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NHTSA ID Number: 10109087
Manufacturer Communication Number: 99924-1519-01_ZX
Summary
Service Manual
Kawasaki
Z1000SX Ninja 1000
Motorcycle Service Manual
First Edition (0) : Sep. 30, 2016
Quick Reference Guide
General Information – 1
Periodic Maintenance – 2
Fuel System (DFI) – 3
Cooling System – 4
Engine Top End – 5
Clutch – 6
Engine Lubrication System – 7
Engine Removal/Installation – 8
Crankshaft/Transmission – 9
Wheels/Tires – 10
Final Drive – 11
Brakes – 12
Suspension – 13
Steering – 14
Frame – 15
Electrical System – 16
Appendix – 17
1 Affected Product
Vehicle
MAKE | MODEL | YEAR |
KAWASAKI | ZX1000 | 2017 |
1 Associated Document
Manufacturer Communications
Z1000SX
Ninja 1000
First Edition (0) : Sep. 30, 2016
99924-1519-01_ZX
https://www.nhtsa.gov/recalls?nhtsaId=10109087
MC-10109087-9999.pdf 14025.563KB
https://static.oemdtc.com/TSB/MC-10109087-9999.pdf
- Formulated with Trizone technology to protect all 3 critical zones: engine, clutch and gearbox
- Race derived technology for maximum engine acceleration
- Extreme high temperature air-cooled performance and water-cooled engine performance
- Excellent shear stability to prevent viscosity breakdown
- Exceeds API SL and JASO MA-2
- 100% Synthetic Ester
- Formulated To Meet The Latest Manufacturers' Specifications
- Improved High Temperature Deposit Protection And Sludge Control
- Ensures Optimum Clutch Performance At Start-Up, Acceleration, And Full Speed
- Standards: Ape Sn, Jasso Ma2
- Optimal lubrication in all operating conditions, ensures low oil consumption
- Very high shear and ageing stability, highest levels of wear protection
- Tested and approved for catalytic converters, optimal engine cleanliness
- Ideally suited for wet clutches
- Specifications and Approvals: API, SM, ACEA A3-04, JASO, MA2
- Full synthetic 5W-40 diesel engine oil with Triple Protection Plus technology protects against wear, deposits, oil breakdown, and improves low-temperature flow
- Exceptional wear protection for longer life in a wide range of heavy-duty engine applications — from pickup trucks to tractors to semi rigs
- Enhanced fuel economy capability of 1.5 percent without compromising engine protection or durability (compared to 15W-40 oils)
- Multi-functional dispersant additives provide an enhanced level of protection against the effects of soot, dirt, and other contaminants (compared to previous formulation)
- Increased shear stability for better viscosity control and optimal engine oil pressure
- 100% Synthetic Double Ester
- Designed for highly modified engines
- Electrochemical bonding to metal parts
- Up to 5x higher film strength
- 0% shear loss on Bosch ASTM D6278 test
- Optimal lubrication in all operating conditions, ensures low oil consumption
- Very high shear and ageing stability, highest levels of wearing protection
- Tested and approved for catalytic converters, optimal engine cleanliness
- Ideally suited for wet clutches
- Specifications and Approvals: API, SM, ACEA A3-04, JASO, MA2
- Please see Product Description regarding the California Proposition 65 Warning
- Practiced and tested extensively with KTM, Husqvarna, Yamaha, Kawasaki, Honda, Aprilia, BMW, Suzuki, Ducati, Triumph, and Moto-Guzzi motorcycles
- High performance full synthetic oil utilizing the latest lubrication technology
- Excellent engine protection in all conditions including extreme high stress racing conditions
- Excellent cold start lubrication, low oil evaporation tendency, suitable for motorcycles with catalytic converters
- XPS synthetic 4-stroke oil is specifically engineered to meet the particular lubrication requirements of Can-Am, Spyder and Sea-Doo vehicles equipped with Rotax 4-TEC 4-stroke engines.
