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2007 Kawasaki Zx600p7f Ninja Zx 6r Service Repair Manual Download
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2007 Kawasaki Zx600p7f Ninja Zx 6r Service Repair Manual Download
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Description
2007 Kawasaki Zx600p7f Ninja Zx 6r Service Repair Manual Download
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:651
DOWNLOADABLE:YES
FILE TYPE:PDF
2007 KAWASAKI ZX600P7F NINJA ZX 6R SERVICE REPAIR MANUAL DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
- This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work.
- A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily.
- Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment.
- Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this servicemanual.
- Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your vehicle.
- Follow the Periodic Maintenance Chart in the Service Manual.
- Be alert for problems and non-scheduled maintenance.
- Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual.
- Genuine parts provided as spare parts are listed in the Parts Catalog.
- In this manual, the product is divided into its major systems and these systems make up the manual’s chapters. The Quick Reference Guide shows you all of the product’s system and assists in locating their chapters.
- Each chapter in turn has its own comprehensive Table of Contents. For example, if you want stick coil information, use the Quick Reference Guide to locate the Electrical System chapter.
- Then, use the Table of Contents on the first page of the chapter to find the Stick Coil section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.
TABLE OF CONTENTS:
2007 Kawasaki Zx600p7f Ninja Zx 6r Service Repair Manual Download
ZX6R_ZX600P7F_2007.............................................................. 1 Quick Reference............................................................. 3 Title....................................................................... 5 Abbreviations............................................................... 6 EMISSION CONTROL INFORMATION................................................ 7 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED.............................. 8 Foreword.................................................................... 9 General Information_1....................................................... 11 Before servicing........................................................ 12 ZX600P7F (Europe) Left Side View........................................ 17 ZX600P7F (Europe) Right Side View....................................... 17 ZX600P7F (US and Canada) Left Side View................................. 18 ZX600P7F (US and Canada) Right Side View................................ 18 General Specifications.................................................. 19 Unit Conversion Table................................................... 22 Periodic Maintenance_2...................................................... 23 Periodic Maintenance Chart.............................................. 25 Torque and Locking Agent................................................ 28 Specifications.......................................................... 34 Special Tools........................................................... 36 Fuel System (DFI)....................................................... 37 Throttle Control System Inspection.................................. 37 Engine Vacuum Synchronization Inspection............................ 37 Special Tool -.................................................. 38 Special Tool -.................................................. 38 Special Tool -.................................................. 39 Special Tool -.................................................. 40 Idle Speed Inspection............................................... 40 Idle Speed Adjustment............................................... 41 Fuel Hose Inspection (fuel leak, damage, installation condition).... 41 Evaporative Emission Control System (California Model).............. 41 Evaporative Emission Control System Inspection.................. 41 Engine Top End.......................................................... 42 Valve Clearance Inspection.......................................... 42 Valve Clearance Adjustment.......................................... 44 Air Suction System...................................................... 46 Air Suction System Damage Inspection................................ 46 Cooling System.......................................................... 47 Coolant Level Inspection............................................ 47 Radiator Hose Damage and Installation Condition Inspection.......... 47 Clutch.................................................................. 48 Clutch Operation Inspection ........................................ 48 Wheels/Tires............................................................ 49 Air Pressure Inspection............................................. 49 Wheel/Tire Damage Inspection........................................ 49 Tire Tread Wear Inspection ......................................... 49 Wheel Bearing Damage Inspection..................................... 50 Drive Train............................................................. 51 Drive Chain Lubrication Condition Inspection........................ 51 Drive Chain Slack Inspection........................................ 51 Drive Chain Slack Adjustment........................................ 52 Wheel Alignment Inspection.......................................... 53 Drive Chain Wear Inspection......................................... 53 Chain Guide Wear Inspection......................................... 54 Brake System............................................................ 54 Brake Fluid Leak (Brake Hose and Pipe) Inspection................... 54 Brake Hose Damage and Installation Condition Inspection............. 54 Brake Operation Inspection.......................................... 55 Brake Fluid Level Inspection........................................ 55 Brake Pad Wear Inspection........................................... 56 Brake Light Switch Operation Inspection............................. 56 Front Forks/Rear Shock Absorber Operation Inspection.................... 57 Front Fork Oil Leak Inspection.......................................... 57 Rear Shock Absorber Oil Leak Inspection................................. 58 Rocker Arm Operation Inspection......................................... 58 Tie-Rod Operation Inspection............................................ 58 Steering System......................................................... 58 Steering Play Inspection................................................ 58 Steering Play Adjustment................................................ 59 Steering Stem Bearing Lubrication....................................... 60 Lights and Switches Operation Inspection................................ 60 Headlight Aiming Inspection............................................. 62 Side Stand Switch Operation Inspection.................................. 63 Engine Stop Switch Operation Inspection................................. 64 Chassis Parts Lubrication .............................................. 65 Pivots: Lubricate with Grease....................................... 65 Points: Lubricate with Grease....................................... 65 Cables: Lubricate with Rust Inhibitor............................... 65 Bolts, Nuts and Fasteners Tightness Inspection.......................... 66 Bolt, Nut and Fastener to be checked................................ 67 Replacement Parts....................................................... 68 Air Cleaner Element Replacement......................................... 68 Fuel Hose Replacement................................................... 69 Coolant Change.......................................................... 72 Radiator Hose and O-ring Replacement.................................... 74 Engine Oil Change....................................................... 75 Oil Filter Replacement.................................................. 75 Brake Hose and Pipe Replacement......................................... 76 Brake Fluid Change...................................................... 76 Front Master Cylinder Disassembly....................................... 78 Rear Master Cylinder Disassembly........................................ 78 Front caliper Disassembly............................................... 79 Front Caliper Assembly.................................................. 80 Rear Caliper assembly................................................... 81 Spark Plug Replacement.................................................. 82 Fuel System (DFI)_3......................................................... 83 Exploded View........................................................... 90 Specifications.......................................................... 92 Special Tools........................................................... 94 DFI Parts Location...................................................... 96 Inlet Air Pressure Sensor [A]....................................... 96 DFI System.............................................................. 