Kawasaki EN500 Vulcan 500 LTD, Vulcan 500 LTD Service Manual
EN500
VULCAN 500 LTD
Motorcycle
Service Manual
Quick Reference Guide
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General Information 1
Fuel System 2
Cooling System 3
Engine Top End 4
Clutch 5
Engine Lubrication System 6
Engine Removal/Installation 7
Crankshaft/Transmission 8
This quick reference guide will assist
you in locating a desired topic or procedure.
•Bend the pages back to match the
black tab of the desired chapter number with the black tab on the edge at
each table of contents page.
•Refer to the sectional table of contents
for the exact pages to locate the specific topic required.
Wheels/Tires 9
Final Drive 10
Brakes 11
Suspension 12
Steering 13
Frame 14
Electrical System 15
Appendix 16
LIST OF ABBREVIATIONS
A ampere(s) lb pound(s)
ABDC after bottom dead center m meter(s)
AC alternating current min minute(s)
ATDC after top dead center N newton(s)
BBDC before bottom dead center Pa pascal(s)
BDC bottom dead center PS horsepower
BTDC before top dead center psi pound(s) per square inch
°C degree(s) Celsius r revolution
DC direct current rpm revolution(s) per minute
F farad(s) TDC top dead center
°F degree(s) Fahrenheit TIR total indicator reading
ft foot, feet V volt(s)
g gram(s) W watt(s)
h hour(s) Ω ohm(s)
L liter(s)
Read OWNER’S MANUAL before operating.
EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of
the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance
with applicable regulations of the California Air Resources Board on vehicles sold in California
only.
1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors
are routed through an oil separator to the intake side of the engine. While the engine is operating,
the vapors are drawn into combustion chamber, where they are burned along with the fuel and air
supplied by the carburetion system.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust
of this motorcycle. The fuel and ignition systems of t his motorcycle have been carefully des
and constructed to ensure an efficient engine with low exhaust pollutant levels.
3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. In
stead, fuel vapors are routed into the r unning engine to be burned, or stored in a canister when
the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.
The Clean Air Act, which is the Federal law covering motor vehicle p
commonly referred to as the Act’s “tampering provisions.”
“Sec. 203(a) The following acts and the causing thereof are prohibited...
(3)(A) for any person to remove or r ender inoperative any device or e
on or in a motor vehicle or motor vehicle engine in compliance with regulations under this
title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer
knowingly to remove or render inoperative any such device or el
sale and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading
motor vehicles or motor vehicle engines, or who operates a fle
ingly to remove or render inoperative any device or element of design installed on or in a
motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purch
aser...”
ollution, contains what is
lement of design installed
ement of design after such
et of motor vehicles know-
igned
-
NOTE
The phrase “remove or render inoperative any device or element of design” has been generally
○
interpreted as follows:
1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance.
2. Tampering could include:
a.Maladjustment of vehicle components such that the emission standards are ex-
ceeded.
b.Use of replacement parts or accessories which adversely affect the performance
or dura bility of the motorcycle.
c.Addition of components or accessories that result in the vehicle exceeding the stan-
dards.
d.Permanently removing, disconnecting, or rendering inoperative any component or
element of design of the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW,
THE VIOLATION OF WHICH IS PUN ISHA BLE BY CIVIL PENALTIES NOT EXCEEDING
$10,000 PER VIOLATION.
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering
inoperative by any person other than for purposes of maintenance, repair, or replacement, of any
device or element of design incorporated into any new vehicle for the purpose of noise control
prior to i ts sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the
vehicle after such device or element of design has been removed or rendered inoperative by
any person.
Among those acts presumed to constitute tampering are the acts listed below:
Replacement of the original exhaust system or muffler with a component not in compliance
•
with Federal regulations.
Removal of the muffler(s) or any internal portion of the muffler(s).
•
Removal of the air box or air box cover.
•
Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such
•
modifications result in increased noise levels.
Foreword
This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop procedures must be understood in order to carry out
maintenance and repair satisfactorily. Whenever the owner has insufficient experience or
doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures
before starting work, and then do the work ca
fully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurem
can only be made if the proper instruments are
used, and the use of substitute tools may adversely affect safe operation.
For the duration of the warranty period,
we recommend that all repairs and scheduled
maintenance be performed in
this service manual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void
To get the longest life out of your vehicle:
Follow the Periodic Maintenance Chart in the
•
Service Manual.
Be alert for problems and non-scheduled
•
maintenance.
Use proper tools and
•
torcycle parts. Special tools, gauges, and
testers that are necessary when servicing
Kawasaki moto
Service Manual. Genuine parts provided as
spare parts are listed in the Parts Catalog.
Follow the p
•
fully. Don’t take shortcuts.
Remember to keep complete records of main-
•
tenance a
parts installed.
rcycles are introduced by the
rocedures in this manual care-
nd repair with dates and any new
genuine Kawasaki Mo-
accordance with
the warranty.
re-
ents
How to Use This Manual
In this manual, the product is divided into its
major systems and these systems make up the
manual’s chapters.
