![Kawasaki VN1600 CLASSIC (2003) [5/575] Vulcan 1600 classic vn1600 classic](/img/pdf.png)
Kawasaki VN1600 CLASSIC (2003) [5/575] Vulcan 1600 classic vn1600 classic
![Kawasaki VN1600 CLASSIC (2003) [5/575] Vulcan 1600 classic vn1600 classic](/views2/1121175/page5/bg5.png)
VULCAN 1600 CLASSIC
VN1600 CLASSIC
Motorcycle
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Quality Assurance Department/Consumer Products & Machinery
Company/Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your Motorcycle dealer for the latest
information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.
© 2003 Kaw asaki Heavy Industries, Ltd. Second Edition (1) : Aug. 25, 2003 (M)
Содержание
- Motorcycle service manual 1
- Tables 1
- Quick reference guide 3
- Motorcycle service manual 5
- Vulcan 1600 classic vn1600 classic 5
- List of abbreviations 6
- Read owner s manual before operating 6
- Emission control information 7
- The phrase remove or render inoperative any device or element of design has been generally interpreted as follows 1 tampering does not include the temporary removal or rendering inoperative of de vices or elements of design in order to perform maintenance 2 tampering could include a maladjustment of vehicle components such that the emission standards are ex ceeded b use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle c addition of components or accessories that result in the vehicle exceeding the stan dards d permanently removing disconnecting or rendering inoperative any component or element of design of the emission control systems 7
- Tampering with noise control system prohibited 8
- Foreword 9
- How to use this manual 9
- Warning 9
- This note symbol indicates points of par ticular interest for more efficient and con venient operation 10
- General information 11
- General information 1 1 11
- Table of contents 11
- 2 general information 12
- Battery ground 12
- Before servicing 12
- Before starting to perform an inspection service or carry out a 12
- Cleaning vehicle before disassembly 12
- Edges of parts 12
- Solvent 12
- Arrangement and cleaning of removed parts 13
- Assembly order 13
- Before servicing 13
- General information 1 3 13
- Inspection 13
- Replacement parts 13
- Storage of removed parts 13
- 4 general information 14
- Before servicing 14
- Gasket o ring 14
- Liquid gasket locking agent 14
- Tightening sequence 14
- Tightening torque 14
- Ball bearing and needle bearing 15
- Before servicing 15
- Circlips cotter pins 15
- General information 1 5 15
- Lubrication 15
- Oil seal grease seal 15
- 6 general information 16
- Before servicing 16
- Direction of engine rotation 16
- Electrical wires 16
- General information 1 7 17
- Model identification 17
- 8 general information 18
- Model identification 18
- General information 1 9 19
- General specifications 19
- 10 general information 20
- General specifications 20
- General information 1 11 21
- Prefixes for units 21
- Unit conversion table 21
- Units of force 21
- Units of length 21
- Units of mass 21
- Units of power 21
- Units of pressure 21
- Units of speed 21
- Units of torque 21
- Units of volume 21
- Periodic maintenance 23
- Periodic maintenance 2 1 23
- Table of contents 23
- 2 periodic maintenance 24
- Periodic maintenance chart 24
- Periodic maintenance 2 3 25
- Periodic maintenance chart 25
- 4 periodic maintenance 26
- Basic torque for general fasteners 26
- Torque and locking agent 26
- Periodic maintenance 2 5 27
- Torque and locking agent 27
- 6 periodic maintenance 28
- Torque and locking agent 28
- Periodic maintenance 2 7 29
- Torque and locking agent 29
- 8 periodic maintenance 30
- Torque and locking agent 30
- Periodic maintenance 2 9 31
- Torque and locking agent 31
- 10 periodic maintenance 32
- Specifications 32
- Periodic maintenance 2 11 33
- Specifications 33
- 12 periodic maintenance 34
- Special tools 34
- Fuel system dfi 35
- Periodic maintenance 2 13 35
- Periodic maintenance procedures 35
- Throttle grip free play 35
- 14 periodic maintenance 36
- Idle speed 36
- Periodic maintenance procedures 36
- Warning 36
- Periodic maintenance 2 15 37
- Periodic maintenance procedures 37
- Warning 37
- 16 periodic maintenance 38
- Cooling system 38
- Periodic maintenance procedures 38
- Periodic maintenance 2 17 39
- Periodic maintenance procedures 39
- Warning 39
- 18 periodic maintenance 40
- Periodic maintenance procedures 40
- Water and coolant mixture ratio when shipping 40
- Air suction valve inspection 41
- Caution 41
- Clutch 41
- Clutch hose and connection inspection 41
- Engine top end 41
- Periodic maintenance 2 19 41
- Periodic maintenance procedures 41
- 20 periodic maintenance 42
- Periodic maintenance procedures 42
- Warning 42
- Caution 43
- Clutch master cylinder cup and dust seal replacement 43
- Periodic maintenance 2 21 43
- Periodic maintenance procedures 43
- 22 periodic maintenance 44
- Periodic maintenance procedures 44
- Engine lubrication system 45
- Periodic maintenance 2 23 45
- Periodic maintenance procedures 45
- Warning 45
- 24 periodic maintenance 46
- Engine oil 46
- Periodic maintenance procedures 46
- Wheel tires 46
- Air pressure when cold 47
- Final drive 47
- Periodic maintenance 2 25 47
- Periodic maintenance procedures 47
