Page 1

MODEL APPLICATION Year

Model

2005

ZX636-C1

2006

ZX636C6F

2006

ZX636D6F

Beginning Frame No. JKBZXJC1□5A000001 JKBZX636CCA000001 ZX636C-000001 JKBZXJC1□6A030001 JKBZX636CCA030001 ZX636C-030001 JKBZXJD1□6A000001

□:This digit in the frame number changes from one machine to another.

Part No.99924-1345-03

Printed in Japan


Ninja ZX-6R

Motorcycle Service Manual


Quick Reference Guide

This quick reference guide will assist you in locating a desired topic or procedure. •Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. •Refer to the sectional table of contents for the exact pages to locate the specific topic required.

General Information

1 j

Periodic Maintenance

2 j

Fuel System (DFI)

3 j

Cooling System

4 j

Engine Top End

5 j

Clutch

6 j

Engine Lubrication System

7 j

Engine Removal/Installation

8 j

Crankshaft/Transmission

9 j

Wheels/Tires

10 j

Final Drive

11 j

Brakes

12 j

Suspension

13 j

Steering

14 j

Frame

15 j

Electrical System

16 j

Appendix

17 j


Ninja ZX-6R

Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.

Š 2004 Kawasaki Heavy Industries, Ltd.

Second Edition (1): Jul. 29, 2005 (M)


LIST OF ABBREVIATIONS A ABDC AC ATDC BBDC BDC BTDC °C DC F °F ft g h L

ampere(s) after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celsius direct current farad(s) degree(s) Fahrenheit foot, feet gram(s) hour(s) liter(s)

lb m min N Pa PS psi r rpm TDC TIR V W Ω

pound(s) meter(s) minute(s) newton(s) pascal(s) horsepower pound(s) per square inch revolution revolution(s) per minute top dead center total indicator reading volt(s) watt(s) ohm(s)

Read OWNER’S MANUAL before operating.


EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only. 1. Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors are routed through an oil separator to the inlet side of the engine. While the engine is operating, the vapors are drawn into combustion chamber, where they are burned along with the fuel and air supplied by the fuel injection system. 2. Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels. The exhaust system of this model motorcycle manufactured primarily for sale in California includes a catalytic converter system. 3. Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister when the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank. The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly referred to as the Act’s “tampering provisions”. “Sec. 203(a) The following acts and the causing thereof are prohibited... (3)(A) for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser. (3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser...”

NOTE ○The phrase “remove or render inoperative any device or element of design” has been generally interpreted as follows. 1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance. 2. Tampering could include. a.Maladjustment of vehicle components such that the emission standards are exceeded. b.Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle. c.Addition of components or accessories that result in the vehicle exceeding the standards. d.Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems. WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10 000 PER VIOLATION.


Foreword 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 service manual. 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. Follow the procedures in this manual carefully. Don’t take shortcuts. Remember to keep complete records of maintenance and repair with dates and any new parts installed.

• • •

• •

How to Use This Manual 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 ignition 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 Ignition Coil section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.

WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.

CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information.

NOTE

○This note symbol indicates points of particular interest for more efficient and convenient operation. a procedural step or work to be • Indicates done.

○Indicates a procedural sub-step or how to do

the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.


GENERAL INFORMATION 1-1

General Information

1

Table of Contents Before Servicing ..................................................................................................................... Model Identification................................................................................................................. General Specifications............................................................................................................ Unit Conversion Table ............................................................................................................

1-2 1-7 1-10 1-13


1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts. Especially note the following.

Battery Ground Before completing any service on the motorcycle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the ground cable (–) first and then the positive (+). When completed with the service, first connect the positive (+) cable to the positive (+) terminal of the battery then the negative (–) cable to the negative terminal.

Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.

Solvent Use a high-flush point solvent when cleaning parts. High -flush point solvent should be used according to directions of the solvent manufacturer.

Cleaning vehicle before disassembly Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.


GENERAL INFORMATION 1-3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.

Storage of Removed Parts After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.

Inspection Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit.

Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.

Assembly Order In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given.


1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.

Tightening Torque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench.

Force Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non -permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove the old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install the new gaskets and replace the used O-rings when re-assembling

Liquid Gasket, Non-permanent Locking Agent For applications that require Liquid Gasket or a Non-permanent Locking Agent, clean the surfaces so that no oil residue remains before applying liquid gasket or non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.


GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing.

Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown. Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.

Oil Seal, Grease Seal Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed. Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing.

Apply specified grease to the lip of seal before installing the seal.

Circlips, Cotter Pins Replace the circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation.


1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified.

Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side).

Electrical Wires A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color.

Instrument Use a meter that has enough accuracy for an accurate measurement. Read the manufacture’s instructions thoroughly before using the meter. Incorrect values may lead to improper adjustments.


