APPENDIX 17-1
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Appendix |
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Table of Contents |
Cable, Wire, and Hose Routing |
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Troubleshooting Guide ........................................................................................................... |
17-48 |
17
17-2 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-3
Cable, Wire, and Hose Routing
1.Attach the clamp on each marking of the clutch cable and throttle cable (accelerator) with the
clutch cable positioned on the upper side. Clamp (Larger Diameter) → Clutch Cable
Clamp (Smaller Diameter) → Throttle Cable (Accelerator)
2.Throttle Cable (Accelerator)
3.Clutch Cable
4.Run the throttle cable (accelerator, left), throttle cable (decelerator, middle) and clutch cable (right) to the inside of the bracket.
5.Hold the throttle cables.
6.Throttle Cable (Decelerator)
7.Run the clutch cable to the outside of the left front fork.
8.Run the brake hose to the inside of the meter unit lead.
17-4 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-5
Cable, Wire, and Hose Routing
1.Be careful not to press the throttle cables by the fuel tank.
2.Run the clutch cable near the engine side.
3.Run the clutch cable under the inlet air temperature sensor lead.
4.Run the secondary injector lead to the inside of the air cleaner housing guide.
5.Hold the inlet air temperature sensor lead.
6.Run the throttle cables between the frame and air cleaner housing.
7.Main Harness
8.Run the main harness as shown in the figure.
9.Run the clutch cable to the inside of the main harness.
10.Run the clutch cable to the outside of the water hose.
17-6 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-7
Cable, Wire, and Hose Routing
1.Fuel Tank Drain Hose
2.Run the fuel tank breather hose as shown in the figure.
3.Run the fuel tank breather hose over the gear position switch lead and fuel pump lead.
4.Run the fuel tank drain hose and fuel tank breather hose over the battery negative (–) cable.
5.Put the breather tank as shown in the figure.
6.Speed Sensor Lead
7.Run the fuel tank drain hose and fuel tank breather hose over the speed sensor lead.
8.Run the speed sensor lead to the hook of the engine sprocket cover.
9.Run the fuel tank drain hose and fuel tank breather hose to the inside of the water hose.
10.Run the gear position switch lead to the inside of the fuel tank drain hose and fuel tank breather hose.
17-8 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-9
Cable, Wire, and Hose Routing
1.Gear Position Switch Lead
2.Sidestand Switch Lead
3.Make sure that each end of the fuel tank drain hose and fuel tank breather hose is out of the lower fairing. Keep each hose end away from the exhaust pipe.
4.Run the fuel tank drain hose and fuel tank breather hose to the inside of the gear position switch lead.
5.Hold the idle adjusting screw cable on the water hose.
17-10 APPENDIX
Cable, Wire, and Hose Routing
1.Run the reserve tank overflow hose under the alternator lead.
2.Run the reserve tank overflow hose into the clamp.
3.Run the reserve tank overflow hose to the inside of the frame.
17-12 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-13
Cable, Wire, and Hose Routing
1.Install the water hose so that white paint mark faces left side.
2.Install the water hose so that white paint mark faces left side.
3.Install the clamp as shown in the figure.
4.Install the outlet hose as shown in the figure.
5.Water Hose
6.Install the clamp as shown in the figure.
7.Install the water hose as shown in the figure.
8.Install the water hose so that white paint mark faces left side.
9.Align the white paint mark of the water hose with the projection on the water pump cover.
10.Install the water pipe as shown in the figure.
11.Install the water hose as shown in the figure.
17-14 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-15
Cable, Wire, and Hose Routing
1.Air Bleeder Hose (Straight Side)
2.Install the air bleeder hose as shown in the figure.
3.Install the water hose as shown in the figure.
4.Install the clamp as shown in the figure.
5.Water Hose
6.Install the clamp as shown in the figure.
7.Run the gear position switch lead to the right side of the outlet hose.
8.Install the inlet hose as shown in the figure.
9.Install the clamp as shown in the figure.
10.Install the breather hose so that white paint mark on the hose faces the rear side of the engine.
11.Install the breather hose as shown in the figure.
12.Install the clamp as shown in the figure.
13.Install the breather hose so that white paint mark on the hose faces the rear side of the engine.
14.Install the water hose to the fitting so that the white paint mark on the hose aligns with the center of the fitting matching surface.
15.Outlet Hose
16.Install the breather hose as shown in the figure.
17.Install the clamp as shown in the figure.
18.Install the water hose to the fitting so that the white paint mark on the hose aligns with the center of the fitting matching surface.