The Quick Reference Guide shows you all
of the product’s system and assists in locating
their chapters. Each chapter in turn has its own
comprehensive Table of Contents.
For example, if you want ignition coil information, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use the
Table of Contents on the first page of the chapter to find the ignition coil section.
Whenever you see these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.
WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in per-
sonal injury, or loss of life.
CAUTION
This caution symbol identifies special
instructions or procedures which, if not
strictly observed, could result in dam-
age to or destruction of equipment.
This manual contains four more symbols (in
addition to WARNING and CAUTION) whi
help you distinguish different types of information.
NOTE
This note symbol indicates points of par-
○
ticular interest for more efficient and con-
venient operation.
Indicates a procedural step or work to be
•
done.
Indicates a procedural sub-step or how to do
○
the work of the procedural step it follows. It
also precedes the te
Indicates a conditional step or w hat action to
take based on the results of the test or inspec-
tion in the proced
lows.
In most chapters an exploded view illustration
of the system com
Contents. In these illustrations you will find the
instructions indicating which parts require specified tighten
agent during assembly.
ing torque, oil, grease or a locking
xt of a NOTE.
ural step or sub-step it fol-
ponents follows the Table of
ch will
GENERAL INFORMATION 1-1
General I nformation
Table of Con tents
Before Servicing ..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-5
General Specifications (EN500-C1 ∼ C6F Models) ................................................................ 1-6
General Specifications (EN500C7F Model ∼)......................................................................... 1-9
Periodic Maintenance Chart ................................................................................................... 1-12
Torque and Locking Agent...................................................................................................... 1-16
Unit Conversion Table ............................................................................................................ 1-21
1
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following
(1) Dirt
Before removal and disassembly, clean the motorcycle. Any dirt entering the engine will shorten
the life of the motorcycle. For the same reason, before installing a new part, clean off any dust or
metal filings.
(2) Battery Ground
Disconnect the ground (–) cable from the battery before performing any disassembly operations
on the motorcycle. This prevents the engine from accidentally turning over while work is being
carried out, sparks from being generated while disconnecting the cables from electrical parts, as
well as damage to the electrical parts themselves. For reinstallation, first connect the positive
cable to the positive (+) terminal of the battery
(3) Installation, Assembly
Generally, installation or assembly is the reverse of removal or disassembly. However, if installation or assembly sequence is given in this Service Manual, follow it. Note parts locations and
cable, wire, and hose routing during removal or disassembly so they can be installed or assembled in the same way. It is preferable to mark and record the locations and routing whenever
possible.
(4) Tightening Sequence
When installing bolts, nuts, or screws for which a tightening sequence is given in this Service
Manual, make sure to follow the sequence. When installing a part with several bolts, nuts, or
screws, start them all in their holes and tighten them to a snug fit, thus ensuring that the part has
been installed in its proper location. Then, tighten them to the specified torque in the tightening
sequence and method indicated. If tightening sequence instructions are not given, tighten them
evenly in a cross pattern. Conversely, to remove a part, first loosen all the bolts, nuts, or screws
that are retaining the part a 1/4-turn before removing them.
(5) Torque
When torque values are given in this Service Manual, use them. Either too little or too much
torque may lead to serious damage. Use a good quality, reliable torque wrench.
(6) Force
Common sense should dictate how much force is necessary in assembly and disassembly. If
a part seems especially difficult to remove or install, stop and examine what may be causing the
problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use
an impact driver for screws (particularly for the removing screws held by non-permanent locking
agent) in order to avoid damaging the screw heads.
(7) Edges
Watch for sharp edges, as they could cause injury through careless handling, especially during
major engine disassembly and assembly. Use a clean piece of thick cloth w hen lifting the engine
or turning it over.
(8) High-Flash Point Solvent
A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is standard solvent (generic name). Always follow manufacturer
and container directions regarding the use of any solvent.
(9) Gasket, O-ring
Replace a gasket or an O-ring with a new part when disassembling. Remove any foreign matter
from the mating surface of the gasket or O-ring to ensure a perfectly smooth surface to prevent
oil or compression leaks.
GENERAL INFORMATION 1-3
Before Servicing
(10)Liquid Gasket, Locking Agent
Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used.
Apply them sparingly. Excessive amount may block engine oil passages and cause serious damage.
(11)Press
When using a press or driver to install a part such as a wheel bearing, apply a small amount of
oil to the area where the two parts come in contact to ensure a smooth fit.
(12)Ball Bearing and Needle Bearing
Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any
ball or needle bearings that were removed with new ones. Install bearings with the m anufacturer
and size marks facing out, applying pressure evenly with a suitable driver. Apply force only to the
end of the race that contacts the press fit portion, and press it evenly over the base component.
(13)Oil Seal and Grease Seal
Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. Oil or grease seals should be pressed into place using a suitable driver, applying a
force uniformly to the end of seal until the face of the seal is even with the end of the hole, unless
instructed otherwise. When pressing in an oil or grease seal which has manufacturer’s m arks,
press it in with the marks facing out.
