![Kawasaki VN1500 (1987-1999) [73/270] Repair if necessary](/img/pdf.png)
Kawasaki VN1500 (1987-1999) [73/270] Repair if necessary
![Kawasaki VN1500 (1987-1999) [73/270] Repair if necessary](/views2/1121179/page73/bg49.png)
+T6
ENGINE
TOP
END
Crylinder
Head
Cylinda
Compression Measurcment
NOTE
O Use the
battery which
is fully charged.
OWarm
up the engine thoroughly.
aStop
the engine.
aRemove
one spark
plug
and attach
the compression
oThe
compression
gauge
adapter: 57001
-1
1 83 can
also
gauge
and adapter firmly
into
the spark
plug
hole.
Do be used.
not
remove
the other spark
plug,
only the
plug
lead.
aFepeat
the measurement for
the
other cvlinoer.
aFor the other
cylinder, remove
both spark
plugs.
NOTE
Special Tools
-
Spark Plug
Wrench, Her( 18:
57qn
-1024
Compreseion
Gauget 57OO1
-2,j21
Compr€ssion caug€ Adapter,
Ml2 x
1.25:5r0ot-1018
ausing
the staner motor,
turn the
engine over with
the
throttle
fully open until the
compression
gauge
stops
rising;
the compression is
fhe highest reading
obtaina-
ble.
Cylinder Comprg€sion Pr€ssuro
Ugable
Range:
Front
Cylinder: 345
-
590 kPa
(3.5
-
6 kg/cmr,
50
-
85
psi)
@gn
r/min
(rpm)
Rear
Cylind€.: 6&5
-
1O8O
kPa
(7.O
-
11 l<g/crn2,
110
-
156
psi)
@300
r/min
(rpm)
olf the
engine is well
broken in. the
crcnking
speed may
become fastet
shutting down
the decompressor.
This
can raise
the ftont cylinder
comprcssion
pre\ture
near
to the rcar
cylindels in some
engines.
alnstall the spa*
plugs.
Torque
-
Spark
Plu$
: 18 N-m
(1.75
kg-m,
12.5 fttb)
The following
table should
be
consulted if the
obtainable compression
reading is not
within
the usable range.
Problem
Diagn06is
Remedy
(Action)
Cylinder compression
is
higher than
usable
range
Carbon
accumulation
on
piston
and cylinder
head,
and in
combustion
chamber
possibly
due to dam-
aged valve
stem
oil seal and/or damaged
piston
oil dngs
(This
may
be
indicared
by white
exhaust
smoke).
Remove the
carbon
deposits and repracr
damaged
parts
if
necessary.
Inconect
cvlinder
head
gasket
thickness.
Replace
the
gasket
with
a standard
Dan,
Damaged
or missing
compression
release
cam
spring
Feplace the sp ng.
Compression
release
weights do not move
smooth-
Replace the
compression release
unit.
Cylinder
compression
is
lower
than usable
range
Gas leakage
around
cylinder head
Replace damaged
gasket
and check
cylinder head warp.
Bad
condition
of
valve
seating
Repair if necessary.
H
LA seizure.
ReDlace the HLA.
Inconect
piston/cylinder
clearance
Replace the
piston
andlor
cylinder
Piston
seizure.
Inspect
the cylinder
and liner
and
replace/repair
the cylinder and/or
piston
as necessary.
Bad condition
ol
piston
ring
and/or
piston
ring
grooves.
Replace the
piston
and/or
the
piston
flngs.
Compression
release
weights
do
not move
smooth-
lv.
Replace
the compression
rel€ase
unit.
