jot: #38 (02064-1101) Main Jet #156 (#18 cyl. 92009-1944) #155 (42,8 cyl. 92063-1332) Coolant Filter Cleaning (AR, G, F, |, NL, S, UK K Models). —©_{~-————— Before winter seascn starts, clean the fiter of carburetor system, ‘eRemove the fuel tank (see Fuel Tank Removal) rain the coolant (se2 Cooling System chapter) ‘eRemove the fer [A] from the cooling hosas [B] of sarburetor system. ‘eBlow off crt and sediment en the fiter with compressed zir. (AR. G.I. NL.S, UK, K Models) Austria, Germary, France, laly, Netherlands, Swiizetland, UK and Korea Models2-16 FUEL SYSTEM Air Cleaner Housing Removal ‘@ Remove: Seat Fuel Tank Inner Rear Faring ‘@ Remove the mounting bolt [A], and take off the upper housing (E] ‘@ Remove: Air cleaner Screan [A] Air Cleaner Elomont [B] Ait Cleaner Drain Hoses Engine Breather Hose Air Duct ‘@ Remove the lower housing mounting bolts[Al, and take off the front housing [B] from the carburetor. Housing installation Notes ‘@Connect the front and rear drain tubes 10 the lower housing (see General Information chapter) ‘@Fit the O-ring [A] of the rear housing in place. @ install the rubber plugs[B] in place. Element Removal @Remove: Air Cleaner Upper Housing Mounting Bolts ‘@Remove the upper housing. {eT ske out the element.FUEL SYSTEM 2-17 Element Installation ‘@Element installation s the reverse of removal @ install the soreon [A] so that the protrusion side faces the carburetor. Element Cleaning and Inspection NOTE On dusty areas. the element should be cleaned more frequentiy than ‘the recommanded interval. Aer riding through cain or on muddy roads, the element should be cleaned immediately. (Since repeated cleaning opens the pores of the foam in the element, replace it with a new one in accordance with the Periodic Mainto- ‘nance Chart. Also if there is 9 break in the element material or any. ‘other demage to the elerment, replace the element with a new one. EES CCleanthe element in a well-ventilated area, and make sure that there are no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquide, do not use _gasoline or @ low flest-point solvent to clean the element. @Take out the air cleaner element [A] trom the lower air cleaner housing, @Clean the element in a bath of high flash-point solvent, and then dry it with compressod air or by shaking it. @Atter cleaning, saturate a clean, lint-free towel with SE class SAE 30 cil and apply the oil to the element by tapping the element outside with the towel. © Visually check the element for tears or breaks, %1f the element has any tears or brezks, replace the element. ‘@ Replace the element according to the Periagie Maintenance Chart (seo General Information chapter) Oil Draining A drain hose [A] is connected to the bottom of the air cleaner housing, o drain ol accumulated at the bottom of the housing. (@ Visually check the drain hose ifthe oll accumulates in the hose. 211 any wator 0” cil accumulates in the tank, dain it by taking off the ain plug [B] at the lower end of the drain hose Pon 1¢ plug in the drain hose after draining. Olt on tures will make them slippery and can cause an accident and inju2.18 FUEL SYSTEM Air Cleaner Housing Installation '@ Be eure to fit the engine brosthor hose and draining hoses into the air cleaner housing (see Cable Routing in the General Infomation Chapter)Fuel Tank Removal Win) Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do notsmeke. Make sure the area is well-ventilated and free from ary source of flame or sparks; this includes ary appliance with pilot ight. ‘CAUTION For California model, i gasoline, solvent, water or any other liquid teers the carisler, the canister’s vapor absorbing capacity is greatly reduced. I! the canister does become contaminated, replace it with ‘@Remove Seat (@Turn the fuel tap to the ON oF RES position. ‘@Pull tho ful hose[A} off the tap. NOTE (©Do not pull ether wo fuel hoses{B), [C] off the tank, other wise fuel will flow out ‘@ Remove the fuel tank mounting bolts [4]. ‘@Disconnect the fuel level sensor lead connector (@ Remove the fuel tank (Drain the fuel tank © Place a suitable container under the fuel tank ‘0Tumm the fuel tap to the PRI position to dain the fuol into the container ©The fuel level sersor [A] is installed at the bottom of the fuel tank, if itis replaced with new one, remove it. Installation Notes ‘@ Read the above WARNING. ‘Route the hoses and leads correctly (see General information chapter). (@Be sure the hoses ae clamped securely to prevent leaks. FUEL SYSTEM 2-192-20 FUEL SYSTEM Inspection ‘@-Visually inspect the gaskets on the tank and cap for any damage. ‘Replace the gaskets if they are damaged. ) from the fuel tank, and open the tank cop. {@ Check to see if the breather and water drain pipes (aso the fuel rerum pipe for the Califomia model) in the tank are not clogged. Check the tank cap breather also, rif they are clogged, remove the tank and drain it, and then blow the breather free with compressed air. ‘CAUTION ‘Donot apply compressed air othe air ventholes [A] on thetank cap. ‘This could cause damage and clogging of the labyrinth in the cap. PGI (Clean the tank in a well-ventilated area, and tate care that there are ‘no sparks or flame anywhere near the working area. Because of the [ ==] om [em [ew wee [aw [om [ae [ve] oe [om [am [2 [om | an 029=038| [a= [se] em] ow [ew [re ta [ae [ae [2m [ae [om [om [ew [em [om ot—oa0| [r= [ox [om[ oe [ om [as wee [om | am [ate [ame [Pat [om [0 039— zal n [om [on [es [ow ve [em [am [om [om [oe [ee [ae loatcoaa| [p= (os [ ss fom [om [oe om [ve fone a [fee lEloan cosa] [2 [20 [r0| 20 [2m |zm[am[am|am [am [ew [om [om [ome] a bsostzose] [ro] [o>] em lem] wel | om [om [om [om ee Slos=om| [m[s[m[rm|oevo[em[emlim [emf faml os Stoecest| [oales[e [em len lan|s[uslielemfom] 6 « Sheses| petetetetstetete babel — 3 etsrcare| Laotet ater tse mmf Lio] 4% lufor—om| [a [ae]in [em [ae [oelasfom] oh 2 zo fen [ee [am [oo foe] om] ee g #5 fee Inlet Valve 1, Measure the clearance (When engine cold) 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4, The shim specified where the lines intersect is the one that will give you the proper clearance. NOTE lf there is no clearance, select « shim which is several sizes smaller and then measure the clearance:ENGINE TOP END 4-17 PRESENT SHIM oa | SYA TAS [Te [a | 77 ae a7 [a [ves [vz] esse was [J Tweenies; [am [205 [20 as Lom [an [am [am | no | os [5 [2 [ae | 28] oo [2m | om [a PECTS] se Tae [oe ee Ds [= ae ee Pam [a aorzone| (AAA [am [a [2m [ae [om | [om foe [ow fo] os [om om [om [er fm [oe 0080.13 (alas [ae [ar [ea [ae [am fom [ow [oe [ow [os [oem [am [ee [em [am fm |e 0340.7] Sa Lae Loe [om [om [oe [ove [oon [om [ae [ow [om [oe [ae |e [ee [aes [oe |e ‘018023 SPECIFIED CLEARANGE/NO CHANGE REQUIRED ‘azezoz| [ae [he [Fe] ae [ee [om [oe | ee [oe [om [om [oe [oe [ee] om [om [om [om caszoas] Cetera [som [om [om [oe [re [a ow em fm [ae | asco] Pelee p= [mpm pew foe toons] [a= tee teees em ee [oe obo fy [eloae=oaa] [f= [om] om [oer om [| om [oe [am [om Eloarcoss| [estes tee[ =m [om [oo [me [oe [ew b-[ase—oss] [2x [20] zm| wo ]e= [se] em | oe] vs] oe [em] ISfoso—osa] [>= [>= [==] om [re] 2m [2m | am] | am |e Freer cd Stospzo7s] [z= [e=[ sm] cm [ae [om [em] oe | oe | om [aon See ee eerie bebe eal ie cee Sfer=oss] [melo [oforlom lem tole) ae chase Valve elas ons] [rs [om [eer [mm te [eT] 4% mogeue th clararce (When engine cold) jSlose—oae] fom fox |e) ce TAS” 2. check present shim size. ons SS 3. Match clearance in vertical column with present 098108) eet shim size in horizontal column, qe the one that will give you the proper clearance 1.19123) NOTE of there is ro clearance. select a shim which is several sizes smaller and then measure the clearance. © Side the rocker arm[B] sideways and change the shim (A). ‘0 Remeasure the valve clearance that are adjusted. Readjust if necessary. CAUTION = ‘Do not put shim stock under the shim. This may cause the shim to ‘pop out at high rpm, causing extensive engine damage. Do not grind the shim. This may cause it to fracture, causing extensive engine damage. Valve Removal ‘Special Tool ~ Valve Spring Compressor Assembly: 7001-241 (A) Valve Spring Compressor Adapter, 022: 57001-1202 co)4-18 ENGINE TOP END Valve Installation ‘e Apply a thin coat of molyodenum disulfide grease to the valve stern bbofore valve installation, @ Install the springs co that the closed coil ond faces downwards [A] Valve Stem [F] Retainer [B] Spring Seats [G] Spring Seat [Cl Oil Seal [H] Closed Coil End [D] Inner Spring (1) Split Keepers [E] Outer Spring Valve Guide Removal @Tap out the valve guide. ‘Special Tool ~ Valve Guide Arbor, 05: 57001-1203 [A] NOTE © Heat the area around the velve guide to 120 ~ 150°C (248 ~ 302'F) Valve Guide Installation €@ Drive the valve guide until its flange touches to the cylinder head ‘Special Tool ~ Valve Guide Arbor, 0: 7001-1203 NOTE (Heat the area around the valve guide hole to 120 ~ 150°C (248 ~ 302) Apply oll to the valve guide outer suriace before valve guide instal- Iation. (©Using the valve guide reamer, ram the valve guide. ‘Special Tool ~ Valve Guide Reamer, 05: 57001-1204 [A] Seat Inspection ‘@Femove the valve {©Check the valve seating surface [A] between the valve [8] and valve seat [C] Measure the outside diameter [D] of the seating pattern on the valve sat +f the outside diometer i too arge or too smal, repair the seat (sve Seat Repair. ‘Valve Seating Surface Outside Diameter Standard: Inlet 30.8~31.0 mem exnaust 263~265 mm ‘© Measura the seat width [E] of the portion where there is no build-up carbon (white portion) of the valve seat with a vernier caliper. 4 the width is too wide, to0 narrow or uneven, repair the seat (see Seat Resale Valve Seating Surface Width ‘Standard: inlet, Exhaust 0.5 ~ 1.0mm.ENGINE TOP END 4-19 Seat Revair (@ Repair tho valve seat with the valve seat cutters. Special Too! ~ Valve Seat Cutter Holder, 0§: 57001-1208 Valve Seat Cutter Holder Bar: 57001-1128 [For inlet Vaive Seat) Valve Seat Cutter, 45° ~ 432: 57001-1115 Valve Seat Cutter, 32° ~ 033: 57001-1199 Valve Seat Cutter, 60° ~ 30: 57001-1123 [For Exhaust Valve Seat] Valve Seat Cutter, 45° ‘Vaive Seat Cutter, 32° Valve Seat Cutter, 60° ~ 930: 57001-1123 Valve Seat Cutter, 60° ~ 33: 57001-1334 rif the manufacturer's instuctions are not available, use the following procedure 927.5: 57001-1114 (930: 57001-1120 ‘Seat Cutter Operation Care: 1. This valve seat cutter is developed to grind the valve for repair. ‘Thoretore the cutter must not be usad for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the diamond particles ray fall of. Do not fail to apply engine oil to the vaive seat cutter before drinding the seat surfzce. Also wash off ground panicles sticking to the cutter with washing ol. NOTE Do notuse @ wie brush to remove the metal panicles from the cutter. It wil take off the diamond particles 4, Setting the vale seat cutter holder in position, operate the cutter in fone hand. Do not epply too much force to the diamond portion. NOTE OP rior to grinding, apply engine oil to the cutter and during the operation, wash off any ground particles sticking to the cutter with washing ol. ‘iter use, wesh it with washing oil and apply thin layer of angina (il before stoxing, Marks Stamped on the Cutter: The marks stamped on the back of the cutter {A represent the following 80" Cutter angie [8] 37.59. Outer diameter of cutter [C1]4-20 ENGINE TOP END Operating Procedures: {@Cioan the seat area carefully, ‘© Coat the seat with machinists dye. @Fit 2 45° cutter into the holder and slide it into the valve guide, ‘@Press down lightly an the handle and tum it right or lof. Grind tho seating surface only unti itis smooth. ‘CAUTION Do not grind the seat too much. Overgrinding will reduce valve clearance by sinking the valve into the head. Hthe vaive sinks too far into the head, It will be impossible to adjust the clearance, and the cylinder head must be replaced. @Mezsure the outside diameter of the seating surface with a vernier caliper. >I the outside ciameter of the seating surface 's too small, repeat the ‘45° grind unti the diameter is within the specified range. AIF the outside diameter of the seating surface is too larga, make the ‘82° grind described below. %If the outside diameter of the seating surface is within the specified range, measure the seat width as described below. (@Giind the soat at 2 32° angle until the seat O.D. io within the specified range. ‘To make the 32° grind, fit 2 32° cutter into the holder, and slide it into the valve guide, (OTutn the holder one turn at a time while pressing down very lightly Chock the soat after aach tur. ‘CAUTION “The 22° cutter removes material vory quickly. Check the seat outside diameter frequently to prevent overgrinding. ‘After making the 32° grind, return to the seat 0.D. measurement step above. (@To measure the seat width, use a vernier caliper to measurs the wicth of the 45° angle portion of the seat at several places around the seat elf the sest width i 100 narrow, repeat the 45° grind until the seat is htly too wide, and then retum to the seat O.D. measurement step abave. Ifthe seat width is too wide, make the 60° grind described below. ‘Ifthe seat width is within the specified range, lap the valve to the seat as described below. {®.Grind the seat at a 60" angle untl the soat width ie within the specified range. (0To make the 60° grind, fit 60° cutter into the holder, and slide it into the valve guide, Tum the holder, while pressing down lightly ‘OAftor making the 60° grind, rotum to the seat width measurement step above, ‘@ Lap the valve to the seat, once the seat width and O.D. are within the ranges specified above. ‘OPut a little coarse grinding compound on the face of the valve in 3 ‘number of places around tho valve head. ‘© Spin the valve against the seat until the grinding compound produces @ smooth, matched surface on both the seat and the valve, (© Repeat the pracess with a fine grinding compound. [A] Lapper [B] Valve Seat [Cc] Valve ‘@'The seating area