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Kawasaki VN1500 '87-'99 Service Manual
Kawasaki VN1500 '87-'99 Service Manual
Motorcycle
Service Manual
Quick ReferenceGuide
Motorcycle
Service Manual
All rightsreserved. No partsof this publicationmay be reproduced,storedin a retrievalsystem,or
transmittedin any form or by any means,electronicmechanicalphotocopying,recordingor other-
wise, without the prior written permissionof Ouality AssuranceDepartment/Consumer Products
Group/KawasakiHeavyIndustries,Ltd., Japan.
No liabilitycan be acceptedfor any inaccuraciesor omissionsin this publication,althoughevery
possiblecare has beentakento make it as completeand accurateas possible.
The right is reservedto make changesat any time without prior notice and without incurringan
obligationto makesuch changesto productsmanufacturedpreviously. Seeyour Motorcycledealer
for the latest informationon productimprovementsincorporatedafter this publication.
All informationcontainedin this publicationis basedon the latestproduct informationavailableat
the time of publication. lllustrationsand photographsin this publicationare intendedfor referencs
use only and may not depictactualmodelcomponentparts.
@ KawasakiHeavyIndustries,
Ltd.,1987,1990,1991,1993,1995, 1997,1999, EighthEdition(1) : N/ar.20,1999 (K)
LIST OF ABBREVIATIONS
A ampere{s} tb pound(sl
ABDC after bottom deadcenter m meter{s}
AC alternatingcurrent min minute(s)
ATDC after top deadcenter N naryton(sl
BBDC before bottom dead center Pa pascal(s)
BDC boftom dead center PS horseporer
BTDC before top deadcenter psi pound(s)persquareinch
"c degree(s) Celsius rwolution
DC direct current rpm revolution(slperminute
F farad(s) TDC top deadcenter
.F
degree(slFahrenheit TIR total indicatorr€ading
ft foot, feet volt{s)
s gram{s) W watt(s)
h hour(sl o ohm(s)
L liter(s)
ReadO,I/NER'SMANI At beforeoperating
EMISSIONCONTBOL INFORMATION
The CleanAir Act, which is the Fede€l law coveringmotor vehiclepollution, contains
what is commonly referredto asthe Act's "tamperingprovisions."
"Sec.203(a)The follorving actsand the causingthereof are prohibited...
(3)(A) for any personto removeor renderihoperativeany deviceor elementof design
installed on or in a motor vehicleor motor vehicle engine in compliancewith
regulationsunder this title prior to its saleand deliveryto the ultimatepurchaser,
or for any manufactureror dealerknowingly to removeor renderinoperativeany
such device or element of designafter such sale and delivery to the ultimate
purchaser.
(3XB) for any personengagedin the businessof repairing,servicing,selling,leasing,or
trading motor vehiclesor motor vehicleengines,or who operatesa fleet of motor
vehiclesknowingly to remove or render inoperativeany deviceor element of
designinstalled on or in a motor vehicle or motor vehicleenginein compliance
with regulationsunder this title following its sale and delivery to the ultimate
ourchaser..."
TAMPEBINGWITII NOISECONTBOLSYSTEMPBOHIBITED
Federallaw prohibitsthe followingacts or the causingthereof: (1) The removalor
rendering inoperativeby any personother than for purposesof maintenance,repair, or
replacement,of any darice or elementof designincorporatedinto any neurvehicle'for
th€_.purposeof noisecontrol prior to i6 sale or delirieryto the ultimatepurchaser or
while it is in use,or (21the useof the vehicleafter grch deviceor elemento:f a".id h.,
beenremoredor renderedinoperativeby any pervrn.
_Amongthoseastspre$medto constitutetamperingaretheactslistedbelow:
. R.eplacem€nt
of_the originalexhaustsystemor mrifflerwith a componentnot in com-
pltancewtth Fedeftrlregulations.
oRemovalof the muffler(s)or any internalportion of the muffler(s).
.Removal of the air box or air box cover.
rModifications to the muffrer(s) or air intake system-'
by cutting,
-- dri ing, or other means
if such modificationsresult in increased
noisetevLis.
Foreword
This manualis designedprimarilyfor useby
trainedmechanicsin a properlyequippedshop. Howto Usethis Manual
However, it contains enough detail and basic
information to make it useful to the owner ln preparing this manual, we divided the
who desiresto perform his own basic main- product into its major systems, Thesesystems
tenance and repair work. A basic knowledge becamethe manual'schapters. All information
of mechanics,the proper use of tools, and for a panicularsystemfrom adiustmentthrough
workshop procedures must be understood in
disassemblyand inspectionis located in a single
order to carry out maintenanceand repair
chapter,
satisfactorily, Wheneverthe owner has insuf-
ficient experienceor doubts his ability to do The Ouick ReferenceGuide showsyou all of
the produst,s systems and assisB in locating
the work, all adjustments,maintenance,and
repair should be carriedout only by qualified their chapters. Each chapter in turn has its
olvn comprehensive Table of Gontents.
mechanics.
The PeriodicMaintenanceChan is locatedin
In order to perform the work efficiently and
the General Information chapter. The chart
to avoid costly mistakes,read the text, thor- givesa time schedulefor required maintenance
oughly familiarize yourself with the procedures
operations,
before starting work, and then do the work
lf you want spark plug information, for
carefully in a clean area. Whenwer special
example,go to the PeriodicMaintenanceChart
tools or equipment are specified, do not use
first. The chart tells lou hovv frequently to
makeshifttools or equipment. Precisionmeas-
clean and gap the plug. Next, use the Ouick
urementscan only be made if the proper in-
ReferenceGuide to locatethe ElectricalSystem
strumentsare used, and the use of substitute
chapter. Then. usethe Tableof Gontentson the
tools may adversely affect safe operation.
first pageof the chapterto find the Spark Plug
For the duration of your warranty period,
especially,we recommendthat all repairsand section.
Whenaneryou see these WARNING and
scheduledmaintenancebe performedin accord-
ance with this service manual, Any owner CAUTION symbols, heed their instructions!
maintenanceor repair procedurenot performed Always follow safe operatingand maintenance
practices.
in accordancewith this manual may void the
warranty.
To get the longest life out of your Motor-
cycre:
oFollow the PeriodicMaintenance Chartin the oThis waming rymbol identifiesspecialinstruc-
ServiceManual, tions or procedures which, if not correctly
.Be alert for problems and non-scheduled followed, could result in perconal iniury. or
maintenance. lossof life.
eUseproper tools and genuineKawasakiMotor-
cycle parts. Special tools, gauges,and testers
that are necessarywhen servicing Kawasaki
motorcyclesare introducedby the SpecialTool oThis caution symbol identifies specialinstruc-
Manual. Genuinepafts providedasspareparts tions or procedureswhicfi, if not strictly ob-
are listed in the PansCatalog. served,could result in damageto or destruc-
rFollow the procedures in this manual car+ tion of equipment.
fully. Don't take shortcuts.
rRemember to keep complete recordsof main- This manual contains five more symbols (in
tenance and repair with dates and any new addition to WARNING and CAUTION) which
pafts installed. will help you distinguish different types of
information.
NOTE
oThis note symbol indicates pointr of partic-
ular interest for more efficient and con-
venient operation.
.Indicates a proceduralstep or work to be
done.
olndicatesa proceduralsub-stepor how to do
the work of the proceduralstep it follows.
It also precedesthe text of a WARNING,
CAUTION, or NOTE.
* lndicatesa conditionalstepor what actionto
take based on the results of the test or
inspectionin the proceduralstep or sub-step
it follows.
*lndicates a conditional $b-step or what
astion to take bas€dupon the resultsof the
conditionalstepit follows.
GeneralInformation
Tableof Contents
BeforeServicing 1-2
Modelldentification. . . . . 14
GeneralSpecifications. ,.. 1-5
Periodicmaintenance Chart. 1-7
Torqueand LockingAgent 1€
Cable.WireandHoseRouting. 1-12
1.2 GENERALINFORMATION
Before Serwicing
forms the pressfit with the basecomponentto avoid damagingthe bearings. This preventsseverestress
on the balls or needlesand races,and preventracesand balls or needlesfrom being dented. Pressa ball
bearinguntil it stops at the stops in the hole or on the shaft.
(13) Oil Sealand GreaseSeal
Replaceany oil or greasesealsthat were removedwith new ones,as removalgenerallydamagesseals.
When pressingin a seal which has manufacture/smarks,press it in with the marksfacing out. Seals
should be pressedinto place using a suitabledrivet which contacts evenlywith the side of seal, until the
{ace of the seal is even with the end of the hole. Beforea shaft passesthrough a seal,apply a little high
temperaturegreaseon the lips to reducerubberto metalfriction.
(14) Circlip.RetainingRing.and CotterPin
Replaceany circlips, retaining rings. and cotter pins that were removed with new ones, as removal
weakensand deformsthem. When installingcirclipsand retainingrings, take careto compressor expand
them only enough to installthem and no more.
(15) Lubrication
Engine wear is generallyat its maximum while the engine is warming up and before all the rubbing
surfaceshave an adequatelubricativefilm. During assembly,oil or grease (whichever is more suitable)
should be appliedto any rubbing surfacewhich has lost its lubricativefilm. Old greaseand dirty oil should
be cleanedoff. Deterioiatedgreasehas lost is lubricativequalityand may containabrasiveforeign panicles.
Don't use iust any oil or grease. Some oils and greasesin particularshould be used only in certain
applicationsand may be harmful if used in an applicationfor which they are not intended. This manual
makesreferenceto molybdenum disulfide grease(MoS" ) in the assemblyol certainengine and chassis
parts. Always check manufacturerrecommendationsbetoreusing such speciallubricants.
(16) Electrical Wires
All the electricalwires are either single-coloror two-color and, with only a few exceptions,must be
connectedto wires of the samecolor. On any of the two-color wires there is a greateramount of one color
and a lesseramount of a second color, so a two-color wire is identified by first the primarycolor and then
"yellow/red" wire;
the secondarycolor. For example,a yellow wire with thin red stripes is refenedto as a
"redlvellow" wire il the colorswere reversedto make red the main color.
it woufd be a
(17) ReplacementParts
When there is a replacementinstruction,replacethesepartswith new ones everytime they are removed.
Thesereplacementpartswill be damagedor losetheir originalfunction once removed.
(18) Inspection
When parts have been disassembled,visually inspectthese parts for the following conditions or-other
damage. lf there is any doubt as to the conditionof them, replacethem with new ones.
Abrasion Crack Hardening Warp
Bent Dent Scratch Wear
Color change Deterioration Seizure
(19) Specifications
SDecificationterms are defined as follows:
"Standards":show dimensionsor performances which brand-new partsor systemshave.
"Service Limits": indicate the usable limits. lf the measurementshows excessivewear or deteriorated
performance,replacethe damagedparts.
14 GENERAL ]NFORMATION
Model ldentification
GeneralSpecifications
VNl500"A1IAZA3/AN
ASIAGI
A AAAglA1UA11tA1AA1g vNl 500-81/B2/B3/BtyB5/B6
DriveTrain:
Primaryreduction system:
Type Gear
Reductionratio 1.s17(8s/56)
Clutchlype: Wetmultidisc
Transmission:
Type 4-speed,constantmesh,returnshift
Gearratios:1st 2.s00(40/16)
znd 1.s90(35/22),41 1-1.375(33t24],
3rd 1.192(31/26),
411-1.03s(29/28)
4th 0.965(28/29),Al 1-0.781125/32)
Finaldrivesystem:
Type Shalt
Reductionratio 2.619(15/21
x33/9)
Overalldriveratio 3.838,411-3.105@Topgear
Finalgearcaseoil:
Type API GL-sHypoidgearoil
SAE90(above5"C)
SAEso(below5"C)
Capacity 22OmL
Frarne:
Type Tubular,doublecradle
Caster(rakeangle) 31" 33' , (E)32.5"
Trail '128
mm 138mm,(E)132mm
Fronttire: Type Tubeless Tube
Size 100i90-1957H
Reartire: Type Tubeless Tube
Size 15O90-15 74Ho|l5cl/90-15M/C74H =-or 150/90815
M/C74H
Frontsuspension:
Type Telescopic
tork
Wheeltravel 150mm
Rearsuspension:
Type Swingarm
Wheeltravel 100mm
Braketype: Front Singledisc
Rear Singledisc
ElectricalEquipment:
Battery 12V20Ah
Headlight: Type Semi-sealedbeam
Butb '12
V 60/55W (quartz-halogen)
Taiubrake light 12V A7127Wxz( )(E)12V s/21WX2
Altemator: Type Three-phaseAC
Ratedoutput 25 A @6000r/min(rpm),14V
Specitications
are subjectt(
to changewithoutnotice,andmaynot applyto everycountry.
OPERATION
Sparkplug - cleanandgapt a o
O a a o
Air suctionvalve- checkt a o a o a a
Air cleanerelement- clean t # a o a
Throttlegrip play - checkt a a a o
ldlespeed- qdiust a o a a
Carburetorsynchronization- checkt o o o
Engineoil - change# o o
6 months a o a a a
Oil lilter - replace a a a o
Oil screen - clean a a a a
Radiatorhoses,connections- checkt a
Coolant - change 2 yeas a
Finalgear caseoil level - checkt a a a
Finalgear caseoil - change O a
Propellershaft joint - lubricate a a
Clutch slavecylindg piston seal - replace 4 years
Brakelining or pad wear - checkt # a a a a a a
fluid levet- checkt
Brake/clutch month a o a a a a a
Brake/clutchfluid - change 2 yeas a
Brake/clutch
mastercylindercup anddust
seal- replace 4 years
Caliperpiston seal and dust seal - reprace 4 years
Brakelight switch - checkt a a a o o a a
Steering - checkl a a a a a a a
Steeringstem bearing- lubricate 2 yeats a
Frontfork oil - change 2 years a
Rearshock absorberoil leak - check T a a a
Frontfo* oil leak - checkt a o a
Tirewear - checkt a a a a a a
Spoketightnessand rim runout - checkt a a a
(vN15008) a a a a
Swingarm pivot - lubricate a a
Baftery elgctrolyte tevel - checkl 6 month o a a a a a
Generallubrication- oerform a a O
Nut, bolt, and fastener tightness - checkt a a a a
: Service more. frequently when operating in severe conditions; dusty, wet, muddy,
, high speed, or frequent
starting/stopping.
: For higher odometerre€dings,repeatat the frequencyintervalestablishedhere.
T : heprace,add, adJust,ctean,or torque if necessary.
GENERALINFORMATION1.7
Whichever TODOMETER
READING
FREOUENCY comesfirst
OPERATION I
- checki
Garburetors,ynchronization a a a a a a a
ldle soeed-- adiusl o a a a a a a
Throttle grip play - check 1 a a a a
Spark plug - cleanand gap t a a a a a o
Air suctionvalve- check J a a a a a a
Air cleanerelement- clean a a a a
Air cleanerelement- replace 5 cleaninqs a
Fuelsystem- checkt o a a
Evaporative emissioncontrolsystem(CA) a a a a a a a
- checkt
Batterv electrolvtelevel- checkt month a a a a a a a
Brakeliqht s\n,itch-. check f a O o a a a a
Brakepadwear- check f a o a a a a
Brake/clutchfluid level- checkI month a a a a a a a
Brake/clutchfluid - chanqe 2 vears a
Steerins- checki a a a a a a a
Final qearcaseoil level- checkt a a a
Final gearcaseoil - change a a
Propellershaftioint - lubricate a a
Nut, bolt. fastenertightness- check1 a a a a
Spoketightnessand rim runout - checki O a a a a a a
(VN1500-8only)
Iire wear- checkt a a a a o o
Enqineoil - chanqe year a a a a
Oil filter - replace a a a a
- clean
Oil screen a a a a
Generallubrication- perform a a a a a a
Front fork oil - chanqe a
Swinqarm pivot -- lubricate a a
Coolant- change 2 yearc a
Radiatorhoses,connections- check1 year a a a a
Steeringstembearing- lubricate 2 years a
Brake/clutchmastercylinder cup and 2 years
dust seal- reolace
Caliperoiston sealand dust seal- replace 2 yearc
Clutch slavecvlinder piston seal- replace 2 years
hoseandpipe- replace
Brake/clurch 4 years
Fuel hose- reolace 4 years
here.
r : For higherodometerreadings,repeatat the frequencyintervaleEtablished
t : Replace,add, adjust,clean,or torque if necessary.
(CA):California
vehicleonly
1€ GENERAL INFORMATION
The foilowing tableslist the tighteningtorque for the majorfasteners,and the partsrequiringuseof
a non-permanentlocking agentor liquid gasket.
Lettercusedin the "Remarks" column mean:
L Apply a non-permanentlocking agentto the threads.
ss Apply siliconesealantto the threads.
M Apply molybdenum disrlfide lubricant (greaseor oil) tq the threads and seatedsr rface, or
washer.
o Apply oil to the threads,seatedzurface,or washer.
b Tightenthe fastenersfollowing the specifiedtoroue.
st stake the fastenerto prwent loosenins.
Torque
Fascner Remarks
N-m kgrn ft-lb
CoolingSystem:
CoolingFanSwitch 7.8 0.80 69 in-lb
BleedValve |
7.8 | 0.80 69 in-lb
WaterPumplmpellerBolt 8.8 | 0.90 78 inlb Left-handed
Threads
WaterPumpCover 9.8 1.0 87 in-lb
EngineTop End:
RockerCaseCoverBolts 8.8 0.90 78 in-lb
RockerShaft 25 2.5 18.0
RockerCaseBoltsandNuts: 12 mm 78 8.0 58 S
8mm 25 2.5 18.0 S
6mm 8.8 0.90 78 in{b s
CylinderHeadNuts 25 2.5 18.0
CylinderNut 25 2.5 18.0
Oil PipeBanjoBolts 12 1.2 104inlb
Camshaft SprocketBolts 15 1.5 11.0
SparkPlugRetainer 12 ,:
'104in-lb
ChainTensionerBolts L
Clutch:
Clutch LeverPivot Nut 5.9 0.60 52 in-lb
MasterCylinderClampBolts 8.8 0.90 78 in-lb
Clutch HoseBanioBolts 25 2.5 18.0
Clutch SlaveCylinder Bolts 8.8 0.90 78 in-lb
BleedValve 7.8 0.80 69 inlb
RH EngineCoverDamperBolts 9.8 1.0 87 in-lb L
ClutchHub Nut 145 15.0 110 o
ClutchPioeJoint 18 1.8 13.0
EngineLubricationSystem:
CrankcaseOil Nozzle 2.9 0.30 26 in-lb
Oil Pressre Relief Valve 20 2.O 14.5 L
Oil PrescrreSwitch 15 1.5 11.0 SS
EngineDrainPlug N 2.O 14.5
Oil Filter 18 1.8 13.0
Oil ScreenPlug 20 2.O 14.5
Oil PipeBanjoBolts 12 1.2 l(X in-lb
GENERAL INFORMATION1-9
Crankshaft /Transmission:
CrankcaseBolts: 10 mm ?o 4.0 29
8mm 21 2.1 15.0
6mm 8.8 0.90 78 in-lb
ExternalShift Mechanism
ReturnSpring Bolt 21 1.1 15.0
GearPositioningLeverBolt 8.8 0.90 78 in-lb
ConnectingRod Big End Cap NUts 59 6.0 +J
'|
PrimaryGear Bolt 45 15.0 110
AlternatorRotor Bolt 6.0 43
CamshaftChainGuideHolderBolts L
StarterClutch Bolt 93 o:,
StarterClutch Coupling Bolt 11.0 L
BalancerGearBolt :,5 Y.C
Shift Drum BearingHolderScrew L
,tt
NeutralSwitch 1 1. 0
Rear-rightStud Tap End L
Wheels/Tires:
FrontAxle Nut 88 9.0
FrontAxle Clamp Bolt 29 ?n 22
RearAxle Nut 110 11.0 80
Air Valve Nuts 1.5 0.15 1 3i n - l b
Final Drive:
Front BevelGearCaseBolts:
6mm 8.8 0.90 78 in-lb
8mm 25 2.5 18.0
DamperCam Nut 225 23 toc o
Drive GearNut 265 27
NeutralSwitch 15 I.C 11.0 L
Oil PipeBanjoBolts 12 1.2 104 in-lb
DrivenGearAssemblyMounting Bolts 25 2.5 18.0
DrivenGearBolt 120 12.1 88
FinalGearCaseMountingNuts 29 3.0 22
PinionGearNut 120 12.O 6t St
FinalGearCaseCover Bolts:
8mm t2 2.3 16.5 L
.,8
10mm 34 ? E L
FinalGearCaseStuds L
DrainBolt 8.8 oso Z S i n - fO
PinionBearingRetainer 245 25 180 Left-handed
Threads
RetainerStop Screw 16 1.6 11.5 L
1-IO GENERAL INFORMATION
Torque
Fastener Remarks
N-m kg-m ft-m
Brakes:
BrakeLeverPivotNut 0. 60 52 inlb
FrontlvlasterCylinderClampBolts 8.8 0. 90 78 inlb
BrakeHoseBanjoBolts 25 2.5 1 8 .0
CaliperMountingBolts 32
BleedValves 7.8 0. 80 69 in-lb
DiscMountingBolts 27 2.8 20
RearMasterCylinderMountingBolts 23 2.3 to. c
CaliperHolderBolt 64 6.5 47
BrakePedalLinkClampBotts 25 2.5 1 8 .0
Suspension:
FrontForkClampBolts: Upper 20 2.O '14.