- Powersport formula with premium anti-wear and anti-corrosion additives
- Designed for high-performance off-road, on-road and PWC 4-stroke engines, including turbo or supercharged Powersports engines
- Provides superior engine and transmission protection against rust and corrosion even in extreme conditions
- Ambient temperature operating range: -31°F / 104°F (-35°C / 40°C)
Last update on 2024-04-11 / Affiliate links / Images from Amazon Product Advertising API
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SEOCONTENT-START
General Information Table of Contents Before Servicing . 1-2 Model Identification. 1-7 General Specifications 1-8 Unit Conversion Table 1-11 Periodic Maintenance Table of Contents Periodic Maintenance Chart . 2-3 Torque and Locking Agent 2-5 Specifications . 2-12 Special Tools 2-14 Periodic Maintenance Procedures 2-15 Fuel System (DFI) 2-15 Air Cleaner Element Replacement 2-15 Idle Speed Inspection . 2-16 Idle Speed Adjustment 2-16 Throttle Control System Inspection. 2-16 Engine Vacuum Synchronization Inspection. 2-17 Fuel System Inspection. 2-20 Fuel Filter Replacement 2-21 Fuel Hose Replacement . 2-23 Evaporative Emission Control System Inspection (Other than US and CA Models) 2-24 Cooling System 2-25 Coolant Level Inspection. 2-25 Cooling System Inspection . 2-26 Coolant Change 2-26 Water Hose and O-ring Replacement. 2-29 Engine Top End . 2-30 Valve Clearance Inspection 2-30 Valve Clearance Adjustment. 2-31 Air Suction System Damage Inspection 2-35 Clutch. 2-36 Clutch Operation Inspection . 2-36 Engine Lubrication System 2-37 Engine Oil Change 2-37 Oil Filter Replacement 2-38 Wheels/Tires 2-38 Air Pressure Inspection. 2-38 Wheels and Tires Inspection. 2-38 Wheel Bearing Damage Inspection 2-39 Final Drive 2-40 Drive Chain Lubrication Condition Inspection . 2-40 Drive Chain Slack Inspection 2-41 Drive Chain Slack Adjustment 2-41 Wheel Alignment Inspection . 2-41 Wheel Alignment Adjustment 2-41 Drive Chain Wear Inspection 2-42 Chain Guide Wear Inspection . 2-42 Brakes 2-43 Brake System Inspection 2-43 Brake Operation Inspection 2-44 Brake Fluid Level Inspection. 2-44 Brake Fluid Change 2-45 Brake Hose and Pipe Replacement 2-46 Master Cylinder Rubber Parts Replacement 2-50 Caliper Rubber Parts Replacement 2-51 Brake Pad Wear Inspection 2-54 Brake Light Switch Operation Inspection 2-55 Suspension 2-56 Suspension System Inspection. 2-56 Steering . 2-57 Steering Play Inspection . 2-57 Steering Play Adjustment 2-57 Steering Stem Bearing Lubrication . 2-59 Electrical System . 2-60 Lights and Switches Operation Inspection 2-60 Headlight Aiming Inspection . 2-62 Side Stand Switch Operation Inspection. 2-63 Engine Stop Switch Operation Inspection. 2-64 Spark Plug Replacement 2-65 Others 2-65 Chassis Parts Lubrication 2-65 Condition of Bolts, Nuts and Fasteners Tightness Inspection 2-66 Fuel System (DFI) Table of Contents Exploded View. 3-4 DFI System 3-10 DFI Components Naming 3-12 DFI Parts Location. 3-17 Specifications 3-21 Special Tools and Sealant . 3-23 DFI Servicing Precautions. 3-25 DFI Servicing Precautions 3-25 Troubleshooting the DFI System . 3-27 Outline 3-27 Inquiries to Rider. 3-31 DFI System Troubleshooting Guide 3-34 Self-Diagnosis . 3-39 Self-Diagnosis Outline . 3-39 Self-Diagnosis Procedures 3-40 Service Code Reading . 3-41 Service Code Erasing 3-42 Backups . 3-44 Main Throttle Sensor (Service Code 11) (DTC P0120, P0123) 3-47 Main Throttle Sensor Removal/Adjustment. 3-47 Main Throttle Sensor Input Voltage Inspection. 3-47 Main Throttle Sensor Resistance Inspection 3-48 Main Throttle Sensor Output Voltage Inspection. 3-48 Intake Air Pressure Sensor #1 (Service Code 12) (DTC P0105, P0107) 3-51 Intake Air Pressure Sensor #1 Removal 3-51 Intake Air Pressure Sensor #1 Installation . 3-51 Intake Air Pressure Sensor #1 Input Voltage Inspection 3-52 Intake Air Pressure Sensor #1 Output Voltage Inspection . 3-53 Intake Air Temperature Sensor (Service Code 13) (DTC P0110, P0112) 3-57 Intake Air Temperature Sensor Removal/Installation 3-57 Intake Air Temperature Sensor Output Voltage Inspection . 3-57 Intake Air Temperature Sensor Resistance Inspection . 3-59 Water Temperature Sensor (Service Code 14) (DTC P0115, P0117). 