Stick Coils 1 2 3 4 Service Code 51 52 53 54
Stick Coil 1 Ignition Stick Coil 2 Ignition Stick Coil 3 Ignition Stick Coil 4 Ignition Coil Service Code 51 Coil Service Code 52 Coil Service Code 53 Coil Service Code 54 Never drop the stick coils, especially on a hard surface. Such a shock to the stick coil can damage it. See the Ignition System section in the Electrical System chapter. OBe sure the battery is fully charged. Turn the ignition switch OFF. Remove the ECU see this chapter . Do not disconnect the ECU connector. Connect a digital...
Periodic Maintenance Procedures Mef
Clean the spark plug, preferably in a sandblasting device, and then clean off any abrasive particles. The plug may also be cleaned using a high-flash point solvent and a wire brush or other suitable tool. If the spark plug center electrode A and or side electrode B are corrected or damaged, or if the insulator C is cracked, replace the plug. Use the standard spark plug or its equivalent. Measure the gaps D with a wire-type thickness gauge. If the gap is incorrect, carefully bend the side...
Note Dfv
OThe output voltage changes according to the local atmospheric pressure. Turn the ignition switch OFF. If the output voltage is within the usable range, check the ECU for its ground, and power supply see this chapter . If the output voltage is out of the standard, remove the seat cover and check the wiring. And if the output voltage is 4.8 V, the ECU is normal. If the wiring is good, check the sensor for various vacuum. If the output voltage for various vacuum is normal, check the ECU for its...
Note Sjk
OThe output voltage changes according to the local atmospheric pressure. Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Inlet Air Pressure Sensor Output Voltage Connections to ECU Meter Y BL lead terminal 17 Meter - BR BK lead terminal 14 3.74 4.26 V DC at the standard atmospheric pressure 101.32 kPa, 76 cmHg abs. Turn the ignition switch OFF. If the output voltage is within the usable range, check the ECU for its ground, and power supply...
Periodic Replacement Parts
ODOMETER READING km x 1000 mile x 1000 Rubber parts of master cylinder and caliper Service more frequently when operating in severe conditions dusty, wet, muddy, high speed or frequent starting stopping. Service more frequently when operating in severe conditions dusty, wet, muddy, high speed or frequent starting stopping. Throttle control system inspection Inspection of throttle grip play. The following tables list the tightening torque for the major fasteners requiring use of a non...
Resistance Inspection
Turn the ignition switch OFF. Disconnect the main throttle sensor connector. Connect a digital meter A to the main throttle sensor connector B . Measure the main throttle sensor resistance. Main Throttle Sensor Resistance Connections BL lead C Standard 4 6kQ if the reading is out of the range, replace the throttle body assy. If the reading is within the range, but the problem still exists, replace the ECU see this chapter . I. Main Throttle Sensor m. Throttle Body Assy Connector I. Main...
Caution
Do not pry the connector part of the coil while removing the coil. Remove the stick coil sub harness connector A from the Stick Coil Connector 4 B disconnect Stick Coil 4 C Stick Coil Connector 3 D disconnect gt Pull the main harness upward and remove the stick coil 3. 1 Remove the spark plugs using the 16 mm plug wrench A . Owner's Tool -Spark Plug Wrench, 16 mm 92110-1146
Poor Running or No Power at High Speed
Spark plug dirty, broken or maladjusted Clean spark plug and adjust plug gap see chapter 2 . Inspect stick coil see chapter 16 . Spark plug cap shorted or not in good contact Reinstall or inspect stick coil see chapter 16 . Replace it with the correct plug see chapter 16 . Air cleaner clogged, poorly sealed or missing Clean element or inspect sealing see chapter 3 . Change fuel. Inspect and clean fuel system see chapter 3 . Fuel pump operates intermittently and often ECU fuse blows. Pump...
Spark Plug Inspection
Fuel Tank see Fuel System DFI chapter Unscrew the thermostat bracket bolt A . Water Temperature Sensor Connector B Left Switch Housing Connector C OIf removing the spark plug 2 or 3. Pull out the stick coil 1 B . Take out the camshaft position sensor connector C from the bracket. Pull out the stick coil 2 D .
