Kawasaki vN1500

Motorcycle

Service Manual
Downloaded free from http://www.vulcanrider.se/

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,

vN1500

Kawasaki

VNl5OOA:
VULCAN88 (USandCanada)
(Othersl
VN-15
VNlSOOB:
VU LCAN 88 SE (USand Canada)
(Othersl
VN-15SE

Motorcycle

Service Manual
All rightsreserved. No partsof this publicationmay be reproduced,storedin a retrievalsystem,or
transmittedin any form or by any means,electronicmechanicalphotocopying,recordingor otherProducts
wise, without the prior written permissionof Ouality AssuranceDepartment/Consumer
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
ABDC
AC
ATDC
BBDC
BDC
BTDC

"c

DC
F
.F
ft

s
h
L

ampere{s}
after bottom deadcenter
alternatingcurrent
after top deadcenter
before bottom dead center
boftom dead center
before top deadcenter
degree(s)
Celsius
direct current
farad(s)
degree(slFahrenheit
foot, feet
gram{s)
hour(sl
liter(s)

tb
m
min
N
Pa
PS
psi
rpm
TDC
TIR
W
o

pound(sl
meter{s}
minute(s)
naryton(sl
pascal(s)
horseporer
pound(s)persquareinch
rwolution
perminute
revolution(sl
top deadcenter
total indicatorrading
volt{s)
watt(s)
ohm(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 applicableregulations of the United States Environmenal Protection Agency and California Air Re
sourcesBoard. Additionally, Kawasakihas incorporatedan evaporativeemissioncontrol
Board
system {3} in compliancewith applicableregulationsof the CaliforniaAir Resources
sold in Californiaonly.
on vehicles
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 Fedel 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 devices or elementsof design in order to perform maintenance2. 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,OOO
PER 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.eplacemnt
of_the originalexhaustsystemor mrifflerwith a componentnot in compltance

wtth 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.
However, it contains enough detail and basic
information to make it useful to the owner
who desiresto perform his own basic maintenance and repair work. A basic knowledge
of mechanics,the proper use of tools, and
workshop procedures must be understood in
order to carry out maintenanceand repair
satisfactorily, Wheneverthe owner has insufficient experienceor doubts his ability to do
the work, all adjustments,maintenance,and
repair should be carriedout only by qualified
mechanics.
In order to perform the work efficiently and
to avoid costly mistakes,read the text, thoroughly familiarize yourself with the procedures
before starting work, and then do the work
carefully in a clean area. Whenwer special
tools or equipment are specified, do not use
makeshifttools or equipment. Precisionmeasurementscan only be made if the proper instrumentsare used, and the use of substitute
tools may adversely affect safe operation.
For the duration of your warranty period,
especially,we recommendthat all repairsand
scheduledmaintenancebe performedin accordance with this service manual, Any owner
maintenanceor repair procedurenot performed
in accordancewith this manual may void the
warranty.
To get the longest life out of your Motorcycre:
oFollow the PeriodicMaintenance
Chartin the
ServiceManual,
.Be alert for problems and non-scheduled
maintenance.
eUseproper tools and genuineKawasakiMotorcycle parts. Special tools, gauges,and testers
that are necessarywhen servicing Kawasaki
motorcyclesare introducedby the SpecialTool
Manual. Genuinepafts providedasspareparts
are listed in the PansCatalog.
rFollow the procedures in this manual car+
fully. Don't take shortcuts.
rRemember to keep complete recordsof maintenance and repair with dates and any new
pafts installed.

Howto Usethis Manual

ln preparing this manual, we divided the
product into its major systems, Thesesystems
becamethe manual'schapters. All information
for a panicularsystemfrom adiustmentthrough
disassemblyand inspectionis located in a single
chapter,
The Ouick ReferenceGuide showsyou all of
the produst,s systems and assisB in locating
their chapters. Each chapter in turn has its
Table of Gontents.
olvn comprehensive
The PeriodicMaintenanceChan is locatedin
the General Information chapter. The chart
givesa time schedulefor required maintenance
operations,
lf you want spark plug information, for
example,go to the PeriodicMaintenanceChart
first. The chart tells lou hovv frequently to
clean and gap the plug. Next, use the Ouick
ReferenceGuide to locatethe ElectricalSystem
chapter. Then. usethe Tableof Gontentson the
first pageof the chapterto find the Spark Plug
section.
Whenaneryou see these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operatingand maintenance
practices.

oThis waming rymbol identifiesspecialinstructions or procedures which, if not correctly

followed, could result in perconal iniury. or
lossof life.

oThis caution symbol identifies specialinstructions or procedureswhicfi, if not strictly observed,could result in damageto or destruction of equipment.
This manual contains five more symbols (in
addition to WARNING and CAUTION) which
will help you distinguish different types of
information.
NOTE
oThis note symbol indicates pointr of particular interest for more efficient and convenient 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 basdupon the resultsof the
conditionalstepit follows.
ln most chaptersan.explodedviqlv illustration 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
Modelldentification. . . . .
,..
General
Specifications.
Periodicmaintenance
Chart.
Torqueand LockingAgent
Cable.WireandHoseRouting.

1-2
14
1-5
1-7
1
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
Dent
Wear
Bent
Scratch
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
Dimensions:
Overalllength
Overallwidth
Overallheight
Wheelbase
Roadclearance
Seatheight
Dryweight
Curbweight: Front
Rear
Fueltankcapacity
Pertormance:
lrinimumtumingradius
Engine:
Type
Coolingsystem
Boreandstroke
Displacement
ratio
Compression
horsepower
Maximum

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

VN1sOGAI/AZA3/A4IA5IA6IA7I AU A9IA1OI
2 390mm,(A)(F)2 385mm,(E)2 410mm,(l) 2 375mm,
895mm
1 190mm,(AXE)1 180mm
1 605mm
150mm,(AXE)lS5 mm
720mm,(A)(E)750mm
2s2 k9,(Car)2s2.5kg,(E)257k9,(G)256kg

2 370 mm,(E)2 410 mm

126kg,(Cal)128kg
154kg,(Cal)154.skg,(E) 1s7kg,(G) 156kg
1 6L

1 210mm,(E)1 195mm
1 635 mm,(E) 1 630 mm
165mn,(E)160mm
710mm,(E)745mm
248kg,(Cal)248.5kg
(E)24eks
121kg,(Cal)121.5kg
1s4kg,(E) 15skg
1 2L

3.0mm,(AXE)2.7 nrn

3.0m

torque
Maximum

4-stroke,SOHC,2-cylinder
Liquid-cooled
102.0x 90.0mm
1 470mL
9.0:1
53.0kW (72PS)@4500r/min(rpm),(Us)(E)51.5kW(70 PS)@4500r/min(rpm)
norm)
(F)50.0kW(-)@4 500r/min(rpmXUTAC's
(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)
norm)
As-(F) 43.5kW(-) @4300r/min(rpmXUTAC's
123.6N-m(12.6kg-m,91ft-lb)@3000r/min(rpm)

Carburetor
system
Startingsystem
system
lgnition
Timingadvance
lgnitiontiming

(G)123.6N-m(12.6kg-m,91ftlb) @300or/minGpmXDlN)
(W)105.9N-m(10.8kg-m,78.1
tt-lb)@2300r/min(rpm)
itlb) @3300r/min(rpm)
A4-(E)112.8N-m(11.5k9-m,83.2
ftlb)
A4-(G)112.8N-m(11.5kg-m,83.2
@3300r/min(rpmXDlN)
KeihinCVK36x 2
Carburetors,
Eleclricstarter
Batteryandcoil (transistorized)
Electronically
advanced
=-,
5"BTDC@800r/min(rpm)

Sparkplug

(F)-,(us)-

or NDX22EPR-Ug
NGKDPRTEA-g
(AXIXU)NGKDPRTEA-g
or ND X22EPR-U9
or ND )Q2EPR-U9
A11- : (U)NGKDPRTEA-g
numbering
method Frontto Rear,1-2
Cylinder
'l-2
Firingorder
Valvetiming:
22'BrDC
Inlet
Open
66"ABDC
Close
26A"
Duration
66.BBDC
Exhaust
Open
26.ATDC
Close
Duralion
272"
(wetsump)
Forcedlubrication
Lubrication
system
SE,SF,or SGclass
Engineoil: Grade
20W-40,20W-50
sAE 10W-40,10W-50,
Viscosity
Capacity
3.5L

(w) 5"BTDC
(rpm)

1 GENERAL INFORMATION
VNl500"A1IAZA3/AN
ASIAGI
A AAAglA1UA11tA1AA1g vNl 500-81/B2/B3/BtyB5/B6
DriveTrain:
Primaryreduction
system:
Type
Reductionratio
Clutchlype:
Transmission:
Type
Gearratios:1st
znd
3rd
4th
Finaldrivesystem:
Type
Reductionratio
Overalldriveratio
Finalgearcaseoil:
Type
Capacity
Frarne:
Type
Caster(rakeangle)
Trail
Fronttire: Type
Size
Reartire:
Type
Size
Frontsuspension:
Type
Wheeltravel
Rearsuspension:
Type
Wheeltravel
Braketype: Front
Rear

Gear
1.s17(8s/56)
Wetmultidisc
4-speed,constantmesh,returnshift
2.s00(40/16)
1.s90(35/22),41 1-1.375(33t24],
1.192(31/26),
411-1.03s(29/28)
0.965(28/29),Al 1-0.781125/32)
Shalt
x33/9)
2.619(15/21
3.838,411-3.105@Topgear
API GL-sHypoidgearoil
SAE90(above5"C)
SAEso(below5"C)
22OmL
Tubular,doublecradle
31"
'128
mm
Tubeless
100i90-19
57H
Tubeless
15O90-15
74Ho|l5cl/90-15M/C74H

33' , (E)32.5"
138mm,(E)132mm
Tube
Tube
=-or

150/90815
M/C74H

Telescopic
tork
150mm
Swingarm
100mm
Singledisc
Singledisc

ElectricalEquipment:
Battery
12V20Ah
Headlight: Type
Semi-sealed
beam
'12
Butb
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
(Au) : AuslrianModel
(Cal): CalifomiaModel

(E) : EuropeanModol
(F) : FrenchModel
(Fi): FinnishModel

"1 (Au)(W)34.9kW (47.sPS)@3

800/min (rpm)
(E)s1.5kW (70 PS) @5000r/min(rpm)
(G)s1.5kW (70PS) @5@0 r/min(rpmXDlN)
84- (E)45.7kW (-) @5000r/min(rpmXUTAC's
norm)
84- (G)47.1kW (64 PS)@500or/min(rpmXDtN)
84- (D(SdXUK)
47.1kW (64 PS)@5000r/min(rpm)
85- (Fi)47.1kW (64 PS)@500or/min(rpm)
(US)_

(G) : WestGeman Model

(l) : ltalianModel
(Sd): SwedishModel

(U) : U.S.A.Model
(UK): UK Model
(W) : Switzertand
Modet

-2 (AUXW)
105.9N-m(1o.8kg-m,78.1
ttlb)
@2300r/min(Ipm)
(E)127.5Nm(13.0kg-m,g4.O
tr-tb)@300or/min(rpm)
(G)'i27.5Nm(13.0k9.m,94.0
ftlb) @3000 r/min(rpmXDtN)
84- (G)117.7N-m(12.0kg-m,86.8
ftlb) @3300r/min(rpmxDtN)
84- (IXSdXUK)
117.7N-m(12.0kg-m,86.8
ft-lb)
@3300r/min(rpm)
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
Air suctionvalve- checkt
Air cleanerelement- clean t #
Throttlegrip play - checkt

Oil screen - clean

Radiatorhoses,connections- checkt
Coolant - change
Finalgear caseoil level - checkt
Finalgear caseoil - change
Propellershaft joint - lubricate
Clutch slavecylindg piston seal - replace
Brakelining or pad wear - checkt #

Brake/clutch
fluid levet- checkt

a
a

o
o
a

a
a

o
o

a
a

ldlespeed- qdiust
Carburetorsynchronization- checkt
Engineoil - change#
Oil lilter - replace

6 months

a
a

a
a
a

a
o
a

o
a

a
a

a
a
a

a
4 years

Brake/clutch
mastercylindercup anddust
seal- replace

4 years

Caliperpiston seal and dust seal - reprace

Brakelight switch - checkt
Steering - checkl

4 years

Steeringstem bearing- lubricate

Frontfork oil - change

2 yeats

a
a

a
a
a

a
a

a
a

a
a
a
a

a
a
a
a

a
a

2 years

Rearshock absorberoil leak - check T

Frontfo* oil leak - checkt

Tirewear - checkt
Spoketightnessand rim runout - checkt
(vN15008)
Swingarm pivot - lubricate

Brake/clutchfluid - change

Nut, bolt, and fastener tightness - checkt

2 yeas

month
2 yeas

Baftery elgctrolyte tevel - checkl

Generallubrication- oerform

a
a
a

6 month

a
a
a
a

a
a

a
a

a
a

a
a

a
a

a
a
a
a

a
a
a

a
a

: Service more. frequently when operating in severe conditions; dusty, wet, muddy,
,
high speed, or frequent
starting/stopping.
: For higher odometerredings,repeatat the frequencyintervalestablishedhere.
: 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.
TODOMETER
READING

Whichever
FREOUENCY comesfirst
OPERATION

- checki
Garburetors,ynchronization

a
o
a

ldle soeed-- adiusl

Throttle grip play - check 1

Spark plug - cleanand gap t
Air suctionvalve- check J
Air cleanerelement- clean
Air cleanerelement- replace

Fuelsystem- checkt

controlsystem(CA)
Evaporative
emission
- checkt
Batterv electrolvtelevel- checkt
Brakeliqht s\n,itch-. check f
Brakepadwear- check f
Brake/clutchfluid level- checkI
Brake/clutchfluid - chanqe
Steerins- checki
Final qearcaseoil level- checkt
Final gearcaseoil - change
Propellershaftioint - lubricate
Nut, bolt. fastenertightness- check1
Spoketightnessand rim runout - checki
(VN1500-8only)
Iire wear- checkt
Enqineoil - chanqe
Oil filter - replace

a
a
a

hoseandpipe- replace
Brake/clurch
Fuel hose- reolace

a
a

a
a

month

month

a
a
a
a
a
a
a
a

a
a
a
a

a
a

a
a
a
a

a
a

a
a

a
o
o
a

a
a
a
a

a
a
a
a

a
a

a
a

2 vears

a
a
a
a
a

a
a
a

a
O

year

a
a
a
a
a

o
a
a
a
a
a
a
a
a

a
a

a
a

2 yearc
2 years

a
a

year

a
a
a
o
a

Generallubrication- perform
Front fork oil - chanqe
Coolant- change
Radiatorhoses,connections- check1
Steeringstembearing- lubricate
Brake/clutchmastercylinder cup and
dust seal- reolace
Caliperoiston sealand dust seal- replace
Clutch slavecvlinder piston seal- replace

a
a
a
a
a
a

5 cleaninqs

- clean
Oil screen

Swinqarm pivot -- lubricate

a
a

a
a

2 years
2 yearc
2 years
4 years
4 years

here.
r : For higherodometerreadings,repeatat the frequencyintervaleEtablished
necessary.
if
clean,
or
torque
:
Replace,
add,
adjust,
t
(CA):California
vehicle
only

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.

Fascner
CoolingSystem:
CoolingFanSwitch
BleedValve
WaterPumplmpellerBolt
WaterPumpCover
EngineTop End:
RockerCaseCoverBolts
RockerShaft
RockerCaseBoltsandNuts: 12 mm
8mm
6mm
CylinderHeadNuts
CylinderNut
Oil PipeBanjoBolts
Camshaft
SprocketBolts
SparkPlugRetainer
ChainTensioner
Bolts
Clutch:
Clutch LeverPivot Nut
MasterCylinderClampBolts
Clutch HoseBanioBolts
Clutch SlaveCylinder Bolts
BleedValve
RH EngineCoverDamperBolts
ClutchHub Nut
ClutchPioeJoint
EngineLubricationSystem:
CrankcaseOil Nozzle
Oil Pressre Relief Valve
Oil PrescrreSwitch
EngineDrainPlug
Oil Filter
Oil ScreenPlug
Oil PipeBanjoBolts

Torque
N-m

kgrn

ft-lb

0.80
0.80
0.90

69 in-lb
69 in-lb
78 inlb

9.8

1.0

87 in-lb

8.8
25
78
25
8.8
25
25
12
15
12

0.90
2.5
8.0
2.5
0.90
2.5
2.5
1.2
1.5

78 in-lb
18.0
58
18.0
78 in{b
18.0
18.0
104inlb
11.0
'104in-lb

7.8
7.8
8.8

|
|
|

,:

Remarks

Left-handed
Threads

S
S

5.9
8.8
25
8.8
7.8
9.8
145
18

0.60
0.90
2.5
0.90
0.80
1.0
15.0
1.8

52 in-lb
78 in-lb
18.0
78 in-lb
69 inlb
87 in-lb
110
13.0

2.9
20
15

0.30
2.O
1.5
2.O
1.8
2.O
1.2

26 in-lb
14.5
11.0
14.5
13.0
14.5
l(X in-lb

N
18
20
12

L
SS

GENERAL INFORMATION1-9
Torque

Fastener
Engine Removal/lnstallation:
EngineMountingBolts
EngineMounting BracketBolts
RightDown Tube Mounting Bolts
Crankshaft /Transmission:
CrankcaseBolts:
10 mm
8mm
6mm
ExternalShift Mechanism
ReturnSpring Bolt
GearPositioningLeverBolt
ConnectingRod Big End Cap NUts
PrimaryGear Bolt
AlternatorRotor Bolt
CamshaftChainGuideHolderBolts
StarterClutch Bolt
StarterClutch Coupling Bolt
BalancerGearBolt
Shift Drum BearingHolderScrew
NeutralSwitch
Rear-rightStud Tap End
Wheels/Tires:
FrontAxle Nut
FrontAxle Clamp Bolt
RearAxle Nut
Air Valve Nuts
Final Drive:
Front BevelGearCaseBolts:
6mm
8mm
DamperCam Nut
Drive GearNut
NeutralSwitch
Oil PipeBanjoBolts
DrivenGearAssemblyMounting Bolts
DrivenGearBolt
FinalGearCaseMountingNuts
PinionGearNut
FinalGearCaseCover Bolts:
8mm
10mm
FinalGearCaseStuds
DrainBolt
PinionBearingRetainer
RetainerStop Screw

Removark

N-m

kg-m

ft-rb

44
24
44

4.5
2.4
4.5

33
'17.5

?o

4.0
2.1
0.90

29
15.0
78 in-lb

21
8.8

21
8.8
59
'|
45

1.1

0.90
6.0
15.0
6.0

55

15.0
78 in-lb
+J

110
43
L

93

o:,

11.0
:,5

Y.C

L
,tt

1 1. 0
L

88
29

9.0

110
1.5

11.0
0.15

8.8
25
225
265
15
12
25
120
29
120

0.90
2.5
23
27

78 in-lb
18.0
toc

I.C

1.2
2.5
12.1
3.0
12.O

11.0
104 in-lb
18.0
88
22
6t

t2

2.3

16.5

34

? E

?n

22
80
1 3i n - l b

.,8

8.8
245

oso
25

Z S i n - fO
180

16

1.6

11.5

St
L
L
L
Left-handed
Threads
L

1-IO GENERAL INFORMATION

Torque

Fastener
N-m
Brakes:
BrakeLeverPivotNut
FrontlvlasterCylinderClampBolts
BrakeHoseBanjoBolts
CaliperMountingBolts
BleedValves
DiscMountingBolts
RearMasterCylinderMountingBolts
CaliperHolderBolt
BrakePedalLinkClampBotts
Suspension:
FrontForkClampBolts: Upper
LOWer

FrontForkDrainBolts
FrontForkBottomAllenBotts
SwingArm PivotShaft
FrontAxleClampBolt
Fear ShockAbsorberl\ilountjng
Nuts
Steering:
Handlebar
ClampBolts
WeightMountingScrews
SteeringStemHeadBolt
SteeringStemLocknut
Ftame :
RightDownTubeMountingBolts
EngineMounting
BracketBolts
BrakePedalLinkClampBotts
ElectricalSystem:
AlternatorRotorBolts
SparkPlugs
CoolingFanSwitch
NeutralSwitch
Oil PressureSwitch

kg-m

ft-m

8.8
25
32
7.8
27
23
64
25

0. 60
0. 90
2.5

52 inlb
78 inlb
1 8 .0

0. 80
2.8
2.3
6.5
2.5

69 in-lb
20

20
52

2.O
5.3

'14.
5
38

20
98
29
30

2.O
1 0 .0
3.0
3. 1

14. 5

59

6.0

zl3

4.O
0. 50

29

44
24
z5
59
18
7.8
15
15

to. c

47
1 8 .0

72
2.
22

43 inlb

4.5
2.4
2.5

33
1 7 .5

6.0
1.75
0. 80
'1.
5

43
't2.
5
69 inlb
11.0

t.c

1 8 .0

11.0

Remarks

GENERALINFORMATION1.11
The tablebelow,relatingtighteningtorqueto threaddiameter,lists*re basictorquefor the bolts
and nuts. Usethis table for only the bolts and nutswhichdo not requirea specifictorquevalue.
threads,
All of thevaluesarefor usewith dry solvent+leaned

General Fastenen
Threadsdia. (mml
c

6
8
10
12
14
16
18
20

Torque
N-m

3.4 - 4.9
5.9- 7.8
14-19
25 -34
44 -61
73-98
115-155
165 -225
225-325

kgm

0.35- 0.50
0.60- 0.80
1.4- 1.9
2.6- 3.5
4.5 -6.2
7.4- 10.O
1 1 . 5- 1 6 . 0
17.O-23
23 - 3:t

ft-lb

30 - zt3in-lb
52 - 69 in-lb
10.0- 13.5
19.0- 25
33-45
54-72
8 3- 1 1 5
125- 165
165- 2'10

1-12 GENERALINFORMATION
Cable,Wire,andHoseRouting
................;,,.......
WidngRouting

1.
2.
3.
4.
5.

Wire Straps
CoolingHoses
SideStandSwitch
RearBrakeLight Switch
FuelPump

(vN1500-B)

1. WireClamps
2. RearFenderRearSection
3. RearTurn SignalLight

1. JunctionBox
2. Sarter Relay
3. Battery(+) Wire
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 Breattrer
Hose
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.
2.
3.
4.
5.
6.
7.
8.

CleanAir Hose
RearVacuumSwitchValve
VacuumHose
HoseStraps
Air BreatherHose
Air Filter
lC lgniter
Breatier

9. CheckValve(VNl500.A)
10. HoseGuide
11. Battery
12. BatteryVent Hos
13, HoseGuides
14. SurgeTank
15, DrainHose

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. Reservoir
TankTube
7. Reservoir
Tank
8. Wireor HoseStraps
9. lgnitionCoil (Front)
10. lgnitionCoil (Rear)
11. Canister

GENERALINFORMATIONT-17
Eyaporatiye Emi$ion control System Hose Routing

l.
2.
3.
4.
5.
5.
7.
8.
9.

HoseStps
EngineBracket
HoseClamp
Canister
Liquid/VaporSeparator
CoolingHose
StarterMotor
StarterMotor Wire
Radiator

,/.-\
, )

1. FuelTank
2. CheckValve(VN150GA)
3. BreatherHose(Blue)
(ReturnPump)
4. Liquid/VaporSeparator
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. Resrvoir
Tank Tube
21. Air BreatherHose

FUEL SYSTEM2-1

Fuel System
Table of Contents
ExplodedView...
Specifications
......,.'.
SpecialTools.
Throttle Grip and Cables..
Throttle CableAdjustment
Carburetorc,
ldle SpeedAdiustment
High Altitude PerformanceAdjustment (US model).
Fuel SystemCleanlinessInspection.
CarburetorSynchronization
ServiceFuel LevelAdjustment . . . . . .
CarburetorRemoval
CarburetorI nstallation
CarburetorSeparation.. ,
CarburetorCombination
CarburetorDisasembly.
GarburetorAssembly.. . . .
Carburetor Inspection,
FuelPump.
Removal
lnstallation Notes . .
Fuel Filter.
Removal
lnstallationNotes. ,
Inspection
Air Cleaner
Element(Housing)Removal
E l e m e n t C l e a n i.n. s. . . .
Air CleanerHousingInstallation... . .
Air CleanerDuct lnstallation
SurgeTank
SurgeTank Removal

Emission
ControlSystem(USCaliforniaVehicleonly)' . . '
Evaporative
Notes. .
PansRemoval/lnstallation
HoseInspection.
.
SeparatorInspection
SeparatorOperationTest
CanisterInspection

2-2
2-5
2-5
2-6
2$
2-7
2-7
2-7
2-7
24
24
2-9
2-10
211
2-11
2-12
2-12
2-14
2-14
2-14
2-15
2-15
2-15
2-15
2-15
2-15
2-15
2-16
2-16
2-17
2-17
2-17
2-17
2-17
2-17
2-17
2-18
2-18

2.2 FUEL SYSTEM

ExplodedView

(D

f---r
IfrPtri
t

?."---x

A-

@-+

va

@-_-1

i\

reu)

R
l,lf

PEB

a
a
(us)(vy)
1. Left Switch Housing
2. Right Switch Housing
3. ThrottleCable(Accelerator)
4. Throtlle Cable(Decelerator)
5. Jet Needle
6. ThrottleValve
7. FloatValveNeedle
8. Float Pivot Pin
9. Float
t0. PilotScrew
11.NeedleJet Holdei
12. MainJet
13. Fuel DrainScrew
14. Botlom Cover
15. FrontCarburetor
16.RearCarburetor
17. FloatChambel
18.ChokeKnob Assembty

./'1

"al

A12:CN

""\.

