Brake Disc

Brake Disc Removal

_• Remove the wheel (see Front/Rear Wheel Removal in the Wheels/Tires chapter).

_• Unscrew the mounting bolts, and take off the disc.

_• Remove the gaskets.

Brake Disc Installation

_• Replace the gaskets with new ones.

_• Install the brake disc on the wheel so that the marked side

[A] faces out.

_• Apply a non-permanent locking agent to the threads of the front and rear brake disc mounting bolts [B].

_• Tighten:

Torque - Brake Disc Mounting Bolts: 27 N·m (2.8 kgf·m, 20

ft·lb)

Brake Disc Wear

_• Measure the thickness of each disc [A] at the point where it has worn the most.

If the disc has worn past the service limit, replace it. Measuring Area [B]

Brake Discs Thickness Standard:

Front:

EX650A Models 4.3  4.7 mm (0.17  0.19 in.)

EX650B Models 4.8  5.2 mm (0.19  0.20 in.)

Rear 4.8  5.2 mm (0.19  0.20 in.) Service Limit:

Front 4.0 mm (0.16 in.)

Rear 4.5 mm (0.18 in.)

Brake Disc Warp

_• Raise the wheel off the ground with jack (see Front/Rear Wheel Removal in the Wheels/Tires chapter).

Special Tools - Jack: 57001-1238

Jack Attachment: 57001-1608

○^{For front disc inspection, turn the handlebar fully to one} side.

_• Set up a dial gauge against the disc [A] as shown and

measure disc runout, while turning [B] the wheel by hand.

If runout exceeds the service limit, replace the disc.

Disc Runout

Standard: 0.15 mm (0.006 in.) or less Service Limit: 0.3 mm (0.01 in.)

Brake Fluid Level Inspection

_• Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter.

Brake Fluid Change

_• Refer to the Brake Fluid Change in the Periodic Mainte- nance chapter.

Brake Line Bleeding

The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed. When air enters the brake lines, brake lever or pedal movement will be partially used in compressing the air. This will make the lever or pedal feel spongy, and there will be a loss in braking power.

NOTE

○^{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 [A] and diaphragm.

_• Fill the reservoir with fresh brake fluid to the upper level

line in the reservoir.

_• Slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the

holes at the bottom of the reservoir.

○^{Bleed the air completely from the master cylinder by this}

operation.

_• Remove the rubber cap from the bleed valve [A] on the caliper.

_• Attach a clear plastic hose [B] to the bleed valve, and run

the other end of the hose into a container.

Brake Fluid

_• Bleed the brake line and the caliper.

○^{Repeat this operation until no more air can be seen com-}

ing out into the plastic hose.

1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].

2. Quickly open and close [B] the bleed valve while hold- ing the brake applied.

3. Release the brake [C].

NOTE

○^{The fluid level must be checked often during the bleed-}

ing operation and replenished with fresh brake fluid as

necessary. If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the beginning since air will have entered the line.

○^{Tap the brake hose lightly from the caliper to the reser-}

voir for more complete bleeding.

○^{Front Brake: First bleeding the right caliper then repeat}

the above steps for the left caliper.

_• Remove the clear plastic hose.

_• Install the diaphragm and reservoir cap.

_• Tighten:

Torque - Front Brake Reservoir Cap Screws: 1.0 N·m (0.10 kgf·m, 9 in·lb)

_• Follow the procedure below to install the rear brake fluid reservoir cap correctly.

○^{First, tighten the rear brake fluid reservoir cap [B] clock-}

wise [C] by hand until slight resistance is felt indicating

that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A].

_• Tighten the bleed valve, and install the rubber cap.

Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

_• Check the fluid level (see Brake Fluid Level Inspection in the Periodic Maintenance chapter).

_• After bleeding is done, check the brake for good braking

power, no brake drag, and no fluid leakage.

Brake Hose

Brake Hose Removal/Installation

_• Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter.

Brake Hose Inspection

_• Refer to the Brake Hose Damage and Installation Condi- tion Inspection in the Periodic Maintenance chapter.

