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Kawasaki Vulcan 1500 Classic Fi Service Manual

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Table of Contents
VULCAN 1500 CLASSIC Fi
VN1500 CLASSIC Fi
Motorcycle
Service Manual

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Table of Contents
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  Also See for Kawasaki Vulcan 1500 Classic Fi

  Summary of Contents for Kawasaki Vulcan 1500 Classic Fi

  • Page 1 VULCAN 1500 CLASSIC Fi VN1500 CLASSIC Fi Motorcycle Service Manual...
  • Page 3 Quick Reference Guide General Information Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires Final Drive 10 j Brakes 11 j Suspension 12 j Steering 13 j Frame 14 j Electrical System 15 j Appendix 16 j This quick reference guide will assist...
  • Page 4 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 5: Emission Control Information

    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Addi-...
  • Page 6 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
  • Page 7: How To Use This Manual

    Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance. • venient operation. Use proper tools and genuine Kawasaki Mo- • torcycle parts. Special tools, gauges, and Indicates a procedural step or work to be testers that are necessary when servicing done.
  • Page 9: Table Of Contents

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Periodic Maintenance Chart ....................1-11 Torque and Locking Agent...................... 1-13 Special Tools and Sealants ....................1-20 Cable, Wire, and Hose Routing ....................1-27...
  • Page 10: General Information

    1-2 GENERAL INFORMATION Before Servicing Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descrip- tions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also required for successful work.
  • Page 11 GENERAL INFORMATION 1-3 Before Servicing (12)Ball Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any ball or needle bearings that were removed with new ones, as removal generally damages bearings.
  • Page 12 1-4 GENERAL INFORMATION Before Servicing (18)Inspection When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones. Abrasion Crack Hardening Warp Bent...
  • Page 13: Model Identification

    GENERAL INFORMATION 1-5 Model Identification VN1500-N1 (US, and Canada) Left Side View VN1500-N1 (US, and Canada) Right Side View...
  • Page 14 1-6 GENERAL INFORMATION Model Identification VN1500-N1 (Europe) Left Side View VN1500-N1 (Europe) Right Side View...
  • Page 15 GENERAL INFORMATION 1-7 Model Identification VN1500-T1 (US, and Canada) Left Side View VN1500-T1 (US, and Canada) Right Side View...
  • Page 16: General Specifications

    1-8 GENERAL INFORMATION General Specifications VN1500-N3 ∼ N4, VN1500-N1 ∼ N2 VN1500N7F ∼ Items N6F/T6F Dimensions Overall Length 2 505 mm (98.6 in.) Overall Width 995 mm (39.2 in.) Overall Height 1 140 mm (44.9 in.) Wheelbase 1 665 mm (65.6 in.) Road Clearance 125 mm (4.9 in.) Seat Height...
  • Page 17 GENERAL INFORMATION 1-9 General Specifications VN1500-N3 ∼ N4, VN1500-N1 ∼ N2 VN1500N7F ∼ Items N6F/T6F Lubrication System Forced lubrication (wet sump) Engine Oil: Grade API SE, SF or SG API SE, SF or SG API SH, SJ or SL with API SH or SJ with JASO MA JASO MA Viscosity...
  • Page 18 1-10 GENERAL INFORMATION General Specifications VN1500-N3 ∼ N4, VN1500-N1 ∼ N2 VN1500N7F ∼ Items N6F/T6F Front Suspension: Type Telescopic fork Wheel Travel 150 mm (5.90 in.) Rear Suspension: Type Swingarm Wheel Travel 95 mm (3.74 in.) Brake Type: Front Single disc Rear Single disc Electrical Equipment...
  • Page 19: Periodic Maintenance Chart

    GENERAL INFORMATION 1-11 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. FREQUENCY Whichever * ODOMETER READING comes ×...
  • Page 20 1-12 GENERAL INFORMATION Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) (0.6) (7.5) (12) (15) (20) (24) INSPECTION Every • • • General lubrication-perform • • • • Nut, bolt, and fastener tightness-inspect † #: Service more frequently when operating in severe conditions;...
  • Page 21: Torque And Locking Agent

