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2007 Vulcan 1500 Classic
2007 Vulcan 1500 Classic
Contents
Table of Contents
Troubleshooting
Bookmarks
Quick Links
9
General Information
71
Fuel System (Dfi) 2-1 Fuel System (Dfi)
191
Cooling System 3-1 Cooling System
211
Engine Top End 4-1 Engine Top End
212
Exploded View
215
Exhaust System Identification
216
Clean Air System
216
Specifications
222
Camshaft Chain Tensioner
224
Rocker Case Cover
225
Rocker Case
228
HLA (Hydraulic Lash Adjuster)
229
Camshafts
234
KACR (Kawasaki Automatic Compression Release)
236
Cylinder Head
239
Valves
246
Cylinders, Piston
252
Mufflers
255
Clutch 5-1 Clutch
256
Exploded View
257
Specifications
258
Clutch Lever
259
Clutch Fluid
261
Clutch Master Cylinder
264
Clutch Slave Cylinder
265
Clutch
275
Engine Lubrication System
276
Engine Oil Flow Chart
278
Exploded View
279
Specifications
280
Engine Oil and Oil Filter
283
Oil Pump
284
Oil Hoses and Pipes
288
Oil Pressure
291
Engine Removal/Installation
VULCAN 1500 CLASSIC Fi
VN1500 CLASSIC Fi
Motorcycle
Service Manual
Chapters
9
General Information
71
Fuel System (Dfi) 2-1 Fuel System (Dfi)
191
Cooling System 3-1 Cooling System
211
Engine Top End 4-1 Engine Top End
212
Exploded View
215
Exhaust System Identification
216
Clean Air System
216
Specifications
222
Camshaft Chain Tensioner
224
Rocker Case Cover
225
Rocker Case
228
HLA (Hydraulic Lash Adjuster)
229
Camshafts
234
KACR (Kawasaki Automatic Compression Release)
236
Cylinder Head
239
Valves
246
Cylinders, Piston
252
Mufflers
255
Clutch 5-1 Clutch
256
Exploded View
257
Specifications
258
Clutch Lever
259
Clutch Fluid
261
Clutch Master Cylinder
264
Clutch Slave Cylinder
265
Clutch
275
Engine Lubrication System
276
Engine Oil Flow Chart
278
Exploded View
279
Specifications
280
Engine Oil and Oil Filter
283
Oil Pump
284
Oil Hoses and Pipes
288
Oil Pressure
291
Engine Removal/Installation
Troubleshooting
Also See for Kawasaki Vulcan 1500 Classic Fi
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Summary of Contents for Kawasaki Vulcan 1500 Classic Fi
Page 1 VULCAN 1500 CLASSIC Fi VN1500 CLASSIC Fi Motorcycle Service Manual...
Page 3 Quick Reference Guide General Information Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires Final Drive 10 j Brakes 11 j Suspension 12 j Steering 13 j Frame 14 j Electrical System 15 j Appendix 16 j This quick reference guide will assist...
Page 4 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
Page 5: Emission Control Information
EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Addi-...
Page 6 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.
Page 7: How To Use This Manual
Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance. • venient operation. Use proper tools and genuine Kawasaki Mo- • torcycle parts. Special tools, gauges, and Indicates a procedural step or work to be testers that are necessary when servicing done.
Page 9: Table Of Contents
GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Periodic Maintenance Chart ....................1-11 Torque and Locking Agent...................... 1-13 Special Tools and Sealants ....................1-20 Cable, Wire, and Hose Routing ....................1-27...
Page 10: General Information
1-2 GENERAL INFORMATION Before Servicing Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descrip- tions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also required for successful work.
Page 11 GENERAL INFORMATION 1-3 Before Servicing (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, as removal generally damages bearings.
Page 12 1-4 GENERAL INFORMATION Before Servicing (18)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 Crack Hardening Warp Bent...
Page 13: Model Identification
GENERAL INFORMATION 1-5 Model Identification VN1500-N1 (US, and Canada) Left Side View VN1500-N1 (US, and Canada) Right Side View...
Page 14 1-6 GENERAL INFORMATION Model Identification VN1500-N1 (Europe) Left Side View VN1500-N1 (Europe) Right Side View...
Page 15 GENERAL INFORMATION 1-7 Model Identification VN1500-T1 (US, and Canada) Left Side View VN1500-T1 (US, and Canada) Right Side View...
Page 16: General Specifications
1-8 GENERAL INFORMATION General Specifications VN1500-N3 ∼ N4, VN1500-N1 ∼ N2 VN1500N7F ∼ Items N6F/T6F Dimensions Overall Length 2 505 mm (98.6 in.) Overall Width 995 mm (39.2 in.) Overall Height 1 140 mm (44.9 in.) Wheelbase 1 665 mm (65.6 in.) Road Clearance 125 mm (4.9 in.) Seat Height...
Page 17 GENERAL INFORMATION 1-9 General Specifications VN1500-N3 ∼ N4, VN1500-N1 ∼ N2 VN1500N7F ∼ Items N6F/T6F Lubrication System Forced lubrication (wet sump) Engine Oil: Grade API SE, SF or SG API SE, SF or SG API SH, SJ or SL with API SH or SJ with JASO MA JASO MA Viscosity...
Page 18 1-10 GENERAL INFORMATION General Specifications VN1500-N3 ∼ N4, VN1500-N1 ∼ N2 VN1500N7F ∼ Items N6F/T6F Front Suspension: Type Telescopic fork Wheel Travel 150 mm (5.90 in.) Rear Suspension: Type Swingarm Wheel Travel 95 mm (3.74 in.) Brake Type: Front Single disc Rear Single disc Electrical Equipment...
Page 19: Periodic Maintenance Chart
GENERAL INFORMATION 1-11 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. FREQUENCY Whichever * ODOMETER READING comes ×...
Page 20 1-12 GENERAL INFORMATION Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) (0.6) (7.5) (12) (15) (20) (24) INSPECTION Every • • • General lubrication-perform • • • • Nut, bolt, and fastener tightness-inspect † #: Service more frequently when operating in severe conditions;...
Page 21: Torque And Locking Agent
GENERAL INFORMATION 1-13 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: EO: Apply engine oil to the threads and the seating surface. G: Apply grease to the threads.
Page 22 1-14 GENERAL INFORMATION Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Water Pump Cover Bolts 87 in·lb Water Pump Drain Bolt 87 in·lb Water Pump Air Bleeder Bolt 87 in·lb Water Pipe Bolts 87 in·lb Radiator Drain Bolt 0.75 65 in·lb Engine Top End...
Page 23 GENERAL INFORMATION 1-15 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Engine Lubrication System Oil Filler Cap 0.15 13 in·lb Oil Screen Plug Engine Oil Drain Bolt Oil Filter (Cartridge type) R, EO Oil Filter Bolt Oil Pressure Relief Valve Oil Pressure Switch Terminal Bolt 0.15 13 in·lb...
Page 24 1-16 GENERAL INFORMATION Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Left Balancer Gear Bolt Starter Clutch Bolt Starter Clutch Coupling Bolts Gear Set Lever Bolt 87 in·lb Shift Shaft Return Spring Pin (Bolt) Shift Shaft Return Spring Pin (Bolt) (Bolt with punch mark) Front Shift Pedal Clamp Bolt mark 10...
Page 25 GENERAL INFORMATION 1-17 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Pinion Gear Nut (Final Gear) 13.0 St, MO Pinion Bearing Retainer (Final Gear) 25.0 Retainer Stop Screw Brakes Caliper Bleed Valves 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.10 8.7 in·lb...
Page 26 1-18 GENERAL INFORMATION Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Frame Downtube Bolts Front Footboard Bracket Bolts Rear Footpeg Bracket Bolts Sidestand Nut Electrical System Spark Plugs Pickup Coil Screws 0.30 26 in·lb Stator Lead Holder Screw 87 in·lb Pickup Coil Lead Holder Bolt 87 in·lb...
Page 27 GENERAL INFORMATION 1-19 Torque and Locking Agent 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.
Page 28: Special Tools And Sealants
1-20 GENERAL INFORMATION Special Tools and Sealants Oil Pressure Gauge, 5 kgf/cm²: Valve Guide Arbor, 7: 57001-125 57001-163 Inside Circlip Pliers: Fork Cylinder Holder Handle: 57001-143 57001-183 Outside Circlip Pliers: Compression Gauge, 20 kgf/cm²: 57001-144 57001-221 Bearing Puller: Valve Spring Compressor Assembly: 57001-158 57001-241 Valve Guide Reamer, 7:...
Page 30 1-22 GENERAL INFORMATION Special Tools and Sealants Oil Seal & Bearing Remover: Head Pipe Outer Race Remover ID > 37 mm: 57001-1058 57001-1107 Head Pipe Outer Race Press Shaft: Valve Seat Cutter, 45° - 32: 57001-1075 57001-1115 Head Pipe Outer Race Driver, 54.5: Valve Seat Cutter, 45°...
Page 31 GENERAL INFORMATION 1-23 Special Tools and Sealants Valve Seat Cutter Holder Bar: Piston Pin Puller Adapter, 14: 57001-1128 57001-1211 Bearing Driver Set: Fork Outer Tube Weight: 57001-1129 57001-1218 Pinion Gear Holder, m1.9: Front Fork Oil Seal Driver: 57001-1165 57001-1219 Valve Seat Cutter, 32° - 33: Jack: 57001-1199 57001-1238...
Page 32 1-24 GENERAL INFORMATION Special Tools and Sealants Valve Seat Cutter, 55° - 35: Bearing Remover Head, 10 × 12: 57001-1247 57001-1266 Oil Filter Wrench: Fork Oil Level Gauge: 57001-1249 57001-1290 Final Gear Case Holder: Bearing Remover Head, 20 × 22: 57001-1250 57001-1293 Bearing Retainer Wrench:...
Page 33 GENERAL INFORMATION 1-25 Special Tools and Sealants Steering Stem Bearing Driver Adapter, 41.5: Drive Shaft Holder: 57001-1345 57001-1407 Piston Ring Compressor Belt, 95 ∼ 108: Flywheel Holder: 57001-1358 57001-1410 Bearing Remover Shaft, 13: Peak Voltage Adapter: 57001-1377 57001-1415 Hand Tester: Filler Cap Driver: 57001-1394 57001-1454...
Page 34 1-26 GENERAL INFORMATION Special Tools and Sealants Fuel Pressure Gauge Adapter: Kawasaki Bond (Silicone Sealant): 57001-1593 56019-120 Fuel Hose: Kawasaki Bond(Liquid Gasket - Black): 57001-1607 92104-1003...
Page 35: Cable, Wire, And Hose Routing
GENERAL INFORMATION 1-27 Cable, Wire, and Hose Routing 1. Front Right Spark Plug Cap 10. Rear Left Spark Plug Cap 2. Rear Right Spark Plug Cap 11. Clutch Hose 3. 2nd Lead from the left ignition coil lower 12. Plastic Clamps side 13.
Page 36 1-28 GENERAL INFORMATION Cable, Wire, and Hose Routing...
Page 37 GENERAL INFORMATION 1-29 Cable, Wire, and Hose Routing - - >: Vacuum Pulsation →: Fuel Flow #1: For Front Cylinder #2: For Rear Cylinder 1. Fuel Tank (left view) 2. Return Fuel Check Valve 3. High Pressure Fuel Hoses 4. Delivery Joint 5.
Page 38 1-30 GENERAL INFORMATION Cable, Wire, and Hose Routing...
Page 39 GENERAL INFORMATION 1-31 Cable, Wire, and Hose Routing #1: For Front Cylinder #2: For Rear Cylinder 1. Thermostat Housing 2. Water Hoses #1 3. Reserve Tank Hose 4. Clamps: Position the screw head as shown. 5. White marks on the hose [2] face forward. 6.
Page 40 1-32 GENERAL INFORMATION Cable, Wire, and Hose Routing 1. Fuel Tank Filler 13. Fuel Tank Breather Hose (Except for Cal- 2. Throttle Assy ifornia Model) 3. Fuel Tank Breather Pipe 14. Run the hose [13] into the right hole of the 4.
Page 41 GENERAL INFORMATION 1-33 Cable, Wire, and Hose Routing 1. Throttle Cables: First, run these cables 9. Vacuum Switch Valve over the hose [10], inside the sensor 10. Water Hose #1 holder hook [23], then under the hose [3], 11. Atmospheric Pressure Sensor (DFI) and connect these cables to the throttle 12.
Page 42 1-34 GENERAL INFORMATION Cable, Wire, and Hose Routing →: Fuel Flow 10. Pump Base Plate 1. Fuel Pump Connector (outside the fuel 11. Base Plate Gasket tank) 12. Outlet Fuel Pipe Joint 2. Bottom of Fuel Tank 13. Fuel Pump Screen (Pump Inlet) 3.
Page 43 GENERAL INFORMATION 1-35 Cable, Wire, and Hose Routing →: Inlet Air Flow 11. Right Rubber Gasket 1. Rear View 12. Right Air Cleaner Cover 2. Air Inlet 13. Locate the glued joint of the gasket within 3. Left Rubber Gasket the angle.
Page 44 1-36 GENERAL INFORMATION Cable, Wire, and Hose Routing...
Page 45 GENERAL INFORMATION 1-37 Cable, Wire, and Hose Routing →: Fuel Flow 1. Vacuum Sensor (with the vacuum hose) 2. Vacuum Hoses for the vacuum sensor and the pressure regulator 3. T-Joint 4. Insert the hose [20] with its mark up and hold the hose with the clamp. 5.
Page 46 1-38 GENERAL INFORMATION Cable, Wire, and Hose Routing #1: For Front Cylinder 11. Run the decelerator throttle cable above the ac- #2: For Rear Cylinder celerator cable from here to the throttle pulley. 1. Vacuum Sensor with vacuum hose 12. Vacuum Switch Valve 2.
Page 47 GENERAL INFORMATION 1-39 Cable, Wire, and Hose Routing - - >: Fuel Flow 8. Vacuum Hoses from 17. Throttle Cable Holder ←→: Vacuum Pulsation Throttle Body 18. Choke Lever Stop Screw →: Bypass Air Flow 9. ISC Hose #2 (blue mark) 19.
Page 48 1-40 GENERAL INFORMATION Cable, Wire, and Hose Routing...
Page 49 GENERAL INFORMATION 1-41 Cable, Wire, and Hose Routing →: Bypass Air Flow #1: For Front Cylinder #2: For Rear Cylinder 1. Rear View 2. Throttle Assy 3. Air Cleaner Base Seal 4. Ignition Coil 2nd Lead Holder 5. Right Side View 6.
Page 50 1-42 GENERAL INFORMATION Cable, Wire, and Hose Routing...
Page 51 GENERAL INFORMATION 1-43 Cable, Wire, and Hose Routing 1. Ignition Coil (Right) Hi-tension Cable Holder 2. Snap-on Strap 3. Ignition Coil (Right) Hi-tension Cable 4. Fitting 5. Right Ignition Coil 6. Thermostat Housing Bracket 7. Reserve Tank Bracket 8. Frame Gusset 9.
Page 52 1-44 GENERAL INFORMATION Cable, Wire, and Hose Routing...
Page 53 GENERAL INFORMATION 1-45 Cable, Wire, and Hose Routing 1. Electric Starter 2. Starter Cable 3. Front Regulator/Rectifier 4. Clamp (Clamp the starter cable and front regulator/rectifier lead.) 5. Regulator/Rectifier Connectors 6. Sidestand Switch Leads 7. Welded Clamp 8. Clamp the leads [6] through the front and rear hooks with a slack as little as possible onto the frame pipe behind the side stand bracket.
Page 54 1-46 GENERAL INFORMATION Cable, Wire, and Hose Routing...
Page 55 GENERAL INFORMATION 1-47 Cable, Wire, and Hose Routing 1. Right Handlebar Switch Lead Connector 2. Left Handlebar Switch Lead Connector 3. Headlight Unit (EUR, AU) 4. Clutch Hose (Run it outside of the frame pipe.) 5. Holder (main harness, clutch hose, and throttle cables) 6.
Page 56 1-48 GENERAL INFORMATION Cable, Wire, and Hose Routing 47. Regulator/Rectifier Lead 48. Oil Pressure Switch/Neutral Switch Connector 49. Sidestand Switch Connector 50. Front Gear Case 51. Rear Regulator/Rectifier Connector 52. Front Regulator/Rectifier Connector 53. Outside Alternator Connector 54. Inside Alternator Connector 55.
Page 57 GENERAL INFORMATION 1-49 Cable, Wire, and Hose Routing Dummy Page...
Page 58 1-50 GENERAL INFORMATION Cable, Wire, and Hose Routing...
Page 59 GENERAL INFORMATION 1-51 Cable, Wire, and Hose Routing 1. Join the headlight, handlebar switch, and 31. Insert the pin with the main harness into turn signal light leads connectors in the the right hole of the frame gusset. headlight unit. 32.
Page 60 1-52 GENERAL INFORMATION Cable, Wire, and Hose Routing...
Page 61 GENERAL INFORMATION 1-53 Cable, Wire, and Hose Routing 1. Fuel Tank Filler Drain Hose 2. Electric Starter Motor Lead 3. Holder 4. Engine Ground, or Battery (–) Lead (Run it downward) 5. Main Harness 6. Coolant Reserve Tank Hose (from the thermostat housing to the coolant reserve tank) 7.
Page 62 1-54 GENERAL INFORMATION Cable, Wire, and Hose Routing 1. Upper Muffler 11. Front 2. 50° 12. Align marks. 3. Muffler Chamber 13. Front Shift Pedal 4. Lower Muffler 14. Rear Shift Pedal 5. Rear Exhaust Pipe 15. (80 mm) (3.15 in.) 6.
Page 63 GENERAL INFORMATION 1-55 Cable, Wire, and Hose Routing 1. Snap-on Strap 2. Front Brake Hose Holders 3. Front Brake Hose 4. Front Brake Caliper 5. Throttle Cable (accelerator) 6. Throttle Cable (decelerator) 7. Handlebar 8. Grommets 9. Front Master Cylinder 10.
Page 64 1-56 GENERAL INFORMATION Cable, Wire, and Hose Routing...
Page 65 GENERAL INFORMATION 1-57 Cable, Wire, and Hose Routing 1. Run the turn signal light lead in front of the upper brake hose [3]. 2. Snap-on Strap ([3] and [20] except for throttle cables) 3. Front Brake Hose 4. Throttle Cable (decelerator) 5.
Page 66 1-58 GENERAL INFORMATION Cable, Wire, and Hose Routing 1. Rear Brake Caliper 10. Brake Pedal 2. Brake Hose Holders 11. View 3. Rear Brake Hose 12. Clevis 4. Brake Hose White Marks (Position here.) 13. Rear Brake Reservoir Cover 5. Clamps 14.
Page 67 GENERAL INFORMATION 1-59 Cable, Wire, and Hose Routing Evaporative Emission Control System (California Model) - - >: Vapor Flow →: Fuel Flow ←→: Vacuum Pulsation 1. Fuel Return Hose 2. Fuel Tank Breather Hose 3. Separator Breather Hose 4. Canister Purge Hose 5.
Page 68 1-60 GENERAL INFORMATION Cable, Wire, and Hose Routing Evaporative Emission Control System (California Model)
Page 69 GENERAL INFORMATION 1-61 Cable, Wire, and Hose Routing Evaporative Emission Control System (California Model) 1. Fuel Tank Filler 2. Throttle Assy 3. Fuel Tank Breather Pipe 4. Filler Drain Pipe 5. Fuel Tank 6. Separator 7. Canister 8. Clips for [13] and [15] 9.