98 DFI System Wiring Diagram...............................................100 Terminal Numbers of ECU Connectors......................................102 DFI Servicing Precautions...............................................103 Troubleshooting the DFI System..........................................105 Outline.............................................................105 Special Tool -..................................................107 Sealant -.......................................................107 DFI Diagnosis Flow Chart............................................109 Inquiries to Rider..................................................109 DFI System Troubleshooting Guide........................................112 Self Diagnosis..........................................................117 Self-diagnosis Outline..............................................117 Self-diagnosis Procedures...........................................118 Self-Diagnosis Flow Chart...........................................119 Service Code Reading............................................120 Service Code Erasing............................................120 Backups.............................................................122 Main Throttle Sensor(Service Code 11)...................................125 Main Throttle Sensor Removal/Adjustment.............................125 Main Throttle Sensor Input Voltage Inspection.......................125 Main Throttle Sensor Output Voltage Inspection......................126 Main Throttle Sensor Resistance Inspection..........................127 Main Throttle Sensor Circuit........................................128 Inlet Air Pressure Sensor(Service Code 12)..............................129 Inlet Air Pressure Sensor Removal...................................129 Inlet Air Pressure Sensor Installation..............................129 Inlet Air Pressure Sensor Input Voltage Inspection..................129 Inlet Air Pressure Sensor Output Voltage Inspection.................130 Inlet Air Pressure Sensor Circuit...................................131 Inlet Air Temperature Sensor(Code13)....................................134 Inlet Air Temperature Sensor Removal/Installation...................134 Inlet Air Temperature Sensor Output Voltage Inspection..............134 Inlet Air Temperature Sensor Resistance Inspection..................135 Inlet Air Temperature Sensor Circuit................................135 Water Temperature Sensor (Code 14)......................................136 Water Temperature Sensor Removal/Installation.......................136 Water Temperature Sensor Output Voltage Inspection..................136 Water Temperature Sensor Circuit....................................137 Water Temperature Sensor Resistance Inspection......................137 Atmospheric Pressure Sensor (Code 15)...................................138 Atmospheric Pressure Sensor Removal.................................138 Atmospheric Pressure Sensor Installation............................138 Atmospheric Pressure Sensor Input Voltage Inspection................138 Atmospheric Pressure Sensor Output Voltage Inspection...............139 Atmospheric Pressure Sensor Circuit.................................140 Atmospheric Pressure/Altitude Relationship..........................141 Crankshaft Sensor (Code 21).............................................142 Crankshaft Sensor Removal/Installation..............................142 Crankshaft Sensor Inspection........................................142 Crankshaft Sensor Circuit...........................................142 Camshaft Position Sensor (Code 23)......................................143 Camshaft Position Sensor Removal/Installation.......................143 Camshaft Position Sensor Inspection.................................143 Camshaft Position Sensor Circuit....................................143 Speed Sensor (Code 24)..................................................144 Speed Sensor Removal/Installation...................................144 Speed Sensor Inspection.............................................144 Speed Sensor Input Voltage Inspection...............................144 Speed Sensor Output Voltage Inspection..............................144 Speed Sensor Circuit................................................145 Gear Position Switch (Code 25)..........................................146 Gear Position Switch Removal/Installation...........................146 Gear Position Switch Inspection.....................................146 Gear Position Switch Input Voltage Inspection.......................146 Gear Position Switch Circuit........................................147 Vehicle Down Sensor (Code 31)...........................................148 Vehicle-down Sensor Removal.........................................148 Vehicle-down Sensor Installation....................................148 Vehicle-down Sensor Inspection......................................149 Vehicle-down Sensor Circuit.........................................151 Sub-Throttle Sensor (Code 32)...........................................152 Subthrottle Sensor Removal/Adjustment...............................152 Subthrottle Sensor Input Voltage Inspection.........................152 Subthrottle Sensor Output Voltage Inspection........................153 Resistance Inspection...............................................155 Subthrottle Sensor Circuit..........................................155 Oxygen Sensor #1,#2: Service Code 33,83.................................156 Oxygen Sensor Removal/Installation..................................156 Oxygen Sensor Inspection............................................156 Oxygen Sensor Circuit...............................................157 Exhaust Butterfly Valve Actuator Sensor (Code 34).......................158 Exhaust Butterfly Valve Actuator Sensor Removal/Installation........158 Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection....158 Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspectio....159 Exhaust Butterfly Valve Actuator Sensor Inspection..................160 Exhaust Butterfly Valve Actuator Sensor Circuit.....................160 Immobilizer Amplifier (Code 35).........................................161 Antenna Resistance Inspection.......................................161 Amplifier Input Voltage Inspection..................................161 Blank Key Dection (Code 36).............................................162 User Key Inspection.................................................162 Immobilizer System Circuit..........................................163 ECU Communication Error (Code 39).......................................164 ECU Communication Line Inspection...................................164 ECU Communication Line Circuit......................................164 Stick Coil #1: Service Code 51,52,53,54.................................165 Stick Coil Removal/Installation.....................................165 Stick Coil Input Voltage Inspection.................................165 Stick Coil Circuit..................................................166 Radiator Fan Relay (Code 56)............................................167 Radiator Fan Relay Removal/Installation.............................167 Radiator Fan Relay Inspection.......................................167 Radiator Fan Relay Circuit..........................................168 Subthrottle Valve Actuator (Code 62)....................................169 Subthrottle Valve Actuator Removal..................................169 Subthrottle Valve Actuator Inspection...............................169 Subthrottle Valve Actuator Resistance Inspection....................169 Subthrottle Valve Actuator Input Voltage Inspection.................170 Subthrottle Valve Actuator Circuit..................................170 Exhaust Butterfly Valve Actuator (Code 63)..............................171 Exhaust Butterfly Valve Actuator Removal............................171 Exhaust Butterfly Valve Actuator Installation.......................171 Exhaust Butterfly Valve Actuator Inspection.........................173 Exhaust Butterfly Valve Actuator Output Voltage Inspection..........173 Exhaust Butterfly Valve Actuator Circuit............................174 Air Switching Valve (Code 64)...........................................175 Air Switching Valve Removal/Installation............................175 Air Switching Valve Inspection......................................175 Air Switching Valve Circuit (Other than Europe Models)..............175 Oxygen Sensor Heaters #1,#2 (Code 67)...................................176 Oxygen Sensor Heater Removal/Installation...........................176 Oxygen Sensor Heater Inspection ....................................176 Oxygen Sensor Circuit...............................................177 Oxygen Sensors-Incorrect Output Voltage (Code 94).......................178 Oxygen Sensor Removal/Installation..................................178 Oxygen Sensor Inspection............................................178 Oxygen Sensor Circuit...............................................179 ECU.....................................................................180 ECU Identification..................................................180 ECU Removal.........................................................180 ECU Installation....................................................181 ECU Power Supply Inspection.........................................181 ECU Power Source Circuit............................................182 ECU Fuse Removal....................................................183 ECU Fuse Installation...............................................183 ECU Fuse Inspection.................................................183 Warning Indicator Light (LED) Inspection................................184 Warning Indicator Light (LED) (FI/Immobilizer) Circuit..............184 Fuel Line...............................................................185 Fuel Pressure Inspection............................................185 Fuel Flow Rate Inspection...........................................186 Fuel Pump...............................................................188 Fuel Pump Removal...................................................188 Fuel Pump Installation..............................................188 Fuel Pump Operation Inspection......................................189 Fuel Pump Operating Voltage Inspection..............................189 Fuel Pump Circuit...................................................190 Fuel Pump Relay.........................................................191 Fuel Pump Relay Removal.............................................191 Fuel Pump Relay Inspection..........................................191 Fuel Injectors..........................................................192 Audible Inspection..................................................192 Injector Signal Test................................................192 Injector Resistance Inspection......................................193 Injector Unit Test..................................................194 Injector Voltage Inspection.........................................194 Injector Fuel Line Inspection.......................................196 Fuel Injector Circuit...............................................197 Throttle Grip and Cables................................................198 Free Play Inspection................................................198 Free Play Adjustment................................................198 Cable Installation..................................................198 Cable Lubrication...................................................198 Throttle Body Assy......................................................199 Idle Speed Inspection...............................................199 Synchronization Inspection..........................................199 Synchronization Adjustment..........................................199 Throttle Body Assy Removal..........................................199 Throttle Body Assy Installation.....................................200 