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Owner’s Manual VN900BCF (2012)

Item # 99987-1701

MSRP

$18.15

Kawasaki Owner’s Manuals include Important Safety Information, Operating Instructions, and Maintenance and Storage Information.

Most items ship to dealer within 5-7 business days for free. Special dealer only items may be excluded.

Additional shipping charges apply to qualified ship to home orders.

Price and specifications are subject to change without notice or liability. Availability is subject to production, stocking and demand. Manufacturers suggested retail prices shown.

WARNING: Cancer and reproductive harm www.P65Warnings.ca.gov

WARRANTY INFORMATION

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VULCAN900 CLASSIC

VULCAN900 CLASSIC LT

VN900 CLASSIC

Motorcycle

Service Manual

Quick Reference Guide

This quick reference guide will assist you in locating a desired topic or procedure.

•Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page.

•Refer to the sectional table of contents for the exact pages to locate the specific topic required.

General Information	1	j

Periodic Maintenance	2	j

Fuel System (DFI)	3	j

Cooling System	4	j

Engine Top End	5	j

Clutch	6	j

Engine Lubrication System	7	j

Engine Removal/Installation	8	j

Crankshaft/Transmission	9	j

Wheels/Tires	10	j

Final Drive	11	j

Brakes	12	j

Suspension	13	j

Steering	14	j

Frame	15	j

Electrical System	16	j

Appendix	17	j

VULCAN900 CLASSIC

VULCAN900 CLASSIC LT

VN900 CLASSIC

Motorcycle

Service Manual

All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your motorcycle dealer for the latest information on product improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.

First Edition (1): Feb. 7, 2006 (M)

LIST OF ABBREVIATIONS

A	ampere(s)	lb	pounds(s)
ABDC	after bottom dead center	m	meter(s)
AC	alternating current	min	minute(s)
ATDC	after top dead center	N	newton(s)
BBDC	before bottom dead center	Pa	pascal(s)
BDC	bottom dead center	PS	horsepower
BTDC	before top dead center	psi	pound(s) per square inch
°C	degree(s) Celsius	r	revolution
DC	direct current	rpm	revolution(s) per minute
F	farad(s)	TDC	top dead center
°F	degree(s) Fahrenheit	TIR	total indicator reading
ft	foot, feet	V	volt(s)
g	gram(s)	W	watt(s)
h	hour(s)	Ω	ohm(s)
L	liter(s)

EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only.

1. Crankcase Emission Control System

This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors are routed through an oil separator to the inlet side of the engine. While the engine is operating, the vapors are drawn into combustion chamber, where they are burned along with the fuel and air supplied by the fuel injection system.

2. Exhaust Emission Control System

This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels.

The exhaust system of this model motorcycle manufactured primarily for sale in California includes a catalytic converter system.

3. Evaporative Emission Control System

Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister when the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.

The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly referred to as the Act’s «tampering provisions.»

«Sec. 203(a) The following acts and the causing thereof are prohibited…

(3)(A) for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser.

(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser…»

NOTE

○The phrase «remove or render inoperative any device or element of design» has been generally interpreted as follows:

1.Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance.

2.Tampering could include:

a.Maladjustment of vehicle components such that the emission standards are exceeded.

b.Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle.

c.Addition of components or accessories that result in the vehicle exceeding the standards.

d.Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION.

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:

•Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations.

•Removal of the muffler(s) or any internal portion of the muffler(s).

•Removal of the air box or air box cover.

•Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such modifications result in increased noise levels.

Foreword

This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.

In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation.

For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty.

To get the longest life out of your vehicle:

•Follow the Periodic Maintenance Chart in the Service Manual.

•Be alert for problems and non-scheduled maintenance.

•Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual. Genuine parts provided as spare parts are listed in the Parts Catalog.

•Follow the procedures in this manual carefully. Don’t take shortcuts.

•Remember to keep complete records of maintenance and repair with dates and any new parts installed.

How to Use This Manual

In preparing this manual, we divided the product into its major systems. These systems became the manual’s chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter.

The Quick Reference Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents.

The Periodic Maintenance Chart is located in the Periodic Maintenance chapter. The chart gives a time schedule for required maintenance operations.

If you want spark plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, use the Quick Reference Guide to locate the Periodic Maintenance chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug section.

Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.

WARNING

This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.

CAUTION

This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment.

This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information.

NOTE

○This note symbol indicates points of particular interest for more efficient and convenient operation.

•Indicatesdone. a procedural step or work to be ○Indicates a procedural sub-step or how to do the work of the procedural step it follows. It

also precedes the text of a NOTE.

Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows.

In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.

GENERAL INFORMATION 1-1

General Information
Table of Contents
	1
Before Servicing ………………………………………………………………………………………………………	1-2
Model Identification…………………………………………………………………………………………………..	1-7
General Specifications………………………………………………………………………………………………	1-10
Unit Conversion Table ………………………………………………………………………………………………	1-13

1-2 GENERAL INFORMATION

Before Servicing

Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.

Especially note the following:

Battery Ground

Before completing any service on the motorcycle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the ground cable (–) first and then the positive (+). When completed with the service, first connect the positive (+) cable to the positive (+) terminal of the battery then the negative (–) cable to the negative terminal.

Edges of Parts

Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.

Solvent

Use a high-flush point solvent when cleaning parts. High -flush point solvent should be used according to directions of the solvent manufacturer.

Cleaning Vehicle before Disassembly

Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.

GENERAL INFORMATION 1-3

Before Servicing

Arrangement and Cleaning of Removed Parts

Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.

Storage of Removed Parts

After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.

Inspection

Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit.

Replacement Parts

Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.

Assembly Order

In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given.

1-4 GENERAL INFORMATION

Before Servicing

Tightening Sequence

Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.

Tightening Torque

Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench. Often, the tightening sequence is followed twice-initial tightening and final tightening with torque wrench.

Force

Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non -permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring

Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used O-rings when re-assembling

Liquid Gasket, Non-permanent Locking Agent

For applications that require Liquid Gasket or a Non-permanent Locking Agent, clean the surfaces so that no oil residue remains before applying liquid gasket or non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.

GENERAL INFORMATION 1-5

Before Servicing

Press

For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing.

Ball Bearing and Needle Bearing

Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown.

Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.

Oil Seal, Grease Seal

Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed. Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing.

Apply specified grease to the lip of seal before installing the seal.

Circlips, Cotter Pins

Replace circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation.

1-6 GENERAL INFORMATION

Before Servicing

Lubrication

It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified.

Direction of Engine Rotation

When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side).

Electrical Wires

A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color.

Instrument

Use a meter that has enough accuracy for an accurate measurement. Read the manufacture’s instructions thoroughly before using the meter. Incorrect values may lead to improper adjustments.

