User manual KAWASAKI VN1600 MEAN STREAK - SERVICE MANUAL

VULCAN 1600 MEAN STREAK VN1600 MEAN STREAK Motorcycle Service Manual Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires Final Drive Brakes Suspension Steering Frame Electrical System This quick reference guide will assist you in locating a desired topic or procedure. Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. Refer to the sectional table of contents for the exact pages to locate the specific topic required. 1j 2j 3j 4j 5j 6j 7j 8j 9j 10 j 11 j 12 j 13 j 14 j 15 j 16 j Appendix 17 j · · VULCAN 1600 MEAN STREAK VN1600 MEAN STREAK All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2003 Kawasaki Heavy Industries, Ltd. First Edition (1) : Jul. 1, 2003 (M) LIST OF ABBREVIATIONS A ABDC AC ATDC BBDC BDC BTDC °C DC F °F ft g h kg kgf L ampere(s) after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celsius direct current farad(s) degree(s) Fahrenheit foot, feet gram(s) (mass) hour(s) (mass) (force) liter(s) lb m min N Pa PS psi r r/min, rpm TDC TIR V W pound(s) meter(s) minute(s) newton(s) pascal(s) horsepower pound(s) per square inch revolution revolution(s) per minute top dead center total indicator reading volt(s) watt(s) ohm(s) Read OWNER'S MANUAL before operating. EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only. 1. Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors are routed through an oil separator to the inlet side of the engine. While the engine is operating, the vapors are drawn into combustion chamber, where they are burned along with the fuel and air supplied by the fuel injection system. 2. Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels. The exhaust system of this model motorcycle manufactured primarily for sale in California includes a catalytic converter system. 3. Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister when the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank. The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly referred to as the Act's "tampering provisions." "Sec. 203(a) The following acts and the causing thereof are prohibited... (3)(A) for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser. (3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser..." The phrase "remove or render inoperative any device or element of design" has been generally interpreted as follows: 1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance. 2. Tampering could include: a.Maladjustment of vehicle components such that the emission standards are exceeded. b.Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle. c.Addition of components or accessories that result in the vehicle exceeding the standards. d.Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems. NOTE WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION. TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. Among those acts presumed to constitute tampering are the acts listed below: Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations. Removal of the muffler(s) or any internal portion of the muffler(s). Removal of the air box or air box cover. Modifications to the muffler(s) or air inlet system by cutting, drilling, or other means if such modifications result in increased noise levels. · · · · Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your vehicle: Follow the Periodic Maintenance Chart in the Service Manual. Be alert for problems and non-scheduled maintenance. Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Special Tool Catalog or Manual. Genuine parts provided as spare parts are listed in the Parts Catalog. Follow the procedures in this manual carefully. Don't take shortcuts. Remember to keep complete records of maintenance and repair with dates and any new parts installed. Guide shows you all of the product's system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. For example, if you want ignition coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Ignition Coil section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices. WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury or loss of life. CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information. · · · NOTE This note symbol indicates points of par ticular interest for more efficient and convenient operation. · Indicates a procedural step or work to be done. Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly. · · How to Use This Manual In this manual, the product is divided into its major systems and these systems make up the manual's chapters. The Quick Reference GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ..................................................................................................................... Model Identification................................................................................................................. General Specifications............................................................................................................ Unit Conversion Table ............................................................................................................ 1-2 1-7 1-9 1-12 1 1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts. Especially note the following: Before completing any service on the motorcycle, disconnect the battery wires from the battery to prevent the engine from accidentally turning over. Disconnect the ground wire (-) first and then the positive (+). When completed with the service, first connect the positive (+) wire to the positive (+) terminal of the battery then the negative (-) wire to the negative terminal. Battery Ground Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts. Solvent Use a high flush point solvent when cleaning parts. High flush point solvent should be used according to directions of the solvent manufacturer. Cleaning vehicle before disassembly Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle. GENERAL INFORMATION 1-3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly. Storage of Removed Parts After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly. Inspection Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit. Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled. Assembly Order In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given. 