5
LOWer 52 5.3 38
FrontForkDrainBolts
FrontForkBottomAllenBotts 20 2.O 14. 5
SwingArm PivotShaft 98 1 0 .0 72
FrontAxleClampBolt 29 3.0 2.
Fear ShockAbsorberl\ilountjngNuts 30 3. 1 22
Steering:
Handlebar ClampBolts 59 6.0 zl3
WeightMountingScrews
SteeringStemHeadBolt 4.O 29
SteeringStemLocknut 0. 50 43 inlb
Ftame :
RightDownTubeMountingBolts 44 4.5 33
EngineMounting BracketBolts 24 2.4 1 7 .5
BrakePedalLinkClampBotts z5 2.5 1 8 .0
ElectricalSystem:
AlternatorRotorBolts 59 6.0 43
SparkPlugs 18 1.75 't2.
5
CoolingFanSwitch 7.8 0. 80 69 inlb
NeutralSwitch 15 '1.
5 11.0
Oil PressureSwitch 15 t.c 11.0
GENERALINFORMATION1.11
The tablebelow,relatingtighteningtorqueto threaddiameter,lists*re basictorquefor the bolts
and nuts. Usethis table for only the bolts and nutswhichdo not requirea specifictorquevalue.
All of thevaluesarefor usewith dry solvent+leaned
threads,
General Fastenen
Torque
Threadsdia. (mml
N-m kgm ft-lb
c 3.4 - 4.9 0.35- 0.50 30 - zt3in-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.O 54-72
16 115-155 1 1 . 5- 1 6 . 0 8 3- 1 1 5
18 165 -225 17.O-23 125- 165
20 225-325 23 - 3:t 165- 2'10
1-12 GENERALINFORMATION
Cable,Wire,andHoseRouting
................;,,.......
WidngRouting
1. Wire Straps
2. CoolingHoses
3. SideStandSwitch
4. RearBrakeLight Switch
5. FuelPump
(vN1500-B)
1. JunctionBox
1. WireClamps 2. Sarter Relay
2. RearFenderRearSection 3. Battery(+) Wire
3. RearTurn SignalLight 4. Battery
GENERALINFORMATION1.13
Cable, Hoseand Wire Rouling
l. Left SwitchHousingWire
2. ClutchHose
3. WireStraps
4. Bnke Hose
5. RightSwitchHousingWire
6. CableGuide
7. ThrottleCables
8. Turn SignalLight or HeadlightStay
9. Cableor HoseGuide
.l0.
Speedometer Cable
11.Clamps
12. CoolingHose
13: ClutchPipe
1-14 GENERAL INFORMATION
CarburetorHoseRouting (CanadianModel)
l. VacuumHose
2. VacuumHoseFitting
3. VacuumHose(To RearVacuumSwitchValve)
4. VacuumHose(To IC lgniter)
5. Air BreattrerHose
6. Air BreatherHoseFitting
7. VacuumPulseHose(To Liguid/VaporSeparator)
8. VacuumHose(To Front VacuumSwitchValve)
9. Front VacuumSwitchValve
10. ChokeKnob
l l. Air BreatfterHose(To Canister)
'12.
PurgeHose(Betweenthe surgetank andthe canister)
(US.CaliforniaModel)
GENERALINFORMATION1.15
HoseRouting
(vNlsoGA)
1 . BreatherHose
2. CheckValve
3. ReturnHose(Red)
'..__
-E
I * l :
i------E--i-
(vN1s00-B)
1. FrontVacuumSwitchValve
2. Wireor HoseStraps
3. Liquid/VaporSeparator
4. Batttry
5. lgnitionCoil (Front)
6. lgnitionCoil (Rear)
7. ReturnHose
8. BreatherHose
9. StarterMotorWire
1. CleanAir Hose
2, VacuumHose
'3.
'4. RearVacuumSwitchValve
HoseGuide
5. Vent Tube
6. ReservoirTankTube
7. ReservoirTank
8. Wireor HoseStraps
9. lgnitionCoil (Front)
10. lgnitionCoil (Rear)
11. Canister
GENERALINFORMATIONT-17
Eyaporatiye Emi$ion control System Hose Routing
l. HoseSt€ps
2. EngineBracket
3. HoseClamp
4. Canister
5. Liquid/VaporSeparator
5. CoolingHose
7. StarterMotor
8. StarterMotor Wire
9. Radiator
,/.-\
, )
1. FuelTank
2. CheckValve(VN150GA)
3. BreatherHose(Blue)
4. Liquid/VaporSeparator(ReturnPump)
5. VacuumPulseHose(White:To Carburetor)
6. BreatherHose(Blue)
7. ReturnHose(Red)
8. Cover
9. Canister
10. BreatherHose(Yellow: To Carburetor)
11. PurgeHose(Green)
12. SurgeTank
I.18 GENERAL]NFORMATION
Engine Top End Ho.e Routing
'!i!
1. VacuumHose(lC lgniter)
,-'.------'- 2. CoolingHose
3. ThermostatHousing
4. FrontVacuumSwitchValve
5. FuelFilter
5. Clut h Hose
7. ThroitleCables
8. VacuumHose(To Front VacuumSwirchValve)
9. CleanAir Hose
10. ClutchHoseStrap
11. CoolingHose
12. VacuumHose(FrontCarburetor)
13. FuelHose(To Carburetor)
14. FuelPump
15. SurgeTank
16. VacuumHose(RearCarburetor)
17. VacuumHose(To RearVacuumSwitchValve)
18. FuelHose(To FuelPump)
19. Air BreatherHoseFitting
20. Res€rvoir
Tank Tube
21. Air BreatherHose
FUEL SYSTEM2-1
Fuel System
Table of Contents
ExplodedView... 2-2
Specifications 2-5
SpecialTools. ......,.'. 2-5
Throttle Grip and Cables.. 2-6
Throttle CableAdjustment 2$
Carburetorc, 2-7
ldle SpeedAdiustment 2-7
High Altitude PerformanceAdjustment (US model). 2-7
Fuel SystemCleanlinessInspection. 2-7
CarburetorSynchronization 24
ServiceFuel LevelAdjustment . . . . . . 24
CarburetorRemoval 2-9
CarburetorI nstallation 2-10
CarburetorSeparation.. , 211
CarburetorCombination 2-11
CarburetorDisasembly. 2-12
GarburetorAssembly.. . . . 2-12
Carburetor Inspection, 2-14
FuelPump. 2-14
Removal 2-14
lnstallation Notes . . 2-15
Fuel Filter. 2-15
Removal 2-15
lnstallationNotes. , 2-15
Inspection 2-15
Air Cleaner 2-15
Element(Housing)Removal 2-15
E l e m e n t C l e a n i.n. s. . . . 2-16
Air CleanerHousingInstallation... . . 2-16
Air CleanerDuct lnstallation 2-17
SurgeTank 2-17
SurgeTank Removal 2-17
ControlSystem(USCaliforniaVehicleonly)' . . '
Emission
Evaporative 2-17
Notes. .
PansRemoval/lnstallation 2-17
HoseInspection. 2-17
SeparatorInspection. 2-17
SeparatorOperationTest 2-18
CanisterInspection 2-18
2.2 FUEL SYSTEM
ExplodedView
(D
f---r
t
I
^
A-
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|
IfrPtri
?."---x
V @-+
6
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va
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reu) €- l,lf
PEB
a
a
./'1
A12:CN
(us)(vy)
1. Left Switch Housing
"al
""\.€
2. Right Switch Housing
3. ThrottleCable(Accelerator)
4. Throtlle Cable(Decelerator) A12:CN
€ (US)(w)
5. Jet Needle
6. ThrottleValve
\ s 6
sBe
7. FloatValveNeedle
8. Float Pivot Pin
9. Float
t0. PilotScrew
11.NeedleJet Holdei
,u&^,
12. MainJet
13. Fuel DrainScrew
14. Botlom Cover
15. FrontCarburetor
16.RearCarburetor g
17. FloatChambel
18.ChokeKnob Assembty t
FUEL SYSTEM2.3
a 1. DrainHose
rlr 2. VacuumSwitchValve
A12:CN
o-l frles 3. Air CleanerDuct
(usxw) I ti uEi i 4. Surge Tank
5. Surge Tank Duct (Front)
i9t 6. Surge Tank Duct (Rear)
u 7. Air CleanerElement
A12:CN 8, Fuel LevelSensor
(us)w) 9. Fuel Tap
(cal)
(cal) CalitorniaModel
(us) U.S.A.Model
(W) SruitzerlandModel
(cN) CanadaModel
u-)
<-'
------46,
vNlsoGB
I
A
a e
I
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it 0 l i
24 FUEL SYSTEM
WHITEJ I
R
H
\ T J
€'
4
YELLOW
1. FuslPump
ffi
p
2. Bnd(ct
3. Uquid/V8porSsp.rsbl
4. Cani*er
FUEL SYSTEM2€
Specifications
Item Standard
ThrottleGrip :
Throttlegripfreeplay 2-3 mm
Carburetors: vN 1500-4 vN1500-8
Make,type Keihin,CVK36
Mainjet: Front # 1 1 2 , ( C a#l1) 1 8 #130
Rear # 11 2 , ( U S X C # 1)1 5 , ( C a#l )1 1 8 #132
Jet needle: Front Ns3S,(cal)N53U,(W)N67F N36P,(cal)N36R,
W)N77D
Rear N67A,(USXC) N53T,(cal) Ns3V,(W) N67G N36Q,(Cal)N36S,(W)N77D
Pilotscrew 1 ll2 turnsout,As-(FG),A4-(EU):2 1/4turnsout,(USX\9-
Servicefuel level:Front 2 - 2! 1 m m
Rear 4.2!1mm
750-850 r/min(rpm)
(W)8s0-950 r/minGpm)
vacuum
Synchronization Lessthan2.7 kPa(2 cm Hg)
SpecialTools
Fuel LevelGaugp:57m1-1017
2€ FUEL SYSTEM
l. ThrottleGrip FreePlay
A. Accelerator
Cable C. AdiustingNuts
B. Decelerator
Cable D. Locknuts
oLoosen the locknuts,and screwboti throttle cable
adiustersin completelyat the upper ends of the
throttle cablesso asto givethe throttle grip plenty of
play.
.While holdingthe thrortlegripstopagainstthe stopper
inside,turn out the decelerator
cableadrusterstopping .Turn out tl|e deceleratorcableadjustingnut in the
at the point wherethe grip just beginsto be turned sameway with the adlusterat the upperend of the
b.ackfrom the completelystoppedposition. Tighten decelerator cablemakinglure that the throttle grip is
the locknut. not tumedbackat all, Tightenthe locknut.
aTurn the acceleratorcable adiustingnut until the
correctthrottle grip free play is obtained.
.Checkthe following.
ostartthe engine.
oTurn the handlebarfrom side to sidewhile idling the
engine.
*lf the speedvaries,the throttle cablemay be poorly
routedor it may be damaged.
oConectany problemb€foreoperatingthe motorcycle.
@ : SwissModel(VNls(XlB)
1. DrainScrew
2. SuitableHose
3. Bottom Cover
rCheckidle speed.
1. VacuumHoseFittings
1. FuelLevelGauge:57001-1017
2. CoastingEnricher
3. UpperEdgeofthe Screw
A. AdjusterBolt 4. "Zero" line
FUEL SYSTEM2-9
oTurn the fuel tap to the ON or RES position to feed Carburetor Removal
fuel to tie carburetor, then turn ou! tie carburetor
drain plug a few turns.
.Read the fuel level in the gaugeand compare it to the
specification- Screw in the carburetor drain plug. ocasolineis extremelyflammableandcan be exPlosive
S€rvice Fuel Level under certain conditions. Turn the ignition switair
From the uppet edgp ol dre coalting enticher OFF. Do not smoke. Make sure dte area is well
moundng lower screw. ventilatedandfrce frcm any rcurceof flameor lparks;
wi$ 8 pilot light.
this indudssany appliance
Flont : below 12 - 32 mm
Rear : below 32 - 52 mm .First removethe following.
Seat
*lf the fuel level is incorrect, removethe carburetorsand FuelTank
separatethem (seeCarburetor Sepration). Drainthe fuel from the carburetor.
.To adjust the fuel level,bend the tang on the float arm Loosenthe tirottle cableadiuster.
to changethe float height. .Then removethe followingfrom the left side.
Throttle CableHolder Screw
SurgeTankDuctClampScrew(Loosen)
CarburetorHolderClampScrew(Loosen)
VacuumHose
A. Float B. Tang
1. Float Tang
2. Float Valve
3. Floa! Mating Edge
4. ChamberRibs A. SurgeTankDuctClampScrew
B. CarburetorHolderClampScrew
NOTE
C. VacuumHose
oDo not push the ndle rcd in during the float height D. CarburetorCoverBracket
masufement. E. C:rburetorCover
2.10 FUEL SYSTEM
rThen removethe follwoingfrom the upperend.
CleanAir SystemHose
Fuel Pumpand Pull the output hosefrom the carbu-
@
retor. olf dirt or durt is allowed to pals through inio d|e
FuelPumpWireConnector carbuntors, the d|rctde may becomerfrrck, possibly
SurgeTank Duct (Front Carburetor) cauringan accident.
l-wAnNrNil
J
oFud .pill.d irom tft€ fud pump & h..:adous. mml
olf dirt gsts through into dte engine. €xcessive engine
wear and polsibly enginedamagewill ocorr.
@rburetortnsallation
.Carburetor installationis the reverseof removal. Note
the following.
olubricate the air cleanerducts and the carburetor
holdercwith a soapand water solution,theo fit the
carburetorsinto them.
owhile aligningthe duct notch onto the surgetank
proiection,fit.eachduct into th€ surgetank asshown.
A. FuelPump C. OutputHose
B. CleanAir SystemHose D. SurgeTank Duct
.fush the surgetank witl the thermostathosingtoward
the front.
aRemovethe carburetorsasshown.
A. Turnthecarburctorassernbly
clockwise.
I'--wAutlruc
i
oFuel spilled from the catburetoF b hazardous.
A. RearCarburetor C. FrontCarburetor
B. FloatChamber D. Screws
A. Choke Rod B. Screws
rb u retor Combinati on
C.ze
.lnstallationis reverse
of removal. NoGthefollowing.
aFit thefrontcarburetor asshown.
to thefloatchamber
A. StarterPlungerLever C. StarterPlunger OTum in the pilot screw and count the number of turns
B. ChokeLink Rod until it seats fully but not tightl, and then remove the
screw. Use this number of turns to set the screw to its
originalposition during assembly.
olnstallthe chokerod to the carburetor. awhile prying out the float pivot pin with an awl or other
suitabletool, pull it out with needlenose pliers.
1. FloatPivotPin
A. ChokeRod
Carbu,etor Asembly
.Note tle following
.lnstall the float on the carburetor.
Carburetor Disassembly oTapthe float pivot pin lightly,to pressit evenlyinto
thefloat chamberbodyasshown.
cAunoN
Do not apply too much bonding agent to the plug, or
th€ pilot gcrew itself may be tixed-
agent. 3. PilotScrew
1. Applya bonding
2. Plug 4. CarburetorBody
1 . M a i nJ e t 2. Needle.let Holder
W
'1.
O ring
2 . Cover
2-14 FUEL SYSTEM
Carburetorlnspection
1. PilotScrew 2. TaperedPortion
FuelPump
Removal
(H .Removethefueltank.
l. Rod 3. ValveNeedle
Wear
2. ValveNeedle
A. FuelPump B. PumpBolts
*lf the plastic tip is damaged,replacethe needle. .Remove the bolts and take the fuel pumpout of the
*lf it does not springout, replacethe needle. frame-
acheck the tapered portion of the pilot screwfor wear aDisconnect the pumpwireconnector.
or oamage. oPullthe fuel hosesoff the fuel pump.
FUEL SYSTEM2.15
lnstallation Nota
to thepumpfittingsasshown.
.Connectthefuelhoses
A. FuelHosefrom Tank C. Arrow
B. FuelHos€to Pump
lnspection
oVisuallyinspectthe fuel filter.
*lf the filter is clear with no signsof dirt or other
contamination,. it is OK and need not be replaced.
ilf tlre filter is dark or looks dirty, replaceit. Also,
check the rest of the fuel sysGmfor contamination.
A. FuelHosefrom Filter
B. FuelHos€to Carburetors
l-wnnruruol
l-
ocasoline b cxlrsmely flammableand can be sxploEiv€
under csnsin conditions. Tum the ignition rwitdr
OFF. Do not 3moke. Make lure the area is well
ventilatedand frss from any rcurcaof flame or :perkr;
thb indudesany appliancewi$ a pilot light.
oBe preparedfor fusl spillsgE.
Installation Notes
alnstallthe fuel filter so that the arrowon it showsthe
fuel flow from the fuel tankto the fuel pump. A. Air CleanerHousing B. Bolts
2.16 FUEL SYSTEM
.Remove the screlysand take the inner cover off the Element Cleaning
(VNl 50GBOnly).
housing
aRemovethe air cleanercoverby takingout the cover .Wash the element in a bath of high flash-point solvent
bolts. and then squeezeit dry.
VNlsOGA
Air CleanerHousinglnsallation
A. Cover C. Element .Note the following.
B. CoverBolts D. ElementBolts oTheright andleft air cleanerhousingareidentical.'Use
the markedR for the right sideand L for the left side.
vt{1500-8
A. Cover C. Element
B. CoverBolts D. ElementBolts
SurgeTank
.To preventgasolinefrom flowing into or out of the
canister, hold the separatorperpendicularto the
Surge Tank Removal grouno.
rRemovethe air cleanerhousing. .Connect the hosesaccordingto the diagramof the
.Removethe thermostathousing. system. Makesurethey do not get pinchedor kinked.
aUnconnectthe air cleanerduct upperend.
.Removethe surgetank from the frame.
