VULCAN 1600
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VULCAN 1600 MEAN STREAK
VN1600 MEAN STREAK
Motorcycle
Service Manual
Quick Reference Guide
General Information 1 j
Periodic Maintenance 2 j
Fuel System (DFI) 3 j
Cooling System 4 j
Engine Top End 5 j
Clutch 6 j
Engine Lubrication System 7 j
Engine Removal/Installation 8 j
This quick reference guide w ill assist
you in locating a desired topic or procedure.
Bend the pages back to match the
•
black tab of the desired chapter number with the black tab on the edge at
each table of contents page.
Refer to the sectional table of con-
•
tents for the exact pages to locate
the specific topic required.
Crankshaft/Transmission 9 j
Wheels/Tires 10 j
Final Drive 11 j
Brakes 12 j
Suspension 13 j
Steering 14 j
Frame 15 j
Electrical System 16 j
Appendix 17 j
VULCAN 1600 MEAN STREAK
VN1600 MEAN STREAK
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Quality Assurance Department/Consumer Products & Machinery
Company/Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your Motorcycle dealer f or the latest
information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.
© 2003 Kawasaki Heavy Industries, Ltd. First Edition (1) : Jul. 1, 2003 (M)
LIST OF ABBREVIATIONS
A
ABDC after bottom dead center m meter(s)
AC
ATDC after top dead center N newton(s)
BBDC before bottom dead center
BDC bottom dead center PS horsepower
BTDC before top dead center
°C degree(s) Celsius r revolution
DC
F farad(s) TDC top dead center
°F degree(s) Fahrenheit
ft foot, feet V volt(s)
g
h hour(s) Ω ohm(s)
kg
kgf (force)
L
ampere(s)
alternating current min
direct current
gram(s) (mass)
(mass)
liter(s)
lb
Pa
psi
r/min, rpm revolution(s) per minute
TIR total indicator reading
W
pound(s)
minute(s)
pascal(s)
pound(s) per square inch
watt(s)
Read OWNER’S MANUAL before operating.
EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of
the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance
with applicable regulations of the California Air Resources Board on vehicles sold in California
only.
1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors
are routed through an oil separator to the inlet side of the engine. While the engine is operating,
the vapors are drawn into combustion chamber, where they are burned along with the fuel and air
supplied by the fuel injection system.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust
of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully
designed and constructed to ensure an efficient engine with low exhaust pollutant levels.
The exhaust system of this model motorcycle manufactured primarily for sale in California in-
cludes a catalytic converter system.
3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. In-
stead, fuel vapors are routed into the running engine to be burned, or stored in a canister when
the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is
commonly referred to as the Act’s "tampering provisions."
"Sec. 203(a) The following acts and the causing thereof are prohibited...
(3)(A) for any person to remove or render inoperative any device or element of design installed
on or in a motor vehicle or 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 vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a
motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser..."
NOTE
The phrase "remove or render inoperative any device or element of design" has been generally
○
interpreted as follows:
1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance.
2. Tampering could include:
a.Maladjustment of vehicle components such that the emission standards are ex-
ceeded.
b.Use of replacement parts or accessories which adversely affect the performance
or durability of the 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 R ECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF F EDERAL LAW,
THEVIOLATIONOFWHICHISPUNISHABLEBYCIVILPENALTIESNOTEXCEEDING
$10,000 PER VIOLATION.
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering
inoperative by any person other than for purposes of maintenance, repair, or replacement, of any
device or element of design i ncorporated 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 M aintenance Chart in the
•
Service Manual.
Be alert for problems and non-scheduled
•
maintenance.
Use proper tools and genuine Kawasaki Mo-
•
torcycle parts. Special tools, gauges, and
testers that are necessary when servicing
Kawasaki motorcycles are introduced by the
Special Tool Catalog or Manual. Genuine
parts provided as spare parts are listed in the
Parts Catalog.
Follow the procedures in this manual care-
•
fully. Don’t take shortcuts.
Remember to keep complete records of main-
•
tenance and repair with dates and any new
parts installed.
