Kawasaki VN1500 User Manual

VULCAN 1500 MEAN STREAK

VN1500 MEAN STREAK

Motorcycle

Service Manual

All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.

© Kawasaki Heavy Industries, Ltd., 2001

First Edition (1) : Jul. 15, 2001 (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)	W	watt(s)
h	hour(s)		ohm(s)
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 cranckcase 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 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.

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.

If you want ignition coil information, for example, 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.

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.

• 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 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

1

General Information

Table of Contents

Before Servicing................................................................................................................................................................	1-2
Model Identification...........................................................................................................................................................	1-4
General Specifications ......................................................................................................................................................	1-6
Torque and Locking Agent................................................................................................................................................	1-8
Special Tools and Sealant...............................................................................................................................................	1-13
Cable, Wire, and Hose Routing......................................................................................................................................	1-20

1-2 GENERAL INFORMATION

Before Servicing

Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also required for successful work.

Especially note the following:

(1) Dirt

Before removal and disassembly, clean the motorcycle. Any dirt entering the engine or other parts will work as an abrasive and shorten the life of the motorcycle. For the same reason, before installing a new part, clean off any dust or metal filings.

(2) Battery Leads

Disconnect the ground (− ) lead from the battery before performing any disassembly operations on the motorcycle. This prevents the engine from accidentally turning over while work is being carried out, sparks from being generated while disconnecting the wires from electrical parts, as well as damage to the electrical parts themselves. For reinstallation, first connect the positive lead to the positive (+) terminal of the battery.

(3) Installation, Assembly

Generally, installation or assembly is the reverse of removal or disassembly. But if this Service Manual has installation or assembly procedures, follow them. Note parts locations and cable, wire, and hose routing during removal or disassembly so they can be installed or assembled in the same way. It is preferable to mark and record the locations and routing as much as possible.

(4) 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 evenly in a cross pattern. This is to avoid distortion of the part and/or causing gas or oil leakage. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and method indicated.

(5) Torque

When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench.

(6) Force

Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removal of screws held by a locking agent) in order to avoid damaging the screw heads.

(7) Edges

Watch for sharp edges, especially during major engine disassembly and assembly. Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over.

(8) High-Flash Point Solvent

A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is Stoddard solvent (generic name). Always follow manufacturer and container directions regarding the use of any solvent.

(9) Gasket, O-Ring

Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leakage.

(10) Liquid Gasket, Non-Permanent Locking Agent

Follow manufacturer’s directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. An example of a nonpermanent locking agent commonly available in North America is Loctite Lock’n Seal (Blue).

(11) Press

A part installed using a press or driver, such as a wheel bearing, should first be coated with oil on its outer or inner circumference so that it will go into place smoothly.

(12) Ball Bearing and Needle Bearing

Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any ball or needle bearings that were removed with new ones, as removal generally damages bearings. Install bearings with the marked side facing out applying pressure evenly with a suitable driver. Only press on the race that forms the press fit with the base component to avoid damaging the bearings. This prevents severe stress on the balls or needles and races, and prevent races and balls or needles from being dented. Press a ball bearing until it stops at the stopper in the hole or on the shaft.

(13) Oil Seal and Grease Seal

Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. When pressing in a seal which has manufacturer’s marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole. Before a shaft passes through a seal, apply a little high temperature grease on the lips to reduce rubber to metal friction.

GENERAL INFORMATION 1-3

Before Servicing

(14) Circlip, Retaining Ring, and Cotter Pin

Replace any circlips and retaining rings, and cotter pins that were removed with new ones, as removal weakens and deforms them. When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more.

(15) Lubrication

Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles.

Don’t use just any oil or grease. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended. This manual makes reference to molybdenum disulfide grease (MoS2) and molybdenum disulfide oil in the assembly of certain engine and chassis parts. The molybdenum disulfide oil is a mixture of engine oil and molybdenum disulfide grease with a weight ratio (10 : 1), which can be made in your work shop. Always check manufacturer recommendations before using such special lubricants.

(16) Electrical Wires

All the electrical wires are either single-color or two-color and, with only a few exceptions, must be connected to wires of the same color. On any of the two-color wires there is a greater amount of one color and a lesser amount of a second color, so a two-color wire is identified by first the primary color and then the secondary color. For example, a yellow wire with thin red stripes is referred to as a "yellow/red" wire; it would be a "red/yellow" wire if the colors were reversed to make red the main color.

