Kawasaki VULCAN 1600 CLASSIC Service Manual

VULCAN 1600 CLASSIC

VN1600 CLASSIC

Motorcycle

Service Manual

Quick Reference Guide

General

Information

1

j

Periodic

Maintenance

2

j

Fuel

System (DFI)

3

j

Cooling System

4

j

Engine

Top End

5

j

Clutch

6

j

Engine

Lubrication System

7

j

Engine

Removal/Installation

8

j

Crankshaft/Transmission

9

j

Wheels/Tires

10

j

Final

Drive

11

j

Brakes

12

j

Suspension

13

j

Steering

14

j

Frame

15

j

Electrical System

16

j

This

quick

reference guide will assistAppendix

17

j

you in locating

a

desired

topic or

pro­

cedure.

•Bend the

pages

back

to

match

the

black

tab

of

the

desired

chapter

num­

ber

with

the

black tab on the edge at

each table of contents page.

•Refer to

the sectional

table

of contents

for the

exact

pages

to locate the

spe­

cific

topic

required.

VULCAN 1600 CLASSIC

VN1600 CLASSIC

Motorcycle

Service Manual

All

rights

reserved.

No

parts

of

this

publication

may

be

reproduced,

stored

in

a

retrieval

syste

transmitted

in

any

form

or by any means, electronic mechanical photocopying,

recording

or

otherwis

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 isorsionsomin

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 ob

to

make

such

changes

to

products

manufactured

previously.

See

your

Motorcycle

dealer

for

the

la

information

on

product improvements incorporated after

this

publication.

All information

contained

in

this

publication is

basedthe lateston

product information

available

at

the

time

of

publication.

Illustrations

and photographs in

this publication are intended

for

reference

use

only and

m

not

depict

actual

model

component

parts.

©

2003

Kawasaki

Heavy

Industries,

Ltd.

Second Edition (1)

:

Aug.

25,

2003 (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) (mass)					W	watt(s)
h	hour(s)					Ω	ohm(s)
kg	(mass)
kgf	(force)
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

emis­

sion

(1)

and

exhaust

emission (2)

control

systems in

compliance

with

applicable

regulations

of

the United States Environmental Protection Agency and California Air

Resources

Board.

Addi­

tionally,

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

thedeinletof sithe

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

whe

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 know­

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

follow­

ing its

sale

and

delivery

to

the

ultimate

purchaser..."

NOTE

The

phrase

"remove

or

render inoperative

any

device

or

element

of

design"

has

been

gener

○interpreted as

follows:

1. Tampering

does

not include

the

temporary removal

or

rendering inoperative

of

de­

vices

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

accessoriesat thresult in

the

vehicle

exceeding the

stan­

dards.

d.Permanently removing,

disconnecting,

or

rendering inoperative

any

component or

element of

design

of

the

emission

control

systems.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE

PROVISIONS

OF

FEDERAL

LAW,

THE VIOLATION

OF

WHICH IS PUNISHABLE BY CIVIL

PENALTIES

NOT EXCEEDING

$10,000

PER

VIOLATION.

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

Federal law

prohibits the following acts or the causing thereof: (1) The removal or rendering

inoperative

by any

person other

than

for purposes

of maintenance, repair, or replacement,

of any

device

or

element

of

design incorporated

into

any

new vehicle for the purpose of

noise

control

prior

to its

sale

or delivery

to

the

ultimate

purchaser

or

while it is in

use,

or (2)

the use of

the

vehicle

after

such

device

or

element

of

design

has

been

removed

or

rendered

inoperative

by

any

person.

Among those

acts

presumed

to

constitute

tampering

are

the acts listed

below:

•Replacement

of

the

original

exhaust

system

or

muffler

with a component

not in

compliance

with

Federal

regulations.

•Removal of

the

muffler(s)

or

any internal

portion

of the

muffler(s).

•Removal of

the

air

box

or

air

box

cover.