Throttle Body Assy Disassembly......................................201 Throttle Body Assy Assembly.........................................202 Nozzle Assembly.........................................................203 Nozzle Assy Removal.................................................203 Nozzle Assy Installation............................................203 Nozzle Assy Disassembly.............................................204 Nozzle Assy Assembly................................................204 Air Cleaner.............................................................206 Air Cleaner Element Removal.........................................206 Air Cleaner Element Installation....................................206 Air Cleaner Element Inspection......................................206 Air Cleaner Housing Removal.........................................206 Air Cleaner Housing Installation....................................207 Air Cleaner Housing Disassembly.....................................208 Air Cleaner Housing Assembly........................................208 Oil Draining........................................................209 Fuel Tank...............................................................210 Fuel Tank Removal...................................................210 Fuel Tank Installation..............................................212 Fuel Tank and Cap Inspection........................................212 Fuel Tank Cleaning..................................................213 The Evaporative Emission Control System.................................214 Parts Removal/Installation..........................................214 Hose Inspection.....................................................214 Separator Inspection................................................214 Separator Operation Test............................................215 Canister Inspection ................................................215 Cooling System_4............................................................217 Exploded View...........................................................218 Special tools...........................................................221 Coolant Flow Chart......................................................222 Coolant.................................................................224 Coolant Deterioration Inspection....................................224 Coolant Level Inspection............................................224 Coolant Draining....................................................224 Coolant Filling.....................................................224 Pressure Testing....................................................224 Cooling System Flushing.............................................225 Coolant Reserve Tank Removal........................................225 Coolant Reserve Tank Installation...................................226 Water Pump..............................................................227 Water Pump Removal..................................................227 Water Pump Installation.............................................227 Water Pump Impeller Disassembly/Assembly............................227 Water Pump Impeller Inspection......................................227 Water Pump Housing Disassembly......................................227 Water Pump Housing Assembly.........................................228 Mechanical Seal Inspection..........................................228 Radiator................................................................229 Radiator and Radiator Fan Removal...................................229 Radiator and Radiator Fan Installation..............................230 Radiator Inspection.................................................232 Radiator Cap Inspection.............................................232 Radiator Filler Neck Inspection.....................................233 Thermostat..............................................................234 Thermostat Removal..................................................234 Thermostat Installation.............................................234 Thermostat Inspection...............................................235 Hoses and Pipes.........................................................236 Hose Installation...................................................236 Hose Inspection.....................................................236 Water Temperature Sensor Removal........................................237 Water Temperature Sensor Inspection.....................................237 Engine Top End_5............................................................239 Exploded View...........................................................240 Special Tools...........................................................247 Clean Air System........................................................249 Air suction valve removal...........................................249 Air Suction Valve Installation......................................249 Air Suction Valve Inspection........................................249 Air Switching Valve Removal.........................................250 Air Switching Valve Installation....................................250 Air Switching Valve Operation Test..................................250 Air Switching Valve Unit Test.......................................250 Clean Air System Hose Inspection....................................250 Cylinder Head Cover.....................................................251 Cylinder Head Cover Removal.........................................251 Cylinder Head Cover Installation....................................251 Camshaft Chain Tensioner................................................253 Camshaft Chain Tensioner Removal....................................253 Camshaft Chain Tensioner Installation...............................253 Camshaft, Camshaft Chain................................................254 Camshaft Removal....................................................254 Camshaft................................................................256 Camshaft Installation...............................................256 Camshaft, Camshaft Cap Wear.........................................259 Camshaft Runout.....................................................260 Cam Wear............................................................260 Camshaft Chain Removal..............................................260 Cylinder Head...........................................................261 Cylinder Compression Measurement....................................261 Cylinder Head Removal...............................................262 Cylinder Head Installation..........................................262 Cylinder Head Warp..................................................263 Valve Clearance Inspection..............................................264 Valve Clearance Adjustment..........................................264 Valve Removal.......................................................264 Valve Installation..................................................264 Valve Guide Removal.................................................265 Valve Guide Installation............................................265 Valve-to-Guide Clearance Measurement (Wobble Method)................266 Valve Seat Inspection...............................................267 Valve Seat Repair...................................................267 Throttle Body Assy Holder Removal.......................................272 Throttle Body Assy Holder Installation..............................272 Muffler.................................................................273 Muffler Body Removal................................................273 Muffler Body Installation...........................................274 Rear Exhaust Pipe Removal...........................................275 Rear Exhaust Pipe Installation......................................276 Front Exhaust Pipe Removal..........................................277 Front Exhaust Pipe Installation.....................................278 Exhaust Butterfly Valve Cable Removal...............................279 Exhaust Butterfly Valve Cable Installation..........................280 Clutch_6....................................................................283 Exploded View...........................................................284 Specifications..........................................................286 Special Tools...........................................................287 Clutch Lever and Cable..................................................288 Clutch Lever Free Play Inspection...................................288 Clutch Lever Free Play Adjustment...................................288 Cable Removal.......................................................288 Cable Installation..................................................288 Cable Lubrication...................................................288 Clutch Lever Installation...........................................288 Clutch Cover............................................................289 Clutch Cover Removal................................................289 Clutch Cover Installation...........................................289 Release Shaft Removal...............................................289 Release Shaft Installation..........................................290 Clutch Cover Disassembly............................................290 Clutch Cover Assembly...............................................291 Clutch..................................................................292 Clutch Removal......................................................292 Clutch Installation.................................................292 Spring Plate Free Play Measurement..................................295 Spring Plate Free Play Adjustment...................................296 Clutch Plate, Wear, Damage Inspection...............................297 Clutch Plate Warp Inspection........................................297 Clutch Spring Free Length Measurement...............................298 Damper Cam Inspection...............................................298 Engine Lubrication System_7.................................................299 Special Tools...........................................................303 Engine Oil and Filter...................................................306 Oil Level Inspection................................................306 Engine Oil Change...................................................306 Oil Filter Replacement..............................................306 Oil Pan Removal.........................................................307 Oil Pan