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Bolts, nuts, or screws must be tightened according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally. Tightening Torque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench. Often, the tightening sequence is followed twice-initial tightening and final tightening with torque wrench. Force Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non -permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary. Gasket, O-ring Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used O-rings when re-assembling Liquid Gasket, Locking Agent For applications that require Liquid Gasket or a Locking Agent, clean the surfaces so that no oil residue remains before applying liquid gasket or locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage. GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown. Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage. Oil Seal, Grease Seal Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed. Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing. Circlips, Cotter Pins Replace circlips or cotter pins that were removed with new ones. Install the circlip with its sharp edge facing outward and its chamfered side facing inward to prevent the clip from being pushed out of its groove when loaded. Take care not to open the clip excessively when installing to prevent deformation. Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified. 1-6 GENERAL INFORMATION Before Servicing Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side). Electrical Wires A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color. GENERAL INFORMATION 1-7 Model Identification VN1600-B1 (US, and Canada) Left Side View: VN1600-B1 (US, and Canada) Right Side View: 1-8 GENERAL INFORMATION Model Identification VN1600-B1 (Europe) Left Side View: VN1600-B1 (Europe) Right Side View: GENERAL INFORMATION 1-9 General Specifications Items Dimensions: Overall length Overall width Overall height Wheelbase Road clearance Seat height Dry mass Curb mass: Fuel tank capacity Fuel Performance: Minimum turning radius Engine: Type Cooling system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque Carburetion system Starting system Ignition system Timing advance Ignition timing Spark plugs Cylinder numbering method Firing order Valve timing: Inlet Open Close Duration Exhaust Open Close Duration Lubrication system Engine oil: Type Viscosity VN1600­B1 2 410 mm (94.9 in.) 850 mm (33.5 in.) 1 100 mm (43.3 in.) 1 705 mm (67.1 in.) 125 mm (4.92 in.) 700 mm (27.6 in.) 290 kg (639 lb) 145 kg (320 lb) 172 kg (379 lb) 17.0 L (4.49 US gal) Unleaded and high-octane gasoline (see Owner's Manual) 3.1 m (10.2 ft) 4-stroke, SOHC, V2-cylinder Liquid-cooled 102 × 95 mm (4.02 × 3.74 in.) 1 552 mL (94.70 cu in.) 9.0 : 1 54 kW (74 PS) @5 300 r/min (rpm), (CAL) (CA) (US) ­ 125 N·m (12.7 kgf·m, 92.2 ft·lb) @2 800 r/min (rpm), (CAL) (CA) (US) ­ DFI (Digital Fuel Injection) System Electric starter Battery and coil (transistorized) Electronically advanced (digital) From 5° BTDC @950 r/min (rpm) 25° BTDC @4 500 r/min (rpm) NGK DPR6EA-9 or ND X20EPR-U9 Front to Rear, 1-2 1-2 22° BTDC 66° ABDC 268° 66° BBDC 26° ATDC 272° Forced lubrication (wet sump) API SE, SF or SG class API SH or SJ class with JASO MA SAE10W-40 Front Rear 1-10 GENERAL INFORMATION General Specifications Items Capacity Drive Train: Primary reduction system: Type Reduction ratio Clutch type Transmission: Type Gear ratios: 1st 2nd 3rd 4th 5th 1st 2nd 3rd 4th 5th Final drive system: Type Reduction ratio Overall drive ratio Final gear case oil: Grade Viscosity Capacity Frame: Type Caster (rake angel) Trail Type Size Rear tire: Type Size Front suspension: Type Wheel travel Rear suspension: Type Wheel travel Brake Type: Front Rear Front tire: VN1600­B1 3.5 L (3.7US qt, when engine is completely disassembled and dry) Gear 1.517 (85/56) Wet multi disc 5-speed, constant mesh, return shift (CAL, CA, US) 2.500 (40/16) 1.750 (35/20) 1.333 (32/24) 1.074 (29/27) 0.867 (26/30) (other than CAL, CA, US) 2.500 (40/16) 1.590 (35/22) 1.192 (31/26) 0.965 (28/29) 0.781 (25/32) Shaft 2.619 (15/21 × 33/9) (CAL, CA, US) 3.445 @ Top gear (other than CAL, CA, US) 3.105 @ Top gear API Service Classification: GL-5 Hypoid gear oil SAE90 (above 5°C), SAE80 (below 5°C) 200 mL (12.2 cu in.) Tubular, double cradle 32° 144 mm (5.67 in.) Tubeless 130/70R17 M/C 62H Tubeless 170/60R17 M/C 72H Telescopic fork (upside-down) 150 mm (5.91 in.) Swingarm, air oil shock absorber 87 mm (3.43 in.) Dual disc Single disc GENERAL INFORMATION 1-11 General Specifications Items Electrical Equipment: Battery Capacity Headlight: Type Bulb Tail/brake light Alternator: Type Rated output VN1600­B1 12 V 18 Ah Semi-sealed beam 12 V 60/55 W (quartz-halogen) 12 V 5/21 W Three-phase AC 23 A × 14 V @6 000 r/min (rpm) Specifications subject to change without notice, and may not apply to every country. CAL: California Model CA: Canadian Model US: United States of America Model 1-12 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Prefix mega kilo centi milli micro Symbol M k c m µ × × × × × Power 1 000 000 1 000 0.01 0.001 0.000001 Units of Length: km m mm × × × 0.6214 3.281 0.03937 = = = mile ft in. Units of Torque: N·m N·m N·m kgf·m kgf·m kgf·m × × × × × × 0.1020 0.7376 8.851 9.807 7.233 86.80 = = = = = = kgf·m ft·lb in·lb N·m ft·lb in·lb Units of Mass: kg g × × 2.205 0.03527 = = lb oz Units of Volume: L L L L L L mL mL mL × × × × × × × × × 0.2642 0.2200 1.057 0.8799 2.113 1.816 0.03381 0.02816 0.06102 = = = = = = = = = gal (US) gal (imp) qt (US) qt (imp) pint (US) pint (imp) oz (US) oz (imp) cu in. Units of Pressure: kPa kPa kPa kgf/cm² kgf/cm² cm Hg × × × × × × 0.01020 0.1450 0.7501 98.07 14.22 1.333 = = = = = = kgf/cm² psi cm Hg kPa psi kPa Units of Speed: km/h × 0.6214 = mph Units of Force: N N kg kg × × × × 0.1020 0.2248 9.807 2.205 = = = = kgf lb N lb Units of Power: kW kW PS PS × × × × 1.360 1.341 0.7355 0.9863 = = = = PS HP kW HP Units of Temperature: PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart .............. Torque and Locking Agent................. Specifications .................................... Special Tools ..................................... Periodic Maintenance Procedures..... Fuel System (DFI)........................... Fuel Hose and Connection Inspection.................................. Throttle Control System Inspection.................................. Idle Speed Inspection .................. Air Cleaner Element Cleaning...... Evaporative Emission Control System Inspection(CAL) ........... Cooling System............................... Radiator Hose and Connection Inspection.................................. Coolant Change ........................... Engine Top End .............................. Air Suction Valve Inspection ........ Clutch.............................................. Clutch Hose and Connection Inspection.................................. Clutch Fluid Level Inspection ....... Clutch Fluid Change .................... Clutch Master Cylinder Cup and Dust SealReplacement ............. Clutch Slave Cylinder Piston Seal Replacement ............................ Engine Lubrication System ............. Engine Oil Change....................... Oil Filter Replacement ................. Wheels/Tires ................................... 2-2 2-4 2-10 2-12 2-13 2-13 2-13 2-13 2-14 2-14 2-15 2-16 2-16 2-16 2-18 2-18 2-19 2-19 2-19 2-20 2-21 2-22 2-22 2-22 2-24 2-24 Tire Inspection ............................. Final Drive....................................... Oil Level Inspection...................... Oil Change ................................... Brakes............................................. Brake Pad Wear Inspection ......... Brake Hose and Connection Inspection.................................. Brake Fluid Level Inspection........ Brake Fluid Change ..................... Brake Master Cylinder Cup and Dust Seal Replacement ............ Caliper Piston/Dust Seals Replacement ............................. Front Brake Light Switch Inspection.................................. Rear Brake Light Switch Check/Adjustment ..................... Suspension ..................................... Front Fork Oil Leak Inspection..... Rear Shock Absorber Oil Leak Inspection ................................. Swingarm Pivot Lubrication ......... Steering .......................................... Stem Bearing Lubrication............. Steering Check ............................ Steering Adjustment..................... Electrical System ............................ Spark Plug Cleaning/Inspection... General Lubrication ........................ Lubrication ................................... Nut, Bolt, and Fastener Tightness .. Tightness Inspection .................... 2-24 2-25 2-25 2-26 2-27 2-27 2-27 2-28 2-29 2-30 2-30 2-30 2-30 2-31 2-31 2-31 2-31 2-32 2-32 2-32 2-32 2-33 2-33 2-33 2-33 2-34 2-34 2 2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. FREQUENCY Whichever comes first 1 INSPECTION Air suction valve (e) - inspect Air cleaner element (e) - clean# Throttle control system (e) - inspect Idle speed (e) - inspect Fuel hoses, connections - inspect Evaporative emission control system (e) (CAL) - inspect Final gear case oil level - inspect Brake pad wear - inspect # Brake light switch - inspect Steering - inspect Tire damage and wear - inspect # Tire air pressure - inspect Wheel damage - inspect Wheel bearing wear and damage - inspect Front fork and rear shock absorber operation General lubrication - perform Nut, bolt, and fastener tightness - inspect Brake/clutch hoses, connections - inspect Brake/clutch fluid level - inspect Coolant hoses, connections - inspect Steering stem bearing - lubricate month year 2 years year year year year Every 6 12 * ODOMETER READING km × 1000 (mile × 1000) 18 24 30 36 See 2­18 2­14 2-13 2-14 2-13 2-15 2­25 2­27 2­30 2­32 2­24 2­24 ­ ­ ­ 2­33 2­34 2­19, 2­27 2­19, 2­28 2­16 2­32 (0.6) (4) (7.5) (12) (15) (20) (24) Page · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· ·· · · · · · · · · · · · · · · · · · · · · · · · · · PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Whichever comes first 1 CHANGE/REPLACE ITEM Spark plug (e) Engine oil # Oil filter Coolant Brake/clutch master cylinder cup and dust seal Caliper piston seal and dust seal Clutch slave cylinder position seal Brake/clutch fluid Final gear case oil Fuel hose 4 years year year 3 years 4 years 4 years 4 years 2 years Every 12 (0.6) (7.5) * ODOMETER READING km × 1000 (mile × 1000) 24 (15) 36 48 See 2­33 2­22 2­24 2­16 2­21, 2­30 2­30 2­22 2­20, 2­29 2­25 (24) (30) Page · · · · · · · · · · · · · · · · ­ # : Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping. * : For higher odometer readings, repeat at the frequency interval established here. : Replace, add, adjust, clean, or torque if necessary. Throttle control system inspection: Inspection of throttle grip play and throttle bore cleanliness. (CAL): California (e): Emission Related Items 2-4 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non -permanent locking agent or liquid gasket. Letters used in the "Remarks" column mean: G: Apply grease to the threads. EO: Apply engine oil to the threads and the seating surface. L: Apply a non-permanent locking agent to the threads. Lh: Left-hand threads. MO: Apply molybdenum disulfide oil to the threads and the seating surface. The molybdenum disulfide oil is a mixture of engine oil and molybdenum disulfide grease with a weight ratio (10 : 1). S: Tighten the fasteners following the specified sequence. SS: Apply silicone sealant. St: Stake the fasteners to prevent loosening. R: Replacement parts AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. Fastener Fuel System: High pressure fuel hose clamp screws Pressure regulator screws Delivery joint screws Throttle body flange bolts Throttle body assy holder bolts Inlet manifold bolts Spark plug lead holder bolts ISC pipe bolts Air cleaner duct holder bolts Right and left air cleaner base bolts Right and left air cleaner base screws Left air cleaner cover Allen bolt Right air cleaner cover Allen bolt Right air cleaner Allen bolts Choke cable plate screw Inlet air temperature sensor nut (DFI) Water temperature sensor (DFI) Fuel pump bolts Return fuel check valve Cooling System: Radiator hose clamp screws Thermostat air bleeder bolt N·m 1.5 4.9 3.4 4.9 11 12 11 11 11 11 2.2 16 16 11 2.9 7.8 18 6.9 20 2.5 7.8 WL: Apply a soap and water solution or rubber lubricant. The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads. Basic Torque for General Fasteners Threads dia. (mm) N·m 3.4 4.9 5.9 7.8 14 19 25 34 44 61 73 98 115 155 165 225 225 325 Torque kgf·m 0.35 0.50 0.60 0.80 1.4 1.9 2.6 3.5 4.5 6.2 7.4 10.0 11.5 16.0 17.0 23.0 23 33 ft·lb 30 43 in·lb 52 69 in·lb 10.0 13.5 19.0 25 33 45 54 72 83 115 125 165 165 240 5 6 8 10 12 14 16 18 20 Torque kgf·m 0.15 0.50 0.35 0.50 1.1 1.2 1.1 1.1 1.1 1.1 0.22 1.6 1.6 1.1 0.30 0.80 1.8 0.70 2.0 0.25 0.80 ft·lb 13 in·lb 43 in·lb 30 in·lb 43 in·lb 97 in·lb 106 in·lb 97 in·lb 97 in·lb 97 in·lb 97 in·lb 19 in·lb 12 12 97 in·lb 26 in·lb 69 in·lb 13 61 in·lb 15 22 in·lb 69 in·lb Remarks Throttle Body Right Side on Cyl. Head Right Side Left Side