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NHTSA ID Number: 10089685
Manufacturer Communication Number: 99924-1517-01
Summary
SERVICE MANUAL
Motorcycle Service Manual
Ninja 650
Ninja 650 ABS
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 | KAWASAKI | 9999 |
1 Associated Document
Manufacturer Communications
99924-1517-01
https://www.nhtsa.gov/recalls?nhtsaId=10089685
MC-10089685-0699.pdf 72139.079KB
https://static.oemdtc.com/TSB/MC-10089685-0699.pdf
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- 🏍️【System Diagnosis Features】The Motocycle diagnostic tool Support engine / ABS / Tire pressure / Anti-theft and other systems, It can quickly read and clear diagnostic trouble codes, view freeze frame, display data stream and do active tests, get vehicle information, You are allowed to perform a complete and deep detection for your motorcycles, rather than send it directly to repair shop, very suitable for diyers.
- 🏍️【Easy To Use】 Code Readers Scan Tools is a handheld motorcycle diagnostic tool for mainstream motorcycle brands and can help technicians diagnose problems faster and make repairs. This tool has functions such as voltage detection, multi-language selection, and unit switching. It has a clear interface and is easy to operate. It is a good helper for motorcycle maintenance.
- 🏍️【Wide Compatibility】Motorcycle Fault Code Readers support the diagnosis of Asian, European and American multi-brand motorcycles, M3-A is suitable for motorcycles of Yamaha, Honda, Kawasaki and OBD2, Supports 11 languages, You can switch the language you need anytime.
- 🏍️【Portable and Convenient】The motorcycle diagnostic requires no Internet connection or setup, and with a lightweight body that can be operated with one hand, you can take it anywhere and use it very conveniently.
- 🏍️【Free Software Upgrade】Connect the device to the computer and wait for the device to be recognized by the computer. After the recognition is successful, a new drive symbol will appear on the computer. Open this and replace the “DIAGNOSE" folder in the drive with the downloaded “DIAGNOSE" upgrade folder, and then power on again. The updated files can be obtained by contacting the customer service.
- 🏍️【Easy To Use】M6 Motorcycle Diagnostic Tool is a handheld motorcycle diagnostic tool for mainstream motorcycle brands and can help technicians diagnose problems faster and make repairs. This tool has functions such as voltage detection, multi-language selection, and unit switching. It has a clear interface and is easy to operate. It is a good helper for motorcycle maintenance.
- 🏍️【104 Service Functions Supported】M6 Motorcycle Diagnostic Tool supports up to 104 service functions that allow technicians to perform factory service procedures such as Oil maintenance lamp reset, ECU reset, making injection adjustments (CO Trimmer), adjusting the throttle valve position sensor (TPS), re-setting auto adaptive parameters, and re-setting the service light, and making idling adjustments.
- 🏍️【Wide Compatibility】support the diagnosis of Asian, European and American multi-brand motorcycles, Supports 11 languages, You can switch the language you need anytime.
- 🏍️【System Diagnosis Features】The Motocycle diagnostic tool Support engine / ABS / Tire pressure / Anti-theft and other systems, It can quickly read and clear diagnostic trouble codes, view freeze frame, display data stream and do active tests, get vehicle information, You are allowed to perform a complete and deep detection for your motorcycles, rather than send it directly to repair shop, very suitable for diyers.
- 🏍️【Read Data Steam】The data stream waveform graph automatically adapts to the data without the need for manual adjustment of amplitude and allows for viewing of specific data streams rather than displaying all data streams at once. It comes equipped with features such as a printer, image viewer, data logging and playback, battery testing, charge detection, error reporting and feedback, and more.
- 🚴🏻【Intelligent dual systemmotorbike tester】 Motorbike Diagnosis + Battery Analysis.
- 🚴🏻【Product Features】 Multi-purpose machine, can be used for motorbike testing,battery testing, car testing, etc.
- 🚴🏻【Signal Simulator】Can simulate crank signals, PWM signals, injector signals, ignition signals.
- 🚴🏻【Support wifi online upgrade】Built-in 2.4G high-speed transmission wif moduleonline cloud service automatic upgrade, convenient and fast.
- 🚴🏻【Supports 13 different languages】English, Chinese Traditional, Spanish, French, Cambodian, Thai, Chinese Turkish.Vietnamese, Indonesian, Portuguese, Japanese, Korean, German.
- 👍【Multifunctional Motorcycle Diagnostic Tool】MT500 PRO is an advanced motorcycle diagnostic tablet developed by ANCEL specifically for motorcycle enthusiasts. Bright 5" touchscreen & Android 5.1.1 OS & 8 Languages; Auto VIN & Scan; Online remote assistance and solve problems, One-click WIFI update; Full systems diagnosis for most popular motorcycle models; 30+ Resets like oil service reset, abs bleeding, etc.
