Make
Type
Link
Brakes
Brake Fluid:
Grade
Brake Pad Lining
Thickness:
Front
Rear
Brake Light Timing:
Front
Rear
Electrical System
Spark Plug:
Type
Gap

Standard
25  35 mm (1.0  1.4 in.)
317.5  318.2 mm (12.50  12.53 in.)

Service Limit
– – –
319 mm (12.6 in.)

ENUMA
EK525RMX3/3D
114 links

– – –
– – –
– – –

DOT4

– – –

3.7 mm (0.15 in.)
4.5 mm (0.18 in.)

1 mm (0.04 in.)
1 mm (0.04 in.)

Pulled ON
ON after about 10 mm (0.39 in.) of pedal travel

– – –
– – –

NGK SILMAR9B9
0.8  0.9 mm (0.031  0.035 in.)

– – –
– – –

2-14 PERIODIC MAINTENANCE
Special Tools
Inside Circlip Pliers:
57001-143

Extension Tube:
57001-1578

Steering Stem Nut Wrench:
57001-1100

Measuring Adapter:
57001-1700

Oil Filter Wrench:
57001-1249

Brake Caliper Piston Pliers ( 16 
57001-1861

Vacuum Gauge:
57001-1369

26):

PERIODIC MAINTENANCE 2-15
Periodic Maintenance Procedures
Fuel System (DFI)
Air Cleaner Element Replacement
NOTE

○In dusty areas, the element should be replaced more
frequently than the recommended interval.

WARNING
If dirt or dust is allowed to pass through into the
throttle body assy, the throttle may become stuck,
possibly causing accident. Replace the air cleaner
element according to the maintenance chart.

NOTICE
If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.
the upper air cleaner housing (see Air Cleaner
• Remove
Housing Removal in the Fuel System (DFI) chapter).
the air cleaner element [A].
• Discard
Install
a
element.
• Install thenewupper
housing (see Air Cleaner
• Housing Installationairincleaner
the Fuel System (DFI) chapter).

Idle Speed Inspection

the engine and warm it up thoroughly.
• Start
the engine idling, turn the handlebars to both sides
• With
[A].
If handlebar movement changes the idle speed, the
throttle cables may be improperly adjusted or incorrectly
routed, or damaged. Be sure to correct any of these
conditions before riding (see Throttle Control System
Inspection and Cable, Wire, and Hose Routing section in
the Appendix chapter).

WARNING
Operation with improperly adjusted, incorrectly
routed or damaged cables could result in an unsafe
riding condition. Follow the service manual to be
make sure to correct any of these conditions.

• Check the idle speed.
Idle Speed
Standard:

1 100 ±50 r/min (rpm)

Idle Speed Adjustment
NOTE

○This motorcycle is equipped with the idle speed control
system. The idle speed is adjusted automatically at the
specified value (1 100 r/min (rpm)) by the idle speed
control system. Therefore, it is not necessary to adjust
the idle speed normally.

2-16 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Throttle Control System Inspection

that the throttle grip [A] moves smoothly from full
• Check
open to close, and the throttle closes quickly and com-

•

pletely by the return spring in all steering positions.
If the throttle grip does not return properly, check the throttle cable routing, grip free play, and cable damage. Then
lubricate the throttle cable.
Check the throttle grip free play [B].
Throttle Grip Free Play
Standard: 2  3 mm (0.08  0.12 in.)

•
•
•
•
•
•

If the free play is incorrect, adjust the throttle cable as
follows.
Loosen the locknuts [A] [B].
Screw both throttle cable adjusters [C] [D] to give the
throttle grip plenty of play.
Turn the decelerator cable adjuster [C] until there is no
play when the throttle grip play completely closed.
Tighten the locknut [A].
Turn the accelerator cable adjuster [D] until 2  3 mm
(0.08  0.12 in.) of throttle grip play is obtained.
Tighten the locknut [B].
If the free play can not be adjusted with the adjusters,
replace the cable.

