Мануал для кавасаки вулкан 800

This service manual covers the 2
file:///C|/Users/MWM/Desktop/Midwest%20Manuals/index%20searchable.html[9/15/2010 10:08:33 AM]
Quick Reference Guide
This quick reference guide will assist
you in locating a desired topic or procedure.
•Bend the pages back to match the
black tab of the desired chapter number with the black tab on the edge at
each table of contents page.
•Refer to the sectional table of contents
for the exact pages to locate the specific topic required.
General Information
1 j
Periodic Maintenance
2 j
Fuel System
3 j
Cooling System
4 j
Engine Top End
5 j
Clutch
6 j
Engine Lubrication System
7 j
Engine Removal/Installation
8 j
Crankshaft/Transmission
9 j
Wheels/Tires
10 j
Final Drive
11 j
Brakes
12 j
Suspension
13 j
Steering
14 j
Frame
15 j
Electrical System
16 j
Appendix
17 j
LIST OF ABBREVIATIONS
A
ABDC
AC
ATDC
BBDC
BDC
BTDC
°C
DC
F
°F
ft
g
h
L
ampere(s)
after bottom dead center
alternating current
after top dead center
before bottom dead center
bottom dead center
before top dead center
degree(s) Celsius
direct current
farad(s)
degree(s) Fahrenheit
foot, feet
gram(s)
hour(s)
liter(s)
lb
m
min
N
Pa
PS
psi
r
rpm
TDC
TIR
V
W
Ω
pounds(s)
meter(s)
minute(s)
newton(s)
pascal(s)
horsepower
pound(s) per square inch
revolution
revolution(s) per minute
top dead center
total indicator reading
volt(s)
watt(s)
ohm(s)
Read OWNER’S MANUAL before operating.
EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporated crankcase emission
(1) and exhaust emission (2) control systems in compliance with applicable regulations of the
United States Environmental Protection Agency.
1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors
are routed through an oil separator to the intake side of the engine. While the engine is operating,
the vapors are drawn into the combustion chamber, where they are burned along with the fuel and
air supplied by the carburetion system.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust
of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully
designed and constructed to ensure an efficient engine with low exhaust pollutant levels.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is
commonly referred to as the Act’s "tampering provisions."
"Sec. 203(a) The following acts and the causing thereof are prohibited...
(3)(A) for any person to remove or render inoperative any device or element of design installed
on or in a motor vehicle or motor vehicle engine in compliance with regulations under this
title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer
knowingly to remove or render inoperative any such device or element of design after such
sale and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading
motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a
motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser..."
NOTE
○The phrase "remove or render inoperative any device or element of design" has been generally
interpreted 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 include:
a.Maladjustment 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.
c.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 CIVIL PENALTIES NOT EXCEEDING
$10,000 PER VIOLATION.
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering
inoperative by any person other than for purposes of maintenance, repair, or replacement, of any
device or element of design incorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the
vehicle after such device or element of design has been removed or rendered inoperative by
any person.
Among those acts presumed to constitute tampering are the acts listed below:
Replacement of the original exhaust system or muffler with a component not in compliance
with Federal regulations.
Removal of the muffler(s) or any internal portion of the muffler(s).
Removal of the air box or air box cover.
Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such
modifications result in increased noise levels.
•
•
•
•
Foreword
This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop procedures must be understood in order to carry out
maintenance and repair satisfactorily. Whenever the owner has insufficient experience or
doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures
before starting work, and then do the work carefully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurements
can only be made if the proper instruments are
used, and the use of substitute tools may adversely affect safe operation.
For the duration of the warranty period,
we recommend that all repairs and scheduled
maintenance be performed in accordance with
this service manual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void the warranty.
To get the longest life out of your vehicle:
Follow the Periodic Maintenance Chart in the
Service Manual.
Be alert for problems and non-scheduled
maintenance.
Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, and
testers that are necessary when servicing
Kawasaki motorcycles are introduced by the
Service Manual. Genuine parts provided as
spare parts are listed in the Parts Catalog.
Follow the procedures in this manual carefully. Don’t take shortcuts.
Remember to keep complete records of maintenance and repair with dates and any new
parts installed.
•
•
•
•
•
How to Use This Manual
In this manual, the product is divited into its
major systems and these systems make up
the manual’s chapters. The Quick Reference
Guide shows you all of the product’s system
and assists in locating their chapters. Each
chapter in turn has its own comprehensive
Table of Contents.
For example, if you want ignition coil information, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use the
Table of Contents on the first page of the chapter to find the Ignition Coil section.
Whenever you see these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.
WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in personal injury, or loss of life.
CAUTION
This caution symbol identifies special
instructions or procedures which, if not
strictly observed, could result in damage to or destruction of equipment.
This manual contains four more symbols (in
addition to WARNING and CAUTION) which will
help you distinguish different types of information.
NOTE
○This note symbol indicates points of par-
ticular interest for more efficient and convenient operation.
a procedural step or work to be
• Indicates
done.
○Indicates a procedural sub-step or how to do
the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action to
take based on the results of the test or inspection in the procedural step or sub-step it follows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require specified tightening torque, oil, grease or a locking
agent during assembly.
GENERAL INFORMATION 1-1
General Information
1
Table of Contents
Before Servicing .....................................................................................................................
Model Identification.................................................................................................................
General Specifications............................................................................................................
Unit Conversion Table ............................................................................................................
1-2
1-5
1-7
1-16
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following:
(1) Dirt
Before removal and disassembly, clean the motorcycle. Any dirt entering the engine will shorten
the life of the motorcycle. For the same reason, before installing a new part, clean off any dust or
metal filings.
(2) Battery Ground
Disconnect the ground (–) wire from the battery before performing any disassembly operations
on the motorcycle. This prevents the engine from accidentally turning over while work is being
carried out, sparks from being generated while disconnecting the wires from electrical parts, as
well as damage to the electrical parts themselves. For reinstallation, first connect the positive
wire to the positive (+) terminal of the battery
(3) Installation, Assembly
Generally, installation or assembly is the reverse of removal or disassembly. However, if installation or assembly sequence is given in this Service Manual, follow 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 is preferable to mark and record the locations and routing whenever
possible.
(4) Tightening Sequence
When installing bolts, nuts, or screws for which a tightening sequence is given in this Service
Manual, make sure to follow the sequence. When installing a part with several bolts, nuts, or
screws, start them all in their holes and tighten them to a snug fit, thus ensuring that the part has
been installed in its proper location. Then, tighten them to the specified torque in the tightening
sequence and method indicated. If tightening sequence instructions are not given, tighten them
evenly in a cross pattern. Conversely, to remove a part, first loosen all the bolts, nuts, or screws
that are retaining the part a 1/4-turn before removing them.
(5) Torque
When torque values are given in this Service Manual, use them. Either too little or too much
torque may lead to serious damage. Use a good quality, reliable torque wrench.
(6) Force
Common sense should dictate how much force is necessary in assembly and disassembly. If
a part seems especially difficult to remove or install, stop and examine what may be causing the
problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use
an impact driver for screws (particularly 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, especially during
major engine disassembly and assembly. Use a clean piece of thick cloth when lifting the engine
or turning it over.
(8) High-Flash Point Solvent
A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is standard solvent (generic name). Always follow manufacturer
and container directions regarding the use of any solvent.
(9) Gasket, O-Ring
Replace a gasket or an O-ring with a new part when disassembling. Remove any foreign matter
from the mating surface of the gasket or O-ring to ensure a perfectly smooth surface to prevent
oil or compression leaks.
(10)Liquid Gasket, Locking Agent
Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used.
Apply them sparingly. Excessive amount may block engine oil passages and cause serious damage.
GENERAL INFORMATION 1-3
Before Servicing
(11) Press
When using a press or driver to install a part such as a wheel bearing, apply a small amount of
oil to the area where the two parts come in contact to ensure a smooth fit.
(12)Ball Bearing and Needle Bearing
Do not remove a ball bearing or a needle bearing unless it 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, applying pressure evenly with a suitable driver. Apply force only to the
end of the race that contacts the press fit portion, and press it evenly over the base component.
(13)Oil Seal and Grease Seal
Replace any oil or 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 driver, applying a
force uniformly to the end of seal until the face of the seal is even with the end of the hole, unless
instructed otherwise. When pressing in an oil or grease seal which has manufacturer’s marks,
press it in with the marks facing out.
(14)Circlip, Retaining Ring, and Cotter Pin
When installing circlips and retaining rings, take care to compress or expand them only enough
to install them and no more. Install the circlip with its chamfered side facing load side as well.
Replace any circlips, retaining rings, and cotter pins that were removed with new ones, as removal weakens and deforms them. If old ones are reused, they could become detached while
the motorcycle is driven, leading to a major problem.
(15)Lubrication
Engine wear is generally at its maximum while the engine is warming up and before all the sliding
surfaces have an adequate lubricative film. During assembly, make sure to apply oil to any sliding
surface or bearing that has been cleaned. Old grease or dirty oil could have lost its lubricative
quality and may contain foreign particles that act as abrasives; therefore, make sure to wipe it off
and apply fresh grease or oil. Some oils and greases in particular should be used only in certain
applications and may be harmful if used in an application for which they are not intended.
(16)Direction of Engine Rotation
To rotate the crankshaft manually, make sure to do so in the direction of positive rotation. Positive rotation is counterclockwise as viewed from the left side of the engine. To carry out proper
adjustment, it is furthermore necessary to rotate the engine in the direction of positive rotation as
well.
(17)Replacement Parts
When there is a replacement instruction, replace these parts with new ones every time they are
removed.
Replacement parts will be damaged or lose their original function once they are removed. Therefore, always replace these parts with new ones every time they are removed. Although the previously mentioned gasket, O-ring, ball bearing, needle bearing, grease seal, oil seal, circlip, and
cotter pin have not been so designated in their respective text, they are replacement parts.
(18)Electrical Wires
All the electrical wires are either one-color or two-color. A two-color wire is identified first by the
primary color and then the stripe color. For example, a yellow wire with thin red stripes is referred
to as a “yellow/red” wire; it would be a “red/yellow” wire if the colors were reversed. Unless instructed otherwise, electrical wires must be connected to wires of the same color.
Two-Color Electrical
1-4 GENERAL INFORMATION
Before Servicing
(19)Inspection
When parts have been disassembled, visually inspect these parts for the following conditions
or other damage. If there is any doubt as to the condition of them, replace them with new ones.
Abrasion
Bent
Color change
Crack
Dent
Deterioration
Hardening
Scratch
Seizure
Warp
Wear
(20)Specifications
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.
GENERAL INFORMATION 1-5
Model Identification
VN800-B5 Left Side View:
VN800-B5 Right Side View:
1-6 GENERAL INFORMATION
Model Identification
VN800-B6 Left Side View:
VN800-B6 Right Side View:
GENERAL INFORMATION 1-7
General Specifications
Items
Dimensions
Overall Length
Overall Width
Overall Height
Wheelbase
Road Clearance
Seat Height
Dry Mass
Curb Mass:
Front
Rear
Fuel Tank Capacity
Performance
Minimum Turning Radius
Engine
Type
Cooling System
Bore and Stroke
Displacement
Compression Ratio
Maximum Horsepower
VN800-B1 ∼ B4
2 390 mm (94.1 in.), (CA) (US) (MY) 2 375 mm (93.5 in.)
940 mm (37.0 in.), (CA) (US) (MY) 930 mm (36.6 in.)
1 125 mm (44.3 in.), (CA) (US) (MY) 1 130 mm (44.5 in.)
1 600 mm (63.0 in.)
135 mm (5.3 in.)
705 mm (27.8 in.)
235 kg (518 lb), (CA) (US) (MY) 234 kg (516 lb),
(CAL) 234.5 kg (517 lb)
116 kg (255 lb), (CA) (US) (MY) 115 kg (254 lb)
138 kg (304 lb), (CAL) 138.5 kg (305 lb)
15.0 L (4.0 us gal)
2.9 m (9.5 ft)
4-Stroke, SOHC, V2-cylinder
Liquid-cooled
88.0 × 66.2 mm (3.46 × 2.61 in.)
805 cm³ (49.1 cu in.)
9.5: 1
40.5 kW (55 PS) @7 000 r/min (rpm),
(CA) (MY) 44.1 kW (60 PS) @7 500 r/min (rpm),
(CH) 24.2 kW (33 PS) @6 000 r/min (rpm),
(FR) 39.3 kW (53 PS) @7 000 r/min (rpm) (UTAC’s norm),
(US) – – –
Maximum Torque
64 N·m (6.5 kgf·m, 47.0 ft·lb) @3 300 r/min (rpm),
(CA) (MY) 64.7 N·m (6.6 kg, 47.7 ft·lb) @3 500 r/min (rpm),
(CH) 55 N·m (5.6 kgf·m, 40.5 ft·lb) @3 000 r/min (rpm),
(FR) (GB) (US) – – –
Carburetion System
Carburetor, Keihin CVK36
Starting System
Electric starter
Ignition System
Battery and coil (transistorized)
Timing Advance
Electronically Advanced (digital igniter)
Ignition Timing
From 5.0° BTDC @1 000 r/min (rpm) to 37.5° BTDC @6 750
r/min (rpm)
Spark Plugs
NGK CR7E or ND U22ESR-N
Cylinder Numbering Method Front to rear, 1-2
Firing order
2-1
Valve Timing:
Inlet
Open
19° BTDC
Close
71° ABDC
Duration
270°
1-8 GENERAL INFORMATION
General Specifications
VN800-B1 ∼ B4
Items
Exhaust
Open
Close
Duration
Lubrication System
Engine Oil:
Grade
Viscosity
Capacity
Drive Train
Primary Reduction System:
Type
Reduction Ratio
Clutch Type
Transmission:
Type
Gear Ratios:
1st
2nd
3rd
4th
5th
Final Drive System:
Type
Reduction Ratio
Overall Drive Ratio
Frame
Type
Caster (Rake Angle)
Trail
Front Tire:
Type
Size
Rear Tire:
Type
Size
Front Suspension:
Type
Wheel Travel
Rear Suspension:
Type
Wheel Travel
Brake Type:
Front
69° BBDC
31° ATDC
280°
Forced lubrication (wet sump)
SE, SF or SG class
SAE10W-40, 10W-50, 20W-40, 20W-50
3.2 L (3.4 US qt)
Gear
2.184 (83/38)
Wet multi disc
5-speed, constant mesh, return shift
2.533
1.650
1.230
1.000
0.857
(38/15)
(33/20)
(32/26)
(29/29)
(24/28)
Chain Drive
2.470 (42/17)
4.625 @Top gear
Tubular, double cradle
32°
122 mm (4.8 in.)
Tube
130/90-16 67H
Tube
140/90-16 71H
Telescopic fork
150 mm (5.9 in.)
Swingarm (uni-trak)
100 mm (3.9 in.)
Single disc
GENERAL INFORMATION 1-9
General Specifications
VN800-B1 ∼ B4
Items
Rear
Electrical Equipment
Battery
Headlight:
Type
Bulb
Tail/brake Light
Alternator:
Type
Rated Output
Drum
12 V 12 Ah
Semi-sealed beam
12 V 60/55 W (quartz-halogen)
12 V 5/21 W × 2, (CA) (US) (MY) 12 V 8/27 W × 2
Three-phase AC
23.5 A × 14 V @8 000 r/min (rpm)
Specifications are subject to change without notice, and may not apply to every country.
(CA): Canada Model
(CAL):California Model
(CH): Switzerland Model
(FR): France Model
(GB): United Kingdom Model
(MY): Malaysia Model
(US): United Sates Model
1-10 GENERAL INFORMATION
General Specifications
Items
Dimensions
Overall Length
Overall Width
Overall Height
Wheelbase
Road Clearance
Seat Height
Dry Mass
Curb Mass:
Front
Rear
Fuel Tank Capacity
Performance
Minimum Turning Radius
Engine
Type
Cooling System
Bore and Stroke
Displacement
Compression Ratio
Maximum Horsepower
Maximum Torque
Carburetion System
Starting System
Ignition System
Timing Advance
Ignition Timing
Spark Plugs
Cylinder Numbering Method
Firing order
Valve Timing:
Inlet
Open
Close
Duration
VN800-B5
VN800-B6 ∼ B7
2 380 mm (93.7 in.), (CA) (US) (MY) 2 375 mm (93.5 in.)
940 mm (37.0 in.), (CA) (US) (MY) 930 mm (36.6 in.)
1 125 mm (44.3 in.), (CA) (US) (MY) 1 130 mm (44.5 in.)
1 600 mm (63.0 in.)
135 mm (5.3 in.)
705 mm (27.8 in.)
235 kg (518 lb), (CA) (US) (MY) 234 kg (516 lb),
(CAL) 234.5 kg (517 lb)
116 kg (255 lb), (CA) (US) (MY) 115 kg (254 lb)
138 kg (304 lb), (CAL) 138.5 kg (305 lb)
15.0 L (4.0 us gal)
2.9 m (9.5 ft)
4-Stroke, SOHC, V2-cylinder
Liquid-cooled
88.0 × 66.2 mm (3.46 × 2.61 in.)
805 cm³ (49.1 cu in.)
9.5: 1
40.5 kW (55 PS) @7 000 r/min (rpm),
(CA) (MY) 44.1 kW (60 PS) @7 500 r/min (rpm),
(CH) 24.2 kW (33 PS) @6 000 r/min (rpm),
(US) – – –
64 N·m (6.5 kgf·m, 47.0 ft·lb) @3 300 r/min (rpm),
(CA) (MY) 64.7 N·m (6.6 kg, 47.7 ft·lb) @3 500 r/min (rpm),
(CH) 55 N·m (5.6 kgf·m, 40.5 ft·lb) @3 000 r/min (rpm),
(GB) (US) – – –
Carburetor, Keihin CVK36
Electric starter
Battery and coil (transistorized)
Electronically Advanced (digital igniter)
From 5.0° BTDC @1 000 r/min (rpm) to 37.5° BTDC @6 750
r/min (rpm)
(CAL) From 5.0° BTDC @1 300 r/min (rpm) to 37.5° BTDC @6
750 r/min (rpm)
NGK CR7E or ND U22ESR-N
Front to rear, 1-2
2-1
19° BTDC
71° ABDC
270°
GENERAL INFORMATION 1-11
General Specifications
Items
Exhaust
Open
Close
Duration
Lubrication System
Engine Oil:
Grade
Viscosity
Capacity
Drive Train
Primary Reduction System:
Type
Reduction Ratio
Clutch Type
Transmission:
Type
Gear Ratios:
1st
2nd
3rd
4th
5th
Final Drive System:
Type
Reduction Ratio
Overall Drive Ratio
Frame
Type
Caster (Rake Angle)
Trail
Front Tire:
Type
Size
Rear Tire:
Type
Size
Front Suspension:
Type
Wheel Travel
Rear Suspension:
Type
Wheel Travel
VN800-B6 ∼ B7
VN800-B5
69° BBDC
31° ATDC
280°
Forced lubrication (wet sump)
SE, SF or SG class
SAE 10W-40, 10W-50, 20W-40,
or 20W-50
3.2 L (3.4 US qt)
API SE, SF, or SG,
API SH or SJ with JASO MA
SAE 10W-40
Gear
2.184 (83/38)
Wet multi disc
5-speed, constant mesh, return shift
2.533
1.650
1.230
1.000
0.857
(38/15)
(33/20)
(32/26)
(29/29)
(24/28)
Chain Drive
2.470 (42/17)
4.625 @Top gear
Tubular, double cradle
32°
122 mm (4.8 in.)
Tube
130/90-16 67H
Tube
140/90-16 71H
Telescopic fork
150 mm (5.9 in.)
Swingarm (uni-trak)
100 mm (3.9 in.)
1-12 GENERAL INFORMATION
General Specifications
Items
Brake Type:
Front
Rear
Electrical Equipment
Battery
Headlight:
Type
Bulb
Tail/brake Light
Alternator:
Type
Rated Output
VN800-B5
VN800-B6 ∼ B7
Single disc
Drum
12 V 12 Ah
Semi-sealed beam
12 V 60/55 W (quartz-halogen)
12 V 5/21 W × 2
(CA) (US) (MY) 12 V 8/27 W × 2
12 V 5/21 W × 2
Three-phase AC
23.5 A @8 000 r/min (rpm), 14 V
Specifications are subject to change without notice, and may not apply to every country.
(CA): Canada Model
(CAL):California Model
(CH): Switzerland Model
(FR): France Model
(GB): United Kingdom Model
(MY): Malaysia Model
(US): United Sates Model
GENERAL INFORMATION 1-13
General Specifications
VN800-B8 ∼, B6F
Items
Dimensions
Overall Length
Overall Width
Overall Height
Wheelbase
Road Clearance
Seat Height
Dry Mass
Curb Mass:
Front
Rear
Fuel Tank Capacity
Performance
Minimum Turning Radius
Engine
Type
Cooling System
Bore and Stroke
Displacement
Compression Ratio
Maximum Horsepower
Maximum Torque
Carburetion System
Starting System
Ignition System
Timing Advance
Ignition Timing
Spark Plugs
Cylinder Numbering Method
Firing order
Valve Timing:
Inlet
Open
Close
Duration
Exhaust
Open
2 380 mm (93.7 in.), (CA) (US) 2 375 mm (93.5 in.)
940 mm (37.0 in.), (CA) (US) 930 mm (36.6 in.)
1 125 mm (44.3 in.), (CA) (US) 1 130 mm (44.5 in.)
1 600 mm (63.0 in.)
135 mm (5.3 in.)
705 mm (27.8 in.)
235 kg (518 lb), (CA) (US) 234 kg (516 lb), (CAL) 234.5 kg
(517 lb)
116 kg (255 lb), (CA) (US) 115 kg (254 lb)
138 kg (304 lb), (CAL) 138.5 kg (305 lb)
15.0 L (4.0 US gal)
2.9 m (9.5 ft)
4-Stroke, SOHC, V2-cylinder
Liquid-cooled
88.0 × 66.2 mm (3.46 × 2.61 in.)
805 cm³ (49.1 cu in.)
9.5: 1
40.5 kW (55 PS) @7 000 r/min (rpm),
(CA) 44.1 kW (60 PS) @7 500 r/min (rpm),
(US) – – –
64 N·m (6.5 kgf·m, 47.0 ft·lb) @3 300 r/min (rpm),
(CA) 64.7 N·m (6.6 kg, 47.7 ft·lb) @3 500 r/min (rpm),
(US) – – –
Carburetor, Keihin CVK36
Electric starter
Battery and coil (transistorized)
Electronically Advanced (digital igniter)
From 5.0° BTDC @1 000 r/min (rpm) to 37.5° BTDC @6 750
r/min (rpm)
(CAL) From 5.0° BTDC @1 300 r/min (rpm) to 37.5° BTDC @6
750 r/min (rpm)
NGK CR7E or ND U22ESR-N
Front to rear, 1-2
2-1
19° BTDC
71° ABDC
270°
69° BBDC
1-14 GENERAL INFORMATION
General Specifications
VN800-B8 ∼, B6F
Items
Close
Duration
Lubrication System
Engine Oil:
Grade
Viscosity
Capacity
Drive Train
Primary Reduction System:
Type
Reduction Ratio
Clutch Type
Transmission:
Type
Gear Ratios:
1st
2nd
3rd
4th
5th
Final Drive System:
Type
Reduction Ratio
Overall Drive Ratio
Frame
Type
Caster (Rake Angle)
Trail
Front Tire:
Type
Size
Rear Tire:
Type
Size
Front Suspension:
Type
Wheel Travel
Rear Suspension:
Type
Wheel Travel
Brake Type:
Front
Rear
31° ATDC
280°
Forced lubrication (wet sump)
API SE, SF, or SG,
API SH or SJ with JASO MA
SAE 10W-40
3.2 L (3.4 US qt)
Gear
2.184 (83/38)
Wet multi disc
5-speed, constant mesh, return shift
2.533
1.650
1.230
1.000
0.857
(38/15)
(33/20)
(32/26)
(29/29)
(24/28)
Chain Drive
2.470 (42/17)
4.625 @Top gear
Tubular, double cradle
32°
123 mm (4.8 in.)
Tube
130/90-16MC 67H
Tube
140/90-16MC 71H
Telescopic fork
150 mm (5.9 in.)
Swingarm (uni-trak)
100 mm (3.9 in.)
Single disc
Drum
GENERAL INFORMATION 1-15
General Specifications
Items
Electrical Equipment
Battery
Headlight:
Type
Bulb
Tail/brake Light
Alternator:
Type
Rated Output
VN800-B8 ∼, B6F
12 V 12 Ah (VN800-B8 Model)
12 V 10 Ah (VN800-B9 ∼ Model)
Semi-sealed beam
12 V 60/55 W (quartz-halogen)
12 V 5/21 W × 2
Three-phase AC
23.5 A @8 000 r/min (rpm), 14 V
Specifications are subject to change without notice, and may not apply to every country.
(CA): Canada Model
(CAL):California Model
(US): United Sates Model
1-16 GENERAL INFORMATION
Unit Conversion Table
Prefixes for Units:
Prefix
mega
kilo
centi
milli
micro
Symbol
M
k
c
m
μ
Units of Length:
×
×
×
×
×
Power
1 000 000
1 000
0.01
0.001
0.000001
Units of Mass:
kg
g
×
×
2.205
0.03527
=
=
lb
oz
km
m
mm
×
×
×
0.6214
3.281
0.03937
=
=
=
mile
ft
in
=
=
=
=
=
=
kgf·m
ft·lb
in·lb
N·m
ft·lb
in·lb
=
=
=
=
=
=
kgf/cm²
psi
cm Hg
kPa
psi
kPa
=
mph
=
=
=
=
PS
HP
kW
HP
Units of Torque:
N·m
N·m
N·m
kgf·m
kgf·m
kgf·m
×
×
×
×
×
×
0.1020
0.7376
8.851
9.807
7.233
86.80
Units of Pressure:
Units of Volume:
L
×
0.2642
=
L
L
L
L
L
mL
mL
mL
×
×
×
×
×
×
×
×
0.2200
1.057
0.8799
2.113
1.816
0.03381
0.02816
0.06102
=
=
=
=
=
=
=
=
gal (US)
gal (imp)
qt (US)
qt (imp)
pint (US)
pint (imp)
oz (US)
oz (imp)
cu in
×
×
×
×
0.1020
0.2248
9.807
2.205
Units of Temperature:
×
×
×
×
×
×
0.01020
0.1450
0.7501
98.07
14.22
1.333
Units of Speed:
km/h
×
0.6214
Units of Power:
Units of Force:
N
N
kg
kg
kPa
kPa
kPa
kgf/cm²
kgf/cm²
cm Hg
=
=
=
=
kg
lb
N
lb
kW
kW
PS
PS
×
×
×
×
1.360
1.341
0.7355
0.9863
PERIODIC MAINTENANCE 2-1
Periodic Maintenance
2
Table of Contents
Periodic Maintenance Chart (United
States and Canada)........................
Periodic Maintenance Chart (Other
than United States and Canada) ....
Torque and Locking Agent.................
Specifications ....................................
Special Tools .....................................
Maintenance Procedure ....................
Fuel System....................................
Fuel Hoses and Connections
Inspection..................................
Throttle Grip Play Inspection........
Idle Speed Inspection ..................
Fuel System Cleanliness
Inspection..................................
Air Cleaner Element Clean ..........
Evaporative Emission Control
System Inspection.....................
Cooling System...............................
Water Hoses and Connections
Inspection..................................
Coolant Change ...........................
Engine Top End ..............................
Air Suction Valve Inspection ........
Valve Clearance Inspection .........
Valve Clearance Adjustment........
Clutch..............................................
Clutch Inspection .........................
Engine Lubrication System .............
Engine Oil Change.......................
Oil Filter Replacement .................
Wheels/Tires...................................
Tire Wear Inspection ....................
Spoke Tightness and Rim Runout
Inspection..................................
Final Drive.......................................
Drive Chain Slack Inspection .......
Drive Chain Wear Inspection .......
2-2
2-4
2-6
2-10
2-12
2-13
2-13
2-13
2-13
2-14
2-15
2-15
2-16
2-16
2-16
2-16
2-18
2-18
2-18
2-19
2-22
2-22
2-23
2-23
2-24
2-24
2-24
2-25
2-26
2-26
2-27
Drive Chain Lubrication................
Brakes.............................................
Brake Lining or Pad Wear
Inspection..................................
Brake Play Inspection ..................
Brake Light Switch Inspection......
Brake Light Timing Adjustment ....
Brake Fluid Level Inspection........
Brake Fluid Change .....................
Bleeding the Brake Line...............
Brake Master Cylinder Cup and
Dust Cover Replacement .........
Caliper Fluid and Dust Seals
Replacement .............................
Brake Camshaft Lubricate ...........
Brake Hoses and Connections
Inspection..................................
Brake Hose Replacement ............
Suspension .....................................
Front Fork Oil Change .................
Front Fork Oil Leak Inspection.....
Rear Shock Absorber Oil Leak
Inspection..................................
Swingarm Pivot Lubrication .........
Uni-trak Linkage Lubrication ........
Steering ..........................................
Steering Inspection ......................
Steering Stem Bearing
Lubrication.................................
Electrical System ............................
Spark Plug Cleaning and
Inspection..................................
Spark Plug Gap Inspection ..........
General Lubrication ........................
Lubrication ..................................
Nut, Bolts, and Fasteners Tightness
Inspection.....................................
Tightness Inspection ....................
2-28
2-29
2-29
2-30
2-31
2-31
2-31
2-32
2-32
2-34
2-34
2-34
2-35
2-35
2-35
2-35
2-36
2-36
2-37
2-37
2-37
2-37
2-38
2-38
2-38
2-39
2-39
2-39
2-40
2-40
2-2 PERIODIC MAINTENANCE
Periodic Maintenance Chart (United States and Canada)
The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in
good running condition. The initial maintenance is vitally important and must not be neglected.
FREQUENCY Whichever
comes
first
* ODOMETER READING
km × 1 000 (mile × 1 000)
0.8
OPERATION
Every
Throttle grip play-inspect * †
Idle speed-Inspect *
Fuel system-inspect *
Evaporative emission control system
(CAL)-inspect †
Fuel hose-replace
4 years
Coolant-change
2 years
Water hoses, connections-inspect * †
year
Engine oil-change *
year
Oil filter-replace
Clutch-Inspect
Drive chain wear-inspect *# †
Drive chain-lubricate #
Drive chain slack-inspect *# †
300 km
800 km
Brake lining or pad wear-inspect * †
Brake fluid level-inspect * †
month
Brake fluid-change
2 years
Brake hose-replace
4 years
Brake hoses, connections-inspect †
Brake master cylinder cup and dust
cover-replace
Caliper fluid seal and dust seal-replace
• •
•
• •
•
•
• •
•
• •
• •
P2-16
• • • • • •
• • • • • • •
•
P2-29
• • • • • •
P2-35
P2-18
P2-18
P2-15
P2-13
P2-14
P2-15
P2-16
P2-13
–
P2-16
P2-23
P2-24
P2-22
P2-27
P2-28
P2-26
P2-31
P2-32
P2-35
P2-34
2 years
Brake camshaft-lubricate
2 years
Steering-inspect * †
Spoke tightness and rim runout-inspect * †
(9) (12) (15) (18) Page
2 years
Brake cable-replace
Tire wear-inspect * †
See
P2-34
Brake light switch-inspect * †
Front fork oil-change
30
2 years
Brake play-inspect * †
Steering stem bearing-lubricate
25
•
•
•
•
•
• • • • • • •
•
•
•
•
• • • • • • •
• • • • • •
•
Fuel hoses, connections-inspect †
20
P2-38
•
•
•
Air cleaner element-clean * †
• •
•
• •
•
•
• •
•
• •
• •
15
• •
•
• •
•
•
• •
•
• •
• •
•
Air suction valve-inspect *
10
(0.5) (3) (6)
Spark plug-clean and gap†
Valve clearance-inspect * †
5
years
• • • • • • •
• • • • • • •
•
•
• • • • • • •
•
•
• • • • • •
• • • • • • •
P2-30
P2-31
–
P2-34
P2-37
P2-38
P2-35
P2-24
P2-25
PERIODIC MAINTENANCE 2-3
Periodic Maintenance Chart (United States and Canada)
FREQUENCY Whichever
comes
first
* ODOMETER READING
km × 1 000 (mile × 1 000)
0.8
OPERATION
Swingarm pivot, uni-trak linkage-lubricate
General lubrication-perform
Nuts, bolts, and fasteners tightness-inspect
*†
Every
5
10
(0.5) (3) (6)
15
20
25
30
See
(9) (12) (15) (18) Page
•
•
•
• • • • • •
•
•
•
•
P2-37
P2-39
P2-40
#: Service more frequently when operating in severe conditions: dusty, wet, muddy, highspeed, or
frequent starting/stopping.
†: For higher odometer readings, repeat at the frequency interval established here.
*: Replace, add, adjust, clean, or torque if necessary.
CAL: California Model only
2-4 PERIODIC MAINTENANCE
Periodic Maintenance Chart (Other than United States and Canada)
The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in
good running condition. The initial maintenance is vitally important and must not be neglected.
FREQUENCY Whichever
comes
first
* ODOMETER READING
km × 1 000 (mile × 1 000)
1
OPERATION
Every
Oil filter-replace
Water hoses, connections-inspect †
Coolant-change
2 years
Clutch-Inspect
Drive chain wear-inspect † #
Drive chain-lubricate #
Drive chain slack-inspect † #
300 mm
800 km
Brake hoses, connections-inspect †
Brake lining or pad wear-inspect † #
Brake fluid level-inspect †
month
Brake fluid-change
2 years
Brake master cylinder cup and dust
cover-replace
Caliper fluid seal and dust seal-replace
• • • • • •
• • • • • •
• • • • • • •
•
P2-35
2 years
2 years
Front fork oil-change
2 years
Spoke tightness and rim runout-inspect
†
Swingarm pivot, uni-trak
linkage-lubricate
General lubrication-perform
P2-18
P2-18
P2-15
P2-13
P2-14
P2-13
P2-23
P2-24
P2-16
P2-22
P2-27
P2-28
P2-26
P2-29
P2-31
P2-32
P2-34
Steering stem bearing-lubricate
Tire wear-inspect †
• •
•
• •
•
•
•
• •
• •
•
4 years
Steering-inspect †
Rear shock absorber oil leak-inspect †
•
•
•
• •
•
• •
•
•
•
• •
• •
•
P2-34
Brake light switch-inspect †
Front fork oil leak-inspect †
See
4 years
Brake play-inspect †
Brake cable-replace
36
P2-16
•
•
6 months
30
•
• • • • • • •
• • • • • •
Air cleaner element-clean† #
Engine oil-change #
24
P2-38
Air suction valve-inspect †
Fuel hoses, connections-inspect †
18
• •
•
• •
•
•
•
• •
• •
•
Valve clearance inspect†
Idle speed-Inspect *
12
(0.6) (4) (7.5) (12) (15) (20) (24) Page
Spark plug-clean and gap †
Throttle grip play-inspect †
6
• • • • •
• • • • •
•
• • • • •
•
•
•
•
•
•
• • • •
• • • • •
•
•
•
•
• •
• •
P2-30
• •
P2-37
P2-31
–
P2-38
P2-35
•
•
• •
• •
•
•
P2-36
P2-36
P2-24
P2-25
P2-37
P2-39
PERIODIC MAINTENANCE 2-5
Periodic Maintenance Chart (Other than United States and Canada)
FREQUENCY Whichever
comes
first
* ODOMETER READING
km × 1 000 (mile × 1 000)
1
OPERATION
Nuts, bolts, and fastener
tightness-inspect †
Every
6
12
18
24
30
36
See
(0.6) (4) (7.5) (12) (15) (20) (24) Page
•
•
•
•
P2-40
#: 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.
2-6 PERIODIC MAINTENANCE
Torque and Locking Agent
The following tables list the tightening torque for the major fasteners requiring use of a
non-permanent locking agent or liquid gasket.
Letters used in the “Remarks” column mean:
L: Apply a non-permanent locking agent to the threads.
MO: Apply molybdenum disulfide oil (mixture of the engine oil and molybdenum disulfide grease in
a weight ratio 10:1).
O: Apply an oil to the threads, seating surface, or washer.
S: Tighten the fasteners following the specified sequence.
SS: Apply silicone sealant.
Fastener
N·m
Torque
kgf·m
ft·lb
Remarks
Fuel System
with white
washer
with black
washer
Fuel Tap Mounting Bolts
2.5
0.25
22 in·lb
Fuel Tap Mounting Bolts
4.9
0.50
43 in·lb
11
11
11
1.1
1.1
1.1
95 in·lb
95 in·lb
95 in·lb
11
11
2.0
18
7.8
11
1.1
1.1
0.2
1.8
0.8
1.1
95 in·lb
95 in·lb
17 in·lb
13
69 in·lb
95 in·lb
12
1.2
104 in·lb
39
25
12
25
25
49
20
11
12
7.8
4.0
2.5
1.2
2.5
2.5
5.0
2.0
1.1
1.2
0.8
29
18
104 in·lb
18
18
36
14.5
95 in·lb
104 in·lb
69 in·lb
132
8.8
12
13.5
0.9
1.2
98
78 in·lb
104 in·lb
L (1)
20
11
2.0
1.1
14.5
95 in·lb
L
Carburetor Holder Plate Mounting Bolts
Air Cleaner Element Cover Mounting Nut
Air Cleaner Housing Mounting Bolts
Cooling System
Water Pump Impeller Nut
Water Hose Fitting Bolts
Water Hose Clamp Screws
Radiator Fan Switch
Water Temperature Sensor
Coolant Drain Plug
Engine Top End
Cylinder Head Cover Bolts
Cylinder Head Nuts:
10 mm
8 mm
Cylinder Head Bolts
Cylinder Nuts
Camshaft Cap Bolts
Camshaft Sprocket Bolts
Camshaft Chain Tensioner Cap Bolts
Camshaft Chain Guide Bolts
Intake Manifold Bolts
Cylinder Head Cover Damper Plate Bolts
Clutch
Clutch Hub Nut
Clutch Spring Bolts
Right Engine Cover Bolts
Engine Lubrication System
Engine Drain Plug
Oil Pump Mounting Bolts
SS
SS
S
S
S
L
L
L,S
O
PERIODIC MAINTENANCE 2-7
Torque and Locking Agent
Fastener
Oil Pump Drive Chain Guide Bolt
Oil Filter
Oil Filter Plate Mounting Bolts
Oil Screen Plug
Oil Pressure Relief Valve
Oil Pressure Switch
Oil Pressure Switch Adapter
Oil Pipe Mounting Bolts (Crankcase Inside)
Oil Pipe Mounting Bolts (Crankcase Outside)
Oil passage Cover Screws (Crankcase Outside)
Engine Removal/Installation
Engine Mounting Nuts
Engine Mounting Bracket Bolts
Down Tube Mounting Bolts
Crankshaft/Transmission
Crankcase Bolts
10 mm
6 mm
Connecting Rod Big End Cap Nuts
Primary Gear Bolt
Balancer Gear Bolt
Starter Motor Clutch Gear Bolt
Starter Motor Clutch Bolts
Output Shaft Bearing Stopper Bolts
Balancer Shaft Bearing Stopper Bolts
Shift Drum Bearing Stopper Bolts
Transmission Cover Bolts
External Shift Mechanism Cover Bolts
Shift Shaft Return Spring Pin
Shift Drum Position Lever Bolt
Neutral Switch
Shift Pedal Pivot Bolt
Shift Pedal Pivot Bolt Nut
Shift Drum Cam Holder Screw
Shift Lever Clamp Bolt
Wheels/Tires
Front Axle Clamp Bolt
Front Axle Nut
Rear Axle Nut
Spoke Nipples
Final Drive
Engine Sprocket Nut
Rear Sprocket Nuts
N·m
12
18
7.8
20
15
15
20
11
5.4
5.4
Torque
kgf·m
1.2
1.8
0.8
2.0
1.5
1.5
2.0
1.1
0.55
0.55
ft·lb
104 in·lb
13
69 in·lb
14.5
11
11
14.5
95 in·lb
48 in·lb
48 in·lb
44
25
44
4.5
2.5
4.5
33
18
33
39
11
46
157
69
69
34
12
11
11
11
11
29
11
15
29
29
12
12
4.0
1.1
4.7
16
7.0
7.0
3.5
1.2
1.1
1.1
1.1
1.1
3.0
1.1
1.5
3.0
3.0
1.2
1.2
29
95 in·lb
34
116
51
51
25
104 in·lb
95 in·lb
95 in·lb
95 in·lb
95 in·lb
22
95 in·lb
11
22
22
104 in·lb
104 in·lb
34
108
98
4.9
3.5
11
10
0.5
25
80
72
43 in·lb
127
74
13
7.5
94
54
Remarks
L
L
SS
L
L
L
S
MO
O
L
L
L
L
L
MO
2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
Rear Sprocket Stud Bolts
Brakes
Torque Link Nuts
Front Caliper Mounting Bolts
Brake Disc Mounting Bolts
Brake Hose Banjo Bolts
Bleed Valve
Rear Brake Lever Clamp Bolt
Front Master Cylinder Clamp Bolts
Brake Lever Pivot Bolt
Brake Lever Pivot Bolt Locknut
Reservoir Cap Screws
Front Brake Light Switch Screws
Suspension
Front Fork Clamp Bolts:
upper
lower
Front Fork Bottom Allen Bolts
Spacer Allen Bolt
Rear Shock Absorber Nuts
Swingarm Pivot Shaft Nut
Rocker Arm Pivot Shaft Nut
Tie-Rod Nuts
Fork Cover Bolts 5 mm
Fork Cover Bolts 6 mm
Steering
Handlebar Holder Bolts
Handlebar Holder Mounting Nuts
Steering Stem Head Bolt
Steering Stem Nut
Frame
Side Stand Pivot Nut
Rear Frame Mounting Bolts
Muffler Bracket Mounting Bolts
Hootpeg Holder Bolts
Electrical System
Alternator Cover Bolts
Timing Inspection Cover Screw
Alternator Rotor Bolt
Stator Coil Bolts
Pickup Coil Bolts
Alternator Lead Clamp Bolts
Spark Plugs
N·m
-
Torque
kgf·m
-
ft·lb
-
34
34
27
34
7.8
25
8.8
1.0
5.9
1.5
1.2
3.5
3.5
2.8
3.5
0.8
2.5
0.90
0.1
0.6
0.15
0.12
25
25
20
25
69 in·lb
18
78 in·lb
9 in·lb
52 in·lb
13 in·lb
10 in·lb
20
34
20
4.4
59
98
98
59
8
13
2.0
3.5
2.0
0.45
6.0
10
10
6.0
0.8
1.3
14.5
25
14.5
39 in·lb
43
72
72
43
11 in·lb
113 in·lb
34
34
44
4.9
3.5
3.5
4.5
0.5
25
25
33
43 in·lb
44
44
25
34
4.5
4.5
2.5
3.5
33
33
18
25
12
4.9
157
13
7.8
7.8
18
1.2
0.5
16
1.3
0.8
0.8
1.8
104 in·lb
43 in·lb
115
113 in·lb
69 in·lb
69 in·lb
13
Remarks
L
L
L
L (1)
O
PERIODIC MAINTENANCE 2-9
Torque and Locking Agent
Fastener
Starter Motor Mounting Bolts
Starter Motor Through Bolts
Starter Motor Terminal Nut
Starter Motor Cable Nuts
Side Stand Switch Mounting Bolt
N·m
11
4.9
11
4.9
3.9
Torque
kgf·m
1.1
0.5
1.1
0.5
0.4
ft·lb
95 in·lb
43 in·lb
95 in·lb
43 in·lb
35 in·lb
Remarks
L
The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and
nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the
values are for use with dry solvent-cleaned threads.
Basic Torque for General Fasteners
Threads
dia. (mm)
5
6
8
10
12
14
16
18
20
N·m
3.4 ∼ 4.9
5.9 ∼ 7.8
14 ∼19
25 ∼ 34
44 ∼ 61
73 ∼ 98
115 ∼ 155
165 ∼ 225
225 ∼ 325
Torque
kgf·m
0.35 ∼ 0.50
0.60 ∼ 0.80
1.4 ∼1.9
2.6 ∼ 3.5
4.5 ∼ 6.2
7.4 ∼ 10.0
11.5 ∼ 16.0
17.0 ∼ 23.0
23 ∼ 33
ft·lb
30 ∼ 43 in·lb
52 ∼ 69 in·lb
10.0 ∼ 13.5
19.0 ∼ 25
33 ∼ 45
54 ∼ 72
83 ∼ 115
125 ∼ 165
165 ∼ 240
2-10 PERIODIC MAINTENANCE
Specifications
Item
Fuel System
Throttle Grip Free Play
Idle Speed
Air Cleaner Element
Cooling System
Coolant:
Type (recommended)
Color
Mixed ratio
Freezing point
Total amount
Engine Top End
Valve Clearance:
Inlet
Exhaust
Clutch
Clutch Lever Free Play
Engine Lubrication System
Engine Oil:
Type
Viscosity
Capacity
Level
Tires
Tread Depth:
Front
DUNLOP
BRIDGESTONE
Rear
DUNLOP
BRIDGESTONE
Standard
Service Limit
– – –
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
1 000 ±50 r/min (rpm)
(CH, CAL) 1 300 ±50 r/min (rpm)
Polyurethane foam
– – –
Permanent type antifreeze
Green
Soft water 50%, Coolant 50%
–35°C (–31°F)
2.4 L (2.5 US qt.)
– – –
0.10 ∼ 0.15 mm (0.004 ∼ 0.006 in.)
0.20 ∼ 0.25 mm (0.008 ∼ 0.010 in.)
– – –
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
– – –
API SE, SF or SG
API SH or SJ with JASO MA
SAE 10W-40
2.7 L (2.9 US qt, when filter is not
removed)
2.9 L (3.1 US qt, when filter is
removed)
3.2 L (3.4 US qt, when engine is
completely dry)
Between upper and lower level lines
(Wait 2 ∼ 3 minutes after idling or
running)
4.5 mm (0.18 in.)
4.8 mm (0.19 in.)
1 mm (0.04 in.)
(DE, AT, CH)
1.6 mm (0.06 in.)
7.3 mm (0.29 in.)
Up to 130 km/h (80 mph):
2 mm (0.08 in.)
7.2 mm (0.28 in.)
Over 130 km/h (80 mph):
3 mm (0.12 in.)
PERIODIC MAINTENANCE 2-11
Specifications
Item
Rim Runout (with tire installed)
Radial
Axial
Final Drive
Drive Chain Slack
Drive Chain Wear (20-link
length)
Brakes
Brake fluid:
Standard
TIR 1.0 mm (0.04 in.) or less
TIR 0.8 mm (0.03 in.) or less
25 ∼ 35 mm (1.0 ∼ 1.4 in.)
317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)
Service Limit
TIR 2.0 mm (0.08 in.)
TIR 2.0 mm (0.08 in.)
– – –
323 mm (12.7 in.)
– – –
Grade
Brake pad lining thickness:
Inner
DOT4
4.5 mm (0.18 in.)
1 mm (0.04 in.)
Outer
Brake light timing:
Front
4.7 mm (0.19 in.)
1 mm (0.04 in.)
Rear
Suspension
Fork Oil:
Viscosity
Amount: When changing oil
disassembly and completely
dry
Fork oil level: (fully
compressed, without spring,
below from the top of the inner
tube)
Electrical System
Spark plug gap
(AT): Austria Model
(CAL):California Model
(CH): Switzerland Model
(DE): Germany Model
Pulled ON
ON after about 15 mm (0.6 in.) of
pedal travel
– – –
– – –
SHOWA SS8 or equivalent
approx. 265 mL (9.0 US oz)
310 ±4 mL (10.5 ±0.14 US oz)
– – –
– – –
– – –
286 ±2 mm (11.26 ±0.08 in.)
– – –
0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)
– – –
2-12 PERIODIC MAINTENANCE
Special Tools
Steering Stem Nut Wrench:
57001-1100
Carburetor Drain Plug Wrench, Hex 3:
57001-1269
Jack:
57001-1238
Fork Oil Level Gauge:
57001-1290
Oil Filter Wrench:
57001-1249
Jack Attachment #3:
57001-1416
PERIODIC MAINTENANCE 2-13
Maintenance Procedure
Fuel System
Fuel Hoses and Connections Inspection
○The fuel hoses are designed to be used throughout the
•
•
•
motorcycle’s life without any maintenance, however, if the
motorcycle is not properly handled, the inside the fuel line
can cause fuel to leak [A] or the hose to burst. Remove
the fuel tank (see Fuel System chapter) and check the
fuel hose.
Replace the fuel hose if any fraying, cracks [B] or bulges
[C] are noticed.
Check that the hoses are securely connected and clamps
are tightened correctly.
When installing, route the hoses according to Cable,
Wire, and Hose Routing section in the Appendix chapter.
When installing the fuel hoses, avoid sharp bending, kinking, flattening or twisting, and route the fuel hoses with a
minimum of bending so that the fuel flow will not be obstructed.
Replace the hose if it has been sharply bent or kinked.
the fuel hose [A] onto the pipe fully and install the plate
• Fit
clamp [B] beyond the raised rib [C].