How to Use This Manual
In this manual, the product is divided into
its major systems and these systems make up
the manual’s chapters. The Quick Reference
Guide shows you all of the product’s system
and assists in locating their chapters. Each
chapter in turn has its own comprehensive Table of Contents.
For example, if you want ignition coil information, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use t he
Table of Contents on the first page of the chapter to find the Ignition Coil section.
Whenever you see these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.
WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in per-
sonal injury or loss of life.
CAUTION
This caution symbol identifies special
instructions or procedures which, if not
strictly observed, could result in dam-
age 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 con-
venient operation.
Indicates a procedural step or work to be
•
done.
Indicates a procedural sub-step or how to do
○
the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action to
take based on the results of the test or inspec-
tion in the procedural step or sub-step it fol-
lows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require specified tightening torque, oil, grease or a locking
agent during assembly.
GENERAL INFORMATION 1-1
General Information
Table of Contents
Before Servicing ..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-7
General Specifications............................................................................................................ 1-9
Unit Conversion Table ............................................................................................................ 1-12
1
1-2 G ENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following:
Battery Ground
Before completing any service on the motorcycle, disconnect the battery wires from the battery to prevent the engine
from accidentally turning over. Disconnect the ground wire
(-) first and then the positive (+). When completed with the
service, first connect the positive (+) wire to the positive (+)
terminal of the battery then the negative (-) wire to the negative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.
Solvent
Use a high flush point solvent when cleaning parts. High
flush point solvent should be used according to directions
of the solvent manufacturer.
Cleaning vehicle before disassembly
Clean the vehicle thoroughly before disassembly. Dirt or
other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease
performance of the vehicle.
Before Servicing
Arrangement and Cleaning of Removed Parts
Disassembled parts are easy to confuse. Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.
Storage of Removed Parts
After all the parts including subassembly parts have been
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.
GENERAL 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 G ENERAL INFORMATION
Before Servicing
Tightening Sequence
Bolts, nuts, or screws must be tightened according to the
specified sequence to prevent case warpage or deformation
which can lead to malfunction. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench. Often, the
tightening sequence is followed twice-initial tightening and
final tightening with torque wrench.
Force
Use common sense during disassembly and assembly,
excessive force c an 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. Rem ove old gaskets and clean the sealing
surfaces thoroughly so that no gasket material or other
material remains. Install new gaskets and replace used
O-rings when re-assembling
Liquid Gasket, Locking Agent
For applications that require Liquid G asket or a Locking
Agent, clean the surfaces so that no oil residue remains before applying liquid gasket or locking agent. Do not apply
them excessively. Excessive application can clog oil passages and cause serious damage.
Before Servicing
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use
smooth movements when installing.
Ball Bearing and Needle Bearing
Do not remove pressed ball or needle unless 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 w henever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.
Circlips, Cotter Pins
Replace circlips or cotter pins that were removed with new
ones. Install the circlip with its sharp edge facing outward
and its chamfered side facing inward to prevent the clip from
being pushed out of its groove when loaded. Take care
not to open the clip excessively when installing to prevent
deformation.
Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply
the specific oil or grease as specified.
1-6 G ENERAL INFORMATION
Before Servicing
Direction o f Engine Rotation
When rotating the crankshaft by hand, the free play
amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed
from output side).
Electrical Wires
A two-color wire is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
wires must be connected to those of the same color.
Model Identification
VN1600-B1 (US, and Canada) Left Side View:
GENERAL INFORMATION 1-7
VN1600-B1 (US, and Canada) Right Side View:
1-8 G ENERAL INFORMATION
Model Identification
VN1600-B1 (Europe) Left Side View:
VN1600-B1 (Europe) Right Side View:
GENERAL INFORMATION 1-9
General Specifications
Items VN1600–B1
Dimensions:
Overall length 2 410 mm (94.9 in.)
Overall width 850 mm (33.5 in.)
Overall height 1 100 mm (43.3 in.)
Wheelbase
Road clearance 125 mm (4.92 in.)
Seat height 700 mm (27.6 in.)
Dry mass 290 kg (639 lb)
Curb mass:
Fuel tank capacity
Fuel Unleaded and high-octane gasoline
Performance:
Minimum turning radius
Engine:
Type
Cooling system Liquid-cooled
Bore and stroke
Displacement 1 552 mL (94.70 cu in.)