L, Lower Duct Throttle Body L, Throttle Body SS S, L PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Fastener Radiator fan switch Radiator fan bolts Water temperature switch Water pump impeller bolt Water pump cover bolts Water pump air bleeder bolt Water pump drain bolt Water pipe bolts Radiator drain Bolt Engine Top End: Spark plugs Spark plug retainers Air suction valve cover bolts Chain tensioner mounting bolts Chain tensioner cap Chain tensioner lockbolt Timing inspection cap Rotor bolt cap Camshaft sprocket bolts Oil hose flange bolts Rocker shafts Rocker case nuts 12 mm 8 mm Rocker case bolts 6 mm Cylinder head nuts Cylinder head jacket plugs Rocker case cover bolts Camshaft chain guide bolts Cylinder nuts Inlet manifold bolts Exhaust pipe cover clamp bolts Premuffler chamber bolts Muffler stay mounting bolts, 8 Upper muffler mounting nuts Upper muffler bracket nut Clutch: Clutch lever pivot bolt Clutch lever pivot bolt locknut Clutch reservoir cap screws Clutch slave cylinder bleed valve Clutch slave cylinder bolts Clutch hose banjo bolts Clutch master cylinder clamp bolts N·m 18 8.3 7.8 8.8 11 11 11 11 2.2 18 12 7.4 11 20 4.9 1.5 1.5 15 9.8 25 78 25 8.8 25 20 8.8 11 25 12 6.9 29 25 25 29 1.0 5.9 1.5 7.8 6.9 25 9.8 Torque kgf·m 1.8 0.85 0.80 0.90 1.1 1.1 1.1 1.1 0.22 1.8 1.2 0.75 1.1 2.0 0.50 0.15 0.15 1.5 1.0 2.5 8.0 2.5 0.90 2.5 2.0 0.90 1.1 2.5 1.2 0.70 3.0 2.5 2.5 3.0 0.10 0.60 0.15 0.80 0.70 2.5 1.0 ft·lb 13 74 in·lb 69 in·lb 78 in·lb 97 in·lb 97 in·lb 97 in·lb 97 in·lb 19 in·lb 13 106 in·lb 65 in·lb 97 in·lb 15 43 in·lb 13 in·lb 13 in·lb 11 87 in·lb 18 58 18 78 in·lb 18 15 78 in·lb 97 in·lb 18 106 in·lb 61 in·lb 21 18 18 21 8.9 in·lb 52 in·lb 13 in·lb 69 in·lb 61 in·lb 18 87 in·lb Remarks SS Lh S S S L MO, S S S S L S L S on Cyl. Head Lower Muffler Si L S 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Starter lockout switch screws Push rod guide bolts Clutch cover bolts Clutch damper cover bolts Clutch damper plate bolts Clutch cover damper screws Clutch hub nut Engine Lubrication System: Oil filler cap Oil screen plug Engine oil drain plug Oil filter (cartridge type) Oil filter pipe Oil pressure relief valve Oil pressure switch terminal screw Oil pressure switch Oil pump mounting bolts Oil hose banjo bolts Oil hose flange bolt (outside) Oil pipe holder bolts (inside) Oil pipe clamp bolts (inside) Right & left crankcase oil nozzles Right crankcase oil nozzle Oil pipe nozzle (left side) Oil baffle bolt Engine Removal/Installation: Downtube bolts and nuts Engine mounting bolts and nuts Engine mounting bracket bolts Engine ground terminal bolt Crankshaft/Transmission: 10 mm Crankcase bolts 8 mm 6 mm Frame ground bracket bolt Crankcase bearing retainer bolts Camshaft chain guide bolts Right, left crankcase oil nozzles Right crankcase oil nozzles Oil baffle bolt Connecting rod big end nuts Oil pressure relief valve Oil filter pipe N·m 1.2 11 11 9.8 9.8 4.9 147 1.5 20 20 18 25 15 1.5 15 11 9.8 9.8 11 11 2.9 2.9 2.9 11 44 44 25 7.8 39 21 11 11 11 11 2.9 2.9 11 59 15 25 Torque kgf·m 0.12 1.1 1.1 1.0 1.0 0.50 15 0.15 2.0 2.0 1.8 2.5 1.5 0.15 1.5 1.1 1.0 1.0 1.1 1.1 0.30 0.30 0.30 1.1 4.5 4.5 2.5 0.80 4.0 2.1 1.1 1.1 1.1 1.1 0.30 0.30 1.1 6.0 1.5 2.5 ft·lb 10 in·lb 95 in·lb 95 in·lb 87 in·lb 87 in·lb 43 in·lb 108 13 in·lb 15 15 13 18 11 13 in·lb 11 97 in·lb 87 in·lb 87 in·lb 97 in·lb 97 in·lb 26 in·lb 26 in·lb 26 in·lb 97 in·lb 32 32 18 69 in·lb 29 15 97 in·lb 97 in·lb 97 in·lb 97 in·lb 26 in·lb 26 in·lb 97 in·lb 44 11 18 S S S Left Crankcase L L ×3 × 1, Lh L MO L SS Remarks L L EO L MO R, EO SS L SS L L ×3 × 1, Lh L PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Fastener Oil hose banjo bolts Primary gear bolt Water pump chain guide spring hook bolt Water pump chain guide bolt Idle shaft holder bolts Oil pressure switch terminal screw Oil pressure switch Oil return pipe bolts (inside) Oil pipe holder bolts (inside) Oil pipe clamp bolts (inside) Left balancer gear bolt Starter clutch bolt Starter clutch coupling bolts Gear set lever bolt Shift shaft return spring pin (bolt) Shift pedal clamp bolt Rear shift lever clamp bolt Shift rod locknuts Shift drum cam bolt Damper cam nut (front gear) Clutch push rod guide bolts Wheels/Tires: Front axle clamp bolts Front axle Rear axle nut Tire air valve nuts Tire air valve caps Air valve cores Final Drive: Oil pipe banjo bolts (front gear) Oil nozzle (front gear) Oil nozzle (front gear) Neutral switch Front gear case bolts: 6 mm 8 mm Speed sensor bolt Damper cam nut (front gear) Drive gear nut (front gear) Driven gear assy mounting bolts Driven gear bolt (front gear) Bearing retainer bolts (front gear) Final gear case drain plug Final gear case mounting nuts N·m 9.8 147 2.9 8.3 8.3 1.5 15 11 11 11 85 85 15 11 39 30 12 9.8 15 195 11 29 108 108 1.5 0.15 0.30 12 2.9 18 15 12 29 9.8 195 265 25 120 8.8 8.8 34 Torque kgf·m 1.0 15 0.30 0.85 0.85 0.15 1.5 1.1 1.1 1.1 8.7 8.7 1.5 1.1 4.0 3.1 1.2 1.0 1.5 20 1.1 3.0 11 11 0.15 0.015 0.030 1.2 0.30 1.8 1.5 1.2 3.0 1.0 20 27 2.5 12 0.90 0.90 3.5 ft·lb 87 in·lb 108 26 in·lb 73 in·lb 73 in·lb 13 in·lb 11 97 in·lb 97 in·lb 97 in·lb 63 63 11 97 in·lb 29 22 106 in·lb 87 in·lb 11 in·lb 144 97 in·lb 21 79.6 79.6 13 in·lb 1.3 in·lb 2.6 in·lb 106 in·lb 26 in·lb 13 11 106 in·lb 21 87 in·lb 144 195 18 89 78 in·lb 78 in·lb 25 Remarks MO SS L L L MO MO L L L (Rear: Lh) L MO (threads) L AL S S L MO (threads) MO, St MO, St L 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Final gear case Studs Final gear case cover bolts: N·m ­ 23 34 127 6.9 7.8 25 1.0 5.9 1.5 1.2 8.8 2.9 34 21 34 64 27 25 18 25 29 29 34 20 98 20 29 5.9 34 5.4 108 88 4.9 34 29 29 44 25 Torque kgf·m ­ 2.3 3.5 13 0.70 0.80 2.5 0.10 0.60 0.15 0.12 0.90 0.30 3.5 2.1 3.5 6.5 2.8 2.5 1.8 2.5 3.0 3.0 3.5 2.0 10 2.0 3.0 0.60 3.5 0.55 11 9.0 0.50 3.5 3.0 3.0 4.5 2.5 ft·lb ­ 17 25 93 61 in·lb 69 in·lb 18 8.9 in·lb 52 in·lb 13 in·lb 11 in·lb 78 in·lb 26 in·lb 25 15 25 47 20 18 13 18 21 21 25 15 72 15 21 52 in·lb 25 48 in·lb 79.6 65 43 in·lb 25 21 21 32 18 Remarks L L L MO, St L 8 mm 10 mm Pinion gear nut (final gear) Bearing retainer bolt Brakes: Caliper bleed valves Brake hose banjo bolts Brake lever pivot bolt Brake lever pivot bolt locknut Front brake reservoir cap screws Front brake light switch screw Front master cylinder clamp bolts Front brake pad spring bolts Front caliper mounting bolts Front caliper assembly bolts Rear caliper mounting bolts Rear caliper holder bolt Brake disc bolts Rear master cylinder mounting bolts Rear master cylinder