Kawasaki Ninja ZX-10R - Service Manual / Repair Manual

KAWASAKI ZX-10 NINJA - SERVICE MANUAL

- English Service Manual, to vehicles Kawasaki ZX-10R Ninja.

 

CONTENTS:


- List of abbreviations
- Country and area codes
- Units of mass
- Units of volume
- Units of force
- Units of length
- Units of torque
- Units of pressure
- Units of speed
- Units of power
- Periodic inspection
- Periodic replacement parts
- Basic torque for general fasteners
- Throttle grip free play
- Throttle body vacuum
- Main throttle sensor output voltage
- Idle speed
- Valve clearance
- Example:
- Adjustment shims
- Clutch lever free play
- Air pressure (when cold)
- Tread depth
- Chain slack
- Drive chain 20-link length
- Standard chain
- Recommended disc brake fluid
- Pad lining thickness
- Sidestand switch operation
- Water and coolant mixture ratio (recommended)
- Recommended engine oil
- Standard spark plug
- Sample diagnosis sheet
- Engine doesn't start, starting difficulty
- Poor running at low speed
- Poor running or no power at high speed:
- Main throttle sensor input voltage
- Input voltage at ecu connector
- Main throttle sensor input voltage
- Input voltage at sensor
- Main throttle sensor output voltage
- Idle speed
- Output voltage at ecu
- Throttle sensor output voltage
- Output voltage at sensor
- Main throttle sensor resistance
- Inlet air pressure sensor input voltage
- Input voltage at ecu
- Inlet air pressure sensor input voltage
- Input voltage at sensor connector
- Inlet air pressure sensor output voltage
- Output voltage at ecu
- Inlet air pressure sensor output voltage

- Output voltage at sensor connector
- Inlet air pressure sensor output voltage connection to adapter
- Inlet air temperature sensor output voltage
- Output voltage at ecu
- Inlet air temperature sensor resistance
- Water temperature sensor output voltage
- Output voltage at ecu
- Atmospheric pressure sensor input voltage
- Input voltage at ecu
- Atmospheric pressure sensor input voltage
- Input voltage at sensor connector
- Atmospheric pressure sensor output voltage
- Output voltage
- Atmospheric pressure sensor output voltage
- Output voltage at sensor
- Speed sensor input voltage
- Input voltage at ecu connector
- Speed sensor input voltage
- Input voltage at sensor
- Speed sensor output voltage
- Output voltage at sensor
- Gear position switch input voltage at 1 ~ 6 gear positions
- Input voltage at 1 ~ 6 gear positions
- Vehicle-down sensor power source voltage
- Power source voltage at sensor
- Vehicle-down sensor output voltage
- Output voltage at sensor
- Subthrottle sensor input voltage
- Input voltage at ecu connector
- Subthrottle sensor input voltage
- Input voltage at sensor
- Subthrottle sensor output voltage
- Output voltage at ecu
- Subthrottle sensor output voltage

- Output voltage at sensor
- Subthrottle sensor resistance
- Oxygen sensor ##1 output voltage
- Oxygen sensor ##1 output voltage (with plugs)
- Oxygen sensor ##1 output voltage (without plugs)
- Exhaust butterfly valve actuator sensor resistance
- Antenna resistance
- Amplifier input voltage
- Input voltage
- Testing relay
- Stick coil input voltage at ecu
- Input voltage at ecu
- Subthrottle valve actuator resistance
- Subthrottle valve actuator input voltage
- Input voltage
- Connections to adapter
- Actuator output voltage (pulley original position)
- Oxygen sensor heaters resistance
- Oxygen sensor heaters power source voltage
- Power source voltage at sensor connector
- Oxygen sensor ##2 output voltage
- Oxygen sensor output voltage (with plugs)
- Oxygen sensor ##2 output voltage (without plugs)
- Ecu identification
- Ecu grounding inspection
- Ecu power source inspection
- Fuel pressure
- Fuel pressure (idling)
- Amount of fuel flow
- Pump operating voltage at pump
- Operating voltage at pump connector
- Injector power source voltage at ecu connector
- Power source voltage at ecu
- Injector power source voltage at injector
- Power source voltage at injector connector
- Injector output voltage at ecu
- Output voltage at ecu
- Injector output voltage at injector
- Output voltage at injector connector
- Injector resistance
- Fuel line maximum pressure
- Radiator cap relief pressure
- Thermostat valve opening temperature
- Camshaft journal, camshaft cap clearance