should be marked about in the middle of the valve face, | Witenes width of lonsegement by machining Ground voiume jw 46 cuter by 32 cuter L by 60’ cutterENGINE TOP END 4-21 the seat arse is not in the right place on the valve, check to be sure the valve is the correct part. [fits it may have been refaced too much replace &. ‘@8e sure to remove all grinding compound before assembly. ‘@When the engine is assembled, be sure to adjust the valve clearance (see Valve Clearance Adjustment). Valve-to-Guide Clearance Measurement (Wobble Method) if a small bore gauge is not avaiable. inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method 2 indicated below ‘incor a new velve [A] ita the guide [8] and set adil gauge against the stem perpendicular it a close as possible to the oylinder head mating surfece. @Move the stem back and forth [C] to measure valve/valve guide ‘osrance. ‘Repeat the measurement in a direction at a ght angle tothe frst, -kit the racing exceeds tne service limit replace the guide. NOTE ‘The reading is not actual valve/valve guide clearance because the ‘measuring point is above the guide. \Valve/Valve Guide Clearance (Wobble Method) ‘Standard Service Limit Inter 0.02 ~ 0.07 mm 048mm Exhaust 0.05 ~ 0.11 mm 0.21 mm4-22 ENGINE TOP END Cylinder, Piston Cylinder Removal ‘@Remove the cylinder head. Remove the cylinder bolts (A) ‘@Remove the cylinder. Cylinder Installation ‘@Apply ongine ol to the cylindor bore. install the cylinder block. Special Tools — Piston Base, 06: 57001-1263 [A] Piston Ring Compressor Assembly: 87001-1094 [8] Piston Removal ‘@Remove the cylinder €@Place clean cloth under the pistons and remove the piston pin snap ‘ings from the outside of each piston ‘@Remove the piston pins ‘Special Tool ~ Piston Pin Puller Assembly: 7001-810 [A] ‘Adapler [8] Piston Installation ‘@Tho top and second rings must be inetallod with tho N or 2N marks on the rings facing up. ‘@The piston ring openings must be positioned as shown below. The ‘openings of the oil ring steel rails must be about 30 - 40° of anale from. the opening of the top ring. [A] Top Ring [0] Oil Ring Expander [B] Second Ring [E] Anow [C] Oil Ring Steet Rails ‘@The amow on the piston head must point toward the front of the engine. ‘CAUTION (Do not reuse snap rings, as removal weakens and deforms them. ‘They could fallout and score the cylinder wallENGINE TOP END 4-23 Cylinder Wear {@Since there is a difference in cylinder wear in diferent directions, take {side-to-side and a front-to-back measurement at each of the 3 locations (total of 6 measurements) shown in the figure “if any of the cylinder inside diameter measurements exceeds the service limit, replace the cylincer [A] 10mm [8] 60mm. [C] 20mm Gylinder inside Diameter ‘Standat 75994 ~ 76.008 mm Service Limit: 76:10mm. Piston Wear ‘@Mecasure the outeido dismetor of each piston 5 mm [4] up fiom the bottom of the piston st a right angle to the direction of the piston pin. if the measurement is under service limit, replace the piston. Piston Diameter ‘Standard: 75.918 ~ 75.938mm Service Limit 75.77 mm4-24 ENGINE TOP END Piston Ring, Pistort Ring Groove Wear (Check for uneven groove wear by inspecting the rina seating, + The Fings should ft perfectly paralol to the greove surfaces. If not, tho piston must be repiacod © Wit ine piston rings in their grooves, make several measurements with 2 thickness gauge to determine piston ring/aroove clearance. Piston Ring/Groove Clearance ‘Standard Service Limit Top 0.03 ~ 0.07 mm 0.7 mm ‘Second (0.03 ~ 0.07 mm 017 mm Piston Ring End Gap ‘© Place the piston ring [A] inside the cylinder. using the piston to locate the ring squarely in place. Set it close to the bottom of the cylinder, where oylinder weer is low. ‘© Measure the gap [8] between the ends of the ring with a thickness gauge. Piston Ring End Gap Standard, Service Limit Top 020 ~ 032mm O7mm Second 020 ~ 0.35 mm o7mmENGINE TOP END 4-25 Carburetor Holder Carburetor Holder Installation ‘install the carburetor holder so that the pipe is upward. Be careful of the clamp screw position (A) EMENIN carburetor holder clamps4-26 ENGINE TOP END Muffler Removal ‘@Romove the following Upper and Lower Fairings Coolant (draining) Radiator Hors (both left and right) @ Remove the nut [A] and tak off the oxhaust pipe holdore [3]. @ Loosen the muffier clamp bolt @ Remove the mufiler mounting bolts [A] Exhaust Pipes [D] Muttier [B] Holders [E] Mounting Bolt [C] Exhaust Gasket —_[F] Clamp.Clutch Table of Contents Exploded View ... Specifications... Clutch Fluid . : Fluid Level Inspection.. Clutch Fluid Changing Bleeding the Clutch Line Master Cylinder: : Installation. Disassembly Assembly Inspection Clutch Slave Cylinder Romoval . Installation... Disassemby’.... Assombly.. Gluten... Removal Installetion.. Friction Plate Wear Friction and Steel Plate Warp... Clutch Spring Free Length Measurement. Cam Damper inspection CLUTCH 5-15-2 CLUTCH Exploded View 1. Starter Lockout Switch G. Apply grease. L. Apply non-permanent locking agent. M. Apply molybdenum disulfide grease. S. Follow the specified tightening sequence. T1: 6.9 N-m(0.60 kg-m, 62 i 72: 7.8 N-m(0.80 kg-m, 69 73:11 N-m(1.1 ka-m, 95 in- 4:18 N-m(1.8 kg-m, 13.0 TS: 25 N-m(2.5 kg-m, 18.0 T6: 130 N-m(13.5 ka-m, 98 in-Ib)5-4 CLUTCH Specifications Item Standard Clutch Fluid: Grace Dor Brand recommended) Castrol Girling- Universal Castrol GT(LMA) Castrol Disc Brake Fluid Castrol Shock Premium Heavy Duty Ee Clutch: Clutch spring free length Friction plate thickness Friction and steel plate warp 46.3 mm 27 ~30mm 42.7 mm 2.5 mm 0.3 mm Special Too! ~ Kawasaki Bond (Silicone Sealant): 56019-120Clutch Fluid Fluid Level Inspection ‘Check the clutch fluid level in the reservor. Lower Level Line(A] Upper Level Line[B} NOTE (O Hold the reservoir horizontal when checking clutch fluid level + Ifthe fluid level is lower than the lower level lne, fill the reservoir to the upper level line in the reservott ESIGN ‘Change the fluld in the clutch line completely if the fluid must be refilled but the type and brand of the fluid that already is in the reservoir are unidentified ‘After chenging the fluid, uee only tho same type and brand of fluid thereafter. Mixing diferent types and brends the clutch to be ineflactive, Itmay also cause the rubber clutch parts to deteriorate. Recommended Clutch Fluid 1.0.7.4 Heavy Duty Brake Fluid Castrol Girling- Universal Castrol GT (LMA) Caetrol Dise Brake Fluid Castrol Shock Premium Heavy Duty NOTE ©Since the clutch fluid is the same as the brake fluid refer to Brake Fluid Section in Brakes for further devas. Clutch Fluid Changing ‘@Romove the reservoir cap, and remove the rubber eap on the bleed valve. ‘@Attacn a clear plastic hose 10 the bleed vaive on the cluteh slave cylinder, and run the other end of the hose into a container. ‘@Fill the reservoir with fresh fui. © Check the clutch fluid 2s follows. ‘©Open the bleed valve. [A] (O'Squeeza the clutch lever and hoid it (6) (Close the bleed valve. [C] (ORolezse the clutch lever. [D] ‘© Repeat this operation until fresh fluid comes out from the plastic hose or the color ofthe fluid changss. ‘©Check the fluid lovel in the rosorvoirofton, replenishing it as necessary NOTE OM the fluid in the reservoir runs completely out any time during fluid changing, the bleeding operation must be dane over again from the boginning since air will have entered the lino. Do not mix two brands of tui CLUTCH 5-55-6 CLUTCH Bleeding the Clutch Line ‘@With the reservoir cap oif, slowly pump the clutch lever several times Until no air bubbles can be seen «ising up through the fluid from the holes at the bottom of the eservoir. This bleeds the air from the master ‘oylindor ond of tho lino NOTE OTep the clutch hose lightly going from the lower end to the upper fend and bleed the air off at the reservoir. ‘eattach 2 clear plastic hose to the bleed valve on the clutch slave ‘ovlinder, and run the ather end of the hose into a container. {@Bleed the clutch line a5 follows: (OPump the cluten lever a few times unti it becomes hand and then hola it squeezed. (A ©Quickly open and close the bieed valve. (B) (ORelease the clutch lever.(C] (ORepeat this operation until no mere air can be seen coming out in to the plastic nose (OCheck the ‘uid level in the reservcir often, replenishing it as necessary. NOTE lf the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the beginning since air will have entered the line. re) Do not mix twe brands of fui.CLUTCH 5-7 Master Cylinder Installation ‘@When installing the clutch master cylinder, be careful of following GThe master cylinder clamp with the arow on it pointing unwards. (8) (oTighten the upper c'amp bolt trst(], and then the lower clamp bolt ‘Torque ~ Upper and Lower Clump Bolt: 11 N-m(1.1 kgm, 95 in-b) © Replace the aluminum washer on each side of the clutch hose fitting with a new one. Tighten the banjo Bott. Torque ~ Banjo Bolt: 25 N-m(2.5 kg-m, 18.0 fib) ‘@ Perform the following aiter installing the master cylinder. Bleed for clutch line (Check for clutch operation Check ‘or fluid leakage Disassembly ‘@Remove the following. (Clutch Lever Dust Cover Primary Cup [A] Secondary Cup [8] Piston [C] Girciip [0] Spring NOTE (©.De nat remove the secondary cup from the piston. Assembly ‘@Clean the disessembled parts with clutch fluid and apply clutch fluid to the inner wall of the cylinder. ‘CAUTION “Take care net to scratch the piston or the inner wall of the cylinder. Inspection {@Check the following for wear. damage, cracks, or deterioration: Cylinder Inner Wall and Piston Primary and Secondary Cups Dust Cover Spring ‘eCheck that the rolof and supply pons on the cylinder are not plugged.5-8 CLUTCH Clutch Slave Cylinder Removal ‘@ Remove the following Banjo Bok [A] Mounting Bolts (B] Slave Cylinder [C] ‘CAUTION Immediately wash away any brake Painted surfaces. ud that spi, tt may damage Perfoin the following ifthe clutch slave cylinder is to be removed but not disassembled, CAUTION "the clutch siave cylinder is removed and left alone, the piston wi be pushed out by the spring and the clutch tuid will drain out. (© Remove the cluteh slave cylinder from the engine with the hose and puch the piston into the oylindor as far as it will go. ‘oSqueeze the clutch lever slowly and howd it with a band. NOTE OHolding the clutch lever keeps the piston trom coming out Installation ‘@Note the following. ‘O Replace the aluminum washers on each side of the elutch hose fitting with new ones ‘©Tighten the banjo bolt to the specified torque (see Exploded View) (OReplace the spacer of the clutch slave cylinder with bolts of the slave cylinder with new one. ‘© Apply nen-permanent locking agent to the two short belts of the slave cylinder mounting bot. (© Check the fluid level in the master cylinder reservoir, and bleed the air in the cluteh line. (0 Check the clutch operation. Disassembly €€ Using compressed air, remove the piston ‘Cover the eylinder opening with 3 clean, heavy cloth [2] oF ace the opening downwards. ‘ORemove the piston by lightly applying compressed ait( A to where the clutch line fits into the slave cylinder. ‘CAUTION ifthe fluid seat is removed from the piston, replace the with @ cylinder opening. 1 you apply high compressed air to the cylinder, the piston may injure your hand or fingers.CLUTCH 5-9 Assembly {@Do the following. Apply clutch fluid to the outside of the piston and the fluid sea Cnstal the uid teal as shown in the figure. Gyiinder [A] Fluid Seal [C] Piston [8] Spring [0] CAUTION Replace the fhild seal with a new one if it was removed from the5-10 CLUTCH Clutch Removal ‘@Remove the following, Lower Fairing Clutch Cover [A] Cluteh Cover Bott (8) Cuutch Spring Bolts [A] ‘Guten Springs Cuuteh Spring Plate(with thrust bearing and pusher)(8] Friction Plots, Stee Plates Cutch Hub ‘Oolding the clutch hub, remove the nut{8] ‘Spectal Too! ~ Clutch Holder: 57001-1243 [A] NOTE When removing the clutch housing, remove the alternator drive chain tensioner for easy handling(see Crankshalt/Transmission chapter) Sleeve [A] Cluten Housing (8) ‘Using the two 6 mm bolts, pull out the sleeve. @To disassemble the clutch hub, remave the following. Cireiip (© Press [C] in the demper spring plate[A], and remove the circlip[B)CLUTCH 5-11 Installation ‘@ Installation is the reverse of removal. Note the following. (© Discard the used clutch hub nut, and install a new nut ‘CAUTION new dry friction plates and steel plates are installed, apply engine oll to the Surfaces of each plate lo avoid clutch plato seizure, ‘@lnsiall the last fiction platefAl, fitting the tangs in the groove on the housing as shown, ‘einstal the alternator rive chain toncioncr, if it was removed (see Cranishatt/Transmission chapter). Tighten the clutch hub nut. Torque ~ Clutch Hub Nut: 130 N-m (13.Skg-m, 96 4b) f@install the clutch pletes and stool plates, starting with a friction plate and alternating them, ‘eBefore installing the clutch spring plate, squeeze the clutch lever ‘slowly and hold it with a band while pushing the spring plate pusher imo the clutch hub. ‘@ Apply molybdenum disulfide groase to the push rod end [A],5-12 CLUTCH (©Tighten the clutch soring bolts, ‘Torque ~ Clutch Spring Bolts: 11 Nam(1.1 kg-m, 95 into) ‘@Appiy silicone sealant[Ajwith 5 mm long[C] to the crankcase halves ‘mating surface[B] on the front and rear sides of the cover mount. @Apply a non-permanent locking agent to the 4 Clutch Cover Bolts Al Friction Plate Wear If any friction plate [A] thickness is less than the service limit, replace the friction plates as a set. Friction Plate Thickness Standaré: 27 ~ 3.0mm. Service Limit: 25 mm Friction and Steel Plate Warp “If any plate is warped over the service limit, replace the plates as a set Friction and Steet Plate Warp Standard: ——_lessthan 0.2 mm Service Limit: 0.3 mm {Al Friction or Steol Plate [C] Surtace Plate {B) Thickness GaugeCLUTCH 5-13 Clutch Spring Free Length Measurement “kif any of the spring[A] is shorter than the service lit, it must be