A12:CN

(US)(w)

\ s 6

sBe
,u&^,
g

FUEL SYSTEM2.3

rlr

A12:CN

(usxw)

o-l frles
I ti uEi i
i9t

1. DrainHose
2. VacuumSwitchValve
3. Air CleanerDuct
4. Surge Tank
5. Surge Tank Duct (Front)
6. Surge Tank Duct (Rear)
7. Air CleanerElement
A12:CN 8, Fuel LevelSensor
9. Fuel Tap

(us)w)

(cal)
(cal) CalitorniaModel

(us) U.S.A.Model

(W) SruitzerlandModel
(cN) CanadaModel

u-)

<-'
------46,

vNlsoGB
I

a
I

\il

rT-t

it 0 l i

24 FUEL SYSTEM

ExaporariwEmbtion Cofitrol Sy$m

(Califomiailodell

@>,\

WHITEJ I
\

'

YELLOW

1. FuslPump
2. Bnd(ct
3. Uquid/V8porSsp.rsbl
4. Cani*er

ffi

FUEL SYSTEM2
Specifications

Standard

Item
ThrottleGrip :
Throttlegripfreeplay

2-3 mm
vN 1500-4

Carburetors:
Make,type
Mainjet:
Jet needle:

Front
Rear
Front
Rear

Pilotscrew
Servicefuel level:Front
Rear

Keihin,CVK36
# 1 1 2 , ( C a#l1) 1 8
# 1)1 5 , ( C a#l )1 1 8
# 11 2 , ( U S X C
Ns3S,(cal)N53U,(W)N67F
N53T,(cal) Ns3V,(W) N67G
N67A,(USXC)
1 ll2 turnsout,As-(FG),A4-(EU):2 1/4turnsout,(USX\92 - 2! 1 m m
4.2!1mm
750-850 r/min(rpm)

vN1500-8
#130
#132
N36P,(cal)N36R,
W)N77D
N36Q,(Cal)N36S,(W)N77D

(W)8s0-950 r/minGpm)
vacuum
Synchronization

Lessthan2.7 kPa(2 cm Hg)

(US) : U.S.A.Model
(C) :CanadaModel

SpecialTools
Fuel LevelGaugp:57m1-1017

(Cal) : CaliforniaModel
(FG) : cermanyModel

(swi) : Switzerland
Model
(EU) : EuropeModel

2 FUEL SYSTEM
Throttle Grip and Cables
Throttle CableAdjustment
.Check throttle grip free play.

Throttle Grip FreePlay

SGndard: 2-3mm

.Turn the acceleratorcableadiusteruntil 2 - 3 mm of

throttlegrip play is obtained.Tightenthe locknut.
*lf the throttle cablescannotbe adiustedby usingthe
cableadjustersat the upperendsofthe throttlc cables,
usetheadiustersat the lowerendsof the cables.
.Removetj,|e fuel tank mountingbolts and move the
tanktowardthe rear.
.First givetie throttle grip plenty of play at the upper
ends of the throttle oables as mentionedabove.
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.

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
at the point wherethe grip just beginsto be turned
b.ackfrom the completelystoppedposition. Tighten
the locknut.

A. Accelerator Cable
B. DeceleratorCable

C. Adiusters
D. Locknuts

A. Accelerator
Cable
B. Decelerator
Cable

C. AdiustingNuts
D. Locknuts

.Turn out tl|e deceleratorcableadjustingnut in the

sameway with the adlusterat the upperend of the
decelerator
cablemakinglure that the throttle grip is
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 problembforeoperatingthe motorcycle.

ooperation with an impropedy adj$ted, incorreEtly

routsd, or damagsd cable could result in an unsafe
riding condition.

FUEL SYSTEM2.7

::::::::::.
ldle Speed Adiustment
.Starttheengineandwarmit up thoroughly.
.Turn the handlebarfrom side to sidewhile idling the
engine.
*lf idle speedvaries,the throttle cablesmay be poorly
routedor they maybe damaged.
.Correctany problembeforeoperatingthe motorcycle.

ooperation witlr an improprly adiusted. incorrecdy

louted, or damagedcable could result in an unsafe
ridingcondition.

.Check idle speedwiti a tachometer.

ldle Spesd
Standard: 750 - 850 r/min hpml
@ 850 - 950 r/min (rpm)

Adiustment
High Altitude Performance
(USmodel)
oTo improve the EMISSIONCONTROL PERFORMANCE of vehicleso'peratedabove/{lq} fert, Kawasaki
recommendsthe following EnvironmentalProtection
modification.
Asencv(EPA)approved
rcfiangi ti'remainlet andpilot let for highaltitudeuse'
High Attituds C.rbutstor Specifications
MainJet VNl5(xr-A
From : #110 D#115
R@r : #112 @D#115
vN1500-8
Front : #ra
Rgar : #1q,
#o
Pilot Jet

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
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 carburetor bottom cover.
aRun the lower endsof the hosesinto a suitablecon'
tainer.
.Turn out each drain plug a few turns and drain the
float chambers.

@ : SwissModel(VNls(XlB)
.Turn the idle adjustingscrewuntil idlespeedis correct'

1. DrainScrew
2. SuitableHose
3. Bottom Cover

A. ldleAdiustingScrew

acheck to seeif watrr or dirt comesouL

.Tighten the drainplugs.
*lf any wateror dirt appeared
duringthe aboveinsFec'
tion, cleanthe fuel system.

2 FUEL,SYSTEM
Caft utetoI Syn chrcnization
OWamuptheengine.
oCheckidlespeedandadiustif necessary.
OAttacha commercially
available
vacuumgaugeto the
vacuumhosefittingsonthecarburetors.

*lf proper carburetorsynchronization

cannot be obtained by using the adiustingbolt, check for dirt or
blockage,
and thencheckthe pilot screwsettings.
.Checkthe carburetorsynchronization
again.
NOTE
oDo not tum the pilot srcwscat"J,ldfsly
during erburetors 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.
1. VacuumHoseFittings

astart the.engineand let it idle to measurethe engine

'inAkcvasuum..
*tf thi intakevacuumdifferencbetweent]le cylinders
exceds
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

synchronize
the butterflyvalves.
owhen the adiusterbolt is umed in, the rearcylinder
vacuum increases. Whenthe bolt is badcd out, the
rearcylindervacuumdecreases.

A. AdjusterBolt

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.
.Scurethe 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
carburetors
usinga suitablehose.
rPreparea fuel hose.
.Connecta fuel levelguge (specialtool) to the carburetor bottom coverwith the hose.
etlold the gaugeverticallyagainstthe side of the carburetor 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
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.
Srvice Fuel Level
From the uppet edgp ol dre coalting enticher
moundng lower screw.
: below 12 - 32 mm
Flont
: below 32 - 52 mm
Rear
*lf the fuel level is incorrect, removethe carburetorsand
separatethem (seeCarburetor Sepration).
.To adjust the fuel level,bend the tang on the float arm
to changethe float height.

A. Float

Carburetor Removal

ocasolineis extremelyflammableandcan be exPlosive

under certain conditions. Turn the ignition switair
OFF. Do not smoke. Make sure dte area is well
ventilatedandfrce frcm any rcurceof flameor lparks;
wi$ 8 pilot light.
this indudssany appliance
.First removethe following.
Seat
FuelTank
Drainthe fuel from the carburetor.
Loosenthe tirottle cableadiuster.
.Then removethe followingfrom the left side.
Throttle CableHolder Screw
SurgeTankDuctClampScrew(Loosen)
CarburetorHolderClampScrew(Loosen)
VacuumHose

B. Tang

olncreasingthe float height lowerstie fuel levelanc

decreasing
the float heightraisesthe fuel level.

A. ThrottleableHolderScrew
B. SurgeTankDuct ClampScrew
C. CarburetorHolderClampScrew

Fuel Levd Adiunmsnt

.Then removethe followingfrom the right side.

CarburetorCover
CarburetorCoverBracket
SurgeTank DuctClampScrew(Loosen)
CarburetorHolderClampScrew(Loosen)
VacuumHose

1.
2.
3.
4.

Float Tang
Float Valve
Floa! Mating Edge
ChamberRibs

NOTE
oDo not push the ndle
masufement.

rcd in during the float height

A. SurgeTankDuctClampScrew
B. CarburetorHolderClampScrew
C. VacuumHose
D. Carburetor
CoverBracket
E. C:rburetorCover

2.10 FUEL SYSTEM

rThen removethe follwoingfrom the upperend.
CleanAir SystemHose
Fuel Pumpand Pull the output hosefrom the carburetor.
FuelPumpWireConnector
SurgeTank Duct (Front Carburetor)

@
olf dirt or durt is allowed to pals through inio d|e
carbuntors, the d|rctde may becomerfrrck, possibly
cauringan accident.

l-wAnNrNil
J

mml

oFud .pill.d irom tft fud pump & h..:adous.

olf dirt gsts through into dte engine. xcessive engine

wear and polsibly enginedamagewill ocorr.

@rburetortnsallation

A. FuelPump

C. OutputHose

.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.

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.
oKGpthe horesfree of ob8truction,
aAfter installingthe carburetors,
performthe following.
oCheckfuel leakage
from the carburetors.

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

A. Taketl|e carburetorset out from btweenthe

cylinderheads.

oAdiustthe followingitemsif necessary.

ldle Speed
CarburetorSynchron
ization
ThrottleCables

FUEL SYSTEM2.11
@rburetor Separation
aRemovethe front carburetor.
oRemovethe followingparts.
ChokeRod MountingPlateScrews
ChokeRod

Screws(3)
Front CarburetorFloatChamber

A. RearCarburetor
B. FloatChamber
A. Choke Rod

C. FrontCarburetor
D. Screws

B. Screws

RearCarburetorChokeRod PivotScrew
ChokeLink Rod

oRemovethe rear carburetorfloat chamberscrewsand

seDarate
the rearcarburetor.

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

A. ChokeLink Rod

B. ChokeRod PivotScrew

Throttle Link RodCotterPinand PlasticWasher

A. Throttle Link Lever

B. Proiections

A. Throttle Link Lever

B. CotterPin

C. PlasticWasher

C. Notches

oconnect the choke link rods and install the plastic

washerandthe throttle link levercotterpin.

2.12 FUEL SYSTEM

olnshll the rear carburetor starter plungr 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

Carburetor Disassembly

Carbu,etor Asembly
.Note tle following
.lnstall the float on the carburetor.
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 ara 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
otier suita.bletool.

A. Float
B. Do not tap here.

C. Tap the pin asfar as

it will go.

FUEL SYSTEM2.13
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.

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
B. F Mark

C. RearCarburetor
D. R Mark

Plug I nstallation

oKeepdirt or other foreignmaterialfrom enteringinto

the float chamber-

olf din get3 into the float chsmber,tre float valyemay

bscoms stud( open, ausing carburtoroverflow and
requiringcarburetorcleaning.
agent. 3. PilotScrew
1. Applya bonding
4. CarburetorBody
2. Plug
oDo not force ths needlaiet holder (air bleodpipel and
main iEt or ovenlghsn drsm. They couldb damaged
rquiring replacement.

.lnstall the O-ringin the coastingenrichersystemcover

sothat the flat sidefacesin,

1 . M a i nJ e t

'1.
O ring
2 . Cover

2. Needle.let Holder

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
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 goodcondition.
O-ringsfor DrainPlugandCoastingEnricher
Diaphragms
for VacuumPistonandCoastingEnricher
*lf any of the O-ringsor diaphragms
are not in good
condition,replace
them.
.Check the plastictip of the float valve needle. lt
sltouldbe smooth,without any grooves,scratches,
or
otherdamage.

2. TaperedPortion

*lf the pilot screwis wornor damaged

on the tapered
portion,it will preventthe enginefrom idlingsmoothly. Replaceit.
.Check that tlte vacuumpistonmovessmoothlyin the
carburetorbody. The surfaceof the pistonmust not
beexcessivelv
worn.
*lf the vacuumpistondoesnot movesmoothly,or if it
is very loosin 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

(H

l. Rod
2. ValveNeedle

Removal
.Removethefueltank.

3. ValveNeedle
Wear

A. FuelPump

*lf the plastic tip is damaged,replacethe needle.

*lf it does not springout, replacethe needle.
acheck the tapered portion of the pilot screwfor wear
or oamage.

B. PumpBolts

.Remove the bolts and take the fuel pumpout of the

frameaDisconnect
the pumpwireconnector.
oPullthe fuel hosesoff the fuel pump.

FUEL SYSTEM2.15

o(iasoline is extremely flammable and can be explosive

Turn dte ignition switah
undel certain conditioB,
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
.Connectthefuelhoses
to thepumpfittingsasshown.
A. FuelHosefrom Tank
B. FuelHosto Pump

C. Arrow

.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. FuelHosto Carburetors
.Be sureto routethe hosessotheywill not be kinkedor
stretched.

FuelFilter
Removal
aRemovethe fuel tank.
.Removethe RH frametoDtubecover.
.Pull the filter off tl|e hose.

Air Cleaner
Element (Housing) Remowl
aRemovethe followingparts.
Seat
FuelTank
FrameTop TubeCover
RadiatorCover
oRemovethe air cleanerhousingmountingbolts.

l-wnnruruol
locasoline 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
(VNl 50GBOnly).
housing

Element Cleaning

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 includs 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.

A. lnnerCover

B. Screws

aRemovethe air cleanercoverby takingout the cover

bolts.

olf dirt or duit b allowed to poEs drrough into dre

carburstors. dre throtds may become dud(. possibly
ca$ing accidnt.
.Wash the element in a bath of high flash-point solvent
and then squeezeit dry.

VNlsOGA
oDo not wring or twbt tho element83it may tsr.
.Saturae the element witlr SAE30 motor oil and
squeeze
out the excess.
.Wrap tlte elementin a cleandry cloth andsqueeze
it as
dry asposible.

A. Cover
B. CoverBolts

C. Element
D. ElementBolts

vt{1500-8

A. Cover
B. CoverBolts

Air CleanerHousinglnsallation
.Note the following.
oTheright andleft air cleanerhousingareidentical.'Use
the markedR for the right sideand L for the left side.

C. Element
D. ElementBolts

aRemovethe boltsto removethe element.

rRemovethe otier sideelementin the samemanner,

A. LH Housing
B. "L" Mark

C. RH Housing
D. "R" Mark

FUEL SYSTEM2.17
Air Cleaner Duct lnstallation
.Note the following.
olnstall the air cleaner duct with its side marked
"UPPER"facingupwards.

EvaporativeEmissionControl System
(US CaliforniaVehicleonly)
The EvaporativeEmissionControl Systemroutesfuel
vapors from the fuel systeminto the running engine or
stores the vapors in a canisterwhen the engine is stopped. . Although no adjustmentsare required, a thorough
visual inspection must be made at the intrvalsspecified
bv the PeriodicMaintenanceChart.

ParB Bemoval/l nstallation N otes

A. Duct

B. "UPPER"Mark

oca3oline is extremely flammable and can be explotivc

under certain conditions. Turn the ignition lwitch
OFF. Do not smoke. Mske sure the a?e. i3 iYll
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 rduced. It the canister does become contaminatodreplaceit with a newone.

SurgeTank
Surge Tank Removal
rRemovethe air cleanerhousing.
.Removethe thermostathousing.
aUnconnect
the 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

l . SurgeTank
2. Air CleanerDuct

3. SurgeTank Duct (Rear)

4. SurgeTank Duct {Front}

.Disconnect the hosesfrom the liquid/vapor separator,

and removethe separatorfrom the motorcycle.
.Visually inspect the separator for cracks and other
damage.
*lf the separator has any cracks or is badly damaged,
reDlaceit with a new one.

2.18 FUEL SYSTEM

&parator OperationTest

oc6oline is extrsmely flammableard can be explosive

undar csrtain conditionr. Tum the ignition switdl
OFF. Do not moke. Make sur th area b well
vontilatodand fre from any sourceof flame or spark;
thb induder any appliancswid| a pilot light.
.Connect the hosesto the sparator,and install the
sparator
on the motorcycle.
aDisconnectt}le breatherhosefrom the separator,
and
iniect about 20 mL of gasolineinto the separator
throughthe hosfitting.
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 sparatorworks well. lf it doesnot, replacethe
separator
with a newone.

Canister lnspection
aRemovethe canister,and disconnectthe hosesfrom
the canister.
.Visually inspect the canister for cracksand other
oamage.
*lf the canisterin crackedor badlydamaged,
replaceit
with a newone.
NOTE
ome canitter is daignd to wo* well {rrough dE
motorcycle's tife without my maintenanceif it is ud
under normataonditions.

Eraporstiro Emi$ion Cot|trol Syrtsm

<-

l.
2.
3.
4.
5.

FuelTank
SurgeTank
RearCarburetor
VacuumSwith Valve
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...
Specifications
Coolant Flow Ghart,. ,

+2

Coolant.
Coolant LevelInspection.
Coolant Draining
Coolant Filling
PressureTesting.
Water Pump.
Visual Leak Inspection
WaterPump,MechanicalSealRemoval'
WaterPump,MechanicalSeallnstallation.

c4

Radiatorand CoolingFan.
Removal
lnstallation
Radiatorlnspection,
RadiatorCap Inspection

c7

Thermostat
Removal
Installation
Inspection.
ThermostatFan Switch.
Removal
lnstallationNote. . .
Inspection.

33
33
34
3-,4
35
36
3
3-6
36
g7
97
$9
39

c9
910
3-10
911
3-11
3-12
3-12
3-12
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, lmpdlr Bolt
6. PumpCoYr
7. Covel Bola
8, Drain Plug
9. R.diator
10. CoolingFan$vidr
11. Grcundmre
12. CoolingFan
13. R.erroir Tank

Tl : 7.8 N-m(0.80kgn,69 in.lbl

T2: 8.8 N.rn(0.9Okgn,78 in{bl
T3: 98 N.m (1.0kgn,87 inlbl

COOLINGSYSTEM}3
Specifications

Standard

Item
Coolant:
Type

Mixed ratio
Freezingpoint

Permanenttype of antifree (soft water and ethyleneglycol

plus corrosionand rust inhibitor chemicalsfor aluminum
enginesand radiators)
Soft water 50%,coolant5096
-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
Valvefull openinglift

80 - 84"C(176- 183"F1
Morethan8 mm@5"C {2(B'F}

Coolant Flow Chart

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

1. WatrPump
2. WaterJacket
3. CylinderHead
4. WatrrPipe
5. WaterHos
6. RadiatorCap
7. Thermostat
8. Reservoir
TankTube
9. Radiator
10. CoolingFan

34 COOLING SYSTEM
Coolant
Coolant Level lnspection
NOTE
achsk the level when the engine is cold (room or
ambienttemperature)
-

oFor refillinS, add the specified mixture of coolant and

soft watet. Adding water alone dilutes the coolant and
degradesits anticorrosion properties,
oThe diluted coolant can attack tie aluminum engine
parts. In an emergency, soft watet can be added. But
the diluied @olant must be retumed to the correct
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 reservoir
tanktlf 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 whn the enline b still hot. W8it
until it coob dwn,
ocoolant on tir3 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
B. Screw

C. FullMark
D. Low Mark

A. Reservoir
Tank
B. FULL Mark

C. LOWMark
D. TankCap

oRemovethe following.
Seat
FuelTank
RadiatorCover

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 dirdlld 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.

A. RadiatorCap

.Drain the coolantfrom the radiator.

aRemovetf|e reservoirtank cover and take tl|e tank off
the frame.
.Pour the coolantinto a suitablecontainer.

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.

water and coolsnt Mircure Ratio (Recommerdodl

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

NOTE
oohooc a sritable mixture 'a,tio W rcferring to {re
coolant manufe.ure I b di rurtio n8.
.Start the engine,warm it up thoroughly until the
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 pressurctsting, do not exceedthe pressulefor

which the system is dsignd. The maximum pressure
is 123 kPa {1.25kg/cm2,18 psi).

A. DrainageOutlet Pasage
(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
B. Adaptr

C. RadiatorCap

A. WaterPipe
tlf the pressure
dropssoon,checkfor leaks.

B. Bolt

WaterPumpCover

WaterPump
Visual Leak lnspection
.Checkthe drainageoutlet p;rssage
at the bottom of the
watr pump body for coolantleaks. Pumpremovalis
not reouired.
tlf the mechanicalseal is damaged,the coolant leaks
through the seal and drains lhrough the passage.
Replace
the watrpumpunit.

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 extrior
srfe of the boty.
ohessthe new mechanical
sealinto the hole by usinga
su'rtable
socketuntil it bottomsout

A. lmpeller
B. Bolt

C. Directionof rotation

.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).
oReplace
the pumpcovergasketwith newones.
oThe watr pump cover rear bolts have aluminum
washen.

A. Flange

B. Chisel
Radiatorand Cooling Fan

.Pull the mechanicalsealout of tie crankcase

pliers.Oiscardthe remotedmechanical
seal.

Removal
.Remove
thefollowing.
RadiatorCover

38 COOLING SYSTEM

A. RadiatorCover

B. Screws

Coolant(Draining)
CoolingFanSwitchConnector

A. Radiator

B. LowerBolts

RadiatorUpperBolt

oThe cooling fan is conncteddiregtly 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
Badiator lnspection
core.
theck theradiator
*lf thereareobstructions
them.
to airflow,remove
*lf thecorrugated
carefully
straighten
finsaredeformed,

Radiator Hoses

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

FanMountingBolts

A. Fan

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
radiatoraore.
2l Hotd tho st3am gun perpendicrer to the core
:urface.
3l Run rha stsm qun hotizontslly following the core
fin direc'tion. Runningit venically nrsy dsmagsdro
ffnr.

B. MountingBolts

lnsallation
.Be sureto attachthe groundwire to the fan mounting
bolt

Badiator Cap lnspection

acheckthe conditionof the top andbottomvalveseals
A. GroundWire

B. MountingBolt

of the radiatorcap,
*lf either of them showsvisibledamage,replacethe
cap.

3-10 COOLING SYSTEM

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

1 . Bottom Valve Seal

2. Top Valve.Seal

3. Valve.Spring

alnstallthe capon a coolingsystempressure

tester.
NOTE
Wet the cap ealing arfaca with wateror coolant to
preventp,esure leaks.
A: FuelFilter
B. Bolts

C, ThermostatHousing

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

Standard: 93 - 123 kPa
(0.95- 125 kg/cm2,14 - 18 psi)

*lf the cap cannot hold the specified pressurq or if it

holds too much pressure,replace it with a new one-

A. Hoses

B. Clamps

.Pull the thermostathousingirut of the frame to the

ngnL
.Removetie thermostatfrom its housins.

COOLINGSYSTEM}11

Housing
A- Thermostat

B. Screws

A. Brackets

lnspection
aRemovethe thermostat,and inspectthe thermostat
valveat roomtemperature.
*lf the valvis open,replacethe valvewith a newone.
.To check valve opening temperature,suspendthe
thermostat in a container of water and raisethe
of the water.
temperature

lnstallation
.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
onto theframebracket-

Thermo3tat Valve Opening Temperature

80 - 84'C (176 - 183"F1

e,*ru< -B

i!t1f,61

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:

srtrf a:rql:o?

!tl;.ir{tl ori.:V trdrofin$dl

11"*8i ., D!*l J'!B -- 08

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

J5:aonnsdl
rltiyr trrJitd t3jiit hui 3il, lhf.nlo
Anituid
-terJ6rd rmgi erb otno

ENGINETOP END +T

EngineTopEnd
Tableof Contents

Specifications.
SpecialTools

4.2
4-6
4-7

Sealant . .

+7

CleanAir System
(US and Switzerlandmodels).

4.4

Exploded View .

Air Suction Valvelnspection.

Vadrum switch Valve Test . CamshaftChain Tensioner.
Bemoval .
Installation.
Rocker CaseCap
Removal
Installation.
RockerShafts, Rocker Arms, Rocker Case. . .
Removal .
I nstallation.
(Hydraulic
HLA
LashAdiuster)
HLA Removal.
HLA lnstallation.
HLA Air Bleeding
Inspection
Camshafts
Removal ,

+a
4-8
4-8
4-8
4-9
4-10
4.10
4-10
4.10
4-10
4-11
4-12
4-12
4-12
4-12
4-13
4-13
4-13

Camshaft SprocketAssembly.
Camshaft, RockerCaseWear
Camshaftchainwear. . . . . .
KACB (KawasakiAutomatic
CompressionRelease)..
Removal .
lnstallation.

4-13
4-14
4-14
4.15
4-r5
4-15
4-15

....

4"15

.....

4-16

Cylinder CompressionMeasurement. . .
....
R e m o v a. l
Installation.

lnstallation(lncludingChain
Timing Procedure).

Inspection
C y l i n d eHr e a d .

. ..

4-16
4{6
4{6

: .......
ValveClearanceAdiustment . . . . . . . .

4-16

Valve
Removal

.........

4'17

.......

4-17

V a l v e .s ..

V a l v ef n s t a l l a t i o n
V a l v eG u i d eF e m o v a l . .

..-

Valve Guide lnstallation

Valve FaceContact Inspection. . . . . . .
ValveSeatOutside
Diameter. . . . . . ..
ValveSeatWidth Inspection. .. . ....
ValveSeat Repair(Valve Lapping) .

4-16

4-17

4-17
4-18
4{8
4-18

4-18

MeasuringValve-to-GuideClearance

(WobbleMerhod)
Cylinders,Pistons

CylinderRemoval
Installation
.".,,
Cylinder
P i s t oRne m o v a l .
........
.......
P i s t o lnn s t a l l a t i o n
Cylinderwear.
.........
Piston
Wear
,..
PistonRing,
PistonRingGroove
Wear. . . .. -..
P i s t o n R i n g E n d G a p . ., .. .. .. .. . .
........
Muffler..
(
f
o
r
V
N
1
5
0
0
A
)
Removal
.,........
lnstallation.
Removal(for VN150GB)
I nstallation.

