Kawasaki VN1600 MEAN STREAK Service Manual

VULCAN 1600 MEAN STREAK

VN1600 MEAN STREAK

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	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
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.

© 2003 Kawasaki Heavy Industries, Ltd.

First Edition (1) : Jul. 1, 2003 (M)

LIST OF ABBREVIATIONS

A	ampere(s)	lb	pound(s)
ABDC	after bottom dead center	m	meter(s)
AC	alternating current	min	minute(s)
ATDC	after top dead center	N	newton(s)
BBDC	before bottom dead center	Pa	pascal(s)
BDC	bottom dead center	PS	horsepower
BTDC	before top dead center	psi	pound(s) per square inch
°C	degree(s) Celsius	r	revolution
DC	direct current	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.

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 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 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 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 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 ............................................................................................................	1-12

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.

GENERAL INFORMATION 1-3

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.

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.

GENERAL INFORMATION 1-5

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 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.

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.

GENERAL INFORMATION 1-7

Model Identification

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

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 INFORMATION 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		1 705 mm (67.1 in.)
	Road clearance		125 mm (4.92 in.)
	Seat height		700 mm (27.6 in.)
	Dry mass		290 kg (639 lb)
	Curb mass:	Front	145 kg (320 lb)
		Rear	172 kg (379 lb)
	Fuel tank capacity		17.0 L (4.49 US gal)
	Fuel		Unleaded and high-octane gasoline
			(see 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		102 × 95 mm (4.02 × 3.74 in.)
	Displacement		1 552 mL (94.70 cu in.)
	Compression ratio		9.0 : 1
	Maximum horsepower		54 kW (74 PS) @5 300 r/min (rpm),
			(CAL) (CA) (US) –
	Maximum torque		125 N·m (12.7 kgf·m, 92.2 ft·lb) @2 800 r/min (rpm),
			(CAL) (CA) (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 5° 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

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 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
		Rated output		23	A × 14 V @6 000 r/min (rpm)
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

1-12 GENERAL INFORMATION

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

Units of Temperature:

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

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......	2-14
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

* ODOMETER READING km × 1000 (mile × 1000)

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 †						•		•		•	2–18
Air cleaner element (e) - clean†#							•			•	2–14
Throttle control system (e) - inspect †				•		•		•		•	2-13
Idle speed (e) - inspect †				•		•		•		•	2-14
Fuel hoses, connections - inspect †					•	•	•	•	•	•	2-13
Evaporative emission control system (e)				•		•		•		•	2-15
(CAL) - inspect †
Final gear case oil level - inspect †						•		•		•	2–25
Brake pad wear - inspect † #					•	•	•	•	•	•	2–27
Brake light switch - inspect †				•	•	•	•	•	•	•	2–30
Steering - inspect †	year			•		•		•		•	2–32
Tire damage and wear - inspect † #						•		•		•	2–24
Tire air pressure - inspect	year					•		•		•	2–24
						•		•		•
Wheel damage - inspect	year					•		•		•	–
Wheel bearing wear and damage - inspect											–
Front fork and rear shock absorber -						•		•		•	–
operation
General lubrication - perform	year					•		•		•	2–33
Nut, bolt, and fastener tightness - inspect †				•	•	•	•	•	•	•	2–34
				•		•		•		•	2–27
Brake/clutch hoses, connections - inspect †											2–19,
Brake/clutch fluid level - inspect †	month			•	•	•	•	•	•	•	2–19,2–28
Coolant hoses, connections - inspect †	year			•		•		•		•	2–16
								•
Steering stem bearing - lubricate	2 years										2–32

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

FREQUENCY

Whichever

* ODOMETER READING

comes

km × 1000 (mile × 1000)

first

1

12

24

36

48

See

CHANGE/REPLACE ITEM

Every

(0.6)

(7.5)

(15)

(24)

(30)

Page

•

•

•

Spark plug (e)

•

•

•

•

2–33

Engine oil #

year

2–22

Oil filter

year

•

•

•

•

2–24

•

Coolant

3 years

2–16

Brake/clutch master cylinder cup and dust seal

4 years

2–21,

2–30

Caliper piston seal and dust seal

4 years

2–30

Clutch slave cylinder position seal

4 years

2–22

Brake/clutch fluid

2 years

•

2–20,

2–29

Final gear case oil

•

•

2–25

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.

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			WL: Apply a soap and water solution or rubber
	for the major fasteners requiring use of a non				lubricant.
	-permanent locking agent or liquid gasket.			The table below, relating tightening torque to
	Letters used in the “Remarks” column mean:			thread diameter, lists the basic torque for the
				bolts and nuts. Use this table for only the bolts
	G: Apply grease to the threads.
				and nuts which do not require a specific torque
	EO: Apply engine oil to the threads and the
				value. All of the values are for use with dry
	seating surface.
				solvent-cleaned threads.
	L: Apply a non-permanent locking agent to
				Basic Torque for General Fasteners
	the threads.
	Lh: Left-hand threads.			Threads							Torque
	MO: Apply molybdenum disulfide oil to the			dia. (mm)				N·m			kgf·m				ft·lb
	threads and the seating surface.	The		5			3.4		4.9		0.35		0.50	30	43 in·lb
	molybdenum disulfide oil is a mixture
				6			5.9		7.8		0.60		0.80	52	69 in·lb
	of engine oil and molybdenum disulfide
				8			14		19		1.4 1.9			10.0		13.5
	grease with a weight ratio (10 : 1).
				10			25		34		2.6		3.5	19.0		25
	S: Tighten the fasteners following the speci-
	fied sequence.			12			44		61		4.5		6.2	33		45
	SS: Apply silicone sealant.			14			73		98		7.4		10.0	54		72
	St: Stake the fasteners to prevent loosening.			16			115		155		11.5		16.0	83		115
	R: Replacement parts			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:
	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

PERIODIC MAINTENANCE 2-5

Torque and Locking Agent

Fastener				Torque			Remarks
			N·m	kgf·m	ft·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
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
		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		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			29	3.0		21
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

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener			Torque			Remarks
		N·m	kgf·m	ft·lb
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		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)		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	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	10 mm	39	4.0		29	S
	8 mm	21	2.1		15	S
	6 mm	11	1.1	97 in·lb		S
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

PERIODIC MAINTENANCE 2-7

Torque and Locking Agent

Fastener			Torque			Remarks
		N·m	kgf·m	ft·lb
Oil hose banjo bolts		9.8	1.0	87	in·lb
Primary gear bolt		147	15	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 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		85	8.7		63	MO
Starter clutch coupling bolts		15	1.5		11	L
Gear set lever bolt		11	1.1	97	in·lb	L
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 in·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
	8 mm	29	3.0		21	S
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)		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

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

	Fastener		Torque		Remarks
		N·m	kgf·m	ft·lb
	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	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 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	11 in·lb
	Front master 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