User manual KAWASAKI VN 1600 CLASSIC - SERVICE MANUAL

VULCAN 1600 CLASSIC VN1600 CLASSIC 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 pro cedure. ·Bend the pages back to match the black tab of the desired chapter num ber 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 spe cific 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 CLASSIC VN1600 CLASSIC Motorcycle Service Manual 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. Second Edition (1) : Aug. 25, 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 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 tionally, 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 in cludes a catalytic converter system. 3. Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. In stead, 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 know ingly 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 follow ing 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 de vices or elements of design in order to perform maintenance. 2. Tampering could include: a.Maladjustment of vehicle components such that the emission standards are ex ceeded. 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 stan dards. 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 in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop proce dures must be understood in order to carry out maintenance and repair satisfactorily. When ever the owner has insufficient experience or doubts his ability to do the work, all adjust ments, maintenance, and repair should be car ried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thor oughly familiarize yourself with the procedures before starting work, and then do the work care fully 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 ad versely 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 Mo torcycle 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 care fully. Don't take shortcuts. Remember to keep complete records of main tenance and repair with dates and any new parts installed. How to Use This Manual In preparing this manual, we divided the prod uct into its major systems. These systems be came the manual's chapters. All information for a particular system from adjustment through disassembly and inspection is located in a sin gle chapter. The Quick Reference Guide shows you all of the product's system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. The Periodic Maintenance Chart is located in the Periodic Maintenance chapter. The chart gives a time schedule for required maintenance operations. If you want spark plug information, for exam ple, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, use the Quick Reference Guide to locate the Periodic Maintenance chap ter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug sec tion. 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 per sonal injury, or loss of life. CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in dam age 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 informa tion. · · NOTE This note symbol indicates points of par ticular interest for more efficient and con venient 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 inspec tion in the procedural step or sub-step it fol lows. 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 spec ified tightening torque, oil, grease or a locking agent during assembly. GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ..................................................................................................................... Model Identification................................................................................................................. General Specifications............................................................................................................ Unit Conversion Table ............................................................................................................ 1-2 1-7 1-9 1-11 1 1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera tion 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, discon nect 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 neg ative 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 ve hicle 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 ac cident. Visually inspect removed parts for corrosion, discol oration, 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 be yond 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 disassem bly, 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 dam age. 