Содержание
- Front cover 1
- Kawasak 1
- Motorcycle 1
- Service manual 1
- Vn1500 1
- Contents 2
- Http manuals magnamaniac com 2
- Quick reference guide 2
- Http manuals magnamaniac com 3
- Kawasaki 3
- Motorcycle 3
- Service manual 3
- Vn1500 3
- Http manuals magnamaniac com 4
- Read o i ner s mani at before operating 4
- Http manuals magnamaniac com 5
- 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 darice or element of design incorporated into any neur vehicle for th _ purpose of noise control prior to i6 sale or deliriery to the ultimate purchaser or while it is in use or 21 the use of the vehicle after grch device or element o f a id h been remored or rendered inoperative by any pervrn 6
- Http manuals magnamaniac com 6
- Tampebing witii noise contbol system pbohibited 6
- We recommend that all dealers observe these provisions of federal law the violation of which is punishable by civil penalties not exceeding 1o ooo per violation 6
- _among those asts pre med to constitute tampering are the acts listed below r eplacem nt of_ the original exhaust system or mriffler with a component not in com 6
- Foreword 7
- How to use this manual 7
- Http manuals magnamaniac com 7
- Http manuals magnamaniac com 8
- General information 9
- Http manuals magnamaniac com 9
- Table of contents 9
- Before serwicing 10
- General information 10
- Http manuals magnamaniac com 10
- General information 1 3 11
- Hardening warp scratch wear seizure 11
- Http manuals magnamaniac com 11
- Wire cross section name of wire color 11
- Wire strands 11
- Http manuals magnamaniac com 12
- Vn15qlb1 left side view 12
- General information 16 13
- General specif ications 13
- Http manuals magnamaniac com 13
- General information 14
- Http manuals magnamaniac com 14
- Http manuals magnamaniac com 15
- Freouency 16
- Fuel system check t 16
- General information 1 16
- Http manuals magnamaniac com 16
- Oil screen clean 16
- Operation 16
- Whichever comes first 16
- Years brake clurch hose and pipe replace 4 years 16
- 80 13 in lb 18
- General information 1 9 18
- Http manuals magnamaniac com 18
- Http manuals magnamaniac com 19
- Io general information 19
- Torque remarks 19
- Http manuals magnamaniac com 20
- 12 general information 21
- Cable wire and hose routing 21
- Http manuals magnamaniac com 21
- Vn1500 b 21
- General information 1 3 22
- Http manuals magnamaniac com 22
- 14 general information 23
- Carburetor hose routing 23
- Http manuals magnamaniac com 23
- General information 1 5 24
- Http manuals magnamaniac com 24
- General information 25
- Http manuals magnamaniac com 25
- Vn1s00 b 25
- Vnlsoga 25
- General information t 17 26
- Http manuals magnamaniac com 26
- Http manuals magnamaniac com 27
- I 8 general nformation 27
- 2 2 5 2 5 2 6 2 2 7 2 7 2 7 2 7 24 24 2 9 28
- Fuel system 28
- Http manuals magnamaniac com 28
- Table of contents 28
- Exploded view 29
- Fuel system 29
- Http manuals magnamaniac com 29
- Ifrptri 29
- Fuel system 2 30
- Http manuals magnamaniac com 30
- Fuel system 2 32
- Http manuals magnamaniac com 32
- Special tools 32
- Specifications 32
- Fuel system 33
- Http manuals magnamaniac com 33
- Throttle cable adjustment 33
- Throttle grip and cables 33
- Fuel system 2 34
- H igh altitude performance adiustment us model 34
- Http manuals magnamaniac com 34
- C a ft u teto i sy n ch rc n izati o n owam up the engine ocheck idle speed and adiust if necessary oattach a commercially available vacuum gauge to the vacuum hose fittings on the carburetors 35
- Fuel system 35
- Http manuals magnamaniac com 35
- Rvice fuel level adiustment 35
- Carburetor removal 36
- Fuel system 2 9 36
- Http manuals magnamaniac com 36
- I wautlruc i 37
- L wannrnil 37
- C ze rb u reto r c o m b i n a ti o n lnstallation is reverse of removal nog the following afit the front carburetor to the float chamber as shown 38
- Fuel system 2 1 38
- Http manuals magnamaniac com 38
- A choke rod 39
- A float b do not tap here c tap the pin as far as it will go 39
- A starter plunger lever c starter plunger b choke link rod 39
- Carbu etor asembly note tle following lnstall the float on the carburetor otap the float pivot pin lightly to press it the float chamber body as shown evenly into 39
- Carbu reto r d isassembly 39
- Float pivot pin 39
- Fuel system 39
- Http manuals magnamaniac com 39
- Olnshll the rear carburetor starter snown plung r lever as 39
- Olnstall the choke rod to the carburetor 39
- Caunon 40
- Fuel system 2 3 40
- Http manuals magnamaniac com 40
- 14 fuel system 41
- Carburetor lnspection 41
- Fuel pump 41
- Http manuals magnamaniac com 41
- Removal remove the fuel tank 41
- Air cleaner 42
- Fuel filter 42
