![Kawasaki VULCAN 1600 CLASSIC (2003) [222/575] 42 engine top end](/img/pdf.png)
Kawasaki VULCAN 1600 CLASSIC (2003) [222/575] 42 engine top end
![Kawasaki VULCAN 1600 CLASSIC (2003) [222/575] 42 engine top end](/views2/1121175/page222/bgde.png)
5-42 ENGINE TOP END
Cylinders, Piston
•
Do not mix up the top ring and second ring.
•
Install the top ring [A] so that the “R” m ark [B] faces up.
•
Install the second ring [C] so that the “RN”mark[D]faces
up.
•
The piston ring openings must be positioned as shown in
the figure. The openings of the oil ring steel rails m ust be
about 30 ∼ 45° [F] of angle from the opening of the top
ring.
Top R i n g [A]
Second Ring [B]
Oil Ring Steel Rails [C]
Oil Ring Expander [D]
Arrow mark [E] must be faced tow ard the engine front.
Opening Positions [G]
•
Face the arrow mark [A] on each piston toward the front
side [B].
○
The front and rear pistons are the same, but they should
be installed in t heir original positions.
CAUTION
Incorrect installation of the piston could cause pis-
ton seizure and result in severe engine damage.
•
Fit a new piston pin snap ring into the side of the piston
so that the ring opening [A] does not coincide with the slit
[B] of the piston pin hole.
•
Apply molybdenum disulfide oil to the outer surface of the
piston pin.
○
The m olybdenum disulfide oil is a mixture of engine oil
and molybdenum disulfide grease with a weight ratio (10
:1).
○
When installing the piston pin snap ring, compress it only
enough to install it and no more.
•
Apply m olybdenum disulfide oil to the cylinder bore.
•
Apply molybdenum disulfide oil to the front and rear of the
piston skirt.
•
Install the rear cylinder first, with the rear piston at TDC.
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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