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 per formance. 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 be fore applying liquid gasket or locking agent. Do not apply them excessively. Excessive application can clog oil pas sages 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 con tact 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. Lubri cation 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. Ro tate 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-A1 (US, and Canada) Left Side View: VN1600-A1 (US, and Canada) Right Side View: 1-8 GENERAL INFORMATION Model Identification VN1600-A1 (Europe) Left Side View: VN1600-A1 (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 Capacity VN1600-A1 2 505 mm (98.62 in.) 1 040 mm (40.9 in.), (AU) 990 mm (39 in.) 1 130 mm (44.5 in.) 1 680 mm (66.1 in.) 130 mm (5.12 in.) 680 mm (26.8 in.) 306 kg (675 lb), (AU) 307 kg (677 lb) 156 kg (345 lb) 181 kg (399 lb), (AU) 182 kg (401 lb) 20 L (5.3 US gal) Unleaded and high-octane gasoline (see VN1600-A1 Owner's Manual) 3.5 m (11.5 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 49 kW (67 PS) @ 4 700 r/min (rpm), (CA) (CAL) (US) ­ 127 N·m (12.95 kgf·m, 93.7 ft·lb) @ 2 700 r/min (rpm), (CA) (CAL) (US) ­ DFI (Digital Fuel Injection) System Electric starter Battery and coil (transistorized) Electronically advanced (digital) From 0° 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 3.5 L (3.7US qt, when engine is completely disassembled and dry) Front Rear 1-10 GENERAL INFORMATION General Specifications Items VN1600-A1 Drive Train: Primary reduction system: Type Gear 1.517 (85/56) Reduction ratio Wet multi disc Clutch type Transmission: 5-speed, constant mesh, return shift Type 2.500 (40/16) Gear ratios: 1st 1.590 (35/22) 2nd 1.192 (31/26) 3rd 0.965 (28/29) 4th 0.781 (25/32) 5th Final drive system: Shaft Type 2.619 (15/21 × 33/9) Reduction ratio 3.105 @ Top gear Overall drive ratio Final gear case oil: API Service Classification: GL-5 Hypoid gear oil Grade SAE90 (above 5°C), SAE80 (below 5°C) Viscosity 200 mL (6.76 US oz) Capacity Frame: Type Tubular, double cradle Caster (rake angel) 32° Trail 168 mm (6.61 in.) Front tire: Type Tubeless Size 130/90 - 16 M/C 67H Rear tire: Type Tubeless Size 170/70B16 M/C 75H Front suspension: Type Telescopic fork Wheel travel 150 mm (5.91 in.) Rear suspension: Type Swingarm Wheel travel 95 mm (3.74 in.) Brake Type: Front Dual disc Rear Single disc Electrical Equipment: Battery Capacity 12 V 18 Ah Headlight: Type Semi-sealed beam Bulb 12 V 60/55 W (quartz-halogen) Tail/brake light 12 V 5/21 W Alternator: Type Three-phase AC, twin rotor Rated output 42A × 14 V @ 6 000 r/min (rpm) Specifications are subject to change without notice, and may not apply to every country. AU: Australia CAL: California CA: Canada US: United States of America GENERAL INFORMATION 1-11 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 Seal Replacement ............ Clutch Slave Cylinder Piston Seal Replacement ............................ Engine Lubrication System ............. Engine Oil Change....................... Oil Filter Replacement ................. Wheel/Tires..................................... Tire Inspection ............................. 2-2 2-4 2-10 2-12 2-13 2-13 2-13 2-13 2-14 2-15 2-15 2-16 2-16 2-17 2-19 2-19 2-19 2-19 2-20 2-20 2-21 2-22 2-23 2-23 2-24 2-24 2-24 Final Drive....................................... Oil Level Inspection...................... Oil Change ................................... Propeller Shaft Joint Lubrication .. 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 .................... 