(17)	Replacement Parts
	When there is a replacement instruction, replace these parts with new ones every time they are removed. These
	replacement parts will be damaged or lose their original function once removed.
(18)	Inspection
	When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If
	there is any doubt as to the condition of them, replace them with new ones.
	Abrasion	Crack	Hardening	Warp
	Bent	Dent	Scratch	Wear
	Color change	Deterioration	Seizure

(19) Specifications

Specification terms are defined as follows:

"Standards" show dimensions or performances which brand-new parts or systems have.

"Service Limits" indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts.

1-4 GENERAL INFORMATION

Model Identification

VN1500-P1 (US, and Canada) Left Side View:

VN1500-P1 (US, and Canada) Right Side View:

GENERAL INFORMATION 1-5

Model Identification

VN1500-P1 (Europe) Left Side View:

VN1500-P1 (Europe) Right Side View:

1-6 GENERAL INFORMATION

General Specifications

Items		VN1500-P1
Dimensions:
Overall length		2410 mm (94.9 in.)
Overall width		850 mm (33.5 in.)
Overall height		1100 mm (43.3 in.)
Wheelbase		1705 mm (67.1 in.)
Road clearance		125 mm (4.92 in.)
Seat height		700 mm (27.6 in.)
Dry mass		289 kg (637 lb)
Curb mass:	Front	144 kg (318 lb)
	Rear	172 kg (379 lb)
Fuel tank capacity		17.0 L (4.49 US gal)
Fuel		Unleaded and high-octane gasoline (see VN1500-P1 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 2 90 mm (4.02 2 3.54 in.)
Displacement		1470 mL (89.70 cu in.)
Compression ratio		9.0 : 1
Maximum horsepower		53 kW (72 PS) @5500 r/min (rpm),
		(AU) 47 kW (64 PS) @ 5300 r/min (rpm), (CA) (CN) (US) –
Maximum torque		114 N1m (11.6 kg1m, 84.1 ft1lb) @3000 r/min (rpm),
		(AU) 108 N1m (11.0 kg1m, 79.7 ft1lb) @3000 r/min (rpm), (CA) (CN) (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 @4500 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	28 BTDC
	Close	72 ABDC
	Duration	280
Exhaust	Open	66 BBDC
	Close	42 ATDC
	Duration	288
Lubrication system		Forced lubrication (wet sump)
Engine oil:	Type	API : SE, SF or SG class
		API SH or SJ class with JASO MA
	Viscosity	SAE10W-40
	Capacity	3.5 L (3.7US qt, when engine is completely disassembled and dry)
Drive Train:
Primary reduction system:
Type		Gear
Reduction ratio		1.517 (85/56)
Clutch type		Wet multi disc

			GENERAL INFORMATION 1-7
General Specifications
Items			VN1500-P1
Transmission:
Type		5-speed, constant mesh, return shift
Gear ratios:		(CA, CN, 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 CA, CN, 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 2 33/9)
Overall drive ratio		(CA, CN, US) 3.445 @ Top gear
		(other than CA, CN, 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
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
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 2 14 V @6 000 r/min (rpm)

