VULCAN 1600 CLASSIC VN1600 CLASSIC
Motorcycle
Service Manual
Quick Reference Guide
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.
General Information |
1 |
Periodic Maintenance |
2 |
Fuel System (DFI) |
3 |
Cooling System |
4 |
Engine Top End |
5 |
Clutch |
6 |
Engine Lubrication System |
7 |
Engine Removal/Installation |
8 |
Crankshaft/Transmission |
9 |
Wheels/Tires |
10 |
Final Drive |
11 |
Brakes |
12 |
Suspension |
13 |
Steering |
14 |
Frame |
15 |
Electrical System |
16 |
Appendix |
17 |
VULCAN 1600 CLASSIC
VN1600 CLASSIC
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.
© 2003 Kawasaki Heavy Industries, Ltd. |
Second Edition (1) : Aug. 25, 2003 (M) |
|
|
|
|
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 |
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) (mass) |
W |
watt(s) |
h |
hour(s) |
Ω |
ohm(s) |
kg |
(mass) |
|
|
kgf |
(force) |
|
|
L |
liter(s) |
|
|
Read OWNER’S MANUAL before operating.
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 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.
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.
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 care-
•fully. 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. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter.
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.
The Periodic Maintenance Chart is located in the Periodic Maintenance chapter. The chart gives a time schedule for required maintenance operations.
If you want spark plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, use the Quick Reference Guide to locate the Periodic Maintenance chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug 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 personal injury, or loss of life.
CAUTION
This caution symbol identifies special instructions or procedures which, if not strictly observed, 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.
•Indicatesdone. a procedural step or work to be ○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 conditional step or what action 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 |
1 |
Table of Contents |
|
Before Servicing ..................................................................................................................... |
1-2 |
Model Identification................................................................................................................. |
1-7 |
General Specifications............................................................................................................ |
1-9 |
Unit Conversion Table ............................................................................................................ |
1-11 |
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:
Before completing any service on the motorcycle, disconnect the battery wires from the battery to prevent the engine from accidentally turning over. Disconnect the ground wire
(–) first and then the positive (+). When completed with the service, first connect the positive (+) wire to the positive (+) terminal of the battery then the negative (–) wire to the negative terminal.
Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.
Use a high flush point solvent when cleaning parts. High flush point solvent should be used according to directions of the solvent manufacturer.
Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.
GENERAL INFORMATION 1-3
Before Servicing
Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.
After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.
Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit.
Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.
In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given.
1-4 GENERAL INFORMATION
Before Servicing
Bolts, nuts, or screws must be tightened according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.
Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench.
Often, the tightening sequence is followed twice-initial tightening and final tightening with torque wrench.
Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non -permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary.
Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used O-rings when re-assembling
For applications that require Liquid Gasket or a Locking agent, clean the surfaces so that no oil residue remains before applying liquid gasket or locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.
GENERAL INFORMATION 1-5
Before Servicing