- Camshaft journal diameter
- Camshaft runout
- Cam height
- Cylinder compression
- Cylinder head warp
- Valve/valve guide clearance (wobble method)
- Valve seating surface outside diameter
- Valve seating surface width
- Spring plate free play
- Spring plate free play
- Clutch plate assembly length (reference)
- Friction plate thickness
- Friction and steel plate warp
- Clutch spring free length
- Oil pressure
- Connecting rod big end bearing insert selection
- Crankshaft main bearing insert selection
- Connecting rod bend
- Connecting rod twist
- Connecting rod big end side clearance
- Connecting rod big end bearing insert/crankpin clearance
- Crankpin diameter
- Crankpin diameter marks
- Connecting rod big end inside diameter marks
- Crankshaft side clearance
- Crankshaft runout
- Crankshaft main bearing insert/journal clearance
- Crankshaft main journal diameter
- Crankshaft main journal diameter marks
- Crankcase main bearing inside diameter marks
- Cylinder inside diameter
- Piston diameter
- Piston ring/groove clearance
- Piston ring groove width
- Piston ring thickness
- Piston ring end gap
- Shift fork ear thickness
- Gear groove width
- Shift fork guide pin diameter
- Shift drum groove width
- Rim runout (with tire installed)
- Axle runout/100 mm (3.94 in.)
- Balance weight
- Link pin outside diameter
- Link plates outside width
- Rear sprocket warp
- Pedal position
- Brake discs thickness
- Disc runout
- Rebound damping force adjustment
- Compression damping force adjustment
- Adjuster protrusion (from the top plug nut surface)
- Spring action
- Fork oil
- Oil level (fully compressed, without spring)
- Spring free length
- Rebound damping force adjustment
- Rebound damping force adjustment
- Spring preload setting
- Spring adjustment
- Damping force adjustment
- Kawasaki-recommended chargers:
- Battery terminal voltage
- Terminal voltage: 11.5 ~ less than 12.8 v
- Terminal voltage: less than 11.5 v
- Table 1 alternator output voltage
- Table 2 stator coil resistance
- Regulator/rectifier resistance (unit: k?)
- Charging voltage
- Crankshaft sensor peak voltage
- Ignition coil winding resistance
- Primary lead connection
- Stick coil primary peak voltage
- Connections:
- Camshaft position sensor peak voltage
- Condition:
- Condition:
- Condition:
- Starter motor brush length
- Commutator diameter
- Testing relay
- Testing turn signal relay
- Air switching valve resistance
- User key indicator light and symbol flashes
- Water temperature sensor
- Connections
- Gear position switch resistance k?
- Relay circuit inspection (with the battery disconnected)
- Relay circuit inspection (with the battery connected)
- Diode circuit inspection
- Emission control information
- 1.
- 2.
- 3.
- Tampering with noise control system prohibited
- Foreword
- General information
- Before starting to perform an inspection service or carry out a
- Battery ground
- Edges of parts
- Solvent
- Cleaning vehicle before disassembly
- Arrangement and cleaning of removed parts
- Storage of removed parts
- Inspection
- Replacement parts
- Assembly order
- Tightening sequence
- Tightening torque
- Force
- Gasket, o-ring
- Liquid gasket, non-permanent locking agent
- Press
- Ball bearing and needle bearing
- Oil seal, grease seal
- Circlips, cotter pins
- Lubrication
- Direction of engine rotation
- Electrical wires
- Instrument
- Zx1000d6f (europe) left side view
- Zx1000d6f (europe) right side view
- Zx1000d6f (united states and canada) left side view
- Zx1000d6f (united states and canada) right side view
- Frame number
- Engine number
- Prefixes for units
- Units of temperature
- Periodic maintenance
- The scheduled maintenance must be done in accordance with this c
- The following tables list the tightening torque for the major fa
- Inside circlip pliers:
- Fuel system (dfi)
- Throttle control system inspection
- Engine vacuum synchronization inspection
- Special tool -
- Special tool -
- Special tool -
- Torque -
- Torque -
- Idle speed inspection
- Idle speed adjustment
- Fuel hose inspection (fuel leak, damage, installation condition)
- Evaporative emission control system (california model)
- Evaporative emission control system inspection
- Cooling system
- Coolant level inspection