Page 70 1-62 GENERAL INFORMATION Cable, Wire, and Hose Routing Evaporative Emission Control System (California Model) 1. Fuel Tank 2. Left Air Cleaner Base 3. Canister Purge Hose (Green, CAL) 4. Canister (CAL) 5. Fuel Breather Hose (right, blue) 6. Rear View 7.
Page 72 2-2 FUEL SYSTEM (DFI) Removal........2-82 Removal........2-99 Installation........2-82 Installation........2-100 Input Voltage Inspection....2-82 Inspection........2-100 Output Voltage Inspection.... 2-83 Fuel Injectors (#1, #2: Fault Code 41, Inlet Air Temperature Sensor (Fault 42)........... 2-103 Code 13) ......... 2-88 Injector Removal ......
Page 73: Specifications
FUEL SYSTEM (DFI) 2-3 Specifications Item Standard 2 ∼ 3 mm Throttle Grip Free Play Air Cleaner Element Paper filter DFI (Digital Fuel Injection) System Make Mitsubishi Electric Idle Speed 950 ±50 r/min (rpm) Throttle Assy: Type × Bore Two barrel type × 36 mm (1.42 in.) ECU (Electronic Control Unit): Digital memory type, with built in IC igniter, sealed Type...
Page 74 Special Tools - Oil Pressure Gauge: 57001-125 Hand Tester: 57001-1394 Filler Cap Driver: 57001-1454 Needle Adapter Set: 57001-1457 Fuel Pressure Gauge Adapter: 57001-1593 Fuel Hose: 57001-1607 Fork Oil Level Gauge: 57001-1290 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
Page 75 FUEL SYSTEM (DFI) 2-5 Specifications Dummy Page...
Page 76: Dfi Parts Location
2-6 FUEL SYSTEM (DFI) DFI Parts Location...
Page 77 FUEL SYSTEM (DFI) 2-7 DFI Parts Location 1. Atmospheric Pressure Sensor (DFI) 2. Water Temperature Sensor (DFI) 3. Ignition Coils 4. Ignition Switch 5. Starter Motor 6. Water Temperature Switch 7. Regulator/Rectifiers 8. Pickup Coils 9. Alternator 10. Sidestand Switch 11.
Page 78 2-8 FUEL SYSTEM (DFI) DFI Parts Location...
Page 79 FUEL SYSTEM (DFI) 2-9 DFI Parts Location 1. Atmospheric Pressure Sensor (DFI) 2. Water Temperature Sensor (DFI) 3. Ignition Coils (see preceding page) 4. Ignition Switch (see preceding page) 5. Starter Motor (see preceding page) 6. Water Temperature Switch (see preceding page) 7.
Page 85 FUEL SYSTEM (DFI) 2-15 DFI System #1: For Front Cylinder #2: For Rear Cylinder 1. ECU (Electronic Control Unit) 2. Pickup Coil #1 3. Pickup Coil #2 4. Pressure Regulator 5. Throttle Sensor (front view) 6. Atmospheric Pressure Sensor 7. Vacuum Sensor 8.
Page 86: Dfi Wiring Diagram
2-16 FUEL SYSTEM (DFI) DFI Wiring Diagram...
Page 87 FUEL SYSTEM (DFI) 2-17 DFI Wiring Diagram Terminal Numbers of ECU Connectors DFI and Electrical Parts Terminal Names DFI: DFI Parts #1: Front Cylinder A: ECU Electronic Control Unit (DFI) #2: Rear Cylinder B. Engine Stop Switch 1. Main Relay Solenoid Ground in ECU C.
Page 88: Dfi Servicing Precautions
2-18 FUEL SYSTEM (DFI) DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V battery as its power source. Do not use any other battery except for a 12 V battery as a power source.
Page 89: General Information
FUEL SYSTEM (DFI) 2-19 DFI Servicing Precautions ○ 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 high pressure in- side the fuel line can cause fuel to leak [A] or the hose to burst.
Page 90 2-20 FUEL SYSTEM (DFI) DFI Servicing Precautions ○ Pull the high pressure fuel hose joint [A] down [B] and make sure it is locked and doesn't come off. ○ To maintain the correct fuel/air mixture (F/A), there must be no inlet air leaks in the DFI system. Be sure to install the oil filler cap [A] after filling the engine oil, using the filler cap driver [B].
Page 91: Throttle Grip And Cables
FUEL SYSTEM (DFI) 2-21 Throttle Grip and Cables Throttle Grip Play Inspection • Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cable. Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Standard: •...
Page 92: Choke Knob Operation
2-22 FUEL SYSTEM (DFI) Throttle Grip and Cables Choke Knob Operation ○ Do not use the choke knob except when the engine has a starting difficulty, like in cold weather or at high altitude. The DFI system has an automatic choke system, using ISC valves, a water temperature sensor, and an atmo- spheric pressure sensor, which provide startability.
Page 93: Throttle Assy
FUEL SYSTEM (DFI) 2-23 Throttle Assy Idle Speed Inspection • Start the engine and warm it up thoroughly. ○ At first the engine will run fast to decrease warm up time (fast idle). ○ Gradually the fast idle will lower to a certain RPM auto- matically.
Page 94: High Altitude Performance Adjustment
Any modification is not necessary in this model since the atmospheric pressure sensor senses atmospheric pres- sure change due to high altitude and the ECU compen- sates the change. (For reference: Mostly, Kawasaki rec- ommends US carburetor models operated above 4 000 feet, EPA-approved modification to improve the EMIS- SION CONTROL PERFORMANCE).
Page 95 FUEL SYSTEM (DFI) 2-25 Throttle Assy • Disconnect: Throttle Sensor Connector [A] (from the throttle sensor) Front and Rear Injector Connectors [B] • Remove the following from the choke cable holder [A] (left -behind view). Screw [B] Choke Cable Plate [C] •...
Page 96 2-26 FUEL SYSTEM (DFI) Throttle Assy • Turn the throttle pulley [A] as shown, and pull out the ac- celerator cable housing [B] from the cable holder [C] (rear view). • Return the pulley, and pull out the decelerator cable hous- ing [D] from the cable holder.
Page 97: Throttle Assy Installation
FUEL SYSTEM (DFI) 2-27 Throttle Assy • Take out the throttle assy [A] from the right side, while tilting it up. ○ Be careful not to damage (dent, nick, flaw, and crack) the flange mating surface and the plastic parts. ○...
Page 98 2-28 FUEL SYSTEM (DFI) Throttle Assy • Apply a thin coating of grease to the throttle cable upper ends. • Install the lower ends of the throttle cables in the throttle pulley. Accelerator Cable [A] Decelerator Cable [B] • Run the throttle cables correctly (see Cable, Wire, and Hose Routing section in the General Information chapter).
Page 99: Throttle Assy Disassembly/Assembly
FUEL SYSTEM (DFI) 2-29 Throttle Assy Throttle Assy Disassembly/Assembly • Remove the throttle assy (see Throttle Assy Removal). • Unscrew two bolts [A], and pull out the ISC pipe #1 [B], and ISC pipe #2 [C] from the hoses [D]. Bottom View [E] •...
Page 100 2-30 FUEL SYSTEM (DFI) Throttle Assy Choke Lever Stop Screw [A]: This screw sets the throttle valve opening when the choke knob is pulled fully. Tampering with the screw could cause malfunction of the choke lever. Rear View [B] Throttle Valve and Throttle Shaft: They are not allowed to remove because of diffi- culty of removal.
Page 101: Air Cleaner
FUEL SYSTEM (DFI) 2-31 Air Cleaner Element Removal • Remove: Allen Bolt and Washer [A] Left Air Cleaner Cover [B] Front [C] • Remove the element [A]. • Push a clean, lint-free towel into the lower air cleaner duct to keep dirt or other foreign material from entering. WARNING If dirt or dust is allowed to pass through into the throttle assy, the throttle may become stuck, possi-...
Page 102: Right Air Cleaner Housing Removal
2-32 FUEL SYSTEM (DFI) Air Cleaner ○ Be careful not to lose the air cleaner base mounting nuts [A]. These nuts and lower air cleaner duct are sold as a unit. • Apply: Non-permanent Locking Agent - Air Cleaner Base Screws •...
Page 103: Right Air Cleaner Housing Installation
FUEL SYSTEM (DFI) 2-33 Air Cleaner Right Air Cleaner Housing Installation • Check to see that the seals [A], [B] and the ISC pipe O -rings [C] are in place. • Apply: Non-permanent Locking Agent - Right Air Cleaner Base Screws •...
Page 104: Lower Air Cleaner Duct Removal
2-34 FUEL SYSTEM (DFI) Air Cleaner Lower Air Cleaner Duct Removal • Remove: Right and Left Air Cleaner Housing (see this chapter) Throttle Assy Holder [A] Air Cleaner Duct Holder [B] Throttle Assy (see this chapter) Inlet Manifold (see this chapter) Front [C] •...
Page 105: Fuel Tank
FUEL SYSTEM (DFI) 2-35 Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
Page 106 2-36 FUEL SYSTEM (DFI) Fuel Tank • Remove: Front Seat (see Frame chapter) Fuel Tank Bolt [A] Fuel Tank Nut [B] • Disconnect the battery (–) terminal. • Raise the lock [B] and disconnect the fuel pump connector [A] (black, 4p). •...
Page 107 FUEL SYSTEM (DFI) 2-37 Fuel Tank • 8 mm plug ( 7.8 ∼ 8.0 mm [A] × L 35 mm Prepare a (1.38 in.) [B] with a rounded end [C]), and a 7.3 ∼ 7.5 mm (0.20 ∼ 0.23 in.) inside diameter fuel hose [D] (e.g. Part No.
Page 108: Fuel Tank Installation
2-38 FUEL SYSTEM (DFI) Fuel Tank • Close the fuel tank cap. • Remove the fuel tank from the vehicle, and place it on a flat surface. CAUTION For California model, if gasoline, solvent, water or any other liquid enters the canister, the canister's vapor absorbing capacity is greatly reduced.
Page 109 FUEL SYSTEM (DFI) 2-39 Fuel Tank • Check that the rubber dampers [A] are in place. If the dampers are damaged or deteriorated, replace them. ○ Remove the plug hoses, and 8 mm plug, then quickly install the fuel hoses one by one. •...
Page 110: Fuel Tank And Cap Inspection
2-40 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank and Cap Inspection • Visually inspect the gasket [A] on the tank cap for any damage. Replace the gasket if it is damaged. • Check to see if the breather pipe [B] in the tank is not clogged.
Page 111 FUEL SYSTEM (DFI) 2-41 Fuel Tank • Check to see if the valve [A] slides smoothly when push- ing it in with a wooden or other soft rod, and see if it comes back to its seat by pressure of the spring [B]. NOTE ○...
Page 112: Evaporative Emission Control System
2-42 FUEL SYSTEM (DFI) Evaporative Emission Control System The Evaporative Emission Control System for California Model routes fuel vapors from the fuel system into the run- ning engine or stores the vapors in a canister when the en- gine is stopped. Although no adjustments are required, a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart.
FUEL SYSTEM (DFI) 2-43 Evaporative Emission Control System Separator Inspection (Periodic Inspection) • Disconnect the hoses from the liquid/vapor separator, and remove the separator from the motorcycle. • Visually inspect the separator for cracks and other dam- aged. If the separator has any cracks or damage, replace it with a new one.
Page 114 2-44 FUEL SYSTEM (DFI) Evaporative Emission Control System...
Page 115: Troubleshooting The Dfi System
FUEL SYSTEM (DFI) 2-45 Troubleshooting the DFI System Outline When an abnormality in the system occurs, the FI indica- tor LED (Light Emitting Diode) light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (electronic control unit).
Page 116 After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Silicone Sealant- Kawasaki Bond: 56019-120 • Always check battery condition before replacing the DFI parts. A fully charged battery is a must for conducting accurate tests of the DFI system.
Page 117 FUEL SYSTEM (DFI) 2-47 Troubleshooting the DFI System ○ If both ends of a harness [A] are far apart, ground [B] the one end [C], using an auxiliary lead [D] and check the continuity between the end [E] and the ground [F]. This enables to check a long harness for continuity.
Page 118 2-48 FUEL SYSTEM (DFI) Troubleshooting the DFI System ○ Electrical Connectors: Connectors [A] Connectors [B]...
Page 119 FUEL SYSTEM (DFI) 2-49 Troubleshooting the DFI System DFI Diagnosis Flow Chart...
Page 120 2-50 FUEL SYSTEM (DFI) Troubleshooting the DFI System NOTE ○ OK: No problem. ○ NG: Problem exists. 1. Inspection starts. • An abnormality occurs in the DFI system, and the FI indicator LED light goes on to alert the rider. •...
Page 121: Problem Chart
FUEL SYSTEM (DFI) 2-51 Troubleshooting the DFI System Problem Chart Problems Startability Idling stability Driveability Inspection items ECU ground and 1 (1) power supply Ignition Switch, C2*, 2 (2) engine stop Switch C15* Spark plug #1, #2 3 (3) 4 (5) ISC valve #1, #2 5 (6) 1 (1) 2 (2) 2 (2) In-tank fuel pump...
Page 122 2-52 FUEL SYSTEM (DFI) Troubleshooting the DFI System Idling stability (C): Unstable idling (rough idling) • The idle speed fluctuates. This can be identified by engine sound or vibration. (D): Incorrect idle speed • The idle speed cannot be adjusted within the speci- fied range.
Page 123: Inquiries To Rider
FUEL SYSTEM (DFI) 2-53 Troubleshooting the DFI System (I): Surge A forward and backward, periodic movement of a mo- torcycle at acceleration, deceleration, or at cruising. (J): Knock A periodic, rattling, thumping or pounding noise caused by spontaneous ignition of the air-fuel mixture in a cylinder, leading to engine damage.
Page 124 2-54 FUEL SYSTEM (DFI) Troubleshooting the DFI System Sample Diagnosis Sheet Rider name Registration No. (license plate No.) Year of initial registration Model Engine No. Frame No. Date problem occured Mileage Environment when problem occurred. □ □ □ □ □ □...
Page 125 FUEL SYSTEM (DFI) 2-55 Troubleshooting the DFI System Rider name Registration No. (license plate No.) Year of initial registration Model Engine No. Frame No. Date problem occured Mileage □ Poor running at choke knob left pulled out fully (push it in fully). □...
Page 126: Ecu
2-56 FUEL SYSTEM (DFI) CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Removal • Remove: Front Seat (see Frame chapter) Battery Holder [A] and Screw [B] • Pull the ECU [C] out. If necessary, disconnect the ECU connectors.
Page 127: Ecu Power Supply Inspection
FUEL SYSTEM (DFI) 2-57 ECU Power Supply Inspection • Visually inspect the terminals [A] of the ECU connectors. If the connector is clogged with mud or dust, blow it off with compressed air. Replace the main harness if the terminals of the main harness connectors are cracked, bent, or otherwise dam- aged.
Page 128 2-58 FUEL SYSTEM (DFI) DFI Power Source Circuit →: Current Fuel Injector #2 [S] ECU [A] In-tank Fuel Pump [U] Junction Box [F] DFI Fuse 15 A [V] Ignition Switch [N] ISC Valve #2 [W] Starter Relay [O] ISC Valve #1 [X] Main Fuse 30 A [P] DFI Main Relay [e] Battery [Q]...
Page 129: Dfi Power Source
FUEL SYSTEM (DFI) 2-59 DFI Power Source DFI Fuse Removal • Remove the front seat (see Frame chapter). • Pull the lock [A] and open the lid [B]. • Pull out the DFI fuse [C] from the case with needle nose pliers.
Page 130: Dfi Main Relay Inspection
2-60 FUEL SYSTEM (DFI) DFI Power Source DFI Main Relay Inspection • Remove the DFI main relay (see above). • Connect the hand tester [A] and one 12 V battery [B] to the relay connector [C] as shown. Special Tool - Hand Tester: 57001-1394 Relay Coil Terminals [1] and [2] Relay Switch Terminals [3] and [4] Testing Relay...
Page 131: Fi Indicator Led Light
FUEL SYSTEM (DFI) 2-61 FI Indicator LED Light Inspection Flow Chart...
Page 132: Led Light Inspection
2-62 FUEL SYSTEM (DFI) FI Indicator LED Light The FI indicator LED light [A] goes ON when the ignition switch is turned ON and the LED light goes OFF 1 ∼ 2 sec- onds later. This is to ensure that the FI indicator LED light has not burned out and the DFI system and the ignition sys- tem function properly.
Page 133: Isc Valves
FUEL SYSTEM (DFI) 2-63 ISC Valves There are two ISC valves; the ISC valve #1 for the front cylinder, and the ISC valve #2 for the rear cylinder. When the engine is cold, each ISC valve is opened according to the coolant temperature by the ECU, providing good starta- bility in cold weather and allowing the engine to run fast for quick warm up (fast idle).
Page 134: Removal/Installation
2-64 FUEL SYSTEM (DFI) ISC Valves Removal/Installation CAUTION Never drop the ISC valves, especially on a hard sur- face. Such a shock to the valve can damage it. ○ The ISC valves are removed during right air cleaner hous- ing removal (see this chapter). ○...
Page 135: Output Voltage Inspection
• After inspection, remove the needle adapters, and apply silicone sealant to the seals of the ECU connector for wa- terproofing. Silicone Sealant- Kawasaki Bond: 56019-120 Output Voltage Inspection • Measure the output voltage at the ECU connector, using the hand tester (special tool).
Page 136: Resistance Inspection
2-66 FUEL SYSTEM (DFI) ISC Valves If the output voltage is correct, check the output voltage at the connectors [A] of the ISC Valves. • Remove the right air cleaner cover (see this chapter). • Disconnect the ISC connectors. • Connect the hand tester to the main harness connectors for each ISC valve.
Page 137 FUEL SYSTEM (DFI) 2-67 ISC Valves → : Signal ECU [A] Junction Box [F] Ignition Switch [N] Starter Relay [O] Main Fuse 30 A [P] Battery [Q] DFI Fuse 15 A [V] ISC Valve #2 [W] ISC Valve #1 [X] DFI Main Relay [e] Ignition Fuse 10 A [f]...
Page 138: Fuel Line
2-68 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove the fuel tank (see Fuel Tank Removal). ○ Be sure to stuff a clean shop towel [A] around the high pressure fuel hose joint [B] of the fuel tank, and plug the joint with a plug [C] ( 7.8 ∼...
Page 139 FUEL SYSTEM (DFI) 2-69 Fuel Line • Measure the fuel pressure with the engine stopped. Fuel Pressure right after Ignition Switch ON, with pump running: Standard: 310 kPa (3.2 kgf/cm², 46 psi) after 3 seconds from Ignition Switch ON, with pump stopped: Standard: 280 kPa (2.9 kgf/cm², 41 psi) •...
Page 140: Pressure Regulator Removal
2-70 FUEL SYSTEM (DFI) Fuel Line ○ Pull the high pressure fuel hose joint [A] up [B] and make sure it is locked and does not come off. • Start the engine and check for fuel leakage. Pressure Regulator Removal ○...