GENERAL INFORMATION 1-7

Model Identification

VN900B6F (US and Canada) Left Side View:

VN900B6F (US and Canada) Right Side View:

Frame Number		Engine Number

[A]Frame Number

[B]Front Fork (Right side)

[A]Engine Number

[B]Right Engine Cover

1-8 GENERAL INFORMATION

Model Identification

VN900B6F (Europe and Australia) Left Side View:

VN900B6F (Europe and Australia) Right Side View:

GENERAL INFORMATION 1-9

Model Identification

VN900D6F (US and Canada) Left Side View:

VN900D6F (US and Canada) Right Side View:

1-10 GENERAL INFORMATION

General Specifications

Items	VN900B6F/D6F
Dimensions
Overall Length	2 465 mm (97.05 in.)
Overall Width	1 005 mm (39.57 in.), (AU) 980 mm (38.6 in.)
Overall Height
(VN900B)	1 065 mm (41.93 in.)
(VN900D)	1 480 mm (58.27 in.)
Wheelbase	1 645 mm (64.76 in.)
Road Clearance	135 mm (5.31 in.)
Seat Height	680 mm (26.8 in.)
Dry Mass
(VN900B)	253 kg (558 lb), (EU) 254 kg (560 lb)
(VN900D)	270 kg (595 lb)
Curb Mass:
Front
(VN900B)	130 kg (287 lb), (EU) 131 kg (289 lb)
(VN900D)	134 kg (295 lb)
Rear
(VN900B)	151 kg (333 lb)
(VN900D)	164 kg (362 lb)
Fuel Tank Capacity	20 L (5.3 US gal)
Performance
Minimum Turning Radius	2.9 m (9.5 ft)
Engine
Type	4-stroke, SOHC, V2-cylinder
Cooling System	Liquid-cooled
Bore And Stroke	88.0 × 74.2 mm (3.46 × 2.92 in.)
Displacement	903 mL (55.1 cu in.)
Compression Ratio	9.5 : 1
Maximum Horsepower	37 kW (50 PS) @5 700 r/min (rpm), (CA) (CAL) (US) –
Maximum Torque	78 N·m (8.0 kgf·m, 58 ft·lb) @3 700 r/min (rpm),
	(CA) (CAL) (US) –
Carburetion System	DFI (Digital Fuel Injection) System
Starting System	Electric starter
Ignition System	Battery and coil (transistorized)
Timing Advance	Electronically advanced (digital)
Ignition Timing	From 0° BTDC @1 000r/min (rpm) to 53° BTDC @5 800 r/min
	(rpm)
	(AU) From 3.5° BTDC @1 000r/min (rpm) to 53° BTDC
	@5 800 r/min (rpm)
Spark Plugs	NGK CPR7EA-9
Cylinder Numbering Method	Front to Rear, 1-2
Firing Order	1-2

	GENERAL INFORMATION 1-11
General Specifications


Items	VN900B6F/D6F
Valve Timing:
Inlet
open	40° BTDC
close	40° ABDC
duration	260°
Exhaust
Open	55° BBDC
Close	25° ATDC
Duration	260°
Lubrication System	Forced lubrication (wet sump)
Engine Oil:
Type	API SE, SF or SG class
	API SH or SJ class with JASO MA
Viscosity	SAE10W-40
Capacity	3.7 L (3.9 US qt)
Drive Train
Primary Reduction System:
Type	Chain
Reduction Ratio	2.184 (83/38)
Clutch Type	Wet multi disc
Transmission:
Type	5-speed, constant mesh, return shift
Gear Ratios:
1st	2.786 (39/14)
2nd	1.889 (34/18)
3rd	1.360 (34/25)
4th	1.107 (31/28)
5th	0.963 (26/27)
Final Drive System:
Type	Belt
Reduction Ratio	2.063 (66/32)
Overall Drive Ratio	4.338 @ Top gear
Frame
Type	Tubular, double cradle
Caster (Rake Angel)	32°
Trail	160 mm (6.30 in.)
Front Tire:
Type	Tubeless
Size	130/90-16M/C 67H
Rim Size	16M/C × MT3.00
Rear Tire:
Type	Tubeless
Size	180/70-15M/C 76H
Rim Size	15M/C × MT4.50

1-12 GENERAL INFORMATION

General Specifications

Items	VN900B6F/D6F
Front Suspension:
Type	Telescopic fork
Wheel Travel	150 mm (5.90 in.)
Rear Suspension:
Type	Swingarm (uni-trak)
Wheel Travel	103 mm (4.06 in.)
Brake Type:
Front	Single disc
Rear	Single disc
Electrical Equipment
Battery:
Capacity	12 V 10 Ah

Headlight:
Type	Semi-sealed beam
Bulb	12 V 60/55W (quartz-halogen)
Tail/brake Light	12 V 5/21 W
Alternator:
Type	Three-phase AC
Rated Output	32 A × 14 V @5 000 r/min (rpm)

Specifications subject to change without notice, and may not apply to every country. AU: Australia

CA: Canada

CAL: California

EU: Europe

US: United States of America

GENERAL INFORMATION 1-13

Unit Conversion Table

Prefixes for Units:

Units of Length:

Prefix	Symbol		Power
mega	M	× 1 000	000
kilo	k	×	1 000
centi	c	×	0.01
milli	m	×	0.001
micro
µ	× 0.000001

Units of Mass:

kg	×	2.205	=	lb
g	×	0.03527	=	oz

km	×	0.6214	=	mile
m	×	3.281	=	ft
mm	×	0.03937	=	in

Units of Torque:

N·m	×	0.1020	=	kgf·m
N·m	×	0.7376	=	ft·lb
N·m	×	8.851	=	in·lb
kgf·m	×	9.807	=	N·m
kgf·m	×	7.233	=	ft·lb
kgf·m	×	86.80	=	in·lb

Units of Volume:				Units of Pressure:
			kPa	×	0.01020	=	kgf/cm²
L	×	0.2642	=	gal (US)		kPa	×	0.1450	=	psi
L	×	0.2200	=	gal (imp)		kPa	×	0.7501	=	cm Hg
L	×	1.057	=	qt (US)		kgf/cm²	×	98.07	=	kPa
L	×	0.8799	=	qt (imp)		kgf/cm²	×	14.22	=	psi
L	×	2.113	=	pint (US)		cm Hg	×	1.333	=	kPa
L	×	1.816	=	pint (imp)
mL	×	0.03381	=	oz (US)		Units of Speed:
mL	×	0.02816	=	oz (imp)		km/h	×	0.6214	=	mph
mL	×	0.06102	=	cu in
Units of Force:				Units of Power:
			kW	×	1.360	=	PS
N	×	0.1020	=	kg		kW	×	1.341	=	HP
N	×	0.2248	=	lb
	PS	×	0.7355	=	kW
kg	×	9.807	=	N		PS	×	0.9863	=	HP
kg	×	2.205	=	lb