- Radiator hose and pipe inspection (coolant leak, damage, install
- Torque -
- Engine top end
- Valve clearance inspection
- Valve clearance adjustment
- Air suction system
- Air suction system damage inspection
- Special tool -
- Clutch
- Clutch operation inspection
- Wheels/tires
- Air pressure inspection
- Wheel/tire damage inspection
- Tire tread wear inspection
- Wheel bearing damage inspection
- Drive train
- Drive chain lubrication condition inspection
- Drive chain slack inspection
- Drive chain slack adjustment
- Torque -
- Wheel alignment inspection
- Drive chain wear inspection
- Chain guide wear inspection
- Brake system
- Brake fluid leak (brake hose and pipe) inspection
- Brake hose damage and installation condition inspection
- Torque -
- Brake operation inspection
- Brake fluid level inspection
- Brake pad wear inspection
- Brake light switch operation inspection
- Suspensions
- Front forks/rear shock absorber operation inspection
- Front fork oil leak inspection
- Rear shock absorber oil leak inspection
- Rocker arm operation inspection
- Tie-rod operation inspection
- Steering system
- Steering play inspection
- Special tools -
- Steering play adjustment
- Special tool -
- Torque -
- Steering stem bearing lubrication
- Steering damper oil leak inspection
- Electrical system
- Lights and switches operation inspection
- Headlight aiming inspection
- Sidestand switch operation inspection
- Engine stop switch operation inspection
- Others
- Chassis parts lubrication
- Pivots: lubricate with grease.
- Points: lubricate with grease.
- Cables: lubricate with rust inhibitor
- Bolts, nuts and fasteners tightness inspection
- Bolt, nut and fastener to be checked
- Replacement parts
- Air cleaner element replacement
- Torque -
- Fuel hose replacement
- Coolant change
- Torque -
- Torque -
- Radiator hose and o-ring replacement
- Torque -
- Engine oil change
- Torque -
- Torque -
- Oil filter replacement
- Special tool -
- Torque -
- Brake hose and pipe replacement
- Torque -
- Brake fluid change
- Torque -
- Torque -
- Master cylinder rubber parts replacement
- Special tool -
- Special tool -
- Torque -
- Caliper rubber parts replacement
- Torque -
- Torque -
- Torque -
- Spark plug replacement
- Owner's tool -
- Torque -
- Fuel system (dfi)
- Dfi system
- Oil pressure gauge, 5 kgf/cm :
- Main throttle sensor [a]
- Dfi system wiring diagram
- Terminal numbers of ecu connectors
- Dfi servicing precautions
- Torque -
- The warning indicator light (led) [a] is used for the fi indicat
- Outline
- Special tool -
- Sealant -

- Special tool -
- Dfi diagnosis flow chart
- Inquiries to rider
- Note
- The warning indicator light (led) [a] is used for the fi indicat
- Self-diagnosis outline
- Self-diagnosis procedures
- Self-diagnosis flow chart
- Service code reading
- Service code erasing
- Backups
- The main throttle sensor is a rotating variable resistor that ch
- Main throttle sensor removal/adjustment
- Input voltage inspection
- Special tool -
- Special tool -
- Output voltage inspection
- Special tool -
- Special tool -
- Resistance inspection
- Main throttle sensor circuit
- Caution
- Removal
- Installation
- Input voltage inspection
- Special tool -
- Special tool -
- Output voltage inspection
- Special tool -
- Special tool -
- Inlet air pressure sensor circuit
- Special tools -
- Removal/installation
- Output voltage inspection
- Special tool -
- Sealant -
- Sensor resistance inspection
- Inlet air temperature sensor circuit
- Removal/installation
- Sealant -
- Torque -
- Output voltage inspection
- Special tool -
- Sealant -
- Sensor resistance inspection
- Water temperature sensor circuit
- Caution
- Removal
- Installation
- Input voltage inspection
- Special tool -
- Special tool -
- Output voltage inspection
- Special tool -
- Special tool -
- Atmospheric pressure sensor circuit
- Atmospheric pressure/altitude relationship
- Crankshaft sensor removal/installation
- Crankshaft sensor inspection
- Crankshaft sensor circuit
- Camshaft position sensor removal/installation
- Camshaft position sensor inspection
- Camshaft position sensor circuit
- Speed sensor removal/installation
- Input voltage inspection
- Special tool -
- Special tool -
- Output voltage inspection
- Special tool -
