Service Limit: 32.6 mm (1.28 in.)

Clutch Housing Finger Inspection

• Visually inspect the clutch housing fingers [A] where the friction plate tangs [B] hit them.

If they are badly worn or if there are groove cuts where the tangs hit, replace the housing. Also, replace the friction plates if their tangs are damaged.

 

Clutch Housing Spline Inspection

• Visually inspect where the teeth [A] on the steel plates wear against the clutch hub splines [B].

If there are notches worn into the splines, replace the clutch hub. Also, replace the steel plates if their teeth are damaged.

 

 

 

 

Engine Lubrication System

Table of Contents

Exploded View........................................................................................................................ 7-2

Engine Oil Flow Chart............................................................................................................. 7-4

Specifications......................................................................................................................... 7-6

Special Tools and Sealant...................................................................................................... 7-7

Engine Oil and Oil Filter.......................................................................................................... 7-8

Oil Level Inspection........................................................................................................... 7-8

Engine Oil Change............................................................................................................ 7-8

Oil Filter Replacement...................................................................................................... 7-8

Oil Pan.................................................................................................................................... 7-9

Oil Pan Removal............................................................................................................... 7-9

Oil Pan Installation............................................................................................................ 7-10

Oil Pressure Relief Valve........................................................................................................ 7-11

Oil Pressure Relief Valve Removal................................................................................... 7-11

Oil Pressure Relief Valve Installation................................................................................ 7-11

Oil Pressure Relief Valve Inspection................................................................................. 7-11

Oil Pump................................................................................................................................. 7-12

Oil Pump Removal............................................................................................................ 7-12

Oil Pump Installation......................................................................................................... 7-13

Oil Pressure Measurement..................................................................................................... 7-14

Oil Pressure Measurement............................................................................................... 7-14

Oil Pressure Switch................................................................................................................ 7-15

Oil Pressure Switch Removal........................................................................................... 7-15

Oil Pressure Switch Installation........................................................................................ 7-15

 

 

Exploded View

 

Exploded View

No.	Fastener	Torque	Remarks
N·m	kgf·m	ft·lb
	Engine Oil Drain Bolt		3.0
	Filter Plate Bolts	9.8	1.0	87 in·lb	L
	Oil Filter	17.2	1.75		EO, R
	Holder Mounting Bolt		2.5		L
	Oil Pan Bolts		1.2	106 in·lb
	Oil Pipe Plate Bolt	9.8	1.0	87 in·lb	L
	Oil Pressure Relief Valve		1.5		L
	Oil Pressure Switch		1.5		SS
	Oil Pump Cover Bolts	9.8	1.0	87 in·lb	L
	Oil Pump Sprocket Bolt		1.2	106 in·lb	L, Lh
	Oil Passage Plug		2.0		L
	Lower Fairing Bracket Bolts		1.2	106 in·lb	L
	Oil Pump Chain Guide Bolts		1.2	106 in·lb	L
	Oil Plate Bolts	9.8	1.0	87 in·lb	L

EO: Apply engine oil. G: Apply grease.

L: Apply a non-permanent locking agent. Lh: Left-hand threads

MO: Apply molybdenum disulfide oil solution.

(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10: 1) R: Replacement Parts

SS: Apply silicone sealant.

 

 

Engine Oil Flow Chart

 

Engine Oil Flow Chart

 

Specifications

Item	Standard
Engine Oil
Type	API SE, SF or SG
	API SH, SJ or SL with JASO MA
Viscosity	SAE 10W-40
Capacity:	1.7 L (1.8 US gt) (when filter is not removed)
	1.9 L (2.0 US gt) (when filter is removed)
	2.4 L (2.5 US gt) (when engine is completely dry)
Level	Between upper and lower level lines
Oil Pressure Measurement Oil Pressure	216 ~ 294 kPa (2.2 ~ 3.0 kgf/cm², 31 ~ 43 psi) at 4 000 r/min (rpm), Oil Temperature 90°C (194°F)

 

Special Tools and Sealant

Oil Pressure Gauge, 10 kgf/cm²: 57001-164

Oil Filter Wrench: 57001-1249

Oil Pressure Gauge Adapter, PT3/8: 57001-1233

Kawasaki Bond (Silicone Sealant): 56019-120

 

Engine Oil and Oil Filter

WARNING

Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury.

Oil Level Inspection

• Check that the engine oil level is between the upper [A] and lower [B] levels in the gauge.

NOTE

○Situate the motorcycle so that it is perpendicular to the

ground.

○If the motorcycle has just been used, wait several min-

utes for all the oil to drain down.

○If the oil has just been changed, start the engine and

run it for several minutes at idle speed. This fills the oil

filter with oil. Stop the engine, then wait several minutes until the oil settles.

CAUTION

Racing the engine before the oil reaches every part can cause engine seizure. If the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not function properly, the oil pressure warning light will light. If this light stays on when the engine is running above idle speed, stop the engine immediately and find the cause.

If the oil level is too high, remove the excess oil, using a syring or some other suitable device.

If the oil level is too low, add the correct amount of oil through the oil filter opening. Use the same type and make of oil that is already in the engine.

NOTE

○If the engine oil type and make are unknown, use any

brand of the specified oil to top off the level in preference

to running the engine with the oil level low. Then at your earliest convenience, change the oil completely.

Engine Oil Change

• Refer to the Engine Oil Change in the Periodic Mainte- nance chapter.

Oil Filter Replacement

• Refer to the Oil Filter Replacement in the Periodic Main- tenance chapter.

