Kawasaki vnis00ciassic tourer Motorcycle Service ManualThis quick reference guide will assist you in locating 8 desired topie or procedure, ‘@Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. ‘Refer to the sectional table of contents for the exact pages to locate the specific topic required. Quick Reference Guide : General Information | Fuel System _ Cooling System | )o) |r Engine Top End Clutch Engine Lubrication System sae Engine Removal/Installation [(Grankshaft‘Transmission | 8 i Wheels/Tires [of Final Drive [10 Brakes ke | Suspension 28 Steering [13 (Frame —‘—~SCSC~*CiS Electrical System 15 [Appendix |= VULCAN NOMAD Kawasaki vn1500 cLassic TOURER Motorcycle Service Manual Al rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, of transmited in any form or'by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission af Quality Assurance DepartmenConsumer Products & Machinery Group/Kawasaki Heavy Industri, Lto., Japan, ‘No lablity can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product Improvements incorporated after this publcation, Al information contained in this publication is based on the latest product information available atthe time of publication. lWustrtions and photographs in this publication are intended for reference use only and may not deplet actual mode component parts. @ Kawasaki Heavy Industries, Lid., 1998, 2000 ‘Second Edttion (1) ;Dee. 28, 2000 (K)LIST OF ABBREVIATIONS a amipereisy cy poundisy ‘aBoc after bottom dead center ™ meter(s) AC alternating current min minute(s) aTDC after top dead center N newion(s) BOC before bottom dead center Pa ppascal(s) BoC bottom dead center Ps. horsepower proc belore top dead center si pound(s) per square inch c egree(s) Celsius t revolution oc direct current spm | revolution(s) per minute F farad\s) Toc top dead center F degrees) Fahrenheit TR toa indicator reading tt foot, feet v volts) @ gram(s) w watt(s) h houris) a ohms) L. Iteris) Read OWNER’S MANUAL before operating.EMISSION CONTROL INFORMATION ‘To protect the environment in which we all ive, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system) (3) in compliance with applicable regutations of the California Air Resources Board on vehicles sol¢ in California only, 4, Grankcase Emission Control System This system eliminates the release ot cranckcase vapors nto the alrmosphere. instead, the vapors are routed through an oil separator to the intake side of the engine. While the engine is operating, the ‘vapors are drawn into combustion chamber, where they are burned along with the fuel and alr supplied by the carburetion system, 2, Exhaust Emission Contiol System ‘This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this ‘motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully designed ‘and constructed to ensure an efficient engine with low exhaust pollutant levels. 3. Evaparative Emission Control System Vapors caused by fuel evaporation in the fuel system are rot vented into the atmosphere. Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister wnen the engine {is stopped, Liquid fuel is caught by a vapor separator and returned to the fuel tank. The Clean Air Act, which is the Foderal law covering moter vehicle pollution, contains what is commonly referred to as the Act's "tempering provisions.” "Sac, 203(a) The following acts and the causing thereot are prohibited... (3\(A)_ for any person to remove or render inoperative any device or element of design installed on or In a motor vehicle or motor vehicle engine in compliance with regulations under this tle prior 10 its sale and delivery to the ultimate purchaser, oF for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design alter such sale and delivery to the ultimate purchaser (9X8) for any person engaged in the business of repairing, servicing. selling, leasing, or teding motor Vehicles or motor vehicle engines, or who operates 2 feet of motor vehicles knowingly to remove Or render inoperative any device or element of design installed on or in a motor vehicle or moter vehicle engine In compliance with regulations inder this ttle folowing its sale and dalvery to the ultimate purchaser.." (Continued on next page.) NOTE The phrase "remove or render inoperative. any device or element of design” has been generally interpreted as follows: 1.Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance. 2 Tampering could inelude: ‘2.Malagjustment of vehicle components such that the emission standards are exceeded. b.Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle. . Addition of components or accessories that result in the vehicle exceeding the standards. d. Permanently removing. disconnecting, or rendering inoperative any component or element ‘of design of the emission control systems. WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY GIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION.TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Fedearl law prohibits the faloning acts or the causing thereof: (1) The removal or rendering inoperative by any person ‘other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated Into any new vehicle for the purpose of noise control prior to ts sale or delivery to the ul ite purchaser or while It is in use, oF (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person, ‘Among those acts presumed to constitute tampering are the acts listed below: Replacement cf the original exhaust system or muffler with a component not in compliance with Federal regulations Removal o the mufflers) or any internal portion ot the mutfer(s), lomoval of the air box of air box cover. Modifications to the mutters) or air intake system by cutting, dling, or other means it such modifications result in increased noise levels,Foreword This manual is designed primariy for use by trained mechanics in a property equipped shop. However, it Contains enough dolall and basic Information to make it useful fo the owner who desires to perform his own basic maintenance and repair work. A basic knowledge ‘of mechanics, the proper use of fools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the ‘owner has insufficient experience or doubts his abilty 10 Jo the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures belore starting work, and then do the work carefully in a clean area. Whenever special fools or equipment are specified, do not use makeshift {ools or equipment. Precision measurements can only be made it the proper instruments are useo, and the use of substitute tools may adversely affect safe ‘operation. For the duration of the warranty period, we rec- ‘ommend ihat all repairs and scheduled maintenance be performed in accordance with this service manual. Any ‘owner maintenance or repair procedure not performed in ‘accordance with this manual may void the warranty. To get the fongest life out of your vehicle: ‘© Follow tne Periodic Maintenance Chart in the Service Manual (© Bo alert for problems and non-scheduled maintanance. © Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, and testers that are Necessary when servicing Kawasaki motorcycles are Introduced by the Special Tool Catalog or Manual Genuine parts provided as spare parts ae listed jn the Paris Catalog, ‘8 Follow the procedures in this manual carefully, Don't take shortouts, © Remember to Keep complete records of maintenance and repair with dates and any naw parts installed. How to Use This Manual Tn preparing this manual, we divided the product into its major systems. These systems became the manual's chapters. All information for a particular system trom ‘adjustment through disassembly and inspection is located ina single chapter, The Quick Reference Guide shows you all of the product's system and assists in locating their chapters. Each chapter in turn has lis own comprehensive Table of Contents. ‘The Periodic Maintenance Chart Is located in the General Information chapter. The chart gives a time schedule for required maintenance operations. IV you want spark plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, use the Quick Reterence Guide to locate the Electrical System chapter. Then, use the Table of Contents on the frst page of the chapter to find the Spark Plug section. Whenever you see thesa WARNING and CAUTION ‘symbols, heed their instructions! Always follow sate operating and maintenance practices. AWARNING This warning symbol Identities special instruc- tions or procedures which, if not correctly tol lowed, could result in personal injury, or loss of lite CAUTION This caution symbol identifies special instruc- tions of procedures which, if not strictly ob- served, could result in damage to or destruction ct equim This manual contains four more symbols (in adalton to WARNING and CAUTION) which will help you distinguish liferant types of information. NOTE This note symbol indicates points of particular in- terest for mare afficient and convenient operation. ® Indicates @ procedural step or work to be done, Indicates a procedural sub-step or how to do the work of the procedural step It follows. I! also precedes the text of a NOTE + Indleates a conditional step or what action to take basad fon the results ofthe test or inspectian in the procedural stop or sub-step i fallows, In most chapters an exploded view jllustrtion of the system components follows the Table of Contents. In these illustrations you will find the Instructions inlcating ushich parts require specified tightening torque, ol, grease or a locking agent during assemblyGENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing, sri ances Model Identification eomee-pesieonsan linn a akon General Specifications. 