GENERAL INFORMATION 1-7 Model Identification ZX636-C1 ∼ (Europe) Left Side View

ZX636-C1 ∼ (Europe) Right Side View


1-8 GENERAL INFORMATION Model Identification ZX636-C1 ∼ (US and Canada) Left Side View

ZX636-C1 ∼ (US and Canada) Right Side View


GENERAL INFORMATION 1-9 Model Identification ZX636D6F (US and Canada) Left Side View

ZX636D6F (US and Canada) Right Side View


1-10 GENERAL INFORMATION General Specifications Items Dimensions Overall Length Overall Width Overall Height Wheelbase Road Clearance Seat Height Dry Mass Curb Mass: Front Rear Fuel Tank Capacity Performance Minimum Turning Radius Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower

Maximum Torque

Carburetion System

Starting System Ignition System Timing Advance Ignition Timing

ZX636-C1 ∼, ZX636D6F (Ninja ZX-6R) 2 065 mm (81.3 in.) 715 mm (28.1 in.) 1 110 mm (43.7 in.) 1 390 mm (54.7 in.) 120 mm (4.7 in.) 820 mm (32.3 in.) 164 kg (362 lb) 95 kg (209 lb) 97 kg (214 lb) 17 L (4.5 US gal) 3.3 m (10.8 ft) 4-stroke, DOHC, 4-cylinder Liquid-cooled 68.0 × 43.8 mm (2.7 × 1.7 in.) 636 mL (38.8 cu in.) 12.9 : 1 95.5 kW (130 PS) @14 000 r/min (rpm), (FR) 78.2 kW (106 PS) @13 000 r/min (rpm), (MY) 90.8 kW (123 PS) @12 500 r/min (rpm), (CA), (CAL), (US) – – – 70.5 N·m (7.1 kgf·m, 52 ft·lb) @11 500 r/min (rpm), (FR) 63 N·m (6.4 kgf·m, 46 ft·lb) @11 500 r/min (rpm), (CA), (CAL), (US) – – – FI (Fuel injection) Primary: KEIHIN TTK 38 × 4 Secondary: KEIHIN Multihole (3 holes) × 4 Electric starter

Battery and coil (transistorized) Electronically advanced (digital igniter in ECU) From 12.5° BTDC @1 300 r/min (rpm) to 35° BTDC @4 600 r/min (rpm) Spark Plug NGK CR9E Cylinder Numbering Method Left to right, 1-2-3-4 Firing Order 1-2-4-3 Valve Timing: Inlet: Open 59° BTDC Close 81° ABDC Duration 320° Exhaust: Open 61° BBDC Close 31° ATDC


GENERAL INFORMATION 1-11 General Specifications Items Duration Lubrication System Engine Oil: Type

ZX636-C1 ∼, ZX636D6F (Ninja ZX-6R) 272° Forced lubrication (wet sump with cooler) API SE, SF or SG API SH or SJ with JASO MA SAE10W-40 4.0 L (4.2 US qt)

Viscosity Capacity Drive Train Primary Reduction System: Type Gear Reduction Ratio 1.891 (87/46) Wet multi disc Clutch Type Transmission: Type 6-speed, constant mesh, return shift Gear Ratios: 1st 2.923 (38/13) 2nd 2.055 (37/18) 3rd 1.666 (35/21) 4th 1.450 (29/20) 5th 1.272 (28/22) 6th 1.153 (30/26) Final Drive System: Type Chain drive Reduction Ratio 2.866 (43/15) Overall Drive Ratio 6.255 @Top gear Frame Type Tubular, diamond Caster (Rake Angle) 25° Trail 106 mm (4.2 in.) Front Tire: Type Tubeless Size 120/65 ZR17 M/C (56 W) Rear Tire: Type Tubeless Size 180/55 ZR17 M/C (73 W) Rim Size: Front 17 × 3.50 Rear 17 × 5.50 Front Suspension: Type Telescopic fork (upside-down) Wheel Travel 120 mm (4.7 in.) Rear Suspension: Type Swingarm (uni-trak) Wheel Travel 135 mm (5.3 in.)


1-12 GENERAL INFORMATION General Specifications Items Brake Type: Front Rear Electrical Equipment Battery Headlight: Type Bulb: High Low Tail/Brake Light Alternator: Type Rated Output

ZX636-C1 ∼, ZX636D6F (Ninja ZX-6R) Dual discs Single disc 12 V 8 Ah Semi-sealed beam 12 V 55 W (quartz-halogen) × 2 12 V 55 W (quartz-halogen) 12 V 0.5/4.1 W (LED) Three-phase AC 22.5 A/14 V @5 000 r/min (rpm)

Specifications subject to change without notice, and may not apply to every country. CA: Canada Model CAL: California Model FR: France Model MY: Malaysia Model US: United States Model


GENERAL INFORMATION 1-13 Unit Conversion Table Prefixes for Units Prefix mega kilo centi milli micro