For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing.
Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.
Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed. Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing.
Replace circlips or cotter pins that were removed with new ones. Install the circlip with its sharp edge facing outward and its chamfered side facing inward to prevent the clip from being pushed out of its groove when loaded. Take care not to open the clip excessively when installing to prevent deformation.
It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified.
1-6 GENERAL INFORMATION
Before Servicing
When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side).
A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color.
GENERAL INFORMATION 1-7
Model Identification
1-8 GENERAL INFORMATION
Model Identification
|
|
|
GENERAL INFORMATION 1-9 |
|
|
|
|
General Specifications |
|
||
|
|
|
|
|
|
|
|
|
Items |
|
VN1600-A1 |
|
Dimensions: |
|
|
|
Overall length |
|
2 505 mm (98.62 in.) |
|
Overall width |
|
1 040 mm (40.9 in.), (AU) 990 mm (39 in.) |
|
Overall height |
|
1 130 mm (44.5 in.) |
|
Wheelbase |
|
1 680 mm (66.1 in.) |
|
Road clearance |
|
130 mm (5.12 in.) |
|
Seat height |
|
680 mm (26.8 in.) |
|
Dry mass |
|
306 kg (675 lb), (AU) 307 kg (677 lb) |
|
Curb mass: |
Front |
156 kg (345 lb) |
|
|
Rear |
181 kg (399 lb), (AU) 182 kg (401 lb) |
|
Fuel tank capacity |
|
20 L (5.3 US gal) |
|
Fuel |
|
Unleaded and high-octane gasoline |
|
|
|
(see VN1600-A1 Owner’s Manual) |
|
Performance: |
|
|
|
Minimum turning radius |
|
|
|
3.5 m (11.5 ft) |
||
|
Engine: |
|
|
|
Type |
|
4-stroke, SOHC, V2-cylinder |
|
Cooling system |
|
Liquid-cooled |
|
Bore and stroke |
|
102 × 95 mm (4.02 × 3.74 in.) |
|
Displacement |
|
1 552 mL (94.70 cu in.) |
|
Compression ratio |
|
9.0 : 1 |
|
Maximum horsepower |
|
49 kW (67 PS) @ 4 700 r/min (rpm), (CA) (CAL) (US) – |
|
Maximum torque |
|
127 N·m (12.95 kgf·m, 93.7 ft·lb) @ 2 700 r/min (rpm), |
|
|
|
(CA) (CAL) (US) – |
|
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 0° BTDC @ 950 r/min (rpm) 25° BTDC @ 4 500 |
|
|
|
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 |
22° BTDC |
|
|
Close |
66° ABDC |
|
|
Duration |
268° |
|
Exhaust |
Open |
66° BBDC |
|
|
Close |
26° ATDC |
|
|
Duration |
272° |
|
Lubrication system |
|
Forced lubrication (wet sump) |
|
Engine oil: |
Type |
API SE, SF or SG class |
|
|
|
API SH or SJ class with JASO MA |
|
|
Viscosity |
SAE10W-40 |
|
|
Capacity |
3.5 L (3.7US qt, when engine is completely disassembled |
|
|
|
and dry) |
|
|
|
|
1-10 GENERAL INFORMATION
General Specifications
|
|
|
Items |
|
VN1600-A1 |
Drive Train: |
|
|
Primary reduction system: |
|
|
Type |
|
|
|
Gear |
|
Reduction ratio |
|
1.517 (85/56) |
Clutch type |
|
Wet multi disc |
Transmission: |
|
|
Type |
|
5-speed, constant mesh, return shift |
Gear ratios: |
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 (15/21 × 33/9) |
Overall drive ratio |
|
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°C) |
|
Capacity |
|
200 mL (6.76 US oz) |
Frame: |
|
|
Type |
|
Tubular, double cradle |
Caster (rake angel) |
|
|
|
32° |
|
Trail |
|
168 mm (6.61 in.) |
Front tire: |
Type |
Tubeless |
|
Size |
130/90 - 16 M/C 67H |
Rear tire: |
Type |
Tubeless |
|
Size |
170/70B16 M/C 75H |
Front suspension: |
Type |
Telescopic fork |
|
Wheel travel |
150 mm (5.91 in.) |
Rear suspension: |
Type |
Swingarm |
|
Wheel travel |
95 mm (3.74 in.) |
Brake Type: |
Front |
|
Dual disc |
||
|
Rear |
Single disc |
Electrical Equipment: |
|
|
Battery |
Capacity |
12 V 18 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, twin rotor |
|
Rated output |
42A × 14 V @ 6 000 r/min (rpm) |
Specifications are subject to change without notice, and may not apply to every country. AU: Australia
CAL: California
CA: Canada
US: United States of America
GENERAL INFORMATION 1-11
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Unit Conversion Table |
|
|
|
|
|
|
|
|
|
||||
|
|
|
|
|
|
|
|
|
|
|
|||
|
Prefixes for Units: |
|
|
|
|
Units of Length: |
|
|
|||||
|
|
|
|
|
|
|
|
|
km |
× |
0.6214 |
= |
mile |
|
Prefix |
|
Symbol |
|
|
Power |
|||||||
|
|
|
|
|
|
m |
× |
3.281 |
= |
ft |
|||
|
|
|
|
|
|
|
|
|
|||||
|
mega |
|
M |
|
× 1 000 000 |
||||||||
|
|
|
|
|
mm |
× |
0.03937 |
= |
in. |
||||
|
kilo |
|
k |
|
× |
1 000 |
|
|
|||||
|
|
|
|
|
|
|
|
|
|
||||
|
centi |
|
c |
|
× |
0.01 |
|
|
|
|
|
|
|
|
milli |
|
m |
|
× |
0.001 |
|
|
Units of Torque: |
|
|
||
|
micro |
|
µ |
|