17-16 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-17
Cable, Wire, and Hose Routing
1.Install the engine ground terminal so that it touches to the stopper.
2.Install the engine ground cable as shown in the figure.
3.Rivet (Fix the heat insulation rubber plate to the frame.)
4.Air Cleaner Drain Hose
5.Breather Hose
6.Water Temperature Sensor Lead
7.Throttle Body Assy #2
8.Throttle Body Assy #3
9.Air Bleeder Hose
10.Gear Position Switch Lead Connector
11.Crankshaft Sensor Lead Connector
12.Oxygen Sensor Lead Connector (Equipped Models)
13.Main Harness
14.Hold the main harness and fix the heat insulation rubber plate to the frame.
15.Exhaust Butterfly Valve Cables
16.Frame Ground
17.Speed Sensor Lead Connector
18.Battery Negative (–) Cable
19.Heat Insulation Rubber Plate
APPENDIX 17-19
Cable, Wire, and Hose Routing
1.Run the oil pressure switch lead/crankshaft sensor lead to the inside of the water hose.
2.Run the oil pressure switch lead/crankshaft sensor lead into the clamp.
3.Oil Pressure Switch Lead/Crankshaft Sensor Lead
4.To Heat Insulation Rubber Plate
17-20 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-21
Cable, Wire, and Hose Routing
1.Throttle Cable (Decelerator)
2.Throttle Cable (Accelerator)
3.Throttle Body Assy
4.Hold the alternator lead.
5.Run the gear position switch lead to the right side of the outlet hose.
6.Run the gear position switch lead between the water hoses.
7.Do not slack the gear position sensor lead in this position.
8.Hold the gear position switch lead.
9.Hold the idle adjusting screw cable end.
10.Run the alternator lead under the water hose.
17-22 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-23
Cable, Wire, and Hose Routing
1.Meter Unit Lead
2.Hold the meter unit lead.
3.Left Switch Housing Lead
4.Ignition Switch Lead
5.Immobilizer Antenna Lead (Equipped Models)
6.Left City Light Lead Connector
7.Hold the left city light lead and front left turn signal light lead, bend the clamp faces backward (Do not fit the leads to the bolt head.).
8.Run the main harness to the front of the headlight (left side).
9.Run the main harness to the rear side of the immobilizer amplifier (equipped models), and hold the main harness to the hook of the air inlet duct.
10.Run the main harness to the front of the headlight (right side).
11.Hold the meter unit lead and right city light lead, bend the clamp faces backward (Do not fit the leads to the bolt head.).
12.Right City Light Lead Connector
13.Right Switch Housing Lead
14.Immobilizer Amplifier (Equipped Models)
15.Crankshaft Sensor Lead
16.Run the oxygen sensor lead (equipped models) and crankshaft sensor lead to the inside of the water hose.
17.Run the oxygen sensor lead (equipped models) and crankshaft sensor lead to the inside of the reserve tank overflow hose.
18.Run the reserve tank overflow hose and oxygen sensor lead (equipped models) into the clamp.
19.Oxygen Sensor Lead (Equipped Models)
17-24 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-25
Cable, Wire, and Hose Routing
1.Hang the front left turn signal lead on the bracket.
2.Immobilizer Antenna Lead (Equipped Models)
3.Ignition Switch Lead
4.Front Left Turn Signal Light Lead
5.Hold the meter unit lead.
6.Hold the meter unit lead to the hook of the air inlet duct.
7.Run the alternator lead to the outside of the main harness.
8.Regulator/Rectifier
9.Alternator Lead
17-26 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-27
Cable, Wire, and Hose Routing
1.Speed Sensor Lead
2.Run the speed sensor lead to the hook of the engine sprocket cover.
3.Run the gear position switch lead to the inside of the fuel tank drain hose, fuel tank breather hose and water hose.
4.Run the air cleaner drain hose to the inside of the water hose, and outside of the alternator lead.
5.Breather Hose
6.Air Cleaner Drain Hose
7.Gear Position Switch Lead
8.Sidestand Switch Lead
9.Run the fuel tank drain hose and fuel tank breather hose to the inside of the gear position switch lead.
10.Hold the gear position switch lead.
11.Hold the air cleaner drain hose.
17-28 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-29
Cable, Wire, and Hose Routing
1.Inlet Air Temperature Sensor Lead
2.Hold the right switch housing lead, radiator fun motor lead and alternator lead.
3.Stick Coil
4.Subthrottle Sensor Lead Connector
5.Main Throttle Sensor Lead Connector
6.Secondary Fuel Injector
7.Alternator Lead
8.Hold the left switch housing lead, immobilizer antenna lead (equipped models), ignition switch lead and horn lead.