4"20
4-21
4-21
4-21
4-22
4-22
4-23
4-23
4-23
4-?3
4-24
+24

4-25
+25
4-26

4-2 ENGINETOP END

ExplodedView

@-q '/Fe-n45
z--@

o_M

Swiuerland Model

Wffireo
q
\

WoEee
Model
A12:Canada
Model

ffi-

Switzerland Model

wo
@@

1 . RockerCaseCap
2 . Spring
3 . Oil Fitter
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
1 2 CarburetorHold,er

o Apply engineoil.
ss Apply siliconesealantT1
f2
T3
T4

8.8N-m(0.S0kg-m,78 in-lb)
2s N-m(2.skg-m,18.0ft-lb)
78 N-m(8.0kg-m,58 fl-tb)
12 N-m(1.2kg-m,104inlb)

L.-%
i . * % . \ ,&
\_3__.,
I

ENGINETOP END 4-3

? @

rffi

s"

r\

@*

#f'ff
\'/
*N*#? &
*#eM
1.
2,
3.
4.
5.
6.
7.
8.
9.
10.

Bod(6rSh8ft
RockorAm (x 3/1 GYlindetl
Rod(sr A]m (x 1/1 GYlinderl
Oil Chamber
Hydraulic LashAdiuster
valYeSpring{lnnert
vslre Spring(Ouetl
Oil Sl
ValveSt m (Exh$3tl
V8lvoSsh (lntakel

M : Apply molybdsnumdi:ulfide grease'

T 1 : 25 Nfl (25 kgF|n,18Oftlbl

4.4 ENGINETOP END

1.
2,
3.
4.
5.
6.
7.

CYlinder
Drain Plug
Piston
Cam$aft Chain
Camshaft Spmcket
Camsh.ft
KACR (Automatic Comprsion
Releasel
8. Camshaft Chain Tensioner

w
*@\

Ld,A

:%,H-@
! v /fe?
'
W.'*%f
6
L :
O :
T1:
T2:

Apply nonfmanent loddng agtrt.

Apply endneoil.
15 N-m (15 kgFm,11O ft.lbl
25 Nrn (25 kgn,18.0 ft.lbl

TOP END 46
L
2.
3.
4.
5,
6.
7.
8.
9.

Nut
ExhaustPipe Holder
ExhaustGasket
Exhaun Pipe (Leftl
ExhaustPipe {Right}
Gasket
PowerChamber
Muffler (Leftl
Muffler (Riqhtl

vN1500-A

O--

@__>

@--\b
@--od

VN1sff}B

$,
(*/

"eD

\
\--

ap

l I

\d

+6 ENGINETOP END
Specifications
Itm

Standard

Sewica Umit

Clo.n Air Systom

(US aod Switze.landmodets):
Vacuum switch valve closing pressure:

Open

Close

Cmshaft, Camshaft Chain:

Cam height

Inlet
Exhaust
Camshaft,rockercaseclearance
Camshaftjoumal diameter
Camshaftbearinginsidediameter
Camshaftchain20-link length

Cylinder Hoad:
Cylindercompressionpressureusablerange
@30O r/min (rpm) by electric starter

Cylinderheadwarp
Valves:
Valve clearance
Valve head thickness:
Valve stem bend
Valve stem diameter
Valve guide insidediameter
Valve/valveguide clearance
(Wobble method):
Valvespring lreelength:
Valveseatingsurface:
width
Outside diameter:
Valveseat cutting angle:

Piston ring groovewidth:

Pison ring end gap.

33.812- 33.912mm
33.494- 33.594mm
0.020- 0.062mm
24.959- 24.980mm
25.000- 25.021mm
127.0- '127
.4 mm

33.71mm
33.39mm
0 . 1 5m m
24.93mm
25.08mm
128.9mm

Frontcylinde[
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 )
0.05mm

lnlet& Exhaust
Inlet
Exhaust

Non-adiustable
'I .0 mm
0.02mmTIR
6.965- 6.980mm
6.955- 6.970mm
7.000- 7.015mm

lnlet
Exhaust
Inner
Outer

0.05- 0.12mm
0.08- 0.16mm
37.8mm
42.3mm

Inlet
Exhaust
Inlet& Exhaust

0 . 5 - I . 0m m
31.9 - 32.1mm
28.9 - 29.1mm
32" 45',55"

Cylindr,Pistons;
Cylinder insidediameter
Piston diameter
Piston/cylinderclearance
Oversize,pislon and rings
Piston ring/grooveclearance:

Piston ring thickness:

35 - 43 kPa(260 - 320 mmHg)

- 1O2.O12
102.0OO
mm
1O1.942 1O1.957
mm
0.043- O.070mm
+0.5mm
Top
Second
Top
Second
Top
Second
Top
Second
oil

0.03 - 0.07mm
0.02 - 0.06mm
0.97 - 0.99mm
1 . 1 7- 1 . 1 9m m
1.02 - 1.04mm
1.21 - '|'.23mm
0.3 - 0.4 mm
0.40 - 0.55mm
0.3 - 0.9 mm

0.5 mm
O.05mmTIR
6.95mm
6.94mm
7.08mm
O.27mm
0.30mm
36.2mm
40.7mm

102.10
mm
101.79
mm
_--O.17mm
0.16mm
0.90mm
1. 1 0m m
t,tzmm

1 . 3 1m m
0.7mm
0-9mm
1 . 2m m

ENGINETOP END +7
Cam Height Measurement

Valve Stem Bcnd

ValYe Head

stem

/n

ter

\y H

Valve head
thickness

--

u
--------

'

/ll
A

-\

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

HexagondWrendr: 57001-1210

valve ssat cuttsr 45'+35! 57001'1116

valye SatCuttel 3:le{35: 57@1-1121
valye satcutter 32"4il'35t 57001'1122
VdlvsSeatCutter55".035: 57001-1247

Sealant

(q(qKor((J
\7

\'

\.7

ValveGuideReamer:57001'162

\7

Kswa$ki Bond (Silicone Ssalantl: 56019{20

CamHeight

48 ENGINE TOP END

CleanAir System(US and Switertand models)
Air Suction Valve lnspection
avisually
inspect
thereeds
forcracks,
folds,warps,
hear

Vacuum Switch Valve Operation

1. DuringCruising(OpenThrottle)

damage,or other damage.

*lf there is any doubt as to the condition of the reed,
replacethe air suctionvalveasan assembly.

A. ValveHolder

2. DuringEngineBraking
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 foreignparticleshaveaccumulated between the reed and the reed contact area.wash
the valveassemblycleanwith high flash-pointsolvent.

oDo not scrape off the depositswidt a scraper as this

could damagthe rubbei, requiring replacementof the
sudion valYeassembly.

HighVacuum
Secondary
air cannotflow,
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

oRelease
the stopperandpushinto the rod.

A. MountingBolts
B. Spring

C. CopperWasher
D. CapBolt
A. PushRod
B. Stopper

C. Push
D. Pushintotherod.

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

push rod does not relum to i$ original pGition once it
moys orrt to take uP cam drairi slack. Obslvs 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 delcribd 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 Yalvs.

lnstullation
.lnstallation is tie reverseof removal. Note the followin&
olnstallthe tensionerbodywith the arrowon it pointing
upwards.

1 . Gasket
2. ChainTensioner

5.
4

CapBolt
Stopper

'I.10 ENGINETOP END

oTightenthe tensionermountingbolts to the specified
torque(seeExplodedView).
oTighten the cap bolt to the specifiedtorque (see
Exploded
View).

lnsbllation
.Note thefollowin&
oReplace
the capgasketwith a newone.
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

.Take out the oil filter springsand oil filters if neces-

.Removethe oil pipebanjo bolt.

aRemovethe water pipe.
rRemove t]te camshaft chain tensioner (see Camshaft
ChainTensionerRemoval).

s:rry.

A. Springs

B. Oil Filters

A. RockerCase
B. WaterPipe

C. Oil PipeBanioBolt

ENGINE TOP END +11

aRemovethe rockercaseboltsand nuts.
.Using the pry points,take lhe rockercaseout of the
cylinderhead.

lnstallation
.Notethefollowin&
on each
olnstallthe rockerarmsand retainersprings
rockershaftasshown.

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

aRemovethe rockershaftsandtakethe rockerarmsout

of tlle rocker case.

NOTE
oThe camdlaft chain tunnd side exhaustrocker am, is
differcnt from the othe6.

A. RockerArms
B. RockerShafts

oBeforeinstallingthe rockershaft, be surethe O-rings

arein place.
oTightenthe rockershafu to the specifiedtorque (see
ExplodedView).
oApply siliconesealantto the mating surfaceof the
oil sea.
rockercaseandthe camshaft
oApply engineoil to the both sidesof rockercaseNut
Washers.
oFit the rockercaseto the cylinderheadwhile holding
up the lashadjusterendof the rockerarms,
oTighten the rocker casebolts and nuts temporarily
following the ti8hteningsequence,and then torque
torque.
themto the specifid

C. DifferentRockerArm

A. 012mm Nuts
B- 08 mm Bolts
.Take out the oil filtersif necessary
oRemove the tash adiuster it necesary (see HLA
Removal).

C. d6 mm Bolts
D. Numberof Tightening
Sequence

oAfter installingthe rocker case,fill the oil chamber

oil.
with engine

+12 ENGINETOP END

A. Apply engineoil.

B. Oil ChamberArea

oReplacethe oil pipe banio bolt copperwasherswith

new ones, and tighten to the specifiedtorque (see
ExplodedView).
oReplacethe rockercasecapgasketwith a newone.

l. HLA Body
2. O-ring
3. Spring(Plunger)

4. Plunger
5. SteelBall
6. Spring(Ball)

oFill a rocker arm with engineoil and then insertt}|e

HLA into the rockerarm.

HLA (Hydraulic LashAdjuster)

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

A. RockerArm

A. RockerArm

B.HLA

B.HLA

rmflml
oBe caretul not to damagEor deform a lash adluster by
tapping it during remoyalor installation.
oDo not drop th lash adiuster or hit it sharply. lf it
is damaged, the plunger will not operate smoothly.

HLA,Air Bleeding
.Fill a container
withengine
oil.

.Preparea pin and cut the needleof it to 2.1 - 2.3 mm

length. Grind the cutting edgeof the needleto smooth
it.
.Push in the steelball of the HLA with the needleof the
pin and move the plungerup and down in the oil bath.

HLA lnstallation
aNote the following.
-Check tlEt the HLA plunger is not damaged.
*If the plunger does damage, replace the HLA.

oDo not push ir the steelb;ll more than 2.1 - 2.3 mm,
Over.stroke of the steel ball may cause the damage of
the H LA.

ENGINETOP END 4-13

q ? )

ffi"2
1. Cut and grind the needle.
2. 2,"1- 2.3 nm

3. HLA
4. Pin

A. FrontCamshaft
B. RearCamshaft

C. Groove

lnspection

oApply cleanengineoil to all cam parts and iournals.

oFit the KACR Unit on to the camshaft.

aRemovethe rockerarm.
.Pull the HLA out of therockerarm.
ePressthe plungerof the HLA with your fingers.
*lf the plungeris into the HLA body, repeatthe air
bleedingoperationandthenpressth plungerflf the plungeris into the HLA bodyagain,replacethe
HLA.

FrontCylinder
oPositionthe crankshaftat front cylinderpistonTDC.

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
B. Camshaft

C. KACR

lnstal lation (Including Chain Timing Procedure)

.Note the following.
oThe front and rear camshafts
are different. The rear
camshafthasa groove.

1 . TimingMarks
2. F mark

+14 ENGINETOP END

RearCylinder
ocheck the camshaftchain timing for the front cylinder.
. Tum drccrankshaftcounterdockwis310"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
B. RearCamshaftSprocket

oEngage
the camshaftchainsprocketwith the camshaft
chainasshown.

C. F Mark
D. R Mark

oApply a non-permanent
lockingagntto the camshaf!
sprocketboltsandtightenthemto the specifiedtorque
(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

remoyd,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 cylinderheadandrockercaseassmbly.
Camchaft,Roc*et CaseClearance
0.020- 01162mn
standard:
SerYicsLimit:

0.15 mm

Camshaft Chain Wear

.Hold thechaintaut with a forceof about5 kgin some
a 2o-linklength.Sincethechain
manner,
andmeasure
at sveral
may wear unevenly,tak measurements

A. Camshaft

B. KACRUnit

Installation
asshown.
.Fit theKACRUnitontothecamshaft

olacs.
*lf any measurement
exceedsthe srvicelimit, replace
the chain.
CamshaftChain20{ink LerEdl
Standald:

SorvicaLimit:

127.A-lttAmm
128.9mm

A. Pin
B, Notch

C. KACRUnit
D. Camshaft

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

ir.
1. 2o-linkLength

KACR
(KawasakiAutomaticCompressionReleae)
Removal
aRemove
tie 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
throttlefully open until the compression
gaugestops
rising;the compression
is fhe highestreadingobtainable.

CrylinderHead
Cylinda CompressionMeasurcment

Cylinder Comprgsion Prssuro Ugable Range:

Front Cylinder:
345 - 590 kPa (3.5 - 6 kg/cmr, 50
- 85 psi) @gn r/min (rpm)

NOTE
O Use the battery which is fully charged.

Rear Cylind.:

OWarm up the engine thoroughly.

aStop the engine.

aRemoveone sparkplug and attachthe compression

gaugeand adapterfirmlyintothe sparkplug hole. Do
not removethe othersparkplug,onlythe plug lead.
aFor the othercylinder,removebothsparkplugs.
Special Tools -

6&5 - 1O8OkPa (7.O - 11 l<g/crn2,

110 - 156 psi) @300 r/min (rpm)

gaugeadapter:57001-1183 can also

oThe compression
be used.
aFepeatthe measurement
for theothercvlinoer.
NOTE

Spark Plug Wrench, Her( 18:

57qn -1024
Compreseion Gauget 57OO1-2,j21
Comprssion caug Adapter,
Ml2 x 1.25:5r0ot-1018

olf the engine is well broken in. the crcnking speed may
become fastet shutting down the decompressor. This
can raise the ftont cylinder comprcssion pre\ture near
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 damrange
agedvalvestem oil seal and/or damagedpiston

Remedy(Action)
Removethe carbondepositsand repracr
damaged parts if necessary.

oil dngs (This may be indicaredby white exhaust

smoke).

Cylindercompression
is lower than usable
range

Inconectcvlinderhead gasketthickness.

Replacethe gasketwith a standard

Dan,

Damagedor missing compressionreleasecam spring

Feplace the sp ng.

Compressionreleaseweights do not movesmooth-

Replacethe compressionreleaseunit.

Gasleakagearound cylinder head

Replacedamagedgasketand check
cylinder head warp.

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

ring grooves.

Replacethe piston and/or the piston

flngs.

Compressionreleaseweights do not movesmoothlv.

Replace
the compression
relase
unit.

oTake the cylinder headoff the cylinder.

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

Remoml
rRemovetlle following.
chapter)
Engine(seeEngineRemoval/lnstallation
RockerCass
Camshafu
Carburetors(seeFuel chapter)
Oil Pipe

NOTE
ogefore insbllitv {re spark plug rcaineL pull dre
camdraftchainup the drain firnnet.

A. Camshaft
Chain

A. Oil Pipe
B. Bolt

C. Carburetor

SparkPlug
SparkPlugRetainer
(Usinga Hexagonal
Wrench:57001-'1210)
CylinderHeadLowerNuts (FrontandRear)

B. Retainer

oTightentJ|esparkplugretainerto tie specifiedtorque.

oTightenthe sparkplugto the specifidtorque.
olnstallthe camshaft.
olnsall tie rockercase.
oTightentl|e sylinderheadlowernutstemporarily.
NOTE'
oTorque dte cylin&r had and cylinder had lower nuts
to the s,ecified torque (w Exploded Vimt) after
rtghEning the rocks c* bolts and nu's to the spe-'
cifid toque.

Valves

VaI ve Clean nce Adju stntent

NOTE
A. SparkPlug
C. CylinderHeadLowerNut
B. SparkPlugRetainer

osine the hydnuli; !a* adju$eB constdrtly maintuin

to inqect or adiust
Ero cleannce. h is not nesry
the vdw clannce.

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ENGINE TOP END +17

Valve Removal

Valve Guide Removal

oPerformthe following.
oUsing ihe valvespring compressorassemblyand adapter
(specialtools),removethe valve.

rPerformthe following.
ousing the valveguidearbor (specialtool), tap out the
valveguide.

'1.

ValveSpringCompressor
Assembly:57001-241
2. AdaDter: 57001-242

Valve lnstallation
oBecarefulof the following.
oApply a thin coat of molybdenumdisulfidegreaseto
the valvestembeforevalveinstallation.
olnstall the springsso that the closedcoil end faces
downwards.

1. ValveStem
2. SpringSeats
3. Oil Seal
4. InnerSpring
5. OuterSpring

6.
7.
8.
9.

1. ValveGuideArbor:57001-163

Vatve Guide tnsallation

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.

Retainer
Spring Seat
ClosedCoil End
Split Keepers

i . ValveGuideReamer:57001-162

4.18 ENGINE TOP END

ValveFace Contact lnspection
rCheckthevalvefaceseating
width.
surface
ousea vrniercaliperto measure
theseatwidth(white
portion)of the valvefacewherethereis no carbon
build-up.
*lf thevalvefaceseating
surface
widthis notwithinthe
specified
range,
replace
thevalvewitha newone.

*lf the valve seating surface width is not within the

specifiedrange,repair the valve seat.

Valve*at Ouaide Diameter

.lf the outsidediameterof the seatingpatternon the
valveseatis too largeor too small,repairthe valveseat.

1. Good

2. Too wide

3. Too narrow

4. Uneven

V.lve SeatingSurfacsOutsids Diameter

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

Valve *at Widh lnspection

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.

1 . Valve
2. ValveSat
SeatingSurfaceOutsideDiamter
4. SeatingSurfaceWidth

vahe SsatCutters
45' - 035 57q11-1116
lnlet Valv3:
32' - 03S.s570{J1-112t2
55' - C35 57001-1247
Exhawt ValYss: 45" - Cas 57001-1116
:t2' - c35 57001.1121
55' - C35 570'J1-1147
Holder and Bal
Holder:

Br::

ValyeSeatingSurfaceWidth (lN and EXI

Standad: 05 - llt mm

57001.1126
570iJ1-11?

*lf the manufacturr's

instructionsarenot available.
use
the followingprocedure.

ENGINETOP END +19

SatCut@rOperatingCals:
'1.
This valve seatcutter must not be used for other
purposes
thanseatrepair.
2. Do not drop or strikethe valveseatcutter,or the diamondparticlesmayfall 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
much force to the diamond Dortion.

1 . OuterDiameterof
Angleof Cutter
3. Cutter

NOTE
oPrior to ginding, apply engine oil to the cutter and
during the operation, wa$ off atry ground particl$
stickingto the cutter with vvadtingoil.

OporatingProcedures:
.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.

1 . Cutter

2. CutterHolder
5-

Bar

) . After use,washit with washingoil and applya thin

layerof engineoil beforestoring.

MarkrStampedon the Cuttel:

The marks stampedon the back of the cutter representthe following.
45" . . . . . .Cutterangle
24.56 - . , . .Outerdiameterof cutter

.Measurethe outside diameterof the seatingsurface

with a verniercaliper.
rlf the outsidediameterof the seatingsurfacis too
is within
small,repeatthe 45" grinduntil thediameter
the specifiedrange.
*lf the outsidediameterof the seatingsurfaceis too
below.
large,makethe 32" grinddescribed
rlf the outsidediameterof the seatingsurfaceis within
the seatwidth asdescribed
the specifiedrange,measure
below.Grind the seat at a 32o angleuntil the seatO.D. is
within the specifiedrange.
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.

oThe 32" Gutter rcmoyes material very quickly. Check

the seat outside diameter frequently to prevent overgrinding.

+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 engagement
by machiningwirh
45- cutter
2. Groundvolumeby 32" cuttnr
3. Groundvolumeby 55ocutter
4. 32"
5.5s'
1. Lapper
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
at severalplacesaroundthe seat.
*lf the seatwidth is too narrow,repeatthe 45" grind
until the seatis slightlytoo wide,and then returnto
the seatO.D.measurement
steDabove.
*lf tlre seatwidth is too wide, maket}re 55o grinddescribedbelow.
.Grind tie seatat a 55o angleuntil the seatwidth is
within the specifiedrange.
OTo makethe 55'grind, fit 55'cutter to the holder,and
slideit intothevalveguide.
oTurnthe holder,whilepressing
down lightly.
oAfter markingthe 55" grind,return to the seatwidth
measurement
stepabove.
.L:p the valveto the seat,oncethe seatwidth andO.D.
arewithin the ranges
specifiedabove.
oPut a little coarsegrindingcompoundon the faceof
the valypin a numberof placesaroundthe valvehead.
ospin th9 valveagainstthe seatuntil the grindingcompoun4/producesa smooth,matchedsurfaceon both
the slt andthe valve.
oRepeAtthe processwith a fihe grinding compound.
.The seatingareashouldbe markedabout in the middle
of the valveface*lf the seatareais not in the right placeon the valve,
checkto be zurethe valveis the correctpart. lf it is,it
mayhavebeenrefacedtoo much:reDlaceit.

3. Valve

Measuring Valve-to-Guide Clearance

(Wobble Method)
lf a smallboregaugeis not available,
inspectthe valve
guide wear by measuringthe valve to valve guide
clearancewith the wobblemethod,as indicatedbelow.
.lnsrt a new valve into the guideandseta dial gauge
againstthe stemperpendicular
to it ascloseaspossible
to the cylindrheadmatingsurface,
aMovbthe stem back and forth to measure
valve/valve
guideclearance.
.Repeatthe measurement
in a directionat a right angle
to the first.
*lf the readingexcedsthe servicelimit, replacethe
guide.

NOTE
aThe ruding is not etual valve/valve guide clearance
becaue the measrring point is above the guide.

Valve/Valve Guide Clearance

(Wobble Method)
Inlet
Exhaust

Standard
0.(F - 0.12 mm
0,08 - 0.16mm

ServiceLimit
O27 mm
o.ql mm

ENGINETOP END 4.21

A. WaterHoles

New Valve [A]

ValveGuide [B]

Move the Valve [c]

oPositionthe crankshaftat TDC.

oApply engineoil to the cylinder bore,pistonring,and
pistonskirt.
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

C. F Mark
A. Front Cylinder
D. R Mark
B. RearCylinder
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
B. CylinderNut

C. CamshaftChainGuide

.Remove
thecylindernuts.
oTakethecvlinderoff thecrankcase.

Cylinder lnstallation
oNotethe following.
oReplacethe cylinder basegasketwith a new one, and
engagethe gasketswith the crankcasewater holes.

A. Camshaft
ChainGuides C. R Mark
B. F Mark

4'2 ENGINETOP END

OTightenthe cylindernutstemporarily.
NOTE
oToryue the cylinder nuts to the specification (see
ExplodedView) after tightening the rccker casebola"
and nutsto the speciliedtoque.

aThe pistonringopeningsmustbe positionedasshown

in thefigure.Theopenings
oflhe oil ringsteelrailsmust
beabout30 - 45'olangle fromtheopeningofthetop
nng,

Front

30'-\45'

30'-4s'

o\aulo

Piston Removal
a Remove
the cylinderblockoPlacea cleancloth underthe pistonsand removethe
pistonpin snapringsfromthe outsideof eachDiston.
ousing the piston pin puller assembly(speciattool),
removethe pistonDins.

vv

Top Rins [A]

SecondRing [B]
Oil RingSteelRails[Cj

@@
Oil Ring Expander[D]
Anow [E]

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

1. PistonPin PullerAssembly:57001-910
2. Adapter

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
Ospread the rail with your thumbs, but only enough to
fit the rail owr the Distono 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
dforms them.
Thgy could fall out and score th
cylindor wall.

Frofi

aDo not mix up the top ringandsecondring.

alnstallthe secondring [A] so thatthe "RN" markfaces
up.
alnstallthe top ring [B] so thatthe "R" markfacesuD.

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 oiamter

Standard:
Servic Limit:

102.000- 102.012mm
102.10mm

Piston Ring End Gap

PistonWear
aMeasure the pislon outsidediameter5 mm up from the
bottom of the piston at a right angle to the direction of
the piston pin.
PistonOutsida Diameter
Standard:
Servic Limit:

1. ThicknessGauge

101 .!t42 - 101 .957 mln

101.79mm

a Place the piston ring inside the cylinder. using the

piston to locate the ing squarelyin place. Set it close
to the bottom of the cylinder, where cylinder wear is
aMeasure the gap between the ends of the ring with a
thicknessgauge.

Piston Ring End Gap

Standard
Top
0.3 - 0.4 mm
o.t|o - 0,55 mm
Second
0.3 - 0.9 mm
Oil

Service Limit
0.7 mm
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
seatingJrThe 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
0,03 - 0.07mm
Top
0.O2- 0.0mm
Second

Service Limit
0 . 1 7m m
O.16mm

1.Gap

2. Piston Ring

+24 ENGINETOP END

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

A, Front Muffler Cover

A. Holders
B. Nuts

C. ExhaustPipeCover

A. PowerChamber
B. RH MountingBolt

C. Clamp Bolt

B. Screws

MufflerClampBolts(Loosen)
MufflerBracketBolt
MufflerAssembly

.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
B. BracketBolt

C. ClampBolt

Front ExhaustPipeCover

aRemovethe front exhaustpipe holdernutsand loosen

the exhaustpipe clampbolt.

