
1. Air Intake Solenoid Valve (Other than US, CA and CAL Models)
2. Engine Stop Switch
3. Starter Button
4. Air Switching Valve
5. Stick Coil #1, #2, #3, #4
6. Spark Plugs
7. Intake Air Temperature Sensor
8. Crankshaft Sensor
9. Secondary Fuel Injector #1
10. Secondary Fuel Injector #2
11. Secondary Fuel Injector #3
12. Secondary Fuel Injector #4
13. Primary Fuel Injector #1
14. Primary Fuel Injector #2
15. Primary Fuel Injector #3
16. Primary Fuel Injector #4
17. Idle Speed Control Valve Actuator
18. Subthrottle Valve Actuator
19. Main Throttle Sensor
20. Subthrottle Sensor
21. Water Temperature Sensor
22. Intake Air Pressure Sensor #2
23. Intake Air Pressure Sensor #1
24. Gear Position Switch
25. Oxygen Sensor (Equipped Models)
26. Joint Connector E
27. ECU
28. Exhaust Butterfly Valve Actuator
29. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector
30. Engine Ground
31. Battery
32. Starter Relay
33. Main Fuse 30 A
34. ECU Fuse 15 A
35. Frame Ground 2
36. Frame Ground 3
37. Frame Ground 1
38. Fuel Pump
39. KIBS Hydraulic Unit
40. Relay Box
41. Fuel Pump Relay
42. ECU Main Relay
43. Fuse Box 1
44. Ignition Fuse 15 A
45. Oil Pressure/Water Temperature/FI/Immobilizer Warning Indicator Light
46. Meter Unit
47. Joint Connector F
48. Vehicle-down Sensor
49. Immobilizer Antenna (Equipped Models)
50. Immobilizer Amplifier (Equipped Models)
51. Ignition Switch
52. Joint Connector A
53. Joint Connector C
54. Joint Connector D
55. Front Wheel Rotation Sensor
56. Rear Wheel Rotation Sensor
Color Codes:
BK: Black GY: Gray PU: Purple
BL: Blue LB: Light Blue R: Red
BR: Brown LG: Light Green V: Violet
CH: Chocolate O: Orange W: White
DG: Dark Green P: Pink Y: Yellow
G: Green
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DFI System Wiring Diagram
Terminal Numbers of ECU ConnectorsOil Cooler Installation
Replace the O-ring [A] with a new one.
Apply grease to the new O-ring.
Install the water hoses and hose clamps [A] as shown in
the figure.
Water Hose (About 300 mm, 11.8 in.) [B]
Water Hose (About 130 mm, 5.1 in.) [C]
Yellow Paint [D]
Tighten:
Torque - Water Hose Clamp S ...
Transmission Assy Installation
Assemble the transmission assy (see Transmission Assy
Assembly).
Be sure that the dowel pins are in position.
Install the transmission assy on the crankcase.
Tighten:
Torque - Transmission Case Bolts: 20 N·m (2.0 kgf·m, 15
ft·lb)
Install:
Shift Shaft (see External Shift Mechani ...
Crankshaft Removal
Split the crankcase (see Crankcase Splitting).
Remove:
Connecting Rod Big End Nuts [A]
Connecting Rod Big End Caps [B]
NOTE
Mark and record the locations of the connecting rods
and their big end caps so that they can be reassembled
in their original positions.
Remove the crank ...