× 0.000001 |
|
|
||||||
|
|
|
|
|
N·m |
× |
0.1020 |
= |
kgf·m |
||||
|
|
|
|
|
|
|
|
|
|||||
|
|
|
|
|
|
|
|
|
N·m |
× |
0.7376 |
= |
ft·lb |
|
Units of Mass: |
|
|
|
|
N·m |
× |
8.851 |
= |
in·lb |
|||
|
|
|
|
|
kgf·m |
× |
9.807 |
= |
N·m |
||||
|
kg |
× |
2.205 |
|
= |
lb |
|
|
kgf·m |
× |
7.233 |
= |
ft·lb |
|
g |
× |
0.03527 |
|
= |
oz |
|
|
kgf·m |
× |
86.80 |
= |
in·lb |
|
Units of Volume: |
|
|
|
|
Units of Pressure: |
|
|
|||||
|
L |
× |
0.2642 |
|
= |
gal (US) |
|
|
kPa |
× |
0.01020 |
= |
kgf/cm² |
|
L |
× |
0.2200 |
|
= |
gal (imp) |
|
|
kPa |
× |
0.1450 |
= |
psi |
|
L |
× |
1.057 |
|
= |
qt (US) |
|
|
kPa |
× |
0.7501 |
= |
cm Hg |
|
L |
× |
0.8799 |
|
= |
qt (imp) |
|
|
kgf/cm² |
× |
98.07 |
= |
kPa |
|
L |
× |
2.113 |
|
= |
pint (US) |
|
|
kgf/cm² |
× |
14.22 |
= |
psi |
|
L |
× |
1.816 |
|
= |
pint (imp) |
|
|
cm Hg |
× |
1.333 |
= |
kPa |
|
mL |
× |
0.03381 |
|
= |
oz (US) |
|
|
|
|
|
|
|
|
mL |
× |
0.02816 |
|
= |
oz (imp) |
|
|
Units of Speed: |
|
|
||
|
mL |
× |
0.06102 |
|
= |
cu in. |
|
|
|
|
|||
|
|
|
|
|
|
|
|
|
km/h |
× |
0.6214 |
= |
mph |
|
Units of Force: |
|
|
|
|
Units of Power: |
|
|
|||||
|
N |
× |
0.1020 |
|
= |
kgf |
|
|
|
|
|||
|
N |
× |
0.2248 |
|
= |
lb |
|
|
kW |
× |
1.360 |
= |
PS |
|
kg |
× |
9.807 |
|
= |
N |
|
||||||
|
|
|
|
kW |
× |
1.341 |
= |
HP |
|||||
|
kg |
× |
2.205 |
|
= |
lb |
|
|
PS |
× |
0.7355 |
= |
kW |
|
|
|
|
|
|
|
|
|
PS |
× |
0.9863 |
= |
HP |
PERIODIC MAINTENANCE 2-1
|
|
|
Table of Contents |
2 |
|
|
|
Periodic Maintenance Chart .............. |
2-2 |
Torque and Locking Agent................. |
2-4 |
Specifications .................................... |
2-10 |
Special Tools ..................................... |
2-12 |
Periodic Maintenance Procedures..... |
2-13 |
Fuel System (DFI)........................... |
2-13 |
Fuel Hose and Connection |
|
Inspection.................................. |
2-13 |
Throttle Control System |
|
Inspection.................................. |
2-13 |
Idle Speed Inspection .................. |
2-14 |
Air Cleaner Element Cleaning...... |
2-15 |
Evaporative Emission Control |
|
System Inspection (CAL) .......... |
2-15 |
Cooling System............................... |
2-16 |
Radiator Hose and Connection |
|
Inspection.................................. |
2-16 |
Coolant Change........................... |
2-17 |
Engine Top End .............................. |
2-19 |
Air Suction Valve Inspection ........ |
2-19 |
Clutch.............................................. |
2-19 |
Clutch Hose and Connection |
|
Inspection.................................. |
2-19 |
Clutch Fluid Level Inspection ....... |
2-20 |
Clutch Fluid Change .................... |
2-20 |
Clutch Master Cylinder Cup and |
|
Dust Seal Replacement ............ |
2-21 |
Clutch Slave Cylinder Piston Seal |
|
Replacement ............................ |
2-22 |
Engine Lubrication System ............. |
2-23 |
Engine Oil Change....................... |
2-23 |
Oil Filter Replacement ................. |
2-24 |
Wheel/Tires..................................... |
2-24 |
Tire Inspection ............................. |
2-24 |
Final Drive....................................... |
2-25 |
Oil Level Inspection...................... |
2-25 |
Oil Change ................................... |
2-26 |
Propeller Shaft Joint Lubrication .. |
2-26 |
Brakes............................................. |
2-27 |
Brake Pad Wear Inspection ......... |
2-27 |
Brake Hose and Connection |
|
Inspection.................................. |
2-27 |
Brake Fluid Level Inspection........ |
2-27 |
Brake Fluid Change ..................... |
2-28 |
Brake Master Cylinder Cup and |
|
Dust Seal Replacement ............ |
2-29 |
Caliper Piston/Dust Seals |
|
Replacement............................. |
2-29 |
Front Brake Light Switch |
|
Inspection.................................. |
2-29 |
Rear Brake Light Switch |
|
Check/Adjustment ..................... |
2-30 |
Suspension..................................... |
2-30 |
Front Fork Oil Leak Inspection..... |
2-30 |
Rear Shock Absorber Oil Leak |
|
Inspection ................................. |
2-31 |
Swingarm Pivot Lubrication ......... |
2-31 |
Steering .......................................... |
2-31 |
Stem Bearing Lubrication............. |
2-31 |
Steering Check ............................ |
2-31 |
Steering Adjustment..................... |
2-32 |
Electrical System ............................ |
2-33 |
Spark Plug Cleaning/Inspection... |
2-33 |
General Lubrication ........................ |