A. Exhaust
Pipe
B- Holder
C. Nuts

D. ClampBolr
E. PowerChamber
F. MountingBolt

ENGINETOP END +25

.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.

oFit the rearexhaustpipeupperendwhilesupporting

the powerchamber.
oscrewthe powerchambermountingboltstemporarily.
olnstallthe rearexhaustpipeholderswhilepullingthe
exhaustpipetowardtheoutside.

lnstallation
.Prformthefollowing.
oReplace
gaskets
with newones.
theexhaust

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.

A. Holders

B. HolderNuts

.Removethe left sidemufflerbracketbolt. andtakethe

mufflerout of the frame.

A. BracketBolt

1 : Attachthe clamps.

.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 bracketboltolnstalltl|e clampsA to tl|e frame.
oTightenthe boltsof tie clampsA.
oTlghtenthe bolt of tl|e clampB.

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
erp
2 . Primary
cup
3. Secondary
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, Stol Plaie
19. Spring Plate
20. Spring (Back Torque Limiterl
21. Cluch Spring

ExplodedView

u.

Holdel

23. Operating Plane

24. Rst iner Ring

-o"
".*t:

L : Apply nonfermanentlockingaqem.
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 }

'l&ub'

CLUTCH 5.3
Specifications
Item
RecommendedClutch Fluid :
Grade
Brand

Slandard

D.O.T.4
CastrolGirling-Universal
CastrolGT (LMA)
CastrolDiscBrakeFluid
CheckShockPremiumHeavyDuty

Clutch :
Clutchleverplay
Clutchspringtree height
clearance
Springplate/pusher
play
plate
Spring
free
Frictionplatethickness
Frictionandsteelplatewarp

Type
4.7mm
0.05 - 0.25mm
0.30 - '1.30mm (Usablerange)
3.3- 3.5mm
Lessthan0.2 mm

PrimaryReduclion:
housinggearbacklash
Primarygear/clutch

0 . 0 3- 0 . 1 0m m

SpecialTool

Baaring Driver Sgt: 57001-1129

ServiceLimit

4.4mm

3 . 1m m
0.3mm
0 . 1 4m m

54 CLUTCH
clutch Fluid changing

Clutch Fluid
Fluid Level Inspection
.Checktheclutchfluid levelin thereservoir.

A. LowerLevelLine

.Remove the LH engine cover (seeCrankshaft/Transmission).

aRemove the reservoir cap, and remove the rubber cap
on the bleedvalve.
.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.

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.
After changing the fluid, use only tte same type and
brand of fluid tfiereafter. Mixing diffelent types and
brandr of lluid loweB the fluid boiling point and could
causo the clutch to & ineffectiye. lt may abo cau3e
the rubb4 clutch parE to dete orate.

1.
2.
3.
4.

RecommendedClutch Fluid

oRepeat this operation until fresh fluid comesout from

the plastic hoseor the color of the fluid changes.
ocheck the fluid level in the reservoiroften, replenishing
it as necessary.

Grade:
B:rnd;

D.O.T.4 Heayy Duty Brake Fluid

CastrolGirling-Unirersal
Castrol GT (LMA)
Castrol Disc Brake Fluid
Check Shock Premium Heary Duty

NOTE
osince the clutd, fluid is dre sme as the bnke fluid.
refer to Bnke Fluid Section in Brckes for further
debils.

ODenthe bleed valve

Pumpthe clutch leverand hold ir.
Closethe bleed valve.
Releasethe clutch lever.

NOTE
otf the fluid in the re&rvoir runs completely .out any
time during fluid changing, the bleeding operction must
be dohe over again from the beginning since air will
have entered the line.

I'_WARN|NG
I
oDo not mix two brandsof fluid.

cLuTcH $5
Bleeding dle Clutch Line
tWith the reservoir
capoff, slowlypumpthe clutchlever
severaltimesuntil no air bubblescan be seenrisingup
throughthe fluid from the holesat the bottom of the
reservoir.This bleedsthe air from the mastercylinder
eid of the line.
NOTE
oTap the cluth he lightly going from the lower end
to the uppcrendand bteedthe air off at the resvoir.
.Attach a clearplastichoseto the bleedvalveon the
clutch slavecylinder,andrun the otherendof the hose
into a container.
.Bleedtheclutchlineasfollows:

MasterCylinder
lnsallation
.Wheninstalling
the clutchmastercylinder,be careful
of following.
oThe master cylinder clamp must be installed with the
rearview mirror holder.
oTighten the upper clamp bolt first, and then the lower
clamp bolt to the specified torque (see Exploded
View).

l . Tightenupperclampbolt first. 3. Clearance

2. LowerClamoBolt

1. Pumpthe clutch levera few times until it becomes

hardandthenhold it squeezed.
2. Quicklyopenandclosethe bleedvalve.
3. Release
theclutchlever.

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
Checkfor clutchoperation
Checkfor fluid leakage

ocheckthefluid levelin the reservoir

often, replenishing
it asnecessary.
NOTE
olf the fluid in the rcservoir runs completely out arry
time duing bleeding,the bleding opention must be
done overagainfrom the beginningsinceair will have
entercdthe lineoRepeatthisoperationuntil freshclutchfluid comesout
from theplastichoseor the colorof the fluid changes.

I wARNtNc
I

-E

oDo not mix two brandsof fluid.

Disassembly
oRemovethe following.
ClutchLever
DustCover
Circlip
Cup,PrimaryCup
.PistonandSecondary
Spring

NOTE
oDo not removethe seondary cup from the pkton.

5 CLUTCH

1. PrimaryCup
2. Secondary
Cup

3. Piston
4. Circlip

Assembly
.Clean th disassembled
parts with clutch fluid and
apply clutch fluid to the inner wall of the cylinder.

A. SlaveCylinder
B. MountingBolts

C. BanioBolt

oRemovetie baniobolt and ftee the cylinderfrom the

nose.
.Performtl|e followingif the clutch slavecylinderis to
be removedbut not disassembled.

olf ths alutdr slavecylinder i3 lemovedand left alone,

rhe pitton will be purhed out by drs lpring and dre
dutah fluadwill drain out.
oTske cre not to scratch the piston or $e inner wall ot
the cyllnder.

lnspection
acheck the followingfor wear,damage,cracks,or deterioration:
CylinderInnerWatlandPiston
PrimaryandSecondary
Cups
DustCover
Spring
.Check that the relief and supplypons on the cylinder
arenot plugged.

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.
NOTE
oHoldingthe clutch levil kpsthe pifion from aming
out.

olmmediatelywips up any brakefluid $at spilb.

maydamagEpaintedor plated 3urfaces.

lnstallation

ClutchSlaveCylinder
Remoml
.Performthe followingif the clutchslavecylinderis
to bedisassembled.
oLoosenthe clutch hosebanjo bolt on the clutch slave
cylinder.
oRemovtie mounting bolts and take off the clutch
slavecylinder.

.Note the following.

oReplacethe aluminumwasherson eachside of the
clutchhosefitting witi newones.
oTighten the banio bolt to the specifiedtorque (see
Exploded
View).
oReplacethe spacerof the clutch slavecylinder with
nelvone,
oApply non-permanentlocking agent to the slave
cylindermountingbolts.
check the fluid levelin tl|e mastercylinderreservoir,
andbleedthe air in tlre clutchline.
ocheckthe clutchoDeration.

cLuTcH $7
Disassembly
allowthe
oLeavingtie clutchslavecylinderremoved,
pistonto moveslowlyout underspringpressure.

Asembly
.Do the following.
oApply clutch fluid to the outsideof the pistonandthe
fluid sal.
olnstallthe fluid sealasshownin tlte figure.

A. OperatingPlate

B. Retainer

.Unscrewthe clutrh hub nut by usingthe air impact

wrench.

l . Cylinder

2. Piston

3. FluidSeal
4.spring

tt-"-."".-,,"4
cAUTt0l{
|
oFeplaca tte fluid lsal with a new one if it wa! remoYad
from ths pistoB,

A. HubNut
.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 (seeCrankshaftflransmissionchapter).
aRemovethe retainerand take the operatingCate out
of the clutchassembly.

D. LimiterSpring
A. SpringPlate
Platrs
E. Friction/Steel
B. ClurchSpring
C. ClutchSpringHolder F. OuterHub

5 CLUTCH
.Take the innerhub, collar, washerand cluth housing
out of the crankcase.

A, lnnerHub
B. Collar

lnstallation
aclutch installationis the reverseof removal. Notethe
following
owhen replacingany one of the following parts,adjust
the spring plate free play (seeClutch Plate Replacement).
SpringPlate
Friction Plate
SteelPlate
owhen installingthe clutch housing,meshtle oil pump
drive gearwith the oil pump gearso that the pumpgear
rns.

C. Washer
D. ClutchHousing

.Pull the nedlebearing,sleeve,and thrust washeroff

the drive$aft-

A. PumpDriveGear

A. NeedleBearing
B. Sleev

C. Washer

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.

O Installthe last friction plate in the shallow groove on the

housing as shown.

1. Oprating
Plate
2. SpringHolder
3. ClutchSpring

.A
6-M.

@so
4.
5.
6.
7.

BackTorqueLimitrr Springs
Clutrh SpringPlate
Outer Hub
lnner Hub

A. LastFrictionPlate

CLUTCH 5-9
oApply greaseto the back torque limiter springsand
attachthemasshown.

1. LimiterSprings

Clutch lnner Hub Disasembly/Assembly

.Using a pressand suitablebearingdriver (special
springs.
ool), compress
thedamper

2. SpringHolder

oTighten the clutch hub nut to the specifiedtorque

holdingthe primarygearbolt (seeExplodedView).

C. BearingDriver: 57001-1129
A. Press
B. DamperSpring D. Retainer

aRemovethe retainer,dampersprings,and dampercam.

A. HubNut

B. PrimaryGearBolt

.Squeezethe clutchleverslowlyandhold it with a band

whilepushthe springplatepusherinto the clutchhub.

A. Pusher

B. Pushin

1. Retainer
2. SpringHolder
3. DamperSpring
4. SpringHolder

5. Spacer
6. DamperCam
7. lnnerHub

$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

SpringPlateFreePlay
UsableRange: 0.30- 1.30mm

hop. On the other hand, if the free play is excessive,the

clutch lever may fel "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.

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)
1.6
2.O
2.3

Part Name
13089n080
13089-1075
130891081

NOTE
olf new f ctionplatasare installed,apply engine oil to
the sufiaces of each plate.
1. Holder
2. Clutch Spring

4. Operating Plate
5. Spring Plare

3. BackTorque Limiter Springs 5. Drive Shaft

aunscrew the hub nut, then take *re holder, operating
plate, and the dutch spring out of the housing.
aReinstall ttrc holder and tighten tlle hub nut lightly.
aTo measure the free play, set the dial gauge "O" against
the clutch spring plate.
aTurn the dutci housing back ard forth . The difference
between the highest and lowest gauge readings is the

Frictionand Steel Plate Damage,Wear

avisually inspect the ftiction and steel plates for signs of
seizure,overheating (discoloration), or uneven wear.
aMeasure the thickness of the friction Dlates at several
POlnts.
*If any plates show signs of damage,or if they have wom
past the service limit, measure the spring plate free
play a.ndadjust it if necessary.

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.

1. Turn back and forth.

2. Up and Down.

Frictionand Steel PlateWarp

Standard:
less than 0.2 mm
ServiceLimit : 0.3 mm

CLUTCH $11
Cam Damper lnspection
rVisuallyinspectthedampercam,damperspring,and
cam follower.
*Replace any damagedparts.

1. Frictionor SteelPlate
2. Thickness
Gauge

3. SurfacePlate

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:
SerYiceLimit:

1. ClutchHousingFinger

4.7 mm
4.4 mm

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

1. ClurchHubSpline

2. SteelPlateTeeth

2. SpringHeight

ENGINELUBRICATIONSYSTEMS1

EngineLubrication$ptem
Tableof Gontents
ExolodedView
EngineOil Flow Chart.
ar-^^:a:^r:^-^

oPtrrrruaLrurrr

SpecialTools.
S e a l a n. .t . . .
EngineOil and Oil Filter.
Oil LevelInsoection
EngineOil Change..
Oil Filter Change
Oil PumpScreenCleaning.
Oil Pump.
Removal
lnstallation
Oil Pipes
Removal
lnstallation

Measrrement
Oil Pressure
Oil Pressure
Measurement

6-2
64
6-6
G6

a6
6-7
6-7
6-7
6-7
6
6
6
6-9
6-9
G9
6-10
6-10
&10

S2 ENGINELUBRICATIONSYSTEM
Exploded Viarv

-@

1*

,ar@

1, Rocker Care.(F?ontl

2.
3.
4.
5.
6.
7.
8.
9.

Baniobolt
Oil Pipe
Rodter Ca!(Rearl
&sa&er Pl96 (LEftl
Filtel
BreadlorPipes(Righl
Cr8nkcase
Haff (Loftl
CraDkcalstlalf (Righrl
to. Oil Pm:sureSruitdr
1 1 . Oil Pr$urGRdief Valy
12. Oil Rrmp
13. Oil Filter Mounting Bolt
14. Oil Filtsl
15. Oil ScrenPlug
16. Oil Scroon
1 7 . Oil Pipe(hside Lsftl
18. Oil PiF (lnride Rightt
1 9 . EndneDrain Plug
m. Oil Nozzls

To R.H.: Grankcase
half

O : Apply engineoil to the gasket.

L : Apply non-pemanentlocking agentto the thrads.
SS: Apdy siliconesealentto flre threads.
Tl ; 29 Nrn (030 kgm, 20 in{bf
T2: 12 Nfl (12 kgrm,104in.lb)
T3: 15 Nrn (15 kgm, 11,0ft{bl
T4: 18 Nfl (14 kgn, 13.0ft{b}
T5: 20 Nrn (2.0kgfl,la5 ft.tbl
T6; 35 Nrn (35 kgrn,25 ft.lbl
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 BevelGearAssmbly
5. Oil Pipe(ln the cnnkcase)
6. Oil Pipe(ouside)
7. Oil Screen
8. Oil Pump
9. ReliefValve
Switch
10. Oil Pressure
11. Oil Filter
Valve
12. Bypass

66 ENGINELUBRICATIONSYSTEM
Specifications
Item
EngineOil:
Grade
Viscosity
Capacity

Oil Pressure
Measurement:
Oil presure@2,000r/min (rpml,
oil temp.l(X)"C(212'F)

Standard

SEor SFclass
SAE 10W40,101,50,2M40, or 20W50
2.5 L (whenfilter is not removedl
2.7 L (Whenfilter is reriroved)
3.5 L (Whenengineiscompletelydry)
345 - z14O
kPa(3.5 - 4.5 kg/cm",50 - 64 psi)

Special Tools
Oil Pressure
Gauge,5
kg/cm,:57001-125

Oil Filtar Wrcndr: 57m1-1249

e
Oil ftsssureGauge
AdaFter:57001-10*t
KawasakiBond (SiliconeSealaml: 56019-120

ENGINE LUBRICATION SYSTEM 6.7

EngineOil and Oil Filter

EngineOil Change
perpendicular
aset the motorcycle
to the groundafter
uptheengine.
warming
.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.
and lowerle{el
.\ linesin the

A. Drain Plug

A. UpperLevel
B. LowerLevel

C. Oil FillerCap
D. Oil LevelGauge

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).
oTightenthe oil screenplug to the specifiedtorque (see
ExplodedView).
.Pour in the specifiedtype and amountof oil.

NOTE
olf the motorcycle has just beal u*d, wait svenl
minut* for all the oil to dnin down.
olf tne oil has just been changed, stan the mgine and
run it for several minutes at idle speed. This fills the oil
filter with oil.
Stop the engine, then wait several
minut$ until the oil seftles.

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
this light stays on when the engine is running above
idle speed, stop the engine immediately and find fie
Gaus.

EngineOil
Grade:
SE or SF class
Viscosity: SAE 10W40, 10W50,20W40, or 20W50
Amount: 35 L (engineis completely dry)
2.7 L (filter is removedl
2.5 L (filter is not removed)

Oil Filter Change

.Drain the engineoil.
oRemovethe oil filter with an oil filter wrench (special
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
not dissfmbled).

in dre filter (Do

.When installing the oil filter, be careful of the

following.
oApplyoil to the gasketbeforeinstallation.
oTightenthe filter with the oil filter wrench(special
tool) to the specifiedtorque (seeExplodedView) or
tighten it with hand(s)about % turns after gasket
contactsmountingsurfaceof engine.
oPourin the specifiedtypeandamountof oil.

Oil Pump Screen Cleaning

.Removethe following.
Engine
Oil (Draining)
Oil Screen
Plug
Oil Screenwith Spring

.Cleanthe screen
with highflash-pointsolvent.
oCleanthe screenthoroughlywheneverthe engineoil is
changed.

NOTE
While cleaning the srnn, drek for any metal panicles
drat might indicate inten al etryine damage.

.Wheninstallingthe screen,becarefulof the following.

*Replacethe screenplug O-ring with new one if it is
damagd.
*Replacethe screenwith a new one if it is damaged
(holesandbrokenwires).
oBsureto put in ihe oil screenwith the rubbergasket
endinside.
oTighten the screenplug the specifiedtorque (see
Exploded
View).
oPourin thespecifiedtypeandamountof oil.

Oil Pump

Bemoval

A. Oil ScreenPlug

.Performthefollowing.
oRemovethe engine(seeEngineRemoval/lnstallation
chapter).
o5plit the crankcase(see Crankshaft/Transmission
chapter).
oRemovethe oil pump bolc, and take off the pump
out of the RH crankcase
half.

ENGINE LUBR]CATIONSYSTEMS9

A. OilPump

B. ReliefValve

oUnscrewthe reliefvalveif necessary.

oRemovetl|e circlip,and pull tie pumpgearout of the
crankcaseif necessary.

A. PumpShaftProiection C.O-rings
B. GearShaftSlot

oTighten ths pump bolts to the spcifiedtorque (see

ExplodedView).
oApply a non-permanent
lockingagentto the threadsof
the reliefvalve(seeExplodedView).

Oil Pipes
Remotnl
.Removetheoutside
oil pipes
asfollows.

A. Circlip
B. PumpShaft

C. Washer
D. PumpGear

Installation
.Note the following.
oNotthe positionof the oil pumpshaftprojectionand
turn the pump gearshaftso that t}te proiectionfits into
the slot.
oReplace
the O{ingswith newonesif they aredamaged.

A. Oil Pipe
.Remove the insideoil pipesfrom the inside.of the
halves.
crankcase
osplit the crankcdse(see Crankshaft/Transmission
chapter).

SlO ENGINE LUBRICAT]ON

SYSTEM
oReplacethe copperwasherson eachsideof the engine
outsidefitting5with newones.
oTightenth banio bolts to the specifiedtorque (see
ExplodedView).

A. Oil Pipe
B. MountingBolts

C- Holder
D. RH CrankcaseHalf

Oil Pressure
Measurement
OiI Presure Measurement
NOTE
oMaetre the oil praJe

A. Oil Pipe
B. MountingBolts

C. Holder
D. LH Crankcase
Half

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
tools)to the switchhole.

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

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

A. Oil Pipe
B. Fitting

C. Oring

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 tmp.

*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
SpecialTools.

7'2
7'2

.
EngineRemoval/lnstallation
Removal
lnstallation

73
73
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
7. EngineMountingBolt (From)
8. EngineMountingBolr (Rearl
T1 ; 24 N+n (2.4kgFm,17.5ftlb)
T2: 44 N{t (4.5kgm,3:t ft{b}

*'t%*".r
, *^^'g

/,'

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
Air CleanerHousing(seeFuel Systemchapter)
Horn
Radiator(secooling Systemchapter)
Tank (seeCoolingSystemchapter)
CoolantReservoir
Footpeg(LH)
Left EngineCover
ClutchSlaveCylinder(seeClutchchapter)
shift Pedal
Muffler and Exhaust Pipes (see EngineTop End
chapter)
CleanAir Hoses
CoolingHose (LH: Pull t]1e hose out of the front
cylinder.)

A. FuelPump
B. CoolingHose

C. SurgeTank Duct
D. SurgeTank

lgnitionSwitch
CoolantReservoir
Tank Bracket
CleanAir Hose(RearCylinder)
lgnitionCoil Assembly(moveit on the frame)

74 ENGINEREMOVAUINSTALLATION
Alternatorand PickupCoil WireConnectors
GroundWireTerminal

A. lgnitionSwitch
B. CleanAir Hose

C. lgnitionCoil Assembly

StarterMotor WireTerminal

A. AlternatorWireConnectors
B. PickupWireConnector
C. GroundWireTerminal

Throttle CableAdjuster

A. StarterMotor

B. Terminal

Oil Pressure
SwitchWireTerminal
NeutralSwitchWireTerminal

A. Throttle Cables

B. Ad.iusters

Carburetor
VacuumHose(BothSide)
RearBrakeLight SwitchWireConnectors

A. Oil Pressure
Switch

B. NeutralSwitch

oPerformthe following.
osupport the enginewith a suitablestand,and remove
the enginemountingboltsandbncket bolts.

ENGINE REMOVAL/INSTALLATION7

C. FrameMountingBolts
A. Right DownTube
B. EngineMountingBolt

A. SuitableStand

oseparatethe right down tube, and move the dowir

tube toward the rear.

A. RightDownTube

B. Pull the hoses'

.Dis6onnctthe 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
B. RightDownTube
C. BracketBolts

D. EngineMounting Bolt
E. Frame Mounting Bolts

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
B. Spring

C. Pin

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. BattryGroundWire

B. Abut 30"

8-1
CRANKSHAFT/TRANSMISSION

Crankshatt/ Transmission
Tableof Gontents
*21

.....',..

Exploded View .

8'2

Specifications.

SpecialTools

8-7

R HB a l a n cW
e re i g hRt e m o v a. l. . . . . .
WeightRemoval.. . . . . . .
LH Balancer

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

::: il; E
::i:H::Hllilll.;::

Splitting.
Assembly.

&11

Replacement

&14

S t a r t eTr o r q u eL i m i t e.r .

& 21
&21
V22

&23

.'.'..

&15

B e m o v a. l

,,..

&23

Crankhaft lnstallation. . . . .

&15

Inspeqtion

....

&23

Connecting Rod Removal.

&15

Connecting Rod lnstallation

&15

Grankhaft/Con necting Rods.

ConnectingRod Big End Bearing

.

B a f a n c. e r

&16
. . .. .

8-17

PrimaG
r ye a r
R e m o v.a l
fnstallation.

M a i nJ o u r n aW
l ear.....

a-17

Cranlchaft SideClearance.' .

8.18
8-19

Right EngineCover

..

Transmission

8'23
&23

Removal.
lnstallation.

Insen/CrankpinWear. . . '
C r a n k h a fR
t u n o u t. . . . . . ' . . '
Crankhaft Main Bearing/

WaterPumpldle ShaftHolder.

...
.....'.

8'23
&24

,'..& 24
,. .
......

&24
&24

Removal.
,..
ExternalShift Mechanism
Installation..
ExternalShift Mechanism

8-25
&25
&26
g-27
V27

Removal .

&19

I nstallation.

8-19

Inspection. .
ExternalShift Mechanism
ShaftsRemoval.. . . . . . .
Transmission

8-19

,....
Transmission
Shaftslnstallation.

&19
&19

T r a n s m i s sDi oi sna s s e m b l y . ' . . . . . . . . 8 ' 2 7

8-27
T r a n s m i s s iAosns e m b l.y. . . . . , . ' . .

Removal .

&19

S h i f t D r u mR e m o v a, l

lnstallation.

a-20
&20

....
Slrift Drum Disassemblv/Assembly

Left EngineCover .
Installation.
StarterMotorclutch, . . . . .

Disassembly
Assembfy.

,...

& 2O

lnspection

,...

8-21

....

&29
8'29

8.2 CRANKSHAFT/TRANSMISSION
ExplodedViw

@9

t.
2.
3.
4.
5.
6.

ConnectingRod
LH BalancarGear
LH BalancalWsight
BalancerShaft
RH BalancrWeight
Clundl
'r. Oneway
Coupling
8 . Starter Mobr (Xutch Gear

Tl r 88 N<n (0.9kgn,78 in.lb|

T2: 15 N{n (15 kghm,11,0ftlbl
9. Starter Torque Limitel
T3: 21 N-rn(2.1kgFm,15.0ft lbl
1 0 . C|ankdraft
T4: 39 N{n (4Ok$m,29 ft lbl
1 1 . Baringlnsert
T5: 59 N{n (6.0kgn; /t:l ft lbl
12. ftimary Gear
13. lvater Pump Drive Sprodcet T6: 93 N<n (95 kg{n,69 ft.lbl
17; 1rt5N{n (15.0kg.m,110ft tbl
14. Bols M6
L : Apply nonfermanent locking agem.
15. Eolts tllS
O : Apply engineoil.
1 6 . Bols MlO

8-3
CRANKSHAFT/TRANSMISSION
L
2.
3.
4.
5.
6.
7.
8.

Ci.in (lrvalsrPumpl
ldh Shaft Sprodct (Al
Clrin Guide
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

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

L : Apply non{smansnt locking agsnt to ths tht8&.

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

@o

kq

84 CRANKSHAFT/TRANSMISSION

@
o

oo@

k@

*@*

wa@u
?