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

AU: Australian Model

CA: California Model

CN: Canadian Model

US: United States of America Model

1-8 GENERAL INFORMATION

Torque and Locking Agent

	The following tables list the tightening torque for the			The table		below, relating tightening torque to thread
	major fasteners requiring use of a non-permanent locking		diameter, lists the basic torque for the bolts and nuts. Use
	agent or liquid gasket.		this table for only the bolts and nuts which do not require
			a specific torque value. All of the values are for use with
	Letters used in the “Remarks” column mean:		dry solvent-cleaned threads.
	G: Apply grease to the threads.		Basic Torque for General Fasteners
	EO: Apply engine oil to the threads and the seating
	surface.			Threads						Torque
	L: Apply a non-permanent locking agent to the		dia. (mm)			N m				kg m				ft lb
	threads.
			5			3.4		4.9		0.35	0.50			30	43 in lb
	Lh: Left-hand threads.
			6			5.9		7.8		0.60	0.80			52	69 in lb
	MO: Apply molybdenum disulfide oil to the threads and
			8			14 19				1.4 1.9				10.0	13.5
	the seating surface. The molybdenum disulfide oil
			10			25		34		2.6	3.5			19.0 25
	is a mixture of engine oil and molybdenum disulfide
	grease with a weight ratio (10 : 1).		12			44		61		4.5	6.2			33	45
	S: Tighten the fasteners following the specified se-		14			73		98		7.4	10.0			54	72
	quence.		16			115		155		11.5	16.0			83	115
	SS: Apply silicone sealant.
			18			165		225		17.0	23.0			125	165
	St: Stake the fasteners to prevent loosening.
			20			225		325		23	33			165	240
	R: Replacement parts
	Fastener			Torque										Remarks
		N m		kg m					ft lb
	Fuel System:
	Vacuum Sensor Nut	9.8		1.0				87 in lb
	Atmospheric Pressure Sensor Nut	9.8		1.0				87 in lb
	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 Cable Holder Screw	3.4		0.35				30 in lb						L
	Throttle Body Flange Bolts	4.9		0.50				43 in lb
	Throttle Assy Holder Bolts	11		1.1				95 in lb						Right Side
	Inlet Manifold Bolts	12		1.2				104 in lb					on Cyl. Head
	Spark Plug Lead Holder Bolts	11		1.1				95 in lb						Right Side
	ISC Pipe Holder Bolts	9.8		1.0				87 in lb
	Air Cleaner Duct Holder Bolts	11		1.1				95 in lb						Left Side
	Right and Left Air Cleaner Base Bolts	11		1.1				95 in lb
	Right and Left Air Cleaner Base Screws	2.2		0.22				19 in lb					L, Lower Duct
	Left Air Cleaner Duct Tapping Screws	2.2		0.22				19 in lb
	Left Air Cleaner Cover Allen Bolt 8	16		1.6					12
	Right Air Cleaner Cover Allen Bolt 8	16		1.6					12
	Right Air Cleaner Allen Bolts	11		1.1				95 in lb					Throttle Body
	Choke Cable Plate Screw	2.9		0.30				26 in lb				L, Throttle Body
	Inlet Air Temperature Sensor Nut (DFI)	7.8		0.80				69 in lb
	Water Temperature Sensor (DFI)	18		1.8					13					SS
	Fuel Pump Bolts	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
	Radiator Fan Switch	18		1.8					13
	Radiator Fan Bolts	8.3		0.85				74 in lb
	Water Temperature Switch	7.4		0.75				65 in lb						SS
	Water Pump Impeller Bolt	8.8		0.90				78 in lb						Lh
	Water Pump Cover Bolts	11		1.1				95 in lb
	Water Pump Air Bleeder Bolt	11		1.1				95 in lb
	Water Pump Drain Bolt	11		1.1				95 in lb
	Water Pipe Bolts	9.8		1.0				87 in lb
	Radiator Drain Bolt	7.4		0.75				65 in lb
	Engine Top End:
	Spark Plugs	18		1.8					13

GENERAL INFORMATION 1-9

Torque and Locking Agent

Fastener			Torque			Remarks
		N m	kg m	ft lb
Spark Plug Retainer		12	1.2	104 in lb
Air Suction Valve Cover Bolts		7.4	0.75	65 in lb
Chain Tensioner Mounting Bolts		11	1.1	95 in lb		S
Chain Tensioner Cap		20	2.0	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	95 in lb		L
Cylinder Nuts		25	2.5	18		S
Inlet Manifold Bolts		12	1.2	104 in lb		on Cyl. Head
Exhaust Pipe Cover Clamp Bolts		6.9	0.70	61 in lb
Chamber Bolts		29	3.0	22
Muffler Stay Mounting Bolts, 8		27	2.8	20		Lower Muffler
Upper Muffler Bracket Bolt and Nut		29	3.0	22
Clutch:
Clutch Lever Pivot Bolt		1.0	0.10	8.7 in lb
Clutch Lever Pivot Bolt Locknut		5.9	0.60	52 in lb
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
Starter Lockout Switch Screws		1.2	0.12	10 in lb
Push Rod Guide Bolts		9.8	1.0	87 in lb		L
Clutch Cover Bolts		11	1.1	95 in lb
Clutch Cover Damper Bolts (outside)		9.8	1.0	87 in lb		L
Clutch Cover Damper Bolts (inside)		9.8	1.0	87 in lb		EO (tip)
Clutch Cover Damper Screws		4.9	0.50	43 in lb		L
Clutch Hub Nut		147	15.0	108		MO
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 Bolt		25	2.5	18		SS
Oil Pressure Relief Valve		15	1.5	11		L
Oil Pressure Switch Terminal Screw		1.5	0.15	13 in lb
Oil Pressure Switch		15	1.5	11		SS
Oil Pump Mounting Bolts		11	1.1	95 in lb
Oil Hose Banjo Bolts		9.8	1.0	87 in lb
Oil Hose Flange Bolt (outside)		9.8	1.0	87 in lb
Oil Pipe Holder Bolts (inside)		11	1.1	95 in lb		L
Oil Pipe Clamp Bolts (inside)		11	1.1	95 in lb		L
Right & Left Crankcase Oil Nozzles		2.9	0.30	26 in lb	2 3
Right Crankcase Oil Nozzle		2.9	0.30	26 in1lb		2 1, Lh
Oil Baffle Bolt		11	1.1	95 in1lb		L
Engine Removal/Installation:
Downtube Bolts and Nuts		44	4.5	32