2-33 |
Lubrication ................................... |
2-33 |
Nut, Bolt, and Fastener Tightness .. |
2-34 |
Tightness Inspection .................... |
2-34 |
2-2 PERIODIC MAINTENANCE
Periodic Maintenance Chart
The scheduled maintenance must 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. |
|||||||||||
FREQUENCY |
Whichever |
|
1 000 km |
|
|
|
|
* ODOMETER |
|||
|
comes |
|
(600 mile) |
|
|
|
|
|
READING |
||
|
|
|
|
|
|
||||||
|
first |
|
|
6 000 km |
|
|
|
|
|
||
|
→ |
|
|
(4 000 mile) |
|
|
|
||||
|
↓ |
|
|
|
12 000 km |
|
|
|
|||
|
|
|
|
|
(7 500 mile) |
|
|
||||
|
|
|
|
|
|
18 000 km |
|||||
|
|
|
|
|
|
(12 000 mile) |
|||||
|
|
|
|
|
|
|
24 000 km |
||||
|
|
|
|
|
|
|
(15 000 mile) |
||||
|
|
|
|
|
|
|
|
|
30 000 km |
||
|
|
|
|
|
|
|
|
|
(20 000 mile) |
||
|
|
|
|
|
|
|
|
|
|
|
36 000 km |
|
|
|
|
|
|
|
|
|
|
|
(24 000 mile) |
OPERATION |
Every |
|
|
|
|
|
|
|
|
|
See Page |
Spark plug (e) - clean and gap † |
|
|
• |
• |
• |
• |
• |
|
• |
|
2–35 |
|
|
|
|
|
|
||||||
Air suction valve (e) - inspect † |
|
|
• |
• |
• |
• |
• |
|
• |
|
2–20 |
|
|
|
|
|
|
||||||
Air cleaner element (e) - clean†# |
|
|
|
• |
|
• |
|
|
• |
|
2–16 |
Throttle control system (e) - inspect † |
|
• |
• |
• |
• |
• |
• |
• |
|
2–14 |
|
|
|
|
|
||||||||
Idle speed (e) - inspect † |
|
• |
|
• |
|
• |
|
|
• |
|
2–15 |
|
|
|
|
|
|
|
|
||||
Fuel hoses, connections - inspect † |
|
|
• |
• |
• |
• |
• |
• |
|
2–14 |
|
|
|
|
|
|
|||||||
Engine oil - change # |
year |
• |
|
• |
|
• |
|
|
• |
|
2–24 |
|
|
|
|
|
|
|
|
||||
Oil filter - replace |
|
• |
|
• |
|
• |
|
|
• |
|
2–26 |
|
|
|
|
|
|
|
|
||||
Evaporative emission control system (e) |
|
• |
• |
• |
• |
• |
• |
|
• |
|
2–17 |
(CAL) - inspect † |
|
|
|
||||||||
|
|
|
|
||||||||
Final gear case oil level - inspect † |
|
|
|
• |
|
• |
|
|
• |
|
2–28 |
|
|
|
|
|
|
|
|
|
|||
Final gear case oil - change |
|
• |
|
|
|
|
|
|
• |
|
2–28 |
|
|
|
|
|
|
|
|
|
|
||
Propeller shaft joint - lubricate |
|
|
|
• |
|
|
|
|
• |
|
2–29 |
|
|
|
|
|
|
|
|
|
|
||
Brake pad wear - inspect † # |
|
|
• |
• |
• |
• |
• |
• |
|
2–29 |
|
Brake light switch - inspect † |
|
• |
• |
• |
• |
• |
• |
• |
|
2–32 |
|
|
|
|
|
||||||||
Steering - inspect † |
|
• |
• |
• |
• |
• |
• |
• |
|
2–34 |
|
|
|
|
|
||||||||
Rear shock absorber oil leak - inspect † |
|
|
|
• |
|
• |
|
|
• |
|
2–33 |
|
|
|
|
|
|
|
|
|
|||
Front fork oil leak - inspect † |
|
|
|
• |
|
• |
|
|
• |
|
2–33 |
|
|
|
|
|
|
|
|
|
|||
Tire wear - inspect † |
|
|
• |
• |
• |
• |
• |
• |
|
2–27 |
|
|
|
|
|
|
|||||||
Swingarm pivot - lubricate |
|
|
|
• |
|
|
|
|
• |
|
2–33 |
|
|
|
|
|
|
|
|
|
|
||
General lubrication - perform |
|
|
|
• |
|
• |
|
|
• |
|
2–36 |
|
|
|
|
|
|
|
|
|
|||
Nut, bolt, and fastener tightness - inspect † |
|
• |
|
• |
|
• |
|
|
• |
|
2–37 |
|
|
|
|
|
|
|
|
||||
Brake/clutch hoses, connections - inspect † |
|
|
• |
• |
• |
• |
• |
|
• |
|
2–21, 2–29 |
Brake/clutch fluid level - inspect † |
month |
• |
• |
• |
• |
• |
• |
|
• |
|
2–21, 2–29 |
Coolant hoses, connections - inspect † |
|
• |
|
|
|
|
|
|
|
|
2–18 |
|
|
|
|
|
|
|
|
|
|
|
|
Brake/clutch fluid - change |
2 years |
|
|
|
|
• |
|
|
|
|
2–22, 2–30 |
|
|
|
|
|
|
|
|
|
|
|
PERIODIC MAINTENANCE 2-3
Periodic Maintenance Chart
|
|
|
|
|
|
|
|
|
|
FREQUENCY |
Whichever |
|
1 000 km |
|
|
* ODOMETER |
|||
|
comes |
|
(600 mile) |
|
|
|
READING |
||
|
|
|
|||||||
|
first |
|
|
6 000 km |
|
|
|
||
|
→ |
|
|
(4 000 mile) |
|||||
|
↓ |
|
|
|
12 000 km |
||||
|
|
|
|
|
(7 500 mile) |
||||
|
|
|
|
|
|
18 000 km |
|||
|
|
|
|
|
|
(12 000 mile) |
|||
|
|
|
|
|
|
|
24 000 km |
||
|
|
|
|
|
|
|
(15 000 mile) |
||
|
|
|
|
|
|
|
|
30 000 km |
|
|
|
|
|
|
|
|
|
(20 000 mile) |
|
|
|
|
|
|
|
|
|
|
36 000 km |
|
|
|
|
|
|
|
|
|
(24 000 mile) |
OPERATION |
Every |
|
|
|
|
|
|
|
See Page |
Brake/clutch master cylinder cup and dust |
4 years |
|
|
|
|
|
|
|
2–23, 2–32 |
seal - replace |
|
|
|
|
|
|
|
||
|
|
|
|
|
• |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Coolant - change |
2 years |
|
|
|
|
|
|
|
2–28 |
|
|
|
|
|
|
|
|
|
|
Caliper piston seal and dust seal - replace |
4 years |
|
|
|
|
• |
|
|
2–32 |
|
|
|
|
|
|
|
|
|
|
Steering stem bearing - lubricate |
2 years |
|
|
|
|
|
|
|
2–34 |
|
|
|
|
|
|
|
|
|
|
Clutch slave cylinder piston seal - replace |
4 years |
|
|
|
|
|
|
|
2–24 |
# : Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.
* : For higher odometer readings, repeat at the frequency interval established here.
† : Replace, add, adjust, clean, or torque if necessary.