Installation................................................307 Oil Pressure Relief Valve Removal.......................................309 Oil Pressure Relief Valve Installation..............................309 Oil Pressure Relief Valve Inspection................................310 Oil Pump Removal........................................................311 Oil Pump Installation...............................................312 Oil Pump Gear Removal...............................................313 Oil Pump Gear Installation..........................................313 Oil Pump Gear Shaft Removal.........................................314 Oil Pump Gear Shaft Installation....................................314 Oil Cooler Removal......................................................315 Oil Cooler Installation.............................................315 Oil Cooler/Oil Filter Case Removal..................................316 Oil Cooler/Oil Filter Case Installation.............................317 Oil Pressure Measurement................................................318 Oil Pressure Switch Removal.............................................319 Oil Pressure Switch Installation....................................319 Engine Removal/Installation_8...............................................321 Exploded View...........................................................322 Special Tool............................................................324 Engine Removal/Installation.............................................325 Engine Removal......................................................325 Engine Installation.................................................328 Crankshaft/Transmission_9...................................................333 Exploded View...........................................................334 Exploded View...........................................................336 Specifications..........................................................338 Special Tools...........................................................341 Crankcase Splitting.....................................................342 Crankcase Assembly..................................................343 Crankshaft and Connecting Rods..........................................348 Crankshaft Removal..................................................348 Crankshaft Installation.............................................348 Connecting Rod Removal..............................................350 Connecting Rod Installation.........................................350 Crankshaft/Connecting Rod Cleaning..................................354 Connecting Rod Bend.................................................354 Connecting Rod Twist................................................354 Connecting Rod Big End Side Clearance...............................354 Connecting Rod Big End Bearing Insert/Crankpin Wear.................355 Crankshaft Side Clearance...........................................356 Crankshaft Runout...................................................357 Crankshaft Main Bearing Insert/Journal Wear.........................357 Piston Removal..........................................................359 Piston Installation.................................................360 Cylinder Wear (Upper Crankcase).....................................361 Piston Wear.........................................................361 Piston Ring, Piston Ring Groove Wear................................361 Piston Ring Groove Width............................................362 Piston Ring Thickness...............................................362 Piston Ring End Gap.................................................362 Starter Idle Gear and Starter Clutch....................................363 Starter Idle Gear Removal...........................................363 Starter Idle Gear Installation......................................363 Starter Clutch Removal..............................................365 Starter Clutch Installation ........................................365 Starter Clutch Disassembly..........................................365 Starter Clutch Assembly.............................................366 Starter Clutch Inspection...........................................366 Transmission............................................................368 Shift Pedal Removal.................................................368 Shift Pedal Installation............................................368 External Shift Mechanism Removal....................................368 External Shift Mechanism Installation...............................369 External Shift Mechanism Inspection.................................369 Transmission Assy Removal...........................................370 Transmission Assy Disassembly.......................................370 Transmission Assy Assembly..........................................371 Special Tool -..................................................371 Transmission Assy Installation......................................372 Transmission Shaft Removal..........................................373 Transmission Shaft Installation.....................................373 Transmission Shaft Disassembly......................................374 Transmission Shaft Assembly.........................................374 Shift Drum and Fork Removal.........................................377 Shift Drum and Fork Installation....................................377 Shift Drum Disassembly..............................................377 Shift Drum Assembly.................................................377 Shift Fork Bending..................................................377 Shift Fork/Gear Groove Wear.........................................378 Shift Fork Guide Pin/Drum Groove Wear...............................378 Gear Dog and Gear Dog Hole Damage...................................378 Wheels/Tires_10.............................................................379 Front Wheel Removal.....................................................384 Exploded View...........................................................380 Specifications..........................................................382 Front Wheel Installation................................................384 Rear Wheel Removal......................................................385 Rear Wheel Installation.................................................386 Wheel Inspection........................................................388 Axle Inspection.........................................................388 Balance Inspection......................................................389 Balance Adjustment......................................................389 Balance Weight Removal..................................................389 Balance Weight Installation.............................................389 Air Pressure Inspection/Adjustment......................................391 Tire Inspection.........................................................391 Tire Removal............................................................391 Tire Installation.......................................................391 Tire Repair.............................................................393 Hub Bearing Removal.....................................................394 Hub Bearing Installation................................................394 Hub Bearing Inspection..................................................394 Hub Bearing Lubrication.................................................395 Final Drive_11..............................................................397 Exploded View...........................................................398 Specifications..........................................................400 Special Tools...........................................................401 Drive Chain.............................................................402 Drive Chain Slack Inspection........................................402 Drive Chain Slack Adjustment........................................402 Wheel Alignment Inspection/Adjustment...............................402 Drive Chain Wear Inspection.........................................402 Drive Chain Lubrication.............................................402 Drive Chain Removal.................................................402 Drive Chain Installation............................................403 Engine Sprocket Removal.................................................406 Engine Sprocket Installation........................................406 Rear Sprocket Removal...............................................407 Rear Sprocket Installation..........................................407 Coupling Installation...............................................408 Coupling Bearing Removal............................................408 Special Tool -Bearing Driver Set................................408 Coupling Bearing Installation.......................................408 Coupling Bearing Inspection.........................................409 Coupling Bearing Lubrication........................................409 Coupling Damper Inspection..........................................409 Sprocket Wear Inspection............................................409 Rear Sprocket Warp Inspection.......................................410 Brakes_12...................................................................411 Exploded View...........................................................414 Specifications..........................................................416 Special Tools...........................................................417 Brake Lever Brake Pedal.................................................418 Brake Lever Position Adjustment.....................................418 Brake Pedal Position Inspection ....................................418 Brake Pedal Position Adjustment ....................................418 Brake Pedal Removal.................................................418 Brake Pedal Installation............................................419 Calipers................................................................420 Front Caliper Removal...............................................420 Rear Caliper Removal................................................420 Caliper Installation................................................420 Front Caliper Disassembly...........................................421 Front Caliper Assembly..............................................421 Rear Caliper Disassembly............................................421 Rear Caliper Assembly...............................................421 Caliper Fluid Seal