- ✅【Wider Motorcycle Coverage Than Others】 Compare with other similar motorcycle scan tool, MT500PRO added more popular motorcycle brands, it' not only compatible with Harley Yamaha Honda Indian Polaris BRP Victory diagnosis.Newly upgraded in 2023 with the addition of two more popular brands fit for Kawasaki Suzuki diagnosis. Plug and play, easy to use
- ✅ [Manufacturer-level Diagnostic] MT500 PRO is a all-system motorcycle diagnostic tool. It can read and clear trouble codes and turn off the CEL when a check engine light comes on. Besides, it can also scan all the available electronic control modules of your motorcycle including Engine, ABS, TPMS, Suspensions, Ignition, EPS, Service system, Meter system, etc. to read/clear fault codes, and view live data.You can quickly and accurately find existing or potential problems, saving time and money
- ✅ [Excluisive Advance Functions, Save Costs For You] MT500 PRO diagnostic tool with almost all daily maintenance services that necessary advanced functions for most motorcycle to meet the market trends and needs. Auto scan, auto VIN recognition, control module programming and coding, ECU setting, instrument coding, maintenance light reset, CO adjustment, idle speed adjustment, A/F value reset, ABS control unit setting etc. Help you solve all kinds of complex maintenance problems easily
- ✅The ANCEL MT500PRO scanner diagnostic tool providing real-time data display for quick and accurate diagnostics. With its user-friendly touch screen interface, the Moto 100 OBD2 code reader allows for easy navigation and interpretation of the data streams. Whether you are a professional mechanic or a motorcycle enthusiast, this code reader is a valuable tool for troubleshooting and maintaining your motorcycle’s performance
- 💯OBDPROG MOTO 100 Diagnostic Scan Tool Compatible with a wide range of Harley Davidson motorcycles, including Touring, Dyna, Softail, Sportster, Touring CVO, and VRSC V-Rod and more.
- 💯OBDPROG MOTO 100 Diagnostic Scan Tool Compatible with Polaris motorcycles, including RANGER, ATV, Snow, RZR, Slingshot, Commercial, LEV, ACE, General, and Generic and more.
- 🍻[Compatible with over 1000 models and makes] For Indian motorcycles (Chieftain, Scout, Scout Sixty, Scout Bobber, Springfield, and more), For BRP motorcycles (Commander, DS, Defender, Maverick, Outlander, Renegade, Traxter, Spyder, Adventure, Boondocker, and more), For Victory motorcycles (Vision, High-Ball, Cross Country, Cross Roads, and more), For Yamaha motorcycles, and Honda motorcycles. Equipped with a 5.0-inch touch screen and offers easy WiFi updates during the first year at no additional cost. After the first year, a yearly software fee of $80 is applicable.
- 🍻[Clear The Check Engine Light Yourself] Provides full system motorcycle obd2 diagnostic, component reset, and relearn functions for these motorcycles. Can retrieve and clear fault codes from the motorcycle's ECU, and analyze information from ABS, Engine, Transmission, Power Steering, and Meter systems.
- 🍻[Monitor your Bike’s Health] Provides multiple displays of live data, including text, graphics, and gauges, allowing motorcycle owners to monitor oil temperature, pressure, transmission temperature, engine speed, engine coolant temperature, and short-term fuel trim.
- 【Topdiag M100 pro Hand-Held Operation】: Jdiag m100 pro motorcycle scanner is hand-held operation, easy to use, simplo and flexible, fast troubleshooting.
- 【Topdiag M100 Pro Widely Used For Motorcycle Repair】：Suitable for motorcycle maintenance technicians andpersonal vehicle maintenance and repair.
- 【Multiple Battery Test Methods】Jdiag m100 pro motorcycle scanner: Multiple test methods for more professional testing of car batteries.
- 【Support Multi-languages】：English,Traditional Chinese, Viotnamese, Indonesian, Thai, Spain;Turkey, Portugel, French, Khmer.
- 【Jdiag m100 pro motorcycle scanner support Motorcycle list】: Hartford, Aeon, Honda, SYM, Yamaha,Suzuki,Kymco,Kawasaki,Piaggio,PGO,KTM, etc
- Fits 2001-2014 Harley Davidson Fuel Injected models with the 4 pin connector (check detailed compatibility list below).
- Converts 4 pin to 16 pin OBD2 connection for use with your J1850 capable OBD2 scanners or readers.
- Compatible with RPMitUP and Harley Droid App.
- Built to last quality cable and moulded plug. 1 feet. See B09VSYV478 for the 6 pin CAN BUS version.
- With the appropriate OBD2 device and software (not included), you can read and erase error codes, view live data like RPM, Horsepower, Torque, Engine temperature etc.
- [Full System Diagnostics] M200 professional scan tool it can request information from motorcycle or send commands to the autocycle modules. It allows the technician to perform factory service procedures such as✅ABS system test✅Freezing data✅Actuator testing✅DTC enquiry✅Clean the injectors✅Troubleshooting✅CO idle speed adjustment✅Adjusting the throttle valve position sensor(TPS)
- [17+ Services] M200 Scanner Diagnostic Tool is designed for home mechanics and workshops, garages. Support almost all the most popular functions of motorcycles, including Engine, ABS, TPMS, Suspensions, Ignition, EPS, Traction control, Radio, LED headlight. Battery detection, Start test, Charging test, Relay test, etc. Help you handle all kinds of complex maintenance problems easily.
- [With Print Function] The tester is equipped with a built-in printer that can generate printed test reports. These reports typically include the battery test results, including voltage, CCA, SOC, and any additional measurements or diagnostic information. The printed report serves as documentation and can be used for reference or for sharing the results with customers or technicians.
- [Battery Tester] Allows you to assess motorcycle battery health and performance.Voltage measurement, include load testing, charging test, start test. By performing a battery test using a motorcycle diagnostic tool, you can identify any battery-related problems early on and take appropriate action.
- [M200 Works With Your Motorcycle] The M200 is capable of accurately monitoring and diagnosing problems on over 14 different makes of motorcycle. This includes AEON, Apprilia, Benelli, Hartford, Honda, Kawasaki, Kymco, Piaggio, PGO, Suzuki, Sym, Vespa, Yamaha.etc., and is a good choice for motorcycle repair shops, and home mechanics.