18 Periodic Maintenance Ghat... saat 1-12 Technical Information ~ K-TRIC (Kawasaki Thretie Responsive ignition Contrl). mats Technical Information - KAWASAKI LOW EXHAUST EMISSION for VNiSODHIGTA (CA... 418 Torque and Locking Agent ran ‘Special Tools and Sealant. ‘ 4-25 Gable, Wire. and Hose Routing 1321-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, ‘ead the precautions given below. To faciltate actual operations, notes, ilusrations, photographs, cautions, and detailed {scriptions have been included in each chapter wherever necessary. This section explains the tems that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts. Especially note the following: (1) Dirt Before removal and disassembly, clean the motorcycle. Any dit entering the engine will shorten the fife of the motorcycle. For the same reason, before instaling a new part, clean off any dust or metal flings. (2), Battery Ground Disconnect the ground (-) wie from the battery betore performing any disassembly operations on the motoreyete This prevents the engine from accidentally turning over while work is being carried out, sparks from being generated while disconnecting the wites fom electrical parts, as well as damage to the electrical parts themselves. For Feinstallation, frst connect the positive wire to the posive (+) terminal ofthe battery (@)_Instalation, Assembly Generally, instalation or assembly is the reverse of removal or disassembly, However, i instalation or assembly sequence Is given in this Service Manual, folow it. Note parts locations and cable, wire, and hose routing during removal or disassembly so they can be installed or assembled in the same way. It i preferable to mark and record the locations and routing whenever possible. (4) Tightening Sequence When installing bolts, quls. or screws for which a tightening sequence is given in this Service Manusl, make sure to foliow the sequence. When instaling a part with several bots, nuts. or serews, start them all in their holes and tighten them to a snug fit, thus ensuring that the part has been installed in ts proper location, Then, tighten them to the specified torque in the tightening sequence and method indicated. I tightening sequence instructions are not given, tighten them evenly ina cross pattern. Conversely, to remove a par, first loosen all the bolts, nuts, or screws that are retaining the part a 1/4-tur before removing them, (5) Torque When torque values are given in this Service Manual, use them. Either 100 litle or too much torque may lead to serious damage. Use a good quali, reliable torque virench. (6) Force Common sense should dictate how much force is necessary n assembly and disassembly. Ifa part seems especially diticut 10 remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using @ wooden or plastic-taced mallet. Use an impact driver for serews (particulary for the removing screws held by non-permanent locking agent) in order to avoid damaging the screw heads, (7) Edges Watch for sharp edges, as they could cause injury through careless handling, especilly during major engine disassembly and assembly. Use a clean piece of thick cleth when liting the engine or turning it over. (8) High-Fiash Point Solvent Ahigh-fiash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North ‘America is standard solvent (generic name). Always folw manulacturer and container directions regarding the use of any solvent (9) Gasket: O-Ring Replace a gasket or an O-ring with @ new part when disassembling. Remove any foreign matter fiom the mating surface ofthe gasket or O-ring to ensure a perfactly smocth surface to prevent al or compression leaks (10) Liquid Gasket, Locking Agent ‘Clean and prepare surfaces whore liquid gasket or non-permanent locking agent willbe used. Apply them sparingly Excessive amount may block engine oll passages and cause serious damage. (11) Press When using a press or driver to install a part such as a wheel beanng, apply a small amount of ol to the area where the twa parts come in contact to ensure a smoot fit (12) Ball Bearing and Needle Bearing ‘Do not remove @ ball bearing or a needle bearing unless i Is absolutely necessary. Replace any ball or needle bearings that were removed with new ones. Install bearings with the manufacturer and size marks facing out, apolying Pressure evenly with a suitable diver. Apply force only to the end ofthe race that contacts the press fit portion, and press it evenly over the base component. (13) OF Seal and Grease Seal Replace any oll of grease seals that were removed with new ones, as removal generally damages seals. Oil or grease seals should be pressed into place using a suitable diver, applying a force uniformly to the end of seal until the face of the seal is even withthe end of the hole, unless instructed otherwise. When pressing in an oll or grease seal which has manufacturer's marks, press it in with the marks facing outGENERAL INFORMATION 1-3 Before Servicing (14) Clip, Retaining Ring, and Cotter Pin ‘When insalng circips and retaining rings, take care to compress or expand them enly enough to lnsal them and ‘no more. install the ciccip with ts chamfered side facing load side as well Replace any ciclips, retaining rings, and cotter pins that were removed with new ones, a remeval weakens and deforms them. Ifold ones are reused, they could become detached while he motorcycle is driven, leading fo a major problem. (15) Lubrication Engine wear is generaly at its maximum while the engine is warming up and befor all he sliding surfaces have an adequate lubricative fim, During assembly, make sure to apply ol to any sliding sutace or bearing that has been cleaned. Old grease or dity oll could have lost its lubrleative quality and may contain foreign particles that act as abrasives; therelore, make sure to wipe it off and apply fresh grease oF ol. Some ols and greases in particular should be used only in certain applications and may be harmful fused in an application for which they are not intended. (16) Direcfon of Engine Rctation To rotate the crankshaft manually, make sure to do so In the direction of postive rotation. Positive rotation counterclockwise as viewed from the let side ofthe engine, To carryout proper adjustment, is furthermore necessary to rotate the engine in ihe erection of postive rotation es wel (17) Replacement Parts ‘When there is a replacement instruction, replace these parts with new ones ever time they are removed Replacement parts wil be damaged of lose thei orginal function ance they are removed. Therelore, always replace these parts with new ones every time they are renoved. Although the previously mantioned gasket, O-ring ball bearing, needle bearing, grease seal ol seal, crip, and cotter pin have not been so designated n thar respective tex they are replacement parts (18) Electrical Wires Al the electrical wires are either one-color oF two-color. A two-color wite is identified first by the primary color and then the stnpe color. For example, a yolow wire with thin red stripes is roterred to as a "yellowited wire: & would be a “redielion” wie it the colors were reversed. Unless instructed otherwise, electrical wires must be connected to wires of the same colo. ‘Two-Color Electrical jor indented on the fire | el Wire (cross~sect ion) Red Wire Strands Ye||ow/Red —/rk— (19) Inspection When parts have been cisassembled, visually Inspect these parts for the following conditions or other damage, It there is any doubt as to the condition of them, replace them with new ones. ‘Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure (20) Speciications ‘Specification terms are defined as follows: “Standards” show dimensions or performances which brand-new parts or systems have “Service Limits" indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts.1-4 GENERAL INFORMATION Model Identification VN1500-G1 (US and Canada) Left Side View: VN1500-G1 (US and Canada) Right Side View:GENERAL INFORMATION 1-5 Model Identification ‘VIN1500-G1 (Australia) Left Side View: VN1500-Gi (Australia) Right Side View:1-6 GENERAL INFORMATION Model Identification \VN1500-G1 (Other than US, Canada, and Australia) Left Side View: ‘VN1500-G1 (Other than US, Canada, and Australia) Right Side View:GENERAL INFORMATION 1-7 Model Identification \VN1500-H1 (Germany, Austria, and Switzerland) Left Side View: VN1500-H1 (Germany, Austria, and Switzerland) Right Side View:1-8 GENERAL INFORMATION General Specifications Teme VNT500-GTGIAIGE VNI500-AIHA Dimensions (Overall lenath 2510 mm - (Overall width 1960 mm - Overall height 41480 mm (max) ~ 1435 mm (rin), 11480 mm (max) ~ 1435 mm (min), (AS) (ML) (US) 140 mm (FG) 1405 mm (max) ~ 1360 mm (min) Wheelbase 1665 mm. Road clearance 435 mm ‘Seat height 720 mm Dry mass 331 kg, (CA) 329.5kg, (US) 929 kg Curb mass: Front 182 kg, (US) 150 kg Rear 197 kg, (CA) 1975 kg Fuel tank capacity 16 Performance: Minimum turning radius | 3.2m = Engine: ‘Type 4-stroke, SOHC, V2-cylinder Cooling system Liquic-cooled Bore and stroke 402 x 90 mm Displacement 4470 mL Compression ratio asst Maximum horsepower Maximum torque Carburetion system Starting systern Ignition aystom Timing advance Fanition timing Spark plugs Cylinder numbering method Firing order Valve timing: Inlet Open Close Duration Open Close Duration