Kawasaki VN900 CLASSIC Service Manual

VULCAN900 CLASSIC

VULCAN900 CLASSIC LT

VN900 CLASSIC

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 contents
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

VULCAN900 CLASSIC

VULCAN900 CLASSIC LT

VN900 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 Division/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.

© 2006 Kawasaki Heavy Industries, Ltd. First Edition (1): Feb. 7, 2006 (M)

LIST OF ABBREVIATIONS

A ampere(s) lb pounds(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

BTDC before top dead center

°C degree(s) Celsius

DC direct current rpm revolution(s) per minute

F farad(s) TDC top dead center

°F degree(s) Fahrenheit TIR total indicator reading

ft foot, feet V volt(s)

g gram(s) W watt(s)

h hour(s) Ω ohm(s)

L liter(s)

bottom dead center

PS

psi

r revolution

horsepower

pound(s) per square inch

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 m otor 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 v ehicles or motor vehicle engines, or who operates a fleet of motor vehicles know­ingly to remove or render inoperative any devic e 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 t hat the emission standards are ex-

ceeded.

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 stan-

dards.

d.Permanently removing, disconnecting, or rendering inoperative any component or

element of design of the emission control systems.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW,

THE VIOLATION OF WHICH IS 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 intake system by cutting, drilling, or other means if such

•

modifications result in increased noise levels.

Foreword

This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic in­formation to make it useful to the owner who de­sires to perform his own basic maintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop proce­dures must be understood in order to carry out
maintenance and repair satisfactorily. When­ever the owner has insufficient experience or
doubts his ability to do the work, all adjust­ments, maintenance, and repair should be car­ried out only by qualified mechanics.

In order to perform the work efficiently and
to avoid costly mistakes, read the text, thor­oughly familiarize yourself with the procedures
before starting work, and then do the work care­fully in a c lean 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

Service 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 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 per-

sonal injury, or loss of life.

CAUTION

This caution symbol identifies special

instructions or procedures which, if not

strictly observed, could result in dam-

age to or destruction of equipment.

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

NOTE

This note symbol indicates points of par-

○

ticular interest for more efficient and con­venient operation.

Indicates a procedural step or work to be

•

done.
Indicates a procedural sub-step or how to do

○

the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action to
take based on the results of the test or inspec­tion 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............................................................................................................ 1-10

Unit Conversion Table ............................................................................................................ 1-13

1

1-2 GENERAL INFORMATION

Before Servicing

Before starting to perform an inspection service or carry out a disassembly and reassembly opera­tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra­tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.

Especially note the following:

Battery Ground

Before completing any service on the motorcycle, discon­nect the battery cables from the battery to prevent the en­gine from accidentally turning over. Disconnect the ground
cable (–) first and then the positive (+). When completed
with the service, first connect the positive (+) cable to the
positive (+) terminal of the battery then the negative (–) ca­ble 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 INFORMATION 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

Generally, when installing a part with several bolts, nuts,
or screws, start them all in their holes and tighten them to
a snug fit. Then tighten them according to the specified se­quence to prevent case warpage or deformation which can
lead to malfunction. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quar­ter turn and then remove them. 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 Ga sket, Non-permanent Locking Agent

For applications that require Liquid Gasket or a
Non-permanent Locking Agent, clean the surfaces so
that no oil residue remains before applying liquid gasket or
non-permanent 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 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.

GENERAL INFORMATION 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.

Apply specified grease to the lip of seal before installing
the seal.

Circlips, Cotter Pins

Replace circlips or cotter pins that were removed with new
ones. Take care not to open the clip excessively when in­stalling to prevent deformation.

1-6 GENERAL INFORMATION

Before Servicing

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.

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.

Instrument

Use a meter that has enough accuracy for an accurate
measurement. Read the m anufacture’s instructions thor­oughly before using the meter. Incorrect values may lead
to improper adjustments.