- 🔥【2022 MOST Worth Buying Motorcycle Diagnostic Tool】MT500 PLUS is an advanced motorcycle diagnostic tablet developed by ANCEL specifically for motorcycle enthusiasts.🥇Bright 5" touchscreen & Android 5.1.1 OS & 8 Languages;🥇Auto VIN & Scan;🥇Online remote assistance and solve problems, One-click WIFI update;🥇Full systems diagnosis for almost of all EU motorcycle models, such as BMW/Yamaha/KTM/Triumph/Ducati, etc.;🥇30+ Resets;✅1-Year Free Update (Value $200);✅9 extra adapter cables (Value $300)
- 【Wider Coverage for Motorcycles】Most motorcycle scanners on the market are mainly fit for BMW. For the convenience of owners who own different motorcycles, we specially added DUCATI, KTM, TRIUMPH, YAMAHA, HONDA, SUZUKI, KAWASAKI. not only that, it also covers scooters, side-by-side motorcycles, snowmobiles, ATVs, etc. It is easy to plug and play. What's more, considering the different interfaces, it is specially equipped with 9 adapter cables (worth over $300), no need to spend extra money to buy
- Fit for BMW/Yamaha/DUCATI/TRIUMPH】For BMW motorcycles, it supports serial C/F/G/H/K/R/S, year 1996 onward. For Yamaha motorcycles, it supports serial A/B/C/D/F/G/M/N/R/S/T/V/W/X/Y/Z, year 2003 onward. For DUCATI motorcycle, it supports serial 1/7/8/9/D/G/H/M/P/S/X, year 1998 onward. For TRIUMPH motorcycle, it supports serial A/B/D/R/S/T, year 1997 onward. Please confirm compatibility via email, message or Q&A before ordering
- 【Manufacturer-level Diagnostic for Motorbike】MT500 PLUS supported do a dealer-level and comprehensive diagnosis for all electronics control modules of your motorcycles, including Engine, ABS, TPMS, Suspensions, Ignition, EPS, Traction control, Radio, LED headlight, Service system, Meter system. It can read and clear fault codes, allows you to easily diagnose engine problems and turn off the warning light. It makes your easily know the car situation and check the problems
- 【30+ Special Service Functions】MT500 PLUS motorbike scan tool covers almost all commonly used resets, such as TPS reset, Oil Reset, ABS Brake Bleeding, EPB Service, ECU reset, instrument coding, CO adjustment, idle speed adjustment, A/F value reset, windshield adjustment, etc. Helping motorcycle users save money and time in maintenance or repair, at least $300/YEAR
Last update on 2024-04-12 / Affiliate links / Images from Amazon Product Advertising API
This product presentation was made with AAWP plugin.
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 . 2-11 Special Tools 2-13 Periodic Maintenance Procedures 2-14 Fuel System (DFI) 2-14 Air Cleaner Element Replacement 2-14 Idle Speed Inspection . 2-15 Idle Speed Adjustment 2-15 Throttle Control System Inspection. 2-16 Engine Vacuum Synchronization Inspection. 2-16 Fuel System Inspection. 2-20 Fuel Filter Replacement 2-20 Fuel Hose Replacement . 2-22 Evaporative Emission Control System Inspection (Equipped Models) . 2-24 Cooling System 2-25 Coolant Level Inspection. 2-25 Cooling System Inspection . 2-25 Coolant Change 2-25 Water Hose and O-ring Replacement. 2-28 Engine Top End . 2-28 Valve Clearance Inspection 2-28 Valve Clearance Adjustment. 2-30 Air Suction System Damage Inspection 2-33 Clutch. 2-34 Clutch Operation Inspection . 2-34 Engine Lubrication System 2-35 Engine Oil Change 2-35 Oil Filter Replacement 2-36 Wheels/Tires 2-36 Air Pressure Inspection. 2-36 Wheels and Tires Inspection. 2-36 Wheel Bearing Damage Inspection 2-37 Final Drive 2-38 Drive Chain Lubrication Condition Inspection . 2-38 Drive Chain Slack Inspection 2-39 Drive Chain Slack Adjustment 2-39 Wheel Alignment Inspection . 2-40 Drive Chain Wear Inspection 2-41 Chain Guide Wear Inspection . 2-41 Brakes 2-42 Brake System Inspection 2-42 Brake Operation Inspection 2-43 Brake Fluid Level Inspection. 2-43 Brake Fluid Change 2-44 Brake Hose and Pipe Replacement 2-46 Master Cylinder Rubber Parts Replacement 2-50 Caliper Rubber Parts Replacement 2-51 Brake Pad Wear Inspection 2-55 Brake Light Switch Operation Inspection 2-55 Suspension 2-56 Suspension System Inspection. 2-56 Steering . 2-58 Steering Play Inspection . 2-58 Steering Play Adjustment 2-58 Steering Stem Bearing Lubrication . 2-60 Electrical System . 2-61 Lights and Switches Operation Inspection 2-61 Headlight Aiming Inspection . 2-63 Side Stand Switch Operation Inspection. 2-64 Engine Stop Switch Operation Inspection. 2-65 Spark Plug Replacement 2-66 Others 2-66 Chassis Parts Lubrication 2-66 Condition of Bolts, Nuts and Fasteners Tightness Inspection 2-67 Fuel System (DFI) Table of Contents Exploded View 3-4 DFI System. 