Compression ratio
Maximum horsepower 54 kW (74 PS) @5 300 r/min (rpm),
Maximum torque 125 N·m (12.7 kgf·m, 92.2 ft·lb) @2 800 r/min (rpm),
Carburetion system DFI (Digital Fuel Injection) System
Starting system
Ignition system Battery and coil (transistorized)
Timing advance
Ignition timing From 5° BTDC @950 r/min (rpm) ∼
Spark plugs NGK DPR6EA-9 or ND X20EPR-U9
Cylinder numbering method
Firing order 1-2
Valve timing:
Inlet Open 22° BTDC
Exhaust
Lubrication system Forced lubrication (wet sump)
Engine oil: Type
Front
Rear 172 kg (379 lb)
Close 66° ABDC
Duration 268°
Open
Close 26° ATDC
Duration
Viscosity
1 705 mm (67.1 in.)
145 kg (320 lb)
17.0 L (4.49 US gal)
(see Owner’s Manual)
3.1 m (10.2 ft)
4-stroke, SOHC, V2-cylinder
102 × 95 mm (4.02 × 3.74 in.)
9.0 : 1
(CAL)(CA)(US)–
(CAL)(CA)(US)–
Electric starter
Electronically advanced (digital)
25° BTDC @4 500 r/min (rpm)
Front to Rear, 1-2
66° BBDC
272°
API SE, SF or SG class
API SH or SJ class with JASO M A
SAE10W-40
1-10 GENERAL INFORMATION
General S pecifications
Items VN1600–B1
Capacity 3.5 L (3.7US qt, when engine is completely
disassembled and dry)
Drive Train:
Primary reduction system:
Type Gear
Reduction ratio 1.517 (85/56)
Clutch type Wet multi disc
Transmission:
Type 5-speed, constant mesh, return shift
Gear ratios: (CAL, CA, US)
1st 2.500 (40/16)
2nd 1.750 (35/20)
3rd 1.333 (32/24)
4th 1.074 (29/27)
5th 0.867 (26/30)
(other than CAL, CA, US)
1st 2.500 (40/16)
2nd 1.590 (35/22)
3rd 1.192 (31/26)
4th 0.965 (28/29)
5th 0.781 (25/32)
Final drive system:
Type Shaft
Reduction ratio 2.619 (15/21 × 33/9)
Overall drive ratio (CAL, CA, US) 3.445 @ Top gear
(other than CAL, CA, US) 3.105 @ Top gear
Final gear case oil:
Grade API Service Classification: GL-5 Hypoid gear oil
Viscosity SAE90 (above 5°C), SAE80 (below 5°C)
Capacity 200 mL (12.2 cu in.)
Frame:
Type Tubular, double cradle
Caster (rake angel) 32°
Trail 144 mm (5.67 in.)
Front tire: Type Tubeless
Size 130/70R17 M/C 62H
Rear tire: Type Tubeless
Size 170/60R17 M/C 72H
Front suspension: Type Telescopic fork (upside-down)
Wheel travel 150 mm (5.91 in.)
Rear suspension: Type Swingarm, air oil shock absorber
Wheel travel 87 mm (3.43 in.)
Brake Type: Front Dual disc
Rear Single disc
GENERAL INFORMATION 1-11
General Specifications
Items VN1600–B1
Electrical Equipment:
Battery Capacity 12 V 18 A h
Headlight: Type
Bulb 12 V 60/55 W (quartz-halogen)
Tail/brake light 12 V 5/21 W
Alternator: Type Three-phase AC
Rated output
Specifications subject to change without notice, and m ay not apply to every country.
