Kawasaki VN1500 User Manual

VULCAN 1500 MEAN STREAK

VN1500 MEAN STREAK

Motorcycle

Service Manual

All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.

LIST OF ABBREVIATIONS

A 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 DC direct current r/min, 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) L liter(s)

ampere(s) lb pound(s)

degree(s) Celsius r revolution



ohm(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 exhaustemission (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 cranckcase vapors into the atmosphere. Instead, the vapors are routed through an oil separator to the inlet 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 fuel injection 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, ignition, and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efﬁcient engine with low exhaust pollutant levels. The exhaust system of this model motorcycle manufactured primarily for sale in California includes a catalytic converter system.

3. Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors are routed into the running 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 pollution, contains what is 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 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 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 element of design after such 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 ﬂeet of motor vehicles knowingly 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 purchaser..."

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 exceeded. b.Use of replacement parts or accessories which adversely affect the performance or

durability of the motorcycle. c.Addition of components or accessories that result in the vehicle exceeding the standards. 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 PUNISHABLE 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 its 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 inlet 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 carefully in a clean area. Whenever special tools or equipment are speciﬁed, do not use makeshift tools or equipment. Precision measurements 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 accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty.

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 genuine Kawasaki Motorcycle

•

parts. Special tools, gauges, and testers that are

necessary when servicing Kawasaki motorcycles are

introduced by the Special Tool Catalog or Manual.

Genuine parts provided as spare parts are listed in the

Parts Catalog.

Follow the procedures in this manual carefully. Don’t

•

take shortcuts.

Remember to keep complete records of maintenance

•

and repair with dates and any new parts installed.

How to Use This Manual

In preparing this manual, we divided the product into its major systems. These systems became 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.

If you want ignition coil information, for example, use the Quick ReferenceGuidetolocate the Electrical System chapter. Then, use the Tableof 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.

This warning symbol identiﬁes special instruc-

tions or procedures which, if not correctly fol-

lowed, could result in personal injury, or loss of

life.

CAUTION

This caution symbol identiﬁes special instruc-

tions or procedures which, if not strictly ob-

served, could result in damage to or destruction

of equipment.

This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information.

NOTE



This note symbol indicates points of particular interest for more efﬁcient and convenient 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

text of a NOTE.

Indicates a conditionalsteporwhataction to take based

on the results of the test or inspection in the procedural

step or sub-step it follows.

In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will ﬁnd the instructions indicating which parts require speciﬁed tightening torque, oil, grease or a locking agent during assembly.

GENERAL INFORMATION 1-1

General Information

Table of Contents

Before Servicing................................................................................................................................................................1-2

Model Identiﬁcation...........................................................................................................................................................1-4

General Speciﬁcations......................................................................................................................................................1-6

Torque and Locking Agent................................................................................................................................................1-8

Special Tools and Sealant...............................................................................................................................................1-13

Cable, Wire, and Hose Routing......................................................................................................................................1-20

1-2 GENERAL INFORMATION

Before Servicing

Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also required for successful work.

Especially note the following:

(1) Dirt

Before removal and disassembly, clean the motorcycle. Any dirt entering the engine or other parts will work as an abrasive and shorten the life of the motorcycle. For the same reason, before installing a new part, clean off any dust or metal ﬁlings.

(2) Battery Leads

Disconnect the ground ( This prevents the engine from accidentally turning over while work is being carried out, sparks from being generated while disconnecting the wires from electrical parts, as well as damage to the electrical parts themselves. For reinstallation, ﬁrst connect the positive lead to the positive (+) terminal of the battery.

(3) Installation, Assembly

Generally, installation or assembly is the reverse of removal or disassembly. But if this Service Manual has installation or assembly procedures, follow them. 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 as much as possible.

(4) Tightening Sequence

Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to asnugﬁt. Then tighten them evenly in a cross pattern. This is to avoid distortion of the part and/or causing gas or oil leakage. Conversely when loosening the bolts, nuts, or screws, ﬁrst loosen all of them by about a quarter turn and then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and method indicated.

(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 removal of screws held by a locking agent) in order to avoid damaging the screw heads.

(7) Edges

Watch for sharp edges, especially during major engine disassembly and assembly. Protect your hands with gloves or a piece of thick cloth when 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 Stoddard solvent (generic name). Always follow manufacturer and container directions regarding the use of any solvent.

(9) Gasket, O-Ring

Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leakage.

(10) Liquid Gasket, Non-Permanent Locking Agent

Follow manufacturer’s directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. An example of a nonpermanent locking agent commonly available in North America is Loctite Lock’n Seal (Blue).