Units of Temperature:

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

Periodic Maintenance Chart ………………………………………………………………………………………	2-3
Torque and Locking Agent…………………………………………………………………………………………	2-6	2
Specifications	2-11

Special Tools …………………………………………………………………………………………………………..	2-13
Periodic Maintenance Procedures………………………………………………………………………………	2-14
Fuel System (DFI)………………………………………………………………………………………………….	2-14
Fuel Hose Inspection (fuel leak, damage, installation condition) ………………………………..	2-14
Throttle Control System Inspection………………………………………………………………………..	2-14
Idle Speed Inspection ………………………………………………………………………………………….	2-15
Idle Speed Adjustment…………………………………………………………………………………………	2-15
Cooling System……………………………………………………………………………………………………..	2-16
Coolant Level Inspection………………………………………………………………………………………	2-16
Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition) ………	2-16
Air Suction System ………………………………………………………………………………………………..	2-17
Air Suction System Damage Inspection………………………………………………………………….	2-17
Engine Top End …………………………………………………………………………………………………….	2-17
Valve Clearance Inspection ………………………………………………………………………………….	2-17
Valve Clearance Adjustment…………………………………………………………………………………	2-17
Clutch…………………………………………………………………………………………………………………..	2-21
Clutch Operation Inspection………………………………………………………………………………….	2-21
Wheels and Tires…………………………………………………………………………………………………..	2-22
Tire Air Pressure Inspection………………………………………………………………………………….	2-22
Wheel/Tire Damage Inspection……………………………………………………………………………..	2-22
Tire Tread Wear Inspection…………………………………………………………………………………..	2-22
Wheel Bearing Damage Inspection ……………………………………………………………………….	2-23
Spoke Tightness and Rim Runout Inspection………………………………………………………….	2-24
Drive Train ……………………………………………………………………………………………………………	2-25
Belt Deflection Inspection …………………………………………………………………………………….	2-25
Belt Deflection Adjustment……………………………………………………………………………………	2-27
Wheel Alignment Inspection/Adjustment ………………………………………………………………..	2-28
Belt Wear and Damage Inspection ………………………………………………………………………..	2-28
Brake System ……………………………………………………………………………………………………….	2-31
Brake Fluid Leak Inspection………………………………………………………………………………….	2-31
Brake Hose Damage and Installation Condition Inspection……………………………………….	2-32
Brake Operation Inspection ………………………………………………………………………………….	2-32
Brake Fluid Level Inspection…………………………………………………………………………………	2-32
Brake Pad Wear Inspection ………………………………………………………………………………….	2-33
Brake Light Switch Operation Inspection ………………………………………………………………..	2-33
Suspensions …………………………………………………………………………………………………………	2-34
Front Forks/Rear Shock Absorber Operation Inspection …………………………………………..	2-34
Front Fork Oil Leak Inspection………………………………………………………………………………	2-35
Rear Shock Absorber Oil Leak Inspection ………………………………………………………………	2-35
Swingarm Pivot Lubrication ………………………………………………………………………………….	2-35
Rocker Arm Operation Inspection………………………………………………………………………….	2-35
Tie-Rod Operation Inspection ……………………………………………………………………………….	2-35
Uni-trak Linkage Lubrication …………………………………………………………………………………	2-36
Steering System ……………………………………………………………………………………………………	2-36
Steering Play Inspection ………………………………………………………………………………………	2-36
Steering Play Adjustment……………………………………………………………………………………..	2-36
Steering Stem Bearing Lubrication ………………………………………………………………………..	2-38

2-2 PERIODIC MAINTENANCE

Electrical System …………………………………………………………………………………………………..	2-39
Lights and Switches Operation Inspection………………………………………………………………	2-39
Headlight Aiming Inspection …………………………………………………………………………………	2-41
Sidestand Switch Operation Inspection ………………………………………………………………….	2-42
Engine Stop Switch Operation Inspection……………………………………………………………….	2-43
Others………………………………………………………………………………………………………………….	2-44
Chassis Parts Lubrication …………………………………………………………………………………….	2-44
Bolts, Nuts and Fasteners Tightness Inspection………………………………………………………	2-45
Evaporative Emission Control SystemInspection (CAL)………………………………………………	2-46
Evaporative Emission Control System Inspection ……………………………………………………	2-46
Replacement Parts ………………………………………………………………………………………………..	2-47
Air Cleaner Element Replacement…………………………………………………………………………	2-47
Engine Oil Change………………………………………………………………………………………………	2-48
Oil Filter Replacement …………………………………………………………………………………………	2-49
Fuel Hose Replacement ………………………………………………………………………………………	2-49
Coolant Change………………………………………………………………………………………………….	2-51
Radiator Hose and O-ring Replacement…………………………………………………………………	2-53
Brake Hose Replacement …………………………………………………………………………………….	2-53
Brake Fluid Change …………………………………………………………………………………………….	2-54
Master Cylinder Rubber Parts Replacement …………………………………………………………..	2-56
Caliper Rubber Parts Replacement ……………………………………………………………………….	2-57
Spark Plug Replacement ……………………………………………………………………………………..	2-60

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected.

Periodic Inspection

FREQUENCY

Whichever

* ODOMETER READING

comes

× 1 000 km

See

first

(× 1 000 mile)

Page

INSPECTION

Every

(0.6)

(4)

(7.5)

(12)

(15)

(20)

(24)

Fuel System

Throttle control system (play, smooth

year

•

2-14

return, no drag) — inspect

Idle speed — inspect

•

2-15

Fuel leak (fuel hose and pipe) — inspect

year

•

2-14

Fuel hose — inspect

year

•

2-14

Fuel hoses installation condition — inspect

year

•

2-14

Cooling System

Coolant level — inspect

•

2-16

Coolant leak (radiator hose and pipe) —

year

•

2-16

inspect

Radiator hose damage — inspect

year

•

2-16

Radiator hose installation condition —

year

•

2-16

inspect

Air Suction System

Air suction system damage — inspect

•

2-17

Evaporative Emission Control System

(CAL)

Evaporative emission control system

•

2-46

function — inspect

Engine Top End

Valve clearance — inspect (US and CA)

•

2-17

Valve clearance — inspect (EU and AU)

Every 42 000 km (26 000 mile)

2-17

Clutch

Clutch operation (play, disengagement,

•

2-21

engagement) — inspect

Wheels and Tires

Tire air pressure — inspect

year

•

2-22

Wheel/tire damage — inspect

•

2-22

Tire tread wear, abnormal wear — inspect

•

2-22

Wheel bearings damage — inspect

year

•

2-23

Spoke tightness and rim runout-inspect

•

2-24

Drive Train

Belt deflection — inspect

•

2-25

Belt wear and damage — inspect

•

2-28

Brake System

Brake fluid leak — inspect

year

•

2-31

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

FREQUENCY

Whichever

* ODOMETER READING

comes

× 1 000 km

See

first

(× 1 000 mile)