Symbol M k c m µ

Units of Length × × × × ×

Power 1 000 000 1 000 0.01 0.001 0.000001

Units of Mass kg g

× ×

2.205 0.03527

= =

lb oz

× × × × × × × × ×

0.2642 0.2200 1.057 0.8799 2.113 1.816 0.03381 0.02816 0.06102

= = = = = = = = =

gal (US) gal (imp) qt (US) qt (imp) pint (US) pint (imp) oz (US) oz (imp) cu in

× × × ×

0.1020 0.2248 9.807 2.205

Units of Temperature

0.6214 3.281 0.03937

= = =

mile ft in

= = = = = =

kgf·m ft·lb in·lb N·m ft·lb in·lb

= = = = = =

kgf/cm² psi cmHg kPa psi kPa

=

mph

= = = =

PS HP kW HP

Units of Torque N·m N·m N·m kgf·m kgf·m kgf·m

× × × × × ×

0.1020 0.7376 8.851 9.807 7.233 86.80

kPa kPa kPa kgf/cm² kgf/cm² cmHg

× × × × × ×

0.01020 0.1450 0.7501 98.07 14.22 1.333

Units of Speed km/h

×

0.6214

Units of Power

Units of Force N N kg kg

× × ×

Units of Pressure

Units of Volume L L L L L L mL mL mL

km m mm

= = = =

kg lb N lb

kW kW PS PS

× × × ×

1.360 1.341 0.7355 0.9863


PERIODIC MAINTENANCE 2-1

Periodic Maintenance 2

Table of Contents Periodic Maintenance Chart (United States, Canada Model)................................................. Periodic Maintenance Chart (Other than United States, Canada Model)............................... Torque and Locking Agent...................................................................................................... Specifications ......................................................................................................................... Special Tools .......................................................................................................................... Maintenance Procedure ......................................................................................................... Fuel System (DFI)................................................................................................................ Throttle Control System Inspection................................................................................... Engine Vacuum Synchronization Inspection..................................................................... Idle Speed Inspection ....................................................................................................... Idle Speed Adjustment...................................................................................................... Fuel Hose Damage and Installation Condition Inspection ................................................ Evaporative Emission Control System (California Model) ................................................... Evaporative Emission Control System Inspection ............................................................ Cooling System.................................................................................................................... Coolant Level Inspection................................................................................................... Radiator Hose Damage and Installation Condition Inspection.......................................... Engine Top End ................................................................................................................... Valve Clearance Inspection .............................................................................................. Valve Clearance Adjustment............................................................................................. Air Suction System .............................................................................................................. Air Suction System Damage Inspection............................................................................ 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 .......................................................................................... 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.............................................. 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..........................................................................................

2-3 2-6 2-9 2-15 2-17 2-18 2-18 2-18 2-18 2-22 2-22 2-22 2-23 2-23 2-24 2-24 2-24 2-25 2-25 2-26 2-29 2-29 2-29 2-29 2-30 2-30 2-30 2-30 2-31 2-32 2-32 2-32 2-33 2-34 2-34 2-35 2-35 2-35 2-35 2-35 2-36 2-36 2-36 2-37 2-37 2-38


2-2 PERIODIC MAINTENANCE Rear Shock Absorber Oil Leak Inspection ........................................................................ Rocker Arm Operation Inspection..................................................................................... Tie-Rod Operation Inspection ........................................................................................... Steering System .................................................................................................................. Steering Play Inspection ................................................................................................... Steering Play Adjustment.................................................................................................. Steering Stem Bearing Lubrication ................................................................................... Electrical System ................................................................................................................. Spark Plug Clean and Gap Inspection.............................................................................. Lights and Switches Operation Inspection........................................................................ Headlight Aiming Inspection ............................................................................................. Side Stand Switch Operation Inspection........................................................................... Engine Stop Switch Operation Inspection......................................................................... Others .................................................................................................................................. Chassis Parts Lubrication ................................................................................................ Bolts, Nuts and Fasteners Tightness Inspection............................................................... Replacement Parts .............................................................................................................. Air Cleaner Element Replacement.................................................................................... Fuel Hose Replacement ................................................................................................... Coolant Change ................................................................................................................ Radiator Hose and O-ring Replacement........................................................................... Engine Oil Change............................................................................................................ Oil Filter Replacement ...................................................................................................... Brake Hose and Pipe Replacement.................................................................................. Brake Fluid Change .......................................................................................................... Master Cylinder Rubber Parts Replacement .................................................................... Caliper Rubber Parts Replacement .................................................................................. Spark Plug Replacement ..................................................................................................

2-38 2-38 2-38 2-39 2-39 2-39 2-40 2-40 2-40 2-42 2-44 2-45 2-46 2-47 2-47 2-48 2-50 2-50 2-50 2-52 2-54 2-55 2-55 2-56 2-56 2-58 2-59 2-62


PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart (United States, Canada Model) The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected.

Periodic Inspection FREQUENCY Whichever comes first

* ODOMETER READING × 1 000 km (× 1 000 mile) 1

INSPECTION Fuel System Throttle control system (play, smooth return, no drag)-inspect

Every

year

Fuel leak (fuel hose and pipe)-inspect

year

Fuel hose and pipe damage-inspect

year

Fuel hose and pipe installation condition-inspect Evaporative Emission Control System (CAL) Evaporative emission control system function-inspect Cooling System

year

Coolant level-inspect Coolant leak (radiator hose and pipe)-inspect

year

Radiator hose damage-inspect

year

Radiator hose installation condition -inspect Engine Top End

year

12

18

24

30

36

(0.6) (4) (7.5) (12) (15) (20) (24)

• • • • • •

• • • • • •

2-18

• • • • •

• •

2-23

• • • •

2-24

Engine vacuum synchronization-inspect Idle speed-inspect

6

See Page

• • • •

• • • •

• • • • • •

• • • •

• • • • •

Valve clearance-inspect

2-18 2-22 2-22 2-22 2-22

2-24 2-24 2-24

2-25

Air Suction System Air suction system damage-inspect Clutch Clutch operation (play, disengagement, engagement)-inspect Wheels and Tires Tire air pressure-inspect