Periodic Maintenance Procedures Prj
If a special lubricant is not available, a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. If the chain appears especially dirty, clean it before lubrication. The O-rings between the side plates seal in the lubricant between the pin and the bushing. To avoid damaging the O-rings and resultant loss of lubricant, observe the following rules. Use only kerosene or diesel oil for cleaning an O -ring drive chain. Any...
Inlet Air Pressure Sensor Service Code 12 Pv 55 86 cmHg
Vv Inlet Air Pressure Sensor Output Voltage V Digital Meter Reading Pv Throttle Vacuum Pressure absolute Ps Standard Atmospheric Pressure absolute ST Standard of Sensor Output Voltage v UR Usable Range of Sensor Output Voltage v UR Usable Range of Sensor Output Voltage v
Basic Torque for General Fasteners
Throttle body assy holder clamp bolts Cylinder head bolts M10 used bolts Throttle body assy holder clamp bolts Front camshaft chain guide bolt upper Front camshaft chain guide bolt lower Camshaft chain tensioner mounting bolts Rear master cylinder push rod locknut Rear shock absorber nuts upper and lower
Crankshaft Sensor Inspection
OThe crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no signals. Crank the engine and measure the peak voltage of the crankshaft sensor see Electrical System chapter in order to check the sensor. Check the wiring for continuity, using the following diagram. Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the...
Camshaft Position Sensor RemovalInstallation
The camshaft position sensor detects the position of the camshaft, and distinguishes the cylinder. See the Ignition system section in the Electric System chapter. Camshaft Position Sensor Inspection OThe camshaft position sensor has no power source, and when the engine stops, the camshaft position sensor generates no signal. Crank the engine and measure the peak voltage of the camshaft position sensor see Electrical System chapter in order to check the sensor. Check the wiring for continuity,...
How to Read Service Codes
OService codes are shown by a series of long and short blinks of the FI indicator LED light as shown below. ORead 10th digit and unit digit as the FI indicator LED light blinks. OWhen there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order. Then after completing all codes, the display is repeated until the self-diagnosis indicator terminal is open. Olf there is no problem, no code and...
Note Qli
OBe sure the battery is fully charged. O The output voltage changes according to the inlet air temperature. Remove the ECU see this chapter . Do not disconnect the ECU connectors. Connect a digital voltmeter to the ECU connector, using needle adapter set. Special Tool - Needle Adapter Set 57001-1457 Measure the sensor output voltage with the engine stopped and the connector joined. Turn the ignition switch ON. Inlet Air Temperature Sensor Output Voltage Connections to ECU Connector Meter Y lead...
Periodic Maintenance Procedures 1
Install the fuel tank see Fuel System DFI chapter . Start the engine and warm it up thoroughly. Tachometer A If the idle speed is out of the specified range, adjust it. Do not measure the idle speed by the tachometer of the meter unit. While idling the engine, inspect the engine vacuum, using the vacuum gauge B . Engine Vacuum Standard 29.7 1.333 kPa 225 10 mmHg at Idle Speed 1 100 50 r min rpm If any vacuum is not within the specifications, first synchronize the 3 and 4 throttle valves to the...
Table of Contents
Periodic Maintenance Torque and Locking Special Periodic Maintenance Procedures 2-13 Fuel System Idle Speed Air Cleaner Element Cleaning 2-18 Cooling Coolant Engine Top End Air Suction Valve Inspection 2-22 Valve Clearance Inspection 2-22 Clutch Adjust Engine Lubrication Engine Oil Oil Filter Tire Wear Air Pressure Final Drive Chain Slack Inspection 2-27 Drive Chain Slack Adjustment 2-27 Drive Chain Wear Inspection 2-28 Drive Chain Brake Pad Wear Inspection 2-29 Caliper Fluid Seal Damage 2-30...
Backups
OThe ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Output Signal Usable Range or Criteria Main Throttle Sensor Output Voltage 0.2 4.8 V If the main throttle sensor system fails the signal is out of the usable range, wiring short or open , the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the D-J method. Also, the main throttle sensor system and inlet air pressure fails, the...
