Kawasaki VULCAN 2000 (2003) User Manual [ru]

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VULCAN 2000

VN2000

Quick R eference 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 will assist you in locating a desired topic or procedure.

•Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page.

•Refer to the sectional table of contents for the exact pages to locate the specific topic required.

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 2000

VN2000

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

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

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

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

LIST OF ABBREVIATIONS

ABDC after bottom dead center m meter(s)

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

F farad(s) TDC top dead center

°F degree(s) Fahrenheit

ft foot, feet V volt(s)

h hour(s) Ω ohm(s)

kgf (force)

ampere(s)

alternating current min

direct current

gram(s) (mass)

(mass)

liter(s)

psi

r/min, rpm revolution(s) per minute

TIR total indicator reading

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 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 f leet of m otor 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 a s follows :

1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in o rder 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 RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL 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 incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:

Replacement of the original exhaust system or muffler with a component not in compliance

•

with Federal regulations.

Removal of the muffler(s) or any internal portion of the muffler(s).

•

Removal of the air box or air box cover.

•

Modifications to the muffler(s) or air inlet system by cutting, drilling, or other means if such

•

modifications result in increased noise levels.

Foreword

This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.

In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation.

For the duration of the warranty period,

we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty.

To get the longest life out of your vehicle:

Follow the Periodic 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 preparing this manual, we divided the product into its major systems. These systems became the manual’s chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter.

The Quick Reference Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents.

The Periodic Maintenance Chart is located in the Periodic Maintenance chapter. The chart gives a time schedule for required maintenance operations.

If you want spark plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, use the Quick Reference Guide to locate the Periodic Maintenance chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug section.

Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.

WARNING

This warning symbol identifies special

instructions or procedures which, if not

correctly followed, could result in per-

sonal injury, or loss of life.

CAUTION

This caution sym bol identifies special

instructions or procedures which, if not

strictly observed, could result in dam-

age to or destruction of equipment.

This m anual 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 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 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

Technical Information – Oxygen Sensor................................................................................. 1-11

Technical Information – Electric Solenoid Operated Decompressor ...................................... 1-16

Technical Information – Dual Balancer Shaft System............................................................. 1-17

Unit Conversion Table ............................................................................................................ 1-19

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 K AWASAKI. Gaskets, O rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.

Assembly Order

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

1-4 GENERAL INFORMATION

Before Servicing

Tightening Sequence

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 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, Or ing

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 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 r emoval 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 free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from right 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

VN2000-A1 (US, and Canada) Left Side View:

GENERAL INFORMATION 1-7

VN2000-A1 (US, and Canada) Right Side View:

1-8 GENERAL INFORMATION

Model Identification

VN2000-A1 (Europe) Left Side View:

VN2000-A1 (Europe) Right Side View:

GENERAL INFORMATION 1-9

General Specifications

Items VN2000-A1

Dimensions:

Overall length 2 535 mm (99.80 in.) Overall width 1 025 mm (40.35 in.), (AU) 985 mm (38.8 in.) Overall height 1 155 mm (45.47 in.) Wheelbase 1 735 mm (68.31 in.) Road clearance Seat height 680 mm (26.8 in.) Dry mass Curb mass: Front 176 kg (388 lb)

Rear 195 kg (429 lb) Fuel tank capacity 21 L (5.5 US gal) Fuel Unleaded and high-octane gasoline

Performance:

Minimum turning radius 3.2 m (10.5 ft)

Engine:

Type 4-stroke, OHV, V2-cylinder Cooling system Liquid-cooled Bore and stroke 103 × 123.2 mm (4.06 × 4.850 in.) Displacement Compression ratio 9.5 : 1 Maximum horsepower 76 kW (103 PS) @4 800 r/min (rpm), (CA) (CAL) (US) – Maximum torque 177 N·m (18.05 kgf·m, 130.6 ft·lb) @3 200 r/min (rpm),

Carburetion system DFI (Digital Fuel Injection) System Starting system Electric starter Ignition system Timing advance Electronically advanced (digital) Ignition timing Front From 13° BTDC @900 r/min (rpm) ~ 51° BTDC

Rear From 15° BTDC @900 r/min (rpm) ~ 51° BTDC

Spark plugs NGK IZFR6F-11 Cylinder numbering method Front to Rear, 1-2 Firing order 1-2 V alve timing:

Inlet

Exhaust Open 69° BBDC

Lubrication system Forced lubrication (semi-dry sump) Engine oil: Type

Open

Close 69° ABDC

Duration

Close 39° ATDC

Duration 288°

Viscosity SAE10W-40

Capacity

135 mm (5.32 in.)

340 kg (750 lb)

(see VN2000-A1 Owner’s Manual)

2 053 mL (125.3 cu in.)

(CA) (CAL) (US) –

Battery and coil (transistorized)

@4 000 r/min (rpm)

39° BTDC

288°

API SE, SF or SG class API SH or SJ class with JASO MA

5.5 L (5.8 US qt, when engine is completely disassembled and dry)

1-10 GENERAL INFORMATION

General Specifications

Items VN2000-A1

Drive Train:

Primary reduction system:

Type Chain

Reduction ratio Clutch type Wet multi disc Transmission:

Type 5-speed, constant mesh, return shift

Gear ratios: 1st 2.550 (51/20)

2nd 3rd 1.218 (39/32) 4th 5th 0.729 (27/37)

Final drive system:

Type Belt

Reduction ratio 2.744 (50/40 × 72/32), (EU) 2.455 (48/44 × 72/32)

Overall drive ratio 3.003 @ Top gear, (EU) 2.687 @ Top gear

Frame:

Type Tubular, double cradle Caster (rake angel) 32° Trail 182 mm (7.17 in.) Front tire: Type Tubeless

Size 150/80 - R16MC 71V

Rear tire: Type Tubeless

Size 200/60 - R16MC 79V

Front suspension: Type Telescopic fork

Wheel travel 150 mm (5.91 in.)

Rear suspension: Type Swingarm with mono-shock (non-link type)

Wheel travel

Brake Type: Front Dual disc

Rear

Electrical Equipment:

Battery Capacity 12 V 18 Ah Headlight: Type Semi-sealed beam

Bulb 12 V 65 W (quartz-halogen)

Tail/brake light 12 V 5/21 W Alternator: Type

Rated output 38A × 14 V @5 000 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 EU: Europe

1.500 (48/32)

1.629 (44/27)

0.939 (31/33)

100 mm (3.94 in.)

Single disc

12 V 55 W (quartz-halogen)

Three-phase AC

Technical Information – Oxygen Sensor

Overview

Kawasaki has adopted an oxygen sensor [A] for the European and California models in addition to the secondary air injection system and honeycomb catalyst. This helps Kasawaki keep the motorcycle with cleaner exhaust gas and cope with the emission regulations.

The oxygen sensor [A] is mounted above the exhaust manifold [B], w hereas the honeycomb catalyst is located inside the silencer in the downstream of the exhaust gas.

GENERAL INFORMATION 1-11

The oxygen sensor uses the substance called zirconia (ZrO

2). The electromotive force varies depending on the

density of the oxygen. The sensor measures the oxygen density of the exhaust gas to detect whether the air/fuel mixture is lean or rich in relation to the optimum air/fuel mixture.

When the ECU is in the oxygen sensor feedback mode, it controls combustion by making the fuel injection amount of the injector rich or lean through the signal from the sensor.

1-12 GENERAL INFORMATION

Technical Information – Oxygen Sensor

Construction and Operation

The oxygen sensor uses, a solid electrolyte called zirco-

nia.

An electrolyte is a substance that has positive (+) and

negative (−) ions and can move freely i n a liquid.

For explanation purposes, picture a solid electrolyte plate as a wall and chambers A and B are divided by this wall. If both sides of the wall have platinum electrodes with holes, the difference in oxygen density (weight) between chambers A and B will move the oxygen from the chamber of higher oxygen density to the chamber of lower oxygen density until the two chambers are about equal in density. What actually moves are the oxygen ions (−) through the wall of the solid electrolyte.

The higher-density-side chamber will receive the “Pt” electrode surface with holes on the solid electrolyte wall and will become minus the oxygen ions (O the O

2− ions reach the “Pt” electrode of the opposite side.

Since the result of this O “e

−” (just like “cells” w ork in a battery), voltage will be built

2− move also brings movement of

within the sensor.

2−). At this point,

The (conceptual) sectional view of the actual element in the oxygen sensor is shown. The sensor is exposed to exhaust gas. The shape of the sensor is tubular since the atmospheric side and exhaust gas side are parted by the wall. That means that the inside of this tubular solid electrolyte is the atmosphere side (higher oxygen density), and the outside of the tube faces the exhaust gas. The outside surface, which is in the stream of exhaust gases, has a coated layer of porous ceramic. Voltage is generated and can be measured because of the difference in oxygen density (positive and negative ions).

Technical Information – Oxygen Sensor

The sensor, uses the fresh air as the oxygen reference, and consists of a passageway to lead the fresh air inside the tubular element. Installed in this passageway is, a air permeable filter that allows the fresh air to pass through, but won’t allow moisture through. This keeps the sensor in touch with the atmosphere.

At a normal temperature, Zirconia (solid electrolyte) is an insulator and not able to sense the gases. Since the exhaust gas temperature does not become hot instantly, it takes sometime before the sensor starts to work. To solve the problem of the slow temperature increase of exhaust gases (which warms the electrolyte element), a built

-in heater located i nside the tubular element increases the temperature of the sensor so it can operate at a low exhaust gas temperature. Furthermore this built-in heater helps keep the sensor at a constant temperature.

GENERAL INFORMATION 1-13

Air/Fuel Ratio Control By Oxygen Sensor

”λ=1” indicates the optimum air/fuel ratio point, meaning the air/fuel ratio at which optimum (complete) combustion can be obtained. In the proximity of this mixture, the purification efficiency of the catalyst will be maximized.

The purification ratio of the three kinds of gas, HC (hydrocarbons), CO (carbon monoxide), Nox (nitrogen oxides) using the ternary (three) catalyst is shown in Fig. 4.

The best purification rate is at the zone where the oxygen sensor ’s signal shows the sharp changes. This zone is called the “window” and if the oxygen sensor signal moves back and forth between the rich side (fuel rich) and lean side (fuel lean) from the oprimum mix ratio (but still within the width of the window), it indicates that the exhaust gas is in a good purification rate zone.

1-14 GENERAL INFORMATION

Technical Information – Oxygen Sensor

Figure 5 shows how the sensor operates the controlling

factors.

There is a sharp voltage drop of about 1V (in reality, about

0.9 V) the sensor uses for control (a standard reference). By utilizing this voltage and using 0.45 V as the reference line, an output larger than the line indicates that exhaust gas is in the lean zone. So, when the system senses a “rich” condition through the sensor’s output voltage, it controls the fuel injection amount to make the fuel gradually leaner. When it reaches a leaner point, the sensor voltage signal drops sharply at the proximity λ=1 and goes below 0.45V. The system, at this level, senses that it has changed to “lean” and reverse the voltage signal to make the fuel richer. It then controls the fuel injection amount to make the fuel gradually richer. When it drops to a richer point, the signal drops sharply at the proximity λ=1 and goes over 0.45V. The system, at this level, senses that it has changed to “rich” and reverse the signal to make the fuel leaner. By having the signal repeat back and forth between the rich and lean sides, it can constantly stay within the window of the good purification rates. Thereby the oxygen sensor, works as a combustion control sensor for the optimum air/fuel ratio.

Technical Information – Oxygen Sensor

Maintenance

1) Periodic Inspections

Periodic inspections or special maintenance is not required for the sensor.

2) Oxygen Sensor Removal and Installation

Handle the oxygen sensor with care. Be careful not to damage sensor wires. Do not service the oxygen sensor while it is hot and not use an inpact wrench while removing or installing the oxygen sensor. Avoid the fouling (damaging) of the sensing part of the sensor with foreign substances such as coolant, battery fluid, anti-corrosion fluid, and brake fluid. Stop using the sensor if it is fouled with these substances. Also stop using the sensor if the head part of the sensor (exposed to the atmosphere) is fouled. Since the sensor has a filter that allows air to escape but stop water, fouling of the sensor head may clog this filter. Being subjected to a flame is also unacceptable for the sensor with the same reason as above.

3) Condition of the Sensor

Perform resistance measurements and visually check for scars, bends, and clogging of the sensor filter.

4) If trouble with the sensor occurs, one of the following

service codes will be displayed. Accordingly, follow the related procedures in the Service Manual for necessary maintenance.

GENERAL INFORMATION 1-15

Service Code Outline of trouble

33 Oxygen sensor is not activated

67 Heater trouble due to wiring short or open

Oxygen sensor output voltage is incorrect

1-16 GENERAL INFORMATION

Technical Information – Electric Solenoid Operated Decompressor

An automatic decompressor (Automatic Compression Reliese) system is installed to the right side of the engine. This decompressor is activated by an electric solenoid to make starting engine easy. When the ignition is switched on and the starter button depressed, the solenoid pulls a fulcrum-mounted link that depresses push rods in each camshaft.

The push rods activate the decompression mechanism to partially open the exhaust valves as the piston nears top dead center, releasing some of compression that can cause resistance during starting.

Releasing the starter button de-activates the solenoid and a spring returns the push rods to their normal operating position.