- Fuel system 2 5 42
- Http manuals magnamaniac com 42
- L wnnruruol 42
- Lnstallation nota connect the fuel hoses to the pump fittings as shown 42
- Air cleaner housing lnsallation 43
- Element cleaning 43
- Fuel system 43
- Http manuals magnamaniac com 43
- Evaporative emission control system us california vehicle only 44
- Fuel system 2 7 44
- Hose inspection periodic lnspection 44
- Http manuals magnamaniac com 44
- Pa rb bemoval l nstal lation n otes 44
- Parator inspection 44
- Surge tank 44
- Fuel system 45
- Http manuals magnamaniac com 45
- Parator operation test 45
- Cooling ptem 46
- Cooling system 46
- Table of contents 46
- Exploded view 47
- Sr ffi 47
- Cooling system 3 48
- Http manuals magnamaniac com 48
- Thermostat valve opening temperature valve full opening lift 80 84 c 176 183 f1 more than 8 mm 5 c 2 b f 48
- When the engine is cold the thermostat is closed so trat the coolant flow restricted through the small hole on the thermostat air hole causing the engine to warm up more quickly 48
- Coolant 49
- Coolant draining 49
- Cooling system 49
- Http manuals magnamaniac com 49
- Cooling system 35 50
- Http manuals magnamaniac com 50
- Cooling system 51
- Http manuals magnamaniac com 51
- Pressure testing remove the radiator cap and install a cooling system 51
- Water pump 51
- Water pump mechanical seal removal 51
- B chisel 52
- Cooling system 7 52
- Http manuals magnamaniac com 52
- Radiator and cooling fan 52
- Removal remove the following radiator cover 52
- Water pump mechanical seal lnstallation 52
- Cooling system 53
- Http manuals magnamaniac com 53
- Badiator cap lnspection acheck the condition of the top and bottom valve seals 54
- Badiator lnspection theck the radiator core lf there are obstructions to air flow remove them lf the corrugated fins are deformed carefully straighten 54
- Cooling system 9 54
- Http manuals magnamaniac com 54
- Lnsallation be sure to attach the ground wire to the fan mounting bolt 54
- 10 cooling system 55
- Http manuals magnamaniac com 55
- Thermostat 55
- Cooling system 11 56
- Http manuals magnamaniac com 56
- Lnstallation 56
- E ru b 57
- Http manuals magnamaniac com 57
- Isflrr inr i r i t r r j_ t tl 57
- Lnsallation noe 57
- N ii 6 sts 57
- R ohroqp r 57
- Rioh ril a 57
- Sqe eh 0b r 6niitfh tqldre p r fic qusr e elplod d v iew rrurrlrqi rt rsool rrkv 57
- Engine top end 58
- Http manuals magnamaniac com 58
- Table of contents 58
- 2 engine top end 59
- Exploded view 59
- Http manuals magnamaniac com 59
- Engine top end 61
- L apply nonf manent loddng ag trt o apply endne oil t1 15 n m 1 5 kgfm 11o ft lbl t2 25 nrn 25 kgn 18 ft lbl 61
- 6 engine top end 63
- Http manuals magnamaniac com 63
- Specifications 63
- Q q k o r j 64
- Stem n 64
- Air suction valve lnspection avisually inspect the reeds for cracks folds warps hear 65
- Clean air system us and switertand models 65
- During engine braking 65
- Engine top end 65
- Gamshaft chain tensioner 65
- High vacuum 65
- Http manuals magnamaniac com 65
- Remoral 65
- Secondary air cannot flow 65
- Vacuum switch valve test 65
- Vacuum sxritch valve closing pressure open close 35 rl t kpa 260 320 mmhql 65
- 2 gasket chain tensioner cap bolt stopper 66
- A chain tensioner 66
- A mounting bolts b spring 66
- A push rod b stopper 66
- A tensioner body b arrow mark 66
- B cap bolt 66
- C copper washer d cap bolt 66
- C push d push into the rod 66
- Engine top end 9 66
- Http manuals magnamaniac com 66
- Lnstallation is tie reverse of removal note the fol lowin olnstall the tensioner body with the arrow on it pointing upwards 66
- Lnstullation 66
- Orelease the stopper and push into the rod 66
- Http manuals magnamaniac com 67
- I 0 engine top end 67
- Rocker case cap 67
- Rocker shafg rocker arms rodcer case 67
- Engine top end 11 68
- Http manuals magnamaniac com 68
- Lnstallation note the followin olnstall the rocker arms and retainer springs on each rocker shaft as shown 68
- 12 engine top end 69
- Hla air bleeding fill a container with engine oil 69
- Hla hydraulic lash adjuster 69
- Hla lnstallation 69
- Hla removal 69
- Http manuals magnamaniac com 69
- Rmflml 69
- Engine top end 4 13 70
- Http manuals magnamaniac com 70
- 14 engine top end 71
- Camsh aft sproc ket assembl y 71
- Http manuals magnamaniac com 71
- Camshaft chain wear hold the chain taut with a force of about 5 kg in some manner and measure a 2o link length since the chain may wear unevenly tak measurements at s veral 72
- Engine top end 15 72
- Http manuals magnamaniac com 72
- Installation fit the kacr unit onto the camshaft as shown 72
- Kacr kawasaki automatic compression releae 72
- Lnspection 72