• year

Wheel/tire damage-inspect Tire tread wear, abnormal wear-inspect Wheel bearing damage-inspect Drive Train Drive chain lubrication condition-inspect # Drive chain slack-inspect # Drive chain wear-inspect # Drive chain guide wear-inspect

year

2-29

2-29

• • • •

• • • •

• • • •

2-30

Every 600 km (400 mile) Every 1 000 km (600 mile)

• •

• •

2-30 2-30 2-31 2-32 2-32

• •

2-34 2-35


2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart (United States, Canada Model) FREQUENCY Whichever comes first

* ODOMETER READING × 1 000 km (× 1 000 mile) 1

INSPECTION Brake System Brake fluid leak (brake hose and pipe)-inspect Brake hose and pipe damage-inspect

Every

year year

Brake pad wear-inspect # Brake hose installation condition-inspect Brake fluid level-inspect Brake operation (effectiveness, play, no drag)-inspect

year 6 months year

Brake light switch operation-inspect Suspensions Front forks/rear shock absorber operation (damping and smooth stroke)-inspect Front forks/rear shock absorber oil leak-inspect

6

12

18

24

30

36

See Page

(0.6) (4) (7.5) (12) (15) (20) (24)

• • • • • • • • • • • • • • • • • • • •

year

Rocker arm operation-inspect Tie-Rods operation-inspect

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • • •

2-35 2-35 2-36 2-35 2-36 2-35 2-36

• • • •

• • • •

• • • •

2-37

• •

2-39

• • • • •

• • • • •

• • • • •

2-40

• •

• •

• •

2-47

2-38 2-38 2-38

Steering System Steering play-inspect Steering stem bearings-lubricate

year

2 years

2-40

Electrical System Spark plug condition – inspect Lights and switches operation-inspect

year

Headlight aiming-inspect

year

Side stand switch operation-inspect

year

Engine stop switch operation-inspect

year

2-42 2-44 2-45 2-46

Others Chassis parts-lubricate Bolts and nuts tightness-inspect

year

2-48

*: For higher odometer readings, repeat at the frequency interval established here. #: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping. CAL: California Model


PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart (United States, Canada Model) Periodic Replacement Parts FREQUENCY Whichever come first

* ODOMETER READING × 1 000 km (× 1 000 mile) 1

CHANGE/REPLACE ITEM Air cleaner element #

Every

Fuel hose

4 years

Coolant

3 years

Radiator hose and O-ring

3 years

Engine oil #

year

Oil filter

year

Brake hose and pipe

4 years

Brake fluid

2 years

Rubber parts of master cylinder and caliper

4 years

Spark plug

12

24

36

48

(0.6) (7.5) (15) (24) (30) Every 18 000 km (12 000 mile)

• •

• •

• •

• • • •

• •

See Page

2-50 2-50 2-52 2-54

• • • • • •

2-55 2-55 2-56 2-56 2-58, 2-59 2-62

*: For higher odometer readings, repeat at the frequency interval established here. #: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.


2-6 PERIODIC MAINTENANCE Periodic Maintenance Chart (Other than United States, Canada Model) The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected.

Periodic Inspection FREQUENCY Whichever comes first

* ODOMETER READING × 1 000 km (× 1 000 mile) 1

INSPECTION Fuel System Throttle control system (play, smooth return, no drag)-inspect

Every

year

Fuel leak (fuel hose and pipe)-inspect

year

Fuel hose and pipe damage-inspect

year

Fuel hose and pipe installation condition-inspect Cooling System

year

Coolant level-inspect Coolant leak (radiator hose and pipe)-inspect

year

Radiator hose damage-inspect

year

Radiator hose installation condition -inspect Engine Top End Valve clearance-inspect Air Suction System

year

30

36

• • • • • •

2-18

• • • •

• • • • • •

• • • •

• • • •

• • • •

• • • •

2-23

• year

Wheel/tire damage-inspect Tire tread wear, abnormal wear-inspect year

Drive Train Drive chain lubrication condition-inspect # Drive chain slack-inspect # Drive chain guide wear-inspect

year

2-18 2-22 2-22 2-22 2-22

2-24 2-24 2-24

2-25

2-29

2-29

• • • •

• • • •

• • • •

2-30 2-30 2-30 2-31

Every 600 km (400 mile)

2-32

Every 1 000 km (600 mile)

2-32

• •

Drive chain wear-inspect # Brake System Brake fluid leak (brake hose and pipe)-inspect

24

Every 42 000 km (26 000 mile)

Clutch Clutch operation (play, disengagement, engagement)-inspect Wheels and Tires

Wheel bearing damage-inspect

18

• • • • • •

Air suction system damage-inspect

Tire air pressure-inspect

12

(0.6) (4) (7.5) (12) (15) (20) (24)

Engine vacuum synchronization-inspect Idle speed-inspect

6

See Page

• •

• •

2-34

• • • • • • •

2-35

2-35


PERIODIC MAINTENANCE 2-7 Periodic Maintenance Chart (Other than United States, Canada Model) FREQUENCY Whichever comes first

* ODOMETER READING × 1 000 km (× 1 000 mile) 1

INSPECTION Brake hose and pipe damage-inspect

Every year

Brake pad wear-inspect # Brake hose installation condition-inspect Brake fluid level-inspect Brake operation (effectiveness, play, no drag)-inspect

year 6 months year

Brake light switch operation-inspect Suspensions Front forks/rear shock absorber operation (damping and smooth stroke)-inspect Front forks/rear shock absorber oil leak-inspect