1. Decompression Solenoid

2. Decompression Lever

3. Decompression Push Rod

4. Holder

5. Decompression Shaft

6. Spring

7. Exhaust Cam

8. Push Rod

GENERAL INFORMATION 1-17

Technical Information – Dual Balancer Shaft System

Dual balancers harmonize primary balance and reduce

vibration.

The VN2000-A1 engine applied two balancer shafts, one [1] is located in front of the front cylinder and another one [2] is behind the rear cylinder.

Each balancer shaft is driven by the chain which driven to the counterclockwise by crankshaft sprocket that rotate to the clockwise viewed from the righr side.

The hydraulically operated chain tensioner is located between crankshaft and rear balancer shaft.

The hydraulic chain tensioner is supplied the oil pressure from lubrication feed pump.

Two chain guides applied, one is between the crankshaft and front balancer shaft and another is under the crankshaft sprocket.

1. Front Balancer Shaft

2. Rear Balancer Shaft

3. Front and Rear Balancer Sprocket

4. Balancer Drive Chain

5. Crankshaft

6. Balancer Drive Sprocket

7. Hydraulic Chain Tensioner

8. Chain Guide (under Crankshaft)

9. Chain Guide (between Crankshaft and Front Balancer Shaft)

1-18 GENERAL INFORMATION

Technical Information – Dual Balancer Shaft System

1. Front Balancer Shaft

2. Rear Balancer Shaft

3. Front and Rear Balancer Sprocket

4. Balancer Drive Chain

5. Crankshaft

6. Balancer Drive Sprocket

7. Hydraulic Chain Tensioner

8. Chain Guide (between Crankshaft and Front Balancer Shaft)

9. Chain Guide (under Crankshaft)

10. Front

11. Le f t

Unit Conversion Table

GENERAL INFORMATION 1-19

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 cm Hg × 1.333 = kPa

kgf/cm²

Units of Speed:

km/h × 0.6214 = mph

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................. 2-5

Specifications .................................... 2-11

Special Tools ..................................... 2-13

Periodic Maintenance Procedures..... 2-14

Steering System: ............................ 2-14

Steering Play Inspection .............. 2-14

Steering Play Adjustment............. 2-14

Steering Stem Bearing

Lubrication................................. 2-15

Brake System: ................................ 2-15

Brake Fluid Leak (Brake Hose

and Pipe)................................... 2-15

Brake Hose Damage and

Installation Connection

Inspection .................................. 2-16

Brake Operation Inspection ......... 2-16

Brake Fluid Level Inspection........ 2-16

Brake Pad Wear Inspection ......... 2-17

Brake Light Switch Operation ...... 2-17

Wheel and Tires:............................. 2-18

Tire Air Pressure Inspection......... 2-18

Wheel/Tire Damage Inspection.... 2-18

Tire Tread Wear Inspection.......... 2-18

Wheel Bearing Damage

Inspection .................................. 2-19

Suspensions ................................... 2-19

Front Forks/Rear Shock Absorber

Operation Inspection ................. 2-19

Front Fork Oil Leak Inspection..... 2-20

Rear Shock Absorber Oil Leak

Inspection ................................. 2-20

Swingarm Pivot Lubrication ......... 2-20

Clutch and Drive Train: ................... 2-21

Clutch Operation .......................... 2-21

Belt Deflection Inspection ........... 2-21

Belt Deflection Adjustment ........... 2-23

Wheel Alignment

Inspection/Adjustment............... 2-24

Belt Wear and Damage

Inspection .................................. 2-25

Electrical System: ........................... 2-27

Spark Plug Condition Inspection.. 2-27

Lights and Switches Operation .... 2-28

Headlight Aiming Inspection ........ 2-30

Side Stand Switch Operation

Inspection.................................. 2-31

Engine Stop Switch Operation

Inspection.................................. 2-32

Fuel System (DFI):.......................... 2-32

Throttle Control System

Inspection.................................. 2-32

Idle Speed Inspection .................. 2-33

Fuel Hose and Connection

Inspection.................................. 2-33

Cooling System............................... 2-34

Coolant Level Inspection.............. 2-34

Radiator Hose and Connection

Inspection.................................. 2-34

Evaporative Emission Control

System Inspection(CAL): ............. 2-35

Evaporative Emission Control

System Inspection..................... 2-35

Air Suction System: ........................ 2-36

Air Switching Valve Operation

Test............................................ 2-36

Others:............................................ 2-36

Chassis P arts Lubrication ............ 2-36

Bolts and Nuts Tightness

Inspection.................................. 2-37

Replacement Parts: ........................ 2-39

Brake Hose and Pipe

Replacement ............................. 2-39

Brake Fluid Change ..................... 2-39

Master Cylinder Rubber Parts

Replacement ............................. 2-41

Caliper Rubber Parts

Replacement ............................. 2-42

Spark Plug Replacement ............. 2-45

Air Cleaner Element

Replacement ............................. 2-46

Engine Oil Change....................... 2-47

Oil Filter Replacement ................. 2-49

Fuel Hose Replacement .............. 2-49

Coolant Change ........................... 2-50

Radiator Hose and O-ring

Replacement ............................. 2-53

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.

Periodic Inspection:

FREQUENCY Whichever

comes

first

1 6 12 18 24 30 36 See

INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) Page

Steering System:

* ODOMETER READING

× 1000 km

( × 1000 mile)

Steering play - inspect year

Steering stem bearing - lubricate 2 year

Brake System:

Brake fluid leak (brake hose and pipe)inspect

Brake hose damage - inspect year

Brake hose installation condition - inspect year

Brake operation (effectiveness, no drag) inspect

Brake fluid level - inspect 6 month

Brake pad wear - inspect #

Brake light switch operation - inspect

Wheels and Tires:

Tire air pressure - inspect year

Wheel/tire damage - inspect

Tire tread wear, abnormal wear - inspect

Wheel bearing damage - inspect year

Suspensions:

Front forks/rear shock absorber operation (smooth stroke) - inspect

Front forks/rear shock absorber oil leak inspect

year

• • • •

•

• • • • • • •

• • • • • •

• • • • • • •

• • •

2–14

2–15

2–16

2–17

2–18

2–19

2–20

Swingarm pivot - lubrication

Clutch and Drive Train:

Clutch operation (play, disengagement, engagement) - inspect

Belt deflection - inspect

Belt wear and damage - inspect

Electrical System:

Spark plug condition - Inspect

Lights and switches operation - inspect year

Headlight aiming - inspect year

Side stand switch operation - inspect year

Engine stop switch operation - inspect year

•

• • • •

• • • • • • •

• • •

2–20

2–21

2–24

2–27

2–28

2–30

2–31

2–32

Periodic Maintenance Chart

PERIODIC MAINTENANCE 2-3

FREQUENCY Whichever

comes

first

1 6 12 18 24 30 36 See

INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) Page

Fuel System:

Throttle control system (play, smooth return, no drag) - inspect

Idle speed - inspect

Fuel leak (fuel hose and pipe) - inspect year

Fuel hoses and pipe damage - inspect year

Fuel hoses and pipe installation condition

- inspect

Cooling System:

Coolant level - inspect

Coolant leak (radiator hose and pipe) inspect

Radiator hose and pipe damage - inspect year

Radiator hose and pipe installation condition - inspect

Evaporative Emission Control System (CAL):

Evaporative emission control system function - inspect

Air Suction System:

year

• • • •

• • • • • • •

* ODOMETER READING

× 1000 km

( × 1000 mile)

2–32

2–33

2–34

2–35

Air suction system damage - inspect

Others:

Chassis parts - lubricate year

Bolts and nuts tightness - inspect

# : 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.

(CAL): California

• • • •

• • •

2–36

2–37

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

Periodic Replacement Parts:

FREQUENCY Whichever

comes

first

1 12 24 36 48 See

CHANGE/REPLACE ITEM Every (0.6) (7.5) (15) (24) (30) Page

* ODOMETER READING

× 1000 km

( × 1000 mile)

Brake hoses and pipes 4 year

Brake fluid 2 year

Rubber parts of master cylinder and caliper 4 year

Spark plug

Air cleaner element #

Engine oil # year

Oil filter year

Fuel hose 4 year

Coolant 3 year

Radiator hose and O-ring 3 year

# : Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or

frequent starting/stopping.

* : For higher odometer readings, r epeat at the frequency interval established here.

• • • • •

• •

•

2–39

•

2–39

2–41

•

2–45

•

2–46

2–47

2–49

•

2–50

2–53

Torque and Locking Agent

PERIODIC MAINTENANCE 2-5

The following tables list the tightening torque

for the m ajor 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

the threads.

G: Apply grease to the threads.

MO: Apply molybdenum disulfide grease oil

solution.

O: Apply oil to the threads and seating sur-

face.

S: Tighten the fasteners following the speci-

fied sequence.

SS: Apply silicone sealant.

Si: Apply silicone grease (ex. PBC grease).

R: Replacement parts

Lh: Left-hand-threads

St: Stake the fasteners to prevent loosening.

AL: Tighten the two clamp bolts alternately

two times to ensure even tightening torque.

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 for 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 ~ 1 6 .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:

Fuel pump bolts 9.8 1.0 87 in·lb S, L

Water temperature sensor 12 1.2 104 in·lb

Oxygen sensor 44 4.5 33

Gear position switch mounting bolts 6.9 0.70 61 in·lb

Gear position switch lead clamp bolts 6.9 0.70 61 in·lb

Camshaft position sensor bolt 9.8 1.0 87 in·lb L

Fuel level sensor mounting bolts 6.9 0.70 61 in·lb L

Speed sensor mounting bolt 9.8 1.0 87 in·lb L

Delivery joint bolts 9.8 1.0 87 in·lb L

Throttle body assy holder bolts 9.8 1.0 87 in·lb L

Inlet manifold bolts 9.8 1.0 87 in·lb L

Air cleaner housing bolts 9.8 1.0 87 in·lb

Air cleaner housing Allen bolts 9.8 1.0 87 in·lb

Cooling System:

Water temperature sensor 12 1.2 104 in·lb

Water pipe bolts 9.8 1.0 87 in·lb

Radiator fan bolts 8.3 0.85 74 in·lb

Reserve tank bolts 6.9 0.70 61 in·lb

Radiator cover bolts 11 1.1 97 in·lb

Water pum p impeller bolt 12 1.2 104 in·lb Lh

Water pipe drain bolt 9.8 1.0 87 in·lb

Water pump air bleeder bolt 7.8 0.80 69 in·lb

Radiator screen screws 6.9 0.70 61 in·lb

Torque

Remarks

2-6 PERIODIC MAINTENANCE

Torque and Locki ng Agent

Fastener

N·m kgf·m ft·lb

Engine Top End:

Rocker case cover bolts 12 1.2 104 in·lb S, AL

Rocker case bolts 15 1.5 11 S

Oil pipe banjo bolts 54 5.5 40

Oil pipe bolts 9.8 1.0 87 in·lb

Upper cylinder head nuts, φ10 mm 15 1.5 11 first, S, MO Upper cylinder head nuts, φ10 mm 29 3.0 21 final, S, MO Upper cylinder head nuts, φ12 mm 29 3.0 21 first, S, MO Upper cylinder head nuts, φ12 mm 88 9.0 65 final, S, MO

Lower cylinder head nuts 25 2.5 18 S

Water jacket plugs 22 2.2 16 L

Water jacket plugs 15 1.5 11 L

Rocker shaft bolts 12 1.2 104 in·lb

Cylinder mounting bolts 25 2.5 18 L

Coolant drain bolt 9.8 1.0 87 in·lb

Push rod cover bolts 12 1.2 104 in·lb

Camshaft chain guide bolts 12 1.2 104 in·lb L

Torque

Remarks

Camshaft chain tensioner bolts 12 1.2 104 in·lb

Inner camshaft cover bolts 12 1.2 104 in·lb

Stopper pin plug 2.5 0.25 22 in·lb L

Middle camshaft cover bolts 12 1.2 104 in·lb

Middle camshaft cover bolts L 35 mm 12 1.2 104 in·lb

Camshaft end cover bolts 12 1.2 104 in·lb

Decompression solenoid bolts 9.8 1.0 87 in·lb

Outer camshaft cover bolts 12 1.2 104 in·lb

Muffler bracket bolts 25 2.5 18

Muffler cover clamp screws 6.9 0.7 61 in·lb

Clutch:

Primary chain upper guide bolts 9.8 1.0 87 in·lb

Primary chain lower guide bolts 9.8 1.0 87 in·lb

Cam damper bolt 69 7.0 51

Inner clutch cover bolts 12 1.2 104 in·lb S, see text

Outside plate bolt 9.8 1.0 87 in·lb L

Clutch hub nut 135 14.0 101 MO

Clutch spring bolts 98 1.0 87 in·lb

Outer clutch cover bolts 12 1.2 104 in·lb S, see text

Plug on outer clutch cover 20 2.0 14

Clutch cover oil drain plug 21 2.1 15

Clutch release lever bolt 5.9 0.60 52 in·lb

Starter lockout switch screw – – – L

Inside plate bolt 9.8 1.0 87 in·lb

Torque and Locking Agent

PERIODIC MAINTENANCE 2-7

Fastener

N·m kgf·m ft·lb

Engine Lubrication System:

Rocker shaft oil pipe bolts 98 1.0 87 in·lb

Cylinder head oil pipe banjo bolts 54 5.4 40

Oil filter 17.5 1.75 12.5

Oil passage bolt 29 3.0 21

Oil passage adapter drain plug 9.8 1.0 87 in·lb

Relief valve 15 1.5 11 L

Camshaft oil pipe bolt 9.8 1.0 87 in·lb

Oil pipe bolt L16 9.8 1.0 87 in·lb L

Oil pipe bolt L30 12 1.2 104 in·lb

Oil pump drive sprocket bolt 29 3.0 21

Oil pump chain tensioner bolt 12 1.2 104 in·lb

Oil pump cover bolts 9.8 1.0 87 in·lb

Inside plate bolt 9.8 1.0 87 in·lb

Outside plate bolt 9.8 1.0 87 in·lb L

Clutch cover drain plug 21 2.1 15

Oil pressure switch 15 1.5 11 SS

Oil passage adapter 20 2.0 14 L

Oil pan plug 20 2.0 14 L

Oil pipe stopper bolt 6.9 0.7 61 in·lb

Oil screen bolt for crank room 9.8 1.0 87 in·lb

Oil pan bolts 15 1.5 11 S

Left oil pan drain plug 20 2.0 14

Right oil pan drain plug 15 1.5 11

Engine Removal/Installation:

Front downtube nuts 88 9.0 65 S, AL

Upper adjusting bolt 9.8 1.0 87 in·lb S

Lower adjusting bolt 9.8 1.0 87 in·lb S

Upper adjusting bolt locknut 49 5.0 36 S

Lower adjusting bolt locknut 49 5.0 36 S

Upper rear engine mounting nut 59 6.0 43 S

Lower rear engine mounting nut 59 6.0 43 S

Upper engine bracket nuts 59 6.0 43 S, AL

Upper engine mounting bolts 44 4.5 33 S

Lower engine bracket bolts 59 6.0 43 S

Front engine mounting nut 44 4.5 33 S

Rear downtube bolts14 108 11.0 80 S, AL

Crankshaft/Transmission:

Connecting rod big end bolts 59 6.0 43 MO

Balancer chain sprocket nut 125 13.0 92.2 MO

Camshaft chain sprocket bolt 29 3.0 22

Camshaft balancer gear bolts 83 8.5 61

Torque

Remarks

2-8 PERIODIC MAINTENANCE

Torque and Locki ng Agent

Fastener

N·m kgf·m ft·lb

Upper balancer chain guide bolts 12 1.2 104 in·lb

Lower balancer chain guide bolts 12 1.2 104 in·lb

Balance chain tensioner bolts 12 1.2 104 in·lb

Bearing retainer screws at output shaft 6.9 0.7 61 in·lb

Bearing retainer bolts – – – L

Speed sensor bolt 9.8 1.0 87 in·lb L

Bearing retainer screws at pulley s haft 6.9 0.7 61 in·lb

Crankcase bolts, φ8 29 3.0 22 S Crankcase bolts, φ6 12 1.2 104 in·lb S

Outer transmission cover bolts 12 1.2 104 in·lb S,see text

Inner transmission cover bolts 12 1.2 104 in·lb S,see text

Transfer gear nut (Output shaft) 196 20.0 145 MO, Lh

Transfer gear nut (Pulley shaft) 78 8.0 58 MO

Gear set lever nut 7.8 0.8 69 in·lb

Shift shaft return spring pin 39 4.0 30 L

Rear shift lever bolt 25 2.5 18

Front shift lever clamp bolt 25 2.5 18

Shift dram cam bolt 12 1.2 104 in·lb L

Rear shift rod locknut 9.8 1.0 87 in·lb Lh

Front shift rod locknut 9.8 1.0 87 in·lb

Engine pulley mounting nut 177 18 130 MO

Wheels/Tires:

Front axle nut 127 13 94

Front axle clamp bolts 20 2.0 15 AL

Rear axle nut 108 11 80

Tire air valve nuts 1.5 0.15 13 in·lb

Tire air valve cap 0.15 0.015 1.3 in·lb

Final Drive:

Engine pulley inside cover bolts 12 1.2 104 in·lb

Engine pulley mounting nut 177 18 130 MO

Rear axle nut 108 11 80

Rear coupling stud bolts 44 4.5 33 L

Ring screws 6.9 0.70 61 in·lb

Rear pulley mounting nuts 69 7.0 51

Brakes:

Brake hose banjo bolts 25 2.5 18

Front brake reservoir cap screws 1.5 0.15 13 in·lb

Brake lever pivot bolt 1.0 0.10 8.7 in·lb Si

Brake lever pivot bolt locknut 5.9 0.60 52 in·lb

Front brake light switch screw 1.2 0.12 10 in·lb

Front master cylinder clamp bolts 8.8 0.90 78 in·lb S

Brake disc bolts 27 2.8 20 L

Torque

Remarks

Torque and Locking Agent

PERIODIC MAINTENANCE 2-9

Fastener

N·m kgf·m ft·lb

Front caliper mounting bolts 25 2.5 18

Front caliper assembly bolts 21 2.1 15

Front brake pad pins 15 1.5 11

Caliper bleed valves 7.8 0.80 69 in·lb

Front brake pad spring bolts 2.9 0.30 26 in·lb

Rear master cylinder mounting bolts 25 2.5 18

Rear master cylinder push rod locknut 17 1.7 12

Brake pedal clamp bolt 25 2.5 18

Rear caliper mounting bolts 34 3.5 25

Suspension:

Upper front fork clamp bolts 20 2.0 15

Lower front fork clamp bolts 34 3.5 25 AL

Cover stopper bolts 4.2 0.43 37 in·lb

Front axle clamp bolts 25 2.5 18 AL

Front fork bottom Allen bolts 23 2.3 17 L

Rear shock absorber mounting bolt and nut 59 6.0 43

Swingarm pivot shaft nut 127 13 94

Steering:

Handlebar clamp bolts 34 3.5 25 O, S

Handlebar holder nuts 34 3.5 25

Steering stem head nut 108 11 80

Upper front fork clamp bolts 20 2.0 15

Steering stem nut 4.9 0.50 43 in·lb

Lower front fork clamp bolts 34 3.5 25 AL

Frame:

Front downtube nuts 88 9.0 65 S

Upper engine bracket nuts 59 6.0 43 S

Upper engine mounting bolts 44 4.5 33 S

Lower engine bracket bolts 59 6.0 43 S

Rear downtube bolts 108 11 80 S

Side stand mounting bolt 44 4.5 33 S

Side stand m ounting nut 44 4.5 33 S

Adjust bolts 9.8 1.0 87 in·lb S

Footboard bracket bolts 34 3.5 25

Front engine mounting nut 44 4.5 33 S

Adjusting bolt locknuts 49 5.0 36 S

Rear engine mounting nuts 59 6.0 43 S

Side stand switch mounting bolt 8.8 0.90 78 in·lb L

Footpeg bracket bolts 25 2.5 18

Muffler bracket mounting bolts 25 2.5 18

Electrical System:

Spark plugs 18 1.8 13

Torque

Remarks

2-10 PERIODIC MAINTENANCE

Torque and Locki ng Agent

Fastener

N·m kgf·m ft·lb

Alternator stator coil mounting bolts 12 1.2 104 in·lb L

Crankshaft sensor mounting bolts 6.9 0.70 61 in·lb

Oil pressure switch 15 1.5 11 SS

Speed sensor mounting bolt 9.8 1.0 87 in·lb L

Gear position switch mounting bolts 4.9 0.50 43 in·lb L

Gear position switch lead clamp bolts 4.9 0.50 43 in·lb L

Side stand switch mounting bolt 8.8 0.90 78 in·lb L

Regulator/rectifier bolts 8.8 0.90 78 in·lb

Oxygen sensor 44 4.5 33

Water temperature sensor 12 1.2 104 in·lb

Camshaft position sensor bolt 9.8 1.0 87 in·lb L

Decompression solenoid bolts 9.8 1.0 87 in·lb

Starter lockout switch screw 1.2 0.12 10 in·lb

Front brake light switch screw 1.2 0.12 10 in·lb

Fuel level sensor mounting bolts 6.9 0.70 61 in·lb L

Fuel pump mounting bolts 9.8 1.0 87 in·lb L, S

Starter motor terminal nut 9.8 1.0 87 in·lb

Starter motor terminal locknut 11 1.1 95 in·lb

Starter motor mounting bolts 9.8 1.0 87 in·lb

Starter motor assembly bolts 4.9 0.50 43 in·lb

Turn signal light lens screws 1.0 0.10 8.7 in·lb

Front turn signal light screws 6.9 0.70 61 in·lb

Tail/brake light unit mounting nuts 5.9 0.60 52 in·lb

Rear turn signal light screws 6.9 0.70 61 in·lb

License plate light lens mounting screws 1.2 0.12 10 in·lb

Torque

Remarks

PERIODIC MAINTENANCE 2-11

Specifications

Item Standard Service Limit

Fuel System (DFI):

Throttle grip free play 2 ~ 3 mm (0.08 ~ 0.12 in.) –––

Idle speed 900 ± 50 r/min (rpm) –––

Air cleaner element Viscous paper element –––

Cooling System:

Coolant:

Type (recommended) Permanent type antifreeze –––

Color Green –––

Mixed ratio Soft water 50%, Coolant 50% –––

Freezing point –35°C (–31°F) –––

Total amount 2.5L(2.6USqt) –––

Engine Top End:

Valve clearance Non-adjustable (hydraulic lash adjusters) –––

Clutch:

Clutch lever free play 2 ∼ 3mm(0.08∼ 0.12 in.) –––

Engine Lubrication System:

Engine oil:

Type API SE , SF or SG –––

API SH or SJ with JASO MA

Viscosity

SAE 10W-40

Capacity 4.4 L (4.7 US qt, when filter –––

is not removed)

4.6 L (4.9 US qt, when filter –––

is removed)

5.5 L (5.8 US qt, when engine –––

is completely disassembled and dry)

Level Between upper and lower level lines –––

(Wait 2 ~ 3 minutes after idling

or running)

Tires:

Tread depth:

Front BRIDGESTONE BATTLAX BT020F 1mm(0.04in.),

4.3 mm (0.17 in.) (DE,AT,CH):1.6mm

Rear BRIDGESTONE BATTLAX BT020R Up to 130 km/h (80 mph):

7.0 mm (0.28 in.) 2 mm (0.08 in.)

Over 130km/h (80mph):

3mm(0.1in.)

Air pressure: ( when cold)

Front

Up to 186 kg (410 lb) load: 250 kPa –––

(2.5 kgf/cm², 36 psi)

Rear Up to 186 kg (410 lb) load: 290 kPa –––

(3.0 kgf/cm², 42 psi)

–––

(0.063 in.)

2-12 PERIODIC MAINTENANCE

Specifications

Item Standard Service Limit

Final Drive:

Drive belt deflection: –––

(44.1 N, 4.5 kgf, 10 lb force) 2.5 ~ 4.0 mm (0.10 ~ 0.16 in.) –––

when installing new belt or engine remounted

Brakes:

Brake fluid

Grade DOT4

Brake pad lining thickness:

Front 4.0 mm (0.16 in.) 1 mm (0.04 in.)

Rear

Brake light timing:

Front Pulled ON –––

Rear

Electrical System:

Spark plug IZFR6F-11 –––

Spark plug gap 1.0 ~ 1.1 mm (0.039 ~ 0.043 in.) –––

2.5 mm (0.10 in.)

7.5 mm (0.30 in.) 1 mm (0.04 in.)

ON after about 10 mm (0.39 in.) of pedal travel

–––

AT: Republic of Austria

CH: Swiss Confederation

DE: Federal Republic of Germany

Special Tools

PERIODIC MAINTENANCE 2-13

Inside Circlip Pliers: 57001–143

Steering Stem Nut Wrench: 57001–1100

Jack: 57001–1238

Spark Plug Wrench, Hex 16: 57001–1262

Jack Attachment : 57001–1571

Drive Belt Tension Gauge: 57001– 1585

Oil Filter Wrench: 57001–1249

2-14 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Steering System:

Steering Play Inspection

Check steering as follows.

•

Use the jack [A] and jack attachment [B] under the frame

○

pipe, and a commercially available jack [C] under the engine to lift the front wheel off the ground.

Special Tools - Jack: 57001-1238

Jack Attachment: 57001-1571

With the front wheel pointing straight ahead, alternately

○

tap each end of the handlebar. The front wheel should swing fully right and left from the force of gravity until the fork hits the stop. If the wheel binds or catches before the stop, the steering is too tight.

Feel for steering looseness by pushing and pulling [A] the

○

fork. If you feel looseness, the steering is too loose.

NOTE

The cables and wiring will have some effect on the mo-

○

tion of the fork which must be taken into account. Be sure the wires and cables are properly routed. The bearings must be in good condition and properly

○

lubricated in order for any test to be valid.

Steering Play Adjustment

Adjust the steering, if necessary. Remove:

•

Nacelle (see Frame chapter) Handlebar (see Steering chapter) Stem Head Nut [A] Washer

Loosen the upper fork clamp bolts on both sides.

•

Remove:

•

O-ring [A] Steering Stem Head [B]

Periodic Maintenance Procedures

Remove the claw washer.

•

Adjust the stem nut [A] with the stem nut wrench [B] by

•

tightening to the specified torque.

Special Tool - Steering Stem Nut Wrench: 57001-1100

Torque - Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb)

Install the stem head.

•

Tighten the following in the order listed.