- Removal aremove tie engine see engine removalnstallation 72
- Aremove one spark plug and attach the compression othe compression gauge adapter 57001 1 1 83 can also gauge and adapter firmly into the spark plug hole do be used not remove the other spark plug only the plug lead afepeat the measurement for the other cvlinoer afor the other cylinder remove both spark plugs note 73
- Ausing the staner motor turn the engine over with the throttle fully open until the compression gauge stops rising the compression is fhe highest reading obtaina ble 73
- Crylinder head 73
- Cylinda compression measurcment 73
- Cylinder compression is higher than usable range 73
- H la seizure 73
- Http manuals magnamaniac com 73
- Piston seizure 73
- Repair if necessary 73
- Replace the compression rel ase unit 73
- T6 engine top end 73
- Http manuals magnamaniac com 74
- Lnstallation 74
- Valves 74
- Http manuals magnamaniac com 75
- Engine top end 17 76
- Http manuals magnamaniac com 76
- Valve guide removal 76
- Valve removal 76
- 035 32 03s s 55 c35 45 cas t2 c35 55 c35 77
- 126 570ij1 11 77
- Engine top end 77
- Http manuals magnamaniac com 77
- Valve at ouaide diameter 77
- Valve face contact lnspection rcheck the valve face seating surface width ouse a v rnier caliper to measure the seat width white portion of the valve face where there is no carbon build up lf the valve face seating surface width is not within the specified range replace the valve with a new one 77
- Valve seat repair valve lappingj using lhe valve seat cutters special tools repair the 77
- Engine top end 19 78
- Http manuals magnamaniac com 78
- 20 engine top end 79
- Http manuals magnamaniac com 79
- Measu ring valve to g uide clearance wobble method 79
- A camshaft chain guides c r mark b f mark 80
- A drain plug b cylinder nut 80
- A water holes 80
- Cylinder bemoval 80
- Cylinder lnstallation 80
- Engine top end 4 1 80
- Gylinders pistons 80
- Http manuals magnamaniac com 80
- Oposition the crankshaft at tdc oapply engine oil to the cylinder bore piston ring and piston skirt oslip the cylinder block onto the piston ouse the cylinder s marked f for the front and r for the rear 80
- Remove the cylinder nuts otake the cvlinder off the crankcase 80
- O aulo 81
- Cylinder wear 82
- Engine top end 4 23 82
- Http manuals magnamaniac com 82
- Piston ring end gap 82
- Piston ring piston ring groove wear 82
- Piston wear 82
- 24 engine top end 83
- Http manuals magnamaniac com 83
- Muffler 83
- Removal for vn1500 4 83
- Engine top end 25 84
- Http manuals magnamaniac com 84
- Lnstallation p rform the following oreplace the exhaust gaskets with new ones 84
- Remoml lfor vn 50gb 84
- 26 engine top end 85
- Http manuals magnamaniac com 85
- Clutch 86
- Clutch 1 86
- Glutch 86
- Http manuals magnamaniac com 86
- Table of contents 86
- Clutch 5 88
- Http manuals magnamaniac com 88
- Special tool 88
- Specifications 88
- A lower level line 89
- B upper level line 89
- Brands of fluid 89
- Clutch 89
- Clutch fluid 89
- Clutch fluid changing 89
- Fluid level inspection check the clutch fluid level in the reservoir 89
- Horizontal when chfiking clutch 89
- Http manuals magnamaniac com 89
- I warn ng i 89
- Lf the fluid level is lower than the lower level line fill the reservoir to the upper level line in the reservoir 89
- Note osince the clutd fluid is dre sme as the bnke fluid refer to bnke fluid section in brckes for further debils 89
- Clutch 5 90
- Disassembly 90
- Http manuals magnamaniac com 90
- I warntnc i 90
- Lnsallation when installing the clutch master cylinder be careful 90
- Master cylinder 90
- Assembly 91
- Clutch 91
- Clutch slave cylinder 91
- Http manuals magnamaniac com 91
- Lnstal lation 91
- Remoml perform the following if the clutch slave cylinder is 91
- Clutch 92
- Clutch 7 92
- Disassembly oleaving tie clutch slave cylinder removed allow the piston to move slowly out under spring pressure 92
- Http manuals magnamaniac com 92
- T cautt0l 92
- Clutch 93
- Http manuals magnamaniac com 93
- Clutch 5 9 94
- Clutch lnner hub disasembly assembly using a press and suitable bearing driver special ool compress the damper springs 94
- Http manuals magnamaniac com 94
- 10 clutch 95
- Ctake care not to shaft 95
- Friction and steel plate damage wear 95
- Friction and steel plate warp lnspection 95
- Friction and steel plate warp standard less than 0 mm service limit 0 mm 95
- Friction plate thickness standard 3 3 5 mm service limit 3 mm 95
- Http manuals magnamaniac com 95
- M i r jl1 95
- Note olf new f ction platas are installed the sufiaces of each plate 95
- Part name 13089n080 13089 1075 130891081 95
- Spring plate free play adjustment 95
- Spring plate free play measurement 95