Engine Vacuum Synchronization Inspection
NOTE

○These procedures are explained on the assumption that
the intake and exhaust systems of the engine are in
good condition.
the motorcycle so that it is vertical.
• Situate
Take
the
body assy off the engine (see Throttle
• Body Assythrottle
Removal in the Fuel System (DFI) chapter).
the purge hoses from the fittings of each throt• Disconnect
tle body.
#1 Hose [A]
#2 Hose [B]
#3 Hose [C]
#4 Hose [D]
○On the US and CA models, remove the plugs instead of
the hoses.

PERIODIC MAINTENANCE 2-17
Periodic Maintenance Procedures
a vacuum gauge and hoses [A] (Special Tool:
• Connect
57001-1369) to the fittings on the throttle body.
Special Tool - Vacuum Gauge: 57001-1369

a highly accurate tachometer lead [A] to one of
• Connect
the stick coil primary leads.

the air switching valve hose end [A] and the air
• Plug
cleaner housing fitting [B].
the air cleaner housing (see Air Cleaner Housing
• Install
Installation in the Fuel System (DFI) chapter).

the following parts temporarily.
• Connect
Fuel Pump Lead Connector [A]
Extension Tube [B]
Special Tool - Extension Tube: 57001-1578

the Kawasaki Diagnostic System (KDS Ver.3).
• Connect
the engine and warm it up thoroughly.
• Start
Using
the KDS Ver.3, start the “Starting ETV engine vac• uum synchronization”
in the “Actuator Tests.”

○The KDS Ver.3 controls the ETV system to maintain the
throttle valve angle constant.

2-18 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
“actuator test”, inspect the throttle body vacuum
• While
using the vacuum gauge [A].
Throttle Body Vacuum
Standard: 29.3 ±1.3 kPa (220 ±10 mmHg)

If any vacuum is not within specifications, adjust the bypass screws [A] with a flat tip screwdriver.

NOTE

○Do not turn the center adjusting screw [B].
○Take care not to fall away the bypass screw.

• Adjust the each vacuum (#1  #4) to the standard value.
the KDS Ver.3, stop the engine vacuum synchro• Using
nization mode with the “Stopping ETV engine vacuum

•

synchronization” in the “Actuator Tests.”
Check the idle speed, using a highly accurate tachometer
[A].
Idle Speed
Standard: 1 100 ±50 r/min (rpm)

NOTICE
Do not measure the idle speed by the tachometer of
the meter unit.
the vacuums as before.
• Check
If all vacuums are within the specification range, finish the
engine vacuum synchronization.
If any vacuum cannot be adjusted within the specification,
replace the bypass screws #1  #4 with new ones, refer
to the following procedure.

PERIODIC MAINTENANCE 2-19
Periodic Maintenance Procedures
the throttle body assy (see Throttle Body Assy
• Remove
Removal in the Fuel System (DFI) chapter).
in the bypass screw [A] with counting the number of
• Turn
turns until it seals fully but not tightly. Record the number

•
•
•
•

of turns.
Remove:
Bypass Screw
Spring [B]
Washer [C]
O-ring [D]
Check the bypass screw hole in the throttle body for carbon deposits.
If any carbons accumulate, wipe the carbons off from the
hole, using a cotton pad penetrated with a high flash-point
solvent.
Replace the bypass screw, spring, washer and O-ring as
a set.
Turn in the bypass screw until it seats fully but not tightly.

NOTICE
Do not over-tighten the bypass screw. The tapered
portion [E] of the bypass screw could be damaged.
out the same number of turns counted when first
• Back
turned in. This is to set the screw to its original position.