Damage...........................................421 Rear Caliper Dust Boot and Friction Boot Damage.....................422 Caliper Piston and Cylinder Damage..................................422 Rear Caliper Holder Shaft Wear......................................422 Brake Pads..............................................................423 Front Brake Pad Removal.............................................423 Front Brake Pad Installation........................................423 Rear Brake Pad Removal .............................................423 Rear Brake Pad Installation.........................................424 Brake Pad Wear Inspection...........................................424 Master Cylinder.........................................................425 Front Master Cylinder Removal.......................................425 Front Master Cylinder Installation..................................425 Rear Master Cylinder Removal........................................426 Rear Master Cylinder Installation...................................426 Front Master Cylinder Disassembly...................................426 Rear Master Cylinder Disassembly....................................426 Master Cylinder Inspection (Visual Inspection)......................426 Master Cylinder Assembly............................................427 Brake Disc Removal......................................................428 Brake Disc Installation.............................................428 Brake Disc Wear.....................................................428 Brake Disc Warp.....................................................428 Brake Fluid Level Inspection............................................429 Brake Fluid Change..................................................429 Brake Line Bleeding.................................................429 Brake Hose Removal/Installation.........................................433 Brake Hose Inspection...............................................433 Suspension_13...............................................................435 Exploded View_Front.....................................................436 Exploded View_Rear......................................................438 Specifications..........................................................440 Special Tools...........................................................441 Front Fork..............................................................443 Rebound Damping Force Adjustment....................................443 Spring Preload Adjustment.......................................443 Compression Damping Force Adjustment............................444 Front Fork Removal (Each Fork Leg)..............................444 Front Fork Installation.........................................445 Front Fork Oil Change...........................................445 Special Tool -Fork Spring Compresser........................445 Special Tool -Fork Spring Stopper...........................446 Special Tool -Fork Piston Rod Puller........................446 Special Tool -Fork Oil Level Gauge..........................447 Front Fork Disassembly..........................................449 Front Fork Assembly.............................................450 Special Tool -Fork Oil Seal Driver..........................451 Inner Tube Inspection...........................................451 Dust Seal Inspection............................................452 Spring Tension..................................................452 Rear Shock Absorber.....................................................453 Rebound Damping Force Adjustment....................................453 Compression Damping Force Adjustment................................453 Spring Preload Adjustment...........................................454 Special Tool -Hook Wrench.......................................454 Rear Shock Absorber Removal.........................................455 Rear Shock Absorber Installation....................................455 Rear Shock Absorber Inspection......................................455 Rear Shock Absorber Scrapping.......................................456 Swingarm................................................................457 Swingarm Removal....................................................457 Special Tool -Swingarm Pivot Nut Wrench.........................457 Swingarm Installation...............................................458 Swingarm Bearing Removal............................................459 Special Tool -Oil Seal Remover..................................459 Swingarm Bearing Installation.......................................459 Special Tool -Bearing Driver Set................................459 Swingarm Bearing, Sleeve Inspection.................................460 Chain Guide Inspection..............................................460 Tie-Rod Removal.........................................................461 Tie-Rod Installation................................................461 Rocker Arm Removal..................................................461 Rocker Arm Installation.............................................462 Tie-Rod and Rocker Arm Bearing Removal..............................463 Special Tool -Bearing Remover Shaft.............................463 Tie-Rod and Rocker Arm Bearing Installation.........................463 Special Tools -Bearing Driver set...............................464 Rocker Arm/Tie-Rod Bearing, Sleeve Inspection.......................465 Rocker Arm/Tie-Rod Bearing Lubrication..............................465 Steering_14.................................................................467 Exploded View...........................................................468 Special Tools...........................................................470 Steering Inspection.....................................................471 Steering Adjustment.................................................471 Stem, Stem Bearing Removal..............................................472 Special Tool - Nut wrench...........................................472 Special Tools -Bearing Puller.......................................473 Stem, Stem Bearing Installation.....................................473 Steering Stem Bearing Lubrication...................................475 Steering Stem Warp..................................................475 Stem Cap Deterioration, Damage......................................475 Handlebar Removal.......................................................476 Handlebar Installation..............................................477 Frame_15....................................................................479 Exploded View...........................................................480 Exploded View...........................................................482 Seats...................................................................479 Rear Seat Removal...................................................486 Rear Seat Installation..............................................486 Front Seat Removal..................................................486 Front Seat Installation.............................................486 Fairings................................................................479 Lower Fairing Removal...............................................487 Lower Fairing Installation..........................................487 Middle Fairing Removal..............................................487 Windshield Removal..................................................489 Windshield Installation.............................................489 Upper Fairing Disassembly...........................................490 Upper Fairing Assembly..............................................490 Upper Fairing Installation..........................................490 Inner Cover Removal.................................................490 Inner Cover Installation............................................491 Center Inner Fairing Removal........................................491 Center Inner Fairing Installation...................................491 Lower Inner Fairing Removal.........................................491 Lower Inner Fairing Installation....................................492 Side Covers.............................................................479 Left Side Cover Removal.............................................493 Left Side Cover Installation........................................493 Right Side Cover Removal............................................493 Right Side Cover Installation.......................................493 Seat Cover Removal......................................................494 Seat Cover Installation.............................................494 Engine Cover............................................................495 Heat Insulation Plate Removal.......................................495 Heat Insulation Plate Installation..................................495 Heat Insulation Rubber Plate Pemoval................................495 Heat Insulation Rubber Plate Installation...........................496 Fenders.................................................................497 Front Fender Removal................................................497 Front Fender Installation...........................................497 Flap and Rear Fender Removal........................................497 Flap and Rear Fender Installation...................................500 Frame...................................................................501 Rear Frame Removal..................................................501 Rear Frame Installation.............................................501 Frame Inspection....................................................501 Sidestand Removal.......................................................502 Sidestand Installation..............................................502 Electrical System_16........................................................503 Parts Location..........................................................505 Exploded View...........................................................506 Wiring US_Canada........................................................512 Wiring Other............................................................514 Wiring Australia........................................................516 Wiring Malaysia.........................................................518 Specifications..........................................................520 Special Tools...........................................................521 Precautions.............................................................522 Wiring Inspection.......................................................523 