push rod locknut Brake pedal clamp bolt Suspension: Upper front fork clamp bolts Lower front fork clamp bolts Front fork top plugs Piston rod nuts or joint rod nut Inner fork bolt (left) Front fork bottom Allen bolt (right) Front axle clamp bolts Protector screws Rear shock absorber nuts Shock absorber air valves Swingarm pivot shaft Steering: Steering stem head nut Steering stem nut Handlebar nuts Upper front fork clamp bolts Lower front fork clamp bolts Frame: Downtube bolts and nuts Rear footpeg bracket bolts Si S L L AL G S AL L PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Fastener Sidestand nut Electrical System: Spark plugs Crankshaft sensor screws Stator lead holder screw Crankshaft sensor lead holder bolt Alternator outer cover bolts Alternator outer cover joint bolts Alternator outer cover damper bolts Alternator outer cover assembly bolts Alternator cover bolts Alternator inner cover bolts Alternator rotor bolt Alternator stator bolts Regulator/rectifier bolts Timing inspection cap Rotor bolt cap Starter motor terminal locknut Starter motor terminal nut Starter motor assembly bolts Starter motor mounting bolts Headlight body mounting nuts Headlight rim screws Headlight mounting screws Headlight body bracket screws Starter lockout switch screw Front brake light switch screw Sidestand switch bolt Radiator fan switch Water temperature switch Oil pressure switch terminal screw Oil pressure switch Neutral switch Speed sensor mounting bolt Turn signal light mounting nuts Front Rear License plate lens screws License plate light mounting screw N·m 44 18 2.9 9.8 2.9 6.9 6.9 6.9 6.9 11 11 78 13 6.5 1.5 1.5 11 4.9 4.9 11 7.8 1.4 2.9 1.2 1.2 1.2 8.8 18 7.8 1.5 15 15 9.8 5.9 6.9 1.0 1.2 Torque kgf·m 4.5 1.8 0.30 1.0 0.30 0.70 0.70 0.70 0.70 1.1 1.1 8.0 1.3 0.66 0.15 0.15 1.1 0.50 0.50 1.1 0.80 0.14 0.30 0.12 0.12 0.12 0.90 1.8 0.80 0.15 1.5 1.5 1.0 0.60 0.70 0.10 0.12 ft·lb 32 13 26 in·lb 87 in·lb 26 in·lb 61 in·lb 61 in·lb 61 in·lb 61 in·lb 97 in·lb 97 in·lb 58 115 in·lb 58 in·lb 13 in·lb 13 in·lb 97 in·lb 43 in·lb 43 in·lb 97 in·lb 69 in·lb 12 in·lb 26 in·lb 11 in·lb 11 in·lb 11 in·lb 78 in·lb 13 69 in·lb 13 in·lb 11 11 87 in·lb 52 in·lb 61 in·lb 8.9 in·lb 11 in·lb Remarks L L WL L L MO L L SS SS 2-10 PERIODIC MAINTENANCE Specifications Item Fuel System (DFI): Throttle grip free play Idle speed Air cleaner element Cooling System: Coolant: Type (recommended) Color Mixed ratio Freezing point Total amount Engine Top End: Valve clearance Clutch: Clutch fluid: Grade Clutch lever free play Engine Lubrication System: Engine oil: Type Viscosity Capacity Standard 2 3 mm (0.08 0.12 in.) 950 ±50 r/min (rpm) Paper filter Service Limit ­­­ ­­­ ­­­ Permanent type antifreeze Green Soft water 50%, Coolant 50% ­ 35°C (­ 31°F) 2.3 L (2.4 US qt) Non-adjustable (hydraulic lash adjusters) ­­­ ­­­ ­­­ ­­­ ­­­ ­­­ DOT4 Non-adjustable ­­­ ­­­ Level Tires: Tread depth: Front API SE, SF or SG API SH or SJ with JASO MA SAE 10W-40 2.9 L (3.1 US qt, when filter is not removed) 3.1 L (3.3 US qt, when filter is removed) 3.5 L (3.7 US qt, when engine is completely disassembled and dry) Between upper and lower level lines (Wait 2 3 minutes after idling or running) ­­­ ­­­ ­­­ ­­­ ­­­ ­­­ DUNLOP D220F STG: 4.4 mm (0.17 in.) Rear DUNLOP D220 STG: 6.9 mm (0.27 in.) 1 mm (0.04 in.), (DE, AT, CH): 1.6 mm (0.063 in.) Up to 130 km/h (80 mph): 2 mm (0.08 in.) Over 130 km/h (80 mph): 3 mm (0.1 in.) Air pressure: (when cold) Front Rear Up to 184 kg (405 lb) load: 250 kPa (2.5 kgf/cm², 36 psi) Up to 184 kg (405 lb) load: 250 kPa (2.5 kgf/cm², 36 psi) ­­­ ­­­ PERIODIC MAINTENANCE 2-11 Specifications Item Final Drive: Final gear case oil: Grade Viscosity Oil level Amount Propeller shaft joint grease Brakes: Brake fluid Grade Brake pad lining thickness: Front Rear Brake light timing: Front Rear Standard Service Limit API Service Classification: GL-5 hypoid gear oil when above 5°C (41°F) SAE90 when below 5°C (41°F) SAE80 Filler opening bottom 200 mL (6.76 US oz) 20 mL (0.68 US oz), high-temperature grease ­­­ ­­­ ­­­ ­­­ ­­­ DOT4 4.0 mm (0.12 in.) 7.5 mm (0.295 in.) Pulled ON ON after about 10 mm (0.39 in.) of pedal travel ­­­ 1 mm (0.04 in.) 1 mm (0.04 in.) ­­­ ­­­ Electrical System: Spark plug gap 0.8 0.9 mm (0.031 0.035 in.) ­­­ AT: Republic of Austria CH: Swiss Confederation DE: Federal Republic of Germany 2-12 PERIODIC MAINTENANCE Special Tools Steering Stem Nut Wrench: 57001­1100 Attachment Jack: 57001­1398 Jack: 57001­1238 Driver-Filler Cap: 57001­1454 PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Fuel System (DFI) Fuel Hose and Connection Inspection The fuel hoses are designed to be used throughout the · · · motorcycle's life without any maintenance, however, if the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (see Fuel System chapter) and check the fuel hose. Replace the fuel hose if any fraying, cracks [B] or bulges [C] are noticed. Check that the hoses are securely connected and clamps are tightened correctly. When installing, route the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter. When installing the fuel hoses, avoid sharp bending, kinking, flattening or twisting, and route the fuel hoses with a minimum of bending so that the fuel flow will not be obstructed. Replace the hose if it has been sharply bent or kinked. Throttle Control System Inspection below). the throttle grip free · Checkfree play is incorrect, play [A]. throttle cable (see If the adjust the Throttle Grip Free Play Standard: 2 3 mm (0.08 0.12 in.) the throttle grip moves smoothly from close to · Check thatand the throttle closes quickly and completely full open, in all steering positions by the return spring. If the throttle grip doesn't return properly, check the throttle cable routing, grip free play, and cable damage. Then lubricate the throttle cable. Run the engine at the idle speed, and turn the handlebar all the way to the right and left to ensure that the idle speed doesn't change. If the idle speed increases, check the throttle grip free play and the cable routing. · throttle cable · If necessary, adjust the and screw the as follows:[B] all the adjusters Loosen the locknuts [A] way in so as to give the throttle grip plenty of play (rear view). Turn out the adjuster of the decelerator cable [C] until there is no play. Tighten the locknut against the adjuster. Turn the adjuster of the accelerator cable [D] until the proper amount of throttle grip free play is obtained and tighten the locknut against the adjuster. 