Kawasaki VN1600 MEAN STREAK Service Manual

VULCAN 1600 MEAN STREAK

VN1600 MEAN STREAK

Motorcycle

Service Manual

Quick Reference Guide

General Information 1 j

Periodic Maintenance 2 j

Fuel System (DFI) 3 j

Cooling System 4 j

Engine Top End 5 j

Clutch 6 j

Engine Lubrication System 7 j

Engine Removal/Installation 8 j

Crankshaft/Transmission 9 j

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 con-

•

tents for the exact pages to locate the specific topic required.

Wheels/Tires 10 j

Final Drive 11 j

Brakes 12 j

Suspension 13 j

Steering 14 j

Frame 15 j

Electrical System 16 j

Appendix 17 j

VULCAN 1600 MEAN STREAK

VN1600 MEAN STREAK

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

ABDC after bottom dead center m meter(s)

ATDC after top dead center N newton(s)

BBDC before bottom dead center

BDC bottom dead center PS horsepower

BTDC before top dead center

°C degree(s) Celsius r revolution

F farad(s) TDC top dead center

°F degree(s) Fahrenheit

ft foot, feet V volt(s)

h hour(s) Ω ohm(s)

kgf (force)

ampere(s)

alternating current min

direct current

gram(s) (mass)

(mass)

liter(s)

psi

r/min, rpm revolution(s) per minute

TIR total indicator reading

pound(s)

minute(s)

pascal(s)

pound(s) per square inch

watt(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 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 in-

cludes a catalytic converter system.

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 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 ex-

ceeded.

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

or durability of the m otorcycle.

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 FEDE RAL LAW,

THEVIOLATIONOFWHICHISPUNISHABLEBYCIVILPENALTIESNOTEXCEEDING $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 t ext, 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 Mo-

•

torcycle 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 main-

•

tenance and repair with dates and any new

parts installed.

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 t o 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 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 text of a NOTE.

Indicates a conditional step or what action to

take based on the results of the test or inspec-

tion in the procedural step or sub-step it fol-

lows. 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................................................................................................................. 1-7

General Specifications............................................................................................................ 1-9

Unit Conversion Table ............................................................................................................ 1-12

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:

Battery Ground

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.

Edges of Parts

Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.

Solvent

Use a high flush point solvent when cleaning parts. High flush point solvent should be used according to directions of the solvent manufacturer.

Cleaning vehicle before disassembly

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.

Before Servicing

Arrangement and Cleaning of Removed Parts

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.

Storage of Removed Parts

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.

GENERAL INFORMAT ION 1-3

Inspection

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

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.

Assembly Order

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

Tightening Sequence

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.

Tightening Torque

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.

Force

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.

Gasket, O-ring

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

Liquid Gasket, Locking Agent

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.

Before Servicing

Press

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.

Ball Bearing and Needle Bearing

Do not remove pressed ball or needle unless r emoval 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.

GENERAL INFORMAT ION 1-5

Oil Seal, Grease Seal

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.

Circlips, Cotter Pins

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.

Lubrication

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

Direction of Engine Rotation

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).

Electrical Wires

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.

Model Identification

VN1600-B1 (US, and Canada) Left Side View:

GENERAL INFORMAT ION 1-7

VN1600-B1 (US, and Canada) Right Side View:

1-8 GENERAL INFORMATION

Model Identification

VN1600-B1 (Europe) Left Side View:

VN1600-B1 (Europe) Right Side View:

GENERAL INFORMAT ION 1-9

General Specifications

Items VN1600–B1

Dimensions:

Overall length 2 410 mm (94.9 in.)

Overall width 850 mm (33.5 in.) Overall height 1 100 mm (43.3 in.) Wheelbase

Road clearance 125 mm (4.92 in.)

Seat height 700 mm (27.6 in.) Dry mass 290 kg (639 lb)

Curb mass:

Fuel tank capacity

Fuel Unleaded and high-octane gasoline

Performance:

Minimum turning radius

Engine:

Type

Cooling system Liquid-cooled Bore and stroke

Displacement 1 552 mL (94.70 cu in.)