*parator Inspection
.Disconnect the hosesfrom the liquid/vapor separator,
and removethe separatorfrom the motorcycle.
.Visually inspect the separator for cracks and other
damage.
l . SurgeTank 3. SurgeTank Duct (Rear) *lf the separator has any cracks or is badly damaged,
2. Air CleanerDuct 4. SurgeTank Duct {Front} reDlaceit with a new one.
2.18 FUEL SYSTEM
¶tor OperationTest Canister lnspection
aRemovethe canister,and disconnectthe hosesfrom
the canister.
.Visually inspect the canister for cracksand other
oc6oline is extrsmely flammableard can be explosive oamage.
undar csrtain conditionr. Tum the ignition switdl *lf the canisterin crackedor badlydamaged,replaceit
OFF. Do not moke. Make sur€ th€ area b well with a newone.
vontilatodand fr€e from any sourceof flame or spark;
thb induder any appliancswid| a pilot light.
NOTE
.Connect the hosesto the s€parator,and install the ome canitter is daignd to wo* well {rrough dE
s€paratoron the motorcycle. motorcycle's tife without my maintenanceif it is ud
aDisconnectt}le breatherhosefrom the separator, and under normataonditions.
iniect about 20 mL of gasolineinto the separator
throughthe hos€fitting.
aDisconnect the fuel returnhosefrom the fuel tank.
rRun tl|e openendof the returnhoseinto the container
levelwith the tank top.
.Start the engine,andlet it idle.
*lf the gasolinein the separatorcomesout of the hose,
the s€paratorworks well. lf it doesnot, replacethe
separator with a newone.
<-
l. FuelTank
2. SurgeTank
3. RearCarburetor
4. VacuumSwith Valve
5. BreatherHose
(Blue)
6. PurgeHose(Green)
7. ReturnHose(Red)
8. VacuumPulseHose
(white)
9. BreatherHose
(Blue)
10. BreatherHose(Yellow)
Separator: return pump
12. Canister
COOLINGSYSTEM+1
Cooling$ptem
Tableof Contents
ExplodedView... +2
Specifications 33
Coolant Flow Ghart,. , 33
Coolant. c4
Coolant LevelInspection. 34
Coolant Draining 3-,4
Coolant Filling 35
PressureTesting. 36
Water Pump. 3€
Visual Leak Inspection 3-6
WaterPump,MechanicalSealRemoval' 36
WaterPump,MechanicalSeallnstallation. g7
Radiatorand CoolingFan. c7
Removal 97
lnstallation $9
Radiatorlnspection, 39
RadiatorCap Inspection c9
Thermostat 910
Removal 3-10
Installation 911
Inspection. 3-11
ThermostatFan Switch. 3-12
Removal 3-12
lnstallationNote. . . 3-12
Inspection. 3-12
3.2 COOLINGSYSTEM
Exploded View
s-0
%n $--o@
q)ffiD
Sr,ffi{
g*t,J \@
%Nr
.fr'/
1. BleodValve
2. Th6rm6t8t
3. RadiatorCsp
4. W&r Pumplmpellsl
5, lmpdl€r Bolt
6. PumpCoY€r
7. Covel Bola
8, Drain Plug
9. R.diator
10. CoolingFan$vidr
11. Grcundmre Tl : 7.8 N-m(0.80kgn,69 in.lbl
12. CoolingFan T2: 8.8 N.rn(0.9Okgn,78 in{bl
13. R€.erroir Tank T3: 98 N.m (1.0kgn,87 inlbl
COOLINGSYSTEM}3
Specifications
Item Standard
Coolant:
Type Permanenttype of antifree (soft water and ethyleneglycol
plus corrosionand rust inhibitor chemicalsfor aluminum
enginesand radiators)
Mixed ratio Soft water 50%,coolant5096
Freezingpoint -€5"C (-31'Fl
Total amount 2.3 L
Radiator:
Radiatorcap relief pressure 93 - 123 kPa(0.95- 1.25kg/cm2,14 - 18 psil
Thermostat:
Valveopeningtemperature 80 - 84"C(176- 183"F1
Valvefull openinglift Morethan8 mm@5"C {2(B'F}
Whenthe engineis cold, the thermostatis closed,so trat the coolantflow restrictedthroughthe
smallholeon the thermostat(airhole),causingthe engine
to warmup morequickly.
1. Wat€rPump
2. WaterJacket
3. CylinderHead
4. WatrrPipe
5. WaterHos€
6. RadiatorCap
7. Thermostat
8. Reservoir
TankTube
9. Radiator
10. CoolingFan
34 COOLING SYSTEM
Coolant
oFor refillinS, add the specified mixture of coolant and
Coolant Level lnspection soft watet. Adding water alone dilutes the coolant and
degradesits anticorrosion properties,
oThe diluted coolant can attack tie aluminum engine
NOTE
parts. In an emergency, soft watet can be added. But
achsk the level when the engine is cold (room or the diluied @olant must be retumed to the correct
ambienttemperature)
- mixture ratio within a few days.
olf coolant must be added often. or dre reservoirtank
has run completely dry; there is probably leakagein the
cooling system. Ched( the rystem for leaks,
Coolant Draining
A. Cover C. FullMark
B. Screw D. Low Mark oRemovethe following.
Seat
FuelTank
RadiatorCover
A. Reservoir
Tank C. LOWMark
B. FULL Mark D. TankCap A. RadiatorCover B. Screws
COOLINGSYSTEM35
oPlacea suitablecontainerbeneaththe radiator.
CoolantDrainPlug
1. Coolant Level
2. ThermostatHousing
A. DrainPlug
RadiatorCap(Loosen) NOTE
oPou in the coolant slowty s that it an axpet the air
from die &gine ard ndiatur,
PressureTesting
.Remove the radiator
cap,andinstalla cooling
system
pressure
testeron the radiatorfiller neck.
NOTE
Wet the cap ealing wrfaces with water or coolant to
prcvent presure leaks.
A. Pressure
Tester C. RadiatorCap
B. Adapt€r
A. WaterPipe B. Bolt
tlf the pressure
dropssoon,checkfor leaks.
WaterPumpCover
WaterPump
NOTE
oThe impeller boh haetefthmdd thrads, thereforc it
musfbe flnad clockwic to ,emote
WaterPump, Mechanical Seallnstallation
.Note the following
NOTE
osince the tepleement mdranical wl h6 an adhmive
coatd body, do not apply liguid g6d<etto the ext€rior
srfe of the boty.
A. Flange B. Chisel
Radiatorand Cooling Fan
Removal
.Pull the mechanicalsealout of tie crankcase .Removethefollowing.
pliers.Oiscardthe remotedmechanical
seal. RadiatorCover
38 COOLING SYSTEM
RadiatorUpperBolt
Coolant(Draining)
CoolingFanSwitchConnector
A. UpperBolt
A. FanSwitchConnector
A. RadiatorHoses B. Clamps
m1
oMen doaning the radiator widr a 3tsam dealer, be
careftrl ol the following to prwent radistor damege'
1l Keepdre isam gun away moredran 05 m from the
FanMountingBolts radiatoraore.
2l Hotd tho st3am gun perpendicrer to the core
:urface.
3l Run rha st€sm qun hotizontslly following the core
fin direc'tion. Runningit venically nrsy dsmagsdro
ffnr.
A. Fan B. MountingBolts
lnsallation
.Be sureto attachthe groundwire to the fan mounting
bolt
Thermostat
Removal
.Removethe following.
FuelTank
Coolant:about200mL (Draining)
FuelFilter
ThermostatHousingBolts
NOTE
Wet the cap ealing arfaca with wateror coolant to
preventp,esure leaks.
A: FuelFilter C, ThermostatHousing
B. Bolts
1. Pressure
Tester z. Kilolaror Lap
Housing
A- Thermostat B. Screws A. Brackets
lnspection
aRemovethe thermostat,and inspectthe thermostat
valveat roomtemperature.
*lf the valv€is open,replacethe valvewith a newone.
.To check valve opening temperature,suspendthe
thermostat in a container of water and raisethe
lnstallation temperatureof the water.
.lnstall the thermostat noting the following.
olnstall the thermostat in the housing so that the air
hole is on toD.
EngineTopEnd
Tableof Contents
ExplodedView
@-q '/Fe-n45
z--@
Swiuerland Model o_M f
Wffireo
q
\
WoEee
Model
A12:Canada
Model
ffi-
Switzerland Model
wo
@@
1 . RockerCaseCap
2 . Spring
3 . Oil Fitter
L.-%
4 . Air SuctionValve
5 . CamshaftOil Seal
6 . RockerCase US Model Al2:CanadaModel
7 . CylinderHead
I . ValveGuide |--__\
o RockerCaseCover(SprocketSide)
1 0 RockerCaseCove.(HLASide)
1 1 SparkPlug Fetainer i . * % . \ ,& I
I
\_3__.,
1 2 CarburetorHold,er
o Apply engineoil.
ss Apply siliconesealant-
T1 8.8N-m(0.S0kg-m,78 in-lb)
f2 2s N-m(2.skg-m,18.0ft-lb)
T3 78 N-m(8.0kg-m,58 fl-tb)
T4 12 N-m(1.2kg-m,104inlb)
ENGINETOP END 4-3
? @
rffi
@*
r\
s"
#f'ff
\'/
*N*#? &
*#eM
1. Bod(6rSh8ft
2, RockorAm (x 3/1 GYlindetl
3. Rod(sr A]m (x 1/1 GYlinderl
4. Oil Chamber
5. Hydraulic LashAdiuster
6. valYeSpring{lnnert
7. vslre Spring(Ouetl
8. Oil S€l
9. ValveSt m (Exh$3tl M : Apply molybdsnumdi:ulfide grease'
10. V8lvoSsh (lntakel T 1 : 25 Nfl (25 kgF|n,18Oftlbl
4.4 ENGINETOP END
1. CYlinder
2, Drain Plug
3. Piston
4. Cam$aft Chain
w
5. Camshaft Spmcket
6. Camsh.ft
7. KACR (Automatic Compr€sion
Releasel
8. Camshaft Chain Tensioner
*€@\
Y
Ld,A
:%,H-@
! v /fe?
'
W.'*%f
6
L : Apply nonf€manent loddng ag€trt.
O : Apply endneoil.
T1: 15 N-m (15 kgFm,11O ft.lbl
T2: 25 Nrn (25 kgn,18.0 ft.lbl
TOP END 46
L Nut vN1500-A O--
2.
3.
ExhaustPipe Holder
ExhaustGasket
@__>
4. Exhaun Pipe (Leftl @--\b
5, ExhaustPipe {Right}
6. Gasket
@--od
7. PowerChamber
8. Muffler (Leftl
9. Muffler (Riqhtl
VN1sff}B
"eD
$, \
(*/
\--
ap
l I
\d
+6 ENGINETOP END
Specifications
stem /n
ter \y H
u
'
/ll
A
CamHeight
Valve head -- -------- -\
thickness
L
ValveGuideAtbor: 57q11-16:l
SpecialTools
Valve SpringCompressorAs.sembly:57(xl1'241
Adapter: 570O1-242
valyeSeatCutterHolder: 57001-1126
Bar:57001-1128
PistonPin PullerAisembly: 57001'910
Adaptcr:57001-1211
fr
R HexagondWrendr: 57001-1210
o
Sealant
(q(qKor((J
\7 \' \.7 \7 Kswa$ki Bond (Silicone Ssalantl: 56019{20
ValveGuideReamer:57001'162
48 ENGINE TOP END
Vacuum Switch Valve Operation
CleanAir System(US and Switertand models)
1. DuringCruising(OpenThrottle)
Air Suction Valve lnspection
avisuallyinspect
thereedsforcracks,
folds,warps,
hear
damage,or other damage.
*lf there is any doubt as to the condition of the reed,
replacethe air suctionvalveasan assembly.
2. DuringEngineBraking
A. ValveHolder B. Reed
VacuumSxritchValveClosingPressure
Open"' Close: 35 - rl:t kPa(260- 320 mmHql
A. MountingBolts C. CopperWasher
B. Spring D. CapBolt
A. PushRod C. Push
B. Stopper D. Pushintotherod.
lnstullation
.lnstallation is tie reverseof removal. Note the fol-
lowin&
olnstallthe tensionerbodywith the arrowon it pointing 1 . Gasket 5. CapBolt
upwards. 2. ChainTensioner 4 Stopper
'I.10 ENGINETOP END
oTightenthe tensionermountingbolts to the specified lnsbllation
torque(seeExplodedView). .Note thefollowin&
oTighten the cap bolt to the specifiedtorque (see oReplace the capgasketwith a newone.
Exploded View). oTightenthe capboltsto the specifiedtorque.
RockerCaseCap
Remoml
oRemovethe engine(see EngineRemoval/lnstallation
chapter).
.Remove the bolts and take off the cover from the
rockercase.
aRemovetlle bolts and take the caDfrom the rocker Rocker ShafG, Rocker Arms, Rodcer Case
Remoml
oRemovethe engine(seeEngineRemovalInstallation
chapter).
aRemovethe rockercasecoversand tie cap.
aRemovethe alternatoroutercover.
NOTE
<iBefore removing dte t@ket dratt or rocker arm,
tum dre crankdraft e that its piston is a TDC of the
compr$ion stroke.
A. Pry Points
A. CamshaftChainTunnel C. DifferentRockerArm
B. Sprin8s
A. RockerArms C. DifferentRockerArm
B. RockerShafts
HLA Removal
aRemovethe rockercase.
aRemovethe rockerarms-
.Pull the HLA out of the rockerarms.
A. RockerArm B.HLA
A. RockerArm B.HLA
rmflml
oBe caretul not to damagEor deform a lash adluster by
HLA,Air Bleeding
.Fill a container
withengine
oil.
.Preparea pin and cut the needleof it to 2.1 - 2.3 mm
tapping it during remoyalor installation. length. Grind the cutting edgeof the needleto smooth
oDo not drop th€ lash adiuster or hit it sharply. lf it it.
.Push in the steelball of the HLA with the needleof the
is damaged, the plunger will not operate smoothly.
pin and move the plungerup and down in the oil bath.
HLA lnstallation
aNote the following. oDo not push ir the steelb;ll more than 2.1 - 2.3 mm,
-Check tlEt the HLA plunger is not damaged. Over.stroke of the steel ball may cause the damage of
*If the plunger does damage, replace the HLA. the H LA.
ENGINETOP END 4-13
q ? )
ffi"2 3. HLA
A. FrontCamshaft C. Groove
1. Cut and grind the needle. B. RearCamshaft
2. 2,"1- 2.3 nm 4. Pin
oApply cleanengineoil to all cam parts and iournals.
lnspection oFit the KACR Unit on to the camshaft.
aRemovethe rockerarm.
.Pull the HLA out of therockerarm.
ePressthe plungerof the HLA with your fingers. FrontCylinder
*lf the plungeris into the HLA body, repeatthe air oPositionthe crankshaftat front cylinderpistonTDC.
bleedingoperationandthenpressth€ plunger-
flf the plungeris into the HLA bodyagain,replacethe
HLA.
Camshafts
Removal
aRemove the rocker casecaD.
aRemove the rocker case.
.Remove the camshaftwith the KACR and seDarateit.
oRemove the camshaftoil seal.
(RearCylinder) B. TimingMark
A. TDCN4ark
A. Front Camshaft
Sprocket C. F Mark
B. RearCamshaftSprocket D. R Mark
NOTE
onghten the rccker ce boltFand nuts to the secifid
torque (ee Exblodd Viewl
1 . TimingMarks
2 . R Mark
Camchaft,Roc*et CaseClearance
standard: 0.020- 01162mn
SerYicsLimit: 0.15 mm
A. Camshaft B. KACRUnit
CamshaftChain20{ink LerEdl
Standald: 127.A-lttAmm
SorvicaLimit: 128.9mm
A. Pin C. KACRUnit
B, Notch D. Camshaft
lnspection
.Visually inspectthe KACRUnit.
*lf the weights do not move smoothly all the way,
replacethe KACRUnit,
deformed,or missing,replace
rlf the springis damaged,
ir.
1. 2o-linkLength
KACR
(KawasakiAutomaticCompressionReleae)
Removal
aRemovetie engine(seeEngineRemova[lnstallation
chapter).
eRemove the camshaft.
.Take the KACR Unit out of the camshaft. A. Weighc B. Spring
+T6 ENGINETOP END
The following table should be consultedif the obtainablecompressionreadingis not within the usablerange.
Problem Diagn06is Remedy(Action)
Cylindercompression Carbonaccumulationon piston and cylinderhead, Removethe carbondepositsand repracr
is higherthan usable and in combustionchamberpossiblydue to dam- damaged parts if necessary.
range agedvalvestem oil seal and/or damagedpiston
oil dngs (This may be indicaredby white exhaust
smoke).
Inconectcvlinderhead gasketthickness. Replacethe gasketwith a standard
Dan,
Damagedor missing compressionreleasecam spring Feplace the sp ng.
Compressionreleaseweights do not movesmooth- Replacethe compressionreleaseunit.
lnstallation
.Note the following.
oReplace thecylinderheadgasketwith a newone.
oTightenthecylinderheadnutstemporarily.
NOTE
ogefore insbllitv {re spark plug rcaineL pull dre
Remoml camdraftchainup the drain firnnet.
rRemovetlle following.
Engine(seeEngineRemoval/lnstallation
chapter)
RockerCas€s
Camshafu
Carburetors(seeFuel chapter)
Oil Pipe
A. Camshaft
Chain B. Retainer
SparkPlug NOTE'
SparkPlugRetainer oTorque dte cylin&r had and cylinder had lower nuts
(Usinga Hexagonal
Wrench:57001-'1210)
to the s,ecified torque (w Exploded Vimt) after
CylinderHeadLowerNuts (FrontandRear)
rtghEning the rocks c* bolts and nu's to the spe-'
cifid toque.
Valves
NOTE
osine the hydnuli; !a* adju$eB constdrtly maintuin
A. SparkPlug C. CylinderHeadLowerNut Ero cleannce. h is not nesry to inqect or adiust
B. SparkPlugRetainer the vdw clannce.
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ENGINE TOP END +17
Valve Removal Valve Guide Removal
oPerformthe following. rPerformthe following.
oUsing ihe valvespring compressorassemblyand adapter ousing the valveguidearbor (specialtool), tap out the
(specialtools),removethe valve. valveguide.
'1.
ValveSpringCompressor
Assembly:57001-241 1. ValveGuideArbor:57001-163
2. AdaDter: 57001-242
1. ValveStem 6. Retainer
2. SpringSeats 7. Spring Seat
3. Oil Seal 8. ClosedCoil End
4. InnerSpring 9. Split Keepers
5. OuterSpring i . ValveGuideReamer:57001-162
4.18 ENGINE TOP END
ValveFace Contact lnspection *lf the valve seating surface width is not within the
rCheckthevalvefaceseating width.
surface specifiedrange,repair the valve seat.
ousea v€rniercaliperto measuretheseatwidth(white
portion)of the valvefacewherethereis no carbon
build-up.
*lf thevalvefaceseatingsurface
widthis notwithinthe
specifiedrange,
replacethevalvewitha newone.
vahe SsatCutters
lnlet Valv€3: 45' - 035 57q11-1116
32' - 03S.s570{J1-112t2
55' - C35 57001-1247
Exhawt ValYss: 45" - Cas 57001-1116
:t2' - c35 57001.1121
55' - C35 570'J1-1147
1 . Valve
2. ValveS€at
Holder and Bal
SeatingSurfaceOutsideDiam€ter
4. SeatingSurfaceWidth Holder: 57001.1126
Br:: 570iJ1-11?€
NOTE
oDo not ue e wirc brud, to remove the metal Nrticl8
from the cutter. lt will take off the diamond particles.