- Tread depth 47
- Warning 47
- 26 periodic maintenance 48
- Final gear case oil 48
- Periodic maintenance procedures 48
- Warning 48
- Brakes 49
- Pad lining thickness 49
- Periodic maintenance 2 27 49
- Periodic maintenance procedures 49
- 28 periodic maintenance 50
- Periodic maintenance procedures 50
- Warning 50
- Periodic maintenance 2 29 51
- Periodic maintenance procedures 51
- 30 periodic maintenance 52
- Caution 52
- Front fork oil leak inspection 52
- Periodic maintenance procedures 52
- Rear brake light switch check adjustment 52
- Suspension 52
- Periodic maintenance 2 31 53
- Periodic maintenance procedures 53
- Steering 53
- 32 periodic maintenance 54
- Periodic maintenance procedures 54
- Warning 54
- Electrical system 55
- General lubrication 55
- Periodic maintenance 2 33 55
- Periodic maintenance procedures 55
- 34 periodic maintenance 56
- Nut bolt and fastener tightness 56
- Periodic maintenance procedures 56
- Periodic maintenance 2 35 57
- Periodic maintenance procedures 57
- Fuel system dfi 59
- Fuel system dfi 3 1 59
- Table of contents 59
- 2 fuel system dfi 60
- Exploded view 63
- Fuel system dfi 3 5 63
- Exploded view 65
- Fuel system dfi 3 7 65
- Dfi parts location 67
- Fuel system dfi 3 9 67
- Dfi system 71
- Fuel system dfi 3 13 71
- Dfi wiring diagram 73
- Fuel system dfi 3 15 73
- Terminal numbers of ecu connectors 73
- 16 fuel system dfi 74
- Dfi wiring diagram 74
- Fuel system dfi 3 17 75
- Specifications 75
- 18 fuel system dfi 76
- Special tools and sealant 76
- Dfi servicing precautions 77
- Fuel system dfi 3 19 77
- 20 fuel system dfi 78
- Outline 78
- Troubleshooting the dfi system 78
- Fuel system dfi 3 21 79
- Troubleshooting the dfi system 79
- 22 fuel system dfi 80
- Troubleshooting the dfi system 80
- Fuel system dfi 3 23 81
- Troubleshooting the dfi system 81
- 24 fuel system dfi 82
- Inquiries to rider 82
- Troubleshooting the dfi system 82
- Fuel system dfi 3 25 83
- Sample diagnosis sheet 83
- Troubleshooting the dfi system 83
- 26 fuel system dfi 84
- Troubleshooting the dfi system 84
- Dfi system troubleshooting guide 85
- Engine doesn t start starting difficulty 85
- Fuel system dfi 3 27 85
- 28 fuel system dfi 86
- Dfi system troubleshooting guide 86
- Dfi system troubleshooting guide 87
- Fuel system dfi 3 29 87
- Poor running at low speed 87
- 30 fuel system dfi 88
- Dfi system troubleshooting guide 88
- Dfi system troubleshooting guide 89
- Fuel system dfi 3 31 89
- 32 fuel system dfi 90
- Dfi system troubleshooting guide 90
- Dfi system troubleshooting guide 91
- Fuel system dfi 3 33 91
- Poor running or no power at high speed 91
- 34 fuel system dfi 92
- Dfi system troubleshooting guide 92
- Dfi system troubleshooting guide 93
- Fuel system dfi 3 35 93
- 36 fuel system dfi 94
- Self diagnosis 94
- Fuel system dfi 3 37 95
- Self diagnosis 95
- Service code reading 95
- 38 fuel system dfi 96
- Self diagnosis 96
- Service code erasing 96
- Fuel system dfi 3 39 97
- Self diagnosis 97
- 40 fuel system dfi 98
- Self diagnosis 98
- Fuel system dfi 3 41 99
- Throttle sensor input voltage 99
- Throttle sensor service code 11 99
- 42 fuel system dfi 100
- Caution 100
- Idle speed 100
- Output voltage inspection 100
- Throttle sensor output voltage 100
- Throttle sensor service code 11 100
- Fuel system dfi 3 43 101
- Resistance inspection 101
- Throttle sensor resistance 101
- Throttle sensor service code 11 101
- 44 fuel system dfi 102
- Inlet air pressure sensor service code 12 102
- Fuel system dfi 3 45 103
- Inlet air pressure sensor input voltage 103
- Inlet air pressure sensor output voltage 103
- Inlet air pressure sensor service code 12 103
- 46 fuel system dfi 104
- Digital volt meter connections 104
- Inlet air pressure sensor service code 12 104
- Fuel system dfi 3 47 105
- Inlet air pressure sensor service code 12 105
- Pv 24 55 cm hg 105
- 48 fuel system dfi 106
- Inlet air pressure sensor service code 12 106
- Pv 55 86 cm hg 106
- Fuel system dfi 3 49 107
- Inlet air temperature sensor output voltage 107
- Inlet air temperature sensor service code 13 107
- 50 fuel system dfi 108
- Inlet air temperature sensor resistance 108
- Inlet air temperature sensor service code 13 108
- Fuel system dfi 3 51 109
- Water temperature sensor output voltage 109
- Water temperature sensor service code 14 109
- 52 fuel system dfi 110
- Water temperature sensor resistance 110
- Water temperature sensor service code 14 110
- Atmospheric pressure sensor input voltage 111
- Atmospheric pressure sensor service code 15 111
- Fuel system dfi 3 53 111
- 54 fuel system dfi 112
- Atmospheric pressure sensor output voltage 112
- Atmospheric pressure sensor service code 15 112
- Atmospheric pressure sensor service code 15 113
- Fuel system dfi 3 55 113
- 56 fuel system dfi 114
- Atmospheric pressure sensor service code 15 114
- Crankshaft sensors 1 2 service code 21 22 115
- Fuel system dfi 3 57 115
- 58 fuel system dfi 116
- Caution 116
- Installation 116
- Vehicle down sensor removal 116
- Vehicle down sensor service code 31 116
- Warning 116
- Fuel system dfi 3 59 117
- Vehicle down sensor output voltage 117
- Vehicle down sensor power source voltage 117
- Vehicle down sensor service code 31 117
- 60 fuel system dfi 118
