VULCAN900 CLASSIC
VULCAN900 CLASSIC LT
VN900 CLASSIC
Motorcycle
Service Manual
Quick Reference Guide
This quick reference guide will assist you in locating a desired topic or procedure.
•Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page.
•Refer to the sectional table of contents for the exact pages to locate the specific topic required.
General Information |
1 |
j |
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Periodic Maintenance |
2 |
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Fuel System (DFI) |
3 |
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Cooling System |
4 |
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Engine Top End |
5 |
j |
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Clutch |
6 |
j |
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Engine Lubrication System |
7 |
j |
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Engine Removal/Installation |
8 |
j |
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Crankshaft/Transmission |
9 |
j |
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Wheels/Tires |
10 |
j |
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Final Drive |
11 |
j |
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Brakes |
12 |
j |
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Suspension |
13 |
j |
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Steering |
14 |
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Frame |
15 |
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Electrical System |
16 |
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Appendix |
17 |
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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 |
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 |
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) |
|
|
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 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 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 Service Manual. Genuine parts provided as spare parts are listed in the Parts Catalog.
•Follow the procedures in this manual carefully. Don’t take shortcuts.
•Remember to keep complete records of maintenance and repair with dates and any new parts installed.
How to Use This Manual
In preparing this manual, we divided the product into its major systems. These systems became the manual’s chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter.
The Quick Reference Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents.
The Periodic Maintenance Chart is located in the Periodic Maintenance chapter. The chart gives a time schedule for required maintenance operations.
If you want spark plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, use the Quick Reference Guide to locate the Periodic Maintenance chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug section.
Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.
WARNING
This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.
CAUTION
This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment.
This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information.
NOTE
○This note symbol indicates points of particular interest for more efficient and convenient operation.
•Indicatesdone. a procedural step or work to be ○Indicates a procedural sub-step or how to do the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows.
In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.
GENERAL INFORMATION 1-1
General Information |
|
Table of Contents |
|
|
1 |
Before Servicing ..................................................................................................................... |
1-2 |
Model Identification................................................................................................................. |
1-7 |
General Specifications............................................................................................................ |
1-10 |