- Speed sensor circuit
- Gear position switch removal/installation
- Gear position switch inspection
- Input voltage inspection
- Special tool -
- Gear position switch circuit
- This sensor has a weight [a] with two magnets inside, and sends
- Removal
- Installation
- Torque -
- Inspection
- Special tool -
- Special tool -
- Sealant -
- Vehicle-down sensor circuit
- The subthrottle sensor is a rotating variable resistor that chan
- Subthrottle sensor removal/adjustment
- Input voltage inspection
- Special tool -
- Special tool -
- Output voltage inspection
- Special tool -
- Special tool -
- Resistance inspection
- Subthrottle sensor circuit
- Oxygen sensor ##1 removal/installation
- Oxygen sensor ##1 inspection
- Special tool -
- Special tool -
- Sealant -
- Oxygen sensor circuit
- Exhaust butterfly valve actuator sensor inspection
- Exhaust butterfly valve actuator sensor circuit
- Antenna resistance inspection
- Amplifier input voltage inspection
- Special tool -
- User key inspection
- Immobilizer system circuit
- Fuel pump relay removal
- Fuel pump relay inspection
- Special tool -
- Fuel pump relay circuit
- Stick coil ##1: service code 51
- Removal/installation
- Input voltage inspection
- Special tool -
- Stick coil circuit
- Subthrottle valve actuator removal
- Subthrottle valve actuator inspection
- Resistance inspection
- Input voltage inspection
- Special tools -
- Subthrottle valve actuator circuit
- Exhaust butterfly valve actuator removal
- Exhaust butterfly valve actuator installation
- Torque -
- Torque -
- Exhaust butterfly valve actuator inspection
- Output voltage inspection
- Special tool -
- Exhaust butterfly valve actuator circuit
- Oxygen sensor heaters removal/installation
- Oxygen sensor heaters inspection
- Special tool -
- Special tool -
- Sealant -
- Oxygen sensor circuit
- Ecu main relay inspection
- Oxygen sensor ##2 removal/installation
- Oxygen sensor ##2 inspection
- Special tool -
- Special tool -
- Sealant -
- Oxygen sensor circuit
- Caution
- Ecu identification
- Ecu removal
- Ecu installation
- Ecu power supply inspection
- Special tool -
- Ecu power source circuit
- Ecu fuse removal
- Ecu fuse installation
- Ecu fuse inspection
- Light (led) inspection
- Warning indicator light (led) (fi/immobilizer) circuit
- Fuel pressure inspection
- Special tools -
- Fuel flow rate inspection
- Special tool -
- Fuel pump removal
- Fuel pump installation
- Torque -
- Operation inspection
- Operating voltage inspection
- Special tools -
- Fuel pump circuit
- Removal/installation
- Power source voltage inspection
- Special tool -
- Special tool -
- Output voltage inspection
- Special tool -
- Special tool -
- Audible inspection
- Special tool -
- Injector signal test
- Special tool -
- Injector resistance inspection
- Injector unit test
- Injector fuel line inspection
- Fuel injector circuit
- Free play inspection
- Free play adjustment
- Cable installation
- Cable lubrication
- Idle speed inspection
- Throttle bore cleaning
- Synchronization inspection
- Synchronization adjustment
- Throttle body assy removal
- Throttle body assy installation
- Torque -
- Torque -
- Throttle body assy disassembly
- Throttle body assy assembly
- Torque -
- Element removal
- Element installation
- Air cleaner element inspection
- Air cleaner housing removal
- Air cleaner housing installation
- Torque -
- Air cleaner housing disassembly
- Air cleaner housing assembly
- Sealant -
- Oil draining
- Air inlet duct removal
- Air inlet duct installation
- Torque -
- Fuel tank removal
- Fuel tank installation
- Fuel tank and cap inspection
- Fuel tank cleaning
- The evaporative emission control system routes fuel vapors from
- Parts removal/installation
- Hose inspection
- Separator inspection
- Separator operation test
- Canister inspection
- Cooling system
- Coolant deterioration inspection
- Coolant level inspection
- Coolant draining
- Coolant filling
- Pressure testing
- Cooling system flushing
- Coolant reserve tank removal
- Coolant reserve tank installation
- Torque -
- Water pump removal
- Water pump installation
- Torque -
- Torque -
- Torque -
- Water pump impeller inspection
- Radiator and radiator fan removal
- Radiator and radiator fan installation
- Torque -
- Torque -
- Torque -
- Torque -