- Vehicle down sensor service code 31 118
- Fuel injectors 1 2 service code 41 42 119
- Fuel system dfi 3 61 119
- Warning 119
- 62 fuel system dfi 120
- Fuel injectors 1 2 service code 41 42 120
- Fuel injectors 1 2 service code 41 42 121
- Fuel system dfi 3 63 121
- Injector fuel line maximum pressure 121
- 64 fuel system dfi 122
- Fuel injectors 1 2 service code 41 42 122
- Injector power source voltage at dfi main relay 122
- Warning 122
- Caution 123
- Fuel injectors 1 2 service code 41 42 123
- Fuel system dfi 3 65 123
- Injector output voltage at ecu 123
- Injector signal test 123
- Injector wiring inspection 123
- Output voltage inspection 123
- 66 fuel system dfi 124
- Fuel injectors 1 2 service code 41 42 124
- Injector resistance 124
- Fuel injectors 1 2 service code 41 42 125
- Fuel system dfi 3 67 125
- 68 fuel system dfi 126
- Fuel pump service code 45 126
- Warning 126
- Fuel pump service code 45 127
- Fuel system dfi 3 69 127
- 70 fuel system dfi 128
- Fuel pump service code 45 128
- Pump operating voltage at pump 128
- Fuel pump service code 45 129
- Fuel system dfi 3 71 129
- Pump operating voltage at pump connector 129
- Pump power source voltage 129
- 72 fuel system dfi 130
- Fuel pump service code 45 130
- Fuel system dfi 3 73 131
- Ignition coil input voltage at ecu 131
- Ignition coils 1 2 service code 51 52 131
- Fi indicator led light 133
- Fuel system dfi 3 75 133
- Led light inspection 133
- Warning 133
- 76 fuel system dfi 134
- Ecu identification 134
- Check the power source voltage of the ecu with a digital voltmeter 135
- Ecu grounding inspection 135
- Ecu power source inspection 135
- Fuel system dfi 3 77 135
- If no continuity check the connector the engine ground lead or main harness and repair or replace them if nec essary battery c in the frame 135
- If the inspection checks good the ecu is damaged re place the ecu the ecu itself cannot be checked or ser viced 135
- If the voltmeter does not read as specified check the fol lowing power source wiring see wiring diagram of dfi power source section in this chapter dfi fuse 15 a see dfi power source section dfi main relay see dfi power source section ignition fuse 10 a see electrical system chapter 135
- With the ecu connector a joined check the following ground leads for continuity with the ignition sw on or off using a digital voltmeter d 135
- 78 fuel system dfi 136
- Caution 136
- Dfi fuse inspection 136
- Dfi fuse removal 136
- Dfi main relay inspection 136
- Dfi main relay removal 136
- Dfi power source 136
- Testing relay 136
- Dfi power source 137
- Dfi power source circuit 137
- Fuel system dfi 3 79 137
- 80 fuel system dfi 138
- Isc valves 138
- Power source voltage at isc valve connector 138
- Fuel system dfi 3 81 139
- Isc valve solenoid resistance 1 2 139
- Isc valves 139
- Output voltage inspection 139
- Output voltage of isc valves 139
- Resistance inspection 139
- 82 fuel system dfi 140
- Isc valves 140
- Fuel line 141
- Fuel pressure 141
- Fuel system dfi 3 83 141
- Warning 141
- 84 fuel system dfi 142
- Fuel line 142
- Fuel pressure idling 142
- Warning 142
- Amount of fuel flow 143
- Fuel line 143
- Fuel system dfi 3 85 143
- Warning 143
- 86 fuel system dfi 144
- Throttle grip and cables 144
- Warning 144
- Fuel system dfi 3 87 145
- Throttle body assy 145
- Warning 145
- 88 fuel system dfi 146
- Throttle body assy 146
- Fuel system dfi 3 89 147
- Throttle body assy 147
- Warning 147
- 90 fuel system dfi 148
- Throttle body assy 148
- Warning 148
- Fuel system dfi 3 91 149
- Throttle body assy 149
- Warning 149
- 92 fuel system dfi 150
- Throttle body assy 150
- Caution 151
- Fuel system dfi 3 93 151
- Throttle body assy 151
- 94 fuel system dfi 152
- Air cleaner 152
- Warning 152
- Air cleaner 153
- Fuel system dfi 3 95 153
- 96 fuel system dfi 154
- Air cleaner 154
- Fuel system dfi 3 97 155
- Fuel tank 155
- Fuel tank removal 155
- Warning 155
- 98 fuel system dfi 156
- Fuel tank 156
- Fuel system dfi 3 99 157
- Fuel tank 157
- Warning 157
- 100 fuel system dfi 158
- Fuel tank 158
- Warning 158
- Fuel system dfi 3 101 159
- Fuel tank 159
- Warning 159
- 102 fuel system dfi 160
- Fuel tank 160
- Fuel tank cleaning 160
- Warning 160
- Evaporative emission control system 161
- Fuel system dfi 3 103 161
- Warning 161
- 104 fuel system dfi 162
- Evaporative emission control system 162
- Hose inspection periodic inspection 162
- Separator operation test 162
- Warning 162
- Cooling system 163
- Cooling system 4 1 163
- Table of contents 163
- Cooling system 4 3 165
- Exploded view 165
- 4 cooling system 166
- Coolant flow chart 166
- Coolant flow chart 167
- Cooling system 4 5 167
- 6 cooling system 168
- Specifications 168
- Cooling system 4 7 169
- Special tools and sealant 169
- 8 cooling system 170
- Coolant 170
- Coolant 171
- Cooling system 4 9 171
- 10 cooling system 172
- Water pump 172
- Cooling system 4 11 173
- Water pump 173
- 12 cooling system 174
- Water pump 174
- Caution 175
- Cooling system 4 13 175
- Radiator 175
- Radiator removal 175
- Warning 175
- 14 cooling system 176
- Caution 176
- Radiator 176
- Radiator inspection 176
- Radiator installation 176
- Cooling system 4 15 177
- Radiator 177
- Radiator cap relief pressure 177
- 16 cooling system 178
- Thermostat 178