replaced ‘clutch Spring Free Length Standard: 463mm Service Limit: 427mm Cam Damper Inspection ‘eVisualy inspect the damper cam{A}, damper springs [C ], and cam, followerfBI. +4 Replace any part that appears damagedENGINE LUBRICATION SYSTEM 6-1 Engine Lubrication System Table of Contents Exploded View .. Engine Oil Flow Chart Specifications... Engine Oil and Oil Filter Oil Level Inspection Engine Oil Change Oil Filter Change... ll Pan, Removal . Installation: se il Pump and Relief Valve. il Pump and Relief Valve Removal Oil Pump and Relief Valve installation... Gil Cooler Removal Installation Inspection Oil Pressure Measurement. Oil Pressure Measurement...6-2_ ENGINE LUBRICATION SYSTEM. Exploded View il Pressure Switch ‘Small note sice ‘Apply non-permanent ‘Apply silicone sealant 412 Nem (1.2 kg-m, 106 ino) 15 Nem (1.5 kg-m, 11.0 feb) 18 Nem (1.8 ko-m, 13.0 fb) 20 Nem (2.0ko-m, 14.5 ft-lb) 25 Nem (2.5kg-m, 18.0 Rb) 29 Nem (3.0 kg-m, 22 fb) 34 Nem (3.5 kg-m, 25 lb) ddaede2 geENGINE LUBRICATION SYSTEM 6-36-4 ENGINE LUBRICATION SYSTEM. Engine Oil Flow Chart 1. Transmission Chamber 2. Balancer Chamber 3. Seren 4 Ol Pump 5. Oil Cooler 6 Relief Valve 7. Oil Filter 8 Bypass ValveENGINE LUBRICATION SYSTEM 6-5 Specifications Item’ Standard Engine Oi | Grade SE, SF, or SG class Viscosity SAE 10W-40, 10W-50, 20W-40, or 20W-50 Capacity 3.2L (when filter is not removed) 3.5L (when filter is removed) Oil Pressure Measurement: Oil pressure @4,000 r/min(rpm), oil temp. 90°C(194°F) ‘Special Tool ~ Kawasaki Bond (Silicone Sealant):6-6 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter Pn ‘Motoreyele operation with ineuficiont, det jorated, or contaminated ‘engine oil will cause accelerated wear and may result in engine or transmission seizure, accident, ana injury. Oil Level Inspection Check the engine oil level between the upper{A] and lower [B) level in the gauge. NOTE 0Situate the motorcycle s0 that its perpendicular to the ground. OM the motorcycle has just been used, weit several minutes for all the off 10 drain down. Off the oi! has just been changed, start the engine and run itfor several ‘minutes at idlespeed. This fils the oil ftee with oil. Stop the engine, then weit several minutes until the of! soto. ‘CAUTION Facing the engine before the ollreaches every part can cause engine ifthe engine oil gete extremely low or i the oll pump or cil passages clog up or otherwise do not function properly, the oil pressure ‘warning light will light. If this Dght stays on when the engine is ‘running above idle speed, stop the engine immediately and find the Engine Oil Change ‘@Set the motoreycie up on its center stand after warming up the engine. @Remove the lower fairing. @Romove the engine drain plugs [A] to drain theo The oil in the fiter can be drained by removing the filer mounting tolis[B] and raking off the filter from the bot. Replace the drain plug gasket with a new one ifit's damaged. ‘Tightan the dean plugs to the specified torque(soe Exploded View). ‘Tigiten the oil fter mounting bolt to the specified torque(see Exploded View). ‘© our in the specified type and amount of oil Engine Oi! Grade SE, SF, or SG class. Viscosity: SAE 10W40, 10W50, 20W50, 20W40, 201V50. Amount: 3.51 (engine is completery dry) 3.54 (tte is removed) 3.21 (filter isnot removed)ENGINE LUBRICATION SYSTEM 6-7 i Filter Change Drain the engine oil @Disconneet the oil pressure switch lead end Remove the oil fer ‘mounting bolt and take off the fitor assembly NOTE © The oll titer bypass valve is assembled in the mounting bolt ‘A. Mounting Bot E. Spring B. O-ring F. Washer C. Filter Cover G. Finer D. Oil Fence ‘@When installing the oil filter. be careful ofthe following. ‘@ Apply cil to the mounting bolt, tum the fiter or the mounting bait to ‘work the filer inte place. Be careful that the fiter grommets do not slip out of pace. Tighten the fiter mounting bolt. ‘Torque ~ Fiter Mounting Bolts: 20 N-m (2.0 kg-m, 14.5 feb) Replace the O-rings with new ones if they are damaged. (© Pour in the specified type and amount of ol. (@Be cerelul not te pinch the oil pressure switch lead[A] betwoen the ‘il filter cover{8] and the oil pan. The cil pressure switch lead must be installed to the comect position to keep away from the mufflers.6-8 ENGINE LUBRICATION SYSTEM Oil Pan Removal ‘@ Remove the following Fairings, Engine Gil (drain) Cooiant (drain) Radiator i Cooter Mufiles Oil Filter Oil ipo [A] Oil Hose Banjo Bolts (8) © Remove the oll pan bolts and take off the ol! pan, Installation Installation is the reverse of removal. Note the following. @Apply a silicone sealant to the ilustated area (Al, threads if the oll pressure switch. and tighten them. ‘Torque — Oil Pressure Switch: 15 N-m(1.5kg-m, 11.0 4D) ‘© Replace the gasket with a new one. ‘Replace the O-rings A] with new ones if they are damaged. The outlet side O-ring[B} between the oil pan and oil pump bracket rust be installed eo that flat side faces the bracket.ENGINE LUBRICATION SYSTEM 6-9 ‘@Agply a non-permanent locking agent to the threads of the four oil pan bolts which are indicated by the tiangular marks[A))6-10 ENGINE LUBRICATION SYSTEM Oil Pump and Relief Valve Oil Pump and Relief Valve Removal ‘@ Remove the following. Oi Pan Oil Sereen Oil Pipe Oil Pump Bracket Bolts ©Pull out the brackot and pump assembly. NOTE OFemove the pickup coll cover, and turn the crankshaft until the ceatches{A] of the pump shaft ends are vertical, ‘@ Remove the oll pump[A] @Unscrev the relief valve [B] Oil Pump and Reliof Valve Installation ‘@Fll the pump with engine oil before instalation ‘eCheck that the collars[A] and O-rings[B] ae ina place. The outlet side O-rings must be installed so that the flat side facas the bracket. ‘@Apply a non-permanent locking agent te the following and tighten ‘them, Relef Vane il Pump Mounting Bolts ‘Torque ~ Oil Pump Mounting Bolts: 12 Nem (1.2kg-m, 104 in-Ib) ‘CAUTION Do not over-apply a non-permanent locking agent to the threads. This may block the oll passage. @Check that the knock pin{A], nozzle, and O-ring (C] arein place. The ‘small hole of the nozzle B] must face the bracket.ENGINE LUBRICATION SYSTEM 6-11 check thet the oil pump shaft catches [A] of both components are vertical ‘© Bejore installing the oil pump, be euro the shaft and rotors turn freely. [A] Thinner Rotors [B] Thicker Rotors6-12 ENGINE LUBRICATION SYSTEM Oil Cooler Removal ‘@ Remove the following Upper and Lower Farings Engine Oil (drain) Oil Hose Banjo Bolts (cooler side) Oil Coole: Mounting Bolts [A] Oil Screen Mounting Bott (3} '@o romove tho oil cooler hoses, remove the mufflers. Installation @ installation isthe reverse of removal. Note the following. ‘@ Replace the washer in each sido of the cil hose fitting with a new one, ‘@ Install the oll hose fitting in the correct position. ‘A Oil Cooler . Projection B. Oil Hose Bracket E Damper ©. Oil Pon ‘Torque ~ Oil Hose Banjo Bolts (8 mem): 15 Nem (1.5 kg-m, 11.0 Rb) (14 mm Cooler Side): 25 Nem@25 kg-m, 18.0 fb) (14 mm Ol! Pan Side): 34 N-m(3.5 kg-m, 25 fb) @ install the screen bracket(A] between the oll cooler bracker(B] and the radiator brackets, C].ENGINE LUBRICATION SYSTEM 6-13 Inspection ‘@Check the oil cooler 4 f there are obstructions to air low, remove them. Self the cortugated fins are deformed, carefully straighten them with blade of a thin screw driver. CAUTION Do not tear the cooler tubes while straightening the fins. “+! the air of the cooler core are blocked by unremovable obstuuctions cr ireperably deformed fine, roplace the oil cooler. ‘CAUTION ‘When cleaning the oll ecoler with comprossed air, be careful ofthe {ollowing to avold damage to the fins. Keep the air nozzle [A] over 0.5 m (20 in.) (B] away from the oil cooler. Blow air perpendicularly to the cooler core. [Never blow air at an angle againet the fine but straight through them inthe direction it natural ar flow. Never shake the air nozzle at a right angle against ine fins; be sure ‘to move it at a level with the fins. OK. 6-14 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement © Warm up the engine, and then stop the engine. (@ Remove the oll passage plug, and attach the gauge and adapter to the plug hole, Special Too! ~ Oil Pressure Gauge, 10 kg/cm: 57001-164 [A] Oil Pressure Gauge Adapter, M18x 1.5: 57001-1278 i) AWARNING ‘Take care against burns from hot engine oil that will drain through the oil passage when the plug id removed. Stat the engine again, Fun the engine at the specified speed, and read theoil pressure gauge. %It the oil pressure is significantly below the specification, inspect the cil pump and reliaf vawve If the of pump and relief valve are not fault, inspect the rest of the lubrication system. 1 Proasure Standard: 195 ~ 294 kPa (2.0 ~ 3.0 kgiem?, 28 ~ 43 psi) (24,000 rimin(epm), oil temp. 90°C (194°F) Stop the engine. ‘@ Remove the oil pressure gauge and adapter €@ install the oil passage plug, ‘Torque ~ Oi Passage Plug: 18 N-m(1.8 ka-m, 13.0 1b)ENGINE REMOVAL / INSTALLATION 7-1 Engine Removal / Installation Table of Contents Exploded View Engine Removal/ Installation... Engine Removal Engine Installation EGSs L)7-2_ENGINE REMOVAL / INSTALLATION Exploded View TH: dane (45 kgm, 33 feb) TR: 20N-m (20 kgm, 14.5 tb)ENGINE REMOVAL / INSTALLATION 7-3 Engine Removal/Installation Engine Removal ‘@ Remove the following. Fairing Engine Oil (Drain) Coolant (Drain) ‘Seat Fuol Tank Radiator Oil Cooter Muffler Air Cleaner Housing Carburetors Fuel Pump and Filter Gluten Stave Cylinder (see Clutch chapter) Engine Sprocket Vacuum Switch Valve and Hoses (US model only) Bote Plato Disconnect wiring from the engine and free them from the clamps. Pickup coil Load Battery Ground Lead [4] Starter Motor Lead (8) 0 Pressure Switch Wire [A] Neutral Switch Lead [A] Side Stand Switch Lead connector [8] Alternator Leads{C]7-4 ENGINE REMOVAL / INSTALLATION ‘eSupport the engine with 2 stand before take out the rear engine ‘mounting bolts @Locsen Allen bolts [A] for supporting collars on the rear upper and lowor engine mounting bolts. @ Remove the front engine mounting bolts [Al, ‘@Remove the down tube Allen belts [8] and take off tho down tubes [el ‘© Remove the rear upper and lower engine mounting bolts [D} ‘@Now the engine is free from the fasteners. ‘@ Remove the engine by incining the engine as shown. Engine Installation {© Using the jack under the engine, install the engine. ‘@install the collar atthe let side of the rear engine bolts. Torque the following. ‘Torque ~ Engine Mounting Bolts : 44 Nem (4.5 kg-m, 33 Mb) (© Front Engine Bracket Bolt © Front Engine Mounting Bolt © Rear Upper and Lower Engine Mounting Bolt © Down Tube Allen Bolt Torque ~ Hear Upper and Lower Allen Bolts : 20 Nem (2.0 kg-m, 14.5 ftp) ‘@Run the leads, cables and hoses correctly (see Cable, Wire and House Routing in General informetion chapter). @ install the removed parts (see appropriate chapters) Adjust Throttle Cables Choke Cable Drive ChainCRANKSHAFT / TRANSMISSION 8-1 Crankshaft / Transmission Table of Contents Exploded View ...... Specifications Crankcase Splitting Crankcase Splitting, Crankcase Assembly Crankshaft and Connecting Rods Crankshaft Removal... Crankshaft Installation Notes Connecting Rod Removal Connecting Rod Installation Notes Connesting Red Big End Becring Insert/Crankpin Wear. Crankshaft Main Bearing Insert/Journal Wear - Crankshaft Side Clearance... 3 Crankshaft Runout Balancer. Belancer Removal Balancor Installation Notes. Damper inspection Needle Bearing Wear : Altornator Shatt/Starter Motor Clutch. Altemator chain and Tensioner Removal Altemator Chain and Tensioner Installaton. Akemator Shatt and Starter Clutch Removal, Akemator Shatt and Starter Clutch installation. Altemator Shait Chain Wear.. Starter Motor Clutch Inspection. ‘Transmission. External Shift Mechanism Removal External Shift Mechanism Installation. External Shift Mechanism Inspection Transmission Shaft Removal Transmission Shaft Installation Transmission Disassembly. Transmission Assembly Shift Drum end Fork Remove Shift Drum and Fork Installation...8-2 CRANKSHAFT / TRANSMISSION Exploded View 2 12.Nem (1.2 kg-m, 104 Ind) 3:15 Nem (1.5kg-m, 11.0 feb) Ta: 18 Nem (1.8 ko-m, 13.0 fb) ‘75:25 Nem (2.5ko-m, 18.0 Wb) ‘Te: 27 Nem (2.8 ko-m, 20 fib) “17: 32.Nem (8.3 kg-m, 24 fob) ‘TB: 59 N-m (6.0 ko-m, 43 tb)CRANKSHAFT / TRANSMISSION 8-38-4 CRANKSHAFT / TRANSMISSION 3. Yellow Paint G_Apply grease. L: Apply non-permanent locking agent. ‘SS: Apply silicone seatant. TH: 9.8 Nem (1.0 kgem, 87 intb) 2: 19 Nem (1.5kg-m, 11.01-) 8: 29/N-m (8.0kg-m, 22{t4b)CRANKSHAFT / TRANSMISSION 8-5 Item ‘Standard Service Li ‘Crankshaft. Connecting Rods: | ‘Connecting rod bend | --- 02/100 mm Connecting rod twist 02/100 mm Connecting rod big end side clearance | 0.13 ~ 0.38. mm 0.50 mm Connecting red big ond bearing | insert/crankpin clearance 0.037 ~ 0.065 mm 010. mm Crankpin diameter: 36.984 ~ 36.000 mm 35.97 mm Marking None 35.984 ~ 35.992 mm —-- ° 35.993 ~ 36.000 mm Connecting rod big end bore diameter, | 39,000 ~ 39.018 mm Marking None 39,000 ~ 39.008 mm ° 39,009 ~ 39.016 mm --- Connecting rod big end besring Insert thickness Black 1.475 ~ 1.480 mm Blue 7.480 ~ 1.485 mm White 1.485 ~ 1.490 mm ‘Connecting rod big end besring insert selection Gon-Rod Big End | Crankpin Diameter Beating Insert Bore Diameter = Marking Markin Size Color Part Number ° ° Blue 92028-1680 None None o None White | _ 92028-1681 None | ° Black | _—_ 82028-1679 Crankshaft main bearing inser/ journal clearance 0,020 ~ 0.044 mm 0.07 mm Crankshaft main journal diometer: 35.984 ~ 36,000 mm 35.96 mm Marking None 35.984 ~ 36.992 mm - 1 35.993 ~ 36.000 mm Crankcase main bearing bore diameter: | 39000 ~ 29016 mm - Marking ° 39,000 ~ 39.008 mm -- None 38,009 ~ 39.016 mm -- Crankshaft main bearing inser thicknoss: | Brown 1.490 ~ 1.494 mm - Black 1.494 ~ 1.498 mm - Bue 1.498 ~ 1.502 mm | = Crankshaft main bearing insert selection: ‘rankcase Main | Crankshaft Main Bearing Inset” Bearing Bore | Joumnel Diameter | Diameter Marking Marking Size Color | Part Number | Journal Nos ° 1 Brown | 92028-1102 | 2.4 [saaea274 | 1.35 None None ave | 92028-1100 | 2.4 sonwetz72 | 1.38 ° None Bleck | 92026-1101 | 2.4 None o o2o28-1273 | 1.38 “Tne bearing inserts for Nos. 2 end 4 journals have on ol groove.8-6 CRANKSHAFT / TRANSMISSION Item Standard Service Limit Crankshaft side clearance 0.05 ~ 0.20 mm 0.40 mm Crankshaft runout Loss than 0.02mm TIR 0.05 mm TIR Alternator Shaft: | Altemator shaft chain 20 link length 198.5 ~ 159.2 mm | 161.2mm Transmission: | Shift fork ear thickness 49 ~50mm 4.8mm Gear shift fork groove width 5.05 ~ 5.15 mm 53mm Shift fork guide pin diameter 79 ~ 80mm 7.8mm Shift drum groove width 8.05 ~ 8.20mm 83mm ‘Special Tool ~ Steering Stem Bearing Driver: 57001-137 Bearing Puller: £7001-158 Inside Cire Pliers: 57001-143, ring Pullor Adaptor: 5700-217 Bearing Driver Set: 57001-1128 Sealant ~ Kawasaki Bond (Silicone Sealan(): 56019-120 Kawasaki Bond (Liquid Gasket — Black): 92104-1003CRANKSHAFT / TRANSMISSION 8-7 Crankcase Splitting Crankcase Splitting @ Remove the engine (see Engine Removal/instalation chapter). {@Set the engine on a clean surface and hold the engine steady while pats are being removed. @ Remove the following parts from the engine. External Shift Mechanism, Alternator Chain Tensioner Starter Motor Oil Pan Alternator il Pump with Bracket Pickup Coil Right Engine Cover Remove the following parts only ifthe crankshatt is to be removed. Cylinder Had Gylinder Block Pistons Alternator Shaft Chain and Sprockets Remove the follawing part only if the transmission drive shaft assembly is to be removed, lutea ‘@Remove the upper crankcase bolts. ‘6 mm Bolt [A] 8 mm Bok [8] ‘@Remove the lower crankcase bolts, 6 mm Bot [A] 9 mm Bott (B] Romoval of bolts[C} is not necessary for crankcase soli. 7mm Bott (D] ‘@Pry the points indicated in the figure [A] to split the crankcase halves. ‘apart, and remove the lower crankcase halt8-8 CRANKSHAFT / TRANSMISSION Crankcase Assembly NOTE ©The upper crankcase hal, the lower crankcase halt, and the crapkshatt main bearing cap are machined at the factory in the assembled state, so the crankcase halves and the main bearing cap ‘must be replaced together as a set. ‘@ Assembly is the reverse of splitting. Note the following, (© Chock that the knock pins [A] aro in piace. Shift drum is in the neutral pesition (neutral positioning lever (Al fits in to the detent [B] on tho shift drum bearing holder) #1 and 4 pistons are at TOC. @With a high flash-point solvent, clean off the mating surfaces of the cerankcases halves and wipe dry. ‘Apply aliquid gasket tothe mating surtace of the lower crankcase hal. Sealant ~ Kawasaki Bond (Silicone Sealant: 56019-1209 CAUTION ‘Do not apply a liquid gasket around the crankshaft main bearing inserts (A). (@ Hold the balancer so that the merk on the balencer weight aligns with the center of the oll passage hole [A ‘© Apply asilicone sealant to the following. Crankcase Mating Surfaces (both upper and lower) ‘©Do not apply assilicone sealant to the area shown [A]CRANKSHAFT / TRANSMISSION 8-9 Tighten the lower crankcase half bolts using the following 4 steps, Lightly tighten all lower crankcase half bolts to a snua fit. The three 9 mm bolts (sequence numborod 1 through 3) have flat washer (oFolowing the sequence numbers on the lower crankcase half tighten the 9 mm bolts. Torque ~ $ mm Bolts First: §.8N-m(1.0kg-m, 87 In-b) Finak 32 Nem (33 kgm, 24 fttb) (OTighten the 7 mm bol, ‘Torque ~ 7 mm Bolt: 18 Nem (18 kg-m, 19.0 fb) (OTighton the 6 mm Bott. ‘Torque - 6 mm Bok: 15 Nem (1.5 kgm, 11.0 fb) ‘easter tightening all crankcase bolts, check the following items. (Drive shaft and output shafts turn freely. While spinning the output shaft, gears shift smoothly from the ist to Gth gear, and 6th to ‘st. ‘oWhen the output shait stays, still the gear can not be shift to 2nd gear ‘or other higher gear positions.8-10 CRANKSHAFT / TRANSMISSION Crankshaft and Connecting Rods Crankshoft Removal ‘@spiit he crankcase. ‘@ Remove the main bearing cap bolts with flat washers, and take off the cap. Crankshaft Installation Notes CAUTION UW the crankshaft or bearing inserts are replaced with a new one, cheek clearance with plactigauge before assembling engine to be sure the correct bearing inserts are installed, @lnstall tho crankshaft main bearing cap with the arrow [A] on it pointing forward. ‘Tighten the main bearing cap bolts. Torque ~ Main Bearing Cap Bolts: $2 N-m ( gam, 28 te). Connecting Rod Removal ‘@Romove the crankshatt. NOTE (Make and record locations of the connecting rods and their big end ‘cans so that they can be,re-assembled in their original positions. ‘@Remove the connecting rods from the crankshaft. ‘CAUTION ‘To prevent damage to the crankpin surfaces, de not allow the big end cap bolts lo bump against them. Connecting Rod Installation Notes (©To minimize vibration, a pair of connecting rod (left two rods or right ‘wo) should have the same weight mark [A]. The left two rods are a par and the right two rods are par. ‘The weight mark is indicated by 2 capital leter, and is stamped on the connecting rod big end (© Before installing the connecting rode, blow the crankshaft cil passages with compressed air to remove any foreign particles or residue that ‘may have accumulated in the passages.Ee ‘1 ne connecting fos o beating insets ae epee! wit new ones | hock saronce with Hostage bor seeming engine we be Sue thr cot beng inser a installed | eon melyoconum siutid eae to th upper ine surlce [A] of a conwctn od ed ‘CAUTION ‘Do not apply grease fo the inner surface [1] of the upper or lower bearing inserts orto the outer surtace of the lower bearing insert. eThe connecting rod bolts are designed to stretch when tightened, ; Never ;ouse them. Roplace the connecting rad big end bolts with new OThe new connecting ‘od bolt and nut are reated with en anti-rust ssclution, be sure to clean the bolt and nut thoroughly with high flssh-point solvent CRANKSHAFT / TRANSMISSION 8-11 AGN ‘Clean the bolts and nuts in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area, this includes any appliance with a pilot ight. Because of the danger of highly flammable liquids, do not use gasoline or low tlash-point solvents to clean the bolts and nuts. ‘CAUTION Immediately dry the bolte and nuts with compressed air after cleaning. Clean and dry the bolts and nuts completely. @ Apply a small amount of engine oil to the threads and seating surfaco of the connecting rod nuts. Tighten the nuts. ‘Torque ~ Connecting Rod Big End Cap Nuts : 15 Nem (1.5 kgm, 11.9 fb) Tighten the nuts 120° more. ‘© Mak [A] the connecting rod big end caps and nuts so that nuts can bbe tumed 120” [8] propetly. Tighton the hexagonal nut by 2 comers8-12 CRANKSHAFT / TRANSMISSION ‘CAUTION Be carelul net lo overtighten the nuts. ‘Be carelul not 0 tum the connecting rod bolts curing the nut tighten- ing. The bolts must be positioned correctly o avoid the bolt heads (#1 and #2 cylinder rear side bolts) contact to the crankease. [A] Bolt Hood [B] Connecting Rod Big End Shoulder [C] Bolt Correct Position [D] Do net over tuin at this position. Connecting Rod Big End Bearing Insert/Crankoin Wear Using a plastigage (press gauge) [A], measure the bearing insert/cankpin [B] clearance. NOTE © Tighten the big end cap nuts to the specified toraue (see Connecting Rod Installation Notes) ©Do not move the connecting red and crankshaft during cleerance ‘measurement, Connecting Rod Big End Bearing InsertiCrarkpin Clearance Standard: 0.037 ~ 0.065 mm Service Limit: 0.10mm Jit Clearance is within the standard, no bearing replacement is required. If clearance is betweon 0.086 mm and tho sorvics limit (0.10 mm), replace the bearing inserts with inserts painted blue [C]. Check insert/crankpin cleerance with a plastgage. The clearance may exceed the standard slightly, but it must not be less than the minimum in order to avoid bearing seizure. If the clearance exceeds the service limit, measure the diameter of the ‘orankpins. ‘Crankpin Diameter Standard: 35.984 ~ 36,000mm. Service Limit: 35.97 mm If any crankpin has wom past the service limit, replace the crankshaft with @ new ene, If the measured crankpin diameters are not fess shan the service limit, but do not coincide with the original diameter markings on the crankshaft, make new marks on it Crankpin Diameter Marks Nene 35984 ~ 35.992mm ° 35.983 ~ 36.000mm ‘A: Crankpin Diameter Marks, "0" mark or no mark ‘@Mezsute the connecting fod big end bore diameter, and mark each ‘connecting rod big end in accordance with the bore diameter. Bore diameter Mark (Around Woight Mark) [A]: "0" or na mark NOTE OTighten the connecting rod big end cap nuts to the specified torque (se Connecting Rod Installation Notes). OThe mark already on the big end should almost coincide with the ‘measurementCRANKSHAFT / TRANSMISSION 8-13 ‘Connecting Rod Big End Bore Diameter ‘None ‘39.000 ~ 99.008 mm ° 39,009 ~ 33.016mm_ ‘esctect the proper beering insert in accordance with the combination cf the connecting rod and crankshaft coding. ‘install the new inserts in the connecting rod and check insert/crankpin clearance with the plastiaaae. Con-r0d BigEnd | Crankpin ‘Bearing Insert Bore Diameter Diameter Movking Mark | Size Color | Pat Number a ‘None ‘None ° None. ‘White | 92028-1681 None’ ° Black | 92028-1679 Crankshaft Main Bearing Insert/Joural Wear @Using 2 plastigage (press gauge) [A], measure the bearing insert/journal [B] clearance, NOTE OTighten the crankcase bolts 10 the specified torque (see Crankcase Assembly Notes). Do not tura the crankshaft during clearance measurement. (Crankshaft Main Bearing Insert Journal Clearance Standard: 0.020 ~ 0.044 mm Service Limit 9.08 mm 4lf clearance is within the standard, no bearing replacement is required. “if clearance is between 0.044 mm and the service limit (0.08 mm), replace the bearing inserts with inserts painted blue [C]. Check insert/journal clearance with the plastigage. The clearance may exceed the standard slightly, but it must not be las than the minimum in order to avoid boaring seizure “rit learance exceeds the service limit, moacure the diameter of the crankshaft main journal. Crankshaft Main Journal Diameter Standard: 36.984 ~ 96.000mm Service Limit: 35.98 mm 4e1f any journal has worn past the service limit, replace the crankshaft with @ new ono. “1 the measured journal diameters are not less than the sarvice mit, but do not coincide with the orignal diameter markings [0] on the crankshaft, make new marks on it. Crankshaft Main Journal Diameter Marks ‘None 126.084 ~ 95.002 mm 1 135.999 ~ 35.000 mm 1D: Crankshaft Main Joumal Diameter Marks, “1” mark or no mark8-14 CRANKSHAFT / TRANSMISSION ‘crankcase haf in accordance with the bore diameter. Bore Diameter Mark "O" or no mark. ‘@Measure the mein bearing bore diameter, and mark the upper ae NOTE Tighten the crankcase bolts to the specified torque (see Crankcase Assembly Notes). ©The mark akesdy on the upper crankcase half should almost coincide with the measurement Crankease Main Bearing Bore Diameter ° ‘29.000 ~ 39,008 mm None 39,000 ~ 29.016 mm ‘@Select the proper bearing insert in accordance with the combination of the crankcase and crankshaft coding. ‘@install the new inserts in the crankcase halves and cap and check insen/journal clearance with a plastigage. Crankease Main] Crankshaft Main Bearing Insert™ Bearing Bore | Journal Diameter Diameter Marking Matki SizeColor_| Pat Number | Joumal Nos. of 1 "Brown | 92026-1102 24 | 92028-1274 | 1,36 None None Blue | 92028-1700 24 920281272 | 1.3.5 ° None Back — | 92028-1701 24 | None 1 92028-1273 | _1,3,5 “The beating inser for Nos. 2 and 4 journals heve an oil groove, Crankshaft Side Clearance @ insert a thickness gauge between the crankcase main bearing and the ‘rank web [A\] at the No. 2 journal [8] to determine clearance, >If the clearance exceeds the service limit, replace the crankcase halves ‘and main bearing cap as a set. ‘The upper crankcase halt, lower orankoase hi ‘cap are machined atthe factory in the assembled state, $0 they must be replaced 2s a set Crankshaf Side Clearance Standard: 0.05 ~ 0.0mm Service Limit: 040mmCRANKSHAFT / TRANSMISSION 8-15 Crankshaft Runout (@ Measure the crankshaft runout “If the measurement oxcoods the servi iit, ropiace the crankshaft CCrankstiat Runout ‘Service Limit: 0.05 mm TIR8-16 CRANKSHAFT / TRANSMISSION Balancer Balancer Removal ‘@ pitt the crankcase. ‘@ Unscrew the balance shaft clamp bolts. and pull off the clamp lever. ‘@ Unscrew the balancer shaft guide pin plato, and take off the plato and ‘uid pin. @Pull me balancer shaft with the ci seal toward the right out of the crankcase. At the same time, the balancer weight and gear assembly comes aff. Balancer Installation Notes ‘@Wher coupling the balancer weight and the goat, observe the follow- ing, ‘©Check thar the damper 1ubbers are in place. (Fit the balancer weight into the geer so that the weight (Al is opposite ‘the mark [B] on the gear. ‘@Fit the copper washers on both sides of the weight and gear assembly ‘The projected side [A] faces toward the assembly. ‘eTum the balancer shaft unt! the fine mark on the end of the shaft points to the front. And then, install the ciamp lever. Tighten the bolt at the rear of the lever frst then tighten the clamp bolt at the front of the lover temporarily ‘@Adjust the balancer gear backlash during the preparation of the motorcycle. The ameunt of backlash can be changed by turning the balencer shait. ‘OStart me engine and let i at idle, Loosen the clamp boit and tum the balancer shaft counterclockwise nti the balancor gear makes a noise. (©Turn the shatt clockwise until the balancer gear stops to make 2 noise, and tighten the ciamp bolt securely.CRANKSHAFT / TRANSMISSION 8-17 Damper Inspection ‘@ Remove the balancer and disassemble the weight and gear assembly. ‘eVisually inspect the rubber dampers (A) if they appear demaged or deteriorated, replace thom. Needle Bearing Wear ‘@Visuelly.check the neadle bearing. The