DFI Servicing Precautions
OWhenever the DFI electrical connections are to be disconnected, first turn off the ignition SW switch , and disconnect the battery - terminal. Do not pull the lead, only the connector. Conversely, make sure that all the DFI electrical connections are firmly reconnected before starting the engine. OWhen disconnecting the vehicle-down sensor connector, raise the lock of the connector. Push the lock of the other connectors. OTo maintain the correct fuel air mixture F A , there must be no inlet...
Note 1
OFor the engine fasteners, check the tightness of them when the engine is cold at room temperature . If there are loose fasteners, retighten them to the specified torque, following the specified tightening sequence. Refer to the appropriate chapter for torque specifications. If torque specifications are not in the appropriate chapter, see the Standard Torque Table in this section. For each fastener, first loosen it by 1 2 turn, then tighten it. If cotter pins are damaged, replace them with new...
Selfdiagnosis Outline
The self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal. The ECU notifies the rider of troubles in DFI system and ignition system by lighting the FI indicator when DFI system and ignition system parts are faulty, and initiates fail-safe function. In case of serious troubles, the ECU stops the injection ignition starter motor operation. Dealer Mode 1 The FI indicator LED light emits service code s to show the problem s which the DFI...
Special Tools 1
Throttle Sensor Setting Adapter 57001-1400 Throttle Sensor Setting Adapter 57001-1538 Throttle Sensor Setting Adapter 57001-1538 Kawasaki Bond Silicone Sealant 56019-120 Throttle Sensor Setting Adapter 57001-1400 Kawasaki Bond Silicone Sealant 56019-120 Fuel Pressure Gauge Adapter 57001-1417 DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. OThis DFI system is designed to be used with a 12 V sealed battery as its power...
Steering
Lift the front wheel off the ground using the jack. Special Tool - Jack 57001-1238 With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop. If the wheel binds or catches before the stop, the steering is too tight. Feel for steering looseness by pushing and pulling the forks. If you feel looseness, the steering is too loose. OThe cables and wiring will have...
Engine Doesnt Start Starting Difficulty
Ignition and engine stop switches not ON Starter lockout switch or neutral switch trouble Inspect and charge see chapter 16 . Starter relays not contacting or operating Inspect the starter relay see chapter 16 . Inspect and replace see chapter 16 . Starter system wiring open or shorted Inspect the wiring see chapter 16 . Inspect and replace see chapter 16 . Inspect and repair or replace see chapter 16 . Inspect and replace see chapter 16 . Starter motor rotating but engine doesn't turn over...
Fuel System DFI 1
DFI Wiring Special DFI Servicing DFI Servicing Troubleshooting the DFI Inquiries to Inquiries to DFI System Troubleshooting DFI System Troubleshooting Self-diagnosis Self-diagnosis Self-diagnosis Self-diagnosis Service Code Clearing Service Code Clearing How to Read Service How to Read Service How to Erase Service How to Erase Service Service Code Service Code Main Throttle Sensor Service Code Main Throttle Sensor Input Voltage Output Voltage Resistance Inlet Air Pressure Sensor Service Code...
Outline
When an abnormality in the system occurs, the FI indicator LED Light Emitting Diode light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU electronic control unit . With the engine stopped and turned in the self-diagnosis mode, the service code A is indicated by the number of times the FI indicator LED light blinks. When due to a malfunction, the FI indicator LED light remains lit, ask the rider about the conditions B...
Engine Lubrication System
Situate the motorcycle so that it is vertical after warming up the engine. Remove the engine oil drain bolt A to drain the oil. OThe oil in the oil filter can be drained by removing the filter Replace the drain bolt gasket B with a new one. Torque - Engine Oil Drain Bolt 20 N m 2.0 kgf m, 14 ftlb Pour in the specified type and amount of oil. 3.1 L 3.3 US qt when filter is not removed 3.3 L 3.5 US qt when filter is removed 3.8 L 4.0 US qt when engine is completely dry
A Warning Jbh
Be sure to bleed the air from the brake line whenever brake lever or pedal action feels soft or spongy after the brake fluid is changed, or whenever a brake line fitting has been loosened for any reason. O The procedure to bleed the front brake line is as follows. Bleeding the rear brake line is the same as for the front brake. Remove the reservoir cap and diaphragm. Fill the reservoir with fresh brake fluid to the upper level lineinthe reservoir. With the reservoir cap off, slowly pump the...