1. Lapper 3. Valve
2. ValveSeat
A. WaterHoles
Gylinders.Pistons
Cylinder Bemoval
.Remove the cylinder head.
.Pull out the camshaftchain guide (inlet side).
.Remove the coolant drain plug to drain the coolanl
A. DrainPlug C. CamshaftChainGuide
B. CylinderNut
.Remove thecylindernuts.
oTakethecvlinderoff thecrankcase.
Cylinder lnstallation
oNotethe following.
oReplacethe cylinder basegasketwith a new one, and ChainGuides C. R Mark
A. Camshaft
engagethe gasketswith the crankcasewater holes. B. F Mark
4'2 ENGINETOP END
NOTE
oThe oil ring rcils have no "top" or "bottom".
NOTE
Olf a new piston or cylinder is used. check piston to
cylinder cleannce (see Specifications), and use new
piston ng.
CAT'TION
Do not rsuse snap ringg as removal weakens aiid aDo not mix up the top ringandsecondring.
d€forms them. Thgy could fall out and score th€ alnstallthe secondring [A] so thatthe "RN" markfaces
cylindor wall. up.
alnstallthe top ring [B] so thatthe "R" markfacesuD.
Frofi
ENGINE TOP END 4-23
CylinderWear
aMeasure the cylinder inside diameter taking a
side-to-side and a front-to-back measufementat each
oI the 3 positions (total of 6 measurements)shown
below.
1. PistonOutside Diameter
2. 5 mm uo from the bottom
Muffler
Removal(for VN1500-4)
oRemovethe following.
Front Muffler Cover
A. Holders C. ExhaustPipeCover
B. Nuts
MufflerClampBolts(Loosen)
MufflerBracketBolt
MufflerAssembly
A. Mufflers C. ClampBolt
B. BracketBolt
Front ExhaustPipeCover
A. ExhaustPipe D. ClampBolr
aRemovethe front exhaustpipe holdernutsand loosen B- Holder E. PowerChamber
the exhaustpipe clampbolt. C. Nuts F. MountingBolt
ENGINETOP END +25
.Pull out rear exhaustpipe upper end while supporting oFit the rearexhaustpipeupperendwhilesupporting
the power chamber, then take them out toward the the powerchamber.
left. oscrewthe powerchambermountingboltstemporarily.
tSeDarate the front and rear mufflers from the muffler olnstallthe rearexhaustpipeholderswhilepullingthe
bracket if necessary. exhaustpipetowardtheoutside.
lnstallation
.P€rformthefollowing.
oReplace gaskets
theexhaust with newones.
A. ExhaustPipe B. Holders
A. ExhaustGasket
lnsallation
.Replacethe exhaustgasketwith newones.
oPerformthe following.
oAttachthe clampsA and B onto the RH muffler.
olnstall the RH exhaustpipe and the holdenonto the
front cylinderhead.
olnstallthe RH muffler bracketbolt.
olnsert the LH muffler connectingpipe into the RH
muffler connectingpipe.
olnstall the LH exhaustpipe and tl|e holdersonto tl|e
rearcylinderhead,
olnstallthe LH muffler bracketbolt-
A. Holders B. HolderNuts olnstalltl|e clampsA to tl|e frame.
oTightenthe boltsof tie clampsA.
oTlghtenthe bolt of tl|e clampB.
.Removethe left sidemufflerbracketbolt. andtakethe
mufflerout of the frame.
A. BracketBolt
1 : Attachthe clamps.
CLUTCH$1
Glutch
Tableof Contents
. . . . . . . . . . . . . . . . . . . . 5. .- .2. . . . .
.......5-3
. . . . . . . . . . . . . . . . . . . .5. -. 3.......
..........5-5
............. 5-5
- ' . . ' ' ' - ' ' , . ' , ' . ' ' ' . , ' , . 'c . o
............5 . ._. .9
. . . . . . . . . . . .5. -. .1.0
5-10
5-11
5-11
5 - 11
S2 CLUTCH
1 . Clutoh Master Cylindel
ExplodedView 2 . Primary erp
3. Secondary cup
4. Piston
5 . Starter Lockout S\.vitch
6 , Master Cylinder Clamp
7 . Banio Bolt
8 . Cluich SlaveCylinder
9. Bleed Valve
1 0 . Phton
1 1 .PuCr Rod
12. Clutah Housing
13. Spring (Damperl
1 4 . Dampor Cam
1 5 . lnner Hub
1 6 . Ou@l Hub
1 7 . F?iclion Plae
18, St€ol Plaie
19. Spring Plate
20. Spring (Back Torque Limiterl
21. Cluch Spring
u. Holdel
23. Operating Plane
24. Rst iner Ring
-o"
".*t:
L : Apply nonfermanentlockingaqem.
'l&ub'
O : Apply engineoil.
Tl : 5.9 N{n (0.60kgn,52 in{bl
T2: 78 N{n (Oao kgn,69 in-tb|
T3;88 Nm (0,90kgrn,78 in{b}
T4r 18 N<n (1.8ksFm,13.0ftlbl
T5r 25 Nfl (25 ksm, 18.Ott lbl
T 6 : 1 4 5N { n ( 1 5 . O k g , 1 1 0 f t - l b }
CLUTCH 5.3
Specifications
SpecialTool
A. LowerLevelLine B. UpperLevelLine
T{OTE
oHold the res€ oir horizontal when chfiking clutch
fluid level.
*lf the fluid level is lower than the lower level line.
fill the reservoirto the upperlevellinein the reservoir.
NOTE
olf the fluid in the rcservoir runs completely out arry
Disassembly
oRemovethe following.
time duing bleeding,the bleding opention must be
done overagainfrom the beginningsinceair will have ClutchLever
DustCover
entercdthe line-
Circlip
oRepeatthisoperationuntil freshclutchfluid comesout .PistonandSecondary Cup,PrimaryCup
from theplastichoseor the colorof the fluid changes. Spring
I wARNtNc
-E I NOTE
oDo not mix two brandsof fluid. oDo not removethe seondary cup from the pkton.
5€ CLUTCH
lnstallation
.Note the following.
oReplacethe aluminumwasherson eachside of the
ClutchSlaveCylinder clutchhosefitting witi newones.
oTighten the banio bolt to the specifiedtorque (see
Exploded View).
Remoml oReplacethe spacerof the clutch slavecylinder with
.Performthe followingif the clutchslavecylinderis nelvone,
to bedisassembled. oApply non-permanentlocking agent to the slave
oLoosenthe clutch hosebanjo bolt on the clutch slave cylindermountingbolts.
cylinder. c€heck the fluid levelin tl|e mastercylinderreservoir,
oRemov€tie mounting bolts and take off the clutch andbleedthe air in tlre clutchline.
slavecylinder. ocheckthe clutchoDeration.
cLuTcH $7
Disassembly
oLeavingtie clutchslavecylinderremoved,allowthe
pistonto moveslowlyout underspringpressure.
Asembly
.Do the following.
oApply clutch fluid to the outsideof the pistonandthe
fluid s€al.
olnstallthe fluid sealasshownin tlte figure.
A. OperatingPlate B. Retainer
l . Cylinder 3. FluidSeal
2. Piston 4.spring
tt-"-."".-,,"4
cAUTt0l{ |
oFeplaca tte fluid lsal with a new one if it wa! remoYad
A. HubNut
from ths pistoB,
.Take the clutch springplate, clutch springand the
clutchspringholderout of the clutchhub.
.Take the back torque limiter springs,friction plates,
steel plates and the outer hub out of the clutch
housing.
Clutch
Remowl
NOTE
oAn a imp*t wendz is rcquird for cludt runowl.
A, lnnerHub C. Washer
B. Collar D. ClutchHousing
A. PumpDriveGear B. PumpGear
1. Op€rating
Plate O Installthe last friction plate in the shallow groove on the
2. SpringHolder housing as shown.
.A
3. ClutchSpring
@so 6-M.
4. BackTorqueLimitrr Springs
5. Clutrh SpringPlate
6. Outer Hub
7. lnner Hub A. LastFrictionPlate
CLUTCH 5-9
oApply greaseto the back torque limiter springsand Clutch lnner Hub Disasembly/Assembly
attachthemasshown. .Using a pressand suitablebearingdriver (special
thedamper
ool), compress springs.
1. LimiterSprings 2. SpringHolder
oTighten the clutch hub nut to the specifiedtorque A. Press C. BearingDriver: 57001-1129
holdingthe primarygearbolt (seeExplodedView). B. DamperSpring D. Retainer
A. HubNut B. PrimaryGearBolt
1. Retainer 5. Spacer
2. SpringHolder 6. DamperCam
3. DamperSpring 7. lnnerHub
A. Pusher B. Pushin 4. SpringHolder
$10 cLuTcH
SpringPlate Free Play Measurement SpringPlateFreePlay
lnsufficient spring plate free play will cause the engine UsableRange: 0.30- 1.30mm
braking effect to be more sudden,resulting in rear wheel
hop. On the other hand, if the free play is excessive,the
clutch lever may fe€l "spongy"or pulsatewhen pulled,
aHold the exha drive shaft steadywith a vise and instau SpringPlate Free Play Adjustment
the clutch parts on an exlra drive shaft. Do not install oMeasure the spring plate free play.
the back torque Iimiter springs and the operating plate. 'llf the free play is not within the usable range, iDstall
oTighten the clutch hub nut to about 29 N-m ( 3 kg-m, dre Star'\dardSteelPlates 2.0 mm ttrick X 6 and 1.6 or
22 ftJb ) of torque to seat the clutch plates closely. 2.3mm thick X 1 ; total 7 plates.
. Measurethe sprhg plate free play again.
m-I-r!Jl1
cTake care not to damage the drive shaft. SteelPlates
Thickness(mm) Part Name
1.6 13089n080
2.O 13089-1075
2.3 130891081
NOTE
olf new f ctionplatasare installed,apply engine oil to
the sufiaces of each plate.
FrictionPlateThickness
Standard: 3.3 - 3,5 mm
ServiceLimit : 3.1 mm
1. Cam 2. CamFollower
1. ClutchHousingFinger 2. FrictionPlateTang
1. ClurchHubSpline 2. SteelPlateTeeth
ENGINELUBRICATIONSYSTEMS1
EngineLubrication$ptem
Tableof Gontents
ExolodedView 6-2
EngineOil Flow Chart. 64
ar-^^:a:^r:^-^
oPtrrrruaLrurrr 6-6
SpecialTools. G6
S e a l a n. .t . . . a6
EngineOil and Oil Filter. 6-7
Oil LevelInsoection 6-7
EngineOil Change.. 6-7
Oil Filter Change 6-7
Oil PumpScreenCleaning. 6€
Oil Pump. 6€
Removal 6€
lnstallation 6-9
Oil Pipes 6-9
Removal G9
lnstallation 6-10
Oil PressureMeasrrement 6-10
Oil Pressure
Measurement &10
S2 ENGINELUBRICATIONSYSTEM
Exploded Viarv
-@
1*
,ar@
1, Rocker Care.(F?ontl
2. Baniobolt
3. Oil Pipe
4. Rodter Ca!€(Rearl To R.H.: Grankcase
half
5. &sa&er Pl96 (LEftl
6. Filtel
7. BreadlorPipes(Righl
8. Cr8nkcase Haff (Loftl
9. CraDkcalstlalf (Righrl
to. Oil Pm:sureSruitdr
1 1 . Oil Pr€$urGRdief Valy€ O : Apply engineoil to the gasket.
12. Oil Rrmp L : Apply non-pemanentlocking agentto the thr€ads.
13. Oil Filter Mounting Bolt SS: Apdy siliconesealentto flre threads.
14. Oil Filtsl Tl ; 29 Nrn (030 kgm, 20 in{bf
15. Oil Scre€nPlug T2: 12 Nfl (12 kgrm,104in.lb)
16. Oil Scroon T3: 15 Nrn (15 kgm, 11,0ft{bl
1 7 . Oil Pipe(hside Lsftl T4: 18 Nfl (14 kgn, 13.0ft{b}
18. Oil PiF (lnride Rightt T5: 20 Nrn (2.0kgfl,la5 ft.tbl
1 9 . EndneDrain Plug T6; 35 Nrn (35 kgrn,25 ft.lbl
m. Oil Nozzls T7r 25 N-m(2.5 kg-m,18.0ft-tbl
ENGINE LUBRICATION
SYSTEM6-3
q2 (h
osw
II
@?
@
,@
<
&%N*NQ
64 ENGINE LUBRICATIONSYSTEM
II
1. RockerArm
2. Oil Filter
3. Oil Pipe(outside)
4. HLA
5. RockerShaft
6. Camshaft
7. Piston
8. Oil Nozzle
9. Oil Pipe(ln the crankcase)
10, AlternatorRotor
1l. Crank$aft
ENGINELUBRICATIONSYSTEME5
,fl_@
+
1. ClutchAssembly
2. DriveShaft
3. OutputShafi
4. Front BevelGearAss€mbly
5. Oil Pipe(ln the cnnkcase)
6. Oil Pipe(ouside)
7. Oil Screen
8. Oil Pump
9. ReliefValve
10. Oil PressureSwitch
11. Oil Filter
12. Bypass Valve
66 ENGINELUBRICATIONSYSTEM
Specifications
Item Standard
EngineOil:
Grade SEor SFclass
Viscosity SAE 10W40,101,50,2M40, or 20W50
Capacity 2.5 L (whenfilter is not removedl
2.7 L (Whenfilter is reriroved)
3.5 L (Whenengineiscompletelydry)
Oil PressureMeasurement:
Oil presure@2,000r/min (rpml,
345 - z14O
kPa(3.5 - 4.5 kg/cm",50 - 64 psi)
oil temp.l(X)"C(212'F)
Special Tools
Oil Pressure
Gauge,5
kg/cm,:57001-125 Oil Filtar Wrcndr: 57m1-1249
Oil ftsssureGauge
AdaFter:57001-10*t
A. Drain Plug
NOTE
EngineOil
olf the motorcycle has just beal u*d, wait svenl
minut* for all the oil to dnin down. Grade: SE or SF class
olf tne oil has just been changed, stan the mgine and Viscosity: SAE 10W40, 10W50,20W40, or 20W50
run it for several minutes at idle speed. This fills the oil Amount: 35 L (engineis completely dry)
filter with oil. Stop the engine, then wait several 2.7 L (filter is removedl
minut$ until the oil seftles. 2.5 L (filter is not removed)
NOTE
oThe oil fiher by?€ss valve is a*mbled .Cleanthe screen
with highflash-pointsolvent.
in dre filter (Do
not dis€sf€mbled). oCleanthe screenthoroughlywheneverthe engineoil is
changed.
Oil Pump
Bemoval
.Performthefollowing.
oRemovethe engine(seeEngineRemoval/lnstallation
chapter).
o5plit the crankcase(see Crankshaft/Transmission
chapter).
oRemovethe oil pump bolc, and take off the pump
A. Oil ScreenPlug out of the RH crankcase
half.
ENGINE LUBR]CATIONSYSTEMS9
Oil Pipes
Remotnl
.Removetheoutside
oil pipes
asfollows.
A. Circlip C. Washer
B. PumpShaft D. PumpGear
A. Oil Pipe
Installation
.Note the following.
oNot€the positionof the oil pumpshaftprojectionand .Remove the insideoil pipesfrom the inside.of the
turn the pump gearshaftso that t}te proiectionfits into crankcase halves.
the slot. osplit the crankcdse(see Crankshaft/Transmission
oReplace the O{ingswith newonesif they aredamaged. chapter).
SlO ENGINE LUBRICAT]ON
SYSTEM
oReplacethe copperwasherson eachsideof the engine
outsidefitting5with newones.
oTightenth€ banio bolts to the specifiedtorque (see
ExplodedView).
Oil Pressure
Measurement
lnsallation
.Note the following.
ocheok that the oil pipe fitting's O{ings are in good
condition,andapplya little of thegreaseto the O{ings
beforeinstallation.
A. Oil Pressure
Gauge;57001-'154
B. Adapter: 57001.1033
C. Oil Pressure
Switch
EngineRemoval,/lnstallation
Tableof Gontents
ExplodedView 7'2
SpecialTools. 7'2
.
EngineRemoval/lnstallation 73
Removal ."...... 73
lnstallation 7'6
7-2 ENGINE REMOVAL/INSTALLATION
ExplodedVieur
@@.
@
@
?
@
'
1. Framc
2. EngineMounting Brackct
3, Brad(at Bolt
4. Down Tubell/loundngBolr (Front)
5. Right HandDown Tube
6. Down Tube Mounting Bolt (Rearl
*'t%*".r
, *^^'g
7. EngineMountingBolt (From)
8. EngineMountingBolr (Rearl
T1 ; 24 N+n (2.4kgFm,17.5ftlb)
T2: 44 N{t (4.5kgm,3:t ft{b}
/,'
SpecialTools
EngineRemoval/lnstallation
Bemoual
.Supportthe motorcycle
perpendicular
to the ground
with the jack stand and the attachment (specialtools).
A. JackStand:57001-1238
B. Attachment:57001-1252
oRemovethe following.
EngineOil (seeEngineLubricationchapter)
Coolant(seeCoolingSystemchapter)
Seat
FUet I anK
FrameToo TubeCover A. FuelPump C. SurgeTank Duct
Air CleanerHousing(seeFuel Systemchapter) B. CoolingHose D. SurgeTank
Horn
Radiator(se€cooling Systemchapter)
CoolantReservoirTank (seeCoolingSystemchapter)
Footpeg(LH)
Left EngineCover
ClutchSlaveCylinder(seeClutchchapter)
shift Pedal
Muffler and Exhaust Pipes (see EngineTop End
chapter) lgnitionSwitch
CleanAir Hoses CoolantReservoir Tank Bracket
CoolingHose (LH: Pull t]1e hose out of the front CleanAir Hose(RearCylinder)
cylinder.) lgnitionCoil Assembly(moveit on the frame)
74 ENGINEREMOVAUINSTALLATION
Alternatorand PickupCoil WireConnectors
GroundWireTerminal
Throttle CableAdjuster
A. StarterMotor B. Terminal
Oil Pressure
SwitchWireTerminal
NeutralSwitchWireTerminal
VacuumHose(BothSide)
Carburetor
RearBrakeLight SwitchWireConnectors
oPerformthe following.
osupport the enginewith a suitablestand,and remove
A. Oil Pressure
Switch B. NeutralSwitch the enginemountingboltsandbncket bolts.
ENGINE REMOVAL/INSTALLATION7€
lnstallation
.Note thefollowing:
oFit the rubber boots into the front bevelgear case
opening.
olnstallthe springinto the insideofthe front bevelgear
toint.
oPutthe pin into the front bevelgearloint.
A. RubberBooG C. Pin
B. Spring
A. ClutchHose B. SlaveCylinder
A. JackStand:57001-1238
B. Anachment: 57001-1252
C. MasterCylinderBanjoBolt
D. Makea clearance.
Crankshatt/ Transmission
Tableof Gontents
ExplodedViw
@9
t. ConnectingRod
2. LH BalancarGear
3. LH BalancalWsight
4. BalancerShaft
5. RH Balanc€rWeight
'r. Oneway
6.
Coupling
Clundl
_ [
t ? W
ffio* 6
q\r f
1. Sfiift shaft
2. Shift LinkagFRod
3. Shift MechanbmArm
4, RerumSpringBolt
5, Ge.r P6itioning Lever
@o
kq
84 CRANKSHAFT/TRANSMISSION
o
o @
oo@ k@
*@*
wa@u
?
