Kawasaki VULCAN 1600 CLASSIC Service Manual
VULCAN 1600 CLASSIC
VN1600 CLASSIC
Motorcycle
Service Manual
Quick Reference Guide
General Information
Periodic Maintenance
Fuel System (DFI
) 3 j
Cooling System
Engine Top End
1 j
2 j
4 j
5 j
Clutch 6 j
Engine Lubrication System
7 j
8 jEngine Removal/Installation
9 jCrankshaft/Transmission
Wheels/Tires 10
Final Dr 11
ive j
j
This quick reference guide will assist
you in locating a desired topic or procedure.
•Bend the pages back to match the
ack tab of the desired chapter num-
bl
ber with the black tab on the edge at
each table of contents page.
•Refer to the sectional table of contents
or t he exact pages to locate the spe-
f
cific topic required.
Brakes j
12
Suspension 13
Steering
14 j
Frame 15
Electrical System
16 j
Appendix 17 j
j
j
VULCAN 1600 CLASSIC
VN1600 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 Assurance Department/Consumer Products & Machinery
Company/Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omis
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
o make such changes to products manufactured previously. See your Motorcycle dealer for the latest
t
information on product improvements incorporated after this publication.
All information contained in this publication is based on t
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.
sions in this publication, although every possible
he latest product information available at the time
© 2003 Kaw asaki Heavy Industries, Ltd. Second
Edition (1) : Aug. 25, 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 r eading
W
pound(s)
minute(s)
pascal(s)
pound(s) per square inch
watt(s)
Read OWNER’S M ANUAL 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 A gency 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
e routed through an oil separator to the inlet side of the engine. While the engine is operating,
ar
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
this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully
of
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 inudes a catalytic converter system.
cl
3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Inead, fuel vapors are routed into the running engine to be burned, or stored in a canister when
st
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
"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
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading
referred to as the Act’s "tampering provisions."
or in a motor vehicle or motor vehicle engine in compliance with regulations under this
on
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.
otor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles know-
m
ingly 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 deces or elements of design in order to perform m aintenance.
vi
2. Tampering could include:
Maladjustment of vehicle components such that the emission standards are ex-
a.
ceeded.
b.Use of replacement parts or accessories which adversely affect the performance
or durab ility 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
eleme
WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW,
THEVIOLATION OF WHICHISPUNISHABLEBYCIVIL PENALTIES NOTEXCEEDING
$10,000 PER VIOLATION.
nt of design of the emission control systems.
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 t o 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
avoid costly mistakes, read the text, thor-
to
oughly 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,
recommend that all repairs and scheduled
we
maintenance be performed in accordance with
this service manual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void the warranty.
To get the longest life out of your vehicle:
Follow the Periodic Maintenance Chart in the
•
Service Manual.
Be alert for problems and non-scheduled
•
maintenance.
Use proper tools and genuine Kawasaki Mo-
•
torcycle parts. Special tools, gauges, and
testers that are necessary when servicing
Kawasaki motorcycles are introduced by the
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 t ake shortcuts.
Remember to keep complete records of main-
•
tenance and repair with dates and any new
parts installed.
How to Use This Manual
In preparing this manual, we divided the product into its major systems. These systems became the manual’s chapters. All information
for a particular system from adjustment through
disassembly and inspection is located in a single chapter.
The Quick Reference Guide shows you all
the product’s system and assists in locating
of
their chapters. Each chapter in turn has its own
comprehensive Table of Contents.
The Periodic Maintenance Chart is located in
he Periodic Maintenance chapter. The chart
t
gives a time schedule for required maintenance
operations.
If you want spark plug information, for exam-
e, go to the Periodic Maintenance Chart first.
pl
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
Always follow safe operating and maintenance
practices.
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in per-
sonal injury, or loss of life.
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
tion to WARNING and CAUTION) which will
addi
help you distinguish different types of information.
symbols, heed their instructions!
WARNING
CAUTION
NOTE
This note symbol indicates points of par-
○
ticular interest for more efficient and convenient operation.
Indicates a procedural step or work to be
•
done.
Indicates a procedural sub-step or how to do
○
the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action to
take based on the results of the test or inspection in the procedural step or sub-step it follows.
In most chapters an exploded view illustration
the system components follows the Table of
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..............................................................................................................
General Specifications............................................................................................................ 1-9
Unit Conversion Table ............................................................................................................ 1-11
... 1-7
1
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following:
Battery Ground
Before completing any service on the motorcycle, disconnect the battery 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 w hen 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 m ost cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service
Manual, follow the procedures given.