•

Torque - Stem Head Nut: 108 N·m (11 kgf·m, 80 ft·lb)

Upper Fork Clamp Bolts: 20 N·m (2.0 kgf·m, 15

in·lb)

Run the throttle cables, brake hose, and clutch cable in

○

accordance with the Cable, Wire, and Hose Routing section in the Appendix chapter. Check and adjust the steering and throttle cables after

•

installation.

WARNING

Do not attempt to ride the m otorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc. The brakes will not function on the first application of the lever if this is not done.

PERIODIC MAINTENANCE 2-15

Steering Stem Bearing Lubrication

Remove the steering stem. (see Steering chapter).

•

Using a high-flash point solvent, wash the upper and

•

lower tapered roller bearings [A] in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean of grease and dirt. Visually check the outer races and the rollers.

•

If the rollers or races are worn, or if either race is dented, replace both races and all the roller bearings as a set (see Steering chapter). Pack the upper and lower tapered roller in the cages with

•

grease, and apply a light coat of grease to the upper and lower outer races. Install the steering stem, and adjust the steering (see

•

Steering chapter).

Brake System:

Brake Fluid Leak (Brake Hose and Pipe)

Apply the brake lever or pedal and inspect the brake fluid

•

leak from the brake hoses [A] and fitting. If the brake fluid leaked from any position, inspect or replace the problem part.

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Brake Hose Damage and Installation Connection Inspection

Inspect the brake hose and fittings for deterioration,

•

cracks and signs of leakage. Thehighpressureinsidethebrakelinecancausefluidto

○

leak [A] or t he hose to burst if the line is not properly maintained. Bend and twist the rubber hose while examining it. Replace the hose if any cracks [B], bulges [C] or leakage are noticed. Tighten any banjo bolts.

Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18

ft·lb)

Inspect the brake hose routing.

•

If any brake hose routing is incorrect, route the brake hose according to Cable, Wire and Hose Routing section in the Appendix chapter.

Brake Operation Inspection

Inspect the operation of the front and rear brake by run-

•

ning the vehicle on the dry road. If the brake operation is insufficiency, inspect the brake system.

WARNING

When inspecting by running the vehicle, note a surrounding traffic situation enough in the place of safety.

Brake F luid Level Inspection

Check that the brake fluid level in the front brake reservoir

•

[A] is above the lower level line [B].

NOTE

Hold the reservoir horizontal by turning the handlebar

○

when checking brake fluid level.

If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [A] in the reservoir [B].

Periodic Maintenance Procedures

Check that the brake fluid level in the rear brake reservoir

•

[A] is between the upper [B] and the lower [C] level lines. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line. Use extra heavy-duty brake fluid only from a container

○

marked DOT4. Brake fluid of DOT4 is installed in the brake system when

○

shipped.

T orque - Front Brake Reservoir Cap Screws: 1.5 N·m (0.15

kgf·m, 13 in·lb)

WARNING

Do not mix two brands of fluid. Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unidentified. After changing the fluid, use only the same type and brand of fluid thereafter.

PERIODIC MAINTENANCE 2-17

Brake Pad Wear Inspection

Check the lining thickness [A] of the pads in each caliper.

•

If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set (see Brakes chapter).

Pad Lining Thickness

Standard:

Front: Rear:

Service Limit: 1 mm (0.04 in.)

Brake Light Switch Operation

Turn on the ignition switch.

•

The brake light [A] should go on when the brake lever is

•

applied or after the brake pedal is depressed about 10 mm (0.39 in.).

If it does not, adjust the brake light switch. While holding the switch body, turn the adjusting nut to

•

adjust the switch.

Switch Body [A] Adjusting Nut [B] Light sooner as the body rises [C] Light later as the body lowers [D]

4.0 mm (0.16 in.)

7.5 mm (0.30 in.)

CAUTION

To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment.

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

If it does not go on, inspect or replace the following item.

Battery (see Electrical System chapter) Brake Light Bulb (see Electrical System chapter) Main Fuse 30 A and Taillight Fuse 10 A (see Electrical System chapter) Front Brake Light Switch [A] ( see Electrical System chapter) Rear Brake Light Switch (see Electrical System chapter) Harness (see Wiring Inspection in Electrical System chapter)

Wheel and Tires:

Tire Air Pressure Inspection

Measure the tire air pressure with an air pressure gauge

•

[A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours.) Adjust the tire air pressure according to the specifications if necessary.

Air Pressure (when cold)

Front Upto186kg(410lb) 250 kPa (2.5 kgf/cm², 36 psi)

Rear

Upto186kg(410lb) 290 kPa (3.0 kgf/cm², 42 psi)

WARNING

To ensure safe handling and stability, use only the recommended standard tires for replacement, inflated to the standard pressure. Use the same manufacture’s tires on both front and rear wheels.

NOTE

Most countries may have their own regulations requiring

○

a minimum tire tread depth; be sure to follow them. Check and balance the wheel when a tire is replaced

○

with a new one (see Wheels/Tires chapter).

Wheel/Tire Damage Inspection

Remove any imbedded stones [A] or other foreign parti-

•

cles [B] from tread. Visually inspect the tire for cracks and cuts replacing the

•

tire in case of damage. Swelling or high spots indicate internal damage, requiring tire replacement. Visually inspect the wheel for cracks, cuts and dents dam-

•

age. If any damage is found, replace the wheel if necessary.

Tire Tread Wear Inspection

As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn). So it is false economy and unsafe to use the tires until they are bald.

Periodic Maintenance Procedures

Measure the tread depth at the center of the tread with a

•

depth gauge [A]. Since the tire may wear unevenly, take measurement at several places. If any measurement is less than the service limit, replace the tire (see Wheels/Tires chapter).

Tread Depth

Front:

Standard: 4.3 mm (0.17 in.) Service Limit: 1 mm (0.04 in.)

(DE, AT, CH) 1.6 mm (0.063 in.)

Rear:

Standard: 7.0 mm (0.28 in.) Service Limit: 2 mm (0.08 in.):

Up to 130 km/h (80 mph)

3mm(0.1in.):

Over to 130 km/h (80 mph)

Wheel Bearing Damage Inspection

Using a jack and attachment, raise the front wheel off the

•

ground (see Wheels/Tires chapter). Turn the handlebar all the way to the right or left.

•

Inspect the roughness of the front wheel bearing by push-

•

ing and pulling [A] the wheel. Spin [B] the front wheel lightly, and check for smoothly

•

turn, roughness, binding or noise. If roughness, binding or noise is found, remove the front wheel and inspect the wheel bearing (see Wheels/Tires chapter).

PERIODIC MAINTENANCE 2-19

Using a jack and attachment, raise the rear wheel off the

•

ground (see Wheels/Tires chapter). Inspect the roughness of the rear wheel bearing by push-

•

ing and pulling [A] the wheel. Spin [B] the rear wheel lightly, and check for smoothly

•

turn, roughness, binding or noise. If roughness, binding or noise is found, remove the rear wheel and inspect the wheel bearing (see Wheels/Tires chapter) and coupling (see Final Drive chapter).

Suspensions

Front Forks/Rear Shock Absorber Operation Inspection

Pump the forks down and up [A] 4 or 5 times, and inspect

•

the smooth stroke. If the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (see Suspension chapter).

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Pump the seat down and up [A] 4 or 5 times, and inspect

•

the smooth stroke.

If the shock absorber does not smoothly or noise is found,

inspect the oil leak (see Rear Shock Absorber Oil Leak

Inspection) or shock absorber clamps (see Suspension

chapter).

Front Fork Oil Leak Inspection

Visually inspect the front forks [A] for oil leakage.

•

Replace or repair any defective parts, if necessary.

Rear Shock Absorber Oil Leak Inspection

Remove:

•

Seats (see Frame chapter) Battery Cover

Visually inspect the shock absorber [A] for oil leakage.

•

If it is oil leaked, replace the shock absorber.

Swingarm Pivot Lubrication

Remove the swingarm (see Suspension chapter).

•

Clean the old grease out of the bearings.

•

Apply grease to the inner surface of the needle bearings

•

[A].

Apply a thin coat of grease to the lips [B] of the grease

•

seals.

Install the swingarm (see Suspension chapter).

•

Periodic Maintenance Procedures

Clutch and Drive Train:

Clutch Operation

Pull the clutch lever just enough to take up the free play

•

[A]. Measure the gap between the lever and the lever holder.

•

If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully. In either case, adjust it.

Clutch Lever Free Play

Standard: 2 ∼ 3mm(0.08∼ 0.12 in.)

WARNING

To avoid a serious burn, never touch the or exhaust pipe during clutch adjustment.

Loosen the locknut [A] at the clutch lever.

•

Turn the adjuster [B] until the proper amount of clutch

•

lever free play is obtained. Tighten the l ocknut securely.

•

If it cannot be done, use the adjuster at the middle of the cable.

PERIODIC MAINTENANCE 2-21

Loosen the locknut [A] at the middle of the clutch cable.

•

Turn the adjusting nut [B] until the proper amount of clutch

•

lever free play is obtained. Tighten the l ocknut securely.

•

WARNING

Be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever, or it could slip into place later, creating enough cable play to prevent clutch disengagement.

After the adjustment, start the engine and check that the

•

clutch does not slip and that it releases properly.

Belt Deflection Inspection

NOTE

Belt deflection must be checked and adjusted when the

○

belt is cold (at room temperature). Belt deflection also should be checked at first 1000 km

○

ride after belt replacement.

Check to see if wheel alignment is properly adjusted.

•

The left and right notches on the belt adjuster should point

○

to the same marks or positions on the swingarm. If they do not, adjust wheel alignment (see Wheel Alignment Inspection/Adjustment).

2-22 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Using the jack and jack attachment under the frame pipe

•

ribs, lift the rear wheel off the ground (see Rear Wheel

Removal in the Wheels/Tires chapter).

Visually inspect the belt for damage (see Belt Wear and

•

Damage Inspection).

If the belt is damaged, replace it with a new one.

Mark the initial belt position [C] on the belt cover window.

•

Using the tension gauge [A], push up 45 N (4.5 kgf, 10

•

lb) of force from under and on the center of the belt at the

gauge of the lower belt cover [B].

Measure the deflection (length between mark [D] and [C])

•

of the belt.

NOTE

Push the belt by the gauge until the top surface [A] of

○

the stopper comes to the 45 N l oaded scale [B], marked “45N”. Push up on the center of the belt. An inaccurate reading

○

will occur if the edge of the belt is pushed up. Look parallel to the belt during inspection. An inaccu-

○

rate reading will occur if looking from any other angle.

Inspect the belt deflection at two positions by rotating the

•

rear wheel.

Special Tools - Drive Belt Tension Gauge: 57001-1585

Inspect the drive belt deflection at arbitrary position, and

•

record the value [A].

Turn the rear wheel 90 degrees.

•

Periodic Maintenance Procedures

Inspect the drive belt deflection, and record the value [B].

•

Decide the belt deflection at the position [C] of one where

•

deflection is large.

PERIODIC MAINTENANCE 2-23

Drive Belt Deflection (with 45 N, 4.5 kgf, 10 lb force)

Standard: 2.5 ~ 4.0 mm (0.10 ∼ 0.16 in.)

Drive Belt Deflection (with 45 N, 4.5 kgf, 10 lb force, when installing new belt or engine remounted)

Standard: 2.5 mm (0.10 in.)

If the deflection is out of the specification, adjust it.

Belt Deflection Adjustment

Remove:

•

Muffler Body (see Engine Top End chapter) Upper Belt Cover

Remove the axle cotter pin, and loosen the axle nut.

•

Using the jack and jack attachment under the frame pipe

•

ribs, lift the rear wheel off the ground (see Rear Wheel Removal in the Wheels/Tires chapter).

Loosen the left and right belt adjuster locknuts [A].

•

If the belt is too tight, back out the left and right belt adjuster nuts [B], and kick the wheel forward until the belt is too loose. Turn in the left and right belt adjuster nuts evenly until the

•

drive belt has the correct amount of deflection. To keep the belt and wheel aligned, the notch on the left

○

belt adjuster should align with the same s wingarm mark [C] that the right belt adjuster notch aligns with.

2-24 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Tighten both belt adjuster locknuts.

•

WARNING

Misalignment of the wheel will result in abnormal

wear, and may result in an unsafe riding condition.

Tighten both belt adjuster locknuts, and make sure

the axle stays aligned.

Tighten the axle nut.

•

Torque - Rear Axle Nut: 108 N·m (11 kgf·m, 80 ft·lb)

Inspect the drive belt deflection (see Drive Belt Deflection

•

Inspection).

Readjust if necessary.

Insert a new cotter pin [A].

•

NOTE

When inserting the cotter pin, if the slots in the nut do

○

not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment. It should be within 30 degree.

○

Loosen once and tighten again when the slot goes past

○

the nearest hole.

Bend the cotter pin [A] over the nut.

•

WARNING

If the rear axle nut is not securely tightened or the

cotter pin is not installed, an unsafe riding condi-

tion may result.

Check the rear brake for weak braking power and brake

•

drag.

Wheel Alignment Inspection/Adjustment

Check that the notch [A] on the left belt adjuster [B] aligns

•

with the same swingarm mark [C] or position that the right

belt adjuster notch aligns with.

If they do not, adjust the belt deflection (see Belt Deflec-

tion Adjustment) and align the wheel alignment.

NOTE

Wheel alignment can be also checked using the

○

straightedge or string method.

WARNING

Misalignment of the wheel will result in abnormal

wear, and may result in an unsafe riding condition.