CAL: California Model
CA: Canadian Model
US: United States of America Model
Semi-sealed beam
23 A × 14 V @6 000 r/min (rpm)
1-12 GENERAL INFORMATION
Unit Conversion Table
Prefixes for Units:
Prefix Symbol Power
mega M × 1 000 000
kilo k × 1 000
centi c ×0.01
milli m × 0.001
micro µ × 0.000001
Units of Mass:
kg × 2.205 = lb
g × 0.03527 = oz
Units of Volume:
L × 0.2642 = gal (US)
L × 0.2200 = gal (imp)
L × 1.057 =
L × 0.8799 = qt (imp)
L×2.113=
L × 1.816 = pint (imp)
mL × 0.03381 = oz (US)
mL × 0.02816 = oz (imp)
mL × 0.06102 = cu in.
qt (US)
pint (US)
Units of Length:
km × 0.6214 = mile
m × 3.281 = ft
mm × 0.03937 = in.
Units of Torque:
N·m × 0.1020 = kgf·m
N·m × 0.7376 = ft·lb
N·m × 8.851 = in·lb
kgf·m × 9.807 = N·m
kgf·m
kgf·m × 86.80 = in·lb
× 7.233 =
ft·lb
Units of Pressure:
kPa × 0.01020 =
kPa × 0.1450 = psi
kPa × 0.7501 = cm Hg
kgf/cm² × 98.07 = kPa
kgf/cm² × 14.22 = psi
cmHg×1.333=kPa
kgf/cm²
Units of Speed:
km/h × 0.6214 = m ph
Units of Force:
N × 0.1020 =
N × 0.2248 = lb
kg × 9.807 = N
kg × 2.205 = lb
Units of Temperature:
kgf
Units of Power:
kW ×1.360=PS
kW ×1.341=HP
PS × 0.7355 = kW
PS
× 0.9863 = HP
PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart .............. 2-2
Torque and Locking Agent ................. 2-4
Specifications .................................... 2-10
Special Tools ..................................... 2-12
Periodic Maintenance Procedures..... 2-13
Fuel System (DFI)........................... 2-13
Fuel Hose and Connection
Inspection .................................. 2-13
Throttle Control System
Inspection .................................. 2-13
Idle Speed Inspection .................. 2-14
Air Cleaner Element Cleaning...... 2-14
Evaporative Emission Control
System Inspection(CAL) ........... 2-15
Cooling System............................... 2-16
Radiator Hose and Connection
Inspection .................................. 2-16
Coolant Change ........................... 2-16
Engine Top End .............................. 2-18
Air Suction Valve Inspection ........ 2-18
Clutch.............................................. 2-19
Clutch Hose and Connection
Inspection .................................. 2-19
Clutch Fluid Level Inspection ....... 2-19
Clutch Fluid Change .................... 2-20
Clutch Master Cylinder Cup and
Dust SealReplacement ............. 2-21
Clutch Slave Cylinder Piston Seal
Replacement ............................ 2-22
Engine Lubrication System ............. 2-22
Engine Oil Change....................... 2-22
Oil Filter Replacement ................. 2-24
Wheels/Tires................................... 2-24
2
Tire Inspection ............................. 2-24
Final Drive....................................... 2-25
Oil Level Inspection...................... 2-25
Oil Change ................................... 2-26
Brakes............................................. 2-27
Brake Pad Wear Inspection ......... 2-27
Brake Hose and Connection
Inspection.................................. 2-27
Brake Fluid Level Inspection ........ 2-28
Brake Fluid Change ..................... 2-29
Brake Master Cylinder Cup and
Dust Seal Replacement . ........... 2-30
Caliper Piston/Dust Seals
Replacement............................. 2-30
Front Brake Light Switch
Inspection.................................. 2-30
Rear Brake Light Switch
Check/Adjustment..................... 2-30
Suspension..................................... 2-31
Front Fork Oil Leak Inspection..... 2-31
Rear Shock Absorber Oil Leak
Inspection ................................. 2-31
Swingarm Pivot Lubrication ......... 2-31
Steering .......................................... 2-32
Stem Bearing Lubrication............. 2-32
Steering Check ............................ 2-32
Steering Adjustment..................... 2-32
Electrical System ............................ 2-33
Spark Plug Cleaning/Inspection... 2-33
General Lubrication ........................ 2-33
Lubrication ................................... 2-33
Nut, Bolt, and Fastener Tightness .. 2-34
Tightness Inspection .................... 2-34
2-2 P ERIODIC M AINTENANCE
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in
good running condition.The initial m aintenance is vitally important and must not be neglected.