- Thermostat valve opening temperature 178
- Cooling system 4 17 179
- Hoses and pipes 179
- Engine top end 181
- Engine top end 5 1 181
- Table of contents 181
- 2 engine top end 182
- Engine top end 5 3 183
- Specifications 183
- 4 engine top end 184
- Specifications 184
- Engine top end 5 5 185
- Specifications 185
- Engine top end 5 7 187
- Exploded view 187
- Engine top end 5 9 189
- Exploded view 189
- Engine top end 5 11 191
- Exploded view 191
- 12 engine top end 192
- Special tools and sealant 192
- Engine top end 5 13 193
- Special tools and sealant 193
- 14 engine top end 194
- 57001 1121 194
- 57001 1199 can also be used instead of valve seat cutter 32 194
- Compression gauge adapter 57001 1183 can also be used 194
- Special tools and sealant 194
- Valve seat cutter 32 194
- Clean air system 195
- Engine top end 5 15 195
- 16 engine top end 196
- Clean air system 196
- Vacuum switch valve installation 196
- Vacuum switch valve operation test 196
- Vacuum switch valve removal 196
- Vacuum switch valve unit test 196
- Clean air system 197
- Engine top end 5 17 197
- Vacuum switch valve closing pressure open close 197
- 18 engine top end 198
- Camshaft chain tensioner 198
- Camshaft chain tensioner 199
- Engine top end 5 19 199
- 20 engine top end 200
- Rocker case cover 200
- Rocker case cover installation 200
- Rocker case cover removal 200
- Engine top end 5 21 201
- Rocker case cover 201
- 22 engine top end 202
- Rocker case 202
- Rocker case removal 202
- Engine top end 5 23 203
- Rocker case 203
- 24 engine top end 204
- Rocker case 204
- Engine top end 5 25 205
- Rocker case 205
- 26 engine top end 206
- Camshafts 206
- Camshafts 207
- Engine top end 5 27 207
- 28 engine top end 208
- Camshafts 208
- Camshaft journal diameter 209
- Camshaft rocker case clearance 209
- Camshafts 209
- Caution 209
- Engine top end 5 29 209
- 30 engine top end 210
- Camshafts 210
- Front camshaft chain removal 210
- Rear camshaft chain removal 210
- Camshafts 211
- Engine top end 5 31 211
- 32 engine top end 212
- Cylinder compression usable range 212
- Cylinder head 212
- Cylinder head 213
- Engine top end 5 33 213
- 34 engine top end 214
- Cylinder head 214
- Cylinder head warp 214
- Cylinder head 215
- Engine top end 5 35 215
- 36 engine top end 216
- Cylinder head 216
- Valve to guide clearance wobble method 216
- Cylinder head 217
- Engine top end 5 37 217
- For exhaust valve seat 217
- For inlet valve seat 217
- Valve seat surface outside diameter seat o d 217
- Valve seat surface width or seat width 217
- 38 engine top end 218
- Cylinder head 218
- Cylinder head 219
- Engine top end 5 39 219
- Cylinders piston 221
- Engine top end 5 41 221
- 42 engine top end 222
- Cylinders piston 222
- Cylinders piston 223
- Engine top end 5 43 223
- 44 engine top end 224
- Cylinder inside diameter 224
- Cylinders piston 224
- Piston cylinder clearance 224
- Piston diameter 224
- Cylinders piston 225
- Engine top end 5 45 225
- Piston ring groove clearance 225
- Piston ring groove width 225
- 46 engine top end 226
- Cylinders piston 226
- Piston ring end gap 226
- Piston ring thickness 226
- Engine top end 5 47 227
- Mufflers 227
- Warning 227
- 48 engine top end 228
- Mufflers 228
- Chamber assembly for other than u s a and canadian models 229
- Chamber installation for other than u s a and canadian models 229
- Chamber removal for other than u s a and canadian models 229
- Engine top end 5 49 229
- Mufflers 229
- 50 engine top end 230
- Mufflers 230
- Warning 230
- Engine top end 5 51 231
- Muffler exhaust pipe installation u s a and canadian models 231
- Muffler removal u s a and canadian models 231
- Mufflers 231
- Rear exhaust pipe removal u s a and canadian models 231
- 52 engine top end 232
- Mufflers 232
- Clutch 233
- Clutch 6 1 233
- Table of contents 233
- Clutch 6 3 235
- Exploded view 235
- 4 clutch 236
- Specifications 236
- Clutch 6 5 237
- Special tools and sealant 237
- 6 clutch 238
- Clutch fluid 238
- Warning 238
- Clutch 6 7 239
- Clutch master cylinder 239
- 8 clutch 240
- Clutch master cylinder 240
- Clutch master cylinder inspection 240
- Clutch 6 9 241
- Clutch slave cylinder 241
- 10 clutch 242
- Clutch slave cylinder 242
- Clutch 243
- Clutch 6 11 243
- 12 clutch 244
- Clutch 244
- Clutch 245
- Clutch 6 13 245
- 14 clutch 246
- Clutch 246
- Clutch 247
- Clutch 6 15 247
- Spring plate gap 247
- 16 clutch 248
- Clutch 248
- Friction or steel plate warp 248
- Friction plate thickness 248
- Steel plates 248
- Cam damper inspection 249
- Clutch 249
- Clutch 6 17 249
- Clutch housing finger inspection 249
- Clutch spring height 249
- Clutch spring height measurement 249
- Outer clutch hub spline inspection 249
- Engine lubrication system 251
- Engine lubrication system 7 1 251
- Table of contents 251
- Engine lubrication system 7 3 253
- Engine oil flow chart 253
- Engine lubrication system 7 5 255
- Exploded view 255
- 6 engine lubrication system 256
- Specifications 256
- Engine lubrication system 7 7 257
- Special tools and sealant 257
- 8 engine lubrication system 258
- Engine oil and oil filter 258
- Warning 258
- Engine lubrication system 7 9 259
- Oil hose removal 259
- Oil pump and oil line 259
- Oil pump installation 259
- Oil pump removal 259