- Spring plate free play usable range 0 0 1 0 mm 95
- Steel plates thickness mm 1 2 o 2 95
- Cam damper lnspection rvisually inspect the damper cam damper spring and 96
- Clutch 11 96
- Clutch spring height measurement lf the spring helght is less than the service limit it must 96
- Http manuals magnamaniac com 96
- Engine lubrication ptem 97
- Engine lubrication system 97
- Http manuals magnamaniac com 97
- Table of gontents 97
- Http manuals magnamaniac com 98
- Engine lubrication system 100
- Http manuals magnamaniac com 100
- Engine lubrication system e5 101
- Http manuals magnamaniac com 101
- Http manuals magnamaniac com 102
- A upper level b lower level 103
- C oil filler cap d oil level gauge 103
- Engine lubrication system 6 103
- Engine oil and oil filter 103
- Engine oil change aset the motorcycle perpendicular to the ground after warming up the engine 103
- Http manuals magnamaniac com 103
- Oil filter change 103
- Oil level lnspection 103
- Bemoval 104
- Ffi engine lubrication system 104
- Http manuals magnamaniac com 104
- Oil pump 104
- Oil pump screen cleaning 104
- A circlip b pump shaft 105
- A oil pump 105
- A pump shaft proiection c o rings b gear shaft slot 105
- Engine lubrcation system s9 105
- Http manuals magnamaniac com 105
- Installation 105
- Oil pipes 105
- Remotnl remove the outside oil pipes as follows 105
- Http manuals magnamaniac com 106
- O i i presu re m easu rement 106
- Oil pressure measurement 106
- Slo engine lubricaton system 106
- Engine lubrication system 611 107
- Http manuals magnamaniac com 107
- Engine removal installation 108
- Engine removal lnstallation 108
- Http manuals magnamaniac com 108
- Table of gontents 108
- Bemoual support the motorcycle perpendicular to the ground 110
- Engine removal lnstallation 110
- Engine removauinstallation 7 110
- Http manuals magnamaniac com 110
- Engine removauinstallation 111
- Http manuals magnamaniac com 111
- Engine removal installation 7 112
- Http manuals magnamaniac com 112
- Http manuals magnamaniac com 113
- Cra n ks hatt t r ans m i ss i o n 114
- Crankshaft transmission 114
- Http manuals magnamaniac com 114
- I h hllilll il e 114
- Table of gontents 114
- Crankshaft transmission 115
- Exploded viw 115
- Http manuals magnamaniac com 115
- Crankshaft transm ission 117
- Crankshaft transmission 86 118
- Http manuals magnamaniac com 118
- Http manuals magnamaniac com 119
- Crankshaftffransmission 7 120
- Http manuals magnamaniac com 120
- Special tools 120
- A damper cam b holder 57001 1025 c needle bearing 121
- Cran kshaft tran i i ission 121
- Crankw 121
- D bearing e washer f starter motor clutch 121
- Http manuals magnamaniac com 121
- Crankshaft trans mission 8 122
- Http manuals magnamaniac com 122
- 1 o crankshaft transtt iission 123
- A primary gear 8 ldle shaft c pins 123
- A sprocket b b water pump chain c camshaft chain 123
- D lower chain guide e rear chain guide 123
- Http manuals magnamaniac com 123
- A 06 mm bolts 14 b 08 mn bolts 1 124
- Asrr mbly 124
- Crankshaft transmission 8 11 124
- Http manuals magnamaniac com 124
- 12 crankshaft transmission 125
- Http manuals magnamaniac com 125
- Cran kshaft transmission 8 3 126
- Http manuals magnamaniac com 126
- Primary gear 126
- 14 crankshaft transmission 127
- A bearings b holding plates 127
- Http manuals magnamaniac com 127
- Replaement 127
- Shift mechanism damper cam front bevel gear case clutrh water pump lmpeller bolt has left handed threads right engine cover engine top end alt rnator covers left engine cover 127
- A crankshaft b long end lh 128
- Bearings oil seal press the oil seal 128
- C short end rh 128
- Connecting rod bemoval 128
- Connecting rod insallation 128
- Cran kshaft i nstal lation othe crankshaft lhend is longer than the rh end 128
- Cran kshaft transmission 8 5 128
- Crankshaft connesting rods 128
- L connecting rods 2 big end caps 3 crankshaft 128
- Remove the connecting rod big end cap nuts and take off the rod and cap with the bearing inserts 128
- 1 6 cran kshaft transmission 129
- Connecting rod big end bearing ln rt crankpin wear measure the bearing insert crankpin clearance with plastigage 129
- Http manuals magnamaniac com 129
- Cran kshaft transmission 8 17 130
- Crankshaft main bearing main journal wear rmeasure the diameter of the crankshaft main iournal 130
- Crankshaft runout 130
- Http manuals magnamaniac com 130
- 18 cran kshaft transmission 131
- Cran kshaft si de ciea ra n ce ameasure crankshaft side clearance 131
- Http manuals magnamaniac com 131
- C c over end 132
- Crankshaft transmission 19 132
- Http manuals magnamaniac com 132
- Left engine cover 132
- Right englne cover 132