6

12

18

24

30

36

See Page

(0.6) (4) (7.5) (12) (15) (20) (24)

• • • • • • • • • • •

year

Rocker arm operation-inspect Tie-Rods operation-inspect

• • • • • •

• • • • • •

• • • • • •

• • • • • •

• • • • • •

2-35 2-36 2-35 2-36 2-35 2-36

2-37

• • •

• • •

• • •

2-38

• •

2-39

• • • • •

• • • • •

• • • • •

2-40

• •

• •

• •

2-47

2-38 2-38

Steering System Steering play-inspect Steering stem bearings-lubricate

year

2 years

2-40

Electrical System Spark plug condition – inspect Lights and switches operation-inspect

year

Headlight aiming-inspect

year

Side stand switch operation-inspect

year

Engine stop switch operation-inspect

year

2-42 2-44 2-45 2-46

Others Chassis parts-lubricate Bolts and nuts tightness-inspect

year

2-48

*: For higher odometer readings, repeat at the frequency interval established here. #: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.


2-8 PERIODIC MAINTENANCE Periodic Maintenance Chart (Other than United States, Canada Model) Periodic Replacement Parts FREQUENCY Whichever come first

* ODOMETER READING × 1 000 km (× 1 000 mile) 1

CHANGE/REPLACE ITEM Air cleaner element #

Every

Fuel hose

4 years

Coolant

3 years

Radiator hose and O-ring

3 years

Engine oil #

year

Oil filter

year

Brake hose and pipe

4 years

Brake fluid

2 years

Rubber parts of master cylinder and caliper

4 years

Spark plug

12

24

36

48

(0.6) (7.5) (15) (24) (30) Every 18 000 km (12 000 mile)

• •

• •

• •

• • • •

• •

See Page

2-50 2-50 2-52 2-54

• • • • • •

2-55 2-55 2-56 2-56 2-58, 2-59 2-62

*: For higher odometer readings, repeat at the frequency interval established here. #: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.


PERIODIC MAINTENANCE 2-9 Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease to the threads. L: Apply a non-permanent locking agent to the threads. MO: Apply molybdenum disulfide grease oil solution. R: Replacement Parts S: Follow the specified tightening sequence. SI: Apply silicone grease. SS: Apply silicone sealant. Fastener Fuel System Air Cleaner Housing Clamp Bolts Air Cleaner Housing Mounting Bolt Air Inlet Duct Mounting Bolts Canister Bracket Mounting Bolt (M6) Canister Bracket Mounting Bolt (M5) Camshaft Position Sensor Bolt Crankshaft Sensor Bolts Delivery Pipe Mounting Screws (Nozzle Assy) Delivery Pipe Mounting Screws (Throttle Body) Exhaust Butterfly Valve Actuator Mounting Bolts Exhaust Butterfly Valve Actuator Pulley Bolt Fuel Hose Mounting Screw Fuel Pump Bolts Nozzle Assy Mounting Bolts Separator Bracket Mounting Bolt Throttle Body Assembly Holder Clamp Bolts Throttle Body Holder Bolts Throttle Cable Holder Bolt Vehicle-down Sensor Bolts Water Temperature Sensor Cooling System Coolant By-pass Fitting Bolt Coolant Drain Bolt (Cylinder) Coolant Drain Bolt (Water Pump) Coolant Reserve Tank Mounting Bolts Impeller Bolt Oil Cooler Mounting Bolts Radiator Bracket Mounting Bolt Radiator Lower Bolt Radiator Upper Bolt Thermostat Housing Cover Bolts Water Hose Clamp Screws

N·m

Torque kgf·m

ft·lb

2.0 6.9 6.9 6.9 0.4 12 5.9 3.4 3.4 6.9 4.9 4.9 9.8 6.9 0.8 3.0 12 3.9 5.9 25

0.20 0.70 0.70 0.70 0.04 1.2 0.60 0.35 0.35 0.70 0.50 0.50 1.0 0.70 0.08 0.30 1.2 0.40 0.60 2.5

17 in·lb 61 in·lb 61 in·lb 61 in·lb 4 in·lb 104 in·lb 52 in·lb 30 in·lb 30 in·lb 61 in·lb 43 in·lb 43 in·lb 87 in·lb 61 in·lb 7 in·lb 27 in·lb 104 in·lb 35 in·lb 52 in·lb 18

8.8 9.8 8.8 6.9 9.8 12 6.9 6.9 12 5.9 2.0

0.90 1.0 0.90 0.70 1.0 1.2 0.70 0.70 1.2 0.60 0.20

78 in·lb 87 in·lb 78 in·lb 61 in·lb 87 in·lb 104 in·lb 61 in·lb 61 in·lb 104 in·lb 52 in·lb 17 in·lb