Page

INSPECTION

Every

(0.6)

(4)

(7.5)

(12)

(15)

(20)

(24)

Brake hose damage — inspect

year

•

2-32

Brake hose installation condition — inspect

year

•

2-32

Brake operation (effectiveness, play, no

year

•

2-32

drag) — inspect

Brake fluid level — inspect

6 months

•

2-32

Brake pad wear — inspect #

•

2-33

Brake light switch operation — inspect

•

2-33

Suspensions

Front forks/rear shock absorber operation

•

2-34

(damping and smooth stroke) — inspect

Front forks/rear shock absorber oil leak —

year

•

2-35

inspect

Swingarm pivot — lubricate

•

2-35

Uni — trak rocker arm operation — inspect

•

2-35

Uni — trak tie rod operation — inspect

•

2-35

Uni — trak rocker arm bearings — lubricate

•

2-36

Uni — trak tie rod bearings — lubricate

•

2-36

Steering System

Steering play — inspect

year

•

2-35

Steering stem bearings — lubricate

2 years

•

2-38

Electrical System

Lights and switches operation — inspect

year

•

2-39

Headlight aiming — inspect

year

•

2-41

Sidestand switch operation — inspect

year

•

2-42

Engine stop switch operation — inspect

year

•

2-43

Others

Chassis parts — lubricate

year

•

2-44

Bolts and nuts tightness — inspect

•

2-45

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.

*: For higher odometer readings, repeat at the frequency interval established here.

(AU): Australia

(CA): Canada (CAL):California (EU): Europe (US): United States

PERIODIC MAINTENANCE 2-5

Periodic Maintenance Chart

Periodic Replacement Parts

FREQUENCY	Whichever	* ODOMETER READING
	comes						× 1 000 km	See

	first					(× 1 000 mile)

											Page
				1	12	24	36	48

CHANGE/REPLACE ITEM	Every	(0.6)	(7.5)	(15)	(24)	(30)
Air cleaner element #				Every 18 000 km (12 000 mile)	2-47
Engine oil #	year		•	•	•	•	•	2-48
Oil filter	year		•	•	•	•	•	2-49
Fuel hose	4 years							•	2-49
Coolant	3 years						•		2-51


Radiator hoses and O-rings	3 years						•		2-53


Brake hoses	4 years							•	2-53
Brake fluid (Front and Rear)	2 years					•		•	2-54
Rubber parts of master cylinder and caliper	4 years							•	2-57
Spark plug							•	•	•	•	2-60

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.

*: For higher odometer readings, repeat at the frequency interval established here.

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket.

Letters used in the “Remarks” column mean: 2T: Apply 2-stroke oil.

L:Apply a non-permanent locking agent to the threads. Lh: Left-hand threads

M:Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil solution.

(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1) S: Tighten the fasteners following the specified sequence.

Si: Apply silicone grease (ex. PBC grease). SS: Apply silicone sealant.

Fastener		Torque			Remarks
N·m	kgf·m	ft·lb

Fuel System
Water Temperature Sensor	12	1.2	106 in·lb
Speed Sensor Mounting Bolt	9.8	1.0	87 in·lb	L
Fuel Pump Bolts	9.8	1.0	87 in·lb	L
Oxygen Sensor	25	2.5	18
Fuel Level Sensor Mounting Bolts	6.9	0.70	61 in·lb	L
Air Cleaner Housing Bolts	9.8	1.0	87	in·lb
Air Cleaner Cover Bolts	4.9	0.50	43 in·lb
Air Cleaner Element Screw	4.9	0.50	43 in·lb
Throttle Body Assy Holder Bolts	9.8	1.0	87 in·lb
Inlet Manifold Bolts	9.8	1.0	87	in·lb	L
Delivery Joint Bolts	9.8	1.0	87	in·lb	L
Delivery Joint Bracket Bolts	9.8	1.0	87	in·lb
Vehicle-down Sensor Bolts	4.9	0.50	43 in·lb
Inlet Air Pressure Sensor Bolt	6.9	0.70	61	in·lb
Inlet Air Temperature Sensor Screw	1.2	0.12	11 in·lb
Cooling System
Radiator Hose Clamp Screws	2.0	0.20	18 in·lb
Water Pump Impeller Bolt	9.8	1.0	87 in·lb
Coolant Drain Bolt	9.8	1.0	87	in·lb
Thermostat Housing Cover Bracket Bolts	6.9	0.70	61 in·lb
Thermostat Housing Cover Bolts	4.9	0.50	43 in·lb	L
Radiator Bolts	6.9	0.70	61	in·lb
Radiator Screen Screws	6.9	0.70	61 in·lb
Radiator Fan Bolts	8.3	0.85	73 in·lb
Water Hose Fitting Bolts	9.8	1.0	87	in·lb
Reserve Tank Bolts	6.9	0.70	61 in·lb
Engine Top End
Cylinder Head nuts (M10) (First)	20	2.0	15	MO, S
Cylinder Head nuts (M10) (Final)	49	5.0	36	MO, S
Cylinder Head nuts (M8)	25	2.5	18	S
Camshaft Cap Bolts	25	2.5	18