    GENERAL INFORMATION 1-13 Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: EO: Apply engine oil to the threads and the seating surface. G: Apply grease to the threads.
  • Page 22 1-14 GENERAL INFORMATION Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Water Pump Cover Bolts 87 in·lb Water Pump Drain Bolt 87 in·lb Water Pump Air Bleeder Bolt 87 in·lb Water Pipe Bolts 87 in·lb Radiator Drain Bolt 0.75 65 in·lb Engine Top End...
  • Page 23 GENERAL INFORMATION 1-15 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Engine Lubrication System Oil Filler Cap 0.15 13 in·lb Oil Screen Plug Engine Oil Drain Bolt Oil Filter (Cartridge type) R, EO Oil Filter Bolt Oil Pressure Relief Valve Oil Pressure Switch Terminal Bolt 0.15 13 in·lb...
  • Page 24 1-16 GENERAL INFORMATION Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Left Balancer Gear Bolt Starter Clutch Bolt Starter Clutch Coupling Bolts Gear Set Lever Bolt 87 in·lb Shift Shaft Return Spring Pin (Bolt) Shift Shaft Return Spring Pin (Bolt) (Bolt with punch mark) Front Shift Pedal Clamp Bolt mark 10...
  • Page 25 GENERAL INFORMATION 1-17 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Pinion Gear Nut (Final Gear) 13.0 St, MO Pinion Bearing Retainer (Final Gear) 25.0 Retainer Stop Screw Brakes Caliper Bleed Valves 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.10 8.7 in·lb...
  • Page 26 1-18 GENERAL INFORMATION Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Frame Downtube Bolts Front Footboard Bracket Bolts Rear Footpeg Bracket Bolts Sidestand Nut Electrical System Spark Plugs Pickup Coil Screws 0.30 26 in·lb Stator Lead Holder Screw 87 in·lb Pickup Coil Lead Holder Bolt 87 in·lb...
  • Page 27 GENERAL INFORMATION 1-19 Torque and Locking Agent The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.
  • Page 28: Special Tools And Sealants

    1-20 GENERAL INFORMATION Special Tools and Sealants Oil Pressure Gauge, 5 kgf/cm²: Valve Guide Arbor, 7: 57001-125 57001-163 Inside Circlip Pliers: Fork Cylinder Holder Handle: 57001-143 57001-183 Outside Circlip Pliers: Compression Gauge, 20 kgf/cm²: 57001-144 57001-221 Bearing Puller: Valve Spring Compressor Assembly: 57001-158 57001-241 Valve Guide Reamer, 7:...
  • Page 29 GENERAL INFORMATION 1-21 Special Tools and Sealants Bearing Puller Adapter: Spark Plug Wrench, Hex 18: 57001-317 57001-1024 Bearing Driver, 32: Damper Cam Holder: 57001-382 57001-1025 Piston Pin Puller Assembly: Driven Gear Holder, m2: 57001-910 57001-1027 Gear Holder, m1.75: Oil Pressure Gauge Adapter, PT 1/8: 57001-1015 57001-1033 Compression Gauge Adapter, M12 ×...
  • Page 30 1-22 GENERAL INFORMATION Special Tools and Sealants Oil Seal & Bearing Remover: Head Pipe Outer Race Remover ID > 37 mm: 57001-1058 57001-1107 Head Pipe Outer Race Press Shaft: Valve Seat Cutter, 45° - 32: 57001-1075 57001-1115 Head Pipe Outer Race Driver, 54.5: Valve Seat Cutter, 45°...
  • Page 31 GENERAL INFORMATION 1-23 Special Tools and Sealants Valve Seat Cutter Holder Bar: Piston Pin Puller Adapter, 14: 57001-1128 57001-1211 Bearing Driver Set: Fork Outer Tube Weight: 57001-1129 57001-1218 Pinion Gear Holder, m1.9: Front Fork Oil Seal Driver: 57001-1165 57001-1219 Valve Seat Cutter, 32° - 33: Jack: 57001-1199 57001-1238...
  • Page 32 1-24 GENERAL INFORMATION Special Tools and Sealants Valve Seat Cutter, 55° - 35: Bearing Remover Head, 10 × 12: 57001-1247 57001-1266 Oil Filter Wrench: Fork Oil Level Gauge: 57001-1249 57001-1290 Final Gear Case Holder: Bearing Remover Head, 20 × 22: 57001-1250 57001-1293 Bearing Retainer Wrench:...
  • Page 33 GENERAL INFORMATION 1-25 Special Tools and Sealants Steering Stem Bearing Driver Adapter, 41.5: Drive Shaft Holder: 57001-1345 57001-1407 Piston Ring Compressor Belt, 95 ∼ 108: Flywheel Holder: 57001-1358 57001-1410 Bearing Remover Shaft, 13: Peak Voltage Adapter: 57001-1377 57001-1415 Hand Tester: Filler Cap Driver: 57001-1394 57001-1454...
  • Page 34 1-26 GENERAL INFORMATION Special Tools and Sealants Fuel Pressure Gauge Adapter: Kawasaki Bond (Silicone Sealant): 57001-1593 56019-120 Fuel Hose: Kawasaki Bond(Liquid Gasket - Black): 57001-1607 92104-1003...
  • Page 35: Cable, Wire, And Hose Routing