1 ∼ 2 mm (0.04 ∼0.08 in.) [D]
Throttle Grip Play Inspection
the throttle grip free play [A].
• Check
If the free play is incorrect, adjust the throttle cable.
Throttle Grip Free Play
Standard:
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
that the throttle grip moves smoothly from full open
• Check
to close, and the throttle closes quickly and completely in
•
all steering positions by the return spring.
If the throttle grip does not return properly, check the throttle cable routing, grip free play, and cable damage. Then
lubricate the throttle cable.
Run the engine at the idle speed, and turn the handlebar
all the way to the right and left to ensure that the idle speed
does not change.
If the idle speed increase, check the throttle cable free
play and the cable routing.
2-14 PERIODIC MAINTENANCE
Maintenance Procedure
•
•
•
•
•
•
•
•
•
•
•
•
•
•
If necessary, adjust the throttle cable as follows.
Loosen the locknuts [A].
Screw the adjusters [B] in completely so as to give the
throttle grip plenty of play.
Turn out the decelerator cable [C] adjuster until there is
no play when the throttle grip is completely closed.
Tighten the locknut.
Turn the accelerator cable [D] adjuster until the proper
amount of throttle grip free play is obtained.
Tighten the locknut.
If the proper amount of free play cannot be obtained by
using the adjusters, use the adjusters middle of the throttle cables.
First give the throttle grip plenty of play by turning the
adjusters at the grip in fully.
Remove the fuel tank (see Fuel Tank Removal).
Loosen the locknuts [A].
Turn the adjusters [B] fully at the middle of the throttle
cables so as to give the throttle grip plenty of play.
With the throttle grip completely closed, turn the decelerator cable [C] adjuster until the inner cable just becomes
tight.
Tighten the locknut.
Turn the accelerator cable [D] adjuster until the correct
throttle grip free play is obtain.
Tighten the locknut.
Idle Speed Inspection
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 before riding (see Cable, Wire, and Hose
Routing section in the Appendix chapter).
•
•
WARNING
Operation with improperly adjusted, incorrectly
routed, or damaged cables could result in an unsafe riding condition.
idle speed.
• Check
If the idle speed is out of the specified range, adjust it.
Idle Speed
Standard:
1 000 ±50 r/min (rpm)
1 300 ±50 r/min (rpm) (Switzerland,
California Model)
PERIODIC MAINTENANCE 2-15
Maintenance Procedure
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 throttle a few times to make sure that
the idle speed is within the specified range. Readjust if
necessary.
•
•
Fuel System Cleanliness Inspection
WARNING
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.
the fuel tank (see Fuel System chapter)
• Remove
Connect
a suitable hose [A] to the fitting at the bottom of
• the carburetor
float bowl.
Run
the
lower
end
of the hose into a suitable container.
• Turn out the drain plug
[B] a few turns and drain the float
• bowl.
Special Tool - Carburetor Drain Plug Wrench, Hex 3:
57001-1269
to see if water or dirt comes out.
• Check
Tighten
the drain plug.
• If any water
or dirt appears during the above inspection,
clean the fuel system (see Carburetor Cleaning and Fuel
Tank Cleaning in Fuel System Chapter).
Air Cleaner Element Clean
the air cleaner element (see Fuel System chap• Remove
ter).
the element by tapping it lightly to loosen dust.
• Clean
Blow
away
the remaining dust by applying compressed
• air [A] from the
inside to the outside (from the clean side
•
to the dirty side).
Visually check the element for tears or breaks and check
the sponge gasket [B] also.
If the element has any tears or breaks, replace the element.
2-16 PERIODIC MAINTENANCE
Maintenance Procedure
Evaporative Emission Control System Inspection
the California canister as follows:
•○Inspect
Remove the canister, and disconnect the hoses from the
canister.
○Visually insect the canister for cracks for cracks and other
damage.
If the canister has any cracks or bad damage, replace it
with a new one.
NOTE
○The canister is designed to work well through the motorcycle’s life without any maintenance if it is used under
normal conditions.
the California liquid/vapor separator as follows:
•○Check
Disconnect the hoses from the liquid/vapor separator, and
remove the separator from the motorcycle.
○Visually inspect the separator for cracks and other damage.
If the separator has any cracks or is badly damaged, replace it with a new one.
Check the hoses of the California evaporative emission
control system as follows:
○Check that the hoses are securely connected and clips
are in position.
○Replace any kinked, deteriorated or damaged hoses.
○Route the hoses according to Cable, Wire, and Hose
Routing section in the Appendix chapter.
○When installing the hoses, avoid sharp bending, kinking,
flattening or twisting, and route the hoses with a minimum
of bending so that the emission flow will not be obstructed.
•
Cooling System
Water Hoses and Connections Inspection
○The
•
high pressure inside the water hose can cause
coolant to leak [A] or the hose to burst if the line is not
properly maintained. Visually inspect the hoses for signs
of deterioration. Squeeze the hoses. A hose should not
be hard and brittle, nor should it be soft or swollen.
Replace the hose if any fraying, cracks [B] or bulges [C]
are noticed.
Check that the hoses are securely connected and clamps
are tightened correctly.
Torque - Water Hose Clamp Screws: 2.0 N·m (0.20 kgf·m,
17 in·lb)
Coolant Change
WARNING
To avoid burns, do not remove the radiator cap or
try to change the coolant when the engine is still
hot. Wait until it cools down. Coolant on tires will
make them slippery and can cause an accident
and injury. Immediately wipe up or wash away any
coolant that spills on the frame, engine, or other
painted parts.
Since coolant is harmful to the human body, do not
use for drinking.
PERIODIC MAINTENANCE 2-17
Maintenance Procedure
• Remove:
Meter Unit (see Electrical System chapter)
Radiator Cap [A]
a container under the drain plug [A] at the bottom
• Place
of the right crankcase.
the coolant from the radiator and engine by remov• Drain
ing the drain plug.
the cap and pump out the coolant using a syringe
• Remove
or some other suitable device.
• Tighten:
Torque - Coolant Drain Plug: 11 N·m (1.1 kgf·m, 95 in·lb)
the radiator up to the radiator filler neck [A] with
• Fill
coolant, and install the radiator cap.
NOTE
○Pour in the coolant slowly so that it can expel the air
from the engine and radiator.
the reserve tank up to the full (“F”) level line with
• Fill
coolant, and install the cap.
CAUTION
Soft or distilled water must be used with the antifreeze (see below for antifreeze) in the cooling system.
If hard water is used in the system, it causes scales
accumulation in the water passages, and considerably reduces the efficiency of the cooling system.
Water and Coolant Mixture Ratio (Recommended)
Soft Water:
50%
Coolant:
50%
Freezing Point:
–35°C (–31°F)
Total Amount:
2.4 L (2.1 US qt)
NOTE
○Choose a suitable mixture ratio by referring to the
coolant manufacturer’s directions.
2-18 PERIODIC MAINTENANCE
Maintenance Procedure
the air from the cooling system as follows.
•○Bleed
Start the engine with the radiator cap removed and run it
until no more air bubbles [A] can be seen in the coolant.
○Tap the water hoses to force any air bubbles caught inside.
○Stop the engine and add coolant up to the radiator filler
neck.
Install the radiator cap.
start the engine, warm it up thoroughly until the radiator
fan turns on and then stop the engine.
Check the coolant level in the reserve tank after the engine cools down.
If the coolant level is lower than the low level line, add
coolant to the full level line.
•
•
•
CAUTION
Do not add more coolant above the full level line.
Engine Top End
Air Suction Valve Inspection
insect the reed [A] for cracks, folds, warps, heat
• Visually
damage, or other damage.
•
If there is any doubt as to the condition of the reed, replace
the air suction valve as an assembly.
Check the reed contact areas [B] of the valve holder for
grooves, scratches, any signs of separation form the
holder, or heat damage.
If there is any doubt as to the condition of the reed contact
areas, replace the air suction valve as an assembly.
If any carbon or other foreign particles have accumulated
between the reed and the reed contact area, wash the
valve assembly with a high flash-point solvent.
CAUTION
Do not scrape off the deposits with a scraper as this
could damage the rubber, requiring replacement of
the suction valve assembly.
Valve Clearance Inspection
NOTE
○Valve clearance must be checked and adjusted when
the engine is cold (at room temperature).
• Remove:
Cylinder Head Cover (see Engine Top End chapter)
•
•
Timing Inspection Cover (Engine Left Side)
Set the front piston at TDC (see Engine Top End chapter).
Using a thickness gauge [A], measure the valve clearance
between the rocker arm [B] and the shim [C].
PERIODIC MAINTENANCE 2-19
Maintenance Procedure
the rear piston at TDC by turning the crankshaft coun• Set
terclockwise 305° (see Engine Top End chapter).
a thickness gauge, measure the valve clearance
• Using
between the rocker arm and the shim.
Valve Clearance
Standard:
IN:
0.10∼ 0.15 mm (0.0039 ∼ 0.0059 in.)
EX:
0.20 ∼ 0.25 mm (0.079 ∼ 0.010 in.)
If the valve clearance is not within the specified range,
first record the clearance, and then adjust it.
Valve Clearance Adjustment
change the valve clearance, side the rocker arm [A]
• To
sideways and change the shim [B]. Replace the shim with
one of a different thickness.
NOTE
○Mark and record the shim locations so that the shims
can be reinstalled in their original positions.
○If there is no clearance, select a shim which is several
sizes smaller and then measure the clearance.
select a new shim which brings the valve clearance
• To
within the specified range, refer to the Valve Clearance
•
Adjustment Charts.
Remeasure any valve clearance that was adjusted.
Readjust if necessary.
CAUTION
Do not put shim stock under the shim. This may
cause the shim to pop out at high rpm, causing extensive engine damage.
Do not grind the shim. This may cause it to fracture,
causing extensive engine damage.
2-20 PERIODIC MAINTENANCE
Maintenance Procedure
VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE
1.
2.
3.
4.
Measure the clearance (when engine is cold).
Check present shim size.
Match clearance in vertical column with present shim size in horizontal column.
Install the shim specified where the lines intersect. This shim will give the proper clearance.
Example:
Present shim is 2.60 mm (0.102 in.)
Measured clearance is 0.25 mm (0.010 in.)
Replace 2.60 mm (0.102 in.) shim with 2.70 mm (0.106 in.) shim.
5. Remeasure the valve clearance and readjust if necessary.
NOTE
○If there is no clearance, select a shim which is several
sizes smaller and then measure the clearance.
PERIODIC MAINTENANCE 2-21
Maintenance Procedure
VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE
1.
2.
3.
4.
Measure the clearance (when engine is cold).
Check present shim size.
Match clearance in vertical column with present shim size in horizontal column.
Install the shim specified where the lines intersect. This shim will give the proper clearance.
Example:
Present shim is 2.55 mm (0.100 in.)
Measured clearance is 0.50 mm (0.020 in.)
Replace 2.55 mm (0.100 in.) shim with 2.75 mm (0.108 in.) shim.
5. Remeasure the valve clearance and readjust if necessary.
NOTE
○If there is no clearance, select a shim which is several
sizes smaller and then measure the clearance.
2-22 PERIODIC MAINTENANCE
Maintenance Procedure
Clutch
Clutch Inspection
Clutch Lever Free Play Inspection
Pull the clutch lever just enough to take up the free play
[A].
Measure the gap between the lever and the lever holder.
If the gap is too wide, the clutch may not release fully. If
the gap is too narrow, the clutch may not engage fully. In
either case, adjust it.
•
•
Clutch Lever Free Play
Standard:
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
Clutch Lever Free Play Adjustment
Loosen the locknut [A] at the clutch lever.
Turn the adjuster [B] until the proper amount of clutch
lever free play is obtained.
Tighten the locknut securely.
If it cannot be done, use the adjuster at the middle of the
cable.
•
•
•
WARNING
To avoid a serious burn, never touch the engine or
exhaust pipe during clutch adjustment.
the locknut [A] at the middle of the clutch cable.
• Loosen
Turn
the
nut [B] until the proper amount of clutch
• lever freeadjuster
play is obtained.
Tighten
the
securely.
• If it cannot belocknut
done, use the mounting nuts at the lower
end of the cable.
• Remove:
Front Right Foot Peg and Brake Petal (see Brakes chap•
•
ter)
Front muffler (see Engine Top End chapter)
Loosen the locknut [A] at the clutch lever.
Turn the adjuster [B] so that 5 ∼ 6 mm (0.20 ∼ 0.24 in.) [C]
of threads are visible
PERIODIC MAINTENANCE 2-23
Maintenance Procedure
the dust cover [A] at the clutch cable lower end out
• Slide
of place.
both adjusting nuts [B] at the clutch cover as far
• Loosen
as they will go.
the clutch outer cable [C] tight and tighten the adjust• Pull
ing nuts against the bracket [D].
the rubber dust cover back onto place.
• Slip
the adjuster at the clutch lever until the free play is
• Turn
correct.
• Tighten the knurled locknut at the clutch lever.
WARNING
Be sure that the outer cable end at the clutch lever
is fully seated in the adjuster at the clutch lever, or
it could slip into place later, creating enough cable
play to prevent clutch disengagement.
the adjustment, start the engine and check that the
• After
clutch does not slip and that it releases properly.
Engine Lubrication System
Engine Oil Change
the motorcycle so that it is vertical after warming
• Situate
up the engine.
the engine drain plug [A] to drain the oil.
•○Remove
The oil in the oil filter can be drained by removing the filter
•
(see Oil Filter Replacement).
Replace the drain plug gasket [B] with a new one if it is
damaged.
Tighten the drain plug.
Torque - Engine Oil Drain Plug: 20 N·m (2.0 kgf·m, 14.5 ft·lb)
• Pour in the specified type and amount of oil.
Recommended Engine Oil
Type:
API SE, SF or SG
API SH or SJ with JASO MA
Viscosity:
SAE 10W40
Capacity:
2.7 L (2.9 US qt) (when filter is not
removed)
2.9 L (3.1 US qt) (when filter is removed)
3.2 L (3.4 US qt) (when engine is
completely dry)
○Although
NOTE
10W-40 engine oil is the recommended oil
for most conditions, the oil viscosity may need to be
changed to accommodate atmospheric conditions in
your riding area.
2-24 PERIODIC MAINTENANCE
Maintenance Procedure
Oil Filter Replacement
the engine oil (see Engine Oil Change).
• Drain
Remove
the oil filter [A] with the oil filter wrench [B].
•
Special Tool - Oil Filter Wrench: 57001-1249
the filter with a new one.
• Replace
Apply
engine
oil to the gasket [A] before installation.
• Tighten the filter
with the oil filter wrench.
•
Torque - Oil Filter: 18 N·m (1.8 kgf·m, 13 ft·lb)
NOTE
○Hand tightening of the oil filter can not be allowed since
it does not reach to this tightening torque.
in the specified type and amount of oil (see Engine
• Pour
Oil Change).
Wheels/Tires
Tire Wear Inspection
As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is
that 90% of all tire failures occur during the last 10% of tread
life (90% worn). So it is false economy and unsafe to use
the tires until they are bald.
Visually inspect the tire for cracks [A] and cuts [B], replacing the tire in case of damage. Swelling or high spots
indicate internal damage, requiring tire replacement.
Remove any imbedded stones [D], nail [C] or other foreign
particles from the tread.
Wear Indicator Position Mark [E]
•
•
the tread depth at the center of the tread with a
• Measure
depth gauge [A]. Since the tire may wear unevenly, take
measurement at several places.
If any measurement is less than the service limit, replace
the tire.
Tread Depth
Standard:
Front:
4.8 mm (0.19 in.) (BRIDGESTONE),
4.5 mm (0.18 in.) (DUNLOP)
Rear:
7.2 mm (0.28 in.) (BRIDGESTONE)
7.3 mm (0.29 in.) (DUNLOP)
Service Limit:
Front:
1 mm (0.04 in.)
Rear:
(DE, AT, CH) 1.6 mm (0.06 in.)
2 mm (0.08 in.) (Up to 130 km/h)
3 mm (0.12 in.) (Over 130 km/h)
PERIODIC MAINTENANCE 2-25
Maintenance Procedure
Wear Indicator [A]
Wear Indicator Position Mark [B]
WARNING
To ensure safe handling and stability, use only the
recommended standard tires for replacement, inflated to the standard pressure.
NOTE
○Most countries may have their own regulations a minimum tire tread depth: be sure to follow them.
○Check and balance the wheel when a tire is replaced
with a new one.
Spoke Tightness and Rim Runout Inspection
that all the spokes are tightened evenly.
• Check
If spoke tightness is uneven or loose, tighten the spoke
nipples evenly.
Torque - Spoke Nipples: 4.9 N·m (0.5 kgf·m, 43 in·lb)
• Check the rim runout.
WARNING
If any spoke breaks, it should be replaced immediately. A missing spoke places an additional load on
the other spokes, which will eventually cause other
spokes to break
• Raise the front/rear wheel off the ground.
Special Tool - Jack: 57001-1238
Jack Attachment #3: 57001-1416
the wheel lightly, and check for roughness or binding.
• Spin
If roughness or binding is found, replace the hub bearings.
the rim for small cracks, dents, bending, or warp• Inspect
ing.
If there is any damage to the rim, it must be replaced.
NOTE
○Avoid the curved part and the uneven part, and measure the rim runout on the side without the mark.
2-26 PERIODIC MAINTENANCE
Maintenance Procedure
the axial [A] and radial [B] rim runout with a dial
• Measure
gauge.
If rim runout exceeds the service limit, check the hub
bearings first. Replace them if they are damaged. If the
problem is not due to the bearings, correct the rim warp
(runout). A certain amount of rim warp can be corrected
by recentering the rim. Loosen some spokes and tighten
others within the standard torque to change the position
of different parts of the rim. If the rim is badly bent, however, it must be replaced.
Rim Runout (with tire installed)
Standard:
Radial
TIR 1.0 mm (0.04 in.) or less
Axial
TIR 0.8 mm (0.03 in.) or less
Service Limit:
Radial
TIR 2.0 mm (0.08 in.)
Axial
TIR 2.0 mm (0.08 in.)
Final Drive
Drive Chain Slack Inspection
Drive Chain Slack Inspection
NOTE
○Check the slack with the motorcycle setting on its side
stand.
○Clean the chain if it is dirty, and lubricate it if it appears
dry.
the wheel alignment (see Wheel Alignment Inspec• Check
tion/Adjustment section in Final Drive chapter).
the rear wheel to find the position where the chain
• Rotate
is tightest.
the vertical movement (chain slack) [A] midway
• Measure
between the sprockets.
If the chain slack exceeds the standard, adjust it.
Drive Chain Slack Adjustment
Standard:
25 ∼ 35 mm (1.0 ∼ 1.4 in.)
PERIODIC MAINTENANCE 2-27
Maintenance Procedure
Drive Chain Slack Adjustment
Remove:
Muffler (see Engine Top End chapter)
Clip [A]
Loosen:
Rear Torque Link Nut [B]
Axle Nut [C]
Chain Adjuster Locknuts [D] (both sides)
Turn the chain adjusting nuts [E] forward or rearward until
the drive chain has the correct amount of chain slack.
The right and left notches on the alignment indicators
should point to the same marks or positions on the
swingarm.
•
•
•
•
WARNING
Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.
both chain adjuster locknuts securely.
• Tighten
Tighten
the
axle nut (see Rear Wheel Installation section
• in Wheels/Tires
chapter).
Torque - Rear Axle Nut: 98 N·m (10 kgf·m, 72 ft·lb)
the wheel, measure the chain slack again at the tight• Turn
est position, and readjust if necessary.
• Tighten:
Torque - Torque Link Nuts: 34 N·m (3.5 kgf·m, 25 in·lb)
the clip to the rear axle and torque link bolt.
• Install
• Check the rear brake.
Drive Chain Wear Inspection
• Remove:
Chain Cover
Rotate
the rear wheel to inspect the drive chain for dam• aged rollers,
and loose pins and links.
•
•
If there is any irregularity, replace the drive chain.
Lubricate the drive chain if it appears dry.
Stretch the chain taut by hanging a 98 N (10 kg, 20 lb)
weight [A] on the chain.
Measure the length of 20 links [B] on the straight part [C] of
the chain from the pin center of the 1st pin to the pin center
of the 21st pin. Since the chain may wear unevenly, take
measurements at several places.
If any measurements exceed the service limit, replace the
chain. Also, replace the front and rear sprockets when the
drive chain is replaced.
Drive Chain 20-link Length
Standard:
317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)
Service Limit: 323 mm (12.7 in.)
2-28 PERIODIC MAINTENANCE
Maintenance Procedure
WARNING
If the drive chain wear exceeds the service limit, replace the chain or an unsafe riding condition may
result. A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the
rear wheel, severely damaging the motorcycle and
causing it to go out of control.
For safety, use only the standard chain.
Standard Chain
Make:
ENUMA
Type:
EK 50 MV-0, Endless
EK50 MV-X, (VN800-B6 ∼, B6F)
Link:
112 Links
Drive Chain Lubrication
a special lubricant is not available, a heavy oil such as
• IfSAE
90 is preferred to a lighter oil because it will stay on
•
the chain longer and provide better lubrication.
If the chain appears especially dirty, clean it before lubrication.
CAUTION
The O-rings between the side plates seal in the lubricant between the pin and the bushing. To avoid
damaging the O-rings and resultant loss of lubricant, observe the following rules.
Use only kerosene or diesel oil for cleaning of the
O-ring of the drive chain.
Any other cleaning solution such as gasoline
or trichloroethylene will cause deterioration and
swelling of the O-ring.
Immediately blow the chain dry with compressed air
after cleaning.
Complete cleaning and drying the chain within 10
minutes.
oil to the sides of the rollers so that oil will penetrate
• Apply
to the rollers and bushings. Apply the oil to the O-rings so
•
that the O-rings will be coated with oil.
Wipe off any excess oil.
Oil Applied Areas [A]
O-ring [B]
PERIODIC MAINTENANCE 2-29
Maintenance Procedure
Brakes
Brake Lining or Pad Wear Inspection
the brake shoes (see Brake Panel Disassembly).
• Remove
Measure
the lining thickness [A].
•○Use a calipers
or scale, and measure at several points as
shown.
If any measurement is less than the service limit, replace
both shoes as a set.
If the lining thickness is greater than the service limit, do
the following before installing the shoes.
○File or sand down any high spots on the surface if the
lining.
○Use a wire brush to remove any foreign particles from the
lining.
Shoe Lining Thickness
Standard:
4.9 ∼ 5.5 mm (0.19 ∼ 0.22 in.)
Service Limit:
2.6 mm (0.10 in.)
off any oil or grease with an oilles cleaning fluid
• Wash
such as trichlorethylene or acetone.
WARNING
There cleaning fluid are usually highly flammable
and harmful if breathed for prolonged periods. Be
sure to heed the fluid manufacture’s warnings.
the brake pad.
• Remove
Inner Pad [A]
•
Outer Pad [B]
Check the lining thickness [C] of the pads in each caliper.
If the lining thickness of either pad is less than the service
limit [D], replace both pads in the caliper as a set.
Pad Lining Thickness
Standard:
Inner Pad
4.5 mm (0.18 in.)
Outer Pad
4.7 mm (0.19 in.)
Service Limit:
1.0 mm (0.04 in.)
2-30 PERIODIC MAINTENANCE
Maintenance Procedure
Brake Play Inspection
Brake Pedal Position Inspection
Check that the brake pedal [A] is in the correct position.
[B] Footpeg
•
Pedal Position [C]
Standard:
About 65 mm (2.6 in.) above footpeg top
If it is incorrect, adjust the brake pedal position.
Brake Pedal Position Adjustment
Loosen the locknut [A], and turn the adjusting bolt [B] until
the brake pedal is correctly positioned.
Tighten the locknut.
Check:
Rear Brake Light Switch
Brake pedal Free Play
•
•
•
NOTE
○If the pedal position cannot be adjusted by turning the
adjusting bolt, the brake pedal may be deformed or incorrectly installed.
Brake Pedal Free Play Inspection
Check the brake pedal free play [A].
○Depress the rear brake pedal lightly by hand until the
brake is applied.
If the free play is incorrect, adjust it.
•
Pedal Free Play
Standard:
20 ∼ 30 mm (0.8 ∼ 0.12 in.)
If the pedal has improper play, adjust it.
Brake Pedal Free Play Adjustment
Turn the adjusting nut [A] at the rear brake until the brake
pedal has the correct amount of play.
Operate the pedal a few times to see that it returns to its
rest position immediately upon release.
Rotate the rear wheels to check for brake drag.
Check braking effectiveness.
If there is any doubt as to the conditions of the brake,
check the brake parts for wear or damage.
•
•
•
•
PERIODIC MAINTENANCE 2-31
Maintenance Procedure
Brake Light Switch Inspection
on the ignition switch.
• Turn
Check
of the rear brake light switch by de• pressingthetheoperation
brake pedal.
If it does not as specified, adjust the brake light timing.
Brake Light Timing
Standard:
On after about 15 mm (0.6 in.) of pedal
travel [A]
Brake Light Timing Adjustment
Brake light timing is adjusted by changing the position of
the rear brake light switch [A].
Adjust the position of the switch so that the brake light
goes on after the specified pedal travel by turning the adjusting nut [B].
•
CAUTION
To avoid damaging the electrical connections inside the switch, be sure that the switch body does
not turn during adjustment.
Brake Fluid Level Inspection
that the brake fluid level in the front brake reservoir
• Check
[A] is above the lower level line [B].
NOTE
○Hold the reservoir horizontal by turning the handlebar
when checking brake fluid level.
If the fluid level is lower than the lower level line, fill the
reservoir to the upper level line [A].
WARNING
Change the brake fluid in the brake line completely
if the brake fluid must be refilled but the type and
brand of the brake fluid that is already in the reservoir are unidentified. After changing the fluid, use
only the same type and brand of fluid thereafter.
Recommended Disc Brake Fluid
Grade:
DOT4
2-32 PERIODIC MAINTENANCE
Maintenance Procedure
Brake Fluid Change
NOTE
○The procedure to change the front brake fluid is as follows.
the brake fluid reservoir.
• Level
Remove
reservoir cap.
• Remove the
the
• caliper. rubber cap from the bleed valve [A] on the
a clear plastic hose [B] to the bleed valve, and run
• Attach
the other end of the hose into a container.
• Fill the reservoir with fresh specified brake fluid.
the brake fluid.
•○Change
Repeat this operation until fresh brake fluid comes out
from the plastic hose or the color of the fluid changes.
1. Open the bleed valve [A].
2. Apply the brake and hold it [B].
3. Close the bleed valve [C].
4. Release the brake [D].
NOTE
○The fluid level must be checked often during the changing operation and replenished with fresh brake fluid. If
the fluid in the reservoir runs out any time during the
changing operation, the brakes will need to be bled
since air will have entered the brake line.
the clear plastic hose.
• Remove
Install
the
• Tighten: reservoir cap.
•
Torque - Reservoir Cap Screw: 1.5 N·m (0.15 kgf·m, 13
in·lb)
the bleed valve, and install the rubber cap.
• Tighten
After
changing
fluid, check the brake for good braking
• power, no brakethedrag,
and no fluid leakage.
Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)
If necessary, bleed the air from the lines.
Bleeding the Brake Line
The brake fluid has a very low compression coefficient so
that almost all the movement of the brake lever or pedal
is transmitted directly to the caliper for braking action. Air,
however, is easily compressed. When air enters the brake
lines, brake lever or pedal movement will be partially used
in compressing the air. This will make the lever or pedal feel
spongy, and there will be a loss in braking power.
WARNING
Be sure to bleed the air from the brake line whenever brake lever or pedal action feels soft or
spongy after the brake fluid is changed, or whenever a brake line fitting has been loosened for any
reason.
PERIODIC MAINTENANCE 2-33
Maintenance Procedure
NOTE
○The procedure to bleed the front brake line is as follows.
the reservoir cap, and fill the reservoir with fresh
• Remove
brake fluid to the upper level line in the reservoir.
the reservoir cap off, slowly pump the brake lever
• With
several times until no air bubbles can be seen rising up
through the fluid from the holes at the bottom of the reservoir.
○Bleed the air completely from the master cylinder by this
operation.
Install the reservoir cap.
Remove the rubber cap from the bleed valve on the
caliper.
Attach a clear plastic hose to the bleed valve, and run the
other end of the hose into a container.
Bleed the brake line and the caliper.
○Repeat this operation until no more air can be seen coming out into the plastic hose.
1. Pump the brake lever until it becomes hard, and apply
the brake and hold it [A].
2. Quickly open and close [B] the bleed valve while holding
the brake applied.
3. Release the brake [C].
•
•
•
•
NOTE
○The fluid level must be checked often during the bleed-
ing operation and replenished with fresh brake fluid as
necessary. If the fluid in the reservoir runs completely
out any time during bleeding, the bleeding operation
must be done over again from the beginning since air
will have entered the line.
○Tap the brake hose lightly from the caliper to the reservoir for more complete bleeding.
the clear plastic hose.
• Remove
Tighten:
•
Torque - Reservoir Cap Screw: 1.5 N·m (0.15 kgf·m, 13
in·lb)
• Tighten the bleed valve, and install the rubber cap.
Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)
the fluid level.
• Check
After
bleeding
done, check the brake for good braking
• power, no brakeis drag,
and no fluid leakage.
2-34 PERIODIC MAINTENANCE
Maintenance Procedure
WARNING
When working with the disc brake, observe the precautions listed below.
1. Never reuse old brake fluid.
2. Do not use fluid from a container that has been left
unsealed or that has been open for a long time.
3. Do not mix two types and brands of fluid for use in
the brake. This lowers the brake fluid boiling point
and could cause the brake to be ineffective. It may
also cause the rubber brake parts to deteriorate.
4. Don’t leave the reservoir cap off for any length of
time to avoid moisture contamination of the fluid.
5. Don’t change the fluid in the rain or when a strong
wind is blowing.
6. Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning of the brake parts. Do not use any other
fluid for cleaning of these parts. Gasoline, engine
oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part
will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake.
7. When handling the disc pads or disc, be careful that
no disc brake fluid or any oil gets on them. Clean off
any fluid or oil that inadvertently gets on the pads or
disc with a high-flash point solvent. Do not use one
which will leave an oily residue. Replace the pads
with new ones if they cannot be cleaned satisfactorily.
8. Brake fluid quickly ruins painted surfaces; any
spilled fluid should be completely wiped up immediately.
9. If any of the brake line fittings or the bleed valve is
opened at any time, the AIR MUST BE BLED FROM
THE BRAKE LINE.
Brake Master Cylinder Cup and Dust Cover
Replacement
to the Master Cylinder section in the Brakes chapter
• Refer
for Master Cylinder Cup and Dust Cover Replacement.
Caliper Fluid and Dust Seals Replacement
to the Calipers section in the Brakes chapter for
• Refer
Caliper Fluid and Dust Seals Replacement.
Brake Camshaft Lubricate
to the Brake Panel and Drum section in the Brakes
• Refer
chapter for the Brake Lubrication.
PERIODIC MAINTENANCE 2-35
Maintenance Procedure
Brake Hoses and Connections Inspection
the brake hose and
• Inspect
cracks and signs of leakage.
fittings for deterioration,
○The high pressure inside the brake line can cause fluid to
leak [A] or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while examining
it.
Replace the hose if any cracks [B] or bulges [C] are noticed.
Tighten any loose fittings.
Brake Hose Replacement
to the Brake
• Refer
Brakes chapter.
Hose Removal/Installation in the
Suspension
Front Fork Oil Change
the front fork (see Front Fork Removal).
• Remove
the top cap.
• Remove
Hold
the
tube vertically in a vise.
• Push the outer
top
plug
[A] down to remove the plug retaining
• ring [B], and then remove
the plug.
• Remove:
Fork Spring [A]
out the fork oil [A] with the fork upside down.
• Pour
the outer tube vertically in a vise.
• Hold
Fill
the
front fork with the specified oil.
•
Fork Oil
Viscosity:
SHOWA SS8 or equivalent
Amount:
When changing oil:
approx. 265 mL (9.0 US oz)
After disassembly
and completely dry:
310 ±4 mL (10.5 ±0.14 US oz)
2-36 PERIODIC MAINTENANCE
Maintenance Procedure
for about five minutes so that any suspended air bub• Wait
bles can surface.
• Measure the oil level, using the fork oil level gauge [A].
Special Tool - Fork Oil level Gauge: 57001-1290
○Set the gauge stopper [B] so that its lower side shows the
oil level distance specified [C].
○Insert the gauge tube into the inner tube [D] and position
the stopper across the top of the inner tube [E].
○Pull the handle slowly to draw out the excess oil until no
more oil comes up the tube.
If no oil is drawn out from the beginning, there is not
enough oil in the fork. Pour in some more oil, then draw
out the excess.
Front Fork Oil Level (Fully compressed without fork
spring)
Standard:
286 ±2 mm (11.26 ±0.08 in.)
the fork spring with the smaller end [A] facing down• Install
ward [B].
Upward [C]
the O-ring on the top plug and replace it with a new
• Check
one if damaged.
down the top plug to install the ring, and then fit the
• Push
ring into the groove of the inner tube.
• Install the front fork (see Suspension chapter).
Front Fork Oil Leak Inspection
the front fork (see Suspension chapter).
• Remove
inspect the front forks for oil leakage, scoring or
• Visually
scratches on the outer surface of the inner tubes.
Replace or repair any defective parts, if necessary.
Rear Shock Absorber Oil Leak Inspection
inspect the shock absorbers [A] for oil leakage.
• Visually
If they are oil leaked, replace shock absorber.
PERIODIC MAINTENANCE 2-37
Maintenance Procedure
Swingarm Pivot Lubrication
grease to the inner surface of the needle bearings
• Apply
in accordance with the Periodic Maintenance Chart.
• Apply a thin coat of grease to the lips of the grease seals.
Uni-trak Linkage Lubrication
grease to the inner surfaces of the needle bearings
• Apply
in accordance with the Periodic Maintenance Chart.
the rocker arm it has grease nipples on the rocker arm
• For
for lubrication. Force grease into the nipple until it comes
•
out both sides of the rocker arm, and wipe off any excess.
Apply a thin coat of grease to the lips of the grease seals.
Steering
Steering Inspection
Steering Inspection
Lift the front wheel off the ground using the jack.
•
Special Tool - Jack: 57001-1238
Jack Attachment #3: 57001-1416
the front wheel pointing straight ahead, alternately
• With
tap each end of the handlebar. The front wheel should
•
swing fully left and right from the force of gravity until the
fork hits the stop.
If the wheel binds or catches before the stop, the steering
is too tight.
Feel for steering looseness by pushing and pulling the
forks.
If you feel looseness, the steering is too loose.
NOTE
○The cables and wiring will have some effect on the motion of the fork which must be taken into account.
○Be sure the wires and cables are properly routed.
○The bearings must be in good condition and properly
lubricated in order for any test to be valid.
Steering Adjustment
Loosen:
Front Fork Clamp Bolts (upper) [A]
Remove:
Searing Stem Head bolt [B]
Steering Stem Head [C] and Handlebar [D] as a set
•
•
2-38 PERIODIC MAINTENANCE
Maintenance Procedure
• Loosen:
Steering Stem Locknut [A].
Adjust
the steering.
•
Special Tool - Steering Stem Nut Wrench: 57001-1100 [B]
If the steering too tight, loosen the stem nut [C] a fraction
of a turn.
If the steering too loose, tighten the stem nut a fraction of
a turn.
NOTE
○Turn the steering stem nut 1/8 turn at a time maximum.
the stem head.
• Install
Tighten:
•
Torque - Steering Stem Head Bolt: 44 N·m (4.5 kgf·m, 33
ft·lb)
Front Fork Clamp Bolts (Upper): 20 N·m (2.0
kgf·m, 14.5 ft·lb)
the handlebar assembly.
• Install
Tighten:
•
Torque - Handlebar Holder Mounting Nuts: 34 N·m (3.5
kgf·m, 25 ft·lb)
the steering again.
• Check
If the steering is still too tight or too loose, repeat the adjustment.
Steering Stem Bearing Lubrication
the steering stem (see Steering chapter).
• Remove
a high flash-point solvent, wash the upper and
• Using
lower tapered roller bearing in the cages, and wipe the
•
•
•
upper and lower outer races, which are press-fitted into
the frame head pipe, clean off grease and dirt.
Visually check the outer races and the roller.
Replace the bearing assemblies if they show wear or
damage.
Pack the upper and lower tapered roller bearing [A] in the
cages with grease, and apply a light coat of grease to the
upper and lower outer races.
Install the steering stem, and adjust the steering.
Electrical System
Spark Plug Cleaning and Inspection
the spark plug (see Electrical System chapter),
• Remove
and visually inspect.
the spark plug, preferably in a sandblasting device,
• Clean
and then clean off any abrasive particles. The plug may
also be cleaned using a high flash-point solvent and a wire
brush or other suitable tool.
If the spark plug electrodes are corroded or damaged,
or if the insulator is cracked, replace the plug. Use the
standard spark plug or its equivalent.
PERIODIC MAINTENANCE 2-39
Maintenance Procedure
Spark Plug Gap Inspection
the gap [A] with a wire-type thickness gauge.
• Measure
If the gap is incorrect, carefully bend the side electrode
[B] with a suitable tool to obtain the correct gap.
Spark Plug Gap:
0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)
General Lubrication
Lubrication
lubricating each part, clean off any rusty spots with
• Before
rust remover and wipe off any grease, oil, dirt, or grime.
• Lubricate the points listed below with indicated lubricant.
○Whenever
NOTE
the vehicle has been operated under
wet or rainy conditions, or especially after using a
high-pressure water spray, perform the general lubrication
Points: Lubricate with Grease.
Clutch Lever Pivot Bolt
Brake Lever Pivot Bolt
Brake Pedal Pivot Bolt
Side Stand Pivot Bolt
Clutch Inner Cable Lower End [A]
Throttle Inner Cable Upper Ends
Speedometer Inner Cable
Rear Brake Cable Joint
Choke Cable Upper End
Cables: Lubricate with Rust Inhabiter
Choke Cable
Throttle Cables
Clutch Cable
Lubricate the cables by seeping the oil between the cable
and housing.
○The cable may be lubricated by using a commercially
available pressure cable lubricator with an aerosol cable
lubricant.
•
2-40 PERIODIC MAINTENANCE
Maintenance Procedure
the cable disconnected at both ends, the cable
• With
should move freely [A] within the cable housing.
If cable movement is not free after lubricating, if the cable
is frayed [B], or if the cable housing is kinked [C], replace
the cable.
Nut, Bolts, and Fasteners Tightness Inspection
Tightness Inspection
the tightness of the bolts and nuts listed here. Also,
• Check
check to see that each cotter pin is in place and in good
condition.
NOTE
○For the engine fasteners, check the tightness of them
when the engine is cold (at room temperature).
If there are loose fasteners, retorque them to the specified torque following the specified tightening sequence.
Refer to the appropriate chapter for torque specifications.
If torque specifications are not in the appropriate chapter,
see the Standard Torque Table. For each fastener, first
loosen it by 1/2 turn, then tighten it.
If cotter pins are damaged, replace them with new ones.
Nut, Bolt and Fastener to be checked
Wheels:
Front Axle Nut
Front Axle Clamp Bolt
Rear Axle Nut
Rear Axle Nut Clip
Brakes:
Front Master Cylinder Clamp Bolts
Caliper Mounting Bolts
Brake Lever Pivot Bolt Locknut
Rear Brake Lever Clamp Bolt
Suspension:
Front Fork Clamp Bolts
Rear Shock Absorber Mounting Nuts
Swingarm Pivot Shaft Nut
Uni-Trak Link Nuts
PERIODIC MAINTENANCE 2-41
Maintenance Procedure
Steering:
Steering Stem Head Bolt
Handlebar Holder Bolts
Handlebar Holder Mounting Nut
Engine:
Engine Mounting Bolts
Engine Mounting Bracket Bolts
Muffler Mounting Bolts
Exhaust Pipe Holder Nuts
Muffler Connecting Clamp Bolt
Clutch Lever Pivot Nut
Clutch Lever Holder Clamp Bolt
Others:
Side Stand Pivot Nut
Muffler Bracket Mounting Bolts
Footpeg Holder Mounting Bolts
Front Fender Mounting Screws
FUEL SYSTEM 3-1
Fuel System
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Throttle Grip and Cables ........................................................................................................
Throttle Grip Free Play Inspection ....................................................................................
Throttle Grip Free Play Adjustment...................................................................................
Throttle Cable Installation .................................................................................................
Throttle Cable Lubrication and Inspection ........................................................................
Choke Cable...........................................................................................................................
Choke Free Play Inspection..............................................................................................
Choke Cable Installation ...................................................................................................
Choke Cable Lubrication and Inspection ..........................................................................
Carburetor ..............................................................................................................................
Idle Speed Inspection .......................................................................................................
Idle Speed Adjustment......................................................................................................
Service Fuel Level Inspection ...........................................................................................
Service Fuel Level Adjustment .........................................................................................
Fuel System Cleanliness Inspection .................................................................................
Pilot Screw Setting............................................................................................................
Carburetor Removal..........................................................................................................
Carburetor Installation.......................................................................................................
Carburetor Disassembly ...................................................................................................
Carburetor Assembly ........................................................................................................
Carburetor Cleaning..........................................................................................................
Carburetor Inspection .......................................................................................................
Air Cleaner..............................................................................................................................
Element Removal..............................................................................................................
Element Cleaning and Inspection .....................................................................................
Air Cleaner Housing Removal...........................................................................................
Air Cleaner Housing Installation........................................................................................
Fuel Tank ................................................................................................................................
Fuel Tank Removal ...........................................................................................................
Fuel Tank Installation ........................................................................................................
Fuel Tank Inspection .........................................................................................................
Fuel Tank Cleaning ...........................................................................................................
Fuel Tap Removal .............................................................................................................
Fuel Tap Installation ..........................................................................................................
Evaporative Emission Control System (California Model Only)..............................................
Parts Removal/Installation ................................................................................................
Hose Inspection ................................................................................................................
Separator Inspection.........................................................................................................
Separator Operation Test..................................................................................................
Canister Inspection ...........................................................................................................
3-2
3-6
3-7
3-8
3-8
3-8
3-8
3-8
3-9
3-9
3-9
3-9
3-10
3-10
3-10
3-10
3-11
3-11
3-12
3-12
3-13
3-14
3-14
3-15
3-16
3-18
3-18
3-18
3-18
3-19
3-20
3-20
3-20
3-21
3-21
3-21
3-22
3-23
3-23
3-23
3-23
3-24
3-24
3
3-2 FUEL SYSTEM
Exploded View
FUEL SYSTEM 3-3
Exploded View
No.
1
2
3
Fastener
Air Cleaner Element Cover Mounting Nut
Air Cleaner Housing Mounting Bolts
Carburetor holder Plate Mounting Bolts
4. Air Cleaner Case (California Model)
5. Clamps (California Model)
6. Plug (United States, Canada and Switzerland Models)
7. Fitting (California Model)
CL: Apply cable lubricant.
G: Apply grease.
N·m
5.9
11
11
Torque
kgf·m
0.6
1.1
1.1
ft·lb
52 in·lb
95 in·lb
95 in·lb
Remarks
3-4 FUEL SYSTEM
Exploded View
FUEL SYSTEM 3-5
Exploded View
No.
1
Fastener
Fuel Tap Mounting Bolts
Fuel Tap Mounting Bolts
N·m
2.5
4.9
Torque
kgf·m
0.25
0.50
ft·lb
22 in·lb
43 in·lb
2. Fuel Tank Cap Seal (California Model)
3. Drain Hose (On and after VN800-B7, Other than California Model)
4. Evaporative Emission Control System (California Model)
5. Canister
6. Separator
Remarks
with white washer
with black washer
3-6 FUEL SYSTEM
Specifications
Item
Carburetor
Make, Type
Idle speed
Main Jet
Main Air Jet
Needle Jet
Jet Needle
Pilot Jet
Pilot Air Jet
Pilot Screw
starter Jet
Service Fuel Level
Float Height
Optional Parts:
Main Jet
Standard
Service Limit
Keihin, CVK36
1000 ±50 r/min (rpm)
(CH) (CAL) 1300 ±50 r/min (rpm)
#135
#100
#6
N2PE
(PF) (PU) (CAL) NBZQ (VN800-B9 ∼, B6F)
#48
#70
(PF) (PU) (CAL) #80 (VN800-B9 ∼, B6F)
1 3/4 turns out, (US) (CAL) –
(PF) (PU) 2.0 turns out (VN800-B9 ∼, B6F)
#70
2.0 ±1 mm (0.08 ±0.04 in.) above the float bowl
mating surface
16.5 ±2 mm (0.65 ±0.08 in.)
– – –
– – –
#130, 132, 138, 140
– – –
–
–
–
–
–
–
–
–
–
–
–
–
– – –
– – –
– – –
– – –
– – –
– – –
(CAL):California Model
(CH): Switzerland Model
(PF): WVTA Approval Model with Pipe Catalytic Converter (Full Power Model)
(PU): WVTA Approval Model with Pipe Catalytic Converter (Left side Traffic Full Power Model)
FUEL SYSTEM 3-7
Special Tools
Fuel Level Gauge:
57001-1017
Pilot Screw Adjuster, A:
57001-1239
Carburetor Drain Plug Wrench, Hex 3:
57001-1269
3-8 FUEL SYSTEM
Throttle Grip and Cables
Throttle Grip Free Play Inspection
to the Throttle Grip Play Inspection in the Periodic
• Refer
Maintenance chapter.
Throttle Grip Free Play Adjustment
to the Throttle Grip Play Inspection in the Periodic
• Refer
Maintenance chapter.
Throttle Cable Installation
the throttle cables in accordance with Cable, Wire,
• Install
and Hose Routing section in Appendix chapter.
the lower ends of the throttle cables in the cable
• Install
bracket on the carburetor after installing the upper ends
•
of the throttle cables in the grip.
After installation, adjust each cable properly.
WARNING
Operation with incorrectly routed or improperly adjusted cables could result in an unsafe riding condition.
Throttle Cable Lubrication and Inspection
the cables are removed, or in accordance with
• Whenever
the Periodic Maintenance Chart, lubricate the throttle
cables (see General Lubrication in the Periodic Maintenance 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 freely in the cable housing.
FUEL SYSTEM 3-9
Choke Cable
Choke Free Play Inspection
that the choke inner cable slides smoothly by mov• Check
ing the choke knob [A] to the push and pull.
If there is any irregularity, replace the choke cable.
Choke Cable Installation
the choke cable in accordance with the Cable,
• Install
Wire, and Hose Routing section in the Appendix chapter.
• After installation, adjust the cable properly.
WARNING
Operation with an incorrectly routed or improperly
adjusted cable could result in an unsafe riding condition.
Choke Cable Lubrication and Inspection
the cable is removed, or in accordance with
• Whenever
the Periodic Maintenance Chart, lubricate the choke cable (see General Lubrication in the Periodic Maintenance
chapter).
○Apply a thin coating of grease to the cable lower end.
○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.
3-10 FUEL SYSTEM
Carburetor
Idle Speed Inspection
to the Idle Speed Inspection in the Periodic Main• Refer
tenance chapter.
Idle Speed Adjustment
to the Idle Speed Adjustment in the Periodic Main• Refer
tenance chapter.
Service Fuel Level Inspection
WARNING
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.
the motorcycle so that it is perpendicular to the
• Situate
ground.
the fuel tank and air cleaner (see Fuel Tank Re• Remove
moval, Air Cleaner Housing Removal).
an auxiliary fuel tank and connect the fuel hose
• Prepare
to the carburetor.
a suitable fuel hose.
• Prepare
Connect
fuel level gauge [A] to the carburetor float
• bowl withthe
the fuel hose.
Special Tool - Fuel Level Gauge: 57001-1017
the gauge vertically against the side of the carburetor
• Hold
body so that the "zero" line [B] is slightly higher than the
float bowl mating surface [C].
Feed fuel to the carburetor, then turn the carburetor drain
plug [D] out a few turns.
Wait until the fuel level in the gauge settles.
•
•
the gauge vertical, slowly lower the gauge until
• Keeping
the "zero" line is even with the float bowl mating surface.
NOTE
○Do not lower the "zero" line below the float bowl mating
surface. If the gauge is lowered and then raised again,
the fuel level measured shows somewhat higher than
the actual fuel level. If the gauge is lowered too far,
dump the fuel into a suitable container and start the
procedure over again.
the fuel level [E] in the gauge and compare to the
• Read
specification.
in the carburetor drain plug.
• Screw
feeding and remove the fuel level gauge.
• Stop
If the fuel level is incorrect, adjust it (see Service Fuel
Level Adjustment).
Service Fuel Level (above the float bowl mating surface)
Standard:
2.0 ±1 mm (0.08 ±0.04 in.)
FUEL SYSTEM 3-11
Carburetor
Service Fuel Level Adjustment
WARNING
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.
the carburetor, and drain the fuel into a suitable
• Remove
container.
the float bowl.
• Remove
Remove
the
pin [A] and take out the float [B].
• When removing
installing the pin, note the following.
•○Be careful not toand
snap the pin holder leg [C].
○When removing it, tap [D] the left end of the pin.
○When installing it, press [E] the right end of the pin.
the tang [A] on the float arm very slightly to change
• Bend
the float height.
the float height tilting the carburetor so that the
• Measure
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 fuel level.