1-4 GENERAL INFORMATION
Before Servicing
Tightening Sequence
Bolts, nuts, or screws must be tightened according to the
specified sequence to prevent case warpage or deformation
which can lead to malfunction. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality t orque wrench.
Often, the tightening sequence is followed twice-initial
ightening and final tightening with torque wrench.
t
Force
Use common sense during disassembly and assembly,
excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non
-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.
Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets
and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing
surfaces thoroughly so that no gasket material or other
material remains. Install new gaskets and replace used
O-rings when re-assembling
Liquid Gasket, Locking Agent
For applications that require Liquid Gasket or a Locking
agent, clean the surfaces so that no oil residue remains before applying liquid gasket or locking agent. Do not apply
them excessively. Excessive application can clog oil passages and cause serious damage.
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
inner and outer race and result in bearing damage.
the
GENERAL INFORMATION 1-5
Oil Seal, Grease Seal
Do not remove pressed oil or grease seals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.
Circlips, Cotter Pins
Replace circlips or cotter pins that were removed with new
ones. Install the circlip with its sharp edge facing outward
and its chamfered side facing inward to prevent the clip from
being pushed out of its groove when loaded. Take care
not to open the clip excessively when installing to prevent
deformation.
Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply
the specific oil or grease as specified.
1-6 GENERAL INFORMATION
Before Servicing
Direction of Engine Rotation
When rotating the crankshaft by hand, the f ree 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-A1 (US, and Canada) Left Side View:
GENERAL INFORMATION 1-7
VN1600-A1 (US, and Canada) Right Side View:
1-8 GENERAL INFORMATION
Model Identification
VN1600-A1 (Europe) Left Side View:
VN1600-A1 (Europe) R ight Side View:
GENERAL INFORMATION 1-9
General Specifications
Items VN1600-A1 ∼
Dimensions:
Overall length 2 505 mm (98.62 in.)
Overall width 1 040 mm (40.9 in.), (AU) 990 mm (39 in.)
Overall height 1 130 mm (44.5 in.)
Wheelbase
Road clearance 130 mm (5.12 in.)
Seat height 680 mm (26.8 in.)
Dry mass 306 kg (675 lb), (AU) 307 kg (677 lb)
Curb mass:
Fuel tank capacity
Fuel Unleaded and high-octane gasoline
Performance:
Minimum turning radius
Engine:
pe
Ty
Cooling system
Bore and stroke
Displacement
Compression ratio
Maximum horsepower
Maximum torque
Carburetion system
Starting system
Ignition system
Timing advance
Ignition timing
Spark plugs
Cylinder numbering method
Firing order
Valve timing:
Inlet Open
Exhaust Open
Lubrication system
Engine oil: Type
Front
Rear 181 kg (399 lb), (AU) 182 kg (401 lb)
Close
Duration
Close
Duration
Viscosity
Capacity
1 680 mm (66.1 in.)
156 kg (345 lb)
20 L (5.3 US gal)
(see VN1600-A1 ∼ Ow
3.5 m (11.5 ft)
4-stroke, SOHC, V2-cylinder
quid-cooled
Li
102 × 95 mm (4.02 × 3.74 in.)
1 552 mL (94.70 cu in.)
9.0 : 1
49 kW (67 PS) @ 4 700 r/min (rpm), (CA) (CAL) (US) –
127 N·m (12.95 kgf·m, 93.7 ft·lb) @ 2 700 r/min (rpm),
(CA) (CAL) (US) –
DFI (Digital Fuel Injection) System
Electric starter
Battery and coil (transistorized)
Electronically advanced (digital)
From 0° BTDC @ 950 r/min (rpm) ∼ 25° BTDC @ 4 500
r/min (rpm)
NGK DPR6EA-9 or ND X20EPR-U9
Front to Rear, 1-2
1-2
22° BTDC
66° ABDC
268°
66° BBDC
26° ATDC
272°
Forced lubrication (wet sump)
API SE, SF or SG class
API SH or SJ class with JASO M A
SAE10W-40
3.5 L (3.7US qt, when engine is completely disassembled
and dry)
ner’s Manual)
1-10 GENERAL INFORMATION
General Specifications
Items V N1600-A1 ∼
Drive Train:
mary reduction system:
Pri
Type
Reduction ratio
Clutch type
Transmission:
Type
Gear ratios: 1st
2nd
3rd
4th
5th
Final drive system:
Type
Reduction ratio
Overall drive ratio
Final gear case oil:
Grade
Viscosity
Capacity
Frame:
pe
Ty
Caster (rake angel)
Trail
Front tire: Type
Size
Rear tire: Type
Size
Front suspension: Type
Wheel travel
Rear suspension: Type
Wheel travel
Brake Type: Front
Rear
Electrical Equipment:
tery Capacity 12 V 18 Ah
Bat
Headlight: T
Tail/brake light 12 V 5/21 W
Alternator: T
Specifications are subject to change without notice, and may not apply to every country.