Model Identification

VN900B6F (US and Canada) Left Side View:

GENERAL INFORMATION 1-7

VN900B6F (US and Canada) Right Side View:

Frame Number

Engine Number

[A] Frame Number
[B] Front Fork (Right side)

[A] Engine Number
[B] Right Engine Cover

1-8 GENERAL INFORMATION

Model Identification

VN900B6F (Europe and Australia) Left Side View:

VN900B6F (Europe and Australia) Right Side View:

Model Identification

VN900D6F (US and Canada) Left Side View:

GENERAL INFORMATION 1-9

VN900D6F (US and Canada) Right Side View:

1-10 GENERAL INFORMATION

General Specifications

Items VN900B6F/D6F

Dimensions

Overall Length 2 465 mm (97.05 in.)

Overall Width 1 005 mm (39.57 in.), (AU) 980 mm (38.6 in.)

Overall Height

(VN900B) 1 065 mm (41.93 in.)

(VN900D) 1 480 mm (58.27 in.)

Wheelbase

Road Clearance 135 mm (5.31 in.)

Seat Height 680mm(26.8in.)

Dry Mass

(VN900B) 253 kg (558 lb), (EU) 254 kg (560 lb)

(VN900D) 270 kg (595 lb)

Curb Mass:

Front

(VN900B) 130 kg (287 lb), (EU) 131 kg (289 lb)

(VN900D) 134 kg (295 lb)

Rear

(VN900B) 151 kg (333 lb)

(VN900D) 164 kg (362 lb)

Fuel Tank Capacity 20L(5.3USgal)

Performance

Minimum Turning Radius 2.9 m (9.5 ft)

Engine

Type 4-stroke, SOHC, V2-cylinder

Cooling System Liquid-cooled

Bore And Stroke 88.0 × 74.2 mm (3.46 × 2.92 in.)

Displacement 903mL(55.1cuin.)

Compression Ratio 9.5 : 1

Maximum Horsepower

Maximum Torque

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 @1 000r/min (rpm) to 53° BTDC @5 800 r/min

Spark Plugs NGK CPR7EA-9

Cylinder Numbering Method Front to Rear, 1-2

Firing Order 1-2

1 645 mm (64.76 in.)

37 kW (50 PS) @5 700 r/min (rpm), (CA) (CAL) (US) –

78 N·m (8.0 kgf·m, 58 ft·lb) @3 700 r/min (rpm),
(CA) (CAL) (US) –

(rpm)
(AU) From 3.5° BTDC @1 000r/min (rpm) to 53° BTDC
@5 800 r/min (rpm)

GENERAL INFORMATION 1-11

General Specifications

Items VN900B6F/D6F

Valve Timing:

Inlet

open 40° BTDC

close 40° ABDC

duration 260°

Exhaust

Open 55° BBDC

Close 25° ATDC

Duration 260°

Lubrication System Forced lubrication (wet sump)

Engine Oil:

Type

Viscosity SAE10W-40

Capacity 3.7L(3.9USqt)

Drive Train

Primary Reduction System:

Type

Reduction Ratio 2.184 (83/38)

Clutch Type Wet multi disc

Transmission:

Type

Gear Ratios:

1st

2nd 1.889 (34/18)

3rd 1.360 (34/25)

4th 1.107 (31/28)

5th 0.963 (26/27)

Final Drive System:

Type Belt

Reduction Ratio 2.063 (66/32)

Overall Drive Ratio 4.338 @ Top gear

Frame

Type Tubular, double cradle

Caster (Rake Angel) 32°

Trail 160 mm (6.30 in.)

Front Tire:

Type Tubeless

Size 130/90-16M/C 67H

Rim Size 16M/C × MT3.00

Rear Tire:

Type Tubeless

Size 180/70-15M/C 76H

Rim Size 15M/C × MT4.50

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

Chain

5-speed, constant mesh, return shift

2.786 (39/14)

1-12 GENERAL INFORMATION

General Specifications

Items VN900B6F/D6F

Front Suspension:

Type

Wheel Travel

Rear Suspension:

Type Swingarm (uni-trak)

Wheel Travel 103 mm (4.06 in.)