Parts Location

1. Front Wheel Rotation Sensor

2. Front Wheel Rotation Sensor Rotor

3. Rear Wheel Rotation Sensor

4. Rear Wheel Rotation Sensor Rotor

5. ABS Indicator Light (LED)

6. ABS Hydraulic Unit

7. ABS Fuse Box

8. ABS Kawasaki Self-diagnosis System Connector

ABS System Wiring Diagram

1. Ignition Switch

2. ABS Hydraulic Unit

3. ABS Self-diagnosis Terminal

4. ABS Kawasaki Self-diagnosis System Connector

5. Front Wheel Rotation Sensor

6. Rear Wheel Rotation Sensor

7. ABS Solenoid Valve Relay

8. ABS Motor Relay

9. Frame Ground

10. Meter Unit

11. Front Brake Switch

12. Water-proof Joint C

13. Ignition Fuse 10 A

14. Main Fuse 30 A

15. Battery 12 V 10 Ah

16. Frame Ground

17. Rear Brake Switch

18. Joint Connector

Terminal Names

1. Ground to Motor

2. Power Supply to ABS Motor Relay

3. Power Supply to ABS Solenoid Valve Relay

4. Ground

5. Front Wheel Rotation Sensor Signal

6. Unused

7. Power Supply to Rear Wheel Rotation Sensor

8. Unused

9. Unused

10. Unused

11. ABS Kawasaki Self-diagnosis System Terminal

12. ABS Indicator Light (LED)

13. Unused

14. Unused

15. Unused

16. Power Supply to Front Wheel Rotation Sensor

17. Unused

18. Power Supply

19. Rear Wheel Rotation Sensor Signal

20. Front Brake Light Switch

21. Rear Brake Light Switch

22. Unused

23. Unused

24. Unused

25. ABS Self-diagnosis Terminal

26. Unused

ABS Servicing Precautions

There are a number of important precautions that should be followed servicing the ABS system.

○^{This ABS system is designed to be used with a 12 V}

sealed battery as its power source. Do not use any

other battery except for a 12 V sealed battery as a power source.

○^{Do not reverse the battery cable connections. This will}

damage the ABS hydraulic unit.

○^{To prevent damage to the ABS parts, do not disconnect}

the battery cables or any other electrical connections

when the ignition switch is ON or while the engine is running.

○^{Take care not to short the leads that are directly con-}

nected to the battery positive (+) terminal to the chassis

ground.

○^{Do not turn the ignition switch ON while any of the ABS}

electrical connectors are disconnected. The ABS hy-

draulic unit memorizes service codes.

○^{Do not spray water on the electrical parts, ABS parts, con-}

nectors, leads and wiring.

○^{If a transceiver is installed on the motorcycle, make sure}

that the operation of the ABS system is not influenced

by electric wave radiated from the antenna. Locate the antenna as far as possible away from the ABS hydraulic unit.

○^{Whenever the ABS electrical connections are to be dis-}

connected, first turn off the ignition switch.

○^{The ABS parts should never be struck sharply, as with}

a hammer, or allowed to fall on a hard surface. Such a

shock to the parts can damage them.

○^{The ABS parts cannot be disassembled. Even if a fault is}

found, do not try to disassemble and repair the ABS parts,

replace it.

○^{The ABS has many brake lines, pipes, and leads. And}

the ABS cannot detect problems with the conventional

braking system (brake disc wear, unevenly worn brake pad, and other mechanical faults). To prevent trouble, check the brake lines and pipes for correct routing and connection, the wiring for correct routing, and the brakes for proper braking power. Be sure to check for fluid leak- age, and bleed the brake line thoroughly.

○^{The ABS indicator light (LED) [A] may light if the tire pres-} sure is incorrect, a non-recommended tire is installed, or the wheel is deformed. If the indicator light lights, remedy the problem and clear the service code.

○^{The ABS indicator light (LED) may come on if the engine} is run with the motorcycle on its stand and the transmis- sion in gear. If the indicator light comes on, just turn the ignition switch OFF, then clear service code 42, which in- dicates a “Faulty front wheel speed sensor”.

○^{When the ABS operates, the ABS makes noise and the}

rider feels the reaction force on the brake lever and brake

pedal. This is a normal condition. It informs the rider that the ABS is operating normally.