(11) Press

A part installed using a press or driver, such as a wheel bearing, should ﬁrst be coated with oil on its outer or inner circumference so that it will go into place smoothly.

(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, as removal generally damages bearings. Install bearings with the marked side facing out applying pressure evenly with a suitable driver. Only press on the race that forms the press ﬁt with the base component to avoid damaging the bearings. This prevents severe stress on the balls or needles and races, and prevent races and balls or needles from being dented. Press a ball bearing until it stops at the stopper in the hole or on the shaft.

(13) Oil Seal and Grease Seal

Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. When pressing in a seal which has manufacturer’s marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole. Before a shaft passes through a seal, apply a little high temperature grease on the lips to reduce rubber to metal friction.

−) lead from the battery before performing any disassembly operations on the motorcycle.

GENERAL INFORMATION 1-3

Before Servicing

(14) Circlip, Retaining Ring, and Cotter Pin

Replace any circlips and retaining rings, and cotter pins that were removed with new ones, as removal weakens and deforms them. When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more.

(15) Lubrication

Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative ﬁlm. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface which has lost its lubricative ﬁlm. Old grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles.

Don’t use just any oil or grease. 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. This manual makes reference to molybdenum disulﬁde grease (MoS parts. The molybdenum disulﬁde oil is a mixture of engine oil and molybdenum disulﬁde grease with a weight ratio (10 : 1), which can be made in your work shop. Always check manufacturer recommendations before using such special lubricants.

(16) Electrical Wires

All the electrical wires are either single-color or two-color and, with only a few exceptions, must be connected to wires of the same color. On any of the two-color wires there is a greater amount of one color and a lesser amount of a second color, so a two-color wire is identiﬁed by ﬁrst the primary color and then the secondary color. For example, a yellow wire with thin red stripes is referred to as a "yellow/red" wire; it would be a "red/yellow" wire if the colors were reversed to make red the main color.

2) and molybdenum disulﬁde oil in the assembly of certain engine and chassis

(17) Replacement Parts

When there is a replacement instruction, replace these parts with new ones every time they are removed. These replacement parts will be damaged or lose their original function once removed.

(18) 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

(19) 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 deteriorated performance, replace the damaged parts.

1-4 GENERAL INFORMATION

Model Identiﬁcation

VN1500-P1 (US, and Canada) Left Side View:

VN1500-P1 (US, and Canada) Right Side View:

Model Identiﬁcation

VN1500-P1 (Europe) Left Side View:

GENERAL INFORMATION 1-5

VN1500-P1 (Europe) Right Side View:

1-6 GENERAL INFORMATION

General Speciﬁcations

Items VN1500-P1

Dimensions:

Overall length Overall width 850 mm (33.5 in.) Overall height 1100 mm (43.3 in.) Wheelbase 1705 mm (67.1 in.) Road clearance 125 mm (4.92 in.) Seat height 700 mm (27.6 in.) Dry mass 289 kg (637 lb) Curb mass: Front 144 kg (318 lb)

Rear 172 kg (379 lb) Fuel tank capacity 17.0 L (4.49 US gal) Fuel Unleaded and high-octane gasoline (see VN1500-P1 Owner’s Manual)

Performance:

Minimum turning radius 3.1 m (10.2 ft)

Engine:

Type 4-stroke, SOHC, V2-cylinder Cooling system Liquid-cooled Bore and stroke 102290 mm (4.02 Displacement 1470 mL (89.70 cu in.) Compression ratio 9.0 : 1 Maximum horsepower 53 kW (72 PS) @5500 r/min (rpm),

Maximum torque 114 N1m (11.6 kg

Carburetion system DFI (Digital Fuel Injection) System Starting system Electric starter Ignition system Battery and coil (transistorized) Timing advance Electronically advanced (digital) Ignition timing From 5BTDC @950 r/min (rpm) 25BTDC @4500 r/min (rpm) Spark plugs NGK DPR6EA-9 or ND X20EPR-U9 Cylinder numbering method Front to Rear, 1-2 Firing order 1-2 Valve timing:

Inlet Open 28BTDC

Close 72ABDC

Duration 280

Exhaust Open 66BBDC

Close 42ATDC

Duration 288 Lubrication system Forced lubrication (wet sump) Engine oil: Type API : SE, SF or SG class

Viscosity SAE10W-40

Capacity 3.5 L (3.7US qt, when engine is completely disassembled and dry)

Drive Train:

Primary reduction system:

Type Gear Reduction ratio 1.517 (85/56)

Clutch type Wet multi disc

2410 mm (94.9 in.)

