Kawasaki vN1500

Motorcycle
Service Manual
 Quick ReferenceGuide

This quick referenceguide will assistyou in

locating a desiredtopic 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
oi contents page.
aRefer to the sectional table of contents for
the exact pagesto locate the specific topic
required,
Kawasaki vN1500
VNl5OOA:
VULCAN88 (USandCanada)
VN-15 (Othersl
VNlSOOB:
VU LCAN 88 SE (USand Canada)
VN-15SE (Othersl

Motorcycle
Service Manual
All rightsreserved. No partsof this publicationmay be reproduced,storedin a retrievalsystem,or
transmittedin any form or by any means,electronicmechanicalphotocopying,recordingor other-
wise, without the prior written permissionof Ouality AssuranceDepartment/Consumer Products
Group/KawasakiHeavyIndustries,Ltd., Japan.
No liabilitycan be acceptedfor any inaccuraciesor omissionsin this publication,althoughevery
possiblecare has beentakento make it as completeand accurateas possible.
The right is reservedto make changesat any time without prior notice and without incurringan
obligationto makesuch changesto productsmanufacturedpreviously. Seeyour Motorcycledealer
for the latest informationon productimprovementsincorporatedafter this publication.
All informationcontainedin this publicationis basedon the latestproduct informationavailableat
the time of publication. lllustrationsand photographsin this publicationare intendedfor referencs
use only and may not depictactualmodelcomponentparts.

@ KawasakiHeavyIndustries,
Ltd.,1987,1990,1991,1993,1995, 1997,1999, EighthEdition(1) : N/ar.20,1999 (K)
 LIST OF ABBREVIATIONS
A ampere{s} tb pound(sl
ABDC after bottom deadcenter m meter{s}
AC alternatingcurrent min minute(s)
ATDC after top deadcenter N naryton(sl
BBDC before bottom dead center Pa pascal(s)
BDC boftom dead center PS horseporer
BTDC before top deadcenter psi pound(s)persquareinch
"c degree(s) Celsius rwolution
DC direct current rpm revolution(slperminute
F farad(s) TDC top deadcenter
.F
degree(slFahrenheit TIR total indicatorr€ading
ft foot, feet volt{s)
s gram{s) W watt(s)
h hour(sl o ohm(s)
L liter(s)

ReadO,I/NER'SMANI At beforeoperating
 EMISSIONCONTBOL INFORMATION

To protect the environment in which we all live, Kawasakihas incorporatedcrankcase

emission(1) and exhaust emission(2) control systemsin compliancewith applicablereg-
ulations of the United States Environmenal Protection Agency and California Air Re
sourcesBoard. Additionally, Kawasakihas incorporatedan evaporativeemissioncontrol
system {3} in compliancewith applicableregulationsof the CaliforniaAir Resources Board
on vehicles sold in Californiaonly.
1. CrankcaseEmissionControl System
This system eliminatesthe releaseof crankcasevapors into the atmosphere. Instead,
the vaporsare routed through an oil separatorto the intake sideof the engine.While
the engineis operating,the vaporsaredrawn into combustionchamber,wherethey are
burnedalongwith the fuel and air suppliedby the carburetionsystem.
2. ExhaustEmissionControl System
This systemreducesthe amount of pollutants dischargedinto the atmosphereby the
exhaustof this motorcycle. The fuel and ignition systemsof this motorcyclehave
beencarefully designedand constructedto encrre an efficient enginewith lorivexhaust
pollutant levels.
3. EvaporativeEmissionControl'System
Vapors causedby fuel waporation in the fuel systemare not vented into the atmos
phere. Instead,fuel vaporsare routed into the runningengineto be burned,or stored
in a canisterwhen the engineis stopped. Liquid fuel is caughtby a vaporseparatorand
returnedto the fuel tank.

The CleanAir Act, which is the Fede€l law coveringmotor vehiclepollution, contains
what is commonly referredto asthe Act's "tamperingprovisions."
"Sec.203(a)The follorving actsand the causingthereof are prohibited...
(3)(A) for any personto removeor renderihoperativeany deviceor elementof design
installed on or in a motor vehicleor motor vehicle engine in compliancewith
regulationsunder this title prior to its saleand deliveryto the ultimatepurchaser,
or for any manufactureror dealerknowingly to removeor renderinoperativeany
such device or element of designafter such sale and delivery to the ultimate
purchaser.
(3XB) for any personengagedin the businessof repairing,servicing,selling,leasing,or
trading motor vehiclesor motor vehicleengines,or who operatesa fleet of motor
vehiclesknowingly to remove or render inoperativeany deviceor element of
designinstalled on or in a motor vehicle or motor vehicleenginein compliance
with regulationsunder this title following its sale and delivery to the ultimate
ourchaser..."

(Continuedon next page.l

 NOTE
. The phrase " removeor rendet inoperativeany device or element of design ,, hasbeen
generally interyreted as follows :
1. Tampe ng does not include the temporary removalor rendering inoperativeof de-
vices or elementsof design in order to perform maintenance-
2. Tamperingcould include :
a. Maladjustmentof vehiclecomponentssuch that the emission standardsare exceeded.
b. use of replacementparts or accessorieswhichadverselyaffect the pedotmanceor
durability of the motorcycle.
c. Addition of componentsot accessories that result in the vehicte exceeding the
standards.
d. Permanentlyremoving,disconnecting,or renderinginoperativeany componentor
element of designof the emission control systems.

WE RECOMMENDTHAT ALL DEALERS OBSERVETHESE PROVISIONSOF

FEDERAL LAW, THE VIOLATIONOF WHICH IS PUNISHABLEBY CIVIL
PENALTIESNOT EXCEEDING$1O,OOOPER VIOLATION.

TAMPEBINGWITII NOISECONTBOLSYSTEMPBOHIBITED
Federallaw prohibitsthe followingacts or the causingthereof: (1) The removalor
rendering inoperativeby any personother than for purposesof maintenance,repair, or
replacement,of any darice or elementof designincorporatedinto any neurvehicle'for
th€_.purposeof noisecontrol prior to i6 sale or delirieryto the ultimatepurchaser or
while it is in use,or (21the useof the vehicleafter grch deviceor elemento:f a".id h.,
beenremoredor renderedinoperativeby any pervrn.

_Amongthoseastspre$medto constitutetamperingaretheactslistedbelow:
. R.eplacem€nt
of_the originalexhaustsystemor mrifflerwith a componentnot in com-
pltancewtth Fedeftrlregulations.
oRemovalof the muffler(s)or any internalportion of the muffler(s).
.Removal of the air box or air box cover.
rModifications to the muffrer(s) or air intake system-'
by cutting,
-- dri ing, or other means
if such modificationsresult in increased
noisetevLis.
 Foreword
This manualis designedprimarilyfor useby
trainedmechanicsin a properlyequippedshop. Howto Usethis Manual
However, it contains enough detail and basic
information to make it useful to the owner ln preparing this manual, we divided the
who desiresto perform his own basic main- product into its major systems, Thesesystems
tenance and repair work. A basic knowledge becamethe manual'schapters. All information
of mechanics,the proper use of tools, and for a panicularsystemfrom adiustmentthrough
workshop procedures must be understood in
disassemblyand inspectionis located in a single
order to carry out maintenanceand repair
chapter,
satisfactorily, Wheneverthe owner has insuf-
ficient experienceor doubts his ability to do The Ouick ReferenceGuide showsyou all of
the produst,s systems and assisB in locating
the work, all adjustments,maintenance,and
repair should be carriedout only by qualified their chapters. Each chapter in turn has its
olvn comprehensive Table of Gontents.
mechanics.
The PeriodicMaintenanceChan is locatedin
In order to perform the work efficiently and
the General Information chapter. The chart
to avoid costly mistakes,read the text, thor- givesa time schedulefor required maintenance
oughly familiarize yourself with the procedures
operations,
before starting work, and then do the work
lf you want spark plug information, for
carefully in a clean area. Whenwer special
example,go to the PeriodicMaintenanceChart
tools or equipment are specified, do not use
first. The chart tells lou hovv frequently to
makeshifttools or equipment. Precisionmeas-
clean and gap the plug. Next, use the Ouick
urementscan only be made if the proper in-
ReferenceGuide to locatethe ElectricalSystem
strumentsare used, and the use of substitute
chapter. Then. usethe Tableof Gontentson the
tools may adversely affect safe operation.
first pageof the chapterto find the Spark Plug
For the duration of your warranty period,
especially,we recommendthat all repairsand section.
Whenaneryou see these WARNING and
scheduledmaintenancebe performedin accord-
ance with this service manual, Any owner CAUTION symbols, heed their instructions!
maintenanceor repair procedurenot performed Always follow safe operatingand maintenance
practices.
in accordancewith this manual may void the
warranty.
To get the longest life out of your Motor-
cycre:
oFollow the PeriodicMaintenance Chartin the oThis waming rymbol identifiesspecialinstruc-
ServiceManual, tions or procedures which, if not correctly
.Be alert for problems and non-scheduled followed, could result in perconal iniury. or
maintenance. lossof life.
eUseproper tools and genuineKawasakiMotor-
cycle parts. Special tools, gauges,and testers
that are necessarywhen servicing Kawasaki
motorcyclesare introducedby the SpecialTool oThis caution symbol identifies specialinstruc-
Manual. Genuinepafts providedasspareparts tions or procedureswhicfi, if not strictly ob-
are listed in the PansCatalog. served,could result in damageto or destruc-
rFollow the procedures in this manual car+ tion of equipment.
fully. Don't take shortcuts.
rRemember to keep complete recordsof main- This manual contains five more symbols (in
tenance and repair with dates and any new addition to WARNING and CAUTION) which
pafts installed. will help you distinguish different types of
information.

NOTE
oThis note symbol indicates pointr of partic-
ular interest for more efficient and con-
venient operation.
.Indicates a proceduralstep or work to be
done.
olndicatesa proceduralsub-stepor how to do
the work of the proceduralstep it follows.
It also precedesthe text of a WARNING,
CAUTION, or NOTE.
* lndicatesa conditionalstepor what actionto
take based on the results of the test or
inspectionin the proceduralstep or sub-step
it follows.
*lndicates a conditional $b-step or what
astion to take bas€dupon the resultsof the
conditionalstepit follows.

ln most chaptersan.explodedviqlv illustra-

tion of the systemcomponentsfollorvsthe
Table of Contents. In theseillustrationsyou
will find the instructionsindicatingwhichparts
requireqecified tighteningtorque, oil, grease
or a lockingagentduringassembly.
 GENERALINFORMATION
T.1

GeneralInformation
Tableof Contents

BeforeServicing 1-2
Modelldentification. . . . . 14
GeneralSpecifications. ,.. 1-5
Periodicmaintenance Chart. 1-7
Torqueand LockingAgent 1€
Cable.WireandHoseRouting. 1-12
1.2 GENERALINFORMATION

Before Serwicing

Beforestarting to servicea motorcycle,carefulreadingof the applicablesection is recommended

to eliminate
unnecessarywork. Photographs,diagrams,notes, cautions, warnings, and detailed descriptions
have been
included wherever necessary. Nevertheless, even a detailed account has limitations,a certai; amount of basic
knowledge is also requiredfor successfulwork.
Especially note the following;
(1) Dirt
Before removal and disassembly,clean the motorcycle. Any dirt enGring the engine or other parts
will
work as an abrasiveand shortenthe life of the motorcycle. For the sameieason, defore installing
a new
part,clean off any dust or metalfilings.
(2) BatteryGround
Remove the ground (-) lead from the battery before performingany disassemblyoperationson
the
motorcycle. When installing,.connectthe positive (+) leadfirs! then the negative
1-j teadto the battery.
This prevents: (a) the possibilityof accidentallyturning the engineover while partiallydisassembled.(b)
sparksat electrical connectionswhich will occur when they are disconnected.
1c1damage to electrical
Dans.
(3) Installation,Assemblv
Generally,installationor assemblyis the reverseof removalor disassembly. But if this ServiceManual
has installationor assemblyprocedures,follow them. Note partslocationsani cable,wire, and hose
routing
during removal or disassemblyso they can be installedor assembledin the sameway. lt is preferable
6
mark and recordthe locationsand routing as much as possibte.
(4) TighteningSequence
Generally.when insulling a part with severalbolts, nuB, or screws,start them all in their holes
and
tighten them to a snug fit. Then tighten them evenly in a cross pattern. This is to avoid distortionof the
part and/or causing gas or oil leakage. Converselywhen looseningthe bolts, nuts,
or screws.first loosen
all of them by about a quanerturn and then removethem. Wherethereis a tightening sequenceindication
in this Service Manual. the bolts, nuts,or screwsmust be tightenedin the ordlr and irethod inoicated.
(5) Torque
When torque valuesare given in this ServiceManual, usethem. Eithertoo little or too much rorquemay
leadto seriousdamage. Usea good quality,reliabletorque wrench,
(5) Force
Common senseshould dictatehow much force is necessaryin assemblyand disassembly.lf a pan seems
especiallydifficult to removeor install,stop and examinewhat may be causing the problem. Whenever
tapping is necessary,tap lightly using a wooden or plastic-facedmallet Use an impact driver for
screws
(particularlyfor the removalof screwsheld by a locking ageno in orderto avoid damaging
the screw heads.
(7) Edses
Watch for sharp edges,especiallyduring major engine disassemblyand assembly. protect your hands
with gloves or a piece of thick cloth when litting the engineor turning it over.
(8) High-FlashPointSotvent
A high-flash point solvent is recommendedto reduce fire danger. A commefcial solvent commonly
availablein North Americais Stoddardsolvent (genericname). Always follow manufacturerand container
directionsregardingthe use of any solvent.
(9) Gasket,O-Ring
Do not reuse a gasket or O-ring once it has been in service. The mating surfacesaround the gasket
. should be free of foreign matterand perfectlysmooth to avoid oil or compressionleaks.
(10) LiquidGasket,Non-Permanent LockingAgent
Follow manufacturer'sdirectionsfor cleaningand preparingsurfaceswhere these compounds
will be
used. Apply sparingly' Excessiveamountsmay block engineoil passagesand causeserious
damage. An
example of a non-permanentlocking agent commonly availablein North America is Loctite Lock,n
Seal
(Blue).
(11) Press
A part installedusing a pressor drivet such as a wheel bearing,shouldfirst be coatedwith oil on tts
outer
or inner circumferenceso that it will go into place smoothly.
(12) Ball Bearingand NeedleBearing
Do not remove a ball bearingor a needlebearing unlessit is absolutelynecessary. Replaceany
ball or
needlebearingsthat were removedwith new ones,as removalgenerallydamagesbeirings. Install
bearings
with the markedside facing out applyingpressureevenlywith a suitabledriver. Only pr& on the race
that
 GENERALINFORMATION1-3

forms the pressfit with the basecomponentto avoid damagingthe bearings. This preventsseverestress
on the balls or needlesand races,and preventracesand balls or needlesfrom being dented. Pressa ball
bearinguntil it stops at the stops in the hole or on the shaft.
(13) Oil Sealand GreaseSeal
Replaceany oil or greasesealsthat were removedwith new ones,as removalgenerallydamagesseals.
When pressingin a seal which has manufacture/smarks,press it in with the marksfacing out. Seals
should be pressedinto place using a suitabledrivet which contacts evenlywith the side of seal, until the
{ace of the seal is even with the end of the hole. Beforea shaft passesthrough a seal,apply a little high
temperaturegreaseon the lips to reducerubberto metalfriction.
(14) Circlip.RetainingRing.and CotterPin
Replaceany circlips, retaining rings. and cotter pins that were removed with new ones, as removal
weakensand deformsthem. When installingcirclipsand retainingrings, take careto compressor expand
them only enough to installthem and no more.
(15) Lubrication
Engine wear is generallyat its maximum while the engine is warming up and before all the rubbing
surfaceshave an adequatelubricativefilm. During assembly,oil or grease (whichever is more suitable)
should be appliedto any rubbing surfacewhich has lost its lubricativefilm. Old greaseand dirty oil should
be cleanedoff. Deterioiatedgreasehas lost is lubricativequalityand may containabrasiveforeign panicles.
Don't use iust any oil or grease. Some oils and greasesin particularshould be used only in certain
applicationsand may be harmful if used in an applicationfor which they are not intended. This manual
makesreferenceto molybdenum disulfide grease(MoS" ) in the assemblyol certainengine and chassis
parts. Always check manufacturerrecommendationsbetoreusing such speciallubricants.
(16) Electrical Wires
All the electricalwires are either single-coloror two-color and, with only a few exceptions,must be
connectedto wires of the samecolor. On any of the two-color wires there is a greateramount of one color
and a lesseramount of a second color, so a two-color wire is identified by first the primarycolor and then
"yellow/red" wire;
the secondarycolor. For example,a yellow wire with thin red stripes is refenedto as a
"redlvellow" wire il the colorswere reversedto make red the main color.
it woufd be a

Wire (cross-section) Nameof WireColor

Red
' WireStrands
Yellow/Red
Yellow
Red

(17) ReplacementParts
When there is a replacementinstruction,replacethesepartswith new ones everytime they are removed.
Thesereplacementpartswill be damagedor losetheir originalfunction once removed.
(18) Inspection
When parts have been disassembled,visually inspectthese parts for the following conditions or-other
damage. lf there is any doubt as to the conditionof them, replacethem with new ones.
Abrasion Crack Hardening Warp
Bent Dent Scratch Wear
Color change Deterioration Seizure
(19) Specifications
SDecificationterms are defined as follows:
"Standards":show dimensionsor performances which brand-new partsor systemshave.
"Service Limits": indicate the usable limits. lf the measurementshows excessivewear or deteriorated
performance,replacethe damagedparts.
14 GENERAL ]NFORMATION

Model ldentification

VN1500-A1 Right SideView

VN15qlB1 Left SideView

 GENERALINFORMATION16

GeneralSpecifications

Items A11INA 413 vN1500-81/BZB3/84/85/86

VN1sOGAI/AZA3/A4IA5IA6IA7I AU A9IA1OI
Dimensions:
Overalllength 2 390mm,(A)(F)2 385mm,(E)2 410mm,(l) 2 375mm, 2 370 mm,(E)2 410 mm
Overallwidth 895mm
Overallheight 1 190mm,(AXE)1 180mm 1 210mm,(E)1 195mm
Wheelbase 1 605mm 1 635 mm,(E) 1 630 mm
Roadclearance 150mm,(AXE)lS5 mm 165mn,(E)160mm
Seatheight 720mm,(A)(E)750mm 710mm,(E)745mm
Dryweight 2s2 k9,(Car)2s2.5kg,(E)257k9,(G)256kg 248kg,(Cal)248.5kg
(E)24eks
Curbweight: Front 126kg,(Cal)128kg 121kg,(Cal)121.5kg
Rear 154kg,(Cal)154.skg,(E) 1s7kg,(G) 156kg 1s4kg,(E) 15skg
Fueltankcapacity 1 6L 1 2L
Pertormance:
lrinimumtumingradius 3.0mm,(AXE)2.7 nrn 3.0m
Engine:
Type 4-stroke,SOHC,2-cylinder
Coolingsystem Liquid-cooled
Boreandstroke 102.0x 90.0mm
Displacement 1 470mL
Compressionratio 9.0:1
Maximum horsepower 53.0kW (72PS)@4500r/min(rpm),(Us)-
(E)51.5kW(70 PS)@4500r/min(rpm)
(F)50.0kW(-)@4 500r/min(rpmXUTAC's norm)
(G)s1.5kW(70 PS)@4500r/min(rpmXDlN)
(W)34.9kW(47.5PS)@3800 r/min(rpm)
A4-(E)44.9kW (61PS)@4300 r/min(rpm)
A4-(G)44.9kW (61PS)@4300r/min(rpmXDlN)
As-(F) 43.5kW(-) @4300r/min(rpmXUTAC's norm)
torque
Maximum 123.6N-m(12.6kg-m,91ft-lb)@3000r/min(rpm)
(F)-,(us)-
(G)123.6N-m(12.6kg-m,91ftlb) @300or/minGpmXDlN)
(W)105.9N-m(10.8kg-m,78.1 tt-lb)@2300r/min(rpm)
A4-(E)112.8N-m(11.5k9-m,83.2 itlb) @3300r/min(rpm)
A4-(G)112.8N-m(11.5kg-m,83.2 ftlb)
@3300r/min(rpmXDlN)
Carburetor system Carburetors,KeihinCVK36x 2
Startingsystem Eleclricstarter
lgnitionsystem Batteryandcoil (transistorized)
Timingadvance Electronically
advanced
lgnitiontiming 5"BTDC@800r/min(rpm) =-, (w) 5"BTDC
(rpm)
Sparkplug NGKDPRTEA-g or NDX22EPR-Ug
(AXIXU)NGKDPRTEA-g or ND X22EPR-U9
A11- : (U)NGKDPRTEA-g or ND )Q2EPR-U9
Cylindernumberingmethod Frontto Rear,1-2
'l-2
Firingorder
Valvetiming:
Inlet Open 22'BrDC
Close 66"ABDC
Duration 26A"
Exhaust Open 66.BBDC
Close 26.ATDC
Duralion 272"
Lubrication
system (wetsump)
Forcedlubrication
Engineoil: Grade SE,SF,or SGclass
Viscosity sAE 10W-40,10W-50, 20W-40,20W-50
Capacity 3.5L
1€ GENERAL INFORMATION

VNl500"A1IAZA3/AN
ASIAGI
A AAAglA1UA11tA1AA1g vNl 500-81/B2/B3/BtyB5/B6
DriveTrain:
Primaryreduction system:
Type Gear
Reductionratio 1.s17(8s/56)
Clutchlype: Wetmultidisc
Transmission:
Type 4-speed,constantmesh,returnshift
Gearratios:1st 2.s00(40/16)
znd 1.s90(35/22),41 1-1.375(33t24],
3rd 1.192(31/26),
411-1.03s(29/28)
4th 0.965(28/29),Al 1-0.781125/32)
Finaldrivesystem:
Type Shalt
Reductionratio 2.619(15/21
x33/9)
Overalldriveratio 3.838,411-3.105@Topgear
Finalgearcaseoil:
Type API GL-sHypoidgearoil
SAE90(above5"C)
SAEso(below5"C)
Capacity 22OmL
Frarne:
Type Tubular,doublecradle
Caster(rakeangle) 31" 33' , (E)32.5"
Trail '128
mm 138mm,(E)132mm
Fronttire: Type Tubeless Tube
Size 100i90-1957H
Reartire: Type Tubeless Tube
Size 15O90-15 74Ho|l5cl/90-15M/C74H =-or 150/90815
M/C74H
Frontsuspension:
Type Telescopic
tork
Wheeltravel 150mm
Rearsuspension:
Type Swingarm
Wheeltravel 100mm
Braketype: Front Singledisc
Rear Singledisc
ElectricalEquipment:
Battery 12V20Ah
Headlight: Type Semi-sealedbeam
Butb '12
V 60/55W (quartz-halogen)
Taiubrake light 12V A7127Wxz( )(E)12V s/21WX2
Altemator: Type Three-phaseAC
Ratedoutput 25 A @6000r/min(rpm),14V

Specitications
are subjectt(
to changewithoutnotice,andmaynot applyto everycountry.

(A) : AustralianModel (E) : EuropeanModol (G) : WestGeman Model (U) : U.S.A.Model

(Au) : AuslrianModel (F) : FrenchModel (l) : ltalianModel (UK): UK Model
(Cal): CalifomiaModel (Fi): FinnishModel (Sd): SwedishModel (W) : Switzertand
Modet
"1 (Au)(W)34.9kW (47.sPS)@3 -2 (AUXW)
800/min (rpm) 105.9N-m(1o.8kg-m,78.1 ttlb)
(E)s1.5kW (70 PS) @5000r/min(rpm) @2300r/min(Ipm)
(G)s1.5kW (70PS) @5@0 r/min(rpmXDlN) (E)127.5Nm(13.0kg-m,g4.Otr-tb)@300or/min(rpm)
84- (E)45.7kW (-) @5000r/min(rpmXUTAC's norm) (G)'i27.5Nm(13.0k9.m,94.0ftlb) @3000 r/min(rpmXDtN)
84- (G)47.1kW (64 PS)@500or/min(rpmXDtN) 84- (G)117.7N-m(12.0kg-m,86.8 ftlb) @3300r/min(rpmxDtN)
84- (D(SdXUK) 47.1kW (64 PS)@5000r/min(rpm) 84- (IXSdXUK) 117.7N-m(12.0kg-m,86.8 ft-lb)
85- (Fi)47.1kW (64 PS)@500or/min(rpm) @3300r/min(rpm)
(US)_ 85- (Fi)117.7N-m(12.0kg-m,86.8 t-tb) @3300r/min(rpm)
(us)-
 PeriodicMaintenanceChart (Other than US and Canada)
The scheduled maintenancemust be done in accordancewith this chart
to keep the motorcyclein good
running condition. The initial maintenance is vitally important and must not
be neglectei.
FREOUENCY.

OPERATION
Sparkplug - cleanandgapt a o
O a a o
Air suctionvalve- checkt a o a o a a
Air cleanerelement- clean t # a o a
Throttlegrip play - checkt a a a o
ldlespeed- qdiust a o a a
Carburetorsynchronization- checkt o o o
Engineoil - change# o o
6 months a o a a a
Oil lilter - replace a a a o
Oil screen - clean a a a a
Radiatorhoses,connections- checkt a
Coolant - change 2 yeas a
Finalgear caseoil level - checkt a a a
Finalgear caseoil - change O a
Propellershaft joint - lubricate a a
Clutch slavecylindg piston seal - replace 4 years
Brakelining or pad wear - checkt # a a a a a a
fluid levet- checkt
Brake/clutch month a o a a a a a
Brake/clutchfluid - change 2 yeas a
Brake/clutch
mastercylindercup anddust
seal- replace 4 years
Caliperpiston seal and dust seal - reprace 4 years
Brakelight switch - checkt a a a o o a a
Steering - checkl a a a a a a a
Steeringstem bearing- lubricate 2 yeats a
Frontfork oil - change 2 years a
Rearshock absorberoil leak - check T a a a
Frontfo* oil leak - checkt a o a
Tirewear - checkt a a a a a a
Spoketightnessand rim runout - checkt a a a
(vN15008) a a a a
Swingarm pivot - lubricate a a
Baftery elgctrolyte tevel - checkl 6 month o a a a a a
Generallubrication- oerform a a O
Nut, bolt, and fastener tightness - checkt a a a a
: Service more. frequently when operating in severe conditions; dusty, wet, muddy,
, high speed, or frequent
starting/stopping.
: For higher odometerre€dings,repeatat the frequencyintervalestablishedhere.
T : heprace,add, adJust,ctean,or torque if necessary.
 GENERALINFORMATION1.7

PeriodicMaintenanceChart (Us and Canada)

The scheduledmaintenancemust be done in accordancewith this chart to keepthe motorcycle in

good running condition, The initial maintenanceis vitally important and must not be neglected.

Whichever TODOMETER
READING
FREOUENCY comesfirst

OPERATION I
- checki
Garburetors,ynchronization a a a a a a a
ldle soeed-- adiusl o a a a a a a
Throttle grip play - check 1 a a a a
Spark plug - cleanand gap t a a a a a o
Air suctionvalve- check J a a a a a a
Air cleanerelement- clean a a a a
Air cleanerelement- replace 5 cleaninqs a
Fuelsystem- checkt o a a
Evaporative emissioncontrolsystem(CA) a a a a a a a
- checkt
Batterv electrolvtelevel- checkt month a a a a a a a
Brakeliqht s\n,itch-. check f a O o a a a a
Brakepadwear- check f a o a a a a
Brake/clutchfluid level- checkI month a a a a a a a
Brake/clutchfluid - chanqe 2 vears a
Steerins- checki a a a a a a a
Final qearcaseoil level- checkt a a a
Final gearcaseoil - change a a
Propellershaftioint - lubricate a a
Nut, bolt. fastenertightness- check1 a a a a
Spoketightnessand rim runout - checki O a a a a a a
(VN1500-8only)
Iire wear- checkt a a a a o o
Enqineoil - chanqe year a a a a
Oil filter - replace a a a a
- clean
Oil screen a a a a
Generallubrication- perform a a a a a a
Front fork oil - chanqe a
Swinqarm pivot -- lubricate a a
Coolant- change 2 yearc a
Radiatorhoses,connections- check1 year a a a a
Steeringstembearing- lubricate 2 years a
Brake/clutchmastercylinder cup and 2 years
dust seal- reolace
Caliperoiston sealand dust seal- replace 2 yearc
Clutch slavecvlinder piston seal- replace 2 years
hoseandpipe- replace
Brake/clurch 4 years
Fuel hose- reolace 4 years

here.
r : For higherodometerreadings,repeatat the frequencyintervaleEtablished
t : Replace,add, adjust,clean,or torque if necessary.
(CA):California
vehicleonly
1€ GENERAL INFORMATION

Torque and LockingAgent

The foilowing tableslist the tighteningtorque for the majorfasteners,and the partsrequiringuseof
a non-permanentlocking agentor liquid gasket.
Lettercusedin the "Remarks" column mean:
L Apply a non-permanentlocking agentto the threads.
ss Apply siliconesealantto the threads.
M Apply molybdenum disrlfide lubricant (greaseor oil) tq the threads and seatedsr rface, or
washer.
o Apply oil to the threads,seatedzurface,or washer.
b Tightenthe fastenersfollowing the specifiedtoroue.
st stake the fastenerto prwent loosenins.
Torque
Fascner Remarks
N-m kgrn ft-lb
CoolingSystem:
CoolingFanSwitch 7.8 0.80 69 in-lb
BleedValve |
7.8 | 0.80 69 in-lb
WaterPumplmpellerBolt 8.8 | 0.90 78 inlb Left-handed
Threads
WaterPumpCover 9.8 1.0 87 in-lb
EngineTop End:
RockerCaseCoverBolts 8.8 0.90 78 in-lb
RockerShaft 25 2.5 18.0
RockerCaseBoltsandNuts: 12 mm 78 8.0 58 S
8mm 25 2.5 18.0 S
6mm 8.8 0.90 78 in{b s
CylinderHeadNuts 25 2.5 18.0
CylinderNut 25 2.5 18.0
Oil PipeBanjoBolts 12 1.2 104inlb
Camshaft SprocketBolts 15 1.5 11.0
SparkPlugRetainer 12 ,:
'104in-lb
ChainTensionerBolts L
Clutch:
Clutch LeverPivot Nut 5.9 0.60 52 in-lb
MasterCylinderClampBolts 8.8 0.90 78 in-lb
Clutch HoseBanioBolts 25 2.5 18.0
Clutch SlaveCylinder Bolts 8.8 0.90 78 in-lb
BleedValve 7.8 0.80 69 inlb
RH EngineCoverDamperBolts 9.8 1.0 87 in-lb L
ClutchHub Nut 145 15.0 110 o
ClutchPioeJoint 18 1.8 13.0
EngineLubricationSystem:
CrankcaseOil Nozzle 2.9 0.30 26 in-lb
Oil Pressre Relief Valve 20 2.O 14.5 L
Oil PrescrreSwitch 15 1.5 11.0 SS
EngineDrainPlug N 2.O 14.5
Oil Filter 18 1.8 13.0
Oil ScreenPlug 20 2.O 14.5
Oil PipeBanjoBolts 12 1.2 l(X in-lb
 GENERAL INFORMATION1-9

Fastener Torque Removark

N-m kg-m ft-rb
Engine Removal/lnstallation:
EngineMountingBolts 44 4.5 33
EngineMounting BracketBolts 24 2.4 '17.5
RightDown Tube Mounting Bolts 44 4.5 55

Crankshaft /Transmission:
CrankcaseBolts: 10 mm ?o 4.0 29
8mm 21 2.1 15.0
6mm 8.8 0.90 78 in-lb
ExternalShift Mechanism
ReturnSpring Bolt 21 1.1 15.0
GearPositioningLeverBolt 8.8 0.90 78 in-lb
ConnectingRod Big End Cap NUts 59 6.0 +J
'|
PrimaryGear Bolt 45 15.0 110
AlternatorRotor Bolt 6.0 43
CamshaftChainGuideHolderBolts L
StarterClutch Bolt 93 o:,
StarterClutch Coupling Bolt 11.0 L
BalancerGearBolt :,5 Y.C
Shift Drum BearingHolderScrew L
,tt
NeutralSwitch 1 1. 0
Rear-rightStud Tap End L
Wheels/Tires:
FrontAxle Nut 88 9.0
FrontAxle Clamp Bolt 29 ?n 22
RearAxle Nut 110 11.0 80
Air Valve Nuts 1.5 0.15 1 3i n - l b
Final Drive:
Front BevelGearCaseBolts:
6mm 8.8 0.90 78 in-lb
8mm 25 2.5 18.0
DamperCam Nut 225 23 toc o
Drive GearNut 265 27
NeutralSwitch 15 I.C 11.0 L
Oil PipeBanjoBolts 12 1.2 104 in-lb
DrivenGearAssemblyMounting Bolts 25 2.5 18.0
DrivenGearBolt 120 12.1 88
FinalGearCaseMountingNuts 29 3.0 22
PinionGearNut 120 12.O 6t St
FinalGearCaseCover Bolts:
8mm t2 2.3 16.5 L
.,8
10mm 34 ? E L
FinalGearCaseStuds L
DrainBolt 8.8 oso Z S i n - fO
PinionBearingRetainer 245 25 180 Left-handed
Threads
RetainerStop Screw 16 1.6 11.5 L
1-IO GENERAL INFORMATION

Torque
Fastener Remarks
N-m kg-m ft-m
Brakes:
BrakeLeverPivotNut 0. 60 52 inlb
FrontlvlasterCylinderClampBolts 8.8 0. 90 78 inlb
BrakeHoseBanjoBolts 25 2.5 1 8 .0
CaliperMountingBolts 32
BleedValves 7.8 0. 80 69 in-lb
DiscMountingBolts 27 2.8 20
RearMasterCylinderMountingBolts 23 2.3 to. c
CaliperHolderBolt 64 6.5 47
BrakePedalLinkClampBotts 25 2.5 1 8 .0
Suspension:
FrontForkClampBolts: Upper 20 2.O '14.
5
LOWer 52 5.3 38
FrontForkDrainBolts
FrontForkBottomAllenBotts 20 2.O 14. 5
SwingArm PivotShaft 98 1 0 .0 72
FrontAxleClampBolt 29 3.0 2.
Fear ShockAbsorberl\ilountjngNuts 30 3. 1 22
Steering:
Handlebar ClampBolts 59 6.0 zl3
WeightMountingScrews
SteeringStemHeadBolt 4.O 29
SteeringStemLocknut 0. 50 43 inlb
Ftame :
RightDownTubeMountingBolts 44 4.5 33
EngineMounting BracketBolts 24 2.4 1 7 .5
BrakePedalLinkClampBotts z5 2.5 1 8 .0
ElectricalSystem:
AlternatorRotorBolts 59 6.0 43
SparkPlugs 18 1.75 't2.
5
CoolingFanSwitch 7.8 0. 80 69 inlb
NeutralSwitch 15 '1.
5 11.0
Oil PressureSwitch 15 t.c 11.0
 GENERALINFORMATION1.11
The tablebelow,relatingtighteningtorqueto threaddiameter,lists*re basictorquefor the bolts
and nuts. Usethis table for only the bolts and nutswhichdo not requirea specifictorquevalue.
All of thevaluesarefor usewith dry solvent+leaned
threads,

General Fastenen
Torque
Threadsdia. (mml
N-m kgm ft-lb
c 3.4 - 4.9 0.35- 0.50 30 - zt3in-lb
6 5.9- 7.8 0.60- 0.80 52 - 69 in-lb
8 14-19 1.4- 1.9 10.0- 13.5
10 25 -34 2.6- 3.5 19.0- 25
12 44 -61 4.5 -6.2 33-45
14 73-98 7.4- 10.O 54-72
16 115-155 1 1 . 5- 1 6 . 0 8 3- 1 1 5
18 165 -225 17.O-23 125- 165
20 225-325 23 - 3:t 165- 2'10
1-12 GENERALINFORMATION

Cable,Wire,andHoseRouting
................;,,.......