○^{Service codes detected once by the ABS hydraulic unit}

will be memorized in the ABS hydraulic unit. Therefore,

after maintenance work is finished, be sure to erase the service codes. Do not erase the service codes during troubleshooting. Wait until all the checks and repair work are finished to prevent duplication of previous service codes and unnecessary maintenance work.

○^{Before delivering the motorcycle to the customer, be}

sure to erase any service codes which might be stored

in the ABS hydraulic unit. Using the self-diagnosis feature, make sure that only start code 12 is shown. A fully charged battery is a must for conducting reliable self-diagnosis. Test run the motorcycle at a speed of more than 20 km/h (12 mph) to see that the ABS indicator light (LED) does not come on. Finally, test run the mo- torcycle at a speed of more than 30 km/h (20 mph) and brake suddenly to see that the motorcycle stops without loss of steering control and the ABS operates normally (The reaction force generated is felt in the brake lever and pedal.). This completes the final inspection.

○^{Color Codes:}

BK: Black BL: Blue BR: Brown

CH: Chocolate DG: Dark Green

G: Green GY: Gray

LB: Light Blue LG: Light Green O: Orange

P: Pink PU: Purple R: Red

W: White Y: Yellow

ABS Troubleshooting Outline

When an abnormality in the system occurs, the ABS in- dicator light (LED) lights up to alert the rider. In addition, the nature of the fault is stored in the memory of the ABS hydraulic unit and when in the self-diagnosis mode, the ser- vice code [A] is indicated by the number of times the ABS indicator light (LED) blinks. The service codes stored in memory are not erased until the mode has been changed to the fault erase mode after the fault has been corrected. Therefore, after correcting the problem, always erase the service codes and then run the self-diagnosis program to confirm normal signal output. When, due to a malfunction, the ABS indicator light (LED) remains lit, get a thorough understanding of the background before starting the repair work. Ask the rider about the conditions [B] under which the problem occurred and try to determine the cause [C]. Do not rely solely on the ABS self-diagnosis function, use common sense; check the brakes for proper braking power, and brake fluid level, search for leaks, etc.

Even when the ABS is operating normally, the ABS indi- cator light (LED) may light up under the conditions listed be- low. Turn the ignition switch OFF to stop blinking or lighting of the indicator light. If the motorcycle runs without erasing the service code, the light may light up again.

○^{After continuous riding on a rough road.}

○^{When the engine is started with the stand raised and the}

transmission engaged, and the rear wheel turns.

○^{When accelerating so abruptly that the front wheel leaves}

the ground.

○^{When the ABS has been subjected to strong electrical}

interference.

○^{When tire pressure is abnormal. Adjust tire pressure.}

○^{When a tire different in size from the standard size is being}

used. Replace with standard size.

○^{When the wheel is deformed. Replace the wheel.}

Much of the ABS troubleshooting work consists of con- firming continuity of the wiring. The ABS parts are assem- bled and adjusted by the manufacturer, so there is no need to disassemble or repair them. Replace the ABS hydraulic unit.

The basic troubleshooting procedures are listed below.

_• Carry out pre-diagnosis inspections as a preliminary in- spection.

_• Determine the fault using the self-diagnosis function.

_• Check wiring and connections from the ABS hydraulic

unit connector to the suspected faulty ABS part, using the

hand tester.

Special Tool - Hand Tester: 57001-1394

_• Visually inspect the wiring for signs of burning or fraying. If any wiring is poor, replace the damaged wiring.

_• Pull each connector [A] apart and inspect it for corrosion,

dirt and damage.

If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it.

_• Check the wiring for continuity.

○^{Use the wiring diagram to find the ends of the lead which}

is suspected of being a problem.

○^{Connect the hand tester between the ends of the leads.}

Special Tool - Hand Tester: 57001-1394

○^{Set the tester to the × 1 Ω range, and read the tester.}

If the tester does not read 0 Ω, the lead is defective. Re-

place the main harness [B] if necessary.

_• Narrow down suspicious parts and close in on the faulty ABS part by repeating the continuity tests.

If no abnormality is found in the wiring or connectors, the ABS parts are the next likely suspects. Check each part one by one.

If an abnormality is found, replace the affected ABS part.

ABS Diagnosis Flow Chart