    GENERAL INFORMATION 1-27 Cable, Wire, and Hose Routing 1. Front Right Spark Plug Cap 10. Rear Left Spark Plug Cap 2. Rear Right Spark Plug Cap 11. Clutch Hose 3. 2nd Lead from the left ignition coil lower 12. Plastic Clamps side 13.
  • Page 36 1-28 GENERAL INFORMATION Cable, Wire, and Hose Routing...
  • Page 37 GENERAL INFORMATION 1-29 Cable, Wire, and Hose Routing - - >: Vacuum Pulsation →: Fuel Flow #1: For Front Cylinder #2: For Rear Cylinder 1. Fuel Tank (left view) 2. Return Fuel Check Valve 3. High Pressure Fuel Hoses 4. Delivery Joint 5.
  • Page 38 1-30 GENERAL INFORMATION Cable, Wire, and Hose Routing...
  • Page 39 GENERAL INFORMATION 1-31 Cable, Wire, and Hose Routing #1: For Front Cylinder #2: For Rear Cylinder 1. Thermostat Housing 2. Water Hoses #1 3. Reserve Tank Hose 4. Clamps: Position the screw head as shown. 5. White marks on the hose [2] face forward. 6.
  • Page 40 1-32 GENERAL INFORMATION Cable, Wire, and Hose Routing 1. Fuel Tank Filler 13. Fuel Tank Breather Hose (Except for Cal- 2. Throttle Assy ifornia Model) 3. Fuel Tank Breather Pipe 14. Run the hose [13] into the right hole of the 4.
  • Page 41 GENERAL INFORMATION 1-33 Cable, Wire, and Hose Routing 1. Throttle Cables: First, run these cables 9. Vacuum Switch Valve over the hose [10], inside the sensor 10. Water Hose #1 holder hook [23], then under the hose [3], 11. Atmospheric Pressure Sensor (DFI) and connect these cables to the throttle 12.
  • Page 42 1-34 GENERAL INFORMATION Cable, Wire, and Hose Routing →: Fuel Flow 10. Pump Base Plate 1. Fuel Pump Connector (outside the fuel 11. Base Plate Gasket tank) 12. Outlet Fuel Pipe Joint 2. Bottom of Fuel Tank 13. Fuel Pump Screen (Pump Inlet) 3.
  • Page 43 GENERAL INFORMATION 1-35 Cable, Wire, and Hose Routing →: Inlet Air Flow 11. Right Rubber Gasket 1. Rear View 12. Right Air Cleaner Cover 2. Air Inlet 13. Locate the glued joint of the gasket within 3. Left Rubber Gasket the angle.
  • Page 44 1-36 GENERAL INFORMATION Cable, Wire, and Hose Routing...
  • Page 45 GENERAL INFORMATION 1-37 Cable, Wire, and Hose Routing →: Fuel Flow 1. Vacuum Sensor (with the vacuum hose) 2. Vacuum Hoses for the vacuum sensor and the pressure regulator 3. T-Joint 4. Insert the hose [20] with its mark up and hold the hose with the clamp. 5.
  • Page 46 1-38 GENERAL INFORMATION Cable, Wire, and Hose Routing #1: For Front Cylinder 11. Run the decelerator throttle cable above the ac- #2: For Rear Cylinder celerator cable from here to the throttle pulley. 1. Vacuum Sensor with vacuum hose 12. Vacuum Switch Valve 2.
  • Page 47 GENERAL INFORMATION 1-39 Cable, Wire, and Hose Routing - - >: Fuel Flow 8. Vacuum Hoses from 17. Throttle Cable Holder ←→: Vacuum Pulsation Throttle Body 18. Choke Lever Stop Screw →: Bypass Air Flow 9. ISC Hose #2 (blue mark) 19.