Battery.................................................................524 Battery Removal.....................................................524 Battery Installation................................................524 Battery Activation..................................................524 Precautions.........................................................527 Charging Condition Inspection.......................................528 Refreshing Charge...................................................528 Charging System.........................................................530 Alternator Cover Removal............................................530 Alternator Cover Installation.......................................530 Stator Coil Removal.................................................530 Stator Coil Installation............................................531 Alternator Rotor Removal............................................531 Alternator Rotor Installation.......................................531 Special Tools -.................................................531 Special Tool -..................................................532 Special Tools -.................................................532 Torque -........................................................532 Alternator Inspection...............................................532 Special Tool -..................................................533 Regulator/Rectifier Removal.........................................533 Regulator/Rectifier Inspection......................................534 Special Tool -..................................................534 Torque -........................................................534 Charging Voltage Inspection.........................................535 Special Tool -..................................................535 Charging System Circuit.............................................536 Crankshaft Sensor Removal.......................................538 Crankshaft Sensor Installation..................................538 Torque -....................................................538 Sealant -...................................................538 Crankshaft Sensor Inspection....................................539 Special Tool -..............................................539 Crankshaft Sensor Peak Voltage..................................539 Special Tools -.............................................540 Stick Coil Removal..............................................540 Stick Coil Installation.........................................540 Stick Coil Inspection...........................................541 Stick Coil Primary Peak Voltage.................................541 Special Tools -.............................................541 Spark Plug Removal..............................................542 Spark Plug Installation.........................................542 Spark Plug Clean and Inspection.................................542 Camshaft Position Sensor Removal................................543 Camshaft Position Sensor Installation...........................543 Torque -....................................................543 Camshaft Position Sensor Inspection.............................543 Special Tool -..............................................544 Camshaft Position Sensor Peak Voltage Inspection................544 Special Tools -.............................................544 Interlock Operation Inspection..................................545 IC Igniter Inspection...........................................546 Ignition System.....................................................537 Ignition System Circuit.............................................547 Electric Starter System.................................................548 Starter Motor Removal...............................................548 Starter Motor Installation..........................................548 Starter Motor Disassembly...........................................549 Starter Motor Assembly..............................................549 Brush Inspection....................................................550 Commutator Cleaning and Inspection..................................550 Armature Inspection.................................................551 Brush Lead Inspection...............................................551 Right-hand End Cover Assembly Inspection............................551 Starter Relay Inspection............................................551 Special Tool -..................................................552 Electric Starter Circuit............................................553 Lighting System.........................................................554 Headlight Beam Horizontal Adjustment................................554 Headlight Beam Vertical Adjustment..................................554 Headlight Bulb Replacement..........................................554 City Light Bulb Replacement.........................................555 Headlight Removal/Installation......................................555 Tail/Brake Light (LED) Removal......................................555 Tail/Brake Light (LED) Installation.................................556 License Plate Light Bulb Replacement................................556 Headlight/Tail Light Circuit........................................557 Turn Signal Light Bulb Replacement..................................557 Turn Signal Light Removal...........................................559 Turn Signal Relay Inspection........................................560 Turn Signal Light Circuit...........................................562 Air Switching Valve Operation Test......................................563 Air Switching Valve Unit Test.......................................563 Fan Motor Inspection....................................................564 Radiator Fan Circuit................................................564 Meter,Gauge,Indicator Unit..............................................565 Meter Unit Removal..................................................565 Meter Unit Disassembly..............................................565 Electronic Combination Meter Unit Inspection........................566 Fuel Level Sensor Line Self-Diagnosis Mode Inspection...............582 Meter Circuit.......................................................583 Immobilizer System......................................................584 Operational Cautions................................................584 Key Registration....................................................584 Special Tool -Key Registration Unit.............................584 Spare User Key Registration Flow Chart..............................589 All Keys Initial Registration Flow Chart............................599 Immobilizer System Parts Replacement............................600 Immobilizer System Inspection...................................602 Immobilizer System Circuit..........................................603 Switches and Sensors....................................................604 Brake Light Timing Inspection.......................................604 Brake Light Timing Adjustment.......................................604 Gear Position Switch Removal........................................604 Gear Position Switch Installation...................................605 Gear Position Switch Inspection.....................................606 Switch Inspection...................................................607 Rear Brake Light Switch Connections.................................607 Side Stand Switch Connections.......................................607 Oil Pressure Switch Connections *...................................607 Water Temperature Sensor Inspection.................................608 Speed Sensor Removal................................................608 Speed Sensor Installation...........................................609 Speed Sensor Inspection.............................................609 Fuel Reserve Switch Inspection......................................610 Oxygen Sensor Removal (Equipped Models).............................610 Oxygen Sensor Installation (Equipped Models)........................611 Oxygen Sensor Inspection (Equipped Models)..........................611 Relay Box...........................................................612 Relay Box Removal...............................................612 Relay Circuit Inspection........................................612 Diode Circuit Inspection........................................613 Relay Box Internal Circuit......................................614 30 A Main Fuse Removal..............................................615 Fuse Box Fuse Removal...........................................615 10 A ECU Fuse Removal...........................................615 Fuse Installation...............................................616 Fuse Inspection.................................................616 Appendix_17.................................................................617 Cable,wire,house routing................................................618 California Model........................................................643 California Model........................................................644 Trouble shooting........................................................646 Engine Doesn't Start, Starting Difficulty:..........................646 Starter motor not rotating:.....................................646 Starter motor rotating but engine doesn't turn over:............646 Engine won't turn over:.........................................646 No fuel flow:...................................................646 No spark; spark weak:...........................................646 Fuel/air mixture incorrect:.....................................646 Compression Low:................................................646 Poor Running at Low Speed:..........................................646 Spark weak:.....................................................646 Fuel/air mixture incorrect:.....................................646 Compression low:................................................647 Run-on (dieseling):.............................................647 Other:..........................................................647 Poor Running or No Power at High Speed:.............................647 Firing incorrect:...............................................647 Fuel/air mixture incorrect:.....................................647 Compression low:................................................647 Knocking:.......................................................647 Miscellaneous:..................................................647 Overheating:........................................................647 