Periodic Maintenance Procedures

Belt Wear and Damage Inspection

Using the jack and jack attachment under the frame pipe

•

ribs, lift the rear wheel off the ground (see Rear Wheel Removal in the Wheels/Tires chapter). Remove:

•

Bolts [A] and Washers Upper Belt Cover [B]

Visually inspect the belt [A] for wear and damage.

•

If the nylon fabric facing of any portion is worn off, and the polyurethane compound is exposed, or belt is damaged, replace the belt immediately with a new one. Otherwise, refer to the Drive Belt Tooth Wear Patterns

•

and perform the according to the table of Drive Belt Wear Analysis. Whenever the belt is replaced, inspect the engine and rear pulleys (see Pulley Wear Inspection in Final D rive chapter).

PERIODIC MAINTENANCE 2-25

WARNING

A belt worn past the nylon fabric facing m ust be replaced. Such a worn belt may cause a serious accident.

2-26 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Drive Belt Tooth Wear and Damage Patterns

A. Belt Cross Section B. Edge Bevel Wear C. Rub Wear D. Stone

PERIODIC MAINTENANCE 2-27

Periodic Maintenance Procedures

Drive Belt Wear and Damage Analysis

Pattern Condition Required Action

1 Internal tooth cracks (slight)

2 Scuffing to side of teeth

3 Fraying edge cord

4 Beveled wear

5 External tooth cracks (severe) Replace the drive belt.

7 Tooth hook wear

8 Stone damage

Severe fractured or missing teeth

O.K. for continued use, but inspect the belt periodically.

O.K. for continued use, but inspect the belt periodically. Also check the pulley flange.

O.K. for continued use, but inspect the belt periodically (replace the belt if excessive).

O.K. for continued use, check the pulley alignment and flange condition.

Replace the drive belt.

Replace the drive belt. Inspect the pulley for wear.

Remove stone, O.K. for continued use it not near edge of the belt. Inspect the pulley for damage.

Electrical System:

Spark Plug Condition Inspection

Visually inspect the spark plugs.

•

If the spark plug center electrode [A] and/or side electrode [B] are corroded or damaged, or if the insulator [C] is cracked, replace the plug. If the spark plug is dirtied or the carbon is accumulated, replace the spark plug. Measure the gap [D] with a wire-type thickness gauge.

•

If the gap is incorrect, replace the spark plug.

Spark Plug Gap: 1.0 ∼ 1.1 mm (0.039 ∼ 0.043 in.)

Use the standard spark plug or its equivalent.

•

Spark Plug : IZFR6F–11

2-28 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Lights and Switches Operation

First Step:

Turn on the ignition switch.

•

The following lights should go on according to below table.

•

Models

United States

Canada

Europe

Australia

Malaysia

Position

Lights

[A]

go on —

—

— —

Li-

[C]

cense

Plate Light

[D]

City

Light

[B]

goesongoesongoes

Tai l light

goesongoes

Neutral

Indicator light [E] in meter unit

goes on

If the light does not go on, inspect or replace the following item.

Battery (see Electrical System chapter) Applicable Bulb (see Electrical System chapter) Main Fuse 30 A and Taillight Fuse 10 A (see Electrical System chapter) Ignition Switch (see Electrical System chapter) Gear Position Switch (for neutral indicator light, see Electrical System chapter) Harness (see Wiring Inspection in Electrical System chapter)

Turn off the ignition switch.

•

The all lights should go off.

•

If the light does not go off, replace the ignition switch.

Second Step:

Turn the ignition switch to P (Park) position.

•

The taillight and license plate light should go on.

•

If the light does not go on, inspect or replace the following item.

Ignition Switch (see Electrical System chapter)

Periodic Maintenance Procedures

Third Step:

Turn on the turn signal switch [A] (left or right position).

•

The left or right turn signal lights [B] (front and rear) ac-

•

cording to the switch position should flash. The turn signal indicator l ight [C] in the meter unit should

•

flash. If the each light does not flash, inspect or replace the following item.

Turn Signal Light Bulb (see Electrical System chapter) Turn Signal Light Indicator Bulb (see Electrical System chapter) Turn Signal Control Relay Fuse 10 A (see Electrical System chapter) Turn Signal Switch (see Electrical System chapter) Turn Signal Control Relay (see Electrical System chapter) Harness (see Wiring Inspection in Electrical System chapter)

Push the turn signal switch.

•

The turn signal lights and indicator light should go off.

•

If the light does not go off, inspect or replace the following item.

Turn Signal Switch (see Electrical System chapter) Turn Signal Control Relay (see Electrical System chapter)

PERIODIC MAINTENANCE 2-29

NOTE

Refer to E lectrical system chapter for the automatic turn

○

signal canceling system.

Fourth Step:

Set the dimmer switch [A] to low beam position.

•

Start the engine.

•

The low beam headlight should go on.

•

If the low beam headlight does not go on, inspect or replace the following item.

Headlight Low Beam Bulb (see Electrical System chapter) Headlight Fuse 10 A (see Electrical System chapter) Dimmer Switch (see Electrical System chapter) Headlight Relay in Relay Box (see Electrical System chapter) Harness (see Wiring Inspection in Electrical System chapter)

2-30 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Set the dimmer switch to high beam position.

•

The l ow beam [A] and high beam [B] headlights should

•

go on. The high beam indicator light [C] should go on.

•

If the high beam headlight and/or high beam indicator light does not go on, inspect or replace the following item.

Headlight High Beam Bulb (see Electrical System chapter) Dimmer Switch (see Electrical System chapter)

Turn off the engine stop switch.

•

The low beam and high beam headlights should stay go-

•

ing on. If the headlights and high beam indicator light does go off, inspect or replace the following item.

Headlight Relay in Relay Box (see Electrical System chapter)

Turn off the ignition switch.

•

The headlights and high beam indicator light should go

•

off.

Headlight Aiming Inspection

Inspect the headlight beam for aiming.

•

If the headlight beam points to one side rather than straight ahead, adjust the horizontal beam.

Headlight Beam Horizontal Adjustment

Remove the cap [A].

•

Turn the horizontal adjuster on the headlight with a screw-

•

driver in or out until the beam points straight ahead. Turn the adjuster clockwise to face the headlight to the

○

left.

If the headlight beam points too low or high, adjust the vertical beam.

Headlight Beam Vertical Adjustment

Remove the cap [A].

•

Turn the vertical adjuster [A] in the headlight in or out with

•

a screwdriver to adjust the headlight vertically. Turn the adjuster clockwise to face the headlight up.

○

Periodic Maintenance Procedures

NOTE

ON high beam, the brightest points should be slightly

○

below horizontal with the motorcycle on i ts wheels and the rider seated. Adjust the headlight to the proper angle according to local regulations. For US model, the proper angle is 0.4 degrees below

○

horizontal. This is 50 m m (2 in.) drop at 7.6 m (25 ft.) measured from the center of the headlight with the motorcycle on its wheels and the rider seated.

50 mm (2 in.) [A] Center of Brightest Spot [B]

7.6m(25ft.) [C]

Side Stand Switch Operation Inspection

Inspect the side stand switch [A] operation accordance to

•

below table.

Sidestand Switch Operation

Side Stand

Up Neutral

Up Neutral Pulled in

Down Neutral

Down Neutral Pulled in

Down In Gear

Down

Gear Position

In Gear

Clutch Lever

Released

Pulled in

Released

Pulled in

Engine Start

Starts

Doesn’t start

Starts

Doesn’t start

Engine Run

Continue running

Stops

PERIODIC MAINTENANCE 2-31

If the side stand switch operation does not work, inspect or replace the following item.

Battery (see Electrical System chapter) Main Fuse 30 A (see Electrical S ystem chapter) Ignition Fuse 10 A (see Electrical System chapter) Ignition Switch (see Electrical System chapter) Side Stand Switch (see Electrical System chapter) Engine Stop Switch (see Electrical S ystem chapter) Starter Button (see Electrical System chapter) Gear Position Switch (see Electrical System chapter) Starter Control Relay (see Electrical System chapter) Relay Box (see Electrical System chapter) Starter Control Relay (see Electrical System chapter) Harness (see Wiring Inspection in Electrical System chapter)

If the all parts are good condition, replace the ECU.

2-32 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Engine S top Switch Operatio n Inspection

First Step:

Turn on the ignition switch.

•

Set the neutral position.

•

Turn the engine stop switch to stop position.

•

Push the start button.

•

The engine does not start.

•

If the engine starts, inspect or replace the following item.

Engine Stop Switch (see Electrical System chapter)

Second Step:

Turn on the ignition switch.

•

Set the neutral position.

•

Turn the engine stop switch to run position.

•

Push the start button and run the engine.

•

Turn the engine stop switch to stop position.

•

Immediately the engine should be stop.

•

If the engine does not stop, inspect or replace the following item.

Engine Stop Switch (see Electrical System chapter) If the engine stop switch is good condition, replace the ECU.

Fuel System (DFI):

Throttle Control System Inspection

Check the throttle grip free play [A].

•

If the free play is incorrect, adjust the throttle cable (see below).

Throttle Grip Free Play

Standard: 2 ~ 3 mm (0.08 ~ 0.12 in.)

Check that the throttle grip moves smoothly from close to

•

full open, and the throttle closes quickly and completely in all steering positions by the return spring. If the throttle grip doesn’t return properly, check the throttle cable routing, grip free play, and cable damage. Then lubricate the throttle cable. Run the engine at the idle speed, and turn the handlebar

•

all the way to the right and left to ensure t hat the idle speed doesn’t change. If the idle speed increases, check the throttle grip free play and the cable routing.

If necessary, adjust the throttle cable as follows:

•

Loosen the locknuts [A] and screw the adjusters [B] all the

○

way in so as to give the throttle grip plenty of play (rear view). Turn out the adjuster of the decelerator cable [D] until

○

thereisnoplay. Tighten the locknut against the adjuster.

○

Turn the adjuster of the accelerator cable [C] until the

○

proper amount of throttle grip free play is obtained and tighten the locknut against the adjuster.

Periodic Maintenance Procedures

Idle Speed Inspection

Start the engine and warm it up thoroughly.

•

At first the engine will run fast to decrease warm up time

○

(fast idle). Gradually the fast idle will lower to a certain RPM auto-

○

matically. This is the idle speed. Check the idle speed.

•

Idle Speed

Standard: 900 ± 50 r/min (rpm)

With the engine idling, turn the handlebar to both sides.

•

If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed or damaged. Be sure to correct any of these conditions before riding (see Cable, Wire, and Hose Routing section in the Appendix chapter).

WARNING

Operation with improperly adjusted, incorrectly routed or damaged cables could result in an unsafe riding condition.

PERIODIC MAINTENANCE 2-33

If the idle speed is out of the specified range, adjust it. Start the engine and warm it up thoroughly.

•

Wait until fast idle speed lowers to a certain value.

○

Turn the adjusting screw [A] until the idle speed is correct.

•

Open and close the throttle a few times to make sure that

○

the idle speed is within the specified range. Readjust if necessary.

Front [B]

Fuel Hose and Connection Inspection

The fuel hose [ A] is designed to be used throughout the

○

motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak or the hose to burst. Remove the fuel tank (see Fuel System (DFI) chapter) and check the fuel hose. Replace the fuel hose if any fraying, cracks [B] or bulges [C] are noticed. Check that the hose joints are securely connected.

•

When installing the fuel hoses, avoid sharp bending, kink-

•

ing, flattening or twisting. Replace the hose if it has been sharply bent or kinked flattening or twisting.

2-34 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Cooling System

Coolant Level Inspection

NOTE

Check the level when the engine is cold (room or ambi-

○

ent temperature).

Check the coolant level in the reserve tank with the motor-

•

cycle held upright. The coolant level should be between the “F” (full) level and the “L” (low) level (In the photo, the mufflers have been removed for clarity).

Front [A]

Reserve Tank [B]

Coolant Level Hose [C]

“F” Level [D]

“L” Level [E] If the coolant level is lower than the “L” level, remove the reserve tank cap, then add coolant to the“F” level.

CAUTION

For refilling, add t he specified mixture of coolant and soft water. Adding water alone dilutes the coolant and degrades its anticorrosion properties. The diluted coolant can attack the aluminum engine parts. In an emergency, soft water can be added, but the diluted coolant must be returned to the correct mixture ratio within a few days. If coolant must be added often or the reserve tank has run completely dry, there is probably leakage in the cooling system. Check the system for leaks. Coolant ruins painted surfaces. Immediately wash away any coolant that spills on the frame, engine, wheels, or other painted parts.

Radiator Hose and Connection Inspection

The high pressure inside the radiator hose can cause

○

coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should i t be soft or swollen. Replace the hose if any fraying, cracks [B] or bulges [C] are noticed. Check that the hoses are securely connected and clamps

•

are tightened correctly.

PERIODIC MAINTENANCE 2-35

Periodic Maintenance Procedures

Evaporative Emission Control System Inspection (CAL):

Evaporative Emission Control System Inspection

Inspect the canister as follows:

•

Remove the r ear inner cover (see Frame chapter).

○

Remove the holder [A] and take out the canister [B].

○

Disconnect the hoses [C] from the canister.

○

Visually inspect the canister for cracks and other damage.

○

If the canister has any cracks or bad damage, replace it with a new one.

NOTE

The canister is designed to work well through the motor-

○

cycle’s life without any maintenance if it is used under normal conditions.

Install the canister and hoses.