3-10 DFI Components Naming . 3-12 DFI Parts Location 3-19 Specifications . 3-22 Special Tools and Sealant 3-24 DFI Servicing Precautions 3-26 DFI Servicing Precautions . 3-26 Troubleshooting the DFI System 3-28 Outline . 3-28 Inquiries to Rider 3-31 DFI System Troubleshooting Guide . 3-34 Self-Diagnosis 3-39 Self-Diagnosis Outline 3-39 Self-Diagnosis Procedures . 3-39 Service Code Reading 3-42 Service Code Erasing . 3-42 Backups 3-43 Main Throttle Sensor (Service Code 11) (DTC P0120, P0123) 3-46 Main Throttle Sensor Removal/Adjustment 3-46 Main Throttle Sensor Input Voltage Inspection . 3-46 Main Throttle Sensor Resistance Inspection 3-47 Main Throttle Sensor Output Voltage Inspection 3-47 Intake Air Pressure Sensor (Service Code 12) (DTC P0105, P0106, P0107) 3-50 Intake Air Pressure Sensor Removal 3-50 Intake Air Pressure Sensor Installation. 3-50 Intake Air Pressure Sensor Input Voltage Inspection 3-51 Intake Air Pressure Sensor Output Voltage Inspection. 3-52 Intake Air Temperature Sensor (Service Code 13) (DTC P0110, P0112). 3-56 Intake Air Temperature Sensor Removal/Installation 3-56 Intake Air Temperature Sensor Output Voltage Inspection . 3-56 Intake Air Temperature Sensor Resistance Inspection . 3-57 Water Temperature Sensor (Service Code 14) (DTC P0115, P0117) 3-59 Water Temperature Sensor Removal/Installation . 3-59 Water Temperature Sensor Output Voltage Inspection. 3-59 Water Temperature Sensor Resistance Inspection. 3-60 Crankshaft Sensor (Service Code 21) (DTC P0335) 3-62 Crankshaft Sensor Removal/Installation. 3-62 Crankshaft Sensor Resistance Inspection 3-62 Crankshaft Sensor Peak Voltage Inspection. 3-62 Rear Wheel Rotation Sensor (Service Code 24) (DTC P2158) 3-63 Rear Wheel Rotation Sensor Signal Inspection 3-63 Gear Position Sensor (Service Code 25) (DTC P0914, P0915, P0917) 3-66 Gear Position Sensor Removal/Installation 3-66 Gear Position Sensor Input Voltage Inspection 3-66 Gear Position Sensor Output Voltage Inspection 3-67 Vehicle-down Sensor (Service Code 31) (DTC C0064) . 3-69 Vehicle-down Sensor Removal. 3-69 Vehicle-down Sensor Installation 3-69 Vehicle-down Sensor Input Voltage Inspection. 3-70 Vehicle-down Sensor Output Voltage Inspection 3-71 Subthrottle Sensor (Service Code 32) (DTC P0220, P0223) . 3-73 Subthrottle Sensor Removal/Adjustment 3-73 Subthrottle Sensor Input Voltage Inspection. 3-73 Subthrottle Sensor Output Voltage Inspection 3-74 Subthrottle Sensor Resistance Inspection 3-76 Oxygen Sensor – not activated (Service Code 33) (DTC P0130, P0132). 3-77 Oxygen Sensor Removal/Installation 3-77 Oxygen Sensor Inspection 3-77 ECU Communication Error (Service Code 39). 3-80 ECU Communication Line Inspection . 3-80 Fuel Injectors (Service Code 41, 42) (DTC P0201, P0202) . 3-81 Fuel Injector Removal/Installation. 3-81 Fuel Injector Audible Inspection 3-81 Fuel Injector Resistance Inspection 3-81 Fuel Injector Power Source Voltage Inspection 3-82 Fuel Injector Output Voltage Inspection 3-83 Fuel Injector Fuel Line Inspection. 3-84 Stick Coils #1, #2 (Service Code 51, 52) (DTC P0351, P0352) . 3-86 Stick Coil Removal/Installation 3-86 Stick Coil Primary Winding Resistance Inspection . 3-86 Stick Coil Input Voltage Inspection 3-86 Radiator Fan Relay (Service Code 56) (DTC P0480) 3-88 Radiator Fan Relay Removal/Installation 3-88 Radiator Fan Relay Inspection 3-88 Subthrottle Valve Actuator (Service Code 62) (DTC P2100) 3-89 Subthrottle Valve Actuator Removal . 3-89 Subthrottle Valve Actuator Inspection . 3-89 Subthrottle Valve Actuator Resistance Inspection 3-89 Subthrottle Valve Actuator Input Voltage Inspection . 3-90 Air Switching Valve (Service Code 64) (DTC P0410). 3-92 Air Switching Valve Removal/Installation 3-92 Air Switching Valve Inspection 3-92 Oxygen Sensor Heater (Service Code 67) (DTC P0030). 3-93 Oxygen Sensor Heater Removal/Installation 3-93 Oxygen Sensor Heater Resistance Inspection . 3-93 Oxygen Sensor Heater Power Source Voltage Inspection . 3-94 Fuel Supply System (Service Code 94) (DTC P0170) . 3-96 Fuel Supply System Inspection. 3-96 Purge Valve (Service Code 3A) (DTC P0443) (Equipped Models) 3-97 Purge Valve Removal/Installation . 3-97 Purge Valve Inspection . 3-97 Warning Indicator Light (LED) 3-99 Yellow Engine Warning/Red Warning Indicator Light (LED) Inspection 3-99 ECU 3-100 ECU Identification . 3-100 ECU Removal . 