rollers in @ needle bearing normally wear very Kite. and wear is dificult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage. ‘If there is any doubt as to the concition of a needle bearing, replace it8-18 CRANKSHAFT / TRANSMISSION Alternator Shaft/Starter Motor Clutch Alternator chain and Tensioner Removal ‘@Remove the right angine cover. {© Lock the altomator shaft chain tensioner. ‘OPush the tensioner guide and the rod stop lever so that the stop lover oops the rod from rewwrning ‘e@Remove the chain guice [C] [A] Alternator Chain Tensioner [B] Boks ‘© Remove the alternator chain tensioner. (@ Hold the alternator coupling with the coupling holder, and remove the coupling nut and sprocket bolt ‘Special Too! ~ Coupling Holder: 57001-1189 [A] Pull the chein, sprocket, and coupling as a set Altemator Chain and Tensioner Installation @ Installation isthe rovereo of removal. Note the following. @Tighton the alternator shaft nut and alternator sprocket bolt. ‘Torque — Alternator Shaft Nut: 59 N-m (6.0 kg-m, 42 fib) ‘Alternator sprocket bolt 25 N-m (25 kg-m, 18.0 f-b) Lock the chain tensioner and install it with the mounting bolts. The tonsionor should bo free from the locked position after installing it Alterator Shaft and Starter Clutch Removal ‘Split the crankcase ‘@ Remove the altemato: chain, ‘@ Remove the coupling bolt atthe left end of the shaft, and then remove the coupling with the rubber dampers. @Holding the starter motor clutch, pull the crankcase, wrnotor shaft off theea eee Alternator Shait and Starter Clutch installation ‘@installaton is the reverse of removal. Note the folowing. ‘eli the starter motor dia gear [A] ic romoved, install it so that the srrall iameter gear side faces to the left {@Tighten the one-way clutch bolt. ‘Torque ~ One-way Clutch Bolt: 12 N-m (1.2 kg-m, 104 nib) Altemator Shaft Chain Wear ‘@Hoid the alternator shaft chain so that it may be pulled tight. ‘@Mcasure the length of 20 links (21 pins) with a verior caliper ‘kif the 20-ink length of the altemator shaft chain is greeter then the service limit replace it. Alternator shaft Chain 20-link lenath Standard: 188.8 ~ 159.2mm Service Limit: 161.2 mm Starter Motor Clutch Inspection ‘® Remove the starer motor (@Turn the starter motor idle gear by hand. When viewed from the left side of the engine, the idle gear should tum counterclockwise freely [A), but chould not turn clockwise [8] CRANKSHAFT / TRANSMISSION 8-19 20s Length8-20 CRANKSHAFT / TRANSMISSION Transmission External Shift Mechanism Removal ‘© Drain the engine ai ‘@ Remove the engine (see Engine Removal/Installation chapter), ‘@ Remove the following. Engine Sprocket ‘Water Pump. External Mechanism Caver @Remove the shift shaft, while moving the shift mechanism arm backward, [A] Neutral Positioning Lever [0] Arm Spring [B] Gear Positioning Lever [E] Retum Spring [C] Shift Mechanism Arm IF] Shift Shaft ‘@ Unscrew the nuts and remove the positioning levers External Shift Mechanism Installation @ Installation is the reverse of removal. Note the following, The positioning levers [A] are identical. The spring [D] painted white is for the gear positioning lever [8] ‘@Tne projected side of the collar must face toward the lever. [C] Change Drum Apply a sicone sealant to the followins. [A] Silicone Seatant Applied Area [1B] Crankcase Meting surface [Cc] 5mm ‘@Apply a non-permanent locking agent to the cover bolts [A].CRANKSHAFT / TRANSMISSION 8-21 ‘@Tighten the extemal shift mechanism cover bolt and neutral switen removed ‘Torque ~ External Shift Mechanism Cover bolts: 9.8 Nem (1.0 ka-m, 87 int) Neutral Switch: 15 Num (1.5 kg-m, 11.0 Rb) @Adiust the shift pedal position correctly ifthe shift pedal linkage was disassembled. (© Loosen the lockriute [C] and turn the rod [D] to adjust the shift pedal positon, ‘OTighten the locknuts. [A] Frame Edae [B] Pedal Correct Position External Shit Mechanism Inspection ‘@ Examine the shift shaft (or any damage. “iF the shaft is bent, staighten or replace it. If the splines [A] are damaged, replace the shatt. ‘kif the springs [B] [C] are demaged in any way, replace thom. “lf the shift mechanism am [D] is damaged in any way, replace the arm, (© Check the return spring pin (D] is not loose XFIf tis loose, unscrew it, apply a non-permanent locking agent to the threads, and tighten it ‘Torque - External shi mechanism Return Spring Pin: 29 Nem (3.0 kg-m, 22-1) ‘© Check the positioning levers [A] [B] and their springs [C] for breaks oF distortion. +f the levers or springs are damaged in any way, replace thom. ‘® Visually inspect the shitt drum pins, pin holder, end pin plate. if they are badly warn or if they show any damage, repiace them. Transmission Shatt Removal NOTE lf the dive shaft assembly isto be disassembled, removed the clutch. Split the crankoese. @Take out the drive and output shaft assambiies. Transmission Shaft Installation €@ installation i the raverse of removal. Note the following. {@ Check to see that the set rings [A] and sot pins [8] are in place in the transmission bearing housings, and blow the oil passages [C] in the bearing housings clean with compressed att8-22 CRANKSHAFT / TRANSMISSION install the drive and output shaft assemblies in the upper crankcase halt. (oThe bearing set pins and rings must match properly with the holes or ‘grooves in the bearing outer races. When they are properly matchad, there is no clearance between the cankzate and the bearing outor reces [A Transmission Disassembly {@Remove tho transmission ehafte ‘@Romove the circlips, isessomble the transmission shafts, Special Too! ~ Outside Cirelip Pliers: 57001-144 ‘@The Sth gear [A] on the output shaft has three steel balls assembled into it for the positive neutral finder mechanism. Remove the 5th gear. (©Set the output shaft in a vertical position holding the Ged geor (B] (Spin the Sth gear quickly [C] and pull itoff upward, Transmission Assembly ‘@ Assembly is the reverse of disassembly. Note the following. ‘@Appiy engine oi liberally to the following: ‘Transmission Shafis Transmission Goars Ball Bearings, Needle Bearings Bushing Steel Balls ‘@Replace the ball boarings with new ones. ‘@ Replace any ciclips removed with new ones. Onstall the circlips [A] so that the opening (B} is aligned with a spline ‘groove [C]. (@ The drive shait gears can be recognized by size ; the goar with tho ‘mallzst diameter being ‘st goat, and the largest one being 6th gear Be sure that all parts are put back in the correct sequence and all Circlips and washers are properly in place. Proper sequence starting with 1st gear [A] (part of drive shaft) is Sth gear [8], toothed washer, circlip, 3r4/4th gear [C], circlip toothed washer, bushing 6th gear [D], 2nd gear [E], thrust washer, needle bearing, circlip, needle bearing outer race.CRANKSHAFT / TRANSMISSION 8-23 ‘oWhen assemaling the 6th gear bushing to the dive shaft, align its of hole [A] with the hole [B] in tne shat. ‘@ The output shaft gears can be recognized by size ; the gear with the largest diemater being ‘st gear, and the smallest one being 6th gear. Be sure that all parts are put back in the correct sequence and all Circlips and washers are property in place. Proper sequence starting ‘with the engine sprocket side & 2nd gear [A], toothed washer, crclip, th gee" [B], circlip, toothed washer, bushing, 4th gear [C], Sra ger [D], toothed washer, ciclip, 5th gear (E] with steel balls, 1st gear [F] trust washer nocdle bearing, and needle bearing outer race. Girclip. CAUTION ‘When installing the 6th [A] gear and steel balls (B] on the output ‘shaft, do not apply grease tothe balls to hold them in place. This will cause the positive neutral finder mechanism to malfunction. After assembling the Sth gear with steel balls in plece on the output ‘shaft, check the ball-locking effect thet the Sth gear does not come ‘ut of the output sheft when moving it up and down by hand, ‘eCheck that each gear spins or slides freely on the transmission shafts without binding after assembly. [IC] Recess Shift Drum and Fork Removal ‘@ Remove the engine (see Engine Removal/Installation chapter). @ Remove the following External Shift Mechanism oll Pen Oil Pump and Bracket ‘@ Unscrew the Allen bolts holding the shift drum bal bearing holder. ‘© Pull out the shift rod [8], and take off the shit forks. ‘@Pull out the shift drum [A] Shift Drum and Fork Installation ‘@ installation isthe reverse of romoval. Note the following. ‘@Apply 2 non-permanent locking agent to the Allon bolts of the shift drum holding plate. ‘@ The shift forks can be identified by ther shape, Install them as shown,WHEELS / TIRES 9-1 Wheels / Tires Table of Contents Exploded View Specifications ... Wheels (Rims) Front Wheel Removal... Front Wheel Installation... Rear Wheel Removal Rear Whee! Installation Notes... Inspection. Axle Inspection ... Whee! Balance Balance Inspection Balance Adjustment... Balance Weight Installation. Balance Weight Removal Air Pressure Inspection/ Adjustment... Inspection... Installation Repair Hub Bearing Removal... Installation Notes ...0m Inspection 3 Speedometer Gear Housing... Disassembly and Assembly. Lubrication9-2 WHEELS / TIRES Exploded View Pt 11004) 2: How okgen 00m)WHEELS / TIRES 9-3 Specifications item Standard Service Limit Wheels: Rel Al osm pagal camm Al yrou/00 o2mm Ties: Tip ea Front | Up ta 182kg (401 b) load 290 kPa (2.9 kg/om®, 41 psi) Rar | Upto 182 kg GOT Byload | 290 KPa 2.9 koe, 4 oD sanded v2on02ni7 Frent_| BRIDGESTONE BATTRAX.T-SOF E METZELER MES@ Lacer vooes ZR17 pear_| BRIDGESTONE BATTHAX ST-SOR E METZELER MESS A Matronic Treveaddeche [Fon [eam Te Peer Samm | Siren under 120 mh, Under 60) mm (Over 120 anh, | Ove 80 gh Zx1109 - 5 ~ tem ‘Standard Service Limit Standard tre TaarOzRTT front | BRIDGESTONE BATTRAXBT:S7F E DUNLOP SPORT D2OHFU METZELER MESS Laser 70056 2817 ear | BRIDGESTONE BAT TRAX BT-s7m E DUNLOP SPORT O2C4P NETZELER MESS A Metric TRG | Ft] ae oneraTone a 1 mm DUNLO® SPORT (Gals) .emm fear] 62mm BRIDGESTONE Zim Gade J, i jesoro0 not | es DUNLOP SPORT 3mm (Over 130 krv/h, (ver gone rT aceawe AR: Asia 8: Swizeland Special Tools - Inside Cirelip Pliers: 57001-143 Bearing Driver Set: 57001-1129 Jack: 57001-1238 Bearing Remover Shaft: 57001-1285, Bearing Remover Head, j 15 x 17: S7001-1267 Bearing Remover Head, j 20x { 22: 57001-12839-4 WHEELS / TIRES Wheels (Rims) Front Wheel Removal ‘eRemove the following, Fairing Speedometer Cable Lower End [A] Brako Caliper Mounting Bolts (2) Loosen right side axle clamp bolts [A] Loosen axle (8] (@Raise the front wheel off the ground, ‘Special Too! ~ Jack: 57001-1238 (@Pull out the axle tothe right and drop the front wheel out of the forks, ‘CAUTION Donot lay the wheel down on one of the dises. This can damage or warp the disc. Place blocks under the wheal 20 thatthe dies do not touch the ground. Front Wheel installation @ installation is the reverse of remaval. Note the following NOTE Put the speedometer gear drive (C] onto the wheel hub notches (A), then instoll the housing [D} so that it fts in the drive notches. [B] ProjectionsWHEELS / TIRES 9-5 CO Fit ihe collar on the right hand side of the hub. O Fit the speedometer gear housing stop[A] to the fork leg stop{B]. ‘eTighten the axle nut and axle clamp bolt ‘Torque ~ Axle Nut: 145 N-m(1.5.0 kg-m, 110 fb) ‘Axle Clamp Bolte: 20 N-nx(20 kg-m, 14.5 ftb) ‘@ Check the front brake. AN ‘Do not aitemat fo drive the motorcycle unl fully depressing the brake lever then pump the brake lever until the pads are against the disc. “The brakes will not function on the frst application of the lever if this is not done. Rear Wheel Removal ‘@Remove the right taining ring [C]. and unserew the axle nut (D1) @Remove the left retaining ring [E], and pull outthe axle [F] ‘OLeosening of the right and le't clamp bolts are not neoded. ‘CAUTION. Loosening of the right and tefl ofthe right and left chain adjuster p blots may cause micalignment ‘eDisangage the drive chain from the rear sprocket toward the left, and remove the roar whoo. CAUTION Do not lay the whee! on the ground with the dise facing down. This ‘ean damage or warp the disc. Place blocks under the wheel so that the dige does not touch the ground.9-6 WHEELS / TIRES Rear Wheel Installation Notes ‘@Engage the drive chain with the rear sprocket, and install the rear wheel ‘Olnsert the axle from the loft side of the wheel, and tighten it ‘Torque ~ Rear Axle Nut: 110 N-m (11.0 ka-m, 80 fb) @ Install the rear breke caliper (see Brakes chapter) Adjust the drive chain slack after installation (see Final Drive chapter) Check the rear brake, NN Do not aitemat to drive the motorcycie until a full brake pedal is obtained by pumping the brake pedal until the pads are against the dice. The brake will net funtion on the first application of the pedal It tis fs notdone. Inspection (@ Raise the front/rear wheel off the ground, ‘Special Tool ~ Jack: 57001-1233 ‘@Spin the wheel lightly, and check for roughness or binding, >If roughness or binding is found, replace the hub bearngs. @ inspect the wheel for small cracks, dents, bending, or werp. If there is any damage to the wheel, replace the wheel ‘@Rorove the whedl, and suppor it without tho tire by the axle @ Messure the sim runout, radial [A] and axial (B}, with a dial gauge. kitrim runout exceeds the service limit, check the hub bearings, Ifthe problem is not due to the bearings, replace the wheel Fim Runout Service Limit: Axial 0.5 mm Radial 0.8mm aN Never attempt to repair a damaged wheel. Wf there is any damage besides wheel bearings, the wheel must be replaced to insure safe ‘operational condition. Axle Inspection ‘@Vicually inspect the front and rear axle for damages. >i the axle is damaged or bent, rep'ace it ‘@Measure the axle runout with a dial gauge. If axie nunout exceeds the sorvice limit, replace the axle. ‘Axle Runout/100 mm ‘Standard: Under 0.05 mm Service Limit: 02mm= WHEELS / TIRES 9-7 Whee! Balance To improve stabilty and decroase vibration at high speed, the front and rear wheels must be kept balanced. ‘Check and balance the wheels when required, or when a tire is replaced with a new one. Balance Inspection jemove the whee! é ‘@Support the whe! so that it can be spun freely. ‘@Spin the wheel lightly, and mark [A] tha wheel at the top when the wheel stops. ‘ORepeat this procedure several times. 