- Radiator inspection
- Radiator cap inspection
- Radiator filler neck inspection
- Thermostat removal
- Thermostat installation
- Torque -
- Torque -
- Torque -
- Torque -
- Thermostat inspection
- Hose installation
- Torque -
- Hose inspection
- Caution
- Water temperature sensor removal
- Water temperature sensor inspection
- Engine top end
- Dummy page

- Exhaust system zx1000d6f
- Compression gauge, 20 kgf/cm :
- Air suction valve removal
- Air suction valve installation
- Torque -
- Air suction valve inspection
- Air switching valve removal
- Air switching valve installation
- Air switching valve operation test
- Air switching valve unit test
- Clean air system hose inspection
- Cylinder head cover removal
- Cylinder head cover installation
- Sealant -
- Torque -
- Camshaft chain tensioner removal
- Camshaft chain tensioner installation
- Torque -
- Torque -
- Torque -
- Camshaft removal
- Camshaft installation
- Torque -
- Torque -
- Torque -
- Camshaft, camshaft cap wear
- Camshaft runout
- Cam wear
- Camshaft chain removal
- Cylinder compression measurement
- Special tools -
- Torque -
- Cylinder head removal
- Cylinder head installation
- Torque -
- Torque -
- Torque -
- Cylinder head warp
- Valve clearance inspection
- Valve removal
- Special tools -
- Valve installation
- Valve guide removal
- Special tool -
- Valve guide installation
- Special tools -
- Special tool -
- Valve-to-guide clearance measurement (wobble method)
- Valve seat inspection
- Valve seat repair
- Special tools -
- Throttle body assy holder removal
- Throttle body assy holder installation
- Torque -
- Warning
- Muffler body removal
- Muffler body installation
- Torque -
- Torque -
- Middle and rear exhaust pipe removal
- Middle and rear exhaust pipe installation
- Torque -
- Torque -
- Torque -
- Front exhaust pipe removal
- Front exhaust pipe installation
- Torque -
- Exhaust butterfly valve cable removal
- Exhaust butterfly valve cable installation
- Torque -
- Torque -
- Torque -
- Clutch
- Clutch holder:
- Clutch lever free play inspection
- Clutch lever free play adjustment
- Cable removal
- Cable installation
- Cable lubrication
- Clutch lever installation
- Torque -
- Clutch cover removal
- Clutch cover installation
- Sealant -
- Torque -
- Release shaft removal
- Release shaft installation
- Clutch cover disassembly
- Clutch cover assembly
- Torque -
- Clutch removal
- Special tool -
- Special tool -
- Clutch installation
- Torque -
- Special tool -
- Torque -
- Torque -
- Spring plate free play measurement
- Spring plate free play adjustment
- Torque -
- Clutch plate, wear, damage inspection
- Clutch plate warp inspection
- Clutch spring free length measurement
- Damper cam inspection
- Engine lubrication system
- Oil pressure gauge, 10 kgf/cm :
- Warning
- Oil level inspection
- Engine oil change
- Oil filter replacement
- Oil pan removal
- Oil pan installation
- Torque -
- Oil pressure relief valve removal
- Oil pressure relief valve installation
- Torque -
- Oil pressure relief valve inspection
- Oil pump removal
- Oil pump installation
- Torque -
- Oil pump gear removal
- Special tool -
- Oil pump gear installation
- Special tool -
- Torque -
- Oil cooler removal
- Oil cooler installation
- Torque -
- Torque -
- Oil cooler/oil filter case removal
- Oil cooler/oil filter case installation
- Torque -
- Torque -
- Oil pressure measurement
- Special tools -
- Torque -
- Oil pressure switch removal
- Oil pressure switch installation
- Sealant -
- Torque -
- Torque -
- Engine removal/installation
- Engine mount nut wrench:
- Engine removal
- Special tool -
- Engine installation
- Torque -
- Torque -
- Torque -
- Special tool -
- Torque -
- Torque -
- Torque -
- Torque -
- Torque -
- Torque -
- Crankshaft/transmission
- Bearing puller:
- Crankcase splitting
- Crankcase assembly
- Sealant -
- Torque -
- Sealant -
- Torque -
- Torque -
- Torque -
- Torque -
- Torque -
- Torque -
- Crankshaft removal
- Crankshaft installation
- Connecting rod removal
- Connecting rod installation
- Crankshaft/connecting rod cleaning
- Connecting rod bend
- Connecting rod twist
- Connecting rod big end side clearance
- Connecting rod big end bearing insert/crankpin wear
- Crankshaft side clearance
- Crankshaft runout