Throttle control system inspection: Inspection of throttle grip play and throttle bore cleanliness. (CAL): California
(e): Emission Related Items
2-4 PERIODIC MAINTENANCE
Torque and Locking Agent
The following tables list the tightening torque |
|
The table below, relating tightening torque to |
|||||||||||||||||
for the major fasteners requiring use of a non |
|
thread diameter, lists the basic torque for the |
|||||||||||||||||
-permanent locking agent or liquid gasket. |
|
bolts and nuts. Use this table for only the bolts |
|||||||||||||||||
|
|
|
|
|
|
|
and nuts which do not require a specific torque |
||||||||||||
Letters used in the “Remarks” column mean: |
|
value. |
All of the values are for use with dry |
||||||||||||||||
L: Apply a non-permanent locking agent to |
|
solvent-cleaned threads. |
|
|
|
|
|||||||||||||
the threads. |
|
|
|
|
|
Basic Torque for General Fasteners |
|||||||||||||
G: Apply grease to the threads. |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Threads |
|
|
|
|
|
Torque |
|
|
|
|||||
MO: Apply molybdenum disulfide grease oil |
|
|
|
|
|
|
|
|
|
||||||||||
solution. |
|
|
|
|
|
dia. (mm) |
|
N·m |
|
kgf·m |
ft·lb |
||||||||
O: Apply oil to the threads and seating sur- |
|
5 |
|
|
3.4 |
4.9 |
|
0.35 |
0.50 |
30 |
43 in·lb |
||||||||
face. |
|
|
|
|
|
6 |
|
|
5.9 |
7.8 |
|
0.60 |
0.80 |
52 |
69 in·lb |
||||
S: Tighten the fasteners following the speci- |
|
|
|
|
|||||||||||||||
|
8 |
|
|
14 |
19 |
|
1.4 1.9 |
10.0 |
13.5 |
||||||||||
fied sequence. |
|
|
|
|
|
|
|
|
|||||||||||
|
|
|
|
|
10 |
|
|
25 |
34 |
|
2.6 |
3.5 |
19.0 25 |
||||||
SS: Apply silicone sealant. |
|
|
|
|
|
|
|
|
|||||||||||
Si: Apply silicone grease (ex. PBC grease). |
|
12 |
|
|
44 |
61 |
|
4.5 |
6.2 |
33 |
45 |
||||||||
R: Replacement parts |
|
|
|
|
|
|
|
|
|
73 |
98 |
|
7.4 |
10.0 |
54 |
72 |
|||
|
|
|
|
|
14 |
|
|
|
|||||||||||
Lh: Left-hand-threads |
|
|
|
|
|
16 |
|
115 |
155 |
11.5 |
16.0 |
83 |
115 |
||||||
St: Stake the fasteners to prevent loosening. |
|
|
|||||||||||||||||
|
18 |
|
165 |
225 |
17.0 |
23.0 |
125 |
165 |
|||||||||||
AL: Tighten the two clamp bolts alternately |
|
|
|||||||||||||||||
|
20 |
|
225 |
325 |
|
23 |
33 |
165 |
240 |
||||||||||
two times to ensure even tightening |
|
|
|
||||||||||||||||
torque. |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
||
Fastener |
|
|
|
|
|
|
|
Torque |
|
|
|
Remarks |
|||||||
|
|
|
|
N·m |
|
kgf·m |
|
ft·lb |
|||||||||||
|
|
|
|
|
|
|
|
|
|
|
|
||||||||
Fuel System: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Throttle body assy holder bolts |
|
|
|
|
11 |
|
|
1.1 |
|
|
95 |
in·lb |
Right Side |
||||||
Inlet manifold bolts |
|
|
|
|
12 |
|
|
1.2 |
|
|
104 in·lb |
on Cyl. Head |
|||||||
Spark plug lead holder bolts |
|
|
|
|
11 |
|
|
1.1 |
|
|
95 |
in·lb |
Right Side |
||||||
ISC pipe holder bolts |
|
|
|
|
11 |
|
|
1.1 |
|
|
95 |
in·lb |
|
|
|
|
|||
Air cleaner duct holder bolts |
|
|
|
|
9.8 |
|
|
1.0 |
|
|
69 |
in·lb |
Left Side |
||||||
Right and left air cleaner base bolts |
|
11 |
|
|
1.1 |
|
|
95 |
in·lb |
|
|
|
|
||||||
Right and left air cleaner base screws |
|
2.2 |
|
|
0.22 |
|
|
19 |
in·lb |
L, Lower Duct |
|||||||||
Left air cleaner cover Allen bolt |
|
8 |
|
|
16 |
|
|
1.6 |
|
|
12 |
|
|
|
|
||||
|
|
|
|
|
|
|
|
|
|
||||||||||
Right air cleaner cover Allen bolt |
|
|
8 |
|
16 |
|
|
1.6 |
|
|
12 |
|
|
|
|
||||
|
|
|
|
|
|
|
|
|
|