Unit Conversion Table ............................................................................................................ |
1-13 |
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.
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
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 Gasket, 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.
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.
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 manufacture’s instructions thoroughly before using the meter. Incorrect values may lead to improper adjustments.
GENERAL INFORMATION 1-7
Model Identification
VN900B6F (US and Canada) Left Side View:
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:
GENERAL INFORMATION 1-9
Model Identification
VN900D6F (US and Canada) Left Side View:
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 |
1 645 mm (64.76 in.) |
Road Clearance |
135 mm (5.31 in.) |
Seat Height |
680 mm (26.8 in.) |
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 |
20 L (5.3 US gal) |
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 |
903 mL (55.1 cu in.) |
Compression Ratio |
9.5 : 1 |
Maximum Horsepower |
37 kW (50 PS) @5 700 r/min (rpm), (CA) (CAL) (US) – |
Maximum Torque |
78 N·m (8.0 kgf·m, 58 ft·lb) @3 700 r/min (rpm), |
|
(CA) (CAL) (US) – |
Carburetion System |
DFI (Digital Fuel Injection) System |
Starting System |
Electric starter |
Ignition System |
Battery and coil (transistorized) |
Timing Advance |
Electronically advanced (digital) |
Ignition Timing |
From 0° BTDC @1 000r/min (rpm) to 53° BTDC @5 800 r/min |
|
(rpm) |
|
(AU) From 3.5° BTDC @1 000r/min (rpm) to 53° BTDC |
|
@5 800 r/min (rpm) |
Spark Plugs |
NGK CPR7EA-9 |
Cylinder Numbering Method |
Front to Rear, 1-2 |
Firing Order |
1-2 |
|
|
|
|
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 |
API SE, SF or SG class |
|
|
API SH or SJ class with JASO MA |
|
Viscosity |
SAE10W-40 |
|
Capacity |
3.7 L (3.9 US qt) |
|
Drive Train |
|
|
Primary Reduction System: |
|
|
Type |
Chain |
|
Reduction Ratio |
2.184 (83/38) |
|
Clutch Type |
Wet multi disc |
|
Transmission: |
|
|
Type |
5-speed, constant mesh, return shift |
|
Gear Ratios: |
|
|
1st |
2.786 (39/14) |
|
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 |
1-12 GENERAL INFORMATION
General Specifications
Items |
VN900B6F/D6F |
Front Suspension: |
|
Type |
Telescopic fork |
Wheel Travel |
150 mm (5.90 in.) |
Rear Suspension: |
|
Type |
Swingarm (uni-trak) |
Wheel Travel |
103 mm (4.06 in.) |
Brake Type: |
|
Front |
Single disc |
Rear |
Single disc |
Electrical Equipment |
|
Battery: |
|
Capacity |
12 V 10 Ah |
|
|
Headlight: |
|
Type |
Semi-sealed beam |
Bulb |
12 V 60/55W (quartz-halogen) |
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
GENERAL INFORMATION 1-13
Unit Conversion Table
Prefixes for Units: |
Units of Length: |
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 |
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 |
× |
7.233 |
= |
ft·lb |
kgf·m |
× |
86.80 |
= |
in·lb |
Units of Volume: |
|
|
|
Units of Pressure: |
|
|
||||
|
|
|
kPa |
× |
0.01020 |
= |
kgf/cm² |
|||
L |
× |
0.2642 |
= |
gal (US) |
|
kPa |
× |
0.1450 |
= |
psi |
L |
× |
0.2200 |
= |
gal (imp) |
|
kPa |
× |
0.7501 |
= |
cm Hg |
L |
× |
1.057 |
= |
qt (US) |
|
kgf/cm² |
× |
98.07 |
= |
kPa |
L |
× |
0.8799 |
= |
qt (imp) |
|
kgf/cm² |
× |
14.22 |
= |
psi |
L |
× |
2.113 |
= |
pint (US) |
|
cm Hg |
× |
1.333 |
= |
kPa |
L |
× |
1.816 |
= |
pint (imp) |
|
|
|
|
|
|
mL |
× |
0.03381 |
= |
oz (US) |
|
Units of Speed: |
|
|
||
mL |
× |
0.02816 |
= |
oz (imp) |
|
km/h |
× |
0.6214 |
= |
mph |
mL |
× |
0.06102 |
= |
cu in |
|
|
|
|
|
|
Units of Force: |
|
|
|
Units of Power: |
|
|
||||
|
|
|
kW |
× |
1.360 |
= |
PS |
|||
N |
× |
0.1020 |
= |
kg |
|
kW |
× |
1.341 |
= |
HP |
N |
× |
0.2248 |
= |
lb |
|
|
|
|
|
|
|
PS |
× |
0.7355 |
= |
kW |
|||||
kg |
× |
9.807 |
= |
N |
|
PS |
× |
0.9863 |
= |
HP |
kg |
× |
2.205 |
= |
lb |
|
|
|
|
|
|
Units of Temperature:
PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart ................................................................................................... |
2-3 |
|
|
Torque and Locking Agent...................................................................................................... |
2-6 |
2 |
|
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 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 conditionThe. initial maintenance is vitally important and must not be neglected.
Periodic Inspection
FREQUENCY |
Whichever |
|
|
|
|
* ODOMETER READING |
|
|||||||
|
comes |
|
|
|
|
|
|
|
× 1 000 km |
See |
||||
|
first |
|
|
|
|
|
|
|
(× 1 000 mile) |
|||||
|
|
|
|
|
|
|
|
|||||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Page |
|
|
|
|
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 |
year |
|
• |
|
|
• |
|
• |
|
• |
2-14 |
|||
return, no drag) - inspect |
|
|
|
|
|
|||||||||
Idle speed - inspect |
|
|
|
|
• |
|
|
• |
|
• |
|
• |
2-15 |
|
Fuel leak (fuel hose and pipe) - inspect |
year |
|
• |
|
|
• |
|
• |
|
• |
2-14 |
|||
Fuel hose - inspect |
year |
|
• |
|
|
• |
|
• |
|
• |
2-14 |
|||
Fuel hoses installation condition - inspect |
year |
|
• |
|
|
• |
|
• |
|
• |
2-14 |
|||
Cooling System |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Coolant level - inspect |
|
|
|
|
• |
|
|
• |
|
• |
|
• |
2-16 |
|
Coolant leak (radiator hose and pipe) - |
year |
|
• |
|
|
• |
|
• |
|
• |
2-16 |
|||
inspect |
|
|
|
|
|
|||||||||
Radiator hose damage - inspect |
year |
|
• |
|
|
• |
|
• |
|
• |
2-16 |
|||
Radiator hose installation condition - |
year |
|
• |
|
|
• |
|
• |
|
• |
2-16 |
|||
inspect |
|
|
|
|
|
|||||||||
Air Suction System |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Air suction system damage - inspect |
|
|
|
|
|
|
|
|
• |
|
• |
|
• |
2-17 |
Evaporative Emission Control System |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(CAL) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Evaporative emission control system |
|
|
|
|
• |
• |
|
• |
• |
• |
• |
• |
2-46 |
|
function - inspect |
|
|
|
|
|
|||||||||
Engine Top End |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Valve clearance - inspect (US and CA) |
|
|
|
|
|
|
|
|
|
|
• |
|
|
2-17 |
Valve clearance - inspect (EU and AU) |
|
|
Every 42 000 km (26 000 mile) |
|
2-17 |
|||||||||
Clutch |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Clutch operation (play, disengagement, |
|
|
|
|
• |
|
|
• |
|
• |
|
• |
2-21 |
|
engagement) - inspect |
|
|
|
|
|
|
|
|
||||||
Wheels and Tires |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Tire air pressure - inspect |
year |
|
|
|
|
|
• |
|
• |
|
• |
2-22 |
||
Wheel/tire damage - inspect |
|
|
|
|
|
|
|
|
• |
|
• |
|
• |
2-22 |
Tire tread wear, abnormal wear - inspect |
|
|
|
|
|
|
|
|
• |
|
• |
|
• |
2-22 |
Wheel bearings damage - inspect |
year |
|
|
|
|
|
• |
|
• |
|
• |
2-23 |
||
Spoke tightness and rim runout-inspect |
|
|
|
|
• |
• |
|
• |
• |
• |
• |
• |
2-24 |
|
Drive Train |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Belt deflection - inspect |
|
|
|
|
• |
• |
|
• |
• |
• |
• |
• |
2-25 |
|
Belt wear and damage - inspect |
|
|
|
|
• |
• |
|
• |
• |
• |
• |
• |
2-28 |
|
Brake System |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Brake fluid leak - inspect |
year |
|
• |
• |
|
• |
• |
• |
• |
• |
2-31 |
|||
2-4 PERIODIC MAINTENANCE
Periodic Maintenance Chart
FREQUENCY |
Whichever |
|
|
|
* ODOMETER READING |
|
||||||||
|
comes |
|
|
|
|
|
|
× 1 000 km |
See |
|||||
|
first |
|
|
|
|
|
|
(× 1 000 mile) |
||||||
|
|
|
|
|
|
|
||||||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Page |
|
|
|
|
|
1 |
6 |
|
12 |
18 |
24 |
30 |
36 |
||
|
|
|
|
|
|
|
||||||||
INSPECTION |
Every |
|
(0.6) |
(4) |
|
(7.5) |
(12) |
(15) |
(20) |
(24) |
|
|||
Brake hose damage - inspect |
year |
|
• |
• |
|
• |
• |
• |
• |
• |
2-32 |
|||
Brake hose installation condition - inspect |
year |
|
• |
• |
|
• |
• |
• |
• |
• |
2-32 |
|||
Brake operation (effectiveness, play, no |
year |