Float Height
Standard:
16.5 ±2 mm (0.65 ±0.08 in.)
NOTE
○Do not push the needle rod [A] in during the float height
measurement [B].
the carburetor, and recheck the fuel level.
• Assemble
If the fuel level cannot be adjusted by this method, the
float or the float valve [C] is damaged.
Fuel System Cleanliness Inspection
to the Fuel System Cleanliness Inspection in the
• Refer
Periodic Maintenance chapter
3-12 FUEL SYSTEM
Carburetor
Pilot Screw Setting
○The pilot screw [A] is set at the factory and should not be
adjusted. But if necessary set the pilot screw as follows.
Turn in the pilot screw and count the number of turns until
it seat fully but not tightly.
○The pilot screw adjuster [B] may be used with the carburetor assembly instated on the engine.
•
Special Tool - Pilot Screw Adjuster: 57001-1239
○Back out the same number of turns counted when turned
in. This is to set the screw to its original portion.
NOTE
○When setting the pilot screw use the “turn out” determined during disassembly. Use the specifications in
this manual only if the original number is unknown.
Carburetor Removal
WARNING
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.
• Remove:
Seats (see Frame chapter)
Fuel Tank (see Fuel Tank Removal)
Air Cleaner Housing (see Air Cleaner Housing Removal)
Bolts [A]
Carburetor Air vent Hose [B]
Carburetor Holder Plate [C]
FUEL SYSTEM 3-13
Carburetor
Choke Cable [A]
the carburetor clamp screw [B].
• Loosen
Remove
• side. the throttle cable ends from the handlebar switch
the carburetor [C].
• Remove
Stuff
piece
of lint-free, clean cloth into the carburetor
• holder to keep
dirt out of the engine.
Vacuum Hose [A]
WARNING
If dirt or dust is allowed to pass through into the
carburetor, the throttle may become stuck, possibly
causing an accident.
CAUTION
IF dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.
Carburetor Installation
the vacuum fitting boss [A] of the carburetor to the
• Fit
projection [B] of the clamp.
the clamp bolt [A].
• Tighten
Install
the
carburetor holder plate [B] and tighten the bolts
• [C].
Torque - Carburetor Holder Plate Mounting Bolts: 11 N·m
(1.1 kgf·m, 95 in·lb)
the cables, harness, and hoses correctly (see Ap• Route
pendix chapter).
• Check fuel leakage from the carburetor.
3-14 FUEL SYSTEM
Carburetor
WARNING
Fuel spilled from the carburetors is hazardous.
the following items if necessary.
• Adjust
Idle Speed
Throttle Cables
Carburetor Disassembly
• Remove the carburetor (see Carburetor Removal).
WARNING
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.
pilot screw is set at the factory and should not be
• The
removed. But if necessary, remove the pilot screw as
follows.
Turn in the pilot screw and count the number of turns until
it seats fully but not tightly, and then remove the screw.
Use this number of turns to set the screw to its original
position during assembly.
For the United States, Canada and Switzerland models,
remove the pilot screw plug as follows:
○Punch a hole in the plug and pry it out with an awl or other
suitable tool.
•
•
CAUTION
During carburetor disassembly, be careful not to
damage the diaphragm. Never use a sharp edge to
remove the diaphragm.
Carburetor Assembly
in the pilot screw [A] fully but not tightly, and then
• Turn
back it out the same number of turns counted during disassembly.
For the United States, Canada and Switzerland models,
install the pilot screw plug as follows:
○Install a new plug [B] in the pilot screw hole of the carburetor body [C], and apply a small amount of a bonding
agent [D] to the circumference of the plug to fix the plug.
•
CAUTION
Do not apply too much bonding agent to the plug or
the pilot screw itself may be fixed.
FUEL SYSTEM 3-15
Carburetor
the carburetor body upside-down, and drop the nee• Turn
dle jet [A] into place so that the smaller diameter end [B]
•
of the jet goes in first.
Carefully screw in the needle jet holder [C]. It will seat
against the needle jet, pushing the end of the jet into the
carburetor bore.
CAUTION
Do not force the needle jet holder [A] and main jet
[B] or overtighten them. They could be damaged
requiring replacement.
the jet needle through the hole in the center of the
• Slip
vacuum piston, and put the spring seat [A] on the top of
•
the needle. Turn the seat so that it does not block the hole
[B] at the bottom of the vacuum piston.
After installing the upper chamber cover, check that the
vacuum piston slides up and down smoothly without binding in the carburetor bore.
Carburetor Cleaning
WARNING
Clean the carburetor in a well-ventilated area, and
take care that there is no sparks or flame anywhere
near the working area; this includes any appliance
with a pilot light. Because of the danger of highly
flammable liquids, do not use gasoline or low flash
-point solvents to clean the carburetor.
3-16 FUEL SYSTEM
Carburetor
CAUTION
Do not use compressed air on an assembled carburetor, or the float may be crushed by the pressure,
and the vacuum piston diaphragms may be damaged.
Remove as many rubber or plastic parts from the
carburetor as possible before cleaning the carburetor with a cleaning solution. This will prevent damage to or deterioration of the parts.
The carburetor body has plastic parts that cannot be removed. Do not use a strong carburetor
cleaning solution which could attack these parts;
instead, use a mild high flash-point cleaning solution safe for plastic parts.
Do not use wire or any other hard instrument to
clean carburetor parts, especially jets, as they may
be damaged.
the carburetor.
• Disassemble
Immerse
all
the
metal parts in a carburetor cleaning solu• tion.
the parts in water.
• Rinse
When
the parts are clean, dry them with compressed air.
• Blow through
the air and fuel passages with compressed
• air.
• Assemble the carburetor.
Carburetor Inspection
WARNING
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.
disassembling the carburetor, check the fuel level
• Before
(see Fuel Level Inspection).
If the fuel level is incorrect, inspect the rest of the carburetor before correcting it.
the carburetor.
• Remove
Turn
the
throttle
cable pulley to check that the throttle but• terfly valve [A] move
smoothly and return by spring tension.
If the throttle valve do not move smoothly, replace the
carburetor.
FUEL SYSTEM 3-17
Carburetor
the carburetor.
• Disassemble
Clean
the
carburetor.
• Check that the O-rings on the float bowl and pilot screw
• and the diaphragm on the vacuum piston are in good con-
•
•
dition.
If any of the O-rings or diaphragms are not in good condition, replace them.
Check the plastic tip [A] of the float valve needle [B]. It
should be smooth, without any grooves, scratches, or
tears.
If the plastic tip is damaged [C], replace the needle.
Push the rod [D] in the other end of the float valve needle,
and then release it [E].
If the rod does not spring out, replace the needle.
the tapered portion [A] of the pilot screw [B] for
• Check
wear or damage.
if the pilot screw is worn or damaged on the tapered portion, it will prevent the engine from idling smoothly. Replace it.
that the vacuum piston [A] moves smoothly in the
• Check
carburetor body. The surface of the piston must not be
excessively worn.
If the vacuum piston does not move smoothly, or if it is
very loose in carburetor body, replace the carburetor.
3-18 FUEL SYSTEM
Air Cleaner
Element Removal
• Remove:
Nut [A] and Washer
Air Cleaner Cover [B]
•
Element [A]
Push a clean, lint-free towel into the carburetor intake to
keep dirt or other foreign material from entering.
WARNING
If dirt or dust is allowed to pass through into the
carburetors, the throttle may become stuck, possibly causing an accident.
CAUTION
If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.
Element Cleaning and Inspection
to the Air Cleaner Element Clean in the Periodic
• Refer
Maintenance chapter.
Air Cleaner Housing Removal
• Remove:
Seat (see Frame chapter)
Fuel Tank (see Fuel Tank Removal)
Mounting Bolts [A] and Surge Tank [B]
Air Cleaner Element (see Air Cleaner Element Removal)
Mounting Bolts [A]
FUEL SYSTEM 3-19
Air Cleaner
the air cleaner housing [A] from the carburetor
• Remove
[B].
the engine breather hose [C], vacuum switch
• Disconnect
valve hose [D] and drain hose [E].
Evaporative Emission Hose [F] (for California Model)
Air Cleaner Housing Installation
• Tighten:
Torque - Air Cleaner Element Cover Mounting Nut: 11 N·m
(1.1 kgf·m, 95 in·lb)
Air Cleaner Housing Mounting Bolts: 11 N·m (1.1
kgf·m, 95 in·lb)
3-20 FUEL SYSTEM
Fuel Tank
Fuel Tank Removal
WARNING
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.
CAUTION
For California model, if gasoline, solvent, water or
any other liquid enters the canister, the canister’s
vapor absorbing capacity is greatly reduced. If the
canister does become contaminated, replace it with
a new one.
the fuel tap [A] to the ON or RES position.
• Turn
• Remove:
Fuel Hose [B]
Fuel Tap Vacuum Hose [C]
• Remove:
Seat (see Frame chapter)
Mounting Bolt [A] and Meter Unit [B] (see Electrical System chapter)
Fuel Tank Mounting Bolts [A]
Fuel Tank
Evaporative Emission Hoses (for California Model).
Fuel Tank Installation
the WARNING mentioned in Fuel Tank removal.
• Read
Route
correctly (see Appendix chapter).
• Be surethethehoses
hoses
are clamped securely to prevent leaks.
• Check the rubber dampers.
• If any damper is damaged or deteriorated, replace it.
FUEL SYSTEM 3-21
Fuel Tank
Fuel Tank Inspection
the fuel tank and drain it.
• Remove
Check
to
if the breather pipe [A] (also the fuel return
• pipe for theseeCalifornia
model) in the tank is not clogged.
Check the tank cap breather also.
If the breather pipe is clogged, blow the pipe free with
compressed air.
If the tank cap breather is clogged, replace the tank cap.
CAUTION
Do not apply compressed air to the air vent holes
[B] in the tank cap. This could cause damage and
clogging of the labyrinth in the cap.
Fuel Tank Cleaning
WARNING
Clean the tank in a well-ventilated area, and take
care that there are no sparks or flame anywhere
near the working area. Because of the danger of
highly flammable liquids, do not use gasoline or low
flash- point solvents to clean the tank.
the fuel tank and drain it.
• Remove
some high flash-point solvent into the fuel tank and
• Pour
shake the tank to remove dirt and fuel deposits.
high flash-point solvent through the tap in all lever
• Pour
positions.
the solvent out of the tank.
• Pour
Remove
• moval). the fuel tap from the tank (see Fuel Tap Rethe fuel tap filter screens in a high flash-point sol• Clean
vent.
the tank and screens with compressed air.
• Dry
Install
the tank filters in the tank.
• Install the
fuel tank (see Fuel Tank Installation).
•
Fuel Tap Removal
the Fuel Tap Position Lever (see Fuel Tank Re• Remove
moval).
the fuel tank and drain it.
• Remove
• Remove:
Bolts [A] and Nylon Flat Washers
Fuel Tap [B]
3-22 FUEL SYSTEM
Fuel Tank
Fuel Tap Installation
sure the O-rings [A] is in good condition to prevent
• Be
leaks.
sure the nylon flat washers [B] are in good condition
• Be
to prevent leaks.
○Do not use steel washers in place of the nylon flat wash-
•
ers, because they will not seal the bolts properly and fuel
will leak.
Be sure to clamp the fuel hoses to the tap to prevent leaks.
Torque - Fuel Tap Bolts: 2.5 N·m (0.25 kgf·m, 22 in·lb) (with
white washer)
Fuel Tap Bolts: 4.9 N·m (0.50 kgf·m, 43 in·lb) (with
black washer)
NOTE
○Be sure to use the black coating washers when the fuel
tap shall be reinstalled.
FUEL SYSTEM 3-23
Evaporative Emission Control System (California Model Only)
The Evaporative Emission Control System routes fuel vapors from the fuel system into the running engine or stores
the vapors in a canister when the engine is stopped. Although no adjustments are required, a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart.
Parts Removal/Installation
WARNING
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.
CAUTION
If gasoline, solvent, water or any other liquid enters
the canister, the canister’s vapor absorbing capacity is greatly reduced. If the canister does become
contaminated, replace it with a new one.
prevent the gasoline from flowing into or out of the
• To
canister, hold the separator perpendicular to the ground.
the hoses according to the diagram of the sys• Connect
tem. Make sure they do not get pinched or kinked.
hoses with a minimum of bending so that the air or
• Route
vapor will not be obstructed.
sure to plug the return hose to prevent fuel spilling
• Be
before fuel tank removal.
WARNING
When removing the fuel tank, be careful not to spill
the gasoline through the return hose. Spilled fuel is
hazardous.
If liquid gasoline flows into the breather hose, remove the
hose and blow it clean with compressed air.
Hose Inspection
to the Evaporative Emission Control System in the
• Refer
Periodic Maintenance chapter.
Separator Inspection
to the Evaporative Emission Control System in the
• Refer
Periodic Maintenance chapter.
3-24 FUEL SYSTEM
Evaporative Emission Control System (California Model Only)
Separator Operation Test
WARNING
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.
the hoses to the separator, and install the sepa• Connect
rator on the motorcycle.
the breather hose from the separator, and in• Disconnect
ject about 20 mL of gasoline [A] into the separator [B]
•
•
•
through the hose fitting.
Disconnect the fuel return hose [C] from the fuel tank [D].
Place the open end of the return hose into the container
and hold it with the same level of the tank top [E].
start the engine, and let it idle.
If the gasoline in the separator comes out of the hose, the
separator works well. If it does not, replace the separator
with a new one.
Canister Inspection
to the Evaporative Emission Control System in the
• Refer
Periodic Maintenance chapter.
COOLING SYSTEM 4-1
Cooling System
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Coolant Flow Chart.................................................................................................................
Coolant ...................................................................................................................................
Coolant Deterioration Inspection.......................................................................................
Coolant Level Inspection...................................................................................................
Coolant Draining ...............................................................................................................
Coolant Filling ...................................................................................................................
Pressure Testing ...............................................................................................................
Reserve Tank Removal.....................................................................................................
Water Pump............................................................................................................................
Water Pump Impeller Removal .........................................................................................
Water Pump Impeller Installation ......................................................................................
Mechanical Seal Replacement .........................................................................................
Water Pump Inspection.....................................................................................................
Radiator, Radiator Fan ...........................................................................................................
Radiator and Radiator Fan Removal ................................................................................
Radiator Fan Installation ...................................................................................................
Radiator Inspection ...........................................................................................................
Radiator Cap Inspection ...................................................................................................
Thermostat .............................................................................................................................
Thermostat Removal.........................................................................................................
Thermostat Installation......................................................................................................
Thermostat Inspection ......................................................................................................
Hose and Pipes ......................................................................................................................
Hose Installation ...............................................................................................................
Hose Inspection ................................................................................................................
Radiator Fan Switch, Water Temperature Sensor ..................................................................
Radiator Fan Switch, Water Temperature Sensor Removal .............................................
Radiator Fan Switch, Water Temperature Sensor Installation ..........................................
Radiator Fan Switch, Water Temperature Sensor Inspection ...........................................
4-2
4-4
4-5
4-6
4-8
4-8
4-8
4-8
4-8
4-9
4-9
4-10
4-10
4-10
4-10
4-11
4-12
4-12
4-13
4-13
4-13
4-15
4-15
4-15
4-15
4-16
4-16
4-16
4-17
4-17
4-17
4-17
4
4-2 COOLING SYSTEM
Exploded View
COOLING SYSTEM 4-3
Exploded View
No.
1
2
3
4
5
6
Fastener
Water Pump Impeller Nut
Water Hose Fitting Bolts
Radiator Hose Clamp Screws
Radiator Fan Switch
Water Temperature Sensor
Coolant Drain Plug
G: Apply grease.
SS: Apply silicone sealant.
N·m
11
11
2.0
18
Torque
kgf·m
1.1
1.1
0.2
1.8
ft·lb
95 in·lb
95 in·lb
17 in·lb
13
7.8
11
0.8
1.1
69 in·lb
95 in·lb
Remarks
SS
SS
4-4 COOLING SYSTEM
Specifications
Item
Standard
Coolant provided when shipping
Type
Permanent type of antifreeze (soft water
and ethylene glycol plus corrosion and rust
inhibitor chemicals for aluminum engines and
radiators)
Color
Green
Mixed Ratio
Soft water 50%, coolant 50%
Freezing Point
–35°C (–31°F)
Total Amount
2.4 L (2.5 US qt) (reserve tank full level
including radiator and engine)
Radiator cap
Relief Pressure
93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 14 ∼ 18
psi)
Thermostat
Valve Opening Temperature
58 ∼ 62°C (136 ∼ 144°F)
Valve Full Opening Lift
8 mm (0.31 in.) or more @75°C (167°F)
Service Limit
– – –
–
–
–
–
–
–
–
–
–
–
–
–
– – –
– – –
– – –
COOLING SYSTEM 4-5
Special Tools
Kawasaki Bond (Silicone Sealant):
56019-120
4-6 COOLING SYSTEM
Coolant Flow Chart
Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion.
When the engine starts, the water pump turns and the coolant circulates.
The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The
thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
When coolant temperature is below 55°C (131°F), the thermostat closes so that the coolant flow is
restricted through the air bleeder hole, causing the engine to warm up more quickly. When coolant
temperature is more than 58 ∼ 62°C (136 ∼ 144°F), the thermostat opens and the coolant flows.
When the coolant temperature goes up beyond 96 ∼ 100°C (205 ∼ 212°F), the radiator fan switch
conducts to operate the radiator fan. The radiator fan draws air through the radiator core when there
is not sufficient air flow such as at low speeds. This increases up the cooling action of the radiator.
When the temperature is below 91°C (196°F), the fan switch opens and the radiator fan stops.
In this way, this system controls the engine temperature within narrow limits where the engine operates most efficiently even if the engine load varies.
The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles
which can cause engine overheating. As the engine warms up, the coolant in the radiator and the
water jacket expands. The excess coolant flows through the radiator cap and hose to the reserve tank
to be stored there temporarily. Conversely, as the engine cools down, the coolant in the radiator and
the water jacket contracts, and the stored coolant flows back to the radiator from the reserve tank.
The radiator cap has two valves. One is a pressure valve which holds the pressure in the system
when the engine is running. When the pressure exceeds 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 14 ∼ 18
psi), the pressure valve opens and releases the pressure to the reserve tank. As soon as pressure
escapes, the valve closes, and keeps the pressure at 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 14 ∼ 18 psi).
When the engine cools down, another small valve (vacuum valve) in the cap opens. As the coolant
cools, the coolant contracts to form a vacuum in the system. The vacuum valve opens and allows the
coolant from the reserve tank to enter the radiator.
COOLING SYSTEM 4-7
Coolant Flow Chart
1. Radiator
5. Water Pump Impeller
2. Fan Switch
6. To Crankcase
3. Water Temperature Sensor
7. From Rear Cylinder Head
4. Right Engine Cover
8. From Front Cylinder Head
9. Thermostat
When the engine is cold, the thermostat is closed so that the coolant flow is restricted through
the air bleeder hole, causing the engine to warm up more quickly.
10. Radiator Cap
11. Reserve Tank
When the engine is very hot, the pressure valve in the radiator cap allows air and vapor to escape into the reserve tank. When the engine cools down, the pressure drop draws the vacuum
valve (another small valve) open, admitting coolant from the reserve tank into the radiator.
4-8 COOLING SYSTEM
Coolant
Coolant Deterioration Inspection
inspect the coolant in the reserve tank.
• Visually
If whitish cotton-like wafts are observed, aluminum parts
in the cooling system are corroded. If the coolant is
brown, iron or steel parts are rusting. In either case, flush
the cooling system.
If the coolant gives off an abnormal smell, check for a
cooling system leak. It may be caused by exhaust gas
leaking into the cooling system.
Coolant Level Inspection
NOTE
○Check the level when the engine is cold (room or ambient temperature).
the coolant level in the reserve tank with the mo• Check
torcycle held perpendicular.
If the coolant level is lower than the low (“L”) level line [A],
add coolant to the full (“F”) level line [B].
Level Gauge [C]
Reserve Tank [D]
CAUTION
For refilling, add the specified mixture of coolant
and soft water. Adding water alone dilutes the
coolant and degrades its anticorrosion properties.
The diluted coolant can attack the aluminum engine parts. In an emergency, soft water alone can
be added. But the diluted coolant must be returned
to the correct mixture ratio within a few days.
If coolant must be added often, or the reserve tank
has run completely dry, there is probably leakage in
the cooling system. Check the system for leaks.
Coolant Draining
to the Coolant Change in the Periodic Maintenance
• Refer
chapter.
Coolant Filling
to the Coolant Change in the Periodic Maintenance
• Refer
chapter.
COOLING SYSTEM 4-9
Coolant
Pressure Testing
the meter unit (see Electrical System chapter).
• Remove
Remove
radiator cap, and install a cooling system
• pressure the
tester [A] on the filler neck.
NOTE
○Wet the cap sealing surfaces with water or coolant to
prevent pressure leaks.
up pressure in the system carefully until the pres• Build
sure reaches 123 kPa (1.25 kgf/cm², 18 psi).
CAUTION
During pressure testing, do not exceed the pressure for which the system is designed. The maximum pressure is 123 kPa (1.25 kgf/cm², 18 psi).
the gauge for at least 6 seconds.
• Watch
If the pressure holds steady, the system is all right.
•
If the pressure drops and no external source is found,
check for internal leaks. Droplets in the engine oil indicate
internal leakage. Check the cylinder head gasket and the
water pump.
Remove the pressure tester, replenish the coolant, and
install the radiator cap.
Reserve Tank Removal
• Remove:
Seat (see Frame chapter)
Fuel Tank (see Fuel System chapter)
Coolant Hose [A]
Muffler (see Engine Top End chapter)
Rear Fender (see Frame chapter)
Rear Wheel (see Wheels/Tires chapter)
Rear Shock Absorber (see Suspension chapter)
Bolts [A] and Rear Wheel Mud Guard [B]
Bolts [A] and Reserve Tank [B]
If necessary, remove the reserve tank mounting bracket.
4-10 COOLING SYSTEM
Water Pump
Water Pump Impeller Removal
• Drain:
Engine Oil (see Engine Oil Change in the Periodic Main•
tenance chapter)
Coolant (see Coolant Draining in the Periodic Maintenance chapter)
Remove:
Right Engine Cover (see Clutch chapter)
Nut [A]
Impeller [B]
Water Pump Impeller Installation
sure to install the rubber seal [A] and sealing seat [B]
• Be
into the impeller [C] by hand until the seat bottoms out.
a little coolant to the sealing seat to give the seal
• Apply
initial lubrication.
sure to install a new O-ring [D] on the shaft.
• Be
Tighten:
•
Torque - Water Pump Impeller Nut: 11 N·m (1.1 kgf·m, 95
in·lb)
Mechanical Seal Replacement
• Remove
Water Pump Impeller (see Water Pump Impeller Re•
moval)
O-ring
Pry the mechanical seal flange [A] off with a small chisel
[B].
the mechanical seal [A] out of the crankcase with
• Pull
pliers.
CAUTION
Be careful not to damage the water pump shaft and
the inner sealing surface of the crankcase.
• Discard the mechanical seal.
NOTE
○Since the replacement mechanical seal has an adhesive coated body, do not apply liquid gasket to the exterior surface of the body.
[A] the new mechanical seal [B] into the hole by
• Press
using a suitable socket [C] until it bottoms out.
CAUTION
Be careful not to damage the water pump shaft and
mechanical seal.
COOLING SYSTEM 4-11
Water Pump
Water Pump Inspection
the drainage outlet passage [A] at the bottom of
• Check
the right crankcase for coolant leaks.
If the mechanical seal is damaged, the coolant leaks
through the seal and drains through the passage. Replace the mechanical seal with a new one.
inspect the impeller [A].
• Visually
If the surface is corroded, or if the blades are damaged,
replace the impeller.
4-12 COOLING SYSTEM
Radiator, Radiator Fan
Radiator and Radiator Fan Removal
WARNING
The radiator fan is connected directly to the battery. The radiator fan may start even if the ignition
switch is off. NEVER TOUCH THE RADIATOR FAN
UNTIL THE RADIATOR FAN CONNECTOR IS DISCONNECTED. TOUCHING THE FAN BEFORE THE
CONNECTOR IS DISCONNECTED COULD CAUSE
INJURY FROM THE FAN BLADES.
• Remove:
Coolant (see Coolant Draining in the Periodic Maintenance chapter)
Seat (see Frame chapter)
Fuel Tank (see Fuel System chapter)
Surge Tank (see Fuel system chapter)
Horn Lead Connectors [A]
Bolts [B] and Horn [C]
Water Hose [A]
Radiator Fan Connector [A]
Fan Switch Lead Connectors [B]
Water Temperature Sensor Lead Connector [C]
Water Hose [D]
Radiator Mounting Bolts [E]
Radiator
Radiator Fan Mounting Bolts [A]
Radiator Fan [B]
CAUTION
Do not touch the radiator core. This could damage
the radiator fins, resulting in loss of cooling efficiency.
COOLING SYSTEM 4-13
Radiator, Radiator Fan
Radiator Fan Installation
sure to attach the ground lead [A] to the fan mounting
• Be
bolt [B].
Radiator Inspection
the radiator core.
• Check
If there are obstructions to air flow, remove them.
If the corrugated fins [A] are deformed, carefully
straighten them.
If the air passages of the radiator core are blocked more
than 20% by unremovable obstructions or irreparably deformed fins, replace the radiator with a new one.
CAUTION
When cleaning the radiator with steam cleaner, be
careful of the following to prevent radiator damage.
Keep the steam gun [A] away more than 0.5 m (1.6
ft) [B] from the radiator core.
Hold the steam gun perpendicular to the core surface.
Run the steam gun following the core fin direction.
Radiator Cap Inspection
the condition of the top [A] and bottom [B] valve
• Check
seals and valve spring [C].
If any one of them shows visible damage, replace the cap
with a new one.
• Install the cap [A] on a cooling system pressure tester [B].
NOTE
○Wet the cap sealing surfaces with water or coolant to
prevent pressure leaks.
4-14 COOLING SYSTEM
Radiator, Radiator Fan
the pressure gauge, pump the pressure tester
• Watching
to build up the pressure until the relief valve opens: the
gauge hand flicks downward. Stop pumping and measure
leak time at once. The relief valve must open within the
specified range in the table below and the gauge hand
must remain within the same range at least 6 seconds.
Radiator Cap Relief Pressure
Standard:
93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 14 ∼ 18
psi)
If the cap cannot hold the specified pressure, or if it holds
too much pressure, replace it with a new one.
COOLING SYSTEM 4-15
Thermostat
Thermostat Removal
• Remove:
Coolant (see Coolant Draining in the Periodic Maintenance chapter)
Seat (see Frame chapter)
Fuel Tank (see Fuel System chapter)
Thermostat Housing Cover Bolts [A]
Thermostat Housing Cover [B]
Thermostat
Thermostat Installation
a new O-ring [A] into the housing.
• Install
Install:
• Thermostat
•
Thermostat Housing Cover
Fill the radiator with coolant (see Cooling System in the
Periodic Maintenance chapter).
Thermostat Inspection
the thermostat, and inspect the thermostat valve
• Remove
[A] at room temperature.
If the valve is open, replace the thermostat with a new
one.
check valve opening temperature, suspend the ther• To
mostat [A] in a container of water and raise the temperature of the water.
○The thermostat must be completely submerged and must
not touch the container sides or bottom. Suspend an accurate thermometer [B] in the water so that the heat sensitive portions [C] are located in almost the same depth.
It must not touch the container, either.
If the measurement is out of the specified range, replace
the thermostat with a new one.
Thermostat Valve Opening Temperature
58 ∼ 62°C (136 ∼ 144°F)
4-16 COOLING SYSTEM
Hose and Pipes
Hose Installation
the hoses and pipes being careful to follow bend• Install
ing direction or diameter. Avoid sharp bending, kinking,
flattening, or twisting.
Install the clamps [A] as near as possible to the hose end
to clear the raised rib or the fitting. This will prevent the
hoses from working loose.
○The clamp screws should be positioned correctly to prevent the clamps from contacting anything.
•
Torque - Water Hose Clamp Screws: 2.0 N·m (0.2 kgf·m, 17
in·lb)
Hose Inspection
to the Water Hose and Connection Inspection in the
• Refer
Periodic Maintenance chapter
COOLING SYSTEM 4-17
Radiator Fan Switch, Water Temperature Sensor
Radiator Fan Switch, Water Temperature Sensor
Removal
CAUTION
The fan switch or the water temperature sensor
should never be allowed to fall on a hard surface.
Such a shock to their parts can damage them.
the coolant (see Coolant Draining in the Periodic
• Drain
Maintenance chapter).
• Remove:
Fuel Tank and Surge Tank (see Fuel System chapter)
Radiator Fan Switch Lead Connector [A]
Cover [B] and Radiator Fan Switch
Water Temperature Sensor Lead Connector [C]
Water Temperature Sensor [D]
Radiator Fan Switch, Water Temperature Sensor
Installation
silicone sealant to the threads of the fan switch and
• Apply
water temperature sensor.
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120
• Tighten the fan switch and water temperature sensor.
Torque - Radiator Fan Switch: 18 N·m (1.8 kgf·m, 13.0 ft·lb)
Water Temperature Sensor: 7.8 N·m (0.80 kgf·m,
69 in·lb)
the coolant and bleed the air from cooling system (see
• Fill
Coolant Filling in the Periodic Maintenance chapter).
Radiator Fan Switch, Water Temperature Sensor
Inspection
• Refer to Electrical System chapter for these inspections.
ENGINE TOP END 5-1
Engine Top End
Table of Contents
Exploded View...................................
Specifications ....................................
Special Tools .....................................
Clean Air System...............................
Air Suction Valve Removal...........
Air Suction Valve Installation........
Air Suction Valve Inspection ........
Vacuum Switch Valve Removal ...
Vacuum Switch Valve Installation
Vacuum Switch Valve Test ...........
Clean Air System Hose
Inspection..................................
Cylinder Head Cover .........................
Cylinder Head Cover Removal ....
Cylinder Head Cover Installation .
Cylinder Head Cover Assembly ...
Camshaft Chain Tensioner ................
Camshaft Chain Tensioner
Removal ....................................
Camshaft Chain Tensioner
Installation .................................
Camshaft, Camshaft Chain ...............
Camshaft Removal ......................
Camshaft Installation ...................
Camshaft, Camshaft Cap Wear
Inspection..................................
Camshaft Runout Inspection........
Cam Wear Inspection ..................
Camshaft Chain Removal ............
Camshaft and Sprocket
Assembly...................................
Rocker Shaft, Rocker Arm.................
Rocker Shaft, Rocker Arm
Removal ....................................
Rocker Shaft, Rocker Arm
Installation .................................
Cylinder Head....................................
Cylinder Compression
Measurement ............................
5-2
5-6
5-8
5-10
5-10
5-10
5-10
5-10
5-10
5-10
5-11
5-12
5-12
5-13
5-13
5-14
5-14
5-14
5-15
5-15
5-16
5-17
5-17
5-17
5-18
5-18
5-19
5-19
5-19
5-20
5-20
Cylinder Head Removal ...............
Cylinder Head Installation ............
Cylinder Head Assembly..............
Cylinder Head Warp Inspection ...
Valves ................................................
Valve Clearance Inspection .........
Valve Clearance Adjustment........
Valve Removal .............................
Valve Installation ..........................
Valve Guide Removal ..................
Valve Guide Installation ...............
Valve-to-Guide Clearance
Measurement (Wobble
Method) .....................................
Valve Seat Inspection ..................
Valve Seat Repair ........................
Cylinder, Pistons................................
Cylinder Removal.........................
Cylinder Installation......................
Piston Removal............................
Piston Installation.........................
Cylinder Wear Inspection.............
Piston Wear Inspection ................
Piston/Cylinder Clearance
Inspection..................................
Cylinder Boring and Honing .........
Piston Ring, Piston Ring Groove
Wear Inspection ........................
Piston Ring Groove Width
Inspection..................................
Piston Ring Thickness Inspection
Piston Ring End Gap Inspection ..
Muffler................................................
Muffler Removal...........................
Muffler Installation........................
Muffler Cover Removal ................
Muffler Cover Installation .............
5-21
5-21
5-22
5-23
5-24
5-24
5-24
5-24
5-24
5-24
5-25
5-25
5-26
5-26
5-31
5-31
5-31
5-31
5-32
5-33
5-33
5-33
5-33
5-34
5-34
5-35
5-35
5-36
5-36
5-36
5-37
5-37
5
5-2 ENGINE TOP END
Exploded View
ENGINE TOP END 5-3
Exploded View
No.
1
2
3
4
5
6
7
8
Fastener
Cylinder Head Cover Bolts
Cylinder Head Nuts (10 mm)
Cylinder Head Nuts (8 mm)
Cylinder Head Bolts
Cylinder Nuts
Camshaft Cap Bolt
Intake Manifold Bolts
Cylinder Head Cover Damper Plate Bolts
G: Apply grease.
L: Apply a non-permanent locking agent.
O: Apply oil.
S: Follow specified tightening sequence.
SS: Apply silicone sealant.
N·m
12
39
25
12
25
25
12
7.8
Torque
kgf·m
1.2
4.0
2.5
1.2
2.5
2.5
1.2
0.8
ft·lb
104 in·lb
29
18.0
104 in·lb
18.0
18.0
104 in·lb
69 in·lb
Remarks
S
S
S
L, S
5-4 ENGINE TOP END
Exploded View
ENGINE TOP END 5-5
Exploded View
No.
1
2
3
Fastener
Camshaft Sprocket Bolts
Camshaft Chain Tensioner Cap Bolts
Camshaft Chain Guide Bolts
4. Rocker Arm Spring (Intake), (Red Paint mark)
5. Exhaust Pipe Holder Nuts
6. Muffler Mounting Bolts
7. Muffler Connecting Clamp Bolt
L: Apply a non-permanent locking agent.
M: Apply molybdenum
O: Apply oil.
N·m
49
20
11
Torque
kgf·m
5.0
2.0
1.1
ft·lb
36
14.5
95 in·lb
Remarks
L
L
5-6 ENGINE TOP END
Specifications
Item
Clean Air System
Standard
Vacuum Switch Valve Closing Open → Close
Pressure
57 ∼ 65 kPa (430 ∼ 490 mmHg)
Camshafts
Cam Height:
Inlet
35.305 ∼ 35.413 mm (1.3900 ∼ 1.3942 in.)
Exhaust
35.033 ∼ 35.141 mm (1.3792 ∼ 1.3835 in.)
Camshaft Journal, Camshaft 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in.)
Cap Clearance
Camshaft Journal Diameter
26.950 ∼ 26.972 mm (1.0610 ∼ 1.0619 in.)
Camshaft Bearing Inside
27.000 ∼ 27.021 mm (1.0630 ∼ 1.0638 in.)
Diameter
Camshaft Runout
TIR 0.02 mm (0.0008 in.) or less
Rocker Arm Inside Diameter
Rocker Shaft Diameter
Cylinder Head
Cylinder Compression
Cylinder Head Warp
Valves
Valve Head Thickness:
Inlet
Exhaust
Valve Stem Bend
Valve Stem Diameter:
Inlet
Exhaust
Valve Guide Inside Diameter
Valve/valve Guide Clearance
(wobble method):
Inlet
Exhaust
Valve Seat Cutting Angle
Valve Seat Surface:
Width
Outside Diameter:
Inlet
Exhaust
Valve Spring Free Length
Cylinder, Piston
Cylinder Inside Diameter
Piston Diameter
Service Limit
– – –
35.21 mm (1.386 in.)
34.93 mm (1.375 in.)
0.16 mm (0.006 in.)
26.92 mm (1.060 in.)
27.08 mm (1.066 in.)
TIR 0.1 mm
(0.004 in.)
16.000 ∼ 16.018 mm (0.6300 ∼ 0.6306 in.) 16.05 mm (0.632 in.)
15.965 ∼ 15.984 mm (0.6285 ∼ 0.6293 in.) 15.94 mm (0.628 in.)
(usable range)
855 ∼ 1 315 kPa (8.7 ∼ 13.4 kgf/cm², 124
∼ 191 psi) @470 r/min (rpm)
–––
0.5 mm (0.02 in.)
0.8 mm (0.03 in.)
TIR 0.01 mm (0.0004 in.) or less
– – –
0.05 mm (0.002 in.)
0.3 mm (0.01 in.)
0.5 mm (0.02 in.)
TIR 0.05 mm
(0.002 in.)
4.975 ∼ 4.990 mm (0.1959 ∼ 0.1965 in.)
4.955 ∼ 4.970 mm (0.1951 ∼ 0.1957 in.)
5.000 ∼ 5.012 mm (0.1969 ∼ 0.1973 in.)
4.96 mm (0.195 in.)
4.94 mm (0.194 in.)
5.07 mm (0.200 in.)
0.03 ∼ 0.12 mm (0.001 ∼ 0.005 in.)
0.10 ∼ 0.18 mm (0.004 ∼ 0.007 in.)
45°, 32°, 60°
0.26 mm (0.010 in.)
0.32 mm (0.013 in.)
– – –
0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.)
30.9 ∼ 31.1 mm (1.216 ∼ 1.224 in.)
26.9 ∼ 27.1 mm (1.059 ∼ 1.067 in.)
40.5 mm (1.59 in.)
– – –
– – –
– – –
38.6 mm (1.52 in.)
88.000 ∼ 88.012 mm (3.4646 ∼ 3.4650 in.) 88.11 mm (3.468 in.)
87.975 ∼ 87.990 mm (3.4636 ∼ 3.4642 in.) 87.83 mm (3.458 in.)
ENGINE TOP END 5-7
Specifications
Item
Piston/Cylinder Clearance
Oversize Pistons and Rings
Piston Ring/Groove Clearance:
Top
Second
Piston Ring Groove Width:
Top
Second
Piston Ring Thickness:
Top and Second
Piston Ring End Gap:
Top
Second
Standard
0.010 ∼ 0.037 mm (0.0004 ∼ 0.0015 in.)
+0.5 mm (0.02 in.)
Service Limit
– – –
– – –
0.03 ∼ 0.07 mm (0.001 ∼ 0.003 in.)
0.02 ∼ 0.06 mm (0.0008 ∼ 0.0024 in.)
0.17 mm (0.007 in.)
0.16 mm (0.006 in.)
1.02 ∼ 1.04 mm (0.0402 ∼ 0.0409 in.)
1.01 ∼ 1.03 mm (0.0397 ∼ 0.0406 in.)
1.12 mm (0.0441 in.)
1.11 mm (0.0437 in.)
0.97 ∼ 0.99 mm (0.0382 ∼ 0.0390 in.)
0.90 mm (0.035 in.)
0.25 ∼ 0.40 mm (0.010 ∼ 0.016 in.)
0.40 ∼ 0.55 mm (0.016 ∼ 0.022 in.)
0.7 mm (0.03 in.)
0.9 mm (0.04 in.)
5-8 ENGINE TOP END
Special Tools
Compression Gauge, 20 kgf/cm²:
57001-221
Valve Seat Cutter, 60° 57001-1123
30:
Valve Spring Compressor Assembly:
57001-241
Valve Seat Cutter Holder Bar:
57001-1128
Piston Pin Puller Assembly:
57001-910
Valve Seat Cutter, 45° 57001-1187
30:
Valve Seat Cutter, 45° 57001-1115
32:
Valve Seat Cutter, 32° 57001-1199
33:
Valve Seat Cutter, 32° 57001-1119
28:
Valve Spring Compressor Adapter,
57001-1202
22:
ENGINE TOP END 5-9
Special Tools
Valve Guide Arbor,
57001-1203
Valve Guide Reamer,
57001-1204
5:
Fork Oil Level Gauge:
57001-1290
5:
Valve Seat Cutter Holder,
57001-1208
Compression Gauge Adapter, M10 × 1.0:
57001-1317
5:
Valve Seat Cutter, 60° 57001-1334
Spark Plug Wrench, Hex 16:
57001-1262
○The
33:
Vacuum Gauge KEK-55-5:
57001-1369
NOTE
following valve seat cutters can be
used instead of the above tools.
Inlet Valves:
Valve Seat Cutter, 55° -
35: 57001-1247
(instead of Valve Seat Cutter: 60° Exhaust Valves:
Valve Seat Cutter, 45° -
32: 57001-1115
(instead of Valve Seat Cutter: 45° Valve Seat Cutter, 32° -
33: 57001-1334)
30: 57001-1187)
30: 57001-1120
(instead of Valve Seat Cutter: 32° -
28: 57001-1119)
5-10 ENGINE TOP END
Clean Air System
Air Suction Valve Removal
• Refer:
Cylinder Head Cover Removal
Air Suction Valve Installation
• Refer:
Cylinder Head Cover Installation
Air Suction Valve Inspection
to the Air Suction Valve Inspection in the Periodic
• Refer
Maintenance chapter.
Vacuum Switch Valve Removal
• Remove:
Seat (see Frame chapter)
•
Fuel Tank and Surge Tank (see Fuel System chapter)
Pull off the hoses [A] and take out vacuum switch valve
[B] with the hose [C].
Vacuum Switch Valve Installation
the vacuum switch valve.
• Install
Route
the hoses correctly (see Appendix chapter).
•
Vacuum Switch Valve Test
the vacuum switch valve. (see Vacuum Switch
• Remove
Valve Removal).
the vacuum gauge [A] and syringe [B] or fork oil
• Connect
level gauge to the vacuum hoses as shown.
Special Tool - Vacuum Gauge KEK-55-5: 57001-1369
Fork Oil Level Gauge: 57001-1290
Air Flow [C]
raise the vacuum (lower the pressure) applied
• Gradually
to the vacuum switch valve, and check the valve operation. When the vacuum is low, the vacuum switch valve
should permit air to flow. When the vacuum raises to
valve closing pressure, it should stop air flow.
Spring [A]
Diaphragm [B]
Valve [C]
Low Vacuum [D]
Secondary Air Flow [E]
ENGINE TOP END 5-11
Clean Air System
If the vacuum switch valve does not operate as described,
replace it with a new one.
NOTE
○To check air flow through the vacuum switch valve, just
blow through the air cleaner hose.
Vacuum Switch Valve Closing Pressure (Open → Close)
Standard:
57 ∼ 65 kPa (430 ∼ 490 mmHg)
High Vacuum [A]
Secondary air cannot flow [B]
Clean Air System Hose Inspection
certain that all the hoses are routed without being flat• Be
tened or kinked, and are connected correctly to the air
cleaner housing, vacuum switch valve, carburetor body,
and cylinder head covers.
If they are not, correct them. Replace them if they are
damaged.
5-12 ENGINE TOP END
Cylinder Head Cover
Cylinder Head Cover Removal
• Remove:
Seat (see Frame chapter)
Fuel Tank (see Fuel System chapter)
(1) For Front Head Cover
Remove:
Air Cleaner Housing (see Fuel System chapter)
Spark Plug Cap [A]
Vacuum Switch Valve Hose [B]
Cover Bolts [C]
•
Cylinder Head Cover [A]
Air Suction Valve
Head Cover Gasket
(2) For Rear Head Cover
Disconnect the Coolant hose [A].
Remove:
Spark Plug Cap [B]
Vacuum Switch Valve Hose [C]
Choke Cable [D]
Cover Bolts [E]
•
•
○Just move everything that is between the cylinder head
cover and the frame out of the may to make room. Then
as a lift the cover up, make sure the spark plug pipe [A]
stays all the way down in the head. If the pipe comes up
with the cover.
ENGINE TOP END 5-13
Cylinder Head Cover
• Remove:
Cylinder Head Cover [A]
Air Suction Valve
Head Cover Gasket
Cylinder Head Cover Installation
the plug pipe [A] was removed, install it with the cham• Iffered
side [B] faces upward, and apply grease to the O
•
-ring [C].
Install:
Pin [D]
Head Cover Gasket [E]
Air Suction Valve [F] (as shown)
the washer with the metal side [A] faces upward.
• Install
Tighten:
•
Torque - Cylinder Head Cover Bolts: 12 N·m (1.2 kgf·m, 104
in·lb)
Cylinder Head Cover Assembly
a non-permanent locking agent to the threads of
• Apply
the damper plate bolts [1 ∼ 7], and tighten them to the
tightening sequence.
[A] Cylinder Head Cover
[B] Damper
[C] Damper Plate
Torque - Cylinder Head Cover Damper Plate Bolts: 7.8 N·m
(0.8 kgf·m, 69 in·lb)
5-14 ENGINE TOP END
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal
• Remove:
Engine (see Engine Removal/installation chapter)
•
Camshaft (see Camshaft Removal)
Cylinder Head (see Cylinder Head Removal)
Remove the camshaft chain tensioner body from the
cylinder.
Camshaft Chain Tensioner Installation
• Refer:
Cylinder Head Installation
Camshaft Installation
ENGINE TOP END 5-15
Camshaft, Camshaft Chain
Camshaft Removal
• Remove:
Cylinder Head Cover (see Cylinder Head Cover Removal)
Tensioner Cap Bolt [A], Washer [B] and Spring
CAUTION
Do not turn over the crankshaft while the tensioner
cap bolt is removed, The tensioner body is loose
from the cylinder while the cap bolt is removed.
Turning the crankshaft could damage the tensioner
body and/or cylinder, and also the valves because
upsetting the camshaft chain timing.
the stopper [A] and push the push rod [B] into
• Release
the tensioner body [C].
[D] Cylinder
[E] Camshaft Chain Guide
NOTE
○Temporary, install the tensioner cap bolt [A] only to pre-
vent the tensioner body from falling into the crankcase.
• Remove:
Camshaft Cap Bolts [A]
•
•
Camshaft Cap [B]
Disengage the camshaft chain [C] from the camshaft
sprocket [D], and remove the camshaft.
Stuff a clean cloth into the chain tunnel to keep any parts
from dropping into the crankcase.
CAUTION
The crankshaft may be turned while the camshaft is
removed. Always pull the chain taut while turning
the crankshaft. This avoids kinking the chain on the
lower (crankshaft) sprocket. A kinked chain could
damage both the chain and the sprocket.
5-16 ENGINE TOP END
Camshaft, Camshaft Chain
Camshaft Installation
• Apply engine oil to all cam parts and journals.
NOTE
○The front and rear camshafts are different.
The rear
camshaft [A] has a groove [B].
the front piston at TDC.
•○Set
Align the front piston TDC mark [A] and timing mark [B]
by turning the crankshaft counterclockwise [C] (left side
view).
the camshaft chain [A] with the camshaft sprocket
• Engage
[B].
○Align the timing mark line [C] on the camshaft sprocket
•
with the cylinder head upper surface [D].
Install the camshaft cap and tighten the cap bolts [E].
Torque - Camshaft Cap Bolts: 25 N·m (2.5 kgf·m, 18.0 ft·lb)
the front camshaft chain tensioner as follows:
•○Install
Remove the cap bolt installed temporarily.
○Hold the tensioner body and push the push rod [A] until
the rod touches to the chain guide [B] lightly.
○Install the spring, washer [C] and cap bolt [D].
Torque - Camshaft Chain Tensioner Cap Bolt: 20 N·m (2.0
kgf·m, 14.5 ft·lb)
NOTE
○Installing the rear camshaft is the same as for the front
camshaft. But noting the following.
the rear piston at TDC.
•○Set
Align the rear piston TDC mark [A] and timing mark [B]
by turning the crankshaft counterclockwise [C] 305° (left
side view).
ENGINE TOP END 5-17
Camshaft, Camshaft Chain
Camshaft, Camshaft Cap Wear Inspection
each clearance between the camshaft journal
• Measure
and the camshaft cap using plastigage (press gauge) [A].
• Tighten:
Torque - Camshaft Cap Bolts: 25 N·m (2.5 kgf·m, 18.0 ft·lb)
NOTE
○Do not turn the camshaft when the plastigage is between the journal and camshaft cap.
If any clearance exceeds the service limit, measure the
diameter of each camshaft journal with a micrometer.
Camshaft Journal, Camshaft Cap Clearance
Standard:
0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in.)
Service Limit: 0.16 mm (0.006 in.)
If the camshaft journal diameter is less than the service
limit, replace the camshaft with a new one and measure
the clearance again.
Camshaft Journal Diameter
Standard:
26.950 ∼ 26.972 mm (1.0610 ∼ 1.0619 in.)
Service Limit: 26.92 mm (1.060 in.)
If the clearance still remains out of the limit, replace the
cylinder head unit.
Camshaft Runout Inspection
the camshaft.
• Remove
Set
the
camshaft
in a camshaft alignment jig or on V
• blocks.
runout with a dial gauge at the specified place
• Measure
as shown.
If the runout exceeds the service limit, replace the shaft.
Camshaft Runout
Service Limit:
TIR 0.1 mm (0.004 in.)
Cam Wear Inspection
the camshaft.
• Remove
Measure
[A] of each cam with a micrometer.
• If the camstheareheight
worn down past the service limit, replace
the camshaft.
Cam Height
Standard
Service Limit
Inlet
35.305 ∼ 35.413 mm
(1.3900 ∼ 1.3942 in.)
35.21 mm
(1.386 in.)
Exhaust
35.033 ∼ 35.141 mm
(1.3792 ∼ 1.3835 in.)
34.93 mm
(1.375 in.)