2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Inspection it · Start the engine and warmfastup thoroughly.warm up time At first the engine will run to decrease (fast idle). Gradually the fast idle will lower to a certain RPM automatically. This is the idle speed. Check the idle speed. · · Idle Speed Standard: 950 ±50 r/min (rpm) With the engine idling, turn the handlebar to both sides. If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed or damaged. Be sure to correct any of these conditions before riding (see Cable, Wire, and Hose Routing section in the Appendix chapter). WARNING Operation with improperly adjusted, incorrectly routed or damaged cables could result in an unsafe riding condition. If the idle speed is out of the specified range, adjust it. Start the engine and warm it up thoroughly. Wait until fast idle speed lowers to a certain value. Turn the adjusting screw [A] until the idle speed is correct. Open and close the throttle a few times to make sure that the idle speed is within the specified range. Readjust if necessary. Front [B] · · Air Cleaner Element Cleaning In dusty areas, the element should be cleaned more After riding through rain or on muddy roads, the element should be cleaned immediately. frequently than the recommended interval. NOTE · Remove: [A] and Washer and Left Air Cleaner Cover [B] Allen Bolt Front [C] · Remove the element [A]. into the lower air cleaner duct · Push a clean, lint-free towel material from entering. to keep dirt or other foreign WARNING If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident. CAUTION If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur. PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures the lightly to loosen dust. · Cleanawayelement by tapping it by applying compressed the remaining dust · Blow from the inside to the outside (from the clean side air [A] · · to the dirty side). Visually check the element for no tears or no breaks and check the sponge gasket [B] also. If the element or gasket has any tears or breaks, replace the element. Install the left air cleaner cover. Torque - Left Air Cleaner Cover Allen Bolt: 16 N·m (1.6 kgf·m, 12 ft·lb) Evaporative Emission Control System Inspection (CAL) · Inspect the canister as follows: Frame chapter). Remove the left side cover (see Remove the band [A] and take out the canister [B]. Visually inspect the canister for cracks and other damage. NOTE If the canister has any cracks or bad damage, replace it with a new one. The canister is designed to work well through the motorcycle's life without any maintenance if it is used under normal conditions. Run the purge hose (green) [A] above the canister breather hose (blue) [B] through the hole [C] into the tool case [D]. Do not run these hoses side by side on the battery side of the canister. This prevents hoses from being flattened when installing the left side cover. Install the canister and the left side cover (see Frame chapter). Face the white mark [E] left as shown. separator as follows: · Check the liquid/vaporfrom the separator, and remove the Disconnect the hoses separator [A] from the motorcycle right side. Front [B] Visually inspect the separator for cracks and other damage. If the separator has any cracks or damage, replace it with a new one. To prevent the gasoline from flowing into or out of the canister, hold the separator perpendicular to the ground. Check the hoses of the evaporative emission control system as follows: Check that the hoses are securely connected and clips are in position. Replace any kinked, deteriorated or damaged hoses. Route the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter. Refer to the diagram of the evaporative emission control system in the Fuel System chapter too. When installing the hoses, avoid sharp bending, kinking, flattening or twisting, and route the hoses with a minimum of bending so that the emission flow will not be obstructed. · 2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cooling System Radiator Hose and Connection Inspection The · high pressure inside the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen. Replace the hose if any fraying, cracks [B] or bulges [C] are noticed. Check that the hoses are securely connected and clamps are tightened correctly. Torque - Radiator Hose Clamp Screws: 2.5 N·m (0.25 kgf·m, 22 in·lb) Coolant Change WARNING To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery, and can cause an accident and injury. Since coolant is harmful to the human body, do not use for drinking. container under the radiator · Place a the drain bolt (front view). drain bolt [A], then remove (see Fuel System (DFI) chapter). · Remove the fuel tank cap [A] in two steps. First turn the Remove the radiator · cap counterclockwise to the first stop. Then push and turn The coolant will drain from the radiator and engine. Front [B] it further in the same direction and remove the cap. the water pump drain bolt [A]. · Removewill drain from the water pump [B].The remaining coolant Place a conduit under the drain hole of the pump cover. The conduit leads to a container. Front [C] PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures · Remove : Cover (see Frame chapter) Right Side · · · Reserve Tank Bolts Turn over the reserve tank [A], remove the cap [B], and pour the coolant into a suitable container. Install the reserve tank. When filling the coolant, choose a suitable mixture ratio by referring to the coolant manufacturer's directions. CAUTION Soft or distilled water must be used with the antifreeze (see Specifications in this chapter) in the cooling system. If hard water is used in the system, it causes scale accumulation in the water passages, and considerably reduces the efficiency of the cooling system. Water and Coolant Mixture Ratio (when shipping) : Soft Water 50 % : Coolant 50 % : Freezing Point - 35°C (- 31°F) : Total Amount 2.3 L (2.4 US qt) Torque - Radiator Drain Bolt: 2.2 N·m (0.22 kgf·m, 19 in·lb) Water Pump Drain Bolt: 11 N·m (1.1 kgf·m, 97 in·lb) · Tighten the drain bolts. · Fill the coolant into the radiator. NOTE the engine and radiator. Fill in the coolant slowly so that it can expel the air from · Check the cooling system for leaks. pump · Bleed the air from the water[B] until [A]. coolant seeps out the Loosen the air bleeder bolt around the bolt, then tighten it. Torque - Water Pump Air Bleeder Bolt: 11 N·m (1.1 kgf·m, 97 in·lb) · Next, loosen the air bleeder bolt [A] on the thermostat housing. · · Front [B] Replenish the coolant into the radiator until the coolant begins to flow out the air bleeder bolt hole (that is, all the remaining air is forced out). Tap the radiator hoses to force any air bubbles caught inside. 