1-10 GENERAL INFORMATION

Torque and Locking Agent

Fastener			Torque			Remarks
		N m	kg m	ft lb
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	95 in lb		S
Jumper Cable Ground Bracket Bolt		9.8	1.0	87 in lb		Left Crankcase
Crankcase Bearing Retainer Bolts		11	1.1	95 in lb		L
Camshaft Chain Guide Bolts		11	1.1	95 in lb		L
Right, Left Crankcase Oil Nozzles		2.9	0.30	26 in lb	2 3
Right Crankcase Oil Nozzles		2.9	0.30	26 in1lb		2 1, Lh
Oil Baffle Bolt		11	1.1	95 in1lb		L
Connecting Rod Big End Nuts		59	6.0	43		MO
Oil Pressure Relief Valve		15	1.5	11		L
Oil Filter Bolt		25	2.5	18		SS
Oil Hose Banjo Bolts		9.8	1.0	87 in1lb
Primary Gear Bolt		147	15.0	108		MO
Water Pump Chain Guide Spring Hook Bolt		2.9	0.30	26 in1lb
Water Pump Chain Guide Bolt		8.3	0.85	73 in1lb
Idle Shaft Holder Bolts		7.8	0.80	69 in1lb
Oil Pressure Switch Terminal Screw		1.5	0.15	13 in1lb
Oil Pressure Switch		15	1.5	11		SS
Oil Pipe Clamp Bolts (inside)		11	1.1	95 in1lb		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	95 in1lb
Shift Shaft Return Spring Pin (Bolt)		39	4.0	29		L
Shift Pedal Clamp Bolt		17	1.7	12		mark 10
Rear Shift Lever Clamp Bolt		12	1.2	104 in1lb
Shift Rod Locknuts		11	1.1	95 in1lb		(Rear: Lh)
Shift Drum Bearing Holder Bolts		11	1.1	95 in1lb		L
Shift Drum Cam Screw		–	–	–		L
Damper Cam Nut (Front Gear)		226	23	166		MO (threads)
Push Rod Guide Bolts		9.8	1.0	87 in1lb		L
Wheels/Tires:
Front Axle Clamp Bolts		25	2.5	18		S
Front Axle		110	11	79.6		S
Rear Axle Nut		110	11	79.6
Tire Air Valve Stem Nuts		1.5	0.15	13 in1lb
Tire Air Valve Caps		0.15	0.015	1.3 in1lb
Air Valve Cores		0.3	0.03	2.6 in1lb
Final Drive:
Oil Pipe Banjo Bolts (Front Gear)		12	1.2	104 in1lb
Oil Nozzle (Front Gear)		2.9	0.30	26 in1lb
Oil Nozzle (Front Gear)		18	1.8	13
Neutral Switch		15	1.5	11
Front Gear Case Bolts:	6 mm	12	1.2	104 in1lb		mark 9
	8 mm	29	3.0	22
Speed Sensor Bolt		9.8	1.0	87 in1lb		L
Damper Cam Nut (Front Gear)		226	23	166		MO (threads)
Drive Gear Nut (Front Gear)		265	27	195		MO, St
Driven Gear Assy Mounting Bolts		25	2.5	18
Driven Gear Bolt (Front Gear)		137	14	101		MO, St
Bearing Retainer Bolts (Front Gear)		8.8	0.9	78 in1lb		L
Final Gear Case Drain Plug		8.8	0.9	78 in1lb