5-18 ENGINE TOP END
Camshaft, Camshaft Chain
Camshaft Chain Removal
Front Camshaft Chain
Remove:
Alternator Rotor (see Electrical System chapter)
Bolts [A] and Black Chain Guide [B]
Bolt [C], Washer [D] and White Chain Guide [E]
Disengage the camshaft chain [F] from the crankshaft
sprocket and then remove the chain.
•
•
Rear Camshaft Chain
Remove:
Primary Gear (see Crankshaft/Transmission chapter)
Clutch (see Clutch chapter)
Bolts [A] and Black Chain Guide [B]
White Chain Guide [C]
Disengage the camshaft chain [D] from the crankshaft
sprocket and then remove the chain.
•
•
Camshaft and Sprocket Assembly
the sprocket bolt [A] and threads of the camshaft.
• Clean
Be
sure
install the pin [B].
• Apply a tonon-permanent
locking agent to the threads of
• the bolt, and tighten it. The
sprockets are identical.
Torque - Camshaft Sprocket Bolts: 49 N·m (5.0 kgf·m, 36
ft·lb)
ENGINE TOP END 5-19
Rocker Shaft, Rocker Arm
Rocker Shaft, Rocker Arm Removal
• Remove:
Cylinder Head Cover (cylinder Head Cover Removal)
Camshaft Cap
Rocker Shafts [A]
Rocker Arms [B] and Springs [C]
Rocker Shaft, Rocker Arm Installation
molybdenum disulfide grease to the rocker shaft.
• Apply
Insert
shaft into the camshaft cap and rocker
• arm sothethatrocker
the notch side [A] faces to the spring side.
Align
the
bolt
holes [B] of the camshaft cap and rocker
• shaft.
5-20 ENGINE TOP END
Cylinder Head
Cylinder Compression Measurement
NOTE
○Use the battery which is fully charged.
up the engine thoroughly.
• Warm
the engine.
• Stop
Remove:
• Seat (see Frame chapter)
Fuel Tank (see Fuel System chapter)
Spark Plugs
Special Tool - Spark Plug Wrench, Hex 16: 57001-1262
the compression gauge [A] and adapter [B] firmly
• Attach
into the spark plug hole.
○Using the starter motor, turn the engine over with the throttle fully open until the compression gauge stops rising; the
compression is the highest reading obtainable.
Special Tool - Compression Gauge, 20 kgf/cm²: 57001-221
Compression Gauge Adapter, M10 × 1.0:
57001-1317
Cylinder Compression
Usable Range:
855 ∼ 1315 kPa (8.7 ∼ 13.4 kgf/cm²,
121 ∼ 191 psi) @470 r/min (rpm)
the measurement for the other cylinders.
• Repeat
Install
the
spark plugs.
•
Torque - Spark Plugs: 18 N·m (1.8 kgf·m, 13 ft·lb)
The following table should be consulted if the obtainable compression reading is not within the usable range.
Problem
Cylinder
compression is
higher than usable
range
Cylinder
compression is
lower than usable
range
Diagnosis
Carbon accumulation on piston and in
combustion chamber possibly due to
damaged valve stem oil seal and/or
damaged piston oil rings (This may be
indicated by white exhaust smoke).
Incorrect cylinder head gasket thickness.
Gas leakage around cylinder head
Bad condition of valve seating
Incorrect valve clearance.
Incorrect piston/cylinder clearance
Piston seizure.
Bad condition of piston ring and/or piston
ring grooves
Remedy (Action)
Remove the carbon deposits
and replace damaged parts if
necessary.
Replace the gasket with a standard
part.
Replace damaged gasket and
check cylinder head warp.
Repair if necessary.
Adjust the valve clearance.
Replace the piston and/or cylinder
Inspect the cylinder and
replace/repair the cylinder and/or
piston as necessary.
Replace the piston and/or the
piston rings.
ENGINE TOP END 5-21
Cylinder Head
Cylinder Head Removal
• Remove:
Engine (see Engine Removal/Installation)
Camshaft (see Camshaft Removal)
Bolts [A] and Intake Manifold [B]
8 mm Cylinder Head Nuts [A]
Cylinder Head Bolt [A]
Cylinder Head Nuts [B]
10 mm Cylinder Head Nuts [C]
Cylinder Head
Cylinder Head Installation
NOTE
○The camshaft cap is machined with the cylinder head,
so if a new cylinder head is installed, use the cap that
is supplied with the new head.
○The rear cylinder head has a breather pipe fitting. Be
careful not to mix up the front and rear heads.
the stopper and push the push rod into the ten• Release
sioner body [A], and tighten the cap bolt [B] only temporar-
•
ily.
Install:
Oil Pipe [C]
White Chain Guide [D]
Knock Pins [E]
New Cylinder Head Gasket
5-22 ENGINE TOP END
Cylinder Head
the cylinder head nuts and bolt following the tight• Tighten
ening sequence [1 ∼ 7].
Torque - Cylinder Head Nuts:
10 mm [1 ∼ 4]: 39 N·m (4.0 kgf·m, 29 ft·lb)
8 mm [5 ∼ 6]: 25 N·m (2.5 kgf·m, 18 ft·lb)
Cylinder Head Bolt [7]: 12 N·m (1.2 kgf·m, 104
in·lb)
Tighten the 8 mm cylinder head nuts.
Torque - Cylinder Head Nuts (8 mm): 25 N·m (2.5 kgf·m, 18
ft·lb)
grease to the O-ring [A].
• Apply
Install
the intake manifold, and tighten the bolts.
•
Torque - Intake Manifold Bolts: 12 N·m (1.2 kgf·m, 104 in·lb)
Cylinder Head Assembly
the rubber dampers [A] between the fins [B] as
• Install
shown.
○The end of the damper should be recessed 3 ∼ 5 mm (0.12
∼ 0.20 in.) [C] inside the top of the lower fin.
Front Cylinder Head
[A] Rubber Dampers (16)
[B] 170 mm (6.69 in.)
[C] 165 mm (6.50 in.)
[D] 159 mm (6.26 in.)
[E] 154 mm (6.06 in.)
[F] 133 mm (5.24 in.)
[G] 140 mm (5.51 in.)
[H] 148 mm (5.83 in.)
[I] 70 mm (2.76 in.)
[J] 79 mm (3.11 in.)
ENGINE TOP END 5-23
Cylinder Head
Rear Cylinder Head
[A] Rubber Dampers (17)
[B] 40 mm (1.57 in.)
[C] 38 mm (1.50 in.)
[D] 36 mm (1.42 in.)
installing the breather pipe fitting [A] in the rear
• When
cylinder head, align the fitting with the mark [B].
[C] Fitting Hose
[D] 37 ∼ 43°
Cylinder Head Warp Inspection
a straightedge across the lower surface of the cylinder
• Lay
head at several positions.
a thickness gauge [A] to measure the space between
• Use
the straightedge [B] and the head.
Cylinder Head Warp
Standard:
Service Limit:
–––
0.05 mm (0.002 in.)
If the cylinder head is warped more than the service limit,
replace it.
If the cylinder head is warped less than the service limit,
repair the head by rubbing the lower surface on emery
paper secured to a surface plate (first No. 200, then No.
400)
5-24 ENGINE TOP END
Valves
Valve Clearance Inspection
to the Valve Clearance Inspection in the Periodic
• Refer
Maintenance chapter.
Valve Clearance Adjustment
to the Valve Clearance Adjustment in the Periodic
• Refer
Maintenance chapter.
Valve Removal
the cylinder head (see Cylinder Head Removal).
• Remove
Swing
open
the rocker arm, and then remove the shims.
•○Mark and record
the shim locations so that the shims can
•
be installed in their original positions.
Using the valve spring compressor assembly, remove the
valve.
Special Tools - Valve Spring Compressor Assembly: 57001
-241 [A]
Valve Spring Compressor Assembly, 22:
57001-1202 [B]
Valve Installation
the oil seal with a new one.
• Replace
a thin coat of molybdenum disulfide grease to the
• Apply
valve stem before valve installation.
[A] Valve Stem
[B] Oil Seal
[C] Spring Seat
[D] Spring
[E] Retainer
[F] Split Keepers
Valve Guide Removal
• Remove:
Valve (see Valve Removal)
•
Oil Seal
Spring Seat
Heat the area around the valve guide to 120 ∼ 150°C (248
∼ 302°F), and hammer lightly on the valve guide arbor [A]
to remove the guide from the top of the head.
CAUTION
Do not heat the cylinder head with a torch. This will
warp the cylinder head. Soak the cylinder head in
oil and heat the oil.
Special Tool - Valve Guide Arbor,
5: 57001-1203
ENGINE TOP END 5-25
Valves
Valve Guide Installation
oil to the valve guide outer surface before installa• Apply
tion.
the area around the valve guide hole to about 120 ∼
• Heat
150°C (248 ∼ 302°F) (see Valve Guide Removal).
the valve guide in from the top of the head using the
• Drive
valve guide arbor. The flange stops the guide from going
in too far.
Special Tool - Valve Guide Arbor,
5: 57001-1203
the valve guide with the valve guide reamer [A]
• Ream
even if the old guide is reused.
Special Tool - Valve Guide Reamer, 5: 57001-1204
Valve-to-Guide Clearance Measurement (Wobble
Method)
If a small bore gauge is not available, inspect the valve
guide wear by measuring the valve to valve guide clearance
with the wobble method as indicated below.
Insert a new valve [A] into the guide [B] and set a dial
gauge against the stem perpendicular to it as close as
possible to the cylinder head mating surface.
Move the stem back and forth [C] to measure valve/valve
guide clearance.
Repeat the measurement in a direction at a right angle to
the first.
If the reading exceeds the service limit, replace the guide.
•
•
•
NOTE
○The reading is not actual valve/valve guide clearance
because the measuring point is above the guide.
Valve/Valve Guide Clearance (Wobble Method)
Standard:
Inlet
0.03 ∼ 0.12 mm (0.001 ∼ 0.005 in.)
Exhaust
0.10 ∼ 0.18 mm (0.04 ∼ 0.007 in.)
Service Limit:
Inlet
0.26 mm (0.010 in.)
Exhaust
0.32 mm (0.013 in.)
5-26 ENGINE TOP END
Valves
Valve Seat Inspection
the valve (see Valve Removal).
• Remove
Check
the
valve seating surface [A] between the valve [B]
• and valve seat
[C].
○Measure the outside diameter [D] of the seating pattern
on the valve seat.
If the outside diameter is too large or too small, repair the
seat (see Seat Repair).
Valve Seating Surface Outside Diameter
Standard:
Inlet
30.9 ∼ 31.1 mm (1.216 ∼ 1.224 in.)
Exhaust
26.9 ∼ 27.1 mm (1.059 ∼ 1.067 in.)
○Measure the seat width [E] of the portion where there is
no build-up carbon (white portion) of the valve seat with a
vernier caliper.
Good [F]
If the width is too wide [G], too narrow [H] or uneven [J],
repair the seat (see Valve Seat Repair).
Valve Seating Surface Width
Standard:
Inlet, Exhaust
0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.)
Valve Seat Repair
• Repair the valve seat with the valve seat cutters [A].
Special Tools -
Valve Seat Cutter Holder, 5: 57001-1208 [B]
Valve Seat Cutter Holder Bar: 57001-1128 [C]
[For Inlet Valve Seat]
Valve Seat Cutter, 45° -
32: 57001-1115
Valve Seat Cutter, 32° -
33: 57001-1199
Valve Seat Cutter, 60° -
33: 57001-1334
or Valve Seat Cutter, 55° -
35: 57001-1247
[For Exhaust Valve Seat]
Valve Seat Cutter, 45° -
30: 57001-1187
or Valve Seat Cutter, 45° -
32: 57001-1115
Valve Seat Cutter, 32° -
28: 57001-1119
or Valve Seat Cutter, 32° -
30: 57001-1120
Valve Seat Cutter, 60° -
30: 57001-1123
If the manufacturer’s instructions are not available, use
the following procedure.
ENGINE TOP END 5-27
Valves
Seat Cutter Operation Care
1. This valve seat cutter is developed to grind the valve for
repair. Therefore the cutter must not be used for other
purposes than seat repair.
2. Do not drop or shock the valve seat cutter, or the diamond particles may fall off.
3. Do not fail to apply engine oil to the valve seat cutter
before grinding the seat surface. Also wash off ground
particles sticking to the cutter with washing oil.
NOTE
○Do not use a wire brush to remove the metal particles
from the cutter. It will take off the diamond particles.
4. Setting the valve seat cutter holder in position, operate
the cutter in one hand. Do not apply too much force to
the diamond portion.
NOTE
○Prior to grinding, apply engine oil to the cutter and during the operation, wash off any ground particles sticking
to the cutter with washing oil.
5. After use, wash it with washing oil and apply thin layer
of engine oil before storing.
Marks Stamped on the Cutter
The marks stamped on the back of the cutter [A] represent
the following.
60° ........................... Cutter angle [B]
37.5 ....................... Outer diameter of cutter [C]
Operating Procedures
Clean the seat area carefully.
Coat the seat with machinist’s dye.
Fit a 45° cutter into the holder and slide it into the valve
guide.
Press down lightly on the handle and turn it right or left.
Grind the seating surface only until it is smooth.
•
•
•
•
CAUTION
Do not grind the seat too much. Overgrinding will
reduce valve clearance by sinking the valve into the
head. If the valve sinks too far into the head, it will
be impossible to adjust the clearance, and the cylinder head must be replaced.
Widened Width [A] of engagement by machining with
45° cutter
Ground Volume [B] by 32° cutter
32° [C]
Correct Width [D]
Ground Volume [E] by 60° cutter
60° [F]
5-28 ENGINE TOP END
Valves
the outside diameter (O.D.) of the seating sur• Measure
face with a vernier caliper.
If the outside diameter of the seating surface is too small,
repeat the 45° grind [A] until the diameter is within the
specified range.
Original Seating Surface [B]
NOTE
○Remove all pittings of flaws from 45° ground surface.
○After grinding with 45° cutter, apply thin coat of machin-
ist’s dye to seating surface. This makes seating surface
distinct and 32° and 60° grinding operation easier.
○When the valve guide is replaced, be sure to grind with
45° cutter for centering and good contact.
If the outside diameter of the seating surface is too large,
make the 32° grind described below.
If the outside diameter [A] of the seating surface is within
the specified range, measure the seat width as described
below.
Grind the seat at a 32° angle [B] until the seat O.D. is
within the specified range.
○To make the 32° grind, fit a 32° cutter into the holder, and
slide it into the valve guide.
○Turn the holder one turn at a time while pressing down
very lightly. Check the seat after each turn.
•
CAUTION
The 32° cutter removes material very quickly.
Check the seat outside diameter frequently to prevent overgrinding.
○After making the 32° grind, return to the seat O.D. mea-
•
surement step above.
To measure the seat width, use a vernier caliper to measure the width of the 45° angle portion of the seat at several places around the seat.
If the seat width is too narrow, repeat the 45° grind until
the seat is slightly too wide, and then return to the seat
O.D. measurement step above.
If the seat width is too wide, make the 60° [A] grind described below.
If the seat width is within the specified range, lap the valve
to the seat as described below.
Grind the seat at a 60° angle until the seat width is within
the specified range.
○To make the 60° grind, fit 60° cutter into the holder, and
slide it into the valve guide.
○Turn the holder, while pressing down lightly.
○After making the 60° grind, return to the seat width measurement step above.
Correct Width [B]
•
ENGINE TOP END 5-29
Valves
the valve to the seat, once the seat width and O.D.
• Lap
are within the ranges specified above.
○Put a little coarse grinding compound on the face of the
valve in a number of places around the valve head.
○Spin the valve against the seat until the grinding com-
pound produces a smooth, matched surface on both the
seat and the valve.
○Repeat the process with a fine grinding compound.
Lapper [A]
Valve Seat [B]
Valve [C]
The seating area should be marked about in the middle
of the valve face.
If the seat area is not in the right place on the valve, check
to be sure the valve is the correct part. If it is, it may have
been refaced too much; replace it.
Be sure to remove all grinding compound before assembly.
When the engine is assembled, be sure to adjust the valve
clearance (see Valve Clearance Adjustment in the Periodic Maintenance chapter).
•
•
•
5-30 ENGINE TOP END
Valves
ENGINE TOP END 5-31
Cylinder, Pistons
Cylinder Removal
• Remove:
Cylinder Head (see Cylinder Head Removal)
Cylinder Nut [A]
Cylinder
Cylinder Installation
NOTE
○If a new cylinder is used, check piston to cylinder clearance (see Piston/Cylinder Clearance), and use new piston ring.
the pin and new cylinder gasket.
• Install
The
piston
ring openings must be positioned as shown in
• the figure. The
openings of the oil ring steel rails must be
about 30° ∼ 45° [F] of angle from the opening of the top
ring.
Top Ring [A]
Second Ring [B]
Oil Ring Steel Rails [C]
Oil Ring Expander [D]
Arrow [E]
Opening Position [G]
engine oil to the cylinder bore and piston skirt.
• Apply
Install
the cylinder [A] so that the tensioner mounting hole
• faces rearward.
• Tighten:
Torque - Cylinder Nuts: 25 N·m (2.5 kgf·m, 18.0 ft·lb)
Piston Removal
the cylinder (see Cylinder Removal).
• Remove
Place
a
clean
cloth under the piston and remove the pis• ton pin snap ring.
• Remove the piston pin.
Special Tool - Piston Pin Puller Assembly: 57001-910 [A]
5-32 ENGINE TOP END
Cylinder, Pistons
spread the ring opening with your thumbs and
• Carefully
then push up on the opposite side of the ring [A] to remove
•
it.
Remove the 3-piece oil ring with your thumbs in the same
manner.
Piston Installation
NOTE
○If a new piston is used, check piston to cylinder clear-
ance (see Piston/Cylinder Clearance), and use new piston ring.
arrow on the piston head must point toward the ex• The
haust side of the cylinder.
a new piston pin snap ring into the side of the piston
• Fit
so that the ring opening [A] does not coincide with the slit
[B] of the piston pin hole.
○When installing the piston pin snap ring, compress it only
enough to install it and no more.
CAUTION
Do not reuse snap rings, as removal weakens and
deforms them. They could fall out and score the
cylinder wall.
the oil ring expander [A] in the bottom piston ring
• Install
groove so the ends [B] butt together.
the oil ring steel rails, one above the expander and
• Install
one below it.
○Spread the rail with your thumbs, but only enough to fit
the rail over the piston.
○Release the rail into the bottom piston ring groove.
NOTE
○The oil ring rails have no “top” or “bottom”.
not mix up the top and second rings.
•○Do
Install the top ring [A] so that the “R” mark [B] faces up.
○Install the second ring [C] so that the “RN” mark [D] faces
up.
ENGINE TOP END 5-33
Cylinder, Pistons
Cylinder Wear Inspection
there is a difference in cylinder wear in different di• Since
rections, take a side-to-side and a front-to-back measurement at each of the 3 locations (total of 6 measurements)
shown in the figure.
If any of the cylinder inside diameter measurements exceeds the service limit, the cylinder will have to be bored
to oversize and then honed.
[A] 10 mm (0.4 in.)
[B] 60 mm (2.4 in.)
[C] 20 mm (0.8 in.)
Cylinder Inside Diameter
Standard:
88.000 ∼ 88.012 mm (3.4646 ∼ 3.4650 in.)
Service Limit: 88.11 mm (3.468 in.)
Piston Wear Inspection
the outside diameter [A] of each piston 5 mm
• Measure
(0.2 in.) [B] up from the bottom of the piston at a right
angle to the direction of the piston pin.
If the measurement is under service limit, replace the piston.
Piston Diameter
Standard:
87.975 ∼ 87.990 mm (3.4636 ∼ 3.4642 in.)
Service Limit: 87.83 mm (3.458 in.)
Piston/Cylinder Clearance Inspection
the piston diameter from the cylinder inside di• Subtract
ameter to get the piston/cylinder clearance.
Piston/Cylinder Clearance
Standard:
0.010 ∼ 0.037 mm (0.0004 ∼ 0.0015 in.)
If the piston/cylinder clearance is less than the specified
range, use a smaller piston or increase the cylinder inside
diameter by honing.
If the piston/cylinder clearance is greater than specified
range, use a larger piston.
If only a piston is replaced, the clearance may exceed
the standard slightly. But it must not to be less than the
minimum in order to avoid piston seizure.
Cylinder Boring and Honing
○There is an oversize piston available. The oversize piston
requires oversize rings.
Oversize Piston and Rings
0.5 mm (0.02 in.) Oversize
boring a cylinder [A], first measure the exact di• Before
ameter of the oversize piston, and then, according to the
standard clearance in the Specifications, determine the
rebore diameter. However, if the amount of boring necessary would make the inside diameter greater than 0.5
mm (0.02 in.) the cylinder block must be replaced.
5-34 ENGINE TOP END
Cylinder, Pistons
○Cylinder inside diameter must not vary more than 0.01
mm (0.0004 in.) at any point.
○Be wary of measurements taken immediately after boring
since the heat affects cylinder diameter.
○In the case of rebored cylinder and oversize piston, the
service limit for the cylinder is the diameter that the cylinder was bored to plus 0.1 mm (0.004 in.) and the service
limit for the piston is the oversize piston original diameter
minus 0.15 mm. (0.006 in.) If the exact figure for the rebored diameter is unknown, it can be roughly determined
by measuring the diameter at the base of the cylinder.
Piston Ring, Piston Ring Groove Wear Inspection
for uneven groove wear by inspecting the ring seat• Check
ing.
•
The rings should fit perfectly parallel to groove surfaces.
If not, replace the piston and all the piston rings.
With the piston rings in their grooves, make several measurements with a thickness gauge [A] to determine piston
ring/groove clearance.
Piston Ring/Groove Clearance
Standard:
Top
0.03 ∼ 0.07 mm (0.0012 ∼ 0.0028 in.)
Second
0.02 ∼ 0.06 mm (0.0008 ∼ 0.0024 in.)
Service Limit:
Top
0.17 mm (0.007 in.)
Second
0.16 mm (0.006 in.)
If the piston ring groove clearance is greater than the service limit, measure the ring thickness and groove width as
follows to decide whether to replace the rings, the piston
or both.
Piston Ring Groove Width Inspection
the piston ring groove width.
•○Measure
Use a vernier caliper at several points around the piston.
Piston Ring Groove Width
Standard:
Top
1.02 ∼ 1.04 mm (0.0402 ∼ 0.0409 in.)
Second
1.01 ∼ 1.03 mm (0.0397 ∼ 0.0406 in.)
Service Limit:
Top
1.12 mm (0.0441 in.)
Second
1.11 mm (0.0437 in.)
If the width of any of the two grooves is wider than the
service limit at any point, replace the piston.
ENGINE TOP END 5-35
Cylinder, Pistons
Piston Ring Thickness Inspection
the piston ring thickness.
•○Measure
Use a micrometer to measure at several points around
the ring.
Piston Ring Thickness
Standard:
Top and Second 0.97 ∼ 0.99 mm 0.0382 ∼ 0.0390 in.)
Service Limit:
Top and Second 0.90 mm 0.035 in.)
If any of the measurements is less than the service limit
on either of the rings, replace all the rings.
NOTE
○When using new rings in a used piston, check for uneven groove wear. The rings should fit perfectly parallel
to the groove sides. If not, replace the piston.
Piston Ring End Gap Inspection
the piston ring [A] inside the cylinder, using the pis• Place
ton to locate the ring squarely in place. Set it close to the
•
bottom of the cylinder, where cylinder wear is low.
Measure the gap [B] between the ends of the ring with a
thickness gauge.
Piston Ring End Gap
Standard:
Top
0.25 ∼ 0.40 mm (0.010 ∼ 0.016 in.)
Second
0.40 ∼ 0.55 mm (0.016 ∼ 0.022 in.)
Service Limit:
Top
0.70 mm (0.03 in.)
Second
0.90 mm (0.04 in.)
If the end gap of either ring is greater than the service
limit, replace all the rings.
5-36 ENGINE TOP END
Muffler
Muffler Removal
Front Muffler
Remove:
Clamp Bolts [A] and Front Exhaust Pipe Cover [B]
•
• Remove the exhaust pipe holder nuts [A]
• Remove:
Muffler Bolts [A]
Clamp Bolts [B]
Front Muffler [C]
Rear Muffler
Remove:
Front Muffler
Clamp Bolts [A] and Rear Exhaust Pipe Cover [B]
Exhaust Pipe Holder Nuts [C]
Bolt [D]
Rear Muffler [E]
•
Muffler Installation
the grommets [A] onto the hooks [B] on the exhaust
• Install
pipe.
• Slip the hook into the brace [C] of the exhaust cover [D].
ENGINE TOP END 5-37
Muffler
the front muffler [A] shall be connected to the rear
• When
muffler [B], the position of clamp bolt head [C] faces outwards as shown.
Muffler Cover Removal
the muffler cover [A] from the muffler as follows:
•○Remove
Hold the both ends on the cover.
○Push [B] the upper end of the cover and then slide up [C]
the cover as shown.
Muffler Cover Installation
the pins [A] of the muffler cover into the hose [B] on
• Insert
the muffler.
NOTE
○Do not move the muffler cover to the front and rear.
CLUTCH 6-1
Clutch
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tool ............................................................................................................................
Clutch Lever and Cable ..........................................................................................................
Lever Free Play Inspection ...............................................................................................
Lever Free Play Adjustment..............................................................................................
Cable Removal .................................................................................................................
Cable Installation ..............................................................................................................
Cable Lubrication ..............................................................................................................
Clutch Lever Installation....................................................................................................
Right Engine Cover ................................................................................................................
Right Engine Cover Removal............................................................................................
Right Engine Cover Installation.........................................................................................
Release Shaft Removal ....................................................................................................
Release Shaft Installation .................................................................................................
Clutch .....................................................................................................................................
Clutch Removal.................................................................................................................
Clutch Installation..............................................................................................................
Clutch Plate, Wear, Damage Inspection ...........................................................................
Clutch Plate Warp Inspection............................................................................................
Clutch Spring Free Length Measurement .........................................................................
6-2
6-4
6-5
6-6
6-6
6-6
6-6
6-6
6-6
6-6
6-7
6-7
6-7
6-7
6-8
6-9
6-9
6-9
6-10
6-10
6-11
6
6-2 CLUTCH
Exploded View
CLUTCH 6-3
Exploded View
No.
1
2
3
Fastener
Right Engine Cover Bolts
Clutch Hub Nut
Clutch Spring Bolts
4. Clutch Lever Pivot Nut
5. Clutch Lever Holder Clamp Bolt
CL: Apply Cable Lubricant.
G: Apply grease.
L: Apply a non-permanent locking agent.
O: Apply oil.
Si: Apply Silicone Grease.
N·m
12
132
8.8
Torque
Remarks
kgf·m
ft·lb
1.2
104 in·lb
L (1)
13.5
98
O
0.9
78 in·lb
6-4 CLUTCH
Specifications
Item
Clutch
Friction Plate Thickness
Friction and Steel Plate Warp
Clutch Spring Free Length:
(On and after VN800-B7)
Standard
2.9 ∼ 3.1 mm (0.114 ∼ 0.122 in.)
0.2 mm (0.008 in.) or less
34.2 mm (1.35 in.)
35.3 mm (1.39 in.)
Service Limit
2.8 mm (0.11 in.)
0.3 mm (0.012 in.)
33.1 mm (1.30 in.)
34.1 mm (1.34 in.)
CLUTCH 6-5
Special Tool
Clutch Holder:
57001-1243
6-6 CLUTCH
Clutch Lever and Cable
Lever Free Play Inspection
to the Clutch Inspection in the Periodic Mainte• Refer
nance chapter.
Lever Free Play Adjustment
to the Clutch Inspection in the Periodic Mainte• Refer
nance chapter.
Cable Removal
the dust cover at the clutch cable lower end out of
• Slide
place.
the nuts, and slide the lower end of the clutch
• Loosen
cable to give the cable plenty of play.
the locknut at the clutch lever, and screw in the
• Loosen
adjuster.
up the slots [A] in the clutch lever, locknut [B], and
• Line
adjuster [C], and then free the cable from the lever.
the clutch inner cable tip from the clutch release
• Free
lever.
the release lever toward the front of the motorcycle
• Push
and tape the release lever to the clutch cover to prevent
•
the release shaft from falling out.
Pull the clutch cable out of the frame.
Cable Installation
the clutch cable correctly (see Appendix chapter).
• Run
Adjust
the clutch cable (see Lever Free Play Adjustment
• in the Periodic
Maintenance chapter).
Cable Lubrication
Whenever the clutch cable is removed, lubricate the
clutch cable as follows.
Apply a thin coating of grease to the cable upper and
lower ends.
Lubricate the cable with a penetrating rust inhibitor.
•
•
Clutch Lever Installation
the clutch lever so that the mating surface [A] of
• Install
the lever holder is aligned with the punch mark [B] of the
handlebar.
CLUTCH 6-7
Right Engine Cover
Right Engine Cover Removal
• Remove:
Engine Oil (drain, see Engine Lubrication System chap-
•
ter)
Coolant (drain, see Cooling System chapter)
Front Right Foot Peg and Brake Pedal (see Brakes
chapter)
Front Muffler (see Engine Top End chapter)
Clutch Cable
Down Tube (see Frame chapter)
Coolant Hose [A]
Clutch Cover Bolts [B]
Coolant Pipe [C] (from the engine)
Turn the release lever [D] toward the rear as shown, and
remove the right engine cover.
Right Engine Cover Installation
the knock pins [A], and replace the cover gasket
• Install
with a new one.
to see that the washer [B] is in place.
• Check
Apply
a
locking agent to the threads of
• the right non-permanent
engine cover bolt [C].
a soap and water solution to the seal [A]. Do not
• Apply
apply a grease or oil to the seal.
• Tighten:
Torque - Right Engine Cover Bolts: 12 N·m (1.2 kgf·m, 104
in·lb)
Release Shaft Removal
CAUTION
Do not remove the clutch release lever and shaft
assembly unless it is absolutely necessary. If removed, the oil seal replacement may be required.
the right engine cover (see Right Engine Cover
• Remove
Removal).
the circlip [A] from the release shaft.
• Remove
Pull
the
lever
• gine cover. and shaft assembly [B] out of the right en-
6-8 CLUTCH
Right Engine Cover
Release Shaft Installation
high-temperature grease to the oil seal lips on the
• Apply
lower ridge of the clutch cover.
oil to the bearing in the hole of the right engine
• Apply
cover.
the release shaft straight into the lower hole of the
• Insert
right engine cover.
CAUTION
When inserting the release shaft, be careful not to
remove the spring of the oil seal.
CLUTCH 6-9
Clutch
Clutch Removal
• Remove:
Right Engine Cover (see Right Engine Cover Removal)
Clutch Spring Bolts [A]
Clutch Springs
Clutch Spring Plate [B] (with thrust bearing and pusher
[C])
Friction Plates, Steel Plates
Clutch Hub Nut [A]
Holding
the clutch hub [B], remove the nut.
○
Special Tool - Clutch Holder: 57001-1243 [C]
• Remove:
Clutch Hub
Spacer [A]
Clutch Housing [B], Needle Bearing and Bushing
Thrust Spacer
Clutch Installation
the following parts on the drive shaft.
• Install
[A] Thrust Spacer
[B] Bushing
[C] Needle Bearing
[D] Clutch Housing
[E] Spacer
[F] Clutch Hub
[G] Washer
[H] Nut
6-10 CLUTCH
Clutch
○Install the thrust spacer [A] so that the stepped side [B]
faces inward.
○Replace the clutch hub nut with a new one.
○Apply oil to the threads and seating surface of the hub nut.
○Holding the clutch hub, tighten the clutch hub nut.
Special Tool - Clutch Holder: 57001-1243
Torque - Clutch Hub Nut: 132 N·m (13.5 kgf·m, 98 ft·lb)
the friction plates and steel plates, starting with a
• Install
friction plate and alternating them.
CAUTION
If new dry friction plates and steel plates are installed, apply engine oil to the surfaces of each
plate to avoid clutch plate seizure.
○Install
•
the last friction plate [A] fitting the tangs in the
grooves in the housing as shown.
Install the clutch spring plate and spring, and tighten the
clutch spring bolts.
Torque - Clutch Spring Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
the right engine cover (see Right Engine Cover In• Install
stallation).
Clutch Plate, Wear, Damage Inspection
inspect the friction and steel plates for signs of
• Visually
seizure, overheating (discoloration), or uneven wear.
the thickness of each friction plate [A] at several
• Measure
points.
If any plates show signs of damage, or if they have worn
past the service limit, replace them with new ones.
Friction Plate Thickness
Standard:
2.9 ∼ 3.1 mm (0.114 ∼ 0.122 in.)
Service Limit:
2.8 mm (0.11 in.)
Clutch Plate Warp Inspection
each friction plate or steel plate on a surface plate
• Place
and measure the gap between the surface plate [A] and
each friction plate or steel plate [B] with a thickness gauge
[C]. The gap is the amount of friction or steel plate warp.
If any plate is warped over the service limit, replace it with
a new one.
Friction and Steel Plate Warp
Standard:
0.2 mm (0.008 in.) or less
Service Limit:
0.3 mm (0.012 in.)
CLUTCH 6-11
Clutch
Clutch Spring Free Length Measurement
the free length of the clutch springs [A].
• Measure
If any spring is shorter than the service limit, it must be
replaced.
Clutch Spring Free Length
Standard:
34.2 mm (1.35 in.)
Service Limit:
33.1 mm (1.30 in.)
On and after VN800-B7 Model
Standard:
35.3 mm (1.39 in.)
Service Limit:
34.1 mm (1.34 in.)
ENGINE LUBRICATION SYSTEM 7-1
Engine Lubrication System
Table of Contents
Exploded View........................................................................................................................
Engine Oil Flow Chart.............................................................................................................
Specifications .........................................................................................................................
Special Tool ............................................................................................................................
Engine Oil and Oil Filter..........................................................................................................
Oil Level Inspection...........................................................................................................
Engine Oil Change............................................................................................................
Oil Filter Change ...............................................................................................................
Oil Screen Cleaning ..........................................................................................................
Oil Pressure Relief Valve........................................................................................................
Oil Pressure Relief Valve Removal/Installation.................................................................
Oil Pressure Relief Valve Inspection.................................................................................
Oil Pump, Oil Pump Drive Chain ...........................................................................................
Oil Pump Removal ...........................................................................................................
Oil Pump Installation .........................................................................................................
Oil Pump Drive Chain Guide Installation ..........................................................................
Oil Pressure Measurement ....................................................................................................
Oil Pressure Measurement ...............................................................................................
Oil Pressure Switch ................................................................................................................
Oil Pressure Switch Removal ..........................................................................................
Oil Pressure Switch Installation .......................................................................................
Oil Pipe ...................................................................................................................................
Oil Pipe (Crankcase Outside) Removal ...........................................................................
Oil Pipe (Crankcase Outside) Installation .........................................................................
Oil Passage Cover Removal/Installation...........................................................................
Oil Pipe (Crankcase Inside) Removal ..............................................................................
Oil Pipe (Crankcase Inside) Installation ............................................................................
7-2
7-4
7-5
7-6
7-7
7-7
7-7
7-7
7-7
7-9
7-9
7-9
7-10
7-10
7-10
7-10
7-11
7-11
7-12
7-12
7-12
7-13
7-13
7-13
7-13
7-14
7-14
7
7-2 ENGINE LUBRICATION SYSTEM
Exploded View
ENGINE LUBRICATION SYSTEM 7-3
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
Fastener
Engine Drain Plug
Oil Pump Mounting Bolts
Oil Pump Drive Chain Guide Bolt
Oil Filter
Oil Filter Plate Mounting Bolts
Oil Screen Plug
Oil Pressure Relief Valve
Oil Pressure Switch
Oil Pressure Switch Adapter
Oil Pipe Mounting Bolts (RH Crankcase Inside)
Oil Pipe Mounting Bolts (LH Crankcase Outside)
Oil Pipe Mounting Bolts (LH Crankcase Inside)
Oil Passage Cover Screws (Crankcase Outside)
G: Apply grease.
L: Apply a non-permanent locking agent.
SS: Apply silicone sealant.
N·m
20
11
12
18
7.8
20
15
15
20
11
5.4
11
5.4
Torque
Remarks
kgf·m
ft·lb
2.0
14.5
1.1
97 in·lb
L
1.2
104 in·lb
L
1.8
13
0.8
69 in·lb
2.0
14.5
1.5
11
L
1.5
11
SS
2.0
14.5
1.1
95 in·lb
L
0.55
48 in·lb
L
1.1
95 in·lb
L
0.55
48 in·lb
L
7-4 ENGINE LUBRICATION SYSTEM
Engine Oil Flow Chart
1. Left Crankcase
2. Right Crankcase
3. Oil Screen Plug
4. Oil Screen
5. Oil Pump
6. Oil Filter
7. Oil Pressure Switch
8. Oil Pipe
9. Crankshaft
10. Relief Valve
11. Output Shaft
12. Drive Shaft
13. Front Cylinder Head
14. Rear Cylinder Head
15. Camshaft Cap
16. Rocker Arm
17. Camshaft
ENGINE LUBRICATION SYSTEM 7-5
Specifications
Item
Engine Oil
Type
(On and after VN800-B6)
Viscosity
(On and after VN800-B6)
Capacity
Oil Pressure Measurement
Oil pressure @4 000 r/min
(rpm), oil temperature 100°C
(212°F)
Standard
SE, SF or SG class
API SE,SF,or SG
API SH or SJ with JASO MA
SAE 10W-40, 10W-50, 20W-40, or 20W-50
SAE 10W-40
2.7 L (2.9 us qt) (when filter is not removed)
2.9 L (3.1 us qt) (when filter is removed)
3.2 L (3.4 us qt) (when engine is completely dry)
355 ∼ 410 kPa (3.6 ∼ 4.2 kgf/cm², 51∼ 60 psi)
Service Limit
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
– – –
– – –
7-6 ENGINE LUBRICATION SYSTEM
Special Tool
Oil Pressure Gauge, 10 kgf/cm²:
57001-164
Oil Filter Wrench:
57001-1249
Oil Pressure Gauge Adapter, PT 1/8:
57001-1033
Kawasaki Bond (Silicone Sealant):
56019-120
ENGINE LUBRICATION SYSTEM 7-7
Engine Oil and Oil Filter
WARNING
Motorcycle operation with insufficient, deteriorated, or contaminated engine oil will cause
accelerated wear and may result in engine or transmission seizure, accident, and injury.
Oil Level Inspection
that the engine oil level is between the upper [A]
• Check
and lower [B] level lines next to the gauge [C].
NOTE
○Situate the motorcycle so that it is perpendicular to the
ground.
○If the motorcycle has just been used, wait several minutes for all the oil to drain down.
○If the oil has just been changed, start the engine and
run it for several minutes at idle speed. This fills the oil
filter with oil. Stop the engine, then wait several minutes
until the oil settles.
CAUTION
Racing the engine before the oil reaches every part
can cause engine seizure.
If the engine oil gets extremely low or if the oil pump
or oil passages clog up or otherwise do not function
properly, the oil pressure warning light will light. If
this light stays on when the engine is running above
the idle speed, stop the engine immediately and find
the cause.
Engine Oil Change
to the Engine Oil Change in the Periodic Mainte• Refer
nance chapter.
Oil Filter Change
to the Oil Filter Replacement in the Periodic Main• Refer
tenance chapter.
Oil Screen Cleaning
the engine oil (see Engine Oil Change in the Peri• Drain
odic Maintenance chapter).
• Remove the oil screen plug [A], spring and washer.
7-8 ENGINE LUBRICATION SYSTEM
Engine Oil and Oil Filter
out the oil screen [A].
• Pull
Clean
the screen with high flash-point solvent.
•
WARNING
Clean the screen in a well-ventilated area, and take
care that there is no spark or frame anywhere near
the working area.
Because of the danger of highly flammable liquids,
do not use gasoline or low-flash point solvents.
the screen carefully for any damage.
• Check
If the screen is damaged, replace it with a new one.
the O-ring [B] the oil screen plug for damage.
• Check
If the O-ring is damaged, replace it with a new one.
• Install:
Oil Screen and Rubber Gasket [C]
•
Washer [D]
Spring [E]
Apply grease to the O-ring, and tighten the plug.
Torque - Oil Screen Plug: 20 N·m (2.0 kgf·m, 14.5 ft·lb)
ENGINE LUBRICATION SYSTEM 7-9
Oil Pressure Relief Valve
Oil Pressure Relief Valve Removal/Installation
the crankcase (see Crankshaft/Transmission chap• Split
ter).
the relief valve [A] from the right crankcase.
• Remove
Apply
a
non-permanent
locking agent to the threads of
• the relief valve, and tighten
it.
Torque - Oil Pressure Relief Valve: 15 N·m (1.5 kgf·m, 11.0
ft·lb)
Oil Pressure Relief Valve Inspection
to see if the steel ball [A] inside the valve slides
• Check
smoothly when pushing it in with a wooden or other soft
rod, and see if it comes back to its seat by valve spring
pressure [B].
NOTE
○Inspect the valve in its assembled state.
Disassembly
and assembly may change the valve performance.
If any rough spots are found during above inspection,
wash the valve clean with a high flash-point solvent and
blow out any foreign particles that may be in the valve with
compressed air.
WARNING
Clean the parts in a well-ventilated area, and take
care that there are no sparks or flame anywhere
near the working area. Because of the danger of
highly flammable liquids, do not use gasoline or low
flash-point solvents.
If cleaning does not solve the problem, replace the relief
valve as an assembly. The relief valve is precision made
with no allowance for replacement of individual parts.
7-10 ENGINE LUBRICATION SYSTEM
Oil Pump, Oil Pump Drive Chain
Oil Pump Removal
the crankcase (see Crankshaft/Transmission chap• Split
ter).
• Remove:
Crankshaft
•
•
Circlip [A]
Remove the sprocket [B] and balancer shaft [C] along with
the oil pump chain [D].
Remove:
Oil Pump Mounting Bolts [E]
Oil Pump Shaft [F], Pump Body, and Rotors
Oil Pump Installation
that the knock pin [A] is in place.
• Check
Apply
grease
to the O-ring [B] on the pump body.
•
a non-permanent locking agent to the threads of
• Apply
the mounting bolts [A], and tighten them.
Torque - Oil Pump Mounting Bolts: 11 N·m (1.1 kgf·m, 95
in·lb)
a new circlip [B] on the shaft so that the sharp edge
• Install
faces away from the sprocket and opening is on the shaft
flat surface [C].
Oil Pump Drive Chain Guide Installation
the chain guide [A] so that the upper surface [B]
• Install
of the chain guide touches the flat surface [C] of the left
•
crankcase.
Apply a non-permanent locking agent to the threads of
the chain guide bolt [D], and tighten it.
Torque - Oil Pump Drive Chain Guide Bolt: 12 N·m (1.2
kgf·m, 104 in·lb)
ENGINE LUBRICATION SYSTEM 7-11
Oil Pressure Measurement
Oil Pressure Measurement
the oil pressure switch (see Oil Pressure Switch
• Remove
Removal) without draining the engine oil.
• Install the gauge and adapter.
Special Tool - Oil Pressure Gauge, 10 kgf/cm²: 57001-164
[A]
Oil Pressure Gauge Adapter, PT 1/8: 57001
-1033 [B]
the engine at the specified speed, and read the oil
• Run
pressure gauge.
If the oil pressure is significantly below the specification,
inspect the oil pump and relief valve.
If the oil pump and relief valve are not at fault. Inspect the
rest of the lubrication system.
Oil Pressure
Standard:
355 ∼ 410 kPa (3.6 ∼ 4.2 kgf/cm², 51 ∼ 60
psi) @4 000 r/min (rpm), oil temp. 100°C
(212 °F)
the engine.
• Stop
Remove
the oil pressure gauge and adapter.
•
WARNING
Take care against burns from hot engine oil that
will drain through the oil passage when the gauge
adapter is removed.
the oil pressure switch (see Oil Pressure Switch
• Install
Installation).
7-12 ENGINE LUBRICATION SYSTEM
Oil Pressure Switch
Oil Pressure Switch Removal
• Remove:
Engine Oil (drain, see Engine Oil Change in the Periodic
Maintenance chapter)
Switch Cover [A]
Switch Lead Terminal [B]
Oil Pressure Switch [C]
Oil Pressure Switch Installation
silicone sealant to the threads of the oil pressure
• Apply
switch, and tighten it.
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120
Torque - Oil Pressure Switch: 15 N·m ( 1.5 kgf·m, 11.0 ft·lb)
ENGINE LUBRICATION SYSTEM 7-13
Oil Pipe
Oil Pipe (Crankcase Outside) Removal
• Remove:
Alternator Cover (see Electrical System chapter)
Oil Pipe Mounting Bolts [A]
Oil Pipe [B]
Oil Pipe (Crankcase Outside) Installation
grease to the O-rings [A].
• Apply
Apply
a non-permanent locking agent to the threads of
• the mounting
bolts, and tighten them.
Torque - Oil Pipe Mounting Bolts (Crankcase Outside): 5.4
N·m ( 0.55 kgf·m, 48 in·lb)
Oil Passage Cover Removal/Installation
• Remove:
Oil Pipe (Crankcase Outside)
•
•
Alternator (see Electrical System chapter)
Left Balancer (see Crankshaft/Transmission chapter)
Oil Passage Cover Screws [A]
Oil Passage Cover [B]
Install a new gasket.
Apply a non-permanent locking agent to the threads of
the cover screws, and tighten them.
Torque - Oil Passage Cover Screws: 5.4 N·m ( 0.55 kgf·m,
48 in·lb)
7-14 ENGINE LUBRICATION SYSTEM
Oil Pipe
Oil Pipe (Crankcase Inside) Removal
the crankcase (see Crankshaft/Transmission chap• Split
ter).
• Remove:
Oil Pipe Mounting Bolts [A]
Oil Pipes [B]
Oil Pipe (Crankcase Inside) Installation
grease to the O-rings [A].
• Apply
Apply
a non-permanent locking agent to the threads of
• the mounting
bolts, and tighten them.
Torque - Oil Pipe Mounting Bolts (Crankcase Inside): 11
N·m (1.1 kgf·m, 95 in·lb)
ENGINE REMOVAL/INSTALLATION 8-1
Engine Removal/Installation
Table of Contents
Exploded View........................................................................................................................
Special Tool ............................................................................................................................
Engine Removal/Installation ...................................................................................................
Engine Removal................................................................................................................
Engine Installation.............................................................................................................
8-2
8-4
8-5
8-5
8-6
8
8-2 ENGINE REMOVAL/INSTALLATION
Exploded View
ENGINE REMOVAL/INSTALLATION 8-3
Exploded View
No.
1
2
3
Fastener
Engine Mounting Nuts
Engine Mounting Bracket Bolts
Down Tube Mounting Bolts
N·m
44
25
44
Torque
kgf·m
4.5
2.5
4.5
ft·lb
32
18
32
Remarks
8-4 ENGINE REMOVAL/INSTALLATION
Special Tool
Jack:
57001-1238
Jack Attachment #3:
57001-1416
ENGINE REMOVAL/INSTALLATION 8-5
Engine Removal/Installation
Engine Removal
• Remove:
Engine Oil (drain, see Engine Lubrication System in the
Periodic Maintenance chapter)
Coolant (drain, see Cooling System in the Periodic Maintenance chapter)
Seat (see Frame chapter)
Fuel Tank (see Fuel System chapter)
Left and Right Side Cover (see Frame chapter)
Muffler (see Engine Top End chapter)
Front Right Foot Peg and Brake Petal (see Brakes chapter)
Clutch Cable
Air Cleaner Housing (see Fuel System chapter)
Carburetor (see Fuel System chapter)
Vacuum Switch Valve
Radiator (see Cooling System chapter)
Thermostat Housing [A]
Water Hose Fitting Bolts [B] and Fittings
Engine Sprocket [A] (see Final Drive chapter)
Ignition Switch [B]
Clamp [C]
Connectors [D]
Shift Lever and Bolt [E]
Oil Pressure Switch Lead [A]
Starter Motor Lead [B]
Neutral Switch Lead Connector [A]
Negative Lead (–) [B]
8-6 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
• Support the frame with the jack.
Special Tool - Jack: 57001-1238
Jack Attachment #3: 57001-1416
the brake lever slowly and hold it with a band
• Squeeze
[A].
WARNING
Be sure to hold the front brake when removing the
engine, or the motorcycle may fall over. It could
cause an accident and injury.
CAUTION
Be sure to hold the front brake when removing the
engine, or the motorcycle may fall over. The engine
or the motorcycle could be damaged.
the engine with a suitable stand [A].
• Support
• Remove:
Down Tube [B] (see Frame chapter)
•
Engine Mounting Bolts [C] and Nuts
Engine Mounting Brackets [D].
Using the stand, take out the engine to the right.
Engine Installation
installing the rubber dampers into the bracket, lu• When
bricate the outer surface of the dampers with a soap and
water solution.
CAUTION
Do not lubricate the rubber damper with engine oil
or petroleum distillates because they will deteriorate the rubbers.
the engine mounting bracket and down tube.