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures radiator up · Fill thethe radiator to the filler neck [A] with coolant. cap. · Install the air bleeder bolt [B]. Tighten · Torque - Thermostat Air Bleeder Bolt: 7.8 N·m (0.80 kgf·m, 69 in·lb) to · Fill the reserve tank upcap.the "F" (full) level line [A] with coolant and install the the fuel tank (see Fuel System (DFI) chapter). · Installthe engine and warm it up thoroughly until the radiStart · ator fan turns on and then stop the engine. the coolant · Checkthe engine islevel in the reserve tank several times while cooling down, and replenish as necessary. If the coolant level is lower than the "L" level line, add coolant to the "F" level line. CAUTION Do not add more coolant above the "F" level line. Engine Top End Air Suction Valve Inspection · Remove the air suction valve (see Engine Top End chapter). · Visually inspect the reeds for cracks, folds, warps, heat damage or other damage. · If there is any doubt as to the condition of the reeds [A], replace the air suction valve as an assembly. Check the reed contact areas [B] of the valve holder for grooves, scratches, any signs of separation from the holder or heat damage. is any as to the · If therereplacedoubtair suctioncondition of the reed contact areas, the valve as an assembly. If any carbon or other foreign particles have accumulated · between the reed and the reed contact area, wash the valve assembly clean with a high-flash point solvent. CAUTION Do not scrape off the deposits with a scraper as this could damage the rubber, requiring replacement of the suction valve assembly. PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Clutch Clutch Hose and Connection Inspection inside cause fluid · The high pressurehose to the clutch line cannot properly to leak [A] or the burst if the line is maintained. Bend and twist the rubber hose while examining it. Replace it if any fraying, cracks [B] or bulges [C] are noticed. Check that the hoses are securely connected and banjo bolts are tightened correctly. Torque - Clutch Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) · installing the clutch hose, route · When Cable, Wire, and Hose Routing the hoses according to section in the Appendix chapter. Replace the hose if it has been sharply bent or kinked. Clutch Fluid Level Inspection fluid · Hold the clutch clutchreservoir horizontal. reservoir is Check that the level of the clutch · between the lower [A] fluid the upper [B] level lines. and If the fluid level is lower than the lower level line, fill the reservoir to the upper level line in the reservoir. Since the clutch fluid is the same as the brake fluid, refer to Brakes Section in the this chapter for further details. Torque - Clutch Reservoir Cap Screws: kgf·m, 13 in·lb) 1.5 N·m (0.15 WARNING Change the fluid in the clutch line completely if the fluid must be refilled but the type and brand of the fluid that already is in the reservoir are unidentified. After changing the fluid, use only the same type and brand of fluid thereafter. Mixing different types and brands of fluid lowers the fluid boiling point and could cause the clutch to be ineffective. It may also cause the rubber clutch parts to deteriorate. 2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Fluid Change · Level the clutch fluid reservoir and remove the reservoir cap. (see Electrical · Remove the alternator outer cover the bleed valveSystem chapter.) and the rubber cap from on the clutch slave cylinder. Attach a clear plastic hose [A] to the bleed valve and run the other end of the hose into a container. Fill the reservoir with fresh fluid. Change the clutch fluid as follows. Open [B] the bleed valve, using a wrench. Pump the clutch lever and hold [C] it. Close [D] the bleed valve. Release [E] the clutch lever. Repeat this operation until fresh fluid comes out from the plastic hose or the color of the fluid changes. Check the fluid level in the reservoir often, replenishing it as necessary. · · · If the fluid in the reservoir runs completely out any time during fluid changing, the bleeding operation must be done over again from the beginning since air will have entered the line. NOTE WARNING Do not mix two brands of fluid. the · After changingfluid fluid, check the clutch for good clutch power and no leakage. · · · If necessary, bleed the air from the lines (see Clutch Line Bleeding in the Clutch chapter). Remove the clear plastic hose. Install the reservoir cap. Tighten the bleed valve, and install the rubber cap. Torque - Clutch Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb) Clutch Slave Cylinder Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Clutch Master Cylinder Cup and Dust Seal Replacement · Remove the clutch master cylinder (see Clutch chapter). the reservoir [A] and · Remove clutch fluid intocapcontainer. diaphragm [B], and pour the a · Unscrew the locknut [C] and pivot bolt [D], and remove the clutch lever [E]. · Pull the dust cover [F] out of place, and remove the circlip [G]. primary · Pull out the[J]. cup [H], piston assembly [I], and return spring Special Tool - Inside Circlip Pliers: 57001-143 CAUTION Do not remove the secondary cup [K] from the piston since removal will damage it. · Check the parts of the clutch master cylinder (see Clutch chapter). If any part shows signs of damage, replace it. all parts · Before assembly, cleanor alcohol. including the master cylinder with clutch fluid CAUTION Use only disc brake fluid, isopropyl alcohol or ethyl alcohol, for cleaning parts. Do not use any other fluid for cleaning these parts. Gasoline, motor oil or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the cylinder. · Apply clutch fluid to the parts removed and to the inner wall of the cylinder. · Take care not to scratch the piston or the inner wall of the cylinder. · Install the push rod with the dust seal fitted into the groove. The push rod round end must be faced inwards. Torque - Clutch Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 8.9 in·lb) Clutch Lever Pivot Bolt Locknut: 5.9 N·m (0.60 kgf·m, 52 in·lb) · Install the clutch master cylinder (see Clutch chapter). 