AU: Australia
L: California
CA
CA: Canada
US: United States of America
ype Semi-sealed beam
Bulb 12 V 60/55 W (quartz-halogen)
ype Three-phase AC, twin rotor
Rated output 42A × 14 V @ 6 000 r/min (rpm)
Gear
(85/56)
1.517
Wet multi disc
5-speed, constant mesh, return shift
2.500 (40/16)
1.590 (35/22)
1.192 (31/26)
0.965 (28/29)
0.781 (25/32)
Shaft
2.619 (15/21 × 33/9)
3.105 @ Top gear
API Service Classification: GL-5 Hypoid gear oil
SAE90 (above 5°C), SAE80 (below 5°C)
200 mL (6.76 US oz)
Tubular, double cradle
32°
mm (6.61 in.)
168
Tubeless
130/90 - 16 M/C 67H
Tubeless
170/70B16 M/C 75H
Telescopic fork
150 mm (5.91 in.)
Swingarm
95 mm (3.74 in.)
Dual disc
Single disc
GENERAL INFORMATION 1-11
Unit Conversion Table
Prefixes for Units: Units of Length:
Prefix
mega
kilo k × 1 000
centi c ×0.01
milli
cro
mi
Symbol
M
m
µ
Power
× 1 000 000
× 0.001
× 0.000001
Units of Mass:
kg
g
×
×
2.205
0.
03527 = =
lb
oz
km
m
mm
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
·m
kgf
×
×
×
×
×
0.6214
3.281
0.03937
7.233
86.
80
=
mile
=
=
=
=
t
f
in.
ft·lb
n·lb
i
Units of Volume:
L
L
L
L
L
L
mL × 0.03381 = oz (US)
mL × 0.02816 = oz (imp)
mL × 0.06102 = cu in.
×
×
×
×
×
×
0.2642
200
0.2
1.057
0.8799
2.113
1.816
=
=
=
=
=
=
gal (US)
(imp)
gal
qt (US)
qt (imp)
pint (US)
pint (imp)
Units of Force:
N × 0.1020 =
N × 0.2248 = lb
kg × 9.807 = N
kg × 2.205 = lb
kgf
Units of Pressure:
kPa
kPa
kPa
/cm²
kgf
kgf/cm²
cm Hg
×
×
×
×
×
×
0.01020
0.1450
0.7501
98.07
14.22
.333
1
=
kgf/cm²
=
p
=
cm Hg
=
kPa
=
psi
=
kPa
Units of Speed:
km/h × 0.6214 = mph
Units of Power:
kW × 1.360 = PS
kW × 1.341 = HP
PS × 0.7355 = kW
PS
× 0.9863 = HP
si
Units of Temperature:
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
nspection .................................. 2-13
I
Idle Speed Inspection .................. 2-14
Air Cleaner Element Cleaning...... 2-15
Evaporative Emission Control
ystem Inspection (CAL) .......... 2-15
S
Cooling System............................... 2-16
Radiator Hose and Connection
nspection .................................. 2-16
I
Coolant Change ........................... 2-17
Engine Top End .............................. 2-19
Air Suction Valve Inspection ........ 2-19
Clutch.............................................. 2-19
Clutch Hose and Connection
nspection .................................. 2-19
I
Clutch Fluid Level Inspection ....... 2-20
Clutch Fluid Change .................... 2-20
Clutch Master Cylinder C up and
ust Seal Replacement ............ 2-21
D
Clutch Slave Cylinder Piston Seal
eplacement ............................ 2-22
R
Engine Lubrication System ............. 2-23
Engine Oil Change....................... 2-23
Oil Filter Replacement ................. 2-24
Wheel/Tires..................................... 2-24
Tire Inspection ............................. 2-24
Final Drive....................................... 2-25
Oil Level Inspection...................... 2-25
Oil Change ................................... 2-26
Propeller Shaft Joint Lubrication .. 2-26
Brakes............................................. 2-27
Brake Pad Wear Inspection ......... 2-27
Brake Hose and Connection
nspection .................................. 2-27
I
Brake Fluid Level Inspection........ 2-27
Brake Fluid Change .....................