  • Page 48 1-40 GENERAL INFORMATION Cable, Wire, and Hose Routing...
  • Page 49 GENERAL INFORMATION 1-41 Cable, Wire, and Hose Routing →: Bypass Air Flow #1: For Front Cylinder #2: For Rear Cylinder 1. Rear View 2. Throttle Assy 3. Air Cleaner Base Seal 4. Ignition Coil 2nd Lead Holder 5. Right Side View 6.
  • Page 50 1-42 GENERAL INFORMATION Cable, Wire, and Hose Routing...
  • Page 51 GENERAL INFORMATION 1-43 Cable, Wire, and Hose Routing 1. Ignition Coil (Right) Hi-tension Cable Holder 2. Snap-on Strap 3. Ignition Coil (Right) Hi-tension Cable 4. Fitting 5. Right Ignition Coil 6. Thermostat Housing Bracket 7. Reserve Tank Bracket 8. Frame Gusset 9.
  • Page 52 1-44 GENERAL INFORMATION Cable, Wire, and Hose Routing...
  • Page 53 GENERAL INFORMATION 1-45 Cable, Wire, and Hose Routing 1. Electric Starter 2. Starter Cable 3. Front Regulator/Rectifier 4. Clamp (Clamp the starter cable and front regulator/rectifier lead.) 5. Regulator/Rectifier Connectors 6. Sidestand Switch Leads 7. Welded Clamp 8. Clamp the leads [6] through the front and rear hooks with a slack as little as possible onto the frame pipe behind the side stand bracket.
  • Page 54 1-46 GENERAL INFORMATION Cable, Wire, and Hose Routing...
  • Page 55 GENERAL INFORMATION 1-47 Cable, Wire, and Hose Routing 1. Right Handlebar Switch Lead Connector 2. Left Handlebar Switch Lead Connector 3. Headlight Unit (EUR, AU) 4. Clutch Hose (Run it outside of the frame pipe.) 5. Holder (main harness, clutch hose, and throttle cables) 6.
  • Page 56 1-48 GENERAL INFORMATION Cable, Wire, and Hose Routing 47. Regulator/Rectifier Lead 48. Oil Pressure Switch/Neutral Switch Connector 49. Sidestand Switch Connector 50. Front Gear Case 51. Rear Regulator/Rectifier Connector 52. Front Regulator/Rectifier Connector 53. Outside Alternator Connector 54. Inside Alternator Connector 55.
  • Page 57 GENERAL INFORMATION 1-49 Cable, Wire, and Hose Routing Dummy Page...
  • Page 58 1-50 GENERAL INFORMATION Cable, Wire, and Hose Routing...
  • Page 59 GENERAL INFORMATION 1-51 Cable, Wire, and Hose Routing 1. Join the headlight, handlebar switch, and 31. Insert the pin with the main harness into turn signal light leads connectors in the the right hole of the frame gusset. headlight unit. 32.
  • Page 60 1-52 GENERAL INFORMATION Cable, Wire, and Hose Routing...
  • Page 61 GENERAL INFORMATION 1-53 Cable, Wire, and Hose Routing 1. Fuel Tank Filler Drain Hose 2. Electric Starter Motor Lead 3. Holder 4. Engine Ground, or Battery (–) Lead (Run it downward) 5. Main Harness 6. Coolant Reserve Tank Hose (from the thermostat housing to the coolant reserve tank) 7.