Page 141 FUEL SYSTEM (DFI) 2-71 Fuel Line • Prepare a plastic hose of the inside diameter 7.5 mm (0.295 in.) × L about 400 mm (15.7 in.) and a measuring cylinder. • Remove: Front Seat (see Frame chapter) Fuel Tank Bolt and Nut ○...
Page 142: Self-Diagnosis
2-72 FUEL SYSTEM (DFI) Self-Diagnosis Self-diagnosis Function The self-diagnosis indicates problems with the parts, wiring, and ECU in the DFI system and ignition system. The ECU [C] always monitors each DFI circuit [A] for problems by measuring the voltage [B]. This circuit includes parts [D], and wiring [E].
Page 143 FUEL SYSTEM (DFI) 2-73 Self-Diagnosis...
Page 144: How To Read Fault Codes
2-74 FUEL SYSTEM (DFI) Self-Diagnosis How to Read Fault Codes ○ Fault codes are shown by a series of long and short blinks of the FI indicator LED light as shown below. ○ Read 10th digit and unit digit as the FI indicator LED light blinks.
Page 145: How To Erase Fault Codes
FUEL SYSTEM (DFI) 2-75 Self-Diagnosis How to Erase Fault Codes ○ When the repair has been done, the LED light will not show fault codes any more. But even if the repair has been done, the ignition switch is turned OFF, or the battery is disconnected, all the fault codes remain in the ECU, which need not be absolutely eraced.
Page 146: Backups
2-76 FUEL SYSTEM (DFI) Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Fault Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the throttle sensor system fails (the signal is out of the usable range, wiring short or open), Throttle Throttle Valve Opening...
Page 147 FUEL SYSTEM (DFI) 2-77 Self-Diagnosis NOTE ○ (1) When the engine load is light like at idling or low speed, the ECU determines injection quantity by calculating from throttle vacuum (vacuum sensor output voltage) and engine speed (pickup coil output voltage). This method is called D-J method. As engine speed increases, and the en- gine load turns middle to heavy, the ECU determines injection quantity by calculating from throttle opening (throttle sensor output voltage) and engine speed.
Page 148: Throttle Sensor (Fault Code 11)
2-78 FUEL SYSTEM (DFI) Throttle Sensor (Fault Code 11) The throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injection quantity, and ignition timing according to engine rpm, and throttle opening.
Page 149: Output Voltage Inspection
FUEL SYSTEM (DFI) 2-79 Throttle Sensor (Fault Code 11) • Connect a digital meter [A] to the throttle sensor connector [B], using two needle adapters [C]. Front [D] Special Tool - Needle Adapter Set: 57001-1457 CAUTION Insert the needle adapter straight along the lead in the connector to prevent short circuit between ter- minals.
Page 150 If the reading is out of the standard range, inspect the throttle sensor resistance. • After throttle sensor inspection, remove the needle adapters, and apply silicone sealant to the seals [A] of the connector [B] for waterproofing. Silicone Sealant- Kawasaki Bond: 56019-120...
Page 151: Resistance Inspection
FUEL SYSTEM (DFI) 2-81 Throttle Sensor (Fault Code 11) Resistance Inspection • Turn the ignition switch OFF. • Disconnect the throttle sensor connector. • Connect a digital meter [A] to the throttle sensor connector [B]. • Measure the throttle sensor resistance. Throttle Sensor Resistance Connections: BL/W lead [C] ←→...
Page 152: Vacuum Sensor (Fault Code 12)
2-82 FUEL SYSTEM (DFI) Vacuum Sensor (Fault Code 12) Removal CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. • Remove the fuel tank (see Fuel Tank section in this chap- ter).
Page 153: Output Voltage Inspection
Turn the ignition switch OFF, remove the needle adapters and apply silicone sealant to the seals of the sensor con- nector for waterproofing. Silicone Sealant- Kawasaki Bond: 56019-120 Output Voltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection.
Page 154 If the output voltage is out of the usable range, replace the sensor. • Turn the ignition switch OFF and remove the needle adapters. • Apply silicone sealant to the seals of the sensor connector for waterproofing. Silicone Sealant- Kawasaki Bond: 56019-120 →: Signal ECU [A] Vacuum Sensor [a]...
Page 155 FUEL SYSTEM (DFI) 2-85 Vacuum Sensor (Fault Code 12) If you need to check the vacuum sensor for vacuum other than 76 cmHg (abs), check the output voltage as follows: ○ Remove the fuel tank (see this chapter). • Remove the vacuum sensor [D] and disconnect the vac- uum hose from the sensor.
Page 156 2-86 FUEL SYSTEM (DFI) Vacuum Sensor (Fault Code 12) Suppose: Pg: Vacuum (gauge) of Throttle Assy Pl: Local Atmospheric Pressure (absolute) measured by a barometer Pv: Vacuum (absolute) of Throttle Assy Vv: Sensor Output Voltage (v) then Pv = Pl – Pg For example, suppose the following data is obtained: Pg = 8 cmHg (vacuum gauge reading) Pl = 70 cmHg (barometer reading)
Page 157 FUEL SYSTEM (DFI) 2-87 Vacuum Sensor (Fault Code 12) Pv = 55 ∼ 86 cmHg Vv: Vacuum Sensor Output Voltage (V) (Digital Meter Reading) Pv: Throttle Vacuum (absolute) Ps: Standard Atmospheric Pressure (absolute) ID: Idling TO: Throttle Full Open ST: Standard of Sensor Output Voltage (v) UR: Usable Range of Sensor Output Voltage (v)
Page 158: Inlet Air Temperature Sensor (Fault Code 13)
(see next diagram). • Remove the needle adapters, and apply silicone sealant to the seals of the ECU connector for waterproofing. Silicone Sealant- Kawasaki Bond: 56019-120 If the wiring is good, check the sensor resistance.
Page 159: Sensor Resistance Inspection
FUEL SYSTEM (DFI) 2-89 Inlet Air Temperature Sensor (Fault Code 13) Sensor Resistance Inspection • Remove the inlet air temperature sensor (see this sec- tion). • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion and threaded portion are submerged.
Page 160: Water Temperature Sensor (Fault Code 14)
Disconnect the sensor connector, and unscrew the water temperature sensor [B]. Top [C] • Apply silicone sealant to the threads of water temperature sensor. Silicone Sealant- Kawasaki Bond: 56019-120 • Tighten: Torque - Water Temperature Sensor: 18 N·m (1.8 kgf·m, 13 ft·lb) •...
Page 161 If the wiring is good, check the water temperature sensor resistance. • Remove the needle adapters, and apply silicone sealant to the seals of the ECU connector for waterproofing. Silicone Sealant- Kawasaki Bond: 56019-120 ECU [A] Water Temperature Sensor [Z]...
Page 162: Sensor Resistance Inspection
2-92 FUEL SYSTEM (DFI) Water Temperature Sensor (Fault Code 14) Sensor Resistance Inspection • Remove the water temperature sensor (see this section). • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion and threaded portion are submerged.
FUEL SYSTEM (DFI) 2-93 Atmospheric Pressure Sensor (Fault Code 15) Removal CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank section in this chap- ter).
Page 164: Output Voltage Inspection
Remove the needle adapters. • Apply silicone sealant to the seals of the sensor connector for waterproofing. Silicone Sealant- Kawasaki Bond: 56019-120 Output Voltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following.
Page 165 FUEL SYSTEM (DFI) 2-95 Atmospheric Pressure Sensor (Fault Code 15) If the output voltage is far out of the usable range, remove the fuel tank, and check the output voltage at the sensor connector [A] (when the wiring is open, the output voltage is about 1.8 V).
Page 166 2-96 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Fault Code 15) If you need to check the atmospheric pressure sensor for various altitudes other than sea level, check the output voltage as follows: ○ Determine the local altitude (elevation). If you know the local atmospheric pressure using a barometer, substitude the atmospheric pressure for Pv (Throttle Vacuum) in the vacuum sensor chart (see Vac- uum Sensor section in this chapter).
Page 167 FUEL SYSTEM (DFI) 2-97 Atmospheric Pressure Sensor (Fault Code 15) H: Altitude (m or feet) SL: Sea Level (0 m) ST: Standard of Sensor Output Voltage (v) UR: Usable Range of Sensor Output Voltage (v) Va: Atmospheric Pressure Sensor Output Voltage (v)
2-98 FUEL SYSTEM (DFI) Pickup Coils (#1, #2: Fault Code 21, 22) Pickup Coil #1: for Front Cylinder (Fault Code 21) Pickup Coil #2: for Rear Cylinder (Fault Code 22) Pickup Coil Removal/Installation • See Ignition System section in Electrical System chapter. Pickup Coil Inspection ○...
Page 169: Vehicle-Down Sensor (Fault Code 31)
FUEL SYSTEM (DFI) 2-99 Vehicle-down Sensor (Fault Code 31) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the motorcycle banks (40 ∼ 50°) or more to either side (in fact falls down), the weight turns and shuts off the signal.
Page 170: Installation
2-100 FUEL SYSTEM (DFI) Vehicle-down Sensor (Fault Code 31) • Remove the screw [B] and take out the vehicle-down sen- sor [A]. • Raise the lock, and disconnect the connector to complete sensor removal. Installation • Install the vehicle-down sensor assy [A] so that the sensor connector [B] faces backward.
Page 171 Remove the needle adapters, and apply silicone sealant to the seals of the vehicle-down sensor connector for wa- terproofing. Silicone Sealant- Kawasaki Bond: 56019-120 If the output voltage is normal, the wiring is suspect. Check the wiring. If the wiring is good, check the ECU for its ground and power supply (see this chapter).
Page 172 2-102 FUEL SYSTEM (DFI) Vehicle-down Sensor (Fault Code 31) →: Signal ECU [A] Junction Box [F] Ignition Switch [N] Starter Relay [O] Main Fuse 30 A [P] Battery [Q] Vehicle-down Sensor [d] Ignition Fuse 10 A [f]...
FUEL SYSTEM (DFI) 2-103 Fuel Injectors (#1, #2: Fault Code 41, 42) Fuel Injector #1: Front Fuel Injector for Front Cylinder (Fault Code 41) Fuel Injector #2: Rear Fuel Injector for Rear Cylinder (Fault Code 42) CAUTION Never drop the injector, especially on a hard sur- face.
Page 174: Injector Installation
2-104 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Fault Code 41, 42) ○ The screen [A] comes off from the pressure regulator [B]. Delivery Joint [C] Front [D] • Clean the screen with high-flash point solvent to remove any particles. WARNING Clean the screen in a well-ventilated area, and take care that there is no spark or flame anywhere near...
Page 175 FUEL SYSTEM (DFI) 2-105 Fuel Injectors (#1, #2: Fault Code 41, 42) • Check that there is no dirt or dust on the injector seating surface [A] of the inlet manifold [B]. • Check that the two dowel pins are in place in the inlet manifold.
Page 176: Power Source Voltage Inspection
2-106 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Fault Code 41, 42) • Connect: Front Injector Connector [A] (BL/R, W/R leads) Rear Injector Connector [B] (BL/G, W/R leads) Fuel Hose [C] to Delivery Joint [D] Vacuum Hose [E] to T-Joint [F] Front [G] •...
Page 177: Output Voltage Inspection
FUEL SYSTEM (DFI) 2-107 Fuel Injectors (#1, #2: Fault Code 41, 42) If the reading is normal, remove the fuel tank, and check the power source voltage at the injector connector [A], using the needle adapter [B]. • Measure the power source voltage with the engine stopped, and the connector joined, using a digital meter.
Page 178: Audible Inspection
2-108 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Fault Code 41, 42) If the output voltage is out of the standard, remove the fuel tank, and check the output voltage at the injector connec- tor [A], using the needle adapter [B] (when the wiring is open, the output voltage is 0 V).
Page 179: Injector Signal Test
FUEL SYSTEM (DFI) 2-109 Fuel Injectors (#1, #2: Fault Code 41, 42) Injector Signal Test • Prepare two test light sets with terminals as shown. Rating of Bulb [A]: 12 V × 3 ∼ 3.4 W Terminal (Width × Thickness) [B]: 1.8 × 0.8 mm (0.07 × 0.03 in.) CAUTION Do not use larger terminals than specified above.
Page 180: Injector Unit Test
2-110 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Fault Code 41, 42) Injector Unit Test • Use two wires [A] and the same test light set [B] as in "Injector Signal Test". Rating of Bulb [C]: 12 V × (3 ∼ 3.4) W 12 V Battery [D] CAUTION Be sure to connect the bulb in series.
Page 181 FUEL SYSTEM (DFI) 2-111 Fuel Injectors (#1, #2: Fault Code 41, 42) →: Signal ECU [A] Junction Box [F] Ignition Switch [N] Starter Relay [O] Main Fuse 30 A [P] Battery [Q] Fuel Injector #1 [R] Fuel Injector #2 [S] DFI Fuse 15 A [V] DFI Main Relay [e] Ignition Fuse 10 A [f]...
Page 182: In-Tank Fuel Pump (Fault Code 45)
2-112 FUEL SYSTEM (DFI) In-tank Fuel Pump (Fault Code 45) Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions.
Page 183: Fuel Filter Cleaning
FUEL SYSTEM (DFI) 2-113 In-tank Fuel Pump (Fault Code 45) Fuel Filter Cleaning ○ The fuel filter cannot be cleaned or checked. If the fuel filter is suspected of clogging or being damaged, replace it with the fuel pump as a set. Fuel Pump Installation •...
Page 184: Operation Inspection
2-114 FUEL SYSTEM (DFI) In-tank Fuel Pump (Fault Code 45) • Secure the fuel level sensor leads [A], and fuel pump leads [B] on the fuel tank [C] with the welded clamps [D]. Front [E] • Install the fuel tank (see this chapter). Operation Inspection NOTE ○...
Page 185: Power Source Voltage Inspection
FUEL SYSTEM (DFI) 2-115 In-tank Fuel Pump (Fault Code 45) • Remove the fuel tank bolt and nut (see Fuel Tank Re- moval in this chapter). • Raise the fuel tank [A] and take out the fuel pump con- nector [B]. •...
Page 186 Wiring for Fuel Pump Power Source (see next diagram) Vehicle-down Sensor (see this chapter) • After inspection, remove the needle adapter, and apply silicone sealant to the seal of the fuel pump connector for waterproofing. Silicone Sealant- Kawasaki Bond: 56019-120...
Page 187 FUEL SYSTEM (DFI) 2-117 In-tank Fuel Pump (Fault Code 45) →: Signal ECU [A] Junction Box [F] Ignition Switch [N] Starter Relay [O] Main Fuse 30 A [P] Battery [Q] In-tank Fuel Pump [U] DFI Fuse 15 A [V] DFI Main Relay [e] Ignition Fuse 10 A [f]...
2-118 FUEL SYSTEM (DFI) Ignition Coils (#1, #2: Fault Code 51, 52) Ignition Coil #1: Ignition Coil for Front Cylinder (Fault Code 51) Ignition Coil #2: Ignition Coil for Rear Cylinder (Fault Code 52) Removal/Installation CAUTION Never drop the ignition coils, especially on a hard surface.
Page 189 FUEL SYSTEM (DFI) 2-119 Ignition Coils (#1, #2: Fault Code 51, 52) →: Signal ECU [A] Engine Stop Switch [B] Ignition Coils [D] Ignition Switch [N] Starter Relay [O] Main Fuse 30 A [P] Battery [Q] Junction Box [F] Ignition Fuse 10 A [f]...
Page 191 COOLING SYSTEM 3-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... 3-10 Cooling System Flushing ....................3-11 Water Pump..........................3-12 Water Pump Removal .......................
3-4 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 as coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
Page 195 COOLING SYSTEM 3-5 Coolant Flow Chart 1. Water Pump 2. Water Jacket 3. Cylinder Head 4. Water Pipe 5. Water Hose 6. Radiator Cap 7. Thermostat 8. Reserve Tank Hose 9. Radiator 10. Radiator Fan 11. Throttle Assy 12. Front 13.
Page 196: Specifications
Valve Opening Temperature Valve Full Opening Lift 8 mm (0.031 in.) or more @75°C (167°F) Special Tools - Bearing Driver Set: 57001-1129 Bearing Remover Shaft: 57001-1265 Bearing Remover Head, 10 × 12: 57001-1266 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
Page 197: Coolant
COOLING SYSTEM 3-7 Coolant Coolant Deterioration Inspection • Remove the right side cover (see Frame chapter). • Visually inspect the coolant [A] in the reserve tank. 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.
Page 198: Coolant Filling
3-8 COOLING SYSTEM Coolant • Place a container under the radiator drain bolt [A], then remove the drain bolt (front view). • Remove the fuel tank (see Fuel System chapter). • Remove the radiator cap [A] in two steps. First turn the cap counterclockwise to the first stop.
Page 199 COOLING SYSTEM 3-9 Coolant Water and Coolant Mixture Ratio (when shipping) Soft Water : 50% Coolant : 50% Freezing Point : − 35°C (− 31°F) : 2.3 L (2.43 US gt) Total Amount • Tighten the drain bolts. Torque - Radiator Drain Bolt: 7.4 N·m (0.75 kgf·m, 65 in·lb) Water Pump Drain Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
Page 200: Pressure Testing
3-10 COOLING SYSTEM Coolant • Fill the reserve tank up to the "F" (full) level line [A] with coolant and install the cap. • Install the fuel tank (see Fuel System chapter). • Start the engine and warm it up thoroughly until the radi- ator fan turns on and then stop the engine.
Page 201: Cooling System Flushing
COOLING SYSTEM 3-11 Coolant Cooling System Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passage and considerably reduce the effi- ciency of the cooling system.
Page 202: Water Pump
3-12 COOLING SYSTEM Water Pump Water Pump Removal • Drain the coolant (see Coolant Draining). • Remove: Water Hose Clamp [A] Water Hose [B] Front [C] • Remove: Water Pump Cover Bolts [A] Water Pump Cover [B] • Remove: Impeller Bolt [A] Impeller [B] NOTE ○...
Page 203: Water Pump Inspection
COOLING SYSTEM 3-13 Water Pump Water Pump Inspection • Check the water pump drainage outlet hose [A] at the bottom of the water pump for coolant leakage. If the mechanical seal is damaged, the coolant leaks through the seal and drain through the passage. Replace the mechanical seal.
Page 204 3-14 COOLING SYSTEM Water Pump • Using a thin-bladed screwdriver, pry out the oil seal. • Press out the mechanical seal [A] and ball bearing [B] from the inside of the right crankcase with the bearing driver set [C]. Special Tool - Bearing Driver Set: 57001-1129 ○...
Page 205: Radiator
COOLING SYSTEM 3-15 Radiator WARNING The radiator fan is connected directly to the bat- tery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DIS- CONNECTED. TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES.
Page 206: Radiator Inspection
3-16 COOLING SYSTEM Radiator Radiator Inspection • Check the radiator core. 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 de- formed fins, replace the radiator with a new one.
Page 207: Radiator Filler Neck Inspection
COOLING SYSTEM 3-17 Radiator Radiator Filler Neck Inspection • Remove the radiator cap. • Check the radiator filler neck for signs of damage. • Check the condition of the top and bottom sealing seats [A] in the filler neck. They must be smooth and clean for the radiator cap to function properly.
Page 208: Thermostat
3-18 COOLING SYSTEM Thermostat Thermostat Removal • Remove: Coolant: Drain about 200 mL Fuel Tank (see Fuel System chapter) Four Water Hoses [A] Bracket Bolts [B] Water Temperature Sensor Connector • Remove the thermostat housing [C] along with the bracket. Front [D] •...