Lubrication system Engine oi Grade Viscosity Exhaust Capacity 47 KW (64 PS) @4700 ofmin (rpm) (us)= 112 Nim (14.4 kgm, 82.6 fib) 123000 r/min (rpm) (us) (Carburetor, Keinin CVK40 x 1 Electric starter Battery and col (trancistorized) Electronically advanced (¢igital) From 0° BTDC @800 r/min (rpm), (CA) From 0” BTDC @1000 v/min (rpm) NGK DPRSEA-9 or ND X18EPR-U Front to Rear, 12 12 ie’ BTDC 62° ABDC. 260° 62° BEDS 22" TOG oer Forced lubrication (wat sump) SE, SF or SG class SAET0W-40, 10W-50, 2OW-40, oF 2OW-50 3.5 L (when engine is completely dry) 47 kW (64 PS) 4700 r/min (rpm) HH Modet: (ST) 82.0 KW (43.5 PS) 23400 r/min (rpm) 112 Nem (11.4 kgm, 82.5 fed) {3000 r/min (rom) HY Modet: (ST) 86 Nim (10 kgm, 723 ttlb) 12000 rimin (rpm) From 9° BTOC @ 1000 rimin (rem)GENERAL INFORMATION 1-9 General Specifications ems VNTS00-GTIGIAIG2 VNIS00-AVH2 Drive Train: Primary reduction system: Type Gear Reduction ratio 1.517 (85/56) Clutch type Wet muti aise =r Transmission: Tre S-speed, constant mesh, return shift | —— Gear ratios: 1st 2.500 (40/16) --- 2nd 1.580 (85/22) 3rd 1.192 (31/26) bon 4th 0.965 (28/29) mae sth 0.781 (25/32) toe Final drive system: Tyre Shaft Reduction ratio 2.619 (1521 x 33/9) Overall érive ratio 3.105 @Top gear --- Final gear case oil: ‘Tyre API GL-S Hypoid gear oll Reg ‘SAE90 (above 5°C) ‘SAEBO (below 5°C) Capacity 200 mL — Fram Type ‘Tubular, double cradle way Caster (rake angle) 32 es Tail 189 mm — Front tre ‘wre Tubeless aoe Size 150780-18 71H sm Rear tre: Type Tubeless ae Size 150/80-16 71H as Front suspension: Type Telescopic fork ss Wheel travel | 150 mm ese Rear suspension: Type ‘Swingarm hsm Wheel travel | 100 mm var Brake Type: Front Dual discs insite Roar Single disc toe Electrical Equipment: Battery 12V 14 Ah “= Headlight: Type Semi-sealed beam ee Bulb 12 V 60/55 W (quartz-halogen) --- Tallbrake light 125/21 Wx 2, 12V521W x2 (Us) (CN) 12 8/27 W x 2 Alternator: Tee Thwee-phase AC Scat Rated output | 424 x 14 V @000 r/min (rpm) mn ‘Specifications are subject to change without notice, and may not apply to every country, AAS = Australian Model FG : German Modet US: USA, Model CA: Califomia Mode! ML: Malaysian Model CN : Canadian Model ‘ST: Swiss Model1-10 GENERAL INFORMATION General Specifications Tes WNI50O-G2A- Dimensions: Overall length 2510 mm Overall win 960 mm Overall height +430 mm Wheetba 1685 mm Road clearance 135 mm Seat height 720 mm Dry mass 332 ka, (CA) 992.5 kg ‘Curb mass: Front 153 kg Rear 197 kg, (CA) 197.5 kg Ful tank capacity wet Performance: Minimum tuning radius 32m Engin Tyee ‘stroke, SOHC, V2-cylinder Cooling system Liguid-cocted Bore and stroke 102 x 90 rom Diepiacement 1470 me ‘Compression ratio 85:1 Maximum horsepower (us)- Maximum torque (us)- Carbureton system Carburetor, Kein CVKEO » 1 Starting system Electric starter Ignition system Battory and col (vansstoized) Timing advance Electronically advanced (digital) Jgnition ining From 0” BTDC @800 r/min (rpm), (CA) From 0° BTOC @1000 rimin (mm) Spark plugs NGK DPRSEA.9 or NO X18EPR-US ylinder numbering method Fring order Valve timing: Iniot pen 1° BTDC ose 62) AB0C Duration 280" Exhaust Open 62° Banc Close 22 TDC Duration 260" Lubrication system Forced lubrication (wet sump) Engine ol Grade API SE, SF, or SG elas, or API SH or SJ with JASO MA Viscosity SAE10W-40, 10W-50, Capacity 20-40, or 200-50 3.5L when engine is completly dry)GENERAL INFORMATION 1-11 General Specifications ems, VNIS00-G2A ~ Drive Train Primary reduction system: Type Goar Reduction ratio 1.517 (86168) (Clutch type ‘Wet muti disc Transmission: Tyre S.speed, constant mesh, return shift Gear ratios: 1st 2.500 (40/18) 2nd 1.590 (95/22) ard 1.192 (31/26) 4th 0.985 (28/29) ih 0.781 (25/32) Final drive systam: Typo Shaft Reduction ratio 2819 (15121 x S89) Overall drive ratio 3.105 @Top gear Final gear cass oii Type API GL-5 Hypoid gear oil ‘SAEGO (above 5°C) SABEO (below 5°C) 200 mL. Tubular, double eradie Caster (rake angle) 32" Trail 189 mm Front tire: Tyre Tubeless Size 150/80-16 71H Rear tire: ype Tubeless. si 160/80818 71H Front suspension: Type Telescopic fork, Wheel travel 480 mm Rear suspension: Type Swingarm Wheel travel 100 mm Broke Type: Front Dual dises Rear Single disc Electrical Equipment: Battery 12V 14h Headlight: Wee Somi-sealed beam Bulb 12.V 60/65 W (quartz-halogen) Tallforake ight 12V 5/21 W x 2, Alternator: pe Three-phase AC Rated output 424 x 14 V 8000 rimin (rpm) ‘Specifications are subject fo change without notice, and may not apply to every country ‘CA: Califomia Mode!1-12 GENERAL INFORMATION Periodic Maintenance Chart “The scheduled maintenance must be done in accordance with this chart to keep the motoreycis in good running condition, The initial maintenance is vitally important and must not be neglected. FREGUENGY | Whichever] 1 000 wm ~ ODOWETER READING comes, {600 mie) first 6 000 km _ (4 000 mie) 1 12 000 (7500 rile) 18.000 %m (12.000 mile) 724.000 kin (1 000 mie) 30,000 Kt {20 000 mie) 36 000 kn (24.000 mie) ‘OPERATION Bey Spark plug = clean and gap alel Tel ‘ir sueton valve - check ¢ e e! ‘Ar cleaner element -cleant @ s a) Thrate gp play - check f e idle speed - aduat ole a] Evaporaive emission control system (GA) check 7 ele | Fuel hoses, connections - check T ele Te] Engine ol - change # snonts|elele ry ifr = replace sry e] Fadlafor hoses, connections ~ check T ° Coolant = change Zyeare = Final gear case oi Tevel - check T o| Tel Tel Final gear case oll change . 1 e| Propel shat jin = lubnicale 2 | Clutch Wud level = check F month Te lelelelelele Clutch Rud = change 2 years 2 Giutch master cyinder cup and dust seal replace | 4 yeare Clutch slave cyinder piston seal - replace a years Brake hoses, connections - check f Te] Brake tring oF pad wear - chock FF ra Brake Tid level - check F month [9 ra Brake Nad change 2 years Brake master cyindar cup and Gust seal replace | years Caliper piston seal and Gust seal - replace a years Brake fight swich = check T elelelelelele| Steering = check f elelelelelele| Steering stem bearing = ubricate Dyess . Front fork ol- change: Z years Fear shock absorber ol Teak check T el tel Te] Front fork of feak - check F © el te] Tire wear check 7 2 elelete| Swingarm pivot - lubricate A el ‘General ubricaion- perform . altel [[lut bo, and fastener nighiness~ check F elle bel ie # : Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed, or frequent starting / stopping, * : For higher odometer readings, repeat at the frequency interval established here, | Replace, add, adjust, clean, or torque if necessary. (CA): California vehicle onlyGENERAL INFORMATION 1-13 Technical Information — K-TRIC (Kawasaki Throttle Responsive Ignition Control) Iva conventional digital ignition system, the IC igniter changes ignition timing according to engine rpm only, However, K-TRIC controls the ignition timing not only aécording to engine rpm, but also according to throttle opening. A throttle sensor [A] is electrically linked to the IC igriter that varies the ignition timing for greater combustion afficioncy: ‘900d acceleration capability and fuel consumption, The throttle sensor is located on the carburetor thatte shatt end, and senses throtle opening, This sensor is a rotating type variable resister that changes voltage according to thrattle opening. The IC igniter senses this voltage change and determines ignition timing not enly according to engine rpm, but also according to throttle opening. ‘Ground Terminal [4] Output Terminal (3) Voltage Terminal {C) The IC igniter digitally memorizes three dimensional igrition timing map, which is determined by test beforehand lor good performance, and when the engine is running, the Igniter provides best ignition timing according to the engine rpm and the throttle opening from low speed to 1/4 0F 1/9 of full-opened throttle, ating (A) Fullopened Throttle (8) 4187 1 nog sow B®onninn @ Adding to the conventional functions, such as dwell control, antitheft land over rev protection, the igniter has a fail safe function. In case of throtle sensor trouble like wiring short or open, ordinary igntion timing does not wark well, and in the worst caso the engine could damage, ‘The igniter senses this trouble and locks ignition timing inte the ignition timing at full throtie open position to prevent engine damage,1-14 GENERAL INFORMATION Technical Information - KAWASAKI LOW EXHAUST EMISSION for VN1500H/G1A (CA) ‘The secondary air injection system [A] helps Kawasaki keep motorcycle exhaust gases below the established emission regulation limits, This system draws air into the exhaust ports, dilutes and burns harmful ingredients in the exhaust gas Jn order to reduce them. This allows the carburetor to be set at a reasonable setting position without adjusting it much leaner, so engine performance and actual riding performance are not spoiled. ‘But, under the trend that the emission regulation becomes more severe, Kawasaki has adopted two catalytic converters inthe premutler chamber (8) in addition to the secondary air injection system. As a result, we can reduce the exhaust {gas emission below the current standards without hurting the output performance and the actual riding feeling at all. The harmful ingredients in the exhaust gas are reduced considerably under running performance ot emission regulation. AS ‘actual examples, carbon monoxide (CO) is reduced about 50%, hydrocarbons (HC) about 40%, nitrogen oxides (NOx) about 20 ~ 30%. Exhaust Gas after Purification Exhaust Gae ater Muar AirFue| Rato ater Cataiyte Convertor Kawasaki Low Exhaust Emission SystemGENERAL INFORMATION 1-15 Technical Information - KAWASAKI LOW EXHAUST EMISSION for VN1S00H/G1A (CA) 1. Exhaust Purification System ‘The bummed gas, which goes out from the combustion chamber, is injected with secondary air (adding necessary oxygen), ‘and is cleaned up while passing through two smal catalytic converters and then goes out to the atmosphere. 