•Modifications

to

the

muffler(s) or

air 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

How

to

Use

This

Manual

trained

mechanics in

a

properly equipped shop.

However,

it

contains

enough

detail and

basic in­

In

preparing this

manual,

we

divided

the

prod­

formation

to

make it useful to

the

owner

who

de­

sires

to

perform

his

own

basic

maintenance

uct into its

major

systems.

These

systems

be­

and

the

manual’s chapters. All information

repair

work.

A

basic

knowledge

of

came

mechanics,

particular

system

from

adjustment

through

the

proper

use

of

tools,

and

workshop

for a

proce­

and inspection

is

located in

a

sin­

disassembly

dures must be understood in order to carry out

maintenance

and

repair

satisfactorily.

When­

gle

chapter.

ever

the

owner

has

insufficient

experience

or

The

Quick

Reference

Guide

shows

you

all

doubts

his

ability

to

do

the

work,

all

of the

product’s system

and

assists in locating

adjust­

chapters.

Each chapter in

turn

has

its

own

ments,

maintenance,

and

repair

should

be

their

car­

Table

of

Contents.

ried

out

only

by

qualified mechanics.

comprehensive

andThe

Periodic

Maintenance

Chart is located

in

In

order

to

perform

the

work

efficiently

to avoid

costly

mistakes,

read

the

text,

the

Periodic

Maintenance

chapter.

The

chart

thor­

required maintenance

gives a time schedule for

oughly familiarize yourself with the

procedures operations.

before starting work, and then do the

work care­

fully in

a

clean

area.

Whenever

special tools

or

If

you

want

spark

plug information,

for

exam­

equipment are

specified,

do

not

use

ple,

go

to the Periodic Maintenance Chart first.

makeshift

chart

tells

you

how

frequently to

clean

and

tools

or

equipment.

Precision

measurements

The

gap

the

plug.

Next,

use

the

Quick Reference

can

only

be

made if

the

proper instruments

are

to locate

the

Periodic

Maintenance

chap­

used,

and

the

use

of

substitute

tools

may

Guide

ad­

Then,

use

the

Table

of Contents

on

the first

versely affect safe

operation.

ter.

warranty

page

of

the

chapter

to

find

the

Spark

Plug sec­

For

the

duration

of

the

period,

we recommend

that

all

repairs

and

scheduled tion.

maintenance

be

performed in

accordance

with

Whenever you see these WARNING and

CAUTION

symbols,

heed

their

instructions!

this

service

manual.

Any

owner

maintenance

or

repair

procedure

not

performed in

accordance

Always follow safe operating and maintenance

practices.

with

this

manual

may

void

the

warranty.

WARNING

To

get

the longest life

out

of

your

vehicle:

•Follow

the

Periodic

Maintenance

Chart in

the

This

warning

symbol

identifies

special

Service

Manual.

instructions

or

procedures

which,

if

not

•Be

alert

for

problems

and

non-scheduled

correctly

followed,

could

result

in

per­

maintenance.

Mo­ sonal

injury,

or

loss

of

life.

•Use

proper

tools

and

genuine

Kawasaki

torcycle

parts.

Special

tools,

gauges,

and

CAUTION

testers that are necessary when servicing

This

caution

symbol

identifies

special

Kawasaki

motorcycles

are introduced

by

the

Special Tool Catalog or Manual.

Genuine

instructions

or procedures which, if not

parts provided as spare parts

are listed in

the

strictly

observed,

could

result

in

dam­

Parts Catalog.

age

to

or

destruction

of

equipment.

•Follow

the

procedures

in

this

manual

care­

This

manual

contains

four

more

symbols (in

fully.

Don’t

take

shortcuts.

addition

to

WARNING and

CAUTION) which will

•Remember

to

keep

complete

records

of main­help

you

distinguish

different

types

of

informa­

tenance

and

repair

with

dates

and

any

new

parts installed.

tion.