3-60 Water Temperature Sensor Removal/Installation 3-60 Water Temperature Sensor Output Voltage Inspection . 3-60 Water Temperature Sensor Resistance Inspection . 3-61 Intake Air Pressure Sensor #2 (Service Code 16) (DTC P2226, P2227, P2228) 3-63 Intake Air Pressure Sensor #2 Removal 3-63 Intake Air Pressure Sensor #2 Installation . 3-63 Intake Air Pressure Sensor #2 Input Voltage Inspection 3-64 Intake Air Pressure Sensor #2 Output Voltage Inspection . 3-65 Crankshaft Sensor (Service Code 21) (DTC P0335). 3-67 Crankshaft Sensor Removal/Installation 3-67 Crankshaft Sensor Resistance Inspection 3-67 Crankshaft Sensor Peak Voltage Inspection 3-67 Rear Wheel Rotation Sensor (Service Code 24) (DTC P2158). 3-68 Rear Wheel Rotation Sensor Signal Inspection. 3-68 Gear Position Sensor (Service Code 25) (DTC P0914, P0915, P0916) 3-70 Gear Position Sensor Removal/Installation 3-70 Gear Position Sensor Input Voltage Inspection. 3-70 Gear Position Sensor Output Voltage Inspection. 3-71 Front Wheel Rotation Sensor (Service Code 27) (DTC P0500). 3-73 Front Wheel Rotation Sensor Signal Inspection. 3-73 Vehicle-down Sensor (Service Code 31) (DTC C0064) 3-75 Vehicle-down Sensor Removal 3-75 Vehicle-down Sensor Installation . 3-76 Vehicle-down Sensor Input Voltage Inspection. 3-76 Vehicle-down Sensor Output Voltage Inspection. 3-77 Subthrottle Sensor (Service Code 32) (DTC P0220, P0223) 3-80 Subthrottle Sensor Removal/Adjustment. 3-80 Subthrottle Sensor Input Voltage Inspection 3-80 Subthrottle Sensor Output Voltage Inspection 3-81 Subthrottle Sensor Resistance Inspection 3-83 Oxygen Sensor – not activated (Service Code 33) (DTC P0130, P0132) 3-84 Oxygen Sensor Removal/Installation 3-84 Oxygen Sensor Inspection. 3-84 Immobilizer Amplifier (Service Code 35, Equipped Models). 3-87 Antenna Resistance Inspection . 3-87 Amplifier Input Voltage Inspection 3-87 Blank Key Detection (Service Code 36, Equipped Models). 3-88 Ignition Key Inspection. 3-88 ECU Communication Error (Service Code 39) (DTC U0001). 3-89 ECU Communication Line Inspection 3-89 Fuel Injectors (Service Code 41, 42, 43, 44) (DTC P0201, P0202, P0203, P0204) 3-90 Fuel Injector Removal/Installation 3-90 Fuel Injector Audible Inspection. 3-90 Fuel Injector Resistance Inspection 3-90 Fuel Injector Power Source Voltage Inspection. 3-91 Fuel Injector Output Voltage Inspection 3-92 Fuel Injector Fuel Line Inspection 3-93 Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54) (DTC P0351, P0352, P0353, P0354) . 3-95 Stick Coil Removal/Installation. 3-95 Stick Coil Primary Winding Resistance Inspection . 3-95 Stick Coil Input Voltage Inspection 3-95 Radiator Fan Relay (Service Code 56) (DTC P0480) 3-97 Radiator Fan Relay Removal/Installation 3-97 Radiator Fan Relay Inspection. 3-97 Subthrottle Valve Actuator (Service Code 62) (DTC P2100). 3-98 Subthrottle Valve Actuator Removal 3-98 Subthrottle Valve Actuator Inspection 3-98 Subthrottle Valve Actuator Resistance Inspection . 3-98 Subthrottle Valve Actuator Input Voltage Inspection. 3-99 Air Switching Valve (Service Code 64) (DTC P0410) 3-101 Air Switching Valve Removal/Installation 3-101 Air Switching Valve Inspection . 3-101 Oxygen Sensor Heater (Service Code 67) (DTC P0030). 3-102 Oxygen Sensor Heater Removal/Installation 3-102 Oxygen Sensor Heater Resistance Inspection . 3-102 Oxygen Sensor Heater Power Source Voltage Inspection 3-103 Fuel Supply System (Service Code 94) (DTC P0170) 3-105 Fuel Supply System Inspection 3-105 Purge Valve (Service Code 3A) (DTC P0443) (Other than US and CA Models). 3-106 Purge Valve Removal/Installation . 3-106 Purge Valve Inspection 3-106 IMU (Inertial Measurement Unit) (Service Code E8E) 3-108 IMU Removal . 3-108 IMU Installation 3-108 IMU Power Supply Inspection 3-108 IMU (Inertial Measurement Unit) Communication Error (Service Code E8F) 3-110 IMU Communication Line Inspection 3-110 Warning Indicator Light (LED) . 3-111 Yellow Engine Warning/Red Warning Indicator Light (LED) Inspection 3-111 ECU. 3-112 ECU Identification 3-112 ECU Removal 3-112 ECU Installation . 3-112 ECU Power Supply Inspection. 3-113 CAN Communication Line . 3-116 CAN Communication Line Resistance Inspection . 3-116 CAN Communication Line . 