Page 209: Hoses And Pipes
COOLING SYSTEM 3-19 Hoses and Pipes • Whenever the water hoses are removed or in accordance with the Periodic Maintenance Chart, check the water hoses and their connections. Hose Installation • Install the hoses and pipes being careful to follow bend- ing direction.
Page 213 ENGINE TOP END 4-3 Exploded View 1. Rear Exhaust Pipe T2: 6.9 N·m (0.70 kgf·m, 61 in·lb) 2. Front Exhaust Pipe M: Apply molybdenum disulfide grease. 3. Upper Muffler PN: Spray a penetrating oil on the nuts and 4. Lower Muffler studs if the nuts are difficult to remove.
Page 214 4-4 ENGINE TOP END Exploded View 1. Coolant Drain Bolts T5: 25 N·m (2.5 kgf·m, 18 ft·lb) 2. KACR Unit EO: Apply engine oil. 3. "R" marked side faces up. L: Apply a non-permanent locking agent. 4. "RN" marked side faces up. MO: Apply molybdenum disulfide oil.
Page 215: Exhaust System Identification
ENGINE TOP END 4-5 Exhaust System Identification Exhaust System US: United States US (CAL): United States (California) CA: Canada AU: Australia GB WVTA (Full H): WVTA Model with Honeycomb Catalytic Converter (Full Power) WVTA (Full H): WVTA Model with Honeycomb Catalytic Converter (Left Side, Full Power) Mark and/or Catalyst Position Exhaust Pipe [A] Pre-Muffler Chamber [B]...
Page 216: Specifications
4-6 ENGINE TOP END Specifications Item Standard Service Limit Clean Air System Open → Close 49.3 ∼ 57.3 kPa Vacuum Switch Valve Closing – – – (370 ∼ 430 mm Hg) Pressure: Camshafts Cam Height: 33.48 ∼ 33.60 mm Exhaust 33.38 mm (1.314 in.) (1.318 ∼...
Page 217 ENGINE TOP END 4-7 Specifications Item Standard Service Limit Valve Guide Inside Diameter: 7.000 ∼ 7.015 mm Exhaust 7.08 mm (0.2787 in.) (0.2756 ∼ 0.2762 in.) 7.000 ∼ 7.015 mm Inlet 7.08 mm (0.2787 in.) (0.2756 ∼ 0.2762 in.) Valve/valve Guide Clearance (Wobble Method): 0.08 ∼...
Page 218 Valve Seat Cutter, 55° - 35: 57001-1247 Fork Oil Level Gauge: 57001-1290 Piston Ring Compressor Belt, 95 ∼ 108: 57001-1358 Filler Cap Driver: 57001-1454 ○ Compression Gauge Adapter, M12 × 1.25: 57001-1183 can also be used. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
Page 219: Air Suction Valve Removal
ENGINE TOP END 4-9 Clean Air System Air Suction Valve Removal • For rear air suction valve removal, remove the rear ex- haust pipe (see this chapter). • Remove the hose [A]. • Unscrew the mounting bolts [B] and remove the rear air suction valve cover [C].
Page 220: Vacuum Switch Valve Removal
4-10 ENGINE TOP END Clean Air System Vacuum Switch Valve Removal • Remove: Fuel Tank (see Fuel System chapter) • Pull off the hoses [A] and take out the vacuum switch valve [B]. Front [C] Vacuum Switch Valve Installation • Install the vacuum switch valve [A] so that the air hole [B] faces downwards.
Page 221: Clean Air System Hose Inspection
ENGINE TOP END 4-11 Clean Air System • Gradually raise the vacuum (lower the pressure) applied to the vacuum switch valve, and check the valve opera- tion. 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.
Page 222: Camshaft Chain Tensioner
4-12 ENGINE TOP END Camshaft Chain Tensioner Removal CAUTION This is a non-return type cam chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.
Page 223 ENGINE TOP END 4-13 Camshaft Chain Tensioner • Screw in the lockbolt [A] finger-tight to hold the ball bear- ing assy temporarily. • Install the retainer [B]. • Install the tensioner body [A] and tighten the mounting bolts [B] to the specified torque. Torque - Chain Tensioner Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
Page 224: Rocker Case Cover
4-14 ENGINE TOP END Rocker Case Cover Removal • Remove the engine (see Engine Removal/Installation chapter). • Remove the bolts [A] and take off the cover [B] from the rocker case. • Take out the oil filter springs [A] and HLA oil filters [B]. Installation •...
Page 225: Rocker Case
ENGINE TOP END 4-15 Rocker Case Removal • Remove the engine (see Engine Removal/Installation chapter). • Remove the rocker case covers (see this chapter). • Remove the alternator outer cover (see Electrical System chapter). • Remove the timing inspection plug and rotor bolt plug. Special Tool - Filler Cap Driver: 57001-1454 •...
Page 226 Torque - Rocker Shafts: 25 N·m (2.5 kgf·m, 18 ft·lb) • Apply silicone sealant [A] to the rocker case mating sur- face and the outer circumference of the plugs as shown. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 ○ Do not apply silicone sealant around the camshaft bear- ing.
Page 227: Rocker Arm Assembly
ENGINE TOP END 4-17 Rocker Case Rocker Arm Assembly • Prepare a flat-end bar [A] and a block [B] with a recess [C]. • Press the oil chamber [D] for the HLA into the rocker arm end [E] until the chamber end is even with the step [F] of the hole.
Page 228: Hla (Hydraulic Lash Adjuster)
4-18 ENGINE TOP END HLA (Hydraulic Lash Adjuster) HLA Removal • Remove the rocker case (see Rocker Case Removal). • Remove the rocker arms. • Pull the HLA [B] out of the rocker arm [A] with your fingers. CAUTION Be careful not to damage or deform a lash adjuster by tapping it during removal or installation.
Page 229: Camshafts
ENGINE TOP END 4-19 Camshafts Removal • Remove the timing inspection plug and rotor bolt plug. Special Tool - Filler Cap Driver: 57001-1454 • Turn the crankshaft counterclockwise [A] and align the "F" mark [B] (TDC mark for the front piston) with the middle of the notch [C].
Page 230 4-20 ENGINE TOP END Camshafts • Install the KACR on each camshaft. ○ The front and rear KACR are the same except for the spring [A]. ○ The rear KACR has a yellow coating spring. Do not con- fuse the springs. VN1500-N4 ∼...
Page 231 ENGINE TOP END 4-21 Camshafts • Next, install the rear camshaft. ○ Check to be sure that the front camshaft chain timing is correct. ○ Turn the crankshaft counterclockwise [A]. • Align the "R" mark [A] (TDC mark for the rear piston) with the middle of the notch [B] (310°...
Page 232: Camshaft Sprocket Installation
4-22 ENGINE TOP END Camshafts Camshaft Sprocket Installation • Use the sprocket marked F for the front camshaft [A] and the sprocket marked R for the rear camshaft [B]. • Apply a non-permanent locking agent to the camshaft sprocket bolts and tighten them to the specified torque. Torque - Camshaft Sprocket Bolts: 15 N·m (1.5 kgf·m, 11 ft·lb) Camshaft/Rocker Case Wear Inspection...
Page 233: Front Camshaft Chain Removal
ENGINE TOP END 4-23 Camshafts If any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer. Camshaft Journal Diameter ( 25) 24.959 ∼ 24.980 mm Standard: (0.9826 ∼ 0.9835 in.) ( 17) 16.966 ∼ 16.984 mm (0.6680 ∼...
4-24 ENGINE TOP END KACR (Kawasaki Automatic Compression Release) Due to the simplicity of the mechanism, no periodic main- tenance is needed. There are only two symptoms of prob- lems with the KACR mechanism [A]; compression is not re- leased during starting, and compression is released during running.
Page 235 ENGINE TOP END 4-25 KACR (Kawasaki Automatic Compression Release) VN1500-N4 ∼ Rear KACR unit [F] ○ The cylinder compression is released while the engine is running (abnormal): the pin [A] stays out the cam [B] and pushes up the exhaust rocker arm.
Page 236: Cylinder Head
4-26 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○ Be sure the battery is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove one spark plug and attach the compression gauge and adapter firmly into the spark plug hole. Do not remove the other spark plug, only the plug lead.
Page 237: Removal
ENGINE TOP END 4-27 Cylinder Head The following table should be consulted if the obtainable compression reading is not within the us- able range. Problem Diagnosis Remedy (Action) Carbon buildup on piston and in combustion chamber possibly due to damaged valve stem, Remove the carbon deposits and valve guide, stem oil seal and/or damaged replace damaged parts if necessary.
Page 238: Installation
4-28 ENGINE TOP END Cylinder Head Installation ○ The front cylinder head [A] has an F mark while the rear cylinder head [B] has an R mark. Be careful not to mix them up. Front [C] CAUTION The cylinder head and rocker case are machined in the assembled state, so they must be used as a set.
Page 239: Valves
ENGINE TOP END 4-29 Valves Valve Clearance Adjustment NOTE ○ Since the hydraulic lash adjusters constantly maintain zero clearance, it is not necessary to inspect or adjust the valve clearance. Valve Removal • Remove the cylinder head (see this chapter). •...
Page 240: Valve Guide Installation
4-30 ENGINE TOP END Valves Valve Guide Installation • Apply oil to the valve guide outer surface before installa- tion. • Heat the area around the valve guide hole to about 120 ∼ 150°C (248 ∼ 302°F) (see Valve Guide Removal). •...
Page 241: Valve Seat Inspection
ENGINE TOP END 4-31 Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • 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 with vernier calipers.
Page 242 4-32 ENGINE TOP END 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 dia- mond particles may fall off.
Page 243 ENGINE TOP END 4-33 Valves • Measure the outside diameter of the seating surface with vernier calipers. 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 ○...
Page 244 4-34 ENGINE TOP END Valves • Lap the valve to the seat, once the seat width and outside diameter 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. ○...
Page 245 ENGINE TOP END 4-35 Valves...
Page 246: Cylinders, Piston
4-36 ENGINE TOP END Cylinders, Piston Cylinder Removal • Remove the cylinder head (see Cylinder Head Removal). • Pull out the front camshaft chain guide [A]. • Remove the cylinder nuts [B]. • Tap lightly up the cylinder with a plastic mallet to separate from the crankcase.
Page 247 ENGINE TOP END 4-37 Cylinders, Piston ○ The front chain guide for the front cylinder has an F mark [A] and the front chain guide for the rear cylinder has an R mark [B]. Be careful not to mix up these chain guides since the front chain guide for the rear cylinder is longer.
Page 248: Cylinder Wear Inspection
4-38 ENGINE TOP END Cylinders, Piston • Face the "Arrow" mark [A] on each piston toward the ex- haust side [B]. ○ The front and rear pistons are the same. Front [C] CAUTION Incorrect installation of the piston could cause pis- ton seizure and result in severe engine damage.
Page 249: Piston Wear Inspection
ENGINE TOP END 4-39 Cylinders, Piston Piston Wear Inspection • Measure the outside diameter [A] of each piston 5 mm (0.20 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 pis- ton.
Page 250: Piston Ring, Piston Ring Groove Wear Inspection
4-40 ENGINE TOP END Cylinders, Piston Piston Ring, Piston Ring Groove Wear Inspection • Check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. •...
Page 251: Piston Ring End Gap Inspection
ENGINE TOP END 4-41 Cylinders, Piston Piston Ring End Gap Inspection • Place the piston ring [A] inside the cylinder, using the pis- ton to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. •...
Page 252: Mufflers
4-42 ENGINE TOP END Mufflers WARNING To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cools down. Exhaust Pipe Removal • Loosen the clamp screws [A]. • Detach the upper clamps [B] by sliding them up or for- ward.
Page 253: Lower Muffler Body Removal
ENGINE TOP END 4-43 Mufflers Lower Muffler Body Removal • Remove: Front and Rear Exhaust Pipe Covers (see above) Chamber Flange Nuts [A] Muffler Body Bracket Bolts [B] • Remove the lower muffler body [C]. NOTE ○ If the chamber flange nuts are difficult to remove, spray a penetrating oil on the studs and nuts.
Page 254: Chamber Removal
4-44 ENGINE TOP END Mufflers Chamber Removal • Remove: Front Exhaust Pipe [A] Rear Exhaust Pipe [B] Lower and Upper Mufflers [C] Right and Left Chamber Bolts [D] • Take out the premuffler chamber [E]. Front [F] Chamber Installation • Replace the muffler flange gasket with new ones.
5-2 CLUTCH Exploded View 1. Starter Lockout Switch T9: 147 N·m (15.0 kgf·m, 108 ft·lb) 2. Clutch Slave Cylinder T10: 6.9 N·m (0.70 kgf·m, 61 in·lb) 3. Cup point side faces outside. EO: Apply engine oil. 4. Clutch Spring Holder (VN1500-N4 ∼) L: Apply a non-permanent locking agent.
Page 257: Specifications
CLUTCH 5-3 Specifications Item Standard Service Limit Clutch Fluid Grade DOT 4 (provided when shipping) – – – Clutch Lever Position No. 1 (to suit rider) 5-way adjustable Clutch Lever Free Play Non-adjustable – – – Clutch Clutch Spring Free Height (VN1500-N1 ∼...
Page 258: Clutch Lever
5-4 CLUTCH Clutch Lever The adjuster has 5 positions so that the clutch lever posi- tion can be adjusted to suit the operator's hand. Position Adjustment • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder (front view).
Page 259: Clutch Fluid
CLUTCH 5-5 Clutch Fluid Fluid Level Inspection • Hold the reservoir horizontal. • Check that the brake fluid level of the clutch reservoir is between the lower [A] and the upper [B] level lines. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line in the reservoir.
Page 260: Clutch Line Bleeding
5-6 CLUTCH Clutch Fluid • After changing the fluid, check the clutch for good clutch power and no fluid leakage. If necessary, bleed the air from the lines (see Clutch Line Bleeding). • Remove the clear plastic hose. • Install the reservoir cap. •...
Page 261: Clutch Master Cylinder
CLUTCH 5-7 Clutch Master Cylinder Clutch Master Cylinder Removal • Disconnect the starter lockout switch connector [A] (front view). • Draw out the clutch fluid from the reservoir with a means like the fork oil level gauge. • Remove the banjo bolt [A] to disconnect the clutch hose from the master cylinder (rear view).
Page 262: Clutch Master Cylinder Disassembly
5-8 CLUTCH Clutch Master Cylinder Clutch Master Cylinder Disassembly • Remove the master cylinder. • Remove the reservoir cap [A] and diaphragm [B], and pour the clutch fluid into a container. • Unscrew the locknut [C] and pivot bolt [D], and remove the clutch lever [E].
Page 263: Clutch Master Cylinder Inspection
CLUTCH 5-9 Clutch Master Cylinder Clutch Master Cylinder Inspection • Disassemble the clutch master cylinder. • Check that there are no scratches, rust or pitting on the inside of the master cylinder [A] and on the outside of the piston [B]. If the master cylinder or piston shows any damage, re- place them.
Page 264: Clutch Slave Cylinder
5-10 CLUTCH Clutch Slave Cylinder Removal • Remove: Alternator Outer Cover (see Electrical System chapter) Banjo Bolt [A] Clutch Slave Cylinder Bolts [B] Slave Cylinder [C] CAUTION Immediately wash away any clutch fluid that spills. It may damage painted surfaces. •...
Page 265: Disassembly
CLUTCH 5-11 Clutch Slave Cylinder • Tighten the slave cylinder bolts [A]. Torque - Clutch Slave Cylinder Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb) • Replace the washers on each side of the clutch hose fit- ting with new ones. •...
Page 266: Clutch Cover Removal
5-12 CLUTCH Clutch Clutch Cover Removal • Drain the engine oil (see Engine Lubrication System chapter). • Remove: Front Exhaust Pipe [A] (see Engine Top End chapter) Downtube [B] (see Frame chapter, but remove the down- tube with the right footboard and rear master cylinder left installed) •...
Page 267: Clutch Installation
CLUTCH 5-13 Clutch • Take the inner clutch hub [A], collar [B], washer [C] and clutch housing [D] out of the crankcase. • Pull the needle bearing [A], sleeve [B], and thrust washer [C] off the drive shaft. Clutch Installation When replacing any one of the following parts, check the spring plate free play (see Spring Plate Free Play Mea- surement).
Page 268: Inner Clutch Hub Disassembly
5-14 CLUTCH Clutch • Apply grease to the back torque limiter springs [A] and install them on the spring holder [B] as shown. • Install: Clutch Spring Holder Clutch Spring Clutch Spring Plate VN1500-N4 ∼ • Install the clutch spring holder outer [A], clutch spring [B] and convex direction of outside [C] on the spring holder [D].
Page 269: Spring Plate Free Play Measurement (Vn1500-N1 ~ N3)
CLUTCH 5-15 Clutch • Remove: Retaining Ring [A] Spring Holder [B] Damper Spring [C] Spring Holder [D] Spacer [E] Damper Cam [F] Inner Clutch Hub [G] Spring Plate Free Play Measurement (VN1500-N1 ∼ Insufficient spring plate free play will cause the engine braking effect to be more sudden, resulting in rear wheel hop.
Page 270: Spring Plate Gap Measurement (Vn1500-N4 ~)
5-16 CLUTCH Clutch ∼ Spring Plate Gap Measurement (VN1500-N4 Insufficient spring plate gap will cause the engine brak- ing effect to be more sudden, resulting in rear wheel hop. On the other hand, if the spring plate gap is excessive, the clutch may slip or the clutch lever may feel "spongy"...
Page 271: Spring Plate Free Play/Gap Adjustment
CLUTCH 5-17 Clutch • Remove the clutch spring plate. • Peel off these strips with a thin-bladed screwdriver. • Measure the pressed thickness [A] of each strip with vernier calipers. ○ The thickness represents the spring plate gap. Spring Plate Gap Usable Range: 1.95 ∼...
Page 272: Friction Or Steel Plate Warp Inspection
5-18 CLUTCH Clutch Friction or Steel Plate Warp Inspection • Place each friction plate or steel plate on a surface plate, and measure the gap between the surface plate [A] and each friction plate or steel plate [B] with a thickness gauge [C].
Page 273: Cam Damper Inspection
CLUTCH 5-19 Clutch Cam Damper Inspection • Disassemble the clutch (see Clutch Inner Hub Disassem- bly). • Visually inspect the damper cam [A], damper spring [B], and cam follower [C]. Replace any damaged parts.
Page 275 ENGINE LUBRICATION SYSTEM 6-1 Engine Lubrication System Table of Contents Engine Oil Flow Chart......................Exploded View........................Specifications ......................... Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Change ....................... Oil Screen Cleaning ......................Oil Pump..........................Removal..........................Installation.........................
Page 276: Engine Oil Flow Chart
6-2 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
6-6 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. Oil Level Inspection • Situate the motorcycle so that it is vertical.
Page 281: Engine Oil Change
ENGINE LUBRICATION SYSTEM 6-7 Engine Oil and Oil Filter Engine Oil Change • Situate the motorcycle so that it is vertical after warming up the engine. • Remove the engine oil drain bolt [A] and drain the oil. Front [B] ○...