Brake Type:

Front

Rear

Electrical Equipment

Battery:

Capacity 12 V 10 Ah

Headlight:

Type

Bulb

Tail/brake Light 12 V 5/21 W

Alternator:

Type Three-phase AC

Rated Output 32 A × 14 V @5 000 r/min (rpm)

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

AU: Australia
CA: Canada

CAL: California

EU: Europe
US: United States of America

Telescopic fork

150 mm (5.90 in.)

Single disc

Single disc

Semi-sealed beam

12 V 60/55W (quartz-halogen)

Unit Conversion Table

GENERAL INFORMATION 1-13

Prefixes for Units:

Prefix Symbol Power

mega M ×1000000

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 =

L × 1.057 =

L × 0.8799 = qt (imp)

L × 2.113 = pint (US)

L × 1.816 = pint (imp)

mL × 0.03381 = oz (US)

mL × 0.02816 =

mL × 0.06102 = cu in

gal (imp)

qt (US)

oz (imp)

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

kgf·m

kgf·m

× 9.807 = N·m

×7.233=

× 86.80 = in·lb

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

cm Hg × 1.333 = kPa

kgf/cm²

Units of Speed:

km/h × 0.6214 = mph

Units of Force:

N × 0.1020 = kg

N × 0.2248 = lb

kg ×9.807=N

kg ×2.205=lb

Units of Temperature:

Units of Power:

kW × 1.360 =

kW × 1.341 = HP

PS × 0.7355 = kW

PS × 0.9863 = HP

PS

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

Periodic Maintenance Chart ................................................................................................... 2-3

Torque and Locking Agent...................................................................................................... 2-6

Specifications ......................................................................................................................... 2-11

Special Tools .......................................................................................................................... 2-13

Periodic Maintenance Procedures.......................................................................................... 2-14

Fuel System (DFI)................................................................................................................ 2-14

Fuel Hose Inspection (fuel leak, damage, installation condition)...................................... 2-14

Throttle Control System Inspection................................................................................... 2-14

Idle Speed Inspection ....................................................................................................... 2-15

Idle Speed Adjustment...................................................................................................... 2-15

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

Coolant Level Inspection................................................................................................... 2-16

Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition) ......... 2-16

Air Suction System .............................................................................................................. 2-17

Air Suction System Damage Inspection............................................................................ 2-17

Engine Top End ................................................................................................................... 2-17

Valve Clearance Inspection .............................................................................................. 2-17

Valve Clearance Adjustment............................................................................................. 2-17

Clutch................................................................................................................................... 2-21

Clutch Operation Inspection.............................................................................................. 2-21

Wheels and Tires ................................................................................................................. 2-22

Tire Air Pressure Inspection.............................................................................................. 2-22

Wheel/Tire Damage Inspection......................................................................................... 2-22

Tire Tread Wear Inspection............................................................................................... 2-22

Wheel Bearing Damage Inspection .................................................................................. 2-23

Spoke Tightness and Rim Runout Inspection................................................................... 2-24

Drive Train ........................................................................................................................... 2-25

Belt Deflection Inspection ................................................................................................. 2-25

Belt Deflection Adjustment................................................................................................ 2-27

Wheel Alignment Inspection/Adjustment .......................................................................... 2-28

Belt Wear and Damage Inspection ................................................................................... 2-28

Brake System ...................................................................................................................... 2-31

Brake Fluid Leak Inspection.............................................................................................. 2-31

Brake Hose Damage and Installation Condition Inspection.............................................. 2-32

Brake Operation Inspection .............................................................................................. 2-32

Brake Fluid Level Inspection............................................................................................. 2-32

Brake Pad Wear Inspection .............................................................................................. 2-33

Brake Light Switch Operation Inspection .......................................................................... 2-33

Suspensions ........................................................................................................................ 2-34

Front Forks/Rear Shock Absorber Operation Inspection .................................................. 2-34

Front Fork Oil Leak Inspection.......................................................................................... 2-35

Rear Shock Absorber Oil Leak Inspection ........................................................................ 2-35

Swingarm Pivot Lubrication .............................................................................................. 2-35

Rocker Arm Operation Inspection..................................................................................... 2-35

Tie-Rod Operation Inspection ........................................................................................... 2-35