3-117 DFI Power Source . 3-118 ECU Fuse Removal . 3-118 ECU Fuse Installation 3-118 ECU Fuse Inspection . 3-118 ECU Main Relay Removal/Installation 3-118 ECU Main Relay Inspection . 3-118 Fuel Line 3-119 Fuel Pressure Inspection . 3-119 Fuel Flow Rate Inspection . 3-120 Fuel Pump . 3-122 Fuel Pump Removal 3-122 Fuel Pump Installation . 3-123 Fuel Pump Operation Inspection . 3-123 Fuel Pump Operating Voltage Inspection 3-124 Pressure Regulator Removal. 3-125 Fuel Pump Relay Removal/Installation 3-125 Fuel Pump Relay Inspection 3-125 Throttle Grip and Cables . 3-127 Free Play Inspection 3-127 Free Play Adjustment. 3-127 Cable Installation . 3-127 Cable Lubrication. 3-127 Throttle Body Assy 3-128 Idle Speed Inspection/Adjustment 3-128 Synchronization Inspection/Adjustment. 3-128 Throttle Body Assy Removal 3-128 Throttle Body Assy Installation. 3-130 Throttle Body Assy Disassembly . 3-131 Throttle Body Assy Assembly 3-132 Air Cleaner. 3-133 Air Cleaner Element Removal/Installation 3-133 Air Cleaner Element Inspection . 3-133 Air Cleaner Oil Draining . 3-133 Air Cleaner Housing Removal 3-133 Air Cleaner Housing Installation. 3-134 Fuel Tank. 3-135 Fuel Tank Removal 3-135 Fuel Tank Installation . 3-137 Fuel Tank and Cap Inspection . 3-139 Fuel Tank Cleaning 3-140 Evaporative Emission Control System (other than US and CA Models) 3-141 Parts Removal/Installation . 3-141 Hose Inspection . 3-141 Purge Valve Inspection 3-141 Canister Inspection . 3-141 Cooling System Table of Contents Exploded View 4-2 Coolant Flow Chart. 4-4 Specifications . 4-6 Special Tools . 4-7 Coolant . 4-8 Coolant Deterioration Inspection. 4-8 Coolant Level Inspection. 4-8 Coolant Draining . 4-8 Coolant Filling . 4-8 Pressure Testing . 4-8 Cooling System Flushing 4-9 Coolant Reserve Tank Removal/Installation . 4-9 Water Pump 4-10 Water Pump Removal. 4-10 Water Pump Installation 4-10 Water Pump Inspection. 4-12 Water Pump Impeller Disassembly/Assembly 4-12 Water Pump Impeller Inspection. 4-12 Water Pump Housing Disassembly 4-12 Water Pump Housing Assembly . 4-13 Mechanical Seal Inspection 4-13 Radiator 4-14 Radiator and Radiator Fan Removal 4-14 Radiator and Radiator Fan Installation . 4-15 Radiator Inspection . 4-16 Radiator Cap Inspection . 4-16 Radiator Filler Neck Inspection . 4-17 Thermostat . 4-18 Thermostat Removal. 4-18 Thermostat Installation 4-18 Thermostat Inspection 4-18 Hose and Pipes 4-20 Hose Installation . 4-20 Hose Inspection 4-20 Water Temperature Sensor 4-21 Water Temperature Sensor Removal/Installation . 4-21 Water Temperature Sensor Inspection . 4-21 Engine Top End Table of Contents Exploded View. 5-2 Exhaust System Identification . 5-6 Specifications 5-9 Special Tools and Sealants . 5-11 Clean Air System. 5-14 Air Suction Valve Removal. 5-14 Air Suction Valve Installation 5-16 Air Suction Valve Inspection 5-16 Air Switching Valve Removal . 5-16 Air Switching Valve Installation 5-17 Air Switching Valve Operation Test 5-17 Air Switching Valve Unit Test . 5-17 Clean Air System Hose Inspection 5-17 Cylinder Head Cover . 5-18 Cylinder Head Cover Removal 5-18 Cylinder Head Cover Installation . 5-18 Camshaft Chain Tensioner 5-20 Camshaft Chain Tensioner Removal 5-20 Camshaft Chain Tensioner Installation . 5-20 Camshaft, Camshaft Chain . 5-21 Camshaft Removal 5-21 Camshaft Installation . 5-22 Camshaft, Camshaft Cap Wear Inspection 5-25 Camshaft Runout Inspection 5-25 Cam Wear Inspection 5-26 Camshaft Chain Removal 5-26 Cylinder Head 5-27 Cylinder Compression Measurement 5-27 Cylinder Head Removal. 5-28 Cylinder Head Installation 5-29 Cylinder Head Warp Inspection . 5-30 Valves 5-31 Valve Clearance Inspection . 5-31 Valve Clearance Adjustment 5-31 Valve Removal . 5-31 Valve Installation 5-31 Valve Guide Removal 5-31 Valve Guide Installation . 5-32 Valve-to-Guide Clearance Measurement (Wobble Method). 5-33 Valve Seat Inspection 5-33 Valve Seat Repair 5-34 Cylinder, Pistons 5-39 Cylinder Removal. 5-39 Cylinder Installation 5-39 Piston Removal 5-40 Piston Installation. 5-41 Cylinder Wear Inspection. 5-42 Piston Wear Inspection 5-42 Piston Ring, Piston Ring Groove Wear Inspection 5-42 Piston Ring Groove Width Inspection 5-42 Piston Ring Thickness Inspection 5-43 Piston Ring End Gap Inspection 5-43 Throttle Body Assy Holder. 