Firing incorrect:...............................................647 Muffler overheating:............................................647 Fuel/air mixture incorrect:.....................................647 Compression high:...............................................648 Engine load faulty:.............................................648 Lubrication inadequate:.........................................648 Oil cooler incorrect:...........................................648 Water temperature meter incorrect:..............................648 Coolant incorrect:..............................................648 Cooling system component incorrect:.............................648 Over Cooling:.......................................................648 Water temperature meter incorrect:..............................648 Cooling system component incorrect:.............................648 Clutch Operation Faulty:............................................648 Clutch slipping:................................................648 Clutch not disengaging properly:................................648 Gear Shifting Faulty:...............................................648 Doesn't go into gear; shift pedal doesn't return:...............648 Jumps out of gear:..............................................648 Overshifts:.....................................................648 Abnormal Engine Noise:..............................................648 Knocking:.......................................................648 Piston slap:....................................................648 Valve noise:....................................................648 Other noise:....................................................648 Abnormal Drive Train Noise:.........................................649 Clutch noise:...................................................649 Transmission noise:.............................................649 Drive line noise:...............................................649 Abnormal Frame Noise:...............................................649 Front fork noise:...............................................649 Rear shock absorber noise:......................................649 Disc brake noise:...............................................649 Other noise:....................................................649 Warning Indicator Light (Oil Pressure Warning) Doesn't Go OFF:......649 Exhaust Smokes Excessively:.........................................649 White smoke:....................................................649 Black smoke:....................................................649 Brown smoke:....................................................649 Handling and/or Stability Unsatisfactory:...........................649 Handlebar hard to turn:.........................................649 Handlebar shakes or excessively vibrates:.......................649 Handlebar pulls to one side:....................................649 Shock absorption unsatisfactory:................................649 Brake Doesn't Hold:.................................................650 Battery Trouble:....................................................650 Battery discharged:.............................................650 Battery overcharged:............................................650 Model Application...........................................................651 tables.......................................................................... 1 LIST OF ABBREVIATIONS....................................................... 6 COUNTRY AND AREA CODES...................................................... 6 Unit Conversion table....................................................... 22 Periodic Maintenance Chart.................................................. 25 Periodic Replacement Parts.................................................. 27 Torque and Locking Agent.................................................... 28 Basic Torque for General Fasteners.......................................... 33 Specifications - Maintenance................................................ 34 Throttle Grip Free Play..................................................... 37 Idle Speed.................................................................. 38 Engine Vacuum............................................................... 38 Main Throttle Sensor Output Voltage......................................... 40 Idle Speed.................................................................. 40 Valve Clearance............................................................. 43 Example:.................................................................... 44 Adjustment Shims............................................................ 45 Clutch Lever Free Play...................................................... 48 Air Pressure (when Cold).................................................... 49 Tread Depth................................................................. 49 Chain Slack................................................................. 51 Drive Chain 20-link Length.................................................. 53 Standard Chain.............................................................. 53 Recommended Disc Brake Fluid................................................ 55 Pad Lining Thickness........................................................ 56 Side Stand Switch Operation................................................. 63 Water and Coolant Mixture Ratio (Recommended)............................... 73 Recommended Engine Oil...................................................... 75 Standard Spark Plug......................................................... 82 Terminal Names..............................................................102 Sample Diagnosis Sheet......................................................110 Engine Won't Turn Over......................................................112 Poor Running at Low Speed...................................................112 Poor Running or No Power at High Speed:.....................................115 Main Throttle Sensor Input Voltage..........................................125 Input Voltage at ECU Connector..............................................125 Main Throttle Sensor Input Voltage..........................................126 Input Voltage at Sensor.....................................................126 Main Throttle Sensor Output Voltage.........................................126 Idle Speed..................................................................126 Output Voltage at ECU.......................................................126 Main Throttle Sensor Output Voltage.........................................127 Output Voltage at Sensor....................................................127 Main Throttle Sensor Resistance.............................................127 Inlet Air Pressure Sensor Input Voltage.....................................129 Input Voltage at ECU........................................................129 Inlet Air Pressure Sensor Input Voltage.....................................130 Input Voltage at Sensor Connector...........................................130 Inlet Air Pressure Sensor Output Voltage....................................130 Output Voltage at ECU.......................................................130 Inlet Air Pressure Sensor Output Voltage....................................131 Output Voltage at Sensor Connector..........................................131 Inlet Air Pressure Sensor Output Voltage Connection to Sensor...............132 Inlet Air Temperature Sensor Output Voltage.................................134 Output Voltage at ECU.......................................................134 Inlet Air Temperature Sensor Resistance.....................................135 Water Temperature Sensor Output Voltage.....................................136 Output Voltage at ECU.......................................................136 Atmospheric Pressure Sensor Input Voltage...................................138 Input Voltage at ECU........................................................138 Atmospheric Pressure Sensor Input Voltage...................................139 Input Voltage at Sensor Connector...........................................139 Atmospheric Pressure Sensor Output Voltage..................................139 Output Voltage..............................................................139 Atmospheric Pressure Sensor Output Voltage..................................140 Output Voltage at Sensor....................................................140 Speed Sensor Input Voltage..................................................144 Input Voltage at Sensor.....................................................144 Speed Sensor Output Voltage.................................................145 Output Voltage at Sensor ...................................................145 Gear Position Switch Input Voltage at 1 ∼ 6 Gear Positions..................146 Input Voltage at 1 ∼ 6 Gear Positions.......................................146 Vehicle-down Sensor Power Source Voltage....................................149 Power Source Voltage at Sensor..............................................149 Vehicle-down Sensor Output Voltage..........................................150 Output Voltage at Sensor....................................................150 Subthrottle Sensor Input Voltage............................................152 Input Voltage at ECU Connector..............................................152 Subthrottle Sensor Input Voltage............................................153 Input Voltage at Sensor.....................................................153 Subthrottle Sensor Output Voltage...........................................153 Output Voltage at ECU.......................................................153 Subthrottle Sensor Output Voltage...........................................154 Output Voltage at Sensor....................................................154 Subthrottle Sensor Resistance...............................................155 Oxygen Sensor Output Voltage................................................156 Oxygen Sensor Output Voltage (with Plugs)...................................156 Oxygen Sensor Output Voltage (without Plugs)................................157 Exhaust Butterfly Valve Actuator Sensor Input Voltage.......................158 Input Voltage at Actuator...................................................158 Wiring Connections..........................................................158 Exhaust Butterfly Valve Actuator Sensor Output Voltage......................159 Output Voltage at Actuator..................................................159 Wiring