Page 282: Oil Filter Change
6-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter Oil Filter Change • Drain the engine oil. • Remove the oil filter [A] with the oil filter wrench [B]. Front [C] Special Tool - Oil Filter Wrench: 57001-1249 NOTE ○ The filter has an oil filter bypass valve which can not be removed.
Page 283: Oil Pump
ENGINE LUBRICATION SYSTEM 6-9 Oil Pump Removal • Remove the engine (see Engine Removal/Installation chapter). • Split the crankcase (see Crankshaft/Transmission chap- ter). • Remove the oil pump mounting bolts, and take off the pump [A] out of the right crankcase. •...
Page 284: Oil Hoses And Pipes
6-10 ENGINE LUBRICATION SYSTEM Oil Hoses and Pipes Outside Oil Hose Removal • Remove the engine (see Engine Removal/Installation chapter). • Remove: Rocker Case Cover (see Engine Top End chapter) Oil Hose Flange Bolts [A] on Front and Rear Rocker Cases Oil Hose Banjo Bolt [B] on Right Crankcase behind Rear Cylinder...
Page 285: Inside Oil Pipe Installation
ENGINE LUBRICATION SYSTEM 6-11 Oil Hoses and Pipes • Remove: Oil Pipe Clamp Bolt [A] Oil Pipe Holder Bolt [B] • Remove the inside oil pipe [C] and the oili return pipe [D] from the left crankcase [E]. • Remove the speparator [F]. Inside Oil Pipe Installation •...
Page 286: Blowby Gas System Inspection
6-12 ENGINE LUBRICATION SYSTEM Oil Hoses and Pipes • Install the transmission gears, and then the left inside oil pipe [A] in the left crankcase [B]. • Install: Oil Pipe Clamp Bolts [C] Oil Pipe Holder Bolt [D] Oil Nozzle [E] O-ring [F] •...
Page 287: Oil Reserve Tank Removal
ENGINE LUBRICATION SYSTEM 6-13 Oil Hoses and Pipes Oil Reserve Tank Removal (VN1500-N1 ∼ N2 Models) • Remove: Right and Left Ignition Coils (see Electrical System chap- ter) Thermostat Housing and Bracket (see Cooling System chapter) Sensor Holder with Vacuum Sensor and Atmospheric Pressure Sensor Right Air Cleaner Housing (see Fuel System chapter) Oil Reserve Tank Hose End from Right Air Cleaner Base...
Page 288: Oil Pressure
6-14 ENGINE LUBRICATION SYSTEM Oil Pressure Oil Pressure Measurement NOTE ○ Measure the oil pressure after the engine is warmed up. • Remove the oil pressure switch lead and unscrew the oil pressure switch [A]. • Attach the oil pressure gauge [B] and adapter [C] to the switch hole.
Page 289 ENGINE LUBRICATION SYSTEM 6-15 Oil Pressure 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 in a well-ventilated area. ○...
7-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Removal • Support the rear part of the frame on the jack [A], and the attachment jack [C]. Front [B] Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398 • Squeeze the brake lever slowly and hold it with a band [A].
Page 295 ENGINE REMOVAL/INSTALLATION 7-5 Engine Removal/Installation • Disconnect: Bands [A] Rear Brake Light Switch Connector [B] Radiator Fan Motor Connector [C] Front [D] • Remove: Radiator (see Cooling System chapter) Front and Rear Shift Pedals (see Crankshaft/Transmis- sion chapter) Alternator Outer Cover (see Electrical System chapter) •...
Page 296: Engine Installation
7-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Support the engine with a commercially available stand [A]. • Remove: Front and Rear Exhaust Pipes (see Engine Top End chapter) Engine Mounting Bracket Bolts [B] Downtube Bolts [C] • Remove the downtube [A] with the right footboard and rear master cylinder installed.
Page 297 ENGINE REMOVAL/INSTALLATION 7-7 Engine Removal/Installation • Apply a thin coat of high temperature grease to the driven gear joint and to the propeller shaft joint. • Push on the lockpin [A] and move back the engine to en- gage the front bevel gear joint with the propeller shaft joint.
Page 298 7-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Install the removed parts (see appropriate chapters). • Adjust the throttle cables (see Fuel System chapter). • Fill the engine with engine oil (see Engine Lubrication System chapter). • Fill the engine with coolant and bleed the air from the cooling system (see Cooling System chapter).
Page 301 T8: 85 N·m (8.7 kgf·m, 63 ft·lb) EO: Apply engine oil. L: Apply a non-permanent locking agent. LG: Apply liquid gasket (Kawasaki Bond: 92104-1003). Lh: Left-hand Threads MO: Apply molybdenum disulfide oil. The molybdenum disulfide oil is a mixture of engine oil and molybdenum disulfide grease with a weight ratio (10 : 1).
Page 302 8-4 CRANKSHAFT/TRANSMISSION Exploded View 1. Each bolt head is numbered 10. 2. Align the punch marks. 3. Align the punch mark with the slit. T1: 9.8 N·m (1.0 kgf·m, 87 in·lb) T2: 17 N·m (1.7 kgf·m, 12 ft·lb) T3: 2.9 N·m (0.30 kgf·m, 26 in·lb) T4: 20 N·m (2.0 kgf·m, 14 ft·lb) 39 N·m (4.0 kgf·m, 29 ft·lb) (Bolt with punch mark) T5: 7.8 N·m (0.80 kgf·m, 69 in·lb)
Page 303 CRANKSHAFT/TRANSMISSION 8-5 Exploded View A: VN1500-N3 Model ∼ 1. Drive Shaft 2. Output Shaft T1: 196 N·m (20.0 kgf·m, 145 ft·lb) EO: Apply engine oil. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil. The molybdenum disulfide oil is a mixture of engine oil and molybdenum disulfide grease with a weight ratio (10 : 1).
Page 304: Specifications
8-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods Connecting Rod Bend – – – TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist – – – TIR 0.2/100 mm (0.008/3.94 in.) 0.16 ∼ 0.46 mm Connecting Rod Big End Side Clearance 0.7 mm (0.0063 ∼...
8-8 CRANKSHAFT/TRANSMISSION Crankcase Disassembly • Remove: Engine (see Engine Removal/Installation chapter) Cylinder Blocks (see Engine Top End chapter) Pistons (see Engine Top End chapter) Clutch (see Clutch chapter) Front Gear Case (see Final Drive chapter) Alternator Inner Cover (see Electrical System chapter) •...
Page 307 CRANKSHAFT/TRANSMISSION 8-9 Crankcase • Remove the following parts from the right end of the bal- ancer shaft. Starter Clutch Bolt [A] Washer [B] Collar [C] Needle Bearing [D] Copper Washer [E] Starter Clutch [F] • Loosen the primary gear bolt [A] while holding the alter- nator rotor steady with the flywheel holder (special tool) (The primary gear can be removed with the engine in the frame).
Page 308 8-10 CRANKSHAFT/TRANSMISSION Crankcase • Remove the idle shaft holder [A] and chain guide [B] from the right crankcase (The idle shaft holder can be removed with the engine in the frame). • Remove the primary gear bolt [A] and take out the water pump drive sprocket [B] and idle shaft sprocket [C] as a set.
Page 309: Assembly
CRANKSHAFT/TRANSMISSION 8-11 Crankcase • Remove the right crankcase bolts. 8 mm Bolts (5) [A] ○ Be sure to remove this bolt [B] • Remove all the left crankcase bolts in the order listed. 6 mm Bolts (14) [A] 8 mm Bolt (1) [B] 10 mm Bolts (3) [C] •...
Page 310 8-12 CRANKSHAFT/TRANSMISSION Crankcase • Support the crankcase bearing boss with a suitable re- tainer [A]. • Using a press and the bearing driver set [C], install a new bearing [B] by pushing the bearing outer race until it bot- toms out. Special Tool - Bearing Driver Set: 57001-1129 CAUTION Support the crankcase bearing boss when pushing...
Page 311 CRANKSHAFT/TRANSMISSION 8-13 Crankcase • Install the transmission assy as a set (see Transmission Installation). • Set the gear set lever to the neutral position. Shift Drum Cam [A] Gear Set Lever [B] Neutral Position [C] • Apply engine oil to the transmission gears, ball bearings, shift drum, and crankshaft main bearing.
Page 312 Oil Return Pipe [D] ○ Apply liquid gasket [A] to the mating surface of the right crankcase. Sealant - Kawasaki Bond (Liquid Gasket - Black): 92104 -1003 ○ Also, apply liquid gasket [A] to the right crankcase mating surface around the hole of the oil screen.
Page 313 CRANKSHAFT/TRANSMISSION 8-15 Crankcase • After tightening all the crankcase bolts, check the follow- ing items. ○ Turn the right crankcase down, and check that the drive shaft and output shaft turn freely. ○ Check that the positive neutral finder operates properly: While spinning the output shaft using an air impact wrench, gears shift smoothly from the 1st, 2nd ·...
Page 314 8-16 CRANKSHAFT/TRANSMISSION Crankcase • Install the crankshaft balancer gear [A] while fitting the alignment notch of the splines onto the alignment tooth. • Install the left balancer [B] while aligning the balancer gear marks (line mark) [C] with the front piston on its top dead center.
Page 315 CRANKSHAFT/TRANSMISSION 8-17 Crankcase ○ Install: Water Pump Idle Shaft Idle Shaft Sprocket [A] Water Pump Drive Sprocket [B] and Chain [C] Washer [D] ○ Install two pins into the water pump idle shaft. ○ Fit the pins into the slots of the idle shaft drive sprocket boss.
Page 316: Crankshaft/Connecting Rods
8-18 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods Connecting Rod Removal • Remove the crankshaft. • Remove the connecting rod big end nuts, and take off the rod and cap along with the bearing inserts from the crankshaft [A]. NOTE ○ Mark and record the locations of the connecting rods [B] and their big end caps [C] with the bearing inserts left attached so that they can be installed in their original positions.
Page 317: Crankshaft/Connecting Rod Cleaning
CRANKSHAFT/TRANSMISSION 8-19 Crankshaft/Connecting Rods ○ When installing the inserts [A], be careful not to damage the insert surface with the edge of the connecting rod [B] or the cap [C]. One way to install inserts is as follows: Installation [D] to Cap Installation [E] to Connecting Rod Push [F] Dowel Pin [G]...
Page 318: Connecting Rod Big End Side Clearance Inspection
8-20 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods Connecting Rod Big End Side Clearance Inspection • Measure the side clearance [B] of the connecting rod big end [A]. ○ Insert a thickness gauge between the big end and either crank web to determine clearance. Connecting Rod Big End Side Clearance 0.16 ∼...
Page 319 CRANKSHAFT/TRANSMISSION 8-21 Crankshaft/Connecting Rods If the clearance exceeds the service limit, measure the diameter of the crankpin [A]. Crankpin Diameter 54.981 ∼ 55.000 mm (2.1646 ∼ 2.1650 in.) Standard: Service Limit: 54.97 mm (2.164 in.) If the crankpin has worn past the service limit, replace the crankshaft with a new one.
Page 320: Crankshaft Runout Inspection
8-22 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods Crankshaft Runout Inspection • Measure the crankshaft runout. If the measurement exceeds the service limit, replace the crankshaft. Crankshaft Runout Standard: TIR 0.02 mm (0.0008 in.) Service Limit: TIR 0.05 mm (0.002 in.) Crankshaft Main Bearing/Journal Wear Inspection •...
Page 321: Starter Clutch
CRANKSHAFT/TRANSMISSION 8-23 Starter Clutch Removal • Remove the clutch cover (see Clutch chapter). • Unscrew the starter clutch bolt [A] while holding the pri- mary gear bolt [B]. • Pull the starter clutch gear and starter clutch along with the right balancer as a set off the balancer shaft. •...
Page 322: Assembly
8-24 CRANKSHAFT/TRANSMISSION Starter Clutch • Pull the coupling [A] out of the right balancer [B]. • Take the one-way clutch [C] out of the coupling. Starter Clutch Gear [D] (for reference) Assembly • Install the one way clutch [A] so that its groove [B] faces outward and its flange [C] fits between the right balancer [D] and the coupling [E].
Page 323: Starter Torque Limiter
CRANKSHAFT/TRANSMISSION 8-25 Starter Torque Limiter Removal • Remove the clutch cover (see Clutch chapter). • Remove the starter clutch gear [A]. • Pull the torque limiter [B] out of the right crankcase. CAUTION Do not disassemble the torque limiter. The torque limiter will be damaged.
Page 324: Water Pump Idle Shaft Holder
8-26 CRANKSHAFT/TRANSMISSION Water Pump Idle Shaft Holder Removal • Remove the clutch cover (see Clutch chapter). • Remove: Starter Clutch Gear (see Starter Clutch Removal) Starter Torque Limiter (see Starter Torque Limiter Re- moval) • Take the end of the spring [A] off the hook. •...
Page 325: Primary Gear
CRANKSHAFT/TRANSMISSION 8-27 Primary Gear Removal • Remove: Clutch Cover (see Clutch chapter) Starter Clutch Gear (see Starter Clutch Removal) Starter Torque Limiter (see Starter Torque Limiter Re- moval) Clutch (see Clutch chapter) • Remove the water pump chain guide [A] and water pump idle shaft holder [B] from the right crankcase.
Page 326: Transmission
8-28 CRANKSHAFT/TRANSMISSION Transmission Shift Pedal Removal • Unscrew the footboard bracket bolts [A] and take off the left front footboad [B]. Front [C] • Unscrew the clamp bolt [A] and pull out the rear shift pedal [B]. • Unscrew the clamp bolt [C] and pull out the front shift pedal [D].
Page 327: External Shift Mechanism Installation
CRANKSHAFT/TRANSMISSION 8-29 Transmission • Remove the shift shaft [A] while pushing [B] the shift mechanism arm [C] towards the shift shaft. • Unscrew the bolt and remove the gear set lever [D] and its spring. External Shift Mechanism Installation • Install the gear set lever [A] and the spring [B] in the crankcase and tighten the bolt [C].
Page 328: Transmission Removal
8-30 CRANKSHAFT/TRANSMISSION Transmission • Check the return spring pin [A] is not loose. If it is loose, unscrew it, apply a non-permanent locking agent to the threads, and tighten it. Torque - Shift Shaft Return Spring Pin: 20 N·m (2.0 kgf·m, 14 ft·lb) Shift Shaft Return Spring Pin: 39 N·m (4.0 kgf·m, 29 ft·lb) (bolt with punch mark)
Page 329: Transmission Installation
CRANKSHAFT/TRANSMISSION 8-31 Transmission Transmission Installation • Install the drive and output shaft assy, shift drum, and output shaft 5th gear shift fork as a set. Drive Shaft Assy [A] Output Shaft Assy [B] Shift Fork (Drive, 3rd Gear) and Shift Drum Assy [C] Shift Fork (Output, 5th Gear) [D] ○...
Page 330: Transmission Disassembly
8-32 CRANKSHAFT/TRANSMISSION Transmission • Disassemble the shift drum assy as shown. Pin Plate [A] Pin [B] Cam [C] Bearing [D] Shift Drum [E] Drive Shaft Shift Fork (No-268) [F] Cotter Pin [G] • Apply a non-permanent locking agent to the threads of the shift drum cam screw [H].
Page 331 CRANKSHAFT/TRANSMISSION 8-33 Transmission • Replace any circlip [A] that were removed with new ones. • Install the circlips so that the opening [B] is aligned with a spline groove [C]. Drive Shaft: (VN1500-N1∼ N2) • Align gear oil holes with the shaft holes [A]. 1.
CRANKSHAFT/TRANSMISSION 8-37 Transmission Shift Fork Guide Pin/Drum Groove Wear Inspection • Measure the diameter of each shift fork guide pin [A], and 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.
Page 336: Ball Bearing, Needle Bearing, And Oil Seal
8-38 CRANKSHAFT/TRANSMISSION Ball Bearing, Needle Bearing, and Oil Seal Ball Bearing and Outer Race Replacement CAUTION Do not remove the ball bearing or needle bearing outer race unless it is necessary. Removal may damage them. • Using a press or puller, remove the ball bearing and/or needle bearing outer race.
Page 337: Oil Seal Inspection
CRANKSHAFT/TRANSMISSION 8-39 Ball Bearing, Needle Bearing, and Oil Seal Oil Seal Inspection • Inspect the oil seal. Replace it if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened or otherwise damaged.
WHEELS/TIRES 9-3 Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Front/Rear Axial TIR 0.8 mm (0.031 in.) or less (with tire TIR 2.0 mm (0.08 in.) installed) Radial TIR 0.8 mm (0.031 in.) or less (with tire TIR 1.5 mm (0.06 in.) installed) Rim Size: Front...
Page 342: Front Wheel Removal
9-4 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove the brake caliper [A] with the hoses installed (see Brakes chapter). • Remove the front axle nut [B]. Front [C] • Loosen: Front Axle Clamp Bolt [A] Front [B] ○ Using the jack [A] and attachment jack [B] under the frame pipe ribs [C], and a commercially available jack [D] under the engine [E], lift the front wheel [F] OFF the ground until the rear wheel [G] touches the ground.
Page 343: Front Wheel Installation
WHEELS/TIRES 9-5 Wheels (Rims) Front Wheel Installation • Fit the shorter collar [A] on the left side and the longer collar [B] on the right side of the hub. Front [C] • Insert the axle from the right side of the wheel. •...
Page 344: Rear Wheel Installation
9-6 WHEELS/TIRES Wheels (Rims) • Remove: Muffler Bodies [A] (see Engine Top End chapter) Rear Fender [B] (see Frame chapter) • Remove: Rear Caliper Mounting Bolts [A] Rear Caliper [B] Caliper Holder Bolt [C] Axle Nut Cotter Pin [D] Axle Nut [E] Front [F] •...
Page 345: Wheel Coupling Removal
WHEELS/TIRES 9-7 Wheels (Rims) • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axel, tighten the nut clockwise [B] up to next alignment. ○...
Page 346: Spoke Tightness Inspection
9-8 WHEELS/TIRES Wheels (Rims) Spoke Tightness Inspection • Check that all the spokes are tightened evenly. If spoke tightness is uneven or loose, tighten the spoke nipples evenly. Torque - Spoke Nipples: 2.9 ∼ 7.4 N·m (0.30 ∼ 0.75 kgf·m, 26 ∼...
Page 347: Axle Inspection
WHEELS/TIRES 9-9 Wheels (Rims) Axle Inspection • Visually inspect the front and rear axles for damage. If the axle is damaged or bent, replace it. • Place the axle on V blocks that are 100 mm [A] apart, and set a dial gauge [B] on the axle at a point halfway between the blocks.
Page 348 41075-1009/41075-0013 30 (1.05 oz) NOTE ○ Balance weights are available from Kawasaki Dealers in 10, 20, and 30 gram (0.35, 0.70 and 1.05 ounce) sizes. An imbalance of less than 10 grams (0.35 ounce) will not usually affect running stability.
Page 349: Tires
WHEELS/TIRES 9-11 Tires Air Pressure Inspection/Adjustment • Measure the tire air pressure with an air pressure gauge [A] (Owner's Tool: 52005-1142) when the tires are cold: when the motorcycle has not been ridden more than a mile during the past 3 hours. Adjust the tire air pressure if necessary.
Page 350: Tire Removal
9-12 WHEELS/TIRES Tires Tire Removal • Remove the following. Wheel (see Front and Rear Wheel Removal) Brake Disc Valve Cap and Valve Core (let out the air) Valve Stem Nut • To maintain wheel balance, mark the air valve position on the tire with chalk so that the tire can be reinstalled in the same position.