11 the wheel stops of iis own ‘accord in various positions, itis well balanced. rIf the wheel elwaye stops in one position, sdjust the wheel balance, Balance Adjustment ‘@lf the wheel always stops in one position, provisionally attach ¢ balance weight [A] on the rim at the marking using adhesive tape. @Rotate the wheel % turn [B], and see whether or not the wheel stops in this position. If itdoes. the comect balance wesght is being used, “Kf the whee! rotatae and the weight goos up, replace the weight with ‘the next heavier Sze. Ifthe wheel rotates and the weight goos down, replace the weight with the next lighter size. Repeat these steps until the wheel remains at rest after being rotated i tum. ‘@Rotate the wheel another tum and then another ‘tum to see if the wheel is correcily balanced. ‘@ Repeat the entire procedure as many times as necessary to achieve ‘correct wheel balance. ‘© Permanently install the balance weight. Balance Weight Part Number Weight(arams) 41075-1014 10 41075.1018 20 41075-1016 30 Balance Weight Installation ‘© Check if the weight portion has any play on the clip plate. Fit itdoes, discerd it PNG Wf the balance weight has any play on the rim, the clip of the weight thes been atretched. Replace the loose balance weight. Do not reuse used balance weight Unbalanced wheels can create an unsafe riding concition.9-8 WHEELS / TIRES @ Lubricate the belance weight biado, tito bead, and rim flange with a ‘soap and weter solution or rubber lubricant. This helps the balance weight slip onto the rim flange. ‘CAUTION ‘Do not lubricate the tire bead with engine oil or petrolaum distilates because they willdeteriorate the tre. @ install balance weight at both sides of the rm flange when required total weight exceeds 40 a as shown. {@Tho balance weight lower than 30 g ean be installed at either sides of the Fim flange. Required Total Weight Weight Selection One Side Other Side 309 x2 De [89 309 +209 ey Do 209x2 309 9 309 De ET 209 309 409 209 | 209 29 20 g or (20.9) 1090) 29 10 g or (209), 100) 109 109 = ‘install the balance on the rim. (OSip the weight on the rim flange by pushing oF lightly hammering the weight in the direction shown in the figure. (OCheck that the blade and weight seat fully on the rim flange, and that the clip ie hooked over the rim ridge and reaches rim flat portion Installing Balance Weight (2) Pross or lightly hammer the weight in. (8) Installation compieted Rime Farge Blade vsWHEELS / TIRES 9-9 Balance Weight Removal 'a) When the tie is not on the rm. ‘@Push the blade pertion toward the outside with a regular tip screw river, and slip the weight off the rim flange ‘@ Discard the used balance weight (b) When tne tre is on the cm, ‘ePry the balance weight off the rim flange using @ regular tip screw iver as shown in the figure. ‘Olnsort a tip of the screw diivor between the tre bead and weight blade the end of the tip teaches the ond of the weight biado. Push the diver grip towarc the tire so that the balance weight slips off the im flange. ‘@ Discard the used balance weight. Air Pressure Inspection/Adjustment ‘@ Measure the tre air pressure with an air pressure gauge [A] when the tires are cold. ‘e Aqjust the bre air pressure according to the specifications if necessary. al ressure (when cold) Front | Upto i83ia | 290 KPa (404 10) (29 kglem?, 41 psi) Fear | Upto 18349 290 KPa (404 16) 29 ka/om?, 41 pei) Inspection ‘AS the be tlead wears down, the tre becomes more susceptible to puncture and allure. An accepted estinate is thai 90% ofall tre failures Secur during the last 10% of tread lile (80% worn). So itis false ‘economy and unsafe to use the ties untl they are bald, ‘eRemove any imbedded stones or other foreign particles from the tread. Visually inspect ihe tire for high spots indicate internal damage, quiring tire replacement Visually inspect the tre for cracks and cuts, replacing the tire in case ‘of damage. Sweling or high spots indicete intemal damage, requing tire replacement. ‘eMeasure the Iread depth at the center of the tread with a dapth gauge Al. Since the tire may wear unevenly, lake measurement at several places. +f any measurement is less than the service limit, replace the tire. Tread Dept rom: Standard: 3.4mm 2X1100-D5~ 4.3 mm (Bridgestone) 4:4 mm (DUNLOP) Service Limit: 1mm. (GAR,S) 1.5mm Rear: Standerd: 5.8mm ZX1100-05~ 6.2. mm (Bridgestone) 5.4 mm (DUNLOP) Service Limi 2'mm (Up to 130 kevh) 3mm (Over 130 krr/h} Push9.10 WHEELS / TIRES To ensure sale hanaing ard stably use only the recommended | andard trestor replacement fated tothe standard pressure. | NOTE ‘Check and balance the wheelwhen 2 tre is replaced with anew one. Standard Tire Front: see Specifications Rear: soo Spactfications Installation (@ inspect the rim and tre, end replace them if necessary. ‘@Clean the seeling surfaces of the rim and tire, and smooth the sealing surfaces of the rim with a fine emery cloth if necessary (@ Remove the air valve and diseard it ‘CAUTION Replace the al valve whenever the tire is replaced. Donot reuse te ar valve. Install a new valve the rim, ° Remove tho valve cap, lubricato the stom seal [A] with @ sop and ‘water solution or rubber lubricant, and pull the valve stern through the rim from the inside out unti it snaps into place, ‘CAUTION Do not use engine oil or petroleum distillates to lubricate the stem because they will deteriorate the rubber. A. Valve Cap ©. Stem Seal E. Valve Seat B. Valve Core D. Valve Stem F. Valve Opened ‘@Appiy a coap and water colution, or rubber lubricant to the rim flange ‘and tire beads. ‘@Check the tie rotation mark on the front and rear tres and install them ‘on the rim according.WHEELS / TIRES 9-11 NOTE The direction of the tive rotation (A) is shown by an arrow |B] on the tre sidewol. {@Position the tire on the rm so that the valve is at the tre balance mark (the chalk mark made during removal, or the yellow paint mark on a new tie) ‘install the tre bead over the rim flange with a tie changer. ‘@ Lubricate the tie beeds end rim flangos with 2 soap and water solution ‘or rubber lubricant 0 help seat the tire beads in the seoling surfaces of the rim while inflating the tire. {@Center the rim in the tire beads, and inflate the tre with compressed sir until the tie beads seat in the sealing surfaces, PENNS Be sure to install the valve core whenever inflating the tie, and do not inflate the tire o more than 400 kPa(4.0 kalcm®, 57 psi). Overin- lation ean explode the tre with possibilty of injury and loss of life. ‘@ Check to see that the rim fines [A] on both sides of the tire sidewalls ‘are parallel with the rim flangos. If the rim fanges and tire sidewall rim lines are not parallel, remove the valve core. (@ Lubricate the rim flanges anc tice beads. ‘Install the valve core and inflate the tire again ‘®Aiter the tie beads seat in tho sim flanges, chock for ar leaks, Cnflate the tire slightly above standard ination. (Ose a soap and water solution or submerge the tire, and chack for ‘bubbles that would indicate leskege. ‘@ Adjust the air pressure to the specified prossure (see Tire Inspection). ‘install the brake diso(s) so that the dize rotation mark aligne with the tire rotation, ‘@ Adjust the wheel balance. Repair Currently two types of repair for tubaless tires have come into wide use. One type s called # temporary (external repair which can be carried ‘ut without removing the tire from the rim, and the ether type is called permanent (internal) repair which requires tire removal. tt is generally Understood that higher running curablity 1S obtained by permanent (intema) repairs than by temporary (extemal) ones. Also, permenent (internal) repairs have the advantage of permitting a therough examina~ tion for secondary damage not visible from oxteral inspection of the tra. For these reasons, Kawasaki does not recommend temporary (external) repair. Orly appropriate permanent (internal) repairs are recommended, Repair methods may vary slighty from make to make. Folow the repair sethods indicated by the manufacturer of the repair ols and matorials 20 that safe results can be obtained9-12 WHEELS / TIRES Hub Bearing Removal ‘@ Remove the wheal, and take out the following, Collars Coupling (out of ear hub) Grosse Seals Circlips Special Tool ~ Inside Circlip Pliers: 57001-143 Speedometer Gear Drive (out of front hub) [B] © Take the bearings ( out of the hub. ‘CAUTION Do not lay the wheel on the ground with the disc facing down. This ‘can damage or warp the disc. Place blocks under the wheel so that the dise dove net touch the ground, ‘Special Tools ~ Bearing Remover Shaft: 57001-1255 Bearing Remover Head, 15 x 017: 57001-1267 Bearing Remover Head, 20 x 022: 57001-1293 Installation Notes ‘@ Before instaling the wheel bearings, blow any dit or foreign particles ‘out of the hub with compressed air to prevent contamination of the bearings. ‘@ Replace the bearings with new ones. ‘@Pross in tho boarings until thoy are bottomed. ‘Special Tool ~ Bearing Driver Set: 57001-1129 [A) NOTE CO Jnstall the bearings so that the marked side faces out. ‘© Roplace the cirline with row ons. ‘Special Tool — Inside Circlip Pliers: 5701-143 ‘© Replace the grease seals with new ones. ‘@ Press in the grease seals so that seal surface is flush with the end of the hole, ‘CApply high temperature groase to tho groase seal lps. Special Tool ~ Beating Driver Set 57001-1129 [A] Inspection NOTE Ot js not necessary to remove ary bearings for inspection. If any ‘bearings are removed, thoy will need to be repleced with new ones. ‘@Spin it by hand to check its condition. IF itis noiey, deos not spin smoothly, ot has any rough spots, it must bbe replaced. ‘@ Examine the bearing seal for tears or leakage. IF the seal is tom oris leaking, replace the bearing,Speedometer Gear Housing Disassembly and Assembly NOTE Olt is recommended that the assembly be replaced rather than ‘attempting 10 repair the components. ‘@lnstall the speedometer gear housing so tt i fits in the speedometer ‘gear drive notches (see Front Whee! Installation Notes). Lubrication ‘@Clean and grease [A] the speodomete” gear housing (8 ] in accord- ‘ance with the Perioaic Maintenance Chart. WHEELS / TIRES 9-13FINAL DRIVE 10-1 Final Drive Table of Contents Exploded View. 10-2 Specifications. sonerncnnnnrnnann 0-3 Drive Chain 10-4 AOA 10-4 10-5 Slack Inspection. Wheel Alignment Adjustment Wear Inspection Lubrication 10-6 Drive Chain Removal. 10-7 Installation Notes 10-7 ‘Sprocket, Coupling... 10-8 oO J Engine Sprocket Removel. 10-8 10-8 10-8 Engine Sprockot Installation Notes Rear Sprocket Removal .. Rear Sprocket Installation. 10-9 Sprocket Warp Inspection . 10-9 Coupling Bearing Removal 10-9 Coupling Bearing Installation Notes 10-9 Coupling Installation Notes... 10-1010-2 FINAL DRIVE Exploded View & Apply grease LE Apply non-permanent locking agent. Tie 39.Nhm (4.0ko-m, 29-1) Ta: 74.Nem (7.5 kg-m, 64 fb) TS: 125 Nem (13.0 kg-m, $4 Mo)FINAL DRIVE 10-3 ‘Specifications Item ‘Standard Service Limit Drive Chain: Make type Enuma, endless ae EKS0ZV-X 110 Link Chain slack 35 ~ 40 mm Less than 35 mm, or more than 45 mm_ 20 link length 3175 ~ 3182 mm 323 mm ‘Sprockets: Rear sprocket warp 05 mm10-4 FINAL DRIVE Drive Chain Slack fnspection NOTE Check the slack with the motorcycle setting on its center stand. Clean the chain itt is dirty. and lubricate it it appears dy. ‘© Check the whee! alignment (see Whee! Alignment Inspection). jotate the rear vihee! to find the position where the chain is tightest ‘@ Measure the vertical movernant (chain slack) [A] midway betwoon tho sprockets “:f the chain slack exceeds the standard, adjust it. Chain Stack Standard: 35 ~ 40mm Usable Rango: Less then 35 mm, or more than 45 mm @ Loosen the left and right chain adjust clamp bolts (Al Loosening of the torque link nutfB) is not needed, (© Tum the chain adjusters[B] forward or rearward with an Allen wrench [A] until the drive chain has the correct amcunt of chain slack. (©The left and right notches on the swing arm should point to the same ‘maiks or positions on the left and night adjustes. PRG Misalignment of the wheel will result in abnormal wear, and may result in an unsafe riding condition. ‘@Tighten the chein adjuster clamp bolts ‘Torque ~ Chain Adjuster Clump Bolts: 39 N-mn(4.0 kg-m, 29 fb) Wheel Alignment Adjustment ‘@Set the motorcycle up on its center stena, ‘©Check to see if whee! alignment is propetly adjusted. The left and right ‘notches [A] on the swing arm should point to the same marks[®] oF positions on the left and right adjusters.FINAL DRIVE 10-5 #1 not, adjust the wheel alignment © Remove the left retaining ring[A] @ Loosen the rear axle shaft [8] {Loosen both ieft and right chain adjuster clamp bolts(C) O Loosening af the require link nut is not required. {© Turn the chain adjusters together to position tho tiangle mark [A] on both left and right chain adjusters atthe parting line [B] of the swing arm end. @Tighton both left and right chain adjuster clamp bolts{C). Tighten the rear onto shaft(0), Torque ~ Axle Nut: 110 Nem (11.0 ke-m, 80 f-b) ‘@ insert the retaining ring[E] to secure the axle shat. ‘@Loosen the chein adjuster clamp bolts{A] again, then turn the ehain adjuster so that the left and right notches on the swing arm point to the came marks{2] of positions on the left and right adjuster. ‘eTighten both chain adjuster clamp bot. ‘Torque - Chain Adjustor Clamp Bolts: 39 Nem (4.0 kg-m, 29 fib) PUN Y the axle nut or clamp bolts are not securely tightened result Wear Inspection @Romove: Chain Cover, ‘@ Rotate the rear wheel to inspect the drive chein for damaged rollers, ‘and Icose pine and links lf there is eny irregularity, replace the drive chain ++Lubricate the drive chain