GENERAL INFORMATION 1-11

Torque and Locking Agent

Fastener			Torque		Remarks
		N m	kg m	ft lb
Final Gear Case Mounting Nuts		34	3.5	25
Final Gear Case Studs		–	–	–	L
Final Gear Case Cover Bolts:	8 mm	23	2.3	17	L
	10 mm	34	3.5	25	L
Pinion Gear Nut (Final Gear)		127	13	93	St, MO
Bearing Retainer Bolt		6.9	0.7	61 in lb	L
Brakes:
Caliper Bleed Valves		7.8	0.8	69 in lb
Brake Hose Banjo Bolts		25	2.5	18
Brake Lever Pivot Bolt		1.0	0.10	8.7 in lb
Brake Lever Pivot Bolt Locknut		5.9	0.60	52 in lb
Front Brake Reservoir Cap Screws		1.5	0.15	13 in lb
Front Brake Light Switch Screw		1.2	0.12	10 in lb
Front Master Cylinder Clamp Bolts		8.8	0.9	78 in lb	G, S
Front Brake Pad Spring Bolts		2.9	0.3	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		20	2.0	15
Lower Front Fork Clamp Bolts		20	2.0	15
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	73
Front Fork Bottom Allen Bolt (right)		20	2.0	15	L
Front Axle Clamp Bolts		25	2.5	18	S
Protector Screws		5.9	0.6	52 in lb
Rear Shock Absorber Nuts		34	3.5	25
Shock Absorber Air Valves		5.4	0.55	47 in lb
Swingarm Pivot Shaft		110	11	79.6	G
Steering:
Steering Stem Head Nut		54	5.5	40
Steering Stem Nut		4.9	0.5	43 in lb
Handlebar Nuts		34	3.5	25
Handlebar End Caps		–	–	–	Lh, L
Handlebar Switch Housing Screws		3.4	0.35	30 in lb
Upper Front Fork Clamp Bolts		20	2.0	15
Lower Front Fork Clamp Bolts		20	2.0	15
Turn Signal Light Mounting Nuts		5.9	0.6	52 in lb
Frame:
Downtube Bolts and Nuts		44	4.5	32
Front Footpeg Bracket Bolts		25	2.5	18
Rear Footpeg Bracket Bolts		25	2.5	18
Sidestand Nut		44	4.5	32
Electrical System:
Spark Plugs		18	1.8	13
Pickup Coil Screws		2.9	0.30	26 in lb
Stator Lead Holder Screw		9.8	1.0	87 in lb	L
Pickup Coil Lead Holder Bolt		9.8	1.0	87 in lb	L
Alternator Outer Cover Bolts		6.9	0.7	61 in lb
Alternator Outer Cover Joint Bolts		6.9	0.7	61 in lb
Alternator Outer Cover Damper Bolts		6.9	0.7	61 in lb	L

1-12 GENERAL INFORMATION

Torque and Locking Agent

Fastener			Torque		Remarks
		N m	kg m	ft lb
Alternator Outer Cover Assembly Bolts		6.9	0.7	61 in lb
Alternator Cover Bolts		11	1.1	95 in lb
Alternator Inner Cover Bolts		11	1.1	95 in lb
Alternator Rotor Bolt		78	8.0	57	MO
Alternator Stator Bolts		13	1.3	113 in lb	L
Regulator/Rectifier Bolts		6.5	0.66	58 in lb
Timing Inspection Cap		1.5	0.15	13 in lb
Rotor Bolt Cap		1.5	0.15	13 in lb
Starter Motor Terminal Locknut		11	1.1	95 in lb
Starter Motor Terminal Nut		4.9	0.50	43 in lb
Starter Motor Assy Bolts		4.9	0.50	43 in lb
Starter Motor Mounting Bolts		11	1.1	95 in lb
Headlight Body Mounting Nuts		7.8	0.8	62 in lb
Headlight Rim Screws		1.4	0.14	12 in lb	L
Headlight Mounting Screws		2.9	0.3	26 in lb
Headlight Body Bracket Screws		1.2	0.12	10 in lb
Handlebar Switch Housing Screws		3.4	0.14	12 in lb
Starter Lockout Switch Screw		1.2	0.12	10 in lb
Front Brake Light Switch Screw		1.2	0.12	10 in lb
Sidestand Switch Bolt		8.8	0.9	78 in lb	L
Radiator Fan Switch		18	1.8	13
Water Temperature Switch		7.8	0.8	69 in lb	SS
Oil Pressure Switch Terminal Screw		1.5	0.15	13 in lb
Oil Pressure Switch		15	1.5	11	SS
Neutral Switch		15	1.5	11
Turn Signal Light Mounting Nuts	Front	5.9	0.60	52 in lb
	Rear	6.9	0.7	61 in lb
License Plate Lens Screws		1.0	0.1	8.7 in lb
License Plate Light Mounting Screw		1.2	0.12	10 in lb