5-44 Throttle Body Assy Holder Removal 5-44 Throttle Body Assy Holder Installation . 5-44 Muffler 5-46 Muffler Body Removal 5-46 Muffler Body Installation. 5-46 Exhaust Pipe Removal. 5-48 Exhaust Pipe Installation 5-49 Clutch Table of Contents Exploded View 6-2 Specifications . 6-4 Special Tool and Sealant 6-5 Clutch Lever and Cable 6-6 Clutch Lever Free Play Inspection 6-6 Clutch Lever Free Play Adjustment 6-6 Clutch Cable Removal 6-6 Clutch Cable Installation . 6-6 Clutch Cable Lubrication. 6-6 Clutch Lever Assembly Installation . 6-6 Clutch Lever and Cable 6-7 Clutch Lever Installation 6-7 Clutch Lever Position Adjustment. 6-8 Clutch Cover. 6-9 Clutch Cover Removal 6-9 Clutch Cover Installation . 6-9 Release Shaft Removal 6-10 Release Shaft Installation . 6-10 Clutch Cover Disassembly 6-10 Clutch Cover Assembly. 6-11 Clutch . 6-12 Clutch Removal. 6-12 Clutch Installation 6-13 Clutch Plate Assembly Length Inspection. 6-16 Clutch Plate Assembly Length Adjustment . 6-16 Clutch Plate, Wear, Damage Inspection . 6-17 Clutch Plate Warp Inspection 6-17 Clutch Housing Finger Inspection. 6-17 Clutch Housing Spline Inspection . 6-17 Clutch Pressure Plate and Clutch Hub Inspection 6-18 Clutch Spring Inspection . 6-18 Engine Lubrication System Table of Contents Exploded View 7-2 Engine Oil Flow Chart. 7-4 Specifications . 7-5 Special Tools and Sealants 7-6 Engine Oil and Oil Filter 7-7 Oil Level Inspection. 7-7 Engine Oil Change 7-7 Oil Filter Replacement 7-7 Oil Pan 7-8 Oil Pan Removal. 7-8 Oil Pan Installation 7-8 Oil Screen. 7-10 Oil Screen Removal 7-10 Oil Screen Installation . 7-10 Oil Screen Cleaning 7-10 Oil Pressure Relief Valve 7-11 Oil Pressure Relief Valve Removal . 7-11 Oil Pressure Relief Valve Installation 7-11 Oil Pressure Relief Valve Inspection. 7-11 Oil Pump. 7-12 Oil Pump Removal 7-12 Oil Pump Installation . 7-12 Oil Pump Drive Gear Removal 7-13 Oil Pump Drive Gear Installation. 7-13 Oil Cooler 7-14 Oil Cooler Removal. 7-14 Oil Cooler Installation 7-14 Oil Pressure Measurement. 7-15 Oil Pressure Measurement . 7-15 Oil Pressure Switch 7-16 Oil Pressure Switch Removal . 7-16 Oil Pressure Switch Installation 7-16 Oil Pipe . 7-17 Oil Pipe Removal 7-17 Oil Pipe Installation . 7-17 Engine Removal/Installation Table of Contents Exploded View 8-2 Special Tool 8-4 Engine Removal/Installation . 8-5 Engine Removal 8-5 Engine Installation. 8-9 Crankshaft/Transmission Table of Contents Exploded View. 9-2 Specifications 9-6 Special Tools and Sealants . 9-8 Crankcase Splitting 9-9 Crankcase Splitting 9-9 Crankcase Assembly . 9-10 Crankshaft and Connecting Rods 9-15 Crankshaft Removal 9-15 Crankshaft Installation . 9-15 Connecting Rod Removal 9-15 Connecting Rod Installation . 9-16 Crankshaft/Connecting Rod Cleaning 9-19 Connecting Rod Bend Inspection 9-20 Connecting Rod Twist Inspection. 9-20 Connecting Rod Big End Side Clearance Inspection 9-20 Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection 9-21 Crankshaft Side Clearance Inspection 9-22 Crankshaft Runout Inspection 9-23 Crankshaft Main Bearing Insert/Journal Wear Inspection . 9-23 Balancer 9-26 Balancer Removal 9-26 Balancer Installation. 9-26 Balancer Adjustment 9-27 Balancer Damper Inspection 9-27 Starter Motor Clutch 9-28 Starter Motor Clutch Removal/Installation 9-28 Starter Motor Clutch Disassembly 9-28 Starter Motor Clutch Assembly 9-28 Starter Motor Clutch Inspection . 9-28 External Shift Mechanism 9-29 Shift Pedal Removal 9-29 Shift Pedal Installation . 9-29 External Shift Mechanism Removal 9-30 External Shift Mechanism Installation . 9-30 External Shift Mechanism Inspection 9-31 Transmission . 9-33 Transmission Shaft Removal . 9-33 Transmission Shaft Installation 9-33 Transmission Shaft Disassembly. 9-33 Transmission Shaft Assembly 9-34 Shift Drum and Fork Removal 9-38 Shift Drum and Fork Installation. 9-38 Shift Drum Disassembly. 9-38 Shift Drum Assembly . 9-39 Shift Fork Bending Inspection 9-39 Shift Fork/Gear Groove Wear Inspection 9-39 Shift Fork Guide Pin/Drum Groove Wear Inspection . 9-39 Gear Dog and Gear Dog Hole Damage Inspection . 9-40 Ball Bearing, Needle Bearing, and Oil Seal. 9-41 Ball and Needle Bearing Replacement. 