- Crankshaft main bearing insert/journal wear
- Piston removal
- Special tool -
- Piston installation
- Special tools -
- Cylinder wear (upper crankcase)
- Piston wear
- Piston ring, piston ring groove wear
- Piston ring groove width
- Piston ring thickness
- Piston ring end gap
- Shift pedal removal
- Shift pedal installation
- Torque -
- Torque -
- Torque -
- External shift mechanism removal
- Special tool -
- External shift mechanism installation
- Torque -
- External shift mechanism inspection
- Torque -
- Transmission shaft removal
- Transmission shaft installation
- Torque -
- Transmission shaft disassembly
- Special tool -
- Special tools -
- Transmission shaft assembly
- Spacial tool -
- Shift drum and fork removal
- Shift drum and fork installation
- Torque -
- Shift drum disassembly
- Shift drum assembly
- Torque -
- Shift fork bending
- Shift fork/gear groove wear
- Shift fork guide pin/drum groove wear
- Gear dog and gear dog hole damage
- Wheels/tires
- Bearing driver set:
- Front wheel removal
- Special tools -
- Front wheel installation
- Torque -
- Torque -
- Rear wheel removal
- Rear wheel installation
- Torque -
- Wheel inspection
- Special tools -
- Axle inspection
- Balance inspection
- Balance adjustment
- Balance weight removal
- Balance weight installation
- Air pressure inspection/adjustment
- Tire inspection
- Tire removal
- Tire installation
- Tire repair
- Hub bearing removal
- Special tools -
- Hub bearing installation
- Special tool -
- Special tool -
- Hub bearing inspection
- Hub bearing lubrication
- Final drive
- Inside circlip pliers:
- Drive chain slack inspection
- Drive chain slack adjustment
- Wheel alignment inspection/adjustment
- Drive chain wear inspection
- Drive chain lubrication
- Drive chain removal
- Drive chain installation
- Engine sprocket removal
- Engine sprocket installation
- Torque -
- Torque -
- Rear sprocket removal
- Rear sprocket installation
- Torque -
- Coupling installation
- Coupling bearing removal
- Special tool -
- Special tool -
- Coupling bearing installation
- Special tool -
- Special tool -
- Special tool -
- Coupling bearing inspection
- Coupling bearing lubrication
- Coupling damper inspection
- Sprocket wear inspection
- Rear sprocket warp inspection
- Brakes
- Inside circlip pliers:
- Brake lever position adjustment
- Brake pedal position inspection
- Brake pedal position adjustment
- Torque -
- Brake pedal removal
- Brake pedal installation
- Torque -
- Torque -
- Torque -
- Front caliper removal
- Rear caliper removal
- Caliper installation
- Torque -
- Front caliper disassembly
- Front caliper assembly
- Rear caliper disassembly
- Rear caliper assembly
- Caliper fluid seal damage
- Rear caliper dust boot and friction boot damage
- Caliper piston and cylinder damage
- Rear caliper holder shaft wear
- Front brake pad removal
- Front brake pad installation
- Torque -
- Rear brake pad removal
- Rear brake pad installation
- Brake pad wear inspection
- Front master cylinder removal
- Front master cylinder installation
- Torque -
- Torque -
- Rear master cylinder removal
- Rear master cylinder installation
- Torque -
- Front master cylinder disassembly
- Rear master cylinder disassembly
- Master cylinder assembly
- Master cylinder inspection (visual inspection)
- Brake disc removal
- Brake disc installation
- Torque -
- Brake disc wear
- Brake disc warp
- Special tools -
- Brake fluid level inspection
- Brake fluid change
- Brake line bleeding
- Torque -
- Torque -
- Torque -
- Brake hose removal/installation
- Brake hose inspection
- Suspension
- Inside circlip pliers:
- Rebound damping force adjustment
- Compression damping force adjustment
- Spring preload adjustment
- Front fork removal (each fork leg)
- Front fork installation
- Torque -
- Torque -

- Front fork oil change
- Special tools -
- Special tool -
- Special tool -
- Special tool -
- Special tool -
- Special tools -
- Torque -
- Front fork disassembly
- Special tool -
- Front fork assembly
- Special tool -
- Torque -
- Special tool -
- Inner tube inspection
- Dust seal inspection
- Spring tension
- Rebound damping force adjustment
- Compression damping force adjustment
- Spring preload adjustment
- Special tool -
- Special tool -
- Rear shock absorber removal