Uni-trak Linkage Lubrication ............................................................................................. 2-36

Steering System ..................................................................................................................2-36

Steering Play Inspection ................................................................................................... 2-36

Steering Play Adjustment.................................................................................................. 2-36

Steering Stem Bearing Lubrication ................................................................................... 2-38

2

2-2 PERIODIC MAINTENANCE

Electrical System ................................................................................................................. 2-39

Lights and Switches Operation Inspection........................................................................ 2-39

Headlight Aiming Inspection ............................................................................................. 2-41

Sidestand Switch Operation Inspection ............................................................................ 2-42

Engine Stop Switch Operation Inspection......................................................................... 2-43

Others.................................................................................................................................. 2-44

Chassis Parts Lubrication ................................................................................................. 2-44

Bolts, Nuts and Fasteners Tightness Inspection............................................................... 2-45

Evaporative Emission Control SystemInspection (CAL)...................................................... 2-46

Evaporative Emission Control System Inspection ............................................................ 2-46

Replacement Parts .............................................................................................................. 2-47

Air Cleaner Element Replacement.................................................................................... 2-47

Engine Oil Change............................................................................................................ 2-48

Oil Filter Replacement ...................................................................................................... 2-49

Fuel Hose Replacement ................................................................................................... 2-49

Coolant Change ................................................................................................................ 2-51

Radiator Hose and O-ring Replacement........................................................................... 2-53

Brake Hose Replacement ................................................................................................. 2-53

Brake Fluid Change .......................................................................................................... 2-54

Master Cylinder Rubber Parts Replacement .................................................................... 2-56

Caliper Rubber Parts Replacement .................................................................................. 2-57

Spark Plug Replacement .................................................................................................. 2-60

PERIODIC MAINTENANCE 2-3

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.

Periodic Inspection

FREQUENCY Whichever

comes

first

1 6 12 18 24 30 36

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

Fuel System

Throttle control system (play, smooth
return, no drag) - inspect

Idle speed - inspect

Fuel leak (fuel hose and pipe) - inspect

Fuel hose - inspect year

Fuel hoses installation condition - inspect year

Cooling System

Coolant level - inspect

Coolant leak (radiator hose and pipe) ­inspect

Radiator hose damage - inspect year

Radiator hose installation condition ­inspect

Air Suction System

Air suction system damage - inspect

Evaporative Emission Control System
(CAL)

Evaporative emission control system
function - inspect

Engine Top End

Valve clearance - inspect (US and CA)

Valve clearance - inspect (EU and AU) Every 42 000 km (26 000 mile) 2-17

Clutch

Clutch operation (play, disengagement,
engagement) - inspect

Wheels and Tires

Tire air pressure - inspect year

Wheel/tire damage - inspect

Tire tread wear, abnormal wear - inspect

Wheel bearings damage - inspect year

Spoke tightness and rim runout-inspect

Drive Train

Belt deflection - inspect

Belt wear and damage - inspect

Brake System

Brake fluid leak - inspect

year

year

year

year

year

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • • • • • •

• • • •

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • • •

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

• • •

•

• • •

• • •

• • •

• • •

See

Page

2-14

2-15

2-14

2-14

2-14

2-16

2-16

2-16

2-16

2-17

2-46

2-17

2-21

2-22

2-22

2-22

2-23

2-24

2-25

2-28

2-31

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

FREQUENCY Whichever

comes

first

1 6 12 18 24 30 36

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

Brake hose damage - inspect year

Brake hose installation condition - inspect year

Brake operation (effectiveness, play, no
drag) - inspect

Brake fluid level - inspect 6 m onths

Brake pad wear - inspect #

Brake light switch operation - inspect

Suspensions

Front forks/rear shock absorber operation
(damping and smooth stroke) - inspect

Front forks/rear shock absorber oil leak ­inspect

Swingarm pivot - lubricate

Uni - trak rocker arm operation - inspect

Uni - trak tie rod operation - inspect

Uni - trak rocker arm bearings - lubricate

Uni - trak tie rod bearings - lubricate

Steering System

Steering play - inspect year

Steering stem bearings - lubricate 2 years

Electrical System

Lights and switches operation - inspect year

Headlight aiming - inspect year

Sidestand switch operation - inspect

Engine stop switch operation - inspect year

Others

Chassis parts - lubricate year

Bolts and nuts tightness - inspect

#: 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.