• Install
Tighten:
•
Torque - Engine Mounting Bracket Bolt: 25 N·m (2.5 kgf·m,
18.0 ft·lb)
Down Tube Mounting Bolts: 44 N·m (4.5 kgf·m, 33
ft·lb)
Engine Mounting Nuts: 44 N·m (4.5 kgf·m, 33 ft·lb)
the leads, cables and hoses correctly (see Cable,
• Run
Wire and Hose Routing in the Appendix chapter).
the removed parts (see appropriate chapters).
• Install
• Adjust:
Throttle Cables (see Fuel System chapter)
•
•
Clutch Cable (see Clutch chapter)
Drive Chain (see Final Drive chapter)
Fill the engine with engine oil (see Engine Lubrication
System in the Periodic Maintenance chapter)
Fill the engine with coolant and bleed the air from the cooling system (see Cooling System in the Periodic Maintenance chapter).
CRANKSHAFT/TRANSMISSION 9-1
Crankshaft/Transmission
Table of Contents
Exploded View...................................
Specifications ....................................
Special Tool .......................................
Crankcase Splitting............................
Crankcase Splitting ......................
Crankcase Assembly ...................
Crankshaft/Connecting Rods.............
Crankshaft Removal ....................
Crankshaft Installation .................
Connecting Rod Removal ...........
Connecting Rod Installation .........
Crankshaft/Connecting Rod
Cleaning ....................................
Connecting Rod Bend Inspection
Connecting Rod Twist Inspection.
Connecting Rod Big End
Bearing Insert/Crankpin Wear
Inspection..................................
Crankshaft Side Clearance
Inspection..................................
Crankshaft Runout Inspection......
Crankshaft Main Bearing/Main
Journal Wear Inspection ...........
Balancer, Starter Motor Clutch ..........
Left Balancer Removal ................
Left Balancer Installation..............
Right Balancer, Starter Motor
Clutch Removal.........................
Right Balancer, Starter Motor
Clutch Installation......................
Starter Motor Clutch Inspection ...
Balancer Damper Inspection .......
Torque Limiter....................................
Torque Limiter Removal ...............
Torque Limiter Inspection.............
9-2
9-6
9-8
9-9
9-9
9-10
9-12
9-12
9-12
9-12
9-12
9-13
9-13
9-13
9-13
9-15
9-15
9-16
9-17
9-17
9-17
9-18
9-19
9-19
9-20
9-21
9-21
9-21
Primary Gear .....................................
Primary Gear Removal ................
Primary Gear Installation .............
Transmission .....................................
Shift Pedal Removal ....................
Shift Pedal Installation .................
External Shift Mechanism
Removal ....................................
External Shift Mechanism
Installation ................................
External Shift Mechanism
Inspection..................................
Transmission Shaft and Shift Fork
Removal ...................................
Transmission Shaft and Shift Fork
Installation .................................
Transmission shaft Disassembly .
Transmission shaft Assembly ......
Shift Drum Removal.....................
Shift Drum Disassembly...............
Shift Drum Assembly ...................
Shift Fork Bending Inspection ......
Shift Fork/Gear Groove Wear
Inspection..................................
Shift Fork Guide Pin/Drum
Groove Wear Inspection ...........
Gear Dog and Gear Dog Hole
Damage Inspection ...................
Ball Bearing, Needle Bearing, and Oil
Seal.................................................
Bearing Oil Seal Installation.........
Water Pump Shaft .............................
Water Pump Shaft Removal ........
Water Pump Shaft Installation .....
9-22
9-22
9-22
9-23
9-23
9-23
9-23
9-24
9-24
9-25
9-25
9-25
9-26
9-26
9-26
9-28
9-28
9-28
9-28
9-29
9-30
9-30
9-31
9-31
9-31
9
9-2 CRANKSHAFT/TRANSMISSION
Exploded View
CRANKSHAFT/TRANSMISSION 9-3
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
11
Fastener
Crankcase Bolts (6 mm)
Crankcase Bolts (10 mm)
Connecting Rod Big End Cap Nuts
Primary Gear Bolt
Balancer Gear Bolt
Starter Motor Clutch Gear Bolt
Starter Motor Clutch Bolts
Output Shaft Bearing Stopper Bolts
Balancer Shaft Bearing Stopper Bolts
Transmission Cover Bolts
External Shift Mechanism Cover Bolts
G: Apply grease.
L: Apply a non-permanent locking agent.
LG: Apply liquid gasket.
MO: Apply molybdenum disulfide oil.
O: Apply Oil.
S: Follow specified tightening sequence.
N·m
11
39
46
157
69
69
34
12
11
11
11
Torque
Remarks
kgf·m
ft·lb
1.1
95 in·lb
4.0
29
S
4.7
34
MO
16
116
O
7.0
51
L
7.0
51
L
3.5
25
L
1.2
104 in·lb
1.1
95 in·lb
1.1
95 in·lb
1.1
95 in·lb
9-4 CRANKSHAFT/TRANSMISSION
Exploded View
CRANKSHAFT/TRANSMISSION 9-5
Exploded View
No.
1
2
3
4
5
6
7
8
Fastener
Shift Drum Cam Holder Screw
Shift Drum Bearing Stopper Bolts
Neutral Switch
Shift Pedal Pivot Bolt
Shift Pedal Pivot Bolt Nut
Shift Lever Clamp Bolt
Shift Shaft Return Spring Pin
Shift Drum Position Lever Bolt
G: Apply grease.
L: Apply a non-permanent locking agent.
O: Apply Oil.
N·m
12
11
15
29
29
12
29
11
Torque
Remarks
kgf·m
ft·lb
1.2
104 in·lb
L
1.1
95 in·lb
1.5
11
3.0
22
3.0
22
1.2
104 in·lb
3.0
22
L
1.1
95 in·lb
9-6 CRANKSHAFT/TRANSMISSION
Specifications
Item
Crankshaft, Connecting Rods
Connecting Rod Big End Side Clearance
Connecting Rod Big End Bearing
Insert/Crankpin Clearance
Crankpin Diameter:
Marking
None
1
Connecting Rod Big End Bore Diameter:
Marking
None
Standard
0.16 ∼ 0.46 mm
(0.006 ∼ 0.018 in.)
0.026 ∼ 0.054 mm
(0.0010 ∼ 0.0021 in.)
42.984 ∼ 43.000 mm
(1.6923 ∼ 1.6929 in.)
42.984 ∼ 42.992 mm
(1.6923 ∼ 1.6926 in.)
42.993 ∼ 43.000 mm
(1.6926 ∼ 1.6929 in.)
46.000 ∼ 46.020 mm
(1.8110 ∼ 1.8118 in.)
46.000 ∼ 46.010 mm
(1.8110 ∼ 1.8114 in.)
46.011 ∼ 46.020 mm
(1.8115 ∼ 1.8118 in.)
Connecting Rod Big End Bearing Insert
Thickness:
Brown
1.483 ∼ 1.487 mm
(0.5839 ∼ 0.5854 in.)
Black
1.487 ∼ 1.491 mm
(0.5854 ∼ 0.5870 in.)
Blue
1.491 ∼ 1.495 mm
(0.5870 ∼ 0.5886 in.)
Connecting rod big end bearing insert selection:
1
None
1
None
– – –
– – –
– – –
– – –
– – –
– – –
13034-1058
Blue
13034-1057
–––
Connecting Rod Twist
–––
Crankshaft Side Clearance
0.05 ∼ 0.55 mm
Crankshaft Runout
– – –
Black
Connecting Rod Bend
Crankshaft Web Length
0.70 mm
(0.028 in.)
0.09 mm
(0.0035 in.)
42.97 mm
(1.692 in.)
– – –
Bearing Insert
Size Color
Part Number
Brown
13034-1059
Con-rod Big End Bore
Crankpin
Diameter Marking
Diameter Marking
None
None
Service Limit
(0.002 ∼ 0.022 in.)
96.85 ∼ 96.95 mm
(38.130 ∼ 38.169 in.)
TIR 0.02 mm
(0.0008 in.) or less
0.2/100 mm
(0.008/3.94 in.)
0.2/100 mm
(0.008/3.94 in.)
0.75 mm
(0.030 in.)
96.6 mm
(3.80 in.)
TIR 0.05 mm
(0.002 in.)
CRANKSHAFT/TRANSMISSION 9-7
Specifications
Item
Crankshaft Main Journal Diameter
Crankcase Main Bearing Bore Diameter
Transmission
Shift Fork Ear Thickness
Gear Shift Fork Groove Width
Shift Fork Guide Pin Diameter
Shift Drum Groove Width
Standard
42.984 ∼ 43.000 mm
(1.6923 ∼ 1.6929 in.)
43.025 mm ∼ 43.041 mm
(1.6939 ∼ 1.6945 in.)
Service Limit
42.96 mm
(1.691 in.)
43.09 mm
(1.696 in.)
4.9 ∼ 5.0 mm
(0.193 ∼ 0.197 in.)
5.05 ∼ 5.15 mm
(0.199 ∼ 0.203 in.)
5.9 ∼ 6.0 mm
4.8 mm
(0.19 in.)
5.2 mm
(0.20 in.)
5.8 mm
(0.232 ∼ 0.236 in.)
6.05 ∼ 6.20 mm
(0.238 ∼ 0.244 in.)
(0.23 in.)
6.3 mm
(0.25 in.)
9-8 CRANKSHAFT/TRANSMISSION
Special Tool
Outside Circlip Pliers:
57001-144
Flywheel Holder:
57001-1313
Bearing Driver Set:
57001-1129
Kawasaki Bond (Liquid Gasket - Black) TB1105:
92104-1003
CRANKSHAFT/TRANSMISSION 9-9
Crankcase Splitting
Crankcase Splitting
the engine (see Engine Removal/Installation
• Remove
chapter).
the engine on a clean surface and hold the engine
• Set
steady while parts are being removed.
• Remove:
Starter Motor (see Electrical System chapter)
Oil Filter (see Engine Lubrication System in the Periodic
Maintenance chapter)
Plate Bolts [A]
Oil Filter Plate [B] and O-rings (2)
Clutch (see Clutch chapter)
Primary Gear (see Primary Gear Removal)
Right Balancer (see Right Balancer, starter Clutch Removal)
Torque Limiter
Water Pump Impeller (see Cooling System chapter)
Left Balancer (see Left Balancer Removal)
Alternator Rotor (see Electrical System chapter)
External Shift Mechanism (see External Shift Mechanism Removal)
Damper [A] and Transmission Cover [B]
•
Cylinder Heads, Cylinders, and Pistons (see Engine Top
End chapter)
Remove the left crankcase bolts in the order listed.
6 mm Bolts [A]
10 mm Bolts [B]
the right crankcase bolts:
• Remove
6 mm Bolts [A]
9-10 CRANKSHAFT/TRANSMISSION
Crankcase Splitting
the engine so that the left crankcase is down.
• Put
Pry
the
[A] to split the crankcase halves apart, and
• remove points
the right crankcase half.
○Tap lightly around the crankcase joint with a plastic mallet,
and split the crankcase. Take care not to damage the
crankcase.
Crankcase Assembly
NOTE
○The right and left crankcase halves are machined at the
factory in the assembled state, so the crankcase halves
must be replaced as a set.
a high-flash point solvent, clean off the mating sur• With
faces of the crankcases halves and wipe dry.
compressed air, blow out the oil passages in the
• Using
crankcase halves.
Check to see that the following parts are in place.
•Left
Crankcase
Oil Pipe (Crankcase Inside)
Oil Pump [A]
Balancer Shaft [B]
Shift Drum
Transmission Shafts and Gears
Shift Forks and Shift Rods
Crankshaft and Connecting Rods
Oil Filter Adapter Bolt [C]
Knock Pins [D]
Right Crankcase
Water Pump Shaft [A]
Relief Valve [B]
Oil Pipe (Crankcase Inside) [C]
liquid gasket [A] to the mating surface of the right
• Apply
crankcase half.
Sealant - Kawasaki Bond (Liquid Gasket - Black) TB1105:
92104-1003
CAUTION
Do not apply liquid gasket to the oil passage [B] and
hole [C].
CRANKSHAFT/TRANSMISSION 9-11
Crankcase Splitting
the right crankcase, fitting the oil pump shaft pro• Install
jection [A] into the water pump shaft slot [B].
• Tighten the right crankcase half 6 mm bolts [A].
Torque - Crankcase Bolts (6 mm): 11 N·m (1.1 kgf·m, 95
in·lb)
the left crankcase half 10 mm bolts [1 ∼ 3] to the
• Tighten
tightening sequence, and then tighten the 6 mm bolts [A].
Torque - Crankcase Bolts (10 mm): 39 N·m (4.0 kgf·m, 29
ft·lb)
Crankcase Bolts (6 mm): 11 N·m (1.1 kgf·m, 95
in·lb)
tightening all crankcase bolts, check the following
• After
items.
○Drive shaft and output shaft turn freely.
○While spinning the output shaft, gears shift smoothly from
the 1st to 5th gear, and 5th to 1st.
○When the output shaft stays still,
the gear can not be
shifted to 2nd gear or other higher gear positions.
9-12 CRANKSHAFT/TRANSMISSION
Crankshaft/Connecting Rods
Crankshaft Removal
the crankcase (see Crankcase Splitting).
• Split
Remove
the crankshaft.
•
Crankshaft Installation
the crankshaft tapered end in to the left crankcase
• Insert
[A].
the left connecting rod [B] into the rear cylinder
• Install
opening [C], and right connecting rod [D] into the front
cylinder opening [E].
Connecting Rod Removal
• Remove the crankshaft (see Crankshaft Removal).
NOTE
○Mark and record the locations of the connecting rods
and their big end caps so that they can be reassembled
in their original positions.
the connecting rod big end cap nuts, and take
• Remove
off the rod and cap with the bearing inserts.
Connecting Rod Installation
CAUTION
To minimize vibration, the connecting rods should
have the same weight mark.
Big End Cap [A]
Connecting Rod [B]
Weight Mark, Alphabet [C]
Diameter Mark (Around Weight Mark) [D]: "O" or no
mark.
CAUTION
If the connecting rods, bearing inserts, or crankshaft are replaced with new ones, select the bearing
insert and check clearance with a plastigage (press
gauge) before assembling engine to be sure the correct bearing inserts are installed.
engine oil to the inner surface of upper and lower
• Apply
bearing inserts [A].
a small amount of molybdenum disulfide oil to the
• Apply
threads [B] and seating surface [C] of the connecting rod
•
big end cap nuts.
Tighten:
Torque - Connecting Rod Big End Cap Nuts: 46 N·m (4.7
kgf·m, 34 ft·lb)
CRANKSHAFT/TRANSMISSION 9-13
Crankshaft/Connecting Rods
Crankshaft/Connecting Rod Cleaning
removing the connecting rods from the crankshaft,
• After
clean them with a high-flash point solvent.
the crankshaft oil passages with compressed air to
• Blow
remove any foreign particles or residue that may have
accumulated in the passages.
Connecting Rod Bend Inspection
the connecting rod big end bearing insets, and
• Remove
reinstall the connecting rod big end cap.
an arbor [A] of the same diameter as the connect• Select
ing rod big end, and insert the arbor through the connect-
•
•
•
ing rod big end.
Select an arbor of the same diameter as the piston pin
and at least 100 mm (3.94 in.) long, and insert the arbor
[B] through the connecting rod small end.
On a surface plate, set the big-end arbor on V block [C].
With the connecting rod held vertically, use a height
gauge to measure the difference in the height of the
arbor above the surface plate over a 100 mm (3.94 in.)
length to determine the amount of connecting rod bend.
If connecting rod bend exceeds the service limit, the connecting rod must be replaced.
Connecting Rod Bend
Service Limit:
TIR 0.2/100 mm (0.008/3.94 in.)
Connecting Rod Twist Inspection
the big-end arbor [A] still on V block [C], hold the con• With
necting rod horizontally and measure the amount that the
arbor [B] varies from being parallel with the surface plate
over a 100 mm (3.94 in.) length of the arbor to determine
the amount of connecting rod twist.
If connecting rod twist exceeds the service limit, the connecting rod must be replaced.
Connecting Rod Twist
Service Limit:
TIR 0.2/100 mm (0.008/3.94 in.)
Connecting Rod Big End Bearing Insert/Crankpin
Wear Inspection
the bearing insert/crankpin [A] clearance with a
• Measure
plastigage [B].
the connecting rod big end cap nuts to the speci• Tighten
fied torque (see Connecting Rod Installation).
NOTE
○Do not move the connecting rod and crankshaft during
clearance measurement.
Connecting Rod Big End Bearing Insert/Crankpin
Clearance
Standard:
0.026 ∼ 0.054 mm (0.0010 ∼ 0.0021 in.)
Service Limit:
0.09 mm (0.035 in.)
9-14 CRANKSHAFT/TRANSMISSION
Crankshaft/Connecting Rods
If clearance is within the standard, no bearing replacement is required.
If clearance is between 0.054 mm (0.0021 in.) and
the service limit (0.09 mm, 0.35 in.), replace the bearing inserts [A] with inserts painted blue [B]. Check
insert/crankpin clearance with the plastigage. The clearance may exceed the standard slightly, but it must not be
less than the minimum in order to avoid bearing seizure.
If the clearance exceeds the service limit, measure the
diameter of the crankpins.
Crankpin Diameter
Standard:
42.984 ∼ 43.000 mm (1.6923 ∼ 1.6929 in.)
Service Limit: 42.97 mm (1.692 in.)
If any crankpin has worn past the service limit, replace the
crankshaft with a new one.
If the measured crankpin diameter [A] is not less than the
service limit, but do not coincide with the original diameter
marking on the crankshaft, make new mark on it.
Crankpin Diameter Mark
None
42.984 ∼ 42.992 mm (1.6923 ∼ 1.6926 in.)
1
42.993 ∼ 43.000 mm (1.6926 ∼ 1.6929 in.)
Crankpin Diameter Mark, "1" mark or no mark [B].
the connecting rod big end bore diameter, and
• Measure
mark each connecting rod big end in accordance with the
•
bore diameter.
Tighten the connecting rod big end cap nuts to the specified torque (see Connecting Rod Installation).
NOTE
○The mark already on the big end should almost coincide
with the measurement because of little wear.
Connecting Rod Big End Bore Diameter Marks
None
46.000 ∼ 46.010 mm (1.8110 ∼ 1.8114 in)
○
46.011 ∼ 46.020 mm (1.8115 ∼ 1.8118 in.)
Big End Cap [A]
Connecting Rod [B]
Weight Mark, Alphabet [C]
Diameter Mark (Around Weight Mark) [D]: “○” or no
mark
CRANKSHAFT/TRANSMISSION 9-15
Crankshaft/Connecting Rods
the proper bearing insert [A] in accordance with the
• Select
combination of the connecting rod and crankshaft coding.
Size Color [B]
Connecting Rod Big End Bearing Insert Selection
Bearing Insert
Con-rod Big End
Bore Diameter
Marking
Crankpin
Diameter
Marking
Size Color
Part Number
None
1
Brown
13034-1059
None
None
○
○
1
Black
13034-1058
Blue
13034-1057
None
the new inserts in the connecting rod and check
• Install
insert/crankpin clearance with the plastigage.
Crankshaft Side Clearance Inspection
• Measure the crankshaft side clearance.
Crankshaft Side Clearance
Standard:
0.05 ∼ 0.55 mm (0.002 ∼ 0.022 in.)
Service Limit:
0.75 mm (0.030 in.)
Crankshaft [A]
Crankcase [B]
Clearance [C]
If the clearance exceeds the service limit, measure the
crankshaft web length [A] to see whether the crankshaft
or the crankcase is faulty.
Crankshaft Web Length
Standard:
96.85 ∼ 96.95 mm (38.130 ∼ 38.169 in.)
Service Limit: 96.6 mm (3.80 in. )
If the length measurement is smaller than the service limit,
replace the crankshaft. Otherwise, replace the crankcase
halves as a set.
NOTE
○The right and left crankcase halves are machined at
the factory in the assembled state, so they must be replaced as a set.
Crankshaft Runout Inspection
the crankshaft runout.
• Measure
If the measurement exceeds the service limit, replace the
crankshaft.
Crankshaft Runout
Standard:
TIR 0.02 mm (0.0008 in.) or less
Service Limit:
TIR 0.05 mm (0.002 in.)
9-16 CRANKSHAFT/TRANSMISSION
Crankshaft/Connecting Rods
Crankshaft Main Bearing/Main Journal Wear
Inspection
the diameter [A] of the crankshaft main journal.
• Measure
If any journal has worn past the service limit, replace the
crankshaft with a new one.
Crankshaft Main Journal Diameter
Standard:
42.984 ∼ 43.000 mm (1.6923 ∼ 1.6929 in.)
Service Limit:
42.96 mm (1.691 in.)
the main
• Measure
crankcase halves.
bearing bore diameter [A] in the
Crankcase Main Bearing Bore Diameter
Standard:
43.025 ∼ 43.041 mm (1.6939 ∼ 1.6945 in.)
Service Limit: 43.09 mm (1.696 in.)
If the diameter exceeds the service limit, replace the
crankcase halves as a set.
NOTE
○The right and left crankcase halves are machined at
the factory in the assembled state, so they must be replaced as a set.
CRANKSHAFT/TRANSMISSION 9-17
Balancer, Starter Motor Clutch
Left Balancer Removal
the alternator cover (see Electrical System chap• Remove
ter).
oil off the outer circumference of the alternator rotor.
• Wipe
Hold
the
alternator rotor steady with the flywheel holder
• [A], and remove
the balancer bolt [B] and washer [C].
Special Tool - Flywheel Holder: 57001-1313
• Remove:
Alternator Rotor (see Electrical System chapter)
Collar, Balancer Gear, and Left Balancer
If the balancer is hard to remove, use a suitable puller.
Left Balancer Installation
the balancer gear bolt and threads in the balancer
• Clean
shaft.
the balancer dampers [A] on the balancer weight
• Install
[B] and balancer gear [C] as shown.
the gear [A] and balancer weight [B] being care• Assemble
ful of the position as shown.
the balancer assembly on the shaft, aligning the
• Install
balancer weight punch mark [C] with the shaft punch mark
[D].
• Install the collar [A].
9-18 CRANKSHAFT/TRANSMISSION
Balancer, Starter Motor Clutch
the alternator rotor (see Electrical System chapter).
• Install
Hold
the
• [A]. alternator rotor steady with the flywheel holder
Special Tool - Flywheel Holder: 57001-1313
a non-permanent locking agent to the threads of
• Apply
the balancer gear bolt [B], and tighten it.
Torque - Balancer Gear Bolt: 69 N·m (7.0 kgf·m, 51 ft·lb)
Right Balancer, Starter Motor Clutch Removal
• Remove:
Alternator Cover (see Electrical System chapter)
•
•
Right Engine Cover (see Clutch chapter)
Wipe oil off the outer circumference of the alternator rotor.
Hold the rotor steady with the flywheel holder [A].
Special Tool - Flywheel Holder: 57001-1313
• Remove:
Starter Motor Clutch Gear Bolt [A]
Washers [B]
Starter Motor Clutch Gear [C]
Torque Limiter [A]
Needle Bearing [B] and Collar [C]
Starter Motor Clutch Assembly [D] and Copper Washer
[E]
If the assembly is hard to remove, use a suitable puller.
the starter motor clutch bolts [A], and separate
• Remove
the right balancer [B] from the starter motor clutch.
CRANKSHAFT/TRANSMISSION 9-19
Balancer, Starter Motor Clutch
Right Balancer, Starter Motor Clutch Installation
sure to install the one-way clutch [A] so that the flange
• Be
[B] of it fits in the coupling recess [C].
a non-permanent locking agent to the threads of
• Apply
the starter clutch bolts, and tighten them.
Torque - Starter Motor Clutch Bolts: 34 N·m (3.5 kgf·m, 25
ft·lb)
the starter motor clutch gear bolt and threads in the
• Clean
balancer shaft.
the starter motor clutch assembly on the shaft,
• Install
aligning the balancer weight punch mark [A] with the
shaft punch mark [B].
• Install:
Copper Washer
•
Collar and Needle Bearing
Torque Limiter
Install the starter motor clutch gear [A] while turning [B]
the gear.
the washer [A] so that the chamfered side [B] faces
• Install
inward.
a non-permanent locking agent to the threads of
• Apply
the starter motor clutch gear bolt [C], and tighten it.
Torque - Starter Motor Clutch Gear Bolt: 69 N·m (7.0 kgf·m,
51 ft·lb)
Starter Motor Clutch Inspection
the engine oil (see Engine Lubrication System in
• Drain
the Periodic Maintenance chapter).
the starter motor (see Electrical System chap• Remove
ter).
the torque limiter gear [A] by hand. When viewed
• Turn
from the left side of the engine, the gear should turn clockwise freely [B], but should not turn counterclockwise.
If the gear does not operate as it should or if it makes
noise, go to the next step.
9-20 CRANKSHAFT/TRANSMISSION
Balancer, Starter Motor Clutch
the starter motor clutch (see Right Balancer,
• Disassemble
Starter Motor Clutch Removal).
inspect:
• Visually
One-way Clutch [A]
Coupling [B]
Starter Motor Clutch Gear Inner Race [C]
If there is any worn or damaged part, replace it.
Balancer Damper Inspection
the left balancer (see Left Balancer Removal).
• Remove
Visually
inspect
the rubber dampers [A].
• If they appear damaged
or deteriorated, replace them.
CRANKSHAFT/TRANSMISSION 9-21
Torque Limiter
Torque Limiter Removal
• Remove:
Right Engine Cover (see Clutch chapter)
Starter Motor Clutch Gear [A] (see Right Balancer,
Starter Motor Clutch Removal)
Torque Limiter [B]
CAUTION
Do not disassemble the torque limiter. The torque
limiter will not function if this is done.
Torque Limiter Inspection
the torque limiter and visually inspect it.
• Remove
If the limiter has wear, discoloration, or other damage,
replace it as a set.
Gear [A]
Hub [B]
Spring [C]
Pinion [D]
Shim [E]
9-22 CRANKSHAFT/TRANSMISSION
Primary Gear
Primary Gear Removal
the alternator cover (see Electrical System chap• Remove
ter).
oil off the outer circumference of the alternator rotor.
• Wipe
Hold
the
• [A]. alternator rotor steady with the flywheel holder
Special Tool - Flywheel Holder: 57001-1313
the primary gear bolt [A], washer [B], and primary
• Remove
gear [C] from the crankshaft.
If necessary, remove the clutch (see Clutch chapter).
Primary Gear Installation
the woodruff key [A] securely in the slot in the crank• Fit
shaft before installing the primary gear.
• Hold the alternator rotor steady with the flywheel holder.
Special Tool - Flywheel Holder: 57001-1313
oil to the threads and seating surface of the primary
• Apply
gear bolt, and tighten it.
Torque - Primary Gear Bolt: 157 N·m (16 kgf·m, 116 ft·lb)
CRANKSHAFT/TRANSMISSION 9-23
Transmission
Shift Pedal Removal
the position of the shift lever on the shift shaft so
• Mark
that it can be installed later in the same position.
• Remove:
Bolts [A]
Footpeg Bracket [B]
Shift Lever [C]
Shift Pedal [D]
Shift Pedal Installation
the shift pedal [A] so that the shift lever [B] positions
• Install
at right angles [C] with the shift rod [D].
this time, the center of the shift pedal is about 4 mm
• At(0.16
in.) [E] higher than the center of the engine bracket
lower mounting bolt [F].
NOTE
○The locknut next to the knurled portion of the rod has
left-hand threads.
•
•
•
If necessary, adjust the pedal position from the standard
position to suit you as follows.
Loosen the front and rear rod locknuts.
Turn the rod to adjust the pedal position.
Tighten the locknuts securely.
External Shift Mechanism Removal
• Remove:
Engine Oil (drain, see Engine Lubrication System in the
Periodic Maintenance chapter)
Shift Pedal (see Shift Pedal Removal)
Engine Sprocket Cover (see Final Drive chapter)
External Shift Mechanism Cover Bolts [A]
the external shift mechanism cover [A] with the
• Remove
shift shaft [B] from the crankcase.
9-24 CRANKSHAFT/TRANSMISSION
Transmission
• Remove:
Bolt [A]
Shift Drum Position Lever [B]
Spring [C]
External Shift Mechanism Installation
the shift drum position lever [A] and spring [B], and
• Install
tighten the bolt [C].
Torque - Shift Drum Position Lever Bolt: 11 N·m ( 1.1 kgf·m,
95 in·lb)
the knock pins [D] and new cover gasket.
• Install
high temperature grease to the oil seal lips.
• Apply
Install
washer to the shift shaft, then insert the shaft
• into thethecover.
the cover with the shaft to the crankcase.
• Install
• Tighten:
Torque - External Shift Mechanism Cover Bolts: 11 N·m
(1.1 kgf·m, 95 in·lb)
External Shift Mechanism Inspection
the shift shaft [A] for any damage.
• Examine
If the shaft is bent, straighten or replace it.
If the splines [B] are damaged, replace the shaft.
If the springs [C] [D] are damaged in any way, replace
them.
If the shift mechanism arm [E] is damaged in any way,
replace it.
the return spring pin [A] is not loose.
• Check
If it is loose, unscrew it, apply a non-permanent locking
agent to the threads, and tighten it.
Torque - Shift Shaft Return spring Pin: 29 N·m ( 3.0 kgf·m,
22 ft·lb)
the shift drum position lever [B] and spring [C] for
• Check
breaks or distortion.
•
If the lever or spring is damaged in any way, replace it.
Visually inspect the shift drum cam [D].
If it is badly worn or shows any damage, replace it.
CRANKSHAFT/TRANSMISSION 9-25
Transmission
Transmission Shaft and Shift Fork Removal
the crankcase (see Crankcase Splitting).
• Split
Remove:
• Shift Rod [A]
•
Shift Forks (2) [B]
Take out the drive shaft [C] and output shaft [D] as a set,
and remove the remainder shift fork.
Transmission Shaft and Shift Fork Installation
the direction of the shift forks as shown.
•○Make
The two forks [A] on the output shaft are identical.
the shift drum [A] as shown.
• Position
Apply
engine
to the transmission shafts and shift fork.
• Install the driveoil shaft
output shaft [C], and shift fork
• [D] on the output shaft[B],
as a set.
the shift drum [A] in the neutral position as shown.
• Set
Apply
oil to the shift forks [B] and shift rod [C], and
• install engine
them.
Transmission shaft Disassembly
the transmission shafts (see Transmission Shaft
• Remove
Removal).
the circlips pliers (special tool), remove the circlips,
• Using
and disassemble the transmission shaft.
Special Tool - Outside Circlip Pliers: 57001-144
4th gear [A] on the output shaft has three steel balls
• The
for the positive neutral finder mechanism.
the 4th gear as follows.
•○Remove
Set the output shaft in a vertical position holding the 3rd
gear [B].
○Spin the 4th gear quickly [C] and pull it off upward.
9-26 CRANKSHAFT/TRANSMISSION
Transmission
Transmission shaft Assembly
the 5th gear [A] on the output shaft with its oil hole
• Install
[B] aligned with the shaft oil hole [C].
the steel balls into the 4th gear holes as shown.
• FitView
A-A’ (see the output shaft illustration)
[A] Gear (4th)
[B] Shaft
[C] Steel Balls
CAUTION
Do not apply grease to the steel balls to hold them
in place. This will cause the positive neutral finder
mechanism to malfunction.
any circlip that were removed with new ones.
• Replace
the circlips [A] so that the opening is aligned with a
• Install
spline groove.
•
[B] Toothed Washer
Check that each gear springs or slides freely on the transmission shaft without binding after assembly.
Shift Drum Removal
• Remove:
Transmission Shafts (see Transmission Shaft Removal)
•
Bolts [A]
Bearing Stopper [B]
While aligning the shift drum cam with the left crankcase
hole, pull out the shift drum [C].
Shift Drum Disassembly
the shift drum (see Shift Drum Removal).
• Remove
While
holding
the shift drum with a vise, remove the shift
• drum cam holder
bolt [A].
•
[B] Shift Drum Cam
[C] Washer
[D] Knock Pin (longer)
Remove the circlip [E].
Special Tool - Outside Circlip Pliers: 57001-144
• Remove:
[F] Spring
[G] Shift Drum Holder
[H] Knock Pin (shorter).
CRANKSHAFT/TRANSMISSION 9-27
Transmission
1. 1st Gear
2. 2nd Gear
3. 3rd Gear
4. 4th Gear
5. 5th (Top) Gear
6. Circlip
7. Circlip
8. Thrust Washer (20.5 × 30 × 1.0)
9. Thrust Washer (20.5 × 30 × 0.5)
10 Thrust Washer (25.3 × 30 × 1.0)
11. Thrust Washer (30 × 38 × 1.0)
12. Toothed Washer
13. Ball Bearing
14. Steel Ball
9-28 CRANKSHAFT/TRANSMISSION
Transmission
Shift Drum Assembly
sure to install the dowel pin.
• Be
Apply
non-permanent locking agent to the threads of
• the shifta drum
cam holder screw, and tighten it.
Torque - Shift Drum Cam Holder Screw: 12 N·m (1.2 kgf·m,
104 in·lb)
Shift Fork Bending Inspection
inspect the shift forks, and replace any fork that is
• Visually
bent. A bent fork could cause difficulty in shifting, or allow
the transmission to jump out of gear when under power.
90° [A]
Shift Fork/Gear Groove Wear Inspection
the thickness of the shift fork ears [A], and mea• Measure
sure the width [B] of the gear grooves.
If the thickness of a shift fork ear is less than the service
limit, the shift fork must be replaced.
Shift Fork Ear Thickness
Standard:
4.9 ∼ 5.0 mm (0.193 ∼ 0.197 in.)
Service Limit:
4.8 mm (0.19 in.)
If the gear groove is worn over the service limit, the gear
must be replaced.
Gear Groove Width
Standard:
5.05 ∼ 5.15 mm (0.199 ∼ 0.203 in.)
Service Limit:
5.2 mm (0.20 in.)
Shift Fork Guide Pin/Drum Groove Wear Inspection
the diameter of each shift fork guide pin [A], and
• Measure
measure the width [B] of each shift drum groove.
If the guide pin on any shift fork is less than the service
limit, the fork must be replaced.
Shift Fork Guide Pin Diameter
Standard:
5.9 ∼ 6.0 mm (0.232 ∼ 0.236 in.)
Service Limit:
5.8 mm (0.23 in.)
If any shift drum groove is worn over the service limit, the
drum must be replaced.
Shift Drum Groove Width
Standard:
6.05 ∼ 6.20 mm (0.238 ∼ 0.244 in.)
Service Limit:
6.30 mm (0.25 in.)
CRANKSHAFT/TRANSMISSION 9-29
Transmission
Gear Dog and Gear Dog Hole Damage Inspection
inspect the gear dogs [A] and gear dog holes [B].
• Visually
Replace any damaged gears or gears with excessively
worn dogs or dog holes.
9-30 CRANKSHAFT/TRANSMISSION
Ball Bearing, Needle Bearing, and Oil Seal
Bearing Oil Seal Installation
installing a bearing other than the following parts,
• When
press it in with the marked side facing out.
Special Tool - Bearing Driver Set: 57001-1129
Right Crankcase
Install the right balancer bearing [A] as follows:
○Temporarily press the bearing into the right crankcase until it is leveled with the outboard end of the bearing housing
[B].
○After installing the left balancer (see Left Balancer Installation), press the bearing until it stops at the shoulder of
the balancer shaft [C].
•
the water pump shaft bearing and seal as shown.
• Install
[A] Oil Seal
[B] Marked Side
[C] Ball Bearing (without seal)
[D] Ball Bearing (both sides seal)
[E] Mechanical Seal (see Cooling System chapter)
the output shaft bearing [A] into the right crankcase
• Install
[B] with the sealed side [C] facing the crankcase.
Left Crankcase
Install the needle bearing [A] into the left crankcase [B]
with the marked side [C] facing inside, and level the bearing with the outboard end of the bearing housing.
•
CRANKSHAFT/TRANSMISSION 9-31
Water Pump Shaft
Water Pump Shaft Removal
the crankcase (see Crankshaft/Transmission chap• Split
ter).
• Remove the circlip [A] from the water pump shaft [B].
Special Tool - Outside Circlip Pliers: 57001-144
the shaft from the outside of the crankcase to the
• Remove
inside.
Water Pump Shaft Installation
the water pump shaft from outside of the crankcase
• Insert
to the inside.
• Install the circlip to the shaft.
Special Tool - Outside Circlip Pliers: 57001-144
WHEELS/TIRES 10-1
Wheels/Tires
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Wheels (Rims) ........................................................................................................................
Front Wheel Removal .......................................................................................................
Front Wheel Installation ....................................................................................................
Rear Wheel Removal........................................................................................................
Rear Wheel Installation.....................................................................................................
Rim and Spokes Removal ................................................................................................
Rim and Spokes Installation .............................................................................................
Spoke Inspection ..............................................................................................................
Rim Inspection ..................................................................................................................
Axle Inspection..................................................................................................................
Balance Inspection............................................................................................................
Balance Adjustment ..........................................................................................................
Tires........................................................................................................................................
Air Pressure Inspection/Adjustment..................................................................................
Tire Inspection ..................................................................................................................
Tire Removal ....................................................................................................................
Tire Installation..................................................................................................................
Hub Bearing............................................................................................................................
Hub Bearing Removal.......................................................................................................
Hub Bearing Installation....................................................................................................
Hub Bearing Inspection.....................................................................................................
Hub Bearing Lubrication ...................................................................................................
Speedometer Gear Housing...................................................................................................
Disassembly and Assembly ..............................................................................................
Lubrication ........................................................................................................................
10-2
10-4
10-5
10-6
10-6
10-6
10-6
10-7
10-7
10-8
10-8
10-8
10-8
10-8
10-9
10-10
10-10
10-10
10-10
10-11
10-12
10-12
10-12
10-13
10-13
10-14
10-14
10-14
10
10-2 WHEELS/TIRES
Exploded View
WHEELS/TIRES 10-3
Exploded View
No.
1
2
3
4
Fastener
Front Axle Nut
Rear Axle Nut
Spoke Nipples
Front Axle Clamp Bolts
N·m
108
98
4.9
34
Torque
kgf·m
11.0
10.0
0.5
3.5
ft·lb
80
72
43 in·lb
25
Remarks
5. Axle Nut Cap (VN800-B5 ∼ B6, Germany Model) (On and after VN800-B7, Europe and United
Kingdom Models)
G: Apply grease.
10-4 WHEELS/TIRES
Specifications
Item
Wheels (Rims)
Rim Size:
Front
Rear
Rim Runout (with tire installed)
Radial
Axial
Axle Runout/100 mm (3.94 in.)
Wheel Balance
Balance Weights
Tires
Air Pressure (when cold):
Front:
Up to 181 kg (399 lb) load
Rear:
Up to 97.5 kg (215 lb) load
97.5 kg ∼ 181 kg load
(215 lb ∼ 399 lb)
Tread Depth:
Front
Rear
Standard
Tires
Front
Rear
Standard
PIRELLI
BRIDGESTONE
DUNLOP
Metzeler
PIRELLI
– – –
– – –
– – –
16 × 3.00
16 × 3.00
TIR 1.0 mm (0.04 in) or less
TIR 0.8 mm (0.03 in.) or less
less than 0.05 mm (0.002 in.)
less than 10 g (0.35 oz)
10 g (0.35 oz), 20 g (0.70 oz), 30
g (1.06 oz)
TIR 2.0 mm (0.08 in.)
TIR 2.0 mm (0.08 in.)
0.2 mm (0.008 in.)
– – –
– – –
200 kPa (2.00 kgf/cm², 28 psi)
– – –
200 kPa (2.00 kgf/cm², 28 psi)
225 kPa (2.25 kgf/cm², 32 psi)
– – –
– – –
BRIDGESTINE: 4.8 mm (0.19 in.)
1 mm (0.04 in)
DUNLOP: 4.5 mm (0.18 in.)
(DE, AT, CH) 1.6 m (0.06 in.)
BRIDGESTONE: 7.2 mm (0.28 in.) Up to 130 km/h (80 mph):
DUNLOP: 7.3 mm (0.29 in.)
2 mm (0.08 in.)
Over 130 km/h (80 mph):
3 mm (0.12 in.)
Make
BRIDGESTONE
DUNLOP
Metzeler
Service Limit
Type
EXEDRA G703
D404F
MARATHON Front
ML2 Plus Front
MT66 Front
EXEDRA G702
D404
Size
VN800-B1 ∼ B7
VN800-B8 ∼, B6F
130/90-16 67H
130/90-16 M/C 67H
130/90-16 67H
130/90-16 M/C 67H
130/90-16 67H
130/90-16 M/C 67H
130/90-16 67H
130/90-16 M/C 73H
130/90-16 M/C 67H
140/90-16 71H
140/90-16 M/C 71H
140/90-16 71H
140/90-16 M/C 71H
MARATHON ME 88
140/90-16 71H
MARATHON ML 2 Plus 140/90B-16 77H
MT 66
AT: Austria Model
CH: Switzerland Model
DE: Germany Model
WARNING
Use the same manufacturer’s tires on both front and
rear wheels.
140/90-16 M/C 71H
140/90-16 M/C 71H
140/90B-16 M/C
77H
WHEELS/TIRES 10-5
Special Tools
Inside Circlip Pliers:
57001-143
Bearing Remover Shaft,
57001-1265
9:
Rim Protector:
57001-1063
Bearing Remover Head,
57001-1267
15 ×
17:
Bead Breaker Assembly:
57001-1072
Bearing Remover Head,
57001-1293
20 ×
22:
Bearing Driver Set:
57001-1129
Jack Attachment #3:
57001-1416
Jack:
57001-1238
10-6 WHEELS/TIRES
Wheels (Rims)
Front Wheel Removal
the front axle nut [A].
• Loosen
Raise
the
front wheel off the ground.
•
Special Tools - Jack: 57001-1238
Jack Attachment #3: 57001-1416
the axle clamp bolt [A].
• Loosen
Pull
out
the axle [B] to the right, and remove the front
• wheel, and
Collars [C].
CAUTION
Do not lay the wheel down on the disc. This can
damage or warp the disc. Place blocks under the
wheel so that the disc does not touch the ground.
Front Wheel Installation
• Tighten:
Torque - Front Axle Nut: 108 N·m (11 kgf·m, 80 ft·lb)
Front Axle Clamp Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb)
• Check the front brake effectiveness. (see Brakes chapter)
WARNING
Do not attempt to drive the motorcycle until a full
brake lever is obtained by pumping the brake lever
until the pads are against the disc. The brake will
not function on the first application of the lever if
this is not done.
Rear Wheel Removal
• Remove:
Muffler (see Engine Top End chapter)
•
Bolt [A] and Speedometer Cable [B]
Raise the rear wheel off the ground.
Special Tools - Jack: 57001-1238
Jack Attachment #3: 57001-1416
WHEELS/TIRES 10-7
Wheels (Rims)
• Remove:
Clip [A], Torque Link Nut [B] and Bolt
Adjusting Nut [C] and Brake Rod [D]
Clip [E] and Axle Nut [F]
•
•
Bolts [A] and Chain Cover [B]
Axle [C]
Remove the drive chain [D] from the rear sprocket toward
the left.
Remove the rear wheel.
Rear Wheel Installation
the speedometer gear in the brake panel so that
• Install
its projections [A] fit into the gear drive notches [B] in the
wheel hub.
Engine the drive chain with the rear sprocket.
Insert the axle from the left side of the wheel.
To prevent a soft, or “spongy feeling” brake, center the
brake panel assembly in the brake drum as follows:
○Tighten the axle nut lightly.
○Install the torque link bolt and nut.
○Spin the wheel, and apply the rear brake, and then tighten
the axle nut to the specified torque.
•
•
•
Torque - Rear Axle Nut: 98 N·m (10.0 kgf·m, 72 ft·lb)
the clip in the rear axle.
• Install
Adjust
the drive chain slack (see Final Drive chapter).
• Install the
removed parts.
•
Torque - Torque Link Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb)
• Check the rear brake effectiveness.
Rim and Spokes Removal
the tire and tube.
• Remove
Remove
the
band.
• Tape or wirerubber
all
the
intersections so that the
• spokes don’t get mixedspokes
up, and unscrew the nipples from
all the spokes with a screwdriver, separate the rim from
the spokes and hub.
10-8 WHEELS/TIRES
Wheels (Rims)
Rim and Spokes Installation
•
If the rim has a mark, install it so that its mark faces
smaller diameter of the dram.
If the rim has an arrow mark, install it so that its mark
points rotating direction.
Tighten the spokes evenly so that the radial (out from the
axle) and axial (side to side) runouts are less than the
service limit. Make sure that the spokes are tightened
evenly within the standard torque range.
Torque - Spoke Nipples: 4.9 N·m (0.5 kgf·m, 43 in·lb)
Spoke Inspection
to the Spoke Tightness and Rim Runout Inspection
• Refer
in the Periodic Maintenance chapter
Rim Inspection
to the Spoke Tightness and Rim Runout Inspection
• Refer
in the Periodic Maintenance chapter
Axle Inspection
inspect the front and rear axle for damages.
• Visually
If the axle is damaged or bent, replace it.
the axle in V blocks that are 100 mm (3.94 in.) [A]
• Place
apart, and set a dial gauge [B] on the axle at a point
halfway between the blocks. Turn [C] the axle to measure the runout. The difference between the highest and
lowest dial readings is the amount of runout.
If axle runout exceeds the service limit, replace the axle.
Axle Runout/100 mm (3.94 in.)
Standard:
0.05 mm (0.002 in.) or less
Service Limit:
0.2 mm (0.008 in.)
Balance Inspection
the wheel.
• Remove
Support
the
wheel so that it can be spun freely.
• Spin the wheel
and mark [A] the wheel at the top
• when the wheellightly,
stops.
○Repeat this procedure several times.
If the wheel stops
of its own accord in various positions, it is well balanced.
If the wheel always stops in one position, adjust the wheel
balance.
WHEELS/TIRES 10-9
Wheels (Rims)
Balance Adjustment
the wheel always stops in one position, provisionally
• Ifattach
a balance weight [A] on the wheel.
○Attach a balance weight loosely to the spoke under the
marking.
Rotate the wheel 1/4 turn [B], and see whether or not
the wheel stops in this position. If it does, the correct
balanceweight is being used.
If the wheel rotates and the weight goes up, replace the
weight with the next heavier size.
If the wheel rotates and the weight goes down, replace
the weight with the next lighter size.
Repeat these steps until the wheel remains at rest after
being rotated 1/4 turn.
Rotate the wheel another 1/4 turn and then another 1/4
turn to see if the wheel is correctly balanced.
Repeat the entire procedure as many times as necessary
to achieve correct wheel balance.
Install the balance weight firmly on the wheel.
○Clamp on the balance weight firmly using pliers [A].
•
•
•
•
•
Balance Weight
Part Number
Weight
41075-1017
10 g (0.35 oz)
41075-1008
20 g (0.70 oz)
41075-1009
30 g (1.06 oz)
10-10 WHEELS/TIRES
Tires
Air Pressure Inspection/Adjustment
the tire air pressure with an air pressure gauge
• Measure
[A] when the tires are cold (that is, when the motorcycle
has not been ridden more than a mile during the past 3
hours.)
Adjust the tire air pressure according to the specifications
if necessary.
Air Pressure (when cold)
Front Up to 181 kg (399 lb)
200 kPa (2.00 kgf/cm², 28 psi)
Rear
Up to 97.5 kg (215 lb)
200 kPa (2.00 kgf/cm², 28 psi)
97.5 ∼ 181 kg (215 ∼
399 lb)
225 kPa (2.25 kgf/cm², 32 psi)
Tire Inspection
to the Tire Wear Inspection in the Periodic Mainte• Refer
nance chapter.
Tire Removal
CAUTION
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.
the wheel.
• Remove
To
maintain
wheel balance, mark [A] the air valve position
• on the tire with
chalk so that the tire can be reinstalled in
•
the same position.
Take out the valve core [B] to let out the air.
○When handling the rim, be careful not to damage the rim
•
flanges.
Lubricate the tire beads and rim flanges on both sides with
a soap and water solution or rubber lubricant. This helps
the tire beads slip off the rim flanges.
CAUTION
Never lubricate with engine oil or petroleum distillates because they will deteriorate the tire.
the beads away from both sides of the rim with the
• Break
bead breaker [A].
Special Tool - Bead Breaker Assembly: 57001-1072
WHEELS/TIRES 10-11
Tires
the tire off the rim with the tire iron [A] of the bead
• Pry
breaker protecting the rim with rim protectors [B].
Special Tool - Rim Protector: 57001-1063
Bead Breaker Assembly: 57001-1072
Tire Installation
WARNING
Use the same manufacture’s tires on both front and
rear wheels.
the tire rotation mark [A] on the front/rear tire and
• Check
install it on the rim accordingly.
NOTE
○The direction of the tire rotation is shown by an arrow
on the tire sidewall.
the tire on the rim so that the air valve [A] is at
• Position
the tire balance mark [B] (the chalk mark made during
•
•
removal or the yellow paint mark on a new tire).
Check and adjust the air pressure after installing.
Install the air valve cap.
10-12 WHEELS/TIRES
Hub Bearing
Hub Bearing Removal
• Remove the wheel, and take out the following.
CAUTION
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.