N
,evJ)
1. DriveShaft
2. DamperCam
3. output shaft
4. Bushing
5, Pin Plae
6. BearingHoldel
7. Shift Drum
1. RH EndneCoYer
2. Oil FillerCap
3. Altsmator Outer CoYer
4. Alternator lnner Covsr
5. LH Engin€CoYel
L : Apply Ioc*ing agBnito d|e drreads.
Tt : 9, N-m (1.Okg-m,87in-lb)
8€ CRANKSHAFT/TRANSMISSION
Specifications
runout
Crankshaft 0.02mm 0.05mmTtR
Crankshaftmain bearing/
journalclearance 0.030- 0.068mm 0.10mm
Crankshaftmainiournaldiameter 81.981- 55.000mm 54,96mm
Crankcasemainbearing
borediameter 55.ff|0 - 55.049mm 55.08mm
Crank$aftsideclearance 0.05- 0.55mm 0,75mm
Crankshaftweb length 96.85- 96.95mm 96.6mm
Transmission:
Shift fork earthickness 5.9- 6.0mm 5.8mm
Gearshift fork groovewidth 6.05- 6.15mm 6.3mm
Shift fork guide pin diameter 7.9- 8.0 mm 7.8mm
Shift drum groovewidth 8.05 - 8.20mm 8.3mm
&7
CRANKSHAFTffRANSMISSION
RonorHolder: 57001-1248
SpecialTools
NOTE
GaarHolder: 57001-1015
oThe flywhel holder (P/N i7@,,-tgtg can E ued
inst@dof the rotor holder (P/Itl izd)l-1249.
FlywheelHolder: 57001.1313
DamporCamHolder: 57001-1025
KarrasakiBond(LiquidGaskeiSilberl:9210+1qE
BsaringDdvsrSst: 57001-1129
8€ CRANKSHAFT/TRAN$I'IISSION
.full th6 starter motor clutch gear out of the starter
Crankw motorclutch,then takeout the torquelimiter.
rLoosentl|e startermotor clutch bolt whileholdingthe
alternatorrotor steadywith rotor holder (special
tool:
Splitting s700r-1248).
.Remove the engine(seeEngineRemoval/lnsallation
chapter).
aset the engineon a cleansurhceand hold tie englne
steadywhilepartsarebeingremoved.
rRemovethe following.
EngineTop
RockerCases
CylinderHeads
CylindersBlock
Pistons
EngineRightSide
WaterPump
Clutch
EngineLeft Side
Front BevelGearCase
AlternatorlnnerCover
oRemovetlre shifl mechanism arin and gearpositioning
leverwith spring.
A. Shift Mechanism
Arm B. GearPositioningLwer
aunscrewthe damper cam nut using a dampercam
holder(specialtool) anddeepsocketwrench.
oRemovethe retainerandneedlebearing.
olnsertthe bolt (012 mm, L100 mm) into tlle engine
mountingbolt hole.
A. Bolt D. Bearing
B. Spacer E. Washer
C. Collar F. StarterMotorClutch
A. FrontChainGuide C. RearChainGuide
B. LowerChainGuide
A. BalancerGear D. Ratchet
B. AlternatorRotor E. Rotor Holder: 57001-1248
C. BalancerGearBolt F. Alt€rnatorRotorBolt
(B)
A. Sprocket D. LowerChainGuide
B. WaterPumpChain E. RearChainGuide
C. Camshaft
Chain
.Pull tie primary g€ar out of the crankshaft,and take .Pull tle water pump sprocketwith its shaft out of
tie idle shaft out of tl|e cnnkcase, The idle shaft hu the insideof the crankcase.
two oins.
A. PrimaryGear C. Pins
8. ldleShaft
A. Sprocket B. Shaft
oRemovethe following.
ldle ShaftSprocket(B) (with flat washer)
WaterPumpChain
CamshaftChain
LowerChainGuide aRemovethe starter motor bolts and the motor out of
RearChainGuide the crankcase.
8-11
CRANKSHAFT/TRANSMISSION
halves.
.Usingthe pry points,splitt}|e crankcas€
A. Bolts B. StarterMotor
Asrr.mbly
.Note thefollowingbeforefitting the crankcase halves.
oWith a high flash-poiritsolvent,oleanoff the mating
A. 08 mm Bolts(5) surfaceof tie crankcasehalvesand wipe dry.
B. Do not fotget to removetJ|isbolt. ousingcompressed air, blow out the oil passages
in the
crankcasehalves.
olnstallthe shift drum and settie gearpositioninglever
to the neutralposition.
bolts (Left Side).
.Removeall tl|e crankcase
AppliedArea.
l: LiquidGasket
A. Washer B. Sprocket(B)
PrimaryGear
A. Sprocket(A) C. Chain
A. Marlc Aligned B. WaterPumpDriveSprocket D. Washer
&14 CRANKSHAFT/TRANSMISSION
ldle Shaft HolderandChainGuide
TorqueLimiter
StarterMotor Clu&h Gear
A. Bearings C. LH CrankcaseHalf
B. Holding
Plates
ShiftMechanism
Damper Cam
Front BevelGearCase
Clutrh
WaterPump(lmpellerBolt hasLeft-handed
Threads)
RightEngineCover
EngineTopEnd
Alt€rnatorCovers A. Bearings C. RH Crankcase
Half
Left EngineCover B. Holding
Plates
Replaement
NOTE
oApply hich temperature greaseto the lips of {E water NOTE
pump shaft oil s@1. aMa* and fecod the locations of the connEting rods
and their big end capsI that Urey can he rea*mbled
in theh oiginal positions.
z<r &
\ili rT)
h\\\\J
w
'1 -<s\
W
s ss
1 .Bearings
2. Oil Seal
3. Pressthe oil seal.
l. Connecting
Rods
2. BigEndCaps
Crankshaft/ConnestingRods 3. Crankshaft
Crankshaft I nstallation
oThecrankshaft LHendis longerthanthe RHend. .Removethe connectingrod big end capnuts,andtake
off the rod andcapwith the bearinginserts.
ConnectingRod Insallation
A. Crankshaft C. Short End(RH) oTo minimize vibration, the connesting rods drould have
B. LongEnd(LH) dre $mo w€ight mark,
&1 6 CRANKSHAFT/TRANSMISSION
NOTE
oTighten the big srd cap nuts to {ze sp*ified torque
(se Exploded Viewl.
oDo not move theconnectingrod and crankdtaft during
clearancemagJrement.
NOTE
oTighten the ap nuts to the qeified torque (9e
Exploded View).
oThe mark already on the big end dtould almost coin'
cide with the mwlrement,
lnsert
1. Bearing 2- ColorSizeMark
Connecting Rod Elig End Inside Diametsr Marks .lnstall the new insertsin the connectingrod andcheck
None: 58.000- 58,010mm clearance
insert/crankpin with the plastigage.
58.011- 58.020mm
CrankshaftRunout
.Measurethe crankshaftrunout.
*lf the measurementexceedsthe servicelimit, replace
thecrankshaft.
OankshaftRunout
Standard: 0il2 mm
ServiceLimitr 0.05 mm TIR
GankshaftRunout
1 . BigEndCap 3. DiameGrMark,
"O" mark or no mark
2. ConnectingRod
1. Crankshaft 3. Clearance
2. Crankcase
.Measurethe main bearingborediameterin the crank- *lf the clearance is greatertian the servicelimit, meas-
casehalves. ure the crankshaftweb length to see whether the
crankshaftor the crankcase is faulty.
CrankshaftWeb Lengrh
C6nkcas€Main BearingBore Diameter Standad: 9685 - 96.95 mm
ServiceLimit: 96.6 mm
Standsld: 55O3{l - 55.Otl9 mm
Serrice Limit: 55.08 mm
NOTE
oThe right and left cnnkcz* haly6 are m*hirzqt at the
*lf they are any signsof seizure,damage, or excessive factory in the a*mbled state, & thay mu& b re
wear,replacethe crankcasehalvesasa set. plaed asa st.
&19
CRANKSHAFT/TRANSMISSION
Bemotral lnsallation
rRemovethe muffler(seeEngineTop Endchapter). .Note the followin&
.Removethe right downtube (seeFramechapter). oBefore installing tlre left enginecover, apply grea3eto
aRemovethe coverbolts. ttre back of the dampersand attaoh them onto the
.Using t}|etap points,takethe cov€roff t}tecnnkcase. alternator outer cover.
A. Tap Here
lnstallation
.Not€ tle following.
oReplace tl|e rightenginecovergasketwith a newone.
oRoutr the hosesand the wires correctly (seeGeneral
Information).
RearBrakeHos€s
RearBrakeLight SwitchWire
Air CleanerDrainHose
StarterMotor Clutdt
Removal
.Removett|e right downtube (seeFramechapter).
.Removethe right enginecover.
A. DrainHose C. Strap .unscrew the starter motor clutch bolt while holding
B. BrakeLight Switchwire D. Clamp the primarygearbolt.
oApply oil to the threads of the starter motor clutch
bolt and tighten i! to the specified torque (see Ex-
plodedView) while holdingthe primarygearbolt.
Disassembly
rRemovethestartermotorclutchassemblv.
.Remove the Allen bolts with the balancerheld in a vise.
A. PrimaryGearBolt C. TorqueLimiter
B. StarterMotor ClutchBolt
.Pull the starter motor clutch gearand starter motor
clutch (with RH balancerweight) as a set off the
balancershaft.
lnstallation
oNotethe following.
olnstallthe callerandcopperwasherasshown.
A. Balancer
Weight B. Allen Bolts
A. CopperWasher B. Caller
olnstallthe startermotorcluichgearasshown.
t . Balancer
Weight
2. OnewayClutch
t. Coupling
StarterMotorClutchGear
Assembly
A. StarterMotorClutchGear .Note the following.
B. Pushand turn clockwise. olnstall the coupling with the groovedsidefacing out.
8.21
CRANKSHAFT/TRANSMISSION
Weight
A. Balancer C. Coupling A. One-wayClutch B. lnnerRace
B. One-wayClutch D. Groove (StarterMotor ClurchGear)
lnspection
.Remove the starter motor clutch gear and torque
limiter, then reinstall the starter motor clutch gear into
the starler motor clutch.
aTurn the starter motor clutch to both side.
oWhen viewed from the right side of the engine, the
clurch should turn clockwisefreelv, but should not
turn counterclockwise.
A. Coupling B. One-wayClutch
Balancer
RH BalancerWeightRemoval
A. Turn freely. C. StarlerMotorClutchGear Seestart€rmotorclutchremoval.
B. Locked
i:-:-iv*N"
1. Gear 3. Hole
2. Weight
A. Bolt C. Balancer
Weight
B. Balancer
Gear A. Balancer
Shaft B. LH Crankcase
Half
&23
CRANKSHAFT/TRANSMISSION
Remomt Remoml
.Removethe muffler (seeEngineTop Endchapter). .Take the springendoff the hook.
.Removethe right downtube (seeFramechapter'). .Unscrewthe bolts and takethe idleshaftholderwith a
aRemovetlle RH enginecover. chainguideout of the crankcase.
aRemovetie starter motor clutch gear.
tPull the torquelimitrr out of the crankcase.
A. Spring C. Holder
A, TorqueLimit€r C. Washer B. Bolts D. ChainGuide
B. StarterMotor ClutchGear
oDo not dilctsnbls drs torquo limitsr. .Pull out the chainguideftom the holder.
Ths torque
limitel will not lunqtion if thb is dons.
lnspection
.Removethe torquelimiterandvisuallyinspectiL Insallation
ilf the limiter haswear,discoloration,
or otherdamage, .Note the following.
replac€it asa set. oPut the washeronto the idle shaft,and fit the knock
pinsinto the crankcase.
l. Gear
2. Friction Plate A. ldle Shaft C. KnockPins
3. Pinion B. Washer
ISSION
&24 CRANKSHAFT/TRANSM
.Pull the primarygearout of the crankshaft,and take
PrimaryGear the pin out of the idleshaft.
Removal
.Removethe followingparts.
Muffler (seeEngineTop Endchapter)
RightDownTube (seeFramechapter)
Right EngineCover
StarterMotor ClutchGear
Clutch
.Removethe wat€r pump chainguideand water pump
idleshaftholderfrom the RH cnnkcase.
A. PrimaryGear C. Pin
B. ldleShaft
lnstallation
.Note the following
A. ChainGuide B. ldle ShaftHolder oFit the primary gear with the notched side facing
towardthe insideof the engine.
A. Primary
Gear B. NotchedPortion
A. GearHolder(57001-1015) C. PrimaryGearBolt
B. PrimaryGear
Transmission
A. Lever C. Bolt
A. Shift Lever B. Front BevelGearCase B. Spring
&26 CRANKSHAFTTTRANSMISSION
olnstalltlte shift leverasshown. Exhrnal Shift Mechanismlnspection
*lf necessary, loosenthe locknutsandturn the shift rod .Examinetheshiftshaftfor anydamage.
to obtainan 88.5 mm leng$ includingthe locknuts.
1. Shift Shaft
2. RetumSpring
3. Shift Mechanism
Arm
4. Arm Spring
A. 88.5 mm Lengh C. Shift Leven oCheckthe shift shaft for bendingor damageto the
B. Shift Rod D. Locknuts splines.
*lf theshaftis benLstraighten or replaceit lfthesplines
aredamaged, replacethe shaft.
oCheckthe return springand arm springfor breaksor
distortion.
*lf the springsare damagedin any way, replacethem.
ooreck the shift mechanism armfor distortion,
*lf the shift mechanismarm is damagedin any way,
replac€the arm.
.Checkthat tbe returnspringbolt is not loose.
O Installthe clutch hoseguide as follows. *lf it is removed,unscrewit, apply a non-permanent
locking agent to the threads,and tighten it to $e
specifiedtorque (seeExplodedView).
theck the gearpositioningleverand springfor breaks
or distortion.
*lf the leveror springis damagedin any way, replace
tnem.
A. ReturnSpringBolt C..Spring
A. HoseGuide B. GearPositioningLever
CRANKSHAFT/TRANSMISSION&27
1. 3rd Gear
2. 2nd Gear
3. SpinQuickly
Drive Shaft
Output Shaft
b$
the shift drum.
1. PinPlate
2. Pin
3. Shift DrumCam
4. Bearing
5. Shift Drum
Wheels,/Tires
Tableof Contents
ExplodedView... 9-2
Specifications 94
SpecialTools. 9-5
Wheels(Rims) 96
FrontWheelRemoval 9€
FrontWheellnsallation 9-6
RearWheel Removal *7
RearWheellnsallation. 97
WheelCouplingRemoral. 9€
W h e eCl o u p l i nl n
gstallation. . ...;. ......... ' 9€
Wheel(Rim) Inspestion (for castwheel) 9'9
Balarrce Weight Installation, ...'.'.'. 9'9
BalanceWeightRemoval. 9-9
Spokelrspection(for wirespokewheell.. . . 9-10
Rim Inspection 9-10
Balance WeightInstallation C10
T i r e s. . . 911
TireAir Pres$re lnspection .......'. 9-11
Tire Inspection 911
Tire Removal' 9-11
Tire lnstallation.. . . . . 9'12
HubBearings.
Removal , '. '.. ' '. 9'12
lnstallation $13
Lubrication 913
Speedometer GearHousing . 913
DisasemblyandAssem bly $13
Lubrication v-^14
9-2 WHEELS/TIRES
Exploded View
vN1500-A
(G): WestGermanModel
EY='=')');"
-s ;#
1. BalancerWeight
2. Front Tire
3, Air Valve
4. Speedom€terGeal
5. Front Axle
6. Front Wheel
7. RearAxle
8. RearTire
9. RoarWheel
a r\
\ \ \
T1:1.5N-m(0.15kgFm,13 in-lb)
T2:88N-m (9.0kg-m,65fr-rb)
T3:110N-m (11.0kg-m,8oft-lb)
rtY
' - v )\
9€
WHEELS/TIRES
vNrSoo_B
T 1 : 1 . 5N - m( 0 . 15 k s - m 1
, 3i n - l b )
T2:. 88 N-m (9.0kg-m,65 ft-lb)
t 5 : 1 1 0N - m ( 11 . 0k g - m8 , 0f t - l b )
T4: 3.9 N-m (0.40ks-m.35 in-lb)
G : Applygrease.
r.-S1-
/.v:),,.
1. Spe.domrt i Gorr
2, Front Axl.
^ ob*
*t/ 3, Brhncar Weight
4. Rim
5. SpokeNippls
6. SFoke
7. Tube
8. Air vdr.
v
tt'
9, Rim Bcnd
10. Flont Tirr
11. RarrAxle
12, B.rd Ptotectol
^\ 13. B.bnaetW.ifht
z"soT 14. R.|' Tir.
""" @
94 WHEELS/TIRES
Specilications
Standardtires:
DUNLOPF'l1J,{A) (E)F11LTL
Front (A11-) BRIDGESTONE EXEDRAL3O9
1OO/90-19
57HTUBELESS ryPE
VN 15OOA
DUNLOPK425A,(A) (E) K425ALTL
Rear (A11-) BRTDGESTONE EXEDRAGs26
150/90-ls 74Ho|ls0/90-15 M/C74HTUBELESS
rypE
Front OUNLOP (E)
F11J, F1lLTT/METZELERMarathon Front
.1OO/90-19
57HTUBETYPE
VNl5OOB DUNLOPK425A,(E) K425ALTT
Rear 150/90-15
74Hor 150/90-15 M/C74HTUBETYPE
l\4ETZELER MarathonEuro
150/90815i/VC74H
Tireair pressure:
Front 200kPa(2.00kg/cm,,28Psi)
up to 97.5kg (215lb)toad 200kPa (2.00kg/cm,,28Psi)
97.5 - 180 kg (215 - 397 lb) load
Rear vN15004(E) 97.s- 185kg (215- 408tb)toad
225kPa(2.25kg/cm,,32Psi)
vN1500A(G) 97.5 - 186 kg (215 - 410jb) load
vN1500B(E) 97.5 - 184 kg (215 - 406 tb) toad
Usethe samemanulacturer's
tirss on bothfrontand
rearwheels.
NOTE
'JMost countriesmay have their own regulationsrequir-
ing a minimumtirc treaddepth:be sure to followthem.
aCheck and balance the wheel whena tire is reDlaced
with a new one.
WHEELS/TIRES9.5
N
BearingRemoverShaft: 5700l-1265
BearingRemoverHead: 5?dt1-1293
96 WHEELS/TIRES
Front Wheellnstallation
Wheels(Rimsl .lnstallationis the reverseof removal. Note the
following,
Front WheelRemoval
NOTE
.Remove the following.
SpeedometerCable Lower End oPut the spedometer gear drive onto the wheel hub
Brake Caliper Mounting Bolts nobtrrjhes..
then install the housing e that it fits in the
drive nofthes.
A. Notches C. Drive
A. CaliperMountingBolts B. AxleNut B. Proiections D. Housing
oFit the qedometer gear housing stop to the fo* lq
stop.
Axle Nut
Axle ClampBolt (Loosen)
1. Housing
Stop 2. Fork LegStop
A. Axle C. Speedometer
Cable oFit the collar on the right hand side of the hub.
B. AxleClampBolt
.Tighten the axle nut to the specified torque (see
Exploded View).
.Use the iack standand the attachment(specialtools: .Tighten the axle clamp bolt to the specified torque
57W1-"1238, 57001-12521 andothersuitablemeansto (seeExplodedView).
lift the front of the motorcvcle. .Checkthe front brake.
.Pull out the axle to the right anddropthe front wheel
out of the fork.
A. Axte Hub
C. Coupling
B. RingGearHub
Tire Bead
l. RadialRunout 2. AxialRunout
RomovingBslanceWeight (widr tire on lim)
Axial Runout
Service Limit 2.O mm
Radial Runout
Service Limitr 2.0 mm
I
\
1. Depth Gauge
Weight
A. Balance
tlf any measurement is less than the servicelimit,
replacethe tire.