 

 

Oil Pan

Oil Pan Removal

• Remove:

Engine Oil (Drain, see Engine Oil Change in the Periodic

Maintenance chapter)

Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter)

Muffler Body (see Muffler Body Removal in the Engine Top End chapter)

Oil Pan Bolts [A] Oil Pan [B] Gasket [C] Damper [D]

 

 

• Remove the following from the oil pan as necessary. Filter Plate Bolts [A]

Filter Plate [B] Filter [C]

 

• Remove the following from the lower crankcase half as necessary.

Oil Screen [A]

Oil Pipe Plate Bolt [B] Oil Pipe Plate [C]

Oil Pipes [D]

Oil Pressure Relief Valve [E]

 

 

Oil Pan

Oil Pan Installation

• Apply grease to the O-rings on the oil pipes [A].

• Install the oil pipe plate [B] so that its guide portion [C] fits

the breather pipe [D] as shown.

• Apply a non-permanent locking agent to the oil pipe plate bolt.

Torque - Oil Pipe Plate Bolt [E]: 9.8 N·m (1.0 kgf·m, 87 in·lb)

If the oil pressure relief valve [F] was removed, install it.

○Apply a non-permanent locking agent to the threads [G]

CAUTION

Do not apply too much non-permanent locking agent to the threads. This may block the oil pas- sage.

of the oil pressure relief valve, and tighten it.

Torque - Oil Pressure Relief Valve: 15 N·m (1.5 kgf·m, 11 ft·lb)

• Apply grease to the O-ring [A] on the oil screen [B] and install it on the lower crankcase half as shown.

• Be sure the damper [C] is on the end of the breather pipe

[D].

 

 

• Replace the oil pan gasket with a new one.

• When installing the oil pan, align [A] the damper [B] on

the breather pipe with the hollow [C] on the oil pan.

• Tighten:

Torque - Oil Pan Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)

 

Oil Pressure Relief Valve

Oil Pressure Relief Valve Removal

• Refer to the Oil Pan Removal.

Oil Pressure Relief Valve Installation

• Refer to the Oil Pan Installation.

Oil Pressure Relief Valve Inspection

• Check to see if the valve [A] slides smoothly when push- ing it in with a wooden or other soft rod, and see if it comes

back to its seat by spring [B] pressure.

NOTE

○Inspect the valve in its assembled state. Disassembly

and assembly may change the valve performance.

WARNING

Clean the oil pressure relief valve in a well -ventilated area, and take care that there is no spark or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvent.

If any rough spots are found during above inspection, wash the valve clean with a high-flash point solvent and blow out any foreign particles that may be in the valve with compressed air.

If cleaning does not solve the problem, replace the oil pressure relief valve as an assembly. The oil pressure relief valve is precision made with no allowance for re- placement of individual parts.

 

 

Oil Pump

Oil Pump Removal

• Drain:

Engine Oil (see Engine Oil Change in the Periodic Main-

tenance chapter)

• Remove:

Clutch (see Clutch Removal in the Clutch chapter)

Oil Pump Cover Bolts [A] Oil Pump Cover [B]

 

 

• Remove:

Inner Rotor [A] for Scavenge Pump

Outer Rotor [B] for Scavenge Pump

 

 

• Remove: Dowel Pin [A]

Pin [B]

Oil Pump Body [C] with Oil Pump Shaft [D] and Pin

 

 

• Remove:

Inner Rotor [A] for Feed Pump

Outer Rotor [B] for Feed Pump

 

 

Oil Pump

Oil Pump Installation

• Apply molybdenum disulfide grease to the portion [A] of the oil pump shaft as shown.

• Install:

Outer Rotor [B] for Feed Pump

Inner Rotor [C] for Feed Pump Oil Pump Shaft [D] and Pin [E] Dowel Pin [F]

Oil Pump Body [G]

Pin [H] and Inner Rotor [I] for Scavenge Pump Outer Rotor [J] for Scavenge Pump

Oil Pump Cover [K]

NOTE

○Thescavenge pump rotors are wider than the feed

pump rotors.

• Apply a non-permanent locking agent to the oil pump cover bolts and tighten them.

Torque - Oil Pump Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

 

Oil Pressure Measurement

Oil Pressure Measurement

• Remove the right lower fairing (see Lower Fairing Re- moval in the Frame chapter).

• Remove the oil passage plug, and attach the adapter [A]

and gauge [B] to the plug hole.

Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, PT3/8: 57001

-1233

• Start the engine and warm up the engine.

• Run the engine at the specified speed, and read the oil

pressure gauge.

If the oil pressure is much lower than the standard, check the oil pump, relief valve, and/or crankshaft bearing insert wear immediately.

If the reading is much higher than the standard, check the oil passages for clogging.

Oil Pressure

Standard: 216 ~ 294 kPa (2.2 ~ 3.0 kgf/cm², 31 ~ 43 psi) at 4 000 r/min (rpm), oil temperature. 90°C (194°F)

• Stop the engine.

WARNING

Take care against burns form hot engine oil that will drain through the oil passage when the gauge adapter is removed.

• Remove the oil pressure gauge and adapter.

 

• Apply a non-permanent locking agent to the oil passage plug, and install it.

Torque - Oil Passage Plug: 20 N·m (2.0 kgf·m, 15 ft·lb)

 

Oil Pressure Switch

Oil Pressure Switch Removal

• Remove:

Engine Oil (Drain, see Engine Oil Change in the Periodic

Maintenance chapter)

Right Lower Fairing (see Lower Fairing Removal in the Frame chapter)

Switch Cover [A] Switch Terminal Bolt [B] Oil Pressure Switch [C]

 

Oil Pressure Switch Installation

• Apply silicone sealant to the threads of the oil pressure switch and tighten it.