Front
Grease Seal [A]
Circlip [B]
Special Tool - Inside Circlip Pliers: 57001-143
Rear
Coupling [A]
Collar [B]
Brake Panel
Circlips [C]
Speedometer Gear Drive [D]
the bearings [A] out of the hub, using the bearing
• Take
remover.
Special Tool - Bearing Remover Shaft: 57001-1265 [B]
Bearing Remover Head, 15 × 17: 57001
-1267 [C]
Bearing Remover Head, 20 × 22: 57001
-1293
Hub Bearing Installation
installing the hub bearings, blow any dirt or foreign
• Before
particles out of the hub with compressed air to prevent
contamination of the bearings.
Replace the bearings with new ones.
Install the front bearings the following sequence.
○Press in the left side bearing [A] until it is bottomed.
•
•
Special Tool - Bearing Driver Set: 57001-1129
○Insert the collar [B] in the hub [C].
○Press in the right side bearing [D] until it is bottomed.
• Press in the rear bearings until they are bottomed.
Special Tool - Bearing Driver Set: 57001-1129
NOTE
○Install the bearings so that the marked side or sealed
side faces out.
• Replace the circlips with new ones.
Special Tool - Inside Circlip Pliers: 57001-143
WHEELS/TIRES 10-13
Hub Bearing
the grease seals with new ones.
• Replace
Press
in
the grease seal [A] so that the seal surface is
• flush [B] with
the end of the hole.
○Apply high temperature grease to the grease seal lips.
Special Tool - Bearing Driver Set: 57001-1129 [C]
Hub Bearing Inspection
○Since the hub bearings are made to extremely close tolerances, the clearance can not normally be measured.
NOTE
○Do not remove any bearings for inspection. If any bearings are removed, they will need to be replaced with
new ones.
each bearing in the hub back and forth [A] while
• Turn
checking for plays, roughness, or binding.
•
If bearing play, roughness, or binding is found, replace
the bearing.
Examine the bearing seal [B] for tears or leakage.
If the seal is torn or is leaking, replace the bearing.
Hub Bearing Lubrication
○Since the
NOTE
hub bearings are packed with grease and
sealed, lubrication is not required.
10-14 WHEELS/TIRES
Speedometer Gear Housing
Disassembly and Assembly
• Remove:
Rear Wheel (see Rear Wheel Removal)
Brake Panel, Brake Shoe
Grease Seal [A]
Speedometer Gear [B]
Washer [C]
the pinion washer [A], and remove the busing, pinion
• Tap
[B], and install the washer [C] facing the alloy surface of
it to upwards.
NOTE
○It is recommended that the assembly be replaced rather
than attempting repair the components.
in the grease seal [A] until it is bottomed.
•○Press
Apply high temperature grease to the grease seal lips.
Special Tool - Bearing Driver Set: 57001-1129
the speedometer gear so
• Install
speedometer gear drive notches
that it fits in the
(see Rear Wheel
Installation).
Lubrication
and grease the pinion, speedometer gear, and gear
• Clean
drive.
FINAL DRIVE 11-1
Final Drive
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Drive Chain.............................................................................................................................
Drive Chain Slack Inspection ............................................................................................
Drive Chain Slack Adjustment .........................................................................................
Wheel Alignment Inspection/Adjustment .........................................................................
Drive Chain Wear Inspection ............................................................................................
Drive Chain Lubrication.....................................................................................................
Drive Chain Removal ........................................................................................................
Drive Chain Installation .....................................................................................................
Drive Chain Replacement .................................................................................................
Sprocket, Coupling .................................................................................................................
Engine Sprocket Removal ...............................................................................................
Engine Sprocket Installation .............................................................................................
Rear Sprocket Removal ...................................................................................................
Rear Sprocket Installation.................................................................................................
Coupling Installation..........................................................................................................
Coupling Bearing Removal ..............................................................................................
Coupling Bearing Installation ............................................................................................
Coupling Bearing Inspection .............................................................................................
Coupling Bearing Lubrication............................................................................................
Coupling Damper Inspection.............................................................................................
Sprocket Wear Inspection.................................................................................................
Rear Sprocket Warp Inspection ........................................................................................
11-2
11-4
11-5
11-6
11-6
11-6
11-6
11-6
11-6
11-6
11-6
11-7
11-10
11-10
11-10
11-11
11-11
11-11
11-11
11-12
11-12
11-12
11-12
11-13
11-13
11
11-2 FINAL DRIVE
Exploded View
FINAL DRIVE 11-3
Exploded View
No.
1
2
Fastener
Engine Sprocket Nut
Rear Sprocket Nut
G: Apply
HO: Apply
L: Apply
MO: Apply
O: Apply
grease.
heavy oil.
a non-permanent locking agent.
molybdenum disulfide oil.
oil.
N·m
127
74
Torque
kgf·m
13
7.5
ft·lb
94
54
Remarks
MO
11-4 FINAL DRIVE
Specifications
Item
Drive Chain
Standard Chain
Make
Type
Link
Sprockets
Rear Sprocket Warp
Standard
ENUMA
EK50MV-O, Endless
EK50MV-X (VN800-B6 ∼, B6F)
112 links
Less-than 0.4 mm (0.015 in.)
Service Limit
– – –
– – –
– – –
0.5 mm (0.02 in.)
FINAL DRIVE 11-5
Special Tools
Inside Circlip Pliers:
57001-143
Bearing Driver Set:
57001-1129
11-6 FINAL DRIVE
Drive Chain
Drive Chain Slack Inspection
to the Drive Chain Slack Inspection in the Periodic
• Refer
Maintenance chapter.
Drive Chain Slack Adjustment
to the Drive Chain Slack Inspection in the Periodic
• Refer
Maintenance chapter.
Wheel Alignment Inspection/Adjustment
that the left and right notches [A] on the chain ad• Check
juster should point to the same marks or points [B] on the
left and right swingarm.
If they do not, adjust the chain slack and align the wheel
alignment (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter).
NOTE
○Wheel
alignment can be also checked using the
straightedge or string method.
WARNING
Misalignment of the wheel will result in abnormal
wear, and may result in an unsafe riding condition.
Drive Chain Wear Inspection
to the Drive Chain Wear Inspection in the Periodic
• Refer
Maintenance chapter.
Drive Chain Lubrication
to the Drive Chain Lubrication in the Periodic Main• Refer
tenance chapter.
Drive Chain Removal
• Remove:
Rear Wheel (see Wheels/Tires chapter)
•
Swingarm (see Suspension chapter)
Engine Sprocket Cover (see Engine Sprocket Removal)
Disengage the drive chain [A] from the engine sprocket
[B], and take it off the chassis.
Drive Chain Installation
the drive chain with the engine sprocket.
• Engage
Install:
• Swingarm (see Suspension chapter)
•
Rear Wheel (see Wheels/Tires chapter)
Engine Sprocket Cover (see Engine Sprocket Cover Installation)
Adjust the chain slack after installing the chain (see the
Drive Chain Slack Adjustment in the Periodic Maintenance chapter).
FINAL DRIVE 11-7
Drive Chain
Drive Chain Replacement
CAUTION
For safety, if the drive chain shall be replaced, replace it using a recommended tool.
Recommended Tool - Type: EK JOINT Tool #50
Brand: ENUMA CHAIN
Body [A]
Handlebar [B]
Cutting and Rivetting Pin [C]
For Cutting [D]
For Rivetting [E]
Plate Holder (A) [F]
Plate Holder (B) [G]
Gauge [H]
Drive Chain Specifications
Type:
EK50MV-X
Link:
112 link (MLJ)
• Remove:
Engine Sprocket Cover (see Engine Sprocket Removal)
[A] the pin head to make it flat.
• Grind
Set
the
cutting and rivetting pin [B] as shown.
•
the pin holder until it touches the link pin.
• Screw
Be
sure
that the cutting pin hits center of the link pin.
•
the handlebar [A] into the body.
• Screw
Turn
the
pin holder with the wrench [B] clockwise to ex• tract the link
pin.
11-8 FINAL DRIVE
Drive Chain
the link pin, link plate and grease seals.
• Replace
Apply
grease
to the link pins [A] and grease the seals [B]
• [C].
the drive chain on the engine and rear sprockets.
• Engage
Insert
the
pins in the drive chain ends.
• Install the link
grease
[C].
• Install the link plateseals
[D]
so
the mark faces out.
• Push the link plate by handthat
or plier to fix it.
• Be sure to set the grease seals
correctly.
•
the plate holder (A) [A] and plate holder (B) [B] on the
• Set
body.
the plate holder (A) to the link plate.
• Fit
Turn
the pin holder by hand until the plate holder (B)
• touches
the other link plate.
the pin holder by a wrench clockwise until two pins
• Turn
of link come into groove of the plate holder (A).
• Take off the plate holder.
the plate holder (B) [A] and the cutting and rivetting
• Set
pin [B] as shown.
FINAL DRIVE 11-9
Drive Chain
the pin holder until the rivetting pin touches the link
• Turn
pin.
the wrench clockwise until the tip of rivetting pin con• Turn
tact with the link pin.
it.
• Rivet
• Repeat the same procedure for the other link pin.
staking, check the staked area of the link pin for
• After
cracks.
the outside diameter [A] of the link pin and link
• Measure
plates width [B].
Link Pin Outside Diameter
Standard:
5.6 ∼ 6.0 mm (0.22 ∼ 0.24 in.)
Link Plates Outside Width
Standard:
21.45 ∼ 21.60 mm (0.84 ∼ 0.85 in.)
•
•
If the reading exceeds the specified length, cut and rejoin
the chain again.
Check:
Movement of the Rollers
Adjust the drive chain slack after installing the chain.
11-10 FINAL DRIVE
Sprocket, Coupling
Engine Sprocket Removal
the bolt [A].
• Remove
Pull
the
engine
sprocket cover [B] to the rear until the
• cover separates from
the alternator cover [C], and remove
it.
out the bended washer [A].
• Flatten
Remove:
• Engine Sprocket Nut [B] and Washer
NOTE
○When loosening the engine sprocket nut, hold the rear
brake on.
the drive chain (see Drive Chain Slack Adjust• Loosen
ment in the Periodic Maintenance chapter).
the drive chain from the rear sprocket toward the
• Remove
right.
the engine sprocket [A] off the output shaft [B] along
• Pull
with the chain.
• Remove the engine sprocket.
Engine Sprocket Installation
the sprocket washer.
• Replace
Install
the
engine sprocket onto the output shaft.
• Apply molybdenum
disulfide oil to the threads of the out• put shaft and the seating
surface of the engine sprocket
•
•
nut.
Engage the drive chain with the engine and rear sprocket.
Tighten:
Torque - Engine Sprocket Nut: 127 N·m (13 kgf·m, 94 ft·lb)
NOTE
○Tighten the nut while applying the rear brake.
the one side of the washer over the nut.
• Bend
Install
trim [A] on the alternator cover end.
• Fit the the
[B] of the engine sprocket cover to the trim.
• Adjust groove
the
drive
slack after installing the sprocket
• (see Drive Chainchain
Slack Adjustment in the Periodic Maintenance chapter).
FINAL DRIVE 11-11
Sprocket, Coupling
Rear Sprocket Removal
the rear wheel (see Wheel/Tires chapter).
• Remove
Remove
rear sprocket nuts [A].
• Remove the
the rear sprocket [B].
•
Rear Sprocket Installation
the sprocket facing the tooth number marking [A]
• Install
outward.
• Tighten:
Torque - Rear Sprocket Nuts: 74 N·m (7.5 kgf·m, 54 ft·lb)
• Install the rear wheel (see Wheels/Tires chapter).
Coupling Installation
the following and install the coupling.
• Grease
Grease Seal [A]
Coupling Internal Surface [B]
Coupling Bearing Removal
• Remove:
Coupling
Grease Seal
Circlip [A]
Special Tool - Inside Circlip Pliers: 57001-143 [B]
• Remove the bearing by tapping from the wheel side.
Special Tool - Bearing Driver Set: 57001-1129 [A]
11-12 FINAL DRIVE
Sprocket, Coupling
Coupling Bearing Installation
the bearing with a new one.
• Replace
Press
in
the
bearing [A] until it is bottomed.
•
Special Tool - Bearing Driver Set: 57001-1129 [B]
the bearing with high temperature grease.
• Pack
Replace
the circlip with a new one.
•
Special Tool - Inside Circlip Pliers: 57001-143
the grease seal with a new one.
• Replace
Press
in
the
seal so that the seal surface is flush
• with the end grease
of the hole.
○Apply high temperature grease to the grease seal lips.
Special Tool - Bearing Driver Set: 57001-1129
Coupling Bearing Inspection
Since the coupling bearing is made to extremely close
tolerances, the clearance can not normally be measured.
NOTE
○It is not necessary to remove the coupling bearing for
inspection. If the bearing is removed, it will need to be
replaced with a new one.
the bearing in the coupling back and forth [A] while
• Turn
checking for plays, roughness, or binding.
•
If bearing play, roughness, or binding is found, replace
the bearing.
Examine the bearing seal [B] for tears or leakage.
If the seal is torn or is leaking, replace the bearing.
Coupling Bearing Lubrication
the bearing with good quality bearing grease. Turn
• Pack
the bearing around by hand a few times to make sure the
grease is distributed uniformly inside the bearing.
Coupling Damper Inspection
the rear wheel coupling, and inspect the rubber
• Remove
dampers [A].
the damper if it appears damaged or deterio• Replace
rated.
FINAL DRIVE 11-13
Sprocket, Coupling
Sprocket Wear Inspection
inspect the engine and rear sprocket teeth for
• Visually
wear and damage.
If the teeth are worn as illustrated, replace the sprocket,
and inspect the drive chain wear (see Drive Chain Wear
Inspection in the Periodic Maintenance chapter).
[A] Worn Tooth (Engine Sprocket)
[B] Worn Tooth (Rear Sprocket)
[C] Direction of Rotation
NOTE
○If a sprocket requires replacement, the chain is probably worn also. When replacing a sprocket, inspect the
chain.
Rear Sprocket Warp Inspection
the rear wheel off the ground (see Wheels/Tires
• Raise
chapter) so that it will turn freely.
a dial gauge [A] against the rear sprocket [B] near the
• Set
teeth as shown, and rotate [C] the rear wheel to measure
the sprocket runout (warp). The difference between the
highest and lowest dial gauge readings is the amount of
runout (warp).
If the runout exceeds the service limit, replace the rear
sprocket.
Rear Sprocket Warp
Standard:
less than 0.4 mm (0.016 in.)
Service Limit:
0.5 mm (0.02 in.)
BRAKES 12-1
Brakes
Table of Contents
Exploded View...................................
Specifications ....................................
Special Tools .....................................
Caliper ...............................................
Caliper Removal ..........................
Caliper Installation .......................
Caliper Disassembly ....................
Caliper Assembly .........................
Caliper Fluid Seal Damage
Inspection..................................
Caliper Dust Boot and Rubber
Boot Damage Inspection...........
Caliper Piston and Cylinder
Damage Inspection ...................
Caliper Holder Shaft Wear
Inspection..................................
Brake Pads ........................................
Brake Pad Removal .....................
Brake Pad Installation ..................
Brake pad Wear Inspection..........
Master Cylinder .................................
Master Cylinder Removal.............
Master Cylinder Installation..........
Master Cylinder Disassembly ......
Master Cylinder Assembly ...........
Master Cylinder Inspection (Visual
Inspection).................................
Brake Disc .........................................
Brake Disc Removal ....................
Brake Disc Installation .................
Brake Disc Wear Inspection.........
12-2
12-6
12-7
12-8
12-8
12-8
12-8
12-9
12-10
12-10
12-10
12-10
12-11
12-11
12-11
12-11
12-12
12-12
12-12
12-12
12-13
12-13
12-14
12-14
12-14
12-14
Brake Disc Warp Inspection.........
Brake Fluid ........................................
Level Inspection ...........................
Brake Fluid Change ....................
Bleeding the Brake Line...............
Brake Hose........................................
Brake Hose Removal/Installation.
Brake Hose Inspection.................
Brake Pedal and Cable......................
Brake Pedal Position Inspection ..
Brake Pedal Position Adjustment.
Brake Pedal Free Play Inspection
Brake Pedal Free Play Adjustment
..................................................
Brake Pedal Removal ..................
Brake Pedal Installation ...............
Brake Cable Lubrication...............
Brake Panel and Drum ......................
Cam Lever Angle Inspection........
Cam Lever Angle Adjustment ......
Brake Panel Removal ..................
Brake Panel Installation ...............
Brake Panel Disassembly ............
Brake Panel Assembly.................
Brake Drum Wear Inspection.......
Brake Shoe Lining Wear
Inspection..................................
Brake Shoe Spring Inspection .....
Brake Camshaft and Camshaft
Hole Wear Inspection................
Brake Lubrication .........................
12-14
12-15
12-15
12-15
12-15
12-16
12-16
12-16
12-17
12-17
12-17
12-17
12-17
12-17
12-18
12-18
12-19
12-19
12-19
12-19
12-19
12-20
12-20
12-21
12-21
12-21
12-21
12-21
12
12-2 BRAKES
Exploded View
BRAKES 12-3
Exploded View
No.
1
2
3
4
5
6
7
8
9
Fastener
Brake Caliper Mounting Bolts
Brake Disc Mounting Bolts
Brake Hose Banjo Bolts
Bleed Valve
Master Cylinder Clamp Bolts
Brake Lever Pivot Bolt
Brake Lever Pivot Bolt Locknut
Reservoir Cap Screws
Front Brake Light Switch Screw
N·m
34
27
34
7.8
8.8
1.0
5.9
1.5
1.2
Torque
kgf·m
3.5
2.8
3.5
0.8
0.90
0.1
0.6
0.15
0.12
10. Clamp (United States and Canada Models) (VN800-B1, Austria Model)
11. Clamp (Other than United States and Canada Model)
L: Apply a non-permanent locking agent
R: Replacement Parts.
Si: Apply silicone grease.
ft·lb
25
20
25
69 in·lb
78 in·lb
9 in·lb
52 in·lb
13 in·lb
10 in·lb
Remarks
L
12-4 BRAKES
Exploded View
BRAKES 12-5
Exploded View
No.
1
2
Fastener
Rear Brake Lever Clamp Bolt
Torque Link Nuts
3. Damper (VN800-B1 ∼ B6, Germany Model)
4. Rear Brake Lever Clamp Bolt
CL: Apply Cable Lubricant.
G: Apply grease.
R: Replacement parts.
N·m
25
34
Torque
kgf·m
2.5
3.5
ft·lb
18
25
Remarks
12-6 BRAKES
Specifications
Item
Front Brake
Brake Lever Position
Brake Lever Free Play
Brake Disc Thickness
Brake Disc Runout
Brake Fluid:
Grade
Rear Brake
Cam Lever Angle
Drum Inside Diameter
Camshaft Diameter
Camshaft Hole Diameter
Standard
Non-adjustable
Non-adjustable
5.8 ∼ 6.2 mm (0.228 ∼ 0.244 in.)
Less than 0.15 mm (0.006 in.)
DOT 4
80 ∼ 90°
180.00 ∼ 180.16 mm (7.088 ∼ 7.095 in.)
16.957 ∼ 16.984 mm (0.6678 ∼ 0.6688 in.)
17.000 ∼ 17.070 mm (0.6695 ∼ 0.6722 in.)
Service Limit
– – –
– – –
5.5 mm (0.21 in.)
0.3 mm (0.012 in.)
– – –
– – –
180.75 mm (7.118 in.)
16.88 mm (0.665 in.)
17.15 mm (0.675 in.)
BRAKES 12-7
Special Tools
Inside Circlip Pliers:
57001-143
Jack:
57001-1238
Jack Attachment #3:
57001-1416
12-8 BRAKES
Caliper
Caliper Removal
the banjo bolt [A] at the brake hose lower end,
• Loosen
and tighten it loosely.
the caliper mounting bolts [B], and detach the
• Unscrew
caliper [C] from the disc.
the banjo bolt and remove the brake hose [D]
• Unscrew
from the caliper (see Brake Hose Removal/Installation).
CAUTION
Immediately wash away any brake fluid that spills.
NOTE
○If the caliper is to be disassembled after removal and if
compressed air is not available, disassemble the caliper
before the brake hose is removed (see Caliper Disassembly).
Caliper Installation
the caliper and brake hose lower end.
•○Install
Replace the washers that are on each side of hose fitting
•
with new ones.
Tighten:
Torque - Caliper Mounting Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)
Brake Hose Banjo Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb)
the fluid level in the brake reservoir.
• Check
the brake line (see Bleeding the Brake Line in the
• Bleed
Periodic Maintenance chapter).
the brake for good braking power, no brake drag,
• Check
and no fluid leakage.
WARNING
Do not attempt to drive the motorcycle until a full
brake lever is obtained by pumping the brake lever
until the pads are against the disc. The brakes will
not function on the first application of the lever if
this is not done.
Caliper Disassembly
the caliper (see Caliper Removal) with the hose
• Remove
installed.
the pads and spring (see Pad Removal).
• Remove
Insert
a
wooden
• caliper opening. board [A] 6 mm (0.24 in.) thick inside the
the brake lever until the piston [B] push the wooden
• Pump
board.
BRAKES 12-9
Caliper
the board and pull out the pistons [A] by hand.
•○Remove
These pistons can also be removed by disconnecting the
hose and applying compressed air to the hose joint opening using the same wooden board. But be careful not to
put your fingers or palm inside the caliper opening during
work.
WARNING
To avoid serious injury, never place your fingers or
palm inside the caliper opening. If you apply compressed air into the caliper, the pistons may crush
your hand or fingers.
CAUTION
Immediately wash away any brake fluid that spills.
the dust seal(s) [A] and fluid seal(s) [B].
• Remove
the caliper holder [C], and shaft rubber friction
• Remove
boots [D].
the bleed valve and rubber cap.
• Remove
Front Caliper [E]
Caliper Assembly
• Clean the caliper parts except for the pads.
CAUTION
For cleaning the parts, use only disc brake fluid,
isopropyl alcohol, or ethyl alcohol.
• Tighten:
Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)
○It is recommended that the fluid seal (piston seal) which
•
•
•
is removed, be replaced with a new one.
Replace the dust seals if they are damaged.
Install the fluid seal. Either side of the seal may face outboard.
Apply brake fluid to the cylinders, pistons, and fluid seals
(piston seals), and push the pistons into the cylinders by
hand. Take care that neither the cylinder nor the piston
skirt gets scratched.
Caliper Body [A]
Outer Pad [B]
Inner pad [C]
Dust Seal [D]
Fluid Seal [E]
Piston [F]
Pad Pin [G]
Caliper Holder Shafts [H]
Rubber Boot [J]
Snap Pin [K]
Front Caliper [L]
12-10 BRAKES
Caliper
the caliper holder shaft rubber boot and dust
• Replace
cover if they are damaged.
a thin coat of silicone grease to the caliper holder
• Apply
shafts and holder holes (Silicone grease is a special high
•
•
temperature, water-resistant grease).
Install the anti-rattle spring in the caliper as shown.
Install the pads (see Brake Pad Installation).
Anti-rattle Spring for Front Caliper [A]
Caliper Fluid Seal Damage Inspection
The fluid seal (piston seal) [A] is placed around the piston to maintain clearance between the pad and the disc. If
the seal is in a poor condition, it could lead the pad to wear
excessively or the brake to drag, which may cause the temperature of the discs or the brake fluid to increase.
Replace the fluid seal if it exhibits any of the conditions
listed below.
○Brake fluid leakage around the pad.
○Brakes overheat.
○Considerable difference in inner and outer pad wear.
○Seal and piston are stuck together.
If the fluid seal is replaced, replace the dust seal [B] as
well. Also, replace all seals every other time the pads are
changed.
•
Caliper Dust Boot and Rubber Boot Damage
Inspection
that the dust boot [C] and rubber boot [D] are not
• Check
cracked, worn, swollwn, or otherwise damaged.
• If they show any damage, replace it.
Caliper Piston and Cylinder Damage Inspection
inspect the piston [E] and cylinder surfaces.
• Visually
Replace the caliper if the cylinder and piston are badly
scores or rusty.
Caliper Holder Shaft Wear Inspection
The caliper body must slide smoothly on the caliper holder
shafts. If the body does not slide smoothly, one pad will
wear more than the other, pad wear will increase, and constant drag on the disc will raise brake and brake fluid temperature.
Check to see that the caliper holder shafts [F] are not
badly worn or stepped, and that the rubber boots are not
damaged.
If the rubber boot is damaged, replace the rubber boot. To
replace the rubber boot, remove the pads and the caliper
bracket.
If the caliper holder shaft is damage, replace the caliper
bracket.
•
BRAKES 12-11
Brake Pads
Brake Pad Removal
the caliper with the hose installed (see Caliper
• Remove
Removal.)
• Remove:
Snap Pin [A]
Pad Pin [B]
the outer pad [A], and then remove the piston
• Remove
side pad [B].
Brake Pad Installation
installation, clean the pads with a high-flash point
• Before
solvent.
[A] the caliper pistons in by hand as far as they will
• Push
go.
• Be sure to install the snap pin [B] for the caliper.
WARNING
Do not attempt to drive the motorcycle until a full
brake lever or pedal is obtained by pumping the
brake lever or pedal until the pads are against the
disc. The brake will not function on the first application of the lever or pedal if this is not done.
Brake pad Wear Inspection
to the Brake Lining or Pad Wear Inspection in the
• Refer
Periodic Maintenance Chapter.
12-12 BRAKES
Master Cylinder
Master Cylinder Removal
the front brake light switch connectors [A].
• Disconnect
Remove
the
banjo bolt [B] to disconnect the brake hose
• from the master
cylinder (see Brake Hose Removal/In-
•
stallation).
Unscrew the clamp bolts [C], and take off the master cylinder [D] as an assembly with the reservoir, brake lever, and
brake switch installed.
CAUTION
Immediately wash away any brake fluid that spills.
Master Cylinder Installation
the front master cylinder to match its mating surface
• Set
[A] to the punched mark [B] of the handlebar.
the upper clamp bolt first, and then the lower
• Tighten
clamp bolt. There will be a gap at the lower part of the
clamp after tightening.
Torque - Master Cylinder Clamp Bolts: 8.8 N·m (0.90 kgf·m,
78 in·lb)
the washers that are on each side of the hose
• Replace
fitting with new ones.
• Tighten:
Torque - Brake Hose Banjo Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb)
the brake line (see Bleeding the Brake Line in the
• Bleed
Periodic Maintenance chapter).
the brake for good braking power, no brake drag,
• Check
and no fluid leakage.
Master Cylinder Disassembly
the master cylinder (see Master Cylinder Re• Remove
moval).
the reservoir cap and diaphragm, and pour the
• Remove
brake fluid into a container.
the pivot nut and pivot bolt, and remove the
• Unscrew
brake lever.
• Pull the dust cover out of place, and remove the circlip.
Special Tool - Inside Circlip Pliers: 57001-143
out the piston [A], secondary cup [B], primary cup [C],
• Pull
and return spring [D].
CAUTION
Do not remove the secondary cup from the piston
since removal will damage it.
BRAKES 12-13
Master Cylinder
Master Cylinder Assembly
assembly, clean all parts including the master
• Before
cylinder with brake fluid or alcohol.
CAUTION
Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning brake parts. Do not use any other fluid for
cleaning these parts, Gasoline, engine oil, or any
other petroleum distillate will cause deterioration of
the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the disc brake.
brake fluid to the removed parts and to the inner
• Apply
wall of the cylinder.
care not to scratch the piston or the inner wall of the
• Take
cylinder.
silicone grease (ex. PBC grease)
• Apply
Brake Lever Pivot Bolt
•
Brake Lever Pivot Contact
Push Rod Contact (Rear)
Dust Covers
Tighten:
Torque - Brake Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 9
in·lb)
Brake Lever Pivot Bolt Locknut: 5.9 N·m (0.60
kgf·m, 52 in·lb)
Master Cylinder Inspection (Visual Inspection)
the master cylinders (see Master Cylinder Re• Remove
moval).
the front master cylinders.
• Disassemble
that there are no scratches, rust or pitting on the
• Check
inner wall [A] of each master cylinder and on outside of
•
each piston [B].
If a master cylinder or piston shows any damage, replace
them.
Inspect the primary cup [C] and secondary cup [D].
If a cup is worn, damaged softened (rotted), or swollen,
the piston assembly should be replaced to renew the
cups.
If fluid leakage is noted at the brake lever, the piston assembly should be replaced to renew the cups.
the dust covers [E] for damage.
• Check
If they are damaged, replace them.
the piston return spring [F] for any damage.
• Check
If the springs are damaged, replace them.
that relief port [G] and supply port [H] are not
• Check
plugged.
If the relief port becomes plugged, the brake pads will
drag on the disc. Blow the ports clean with compressed
air.
Front Master Cylinder [J]
12-14 BRAKES
Brake Disc
Brake Disc Removal
the wheel (see Wheels/Tires chapter).
• Remove
Unscrew
the mounting bolts [A], and take off the disc [B].
•
Brake Disc Installation
the brake disc on the wheel so that the marked side
• Install
[A] faces out.
• Tighten:
Torque - Brake Disc Mounting Bolts: 27 N·m (2.8 kgf·m, 20
ft·lb)
Brake Disc Wear Inspection
the thickness of the disc [A] at the point where it
• Measure
has worn the most.
If the disc has worn past the service limit, replace it.
[B] Measuring Area
Disc Thickness
Standard:
Service Limit:
5.8 ∼ 6.2 mm (0.228 ∼ 0.244 in.)
5.5 mm (0.21 in.)
Brake Disc Warp Inspection
up the motorcycle so that the wheel is off the ground
• Jack
(see Wheels/Tires chapter).
Special Tool - Jack: 57001-1238
Jack Attachment #3: 57001-1416
○For front disc inspection, turn the handlebar fully to one
•
side.
Set up a dial gauge against the disc [A] as shown and
measure disc runout, while turning [B] the wheel by hand.
If runout exceeds the service limit, replace the disc.
Disc Runout
Standard:
Service Limit:
0.15 mm (0.006 in.) or less
0.3 mm (0.012 in.)
BRAKES 12-15
Brake Fluid
Level Inspection
to the Brake Fluid Level Inspection in the Periodic
• Refer
Maintenance chapter.
Brake Fluid Change
to the Brake Fluid Change in the Periodic Mainte• Refer
nance chapter.
Bleeding the Brake Line
to the Bleeding the Brake Line in the Periodic Main• Refer
tenance chapter.
12-16 BRAKES
Brake Hose
Brake Hose Removal/Installation
CAUTION
Brake fluid quickly ruins painted or plastic surfaces; any spilled fluid should be completely wiped
up immediately with wet cloth.
removing the brake hose, take care not to spill the
• When
brake fluid on the painted or plastic parts.
removing the brake hose, temporarily secure the
• When
end of the brake hose to some high place to keep fluid
•
•
•
loss to a minimum.
There are washers on each side of the brake hose fitting.
Replace them with new ones when installing.
When installing the hoses, avoid sharp bending, kinking,
flattening or twisting, and route the hoses according to
Cable, Wire and Hose Routing section in General Information chapter.
Tighten:
Torque - Brake Hose Banjo Bolts: 34 N·m (3.5 kgf·m, 25
ft·lb)
the brake line after installing the brake hose (see
• Bleed
Bleeding the Brake Line).
Brake Hose Inspection
to the Brake Hoses and Connections Inspection in
• Refer
the Periodic Maintenance chapter.
BRAKES 12-17
Brake Pedal and Cable
Brake Pedal Position Inspection
to the Brake Play Inspection in the Periodic Main• Refer
tenance chapter.
Brake Pedal Position Adjustment
to the Brake Play Inspection in the Periodic Main• Refer
tenance chapter.
Brake Pedal Free Play Inspection
to the Brake Play Inspection in the Periodic Main• Refer
tenance chapter.
Brake Pedal Free Play Adjustment
to the Brake Play Inspection in the Periodic Main• Refer
tenance chapter.
Brake Pedal Removal
• Remove:
Bolts [A]
Footpeg Bracket [B]
Cotter Pin [A]
Joint Pin [B]
Brake Cable [C]
the locknut [A] and adjusting bolt [B].
• Loosen
Remove:
• Brake Pedal Spring [C]
Brake Switch Spring [D]
Brake Switch [E]
Bolt [F] and Rear Brake Lever [G]
Brake Pedal
12-18 BRAKES
Brake Pedal and Cable
Brake Pedal Installation
the punch mark [A] on the brake pedal shaft with the
• Align
punch mark [B] on the brake pedal lever.
• Tighten:
Torque - Rear Brake Lever Clamp Bolt: 25 N·m (2.5 kgf·m,
18 ft·lb)
• Adjust the brake pedal free play.
Brake Cable Lubrication
to the General Lubrication in the Periodic Mainte• Refer
nance chapter.
BRAKES 12-19
Brake Panel and Drum
Cam Lever Angle Inspection
that the rear brake cam lever comes to an 80° ∼
• Check
90° angle [A] with the rear brake rod when the rear brake
is fully applied.
If it does not, adjust the rear brake cam lever angle.
Cam Lever Angle
Standard:
80° ∼ 90°
WARNING
Since a cam lever angle greater than 90° reduces
braking effectiveness, cam lever angle adjustment
should not be neglected.
Cam Lever Angle Adjustment
• Remove:
Rear Wheel (see Wheels/Tires chapter)
Cam Lever Bolt and Cam Lever
○Before removing the brake cam lever, mark the position
•
of the cam lever.
Mount the cam lever at a new position so that the cam
lever moves one screw thread from the original position
to the rear.
WARNING
A change in cam lever angle is caused by wear of
internal brake parts. Whenever the cam lever angle
is adjusted, also check for drag and proper operation, taking particular note of the brake lining wear
indicator position.
In case of doubt as to braking effectiveness, disassemble and inspect all internal brake parts. Worn
parts could cause the brake to lock or fall.
the rear wheel (see Wheels/Tires chapter).
• Install
Adjust
the rear brake play (see Brakes in the Periodic
• Maintenance
chapter).
Brake Panel Removal
the rear wheel (see Wheels/Tires chapter).
• Remove
Separate
the brake panel [A] from the wheel.
•
Brake Panel Installation
the brake panel to the rear wheel, and then install the
• Fit
rear wheel (see Wheels/Tires chapter).
12-20 BRAKES
Brake Panel and Drum
Brake Panel Disassembly
the brake panel (see Brake Panel Removal).
• Remove
Using
a
clean
cloth around the linings to prevent grease
• or oil from getting
on them, remove the brake shoes [A]
by pulling up on the center of the linings.
removing the brake cam lever [A], mark [B] the
• Before
position of the cam lever so that it can be installed later in
the same position.
Brake Panel Assembly
the old grease from the camshaft and regrease it.
•○Clean
Apply grease to the center of shaft and very lightly on the
•
cam surfaces. Do not overgrease.
Push the camshaft into the panel so that the triangular
mark [A] on the cam surface points toward the center of
the panel.
WARNING
Improper installation will cause ineffective braking.
the springs [A] onto the brake shoes as shown.
•○Fit
The brake shoe springs are identical.
a clean cloth around the linings to prevent grease
• Wrap
or oil from getting on them, and install the shoes on the
brake panel.
the seal ring and fit the indicator [A] on the serration
• Install
so that it points to the extreme left of the USABLE RANGE
•
[B].
Install the cam lever in its original position on the
camshaft, and tighten its bolt.
BRAKES 12-21
Brake Panel and Drum
Brake Drum Wear Inspection
the rear wheel (see Wheels/Tires chapter).
• Remove
Measure
the inside diameter [A] of the drum.
•○Use calipers
and measure at several points.
If any measurement is greater than the service limit, replace the wheel hub.
If the drum is worn unevenly or scored, lightly turn the
drum on a brake drum lathe or replace the wheel hub. Do
not turn the drum beyond the service limit.
Drum Inside Diameter
Standard:
180.00 ∼ 180.16 mm (7.088 ∼ 7.095 in.)
Service Limit:
180.75 mm (7.118 in.)
Brake Shoe Lining Wear Inspection
to the Brake Lining or Pad Wear Inspection in the
• Refer
Periodic Maintenance chapter.
Brake Shoe Spring Inspection
inspect the brake shoe springs for brakes or dis• Visually
tortion.
If the springs are damaged in any way, replace them.
Brake Camshaft and Camshaft Hole Wear Inspection
the brake camshaft (see Brake Panel Disassem• Remove
bly).
the shaft diameter [A].
• Measure
If any measurement is less than the service limit, replace
the camshaft.
Camshaft Diameter
Standard:
16.957 ∼ 16.984 mm (0.6678 ∼ 0.6688 in.)
Service Limit: 16.88 mm (0.665 in.)
the inside diameter [B] of the camshaft hole in
• Measure
the brake panel.
If any measurement is larger than the service limit, replace the brake panel.
Camshaft Hole Diameter
Standard:
17.000 ∼ 17.070 mm (0.6695 ∼ 0.6722 in.)
Service Limit: 17.15 mm (0.675 in.)
Brake Lubrication
all old grease out of the brake parts with a cloth.
• Clean
Apply
high-temperature
to the following:
• Brake Shoe Anchor Pingrease
[A]
•
•
Spring Ends [B]
Cam Surfaces [C]
Camshaft Groove [D]
Lubricate the brake pedal by applying a multi-purpose
grease to the pedal pivot shaft groove.
Clean any excess grease from the parts before assembly.
SUSPENSION 13-1
Suspension
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Front Fork ...............................................................................................................................
Front Fork Removal (each fork leg) ..................................................................................
Front Fork Installation .......................................................................................................
Fork Oil Change................................................................................................................
Front Fork Disassembly ....................................................................................................
Front Fork Assembly.........................................................................................................
Inner Tube Inspection .......................................................................................................
Dust Seal Inspection .........................................................................................................
Spring Tension ..................................................................................................................
Rear Shock Absorber ............................................................................................................
Spring Preload Adjustment ...............................................................................................
Rear Shock Absorber Removal ........................................................................................
Rear Shock Absorber Installation .....................................................................................
Rear Shock Absorber Scrapping ......................................................................................
Swingarm................................................................................................................................
Swingarm Removal...........................................................................................................
Swingarm Installation .......................................................................................................
Swingarm Bearing Removal .............................................................................................
Swingarm Bearing Installation ..........................................................................................
Swingarm Bearing, Sleeve Inspection ..............................................................................
Swingarm Lubrication .......................................................................................................
Drive Chain Slider Inspection............................................................................................
Tie-Rod, Rocker Arm ..............................................................................................................
Tie-Rod Removal ..............................................................................................................
Tie-Rod Installation ...........................................................................................................
Rocker Arm Removal........................................................................................................
Rocker Arm Installation.....................................................................................................
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection .............................................................
Rocker Arm/Tie-Rod Lubrication.......................................................................................
13-2
13-6
13-7
13-8
13-8
13-8
13-8
13-9
13-10
13-12
13-12
13-12
13-13
13-13
13-13
13-13
13-14
13-15
13-15
13-15
13-15
13-16
13-16
13-16
13-16
13-17
13-17
13-17
13-17
13-17
13-18
13-18
13
13-2 SUSPENSION
Exploded View
SUSPENSION 13-3
Exploded View
No.
1
2
3
4
5
6
Fastener
Front Fork Clamp Bolts (upper)
Front Fork Clamp Bolts (lower)
Front Fork Bottom Allen Bolts
Fork Cover Bolts 5 mm
Fork Cover Bolts 6 mm
Spacer Allen Bolt
N·m
20
34
20
8
13
4.4
7. Lower Fork Covers (VN800-B1 ∼ B7 Model)
8. Lower Fork Covers and Other Parts (VN800-B8 ∼, B6F Model)
L: Apply a non-permanent Locking agent.
Torque
kgf·m
2.0
3.5
2.0
0.8
1.3
0.45
ft·lb
14.5
25
14.5
11 in·lb
113 in·lb
39 in·lb
Remarks
L
13-4 SUSPENSION
Exploded View
SUSPENSION 13-5
Exploded View
No.
1
2
3
4
Fastener
Rear Shock Absorber Nuts
Swing Arm Pivot Shaft Nut
Rocker Arm Pivot Shaft Nut
Tie-Rod Nuts
G: Apply grease.
N·m
59
98
98
59
Torque
kgf·m
6.0
10.0
10.0
6.0
ft·lb
43
72
72
43
Remarks
13-6 SUSPENSION
Specifications
Item
Front Fork
Fork Oil:
Viscosity
Capacity (per side):
When changing oil
After disassembly and completely dry
Fork Spring Free Length
Rear Shock Absorber
Spring Preload
Standard
SHOWA SS8 or equivalent
Approx, 265 mL (9.0 US oz)
310 ±4 mL (10.5 ±0.14 US oz)
547.2 mm (21.54 in.)
1st step
Service Limit
– – –
– – –
– – –
536 mm (21.1 in.)
(Adjustable Range)
1st ∼ 7th steps
SUSPENSION 13-7
Special Tools
Fork Cylinder Holder Handle:
57001-183
Front Fork Oil Seal Driver:
57001-1219
Fork Cylinder Holder Adapter:
57001-1057
Jack:
57001-1238
Oil Seal & Bearing Remover:
57001-1058
Fork Oil Level Gauge:
57001-1290
Bearing Driver Set:
57001-1129
Jack Attachment #3:
57001-1416
Fork Outer Tube Weight:
57001-1218
13-8 SUSPENSION
Front Fork
Front Fork Removal (each fork leg)
the front wheel axle nut (see wheels/Tires chap• Loosen
ter)
• Raise the front wheel off the ground.
Special Tools - Jack: 57001-1238
Jack Attachment #3: 57001-1416
• Remove:
Caliper (for left fork only) (see Wheels/Tires chapter)
•
Front Fender (see Frame chapter)
Front Fork Upper Clamp Bolt [A]
Front Fork Lower Clamp Bolt [B]
With a twisting motion, work the fork leg down and out.
NOTE
○If the fork is tight, tap lightly around the base of the stem
head with a plastic mallet.
Front Fork Installation
VN800-B8 model, note the following procedure.
•○For
Install the spacer [A] so that the distance between the
fork top end [B] and the upper surface [C] of the spacer is
249.6 mm (9.83 in.) [D].
Torque - Spacer Allen Bolt: 4.4 N·m (0.45 kgf·m, 39 in·lb)
○Insert the washer, rubber seat and fork lower cover to the
inner tube.
the clamp bolt (lower) clockwise posing the fork leg
• Turn
upward fully.
the fork so that the top end [A] of the inner tube is
• Install
flush with the upper surface of the steering stem head.
• Tighten:
Torque - Front Fork Clamp Bolt (Lower): 34 N·m (3.5 kgf·m,
25 ft·lb)
Front Fork Clamp Bolt (Upper): 20 N·m (2.0 kgf·m,
14.5 ft·lb)
• Install the removed parts (see appropriate chapters).
Fork Oil Change
to the Front Fork Oil Change in the Periodic Main• Refer
tenance chapter.
SUSPENSION 13-9
Front Fork
Front Fork Disassembly
the front fork (see Front Fork Removal).
• Remove
Drain
the
fork oil (see Fork Oil Change in the Periodic
• Maintenance
chapter).
Tap
the
point
suitable tool to separate the dust
• seal cover [B][A]fromwiththea outer
tube [C].
the front fork horizontally in a vise [A].
• Hold
Stop
the
• tools. cylinder unit [B] from turning by using the special
the Allen bolt [C], and take the gasket out of the
• Unscrew
bottom of the outer tube.
Special Tool - Fork Cylinder Holder Handle: 57001-183 [D]
Fork Cylinder Holder Adapter: 57001-1057
[E]
• Take the cylinder unit out of the inner tube.
the cylinder unit [A] and short spring [B] from the
• Remove
inner tube.
the inner tube from the outer tube as follows:
•○Separate
Slide up the dust seal [A].
○Remove the retaining ring [B] from the outer tube.
○Grasp the inner tube and stroke the outer tube up and
down several times. The shock to the fork seal separates
the inner tube from the outer tube.
If the tubes are tight, use a fork outer tube weight [A].
Special Tool - Fork Outer Tube Weight: 57001-1218
13-10 SUSPENSION
Front Fork
the inner tube guide bushing [A], outer tube
• Remove
guide bushing [B], washer [C] and oil seal [D] from the
•
inner tube.
Remove the cylinder base from the bottom of the outer
tube.
Front Fork Assembly
the following parts with new one.
• Replace
Oil Seal
•
Guide Bushings
Bottom Allen Bolt Gasket
Install the following parts onto the inner tube.
Dust Seal
Retaining Ring
Oil Seal
Washer
Outer Tube Guide Bushing
Inner Tube Guide Bushing
the cylinder unit [A] into the inner tube [B].
• Insert
Install
the cylinder base [C] on the cylinder unit.
• Insert the
inner tube, cylinder unit, cylinder base as a set
• into the outer
tube [D].
Replace
the
bottom
Allen bolt gasket with a new one.
• Stop the cylinder from
turning by using the fork cylinder
• holder.
Special Tool - Fork Cylinder Holder Handle: 57001-183
Fork Cylinder Holder Adapter: 57001-1057
a non-permanent locking agent to the Allen bolt and
• Apply
tighten it.
Torque - Front Fork Bottom Allen Bolt: 20 N·m (2.0 kgf·m,
14.5 ft·lb)
• Fit the new outer guide bushing [A] into the outer tube.
NOTE
○When assembling the new outer tube guide bushing,
hold the used guide bushing [B] against the new bushing and tap the used guide bushing with the fork oil seal
driver [C] until it stops.
Special Tool - Front Fork Oil Seal Driver: 57001-1219
installing the washer, install the oil seal by using the
• After
fork oil seal driver.
• Install the retaining ring and dust seal by hand.
SUSPENSION 13-11
Front Fork
the notch [A] of the dust seal cover rearward [B] and
• Face
install the dust seal cover by tapping with the fork outer
tube weight [C] until it stops.
Special Tool - Fork Outer Tube Weight: 57001-1218
• Stake [A] the dust seal cover with a punch.
VN800-B8 model, note the following procedure.
•○For
Install the spacer [A] (see Front Fork Installation).
○Insert:
Washer [B]
Rubber Seat [C]
Lower Cover [D]
in the specified type and amount of oil (see the Front
• Poor
Fork Oil Change in the Periodic Maintenance chapter).
• Install the fork leg (see Front Fork Installation).
13-12 SUSPENSION
Front Fork
Inner Tube Inspection
inspect the inner tube, and repair any damage.
• Visually
Nicks
or
rust damage can sometimes be repaired by using
• a wet-stone
to remove sharp edges or raised areas which
cause seal damage.
If the damage is not repairable, replace the inner tube.
Since damage to the inner tube damages the oil seal,
replace the oil seal whenever the inner tube is repaired
or replaced.
CAUTION
If the inner tube is badly bent or creased, replace
it. Excessive bending, followed by subsequent
straightening, can weaken the inner tube.
assemble the inner and outer tubes, and
• Temporarily
pump them back and forth manually to check for smooth
•
operation.
If you feel binding or catching, the inner and outer tubes
must be replaced.
WARNING
A straightened inner or outer fork tube may fall in
use, possibly causing an accident. Replace a badly
bent or damaged inner or outer tube and inspect the
other tube carefully before reusing it.
Dust Seal Inspection
the dust seal [A] for any signs of deterioration or
• Inspect
damage.
Replace it if necessary.
Spring Tension
a spring becomes shorter as it weakens, check its
• Since
free length [A] to determine its condition.
If the spring of either fork leg is shorter than the service
limit, it must be replaced. If the length of a replacement
spring and that of the remaining spring vary greatly, the
remaining spring should also be replaced in order to keep
the fork legs balanced for motorcycle stability.
Fork Spring Free Length
Standard:
547.2 mm (21.54 in.)
Service Limit:
536 mm (21.1 in.)
SUSPENSION 13-13
Rear Shock Absorber
Spring Preload Adjustment
the rear shock absorber from the frame (see
• Remove
Rear Shock Absorber Removal).
adjust the sprint force, turn the adjusting sleeve [A] on
• To
the shock absorber to the desired position with the stem
nut wrench.
Special Tool - Steering Stem Nut Wrench: 57001-1100
○The standard adjusting sleeve for an average-build of 68
kg (150 lb) with no passenger and no accessories is it
step from the weakest position.
Spring Preload Adjustment
Adjuster Position
Spring Tension
1
2
Weakest
3
4
5
←
STD
→
6
7
Stronger
Rear Shock Absorber Removal
• Remove:
Muffler (see Engine Top End chapter)
•
Storage Box, Tool Kit Container (see Frame chapter)
Using the jack, raise the rear wheel off the ground.
Special Tool - jack: 57001-1238
Jack Attachment #3: 57001-1416
• Squeeze the brake lever slowly and it with a band [A].
WARNING
Be sure to hold the front brake when removing the
shock absorber, or the motorcycle may fall over. It
could cause an accident and injury.
• Remove:
Lower Shock Absorber Bolt [A]
Lower Tie-Rod Bolt [B]
Upper Shock Absorber Bolt [C]
Rear Shock Absorber
Rear Shock Absorber Installation
the rocker arm needle bearings with grease.
• Pack
Install
the rear shock absorber so that the CAUTION label
• faces rearward.