9-41 Ball and Needle Bearing Wear Inspection 9-41 Oil Seal Inspection . 9-41 Wheels/Tires Table of Contents Exploded View 10-2 Specifications . 10-4 Special Tools 10-5 Wheels (Rims) 10-6 Front Wheel Removal . 10-6 Front Wheel Installation 10-6 Rear Wheel Removal 10-8 Rear Wheel Installation. 10-9 Wheel Inspection 10-10 Axle Inspection 10-11 Balance Inspection 10-11 Balance Adjustment 10-11 Balance Weight Removal 10-12 Balance Weight Installation. 10-12 Tires 10-14 Air Pressure Inspection/Adjustment 10-14 Tire Inspection 10-14 Tire Removal. 10-14 Tire Installation 10-14 Tire Repair 10-16 Hub Bearing 10-17 Hub Bearing Removal. 10-17 Hub Bearing Installation 10-17 Hub Bearing Inspection. 10-18 Hub Bearing Lubrication . 10-18 Final Drive Table of Contents Exploded View 11-2 Specifications . 11-4 Special Tools 11-5 Drive Chain. 11-6 Drive Chain Slack Inspection 11-6 Drive Chain Slack Adjustment 11-6 Wheel Alignment Inspection/Adjustment 11-6 Drive Chain Wear Inspection 11-6 Drive Chain Lubrication. 11-6 Drive Chain Removal 11-6 Drive Chain Installation . 11-7 Drive Chain Replacement . 11-7 Sprocket, Coupling . 11-11 Engine Sprocket Removal 11-11 Engine Sprocket Installation . 11-11 Engine Sprocket Cover Disassembly 11-12 Engine Sprocket Cover Assembly 11-12 Rear Sprocket Removal 11-13 Rear Sprocket Installation. 11-13 Coupling Installation 11-13 Coupling Bearing Removal . 11-14 Coupling Bearing Installation 11-14 Coupling Bearing Inspection . 11-15 Coupling Bearing Lubrication 11-15 Coupling Damper Inspection. 11-15 Sprocket Wear Inspection. 11-15 Rear Sprocket Warp Inspection 11-16 Brakes Table of Contents Exploded View 12-3 Specifications . 12-8 Special Tools 12-9 Brake Lever, Brake Pedal. 12-10 Brake Lever Position Adjustment 12-10 Brake Pedal Position Inspection . 12-10 Brake Pedal Position Adjustment 12-10 Brake Pedal Removal . 12-10 Brake Pedal Installation 12-11 Calipers 12-12 Front Caliper Removal 12-12 Rear Caliper Removal. 12-12 Caliper Installation 12-12 Front Caliper Disassembly 12-12 Front Caliper Assembly. 12-13 Rear Caliper Disassembly 12-13 Rear Caliper Assembly . 12-13 Caliper Fluid Seal Damage Inspection 12-13 Caliper Dust Seal Damage Inspection 12-13 Rear Caliper Dust Boot and Friction Boot Damage Inspection. 12-14 Caliper Piston and Cylinder Damage Inspection 12-14 Rear Caliper Holder Shaft Wear Inspection 12-14 Brake Pads. 12-15 Front Brake Pad Removal. 12-15 Front Brake Pad Installation 12-15 Rear Brake Pad Removal 12-15 Rear Brake Pad Installation 12-16 Brake Pad Wear Inspection 12-16 Master Cylinder 12-17 Front Master Cylinder Removal 12-17 Front Master Cylinder Installation . 12-17 Rear Master Cylinder Removal. 12-17 Rear Master Cylinder Installation 12-18 Front Master Cylinder Disassembly 12-18 Rear Master Cylinder Disassembly. 12-18 Master Cylinder Assembly 12-18 Master Cylinder Inspection (Visual Inspection). 12-19 Brake Disc 12-20 Brake Disc Removal . 12-20 Brake Disc Installation 12-20 Brake Disc Wear Inspection 12-20 Brake Disc Warp Inspection 12-21 Brake Fluid . 12-22 Brake Fluid Level Inspection. 12-22 Brake Fluid Change 12-22 Brake Line Bleeding 12-22 Brake Hose. 12-26 Brake Hose Removal/Installation 12-26 Brake Hose and Pipe Inspection. 12-26 Anti-Lock Brake System . 12-27 Parts Location . 12-27 ABS Servicing Precautions . 12-31 ABS Troubleshooting Outline 12-33 Inquiries to Rider. 12-36 Self-diagnosis Outline . 12-40 Self-diagnosis Procedures 12-40 Service Code Clearing Procedures. 12-41 How to Read Service Codes. 12-44 How to Erase Service Codes 12-44 Yellow ABS and Yellow Warning Indicator Lights (LED) Inspection 12-47 Solenoid Valve Inspection (Service Code 13, 14, 17, 18). 12-47 ABS Solenoid Valve Relay Inspection (Service Code 19) 12-48 Front, Rear Wheel Rotation Difference Abnormal (Service Code 25) 12-48 ABS Motor Relay Inspection (Service Code 35) . 12-49 Front Wheel Rotation Sensor Signal Abnormal (Service Code 42) 12-49 Front Wheel Rotation Sensor Wiring Inspection (Service Code 43) 12-50 Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44). 12-51 Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45) 12-51 Power Supply Voltage Abnormal (Low-Voltage) (Service Code 52) . 