Remarks

L

L, S

L

SS L

S


2-10 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Water Hose Fitting Bolts Water Pump Cover Bolts Water Temperature Sensor Engine Top End Air Suction Valve Cover Bolts Camshaft Cap Bolts Camshaft Chain Tensioner Cap Bolt Camshaft Chain Tensioner Mounting Bolts Cam Sprocket Mounting Bolts Coolant Drain Bolt (Cylinder) Crankshaft Sensor Cover Bolts Cylinder Head Bolts (M9) Cylinder Head Bolts (M6) Cylinder Head Cover Bolts Exhaust Butterfly Valve Actuator Mounting Bolts Exhaust Butterfly Valve Actuator Pulley Bolt Exhaust Butterfly Valve Cable Adjuster Locknuts Exhaust Butterfly Valve Cable Locknuts Exhaust Butterfly Valve Cover Bolt Exhaust Pipe Clamp Bolt Exhaust Pipe Manifold Holder Nuts Exhaust Pipe Mounting Bolt Front Camshaft Chain Guide Bolt (Lower) Front Camshaft Chain Guide Bolt (Upper) Muffler Body Clamp Bolt Muffler Body Mounting Bolts Muffler Rear Cover Bolts Muffler Upper Cover Bolts Rear Camshaft Chain Guide Bolt Spark Plugs Throttle Body Assy Holder Clamp Bolts Throttle Body Holder Bolts Water Passage Plug (Left) Water Passage Plugs (Upper) Clutch Clutch Cover Bolt (M6, L = 50 mm) Clutch Cover Bolt (M6, L = 40 mm) Clutch Cover Bolts (M6, L = 30 mm) Clutch Hub Nut Clutch Lever Clamp Bolts Clutch Spring Bolts Oil Filler Plug Sub Clutch Hub Bolts

N·m 12 12 25

Torque kgf·m 1.2 1.2 2.5

ft·lb 104 in·lb 104 in·lb 18

12 12 20 11 15 9.8 9.8 39 12 9.8 6.9 4.9 6.9 6.9 6.9 17 17 25 12 25 17 25 6.9 6.9 25 13 2.9 12 20 20

1.2 1.2 2.0 1.1 1.5 1.0 1.0 4.0 1.2 1.0 0.70 0.50 0.70 0.70 0.70 1.7 1.7 2.5 1.2 2.5 1.7 2.5 0.70 0.70 2.5 1.3 0.30 1.2 2.0 2.0

104 in·lb 104 in·lb 15 97 in·lb 11 87 in·lb 87 in·lb 29 104 in·lb 87 in·lb 61 in·lb 43 in·lb 61 in·lb 61 in·lb 61 in·lb 12 12 18 104 in·lb 18 12 18 61 in·lb 61 in·lb 18 113 in·lb 26 in·lb 104 in·lb 15 15

12 12 12 135 7.8 8.8 1.5 25

1.2 1.2 1.2 14 0.80 0.90 0.15 2.5

104 in·lb 104 in·lb 104 in·lb 100 69 in·lb 78 in·lb 13 in·lb 18

Remarks

L SS L S

L L (1) MO, S S

L L L

L (1) L (1) R S

L


PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Fastener Engine Lubrication System Coolant Drain Bolt (Water Pump) Engine Oil Drain Bolt Impeller Bolt Oil Cooler Mounting Bolts Oil Filter Oil Filter Mounting Bolt Oil Jet Nozzle Bolts Oil Pan Bolts Oil Pan Clamp Bolt Oil Passage Plug (Left Side) Oil Passage Plug (Right Side) Oil Pipe Bolts Oil Pressure Relief Valve Oil Pressure Switch Oil Pressure Switch Terminal Bolt Water Hose Clamp Screws Water Pump Cover Bolts Engine Removal/Installation Adjusting Collar Locknut Lower Engine Mounting Bolt Lower Engine Mounting Nut Middle Engine Mounting Bolt Middle Engine Mounting Nut Upper Engine Mounting Bolts Crankshaft/Transmission Breather Plate Bolts Connecting Rod Big End Nuts Crankcase Bolts (M8) Crankcase Bolts (M7, L = 38 mm) Crankcase Bolt (M7, L = 70 mm) Crankcase Bolts (M6, L = 65 mm) Crankcase Bolts (M6, L = 50 mm) Crankcase Bolts (M6, L = 38 mm) Crankcase Bolt (M6, L = 95 mm) Crankcase Bolt (M6, L = 85 mm) Crankcase Bolt (M6, L = 35 mm) Neutral Switch Gear Positioning Lever Bolt Harness Clamp Bolt Oil Passage Plug (Left Side) Oil Passage Plug (Right Side) Oil Pressure Switch

N·m

Torque kgf·m

ft·lb

Remarks

8.8 29 9.8 12 31 25 6.9 9.8 9.8 20 15 12 15 15 1.5 2.0 12

0.90 3.0 1.0 1.2 3.2 2.5 0.70 1.0 1.0 2.0 1.5 1.2 1.5 1.5 0.15 0.20 1.2

78 in·lb 22 87 in·lb 104 in·lb 23 18 61 in·lb 87 in·lb 87 in·lb 15 11 104 in·lb 11 11 13 in·lb 17 in·lb 104 in·lb

49 10 44 10 44 44

5.0 1.0 4.5 1.0 4.5 4.5

36 87 in·lb 33 87 in·lb 33 33

S S S S S S

5.9 see the text 31 27 20 12 12 12 12 12 12 15 12 8.8 20 15 15

0.60 ← 3.2 2.8 2.0 1.2 1.2 1.2 1.2 1.2 1.2 1.5 1.2 0.90 2.0 1.5 1.5

52 in·lb ← 23 20 14 104 in·lb 104 in·lb 104 in·lb 104 in·lb 104 in·lb 104 in·lb 11 104 in·lb 78 in·lb 15 11 11