- 10 engine lubrication system 260
- Oil pump and oil line 260
- Engine lubrication system 7 11 261
- Oil pump and oil line 261
- 12 engine lubrication system 262
- Oil pump and oil line 262
- Engine lubrication system 7 13 263
- Oil pump and oil line 263
- 14 engine lubrication system 264
- Oil pump and oil line 264
- Engine lubrication system 7 15 265
- Oil pressure 265
- Warning 265
- 16 engine lubrication system 266
- Oil pressure 266
- Engine removal installation 267
- Engine removal installation 8 1 267
- Table of contents 267
- Engine removal installation 8 3 269
- Exploded view 269
- 4 engine removal installation 270
- Specifications 270
- Engine removal installation 271
- Engine removal installation 8 5 271
- Warning 271
- 6 engine removal installation 272
- Engine removal installation 272
- Engine removal installation 273
- Engine removal installation 8 7 273
- 8 engine removal installation 274
- Engine removal installation 274
- Engine removal installation 275
- Engine removal installation 8 9 275
- Warning 275
- Crankshaft transmission 277
- Crankshaft transmission 9 1 277
- Table of contents 277
- Crankshaft transmission 9 3 279
- Exploded view 279
- Crankshaft transmission 9 5 281
- Exploded view 281
- 6 crankshaft transmission 282
- Specifications 282
- Crankshaft transmission 9 7 283
- Specifications 283
- 8 crankshaft transmission 284
- Special tools and sealants 284
- Crankcase 285
- Crankcase disassembly 285
- Crankshaft transmission 9 9 285
- 10 crankshaft transmission 286
- Crankcase 286
- Crankcase 287
- Crankshaft transmission 9 11 287
- 12 crankshaft transmission 288
- Crankcase 288
- Caution 289
- Crankcase 289
- Crankcase assembly 289
- Crankshaft transmission 9 13 289
- 14 crankshaft transmission 290
- Crankcase 290
- Crankcase 291
- Crankshaft transmission 9 15 291
- 16 crankshaft transmission 292
- Crankcase 292
- Crankcase 293
- Crankshaft transmission 9 17 293
- 18 crankshaft transmission 294
- Crankcase 294
- Crankcase 295
- Crankshaft transmission 9 19 295
- 20 crankshaft transmission 296
- Crankcase 296
- Crankcase 297
- Crankshaft transmission 9 21 297
- 22 crankshaft transmission 298
- Crankcase 298
- Starter torque limiter check 298
- Crankshaft connecting rods 299
- Crankshaft transmission 9 23 299
- 24 crankshaft transmission 300
- Connecting rod bend 300
- Connecting rod twist 300
- Crankshaft connecting rods 300
- Connecting rod big end bearing crankpin clearance 301
- Connecting rod big end side clearance 301
- Crankshaft connecting rods 301
- Crankshaft transmission 9 25 301
- 26 crankshaft transmission 302
- Big end bearing insert selection 302
- Connecting rod big end inside diameter marks 302
- Crankpin diameter 302
- Crankpin diameter marks 302
- Crankshaft connecting rods 302
- Caution 303
- Crankcase main bearing bore diameter 303
- Crankshaft connecting rods 303
- Crankshaft main bearing journal wear 303
- Crankshaft main journal diameter 303
- Crankshaft runout 303
- Crankshaft side clearance 303
- Crankshaft transmission 9 27 303
- Crankshaft web length 303
- 28 crankshaft transmission 304
- Primary gear 304
- Crankshaft transmission 9 29 305
- Primary gear 305
- 30 crankshaft transmission 306
- External shift mechanism removal 306
- Shift pedal installation 306
- Shift pedal removal 306
- Transmission 306
- Crankshaft transmission 9 31 307
- Transmission 307
- 32 crankshaft transmission 308
- Transmission 308
- Transmission installation 308
- Transmission removal 308
- Crankshaft transmission 9 33 309
- Transmission 309
- 34 crankshaft transmission 310
- Transmission 310
- Crankshaft transmission 9 35 311
- Gear dog and gear dog hole damage 311
- Gear groove width 311
- Shift drum groove width 311
- Shift fork bending 311
- Shift fork ear thickness 311
- Shift fork gear groove wear 311
- Shift fork guide pin diameter 311
- Shift fork guide pin drum groove wear 311
- Transmission 311
- 36 crankshaft transmission 312
- Transmission 312
- Ball bearing needle bearing and oil seal 313
- Crankshaft transmission 9 37 313
- 38 crankshaft transmission 314
- Ball bearing needle bearing and oil seal 314
- Oil seal inspection 314
- Table of contents 315
- Wheels tires 315
- Wheels tires 10 1 315
- Exploded view 317
- Wheels tires 10 3 317
- 4 wheels tires 318
- Specifications 318
- Warning 318
- Special tools 319
- Wheels tires 10 5 319
- 6 wheels tires 320
- Warning 320
- Wheels rims 320
- Warning 321
- Wheels rims 321
- Wheels tires 10 7 321
- 8 wheels tires 322
- Caution 322
- Rear wheel removal 322
- Warning 322
- Wheels rims 322
- Warning 323
- Wheels rims 323
- Wheels tires 10 9 323
- 10 wheels tires 324
- Warning 324
- Wheels rims 324
- Rim runout 325
- Warning 325
- Wheel coupling installation 325
- Wheel inspection 325
- Wheels rims 325
- Wheels tires 10 11 325
- 12 wheels tires 326
- Axle runout 100 mm 326
- Warning 326
- Wheels rims 326
- Balance weight 327
- Warning 327
- Wheels rims 327
- Wheels tires 10 13 327
- 14 wheels tires 328
- Wheels rims 328
- Warning 329
- Wheels tires 10 15 329
- 16 wheels tires 330
- Warning 330
- Warning 331
- Wheels tires 10 17 331
- 18 wheels tires 332
- Hub bearings wheel bearings 332
- Hub bearings wheel bearings 333
- Wheels tires 10 19 333
- Final drive 335
- Final drive 11 1 335