Compression ratio Maximum horsepower 54 kW (74 PS) @5 300 r/min (rpm),

Maximum torque 125 N·m (12.7 kgf·m, 92.2 ft·lb) @2 800 r/min (rpm),

Carburetion system DFI (Digital Fuel Injection) System

Starting system Ignition system Battery and coil (transistorized) Timing advance

Ignition timing From 5° BTDC @950 r/min (rpm) ∼

Spark plugs NGK DPR6EA-9 or ND X20EPR-U9

Cylinder numbering method Firing order 1-2 Valve timing:

Inlet Open 22° BTDC

Exhaust

Lubrication system Forced lubrication (wet sump) Engine oil: Type

Front

Rear 172 kg (379 lb)

Close 66° ABDC Duration 268°

Open Close 26° ATDC Duration

Viscosity

1 705 mm (67.1 in.)

145 kg (320 lb)

17.0 L (4.49 US gal)

(see Owner’s Manual)

3.1 m (10.2 ft)

4-stroke, SOHC, V2-cylinder

102 × 95 mm (4.02 × 3.74 i n.)

9.0 : 1

(CAL)(CA)(US)–

Electric starter

Electronically advanced (digital)

25° BTDC @4 500 r/min (rpm)

Front to Rear, 1-2

66° BBDC

272°

API SE, SF or SG class API SH or SJ class with JASO MA

SAE10W-40

1-10 GENERAL INFORMATION

General Specifications

Items VN1600–B1

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

Transmission:

Type 5-speed, constant mesh, return shift

Gear ratios: (CAL, CA, 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 CAL, CA, 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 (15/21 × 33/9) Overall drive ratio (CAL, CA, US) 3.445 @ Top gear

(other than CAL, CA, 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°C)

Capacity 200 mL (12.2 cu in.)

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

GENERAL INFORMATION 1-11

General Specifications

Items VN1600–B1

Electrical E quipment:

Battery Capacity 12 V 18 Ah Headlight: Type

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

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

Rated output

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

CAL: California Model

CA: Canadian Model US: United States of America Model

Semi-sealed beam

23 A × 14 V @6 000 r/min (rpm)

1-12 GENERAL INFORMATION

Unit Conversion Table

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 = gal (US) L × 0.2200 = gal (imp) L × 1.057 = L × 0.8799 = qt (imp) L×2.113= L × 1.816 = pint (imp) mL × 0.03381 = oz (US) mL × 0.02816 = oz (imp) mL × 0.06102 = cu in.

qt (US)

pint (US)

Units of Length:

km × 0.6214 = mile m × 3.281 = ft mm × 0.03937 = in.

Units of Torque:

N·m × 0.1020 = kgf·m N·m × 0.7376 = ft·lb N·m × 8.851 = in·lb kgf·m × 9.807 = N·m kgf·m kgf·m × 86.80 = in·lb

× 7.233 =

ft·lb

Units of Pressure:

kPa × 0.01020 = kPa × 0.1450 = psi kPa × 0.7501 = cm Hg kgf/cm² × 98.07 = kPa kgf/cm² × 14.22 = psi cmHg×1.333=kPa

kgf/cm²

Units of Speed:

km/h × 0.6214 = mph

Units of Force:

N × 0.1020 = N × 0.2248 = lb kg × 9.807 = N kg × 2.205 = lb

Units of Temperature:

kgf

Units of Power:

kW ×1.360=PS kW ×1.341=HP PS × 0.7355 = kW PS

× 0.9863 = HP

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

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...... 2-14

Evaporative Emission Control

System Inspection(CAL) ........... 2-15

Cooling System............................... 2-16

Radiator Hose and Connection

Inspection .................................. 2-16

Coolant Change ........................... 2-16

Engine Top End .............................. 2-18

Air Suction Valve Inspection ........ 2-18

Clutch.............................................. 2-19

Clutch Hose and Connection

Inspection .................................. 2-19

Clutch Fluid Level Inspection ....... 2-19

Clutch Fluid Change .................... 2-20

Clutch Master Cylinder Cup and

Dust SealReplacement ............. 2-21

Clutch Slave Cylinder Piston Seal

Replacement ............................ 2-22

Engine Lubrication System............. 2-22

Engine Oil Change....................... 2-22

Oil Filter Replacement ................. 2-24

Wheels/Tires................................... 2-24

Tire Inspection ............................. 2-24

Final Drive....................................... 2-25

Oil Level Inspection...................... 2-25

Oil Change ................................... 2-26

Brakes............................................. 2-27

Brake Pad Wear Inspection ......... 2-27

Brake Hose and Connection

Inspection .................................. 2-27

Brake Fluid Level Inspection........ 2-28

Brake Fluid Change ..................... 2-29

Brake Master Cylinder Cup and

Dust Seal Replacement ............ 2-30

Caliper Piston/Dust Seals

Replacement............................. 2-30

Front Brake Light Switch

Inspection .................................. 2-30

Rear Brake Light Switch

Check/Adjustment..................... 2-30

Suspension..................................... 2-31

Front Fork Oil Leak Inspection..... 2-31

Rear Shock Absorber Oil Leak

Inspection ................................. 2-31

Swingarm Pivot Lubrication ......... 2-31

Steering .......................................... 2-32

Stem Bearing Lubrication............. 2-32

Steering Check ............................ 2-32

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

comes

first

1 6 12 18 24 30 36 See

INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) Page

Air suction valve (e) - inspect †

Air cleaner element (e) - clean†#

Throttle control system (e) - inspect †

Idle speed (e) - inspect †

Fuel hoses, connections - inspect †

Evaporative emission control system (e) (CAL) - inspect †

Final gear case oil level - inspect †

Brake pad wear - inspect † #

Brake light switch - inspect †

Steering - inspect † year

Tire damage and wear - inspect † #

Tire air pressure - inspect year

Wheel damage - inspect year

Wheel bearing wear and damage - inspect

Front fork and rear shock absorber operation

General lubrication - perform year

Nut, bolt, and fastener tightness - inspect †

Brake/clutch hoses, connections - inspect †

Brake/clutch fluid level - inspect † month

Coolant hoses, connections - inspect † year

Steering stem bearing - lubricate 2 years

• • • •

• • • • • • •

• • • •

• • • • • • •

• • • •

• • •

• • • • • •

• • •

• • • • • •

• • •

* ODOMETER READING

km × 1000 (mile × 1000)

2–18

• •

•

2–14

2-13

2-14

2-13

2-15

2–25

2–27

2–30

2–32

2–24

2–33

2–34

2–19,

2–27

2–19,

2–28

2–16

2–32

–

Periodic Maintenance Chart

PERIODIC MAINTENANCE 2-3

FREQUENCY Whichever

comes

first

1 12 24 36 48 See

CHANGE/REPLACE ITEM Every (0.6) (7.5) (15) (24) (30) Page

Spark plug (e)

Engine oil # year

Oil filter year

Coolant 3 years

Brake/clutch master cylinder cup and dust seal 4 years

Caliper piston seal and dust seal 4 years 2–30

Clutch slave cylinder position seal 4 years 2–22

Brake/clutch fluid 2 years

Final gear case oil

Fuel hose 4 years

# : 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.

• • • •

• •

* ODOMETER READING

km × 1000 (mile × 1000)

• • •

•

2–33

2–22

2–24

2–16

2–21,

2–30

2–20,

2–29

2–25

–

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

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 speci-

fied sequence.

SS: Apply silicone sealant.

St: Stake the fasteners to prevent loosening.

R: Replacement parts

AL: Tighten the two clamp bolts alternately

two times to ensure even tightening torque.