||||||||||
Right air cleaner Allen bolts |
|
|
|
|
11 |
|
|
1.1 |
|
|
95 |
in·lb |
Throttle Body |
||||||
Choke cable plate screw |
|
|
|
|
2.9 |
|
|
0.30 |
|
|
26 |
in·lb |
L, Throttle Body |
||||||
Inlet air temperature sensor nut (DFI) |
|
7.8 |
|
|
0.80 |
|
|
69 |
in·lb |
|
|
|
|
||||||
Water temperature sensor (DFI) |
|
|
|
|
18 |
|
|
1.8 |
|
|
13 |
|
SS |
|
|
||||
Fuel pump bolts |
|
|
|
|
9.8 |
|
|
1.0 |
|
|
87 |
in·lb |
|
S, L |
|
||||
Cooling System: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Radiator hose clamp screws |
|
|
|
|
2.5 |
|
|
0.25 |
|
|
22 |
in·lb |
|
|
|
|
|||
Radiator fan switch |
|
|
|
|
18 |
|
|
1.8 |
|
|
13 |
|
|
|
|
||||
Radiator fan bolts |
|
|
|
|
8.3 |
|
|
0.85 |
|
|
74 |
in·lb |
|
|
|
|
|||
Water temperature switch |
|
|
|
|
7.8 |
|
|
0.80 |
|
|
69 |
in·lb |
|
SS |
|
|
|||
Water pump impeller bolt |
|
|
|
|
8.8 |
|
|
0.90 |
|
|
78 |
in·lb |
|
Lh |
|
|
|||
Water pump cover bolts |
|
|
|
|
11 |
|
|
1.1 |
|
|
97 |
in·lb |
|
|
|
|
|||
Water pump air bleeder bolt |
|
|
|
|
11 |
|
|
1.1 |
|
|
97 |
in·lb |
|
|
|
|
|||
Water pump drain bolt |
|
|
|
|
11 |
|
|
1.1 |
|
|
97 |
in·lb |
|
|
|
|
|||
Water pipe bolts |
|
|
|
|
11 |
|
|
1.1 |
|
|
97 |
in·lb |
|
|
|
|
PERIODIC MAINTENANCE 2-5
Torque and Locking Agent
|
|
|
|
|
|
|
|
|
Fastener |
|
|
|
|
Torque |
|
|
Remarks |
|
|
|
N·m |
kgf·m |
ft·lb |
|||
|
|
|
|
|
||||
Radiator drain bolt |
|
|
|
7.4 |
0.75 |
65 |
in·lb |
|
Water temperature sensor (DFI) |
|
|
|
18 |
1.8 |
13 |
SS |
|
Engine Top End: |
|
|
|
|
|
|
|
|
Spark plugs |
|
|
|
18 |
1.8 |
13 |
|
|
Spark plug retainer |
|
|
|
12 |
1.2 |
104 in·lb |
|
|
Air suction valve cover bolts |
|
|
|
7.4 |
0.75 |
65 |
in·lb |
|
Chain tensioner mounting bolts |
|
|
|
11 |
1.1 |
95 |
in·lb |
S |
Chain tensioner cap |
|
|
|
20 |
2.0 |
14 |
S |
|
Chain tensioner lockbolt |
|
|
|
4.9 |
0.50 |
43 |
in·lb |
S |
Timing inspection cap |
|
|
|
1.5 |
0.15 |
13 |
in·lb |
|
Rotor bolt cap |
|
|
|
1.5 |
0.15 |
13 |
in·lb |
|
Camshaft sprocket bolts |
|
|
|
15 |
1.5 |
|
11 |
L |
Oil hose flange bolts |
|
|
|
9.8 |
1.0 |
87 |
in·lb |
|
Rocker shafts |
|
|
|
25 |
2.5 |
18 |
|
|
Rocker case nuts: |
12 mm |
78 |
8.0 |
58 |
MO, S |
|||
|
8 mm |
25 |
2.5 |
18 |
S |
|||
Rocker case bolts |
6 mm |
8.8 |
0.90 |
78 in·lb |
S |
|||
Cylinder head nuts |
|
|
|
25 |
2.5 |
18 |
S |
|
Cylinder head jacket plugs |
|
|
|
20 |
2.0 |
14 |
L |
|
Rocker case cover bolts |
|
|
|
8.8 |
0.90 |
78 |
in·lb |
S |
Camshaft chain guide bolts |
|
|
|
11 |
1.1 |
95 |
in·lb |
L |
Cylinder nuts |
|
|
|
25 |
2.5 |
18 |
S |
|
Inlet manifold bolts |
|
|
|
12 |
1.2 |
104 in·lb |
on Cyl. Head |
|
Exhaust pipe cover clamp bolts |
|
|
|
6.9 |
0.70 |
61 |
in·lb |
|
Chamber bolts |
|
|
|
29 |
3.0 |
22 |
except US, CA |
|
Muffler stay mounting bolts and nuts, |
|
8 |
25 |
2.5 |
18 |
|
||
|
|
|||||||
Muffler bracket bolt and nut |
|
|
|
29 |
3.0 |
22 |
|
|
Clutch: |
|
|
|
|
|
|
|
|
Clutch lever pivot bolt |
|
|
|
1.0 |
0.10 |
8.7 in·lb |
Si |
|
Clutch lever pivot bolt locknut |
|
|
|
5.9 |
0.60 |
52 |
in·lb |
|
Clutch reservoir cap crews |
|
|
|
1.5 |
0.15 |
13 |
in·lb |
|
Clutch slave cylinder bleed valve |
7.8 |
0.80 |
69 |
in·lb |
|
|||
Clutch slave cylinder bolts |
|
|
|
6.9 |
0.70 |
61 |
in·lb |
L |
Clutch hose banjo bolts |
|
|
|
25 |
2.5 |
18 |
|
|
Clutch master cylinder clamp bolts |
11 |
1.1 |
95 |
in·lb |
S |
|||
Starter lockout switch screws |
|
|
|
1.2 |