FREQUENCY Whichever
comes
first
1 6 12 18 24 30 36 See
INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) Page
Air suction valve (e) - inspect †
Air cleaner element (e) - clean†#
Throttle control system (e) - inspect †
Idle speed (e) - inspect †
Fuel hoses, connections - inspect †
Evaporative emission control system (e)
(CAL) - inspect †
Final gear case oil level - inspect †
Brake pad wear - inspect † #
Brake light switch - inspect †
Steering - inspect † year
Tire damage and wear - inspect † #
Tire air pressure - inspect year
Wheel damage - inspect year
Wheel bearing wear and damage - inspect
Front fork and rear shock absorber operation
• • • •
• • • •
• • • •
• • • • • • •
• • • •
• • •
• • • • • •
• • •
• • • • • •
• • •
• • •
• • •
• • •
• • •
* ODOMETER READING
km × 1000 (mile × 1000)
2–18
• •
2–14
2-13
2-14
2-13
2-15
2–25
2–27
2–30
2–32
2–24
2–24
–
–
–
General lubrication - perform year
Nut, bolt, and fastener tightness - inspect †
Brake/clutch hoses, connections - inspect †
Brake/clutch fluid level - inspect † month
Coolant hoses, connections - inspect † year
Steering stem bearing - lubricate 2 years
• • •
• • • •
• • • • • • •
• • • • • • •
• • • •
•
2–33
2–34
2–19,
2–27
2–19,
2–28
2–16
2–32
Periodic Maintenance Chart
PERIODIC MAINTENANCE 2-3
FREQUENCY Whichever
comes
first
1 12 24 36 48 See
CHANGE/REPLACE ITEM Every (0.6) (7.5) (15) (24) (30) Page
Spark plug (e)
Engine oil # year
Oil filter year
Coolant 3 years
Brake/clutch master cylinder cup and dust seal 4 years
Caliper piston seal and dust seal 4 years 2–30
Clutch slave cylinder position seal 4 years 2–22
Brake/clutch fluid 2 years
Final gear case oil
Fuel hose 4 years
# : Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or
frequent starting/stopping.
* : For higher odometer readings, repeat at the frequency interval established here.
† : Replace, add, adjust, clean, or torque if necessary.
• • • •
• • • •
• •
* ODOMETER READING
km × 1000 (mile × 1000)
• • •
•
•
•
2–33
2–22
2–24
2–16
2–21,
2–30
2–20,
2–29
2–25
–
Throttle control system inspection: Inspection of throttle grip play and throttle bore cleanliness.
(CAL): California
(e): Emission Related Items
2-4 P ERIODIC M AINTENANCE
Torque and Locking Agent
The following tables list the tightening torque
for the major fasteners requiring use of a non
-permanent locking agent or liquid gasket.
Letters used in the “Remarks” column mean:
G: Apply grease to the threads.
EO: Apply engine oil to the threads and the
seating surface.
L: Apply a non-permanent locking agent to
the threads.
Lh: Left-hand threads.
MO: Apply molybdenum disulfide oil to the
threads and the seating surface. The
molybdenum disulfide oil is a mixture
of engine oil and molybdenum disulfide
grease w ith a w eight ratio (10 : 1).
S: Tighten the fasteners following the speci-
fied sequence.
SS: Apply silicone sealant.
St: Stake the fasteners to prevent loosening.
R: Replacement parts
AL: Tighten the two clamp bolts alternately
two times to ensure even tightening
torque.
WL: Apply a soap and water solution or rubber
lubricant.
The table below, relating tightening torque to
thread diameter, lists the basic torque for the
bolts and nuts. Use this table for only the bolts
and nuts which do not require a specific torque
value. All of the values are f or use with dry
solvent-cleaned threads.