GENERAL INFORMATION 1-13

Special Tools and Sealant

Oil Pressure Gauge, 5 kg/cm2: 57001-125		Valve Guide Arbor, 7: 57001-163

Inside Circlip Pliers: 57001-143		Compression Gauge: 57001-221

Outside Circlip Pliers: 57001-144		Valve Spring Compressor Assembly: 57001-241

Bearing Puller: 57001-158

Valve Spring Compressor Adapter, 28.2: 57001-243

Valve Guide Reamer, 7: 57001-162		Bearing Puller Adapter: 57001-317

1-14 GENERAL INFORMATION

Special Tools and Sealant

Bearing Driver: 57001-382		Damper Cam Holder: 57001-1025

Piston Pin Puller Assembly: 57001-910		Driven Gear Holder: 57001-1027

Gear Holder: 57001-1015		Oil Pressure Gauge Adapter, PT 1/8: 57001-1033

Compression Gauge Adapter, M12 2 1.25: 57001-1018		Oil Seal & Bearing Remover: 57001-1058

Spark Plug Wrench, Hex 18: 57001-1024		Head Pipe Outer Race Press Shaft: 57001-1075

GENERAL INFORMATION 1-15

Special Tools and Sealant

Head Pipe Outer Race Driver: 57001-1077		Valve Seat Cutter, 45 - 35: 57001-1116

Piston Ring Compressor Grip: 57001-1095

Valve Seat Cutter, 32 - 35: 57001-1121

Steering Stem Nut Wrench: 57001-1100

Valve Seat Cutter, 32 – 38.5 : 57001–1122

Head Pipe Outer Race Remover: 57001-1107

Valve Seat Cutter Holder, 7: 57001-1126

Valve Seat Cutter, 45 - 32: 57001-1115		Valve Seat Cutter Holder Bar: 57001-1128

1-16 GENERAL INFORMATION

Special Tools and Sealant

Bearing Driver Set: 57001-1129		Jack: 57001-1238

Pinion Gear Holder: 57001-1165		Timing Light: 57001-1241

Hexagon Wrench, Hex 27: 57001-1210

Valve Seat Cutter, 55 - 35: 57001-1247

Piston Pin Puller Adapter: 57001-1211		Oil Filter Wrench: 57001-1249

Fork Outer Tube Weight: 57001-1218		Final Gear Case Holder: 57001-1250

GENERAL INFORMATION 1-17

Special Tools and Sealant

Bearing Remover Shaft, 9: 57001-1265		Flywheel Holder : 57001–1313

Bearing Remover Head, 10 2 12: 57001-1266

Steering Stem Bearing Driver: 57001-1344

Fork Piston Rod Puller, M12 x 1.25 : 57001–1289		Steering Stem Bearing Driver Adapter: 57001-1345

Fork Oil Level Gauge: 57001-1290

Piston Ring Compressor Belt, 95 108: 57001-1358

Bearing Remover Head, 20 2 22: 57001-1293		Bearing Remover Shaft, 13: 57001-1377

1-18 GENERAL INFORMATION

Special Tools and Sealant

Hand Tester: 57001-1394		Driver-Filler Cap: 57001–1454

Attachment Jack: 57001-1398

Needle Adapter Set: 57001–1457

Drive Shaft Holder: 57001-1407

Valve Seat Cutter, 45 - 40: 57001-1496

Flywheel Holder: 57001-1410

Valve Seat Cutter, 55 - 38.5: 57001-1497

Fuel Pressure Gauge Adapter: 57001-1417		Fork Cylinder Holder: 57001-1502

GENERAL INFORMATION 1-19

Special Tools and Sealant

Kawasaki Bond (Silicone Sealant): 56019–120		Kawasaki Bond (Liquid Gasket-Black): 92104-1003

1-20 GENERAL INFORMATION

Cable, Wire, and Hose Routing

F: Front

1.Indicator Lights

2.Fuel Tank

3.Fuel Pump Base

4.Two Clamps (fuel pump leads)

5.Plastic Caps

6.Snap-on Plastic Clamps

7.Fuel Tank Breather Hose

8.Fuel Pump Harness

9.Run the harness [8] under the hose [7].