- Table of contents 335
- Exploded view 337
- Final drive 11 3 337
- Exploded view 339
- Final drive 11 5 339
- 6 final drive 340
- Specifications 340
- Final drive 11 7 341
- Special tools 341
- 8 final drive 342
- Final gear case and oil 342
- Final drive 11 9 343
- Final gear case and oil 343
- 10 final drive 344
- Final gear case and oil 344
- Final drive 11 11 345
- Final gear case and oil 345
- 12 final drive 346
- Final gear case and oil 346
- Pinion gear removal 346
- Final drive 11 13 347
- Final gear case and oil 347
- 14 final drive 348
- Final gear case and oil 348
- Final drive 11 15 349
- Final gear case and oil 349
- Preload for pinion gear bearing 349
- Shims for preload adjustment 349
- 16 final drive 350
- Bevel gear inspection 350
- Final gear case and oil 350
- Pinion gear joint inspection 350
- Final drive 11 17 351
- Final gear case and oil 351
- 18 final drive 352
- Final gear case and oil 352
- Final drive 11 19 353
- Final gear case and oil 353
- 20 final drive 354
- Correct tooth contact pattern no adjustment is required 354
- Final gear case and oil 354
- Incorrect tooth contact patterns example 1 354
- Incorrect tooth contact patterns example 2 354
- Final drive 11 21 355
- Propeller shaft 355
- 22 final drive 356
- Propeller shaft 356
- Propeller shaft inspection 356
- Sliding joint inspection 356
- Final drive 11 23 357
- Front bevel gears 357
- 24 final drive 358
- Front bevel gears 358
- Final drive 11 25 359
- Front bevel gears 359
- 26 final drive 360
- Front bevel gears 360
- Final drive 11 27 361
- Front bevel gears 361
- 28 final drive 362
- Front bevel gears 362
- Preload for driven gear bearing 362
- Final drive 11 29 363
- Front bevel gears 363
- Preload measurement with spring scale 363
- 30 final drive 364
- Front bevel gears 364
- Final drive 11 31 365
- Front bevel gear backlash at the gear tooth 365
- Front bevel gears 365
- 32 final drive 366
- Front bevel gears 366
- Bevel gear inspection 367
- Cam damper inspection 367
- Final drive 11 33 367
- Front bevel gears 367
- 34 final drive 368
- Bearing and oil seal 368
- Bearing and oil seal 369
- Final drive 11 35 369
- Brakes 371
- Brakes 12 1 371
- Table of contents 371
- Brakes 12 3 373
- Exploded view 373
- Brakes 12 5 375
- Exploded view 375
- 6 brakes 376
- Specifications 376
- Brakes 12 7 377
- Special tool 377
- 8 brakes 378
- Brake lever brake pedal 378
- Pedal position 378
- Brake lever brake pedal 379
- Brake pedal removal 379
- Brakes 12 9 379
- 10 brakes 380
- Brake lever brake pedal 380
- Brake pedal installation 380
- Warning 380
- Brakes 12 11 381
- Calipers 381
- Warning 381
- 12 brakes 382
- Calipers 382
- Warning 382
- Brakes 12 13 383
- Calipers 383
- Rear caliper disassembly 383
- 14 brakes 384
- Calipers 384
- Warning 384
- Brakes 12 15 385
- Calipers 385
- 16 brakes 386
- Brake pads 386
- Warning 386
- Brake pad wear inspection 387
- Brake pads 387
- Brakes 12 17 387
- Rear brake pad installation 387
- Warning 387
- 18 brakes 388
- Master cylinder 388
- Brakes 12 19 389
- Master cylinder 389
- Rear master cylinder removal 389
- 20 brakes 390
- Caution 390
- Front master cylinder disassembly 390
- Master cylinder 390
- Rear master cylinder installation 390
- Warning 390
- Brakes 12 21 391
- Master cylinder 391
- 22 brakes 392
- Master cylinder 392
- Master cylinder inspection 392
- Brake discs 393
- Brakes 12 23 393
- Disc runout 393
- Front disc thickness 393
- Rear disk thickness 393
- 24 brakes 394
- Brake fluid 394
- Warning 394
- Brake fluid 395
- Brakes 12 25 395
- 26 brakes 396
- Brake fluid 396
- Warning 396
- Brake hose removal installation 397
- Brake hoses 397
- Brakes 12 27 397
- Caution 397
- Suspension 399
- Suspension 13 1 399
- Table of contents 399
- Exploded view 401
- Suspension 13 3 401
- Exploded view 403
- Suspension 13 5 403
- 6 suspension 404
- Specifications 404
- Special tools 405
- Suspension 13 7 405
- 8 suspension 406
- Front fork 406
- Front fork oil level fully compressed without fork spring 406
- Caution 407
- Front fork 407
- Front fork removal 407
- Suspension 13 9 407
- Warning 407
- 10 suspension 408
- Front fork 408
- Warning 408
- Front fork 409
- Suspension 13 11 409
- 12 suspension 410
- Front fork 410
- Caution 411
- Dust seal inspection 411
- Front fork 411
- Inner tube outer tube inspection 411
- Suspension 13 13 411
- Warning 411
- 14 suspension 412
- Front fork 412
- Spring free length 412
- Spring tension 412
- Rear shock absorber 413
- Rebound damping adjustment 413
- Spring preload adjustment 413
- Suspension 13 15 413
- Warning 413
- 16 suspension 414
- Caution 414
- Rear shock absorber 414
- Rear shock absorber inspection 414
- Rear shock absorber installation 414
- Rear shock absorber removal 414
- Warning 414
- Rear shock absorber 415
- Suspension 13 17 415
- 18 suspension 416
- Swingarm 416
- Warning 416
- Caution 417
- Suspension 13 19 417
- Swingarm 417
- Swingarm installation 417
- 20 suspension 418
- Caution 418
- Swingarm 418
- Swingarm bearing installation 418
- Swingarm bearing removal 418
- Swingarm bearing sleeve inspection 418
- Grease seal and needle bearing lubrication 419
- Suspension 13 21 419
- Swingarm 419
- Steering 421
- Steering 14 1 421
- Table of contents 421
- Exploded view 423