(14)Circlip, Retaining Ring, and Cotter Pin
When installing circlips and retaining rings, take care to compress or expand them only enough
to install them and no more. Install the circlip with its chamfered side facing load side as well.
Replace any circlips, retaining rings, and cotter pins that were removed with new ones, as removal weakens and deforms them. If old ones are reused, they could become detached while
the motorcycle is driven, leading to a major problem.
(15)Lubrication
Engine wear is generally at its maximum while the engine is warming up and before all the sliding
surfaces have an adequate lubricative film. During assembly, make sure to apply oil to any sliding
surface or bearing that has been cleaned. Old grease or dirty oil could have lost its lubricative
quality and may contain foreign particles that act as abrasives; therefore, make sure to wipe it off
and apply fresh grease or oil. Some oils and greases in particular should be used only in certain
applications and may be harmful if used in an application for which they are not intended.
(16)Direction of Engine Rotation
To rotate the crankshaft manually, make sure to do so in the direction of positive rotation. Positive rotation is counterclockwise as viewed from the left side of the engine. To carry out proper
adjustment, it is furthermore necessary to rotate the engine in the direction of positive rotation as
well.
(17)Replacement Parts
When there is a replacement instruction, replace these parts with new ones every time they are
removed.
Replacement parts will be damaged or lose their original function once they are removed. Therefore, always replace these parts with new ones every time they are removed. Although the previously mentioned gasket, O-ring, ball bearing, needle bearing, grease seal, oil seal, circlip, and
cotter pin have not been so designated in their respective text, they are replacement parts.
(18)Electrical Leads
All the electrical leads are either one-color or two-color. A two-color lead is identified first by
the primary color and then the stripe color. For example, a yellow lead with thin red stripes is
referred to as a “yellow/red” lead; it would be a “red/yellow” lead if the colors were reversed.
Unless instructed otherwise, electrical leads must be connected to leads of the s ame color.
1-4 GENERAL INFORMATION
Before Servicing
Two-Color Electrical
(19)Inspection
When parts have been disassembled, visually inspect these parts for the following conditions
or other damage. If there is any doubt as to the condition of them, replace them with new ones.
Abrasion Crack Hardening Warp
Bent Dent Scratch Wear
Color change Deterioration Seizure
(20)Specifications
Specification terms are defined as follows:
“Standards” show dimensions or performances which brand-new parts or systems have.
“Service Limits” indicate the usable limits. If the measurement shows excessive wear or deteri-
orated performance, replace the dam aged parts.
Model Identification
GENERAL INFORMATION 1-5
1-6 GENERAL INFORMATION
General Specifications (EN500-C1 ∼ C6F Models)
Items EN500-C1 ∼ C5 EN500-C6 ∼ C6F
Dimensions
Overall Length 2 320 mm (91.3 in.) ←
Overall Width 830 mm (32.7 in.) ←
Overall Height 1 125 mm (44.3 in.) ←
Wheelbase 1 595 mm (62.8 in.) ←
Road Clearance 120 mm (4.92 in.) ←
Seat Height 715 mm (31.5 in.) ←
Dry Weight 199 kg (438 lb) (CAL) 199.5 kg (440 lb) ←
Curb Weight:
Front 95 kg (209 lb) ←
Rear 119 kg (262 lb) (CAL) 119.5 (263 lb) ←
Fuel Tank C apacity 15.0 L (3.9 US gal) ←
Performance
Minimum Turning Radius 2.8 m (9.2 ft) ←
Engine
Type
Cooling System
Bore And Stroke 74.0 × 58.0 mm (2.9 × 2.3 in.)
Displacement 498 cm³ (30.4 cu in.) ←
Compression Ratio 10.2 ←
Maximum Horsepower 34 kW (46 PS) @8 000 r/min (rpm),
Maximum Torque 45 N·m (4.6 kgf·m, 33 ft·lb)
Carburetion System Carburetors, Keihin CVK32 × 2 ←
Starting System Electric starter ←
Ignition System Battery and coil (transistorized) ←
Timing Advance Electronically advanced ←
Ignition Timing
Spark Plugs NGK DR9EA or ND X27ESR-U
Cylinder Numbering M ethod Left to right, 1-2 ←
Firing Order 1-2 ←
Valve Timing:
Inlet:
Open 27° BTDC ←
Close 47° ABDC ←
Duration 254° ←
Exhaust:
Open 52° BBDC ←
Close 22° ATDC ←
4-stroke, DOHC, 2-cylinder
Liquid-cooled ←