,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 EnginCoYel
L : Apply Ioc*ing agBnito d|e drreads.
Tt : 9, N-m (1.Okg-m,87in-lb)

8 CRANKSHAFT/TRANSMISSION
Specifications

Item

ServiceLimit

Standard

Crankshaft/Gonnecting Rods:
Connectingrod big end sideclearance
Connectingrod big end bearing
inserVcrankpinclearance
Crankpindiameter:
None
Marking

0.16- 0.216
mm

0.7mm

0.026- 0.057mm
54.981- 55.000mm
54.981- 54.991mm
54.992- 55.000mm
58.0fi) - 58.020mm
58.dD - 58.010mm
58.011-58.020mm

Connectingrod big end bore diameter:

None
Marking
Connectingrod big end bearing
Brown
insertthickness:
Black
Blue

0 . 1 0m m
54.97mm

- 1.2187
mm
1,2183
1.487- 1.491mm
- 1.495mm
1.2191

Connectingrod big end bearinginsertselection:

Con-rodBig End
CrankpinDiameter
BoreDiameter
Marking
Marking
None

Bearinglnsert
Size Color

PartNumber

Brown

92028-1476

Black

92024-1475

None

Blue

92028-1474

None

runout
Crankshaft

0.02mm

0.05mmTtR

Crankshaftmain bearing/

journalclearance
mainiournaldiameter
Crankshaft
Crankcase
mainbearing
borediameter
Crank$aftsideclearance
web length
Crankshaft
Transmission:
Shift fork earthickness
Gearshift fork groovewidth
Shift fork guide pin diameter
Shift drum groovewidth

0.030- 0.068mm
81.981- 55.000mm
55.ff|0 - 55.049mm
0.05- 0.55mm
96.85- 96.95mm
5.9- 6.0mm
6.05- 6.15mm
7.9- 8.0 mm
8.05 - 8.20mm

0.10mm
54,96mm
55.08mm
0,75mm
96.6mm
5.8mm
6.3mm
7.8mm
8.3mm

&7
CRANKSHAFTffRANSMISSION
SpecialTools

RonorHolder: 57001-1248

Circlip PfieB: 570{)1-14d

GaarHolder: 57001-1015

NOTE
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

Crankw
Splitting
.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.

.full th6 starter motor clutch gear out of the starter

motorclutch,then takeout the torquelimiter.
rLoosentl|e startermotor clutch bolt whileholdingthe
alternatorrotor steadywith rotor holder (special
tool:
s700r-1248).

A. StarterMotor ClutchGear. C. TorqueLimiter

B. Bolt

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

washerandstartermotor clutchoff the balancer
shaft.

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
B. Spacer
C. Collar

A. Damper
Cam
D. Retainer
B. Holder:57001-1025E. Bolt
Bearing
C. Needle

D. Bearing
E. Washer
F. StarterMotorClutch

.Loosen the Wimary gearbolt while holdingthe alternator rotor steadywith the rotor holder (special
tool:
57001-12481.

CRANKSHAFT/TRANS|MISSION8.9

A. PrimaryGear

A. Bolt
Gear
B. Balancer

C. BalancerWeight
D. Spacer

.Removeth front chainguide,lower chainguide,and

rearchainguidefrom the left handcrankcase.
oLoosen the balancergear bolt by usingthe rotor
holder(specialtool).

A. FrontChainGuide
B. LowerChainGuide

C. RearChainGuide

.Remove the chain guide and idle shaft holderfrom

the righthandcrankcase.
D. Ratchet
A. Balancer
Gear
B. AlternatorRotor E. Rotor Holder: 57001-1248
C. Balancer
GearBolt F. AltrnatorRotorBolt

aRemovethe alternatorrotor bolt by usingthe rotor

holder(special
tool: 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
st.

(B)
A. Sprocket
B. WaterPumpChain
C. Camshaft
Chain

A. WaterPumpDrive Sprocket
B. ldleShaft

C. Sprocket (A)
D. Chain

.Pull tie primary gar out of the crankshaft,and take

tie idle shaft out of tl|e cnnkcase, The idle shaft hu
two oins.

A. PrimaryGear
8. ldleShaft

D. LowerChainGuide
E. RearChainGuide

.Pull tle water pump sprocketwith its shaft out of

the insideof the crankcase.

C. Pins
A. Sprocket

oRemovethe following.
ldle ShaftSprocket(B) (with flat washer)
WaterPumpChain
CamshaftChain
LowerChainGuide
RearChainGuide

B. Shaft

aRemovethe starter motor bolts and the motor out of

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.
half.
oRemove
the followingfrom the LH crankcase
Crankshaft
Gears
Transmission
Shift Drum

Asrr.mbly
A. 08 mm Bolts(5)
B. Do not fotget to removetJ|isbolt.

.Removeall tl|e crankcase

bolts (Left Side).

A. 06 mm Bolts(14)
B. 08 mn Bolts(1)

C. 010mm Bolts(3)

halves.
.Note thefollowingbeforefitting the crankcase
oWith a high flash-poiritsolvent,oleanoff the mating
surfaceof tie crankcasehalvesand wipe dry.
ousingcompressed
in the
air, blow out the oil passages
crankcasehalves.
olnstallthe shift drum and settie gearpositioninglever
to the neutralposition.

A. Shift DrumPinPlate
Lever
B. GearPositioning

C. NeutralPosition

&12 CRANKSHAFT/TRANSMISSION
oApply engine oil to the transmissiongears, ball
bearings,shift drum, and crankshaftmain bearing
inserts.
ocheckto seethat the followingpartsarein placein the
LH crankcase
half.

l: LiquidGasket
AppliedArea.

A. Transmission
Gears
B. Shift Forks
c. shift Rod
D. Shifr Drum

E. Crankshaft
F. Balancer
Shaft
G. KnockPin
H. O-ring

.Tightenthe crankcase
boltsasfollows.
olightly tightenall the boltsto a snugfit.
oTorquethe 8 mm and 10 mm bolts to the tightening
sequence,and tien tighten the 6 mm bolts to the
specifiedtorque(seeExplodedView).
Bola TiqhteningOrdsr

oCheckto seetiat the followingpartsarein placein the

RH crankcase
half.

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
followingitems.
oTurn the RH crankcas
half down, and checkthat the
driv shaft andoutput shaft turn freely.
oBe sure the neutnl finder operatsproperly (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.

EngineRightSide
CamshaftChainandChainGuides
StarterMotorClutch(RH Balancer)
ldle ShaftSprocket(B)

A. Washer

B. Sprocket(B)

PrimaryGear

A. Output Shaft
B. Shift Drum

C. RapidlySpinning

.lnstall the following

EngineLeft Side
CamshaftChainandChainGuide
Weight
LH Balancer
Alternator Rotor

A. PrimaryGear

B. NotchedSide

ldle Shaft
ldle ShaftSprocket(A), WaterPumpDrive
Sprocket,andchainasa set.

A. Marlc Aligned

A. Sprocket(A)
B. WaterPumpDriveSprocket

C. Chain
D. Washer

&14 CRANKSHAFT/TRANSMISSION
ldle Shaft HolderandChainGuide
TorqueLimiter
StarterMotor Clu&h Gear

A. TorqueLimiter
B. ldle ShaftHolder
. ChainGuide

A. Bearings
B. Holding
Plates

C. LH CrankcaseHalf

A. Bearings
B. Holding
Plates

C. RH Crankcase
Half

D. Starter Motor Clutch Gear

E. Turn Clockwise

ShiftMechanism
Damper
Cam
Front BevelGearCase
Clutrh
WaterPump(lmpellerBolt hasLeft-handed
Threads)
RightEngineCover
Engine
TopEnd
AltrnatorCovers
Left EngineCover

oApply non-permanent
lockingagentto the threadsof
the shift return spring bolt, and tighten it to tie
specified
torque(seeExplodedView).
oApplysiliconesalantto 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 dmblad 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

8.15
CRANKSHAFT/TRANSMISSION
O Replacethe water pump shaft bearingsand oil sealwith
new ones. Pressthe oil seal into the RH crankcasehalf
from the insideof the case.

ConnectingRod Bemoval
oRemovethe crankshaft.
.Remove the connectingrods from the crankshaft.

NOTE
oApply hich temperature greaseto the lips of {E water
pump shaft oil s@1.

NOTE
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)
'1
-<s\

h\\\\J

ss

1 .Bearings
2. Oil Seal
the oil seal.
3. Press
oTighten the engine oil drain plug to the specified
torque (seeExploded View).

Crankshaft/ConnestingRods
Crankshaft I nstallation
oThecrankshaft
LHendis longerthanthe RHend.

l. Connecting
Rods
2. BigEndCaps
3. Crankshaft

.Removethe connectingrod big end capnuts,andtake

off the rod andcapwith the bearinginserts.

ConnectingRod Insallation

A. Crankshaft
B. LongEnd(LH)

C. Short End(RH)

oTo minimize vibration, the connesting rods drould have

dre $mo wight 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

1. BigEndCap
2. ConnectingRod

3. WeightMark,Alphabet

olf dre connec{ing rods, bearing inssrB, ot crankshaft

ar mplaced with new on6, 3elect d|e beadng insert
and .tr6d( .Nsarancewitft a plastigage before asembling
engine to be sun the coared bearing insert3 are installed.
.Apply engineoil to the big end bearinginserts.
.Tighten the big end cap nuts to the specified torque
(seeExploded View).

Connecting Rod Big End Bearing

ln*rt/Crankpin Wear
.Measurethe bearinginsert/crankpin
clearance
with
plastigage.

l. Crankpin

2. Plastigage

tlf clearance
is within the standard,no bearingreplacementis required.
*lf clearance
is between0.057mm andthe servicelimit
(0.10 mm), replacethe bearinginsertswith inserts
paintd blue. Check insert/crankpinclearancewith
plastigage. The clearancemay exceedthe standard
sliehtly, but it must not be lessthan the minimum in
orderto avoidbearingseizure.
*lf clearancexceedsthe servicelimit. measuretie
diameterof the cnnkpins.

CrankpinDiemete.
Standad:
ServiceLimit:

54.981 - 55.qn mm
54.97 mm

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.
CrankpinDiameterMarks
None:
54.981- 54.901mm
O :
54.9!12- 55.0dt mm

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

2- ColorSizeMark

lnsert
1. Bearing
Connecting Rod Elig End Inside Diametsr Marks
58.000- 58,010mm
None:

.lnstall the new insertsin the connecting

rod andcheck
with the plastigage.
clearance
insert/crankpin

58.011- 58.020mm

CrankshaftRunout
.Measurethe crankshaftrunout.
*lf the measurement
exceedsthe servicelimit, replace
thecrankshaft.
OankshaftRunout
Standard:
ServiceLimitr

0il2 mm
0.05 mm TIR

GankshaftRunout

3. DiameGrMark,
"O" mark or no mark

1 . BigEndCap
2. ConnectingRod

.Selectthe properbearinginsertin accordanc

with the
combination of the connectingrod and crankshaft
coding.

Big End Bearinglnsert Selection

Con-rodBig Crankpin
BearingInsrt
End BoreDia Diameter
SizeColor PartNumber
meterMarking
Mark
92028-1474
None
Blue
o
None
None

None

Black

s
92028-147

Brown

92028-1476

CrankshaftMain Bearing/MainJournal Wear

rMeasure
mainiournal.
of thecrankshaft
thediameter
crankshaft Main Joumal Dhmctel
Standad:

SerriceUmit:

54.981- 55,qD mm
54.96mm

&18 CRANKSHAFT/TRANSMISSION
Crankshaft Side CIearance
aMeasure
crankshaft
sideclearance,
Crankshaft Side Clearance,
Standard:
Serrice Limit:

0.G5- 055 mm
0,75 mm

*lf any journal has worn pastthe servicelimit, replace

thecrankshaft
with a newone.
1. Crankshaft
2. Crankcase
.Measurethe main bearingborediameterin the crankcasehalves.

C6nkcasMain BearingBore Diameter

Standsld:
Serrice Limit:

55O3{l - 55.Otl9 mm
55.08 mm

3. Clearance

*lf the clearance

is greatertian the servicelimit, measure the crankshaftweb length to see whether the
crankshaft
is faulty.
or the crankcase
CrankshaftWeb Lengrh
Standad:
9685 - 96.95 mm
ServiceLimit:
96.6 mm

*lf the lengthmeasurement

is smallerthan the service
limit, replacethe crankshaft. Otherwise,replacethe
crankcase
halvesasa set"

*lf they are any signsof seizure,damage,

or excessive
wear,replacethe crankcase
halvesasa set.

NOTE
oThe right and left cnnkcz* haly6 are m*hirzqt at the
factory in the a*mbled state, & thay mu& b re
plaed asa st.

&19
CRANKSHAFT/TRANSMISSION
Right EnglneCover

Left EngineCover

Bemotral
rRemovethe muffler(seeEngineTop Endchapter).
.Removethe right downtube (seeFramechapter).
aRemovethe coverbolts.
.Using t}|etap points,takethe covroff t}tecnnkcase.

lnsallation
.Note the followin&
oBefore installing tlre left enginecover, apply grea3eto
ttre back of the dampersand attaoh them onto the
alternator outer cover.

A. Damper

B. Altemator Outcr Cover

A. Tap Here
o Instllthe left enginecoverabovethe enginebracket

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

A. Front BevelGearCas
B. EngineBracket

End
C. C-over

StarterMotor Clutdt

A. DrainHose
B. BrakeLight Switchwire

C. Strap
D. Clamp

Removal
.Removett|e right downtube (seeFramechapter).
.Removethe right enginecover.
.unscrew the starter motor clutch bolt while holding
the primarygearbolt.

oApply oil to the threads of the starter motor clutch

bolt and tighten i! to the specified torque (see ExplodedView) while holdingthe primarygearbolt.

Disassembly
rRemove
thestartermotorclutchassemblv.
.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
B. Pushand turn clockwise.

.Note the following.

olnstall the coupling with the groovedsidefacing out.

8.21
CRANKSHAFT/TRANSMISSION

Weight
A. Balancer
B. One-wayClutch

C. Coupling
D. Groove

A. One-wayClutch B. lnnerRace

(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

A. Turn freely.
B. Locked

C. StarlerMotorClutchGear

*lf the startermotor clutchdoesnot operateasit should

or if it makesnoise,go to the nextstep.
.Disassemble
the startermotorclutch.
*lf the one-wayclutch installationis incorrect,reinstall
ir.
*Visually inspec!the clutch partsfor damage:one-way
clutch,couplingand startermotorclutchgearpart,replaceit.
*lf tiere is any worn or damaged

RH BalancerWeightRemoval
Seestartrmotorclutchremoval.

LH BalancerWeightRemoval
aRemove the engine.
oRemovethe shift leverrear end.
.Remove the pickupcoils.
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
B. lnnerCover

C. Tap Here
D. PickupCoils

.Loosen the LH balancergearbolt while holdingthe

alternatorrotor with a flywheelholder(specialtool).
'- -

?'\

-"

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

3. Hole

oTightenthe balancergearbolt to the specifiedtorque

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

A. Balancer
Gear
B. AlternatorRotor
C. Bolts

D. Rotor Holder:
57001-1248

.Remove the alternatorrotor bolt by usingthe rotor

holder(special
tool: 57001-1248).
aTaketh alternatorrotor with soacerand ratchetoff
the crankshaft.
.Removetie balancergearbolt, and take the balancer
gei , spacer,balanoerweightoff the balancershaftasa
set.

A. Bolt
B. Balancer
Gear

Balancer Shaft Removat

iSplit thecrankcase
(seeCrankcase
Splitting).
aPulltheshaftoutof thecrankcase-

Balancer Shaft I ns'3IIati on

.Note t}le following.
oFit the balancershaft into the bearing in the LH
cnnkcasehalf asshown.

C. Balancer
Weight
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
B. Bolts

A, TorqueLimitr
C. Washer
B. StarterMotor ClutchGear

oDo not dilctsnbls drs torquo limitsr.

limitel will not lunqtion if thb is dons.

Ths torque

lnspection
.Removethe torquelimiterandvisuallyinspectiL
ilf the limiter haswear,discoloration,
or otherdamage,
replacit asa set.

l. Gear
2. Friction Plate
3. Pinion

C. Holder
D. ChainGuide

.Pull out the chainguideftom the holder.

Insallation
.Note the following.
oPut the washeronto the idle shaft,and fit the knock
pinsinto the crankcase.

A. ldle Shaft
B. Washer

C. KnockPins

ISSION
&24 CRANKSHAFT/TRANSM
.Pull the primarygearout of the crankshaft,and take
the pin out of the idleshaft.

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

A. PrimaryGear
B. ldleShaft

A. ChainGuide

B. ldle ShaftHolder

C. Pin

lnstallation
.Note the following
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.

Gear
A. Primary

A. WaterPump'DriveSprocket D. Chain
B. ldle Shaft
E. PrimaryGearBolt
C. Sprocket(A)

B. NotchedPortion

oWhenthe watr pump idle shaft is installed,fit t}te

pin into the sprocketrecesses.
oTightenthe primarygearbolt to the specifiedtorque
(seeExplodedView) while holdingthe primarygear
with a gearholder(specialtool).

8.25
CRANKSHAFT/TRANSMISSION
.Remove the shift shaft,while pushingthe shift mechanismarm forward.

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

oTightenth clutch hub nut to the specified

mrque(see
ExplodedView).

A. Shift Shaft
B. Shiff Mechanism
Arm

C. Push
D.GearPositioning
Lever

.Unscrewthe bolt andremovethe gearpositioninglevr

and its springtogether.

Transmission
Extemal Shift mechanism Remoml
.Rernovetie following.
LH EngineCover
Engine(seeEngineRemoval/lnstallation
chapter)
Shift LeverRearEnd
Front BevelGearCase

A. Shift Lever

B. Front BevelGearCase

External Shift Mechanism lnstallation

.Note the following.
oPositionthe gear positioningleverand springin tie
crankcase
andscrewin the bolt asshown.

A. Lever
B. Spring

C. Bolt

&26 CRANKSHAFTTTRANSMISSION
olnstalltlte shift leverasshown.
*lf necessary,
loosenthe locknutsandturn the shift rod
to obtainan 88.5 mm leng$ includingthe locknuts.

Exhrnal Shift Mechanismlnspection

.Examine
theshiftshaftfor anydamage.

1. Shift Shaft
2. RetumSpring
3. Shift Mechanism
Arm
4. Arm Spring
A. 88.5 mm Lengh
B. Shift Rod

C. Shift Leven
D. Locknuts

O Installthe clutch hoseguide as follows.

A. HoseGuide

oCheckthe shift shaft for bendingor damageto the

splines.
*lf theshaftis benLstraighten
or replaceit lfthesplines
replacethe shaft.
aredamaged,
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,
replacthe arm.
.Checkthat tbe returnspringbolt is not loose.
*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
B. GearPositioningLever

C..Spring

CRANKSHAFT/TRANSMISSION&27
.Visually inspectthe shift drum cam.
rrlf it is badlyworn or if it showsanydamage,
replaceit.

Transmission Shaf:* Remotal

.Removethe engine.
.Split tie crankcase.
.Pull out the shift rod and take tie shift forks out of
gears.
the transmission
.Take out the driveshaftandoutputshaftasa set.

TnnsmigsionDissembly
shafts.
.Remove
thetransmission
tool: 57001144)to
.Usingthe circlippliers(special
shaft'
the
transmission
disassemble
circlips,
the
remove
.The 3rd gearon theoutputshafthasthreestelballs
Re
in it for the positiveneutralfindermechanism.
movethe 3rd gearasthe follows.
oset the output shaftin a verticalpositionholdingthe
2nd gar.
ospinthe 3rd gearquicklyand pull it off upward.

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

A. Shift Rod
B. Shift Forks
C. DriveShaft

D. OutputShaft
E. Shift Drum

TnnsmissionAwmblv

Transmi ssion Shaf/s In stallati on

.Note the following.
ocheckthe positionof the shift forksasshown.
oFit tlle drive and outDut shaftsas a set into the LH
crankcasehalf, while placingthe shift fork onto the
driveshaft.

A. Drive Shaft
B. Output Shaft

C. Shift Fork For DriveShaft

D. Shift Fork For Outprit'Shaft

.Note thefollowing.
oReplace
any circlip that wereremovedwith new ones.
olnstallthe circlipsso that tl|e openingis alignedwith a
splinegroove.

1. Circlip
2. ToothedWasher

3. Groove

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
B. Bushing

A. 3rd Gear
B. SteelBalls

Drive Shaft

1. Top (4th)Gear
2. OilHole
3. 2nd Gear
4. 3rd Gear
5. l st Gear(DriveShaft)
6. Circlip

7. NeedleBearing
8. ThrustWashr
9. Circlip
10. Washer
11. BallBearing

C. Recess
D. SmallHole

CRANKSHAFT/TRANSMISSION8.29
Output Shaft

Top (4th) Gear

2. Oil Hote
2nd Gezr
Oil Hole
5 . 3rd Gear
.t.

ll. Circlip
12. SteelBall
13. Washer
14. NeedleBearing
15. Circlip

6. I st Gear
7 . BallBearing
8 . Circlip
9 . Bushing
1 0 . ToothedWasher

bIy
Shi ft Drum Di nssembIy/Assem
oDisassemble
the shift drumasshown.
oDo not apply gre6 to dre stel 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
the shift drum.

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

A. Bolts
B. BearingHolder

C. Shift Drum

.Whenassembling
the shift drum,notethefollowing.
oThe pin platemustbe 'rnstalled
in the correctposition,
andmustfit onto the pin plateasshown.

8.30 CRANKSHAFT/TRANSMISSION

A. Pin
B. Shift DrumCam

C. Partof the aluminum-

oApply a non-permanent
lockingagentto the threadsof
the pin plate screw.

9.1
WHEELS/TIRES

Wheels,/Tires
Tableof Contents
ExplodedView...
Specifications
SpecialTools.
Wheels(Rims)

FrontWheelRemoval
FrontWheellnsallation
Removal
RearWheel
RearWheellnsallation.
WheelCouplingRemoral.
. ...;. ......... '
W h e eCl o u p l i nl n
gstallation.
(for castwheel)
Wheel(Rim) Inspestion
...'.'.'.
Weight
Installation,
Balarrce
BalanceWeightRemoval.
Spokelrspection(for wirespokewheell.. . .
Rim Inspection
WeightInstallation
Balance
T i r e s. . .
.......'.
lnspection
TireAir Pres$re
Tire Inspection
Tire Removal'
Tire lnstallation.. . . . .
HubBearings.
, '. '.. ' '.
Removal
lnstallation
Lubrication
.
GearHousing
Speedometer
bly
DisasemblyandAssem
Lubrication

9-2
94
9-5
96
9
9-6
*7
97
9
9
9'9
9'9
9-9
9-10
9-10
C10
911
9-11
911
9-11
9'12
9'12
$13
913
913
$13
v-^14

9-2 WHEELS/TIRES

Exploded View
vN1500-A
(G): WestGermanModel

-s
1. BalancerWeight
2. Front Tire
3, Air Valve
4. SpeedomterGeal
5. Front Axle
6. Front Wheel
7. RearAxle
8. RearTire
9. RoarWheel
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)

='=')');"
EY
;#

a
r\
\ \ \
rtY
' - v )\

9
WHEELS/TIRES

vNrSoo_B

, 3i n - l b )
T 1 : 1 . 5N - m( 0 . 15 k s - m 1
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:),,.
^

*t/

ob*

v
tt'

^\

z"soT
""" @

1. Spe.domrt i Gorr
2, Front Axl.
3, Brhncar Weight
4. Rim
5. SpokeNippls
6. SFoke
7. Tube
8. Air vdr.
9, Rim Bcnd
10. Flont Tirr
11. RarrAxle
12, B.rd Ptotectol
13. B.bnaetW.ifht
14. R.|' Tir.

94 WHEELS/TIRES
Specilications
Item

Standard

Wheels:
Rimrunout:

VN1500A
Axial
Radial
VN15OOB
Axial
Radial

Axlerunouv100
mm:
Wheelbalance
Balanceweights
Tiros:
Tiretreaddepth:

Front
Rear

ServiceLimit

TIR0.5mm
TIR0.8mm
TIR 0.8 mmor less(withtire installed)
TIR 1.0mm or less(withtire installed)
TIR0.05mmor less
Lessthan 10 g
109,209,309

TIR 2.0 mm
TIR 2.0 mm
TIR 0.2 mm

'I mm

4.4mm(DUNLOP)
4.3mm(BRIDGESTONE)
7.3mm
6.2mm (BRIDGESTONE)

2mm

Standardtires:
Front
VN 15OOA

Rear
Front
VNl5OOB
Rear

DUNLOPF'l1J,{A) (E)F11LTL
(A11-) BRIDGESTONE
EXEDRAL3O9
1OO/90-19
57HTUBELESS
ryPE
DUNLOPK425A,(A) (E) K425ALTL
(A11-) BRTDGESTONE
EXEDRAGs26
150/90-ls 74Ho|ls0/90-15 M/C74HTUBELESS
rypE
(E)
OUNLOP
F11J, F1lLTT/METZELERMarathon
Front
.1OO/90-19
57HTUBETYPE
DUNLOPK425A,(E) K425ALTT
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

vN1500A(G)

97.5 - 186 kg (215 - 410jb) load

vN1500B(E)

97.5 - 184 kg (215 - 406 tb) toad

(E) EuropeanModel
(G) WestGermanModel

(A)AustralianModel

Usethe samemanulacturer's
tirss on bothfrontand
rearwheels.
NOTE
'JMost countriesmay have their own regulationsrequiring a minimumtirc treaddepth:be sure to followthem.
aCheck and balance the wheel whena tire is reDlaced
with a new one.

225kPa(2.25kg/cm,,32Psi)

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
.lnstallationis the reverseof removal. Note the

Wheels(Rimsl

following,

Front WheelRemoval
.Remove the following.
SpeedometerCable Lower End
Brake Caliper Mounting Bolts

A. CaliperMountingBolts

B. AxleNut

NOTE
oPut the spedometer gear drive onto the wheel hub
nobtrrjhes..
then install the housing e that it fits in the
drive nofthes.