3-100 ECU Installation 3-100 ECU Power Supply Inspection 3-101 DFI Power Source 3-104 ECU Fuse Removal 3-104 ECU Fuse Installation . 3-104 ECU Fuse Inspection 3-104 ECU Main Relay Removal/Installation 3-104 ECU Main Relay Inspection 3-104 Fuel Line. 3-105 Fuel Pressure Inspection 3-105 Fuel Flow Rate Inspection 3-106 Fuel Pump 3-108 Fuel Pump Removal . 3-108 Fuel Pump Installation 3-109 Fuel Pump Operation Inspection 3-109 Fuel Pump Operating Voltage Inspection . 3-109 Pressure Regulator Removal 3-111 Fuel Pump Relay Removal/Installation. 3-111 Fuel Pump Relay Inspection . 3-111 Throttle Grip and Cables 3-113 Throttle Grip Free Play Inspection 3-113 Throttle Grip Free Play Adjustment. 3-113 Throttle Cable Installation . 3-113 Throttle Cable Lubrication. 3-113 Throttle Body Assy . 3-114 Idle Speed Inspection/Adjustment 3-114 Throttle Bore Cleaning 3-114 Synchronization Inspection/Adjustment 3-114 Throttle Body Assy Removal. 3-114 Throttle Body Assy Installation 3-116 Throttle Body Assy Disassembly 3-117 Throttle Body Assy Assembly . 3-118 Air Cleaner 3-120 Air Cleaner Element Removal/Installation 3-120 Air Cleaner Element Inspection 3-120 Air Cleaner Oil Draining 3-120 Air Cleaner Housing Removal. 3-120 Air Cleaner Housing Installation 3-121 Fuel Tank 3-122 Fuel Tank Removal . 3-122 Fuel Tank Installation 3-125 Fuel Tank and Cap Inspection 3-127 Fuel Tank Cleaning . 3-127 Evaporative Emission Control System (Equipped Models) 3-128 Parts Removal/Installation 3-128 Hose Inspection 3-128 Purge Valve Inspection . 3-128 Canister Inspection 3-128 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 . 4-9 Coolant Reserve Tank Installation 4-10 Water Pump 4-11 Water Pump Removal. 4-11 Water Pump Installation 4-11 Water Pump Inspection. 4-12 Mechanical Seal Inspection 4-12 Water Pump Housing Disassembly 4-13 Water Pump Housing Assembly . 4-13 Impeller Assembly. 4-13 Pump Impeller Inspection . 4-13 Radiator 4-14 Radiator and Radiator Fan Removal 4-14 Radiator and Radiator Fan Installation . 4-15 Radiator Inspection . 4-15 Radiator Cap Inspection . 4-16 Radiator Filler Neck Inspection . 4-16 Thermostat . 4-17 Thermostat Removal. 4-17 Thermostat Installation 4-17 Thermostat Inspection 4-18 Water Hose and Pipes 4-19 Water Hose Installation. 4-19 Water Hose Inspection 4-19 Water Hose and O-ring Replacement. 4-19 Water Temperature Sensor 4-20 Water Temperature Sensor Removal/Installation . 4-20 Water Temperature Sensor Inspection . 4-20 Engine Top End Table of Contents Exploded View. 5-2 Exhaust System Identification . 5-6 Specifications 5-8 Special Tools and Sealant . 5-10 Clean Air System. 5-12 Air Suction Valve Removal. 5-12 Air Suction Valve Installation 5-12 Air Suction Valve Inspection 5-13 Air Switching Valve Removal . 5-13 Air Switching Valve Installation 5-13 Air Switching Valve Operation Test 5-13 Air Switching Valve Unit Test . 5-13 Clean Air System Hose Inspection 5-14 Cylinder Head Cover . 5-15 Cylinder Head Cover Removal 5-15 Cylinder Head Cover Installation . 5-15 Camshaft Chain Tensioner 5-17 Camshaft Chain Tensioner Removal 5-17 Camshaft Chain Tensioner Installation . 5-17 Camshaft, Camshaft Chain . 5-19 Camshaft Removal 5-19 Camshaft Installation . 5-21 Camshaft, Camshaft Cap Wear Inspection 5-24 Camshaft Runout Inspection 5-24 Cam Wear Inspection 5-25 Camshaft Chain Removal 5-25 Cylinder Head 5-26 Cylinder Compression Measurement 5-26 Cylinder Head Removal. 5-27 Cylinder Head Installation 5-28 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). 5-32 Valve Seat Inspection 5-33 Valve Seat Repair 5-33 Cylinder, Pistons 5-38 Cylinder Removal. 5-38 Cylinder Installation 5-38 Piston Removal 5-39 Piston Installation. 5-39 Cylinder Wear Inspection. 5-40 Piston Wear Inspection 5-41 Piston Ring, Piston Ring Groove Wear Inspection 5-41 Piston Ring Groove Width Inspection 5-41 Piston Ring Thickness Inspection 5-42 Piston Ring End Gap Inspection 5-42 Throttle Body Assy Holder. 5-43 Throttle Body Assy Holder Removal 5-43 Throttle Body Assy Holder Installation . 5-43 Muffler 5-44 Muffler Removal. 5-44 Muffler Installation 5-45 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 . 6-7 Clutch Lever Removal. 6-7 Clutch Lever Installation 6-8 Clutch Lever Position Adjustment. 6-8 Clutch Cover. 6-9 Clutch Cover Removal 6-9 Clutch Cover Installation . 6-9 Release Shaft Removal 6-9 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 Measurement. 6-16 Clutch Plate Assembly 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 . 