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

spec­

ified tightening torque, oil, grease or

a locking

agent

during

assembly.

GENERAL INFORMATION 1-1

General	Information	1
Table	of Contents
Before Servicing.....................................................................................................................		1-2
Model Identification..............................................................................................................	...	1-7
General Specifications........................................................................................................	..	1-9
Unit Conversion Table............................................................................................................		1-11

1-2 GENERAL INFORMATION

Before

Servicing

Before

starting

to

perform

an inspection

service

or

carry out

a

disassembly and

reassembly

opera­

tion

on

a

motorcycle,

read

the

precautions

givenow. Tobelfacilitate

actual operations,

notes, illustra-

tions,

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,

nect the

battery wires

from

the

battery to

prevent the

from

accidentally

turning over. Disconnect

the

ground

(–) first

and

then

the

positive (+).

When

completed with

service,

first

connect

the positive (+) wire

to

the

positive

terminal

of the

battery

then

the

negative (–)

wire

to

ative

terminal.

Edges

of

Parts

Lift large

or

heavy

parts

wearing

gloves

to

prevent

from

possible

sharp

edges

on

the

parts.

Solvent
Use	a high	flush	point solvent when cleaning parts
flush	point solvent		should be used according to
of the solvent		manufacturer.

Cleaning vehicle before disassembly
Clean the vehicle thoroughly before disassembly. Dirt
other foreign	materials entering into sealed areas during
hicle disassembly can cause excessive wear and
performance	of the vehicle.

								GENERAL INFORMATION 1-3
Before Servicing
Arrangement and Cleaning				of		Removed Parts
Disassembled parts are easy to							confuse.	Arrange
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
cleaned,	store	the	parts	in	a clean area.	Put a
or plastic sheet over the parts to protect from							any
materials	that	may	collect	before re-assembly.

Inspection
Reuse		of worn or damaged parts may lead to serious
cident.		Visually inspect		removed parts for corrosion,
oration,		or other damage. Refer to the appropriate
of this		manual	for service limits on individual parts.
the	parts if any damage has been found or if the part
yond	its service limit.
Replacement			Parts
Replacement Parts must be KAWASAKI genuine
recommended by KAWASAKI. Gaskets, O-rings, Oil
Grease		seals,	circlips	or cotter pins must be replaced
new	ones whenever			disassembled.

Assembly Order
In	most cases	assembly	order	is the reverse	of
bly,	however, if assembly		order is provided in		this
Manual, follow		the procedures		given.

1-4 GENERAL INFORMATION

Before	Servicing
Tightening		Sequence
Bolts, nuts, or screws must be tightened according
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
lead to serious damage. Tighten fasteners to the
torque using a good quality torque wrench.
Often, the tightening sequence is followed twice-
tightening	and		final	tightening		with			torque wrench.

Force

Use common sense during disassembly and assembly,

excessive

force

can

cause

expensive or hard to repair

age.

When

necessary,

remove

screws

that

have

-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

and O-rings after disassembly can reduce sealing

formance. Remove old gaskets and clean the

surfaces

thoroughly

so

that

no

gasket

material

or

material

remains.

Install

new

gaskets

and

replace

O-rings when re-assembling

Liquid

Gasket,

Locking

Agent

For

applications

that

require

Liquid

Gasket

or

a

agent,

clean

the

surfaces

so

that

no

oil residue

remains

fore applying liquid

gasket

or locking

agent. Do

not

them excessively. Excessive application can clog oil

sages

and

cause

serious

damage.

GENERAL INFORMATION 1-5

Before Servicing

Press
For	items	such	as bearings or oil	seals that
pressed into		place,	apply small amount	of oil to the
tact area. Be sure to maintain proper alignment
smooth	movements		when installing.