A. Notches
B. Proiections
oFit the qedometer
stop.

C. Drive
D. Housing
gear housing stop to the fo*

lq

Axle Nut
Axle ClampBolt (Loosen)

1. Housing
Stop
A. Axle
B. AxleClampBolt

C. Speedometer
Cable

.Use the iack standand the attachment(specialtools:

57W1-"1238,
57001-12521
andothersuitablemeansto
lift the front of the motorcvcle.
.Pull out the axle to the right anddropthe front wheel
out of the fork.

tml
oDo not lay the wheel doun on dte disc. This can
damage or warp dle disc. Place blocks under the
wheel so that the disc do not touch the ground.

2. Fork LegStop

oFit the collar on the right hand side of the hub.

.Tighten the axle nut to the specified torque (see

Exploded
View).
.Tighten the axle clamp bolt to the specified torque
(seeExplodedView).
.Checkthe front brake.

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
funcjtion on the first application of the lever if this is
not done,

WHEELS/TIRES 97
Rear Wheel Remowl
rRemovethe following.
Muffler(seeEngineTop Endchapter)
BrakeCaliperMountingBolts
CaliDerHolderBolt

Bear Wheellnstallation
.Notethefollowing.
oApplymolybdenum
grease
to thegrease
seal.
disulfide
oApply molybdenum
disulfidegreaseto the splined
portionof tlle ringgearhub.

A. Muffler
C. CaliperHolderBolt
B. CaliperMountingBolts

A. FinalGearCase

B. RingGearHub

oBesureto inserttheoollaron both sidesof the hub.

Axle Nut Cotter Pin
AxleNut

A. CotterPin

B. Axle Nut

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
toward the right to disengagethe wheel from the final
gearca9e.

1. LHCollar
2. RHCollar
3. RearHub
4. Coupling

5. RingGearHub
Portion
6. Splines
7. Grease
Seal

olnsert tl|e rear axle into the final gear castoward the
LH to RH, and fit the splinedportion of the ringgear
hub andwheelcouplinghub.

9 IVHEELS/TIRES
WheelCoupl i ng I nstallation
.Note thefollowing.
oApplymolybdenum
grease
disulfide
to theO-ring.

A. Axte
B. RingGearHub

Hub
C. Coupling

o'Iightn $e axle nut to the specified torque (se

ExplodedView).
oTighten the rear brake caliper mounting bolls to the
specifiedtorque(seExplodedView).
oTiShtgnthe calipr 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 pdal is obtained by pumping th. brak6 pedal
until the pads are against the disc. Th6 b6ke will not
funqtion on the fiBt application of th psdal if this is
not dong.

A. Gring

Wheel(Rim) lnspection(for castwheel)

rRemovet}le tire from the wheel.
.Measurethe rim runoutby usingthe dialgauge.

Wheel Coupling Removal

.Removeth rearwheel(seeRearWheelRemoval).
aRemoveth couplingretainer.
.Rmovethe wheelcouplingwith suitablebearingpuller
if necessary.

A, WheelCoupling

B. CouplingRetainer

1. RadialRunout

2. Axial Runout

99
WHEELS/TIRES
*lf rim runoutexceeds
limit, checkthc wheel
the service
bearings.
*lf the problemis not due to the bearings,the wheel
mustbe replaced.
Axial Runout
Service Limit:

Weight(grams)

PanNumber
4'1075-1014
41075-1015
41075-1016

10
20
30

0.5 mm

Radial Runout
Ssrvice Limit:

&lance Weight

0.8 mm

ln3talling Balance Weight

(a) Pressor lightly hammer the weight in.

oNevsr atternpt to tepir a damaged whel. lf there is

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

Tire Bead

Batancc Weight lnstal lation

thck if the weightportion hasanyplay on the blade
and{lip plate.
*lf it does,discardit.
.Lubricatethe balanceweightblade,tire bead,and rim
flange witlt a soap and water solution or rubber
lubricant. This helpsthe balancweightslip onto the
rim flange.

(b) Installationcompleted.

oDo not tubricate the tile bead widl engine oil or

ga3olinbecauie thsy will dsteriorote ths tirs.

.lnstall the balancewighton the rim.

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

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 blance wigha,

Clip

Balance Weight Removal

(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
.Measure
therimrunoutby usinga dialgauge.

(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 raches
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
Radial Runout
Service Limitr

Spoke lnspection (for wire-spoke wheel)

.Checkthat all the spokesaretightenedevenly.
*lf spoketightnessis unevenor loose,tightenthe spoke
nipplesto the specifiedtorque evenly(seeExploded
View).

olf any 3pokebrsakr, it $ould be replacdimmediately'

A missingspok6 placesan dditional load on the other
spokes,which witl eyentrally euse odrer 3poket to
break.

2.O mm
2.0 mm

A repaired wheel part may fail in use, possibls causing

an accident. lf any wheel part is bent. dsnted, cracked,
oa warped, replace it.

BalanceWeightInstallation
.lnstallthebalance
weighton thespokenipple.
usinga pliers.
oAttacha balanc
weightsecurely

911
WHEELS/TIRES

I
\

1. Depth Gauge

Weight
A. Balance

tlf any measurement is less than the servicelimit,

replacethe tire.

Balancs Weight

Weight(grams)

PartNumber
41075-1007
4'I075.'I008
41075.1009

10
20
30

.'_1T...................

Tire Trsad Depth

Front
Standald:
ServiceLimit:
Real
Standard:
SeruiceLimit

4.4 mm
1 mm
73 mm
2 mm

TireAir Pressurelnspection
NOTE

NOTE

oMeastretire prffsure when the tires arc cold (that is,

when the motorcycte has not beenridden more than a
mile during the past3 hours).

oFor the VN\5O&B. replace the rim band with e new

one wtteneverthe tire is repleed.

Tire Air Pressure(whencold)

Load

Air Pressure

200kPa
(2.00kgrlcm',
28 psi)

Front
Up to 97.5 kg
( 2 1 5l b )

200 kPa
(2.O0kglamz, 28 psil

Tire Removal
.Note the following.
oWhenremovingthe rear tire, removethe valvestem
nut, balancernut, andfully loosenthe beadprotector
nut (VN1500-B).

97.5-l80kg
(21s -397 t6)

97.5(21597.s (215-

185ks
408rb)
186ks
410rb)

225 kPz
(2.25kglcm2, 32 psi\

.5 184 kg
i>:iE (E., 97
(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
acheckthe tire rotationmark on the reartire and
installit on therimaccordingly.

Ail Valve

NOTE
oThe direction of the tire roation i8 st own hy an arrow
on the rar tire sidev,all.

1. PlasticCap
2. ValveCore
3. StemSeal

3. Air Valve
1 . RotationMark(Arrow)
2. Balance
Mark (YellowPaint)

4. ValveStem
5. ValveSeat
6. ValveOpened

.lnstall a newvalvein the rim.

oRemovetlle valvecap, lubricatethe stemwith a soap
and water solution,and pull the stemthroughthe rim
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: Tubol3sti.6 arc i$talled. Do not

inliall t$e-type tirc on this motorcvdc.
oFor VN15O0.B:Tube tires sre in311d.Do not inttsll
tublest-typstirss on this motorcryde.
oThe Econnonded ltandard tina mu3t be urd fol
rsplacamel .
.Aftr installing the bead protector and balancer,
tighten the nuts to ihe specifiedtorque (VN150GB:
seeExplodedView).

1. Apply soapandwatersolution.
2, Pullthe stemout.

oDo not useengineoil or petroleumdistillates

to lubricatethe stmbecuasethey will deterioratcthe rubber.

VN15OCA3 (Canada)and VNl5(XlA4 Rubber-typeair valveand air valve hole modified

wheelsareusedon the front wheels.

lnsallation
aRemovethe air valveanddiscardiL

oRcplacethe rubber-typair vahe wheneverdte tire is

rcplacd.
oDo not reusedre air valve.

HubBearings
Removal
.Removethe hubbearings
by usingthebearing
remover
shaftandheads(specialtools).
oRemovethe bearingretainer.
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. Bearing
Remover
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 bearings
by usingthe bearingdriverset
129).
(special
tool: 57001-'l

Turn back and forth [A]

Shield IB]

GearHousing
Speedometer

1. BearingDriverHolder
2. Driver(Large)

3. Driver(Small)

D i lassem b Iy an d Assemb I Y
NOTE
ott is recommendedthat the a*mbly be replacednther
t an aftempting to rcpair the components.

NOTE
oln&all he b@rings e that the markd or $ielded sides
hcc out.

gear housingso that it fits in

.lnstall the speedometer
geardrive notches(seeFront Wheel
the speedometer
lnstallation).

9-l4WHEEIS/TIRES
Lubrication
.Cleanandgrease
gearhousing.
thespeedometer

GearHousing
l. speedometer
2. Grease.

FINAL DRIVE lGl

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

1O-2 FINAL DRIVE

View
Exploded

$
@h

1 . Oil Pipe
2- Drive GeatShim
3. DdYsGsar
4- DriveGearShaft
5 . l'leurr.l Savitct
6. Front BevelGesrCse
7 . Drivsn GearShin
8 , Ddren Ge8t
9. F ont EeYelGaarAsembly
10. BaringHousing
1 1 . Collal (PrlosdAdiun)
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,11.0
ft.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 . Propellr Shaft Joint

2. Propellar Shaft
3. Ealing Retainsr (Left{anded Thredsl
4 . Plnion Gaar Shim
5 . Pinion Ger
6. Ring Gsai
7 . Bolt M10
L Bolt M8
9. Final Bevel Gal A$smbly
10. Filler Plug
1 1 . Final Gear Cate
12. Ring Gear$rim

G : Apply greale.
L : Agply non{ejmanent lod(ing agent.
ST: Staked|e fastenrs.
Tl : 88 Nrn (0.90kgrn, 78 in{bl
T2: 16 N{n (1.6kgfl,115 ft'lbl
Tlt r 23 N-rn (23 ks{, 165 ft{bl
T4: 29 N-rn(3.0k$m, 22 tt{bl
T5: 34 N.rn (35 kgim,25 ft lbl
T6: 120 N"rn(12.0ksm,87 ft{b}
T7: 2tl5 Nrn P5 ks{, 180ft{bl

1G4 FINAL DRIVE

Specifications
Item
Final GearCaseOil:

Standard
Grade
Viscosity

Amount
Oil Level
FinalGearCase:
Finalbwel gearbacklash
Front Bevel Gear:
Preloadfor drivengearbearings
Front bwel gearbacklash

API GL HypoidGearOil
Whenabove5"C (41'F) SAE90
Whenbelow5'C (41"F)SAE80
2(X)mL
Bottomof filler opening
0.06 - 0.09 mm (at gearhub spline)
0.10 - 0.15 mm (at geartooth)

0.5 - 0.9N-m(0.05- 0.09kg-m,4- I inib)

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& BaringRemover:57001-1058

Jack Standr 57(x11-1238

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

Oil SealDrivel: 57001-1101

Final GoarC..e Holdr: 51001-1250

-\e\

VPlnionGearHolder; 57001-1165

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

BaringRetainelWren.fi: 5?qr1'1251

10 FINAL DRIVE
.After the oil has completelydrainedout, install the
drainplugwith a newgasket.
.Fill the final gearcasewilh the specifiedoil andquantity.

FinalGoarCaseOil
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 lrypoadgaroil
Vircoity:
Whd| aboreS"C (41'Fl SAEgtt
who bdd 50c (41'Fl sAE S0

NOTE
'GL6"
oThe wm
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
B. Oil LevelLine

C. Filler Plug

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

leakage,remedy it if necssary,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
oil will pickup any sdimentanddrainasily.Stopthe
motorcycleand turn it off.
aPlacean oil pan beneaththe final gearcase,and remove
tlle drainplug.

FinalGearGasg
Ranoval
*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
lftlt inrdrortsn{y gatr on thm wttb a high flrdt.poim
aolYgnt.

NOTE
olf the find gar ee is fit of oil, plee {re w
dre btathar hole ls on top,

s that

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
surfaceon the ringgearhub.
sealing

A. SmallDiameterEnd

.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 -

oDo not hsat dr6 case with a torch.

c83e.

Thb will rvsrp $s

.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
Washer
7. BallBearing
3. PinionGearJoint 8. FinalGearCaseCover
4. Oring
9 . CoverMountingBolts
5. RingGearHub
1 0 . RingGearShim(s)

I l. RingGear
16. Ball Bearing(Four-pointContact)
12. Studs
17. PinionGear
i3. PinionBearing
Retainer 18. Oil Seal
14. Oil Seal
19. NeedleBearing
15. FinalGearCase

A. PinionGearHolder: 57001-1165

1. Oil Seal& Bearing

Remover:57001-1058

.Remove the oil seal on tie pinion bearingretainer

withoutremovingthe pinion.
ounscrewthe pinion nut usingthe pinion gearholder
(special
tool).

o Removethe washerand pinion joint with the O-ring.

o Pull out the oil sealon the pinion bearingretainerusing
a suitablepuller.
O Removethe pinion gear and its retainer.
O Removethe Allen plug and then unscrew the retainer
with the final gear case holder and bearing retainer
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 piniongearassmbly

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
2. PinionGear

3. Shim
4. Plug

Assembly Note6
.The ring gearand pinion are lappedas a set in the
factory to get the best tooth contact. They must be
installedasa pair,neverreplaceonewithout the otir.

A. Oil Holes

B. NeedleBearing

aBlow the breatherhole in the final gear cage cover

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 kep 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
removed.
.lnstall the pinion gearretainer. Note the following.
oReinstall the original pinion gear shim(s) to keep the
gear baklashand the tooth contact unchanged.
ousing the final gear case holder and bearing retainer
wrench (specialtools: 57001-1250and 57001-1251),
tightn the pinion gear retainer to the specifiedtorque
(seeExploded View).
oUsing the pinion gear holder (special tool: 57001ll65), tighten the pinion nut to t}le specified torque
(seeExploded View).
ostake the pinion nut with a punch.

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).

Bevel Gear lnspection

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

A. Checkspllnedportion.

BaII Bearing I nspection

Sincethe ball bearingis made to extremelyclose
tolerances,
the wearmustbe ludgedby feel rathertban
measurement.
.spin the bearingby handto checkits condition.
*lf therebearingis noisy,doesnot spin smoothly,or
hasanyroughspots,replaceit (asa gearset).

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
replacelt.
bearing,

Oil Seallnspection
alnsDectthe oil seals.
tReplace any if the lips are misshapen,discolored
(indicating that the rubber hasdeteriorated),hardened,
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

0.15
u.5
0.6
0.7
0.8
0.9
1.0
'1.2

PartNumber
92025-1783
92025-1784
92025-1185
92025-1786
92025-1787
92025-1788
92025-1789
92025-1190

(mm)
Thickness

0.10
0.15
0.5
0.6
0.7
0.8
0.9
1.0
1.2

PartNumber

92025-1733
92025-11?4
92025-1735
92025-1736
92025-1737
92025-1738
92025-"t739
92025-1740
92025-1741

1G12 FINAL DRIVE

NOTE
gear
c,{,rsedrese dzimsfor
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 ringgearassembly
with the primary(1.0mm
rhic{rnesr)shim,and tightenthe covermountingbolts
torque(seeExplodedView).
to the specified
oCheckthe backlash
duringthe tighteningof the cover
mountingbolts,andstoptighteningthemimmediately
disappears.
Then,changethe ringgear
if the backlash
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 bearingretainer
to 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
.Remove the ring gearassemblyand pinion gearfrom
and
the final gearcase(see Ring Gear Disassembly
PinionGearDisassembly).
rVisually checkthe bevelgearsfor scoringchipping,or
otherdamage.
tReplace the bevel gears as a st if either gear is
damaged.

Pinion GearBearinglnspection
rDisassemblethe pinion gear (see Pinion Gear Dis'
assembly).
.Visually inspetthe bearings
color change,
for abrasion,
or otherdamage.
ilf thereis any doubt as to the conditionof a bearing,
replaceit.

oslip the propellershaft off the drivengearioint by

pushingon the lock pin throughthe access
hole.

of Propellershaft ftom
Disengagemnt
D:ive GearJoint

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
2. UniversalJoint
3. LockingPin

A. LockingPinAccessHole

Spring
) - DrivenGearJoint

.Remove the circlip from tf|e rearendof the propeller

shaftusinga circlippliers.
aRemovethe washerand pull out the propellershaft
slidingioint.

FINAL DRIVE 1G15

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

t . O-ring
2. Washer
t.

4. PropellerShaft
5 . SlidingJoint

Circlip

lnsallation Notes
.Check the Oring on the rearendof the propellershaft
for any kind of damage,and replaceit if necessary.
.Lubricatethe propellershaftioint (seePropellerShaft
Joint Lubrication).
aAfter connectingthe propellershaftto the drivengear
ioint, pull tlle propellershaft rearwardto checkthat
the shaftis securedin placeby t}le lockingpin.

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.

A, Checkuniversal
'oint.
B. Inspectsplinedportion.

Sliding Joint l nsp*tion

.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

Front Gear CaseRemovat
rRemove the following.
Engine (seeEngine Removal/lnstallationchapter)
Shift LinkageLever Rear End
Front Gear Case

.Note the following.

oTighten the front gear casemounting bolts to the
specifiedtorque(seeExplodedView).
owhen installingthe oil pipe,pustrit down and torque
thefront banjobolt first to the specification.

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
B. Shift LinkageLever

C. FrontGearCase

Front GearCaseDisassembly
(includingdrivegearremoml)

oThe camfollowerandthe damperspringcomeoff with

the gearcase,

A. Cam Follower

B. DamperSpring

aRemovthe following.
Front GearCase
CamFollower
DamperSpring
RubberBoots
.Removethe driven gearassemblymountingbolts and
pry the assembly
off the case.

A. DrivenGearAssemblyMountingBolts
B. DrivenGearAssembly
C. RubberBoots
D. DriveGearAssemblv

FINAL DRIVE IG17

A. Pry Points

C. Catththe visehere.
A. DriveGear
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

oPryopenthe drivegearnut with a smallchisel.

ounscrewthe drivegearnut holdingthe drivegearshaft
with the holder(specialtool).

B. BearineHolder

.Remove the drive gear shaft ball bearingusingthe

tool: 57001-1129).
bearingdriverset (special

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 st.
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

bevelgearbacklash
andtooth contact,whenanyof the
parts are replaced(see Front Bevel
backlash-related
GearAdlustment).
.After completingall adiustment,re-assemble
the front
geatcate.
oReplace
the drlvegearnut with a newone.
oApply oil to the threadsand seatingsurfaceof the
nut, and tighten it to the specifiedtorque (seExplodedView).
oLoosenthe nut completely and retightenit to the
specifiedtorque(seeExplodedView).
ostakethe nut to secureit in place.

Driven Gear Dinssembly

.Holdingthe drivengearjoint wit}t the driven gear
holder(specialtool), unscrewthe driven gear bolt.

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.

olnstall the driven gear assemblyso that the oil hole

on the housingalignswith the oil hole in the case.
olnstalltheshim.
oTightnthe drivengearassembly
mountingboltsto the
specifiedtorque(seeExplodedView).

A. Vise
B. DrivenGearHolder:5700'l-1027

.Remove the driven gearjoint with the O-ring.

FINAL DRIVE

10.19

.After completing the bearing preload adiustmnt,

the drivengearassembly.
re-assemble
ousing the bearingdriver set (specialtool: 570011129),pressthe oil sealin until the faceof the sealis
levelwith the endof the bearinghousinghole.
oTightenthe drivengearbolt to the specified
torque (see
View).
Exploded
ostakethe drivengearbolt to preventit from loosening.

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
tool: 57001-158
and57001-317).
adapter(special

A. StakingPoint

B. Pin Hole

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 barings.

DrivenGearAssembly
.Note the following.
oThe drive and drivengearsare lappedas a set at the
factory to get the besttooti contact. They must be
replacedasa st.
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

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.

C. Bolt
A. DamoerCam
B. Holder:57001-1025

IG2O FINAL DRIVE

Damper Cam lnstallation Notes
aReplace
the dampercamnut with a newone.
.Tighten the dampercam nut to the specifiedtorque
(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.

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 necessary
wheneverthe bolt is
Ioosned,even if the purposeis not to replacethe
parts.

Front BevelGear Adiustment Procedure

Preloadthe driven gear bearings.

Assemble
the front gearcasecompletely.

partsare replaced,
Whenany of the backlash-related
or the drivengearbolt is loosened;
evenif the purposeis
not to replacethe parts,be sureto checkandadiustthe
bearingpreloadand the bevelgearbacklashand tooth
contactby replacing
shims.

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.

.Apply a little engine oil !o the beatings,and turn the

gear shaft more than 5 turns to allow the bearingsto
seat.
oMeasure the bearing preload. Bearing preload is
defined as the force or torque which is neededto st2rt
the gearshaft turning.

1. SpringScale 3. DrivenGearHolder: 57001-1027

4. 200 mm
2. Hole
*lf the preloadis out of specifiedrange,replacethe
bearingcollar and/or spacer. To increasepreload,
decrease
the stacklengthof the collarand spacer.To
preloadincrease
the stacklengthof the collar
decrease
andspacer.
*Change the stacklengtha littleat a time.
aRe-check the bearing preload, and re-adjust if
necesEary.

Collarsfo. PreloadAdiwtmnt
Length(mm)

22.8
22.9
23.0
23:1
Prsloadfor DrivenGearBoaring
UsingSpringScale:
25 - 4.5 N (025 - 0.45 ks,0.6 - 1.0 lbl
U.ingTonque
Wrendr:
05 - 09 N{n (0.05- 0O9 kg"m.4- 8 inJb)

.25.5

23.4
z)-)

23.6
z5. t

23.8
23.9
24.O
24.1

PartNumber

92027-1152
92027-1153
92027-1154
92027-1155
92027-1156
92027-1157
92027-"t158
92027-1159
92027-1160
92027-1161
92027-"t162
92027-1163
92027-"t164
92027-"t165

NOTE
oPreloadcan be masrred either with a Wring sale or a
bem-rype torque wrench. When measJrcdwith a
gring wle, the preload is d$ignafud by force (N, kg,
lb), and when masJred whh a torque wrench,it is
d8ignated by torque (N-n, kgfl, in-lbJ.
ousing &dng *ale:
Hook the *ring wle on the handleat a point 200
mm apart from the cenEr of the gar c7ft.
Hold the bearinghousing ih a vise dlat the g@r
Ctaft axis is tErtial;
Appty force to dE handle
horizontally and at a riglrt angleto it,

Spacersfor PreloadAdiustmsnt
(mm)
Thickness
1.70
1.72
1.74
t./o

"t.78
1.80

PartNumber
92025-1072
'92025-1073
92025-1074
92025-107
5
92025-1076
92025-1077

1G22 FINAL DRIVE

BearingPreloadingMedranirm

(A) BeforeTightening

(B) After Tightening

Under
No Preload

Under
Preload

lnitial
Clearance

Clearance

Under
No fteload

l. Bearing
Housing
2. TaperedRollerBearing
3. Spacer
4. Collar
5. TaperedRollerBearing

Backlashadtujtment
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 contatadiustmentsarc fini$d.

.lnstall the drivengearassembly

to the front gearcase
with the primaryshim(1.0mm thickness),
andtighten
the mountingbolts to the specifiedtorque (seeEx.
plodedView).
oCheckbacklashduringthe tighteningof the mounting
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
gauge.

.Set up a dial gaugeagainsta drivegeartooth to check

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-adjust
asnecessary.

NOTE
ott is OK to packtwo slrims. Do not pack three or more
Critns.

Front Eeyel Gear Backlash (rt fie gcar too6l

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.

'1.

Holder:57001-1049 3. Movethe drivegear.

2. Holdthe drivengear.

Shimsfor DriYe Ge.r

(mm)
Thickness

0.15
0.5
0.6
o.7
0.8
0.9
1.0
1.1
1.2

PartNumber
92025-1688
9202s-1689
9202s-1690
92025-1691
9202s-1692
92025-1693
92025-1694
92025-1695
92025-'t696

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

and reverse(coast) directions, while creating a drag on
the drive gear.
oCheck the drive pattern and coast pattern of the bevel
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,
following the examples shown. Then erasethe tooth
contact patterns, and check them again- Also check
the backlashevery time the shimsare replaced. Repat
the shim changeprocedureas necessary.
NOTE
olf the backla$ goes out of standard nngE after
changing dzims, corr*t the backla$ before checking
the tooth contact Daftem.
olt is OK to pack two drims. Do not pack three or more
{tims.

Corleet Tooth Contact Pattern

Shims for Driven Geal

Thickness(mm)

0.1
0.15
0.5
0.6
0.7
0.8
0.9
1.0
1.2

PartNumber
92025-1826
92025-1818
92025-1819
92025-1820
9202s-182'l
92025.1822
92025-1823
92025-1824
92025-1825

Toot r contact adiustmenl

oCleanany dirt and oil off the bevelgearteeth.
oApply checking compound'to 4 or 5 teeth on tt|e
driven gear.

Heel

1 . DriveGear
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.
*Replacthe part if it appearsdamaged.

l. Spring
2. CamFollower

3. DamperCam
4. OutputShaft

FINAL DRIVE 1G25

Ball Bearinglnspection
.Since the ball bearingis madeto extremlyclose
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
baring,replaceit.

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

BRAKES11-1

Brakes
Tableof Contents
ExplodedView
Specifications
SpecialTools.