7-6 Special Tools and Sealant 7-7 Engine Oil and Oil Filter 7-8 Oil Level Inspection. 7-8 Engine Oil Change 7-8 Oil Filter Replacement 7-8 Oil Pan 7-9 Oil Pan Removal. 7-9 Oil Pan Installation 7-10 Oil Screen. 7-12 Oil Screen Removal 7-12 Oil Screen Installation . 7-12 Oil Screen Cleaning 7-12 Oil Pressure Relief Valve 7-13 Oil Pressure Relief Valve Removal . 7-13 Oil Pressure Relief Valve Installation 7-13 Oil Pressure Relief Valve Inspection. 7-13 Oil Pumps. 7-14 Oil Pump Chain and Sprocket Removal . 7-14 Oil Pump Chain and Sprocket Installation 7-14 Oil Pump Removal 7-14 Oil Pump Installation . 7-16 Oil Pressure Measurement. 7-18 Oil Pressure Measurement . 7-18 Oil Pressure Switch 7-19 Oil Pressure Switch Removal . 7-19 Oil Pressure Switch Installation 7-19 Oil Pipes . 7-20 Oil Pipe Removal 7-20 Oil Pipe Installation . 7-20 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. 8-8 Crankshaft/Transmission Table of Contents Exploded View. 9-2 Specifications 9-6 Special Tools and Sealants . 9-9 Crankcase Splitting 9-10 Crankcase Splitting 9-10 Crankcase Assembly . 9-12 Crankshaft and Connecting Rods 9-21 Crankshaft Removal 9-21 Crankshaft Installation . 9-21 Connecting Rod Removal 9-21 Connecting Rod Installation . 9-22 Crankshaft/Connecting Rod Cleaning 9-25 Connecting Rod Bend Inspection 9-26 Connecting Rod Twist Inspection. 9-26 Connecting Rod Big End Side Clearance Inspection 9-26 Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection 9-27 Crankshaft Side Clearance Inspection 9-28 Crankshaft Runout Inspection 9-29 Crankshaft Main Bearing Insert/Journal Wear Inspection . 9-29 Balancer 9-31 Balancer Removal 9-31 Balancer Installation. 9-31 Balancer Shaft Bearing Insert/Journal Wear Inspection . 9-31 Starter Motor Clutch 9-34 Starter Motor Clutch Removal/Installation 9-34 Starter Motor Clutch Inspection . 9-34 Starter Motor Clutch Disassembly 9-34 Starter Motor Clutch Assembly 9-34 External Shift Mechanism 9-35 Shift Pedal Removal 9-35 Shift Pedal Installation . 9-35 External Shift Mechanism Removal 9-36 External Shift Mechanism Installation . 9-37 External Shift Mechanism Inspection 9-38 Transmission . 9-40 Transmission Assy Removal 9-40 Transmission Assy Installation. 9-41 Transmission Assy Disassembly . 9-42 Transmission Assy Assembly 9-42 Transmission Shaft Removal . 9-44 Transmission Shaft Installation 9-44 Transmission Shaft Disassembly. 9-45 Transmission Shaft Assembly 9-45 Shift Drum and Fork Removal 9-48 Shift Drum and Fork Installation. 9-48 Shift Drum Disassembly. 9-48 Shift Drum Assembly . 9-48 Shift Fork Bending Inspection 9-48 Shift Fork/Gear Groove Wear Inspection 9-48 Shift Fork Guide Pin/Drum Groove Wear Inspection . 9-48 Gear Dog and Gear Dog Hole Damage Inspection . 9-49 Ball Bearing, Needle Bearing, and Oil Seal. 9-50 Ball and Needle Bearing Replacement. 9-50 Ball and Needle Bearing Wear Inspection 9-50 Oil Seal Inspection . 9-50 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 10-7 Rear Wheel Installation. 10-8 Wheel Inspection 10-11 Axle Inspection 10-11 Balance Inspection 10-12 Balance Adjustment 10-12 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 Drive Chain Installation . 11-8 Sprocket, Coupling . 11-11 Engine Sprocket Removal 11-11 Engine Sprocket Installation . 11-11 Rear Sprocket Removal 11-12 Rear Sprocket Installation. 11-12 Coupling Installation 11-13 Coupling Bearing Removal . 11-13 Coupling Bearing Installation 11-14 Coupling Bearing Inspection . 11-14 Coupling Bearing Lubrication 11-14 Coupling Damper Inspection. 11-15 Sprocket Wear Inspection. 11-15 Rear Sprocket Warp Inspection 11-15 Brakes Table of Contents Exploded View 12-3 Specifications . 12-10 Special Tools 12-11 Brake Lever, Brake Pedal. 12-12 Brake Lever Position Adjustment 12-12 Brake Pedal Position Inspection . 12-12 Brake Pedal Position Adjustment 12-12 Brake Pedal Removal . 12-12 Brake Pedal Installation 12-13 Calipers 12-14 Front Caliper Removal 12-14 Front Caliper Installation . 12-14 Rear Caliper Removal. 12-14 Rear Caliper Installation 12-15 Front Caliper Disassembly 12-15 Front Caliper Assembly. 12-15 Rear Caliper Disassembly 12-15 Rear Caliper Assembly . 12-16 Caliper Fluid Seal Damage Inspection 12-16 Caliper Dust Boot and Friction Boot Damage Inspection 12-16 Caliper Piston and Cylinder Damage Inspection 12-17 Caliper Holder Shaft/Pin/Collar Inspection 12-17 Brake Pads. 12-18 Front Brake Pad Removal. 