L ← MO, S S S S S S S S S L

S EO, R L L

L

L SS

L

L L SS


2-12 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Oil Pressure Switch Terminal Bolt Plate Screws Shift Drum Bearing Holder Bolts Shift Drum Cam Holder Bolt Shift Lever Bolt Shift Pedal Mounting Bolt Shift Shaft Return Spring Pin Tie-Rod Locknuts Wheels/Tires Front Axle Clamp Bolts Front Axle Nut Rear Axle Nut Final Drive Engine Sprocket Cover Bolts Engine Sprocket Nut Rear Axle Nut Rear Sprocket Nuts Chain Cover Bolts Engine Sprocket Cover Socket Bolt Brakes Bleed Valves Brake Hose Banjo Bolts Brake Lever Pivot Bolt Brake Lever Pivot Bolt Locknut Brake Pedal Bolt Front Brake Light Switch Screw Front Brake Reservoir Cap Stopper Screw Front Brake Disc Mounting Bolts Front Brake Pad Pins Front Caliper Assembly Bolts Front Caliper Mounting Bolts Front Master Cylinder Bleed Valve Front Master Cylinder Clamp Bolts Rear Brake Disc Mounting Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut Suspension Front Axle Clamp Bolts Front Fork Bottom Allen Bolts Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Front Fork Top Plugs

N·m 1.5 5.9 12 12 6.9 25 28 6.9

Torque kgf·m 0.15 0.60 1.2 1.2 0.70 2.5 2.9 0.70

ft·lb 13 in·lb 52 in·lb 104 in·lb 104 in·lb 61 in·lb 18 21 61 in·lb

20 127 127

2.0 13 13

15 94 94

6.9 125 127 59 4.9 15

0.70 13 13 6.0 0.50 1.5

61 in·lb 92 94 43 43 in·lb 11

7.8 34 1.0 5.9 8.8 1.2 1.2 27 15 22 34 5.9 8.8 27 25 25 18

0.80 3.5 0.10 0.60 0.90 0.12 0.12 2.8 1.5 2.2 3.5 0.60 0.90 2.8 2.5 2.5 1.8

69 in·lb 25 9 in·lb 52 in·lb 78 10 in·lb 10 in·lb 20 11 16 25 52 in·lb 78 in·lb 20 18 18 13

20 35 25 20 35

2.0 3.5 2.5 2.0 3.5

15 26 18 15 26

Remarks

L L L

L

AL

MO

L

SI

L

S L

AL L AL


PERIODIC MAINTENANCE 2-13 Torque and Locking Agent Fastener Piston Rod Nuts Rear Shock Absorber Bracket Nut Rear Shock Absorber Nut (Lower) Rear Shock Absorber Nut (Upper) Swingarm Pivot Adjusting Collar Swingarm Pivot Adjusting Collar Locknut Swingarm Pivot Shaft Nut Tie-Rod Nuts Uni-Trak Rocker Arm Nut Steering Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Handlebar Bolts Handlebar Position Bolts Steering Stem Head Nut Steering Stem Nut Switch Housing Screws Frame Air Inlet Duct Mounting Bolts Front Fender Mounting Bolts Front Footpeg Bracket Bolts Rear Footpeg Bracket Bolts Rear Frame Bolts Side Stand Bolt Side Stand Bracket Bolts Side Stand Switch Bolt Side Stand Switch Bracket Bolt Windshield Mounting Bolts Electrical System Alternator Cover Bolts Alternator Lead Holding Plate Bolts Alternator Rotor Bolt Camshaft Position Sensor Bolt Crankshaft Sensor Bolts Crankshaft Sensor Cover Bolts Engine Ground Lead Terminal Bolt Front Brake Light Switch Screw Front Turn Signal Light Lens Screws Front Turn Signal Light Mounting Screws Headlight Mounting Screws Licence Light Assembly Screws Licence Light Mounting Screws Meter Mounting Screws

N·m 20 59 34 34 20 98 108 59 34

Torque kgf·m 2.0 6.0 3.5 3.5 2.0 10 11 6.0 3.5

ft·lb 15 43 25 25 15 72 81 43 25

Remarks

25 20 25 9.8 78 20 3.5

2.5 2.0 2.5 1.0 8.0 2.0 0.36

18 15 18 87 in·lb 58 15 31 in·lb

AL

6.9 3.9 25 25 59 44 49 8.8 3.9 0.4

0.70 0.40 2.5 2.5 6.0 4.5 5.0 0.90 0.40 0.04

61 35 in·lb 18 18 44 32 36 78 in·lb 35 in·lb 4 in·lb

L

12 6.9 110 12 5.9 9.8 9.8 1.2 1.0 1.2 1.2 0.9 1.2 1.2

1.2 0.70 11 1.2 0.60 1.0 1.0 0.12 0.10 0.12 0.12 0.09 0.12 0.12

104 in·lb 61 in·lb 81 104 in·lb 52 in·lb 87 in·lb 87 in·lb 10 in·lb 9 in·lb 10 in·lb 10 in·lb 8 in·lb 10 in·lb 10 in·lb

L

L (2) G L L L

L

L (1)