2-25 2-25 2-26 2-26 2-27 2-27 2-27 2-27 2-28 2-29 2-29 2-29 2-30 2-30 2-30 2-31 2-31 2-31 2-31 2-31 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 1 000 km * ODOMETER READING (600 mile) 6 000 km (4 000 mile) 12 000 km (7 500 mile) 18 000 km (12 000 mile) 24 000 km (15 000 mile) 30 000 km (20 000 mile) 36 000 km (24 000 mile) See Page OPERATION Spark plug (e) - clean and gap Air suction valve (e) - inspect Air cleaner element (e) - clean# Throttle control system (e) - inspect Idle speed (e) - inspect Fuel hoses, connections - inspect Engine oil - change # Oil filter - replace Evaporative emission control system (e) (CAL) - inspect Final gear case oil level - inspect Final gear case oil - change Propeller shaft joint - lubricate Brake pad wear - inspect # Brake light switch - inspect Steering - inspect Rear shock absorber oil leak - inspect Front fork oil leak - inspect Tire wear - inspect Swingarm pivot - lubricate General lubrication - perform Nut, bolt, and fastener tightness - inspect Brake/clutch hoses, connections - inspect Brake/clutch fluid level - inspect Coolant hoses, connections - inspect Brake/clutch fluid - change Every · · year · · · · ··· ··· · ··· · ··· · · ··· · · · · · · · · · · · · · · · · · · · · · · · · ·· ·· · · month 2 years ·· ·· ·· · · ·· · · ·· ·· · · ·· · ·· ·· · ·· · ·· · · ·· · · · ·· ·· ·· · · ·· · · · ·· ·· 2­35 2­20 2­16 2­14 2­15 2­14 2­24 2­26 2­17 2­28 2­28 2­29 2­29 2­32 2­34 2­33 2­33 2­27 2­33 2­36 2­37 2­21, 2­29 2­21, 2­29 2­18 2­22, 2­30 PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Whichever comes first 1 000 km * ODOMETER READING (600 mile) 6 000 km (4 000 mile) 12 000 km (7 500 mile) 18 000 km (12 000 mile) 24 000 km (15 000 mile) 30 000 km (20 000 mile) 36 000 km (24 000 mile) See Page 2­23, 2­32 OPERATION Brake/clutch master cylinder cup and dust seal - replace Coolant - change Caliper piston seal and dust seal - replace Steering stem bearing - lubricate Clutch slave cylinder piston seal - replace Every 4 years 2 years 4 years 2 years 4 years · · 2­28 2­32 2­34 2­24 # : 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: L: Apply a non-permanent locking agent to the threads. G: Apply grease to the threads. MO: Apply molybdenum disulfide grease oil solution. O: Apply oil to the threads and seating sur face. S: Tighten the fasteners following the speci fied sequence. SS: Apply silicone sealant. Si: Apply silicone grease (ex. PBC grease). R: Replacement parts Lh: Left-hand-threads St: Stake the fasteners to prevent loosening. AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. Fastener Fuel System: Throttle body assy holder bolts Inlet manifold bolts Spark plug lead holder bolts ISC pipe holder 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 8 Right air cleaner cover Allen bolt 8 Right air cleaner Allen bolts Choke cable plate screw Inlet air temperature sensor nut (DFI) Water temperature sensor (DFI) Fuel pump bolts Cooling System: Radiator hose clamp screws 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 N·m 11 12 11 11 9.8 11 2.2 16 16 11 2.9 7.8 18 9.8 2.5 18 8.3 7.8 8.8 11 11 11 11 The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads. Basic Torque for General Fasteners Threads dia. (mm) 5 6 8 10 12 14 16 18 20 N·m 3.4 4.9 5.9 7.8 14 19 25 34 44 61 73 98 115 155 165 225 225 325 Torque kgf·m 0.35 0.50 0.60 0.80 1.4 1.9 2.6 3.5 4.5 6.2 7.4 10.0 11.5 16.0 17.0 23.0 23 33 ft·lb 30 43 in·lb 52 69 in·lb 10.0 13.5 19.0 25 33 45 54 72 83 115 125 165 165 240 Torque kgf·m 1.1 1.2 1.1 1.1 1.0 1.1 0.22 1.6 1.6 1.1 0.30 0.80 1.8 1.0 0.25 1.8 0.85 0.80 0.90 1.1 1.1 1.1 1.1 ft·lb 95 in·lb 104 in·lb 95 in·lb 95 in·lb 69 in·lb 95 in·lb 19 in·lb 12 12 95 in·lb 26 in·lb 69 in·lb 13 87 in·lb 22 in·lb 13 74 in·lb 69 in·lb 78 in·lb 97 in·lb 97 in·lb 97 in·lb 97 in·lb Remarks Right Side on Cyl. Head Right Side Left Side L, Lower Duct Throttle Body L, Throttle Body SS S, L SS Lh PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Fastener Radiator drain bolt Water temperature sensor (DFI) Engine Top End: Spark plugs Spark plug retainer 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 Chamber bolts Muffler stay mounting bolts and nuts, 8 Muffler bracket bolt and nut Clutch: Clutch lever pivot bolt Clutch lever pivot bolt locknut Clutch reservoir cap crews Clutch slave cylinder bleed valve Clutch slave cylinder bolts Clutch hose banjo bolts Clutch master cylinder clamp bolts Starter lockout switch screws Push rod guide bolts Clutch cover bolts Clutch damper cover bolts (outside) Clutch cover damper plate bolts Clutch cover damper