Cooling System
Radiator Hose and Connection Inspection OThe high pressure inside the radiator hose can cause coolant to leak A or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen. Replace the hose if any fraying, cracks B or bulges C are noticed. Check that the hoses are securely connected and clamps are tightened correctly. Torque - Radiator Hose Clamp...
Kawasaki Z750 Reserve Tank
To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still Coolant on tires will make them slippery and can Since coolant is harmful to the human body, do not Place a container under the water pump drain bolt A , then remove the drain bolt. Remove the fuel tank see Fuel System DFI chapter . Remove the radiator cap A in two steps. First turn the cap counterclockwise to the first stop. Then push and turn it further in the same direction and remove the...
Clutch
Pull the clutch lever just enough to take up the free play A . Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully. In either case, adjust it. Clutch Lever Free Play Standard 2 3 mm 0.08 0.12 in. To avoid a serious burn, never touch the engine or exhaust pipe during clutch adjustment. 1 Turn the adjuster A so that 5 of threads are visible.
Periodic Maintenance Procedures Ogm
If any one vacuum measurement is out of the standard measurement after synchronization, adjust the bypass screws A . Front B Special Tool - Pilot Screw Adjuster, C 57001-1292 Adjust the lowest vacuum between 1 and 2 to the highest of 1 and 2. Adjust the lowest vacuum between 3 and 4 to the highest of 3 and 4. Open and close the throttle valves after each measurement and adjust the idle speed as necessary. Inspect the vacuums as before. If all vacuums are within the specification, finish the...
Engine Top End
Remove the air suction valve see Engine Top End chapter . Visually inspect the reeds for cracks, folds, warps, heat damage or other damage. lf there is any doubt as to the condition of the reeds A , replace the air suction valve as an assembly. Check the reed contact areas B of the valve holder for grooves, scratches, any signs of separation from the holder or heat damage. If there is any doubt as to the condition of the reed contact areas, replace the air suction valve as an assembly. If any...
Fuel System DFI
OThe fuel hoses are designed to be used throughout the motorcycle's life without any maintenance, however, if the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak A or the hose to burst. Remove the fuel tank see Fuel System DFI chapter and check the fuel hoses. Replace the hose if any fraying, cracks B or bulges C are noticed. Check that the hoses are routed according to Cable, Wire, and Hose Routing section in the Appendix chapter. Replace the...
Special Tools
Steering Stem Nut Wrench 57001-1100 Spark Plug Wrench Owner's Tool 92110-1146
Technical Information TailBrake Lights Employing LED 1
The emitting color differs according to the materials of semi-conductors. Materials of Semi-Conductor and Emitting Color Materials of Semi-Conductor and Emitting Color P Phosphorus N Nitrogen Al Aluminum Technical Information - KAWASAKI LOW EXHAUST EMISSION SYSTEM Since the emission regulations become more severe, Kawasaki has adopted a type of simplified KAWASAKI LOW EXHAUST EMISSION SYSTEM KLEEN , which have no catalyst protection system, according to each regulation of different countries....
General Specifications
79 kW 107 PS 10 500 r min rpm , MY, AU 80 kW 109 PS 11 000 r min rpm HR 78.2 kW 106 PS 11 000 r min rpm 75 Nm 7.6 kgfm, 55 ftlb 8 200 r min rpm , HR 73 N m 7.4 kgf m, 54 ft lb 8 200 r min rpm FI Fuel Injection KEIHIN TTK34 x 4 Electronically advanced digital igniter From 10 BTDC 1 100 r min rpm to 37 BTDC 5 800 r min rpm 6-speed, constant mesh, return shift 12 V 0.5 3.8 W LED , CA 12 V 0.5 5W LED Specifications are subject to change without notice, and may not apply to every country. AU...