year

year

year

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • • •

• • • •

• • • •

* ODOMETER READING

×1000km

(× 1 000 mile)

• • • • • •

• • •

• • •

•

• • •

• • •

•

•

•

• • •

• • •

• • •

• • •

• • •

See

Page

2-32

2-32

2-32

2-32

2-33

2-33

2-34

2-35

2-35

2-35

2-35

2-36

2-36

2-35

2-38

2-39

2-41

2-42

2-43

2-44

2-45

(AU): Australia
(CA): Canada
(CAL):California
(EU): Europe
(US): United States

PERIODIC MAINTENANCE 2-5

Periodic Maintenance Chart

Periodic Replacement Parts

FREQUENCY Whichever

comes

first

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

Air c leaner element # Every 18 000 km (12 000 mile) 2-47

Engine oil # year

Oil filter year

Fuel hose 4 years

Coolant 3 years

Radiator hoses and O-rings

Brake hoses 4 years

Brake fluid (Front and Rear) 2 years

Rubber parts of master cylinder and caliper 4 years

Spark plug

#: 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.

3 years

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

1 12 24 36 48

• • • • •

• • • • •

•

•

• •

• • • •

See

Page

2-48

2-49

2-49

•

2-51

2-53

2-53

•

2-54

2-57

•

2-60

2-6 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:

2T: Apply 2-stroke oil.

L: Apply a non-permanent locking agent to the threads.

Lh: Left-hand threads

M: Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil solution.

(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)

S: Tighten the fasteners following the specified sequence.

Si: Apply silicone grease (ex. PBC grease).

SS: Apply silicone sealant.

Fastener

Fuel System

Water Temperature Sensor 12 1.2 106 in·lb

Speed Sensor Mounting Bolt 9.8 1.0 87 in·lb L

Fuel Pump Bolts 9.8 1.0 87 in·lb L

Oxygen Sensor 25 2.5 18

Fuel Level Sensor Mounting Bolts 6.9 0.70 61 in·lb L

Air Cleaner Housing Bolts 9.8 1.0 87 in·lb

Air Cleaner Cover Bolts

Air Cleaner Element Screw 4.9 0.50 43 in·lb

Throttle Body Assy Holder Bolts 9.8 1.0 87 in·lb

Inlet Manifold Bolts

Delivery Joint Bolts 9.8 1.0 87 in·lb L

Delivery Joint Bracket Bolts 9.8 1.0 87 in·lb

Vehicle-down Sensor Bolts 4.9 0.50 43 in·lb

Inlet Air Pressure Sensor Bolt 6.9 0.70 61 in·lb

Inlet Air Temperature Sensor Screw 1.2 0.12 11 in·lb

Cooling System

Radiator Hose Clamp Screws 2.0 0.20 18 in·lb

Water Pump Impeller Bolt 9.8 1.0 87 in·lb

Coolant Drain Bolt

Thermostat Housing Cover Bracket Bolts 6.9 0.70 61 in·lb

Thermostat Housing Cover Bolts 4.9 0.50 43 in·lb L

Radiator Bolts 6.9 0.70 61 in·lb

Radiator Screen Screws 6.9 0.70 61 in·lb

Radiator Fan Bolts 8.3 0.85 73 in·lb

Water Hose Fitting Bolts 9.8 1.0 87 in·lb

Reserve Tank Bolts 6.9 0.70 61 in·lb

Engine Top End

Cylinder Head nuts (M10) (First)

Cylinder Head nuts (M10) (Final) 49 5.0 36 MO, S

Cylinder Head nuts (M8) 25 2.5 18 S

Camshaft Cap Bolts 25 2.5 18

N·m kgf·m ft·lb

4.9 0.50 43 in·lb

9.8 1.0 87 in·lb L

9.8 1.0 87 in·lb

20 2.0 15

Torque

Remarks

MO, S