Basic Torque for General Fasteners
Threads Torque
dia. (mm) N·m
5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb
6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb
8 14 ∼19 1.4 ∼1.9 10.0 ∼ 13.5
10 25 ∼ 34 2.6 ∼ 3.5 19.0 ∼ 25
12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45
14 73 ∼ 98 7.4 ∼ 10.0 54 ∼ 72
16 115 ∼ 155 11 .5 ∼ 16.0 83 ∼ 115
18 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165
20 225 ∼ 325 23 ∼ 33 165 ∼ 240
kgf·m ft·lb
Fastener
N·m kgf·m ft·lb
Fuel System:
High pressure fuel hose clamp screws 1.5 0.15 13 in·lb
Pressure regulator screws 4.9 0.50 43 in·lb
Delivery joint screws 3.4 0.35 30 in·lb Throttle Body
Throttle body flange bolts 4.9 0.50 43 in·lb
Throttle body assy holder bolts 11 1.1 97 in·lb Right Side
Inlet manifold bolts 12 1.2 106 in·lb on Cyl. Head
Spark plug lead holder bolts 11 1.1 97 in·lb Right Side
ISC pipe bolts 11 1.1 97 in·lb
Air cleaner duct holder bolts 11 1.1 97 in·lb Left Side
Right and left air cleaner base bolts 11 1.1 97 in·lb
Right and left air cleaner base screws 2.2 0.22 19 in·lb L, Lower Duct
Left air cleaner cover Allen bolt 16 1.6 12
Right air cleaner cover Allen bolt 16 1.6 12
Right air cleaner Allen bolts 11 1.1 97 in·lb Throttle Body
Choke cable plate screw 2.9 0.30 26 in·lb L, Throttle Body
Inlet air temperature sensor nut (DFI) 7.8 0.80 69 in·lb
Water temperature sensor (DFI) 18 1.8 13 SS
Fuel pump bolts 6.9 0.70 61 in·lb S, L
Return fuel check valve 20 2.0 15
Cooling System:
Radiator hose clamp screws 2.5 0.25 22 in·lb
Thermostat air bleeder bolt 7.8 0.80 69 in·lb
Torque
Remarks
Torque and Locking Agent
PERIODIC MAINTENANCE 2-5
Fastener
Radiator fan switch
Radiator fan bolts
Water temperature switch 7.8 0.80 69 in·lb SS
Water pump impeller bolt 8.8 0.90 78 in·lb Lh
Water pump cover bolts 11 1.1 97 in·lb
Water pump air bleeder bolt 11 1.1 97 in·lb
Water pump drain bolt 11 1.1 97 in·lb
Water pipe bolts 11 1.1 97 in·lb
Radiator drain Bolt 2.2 0.22 19 in·lb
Engine Top End:
Spark plugs 18 1.8 13
Spark plug retainers 12 1.2 106 in·lb
Air suction valve cover bolts 7.4 0.75 65 in·lb
Chain tensioner mounting bolts 11 1.1 97 in·lb S
Chain tensioner cap 20 2.0 15 S
Chain tensioner lockbolt 4.9 0.50 43 in·lb S
Timing inspection cap 1.5 0.15 13 in·lb
Rotor bolt cap 1.5 0.15 13 in·lb
Camshaft sprocket bolts 15 1.5 11 L
Oil hose flange bolts 9.8 1.0 87 in·lb
Rocker shafts 25 2.5 18
Rocker case nuts 12 mm 78 8.0 58 MO, S
8mm 25 2.5 18 S
Rocker case bolts 6 mm 8.8 0.90 78 in·lb S
Cylinder head nuts 25 2.5 18 S
Cylinder head jacket plugs 20 2.0 15 L
Rocker case cover bolts 8.8 0.90 78 in·lb S
Camshaft chain guide bolts 11 1.1 97 in·lb L
Cylinder nuts 25 2.5 18 S
Inlet manifold bolts 12 1.2 106 in·lb on Cyl. Head
Exhaust pipe cover clamp bolts 6.9 0.70 61 in·lb
Premuffler chamber bolts
Muffler stay mounting bolts, 8 25 2.5 18 Lower Muffler
Upper muffler mounting nuts 25 2.5 18