BrakePedal
BrakePedalPositionAdjustment. . . ,
Caliper..
Front Caliper Removal
RearCaliper Removal
CaliperInstallation
DisassemblyNotes,

AssemblyNotes.. ,
Brake Pads.
Removal
lnsellation Notes

LiningWear.
MasterCylinderc
Front MasterCylinderInstallation
RearMasterCylinderRemoval

RearMasterCylinderInstallation
lnspectionand Adjustmentafter Installation

Disassembly.
Assembly.
Inspection(Visually).
BrakeDisc.

Wear
Warp...
BrakeFluid
Fluid LevelInspection.
BrakeFluidChange..
Bleeding
the BrakeLine.

11-2
114
114
11-5
11-5
11-5
11-5
11
11-6
11
11.6
116
11-6
11-7
11-7
11-7
11-7
11-7
11
11
11
11
11
11-9
11-9
11-9
11
11-9
... . 11-10
. . 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

CIt'
".vq

@@

1 . Front MasterCylinderAssembty
2 . Diaph.agm
3 , MasterCylinder
4 . Front BrakeLight Switch
5 . MasterCylinderClamp
5 . Piston
7 . Brake HoseClamp
L Fronl CaliperAssembly
I . Brake Pads
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-

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
Bola
3, BrakePedalLink CNamp
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

BrakeDiscs;
DiscThickness:
Front VN150OA
VNlSOOB
Rear
Discrunout

5.0mm

4.8- 5.1mm
5.8- 6.1mm
6.8- 7.1mm
Under
0.15mm

BrakeFluid:
Grade
Brand(recommended)

D.O.T.4
CastrolGirling-Universal
CastrolGT (LMA)
CastrolDiscBrakeFluid
CheckShockPremiumHeavyDuty

lmm

4.5mm
5.5mm
6.0mm
0.3mm

BRAKES11.5
the
.Whenthe brakepedalis in its restposition,measure
length@ indicatedin the figure.
*lf the length @ is not within the specifiedlength,
adiusta nut.

Brake Pedal
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
2 . Locknut
Lensth@
Standad:

3. Clevis

165mm

Caliper
A. Footpeg
B. BrakePedal

C. Pedal Positlon

rlf it is not, checkthe punch marksat the brakepedal

link pivot shaft, and the mastercylinder push rod
lencth.

A. PivotShafts

Front Caliper Removal

.Disconnectthe speedometer
cablelowerend.
.Loosen the banjo bolt at the caliper,and tighten it
lightly.
.Remove the calipermountingbolts and take off t}te
caliper.

B. Marks
NOTE

ausually it's not n*e&ry to adiust the pedal position,

but alwaysadiu# it when the master cylinder is dis
asembled.
olf the push rod length cannot be adjustedby turning
the clevis, the bnke pedal may be deformedor incorrectly installed.

A. CaliperMountingBolts
B. BanioBol:

C. Caliper
D. BrakeHose

aDisconnect
the brakehosefrom ihe caliper.
*lf the caliperis to bedisassembled
afterremovalandif
removethe pistonusing
compressed
air is not available,
the brakehose
the followingstepsbeforedisconnecting
from the caliDer.

11.6 BRAKES
oRemovethe pads.
oPumpthe brakeleveror pedalto removet}|e caliper
piston.
NOTE
olmmediately wipe up any brake fluid that Wills.

oTo avoid serious iniury, neyer place your fingerc or

palm inlide the caliper opening. lf you apply compr$sed air into the caliper, ihe piston may cru3hyour
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
A. Caliper
C. BrakeHose
B.Caliper
Mounting
Bolts

Caliper lnstallation

fluid seal,and push the piston into the cylinderby

hand. Take care tlrat neither the cvlindernor the
pistonskirt get scratched.
.Apply a thin coatof PBC(Poly Butyl Cuprysil)grease
to the caliperholdershaftsandholderholes.(PBCis a
grease).
specialhightemperature,
water-resistant
.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

deprssing dre breke lever or pdal then pump the
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,

1. AntirattleSpring

BrakePads
Dinssembly Notes
.Usingcompressed
air,remove
thepiston.

oCoverthe caliperopeningwith a clean,heavyclothoRemovethe pistonby lightly applyingcompressed

air
to whereth brakeline fits into the caliDer.

Removal
rRemove the caliper (see Front or Rear Caliper
Removal).

BRAKES11-7
.Take off the piston side pad from the caliper holder.
.Push the caliper holder to the piston side,and then
removethe pad from the caliper holder shaft.

MasterCylinders
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.

3. Pushthecaliperholder.

1. Pad
2. CaliperHolder

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

l. Tightenupperclampbolt first.
2. LowerClampBoll
oDo not attempt to driye the motolcrycle until fully
depresing dre brake levr 01 pdal dren pump dre
brake lever or pedal until the pad3 ars agaiffit dre disc.
The brake will not tunction on the filst application of
$e leveror pedal if this is not done.

Lining Wear
rlf the liningthickness
of eitherpadis lessthanthe
servicelimit, replace both pads in the caliper as a set.
Pad Lining Thickness
Standard:
ServiceLimit:

3. Mirror Holder
4. Clearance-

ouse a new flat washeron eachsideof the brakehose

fitting.
oTighrenthe banjo bolts to the specifiedorque (see
Exploded
View).

Rear Master Cylinder Removal

.Note the following.
oRemovethe cotter pin and then pull the joint pin out
of the pushrod clevisand brakepedal.

5.0 mm
I mm

1. LiningThickness
2- Service
Limit

A. Clevis
B. CotterPin

C. JointPin
D. PushRod

1I.8 BRAKBS
Rear Master Cylinder lnstallation
.Note thefollowing.
oReplace
the aluminumwasheron eachsideof thebrake
hosefitting with a new one. Be sure that the metal
pipe is properlyfitted into the U-shapednotch in the
mastercylinder.
oTightenthe banjo bolG to the specifiedtorque (see
ExplodedView).
oTightentle rear mastercylinder mountingbolts (2)
to thespecifiedtorque(seeExplodedView).

Insp*tion and Adiustment after lnstullation

oCheckandadlustthe followingitemsBrakePedalPosition
RearBrakeLight SwitchPosition
BrakeLineAir Bleed
BrakeDrag
BrakingPower
BrakeFluid Leak

Dinssembly
rRemovethe followingparts.
DustCover
Retainer
Pistonwith Secondary
Cup
PrimaryCup
Spring

oExcept tor the disc pads and disc; use only disc brake
fluid, isopropyl alcohol, or ethyl alcohol, for deaning
brake part!. Do not uis any other fluid for deaning
these parts. Gasoline,engine oil, or any other petro,
leum distillate will cass detedoration of dte rubber
parts. Oil spilled on any part will be diffic[lt to
wash off compltely, and will eventually deterioiete
the rubber used in the disc bEke.
oTake care not to scratchth Distonor the inner wall of
the cvlinder.

lnspection (Visually)
.Checkthat thereare no scratches,
wear,rust or pitting
on the followingparts.
Insideof the MasterCvlinder
Outsideof the Piston
PrimaryCups
Secondary
Cups
DustCovers
ReturnSprings
ReliefandSupplyPortPlugged
*lf they aredamaged,
replactiem.

oDo not removedre secordaryanp from the pbton since

rcmovslwill damagedrem.

q&
1. Primary
Cup
2. Secondary
Cup
3. Piston

4. Retainer
5. DustCover

Assembly
.Note thefollowing.
oBeforeassembly,cleanall parts includingthe master
cylinderwitlr brakefluid or alcoho,.
oApply brake fluid to the removedparts and to the
innerwallof the cylinder.

l. Reservoir
2. Diaphragm
3. RelifPort
4. SupplyPort
5. Cylinder
6. ReturnSpring
7. PrimaryCup
8. Piston
9. Secondary
Cup
10. DustCover
I 1. BrakeLever

BRAKES 11-9

'.:.*.:i::1........

BrakeDisc
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

VN15O0-A
VN1500-B

A. Lower Level Line

Standard
48 - 5.1 mm
53 - 6.1 mm

Limit
SerYice
45 mm
55 mm

B. UpperLevelLine

Rear Brake Fluid Reservoir

Rear Disc Thickness

Standard:
ServiceLimit

6.8 - 7.1 mm
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

Dbc Runout
Standard: Under0.15 mm
ServiceLimit: 03 mm

ochange the brake fluid in dre brake line completely if

the brake fluid must be re{illed but the type and brard
of dre brake fluid that aheady is in the rg3srvoir ars
unidentified. Aftsr cfianging the fluid, use only dre

I1.10 BRAKES
$me type and brand of fluid thereafter. Mixing
differsnt types and brands of brske fluid lowers the
brake fluid boiling point and co{ld cause the brake to
be ineffectiye. lt may also cause dre rubber brak parts
to deteliorate.

Rcommended Dirc Brake Fluid

Type
Brand

D.O.T.4
Check Sho.r( Premium Heavy Duty
Crstrql Gidin g.unive'ssl
Cactrol GT (f-MA)

ocheckthe fluid levelin the reservoiroften,replenishing

it asnecessary.
NOTE
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
haveenteredthe line.
oRepeatthis operationuntil fresh brake fluid comes
out from the plastichoseor the color of the fluid
cnanges.

Castrol Dbc Brake Fluid

Bnke Fluid Change

NOTE
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.

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

fluid in dle b|8ke line completrly if ths blak fluid
must be refilld but tre type and brand of the brake
fluid that b already in d|g roservoir are unidentified.

.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 reservoir
cap 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 mastrcvlinderand 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.
2. Pumo the brake leverand hold it
5. Close the bleed valve.
4. Releasethe brake lever.

.Attach a clearplastichosto the bleedvalveon the

caliper, and run the other end of the hose into a
container.
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 longtime3. 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 deteriorate.
4. Don't leavethe reservoircapoff for any lengthof
of the fluid.
time to avoidmoisturcontamination
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 causedeterioration 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.
1. Pump the brake lever until it becomes hard, and apply
the brakeleverand hold it.
2. Ouickly open and ctose the valve while holding the
brakeleverapplied.
3. Releasethe brakelever.

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

8. Brakefluid quickly ruins paintedsurfaces;any

fluid should be completely washed
immediately.

9. lf any of the brakeline fittingsor the bleedvalve

is openedat any time, the AIR MUST BE BLED
FROMTHE BRAKE.

l2-1
susPENsroN

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

12-2 SUSPENSTON
Exploded View

^4-*

a-@
o

^/1

4ioA.o,

i'o-t

qt

/.A

gF{9

@
@tD

o
@{J

-P
,g

@o@

1. Front Fork Lsg

2. Cap
3. Top Plug
4. Sp*er
5. ForkSpdng
6. Inmr Tubo
7. GuideBulh
8. Durt SalCap
9. Du3tSoal
10. Oil Sal

11. GuideBulh
12. CylinderPition Unit
13. C]ylinder
14. SihoftSpring
15. GylinderBase
16. OuterTubs
17. Axle ClampBolt
18. DrainBolt
19. Bottom Allsn Bolt

L : Apply non.pormanentlocking agent.

Tl : 20 N{n (2.0kgrn, 145 ft-lbl
T2 : 29 N-m (3O kgFm, 22 ft{b}
T3: 52 N.rn(53 kgrn 38 ft{b}

12
susPENsloN

es

sB

y*
@

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

FrontFork:
Forkoil:

Standard

VNlsOGA
Viscosity
SAE1OW2O
AmounVUnit
z136
+2.5mL
Whenchanging
oil 370mL

Forkoil level(Fullycompressedl 124x7 mm

Forkspringfreelength
475.5mm

ServiceLimit

vN 1500-8

<_
474 !2.5 mL
rt05 mL
1zl0t7 mm
412.5 mm

RearSuspension:
Rearshockabsorberspring
adjusterposition

2 of 5 positions

SpecialTools

BearingDriyer Set: 57q)i-f 129

From Fork CYinder Holder Handle: 57001-183

H.ndle Adapen 57001-1057

Oil Sealand BearingRemover:57d)1.168

F ont Orter TubsWeight: 5ZOO1-1218

Fork Oil SeelDriyert 57q11-1219

Jad( Stand: 570/J1-12aB

Atta.fiment: 57001-125.2

z166mm
404 mm

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.
Handlebar{Slideto eachside}
Capand Fork Top Plug

Front Fo* Oil

viscosity
sAE 10w2o
Amount per side
When changingoil:
About 370 mL
vN1500-A

vN1500-8

About ttos mL

After disasembly and

completely dryi
436 t25 mL
VN1500-A
474 !25 mL
VN1500-B
NOTE
Qump the fo* enough tim6 to expel the air form the
upper d lower chambe,s,

A. Handlebar
B. Retainer

C. Top Plug

.With the fork fully compressed

insert a tape measure
the distancefrom
or rod in the inneriube,andmeasure
the top of the innertubeto the oil.

ForkSpring
DrainScrew

l OilLevel

Fork Oil Level (Fully Complessedl

A. DrainScrew

.Allow the oil to draininto a suitablecontainer.lf you

pumpthe fork legsto forceout the oil, be sureto catch
asit squirtsout.
theoil in a container

vN1500-A
vN1s00-B

124 fl nm
ltlo i7 mm

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

or add oil and recheckthe oil level
oChange the oil of the other fork leg in the same
manner.

12

SUSPENSION

Removal (each fork leg)

.Using the jack stand and the attachment (special
toofs: 57001-1238or 12521or other suitablemeans
to llft the front of the motorcycle.
rRemovethe following.
Caliper(fromthe fork legto be removed.)
Front Wheel(seeWheelsflires
chapter)
Front Fender
.Loosnthe upperandlowerfork clampbolts.
.With a twistingmotion, work the fork leg down and
out

oTightenthe upper and lower fork clamp bolts to the

specified
torque(seeExplodedView).
oTightenthe caliper mountingbolts to the specified
torque(seeExplodedView in Brakechapter).
oCheckthe front brakeafter lnstallation.

oDo not attempt to ddve dre motororyaleumil futly

deprsssingthe brake levr, 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.

A. UpperClampBolt

B. LowerClampBolt

Dis*sembly
.Performthe following.
oRemove
the retainerandtakeoff the top plug.
oPullout the spacer,washer,andthefork spring.
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

A. Stm Head
B. lnnerTube

C. Aligned

oRemovethe piston and cylinder unit and the short

springfrom the top of the front fork tube.
oPrvthe dustsealcoverout of the fork tube.

susPENsloN12-7

A. DustSealCover

B. Pry Poini

oRemovethe dust sealand the retainrfrom the outer

tube.

fr

$
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 outrtube.
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.

1. Driver:57001-1219
2. UsedGuideBush
3. Slit (towardthe left or right)
4. NewGuideBush
5. Tap

GuideBush

Oil *al and Dust Seallnspecdon

*lf dustsealhasanydamage
or wear,replace
it.
.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 rmovesharpedgesor 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

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

Exc6$iye bsnding, followed by subcequent straightsning, canwsokendte inner tube.

Guide Bush lnspection

*Replace the guide bushesif they are damagedor worn.

2- DustSeal

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
Position

Spring
Setting Load Road Speed
Force
Soft

I
5

4
5

J
StIonger

Hard

Light Good

Low

tI tI tI

,t ,t 't

Heavy Bad

High

.Check to seethat both adiustingsleeves

are turned to
position.
the samerelative
1 . ForkSpring

2. FreeLength
Fork Sp ng Length
vN1500-A
Standad:
SerYiceLimit:
VNlsq'-B
St ndard;
Service Limit:

4755 mm
466 mm
412,5mm
ll{t4 mm

oll both sprins adiusting sleevB are not adiusted equsl'

ly, handling may be impailed and a hazardouscondi'
tion may r$ult.
NOTE
oBe s.rre to tum back the adiuiing sleate counfutclockwis from pNition 5 wlrq, eftening the *ring action.

Rear Shock Absorber

Adjustment
The rear shockabsorberhas 5 posllions so that the
spring can be adjustedfor different road and loading
conditions.

Remotral
.Using the iack standandthe attachment(specialtools:
57001-1238or 12521or other suitablemeansto Iift
the rearof the motorcycle.
.Removethe cap nu! lockwasher,
andflat washerfrom
the both endsof the rearshockabsorber.
rPull the rearshockabsorberoff the frame.

lnsallation Notes

rTighten the mountingnutsto the specifiedtorque(see

View).
Exploded
.Adjust the rearshockabsorberposition.

l . Lower Cover

2. AdiustingSleeve
5-

PositioningMarks

lf tie spring action feelstoo soft or too stiff, adjust it

in accordancewith the following table.

Rear Shock Absorber Wear

aRemovethe rearshockabsorbers.
.Visuallyinspectthe followingltems.
Stroke
Compression
Oil Leakage
OtherDamage
*lf there is any damageto the rearshockabsorber,or
one unit feels weakertian the other, replaceboth
asa set.
shockabsorbers

12-10 SUSPENSION
Bushing Wear
avisually
inspect
therubber
bushing.
tlf thyshowanysigns
of damage,
replace
them.

oPull back the swing arm and take ifoff. A cap on each
sldeof the swingarm will alsodrop off.

SwingArm

alnstallationis the reverseof removal. Note the following.

oTightenthe pivot shaft to the specifiedtorque (see
ExplodedView).
oTightenthe rear shockabsorbernuts to the specified
torque(seeExplodedView).
oTighten the calipermountingbolts to the specified
torque(seeExplodedView).
oMove the swing arm up and down to check for
abnormalfriction.

lnstallation

Removal
aUsing the iack stand and the attachment (special
iools: 57001-'1238
or 12521or other suitablemeans
to lift the rearof the motorcycle.
aRemovethe following.
RearWheel(seeWheels/Tires
chapter)
RearCaliper(seeBrakechapter)
Muffler(seeEngineTop Endchapter)
SwingArm Covers
RH RearShockAbsorber
FinalGearCase(seeFinalDrivechapter)

A. RH RearShockAbsorber
B. SwingArm
C. Cover
D. BrakeHose(takethe hoseout of the holder)

GreaseSealand Needle Bearing

Removal/Assembly
.Notethefollowing.
oRemove
theneedle
bearing
usinga oil sealandbearing
(special
remover
tool).

.Uns6rewthe pivot shaftandpull it out.

A. SwingArm

B. PivotShaft

A. Oil SealandBearingRemoveri57001-1058
B. NeedleBearing
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.
B. NeedleBearing

Seal
C. Grease

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...
SpecialTools.
Steering.
Adjustment.
Steering Stem
Removal
lnstallation
S t e e r i nSgt e mB e a r i n g .
BearingLubrication,. . . .
gearingWear,Damage.
Damage.
StemCapDeterioration,
S t e e r i nSgt e mW a r p. . . . .

.... '...

'. '.... '.

..'.'....

13'2
13-3
134
134
134
134
136
137
1;-7
13'7
13-7
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

"

A " , e @
@@/N

@S/r
d

P--{D

rc_o

@-)

e-o
e%t.

1. Handlsbst
2. Gollar
3. Handl. Holdel
4. Stsm HsadBolt
5. llta$r
6. SteeringStem Hed
7. St6mNutT:6mm
8. StemNut T 3 10 mm
9. StemCap
10. Foller Baling.(UpFll
11. RollsrBaring(Loworl
12. GrassSe.l
13. SteeringStem Base
14. Frame

STEERING13
SpecialTools

Driver PressShaft: 57001-1075

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

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

Steering
Adiustment
oCheck
asfollows.
steering

ouse the jack stand and the attachment(specialtools:

57001-1238,5700'l-1252\to lift the front wheeloff
the ground.
owith ttle front wheel pointing straightaheadaltrnately tap each end of the handlebar. The front
wheelshouldsriing fully left and right from the force
of gravityuntil the fork hir the stop.
*lf tl|e wheel binds or catchesbefore the stop, the
steeringis too tight.
oFeel for steeringlooseness
by pushingand pullingthe
forks.
*lf you feel looseness
on the forks, the sGeringis too
loose.

.Tighten the steeringstem headbolt to the specified

torque(seeExplodedView).
.Tighten the front fork lower clamp bolc to the specified torque (see Exploded View in Suspension
chapter).
.Checkthe steeringagain.
*lf the steeringis still too tight or too loose,repeatthe
adiustment.
alnstallthe removedDarts.

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.
.Removethe followingparts.
FuelTank
Fork LowerClampBolts(bothsides)
StemHeadBolt (Loosen)
.Adjust the steeringwith the stemnut wrench(special
tool).

SteeringStem
Removal
.Removethe following.
FuelTank
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

A. HeadlightLowerBolts

B. StemBase

.Remove the stem head bolt and flat washer.

.Pull up the steeringstem head with the handlebarand
headlightunit.

A. StemHeadBolt
B. washer

B. Cap

aRemovethe upper taperedroller bearinginner raceinto the headpipe,

.To removethe ouler racespressed
(special
tool) asshown
installthe stembearingremover
remover
to drive
bearing
hammer
the
stem
and
below,
it out.

NOTE
otf either steeringstembearingis damaged,it is rudrl'
mended that both the upper and lower baings (in'
st ould be replacedwith new on6'
cluding ouw lE,ces)

C. Handlebar
Unit
D. Headlight
57001-1107
Remover:
1. StemBearing

rPushup on the stembase,andremovethe steeringstem

locknutswith the stemcap usingthe stemnut wrench
(specialtool), thcn removethe sieeringstemand stem
base(singleunit).

.TaD the bottom of the lowerinnerracewith a chisel.

oPry the innerraceout of the stemwith a suitablemetal
lever.

136 STEERING

1 . Grease
Seal
2. LowerInnerRace

3. TapHear

lnstallation
.lnstallation is reverse
of removal. Note the following.
oApply greaseto the outer racs,and then drivethem
into the headpipeusingthe driversandthe driverpress
shaft(specialtools).

l. StemBearing
Driver:57001-137
2. Adapten 57W1-1O74
rThe following four stepsshould be prformedafter
steringbearinginstallation.This proceduresettlesthe
bearings
in place.
ousingthe stemnut wrench,tightenthe stemlocknut to
39 N-m (4.0 kg-m,29 ft-lb) oftorque. (To tightenthe
steringstem locknutto the spcifiedtorque,hook the
wrenchon the stemlocknut,and pull the wrenchat the
holeby 22.2 kg forcein the directionshown.)

'I
80 mm

Kg

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

l. Driver
Press
Shaft:57001-1075
2. Drtuer:57001-1
106
3. Driver:57001-1076

oApply.gfeaseto tle lower taperedroller bearing,and

drive it onto the steeringstemusingthe stembearing
driverandadaprcr(special
tools).

checkthat there is no play andthe steeringstemturns

smoothlywithout rattling.
*lf not, the steeringstembearingmaybe damaged.
oAgainback out the stem locknut a fraction of a turn
until it turnslightly.
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
Throtile Cables
ChokeCable
Front Brake

STEERING1&7
SteeringStem Bearing
Bearing Lubrication
.Perform the following.
oRemovethe steeringstem.
ousing a high flash-pointsolvent,washthe upper and
in thecages.
lowertaperedroller bearings
owipe the upper and lower outer races,which are
press-fittedinto the frame headpipe,cleanoff grease
anddirt.
oVisuallycheckthe outerracesandthe rollrs.
*Replace the bearingassmblies
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 greassealif necessary.

Steering Stem Warp

*lf the steering
thesteering
stemshaftis bent,replace
stem.

FRAME 1'&1

Frame
Tableof Gontents
ExplodedVia^l
Right Down Tube
Removal(To AccessRight EngineCoverl. .
RearFender
RearFender RearSectionRemoval.
RearFenderFront SectionRemonal.
Footpeg,
Right Footpeg Removal
Right Footpeg Installation

1+2
1+5
1+5
1+5
1+5
146
1+6
AA
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.

.,^@

ost

<,-@

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

1.
2.
3,
4.
5.
6.
7.
8,
9,
10,

F ame Top Tube Coyer LH

Frame Top Tub Cover RH
Fud Filter Bracket
Frame
EngineMounting Brackgt
Right Dol/vn Tube
Front Footpeg LH
Footpeg Bracket
Footpeg Bracket
Front Footpeg RH

1 1 .Rear Footpeg LH
12. Footpg Bracket
13. Footpeg Blacket
14. Rear Footpeg RH
15, Baak Frame

FRAME 14

@q

___9_
-/

1.
2.
3.
4.
5.
6.
7.

Front Fndsr
Rider's Sest
Pa$enger's Sat
Rear Fender Front Section
Rear Fender Rear Section
Seat
Rear Fender

,,t',

L-

1.1

vN1500-8

/Eurqeanudrel

ffi\
(

EuropeanModel

T'I4 FRAME
1. Battery Band
2. Battery C.se
3. Elestric PartsBr*ket
4, Fuel PumpBrsdct
5, lgnitr &ad(et
6. lgnruon CoiaBFckst
7. liide Stand
8. SideStandSwitch
G : Apply grease.

Fr
\l

s*

FRAME 1/L5
Right Down Tube

Remoml(To AccessBight EngineCover)

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

A. EngineMountingBolts
B. BracketBolts

C. DownTubeBola

.Take tlle right down tube out of the frametowatd the

rear
A. Stand

aRemovethe radiatorcorr.
oUnscrewthe radiatorlowermountingbolts.

A. DownTube

A. Radiator

B. LowerMountingBolts

RearFender
.Remove the coolant reservoirtank covr(seeCooling
Systemchapter),and take the tank out of the bracket.
aRemovethe fuel tank and RHframetop tube cover.
.Disconnectthe rearbrakelightswitchwireconnectors.
.Unbolt the following,

Rear Fender Rear Section Remotnl

.Disconnectthe rear turn signaland tail li8ht wire
connectors.