(CH, DE) 25 kw (34 PS) @7 000 r/min (rpm),
(FR) 33 kw (45 PS) @8 000 r/min (rpm)
(US) –
@6 000 r/min (rpm),
(CH, DE) 39 N·m (4.0 kgf·m, 29 ft·lb)
@4 200 r/min (rpm), (US) –
From 10° BTDC @1 300 r/min (rpm) to
35° B TDC @8 000 r/min (rpm)
or NGK DR8EA or ND X24ESR-U
←
←
←
←
←
←
GENERAL INFORMATION 1-7
General Specifications (EN500-C1 ∼ C6F Models)
Items EN500-C1 ∼ C5 EN500-C6 ∼ C6F
Duration 254° ←
Lubrication System Forced lubrication (wet sump) ←
Engine Oil:
Grade SE, SF or SG class API SE, SF or SG
API SH or SJ with
JASO MA
Viscosity SAE10W-40, 10W-50, 20W-40, or 20W-50 SAE10W-40
Capacity 3.4 L (3.59 US qt) ←
Drive Train
Primary Reduction System:
Type Chain ←
Reduction Ratio 2.652 (61/23) ←
Clutch Type Wet multi disc ←
Transmission
Type
Gear Ratios:
1st 2.571 (36/14) ←
2nd 1.722 (31/18) ←
3rd 1.333 (28/21) ←
4th 1.125 (27/24) ←
5th 0.961 (25/26) ←
6th 0.851 (23/27) ←
Final drive system
Type Chain drive ←
Reduction Ratio 2.625 (42/16) ←
Overall Drive Ratio 5.930 @ Top gear ←
Frame
Type Tubular, double cradle ←
Caster (Rake Angle) 33° ←
Trail 151 mm (5.9 in.) ←
Rim Size:
Front 19 MC × MT 2.15 ←
Rear 15 MC × MT 3.00 ←
Front Tire:
Type Tube ←
Size 100/90-19 57S ← (C6 ∼ C7)
Rear Tire:
Type Tube ←
Size 140/90-15 M /C 70S ←
Front Suspension:
Type Telescopic fork ←
Wheel Travel 150 mm (5.9 in.) ←
6-speed constant mesh, return shift
100/90-19 M/C
57S (C8 ∼)
←
1-8 GENERAL INFORMATION
General Specifications (EN500-C1 ∼ C6F Models)
Items EN500-C1 ∼ C5 EN500-C6 ∼ C6F
Rear Suspension:
Type Swing arm ←
Wheel Travel 100 mm (3.9 in.) ←
Brake Type:
Front Single disc ←
Rear Drum ←
Electrical Equipment
Battery 12 V 12 Ah ←
Headlight:
Type Semi-sealed beam ←
Bulb 12 V 60/55 W (quartz-halogen) ←
Tail/brake Light 12 V 8/27 W
(AT, CH, EUR, DE, FR, GR, IT, KR, NL, NO,
ES, SE, GB)
12 V 5/21 W
Alternator:
Type Three-phase AC ←
Rated Output 17 A @6 000 r/min (rpm), 14 V ←
12 V 5/21 W
Specifications subject to change without notice, and may not apply to every country.
AT: Austria Model
CA: Canada Model
CAL: California Model
CH: Switzerland Model
DE: Germany Model
ES: Spain Model
EUR: E u rope Model
FR: France Model
GB: United Kingdom Model
GR: Greece Model
IT: Italy Model
KR: Korea Model
NL: Netherlands Model
NO: Norway Model
SE: Sweden Model
US: United States Model
GENERAL INFORMATION 1-9
General Specifications (EN500C7F Model ∼)
Items EN500C7F ∼
Dimensions
Overall Length 2 320 mm (91.3 in.)
Overall Width 830 mm (32.7 in.)
Overall Height 1 125 mm (44.3 in.)
Wheelbase 1 595 m m (62.8 in.)
Road Clearance 120 mm (4.92 in.)
Seat Height 715 mm (31.5 in.)
Dry Weight 199 kg (438 lb) (CAL) 199.5 kg (440 lb)
Curb Weight:
Front 95 kg (209 lb)
Rear 119 kg (262 lb) (CAL) 119.5 (263 lb)
Fuel Tank Capacity 15.0 L (3.9 US gal)
Performance
Minimum Turning Radius 2.8 m (9.2 ft)
Engine
Type 4-stroke, DOHC, 2-cylinder
Cooling System Liquid-cooled
Bore And Stroke 74.0 × 58.0 mm (2.9 × 2.3 in.)
Displacement 498 cm³ (30.4 cu in.)
Compression Ratio
Maximum Horsepower
Maximum Torque 45 N·m (4.6 kgf·m, 33 ft·lb)
Carburetion System Carburetors, Keihin CVK 32 × 2
Starting System Electric starter
Ignition System Battery and coil (transistorized)
Timing Advance Electronically advanced
Ignition Timing
Spark Plugs NGK DR9EA or ND X27ESR-U
Cylinder Numbering Method Left to right, 1-2
Firing Order 1-2
V alve Timing:
Inlet:
Open 27° BTDC
Close 47° ABDC
Duration
Exhaust:
Open 52° BBDC
Close 22° ATDC
Duration 254°
10.2
34 kW (46 PS) @8 000 r/min (rpm),
(US) –
@6 000 r/min (rpm),
From 10° BTDC @1 300 r/min (rpm) to
35° BTDC @8 000 r/min (rpm)
or NGK DR8EA or ND X24ESR-U
254°
1-10 GENERAL INFORMATION
General Specifications (EN500C7F Model ∼)
Items EN500C7F ∼
Lubrication System Forced lubrication (wet sump)
Engine Oil:
Grade API SE, SF or SG class
API SH, SJ or SL with JASO MA
Viscosity
Capacity 3.4L(3.59USqt)
Drive Train
Primary Reduction System:
Type Chain
Reduction Ratio 2.652 (61/23)
Clutch Type Wet multi disc
Transmission
Type 6-speed constant mesh, return shift
Gear Ratios:
1st 2.571 (36/14)
2nd
3rd
4th
5th 0.961 (25/26)
6th 0.851 (23/27)
Final drive system
Type Chain drive
Reduction Ratio 2.625 (42/16)
Overall Drive Ratio 5.930 @ Top gear
Frame
Type Tubular, double cradle
Caster (Rake Angle) 33°
Trail 151 mm (5.9 in.)