○

Route the hoses according to Cable, Wire, and Hose

○

Routing section in the Appendix chapter. Refer to the diagram of the evaporative emission control system in the Fuel System (DFI) chapter too. Install t he rear inner cover (see Frame chapter).

○

Check the liquid/vapor separator as follows:

•

Remove the r ear inner cover (see Frame chapter).

○

Remove the band [A] and take out the separator [B].

○

Disconnect the hoses [C] from the separator.

○

Visually inspect the separator for cracks and other dam-

○

age. If the separator has any cracks or damage, replace it with a new one. To prevent the gasoline from flowing into or out of the

○

canister, hold t he separator perpendicular to the ground. Check the hoses of the evaporative emission control sys-

•

tem as follows: Check that the hoses are securely connected and clips

○

are in position. Replace any kinked, deteriorated or damaged hoses.

○

Route the hoses according to Cable, Wire, and Hose

○

Routing section in the Appendix chapter. Refer to the diagram of the evaporative emission control system in the Fuel System chapter too. When installing the hoses, avoid sharp bending, kinking,

○

flattening or twisting, and route the hoses with a minimum of bending so that the emission flow will not be obstructed.

2-36 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Air Suction System:

Air Switching Valve Operation Test

Pull the air switching valve hose [A] out of the right air

•

cleaner base. Start the engine and run it at idle speed.

•

Plug the air switching valve hose end with your finger and

•

feel vacuum pulsing in the hose. If there is no vacuum pulsation, check the hose line for leak. If there is no leak, check the air switching valve (see Air Switching Valve Inspection in Electrical System chapter).

Others:

Chassis Parts Lubrication

Before lubricating each part, clean off any rusty spots with

•

rust remover and wipe off any grease, oil, dirt, or grime. Lubricate the points listed below with indicated lubricant.

•

NOTE

Whenever the vehicle has been operated under

○

wet or rainy conditions, or especially after using a high-pressure water spray, perform the general lubrication.

Points: Lubricate with Grease.

Throttle Inner Cable Upper Ends [A]

Clutch Inner Cable Upper End

Clutch Lever Pivot (Apply silicone grease)

Brake Lever Pivot (A pply silicone grease)

Brake Pedal Pivot

Side stand

Cable: Lubricate with Cable Lubricant.

Throttle Cables

Clutch Cable Lubricate the cables by seeping the oil between the cable

•

and housing. The cable may be lubricated by using a commercially

○

available pressure cable lubricator [A] with an aerosol cable lubricant [B].

Periodic Maintenance Procedures

With the cable disconnected at both ends, the cable

•

should move freely [A] within the cable housing. If cable m ovement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable.

Bolts and Nuts Tightness Inspection

Check the tightness of the bolts and nuts listed here. A lso,

•

check to see that each cotter pin is in place and in good condition.

NOTE

For the engine fasteners, check the tightness of them

○

when the engine is cold (at room temperature).

If there are loose fasteners, retighten them to the specified torque, following the specified tightening sequence. Refer to the appropriate chapter for torque specifications. If torque specifications are not in the appropriate chapter, see the Standard Torque Table in this chapter. For each fastener, first loosen it by 1/2 turn, then tighten it. If cotter pins are damaged, replace them with new ones.

PERIODIC MAINTENANCE 2-37

2-38 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Nut, Bolt and Fastener to be checked

Wheels:

Front Axle

Front Axle Clamp Bolts

Rear Axle Nut

Rear Axle Nut Cotter Pin Brakes:

Front Master Cylinder Clamp Bolts

Caliper Mounting Bolts

Rear Master Cylinder Mounting Bolts

Brake Lever Pivot Nut

Brake Pedal Bolt

Brake Rod Joint Cotter Pin Suspension:

Front Fork Clamp Bolts

Front Fender Mounting Bolts

Rear Shock Absorber Mounting Nuts

Swingarm Pivot Shaft Nut Steering:

Stem Head N ut

Handlebar Clamp Bolts

Engine:

Throttle Cable Adjuster Locknuts

Engine Mounting Bolts and Nuts

Shift Pedal Bolts

Muffler Mounting Bolt and Nut

Exhaust Pipe Holder Nuts

Clutch Lever Pivot Nut

Radiator Mounting Bolt

Radiator Bracket Bolts Others:

Side Stand Bolt and Nut

Footboard Bracket Bolts

Footpeg Bracket Mounting Bolts

Downtube Bolts

Periodic Maintenance Procedures

Replacement Parts:

Brake Hose and Pipe Replacement

CAUTION

Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely w ashed away immediately.

When removing the brake hose [A], take care not to spill

•

the brake fluid on the painted or plastic parts. Immediately wash away any brake fluid that spills.

•

Install new brake hoses and pipes.

•

There are washers [B] on each side of the brake hose

•

fitting. Replace them with new ones when installing. Tighten the banjo bolts [C] on the hose fittings.

•

Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18

ft·lb)

When installing the hoses [A], avoid sharp bending, kink-

•

ing, flattening or twisting, and route the hoses according to Cable, Wire, and Hose Routing section in the General Information chapter. Fill the brake line after installing the brake hose (see

•

Brake Fluid Change).

PERIODIC MAINTENANCE 2-39

Brake Fluid C hange

NOTE

The procedure to change the front brake fluid is as fol-

○

lows. Changing the rear brake fluid is almost the same as for the front brake.

Level the brake fluid reservoir.

•

Remove the reservoir cap [A], plate [B] and diaphragm

•

[C].

2-40 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Follow the procedure below to install the rear brake fluid

•

reservoir cap correctly. First, tighten the rear brake fluid reservoir cap [B] clock-

○

wise [C] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A].

Remove the rubber cap from the bleed valve [A] on the

•

front caliper [B]. Attach a clear plastic hose [C] to the bleed valve, and run

•

the other end of the hose into a container. Fill the reservoir with new brake fluid.

•

Temporarily install the reservoir cap.

•

Change the brake fluid as follows:

•

NOTE

The fluid level must be checked often during the chang-

○

ing operation and replenished with fresh brake fluid. If the fluid in the reservoir runs out any time during the changing operation, the brakes will need to be bled since air will have entered the brake line.

Repeat this operation until fresh brake fluid comes out

○

from the plastic hose or the color of the fluid changes.

Open the bleed valve [A].

Pump the brake lever and hold it [B].

Close the bleed valve [C].

Release the brake lever [D].

Front Brake : Repeat the above steps for other caliper.

Remove the clear plastic hose.

•

Install the reservoir cap.

•

Tighten the bleed valves, and install the rubber caps.

•

Torque - Caliper Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb)

Front Brake Reservoir Cap Screws: 1.5 N·m (0.15

kgf·m, 13 in·lb)

Periodic Maintenance Procedures

For the rear brake caliper [A], change the brake fluid for

○

two bleed valves [B]. After changing the fluid, check the brake for good braking

•

power, no brake drag, and no fluid leakage. If necessary, bleed the air from the lines (see Brakes chapter).

Master Cylinder Rubber Parts Replacement

Front Master Cylinder Disassembly:

Remove the front master cylinder.

•

Remove the reservoir cap [A], plate [B], and diaphragm

•

[C]. Unscrew the locknut [D] and pivot bolt [E], and remove

•

the brake lever. Pull the dust cover [F] out of place, and remove the circlip

•

[G].

Special Tool - Inside Circlip Pliers: 57001–143

Pull out the piston assy [H], and return spring [I].

•

PERIODIC MAINTENANCE 2-41

Rear Master Cylinder Disassembly:

NOTE

Do not remove the push rod [A] for master cylinder dis-

○

assembly since removal requires brake pedal position adjustment.

Remove the rear master cylinder (see Brakes chapter).

•

Slide the dust cover [B] out of place, and remove the cir-

•

clip [C].

Special Tool - Inside Circlip Pliers: 57001–143

Pull out the push rod with the piston stop [D].

•

Take off the piston assy [E], and return spring [F].

•

Replace:

•

Diaphragm [G] Brake Hose [H] O-ring [I]

2-42 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Master Cylinder Assembly:

Before assembly, clean all parts including the master

•

cylinder with brake fluid or alcohol.

CAUTION

Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the disc brake.

Apply brake fluid to the new parts and to the inner wall of

•

the cylinder. Take care not to scratch the piston or the inner wall of the

•

cylinder.

CAUTION

Do not remove the secondary cup from the piston since removal will damage it.

Tighten the brake lever pivot bolt and the locknut.

•

Silicone Grease -

Brake Lever Pivot Bolt, Brake Lever Pivot Con-

tact, Piston Rod Contact, Dust Cover

Torque - Brake Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 8.7

in·lb)

Brake Lever Pivot Locknut: 5.9 N·m (0.60 kgf·m,

52 in·lb)

Caliper Rubber Parts Replacement

Front Caliper Disassembly:

Loosen the front caliper assembly bolts [A] and banjo bolt

•

[B] and tighten them loosely. Remove:

•

Front Caliper (see Brakes chapter) [C]

Brake Pad

Front Caliper Assembly Bolts

O-rings

Using compressed air, remove the pistons. One way to

•

remove the pistons is as follows. Install a rubber gasket [A] and a wooden board [B] more

○

than 10 mm (0.4 in.) thick on the caliper half, and fasten them together with a suitable bolt and nut as shown. Leave one of the oil passages [C] open. Lightly apply compressed air [D] to the oil passage until

○

the pistons hit the rubber gasket. Block the hose joint opening [E] during this operation i f the caliper half has the opening.

[F] Bolt and Nut

[G] Oil Passage Sealed by Rubber Gasket

[H] Push down.

Periodic Maintenance Procedures

WARNING

To avoid serious injury, never place your fingers or palm in front of the piston. If you apply compressed air into the caliper, the piston may crush your hand or fingers.

Pull out the pistons by hand.

○

Remove the dust seals [A] and fluid seals [B].

•

Remove the bleed valve [C] and rubber cap [D].

•

Repeat the previous step to remove the pistons from the

•

other side of the caliper body.

NOTE

If compressed air is not available, do as follows for both

○

calipers coincidentally, with the brake hose connected to the caliper. Prepare a container for brake fluid, and perform the

○

work above it. Remove the spring and pads (see Brakes chapter).

○

Pump the brake lever until the pistons come out of the

○

cylinders, and then disassemble the caliper.

PERIODIC MAINTENANCE 2-43

Front Caliper Assembly:

Clean the caliper parts except for the pads.

•

CAUTION

For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol.

Install the bleed valve and rubber cap.

•

Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

Replace the fluid seals [A] with new ones.

•

Apply brake fluid to the fluid seals, and install them into

○

the cylinders by hand. Replace the dust seals [B] with new ones if they are dam-

•

aged. Apply brake fluid to t he dust seals, and install them into

○

the cylinders by hand.

Replace the O-ring [A].

•

Apply brake fluid to t he outside of the pistons, and push

•

them into each cylinder by hand. Be sure to install the O-rings.

•

Tighten:

•

Torque - Front Caliper Assembly Bolts: 21 N·m (2.1 kgf·m,

15 ft·lb)

Install the pads (see Brakes chapter).

•

Wipe up any spilled brake fluid on the caliper w ith wet

•

cloth.

2-44 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Rear Caliper Disassembly:

Remove the caliper with the hose installed (see Brakes

•

chapter). Remove the pads (see Brakes chapter).

•

Pull out the caliper holder [A].

•

Insert a wooden board [A] 5 mm (0.2 in.) thick inside the

•

caliper opening. Pump the brake pedal until the pistons [B] push the

•

wooden board.

Remove the board and pull out the piston [A] by hand.

•

These pistons can also be removed by disconnecting the

○

hose and applying compressed air to the hose joint opening using the same wooden board. But be careful not to put your fingers or palm inside the caliper opening during work.

WARNING

To avoid serious injury, never place your fingers or palm inside the caliper opening. If you apply com pressed air into the caliper, the pistons may crush your hand or fingers.

CAUTION

Immediately w ash away any brake fluid that spills.

Remove the anti rattle spring [A].

•

Remove the dust seals [B] and fluid seals [C].

•

Remove the rubber friction boots [D].

•

Remove the bleed valves [E] and rubber caps [F].

•

Periodic Maintenance Procedures

Rear Caliper Assembly:

Tighten the bleed valve.

•

Torque - Caliper Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

It is recommended that the fluid seal (piston seal) which

○

is removed, be replaced with a new one. Replace the dust seals [A].

•

Replace the fluid seal [B]. Either side of the seal may face

•

outboard.

Install the anti-rattle spring [A] in the caliper as shown.

•

Apply brake fluid to the cylinders, pistons, and fluid seals

•

(piston seals), and push the pistons into the cylinders by hand. Take care that neither the cylinder nor the piston skirt gets scratched.

PERIODIC MAINTENANCE 2-45

Replace the caliper holder shaft rubber friction boot [A]

•

and dust boot [B]. Apply a thin coat of silicone or PBC grease to the caliper

•

holder shaft [C] and holder holes (Silicone or PBC grease is a special high temperature, water-resistance grease). Install the pads (see Brake Pad Installation).

•

Spark Plug Replacement

Remove:

•

Fuel Tank (for Rear Spark Plug, see Fuel System chapter) Spark Plug Caps [A]

Remove the spark plug using the 16 mm (0.63 in.) plug

•

wrench vertically.

Special Tool - Spark Plug Wrench, Hex16: 57001-1262

CAUTION

The insulator [A] of the spark plug may break if when the w rench is inclined during loosening.