Ball Bearing	and	Needle		Bearing
Do not remove pressed ball or needle unless
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and
marks facing	out. Press		the	bearing into	place	by
pressure on the correct bearing race as shown.
Pressing the incorrect race				can cause	pressure between
the inner and	outer	race	and result in bearing			damage

Oil Seal,		Grease	Seal
Do	not remove pressed oil or grease seals unless
is necessary. Replace with new ones whenever
Press	new oil seals		with manufacture	and size marks
out.	Make	sure the seal is aligned		properly when

Circlips, Cotter

Pins

Replace circlips or cotter pins that were removed with

ones. Install

the

circlip

with its sharp

edge

facing

and its

chamfered

side

facing inward to

prevent

the

clip

being

pushed

out

of

its

groove

when

loaded.

Take

not

to

open

the

clip excessively

when installing

to

deformation.

Lubrication

It is important

to lubricate

rotating

or

sliding

parts

assembly to

minimize wear

during initial

operation.

Lubri

cation

points

are

called out

throughout

this

manual,

the

specific

oil

or

grease

as

specified.

1-6 GENERAL INFORMATION

Before		Servicing
Direction		of	Engine	Rotation
When		rotating the		crankshaft	by	hand,	the free
amount of rotating direction will					affect	the	adjustment
tate	the	crankshaft to positive direction (clockwise
from	output		side).

Electrical Wires
A two-color wire is identified first by			the	primary color
then	the stripe	color. Unless instructed		otherwise,	electrical
wires	must be	connected to those	of	the same	color

GENERAL INFORMATION 1-7

Model Identification

VN1600-A1 (US, and Canada) Left Side View:

VN1600-A1 (US, and Canada) Right Side View:

1-8 GENERAL INFORMATION

Model Identification

VN1600-A1 (Europe) Left Side View:

VN1600-A1 (Europe) Right Side View:

GENERAL

INFORMATION

1-9

General

Specifications

Dimensions:

Items

VN1600-A1

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

1 680 mm (66.1 in.)

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:

Front

156

kg

(345

lb)

Rear

181

kg

(399

lb),

(AU)

182

kg

(401

lb)

Fuel

tank

capacity

20 L (5.3 US gal)

Fuel

Unleaded and high-octane gasoline

Performance:

(see

VN1600-A1

Owner’s Manual)

Minimum

turning radius

3.5

m

(11.5

ft)

Engine:

Type

4-stroke, SOHC, V2-cylinder

Cooling

system

Liquid-cooled

Bore

and

stroke

102

×

95

mm

(4.02

× 3.74 in.)

Displacement

1

552

mL

(94.70

cu

in.)

Compression

ratio

9.0

:

1

Maximum

horsepower

49

kW

(67

PS) @ 4 700 r/min

(rpm),

(CA) (CAL) (US) –

Maximum

torque

127

N·m

(12.95

kgf·m,

93.7

ft·lb) @ 2

700

r/min

(rpm),

(CA)

(CAL)

(US)

–

Carburetion

system

DFI (Digital Fuel Injection) System

Starting

system

Electric

starter

Ignition

system

Battery

and

coil

(transistorized)

Timing

advance

Electronically

advanced

(digital)

Ignition

timing

From

0°

BTDC

@ 950

r/min

(rpm)25° BTDC

@ 4

500

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

22°

BTDC

Close

66°

ABDC

Duration

268°

Exhaust

Open

66°

BBDC

Close

26°

ATDC

Duration

272°

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)

1-10 GENERAL INFORMATION

General

Specifications

Drive

Train:

Items

VN1600-A1

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:

1st

2.500

(40/16)

2nd

1.590

(35/22)

3rd

1.192

(31/26)

4th

0.965

(28/29)

Final

drive

system: 5th

0.781

(25/32)

Type

Shaft

Reduction

ratio

2.619

(15/21

×

33/9)

Overall

drive

ratio

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

(6.76

US oz)

Frame:

Type

Tubular,

double

cradle

Caster

(rake angel)

32°

Trail

168 mm

(6.61

in.)