2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Slave Cylinder Piston Seal Replacement · Remove the alternator outer cover (see Electrical System chapter) · Loosenitthe banjo bolt [A] at the clutch pipe lower end, and tighten loosely. the detach · Unscrewwith slave cylinder bolts [B] andengine. the slave cylinder the pipe installed from the · Pump the clutch lever until the piston comes out of the cylinder. · Unscrew the banjo bolt and remove the slave cylinder [C]. CAUTION Immediately wash away any clutch fluid that spills. It may damage painted surfaces. If the clutch slave cylinder is removed and left alone, the piston will be pushed out by spring force. NOTE · Remove the spring and piston seal. CAUTION Replace the piston seal with a new one if it was removed from the piston. assembly, apply clutch · Beforeand the piston seal. fluid to the outside of the piston piston · Install the [A] seal as shown. Cylinder Piston [B] Piston Seal [C] Spring [D] Engine Lubrication System Engine Oil Change the motorcycle so that it is vertical after warming · Situateengine. up the · Remove the engine oil drain plug [A] and drain the oil. PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures · Remove: Plug [A] Oil Screen · Remove the oil screen [A], the spring [B], and the washer [C]. screen high-flash point solvent and · Clean the oilparticles with ato it. remove any stuck · Clean the screen thoroughly whenever the engine oil is changed. WARNING Clean the screen in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents. While cleaning the screen, check for any metal particles that might indicate internal engine damage. NOTE · Check the screen carefully for any damage of holes, broken wires, and so on. · If the screen is damaged, replace it. Be sure to put in the oil screen with the rubber gasket end inside. Replace the screen plug O-ring with new one. Torque - Oil Screen Plug: 20 N·m (2.0 kgf·m, 15 ft·lb) The oil in the filter can be drained by removing the filter (see Oil Filter Change in this section). Replace the drain plug gasket with a new one if it is damaged. Torque - Engine Oil Drain Plug , Oil Screen Plug: 20 N·m (2.0 kgf·m, 15 ft·lb) Oil Filter: 18 N·m (1.8 kgf·m, 13 ft·lb) oil filler cap [A] · Remove thethe specified typewith the driver-filler cap [B] and pour in and amount of oil. Clutch Cover [C] Special Tool - Driver-Filler Cap: 57001­1454 Torque - Oil Filler Cap: 1.5 N·m (0.15 kgf·m, 13 in·lb) 2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Oil Type: Viscosity: Amount: API SE, SF or SG class API SH or SJ class with JASO MA SAE 10W-40 2.9 L (3.1 US qt, when filter is not removed) 3.1 L (3.3 US qt, when filter is removed) 3.5 L (3.7 US qt, when engine is completely disassembled and dry) Although NOTE 10W-40 engine oil is the recommended oil for most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area. Oil Filter Replacement · Drain the engine oil (see Engine Oil Change in this section). the oil filter · Removethe oil filter. [A] with the oil filter wrench [B] and discard Special Tool - Oil Filter Wrench: 57001-1249 The filter has an oil filter bypass valve which can not be removed. oil filter with the new one. · Replace thethe gasket of the new filter before installation. Apply oil to · Tighten the filter with the oil filter wrench. · Pour in the specified type and amount of oil. · Torque - Oil Filter: 18 N·m (1.8 kgf·m, 13 ft·lb) NOTE Wheels/Tires Tire Inspection As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn). So it is false economy and unsafe to use the tires until they are bald. Remove any imbedded stones or other foreign particles from the tread. Visually inspect the tire for cracks and cuts, replacing the tire in case of damage. Swelling or high spots indicate internal damage, requiring tire replacement. · · PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures the center of · Measure the tread depth at tire may wearthe tread with a depth gauge [A]. Since the unevenly, take measurement at several places. If any measurement is less than the service limit, replace the tire (see Wheels/Tires chapter). Tread Depth Front: Standard: Service Limit: Rear: Standard: Service Limit: 4.4 mm (0.17 in.) 1 mm (0.04 in.) (DE, AT, CH) 1.6 mm (0.063 in.) 6.9 mm (0.27 in.) 2 mm (0.08 in.): Up to 130 km/h (80 mph) 3 mm (0.1 in.): Over to 130 km/h (80 mph) · Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours.) Adjust the tire air pressure according to the specifications if necessary. Air Pressure (when cold) Front Up to 184 kg (405 lb) Rear Up to 184 kg (405 lb) 250 kPa (2.5 kgf/cm², 36 psi) 250 kPa (2.5 kgf/cm², 36 psi) WARNING To ensure safe handling and stability, use only the recommended standard tires for replacement, inflated to the standard pressure. Use the same manufacture's tires on both front and rear wheels. Most countries may have their own regulations requiring a minimum tire tread depth; be sure to follow them. Check and balance the wheel when a tire is replaced with a new one (see Wheels/Tires chapter). Final Drive Oil Level Inspection NOTE WARNING Motorcycle operation with insufficient, deteriorated, or contaminated oil causes accelerated wear and may result in seizure of the pinion and ring gears. Seizure can lock the rear wheel and skid the rear tire, with consequent less of control. perpendicular to the ground. · Support the motorcycle[A], using the driver-filler cap [B]. · Unscrew the filler plug Special Tool - Driver-Filler Cap: 57001­1454 2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures · The oil level [A] should come to the bottom of the filler opening. · If it is low, first check the final gear case for oil leakage, remedy it if necessary, and add oil through the filler opening. Use the same type and brand of oil that is already in the final gear case. Install the filler plug. Oil Change running that the · Warm up the oil bysediment the motorcycle so Stop the oil will pick up any and drain easily. · motorcycle and turn the ignition switch OFF. Place an oil pan beneath the final gear case, and remove the filler cap and drain plug [A]. WARNING When draining or filling the final gear case, be careful that no oil gets on the tire, spoke, or rim. Clean off any oil that inadvertently gets on them with a high-flash point solvent. the has completely · After with oilnew gasket. drained out, install the drain plug a Torque - Final Gear Case Drain Plug: 8.8 N·m (0.90 kgf·m, 78 in·lb) · Fill the final gear case with the specified oil and quantity. Final Gear Case Oil: Amount: 200 mL (6.76 US oz) Grade: Viscosity: API GL-5 hypoid gear oil When above 5°C (41°F) SAE 90 When below 5°C (41°F) SAE 80