0.12 |
10 |
in·lb |
|
Push rod guide bolts |
|
|
|
11 |
1.1 |
95 |
in·lb |
L |
Clutch cover bolts |
|
|
|
11 |
1.1 |
95 |
in·lb |
|
Clutch damper cover bolts (outside) |
9.8 |
1.0 |
87 |
in·lb |
L |
|||
Clutch cover damper plate bolts |
|
|
|
9.8 |
1.0 |
87 |
in·lb |
EO (tip) |
Clutch cover damper screws |
|
|
|
4.9 |
0.50 |
43 in·lb |
L |
|
Clutch hub nut |
|
|
|
147 |
15.0 |
108 |
MO |
|
|
|
|
|
|
|
|
|
|
2-6 PERIODIC MAINTENANCE
Torque and Locking Agent
|
|
|
|
|
|
|
Fastener |
|
|
Torque |
|
|
Remarks |
|
N·m |
kgf·m |
ft·lb |
|||
|
|
|
||||
Engine Lubrication System: |
|
|
|
|
|
|
Oil filler cap |
|
1.5 |
0.15 |
13 |
in·lb |
|
Oil screen plug |
|
20 |
2.0 |
|
14 |
|
Engine oil drain plug |
|
20 |
2.0 |
|
14 |
|
Oil filter (cartridge type) |
|
18 |
1.8 |
|
13 |
R, EO |
Oil filter Pipe |
|
25 |
2.5 |
|
18 |
SS |
Oil pressure relief valve |
|
15 |
1.5 |
|
11 |
L |
Oil pressure switch terminal screw |
1.5 |
0.15 |
13 |
in·lb |
|
|
Oil pressure switch |
|
15 |
1.5 |
|
11 |
SS |
Oil pump mounting bolts |
|
11 |
1.1 |
95 |
in·lb |
|
Oil hose banjo bolts |
|
9.8 |
1.0 |
87 |
in·lb |
|
Oil hose flange bolt (outside) |
|
9.8 |
1.0 |
87 |
in·lb |
|
Oil pipe holder bolts (inside) |
|
11 |
1.1 |
95 |
in·lb |
L |
Oil pipe clamp bolts (inside) |
|
11 |
1.1 |
95 |
in·lb |
L |
Right & left crankcase oil nozzles |
2.9 |
0.30 |
26 |
in·lb |
× 3 |
|
Right crankcase oil nozzle |
|
2.9 |
0.30 |
26 |
in·lb |
× 1, Lh |
Oil baffle bolt |
|
11 |
1.1 |
95 |
in·lb |
L |
Engine Removal/Installation: |
|
|
|
|
|
|
Downtube bolts and nuts |
|
44 |
4.5 |
|
33 |
|
Engine mounting bolts and nuts |
|
44 |
4.5 |
|
33 |
|
Engine mounting bracket bolts |
|
25 |
2.5 |
|
18 |
|
Engine ground terminal bolt |
|
7.8 |
0.80 |
69 |
in·lb |
|
Crankshaft/Transmission: |
|
|
|
|
|
|
Crankcase bolts: |
10 mm |
39 |
4.0 |
|
29 |
S |
|
8 mm |
21 |
2.1 |
|
15 |
S |
|
6 mm |
11 |
1.1 |
95 in·lb |
S |
|
Frame ground bracket bolt |
|
1.1 |
1.1 |
95 |
in·lb |
Left Crankcase |
Crankcase bearing retainer bolts |
11 |
1.1 |
95 |
in·lb |
L |
|
Camshaft chain guide bolts |
|
11 |
1.1 |
95 |
in·lb |
L |
Right, left crankcase oil nozzles |
|
2.9 |
0.30 |
26 |
in·lb |
× 3 |
Right crankcase oil nozzles |
|
2.9 |
0.30 |
26 |
in·lb |
× 1, Lh |
Oil baffle bolt |
|
11 |
1.1 |
95 |
in·lb |
L |
Connecting rod big end nuts |
|
59 |
6.0 |
|
43 |
MO |
Oil pressure relief valve |
|
15 |
1.5 |
|
11 |
L |
Oil filter Pipe |
|
25 |
2.5 |
|
18 |
SS |
Oil hose banjo bolts |
|
9.8 |
1.0 |
87 |
in·lb |
|
Primary gear bolt |
|
147 |
15.0 |
108 |
MO |
|
Water pump chain guide spring hook bolt |
2.9 |
0.30 |
26 |
in·lb |
|
|
Water pump chain guide bolt |
|
8.3 |
0.85 |
73 |
in·lb |
|
Idle shaft holder bolts |
|
8.3 |
0.85 |
73 |
in·lb |
|
Oil pressure switch terminal screw |
1.5 |
0.15 |
13 |
in·lb |
|
|
Oil pressure switch |
|
15 |
1.5 |
|
11 |
SS |
Oil pipe clamp bolts (inside) |
|
11 |
1.1 |
95 |
in·lb |
L |
PERIODIC MAINTENANCE 2-7
Torque and Locking Agent
|
|
|
|
|
|
|
Fastener |
|
|
Torque |
|
|
Remarks |
|
N·m |
kgf·m |
ft·lb |
|||
|
|
|
||||
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·lb |
|
Shift shaft return spring pin (bolt) |
39 |
4.0 |
29 |
L |
||
Shift pedal clamp bolt |
|
25 |
2.5 |
18 |
|
|
Shift pedal clamp bolts (VN1600–A2 ) |
30 |
3.1 |
22 |
|
||
Rear shift lever clamp bolt |
|
12 |
1.2 |
104 in·lb |
|
|
Shift rod locknuts |
|
11 |
1.1 |
95 |
in·lb |
(Rear: Lh) |
Shift drum bearing holder bolts |