12-52 Power Supply Voltage Abnormal (Over-Voltage) (Service Code 53) 12-52 ABS Solenoid Valve Relay Supply Voltage Inspection (Low-Voltage) (Service Code 54) 12-52 ECU Inspection (Service Code 55) . 12-53 CAN Communication (Transmission)/CAN Bus OFF Monitor Inspection (Service Code 57) 12-53 ECU Communication Line Inspection (Service Code 62) . 12-54 IMU Communication Line Inspection (Service Code 63) 12-55 Output Fluid Pressure Sensor (Front Brake) Wiring Inspection (Service Code 83) 12-55 Output Fluid Pressure Sensor (Front Brake) Offset Abnormal (Service Code 84) . 12-56 Fluid Pressure Sensor Supply Voltage Inspection (Service Code 89) 12-56 IMU Inspection (Service Code 94) 12-56 ABS Hydraulic Unit Removal 12-56 ABS Hydraulic Unit Installation . 12-58 ABS Hydraulic Unit Inspection 12-58 Front Wheel Rotation Sensor Removal 12-59 Front Wheel Rotation Sensor Installation . 12-60 Rear Wheel Rotation Sensor Removal. 12-60 Rear Wheel Rotation Sensor Installation 12-61 Wheel Rotation Sensor Inspection 12-61 Wheel Rotation Sensor Air Gap Inspection 12-61 Wheel Rotation Sensor Rotor Inspection 12-62 ABS Solenoid Valve Relay Fuse (15 A) Removal. 12-62 ABS Motor Relay Fuse (25 A) Removal . 12-62 Fuse Installation 12-62 Fuse Inspection. 12-62 Suspension Table of Contents Exploded View 13-2 Specifications . 13-6 Special Tools 13-7 Front Fork. 13-9 Rebound Damping Force Adjustment 13-9 Spring Preload Adjustment . 13-9 Compression Damping Force Adjustment (Right Side Only) 13-10 Front Fork Removal (Each Fork Leg) . 13-10 Front Fork Installation . 13-11 Fork Oil Change 13-11 Front Fork Disassembly 13-21 Front Fork Assembly. 13-22 Inner Tube, Outer Tube Inspection . 13-23 Dust Seal Inspection . 13-24 Spring Tension Inspection. 13-24 Rear Shock Absorber . 13-25 Rebound Damping Force Adjustment. 13-25 Spring Preload Adjustment . 13-25 Rear Shock Absorber Removal 13-25 Rear Shock Absorber Installation . 13-26 Rear Shock Absorber Inspection 13-27 Rear Shock Absorber Scrapping 13-27 Rear Shock Absorber Bearing Removal. 13-27 Rear Shock Absorber Bearing Installation 13-27 Swingarm 13-28 Swingarm Removal. 13-28 Swingarm Installation 13-29 Swingarm Bearing Removal . 13-30 Swingarm Bearing Installation 13-30 Swingarm Bearing, Sleeve Inspection 13-31 Swingarm Bearing Lubrication 13-31 Chain Guide Inspection. 13-31 Tie-Rod, Rocker Arm 13-32 Tie-Rod Removal 13-32 Tie-Rod Installation . 13-32 Rocker Arm Removal 13-32 Rocker Arm Installation. 13-33 Tie-Rod and Rocker Arm Bearing Removal 13-34 Tie-Rod and Rocker Arm Bearing Installation. 13-34 Rocker Arm/Tie-Rod Bearing, Sleeve Inspection . 13-35 Rocker Arm/Tie-Rod Bearing Lubrication . 13-35 Steering Table of Contents Exploded View 14-2 Special Tools 14-4 Steering 14-5 Steering Inspection . 14-5 Steering Adjustment 14-5 Steering Stem. 14-6 Stem, Stem Bearing Removal. 14-6 Stem, Stem Bearing Installation 14-7 Steering Stem Bearing Lubrication . 14-9 Steering Stem Warp Inspection 14-9 Stem Cap Deterioration, Damage Inspection . 14-10 Handlebar. 14-11 Handlebar Removal 14-11 Handlebar Installation . 14-11 Frame Table of Contents Exploded View. 15-2 Seats . 15-10 Rear Seat Removal 15-10 Rear Seat Installation. 15-10 Front Seat Removal. 15-10 Front Seat Installation 15-10 Fairings 15-11 Middle Fairing Removal . 15-11 Middle Fairing Installation 15-12 Lower Fairing Removal 15-13 Lower Fairing Installation . 15-14 Lower Fairing Disassembly 15-15 Lower Fairing Assembly. 15-16 Rear Lower Fairing Removal . 15-16 Rear Lower Fairing Installation 15-16 Windshield Removal 15-17 Windshield Installation . 15-17 Upper Fairing Removal 15-17 Upper Fairing Installation . 15-17 Upper Fairing Disassembly 15-18 Upper Fairing Assembly. 15-18 Windshield Bracket Disassembly. 15-18 Windshield Bracket Assembly 15-19 Windshield Bracket Assembly Removal 15-21 Windshield Bracket Assembly Installation . 15-21 Covers . 15-22 Side Cover Removal 15-22 Side Cover Installation . 15-22 Left Lower Side Fairing Removal. 15-22 Left Lower Side Fairing Installation . 15-22 Seat Cover Removal 15-23 Seat Cover Installation. 15-23 Meter Cover Removal 15-23 Meter Cover Installation 15-24 Fenders . 15-26 Front Fender Removal. 15-26 Front Fender Installation 15-26 Flap and Rear Fender Removal. 