1) Secondary Air Injection System In order to oxidize CO, and HC by the catalysts, the proper amount of oxygen is necessary. As criginal combustion {gas has litie remaining oxygen, air is injected in the exhaust ports by the secondary air injection system in order to ‘Supply enough oxygen to the combustion gas to purify CO, and HC to a certain extent as well as prepare for activation Of the catalysts, As the carburetor is set at richer level [A], and airtuel mixture (A/F) is about 11 ~ 14, NOx is at lower level from the beginning as shown in the figure. And, A/F becomes lean (about 13,5 ~ 15) after the combustion ‘chambers owing to secondary air injection and combustion. Exhaust Gas before Purification ® ete 5 Nox 2 co & on ea eT we AF 2) Catalytic Converters [A] ‘A converter is made of a punched metal pipe of stainless steel [C], and its surface is covered with alumina [D] upon which platinum and rhodium [E] as catalysts are applied. Generally, the temperature of the exhaust gas must ‘be higher than the activation temperature, so the converters are installed in the premuffler chamber [8] where the temperature of exhaust gas is stil high. And, the converters will be activated even under low load conditions, ‘After the exhaust gas is diluted with the secondary air injection system, the catalytic converters work efficiently to reduce CO, HC. and NOx. Accordingly, we can keep it within regulation, Catalytic Converter1-16 GENERAL INFORMATION ‘Technical Information — KAWASAKI LOW EXHAUST EMISSION for VN1S00H/G1A (CA) 2, Maintenance ‘Special maintenance is not necessary except for the inspection of the air suction valve (which has been described in this Service Manual). 1) Replacement of Premutier Chamber Its impossible to replace only the catalytic converters because they are welded in the chamber. So, inthe following ‘case, the replacement of the premuftler chamber is also necessary. {In case of using not-appointed fuel (leaded gasoline, etc.): Purlication efficiency decreases in a very short period because lead poisons the catalytic converters. Although the ‘appearance of the converter and engine performance are not effected, the replacement of the premuler charnber is necessary to secure the purification efficiency of exhaust 9 In case catalytic converters melt down by overheating Especially in the case that a lot of unburned gasoline flows into the catalytic converters under the extreme running condition far beyond common sense, there is a possibilty that the catalysts overreact and that catalytic converters overheat severely. If they molt down, it causes poor engine performance, ceterioration of emission noise level and purification efficiency. So, the premutler chamber must be replaced, 2) Durability Ithas the same durability as a conventional premuitiar chamber. 3) Disposal to Waste ‘As any harmiul toxic substance Is not used especialy it can be disposed as usual industrial wastes. The body of the chamber is made of steel. The catalytic converter Is made of stainiess steel which has alumina on its surface, land the main ingredients of catalysts are platinum and rhodium,GENERAL INFORMATION 1-17 Technical Information - KAWASAKI LOW EXHAUST EMISSION for VN1S500H/G1A (CA) 3. Handling Precautions 1) Use only unleaded gasoline Usage of leaded gasoline is prohibited completely. Only fuel and additives which are specified in the Owner's Manuel can be used. 2) Use specified engine oil which is described in the Owner's Manual In case of some ingredients which give bad etfects 10 the catalysts (such as phosphorus “P", ead °Pb’, sullur included, the punfication efficiency decreases. 8) Coasting (such es cranking while going down a slope) is prohibited with the ignition system OFF The engine running without igniting causes a great flow of unburned gasoline and the decreasing of purtication ficiency, and melting down of catalysts at the activation temperature or higher. bare (Do not caast the motoreycle with the jgrition switch [Al nor tha engine stop switch [8] OFF Do not run the engine nor coast the motorcycle under the misfire which occurs by delects such as a bad connection with the spark plug at the secondary wiring [0] of the ignition coll {C) Do not run the engine nor coast the motorcycle under the condition that the primary wing [E] ofthe fgntion coll does not connect completely (misfire) JC Igniter (F] lanition System Do not run the engine even ifanly one cylinder has a misfire or has unstable running. in this case, request the nearest ssorvice facility to correct i, If you have no choice but running by yoursel, keep engine rpm as low as possible and try to finish running at the shortest period. When the battery is dead, do not push-start. Connect another ful-charged hattery with jumper cables, and start he engine.1-18 GENERAL INFORMATION Technical information — KAWASAKI LOW EXHAUST EMISSION for VN1500H/G1A (CA) 4, Additional information 1} Secondary Air Injection System ‘The mechanism is simple and power loss s minimum because the system uses the vacuum pressure created by exhaust pulses. The secondary injection air helps the fuer mixture burn more completly (Primary air means air which flows through the inet pipe). As the exhaust valve opens, and the burned fuel passes the exhaust vale, a stream of Iresh ai is Introduced through the air suction val. This fresh air burns the unbumed gas and converts the carton monoxide (CO) and hydrocarbens (HC) into harmigss carton dioxide (CC) and water (H:0), 00+ 1/2 Or — O0z HE +0: — 002+ H:0 The secondary air injecton system consiss of a vacuum switch valve, and two air suction valves. Without using an ait pump, the air suction valve can draw lresh air ino the exhaust passage near the exhaust valves by vacuum that exhaust pulees generate Air Suction Valves ‘The ar suction valves is check valve which allows fresh ai to flow only Hom the air cleaner via ai hoses into the exhaust ort and prevents return lov. Remove and inspect tne air suction valves periodical (see Engine Top End chapter inthis Service Manual). Also, remove and inspect the air suction valves whenever the idle speed Is Unstable, engine power is {realy reduced, or there are abnormal engine noises. Vacuum Switch Valve ‘Although the vacuum switch valve usually permits secondary air tow, closes when a high vacuum (low pressure) is ‘developed atthe inlet pipe during engine braking. This is to shutoff secondary ait flow and prevent explosions in the ‘exhaust ports which might be caused by extra unburned fue! in the exhaust during deceleration, These explosions, or backfiring inthe exhaust system could damage the air suction valves. Regular inspection of the vacuum switch valve is not needed, if backring occurs frequently in the exhaust system during engine braking ori there are abnormal engine noises, check the vacuum swiich valves described in the text (see Engine ‘Top End chapter inthis Service Manual) ‘Secondary Alr Injection System @ 1 A Sueton Valves 4 Ai Cleaner Duct 7. et Pipe 2 Vacuum Switch Valve 5 inlet Vave 8, Carburetor 3. alr Hoses: © Exnaust VaveGENERAL INFORMATION 1-19 Technical Information - KAWASAKI LOW EXHAUST EMISSION for VN1500H/G1A (CA) 2) Operation of Thrae-way Catalytic Converter The three-way catalysts are used for the catalytic converters. The converters can clean up carbon monoxide (CO), hydrocarbons (HC), and nitrogen oxides (NOx) at the same time. CO and HC are oxidized (0 is added) by platinum (Pt) and convarted to harmless carton dioxide gas (CO2) and water (Ht 20), and then the exhaust gas Is cleaned up: CO+ 172.02 — Coz HO +O: — CO: +H:0 NOx is reduced (0 is removed) by rhodium (Rh) and converted to harmless nitrogen (Na) and oxygen (Os), andthe exhaust (gas Is cleaned up, NOx — Ne+ Oe 8) Property of Catalyst Most catalysts are powders of metal or of metalic compounds, and they incrsese the rate of a chemical reaction, Catalysts ‘are supposed to act in some way to loosen the bonds af the reacting substances. In cther words, they lower the energy ‘of activation, thus allowing the reaction to proceed more rapidly. To activate catalysts, the temperature of the exhaust ‘948 must be higher than the activation temperature that is 220° ~ 230°C for new catalysts, and 270° ~ 280 °C for used catalysts (after 10000 ~ 20000 km ride), Energy of Activation (bons) Calas loners ‘the energy Enecgy —> Galore Value Reactant Tine ‘The catalyst itself undergoes no permanent chemical change, or can be recovered when the chemical reaction is completed. So, the premultier chamber with built-in catalyst has the same durabily &s the conventional premuftier chamber. The mechanism of catalytic action is supposed to be a surface phenomenon in which reactants are adsorbed onto a small portion of the surface of the catalyst, The catalytic converter is made of siainless steel and the surface is applied by alumina (aluminum oxide Ales). The alumina adheres to the stainless stee) wall and the catalyst adheres to the alumina very well. The alumina suriace is not uniform and thers are