NOTE

○A throttle body has different “turns out” of the bypass
screw for each individual unit. On setting the bypass
screw, use the “turns out” determined during disassembly.
the same procedure for other bypass screws.
• Repeat
Repeat
the synchronization.
• If the vacuums
are correct, check the output voltage of
the throttle position sensor (see Throttle Position Sensor
Output Voltage Inspection in the Self-Diagnosis System
chapter).
Special Tool - Measuring Adapter: 57001-1700
Throttle Position Sensor Output Voltage
Connections to Adapters:
(1) Digital Meter (+) → Y (sensor V) lead
Digital Meter (–) → BK (sensor BK) lead
(2) Digital Meter (+) → W (sensor V/W) lead
Digital Meter (–) → BK (sensor BK) lead
Standard: (1) DC 1.20  1.60 V at full throttle opening
(for reference)
(2) DC 3.40  3.80 V at full throttle opening
(for reference)

If the output voltage is out of the standard, check the input
voltage of the throttle position sensor (see Throttle Position Sensor Input Voltage Inspection in the Self-Diagnosis
System chapter).

2-20 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the air cleaner housing (see Air Cleaner Housing
• Remove
Removal in the Fuel System (DFI) chapter).
the vacuum gauge hoses and install the purge
• Remove
hoses or plugs onto the original position.
• Install the removed parts (see appropriate chapters).

Fuel System Inspection
Fuel Hose Inspection (fuel leak, damage, installation
condition)
○If the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the
hose to burst. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) and check the
fuel hose.
Replace the primary and secondary fuel hoses if any fraying, cracks [B] or bulges [C] are noticed.
that the primary and secondary fuel hoses are
• Check
routed according to Cable, Wire, and Hose Routing section in the Appendix chapter.
Replace the hose if it has been sharply bent or kinked.
Hose Joints [A]
Fuel Hose [B]

that the fuel hose joints are securely connected.
•○Check
Push and pull [A] the fuel hose joint [B] back and forth
more than two times, and make sure it is locked.

WARNING
Leaking fuel can cause a fire or explosion resulting
in serious burns. Make sure the hose joint is installed correctly on the delivery pipe by sliding the
joint.
If it does not locked, reinstall the hose joint.

Fuel Filter Replacement

WARNING
Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential
for serious burns. Make sure the area is well ventilated and free from any source of flame or sparks;
this includes any appliance with a pilot light. Do not
smoke. Turn the ignition switch off. Disconnect the
battery (-) terminal. To avoid fuel spills, draw it from
the tank when the engine is cold. Be prepared for
fuel spillage; any spilled fuel must be completely
wiped up immediately.

NOTICE
Never drop the fuel pump especially on a hard surface. Such a shock to the pump can damage it.

PERIODIC MAINTENANCE 2-21
Periodic Maintenance Procedures

• Remove:
Fuel Pump (see Fuel Pump Removal)
• Disconnect:
Lead Terminals [A]
Remove:
• Screws [B]
Fuel Reserve Switch Bracket [C]

• Remove:
Upper Housing [A] (with Pressure Regulator [B])
NOTE

○So the O-rings [C] are on the fuel passage, the upper
housing might be hard to remove.

• Remove:
O-rings [A]
Lower Housing [B]

out the fuel filter [A] from the lower housing [B].
•○Pull
Wrap the fuel filter with the clean cloth.
• Replace the fuel filter with a new one.

the following parts with new ones.
• Replace
O-rings [A]
Screws [B]

2-22 PERIODIC MAINTENANCE
Periodic Maintenance Procedures

• Assemble:
Fuel Filter
Lower Housing
Install the lower housing assembly [A] to the base [B].
○Insert the arms of the base into the grooves [C] of the
housing.
Install:
O-rings [D]
Upper Housing
Fuel Reserve Switch Bracket

•
•

the leads to the guides [A].
• Hold
Fit
the
and groove [B].
• Tightenterminal
• Connect:the screw [C] on both sides.
• Fuel Pump Lead [D]
Fuel Reserve Switch Lead [E]

Fuel Hose Replacement

the fuel tank (see Fuel Tank Removal in the Fuel
• Remove
System (DFI) chapter).
Primary Fuel Hose [A]
Secondary Fuel Hose [B]

sure to place a piece of cloth around the fuel hose joint.
• Be
off the dirt of the surface [A] around the connection
• Wipe
using a cloth or a soft brush.