Front

tire:

Type

Tubeless

Size

130/90 - 16 M/C 67H

Rear

tire:

Type

Tubeless

Size

170/70B16 M/C

75H

Front

suspension:

Type

Telescopic

fork

Wheel

travel

150

mm

(5.91

in.)

Rear

suspension:

Type

Swingarm

Wheel

travel

95

mm

(3.74

in.)

Brake

Type:

Front

Dual

disc

Electrical

Equipment:Rear

Single

disc

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, twin rotor

Rated

output

42A × 14 V @ 6 000 r/min (rpm)

Specifications

are

subject to

change without

notice, and may not apply to every country.

AU:

Australia

CAL:

California

CA:

Canada

US:

United

States

of America

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	=	qt	(US)
L	×	0.8799	=	qt	(imp)
L	×	2.113	=	pint	(US)
L	×	1.816	=	pint	(imp)
mL	×	0.03381	=	oz	(US)
mL	×	0.02816	=	oz	(imp)
mL	×	0.06102	=	cu	in.
Units	of	Force:
N	×	0.1020	=	kgf
N	×	0.2248	=	lb
kg	×	9.807	=	N
kg	×	2.205	=	lb

Units of Temperature:

GENERAL INFORMATION 1-11

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	×	7.233	=	ft·lb
kgf·m	×	86.80	=	in·lb

Units	of	Pressure:
kPa	×	0.01020	=	kgf/cm²
kPa	×	0.1450	=	psi
kPa	×	0.7501	=	cm Hg
kgf/cm²	×	98.07	=	kPa
kgf/cm²	×	14.22	=	psi
cm Hg	×	1.333	=	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

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents	2

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......	2-15
Evaporative							Emission		Control
System						Inspection (CAL) ..........				2-15
Cooling System...............................										2-16
Radiator						Hose and			Connection
Inspection..................................										2-16
Coolant				Change ...........................						2-17
Engine			Top End..............................							2-19
Air	Suction						Valve	Inspection ........		2-19
Clutch..............................................										2-19
Clutch			Hose and					Connection
Inspection..................................										2-19
Clutch			Fluid				Level Inspection .......			2-20
Clutch			Fluid				Change		....................	2-20
Clutch Master Cylinder Cup and
Dust			Seal				Replacement ............			2-21
Clutch Slave Cylinder Piston Seal
Replacement ............................										2-22
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
Inspection..................................						2-27
Brake	Fluid		Level		Inspection........	2-27
Brake	Fluid		Change.....................			2-28
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		itchSw
Check/Adjustment .....................						2-30
Suspension		.....................................				2-30
Front Fork Oil Leak Inspection.....						2-30
Rear	Shock		Absorber l OiLeak
Inspection .................................						2-31
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

2-2 PERIODIC MAINTENANCE

Periodic Maintenance Chart
The scheduled maintenance must be done in accordance		with	this chart to keep the motorcycle in
good running conditionThe. initial maintenance is vitally important and must not be neglected.
FREQUENCY Whichever	1 000 km			* ODOMETER
comes	(600	mile)		READING
first	6	000	km
→	(4	000	mile)
↓		12	000	km
		(7	500	mile)

18 000

km

(12

000

mile)

24

000 km

(15

000

mile)

30 000

km

(20

000 mile)

36

000

km

(24

000

mile)

OPERATION

Every

• • • • •

•

See Page

Spark

plug (e)

- clean and

gap †

2–35

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

emission

control

system

(e)

•

•

•

•

•

•

•

2–17

(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 †

month

•

•

•

•

•

•

2–21,

2–29

Coolant hoses, connections - inspect †

•

•

2–18

Brake/clutch

fluid

- change

2 years

2–22,

2–30

	PERIODIC		MAINTENANCE 2-3
Periodic Maintenance Chart
FREQUENCY Whichever	1 000 km				* ODOMETER
comes	(600	mile)			READING
first	6	000		km
→	(4	000		mile)
↓		12		000	km
		(7	500		mile)

18

000

km

(12

000

mile)

24

000

km

(15

000

mile)

30

000 km

(20

000

mile)

36

000

km

(24

000

mile)

OPERATION

Every

See

Page

Brake/clutch

master

cylinder cup

and dust

4

years

2–23,

2–32

seal

- replace

•

Coolant

- change

2

years

2–28

Caliper

piston

seal

and

dust

seal - replace4

years

•

2–32

Steering stem bearing - lubricate

2

years

2–34

Clutch

slave cylinder piston seal - replace

4

years

2–24

#

:

Service

more

frequentlywhen 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.