PERIODIC MAINTENANCE 2-7

Torque and Locking Agent

Fastener		Torque		Remarks
N·m	kgf·m	ft·lb

Cylinder Head Cover Bolts	12	1.2	106 in·lb
Cylinder Head Outer Cover Bolts	9.8	1.0	87 in·lb
Plug (PT1/4)	15	1.5	11	L
Plug (PT1/2)	20	2.0	15	L
Muffler Mounting Bolts	25	2.5	18
Muffler Mounting Nut	25	2.5	18
Muffler Joint Clamp Bolt	17	1.7	12
Exhaust Pipe Cover Clamp Bolts	6.9	0.70	61 in·lb
Exhaust Pipe Cover Bolts	6.9	0.70	61 in·lb
Exhaust Pipe Holder Nuts	17	1.7	12
Camshaft Sprocket Bolts	49	5.0	36	L
Camshaft Chain Tensioner Cap Bolts	20	2.0	15
Camshaft Chain Guide Bolts	9.8	1.0	87 in·lb	L
Clutch
Right Engine Cover Mounting Bolts	9.8	1.0	87 in·lb	L (1)
Clutch Spring Bolts	9.8	1.0	87 in·lb
Clutch Hub Nut	130	13.2	95.9
Clutch Lever Clamp Bolts	7.8	0.80	69 in·lb	S
Engine Lubrication
Engine Oil Drain Plug	20	2.0	15
Oil Pump Cover Bolt	9.8	1.0	87 in·lb	L
Oil Pump Drive Chain Guide Bolt	9.8	1.0	87 in·lb	L
Oil Filter Plate Bolts	7.8	0.80	69 in·lb
Oil Pressure Switch	15	1.5	11	SS
Oil Pipe Bolts	9.8	1.0	87 in·lb	L
Oil Return Pipe Bolts	9.8	1.0	87 in·lb
Oil Pressure Switch Adapter	20	2.0	15
Oil Filter	18	1.8	13
Oil Screen Plug	20	2.0	15
Oil Pressure Relief Valve	15	1.5	11	L
Engine Removal/Installation
Engine Mounting Nuts	44	4.5	32
Engine Mounting Bracket Bolts (M10)	44	4.5	32
Engine Mounting Bracket Bolts (M8)	25	2.5	18
Downtube Bolts	44	4.5	32
Crankshaft/Transmission
Balancer Gear Bolt	69	7.0	51
Starter Motor Clutch Gear Bolt	69	7.0	51
Primary Gear Bolt	98	10	72	MO
Connecting Rod Big End Bolts	46	4.7	34	MO
Shift Drum Bearing Stopper Bolts	9.8	1.0	87 in·lb	L
Shift Drum Cam Bolt	12	1.2	106 in·lb	L
Neutral Switch	15	1.5	11

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener			Torque		Remarks
N·m	kgf·m	ft·lb

Rear Shift Lever Clamp Bolt	12		1.2	106 in·lb
Shift Pedal Clamp Bolt	12		1.2	106 in·lb
Shift Rod Locknut (Front)	9.8			87 in·lb
	1.0
Oil Nozzle	3.9		0.40	34 in·lb
Shift Rod Locknut (Rear)	9.8		1.0	87 in·lb	Lh
Rear Shift Pedal Pad Screw	6.9		0.70	61 in·lb
Shift Drum Position Lever Bolt	9.8		1.0	87 in·lb
Shift Shaft Return Spring Pin	29		3.0	21	L
Bearing Retainer Bolts	9.8		1.0	87 in·lb	L
Balancer Shaft Bearing Stopper Plate Bolts	9.8		1.0	87 in·lb
Crankcase Bolts (M10)	39		4.0	29	S
Crankcase Bolts (M6)	9.8		1.0	87 in·lb	S
Engine Ground Lead Bolt	9.8		1.0	87 in·lb
Clamp Mounting Bolts	9.8		1.0	87 in·lb
External Shift Mechanism Cover Bolts	9.8		1.0	87 in·lb
Wheels/Tires
Front Axle Nut	108		11.0	79.7
Front Axle Clamp Bolt	20		2.0	15
Rear Axle Nut	108		11.0	79.7
Spoke Nipples	5.2		0.53	46 in·lb
Final Drive
Rear Pulley Mounting Nuts	59		6.0	44
Rear Pully Plate Bolts	6.9		0.70	61 in·lb	L
Engine Pully Mounting Nut	127		13.0	93.7	M
Engine Pullly Plate Bolts	9.8		1.0	87 in·lb
Engine Pulley Cover Bolts	9.8		1.0	87 in·lb
Engine Pulley Cover Clamp Mounting Bolt	9.8		1.0	87 in·lb
Drive Belt Guide Bolts	9.8		1.0	87 in·lb
Brakes
Bleed Valves	7.8		0.80	69 in·lb
Brake Hose Banjo Bolts	25		2.5	18
Brake Lever Pivot Bolt	1.0		0.10	88 in·lb	Si
Brake Lever Pivot Locknut	5.9		0.60	52 in·lb
Brake Pedal Clamp Bolt	25		2.5	18
Front Brake Disc Mounting Bolts	27		2.8	20	L
Front Brake Light Switch Screw				11 in·lb
1.2		0.12
Front Brake Reservoir Cap Screws	1.5		0.15	13 in·lb
Front Caliper Mounting Bolts	34		3.5	25
Front Master Cylinder Clamp Bolts	8.8		0.90	78 in·lb	S
Rear Brake Disc Mounting Bolts	27		2.8	20	L
Rear Caliper Mounting Bolts	34		3.5	25
Rear Master Cylinder Mounting Bolts	25		2.5	18
Rear Master Cylinder Push Rod Locknut	17		1.7	12

PERIODIC MAINTENANCE 2-9

Torque and Locking Agent

Fastener		Torque		Remarks
N·m	kgf·m	ft·lb

Suspension
Swingarm Pivot Shaft Nut	98	10	72
Rear Shock Absorber Nuts	59	6.0	44
Lower Tie-Rod Nut	59	6.0	44
Upper Tie-Rod Nut	108	11.0	80
Rocker Arm Pivot Shaft Nut	59	6.0	44
Upper Front Fork Clamp Bolts	20	2.0	15
Lower Front Fork Clamp Bolts	34	3.5	25
Front Fork Bottom Allen Bolts	20	2.0	15	L
Front Fork Upper Cover Stopper Bolts	4.2	0.43	37 in·lb
Steering
Handlebar Holder Nuts	34	3.5	25
Handlebar Clamp Bolts	34	3.5	25	S, 2T
Steering Stem Head Bolt	49	5.0	36
Steering Stem Nut	4.9	0.50	43 in·lb
Frame
Sidestand Mounting Nut	44	4.5	32
Sidestand Mounting Bolt	44	4.5	32
Footboard Bracket Bolts	34	3.5	25
Left Footpeg Bracket Bolts	25	2.5	18
Right Footpeg Bracket Bolts	25	2.5	18
Lower Muffler Bracket Bolts	34	3.5	25
Upper Muffler Bracket Bolts	34	3.5	25
Electrical System
Alternator Outer Cover Bolts	9.8	1.0	87 in·lb
Tail/Brake Light Unit Mounting Nuts	5.9	0.60	52 in·lb
Alternator Cover Bolts	9.8	1.0	87 in·lb
Timing Inspection Plate Bolts	9.8	1.0	87 in·lb
Alternator Lead Holder Plate Bolts	5.9	0.60	52 in·lb
Stator Coil Bolts	12	1.2	106 in·lb	L
Alternator Rotor Bolt (First)	69	7.0	51	S
Alternator Rotor Bolt (Final)	160	16.3	118	S, MO
Regulator/Rectifier Bolts	6.9	0.70	61 in·lb
Starter Motor Mounting Bolts	9.8	1.0	87 in·lb
Starer Relay Terminal Screws	3.9	0.40	34 in·lb
Starter Motor Cable Terminal Nut	5.9	0.60	52 in·lb
Starter Motor Terminal Locknut	11	1.1	97 in·lb
Starter Motor Through Bolts	4.9	0.50	43 in·lb
Headlight Rim Screws	2.9	0.30	26 in·lb	L
Crankshaft Sensor Bolts	5.9	0.60	52 in·lb
Ignition Coil Bracket Bolt	9.8	1.0	87 in·lb
Ignition Coil Mounting Nuts	6.9	0.70	61 in·lb
Fuel Level Sensor Mounting Bolts	6.9	0.70	61 in·lb