• Tighten:
Torque - Rear Shock Absorber Nuts: 59 N·m (6.0 kgf·m, 43
ft·lb)
Tie-Rod Nuts: 59 N·m (6.0 kgf·m, 43 ft·lb)
13-14 SUSPENSION
Rear Shock Absorber
Rear Shock Absorber Scrapping
WARNING
Since the rear shock absorber contains nitrogen
gas, do not incinerate the rear shock absorber without first releasing the gas or it may explode.
Before a rear shock absorber is scrapped, drill a
hole at the point [A] shown to release the nitrogen
gas completely. Wear safety glasses when drilling
the hole, as the gas may blow out bits of drilled
metal when the hole opens.
SUSPENSION 13-15
Swingarm
Swingarm Removal
• Remove:
Muffler (see Engine Top End chapter)
Rear Wheel (see Wheels/Tires chapter)
Upper Shock Absorber Bolt
Bolts [A] and Rear Wheel Mud Guard [B]
Nut [A] and Brake Cable [B]
•
Upper Tie-Rod Bolt [A]
Cap and Swingarm Pivot Nut [B]
Pull off the pivot shaft and remove the swingarm.
Swingarm Installation
plenty of grease to the needle bearings and grease
• Apply
seals.
• Tighten:
Torque - Swingarm Pivot Shaft Nut: 9.8 N·m (10.0 kgf·m, 72
ft·lb)
Upper Tie-Rod Nut: 59 N·m (6.0 kgf·m, 43 ft·lb)
Rear Shock Absorber Nut: 59 N·m (6.0 kgf·m, 43
ft·lb)
• Install the removed parts (see appropriate chapters).
Swingarm Bearing Removal
• Remove:
Swingarm
•
Grease Seals
Sleeve
Remove the needle bearings.
Special Tool - Oil Seal & Bearing Remover: 57001-1058 [A]
13-16 SUSPENSION
Swingarm
Swingarm Bearing Installation
plenty of grease to the needle bearings.
• Apply
Install
• out. the bearings so that the manufacturer’s marks face
Special Tool - Bearing Driver Set: 57001-1129
Swingarm Bearing, Sleeve Inspection
CAUTION
Do not remove the bearings for inspection. Remove
may damage them.
inspect the swingarm sleeves and needle bear• Visually
ings.
rollers in a needle bearing normally wear very little,
• The
and wear is difficult to measure. Instead of measuring,
inspect the bearing in the swingarm for abrasion, color
change, or other damage.
If there is any doubt as to the condition of any of the needle bearings or sleeve, replace the sleeve, and needle
bearings as a set.
Swingarm Lubrication
to the Swingarm Pivot Lubrication in the Periodic
• Refer
Maintenance chapter.
Drive Chain Slider Inspection
inspect the sliders [A].
• Visually
If they are damaged, cut or abnormal weared, replace
them.
SUSPENSION 13-17
Tie-Rod, Rocker Arm
Tie-Rod Removal
the muffler (see Engine Top End chapter).
• Remove
Squeeze
• [A]. the brake lever slowly and hold it with a band
• Using the jack, raise the rear wheel off the ground.
Special Tool - Jack: 57001-1238
Jack Attachment #3: 57001-1416
• Remove:
Storage Box (see Frame chapter)
Regulator/Rectifier (see Electrical system chapter)
Upper and Lower Tie-Rod Bolts [A]
Tie-Rod [B]
Tie-Rod Installation
grease to the inside of the needle bearings and
• Apply
grease seals.
• Tighten:
Torque - Tie-Rod Nuts: 59 N·m (6.0 kgf·m, 43 ft·lb)
Rocker Arm Removal
the muffler (see Engine Top End chapter).
• Remove
Squeeze
brake lever slowly and hold it with a band.
• Using thethe
jack,
raise the rear wheel off the ground.
•
Special Tool - Jack: 57001-1238
Jack Attachment #3: 57001-1416
the swingarm pivot shaft nut.
• Loosen
Remove:
• Lower Rear Shock Absorber Bolt and Nut [A]
Lower Tie-Rod Bolt and Nut [B]
Rocker Arm Pivot Shaft and Nut [C]
Rocker Arm [D]
Rocker Arm Installation
grease to the inside of the needle bearings and
• Apply
grease seals.
• Tighten:
Torque - Swingarm Pivot Shaft Nut: 98 N·m (10 kgf·m, 72
ft·lb)
Rocker Arm Pivot Shaft Nut: 98 N·m (10 kgf·m, 72
ft·lb)
Tie-Rod Nuts: 59 N·m (6.0 kgf·m, 43 ft·lb)
Rear Shock Absorber Nut: 59 N·m (6.0 kgf·m, 43
ft·lb)
13-18 SUSPENSION
Tie-Rod, Rocker Arm
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection
CAUTION
Do not remove the bearings for inspection. Remove
may damage them.
inspect the swingarm sleeves and needle bear• Visually
ings.
rollers in a needle bearing normally wear very little,
• The
and wear is difficult to measure. Instead of measuring,
inspect the bearing for abrasion, color change, or other
damage.
If there is any doubt as to the condition of any of the needle bearings or sleeve, replace the sleeve, and needle
bearings as a set.
Rocker Arm/Tie-Rod Lubrication
to the Uni-Trak Linkage Lubrication in the periodic
• Refer
Maintenance chapter.
STEERING 14-1
Steering
Table of Contents
Exploded View........................................................................................................................
Special Tools ..........................................................................................................................
Steering .................................................................................................................................
Steering Inspection ...........................................................................................................
Steering Adjustment..........................................................................................................
Steering Stem.........................................................................................................................
Steering Stem, Stem Bearing Removal ............................................................................
Steering Stem, Stem Bearing Installation .........................................................................
Stem Bearing Lubrication .................................................................................................
Steering Stem Warp Inspection ........................................................................................
Handlebar ...............................................................................................................................
Handlebar Removal ..........................................................................................................
Handlebar Installation .......................................................................................................
14-2
14-4
14-5
14-5
14-5
14-6
14-6
14-8
14-9
14-9
14-10
14-10
14-10
14
14-2 STEERING
Exploded View
STEERING 14-3
Exploded View
No.
1
2
3
4
Fastener
Handlebar Holder Bolts
Handlebar Holder Mounting Nuts
Steering Stem Head Bolt
Steering Stem Nut
AD: Apply adhesive agent.
G: Apply grease.
L: Apply a non-permanent locking agent.
N·m
34
34
44
4.9
Torque
kgf·m
3.5
3.5
4.5
0.5
ft·lb
25
25
32
43 in·lb
Remarks
14-4 STEERING
Special Tools
Steering Stem Bearing Driver:
57001-137
Head Pipe Outer Race Driver,
57001-1106
Steering Stem Bearing Driver Adapter,
57001-1074
34.5:
Head Pipe Outer Race Remover ID > 37 mm:
57001-1107
Head Pipe Outer Race Press Shaft:
57001-1075
Jack:
57001-1238
Head Pipe Outer Race Driver,
57001-1076
Jack Attachment #3:
57001-1416
Steering Stem Nut Wrench:
57001-1100
51.5:
46.5:
STEERING 14-5
Steering
Steering Inspection
to the Steering Inspection in the Periodic Mainte• Refer
nance chapter.
Steering Adjustment
to the Steering Inspection in the Periodic Mainte• Refer
nance chapter.
14-6 STEERING
Steering Stem
Steering Stem, Stem Bearing Removal
• Remove:
Seat (see Frame chapter)
•
•
Meter unit (see Electrical System chapter)
Fuel Tank (see Fuel System chapter)
Headlight Unit (see Electrical System chapter)
Headlight Mounting Bracket Bolts [A]
Disconnect the front turn signal lead connectors [B].
Remove the headlight body with bracket [C].
the cable clamp mounting bolt [A] and cable
• Remove
clamp [B] (both side).
• Remove:
Brake Hose Grommets [A]
Caliper Mounting Bolts [B]
Front Wheel (see Wheels/Tires chapter)
Front Fender (see Frame chapter)
the front fork upper clamp bolts [A].
• Loosen
Remove:
• Steering Stem Head Bolt [B]
Steering Stem Head [C] and Handlebar as a set
• Remove:
Bolts [A]
Upper Fork Covers [B]
STEERING 14-7
Steering Stem
• Remove:
Turn Signal Light Bracket Clamp Bolts [A]
•
•
Turn Signal Lights [B]
Steering Stem Base Cover [C]
Loosen the front fork lower clamp bolts.
Remove the front fork assembly.
VN800-B1 ∼ B7 model, note the following procedure.
•○For
Remove:
Lower Fork Cover Bolts [A]
Lower Fork Covers [B]
up the steering stem base [A], and remove the
• Pushing
steering stem locknut [B], steering stem nut [C] and steering stem cap [D], then remove the steering stem [E] and
stem base.
Special Tool - Steering Stem Nut Wrench: 57001-1100 [F]
• Remove the upper stem bearing inner race.
• Drive out the bearing outer races from the head pipe.
Special Tool - Head Pipe Outer Race Remover ID > 37 mm:
57001-1107 [A]
NOTE
○If either steering stem bearing is damaged, it is recommended that both the upper and lower bearings (including outer races) should be replaced with new ones.
the lower bearing inner race (with its grease seal)
• Remove
which is pressed onto the steering stem with a suitable
commercially available bearing puller.
14-8 STEERING
Steering Stem
Steering Stem, Stem Bearing Installation
the bearing outer races with new ones.
• Replace
Apply
grease
to the outer races, and drive them into the
• head pipe at the
same time.
Special Tool - Head Pipe Outer Race Press Shaft: 57001
-1075 [A]
Head Pipe Outer Race Driver, 46.5: 57001
-1106 [B]
Head Pipe Outer Race Driver, 51.5: 57001
-1076 [C]
the bearing inner races with new ones.
• Replace
Apply
grease
to the lower bearing inner race [A], and drive
• it onto the steering
stem.
Special Tool - Steering Stem Bearing Driver: 57001-137
[B]
Steering Stem Bearing Driver Adapter,
34.5: 57001-1074 [C]
grease to the upper bearing inner race, and install
• Apply
it in the head pipe.
the steering stem into the head pipe.
• Insert
Install
steering stem cap [A] and steering stem nut [B] and
• hand tighten
it and steering stem locknut [C].
the inner races in place as follows:
•○Settle
Tighten the steering stem nut to 39 N·m (4.0 kgf·m, 29
ft·lb) of torque. (To tighten the steering stem nut to the
specified torque, hook the wrench on the steering stem
nut, and pull the wrench at the hole by 220 N (22.2 kg) [B]
force in the direction shown.)
Special Tool - Steering Stem Nut Wrench: 57001-1100 [A]
○Check that there is no play and the steering stem turns
smoothly without rattles. If not, steering stem bearings
may be damaged.
○Again back out the stem locknut a fraction of a turn until
it turns lightly.
Turn the steering stem locknut lightly clockwise until it just
becomes hard to turn. Do not overtighten, or the steering
will be too tight.
•
Torque - Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb)
is reverse of removal, note the following.
• installation
Lower Fork Covers
Each Fork Leg (see Suspension chapter)
Turn Signal Lights
Steering Stem Base Cover with Upper Fork Covers
Steering Stem Head and Handlebar as a set
STEERING 14-9
Steering Stem
VN800-B1 ∼ B7 model, note the following procedure.
•○For
Tighten the lower fork cover bolts.
Torque - Lower Fork Cover Bolts (5 mm): 8 N·m (0.8 kgf·m,
71 in·lb)
Lower Fork Cover Bolts (6 mm): 13 N·m (1.3 kgf·m,
115 in·lb)
tighten the fork clamp bolts (upper).
•○Temporarily
Check that the top end of the inner tube is flush with the
•
upper surface of the steering stem head (see Suspension
chapter).
Tighten the fork clamp bolts (upper) and then the steering
stem head bolt, and finally the fork clamp bolts (lower).
Torque - Fork Clamp Bolts (Upper): 20 N·m (2.0 kgf·m, 14
ft·lb)
Steering Stem Head Bolt: 44 N·m (4.5 kgf·m, 32
ft·lb)
Fork Clamp Bolts (Lower): 34 N·m (3.5 kgf·m, 25
ft·lb)
the removed parts.
• Install
Front wheel (see Wheels/Tires chapter)
•
Front Calliper (see Breaks chapter)
Check the front brake effectiveness.
WARNING
Do not attempt to ride the motorcycle until a full
brake lever is obtained by pumping the brake lever
until the pads are against the disc. The brakes will
not function on the first application of the lever if
this is not done.
WARNING
Do not impede the handlebar turning by routing the
cables, harnesses and hoses improperly (see Appendix chapter).
Stem Bearing Lubrication
to the Steering Stem Bearing Lubrication in the Pe• Refer
riodic Maintenance chapter.
Steering Stem Warp Inspection
the steering stem is removed, or if the steering
• Whenever
cannot be adjusted for smooth action, check the steering
stem for straightness.
If the steering stem [A] is bent replace the steering stem.
14-10 STEERING
Handlebar
Handlebar Removal
• Remove:
Clutch Cable Upper End
•
Left Handlebar Switch Housing
Front Brake Master Cylinder
Right Handlebar Switch Housing
Throttle Grip
Handlebar Holder Bolts [A] and Handlebar Holder
Remove the handlebar [B] from the steering stem head.
Handlebar Installation
the handlebar to match its punched mark [A] to the
• Set
lower mating surface [B] of the clamp rear part.
the front holder bolts first, and then the rear holder
• Tighten
bolts. There will be a gap [A] at the rear part of the clamp
after tightening.
Torque - Handlebar Holder Bolts: 34 N·m (3.5 kgf·m, 25
ft·lb)
front half of the right handlebar switch housing [A]
• The
has a small projection [B]. Fit the projection into the small
hole [C] in the handlebar.
the left handlebar switch housing [A] to match its mat• Set
ing surface [B] to the punched mark [C] of the handlebar.
the handlebar switch housings and tighten it.
• Install
Install:
• Clutch Cable (see Clutch chapter)
•
Front Master Cylinder (see Brakes chapter)
Check and adjust the rear view mirrors.
FRAME 15-1
Frame
Table of Contents
Exploded View........................................................................................................................
Seat ........................................................................................................................................
Seat Removal ...................................................................................................................
Seat Installation ................................................................................................................
Side Covers ............................................................................................................................
Left Side Cover Removal ..................................................................................................
Left Side Cover Installation ...............................................................................................
Right Side Cover Removal ...............................................................................................
Right Side Cover Installation.............................................................................................
Fenders ..................................................................................................................................
Front Fender Removal ......................................................................................................
Rear Fender Removal.......................................................................................................
Rear Fender Installation....................................................................................................
Battery Case...........................................................................................................................
Battery Case Removal ......................................................................................................
Down Tube .............................................................................................................................
Down Tube Removal .......................................................................................................
Down Tube Installation .....................................................................................................
Storage Box, Tool Kit Container ............................................................................................
Storage Box Removal .......................................................................................................
Tool Kit Container Removal .............................................................................................
15-2
15-5
15-5
15-5
15-6
15-6
15-6
15-6
15-6
15-7
15-7
15-7
15-7
15-8
15-8
15-9
15-9
15-9
15-10
15-10
15-10
15
15-2 FRAME
Exploded View
FRAME 15-3
Exploded View
No.
1
2
3
4
Fastener
Side Stand Pivot Nut
Rear Frame Mounting Bolts
Muffler Bracket Mounting Bolts
Footpeg Holder Bolts
G: Apply grease.
N·m
44
44
25
34
Torque
kgf·m
4.5
4.5
2.5
3.5
ft·lb
32
32
18
25
Remarks
15-4 FRAME
Exploded View
1. Reflector-Reflex, FR (United States and Canada Models)
2. Front Fender Mounting Screws
FRAME 15-5
Seat
Seat Removal
the seat mounting bolt [A].
• Remove
Pull
[B]
the
to unhook the front and rear hooks [C],
• and removeseat
it.
Seat Installation
the front hook [A] into the brace [B] on the frame.
• Insert
Slip
the
• fender. rear hooks [C] under the loop [D] on the rear
15-6 FRAME
Side Covers
Left Side Cover Removal
• Remove the screw [A], and pull [B] the left cover forward.
Left Side Cover Installation
the projection [A] into the slot [B] on the frame, and
• Fit
tighten the screw.
Right Side Cover Removal
the ignition switch key into the right side cover lock
• Insert
[A], turning the key counterclockwise, pulling out the rear
of the cover, and remove it forward.
Right Side Cover Installation
the front projections [A] into the slot [B] on the frame,
• Fit
and then fit the rear projection [C] into the hole [D] of the
•
bracket.
Lock the cover with the ignition switch key.
FRAME 15-7
Fenders
Front Fender Removal
the front wheel off the ground.
• Raise
Unscrew
• -wards. the bolts [A] and pull the front fender [B] to rear
Rear Fender Removal
• Remove:
Seat (see Seat Removal)
Connectors [A]
Rear Fender Bolts [B]
Rear Frame Mounting Bolts [C] (both side)
Rear Fender Assembly.
• Remove:
Bolts [A] (both side)
Rear Frames [B] with Turn Signal Lights
loop [C]
the following parts from the rear fender.
• Remove
Bolts [A] and Tail/Brake Light Unit
Bolts [B] and License Plate Bracket
Rear Fender Installation
is reverse of removal, note the following.
•○Installation
Be sure the harness in place (see Appendix chapter)
○Tighten:
Torque - Rear Frame Mounting Bolts: 44 N·m (4.5 kgf·m, 32
ft·lb)
15-8 FRAME
Battery Case
Battery Case Removal
• Remove:
Seat (see Seat Removal)
Rear Fender (see Rear Fender Removal)
Fuel Tank (see Fuel System chapter)
Bolts [A] and Battery Cover [B]
Battery
Coolant Hose [C]
Surge Tank [D]
• Remove:
IC Igniter [A]
Junction Box [B]
Starter Relay, Main Fuse [C]
Turn Signal Relay [D]
Choke Cable Holder Screw [E]
Coolant Hose
Evapo, System Hoses (for California Model)
• Remove:
Right Side Cover
•
Storage Box
Upper Tie-Rod Nut [A]
Regulator/Rectifier [B]
Take out the upper tie-rod bolt [C].
Special Tool - Jack: 57001-1238
• Remove the battery case [A] from the frame.
FRAME 15-9
Down Tube
Down Tube Removal
• Remove:
Footpeg and Brake Pedal (see Brakes chapter)
Front Muffler (see Engine Top End chapter)
Clutch Cable Clamps
Engine Bracket Bolts [A]
Bolts [B] and Down Tube Assembly [C]
Air Cleaner Drain Hose [D]
Down Tube Installation
• Tighten:
Torque - Down Tube Mounting Bolts: 44 N·m (4.5 kgf·m, 33
ft·lb)
• Tighten:
Torque - Engine Mounting Bracket Bolts:
kgf·m, 18 ft·lb)
25 N·m (2.5
15-10 FRAME
Storage Box, Tool Kit Container
Storage Box Removal
• Remove:
Muffler (see Engine Top End chapter)
Right Side Cover (see Right Side Cover Removal)
Screws [A] and Lower Cover
Canister and Separator (for California Model)
Bolts [A]
Bracket [B]
Storage Box Base [C]
Tool Kit Container Removal
the left side cover (see Left Side Cover Re• Remove
moval).
the tool kit cover with the ignition switch key, and
• Open
take out the tool kit.
• Remove:
Ignition Coil [A]
Clamp [B]
Connectors [C]
Bolts [D]
Tool Kit Container [E]
ELECTRICAL SYSTEM 16-1
Electrical System
Table of Contents
Exploded View...................................
Parts Location....................................
Wiring Diagram (VN800-B1 ∼ B4,
United States, and Canada) ...........
Wiring Diagram (VN800-B1 ∼ B4,
Australia).........................................
Wiring Diagram (VN800-B1 ∼ B4,
Europe and Others) ........................
Wiring Diagram (VN800-B5 ∼ B8,
United States, and Canada) ...........
Wiring Diagram (VN800-B5 ∼ B8,
Australia).........................................
Wiring Diagram (VN800-B5 ∼ B7,
Europe and Others) ........................
Wiring Diagram (VN800-B8, other
than United States, Canada, and
Australia).........................................
Wiring Diagram (VN800-B9 ∼, B6F
United States, and Canada) ...........
Wiring Diagram (VN800-B9 ∼, B6F
Australia).........................................
Wiring Diagram (VN800-B9 ∼, B6F
other than United States, Canada,
and Australia)..................................
Specifications ....................................
Special Tools .....................................
Precautions........................................
Electrical Wiring.................................
Wiring Inspection .........................
Battery ...............................................
Battery Removal ..........................
Electrolyte Filling..........................
Initial Charge................................
Precautions ..................................
Interchange ..................................
Charging Condition Inspection.....
Refreshing Charge.......................
Charging System ..............................
Alternator Cover Removal............
Alternator Cover Installation ........
Stator Coil Removal ....................
Stator Coil Installation ..................
Alternator Rotor Removal ............
Alternator Rotor Installation ........
Alternator Inspection ....................
Regulator/Rectifier Inspection......
16-3
16-11
16-12
16-14
16-16
16-18
16-20
16-22
16-24
16-26
16-28
16-30
16-32
16-33
16-34
16-36
16-36
16-37
16-37
16-37
16-38
16-38
16-39
16-39
16-40
16-42
16-42
16-42
16-42
16-42
16-43
16-43
16-44
16-45
Charging Voltage Inspection ........
Ignition System ..................................
Pickup Coil Removal ...................
Pickup Coil Installation.................
Pickup Coil Inspection..................
Ignition Coil Removal ..................
Ignition Coil Inspection.................
Spark Plug Removal ...................
Spark Plug Installation .................
Spark Plug Cleaning and
Inspection..................................
Spark Plug Gap Inspection ..........
IC Igniter Inspection .....................
IC Igniter Checker Inspection.......
Electric Starter System ......................
Starter Motor Removal.................
Starter Motor Installation..............
Starter Motor Disassembly...........
Starter Motor Assembly ...............
Brush Inspection ..........................
Commutator Cleaning and
Inspection..................................
Armature Inspection ....................
Brush Plate Inspection .................
Terminal Inspection ......................
Starter Relay Inspection...............
Lighting System ................................
Headlight Beam Horizontal
Adjustment ...............................
Headlight Beam Vertical
Adjustment ................................
Headlight Bulb Replacement .......
Headlight Unit, Housing Removal
..................................................
Tail/Brake Light Bulb
Replacement ............................
License Plate Light Bulb
Replacement .............................
Turn Signal Light Bulb
Replacement .............................
Turn Signal Relay Inspection .......
Radiator Fan System.........................
Fan System Circuit Inspection .....
Fan Motor Inspection ...................
Meter Unit ..........................................
Meter Unit Removal ....................
16-47
16-49
16-50
16-50
16-50
16-51
16-52
16-53
16-54
16-54
16-54
16-54
16-55
16-58
16-58
16-58
16-58
16-59
16-59
16-60
16-60
16-60
16-61
16-61
16-63
16-63
16-63
16-64
16-64
16-67
16-67
16-68
16-68
16-70
16-70
16-70
16-71
16-71
16
16-2 ELECTRICAL SYSTEM
Meter Unit Installation ..................
Meter Units Disassembly .............
Bulb Replacement........................
Switch and Sensor.............................
Brake Light Timing Inspection .....
Brake Light Timing Adjustment ...
Switch Inspection .........................
Radiator Fan Switch Inspection ...
Water Temperature Sensor
Inspection..................................
Junction Box ......................................
16-71
16-71
16-71
16-72
16-72
16-72
16-72
16-73
16-74
16-75
Junction Box Fuse Circuit
Inspection..................................
Starter Circuit/Headlight Relay
Inspection..................................
Diode Circuit Inspection ...............
Fuses.................................................
30 A Main Fuse Removal.............
Junction Box Fuse ......................
Fuse Installation...........................
Fuse Inspection............................
16-75
16-75
16-76
16-78
16-78
16-78
16-78
16-78
ELECTRICAL SYSTEM 16-3
Exploded View
Dummy Page
16-4 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 16-5
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
Fastener
Alternator Cover Bolts
Timing Inspection Cover Screw
Alternator Rotor Bolt
Stator Coil Bolts
Pickup Coil Bolts
Alternator Lead Clamp Bolts
Starter Motor Mounting Bolts
Starter Motor Through Bolts
Starter Motor Terminal Nut
Starter Motor Cable Nuts
AD: Apply
G: Apply
L: Apply
O: Apply
adhesive agent.
grease.
a non-permanent locking agent.
oil.
N·m
12
4.9
157
13
7.8
7.8
11
4.9
11
4.9
Torque
kgf·m
1.2
0.5
16
1.3
0.8
0.8
1.1
0.5
1.1
0.5
ft·lb
104 in·lb
43 in·lb
116
115 in·lb
69 in·lb
69 in·lb
97 in·lb
43 in·lb
97 in·lb
43 in·lb
Remarks
L
O
L
16-6 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 16-7
Exploded View
No.
1
2
Fastener
Spark Plugs
Side Stand Switch Mounting Bolts
L: Apply a non-permanent locking agent.
N·m
18
3.9
Torque
kgf·m
ft·lb
18
13
0.4
35 in·lb
Remarks
L
16-8 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 16-9
Exploded View
1. Tail Light (United States and Canada Models)
2. License Plate Holder (United States Model)
3. License Plate Holder (Canada Model)
4. Tail Light (On and after VN800-B5, Other than United States and Canada Models)
5. License Plate Holder (On and after VN800-B5, Australia Model)
6. Tail Light and License Lamp Assembly (VN800-B1 ∼ B4, Other than United States and Canada
Models)
7. License Light Damper (VN800-B3 ∼ B4)
8. License Light Damper (VN800-B1∼ B2)
9. License Plate Bracket (VN800-B1 ∼ B3, Italy Model)
16-10 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 16-11
Parts Location
1. Starter Lockout Switch
2. Ignition Coils
3. Battery
4. Starter Relay and Main
Fuse
5. IC Igniter
6. Junction Box
7. Oil Pressure Switch
8. Side Stand Switch
9. Pickup Coil
10. Alternator
11. Neutral Switch
12. Regulator/Rectifier
13. Turn Signal Relay
14. Front Brake Light Switch
15. Water Temperature Sensor
16. Radiator Fan Switch
17. Rear Brake Light Switch
18. Starter Motor
16-12 ELECTRICAL SYSTEM
Wiring Diagram (VN800-B1 ∼ B4, United States, and Canada)
ELECTRICAL SYSTEM 16-13
Wiring Diagram (VN800-B1 ∼ B4, United States, and Canada)
16-14 ELECTRICAL SYSTEM
Wiring Diagram (VN800-B1 ∼ B4, Australia)
ELECTRICAL SYSTEM 16-15
Wiring Diagram (VN800-B1 ∼ B4, Australia)
16-16 ELECTRICAL SYSTEM
Wiring Diagram (VN800-B1 ∼ B4, Europe and Others)
ELECTRICAL SYSTEM 16-17
Wiring Diagram (VN800-B1 ∼ B4, Europe and Others)
16-18 ELECTRICAL SYSTEM
Wiring Diagram (VN800-B5 ∼ B8, United States, and Canada)
ELECTRICAL SYSTEM 16-19
Wiring Diagram (VN800-B5 ∼ B8, United States, and Canada)
16-20 ELECTRICAL SYSTEM
Wiring Diagram (VN800-B5 ∼ B8, Australia)
ELECTRICAL SYSTEM 16-21
Wiring Diagram (VN800-B5 ∼ B8, Australia)
16-22 ELECTRICAL SYSTEM
Wiring Diagram (VN800-B5 ∼ B7, Europe and Others)
ELECTRICAL SYSTEM 16-23
Wiring Diagram (VN800-B5 ∼ B7, Europe and Others)
16-24 ELECTRICAL SYSTEM
Wiring Diagram (VN800-B8, other than United States, Canada, and Australia)
ELECTRICAL SYSTEM 16-25
Wiring Diagram (VN800-B8, other than United States, Canada, and Australia)
16-26 ELECTRICAL SYSTEM
Wiring Diagram (VN800-B9 ∼, B6F United States, and Canada)
ELECTRICAL SYSTEM 16-27
Wiring Diagram (VN800-B9 ∼, B6F United States, and Canada)
16-28 ELECTRICAL SYSTEM
Wiring Diagram (VN800-B9 ∼, B6F Australia)
ELECTRICAL SYSTEM 16-29
Wiring Diagram (VN800-B9 ∼, B6F Australia)
16-30 ELECTRICAL SYSTEM
Wiring Diagram (VN800-B9 ∼, B6F other than United States, Canada, and Australia)
ELECTRICAL SYSTEM 16-31
Wiring Diagram (VN800-B9 ∼, B6F other than United States, Canada, and Australia)
16-32 ELECTRICAL SYSTEM
Specifications
Item
Battery
Type
Capacity
Voltage
Charging System
Type
Charging Voltage
Alternator Output Voltage
Stator Coil Resistance
Ignition System
Pickup Coil Resistance
Ignition Coil:
3 Needle Arcing Distance
Winding Resistance:
Primary Windings
Secondary Windings
Spark Plug:
Type
Gap
IC Igniter Inspection
Electric Starter System
Starter Motor:
Carbon Brush Length
Commutator Diameter
Switch and Sensor
Rear Brake Lights Switch
Timing
Engine Oil Pressure Switch
Connections
Fan Switch Connections:
Rising Temperature
Falling Temperature
Water Temperature Sensor
Resistance:
Rising Temperature
Falling Temperature
Standard
Service Limit
Sealed Battery
12 V 12 Ah (VN800-B1 ∼ B8)
12 V 10 Ah (VN800-B9 ∼, B6F)
12.8 V or more
– – –
– – –
Three-phase AC
14 ∼ 15 V @4000 r/min (rpm), night
50 ∼ 80 V
0.3 ∼ 0.5 Ω
–
–
–
–
380 ∼ 570 Ω
– – –
6 mm (0.24 in.) or more
– – –
2.3 ∼ 3.5 Ω
12.0 ∼ 18.0 Ω
– – –
– – –
NGK CR7E or ND U22ESR-N
0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)
in the text
– – –
12.0 ∼ 12.5 mm (0.47 ∼ 0.49 in.)
28 mm (1.10 in.)
5.5 mm (0.22 in.)
27 mm (1.06 in.)
– – –
–
–
–
–
–
–
–
–
On after about 15 mm (0.59 in.) pedal travel
– – –
When engine is stopped: ON
When engine is running: OFF
– – –
– – –
From OFF to ON @96 ∼ 100°C (205 ∼ 212°F)
From On to OFF @91°C (196°F) or less
– – –
– – –
From OFF to ON @113 ∼ 117°C (235 ∼
243°F)
From ON to OFF @108°C (226°F) or less
– – –
– – –
ELECTRICAL SYSTEM 16-33
Special Tools
Rotor Puller, M16/M18/M20/M22 × 1.5:
57001-1216
Hand Tester:
57001-1394
Spark Plug Wrench, 16 mm (Owner’s Tool):
92110-1132
Harness Adapter #13:
57001-1399
Flywheel Holder:
57001-1313
Peak Voltage Adapter:
57001-1415
Igniter Checker Assembly:
57001-1378
16-34 ELECTRICAL SYSTEM
Precautions
There are a number of important precautions that are
musts when servicing electrical systems. Learn and observe all the rules below.
○Do not reverse the battery lead connections. This will
burn out the diodes on the electrical parts.
○Always check battery condition before condemning other
parts of an electrical system A fully charged battery is a
must for conducting accurate electrical system tests.
○The electrical parts should never be struck sharply, as
with a hammer, or allowed to fall on a hard surface. Such
a shock to the parts can damage them.
○To prevent damage to electrical parts, do not disconnect
the battery leads or any other electrical connections when
the ignition switch is on, or while the engine is running.
○Because of the large amount of current, never keep the
starter button pushed when the starter motor will not turn
over, or the current may burn out the starter motor windings.
○Do not use a meter illumination bulb rated for other than
voltage or wattage specified in the wiring diagram, as the
meter or gauge panel could be warped by excessive heat
radiated from the bulb.
○Take care not to short the leads that are directly connected to the battery positive (+) terminal to the chassis
ground.
○Troubles may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the failure. If the failure was caused by some
other item or items, they must be repaired or replaced, or
the new replacement will soon fail again.
○Make sure all connectors in the circuit are clean and tight,
and examine wires for signs of burning, fraying, etc. Poor
wires and bad connections will affect electrical system operation.
○Measure coil and winding resistance when the part is cold
(at room temperature).
○Color Codes:
BK
Black
G
Green
P
Pink
BL
Blue
GY
Gray
PU
Purple
BR
Brown
LB
Light blue
R
Red
CH Chocolate
LG
Light green
W
White
DG Dark green
O
Orange
Y
Yellow
○Electrical Connectors
Female Connectors [A]
ELECTRICAL SYSTEM 16-35
Precautions
Male Connectors [B]
16-36 ELECTRICAL SYSTEM
Electrical Wiring
Wiring Inspection
inspect the wiring for signs of burning, fraying,
• Visually
etc.
If any wiring is poor, replace the damaged wiring.
Pull each connector [A] apart and inspect it for corrosion,
dirt, and damage.
If the connector is corroded or dirty, clean it carefully. If it
is damaged, replace it.
Check the wiring for continuity.
○Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
○Connect the hand tester between the ends of the leads.
•
•
Special Tool - Hand Tester: 57001-1394
○Set the tester to the × 1 Ω range, and read the tester.
If the tester does not read 0 Ω, the lead is defective. Replace the lead or the wiring harness [B] if necessary.
ELECTRICAL SYSTEM 16-37
Battery
Battery Removal
• Remove:
Seats (see Frame Chapter)
•
Screws [A]
Battery Cover [B]
Disconnect the negative (–) lead [C] and then positive (+)
lead [D].
CAUTION
Be sure to disconnect the negative (–) lead first.
Electrolyte Filling
CAUTION
Do not remove the aluminum seal sheet [A] sealing
the filler ports [B] until just before use.
Be sure to use the dedicated electrolyte container
for correct electrolyte volume.
to see that there is no peeling, tears or holes in the
• Check
seal sheet on the top of the battery.
the battery on a level surface.
• Place
• Remove the seal sheet.
NOTE
○A battery whose seal sheet has any peeling, tears, or
holes, requires a refreshing charge (initial charge).
the electrolyte container out of the vinyl bag.
• Take
Detach
the seal caps [A] from the container.
•
NOTE
○Do not discard the seal caps because it is used as the
battery plugs later.
○Do not peel back or pierce the seals [B] on the container.
the electrolyte container upside down aligning six
• Place
seals with the six battery filler ports.
the container down strongly enough to break the
• Push
seals. Now the electrolyte should start to flow into the
battery.
NOTE
○Do not tilt the container as the electrolyte flow may be
interrupted.
16-38 ELECTRICAL SYSTEM
Battery
sure air bubbles [A] are coming up from all six filler
• Make
ports.
○Leave the container this way for 5 minutes or longer.
NOTE
○If no air bubbles are coming up from a filler port, tap [B]
the bottom of the container two or three times. Never
remove the container from the battery.
CAUTION
Fill the electrolyte into battery until the container is
completely emptied.
certain that all the electrolyte has flowed out.
• Be
Tap
the bottom the same way as above if there is any
• electrolyte
left in the container.
Now
pull
the
gently out of the battery.
• Let the batterycontainer
sit
for
20
During this time, the
• electrolyte permeates the minutes.
special separators and the gas
•
generated by chemical reaction is released.
Fit the seal caps [A] tightly into the filler ports until the seal
cap is at the same level as the top of the battery.
NOTE
○Do not hammer. Press down evenly with both hands.
CAUTION
Once you install the seal caps after filling the battery, never remove it, nor add any water or electrolyte.
Initial Charge
While a sealed battery can be used after only filling with electrolyte, a battery may not be able to
sufficiently move a starter motor to start an engine in the cases shown in the table below, where an
initial charge is required before use. However, if a battery shows a terminal voltage of higher than
12.8 V after 10 minutes of filling (Note 1), no initial charge is necessary.
Condition requiring initial charge
At low temperatures (lower than 0°C)
Battery has been stored in high temperature and humidity.
Seal has been removed, or broken-peeling, tear or hole.
Battery as old as 2 years or more after manufacture.
Battery manufacturing date is printed on battery top.
Example)
12
10
93
T1
Mfg.
Day
Month
Year
location
Charging method
1.4 A × 2 ∼ 3 hours (VN800-B1 ∼ B8)
1.2 A × 2 ∼ 3 hours
1.4 A × 15 ∼ 20 hours
(VN800-B1 ∼ B8)
1.2 A × 15 ∼ 20 hours
Note 1: Terminal voltage-To measure battery terminal voltage, use a digital voltmeter.
Precautions
1) No need of topping-up
No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the
seal cap to add water is very dangerous. Never do that.
2) Refreshing charge
ELECTRICAL SYSTEM 16-39
Battery
If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been
discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification
(see the this chapter).
When a fast charge is inevitably required, do it following precisely the maximum charge current
and time conditions indicated on the battery.
CAUTION
This battery is designed to sustain no unusual deterioration if refresh-charged according
to the method specified above. However, the battery’s performance may be reduced noticeably if charged under conditions other than given above.
Never remove the seal cap during refresh charge.
If by chance an excessive amount of gas is generated due to overcharging, the safety valve
operates to keep the battery safe.
3) When you do not use the motorcycle for months
Give a refresh charge before you store the motorcycle and store it with the negative lead removed. Give a refresh charge once a month during storage.
4) Battery life
If the battery will not start the engine even after several refresh charges, the battery has exceeded its useful life. Replace it. (Provided, however, the vehicle’s starting system has no problem.)
WARNING
Keep the battery away from sparks and open flames during charging, since the battery
gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger,
connect the battery to the charger before turning on the charger. This procedure prevents
sparks at the battery terminals which could ignite any battery gases.
No fire should be drawn near the battery, or no terminals should have the tightening loosened.
The electrolyte contains sulfuric acid. Be careful not to have it touch your skin or eyes. If
touched, wash it off with liberal amount of water. Get medical attention if severe.
Interchange
A sealed battery can fully display its performance only when combined with a proper vehicle electric
system. Therefore, replace a sealed battery only on a motorcycle which was originally equipped with
a sealed battery.
Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original
equipment, the sealed battery’s life will be shortened.
Charging Condition Inspection
Battery charging condition can be checked by measuring
battery terminal voltage.
Remove the seat (see Frame chapter).
Disconnect the battery terminal leads.
•
•
CAUTION
Be sure to disconnect the negative terminal (–) lead
first.
• Measure the battery terminal voltage.
16-40 ELECTRICAL SYSTEM
Battery
NOTE
○Measure with a digital voltmeter [A] which can be read
to one decimal place voltage.
If the reading is below the specified, refreshing charge is
required.
Battery Terminal Voltage
Standard:
12.8 V or more
Refreshing Charge
the battery terminal leads (see Charging Con• Disconnect
dition Inspection).
the battery [A] .
• Remove
by following method according to the bat• Refresh-charge
tery terminal voltage.
CAUTION
This battery is sealed type. Never remove seal caps
[B] even at charging. Never add water. Charge with
current and time as stated below.
Terminal Voltage: 11.5 ∼ less than 12.8 V
Standard Charge
1.4 A × 5 ∼ 10 h (VN800-B1 ∼ B8)
1.2 A × 5 ∼ 10 h
Quick Charge
6.0 A × 1.0 h (VN800-B1 ∼ B8)
5.0 A × 1.0 h
CAUTION
If possible, do not quick charge. If the quick charge
is done due to unavoidable circumstances, do standard charge later on.
Terminal Voltage: less than 11.5 V
Charging Method:
1.4 A × 20 h (VN800-B1 ∼ B8)
1.2 A × 20 h
NOTE
○Increase the charging voltage to a maximum voltage of
25 V if the battery will not accept current initially. Charge
for no more than five minutes at the increased voltage
then check if the battery is drawing current. If the battery will accept current decrease the voltage and charge
by the standard charging method described on the battery case. If the battery will not accept current after 5
minutes, replace the battery.
Battery [A]
Battery Charger [B]
Standard Charging Amperage [C]
Current start to flow [D]
ELECTRICAL SYSTEM 16-41
Battery
battery condition after refreshing charge.
•○Determine
Determine the condition of the battery 30 minutes after
completion of the charge by measuring the terminal voltage according to the table below.
Criteria
12.8 V or higher
12.0 ∼ 12.8 V or lower
12.0 V or lower
Judgement
Good
Charge insufficient → Recharge.
Unserviceable → Replace
16-42 ELECTRICAL SYSTEM
Charging System
Alternator Cover Removal
the engine oil (see Lubrication System chapter).
• Drain
Remove:
• Engine Sprocket Cover (see Final Drive chapter)
Left Side Cover (see Frame chapter)
Bolt [A] and Ignition Switch [B]
Clamp [C]
Alternator Lead Connector [D]
Pickup Coil Lead Connector [E]
Bolt [A]
Shift Lever [B]
Bolts [C]
Footpeg [D] and Shift Pedal as a set.
Bolts [E]
Alternator Cover [F]
Alternator Cover Installation
to see that the knock pins [A] are in place.
• Check
Apply
a
locking agent to the threads of
• the covernon-permanent
bolt [B].
Stator Coil Removal
• Remove:
Alternator Cover (see Alternator Cover Removal)
•
Bolts [A] and Clamps [B]
Pickup Coil and Alternator Lead Grommets [C]
Stator Coil Bolts [D]
Remove the stator coil [E] from the alternator cover.
Stator Coil Installation
• Tighten:
Torque - Stator Coil Bolts: 13 N·m (1.3 kgf·m, 113 in·lb)
adhesive agent to the circumference of the alterna• Apply
tor lead and pickup coil lead grommets, and fit the grommets into the notch of the cover securely.
○First install the alternator lead grommet and then pickup
•
coil lead grommet.
Secure the alternator lead and pickup coil lead with
clamps, and tighten the bolts.
Torque - Alternator Lead Clamp Bolts: 7.8 N·m (0.80 kgf·m,
69 in·lb)
the alternator cover (see Alternator Cover Installa• Install
tion).
ELECTRICAL SYSTEM 16-43
Charging System
Alternator Rotor Removal
• Remove:
Alternator Cover (see Alternator Cover Removal).
oil off the outer circumference of the rotor.
• Wipe
Hold
the
alternator rotor steady with the flywheel holder
• [A], and remove
the rotor bolt [B].
Special Tool - Flywheel Holder: 57001-1313
the rotor puller [A], remove the alternator rotor from
• Using
the crankshaft.
Special Tool - Rotor Puller, M16/M18/M20/M22 × 1.5: 57001
-1216
NOTE
○Screw in the puller while tapping the head [B] of the
puller with a hammer.
CAUTION
Do not attempt to strike the alternator rotor itself.
Striking the rotor can cause the magnets to lose
their magnetism.
Alternator Rotor Installation
a cleaning fluid, clean off any oil or dirt on the fol• Using
lowing portions and dry them with a clean cloth.
•
[A] Crankshaft Tapered Portion
[B] Alternator Rotor Tapered Portion
Fit the woodruff key securely in the slot [C] in the crankshaft before installing the alternator rotor.
installing the alternator rotor, align the rotor mark
• When
[A] with the left balancer mark [B].
oil to the threads and seating surface of the alter• Apply
nator rotor bolt.
the alternator rotor bolt while holding the alterna• Tighten
tor rotor steady with the flywheel holder.
Special Tool - Flywheel Holder: 57001-1313
Torque - Alternator Rotor Bolt: 157 N·m (16 kgf·m, 118 ft·lb)
the alternator cover (see Alternator Cover Installa• Install
tion).
16-44 ELECTRICAL SYSTEM
Charging System
Alternator Inspection
There are three types of alternator failures: short, open
(wire burned out), or loss in rotor magnetism. A short or
open in one of the coil wires will result in either a low output,
or no output at all. A loss in rotor magnetism, which may be
caused by dropping or hitting the alternator, by leaving it
near an electromagnetic field, or just by aging, will result in
low output.
To check the alternator output voltage, do the following
procedures.
○Turn off the ignition switch.
○Remove the left side cover (see Frame chapter).
○Disconnect the alternator lead connector [A].
○Connect the hand tester as shown in the table 1.
○start the engine.
○Run it at the rpm given in the table 1.
○Note the voltage readings (total 3 measurements).
•
Table 1 Alternator Output Voltage
Connections
Tester
Range
Tester (+) to
Tester (–) to
Reading
@4 000 rpm
250 V AC
One Black lead
Another Black lead
50 ∼ 80 V
If the output voltage shows the value in the table, the alternator operates properly and the regulator/rectifier is damaged. A much lower reading than that given in the table
indicates that the alternator is defective.
Check the stator coil resistance as follows:
○Stop the engine.
○Connect the hand tester as shown in the table 2.
○Note the readings (total 3 measurement).
•
Table 2 Stator Coil Resistance
•
Connections
Tester
Range
Tester (+) to
×1Ω
One Black lead
Tester (–) to
Reading
Another Black lead 0.3 ∼ 0.5 Ω
If there is more resistance than shown in the table, or no
hand tester reading (infinity) for any two leads, the stator
has an open lead and must be replaced. Much less than
this resistance means the stator is shorted, and must be
replaced.
Using the highest resistance range of the hand tester,
measure the resistance between each of the black leads
and chassis ground.
Any hand tester reading less than infinity (∞) indicates a
short, necessitating stator replacement.
If the stator coils have normal resistance, but the voltage
check showed the alternator to be defective; then the rotor
magnets have probably weakened, and the rotor must be
replaced.
Special Tool - Hand Tester: 57001-1394
ELECTRICAL SYSTEM 16-45
Charging System
Regulator/Rectifier Inspection
• Remove:
Left Side Cover (see Frame chapter)
Connector [A] (disconnect)
Tool Kit Container Bolts [B]
Bolts [A] and Regulator/Rectifier [B]
Rectifier Circuit Check
Check the rectifier resistance as follows.
Disconnect the regulator/rectifier connector.
Connect the hand tester (special tool) to the regulator/rectifier as shown in the table, and check the resistance in
both directions of each diode in the rectifier following the
table.
The resistance should be low in one direction and more
than ten times as much in the other direction. If any two
leads are low or high in both directions, the rectifier is
defective and the regulator/rectifier must be replaced.
•
•
•
NOTE
○The actual meter reading varies with the meter used
and the individual rectifier, but, generally speaking the
lower reading should be from zero to one half the scale.
No.
Connections
Tester (+)
1
BK1
2
BK2
3
BK3
4
BK1
5
BK2
6
BK3
7
8
BK/BL
Tester (–)
BK/BL
BK1
1/2 scale
or
BK2
or less
× 100Ω
10
BK1
12
∞
× 10Ω
BK3
BK/W
Tester Range
BK/W
9
11
Reading
BK2
BK3
∞
16-46 ELECTRICAL SYSTEM
Charging System
Regulator Circuit Check
To test the regulator out of circuit, use three 12 V batteries
and a test light (12 V 3 ∼ 6 W bulb in a socket with leads).
CAUTION
The test light works as an indicator and also a current limiter to protect the regulator/rectifier from excessive current. Do not use an ammeter instead of
a test light.
the 1st step regulator circuit test.
•○Do
Connect the test light and the 12 V battery to the regulator/rectifier as shown.
○Check BK1, BK2 and BK3 terminal respectively.
If the test light turns on, the regulator/rectifier is defective.
Replace it.
If the test light does not turn on, continue the test.
the 2nd step regulator circuit test.
•○Do
Connect the test light and the 12 V battery in the same
manner as specified in the "1st step regulator circuit test".
○Apply 12 V to the BK/R terminal.
○Check BK1, BK2 and BK3 terminal respectively.
If the test light turns on, the regulator/rectifier is defective.
Replace it.
If the test light does not turn on, continue the test.
the 3rd step regulator circuit test.
•○Do
Connect the test light and the 12 V battery in the same
manner as specified in the "1st step regulator circuit test".
○Momentarily apply 24 V to the BK/R terminal by adding a
12 V battery.
○Check BK1, BK2, and BK3 terminals respectively.
CAUTION
Do not apply more than 24 V to the regulator/rectifier and do not leave the 24 V applied for more than
a few seconds, or the unit will be damaged.
If the test light did not light when the 24 V was applied
momentarily to the BK/R terminal, the regulator/rectifier
is defective. Replace it. .
If the regulator/rectifier passes all of the tests described,
it may still be defective. If the charging system still does
not work properly after checking all of the components
and the battery, test the regulator/rectifier by replacing it
with a known good unit.
ELECTRICAL SYSTEM 16-47
Charging System
Charging Voltage Inspection
the battery condition (see Battery section).
• Check
Warm
up
• conditions.the engine to obtain actual alternator operating
the left side covers (see Frame chapter).
• Remove
Check
that
the ignition switch is turned off, and connect
• the hand tester
[A] as shown in the table.
Special Tool - Hand Tester: 57001-1394
the engine, and note the voltage readings at vari• start
ous engine speeds with the headlight turned on and then
turned off. (To turn off the headlight of United States,
Canada and Australia models, disconnect the headlight
connector.) The readings should show nearly battery voltage when the engine speed is low, and, as the engine
speed rises, the readings should also rise. But they must
be kept under the specified voltage.