screws Clutch hub nut N·m 7.4 18 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 29 1.0 5.9 1.5 7.8 6.9 25 11 1.2 11 11 9.8 9.8 4.9 147 Torque kgf·m 0.75 1.8 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 3.0 0.10 0.60 0.15 0.80 0.70 2.5 1.1 0.12 1.1 1.1 1.0 1.0 0.50 15.0 ft·lb 65 in·lb 13 13 104 in·lb 65 in·lb 95 in·lb 14 43 in·lb 13 in·lb 13 in·lb 11 87 in·lb 18 58 18 78 in·lb 18 14 78 in·lb 95 in·lb 18 104 in·lb 61 in·lb 22 18 22 8.7 in·lb 52 in·lb 13 in·lb 69 in·lb 61 in·lb 18 95 in·lb 10 in·lb 95 in·lb 95 in·lb 87 in·lb 87 in·lb 43 in·lb 108 Remarks SS S S S L MO, S S S S L S L S on Cyl. Head except US, CA Si L S L L EO (tip) L MO 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener 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 baffle bolt Engine Removal/Installation: Downtube bolts and nuts Engine mounting bolts and nuts Engine mounting bracket bolts Engine ground terminal bolt Crankshaft/Transmission: Crankcase bolts: 10 mm 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 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 pipe clamp bolts (inside) N·m 1.5 20 20 18 25 15 1.5 15 11 9.8 9.8 11 11 2.9 2.9 11 44 44 25 7.8 39 21 11 1.1 11 11 2.9 2.9 11 59 15 25 9.8 147 2.9 8.3 8.3 1.5 15 11 Torque kgf·m 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 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 1.0 15.0 0.30 0.85 0.85 0.15 1.5 1.1 ft·lb 13 in·lb 14 14 13 18 11 13 in·lb 11 95 in·lb 87 in·lb 87 in·lb 95 in·lb 95 in·lb 26 in·lb 26 in·lb 95 in·lb 33 33 18 69 in·lb 29 15 95 in·lb 95 in·lb 95 in·lb 95 in·lb 26 in·lb 26 in·lb 95 in·lb 43 11 18 87 in·lb 108 26 in·lb 73 in·lb 73 in·lb 13 in·lb 11 95 in·lb S S S Left Crankcase L L ×3 × 1, Lh L MO L SS MO Remarks R, EO SS L SS L L ×3 × 1, Lh L SS L PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Fastener 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 Shift pedal clamp bolts (VN1600­A2 ) Rear shift lever clamp bolt Shift rod locknuts Shift drum bearing holder bolts Shift drum cam screw Damper cam nut (front gear) Push rod guide bolts Wheels/Tires: Front axle clamp bolts Front axle Rear axle nut Tire air valve stem 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 Final gear case studs Final gear case cover bolts: 8 mm 10 mm Pinion gear nut (final gear) Bearing retainer bolt Brakes: Caliper bleed valves Brake hose banjo bolts N·m 85 85 15 11 39 25 30 12 11 11 15 195 9.8 20 108 108 1.5 0.15 0.3 12 2.9 18 15 12 29 9.8 195 265 25 137 8.8 8.8 34 ­ 23 34 130 6.9 7.8 25 Torque kgf·m 8.7 8.7 1.5 1.1 4.0 2.5 3.1 1.2 1.1 1.1 1.5 20 1.0 2.0 11.0 11.0 0.15 0.015 0.03 1.2 0.30 1.8 1.5 1.2 3.0 1.0 20 27 2.5 14 0.9 0.9 3.5 ­ 2.3 3.5 13 0.7 0.8 2.5 ft·lb 63 63 11 95 in·lb 29 18 22 104 in·lb 95 in·lb 95 in·lb 11 144 87 in·lb 14 79.6 79.6 13 in·lb 1.3 in·lb 2.6 in·lb 104 in·lb 26 in·lb 13 11 104 in·lb 22 87 in·lb 144 195 18 101 78 in·lb 78 in·lb 25 ­ 17 25 94 61 in·lb 69 in·lb 18 Remarks MO MO L L (Rear: Lh) L L MO (threads) L AL S L MO (threads) MO, St MO, St L L L L St, MO L 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener 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 caliper mounting 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 Front fork bottom allen bolt Front axle clamp bolts Rear shock absorber nuts Swingarm pivot shaft Steering: Steering stem head nut Steering stem nut Handlebar clamp bolts Handlebar holder nuts Upper front fork clamp bolts Lower front fork clamp bolts Turn signal light mounting nuts Frame: Downtube bolts and nuts Footboard bracket bolts Footpeg bracket bolts Sidestand nut Electrical System: Spark plugs Crankshaft sensor screws Stator lead holder screw Inside stator holder bolts Crankshaft sensor lead holder bolt Alternator outer cover bolts Alternator outer cover joint bolts Alternator outer cover damper bolts N·m 1.0 5.9 1.5 1.2 8.8 34 34 64 27 25 18 25 20 29 22 20 30 20 34 108 88 5 34 34 20 29 5.9 44 34 25 44 18 2.9 9.8 11 2.9 6.9 6.9 6.9 Torque kgf·m 0.10 0.60 0.15 0.12 0.9 3.5 3.5 6.5 2.8 2.5 1.8 2.5 2.0 3.0 2.2 2.0 3.1 2.0 3.5 11.0 9.0 0.5 3.5 3.5 2.0 3.0 0.6 4.5 3.5 2.5 4.5 1.8 0.30 1.0 1.1 0.30 0.70 0.70 0.70 ft·lb 8.7 in·lb 52 in·lb 13 in·lb 10 in·lb 78 in·lb 25 25 47 20 18 13 18 14 21 16 14 22 14 25 79.6 65 43 in·lb 25 