if it appears dry. ‘@Stretoh tho chain taut by hanging a 98 N (10 kg, 20 Ib) weight [A] ‘on the chain, ‘@ Measure the length of 20 links [A] on the straight part of the chain fiom the pin center of the ist pin to the pin center of the 21st pin. Since the chain may wear unevenly, take measurements at several places. If any measurements exceed the service limi, replace the chain. Atso, repiace the front and rear sprockets when the drive chain is replaced, ‘Chain 2o-ink Length Standard: 317.5 ~ 318.2mm Servee Limit: 323mm Vet and Bed 20h IR10-6 FINAL DRIVE PMG |W ne drive chain wear exceeds the service limit, replace the chaia| or an unsafe riding concition may result A chain that brakes or Jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control. For safely, use only the standard chain. itis an endless type and should not be cut fo instalation. ‘Standard Chain Mark: ENUMA Type: EKSOZVX Link: 110 Link Lubrication ‘The chain should be lubricated with a lubricant which will both prevent the exterior from racing and also absorb shock and reduce friction in the interior of tho chain. An effective, good quality lubricant ‘specially formulated for chairs is best fo: regular chain lubrication, fa ‘special lubricant is not available, a heavy oil such as SAE 90 is preferred 10 lighter oil because it will stay on the chain longer and provide bettar lubrication, if the chain appears especielly dirty, clean it before lubrication, ‘CAUTION ‘The O-rings between the side piates seal inthe lubricant between the pin and tho bushing. To avoid damaging the O-rings and resultent loss of lubricant, observe the following rules. Use only kerosene or diesel oll for cleaning an O-ring drive chain. ‘Any other cleaning solution such as gasoline or trichioroethylene will ‘cause doterioration and ewiling of the O-ring. Immediately blow the chain dry with compressed air alter cleaning. Complete cleaning and drying the chain within 10 minutes. ‘@ Apply clo the sides of the rollers ¢o that oil will penotrate to the roller ‘and bushings. Apply the of to the O-rings so that the O-rings will be coated with ol. Wipe off any excess oil Apply oF,FINAL DRIVE 10-7 Drive Chain Removal ‘@Rerrove the following. Clutch Slave Cylinder(see Clutch chapter) Sprocket Cover Engine Sprocket Nut NOTE (When loosening the engine sprocket nut{ A], insert the steel rod into the 10d hole[B) to hold the sprocket. Rear Wheel (see Wheels/Tires) ‘Swing Arm (see Suspension chapter) {@Pull tho engine sprocket off the output shaft with the drive chain, and then separate them, Installation Notes (@ Adjust the chain slack after installing the chain.10-8 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal Loosen the drive chain ‘@ Romove the following, Clutch Sleve Cyinder(see Clutch chapter) ‘Sprocket Cover Engine Sprocket nut NOTE When foosening the engine sprocket nut{A), insert the steel 1od into the rod hole [6] t0 hold the sprocket. @ Remove the drive chain from the rear sprocket. NOTE OMf itis aifficutt to remove the dive chain trom the rear sprocket. remove the rear axle (see Wheels/Tires chepter) ‘@Pull the engine sprocket off the output shatt. Engine Sprocket Installation Notes ‘@install the engine sprockat onto the output shaft with the drive chain Ageged. @Atter torquing the engine sprocket nut(AJ, bend the one side] of the washer over the nut. NOTE Tighten the nut while epplying the rear brake. Torque — Engine Sprocket Nut :125 N-m (13.0 kg, 94 fib) @Acjust the drive chain slack after installing the sprocket (see Drive Chain Slack Adjustment). Rear Sprocket Removal ‘@Remove the rear wheel (see Wheel/Tires chapter. ‘CAUTION ‘Do not lay the wheel on the ground with the disc facing down. This, ‘can damage or warp the disc. Place blocks under the wheel so the dise does not touch the ground. (@ Remove the rear sprocket nuts. @ Remove the rear sprocket.FINAL DRIVE 10-9 Rear Sprocket Installation ‘instalation is the reverse of removal, Note the following. Install the sprocket fecing the tooth number marking outward A] (@Tightan the rear sprocket nuts. Torque ~ Rear Sprocket Nut : 74 Nem (7.5 kg-m, $4 fb) Install the rear wheel(see Wheets/ Tres chepter). ‘Sprocket Warp Inspection ‘@Set the motorcycle on its center stands. {Set a dial gauge [A] against the roar sprocket [B] near the teeth as shown, and rotate [C] the rear wheel to measure the sprocket runout (warp). The difference between the highest and lowest dial gauge readings is the emount of runout (warp) rif the runout exceeds the service limit, replace the rear sprocket Rear Sprocket Warp Standard: Under 0.4mm Service Limit 0.5mm Coupling Bearing Removal @FRemove the coupiing. @Remove the ciclip. ‘Special! Tool ~ Inside Circlip Pliers: §7001-143 ‘@ Remove the bearing by tapping from the wheel side. Special Tool ~ Bearing Driver Set: 57001-1129 [A) Coupling Bearing Installation Notes ‘@ Replace the bearing with a nevr one. {© Prose in the bosring until it is bottomed, Special Tool ~ Bearing Driver Set 57001-1129 ‘@ Pack the bearing with high temperature grease. ‘@ Replace the circlio with a new one. Insie Clrctip Pi ‘Special Too! '57001-148 [Al10-10 FINAL DRIVE Coupling Installation Notes ‘@Use an cilless solvent to thoroughly clesn any oil off the damper [C]. hut, and coupling}. ‘install tho damper into tho roar hub. (@Use alte achesive to festen the spacers[B] into the coupling during assembling insert the coupling into the ear hub, NOTE OAMways use a soap and water solution to ease inserting the coupling into the hub. Never use such lubricant that leaves oily residue.BRAKES 11-1 Brakes Table of Contents Exploded View Specifications. Brake Pedal Breke Pedal Position Adjustment Roar Brake Light Switch Adjustment Calipers... f Front Caliper Removal Rear Caliper Removal Caliper Installation Disassembly Notes. Assembly Notes. Brake Pads, Removal Inctalletion Notes Lining Wear ‘Master Cylinder: Front Mester Cylinder Installation. Rear Master Cylinder Removal Note. Rear Master Installation Notes... Inspection and Adjustment after Installation... Disassembly Assembly Notes. Inspection (Visual Inspection) Brake Disc... Weer. Warp aren Brake Fluid. Level Inspection.. ‘Change... Bipeding the Brake Line': Follow the spectfied tightening sequence. 11-2 BRAKES 1. Front Brake Light Switch 2. Rear Brake Light Switch ‘TH: 5.0 N-m (0.60 kg-m, 52 in-16) ‘72: 7.8 Nem (0.80 kg-m, 69 in-1b) 3: 88 N-m (0.90 kg-m, 78 in-1b) Exploded View G: Apply grease.BRAKES 11-311-4 BRAKES Specifications Item Standard Service Limit Brake Pedal: Brake pedal position Rear brake light switch 45 mm below top of footpeg ‘ON after about 10 mm pedal travel Brake Pad: Pad lining thickness: Front 4.0mm aie Rear 40mm nen Brake Discs: Disc thickness: Front 43 ~51.mm 45mm Rear 58 ~61 mm 50mm Disc runout =3 een Dora,BRAKES 11-5 Brake Pedal Brake Pedal Position Adjustment ‘@Cneok that the brake pedal[E] is in the correct position. Pedal Pesiion(A] ‘Standard: About 45 mm below top of footpeg. [C] Footpes NOTE Usually its not necessary to adjust the podel position, but always agjust rt when the master cyiinder(6} is disassembled. Of the pedal position cannot be edjusted by turning the clevis (0), the brake pedal may be deformed or incorrectly installed. ‘@Vshen the brake pedal isin its rest position, measure the length (A) indicated in the faure. If the length (A) is not within the specified length, adjust a lock ut(C), Length (A) Standard: 80 41 mm Rear Broke Light Switch Adjustment ‘@Ccheck the operation of the rear brake light switch by depressing the brake padal(A]. The brake light should go on after about 10 mm of pedal travel[B] iF it does not, edjust the brake light ewitch(A]. ‘@ Tum the adjusting nut[B] to adjust the switch, [C] Light sooner. [0] Light later. ‘CAUTION “To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment.11-6 BRAKES Calipers Front Caliper Removal ‘@Remave the following if the caliper is to be completely Brake Hose Banjo Bolt (at the caliper) ‘CAUTION Immediately wipe up any brake fluid that spills. @ Remove the following, Caliper Mounting Bolts (C} ‘CAUTION ‘Do not loosen the caliper bolts, Take out only the caliper mounting bolts for caliper removal. Loosening the caliper bolts will cause brake fluid leakage. [A] Banjo Bott Do not loosen the caliper bolts(B] >If the caliper is to be disassembled alter removal and if compressed air 'S not available, remove the piston using the following steps before disconnecting the brake hose from the caliper (© Remove the pads. (© Pump the brake lever to remove the caliper piston. CAUTION Immediately wipe up any brake fluid that spits. Rear Caliper Removal (@ Remove tie rear caliper in the same way as the iront caliper [Al Banjo Bolt __{B] Caliper Mounting Bots [C] Torque Link Bott Caliper Installation OTighten the caliper mounting botts Torque —Front Caliper Mounting Bolt: 34 Nem(9.5 kg-m, 25 f-10) Rear Caliper Mounting Bolt: 25 N-m(2.5 kg-m, 18 fb) Connect the brake hose to the caliper putting # new flat washer on each side of the brake hose fitting. Tighten the banjo bott. ‘Torque ~ Banjo boit 25 N-m(2.5 kg-m, 18 fb)BRAKES 11-7 © Check the fluid level in the master cylinder (reservoir), and bleed the brake line (see Bleeding the Brake) © Check the brake for weak braking power, brake drag, and ‘uid leakege. PGS ‘Do not attempt o drive the motorcycle untita full brake lever or pedal is obtained by pumping the brake lever or pedal unti the pads are against the disc. The brakes will not function on the first application of the lever or pedal it thie ie nat done. Disassembly Notes ‘@To disassomble the front caliper, partorm the following. ‘Remove the following. Broke Pads Caliper Bots Piston Insulators (OUsina comaressed air, remove the pistons. One way to remove the pistone is as follows. ‘Olnstall @ wooden board(C] more then 10 mm thick end 2 rubber ‘qesket{ 3} on the caliper half as shown. Leave one of the oil passages open [A] Bolt and Nut _[D] Oil Passage sealed by Rubber Gasket [E] Oil Passage COLightly apply compressed air(A] to the oil passage untl the pistons hit the rubber gasket. Block the hose joint opening during this operation if the calipor half hae opering [8] Clon ENN To avoid serious injury, never place your fingers or palm inside the caliper opening. you apply compressed air into the caliper. the piston may crush your hand or fingers. Assembly Notes ‘@ Apply bieke fluid to the outside of the pieton and the fluid seal, and posh the piston into the eylindsr by hand. Take cere that neither the Cylinder ner the piston skirt get scratched. ‘@ Apply a thin coat of PBC(Poly Buty! Cuprysil) grease to the caliper hholder shafts and holder holes. (PBC is a special high temperature, water-resistant grease)11-8 BRAKES Tighten the front caliper mounting bolts. ‘Torque ~ Front Caliper Mounting Bolts : 34 N-m(3.5 kg-m, 25 feb).BRAKES 11-9 Brake Pads Removal Remove the caliper (see Front or Rear Caliper Removal) ‘@ Remove the following to remove the front caliper pads. Serews(A] Pad Spring [8] Clip [AI Pad Pin [8] Pads (Cl Installation Notes ‘@Push the caliper pistons in by hand as far as they will go. ‘@For the front caliper the pad pin clip must be “outside” of the pads. PON ‘Do not attempt to drive the motoreyele until afl brake lever or pedal ‘a obtained by pumping the brake lever or pedal until the pads are against the disc. The brake will not function on the fiat epplication of the lever or pedal i his snot done. Lining Wear srIF tho ining thickness of either pad is less than the service limit replace bboth pads in the caliper as a set, Pad Lining Thickness [A] ‘Standard: 4.0mm. ‘Service Limit (8]: 1 mm11-10 BRAKES Master Cylinder Front Master Cylinder Installation @The Mester cylinder clamp must be installed with the arow mark upward(C]. @ Torque the upper clamp bolt[Al first, and then the lower clamp bolts [B]. Thore will bo a gap at tho lower part ofthe clamp after tghtoning, ‘Torque ~ Upper/Lower Clamp Bolts :11 N-m(1.1 ka-m, 95 indb) (© Uso a new flat washor on cach side of the brake hose fitting, Tighten the banjo bolts. ‘Torque ~ Banjo Bolte: 25 N-m(2.5 kg-m,18 fib) Rear Master Cylinder Removal Note ‘@Romove the cotter pin{3] and thon pull the joint pin[C ] out of the Push rod clevis{ A] and breke peel Rear Master Installation Notes ‘@Use a new flat washer on each side of the brake hose fitting. Be sure that the metal pipe is properly fitted into the projection(A J on the master cylinder [8] Metal Pine Tighten the banjo bolts. Torque ~ Banjo Bolts :25 N-en(2.5kg-m, 18 tb) ‘@Tighten the rear master cylinder mounting botts (2).. ‘Torque ~ Master Cylinder Mounting Bolts: 23 N-m(2.3 kg-m, 16.5 ft-1b)11-12 BRAKES inspection’ Visual Inspection) Disassemble the front and rear master cylinders. ‘@Chock that there are no scratches, rust or pitting on the inner wall of each mastor cylinder [A] and on the ouside of each piston[B), ‘1! amaster cylinder or piston shows any damage, replace them. @ Inspect the primary [C} and secondary [D] cups. 11 6 cup is worn, damaged, softened (rotted), er swollen, the piston assembly should be repiaced to renew the cups. “Ii fluid leakage is noted at the brake lever the piston assembly should bbe replaced to renew tho cups, @Check the dust covers (E] for damage eI they ere demaged, replace them. ‘@Check that reli (F) and supply (G] ports are not plugged, Ifthe refit port becomes plugged. the brake pads willdrag on the disc. Blow the ports ciean with comprosced air ‘© Check the piston retuin springs [H] for any damaged, Ifthe springs are damaged, replace them,Brake Disc Wear ‘Replace the dise (AJ ifit has worn past the service limit. Front Dice Thicknoss ‘Standard: 48—5.1 mm Service Limit 4.5mm [B] Measuring Area Die Thickness Standar 58-61 mm Service Limit’ 5.0mm. Warp ‘kif runout exceeds the sewice limit, replace the ciso{A} Dise Funout ‘Slandard: Under 0.2mm Service Limit, 0.3mm. [B] Measuring Area BRAKES 11-1311-14 BRAKES Brake Fluid Level Inspection In accordance with the Poriodie Maintenance Char, inspect the brake fluid level in the front and rear brake tid reservoirs. {© Check that the brake fluid leve! in the front brake reservoir [A] is above the lower leve line [8] NOTE OHold the reservoir horicontel by turning the handlebar when checking brake futd level “IF the fluid level is lower than the lower laval line fil the reservoir ta the ‘upper lave lino [A] in the reservoir [8] (@ Remove the seat. and check that the brake fluid level in the rear brake: reservoir [A] i between the upper [8] and the lowor [C] level tines. Ifthe fuid level is lower than the lower level line, fill the reservoir tothe upper level ine. ANS ‘Change the brake fluid in the brake line completely # the brake fluid must be refiled but the type and brand of the brake fluid that Is already in the reservolr are unidentified. After changing the fl ‘only the some type and brand of fluid thereafter. Recommended Dise Brake Fluld Grade: D.O.T.4 Change = E OThe procedure to change the font brake fluid is as follows. Changing the rear brake fluid is the same as for the front brake.BRAKES 11-15 @ Level the brake fluid reservoir. @ Remove the reservoir cep. (@ Remove the rubber cap from tne bleed vave [A] on the caliper. @ tach a clear piastic hose [B] to the bleed valve, and run the other ‘ond of the hose into a container fe hange the brake fluid as follows: ‘Repeat this operation until fresh brake fluid comes out trom the plastic hose or the calor of the fluid changes. 