9.Air Switching Valve Lead Connector
10.Run the radiator fun motor lead under the small cover.
11.Small Cover (Cover the ignition switch lead, immobilizer antenna lead (equipped models) and right switch housing lead.)
12.Big Cover (Cover the radiator fun motor lead, horn lead, left switch housing lead and ignition switch lead.)
13.Run the alternator lead under the all leads and covers.
14.Left Switch Housing Lead
15.Horn Lead
16.Run the right switch housing lead under the all leads and covers (Exclude alternator lead).
17.Run the each lead to the outside of the radiator mount position.
18.Immobilizer Antenna Lead (Equipped Models)
19.Ignition Switch Lead
17-30 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-31
Cable, Wire, and Hose Routing
1.Oxygen Sensor Lead Connector (Equipped Models)
2.Hold the main harness and fix the clamp to the frame.
3.Battery Negative (–) Cable
4.Speed Sensor Lead
5.Hold the primary injector lead and water temperature sensor lead.
6.Fuel Injector Lead
7.Run the fuel injector lead to the front of the secondary fuel hose.
8.Run the starter motor cable into the hole.
9.Run the battery positive (+) cable behind the diverging point of the main harness.
10.Battery Positive (+) Cable
17-32 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-33
Cable, Wire, and Hose Routing
1.Run the main harness between the exhaust butterfly valve actuator and rear fender.
2.Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector
3.Relay Box
4.Turn Signal Relay
5.ECU
6.Fuse Box
7.Exhaust Butterfly Valve Actuator Lead Connector
8.Exhaust Butterfly Valve Actuator Sensor Lead Connector
9.Fuel Pump Lead Connector
10.Hold the main harness, exhaust butterfly valve actuator sensor lead and exhaust butterfly valve actuator lead.
11.Hold the exhaust butterfly valve cables and fuel pump lead.
12.Tail/Brake Light (LED) Lead Connector
13.Run the rear left and right turn signal light leads and license plate light lead into the hole.
14.Run the main harness from this position to the outside of the frame.
15.Rear Right Turn Signal Light Lead Connector
16.Rear Left Turn Signal Light Lead Connector
17.License Plate Light Lead Connector
18.Run the rear left and right turn signal light leads and license plate light lead and tail/brake light (LED) lead to the groove of the rear fender.
19.Run the vehicle-down sensor lead in this position as shown in the figure.
20.Vehicle-down Sensor
17-34 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-35
Cable, Wire, and Hose Routing
1.Run the rear left and right turn signal light leads and license plat light lead into the hole.
2.Hold the rear left and right turn signal light lead and license plat light lead.
3.Run the rear brake light switch lead to the outside of the exhaust butterfly valve cables.
4.Run the rear brake light switch lead to the outside of the brake hose.
5.Rear Brake Light Switch Lead
17-36 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-37
Cable, Wire, and Hose Routing
1.Exhaust Butterfly Valve Cable (Open)
2.Exhaust Butterfly Valve Cable (Close)
3.Run the exhaust butterfly valve cables into the clamp.
4.Run the exhaust butterfly valve cables to the inside of the rear brake light switch lead.
5.Align the exhaust butterfly valve cables, and then hold the them as shown in the figure.
6.Hold the exhaust butterfly valve cables and fuel pump lead.
7.Run the exhaust butterfly valve cables between the frame and main harness.
APPENDIX 17-39
Cable, Wire, and Hose Routing
1.Seat Lock Cable
2.Run the seat lock cable into the hole of the seat lock cover.
17-40 APPENDIX
Cable, Wire, and Hose Routing
1.Brake Hoses
2.Clamps
17-42 APPENDIX
Cable, Wire, and Hose Routing
California, Southeast Asia and Thailand Models
APPENDIX 17-43
Cable, Wire, and Hose Routing
1.Green Hose (From canister to air switching valve)
2.Red Hose (From separator to fuel tank)
3.White Hose (From separator to throttle body assy #2)
4.Blue Hose (From separator to fuel tank)
5.Blue Hose (From separator to canister)
6.Hang the front left turn signal lead on the bracket.
17-44 APPENDIX
Cable, Wire, and Hose Routing
California, Southeast Asia and Thailand Models
APPENDIX 17-45
Cable, Wire, and Hose Routing
1.Run the blue hose and red hose under each lead in this position.
2.Run the white hose over each lead.
3.Run the blue hose and red hose under each lead.
4.Run the blue hose and red hose over the main harness, and under the inlet air temperature sensor.