25 14 21 52 in·lb 33 25 18 33 13 26 in·lb 87 in·lb 95 in·lb 26 in·lb 61 in·lb 61 in·lb 61 in·lb Remarks G, S L AL L AL G AL front rear, L L L L L L PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Fastener 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 rim screws Headlight unit bracket screws Starter lockout switch screw Front brake light switch screw Sidestand switch bolt Radiator fan switch Radiator fan bolts Fuel level sensor mounting bolts Fuel pump mounting bolts Water temperature switch Water temperature sensor Oil pressure switch terminal screw Oil pressure switch Neutral switch Speed sensor mounting bolt Turn signal light mounting screws Turn signal light lens screws Tail/brake light mounting nuts Tail/brake light lens screws Tail/brake light assembly screws N·m 6.9 11 11 78 13 6.5 1.5 1.5 11 4.9 4.9 11 2.9 1.0 1.2 1.2 8.8 18 8.3 6.9 9.8 7.8 18 1.5 15 15 9.8 6.9 1.0 5.9 1.2 1.2 Torque kgf·m 0.70 1.1 1.1 8.0 1.3 0.66 0.15 0.15 1.1 0.50 0.50 1.1 0.30 0.10 0.12 0.12 0.90 1.8 0.85 0.70 1.0 0.80 1.8 0.15 1.5 1.5 1.0 0.70 0.10 0.60 0.12 0.12 ft·lb 61 in·lb 95 in·lb 95 in·lb 58 113 in·lb 57 in·lb 13 in·lb 13 in·lb 95 in·lb 43 in·lb 43 in·lb 95 in·lb 26 in·lb 8.7 in·lb 10 in·lb 10 in·lb 78 in·lb 13 7.4 in·lb 61 in·lb 87 in·lb 69 in·lb 13 13 in·lb 11 11 8.7 in·lb 61 in·lb 8.7 in·lb 52 in·lb 10 in·lb 10 in·lb Remarks MO L L L L S SS SS G SS L 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 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) ­­­ ­­­ ­­­ ­­­ ­­­ ­­­ Tires: Tread depth: Front BRIDGESTONE EXEDRA G721: 4.3 mm (0.17 in.) BRIDGESTONE EXEDRA G722: 7.2 mm (0.28 in.) 1 mm (0.04 in.), (DE, AT, CH): 1.6 mm (0.063 in.) Rear Up to 130 km/h (80 mph): 2 mm (0.08 in.) Over 130km/h (80mph): 3 mm (0.1 in.) Air pressure: (when cold) Front Rear Up to 186 kg (410 lb) load: 200 kPa (2.0 kgf/cm², 28 psi) Up to 186 kg (410 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 Electrical System: Spark plug gap 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 4.5 mm (0.18 in.) 7.5 mm (0.295 in.) Pulled ON ON after about 10 mm (0.39 in.) of pedal travel 0.8 0.9 mm (0.031 0.035 in.) ­­­ 1 mm (0.04 in.) 1 mm (0.04 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 Filler Cap Driver : 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 in side 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, kink ing, flattening or twisting, and route the fuel hoses with a minimum of bending so that the fuel flow will not be ob structed. Replace the hose if it has been sharply bent or kinked. Throttle Control System Inspection Throttle Grip Play Inspection Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cable (see below). · 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 throt tle 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 Grip Free Play Standard: 2 3 mm (0.08 0.12 in.) · throttle cable · If necessary, adjust the and screw the as follows:[B] all the Loosen the locknuts [A] adjusters 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 Throttle Bore Cleaning Check the throttle bore for cleanliness as follows: Remove the air cleaner cover Allen bolt [A] and take off the right air cleaner cover [B]. Front [C] · Check the throttle bores [A] at the throttle valves [B] and around them for carbon deposits by opening the valves. If any carbon accumulates, wipe the carbon off the throttle bores around the throttle valves, using a lint-free cloth [C] penetrated with a high-flash point solvent. Front [D] 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 auto matically. 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] · · PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Air Cleaner Element Cleaning NOTE In dusty areas, the element should be cleaned more frequently than the recommended interval. After riding through rain or on muddy roads, the element should be cleaned immediately. · Remove: and Washer [A] 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 en gine wear and possibly engine damage will occur. 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. 2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures 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 dam age. 