Upper muffler bracket nut 29 3.0 21
Clutch:
Clutch lever pivot bolt 1.0 0.10 8.9 in·lb
Clutch lever pivot bolt locknut 5.9 0.60 52 in·lb Si
Clutch reservoir cap screws 1.5 0.15 13 in·lb
Clutch slave cylinder bleed valve 7.8 0.80 69 in·lb
Clutch slave cylinder bolts 6.9 0.70 61 in·lb L
Clutch hose banjo bolts 25 2.5 18
Clutch master cylinder clamp bolts 9.8 1.0 87 in·lb S
N·m
18 1.8 13
8.3 0.85 74 in·lb
29 3.0 21
Torque
Remarks
kgf·m ft·lb
2-6 P ERIODIC M AINTENANCE
Torque and Locking Agent
Fastener
Starter lockout switch screws
Push rod guide bolts 11 1.1 95 in·lb L
Clutch cover bolts 11 1.1 95 in·lb
Clutch damper cover bolts 9.8 1.0 87 in·lb L
Clutch damper plate bolts 9.8 1.0 87 in·lb EO
Clutch cover damper screws 4.9 0.50 43 in·lb L
Clutch hub nut 147 15 108 MO
Engine Lubrication System:
Oil filler cap 1.5 0.15 13 in·lb
Oil screen plug 20 2.0 15
Engine oil drain plug 20 2.0 15
Oil filter (cartridge type)
Oil filter pipe
Oil pressure relief valve
Oil pressure switch terminal screw 1.5 0.15 13 in·lb
Oil pressure switch 15 1.5 11 SS
Oil pump mounting bolts 11 1.1 97 in·lb
Oil hose banjo bolts 9.8 1.0 87 in·lb
Oil hose flange bolt (outside) 9.8 1.0 87 in·lb
Oil pipe holder bolts (inside) 11 1.1 97 in·lb L
Oil pipe clamp bolts (inside) 11 1.1 97 in·lb L
Right & left crankcase oil nozzles 2.9 0.30 26 in·lb ×3
Right crankcase oil nozzle 2.9 0.30 26 in·lb ×1,Lh
Oil pipe nozzle (left side) 2.9 0.30 26 in·lb
Oil baffle bolt 11 1.1 97 in·lb L
Engine Removal/Installation:
Downtube bolts and nuts 44 4.5 32
Engine mounting bolts and nuts 44 4.5 32
Engine mounting bracket bolts 25 2.5 18
Engine ground terminal bolt 7.8 0.80 69 in·lb
Crankshaft/Transmission:
Crankcase bolts
Frame ground bracket bolt 11 1.1 97 in·lb Left Crankcase
Crankcase bearing retainer bolts 11 1.1 97 in·lb L
Camshaft chain guide bolts 11 1.1 97 in·lb L
Right, l eft crankcase oil nozzles 2.9 0.30 26 in·lb ×3
Right crankcase oil nozzles 2.9 0.30 26 in·lb ×1,Lh
Oil baffle bolt 11 1.1 97 in·lb L
Connecting rod big end nuts 59 6.0 44 MO
Oil pressure relief valve 15 1.5 11 L
Oil filter pipe 25 2.5 18 SS
10 mm
8mm 21 2.1 15 S
6mm 11 1.1 97 in·lb S
N·m
1.2 0.12 10 in·lb
18 1.8 13
25 2.5 18
15 1.5 11 L
39 4.0 29
Torque
Remarks
kgf·m ft·lb
R, EO
SS
S
Torque and Locking Agent
PERIODIC MAINTENANCE 2-7
Fastener
Oil hose banjo bolts
Primary gear bolt 147 15 108
Water pump chain guide spring hook bolt 2.9 0.30 26 in·lb
Water pump chain guide bolt 8.3 0.85 73 in·lb
Idle shaft holder bolts 8.3 0.85 73 in·lb
Oil pressure switch terminal screw 1.5 0.15 13 in·lb
Oil pressure switch 15 1.5 11 SS
Oil return pipe bolts (inside) 11 1.1 97 in·lb L
Oil pipe holder bolts (inside) 11 1.1 97 in·lb L
Oil pipe clamp bolts (inside) 11 1.1 97 in·lb L
Left balancer gear bolt 85 8.7 63 MO
Starter clutch bolt
Starter clutch coupling bolts
Gear set lever bolt
Shift shaft return spring pin (bolt) 39 4.0 29 L