Brake Master Cylinder Cup and
Dust Seal Replacement ............ 2-29
Caliper Piston/Dust Seals
Replacement ............................. 2-29
Front Brake Light Switch
Inspection .................................. 2-29
Rear Brake Light Switch
heck/Adjustment ..................... 2-30
C
Suspension ..................................... 2-30
Front Fork Oil Leak Inspection..... 2-30
Rear Shock Absorber Oil Leak
nspection ................................. 2-31
I
Swingarm Pivot Lubrication ......... 2-31
Steering .......................................... 2-31
Stem Bearing Lubrication............. 2-31
Steering Check ............................ 2-31
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
2-28
2
2-2 PERIODIC MAINTENANCE
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in
good running condition.The initial maintenance is vitally important and must not be neglected.
FREQUENCY Whichever 1 000 km * ODOMETER
comes (600 mile)
first 6 000 km
→ (4 000 mile)
↓ 12 000 km
(7 500 mile)
000 km
18
(12 000 mile)
24 000 km
(15 000 mile)
30
(20 000 mile)
OPERATION Every See Page
k plug (e) - clean and gap † 2–35
Spar
Air suction valve (e) - inspect † 2–20
Air cleaner element (e) - clean†# 2–16
Throttle control system (e) - inspect † 2–14
Idle speed (e) - inspect † 2–15
Fuel hoses, connections - inspect † 2–14
Engine oil - change # year 2–24
Oil filter - replace 2–26
Evaporative em ission control system (e)
(CAL) - inspect †
Final gear case oil level - inspect † 2–28
Final gear case oil - change 2–28
Propeller shaft joint - lubricate 2–29
Brake pad wear - inspect † # 2–29
Brake light switch - inspect † 2–32
Steering - inspect † 2–34
Rear shock absorber oil leak - inspect † 2–33
Front fork oil leak - inspect † 2–33
Tire wear - inspect † 2–27
Swingarm pivot - lubricate 2–33
General lubrication - perform 2–36
Nut, bolt, and fastener tightness - inspect † 2–37
Brake/clutch hoses, connections - inspect † 2–21, 2–29
Brake/clutch fluid level - inspect †
Coolant hoses, connections - inspect † 2–18
Brake/clutch fluid - change 2 years 2–22, 2–30
month 2–21, 2–29
• • • • • •
• • • • • •
• • •
• • • • • • •
• • • •
• • • • • •
• • • •
• • • •
• • • • • • •
• • •
• •
• •
• • • • • •
• • • • • • •
• • • • • • •
• • •
• • •
• • • • • •
• •
• • •
• • • •
• • • • • •
• • • • • • •
•
•
READING
000 km
36 000 km
24 000 mile)
(
2–17
PERIODIC MAINTENANCE 2-3
Periodic Maintenance Chart
FREQUENCY Whichever 1 000 km * ODOMETER
comes
first 6 000 km
→
↓ 12 000 km
OPERATI ON Every See Page
Brake/clutch master cylinder cup and dust
- replace
seal
Coolant - change
Caliper piston seal and dust seal - replace 4 years 2–32
Steering stem bearing - lubricate 2 years
Clutch slave cylinder piston seal - replace 4 years 2–24
# : Service more freque
frequent starting/stopping.
* : For higher odometer readings, repeat at the frequency interval established here.
† : Replace, add, adjust,
ntl
y when operating in severe conditions; dusty, wet, muddy, high speed or
ean, or torque if necessary.
cl
4 years 2–23, 2–32
2 years
(600 mile)
(4 000 mile)
(7 500 mile)
18 000 km
(12 000 mile)
24 000 km
(15 000 mile)
30 000 km
(20 000 mile)
•
•
READING
36 000 km
(24 000 mile)
2–28
2–34
Throttle control system inspection: Inspection of throttle grip play and throttle bore cleanliness.
(CAL)
: California
(e): Emission Related Items
2-4 PERIODIC MAINTENANCE
Torque and Locking Agent
The following tables list the tightening torque
for the major fasteners requiring use of a non
-permanent locking agent or liquid gasket.
Letters used in the “Remarks” column mean:
L: Apply a non-permanent locking agent to
he threads.
t
G: Apply grease to the threads.
MO: Appl
O: Apply oil to the threads and seating sur-
S: Tighten the fasteners following the s peci-
SS: Appl
Si: Apply silicone grease (ex. PBC grease).