Rim Size:
Front 19 MC × MT 2.15
Rear 15 MC × MT 3.00
Front Tire:
Type Tube
Size 100/90-19 M/C 57S
Rear Tire:
Type Tube
Size 140/90-15 M/C 70S
Front Suspension:
Type Telescopic fork
Wheel Travel 150 mm (5.9 in.)
Rear Suspension:
Type Swing arm
Wheel Travel 100 mm (3.9 in.)
SAE10W-40
1.722 (31/18)
1.333 (28/21)
1.125 (27/24)
GENERAL INFORMATION 1-11
General Specifications (EN500C7F Model ∼)
Items EN500C7F ∼
Brake Type:
Front
Rear Drum
Electrical Equipment
Battery 12 V 12 Ah
Headlight:
Type Semi-sealed beam
Bulb 12 V 60/55 W (quartz-halogen)
Tail/brake Light 12 V 5/21 W
Alternator:
Type Three-phase AC
Rated Output 17 A @6 000 r/min (rpm), 14 V
Specifications subject to change without notice, and may not apply to every country.
CA: Canada Model
CAL: California Model
US: United States Model
Single disc
1-12 GENERAL INFORMATION
Periodic Maintenance Chart
The scheduled maintenance m ust be done in accordance with this chart to keep the motorcycle in
good running condition. The initial maintenance is vitally important and must not be neglected.
( Other than United States and Canada Models)
FREQUENCY Whichever
comes
first
OPERATION
Carburetor synchronization - inspect †
Idle speed - adjust †
Throttle grip play - inspect †
Spark plug - clean and gap †
Valve clearance - inspect †
Air suction valve - inspect †
Air cleaner element - clean † #
Fuel hose, connections - inspect †
Battery electrolyte level - inspect † 6 month
Brake play - inspect †
Brake light switch - inspect †
Brake lining or pad wear - inspect †#
Brake fluid level - inspect † month
Brake fluid - change † 2 years
Brake hose, connections - inspect †
Brake master cylinder cup and dust
seal - replace
Caliper fluid seal and dust seal - replace 4 years
Every
4 years
*ODOMETER
READING
× 1 000 km
(× 1 000 mile)
1 6 12 18 24 30 36
(0.6) (4.0) (7.5) (12) (15) (20) (24)
• • •
• • • •
• • • •
• • • • • •
•
• • • • • •
• • •
• • • • • •
• • • • • •
• • • • • • •
• • • • • • •
• • • • • •
• • • • • • •
•
• • • • • •
Brake cable - replace 2 years
Clutch - adjust
Steering - inspect †
Drive chain wear - inspect †#
Drive chain - lubricate # 600 km
Drive chain slack - i nspect †# 1000 km
Spoke tightness and rim runout inspect †
Nut, bolts, and fasteners tightness inspect †
Tire wear - inspect †
Engine oil - change # 6 month
Oil filter - replace
General lubrication - perform #
Front fork oil - change 2 years
Front fork oil leak - inspect †
•
• • • • • • •
• • • • • • •
• • • • • •
• • • • • •
• • • • • • •
• • • • • • •
• • • •
• • • • • •
• • • • • • •
• • • •
• • •
•
• • •
Periodic Maintenance Chart
GENERAL INFORMATION 1-13
FREQUENCY Whichever
comes
first
1 6 12 18 24 30 36
OPERATION Every (0.6) (4.0) (7.5) (12) (15) (20) (24)
Swingarm pivot - lubricate
Radiator hoses, connections - inspect †
Coolant - change 2 years
Coolant filter - clean year
Steering stem bearing - lubricate 2 years
Rear shock absorber oil leak - inspect †
#: Service more frequently when operating in severe conditions dusty, wet, muddy, high speed, or
frequent starting/stopping.
†: Replace, add, adjust, clean, or torque if necessary.
*: For higher odometer readings, repeat at the frequency interval established here.