3.54 in.)

(AU) 47 kW (64 PS) @ 5300 r/min (rpm), (CA) (CN) (US) –

m, 84.1 ft1lb) @3000 r/min (rpm),

(AU) 108 N



API SH or SJ class with JASO MA

m (11.0 kg

m, 79.7 ft1lb) @3000 r/min (rpm), (CA) (CN) (US) –

GENERAL INFORMATION 1-7

General Speciﬁcations

Items VN1500-P1

Transmission:

Type 5-speed, constant mesh, return shift Gear ratios: (CA, CN, US)

1st 2.500 (40/16) 2nd 1.750 (35/20) 3rd 1.333 (32/24) 4th 1.074 (29/27) 5th 0.867 (26/30)

(other than CA, CN, US) 1st 2.500 (40/16) 2nd 1.590 (35/22) 3rd 1.192 (31/26) 4th 0.965 (28/29) 5th 0.781 (25/32)

Final drive system:

Type Shaft Reduction ratio 2.619 (15/21233/9) Overall drive ratio (CA, CN, US) 3.445 @ Top gear

(other than CA, CN, US) 3.105 @ Top gear

Final gear case oil:

Grade API Service Classiﬁcation: GL-5 Hypoid gear oil Viscosity SAE90 (above 5C), SAE80 (below 5 Capacity 200 mL

Frame:

Type Tubular, double cradle Caster (rake angel) 32 Trail 144 mm (5.67 in.) Front tire: Type Tubeless

Size 130/70R17 M/C 62H

Rear tire: Type Tubeless

Size 170/60R17 M/C 72H

Front suspension: Type Telescopic fork (upside-down)

Wheel travel 150 mm (5.91 in.)

Rear suspension: Type Swingarm, air oil shock absorber

Wheel travel 87 mm (3.43 in)

Brake Type: Front Dual disc

Rear Single disc

Electrical Equipment:

Battery Headlight: Type Semi-sealed beam

Tail/brake light 12 V 5/21 W Alternator: Type Three-phase AC

Speciﬁcations are subject to change without notice, and may not apply to every country.

AU: Australian Model CA: California Model CN: Canadian Model US: United States of America Model

Capacity

Bulb 12 V 60/55 W (quartz-halogen)

Rated output 23 A214 V @6 000 r/min (rpm)



12 V 18 Ah



1-8 GENERAL INFORMATION

Torque and Locking Agent

The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket.

Letters used in the “Remarks” column mean:

G: Apply grease to the threads.

EO: Apply engine oil to the threads and the seating

surface.

L: Apply a non-permanent locking agent to the

threads.

Lh: Left-hand threads.

MO: Apply molybdenum disulﬁde oil to the threads and

the seating surface. The molybdenum disulﬁde oil is a mixture of engine oil and molybdenum disulﬁde grease with a weight ratio (10 : 1).

S: Tighten the fasteners following the speciﬁed se-

quence.

SS: Apply silicone sealant.

St: Stake the fasteners to prevent loosening.

R: Replacement parts

Fastener

Fuel System:

Vacuum Sensor Nut 9.8 1.0 87 in Atmospheric Pressure Sensor Nut 9.8 1.0 87 in High Pressure Fuel Hose Clamp Screws 1.5 0.15 13 in Pressure Regulator Screws 4.9 0.50 43 in Delivery Joint Screws 3.4 0.35 30 in Throttle Cable Holder Screw 3.4 0.35 30 in1lb L Throttle Body Flange Bolts 4.9 0.50 43 in Throttle Assy Holder Bolts 11 1.1 95 in Inlet Manifold Bolts 12 1.2 104 in Spark Plug Lead Holder Bolts 11 1.1 95 in ISC Pipe Holder Bolts 9.8 1.0 87 in Air Cleaner Duct Holder Bolts 11 1.1 95 in1lb Left Side Right and Left Air Cleaner Base Bolts 11 1.1 95 in Right and Left Air Cleaner Base Screws 2.2 0.22 19 in Left Air Cleaner Duct Tapping Screws 2.2 0.22 19 in1lb Left Air Cleaner Cover Allen Bolt8 16 1.6 12 Right Air Cleaner Cover Allen Bolt Right Air Cleaner Allen Bolts 11 1.1 95 in Choke Cable Plate Screw 2.9 0.30 26 in1lb L, Throttle Body Inlet Air Temperature Sensor Nut (DFI) 7.8 0.80 69 in1lb Water Temperature Sensor (DFI) 18 1.8 13 SS Fuel Pump Bolts 6.9 0.70 61 in1lb S, L Return Fuel Check Valve 20 2.0 15