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 The

table below, relating tightening torque to

for the

major

fasteners

requiring

use

of a

nonthread

diameter,

lists the basic

torque for

the

-permanent

locking

agent

or liquid

gasket.

bolts

and nuts. Use this table for

only the

bolts

and

nuts which do not require a specific torque

Letters

used in

the

“Remarks”

column mean:

value.

All

of

the values are for use with dry

L: Apply a

non-permanent locking

agent

to

solvent-cleaned

threads.

the

threads.

to

the

threads.

Basic Torque

for

General

Fasteners

G: Apply

grease

Threads

Torque

MO: Apply

molybdenum

disulfide

grease

oil

dia.

(mm)

N·m

kgf·m

ft·lb

solution.

O: Apply

oil

to

the

threads

and

seating

sur­

5

3.4

4.9

0.35

0.50

30

43 in·lb

face.

6

5.9

7.8

0.60

0.80

52

69 in·lb

S: Tighten

the

fasteners following

the

speci­

8

14 19

1.4 1.9

10.0

13.5

fied

sequence.

10

25

34

2.6

3.5

19.0

25

SS: Apply silicone

sealant.

Si: Apply silicone

grease (ex.

PBC

grease).

12

44

61

4.5

6.2

33

45

R: Replacement

parts

14

73

98

7.4

10.0

54

72

Lh: Left-hand-threads

16

115

155 11.5

16.0

83 115

St: Stake

the

fasteners

to

prevent loosening.

18

165

225

17.0

23.0

125

165

AL: Tighten

the

two

clamp

bolts

alternately

two

times

to

ensure

even

tightening

20

225

325

23

33

165

240

torque.

Fastener

Torque

Remarks

N·m

kgf·m

ft·lb

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 8bolt

16

1.6

12

Right air cleaner cover Allen 8bolt

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

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

8.3

0.85

74

in·lb

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

												PERIODIC		MAINTENANCE			2-5
Torque		and			Locking					Agent
					Fastener							Torque			Remarks
											N·m	kgf·m	ft·lb
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	11	1.1	95	in·lb	S
Chain		tensioner					cap				20	2.0	14		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	14		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		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		1.2	0.12	10	in·lb
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

2-6 PERIODIC MAINTENANCE

Torque

and

Locking

Agent

Fastener

Torque

Remarks

N·m

kgf·m

ft·lb

Engine

Lubrication

System:

Oil

filler

cap

1.5

0.15

13

in·lb

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:

10 mm

39

4.0

29

S

8 mm

21

2.1

15

S

6 mm

11

1.1

95

in·lb

S

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

11

1.1

95

in·lb

L

Connecting

rod

big

end

nuts

59

6.0

43

MO

Oil

pressure

relief

valve

15

1.5

11

L

Oil

filter

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 bolt2.9

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

pipe

clamp

bolts

(inside)

11

1.1

95

in·lb

L

														PERIODIC		MAINTENANCE 2-7
Torque			and				Locking			Agent
							Fastener							Torque			Remarks
													N·m	kgf·m	ft·lb
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	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
										8 mm			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	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	in·lb		L
Final gear case drain plug													8.8	0.9	78	in·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)													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

2-8 PERIODIC MAINTENANCE

Torque	and			Locking Agent
				Fastener							Torque			Remarks
										N·m	kgf·m	ft·lb
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		front
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