- Starter motor clutdt 132
- A copper washer 133
- Assembly 133
- Disassembly rremove the starter motor clutch assemblv 133
- Http manuals magnamaniac com 133
- Lnstallation 133
- Balancer 134
- Cran kshaft transmission 8 1 134
- Http manuals magnamaniac com 134
- Lh balancer weight removal 134
- Lnspection 134
- Rh balancer weight removal see start r motor clutch removal 134
- 22 crankshaft transiviission 135
- Ba la ncer shaft i ns 3 i i ati o n 135
- Balancer shaft removat isplit the crankcase see crankcase splitting apull the shaft out of the crankcase 135
- Http manuals magnamaniac com 135
- I iv n 135
- Lh balancer weight lnstallation 135
- Rh balancer weight lnstallation see starter motor clutch installation 135
- Crankshaft transmission 23 136
- Http manuals magnamaniac com 136
- Starter torque limiter water pump ldle shaft holder 136
- 24 cran kshaft transm ission 137
- A primary gear 137
- A primary gear b ldle shaft 137
- Http manuals magnamaniac com 137
- Primary gear 137
- C push d gear positioning lever 138
- Crankshaft transmission 8 5 138
- Http manuals magnamaniac com 138
- Transmission 138
- 26 crankshaftttransmission 139
- Exhrnal shift mechanism lnspection examine the shift shaft for any damage 139
- Http manuals magnamaniac com 139
- Crankshaft transmission 27 140
- Http manuals magnamaniac com 140
- Tnnsmigsion dissembly remove the transmission shafts using the circlip pliers special tool 57001144 to remove the circlips disassemble the transmission shaft the 3rd gear on the output shaft has three st el balls in it for the positive neutral finder mechanism re 140
- Tnnsmission awmblv 140
- Transm i ssi on sh af s i n stal lati o n 140
- 28 crankshaft transmission 141
- Http manuals magnamaniac com 141
- Crankshaft transmission 8 9 142
- Http manuals magnamaniac com 142
- Sh i ft d ru m d i nssem b i y assem b i y 142
- Ytift drum removal aremove the transmission gear as a set 142
- A pin b shift drum cam 143
- Crankshaft transmission 143
- Http manuals magnamaniac com 143
- Http manuals magnamaniac com 144
- Table of contents 144
- Wheels tires 144
- Z s o t 146
- Http manuals magnamaniac com 147
- Item standard service limit 147
- Kpa 2 0 kg cm 28 psi 147
- Kpa 2 5 kg cm 32 psi 147
- Specilications 147
- Wheels tires 147
- Http manuals magnamaniac com 148
- Special tools 148
- Wheels tires 9 148
- Front wheel lnstallation lnstallation is the reverse of removal note the 149
- Front wheel removal 149
- Http manuals magnamaniac com 149
- Wheels rimsl 149
- Wheels tires 149
- A final gear case b ring gear hub 150
- Bear wheel lnstallation note the following oapply molybdenum disulfide grease to the grease seal oapply molybdenum disulfide grease to the splined portion of tlle ring gear hub 150
- Http manuals magnamaniac com 150
- Lh collar 2 rh collar 3 rear hub 4 coupling 150
- Ring gear hub 6 splines portion 7 grease seal 150
- Wheels tires 97 150
- A axte b ring gear hub c coupling hub 151
- A gring 151
- Http manuals magnamaniac com 151
- Ivheels tires 151
- Wheel cou pl i n g i nstal lation note the following oapply molybdenum disulfide grease to the o ring 151
- Wheel rim lnspection for cast wheel 151
- Http manuals magnamaniac com 152
- Wheels tires 99 152
- Balance weight i nstal lation lnstall the balance weight on the spoke nipple oattach a balanc weight securely using a pliers 153
- Http manuals magnamaniac com 153
- Rim lnspection measure the rim runout by using a dial gauge 153
- Wheels tires 153
- Http manuals magnamaniac com 154
- Http manuals magnamaniac com 155
- Hub bearings 155
- Lnsallation 155
- Removal remove the hub bearings by using the bearing remover 155
- Tire lnstallation acheck the tire rotation mark on the rear tire and install it on the rim accordingly 155
- Wheels tires 155
- Http manuals magnamaniac com 156
- Lnstallation lnstalt the bearings by using the bearing driver set special tool 57001 l 129 156
- Lubrication 156
- Speedometer gear housing 156
- Wheelsfiires 9 3 156
- Http manuals magnamaniac com 157
- Final drive 158
- Http manuals magnamaniac com 158
- Table of contents 158
- Exploded view 159
- Http manuals magnamaniac com 159
- Final drive 10 160
- Http manuals magnamaniac com 160
- Http manuals magnamaniac com 161
- A drain plug b oil level line 163
- Final drive 163
- Final gear gasg 163
- Final goar case oil 163
- Http manuals magnamaniac com 163
- I wtnunre i 163
- Oil level lrcpection 163
- Ranoval 163
- Disassembly 164
- Final drive 1g7 164
- Http manuals magnamaniac com 164
- I nstallation notes 164
- G8 final drive 165
- Http manuals magnamaniac com 165
- Final d rive 1g9 166
- Http manuals magnamaniac com 166