Page 351 WHEELS/TIRES 9-13 Tires • Insert the valve of the rear tube in the rear rim. Torque - Tire Air Valve Stem Nuts: 1.5 N·m (0.15 kgf·m, 13 in·lb) Valve Cap [A] Valve Stem [B] Rim Band [C] Rear Tube [D] Rear Rim [E] •...
Page 352 9-14 WHEELS/TIRES Tires • Check to see that the bead lines [A] on both sides of the tire sidewalls are parallel with the rim flanges [B]. If the rim flanges and tire sidewall bead lines are not par- allel, remove the valve core. •...
Page 353: Hub Bearings (Wheel Bearings)
WHEELS/TIRES 9-15 Hub Bearings (Wheel Bearings) Removal • Remove the wheel, and take out the following. Collars Grease Seals [A] Circlips [B] Coupling [C] (out of rear hub) Front Hub [D] Rear Hub [E] Special Tool - Inside Circlip Pliers: 57001-143 •...
Page 354: Inspection
9-16 WHEELS/TIRES Hub Bearings (Wheel Bearings) • Replace the grease seals with new ones. • Press in the grease seals [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] Inspection ○...
Page 355 FINAL DRIVE 10-1 Final Drive Table of Contents Exploded View........10-2 Sliding Joint Inspection ....10-25 Specifications ........10-6 Front Bevel Gears ......10-26 Final Gear Case Oil ......10-7 Front Gear Case Removal ... 10-26 Oil Level Inspection...... 10-7 Front Gear Case Installation ..
Page 358 10-4 FINAL DRIVE Exploded View VN1500-N1 ∼ N3 Final Gear Case 1. Spring Pin L: Apply a non-permanent locking agent. 2. Retainer Stop Screw Lh: Left-hand Threads T1: 8.8 N·m (0.90 kgf·m, 78 in·lb) MO: Apply molybdenum disulfide oil. T2: 34 N·m (3.5 kgf·m, 25 ft·lb), 10 The molybdenum disulfide oil is a mixture T3: 23 N·m (2.3 kgf·m, 17 ft·lb), 8 of engine oil and molybdenum disulfide...
Page 359 FINAL DRIVE 10-5 Exploded View VN1500-N4 ∼ Final Gear Case T1: 8.8 N·m (0.90 kgf·m, 78 in·lb) Lh: Left-hand Threads T2: 34 N·m (3.5 kgf·m, 25 ft·lb), 10 MO: Apply molybdenum disulfide oil. T3: 23 N·m (2.3 kgf·m, 17 ft·lb), 8 The molybdenum disulfide oil is a mixture T4: 127 N·m (13 kgf·m, 94 ft·lb) of engine oil and molybdenum disulfide...
Page 360: Specifications
10-6 FINAL DRIVE Specifications Item Standard Final Gear Case Oil Grade API: GL-5 hypoid gear oil Viscosity When above 5°C (41°F): SAE90 When below 5°C (41°F): SAE80 Oil Level Filler opening bottom Amount 200 mL (6.8 US oz) 0.06 ∼ 0.09 mm (0.0204 ∼ 0.0035 in.) (at gear hub spline) Final Bevel Gear Backlash Propeller Shaft Joint Grease 20 mL (0.68 US oz), high-temperature grease...
Page 361: Oil Level Inspection
FINAL DRIVE 10-7 Final Gear Case Oil Oil Level Inspection • Support the motorcycle perpendicular to the ground. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398 • Unscrew the filler plug [A], using the filler cap driver [B] (special tool). Special Tool - Filler Cap Driver: 57001-1454 ○...
Page 362: Final Gear Case
10-8 FINAL DRIVE Final Gear Case Removal If the final gear case is to be disassembled, drain the final gear case oil. • Remove the rear wheel (see Wheels/Tires chapter). • Remove the left shock absorber [A] from its studs by tak- ing off the nuts.
Page 363 FINAL DRIVE 10-9 Final Gear Case • To remove the ring gear oil seal [A], heat the ring gear assy in an oil bath to 120 ∼ 150°C (248 ∼ 302°F), then pry out the oil seal with an awl or other tool. Be careful not to scratch the sealing surface on the ring gear hub.
Page 364 10-10 FINAL DRIVE Final Gear Case Final Gear Case (VN1500 N1∼ N3) 1. Pinion Gear Nut 2. Washer 3. Pinion Gear Joint 4. O-ring 5. Ring Gear Hub 6. Ring Gear Oil Seal 7. Ball Bearing 8. Final Gear Case Cover 9.
Page 365 FINAL DRIVE 10-11 Final Gear Case Final Gear Case (VN1500-N4 ∼) 1. Pinion Gear Nut 14. Pinion Gear Shim(s) 2. Washer 15. O-ring 3. Shim(s) for Preload 16. Oil Seal 4. Pinion Gear Joint 17. Tapered Roller Bearings 5. O-ring 18.
Page 366: Pinion Gear Removal (Vn1500-N4 )
10-12 FINAL DRIVE Final Gear Case VN1500-N1 ∼ N3 • Remove the retainer stop screw [A] and then unscrew the pinion bearing retainer with the bearing retainer wrench [C], while holding the final gear case with a holder [B]. NOTE ○...
Page 367: Pinion Gear Installation (Vn1500-N4 )
FINAL DRIVE 10-13 Final Gear Case • Drive out the bearing outer race from the pinion gear bear- ing housing [A]. Special Tool - Oil Seal & Bering Remover: 57001-1058 [B] • Drive out the tapered roller bearing [A] in the pinion gear bearing housing [B] and the oil seal [C] using the bearing driver set [D].
Page 368 10-14 FINAL DRIVE Final Gear Case • Insert the pinion gear [A]. ○ Install the pinion gear with the tapered roller bearing as [B] one unit. • Check the O-ring [C] on the pinion gear joint [D] for any kind of damage. Replace it if necessary.
FINAL DRIVE 10-15 Final Gear Case Pinion Gear Bearing Preload Adjustment (VN1500-N4 ∼ Preload Measurement • Check and adjust the bearing preload in the following case. ○ When any of the parts listed below are replaced with new ones. Tapered roller bearings Bevel gears Bearing housing Pinion gear joint...
Page 370 10-16 FINAL DRIVE Final Gear Case Preload Adjustment • To increase preload, decrease the thickness of the size of the shim(s). To decrease preload increase the thickness of the shim(s). • Change the thickness a little at a time. • Re-adjust the bearing preload, and re-adjust if necessary.
Page 371: Assembly
FINAL DRIVE 10-17 Final Gear Case Assembly ○ The ring gear and pinion gear are lapped as a set in the factory to get the best tooth contact. They must be in- stalled as a pair, and never replace one without the other. •...
Page 372: Bevel Gear Inspection
10-18 FINAL DRIVE Final Gear Case VN1500-N1 ∼ N3 • Install the pinion bearing retainer. • Reinstall the original pinion gear shim(s) to keep the gear backlash and the tooth contact unchanged. • Using a holder [B] and bearing retainer wrench [C], tighten the pinion bearing retainer.
Page 373: Final Bevel Gear Adjustment
FINAL DRIVE 10-19 Final Gear Case Final Bevel Gear Adjustment ○ The backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged. • After replacing any of the backlash-related parts, be sure to check and adjust the backlash and tooth contact of the bevel gears.
Page 374: Backlash Adjustment
10-20 FINAL DRIVE Final Gear Case Ring Gear Shims for Backlash Pinion Gear Shims for Tooth Contact Adjustment Adjustment Parts Number Thickness (mm) Parts Number Thickness (mm) VN1500-N1 ∼ N3 VN1500-N4 ∼ 0.15 92025-1783 0.10 92025-1733 – – – 92025-1784 0.15 92025-1734 92180-0009...
Page 375: Tooth Contact Adjustment
FINAL DRIVE 10-21 Final Gear Case • Mount a dial gauge [D] on a vise so that the tip of the gauge is against the splines of the ring gear hub. • To measure the backlash, turn the ring gear hub [B] back and forth [C] while holding the pinion gear steady with the pinion gear holder [A].
Page 376: Bevel Gear Inspection
10-22 FINAL DRIVE Final Gear Case • Turn the pinion gear for one revolution [B] back and forth, while creating a drag on the ring gear hub [A]. VN1500-N4 ∼ • Hold the pinion gear assembly with the final gear case holder [A].
Page 377 FINAL DRIVE 10-23 Final Gear Case Correct Tooth Contact Pattern: No adjustment is required. Heel [A] Bottom [B] Top [C] Toe [D] Incorrect Tooth Contact Patterns (Example 1) ○ Decrease the thickness of the pinion gear shim(s) by 0.05 mm to correct the pattern shown above. Heel [A] Bottom [B] Top [C]...
Page 378: Propeller Shaft
10-24 FINAL DRIVE Propeller Shaft Removal • Remove: Rear Wheel (see Wheels/Tires chapter) Final Gear Case (see this chapter) • Remove the propeller shaft from the front driven gear joint. ○ Turn the propeller shaft so that the lockpin access hole [A] in the propeller shaft comes outside.
Page 379: Propeller Shaft Joint Lubrication
FINAL DRIVE 10-25 Propeller Shaft Propeller Shaft Joint Lubrication • Wipe the old grease off the propeller shaft sliding joint and pinion joint. • Pack the propeller shaft sliding joint with 20 mL (16 grams (0.56 US oz)) of high temperature grease [A]. Propeller Shaft Inspection •...
Page 380: Front Bevel Gears
10-26 FINAL DRIVE Front Bevel Gears Front Gear Case Removal • Remove: Engine (see Engine Removal/Installation chapter) Rear Shift Lever [A] ○ The speed sensor connector [B] is disconnected during engine removal. • Unscrew the front gear case bolts [C] and remove the front gear case [D].
Page 381: Front Gear Case Assembly
FINAL DRIVE 10-27 Front Bevel Gears • Remove the drive gear assy as follows. ○ Pry off the gear case cap [A] with a tool. ○ Pry open the drive gear nut [A] with a small chisel. ○ Install: Damper Spring Cam Follower [B] ○...
Page 382 10-28 FINAL DRIVE Front Bevel Gears • Be sure to check and adjust the bearing preload, the bevel gear backlash, and the tooth contact, when any of the backlash-related parts are replaced (see Front Bevel Gear Adjustment). • After completing all adjustment, reassemble the front gear case.
Page 383: Driven Gear Disassembly
FINAL DRIVE 10-29 Front Bevel Gears Driven Gear Disassembly • Holding the driven gear joint with the driven gear holder [A] in a vise, unscrew the driven gear bolt [B]. Special Tool - Driven Gear Holder, m2: 57001-1027 • Remove the driven gear joint [A] with the O-ring [B]. •...
Page 384: Damper Cam Removal
10-30 FINAL DRIVE Front Bevel Gears Damper Cam Removal • Remove the front gear case (see Front Gear Case Re- moval). • Remove the retainer and needle bearing of the output shaft. • Remove the clutch push rod guide [A] and bolts, and crankcase bearing upper retainer and bolts.
10-32 FINAL DRIVE Front Bevel Gears Preload Adjustment • Install the driven gear assy, and tighten the driven gear nut to the specified torque. Torque - Driven Gear Bolt: 118 N·m (12.0 kgf·m, 87 ft·lb) ○ Do not install the oil seal, and O-ring, and do not stake the bolt until the correct bearing preload is obtained.
Page 387 FINAL DRIVE 10-33 Front Bevel Gears Collars for Preload Adjustment Spacers for Preload Adjustment Length (mm) Part Number Thickness (mm) Part Number 22.8 92027-1152 1.70 92025-1072 22.9 92027-1153 1.72 92025-1073 23.0 92027-1154 1.74 92025-1074 23.1 92027-1155 1.76 92025-1075 23.2 92027-1156 1.78 92025-1076 23.3...
Page 388: Backlash Adjustment
10-34 FINAL DRIVE Front Bevel Gears Backlash Adjustment • Clean any dirt and oil off bevel gear teeth with a high-flash point solvent. • Install the drive gear with the primary shim (1.0 mm (0.04 in.) thickness), and tighten the nut to the specified torque. Torque - Drive Gear Nut: 265 N·m (27.0 kgf·m, 195 ft·lb) NOTE ○...
Page 389: Tooth Contact Adjustment
FINAL DRIVE 10-35 Front Bevel Gears Tooth Contact Adjustment • Clean any dirt and oil off the bevel gear teeth with a high -flash point solvent. • Apply checking compound to 4 or 5 teeth on the driven gear. NOTE ○...
Page 390: Bevel Gear Inspection
10-36 FINAL DRIVE Front Bevel Gears Incorrect Tooth Contact Patterns (Example 1) • Increase the thickness of the drive gear shim(s) by 0.05 mm, and/or increase the thickness of the driven gear shim(s) by 0.05 mm to correct the pattern shown below. Repeat in 0.05 mm steps if necessary.
Page 391: Cam Damper Inspection
FINAL DRIVE 10-37 Front Bevel Gears Cam Damper Inspection • Visually inspect the spring [A], cam follower [B], damper cam [C], and output shaft [D]. Replace the damaged parts.
Page 392: Bearing And Oil Seal
10-38 FINAL DRIVE Bearing and Oil Seal Ball or Needle Bearing Replacement • Using the bearing driver set or the oil seal & bearing re- mover (special tool), remove the bearings. Special Tools - Oil Seal & Bearing Remover: 57001-1058 Bearing Driver Set: 57001-1129 NOTE ○...
Page 393: Ball Bearing Wear
FINAL DRIVE 10-39 Bearing and Oil Seal Ball Bearing Wear CAUTION Do not remove the ball bearings for inspection. Re- moval may damage them. • Check the ball bearings. ○ Since the ball bearings are made to extremely close toler- ances, the wear must be judged by feel rather than mea- surement.
Page 395 BRAKES 11-1 Brakes Table of Contents Exploded View........................11-2 Specifications ......................... 11-4 Brake Lever, Brake Pedal....................... 11-5 Brake Lever Position Adjustment..................11-5 Brake Pedal Position Adjustment..................11-5 Brake Pedal Removal ....................... 11-6 Brake Pedal Installation ....................11-7 Calipers ..........................11-8 Front Caliper Removal ......................
11-4 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position No.1 5-way adjustable Brake Lever Free Play Non-adjustable – – – Pedal Free Play Non-adjustable – – – Pedal Position About 95 mm (3.74 in.) (height from pedal tip –...
Page 399: Brake Lever, Brake Pedal
BRAKES 11-5 Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator's hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder (right side view).
Page 400: Brake Pedal Removal
11-6 BRAKES Brake Lever, Brake Pedal • Remove the right front footboard bracket bolts [A] and turn over the footboard [B]. • Loosen the locknut [A] and turn the push rod with the hex head [B] to achieve the correct pedal position. If the length [C] shown is 8 ±1 mm (0.315 ±0.039 in.), the pedal position will be within the standard range.
Page 401: Brake Pedal Installation
BRAKES 11-7 Brake Lever, Brake Pedal • Detach the front footboard [A], and pull off the brake pedal [B]. Brake Pedal Installation • Apply grease to the brake pedal shaft. • Install the pedal shaft [A] so that the punched mark on the shaft is aligned [B] with the punched mark on the brake lever [C].
Page 402: Calipers
11-8 BRAKES Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B]. Front [C] • Twist [A] the caliper outboard to clear the disc, and then take off the caliper.
Page 403: Caliper Disassembly
BRAKES 11-9 Calipers Caliper Disassembly NOTE ○ The procedure to disassemble the front caliper is as follows. The rear caliper disassembly is the same as for the front caliper. • Remove the caliper (see Caliper Removal) with the hose installed. •...
Page 404: Caliper Piston And Cylinder Damage
11-10 BRAKES Calipers 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] • Replace the rubber boots if they are damaged. •...
Page 405: Rubber Boot/Caliper Holder Shaft Wear
BRAKES 11-11 Calipers Rubber Boot/Caliper Holder Shaft Wear • Check that the rubber boots [F] are not cracked, worn, swollen, or otherwise damaged. If they show any damage, remove the caliper holder and replace the boots. ○ The caliper body must slide smoothly on the caliper holder shafts [G] of the caliper holder [H].
Page 406: Brake Pads
11-12 BRAKES Brake Pads Front Brake Pad Removal • Remove the caliper with the hose installed (see Front Caliper Removal). • Remove: Snap Pin [A] Pad Pin [B] • Remove the jaw side pad [A], and then remove the piston side pad [B].
Page 407: Brake Pad Wear Inspection
BRAKES 11-13 Brake Pads Brake Pad Wear Inspection In accordance with the Periodic Maintenance Chart, in- spect the brake pads for wear. • Remove the pads. Jaw (Inner) Side Pad [A] Piston Side 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.
Page 408: Master Cylinder
11-14 BRAKES Master Cylinder Front Master Cylinder Removal • Disconnect the front brake light switch connectors [A] (front view). • Draw out the brake fluid from the reservoir with a means like the fork oil level gauge. • Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder (see Brake Hose Removal/In- stallation).
BRAKES 11-15 Master Cylinder Rear Master Cylinder Removal/Installation ○ The rear master cylinder is removed or installed during brake pedal removal or installation (see Brake Pedal Re- moval or Installation). NOTE ○ Before removing the right front footboard, loosen the rear master cylinder banjo bolt [A] and mounting bolts [B].
Page 410: Master Cylinder Assembly
11-16 BRAKES Master Cylinder Master Cylinder Assembly • Before assembly, clean all parts including the master cylinder with brake fluid or alcohol. CAUTION Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts.
Page 411: Master Cylinder Inspection
BRAKES 11-17 Master Cylinder Master Cylinder Inspection • Disassemble the front and rear master cylinders. • Check that there are no scratches, rust or pitting on the inner wall [A] of each master cylinder and on the outside of each piston [B]. If the cylinder or piston shows any damage, replace them.
Page 412: Brake Discs
11-18 BRAKES Brake Discs Brake Disc Removal • Remove the wheel (see Wheels/Tires chapter). • Unscrew the mounting bolts, and take off the disc. Brake Disc Installation • Install the brake disc [A] on the wheel so that the marked side [B] faces out.
Page 413: Brake Fluid
BRAKES 11-19 Brake Fluid Level Inspection ○ In accordance with the Periodic Maintenance Chart, in- spect the brake fluid level in the front and rear brake fluid reservoirs. • Check that the brake fluid level in the front brake reservoir [A] is between the upper [B] and the lower [C] level lines.
Page 414: Brake Fluid Change
11-20 BRAKES Brake Fluid Brake Fluid Change NOTE ○ The procedure to change the front brake fluid is as fol- lows. Changing the rear brake fluid is almost the same as for the front brake. • Level the brake fluid reservoir. •...
Page 415: Brake Line Bleeding
BRAKES 11-21 Brake Fluid Brake Line Bleeding 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.
Page 416 11-22 BRAKES Brake Fluid • Remove the clear plastic hose. • Tighten: Torque - Caliper Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) Front Brake Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb) ○ For the rear caliper [A], bleed the brake line for two bleed valves [B].
Page 417: Brake Hoses
BRAKES 11-23 Brake Hoses Brake Hose Removal/Installation CAUTION Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away immediately. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts. •...