2-10 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener		Torque		Remarks
N·m	kgf·m	ft·lb

Spark Plugs	18	1.8	13 in·lb
Sidestand Switch Mounting Bolts	8.8	0.90	78 in·lb	L

The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners

Threads Diameter				Torque
(mm)	N·m	kgf·m	ft·lb
5	3.4		4.9	0.35		0.50	30	43 in·lb
6	5.9		7.8	0.60		0.80	52	69 in·lb
8	14		19	1.4		1.9	10.0	13.5
10	25		34	2.6		3.5	19.0	25
12	44		61	4.5		6.2	33		45
14	73		98	7.4	10.0	54		72
16	115		155	11.5		16.0	83	115
18	165		225	17.0		23.0	125		165
20	225		325	23.0		33.0	165		240

			PERIODIC MAINTENANCE 2-11
Specifications


Item		Standard		Service Limit
Fuel System
Throttle Grip Free Play	2 3 mm (0.08 0.12 in.)		– – –
Idle Speed	1 000 ±50 r/min (rpm)		– – –
Air Cleaner Element	Polyurethane Foam		– – –
Cooling System
Coolant:
Type (recommended)	Permanent type of antifreeze	– – –
Color	Green			– – –
Mixed Ratio	Soft water 50%, Coolant 50%	– – –
Freezing Point	–35°C (–31°F)		– – –
Total Amount	2.2 L (2.3 US qt)		– – –
Engine Top End
Valve Clearance:
Exhaust	0.20	0.25 mm (0.0079	0.0098 in.)	– – –
Inlet	0.10	0.15 mm (0.0039	0.0059 in.)	– – –
Clutch
Clutch Lever Free Play	2 3 mm (0.08 0.12 in.)		– – –
Engine Lubrication System
Engine Oil:
Type	API SE, SF or SG		– – –
	API SH, SJ or SL with JASO MA
Viscosity	SAE 10W-40		– – –
Capacity	3.0 L (3.2 US qt) (when filter is not	– – –
	removed)
	3.2 L (3.4 US qt) (when filter is removed)	– – –
	3.7 L (3.9 US qt) (when engine is	– – –
	completely dry)
Level	Between upper and lower level lines	– – –
	(after idling or running)
Wheels/Tires
Tread Depth:
Front	4.5 mm (0.18 in.)		1 mm (0.04 in.),
				(AT, CH, DE)
				1.6 mm (0.06 in.)
Rear	7.4 mm (0.29 in.)		Up to 130 km/h (80 mph):
				2 mm (0.08 in.),
				Over 130 km/h (80 mph):
				3 mm (0.1 in.)
Air Pressure (when Cold):
Front	Up to 180 kg (397 lb) load:	– – –
	200 kPa (2.00 kgf/cm², 28 psi)
Rear	Up to 97.5 kg (215 lb) load:	– – –
	200 kPa (2.00 kgf/cm², 28 psi)
	97.5	180 kg (215 397 lb) load:
	225 kPa (2.25 kgf/cm², 32 psi)

2-12 PERIODIC MAINTENANCE

Specifications

Item	Standard	Service Limit
Final Drive
Drive Belt Deflection:			– – –
(45 N, 4.6 kgf, 10 lb fprce)	1.5 4.0 mm (0.059	0.16 in.)	– – –
When Installing New Belt	1.5 mm (0.059 in.)		– – –
or Engine Remounted
Brakes
Brake Fluid:
Grade	DOT4		– – –
Brake Pad Lining

Thickness:
Front	4.5 mm (0.18 in.)		1 mm (0.04 in.)
Rear	7.0 mm (0.28 in.)		1 mm (0.04 in.)
Brake Light Timing:
Front	Pulled ON		– – –
Rear	ON after about 10 mm (0.39 in.) of	– – –
	pedal travel

Electrical System
Spark Plug Gap	0.8 0.9 mm (0.03	0.04 in.)	– – –
AT: Austria
CH: Switzerland
DE: Germany

PERIODIC MAINTENANCE 2-13

Special Tools

Inside Circlip Pliers: 57001-143

Oil Filter Wrench: 57001-1249

Steering Stem Nut Wrench: 57001-1100

Spark Plug Wrench, Hex 16: 57001-1262


Jack:		Tension Gauge:
57001-1238	57001-1585

2-14 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Fuel System (DFI)

Fuel Hose Inspection (fuel leak, damage, installation condition)

○The fuel hose is designed to be used throughout the motorcycle’s life without any maintenance. However, if the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) and check the fuel hose. Replace the fuel hose if any fraying, cracks [B] or bulges

[C] are noticed.

•Check that the hoses are routed according to Cable, Wire and Hose Routing section in the Appendix chapter.

Replace the hose if it has been sharply bent or kinked. Hose Joints [A]

Fuel Hose [B]

•Check that the hose joints are securely connected. ○Push and pull [A] the hose joint [B] back and forth more

than two times, and make sure it is locked. If it does not locked, reinstall the hose joint.

WARNING

Make sure the hose joint is installed correctly on the delivery pipe by sliding the joint, or the fuel could leak.

Throttle Control System Inspection

•Check the throttle grip free play [A].

If the free play is incorrect, adjust the throttle cable.

Throttle Grip Free Play

Standard: 2 3 mm (0.08 0.12 in.)

•Check that the throttle grip moves smoothly from close to full open, and the throttle closes quickly and completely in all steering positions by the return spring.

If the throttle grip doesn’t return properly, check the throttle cable routing, grip free play, and cable damage. Then lubricate the throttle cable.

•Run the engine at the idle speed, and turn the handlebar all the way to the right and left to ensure that the idle speed doesn’t change.

If the idle speed increases, check the throttle grip free play and the cable routing.

PERIODIC MAINTENANCE 2-15

Periodic Maintenance Procedures

•If necessary, adjust the throttle cable as follows: ○Loosen the locknuts [A] and screw the adjusters [B] all the

way in so as to give the throttle grip plenty of play. ○Turn out the adjuster of the decelerator cable [D] until

there is no play.

○Tighten the locknut against the adjuster.

○Turn the adjuster of the accelerator cable [C] until the proper amount of throttle grip free play is obtained and tighten the locknut against the adjuster.

Idle Speed Inspection

•Start the engine and warm it up thoroughly.

○At first the engine will run fast to decrease warm up time (fast idle).