corners, edges, dislocations, and grain boundaries. Catalyst 's applied on the alumina and this makes the catalyst surface rough. The rougher the surface is, the more actively the eatalyst adsorbs the reactants, If various impurities lke lead are adsorbed, they black the small portion of the catalyst surface, preventing adsorption of (CO, HC, and NOx. This is the reason why leaded luel poisons the catalyst without any break on the surface or generation of heat Catalysts are generally afficiont in small quantiias. A catalyst can catalyze the reaction of ssveral thousand to milion timas its weight In reactants. The three-way catalyst is a blend of platinum (Pt) and rhodium (Fh) which are expensive, But a converter uses only about 0.1 gram of Pt and 0.1 gram of Fh.1-20 GENERAL INFORMATION Technical Information — KAWASAKI LOW EXHAUST EMISSION for VN1SOOH/G1A (CA) Catalyst (Rt, Rh) ‘Staliess Steel (suppor) 4) Recognition of Premier Chamber ‘The premuiler chamber with built-in catalyst can be distinguished, using the following marks. Weds Premier Ohanber Promalier Chamber wh Catalst "86 VNTSOO-ET = RHI Mas "98 VNTBOO-FT HTT = "98 VNI600-Gt 198 YNI500-Gt = Leto BE VNISGO-HT, GS RATES =Torque and Locking Agent The following tables list the tightening torque for the ‘major fasteners requiring use of a non-permanent locking agent or liquid gasket. Lottore used jn the *Flemarks” column mea: G: Apply grease to the threads. EO: Apoly engine cil to the threads and the seating GENERAL INFORMATION 1-21 The table below, relating tightening torque to thread diameter, ists the basic torque for the bots and nuts. Use this table for only the bolts and nuts which do not requite a specific torque value, All of the values are for use with dry solvent-cleaned threads, Basic Torque for General Fasteners aoe Trends os L: Apply @ non-permanent locking agent to the sia. (mm) [Wm kam ihe Lt aera hacia 5 34~49 [035~050 | 30~43inib O: Apply oll to the threads and seating surface. $ Bie TEs) ORT AER | ER 'S: Tighten the fasteners following the specified se- * ae 1418 | 100~ 134) em to | ass | 2ense | teo~2s 5: Space sealant we | asset | ascaz | 's0—es Se eects prov tearing will geste! leat etace w Ropaconer pare is | tents |stsz9ea| omits te | tes 208 | 170~280| r2s~1e8 20 | asses | 2533 | ies 240 Fastener | rear al Sa i ae Bote 2 12 | tobe Ral tap Pale Seovs os | cos | thw fr cltner Due Hole Bots 23 ‘>| arimb Ai Clara Base Bate te io | ome Ai Geter Base Serevs 22 | aa | Same {st Alene’ Det Tapping Screws 22 | om | tomb au Cesee on Savi ts | oom | ame Sige tk St ss | oom | etme ada Hes Cp Sree zs | oa | cent Carla At lode Bot is | ce | comm Flr fan Sh if 12 ‘3 Gar Torpetre Sieh ze | ceo | cme | ss Wat Purp npr Bot 3 vo | ame | oth Wit Pur Cover Soe 38 to | ome Mat Ppe Bots oa io | arb Feiaor rah Sot ma | ois | cont Engine Top Ene Sor Pose rm 1 130 Sherk Fes bat iB (2 | smb Ar Suen Valve Cover Bos mm | of | some Chain Tersone orig Bots 2 10 «| ame | 8 ats broone ne 2 2 5 s Grin Tense Lact & | co | am | 8 Frat Pe is | os | jamb Catal prtiet Ble "e ts Be L Ox owe Fane Ble 33 10 | orm Pc Sha 2 ‘a0 | Fear case Nas emm | 78 30 | cos im | & 2 ra 3 rocker Case Bots mm | aa | co | mm | 8 Ojince ees Nas os 28 van 5 Fela Case Cove Bohs | cae: | ene || Camano chan Gude Ses os wo | ome |1-22 GENERAL INFORMATION Torque and Locking Agent Torque Fastener tar oo fe Remarks Exhaust Pipe Cover Clamp Screws cr 70 BT inte Cluteh: Clutch Lever Pivot Bolt 10 o10 Simi Clutch Lever Pivot Bolt Locknut 59 0.80 52 into ‘Clutch Reservoir Cap Screws 15 05 4 nib Clutch Stave Cylinder Bleed Valve 78 0.80 59 inib Clutch Slave Cylinder Bolts - - - L ‘Olutch Hose Banjo Bolts 25 25 180) lutch Master Cylinder Clamp Bolts 28 10 87 intb 8 Starter Lockout Switch Screws. 12 oe 10 into Puch Rod Guide Bolts 28 10 87 intb L Clutch Cover Bots 28 10 57 ini ‘Clutch Cover Damper Bolts (outside) 28 10 87 int L ‘Clutch Cover Damper Bolts (inside) 28 10 87 intb EO tip) Glutch Cover Damper Serows, 49 050 43 inib L Clutch Hub Nut 145 18.0 110 50 Engine Lubrication System: il Filler Plug 18 06 43 nib (Oil Screen Plug 20 20 143, Engine Oil Drain Plug 20 20 45 (i Filter (Cartridge type) 18 18 130 RO Ol Filter Bott 25 25 180 SS il Pressure Relief Valve 18 15 11.0 L Ol Pressure Switch Terminal Bolt 15 018 13 ino i Pressure Switch 15 15 140 ss Gil Pump Mounting Bolts 28 1.0 87 int i) Hose Banjo Bolts a8 10 87 ini (il Hose Flange Bolt outside) 38 10 a7 ino il Pipe Hoder Botts (inside) 88 0.90 7B inib L i Pipe Clamp Bolts (iniside) 38 10 87 inib if Crankcase Gil Nozzle 34 0.38 30 init Engine Removai/instellation: Downtube Botts 44 4s 33 Engine Mounting Bots and Nuts 44 45 33 Engine Mounting Bracket Bolts 23 23 165 Engine Ground Terminal Bott 78 9.80 69 ind CrankshatyTransmission: CCrankease Batts 10mm 39 49 23 s mm 21 24 150 s 6mm os 10 87 ini s ‘Crankease Bearing Retainer Bolts 98 10 87 ini L Camshatt Chain Guide Bolts oa 10 87 ini L Crankcase Oil Nozzles 34 0.38 30 imib ‘Connecting Rod Big End Nuts 59 60 43 FO (ll Pressure Heliot Valve 18 15 110 L (ll Hose Banjo Bolts 98 10 87 ini Primary Gear Bolt 145 150 110 FO ‘Water Pump Chain Guide Spring Hook Bolt 29 0.30 28 ini Water Pump Chain Guide Bolt 78 0.80 69 ini Idle Shaft Holder Botts 738 0.80 89 ini Oj Pressure Switch Terminal Bolt 15 015 13 int i Preseure Switch 18 15 11.0 ss Ol Pipe Clamp Bolts (inside) 28 10 a7 ini L Lett Balancer Gear Bot 85 87 63 FO Starter Ciutch Bolt 85 87 83 Es} Starter Clutch Coupling Bolts 18 18 11.0 it Gear Set Lever Bolt 38 1.0 87 initGENERAL INFORMATION 1-23 Torque and Locking Agent Torque. "astener 7m ‘en ae Romarks ‘Shift Shalt Return Spring Pin (Son) 20 28 145 Tc Front Shift Pedal Clamp Bolts 2 42 104 ini ear Shift Peoal Clamp Bolt 2 12 108 into Shift Lover Clamp Bolts oa 10 87 ini Shift Rod Locknuts oa 1.0 87 inib | (Rear Lh) Shift Drum Bearing Holder Bolts 28 10 87 ini L Shift Drum Cam Screw 5 - - L Damper Cam Nut (Front Gear) 226 23.0 168 | £0 (threads) Push Flod Guide Bolts 28 10 87 nib L Wheels/Tires: Front Axle Glamp Bolts 34 35 25 5 Front Axle Nut 110 110 a0 s Rear Axio Nut 110 11.9 80 Rear Tire Air Valve Nuts 18 ots 12 nib R Final Orive: (ll Pipe Banjo Bolts (Front Goat) 2 412 104 ini Oil Nozzte (Front Gear) 29 0.30 28 int Oi Plug (Front Gear) 18 18 13.0 Neutral Switch 18 18 1.0 Front Gear Case Bolts: @mm 88 10 B7 ini amm 25 25 180 Damper Cam Nut (Front Gear) 226 230 168 | EO (threads) Drive Gear Nut (Front Gear) 265 27.0 195 £0, St Driven Gear Assy Mounting Bolts 25 25 180 Driven Gear Bott (Front Gear) 195 140 100 £0, $1 Bearing Retainer Botts (Front Gear) Bg 0.90 78 ini Final Gear Case Drain Plug 8a 0.90 7B ind Final Gear Case Mounting Nuts 34 a5 25 Final Gear Case Studs - - a L Final Gear Case Cover Bolts: 8mm 23. 23 165 s0mm 34. as 25 Pinion Gear Nut (Final Geer) 420 120 87 St.0 Pinion Bearing Retainer (Final Gear) 245; 25.0 180 Uh Retainer Stop Screw 16 16 15 L Brakes: Caliper Bleed Valves 78 0.80 69 int Brake Hose Banjo Bolts 25 25 180 Brake Lever Pivot Bolt 10 10 gintb Brake Lever Pivot Bott Locknut 59 0.60 52 inib Front Brake Reservoir Cap Screws 15 05 13 inib Front Brake Light Switch Screws 12 012 30 ini Front Master Cylinder Clamp Bolts a8 4.0 87 ino s Front Caliper Mounting Bats 34 3s 2 Rear Caliger Mounting Bolts 2 33 24 (Gaikia Model) 23 23 165 Rear Caliper Holder Bolts 64 65 a7 Brake Disc Bolts 27 28 20.0 L Rear Master Cynder Mounting Bolts 25 25 180 (Gaik2 Model). 34 35 24 Fear Master Cylinder Push Rod Locknut 18 18 130 Brake Pedal Clamp Bolt 23 23 165 ‘Supension: Upper Front Fork Clamp Bolts 20 20 145 Lower Front Fork Clamp Bolts, 38 Eg 25 Front Fork Lower Cover Botts 74 o75 85 ini Front Fork Cover Screws 44 045 39 jn Front Fork Bottom Allen Bolts, 20 20 145 L Front Axle Clamp Bolts 34 35, 25 s1-24 GENERAL INFORMATION Torque and Locking Agent Torque Fastener sR ta Fie Remarks Fear Shook Absorber Nuls a4 35 25 ‘Swingarm Pivot Shalt 125 130 94 6 Steering: ‘Steering Stem Head Nut 88 20 65 Steering Stem Nut 20 20 145; Handlebar Clamp Bolts 4 35 25 s Handle Holder Nuts 34 35 25 Handlebar End Caps -~ - - Lak Handlebar Switch Housing Screws 34 0.35 20 ini Upper Front Fork Clamp Bolts 20 20 145, Lower Front Fork Clamp Bolts 34 35 25 Headlight Cover Bolts 6 74 078 65 ini Upper Fork Cover Bolts 6 44 045 39 ini Brake Joint Boks 14 0.75 65 inib ‘Turn Signal Lignt Holder Bolts 74 075 65 inp Frame: Front Fender Bolts 69 070 61 init Downtube Bolts 4 45 33 Front Featpeg Bolts 36 35 25 ear Footpeg Bracket Bolts 20 20 145 Sidestand Nuts “8 45 33 Electrical System: ‘Spark Plugs: 18 18 130 Pickup Coil Screws 28 0.30 28 inl Alternator Outer Cover Bots 12 12 104 int Alternator Outer Cover Damper Bolis 38 10 87 inl EO (tip) Alternator Cover Bots 98 19 a7 inl Alternator Inner Gover Botts 98 10 87 inte ‘Atenator Rotor Bolt 78 80 57 EO Alternator Outer Stator Bolts 13 13 1143 ini iB ‘Atternator Inner Stator Bolts 13 13 113 mo E Inner Stator Holder Bolts 13 13 149 init L Timing Inspection Plugs 15 05 1Binib ‘Stator Lead Clamp Screws 98 19 87 inl L Starter Motor Tarminal Locknut 1 1 95 int Starter Motor Terminal Nut 49 0.50 43 into Starter Motor Assy Boks 49 0.60 43 int ‘Starter Motor Mounting Botts 38 1.0 87 ino Headlight Body Mounting Screws (inside) 29 930 28 ini L Headlight Rim Screws, 10 010 9 int Handlebar Switch Housing Screws 34 0.35 30 ini Radiator Fan Switch 18 18 180 Water Temperature Switch 78 0.80 a9 ino 8s il Pressure Switch Terminal Bolt 18 0s 19 into Oi Pressure Swatch 15 15 11.0 8s Neutral Switen 15 15 1.0 ‘Tuen Signal Light Soraws 1 0.10 8 init Turn Signal Light Mounting Nuts 59. 