2-14 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Neutral Switch Rear Turn Signal Light Lens Screws Rear Turn Signal Light Mounting Screws Regulator/Rectifier Bolts Side Stand Switch Bolt Side Stand Switch Bracket Bolt Spark Plugs Speed Sensor Bolt Stator Coil Bolts Starter Motor Cable Terminal Bolt Starter Motor Clutch Bolts Starter Motor Mounting Bolts Starter Relay Cable Terminal Bolts Switch Housing Screws Tail/Brake Light Mounting Bolts Timing Rotor Bolt Vehicle-down Sensor Bolts Water Temperature Sensor

N·m 15 1.0 1.2 6.9 8.8 3.9 13 12 12 2.7 34 11 3.9 3.5 4.0 45 5.9 25

Torque kgf·m 1.5 0.10 0.12 0.70 0.90 0.40 1.3 1.2 1.2 0.28 3.5 1.1 0.40 0.36 0.40 4.5 0.60 2.5

ft·lb 11 9 in·lb 10 in·lb 61 in·lb 78 in·lb 35 in·lb 113 in·lb 104 in·lb 104 in·lb 24 in·lb 25 97 in·lb 35 in·lb 31 in·lb 35 in·lb 33 52 in·lb 18

Remarks L

L L

L L

SS

The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners Threads Diameter (mm) 5 6 8 10 12 14 16 18 20

N·m 3.4 ∼ 4.9 5.9 ∼ 7.8 14 ∼ 19 25 ∼ 34 44 ∼ 61 73 ∼ 98 115 ∼ 155 165 ∼ 225 225 ∼ 325

Torque kgf·m 0.35 ∼ 0.50 0.60 ∼ 0.80 1.4 ∼ 1.9 2.6 ∼ 3.5 4.5 ∼ 6.2 7.4 ∼ 10.0 11.5 ∼ 16.0 17.0 ∼ 23.0 23.0 ∼ 33.0

ft·lb 30 ∼ 43 in·lb 52 ∼ 69 in·lb 10 ∼ 13.5 19 ∼ 25 33 ∼ 45 54 ∼ 72 83 ∼ 115 125 ∼ 165 165 ∼ 240


PERIODIC MAINTENANCE 2-15 Specifications Item Fuel System (DFI) Throttle Grip Free Play Idle Speed Throttle Body Vacuum Air Cleaner Element Cooling System Coolant: Type (Recommended) Color Mixed Ratio Freezing Point Total Amount Engine Top End Valve Clearance: Exhaust Inlet Clutch Clutch Lever Free Play Engine Lubrication System Engine Oil: Type Viscosity Capacity

Level Wheels/Tires Tread Depth: Front

Rear

Air Pressure (when Cold): Front Rear

Standard

Service Limit

2 ∼ 3 mm (0.08 ∼ 0.12 in.) 1 300 ±50 r/min (rpm) 27.3 ±1.3 kPa (205 ±10 mmHg) at idle speed Viscous paper element

– – – –

Permanent type antifreeze Green Soft water 50%, coolant 50% –35°C (–31°F) 2.6 L (2.7 US qt)

– – –

0.22 ∼ 0.31 mm (0.0087 ∼ 0.0122 in.) 0.11 ∼ 0.19 mm (0.0043 ∼ 0.0075 in.)

– – – – – –

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

– – –

API SE, SF or SG API SH or SJ with JASO MA SAE 10W-40 3.4 L (3.6 US qt) (when filter is not removed) 3.6 L (3.8 US qt) (when filter is removed) 4.0 L (4.2 US qt) (when engine is completely dry) Between upper and lower level lines (Wait 2 ∼ 3 minutes after idling or running)

– – –

BRIDGESTONE: 3.6 mm (0.14 in.)

BRIDGESTONE: 5.8 mm (0.23 in.)

Up to 180 kg (397 lb) load: 250 kPa (2.5 kgf/cm², 36 psi) Up to 180 kg (397 lb) load: 290 kPa (2.9 kgf/cm², 42 psi)

– – – –

– – – – –

– – – –

– – – –

– – – – –

– – – –

– – – –

– – – – –

1 mm (0.04 in.), (AT, CH, DE) 1.6 mm (0.06 in.) Up to 130 km/h (80 mph): 2 mm (0.08 in.), Over 130 km/h (80 mph): 3 mm (0.12 in.) – – – – – –


2-16 PERIODIC MAINTENANCE Specifications Item Final Drive Drive Chain Slack Drive Chain Wear (20-link Length) Standard Chain: Make Type Link Brakes Brake Fluid: Grade Brake Pad Lining Thickness: Front Rear Brake Light Timing: Front Rear Electrical System Spark Plug Gap AT: Austria CH: Switzerland DE: Germany

Standard 30 ∼ 35 mm (1.2 ∼ 1.4 in.) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)

Service Limit – – – 323 mm (12.7 in.)

ENUMA EK520MVXL 110 links

– – – – – – – – –

DOT4

– – –

4.0 mm (0.16 in.) 5.0 mm (0.20 in.)

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

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

– – – – – –

0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)

– – –


PERIODIC MAINTENANCE 2-17 Special Tools Inside Circlip Pliers: 57001-143

Pilot Screw Adjuster, C: 57001-1292

Steering Stem Nut Wrench: 57001-1100

Extension Tube: 57001-1578

Jack: 57001-1238

Jack Attachment: 57001-1608

Oil Filter Wrench: 57001-1249


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2005 Kawasaki ZX636-C1Service Repair Manual  
2005 Kawasaki ZX636-C1Service Repair Manual  
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