Page 421 SUSPENSION 12-3 Exploded View 1. Air Valves T1: 34 N·m (3.5 kgf·m, 25 ft·lb) T2: 108 N·m (11.0 kgf·m, 80 ft·lb) T3: 5.4 N·m (0.55 kgf·m, 47 in·lb) G: Apply grease. W: Apply a soap and water solution or rubber lubricant.
Page 422: Specifications
12-4 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner Tube Diameter 41 mm ( 1.6 in.) Fork Spring Setting Non-adjustable Air Pressure Atmospheric pressure (Non-adjustable) Rebound Damper Setting Non-adjustable Fork Oil Viscosity SHOWA SS-8 or equivalent Fork Oil Capacity 467 ±2.5 mL (15.8 ±0.08 US oz) (completely dry) approx.
Page 423: Front Fork
SUSPENSION 12-5 Front Fork Fork Oil Change The oil should be changed in accordance with the Periodic Maintenance Chart. • Remove the front fork (see Front Fork Removal). • Remove the top cap. • Hold the outer tube vertically in a vise. •...
Page 424: Removal (Each Fork Leg)
12-6 SUSPENSION Front Fork • Install the fork spring with the smaller diameter end [A] facing down [B]. • Tighten: Torque - Front Fork Clamp Bolts (Lower): 20 N·m (2.0 kgf·m, 14.5 ft·lb) Front Fork Clamp Bolts (Upper): 20 N·m (2.0 kgf·m, 14.5 ft·lb) Front Axle Clamp Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb) Front Axle Nut: 108 N·m (11.0 kgf·m, 80 ft·lb)
Page 425: Installation
SUSPENSION 12-7 Front Fork CAUTION Cover the fuel tank with a towel to protect the painted surface. • Remove the handlebar [A] by taking off the clamp bolts (see Handlebar Removal in the Steering chapter). • Remove the cable holder [B] by unscrewing two bolts [C]. •...
Page 426 12-8 SUSPENSION Front Fork • Install the fork leg [A] and push [B] it up tightly against the stem bottom. • Temporarily tighten the lower fork clamp bolts [C]. • Apply a soap and water solution or rubber lubricant to the rubber dampers [A] and install the upper fork covers [B], four well nuts [C], and two clamps [D].
Page 427: Disassembly
SUSPENSION 12-9 Front Fork Disassembly • Remove the front fork (see Front Fork Removal in this chapter). • Remove the fork cover [A]. The washer [B], and damper [C] come off. • Unscrew the bolt [A], and remove the spacer [B]. •...
Page 428: Assembly
12-10 SUSPENSION Front Fork • Separate the inner tube from the outer tube as follows: ○ Remove the dust seal [A] from the outer tube. ○ Remove the retaining ring [B] from the outer tube. ○ Use the fork outer tube weight [A] to separate the outer tube [B] from the inner tube [C].
Page 429 SUSPENSION 12-11 Front Fork • Install the new guide bushing [A] with a used guide bush- ing [B] on it by tapping the used guide bushing with fork oil seal driver [C] until it stops. ○ The split [D] of the bushing should face toward the side [E] of the vehicle.
Page 430: Inner Tube, Outer Tube Inspection
12-12 SUSPENSION Front Fork • Install the spacer [A] so that the distance [B] between the inner tube top [C] and the spacer top is 249.6 mm (9.83 in.). • Tighten: Torque - Spacer Bolt: 3.9 N·m (0.40 kgf·m, 35 in·lb) •...
Page 431: Spring Inspection
SUSPENSION 12-13 Front Fork Spring Inspection • Since the fork spring [A] becomes shorter as it weakens, check its free length [B] 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 the 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.
Page 432: Rear Shock Absorber
12-14 SUSPENSION Rear Shock Absorber Rebound Damping Adjustment The rebound damping force adjuster on each rear shock absorber has 4 positions so that the rebound damping force can be adjusted for different road and loading conditions. The numbers on the adjuster show the setting position. •...
Page 433: Removal
SUSPENSION 12-15 Rear Shock Absorber ○ Take off the air valve caps on the right and left shock absorbers. Air Valve [A] Front [B] ○ Check the air pressure with a commercial air pressure gauge. NOTE ○ Do not use tire gauges for checking air pressure. They may not indicate the correct air pressure because of air leakage that occur when the gauge is applied to the valve.
Page 434: Installation
12-16 SUSPENSION Rear Shock Absorber • Squeeze the brake lever slowly and hold it with a band [A]. Front [B] CAUTION Be sure to hold the front brake when removing the shock absorber, or the motorcycle may fall over. The motorcycle could be damaged. WARNING Be sure to hold the front brake when removing the shock absorber, or the motorcycle may fall over.
Page 435: Swingarm
SUSPENSION 12-17 Swingarm Removal • Before removing the swingarm, unscrew the banjo bolt [A] on the rear caliper [B]. ○ Temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum. • Immediately wash away any brake fluid that spills.
Page 436: Swingarm Bearing Removal
12-18 SUSPENSION Swingarm • Move the swingarm up and down [A] to check for abnor- mal friction, and push and pull [B] it to check for bearing play. • Tighten: Torque - Rear Shock Absorber Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear Footpeg Bracket Bolts: 20 N·m (2.0 kgf·m, 14 ft·lb)
Page 437: Swingarm Bearing Installation
SUSPENSION 12-19 Swingarm Swingarm Bearing Installation • Apply plenty of grease to the needle bearings, and sleeve. • Be sure to install the needle bearings so that the man- ufacturer's marks are faced out. This prevents bearing damage. • Position the bearings [A] as shown, using a suitable bear- ing driver in the bearing driver set.
13-4 STEERING Handlebar Handlebar Removal • Remove: Clutch Master Cylinder Left Handlebar Switch Housing Front Brake Master Cylinder Right Handlebar Switch Housing Throttle Grip Handlebar Holder Bolts [A] • Remove the handlebar [B] from the stem head. Handlebar Installation • Set the handlebar to match its punched mark [A] to the lower mating surface [B] of the clamp rear part.
Page 443: Steering Inspection
STEERING 13-5 Steering Steering Inspection • Check steering as follows. ○ Use the jack [A], the attachment jack [B] under the frame pipe ribs [C], and a commercially available jack [D] under the engine [E] to lift the front wheel [F] off the ground. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398 ○...
Page 444 13-6 STEERING Steering • Adjust the stem nut [A] with the stem nut wrench [B] by tightening to the specified torque (left side view). Special Tool - Steering Stem Nut Wrench: 57001-1100 Torque - Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb) •...
Page 445: Steering Stem
STEERING 13-7 Steering Stem Removal • Using the jack [A] and attachment jack [B] under the frame pipe ribs [C], and a commercially available jack [D] under the engine [E], lift the front wheel [F] OFF the ground until the rear wheel [G] touches the ground. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398 CAUTION...
Page 446 13-8 STEERING Steering Stem • Remove: O-ring [A] (rear view) Front Fork Clamp Bolts (upper) [B] Steering Stem Head [C] NOTE ○ Be sure to remove the O-ring for removal of the steering stem head. • Unscrew the upper bolts [A], and then the lower bolts [B], and take off the headlight body and headlight cover [C] as a set.
Page 447: Installation
STEERING 13-9 Steering Stem Installation • Install: Steering Stem [A] Bearings [B] New O-ring [C] (I.D. 34.5 × 2 mm) Stem Cap [D] Stem Nut Claw Washer • Install the fork leg [A] and push [B] it up tightly against the stem bottom.
Page 448: Steering Stem Warp Inspection
13-10 STEERING Steering Stem • Install: Steering Stem Head O-ring, Washer, and Stem Head Nut • Temporarily tighten the front fork clamp bolts (upper). ○ Check that the top end [A] of the inner tube is 0 ∼ 0.5 mm (0 ∼...
Page 449: Steering Stem Bearing
STEERING 13-11 Steering Stem Bearing Stem Bearing Removal • Remove the steering stem (see Steering Stem Removal). • Drive out the bearing outer races from the head pipe. Special Tool - Head Pipe Outer Race Remover: 57001 -1107 [A] NOTE ○...
Page 450: Stem Bearing Lubrication
13-12 STEERING Steering Stem Bearing ○ Check that there is no play and the steering stem turns smoothly without rattles. If not, the steering stem bearings may be damaged and must be replaced. • Remove the stem nut. • Install the O-rings and adjust the steering (see Steering Adjustment).
Page 451 FRAME 14-1 Frame Table of Contents Exploded View........................14-2 Seats ............................14-4 Front Seat Removal ......................14-4 Front Seat Installation ....................... 14-4 Rear Seat Removal......................14-4 Rear Seat Installation......................14-4 Side Covers ..........................14-5 Left Side Cover Removal ....................14-5 Left Side Cover Installation ....................
Page 452: Exploded View
14-2 FRAME Exploded View T1: 25 N·m (2.5 kgf·m, 18 in·lb) T2: 44 N·m (4.5 kgf·m, 32 ft·lb) T3: 34 N·m (3.5 kgf·m, 25 ft·lb) G: Apply grease. WL: Apply a soap and water solution or rubber lubricant. A: VN1500-N1 Model B: VN1500-N1 ∼...
14-4 FRAME Seats Front Seat Removal • Remove the front seat bolts [A] on both sides (left view). • Pull the front seat [B] forward and remove it. Front Seat Installation • Insert the rear part [A] of the front seat under the rear seat, then slip the seat hook [B] under the washer [C].
Page 455: Side Covers
FRAME 14-5 Side Covers Left Side Cover Removal • Insert the ignition switch key [A] into the left side cover, and turn the key clockwise until the key slot is vertical [B]. • Pull [B] the rear part of the left side cover towards you, push [A] the left side cover slightly forward, and remove Left Side Cover Installation •...
Page 456: Right Side Cover Installation
14-6 FRAME Side Covers Right Side Cover Installation • Run the reserve tank hose [A] and the reserve tank over- flow hose [B] as shown. Into a Clamp [C] on Engine Bottom...
Page 457: Fenders
FRAME 14-7 Fenders Front Fender Removal CAUTION Be careful not to scratch the painted surface during removal or installation. • Remove the mounting bolts [A] on both sides to separate the fender from the front fork (right side view). • Move back the fender with the wheel installed and re- moved it.
Page 458: Tool Box
14-8 FRAME Tool Box Removal • Remove the left side cover (see Left Side Cover Re- moval). • Pinch the tab [A] and move the tool box [B] forward to clear the rear stopper [C]. • Pull the tool box out. Front [D]...
Page 459: Battery Case
FRAME 14-9 Battery Case Battery Case Removal • Remove (left view): Front Seat (see Front Seat Removal) Screw [A] and Battery Holder [B] Battery [C] (see Electrical System chapter) ECU [D] (see Fuel System chapter) Rear Wheel (see Wheels/Tires chpater) •...
Page 460: Downtube
14-10 FRAME Downtube Removal • Using the jack and the attachment jack, raise the rear wheel off the ground (see Wheels/Tires chapter). Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398 • Remove: Brake Fluid Reservoir Cover Brake Fluid Reservoir [A] •...
Page 461: Front Footboard, Sidestand
FRAME 14-11 Front Footboard, Sidestand Footboard Removal ○ The left front footboard is removed during shift pedal re- moval (see Crankshfaft/Transmission chapter). ○ The right front footboard is removed during brake pedal removal (see Brakes chapter). Footboard Disassembly • Remove the front footboard. •...
Page 462: Frame Inspection
14-12 FRAME Frame Frame Inspection • Visually inspect the frame [A] for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.
Page 463 ELECTRICAL SYSTEM 15-1 Electrical System Table of Contents Electrical Parts Location ......................15-4 VN1500-N1 ∼ N2 Wiring Diagram (Canada, and U.S.) ............15-6 VN1500-N3 ∼ Wiring Diagram (Canada, and U.S.) ..............15-8 VN1500-N Wiring Diagram (Except for Australia, Canada, and U.S.)........15-10 VN1500-N Wiring Diagram (Australia)..................
Page 479 T3: 1.5 N·m (0.15 kgf·m, 13 in·lb) T4: 15 N·m (1.5 kgf·m, 11.0 ft·lb) T5: 1.0 N·m (0.10 kgf·m, 9 in·lb) T6: 5.9 N·m (0.60 kgf·m, 52 in·lb) SS: Apply silicone sealant (Kawasaki Bond: 56019-120). AU: Australia Model CA: Canada Model US: United States Model...
Page 480 15-18 ELECTRICAL SYSTEM Exploded View...
Page 481 The molybdenum disulfide oil is a mixture of engine oil and molybdenum disulfide grease with a weight ratio (10 : 1). Si: Apply silicone grease. SS: Apply silicone sealant (Kawasaki Bond: 59019-120). WL: Apply a soap and water solution or rubber lubricant.
Page 482: Specifications
15-20 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed Battery Model Name FTZ16-BS Capacity 12 V 18 Ah Voltage 12.5 V or more Charging System Alternator Type Three-phase AC with delta connection, and twin magnet rotor 14 ∼ 15 V @3 000 r/min (rpm) DC Battery Charging Voltage 64 ∼...
Page 483 Special Tools - Spark Plug Wrench, Hex 18: 57001-1024 Jack: 57001-1238 Timing Light: 57001-1241 Hand Tester: 57001-1394 Attachment Jack: 57001-1398 Flywheel Holder: 57001-1410 Peak Voltage Adapter: 57001-1415 Filler Cap Driver: 57001-1454 Needle Adapter Set - Hand Tester: 57001-1457 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
Page 484: Servicing Precautions
15-22 ELECTRICAL SYSTEM Servicing Precautions There are a number of important precautions that should be followed servicing electrical systems. ○ Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○ Always check battery condition before condemning other parts of an electrical system.
Page 485 ELECTRICAL SYSTEM 15-23 Servicing Precautions Connectors [B]...
Page 486: Electrical Wiring
15-24 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, 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.
Page 487: Battery
ELECTRICAL SYSTEM 15-25 Battery Battery Removal • Remove: Front Seat (see Frame chapter) Screw [A] and Battery Holder [B] • Slide the black and red cap out. • Disconnect the negative (–) cable [C] from the battery first and then the positive (+) cable [D] from the battery. Front [E] •...
Page 488: Electrolyte Filling
15-26 ELECTRICAL SYSTEM Battery • Put the battery holder [A] on the vehicle-down sensor bracket and insert the screw [B] through the battery holder and vehicle-down sensor bracket. • Tighten the screw securely. • Install the front seat (see Frame chapter). Electrolyte Filling •...
Page 489: Initial Charge
ELECTRICAL SYSTEM 15-27 Battery • Place the electrolyte container upside down aligning the six seals with the six battery filler ports. • Push the container down strongly enough to break the seals. Now the electrolyte should start to flow into the battery.
Page 490: Precautions
15-28 ELECTRICAL SYSTEM Battery Condition requiring initial charge Charging method 1.8 A × 2 ∼ 3 hours At low temperature (lower than 0°C) Battery has been stored under high temperature and humidity. Seal sheet has been removed, or broken-peeling, tear or hole. Battery two or more years old from date of manufacture.
Page 491: Charging Condition Inspection
ELECTRICAL SYSTEM 15-29 Battery Charging Condition Inspection ○ Battery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter. • Remove the front seat (see Frame chapter). • Disconnect the battery terminals. CAUTION Be sure to disconnect the negative terminal first. •...
Page 492 15-30 ELECTRICAL SYSTEM Battery 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 5 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.
Page 493: Charging System
ELECTRICAL SYSTEM 15-31 Charging System Alternator Outer Cover Removal • Remove (left side view): Left Front Footboad [A] (see Crankshaft/Transmission chapter) Rear Shift Pedal [B] (see Crankshaft/Transmission chapter) Front Shift Pedal [C] (see Crankshaft/Transmission chapter) • Unscrew the bolts [D] and take off the alternator outer cover [E].
Page 494: Alternator Cover Assembly
15-32 ELECTRICAL SYSTEM Charging System Alternator Cover Assembly • Install each shift shaft grease seal [A] with the lip [B] facing inside the alternator cover [C] until the seal side is flat [D] with the end of the hole. • Apply a little high temperature grease on the lips.
Page 495: Alternator Inner Cover Installation
ELECTRICAL SYSTEM 15-33 Charging System Alternator Inner Cover Installation • Replace the gasket with a new one. • Install the alternator inner cover. • Tighten: Torque - Alternator Inner Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Move the engine into its original position and tighten the engine mounting bolts.
Page 496: Alternator Outside Stator Installation
Apply silicone sealant to all the sides of the grommets as shown, and fit the grommets into the notch of the alterna- tor cover. Kawasaki Bond (Silicone Sealant): 56019-120 ○ First, install the grommet [D] of the alternator leads, and then the grommet [E] of the pickup coil leads with the round mark [F] up.
Page 497: Alternator Inside Stator Removal
ELECTRICAL SYSTEM 15-35 Charging System Alternator Inside Stator Removal • Remove the alternator outer cover, the alternator cover, the alternator inner cover, and the alternator rotor (see Alternator Rotor Removal). • Unscrew the inside stator bolts [A] and take the inside stator [B] and holder [C] off the left crankcase.
Page 498: Charging Voltage Inspection
15-36 ELECTRICAL SYSTEM Charging System Charging Voltage Inspection • Check the battery condition. • Warm up the engine to obtain actual alternator operating conditions. • Remove the front seat (see Frame chapter). • Check that the ignition switch is turned off, and connect the hand tester to the battery to the battery as shown in the table.
Page 499: Regulator/Rectifier Removal
ELECTRICAL SYSTEM 15-37 Charging System Alternator Output Voltage Connections Reading Tester @3 000 Range Tester (+) to Tester (–) to 60 ∼ 90 V 250 V AC One yellow lead Another yellow lead If the output voltage shows the value in the table, the alter- nator operates properly and the regulator/rectifier is dam- aged.
Page 500 15-38 ELECTRICAL SYSTEM Charging System • Remove the cover bolts [A] and take off the regulator/rec- tifier cover [B]. • Remove the regulator/rectifier bolts [A] and take off the rear regulator/rectifier [B]. • Remove the regulator/rectifier mounting bolts and take off the front regulator/rectifier [A].
Page 501: Rectifier Inspection
ELECTRICAL SYSTEM 15-39 Charging System Rectifier Inspection • Remove the alternator outer cover (see Alternator Outer Cover Removal). • Check the rectifier resistance as follows. • Disconnect the regulator/rectifier connector. • Connect the hand tester (special tool) to the regulator/rec- tifier as shown in the table, and check the resistance in both directions of each diode in the rectifier following the table.
Page 502 15-40 ELECTRICAL SYSTEM Charging System • Do the 1st step regulator circuit test. ○ Connect the test light and the 12 V battery to the regula- tor/rectifier as shown. ○ Check BK1, BK2, BK3 terminals respectively. If the test light turns on, the regulator/rectifier is defective. Replace it.
Page 503 ELECTRICAL SYSTEM 15-41 Charging System Charging System 1. Alternator #1 (outside) 2. Regulator/Rectifier #1 (rear) 3. Alternator #2 (inside) 4. Regulator/Rectifier #2 (front) 5. Controller 6. Ignition Switch 7. Load 8. Main Fuse 30 A 9. Starter Relay 10. Battery 12 V × 18 Ah 11.
Page 504: Ignition System
15-42 ELECTRICAL SYSTEM Ignition System Ignition System Circuit #1: For Front Cylinder #2: For Rear Cylinder 1. Ignition Switch 11. Main Fuse 30 A 2. Engine Stop Switch 12. Battery 3. Starter Button 13. ECU (DFI) 4. Spark Plugs 14. Pickup Coil #1 5.