Cooling System:

Radiator Hose Clamp Screws 2.5 0.25 22 in1lb Thermostat Air Bleeder Bolt 7.8 0.80 69 in1lb Radiator Fan Switch 18 1.8 13 Radiator Fan Bolts 8.3 0.85 74 in1lb Water Temperature Switch 7.4 0.75 65 in1lb SS Water Pump Impeller Bolt 8.8 0.90 78 in1lb Lh Water Pump Cover Bolts 11 1.1 95 in1lb Water Pump Air Bleeder Bolt 11 1.1 95 in1lb Water Pump Drain Bolt 11 1.1 95 in1lb Water Pipe Bolts 9.8 1.0 87 in1lb Radiator Drain Bolt 7.4 0.75 65 in1lb

Engine Top End:

Spark Plugs 18 1.8 13



N1m kg1m ft1lb

16 1.6 12

The table below, relating tightening torque to thread diameter, 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.

Basic Torque for General Fasteners

Threads Torque

dia. (mm) N

5 3.4 6 5.9 7.8 0.60 0.80 52 69 in1lb

8 14 10 25 12 44 61 4.5 6.2 33 45 14 73 16 115 18 165 20 225

Torque

4.9

98 155 225 325

kg1m ft1lb

1.4

2.6

7.4

1 1 1 1 1

1 1

lb lb lb lb lb

lb lb

0.50

1.9

3.5

10.0

16.0

23.0 33

Throttle Body

on Cyl. Head

L, Lower Duct

Throttle Body

0.35

11.5

17.0

10.0

19.0

83 125 165

Remarks

Right Side

43 in

13.5

115

165 240

Torque and Locking Agent

GENERAL INFORMATION 1-9

Fastener

Spark Plug Retainer 12 1.2 104 in Air Suction Valve Cover Bolts 7.4 0.75 65 in1lb Chain Tensioner Mounting Bolts 11 1.1 95 in1lb S Chain Tensioner Cap 20 2.0 15 S Chain Tensioner Lockbolt 4.9 0.50 43 in1lb S Timing Inspection Cap 1.5 0.15 13 in Rotor Bolt Cap 1.5 0.15 13 in Camshaft Sprocket Bolts 15 1.5 11 L Oil Hose Flange Bolts 9.8 1.0 87 in1lb Rocker Shafts 25 2.5 18 Rocker Case Nuts 12 mm 78 8.0 58 MO, S

8mm 25 2.5 18 S Rocker Case Bolts 6 mm 8.8 0.90 78 in Cylinder Head Nuts 25 2.5 18 S Cylinder Head Jacket Plugs 20 2.0 15 L Rocker Case Cover Bolts 8.8 0.90 78 in Camshaft Chain Guide Bolts 11 1.1 95 in1lb L Cylinder Nuts 25 2.5 18 S Inlet Manifold Bolts 12 1.2 104 in1lb on Cyl. Head Exhaust Pipe Cover Clamp Bolts 6.9 0.70 61 in Chamber Bolts 29 3.0 22 Mufﬂer Stay Mounting Bolts,8 27 2.8 20 Lower Mufﬂer Upper Mufﬂer Bracket Bolt and Nut 29 3.0 22

Clutch:

Clutch Lever Pivot Bolt 1.0 0.10 8.7 in1lb Clutch Lever Pivot Bolt Locknut 5.9 0.60 52 in Clutch Reservoir Cap Screws 1.5 0.15 13 in Clutch Slave Cylinder Bleed Valve 7.8 0.80 69 in Clutch Slave Cylinder Bolts 6.9 0.70 61 in Clutch Hose Banjo Bolts 25 2.5 18 Clutch Master Cylinder Clamp Bolts 9.8 1.0 87 in Starter Lockout Switch Screws 1.2 0.12 10 in Push Rod Guide Bolts 9.8 1.0 87 in Clutch Cover Bolts 11 1.1 95 in Clutch Cover Damper Bolts (outside) 9.8 1.0 87 in Clutch Cover Damper Bolts (inside) 9.8 1.0 87 in Clutch Cover Damper Screws 4.9 0.50 43 in Clutch Hub Nut 147 15.0 108 MO

Engine Lubrication System:

Oil Filler Cap 1.5 0.15 13 in1lb Oil Screen Plug 20 2.0 15 Engine Oil Drain Plug 20 2.0 15 Oil Filter (Cartridge type) 18 1.8 13 R, EO Oil Filter Bolt 25 2.5 18 SS Oil Pressure Relief Valve 15 1.5 11 L Oil Pressure Switch Terminal Screw 1.5 0.15 13 in1lb Oil Pressure Switch 15 1.5 11 SS Oil Pump Mounting Bolts 11 1.1 95 in1lb Oil Hose Banjo Bolts 9.8 1.0 87 in1lb Oil Hose Flange Bolt (outside) 9.8 1.0 87 in1lb Oil Pipe Holder Bolts (inside) 11 1.1 95 in1lb L Oil Pipe Clamp Bolts (inside) 11 1.1 95 in1lb L Right & Left Crankcase Oil Nozzles 2.9 0.30 26 in1lb Right Crankcase Oil Nozzle 2.9 0.30 26 in1lb Oil Bafﬂe Bolt 11 1.1 95 in1lb L

Engine Removal/Installation:

Downtube Bolts and Nuts 44 4.5 32

Torque

kg1m ft1lb

Remarks

EO (tip)

1, Lh

1-10 GENERAL INFORMATION

Torque and Locking Agent

Fastener

Engine Mounting Bolts and Nuts 44 4.5 32 Engine Mounting Bracket Bolts 25 2.5 18 Engine Ground Terminal Bolt 7.8 0.80 69 in1lb

Crankshaft/Transmission:

Crankcase Bolts 10 mm 39 4.0 29 S

8mm 21 2.1 15 S

6mm 11 1.1 95 in Jumper Cable Ground Bracket Bolt 9.8 1.0 87 in1lb Left Crankcase Crankcase Bearing Retainer Bolts 11 1.1 95 in1lb L Camshaft Chain Guide Bolts 11 1.1 95 in1lb L Right, Left Crankcase Oil Nozzles 2.9 0.30 26 in1lb Right Crankcase Oil Nozzles 2.9 0.30 26 in Oil Bafﬂe Bolt 11 1.1 95 in Connecting Rod Big End Nuts 59 6.0 43 MO Oil Pressure Relief Valve 15 1.5 11 L Oil Filter Bolt 25 2.5 18 Oil Hose Banjo Bolts 9.8 1.0 87 in1lb Primary Gear Bolt 147 15.0 108 MO Water Pump Chain Guide Spring Hook Bolt 2.9 0.30 26 in1lb Water Pump Chain Guide Bolt 8.3 0.85 73 in Idle Shaft Holder Bolts 7.8 0.80 69 in Oil Pressure Switch Terminal Screw 1.5 0.15 13 in1lb Oil Pressure Switch 15 1.5 11 SS Oil Pipe Clamp Bolts (inside) 11 1.1 95 in Left Balancer Gear Bolt 85 8.7 63 MO Starter Clutch Bolt 85 8.7 63 MO Starter Clutch Coupling Bolts 15 1.5 11 L Gear Set Lever Bolt 11 1.1 95 in Shift Shaft Return Spring Pin (Bolt) 39 4.0 29 L Shift Pedal Clamp Bolt 17 1.7 12 mark 10 Rear Shift Lever Clamp Bolt 12 1.2 104 in Shift Rod Locknuts 11 1.1 95 in Shift Drum Bearing Holder Bolts 11 1.1 95 in Shift Drum Cam Screw – – – L Damper Cam Nut (Front Gear) 226 23 166 MO (threads) Push Rod Guide Bolts 9.8 1.0 87 in

Wheels/Tires:

Front Axle Clamp Bolts 25 2.5 18 S Front Axle 110 11 79.6 S Rear Axle Nut 110 11 79.6 Tire Air Valve Stem Nuts 1.5 0.15 13 in1lb Tire Air Valve Caps 0.15 0.015 1.3 in1lb Air Valve Cores 0.3 0.03 2.6 in1lb

Final Drive:

Oil Pipe Banjo Bolts (Front Gear) 12 1.2 104 in1lb Oil Nozzle (Front Gear) 2.9 0.30 26 in1lb Oil Nozzle (Front Gear) 18 1.8 13 Neutral Switch 15 1.5 11 Front Gear Case Bolts: 6 mm 12 1.2 104 in1lb mark 9

8mm 29 3.0 22 Speed Sensor Bolt 9.8 1.0 87 in1lb L Damper Cam Nut (Front Gear) 226 23 166 MO (threads) Drive Gear Nut (Front Gear) 265 27 195 MO, St Driven Gear Assy Mounting Bolts 25 2.5 18 Driven Gear Bolt (Front Gear) 137 14 101 MO, St Bearing Retainer Bolts (Front Gear) 8.8 0.9 78 in1lb L Final Gear Case Drain Plug 8.8 0.9 78 in1lb