- Steering 14 3 423
- 4 steering 424
- Special tools 424
- Handlebar 425
- Handlebar installation 425
- Handlebar removal 425
- Steering 14 5 425
- 6 steering 426
- Steering 426
- Steering adjustment 426
- Steering check 426
- Caution 427
- Steering 14 7 427
- Steering stem 427
- Steering stem removal 427
- Warning 427
- 8 steering 428
- Steering stem 428
- Steering 14 9 429
- Steering stem 429
- 10 steering 430
- Steering stem 430
- Warning 430
- Steering 14 11 431
- Steering stem bearing 431
- 12 steering 432
- Steering stem bearing 432
- Frame 15 1 433
- Table of contents 433
- Exploded view 435
- Frame 15 3 435
- Exploded view 437
- Frame 15 5 437
- 6 frame 438
- Special tools 438
- Frame 15 7 439
- Front seat installation 439
- Front seat removal 439
- Rear seat installation 439
- Rear seat removal 439
- 8 frame 440
- Caution 440
- Left side cover installation 440
- Left side cover removal 440
- Right side cover removal installation 440
- Side covers 440
- Caution 441
- Fenders 441
- Frame 15 9 441
- Front fender removal 441
- Rear fender removal 441
- 10 frame 442
- Battery case removal 442
- Battery case tool box 442
- Tool box removal 442
- Frame 15 11 443
- Front footboard sidestand 443
- 12 frame 444
- Downtube installation 444
- Downtube removal 444
- Frame 15 13 445
- Frame inspection 445
- Warning 445
- Electrical system 447
- Electrical system 16 1 447
- Table of contents 447
- 2 electrical system 448
- Electrical system 16 5 451
- Exploded view 451
- Electrical system 16 7 453
- Exploded view 453
- Electrical system 16 9 455
- Exploded view 455
- Electrical system 16 11 457
- Exploded view 457
- 12 electrical system 458
- Specifications 458
- Electrical system 16 13 459
- Special tools 459
- 20 electrical system 466
- Electrical parts location 466
- Electrical parts location 467
- Electrical system 16 21 467
- 22 electrical system 468
- Servicing precautions 468
- Electrical system 16 23 469
- Servicing precautions 469
- 24 electrical system 470
- Electrical wiring 470
- Battery 471
- Battery installation 471
- Battery removal 471
- Caution 471
- Electrical system 16 25 471
- 26 electrical system 472
- Battery 472
- Battery 473
- Electrical system 16 27 473
- Warning 473
- 28 electrical system 474
- Battery 474
- Caution 474
- Initial charge 474
- Precautions 474
- Warning 474
- Battery 475
- Battery terminal voltage 475
- Electrical system 16 29 475
- Warning 475
- 30 electrical system 476
- Battery 476
- Terminal voltage 11 less than 12 v 476
- Terminal voltage less than 11 v 476
- Alternator cover removal installation 477
- Alternator outer cover installation 477
- Alternator outer cover removal 477
- Charging system 477
- Electrical system 16 31 477
- 32 electrical system 478
- Alternator cover assembly 478
- Alternator inner cover removal 478
- Charging system 478
- Charging system 479
- Electrical system 16 33 479
- 34 electrical system 480
- Charging system 480
- Charging system 481
- Electrical system 16 35 481
- 36 electrical system 482
- Alternator inside stator installation 482
- Alternator inspection 482
- Battery charging voltage 482
- Charging system 482
- Charging voltage inspection 482
- Alternator output voltage 483
- Charging system 483
- Electrical system 16 37 483
- Stator coil resistance 483
- 38 electrical system 484
- Charging system 484
- Regulator rectifier removal 484
- Charging system 485
- Electrical system 16 39 485
- Rectifier circuit inspection 485
- 40 electrical system 486
- Charging system 486
- Charging system 487
- Charging system circuit 487
- Electrical system 16 41 487
- Caution 489
- Electrical system 16 43 489
- Ignition coil installation 489
- Ignition coil removal 489
- Ignition system 489
- Warning 489
- 44 electrical system 490
- Ignition coil winding resistance 490
- Ignition system 490
- Needle arcing distance 490
- Warning 490
- Electrical system 16 45 491
- Ignition system 491
- Primary lead connections 491
- Recommended tool peak voltage adapter 491
- 46 electrical system 492
- Ignition coil primary peak voltage 492
- Ignition system 492
- Warning 492
- Connections 493
- Crankshaft sensor peak voltage 493
- Electrical system 16 47 493
- Ignition system 493
- Recommended tool peak voltage adapter 493
- 48 electrical system 494
- Connections 494
- Ignition system 494
- Ignition timing 494
- Ignition timing inspection 494
- Condition 495
- Connection 495
- Electrical system 16 49 495
- Ignition system 495
- Interlock operation voltage 495
- 50 electrical system 496
- Ic igniter inspection 496
- Ignition system 496
- 52 electrical system 498
- Ignition system 498
- Ignition system circuit 498
- Caution 499
- Electrical system 16 53 499
- Starter motor 499
- Starter motor installation 499
- Starter motor removal 499
- 54 electrical system 500
- Starter motor 500
- Electrical system 16 55 501
- Starter motor 501
- 56 electrical system 502
- Commutator diameter 502
- Starter motor 502
- Starter motor brush length 502
- Electrical system 16 57 503
- Starter motor 503
- Testing relay 503
- 58 electrical system 504
- Electric starter circuit 504
- Starter motor 504
- Electrical system 16 59 505
- Lighting system 505
- 60 electrical system 506
- Lighting system 506
- Caution 507
- City light bulb replacement other than us ca and au 507