•
• • •
• • •
• • •
*ODOMETER
READING
× 1 000 km
(× 1 000 mile)
•
•
1-14 GENERAL INFORMATION
Periodic Maintenance Chart
(United States and Canada Models)
FREQUENCY
OPERATION Every (0.5) (3.1) (6.2) (9.3) (12) (16) (20)
Carburetor synchronization - inspect †
Idle speed - adjust †
Throttle grip play - inspect †
Spark plug - clean and gap †
Valve clearance - inspect †
Air suction valve - inspect †
Air cleaner element - clean
Air c leaner element - replace 5 cleaning
Fuel system - inspect
Fuel hose, connections - inspect †
Evaporative emission control system (CAL) inspect
Whichever
comes
first
0.8 5 10 15 20 25 30
• • • • • • •
• • • • • • •
• • • •
• • • • • •
• • • •
• • • • • •
• • • •
• • •
• • • • • •
• • • • • • •
*ODOMETER
READING
× 1 000 km
(× 1 000 mile)
•
Radiator Hoses, connections - inspect † year
Drive chain - lubricate # 600 km
Drive chain slack - inspect †# 1 000 km
Spoke tightness and rim runout - inspect †
Rim runout - inspect †
Fuel hose-replace 4 years
Brake hose-replace 4 years
Battery electrolyte level - inspect † m onth
Brake play - inspect †
Brake light switch - inspect †
Brake lining or pad wear - inspect †
Brake fluid level - inspect † month
Brake fluid - change † 2 years
Brake hose, connections - inspect †
Brake master cylinder cup and dust seal replace
Caliper fluid seal and dust seal - replace 2 years
Brake cable - replace 2 years
2 years
• • • •
• • • • • • •
• • • • • • •
• • • • • • •
• • • • • • •
• • • • • • •
• • • • • •
• • • • • • •
•
• • • • • •
Brake camshaft - lubricate 2 years
Clutch - adjust
Steering - inspect †
Drive chain wear - inspect †#
Nut, bolts, and fasteners tightness - inspect †
Tire wear - inspect †
•
• • • • • • •
• • • • • • •
• • • • • •
• • • •
• • • • • •
Periodic Maintenance Chart
GENERAL INFORMATION 1-15
FREQUENCY
OPERATION Every (0.5) (3.1) (6.2) (9.3) (12) (16) (20)
Engine oil - change year
Oil filter - replace
General lubrication - perform #
Front fork oil - change
Swingarm pivot - lubricate
Coolant - change 2years
Coolant filter - clean year
Steering stem bearing - lubricate 2years
#: Service more frequently when operating in severe conditions dusty, wet, muddy, high speed, or
frequent starting/stopping.
†: Replace, add, adjust, clean, or torque if necessary.
*: For higher odometer readings, repeat at the frequency interval established here.
CAL: California Model
Whichever
comes
first
0.8 5 10 15 20 25 30
• • • •
• • • •
• • • • • •
• • •
• • •
*ODOMETER
READING
× 1 000 km
(× 1 000 mile)
•
•
•
1-16 GENERAL INFORMATION
Torque and Locking Agent
Tighten all bolts and nuts to the proper torque using an accurate torque wrench. An insufficiently
tightened bolt or nut may become damaged or fall off, possibly resulting in damage to the motorcycle
and injury to the rider. A bolt or nut which is overtightened may become damaged, strip an internal
thread, or break and then fall out. The following table lists the tightening torque for the major bolts
and nuts, and the parts requiring use of a non-permanent locking agent or liquid gasket.
When checking the tightening torque of the bolts and nuts, first loosen the bolt or nut by half a turn
and then tighten it to the specified torque.
Letters used in the “Remarks” column mean:
L: Apply a non-permanent locking agent to the threads.
Lh: Left-hand threads.
LG: Apply liquid gasket to the threads.
S: Tighten the fasteners following the specified sequence.
SS: Apply silicone sealant to the threads.
Fastener
Fuel System
Fuel Tap Mounting Bolts
Cooling System
Radiator Hose Clamp Screws
Radiator Fan Switch
Thermostat Housing Bolts 11 1.1 95 in·lb
Water Temperature Switch 7.8 0.8 69 in·lb SS