Fastener

Fuel System:

High pressure fuel hose clamp screws 1.5 0.15 13 in·lb

Pressure regulator screws 4.9 0.50 43 in·lb

Delivery joint screws 3.4 0.35 30 in·lb Throttle Body

Throttle body flange bolts 4.9 0.50 43 in·lb

Throttle body assy holder bolts 11 1.1 97 in·lb Right Side

Inlet manifold bolts 12 1.2 106 in·lb on Cyl. Head

Spark plug lead holder bolts 11 1.1 97 in·lb Right Side

ISC pipe bolts 11 1.1 97 in·lb

Air cleaner duct holder bolts 11 1.1 97 in·lb Left Side

Right and left air cleaner base bolts 11 1.1 97 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 16 1.6 12

Right air cleaner cover Allen bolt 16 1.6 12

Right air cleaner Allen bolts 11 1.1 97 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 6.9 0.70 61 in·lb S, L

Return fuel check valve 20 2.0 15

Cooling System:

Radiator hose clamp screws 2.5 0.25 22 in·lb

Thermostat air bleeder bolt 7.8 0.80 69 in·lb

WL: Apply a soap and water solution or rubber

lubricant.

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·m

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

Torque

N·m kgf·m ft·lb

kgf·m ft·lb

Remarks

Torque and Locking Agent

PERIODIC MAINTENANCE 2-5

Fastener

Radiator fan switch

Radiator fan bolts

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

Radiator drain Bolt 2.2 0.22 19 in·lb

Engine Top End:

Spark plugs 18 1.8 13

Spark plug retainers 12 1.2 106 in·lb

Air suction valve cover bolts 7.4 0.75 65 in·lb

Chain tensioner mounting bolts 11 1.1 97 in·lb S

Chain tensioner cap 20 2.0 15 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

8mm 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 15 L

Rocker case cover bolts 8.8 0.90 78 in·lb S

Camshaft chain guide bolts 11 1.1 97 in·lb L

Cylinder nuts 25 2.5 18 S

Inlet manifold bolts 12 1.2 106 in·lb on Cyl. Head

Exhaust pipe cover clamp bolts 6.9 0.70 61 in·lb

Premuffler chamber bolts

Muffler stay mounting bolts, 8 25 2.5 18 Lower Muffler

Upper muffler mounting nuts 25 2.5 18

Upper muffler bracket nut 29 3.0 21

Clutch:

Clutch lever pivot bolt 1.0 0.10 8.9 in·lb

Clutch lever pivot bolt locknut 5.9 0.60 52 in·lb Si

Clutch reservoir cap screws 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 9.8 1.0 87 in·lb S

N·m

18 1.8 13

8.3 0.85 74 in·lb

29 3.0 21

Torque

kgf·m ft·lb

Remarks

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Starter lockout switch screws

Push rod guide bolts 11 1.1 95 in·lb L

Clutch cover bolts 11 1.1 95 in·lb

Clutch damper cover bolts 9.8 1.0 87 in·lb L

Clutch damper plate bolts 9.8 1.0 87 in·lb EO

Clutch cover damper screws 4.9 0.50 43 in·lb L

Clutch hub nut 147 15 108 MO

Engine Lubrication System:

Oil filler cap 1.5 0.15 13 in·lb

Oil screen plug 20 2.0 15

Engine oil drain plug 20 2.0 15

Oil filter (cartridge type)

Oil filter pipe

Oil pressure relief valve

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 97 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 97 in·lb L

Oil pipe clamp bolts (inside) 11 1.1 97 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 pipe nozzle (left side) 2.9 0.30 26 in·lb

Oil baffle bolt 11 1.1 97 in·lb L

Engine Removal/Installation:

Downtube bolts and nuts 44 4.5 32

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 in·lb

Crankshaft/Transmission:

Crankcase bolts

Frame ground bracket bolt 11 1.1 97 in·lb Left Crankcase

Crankcase bearing retainer bolts 11 1.1 97 in·lb L

Camshaft chain guide bolts 11 1.1 97 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 97 in·lb L