PERIODIC MAINTENANCE 2-23
Periodic Maintenance Procedures
When removing with flat tip screwdriver
Insert the flat tip screwdriver [A] into slit on the joint lock
[B].
Turn the driver to disconnect the joint lock.
When removing with fingers
Open and push up [C] the joint lock with your fingers.

•
•
•

NOTICE
Prying or excessively widening the joint lock ends
for fuel hose removal will permanently deform the
joint lock, resulting in a loose or incomplete lock
that may allow fuel to leak and create the potential
for a fire explosion. To prevent fire or explosion
from a damaged joint lock, do not pry or excessively
widen the joint lock ends when removing the fuel
hose. The joint lock has a retaining edge that locks
around the housing.

• Pull [A] the fuel hose joint [B] out of the outlet pipe.
WARNING
Fuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared
for fuel spillage; any spilled fuel must be completely
wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the
pipe. Cover the hose connection with a clean shop
towel to prevent fuel spillage.
the outlet pipe.
• Clean
Cover
the outlet pipe with the vinyl bag to keep it clean.
•
the vinyl bag on the pipe.
• Remove
Check
that
there are no flaws, burrs, and adhesion of
• foreign materials
on the outlet pipe [A].

the fuel hose with a new one.
• Replace
Run
the
fuel
hose correctly (see Cable, Wire, and Hose
• Routing section
in the Appendix chapter).
the fuel hose joint [A] straight onto the outlet pipe
• Insert
until the hose joint clicks.
• Push [B] the joint lock [C].

2-24 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
and pull [A] the fuel hose joint [B] back and forth
• Push
more than two times and make sure it is locked and does
not come off.

WARNING
Leaking fuel can cause a fire or explosion resulting
in severe burns. Make sure the fuel hose joint is
installed correctly on the delivery pipe and that it
doesn’t leak.

•
•

If it comes off, reinstall the hose joint.
Install the removed parts (see appropriate chapters).
Start the engine and check the fuel hose for leaks.

Evaporative Emission Control System Inspection
(Other than US and CA Models)

the canister as follows.
•○Inspect
Remove the upper fairing (see Upper Fairing Removal in
the Frame chapter).

○Remove the canister [A].
○Visually inspect the canister for cracks or other damage.
If the canister has any cracks or bad damage, replace it
with a new one.

NOTE

○The canister is designed to work well through the motorcycle’s life without any maintenance if it is used under
normal conditions.
the purge valve (see Purge Valve Inspection in
• Inspect
the Self-Diagnosis System chapter).

○Check that the hoses are securely connected and clips
are in position.

○Replace any kinked, deteriorated or damaged hoses.
○Run the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter.
○When installing the hoses, avoid sharp bending, kinking,
flattening or twisting, and run the hoses with a minimum of
bending so that the emission flow will not be obstructed.

Cooling System
Coolant Level Inspection
NOTE

○Check the level when the engine is cold (room or ambient temperature).
the coolant level in the reserve tank [A] with
• Check
the motorcycle held perpendicular (Do not use the side
stand).
If the coolant level is lower than the “L” level line [B], unscrew the reserve tank cap and add coolant to the “F”
level line [C].
“L”: Low
“F”: Full

PERIODIC MAINTENANCE 2-25
Periodic Maintenance Procedures

○Remove the right lower fairing to remove the reserve tank
cap [A] (see Lower Fairing Removal in the Frame chapter).

NOTICE
For refilling, add the specified mixture of coolant
and soft water. Adding water alone dilutes the
coolant and degrades its anticorrosion properties.