WidngRouting

1. Wire Straps
2. CoolingHoses
3. SideStandSwitch
4. RearBrakeLight Switch
5. FuelPump

(vN1500-B)

1. JunctionBox
1. WireClamps 2. Sarter Relay
2. RearFenderRearSection 3. Battery(+) Wire
3. RearTurn SignalLight 4. Battery
 GENERALINFORMATION1.13
Cable, Hoseand Wire Rouling

l. Left SwitchHousingWire
2. ClutchHose
3. WireStraps
4. Bnke Hose
5. RightSwitchHousingWire
6. CableGuide
7. ThrottleCables
8. Turn SignalLight or HeadlightStay
9. Cableor HoseGuide
.l0.
Speedometer Cable
11.Clamps
12. CoolingHose
13: ClutchPipe
1-14 GENERAL INFORMATION
CarburetorHoseRouting (CanadianModel)

l. VacuumHose
2. VacuumHoseFitting
3. VacuumHose(To RearVacuumSwitchValve)
4. VacuumHose(To IC lgniter)
5. Air BreattrerHose
6. Air BreatherHoseFitting
7. VacuumPulseHose(To Liguid/VaporSeparator)
8. VacuumHose(To Front VacuumSwitchValve)
9. Front VacuumSwitchValve
10. ChokeKnob
l l. Air BreatfterHose(To Canister)
'12.
PurgeHose(Betweenthe surgetank andthe canister)

(US.CaliforniaModel)
 GENERALINFORMATION1.15
HoseRouting

1. CleanAir Hose 9. CheckValve(VNl500.A)

2. RearVacuumSwitchValve 10. HoseGuide
3. VacuumHose 11. Battery
4. HoseStraps 12. BatteryVent Hos€
5. Air BreatherHose 13, HoseGuides
6. Air Filter 14. SurgeTank
7. lC lgniter 15, DrainHose
8. Breatier
1.16 GENERAL INFORMATION
Evaporative Emission Control System Hose Routing

(vNlsoGA)
1 . BreatherHose
2. CheckValve
3. ReturnHose(Red)

'..__
-E

I * l :
i------E--i-

(vN1s00-B)

1. FrontVacuumSwitchValve
2. Wireor HoseStraps
3. Liquid/VaporSeparator
4. Batttry
5. lgnitionCoil (Front)
6. lgnitionCoil (Rear)
7. ReturnHose
8. BreatherHose
9. StarterMotorWire

1. CleanAir Hose
2, VacuumHose
'3.
'4. RearVacuumSwitchValve
HoseGuide
5. Vent Tube
6. ReservoirTankTube
7. ReservoirTank
8. Wireor HoseStraps
9. lgnitionCoil (Front)
10. lgnitionCoil (Rear)
11. Canister
 GENERALINFORMATIONT-17
Eyaporatiye Emi$ion control System Hose Routing

l. HoseSt€ps
2. EngineBracket
3. HoseClamp
4. Canister
5. Liquid/VaporSeparator
5. CoolingHose
7. StarterMotor
8. StarterMotor Wire
9. Radiator

,/.-\
, )

1. FuelTank
2. CheckValve(VN150GA)
3. BreatherHose(Blue)
4. Liquid/VaporSeparator(ReturnPump)
5. VacuumPulseHose(White:To Carburetor)
6. BreatherHose(Blue)
7. ReturnHose(Red)
8. Cover
9. Canister
10. BreatherHose(Yellow: To Carburetor)
11. PurgeHose(Green)
12. SurgeTank
I.18 GENERAL]NFORMATION
Engine Top End Ho.e Routing

'!i!
1. VacuumHose(lC lgniter)
,-'.------'- 2. CoolingHose
3. ThermostatHousing
4. FrontVacuumSwitchValve
5. FuelFilter
5. Clut h Hose
7. ThroitleCables
8. VacuumHose(To Front VacuumSwirchValve)
9. CleanAir Hose
10. ClutchHoseStrap
11. CoolingHose
12. VacuumHose(FrontCarburetor)
13. FuelHose(To Carburetor)
14. FuelPump
15. SurgeTank
16. VacuumHose(RearCarburetor)
17. VacuumHose(To RearVacuumSwitchValve)
18. FuelHose(To FuelPump)
19. Air BreatherHoseFitting
20. Res€rvoir
Tank Tube
21. Air BreatherHose
 FUEL SYSTEM2-1

Fuel System
Table of Contents

ExplodedView... 2-2
Specifications 2-5
SpecialTools. ......,.'. 2-5
Throttle Grip and Cables.. 2-6
Throttle CableAdjustment 2$
Carburetorc, 2-7
ldle SpeedAdiustment 2-7
High Altitude PerformanceAdjustment (US model). 2-7
Fuel SystemCleanlinessInspection. 2-7
CarburetorSynchronization 24
ServiceFuel LevelAdjustment . . . . . . 24
CarburetorRemoval 2-9
CarburetorI nstallation 2-10
CarburetorSeparation.. , 211
CarburetorCombination 2-11
CarburetorDisasembly. 2-12
GarburetorAssembly.. . . . 2-12
Carburetor Inspection, 2-14
FuelPump. 2-14
Removal 2-14
lnstallation Notes . . 2-15
Fuel Filter. 2-15
Removal 2-15
lnstallationNotes. , 2-15
Inspection 2-15
Air Cleaner 2-15
Element(Housing)Removal 2-15
E l e m e n t C l e a n i.n. s. . . . 2-16
Air CleanerHousingInstallation... . . 2-16
Air CleanerDuct lnstallation 2-17
SurgeTank 2-17
SurgeTank Removal 2-17
ControlSystem(USCaliforniaVehicleonly)' . . '
Emission
Evaporative 2-17
Notes. .
PansRemoval/lnstallation 2-17
HoseInspection. 2-17
SeparatorInspection. 2-17
SeparatorOperationTest 2-18
CanisterInspection 2-18
 2.2 FUEL SYSTEM

ExplodedView

(D

f---r
t
I
^
A-
l
|

IfrPtri
?."---x
V @-+
6
g
g
va
n p

@-_-1
!

i\ R
reu) €- l,lf

PEB
a
a
./'1
A12:CN
(us)(vy)
1. Left Switch Housing
"al
""\.€
2. Right Switch Housing
3. ThrottleCable(Accelerator)
4. Throtlle Cable(Decelerator) A12:CN
€ (US)(w)
5. Jet Needle
6. ThrottleValve
\ s 6
sBe
7. FloatValveNeedle
8. Float Pivot Pin
9. Float
t0. PilotScrew
11.NeedleJet Holdei
,u&^,
12. MainJet
13. Fuel DrainScrew
14. Botlom Cover
15. FrontCarburetor
16.RearCarburetor g
17. FloatChambel
18.ChokeKnob Assembty t
 FUEL SYSTEM2.3

a 1. DrainHose
rlr 2. VacuumSwitchValve
A12:CN
o-l frles 3. Air CleanerDuct
(usxw) I ti uEi i 4. Surge Tank
5. Surge Tank Duct (Front)
i9t 6. Surge Tank Duct (Rear)
u 7. Air CleanerElement
A12:CN 8, Fuel LevelSensor
(us)w) 9. Fuel Tap

(cal)

(cal) CalitorniaModel
(us) U.S.A.Model
(W) SruitzerlandModel
(cN) CanadaModel

u-)
<-'
------46,
vNlsoGB
I

A
a e
I

$ rT-t
\il

it 0 l i
 24 FUEL SYSTEM

ExaporariwEmbtion Cofitrol Sy$m

@>,\
(Califomiailodell

WHITEJ I
R
H
\ T J

€'

4
YELLOW

1. FuslPump
ffi
p
2. Bnd(ct
3. Uquid/V8porSsp.rsbl
4. Cani*er
 FUEL SYSTEM2€

Specifications

Item Standard
ThrottleGrip :
Throttlegripfreeplay 2-3 mm
Carburetors: vN 1500-4 vN1500-8
Make,type Keihin,CVK36
Mainjet: Front # 1 1 2 , ( C a#l1) 1 8 #130
Rear # 11 2 , ( U S X C # 1)1 5 , ( C a#l )1 1 8 #132
Jet needle: Front Ns3S,(cal)N53U,(W)N67F N36P,(cal)N36R,
W)N77D
Rear N67A,(USXC) N53T,(cal) Ns3V,(W) N67G N36Q,(Cal)N36S,(W)N77D
Pilotscrew 1 ll2 turnsout,As-(FG),A4-(EU):2 1/4turnsout,(USX\9-
Servicefuel level:Front 2 - 2! 1 m m
Rear 4.2!1mm
750-850 r/min(rpm)
(W)8s0-950 r/minGpm)
vacuum
Synchronization Lessthan2.7 kPa(2 cm Hg)

(US) : U.S.A.Model (Cal) : CaliforniaModel (swi) : Switzerland

Model
(C) :CanadaModel (FG) : cermanyModel (EU) : EuropeModel

SpecialTools

Fuel LevelGaugp:57m1-1017
2€ FUEL SYSTEM

.Turn the acceleratorcableadiusteruntil 2 - 3 mm of

Throttle Grip and Cables
throttlegrip play is obtained.Tightenthe locknut.
*lf the throttle cablescannotbe adiustedby usingthe
cableadjustersat the upperendsofthe throttlc cables,
Throttle CableAdjustment usetheadiustersat the lowerendsof the cables.
.Check throttle grip free play. .Removetj,|e fuel tank mountingbolts and move the
tanktowardthe rear.
.First givetie throttle grip plenty of play at the upper
Throttle Grip FreePlay ends of the throttle oables as mentionedabove.
SGndard: 2-3mm Tightentle locknuts.
.Loosen the locknuts,and screwboth throttle cable
adjustingnuts in fully at the lowerendsof the throttle
cables soasto givethe throttlegrip plentyof play.

l. ThrottleGrip FreePlay

rlf the free play is incorrect,adiustthe throttle cables.

A. Accelerator
Cable C. AdiustingNuts
B. Decelerator
Cable D. Locknuts
oLoosen the locknuts,and screwboti throttle cable
adiustersin completelyat the upper ends of the
throttle cablesso asto givethe throttle grip plenty of
play.
.While holdingthe thrortlegripstopagainstthe stopper
inside,turn out the decelerator
cableadrusterstopping .Turn out tl|e deceleratorcableadjustingnut in the
at the point wherethe grip just beginsto be turned sameway with the adlusterat the upperend of the
b.ackfrom the completelystoppedposition. Tighten decelerator cablemakinglure that the throttle grip is
the locknut. not tumedbackat all, Tightenthe locknut.
aTurn the acceleratorcable adiustingnut until the
correctthrottle grip free play is obtained.
.Checkthe following.
ostartthe engine.
oTurn the handlebarfrom side to sidewhile idling the
engine.
*lf the speedvaries,the throttle cablemay be poorly
routedor it may be damaged.
oConectany problemb€foreoperatingthe motorcycle.

ooperation with an impropedy adj$ted, incorreEtly

A. Accelerator Cable C. Adiusters routsd, or damagsd cable could result in an unsafe
B. DeceleratorCable D. Locknuts riding condition.
 FUEL SYSTEM2.7
Adiustment
High Altitude Performance
(USmodel)
::::::::::. oTo improve the EMISSIONCONTROL PERFORM-
ANCE of vehicleso'peratedabove/{lq} fert, Kawasaki
ldle Speed Adiustment recommendsthe following EnvironmentalProtection
.Starttheengineandwarmit up thoroughly. Asencv(EPA)approved modification.
.Turn the handlebarfrom side to sidewhile idling the rcfiangi ti'remainlet andpilot let for highaltitudeuse'
engine.
*lf idle speedvaries,the throttle cablesmay be poorly High Attituds C.rbutstor Specifications
routedor they maybe damaged. MainJet VNl5(xr-A
.Correctany problembeforeoperatingthe motorcycle.
From : #110 €D#115
R@r : #112 @D#115
vN1500-8
Front : #ra
Rgar : #1q,
Pilot Jet #o

ooperation witlr an improp€rly adiusted. incorrecdy

louted, or damagedcable could result in an unsafe
ridingcondition. lnwction
Fuel System Cleanline56

ocarolino b exusm.ly flrtnmrble and can bo axplotivs

undg] csrtain condilions. Tum the imition rwitdl
OFF. Do not tmok3. Mlko rule tha aloa is mll
.Check idle speedwiti a tachometer. ventilaed and frco from any rcurce of fleme or rpcrkl;
$b indudcs any rpgli.nce widl a pilot light.

.Connect a suitable hose to the fitting at each car-

buretor bottom cover.
aRun the lower endsof the hosesinto a suitablecon'
ldle Spesd tainer.
.Turn out each drain plug a few turns and drain the
Standard: 750 - 850 r/min hpml float chambers.
@ 850 - 950 r/min (rpm)

@ : SwissModel(VNls(XlB)

.Turn the idle adjustingscrewuntil idlespeedis correct'

1. DrainScrew
2. SuitableHose
3. Bottom Cover

acheck to seeif watrr or dirt comesouL

.Tighten the drainplugs.
*lf any wateror dirt appeared duringthe aboveinsFec'
A. ldleAdiustingScrew tion, cleanthe fuel system.
2€ FUEL,SYSTEM
Caft utetoI Syn chrcnization
OWamuptheengine.
oCheckidlespeedandadiustif necessary.
OAttacha commercially vacuumgaugeto the
available
vacuumhosefittingsonthecarburetors.
1. VacuumHoseFittings
astart the.engineand let it idle to measurethe engine
'inAkcvasuum..
*tf thi intakevacuumdifferenc€betweent]le cylinders
exc€eds tlte limit, synchronize
the carburetors.
GarburetorSyndronization Vacuufil
Leo than 2.7 kP. (2 crnHg)difference betweentwo
calbuletols
.Witi the engine idling turn tl|e adiuster bolt to
synchronizethe butterflyvalves.
owhen the adiusterbolt is umed in, the rearcylinder
vacuum increases. Whenthe bolt is badcd out, the
rearcylindervacuumdecreases.
A. AdjusterBolt
*lf proper carburetorsynchronization cannot be ob-
tained by using the adiustingbolt, check for dirt or
blockage,and thencheckthe pilot screwsettings.
.Checkthe carburetorsynchronization again.
NOTE
oDo not tum the pilot s€rcwscat"J,ldfsly
during erbure-
tors syndrronization. You may causepoor running at
low ergine spaed.
rCheckidle speed.
&rvice Fuel LevelAdiustment
NOTE
o@rburetor fud lerEl cannot he cheked with the
arburetors removed. ff therc is any doubt, drack tlre
fuel level hefote runoving the carburetors.
ocasolino i: extremely flammableand can be explosive
under certain conditiom. Tum tho ignition switdl
OFF. Do not smoke. Make sure the area is well
yentilated and fle€ from any soutcsof flame or !p6lks;
thb indud$ any appli.ncewidr a pilot light.
.S€curethe motorcyclein a true verticalposition.
oWhentie enginehas beenremoved,set it on a flat
surfacewith tl|e carburetorsinstalled. Put the fuel
tank on a bench, and connectthe fuel tap to the
carburetorsusinga suitablehose.
rPreparea fuel hose.
.Connecta fuel levelguge (specialtool) to the carbure-
tor bottom coverwith the hose.
etlold the gaugeverticallyagainstthe side of the car-
buretor body so tiat the "zero" line is at the upper
edgeofthe coastingenrichermountingsciew.
1. FuelLevelGauge:57001-1017
2. CoastingEnricher
3. UpperEdgeofthe Screw
4. "Zero" line
 FUEL SYSTEM2-9
oTurn the fuel tap to the ON or RES position to feed Carburetor Removal
fuel to tie carburetor, then turn ou! tie carburetor
drain plug a few turns.
.Read the fuel level in the gaugeand compare it to the
specification- Screw in the carburetor drain plug. ocasolineis extremelyflammableandcan be exPlosive
S€rvice Fuel Level under certain conditions. Turn the ignition switair
From the uppet edgp ol dre coalting enticher OFF. Do not smoke. Make sure dte area is well
moundng lower screw. ventilatedandfrce frcm any rcurceof flameor lparks;
wi$ 8 pilot light.
this indudssany appliance
Flont : below 12 - 32 mm
Rear : below 32 - 52 mm .First removethe following.
Seat
*lf the fuel level is incorrect, removethe carburetorsand FuelTank
separatethem (seeCarburetor Sepration). Drainthe fuel from the carburetor.
.To adjust the fuel level,bend the tang on the float arm Loosenthe tirottle cableadiuster.
to changethe float height. .Then removethe followingfrom the left side.
Throttle CableHolder Screw
SurgeTankDuctClampScrew(Loosen)
CarburetorHolderClampScrew(Loosen)
VacuumHose

A. Float B. Tang

olncreasingthe float height lowerstie fuel levelanc A. Throttle€ableHolderScrew

the float heightraisesthe fuel level.
decreasing B. SurgeTankDuct ClampScrew
C. CarburetorHolderClampScrew
Fuel Levd Adiunmsnt
.Then removethe followingfrom the right side.
CarburetorCover
CarburetorCoverBracket
SurgeTank DuctClampScrew(Loosen)
CarburetorHolderClampScrew(Loosen)
VacuumHose

1. Float Tang
2. Float Valve
3. Floa! Mating Edge
4. ChamberRibs A. SurgeTankDuctClampScrew
B. CarburetorHolderClampScrew
NOTE
C. VacuumHose
oDo not push the ndle rcd in during the float height D. CarburetorCoverBracket
masufement. E. C:rburetorCover
2.10 FUEL SYSTEM
rThen removethe follwoingfrom the upperend.
CleanAir SystemHose
Fuel Pumpand Pull the output hosefrom the carbu-
@
retor. olf dirt or durt is allowed to pals through inio d|e
FuelPumpWireConnector carbuntors, the d|rctde may becomerfrrck, possibly
SurgeTank Duct (Front Carburetor) cauringan accident.

l-wAnNrNil
J
oFud .pill.d irom tft€ fud pump & h..:adous. mml
olf dirt gsts through into dte engine. €xcessive engine
wear and polsibly enginedamagewill ocorr.

@rburetortnsallation
.Carburetor installationis the reverseof removal. Note
the following.
olubricate the air cleanerducts and the carburetor
holdercwith a soapand water solution,theo fit the
carburetorsinto them.
owhile aligningthe duct notch onto the surgetank
proiection,fit.eachduct into th€ surgetank asshown.
A. FuelPump C. OutputHose
B. CleanAir SystemHose D. SurgeTank Duct
.fush the surgetank witl the thermostathosingtoward
the front.
aRemovethe carburetorsasshown.

A. Not h B- SurgeTank Projection

A. Turnthecarburctorassernbly
clockwise.

oKG€pthe horesfree of ob8truction,

aAfter installingthe carburetors,

performthe following.
oCheckfuel leakage from the carburetors.

I'--wAutlruc
i
oFuel spilled from the catburetoF b hazardous.

oAdiustthe followingitemsif necessary.

ldle Speed
A. Taketl|e carburetorset out from b€tweenthe CarburetorSynchron ization
cylinderheads. ThrottleCables
 FUEL SYSTEM2.11

@rburetor Separation Screws(3)

Front CarburetorFloatChamber
aRemovethe front carburetor.
oRemovethe followingparts.
ChokeRod MountingPlateScrews
ChokeRod

A. RearCarburetor C. FrontCarburetor
B. FloatChamber D. Screws
A. Choke Rod B. Screws

oRemovethe rear carburetorfloat chamberscrewsand

RearCarburetorChokeRod PivotScrew the rearcarburetor.
seDarate
ChokeLink Rod

rb u retor Combinati on
C.ze
.lnstallationis reverse
of removal. NoGthefollowing.
aFit thefrontcarburetor asshown.
to thefloatchamber

A. ChokeLink Rod B. ChokeRod PivotScrew

Throttle Link RodCotterPinand PlasticWasher

A. Throttle Link Lever C. Notches

B. Proiections

oconnect the choke link rods and install the plastic

A. Throttle Link Lever C. PlasticWasher
B. CotterPin washerandthe throttle link levercotterpin.
2.12 FUEL SYSTEM
olnshll the rear carburetor starter plung€r lever as
snown.

A. Pilot Screw Plug

A. StarterPlungerLever C. StarterPlunger
B. ChokeLink Rod
olnstallthe chokerod to the carburetor.
OTum in the pilot screw and count the number of turns
until it seats fully but not tightl, and then remove the
screw. Use this number of turns to set the screw to its
originalposition during assembly.
awhile prying out the float pivot pin with an awl or other
suitabletool, pull it out with needlenose pliers.

1. FloatPivotPin

A. ChokeRod
Carbu,etor Asembly
.Note tle following
.lnstall the float on the carburetor.
Carburetor Disassembly oTapthe float pivot pin lightly,to pressit evenlyinto
thefloat chamberbodyasshown.

ocasollne is er(ttemely flammable and can be €xplosive

undor certain conditions. Tum the ignition switch
OFF. fro not smoke. Make surc the ar€a is well
ventilated and fros from any sourceof flame or sparks;
dri3 includes any appliancewi$ a pilot light.

oDuring carburetor disassembly, be careful not to

damage t't€ diaphragm. Neyer use a sharp edge to
removethe disphragm.

oRemove the pilot screw plug asfollows:

oPunch a hole in the plug and pry lt out with an awl or A. Float C. Tap the pin asfar as
otier suita.bletool. B. Do not tap here. it will go.

oReplace the float chamber and bottom cover O-rings
with new oneswhen installing.
alnstall the front carburetor onto the F markedchamber
and the rear carburetor onto the R marked chamber
respectively.
FUEL SYSTEM2.13
oTurn in the pilot screw fully but not tightly. and then
back it out the same number of turns counted during
d isassem bly.
oA carburetorhasdifferent"turns out" of the pilot screw
Jor each individual unit. When setting the pilot screw,
usethe "tums out" determinedduring disassembly.Use
the speciticationsin this manual only if the original
numbet is unknown.
aFor the US and SwiEerland models, install the oilot
screw plug as follows:
o lnstall a new plug in the pilot screrr/hole. and apply a
small amount o{ a bonding agent to the circumference
of the plug to fix the plug.

cAunoN
Do not apply too much bonding agent to the plug, or
th€ pilot gcrew itself may be tixed-

A. Front Carburetor C. RearCarburetor Plug I nstallation

B. F Mark D. R Mark

oKeepdirt or other foreignmaterialfrom enteringinto

the float chamber-

olf din get3 into the float chsmber,tre float valyemay

bscoms stud( open, ausing carbur€toroverflow and
requiringcarburetorcleaning.

agent. 3. PilotScrew
1. Applya bonding
2. Plug 4. CarburetorBody

oDo not force ths needlaiet holder (air bleodpipel and

main iEt or ovenlghsn drsm. They couldb€ damaged .lnstall the O-ringin the coastingenrichersystemcover
r€quiring replacement. sothat the flat sidefacesin,

1 . M a i nJ e t 2. Needle.let Holder
W
'1.
O ring
2 . Cover
2-14 FUEL SYSTEM
Carburetorlnspection

ocasoline ir extremely llammable and can be explosiye

under ccrtain conditions. Tum dre ignition switdl
OFF. Do not smoke. Make sure the area is well
ventilated and lree from any 3outce of flame or sparks;
this includesany appliancewitft a pilot light.

1. PilotScrew 2. TaperedPortion

aMovethe chokeleverto checkthat the starterplungers

movesmoothlyandreturnby springtension.
tlf the starterplungersdo not work properly,replace
thecarburetor.
aTurn the throttle lever to check that the throttle
butterfly valvesmove smoothlyand return by spring
tension.
rlf the throttle valvesdo not move smoothly,replace
thecarburetors.
.Check that theO-ringsanddiaphragms arein goodcon-
dition.
O-ringsfor DrainPlugandCoastingEnricher
Diaphragms for VacuumPistonandCoastingEnricher
*lf any of the O-ringsor diaphragms are not in good
condition,replacethem.
.Check the plastictip of the float valve needle. lt
sltouldbe smooth,without any grooves,scratches,or
otherdamage.
*lf the pilot screwis wornor damaged on the tapered
portion,it will preventthe enginefrom idlingsmooth-
ly. Replaceit.
.Check that tlte vacuumpistonmovessmoothlyin the
carburetorbody. The surfaceof the pistonmust not
beexcessivelv worn.
*lf the vacuumpistondoesnot movesmoothly,or if it
is very loos€in tie carburetorbody, replaceboth the
bodyandthe vacuumpiston.
rCheck the inlet vacuum passage for the coasting
enrichersystem,if backfiringoccurstoo often-
*lf the passage is clogged,
blowit clearwith compressed
air.

FuelPump

Removal
(H .Removethefueltank.

l. Rod 3. ValveNeedle
Wear
2. ValveNeedle

A. FuelPump B. PumpBolts

*lf the plastic tip is damaged,replacethe needle. .Remove the bolts and take the fuel pumpout of the
*lf it does not springout, replacethe needle. frame-
acheck the tapered portion of the pilot screwfor wear aDisconnect the pumpwireconnector.
or oamage. oPullthe fuel hosesoff the fuel pump.
 FUEL SYSTEM2.15

o(iasoline is extremely flammable and can be explosive

undel certain conditioB, Turn dte ignition switah
OFF. Do not snoke. Make surs the arot b wdl
yentilated and free lrom any source of flame ot sparkt;
drb includesany apdiance wilft a pilot light.
oBe prcpared for fuel spillage.

lnstallation Nota
to thepumpfittingsasshown.
.Connectthefuelhoses
A. FuelHosefrom Tank C. Arrow
B. FuelHos€to Pump

.Be sureto route the hosesso they will not be kinked

or stretched,

lnspection
oVisuallyinspectthe fuel filter.
*lf the filter is clear with no signsof dirt or other
contamination,. it is OK and need not be replaced.
ilf tlre filter is dark or looks dirty, replaceit. Also,
check the rest of the fuel sysGmfor contamination.
A. FuelHosefrom Filter
B. FuelHos€to Carburetors

.Be sureto routethe hosessotheywill not be kinkedor

stretched. Air Cleaner

Element (Housing) Remowl

aRemovethe followingparts.
FuelFilter Seat
FuelTank
FrameTop TubeCover
Removal RadiatorCover
aRemovethe fuel tank. oRemovethe air cleanerhousingmountingbolts.
.Removethe RH frametoDtubecover.
.Pull the filter off tl|e hose.

l-wnnruruol
l-
ocasoline b cxlrsmely flammableand can be sxploEiv€
under csnsin conditions. Tum the ignition rwitdr
OFF. Do not 3moke. Make lure the area is well
ventilatedand frss from any rcurcaof flame or :perkr;
thb indudesany appliancewi$ a pilot light.
oBe preparedfor fusl spillsgE.

Installation Notes
alnstallthe fuel filter so that the arrowon it showsthe
fuel flow from the fuel tankto the fuel pump. A. Air CleanerHousing B. Bolts
2.16 FUEL SYSTEM
.Remove the screlysand take the inner cover off the Element Cleaning
(VNl 50GBOnly).
housing

oclcan dre elemont in a well-ysntilated area, and tske

care that there is no spark or flams snywharo nesr ths
working ar.a; this includ€s any appliancewith . pilot
light, Bscau3e of the danger of highly fl.mm8ble
liquids, do not u3e gfsoline or low flashpoint solvents
to dsan the element. A lirs or explcion could result.

aRemovethe air cleanerelement.

olf dirt or duit b allowed to poEs drrough into dre

carburstors. dre throtds may become dud(. possibly
A. lnnerCover B. Screws ca$ing accid€nt.

aRemovethe air cleanercoverby takingout the cover .Wash the element in a bath of high flash-point solvent
bolts. and then squeezeit dry.

VNlsOGA

oDo not wring or twbt tho element83it may ts€r.

.Saturae the element witlr SAE30 motor oil and

squeeze out the excess.
.Wrap tlte elementin a cleandry cloth andsqueeze
it as
dry asposible.

Air CleanerHousinglnsallation
A. Cover C. Element .Note the following.
B. CoverBolts D. ElementBolts oTheright andleft air cleanerhousingareidentical.'Use
the markedR for the right sideand L for the left side.
vt{1500-8

A. Cover C. Element
B. CoverBolts D. ElementBolts

aRemovethe boltsto removethe element. A. LH Housing C. RH Housing

rRemovethe otier sideelementin the samemanner, B. "L" Mark D. "R" Mark
 FUEL SYSTEM2.17
Air Cleaner Duct lnstallation
.Note the following. EvaporativeEmissionControl System
olnstall the air cleaner duct with its side marked (US CaliforniaVehicleonly)
"UPPER"facingupwards.

The EvaporativeEmissionControl Systemroutesfuel

vapors from the fuel systeminto the running engine or
stores the vapors in a canisterwhen the engine is stop-
ped. . Although no adjustmentsare required, a thorough
visual inspection must be made at the int€rvalsspecified
bv the PeriodicMaintenanceChart.

ParB Bemoval/l nstallation N otes

oca3oline is extremely flammable and can be explotivc

under certain conditions. Turn the ignition lwitch
A. Duct B. "UPPER"Mark
OFF. Do not smoke. Mske sure the a?e. i3 iY€ll
yentilated and frce from any source of flame or sparks;
this includesany applisncewith a pilot light'
oLubricatethe air cleanerduct endswith a soapand
watersolution,then fit the duct into the surgetankor
air cleanerhousing.

olf g8toline,solyent,waterot any otlEr liquid efierc the

cankter, the canbtsr's yapor Ebsorbingcapacity is
greatly r€duced. It the canister does become con-
taminatodreplaceit with a newone.

SurgeTank
Surge Tank Removal
rRemovethe air cleanerhousing.
.Removethe thermostathousing.
aUnconnectthe air cleanerduct upperend.
.Removethe surgetank from the frame.
.To preventgasolinefrom flowing into or out of the
canister, hold the separatorperpendicularto the
grouno.
.Connect the hosesaccordingto the diagramof the
system. Makesurethey do not get pinchedor kinked.

Hose Inspection (Periodic lnspection)

acheck that the hosesare securelyconnected.
.Replac€ any kinked, deterioratedor damagedhoses.
\

*parator Inspection
.Disconnect the hosesfrom the liquid/vapor separator,
and removethe separatorfrom the motorcycle.
.Visually inspect the separator for cracks and other
damage.
l . SurgeTank 3. SurgeTank Duct (Rear) *lf the separator has any cracks or is badly damaged,
2. Air CleanerDuct 4. SurgeTank Duct {Front} reDlaceit with a new one.
2.18 FUEL SYSTEM
&parator OperationTest Canister lnspection
aRemovethe canister,and disconnectthe hosesfrom
the canister.
.Visually inspect the canister for cracksand other
oc6oline is extrsmely flammableard can be explosive oamage.
undar csrtain conditionr. Tum the ignition switdl *lf the canisterin crackedor badlydamaged,replaceit
OFF. Do not moke. Make sur€ th€ area b well with a newone.
vontilatodand fr€e from any sourceof flame or spark;
thb induder any appliancswid| a pilot light.
NOTE
.Connect the hosesto the s€parator,and install the ome canitter is daignd to wo* well {rrough dE
s€paratoron the motorcycle. motorcycle's tife without my maintenanceif it is ud
aDisconnectt}le breatherhosefrom the separator, and under normataonditions.
iniect about 20 mL of gasolineinto the separator
throughthe hos€fitting.
aDisconnect the fuel returnhosefrom the fuel tank.
rRun tl|e openendof the returnhoseinto the container
levelwith the tank top.
.Start the engine,andlet it idle.
*lf the gasolinein the separatorcomesout of the hose,
the s€paratorworks well. lf it doesnot, replacethe
separator with a newone.

Eraporstiro Emi$ion Cot|trol Syrtsm

<-

l. FuelTank
2. SurgeTank
3. RearCarburetor
4. VacuumSwith Valve
5. BreatherHose
(Blue)
6. PurgeHose(Green)
7. ReturnHose(Red)
8. VacuumPulseHose
(white)
9. BreatherHose
(Blue)
10. BreatherHose(Yellow)
Separator: return pump
12. Canister
 COOLINGSYSTEM+1

Cooling$ptem
Tableof Contents

ExplodedView... +2
Specifications 33
Coolant Flow Ghart,. , 33
Coolant. c4
Coolant LevelInspection. 34
Coolant Draining 3-,4
Coolant Filling 35
PressureTesting. 36
Water Pump. 3€
Visual Leak Inspection 3-6
WaterPump,MechanicalSealRemoval' 36
WaterPump,MechanicalSeallnstallation. g7
Radiatorand CoolingFan. c7
Removal 97
lnstallation $9
Radiatorlnspection, 39
RadiatorCap Inspection c9
Thermostat 910
Removal 3-10
Installation 911
Inspection. 3-11
ThermostatFan Switch. 3-12
Removal 3-12
lnstallationNote. . . 3-12
Inspection. 3-12
3.2 COOLINGSYSTEM

Exploded View

s-0
%n $--o@
q)ffiD

Sr,ffi{
g*t,J \@

%Nr
.fr'/
1. BleodValve
2. Th6rm6t8t
3. RadiatorCsp
4. W&r Pumplmpellsl
5, lmpdl€r Bolt
6. PumpCoY€r
7. Covel Bola
8, Drain Plug
9. R.diator
10. CoolingFan$vidr
11. Grcundmre Tl : 7.8 N-m(0.80kgn,69 in.lbl
12. CoolingFan T2: 8.8 N.rn(0.9Okgn,78 in{bl
13. R€.erroir Tank T3: 98 N.m (1.0kgn,87 inlbl
 COOLINGSYSTEM}3

Specifications

Item Standard
Coolant:
Type Permanenttype of antifree (soft water and ethyleneglycol
plus corrosionand rust inhibitor chemicalsfor aluminum
enginesand radiators)
Mixed ratio Soft water 50%,coolant5096
Freezingpoint -€5"C (-31'Fl
Total amount 2.3 L
Radiator:
Radiatorcap relief pressure 93 - 123 kPa(0.95- 1.25kg/cm2,14 - 18 psil
Thermostat:
Valveopeningtemperature 80 - 84"C(176- 183"F1
Valvefull openinglift Morethan8 mm@5"C {2(B'F}

Coolant Flow Chart

Whenthe engineis cold, the thermostatis closed,so trat the coolantflow restrictedthroughthe
smallholeon the thermostat(airhole),causingthe engine
to warmup morequickly.

1. Wat€rPump
2. WaterJacket
3. CylinderHead
4. WatrrPipe
5. WaterHos€
6. RadiatorCap
7. Thermostat
8. Reservoir
TankTube
9. Radiator
10. CoolingFan
34 COOLING SYSTEM

Coolant
oFor refillinS, add the specified mixture of coolant and
Coolant Level lnspection soft watet. Adding water alone dilutes the coolant and
degradesits anticorrosion properties,
oThe diluted coolant can attack tie aluminum engine
NOTE
parts. In an emergency, soft watet can be added. But
achsk the level when the engine is cold (room or the diluied @olant must be retumed to the correct
ambienttemperature)
- mixture ratio within a few days.
olf coolant must be added often. or dre reservoirtank
has run completely dry; there is probably leakagein the
cooling system. Ched( the rystem for leaks,

asupportthe motorcycleperpendicular to the ground.

.Checkthe coolantlevelin the reservoirtank-
tlf the coolantlevel is lowerthan the LOW mark.add
coolantto tl|e FULL mark.
oRemovetie reservoirtank cover and open the tank
caD.

Coolant Draining

oTo eyoid bum3, do not rumoye dte radiator aap or try

to drangs the coolant wh€n the enline b still hot. W8it
until it coob dwn,
ocoolant on tir€3 will make dtem slippery and c.n cau3e
.n accident 8nd iniury. lmmodiately wip€ up or wah
away any coolant that 3pills on the fiame, engine, or
0th0r painted parb.
osince coolant i: harmful to dre human body, do not
drink it.

A. Cover C. FullMark
B. Screw D. Low Mark oRemovethe following.
Seat
FuelTank
RadiatorCover

A. Reservoir
Tank C. LOWMark
B. FULL Mark D. TankCap A. RadiatorCover B. Screws
 COOLINGSYSTEM35
oPlacea suitablecontainerbeneaththe radiator.
CoolantDrainPlug

1. Coolant Level
2. ThermostatHousing
A. DrainPlug

RadiatorCap(Loosen) NOTE
oPou in the coolant slowty s that it an axpet the air
from die &gine ard ndiatur,

.Fitl the reservoirtank up to the FULL mark with

coolant,andinttall the cap.

o6oft or dirdll€d wstst mu't b. utod widt th! .mifteo:s

b3€ balou for andfrrezol ir th3 cooling.v.sn.
olf hard wlt3r ir u$d in $a lvttsm, it crursl rcds
acqrmulrtion in dre trstoi panage, and cfiridonbly
rrducaa$€ €dfi.toncyof lit coolirg 3y3ttm.

water and coolsnt Mircure Ratio (Recommerdodl

Soft Watsr : 50%
A. RadiatorCap Coolant : 50%
FreozingPoint : -35oc (-3l"Fl

.Drain the coolantfrom the radiator.

aRemovetf|e reservoirtank cover and take tl|e tank off NOTE
the frame. oohooc€ a sritable mixture 'a,tio W rcferring to {re
.Pour the coolantinto a suitablecontainer.
coolant manufe.ure I b di rurtio n8.

.Start the engine,warm it up thoroughly until the

Coolant Filling
.Tighten the dnin plug at the bottom of the radiator
securery.
.Fill the radiator uD to the radiator flller neckwith
coolant,andinstallthe radiatorcap.
radiatorfan turnson andthenstopthe engine.
aCheckthe coolantlevelin the reservoirtank after the
enginecoolsdown.
*lf the coolantlevel is lowerthan the LOWmark,add
coolantup to the FULL mark.
oDo not add more coolam 8boyo $e FULL m.*.
3€ COOLING SYSTEM

PressureTesting
.Remove the radiator
cap,andinstalla cooling
system
pressure
testeron the radiatorfiller neck.

NOTE
Wet the cap ealing wrfaces with water or coolant to
prcvent presure leaks.

.Build up pressurein the system carefully until the

pressure
reaches123 kPa(1.25 kg/cm' ,18 psi).

oDuring pressurct€sting, do not exceedthe pressulefor

which the system is d€sign€d. The maximum pressure A. DrainageOutlet Pasage
is 123 kPa {1.25kg/cm2,18 psi). (at the bottom of the pumpbody)
B. WaterPump
awatch the gaugefor at least6 seconds.
*lf the pressureholds steady,the systemis all right.

WaterPump; Mechanical SealRemoval

.Remove the following parts.
Radiator Cover (seeRadiator Removal)
Radiator Lower Bolts (seeRadiator Removal)
Water Pioe

A. Pressure
Tester C. RadiatorCap
B. Adapt€r

A. WaterPipe B. Bolt
tlf the pressure
dropssoon,checkfor leaks.
WaterPumpCover

WaterPump

Visual Leak lnspection

.Checkthe drainageoutlet p;rssage
at the bottom of the
wat€r pump body for coolantleaks. Pumpremovalis
not reouired.
tlf the mechanicalseal is damaged,the coolant leaks
through the seal and drains lhrough the passage.
Replacethe wat€rpumpunit. A. WaterPumpCover B. CoverBolts
 COOLINGSYSTEM+7
lmpellerBolt

oB€ careful not to damagedre water pump sh.ft and

O*ing, and dra inner sealingsurfacsof the Gtankese.

NOTE
oThe impeller boh haetefthmdd thrads, thereforc it
musfbe flnad clockwic to ,emote
WaterPump, Mechanical Seallnstallation
.Note the following

NOTE
osince the tepleement mdranical wl h6 an adhmive
coatd body, do not apply liguid g6d<etto the ext€rior
srfe of the boty.

ohessthe new mechanical sealinto the hole by usinga

socketuntil it bottomsout
su'rtable

A. lmpeller C. Directionof rotation

B. Bolt

.Pry the mechanical

sealflangeoff with a smallchis€|.

1. MechanicalSeal 2. Tap Here

oApply a little coolantto the slidingsurfaceto givethe

mechanical sealinitial lubrication.
oTightenthe impellerbolt to the specifiedtorque(see
ExplodedView).
oReplacethe pumpcovergasketwith newones.
oThe wat€r pump cover rear bolts have aluminum
washen.

A. Flange B. Chisel
Radiatorand Cooling Fan

Removal
.Pull the mechanicalsealout of tie crankcase .Removethefollowing.
pliers.Oiscardthe remotedmechanical
seal. RadiatorCover
38 COOLING SYSTEM

A. RadiatorCover B. Screws A. Radiator B. LowerBolts

RadiatorUpperBolt
Coolant(Draining)
CoolingFanSwitchConnector

oThe cooling fan is conn€cteddiregtly to the battery.

The cooling fan may start eyen if the ignition switchis
off. NEVER TOUCHTHE COOLINGFAN UNTIL
THE Cq'LING FAN CONNECTORIS DISCON.
NECTED, TOUCHINGTHE FAN BEFORETHE
CONNECTORIS DISCONNECTED COULDCAUSE
INJURYFROMTHE FAN BLADES.

A. UpperBolt

Left and RightTop TubeCovers

A. FanSwitchConnector

Cooling Fan Switch

Radiator Lower Bolts A. Top TubeCovers
 COOLING SYSTEM }9
Radiator Hoses Badiator lnspection
theck theradiator core.
*lf thereareobstructions
to airflow,removethem.
*lf thecorrugated
finsaredeformed, carefully
straighten
Inem.
*lf the air passages
of the radiator core ate blocked more
thzn 20o/oby unremovableobstructionsor irreparably
deformed fins, replace the radiator with a new on€.

A. RadiatorHoses B. Clamps
m1
oMen doaning the radiator widr a 3tsam dealer, be
careftrl ol the following to prwent radistor damege'
1l Keepdre isam gun away moredran 05 m from the
FanMountingBolts radiatoraore.
2l Hotd tho st3am gun perpendicrer to the core
:urface.
3l Run rha st€sm qun hotizontslly following the core
fin direc'tion. Runningit venically nrsy dsmagsdro
ffnr.