Water Pump Cover Bolts 11 1.1 95 in·lb
Water Pump Shaft 25 2.5 18 Lh
Water Pump Impeller 9.8 1.0 87 in·lb Lh
Water Pipe Screws 4.9 0.5 43 in·lb
Coolant Passage Blank Caps 9.8 1.0 87 in·lb L
Coolant Drain Plug 11 1.1 95 in·lb
Engine Top End
Air Suction Valve Cap Bolts 11 1.1 95 in·lb
Cylinder Head Cover Bolts 9.8 1.0 87 in·lb
Camshaft Cap Bolts 12 1.2 104 in·lb S
Rocker Shafts 39 4.0 29
Valve Adjuster Locknuts 25 2.5 18
Camshaft Sprocket Bolts 15 1.5 11 L
Cylinder Head Bolts (M10) 51 5.2 38 S
Cylinder Head Bolts (M6) 9.8 1.0 87 in·lb S
Cam Chain Tensioner Mounting Bolts 11 1.1 95 in·lb
Cam C hain Tensioner Cap Bolt 4.9 0.5 43 in·lb
Main Oil Pipe Upper Banjo Bolts M8 12 1.2 104 in·lb
Main Oil Pipe Lower Banjo Bolt M10 20 2.0 14.5
Oil Pipe Bolts (in the cylinder head) 11 1.1 95 in·lb
Oil Pipe Mounting Bolt
N·m kgf·m ft·lb
4.9 0.5 43 in·lb with black
2.5 0.25 22 in·lb with white
2.5 0.25 22 in·lb
18 1.8 13
11 1.1 95 in·lb
Torque
Remarks
washer
washer
Torque and Locking Agent
GENERAL INFORMATION 1-17
Fastener
Clutch
Oil Filler Plug
Clutch Hub Nut
Clutch Spring Bolts 9.3 0.95 82 in·lb
Clutch Cable Holder Bolt 11 1.1 95 in·lb
Clutch Cover Bolts 11 1.1 95 in·lb
Clutch Cover Damper Plate Bolts 9.8 1.0 87 in·lb L
Engine Lubrication System
Oil Passage Plug 18 1.8 13
Oil Filter Mounting Stud 25 2.5 18 L
Oil Filter (Cartridge Type) 17 1.75 12.5
Oil Pipe for Balancer Shaft Banjo B olt 20 2.0 14.5
Oil Pipe for Drive Shaft Upper Banjo Bolt M6 7.8 0.80 69 in·lb
Oil Pipe for Drive Shaft Lower Banjo Bolt M8 12 1.2 104 in·lb
Oil Pipe for Output Shaft Upper Banjo Bolt M6 7.8 0.80 69 in·lb
Oil Pipe for Output Shaft Lower Banjo Bolt M8 12 1.2 104 in·lb
Oil Pipe for O utput Shaft Mounting Bolt 11 1.1 95 in·lb L
Oil Pump Outer Oil Pipe Bolt 11 1.1 95 in·lb L
Oil Pum p Mounting Bolts 11 1.1 95 in·lb L
Relief Valve 15 1.5 11 L
Oil Pressure Switch 15 1.5 11 SS
Engine Oil D rain Plug 29 3.0 22
Oil Pan Mounting Bolts 11 1.1 95 in·lb
Breather Body Bolt 5.9 0.6 52 in·lb
Engine Removal/Installation
Engine Mounting Nuts 44 4.5 33
Engine Mounting Bracket Nuts 25 2.5 18
Engine Mounting Bracket Bolts 25 2.5 18
Crankshaft/Transmission
Crankcase Bolts (M8) 27 2.8 20 S
Crankcase Bolts (M6) 12 1.2 104 in·lb S
Upper Primary Chain Guide Mounting Nut 11 1.1 95 in·lb L
Lower Primary Chain Guide Mounting Bolt 11 1.1 95 in·lb L
Connecting Rod Big End Cap Nuts 36 3.7 27
Return Spring Pin 20 2.0 14.5 L
Gear Positioning Lever Pivot Stud – – – L
Gear Positioning Lever Nut 11 1.1 95 in·lb
Shift Lever Clamp Bolts 11 1.1 95 in·lb
Shift Linkage Rod Lock Nuts 11 1.1 95 in·lb Lh (1)
Shift Pedal Mounting Bolt 8.8 0.9 78 in·lb
Shift Drum Bearing Holder Bolts 11 1.1 95 in·lb L
N·m kgf·m ft·lb
1.5 0.15 13 in·lb
132 13.5 98
Torque
Remarks
(planted side)
(planted side)
1-18 GENERAL INFORMATION
Torque and Locking Agent
Fastener
Shift Drum Cam Pin Plate Screw – – – L
Shift R od Stopper Bolt 11 1.1 95 in·lb
External Shift Mechanism Cover Bolts 11 1.1 95 in·lb
Neutral Switch 15 1.5 11
Wheels/Tires
Front Axle Nut 88 9.0 65
Front Axle Clamp Allen Bolt 34 3.5 25
Rear Axle Nut 88 9.0 65
Spoke Nipples
Torque Link Nuts 34 3.5 25
Final Drive
Engine Sprocket Nut 127 13 94
Rear Sprocket Nuts 74 7.5 54
Rear Coupling Studs – – –
Drive Chain Guide Bolts 11 1.1 95 in·lb
Brakes
Brake Hose Banjo Bolts 25 2.5 18
Reservoir Cap Screws 1.5 0.15 13 in·lb
Brake Lever Pivot Bolt 1.0 0.1 9in·lb
Brake Lever Pivot Locknut 5.9 0.6 52 in·lb
Master Cylinder Clamp Bolts 11 1.1 95 in·lb S
Front Brake Light Switch Mounting Screw
Caliper M ounting Bolts
Caliper Bleed Valves
Brake Disc Mounting Bolts 27 2.8 20 L
Brake Pedal Mounting Bolt 25 2.5 18