- Bevel gear lnspection avisually check the bevel gears for scoring chipping or 167
- Gio final drive 167
- Http manuals magnamaniac com 167
- Oil seal lnspection 167
- Http manuals magnamaniac com 168
- Ffik bottot 169
- Ffir 0 169
- G12 final drive 169
- Http manuals magnamaniac com 169
- Nf i lm 169
- Final drive 1g13 170
- Http manuals magnamaniac com 170
- Http manuals magnamaniac com 171
- Pinion gear bearing lnspection 171
- Propeller shaft 171
- Removal 171
- Http manuals magnamaniac com 172
- Lnsallation notes 172
- Front bevel gears 173
- Front gear case disassembly including drive gear remoml 173
- Front gear case lnstaltation 173
- Front gear case removat 173
- G16 final drive 173
- Http manuals magnamaniac com 173
- Final drive ig17 174
- Http manuals magnamaniac com 174
- Driven gear dinssembly holding the driven gear joint holder special tool unscrew 175
- Driver 57001 382 shaft drive gear 175
- Front gear case assembly incl uding d ri ve gear instal lation 175
- G18 final drive 175
- Http manuals magnamaniac com 175
- Driven gear assembly 176
- Http manuals magnamaniac com 176
- Damper cam lnstallation notes 177
- Http manuals magnamaniac com 177
- Ig2o final drive 177
- 1072 92025 1073 92025 1074 92025 107 5 92025 1076 92025 1077 178
- 1152 92027 1153 92027 1154 92027 1155 92027 1156 92027 1157 92027 t158 92027 1159 92027 1160 92027 1161 92027 t162 92027 1163 92027 t164 92027 t165 178
- 22 23 23 1 178
- 23 24 o 24 178
- Calrnon 178
- Final drive 1g2i 178
- Http manuals magnamaniac com 178
- Part number 178
- G22 final drive 179
- Http manuals magnamaniac com 179
- 0 0 o 0 0 1 1 1 1 180
- 0 5 0 0 0 0 0 1 1 180
- 1 holder 57001 1049 2 hold the driven gear 3 move the drive gear 180
- 1688 9202s 1689 9202s 1690 92025 1691 9202s 1692 92025 1693 92025 1694 92025 1695 92025 t696 180
- 1826 92025 1818 92025 1819 92025 1820 9202s 182 l 92025 822 92025 1823 92025 1824 92025 1825 180
- Drive gear driven gear 1 180
- Final drive 1g23 180
- Http manuals magnamaniac com 180
- On tt e 180
- Part number 180
- Thickness mm part number 180
- Bevel gear lnspection rvisually check the bevel gears for scoring chipping or 181
- Drive gear 2 driven gear 181
- G24 final drive 181
- Http manuals magnamaniac com 181
- Ball bearing lnspection since the ball bearing is made to extrem ly close tolerances the wear must be iudged by feel rather than 182
- Final drive 1g25 182
- Http manuals magnamaniac com 182
- Needle b earing i nspection 182
- Oil seal lnspection 182
- Tapered roller bearing lnspection visually inspect the bearing for abrasion color change or other damage lf there is any doubt as to tlle condition of a bearing reolace it 182
- Brakes 183
- Http manuals magnamaniac com 183
- Table of contents 183
- Http manuals magnamaniac com 185
- Brake pedal 187
- Brake pedal position adiustment 187
- Brakes 11 187
- Caliper 187
- Http manuals magnamaniac com 187
- A caliper c brake hose b caliper mounting bolts 188
- Assembly notes oapply brake fluid to the outside of the piston and the 188
- Brake pads 188
- Brakes 188
- Caliper lnstallation 188
- Dinssembly notes using compressed air remove the piston 188
- Http manuals magnamaniac com 188
- L apply compressed air 2 cloth 188
- Removal rremove the caliper see 188
- A clevis b cotter pin c joint pin d push rod 189
- Brakes 11 7 189
- Front maser cylinder lnstallation 189
- Http manuals magnamaniac com 189
- L tighten upper clamp bolt first 3 mirror holder 2 lower clamp boll 4 clearance 189
- Lining thickness 2 service limit 189
- Lining wear rlf the lining thickness of either pad is less than the 189
- Lnstallation notes 189
- Master cylinders 189
- Ouse a new flat washer on each side of the brake hose fitting otighren the banjo bolts to the specified orque see exploded view 189
- Pad 2 caliper holder 3 push the caliper holder 189
- Rear master cylinder removal note the following oremove the cotter pin and then pull the joint pin out of the push rod clevis and brake pedal 189
- Assembly 190
- Dinssembly 190
- Http manuals magnamaniac com 190
- I brakbs 190
- Primary cup 2 secondary cup 3 piston 190
- Rear master cylinder lnstallation 190
- Brake disc 191
- Brakes 11 9 191
- Fluid level lnspection 191
- Http manuals magnamaniac com 191
- Http manuals magnamaniac com 192
- I1 0 brakes 192
- Brakes 11 11 193
- Http manuals magnamaniac com 193
- Http manuals magnamaniac com 194
- Suspension 194
- Suspensron l2 1 194
- Table of contents 194
- 2 suspenston 195
- Exploded view 195
- Http manuals magnamaniac com 197
- Fork oil change each fork leg 198
- Front fork 198
- Http manuals magnamaniac com 198
- Suspenslon 12 198
- Http manuals magnamaniac com 199
- Http manuals magnamaniac com 200