- Special tools -
- Rear shock absorber installation
- Torque -
- Rear shock absorber inspection
- Rear shock absorber scrapping
- Swingarm removal
- Special tool -
- Swingarm installation
- Torque -
- Special tool -

- Torque -
- Torque -
- Swingarm bearing removal
- Special tool -
- Special tools -
- Swingarm bearing installation
- Special tool -
- Swingarm bearing, sleeve inspection
- Swingarm pivot lubrication
- Chain guide inspection
- Tie-rod removal
- Special tools -
- Tie-rod installation
- Torque -
- Rocker arm removal
- Special tools -
- Rocker arm installation
- Torque -
- Tie-rod and rocker arm bearing removal
- Special tools -
- Tie-rod and rocker arm bearing installation
- Special tools -
- Rocker arm/tie-rod bearing, sleeve inspection
- Rocker arm/tie-rod bearing lubrication
- Steering
- Bearing puller adapter:
- Steering inspection
- Steering adjustment
- Steering damper removal
- Steering damper installation
- Damping force adjustment
- Steering damper oil leak inspection
- Stem, stem bearing removal
- Special tool -
- Special tool -
- Special tools -
- Stem, stem bearing installation
- Special tools -
- Special tools -

- Special tool -
- Torque -
- Torque -
- Steering stem bearing lubrication
- Steering stem warp
- Stem cap deterioration, damage
- Handlebar removal
- Handlebar installation
- Torque -
- Torque -
- Frame
- Rear seat removal
- Rear seat installation
- Front seat removal
- Front seat installation
- Lower fairing removal
- Lower fairing installation
- Middle fairing removal
- Middle fairing installation
- Windshield removal
- Windshield installation
- Torque -
- Upper fairing removal
- Upper fairing disassembly
- Upper fairing assembly
- Upper fairing installation
- Upper inner fairing removal
- Upper inner fairing installation
- Center inner fairing removal
- Center inner fairing installation
- Right and left inner fairing removal
- Right and left inner fairing installation
- Side cover removal
- Side cover installation
- Seat cover removal
- Seat cover installation
- Front fender removal
- Front fender installation
- Torque -
- Rear fender rear removal
- Rear fender rear installation
- Rear fender front removal
- Rear fender front installation
- Rear frame removal
- Rear frame installation
- Torque -
- Frame inspection
- Sidestand removal
- Sidestand installation
- Torque -
- Torque -
- Electrical system
- Dummy page
- Hand tester:
- There are a number of important precautions that are musts when
- Wiring inspection
- Special tool -
- Battery removal
- Battery installation
- Battery activation
- Precautions
- 1)
- 2)
- 3)
- 4)
- Interchange
- Charging condition inspection
- Refreshing charge
- Alternator cover removal
- Alternator cover installation
- Sealant -
- Torque -
- Stator coil removal
- Stator coil installation
- Torque -
- Sealant -
- Torque -
- Alternator rotor removal
- Special tools -
- Special tool -
- Alternator rotor installation
- Special tools -
- Torque -
- Alternator inspection
- Special tool -
- Regulator/rectifier inspection
- Special tool -
- Torque -
- Charging voltage inspection
- Special tool -
- Charging system circuit
- Crankshaft sensor removal
- Crankshaft sensor installation
- Torque -
- Sealant -
- Crankshaft sensor inspection
- Special tool -
- Crankshaft sensor peak voltage inspection
- Special tools -
- Stick coil (ignition coil together with spark plug cap) removal
- Stick coil (ignition coil together with spark plug cap) installa
- Stick coil (ignition coil together with spark plug cap) inspecti
- Stick coil primary peak voltage
- Special tools -
- Spark plug removal
- Spark plug installation
- Spark plug condition inspection
- Camshaft position sensor removal
- Camshaft position sensor installation
- Torque -
- Camshaft position sensor inspection
- Special tool -
- Camshaft position sensor peak voltage inspection
- Special tool -
- Interlock operation inspection
- Ic igniter inspection
- Ignition system circuit
- Starter idle gear removal
- Starter idle gear installation
- Sealant -
- Torque -
- Torque -
- Starter clutch removal
- Special tools -
- Starter clutch installation
- Special tools -
- Torque -
- Starter clutch disassembly
- Starter clutch assembly
- Starter clutch inspection
- Starter motor removal
- Starter motor installation