10.Indicator Light Connector : Insert the main harness side connector into the

connector hole of the bracket

[13]and join the connector.

11.Main Harness

12.Ignition Switch Connector : Join the connector and fit them into the hole of the bracket

13.Indicator Unit Bracket

14.Ignition Switch

15.Press each end of clamps by hands against the bottom of the tank. And then, make sure that the ends touch the bottom of the tank.

GENERAL INFORMATION 1-21

Cable, Wire, and Hose Routing

F: Front

1.Front Right Spark Plug Cap

2.Rear Right Spark Plug Cap

3.2nd Lead from the left ignition coil lower side

4.2nd Lead from the right ignition coil lower side

5.Ignition Coil for Rear Spark Plugs

6.Ignition Coil for Front Spark Plugs

7.2nd Lead from the left ignition coil upper side

8.2nd Lead from the right ignition coil upper side

9.Front Left Spark Plug Cap

10.Rear Left Spark Plug Cap

11.Clutch Hose

12.Plastic Snap-on Clamps

13.Strap

14.BK/G Primary Lead

15.R/G Primary Lead

16.BK Primary Lead

17.R/G Primary Lead

18.Align the white mark with the back of the clamp [12].

19.Canister Purge Hose (green, CA)

1-22 GENERAL INFORMATION

Cable, Wire, and Hose Routing

!:	Inlet Air Flow	10.	Right Air Cleaner Base
1.	Rear View	11.	Right Rubber Gasket
2.	Air Inlet	12.	Right Air Cleaner Cover
3.	Left Rubber Gasket	13.	Locate the glued joint of the gasket within the angle.
4.	Left Air Cleaner Cover	14.	Elbow Joint: connected to crankcase breather hose
5.	Air Cleaner Element	15.	Top
6.	Left Air Cleaner Base	16.	White Mark on Hose [8] (front side): Position here.
7.	Lower Air Cleaner Duct	17.	Plug
8.	Vacuum Switch Valve Hose	18.	Run this drain hose between cylinders.
9.	To Vacuum Switch Valve

GENERAL INFORMATION 1-23

Cable, Wire, and Hose Routing

!:	Bypass Air Flow	9.	Vacuum Sensor and Pressure	18.	ISC Valve #2 (rear cylinder)
F:	Front		Regulator	19.	ISC Valve Inlets
1.	Rear View	10.	Strap (holds [4], [6], and [11])	20.	Blue Mark on Top
2.	Throttle Assy	11.	Vacuum Switch Valve Hose	21.	ISC Valve #1 (front cylinder)
3.	Air Cleaner Base Seal	12.	Right Air Cleaner Base Bolts	22.	Inlet Air Temperature Sensor
4.	Spark Plug Lead Holder	13.	Right Air Cleaner Base	23.	Section B-B
5.	Right Side View	14.	O-rings	24.	Crankcase Breather Hose
6.	Harness of Inlet Air Tempera-	15.	ISC Valve Hose #2 (red)	25.	Clamp these leads [6] with a
	ture Sensor & ISC Valves	16.	ISC Valve Hose #1 (blue)		slack as little as possible.
7.	T-Joint	17.	Lower Air Cleaner Duct	26.	Back of Right Air Cleaner Base

8.Vacuum Hose from Throttle Body

1-24 GENERAL INFORMATION

Cable, Wire, and Hose Routing

- - !:	Vacuum Pulsation	5.	Fuel Injector #1	13.	Low Pressure (Return) Fuel Hose
!:	Fuel Flow	6.	Fuel Injector #2	14.	Vacuum Hoses from Throttle Body
#1:	For Front Cylinder	7.	Pressure Regulator	15.	Front
#2:	For Rear Cylinder	8.	Throttle Body	16.	Vacuum Hose (white, CA)
1.	Fuel Tank (left view)	9.	Inlet Manifold	17.	T-Joint
2.	Return Fuel Check Valve	10.	Throttle Assy (top view)	18.	Vacuum Switch Valve
3.	High Pressure Fuel Hoses	11.	Throttle Pulley	19.	Vacuum Sensor
4.	Delivery Joint	12.	Throttle Sensor	20.	Throttle Vacuum Hose