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 sys tem 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 di agram 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. · 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) PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures 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 The conduit leads to a container. Front [C] Place a conduit under the drain hole of the pump cover. · 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 an tifreeze (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 consider ably reduces the efficiency of the cooling system. 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures 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: 7.4 N·m (0.75 kgf·m, 65 in·lb) Water Pump Drain Bolt: 11 N·m (1.1 kgf·m, 95 in·lb) · Tighten the drain bolts. · Fill the coolant into the radiator. NOTE Fill in the coolant slowly so that it can expel the air from the engine and radiator. · Check the cooling system for leaks. · Bleed the air from the water pump [A]. coolant seeps out Loosen the air bleeder bolt [B] until the around the bolt, then tighten it. Torque - Water Pump Air Bleeder Bolt: 11 N·m (1.1 kgf·m, 95 in·lb) · Tap the radiator hoses to force any air bubbles caught inside. radiator up · Fill thethe radiator to the filler neck [A] with coolant. cap. · Install 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 radi · Startfan turns on and then stop the engine. ator the coolant · Checkthe engine islevel in the reserve tank several times while cooling down, and replenish as nec essary. 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. PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Engine Top End Air Suction Valve Inspection · Remove the air suction valve (see Engine Top End chap ter). · 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. 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 exam ining it. Replace it if any fraying, cracks [B] or bulges [C] are no ticed. 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 accord ing to section in the Ap pendix chapter. Replace the hose if it has been sharply bent or kinked. 2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Fluid Level Inspection f · Hold the clutch cluid reservoir horizontal. reservoir is Check that the lutch fluid level of the clutch · 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. Since the clutch fluid is the same as the brake fluid, refer to Brake Fluid Section in the Brakes 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. Clutch Fluid Change · Level the clutch fluid reservoir and remove the reservoir cap. Electrical · Remove the alternator outer cover (seebleed valveSystem chapter.) and the rubber cap from the 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. PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures 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) Clutch Master Replacement Cylinder Cup and Dust Seal · 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 re turn spring Special Tool - Inside Circlip Pliers: 57001-143 CAUTION Do not remove the secondary cup [K] from the pis ton 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 deterio ration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventu ally deteriorate the rubber used in the cylinder. 2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures · 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, 8.7 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). Clutch Slave Cylinder Piston Seal Replacement the clutch slave cylinder (see Clutch chapter). · Removethe banjo bolt [A] at the clutch pipe lower end, and Loosen · tighten it 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 re moved 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] PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Engine Lubrication System Engine Oil Change Si the motorcycle so that it is vertical after warming · uptuateengine. the · Remove the engine oil drain plug [A] and drain the oil. · Remove: Plug [A] (Engine right side) Oil Screen · Remove the oil screen [A], the spring [B], and the washer [C]. Clean the oil screen with a high-flash point solvent and · remove any particles stuck to it. · 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.