[B] Inclined Spark Plug Wrench [C] Contact (Spark Plug and Plug Wrench) [D] Bad [E] Vertically Spark Plug Wrench [F] Good

2-46 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Insert new spark plug in the plug hole, and finger-tighten

•

it first. Using the plug wrench [A] vertically, tighten the plug.

•

CAUTION

The insulator of the spark plug may break if when the wrench is inclined during tightening.

Special Tool - Spark Plug Wrench, Hex16: 57001-1262

Torque - Spark Plugs: 18 N·m (1.8 kgf·m, 13 ft·lb)

Install the spark plug caps securely.

•

Be sure the spark plug caps are installed by pulling up it

○

lightly.

Air Cleaner Element Replacement

WARNING

If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident.

CAUTION

If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.

Remove:

•

Air Cleaner Cover Screws [A]

Air Cleaner Cover [B]

Unscrew the air cleaner element screw [A] and remove

•

the air cleaner element [B]. Discard:

•

Air Cleaner Element

Periodic Maintenance Procedures

Install a new element [A] with the mesh side facing up

•

-ward.

CAUTION

Use only the recommended air cleaner element (Kawasaki part number 11013–0002). Using another air cleaner element will w ear the engine prematurely or lower the engine performance.

Engine Oil Change

Situate the motorcycle so that it is vertical after warning

•

up the engine. Remove the oil filler cap [A] on the transmission cover [B].

•

PERIODIC MAINTENANCE 2-47

Remove the left [ A] and right [B] oil pan drain plugs and

•

drain the oil.

Remove the clutch drain plug [A] on the outside clutch

•

cover [B]. The oil in the oil filter can be drained by removing the filter

○

(see Oil Filter Change).

Replace the gasket [A] for left drain plug [B] with a new one if it is damaged. Replace the O-ring [C] for right drain plug [D] with a new one.

2-48 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Replace the O-ring [A] for drain plug [B] on the outside clutch cover [C].

Tighten the drain plugs.

•

Torque - Left Oil Pan Drain Plug: 15 N·m (1.5 kgf·m, 11 ft·lb)

Right Oil Pan Drain Plug: 20 N·m (2.0 k gf·m, 15

ft·lb)

Clutch Drain Plug: 20 N ·m (2.0 kgf·m, 15 ft·lb)

Remove the oil filler cap [A] and pour in the specified type

•

and amount of oil.

Transmission Cover [B]

Engine Oil

Typ e :

Viscosity: Amount:

API SE, SF or SG class API SH or SJ class with JASO MA SAE 10W-40

4.4 L (4.7 US qt, when filter is not removed)

4.6 L (4.9 US qt, when filter is removed)

5.5 L (5.8 US qt, when engine is completely disassembled and dry)

NOTE

Although 10W-40 engine oil is the recommended oil

○

for most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area.

Check the oil level (see Engine Lubrication System chap-

•

ter).

Periodic Maintenance Procedures

Oil Filter Replacement

Drain the engine oil (see Engine Oil Change in this sec-

•

tion). Remove the oil filter [A] with the oil filter wrench [B] and

•

discard the oil filter.

Special Tool - Oil Filter Wrench: 57001-1249

NOTE

The filter has an oil filter bypass valve which can not be

○

removed.

Replace the oil filter with the new one.

•

Apply oil to the gasket of the new filter before installation.

•

Tighten the filter with the oil filter wrench.

•

Pour in the specified type and amount of oil.

•

Torque - Oil Filter: 18 N·m (1.8 kgf·m, 13 ft·lb)

Fuel Hose Replacement

Remove the fuel tank (see Fuel System (DFI) chapter).

•

Remove or disconnect:

•

Air Switching Valve (see Engine Top End chapter) Vacuum Hoses on Throttle Body Assy (see Fuel System (DFI) chapter). Injector Connectors (see Injector Removal in the Fuel System (DFI) chapter).

PERIODIC MAINTENANCE 2-49

Push[A]thejointlockclaws[B].

•

Pull [A] the joint lock [B] as shown.

•

Pull the fuel hose joint [C] out of the delivery pipe.

•

WARNING

Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe. Cover the hose connection with a clean shop towel to prevent fuel spillage.

2-50 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Install the new fuel hose.

•

Pull [A] the joint lock [B] fully as shown.

•

Insert the fuel hose joint [A] straight onto the delivery pipe.

•

Push [B] the joint lock [C] until the hose joint clicks.

•

Push and pull [A] the fuel hose joint [B] back and forth

•

more than two times and make sure it is locked and doesn’t come off.

WARNING

Make sure the fuel hose joint is installed correctly on the delivery pipe or the fuel could leak.

If it comes off, reinstall the hose joint. Run the fuel hose in accordance with the Cable, Wire and

•

Hose Routing section in the Appendix chapter. Install the removed part

•

Start the engine and check the fuel hose for leaks.

•

Coolant Change

WARNING

To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will m ake them slippery, and can cause an accident and injury. Since coolant is harmful to the human body, do not use for drinking.

Place a container under the radiator drain bolt [A], then

•

remove the drain bolt.

Periodic Maintenance Procedures

Remove the fuel tank (see Fuel System chapter).

•

Remove the radiator cap [A] in two steps. First turn the

•

cap counterclockwise to the first stop. Then push and turn it further in the same direction and remove the cap. The coolant will drain from the radiator and engine.

○

Front [B]

Suck [A] the coolant with a hose [B] and pour the coolant

•

into a suitable container. Install the reserve tank.

•

PERIODIC MAINTENANCE 2-51

When filling the coolant, choose a suitable mixture ratio

•

by referring to the coolant manufacturer’s directions.

CAUTION

Soft or distilled water must be used with the antifreeze (see Specifications in this chapter) in the cooling system. If hard water is used in the system, it causes scale accumulation in the water passages, and considerably reduces the efficiency of the cooling system.

Water and Coolant Mixture Ratio (when shipping)

Soft Water Coolant Freezing Point Total Amount

Tighten the drain bolts.

•

Torque - Coolant Drain Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)

Pour the coolant into the radiator.

•

Pour in the coolant slowly so that it can expel the air

○

from the engine and radiator.

50%

−35°C (−31°F)

2.6 L (2.5 US gt.)

NOTE

Check the cooling system for leaks.

•

2-52 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Loosen the air bleeder bolt [A] on the thermostat housing.

•

Front [B] Replenish the coolant into the radiator until the coolant

•

begins to flow out the air bleeder bolt hole (that is, all the remaining air is forced out). Tap the radiator hoses to force any air bubbles caught

•

inside.

Fill the radiator up to the filler neck [A] with coolant.

•

Install the radiator cap.

•

Tighten the air bleeder bolt [B].

•

Torque - Thermostat Air Bleeder Bolt: 7.8 N·m (0.80 kgf·m,

69 in·lb)

Fill the reserve tank up to the “F” (full) level line [A] with

•

coolant and install the cap (in the photo, the muffler has been removed for clarity). Install the fuel tank (see Fuel System chapter).

•

Start the engine and warm it up thoroughly until the radi-

•

ator fan turns on and then stop the engine. Check the coolant level in the reserve tank several times

•

while the engine is cooling down, and replenish as necessary. If the coolant level is lower than the “L” level line [B], add coolant to the “F” level line.

CAUTION

Do not add more coolant above the “F” level line.

Periodic Maintenance Procedures

Radiator Hose and O-ring Replacement

Drain the coolant (see Coolant Change in the Periodic

•

Maintenance chapter). Remove:

•

Thermostat [A] Bracket [B] (see Thermostat Removal in the Cooling System chapter) Upper Engine Bracket [C] (see Engine Removal/Installation chapter)

Loosen the radiator hose clam ps and remove the hoses

•

[D]. Unscrew the bolts and remove the water pipes [E] and

•

O-rings [F]. Apply grease to the new O-ring and install the water pipes.

•

Torque the water pipe bolts [G].

•

Torque - Water Pipe Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

For the water pipe bolt on the rear cylinder, apply a non

○

-permanent locking agent [L]. Install the new radiator hose and tighten the hose clamps

•

securely. Fill the coolant (see Coolant Change in the Periodic Main-

•

tenance chapter). Check the cooling system for leaks.

•

PERIODIC MAINTENANCE 2-53

Fuel System (DFI)

Table of Contents

Exploded View................................... 3-4

DFI Parts Location ............................. 3-8

Specifications .................................... 3-11

Special Tools and Sealant ................. 3-13

DFI System........................................ 3-14

DFI Servicing Precautions ................. 3-18

Troubleshooting the DFI System ....... 3-19

Outline ............................................ 3-19

Inquiries to Rider............................. 3-23

DFI System Troubleshooting Guide .. 3-26

Self-Diagnosis ................................... 3-36

Self-diagnosis Outline..................... 3-36

Self-diagnosis Procedures.............. 3-36

Service Code Clearing Procedures 3-37

How to Read Service Codes........... 3-39

How to Erase Service Codes.......... 3-40

Service Code Table......................... 3-41

Backups .......................................... 3-43

Main Throttle Sensor (Service Code

11) ................................................... 3-45

Main Throttle Sensor

Removal/Adjustment................. 3-45

Input Voltage Inspection............... 3-45

Output Voltage Inspection............ 3-46

Resistance Inspection.................. 3-47

Inlet Air Pressure Sensor (Service

Code 12) ......................................... 3-48

Removal ....................................... 3-48

Installation.................................... 3-48

Input Voltage Inspection............... 3-48

Output Voltage Inspection............ 3-49

Inlet Air Temperature Sensor (Service

Code 13) ......................................... 3-53

Removal/Installation..................... 3-53

Output Voltage Inspection............ 3-53

Sensor Resistance Inspection ..... 3-54

Water Temperature Sensor (Service

Code 14) ......................................... 3-55

Removal/Installation..................... 3-55

Output Voltage Inspection............ 3-55

Water Temperature Sensor

Resistance Inspection ............... 3-56

Atmospheric Pressure Sensor

(Service Code 15)........................... 3-57

Removal ....................................... 3-57

Installation.................................... 3-57

FUEL SYSTEM (DFI) 3-1

Input Voltage Inspection............... 3-57

Output Voltage Inspection............ 3-58

Crankshaft Sensor (Service Code

21)................................................... 3-61

Crankshaft Sensor

Removal/Installation.................. 3-61

Crankshaft Sensor Inspection ...... 3-61

Camshaft Position Sensor (Service

Code 23) ......................................... 3-62

Camshaft Position Sensor

Removal/Installation.................. 3-62

Camshaft Position Sensor

Inspection.................................. 3-62

Speed Sensor (Service Code 24)...... 3-64

Speed Sensor

Removal/Installation.................. 3-64

Speed Sensor Inspection............. 3-64

Input Voltage Inspection............... 3-64

Output Voltage Inspection............ 3-64

Gear Position Switch (Service Code

25)................................................... 3-66

Gear Position Switch

Removal/Installation.................. 3-66

Gear Position Switch Inspection .. 3-66

Vehicle-down Sensor (Service Code

31)................................................... 3-68

Vehicle-down Sensor Removal.... 3-68

Installation .................................... 3-68

Vehicle-down Sensor Inspection.. 3-68

Subthrottle Sensor (Service Code

32)................................................... 3-70

Subthrottle Sensor

Removal/Adjustment ................. 3-70

Input Voltage Inspection............... 3-70

Output Voltage Inspection............ 3-71

Resistance Inspection.................. 3-72

Oxygen Sensor-not activated

(Service Code 33)........................... 3-73

Oxygen Sensor

Removal/Installation.................. 3-73

Oxygen Sensor Inspection........... 3-73

Oxygen Sensor Heater

Inspection.................................. 3-74

Fuel Injectors (#1, #2: Service Code

41, 42)............................................. 3-75

Injector Removal .......................... 3-75

3-2 FUEL SYSTEM (DFI)