Connecting rod big end nuts 59 6.0 44 MO

Oil pressure relief valve 15 1.5 11 L

Oil filter pipe 25 2.5 18 SS

10 mm

8mm 21 2.1 15 S

6mm 11 1.1 97 in·lb S

N·m

1.2 0.12 10 in·lb

18 1.8 13

25 2.5 18

15 1.5 11 L

39 4.0 29

Torque

kgf·m ft·lb

Remarks

R, EO

Torque and Locking Agent

PERIODIC MAINTENANCE 2-7

Fastener

Oil hose banjo bolts

Primary gear bolt 147 15 108

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 return pipe bolts (inside) 11 1.1 97 in·lb L

Oil pipe holder bolts (inside) 11 1.1 97 in·lb L

Oil pipe clamp bolts (inside) 11 1.1 97 in·lb L

Left balancer gear bolt 85 8.7 63 MO

Starter clutch bolt

Starter clutch coupling bolts

Gear set lever bolt

Shift shaft return spring pin (bolt) 39 4.0 29 L

Shift pedal clamp bolt 30 3.1 22

Rear shift lever clamp bolt 12 1.2 106 in·lb

Shift rod locknuts 9.8 1.0 87 in·lb (Rear: Lh)

Shift drum cam bolt 15 1.5 11 i n·lb L

Damper cam nut (front gear) 195 20 144 MO (threads)

Clutch push rod guide bolts 11 1.1 97 in·lb L

Wheels/Tires:

Front axle clamp bolts 29 3.0 21 AL

Front axle 108 11 79.6

Rear axle nut 108 11 79.6

Tire air valve nuts 1.5 0.15 13 in·lb

Tire air valve caps 0.15 0.015 1.3 in·lb

Air valve cores 0.30 0.030 2.6 in·lb

Final Drive:

Oil pipe banjo bolts (front gear) 12 1.2 106 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 1.2 106 in·lb S

8mm 29 3.0 21 S

Speed sensor bolt

Damper cam nut (front gear)

Drive gear nut (front gear)

Driven gear assy mounting bolts 25 2.5 18

Driven gear bolt (front gear) 120 12 89 MO, St

Bearing retainer bolts (front gear) 8.8 0.90 78 in·lb L

Final gear case drain plug 8.8 0.90 78 in·lb

Final gear case mounting nuts 34 3.5 25

N·m

9.8 1.0 87 in·lb

85 8.7 63

15 1.5 11 L

11 1.1 97 in·lb L

9.8 1.0 87 in·lb L

195 20 144

265 27 195

Torque

kgf·m ft·lb

Remarks

MO (threads)

MO, St

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Final gear case Studs

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 MO, St

Bearing retainer bolt 6.9 0.70 61 in·lb L

Brakes:

Caliper bleed valves 7.8 0.80 69 in·lb

Brake hose banjo bolts 25 2.5 18

Brake lever pivot bolt 1.0 0.10 8.9 in·lb Si

Brake l ever 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 11 i n·lb

Front m aster cylinder clamp bolts 8.8 0.90 78 in·lb S

Front brake pad spring bolts 2.9 0.30 26 in·lb

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 29 3.0 21

Lower front fork clamp bolts 29 3.0 21

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 72

Front fork bottom Allen bolt (right) 20 2.0 15 L

Front axle clamp bolts 29 3.0 21 AL

Protector screws 5.9 0.60 52 in·lb

Rear shock absorber nuts 34 3.5 25

Shock absorber air valves 5.4 0.55 48 in·lb

Swingarm pivot shaft 108 11 79.6 G

Steering:

Steering stem head nut 88 9.0 65

Steering stem nut 4.9 0.50 43 in·lb S

Handlebar nuts 34 3.5 25

Upper front fork clamp bolts 29 3.0 21

Lower front fork clamp bolts 29 3.0 21 AL

Frame:

Downtube bolts and nuts 44 4.5 32

Rear footpeg bracket bolts 25 2.5 18 L

N·m

– – – L

Torque

kgf·m ft·lb

Remarks

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