Balancs Weight
PartNumber Weight(grams)
41075-1007 10 Tire Trsad Depth
4'I075.'I008 20
41075.1009 30 Front
Standald: 4.4 mm
ServiceLimit: 1 mm
Real
.'_1T................... Standard:
SeruiceLimit
73 mm
2 mm
TireAir Pressurelnspection
NOTE NOTE
oMeastretire prffsure when the tires arc cold (that is,
oFor the VN\5O&B. replace the rim band with e new
when the motorcycte has not beenridden more than a
one wtteneverthe tire is repleed.
mile during the past3 hours).
@ EuropeanModel @ WestGermanModel
Tirelnspection
avisually inspectthe tire for cracksand cuts. Replacethe
tire if badly damaged.
a Measurethe tead depth at the center ot the tread with
a depth gauge. A. BeadProtectorNut B. Balancer
Nut
9.12 WHEELS/TIRES
1. PlasticCap 4. ValveStem
2. ValveCore 5. ValveSeat
3. StemSeal 6. ValveOpened
lnsallation
aRemovethe air valveanddiscardiL
HubBearings
Removal
.Removethe hubbearings
by usingthebearing
remover
oRcplacethe rubber-typ€air vahe wheneverdte tire is shaftandheads(specialtools).
rcplac€d. oRemovethe bearingretainer.
oDo not reusedre air valve. oRemovethe RH bearingfirst
WHEELSfiIRES 9.13
Lubrication
NOTE
asince tlre barings on dte rear whel hub are peked
with grea* and $ielded on both sides' they are not
requiredto be removedfor lubrication-
1. BearingRemover
Shaft:57001-1265
2. BearingRemoverHead: 570O1-1267,1293
oDo not lay dre wheel on lhe ground with the di*
tacing down. Thi! can damage or warp the dlsc. Place
blodc under lbs wheel so d|e ditc do€| not toudr dle
ground.
lnstallation
.lnstalt the bearingsby usingthe bearingdriverset
(special 129).
tool: 57001-'l Turn back and forth [A]
Shield IB]
GearHousing
Speedometer
GearHousing
l. speedometer
2. Grease.
FINAL DRIVE lGl
FinalDrive
Tableof Contents
ExplodedViaitr 1G2
Specifications 10-4
S p e c iTaol ols..... 1(}4
FinalGearCase Oil 1G6
Oil Level Inspection 1G6
Oil Change. 1G6
F i n aGl earCase.... 1G6
Removal 106
lnsallation notes.. . 1f}.7
Disassembly. 1G9
AssemblyNotes.. . 1G9
BevelGear Inspection 1G10
PinionJoint Inspection 1G10
Ball Bearinglnspection 1G10
NeedleBearingInspestion. 1G10
Oil SealInspection . . . . . 1Gl0
Final BevelGearAdjustment. . . . . , . 10-11
BevelGearlnspection 1G14
PinionGear Bearing lnspection.. . . . . 1G14
Oil SealInspection .. ... . 1G.14
PropellerShaft 1G14
Removal 1G14
lnstallation Notes . . t&15
SlidingJoint Inspection... . . . . . 1015
PropellerShaft Inspection. 1(}15
SlidingJoint Ingection, 10-15
Front Be\relGean . , . 1G16
Front GearCaseRemoval 1G16
Front GearCaseInstallation tG16
Front GearCaseDisassembly(includingdrivegearremoval).. . . ' ' 1 G 1 6
Front GearCaseAssembly{includingdrivegearinstallation) . . . ' ' 1 G 1 8
DrivenGearDisassembly. 1G18
DrivenGearAssembly.. . 1G19
DamperCam Removal. 1S19
DamperCam Installation Notes, . . 1G20
FronB t e v eGl e a r A d i u s t m e n t , . . . . . . . . . . . . . 1G.20
BevelGear lnspection 1o.24
Cam Damperlnspection 1G24
Ball Bearing Inspection 1G25
TaperedRollerBearingInspection.... '. 1G25
NeedleBearinglnspection. 1G25
Oil Seallnspection. ... . 1o.25
1O-2 FINAL DRIVE
View
Exploded
$ 1 . Oil Pipe
2- Drive GeatShim
3. DdYsGsar
4- DriveGearShaft
5 . l'leurr.l Savitct
6. Front BevelGesrCse
@h 7 . Drivsn GearShin
8 , Ddren Ge8t
9. F ont EeYelGaarAsembly
10. B€aringHousing
1 1 . Collal (Pr€losdAdiun)
12. Spacer(Moed Adiurtl
13. Drivsn GsarJoint
14. .CamFollower
-g_
Specifications
Item Standard
Final GearCaseOil: Grade API GL€ HypoidGearOil
Viscosity Whenabove5"C (41'F) SAE90
Whenbelow5'C (41"F)SAE80
Amount 2(X)mL
Oil Level Bottomof filler opening
FinalGearCase:
Finalbwel gearbacklash 0.06 - 0.09 mm (at gearhub spline)
0.10 - 0.15 mm (at geartooth)
Front Bevel Gear:
Preloadfor drivengearbearings 0.5 - 0.9N-m(0.05- 0.09kg-m,4- I inib)
Front bwel gearbacklash 0.10- 0.15mm (at geartooth)
SpecialTools
DrirenGearHolder: 57001-1027
Mapter: 57001317
w
BeadngDriverSetl 57001-1129
Afiadrment: 57OO1-1A2
-\e\
V-
::@:)
NOTE
oThe wm 'GL6" indiaa'fs a Sdity etd dditiE
nting. A 'GL6" tzd hypoid g@r oll en al'p b
ud.
Oil Change
.Warm up the oil by runningthe motorcyclesothat tie FinalGearGasg
oil will pickup any s€dimentanddrain€asily.Stopthe
motorcycleand turn it off.
aPlacean oil pan beneaththe final gearcase,and remove Ranoval
tlle drainplug. *lf thefinalgearcaseis to bedisassembled,
drainthefinal
gearcaseoil.
a Removethe rearwheel (seeWheel/Tireschapter).
a Removethe left shockabso6erfrom iG studs by taking
off the nuts.
aRemovethe final gearcaseby takingoff the nuts. The
springcomesoff with the case.
I wtnunre
-- i
o h.n draining or filling ths\final gear cara, be aalsfrrl
tha no oil gG on d|g titr or rim. Oean off any oil NOTE
lftlt inrdrortsn{y gatr on th€m wttb a high flrdt.poim olf the find gar ee is fit of oil, plee {re w s that
aolYgnt. dre btathar hole ls on top,
FINAL DRIVE 1G7
Disassembly
oRemovethe final gearcasecover bolts.
.Use three cover bolts to remove the ring gearassembly
from the gear case. The shim(s) comes off with the
assemblv.
A. FinalGearCaseNuts
B. BreatherHole
C. RearShockAbsorber(LH)
Installation Notes
OLubricate the propellershaft ioint (see PropellerShaft
Joinl Lubrication).
alnstall the spring so that the small diameter end faces
toward the final gear case- NOTE
oDo not sp{aE dle ring gearasmbty (riry gar, ring
gcarhub, and final gar ca'€coved, but the oil sl can
be rcmotnd.
A. SmallDiameterEnd oDo not hsat dr6 case with a torch. Thb will rvsrp $s
c83e.
A. PinionGearHolder: 57001-1165
A. Allen Plug
B. FinalGearCaseHolder(57001-1250)
Wrench(57001-1251)
C. BearingRetainer
NOTE
ome badng reainer haslefthandd thrads, therefore
it mustbe tumedclo*wi* in rcmoval.
Assembly Note6
.The ring gearand pinion are lappedas a set in the
factory to get the best tooth contact. They must be aBlow the breatherhole in the final gear cage cover
installedasa pair,neverreplaceonewithout the oti€r. air.
oleanwith comDressed
1GIO FINAL DRIVE
Pinion Gear Joint lnspection
.Visuallyinspectthe splinesof the piniongearjoint.
rlf they are badly worn or chipped,replacethe joint
wit$ a new one. Also, inspectthe propellershaft
joint.
sliding
A. Breather Hole
Eackla3h-RelatedPartt
1 .PinionGear
2. PinionGearShim(s)
3. RingGearAsembly
RingGearShim(s)
5. FinalGearCase
Backla3hAdi$tment
tlean anydirt andoil off the bevelgearteeth.
aPressthe ring gearassemblyslowly with an oil seal
driver (57001-1104)to firmly seat the ball bearing.
.lnstall the piniongearassembly with the primary(1.0
mm d|icknes) shim,andtightenbearingretainerto the
specifiedtorque(seeExplodedView). 'tlf the backlashis not within the limit, replacethe ring
.lnstall the ringgearassemblywith the primary(1.0mm
gearshims.To increase backlash,increase the thickness
rhic{rnesr)shim,and tightenthe covermountingbolts
of the shim(s). To decreasebacklash,decreasethe
to the specifiedtorque(seeExplodedView).
oCheckthe backlash duringthe tighteningof the cover thicknessof the shim(s).
achangethe thickness a lltde at a tim€.
mountingbolts,andstoptighteningthemimmediately .Re{heck the backlash, andre-adiustasnecessary.
if the backlashdisappears.Then,changethe ringgear
shimto a thickerone.
Toodr contast adiustment
rCleanany dirt andoil off the bevelgearteeth.
nF."I-lm
oDo not iGtall ths O{ing3during adiGtment.
.Apply checkingcompoundto 4 or 5 teeth of the
piniongear.
' NOTE
oApply cheking compoundto dte teed, in a thin, evqt
aMount a dial gauge [D] on a vise so that the tip of the coat whh a hirly *iff paint bru{r. ff reind too
gauge is againstthesplinedportion ofthe ring gearhub. thi*ly, tlre exff't tooth patem may not appar.
aTo measurethe backlash,tum the ring gear hub [B] oThe dteking compound must be snooth and firm,
back and forth [C] while holding the pinion gearsteady with the consi*encyof tood, p&e.
with the pinion gear holder [A].
o&&ial compoundsare anilable at artomotive srpply
The difference
between the highest and the lowest gauge reading is Etorgs for the pupoe of &eking differcntial gar
the amount ol backlash. tooth paftemsand con&t.
o Measurebacklashat three locationsequally spacedon
the splines. a lnstall the shim(s) and pinion gear assembly,and
tightenthe bearingretainerto the specifiedtorque(see
ExplodedView).
Final B3vsl Gear Backlash: 0.06 - O.O9 mm
alnstallthe shim(s)and ringgearassembly, and tighten
(at dng gear hub splinesl
the @ver boltsto the specifiedtoique (seeExploded
View).
aTurn the piniongearfor one revolution[B] backand
Consot Too$ Contact Pattern forth,whilecreatinga dragon the ringgearhub [A].
a Removethe ring and piniongearassemblies to check
the drive pattem and coast pattem of the bevel gear
teeth. The tooth contact Dattemsof both (drive and
coast)sidesshouldbecentrallylocatedbetweenthetop
ffik-Bottot and bottomof the tooth. The drivepattemcan be a little
-ffir"0 closer to the toe and the coast pattem can be a
somewhatlongerandcloserto the toe.
FINAL DRIVE 1G13
*lf the tooth contact pattern is incorrecl, replace the
pinion gear shim(s), following the examplesshown.
Then erasethe tooth contact patterns,and check them
again. Also check the backlasheverytime the shim(s)
are replaced. Repeat the shim change procedure as
necessarv.
NOTE
olf the fukla$ is out of the standard nngp after
changingthe pinion gear&im(s), rql*e the ring g:@r
$im(s) to conect the backh* More cheking the
tooth cont&'t pattern.
Bottom
Top
Heel
1G14 FINAL DRIVE
Pinion GearBearinglnspection
rDisassemblethe pinion gear (see Pinion Gear Dis' Disengagem€ntof Propellershaft ftom
assembly). D:ive GearJoint
.Visually inspe€tthe bearings color change,
for abrasion,
or otherdamage.
ilf thereis any doubt as to the conditionof a bearing,
replaceit.
t
PropellerShaft
Removal
.Rqmovethe following.
RearWheel
FinalGearCase
aRemovethe propellershaftfrom the front drivengear
ioint.
oTurn the propellershaftso that the lockingpin access
holeon tl|e propellershaftcomesoutside.
l . PropellerShaft Spring
2. UniversalJoint ) - DrivenGearJoint
3. LockingPin
t . O-ring 4. PropellerShaft
2. Washer 5 . SlidingJoint
t. Circlip
lnsallation Notes
.Check the Oring on the rearendof the propellershaft
for any kind of damage,and replaceit if necessary.
.Lubricatethe propellershaftioint (seePropellerShaft A, Checkuniversal'oint.
Joint Lubrication). B. Inspectsplinedportion.
aAfter connectingthe propellershaftto the drivengear
ioint, pull tlle propellershaft rearwardto checkthat
the shaftis securedin placeby t}le lockingpin.
High TemperatureGrease
A. SlidingJoint
B. Checkthe splinedportion.
1G16 FINAL DRIVE
Front Gear Caselnstaltation
Front Bevel Gears .Note the following.
oTighten the front gear casemounting bolts to the
specifiedtorque(seeExplodedView).
Front Gear CaseRemovat owhen installingthe oil pipe,pustrit down and torque
rRemove the following.
thefront banjobolt first to the specification.
Engine (seeEngine Removal/lnstallationchapter)
Shift LinkageLever Rear End
Front Gear Case
A. DrivenGearAssemblyMountingBolts
B. DrivenGearAssembly
C. RubberBoots
A. Cam Follower B. DamperSpring D. DriveGearAssemblv
FINAL DRIVE IG17
A. Cap
A. Bearing B. BearineHolder
l . Driver:57001-382
2 . Shaft
J. DriveGear
milm
owhen stsking the nut, be caretul not to apply shock io
lhe shaft and iG bearing. Sudr a drod< could damage
dre 3h.ft and/ol bearing.
A. Vise
B. DrivenGearHolder:5700'l-1027
olnstall the driven gear assemblyso that the oil hole
on the housingalignswith the oil hole in the case.
olnstalltheshim.
oTight€nthe drivengearassembly mountingboltsto the
specifiedtorque(seeExplodedView). .Remove the driven gearjoint with the O-ring.
FINAL DRIVE 10.19
A. Joint B. O+ing
m
owhen staking the bolt, be careftil not to apply shock to
dre ddyen ge.r and lheil bearingr. Such a drock could
damagethe driyen gear and/or b€arings.
DrivenGearAssembly
.Note the following.
oThe drive and drivengearsare lappedas a set at the
factory to get the besttooti contact. They must be Damper Cam Bemoval
replacedasa s€t. aRemovethe front gearcase.
oBe sureto checkandadrustthe bearingpreloadandthe .lnsert a bolt (012 mm, Ll00 mm) into the engine
bevelgearbacklashandtooth contact(seeFront Bevel mountingbolt holeasshown.
GearAdjustment). .Holding the danper cam with the dampercam holder
oDriv€ the taperedroller bearinginner raceonto the (specialtool), unscrewthe dampercam nut usinga
drivengearshaftusingthe bearingdriver(specialtool). deepsocket.
1. Driver:57001-382
2. RollerBearing A. DamoerCam C. Bolt
3. DrivenGear B. Holder:57001-1025
IG2O FINAL DRIVE
Damper Cam lnstallation Notes Front BevelGear Adiustment Procedure
aReplace the dampercamnut with a newone.
.Tighten the dampercam nut to the specifiedtorque Preloadthe driven gear bearings.
(seeExplodedView).
oApply a small amount of oil to the threadsand the
seatingsurfaceof the nut.
Backlarh{slatedParts
I . DriveGear
2. Collar
3. DriveGearShim(s)
4. Ball Bearing
5. DriveGearShaft
6. Front GearCase
7. DrivenGear
8. TaperedRollerBearing
9. DrivenGearShim(s)
10. DrivenGearBearingHousing
11. DrivenGearroint
Partswhidt influencebearing
plsload only
12. Collar(PreloadAdjustment)
13. Spacer(PreloadAdlustment)
i4. TaperedRollerBearing
*15. DrivenGearBolt
cAlrnoN
To start with- choose a shim or collar so that the
bea.ings ar€ iust SNUG with NO play and also with NO
preload.
Any over-prcload on the bearings could damage the
b6arings. 1. SpringScale 3. DrivenGearHolder: 57001-1027
2. Hole 4. 200 mm
Collarsfo. PreloadAdiwtm€nt
Length(mm) PartNumber
22.8 92027-1152
22.9 92027-1153
23.0 92027-1154
23:1 92027-1155
Prsloadfor DrivenGearBoaring 92027-1156
UsingSpringScale: .25.5 92027-1157
25 - 4.5 N (025 - 0.45 ks,0.6 - 1.0 lbl 23.4 92027-"t158
U.ingTonque Wrendr: z)-) 92027-1159
05 - 09 N{n (0.05- 0O9 kg"m.4- 8 inJb) 23.6 92027-1160
z5. t 92027-1161
23.8 92027-"t162
23.9 92027-1163
24.O 92027-"t164
24.1 92027-"t165
NOTE
oPreloadcan be masrred either with a Wring sale or a
bem-rype torque wrench. When measJrcdwith a
Spacersfor PreloadAdiustmsnt
gring wle, the preload is d$ignafud by force (N, kg,
lb), and when masJred whh a torque wrench,it is (mm)
Thickness PartNumber
d8ignated by torque (N-n, kgfl, in-lbJ. 1.70 92025-1072
ousing &dng *ale: 1.72 '92025-1073
Hook the *ring wle on the handleat a point 200 1.74 92025-1074
mm apart from the cenEr of the gar c7€ft. t./o 92025-107
5
Hold the bearinghousing ih a vis€e dlat the g@r "t.78
92025-1076
Ctaft axis is tErtial; Appty force to dE handle
horizontally and at a riglrt angleto it,
1.80 92025-1077
1G22 FINAL DRIVE
BearingPreloadingMedranirm
Under Under
No Preload Preload
lnitial
Clearance Clearance
Under
No fteload
l. BearingHousing
2. TaperedRollerBearing
3. Spacer
4. Collar
5. TaperedRollerBearing
Heel Heel
1. DriveGear
2. DrivenGear
Ball Bearinglnspection
.Since the ball bearingis madeto extrem€lyclose
thewearmustbeiudgedby feelratherthan
tolerances,
measurement. Clean the bearing in a high flash-point
solven!,dry it (do not spin the bearingwhile it is dry),
and oil it with engineoil.
.Spin the bearingby hand to check its condition.
*lf the bearint is noisy, does not spin smoothly, or has
any rough spots, replaceit.
NeedleBearingInspection
aThe rolleIsin a needlebearingnormallywear very little,
and wear is difficult to measure. lnsteadof measuring.
visually inspect the bearingfor abrasion,color change,
or other damage,
*lf there is anv doubt as to the condition ot a needle
b€aring,replaceit.
Oil Seallnspection
alnspect the oil seals.
*Replace it it the lips are misshapen,discolored (indicat-
ing that the rubber has deteriorated), hardened, or
otherwisedamaged.