- Electrical system 16 61 507
- Headlight body removal 507
- Lighting system 507
- 62 electrical system 508
- Lighting system 508
- Tail brake light bulb replacement 508
- Electrical system 16 63 509
- Headlight tail light circuit 509
- Lighting system 509
- 64 electrical system 510
- Automatic turn signal canceling system 510
- Wiring inspection 510
- Automatic turn signal canceling system 511
- Connections 511
- Electrical system 16 65 511
- 66 electrical system 512
- Automatic turn signal canceling system 512
- Testing turn signal control relay inspection 512
- Automatic turn signal canceling system 513
- Electrical system 16 67 513
- 68 electrical system 514
- Automatic turn signal canceling system 514
- Turn signal cancelling system circuit 514
- Electrical system 16 69 515
- Fan motor inspection 515
- Fan system circuit inspection 515
- Radiator fan circuit 515
- Radiator fan system 515
- Warning 515
- 70 electrical system 516
- Oil pressure light delay unit inspection 516
- Oil pressure light delay unit removal 516
- Oil pressure warning system 516
- Oil pressure warning system circuit 516
- Electrical system 16 71 517
- Lighting delay time 517
- Oil pressure warning system 517
- 72 electrical system 518
- Caution 518
- Meter gauge 518
- Meter unit removal 518
- Electrical system 16 73 519
- Meter gauge 519
- 74 electrical system 520
- Meter gauge 520
- Connections 521
- Electrical system 16 75 521
- Meter gauge 521
- 76 electrical system 522
- Meter gauge 522
- Electrical system 16 77 523
- Meter gauge 523
- 78 electrical system 524
- Example 524
- Meter gauge 524
- Connections 525
- Electrical system 16 79 525
- Meter gauge 525
- 80 electrical system 526
- Fuel level warning indicator led light connections 526
- Meter gauge 526
- Oil pressure warning indicator led light connections 526
- Electrical system 16 81 527
- Fi indicator led light connections 527
- Meter gauge 527
- Water temperature warning indicator led light connections 527
- 82 electrical system 528
- Meter gauge 528
- Neutral indicator light connections 528
- Electrical system 16 83 529
- High beam indicator light connections 529
- Meter gauge 529
- 84 electrical system 530
- Meter gauge 530
- Meter unit circuit 530
- Electrical system 16 85 531
- Water temperature warning system 531
- 86 electrical system 532
- Fuel level sensor inspection 532
- Fuel level sensor resistance 532
- Switch and sensors 532
- Electrical system 16 87 533
- Switch and sensors 533
- 88 electrical system 534
- Switch and sensors 534
- Electrical system 16 89 535
- Fan switch resistance 535
- Switch and sensors 535
- 90 electrical system 536
- Switch and sensors 536
- Water temperature switch resistance 536
- Electrical system 16 91 537
- Engine lubrication system is in good condition 537
- Switch and sensors 537
- 92 electrical system 538
- Fuse circuit inspection 538
- Junction box 538
- Junction box fuse circuit inspection 538
- Starter circuit headlight relay inspection 538
- Diode circuit inspection 539
- Electrical system 16 93 539
- Junction box 539
- Relay circuit inspection with the battery connected 539
- Relay circuit inspection with the battery disconnected 539
- 94 electrical system 540
- Junction box 540
- Junction box internal circuit 540
- Electrical system 16 95 541
- Appendix 543
- Appendix 17 1 543
- Table of contents 543
- Appendix 17 3 545
- Cable wire and hose routing 545
- Appendix 17 5 547
- Cable wire and hose routing 547
- 6 appendix 548
- Cable wire and hose routing 548
- Appendix 17 7 549
- Cable wire and hose routing 549
- Appendix 17 9 551
- Cable wire and hose routing 551
- Appendix 17 11 553
- Cable wire and hose routing 553
- Appendix 17 13 555
- Cable wire and hose routing 555
- 14 appendix 556
- Cable wire and hose routing 556
- Appendix 17 15 557
- Cable wire and hose routing 557
- Appendix 17 17 559
- Cable wire and hose routing 559
- 18 appendix 560
- Cable wire and hose routing 560
- Appendix 17 19 561
- Cable wire and hose routing 561
- 20 appendix 562
- Cable wire and hose routing 562
- Appendix 17 21 563
- Cable wire and hose routing 563
- 22 appendix 564
- Cable wire and hose routing 564
- Appendix 17 23 565
- Cable wire and hose routing 565
- Appendix 17 25 567
- Cable wire and hose routing 567
- 26 appendix 568
- Cable wire and hose routing 568
- Appendix 17 27 569
- Cable wire and hose routing 569
- 28 appendix 570
- Engine doesn t start starting difficulty 570
- Poor running at low speed 570
- Troubleshooting guide except dfi 570
- Appendix 17 29 571
- Overheating 571
- Poor running or no power at high speed 571
- Troubleshooting guide except dfi 571
- 30 appendix 572
- Abnormal engine noise 572
- Clutch operation faulty 572
- Gear shifting faulty 572
- Over cooling 572
- Troubleshooting guide except dfi 572
- Abnormal drive train noise 573
- Abnormal frame noise 573
- Appendix 17 31 573
- Exhaust smokes excessively 573
- Handling and or stability unsatisfactory 573
- Oil pressure warning light goes on 573
- Troubleshooting guide except dfi 573
- 32 appendix 574
- Battery trouble 574
- Brake doesn t hold 574
- Troubleshooting guide except dfi 574
- Model application 575
- Part no 9924 1309 02 575
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