- Torque -
- Torque -
- Starter motor disassembly
- Starter motor assembly
- Torque -
- Torque -
- Brush inspection
- Commutator cleaning and inspection
- Armature inspection
- Special tool -
- Brush lead inspection
- Special tool -
- Right-hand end cover assembly inspection
- Special tool -
- Starter relay inspection
- Special tool -
- Torque -
- Electric starter circuit
- This motorcycle adopt the daylight system and have a headlight r
- Headlight beam horizontal vertical adjustment
- Headlight beam vertical adjustment
- Headlight bulb replacement
- City light bulb replacement
- Headlight removal/installation
- Torque -
- Tail/brake light (led) removal
- Tail/brake light (led) installation
- License plate light bulb replacement
- Torque -
- Headlight/tail light circuit
- Turn signal light bulb replacement
- Torque -
- Turn signal relay inspection
- Turn signal light circuit
- Air switching valve operation test
- Air switching valve unit test
- Special tool -
- Fan motor inspection
- Radiator fan circuit
- Meter unit removal/installation
- Torque -
- Meter unit disassembly
- Electronic combination meter unit inspection
- Meter unit circuit
- This motorcycle is equipped with an immobilizer system to protec
- Operational cautions
- Key registration
- Special tool -
- Spare user key registration flow chart
- Special tool -
- All keys initial registration flow chart
- Immobilizer system parts replacement
- Immobilizer system inspection
- Immobilizer system circuit
- Brake light timing inspection
- Brake light timing adjustment
- Switch inspection

- Special tool -
- Rear brake light switch connections
- Sidestand switch connections
- Oil pressure switch connections *
- Water temperature sensor inspection
- Speed sensor removal
- Speed sensor installation
- Torque -
- Speed sensor inspection
- Fuel reserve switch inspection
- Special tool -
- Oxygen sensor removal (europe models)
- Oxygen sensor installation (europe models)
- Torque -
- Oxygen sensor inspection (europe models)
- Oxygen sensor heater inspection (europe models)
- Gear position switch removal
- Gear position switch installation
- Torque -
- Gear position switch inspection
- Special tool -
- The relay box [a] has relays and diodes. The relays and diodes c
- Relay box removal
- Relay circuit inspection
- Diode circuit inspection
- Relay box internal circuit
- 30 a main fuse removal
- Fuse box fuse removal
- 15 a ecu fuse removal
- Fuse installation
- Fuse inspection
- Appendix
- California model
- California model
- Note
- Engine doesn't start, starting difficulty:
- Starter motor not rotating:
- Starter motor rotating but engine doesn't turn over:
- Engine won't turn over:
- No fuel flow:
- No spark; spark weak:
- Fuel/air mixture incorrect:
- Compression low:
- Poor running at low speed:
- Spark weak:
- Fuel/air mixture incorrect:
- Compression low:
- Other:
- Poor running or no power at high speed:
- Firing incorrect:
- Fuel/air mixture incorrect:
- Compression low:
- Knocking:
- Miscellaneous:
- Overheating:
- Firing incorrect:
- Muffler overheating:
- Fuel/air mixture incorrect:
- Compression high:
- Engine load faulty:
- Lubrication inadequate:
- Oil cooler incorrect:
- Gauge incorrect:
- Coolant incorrect:
- Cooling system component incorrect:
- Over cooling:
- Gauge incorrect:
- Cooling system component incorrect:
- Clutch operation faulty:
- Clutch slipping:
- Clutch not disengaging properly:
- Gear shifting faulty:
- Doesn't go into gear; shift pedal doesn't return:
- Jumps out of gear:
- Overshifts:
- Abnormal engine noise:
- Knocking:
- Piston slap:
- Valve noise:
- Other noise:
- Abnormal drive train noise:
- Clutch noise:
- Transmission noise:
- Drive line noise:
- Abnormal frame noise:
- Front fork noise:
- Rear shock absorber noise:
- Disc brake noise:
- Other noise:
- Oil pressure warning light goes on:
- Exhaust smokes excessively:
- White smoke:
- Black smoke:
- Brown smoke:
- Handling and/or stability unsatisfactory:
- Handlebar hard to turn:
- Handlebar shakes or excessively vibrates:
- Handlebar pulls to one side:
- Shock absorption unsatisfactory:
- Brake doesn't hold:
- Battery trouble:
- Battery discharged:
- Battery overcharged:
- Toc
- The following tables list the tightening torque for the major fa