BRAKES11-1
Brakes
Tableof Contents
ExplodedView 11-2
Specifications 114
SpecialTools. 114
BrakePedal 11-5
BrakePedalPositionAdjustment. . . , 11-5
Caliper.. 11-5
Front Caliper Removal 11-5
RearCaliper Removal 11€
CaliperInstallation 11-6
DisassemblyNotes, 11€
AssemblyNotes.. , 11.6
Brake Pads. 116
Removal 11-6
lnsellation Notes 11-7
LiningWear. 11-7
MasterCylinderc 11-7
Front MasterCylinderInstallation 11-7
RearMasterCylinderRemoval 11-7
RearMasterCylinderInstallation 11€
lnspectionand Adjustmentafter Installation 11€
Disassembly. 11€
Assembly. 11€
Inspection(Visually). 11€
BrakeDisc. 11-9
Wear 11-9
Warp... 11-9
BrakeFluid 11€
Fluid LevelInspection. 11-9
BrakeFluidChange.. ... . 11-10
Bleedingthe BrakeLine. . . 11-10
11.2 BRAKES
ExplodedView
so
@ n
@^-6"s @@
9
1 . Front MasterCylinderAssembty
2 . Diaph.agm
3 , MasterCylinder
4 . Front BrakeLight Switch
CIt' 5 . MasterCylinderClamp
5 . Piston
7 . Brake HoseClamp
L Fronl CaliperAssembly
I . Brake Pads
w
ssn@g-
Y I . RearCaliperAssembly
2 . Piston
3 . Caliper
4 . Brake Pads
5 . CaliperHolder
6 . Brake Disc
7 . CaliperHolder
8 . Real MasterCylinderAssembly
9 . Diaphragm
10 . ReservoirTank
ll . PushRocl
'12. Piston
13 . MasterCylinder
114 BRAKES
1. RearBjakePedal
2. Front FootpsgBrac*et
3, BrakePedalLink CNamp Bola
G : Apply greale.
T1: 25 N-m (25 kgn, 18J ft{b}
V
U SpecialTool
n
tl CirclipPliers:57001-1tB
H
I
Specificaions
Pedal Position
Sandard: About 65 mm above top of footpeg
-- ll
l . MasterCylinder 3. Clevis
2 . Locknut
Lensth@
Standad: 165mm
Caliper
A. Footpeg C. Pedal Positlon
B. BrakePedal
Front Caliper Removal
.Disconnectthe speedometercablelowerend.
rlf it is not, checkthe punch marksat the brakepedal .Loosen the banjo bolt at the caliper,and tighten it
link pivot shaft, and the mastercylinder push rod lightly.
lencth. .Remove the calipermountingbolts and take off t}te
caliper.
A. PivotShafts B. Marks
A. CaliperMountingBolts C. Caliper
B. BanioBol: D. BrakeHose
NOTE
ausually it's not n*e&ry to adiust the pedal position,
but alwaysadiu# it when the master cylinder is dis aDisconnect the brakehosefrom ihe caliper.
asembled. *lf the caliperis to bedisassembled afterremovalandif
olf the push rod length cannot be adjustedby turning compressed removethe pistonusing
air is not available,
the clevis, the bnke pedal may be deformedor incor- the followingstepsbeforedisconnecting the brakehose
rectly installed. from the caliDer.
11.6 BRAKES
oRemovethe pads.
oPumpthe brakeleveror pedalto removet}|e caliper
piston.
oTo avoid serious iniury, neyer place your fingerc or
palm inlide the caliper opening. lf you apply com-
NOTE
pr$sed air into the caliper, ihe piston may cru3hyour
olmmediately wipe up any brake fluid that Wills. hand or fingerc.
air.
l. Applycompressed 2. Cloth
Assembly Notes
oApplybrakefluid to the outsideof thepistonandthe
fluid seal,and push the piston into the cylinderby
A. Caliper C. BrakeHose hand. Take care tlrat neither the cvlindernor the
B.CaliperMounting
Bolts pistonskirt get scratched.
.Apply a thin coatof PBC(Poly Butyl Cuprysil)grease
to the caliperholdershaftsandholderholes.(PBCis a
specialhightemperature, grease).
water-resistant
Caliper lnstallation .lnstall the anti-rattlespringin the calipersas shown.
.Note the following.
oTighten the caliper mountingbolts to the specified
torque(seeExplodedView).
oconnectthe brakehoseto the caliperputting a new
flat washeron each side of tl|e brake hose fitting.
oTighten the banio bolt to the specifiedtorque (see
ExplodedView).
oCheckthe fluid levelin tie mastercylinder(reservoir),
and bleed the brake line (seeBleedingthe Brake).
oCheckthe brakefor weakbrakingpower,brakedrag,
andfluid leakage.
BrakePads
Dinssembly Notes
.Usingcompressed thepiston.
air,remove
oCoverthe caliperopeningwith a clean,heavycloth- Removal
oRemovethe pistonby lightly applyingcompressedair rRemove the caliper (see Front or Rear Caliper
to whereth€ brakeline fits into the caliDer. Removal).
BRAKES11-7
.Take off the piston side pad from the caliper holder.
.Push the caliper holder to the piston side,and then MasterCylinders
removethe pad from the caliper holder shaft.
1. Pad 3. Pushthecaliperholder.
2. CaliperHolder
lnstallation Notes
.Push the caliper pistons in by hand as far as they will
go.
Lining Wear
rlf the liningthickness
of eitherpadis lessthanthe Rear Master Cylinder Removal
servicelimit, replace both pads in the caliper as a set. .Note the following.
oRemovethe cotter pin and then pull the joint pin out
Pad Lining Thickness of the pushrod clevisand brakepedal.
Standard: 5.0 mm
ServiceLimit: I mm
q&
1. PrimaryCup 4. Retainer
2. Secondary
Cup 5. DustCover l. Reservoir
3. Piston 2. Diaphragm
3. Reli€fPort
4. SupplyPort
5. Cylinder
Assembly 6. ReturnSpring
.Note thefollowing. 7. PrimaryCup
oBeforeassembly,cleanall parts includingthe master 8. Piston
cylinderwitlr brakefluid or alcoho,. 9. SecondaryCup
oApply brake fluid to the removedparts and to the 10. DustCover
innerwallof the cylinder. I 1. BrakeLever
BRAKES 11-9
BrakeDisc '.:.*.:i::1........
Wear Fluid Level lnspection
*Replacethe disc if it hasworn pastthe servicelimit. .Check the brakefluid levelin the reservoir.
'1.
BrakeDisc 2. llleasuring
Area
Warp
tlf runoutexceeds
the servicelimit, replacethe disc.
A. UpperLevelLine B. LowerLevelLine
NOTE
oHold the reservoir horizontal when checking brake
fluid level.
1. BrakeDisc 2. Measuring
Area
ochange the brake fluid in dre brake line completely if
Dbc Runout the brake fluid must be re{illed but the type and brard
Standard: Under0.15 mm of dre brake fluid that aheady is in the rg3srvoir ars
ServiceLimit: 03 mm unidentified. Aftsr cfianging the fluid, use only dre
I1.10 BRAKES
$me type and brand of fluid thereafter. Mixing ocheckthe fluid levelin the reservoiroften,replenishing
differsnt types and brands of brske fluid lowers the it asnecessary.
brake fluid boiling point and co{ld cause the brake to
be ineffectiye. lt may also cause dre rubber brak€ parts NOTE
to deteliorate.
olf the fluid in the rcervoir runs completely out any
time during fluid changing,the bleedingopention must
be done over again from the beginning sinceair will
R€commended Dirc Brake Fluid
haveenteredthe line.
Type D.O.T.4
Brand Check Sho.r( Premium Heavy Duty oRepeatthis operationuntil fresh brake fluid comes
Crstrql Gidin g.unive'ssl out from the plastichoseor the color of the fluid
Cactrol GT (f-MA) cnanges.
Castrol Dbc Brake Fluid
NOTE
oThe procedure to bleed the front bnke line is a
follov,n Eleding the rar bnke line is {re sme
as for the front bnke.
NOTE
oTap the bnke hoe lightly going from the caliperto fie
recrwir side and let the air off from the reervoir
whenthe btdcelever hasa qonge feling.
l. Neverreuseold brakefluid.
2. Do not usefluid from a containerthat hasbeen
left unsealed or that hasbeenopenfor a longtime-
3. Do not mix two lypesand brandsof fluid for use
in the brake. This lowersthe brakefluid boiling
point and couldcausethe braketo be ineffective.
It may also causethe rubberbrakepartsto dete-
riorate.
4. Don't leavethe reservoircapoff for any lengthof
time to avoidmoistur€contamination of the fluid.
5. Don't changethe fluid in the rain or when a
strongwindis blowing.
6. Exceptfor t}te disc padsand disc, use only disc
brakefluid, isopropylalcohol,or ethyl alcoholfor
cleaningbrakepans. Do not useany other fluid
for cleaningtheseparts. Gasolingengineoil, or
any other petroleumdistillatewill causedeteriora-
tion of the rubberparts. Oil spilledon any part
will be difficult to washoff completelyand will
eventually deterioratetie rubber used in the
discbrake.
7. When handlingthe disc padsor disc, be careful
that no disc brakefluid or any oil getson them,
Cleanoff any fluid or oil that inadvertentlygets
on the padsor discwith a highflash-pointsolvent.
Do not useone whichwill leavean oily residue.
Replacethe padswith newonesif they cannotbe
cleanedsatisfactorilv.
8. Brakefluid quickly ruins paintedsurfaces;any
1. Pump the brake lever until it becomes hard, and apply fluid should be completely washed
the brakeleverand hold it. immediately.
2. Ouickly open and ctose the valve while holding the 9. lf any of the brakeline fittingsor the bleedvalve
brakeleverapplied. is openedat any time, the AIR MUST BE BLED
3. Releasethe brakelever. FROMTHE BRAKE.
NOTE
off the fluid in the res€ oir runs completely out any
time during bleeding, the bleeding opention mu$ be
done over again from the beginning since air will have
entered the line.
NOTE
alf the bmke lever action still feels fift or gongy, tap
the bnke hose lightly from futtom to top end or air
will rise up to the top paft of the hoe, slowty pump
the brake lever as the ame manner as above
l2-1
susPENsroN
Suspension
Tableof Contents
ExplodedView... 12-2
Specifications 124
SpeciafTools. 12-4
Front Fork 12-5
Fork Oil Change. 12-5
Removal(eachfork legl . .. . 12-6
Installation(eachfork les) . . . . 12-6
Disassembly. 12'6
Assembly. 12'7
InnerTubeInspection. 12-8
GuideBushInspection 12-8
Oil SealandDustSealInspection PA
SpringTension 124
RearShockAbsorber. . . . 12-9
Adjustment. 12-9
Removal 12-9
lnsallationNotes.. 12-9
RearShockAbsorberWear 12-9
Bushing Wear. .' 12'10
SwingArm .. 12-10
Removal .'""' 12-10
fnstalfation ..... 12-10
Grease SealandNeedle Bearing Removal/Assembly .. .. . 12-10
Grease SealandNeedle Bearing Lubrication.
' '.. '..... 12-11
Sleweand NeedleBearingWear. . . .
12-2 SUSPENSTON
Exploded View
-P
,g
@o@€
es
6 sB
y*
@ K
1. RearShockAbsorber
2. S:wingArm
3. Pivot Shaft
4. SwingArm Cover(LHl
5. SwingArm CoYer(RHl
Specifications
NOTE
Qump the fo* enough tim6 to expel the air form the
upper d lower chambe,s,
ForkSpring
DrainScrew
l OilLevel
Removal (each fork leg) oTightenthe upper and lower fork clamp bolts to the
.Using the jack stand and the attachment (special torque(seeExplodedView).
specified
toofs: 57001-1238or 12521or other suitablemeans oTightenthe caliper mountingbolts to the specified
to llft the front of the motorcycle. torque(seeExplodedView in Brakechapter).
rRemovethe following. oCheckthe front brakeafter lnstallation.
Caliper(fromthe fork legto be removed.)
Front Wheel(seeWheelsflires chapter)
Front Fender
.Loos€nthe upperandlowerfork clampbolts.
.With a twistingmotion, work the fork leg down and
out
Dis*sembly
.Performthe following.
oRemove the retainerandtakeoff the top plug.
oPullout the spacer,washer,andthefork spring.
A. UpperClampBolt B. LowerClampBolt oRemove the fork leg.
oPourout the fork oil.
ostop the cylinderfrom turning by usingthe front fork
cylinder holder handle and adapter(specialtools).
Unscrewthe Allen bolt and take the bolt, and gasket
out ofthe bottomof the outertube.
Installation (each fork leg)
.Performthe following.
olnstallthe removedDarts.
olf the fork leg was disassembled, check the fork oil
level.
olnstall the fork tube so that the inner tube toD end
is alignedwith the upper surfaceof the stem head.
1. Wrench 5. Handle:57001-183
2. Bolt 6. OuterTube
3. Cylinder 7. lnnerTube
4. Adapter:57001-1057
fr
oRemovethe dust sealand the retain€rfrom the outer
tube.
1. lnnerTube
$
2. ForkOuterTubeWeight:57001-1218
3. OuterTube
4. Strok€
Assembly
.Assembly is the reverseof disassembly. Note the
A. DustSeal B. Retainer following.
€heck the top plugO-ringsfor damage.
tReplacethemwith newonesif damaged.
oReplace theoil sealremovedwith a newone.
olnspectthe guide bush (seeGuide Bushlnspection).
*Replaceit with newonesif necessary.
oApplya non-permanent lockingagentto the Allenbolt.
oTighten the Allen bolt to the specifiedtorque (s€€
ExplodedView), usingthe ftont fork cylinderholder
handleand holderadapter(specialtools) to stop the
oMountthe weight(special tool) on tie top of tie outer cylinderfrom turning.
tube, by fitting the stepof the weight(specialtool) to olnstallthe guidebushwith a usedguidebushon it by
the top cornerof t}le out€rtube. tappingthe usedguidebushwith the fork oil sealdriver
oHoldingthe inner lube by handin a verticalposition, (specialtool) until it stops. The slit of the bushmust
strokethe outer tube severaltimes and pull it down. befacedtowardthe left or right.
12-8 SUSPENSTON
'1.
GuideBush
1. Driver:57001-1219
2. UsedGuideBush
3. Slit (towardthe left or right) Oil *al and Dust Seallnspecdon
4. NewGuideBush *lf dustsealhasanydamage
or wear,replace
it.
5. Tap .Replace the oil seal with a new one whenever it has
been removed.
tI tI tI
5
4
5
J
StIonger
I
Hard
,t ,t 't
Heavy Bad High
are turned to
.Check to seethat both adiustingsleeves
the samerelativeposition.
1 . ForkSpring
2. FreeLength
Fork Sp ng Length oll both sprins adiusting sleevB are not adiusted equsl'
ly, handling may be impailed and a hazardouscondi'
vN1500-A
tion may r$ult.
Standad: 4755 mm
SerYiceLimit: 466 mm NOTE
VNlsq'-B
St ndard; 412,5mm oBe s.rre to tum back the adiuiing sleate counfutclock-
ll{t4 mm wis€ from pNition 5 wlrq, eftening the *ring action.
Service Limit:
lnsallation Notes
rTighten the mountingnutsto the specifiedtorque(see
Exploded View).
.Adjust the rearshockabsorberposition.
Bushing Wear oPull back the swing arm and take ifoff. A cap on each
avisuallyinspect
therubberbushing. sldeof the swingarm will alsodrop off.
tlf th€yshowanysigns
of damage,
replace
them.
lnstallation
SwingArm alnstallationis the reverseof removal. Note the fol-
lowing.
oTightenthe pivot shaft to the specifiedtorque (see
Removal ExplodedView).
aUsing the iack stand and the attachment (special oTightenthe rear shockabsorbernuts to the specified
iools: 57001-'1238 or 12521or other suitablemeans torque(seeExplodedView).
to lift the rearof the motorcycle. oTighten the calipermountingbolts to the specified
aRemovethe following. torque(seeExplodedView).
RearWheel(seeWheels/Tires chapter) oMove the swing arm up and down to check for
RearCaliper(seeBrakechapter) abnormalfriction.
Muffler(seeEngineTop Endchapter)
SwingArm Covers
RH RearShockAbsorber
FinalGearCase(seeFinalDrivechapter)
A. Oil SealandBearingRemoveri57001-1058
B. NeedleBearing
A. SwingArm B. PivotShaft C. GreaseSeal
susPENstoN12-11
olnsert the needlebearingusing bearing driver set
(special 129) so that marked side faces
tool: 57001-1
outside.
A. Applygrease. C. Grease
Seal
B. NeedleBearing
Steering
Tableof Contents
ExplodedView... 13'2
SpecialTools. 13-3
Steering. 134
Adjustment. 134
Steering Stem 134
Removal 134
lnstallation 136
S t e e r i nSgt e mB e a r i n g . .... '... 137
BearingLubrication,. . . . 1;-7
gearingWear,Damage. 13'7
StemCapDeterioration, Damage. '. '.... '. 13-7
S t e e r i nSgt e mW a r p. . . . . ..'.'.... 13'7
13.2 STEERING
ExplodedView
@
G:Applygrease
L : Apdy nonfermanentlockingagent. oy
o
4 " g
A " , e @
@@/N€
@S/r
d
P--{D
rc-
1. Handlsbst
2. Gollar
3. Handl. Holdel
e-o 7. St6mNutT:6mm
8. StemNut T 3 10 mm
9. StemCap
Driver(Upper):57m1't 106
Adapter: 57001-1074
Driver(Lowerl: 57001-1076
JackStand: 57001-1238
StemNut Wrench:57m1-l l(Xl
Attidrment: 570'01-1252
StemBa.ringRemorer:57(x11-1107
q
s
134 STEERING
NOTE
Steering
oTurn the locknut l/8 turn at a time maximum-
Adiustment
oCheck asfollows.
steering
ouse the jack stand and the attachment(specialtools:
57001-1238,5700'l-1252\to lift the front wheeloff
the ground. .Tighten the steeringstem headbolt to the specified
owith ttle front wheel pointing straightaheadalt€r- torque(seeExplodedView).
nately tap each end of the handlebar. The front .Tighten the front fork lower clamp bolc to the spe-
wheelshouldsriing fully left and right from the force cified torque (see Exploded View in Suspension
of gravityuntil the fork hir the stop. chapter).
*lf tl|e wheel binds or catchesbefore the stop, the .Checkthe steeringagain.
steeringis too tight. *lf the steeringis still too tight or too loose,repeatthe
oFeel for steeringlooseness by pushingand pullingthe adiustment.
forks. alnstallthe removedDarts.
*lf you feel looseness on the forks, the sGeringis too
loose.
NOTE
oThe cablesand wiring will have sme effet on dre
motion of the fork which mustbe taken into aeount.
Be gtte the wit6 and ables are prcperly routed.
ome bearing' must be in good condition and properly
lubricatedin order for any test to be valid.
A. StemHeadBolt
B. StemNut Wrench:57001-1
100
A. Locknuts B. Cap
A. StemHeadBolt C. Handlebar
B. washer D. Headlight
Unit
57001-1107
Remover:
1. StemBearing
1 . Grease
Seal 3. TapHear l. StemBearing
Driver:57001-137
2. LowerInnerRace 2. Adapten 57W1-1O74
'I
80 mm
Kg
1. StemNut Wrench:57001-1100 3 . 2 2 . 2 k s
2. 180mm
SteeringStem Bearing
Bearing Lubrication
.Perform the following.
oRemovethe steeringstem.
ousing a high flash-pointsolvent,washthe upper and
lowertaperedroller bearingsin thecages.
owipe the upper and lower outer races,which are
press-fittedinto the frame headpipe,cleanoff grease
anddirt.
oVisuallycheckthe outerracesandthe roll€rs.
*Replace the bearingass€mblies if they show wear or
damage.
oPackthe upperand lowertaperedrollerbearings in the
cageswith grease,and apply light coat of greaseto
the upperand lowerouterraces.
olnstallthe steeringstem,andadjustthe steering.
BearingWear,Damage
*Replacethe bearingassemblies
lf theyshowdamage.