Shift pedal clamp bolt 30 3.1 22
Rear shift lever clamp bolt 12 1.2 106 in·lb
Shift rod locknuts 9.8 1.0 87 in·lb (Rear: Lh)
Shift drum cam bolt 15 1.5 11 in·lb L
Damper cam nut (front gear) 195 20 144 MO (threads)
Clutch push rod guide bolts 11 1.1 97 in·lb L
Wheels/Tires:
Front axle clamp bolts 29 3.0 21 AL
Front axle 108 11 79.6
Rear axle nut 108 11 79.6
Tire air valve nuts 1.5 0.15 13 in·lb
Tire air valve caps 0.15 0.015 1.3 in·lb
Air valve cores 0.30 0.030 2.6 in·lb
Final Drive:
Oil pipe banjo bolts (front gear) 12 1.2 106 in·lb
Oil nozzle (front gear) 2.9 0.30 26 in·lb
Oil nozzle (front gear) 18 1.8 13
Neutral switch 15 1.5 11
Front gear case bolts: 6 mm 12 1.2 106 in·lb S
8mm 29 3.0 21 S
Speed sensor bolt
Damper cam nut (front gear)
Drive gear nut (front gear)
Driven gear assy mounting bolts 25 2.5 18
Driven gear bolt (front gear) 120 12 89 MO, St
Bearing retainer bolts (front gear) 8.8 0.90 78 in·lb L
Final gear case drain plug 8.8 0.90 78 in·lb
Final gear case mounting nuts 34 3.5 25
N·m
9.8 1.0 87 in·lb
85 8.7 63
15 1.5 11 L
11 1.1 97 in·lb L
9.8 1.0 87 in·lb L
195 20 144
265 27 195
Torque
Remarks
kgf·m ft·lb
MO
MO
MO (threads)
MO, St
2-8 P ERIODIC M AINTENANCE
Torque and Locking Agent
Fastener
Final gear case Studs
Final gear case cover bolts: 8 mm 23 2.3 17 L
10 mm 34 3.5 25 L
Pinion gear nut (final gear) 127 13 93 MO, St
Bearing retainer bolt 6.9 0.70 61 in·lb L
Brakes:
Caliper bleed valves 7.8 0.80 69 in·lb
Brake hose banjo bolts 25 2.5 18
Brake lever pivot bolt 1.0 0.10 8.9 in·lb Si
Brake lever pivot bolt locknut 5.9 0.60 52 in·lb
Front brake reservoir cap screws 1.5 0.15 13 in·lb
Front brake light switch screw 1.2 0.12 11 in·lb
Front master cylinder clamp bolts 8.8 0.90 78 in·lb S
Front brake pad spring bolts 2.9 0.30 26 in·lb
Front caliper mounting bolts 34 3.5 25
Front caliper assembly bolts 21 2.1 15
Rear caliper mounting bolts 34 3.5 25
Rear caliper holder bolt 64 6.5 47
Brake disc bolts 27 2.8 20 L
Rear master cylinder mounting bolts 25 2.5 18
Rear m aster cylinder push rod locknut 18 1.8 13
Brake pedal clamp bolt 25 2.5 18
Suspension:
Upper front fork clamp bolts 29 3.0 21
Lower front fork clamp bolts 29 3.0 21
Front fork top plugs 34 3.5 25
Piston rod nuts or joint rod nut 20 2.0 15
Inner fork bolt (left) 98 10 72
Front fork bottom Allen bolt (right) 20 2.0 15 L
Front axle clamp bolts 29 3.0 21 AL
Protector screws 5.9 0.60 52 in·lb
Rear shock absorber nuts 34 3.5 25
Shock absorber air valves 5.4 0.55 48 in·lb
Swingarm pivot shaft 108 11 79.6 G
Steering:
Steering stem head nut 88 9.0 65
Steering stem nut 4.9 0.50 43 in·lb S
Handlebar nuts 34 3.5 25
Upper front fork clamp bolts 29 3.0 21
Lower front fork clamp bolts 29 3.0 21 AL
Frame:
Downtube bolts and nuts 44 4.5 32
Rear footpeg bracket bolts 25 2.5 18 L
N·m
– – – L
Torque
Remarks
kgf·m ft·lb
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