4. Open the bleed valve [A] 2. Apply the brake and hold it (BI. 3. Close the bleed valve {C] 4. Release the brake (D] NOTE (©The fluid level must be checked often during whe changing operation and replenished with fresh brake fluid. Ifthe fluid in the reservoir runs out any time during the changing operation. the brakes will need to be bled since air will have entered the brake line. (oF ront Brake: Repeat the above steps for the other caliper. (Rear Brake: Repeat the above steps forthe other bleed valve. ‘@Remove the clear plastic hose ‘install the reservoir cap. @TTighten the bieed vaive, and install the rubber cap. Torque ~ Caliper Bleed Valve: 7.8 Nem (08 kg-m, 69 in-b) ‘@Atter chenging the fluid, check tho broke for good braking pows brake drag, and no fluid leakage. If necessary, bleed the air from the lines. Bleeding the Brake Line ‘The brake fluid has a very jow compression coetficient so that almost all the movernent of the brake lever or pedal is transmitted directly to the caliper for braking aetion. Air, however, is easily compressed. When air tenters the brake lines, brake lever or pedel movemont will bo partially used in compressing the air. This will make the lever or pedal fee! ‘spongy, and there will be a loss in braking power. PENS ure to bleed the alr from the brake line whenever brake lever or pedal action feels soft or spongy after the brake fluid is changed, or whenever a brake line fiting hae been loosened for any reason.11-16 BRAKES NOTE The procedure to bleed the front brake line is as follows. Bleeding the rear brake line is the samme as for the front brake. @ Remove the reservoir cap, and fil the reservoir with fresh brake fluid to the upper level line in the reservoir. ‘@With the reservoir cap off. slowly pumo the brake lever several times until ne air bubbles can be seen rising up through the fluid from the holes at the bettom of the reservoir. (0 Bleed the air compietaly from the master cylinder by this operation, install the reservoir cap. (@ Remove the rubber cap from the bleed vaive on the caliper. ‘@ Attach a cloar plactic hose to the bleed valve, and run the other end of the hose into 2 container. ‘Bleed the brake line and tne caliper as follows: (Repeat this operation until no more air can be seen coming out into the plastic hose. 1. Pump the brake lever untt it becomes hard, and apply the brake ‘and hold it [A] 2 Quickly open and close[B) the bleed valve while holding the brake applied. 3. Release the broke [C]. NOTE The fluid level must be checked often during the bleeding operation and replenished with fresh brake tluid as necessary. If the fluid in the reservoir runs completely out any time during bleeding, the blesting operation must be done over again trom the beginning Since at wil have entered the tne. OTap the brake hose lightly fom the caliper to the reservoir for more complete bleeding. Front Brake: Ropost the above stops for tho other caliper © Rear Brake: Repeat the above steps forthe other bleed valve. {@ Remove the clear plastic hose. (Tighten the bleed valve, and install the rubber cep. ‘Torque ~ Caliper Bleed Valve: 7.8 N-m (0.8 ko-m, 69 in-tb) (Check the fluid level ‘@ After bleeding is done, check the brake for good braking power, no brake diag, and no fluid leakage.SUSPENSION 12-1 Suspension Table of Contents Exploded View ... Specifications Front Fork nesses Rebound Damping Force Adjustment. Spring Proload Adjustment Fork Oil Change Removal (each fork leg). Installation Disassembly Assembly, Innor Tube Inspection Dust Seal Inspection .. Spring Tension Rear Suspension... Reer Shock Absorber... Rebound Damping Force Adjustment... Spring Preload Adjustment... Removal - Installation. Scrapping en. ‘Swing Arm... Removal Installation .... Tie-Rod, Rocker Arm: Tie-Rod Removal Tie-Rod Installation Rocker Arm Removal Rocker Arm Installation... Needle Bearing Inspection bi Tie-Rod. Rocker Arm Sigeve Inspection Tie-Rod, Rocker Arm Noedle Bearing Lubrication.12-2 SUSPENSION Exploded View Pol | a6 Lac) 5 eS J 2 eo fs : @& a g a Ss Se ° S Se Se : U U 3 ® 8 e & &, . Que § © OW) G: Apply grease [E_Apt norpenvanent locking ast, te. een oeieaca asia ge: Th 2thm (tem 148m) Te Ainm@item icons) ‘TS: 23 N-m (2.3 kg-m, 16.5 ft-lb) Ta: 28 Nem (2.9 kg-m, 21 ft-lb) je mhneskem ann) Te othe ezigms ase) Th sim @egmase)SUSPENSION 12-312-4 SUSPENSION Specifications Item Standard Front Fork: Damper adjuster position Spring preload adjuster position 2nd click (clockwsse) 6th mark from top Fork ci Viscosity SAE 10W-20 Amount per unit | 465 + 4 mL * 467 + A mL. 410 mL: When changing oi Fork oil level 133 + 2mm 131 + 2mm (Fully compressed, without spring) Fork spring free length 295 mm * 296 mm. 289 mm Rear Suspension: Rear shock absorber damper adjuster position #2 124 Rear shock absorber spring preload adjustment 19mm (compressed from spring free length) 19 ~ 31mm ():2X1100-D3~ ‘Special Tool ~ Fork Gylinder Holder Handle: $7001-183 il Seal & Bearing Remover: 57001-1058 Steering Stem Nut Wrench: 57001-1100 Boaring Driver Sot: 57001-1129 Fork Outer Tube Weight 57001-1218, Front Fork Oll Seal Driver: 57001-1219 Fork Oil Level Gauge: 57001-1290 Hexagon Wrench, Hex 29: 57001-1335Front Fork Rebound Damping Force Adjustment {@7o adjust the rebound damping force, turn the adjuster (A] clockwise Until you feel @ click (B]. Each adjuster has 4 adjustment clicks. Be Sure to turn both adjusters by the same number of clicks. \f oth adjusters are not adjusted equally, hancling may be impaired and a hazardous condition may result ‘oThe damping force can be left soft for averege riding. But it should bbe adjusted harder for high speed riding or riding with a passenger. If the damping feole too soft or too stiff, adjust it in accordance with the following table. Rebound Damping Force Adjustment ‘Adjuster | Damping Position | Fore | Setting | Load | Road | Speed 1 Weak | Sot | Light | Good | Low F t t t tie ef 1 4 t t t + 4 | stong | Hard | Heaw | Bad High (oThe standard adjuster setting for an average-build nder of 68 kg (150 Ib)with no passenger and no accessories is the 2nd click position. Spting Preload Adjustment ‘@Turn the adjust] into increase sping preload and out to decrease spring preted, Each adjuster hes @ adjustment marks [B]. Be sure 10 position both adjuster co the same mark. H bom adjusters are not adjusted equally, handling may be impaired and a hazardous condition may resut. ° “The spring proload can be loft soft for average riding. But it should bbe adjusted harder for high speed riding or riding with a passenger. If the spring action feals too soft or too sti, adjust It in accordance with the following table. Spring Action Aguster| Dumping Poston | Force | sering | toad | Road | Speed @ | weak | sot | tight | Good | tow 1 t T T T T 1 1 oa te 1 1 1 | swong | Ha | teow | sea | igh (The standard adjuster eating for an averago-buid rider of 68 kg(150 Ib) wath no passenger and no accessories is the th mark position from the top. SUSPENSION 12-512-6 SUSPENSION Fork Oil Change @Remove the following. Seat Fuel Tenk Upper Fairing Lower Fairing Fork Leg Fork Top Bolt Spring Seat Main Spring ‘@Pour out the fork ol into a suitable container. Pump as necessary to ‘empty out al the of. ‘© Four in the speciied type and amount of oil Front Fork Ol Viscosity: ‘SAE 10-20 Amount per side: When changing oi: 410 mL After disassembly and completely dry: ZX1100-01,D2 465 £4 mL Zxrv00-D3~ 467 + 4 mL. Jr If necessary, measure the ol lovel as follows, ‘Hold the cuter tube vertically in a vise. ‘© Pump the inner tube several times to expel air bubbles, (OWait until the cl level settle. (OWith the fork fully compressed, insert @ tape measure or rad into the inner tubo, and measure the distance from the top of the inner tube to the oil NOTE (©Fork oil level may also be measured using the fork oil level gauge (special too!). ‘Special Tool ~ Fork Oil Level Gauge: 57001-1290 [A] (©Set the gauge stopper [B) so that its lower side shows the oil level distance specified © Level (tally compressed, without spring) Standard: ZX1100-D1,02 133 + 2mm ZXV10003~ 131 = 2mm. {trom the top of the inner tube) (OWith the fork fully compressed. insert the gauge tube into the inner tube and postion the stopper across the inner tube top end. NOTE Adjust the ofl level with the fork fully compressed and without the fork spring. OPosition the stopper so that the gauge tube is the center of inner tube diameter or the specified oil level cannot be obtained. (OPull the handle slow/y to pump out the excess cil until the oil ne longer comes out, “If no oil is pumped cut, thee is insufficient oil in the inner tube, Pour enough oil, then pump out the excess oil as shown above, @Change the ol of the other fork leg in the same manner. (@ install the fork (see Installation Notes)SUSPENSION 12-7 Removal (each fork leg) “@Loosen the fork top plug beforehand it the fork legis to be disassem- bed ‘eRemove the following Upper Faiting Lower Fairing Front Fender Front Wheel Fork Clamp Bolts end Nute(Uppor [A] and lower (8), loosen) ‘@ With a twisting motion, work the fork leg down and out Installation ‘@Pull back the fork leg ‘@Tighten the front fork upper clamp bots ‘Torque ~ Front Fork Upper Clamp Bolts: 28 N-m(2.9 kg-m, 21 feb) ‘Tighten the steering stem nead nut ‘Torque — Steering Stem Hood Nut: 38 N-mm(4.0 ko-m, 29 fb) ‘e Tighten the front fork lower clamp bolts. ‘Torque ~ Front Fork Lower Clamp Bolts : FL Nem gen, "15 (4b) ‘@ Adjust the following. Rebound Damping Force Spring Preload Disassembly {Drain the fork oll (see Fork Oil Change’, ‘@ Unscrew the Allen bolt [A], and take the gasket out of the bottom of the cuter tube. ‘Special Tool ~ Fork Cylinder Holder Handle: 5700-189 [ Hexagon Wrench, Hex 29: 97001-1335 [C) ‘@Hold the fork outer tube in a vice. @ Stopping the oylinder from turning by using the special tools, unscrew the Allen bolt12-8 SUSPENSION |@Use the fork oute: tube weight [A] to separate the inner tube[B] from the outer tube [Cl] ‘Holding the inne: tube by hand in a vertical position, pull down [D] ‘the outer tube several times to pull out the inner tube. ‘Special Tool ~ Fork Outer Tube Weight: 57001-1218 ‘OThe oil seal [A] washer(B], and gauge bushes [C] come off with the inner tube. Assembly ‘@Assembly I the reverse of disassembly. Note the following, heck the top plug O-ring and replace it with a new one if necessary. ‘@Repiace the following parts removed with a new one, Guide Bushes Oil Seal Bottom Allen Bolt Gasket ‘@install the cylinder base [A] so that the small diameter end [8] of it ‘comes to the cylinder. [C] Large Diameter End ‘@Apply a non-permanent locking agent to the following. Eottom Allen Bolt Threads ‘@TTighten the bottom Allen bolt and fork top bolt. ‘Torque ~ Bottom Allen Bolt: 81 Nen(6.2 kgm, 45 fib) Fork Top Bolt (ater fork leg installation): 23 N-m(2.3 kg-m, 165 feb) ‘@Fit the new outer guide bush [A] into the outer tube. NOTE (OHold the used guide bush [8] against the new one, and tap the used guide bush ‘Special Tool ~ Fork Oil Soal Driver: 57001-1219 [C]SUSPENSION 12-9 ‘@Pour in the type and amount of fork ol specified install the top boltfA] so that the rod[D] of it inserts into the center hole [E]ot the damping valve. The sping seat[C] must be fitted onto the stepped portion|B) of the top bort Inner Tube Inspection isually inspect the inne: tube, and repair any damage. ‘@Nicks or rust damage can sometimes be repaired by using @ wet- stone ‘to remove sharp edges or raised areas which cauise seal damage. kIF the damage is not repairable, replace the inner tube. Since damege to the inner tube damages the oil seal, replace the oil seal whenever the inner tube is repaired or replaced. ‘@Temporarily sesemble tho inner and outer tubes. and pump them back and forth manually 1o check for smooth operation ‘CAUTION Thine inner tube is badly bent or creased, replace it. Excessive benaing, lowed by subsequent straightening can weaken the inner tube. Dust Seal Inspection ‘@ Inspect the dust seal [A]for any signs of doterioration or damage. Replace itt necessary. Spring Tension ‘@Since a spring becomes shorter as it weakens, check its free length [A] to determine its condition, 4k the spring of either fork lea is shorter than the serve limit it must wee be replaced, If the length of a replacement soring and that of the ore remaining spring vary greatly, the remsining spring should also be replaced in order to keep the fork legs balanced for motorcycle stability. ® Spring Free Lenath \ Standard: 298mm, ZX1100-D9~: 296 mm \ Service Limit: 239mm