Connections..........................................................159 Exhaust Butterfly Valve Actuator Sensor Resistance..........................160 Antenna Resistance..........................................................161 Amplifier Input Voltage.....................................................161 Input Voltage...............................................................161 Wiring Connections..........................................................164 Stick Coil Input Voltage at ECU.............................................165 Input Voltage at ECU........................................................165 Subthrottle Valve Actuator Resistance.......................................169 Subthrottle Valve Actuator Input Voltage....................................170 Input Voltage at Sensor.....................................................170 Connections.................................................................173 Actuator Output Voltage (Pulley Original Position)..........................173 Oxygen Sensor Resistance....................................................176 Oxygen Sensor Heaters Power Source Voltage..................................176 Power Source Voltage at Sensor Connector....................................176 Oxygen Sensor Output Voltage................................................178 Oxygen Sensor Output Voltage (with Plugs)...................................178 Oxygen Sensor Output Voltage (without Plugs)................................179 ECU Identification..........................................................180 ECU Grounding Inspection....................................................181 ECU Power Source Inspection.................................................182 Fuel Pressure...............................................................185 Fuel Pressure (Idling)......................................................186 Amount of Fuel Flow.........................................................187 Pump Operating Voltage at Pump..............................................189 Operating Voltage at Pump Connector.........................................189 Testing Relay...............................................................191 Secondary Fuel Injector Resistance..........................................193 Primary Injector Resistance.................................................193 Secondary Fuel Injector Power Source Voltage................................194 Primary Fuel Injector Power Source Voltage..................................194 Power Source Voltage at Injector Connector..................................194 Secondary Fuel Injector Output Voltage......................................195 Primary Fuel Injector Output Voltage........................................195 Output Voltage at Injector Connector........................................195 Fuel Line Maximum Pressure..................................................196 Radiator Cap Relief Pressure................................................232 Thermostat Valve Opening Temperature........................................235 Camshaft Journal, Camshaft Cap Clearance....................................259 Camshaft Journal Diameter...................................................260 Camshaft Runout.............................................................260 Cam Height..................................................................260 Cylinder Compression........................................................261 Cylinder Head Warp..........................................................263 Valve/Valve Guide Clearance (Wobble Method).................................266 Valve Seating Surface Outside Diameter......................................267 Valve Seating Surface Width.................................................267 Spring Plate Free Play .....................................................296 Spring Plate Free Play......................................................296 Clutch Plate Assembly Length (Reference)....................................297 Friction Plate Thickness....................................................297 Friction and Steel Plate Warp...............................................297 Clutch Spring Free Length...................................................298 Oil Pressure................................................................318 Connecting Rod Big End Bearing Insert Selection.............................340 Crankshaft Main Bearing Insert Selection (Engine No. ∼ ZX600PE..............340 Crankshaft Main Bearing Insert Selection (Engine No. ZX600PE0085............340 Connecting Rod Bend.........................................................354 Connecting Rod Twist........................................................354 Connecting Rod Big End Side Clearance.......................................354 Connecting Rod Big End Bearing Insert/Crankpin Clearance....................355 Crankpin Diameter...........................................................355 Crankpin Diameter Marks.....................................................355 Connecting Rod Big End Inside Diameter Marks................................356 Crankshaft Side Clearance...................................................356 Crankshaft ##3 Main Journal Width...........................................356 Crankshaft Runout...........................................................357 Crankshaft Main Bearing Insert/Journal Clearance............................357 Crankshaft Main Journal Diameter............................................357 Crankshaft Main Journal Diameter Marks......................................357 Crankcase Main Bearing Inside Diameter Marks................................358 (Engine No. ∼ ZX600PE008560)................................................358 (Engine No. ZX600PE008561 ∼)................................................358 Cylinder Inside Diameter....................................................361 Piston Diameter.............................................................361 Piston Ring/Groove Clearance................................................361 Piston Ring Groove Width....................................................362 Piston Ring Thickness.......................................................362 Piston Ring End Gap.........................................................362 Shift Fork Ear Thickness....................................................378 Gear Groove Width...........................................................378 Shift Fork Guide Pin Diameter...............................................378 Shift Drum Groove Width.....................................................378 Rim Runout (with tire installed)............................................388 Axle Runout/100 mm (3.94 in.)...............................................388 Balance Weight..............................................................390 Link Pin Outside Diameter...................................................405 Link Plates Outside Width...................................................405 Rear Sprocket Warp..........................................................410 Pedal Position..............................................................418 Brake Discs Thickness.......................................................428 Disc Runout.................................................................428 Rebound Damping Force Adjustment............................................443 Spring Action...............................................................443 Compression Damping Force Adjustment........................................444 Fork Oil....................................................................446 Oil Level (fully compressed, without spring)................................447 Spring Free Length..........................................................452 Rebound Damping Force Adjustment............................................453 Spring Preload Setting......................................................454 Spring Adjustment...........................................................454 Kawasaki-recommended chargers...............................................526 Battery Terminal Voltage....................................................528 Terminal Voltage: 11.5 ∼ less than 12.8 V...................................529 Terminal Voltage: less than 11.5 V..........................................529 Table 1 Alternator Output Voltage...........................................532 Table 2 Stator Coil Resistance..............................................533 Regulator/Rectifier Resistance (Unit: kΩ)...................................534 Charging Voltage............................................................535 Crankshaft Sensor Peak Voltage..............................................540 Ignition Coil Winding Resistance............................................541 Primary Lead Connection.....................................................541 Stick Coil Primary Peak Voltage.............................................542 Connections:................................................................544 Camshaft Position Sensor Peak Voltage.......................................544 Condition...................................................................545 Condition...................................................................545 Condition...................................................................545 Starter Motor Brush Length..................................................550 Commutator Diameter.........................................................550 Testing Relay...............................................................552 Testing Turn Signal Relay...................................................561 Testing Turn Signal Relay...................................................561 Air Switching Valve Resistance..............................................563 LCD segment actions for 1.5 seconds.........................................567 Electric Source Voltage.....................................................572 User Key Indicator Flashes..................................................587 Immobilizer Relational Parts Replacement Chart..............................602 Gear Position Switch Resistance kΩ..........................................606 Water Temperature Sensor....................................................608 Connections.................................................................610 Relay Circuit Inspection (with the battery disconnected)....................613 Relay Circuit Inspection (with the battery connected).......................613 Diode Circuit Inspection....................................................613
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