A. Fan B. MountingBolts

lnsallation
.Be sureto attachthe groundwire to the fan mounting
bolt

Badiator Cap lnspection

acheckthe conditionof the top andbottomvalveseals
of the radiatorcap,
*lf either of them showsvisibledamage,replacethe
A. GroundWire B. MountingBolt cap.
3-10 COOLING SYSTEM

Thermostat

Removal
.Removethe following.
FuelTank
Coolant:about200mL (Draining)
FuelFilter
ThermostatHousingBolts

1 . Bottom Valve Seal 3. Valve.Spring

2. Top Valve.Seal

alnstallthe capon a coolingsystempressure

tester.

NOTE
Wet the cap ealing arfaca with wateror coolant to
preventp,esure leaks.

A: FuelFilter C, ThermostatHousing
B. Bolts

CoolingHoses(LH and Lower)

1. Pressure
Tester z. Kilolaror Lap

awatching the pressuregauge, pump the pressuretester

to build up the pressureuntilthe reliefvalve opens: the
gauge hand flick downward. Stop pumping at once.
The reliefvalve must open within the specifiedrange in
the table below and the gauge hand must remainwithin
the samerangeat least6 seconds-

RadiatorCap Relief Pressure

A. Hoses B. Clamps
Standard: 93 - 123 kPa
(0.95- 125 kg/cm2,14 - 18 psi)

.Pull the thermostathousingirut of the frame to the

*lf the cap cannot hold the specified pressurq or if it ngnL
holds too much pressure,replace it with a new one- .Removetie thermostatfrom its housins.
 COOLINGSYSTEM}11

Housing
A- Thermostat B. Screws A. Brackets

lnspection
aRemovethe thermostat,and inspectthe thermostat
valveat roomtemperature.
*lf the valv€is open,replacethe valvewith a newone.
.To check valve opening temperature,suspendthe
thermostat in a container of water and raisethe
lnstallation temperatureof the water.
.lnstall the thermostat noting the following.
olnstall the thermostat in the housing so that the air
hole is on toD.

A. Air Hole B. Thermostat 1. Thermostat 2. Thermometer

*lf the measurementis out of the service limit range,

replacethe thermostat.

oBesureto installthe o-ring in the housing.

olnstall the fuel filter bracketwith thermostathousing Thermo3tat Valve Opening Temperature
onto theframebracket- 80 - 84'C (176 - 183"F1
 i!t1f,61€ e,*ru< -B tni?uotl l6lrsnrBdT,r.

lnsallation NoE ' r'ohroqp'r\

sqE&[Eh 0b &r{6niitFh$tqldre*p*r'fic$ @!qusr('$e
Elplod.d V.iew). rrurrlrqi{rt rsool'| rrkv
.rto yto & rhiw rvlrv rdl s;eiqar nrqir ri cvkv art] 1l*
la{i btrq?li ..e:\'16rJ{ar5i gniqr:].. 9!iiv t"€riJ dTa
etl: o<ier l,r,: 13ic'a : :3rii6ln..,:: ; r,i Jlri:inrrrh
."::l\'r, 9ril ,(: i-7_-jEl:itlmg: n{ii}6\!sts$\
gi-iwoli.11 ir i.l Itliies lritaollt.lid, siJ llrtafrlr
ii5 rrit rnri! ri gnitrarl giir oi t6Jrcitrerli r(t il6t:nlc
.qo: no ri Jori

irJ4{:.fll .l tntromtsdl .g rioH ril. .A,

,iSflrr,inr:: . .i! ., r i- t,, , ,, ,

.r:,:;,.;r;;.J_;"t:tl:

.gniarorisd: ni lnirO rrf lineni ot elu?98c

srtrf a:rql:o? !tl;.ir{tl ori.:V trdrofin$dl J5:aonnsdl rltiyr trrJitd t3jiit hui 3il, lhf.nlo
Anituid
11"*8i ., D!*l J'!B -- 08 -terJ6rd rmgi erb otno
 ENGINETOP END +T

EngineTopEnd
Tableof Contents

Exploded View . 4.2 Inspection .... 4"15

Specifications. 4-6 C y l i n d eHr e a d . ..... 4-16
SpecialTools 4-7 Cylinder CompressionMeasurement. . . 4-16
Sealant . . +7 R e m o v a. l .... 4{6
CleanAir System Installation. . .. 4{6
(US and Switzerlandmodels). 4.4 V a l v e .s .. : ....... 4-16
Air Suction Valvelnspection. +a ValveClearanceAdiustment . . . . . . . . 4-16
Vadrum switch Valve Test . - 4-8 Valve
Removal ......... 4'17
CamshaftChain Tensioner. 4-8 V a l v ef n s t a l l a t i o n ....... 4-17
Bemoval . 4-8 V a l v eG u i d eF e m o v a l . . ..- 4-17
Installation. 4-9 Valve Guide lnstallation 4-17
Rocker CaseCap 4-10 Valve FaceContact Inspection. . . . . . . 4-18
Removal 4.10 Diameter. . . . . . ..
ValveSeatOutside 4{8
Installation. 4-10 ValveSeatWidth Inspection. .. . .... 4-18
RockerShafts, Rocker Arms, Rocker Case. . . 4.10 ValveSeat Repair(Valve Lapping) . 4-18
Removal . 4-10 MeasuringValve-to-GuideClearance
I nstallation. 4-11 (WobbleMerhod) 4"20
HLA (Hydraulic LashAdiuster) 4-12 Cylinders,Pistons 4-21
HLA Removal. 4-12 CylinderRemoval 4-21
HLA lnstallation. 4-12 Cylinder Installation .".,, 4-21
HLA Air Bleeding 4-12 P i s t oRne m o v a l . ........ 4-22
Inspection 4-13 P i s t o lnn s t a l l a t i o n ....... 4-22
Camshafts 4-13 Cylinderwear. ......... 4-23
Removal , 4-13 Piston Wear ,.. 4-23
lnstallation(lncludingChain PistonRing,
Timing Procedure). 4-13 PistonRingGroove Wear. . . .. -.. 4-23
Camshaft SprocketAssembly. 4-14 P i s t o n R i n g E n d G a p . ., .. .. .. .. . . 4-?3
Camshaft, RockerCaseWear 4-14 Muffler.. ........ 4-24
Camshaftchainwear. . . . . . 4.15 Removal ( f o r
V N 1 5 0 0 - A )
.,........ +24
KACB (KawasakiAutomatic lnstallation. 4-25
CompressionRelease).. 4-r5 Removal(for VN150GB) +25
Removal . 4-15 I nstallation. 4-26
lnstallation. 4-15
4-2 ENGINETOP END

ExplodedView

@-q '/Fe-n45
z--@
Swiuerland Model o_M f
Wffireo
q
\

WoEee
Model
A12:Canada
Model

ffi-
Switzerland Model

wo
@@

1 . RockerCaseCap
2 . Spring
3 . Oil Fitter

L.-%
4 . Air SuctionValve
5 . CamshaftOil Seal
6 . RockerCase US Model Al2:CanadaModel
7 . CylinderHead
I . ValveGuide |--__\
o RockerCaseCover(SprocketSide)
1 0 RockerCaseCove.(HLASide)
1 1 SparkPlug Fetainer i . * % . \ ,& I
I

\_3__.,
1 2 CarburetorHold,er

o Apply engineoil.
ss Apply siliconesealant-
T1 8.8N-m(0.S0kg-m,78 in-lb)
f2 2s N-m(2.skg-m,18.0ft-lb)
T3 78 N-m(8.0kg-m,58 fl-tb)
T4 12 N-m(1.2kg-m,104inlb)
 ENGINETOP END 4-3

? @
rffi

@*
r\
s"

#f'ff
\'/
*N*#? &
*#eM
1. Bod(6rSh8ft
2, RockorAm (x 3/1 GYlindetl
3. Rod(sr A]m (x 1/1 GYlinderl
4. Oil Chamber
5. Hydraulic LashAdiuster
6. valYeSpring{lnnert
7. vslre Spring(Ouetl
8. Oil S€l
9. ValveSt m (Exh$3tl M : Apply molybdsnumdi:ulfide grease'
10. V8lvoSsh (lntakel T 1 : 25 Nfl (25 kgF|n,18Oftlbl
4.4 ENGINETOP END
1. CYlinder
2, Drain Plug
3. Piston
4. Cam$aft Chain

w
5. Camshaft Spmcket
6. Camsh.ft
7. KACR (Automatic Compr€sion
Releasel
8. Camshaft Chain Tensioner

*€@\
Y

Ld,A

:%,H-@
! v /fe?
'
W.'*%f
6
L : Apply nonf€manent loddng ag€trt.
O : Apply endneoil.
T1: 15 N-m (15 kgFm,11O ft.lbl
T2: 25 Nrn (25 kgn,18.0 ft.lbl
 TOP END 46
L Nut vN1500-A O--
2.
3.
ExhaustPipe Holder
ExhaustGasket
@__>
4. Exhaun Pipe (Leftl @--\b
5, ExhaustPipe {Right}
6. Gasket
@--od
7. PowerChamber
8. Muffler (Leftl
9. Muffler (Riqhtl

VN1sff}B

"eD
$, \
(*/
\--

ap
l I
\d
+6 ENGINETOP END

Specifications

It€m Standard Sewica Umit

Clo.n Air Systom
(US aod Switze.landmodets):
Vacuum switch valve closing pressure:
Open Close 35 - 43 kPa(260 - 320 mmHg)
C€mshaft, Camshaft Chain:
Cam height Inlet 33.812- 33.912mm 33.71mm
Exhaust 33.494- 33.594mm 33.39mm
Camshaft,rockercaseclearance 0.020- 0.062mm 0 . 1 5m m
Camshaftjoumal diameter 24.959- 24.980mm 24.93mm
Camshaftbearinginsidediameter 25.000- 25.021mm 25.08mm
Camshaftchain20-link length 127.0- '127
.4 mm 128.9mm
Cylinder Hoad:
Cylindercompressionpressureusablerange Frontcylinde[
@30O r/min (rpm) by electric starter 345 - 590 kPa (3.5 - 6 kg/cm2,
50 - 85 psi)
Rearcylinder
685 - 1080kPa (7.O- 11 kslcnr2,
1 1 0 - 1 5 6p s i )
Cylinderheadwarp
0.05mm
Valves:
Valve clearance Non-adiustable
Valve head thickness: lnlet& Exhaust 'I .0 mm
0.5 mm
Valve stem bend 0.02mmTIR O.05mmTIR
Valve stem diameter Inlet 6.965- 6.980mm 6.95mm
Exhaust 6.955- 6.970mm 6.94mm
Valve guide insidediameter 7.000- 7.015mm 7.08mm
Valve/valveguide clearance
(Wobble method): lnlet 0.05- 0.12mm O.27mm
Exhaust 0.08- 0.16mm 0.30mm
Valvespring lreelength: Inner 37.8mm 36.2mm
Outer 42.3mm 40.7mm
Valveseatingsurface:
width 0 . 5 - I . 0m m
Outside diameter: Inlet 31.9 - 32.1mm
Exhaust 28.9 - 29.1mm
Valveseat cutting angle: Inlet& Exhaust 32" 45',55"
Cylind€r,Pistons;
Cylinder insidediameter 102.0OO- 1O2.O12
mm 102.10
mm
Piston diameter -
1O1.942 1O1.957mm 101.79
mm
Piston/cylinderclearance 0.043- O.070mm
Oversize,pislon and rings +0.5mm _---
Piston ring/grooveclearance:
Top 0.03 - 0.07mm O.17mm
Second 0.02 - 0.06mm 0.16mm
Piston ring thickness: Top 0.97 - 0.99mm 0.90mm
Second 1 . 1 7- 1 . 1 9m m 1. 1 0m m
Piston ring groovewidth: Top 1.02 - 1.04mm t,tzmm
Second 1.21 - '|'.23mm 1 . 3 1m m
Pison ring end gap. Top 0.3 - 0.4 mm 0.7mm
Second 0.40 - 0.55mm 0-9mm
oil 0.3 - 0.9 mm 1 . 2m m
 ENGINETOP END +7

ValYe Head Valve Stem Bcnd Cam Height Measurement

stem /n
ter \y H
u
'
/ll
A
CamHeight
Valve head -- -------- -\
thickness
L
ValveGuideAtbor: 57q11-16:l
SpecialTools

Valve SpringCompressorAs.sembly:57(xl1'241
Adapter: 570O1-242

valyeSeatCutterHolder: 57001-1126

Bar:57001-1128
PistonPin PullerAisembly: 57001'910
Adaptcr:57001-1211

fr
R HexagondWrendr: 57001-1210
o

valve ssat cuttsr 45'+35! 57001'1116

valye S€atCuttel 3:le{35: 57@1-1121
valye s€atcutter 32"4il'35t 57001'1122
VdlvsSeatCutter55".035: 57001-1247

Sealant
(q(qKor((J
\7 \' \.7 \7 Kswa$ki Bond (Silicone Ssalantl: 56019{20

ValveGuideReamer:57001'162
48 ENGINE TOP END
Vacuum Switch Valve Operation
CleanAir System(US and Switertand models)

1. DuringCruising(OpenThrottle)
Air Suction Valve lnspection
avisuallyinspect
thereedsforcracks,
folds,warps,
hear
damage,or other damage.
*lf there is any doubt as to the condition of the reed,
replacethe air suctionvalveasan assembly.

2. DuringEngineBraking
A. ValveHolder B. Reed

oCheck the reed contact areasof the valve holder for

grooves, scratches,any signs of separation from the
holder, or heat damage.
*lf there is any doubt as to the condition of the reed
contact areas, replace the air suction valve as an
assembly.
alf any carbonor other foreignparticleshaveaccumu-
lated between the reed and the reed contact area.wash
the valveassemblycleanwith high flash-pointsolvent.

oDo not scrape off the depositswidt a scraper as this HighVacuum

could damag€the rubbei, requiring replacementof the Secondary
air cannotflow,
sudion valYeassembly.

VacuumSxritchValveClosingPressure
Open"' Close: 35 - rl:t kPa(260- 320 mmHql

VacuumSwitch Valve Test

oCheckthe vacuumswitch valveby blowingair into the
air hosefitting.
owhen the vacuumappliedto the vacuumhosefitting of
the valve is low, the vacuumswitch valve is opened
and air flows ihrough the air hosefittings.
owhen the vacuumrisesgraduallyand reachesa certain
Ievel,the valveis closedand air doesnot flow,
*lf the vacuum switch valve does not oDerate as
described,replacethe valve.
GamshaftChainTensioner
Remoral
.Remove the camshaftchain tensionercaDbolt and take
off the copper washerand the spring.
.Remove the mounting bolts and take off the camshaft
chain tensioner.
 ENGINE TOP END +9

A. ChainTensioner B. capBolt A. TensionerBodY B. Arrow Mark

the stopperandpushinto the rod.

oRelease

A. MountingBolts C. CopperWasher
B. Spring D. CapBolt

A. PushRod C. Push
B. Stopper D. Pushintotherod.

This is a non-retrrn type can chain tensioner. The

push rod does not relum to i$ original pGition once it
moy€s orrt to take uP cam drairi slack. Obs€lvs all the
rules listed below:
olvhen removing dre tensionet, do not t|ke out dle
moulrting bol$ only halflvay. Retightening thd mount'
ing bolt! Irom this pocition could damagethe temion€]
and dro camshaft dtain, Once the boit3 are loGsned,
dre tenaaonermust be temoysd and Jesetas delcrib€d in
',cbaan TeGioner lffitallation."
oDo not turn ovel ths crenkshaft while th€ teEioner is
removed. This could up6.t the cam drain timing, and
dam8gedre Yalv€s.

lnstullation
.lnstallation is tie reverseof removal. Note the fol-
lowin&
olnstallthe tensionerbodywith the arrowon it pointing 1 . Gasket 5. CapBolt
upwards. 2. ChainTensioner 4 Stopper
'I.10 ENGINETOP END
oTightenthe tensionermountingbolts to the specified lnsbllation
torque(seeExplodedView). .Note thefollowin&
oTighten the cap bolt to the specifiedtorque (see oReplace the capgasketwith a newone.
Exploded View). oTightenthe capboltsto the specifiedtorque.

RockerCaseCap

Remoml
oRemovethe engine(see EngineRemoval/lnstallation
chapter).
.Remove the bolts and take off the cover from the
rockercase.
aRemovetlle bolts and take the caDfrom the rocker Rocker ShafG, Rocker Arms, Rodcer Case

Remoml
oRemovethe engine(seeEngineRemovalInstallation
chapter).
aRemovethe rockercasecoversand tie cap.
aRemovethe alternatoroutercover.

NOTE
<iBefore removing dte t@ket dratt or rocker arm,
tum dre crankdraft e that its piston is a TDC of the
compr$ion stroke.

A. RockerCaseCover B. RockerCaseCap .Removethe oil pipebanjo bolt.

aRemovethe water pipe.
rRemove t]te camshaft chain tensioner (see Camshaft
ChainTensionerRemoval).
.Take out the oil filter springsand oil filters if neces-
s:rry.

A. RockerCase C. Oil PipeBanioBolt

A. Springs B. Oil Filters B. WaterPipe
 ENGINE TOP END +11
aRemovethe rockercaseboltsand nuts. lnstallation
.Using the pry points,take lhe rockercaseout of the .Notethefollowin&
cylinderhead. on each
olnstallthe rockerarmsand retainersprings
rockershaftasshown.

A. Pry Points
A. CamshaftChainTunnel C. DifferentRockerArm
B. Sprin8s

oBeforeinstallingthe rockershaft, be surethe O-rings

aRemovethe rockershaftsandtakethe rockerarmsout arein place.
of tlle rocker case. oTightenthe rockershafu to the specifiedtorque (see
ExplodedView).
oApply siliconesealantto the mating surfaceof the
rockercaseandthe camshaft oil sea.
NOTE oApply engineoil to the both sidesof rockercaseNut
Washers.
oThe camdlaft chain tunnd side exhaustrocker am, is oFit the rockercaseto the cylinderheadwhile holding
differcnt from the othe6. up the lashadjusterendof the rockerarms,
oTighten the rocker casebolts and nuts temporarily
following the ti8hteningsequence,and then torque
themto the specifi€dtorque.

A. RockerArms C. DifferentRockerArm
B. RockerShafts

A. 012mm Nuts C. d6 mm Bolts

B- 08 mm Bolts D. Numberof Tightening
Sequence

.Take out the oil filtersif necessary

oRemove the tash adiuster it necesary (see HLA oAfter installingthe rocker case,fill the oil chamber
Removal). with engineoil.
+12 ENGINETOP END

A. Apply engineoil. B. Oil ChamberArea l. HLA Body 4. Plunger

2. O-ring 5. SteelBall
oReplacethe oil pipe banio bolt copperwasherswith 3. Spring(Plunger) 6. Spring(Ball)
new ones, and tighten to the specifiedtorque (see
ExplodedView). oFill a rocker arm with engineoil and then insertt}|e
oReplacethe rockercasecapgasketwith a newone. HLA into the rockerarm.

HLA (Hydraulic LashAdjuster)

HLA Removal
aRemovethe rockercase.
aRemovethe rockerarms-
.Pull the HLA out of the rockerarms.

A. RockerArm B.HLA

A. RockerArm B.HLA

rmflml
oBe caretul not to damagEor deform a lash adluster by
HLA,Air Bleeding
.Fill a container
withengine
oil.
.Preparea pin and cut the needleof it to 2.1 - 2.3 mm
tapping it during remoyalor installation. length. Grind the cutting edgeof the needleto smooth
oDo not drop th€ lash adiuster or hit it sharply. lf it it.
.Push in the steelball of the HLA with the needleof the
is damaged, the plunger will not operate smoothly.
pin and move the plungerup and down in the oil bath.

HLA lnstallation
aNote the following. oDo not push ir the steelb;ll more than 2.1 - 2.3 mm,
-Check tlEt the HLA plunger is not damaged. Over.stroke of the steel ball may cause the damage of
*If the plunger does damage, replace the HLA. the H LA.
 ENGINETOP END 4-13

q ? )
ffi"2 3. HLA
A. FrontCamshaft C. Groove
1. Cut and grind the needle. B. RearCamshaft
2. 2,"1- 2.3 nm 4. Pin
oApply cleanengineoil to all cam parts and iournals.
lnspection oFit the KACR Unit on to the camshaft.
aRemovethe rockerarm.
.Pull the HLA out of therockerarm.
ePressthe plungerof the HLA with your fingers. FrontCylinder
*lf the plungeris into the HLA body, repeatthe air oPositionthe crankshaftat front cylinderpistonTDC.
bleedingoperationandthenpressth€ plunger-
flf the plungeris into the HLA bodyagain,replacethe
HLA.

Camshafts

Removal
aRemove the rocker casecaD.
aRemove the rocker case.
.Remove the camshaftwith the KACR and seDarateit.
oRemove the camshaftoil seal.

A. TDC Mark (Front Cylinder) B. Timing Mark

oEngagethe camshaft chain sprocket with the camshaft

chainasshown.

A. Oil Seal C. KACR

B. Camshaft

lnstal lation (Including Chain Timing Procedure)

.Note the following.
oThe front and rear camshafts
are different. The rear 1 . TimingMarks
camshafthasa groove. 2. F mark
+14 ENGINETOP END
RearCylinder
ocheck the camshaftchain timing for the front cylinder.
. Tum drccrankshaftcounterdockwis€310"from theT/F
mark (left sideview) to align theT/R (TDC mark).
Camshaft Sprocket Assembly
.Note the following.
ouse the sprocketmarked F for the front cylinder
camshaftand R for the rearcylindercamshaft-

(RearCylinder) B. TimingMark
A. TDCN4ark
A. Front Camshaft
Sprocket C. F Mark
B. RearCamshaftSprocket D. R Mark

oApply a non-permanent lockingag€ntto the camshaf!

oEngagethe camshaftchainsprocketwith the camshaft sprocketboltsandtightenthemto the specifiedtorque
chainasshown. (seeExplodedVlew).
olf the camshafts
are replacedwith new ones,applya
thin coatof a molybdenum disulfidegreaseto all cam
partsandjournals.

Camshaft, Rocker CaseWear

rNote thefollowing.
oMeasureeachclearance betweenthe camshaftand the
rockercaseusingplastigage
(pressgauge).

NOTE
onghten the rccker ce boltFand nuts to the secifid
torque (ee Exblodd Viewl

1 . TimingMarks
2 . R Mark

oThe crankshaft may be turned whilo dre camshaft is

remoy€d,but alwaF pull dre dEin taut whils tuming
tl|s orankrhaft. This ayoids kinking dre d|.in on t're
lower {crankshaftl sprocket. A kinked drain could
drmsgeboth the drain and the sprockst. l. Plastigage
Width
 ENGINETOP END +15
NOTE
o^o not turn the camshaftwhen the pleigage is be'
tweq, theioumal and ruker czs€,.

*lf any clearance exceedsthe servicelimit, replacethe

camshaftwilh a new one and measurethe clearance
again.
*lf the clearancestill remainsout of the limit, replace
the cylinderheadandrockercaseass€mbly.

Camchaft,Roc*et CaseClearance
standard: 0.020- 01162mn
SerYicsLimit: 0.15 mm
A. Camshaft B. KACRUnit

Camshaft Chain Wear Installation

.Hold thechaintaut with a forceof about5 kgin some .Fit theKACRUnitontothecamshaft
asshown.
manner,andmeasure a 2o-linklength.Sincethechain
may wear unevenly,tak€ measurements at s€veral
olac€s.
exceedsthe s€rvicelimit, replace
*lf any measurement
the chain.

CamshaftChain20{ink LerEdl
Standald: 127.A-lttAmm
SorvicaLimit: 128.9mm

A. Pin C. KACRUnit
B, Notch D. Camshaft

lnspection
.Visually inspectthe KACRUnit.
*lf the weights do not move smoothly all the way,
replacethe KACRUnit,
deformed,or missing,replace
rlf the springis damaged,
ir.

1. 2o-linkLength

KACR
(KawasakiAutomaticCompressionReleae)

Removal
aRemovetie engine(seeEngineRemova[lnstallation
chapter).
eRemove the camshaft.
.Take the KACR Unit out of the camshaft. A. Weighc B. Spring
+T6 ENGINETOP END

ausing the stanermotor,turn the engineoverwith the

CrylinderHead throttlefully open until the compression gaugestops
rising;the compression is fhe highestreadingobtaina-
ble.
Cylinda CompressionMeasurcment
Cylinder Comprg€sion Pr€ssuro Ugable Range:
NOTE Front Cylinder: 345 - 590 kPa (3.5 - 6 kg/cmr, 50
O Use the battery which is fully charged. - 85 psi) @gn r/min (rpm)
Rear Cylind€.: 6&5 - 1O8OkPa (7.O - 11 l<g/crn2,
OWarm up the engine thoroughly. 110 - 156 psi) @300 r/min (rpm)
aStop the engine.
aRemoveone sparkplug and attachthe compression gaugeadapter:57001-1183 can also
oThe compression
gaugeand adapterfirmlyintothe sparkplug hole. Do be used.
not removethe othersparkplug,onlythe plug lead. aFepeatthe measurement
for theothercvlinoer.
aFor the othercylinder,removebothsparkplugs.
NOTE
Special Tools - Spark Plug Wrench, Her( 18:
57qn -1024 olf the engine is well broken in. the crcnking speed may
Compreseion Gauget 57OO1-2,j21 become fastet shutting down the decompressor. This
Compr€ssion caug€ Adapter, can raise the ftont cylinder comprcssion pre\ture near
Ml2 x 1.25:5r0ot-1018 to the rcar cylindels in some engines.

alnstall the spa* plugs.

Torque - Spark Plu$ : 18 N-m (1.75kg-m, 12.5fttb)

The following table should be consultedif the obtainablecompressionreadingis not within the usablerange.
Problem Diagn06is
Cylindercompression Carbonaccumulationon piston and cylinderhead,
is higherthan usable and in combustionchamberpossiblydue to dam-
range agedvalvestem oil seal and/or damagedpiston
oil dngs (This may be indicaredby white exhaust
smoke).
Inconectcvlinderhead gasketthickness.
Damagedor missing compressionreleasecam spring
Compressionreleaseweights do not movesmooth-
Remedy(Action)
Removethe carbondepositsand repracr
damaged parts if necessary.
Replacethe gasketwith a standard
Dan,
Feplace the sp ng.
Replacethe compressionreleaseunit.

Cylindercompression Gasleakagearound cylinder head Replacedamagedgasketand check

is lower than usable cylinder head warp.
range
Bad condition of valve seating Repairif necessary.
HLA seizure. ReDlacethe HLA.
Inconectpiston/cylinderclearance Replacethe piston andlor cylinder
Pistonseizure. Inspectthe cylinderand liner and
replace/repairthe cylinderand/or
piston as necessary.
Bad condition ol piston ring and/or piston Replacethe piston and/or the piston
ring grooves. flngs.
Compressionreleaseweights do not movesmooth- Replace
the compression
rel€ase
unit.
lv.
 oTake the cylinder headoff the cylinder.

lnstallation
.Note the following.
oReplace thecylinderheadgasketwith a newone.
oTightenthecylinderheadnutstemporarily.

NOTE
ogefore insbllitv {re spark plug rcaineL pull dre
Remoml camdraftchainup the drain firnnet.
rRemovetlle following.
Engine(seeEngineRemoval/lnstallation
chapter)
RockerCas€s
Camshafu
Carburetors(seeFuel chapter)
Oil Pipe

A. Camshaft
Chain B. Retainer

oTightentJ|esparkplugretainerto tie specifiedtorque.

oTightenthe sparkplugto the specifi€dtorque.
A. Oil Pipe C. Carburetor olnstallthe camshaft.
B. Bolt olnsall tie rockercase.
oTightentl|e sylinderheadlowernutstemporarily.

SparkPlug NOTE'
SparkPlugRetainer oTorque dte cylin&r had and cylinder had lower nuts
(Usinga Hexagonal
Wrench:57001-'1210)
to the s,ecified torque (w Exploded Vimt) after
CylinderHeadLowerNuts (FrontandRear)
rtghEning the rocks c* bolts and nu's to the spe-'
cifid toque.

Valves

VaI ve Clean nce Adju stntent

NOTE
osine the hydnuli; !a* adju$eB constdrtly maintuin
A. SparkPlug C. CylinderHeadLowerNut Ero cleannce. h is not nesry to inqect or adiust
B. SparkPlugRetainer the vdw clannce.
 .rsbni;r'J )rit :t,i, t\3i rsbfi;i.ij gdJ rrsTa

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 ENGINE TOP END +17
Valve Removal Valve Guide Removal
oPerformthe following. rPerformthe following.
oUsing ihe valvespring compressorassemblyand adapter ousing the valveguidearbor (specialtool), tap out the
(specialtools),removethe valve. valveguide.

'1.
ValveSpringCompressor
Assembly:57001-241 1. ValveGuideArbor:57001-163
2. AdaDter: 57001-242

Vatve Guide tnsallation

Valve lnstallation
oBecarefulof the following.
oApply a thin coat of molybdenumdisulfidegreaseto
the valvestembeforevalveinstallation.
olnstall the springsso that the closedcoil end faces
downwards.
rPerformthe following.
ousing the valveguidearbor (specialtool), drivein the
valveguideuntil its flangetouchestie cylinderhead.
NOTE
oHeat the area arcund the valve guide to 120 -
t^dc (2/t8 - 302"F).
oApply oil to the vatveguide outer strface beforc wlve
guide installation.
alJsing the valvegaide reamer (geial tool), ram the
valveguide.

1. ValveStem 6. Retainer
2. SpringSeats 7. Spring Seat
3. Oil Seal 8. ClosedCoil End
4. InnerSpring 9. Split Keepers
5. OuterSpring i . ValveGuideReamer:57001-162
4.18 ENGINE TOP END
ValveFace Contact lnspection *lf the valve seating surface width is not within the
rCheckthevalvefaceseating width.
surface specifiedrange,repair the valve seat.
ousea v€rniercaliperto measuretheseatwidth(white
portion)of the valvefacewherethereis no carbon
build-up.
*lf thevalvefaceseatingsurface
widthis notwithinthe
specifiedrange,
replacethevalvewitha newone.

Valve*at Ouaide Diameter

.lf the outsidediameterof the seatingpatternon the
valveseatis too largeor too small,repairthe valveseat. 1. Good 2. Too wide

V.lve SeatingSurfacsOutsids Diameter

Standard lnlct 31.9 - Sl.1 mm
ExhsGt 289 - 29,1 mm

Valve *at Widh lnspection 3. Too narrow 4. Uneven

rCheckthe valveseatingsurfacewidth.
ouse a vernieroaliperto measurethe seatwidth (white
portion) of the valve seat where there is no carbon
build-up.

Valve SeatRepair (Valve LappingJ

.Usinglhe valveseatcutters(special
tools),repairthe
valveseat.

vahe SsatCutters
lnlet Valv€3: 45' - 035 57q11-1116
32' - 03S.s570{J1-112t2
55' - C35 57001-1247
Exhawt ValYss: 45" - Cas 57001-1116
:t2' - c35 57001.1121
55' - C35 570'J1-1147
1 . Valve
2. ValveS€at
Holder and Bal
SeatingSurfaceOutsideDiam€ter
4. SeatingSurfaceWidth Holder: 57001.1126
Br:: 570iJ1-11?€

ValyeSeatingSurfaceWidth (lN and EXI *lf the manufactur€r's

instructionsarenot available.
use
Standad: 05 - llt mm the followingprocedure.
 ENGINETOP END +19
S€atCut@rOperatingCals:
'1.
This valve seatcutter must not be used for other
purposesthanseatrepair.
2. Do not drop or strikethe valveseatcutter,or the dia-
mondparticlesmayfall off.
3. Be sure to apply engineoil to the valveseatcutter
before grinding the seat surface. Also wash off
groundparticlessticking to the cutter with washing
oil.

NOTE
oDo not ue e wirc brud, to remove the metal Nrticl8
from the cutter. lt will take off the diamond particles.

4. Setting the valv€ seat cutter holder in posilion,

operate the cutter in one hand. Do not apply too
1 . OuterDiameterof
much force to the diamond Dortion.
Angleof Cutter
3. Cutter
NOTE
oPrior to ginding, apply engine oil to the cutter and
during the operation, wa$ off atry ground particl$ OporatingProcedures:
stickingto the cutter with vvadtingoil. .Clean the seatareacarefully.
.Coat the seat with machinist'sdye.
.Fit z 45" cutter to the holder and slide it into the valve
guide.
.Press down lightly on the handle and turn it right or
left. Grind the seatingsurface only until it is smooth.

oDo not grind the seattoo much, Oyergrinding $ill

rsducevalvedearanceby sinkingthe valveinto the
head. ]f the vslvesink too far into the head,it will
be impolsible to adjwt $e deamnce,and the clrlinder
headmustbe replaced.

.Measurethe outside diameterof the seatingsurface

with a verniercaliper.
rlf the outsidediameterof the seatingsurfac€is too
small,repeatthe 45" grinduntil thediameter is within
the specifiedrange.
*lf the outsidediameterof the seatingsurfaceis too
1 . Cutter large,makethe 32" grinddescribed below.
2. CutterHolder rlf the outsidediameterof the seatingsurfaceis within
5- Bar the specifiedrange,measure the seatwidth asdescribed
below-
.Grind the seat at a 32o angleuntil the seatO.D. is
) . After use,washit with washingoil and applya thin within the specifiedrange.
layerof engineoil beforestoring. oTo makethe 32ogrind,fit a 32" cutter to the holder,
andslideit into the valveguide.
oTurn the holderoneturn at a time whilepressing down
very lightly- Checkthe seatafter eachturn.

MarkrStampedon the Cuttel:

The marks stampedon the back of the cutter re-
presentthe following. oThe 32" Gutter rcmoyes material very quickly. Check
45" . . . . . .Cutterangle the seat outside diameter frequently to prevent over-
24.56 - . , . .Outerdiameterof cutter grinding.
+20 ENGINETOP END
aBe sure to remove all grinding compound befole
assembly.
.When the engine is assembled, be sure to adjust the
valveclearance(seeValve ClearanceAdjustmen!).

1. Widenedwidth of engagementby machiningwirh

45- cutter
2. Groundvolumeby 32" cuttnr
3. Groundvolumeby 55ocutter
4. 32"
5.5s'

1. Lapper 3. Valve
2. ValveSeat

oAfter makingthe 32' grind, return to the seatO.D.

measurement stepabove.
.To measuretl|e seatwidth. use a vernier calioerto
measurethe width of t$e 45o angleportion of the seat Measuring Valve-to-Guide Clearance
at severalplacesaroundthe seat. (Wobble Method)
*lf the seatwidth is too narrow,repeatthe 45" grind lf a smallboregaugeis not available,inspectthe valve
until the seatis slightlytoo wide,and then returnto guide wear by measuringthe valve to valve guide
the seatO.D.measurement steDabove. clearancewith the wobblemethod,as indicatedbelow.
*lf tlre seatwidth is too wide, maket}re 55o grinddes- .lns€rt a new valve into the guideandseta dial gauge
cribedbelow. againstthe stemperpendicular to it ascloseaspossible
.Grind tie seatat a 55o angleuntil the seatwidth is to the cylind€rheadmatingsurface,
within the specifiedrange. aMovbthe stem back and forth to measure valve/valve
OTo makethe 55'grind, fit 55'cutter to the holder,and guideclearance.
slideit intothevalveguide. .Repeatthe measurement in a directionat a right angle
oTurnthe holder,whilepressing down lightly. to the first.
oAfter markingthe 55" grind,return to the seatwidth *lf the readingexc€edsthe servicelimit, replacethe
measurement stepabove. guide.
.L:p the valveto the seat,oncethe seatwidth andO.D.
arewithin the ranges specifiedabove.
oPut a little coarsegrindingcompoundon the faceof NOTE
the valypin a numberof placesaroundthe valvehead.
ospin th9 valveagainstthe seatuntil the grindingcom- aThe ruding is not etual valve/valve guide clearance
poun4/producesa smooth,matchedsurfaceon both becaue the measrring point is above the guide.
the s€lt andthe valve.
oRepeAtthe processwith a fihe grinding compound.
.The seatingareashouldbe markedabout in the middle Valve/Valve Guide Clearance
of the valveface- (Wobble Method)
*lf the seatareais not in the right placeon the valve, Standard ServiceLimit
checkto be zurethe valveis the correctpart. lf it is,it Inlet 0.(F - 0.12 mm O27 mm
mayhavebeenrefacedtoo much:reDlaceit. Exhaust 0,08 - 0.16mm o.ql mm
 ENGINETOP END 4.21

A. WaterHoles

oPositionthe crankshaftat TDC.

oApply engineoil to the cylinder bore,pistonring,and
New Valve [A] Move the Valve [c] pistonskirt.
ValveGuide [B] oslip the cylinderblockonto the piston.
ousethe cylinder'smarkedF for the front andR for the
rear.

Gylinders.Pistons

Cylinder Bemoval
.Remove the cylinder head.
.Pull out the camshaftchain guide (inlet side).
.Remove the coolant drain plug to drain the coolanl

A. Front Cylinder C. F Mark

B. RearCylinder D. R Mark
oThe front and rear camshaft chain guides a.e not
identical.
Use ttLemarked F for the front cylinder and R for the
rear cylinder.

A. DrainPlug C. CamshaftChainGuide
B. CylinderNut

.Remove thecylindernuts.
oTakethecvlinderoff thecrankcase.

Cylinder lnstallation
oNotethe following.
oReplacethe cylinder basegasketwith a new one, and ChainGuides C. R Mark
A. Camshaft
engagethe gasketswith the crankcasewater holes. B. F Mark
4'2 ENGINETOP END

OTightenthe cylindernutstemporarily. aThe pistonringopeningsmustbe positionedasshown

in thefigure.Theopenings
oflhe oil ringsteelrailsmust
NOTE beabout30 - 45'olangle fromtheopeningofthetop
oToryue the cylinder nuts to the specification (see nng,
ExplodedView) after tightening the rccker casebola" Front
and nutsto the speciliedtoque. 30'-\45' 30'-4s'
^

Piston Removal o\aulo

a Remove the cylinderblock-
oPlacea cleancloth underthe pistonsand removethe
pistonpin snapringsfromthe outsideof eachDiston.
6
i l
ousing the piston pin puller assembly(speciattool),
removethe pistonDins. vv
@@
Top Rins [A] Oil Ring Expander[D]
SecondRing [B] Anow [E]
Oil RingSteelRails[Cj

NOTE
oThe oil ring rcils have no "top" or "bottom".

alnstall the oil ring expander [A] in the bottom piston

ing groove so the ends [B] but together.
alnstallthe oilring steelrails.one abovethe exDanderand
one below it
1. PistonPin PullerAssembly:57001-910 Ospread the rail with your thumbs, but only enough to
2. Adapter fit the rail owr the Diston-
o Releasethe rail into the bottom piston ring groove.
Piston lnstallation

NOTE
Olf a new piston or cylinder is used. check piston to
cylinder cleannce (see Specifications), and use new
piston ng.

aThe anow [A] on each piston head must point fonrard.