12-18 Front Brake Pad Installation 12-18 Rear Brake Pad Removal . 12-19 Rear Brake Pad Installation 12-19 Brake Pad Wear Inspection 12-19 Master Cylinder 12-20 Front Master Cylinder Removal 12-20 Front Master Cylinder Installation . 12-20 Rear Master Cylinder Removal. 12-21 Rear Master Cylinder Installation 12-21 Front Master Cylinder Disassembly 12-22 Rear Master Cylinder Disassembly. 12-22 Master Cylinder Assembly 12-22 Master Cylinder Inspection (Visual Inspection). 12-23 Brake Disc 12-24 Brake Disc Removal . 12-24 Brake Disc Installation 12-24 Brake Disc Wear Inspection 12-24 Brake Disc Warp Inspection 12-25 Brake Fluid . 12-26 Brake Fluid Level Inspection. 12-26 Brake Fluid Change 12-26 Brake Line Bleeding 12-26 Brake Hose. 12-29 Brake Hose Removal/Installation 12-29 Brake Hose and Pipe Inspection. 12-29 Anti-Lock Brake System (Equipped Models) 12-30 Parts Location . 12-30 ABS Servicing Precautions . 12-34 ABS Troubleshooting Outline 12-36 Inquiries to Rider. 12-39 Self-diagnosis Outline . 12-43 Self-diagnosis Procedures 12-43 Service Code Clearing Procedures. 12-44 How to Read Service Codes. 12-47 How to Erase Service Codes 12-47 Yellow ABS Indicator Light (LED) Inspection 12-49 Solenoid Valve Inspection (Service Code 13, 14, 17, 18). 12-49 ABS Solenoid Valve Relay Inspection (Service Code 19) 12-49 Front, Rear Tire Abnormal (Service Code 25) 12-50 ABS Motor Relay Inspection (Service Code 35) . 12-50 Front Wheel Rotation Sensor Signal Abnormal (Service Code 42) 12-51 Front Wheel Rotation Sensor Wiring Inspection (Service Code 43) 12-52 Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44). 12-52 Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45) 12-53 Power Supply Voltage Abnormal [Low-Voltage] (Service Code 52) 12-53 Power Supply Voltage Abnormal [Over-Voltage] (Service Code 53) 12-54 ABS Solenoid Valve Relay Supply Voltage Inspection [Low-Voltage] (Service Code 54). 12-54 ECU Inspection (Service Code 55) . 12-54 ABS Hydraulic Unit Removal 12-55 ABS Hydraulic Unit Installation . 12-57 ABS Hydraulic Unit Inspection 12-58 Front Wheel Rotation Sensor Removal 12-58 Front Wheel Rotation Sensor Installation . 12-59 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 Front Fork Removal (Each Fork Leg) . 13-9 Front Fork Installation (Each Fork Leg) 13-9 Front Fork Oil Change 13-9 Front Fork Disassembly 13-11 Front Fork Assembly. 13-12 Inner Tube, Outer Tube Inspection . 13-14 Dust Seal Inspection . 13-14 Spring Tension Inspection. 13-14 Rear Shock Absorber . 13-15 Spring Preload Adjustment . 13-15 Rear Shock Absorber Removal 13-15 Rear Shock Absorber Installation . 13-16 Rear Shock Absorber Inspection 13-16 Rear Shock Absorber Scrapping 13-17 Rear Shock Absorber Bearing Removal. 13-17 Rear Shock Absorber Bearing Installation 13-17 Swingarm 13-18 Swingarm Removal. 13-18 Swingarm Installation 13-19 Swingarm Bearing Removal . 13-20 Swingarm Bearing Installation 13-21 Swingarm Bearing, Sleeve Inspection 13-22 Swingarm Bearing Lubrication 13-22 Chain Guide Inspection. 13-22 Tie-Rod, Rocker Arm 13-23 Tie-Rod Removal 13-23 Tie-Rod Installation . 13-24 Rocker Arm Removal 13-24 Rocker Arm Installation. 13-25 Tie-Rod and Rocker Arm Bearing Removal 13-25 Tie-Rod and Rocker Arm Bearing Installation. 13-26 Rocker Arm/Tie-Rod Bearing, Sleeve Inspection . 13-27 Rocker Arm/Tie-Rod Bearing Lubrication . 13-27 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 Steering Stem, Stem Bearing Removal 14-6 Steering Stem, Stem Bearing Installation . 14-7 Steering Stem Bearing Lubrication . 14-9 Steering Stem Warp Inspection 14-9 Stem Cap Deterioration, Damage Inspection . 14-9 Handlebars . 14-10 Handlebar Removal 14-10 Handlebar Installation . 14-10 Frame Table of Contents Exploded View 15-3 Seats 15-14 Rear Seat Removal. 15-14 Rear Seat Installation 15-14 Front Seat Removal 15-14 Front Seat Installation . 15-14 Fairings. 15-15 Upper Inner Fairing Removal 15-15 Upper Inner Fairing Installation. 15-16 Lower Inner Fairing Removal 15-17 Lower Inner Fairing Installation. 15-18 Fairing Cover Removal . 15-18 Fairing Cover Installation 15-19 Middle Fairing Removal 15-20 Middle Fairing Installation . 15-22 Middle Fairing Disassembly 15-23 Middle Fairing Assembly. 15-24 Upper Fairing Removal. 15-25 Upper Fairing Installation 15-25 Covers 15-27 Frame Cover Removal 15-27 Frame Cover Installation. 15-27 Side Cover Removal. 15-27 Side Cover Installation 15-27 Ignition Switch Cover Removal. 