R: Replacement parts
Lh: Lef
St: Stake the fasteners to prevent loosening.
AL: Tighten the two clamp bolts alternately
Fuel System:
Throttle body 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 11 1.1 95 in·lb
Air cleaner duct holder bolts 9.8 1.0 69 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 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
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 9.8 1.0 87 in·lb S, L
Cooling System:
Radiator hose clamp screws 2.5 0.25 22 in·lb
Radiator fan switch 18 1.8 13
Radiator fan bolts
Water temperature switch 7.8 0.80 69 in·lb
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
y molybdenum disulfide grease oil
solution.
ce.
fa
ied sequence.
f
y silicone sealant.
t-hand-threads
two times to ensure even tightening
orque.
t
Fastener
The table below, relating tightening torque to
ead diameter, lists the basic torque for the
thr
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 for use with dry
solvent-cleaned threads.
Basic Torque for General Fasteners
Threads
dia. (mm)
5
6
8
10
12
14
16
18
20
Torque
N·m kgf·m ft·lb
8.3 0.85 74 in·lb
N·m
3.4 ∼ 4.
5.9 ∼ 7.8
14 ∼19
25 ∼ 34
44 ∼ 61
73 ∼ 98
115 ∼ 155
165 ∼ 225
225 ∼ 325
Torque
kgf·m ft·lb
9
0.35 ∼ 0.
0.60 ∼ 0.80
1.4 ∼1.9
2.6 ∼ 3.5
4.5 ∼ 6.2
7.4 ∼ 10.0
11.5 ∼ 16.0
17.0 ∼ 23.0
23 ∼ 33
50
30 ∼ 43
52 ∼ 69 in·lb
10.0 ∼ 13.5
19.0 ∼ 25
33 ∼ 45
54 ∼ 72
83 ∼ 115
125 ∼ 165
165 ∼ 240
Remarks
L, Throttle Body
SS
in·lb
Torque and Locking Agent
PERIODIC MAINTENANCE 2-5
Fastener
Radiator drain bolt 7.4 0.75 65 in·lb
Water temperature sensor (DFI) 18 1.8 13 SS
Engine Top End:
Spark plugs 18 1.8 13
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
Chain tensioner cap
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
Rocker case bolts 6
Cylinder head nuts
Cylinder head jacket plugs
Rocker case cover bolts 8.8 0.90 78 in·lb
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 except US, CA
Muffler stay mounting bolts and nuts, 8 25 2.5 18
Muffler bracket bolt and nut 29 3.0 22
Clutch:
Clutch lever pivot bolt 1.0 0.10 8.7 in·lb Si
Clutch lever pivot bolt locknut 5.9 0.60 52 in·lb
Clutch reservoir cap crews 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 11 1.1 95 in·lb S
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 (outside) 9.8 1.0 87 in·lb L
Clutch cover damper plate bolts 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
mm 78 8.0 58 MO, S
8mm 25 2.5 18 S
mm 8.8 0.90 78 in·lb S
N·m
11 1.1 95 in·lb
20 2.0 14
25 2.5 18
20 2.0 14 L
1.2 0.12 10 in·lb
Torque
kgf·m ft·lb
Remarks
S
S
S
S
2-6 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
Engine Lubrication System:
Oil filler cap
Oil screen plug 20 2.0 14
Engine oil drain plug 20 2.0 14
Oil filter (cartridge type) 18 1.8 13 R, EO
Oil filter Pipe 25 2.5 18 SS
Oil pressure relief valve 15 1.5 11 L
Oil pressure switch terminal screw 1.5 0.15 13 in·lb
Oil pressure switch 15 1.5 11 SS
Oil pump mounting bolts 11 1.1 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 ×3
Right crankcase oil nozzle 2.9 0.30 26 in·lb ×1, Lh
Oil baffle bolt 11 1.1 95 in·lb L
Engine Removal/Installation:
Downtube bolts and nuts 44 4.5 33
Engine mounting bolts and nuts 44 4.5 33
Engine mounting bracket bolts 25 2.5 18
Engine ground terminal bolt 7.8 0.80 69 in·lb
Crankshaft/Transmission:
Crankcase bolts: 1
Frame ground bracket bolt 1.1 1.1 95 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 ×3
Right crankcase oil nozzles 2.9 0.30 26 in·lb ×1, Lh