Torque Link Nuts 34 3.5 25
Brake Cam Lever Bolt
Suspension
Front Fork Top Plug 23 2.3 16.5
Front Fork Upper Clamp Allen Bolts 20 2.0 14.5
Front Fork Lower Clamp Allen Bolts 29 3.0 22
Front Fork Bottom Allen Bolt 29 3.0 22 L
Rear Shock Absorber Upper Mounting Bolt 25 2.5 18
Rear Shock Absorber Lower Mounting Bolt 34 3.5 25
Swingarm Pivot Nut 88 9.0 65
Steering
Handlebar Mounting Nuts 34 3.5 25
Steering Stem Head Bolt 44 4.5 33
N·m kgf·m ft·lb
5.2 0.53 46 in·lb
59 6.0 43 (Self Locknut)
1.2 0.12 10 in·lb
34 3.5 25
7.8 0.8 69 in·lb
19 1.9 14
Torque
(planted side)
Remarks
L
Torque and Locking Agent
GENERAL INFORMATION 1-19
Fastener
Steering S tem Nut
Frame
Side Stand Mounting Bolt 44 4.5 33
Footpeg Holder Bolts (M10) 34 3.5 25
Footpeg Holder Bolts (M12) 54 5.5 39
Muffler Bracket Bolts (M8) 25 2.5 18
Muffler Bracket Bolts (M10) 34 3.5 25
Electrical System
Front Brake Light Switch Mounting Screw 1.2 0.12 10 in·lb
Crankshaft Sensor Mounting Allen Bolts 8.3 0.85 74 in·lb L
Timing Inspection Plug 2.5 0.25 22 in·lb
Alternator Rotor Bolt Plug 1.5 0.15 13 in·lb
Alternator Cover Bolts 11 1.1 95 in·lb
Alternator Cover Allen Bolt 13 1.3 113 in·lb
Alternator Lead Clamp Screws 2.9 0.30 26 in·lb
Spark Plug 14 1.4 10
Alternator Stator Allen Bolts 12 1.2 104 in·lb
Alternator Rotor Bolt 69 7.0 51
Starter Motor Mounting Bolts
Starter Chain Guide Screws
Starter Motor Through Bolts
Starter Motor Terminal Nut 6.9 0.7 65 in·lb
Starter Motor Cable Clamp Nut 4.9 0.5 43 in·lb
Starter Clutch Allen Bolts 34 3.5 25 L
Side Stand Switch Mounting Screw 3.9 0.4 35 in·lb L
Oil Pressure Switch 15 1.5 11
Neutral Switch 15 1.5 11
Tail Light Mounting Nuts 5.9 0.6 52 in·lb
N·m kgf·m ft·lb
Hand
-Tighten
(about
4.9)
11 1.1 95 in·lb
4.9 0.5 43 in·lb L
6.9 0.7 65 in·lb
Torque
Hand
-Tighten
(about
0.5)
Hand
-Tighten
(about 43
in·lb)
Remarks
1-20 GENERAL INFORMATION
Torque and Locking Agent
The table relating tightening torque to thread diam eter, lists the basic torque for the bolts and nuts.
Use this table for only the bolts and nuts which do not require a specific torque value. All of the values
are for use with dry solvent-cleaned threads.
General Fasteners
Threads Torque
Diameter (mm) N·m kgf·m ft·lb
5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb
6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb
8 14 ∼ 19 1.4 ∼ 1.9 10.0 ∼ 13.5
10 25 ∼ 34 2.6 ∼ 3.5 19.0 ∼ 25
12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45
14 73 ∼ 98 7.4 ∼ 10.0 54 ∼ 72
16 115 ∼ 155 11.5 ∼ 16.0 83 ∼ 115
18 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165
20 225 ∼ 325 23 ∼ 33 165 ∼ 240
Unit Conversion Table
GENERAL INFORMATION 1-21
Prefixes for Units
Prefix Symbol Power
mega M × 1 000 000
kilo k × 1 000
centi c ×0.01
milli m ×0.001
micro μ × 0.000001
Units of Mass
kg ×2.205=lb
g × 0.03527 = oz
Units of Volume
L × 0.2642 =
L × 0.2200 = gal (imp)
L × 1.057 = qt (US)
L × 0.8799 = qt (imp)
L × 2.113 = pint (US)
L × 1.816 = pint (imp)
mL × 0.03381 = oz (US)
mL × 0.02816 = oz (imp)
mL × 0.06102 = cu in
gal (US)
Units of Length
km × 0.6214 = mile
m × 3.281 =
mm × 0.03937 = in
ft
Units of Torqu e
N·m × 0.1020 = kg·m
N·m × 0.7376 = ft·lb
N·m × 8.851 = in·lb
kgf·m × 9.807 = N·m
kgf·m × 7.233 = ft·lb
kgf·m × 86.80 = in·lb
Units of Pressure
kPa × 0.01020 = kg/cm²
kPa × 0.1450 = psi
kPa × 0.7501 = cmHg
kg/cm² × 98.07 = kPa
kg/cm² × 14.22 = psi
cmHg×1.333=kPa
Units of Speed
km/h × 0.6214 = mph
Units of Force
N × 0.1020 = kg
N × 0.2248 = lb
kg ×9.807=N
kg ×2.205=lb
Units of Temperature
Units of Power
kW ×1.360=PS
kW ×1.341=HP
PS × 0.7355 = kW
PS × 0.9863 = HP
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