Torque

kg1m ft1lb

Remarks

1, Lh

(Rear: Lh)

Torque and Locking Agent

GENERAL INFORMATION 1-11

Fastener

Final Gear Case Mounting Nuts 34 3.5 25 Final Gear Case Studs – – – L Final Gear Case Cover Bolts: 8 mm 23 2.3 17 L

10 mm 34 3.5 25 L Pinion Gear Nut (Final Gear) 127 13 93 St, MO Bearing Retainer Bolt 6.9 0.7 61 in

Brakes:

Caliper Bleed Valves 7.8 0.8 69 in1lb Brake Hose Banjo Bolts 25 2.5 18 Brake Lever Pivot Bolt 1.0 0.10 8.7 in1lb Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in1lb Front Brake Reservoir Cap Screws 1.5 0.15 13 in Front Brake Light Switch Screw 1.2 0.12 10 in Front Master Cylinder Clamp Bolts 8.8 0.9 78 in1lb G, S Front Brake Pad Spring Bolts 2.9 0.3 26 in1lb Front Caliper Mounting Bolts 34 3.5 25 Front Caliper Assembly Bolts 21 2.1 15 Rear Caliper Mounting Bolts 34 3.5 25 Rear Caliper Holder Bolt 64 6.5 47 Brake Disc Bolts 27 2.8 20 L Rear Master Cylinder Mounting Bolts 25 2.5 18 Rear Master Cylinder Push Rod Locknut 18 1.8 13 Brake Pedal Clamp Bolt 25 2.5 18

Suspension:

Upper Front Fork Clamp Bolts 20 2.0 15 Lower Front Fork Clamp Bolts 20 2.0 15 Front Fork Top Plugs 34 3.5 25 Piston Rod Nuts or Joint Rod Nut 20 2.0 15 Inner Fork Bolt (left) 98 10 73 Front Fork Bottom Allen Bolt (right) 20 2.0 15 L Front Axle Clamp Bolts 25 2.5 18 S Protector Screws 5.9 0.6 52 in Rear Shock Absorber Nuts 34 3.5 25 Shock Absorber Air Valves 5.4 0.55 47 in Swingarm Pivot Shaft 110 11 79.6 G

Steering:

Steering Stem Head Nut 54 5.5 40 Steering Stem Nut 4.9 0.5 43 in1lb Handlebar Nuts 34 3.5 25 Handlebar End Caps – – – Lh, L Handlebar Switch Housing Screws 3.4 0.35 30 in1lb Upper Front Fork Clamp Bolts 20 2.0 15 Lower Front Fork Clamp Bolts 20 2.0 15 Turn Signal Light Mounting Nuts 5.9 0.6 52 in1lb

Frame:

Downtube Bolts and Nuts 44 4.5 32 Front Footpeg Bracket Bolts 25 2.5 18 Rear Footpeg Bracket Bolts 25 2.5 18 Sidestand Nut 44 4.5 32

Electrical System:

Spark Plugs 18 1.8 13 Pickup Coil Screws 2.9 0.30 26 in1lb Stator Lead Holder Screw 9.8 1.0 87 in1lb Pickup Coil Lead Holder Bolt 9.8 1.0 87 in1lb Alternator Outer Cover Bolts 6.9 0.7 61 in1lb Alternator Outer Cover Joint Bolts 6.9 0.7 61 in1lb Alternator Outer Cover Damper Bolts 6.9 0.7 61 in1lb L