○Gradually the fast idle will lower to a certain RPM automatically. This is the idle speed.

•Check the idle speed.

Idle Speed
Standard:	1 000 ±50 r/min (rpm)

•With the engine idling, turn the handlebar to both sides. If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed or damaged. Be sure to correct any of these conditions before riding (see Cable, Wire and Hose Routing section in the Appendix chapter).

WARNING

Operation with improperly adjusted, incorrectly routed or damaged cables could result in an unsafe riding condition.

If the idle speed is out of the specified range, adjust it.

Idle Speed Adjustment

•Start the engine and warm it up thoroughly. ○Wait until fast idle speed lowers to a certain value.

•Turn the adjusting screw [A] until the idle speed is correct. ○Open and close the throttle a few times to make sure that the idle speed is within the specified range. Readjust if

necessary. Front [B]

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Cooling System

Coolant Level Inspection

NOTE

○Check the level when the engine is cold (room or ambient temperature).

•Check the coolant level in the reserve tank [A] with the motorcycle held upright.

If the coolant level is lower than the “L” level line [B], remove the reserve tank cover and unscrew the reserve tank cap, and add coolant to the “F” level line [C].

“L”: low “F”: full

CAUTION

For refilling, add the specified mixture of coolant and soft water. Adding water alone dilutes the coolant and degrades its anticorrosion properties. The diluted coolant can attack the aluminum engine parts. In an emergency, soft water alone can be added. But the diluted coolant must be returned to the correct mixture ratio within a few days.

If coolant must be added often or the reservoir tank has run completely dry, there is probably leakage in the cooling system. Check the system for leaks.

Coolant ruins painted surfaces. Immediately wash away any coolant that spills on the frame, engine, wheels or other painted parts.

Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition)

○The high pressure inside the radiator hose and pipe can cause coolant to leak [A] or the hose to burst if the line is not properly maintained.

•Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and

brittle, nor should it be soft or swollen.

Replace the hose if any fraying, cracks [B] or bulges [C] are noticed.

•Check that the hoses are securely connected and clamps are tightened correctly.

Torque — Radiator Hose Clamp Screws: 2.0 N·m (0.20 kgf·m, 18 in·lb)

PERIODIC MAINTENANCE 2-17

Periodic Maintenance Procedures

Air Suction System

Air Suction System Damage Inspection

•Pull the air switching valve hose [A] out of the right air cleaner housing.

•Start the engine and run it at idle speed.

•Plug the air switching valve hose end with your finger and feel vacuum pulsing in the hose.

If there is no vacuum pulsation, check the hose line for leak. If there is no leak, check the air switching valve (see Air Switching Valve Unit Test in the Electrical System chapter) or air suction valve (see Air Suction Valve Inspection in the Engine Top End chapter).

Engine Top End

Valve Clearance Inspection

NOTE

○Valve clearance must be checked and adjusted when the engine is cold (room temperature).

•Remove:Cylinder Head Cover (see Cylinder Head Cover Removal in the Engine Top End chapter)

Timing Inspection Plate (Engine Left Side)

•Set the front piston at TDC (see Camshaft Installation in the Engine Top End chapter).

•Using a thickness gauge [A], measure the valve clearance between the rocker arm [B] and the shim [C].

•Set the rear piston at TDC by turning the crankshaft counterclockwise 305° (see Crankshaft Installation in the Crankshaft/Transmission chapter).

•Using a thickness gauge, measure the valve clearance between the rocker arm and the shim.

Valve Clearance
Standard:
Exhaust:	0.20	0.25 mm (0.079	0.0098 in.)
Inlet:	0.10	0.15 mm (0.0039	0.0059 in.)

If the valve clearance is not within the specified range and then adjust it.

Valve Clearance Adjustment

•To change the valve clearance, slide [A] the rocker arm [B] sideways and change the shim [C]. Replace the shim with one of a different thickness.

NOTE

○Mark and record the shim locations so that the shims can be reinstalled in their original positions.

○If there is no clearance, select a shim which is several sizes smaller and then measure the clearance.

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•To select a new shim which brings the valve clearance within the specified range, refer to the Valve Clearance Adjustment Charts.

•Remeasure any valve clearance that was adjusted. Readjust if necessary.

CAUTION

Do not put shim stock under the shim. This may cause the shim to pop out at high rpm, causing extensive engine damage.

Do not grind the shim. This may cause it to fracture, causing extensive engine damage.

PERIODIC MAINTENANCE 2-19

Periodic Maintenance Procedures

VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE

1.Measure the clearance (when engine is cold).

2.Check present shim size.

3.Match clearance in vertical column with present shim size in horizontal column.

4.Install the shim specified where the lines intersect. This shim will give the proper clearance.

Example: Present shim is 2.60 mm (0.102 in.) Measured clearance is 0.25 mm (0.010 in.)

Replace 2.60 mm (0.102 in.) shim with 2.70 mm (0.106 in.) shim. 5. Remeasure the valve clearance and readjust if necessary.

NOTE

○If there is no clearance, select a shim which is several sizes smaller and then measure the clearance.

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE

1.Measure the clearance (when engine is cold).

2.Check present shim size.

3.Match clearance in vertical column with present shim size in horizontal column.

4.Install the shim specified where the lines intersect. This shim will give the proper clearance.

Example: Present shim is 2.55 mm (0.100 in.) Measured clearance is 0.50 mm (0.020 in.)

Replace 2.55 mm (0.100 in.) shim with 2.75 mm (0.108 in.) shim. 5. Remeasure the valve clearance and readjust if necessary.

NOTE

○If there is no clearance, select a shim which is several sizes smaller and then measure the clearance.

PERIODIC MAINTENANCE 2-21

Periodic Maintenance Procedures

Clutch

Clutch Operation Inspection

Clutch Lever Free Play Inspection

•Pull[A]. the clutch lever just enough to take up the free play

•Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully. In either case, adjust it.

Clutch Lever Free Play

Standard: 2 3 mm (0.08 0.12 in.)

Clutch Lever Free Play Adjustment

•Loosen the locknut [A] at the clutch lever.

•Turn the adjuster [B] until the proper amount of clutch lever free play is obtained.

•Tighten the locknut securely.

If it cannot be done, use the adjuster at the middle of the cable.

WARNING

To avoid a serious burn, never touch the engine or exhaust pipe during clutch adjustment.

•Loosen the locknut [A] at the middle of the clutch cable.

•Turn the adjuster nut [B] until the proper amount of clutch lever free play is obtained.

•Tighten the locknut securely.

If it cannot be done, use the mounting nuts at the lower end of the cable.

•Slide the dust cover [A] at the clutch cable lower end out of place.

•Loosen both adjusting nuts [B] at the clutch cover as far as they will go.

•Pull the clutch outer cable [C] tight and tighten the adjusting nuts against the bracket [D].