Page 505 ELECTRICAL SYSTEM 15-43 Ignition System...
Page 506: Ignition Coil Removal
15-44 ELECTRICAL SYSTEM Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plugs, ignition coils, or their cables while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running.
Page 507: Ignition Coil Installation
ELECTRICAL SYSTEM 15-45 Ignition System • Remove the cover [A]. • Remove the mounting nuts [B]. • Take out the #2 ignition coil [C]. • Disconnect the primary leads. • Pull off the high-tension cables [D] from the spark plugs. Ignition Coil Installation •...
Page 508: Spark Plug Removal
15-46 ELECTRICAL SYSTEM Ignition System • Measure the primary winding resistance as follows. ○ Connect the hand tester between the coil terminals. ○ Set the tester to the × 1 Ω range, and read the tester. • Measure the secondary winding resistance as follows. ○...
Page 509 ELECTRICAL SYSTEM 15-47 Ignition System • Install the peak voltage adapter [A] into the hand tester [B]. Special Tool - Hand Tester: 57001-1394 • Connect the adapter between the ignition coil primary lead terminal and the engine ground with the primary lead left connected.
Page 510: Ignition Timing Inspection
15-48 ELECTRICAL SYSTEM Ignition System Ignition Timing Inspection • Remove the alternator outer cover (see Alternator Outer Cover Removal). • Remove the timing inspection plug. Special Tool - Filler Cap Driver: 57001-1454 • Attach the timing light [A] to the front ignition coil lead in the manner prescribed by the manufacturer.
Page 511: Pickup Coil Inspection
ELECTRICAL SYSTEM 15-49 Ignition System Pickup Coil Inspection • Remove the alternator outer cover (see Alternator Outer Cover Removal). • Remove all the spark plug caps but do not remove the spark plugs. • Disconnect the pickup coil lead connector. •...
Page 512: Ic Igniter Inspection
15-50 ELECTRICAL SYSTEM Ignition System • Set the hand tester [A] to the × 100 Ω range and lead it to the pickup coil lead connector [B]. Connections Tester Connections Front Pickup Coil: BK/Y ←→ Rear Pickup Coil: BK/R ←→ BK/W If there is more resistance than the specified value, the coil has an open lead and must be replaced.
Page 513 ELECTRICAL SYSTEM 15-51 Ignition System...
Page 514: Starter Motor
15-52 ELECTRICAL SYSTEM Starter Motor Removal • Unscrew the bracket bolts [A] and take off the regula- tor/rectifier [B] with its bracket [C]. • Remove: Starter Motor Terminal Nut and Cable [A] Starter Motor Bolts [B] • Pull the starter motor [A] toward the left and remove it. CAUTION Never drop the starter motor, especially on a hard surface.
Page 515: Disassembly
ELECTRICAL SYSTEM 15-53 Starter Motor • Replace the O-ring [A] with a new one. • Apply a small amount of engine oil to the O-ring. • Tighten: Torque - Starter Motor Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Starter Motor Terminal Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb) Disassembly •...
Page 516: Assembly
15-54 ELECTRICAL SYSTEM Starter Motor Assembly • Holding the springs [A] with plastic washers [B], insert the brushes. ○ Fit the brush wire into the holder groove. • Align the tang [C] with the terminal bolt [D]. • Put the armature [A] among the brushes, and remove the plastic washers [B].
Page 517: Brush Inspection
ELECTRICAL SYSTEM 15-55 Starter Motor ○ The line on the yoke should align [A] with the line on the left cover. • Tighten: Torque - Starter Motor Assy Bolts: 4.9 N·m (0.50 kgf·m, 43 in·lb) Brush Inspection • Measure the length [A] of each brush. If any is worn down to the service limit, replace the carbon brush holder assy [B] and the terminal bolt assy [C].
Page 518: Brush Wire Inspection
15-56 ELECTRICAL SYSTEM Starter Motor 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 mo- tor components 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.
Page 519 ELECTRICAL SYSTEM 15-57 Starter Motor Electric Starter Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Junction Box 5. Starter Circuit Relay 6. Ignition Fuse 10 A 7. Starter Lockout Switch 8. Neutral Switch 9. Starter Motor 10.
Page 520: Lighting System
15-58 ELECTRICAL SYSTEM Lighting System US, Canada, and Australia models have a full-time head- light system with a headlight relay in the junction box. In these models, the headlight does not go on when the igni- tion switch and the engine stop switch are first turned on. The headlight comes on when the engine starts running and stays on even if the engine stalls.
Page 521: Headlight Body Removal
ELECTRICAL SYSTEM 15-59 Lighting System • Pull the headlight unit and drop it out. • Pull the headlight connector [A]. • Remove the headlight dust cover. • Push the hook [A] to unlock. • Take out the bulb [A]. CAUTION When handling the quartz-halogen bulb, never touch the glass portion with bare hands.
Page 522: Tail/Brake Light Bulb Replacement
15-60 ELECTRICAL SYSTEM Lighting System • Disconnect the wiring connectors [A]. • Remove the headlight body bolts and nuts [B], then take off the body [C]. Tail/Brake Light Bulb Replacement • Take out the screws [A] in the taillight lens. •...
Page 523 ELECTRICAL SYSTEM 15-61 Lighting System Headlight Circuit (Except for Australia, Canada, and U.S.) Headlight Circuit (Australia, Canada, and U.S.) 1. Ignition Switch 7. Headlight 2. Headlight Switch 8. City Light 3. Junction Box 9. Dimmer Switch 10. Alternator 4. Taillight Fuse 10 A 5.
Page 524: Automatic Turn Signal Canceling System
15-62 ELECTRICAL SYSTEM Automatic Turn Signal Canceling System Automobiles use a turn signal canceling system actuated by steering wheel turn. But, motorcycles turn with a bank additionally, and so have a smaller steer angle. This makes difficult to adopt an automobile type turn signal canceling system because of inaccurate operation in motorcycles.
Page 525: Wiring Inspection
ELECTRICAL SYSTEM 15-63 Automatic Turn Signal Canceling System Wiring Inspection • Connect all the connectors. • Remove the right side cover (see Frame chapter). • Remove the coolant reserve tank bolts and hanging re- serve tank. • Remove the turn signal control unit [A]. Front [B] •...
Page 526: Turn Signal Switch Inspection
15-64 ELECTRICAL SYSTEM Automatic Turn Signal Canceling System • Set the hand tester to the DC25 V range and connect it to the LB wire terminal [A] and battery (–) terminal as shown. Connections Hand Tester (+) → LB Wire Terminal Hand Tester (–) →...
Page 527: Turn Signal Control Unit Inspection
ELECTRICAL SYSTEM 15-65 Automatic Turn Signal Canceling System Turn Signal Control Unit Inspection CAUTION Never drop the turn signal control unit, especially on a hard surface. Such a shock to the unit can damage it. • Remove the right side cover (see Frame chapter). •...
Page 528 15-66 ELECTRICAL SYSTEM Automatic Turn Signal Canceling System • With the front pin [A] up and the rear pin [B] down, insert the new bulb by aligning the rear pin with the groove in the walls of the socket [C]. •...
Page 529: Radiator Fan System
ELECTRICAL SYSTEM 15-67 Radiator Fan System WARNING The radiator fan is connected directly to the bat- tery. The 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.
Page 530: Oil Pressure Warning System
15-68 ELECTRICAL SYSTEM Oil Pressure Warning System Motorcycle operation with low engine oil level, even if it is higher than the lower level line, will cause oil level change when sudden acceleration, or deceleration, and may lead flicker of the oil pressure warning light because of too rapid response of the oil pressure switch.
Page 531 ELECTRICAL SYSTEM 15-69 Oil Pressure Warning System • Turn the ignition switch ON. • Ground the oil pressure switch lead to the engine, then the oil pressure warning LED light should be lit with a delay. • Measure this delay time from grounding of the switch lead to lighting of the warning LED light.
Page 532: Meter, Gauge
15-70 ELECTRICAL SYSTEM Meter, Gauge Meter Unit Removal • Remove the bolt [A], and lift up the tail of the cover [B]. • Push the cover forward a little, and remove the meter cover. • Remove the meter unit [A]. ○...
Page 533 ELECTRICAL SYSTEM 15-71 Meter, Gauge • Remove the screw [A] on the lower cover to free the speedometer. • Remove the screw [B] on the indicator panel to remove the panel. • Lifting the speedometer [B] with the indicator panel [C] attached, pull out the FI indicator LED light [D] and oil pressure warning LED light [E] from the lower cover [A].
Page 534: Meter Unit Assembly
15-72 ELECTRICAL SYSTEM Meter, Gauge Meter Unit Assembly • Connect the connector of the indicator panel to the speedometer. • Put in the oil pressure warning LED light [A] and FI indi- cator LED light [B] to the lower cover. Oil Pressure Warning LED Light: Orange Lead and Green Lead FI Indicator LED Light: Red Lead and White Lead...
Page 535 ELECTRICAL SYSTEM 15-73 Meter, Gauge • Push the mode select button to CLOCK. • Push the reset button [A] more than 2 seconds, then the display turns to the HOUR/MINUTE mode [B]. ○ In the HOUR/MINUTE mode, the numbers flash on the display.
Page 536 15-74 ELECTRICAL SYSTEM Meter, Gauge LCD Segment Inspection • Remove the meter unit [A] (see Meter Unit Removal). CAUTION Do not drop the meter unit. Such a shock to the meter unit can damage it. Place the meter facing up. If a meter is left upside down or sideways for any length of time, it will malfunction.
Page 537 ELECTRICAL SYSTEM 15-75 Meter, Gauge Speedometer Inspection • If an oscillator is unavailable, check the speedometer as follows. ○ Install the meter unit. ○ Use the jack and the attachment jack to lift the rear wheel. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398 ○...
Page 538 15-76 ELECTRICAL SYSTEM Meter, Gauge ODO Meter Inspection • Turn the display [A] into ODO. • During the speedometer inspection with an oscillator, ver- ify that the odometer reading increases. If it does not increase, replace the speedometer assem- bly. TRIP Meter Inspection •...
Page 539 ELECTRICAL SYSTEM 15-77 Meter, Gauge Distance Sensor Inspection • Install the meter unit (see Meter Unit Installation). • Disconnect the connector of the speed sensor (see Speed Sensor Removal). • Connect the oscillator [C] to the LG/R terminal [B] of the connector [A] on the main harness.
Page 540 15-78 ELECTRICAL SYSTEM Meter, Gauge LED and Indicator Light Inspection • Connect the 12 V battery to the meter terminals in the same way as in the LCD segment inspection. FI Indicator LED Light Connections Battery Negative Cable (–) to Terminal [2] •...
Page 541 ELECTRICAL SYSTEM 15-79 Meter, Gauge Speedometer Illumination LED Light Connections Battery Positive Cable (+) to Terminal [10] • Connect the terminal [10] ○ The Illumination LED light lights. • Disconnect the terminal [10]. ○ The Illumination LED light disappears. If there is any problem, replace the speedometer assem- bly.
Page 542 15-80 ELECTRICAL SYSTEM Meter, Gauge If there is any problem, inspect the bulb, bulb socket [A] and wiring of the indicator panel [B] for continuity. If they are normal, replace the speedometer. Special Tools - Hand Tester: 57001-1394 Needle Adapter Set: 57001-1457 Neutral Indicator Light Connections Battery Negative Cable (–) to Terminal [1] •...
Page 543: Water Temperature Warning System Check
ELECTRICAL SYSTEM 15-81 Meter, Gauge 1. Oil Pressure Warning Light Delay Unit 16. Ignition Switch 2. Speed Sensor 17. Water Temperature Switch 3. Odo/Trip/Clock Meter 18. E.C.U. (Electronic Control Unit) 4. Speedometer 19. Ignition Fuse 10 A 5. Fuel Level Gauge 20.
Page 544 15-82 ELECTRICAL SYSTEM Meter, Gauge • Inspect the water temperature warning LED light and the system wiring (see Fuel System chapter). ○ Turn on the ignition switch. ○ Disconnect the water temperature switch lead [A], then ground it to the frame or engine using an auxiliary lead. If the water temperature warning LED light is lit, inspect the water temperature switch [B] (see Switches and Sen- sors section).
Page 545: Fuel Gauge Operation Inspection
ELECTRICAL SYSTEM 15-83 Meter, Gauge Fuel Gauge Operation Inspection • Remove: Speedometer Cover (see Meter Unit Removal) Fuel Tank Bolts (see Fuel System chapter) • Lift the fuel tank front part a little and pull the fuel gauge connector forward. •...
ELECTRICAL SYSTEM 15-85 Switch and Sensors Fuel Reserve Switch Inspection • Remove: Fuel Pump (see Fuel System chapter) • Connect the test light (12 V 3W bulb in a socket with wires) and the 12 V battery to the fuel pump connector as shown. 12 V Battery [A] Test Light [B] Fuel Pump Connector [C]...
Page 548: Speed Sensor Inspection
15-86 ELECTRICAL SYSTEM Switch and Sensors Speed Sensor Inspection • Remove: Speed Sensor (see Speed Sensor Removal) • Connect the speed sensor connector [A] with a battery [B], 10 kΩ resistor [C] and hand tester [D] as shown. • Set the tester to the DC 25 V range. Special Tool - Hand Tester: 57001-1394 •...
Page 549: Radiator Fan Switch Removal
ELECTRICAL SYSTEM 15-87 Switch and Sensors Radiator Fan Switch Removal CAUTION Never drop the fan switch, especially on a hard sur- face. Such a shock to the part can damage it. • Drain the coolant (see Coolant Draining). • Remove: Front Guard (see Frame chapter) Regulator/Rectifire (see this chapter) •...
Page 550: Water Temperature Switch Removal
15-88 ELECTRICAL SYSTEM Switch and Sensors Water Temperature Switch Removal CAUTION The water temperature switch should never be al- lowed to fall on a hard surface. Such a shock to the part can damage it. • Drain the coolant (see Coolant Draining in the Cooling System chapter).
Page 551: Fuel Level Sensor Removal
ELECTRICAL SYSTEM 15-89 Switch and Sensors Fuel Level Sensor Removal • Remove the fuel tank (see Fuel System chapter). • Turn the fuel tank upside down. • Open the clamps [A] and take off the fuel level sensor lead [B]. •...
Page 552: Diode (Rectifier) Inspection
15-90 ELECTRICAL SYSTEM Switch and Sensors Diode (Rectifier) Inspection • Remove the fuel tank (see Fuel System chapter). • Disconnect the diode assemblies [A]. • Set the hand tester to the × 100 Ω range. Special Tool - Hand Tester: 57001-1394 •...
Page 553: Junction Box
ELECTRICAL SYSTEM 15-91 Junction Box The junction box [A] has fuses [B], relays, and diodes. The relays and diodes can not be removed. Front [C] Junction Box Fuse Circuit Inspection • Remove the right side cover (see Frame chapter). • Remove the junction box.
15-92 ELECTRICAL SYSTEM Junction Box Starter Circuit/Headlight Relay Inspection • Remove the junction box. • Check conductivity of the following numbered terminals 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 junc- tion box.
Page 555: Diode Circuit Inspection
ELECTRICAL SYSTEM 15-93 Junction Box Diode Circuit Inspection • Remove the junction box. • Check conductivity of the following pairs of terminals. Diode Circuit Inspection Tester *13-8, *13-9, 12-11, 12-14, 15-14, 16-14 Connection (*): US, Canada, and Australia Models only The resistance should be low in one direction and more than ten times as much in the other direction.
Page 556 15-94 ELECTRICAL SYSTEM Junction Box Junction Box Internal Circuit (Australia, Canada, and U.S.) Junction Box Internal Circuit (Except for Australia, Canada, and U.S.) Accessory Fuse 10 A [A] Headlight Fuse 10 A [F] Fan Fuse 10 A [B] Headlight Relay [G] Fan Fuse 15 A [B] (VN1500-N4 ∼, U.S.
Page 557: Fuse
ELECTRICAL SYSTEM 15-95 Fuse Main Fuse Removal • Remove the right side cover (see Frame chapter). • Remove the junction box and the reserve tank. • Remove the starter relay [A]. • Pull out the main fuse [B] from the starter relay with needle nose pliers.
Page 559 APPENDIX 16-1 Appendix Table of Contents Troubleshooting Guide (except DFI) ..................16-2 General Lubrication ........................ 16-7 Lubrication (Periodic Maintenance) .................. 16-7 Nut, Bolt, and Fastener Tightness ..................16-8 Tightness Inspection (Periodic Inspection) ............... 16-8 Unit Conversion Table ......................16-9...
Page 560: Troubleshooting Guide (Except Dfi)
16-2 APPENDIX Troubleshooting Guide (except DFI) NOTE Spark plug dirty, broken, or gap malad- ○ Refer to Fuel System chapter for most of justed DFI troubleshooting guide. Spark plug cap or high tension cable trouble ○ This is not an exhaustive list, giving every Spark plug cap shorted or not in good con- possible cause for each problem listed.
Page 561 APPENDIX 16-3 Troubleshooting Guide (except DFI) Fuel pump trouble Cylinder head not sufficiently tightened Compression low: down Spark plug loose Cylinder, piston worn Cylinder head not sufficiently tightened Piston ring bad (worn, weak, broken, or down sticking) Cylinder, piston worn Piston ring/groove clearance excessive Piston ring bad (worn, weak, broken, or Cylinder head gasket damaged...
Page 562: Gear Shifting Faulty
16-4 APPENDIX Troubleshooting Guide (except DFI) Fuel/air mixture incorrect: Engine oil viscosity too high Throttle assy loose Engine oil level too high Throttle assy O-ring damage Clutch housing frozen on drive shaft Air cleaner duct loose Clutch slave cylinder trouble Air cleaner poorly sealed, or missing Clutch hub nut loose Air cleaner O-ring damaged...
Page 563: Abnormal Frame Noise
APPENDIX 16-5 Troubleshooting Guide (except DFI) Abnormal Frame Noise: HLA aeration due to low oil level Air in HLA Front fork noise: Metal chips or dust jammed in HLA Oil insufficient or too thin Engine operated in red zone Spring weak or broken Valve spring broken or weak Rear shock absorber noise: Camshaft bearing portion worn...
Page 564 16-6 APPENDIX Troubleshooting Guide (except DFI) Tire air pressure too low Rear shock absorber oil leaking Handlebar shakes or excessively vibrates: Brake Doesn't Hold: Tire worn Swingarm sleeve or pivot bearings worn Air in the brake line Wheel rim warped, or not balanced Pad or disc worn Spokes loose Brake fluid leakage...
Page 565: General Lubrication
APPENDIX 16-7 General Lubrication Lubrication (Periodic Maintenance) • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○ Perform the general lubrication in accordance with the Periodic Maintenance Chart or whenever the vehicle has been operated under wet or rainy conditions, or especially after using a high -pressure water spray.
Page 566: Nut, Bolt, And Fastener Tightness
16-8 APPENDIX Nut, Bolt, and Fastener Tightness Tightness Inspection (Periodic Inspection) • Check the tightness of the bolts and nuts listed here in accordance with the Periodic Maintenance Chart. Also, check to see that each cotter pin is in place and in good condition.
Page 567: Unit Conversion Table
APPENDIX 16-9 Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 N·m ×...