14.6 FRAME

A. hsgengpr
Sat mountingBols (VNt 50GA)

A. Turn SignalLight Connectors

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
B. FenderBolt

C. BackFrame8o16

aTake tle rear fender rar section witi the passenger

seat and the back frame out of tl|e ftame, and then
separatethem if necesory.
oRemovetl|e rear backframe bolts anddisonnect
the
turn signalwire connectors.

A. RearFenderFront Section B. Bolls

Footpeg

A. BackFrameBolt

Bigtht Footpeg Removal

.Remo\ the RH exhaustpipe.
oRemovethe exhaustpipeholders.
oloosenthe exhaustpipeclampscrew.
oPullthe exhaustpipeout of the muffler.
.Removethe brakepedallink clampbolt.
.Removthe footpegmountingbolB,

FRAME 1+7

A. BrakePedalLink ClampBolt
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.

A. Alignthe punchmarks.

1$38 ELECTRICALSYSTEM
*lf the relaydoesnot work asspecified,
thenreplacethe
junctionbox.
Relay Girouit Inspeaion {with the battery disconncd}
METERCONNECTIONMETERREADINC(9)
FAN
RELAY

HEADLICHT
RETAY

*7-8
*7 -13

STARTER
RELAY

11-13
12-13

*The resistance
shouldbe low in onedirectionandmore
than ten timesas much in the other direction. lf any
diodeshowslow or highin both directions,the diodeis
defectiveandthe diodeassemblymustbe replaced.

RelayCircsit In$sction (with the batteryconn6ed)

BATTERY
METER
METER
CONNECTION READINC
CONNECTION
(0)

HTADIICH'I
STARTER

Terminals
for DiodeCircuit Inspection
r*11-12, i13-8, +13-9. 12-14,.t5-14,16_14
* US/QnadaModelOnly
*'* VN150GA9-

*,'.vN150GA9-

FAN

Diode Circuit lnspection

.Rmovethejunctionbox from the motorcycle.
.Pull off the connectors
from the junctionbox.
.Check conductivityof the following pair of terminals.

2-4

.7 -8

9-13

1 1- ' 1 3

11-12

0
0

NOTE
oThe &tual meter ,@ding varia with dte meter ud
and the individual diode, but. gercn y q@kiry, the
loy,Er tding *ould be from zero to one half d\e
*ale.

* US/ CANADAMODELONLY
,,r,vN1sflrAgJunction 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

VN15OO-A2-Aa / 82-86

Wiring Diag.am (Orher than US and Canadal

@ 0

l l

RightTu.nSi9tulhdharor

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

12v 6ry55W

O'tr Lionr

rH{rwe
ridr 12v 2r w

adTls",Y+q>BvY
\v,/+J-c +CFcy-

Lianit2 v 2r w

fd-l-"*r"*-"*r"

F,6r ii4tr torn Siodl

\-4_F6-+{}-c-

$$f

fiA
NX

4hs

t{
94

\9./
I
1 2 V2 . 5a x 2

-k
oil

I Sr.rt . Loctoor Switd

LCFT HANDLEBAR S{VIICH OOI{NECTIOI{S

Tum Sicnl Swiid

Color

Dimm.r Swildl

GY

Color

R/BK

8L/Y

SterE Lo.*our Switrh

HI

Color
Ralaeed

LO

Pull.d in

BK/Y

8K

BK/R

rA
[8{

ELECTRICAL SYSTEM 15.39

BL

VN150GA only

n-l

AK

12V5W

J+s
fifiil
YTY

8K
BL
BR
CH

fl

rA:

G
GY
LB
LG

I\cYI

RTGHT HA!{OLEaAR SffUYCH COt{ltECTtOl{S

Starter Buiton

Headliqht Switch

Enqine Stop Switch

Color
OFF

Color

RUN

ON

R/8L

BL

SKTY

Color

BK

(98051.1069A,1092A)

15.4O ELECTRICAL SYSTEM

VN15OO-A9- Wiring Diagram (US and Canada)
1. Froar Srake Liohr Swnch

t
t

l
l

;#"-T---rr

/A
{oto}

tY
t l

I I

VD

!+

ffif.H

:::""
iii::-

-{.

L\fffrHffi
i.i

35

Eq:;*6

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.

( E J l lGY" ->G
*DE
DE
/'-]:5--!

r2 v 23law

\:=.}

/>fi

sL +E-

Br

(9JJHffi"s

a3

0!
4U

t=
1 r

t l

I
t -

r---{on

EX

;oi

OH

nn

,-:\\

g/

T!'J"..o

E]6:.

t l

5 3 6 d .

?2
(1,

A"

l f

l.

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
-Bun-fr- B!ll-J+!
^
-n(FRtlfftu\l

t--nt3
-----T..-.v
B(/Yil (-)
acc.sry

BK/y----{.E/

:
I
I

N(
AK
AL
gF
CH
DG

EW
HTJIJ

o9o

.l_L
t

ri-

tt

[e/]

l/.|ll

. r " -':l g

Innl

-A
r

/l

L.ad.

ilE*9''
GY ----fi6\
c E<x./y,E<F

/arak.uehB
!i r.tzvaatw"z

GY

!a

nfltll:'il'''
rum

F.r Leh
shar
Lisnt12v 23w

APPENDIX1S1

Appendix
Tableof Contents

for Racing
Additional Considerations
Carburstor
SparkPlug
SparkPlugInspection
T r o u b l e s h o o tG
i nugi d e . .
General
Lubrication....
Lubrication
Nut, Bolt, and FastenerTightness
TightnessInspection
Unit Conversion
Table . . ..

.......

16-2
16-2
16-2
16-2
16"4
16
168
16
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 RECOMMENDSTHAT ALL RIDERS RIDE SAFELY AND
OBEY ALL LAWSAND REGULATIONS
CONCERNING 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 motorcycle under abnormalconditionssuch as racing,and
Kawasakishall not be liable for any damageswhich
mightarisfrom suchuse.
.Kawasaki'sLimited MotorcycleWarrantyand Limited
EmissionControl SystsmsWarranty specificallyexclude 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 alterationsutilizingthis information.
.When tie motorcycleis operatrdon public roads,it
m|lst be in is originalstate in 'ordr 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 temperatureis 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
electrodes
andthe 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 improved 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 richermixture.

Spark Plug:
The spark plug ignitesthe fuefair mixture in the
combustioncharnber.To do this effectivelyand at the
propertime, the correctspark plug must be usd,and
the sparkplugmustbe kept cleanandadiusted.
Test haveshown the plug listd in tlre "Electrical
System"chapterto bethe bestplugfor generaluse.
Sincesparkplug requirements
changewith the ignition and carburetionadjustments
and with ridingconditions, whetheror not a sparkplug of a correct heat range
is usedshouldbe determinedby removingand inspecting the plug.

I . Terminal
2. lnsulator
3. cement

4. Gasket
5. CenterElectrode
6. SideElectrode

SparkPlug lnspection
.Removethe sparkplugand inspecttl|e ceramicinsulator.

APPENDIX1G3
Spa* Plug Condition

Carbon Fouling

Oil Fouling

*Whetheror not the right temperature

plugis beingused
can be ascertainedby noting t$e condition of the
ceramicinsulatoraroundthe electrode.A light brown
color indicatesthe correctplug is being used. lf the
ceramicis white, the plug is operatingat too high a
temperatureand it shouldbe replacedwith the next
coldertype.

olf the spark plug ir replaced with a tyFe odror dran the
standard plug, mako certain the replacemem plug has
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 $e plug reach b too short, ca.bon will build up on
the plug hole threads in the .rylinder heed, cau:ing overheating and making it very dilfidrlt to insert the
coJrect spark plug later.
olf the reach b too long, carbon will build up on the expos6d spark plug thrcad: caBing ovedreating.
preignition, and po$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

Carbon
buildsup here

Correctreach

Normal Operation

Overheating

Standad Spark Plug Thread:

Diameter: 12 mm
Pitch:
125 mm
Readr:
19.0 mm

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
in enginedamage)or too cold (with poor performance,
misfhing,and sta ing).

164 APPENDIX
TroubleshootingGuide
NOTE
oThis is not an exhaustive list, giving every posible
cau*s
for e*h problem li&ed. lt is ment simply as a
rough guide tu. assisrthe trcubleshootingfor sme of
the morecommondiff icutti*.
Engine Doesn't Start, Starting Difficultyl
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 ovr:
Valveseizure
Rockerarm seizure
Cylinder,pistonseizure
seizure
Crankshaft
Connecting
rod smallendseizure
Connecting
rod big endseizure
gearor bearingseizure
Transmission
Camshaftseizure
bearingseizure
Balancer
No tuel flow:
Fueltank air ventobs$ucted
Fuelpumptrouble
Fueltap clogged
Fuellineclogged
Floatvalveclogged
Engineflooded!
Fuellevelin carburetorfloat bowl too high
Floatvalveworn or stuckoDen
Startingtechniquefaulty
(Whenflooded,crank the enginewith the throttle
fully open to allow more air to reach the
engine.)
No 3park;sparkweak:
Batteryvoltagelow
Sparkplugdirty, broken,or maladjusted
Sparkplugcapor hightensionwiringtrouble
Sparkplugcapnot in goodcontact
Sparkplugincorrect
lC ignitertrouble
Neutral, starter lockout, or side stand switch
trouble
Pickupcoil trouble
lgnitioncoil trouble
lgnitionor enginestopswitchshorted
Wiringshortedor open
Fuseblown
Compreasion
Lowr
Sparkplugloose
Cylinderheadnot sufficientlytightneddown

Cylinder,pistonworn
Pistonringbad{worn,weakbroken,or sticking}
Pistonringlgrooveclearance
excessive
Cylinderheadgasketdamaged
Cylinderheadwarped
Valvespringbrokenor weak
Valve not seatingproperly (valvebent, worn, or
on the seatingsurface)
carbonaccumulation
Hydrauliclashadjustrdamaged(worn,seizure,or
springbroken)
clogged
Hydrauliclashadjusteroil p4ssage

Poor Runningor at Low Speed:

Spsrkwe8k:
Batteryvoltagelow
Sparkplugdirty, broken,or matadiusted
Sparkplugcapor hightensionwiringtrouble
SparkPlugcapshortedor not in goodcontact
Sp k plugincorrect
lC ignitertrouble
Pickupcoil trouble
lgnitioncoil trouble
Fuel/airmlxl re incorect:
Pilotscrewmaladiusted
, Pilot jet, or air passage
clogged .
Needlejet (air bleedpipe),bleedholesclogged
Pilot passage
clogged
Air cleanerclogged,poorly sealed,or missing
Stzrtrplungerstuckopen
Fuel levelin carburetorfloat bowl too highor too
low
Fueltank air ventobstructed
Carburetorholderloose
Air cleaneror surgetank duct loose
Fuelpumptrouble
Backfiringwhen deceleration:
Vacuumswitchvalvebroken
Air suctionvalvetrouble
Other:
lC ignitrtrouble
not synchronizin!
Carburetors
Carburetorvacuumpistondoesn'tslidesmoothly
Engineoil viscositytoo high
Drivetrain tiouble
Finalgearcaseoil viscositytoo high
Brakedragging
Air suctionvalvetrouble
Vacuumswitchvalvetrouble

APPENDIX1G5
Poor Runningor No Powerat High Speed:
Firingincorresti
Sparkplugdirty, broken,or maladiusted
Sparkplugcapshortedor not in goodcontact
Sparkplugincorrect
lC ignitertrouble
PickuDcoil trouble
lgnitioncoil trouble
Fuel/airmixtureincorrcct:
Starterplungerstuckopen
Mainjet cloggedor wrongsize
Jet needleor needleiet worn
Air.iet clogged
Fuel lewl in carburetorfloat bowl too highor too
Bleedholesof air bleedpipeor needleiet clogged
Air cleanerclogged,poorlysaled, or missing
Air cleaneror surgetankduct poorly sealed
Waterof foreign matter in fue,
Fueltap clogged
Fuellineclogged
Fuelpumptrouble
Knod(ingr
Carbonbuilt up in combustionchamber
Fuelpoorqualityor incorrect
Sparkplugincorrect
lC ignitertrouble
Backfiring whendeceleration:
Vacuumswitchvalvebroken
Air suctionvalvetrouble
MLcellaneo$:
Throttlevalvewon't fully open
Carburetorvacuumpistondon't slidesmoothly
Brakedragging
Clutchslipping
Overheating
Engineoil leveltoo high
Engineoil viscositytoo high
Drivetraintrouble
Finalgearcaseoil viscositytoo high
Air suctionyalvetrouble
Vacuumswitchvalvetrouble
mechanism
malfunctioning
Balancer

Engineloadfaultyi
Clutchslipping
Engineoil leveltoo high
Engineoil viscositytoo high
Drivetrain trouble
Finalgearcaseoil viscositytoo high
Brakedragging
Lubricationinadequate:
Engineoil leveltoo low
Engineoil poor qualityor incorrect
Gaugeincorred:
gaugebroken
Watertemperature
Watertemperaturesensorbroken
Coolantincorrecl:
Coolantleveltoo low
Coolantdeteriorated
Coolingsystemcomponentincorlect:
Radiatorclogged
Thermostattrouble
Radiatorcaptrouble
Thermostatic
fan switchtrouble
Fanrelaytrouble
Fanmotor broken
Fanbladedamaged
waterpumpnot turning
Waterpumpimpellerdamaged

Over Cooling:
Gaugeincorrect:
gaugebroken
Watertemperature
rnsor broken
Watertemperature
Coolingsystemaomponentincorrect!
Thermostatic
fan switchtouble
Thermostattrouble

Clutch Operation Faulty :

Overheating:
Firingincorrect:
Sparkplug,broken,or maladjusted
Sparkpluginconect
lC ignitertrouble
Fuel/air mlxtrrc incorrect;
Mainjet cloggedor wrongsize
Fuellevelin carburetorfloat bowl too low
Carburetorholderloose
Air cleanerpoorly sealed,
or missing
Air cleaneror surgetankduct poorly sealed
Air cleanerduct loose

Clutchslipping:
Frictionplatewornor warped
SGelplateworn or warped
Clutchspringbrokenor weak
Clutchslavecylindertrouble
CIurchhub or housingunevenlyworn
Clutdr not dbengsgingpropsrly:
Clutchplatewarpedor too rough
Engineoil deteriorated
Engineoil viscositytoo high
Engineoil leveltoo high
Clutchhousingfrozenon dliveshaft
Clutchslavecylindertrouble
Clutchhub locknutloose
Air in the clutchfluid line

16.6 APPENDIX
Clutchfluid leak
Clutchfluid deteriorated
Primaryor secondary
cup damaged
MasGrcylinderscratched
inside
Gear Shifting Faulty:
Dosnt go into gear;rhaft pedaldo6nt lsturn:
Clutchnot disengaging
Shift fork bent or seized
c'earstuck on the sltaft
Gearpositioningleverbinding
Shift returnspringweakor broken
Shift returnspringbolt loose
arm springbroken
Shift mechanism
arm broken
Shift mechanism
Shift pawlbroken
JumF out of gar:
Shift fork worn
Geargroor worn
Geardogsand/or dog holesworn
Shift drumgrooraworn
Gearpositioningleverspringweakor broken
Shift fork pin worn
Driveshaft, output shaft, and/or gearsplinesworn
Ovenhifts:
Gearpositioningle\r springweakor broken
arm springbroken
Shift mechanism
Abnormal Engine Noise:
Knoddng:
lC ignitertrouble
Carbonbuilt up in combustionchamber
Fuelpoorqualityor inconect
Sparkplugincorrect
Overheating
Pbtondap:
Cylinder/piston
clearance
excessive
Cylinder,pistonworn
Connecting
rod bent
Pistonpin, pistonholesworn
Valvenoise:
Engine not sufficiently warmed up after lash
adius&rinstallation
(worn,seizure,or
Hydrauliclashadjusterdamaged
springbroken)
Air in hydrauliclastradiuster
Metal chips or dust jammed in hydraulic lash
adiuster
Engineoperatedin red zone
Valvespringbrokenor weak
Camshaftbearingworn
Odrernoise:
Connecting
rod smallendclearance
excessive
Connecting
rod bigendclearance
excessive
Pistonringworn,brokenor stuck
Pistonseizure,damage
Cylinderheadgasketleaking
Exhaustpipeleakingat cylinderheadconnection
Crankshaft
runoutexcessive
Enginemountsloose
Crankshaft
bearingworn

Primarygearworn or chipped
Camshaftchaintnsionertrouble
Camshaftchain,sprocket,guideworn
Air suctionvalvedamaged
Vacuumswitchrralvedamaged
gearwornor chipped
Balancer
shaftpositionmaladiusted
Balancer
bearingworn
Balancer
Waterpumpchain,sprocketworn
Abnormal Drive Train Noise :
Glut*r noire:
Weakor damagedrubberdamper
excessive
Clutchhousingfrictionplateclearance
Clutchhousinggearworn
Tnnarni$ion noise:
Bearings
worn
Transmissiongearsworn or chipped
Metalchipsiammedin gearGeth
Engineoil insufficient
Drivelinenoice:
Bevelgearbearingsworn
Bevelgearsworn or chipped
Bevelgearsmaladiusted
Rearwheelcouplingdamaged
lnsufficientlubricant
Abnormal Frame Noise:
Front fork noise:
Oil insufficientor too thin
Springweakor broken
Rsarshockab6orbsrnoiao:
Shockabsorberdamaged
Dilc brakenobe:
Padinstalledincorrectly
Padsurfaceglazed
Discwarped
Calipertrouble
Othe?nobe:
Bracket,nut, bolt, etc. not properlymountedor
tightned

WarningLight GosOn:
Oil Pressure
Engineoil pumpdamaged
Engineoil screenclogged
Engineoil filter clogged
Engineoil le\l too low
Engineoil viscositytoo low
worn
Camshaftbearings
worn
Crankshaftbearings
Oil presureswitchdamaged
Wiringdamaged
Reliefvalvestuckopen
O{ing at t}te oil pipein tl|e cnnkcasedamaged

ExhaustSmokesExcessively
:
Uvhitesmoke;
Pistonoil ring worn
Cylinderworn
Valveoil sealdamaged
Valveguidewom
Engineoil levltoo high

APPENDIX1G7
Blacksmoke:
Air cleanerclogged
Mainjet too largeor fallenoff
Starterplungerstuckopen
Fuellevelin carburetorfloat bowl too high
Brown3moks:
Mainje! too small
Fuellevelin carburetorfloat bowl too low
Air cleaneror surgetank duct loose
Air cleanerpoorlysealedor missing

Handlingand/or Stability Unsatisfactory:

Handlebar
hardto tr]n:
Steerintstmlocknuttoo tight
damaged
Bearing
Steering
bearinglubricationinadequate
stembent
Steering
Tireair pressure
too low
Handlebarshak6 ol excelEiyelyriblates;
Tireworn.
Swingarrdpivot bearingworn
Rimwarped,or not balanced
lVheelbearingworn
Handlebar
clamploose
stemheadnut loos
Steering
Hrndlebrpulls to ons ride:
Framebent
lvhelmisalignment
Swingarmbentor twisted
maladiusted
Steering
Frontfork bent
(oil level)
Right/leftfork legsunbalanced
Shod(aborption unrati3factory:
(Toohard)
Frontfork oil excessive
Frontfork oil viscositytoo high
Tireair pressure
too 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
pad
Contamina@d
Brakefl uid deteriorated
Primaryor secondary
cup damaged
Mastercylinderscratched
inside

BatteryDischarged:
Battery faulty (eg., plates sulphated,shorted
through sedimentation,electrolyte level too
low)
Batteryleadsmakingpoor contact
(eg.,bulb of excessiwwattage)
Loadexcessive

lgnitionswitchtrouble
Alternatortrouble
Wiringfaulty
Battery Overcharged:
Alternatortrouble
Regulatorrectifier trouble

1G8 APPENDIX
Also,checkto seethat eachcotterpin is in placeandin
goodcondition.

GeneralLubrication

NOTE
Lubrication
.Before lubricatingeachpart, cleanoff any rusty spots
with rust removerand wipe off any grease,oil, dirt,
or grime.
.Lubricate the points listed below witi indicated
lubricantNOTE
owhenever the vehicle h6 been opented wd or
rainy conditions, or 8peially after using a highpresunespny n6ter. perform the genenl lubiation.
PiYots: Lubricatswittt Motor Oil.
SideStand
ClutchLever
BrakeLever
BrakePedal
RearBrakeRod Joint
Point: Lubricatewith Grease.
Throttle lnnerCablesLowerEnd
Speedometer
InnerCablet
+Grease
the lowerpart of the innroablesparingly.
Cabl$; Lubricatewith ilotor Oil.
ChokeCable
ThrottleCables
CableLubrication

1 . Cable
2 . Pressure
ableLuber: K55019{21

Nut, Bolt, and FasenerTightness

Tightnesslnspection
theck the tightness
of the boltsandnutslistedhere.

oFor the engine fasteners.check the tightnes of them

whenthe engineis cold (at room tempercture).
*lf there are loose fasteners,retorque them to the
specified torque following the specifiedtightening
sequence.Refer'tothe appropriatechapterfor torque
specifications.lf torque specifications
are not in the
appropriatechapter, see the basictorque table (see
Torqueand Lirking Agent in the GeneralInformation
chapter).
For each fastener,'first loosnit by l/a turn, then
tightenit.
*lf cottr pins are damaged,replacethem with new
ones.
Nut, Bolt,and Fas@ner
to be dlecked
Wheels:
Front Axle Nut
Front Axle ClampBolts
RearAxle Nut
RearAxle Nut Crtter Pin
Brakes:
Front MasterCylinderClampBolts
FrontC.aliper
MountingBolts
RearMasterCylinderMountingBolts
RearCaliperHolderMountingBolts
RearCaliperMountingBolts
BrakeLeverPivotNut
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
ClutchMasterCylinderClampBolts
ClutchLeverPivotNut
RadiatorMountbg Bolts
shift PedalBolt
Others:
SideStandNut
RearFrameMountingBolts
RightDownTubeMountingBolts
BackFrameMountingBolts
FootpegBracketMountingBolts
FinalGearCaseMountingNuts

APPENDIX1G9
Unitsof Length:

Table
Unit Conversion

k
m
m
mm

Prefixesfor Units:
Prefix
mega
kilo
centi
milli
micro

x 1,000,000
x 1,0O0
x 0.01
x 0.001
x 0.000001

tt

=
3.281
0.03937 =

mile
ft
in

0.1020
o.7376
8.85r

kgm
ft-lb
in-lb

Units of Torque:
N-m
N-m
N-m

x
x

Kg-m

ksm
ksm

x
x

9.807
7.233
86.80

=
=
=

N-m
ft-lb
in-lb

tb
oz

2.205
0.03527=

x
x

0.6214

Power

Symbol
M
k
c
m

Unitsof Mass:
k
g

x
x

Units of Pr6sure:
kPa
kPa
kPa
kg/cm2
kg/cm'
cm Hg

Unitsof Volume:
L
L
L
L

x
x
x

x
x
x
x
x

L
mL
ML
mL

sal(us)

o.2642
o.2200
1.057
0.8799
2.113
1.816
0.03381 =
0.02816=
0.06102=

Unitsof Force:
N
x
N
x
x
kg
x
kg

gal (imp)

qt (us)
qt (imp)
pint (US)
pint (imp)

oz(us)

0.01020=
0.1450 =
0.7501 =
98.07
14.22
1.333

kg/cm'
psi
cm Hg

o.6214

mph

1.360
1.341

PS
HP

kPa
psi
kPa

Units of Speed:

oz (imp)
cu in

km/h

Unitsof Power:
k
W
x
k
W
x
PS
x
PS
x

0.1020 - k g
o.2248 = t b
9.807
2.205

x
x
x
x
x
x

=
N
= t b

0.735s = k w
0.9863 = H P

Units of Temperature:

s ('Fj 40)_ 40_ .c

9 fcj40) _40_.F

.F

r
40

-40

'c

,20

32
20 lao

o i
4A

5a

60 |

104

80

tool

12o

l4o

160

llso

2oo i22o

24oi 260 2aoi

r2o

ir4o

3oo

32o

MODELAPPLICATION
Year

Model

1987 vN1500-41

vN1500-81
1988 vN1500-42

vN1500-82

1989 vN1500-43
vN1500-83
1990 vN1500-A3
vN1500-83
1991 vN1500-A5

vN'1500-85
1992 vN1500-45
vN1500-86

'1993 vN1500-A7
1994 vN1500-A8
1995 vN1500-A9

1996
1997
1998
1999

vN1500-A10
vN1500-A11
vN1s00-A12
vN1500-4t 3

Beginning
FrameNo.
JKBVNMIt]HAOOOO2l
JKBVNAB1trHA00001
1,or
JKBVNABl
!H85OOOO1
JKBVNMlnJA001001,or
wN50A-001001
JKBVNAB'1
DJAOOOSOl,or
JKBVNAB,l
!J85OO6O1,Or
wN50A-003001

JKBVNM1trKA003001,or
wN50A-003001
JKBVNAB1nKA002001,or
wN50B-002001
JKBVNAAI
trLAOO3OO'I,or
wN50A-004001
JKBVNABI
NLBsOI40l,or
wN508-003001
JKBVNAA1trMA006001,or
vTN50A-006001

wNs0B-00s001
JKBVNAAI
NNAOOgOOI,or
wN50A-009001
wN50B-009001
JKBVNAA'I
trPAO13OO1
JKBVNAAlNRAO2OOOl
JKBVNAAl NSAO2600l

JKBVNMl ITAO4OOO1
JKBVNAAlIVAO60OO1
JKBVNMl !WAO7sOO1
JKBVNAA1trXAO85OO1

}lKawasaki

KAWASAKI HEAVY INDUSTRIES,LTD.

ConrunerPrcductu& rchlneryGroup

Part No. 9992't-1078-08

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