CAT'TION
Do not rsuse snap ringg as removal weakens aiid
d€forms them. Thgy could fall out and score th€
cylindor wall.
aDo not mix up the top ringandsecondring.
alnstallthe secondring [A] so thatthe "RN" markfaces
up.
alnstallthe top ring [B] so thatthe "R" markfacesuD.

Frofi
 ENGINE TOP END 4-23

CylinderWear
aMeasure the cylinder inside diameter taking a
side-to-side and a front-to-back measufementat each
oI the 3 positions (total of 6 measurements)shown
below.

Cylinder lnside oiam€ter

Standard: 102.000- 102.012mm 1. ThicknessGauge
Servic€ Limit: 102.10mm

Piston Ring End Gap

PistonWear a Place the piston ring inside the cylinder. using the
aMeasure the pislon outsidediameter5 mm up from the piston to locate the ing squarelyin place. Set it close
bottom of the piston at a right angle to the direction of
to the bottom of the cylinder, where cylinder wear is
the piston pin.
aMeasure the gap between the ends of the ring with a
PistonOutsida Diameter
101 .!t42 - 101 .957 mln thicknessgauge.
Standard:
Servic€ Limit: 101.79mm

Piston Ring End Gap

Standard Service Limit
Top 0.3 - 0.4 mm 0.7 mm
Second o.t|o - 0,55 mm 0.9 mm
Oil 0.3 - 0.9 mm 1 . 2m m

1. PistonOutside Diameter
2. 5 mm uo from the bottom

PistonRing, PistonRing GrooveWear

acheck for uneven groove wear by inspecting the ring
seating-
JrThe rings should fit perfectly parallel to the groove
surfaces. lf not, the piston must be replaced.
owith the piston rings in their grooves, make several
measurementswith a thickness gauge to determine
piston ring/groove clearance,

Piston Ring GrooveClearance

Standard Service Limit 1.Gap 2. Piston Ring
Top 0,03 - 0.07mm 0 . 1 7m m
Second 0.O2- 0.0€mm O.16mm
+24 ENGINETOP END

Muffler

Removal(for VN1500-4)
oRemovethe following.
Front Muffler Cover

A. Holders C. ExhaustPipeCover
B. Nuts

A, Front Muffler Cover B. Screws

MufflerClampBolts(Loosen)
MufflerBracketBolt
MufflerAssembly

A. PowerChamber C. Clamp Bolt

B. RH MountingBolt

.Pull the RH exhaustpipe out of the muffler.

.Remove the powerchamberRH mountingbolt.
.Remove the rear exhaustpipe holder nuts, LH power
chamber mounting bolt, and loosenthe exhaustpipe
clampbolt.

A. Mufflers C. ClampBolt
B. BracketBolt

Front ExhaustPipeCover

A. ExhaustPipe D. ClampBolr
aRemovethe front exhaustpipe holdernutsand loosen B- Holder E. PowerChamber
the exhaustpipe clampbolt. C. Nuts F. MountingBolt

.Pull out rear exhaustpipe upper end while supporting
the power chamber, then take them out toward the
left.
tSeDarate the front and rear mufflers from the muffler
bracket if necessary.
ENGINETOP END +25
oFit the rearexhaustpipeupperendwhilesupporting
the powerchamber.
oscrewthe powerchambermountingboltstemporarily.
olnstallthe rearexhaustpipeholderswhilepullingthe
exhaustpipetowardtheoutside.

lnstallation
.P€rformthefollowing.
oReplace gaskets
theexhaust with newones.

A. ExhaustPipe B. Holders

oTighten the holder nuts, power chambermounting

bolts,andexhaustpipeclampbolt securely.
olnstallthe front exhaustpipe.
olnstallthe mufflerassembly.
olnstallthe mufflerandexhaustpipecovers.

A. ExhaustGasket

oAttach the rear exhaustpipe to the power chamber,

thenfit the chamberinto the framebracket.
Remomllfor VN|50GB)
.Loosenthe mufflerclamobolt.

A. PowerChamber B. Bracket A. ClampBolt

+26 ENGINETOP END
.Removethe left sideexhaustpipeholdernuts. .Removethe right sideexhaustpipeholdernuts.
.Remove the right side muffler bracketbolt, and take
the mufflerout of tie frame.

lnsallation
.Replacethe exhaustgasketwith newones.
oPerformthe following.
oAttachthe clampsA and B onto the RH muffler.
olnstall the RH exhaustpipe and the holdenonto the
front cylinderhead.
olnstallthe RH muffler bracketbolt.
olnsert the LH muffler connectingpipe into the RH
muffler connectingpipe.
olnstall the LH exhaustpipe and tl|e holdersonto tl|e
rearcylinderhead,
olnstallthe LH muffler bracketbolt-
A. Holders B. HolderNuts olnstalltl|e clampsA to tl|e frame.
oTightenthe boltsof tie clampsA.
oTlghtenthe bolt of tl|e clampB.
.Removethe left sidemufflerbracketbolt. andtakethe
mufflerout of the frame.

A. BracketBolt

1 : Attachthe clamps.
 CLUTCH$1

Glutch
Tableof Contents

. . . . . . . . . . . . . . . . . . . . 5. .- .2. . . . .
.......5-3
. . . . . . . . . . . . . . . . . . . .5. -. 3.......

..........5-5
............. 5-5

- ' . . ' ' ' - ' ' , . ' , ' . ' ' ' . , ' , . 'c . o

. . . . . . . ...... . . . ... 5-7

............5 . ._. .9
. . . . . . . . . . . .5. -. .1.0

5-10
5-11

5-11
5 - 11
S2 CLUTCH
1 . Clutoh Master Cylindel
ExplodedView 2 . Primary erp
3. Secondary cup
4. Piston
5 . Starter Lockout S\.vitch
6 , Master Cylinder Clamp
7 . Banio Bolt
8 . Cluich SlaveCylinder
9. Bleed Valve
1 0 . Phton
1 1 .PuCr Rod
12. Clutah Housing
13. Spring (Damperl
1 4 . Dampor Cam
1 5 . lnner Hub
1 6 . Ou@l Hub
1 7 . F?iclion Plae
18, St€ol Plaie
19. Spring Plate
20. Spring (Back Torque Limiterl
21. Cluch Spring
u. Holdel
23. Operating Plane
24. Rst iner Ring

-o"
".*t:

L : Apply nonfermanentlockingaqem.

'l&ub'
O : Apply engineoil.
Tl : 5.9 N{n (0.60kgn,52 in{bl
T2: 78 N{n (Oao kgn,69 in-tb|
T3;88 Nm (0,90kgrn,78 in{b}
T4r 18 N<n (1.8ksFm,13.0ftlbl
T5r 25 Nfl (25 ksm, 18.Ott lbl
T 6 : 1 4 5N { n ( 1 5 . O k g , 1 1 0 f t - l b }
 CLUTCH 5.3

Specifications

Item Slandard ServiceLimit

RecommendedClutch Fluid :
Grade D.O.T.4
Brand CastrolGirling-Universal
CastrolGT (LMA)
CastrolDiscBrakeFluid
CheckShockPremiumHeavyDuty
Clutch :
Clutchleverplay Type
Clutchspringtree height 4.7mm 4.4mm
Springplate/pusher clearance 0.05 - 0.25mm
Spring platefree play 0.30 - '1.30mm (Usablerange)
Frictionplatethickness 3.3- 3.5mm 3 . 1m m
Frictionandsteelplatewarp Lessthan0.2 mm 0.3mm
PrimaryReduclion:
housinggearbacklash
Primarygear/clutch 0 . 0 3- 0 . 1 0m m 0 . 1 4m m

SpecialTool

Baaring Driver Sgt: 57001-1129

54 CLUTCH
clutch Fluid changing
Clutch Fluid .Remove the LH engine cover (seeCrankshaft/Transmis-
sion).
aRemove the reservoir cap, and remove the rubber cap
Fluid Level Inspection on the bleedvalve.
.Checktheclutchfluid levelin thereservoir. .Attach a clear plastic hose to the bleed valve on the
clutch slave cylinder, and run the other end of the
hose into a container.
.Fill the reservoirwith fresh fluid.
.Change the clutch fluid as follows.

A. LowerLevelLine B. UpperLevelLine

T{OTE
oHold the res€ oir horizontal when chfiking clutch
fluid level.

*lf the fluid level is lower than the lower level line.
fill the reservoirto the upperlevellinein the reservoir.

ochange the fluid in th€ clutch line comgletely il the

fluid must be refilled but the type and brand of dre
tluid th.t already is in tlre reservoirare unideniified. 1. ODenthe bleed valve
After changing the fluid, use only tte same type and 2. Pumpthe clutch leverand hold ir.
brand of fluid tfiereafter. Mixing diffelent types and 3. Closethe bleed valve.
brandr of lluid loweB the fluid boiling point and could 4. Releasethe clutch lever.
causo the clutch to & ineffectiye. lt may abo cau3e
the rubb4 clutch parE to dete orate.
oRepeat this operation until fresh fluid comesout from
the plastic hoseor the color of the fluid changes.
RecommendedClutch Fluid ocheck the fluid level in the reservoiroften, replenishing
Grade: D.O.T.4 Heayy Duty Brake Fluid it as necessary.
B:rnd; CastrolGirling-Unirersal
Castrol GT (LMA) NOTE
Castrol Disc Brake Fluid otf the fluid in the re&rvoir runs completely .out any
Check Shock Premium Heary Duty time during fluid changing, the bleeding operction must
be dohe over again from the beginning since air will
have entered the line.
NOTE
osince the clutd, fluid is dre sme as the bnke fluid. I'_WARN|NG
I
refer to Bnke Fluid Section in Brckes for further
debils. oDo not mix two brandsof fluid.
 cLuTcH $5
Bleeding dle Clutch Line
capoff, slowlypumpthe clutchlever
tWith the reservoir MasterCylinder
severaltimesuntil no air bubblescan be seenrisingup
throughthe fluid from the holesat the bottom of the
reservoir.This bleedsthe air from the mastercylinder lnsallation
eid of the line. the clutchmastercylinder,be careful
.Wheninstalling
of following.
NOTE oThe master cylinder clamp must be installed with the
oTap the cluth he lightly going from the lower end rearview mirror holder.
to the uppcrendand bteedthe air off at the resvoir. oTighten the upper clamp bolt first, and then the lower
clamp bolt to the specified torque (see Exploded
.Attach a clearplastichoseto the bleedvalveon the View).
clutch slavecylinder,andrun the otherendof the hose
into a container.
.Bleedtheclutchlineasfollows:

l . Tightenupperclampbolt first. 3. Clearance

2. LowerClamoBolt

oReplacethe aluminum washeron each slde of the

clutchhosefitting with a newone.
oTighGn tie banio bolt to the specifiedrcrque tsee
ExplodedView).
.Perform the following after installing the master
cylinder.
Bleedfor clutchline
1. Pumpthe clutch levera few times until it becomes
Checkfor clutchoperation
hardandthenhold it squeezed.
Checkfor fluid leakage
2. Quicklyopenandclosethe bleedvalve.
3. Releasetheclutchlever.
ocheckthefluid levelin the reservoir
often, replenishing
it asnecessary.

NOTE
olf the fluid in the rcservoir runs completely out arry
Disassembly
oRemovethe following.
time duing bleeding,the bleding opention must be
done overagainfrom the beginningsinceair will have ClutchLever
DustCover
entercdthe line-
Circlip
oRepeatthisoperationuntil freshclutchfluid comesout .PistonandSecondary Cup,PrimaryCup
from theplastichoseor the colorof the fluid changes. Spring

I wARNtNc
-E I NOTE
oDo not mix two brandsof fluid. oDo not removethe seondary cup from the pkton.
5€ CLUTCH

1. PrimaryCup 3. Piston A. SlaveCylinder C. BanioBolt

2. Secondary
Cup 4. Circlip B. MountingBolts

oRemovetie baniobolt and ftee the cylinderfrom the

nose.
Assembly .Performtl|e followingif the clutch slavecylinderis to
.Clean th€ disassembled parts with clutch fluid and be removedbut not disassembled.
apply clutch fluid to the inner wall of the cylinder.

olf ths alutdr slavecylinder i3 lemovedand left alone,

rhe pitton will be purhed out by drs lpring and dre
dutah fluadwill drain out.
oTske c€re not to scratch the piston or $e inner wall ot
the cyllnder. oRemovethe clutch slavecylinderfrom the enginewiti
the hoseand pushthe pistoninto the cylinderasfar as
it will go.
oSqueezethe clutch lever slowly and hold it with a
band.
lnspection
acheck the followingfor wear,damage,cracks,or dete- NOTE
rioration: oHoldingthe clutch levil k€€psthe pifion from aming
CylinderInnerWatlandPiston out.
PrimaryandSecondary Cups
DustCover
Spring
.Check that the relief and supplypons on the cylinder olmmediatelywips up any brakefluid $at spilb.
arenot plugged. maydamagEpaintedor plated 3urfaces.

lnstallation
.Note the following.
oReplacethe aluminumwasherson eachside of the
ClutchSlaveCylinder clutchhosefitting witi newones.
oTighten the banio bolt to the specifiedtorque (see
Exploded View).
Remoml oReplacethe spacerof the clutch slavecylinder with
.Performthe followingif the clutchslavecylinderis nelvone,
to bedisassembled. oApply non-permanentlocking agent to the slave
oLoosenthe clutch hosebanjo bolt on the clutch slave cylindermountingbolts.
cylinder. c€heck the fluid levelin tl|e mastercylinderreservoir,
oRemov€tie mounting bolts and take off the clutch andbleedthe air in tlre clutchline.
slavecylinder. ocheckthe clutchoDeration.
 cLuTcH $7
Disassembly
oLeavingtie clutchslavecylinderremoved,allowthe
pistonto moveslowlyout underspringpressure.

Asembly
.Do the following.
oApply clutch fluid to the outsideof the pistonandthe
fluid s€al.
olnstallthe fluid sealasshownin tlte figure.

A. OperatingPlate B. Retainer

.Unscrewthe clutrh hub nut by usingthe air impact

wrench.

l . Cylinder 3. FluidSeal
2. Piston 4.spring

tt-"-."".-,,"4
cAUTt0l{ |
oFeplaca tte fluid lsal with a new one if it wa! remoYad
A. HubNut
from ths pistoB,
.Take the clutch springplate, clutch springand the
clutchspringholderout of the clutchhub.
.Take the back torque limiter springs,friction plates,
steel plates and the outer hub out of the clutch
housing.

Clutch

Remowl

NOTE
oAn a imp*t wendz is rcquird for cludt runowl.

.Removethe muffler(seeEngineTop Endchapter).

.Place a suitablestandunder the crankcase
to support
the engine.
tRemovethe right downtube (seeFramechapter).
.Remove the right enginecover (seeCrankshaftflrans-
missionchapter). A. SpringPlate D. LimiterSpring
aRemovethe retainerand take the operatingCate out B. ClurchSpring Platrs
E. Friction/Steel
of the clutchassembly. C. ClutchSpringHolder F. OuterHub
5€ CLUTCH
.Take the innerhub, collar, washerand cluth housing lnstallation
out of the crankcase. aclutch installationis the reverseof removal. Notethe
following
owhen replacingany one of the following parts,adjust
the spring plate free play (seeClutch Plate Replace-
ment).
SpringPlate
Friction Plate
SteelPlate
owhen installingthe clutch housing,meshtle oil pump
drive gearwith the oil pump gearso that the pumpgear
rns.

A, lnnerHub C. Washer
B. Collar D. ClutchHousing

.Pull the ne€dlebearing,sleeve,and thrust washeroff

the drive$aft-

A. PumpDriveGear B. PumpGear

olf mw dry 3t3el plsca .nd fristion plabc are i$6llod,

apply onltns oil to the $rfacss of eadr pLb to avoid
dubh plsts 3siznrc.
A. NeedleBearing C. Washer
B. Sleev€

1. Op€rating
Plate O Installthe last friction plate in the shallow groove on the
2. SpringHolder housing as shown.

.A
3. ClutchSpring

@so 6-M.
4. BackTorqueLimitrr Springs
5. Clutrh SpringPlate
6. Outer Hub
7. lnner Hub A. LastFrictionPlate
 CLUTCH 5-9
oApply greaseto the back torque limiter springsand Clutch lnner Hub Disasembly/Assembly
attachthemasshown. .Using a pressand suitablebearingdriver (special
thedamper
ool), compress springs.

1. LimiterSprings 2. SpringHolder

oTighten the clutch hub nut to the specifiedtorque A. Press C. BearingDriver: 57001-1129
holdingthe primarygearbolt (seeExplodedView). B. DamperSpring D. Retainer

aRemovethe retainer,dampersprings,and dampercam.

A. HubNut B. PrimaryGearBolt

.Squeezethe clutchleverslowlyandhold it with a band

whilepushthe springplatepusherinto the clutchhub.

1. Retainer 5. Spacer
2. SpringHolder 6. DamperCam
3. DamperSpring 7. lnnerHub
A. Pusher B. Pushin 4. SpringHolder
$10 cLuTcH
SpringPlate Free Play Measurement
lnsufficient spring plate free play will cause the engine
braking effect to be more sudden,resulting in rear wheel
hop. On the other hand, if the free play is excessive,the
clutch lever may fe€l "spongy"or pulsatewhen pulled,
aHold the exha drive shaft steadywith a vise and instau
the clutch parts on an exlra drive shaft. Do not install
the back torque Iimiter springs and the operating plate.
oTighten the clutch hub nut to about 29 N-m ( 3 kg-m,
22 ftJb ) of torque to seat the clutch plates closely.
SpringPlateFreePlay
UsableRange: 0.30- 1.30mm
SpringPlate Free Play Adjustment
oMeasure the spring plate free play.
'llf the free play is not within the usable range, iDstall
dre Star'\dardSteelPlates 2.0 mm ttrick X 6 and 1.6 or
2.3mm thick X 1 ; total 7 plates.
. Measurethe sprhg plate free play again.

m-I-r!Jl1
cTake care not to damage the drive shaft. SteelPlates
Thickness(mm) Part Name
1.6 13089n080
2.O 13089-1075
2.3 130891081

NOTE
olf new f ctionplatasare installed,apply engine oil to
the sufiaces of each plate.

1. Holder 4. Operating Plate

2. Clutch Spring 5. Spring Plare
Frictionand Steel Plate Damage,Wear
3. BackTorque Limiter Springs 5. Drive Shaft
avisually inspect the ftiction and steel plates for signs of
seizure,overheating (discoloration), or uneven wear.
aunscrew the hub nut, then take *re holder, operating
aMeasure the thickness of the friction Dlates at several
plate, and the dutch spring out of the housing.
POlnts.
aReinstall ttrc holder and tighten tlle hub nut lightly.
*If any plates show signs of damage,or if they have wom
aTo measure the free play, set the dial gauge "O" against
past the service limit, measure the spring plate free
the clutch spring plate.
play a.ndadjust it if necessary.
aTurn the dutci housing back ard forth . The difference
between the highest and lowest gauge readings is the
amount of free play.

FrictionPlateThickness
Standard: 3.3 - 3,5 mm
ServiceLimit : 3.1 mm

Frictionand SteelPlate Warplnspection

*If any plate is warped over the service limit, replace the
platesas a set.

Frictionand Steel PlateWarp

1. Turn back and forth. Standard: less than 0.2 mm
2. Up and Down. ServiceLimit : 0.3 mm
 CLUTCH $11

Cam Damper lnspection

rVisuallyinspectthedampercam,damperspring,and
cam follower.
*Replace any damagedparts.

1. Frictionor SteelPlate 3. SurfacePlate

2. ThicknessGauge

Cluth Housing Finger lnspection

rVisually inspectthe fingersof the clutchhousingwhere
the tangsof the friction plateshit them.
*lf they arebadlyworn or if therearegroovescut where
the tangshit, replacethe housing. Also, replacethe
friction platesif their tangsaredamaged.

1. Cam 2. CamFollower

Clutch Spring Height Measurement

*lf thespringhelght limit,it must
is lessthantheservice
be reDlaced.
Clutdr Spring Height
Standard: 4.7 mm
SerYiceLimit: 4.4 mm

1. ClutchHousingFinger 2. FrictionPlateTang

Clutch Hub Spline lnspection

rVisually inspectwhere t}|e teeth on the steel plates
wearagainstthe splinesofthe clutchhub.
*lf ttrereare notchesworn into the splines,replacethe
clutch hub. Also, replacethe steelplatesif their teeth
aredamaged.

1. Clut h Spring 2. SpringHeight

1. ClurchHubSpline 2. SteelPlateTeeth
 ENGINELUBRICATIONSYSTEMS1

EngineLubrication$ptem
Tableof Gontents
ExolodedView 6-2
EngineOil Flow Chart. 64
ar-^^:a:^r:^-^
oPtrrrruaLrurrr 6-6
SpecialTools. G6
S e a l a n. .t . . . a6
EngineOil and Oil Filter. 6-7
Oil LevelInsoection 6-7
EngineOil Change.. 6-7
Oil Filter Change 6-7
Oil PumpScreenCleaning. 6€
Oil Pump. 6€
Removal 6€
lnstallation 6-9
Oil Pipes 6-9
Removal G9
lnstallation 6-10
Oil PressureMeasrrement 6-10
Oil Pressure
Measurement &10
 S2 ENGINELUBRICATIONSYSTEM

Exploded Viarv

-@
1*
,ar@

1, Rocker Care.(F?ontl
2. Baniobolt
3. Oil Pipe
4. Rodter Ca!€(Rearl To R.H.: Grankcase
half
5. &sa&er Pl96 (LEftl
6. Filtel
7. BreadlorPipes(Righl
8. Cr8nkcase Haff (Loftl
9. CraDkcalstlalf (Righrl
to. Oil Pm:sureSruitdr
1 1 . Oil Pr€$urGRdief Valy€ O : Apply engineoil to the gasket.
12. Oil Rrmp L : Apply non-pemanentlocking agentto the thr€ads.
13. Oil Filter Mounting Bolt SS: Apdy siliconesealentto flre threads.
14. Oil Filtsl Tl ; 29 Nrn (030 kgm, 20 in{bf
15. Oil Scre€nPlug T2: 12 Nfl (12 kgrm,104in.lb)
16. Oil Scroon T3: 15 Nrn (15 kgm, 11,0ft{bl
1 7 . Oil Pipe(hside Lsftl T4: 18 Nfl (14 kgn, 13.0ft{b}
18. Oil PiF (lnride Rightt T5: 20 Nrn (2.0kgfl,la5 ft.tbl
1 9 . EndneDrain Plug T6; 35 Nrn (35 kgrn,25 ft.lbl
m. Oil Nozzls T7r 25 N-m(2.5 kg-m,18.0ft-tbl
 ENGINE LUBRICATION
SYSTEM6-3

q2 (h

osw

II
@?
@

,@
<
&%N*NQ
64 ENGINE LUBRICATIONSYSTEM

EngineOil Flow Ghart

II

1. RockerArm
2. Oil Filter
3. Oil Pipe(outside)
4. HLA
5. RockerShaft
6. Camshaft
7. Piston
8. Oil Nozzle
9. Oil Pipe(ln the crankcase)
10, AlternatorRotor
1l. Crank$aft
ENGINELUBRICATIONSYSTEME5

,fl_@
+

1. ClutchAssembly
2. DriveShaft
3. OutputShafi
4. Front BevelGearAss€mbly
5. Oil Pipe(ln the cnnkcase)
6. Oil Pipe(ouside)
7. Oil Screen
8. Oil Pump
9. ReliefValve
10. Oil PressureSwitch
11. Oil Filter
12. Bypass Valve
66 ENGINELUBRICATIONSYSTEM

Specifications

Item Standard
EngineOil:
Grade SEor SFclass
Viscosity SAE 10W40,101,50,2M40, or 20W50
Capacity 2.5 L (whenfilter is not removedl
2.7 L (Whenfilter is reriroved)
3.5 L (Whenengineiscompletelydry)
Oil PressureMeasurement:
Oil presure@2,000r/min (rpml,
345 - z14O
kPa(3.5 - 4.5 kg/cm",50 - 64 psi)
oil temp.l(X)"C(212'F)

Special Tools

Oil Pressure
Gauge,5
kg/cm,:57001-125 Oil Filtar Wrcndr: 57m1-1249

Oil ftsssureGauge
AdaFter:57001-10*t

KawasakiBond (SiliconeSealaml: 56019-120

 ENGINE LUBRICATION SYSTEM 6.7
EngineOil Change
EngineOil and Oil Filter to the groundafter
perpendicular
aset the motorcycle
warming uptheengine.
.Removethe enginedrain plugto drainthe oil.

oMotorcycle operation with insufficient, deteriorated,ol

contaminated engineoil will causeacceleratedwear and
may result in engine or transmissionseizure,accident,
and iniury.

Oil Level lnspection

asituate the motorcycle so that it is perpendicularto the
grou\l.
.Check\hat the engineoil levelis between$e upper
gauge.
.\ linesin the
and lowerle{el

A. Drain Plug

oThe oil in the oil screen chamber can be drained by

removingthe oil screenplug (seeOil ScreenCleaning).
oThe oil in the filter can be drained by removing the
filter (seeOil Fil@r Change).
*Replacethe drain plug gasketwith a new one if it is
damaged.
.Tighten the drain plug to the specifiedtorque (see
ExplodedView).
oTighten the oil filter with the oil filter wrench (special
tool) to the specifiedtorque (seeExploded View).
A. UpperLevel C. Oil FillerCap oTightenthe oil screenplug to the specifiedtorque (see
B. LowerLevel D. Oil LevelGauge ExplodedView).
.Pour in the specifiedtype and amountof oil.

NOTE
EngineOil
olf the motorcycle has just beal u*d, wait svenl
minut* for all the oil to dnin down. Grade: SE or SF class
olf tne oil has just been changed, stan the mgine and Viscosity: SAE 10W40, 10W50,20W40, or 20W50
run it for several minutes at idle speed. This fills the oil Amount: 35 L (engineis completely dry)
filter with oil. Stop the engine, then wait several 2.7 L (filter is removedl
minut$ until the oil seftles. 2.5 L (filter is not removed)

oRacing the engine before the oil reachesevery part can

causeengiireseizure.
olf the engine oil gets extremely low or if the oil pump
or oil passagesclog up or otherwi6edo not function
properly, the oil pfessurewarning light will light. lf Oil Filter Change
this light stays on when the engine is running above .Drain the engineoil.
oRemovethe oil filter with an oil filter wrench (special
idle speed, stop the engine immediately and find fie
Gaus€. tool).
ffi ENGINE LUBRICATION SYSTEM

A. Oil Filter B. Wrench: 57001-1249 A. Oil Screen B. Spring

NOTE
oThe oil fiher by?€ss valve is a*mbled .Cleanthe screen
with highflash-pointsolvent.
in dre filter (Do
not dis€sf€mbled). oCleanthe screenthoroughlywheneverthe engineoil is
changed.

.When installing the oil filter, be careful of the

following. NOTE
oApplyoil to the gasketbeforeinstallation.
oTightenthe filter with the oil filter wrench(special While cleaning the srnn, drek for any metal panicles
tool) to the specifiedtorque (seeExplodedView) or drat might indicate inten al etryine damage.
tighten it with hand(s)about % turns after gasket
contactsmountingsurfaceof engine.
oPourin the specifiedtypeandamountof oil.
.Wheninstallingthe screen,becarefulof the following.
*Replacethe screenplug O-ring with new one if it is
damag€d.
*Replacethe screenwith a new one if it is damaged
(holesandbrokenwires).
Oil Pump Screen Cleaning oB€sureto put in ihe oil screenwith the rubbergasket
.Removethe following. endinside.
Engine Oil (Draining) oTighten the screenplug the specifiedtorque (see
Oil ScreenPlug Exploded View).
Oil Screenwith Spring oPourin thespecifiedtypeandamountof oil.

Oil Pump

Bemoval
.Performthefollowing.
oRemovethe engine(seeEngineRemoval/lnstallation
chapter).
o5plit the crankcase(see Crankshaft/Transmission
chapter).
oRemovethe oil pump bolc, and take off the pump
A. Oil ScreenPlug out of the RH crankcase
half.
 ENGINE LUBR]CATIONSYSTEMS9

A. OilPump B. ReliefValve A. PumpShaftProiection C.O-rings

B. GearShaftSlot

oTighten ths pump bolts to the sp€cifiedtorque (see

oUnscrewthe reliefvalveif necessary. ExplodedView).
oRemovetl|e circlip,and pull tie pumpgearout of the oApply a non-permanent lockingagentto the threadsof
crankcaseif necessary. the reliefvalve(seeExplodedView).

Oil Pipes

Remotnl
.Removetheoutside
oil pipes
asfollows.

A. Circlip C. Washer
B. PumpShaft D. PumpGear

A. Oil Pipe
Installation
.Note the following.
oNot€the positionof the oil pumpshaftprojectionand .Remove the insideoil pipesfrom the inside.of the
turn the pump gearshaftso that t}te proiectionfits into crankcase halves.
the slot. osplit the crankcdse(see Crankshaft/Transmission
oReplace the O{ingswith newonesif they aredamaged. chapter).
SlO ENGINE LUBRICAT]ON
SYSTEM
oReplacethe copperwasherson eachsideof the engine
outsidefitting5with newones.
oTightenth€ banio bolts to the specifiedtorque (see
ExplodedView).

A. Oil Pipe C- Holder

B. MountingBolts D. RH CrankcaseHalf

Oil Pressure
Measurement

OiI Presure Measurement

NOTE
oMaetre the oil praJe after the engineis watmedup.

.Removethe oil pressureswitch wire and unscrewthe

oil pressureswitch, and take t}te switch out of the
enginetowardthe rear.
.Attach an oil pressuregaugeand adapter (special
A. Oil Pipe C. Holder tools)to the switchhole.
B. MountingBolts D. LH Crankcase
Half

lnsallation
.Note the following.
ocheok that the oil pipe fitting's O{ings are in good
condition,andapplya little of thegreaseto the O{ings
beforeinstallation.

A. Oil Pressure
Gauge;57001-'154
B. Adapter: 57001.1033
C. Oil Pressure
Switch

A. Oil Pipe C. Oring

B. Fitting
 ENGINELUBRICATIONSYSTEM611
Oil Pro$ure
Standard: Mors than 345 - 'ltl(l kPa
(3.5 - 4.5 kg/cm'.50 - 54 psi)
@2(xx! r/min (rpm),
' l(xr'c (zrfn qf oil t€mp.

*lf the oil pressureis much lower than the standard,

check the oil pump, relief valve,and/or crankshaft
bearinginsertfor wearimmediately.
.When installingthe oil pressureswitch,apply silicone
sealantto the threadsof the switch, and tighten it to
the specifiedtorque(seeExplodedView).
 7.7
ENGINE REMOVAL/INSTALLATION

EngineRemoval,/lnstallation
Tableof Gontents

ExplodedView 7'2
SpecialTools. 7'2
.
EngineRemoval/lnstallation 73
Removal ."...... 73
lnstallation 7'6
7-2 ENGINE REMOVAL/INSTALLATION

ExplodedVieur

@@.
@

@
?
@

'
1. Framc
2. EngineMounting Brackct
3, Brad(at Bolt
4. Down Tubell/loundngBolr (Front)
5. Right HandDown Tube
6. Down Tube Mounting Bolt (Rearl
*'t%*".r
, *^^'g

7. EngineMountingBolt (From)
8. EngineMountingBolr (Rearl

T1 ; 24 N+n (2.4kgFm,17.5ftlb)
T2: 44 N{t (4.5kgm,3:t ft{b}
/,'

SpecialTools

&Gk Stand: 57001-1238 -1252

Ataclr merfi: 57OO1
 ENGINE REMOVAUINSTALLATION7€

EngineRemoval/lnstallation

Bemoual
.Supportthe motorcycle
perpendicular
to the ground
with the jack stand and the attachment (specialtools).

A. CleanAir Hose B. CoolingHose

Cooling Hose (RH: Pull the hoseout of the rear

cylinder,)
SurgeTank Duct
ThermostatHousingwith the ooolinghose.
SurgeTank

A. JackStand:57001-1238
B. Attachment:57001-1252

oRemovethe following.
EngineOil (seeEngineLubricationchapter)
Coolant(seeCoolingSystemchapter)
Seat
FUet I anK
FrameToo TubeCover A. FuelPump C. SurgeTank Duct
Air CleanerHousing(seeFuel Systemchapter) B. CoolingHose D. SurgeTank
Horn
Radiator(se€cooling Systemchapter)
CoolantReservoirTank (seeCoolingSystemchapter)
Footpeg(LH)
Left EngineCover
ClutchSlaveCylinder(seeClutchchapter)
shift Pedal
Muffler and Exhaust Pipes (see EngineTop End
chapter) lgnitionSwitch
CleanAir Hoses CoolantReservoir Tank Bracket
CoolingHose (LH: Pull t]1e hose out of the front CleanAir Hose(RearCylinder)
cylinder.) lgnitionCoil Assembly(moveit on the frame)
74 ENGINEREMOVAUINSTALLATION
Alternatorand PickupCoil WireConnectors
GroundWireTerminal

A. lgnitionSwitch C. lgnitionCoil Assembly

B. CleanAir Hose

StarterMotor WireTerminal A. AlternatorWireConnectors

B. PickupWireConnector
C. GroundWireTerminal

Throttle CableAdjuster

A. StarterMotor B. Terminal

Oil Pressure
SwitchWireTerminal
NeutralSwitchWireTerminal

A. Throttle Cables B. Ad.iusters

VacuumHose(BothSide)
Carburetor
RearBrakeLight SwitchWireConnectors

oPerformthe following.
osupport the enginewith a suitablestand,and remove
A. Oil Pressure
Switch B. NeutralSwitch the enginemountingboltsandbncket bolts.
 ENGINE REMOVAL/INSTALLATION7€

A. SuitableStand A. Right DownTube C. FrameMountingBolts

B. EngineMountingBolt

oseparatethe right down tube, and move the dowir

tube toward the rear.

A. RightDownTube B. Pull the hoses'

.Dis6onn€ctthe propellershaftfrom the engine.

oRemovethe propellershaftcover.
oPull backthe bootsandpushon the lockingpin a little
with a wire,then slip the engineunit towardthe front
andright sideof the vehicle.

A. EngineBracket D. EngineMounting Bolt

B. RightDownTube E. Frame Mounting Bolts
C. BracketBolts A. Boots B. Pushtle pin.
7.6 ENGINE REMOVAL/INSTALLATION

lnstallation
.Note thefollowing:
oFit the rubber boots into the front bevelgear case
opening.
olnstallthe springinto the insideofthe front bevelgear
toint.
oPutthe pin into the front bevelgearloint.

A. Pushin the pin.

oTighten the enginemountingbolts to the specified

torque(seeExplodedView).
oRoutethe clutch hoseasfollow.

A. RubberBooG C. Pin
B. Spring

oset the iackstandandtie attachment(special

tools)on
the bottomof the frameasshown.

A. ClutchHose B. SlaveCylinder

oRoute the wlring accordingto the diagnms (see

GeneralInformationchapter).
oconnectthe batterygroundwire terminalto th€ engine
asshown,

A. JackStand:57001-1238
B. Anachment: 57001-1252
C. MasterCylinderBanjoBolt
D. Makea clearance.

owhen fitting the engineinto the propellershaftioint,

pushin the pin at the front bevelgearjoint. A. Batt€ryGroundWire B. Abut 30"
 8-1
CRANKSHAFT/TRANSMISSION

Crankshatt/ Transmission
Tableof Gontents

Exploded View . 8'2 B a f a n c. e r .....',.. *21

Specifications. 8€ e re i g hRt e m o v a. l. . . . . .
R HB a l a n cW & 21
SpecialTools 8-7 LH Balancer WeightRemoval.. . . . . . . &21
Sealant . . 8-7 R HB a l a n c e r W e i g h t l n s t a l l a t i o n . , ,&
. .2
.2
Crankcase 8.8 e re i g hItn s t a l l a t i o.n. .., ,
L H B a l a n cW V22
Splitting.
Assembly.
H

&11 ::: il; E

::i:H::Hllilll.;:: .'.'.. &23
Replacement &14 S t a r t eTr o r q u eL i m i t e.r .
Grankhaft/Con necting Rods. &15 B e m o v a. l ,,.. &23
Crankhaft lnstallation. . . . . &15 Inspeqtion .... &23
Connecting Rod Removal. &15 WaterPumpldle ShaftHolder. .. 8'23
Connecting Rod lnstallation &15 Removal. &23
ConnectingRod Big End Bearing lnstallation. ... 8'23
. Insen/CrankpinWear. . . ' &16 PrimaG
r ye a r .....'. &24
t u n o u t. . . . . . ' . . '
C r a n k h a fR . . .. . 8-17 R e m o v.a l ,'..& 24
Crankhaft Main Bearing/ fnstallation. ,. . &24
M a i nJ o u r n aW
l ear..... a-17 Transmission ...... &24
Cranlchaft SideClearance.' . 8.18 Removal.
ExternalShift Mechanism ,.. 8-25
Right EngineCover 8-19 Installation..
ExternalShift Mechanism &25
Removal . &19 Inspection. .
ExternalShift Mechanism &26
I nstallation. 8-19 TransmissionShaftsRemoval.. . . . . . . g-27

Left EngineCover . 8-19 Shaftslnstallation.

Transmission ,.... V27
Installation. &19 T r a n s m i s sDi oi sna s s e m b l y . ' . . . . . . . . 8 ' 2 7
StarterMotorclutch, . . . . . &19 T r a n s m i s s iAosns e m b l.y. . . . . , . ' . . 8-27
Removal . &19 S h i f t D r u mR e m o v a, l .... &29
lnstallation. a-20 ....
Slrift Drum Disassemblv/Assembly 8'29
Disassembly &20
Assembfy. ,... & 2O
lnspection ,... 8-21
8.2 CRANKSHAFT/TRANSMISSION

ExplodedViw

@9

t. ConnectingRod
2. LH BalancarGear
3. LH BalancalWsight
4. BalancerShaft
5. RH Balanc€rWeight
'r. Oneway
6.
Coupling
Clundl

8 . Starter Mobr (Xutch Gear Tl r 88 N<n (0.9kgn,78 in.lb|

9. Starter Torque Limitel T2: 15 N{n (15 kghm,11,0ftlbl
1 0 . C|ankdraft T3: 21 N-rn(2.1kgFm,15.0ft lbl
1 1 . B€aringlnsert T4: 39 N{n (4Ok$m,29 ft lbl
12. ftimary Gear T5: 59 N{n (6.0kgn; /t:l ft lbl
13. lvater Pump Drive Sprodcet T6: 93 N<n (95 kg{n,69 ft.lbl
14. Bols M6 17; 1rt5N{n (15.0kg.m,110ft tbl
15. Eolts tllS L : Apply nonfermanent locking agem.
1 6 . Bols MlO O : Apply engineoil.
 8-3
CRANKSHAFT/TRANSMISSION
L Ci.in (lrvalsrPumpl
2. ldh Shaft Sprodct (Al
3. Clrin Guide
4.
5.
6.
7.
8.
ldls Shaft
ldle Shaft Spro.i(er (Bl
ldle Shaft Holdel
GhainGuide
Cldn {Wrbr ftrmg Drinl
d-ft' \t/

_ [

t ? W
ffio* 6
q\r f

1. Sfiift shaft
2. Shift LinkagFRod
3. Shift MechanbmArm
4, RerumSpringBolt
5, Ge.r P6itioning Lever

L : Apply non{smansnt locking agsnt to ths tht€8&.