Torque

kg1m ft1lb

Remarks

L L

1-12 GENERAL INFORMATION

Torque and Locking Agent

Fastener

Alternator Outer Cover Assembly Bolts 6.9 0.7 61 in Alternator Cover Bolts 11 1.1 95 in1lb Alternator Inner Cover Bolts 11 1.1 95 in1lb Alternator Rotor Bolt 78 8.0 57 MO Alternator Stator Bolts 13 1.3 113 in1lb L Regulator/Rectiﬁer Bolts 6.5 0.66 58 in Timing Inspection Cap 1.5 0.15 13 in Rotor Bolt Cap 1.5 0.15 13 in1lb Starter Motor Terminal Locknut 11 1.1 95 in1lb Starter Motor Terminal Nut 4.9 0.50 43 in1lb Starter Motor Assy Bolts 4.9 0.50 43 in1lb Starter Motor Mounting Bolts 11 1.1 95 in Headlight Body Mounting Nuts 7.8 0.8 62 in Headlight Rim Screws 1.4 0.14 12 in1lb L Headlight Mounting Screws 2.9 0.3 26 in1lb Headlight Body Bracket Screws 1.2 0.12 10 in Handlebar Switch Housing Screws 3.4 0.14 12 in1lb Starter Lockout Switch Screw 1.2 0.12 10 in Front Brake Light Switch Screw 1.2 0.12 10 in1lb Sidestand Switch Bolt 8.8 0.9 78 in Radiator Fan Switch 18 1.8 13 Water Temperature Switch 7.8 0.8 69 in1lb SS Oil Pressure Switch Terminal Screw 1.5 0.15 13 in Oil Pressure Switch 15 1.5 11 SS Neutral Switch 15 1.5 11 Turn Signal Light Mounting Nuts Front 5.9 0.60 52 in

Rear 6.9 0.7 61 in License Plate Lens Screws 1.0 0.1 8.7 in License Plate Light Mounting Screw 1.2 0.12 10 in

Torque

kg1m ft1lb

Remarks

Special Tools and Sealant

GENERAL INFORMATION 1-13

Oil Pressure Gauge, 5 kg/cm2: 57001-125

Inside Circlip Pliers: 57001-143

Outside Circlip Pliers: 57001-144

Valve Guide Arbor,

Compression Gauge: 57001-221

Valve Spring Compressor Assembly: 57001-241

7: 57001-163

Bearing Puller: 57001-158

Valve Guide Reamer, 7: 57001-162

Valve Spring Compressor Adapter,

Bearing Puller Adapter: 57001-317

28.2: 57001-243

1-14 GENERAL INFORMATION

Special Tools and Sealant

Bearing Driver: 57001-382

Piston Pin Puller Assembly: 57001-910

Gear Holder: 57001-1015

Damper Cam Holder: 57001-1025

Driven Gear Holder: 57001-1027

Oil Pressure Gauge Adapter, PT 1/8: 57001-1033

Compression Gauge Adapter, M12

Spark Plug Wrench, Hex 18: 57001-1024

1.25: 57001-1018

Oil Seal & Bearing Remover: 57001-1058

Head Pipe Outer Race Press Shaft: 57001-1075

Special Tools and Sealant

GENERAL INFORMATION 1-15

Head Pipe Outer Race Driver: 57001-1077

Piston Ring Compressor Grip: 57001-1095

Steering Stem Nut Wrench: 57001-1100



Valve Seat Cutter, 45

Valve Seat Cutter, 32

Valve Seat Cutter, 32– 38.5 : 57001–1122

35: 57001-1116



35: 57001-1121

Head Pipe Outer Race Remover: 57001-1107

Valve Seat Cutter, 45- 32: 57001-1115

Valve Seat Cutter Holder,

Valve Seat Cutter Holder Bar: 57001-1128

7: 57001-1126

1-16 GENERAL INFORMATION

Special Tools and Sealant

Bearing Driver Set: 57001-1129

Pinion Gear Holder: 57001-1165

Hexagon Wrench, Hex 27: 57001-1210

Jack: 57001-1238

Timing Light: 57001-1241

Valve Seat Cutter, 55- 35: 57001-1247

Piston Pin Puller Adapter: 57001-1211

Fork Outer Tube Weight: 57001-1218

Oil Filter Wrench: 57001-1249

Final Gear Case Holder: 57001-1250

Special Tools and Sealant

GENERAL INFORMATION 1-17

Bearing Remover Shaft, 9: 57001-1265

Bearing Remover Head, 10212: 57001-1266

Fork Piston Rod Puller, M12 x 1.25 : 57001–1289

Flywheel Holder : 57001–1313

Steering Stem Bearing Driver: 57001-1344

Steering Stem Bearing Driver Adapter: 57001-1345

Fork Oil Level Gauge: 57001-1290

Bearing Remover Head, 20222: 57001-1293

Piston Ring Compressor Belt,

Bearing Remover Shaft,

13: 57001-1377

95 108: 57001-1358

1-18 GENERAL INFORMATION

Special Tools and Sealant

Hand Tester: 57001-1394

Attachment Jack: 57001-1398

Drive Shaft Holder: 57001-1407

Driver-Filler Cap: 57001–1454

Needle Adapter Set: 57001–1457

Valve Seat Cutter, 45- 40: 57001-1496

Flywheel Holder: 57001-1410

Fuel Pressure Gauge Adapter: 57001-1417

Valve Seat Cutter, 55

Fork Cylinder Holder: 57001-1502



- 38.5: 57001-1497

GENERAL INFORMATION 1-19

Special Tools and Sealant

Kawasaki Bond (Silicone Sealant): 56019–120 Kawasaki Bond (Liquid Gasket-Black): 92104-1003