15-26 Flap and Rear Fender Installation 15-27 Frame 15-29 Frame Inspection . 15-29 Rear Frame Removal. 15-29 Rear Frame Installation 15-29 Rear Frame Bracket Removal . 15-29 Rear Frame Bracket Installation 15-29 Battery Case 15-30 Battery Case Removal. 15-30 Battery Case Installation 15-30 Guard. 15-31 Mud Guard Removal 15-31 Mud Guard Installation. 15-31 Side Stand. 15-32 Side Stand Removal 15-32 Side Stand Installation . 15-32 Electrical System Table of Contents Exploded View 16-4 Specifications . 16-10 Special Tools and Sealant 16-11 Parts Location. 16-13 Wiring Diagram (US, CA and CAL Models) 16-16 Wiring Diagram (Other than US, CA and CAL Models) 16-18 Precautions. 16-20 Electrical Wiring 16-21 Wiring Inspection 16-21 Battery 16-22 Battery Removal . 16-22 Battery Installation 16-22 Battery Activation 16-22 Precautions . 16-25 Interchange . 16-26 Charging Condition Inspection 16-26 Refreshing Charge 16-26 Charging System 16-28 Alternator Cover Removal. 16-28 Alternator Cover Installation 16-28 Stator Coil Removal 16-28 Stator Coil Installation . 16-29 Alternator Rotor Removal . 16-29 Alternator Rotor Installation 16-30 Charging Voltage Inspection. 16-32 Alternator Inspection . 16-32 Regulator/Rectifier Removal. 16-34 Regulator/Rectifier Installation 16-34 Regulator/Rectifier Inspection. 16-34 Ignition System. 16-37 Crankshaft Sensor Removal. 16-37 Crankshaft Sensor Installation 16-38 Crankshaft Sensor Inspection. 16-39 Crankshaft Sensor Peak Voltage Inspection. 16-40 Timing Rotor Removal 16-40 Timing Rotor Installation . 16-40 Stick Coil Removal 16-41 Stick Coil Installation. 16-41 Stick Coil Inspection 16-41 Stick Coil Primary Peak Voltage Inspection 16-41 Spark Plug Removal . 16-42 Spark Plug Installation 16-42 Spark Plug Condition Inspection. 16-43 Interlock Operation Inspection 16-43 IC Igniter Inspection 16-44 Electric Starter System. 16-47 Starter Motor Removal 16-47 Starter Motor Installation. 16-47 Starter Motor Disassembly 16-47 Starter Motor Assembly 16-48 Brush Inspection . 16-50 Commutator Cleaning and Inspection. 16-50 Armature Inspection 16-51 Brush Lead Inspection 16-51 Right-hand End Cover Inspection. 16-51 Starter Relay Inspection 16-51 Lighting System 16-54 Headlight Beam Horizontal Adjustment 16-54 Headlight Beam Vertical Adjustment. 16-54 Headlight (LED) Assembly Removal/Installation 16-54 Headlight Harness Circuit Inspection 16-54 City Light Input Voltage Inspection 16-55 Headlight Lo Beam Input Voltage Inspection 16-55 City Light (LED) Removal/Installation . 16-55 Tail/Brake Light (LED) Removal 16-56 Tail/Brake Light (LED) Installation. 16-56 License Plate Light Bulb Replacement . 16-56 Turn Signal Light Bulb Replacement 16-58 Turn Signal Relay Inspection 16-59 Air Switching Valve . 16-62 Air Switching Valve Operation Test . 16-62 Air Switching Valve Unit Test 16-62 Radiator Fan System 16-64 Fan Motor Inspection 16-64 Meter, Gauge, Indicator Unit. 16-66 Meter Unit Removal 16-66 Meter Unit Installation . 16-66 Meter Unit Disassembly/Assembly . 16-66 Meter Operation Inspection. 16-66 Meter System Inspection 16-70 Meter Unit Inspection 16-71 Fuel Level Sensor Line Self-Diagnosis Mode Inspection 16-79 Immobilizer System (Equipped Models) . 16-81 Operational Cautions 16-81 Key Registration 16-81 Immobilizer System Parts Replacement. 16-99 Immobilizer System Inspection . 16-101 Immobilizer System Circuit . 16-102 Switches and Sensors 16-103 Brake Light Timing Inspection. 16-103 Brake Light Timing Adjustment . 16-103 Switch Inspection 16-103 Water Temperature Sensor Inspection . 16-104 Oxygen Sensor Removal 16-104 Oxygen Sensor Installation . 16-105 Oxygen Sensor Inspection 16-105 Fuel Level Sensor Inspection 16-105 Gear Position Sensor Removal. 16-105 Gear Position Sensor Installation 16-106 Gear Position Sensor Inspection 16-106 Outside Temperature Sensor Removal. 16-106 Outside Temperature Sensor Installation 16-107 Relay Box . 16-108 Relay Box Removal/Installation 16-108 Relay Circuit Inspection 16-108 Diode Circuit Inspection 16-109 Fuse 16-111 30 A Main/15 A ECU Fuse Removal. 16-111 Fuse Box Fuse Removal. 16-111 Fuse Installation 16-111 Fuse Inspection. 16-111
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