Tl ; 88 Nm (090 kg-n.78 in-lbl
T2: 21 N-m (2.1kgn,15 ft.lbl

@o

kq
84 CRANKSHAFT/TRANSMISSION

o
o @
oo@ k@
*@*
wa@u

?
N
,evJ)
1. DriveShaft
2. DamperCam
3. output shaft
4. Bushing
5, Pin Plae
6. BearingHoldel
7. Shift Drum

Tl ; 225 N-m (23 kg.m,165ftlb)

L : Apply loddng agentro dts threads.
 CRANKSHAFT/TRANSMISSION86

1. RH EndneCoYer
2. Oil FillerCap
3. Altsmator Outer CoYer
4. Alternator lnner Covsr
5. LH Engin€CoYel
L : Apply Ioc*ing agBnito d|e drreads.
Tt : 9, N-m (1.Okg-m,87in-lb)
8€ CRANKSHAFT/TRANSMISSION

Specifications

Item Standard ServiceLimit

Crankshaft/Gonnecting Rods:
Connectingrod big end sideclearance 0.16- 0.216
mm 0.7mm
Connectingrod big end bearing
inserVcrankpinclearance 0.026- 0.057mm 0 . 1 0m m
Crankpindiameter: 54.981- 55.000mm 54.97mm
Marking None 54.981- 54.991mm
54.992- 55.000mm
Connectingrod big end bore diameter: 58.0fi) - 58.020mm
Marking None 58.dD - 58.010mm
58.011-58.020mm
Connectingrod big end bearing
insertthickness: Brown - 1.2187
1,2183 mm
Black 1.487- 1.491mm
Blue - 1.495mm
1.2191
Connectingrod big end bearinginsertselection:
Con-rodBig End Bearinglnsert
CrankpinDiameter
BoreDiameter
Marking Size Color PartNumber
Marking
Brown 92028-1476
None
None
Black 92024-1475
o
None Blue 92028-1474

runout
Crankshaft 0.02mm 0.05mmTtR
Crankshaftmain bearing/
journalclearance 0.030- 0.068mm 0.10mm
Crankshaftmainiournaldiameter 81.981- 55.000mm 54,96mm
Crankcasemainbearing
borediameter 55.ff|0 - 55.049mm 55.08mm
Crank$aftsideclearance 0.05- 0.55mm 0,75mm
Crankshaftweb length 96.85- 96.95mm 96.6mm
Transmission:
Shift fork earthickness 5.9- 6.0mm 5.8mm
Gearshift fork groovewidth 6.05- 6.15mm 6.3mm
Shift fork guide pin diameter 7.9- 8.0 mm 7.8mm
Shift drum groovewidth 8.05 - 8.20mm 8.3mm
 &7
CRANKSHAFTffRANSMISSION
RonorHolder: 57001-1248
SpecialTools

Circlip PfieB: 570{)1-14d

NOTE
GaarHolder: 57001-1015
oThe flywhel holder (P/N i7@,,-tgtg can E ued
inst@dof the rotor holder (P/Itl izd)l-1249.

FlywheelHolder: 57001.1313

DamporCamHolder: 57001-1025

KarrasakiBond(LiquidGaskeiSilberl:9210+1qE

BsaringDdvsrSst: 57001-1129
8€ CRANKSHAFT/TRAN$I'IISSION
.full th6 starter motor clutch gear out of the starter
Crankw motorclutch,then takeout the torquelimiter.
rLoosentl|e startermotor clutch bolt whileholdingthe
alternatorrotor steadywith rotor holder (special
tool:
Splitting s700r-1248).
.Remove the engine(seeEngineRemoval/lnsallation
chapter).
aset the engineon a cleansurhceand hold tie englne
steadywhilepartsarebeingremoved.
rRemovethe following.
EngineTop
RockerCases
CylinderHeads
CylindersBlock
Pistons
EngineRightSide
WaterPump
Clutch
EngineLeft Side
Front BevelGearCase
AlternatorlnnerCover
oRemovetlre shifl mechanism arin and gearpositioning
leverwith spring.

A. StarterMotor ClutchGear. C. TorqueLimiter

B. Bolt

.Take the bolt, spacer,collar, needlebearing,copper

washerandstartermotor clutchoff the balancershaft.

A. Shift Mechanism
Arm B. GearPositioningLwer
aunscrewthe damper cam nut using a dampercam
holder(specialtool) anddeepsocketwrench.
oRemovethe retainerandneedlebearing.
olnsertthe bolt (012 mm, L100 mm) into tlle engine
mountingbolt hole.

A. Bolt D. Bearing
B. Spacer E. Washer
C. Collar F. StarterMotorClutch

A. DamperCam D. Retainer .Loosen the Wimary gearbolt while holdingthe alter-

B. Holder:57001-1025E. Bolt nator rotor steadywith the rotor holder (special
tool:
C. Needle
Bearing 57001-12481.
 CRANKSHAFT/TRANS|MISSION8.9

A. PrimaryGear A. Bolt C. BalancerWeight

B. Balancer
Gear D. Spacer

.Removeth€ front chainguide,lower chainguide,and

rearchainguidefrom the left handcrankcase.

oLoosen the balancergear bolt by usingthe rotor

holder(specialtool).

A. FrontChainGuide C. RearChainGuide
B. LowerChainGuide

.Remove the chain guide and idle shaft holderfrom

the righthandcrankcase.

A. BalancerGear D. Ratchet
B. AlternatorRotor E. Rotor Holder: 57001-1248
C. BalancerGearBolt F. Alt€rnatorRotorBolt

aRemovethe alternatorrotor bolt by usingthe rotor

holder(specialtool: 57001-1248).
.Take the alternatorrotor with spacerandratchetoff
the crankshaft.
.Removethe balancergearbolt, and takethe balancer
gear,spacer,and balancerweightoff the balancer
shaft
A. ldle Shaft Holder B. ChainGuide
&1 O CRANKSHAFT/TRANSTT,IISSION
rRemovethe primarygearbolt and take out tl|e water
pump drive sprocketand idle shaft sprocket(A) asa
s€t.

(B)
A. Sprocket D. LowerChainGuide
B. WaterPumpChain E. RearChainGuide
C. Camshaft
Chain

A. WaterPumpDrive Sprocket C. Sprocket (A)

B. ldleShaft D. Chain

.Pull tie primary g€ar out of the crankshaft,and take .Pull tle water pump sprocketwith its shaft out of
tie idle shaft out of tl|e cnnkcase, The idle shaft hu the insideof the crankcase.
two oins.

A. PrimaryGear C. Pins
8. ldleShaft
A. Sprocket B. Shaft

oRemovethe following.
ldle ShaftSprocket(B) (with flat washer)
WaterPumpChain
CamshaftChain
LowerChainGuide aRemovethe starter motor bolts and the motor out of
RearChainGuide the crankcase.
 8-11
CRANKSHAFT/TRANSMISSION
halves.
.Usingthe pry points,splitt}|e crankcas€

A. Bolts B. StarterMotor

rRemove the cnnkcasebolts (Right Side).

A. Pry Polnt (Front) B. Pry Point (Rear)

aTurnthe crankcase LH sidedown.

.Lift off the RH crankcasehalf.
oRemove the followingfrom the LH crankcase
half.
Crankshaft
Transmission Gears
Shift Drum

Asrr.mbly
.Note thefollowingbeforefitting the crankcase halves.
oWith a high flash-poiritsolvent,oleanoff the mating
A. 08 mm Bolts(5) surfaceof tie crankcasehalvesand wipe dry.
B. Do not fotget to removetJ|isbolt. ousingcompressed air, blow out the oil passages
in the
crankcasehalves.
olnstallthe shift drum and settie gearpositioninglever
to the neutralposition.
bolts (Left Side).
.Removeall tl|e crankcase

A. 06 mm Bolts(14) C. 010mm Bolts(3) A. Shift DrumPinPlate C. NeutralPosition

B. 08 mn Bolts(1) B. GearPositioning
Lever
&12 CRANKSHAFT/TRANSMISSION
oApply engine oil to the transmissiongears, ball
bearings,shift drum, and crankshaftmain bearing
inserts.
ocheckto seethat the followingpartsarein placein the
LH crankcasehalf.

AppliedArea.
l: LiquidGasket

.Tightenthe crankcase boltsasfollows.

olightly tightenall the boltsto a snugfit.
A. TransmissionGears E. Crankshaft oTorquethe 8 mm and 10 mm bolts to the tightening
B. Shift Forks F. Balancer
Shaft sequence,and tien tighten the 6 mm bolts to the
c. shift Rod G. KnockPin specifiedtorque(seeExplodedView).
D. Shifr Drum H. O-ring
Bola TiqhteningOrdsr

oCheckto seetiat the followingpartsarein placein the

RH crankcasehalf.

A. Oil Pump B. KnockPin

oApply liquid gasket to the mating surface of the

crankcasehalf.
 8.13
CRANKSHAFT/TRANSMISSION
.After tighteningall the crankcasebols, check the EngineRightSide
followingitems. CamshaftChainandChainGuides
oTurn the RH crankcas€ half down, and checkthat the StarterMotorClutch(RH Balancer)
driv€ shaft andoutput shaft turn freely. ldle ShaftSprocket(B)
oBe sure the neutnl finder operat€sproperly (while
slowly spinningthe output shaft,gearscan be shifted
from neutralto lst gearand 1stto neutal).
ocheck that tlte gearsshift smootlly from neutral to 4th
gear,and 4tl| to neutral,while rapidly spinningthe
output shaft.

A. Washer B. Sprocket(B)

PrimaryGear

A. Output Shaft C. RapidlySpinning

B. Shift Drum

.lnstall the following

EngineLeft Side
CamshaftChainandChainGuide A. PrimaryGear B. NotchedSide
LH Balancer Weight
Alternator Rotor
ldle Shaft
ldle ShaftSprocket(A), WaterPumpDrive
Sprocket,andchainasa set.

A. Sprocket(A) C. Chain
A. Marlc Aligned B. WaterPumpDriveSprocket D. Washer
&14 CRANKSHAFT/TRANSMISSION
ldle Shaft HolderandChainGuide
TorqueLimiter
StarterMotor Clu&h Gear

A. Bearings C. LH CrankcaseHalf
B. Holding
Plates

A. TorqueLimiter D. Starter Motor Clutch Gear

B. ldle ShaftHolder E. Turn Clockwise
€. ChainGuide

ShiftMechanism
Damper Cam
Front BevelGearCase
Clutrh
WaterPump(lmpellerBolt hasLeft-handed
Threads)
RightEngineCover
EngineTopEnd
Alt€rnatorCovers A. Bearings C. RH Crankcase
Half
Left EngineCover B. Holding
Plates

oApply non-permanent lockingagentto the threadsof

the shift return spring bolt, and tighten it to tie
specifiedtorque(seeExplodedView).
oApplysilicones€alantto the threadsof the oil pressure
switch, and tighten it to the specified torque (s€€
ExplodedView).

Replaement

oThe left and right ctrnlgs h.lv6. ar€ madtin d 8t tts

fcory 3ntio d€mblad 3trte, to tt. clankcate halyos
nui br lopLcod ar a rsc

.Remove the usablepart from the old case,and insEll

them on tie new cases.Note the followin&
oAfter removingtlle bearingholding plates,install the
ball bearingswith new ones usinga bearingdriver set
(specialtool: 57001-1
129). A. Shift RetumSpringBolt B. Oil Pressure
Switch
 CRANKSHAFT/TRANSMISSION
8.15
O Replacethe water pump shaft bearingsand oil sealwith ConnectingRod Bemoval
new ones. Pressthe oil seal into the RH crankcasehalf oRemovethe crankshaft.
from the insideof the case. .Remove the connectingrods from the crankshaft.

NOTE
oApply hich temperature greaseto the lips of {E water NOTE
pump shaft oil s@1. aMa* and fecod the locations of the connEting rods
and their big end capsI that Urey can he rea*mbled
in theh oiginal positions.

z<r &
\ili rT)
h\\\\J
w
'1 -<s\

W
s ss
1 .Bearings
2. Oil Seal
3. Pressthe oil seal.

oTighten the engine oil drain plug to the specified

torque (seeExploded View).

l. Connecting
Rods
2. BigEndCaps
Crankshaft/ConnestingRods 3. Crankshaft

Crankshaft I nstallation
oThecrankshaft LHendis longerthanthe RHend. .Removethe connectingrod big end capnuts,andtake
off the rod andcapwith the bearinginserts.

ConnectingRod Insallation

A. Crankshaft C. Short End(RH) oTo minimize vibration, the connesting rods drould have
B. LongEnd(LH) dre $mo w€ight mark,
&1 6 CRANKSHAFT/TRANSMISSION

NOTE
oTighten the big srd cap nuts to {ze sp*ified torque
(se Exploded Viewl.
oDo not move theconnectingrod and crankdtaft during
clearancemagJrement.

ConnestingRod Big End

BearingInsert/GrankpinClearance
Standard: 0.026- 0,057mm
ServiceLimit: 0.10 mm

tlf clearance is within the standard,no bearingreplace-

mentis required.
*lf clearance is between0.057mm andthe servicelimit
(0.10 mm), replacethe bearinginsertswith inserts
1. BigEndCap 3. WeightMark,Alphabet paint€d blue. Check insert/crankpinclearancewith
2. ConnectingRod plastigage. The clearancemay exceedthe standard
sliehtly, but it must not be lessthan the minimum in
orderto avoidbearingseizure.
*lf clearanc€exceedsthe servicelimit. measuretie
diameterof the cnnkpins.
olf dre connec{ing rods, bearing inssrB, ot crankshaft
ar€ mplaced with new on6, 3elect d|e beadng insert
CrankpinDiemete.
and .tr6d( .Nsarancewitft a plastigage before asembling
engine to be sun the coared bearing insert3 are in- Standad: 54.981 - 55.qn mm
stalled. ServiceLimit: 54.97 mm

.Apply engineoil to the big end bearinginserts.

.Tighten the big end cap nuts to the specified torque
(seeExploded View).
ilf any crankpinhasworn pastthe servicelimit, replace
the crankshaftwith a newone.
*lf the measured crankpindiametersare not lesstlan
the servicelimit, but do not coincidewith ttre original
diametermarkingson the crankshaft,makenew marks
on it.

Connecting Rod Big End Bearing

ln*rt/Crankpin Wear CrankpinDiameterMarks
.Measurethe bearinginsert/crankpin
clearance
with None: 54.981- 54.901mm
plastigage. O : 54.9!12- 55.0dt mm

l. Crankpin 2. Plastigage Marks,"O" markor no mark

El:CrankpinDiameter
 CRANKSHAFT/TRANSMISSION8-17
.Measure the connecting rod big end inside diameter,
and mark each connecting rod big end in accordance
with the insidediameter.

NOTE
oTighten the ap nuts to the qeified torque (9e
Exploded View).
oThe mark already on the big end dtould almost coin'
cide with the mwlrement,

lnsert
1. Bearing 2- ColorSizeMark

Connecting Rod Elig End Inside Diametsr Marks .lnstall the new insertsin the connectingrod andcheck
None: 58.000- 58,010mm clearance
insert/crankpin with the plastigage.
58.011- 58.020mm

CrankshaftRunout
.Measurethe crankshaftrunout.
*lf the measurementexceedsthe servicelimit, replace
thecrankshaft.

OankshaftRunout
Standard: 0il2 mm
ServiceLimitr 0.05 mm TIR

GankshaftRunout

1 . BigEndCap 3. DiameGrMark,
"O" mark or no mark
2. ConnectingRod

.Selectthe properbearinginsertin accordanc€

with the
combination of the connectingrod and crankshaft
coding.

Big End Bearinglnsert Selection

Con-rodBig Crankpin BearingIns€rt
End BoreDia Diameter
meterMarking Mark SizeColor PartNumber CrankshaftMain Bearing/MainJournal Wear
o None Blue 92028-1474 rMeasure mainiournal.
of thecrankshaft
thediameter
None None
Black s
92028-147 crankshaft Main Joumal Dhmctel
Standad: 54.981- 55,qD mm
None Brown 92028-1476 SerriceUmit: 54.96mm
&18 CRANKSHAFT/TRANSMISSION

Crankshaft Side CIearance

aMeasure
crankshaftsideclearance,
Crankshaft Side Clearance,
Standard: 0.G5- 055 mm
Serrice Limit: 0,75 mm

*lf any journal has worn pastthe servicelimit, replace

thecrankshaft
with a newone.

1. Crankshaft 3. Clearance
2. Crankcase

.Measurethe main bearingborediameterin the crank- *lf the clearance is greatertian the servicelimit, meas-
casehalves. ure the crankshaftweb length to see whether the
crankshaftor the crankcase is faulty.

CrankshaftWeb Lengrh
C6nkcas€Main BearingBore Diameter Standad: 9685 - 96.95 mm
ServiceLimit: 96.6 mm
Standsld: 55O3{l - 55.Otl9 mm
Serrice Limit: 55.08 mm

*lf the lengthmeasurement is smallerthan the service

limit, replacethe crankshaft. Otherwise,replacethe
crankcase halvesasa set"

NOTE
oThe right and left cnnkcz* haly6 are m*hirzqt at the
*lf they are any signsof seizure,damage, or excessive factory in the a*mbled state, & thay mu& b re
wear,replacethe crankcasehalvesasa set. plaed asa st.
 &19
CRANKSHAFT/TRANSMISSION

Right EnglneCover Left EngineCover

Bemotral lnsallation
rRemovethe muffler(seeEngineTop Endchapter). .Note the followin&
.Removethe right downtube (seeFramechapter). oBefore installing tlre left enginecover, apply grea3eto
aRemovethe coverbolts. ttre back of the dampersand attaoh them onto the
.Using t}|etap points,takethe cov€roff t}tecnnkcase. alternator outer cover.

A. Damper B. Altemator Outcr Cover

A. Tap Here

o Inst€llthe left enginecoverabovethe enginebracket

lnstallation
.Not€ tle following.
oReplace tl|e rightenginecovergasketwith a newone.
oRoutr the hosesand the wires correctly (seeGeneral
Information).
RearBrakeHos€s
RearBrakeLight SwitchWire
Air CleanerDrainHose

A. Front BevelGearCas€ End

C. C-over
B. EngineBracket

StarterMotor Clutdt

A. DrainHose
B. BrakeLight Switchwire
Removal
.Removett|e right downtube (seeFramechapter).
.Removethe right enginecover.
C. Strap .unscrew the starter motor clutch bolt while holding
D. Clamp the primarygearbolt.
 oApply oil to the threads of the starter motor clutch
bolt and tighten i! to the specified torque (see Ex-
plodedView) while holdingthe primarygearbolt.

Disassembly
rRemovethestartermotorclutchassemblv.
.Remove the Allen bolts with the balancerheld in a vise.

A. PrimaryGearBolt C. TorqueLimiter
B. StarterMotor ClutchBolt
.Pull the starter motor clutch gearand starter motor
clutch (with RH balancerweight) as a set off the
balancershaft.

lnstallation
oNotethe following.
olnstallthe callerandcopperwasherasshown.

A. Balancer
Weight B. Allen Bolts

.Pull the couplingout of the balancer.

.Takethe one-wayclutchout of the coupling.

A. CopperWasher B. Caller

olnstallthe startermotorcluichgearasshown.

t . Balancer
Weight
2. OnewayClutch
t. Coupling
StarterMotorClutchGear

Assembly
A. StarterMotorClutchGear .Note the following.
B. Pushand turn clockwise. olnstall the coupling with the groovedsidefacing out.
 8.21
CRANKSHAFT/TRANSMISSION

Weight
A. Balancer C. Coupling A. One-wayClutch B. lnnerRace
B. One-wayClutch D. Groove (StarterMotor ClurchGear)

oApply a non-permanentlocking agentto the threadsof

the Allen bolts, and tighten them to ihe specified
torque (seeExplodedView).

lnspection
.Remove the starter motor clutch gear and torque
limiter, then reinstall the starter motor clutch gear into
the starler motor clutch.
aTurn the starter motor clutch to both side.
oWhen viewed from the right side of the engine, the
clurch should turn clockwisefreelv, but should not
turn counterclockwise.

A. Coupling B. One-wayClutch

Balancer

RH BalancerWeightRemoval
A. Turn freely. C. StarlerMotorClutchGear Seestart€rmotorclutchremoval.
B. Locked

*lf the startermotor clutchdoesnot operateasit should

or if it makesnoise,go to the nextstep.
.Disassemble the startermotorclutch.
*lf the one-wayclutch installationis incorrect,reinstall LH BalancerWeightRemoval
ir. aRemove the engine.
*Visually inspec!the clutch partsfor damage:one-way oRemovethe shift leverrear end.
clutch,couplingand startermotorclutchgear- .Remove the pickupcoils.
*lf tiere is any worn or damaged part,replaceit. aRemovethe alternatorinner cover.
&22 CRANKSHAFT/TRANSIVIISSION
RH Balancer Weight lnstallation
Seestartermotorclutchinstallation.

LH Balancer Weight lnstallation

.Note the following.
oFit the balancer gear onto the balancer weight as
follow.

A. Shift Lever C. Tap Here

B. lnnerCover D. PickupCoils

.Loosen the LH balancergearbolt while holdingthe

alternatorrotor with a flywheelholder(specialtool).

'- - ?'\ -"

i:-:-iv*N"
1. Gear 3. Hole
2. Weight

oTightenthe balancergearbolt to the specifiedtorque

(seeExplodedView).
oTighten the alternator rotor bolt to the specified
torque (see Exploded in Electrical chapter).

A. BalancerGear D. Rotor Holder: Balancer Shaft Removat

B. AlternatorRotor 57001-1248 iSplit thecrankcase
(seeCrankcase
Splitting).
C. Bolts aPulltheshaftoutof thecrankcase-
.Remove the alternatorrotor bolt by usingthe rotor
holder(specialtool: 57001-1248).
aTaketh€ alternatorrotor with soacerand ratchetoff Balancer Shaft I ns'3IIati on
the crankshaft. .Note t}le following.
.Removetie balancergearbolt, and take the balancer oFit the balancershaft into the bearing in the LH
gei , spacer,balanoerweightoff the balancershaftasa cnnkcasehalf asshown.
set.

A. Bolt C. Balancer
Weight
B. Balancer
Gear A. Balancer
Shaft B. LH Crankcase
Half
 &23
CRANKSHAFT/TRANSMISSION

Starter Torque Limiter WaterPump ldle Shaft Holder

Remomt
.Removethe muffler (seeEngineTop Endchapter).
.Removethe right downtube (seeFramechapter').
aRemovetlle RH enginecover.
aRemovetie starter motor clutch gear.
tPull the torquelimitrr out of the crankcase.
Remoml
.Take the springendoff the hook.
.Unscrewthe bolts and takethe idleshaftholderwith a
chainguideout of the crankcase.

A. Spring C. Holder
A, TorqueLimit€r C. Washer B. Bolts D. ChainGuide
B. StarterMotor ClutchGear

oDo not dilctsnbls drs torquo limitsr. .Pull out the chainguideftom the holder.
Ths torque
limitel will not lunqtion if thb is dons.

lnspection
.Removethe torquelimiterandvisuallyinspectiL Insallation
ilf the limiter haswear,discoloration,
or otherdamage, .Note the following.
replac€it asa set. oPut the washeronto the idle shaft,and fit the knock
pinsinto the crankcase.

l. Gear
2. Friction Plate A. ldle Shaft C. KnockPins
3. Pinion B. Washer
 ISSION
&24 CRANKSHAFT/TRANSM
.Pull the primarygearout of the crankshaft,and take
PrimaryGear the pin out of the idleshaft.

Removal
.Removethe followingparts.
Muffler (seeEngineTop Endchapter)
RightDownTube (seeFramechapter)
Right EngineCover
StarterMotor ClutchGear
Clutch
.Removethe wat€r pump chainguideand water pump
idleshaftholderfrom the RH cnnkcase.

A. PrimaryGear C. Pin
B. ldleShaft

lnstallation
.Note the following
A. ChainGuide B. ldle ShaftHolder oFit the primary gear with the notched side facing
towardthe insideof the engine.

.Remove the primary gearbolt by usinga air impact

wrench,and take tlre out water pump drivesprocket
andidle shaftsprocket(A) asa set.

A. Primary
Gear B. NotchedPortion

oWhenthe wat€r pump idle shaft is installed,fit t}te

pin into the sprocketrecesses.
A. WaterPump'DriveSprocket D. Chain oTightenthe primarygearbolt to the specifiedtorque
B. ldle Shaft E. PrimaryGearBolt (seeExplodedView) while holdingthe primarygear
C. Sprocket(A) with a gearholder(specialtool).
 8.25
CRANKSHAFT/TRANSMISSION
.Remove the shift shaft,while pushingthe shift mech-
anismarm forward.

A. GearHolder(57001-1015) C. PrimaryGearBolt
B. PrimaryGear

oTightenth€ clutch hub nut to the specified

mrque(see A. Shift Shaft C. Push
ExplodedView). B. Shiff Mechanism
Arm D.GearPositioning
Lever

.Unscrewthe bolt andremovethe gearpositioninglev€r

and its springtogether.

Transmission

Extemal Shift mechanism Remoml External Shift Mechanism lnstallation

.Rernovetie following. .Note the following.
LH EngineCover oPositionthe gear positioningleverand springin tie
Engine(seeEngineRemoval/lnstallation
chapter) crankcase andscrewin the bolt asshown.
Shift LeverRearEnd
Front BevelGearCase

A. Lever C. Bolt
A. Shift Lever B. Front BevelGearCase B. Spring
&26 CRANKSHAFTTTRANSMISSION
olnstalltlte shift leverasshown. Exhrnal Shift Mechanismlnspection
*lf necessary, loosenthe locknutsandturn the shift rod .Examinetheshiftshaftfor anydamage.
to obtainan 88.5 mm leng$ includingthe locknuts.

1. Shift Shaft
2. RetumSpring
3. Shift Mechanism
Arm
4. Arm Spring

A. 88.5 mm Lengh C. Shift Leven oCheckthe shift shaft for bendingor damageto the
B. Shift Rod D. Locknuts splines.
*lf theshaftis benLstraighten or replaceit lfthesplines
aredamaged, replacethe shaft.
oCheckthe return springand arm springfor breaksor
distortion.
*lf the springsare damagedin any way, replacethem.
ooreck the shift mechanism armfor distortion,
*lf the shift mechanismarm is damagedin any way,
replac€the arm.
.Checkthat tbe returnspringbolt is not loose.
O Installthe clutch hoseguide as follows. *lf it is removed,unscrewit, apply a non-permanent
locking agent to the threads,and tighten it to $e
specifiedtorque (seeExplodedView).
theck the gearpositioningleverand springfor breaks
or distortion.
*lf the leveror springis damagedin any way, replace
tnem.

A. ReturnSpringBolt C..Spring
A. HoseGuide B. GearPositioningLever
 CRANKSHAFT/TRANSMISSION&27

.Visually inspectthe shift drum cam. TnnsmigsionDissembly

rrlf it is badlyworn or if it showsanydamage,
replaceit. .Remove thetransmissionshafts.
.Usingthe circlippliers(special tool: 57001144)to
remove the disassemble
circlips, the shaft'
transmission
.The 3rd gearon theoutputshafthasthreest€elballs
in it for the positiveneutralfindermechanism. Re
movethe 3rd gearasthe follows.
oset the output shaftin a verticalpositionholdingthe
2nd gar.
ospinthe 3rd gearquicklyand pull it off upward.
Transmission Shaf:* Remotal
.Removethe engine.
.Split tie crankcase.
.Pull out the shift rod and take tie shift forks out of
the transmissiongears.
.Take out the driveshaftandoutputshaftasa set.

1. 3rd Gear
2. 2nd Gear
3. SpinQuickly

A. Shift Rod D. OutputShaft

B. Shift Forks E. Shift Drum
C. DriveShaft
TnnsmissionAwmblv
.Note thefollowing.
Transmi ssion Shaf/s In stallati on oReplace any circlip that wereremovedwith new ones.
.Note the following. olnstallthe circlipsso that tl|e openingis alignedwith a
ocheckthe positionof the shift forksasshown. splinegroove.
oFit tlle drive and outDut shaftsas a set into the LH
crankcasehalf, while placingthe shift fork onto the
driveshaft.

A. Drive Shaft C. Shift Fork For DriveShaft 1. Circlip 3. Groove

B. Output Shaft D. Shift Fork For Outprit'Shaft 2. ToothedWasher
8-28 CRANKSHAFT/TRANSMISSION
olnstall the gearbushingon the output shaftwith its oil
holealignedwith the shaftoil hole.
oFit the steel balls into the 3rd gear holes that are
smallerthan the other holesas seenfrom the outsideof
the gear, and then install the gear on the shaft so that
the steel balls alien with the recesses
in the shaft.

A. Oil.Holes A. 3rd Gear C. Recess

B. Bushing B. SteelBalls D. SmallHole

Drive Shaft

1. Top (4th)Gear 7. NeedleBearing

2. OilHole 8. ThrustWash€r
3. 2nd Gear 9. Circlip
4. 3rd Gear 10. Washer
5. l st Gear(DriveShaft) 11. BallBearing
6. Circlip
 CRANKSHAFT/TRANSMISSION8.29

Output Shaft

Top (4th) Gear 6. I st Gear ll. Circlip

2. Oil Hote 7 . BallBearing 12. SteelBall
.t. 2nd Gezr 8 . Circlip 13. Washer
Oil Hole 9 . Bushing 14. NeedleBearing
5 . 3rd Gear 1 0 . ToothedWasher 15. Circlip

Shi ft Drum Di nssembIy/Assem

bIy
oDisassemble
the shift drumasshown.
oDo not apply gre6€ to dre st€el balb to hold drern in
place, This will cause the Foritive nerstrd finder
medranism to maltunstion.

ytift Drum Removal

aRemove theTransmission
Gearasa set.
.Remove the bolts and take off the bearing holder and

b$
the shift drum.

1. PinPlate
2. Pin
3. Shift DrumCam
4. Bearing
5. Shift Drum

.Whenassemblingthe shift drum,notethefollowing.

A. Bolts C. Shift Drum oThe pin platemustbe 'rnstalledin the correctposition,
B. BearingHolder andmustfit onto the pin plateasshown.
8.30 CRANKSHAFT/TRANSMISSION

A. Pin C. Partof the aluminum-

B. Shift DrumCam

oApply a non-permanentlockingagentto the threadsof

the pin plate screw.
 9.1
WHEELS/TIRES

Wheels,/Tires
Tableof Contents

ExplodedView... 9-2
Specifications 94
SpecialTools. 9-5
Wheels(Rims) 96
FrontWheelRemoval 9€
FrontWheellnsallation 9-6
RearWheel Removal *7
RearWheellnsallation. 97
WheelCouplingRemoral. 9€
W h e eCl o u p l i nl n
gstallation. . ...;. ......... ' 9€
Wheel(Rim) Inspestion (for castwheel) 9'9
Balarrce Weight Installation, ...'.'.'. 9'9
BalanceWeightRemoval. 9-9
Spokelrspection(for wirespokewheell.. . . 9-10
Rim Inspection 9-10
Balance WeightInstallation C10
T i r e s. . . 911
TireAir Pres$re lnspection .......'. 9-11
Tire Inspection 911
Tire Removal' 9-11
Tire lnstallation.. . . . . 9'12
HubBearings.
Removal , '. '.. ' '. 9'12
lnstallation $13
Lubrication 913
Speedometer GearHousing . 913
DisasemblyandAssem bly $13
Lubrication v-^14
9-2 WHEELS/TIRES

Exploded View

vN1500-A
(G): WestGermanModel

EY='=')');"
-s ;#

1. BalancerWeight
2. Front Tire
3, Air Valve
4. Speedom€terGeal
5. Front Axle
6. Front Wheel
7. RearAxle
8. RearTire
9. RoarWheel
a r\
\ \ \
T1:1.5N-m(0.15kgFm,13 in-lb)
T2:88N-m (9.0kg-m,65fr-rb)
T3:110N-m (11.0kg-m,8oft-lb)
rtY
' - v )\
 9€
WHEELS/TIRES

vNrSoo_B

T 1 : 1 . 5N - m( 0 . 15 k s - m 1
, 3i n - l b )
T2:. 88 N-m (9.0kg-m,65 ft-lb)
t 5 : 1 1 0N - m ( 11 . 0k g - m8 , 0f t - l b )
T4: 3.9 N-m (0.40ks-m.35 in-lb)
G : Applygrease.

r.-S1-
/.v:),,.
1. Spe.domrt i Gorr
2, Front Axl.

^ ob*
*t/ 3, Brhncar Weight
4. Rim
5. SpokeNippls
6. SFoke
7. Tube
8. Air vdr.
v
tt'
9, Rim Bcnd
10. Flont Tirr
11. RarrAxle
12, B.rd Ptotectol
^\ 13. B.bnaetW.ifht
z"soT 14. R.|' Tir.
""" @
94 WHEELS/TIRES

Specilications

Item Standard ServiceLimit

Wheels:
Rimrunout: VN1500A
Axial TIR0.5mm
Radial TIR0.8mm
VN15OOB
Axial TIR 0.8 mmor less(withtire installed) TIR 2.0 mm
Radial TIR 1.0mm or less(withtire installed) TIR 2.0 mm
Axlerunouv100mm: TIR0.05mmor less TIR 0.2 mm
Wheelbalance Lessthan 10 g
Balanceweights 109,209,309
Tiros:
Tiretreaddepth: Front 4.4mm(DUNLOP) 'I mm
4.3mm(BRIDGESTONE)
Rear 7.3mm 2mm
6.2mm (BRIDGESTONE)

Standardtires:
DUNLOPF'l1J,{A) (E)F11LTL
Front (A11-) BRIDGESTONE EXEDRAL3O9
1OO/90-19
57HTUBELESS ryPE
VN 15OOA
DUNLOPK425A,(A) (E) K425ALTL
Rear (A11-) BRTDGESTONE EXEDRAGs26
150/90-ls 74Ho|ls0/90-15 M/C74HTUBELESS
rypE
Front OUNLOP (E)
F11J, F1lLTT/METZELERMarathon Front
.1OO/90-19
57HTUBETYPE
VNl5OOB DUNLOPK425A,(E) K425ALTT
Rear 150/90-15
74Hor 150/90-15 M/C74HTUBETYPE
l\4ETZELER MarathonEuro
150/90815i/VC74H

Tireair pressure:
Front 200kPa(2.00kg/cm,,28Psi)
up to 97.5kg (215lb)toad 200kPa (2.00kg/cm,,28Psi)
97.5 - 180 kg (215 - 397 lb) load
Rear vN15004(E) 97.s- 185kg (215- 408tb)toad
225kPa(2.25kg/cm,,32Psi)
vN1500A(G) 97.5 - 186 kg (215 - 410jb) load
vN1500B(E) 97.5 - 184 kg (215 - 406 tb) toad

(E) EuropeanModel (A)AustralianModel

(G) WestGermanModel

Usethe samemanulacturer's
tirss on bothfrontand
rearwheels.

NOTE
'JMost countriesmay have their own regulationsrequir-
ing a minimumtirc treaddepth:be sure to followthem.
aCheck and balance the wheel whena tire is reDlaced
with a new one.
 WHEELS/TIRES9.5

SpecialTools Jack Stand: 57001-1238

circlip Plien: 57001-1/|i'

Rtm Protedtor: 570O1-106!t Attachment: 57901-1?5.2

N
BearingRemoverShaft: 5700l-1265

BearingDdverSet: 57001-1129 BesringRemouerHead: 57001-1267

BearingRemoverHead: 5?dt1-1293
96 WHEELS/TIRES

Front Wheellnstallation
Wheels(Rimsl .lnstallationis the reverseof removal. Note the
following,
Front WheelRemoval
NOTE
.Remove the following.
SpeedometerCable Lower End oPut the spedometer gear drive onto the wheel hub
Brake Caliper Mounting Bolts nobtrrjhes..
then install the housing e that it fits in the
drive nofthes.

A. Notches C. Drive
A. CaliperMountingBolts B. AxleNut B. Proiections D. Housing
oFit the qedometer gear housing stop to the fo* lq
stop.
Axle Nut
Axle ClampBolt (Loosen)

1. Housing
Stop 2. Fork LegStop

A. Axle C. Speedometer
Cable oFit the collar on the right hand side of the hub.
B. AxleClampBolt
.Tighten the axle nut to the specified torque (see
Exploded View).
.Use the iack standand the attachment(specialtools: .Tighten the axle clamp bolt to the specified torque
57W1-"1238, 57001-12521 andothersuitablemeansto (seeExplodedView).
lift the front of the motorcvcle. .Checkthe front brake.
.Pull out the axle to the right anddropthe front wheel
out of the fork.

tml Do not attempt to drive the motorcvcle until a full

braks lever is obtained by purnping the brake l6ver until
the pads are against the disc. The brakes will not
oDo not lay the wheel doun on dte disc. This can
funcjtion on the first application of the lever if this is
damage or warp dle disc. Place blocks under the
not done,
wheel so that the disc do not touch the ground.
 WHEELS/TIRES 97

Rear Wheel Remowl Bear Wheellnstallation

rRemovethe following. .Notethefollowing.
Muffler(seeEngineTop Endchapter) oApplymolybdenum disulfide to thegrease
grease seal.
BrakeCaliperMountingBolts oApply molybdenum disulfidegreaseto the splined
CaliDerHolderBolt portionof tlle ringgearhub.

A. Muffler C. CaliperHolderBolt A. FinalGearCase B. RingGearHub

B. CaliperMountingBolts

oBesureto inserttheoollaron both sidesof the hub.

Axle Nut Cotter Pin

AxleNut

A. CotterPin B. Axle Nut 1. LHCollar 5. RingGearHub

2. RHCollar Portion
6. Splines
3. RearHub 7. GreaseSeal
4. Coupling
eUsethe iack standand the attachment(special tools:
57001-1238,57001-1252)or other suitablemeansto
lift the rearof the motorcycle.
oPull the axle toward ti€ left, and slidethe rearwheel olnsert tl|e rear axle into the final gear cas€toward the
toward the right to disengagethe wheel from the final LH to RH, and fit the splinedportion of the ringgear
gearca9e. hub andwheelcouplinghub.
9€ IVHEELS/TIRES
WheelCoupl i ng I nstallation
.Note thefollowing.
oApplymolybdenum disulfide grease
to theO-ring.