- Suspenslon 12 7 200
- 8 suspenston 201
- Guide bush lnspection 201
- Http manuals magnamaniac com 201
- Oil al and dust seal lnspecdon lf dust seal has any damage or wear replace it 201
- 10 suspension 203
- Bushing wear avisually inspect the rubber bushing tlf th y show any signs of damage replace them 203
- Grease seal and needle bearing removal assembly note the following oremove the needle bearing using a oil seal and bearing remover special tool 203
- Http manuals magnamaniac com 203
- Lnstallation 203
- Swing arm 203
- Grexe seal and needle bearing lubrication 204
- Http manuals magnamaniac com 204
- Slebve and needle bearing wear 204
- Suspenston 12 11 204
- Http manuals magnamaniac com 205
- Steering 205
- Steering 1 1 205
- Table of contents 205
- Exploded view 206
- Http manuals magnamaniac com 206
- Steering 206
- Http manuals magnamaniac com 207
- Steering 13 207
- Adiustment ocheck steering as follows 208
- Http manuals magnamaniac com 208
- Steering 208
- Steering stem 208
- Http manuals magnamaniac com 209
- Steering 1 5 209
- Http manuals magnamaniac com 210
- L driver press shaft 57001 1075 2 drtuer 57001 1 106 3 driver 57001 1076 210
- Steering 210
- Bearing lubrication 211
- Bearing wear damage 211
- Http manuals magnamaniac com 211
- Steering 1 7 211
- Steering stem bearing 211
- Steering stem warp lf the steering stem shaft is bent replace the steering stem 211
- Stem cap deterioration damage 211
- 2 1 5 1 5 1 5 1 5 146 1 6 aa 1 7 212
- Http manuals magnamaniac com 212
- Table of gontents 212
- 12 13 14 15 213
- 2 frame 213
- Exploded viar 213
- K o rffi 213
- T1 24 n m 24 kgn 175 ft lbl t2 44 n n 45 ksrn 3i ft lbl g apply grcase 213
- Http manuals magnamaniac com 215
- Frame 1 l5 216
- Http manuals magnamaniac com 216
- Rear fender 216
- Rear fender rear section remotnl disconnect the rear turn signal and tail li8ht wire connectors 216
- Remoml to access bight engine cover 216
- Right down tube 216
- A hsgengpr sat mounting bols vnt 50ga 217
- Footpeg 217
- Http manuals magnamaniac com 217
- Rear fender front section remoml 217
- Frame 1 7 218
- Http manuals magnamaniac com 218
- Electrical system 219
- Vn1500 a1 a8 b1 b6 wiring diagram us and canada 221
- I i i i 256
- 4_f6 c 257
- Bk y 8k bk r 257
- Rh rwe 257
- V j c cfcy 257
- Vn1500 a2 a8 b2 b6 wiring diagram other than us and canada 257
- Vn15oo a2 aa 82 86 wiring diag am orher than us and canadal 257
- J s fifiil 258
- E j l l 259
- Ffi f h iii 259
- Http manuals magnamaniac com 259
- I f s e i i 259
- L ff frhffi 259
- Vn1500 a9 wiring diagram us and canada 259
- E e e c l c d 260
- E ek b y l l u20ac l r arak uehb bun fr b ll j i tzvaatw z n f r t l f f t u l 260
- T v i b yil 260
- Appendix 261
- Http manuals magnamaniac com 261
- Table of contents 261
- Additional considerations for racing 262
- Appendix 262
- Carbureton 262
- Http manuals magnamaniac com 262
- Spark plug lnspection remove the spark plug and inspect tl e ceramic insu lator 262
- Appendix 1g3 263
- Carbon builds up here 263
- Http manuals magnamaniac com 263
- Note othe heat nngc of the spark plug fu etions like a thermo at for the engine using the wrotry type of qark plug en make the engine run too hot reiting in engine damage or too cold with poor performance misfhing and sta ing 263
- Too short correct reach 263
- Whether or not the right temperature plug is being used can be ascertained by noting t e condition of the ceramic insulator around the electrode a light brown color indicates the correct plug is being used lf the ceramic is white the plug is operating at too high a temperature and it should be replaced with the next colder type 263
- Appendix 264
- Http manuals magnamaniac com 264
- Poor running or at low speed 264
- Troubleshooting guide 264
- Appendix 1g5 265
- Clutch operation faulty 265
- Http manuals magnamaniac com 265
- Overheating 265
- Poor running or no power at high speed 265
- Appendix 266
- Exhaust smokes excessively 266
- Http manuals magnamaniac com 266
- Oil pressure warning light go s on 266
- Appendix 1g7 267
- Battery discharged 267
- Brake doesnt hold 267
- Handling and or stability unsatisfactory 267
- Http manuals magnamaniac com 267
- G8 appendix 268
- General lubrication 268
- Http manuals magnamaniac com 268
- Nut bolt and fasener tightness 268
- Tightness lnspection theck the tightness of the bolts and nuts listed here 268
- Fcj40 _40_ f s fj 40 _ 40 _ c 269
- Http manuals magnamaniac com 269
- Ksm ksm 269
- O 376 8 5r 269
- S 0 863 269
- Sal us 269
- Http manuals magnamaniac com 270
- Lkawasaki 270
- Model application 270
- Part no 9992 t 1 078 08 270
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