Oil baffle bolt
Connecting rod big end nuts 59 6.0 43 MO
Oil pressure relief valve 15 1.5 11 L
Oil f ilter Pipe 25 2.5 18 SS
Oil hose banjo bolts 9.8 1.0 87 in·lb
Primary gear bolt 147 15.0 108 MO
Water pump chain guide spring hook bolt 2.9 0.30 26 in·lb
Water pump chain guide bolt 8.3 0.85 73 in·lb
Idle shaft holder bolts 8.3 0.85 73 in·lb
Oil pressure switch terminal screw 1.5 0.15 13 in·lb
Oil pressure switch
Oil pipe clamp bolts (inside)
0 mm 39 4.0 29 S
8mm 21 2.1 15 S
6mm 11 1.1 95 in·lb S
N·m
1.5 0.15 13 in·lb
11 1.1 95 in·lb L
15 1.5 11
11 1.1 95 in·lb L
Torque
kgf·m ft·lb
Remarks
SS
Torque and Locking Agent
PERIODIC MAINTENANCE 2-7
Fastener
Left balancer gear bolt
Starter clutch bolt
Starter clutch coupling bolts 15 1.5 11 L
Gear set lever bolt 11 1.1 95 in·lb
Shift shaft return spring pin (bolt) 39 4.0 29 L
Shift pedal clamp bolt 25 2.5 18
Shift pedal clamp bolts (VN1600–A2 ∼) 30 3.1 22
Rear shift lever clamp bolt 12 1.2 104 in·lb
Shift rod locknuts 11 1.1 95 in·lb (Rear: Lh)
Shift drum bearing holder bolts 11 1.1 95 in·lb L
Shift drum cam screw 15 1.5 11 L
Damper cam nut (front gear) 195 20 144 MO (threads)
Push rod guide bolts 9.8 1.0 87 in·lb L
Wheels/Tires:
Front axle clamp bolts 20 2.0 14 AL
Front axle 108 11.0 79.6 S
Rear axle nut 108 11.0 79.6
Tire air valve stem nuts 1.5 0.15 13 in·lb
Tire air valve caps 0.15 0.015 1.3 in·lb
Air valve cores 0.3 0.03 2.6 in·lb
Final Drive:
Oil pipe banjo bolts (front gear) 12 1.2 104 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 1.2 104 in·lb
8mm 29 3.0 22
Speed sensor bolt 9.8 1.0 87 in·lb L
Damper cam nut (front gear) 195 20 144 MO (threads)
Drive gear nut (front gear) 265 27
Driven gear assy mounting bolts 25 2.5 18
Driven gear bolt (front gear)
Bearing retainer bolts (front gear) 8.8 0.9 78 in·lb L
Final gear case drain plug 8.8 0.9 78 in·lb
Final gear case m ounting 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) 130 13 94 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
N·m
85 8.7 63
85 8.7 63
137 14 101
Torque
kgf·m ft·lb
195 MO, St
Remarks
MO
MO
MO, St
2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
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 caliper mounting bolts 34 3.5 25
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 14
Lower front fork clamp bolts 29 3.0 21 AL
Front fork top plugs 22 2.2 16
Piston rod nuts or joint rod nut 20 2.0 14
Front fork bottom allen bolt 30 3.1 22 L
Front axle clamp bolts 20 2.0 14 AL
Rear shock absorber nuts 34 3.5 25
Swingarm pivot shaft 108 11 . 0 79.6 G
Steering:
Steering stem head nut 88 9.0 65
Steering stem nut 5 0.5 43 in·lb
Handlebar clamp bolts 34 3.5 25
Handlebar holder nuts 34 3.5 25
Upper front fork clamp bolts 20 2.0 14
Lower front fork clamp bolts 29 3.0 21 AL
Turn signal light mounting nuts 5.9 0.6 52 in·lb
Frame:
Downtube bolts and nuts 44 4.5 33
Footboard bracket bolts 34 3.5 25
Footpeg bracket bolts 25 2.5 18 rear, L
Sidestand nut 44 4.5 33
Electrical System:
Spark plugs 18 1.8 13
Crankshaft sensor screws 2.9 0.30 26 in·lb
Stator lead holder screw 9.8 1.0 87 in·lb L
Inside stator holder bolts 11 1.1 95 in·lb L
Crankshaft sensor lead holder bolt 2.9 0.30 26 in·lb L
Alternator outer cover bolts 6.9 0.70 61 in·lb
Alternator outer cover joint bolts 6.9 0.70 61 in·lb L
Alternator outer cover damper bolts 6.9 0.70 61 in·lb L
N·m
Torque
kgf·m ft·lb
Remarks
front
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