0.60 52 inibSpecial Tools and Sealant ll Pressure Gauge, 5 ka/em® 57001-1285 GENERAL INFORMATION 1-25 Valve Guide Arbor, 37: 87001-1683 ¢ Inside Cirlip Pliers: $7007-149, Fork Cylinder Holder Handle: S7001-183 ko ZZ fp ‘Outeide Cirlip Pliers: §7007-144 ‘Compression Gauge: 5700-221 JE ‘Searing Puller: 57007-158 ‘Valve Spring Compressor Assembly: 57001-241 Valve Guide Reamer, o7: 57001-162 Valve Spring Compressor Adapter, 328.2: 57001-248 a &1-26 GENERAL INFORMATION Special Tools and Sealant Bearing Puller Adapt 7001-317 Compression Gauge Adapter, M12 x 1.28: 57001-1018 Bearing Driver: 7001-362 Spark Plug Wrench, Hex 18: 67001-1028 Piston Pin Puller Assarbly: S7007-910 Damper Cam Holder: 57003-1025 (Gear Holder: $7007-1015 Driven Gear Holder: 57001-1027 Fuel Level Gauge: 87001-1017 il Pressure Gauge Adapter, PT 18: 57001-1033 "Sey 9GENERAL INFORMATION 1-27 Special Tools and Sealant Fork Cylinder Holder Adapter: 57001-1057 ‘Steering Stem Nut Wrench: 87001-1100 PRS Oil Seal & Bearing Remover: 57001-1058 Head Pipe Outer Race Remover: 57001-1107 SS Head Pipe Outer Race Press Shatt: 87001-1075 ‘Valve Seat Gutter, 45° - 692 S7001-1115 Head Pipe Outer Race Driver: S7001-1077 © Piston Ring Compressor Grip: 87001-1095 Valve Seat Cutter, 32° - 098: STOOT-112i sy 21-28 GENERAL INFORMATION Special Tools and Sealant Vatve Seot Cutter Holder, 67: 57001-1126 Piston Pin Pller Adapter: 87001-1211 i St. @ ‘Valve Seat Cutter Holder Bar: 87001-1128 Fork Outer Tube Weight: 87001-1218 Sy ‘Bepring Driver Set: 87001-1128 Front Fork Oll Seal Driver: 57007-1219 _& ack, 5700-1288 Hexagon Wrench, Hex 27: 57001-1210GENERAL INFORMATION 1-29 Special Tools and Sealant Valve Seat Cutter, 85° 098: 57001-1247 Carburetor Drain Plug Wrench, Hex 3: 87001-1268 Oil Filter Wrench: 57001-1289 Fork Oil Level Gauge: 57001-1280 ae Bearing Retainer Wrench: 67001-1251 Pilot Screw Adjuster, : §7001-1202 Bearing Remover Shaft, 08: 57001-1265, ‘Bearing Remover Head, 020 x 022: $7001-1283 & Bearing Remover Head, 10 « #12 57001-1266 ‘Steering Stem Bearing Driver: $7007-1348 % |S1-30 GENERAL INFORMATION Special Tools and Sealant ‘Steering Stem Bearing Driver Adaptor: 57001-1945 Hand Tester: 87001-1308 eg Piston Ring Compressor Belt, 095 ~ 108; S7001-13568 Bearing Remover Shaft, 913: 57001-1377 ‘Attachment Jack: 57007-1398 ee Igniter Checker Assembiy: $7001-1978 Throttle Sensor Setting Adapter: §7001-1400 Harness Adapter #9; 57001-1389, Drive Shalt Holder: 67001-1407GENERAL INFORMATION 1-31 Special Tools and Sealant Flywheel Holder: 57001-1410 Kawasaki Bond (Liguld Gasket-Black): 92108-1003 “We, & f aki Bond (Silicone Sealant): $6019-120, “We & oO1-32 GENERAL INFORMATION Cable, Wire, and Hose Routing 1. Front Right Spark Plug Cap 2. Reear Right Spark Plug Cap 3. Lead from the lower side of the let ignition coil 4, Lead from the lower side of the right ignition coit 5. Ignition Coll for Rear Spark Plugs 6. Ignition Gol for Front Spark Plugs 7. Lead from the upper side of the fet ignition coll 8. Lead from the upper side of the right ignition coil 9. Front Left Spark Plug Cap 10. Rear Left Spark Plug Cap 11. Clutch Hose 12. Plastic Clamps. 12. Strap (let sie onty) 14. Green Hose (California Model: CA) 15. Right and lett side view are symmetrical 16. FrontCable, Wire, and Hose Routing GENERAL INFORMATION 1-33 1. Water Hose (To rear cylinder head) 2. Fuel Fitter 3. Fuel Pump 4. Carburetor 5. Reserve Tank Hose: 6, Carburetor Vent Hose (Yellow Hose to canister, CA) 7. Water Hose (To radiator) 8, Tecrostat Housing 9. Main Harness 10. Water Hose (To front cylindar head) 11, Fuel Hose 12, Fuel Tap 13. Surge Tank 14. Vacuum Switch Hose (To rear cylinder head) 45. Lower Air Gleaner Duct 16. Vacuum Switch Hose (To front cylinder head) 17. ition Switch 18. Choke Knob 19, Choke Cable 20, Plastic Clamp 21. Vacuum Switch Hose (To lower air cleaner duct) 22, Front1-34 GENERAL INFORMATION Cable, Wire, and Hose Routing 1. Fuel Fiter {8 Vacuum Switch Hose (To rear cylinder head) 2, Fuel Pump 8. Lower Alr Cleaner Duct 8. Fusl Hoses 10. Ther air hole faces downward. 4. White Marks 11. Vacuum Switch Valve 5. Clamps. 42. Vacuum Switch Hose (To front cylinder head) 8. Fuol Tank 18. Face the white mark loft. 7. Vacuum Switch Hoses 14, FrontGENERAL INFORMATION 1-35 Cable, Wire, and Hose Routing 1. Thermostat Housing 8. Overflow Hose: Run the hose behind the reserve tank 2. Water Hoses and between the Igniter and the starter relay. 3. Reserve Tank Hose 10, Run the hose inside the frame. 4, Clamps 17. Run the hose through the upper holder. 5, White marks face front, 12, Insert the hose into the clamp on the rear side ot the engine. 6. Water Purp 18. Water Pump Drainage Outlet Hose 7. Insert the hose untl it touches 14 Align the mark and clamp end. the water outlet (A = 10 ~ 13 mm) 18. White mark faces rear, 8. Reserve Tank 16, Front1-36 GENERAL INFORMATION Cable, Wire, and Hose Routing =: Coolant Flow 1. Upper Water Pipe ? fnanfld?Sha fhe vacutn sanat hove Beteen the vacuum switch valve and lower air cleaner duct 3. Coolant Fiter 4. Coolant Filter Housing 5 area Genres setae baton 6. Water Hose: Run the hose under the accelerator pump, 7 Coolant Valve 8. Install the plastic clamp from outside of the engine. 9. Grankcase Breather Hose to Air Cleaner 10. Lower Water Pipe 11. Face the clamp tab upward. 12. Face the clip tab downward 13. Accelerator Pump 14. Vacuum Switch Hose 15, Outside 16. Carburetor 17. Intake Manifold 18 FrontGENERAL INFORMATION 1-37 Cable, Wire, and Hose Routing 1. Electric Starter 11. Harness (Alternator Leads 20. Clamp 2. Starter Lead ‘and Pickup Goll Leads) 21. Bolt 8, Regulator/Rectiers 12.Bolt 22. Clutch Salve Cylinder 4, Clamp 13. Holder Bleed Valve 5, Ragulator/Rectifier Connectors 14, Do not run wiring 23, Clamp (Neutral Switch, 6; Sidestand Switch Lead around fer Oil Pressure Switch, and 7. Welded Clamp 15. Allernator Outer Cover Sidestand Switch Leads) 8. Clamp the sidestand switch with ‘18. Flubber Boot 24. Face the band end f bit tightness onto the frame pipe 17. Band downnaid as shown, bbehined the sidastand bracket. 18. Upper Washer (14 x 62mm) 25. Lett Crenkease 9. Clutch Hose 19. Lower Washer (p25 x"8.2mm)} 26. Engine Ol Pipe 10. Upper Helder 27. Front1-38 GENERAL INFORMATION Cable, Wire, and Hose Routing (80mm) 7. Right Muller Cover 1. Lof Silencer 2. Bolt applied antiseize device 8. Rear Exhaust Pipe Cover 3. Chamber 9. Clamp Botts 4. Right Sliencer 10. Clamps 5. Rear Exhaust Pipe 11. Front 12. Align marks. 6. Front Exhaust PipeGENERAL INFORMATION 1-39 Cable, Wire, and Hose Routing 1. Run the right front signal ight lead in front of the brake hose. 10, Throttle Cable (accelerator) 2, Insert the strap Into the handlebar (Handlebar Switch Leads and 11. Choke Cable Brake Hose): Do not run the thottle cables through the starp. 12, Speedometer Gear (right side) 3. Front Brake Hose 13. Spesdometer Cable 4, Throttle Cable (decelerator| 14, Holder (Speedometer Cabie) 5, Carburetor 15, Main Harmess 68. To speedometer 16. Grip End 7. Clamp (Left Front Signal Light Lead) 17. Apply adhesive to the grip 8. Left Front Signal Light Lead ‘end cap end screw in 2, Insert the strap into the handlebar the cap counterclockwise, (Handlebar Switch Leads and Clutch Hose). 18, Clutch Hose 19. From1-40 GENERAL INFORMATION Cable, Wire, and Hose Routing 1. Headlight Connector 2. Lett Handlebar Switch Lead Connector 3, Headlight Unit 4, Clutch Hose 5. Holder (Main Harnass, Clutch Hose, and Throttle Cables) 6, Water Hose 7. Main Harness 8, Straps (Clutch Hose) 9. Fun the clutch hose between the surge tank and frame pipg 10. Write Mark (Position here.) 414. Turn Signal Control Unit 12, Junction Box 1. Right Rear Signal Light Connectors 14 Tall8rake Light Connectors 15. Lott Rear Signal Light Connectors 16. Headlight Connector 17. Right Front Signal Light Connectors with Gray Lead 18. Left Front Signal Light Connectors with Green Lead 19, Horm Leads (insert the horn terminals '50 that both leads hang down.) 20. Ignition Switch Connector 21. Strap (Ignition Switch and Hom Leads) G2/H2 Model: Do not clamp Horn Leads 22. Strap (Ignition Switch Lead) 23. Horn 24. Ignition Switch 25, Upper Holder 26. Lower Holders 27. Electc Starter 28, Reguator Rectifiers 29. Sidestand Switch Lead 30, Welded Clamp 31. Strap (Sidestand Switch Leed) 32. Neutral Switch 33, White Paint on Engine Side of Clutch Hose 34, Straps (Rear Main Harness) 35. Harness (Alternator and Pickup Coil Leads) 36, Fun the harness over the crs pipe. 37. FrontGENERAL INFORMATION 1-41 Cable, Wire, and Hose Routing 4) Fuel Tank 8. Fun the hoses jn front of the swingarm pivot and cross pipe. 2. Clips 9. Fuel Tank Breather Hose (Except for California Model) 3, Upper Holder 410, Install the {uel level sensor so that its leads face the let side 4, Swingarm Pivot 11, Install the fuel level sensor cover so that the hose faces backward, 5. C1oss Pipe 12, Reserve Tank Overflow Hose 6. Clamp 1, Fuel Lavel Sensor Drain Hoss: Fun the hose on the right side 7. Bolt of the carburetor vent hose. 14, Front1-42 GENERAL INFORMATION Cable, Wire, and Hose RoutingGENERAL INFORMATION 1-43 Cable, Wire, and Hose Routing 4, Headiight Unit 2 Clamp: Face the accessory connectors backward. 