A. Axte Hub
C. Coupling
B. RingGearHub

o'Iight€n $e axle nut to the specified torque (s€e

ExplodedView).
oTighten the rear brake caliper mounting bolls to the
specifiedtorque(se€ExplodedView). A. Gring
oTiShtgnthe calip€r holder bolt to the specifiedtorque
(seeExplodedView).
oReplacetl|e cotterpin with a newone,
olnst:ll the muffler (seeEngineTop Endchapter).

Do not attempt to driv€ the motorq/cle until a full

brake p€dal is obtained by pumping th€. brak6 pedal
until the pads are against the disc. Th6 b6ke will not Wheel(Rim) lnspection(for castwheel)
funqtion on the fiBt application of th€ psdal if this is rRemovet}le tire from the wheel.
not dong. .Measurethe rim runoutby usingthe dialgauge.

Wheel Coupling Removal

.Removeth€ rearwheel(seeRearWheelRemoval).
aRemoveth€ couplingretainer.
.R€movethe wheelcouplingwith suitablebearingpuller
if necessary.

A, WheelCoupling B. CouplingRetainer 1. RadialRunout 2. Axial Runout

 99
WHEELS/TIRES
*lf rim runoutexceeds
the servicelimit, checkthc wheel &lance Weight
bearings. PanNumber Weight(grams)
*lf the problemis not due to the bearings,the wheel
4'1075-1014 10
mustbe replaced.
41075-1015 20
41075-1016 30
Axial Runout
Service Limit: 0.5 mm
Radial Runout
ln3talling Balance Weight
Ssrvice Limit: 0.8 mm

(a) Pressor lightly hammer the weight in.

oNevsr atternpt to tep€ir a damaged wh€el. lf there is

8ny d8magp becides wheel bearingt, dle wheel mu3t be
rgplaced to inturc 38fe opsrational cotldition.

Tire Bead

Batancc Weight lnstal lation

th€ck if the weightportion hasanyplay on the blade
and{lip plate.
*lf it does,discardit. (b) Installationcompleted.
.Lubricatethe balanceweightblade,tire bead,and rim
flange witlt a soap and water solution or rubber
lubricant. This helpsthe balanc€weightslip onto the
rim flange.

oDo not tubricate the tile bead widl engine oil or

ga3olin€becauie thsy will dsteriorote ths tirs.

.lnstall the balancew€ighton the rim.

oslip the weighton the rim flangeby pushingor lightly
hammeringtie weightin the directionshown in the Clip
figure.
ocheck that the bladeand weightseatfully on the rim
flange,and that th€ clip is hookedover the rim ridge
andreaches rim flat Dortion.

Balance Weight Removal

olf the balance lyeight has any play on the rim flange,
the blade and/or dip h.ve been 3uetdred. Rcplace
the loo.e balancs weight
oDo not raur€ used b€lance w€igha,
(a)Whenthe tire is not on the rim.
.Push the blade portion toward the oulside with a
regulartip screwdriver,and slipthe weightoff the rim
flange,
.Discardthe usedbalanceweight.
910 WHEELS/TIRES
RemovingBalanceWeight (without tile on riml Rim lnspection
therimrunoutby usinga dialgauge.
.Measure

(b)Whenthe tire is on the rim.

.Pry the Balanceweight off the rim flangeusinga
regulartip screwdriverasshownin the figure.
olnserta tip of the screwdriver betweenthe tire bead
and weight blade until the end of the tip r€aches
the endof the weightblade.
oPush the driver grip toward the tire so that the
balanceweightslip s off tie rim flange.
oDiscardthe usedbalanceweight.

l. RadialRunout 2. AxialRunout
RomovingBslanceWeight (widr tire on lim)

*lf rim runout exceedsthe servicelimit, check and

performthe following.
oRecentering th€ rim.
oRetightening the spokenipplesto the specifiedtorque
(seeExplodedView).
rlf the rimsis badlybent,it mustbe replaced.

Axial Runout
Service Limit 2.O mm
Radial Runout
Service Limitr 2.0 mm

A repaired wheel part may fail in use, possibls causing

an accident. lf any wheel part is bent. dsnted, cracked,
Spoke lnspection (for wire-spoke wheel) oa warped, replace it.
.Checkthat all the spokesaretightenedevenly.
*lf spoketightnessis unevenor loose,tightenthe spoke
nipplesto the specifiedtorque evenly(seeExploded
View).

olf any 3pokebrsakr, it $ould be replac€dimmediately'

A missingspok6 placesan dditional load on the other BalanceWeightInstallation
spokes,which witl eyentrally euse odrer 3poket to weighton thespokenipple.
.lnstallthebalance
break. oAttacha balanc€ usinga pliers.
weightsecurely
 911
WHEELS/TIRES

I
\

1. Depth Gauge

Weight
A. Balance
tlf any measurement is less than the servicelimit,
replacethe tire.
Balancs Weight
PartNumber Weight(grams)
41075-1007 10 Tire Trsad Depth
4'I075.'I008 20
41075.1009 30 Front
Standald: 4.4 mm
ServiceLimit: 1 mm
Real
.'_1T................... Standard:
SeruiceLimit
73 mm
2 mm
TireAir Pressurelnspection
NOTE NOTE
oMeastretire prffsure when the tires arc cold (that is,
oFor the VN\5O&B. replace the rim band with e new
when the motorcycte has not beenridden more than a
one wtteneverthe tire is repleed.
mile during the past3 hours).

Tire Air Pressure(whencold)

Tire Removal
Load Air Pressure .Note the following.
Front
200kPa oWhenremovingthe rear tire, removethe valvestem
(2.00kgrlcm',
28 psi) nut, balancernut, andfully loosenthe beadprotector
Up to 97.5 kg 200 kPa nut (VN1500-B).
( 2 1 5l b ) (2.O0kglamz, 28 psil
97.5-l80kg
(21s -397 t6)
97.5- 185ks
(215- 408rb) 225 kPz
z 97.s - 186ks (2.25kglcm2, 32 psi\
(215- 410rb)
-
i>:iE (E., 97.5 184 kg
(21s- 406tb)

@ EuropeanModel @ WestGermanModel

Tirelnspection
avisually inspectthe tire for cracksand cuts. Replacethe
tire if badly damaged.
a Measurethe tead depth at the center ot the tread with
a depth gauge. A. BeadProtectorNut B. Balancer
Nut
9.12 WHEELS/TIRES

Tire lnstallation Ail Valve

acheckthe tire rotationmark on the reartire and
installit on therimaccordingly.
NOTE
oThe direction of the tire roation i8 st own hy an arrow
on the rar tire sidev,all.

1. PlasticCap 4. ValveStem
2. ValveCore 5. ValveSeat
3. StemSeal 6. ValveOpened

.lnstall a newvalvein the rim.

oRemovetlle valvecap, lubricatethe stemwith a soap
1 . RotationMark(Arrow) 3. Air Valve and water solution,and pull the stemthroughthe rim
2. Balance Mark (YellowPaint) from the insideout until it snapsinto place.

oPositionthe tire on the rim so that the air valveis at

the tire balancemark (the yellow paintmarkon a new
tir€).

oFor VNls(xt-A: Tubol€3sti.6 arc i$talled. Do not

inliall t$e-type tir€c on this motorcvdc.
oFor VN15O0.B:Tube tires sre in3€11€d.Do not inttsll
tub€lest-typstirss on this motorcryde.
oThe Econnonded ltandard tina mu3t be ur€d fol 1. Apply soapandwatersolution.
rsplacamel . 2, Pullthe stemout.

.Aft€r installing the bead protector and balancer,

tighten the nuts to ihe specifiedtorque (VN150GB:
seeExplodedView).
oDo not useengineoil or petroleumdistillates to lubri-
catethe st€mbecuasethey will deterioratcthe rubber.
VN15OCA3 (Canada)and VNl5(XlA4 -
Rubber-typeair valveand air valve hole modified
wheelsareusedon the front wheels.

lnsallation
aRemovethe air valveanddiscardiL
HubBearings

Removal
.Removethe hubbearings
by usingthebearing
remover
oRcplacethe rubber-typ€air vahe wheneverdte tire is shaftandheads(specialtools).
rcplac€d. oRemovethe bearingretainer.
oDo not reusedre air valve. oRemovethe RH bearingfirst
 WHEELSfiIRES 9.13

Lubrication
NOTE
asince tlre barings on dte rear whel hub are peked
with grea* and $ielded on both sides' they are not
requiredto be removedfor lubrication-

.For front hub bearing,turn each bearingback and

or binding.
forth whilecheckingfor roughness
tlf roughnesor bindingis found, replacethe bearing'
rlf it is noisy,doesnot spinsmoothly,or hasany rough
spots,it mustbe replaced.

1. BearingRemover
Shaft:57001-1265
2. BearingRemoverHead: 570O1-1267,1293

oDo not lay dre wheel on lhe ground with the di*
tacing down. Thi! can damage or warp the dlsc. Place
blodc under lbs wheel so d|e ditc do€| not toudr dle
ground.

lnstallation
.lnstalt the bearingsby usingthe bearingdriverset
(special 129).
tool: 57001-'l Turn back and forth [A]
Shield IB]

GearHousing
Speedometer

3. Driver(Small) D i lassem b Iy an d Assemb I Y

1. BearingDriverHolder
2. Driver(Large) NOTE
ott is recommendedthat the a*mbly be replacednther
t an aftempting to rcpair the components.
NOTE gear housingso that it fits in
.lnstall the speedometer
oln&all he b@rings e that the markd or $ielded sides the speedometergeardrive notches(seeFront Wheel
hcc out. lnstallation).
9-l4WHEEIS/TIRES
Lubrication
.Cleanandgrease gearhousing.
thespeedometer

GearHousing
l. speedometer
2. Grease.
 FINAL DRIVE lGl

FinalDrive
Tableof Contents

ExplodedViaitr 1G2
Specifications 10-4
S p e c iTaol ols..... 1(}4
FinalGearCase Oil 1G6
Oil Level Inspection 1G6
Oil Change. 1G6
F i n aGl earCase.... 1G6
Removal 106
lnsallation notes.. . 1f}.7
Disassembly. 1G9
AssemblyNotes.. . 1G9
BevelGear Inspection 1G10
PinionJoint Inspection 1G10
Ball Bearinglnspection 1G10
NeedleBearingInspestion. 1G10
Oil SealInspection . . . . . 1Gl0
Final BevelGearAdjustment. . . . . , . 10-11
BevelGearlnspection 1G14
PinionGear Bearing lnspection.. . . . . 1G14
Oil SealInspection .. ... . 1G.14
PropellerShaft 1G14
Removal 1G14
lnstallation Notes . . t&15
SlidingJoint Inspection... . . . . . 1015
PropellerShaft Inspection. 1(}15
SlidingJoint Ingection, 10-15
Front Be\relGean . , . 1G16
Front GearCaseRemoval 1G16
Front GearCaseInstallation tG16
Front GearCaseDisassembly(includingdrivegearremoval).. . . ' ' 1 G 1 6
Front GearCaseAssembly{includingdrivegearinstallation) . . . ' ' 1 G 1 8
DrivenGearDisassembly. 1G18
DrivenGearAssembly.. . 1G19
DamperCam Removal. 1S19
DamperCam Installation Notes, . . 1G20
FronB t e v eGl e a r A d i u s t m e n t , . . . . . . . . . . . . . 1G.20
BevelGear lnspection 1o.24
Cam Damperlnspection 1G24
Ball Bearing Inspection 1G25
TaperedRollerBearingInspection.... '. 1G25
NeedleBearinglnspection. 1G25
Oil Seallnspection. ... . 1o.25
1O-2 FINAL DRIVE

View
Exploded

$ 1 . Oil Pipe
2- Drive GeatShim
3. DdYsGsar
4- DriveGearShaft
5 . l'leurr.l Savitct
6. Front BevelGesrCse
@h 7 . Drivsn GearShin
8 , Ddren Ge8t
9. F ont EeYelGaarAsembly
10. B€aringHousing
1 1 . Collal (Pr€losdAdiun)
12. Spacer(Moed Adiurtl
13. Drivsn GsarJoint
14. .CamFollower

ST; Stakeths fastenen.

T1 : 88 Nfl (0.90kgn,78 in.lbl
T2: 12 Nfl (12 ksn,104 inlbl
T3: 15 Nrn (15 kgFm,11.0ft.lbl
T4: 25 Nm (25 kgn, 18.Oft{bl
T5: 120 Nfl (12.1kgm, 88 ft lbl
T6: 265 N (27 ks{n, 195ft.lb)
 FINAL DRIVE 10.3

-g_

1 . Propell€r Shaft Joint G : Apply greale.

2. Propellar Shaft L : Agply non{ejmanent lod(ing agent.
3. E€aling Retainsr (Left{anded Thredsl ST: Staked|e fasten€rs.
4 . Plnion Gaar Shim Tl : 88 Nrn (0.90kgrn, 78 in{bl
5 . Pinion Ger T2: 16 N{n (1.6kgfl,115 ft'lbl
6. Ring Gsai Tlt r 23 N-rn (23 ks{, 165 ft{bl
7 . Bolt M10 T4: 29 N-rn(3.0k$m, 22 tt{bl
L Bolt M8 T5: 34 N.rn (35 kgim,25 ft lbl
9. Final Bevel G€al A$smbly T6: 120 N"rn(12.0ksm,87 ft{b}
10. Filler Plug T7: 2tl5 Nrn P5 ks{, 180ft{bl
1 1 . Final Gear Cate
12. Ring Gear$rim
1G4 FINAL DRIVE

Specifications

Item Standard
Final GearCaseOil: Grade API GL€ HypoidGearOil
Viscosity Whenabove5"C (41'F) SAE90
Whenbelow5'C (41"F)SAE80
Amount 2(X)mL
Oil Level Bottomof filler opening
FinalGearCase:
Finalbwel gearbacklash 0.06 - 0.09 mm (at gearhub spline)
0.10 - 0.15 mm (at geartooth)
Front Bevel Gear:
Preloadfor drivengearbearings 0.5 - 0.9N-m(0.05- 0.09kg-m,4- I inib)
Front bwel gearbacklash 0.10- 0.15mm (at geartooth)

SpecialTools

BearingPuller: 57dt1-158 DamperCam Holden 57q11-1025

DrirenGearHolder: 57001-1027

Mapter: 57001317

BearingDriver: 57001382 DialGaugeHolder; 57001-1049

 FINAL DRIVE
Oil Seal& B€aringRemover:57001-1058 Jack Standr 57(x11-1238

w
BeadngDriverSetl 57001-1129
Afiadrment: 57OO1-1A2

Oil SealDrivel: 57001-1101 Final GoarC..e Hold€r: 51001-1250

-\e\
V-

PlnionGearHolder; 57001-1165 B€aringRetainelWren.fi: 5?qr1'1251

::@:)

D Yo Gear Holdel: 570'J1-1?,26

10€ FINAL DRIVE
.After the oil has completelydrainedout, install the
FinalGoarCaseOil drainplugwith a newgasket.
.Fill the final gearcasewilh the specifiedoil andquan-
tity.
Oil Levellrcpection
.Supportth€ motorcycleperpendicular to the ground.
.Unscrewthe filler plug. The oil levelshouldcometo
the bottomof tlre filler opening
Final Gsar Cce Oi!:
Amount 20OmL
Grado AP! GL€ lrypoadg€aroil
Vircoity:
Whd| aboreS"C (41'Fl SAEgtt
wh€o bdd 50c (41'Fl sAE S0

NOTE
oThe wm 'GL6" indiaa'fs a Sdity etd dditiE
nting. A 'GL6" tzd hypoid g@r oll en al'p b
ud.

.Be surethe O+ingis in place,and lnstallthe filler plug.

A. DrainPlug C. Filler Plug
B. Oil LevelLine

*lf it is lorv, first check the final gear casefor oil

leakage,remedy it if nec€ssary,and add oil throughtie
filler opening. Usethe sametype and brandof oil that
is alreadyin the fioal gearcase.
.lnstall the filler Plug.

Oil Change
.Warm up the oil by runningthe motorcyclesothat tie FinalGearGasg
oil will pickup any s€dimentanddrain€asily.Stopthe
motorcycleand turn it off.
aPlacean oil pan beneaththe final gearcase,and remove Ranoval
tlle drainplug. *lf thefinalgearcaseis to bedisassembled,
drainthefinal
gearcaseoil.
a Removethe rearwheel (seeWheel/Tireschapter).
a Removethe left shockabso6erfrom iG studs by taking
off the nuts.
aRemovethe final gearcaseby takingoff the nuts. The
springcomesoff with the case.

I wtnunre
-- i
o h.n draining or filling ths\final gear cara, be aalsfrrl
tha no oil gG on d|g titr or rim. Oean off any oil NOTE
lftlt inrdrortsn{y gatr on th€m wttb a high flrdt.poim olf the find gar ee is fit of oil, plee {re w s that
aolYgnt. dre btathar hole ls on top,
 FINAL DRIVE 1G7
Disassembly
oRemovethe final gearcasecover bolts.
.Use three cover bolts to remove the ring gearassembly
from the gear case. The shim(s) comes off with the
assemblv.

A. FinalGearCaseNuts
B. BreatherHole
C. RearShockAbsorber(LH)

A. Jackthe coverup with bolts.

B- FinalGearCaseCover

Installation Notes
OLubricate the propellershaft ioint (see PropellerShaft
Joinl Lubrication).
alnstall the spring so that the small diameter end faces
toward the final gear case- NOTE
oDo not sp{aE dle ring gearasmbty (riry gar, ring
gcarhub, and final gar ca'€coved, but the oil sl can
be rcmotnd.

aTo removethe ring'gear oil seal,soakthe ring gear

assembly in oil heatedro 120- 150"c (2l|8- 3{t2"F},
then punchthe oil sealand pry it out with an awl or
other iuitable tool. Be careful nol to scratchthe
sealingsurfaceon the ringgearhub.

A. SmallDiameterEnd oDo not hsat dr6 case with a torch. Thb will rvsrp $s
c83e.

.Fit the pinion gearsplinesinto the propellershaftjoint

whileturningthe ringgearhub.
.Tighten the final gear casemounting nuts to the
specifiedtorque(seeExplodedView).
*lf the final gearcaseoil wasdrained,fill the casewith
o -
.Removetre snapring and pull out the needlebearing
outerrace.
*lf the oil sealis damagedremoveit usingthe'oil seal
andbearingremover(specialtool).
1G8 FINAL DRIVE
Final GearCase

1 . PinionGearNut 6 . Oil Seal I l. RingGear 16. Ball Bearing(Four-pointContact)

Washer 7. BallBearing 12. Studs 17. PinionGear
3. PinionGearJoint 8. FinalGearCaseCover i3. PinionBearing
Retainer 18. Oil Seal
4. Oring 9 . CoverMountingBolts 14. Oil Seal 19. NeedleBearing
5. RingGearHub 1 0 . RingGearShim(s) 15. FinalGearCase

A. PinionGearHolder: 57001-1165

1. Oil Seal& Bearing

Remover:57001-1058
o Removethe washerand pinion joint with the O-ring.
o Pull out the oil sealon the pinion bearingretainerusing
a suitablepuller.
.Remove the oil seal on tie pinion bearingretainer O Removethe pinion gear and its retainer.
withoutremovingthe pinion. O Removethe Allen plug and then unscrew the retainer
ounscrewthe pinion nut usingthe pinion gearholder with the final gear case holder and bearing retainer
(special
tool). wrench (specialtools).
 FINAL D.RIVE1G9
.Use a suitabledriver to drive in the oil rals being
carefulof installatlondirectionanddepth.

A. Allen Plug
B. FinalGearCaseHolder(57001-1250)
Wrench(57001-1251)
C. BearingRetainer

NOTE
ome badng reainer haslefthandd thrads, therefore
it mustbe tumedclo*wi* in rcmoval.

oTaketie retainerand piniongearass€mbly out of the

final gearcase.
oPullout the shimandplugfrom the final gearcase.

oAlign the oil hole in the needlebearingouterracewith

thJ hole on the bearinghousing(pinion gear side).

l. PinionGearJoint 3. Shim A. Oil Holes B. NeedleBearing

2. PinionGear 4. Plug

Assembly Note6
.The ring gearand pinion are lappedas a set in the
factory to get the best tooth contact. They must be aBlow the breatherhole in the final gear cage cover
installedasa pair,neverreplaceonewithout the oti€r. air.
oleanwith comDressed
1GIO FINAL DRIVE
Pinion Gear Joint lnspection
.Visuallyinspectthe splinesof the piniongearjoint.
rlf they are badly worn or chipped,replacethe joint
wit$ a new one. Also, inspectthe propellershaft
joint.
sliding

A. Breather Hole

.Reinstall the original ring gear shim(s) to ke€p the gear

backlashand the tooth contact unchanged.
.Apply a non-permanentlocking agent to the threadsof
the cover bolts, and tighten them to the specified
torque (seeExploded View).
.Apply a non-permanentlocking agent to the threadsof
each stud and install them to the case if they were A. Checkspllnedportion.
removed.
.lnstall the pinion gearretainer. Note the following.
oReinstall the original pinion gear shim(s) to keep the
gear ba€klashand the tooth contact unchanged.
ousing the final gear case holder and bearing retainer
wrench (specialtools: 57001-1250and 57001-1251),
tight€n the pinion gear retainer to the specifiedtorque BaII Bearing I nspection
(seeExploded View). Sincethe ball bearingis made to extremelyclose
oUsing the pinion gear holder (special tool: 57001- tolerances,the wearmustbe ludgedby feel rathertban
ll65), tighten the pinion nut to t}le specified torque measurement.
(seeExploded View). .spin the bearingby handto checkits condition.
ostake the pinion nut with a punch. *lf therebearingis noisy,doesnot spin smoothly,or
hasanyroughspots,replaceit (asa gearset).

owhen 3takingdre nut, be carefulnot to apply lhock to

th€ pinion and its bearing. Suc{ra thock could damage
th? pinion snd/or be$ing.
olnsert the plug into the Allen plug hole, and apply a
non-permanentlocking agent to the tireads of tle
Allen plug,then tightenthe Allen plugto the specified
torque (seeExplodedView).
Needte Bearing lnspection
.The rollers in a needlebearingnormally wear very
little, and wear is difficult to measure. Insteadof
measuring,inspect the bearingfor abrasion,color
change, or otherdamage.
rlf there is any doubt as to the conditionof a needle
bearing, replacelt.

Bevel Gear lnspection Oil Seallnspection

avisuallycheckthe bevelgears chipping,
for scoring, or alnsDectthe oil seals.
other damage. tReplace any if the lips are misshapen,discolored
*Replace the bevel gears as a set if either gear is (indicating that the rubber hasdeteriorated),hardened,
damaged. or otherwisedamaged.
 FINAL DRIVE 1G11

Final Bevel Gear Adiustment

The backlashand tooth oontast pattern of the bevel gears must be correct to prevent the gearsfrom making noise
and beingdamaged.
Afterieplacing any of the backlash-relatedparts, be sure to check and adrustthe backlashand tooth contact of the
bevelgears. First, adiust backlash,and then tooth contact by replacingshims.

Eackla3h-RelatedPartt

1 .PinionGear
2. PinionGearShim(s)
3. RingGearAsembly
RingGearShim(s)
5. FinalGearCase

Pinion Ge.r $rimr for Too$ ContactAdiunment

Ring Gear Shimstor BacklashAdiunment (mm)
Thickness PartNumber
(mm)
Thickness PartNumber 0.10 92025-1733
0.15 92025-1783 0.15 92025-11?4
u.5 92025-1784 0.5 92025-1735
0.6 92025-1185 0.6 92025-1736
0.7 92025-1786 0.7 92025-1737
0.8 92025-1787 0.8 92025-1738
0.9 92025-1788 0.9 92025-"t739
1.0 92025-1789 1.0 92025-1740
'1.2 92025-1190 1.2 92025-1741
1G12 FINAL DRIVE
NOTE
c,{,rsedrese dzimsfor gear hackladr and tooth contact
adjustmart.
Backla3hAdi$tment
tlean anydirt andoil off the bevelgearteeth.
aPressthe ring gearassemblyslowly with an oil seal
driver (57001-1104)to firmly seat the ball bearing.
.lnstall the piniongearassembly with the primary(1.0
mm d|icknes) shim,andtightenbearingretainerto the
specifiedtorque(seeExplodedView).
.lnstall the ringgearassemblywith the primary(1.0mm
rhic{rnesr)shim,and tightenthe covermountingbolts
to the specifiedtorque(seeExplodedView).
oCheckthe backlash duringthe tighteningof the cover
mountingbolts,andstoptighteningthemimmediately
if the backlashdisappears.Then,changethe ringgear
shimto a thickerone.
nF."I-lm
oDo not iGtall ths O{ing3during adiGtment.
aMount a dial gauge [D] on a vise so that the tip of the
gauge is againstthesplinedportion ofthe ring gearhub.
aTo measurethe backlash,tum the ring gear hub [B]
back and forth [C] while holding the pinion gearsteady
with the pinion gear holder [A].
The difference
between the highest and the lowest gauge reading is
the amount ol backlash.
o Measurebacklashat three locationsequally spacedon
the splines.
Final B3vsl Gear Backlash: 0.06 - O.O9 mm
(at dng gear hub splinesl
Consot Too$ Contact Pattern
ffik-Bottot
-ffir"0
'tlf the backlashis not within the limit, replacethe ring
gearshims.To increase backlash,increase the thickness
of the shim(s). To decreasebacklash,decreasethe
thicknessof the shim(s).
achangethe thickness a lltde at a tim€.
.Re{heck the backlash, andre-adiustasnecessary.
Toodr contast adiustment
rCleanany dirt andoil off the bevelgearteeth.
.Apply checkingcompoundto 4 or 5 teeth of the
piniongear.
' NOTE
oApply cheking compoundto dte teed, in a thin, evqt
coat whh a hirly *iff paint bru{r. ff reind too
thi*ly, tlre exff't tooth patem may not appar.
oThe dteking compound must be snooth and firm,
with the consi*encyof tood, p&e.
o&&ial compoundsare anilable at artomotive srpply
Etorgs for the pupoe of &eking differcntial gar
tooth paftemsand con&t.
a lnstall the shim(s) and pinion gear assembly,and
tightenthe bearingretainerto the specifiedtorque(see
ExplodedView).
alnstallthe shim(s)and ringgearassembly, and tighten
the @ver boltsto the specifiedtoique (seeExploded
View).
aTurn the piniongearfor one revolution[B] backand
forth,whilecreatinga dragon the ringgearhub [A].
a Removethe ring and piniongearassemblies to check
the drive pattem and coast pattem of the bevel gear
teeth. The tooth contact Dattemsof both (drive and
coast)sidesshouldbecentrallylocatedbetweenthetop
and bottomof the tooth. The drivepattemcan be a little
closer to the toe and the coast pattem can be a
somewhatlongerandcloserto the toe.
 FINAL DRIVE 1G13
*lf the tooth contact pattern is incorrecl, replace the
pinion gear shim(s), following the examplesshown.
Then erasethe tooth contact patterns,and check them
again. Also check the backlasheverytime the shim(s)
are replaced. Repeat the shim change procedure as
necessarv.

lncorrect Toodr CoDtact Patterns

NOTE
olf the fukla$ is out of the standard nngp after
changingthe pinion gear&im(s), rql*e the ring g:@r
$im(s) to conect the backh* More cheking the
tooth cont&'t pattern.

Example 1: Decreasethe thickness of the pinion gear

shim(s) by 0.05 mm to correct the pattern shown below.

Example2: lncreasetie thicknes of the pinion gear

shim(s)by 0,05 mm to correctthe patternshownbelow.

Bottom

Top
Heel
1G14 FINAL DRIVE

Bevel Gear lnsprction oslip the propellershaft off the drivengearioint by

.Remove the ring gearassemblyand pinion gearfrom pushingon the lock pin throughthe access
hole.
the final gearcase(see Ring Gear Disassembly and
PinionGearDisassembly).
rVisually checkthe bevelgearsfor scoringchipping,or
otherdamage.
tReplace the bevel gears as a s€t if either gear is
damaged.

Pinion GearBearinglnspection
rDisassemblethe pinion gear (see Pinion Gear Dis' Disengagem€ntof Propellershaft ftom
assembly). D:ive GearJoint
.Visually inspe€tthe bearings color change,
for abrasion,
or otherdamage.
ilf thereis any doubt as to the conditionof a bearing,
replaceit.

Oil Seal lnspection

.lnspectt}le oil seals.
*Replace any if the lips are misshapen,discolored
(indicatingthat the rubberdeteriorated),
hardened,or
otherwisedamaged.

t
PropellerShaft

Removal
.Rqmovethe following.
RearWheel
FinalGearCase
aRemovethe propellershaftfrom the front drivengear
ioint.
oTurn the propellershaftso that the lockingpin access
holeon tl|e propellershaftcomesoutside.

l . PropellerShaft Spring
2. UniversalJoint ) - DrivenGearJoint
3. LockingPin

.Remove the circlip from tf|e rearendof the propeller

shaftusinga circlippliers.
aRemovethe washerand pull out the propellershaft
A. LockingPinAccessHole slidingioint.
 FINAL DRIVE 1G15

Propetler Shaft tnspection

.Check that the universal joint workssmoothlywithout
rattlingor sticking.
tlf it doesnot work smoothly,the needlebearings of
the universalloint aredamaged.Replacethe propeller
shaftassembly witl a newone.
.Visually inspectthe bearingof the shaftand the wear
of the splinedsectionat tlte rearendof the shaft.
*lf it is bent at all, replacethe propellershaftassembly.
Do not attempt to straightena bent shaft.

t . O-ring 4. PropellerShaft
2. Washer 5 . SlidingJoint
t. Circlip

lnsallation Notes
.Check the Oring on the rearendof the propellershaft
for any kind of damage,and replaceit if necessary.
.Lubricatethe propellershaftioint (seePropellerShaft A, Checkuniversal'oint.
Joint Lubrication). B. Inspectsplinedportion.
aAfter connectingthe propellershaftto the drivengear
ioint, pull tlle propellershaft rearwardto checkthat
the shaftis securedin placeby t}le lockingpin.

Sliding Joint l nsp*tion

Sliding Joint Lubrication
.Wipe off the old greasefrom the propellershaftsliding
ioint andpinionloint.
.Pack the propellershaft sliding joint with 20 mL
(15 grams)of hightemperature grqrse.
.Visually inspectthe intemal splinesof the propeller
shaftslidingloint.
*lf they are badly worn or chipped,replacethe joint
with a newone.

PropollorShrft SlidlngJoint kbria.tion

High TemperatureGrease

A. SlidingJoint
B. Checkthe splinedportion.
1G16 FINAL DRIVE
Front Gear Caselnstaltation
Front Bevel Gears .Note the following.
oTighten the front gear casemounting bolts to the
specifiedtorque(seeExplodedView).
Front Gear CaseRemovat owhen installingthe oil pipe,pustrit down and torque
rRemove the following.
thefront banjobolt first to the specification.
Engine (seeEngine Removal/lnstallationchapter)
Shift LinkageLever Rear End
Front Gear Case

l . Pushdown this Doint.

2 . Torque the front banio bolt fast.
ocheck that the shift shaft oil seal and reDlace it if
necessarv.

A. Oil Pipe C. FrontGearCase

B. Shift LinkageLever
Front GearCaseDisassembly
(includingdrivegearremoml)
aRemov€the following.
Front GearCase
CamFollower
DamperSpring
oThe camfollowerandthe damperspringcomeoff with RubberBoots
the gearcase, .Removethe driven gearassemblymountingbolts and
pry the assembly
off the case.

A. DrivenGearAssemblyMountingBolts
B. DrivenGearAssembly
C. RubberBoots
A. Cam Follower B. DamperSpring D. DriveGearAssemblv
 FINAL DRIVE IG17

A. Pry Points A. DriveGear C. Catththe visehere.

B. Holder: 5700"i.-1226

aRemove the drive gear.

oPry off the gear casecap with a suitabletoois.

oPull off the drivegearshaft with the drivegear,collar,

andshim(s).
.Removethe bearingholderfrom the gearcase.

A. Cap

A. Bearing B. BearineHolder

oPryopenthe drivegearnut with a smallchisel.

ounscrewthe drivegearnut holdingthe drivegearshaft .Remove the drive gear shaft ball bearingusingthe
with the holder(specialtool). bearingdriverset (special
tool: 57001-1129).
1G18 FINAL DRIVE
Front Gear CaseAssembly
(incl uding dri vegear installation )
.Note thefollowing.
oThe drive and driven gearare lappedas a set in the
factory to get the best tooth contact. They mustbe
reDlaced asa s€t.
oPressthe drivegearand shaftassembly slowlywith the
driver (specialtool) to firmly seattJ|egearonto the
shaft-

A. Oil Holes B. Shims

*lf the oil pipe wasremoved,usea new flat washeron

eachsideof the fittings,andtightenthe banioboltsto
the specifiedtorque(seeExplodedView).

l . Driver:57001-382
2 . Shaft
J. DriveGear

.Be sureto checkandadjustth€ bearingpreloadandthe Driven Gear Dinssembly

bevelgearbacklash andtooth contact,whenanyof the .Holdingthe drivengearjoint wit}t the driven gear
backlash-related parts are replaced(see Front Bevel holder(specialtool), unscrewthe driven gear bolt.
GearAdlustment).
.After completingall adiustment,re-assemblethe front
geatcate.
oReplace the drlvegearnut with a newone.
oApply oil to the threadsand seatingsurfaceof the
nut, and tighten it to the specifiedtorque (s€eEx-
plodedView).
oLoosenthe nut completely and retightenit to the
specifiedtorque(seeExplodedView).
ostakethe nut to secureit in place.

milm
owhen stsking the nut, be caretul not to apply shock io
lhe shaft and iG bearing. Sudr a drod< could damage
dre 3h.ft and/ol bearing.

A. Vise
B. DrivenGearHolder:5700'l-1027
olnstall the driven gear assemblyso that the oil hole
on the housingalignswith the oil hole in the case.
olnstalltheshim.
oTight€nthe drivengearassembly mountingboltsto the
specifiedtorque(seeExplodedView). .Remove the driven gearjoint with the O-ring.

A. Joint B. O+ing
.Removethe drivengearfrom the bearinghousing.
aRemovethe collarandthe spacer from the drivengear.
.Remove the oil sealfrom the housingwith a hook,
andpull the taperedrollerbearingout of the housing.
.Remove the taperedroller bearingwhich is pressed
onto the drivengearshaftwith the bearingpuller and
adapter(specialtool: 57001-158 and57001-317).
DrivenGearAssembly
.Note the following.
oThe drive and drivengearsare lappedas a set at the
factory to get the besttooti contact. They must be
replacedasa s€t.
oBe sureto checkandadrustthe bearingpreloadandthe
bevelgearbacklashandtooth contact(seeFront Bevel
GearAdjustment).
oDriv€ the taperedroller bearinginner raceonto the
drivengearshaftusingthe bearingdriver(specialtool).
1. Driver:57001-382
2. RollerBearing
3. DrivenGear
FINAL DRIVE 10.19
.After completing the bearing preload adiustm€nt,
re-assemble the drivengearassembly.
ousing the bearingdriver set (specialtool: 57001-
1129),pressthe oil sealin until the faceof the sealis
levelwith the endof the bearinghousinghole.
oTightenthe drivengearbolt to the specifiedtorque (see
Exploded View).
ostakethe drivengearbolt to preventit from loosening.
A. StakingPoint B. Pin Hole
m
owhen staking the bolt, be careftil not to apply shock to
dre ddyen ge.r and lheil bearingr. Such a drock could
damagethe driyen gear and/or b€arings.
Damper Cam Bemoval
aRemovethe front gearcase.
.lnsert a bolt (012 mm, Ll00 mm) into the engine
mountingbolt holeasshown.
.Holding the danper cam with the dampercam holder
(specialtool), unscrewthe dampercam nut usinga
deepsocket.
A. DamoerCam C. Bolt
B. Holder:57001-1025
IG2O FINAL DRIVE
Damper Cam lnstallation Notes Front BevelGear Adiustment Procedure
aReplace the dampercamnut with a newone.
.Tighten the dampercam nut to the specifiedtorque Preloadthe driven gear bearings.
(seeExplodedView).
oApply a small amount of oil to the threadsand the
seatingsurfaceof the nut.

Front Bevel Gear Adjustment

In order to preventone gearfrom movingawayfrom
the other gear under load, the taperedroller bearings
must be properlypreloaded.Alsothe backlash(distance
one gearwill movebackand forth without movingthe
otler gear)and tooth contact pattem of the bevelgears
mustbe correct'to preventthe gearsfrom makingnoise
andbeingdamaged.
Above three adiustmentsare of critical importance
and must be carried out in the correctseouenceand
method.
the front gearcasecompletely.
Assemble
Whenany of the backlash-related partsare replaced,
or the drivengearbolt is loosened;
evenif the purposeis
not to replacethe parts,be sureto checkandadiustthe
bearingpreloadand the bevelgearbacklashand tooth
contactby replacingshims.

Backlarh{slatedParts

I . DriveGear
2. Collar
3. DriveGearShim(s)
4. Ball Bearing
5. DriveGearShaft
6. Front GearCase
7. DrivenGear
8. TaperedRollerBearing
9. DrivenGearShim(s)
10. DrivenGearBearingHousing
11. DrivenGearroint

Partswhidt influencebearing
plsload only

12. Collar(PreloadAdjustment)
13. Spacer(PreloadAdlustment)
i4. TaperedRollerBearing
*15. DrivenGearBolt

*Preloadadiustmentis necessarywheneverthe bolt is

Ioos€ned,even if the purposeis not to replacethe
parts.
 FINAL DRIVE 1G2I
'P.€loadadiustment
alnstall the ddven gear assembly,and tighten the driven
gear nut to the specifiedtorque (see ExplodedView).
Do not installthe oil sealand do not stakethe bolt until
the coFect bearingpreloadis obtained.

cAlrnoN
To start with- choose a shim or collar so that the
bea.ings ar€ iust SNUG with NO play and also with NO
preload.
Any over-prcload on the bearings could damage the
b6arings. 1. SpringScale 3. DrivenGearHolder: 57001-1027
2. Hole 4. 200 mm

*lf the preloadis out of specifiedrange,replacethe

bearingcollar and/or spacer. To increasepreload,
the stacklengthof the collarand spacer.To
decrease
preloadincrease
decrease the stacklengthof the collar
andspacer.
.Apply a little engine oil !o the beatings,and turn the
*Change the stacklengtha littleat a time.
gear shaft more than 5 turns to allow the bearingsto
aRe-check the bearing preload, and re-adjust if
seat.
necesEary.
oMeasure the bearing preload. Bearing preload is
defined as the force or torque which is neededto st2rt
the gearshaft turning.