•Slip the rubber dust cover back onto place.

•Turn the adjuster at the clutch lever until the free play is correct.

•Tighten the knurled locknut at the clutch lever.

WARNING

Be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever, or it could slip into place later, creating enough cable play to prevent clutch disengagement.

•After the adjustment, start the engine and check that the clutch does not slip and that it releases properly.

2-22 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Wheels and Tires

Tire Air Pressure Inspection

•Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3

hours).

Adjust the tire air pressure according to the specifications if necessary.

Air Pressure (when cold)

Front: Up to 180 kg (397 lb)

200 kPa (2.00 kgf/cm², 28 psi) Rear: Up to 97.5 kg (215 lb)

200 kPa (2.00 kgf/cm², 28 psi)

97.5 180 kg (215 397 lb)

225 kPa (2.25 kgf/cm², 32 psi)

WARNING

To ensure safe handling and stability, use only the recommended standard tires for replacement, inflated to the standard pressure.

NOTE

○Most countries may have their own regulations requiring a minimum tire tread depth; be sure to follow them.

○Check and balance the wheel when a tire is replaced with a new one.

Wheel/Tire Damage Inspection

•Remove any imbedded stones [A] or other foreign particles [B] from tread.

•Visually inspect the tire for cracks and cuts replacing the tire in case of damage. Swelling or high spots indicate internal damage, requiring tire replacement.

•Visuallyage. inspect the wheel for cracks, cuts and dents dam-

If any damage is found, replace the wheel if necessary.

Tire Tread Wear Inspection

As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn). So it is false economy and unsafe to use the tires until they are bald.

PERIODIC MAINTENANCE 2-23

Periodic Maintenance Procedures

•Measure the tread depth at the center of the tread with a depth gauge [A]. Since the tire may wear unevenly, take

measurement at several places.

If any measurement is less than the service limit, replace the tire.

Tread Depth
Standard:
Front	4.5 mm (0.18 in.)
Rear	7.4 mm (0.29 in.)

Service Limit:

Front	1 mm (0.04 in.) (DE, AT, CH) 1.6 mm
	(0.063 in.)
Rear	2 mm (0.08 in.): Up to 130 km/h (80 mph)
	3 mm (0.1 in.): Over to 130 km/h (80
	mph)

Wheel Bearing Damage Inspection

•Using a jack raise the front wheel off the ground (see Front Wheel Removal in the Wheels/Tires chapter).

•Turn the handlebar all the way to the right or left.

•Inspect the roughness of the front wheel bearing by pushing and pulling [A] the wheel.

•Spin [B] the front wheel lightly, and check for smoothly turn, roughness, binding or noise.

If roughness, binding or noise is found, remove the front wheel (see Front Wheel Removal in the Wheel/Tires chapter) and inspect the wheel bearing (see Hub Bearing Inspection in the Wheels/Tires chapter).

•Using a jack raise the rear wheel off the ground (see Rear Wheel Removal in the Wheels/Tires chapter).

•Inspect the roughness of the rear wheel bearing by pushing and pulling [A] the wheel.

•Spin [B] the rear wheel lightly, and check for smoothly turn, roughness, binding or noise.

If roughness, binding or noise is found, remove the rear wheel (see Rear Wheel Removal in the Wheel/Tires chapter) and inspect the wheel bearing (see Hub Bearing Inspection in the Wheels/Tires chapter) and coupling (see Coupling Bearing Inspection in the Final Drive chapter).

2-24 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Spoke Tightness and Rim Runout Inspection

•Check that all the spokes are tightened evenly.

If spoke tightness is uneven or loose, tighten the spoke nipples evenly.

Torque — Spoke Nipples: 5.2 N·m (0.53 kgf·m, 46 in·lb)

•Check the rim runout.

WARNING

If any spoke breaks, it should be replaced immediately. A missing spoke places an additional load on the other spokes, which will eventually cause other spokes to break

•Raise the front/rear wheel off the ground.

Special Tool — Jack: 57001-1238

•Spin the wheel lightly, and check for roughness or binding.

If roughness or binding is found, replace the hub bearings.

•Inspecting. the rim for small cracks, dents, bending, or warp-

If there is any damage to the rim, it must be replaced.

NOTE

○Avoid the curved part and the uneven part, and measure the rim runout on the side without the mark.

•Measuregauge. the axial [A] and radial [B] rim runout with a dial If rim runout exceeds the service limit, check the hub bearings first. Replace them if they are damaged. If the problem is not due to the bearings, correct the rim warp (runout). A certain amount of rim warp can be corrected by recentering the rim. Loosen some spokes and tighten others within the standard torque to change the position of different parts of the rim. If the rim is badly bent, however, it must be replaced.

Rim Runout (with tire installed)

Standard:
Radial	1.0 mm (0.039 in.)
Axial	0.8 mm (0.03 in.)
Service Limit:
Radial	2.0 mm (0.079 in.)
Axial	2.0 mm (0.079 in.)

PERIODIC MAINTENANCE 2-25

Periodic Maintenance Procedures

Drive Train

Belt Deflection Inspection

NOTE

○Belt deflection must be checked and adjusted when the belt is cold (at room temperature).

○Belt deflection also should be checked at first 1000 km ride after belt replacement.

•Check to see if wheel alignment is properly adjusted. ○The left and right notches on the belt adjuster should point

to the same marks or positions on the swingarm.

If they do not, adjust wheel alignment (see Wheel Alignment Inspection/Adjustment).

•Remove:Reserve Tank Cover (see Reserve Tank Removal in the Cooling System chapter)

•Using the jack under the frame, lift the rear wheel off the ground (see Rear Wheel Removal in the Wheels/Tires chapter).

•Visually inspect the belt for damage (see Belt Wear and Damage Inspection).

If the belt is damaged, replace it with a new one.

•Mark the initial belt position [A] on the belt cover window.

•Using the tension gauge [A], push up 45 N (4.5 kgf, 10 lb) of force from under and on the center of the belt at the front side of the swingarm cross pipe [B].

•Measure the deflection (length between initial belt position [A] and position [B] after it measure it) of the belt (at the belt cover window).

2-26 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

NOTE

○Push the belt by the gauge until the top surface [A] of the stopper comes to the 45 N loaded scale [B], marked “45N”.

○Push up on the center of the belt. An inaccurate reading will occur if the edge of the belt is pushed up.

○Look parallel to the belt during inspection. An inaccurate reading will occur if looking from any other angle.

•Inspect the belt deflection at two positions by rotating the rear wheel.

Special Tool — Tension Gauge: 57001-1585

•Inspect the drive belt deflection at arbitrary position, and record the value [A].

•Turn the rear wheel 90 degrees.

•Inspect the drive belt deflection, and record the value [B].

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