Frame
Tableof Gontents
ExplodedVia^l 1+2
Right Down Tube 1+5
Removal(To AccessRight EngineCoverl. . 1+5
RearFender 1+5
RearFender RearSectionRemoval. 1+5
RearFenderFront SectionRemonal. 146
Footpeg, 1+6
Right Footpeg Removal AA
Right Footpeg Installation 1+7
1+2 FRAME
Exploded Viar
f&
(? \^
\se
€)
.,^@
os-
t
<,-@
@@,AW
*K*-o, N
rffi
___9_ @q
-/
,,t',
1. Front F€ndsr
2.
3.
4.
5.
Rider's Sest
Pa$enger's S€at
Rear Fender Front Section
Rear Fender Rear Section
L- 1.1
6. Seat
7. Rear Fender
vN1500-8
/Eurqeanudrel
ffi\
(
EuropeanModel
T'I4 FRAME
1. Battery Band
2. Battery C.se
I
s*
3. Elestric PartsBr*ket
4, Fuel PumpBrsdct
5, lgnit€r &ad(et
6. lgnruon CoiaBFckst
7. liide Stand
8. SideStandSwitch
G : Apply grease.
Fr
\l
FRAME 1/L5
A. EngineMountingBolts C. DownTubeBola
B. BracketBolts
A. Stand
aRemovethe radiatorcor€r.
oUnscrewthe radiatorlowermountingbolts.
A. DownTube
A. Radiator B. LowerMountingBolts
RearFender
.Remove the coolant reservoirtank cov€r(seeCooling
Systemchapter),and take the tank out of the bracket.
aRemovethe fuel tank and RHframetop tube cover. Rear Fender Rear Section Remotnl
.Disconnectthe rearbrakelightswitchwireconnectors. .Disconnectthe rear turn signaland tail li8ht wire
.Unbolt the following, connectors.
14.6 FRAME
RearFenderFront SectionRemoml
aRemovethe rearfender rearsection.
rRemovethe rearfenderfront sectionbolts and put it
down.
A. RearFenderRearSection C. BackFrame8o16
B. FenderBolt
Footpeg
METERCONNECTIONMETERREADINC(9) Terminals
for DiodeCircuit Inspection
FAN r*11-12, i13-8, +13-9. 12-14,.t5-14,16_14
RELAY
* US/QnadaModelOnly
*'* VN150GA9-
HEADLICHT *7-8 @
RETAY *7 -13
STARTER 11-13
RELAY
*The resistance
shouldbe low in onedirectionandmore
12-13
than ten timesas much in the other direction. lf any
*,'.vN150GA9- diodeshowslow or highin both directions,the diodeis
defectiveandthe diodeassemblymustbe replaced.
RelayCircsit In$sction (with the batteryconn€6ed)
NOTE
BATTERY METER
METER oThe &tual meter ,@ding varia with dte meter ud
CONNECTION READINC
CONNECTION
+ (0) - and the individual diode, but. gercn y q@kiry, the
FAN 2-4 0 loy,Er tding *ould be from zero to one half d\e
*ale.
HTADIICH'I .7 -8 9-13 0
STARTER 1 1- ' 1 3 11-12 0
* US/ CANADAMODELONLY
,,r,vN1sflrAg-
"!
f--l'r
ii"ii
-l-h8i i
Idttt
-+l!l
@ o o
tt-'' i
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:
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modcle
o
VN15OO-A2-Aa / 82-86 Wiring Diag.am (Orher than US and Canadal
o @ 0
l l
RightTu.nSi9tulhdharor
Ugln12V 3W
L.t TumSig..l lhdic.tor
12v 6ry55W
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ridr 12v 2r w adTls",Y+q>BvY
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15.4O ELECTRICAL SYSTEM
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8. Acc.sery F!e. 1O A
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APPENDIX1S1
Appendix
Tableof Contents
16
162 APPENDIX
Whena plugof the correctheat rangeis beingused,
Additional Considerationsfor Racing the electrodeswill stay hot enoughto kedp all the
carbon burned off, but mol enough to keep from
damagingthe engine and the plug itself. This tem-
This motorcyclehasbeenmanufacturedfor usein a peratureis about400 - 800"C(750- 1,450"F)and can
reasonableand prudentmannerand as a vehicleonly. be judged by noting the condition and color of the
However,somemay wish to subiectthis motorcycleto ceramicinsulatoraround the centerelectrode. lf the
abnormaloperation,suchaswould be experienced under ceramicis cleanand of a light brown color, the plug is
racingconditions. KAWASAKI STRONGLY RECOM- operatingat the right temperature.
MENDSTHAT ALL RIDERS RIDE SAFELY AND A spark plug for higher operatingtemperaturesis
OBEY ALL LAWSAND REGULATIONS CONCERN- used for racing. Sdch a plug is designedfor better
ING THEIR MOTORCYCLE AND ITS OPERATION. coolingefficiencyso that it will not overheatand thus
Racingshould.bedone undersupervised conditions, is often calleda "colder" plug. lf a sparkplug witlr
and recognizedsanctioningbodiesshouldbe contacted too higha heatrangeis used- that is,a "cold" plugthat
for further details. For thosewho desireto participate cools itself too well - the plug will stay too cool to
in competitiveracing or related use, tl|e following burn off the carbon,and the carbonwill correcton the
technical information may prove useful. However, electrodesandthe ceramicinsulator.
pleasenoG the followingimportantpoints.
The carbonon the electrodesconductselectrici.ty,
aYou are entirelyresponsible for the useof your motor- and can short the centerelectrodeto groundby either
cycle under abnormalconditionssuch as racing,and coatingthe ceramicinsulatoror bridgingacrossthe gap.
Kawasakishall not be liable for any damageswhich Such a short will preventan effectivespark. Carbon
mightaris€from suchuse. buildupon the plugcanalsocauseotler troubles. lt can
.Kawasaki'sLimited MotorcycleWarrantyand Limited
heat up redhot and causepreignitionand knocking,
EmissionControl SystsmsWarranty specificallyex- which may eventuallyburn a hole in the top of the
clude motorcycleswhich are used in comDetitiveor piston.
related uses. Pleaseread the warranty carefully.
.Motorcycleracingis a \€ry sophisticated spori,subiect
to many yariables. The following information is
SparkPlug
theoretioalonly, and Kawasakishall not be liablefor
any damages which might arisefrom alterationsutili-
zingthis information.
.When tie motorcycleis operatrdon public roads,it
m|lst be in is originalstate in 'ord€r to ensuresafety
andcomplianc€ with applicableregulations.
Carbureton
Sometimesan alGration may be desirablefor im-
proved performanceunder special conditions when
proper mixture is not obtainedafter the carburetorhas
beenproperlyadiusted,and all partscleanedandfound
to befunctioningproperly.
lf the enginestill exhibits symptomsof overly lean
carburetionafter all maintenance and adjustmentsare
correctlyperformed,tie mainiet canbe replacedwith a
smalleror largerone. A smallernumberedjet givesa
leanermixture and a largernumberediet a richermix-
ture.
Spark Plug:
The spark plug ignitesthe fuefair mixture in the
combustioncharnber.To do this effectivelyand at the
propertime, the correctspark plug must be us€d,and I . Terminal 4. Gasket
the sparkplugmustbe kept cleanandadiusted. 2. lnsulator 5. CenterElectrode
Test haveshown the plug list€d in tlre "Electrical 3. cement 6. SideElectrode
System"chapterto bethe bestplugfor generaluse.
Sincesparkplug requirements changewith the igni-
tion and carburetionadjustments and with ridingcondi-
tions, whetheror not a sparkplug of a correct heat range SparkPlug lnspection
is usedshouldbe determinedby removingand inspect- .Removethe sparkplugand inspecttl|e ceramicinsu-
ing the plug. lator.
APPENDIX1G3
Spa* Plug Condition
*Whetheror not the right temperatureplugis beingused Standad Spark Plug Thread:
can be ascertainedby noting t$e condition of the Diameter: 12 mm
ceramicinsulatoraroundthe electrode.A light brown Pitch: 125 mm
color indicatesthe correctplug is being used. lf the
Readr: 19.0 mm
ceramicis white, the plug is operatingat too high a
temperatureand it shouldbe replacedwith the next
coldertype. NOTE
oThe heat nngc of the spark plug fu,Etions like a
thermo*at for the engine. Using the wrotry type of
qark plug en make the enginerun too hot (reiting
olf the spark plug ir replaced with a tyFe odror dran the in enginedamage)or too cold (with poor performance,
standard plug, mako certain the replacemem plug has misfhing,and sta ing).
t're sams drread pitch and readr (length of threaded
portion) and the same insulator type (regulal typs 01
proiected typel as the standard plug.
olf $e plug reach b too short, ca.bon will build up on
the plug hole threads in the .rylinder heed, cau:ing over-
heating and making it very dilfidrlt to insert the
coJrect spark plug later.
olf the reach b too long, carbon will build up on the ex-
pos6d spark plug thrcad: caBing ovedreating.
preignition, and po$ibly buming a hols in the p&ton
top. In addition, it may be impossibleto lemoye the
plug without damaging the cvlinder head.
Plug Reach
Carbon
buildsup here
164 APPENDIX
Cylinder,pistonworn
TroubleshootingGuide Pistonringbad{worn,weakbroken,or sticking}
Pistonringlgrooveclearanceexcessive
Cylinderheadgasketdamaged
NOTE
Cylinderheadwarped
oThis is not an exhaustive list, giving every posible Valvespringbrokenor weak
cau*s€for e*h problem li&ed. lt is ment simply as a Valve not seatingproperly (valvebent, worn, or
rough guide tu. assisrthe trcubleshootingfor sme of carbonaccumulation on the seatingsurface)
the morecommondiff icutti*. Hydrauliclashadjust€rdamaged(worn,seizure,or
springbroken)
Engine Doesn't Start, Starting Difficultyl Hydrauliclashadjusteroil p4ssage
clogged
Startelmotor not rotating;
Starterlockoutor neutralswitchtrouble
Startermotortrouble
Batteryvoltagelow
Relaysnot contactingor operating
Starterbutton not contacting
Wiringopenor shorted
lgnitionswitchtrouble
Enginestopswitchtrouble
Fuseblown
Startermotor lotating but enginedoesnt tum oysr:
startermotor clutchtrouble
EnginarYon'ttum ov€r:
Valveseizure
Rockerarm seizure
Cylinder,pistonseizure
Crankshaft seizure Poor Runningor at Low Speed:
Connecting rod smallendseizure Spsrkwe8k:
Connecting rod big endseizure Batteryvoltagelow
Transmission gearor bearingseizure Sparkplugdirty, broken,or matadiusted
Camshaftseizure Sparkplugcapor hightensionwiringtrouble
Balancer bearingseizure SparkPlugcapshortedor not in goodcontact
No tuel flow: Sp k plugincorrect
Fueltank air ventobs$ucted lC ignitertrouble
Fuelpumptrouble Pickupcoil trouble
Fueltap clogged lgnitioncoil trouble
Fuellineclogged Fuel/airmlxl re incorect:
Floatvalveclogged Pilotscrewmaladiusted
Engineflooded! , Pilot jet, or air passage
clogged .
Fuellevelin carburetorfloat bowl too high Needlejet (air bleedpipe),bleedholesclogged
Floatvalveworn or stuckoDen Pilot passage clogged
Startingtechniquefaulty Air cleanerclogged,poorly sealed,or missing
(Whenflooded,crank the enginewith the throttle Stzrt€rplungerstuckopen
fully open to allow more air to reach the Fuel levelin carburetorfloat bowl too highor too
engine.) low
No 3park;sparkweak: Fueltank air ventobstructed
Batteryvoltagelow Carburetorholderloose
Sparkplugdirty, broken,or maladjusted Air cleaneror surgetank duct loose
Sparkplugcapor hightensionwiringtrouble Fuelpumptrouble
Sparkplugcapnot in goodcontact Backfiringwhen deceleration:
Sparkplugincorrect Vacuumswitchvalvebroken
lC ignitertrouble Air suctionvalvetrouble
Neutral, starter lockout, or side stand switch Other:
trouble lC ignit€rtrouble
Pickupcoil trouble Carburetors not synchronizin!
lgnitioncoil trouble Carburetorvacuumpistondoesn'tslidesmoothly
lgnitionor enginestopswitchshorted Engineoil viscositytoo high
Wiringshortedor open Drivetrain tiouble
Fuseblown Finalgearcaseoil viscositytoo high
Compreasion Lowr Brakedragging
Sparkplugloose Air suctionvalvetrouble
Cylinderheadnot sufficientlytight€neddown Vacuumswitchvalvetrouble
APPENDIX1G5
Poor Runningor No Powerat High Speed: Engineloadfaultyi
Firingincorresti Clutchslipping
Sparkplugdirty, broken,or maladiusted Engineoil leveltoo high
Sparkplugcapshortedor not in goodcontact Engineoil viscositytoo high
Sparkplugincorrect Drivetrain trouble
lC ignitertrouble Finalgearcaseoil viscositytoo high
PickuDcoil trouble Brakedragging
lgnitioncoil trouble Lubricationinadequate:
Fuel/airmixtureincorrcct: Engineoil leveltoo low
Starterplungerstuckopen Engineoil poor qualityor incorrect
Mainjet cloggedor wrongsize Gaugeincorred:
Jet needleor needleiet worn Watertemperature gaugebroken
Air.iet clogged Watertemperaturesensorbroken
Fuel lewl in carburetorfloat bowl too highor too Coolantincorrecl:
Coolantleveltoo low
Bleedholesof air bleedpipeor needleiet clogged Coolantdeteriorated
Air cleanerclogged,poorlysaled, or missing Coolingsystemcomponentincorlect:
Air cleaneror surgetankduct poorly sealed Radiatorclogged
Waterof foreign matter in fue, Thermostattrouble
Fueltap clogged Radiatorcaptrouble
Fuellineclogged Thermostatic fan switchtrouble
Fuelpumptrouble Fanrelaytrouble
Knod(ingr Fanmotor broken
Carbonbuilt up in combustionchamber Fanbladedamaged
Fuelpoorqualityor incorrect waterpumpnot turning
Sparkplugincorrect Waterpumpimpellerdamaged
lC ignitertrouble
Backfiring whendeceleration:
Vacuumswitchvalvebroken
Air suctionvalvetrouble
MLcellaneo$:
Throttlevalvewon't fully open
Carburetorvacuumpistondon't slidesmoothly Over Cooling:
Brakedragging Gaugeincorrect:
Clutchslipping Watertemperature gaugebroken
Overheating Watertemperature rnsor broken
Engineoil leveltoo high Coolingsystemaomponentincorrect!
Engineoil viscositytoo high Thermostatic fan switchtouble
Drivetraintrouble Thermostattrouble
Finalgearcaseoil viscositytoo high
Air suctionyalvetrouble
Vacuumswitchvalvetrouble
Balancer mechanism malfunctioning
BrakeDoesntHold:
Air in the brakeline
Pador discworn
Brakefluid leak
Discwaroed
Contamina@d pad
Brakefl uid deteriorated
Primaryor secondary cup damaged
Mastercylinderscratched inside
BatteryDischarged:
Battery faulty (eg., plates sulphated,shorted
through sedimentation,electrolyte level too
low)
Batteryleadsmakingpoor contact
Loadexcessive (eg.,bulb of excessiwwattage)
1G8 APPENDIX
Also,checkto seethat eachcotterpin is in placeandin
GeneralLubrication goodcondition.
NOTE
Lubrication
oFor the engine fasteners.check the tightnes of them
.Before lubricatingeachpart, cleanoff any rusty spots
whenthe engineis cold (at room tempercture).
with rust removerand wipe off any grease,oil, dirt,
or grime. *lf there are loose fasteners,retorque them to the
.Lubricate the points listed below witi indicated
specified torque following the specifiedtightening
lubricant-
sequence.Refer'tothe appropriatechapterfor torque
specifications.lf torque specifications
are not in the
NOTE
appropriatechapter, see the basictorque table (see
owhenever the vehicle h6 been opented wd or Torqueand Lirking Agent in the GeneralInformation
rainy conditions, or 8peially after using a high- chapter).
presunespny n6ter. perform the genenl lubiation. For each fastener,'first loos€nit by l/a turn, then
tightenit.
*lf cott€r pins are damaged,replacethem with new
PiYots: Lubricatswittt Motor Oil.
ones.
SideStand
ClutchLever
BrakeLever Nut, Bolt,and Fas@nerto be dlecked
BrakePedal Wheels:
RearBrakeRod Joint Front Axle Nut
Front Axle ClampBolts
Point: Lubricatewith Grease. RearAxle Nut
Throttle lnnerCablesLowerEnd RearAxle Nut Crtter Pin
Speedometer InnerCablet Brakes:
+Greasethe lowerpart of the inn€roablesparingly. Front MasterCylinderClampBolts
FrontC.aliperMountingBolts
Cabl$; Lubricatewith ilotor Oil. RearMasterCylinderMountingBolts
ChokeCable RearCaliperHolderMountingBolts
ThrottleCables RearCaliperMountingBolts
BrakeLeverPivotNut
CableLubrication BrakePedalBolt
BrakeRodJoint Cotter Pin
Susoension:
Front ForkClamDBolts
Front FenderMountingBolts
RearShockAbsorberMountingBolt andNuts
SwingArm PivotShaftNuts
Steering:
StemHeadNut
Handlebar ClampBolts
HandleGrio Bar Bolts
Engine:
EngineMountingBolts
RockerCaseNuts
€ylinderHeadNuts
ExhaustPipeMountingNuts
MufflerMountingBolts
ExhaustPipeand MufflerConnecting
ClampBolts
1 . Cable ClutchMasterCylinderClampBolts
2 . Pressure
€ableLuber: K55019{21 ClutchLeverPivotNut
RadiatorMountbg Bolts
shift PedalBolt
Others:
SideStandNut
RearFrameMountingBolts
Nut, Bolt, and FasenerTightness RightDownTubeMountingBolts
BackFrameMountingBolts
FootpegBracketMountingBolts
Tightnesslnspection FinalGearCaseMountingNuts
theck the tightness
of the boltsandnutslistedhere.
APPENDIX1G9
Unitsof Length:
Table
Unit Conversion
k m x 0.6214 mile
m x 3.281 = ft
Prefixesfor Units: mm x 0.03937 = in
Prefix Symbol Power
mega M x 1,000,000
kilo k x 1,0O0
Units of Torque:
centi c x 0.01
milli m x 0.001 N-m x 0.1020 kgm
micro tt x 0.000001 N-m x o.7376 ft-lb
N-m X 8.85r in-lb
Kg-m X 9.807 = N-m
ksm x 7.233 = ft-lb
Unitsof Mass: ksm x 86.80 = in-lb
k g x 2.205 tb
g x 0.03527= oz
Units of Pr6sure:
kPa x 0.01020= kg/cm'
Unitsof Volume: kPa x 0.1450 = psi
L x o.2642 sal(us) kPa x 0.7501 = cm Hg
L x o.2200 gal (imp) kg/cm2 x 98.07 kPa
L x 1.057 qt (us) kg/cm' x 14.22 psi
L X 0.8799 qt (imp) cm Hg x 1.333 kPa
I x 2.113 pint (US)
L x 1.816 pint (imp)
mL x 0.03381 = oz(us)
ML x 0.02816= oz (imp) Units of Speed:
mL x 0.06102= cu in km/h x o.6214 mph
Units of Temperature:
.F
r 32 5a 104
40 ,20 20 lao 60 | 80 tool 12o l4o 160 llso 2oo i22o 24oi 260 2aoi 3oo 32o
}lKawasaki
KAWASAKI HEAVY INDUSTRIES,LTD.
ConrunerPrcductu& rchlneryGroup