15-27 Ignition Switch Cover Installation 15-28 Fuel Tank Side Cover Removal 15-28 Fuel Tank Side Cover Installation . 15-28 Seat Cover Removal. 15-29 Seat Cover Installation 15-30 Fenders 15-31 Front Fender Removal 15-31 Front Fender Installation . 15-31 Rear Fender Removal. 15-31 Rear Fender Installation 15-33 Flap Removal 15-33 Flap Installation. 15-33 Frame . 15-34 Frame Inspection 15-34 Battery Case. 15-35 Battery Case Removal 15-35 Battery Case Installation . 15-35 Guard 15-36 Mud Guard Removal. 15-36 Mud Guard Installation 15-36 Windshield 15-37 Windshield Height Adjustment 15-37 Windshield Removal . 15-37 Windshield Installation 15-37 Side Stand 15-38 Side Stand Removal . 15-38 Side Stand Installation 15-39 Rear View Mirrors. 15-41 Rear View Mirror Removal 15-41 Rear View Mirror Installation. 15-41 Electrical System Table of Contents Exploded View 16-4 Specifications . 16-10 Special Tools and Sealant 16-11 Parts Location. 16-12 Wiring Diagram (ER650G) 16-14 Wiring Diagram (ER650H) 16-16 Precautions. 16-18 Electrical Wiring 16-19 Wiring Inspection 16-19 Battery 16-20 Battery Removal . 16-20 Battery Installation 16-20 Battery Activation 16-21 Precautions . 16-23 Interchange . 16-24 Charging Condition Inspection 16-24 Refreshing Charge 16-24 Charging System 16-26 Alternator Cover Removal. 16-26 Alternator Cover Installation 16-26 Stator Coil Removal 16-27 Stator Coil Installation . 16-28 Alternator Rotor Removal . 16-28 Alternator Rotor Installation 16-29 Charging Voltage Inspection. 16-31 Alternator Inspection . 16-31 Regulator/Rectifier Removal. 16-33 Regulator/Rectifier Installation 16-33 Regulator/Rectifier Inspection. 16-33 Ignition System. 16-36 Crankshaft Sensor Removal. 16-36 Crankshaft Sensor Installation 16-37 Crankshaft Sensor Inspection. 16-37 Crankshaft Sensor Peak Voltage Inspection. 16-38 Timing Rotor Removal 16-38 Timing Rotor Installation . 16-38 Stick Coil Removal 16-39 Stick Coil Installation. 16-39 Stick Coil Inspection 16-39 Stick Coil Primary Peak Voltage Inspection 16-39 Spark Plug Removal . 16-40 Spark Plug Installation 16-40 Spark Plug Condition Inspection. 16-41 Interlock Operation Inspection 16-41 IC Igniter Inspection 16-42 Electric Starter System. 16-45 Starter Motor Removal 16-45 Starter Motor Installation. 16-45 Starter Motor Disassembly 16-46 Starter Motor Assembly 16-47 16-2 ELECTRICAL SYSTEM Brush Inspection . 16-48 Commutator Cleaning and Inspection. 16-49 Armature Inspection 16-49 Brush Lead Inspection 16-49 Right-hand End Cover Inspection. 16-49 Starter Relay Inspection 16-50 Lighting System 16-52 Headlight Beam Horizontal Adjustment 16-52 Headlight Beam Vertical Adjustment. 16-52 Headlight Bulb Replacement 16-52 Headlight Unit Removal 16-53 Headlight Unit Installation . 16-53 City Light Bulb Replacement. 16-54 Tail/Brake Light (LED) Unit Removal 16-54 Tail/Brake Light (LED) Unit Installation . 16-54 License Plate Light Bulb Replacement . 16-55 Front Turn Signal Light Bulb Replacement . 16-56 Rear Turn Signal Light Bulb Replacement 16-57 Turn Signal Relay Inspection 16-58 Switches and Sensors 16-60 Brake Light Timing Inspection. 16-60 Brake Light Timing Adjustment . 16-60 Switch Inspection 16-60 Water Temperature Sensor Removal/Installation . 16-60 Water Temperature Sensor Inspection . 16-61 Rear Wheel Rotation Sensor Removal. 16-61 Rear Wheel Rotation Sensor Installation 16-61 Rear Wheel Rotation Sensor Inspection. 16-61 Fuel Level Sensor Inspection 16-61 Oxygen Sensor Removal 16-62 Oxygen Sensor Installation . 16-62 Oxygen Sensor Inspection 16-63 Gear Position Sensor Removal. 16-63 Gear Position Sensor Installation 16-64 Gear Position Sensor Inspection 16-64 Accessory Relay Inspection 16-64 Air Switching Valve . 16-66 Air Switching Valve Operation Test . 16-66 Air Switching Valve Unit Test 16-66 Radiator Fan System 16-68 Fan Motor Removal 16-68 Fan Motor Installation . 16-68 Fan Motor Inspection 16-68 Meter, Gauge, Indicator Unit. 16-69 Meter Unit Removal 16-69 Meter Unit Installation . 16-69 Meter Unit Disassembly/Assembly . 16-69 Meter Operation Inspection. 16-70 Meter System Inspection 16-71 Meter Unit Inspection 16-72 Fuel Level Sensor Line Self-Diagnosis Mode Inspection 16-79 Relay Box . 16-82 Relay Box Removal 16-82 Relay Box Installation . 16-82 Relay Circuit Inspection 16-82 Diode Circuit Inspection 16-83 Fuses 16-85 Main Fuse (30 A) Removal . 16-85 Fuse Box Fuse Removal. 16-85 Fuse Installation 16-85 Fuse Inspection. 16-86
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