3. Frame Ground Terminal 4, Fan Motor Connector (Upper) 5, Rear Brake Light Switch Connector (Lower) 6. Fue! Pump Connector: Connect it with the fuel pump bracket between, 7. Sposdomoter Connector 8. Fue! Pump Diode 9, Meter Indicator Light Connector 10. Fuel Pump Yellow Wiring: Run it under the fuel hose: 11. Fuel Level Sensor Connector 12, Throttle Sensor Connector 18, Surge Tank Bracket 14, White Mark: Align it sith surge tank bracket. 18. Front Accessory Connectors 16. ignition Switch Connector 17. Engine Ground Terminal 18. IC igniter Connectors 19. Ot Pressure Light Delay Unit Connector 20. Starter Relay Connector 21. Pun these harness through the right and left lower holders, 22, Battary Negative Terminal 23, Right Rear Turn Signal Light Connectors 24. Starp (Battery Negative and Postive Leads, and Main Hames): Run the positive lead from rear to front and negative lead from front to rear. 25. Upper Holder 26. Aerator Outer Cover 27. Fun right and left harness into the notches of the battery case. 28. Junction Box 29, Rear Accessory Connectors 30. Battery 81. Battery Positive Terminal 32, Battery Band 33, TailBrake Light Connectors 34. Left Rear Tum Siganl Light Connectors 35, Clamps | 36, Right Rear Turn Signal Leads with 6 clamps (CN, ML. US) and with 7 clamps (Except for CN, ML, US) 37, Left Fear Turn Signal Leads and Tai/Brake Light Leads with 6 clamps (CN, ML, US) and with 7 clamps (Except for GN, ML US) CN: Canadian Model ML: Malaysian Mode! US: United States 38, Front1-44 GENERAL INFORMATION Cable, Wire, and Hose RoutingGENERAL INFORMATION 1-45, Cable, Wire, and Hose Routing 1 2 3 4 5 6 7 8 9 10 " 12 13 4 15, 18 17. 8 13, 20. 2 2. 23, 24 25, 26. 21, 28. 29, Fight lgniton Col Radiator Fan Connector Frame Pipe Fear Brake Light Switch Connector Frame Ground Terminal Alternatar Leads and Pickup Col Leads into Altemator Cover Electric Starter Lead to Electric Starter Engine (Top View) Clutch Hose Engine Ground Lead (Battery Neagatve Lead) Fuel Tank Breather Hose (Except for California Mode Fuel Level Senso: Drain Hose Upper Holder Do not pinch hemess between the battery case and frame around here, Strap (Battery Posiive and Negative Leads. and Main Harness): Run the positve feed from rear to front and negative laad from rent o rear Battery Postve Lead IC igniter 0} Prossure Light Delay Unit IC laiter Wiring Fight and Lett Lower Holders Engine Ground Lead Terminal with the lead imost running vertical Insert the horn terminals so that both leads hang down, Strap (Rear Brake Light Switch, Raclator Fan, and Hom Leads) GalHt2 Model Do not clamp Horn Leads Right Horn Lead Strap (Radiator Fan and Rear Brake Light Swich Leads): clamp the rear brake ight switch lead with a bit tightness. Rear Brake Light Switch Lead Rear Brake Light Switch Front Starter Relay1-46 GENERAL INFORMATION Cable, Wire, and Hose Routing 1. Front Brake Hose: 5. Right and Left Grommets, 2. Brake Joint 6, Right and Left Brake Hose Holders 3, Right Lower Front Brake Hose 7. Right and Left Front Calipers 4, Left Lower Frant Brake Hose 8. FrontGENERAL INFORMATION 1-47 Cable, Wire, and Hose Routing ~G2A Models 1. Rear Caliper 8 Strap 2. Holder 9, Rear Brake Master Cylinder 3. White Mark (Position here.) 10. Rear Brake Reservoir 4. Clamps 11. Rear Brake Reservoir Cover 5. Rear Caliper Holder Bolt 42. Rear Brake Rad Joint Pin 8. Rear Brake Hose 18. Push Rod Clovis 7.White Mark (Position here.) 14, Front1-48 GENERAL INFORMATION Cable, Wire, and Hose Routing 1. Rear Caliper 2. Holder 3. White Mark (Position here.) 4. Clamps 5. Rear Caliper Holder Bolt 5. Rear Brake Hose 7. White Mark (Position here.) 8. Strap 9, Rear Brake Master Cylinder 10. Fear Brake Reservoir 11. Rear Brake Reservoir Cover 42. Rear Brake Rod Joint Pin 18. Push Rod Clevis 14, FrontGENERAL INFORMATION 1-49 Cable, Wire, and Hose Rot 9 Evaporative Emission Control System (California Model only) Fuel Filter (Vent Hose) Air Cleaner (Purge) White (Vacuum) Canister Vacuum Switch Valve White (Vacuum) —Vapar Flow — Fuel Flow ——: Vacuum Pulsation Flow1-50 GENERAL INFORMATION Cable, Wire, and Hose Routing Evaporative Emission Control System (California Model only)Cable, Wire, and Hose Routing GENERAL INFORMATION 1-51 Evaporative Emission Control System (California Model only) 1. Fuel Tank 2. Red Hose (let) 3. Blue Hose (right) 4. Band 5. Vacuum Switch Valve 8. White Hose 7. Carburetor 8. To the alr cleaner ‘9, Fun the hose through the upper holder. 10. Run the hose through the hale ofthe tool box. 11, Yellow Hose (Carburetor vent hose to the canister) 12. Blue Hose (Separator othe canister), Do not run through upper holder 13. Green Hose (Air clesner housing fo the canister) 14, Canister: Install horizontal 15. Separator 16, Tool Case Hole 17, Fame Pipes 18, Rubber Band 18, Do not pinch these hoses between the fuel lank and trame pipes. 20. FrontFUEL SYSTEM 2-1 Fuel System Table of Contents Exploded View. a 22 |nlet System. “ 28 Specifications 28 Thratte Grip and Cables. 24 Free Play Inspection, Free Play Adjustment. Throttle Cable instalation. Tote Cale Lubretton and inspection. Choke Cable... Fiee Play Inspection... Choke Cable Installation... ‘Choke Gable Lubrication and Inspection. Carburetor Idle Spaed Inspection, Idle Speed Adjustment, High Altitude Performance Adjustment Fuel System Cleanliness Inspection... Service Fuel Level inspection. Service Fuel Level Adjustment Carburetor Removal... Carburetor Installation Carburetor Disassembly Carburetor Assembly Carburetor Cleaning... Carburetor Inspection sn. 218 Coolant Valve inspection i 220 Coolant Fiter Cleaning a 220 Inlet Manifold Removals. 220 Inet Manifold installation, Fuel Pump... ect Removal... Installation, Fuel Filter inspection. Al Cleaner : Element Removal... Element Gieaning and inepection Lett Air Cleaner Housing Removal... Fight Air Cleanor Housing Removal Right Air Cleaner Housing Installation... Lower Air Cleaner Duct Removal ‘Surge Tank Removal ‘Surge Tenk [nstalation.... Fuel Tank, Fuel Tank Removal. . Fuel Tank Installation no Fuol Tank and Cap Inspection Fuel Tank Cleaning, Fuel Tap Removal... Fuel Tap Installation Fue! Tap Inspection... Evaporative Emission Gonirl System. Parts Removallnstaliation.. Hose Inspection (Periagc inspection. Separator inggection (Periadic Inspection). ‘Separator Operation Test... Canister Inspection (Periodic Inspection). 227 2-28 228 B28 2.29 220 229 229 230 2202-2 FUEL SYSTEM Exploded View xcept for (CA)FUEL SYSTEM 2-3 Exploded View ‘Throttle Cable (accelerator) Throttle Cable (decelerator) ‘Choke Cable Pilot Screw Pilot (Stow) Jet Neale Jet Needle Jet Holder Main Jet Plug (US. ST, CA) et Needle Electric Fuel Pump , Throttle Switeh Aoly grease ‘Apply cable Lticant Caitonia Moda! Swies Medel United Siates MoExploded ViewFUEL SYSTEM 2-5 Exploded View 1. Vacuum Switch Valve 2 Lower Air Cleaner Duct 5. At Cleaner Element 4. Fuel Level Sensor 5: Inlet Manifold S; Follow the specific tightening sequence TH: 12.Nem (1.2 kgm, 104 ind) T2:0.8 Nim (0.08 kam, 7 in) 73: 8.8 Nim (1.0 kgm, 87 inib) T4: 22 Nim (0.22 kg, 19 ina) TS: 6.9 Nim (0.7 kgm, 61 ini) V6: 2.2 Nom (0.22 kgm, 19 Irth)Inlet SystemFUEL SYSTEM 2-7 infet System Stopper ‘Surge Tank Inlet Left Air Cleaner Cover Upper Air Cleaner Dust Ar Cleaner Bases ‘Ait Cleaner Element Lower Air Cleaner Duct Right Air Cleaner Cover Drain Hose Plug O-ring Fun the drain hose between cylinders Front2-8 FUEL SYSTEM Specifications Tem Standard Throitle Grip Free Play Carburetor: Make, Type (dle speed Pilot screw (tums out, for reference) Service fue! level Float height Main jet Main air jot Needle jet et needie Pilot jt (slow jet) Pilot ai Jet (slow air jet) Starter jet ‘Throttle valve angle High altitude carburetor specifications (US) Pilot jet Main jot 23mm KEIHIN Ovo. 1800 + 50 r/min (rpm), (CA) (FG) (AR) (ST) 1 000 50 r/min (rpm) G2/H2 Model: 1.000 = 50 vimin (rpm) (1.9/6 = 14), (ST) (1-1/4 = 14) G2/H2 Model: 1 3/4 = 1/4 (0 ~ 2mm below the float bow! mating surface 19022mm #142 #100 #6 (PINo. 16017 -1276) NePY 45 #95 #65; 10 a2. 140 (AR) = Austrian Model (US) : US.A, Medel Pilot Screw (A} Pilot Jet [8] Jet Needle (6) Needle Jet [0] Pilot Airdet (E] Main Air Jet [F] Valve Seat (G] Float Valve (H Needle Jet Holder (i Main Jet lJ} ‘Special Tools ~ Pilot Screw Adjuster, C: 57001-1262 Carburstor Drain Plug Wrench, Hex 3: 57001-1269 o Fuel Level Gauge: 57001-1017 (ST) : Switzerland Mode! (FG) : Germany Mode! (CA): California Model 56 60008Throttle Grip and Cables Free Play Inspection ‘© Check the throtle grip free play [A ‘ifthe free play is incorrect, adjust the throtte cable. Throtle Grip Free Play Standard: 2~3 mm ‘© Check that the throttle grip moves smoothly from full open to close, and the throtle closes quickly and completely in all steering positions by the return spring, ifthe throttle grip does not return properly, check the throttle cable routing, orp fr8e play, and cable damage. Then lubricate the throtle cable ‘@ Fun the engine at the idle speed, and tum the handlebar all the way to the right and left to ensure that the idle speed does not change, ifthe idle speed increase, check the throttle cable free play and the cable routing. Free Play Adjustment (© Loosen the locknuts [A] and screw the adjusters [6] all the way in so as to give the thratie grip plenty of play. Turn out the decelerator cable [C] adjuster unti there is no play, (© Tighten the locknut (© Turn the accelerator cable [D] adjuster until the proper amount of throttle grip free play is obtained and tighten the lockrut, 4 If the proper amount of free play cannot be obtained by using the Adiustere at the throttle grip, use the adlusters in the middle