Collarsfo. PreloadAdiwtm€nt
Length(mm) PartNumber
22.8 92027-1152
22.9 92027-1153
23.0 92027-1154
23:1 92027-1155
Prsloadfor DrivenGearBoaring 92027-1156
UsingSpringScale: .25.5 92027-1157
25 - 4.5 N (025 - 0.45 ks,0.6 - 1.0 lbl 23.4 92027-"t158
U.ingTonque Wrendr: z)-) 92027-1159
05 - 09 N{n (0.05- 0O9 kg"m.4- 8 inJb) 23.6 92027-1160
z5. t 92027-1161
23.8 92027-"t162
23.9 92027-1163
24.O 92027-"t164
24.1 92027-"t165
NOTE
oPreloadcan be masrred either with a Wring sale or a
bem-rype torque wrench. When measJrcdwith a
Spacersfor PreloadAdiustmsnt
gring wle, the preload is d$ignafud by force (N, kg,
lb), and when masJred whh a torque wrench,it is (mm)
Thickness PartNumber
d8ignated by torque (N-n, kgfl, in-lbJ. 1.70 92025-1072
ousing &dng *ale: 1.72 '92025-1073
Hook the *ring wle on the handleat a point 200 1.74 92025-1074
mm apart from the cenEr of the gar c7€ft. t./o 92025-107
5
Hold the bearinghousing ih a vis€e dlat the g@r "t.78
92025-1076
Ctaft axis is tErtial; Appty force to dE handle
horizontally and at a riglrt angleto it,
1.80 92025-1077
1G22 FINAL DRIVE
BearingPreloadingMedranirm

(A) BeforeTightening (B) After Tightening

Under Under
No Preload Preload

lnitial
Clearance Clearance

Under
No fteload

l. BearingHousing
2. TaperedRollerBearing
3. Spacer
4. Collar
5. TaperedRollerBearing

Backlashadtujtment .Set up a dial gaugeagainsta drivegeartooth to check

acleanany dirt andoil off bevelgearteeth.
.lnstall the drive gearwith the primaryshim (1.0 mm
thickness),andtightenthe nut to the specifiedtorque
(seeExplodedView).
NOTE
oDo not stake the hed of the nut until both backlaC,
and tooth conta€tadiustmentsarc fini$d.
gearbacklash.Thegaugeslemmustbe in line with the
directionof tooth travel.
.To measurethe backlash, movethe drivegearbackand
forth while holding the driven gear steady with a
suitabletool. The Differencebetweenthe highestand
lowestgaugereadings is the amountof backlash-
*lf the backlashis not within the limit, replacethe gear
shim(s)at the drive and/or drivengear. To increase
backlash,increasethe thicknessof the shimft). To
decreasebacklash, decreasethe thickness of the
shim(s).
*Changethe thicknessa little at a time.
.Re{heck the backlash, andre-adjustasnecessary.

.lnstall the drivengearassembly to the front gearcase

with the primaryshim(1.0mm thickness), andtighten NOTE
the mountingbolts to the specifiedtorque (seeEx.
plodedView). ott is OK to packtwo slrims. Do not pack three or more
oCheckbacklashduringthe tighteningof the mounting Critns.
bolts, and stop tighteningthem immediatelyif the
backlashdisappears.Then, changethe shim to a
thickerone.
.lnstall the dial gaugeholder(specialtool) with 6 mm
bolts and nuts on the front gearcaseto mount a dial Front Eeyel Gear Backlash (rt fie gcar too6l
gauge. 0.10 - 0.15 mm
 FINAL DRIVE 1G23
NOTE
oApply chtking compound to the teeth in a thin,evm
coat with a fairly *iff paint brudl. lf painted too
thickly, the exact tooth paftem may not appear.
oThe ch&king compound must be smooth and firm,
with the consistency of too{7 paste.
osp*ial compounds are at/ailable from automotive
sllpply stor6 for d\e purpos of checking differential
gear tootl, patterns and contact. us this for dr$king
the bevel gears.

.Turn the driven gear for 3 or 4 revolutionsin the drive

and reverse(coast) directions, while creating a drag on
the drive gear.
'1. oCheck the drive pattern and coast pattern of the bevel
Holder:57001-1049 3. Movethe drivegear.
2. Holdthe drivengear. gear teeth. The tooth contact patternsof both drive
and coast sides should be centrally located between
the top and bottom of the tooth, and little closer to
the toe of the tooth.
rlf the tooth contact pattern is incorrect, replace the
shim(s) at the drive gear and shim(s) ai the drive geat,
Shimsfor DriYe Ge.r following the examples shown. Then erasethe tooth
contact patterns, and check them again- Also check
(mm)
Thickness PartNumber
the backlashevery time the shimsare replaced. Rep€at
0.15 92025-1688 the shim changeprocedureas necessary.
0.5 9202s-1689
0.6 9202s-1690 NOTE
o.7 92025-1691
olf the backla$ goes out of standard nngE after
0.8 9202s-1692
0.9 92025-1693 changing dzims, corr*t the backla$ before checking
1.0 92025-1694 the tooth contact Daftem.
olt is OK to pack two drims. Do not pack three or more
1.1 92025-1695
{tims.
1.2 92025-'t696

Corleet Tooth Contact Pattern

Shims for Driven Geal

Thickness(mm) PartNumber
0.1 92025-1826
0.15 92025-1818
0.5 92025-1819
0.6 92025-1820 Heel
0.7 9202s-182'l
0.8 92025.1822
0.9 92025-1823
1.0 92025-1824
1.2 92025-1825

Toot r contact adiustmenl

oCleanany dirt and oil off the bevelgearteeth.
oApply checking compound'to 4 or 5 teeth on tt|e 1 . DriveGear
driven gear. DrivenGear
1G24 FINAL DRIVE
lncorrectToodr Contact Pattems
Example1: lncreasethe thicknessof the drive gear
shim(s)by 0.05 mm,and/orincrease
the thicknessof the
drivengearshim(s)by 0.05 mm to correctthe pattern
shownbelow. Repeatin 0.05 mm stepsif necessary.
Example2: Decreasethe thicknessof the drive gear
shim(s)by 0.05 mm, and/or decrease
the thicknessof
th€ driven gear shim(s)by 0.05 mm to correct the
pattern shown below. Repeatin 0.05 mm stepsif
necessarv.

Heel Heel

1. DriveGear
2. DrivenGear

Bevel Gear lnspection

rVisuallycheckthe bevelgears
for scoringchipping,
or
other damage,
*Replace the bevel gears as a set if either gear is
damaged.

Cam Damper lnspection

.Visually inspectthe damp'ercam,camfollower,spring,
andshaft. l. Spring 3. DamperCam
*Replac€the part if it appearsdamaged. 2. CamFollower 4. OutputShaft
 FINAL DRIVE 1G25

Ball Bearinglnspection
.Since the ball bearingis madeto extrem€lyclose
thewearmustbeiudgedby feelratherthan
tolerances,
measurement. Clean the bearing in a high flash-point
solven!,dry it (do not spin the bearingwhile it is dry),
and oil it with engineoil.
.Spin the bearingby hand to check its condition.
*lf the bearint is noisy, does not spin smoothly, or has
any rough spots, replaceit.

Tapered Roller Bearing lnspection

.Visually inspectthe bearingfor abrasion,color change,
or otherdamage.
*lf thereis any doubt asto tlle conditionof a bearing,
reolaceit.

NeedleBearingInspection
aThe rolleIsin a needlebearingnormallywear very little,
and wear is difficult to measure. lnsteadof measuring.
visually inspect the bearingfor abrasion,color change,
or other damage,
*lf there is anv doubt as to the condition ot a needle
b€aring,replaceit.

Oil Seallnspection
alnspect the oil seals.
*Replace it it the lips are misshapen,discolored (indicat-
ing that the rubber has deteriorated), hardened, or
otherwisedamaged.
 BRAKES11-1

Brakes
Tableof Contents

ExplodedView 11-2
Specifications 114
SpecialTools. 114
BrakePedal 11-5
BrakePedalPositionAdjustment. . . , 11-5
Caliper.. 11-5
Front Caliper Removal 11-5
RearCaliper Removal 11€
CaliperInstallation 11-6
DisassemblyNotes, 11€
AssemblyNotes.. , 11.6
Brake Pads. 116
Removal 11-6
lnsellation Notes 11-7
LiningWear. 11-7
MasterCylinderc 11-7
Front MasterCylinderInstallation 11-7
RearMasterCylinderRemoval 11-7
RearMasterCylinderInstallation 11€
lnspectionand Adjustmentafter Installation 11€
Disassembly. 11€
Assembly. 11€
Inspection(Visually). 11€
BrakeDisc. 11-9
Wear 11-9
Warp... 11-9
BrakeFluid 11€
Fluid LevelInspection. 11-9
BrakeFluidChange.. ... . 11-10
Bleedingthe BrakeLine. . . 11-10
11.2 BRAKES

ExplodedView

Ti : 5.9 N-m(0.60kg m, 52 in-lb)

T2: 7.8 N-m (0.80kg m, 69 inlb)
T3: 8.8 N-m (0.90kg m, 78 in-tb)
T4 : 27 N-m(2.8kg m, 20 ft-tb)
T5: 25 N-m (2,5k9 m, 18.0ftnb)
T6 : 32 N-m (3.3kg m, 24 ft-lb)

so

@ n

@^-6"s @@
9

1 . Front MasterCylinderAssembty
2 . Diaph.agm
3 , MasterCylinder
4 . Front BrakeLight Switch

CIt' 5 . MasterCylinderClamp
5 . Piston
7 . Brake HoseClamp
L Fronl CaliperAssembly
I . Brake Pads

".vq 10 . Caliper Holder

11 . Piston
12 . Calipel
13 . Brake Disc
 BRAKES11€

T1 : 7.8 N-m (0.80kg m, 69 in-lb)

T2: 23 N-m(2.3kg m, 16.5ftnb)
T3 : 25 N-m(2.5kg m, 18.0ftlb)
T4: 32 N-m (3.3kg m, 24 ft-lb)
T5: 6rt N-m(6.5kg m, 47 ftjb)
T6: 27 N-m(2.8kg m, 20 ft-lb)

w
ssn@g-

Y I . RearCaliperAssembly
2 . Piston
3 . Caliper
4 . Brake Pads
5 . CaliperHolder
6 . Brake Disc
7 . CaliperHolder
8 . Real MasterCylinderAssembly
9 . Diaphragm
10 . ReservoirTank
ll . PushRocl
'12. Piston
13 . MasterCylinder
114 BRAKES
1. RearBjakePedal
2. Front FootpsgBrac*et
3, BrakePedalLink CNamp Bola
G : Apply greale.
T1: 25 N-m (25 kgn, 18J ft{b}

V
U SpecialTool
n
tl CirclipPliers:57001-1tB

H
I

Specificaions

Item Standard ServiceLimit

Brake Pedal:
Brakepedal position 65 mm abovetop of footpeg
Brake Pads:
Padlining thickness 5.0mm lmm
BrakeDiscs;
DiscThickness:
Front VN150OA 4.8- 5.1mm 4.5mm
VNlSOOB 5.8- 6.1mm 5.5mm
Rear 6.8- 7.1mm 6.0mm
Discrunout Under0.15mm 0.3mm
BrakeFluid:
Grade D.O.T.4
Brand(recommended) CastrolGirling-Universal
CastrolGT (LMA)
CastrolDiscBrakeFluid
CheckShockPremiumHeavyDuty
 BRAKES11.5
.Whenthe brakepedalis in its restposition,measure
the
Brake Pedal length@ indicatedin the figure.
*lf the length @ is not within the specifiedlength,
adiusta nut.
Brake PedalPosition Adiustment
.Check that the brake pedal is in the correct position.

Pedal Position
Sandard: About 65 mm above top of footpeg

-- ll
l . MasterCylinder 3. Clevis
2 . Locknut

Lensth@
Standad: 165mm

Caliper
A. Footpeg C. Pedal Positlon
B. BrakePedal
Front Caliper Removal
.Disconnectthe speedometercablelowerend.
rlf it is not, checkthe punch marksat the brakepedal .Loosen the banjo bolt at the caliper,and tighten it
link pivot shaft, and the mastercylinder push rod lightly.
lencth. .Remove the calipermountingbolts and take off t}te
caliper.

A. PivotShafts B. Marks
A. CaliperMountingBolts C. Caliper
B. BanioBol: D. BrakeHose
NOTE
ausually it's not n*e&ry to adiust the pedal position,
but alwaysadiu# it when the master cylinder is dis aDisconnect the brakehosefrom ihe caliper.
asembled. *lf the caliperis to bedisassembled afterremovalandif
olf the push rod length cannot be adjustedby turning compressed removethe pistonusing
air is not available,
the clevis, the bnke pedal may be deformedor incor- the followingstepsbeforedisconnecting the brakehose
rectly installed. from the caliDer.
11.6 BRAKES
oRemovethe pads.
oPumpthe brakeleveror pedalto removet}|e caliper
piston.
oTo avoid serious iniury, neyer place your fingerc or
palm inlide the caliper opening. lf you apply com-
NOTE
pr$sed air into the caliper, ihe piston may cru3hyour
olmmediately wipe up any brake fluid that Wills. hand or fingerc.

Rear Caliper Removal

.Remove the rearcaliperin the sameway on the front
caliper.

air.
l. Applycompressed 2. Cloth

Assembly Notes
oApplybrakefluid to the outsideof thepistonandthe
fluid seal,and push the piston into the cylinderby
A. Caliper C. BrakeHose hand. Take care tlrat neither the cvlindernor the
B.CaliperMounting
Bolts pistonskirt get scratched.
.Apply a thin coatof PBC(Poly Butyl Cuprysil)grease
to the caliperholdershaftsandholderholes.(PBCis a
specialhightemperature, grease).
water-resistant
Caliper lnstallation .lnstall the anti-rattlespringin the calipersas shown.
.Note the following.
oTighten the caliper mountingbolts to the specified
torque(seeExplodedView).
oconnectthe brakehoseto the caliperputting a new
flat washeron each side of tl|e brake hose fitting.
oTighten the banio bolt to the specifiedtorque (see
ExplodedView).
oCheckthe fluid levelin tie mastercylinder(reservoir),
and bleed the brake line (seeBleedingthe Brake).
oCheckthe brakefor weakbrakingpower,brakedrag,
andfluid leakage.

oDo not attempt to drive dre motorcycle until fully

depr€ssing dre breke lever or p€dal then pump the 1. AntirattleSpring
brake lever or pedal until dre pads are against dre dbc.
The bhkes will not funotion on the first appliEtion of
dre lever or psdal it dris is not done,

BrakePads
Dinssembly Notes
.Usingcompressed thepiston.
air,remove
oCoverthe caliperopeningwith a clean,heavycloth- Removal
oRemovethe pistonby lightly applyingcompressedair rRemove the caliper (see Front or Rear Caliper
to whereth€ brakeline fits into the caliDer. Removal).
 BRAKES11-7
.Take off the piston side pad from the caliper holder.
.Push the caliper holder to the piston side,and then MasterCylinders
removethe pad from the caliper holder shaft.

Front Maser Cylinder lnstallation

fwhen installing the front master cylinder, note the
following.
oThe master cylinder clamp must be installed with the
rear view minor holder upward.
oTi$ten the upper clamp bolt first, and then the lower
clamp bolt to the specified torque (see Exploded
View). There will be a gap at the lower part ofthe
clamp after tightening.

1. Pad 3. Pushthecaliperholder.
2. CaliperHolder

lnstallation Notes
.Push the caliper pistons in by hand as far as they will
go.

l. Tightenupperclampbolt first. 3. Mirror Holder

2. LowerClampBoll 4. Clearance-
oDo not attempt to driye the motolcrycle until fully
depresing dre brake lev€r 01 p€dal dren pump dre
ouse a new flat washeron eachsideof the brakehose
brake lever or pedal until the pad3 ars agaiffit dre disc.
The brake will not tunction on the filst application of fitting.
oTighrenthe banjo bolts to the specifiedorque (see
$e leveror pedal if this is not done.
Exploded View).

Lining Wear
rlf the liningthickness
of eitherpadis lessthanthe Rear Master Cylinder Removal
servicelimit, replace both pads in the caliper as a set. .Note the following.
oRemovethe cotter pin and then pull the joint pin out
Pad Lining Thickness of the pushrod clevisand brakepedal.
Standard: 5.0 mm
ServiceLimit: I mm

1. LiningThickness A. Clevis C. JointPin

2- Service
Limit B. CotterPin D. PushRod
1I.8 BRAKBS
Rear Master Cylinder lnstallation
.Note thefollowing.
oReplace the aluminumwasheron eachsideof thebrake oExcept tor the disc pads and disc; use only disc brake
hosefitting with a new one. Be sure that the metal fluid, isopropyl alcohol, or ethyl alcohol, for deaning
pipe is properlyfitted into the U-shapednotch in the
brake part!. Do not uis any other fluid for deaning
mastercylinder. these parts. Gasoline,engine oil, or any other petro,
oTightenthe banjo bolG to the specifiedtorque (see
leum distillate will cass€ detedoration of dte rubber
ExplodedView). parts. Oil spilled on any part will be diffic[lt to
oTightentle rear mastercylinder mountingbolts (2)
wash off compl€tely, and will eventually deterioiete
to thespecifiedtorque(seeExplodedView).
the rubber used in the disc bEke.

oTake care not to scratchth€ Distonor the inner wall of

the cvlinder.
Insp*tion and Adiustment after lnstullation
oCheckandadlustthe followingitems-
BrakePedalPosition
RearBrakeLight SwitchPosition
BrakeLineAir Bleed
BrakeDrag
BrakingPower
BrakeFluid Leak lnspection (Visually)
.Checkthat thereare no scratches, wear,rust or pitting
on the followingparts.
Insideof the MasterCvlinder
Dinssembly Outsideof the Piston
rRemovethe followingparts. PrimaryCups
DustCover Secondary Cups
Retainer DustCovers
Pistonwith Secondary
Cup ReturnSprings
PrimaryCup ReliefandSupplyPortPlugged
Spring *lf they aredamaged, replac€tiem.

oDo not removedre secordaryanp from the pbton since

rcmovslwill damagedrem.

q&
1. PrimaryCup 4. Retainer
2. Secondary
Cup 5. DustCover l. Reservoir
3. Piston 2. Diaphragm
3. Reli€fPort
4. SupplyPort
5. Cylinder
Assembly 6. ReturnSpring
.Note thefollowing. 7. PrimaryCup
oBeforeassembly,cleanall parts includingthe master 8. Piston
cylinderwitlr brakefluid or alcoho,. 9. SecondaryCup
oApply brake fluid to the removedparts and to the 10. DustCover
innerwallof the cylinder. I 1. BrakeLever
 BRAKES 11-9

BrakeDisc '.:.*.:i::1........
Wear Fluid Level lnspection
*Replacethe disc if it hasworn pastthe servicelimit. .Check the brakefluid levelin the reservoir.

Front Brake Fluid Reservoir

'1.
BrakeDisc 2. llleasuring
Area

Front Disc Thid(ness A. Lower Level Line B. UpperLevelLine

Standard Limit
SerYice
VN15O0-A 48 - 5.1 mm 45 mm
VN1500-B 53 - 6.1 mm 55 mm Rear Brake Fluid Reservoir

Rear Disc Thickness

Standard: 6.8 - 7.1 mm
ServiceLimit 6 mm

Warp
tlf runoutexceeds
the servicelimit, replacethe disc.

A. UpperLevelLine B. LowerLevelLine

NOTE
oHold the reservoir horizontal when checking brake
fluid level.

*lf the fluid level is lower than the lowerlevelline,fill

the reservoirto the upper level line of the reservoir.

1. BrakeDisc 2. Measuring
Area
ochange the brake fluid in dre brake line completely if
Dbc Runout the brake fluid must be re{illed but the type and brard
Standard: Under0.15 mm of dre brake fluid that aheady is in the rg3srvoir ars
ServiceLimit: 03 mm unidentified. Aftsr cfianging the fluid, use only dre
I1.10 BRAKES
$me type and brand of fluid thereafter. Mixing ocheckthe fluid levelin the reservoiroften,replenishing
differsnt types and brands of brske fluid lowers the it asnecessary.
brake fluid boiling point and co{ld cause the brake to
be ineffectiye. lt may also cause dre rubber brak€ parts NOTE
to deteliorate.
olf the fluid in the rcervoir runs completely out any
time during fluid changing,the bleedingopention must
be done over again from the beginning sinceair will
R€commended Dirc Brake Fluid
haveenteredthe line.
Type D.O.T.4
Brand Check Sho.r( Premium Heavy Duty oRepeatthis operationuntil fresh brake fluid comes
Crstrql Gidin g.unive'ssl out from the plastichoseor the color of the fluid
Cactrol GT (f-MA) cnanges.
Castrol Dbc Brake Fluid

oDo not mix two blands of fluid. Chan$ dre brake

Bnke Fluid Change
fluid in dle b|8ke line completrly if ths blak€ fluid
must be refill€d but tre type and brand of the brake
NOTE
fluid that b already in d|g roservoir are unidentified.
oThe prccedure to drange the front bnke fluid is as
fo ot s. Changingtte rcar bnke fluid is the sme as
for the frcnt brake.

.Removethe reservoircap,and removethe rubbercap

on the bleedvalve.
.Attach a clear plastichoseto the bleedvalveon the
caliper, and run the other end of the hoseinto a
container.
.Changethe brakefluid asfollows:

Bleeding the Brake Line

NOTE
oThe procedure to bleed the front bnke line is a
follov,n Eleding the rar bnke line is {re sme
as for the front bnke.

Bleed the air after the brake partsare removedor

disassembled.

awith the reservoircap off, fill tle reservoirwith fresh

brakeoil.
.Slowly pump the brake lever or pedal severaltimes
until no air bubblescan be seenrisingup throughthe
fluid from the holesat the bottom of the reservoir.
This bleedsthe air from the mast€rcvlinderand the
brakeline.

NOTE
oTap the bnke hoe lightly going from the caliperto fie
recrwir side and let the air off from the reervoir
whenthe btdcelever hasa qonge feling.

1 . Ooen the bleed Valve. .Attach a clearplastichos€to the bleedvalveon the

2. Pumo the brake leverand hold it caliper, and run the other end of the hose into a
5. Close the bleed valve. container.
4. Releasethe brake lever. rBleedthe brakelineandthe caliperasfollows:
 BRAKES11-11

owhen working with the disc brake, obseryethe

precautions
Iistedbelow.

l. Neverreuseold brakefluid.
2. Do not usefluid from a containerthat hasbeen
left unsealed or that hasbeenopenfor a longtime-
3. Do not mix two lypesand brandsof fluid for use
in the brake. This lowersthe brakefluid boiling
point and couldcausethe braketo be ineffective.
It may also causethe rubberbrakepartsto dete-
riorate.
4. Don't leavethe reservoircapoff for any lengthof
time to avoidmoistur€contamination of the fluid.
5. Don't changethe fluid in the rain or when a
strongwindis blowing.
6. Exceptfor t}te disc padsand disc, use only disc
brakefluid, isopropylalcohol,or ethyl alcoholfor
cleaningbrakepans. Do not useany other fluid
for cleaningtheseparts. Gasolingengineoil, or
any other petroleumdistillatewill causedeteriora-
tion of the rubberparts. Oil spilledon any part
will be difficult to washoff completelyand will
eventually deterioratetie rubber used in the
discbrake.
7. When handlingthe disc padsor disc, be careful
that no disc brakefluid or any oil getson them,
Cleanoff any fluid or oil that inadvertentlygets
on the padsor discwith a highflash-pointsolvent.
Do not useone whichwill leavean oily residue.
Replacethe padswith newonesif they cannotbe
cleanedsatisfactorilv.
8. Brakefluid quickly ruins paintedsurfaces;any
1. Pump the brake lever until it becomes hard, and apply fluid should be completely washed
the brakeleverand hold it. immediately.
2. Ouickly open and ctose the valve while holding the 9. lf any of the brakeline fittingsor the bleedvalve
brakeleverapplied. is openedat any time, the AIR MUST BE BLED
3. Releasethe brakelever. FROMTHE BRAKE.

ocheck the fluid levelin the reservoiroften,replenishing

it asnecessary,

NOTE
off the fluid in the res€ oir runs completely out any
time during bleeding, the bleeding opention mu$ be
done over again from the beginning since air will have
entered the line.

oRepeat this operation until no more air can be seen

comingout into the plastichose.

NOTE
alf the bmke lever action still feels fift or gongy, tap
the bnke hose lightly from futtom to top end or air
will rise up to the top paft of the hoe, slowty pump
the brake lever as the ame manner as above
 l2-1
susPENsroN

Suspension
Tableof Contents

ExplodedView... 12-2
Specifications 124
SpeciafTools. 12-4
Front Fork 12-5
Fork Oil Change. 12-5
Removal(eachfork legl . .. . 12-6
Installation(eachfork les) . . . . 12-6
Disassembly. 12'6
Assembly. 12'7
InnerTubeInspection. 12-8
GuideBushInspection 12-8
Oil SealandDustSealInspection PA
SpringTension 124
RearShockAbsorber. . . . 12-9
Adjustment. 12-9
Removal 12-9
lnsallationNotes.. 12-9
RearShockAbsorberWear 12-9
Bushing Wear. .' 12'10
SwingArm .. 12-10
Removal .'""' 12-10
fnstalfation ..... 12-10
Grease SealandNeedle Bearing Removal/Assembly .. .. . 12-10
Grease SealandNeedle Bearing Lubrication.
' '.. '..... 12-11
Sleweand NeedleBearingWear. . . .
12-2 SUSPENSTON

Exploded View

^4-* a-@ gF{9

o @
i'o-t /.A @tD
^/1 qt
4ioA.o, o
@{J

-P
,g

@o@€

1. Front Fork Lsg 11. GuideBulh L : Apply non.pormanentlocking agent.

2. Cap 12. CylinderPition Unit Tl : 20 N{n (2.0kgrn, 145 ft-lbl
3. Top Plug 13. C]ylinder T2 : 29 N-m (3O kgFm, 22 ft{b}
4. Sp*er 14. SihoftSpring T3: 52 N.rn(53 kgrn 38 ft{b}
5. ForkSpdng 15. GylinderBase
6. Inmr Tubo 16. OuterTubs
7. GuideBulh 17. Axle ClampBolt
8. Durt S€alCap 18. DrainBolt
9. Du3tSoal 19. Bottom Allsn Bolt
10. Oil S€al
 12€
susPENsloN

es
6 sB

y*
@ K

1. RearShockAbsorber
2. S:wingArm
3. Pivot Shaft
4. SwingArm Cover(LHl
5. SwingArm CoYer(RHl

T1 : 30 N{n (3.1kgrn, 22 ft lbl

T2: 98 N{n (10Okgfl,72 ft{bl
124 SUSPENSTON

Specifications

Item Standard ServiceLimit

FrontFork: VNlsOGA vN 1500-8
Forkoil: Viscosity SAE1OW2O <_
AmounVUnit z136
+2.5mL 474 !2.5 mL
Whenchanging
oil 370mL rt05 mL

Forkoil level(Fullycompressedl 124x7 mm 1zl0t7 mm

Forkspringfreelength 475.5mm z166mm
412.5 mm 404 mm
RearSuspension:
Rearshockabsorberspring
adjusterposition 2 of 5 positions

BearingDriyer Set: 57q)i-f 129

SpecialTools

From Fork CYinder Holder Handle: 57001-183

H.ndle Adapen 57001-1057

Oil Sealand BearingRemover:57d)1.168 Fork Oil SeelDriyert 57q11-1219

Jad( Stand: 570/J1-12aB

Atta.fiment: 57001-125.2
F ont Orter TubsWeight: 5ZOO1-1218
 susPENsloN12€
NOTE
Front Fork oApply non-permanent locking agcnt to the threads of
the dnin erew and gasket.
Fork Oil Change(each fork leg)
.Remove lhe following. Front Fo* Oil
Handlebar{Slideto eachside} viscosity sAE 10w2o
Capand Fork Top Plug Amount per side
When changingoil:
vN1500-A About 370 mL
vN1500-8 About ttos mL
After disasembly and
completely dryi
VN1500-A 436 t25 mL
VN1500-B 474 !25 mL

NOTE
Qump the fo* enough tim6 to expel the air form the
upper d lower chambe,s,

.With the fork fully compressed insert a tape measure

or rod in the inneriube,andmeasure the distancefrom
the top of the innertubeto the oil.
A. Handlebar C. Top Plug
B. Retainer

ForkSpring
DrainScrew

l OilLevel

Fork Oil Level (Fully Complessedl

vN1500-A 124 fl nm
vN1s00-B ltlo i7 mm
A. DrainScrew

*lf the oil is above or below the specified level, remove

.Allow the oil to draininto a suitablecontainer.lf you or add oil and recheckthe oil level
pumpthe fork legsto forceout the oil, be sureto catch oChange the oil of the other fork leg in the same
asit squirtsout.
theoil in a container manner.
12€ SUSPENSION

Removal (each fork leg) oTightenthe upper and lower fork clamp bolts to the
.Using the jack stand and the attachment (special torque(seeExplodedView).
specified
toofs: 57001-1238or 12521or other suitablemeans oTightenthe caliper mountingbolts to the specified
to llft the front of the motorcycle. torque(seeExplodedView in Brakechapter).
rRemovethe following. oCheckthe front brakeafter lnstallation.
Caliper(fromthe fork legto be removed.)
Front Wheel(seeWheelsflires chapter)
Front Fender
.Loos€nthe upperandlowerfork clampbolts.
.With a twistingmotion, work the fork leg down and
out

oDo not attempt to ddve dre motororyaleumil futly

deprsssingthe brake lev€r, dren pumping tfte brake
leveruntil the Fad3a16agai$t tlis disc. The brakewill
not function on dre 613t applicati,onof $e leYsrif this
k not done.

Dis*sembly
.Performthe following.
oRemove the retainerandtakeoff the top plug.
oPullout the spacer,washer,andthefork spring.
A. UpperClampBolt B. LowerClampBolt oRemove the fork leg.
oPourout the fork oil.
ostop the cylinderfrom turning by usingthe front fork
cylinder holder handle and adapter(specialtools).
Unscrewthe Allen bolt and take the bolt, and gasket
out ofthe bottomof the outertube.
Installation (each fork leg)
.Performthe following.
olnstallthe removedDarts.
olf the fork leg was disassembled, check the fork oil
level.
olnstall the fork tube so that the inner tube toD end
is alignedwith the upper surfaceof the stem head.

1. Wrench 5. Handle:57001-183
2. Bolt 6. OuterTube
3. Cylinder 7. lnnerTube
4. Adapter:57001-1057

oRemovethe piston and cylinder unit and the short

A. St€m Head C. Aligned springfrom the top of the front fork tube.
B. lnnerTube oPrvthe dustsealcoverout of the fork tube.
 susPENsloN12-7

A. DustSealCover B. Pry Poini

fr
oRemovethe dust sealand the retain€rfrom the outer
tube.

1. lnnerTube
$
2. ForkOuterTubeWeight:57001-1218
3. OuterTube
4. Strok€

oTakethecylinderbaseoff the outertube.

oTakethefork innerpartsout of the innertube.

A. DustSeal B. Retainer
oMountthe weight(special tool) on tie top of tie outer
tube, by fitting the stepof the weight(specialtool) to
the top cornerof t}le out€rtube.
oHoldingthe inner lube by handin a verticalposition,
strokethe outer tube severaltimes and pull it down.
Assembly
.Assembly is the reverseof disassembly. Note the
following.
€heck the top plugO-ringsfor damage.
tReplacethemwith newonesif damaged.
oReplace theoil sealremovedwith a newone.
olnspectthe guide bush (seeGuide Bushlnspection).
*Replaceit with newonesif necessary.
oApplya non-permanent lockingagentto the Allenbolt.
oTighten the Allen bolt to the specifiedtorque (s€€
ExplodedView), usingthe ftont fork cylinderholder
handleand holderadapter(specialtools) to stop the
cylinderfrom turning.
olnstallthe guidebushwith a usedguidebushon it by
tappingthe usedguidebushwith the fork oil sealdriver
(specialtool) until it stops. The slit of the bushmust
befacedtowardthe left or right.
12-8 SUSPENSTON

'1.
GuideBush

1. Driver:57001-1219
2. UsedGuideBush
3. Slit (towardthe left or right) Oil *al and Dust Seallnspecdon
4. NewGuideBush *lf dustsealhasanydamage
or wear,replace
it.
5. Tap .Replace the oil seal with a new one whenever it has
been removed.

ouse the fork oil sealdriver (specialtool) to installthe

oil sealin thefront fork.
olnstallthe dust sealcoverwith a oil sealdriver(special
tool).

lnner Tube lnspection

*lf the innertube is damaged,
replaceit.
.Nicki or rust damagecan sometimesbe repairedby
usinga wet-stoneto r€movesharpedgesor raisedareas
whichcausesealdamage.
*lf the damageis not repairable,replacethe innertube.
Sincedamageto the inner tube damages the oil seal,
replacethe oil sealwheneverthe inner tubeis reDaired
or reDlaced.
1. Oil Seal 2- DustSeal

olf dre innel tube i3 badty bent or creasod, teplac€ it,

Exc6$iye bsnding, followed by subcequent straight-
sning, canwsokendte inner tube.
Guide Bush lnspection
*Replace the guide bushesif they are damagedor worn.
Spring Tension
*lf the spring of either fork leg is sltorter than the
servicelimit, it must be replaced. lf the lengthof a
replacementspringand that of the remainingspring
vary greatly, the remainingspring should also be
replacedin order to keepthe fork legsbalancedfor
motorcyclestability.
 12-9
susPENsroN
SpringAdiuster
Spring
Position Setting Load Road Speed
Force
I Soft Light Good Low

tI tI tI
5

4
5
J
StIonger
I
Hard
,t ,t 't
Heavy Bad High

are turned to
.Check to seethat both adiustingsleeves
the samerelativeposition.

1 . ForkSpring
2. FreeLength

Fork Sp ng Length oll both sprins adiusting sleevB are not adiusted equsl'
ly, handling may be impailed and a hazardouscondi'
vN1500-A
tion may r$ult.
Standad: 4755 mm
SerYiceLimit: 466 mm NOTE
VNlsq'-B
St ndard; 412,5mm oBe s.rre to tum back the adiuiing sleate counfutclock-
ll{t4 mm wis€ from pNition 5 wlrq, eftening the *ring action.
Service Limit:

Rear Shock Absorber

Remotral
.Using the iack standandthe attachment(specialtools:
Adjustment 57001-1238or 12521or other suitablemeansto Iift
The rear shockabsorberhas 5 posllions so that the the rearof the motorcycle.
spring can be adjustedfor different road and loading .Removethe cap nu! lockwasher, andflat washerfrom
conditions. the both endsof the rearshockabsorber.
rPull the rearshockabsorberoff the frame.

lnsallation Notes
rTighten the mountingnutsto the specifiedtorque(see
Exploded View).
.Adjust the rearshockabsorberposition.

Rear Shock Absorber Wear

aRemovethe rearshockabsorbers.
l . Lower Cover .Visuallyinspectthe followingltems.
2. AdiustingSleeve Compression Stroke
5- PositioningMarks Oil Leakage
OtherDamage
*lf there is any damageto the rearshockabsorber,or
lf tie spring action feelstoo soft or too stiff, adjust it one unit feels weakertian the other, replaceboth
in accordancewith the following table. shockabsorbers asa set.
12-10 SUSPENSION

Bushing Wear oPull back the swing arm and take ifoff. A cap on each
avisuallyinspect
therubberbushing. sldeof the swingarm will alsodrop off.
tlf th€yshowanysigns
of damage,
replace
them.

lnstallation
SwingArm alnstallationis the reverseof removal. Note the fol-
lowing.
oTightenthe pivot shaft to the specifiedtorque (see
Removal ExplodedView).
aUsing the iack stand and the attachment (special oTightenthe rear shockabsorbernuts to the specified
iools: 57001-'1238 or 12521or other suitablemeans torque(seeExplodedView).
to lift the rearof the motorcycle. oTighten the calipermountingbolts to the specified
aRemovethe following. torque(seeExplodedView).
RearWheel(seeWheels/Tires chapter) oMove the swing arm up and down to check for
RearCaliper(seeBrakechapter) abnormalfriction.
Muffler(seeEngineTop Endchapter)
SwingArm Covers
RH RearShockAbsorber
FinalGearCase(seeFinalDrivechapter)

A. RH RearShockAbsorber GreaseSealand Needle Bearing

B. SwingArm Removal/Assembly
C. Cover .Notethefollowing.
D. BrakeHose(takethe hoseout of the holder) oRemove theneedlebearing
usinga oil sealandbearing
remover(special
tool).

.Uns6rewthe pivot shaftandpull it out.

A. Oil SealandBearingRemoveri57001-1058
B. NeedleBearing
A. SwingArm B. PivotShaft C. GreaseSeal
 susPENstoN12-11
olnsert the needlebearingusing bearing driver set
(special 129) so that marked side faces
tool: 57001-1
outside.

Grexe Seal and Needle Bearing Lubrication

aApply greaseto the innersurfacesofthe needlebearings
in accordancewith the PeriodicMaintenanceChart.
aApply a thin coat ot greaseto the lips ofthe greaseseals.

A. Applygrease. C. Grease
Seal
B. NeedleBearing

Slebveand Needle Bearing Wear .

aVisually inspect the swingarm sleeve and needle
bearing.
*lf there is any damageto them, replacethem as a set.
 STEERING1}1

Steering
Tableof Contents

ExplodedView... 13'2
SpecialTools. 13-3
Steering. 134
Adjustment. 134
Steering Stem 134
Removal 134
lnstallation 136
S t e e r i nSgt e mB e a r i n g . .... '... 137
BearingLubrication,. . . . 1;-7
gearingWear,Damage. 13'7
StemCapDeterioration, Damage. '. '.... '. 13-7
S t e e r i nSgt e mW a r p. . . . . ..'.'.... 13'7
13.2 STEERING

ExplodedView

T1 : 20 N{n (2.0ksm, 145 ft{b}

T2: 39 N{n {4.0kg-m,29ft"lbl
T3: 52 Nrn (53 kg.m,38ft-lbl
T4 : 59 N.m {6.0kgfl,43 ft-lbl

@
G:Applygrease
L : Apdy nonfermanentlockingagent. oy
o
4 " g

A " , e @
@@/N€
@S/r
d

P--{D
rc-
1. Handlsbst
2. Gollar
3. Handl. Holdel

€_o 4. Stsm HsadBolt

5. llta$€r
@-€) 6. SteeringStem H€ed

e-o 7. St6mNutT:6mm
8. StemNut T 3 10 mm
9. StemCap

e%t. 10. Foller B€aling.(UpFll

11. RollsrB€aring(Loworl
12. Gr€assSe.l
13. SteeringStem Base
14. Frame
 STEERING13€
Driver PressShaft: 57001-1075
SpecialTools
StemBearingDriver: 57001-131-/

Driver(Upper):57m1't 106

Adapter: 57001-1074

Driver(Lowerl: 57001-1076

JackStand: 57001-1238
StemNut Wrench:57m1-l l(Xl

Attidrment: 570'01-1252
StemBa.ringRemorer:57(x11-1107

q
s
134 STEERING

NOTE
Steering
oTurn the locknut l/8 turn at a time maximum-

Adiustment
oCheck asfollows.
steering
ouse the jack stand and the attachment(specialtools:
57001-1238,5700'l-1252\to lift the front wheeloff
the ground. .Tighten the steeringstem headbolt to the specified
owith ttle front wheel pointing straightaheadalt€r- torque(seeExplodedView).
nately tap each end of the handlebar. The front .Tighten the front fork lower clamp bolc to the spe-
wheelshouldsriing fully left and right from the force cified torque (see Exploded View in Suspension
of gravityuntil the fork hir the stop. chapter).
*lf tl|e wheel binds or catchesbefore the stop, the .Checkthe steeringagain.
steeringis too tight. *lf the steeringis still too tight or too loose,repeatthe
oFeel for steeringlooseness by pushingand pullingthe adiustment.
forks. alnstallthe removedDarts.
*lf you feel looseness on the forks, the sGeringis too
loose.