Charging Voltage
Tester Range
25 V DC
Connections
Tester (+) to
Tester (–) to
White
Black/Yellow
Reading
14 ∼ 15 V
off the ignition switch to stop the engine, and discon• Turn
nect the hand tester.
If the charging voltage is kept between the values given in
the table, the charging system is considered to be working
normally.
If the charging voltage is much higher than the values
specified in the table, the regulator/rectifier is defective
or the regulator/rectifier leads are loose or open.
If the charging voltage does not rise as the engine speed
increases, then the regulator/rectifier is defective or the
alternator output is insufficient for the loads. Check the
alternator and regulator/rectifier to determine which part
is defective.
16-48 ELECTRICAL SYSTEM
Charging System
Charging System Circuit
1. Ignition Switch
2. Alternator
3. Regulator/Rectifier
4. Battery
5. Main Fuse 30 A
6. Load
ELECTRICAL SYSTEM 16-49
Ignition System
16-50 ELECTRICAL SYSTEM
Ignition System
WARNING
The ignition system produces extremely high voltage. Do not touch the spark plugs, ignition coils, or
spark plug leads while the engine is running, or you
could receive a severe electrical shock.
CAUTION
Do not disconnect the battery leads or any other
electrical connections when the ignition switch is
on, or while the engine is running. This is to prevent
IC igniter damage.
Do not install the battery backwards. The negative
side is grounded. This is to prevent damage to the
diodes and IC igniter.
Pickup Coil Removal
• Remove:
Alternator Cover (see Alternator Cover Removal)
•
Bolts [A] and Clamps [B]
Pickup Coil Grommet [C]
Pickup Coil Bolt [D]
Remove the pickup coil [E] from the alternator cover.
Pickup Coil Installation
• Tighten:
Torque - Pickup Coil Bolts: 7.8 N·m (0.80 kgf·m, 69 in·lb)
the pickup coil lead on the alternator cover (see
• Install
Stator Coil Installation).
Pickup Coil Inspection
• Remove:
Left Side Cover (see Frame chapter)
•
Pickup Coil Lead Connector [A]
Set the hand tester to the × 100 Ω range and connect it
between the terminals in the connector.
Special Tool - Hand Tester: 57001-1394
If there is more resistance than the specified value, the
coil has an open lead and must be replaced. Much less
than this resistance means the coil is shorted, and must
be replaced.
Pickup Coil Resistance
Standard:
380 ∼ 570 Ω
the highest resistance range of the tester, measure
• Using
the resistance between the pickup coil leads and chassis
ground.
Any tester reading less than infinity (∞) indicates a short,
necessitating replacement of the pickup coil assembly.
ELECTRICAL SYSTEM 16-51
Ignition System
Pickup Coil Peak Voltage Inspection
Remove the left Side Cover (see Frame chapter).
Remove all the spark plug caps but do not remove the
spark plugs.
Disconnect the pickup coil lead connector.
Connect a commercially available peak voltage adapter
[A] to the hand tester [B].
•
•
•
•
Special Tool - Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
the adapter probes into the connector [C] of the
• Insert
pickup coil as shown.
Special Tool - Hand Tester: 57001-1394
Connections: Adapter (R, +)
Pickup Coil:
Adapter (BK, –)
←→
Y
BK
NOTE
○Be sure the battery is fully charged.
Hand Tester Range:
× DC 10 V
the ignition switch and the engine stop switch ON.
• Turn
Pushing
the starter button, turn the engine 4 ∼ 5 seconds
• with the transmission
in neutral to measure the pickup coil
•
peak voltage.
Repeat the measurements 5 or more times.
Pickup Coil Peak Voltage
Standard:
2.5 V or more
If the reading is less than the specified value, replace the
pickup coil.
If the peak voltage adapter is not available, the coil can
be checked for the broken or badly shorted winding with
the hand tester (see Pickup Coil Inspection).
Ignition Coil Removal
Front
Remove:
Nuts [A]
Primary Lead Connectors [B]
Spark Plug Cap [C]
Ignition Coil
•
Rear
Left Side Cover and Seat (see Frame chapter)
Spark Plug Cap [A]
Primary Lead Connectors [B]
Bolts [C], Collars, and Ignition Coil
16-52 ELECTRICAL SYSTEM
Ignition System
Ignition Coil Inspection
the ignition coils (see Ignition Coil Removal).
• Remove
Measure
the arcing distance with the suitable commer• cially available
coil tester [A] to check the condition of the
•
ignition coil [B].
Connect the ignition coil (with the spark plug cap left attached at the end of the spark plug lead) to the tester in
the manner prescribed by the manufacturer and measure
the arcing distance.
Ignition Coil Arcing Distance:
Standard:
6 mm (0.24 in.) or more
WARNING
To avoid extremely high voltage shocks, do not
touch the coil body or leads.
•
If the distance reading is less than the specified value, the
ignition coil or spark plug caps are defective.
To determine which part is defective, measure the arcing
distance again with the spark plug caps removed from the
ignition coil. Remove the caps by turning them counterclockwise.
If the arcing distance is subnormal as before, the trouble
is with the ignition coil itself. If the arcing distance is now
normal, the trouble is with the spark plug caps.
If the coil tester is not available, the coil can be checked
for a broken or badly shorted winding with the hand tester.
NOTE
○The hand tester cannot detect layer shorts and shorts
resulting from insulation breakdown under high voltage.
the primary winding resistance [A] as follows.
•○Measure
Connect the hand tester between the coil terminals.
○Set the tester to the × 1 Ω range, and read the tester.
the secondary winding resistance [B] as follows.
•○Measure
Remove the plug caps by turning them counterclockwise.
○Connect the tester between the spark plug leads.
○Set the tester to the × 1 kΩ range and read the tester.
Ignition Coil Winding Resistance
Primary Windings:
2.3 ∼ 3.5 Ω
Secondary Windings:
12.0 ∼ 18.0 kΩ
If the tester does not read as specified, replace the coil.
○To install the plug cap, turn it clockwise.
Ignition Coil Primary Peak Voltage Inspection
NOTE
○Be sure the battery is fully charged.
ELECTRICAL SYSTEM 16-53
Ignition System
the fuel tank (see Fuel System chapter).
• Remove
Remove
all the spark plugs caps but do not remove the
• spark plugs.
new spark plugs [A] into all the spark plug caps,
• Install
and ground them onto the engine.
a commercially available peak voltage adapter [B]
• Install
into the hand tester [C].
Special Tool - Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
Special Tool - Hand Tester: 57001-1394
Hand Tester Range:
× DC 250 V
the adapter between the ignition coil primary
• Connect
lead terminals [D] and ground.
[E] Battery
[F] Ignition Coil
[G] IC igniter
Primary Lead Connection:
Adapter (BK,
–)
Adapter (R, +)
Front Ignition Coil
Green
←→
Ground
Rear Ignition Coil
Black/White
←→
Ground
WARNING
To avoid extremely high voltage shocks, do not
touch the spark plugs or tester connections.
the ignition switch and the engine stop switch ON.
• Turn
Pushing
starter button, turn the engine 4 ∼ 5 seconds
• with the the
transmission in neutral to measure the primary
•
peak voltage.
Repeat the measurements 5 or more times for one ignition
coil.
Ignition Coil Primary Peak Voltage
Standard:
120 V or more
the test for the other ignition coil.
• Repeat
If the reading is less than the specified value, check the
following.
Ignition Coil (see Ignition Coil Inspection)
Pickup Coil (see Pickup Coil Inspection)
IC Igniter ( see IC Inspection)
Spark Plug Removal
• Remove:
Seat (see Frame chapter)
•
Spark Plug Caps
Remove the spark plugs using the 16 mm plug wrench
[A].
Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-1132
16-54 ELECTRICAL SYSTEM
Ignition System
Spark Plug Installation
the spark plug vertically into the plug hole with the
• Insert
plug installed in the plug wrench.
Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-1132
• Tighten:
Torque - Spark Plugs: 18 N·m (1.8 kgf·m, 13 ft·lb)
the plug caps securely.
• Fit
Pull
up the spark plug caps lightly to make sure of the
• installation
of the spark plug caps.
Spark Plug Cleaning and Inspection
to the Spark Plug Cleaning and Inspection in the
• Refer
Periodic Maintenance chapter.
Spark Plug Gap Inspection
to the Spark Plug Gap Inspection in the Periodic
• Refer
Maintenance chapter.
IC Igniter Inspection
CAUTION
When inspecting the IC igniter observe the following to avoid damage to the IC Igniter.
Do not disconnect the IC igniter with the ignition
switch on. This may damage the IC igniter.
Do not disconnect the battery leads while the engine is running. This may damage the IC igniter.
Igniter Input Voltage Check
Remove:
Seat (see Frame chapter)
•
• Disconnect the igniter connectors [A] of the main harness.
the tester to the DC25 V range, and connect it be• Set
tween the BR/W wire terminal [A] and BK/Y wire terminal
[B].
Special Tool - Hand Tester: 57001-1394
Connection:
Tester Positive
Tester Negative
→
Brown/White Wire
→
Black/Yellow Wire
the ignition switch on.
• Turn
• Read the voltage of the tester.
Igniter Input Voltage
Standard:
Battery Voltage
If it is none or low voltage, check the battery voltage, ignition switch and ignition fuse of the junction box.
ELECTRICAL SYSTEM 16-55
Ignition System
Ignition Coil primary Peak Voltage Check
Refer:
Ignition Coil Primary Peak Voltage Inspection
Pickup Coil Peak Voltage Check
Refer:
Pickup Coil Peak Voltage Inspection
•
•
Emergency Engine Stop Function Check
Remove:
Seat (see Frame chapter)
•
NOTE
○Check the voltage of the emergency engine stop function with the motorcycle setting of its sidestand and its
transmission being first gear position.
the tester to the DC 25 V range, and connect it be• Set
tween the G/BK wire terminal [B] and frame ground [C].
Junction box [A].
Special Tool - Hand Tester: 57001-1394
Connection:
Tester Positive
Tester Negative
→
Green/Black Wire
→
Frame Ground
the ignition switch on.
• Turn
• Push the starter button, and read the voltage of the tester.
Emergency Engine Stop Voltage
About 6 ∼ 13.4 V
Standard:
If it is within the specified voltage, the emergency engine
stop voltage is normal.
Next to grip the clutch lever and start the engine.
○The motorcycle setting on its sidestand and its transmission being first gear position.
Slowly free the clutch lever then check the engine idling.
If the engine does not stop, igniter is defective.
•
•
IC Igniter Checker Inspection
• Remove:
Seat (see Frame chapter).
•
Battery Cover [A]
Battery [B]
Pull the connectors out of the IC igniter [C].
16-56 ELECTRICAL SYSTEM
Ignition System
check the condition of the IC igniter, connect the igniter
• To
checker [A] to the IC igniter.
Special Tools - Igniter Checker Assembly: 57001-1378
Harness Adapter #12: 57001-1399
○Turn the select knob to “C” position.
NOTE
○When using the igniter checker, refer to the manufacturer’s instructions.
○The igniter checker can detect the simulated dynamic
characteristics; igniter response to r.p.m., interlock circuit signal, and engine overspeed limiter signal.
○The igniter checker cannot inspect the condition of the
CDI unit.
If the condition of the IC igniter is abnormal, replace the
IC igniter.
If the igniter checker is not available, refer to IC igniter
inspection.
ELECTRICAL SYSTEM 16-57
Ignition System
Ignition System Circuit
1. Junction Box
2. Ignition Switch
3. Engine Stop Switch
4. Starter Button
5. Spark Plugs
6. Diodes
7. Ignition Fuse 10 A
8. Ignition Coils
9. Neutral Switch
10. Rectifier
11. Starter Lockout Switch
12. Side Stand Switch
13. Main Fuse 30 A
14. Battery
15. IC Igniter
16. Pickup Coil
16-58 ELECTRICAL SYSTEM
Electric Starter System
Starter Motor Removal
the engine oil (see Lubrication System chapter).
• Drain
Remove
• bolts [B].the starter motor cable nut [A] and the mounting
• Pull out the starter motor [C].
Starter Motor Installation
CAUTION
Do not tap the starter motor shaft or body. Tapping
the shaft or body could damage the motor.
installing the starter motor, clean the starter mo• When
tor legs [A] and crankcase [B] where the starter motor is
•
•
•
grounded.
Replace the O-ring [C] with the new one.
Apply a small amount of grease to the O-ring.
Tighten:
Torque - Starter Motor Mounting Bolts: 11 N·m (1.1 kgf·m,
95 in·lb)
Starter Motor Cable Nut: 4.9 N·m (0.50 kgf·m, 43
in·lb)
in the specified type and amount of oil (see Engine
• Pour
Lubrication System chapter).
Starter Motor Disassembly
off the starter motor through bolts [A] and remove
• Take
both end covers [B] and pull the armature out of the yoke
[C].
the terminal nut [A], and remove the terminal as• Remove
sembly [B] from the yoke.
ELECTRICAL SYSTEM 16-59
Electric Starter System
Starter Motor Assembly
the terminal assembly in the yoke.
• Install
Tighten:
•
Torque - Starter Motor Terminal Nut: 11 N·m (1.1 kgf·m, 95
in·lb)
the projection [A] of the brush plate into the yoke notch
• Fit
[B].
holding the springs [A] with suitable washers [B],
• After
insert the brushes as shown.
the armature, and then pull out the washers to re• Insert
lease the springs.
the long tongue [A] of the bush plate into the end cover
• Fit
groove [B].
the yoke, brush plate, and end covers are properly
• When
assembled, the lines [A] on the yoke and cover should be
•
aligned.
Tighten:
Torque - Starter Motor Through Bolts: 4.9 N·m (0.50 kgf·m,
43 in·lb)
Brush Inspection
the length [A] of each brush.
• Measure
If any is worn down to the service limit, replace the brush
plate [B] and the terminal assembly [C].
Starter Motor Brush Length
Standard:
12.0 ∼ 12.5 mm (0.47 ∼ 0.49 in.)
Service Limit:
5.5 mm (0.22 in.)
16-60 ELECTRICAL SYSTEM
Electric Starter System
Commutator Cleaning and Inspection
the commutator surface [A] if necessary with fine
• Smooth
emery cloth [B], and clean out the grooves.
the diameter [A] of the commutator [B].
• Measure
Replace the starter motor with a new one if the commutator diameter is less than the service limit.
Commutator Diameter
Standard:
28 mm (1.10 in.)
Service Limit:
27 mm (1.06 in.)
Armature Inspection
the × 1 Ω hand tester range, measure the resis• Using
tance between any two commutator segments [A].
Special Tool - Hand Tester: 57001-1394
•
If there is a high resistance or no reading (∞) between any
two segments, a winding is open and the starter motor
must be replaced.
Using the highest hand tester range, measure the resistance between the segments and the shaft [B].
If there is any reading at all, the armature has a short and
the starter motor must be replaced.
NOTE
○Even if the foregoing checks show the armature to be
good, it may be defective in some manner not readily
detectable with the hand tester. If all other starter motor
and starter motor circuit components check good, but
the starter motor still does not turn over or only turns
over weakly, replace the starter motor with a new one.
Brush Plate Inspection
Using the × 1 Ω hand tester range, measure the re• sistance
between the brush plate [A] and the negative
brushes [B].
Special Tool - Hand Tester: 57001-1394
•
•
If there is not close to zero ohms, the brush plate has an
open. Replace the brush plate assembly.
Using the highest hand tester range, measure the resistance between the brush plate and the positive brush
holders [C].
If there is any reading, the brush holder has a short. Replace the brush plate assembly.
ELECTRICAL SYSTEM 16-61
Electric Starter System
Terminal Inspection
the × 1 Ω hand tester range, measure the resis• Using
tance between the terminal [A] and the positive brushes
[B].
Special Tool - Hand Tester: 57001-1394
•
If there is not close to zero ohms, the terminal assembly
has an open. Replace the terminal assembly.
Using the highest hand tester range, measure the resistance between the terminal and the yoke [C].
If there is any reading, the terminal assembly has a short.
Replace the terminal assembly.
Starter Relay Inspection
• Remove:
Seat (see Frame chapter)
•
Stater Relay
Connect the hand tester [A] and 12 V battery [B] to the
starter relay [C] as shown.
Special Tool - Hand Tester: 57001-1394
If the relay does not work as specified, the relay is defective. Replace the relay.
Testing Relay
Tester Range:
Criteria:
× 1 Ω range
When battery is connected → 0 Ω
When battery is disconnected → ∞ Ω
16-62 ELECTRICAL SYSTEM
Electric Starter System
Electric Starter Circuit
1. Ignition Switch
2. Engine Stop Switch
3. Starter Button
4. Junction Box
5. Diode
6. Starter Circuit Relay
7. Ignition Fuse 10 A
8. Starter Lockout Switch
9. Rectifier
10. Neutral Switch
11. Starter Motor
12. Starter Relay
13. Main Fuse 30 A
14. Battery
ELECTRICAL SYSTEM 16-63
Lighting System
The United States, Canada, and Australia models adopt
the daylight system and have a headlight relay in the junction box. In these models, the headlight does not go on
when the ignition switch and the engine stop switch are first
turned on. The headlight comes on after the starter button is
released and stays on until the ignition switch is turned off.
The headlight will go out momentarily whenever the starter
button is pressed and come back on when the button is released.
Headlight Beam Horizontal Adjustment
the horizontal adjuster [A] on the headlight in or out
• Turn
until the beam points straight ahead.
Headlight Beam Vertical Adjustment
the vertical adjuster [B] on the headlight in or out to
• Turn
adjust the headlight vertically.
NOTE
○On high beam, the brightest points should be slightly
below horizontal with the motorcycle on its wheels and
the rider seated. Adjust the headlight(s) to the proper
angle according to local regulations.
○For United States model, the proper angle is 0.4 degrees below horizontal. This is 50 mm (2 in.) drop at
7.6 m (25 ft) measured from the center of the headlights
with the motorcycle on its wheels and the rider seated.
50 mm (2 in.) [A]
Center of Brightest Spot [B]
7.6 m (25 ft) [C]
Height of Headlight Center [D]
16-64 ELECTRICAL SYSTEM
Lighting System
Headlight Bulb Replacement
• Remove:
Headlight Unit and Dust Cover [A]
•
Hook [B]
Replace the headlight bulb [C].
CAUTION
When handling the quartz-halogen bulb, never
touch the glass portion with bare hands. Always
use a clean cloth. Oil contamination from hands or
dirty rags can reduce bulb life or cause the bulb to
explode.
NOTE
○Clean off any contamination that inadvertently gets on
the bulb with alcohol or soap and water solution.
the dust cover [A] with the Top mark [B] upward onto
• Fit
the bulb [C] firmly as shown.
•
Good [D]
Bad [E]
After installation, adjust the headlight aim (see this chapter).
Headlight Unit, Housing Removal
• Remove:
Screws [A] (both sides)
Headlight Unit [A]
Headlight Connector [B]
Turn Signal Light Lead Connectors [C]
ELECTRICAL SYSTEM 16-65
Lighting System
Bolts [A]
Headlight Housing [B]
Headlight Circuit (VN800-B1 ∼, United States, Canada and Australia)
1. Ignition Switch
2. High Beam Indicator Light
3. Headlight
4. Junction Box
5. Diodes
6. Headlight Circuit Relay
7. Headlight Fuse 10 A
8. Dimmer Switch
9. Alternator
10. Main Fuse 30 A
11. Battery
16-66 ELECTRICAL SYSTEM
Lighting System
Headlight Circuit (VN800-B1 ∼ B7, Other than United States, Canada and Australia)
Headlight Circuit (VN800-B8 ∼, B6F Other than United States, Canada and Australia)
1. Ignition Switch
2. High Beam Indicator Light
3. Headlight
4. Junction Box
5. Diodes
6. Headlight Circuit Relay
7. Headlight Fuse 10 A
8. Dimmer Switch
9. Alternator
10. Main Fuse 30 A
11. Battery
12. City Light
13. Headlight Switch
14. Taillight Fuse 10 A
ELECTRICAL SYSTEM 16-67
Lighting System
Tail/Brake Light Bulb Replacement
the tail/brake light lens screws [A] and take off
• Remove
the lens [B]
the bulb [A] in the socket, turn it counter clockwise
• Push
[B] and pull it out.
the front pin [A] up and the rear pin [B] down insert
• With
the new bulb by aligning the front pin with the groove in
•
•
the walls of the socket [C].
Push the bulb in, turn it clockwise and release it, it should
lock in position.
Tighten the lens screws be careful not to overtighten
them.
License Plate Light Bulb Replacement
the license plate light lens screws [A] and take
• Remove
off the lens [B]
remove the wedge type bulb [A] pull the bulb out of the
• To
socket [B].
CAUTION
Do not turn the bulb. Pull the bulb out to prevent
damage to the bulb. Do not use bulb rated greater
wattage than the specified value.
16-68 ELECTRICAL SYSTEM
Lighting System
Turn Signal Light Bulb Replacement
the turn signal light lens screws [A] and remove
• Remove
the lens [B].
the bulb [A] in the socket and turn the bulb counter• Push
clockwise.
• Replace the bulb.
Turn Signal Relay Inspection
• Remove:
Seats (see Frame chapter)
Turn Signal Relay [A]
one 12 V battery and turn signal lights as indi• Connect
cated in the figure, and count how may times the lights
flash for one minute.
Turn Signal Relay [A]
Turn Signal Lights [B]
12 V Battery [C]
If the lights do not flash as specified, replace the turn signal relay.
Testing Turn Signal Relay
Load
Flashing times (c/m*)
The Number of
Turn Signal Lights
Wattage (W)
1**
21 or 23
140-250
2
42 or 46
75-95
(*): Cycle(s) per minute
(**): Correspond to “one light burned out”
ELECTRICAL SYSTEM 16-69
Lighting System
Turn Signal Light Circuit
A: United States and Canada Model
B: VN800-B8 ∼, other than United States, Canada and Australia Model
1. Ignition Switch
2. Turn Signal Indicator
3. Front Right Turn Signal Light
4. Front Left Turn Signal Light
5. Turn Signal Switch
6. Main Fuse 30 A
7. Battery
8. Junction Box
9. Turn Signal Lights Fuse 10 A
10. Turn Signal Relay
11. Rear Right Turn Signal Light
12. Rear Left Turn Signal Light
16-70 ELECTRICAL SYSTEM
Radiator Fan System
Fan System Circuit Inspection
the Fuel Tank (see Fuel System chapter).
• Remove
Turn
on
the
ignition switch.
• Disconnect the
from the radiator fan switch [A].
• Using an auxiliaryleads
wire
[B], connect the radiator fan switch
• leads.
If the fan rotates, inspect the fan switch.
If the fan does not rotate, inspect the following.
Leads and Connectors
Main Fuse and Fan Fuse
Fan Motor
Fan Motor Inspection
the Fuel Tank (see Fuel System chapter).
• Remove
Disconnect
the 2-pin connector [A] in the fan motor leads.
• Using two auxiliary
wires, supply battery [B] power to the
• fan motor.
If the fan does not rotate, the fan motor is defective and
must be replaced.
Radiator Fan Circuit
1. Radiator Fan
2. Radiator Fan Switch
3. Junction Box
4. Fan Fuse 10 A
5. Main Fuse 30 A
6. Battery
ELECTRICAL SYSTEM 16-71
Meter Unit
Meter Unit Removal
the bolt [A], and separate the meter unit [B] from
• Remove
the fuel tank.
• Remove:
Connectors [A]
Speedometer Cable [B]
CAUTION
Place the meter so that the face is up. If a meter is
left upside down or sideways for any length of time,
it will malfunction.
Meter Unit Installation
the tongue [A] of the meter bracket into the damper
• Insert
slit [B] on the fuel tank.
Meter Units Disassembly
• Remove:
Meter Unit
Screw and Knob [A]
Screws [B]
Speedometer [C]
Bulb Replacement
remove the wedge-base type bulb [A], pull the bulb out
• To
of the socket [B].
CAUTION
Do not turn the bulb. Pull the bulb out to prevent
damage to the bulb. Do not use bulb rated for
greater wattage than the specified value.
16-72 ELECTRICAL SYSTEM
Switch and Sensor
Brake Light Timing Inspection
to the Brake Light Switch Inspection in the Periodic
• Refer
Maintenance chapter
Brake Light Timing Adjustment
to the Brake Light Timing Adjustment in the Periodic
• Refer
Maintenance chapter
Switch Inspection
the hand tester, check to see that only the con• Using
nections shown in the table have continuity (about zero
ohms).
○For the handlebar switches and the ignition switch, refer
to the tables in the Wiring Diagram.
If the switch has an open or short, repair it or replace it
with a new one.
Special Tool - Hand Tester: 57001-1394
Rear Brake Light Switch Connections
Side Stand Switch Connections
Neutral Switch Connections
Oil Pressure Switch Connections*
*: Engine lubrication system is in good condition
ELECTRICAL SYSTEM 16-73
Switch and Sensor
Radiator Fan Switch Inspection
the fan switch (see Cooling System chapter).
• Remove
Suspend
the switch [A] in a container of coolant so that
• the temperature-sensing
projection and threaded portion
•
are submerged.
Suspend an accurate thermometer [B] in the coolant so
that the sensitive portions [C] are located in almost the
same depth.
NOTE
○The switch and thermometer must not touch the container sides or bottom.
the container over a source of heat and gradu• Place
ally raise the temperature of the coolant while stirring the
•
coolant gently.
Using the hand tester, measure the internal resistance
of the switch across the terminals at the temperatures
shown in the table.
Special Tool - Hand Tester: 57001-1394
If the hand tester does not show the specified values, replace the switch.
Radiator Fan Switch Resistance
Rising temperature:
○
From OFF to ON at 96 ∼ 100°C (205 ∼ 212°F)
○Falling temperature:
From ON to OFF at 91°C (196°F) or less
ON: Less than 0.5 Ω
OFF: More than 1 MΩ
16-74 ELECTRICAL SYSTEM
Switch and Sensor
Water Temperature Sensor Inspection
the water temperature sensor (see Cooling Sys• Remove
tem chapter).
the sensor [A] in a container of coolant so that
• Suspend
the temperature-sensing projection and threaded portion
•
are submerged.
Suspend an accurate thermometer [B] in the coolant so
that the sensitive portions [C] are located in almost the
same depth.
NOTE
○The sensor and thermometer must not touch the container side or bottom.
the container over a source of heat and gradu• Place
ally raise the temperature of the coolant while stirring the
•
coolant gently.
Using the hand tester, measure the internal resistance of
the sensor across the terminal and the body at the temperatures shown in the table.
Special Tool - Hand Tester: 57001-1394
If the hand tester does not show the specified values, replace the sensor.
Water Temperature Sensor Resistance
Rising temperature:
○
From OFF to ON at 113 ∼ 117°C (235 ∼ 243°F)
Falling temperature:
From ON to OFF at 108°C (226°F) or less
ON: Less than 0.5 Ω
OFF: More than 1 MΩ
ELECTRICAL SYSTEM 16-75
Junction Box
The junction box [A] has fuses [B], relays, and diodes.
The relays and diodes can not be removed.
Junction Box Fuse Circuit Inspection
the seats (see Frame chapter).
• Remove
Remove
junction box.
• Pull off thetheconnectors
the junction box.
• Make sure all connectorfrom
terminals
• none of them have been bent. are clean and tight, and
•
Clean the dirty terminals, and straighten slightly-bent terminals.
Check conductivity of the numbered terminals with the
hand tester.
If the tester does not read as specified, replace the junction box.
Special Tool - Hand Tester: 57001-1394
Fuse Circuit Inspection
Tester Connection
1-1A
1-2
3A-4
6-5
6-10
6-7
6-17
Tester Reading (Ω)
0
0
0
0
0
0
0
Tester Connection
1A-8
2-8
3A-8
6-2
6-3A
17-3A
Starter Circuit/Headlight Relay Inspection
the junction box.
• Remove
conductivity of the following numbered terminals
• Check
by connecting the hand tester and one 12 V battery to the
junction box as shown.
If the tester does not read as specified, replace the junction box.
Special Tool - Hand Tester: 57001-1394
Tester Reading (Ω)
∞
∞
∞
∞
∞
∞
16-76 ELECTRICAL SYSTEM
Junction Box
Relay Circuit Inspection (with the battery disconnected)
Headlight
Relay
Tester
Connection
*7-8
*7-13
Tester Reading
(Ω)
∞
∞
(+) (-)
*13-9
Not ∞ **
Starter Circuit
Relay
Tester
Connection
9-11
12-13
(+) (-)
13-11
(+) (-)
12-11
(*): VN800-B1 ∼ B7, United States, Canada and Australia Models
VN800-B8 ∼, B6F All Model
(**): The actual reading varies with the hand tester used.
(+): Apply tester positive lead.
(–): Apply tester negative lead.
Relay Circuit Inspection (with the battery connected)
Battery
Connection
Tester
Tester Reading
Connection
(+) (–)
Headlight Relay
(Ω)
*9-13
*7-8
0
(+) (–)
Starter Circuit
Relay
11-12
13-11
Not ∞ **
(*): VN800-B1 ∼ B7, United States, Canada and Australia
Models
VN800-B8 ∼, B6F All Model
(**): The actual reading varies with the hand tester used.
(+): Apply tester positive lead.
(–): Apply tester negative lead.
Diode Circuit Inspection
the junction box.
• Remove
• Check conductivity of the following pairs of terminals.
Diode Circuit Inspection
Tester Connection
*13-8, *13-9, 12-11, 12-14, 15-14, 16-14
(*): VN800-B1 ∼ B7, United States, Canada and Australia
Models
VN800-B8 ∼, B6F All Model
The resistance should be low in one direction and more
than ten times as much in the other direction. If any diode
shows low or high in both directions, the diode is defective
and the junction box must be replaced.
NOTE
○The actual meter reading varies with the meter used
and the individual diodes, but, generally speaking, the
lower reading should be from zero to one half the scale.
Tester Reading
(Ω)
∞
∞
∞
Not ∞ **
ELECTRICAL SYSTEM 16-77
Junction Box
Junction Box Internal Circuit (VN800-B1∼B7, United States, Canada and Australia)
(VN800-B8, All Model)
Junction Box Internal Circuit (VN800-B1 ∼ B7, Other than United States, Canada
and Australia)
A. Accessory Fuse 10 A
B. Fan Fuse 10 A
C. Turn Signal Relay Fuse 10 A
D. Horn Fuse 10 A
E. Ignition Fuse 10 A
F. Headlight Fuse 10 A
G. Headlight Relay
H. Headlight Diodes
I. Starter Diode
J. Starter Circuit Relay
K. Interlock Diodes
L. Taillight Fuse 10 A
16-78 ELECTRICAL SYSTEM
Fuses
30 A Main Fuse Removal
• Remove:
Seat (see Frame chapter)
•
30 A Main Fuse Connector [A]
Pull out the main fuse [B] from the starter relay with needle
nose pliers.
Junction Box Fuse
• Remove:
Seat (see Frame chapter)
•
•
Battery Leads
Junction Box
Unlock the hook to lift up the lid [A].
Pull the fuses [B] straight out of the junction box with needle nose pliers.
Fuse Installation
fails during operation, inspect the electrical sys• Iftema fuse
to determine the cause, and then replace it with a
•
new fuse of proper amperage.
Install the junction box fuses on the original position as
specified on the lid.
Fuse Inspection
the fuse (see Fuse Removal).
• Remove
Inspect
the
element.
• If it is blownfuse
out, replace the fuse. Before replacing a
blown fuse, always check the amperage in the affected
circuit. If the amperage is equal to or greater than the
fuse rating, check the wiring and related components for
a short circuit.
Housing [A]
Fuse Element [B]
Terminals [C]
Blown Element [D]
CAUTION
When replacing a fuse, be sure the new fuse
matches the specified fuse rating for that circuit.
Installation of a fuse with a higher rating may cause
damage to wiring and components.
APPENDIX 17-1
Appendix
Table of Contents
Troubleshooting Guide ...........................................................................................................
Cable, Wire, and Hose Routing ..............................................................................................
17-2
17-7
17
17-2 APPENDIX
Troubleshooting Guide
NOTE
○This is not an exhaustive list, giving every
possible cause for each problem listed. It
is meant simply as a rough guide to assist
the troubleshooting for some of the more
common difficulties.
Engine Doesn’t start, starting
Difficulty:
Starter motor not rotating:
starter lockout or neutral switch trouble
starter motor trouble
Battery voltage low
starter relays not contacting or operating
starter button not contacting
Wiring open or shorted
Ignition switch trouble
Engine stop switch trouble
Fuse blown
Starter motor rotating but engine doesn’t
turn over:
starter clutch trouble
Torque limiter trouble
Engine won’t turn over:
Valve seizure
Rocker arm seizure
Cylinder, piston seizure
Crankshaft seizure
Connecting rod small end seizure
Connecting rod big end seizure
Transmission gear or bearing seizure
Camshaft seizure
Balancer bearing seizure
No fuel flow:
No fuel in tank
Fuel tap vacuum hose clogged
Fuel tank air vent obstructed
Fuel tap clogged
Fuel line clogged
Float valve clogged
Engine flooded:
Fuel level in carburetor float bowl too high
Float valve worn or stuck open
starting technique faulty
(When flooded, crank the engine with the
throttle fully opened to allow more air to
reach the engine.)
No spark; spark weak:
Battery voltage low
Spark plug dirty, broken, or maladjusted
Spark plug cap or high tension wiring trouble
Spark plug cap shorted or not in good contact
Spark plug incorrect
IC igniter trouble
Neutral, starter lockout, or side stand switch
trouble
Pickup coil trouble
Ignition coil trouble
Ignition or engine stop switch shorted
Wiring shorted or open
Fuse blown
Fuel/air mixture incorrect:
Pilot screw and/or idle adjusting screw maladjusted
Pilot jet, or air passage clogged
Air cleaner clogged, poorly sealed, or missing
starter jet clogged
Compression Low:
Spark plug loose
Cylinder head not sufficiently tightened
down
No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent,
worn, or carbon accumulation on the
seating surface)
Poor Running at Low Speed:
Spark weak:
Battery voltage low
Spark plug dirty, broken, or maladjusted
Spark plug cap or high tension wiring trouble
Spark plug cap shorted or not in good contact
Spark plug incorrect
IC igniter trouble
Pickup coil trouble
Ignition coil trouble
Fuel/air mixture incorrect:
Pilot screw maladjusted
Pilot jet, or air passage clogged
Air bleed pipe bleed holes clogged
Air cleaner clogged, poorly sealed, or missing
Choke plunger stuck open
Fuel level in carburetor float bowl too high
or too low
Fuel tank air vent obstructed
Carburetor holder loose
Air cleaner duct loose
Air cleaner O-ring damaged
APPENDIX 17-3
Troubleshooting Guide
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened
down
No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring/groove clearance excessive
Cylinder head warped
Cylinder head gasket damaged
Valve spring broken or weak
Valve not seating properly (valve bent,
worn, or carbon accumulation on the
seating surface)
Other:
IC igniter trouble
Carburetor vacuum piston doesn’t slide
smoothly
Carburetor vacuum piston diaphragm damage
Engine oil viscosity too high
Drive train trouble
Brake dragging
Air suction valve trouble
Vacuum switch valve trouble
Coasting enricher trouble
Poor Running or No Power at High
Speed:
Firing incorrect:
Spark plug dirty, broken, or maladjusted
Spark plug cap or high tension wiring trouble
Spark plug cap shorted or not in good contact
Spark plug incorrect
IC igniter trouble
Pickup coil trouble
Ignition coil trouble
Fuel/air mixture incorrect:
Choke plunger stuck open
Main jet clogged or wrong size
Jet needle or needle jet worn
Air jet clogged
Fuel level in carburetor float bowl too high
or too low
Bleed holes of needle jet holder or needle
jet clogged
Air cleaner clogged, poorly sealed, or missing
Air cleaner duct loose
Air cleaner O-ring damaged
Water or foreign matter in fuel
Carburetor holder loose
Fuel tank air vent obstructed
Fuel tap clogged
Fuel line clogged
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened
down
No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent,
worn, or carbon accumulation on the
seating surface.)
Knocking:
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
IC igniter trouble
Miscellaneous:
Throttle valve won’t fully open
Carburetor vacuum piston doesn’t slide
smoothly
Carburetor vacuum piston diaphragm damaged
Brake dragging
Clutch slipping
Overheating
Engine oil level too high
Engine oil viscosity too high
Drive train trouble
Air suction valve trouble
Vacuum switch valve trouble
Coasting enricher trouble
Balancer mechanism malfunctioning
Overheating:
Firing incorrect:
Spark plug dirty, broken, or maladjusted
Spark plug incorrect
IC igniter trouble
Fuel/air mixture incorrect:
Main jet clogged or wrong size
Fuel level in carburetor float bowl too low
Carburetor holder loose
Air cleaner duct loose
Air cleaner poorly sealed, or missing
Air cleaner O-ring damaged
Air cleaner clogged
Compression high:
Carbon built up in combustion chamber
Engine load faulty:
Clutch slipping
Engine oil level too high
Engine oil viscosity too high
17-4 APPENDIX
Troubleshooting Guide
Drive train trouble
Brake dragging
Lubrication inadequate:
Engine oil level too low
Engine oil poor quality or incorrect
Coolant incorrect:
Coolant level too low
Coolant deteriorated
Cooling system component incorrect:
Radiator fin damaged
Radiator clogged
Thermostat trouble
Radiator cap trouble
Radiator fan switch trouble
Fan motor broken
Fan blade damaged
Water pump not turning
Water pump impeller damaged
Over Cooling:
Cooling system component incorrect:
Radiator fan switch trouble
Thermostat trouble
Clutch Operation Faulty:
Clutch slipping:
Friction plate worn or warped
Steel plate worn or warped
Clutch spring broken or weak
Clutch hub or housing unevenly worn
No clutch lever play
Clutch inner cable catching
Clutch release mechanism trouble
Clutch not disengaging properly:
Clutch plate warped or too rough
Clutch spring compression uneven
Engine oil deteriorated
Engine oil viscosity too high
Engine oil level too high
Clutch housing frozen on drive shaft
Clutch hub nut loose
Clutch hub spline damaged
Clutch friction plate installed wrong
Clutch lever play excessive
Clutch release mechanism trouble
Gear Shifting Faulty:
Doesn’t go into gear; shift pedal doesn’t
return:
Clutch not disengaging
Shift fork bent or seized
Gear stuck on the shaft
Gear positioning lever binding
Shift return spring weak or broken
Shift return spring pin loose
Shift mechanism arm spring broken
Shift mechanism arm broken
Shift pawl broken
Jumps out of gear:
Shift fork worn, bent
Gear groove worn
Gear dogs and/or dog holes worn
Shift drum groove worn
Gear positioning lever spring weak or broken
Shift fork pin worn
Drive shaft, output shaft, and/or gear
splines worn
Overshifts:
Gear positioning lever spring weak or broken
Shift mechanism arm spring broken
Abnormal Engine Noise:
Knocking:
IC igniter trouble
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
Overheating
Piston slap:
Cylinder/piston clearance excessive
Cylinder, piston worn
Connecting rod bent
Piston pin, piston pin hole worn
Valve noise:
Valve clearance incorrect
Valve spring broken or weak
Camshaft bearing worn
Rocker arm worn
Rocker shaft worn
Other noise:
Connecting rod small end clearance excessive
Connecting rod big end clearance excessive
Piston ring worn, broken, or stuck
Piston seizure, damage
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head connection
Crankshaft runout excessive
Engine mounts loose
Crankshaft bearing worn
Primary gear worn or chipped
Camshaft chain tensioner trouble
Camshaft chain, sprocket, guide worn
Air suction valve damaged
Vacuum switch valve damaged
Alternator rotor loose
APPENDIX 17-5
Troubleshooting Guide
Abnormal Drive Train Noise:
Clutch noise:
Clutch rubber damper weak or damaged
Clutch housing/friction plate clearance excessive
Clutch housing gear worn
Transmission noise:
Bearings worn
Transmission gears worn or chipped
Metal chips jammed in gear teeth
Engine oil insufficient
Drive chain noise:
Drive chain adjusted improperly
Drive chain worn
Rear and/or engine sprocket worn
Chain lubrication insufficient
Rear wheel misaligned
Abnormal Frame Noise:
Front fork noise:
Oil insufficient or too thin
Spring weak or broken
Rear shock absorber noise:
Shock absorber damaged
Disc brake noise:
Pad installed incorrectly
Pad surface glazed
Disc warped
Caliper trouble
Drum brake noise:
Brake linings overworn or worn unevenly
Drum worn unevenly or scored
Brake springs weak or broken
Foreign matter in hub
Brake not properly adjusted
Other noise:
Bracket, nut, bolt, etc.
not properly
mounted or tightened
Oil Pressure Warning Light Goes On:
Engine oil pump damaged
Engine oil screen clogged
Engine oil level too low
Engine oil viscosity too low
Camshaft bearings worn
Crankshaft bearings worn
Oil pressure switch damaged
Wiring faulty
Relief valve stuck open
O-ring at the oil passage in the crankcase
damaged
Exhaust Smokes Excessively:
White smoke:
Piston oil ring worn
Cylinder worn
Valve oil seal damaged
Valve guide worn
Engine oil level too high
Black smoke:
Air cleaner clogged
Main jet too large or fallen off
Choke plunger stuck open
Fuel level in carburetor float bowl too high
Brown smoke:
Main jet too small
Fuel level in carburetor float bowl too low
Air cleaner duct loose
Air cleaner O-ring damaged
Air cleaner poorly sealed or missing
Handling and/or Stability
Unsatisfactory:
Handlebar hard to turn:
Cable routing incorrect
Hose routing incorrect
Wiring routing incorrect
Steering stem locknut too tight
Steering stem bearing damaged
Steering stem bearing lubrication inadequate
Steering stem bent
Tire air pressure too low
Handlebar shakes or excessively vibrates:
Tire worn
Swingarm pivot bearings worn
Rim warped, or not balanced
Wheel bearing worn
Handlebar holder loose
Steering stem head bolt loose
Handlebar pulls to one side:
Frame bent
Wheel misalignment
Swingarm bent or twisted
Steering maladjusted
Front fork bent
Right and left front fork oil level uneven
Shock absorption unsatisfactory:
(Too hard)
Front fork oil excessive
Front fork oil viscosity too high
Rear shock absorber adjustment too hard
Tire air pressure too high
Front fork bent
(Too soft)
Tire air pressure too low
Front fork oil insufficient and/or leaking
Front fork oil viscosity too low
Rear shock adjustment too soft
Front fork, rear shock absorber spring weak
Rear shock absorber oil leaking
17-6 APPENDIX
Troubleshooting Guide
Brake Doesn’t Hold:
Disc brake:
Air in the brake line
Pad or disc worn
Brake fluid leakage
Disc warped
Contaminated pad
Brake fluid deteriorated
Primary or secondary cup damaged in master cylinder
Master cylinder scratched inside
Drum brake:
Brake maladjusted
Brake linings or drum worn
Overheated
Water in brake drum
Brake cam, camshaft worn
Brake lining contaminated with oil
Battery Trouble:
Battery discharged:
Battery faulty (e.g., plates sulphated,
shorted through sedimentation, electrolyte insufficient)
Battery leads making poor contact
Load excessive (e.g., bulb of excessive
wattage)
Ignition switch trouble
Alternator trouble
Wiring faulty
Regulator/rectifier trouble
Battery overcharged:
Regulator/rectifier trouble
Battery faulty
APPENDIX 17-7
Cable, Wire, and Hose Routing
1. Clamp (Left and Right Handlebar Switch Leads)
2. Clamp (Brake Hose and Right Handlebar Switch Lead)
3. Damper (Install to the band)
4. Grommet
5. Strap (Air Vent Hose, Fuel Tank Drain Hose)
6. Clamp
17-8 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-9
Cable, Wire, and Hose Routing
1. Rectifiers
2. Bracket
3. LH Switch Lead Connector
4. RH Switch Lead Connector
5. LH Switch Lead Connector
6. Radiator Fan Lead Connector
7. Rear Brake Light Switch Lead Connector
8. Side Stand Switch Lead Connector
9. Main Harness
10. Throttle Cables
11. Rear Turn Signal Light Leads
12. Insert the clamp to the hole on the frame.
13. Band
14. Insert the clamp to the hole on the frame.
15. Clamps (Left and Right)
16. Bands (Left: Side Stand Switch Leads, Radiator Fan Leads, Right: Rear Brake Light Switch
Leads)
17. Bands (Right: Rear Brake Light Switch Leads, Clutch Cable, Left: Side Stand Switch Leads)
18. Clamp (Install it together with the front ignition coil installation bolt)
19. Clamp (Insert it into the frame gusset)
20. Run the leads between the frame and the radiator (Left: Side Stand Switch Leads and Radiator
Fan Leads, Right: Rear Brake Light Switch Leads)
21. Clamp (Clamp the fuel tank drain hose and speedometer cable)
17-10 APPENDIX
Cable, Wire, and Hose Routing
1. Fuel Tank Drain Hose
2. Clamp
3. Tighten the lead to the crankcase.
4. Starter Motor Lead
5. Alternator Leads
6. Ignition Switch
7. Choke Knob
8. Insert the clamp into the hole on the frame.
9. Clamp
APPENDIX 17-11
Cable, Wire, and Hose Routing
1. Clamp (Attached rubber)
2. Front Brake Hose
3. Bleed Valve
4. Front Caliper Mounting Bolts
5. Clamp (Attached rubber)
6. Brake Disc
7. Brake Hose Banjo Bolt
8. Front Brake Caliper
9. Clamps (Speedometer Cable)
10. Speedometer Cable
11. Brake Cable End Mount
12. Clamp (Brake Cable)
13. Brake Cable
14. Brake Pedal
15. Rear Brake Light Switch
17-12 APPENDIX
Cable, Wire, and Hose Routing
1. Clamp
2. Fuel Tank Drain Hose
3. Clamp (Fuel tank drain and breather
hoses)
4. starter Motor Lead
5. Carburetor Air Vent Hose
6. Starter Motor Lead Clamp
7. Run the vent hose through right side of
the frame and insert the end of it into the
bracket of the storage box.
8. Coolant Reserve Tank Return Hose
9. Main Harness
10. Band (Clamp the main harness)
APPENDIX 17-13
Cable, Wire, and Hose Routing
VN800-B7 ∼ B8 Model
1. Fuel Tank Drain Hose
2. Fuel Tank Breather Hose
3. Clamp (Fuel tank drain and speed meter cable)
4. Clamp (Speed meter cable and breather hose)
17-14 APPENDIX
Cable, Wire, and Hose Routing
1. Vacuum Switch Valve
2. Fuel Hose
3. Vacuum Hose
4. Throttle Sensor
5. Choke Cable Joint
6. Air Vent Joint
7. Band (Tighten the band as shown)
8. Air Cleaner Drain Hose
9. Clutch Cover
10. Catch Tank
11. Clamp (Install the clamp horizontally)
12. Roll the hose with clamp.
APPENDIX 17-15
Cable, Wire, and Hose Routing
1. Install the hose with the mark upside.
2. Radiator
3. Align the marks.
4. Right Engine Cover
5. Hose (between the thermostat and the reserve tank)
17-16 APPENDIX
Cable, Wire, and Hose Routing
Evaporative Emission Control System (California Model)
1. Vacuum Hose (White)
2. Clamp (Clamp the vacuum hose and the
fuel return hose)
3. Clamp
4. Run the fuel return hose inside the water
hose
5. Clamp
6. Fuel Return Hose (Red)
7. Fuel Tank Breather Hose (Blue)
8. Clamp
9. Vent Hose (Yellow)
10. Canister Purge Hose (Green)
11. Run the fuel tank breather hose through
this hole
12. Clamp
13. Hose (Blue, between the separator and
the canister)
14. Canister
15. Vacuum hose (White)
16. Band
17. Separator
MODEL APPLICATION
Year
Model
1996
VN800-B1
1997
VN800-B2
1998
VN800-B3
1999
VN800-B4
2000
VN800-B5
2001
VN800-B6
2002
VN800-B7
2003
VN800-B8
2004
VN800-B9
2005
VN800-B10
2006
VN800B6F
Beginning Frame No.
JKBVNCB1□TA030001,
VN800A-030001, or
VN800B-000001 (Germany)
JKBVNCB1□VA050001,
VN800A-050001, or
VN800B-005001 (Germany)
JKBVNCB1□WA063001,
JKBVNCB1□WB50005,
VN800A-063001, or
VN800B-008001 (Germany)
JKBVNCB1□XA075001,
JKBVNCB1□XB502701, or
JKBVN800ABA075001
JKBVN800ABA083001,
JKBVNCB1□YA083001, or
JKBVNCB1□YB506101
JKBVNCB1□IA089001,
JKBVNCB1□IB509801,
JKBVNCB1□IB089001, or
JKBVN800ABA089001
JKBVNCB1□2A095001,
JKBVNCB1□2B513701, or
JKBVN800ABA095001
JKBVNCB1□3A99001,
JKBVNCB1□3B517301, or
JKBVN800ABA99001
JKBVNCB1□4B520701, or
JKBVNCB1□4A103001, or
JKBVN800ABA103001
JKBVNCB1□5A109001, or
JKBVNCB1□5B523901, or
JKBVN800ABA109001
JKBVNCB1□6A114001, or
JKBVN800ABA114001
□:This digit in the frame number changes from one machine to another.