of the theotle cables, © Give the throttle grip plenty of play by turning the adjusters atthe grip in fully (© Remove the fuel tank (see Fuel Tank Removal) © Loosen the focknuts [A] and turn the adjusters in the mile of the throtle cables all the way into give the throttle grip plenty of play. © With the throtte grip fully olosed, turn the decelerator cable adjuster [B] until the inner cable just becomes tight and tighten the lacknut ‘© Tum the accelerator cable adjuster [C] until the correct throttle grip {ee play is obtained and tighten the locknua. Front (D} PGS Operation with incorrectly routed or improperly adjusted ci bles could result In an unsafe riding condition. Throttle Cable Installation © install the throttle cables in accordance with the Cable, Wire, and Hose Routing section in the General niormation chapter. © install the lower ends of the throttle cables in the bracket on the carburetor after installing the upper ends of the throttle cable in the ori. (© Alter installation, adjust each cable properly FOG Operation with incorrectly routed or Improperly adjusted ca- bles could result in an unsate riding condition. Throttle Cable Lubrication and Inspection ‘@ Whenever the cables are removed, or in accordance with the Periodic Maintenance Chart, lubricate the throtle cabies (see General Lubrication in the Appendix chapter). © Apply a thin coating of grease to the cable upper ends @.Use a commercially available pressure cable lubricator to lubricate the cables, (© With the cable disconnected at both ends, the cable should move Iteely in the cable housing FUEL SYSTEM 2-92-10 FUEL SYSTEM Choke Cable Free Play Inspection ‘© Chock that the choke inner cable slides smoothly by moving the choke knob [A] to the front and rear, 4! there is any irregularity, replace the choke cable. Choke Cable Installation © install the choke cable in accordance with the Cable, Wire, and Hose Routing section in the General information chapter. © After installation, check that the choke kuob moves smoothly PG Operation with an incorrectly routed cable could result in an unsafe riding condition. Choke Cable Lubrication and Inspection ‘© Whenever the cable is removed, or in accordance with the Periodic Maintenance Chart, lubricate the choke cable (sea General Lubrica tion in the Appendix chapter), Use a commercially available pressure cable lubricator to lubricate the cable. With the cable disconnected at both ends, the cable should move freely in the cable housing,FUEL SYSTEM 2-11 Carburetor Idle Speed Inspection ‘@ Start the engine and warm it up thoroughly. ‘© With the engine idling, turn the handlebar to both sides. if handlebar movement changes the idle speed, the throttle cables may be Improperly adjusted or incorrectly routed, or damaged. Be sure to correct any of these conditions betore riding (see Cable, Wire, ‘and Hose Routing section in the General Information chapter) WARNING Operation with improperly adjusted, incorrectly routed, or damaged cables could result in an unsate riding condition © Chock idle speed, Ifthe idle speed is out of the specified range, adjust it Idle Speed ‘Standard: 800 = 50 rimin (rpm), (California and 1500 H) 1000 = Sorimin (rpm) Idle Speed Adjustment (© Start the engine and warm it up thoroughly. © Turn the adjusting screw [A] until the idle speed is correct. Open and close the throtte a few times to make sure that the idle speed is within the specified range, Readjust it necessary. Front [8] High Altitude Performance Adjustment ‘To improve the EMISSION CONTROL PERFORMANCE of US Model ‘operated above 4000 feet, Kawasak! recommends the following Environmental Protection Agency (EPA) approved modification. ‘© Change the main jet and pilot jt for high altitude use, High Altitude Carburetor Specifications Pilot Jet: 642 (92084-1135) Main Jet: #140 (#2063-1013) Fuel System Cleanliness Inspection PIS Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free trom any source of flame or sparks; this includes any appliance with @ pilot light.2-12 FUEL SYSTEM Carburetor © Remove: Fuel Tank (see Fuel Tank Removal) Fuel Pump (see Fuel Pump Removal) Fight Air Cleaner Base, Upper Air Cleaner Duct, and Right Air Cleaner Base Holder [A] '@ Place a conduit under the carburetor drain hose [8]. The conduit leads to a suitable container, Front C} (© Turn the fuel tap to the RES position (© Turn out the drain plug 2 few turns and drain the float bow Special Tool - Carburetor Drain Plug Wrench, Hex 3: 57001-1269 © Check to see if water or dirt comes out (© Tighten the drain plug and turn the fuel tap to the OFF position ++ I! any water of ditt appears during the above inspection, clean the fuel systom (see Carburetor Cleaning and Fuel Tank Cleaning) Service Fue! Level Inspection Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF, Oo not smoke. Make sure the area |s wellventilated and free from ‘any source of flame or sparks; this Includes any appliance with a pilot light, ‘© Remove the carburetor, and hold it upright on a stand (see Carburetor Removal. ‘© Prepare an auxiliary fuel tank and connect the fuel hose to the carburetor. ‘© Prepare a fuel hose (6 mm in outer diameter and about 300 mm long). ‘© Connect the fuel level gauge [A] to the carburetor float bow with the fuel house ‘Special Too! Fuol Level Gauge: 57001-1017 (© Hoid the gauge [A] vertically against the side of the carburetor body ‘0 that the middle line [8] is several milimeters higher than the float ‘bow! mating surface (C]. ‘© Turn the fuel tap to the ON position to feed fuel to the carburetor and gauge, then turn the carburetor drain plug {D] out a few turns. ‘Special Tool Carburetor Drain Plug Wrench, Hex 3: 57001-1269 Wait unt the fuel evel inthe gauge sees. ‘© Keeping the gauge vertical, siowly lower the gauge until the middle line is even withthe float bow! mating surtace. NoTE Do net lower the mide line below the Hoat bow mating surface. It the gauge is iwvered and then raised again, the ful level measured shows somewhat higher than the actual ful level. fhe gauge is lowered 00 far dump the fue) out of ito a suitable container and start the procedure over again. «© Fad the fuel level [En the gauge and compare tothe speciation Tighten the drain plug and remove the fuel level gauge. Hit the fuel level is incorrect, adjust W (see Service Fuel Level Adjustment, Service Fuel Level ‘Standard: 0 ~2:mm below the float bow mating surface L 192050036 tiFUEL SYSTEM 2-13 Carburetor Service Fue! Level Adjustment PMG Gasoline js extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not ‘smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. ‘© Remove the carburetor, and drain the fuel into a container Remove the float bow! (ses Carburetor Disassembly), (© Tap the pivot pin (A] out and remove the floats [2 ‘© \When removing and instaling the pin, note the following Be careful not fo break the pin holder legs (Cl When remeving the pin, tap [D) the let end of the pin. When installing the pin, tap [E] the right end of the pin, Front {F] (© Bend the tang [A] on the float arm very slightly to change the float noah | ® ‘© Measure the float height titing the carburetor so that the tang on the float just touches the needle rod in the float valve. increasing the float height lowers the fuel level and decreasing the float height raises the tuel level, Float Height Standard: 19 £2mm ‘© Assemble the carburetor, and recheck the fuel level +f the fuel level cannot be adjusted by this method, the float or the float valve is damaged. Float Valve Needle Rod (contacted but unloaded) [8] Flat {©} Float Height [D] | ® ~S Float Bow! Mating Surface [A] Carburetor Removal Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke, Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.2-14 FUEL SYSTEM Carburetor (© Remove: Fuel Tank (see Fuel Tark Removal) (Choke Knob [A] Right Air Cleaner Housing (see Air Cleaner Housing Removal) Carburetor Hoses PO ‘© Remove the surge tank (see this chapter), ‘© Drain the coolant (see Cooling System chapter) © Remove: Throttle Sensor Lead Connector [A] Cooling Hose [8] ‘© Loosen the carburetor lamp screw [C] Front {0} @ Remove Fight Ar Cleaner Base Holder (A) Take out the carburetor and remove the coolant vaive lower hose |B} from the float bow Front (C] ‘© Romove the right handlebar switch housing and remove the throttle cable upper ends. Accelerator Cable (A) Decelerator Cable (8) © Remove the carburetor and throttle cable lower ends. © Stutt piece of linttree, clean cloth into the inlet manifold to Keep itt cout of the engine, I dirt or dust is allowed to pass through into the carburetor, the throttle may become stuck, possibly causing an accident. CAUTION I dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.FUEL SYSTEM 2-15 Carburetor Carburetor Installation install the holder clamp [A] as shown being careful of the screw position and the screw head [B] direction, ‘© Tighten the clamp screw so that the tab opening [C] is 12 ~ 13 mm. Front [D] (© Fit the ridge (A) into the notch [B] on the inlet manifold © Install the throttle cable lower ends. ‘Accelerator Cable [A] Decelerator Cable [B) © ‘instal the throttle cable holder [A] as shown, ‘© Pun the carburetor vent hose, vacuum hose, coolant hose, and fuel hose according to the Cable, Wire, and Hose Routing section of the General Information chapter ‘© Turn the throttle grip and make sure that the throttle lever does not Contact the holder screw or fuel and coolant hoses.