Injector Installation ....................... 3-75

Audible Inspection........................ 3-78

Power Source Voltage Inspection 3-78

Output Voltage Inspection............ 3-79

Injector Signal Test....................... 3-79

Injector Resistance Inspection ..... 3-80

Injector Unit Test .......................... 3-81

Fuel P ump (Service Code 45) ........... 3-82

Fuel Pump Removal .................... 3-82

Fuel Pump Installation ................. 3-82

Pressure Regulator Removal....... 3-83

Pump Screen, Fuel Filter

Cleaning .................................... 3-83

Operation Inspection.................... 3-83

Operating Voltage Inspection....... 3-84

Power Source Voltage Inspection 3-85

Operating Voltage Inspection....... 3-85

Ignition Coils (#1, #2: Service Code

51, 52)............................................. 3-87

Removal/Installation..................... 3-87

Input Voltage Inspection............... 3-87

Starter Control Relay (Service Code

55)................................................... 3-88

Starter Control Relay Removal

and Installation .......................... 3-88

Starter Control Relay Inspection.. 3-88

Radiator Fan Relay (Service Code

56)................................................... 3-89

Radiator Fan Relay

Removal/Installation.................. 3-89

Radiator Fan Relay Inspection..... 3-89

Subthrottle Valve Actuator (Service

Code 62) ......................................... 3-90

Subthrottle Valve Actuator

Removal .................................... 3-90

Subthrottle Valve Actuator

Inspection .................................. 3-90

Resistance Inspection.................. 3-90

Input Voltage Inspection............... 3-91

Air Switching Valve (Service Code

64)................................................... 3-93

Air Switching Valve

Removal/Instalation................... 3-93

Air Sw itching Valve Inspection ..... 3-93

Decompression Solenoid (Service

Code 66) ......................................... 3-94

Decompression Solenoid

Removal/Installation.................. 3-94

Decompression Solenoid

Inspection .................................. 3-94

Oxygen Sensor Heater (Service

Code 67) ......................................... 3-95

Oxygen Sensor Heater

Removal/Installation.................. 3-95

Oxygen Sensor Heater Inspection

.................................................. 3-95

Oxygen Sensor Heater

Inspection.................................. 3-95

Oxygen Sensor Heater

Inspection.................................. 3-96

Subthrottle Motor Driver (Service

Code 85) ......................................... 3-97

Subthrottle Motor Driver

Removal/Installation.................. 3-97

Subthrottle Motor Driver

Inspection.................................. 3-97

Oxygen Sensor – Incorrect Output

Voltage (Service Code 94).............. 3-98

Oxygen Sensor

Removal/Installation.................. 3-98

Oxygen Sensor Inspection........... 3-98

Oxygen Sensor Heater

Inspection.................................. 3-99

FI Indicator LED Light ........................ 3-100

LED Light Inspection.................... 3-101

ECU ................................................... 3-102

ECU Removal .............................. 3-102

ECU Installation ........................... 3-102

ECU Power Supply Inspection..... 3-102

Fuel Line............................................ 3-104

Fuel Pressure Inspection ............. 3-104

Fuel Flow Rate Inspection ........... 3-107

Throttle Grip and Cables ................... 3-109

Throttle Grip Free Play Inspection 3-109 Throttle Grip Free Play

Adjustment ................................ 3-109

Cable R emoval/Installation .......... 3-109

Cable Lubrication and Inspection. 3-109

Throttle Body Assy ............................ 3-110

Idle Speed Check......................... 3-110

Idle Speed Adjustment................. 3-110

Throttle Bore Cleaning ................. 3-110

High Altitude Performance

Adjustment ................................ 3-110

Throttle Body Assy and Intake

Manifold Removal ..................... 3-110

Throttle Body Assy and Intake

manifold Installation .................. 3-112

Air Cleaner......................................... 3-115

Element Removal......................... 3-115

Air Cleaner Housing Removal...... 3-115

Air Cleaner Housing Installation... 3-116

Fuel Tank ........................................... 3-117

Fuel Tank Removal ...................... 3-117

Fuel Tank Installation ................... 3-119

Fuel Tank and Cap Inspection ..... 3-121

Fuel Tank Cleaning ...................... 3-121

Evaporative Emission Control

System............................................ 3-122

Parts Removal/Installation ........... 3-122

Canister Installation ..................... 3-122

Canister Inspection (Periodic

Inspection)................................. 3-122

FUEL SYSTEM (DFI) 3-3

Separator Inspection (Periodic

Inspection)................................. 3-122

Hose Inspection (Periodic

Inspection)................................. 3-122

Separator Operation Test............. 3-123

3-4 FUEL SYSTEM (DFI)

Exploded View

FUEL SYSTEM (DFI) 3-5

No. Fastener

N·m kgf·m ft·lb

1 Fuel pump bolts 9.8 1.0 87 in·lb S, L

2 Water temperature sensor 12 1.2 104 in·lb

3 Oxygen sensor 44 4.5 33

4 Gear position switch mounting bolts 6.9 0.7 61 in·lb

5 Gear position switch lead clamp bolts 6.9 0.7 61 in·lb

6 Camshaft position sensor bolt 9.8 1.0 87 in·lb L

7. Exhaust pipe

8. Inlet air pressure sensor

9. Camshaft position sensor

10. Atmospheric pressure sensor

11. Vehicle-down sensor

12. ECU (Electronic control unit)

13. Relay box

14. Battery case

15. Fuel pump

16. Fuse 30A

17. Gear position switch

18. Canister

19. Separater

CAL: California Model

EU: European Model

R: Replacement Parts

L: Apply a non-permanent locking agent.

G: Apply grease.

CL: Apply cable lubricant.

S: Follow the specified tightening sequence. SS: Apply silicone sealant (Three Bond: TB1211F) AD: Apply adhesive cement.

Lh: Left-hand Threads

Torque

Remarks

3-6 FUEL SYSTEM (DFI)

Exploded View

FUEL SYSTEM (DFI) 3-7

No. Fastener

N·m kgf·m ft·lb

1 Fuel level sensor mounting bolts 6.9 0.70 61 in·lb L

2 Speed sensor mounting bolt 9.8 1.0 87 in·lb L

3 Delivery joint bolts 9.8 1.0 87 in·lb L

4 Throttle body assy holder bolts 9.8 1.0 87 in·lb L

5 Inlet manifold bolts 9.8 1.0 87 in·lb L

6 Air cleaner housing bolts 9.8 1.0 87 in·lb

7 Air cleaner housing Allen bolts 9.8 1.0 87 in·lb

8. Fuel level sensor

9. Speed sensor

10. Sub harness

11. O-rings

12. #1, Injector

13. Seals

14. Delivery pipe

15. Throttle body assy

16. Idle adjuster

17. #2, Injector

18. Air cleaner cover

19. Air cleaner element

20. Air cleaner housing

21. Inlet air temperature sensor L: Apply a non-permanent locking agent.

R: Replacement Parts

G: Apply grease.

Torque

Remarks

3-8 FUEL SYSTEM (DFI)

DFI Parts Location

1. Ignition Coil #1

2. Fuel Pum p

3. Ignition Coil #2

4. Atmospheric Pressure Sensor

5. Main Fuse 30A

6. Fuse Box

7. Vehicle Down Sensor

8. ECU

9. Sealed Battery

10. Relay Box

11. Crankshaft Sensor

12. Air Switching Valve

13. Injector #2

14. Injector #1

15. Water Temperature Sensor

16. Main Throttle Sensor

17. Subthrottle Sensor

18. Subthrottle Valve Actuator

19. Inlet Air Pressure Sensor

20. Camshaft Position Sensor

21. Inlet Air Temperature Sensor

22. Oxygen Sensor (California, Europe and UK Models)

23. Gear Position Switch

24. Speed Sensor

DFI Parts Location

FUEL SYSTEM (DFI) 3-9

3-10 FUEL SYSTEM (DFI)

DFI Parts Location

FUEL SYSTEM (DFI) 3-11

Specifications

Item Standard

Throttle Grip Free Play: 2 ~ 3 mm (0.08 ~ 0.12 in.) Air Cleaner Element: Viscous paper element DFI System:

Make: Denso Idle Speed: 900 ± 50 r/min (rpm) Throttle Body Assy:

Type × Bore Two barrel type × φ 46 mm (1.81 in.)

ECU (Electronic Control U nit):

Type Digital memory type, with built in IC igniter,

sealed with resin

Fuel Pressure (high pressure line):

Right after Ignition SW ON 304 kPa (3.1 kgf/cm², 44 psi) with fuel pump running After pump runs 3 sec. and stops. 280 kPa (2.9 kgf/cm², 41 psi) with fuel pump stopped With engine idling 304 kPa (3.1 kgf/cm², 44 psi) with fuel pump running

Throttle Sensor:

Input voltage 4.75 ~ 5.25 V DC between BL/W and BR/BK leads Output voltage 1.02~ 4.62 V DC between Y/W and BR/BK leads

Resistance 4~6kΩ Atmospheric Pressure Sensor or Inlet Air Pressure Sensor:

Input voltage 4.75 ~ 5.25 V DC

Output voltage 3.80 ~ 4.20 V DC at standard atmospheric pressure Inlet Air Temperature Sensor:

Resistance

Water Temperature Sensor:

Resistance 1.055 ~ 1.199 k Ω at 40° C (104° F)

Vehicle-down Sensor:

Detection angle More than 45° ± 5° for each bank

Detection time Within 0.5 ~ 1.0 sec. Fuel Injectors:

Type INP– 284

Static injection quantity 379.9 ~ 403.5 mL/min

Nozzle type × diameter One spray type with 12 holes

Resistance Fuel Pump:

Type Friction pump

Discharge 67 mL or m ore for 3 seconds

Speed Sensor:

Input voltage at sensor about 9 ~ 11 V DC at Ignition SW ON

Output voltage at sensor about 0.05 ~ 0.07 V DC at Ignition SW ON and 0 km/h

Subthrottle Sensor: Non-adjustable and non-removable

Input Voltage 4.75 ~ 5.25 V DC between BL/W and BR/BK l eads

Output Voltage 1.02~ 4.62 V DC between Y and BR/BK leads

Resistance 4~6kΩ

Non-adjustable and non-removable

(at idle throttle opening to full throttle opening)

1.6 ~ 3.7 kΩ at 20° C (68° F)

0.24 ~ 0.43 kΩ at 80° C (176° F)

0.151 ~ 0.162 kΩ at 100° C (212° F)

11.7 ~ 12.3 Ω at 20° C (68° F)

(at idle throttle opening to full throttle opening)

3-12 FUEL SYSTEM (DFI)

Specifications

Item Standard

Subthrottle Valve Actuator:

Resistance about 5 ~ 7 Ω

Input Voltage about 8.5 ~ 10.5 V DC

Oxygen Sensor:

Output Voltage (rich) 0.7 ~ 0.8 V

Output Voltage (lean) approx. 0.1 V

Heater Resistance 14.1 ~ 19.3 Ω at 20 °C (68 °F)

Special Tools and Sealant

FUEL SYSTEM (DFI) 3-13

Oil Pressure Gauge, 5 kg/cm² : 57001–125

Fork Oil Level Gauge : 570101–1290

Hand Tester : 57001–1394

Needle Adapter Set : 57001–1457

Kawasaki Bond (Silicone Sealant) : 56019–120

Throttle Sensor Setting Adapter: 57001–1400

Fuel Pressure Gauge Adapter : 57001–1593

Fuel Hoses: 57001–1607

3-14 FUEL SYSTEM (DFI)

DFI System

DFI System Wiring Diagram

DFI System

Part Name

1. FI Indicator LED Light

2. Speedometer

3. Ignition Switch

4. Engine Stop Switch

5. Starter Button

6. Ignition Coil #1

7. Ignition Coil #2

8. Air Switching Valve

9. Atmospheric P ressure Sensor

10. Inlet Air Pressure Sensor

11. Water Temperature Sensor

12. Joint Connector

13. Main Throttle Sensor

14. Subthrottle Sensor

15. Injector #2

16. Injector #1

17. Subthrottle Valve Actuator

18. Inlet A ir Temperature Sensor

19. Crankshaft Sensor

20. Camshaft position Sensor

21. Gear Position Switch

22. Speed Sensor

23. Oxygen Sensor (California and European Models)

24. Self-diagnosis Terminal

25. ECU (Electric Control Unit)

26. Fuel Pump

27. Frame Ground

28. Battery

29. Main Fuse 30A

30. Vehicle-down Sensor

31. Relay Box

32. Fuel Pump Relay

33. ECU Main Relay

34. Compression Release Solenoid Fuse 10A

35. ECU Fuse 10A

36. Ignition Fuse 10A

37. Fuse Box

FUEL SYSTEM (DFI) 3-15

3-16 FUEL SYSTEM (DFI)

DFI System

Kawasaki VULCAN 2000 (2003) User Manual [ru]

Specifications and Main Features

Frequently Asked Questions

User Manual

LIST OF ABBREVIATIONS

EMISSION CONTROL INFORMATION

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

Foreword

General Information

Battery Ground

Edges of Parts

Solvent

Cleaning vehicle before disassembly

Arrangement and Cleaning of Removed Parts

Storage of Removed Parts

Inspection

Replacement Parts

Assembly Order

Tightening Sequence

Tightening Torque

Force

Liquid Gasket, Locking Agent

Press

Ball Bearing and Needle Bearing

Oil Seal, Grease Seal

Circlips, Cotter Pins

Lubrication

Direction of Engine Rotation

Electrical Wires

VN2000-A1 (US, and Canada) Left Side View:

VN2000-A1 (US, and Canada) Right Side View:

VN2000-A1 (Europe) Left Side View:

VN2000-A1 (Europe) Right Side View:

Overview

Construction and Operation

Air/Fuel Ratio Control By Oxygen Sensor

Maintenance

Prefixes for Units:

Units of Mass:

Units of Volume:

Units of Length:

Units of Torque:

Units of Pressure:

Units of Speed:

Units of Force:

Units of Temperature:

Units of Power:

Periodic Maintenance

Periodic Inspection:

Periodic Replacement Parts:

Basic Torque for General Fasteners

Inside Circlip Pliers: 57001–143

Steering Stem Nut Wrench: 57001–1100

Jack: 57001–1238

Spark Plug Wrench, Hex 16: 57001–1262

Jack Attachment : 57001–1571

Drive Belt Tension Gauge: 57001– 1585

Oil Filter Wrench: 57001–1249

Steering System:

Steering Play Inspection

Steering Play Adjustment

Steering Stem Bearing Lubrication

Brake System:

Brake Fluid Leak (Brake Hose and Pipe)

Brake Hose Damage and Installation Connection Inspection

Brake Operation Inspection

Brake F luid Level Inspection

Brake Pad Wear Inspection

Pad Lining Thickness

Brake Light Switch Operation

Wheel and Tires:

Tire Air Pressure Inspection

Air Pressure (when cold)

Wheel/Tire Damage Inspection

Tire Tread Wear Inspection

Tread Depth

Wheel Bearing Damage Inspection

Suspensions

Front Forks/Rear Shock Absorber Operation Inspection

Front Fork Oil Leak Inspection