1-20 GENERAL INFORMATION

Cable, Wire, and Hose Routing

F: Front

1. Indicator Lights

2. Fuel Tank

3. Fuel Pump Base

4. Two Clamps (fuel pump leads)

5. Plastic Caps

6. Snap-on Plastic Clamps

7. Fuel Tank Breather Hose

8. Fuel Pump Harness

9. Run the harness [8] under the hose [7].

10. Indicator Light Connector : Insert the main harness side connector into the connector hole of the bracket [13] and join the connector.

11. Main Harness

12. Ignition Switch Connector : Join the connector and ﬁt them into the hole of the bracket [13].

13. Indicator Unit Bracket

14. Ignition Switch

15. Press each end of clamps by hands against the bottom of the tank. And then, make sure that the ends touch the bottom of the tank.

Cable, Wire, and Hose Routing

GENERAL INFORMATION 1-21

F: Front 11.

Front Right Spark Plug Cap

Rear Right Spark Plug Cap

2nd Lead from the left ignition coil lower side

2nd Lead from the right ignition coil lower side

Ignition Coil for Rear Spark Plugs

Ignition Coil for Front Spark Plugs

2nd Lead from the left ignition coil upper side

2nd Lead from the right ignition coil upper side

Front Left Spark Plug Cap

10.

Rear Left Spark Plug Cap

Clutch Hose

12.

Plastic Snap-on Clamps

13.

Strap

14.

BK/G Primary Lead

15.

R/G Primary Lead

16.

BK Primary Lead

17.

R/G Primary Lead

18.

Align the white mark with the back of the clamp [12].

19.

Canister Purge Hose (green, CA)

1-22 GENERAL INFORMATION

Cable, Wire, and Hose Routing

Inlet Air Flow

Rear View

Air Inlet

Left Rubber Gasket

Left Air Cleaner Cover

Air Cleaner Element

Left Air Cleaner Base

Lower Air Cleaner Duct

Vacuum Switch Valve Hose

To Vacuum Switch Valve

10.

Right Air Cleaner Base

11.

Right Rubber Gasket

12.

Right Air Cleaner Cover

13.

Locate the glued joint of the gasket within the angle.

14.

Elbow Joint: connected to crankcase breather hose

15.

Top

16.

White Mark on Hose [8] (front side): Position here.

17.

Plug

18.

Run this drain hose between cylinders.

Cable, Wire, and Hose Routing

GENERAL INFORMATION 1-23

: Bypass Air Flow

F: Front

1. Rear View

2. Throttle Assy

3. Air Cleaner Base Seal

4. Spark Plug Lead Holder

5. Right Side View

6. Harness of Inlet Air Temperature Sensor & ISC Valves

7. T-Joint

8. Vacuum Hose from Throttle Body

9. Vacuum Sensor and Pressure Regulator

10. Strap (holds [4], [6], and [11])

11. Vacuum Switch Valve Hose

12. Right Air Cleaner Base Bolts

13. Right Air Cleaner Base

14. O-rings

15. ISC Valve Hose #2 (red)

16. ISC Valve Hose #1 (blue)

17. Lower Air Cleaner Duct

18. ISC Valve #2 (rear cylinder)

19. ISC Valve Inlets

20. Blue Mark on Top

21. ISC Valve #1 (front cylinder)

22. Inlet Air Temperature Sensor

23. Section B-B

24. Crankcase Breather Hose

25. Clamp these leads [6] with a slack as little as possible.

26. Back of Right Air Cleaner Base

1-24 GENERAL INFORMATION

Cable, Wire, and Hose Routing

--!:

Vacuum Pulsation

Fuel Flow

#1:

For Front Cylinder

#2:

For Rear Cylinder

Fuel Tank (left view)

Return Fuel Check Valve

High Pressure Fuel Hoses

Delivery Joint

Fuel Injector #1

Fuel Injector #2

Pressure Regulator

Throttle Body

Inlet Manifold

10.

Throttle Assy (top view)

11.

Throttle Pulley

12.

Throttle Sensor

13.

Low Pressure (Return) Fuel Hose

14.

Vacuum Hoses from Throttle Body

15.

Front

16.

Vacuum Hose (white, CA)

17.

T-Joint

18.

Vacuum Switch Valve

19.

Vacuum Sensor

20.

Throttle Vacuum Hose

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