|
• |
• |
|
• |
• |
• |
• |
• |
2-32 |
|||
drag) - inspect |
|
|
||||||||||||
Brake fluid level - inspect |
6 months |
|
• |
• |
|
• |
• |
• |
• |
• |
2-32 |
|||
Brake pad wear - inspect # |
|
|
|
|
|
|
• |
|
• |
• |
• |
• |
• |
2-33 |
Brake light switch operation - inspect |
|
|
|
|
• |
• |
|
• |
• |
• |
• |
• |
2-33 |
|
Suspensions |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Front forks/rear shock absorber operation |
|
|
|
|
|
|
|
|
• |
|
• |
|
• |
2-34 |
(damping and smooth stroke) - inspect |
|
|
|
|
|
|
|
|
|
|
||||
Front forks/rear shock absorber oil leak - |
year |
|
|
|
|
|
• |
|
• |
|
• |
2-35 |
||
inspect |
|
|
|
|
|
|
|
|||||||
Swingarm pivot - lubricate |
|
|
|
|
|
|
|
|
|
|
• |
|
|
2-35 |
|
|
|
|
|
|
|
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Uni - trak rocker arm operation - inspect |
|
|
|
|
|
|
|
|
• |
|
• |
|
• |
2-35 |
Uni - trak tie rod operation - inspect |
|
|
|
|
|
|
|
|
• |
|
• |
|
• |
2-35 |
Uni - trak rocker arm bearings - lubricate |
|
|
|
|
|
|
|
|
|
|
• |
|
|
2-36 |
|
|
|
|
|
|
|
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Uni - trak tie rod bearings - lubricate |
|
|
|
|
|
|
|
|
|
|
• |
|
|
2-36 |
|
|
|
|
|
|
|
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Steering System |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Steering play - inspect |
year |
|
• |
|
|
• |
|
• |
|
• |
2-35 |
|||
Steering stem bearings - lubricate |
2 years |
|
|
|
|
|
|
|
• |
|
|
2-38 |
||
|
|
|
|
|
|
|
|
|
|
|||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Electrical System |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Lights and switches operation - inspect |
year |
|
|
|
|
|
• |
|
• |
|
• |
2-39 |
||
Headlight aiming - inspect |
year |
|
|
|
|
|
• |
|
• |
|
• |
2-41 |
||
Sidestand switch operation - inspect |
year |
|
|
|
|
|
• |
|
• |
|
• |
2-42 |
||
Engine stop switch operation - inspect |
year |
|
|
|
|
|
• |
|
• |
|
• |
2-43 |
||
Others |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Chassis parts - lubricate |
year |
|
|
|
|
|
• |
|
• |
|
• |
2-44 |
||
Bolts and nuts tightness - inspect |
|
|
|
|
• |
|
|
• |
|
• |
|
• |
2-45 |
|
#: 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.
(AU): Australia
(CA): Canada (CAL):California (EU): Europe (US): United States
PERIODIC MAINTENANCE 2-5
Periodic Maintenance Chart
Periodic Replacement Parts
FREQUENCY |
Whichever |
* ODOMETER READING |
|
||||||||
|
comes |
|
|
|
|
|
× 1 000 km |
See |
|||
|
|
|
|
|
|
||||||
|
first |
|
|
|
|
(× 1 000 mile) |
|||||
|
|
|
|
|
|||||||
|
|
|
|
|
|
|
|
|
|
|
Page |
|
|
|
|
1 |
12 |
24 |
36 |
48 |
|||
|
|
|
|
|
|||||||
CHANGE/REPLACE ITEM |
Every |
(0.6) |
(7.5) |
(15) |
(24) |
(30) |
|
||||
Air cleaner element # |
|
|
|
Every 18 000 km (12 000 mile) |
2-47 |
||||||
Engine oil # |
year |
|
• |
• |
• |
• |
• |
2-48 |
|||
Oil filter |
year |
|
• |
• |
• |
• |
• |
2-49 |
|||
Fuel hose |
4 years |
|
|
|
|
|
|
• |
2-49 |
||
Coolant |
3 years |
|
|
|
|
|
• |
|
2-51 |
||
|
|
|
|
|
|
|
|||||
|
|
|
|
|
|
|
|
|
|
|
|
Radiator hoses and O-rings |
3 years |
|
|
|
|
|
• |
|
2-53 |
||
|
|
|
|
|
|
|
|||||
Brake hoses |
4 years |
|
|
|
|
|
|
• |
2-53 |
||
Brake fluid (Front and Rear) |
2 years |
|
|
|
|
• |
|
• |
2-54 |
||
Rubber parts of master cylinder and caliper |
4 years |
|
|
|
|
|
|
• |
2-57 |
||
Spark plug |
|
|
|
|
|
|
• |
• |
• |
• |
2-60 |
#: 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.
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 |
|
Torque |
|
|
Remarks |
|
N·m |
kgf·m |
ft·lb |
||||
|
|
|||||
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 |
4.9 |
0.50 |
43 |
in·lb |
|
|
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 |
9.8 |
1.0 |
87 |
in·lb |
L |
|
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 |
9.8 |
1.0 |
87 |
in·lb |
|
|
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) |
20 |
2.0 |
15 |
MO, S |
||
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 |
|
||
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