NOTE
oThe cablesand wiring will have sme effet on dre
motion of the fork which mustbe taken into aeount.
Be gtte the wit6 and ables are prcperly routed.
ome bearing' must be in good condition and properly
lubricatedin order for any test to be valid.

*Ad.iustthe steeringif necessary. SteeringStem

.Removethe followingparts.
FuelTank
Fork LowerClampBolts(bothsides) Removal
StemHeadBolt (Loosen) .Removethe following.
.Adjust the steeringwith the stemnut wrench(special FuelTank
tool). FrontCaliper
FrontWheel
Front Fender
Front Fork Legs
aRemovethe clamp, free the brake hose from the
left sideof the stem base,and move the front brake
assembly asa setto the rear.

A. StemHeadBolt
B. StemNut Wrench:57001-1
100

*lf the steering is too tight, loosen the stem locknut a

fraction of a turn.
*lf the steeringis loose,tighten the locknut a fraction of
a turn- A. Clamp B. BrakeHose
 STEERING1}5
.Remove the headlight lower bolts from the bottom of
the stem base.

A. Locknuts B. Cap

aRemovethe upper taperedroller bearinginner race-

.To removethe ouler racespressed into the headpipe,
A. HeadlightLowerBolts B. StemBase installthe stembearingremover(specialtool) asshown
below, and hammerthe stembearing remover to drive
it out.

.Remove the stem head bolt and flat washer.

.Pull up the steeringstem head with the handlebarand NOTE
headlightunit. otf either steeringstembearingis damaged,it is rudrl'
mended that both the upper and lower baings (in'
cluding ouw lE,ces) st ould be replacedwith new on6'

A. StemHeadBolt C. Handlebar
B. washer D. Headlight
Unit

57001-1107
Remover:
1. StemBearing

rPushup on the stembase,andremovethe steeringstem

locknutswith the stemcap usingthe stemnut wrench .TaD the bottom of the lowerinnerracewith a chisel.
(specialtool), thcn removethe sieeringstemand stem oPry the innerraceout of the stemwith a suitablemetal
base(singleunit). lever.
136 STEERING

1 . Grease
Seal 3. TapHear l. StemBearing
Driver:57001-137
2. LowerInnerRace 2. Adapten 57W1-1O74

rThe following four stepsshould be p€rformedafter

st€eringbearinginstallation.This proceduresettlesthe
bearingsin place.
ousingthe stemnut wrench,tightenthe stemlocknut to
lnstallation 39 N-m (4.0 kg-m,29 ft-lb) oftorque. (To tightenthe
.lnstallation is reverse
of removal. Note the following. st€eringstem locknutto the sp€cifiedtorque,hook the
oApply greaseto the outer rac€s,and then drivethem wrenchon the stemlocknut,and pull the wrenchat the
into the headpipeusingthe driversandthe driverpress holeby 22.2 kg forcein the directionshown.)
shaft(specialtools).

'I
80 mm

Kg

1. StemNut Wrench:57001-1100 3 . 2 2 . 2 k s
2. 180mm

c€heckthat there is no play andthe steeringstemturns

smoothlywithout rattling.
*lf not, the steeringstembearingmaybe damaged.
l. Driver
PressShaft:57001-1075 oAgainback out the stem locknut a fraction of a turn
2. Drtuer:57001-1
106 until it turnslightly.
3. Driver:57001-1076 oTurn the stem locknut lightly clockwiseuntil it iust
becomeshard to turn. Do not overtighten,or the
steeringwlll be too tight.
oCheckandadjustthe followingafter instaltation.
SteerlngAdiustment
ClutchHose
oApply.gfeaseto tle lower taperedroller bearing,and Throtile Cables
drive it onto the steeringstemusingthe stembearing ChokeCable
driverandadaprcr(special tools). Front Brake
 STEERING1&7

SteeringStem Bearing

Bearing Lubrication
.Perform the following.
oRemovethe steeringstem.
ousing a high flash-pointsolvent,washthe upper and
lowertaperedroller bearingsin thecages.
owipe the upper and lower outer races,which are
press-fittedinto the frame headpipe,cleanoff grease
anddirt.
oVisuallycheckthe outerracesandthe roll€rs.
*Replace the bearingass€mblies if they show wear or
damage.
oPackthe upperand lowertaperedrollerbearings in the
cageswith grease,and apply light coat of greaseto
the upperand lowerouterraces.
olnstallthe steeringstem,andadjustthe steering.

BearingWear,Damage
*Replacethe bearingassemblies
lf theyshowdamage.

Stem Cap Deterioration. Damage

tReplace the greas€sealif necessary.

Steering Stem Warp

*lf the steering
stemshaftis bent,replace
thesteering
stem.
 FRAME 1'&1

Frame
Tableof Gontents

ExplodedVia^l 1+2
Right Down Tube 1+5
Removal(To AccessRight EngineCoverl. . 1+5
RearFender 1+5
RearFender RearSectionRemoval. 1+5
RearFenderFront SectionRemonal. 146
Footpeg, 1+6
Right Footpeg Removal AA
Right Footpeg Installation 1+7
1+2 FRAME

Exploded Viar

f&
(? \^
\se
€)

T1 ; 24 N-m(24 kgn, 175 ft-lbl

T2; 44 N<n {45 ksrn, 3i} ft-lbl
G : Apply grcase.

.,^@
os-
t
<,-@

@@,AW
*K*-o, N
rffi

1. F ame Top Tube Coyer LH 1 1 .Rear Footpeg LH

2. Frame Top Tub€ Cover RH 12. Footp€g Bracket
3, Fud Filter Bracket 13. Footpeg Blacket
4. Frame 14. Rear Footpeg RH
5. EngineMounting Brackgt 15, Baak Frame
6. Right Dol/vn Tube
7. Front Footpeg LH
8, Footpeg Bracket
9, Footpeg Bracket
10, Front Footpeg RH
 FRAME 14€

___9_ @q
-/
,,t',

1. Front F€ndsr
2.
3.
4.
5.
Rider's Sest
Pa$enger's S€at
Rear Fender Front Section
Rear Fender Rear Section
L- 1.1
6. Seat
7. Rear Fender

vN1500-8

/Eurqeanudrel

ffi\
(

EuropeanModel
T'I4 FRAME
1. Battery Band
2. Battery C.se
I
s*
3. Elestric PartsBr*ket
4, Fuel PumpBrsdct
5, lgnit€r &ad(et
6. lgnruon CoiaBFckst
7. liide Stand
8. SideStandSwitch

G : Apply grease.

Fr
\l
 FRAME 1/L5

Right Down Tube

Remoml(To AccessBight EngineCover)

.Removetle muffler (seeEngineTop End6hapter).
.Place suitablestand undertlte crankcaseto support the
engine.

A. EngineMountingBolts C. DownTubeBola
B. BracketBolts

.Take tlle right down tube out of the frametowatd the

rear

A. Stand

aRemovethe radiatorcor€r.
oUnscrewthe radiatorlowermountingbolts.

A. DownTube

A. Radiator B. LowerMountingBolts

RearFender
.Remove the coolant reservoirtank cov€r(seeCooling
Systemchapter),and take the tank out of the bracket.
aRemovethe fuel tank and RHframetop tube cover. Rear Fender Rear Section Remotnl
.Disconnectthe rearbrakelightswitchwireconnectors. .Disconnectthe rear turn signaland tail li8ht wire
.Unbolt the following, connectors.
14.6 FRAME

A. Turn SignalLight Connectors Sat mountingBols (VNt 50GA)

A. hsgengpr
B. Tail LightConnectors

oRemovetie rear fender rear sectionbolts.

rRemoveboth of the backframebolts.

RearFenderFront SectionRemoml
aRemovethe rearfender rearsection.
rRemovethe rearfenderfront sectionbolts and put it
down.

A. RearFenderRearSection C. BackFrame8o16
B. FenderBolt

aTake tle rear fender r€ar section witi the passenger

seat and the back frame out of tl|e ftame, and then
separatethem if necesory.
oRemovetl|e rear backframe bolts anddis€onnect the A. RearFenderFront Section B. Bolls
turn signalwire connectors.

Footpeg

Bigtht Footpeg Removal

.Remo\€ the RH exhaustpipe.
oRemovethe exhaustpipeholders.
oloosenthe exhaustpipeclampscrew.
oPullthe exhaustpipeout of the muffler.
.Removethe brakepedallink clampbolt.
A. BackFrameBolt .Remov€the footpegmountingbolB,
 FRAME 1+7

A. BrakePedalLink ClampBolt A. Alignthe punchmarks.

B. FootpegMountingBolt
C. FootpegAssembly.

.Pull out the footpegassembly

towardthe right.

Right Footpeg lnstallation

.Note the following.
oWheninstallingthe footpeg assembly,align the link
punchmarkwith the shaftpunchmark.

A. Align the punchmarks.

olf the footpeg assemblyis disassembled,align the inside

link punch mark with the shaft punch mark.
1$38 ELECTRICALSYSTEM
*lf the relaydoesnot work asspecified,
thenreplacethe
junctionbox. Diode Circuit lnspection
.R€movethejunctionbox from the motorcycle.
.Pull off the connectors
from the junctionbox.
Relay Girouit Inspeaion {with the battery disconn€cd} .Check conductivityof the following pair of terminals.

METERCONNECTIONMETERREADINC(9) Terminals
for DiodeCircuit Inspection
FAN r*11-12, i13-8, +13-9. 12-14,.t5-14,16_14
RELAY
* US/QnadaModelOnly
*'* VN150GA9-
HEADLICHT *7-8 @

RETAY *7 -13
STARTER 11-13
RELAY
*The resistance
shouldbe low in onedirectionandmore
12-13
than ten timesas much in the other direction. lf any
*,'.vN150GA9- diodeshowslow or highin both directions,the diodeis
defectiveandthe diodeassemblymustbe replaced.
RelayCircsit In$sction (with the batteryconn€6ed)
NOTE
BATTERY METER
METER oThe &tual meter ,@ding varia with dte meter ud
CONNECTION READINC
CONNECTION
+ (0) - and the individual diode, but. gercn y q@kiry, the
FAN 2-4 0 loy,Er tding *ould be from zero to one half d\e
*ale.

HTADIICH'I .7 -8 9-13 0
STARTER 1 1- ' 1 3 11-12 0
* US/ CANADAMODELONLY
,,r,vN1sflrAg-

Junction Box Intsrnal Circuit

vNl 5O0-Al-A8/Bl -86 {US AND CANADA}

"!
f--l'r
ii"ii
-l-h8i i
Idttt
-+l!l
@ o o
tt-'' i
.----t
:
6 6 --- for Us/Canadian
modcle

VN15OO-A9- (US AND CANADAI

o
VN15OO-A2-Aa / 82-86 Wiring Diag.am (Orher than US and Canadal

o @ 0

l l

RightTu.nSi9tulhdharor

Ugln12V 3W
L.t TumSig..l lhdic.tor

12v 6ry55W

O'tr Lionr

rH{rwe
F,6r ii4tr torn Siodl
ridr 12v 2r w adTls",Y+q>BvY
\v,/+J-c +CFcy-

Lianit2 v 2r w fd-l-"*r"*-"*r"
\-4_F6-+{}-c-

fiA
NX $$f
4hs
t{
94
E

\9./
rA
[8{
I
1 2 V2 . 5a x 2
-k
I Sr.rt . Loctoor Switd oil

LCFT HANDLEBAR S{VIICH OOI{NECTIOI{S

Tum Sicn€l Swiid Dimm.r Swildl SterE Lo.*our Switrh
Color o GY Color R/BK 8L/Y Color BK/Y 8K BK/R
HI Ralaeed
N
R LO Pull.d in
 ELECTRICAL SYSTEM 15.39

BL

VN150GA only
AK n-l 12V5W

8K
J+s fl BL
fifiil
YTY BR

rA:
CH

G
GY
I\cYI LB
LG
o

RTGHT HA!{OLEaAR SffUYCH COt{ltECTtOl{S

Enqine Stop Switch Headliqht Switch Starter Buiton
Color Color R/8L BL SKTY Color BK
OFF

RUN ON
(98051.1069A,1092A)
 15.4O ELECTRICAL SYSTEM

VN15OO-A9- Wiring Diagram (US and Canada)

1. Froar Srake Liohr Swnch

t l

:::""
t l

;#"-T---rr /A
{oto}
tY ffif.H -{. iii::-
d
t l

VD
!+
I I
L\fffrHffi i.i Eq:;*6

35
i FsEii;

Aight Tu6 Sighar Indi.aror

Indicdor Ughi 12 V 3w

Lelr Turn Sign.l Indic.tor

1 2v 6 0 / 5 5 w
@lr

gr.
*DE
/'-]:5--!
r2 v 23law
( E J l lGY" ->G
DE
\:=.}

/>fi sL +E- Br
(9JJHffi"s
a3

0! t=
4U 1 r
t l
EX E]6:.
;oi

r---{on
t -
I
OH
,-:\\
g/
t l
nn
?2 5 3 6 d .
A"
a
l f
l.
T!'J"..o (1, o
1. Srarter bctout Srir.h [:;*" E
F
-;--
 7, Headlight F.l.y Fus. 10 A
8. Acc.sery F!e. 1O A

5, Tlh SignalR.l.v Fus. IOA

"';i
xi:

: e E , e sE . E :E clCd

r--rt l3 \ I
-e*,"-EK-B*,y+l -]-l\€-l !i r.tzvaatw"z
/arak.uehB
-Bun-fr- B!ll-J+! ^
-n€(FRtlfftu\l
t--nt3
-----T..-.v /l
I
B(/Yil (-)
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 APPENDIX1S1

Appendix
Tableof Contents

Additional Considerations for Racing 16-2

Carburstor 16-2
SparkPlug 16-2
SparkPlugInspection 16-2
T r o u b l e s h o o tG
i nugi d e . . ....... 16"4
General Lubrication.... 16€
Lubrication
Nut, Bolt, and FastenerTightness 168
TightnessInspection 16€
Unit Conversion Table . . .. 1&9

16
162 APPENDIX
Additional Considerationsfor Racing
This motorcyclehasbeenmanufacturedfor usein a
reasonableand prudentmannerand as a vehicleonly.
However,somemay wish to subiectthis motorcycleto
abnormaloperation,suchaswould be experienced under
racingconditions. KAWASAKI STRONGLY RECOM-
MENDSTHAT ALL RIDERS RIDE SAFELY AND
OBEY ALL LAWSAND REGULATIONS CONCERN-
ING THEIR MOTORCYCLE AND ITS OPERATION.
Racingshould.bedone undersupervised conditions,
and recognizedsanctioningbodiesshouldbe contacted
for further details. For thosewho desireto participate
in competitiveracing or related use, tl|e following
technical information may prove useful. However,
pleasenoG the followingimportantpoints.
aYou are entirelyresponsible for the useof your motor-
cycle under abnormalconditionssuch as racing,and
Kawasakishall not be liable for any damageswhich
mightaris€from suchuse.
.Kawasaki'sLimited MotorcycleWarrantyand Limited
EmissionControl SystsmsWarranty specificallyex-
clude motorcycleswhich are used in comDetitiveor
related uses. Pleaseread the warranty carefully.
.Motorcycleracingis a \€ry sophisticated spori,subiect
to many yariables. The following information is
theoretioalonly, and Kawasakishall not be liablefor
any damages which might arisefrom alterationsutili-
zingthis information.
.When tie motorcycleis operatrdon public roads,it
m|lst be in is originalstate in 'ord€r to ensuresafety
andcomplianc€ with applicableregulations.
Whena plugof the correctheat rangeis beingused,
the electrodeswill stay hot enoughto kedp all the
carbon burned off, but mol enough to keep from
damagingthe engine and the plug itself. This tem-
peratureis about400 - 800"C(750- 1,450"F)and can
be judged by noting the condition and color of the
ceramicinsulatoraround the centerelectrode. lf the
ceramicis cleanand of a light brown color, the plug is
operatingat the right temperature.
A spark plug for higher operatingtemperaturesis
used for racing. Sdch a plug is designedfor better
coolingefficiencyso that it will not overheatand thus
is often calleda "colder" plug. lf a sparkplug witlr
too higha heatrangeis used- that is,a "cold" plugthat
cools itself too well - the plug will stay too cool to
burn off the carbon,and the carbonwill correcton the
electrodesandthe ceramicinsulator.
The carbonon the electrodesconductselectrici.ty,
and can short the centerelectrodeto groundby either
coatingthe ceramicinsulatoror bridgingacrossthe gap.
Such a short will preventan effectivespark. Carbon
buildupon the plugcanalsocauseotler troubles. lt can
heat up redhot and causepreignitionand knocking,
which may eventuallyburn a hole in the top of the
piston.
SparkPlug

Carbureton
Sometimesan alGration may be desirablefor im-
proved performanceunder special conditions when
proper mixture is not obtainedafter the carburetorhas
beenproperlyadiusted,and all partscleanedandfound
to befunctioningproperly.
lf the enginestill exhibits symptomsof overly lean
carburetionafter all maintenance and adjustmentsare
correctlyperformed,tie mainiet canbe replacedwith a
smalleror largerone. A smallernumberedjet givesa
leanermixture and a largernumberediet a richermix-
ture.

Spark Plug:
The spark plug ignitesthe fuefair mixture in the
combustioncharnber.To do this effectivelyand at the
propertime, the correctspark plug must be us€d,and I . Terminal 4. Gasket
the sparkplugmustbe kept cleanandadiusted. 2. lnsulator 5. CenterElectrode
Test haveshown the plug list€d in tlre "Electrical 3. cement 6. SideElectrode
System"chapterto bethe bestplugfor generaluse.
Sincesparkplug requirements changewith the igni-
tion and carburetionadjustments and with ridingcondi-
tions, whetheror not a sparkplug of a correct heat range SparkPlug lnspection
is usedshouldbe determinedby removingand inspect- .Removethe sparkplugand inspecttl|e ceramicinsu-
ing the plug. lator.
 APPENDIX1G3
Spa* Plug Condition

Carbon Fouling Oil Fouling Normal Operation Overheating

*Whetheror not the right temperatureplugis beingused Standad Spark Plug Thread:
can be ascertainedby noting t$e condition of the Diameter: 12 mm
ceramicinsulatoraroundthe electrode.A light brown Pitch: 125 mm
color indicatesthe correctplug is being used. lf the
Readr: 19.0 mm
ceramicis white, the plug is operatingat too high a
temperatureand it shouldbe replacedwith the next
coldertype. NOTE
oThe heat nngc of the spark plug fu,Etions like a
thermo*at for the engine. Using the wrotry type of
qark plug en make the enginerun too hot (reiting
olf the spark plug ir replaced with a tyFe odror dran the in enginedamage)or too cold (with poor performance,
standard plug, mako certain the replacemem plug has misfhing,and sta ing).
t're sams drread pitch and readr (length of threaded
portion) and the same insulator type (regulal typs 01
proiected typel as the standard plug.
olf $e plug reach b too short, ca.bon will build up on
the plug hole threads in the .rylinder heed, cau:ing over-
heating and making it very dilfidrlt to insert the
coJrect spark plug later.
olf the reach b too long, carbon will build up on the ex-
pos6d spark plug thrcad: caBing ovedreating.
preignition, and po$ibly buming a hols in the p&ton
top. In addition, it may be impossibleto lemoye the
plug without damaging the cvlinder head.

Plug Reach

Too short Correctreach

Carbon
buildsup here
164 APPENDIX
Cylinder,pistonworn
TroubleshootingGuide Pistonringbad{worn,weakbroken,or sticking}
Pistonringlgrooveclearanceexcessive
Cylinderheadgasketdamaged
NOTE
Cylinderheadwarped
oThis is not an exhaustive list, giving every posible Valvespringbrokenor weak
cau*s€for e*h problem li&ed. lt is ment simply as a Valve not seatingproperly (valvebent, worn, or
rough guide tu. assisrthe trcubleshootingfor sme of carbonaccumulation on the seatingsurface)
the morecommondiff icutti*. Hydrauliclashadjust€rdamaged(worn,seizure,or
springbroken)
Engine Doesn't Start, Starting Difficultyl Hydrauliclashadjusteroil p4ssage
clogged
Startelmotor not rotating;
Starterlockoutor neutralswitchtrouble
Startermotortrouble
Batteryvoltagelow
Relaysnot contactingor operating
Starterbutton not contacting
Wiringopenor shorted
lgnitionswitchtrouble
Enginestopswitchtrouble
Fuseblown
Startermotor lotating but enginedoesnt tum oysr:
startermotor clutchtrouble
EnginarYon'ttum ov€r:
Valveseizure
Rockerarm seizure
Cylinder,pistonseizure
Crankshaft seizure Poor Runningor at Low Speed:
Connecting rod smallendseizure Spsrkwe8k:
Connecting rod big endseizure Batteryvoltagelow
Transmission gearor bearingseizure Sparkplugdirty, broken,or matadiusted
Camshaftseizure Sparkplugcapor hightensionwiringtrouble
Balancer bearingseizure SparkPlugcapshortedor not in goodcontact
No tuel flow: Sp k plugincorrect
Fueltank air ventobs$ucted lC ignitertrouble
Fuelpumptrouble Pickupcoil trouble
Fueltap clogged lgnitioncoil trouble
Fuellineclogged Fuel/airmlxl re incorect:
Floatvalveclogged Pilotscrewmaladiusted
Engineflooded! , Pilot jet, or air passage
clogged .
Fuellevelin carburetorfloat bowl too high Needlejet (air bleedpipe),bleedholesclogged
Floatvalveworn or stuckoDen Pilot passage clogged
Startingtechniquefaulty Air cleanerclogged,poorly sealed,or missing
(Whenflooded,crank the enginewith the throttle Stzrt€rplungerstuckopen
fully open to allow more air to reach the Fuel levelin carburetorfloat bowl too highor too
engine.) low
No 3park;sparkweak: Fueltank air ventobstructed
Batteryvoltagelow Carburetorholderloose
Sparkplugdirty, broken,or maladjusted Air cleaneror surgetank duct loose
Sparkplugcapor hightensionwiringtrouble Fuelpumptrouble
Sparkplugcapnot in goodcontact Backfiringwhen deceleration:
Sparkplugincorrect Vacuumswitchvalvebroken
lC ignitertrouble Air suctionvalvetrouble
Neutral, starter lockout, or side stand switch Other:
trouble lC ignit€rtrouble
Pickupcoil trouble Carburetors not synchronizin!
lgnitioncoil trouble Carburetorvacuumpistondoesn'tslidesmoothly
lgnitionor enginestopswitchshorted Engineoil viscositytoo high
Wiringshortedor open Drivetrain tiouble
Fuseblown Finalgearcaseoil viscositytoo high
Compreasion Lowr Brakedragging
Sparkplugloose Air suctionvalvetrouble
Cylinderheadnot sufficientlytight€neddown Vacuumswitchvalvetrouble
 APPENDIX1G5
Poor Runningor No Powerat High Speed: Engineloadfaultyi
Firingincorresti Clutchslipping
Sparkplugdirty, broken,or maladiusted Engineoil leveltoo high
Sparkplugcapshortedor not in goodcontact Engineoil viscositytoo high
Sparkplugincorrect Drivetrain trouble
lC ignitertrouble Finalgearcaseoil viscositytoo high
PickuDcoil trouble Brakedragging
lgnitioncoil trouble Lubricationinadequate:
Fuel/airmixtureincorrcct: Engineoil leveltoo low
Starterplungerstuckopen Engineoil poor qualityor incorrect
Mainjet cloggedor wrongsize Gaugeincorred:
Jet needleor needleiet worn Watertemperature gaugebroken
Air.iet clogged Watertemperaturesensorbroken
Fuel lewl in carburetorfloat bowl too highor too Coolantincorrecl:
Coolantleveltoo low
Bleedholesof air bleedpipeor needleiet clogged Coolantdeteriorated
Air cleanerclogged,poorlysaled, or missing Coolingsystemcomponentincorlect:
Air cleaneror surgetankduct poorly sealed Radiatorclogged
Waterof foreign matter in fue, Thermostattrouble
Fueltap clogged Radiatorcaptrouble
Fuellineclogged Thermostatic fan switchtrouble
Fuelpumptrouble Fanrelaytrouble
Knod(ingr Fanmotor broken
Carbonbuilt up in combustionchamber Fanbladedamaged
Fuelpoorqualityor incorrect waterpumpnot turning
Sparkplugincorrect Waterpumpimpellerdamaged
lC ignitertrouble
Backfiring whendeceleration:
Vacuumswitchvalvebroken
Air suctionvalvetrouble
MLcellaneo$:
Throttlevalvewon't fully open
Carburetorvacuumpistondon't slidesmoothly Over Cooling:
Brakedragging Gaugeincorrect:
Clutchslipping Watertemperature gaugebroken
Overheating Watertemperature rnsor broken
Engineoil leveltoo high Coolingsystemaomponentincorrect!
Engineoil viscositytoo high Thermostatic fan switchtouble
Drivetraintrouble Thermostattrouble
Finalgearcaseoil viscositytoo high
Air suctionyalvetrouble
Vacuumswitchvalvetrouble
Balancer mechanism malfunctioning

Clutch Operation Faulty :

Clutchslipping:
Frictionplatewornor warped
SGelplateworn or warped
Overheating: Clutchspringbrokenor weak
Firingincorrect: Clutchslavecylindertrouble
Sparkplug,broken,or maladjusted CIurchhub or housingunevenlyworn
Sparkpluginconect Clutdr not dbengsgingpropsrly:
lC ignitertrouble Clutchplatewarpedor too rough
Fuel/air mlxtrrc incorrect; Engineoil deteriorated
Mainjet cloggedor wrongsize Engineoil viscositytoo high
Fuellevelin carburetorfloat bowl too low Engineoil leveltoo high
Carburetorholderloose Clutchhousingfrozenon dliveshaft
Air cleanerpoorly sealed,or missing Clutchslavecylindertrouble
Air cleaneror surgetankduct poorly sealed Clutchhub locknutloose
Air cleanerduct loose Air in the clutchfluid line
16.6 APPENDIX
Clutchfluid leak Primarygearworn or chipped
Clutchfluid deteriorated Camshaftchaint€nsionertrouble
Primaryor secondary cup damaged Camshaftchain,sprocket,guideworn
MasGrcylinderscratched inside Air suctionvalvedamaged
Vacuumswitchrralvedamaged
Balancer gearwornor chipped
Gear Shifting Faulty: Balancer shaftpositionmaladiusted
Dosnt go into gear;rhaft pedaldo€6nt lsturn: Balancer bearingworn
Clutchnot disengaging Waterpumpchain,sprocketworn
Shift fork bent or seized
c'earstuck on the sltaft Abnormal Drive Train Noise :
Gearpositioningleverbinding Glut*r noire:
Shift returnspringweakor broken Weakor damagedrubberdamper
Shift returnspringbolt loose Clutchhousingfrictionplateclearance
excessive
Shift mechanism arm springbroken Clutchhousinggearworn
Shift mechanism arm broken Tnnarni$ion noise:
Shift pawlbroken Bearings worn
JumF out of g€ar: Transmissiongearsworn or chipped
Shift fork worn Metalchipsiammedin gearGeth
Geargroor€ worn Engineoil insufficient
Geardogsand/or dog holesworn Drivelinenoice:
Shift drumgrooraworn Bevelgearbearingsworn
Gearpositioningleverspringweakor broken Bevelgearsworn or chipped
Shift fork pin worn Bevelgearsmaladiusted
Driveshaft, output shaft, and/or gearsplinesworn Rearwheelcouplingdamaged
Ovenhifts: lnsufficientlubricant
Gearpositioningle\€r springweakor broken
Shift mechanism arm springbroken Abnormal Frame Noise:
Front fork noise:
Oil insufficientor too thin
Abnormal Engine Noise: Springweakor broken
Knoddng: Rsarshockab6orbsrnoiao:
lC ignitertrouble Shockabsorberdamaged
Carbonbuilt up in combustionchamber Dilc brakenobe:
Fuelpoorqualityor inconect Padinstalledincorrectly
Sparkplugincorrect Padsurfaceglazed
Overheating Discwarped
Pbtondap: Calipertrouble
Cylinder/piston clearanceexcessive Othe?nobe:
Cylinder,pistonworn Bracket,nut, bolt, etc. not properlymountedor
Connecting rod bent tight€ned
Pistonpin, pistonholesworn
Valvenoise: Oil Pressure
WarningLight Go€sOn:
Engine not sufficiently warmed up after lash Engineoil pumpdamaged
adius&rinstallation Engineoil screenclogged
Hydrauliclashadjusterdamaged (worn,seizure,or Engineoil filter clogged
springbroken) Engineoil le\€l too low
Air in hydrauliclastradiuster Engineoil viscositytoo low
Metal chips or dust jammed in hydraulic lash Camshaftbearings worn
adiuster Crankshaftbearings worn
Engineoperatedin red zone Oil presureswitchdamaged
Valvespringbrokenor weak Wiringdamaged
Camshaftbearingworn Reliefvalvestuckopen
Odrernoise: O{ing at t}te oil pipein tl|e cnnkcasedamaged
Connecting rod smallendclearance
excessive
Connecting rod bigendclearance
excessive
Pistonringworn,brokenor stuck ExhaustSmokesExcessively
:
Pistonseizure,damage Uvhitesmoke;
Cylinderheadgasketleaking Pistonoil ring worn
Exhaustpipeleakingat cylinderheadconnection Cylinderworn
Crankshaft runoutexcessive Valveoil sealdamaged
Enginemountsloose Valveguidewom
Crankshaft bearingworn Engineoil lev€ltoo high
 APPENDIX1G7
Blacksmoke: lgnitionswitchtrouble
Air cleanerclogged Alternatortrouble
Mainjet too largeor fallenoff Wiringfaulty
Starterplungerstuckopen
Fuellevelin carburetorfloat bowl too high
Brown3moks: Battery Overcharged:
Mainje! too small Alternatortrouble
Fuellevelin carburetorfloat bowl too low Regulatorrectifier trouble
Air cleaneror surgetank duct loose
Air cleanerpoorlysealedor missing

Handlingand/or Stability Unsatisfactory:

Handlebar hardto tr]n:
Steerintst€mlocknuttoo tight
Bearing damaged
Steering bearinglubricationinadequate
Steering stembent
Tireair pressure too low
Handlebarshak6 ol excelEiyelyriblates;
Tireworn.
Swingarrdpivot bearingworn
Rimwarped,or not balanced
lVheelbearingworn
Handlebar clamploose
Steering stemheadnut loos€
Hrndleb€rpulls to ons ride:
Framebent
lvhe€lmisalignment
Swingarmbentor twisted
Steering maladiusted
Frontfork bent
Right/leftfork legsunbalanced (oil level)
Shod(aborption unrati3factory:
(Toohard)
Frontfork oil excessive
Frontfork oil viscositytoo high
Tireair pressuretoo high
Frontfork bent
(Too soft)
Frontfork oil insufficientand/orleaking
Frontfork oil viscositytoo low
Frontfork, rearshockabsorberspringweak
Rearshockabsorberoil leaking

BrakeDoesntHold:
Air in the brakeline
Pador discworn
Brakefluid leak
Discwaroed
Contamina@d pad
Brakefl uid deteriorated
Primaryor secondary cup damaged
Mastercylinderscratched inside

BatteryDischarged:
Battery faulty (eg., plates sulphated,shorted
through sedimentation,electrolyte level too
low)
Batteryleadsmakingpoor contact
Loadexcessive (eg.,bulb of excessiwwattage)
1G8 APPENDIX
Also,checkto seethat eachcotterpin is in placeandin
GeneralLubrication goodcondition.

NOTE
Lubrication
oFor the engine fasteners.check the tightnes of them
.Before lubricatingeachpart, cleanoff any rusty spots
whenthe engineis cold (at room tempercture).
with rust removerand wipe off any grease,oil, dirt,
or grime. *lf there are loose fasteners,retorque them to the
.Lubricate the points listed below witi indicated
specified torque following the specifiedtightening
lubricant-
sequence.Refer'tothe appropriatechapterfor torque
specifications.lf torque specifications
are not in the
NOTE
appropriatechapter, see the basictorque table (see
owhenever the vehicle h6 been opented wd or Torqueand Lirking Agent in the GeneralInformation
rainy conditions, or 8peially after using a high- chapter).
presunespny n6ter. perform the genenl lubiation. For each fastener,'first loos€nit by l/a turn, then
tightenit.
*lf cott€r pins are damaged,replacethem with new
PiYots: Lubricatswittt Motor Oil.
ones.
SideStand
ClutchLever
BrakeLever Nut, Bolt,and Fas@nerto be dlecked
BrakePedal Wheels:
RearBrakeRod Joint Front Axle Nut
Front Axle ClampBolts
Point: Lubricatewith Grease. RearAxle Nut
Throttle lnnerCablesLowerEnd RearAxle Nut Crtter Pin
Speedometer InnerCablet Brakes:
+Greasethe lowerpart of the inn€roablesparingly. Front MasterCylinderClampBolts
FrontC.aliperMountingBolts
Cabl$; Lubricatewith ilotor Oil. RearMasterCylinderMountingBolts
ChokeCable RearCaliperHolderMountingBolts
ThrottleCables RearCaliperMountingBolts
BrakeLeverPivotNut
CableLubrication BrakePedalBolt
BrakeRodJoint Cotter Pin
Susoension:
Front ForkClamDBolts
Front FenderMountingBolts
RearShockAbsorberMountingBolt andNuts
SwingArm PivotShaftNuts
Steering:
StemHeadNut
Handlebar ClampBolts
HandleGrio Bar Bolts
Engine:
EngineMountingBolts
RockerCaseNuts
€ylinderHeadNuts
ExhaustPipeMountingNuts
MufflerMountingBolts
ExhaustPipeand MufflerConnecting
ClampBolts
1 . Cable ClutchMasterCylinderClampBolts
2 . Pressure
€ableLuber: K55019{21 ClutchLeverPivotNut
RadiatorMountbg Bolts
shift PedalBolt
Others:
SideStandNut
RearFrameMountingBolts
Nut, Bolt, and FasenerTightness RightDownTubeMountingBolts
BackFrameMountingBolts
FootpegBracketMountingBolts
Tightnesslnspection FinalGearCaseMountingNuts
theck the tightness
of the boltsandnutslistedhere.
 APPENDIX1G9
Unitsof Length:
Table
Unit Conversion
k m x 0.6214 mile
m x 3.281 = ft
Prefixesfor Units: mm x 0.03937 = in
Prefix Symbol Power
mega M x 1,000,000
kilo k x 1,0O0
Units of Torque:
centi c x 0.01
milli m x 0.001 N-m x 0.1020 kgm
micro tt x 0.000001 N-m x o.7376 ft-lb
N-m X 8.85r in-lb
Kg-m X 9.807 = N-m
ksm x 7.233 = ft-lb
Unitsof Mass: ksm x 86.80 = in-lb
k g x 2.205 tb
g x 0.03527= oz
Units of Pr6sure:
kPa x 0.01020= kg/cm'
Unitsof Volume: kPa x 0.1450 = psi
L x o.2642 sal(us) kPa x 0.7501 = cm Hg
L x o.2200 gal (imp) kg/cm2 x 98.07 kPa
L x 1.057 qt (us) kg/cm' x 14.22 psi
L X 0.8799 qt (imp) cm Hg x 1.333 kPa
I x 2.113 pint (US)
L x 1.816 pint (imp)
mL x 0.03381 = oz(us)
ML x 0.02816= oz (imp) Units of Speed:
mL x 0.06102= cu in km/h x o.6214 mph

Unitsof Force: Unitsof Power:

N x 0.1020 - k g k W x 1.360 PS
N x o.2248 = t b k W x 1.341 HP
kg x 9.807 = N PS x 0.735s = k w
kg x 2.205 = t b PS x 0.9863 = H P

Units of Temperature:

9 fcj40) _40_.F s ('Fj 40)_ 40_ .c

.F
r 32 5a 104
40 ,20 20 lao 60 | 80 tool 12o l4o 160 llso 2oo i22o 24oi 260 2aoi 3oo 32o

-40 o i r2o ir4o

'c 4A
 MODELAPPLICATION
Year Model Beginning
FrameNo.
1987 vN1500-41 JKBVNMIt]HAOOOO2l
vN1500-81 JKBVNAB1trHA00001
1,or
JKBVNABl
!H85OOOO1
1988 vN1500-42 JKBVNMlnJA001001,or
wN50A-001001
vN1500-82 JKBVNAB'1
DJAOOOSOl,or
JKBVNAB,l
!J85OO6O1,Or
wN50A-003001
1989 vN1500-43 JKBVNM1trKA003001,or
wN50A-003001
vN1500-83 JKBVNAB1nKA002001,or
wN50B-002001
1990 vN1500-A3 JKBVNAAItrLAOO3OO'I,or
wN50A-004001
vN1500-83 JKBVNABINLBsOI40l,or
wN508-003001
1991 vN1500-A5 JKBVNAA1trMA006001,or
vTN50A-006001
vN'1500-85 wNs0B-00s001
1992 vN1500-45 JKBVNAAI
NNAOOgOOI,or
wN50A-009001
vN1500-86 wN50B-009001
'1993 vN1500-A7
JKBVNAA'I
trPAO13OO1
1994 vN1500-A8 JKBVNAAlNRAO2OOOl
1995 vN1500-A9 JKBVNAAl NSAO2600l
1996 vN1500-A10 JKBVNMl ITAO4OOO1
1997 vN1500-A11 JKBVNAAlIVAO60OO1
1998 vN1s00-A12 JKBVNMl !WAO7sOO1
1999 vN1500-4t 3 JKBVNAA1trXAO85OO1

}lKawasaki
KAWASAKI HEAVY INDUSTRIES,LTD.
ConrunerPrcductu& rchlneryGroup

Part No. 9992't-1078-08 Printedin JaDan