|
11 |
1.1 |
95 |
in·lb |
L |
Shift drum cam screw |
|
15 |
1.5 |
|
11 |
L |
Damper cam nut (front gear) |
|
195 |
20 |
144 |
MO (threads) |
|
Push rod guide bolts |
|
9.8 |
1.0 |
87 |
in·lb |
L |
Wheels/Tires: |
|
|
|
|
|
|
Front axle clamp bolts |
|
20 |
2.0 |
14 |
AL |
|
Front axle |
|
108 |
11.0 |
79.6 |
S |
|
Rear axle nut |
|
108 |
11.0 |
79.6 |
|
|
Tire air valve stem nuts |
|
1.5 |
0.15 |
13 |
in·lb |
|
Tire air valve caps |
|
0.15 |
0.015 |
1.3 in·lb |
|
|
Air valve cores |
|
0.3 |
0.03 |
2.6 in·lb |
|
|
Final Drive: |
|
|
|
|
|
|
Oil pipe banjo bolts (front gear) |
|
12 |
1.2 |
104 in·lb |
|
|
Oil nozzle (front gear) |
|
2.9 |
0.30 |
26 |
in·lb |
|
Oil nozzle (front gear) |
|
18 |
1.8 |
13 |
|
|
Neutral switch |
|
15 |
1.5 |
|
11 |
|
Front gear case bolts: |
6 mm |
12 |
1.2 |
104 in·lb |
|
|
|
8 mm |
29 |
3.0 |
22 |
|
|
Speed sensor bolt |
|
9.8 |
1.0 |
87 |
in·lb |
L |
Damper cam nut (front gear) |
|
195 |
20 |
144 |
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 |
in·lb |
L |
|
Final gear case drain plug |
|
8.8 |
0.9 |
78 |
in·lb |
|
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) |
|
130 |
13 |
94 |
St, MO |
|
Bearing retainer bolt |
|
6.9 |
0.7 |
61 |
in·lb |
L |
Brakes: |
|
|
|
|
|
|
Caliper bleed valves |
|
7.8 |
0.8 |
69 |
in·lb |
|
Brake hose banjo bolts |
|
25 |
2.5 |
18 |
|
2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
|
|
|
|
|
|
|
Fastener |
|
Torque |
|
|
Remarks |
|
N·m |
kgf·m |
ft·lb |
||||
|
|
|||||
Brake lever pivot bolt |
1.0 |
0.10 |
8.7 in·lb |
|
||
Brake lever pivot bolt locknut |
5.9 |
0.60 |
52 |
in·lb |
|
|
Front brake reservoir cap screws |
1.5 |
0.15 |
13 |
in·lb |
|
|
Front brake light switch screw |
1.2 |
0.12 |
10 |
in·lb |
|
|
Front master cylinder clamp bolts |
8.8 |
0.9 |
78 |
in·lb |
G, S |
|
Front caliper mounting bolts |
34 |
3.5 |
|
25 |
|
|
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 |
|
14 |
|
|
Lower front fork clamp bolts |
29 |
3.0 |
|
21 |
AL |
|
Front fork top plugs |
22 |
2.2 |
|
16 |
|
|
Piston rod nuts or joint rod nut |
20 |
2.0 |
|
14 |
|
|
Front fork bottom allen bolt |
30 |
3.1 |
|
22 |
L |
|
Front axle clamp bolts |
20 |
2.0 |
|
14 |
AL |
|
Rear shock absorber nuts |
34 |
3.5 |
|
25 |
|
|
Swingarm pivot shaft |
108 |
11.0 |
79.6 |
G |
||
Steering: |
|
|
|
|
|
|
Steering stem head nut |
88 |
9.0 |
|
65 |
|
|
Steering stem nut |
5 |
0.5 |
43 |
in·lb |
|
|
Handlebar clamp bolts |
34 |
3.5 |
|
25 |
|
|
Handlebar holder nuts |
34 |
3.5 |
|
25 |
|
|
Upper front fork clamp bolts |
20 |
2.0 |
|
14 |
|
|
Lower front fork clamp bolts |
29 |
3.0 |
|
21 |
AL |
|
Turn signal light mounting nuts |
5.9 |
0.6 |
52 |
in·lb |
|
|
Frame: |
|
|
|
|
|
|
Downtube bolts and nuts |
44 |
4.5 |
|
33 |
|
|
Footboard bracket bolts |
34 |
3.5 |
|
25 |
front |
|
Footpeg bracket bolts |
25 |
2.5 |
|
18 |
rear, L |
|
Sidestand nut |
44 |
4.5 |
|
33 |
|
|
Electrical System: |
|
|
|
|
|
|
Spark plugs |
18 |
1.8 |
|
13 |
|
|
Crankshaft sensor screws |
2.9 |
0.30 |
26 |
in·lb |
|
|
Stator lead holder screw |
9.8 |
1.0 |
87 |
in·lb |
L |
|
Inside stator holder bolts |
11 |
1.1 |
95 |
in·lb |
L |
|
Crankshaft sensor lead holder bolt |
2.9 |
0.30 |
26 |
in·lb |
L |
|
Alternator outer cover bolts |
6.9 |
0.70 |
61 |
in·lb |
|
|
Alternator outer cover joint bolts |
6.9 |
0.70 |
61 |
in·lb |
L |
|
Alternator outer cover damper bolts |
6.9 |
0.70 |
61 |
in·lb |
L |