  • Page 62 1-54 GENERAL INFORMATION Cable, Wire, and Hose Routing 1. Upper Muffler 11. Front 2. 50° 12. Align marks. 3. Muffler Chamber 13. Front Shift Pedal 4. Lower Muffler 14. Rear Shift Pedal 5. Rear Exhaust Pipe 15. (80 mm) (3.15 in.) 6.
  • Page 63 GENERAL INFORMATION 1-55 Cable, Wire, and Hose Routing 1. Snap-on Strap 2. Front Brake Hose Holders 3. Front Brake Hose 4. Front Brake Caliper 5. Throttle Cable (accelerator) 6. Throttle Cable (decelerator) 7. Handlebar 8. Grommets 9. Front Master Cylinder 10.
  • Page 64 1-56 GENERAL INFORMATION Cable, Wire, and Hose Routing...
  • Page 65 GENERAL INFORMATION 1-57 Cable, Wire, and Hose Routing 1. Run the turn signal light lead in front of the upper brake hose [3]. 2. Snap-on Strap ([3] and [20] except for throttle cables) 3. Front Brake Hose 4. Throttle Cable (decelerator) 5.
  • Page 66 1-58 GENERAL INFORMATION Cable, Wire, and Hose Routing 1. Rear Brake Caliper 10. Brake Pedal 2. Brake Hose Holders 11. View 3. Rear Brake Hose 12. Clevis 4. Brake Hose White Marks (Position here.) 13. Rear Brake Reservoir Cover 5. Clamps 14.
  • Page 67 GENERAL INFORMATION 1-59 Cable, Wire, and Hose Routing Evaporative Emission Control System (California Model) - - >: Vapor Flow →: Fuel Flow ←→: Vacuum Pulsation 1. Fuel Return Hose 2. Fuel Tank Breather Hose 3. Separator Breather Hose 4. Canister Purge Hose 5.
  • Page 68 1-60 GENERAL INFORMATION Cable, Wire, and Hose Routing Evaporative Emission Control System (California Model)
  • Page 69 GENERAL INFORMATION 1-61 Cable, Wire, and Hose Routing Evaporative Emission Control System (California Model) 1. Fuel Tank Filler 2. Throttle Assy 3. Fuel Tank Breather Pipe 4. Filler Drain Pipe 5. Fuel Tank 6. Separator 7. Canister 8. Clips for [13] and [15] 9.
  • Page 70 1-62 GENERAL INFORMATION Cable, Wire, and Hose Routing Evaporative Emission Control System (California Model) 1. Fuel Tank 2. Left Air Cleaner Base 3. Canister Purge Hose (Green, CAL) 4. Canister (CAL) 5. Fuel Breather Hose (right, blue) 6. Rear View 7.
  • Page 71 FUEL SYSTEM (DFI) 2-1 Fuel System (DFI) Table of Contents Specifications ........Canister Inspection (Periodic DFI Parts Location......Inspection)......... 2-42 Exploded View........2-10 Hose Inspection (Periodic DFI System........2-14 Inspection)......... 2-42 DFI Wiring Diagram ......2-16 Separator Inspection (Periodic DFI Servicing Precautions ....2-18 Inspection).........
  • Page 72 2-2 FUEL SYSTEM (DFI) Removal........2-82 Removal........2-99 Installation........2-82 Installation........2-100 Input Voltage Inspection....2-82 Inspection........2-100 Output Voltage Inspection.... 2-83 Fuel Injectors (#1, #2: Fault Code 41, Inlet Air Temperature Sensor (Fault 42)........... 2-103 Code 13) ......... 2-88 Injector Removal ......
  • Page 73: Specifications

    FUEL SYSTEM (DFI) 2-3 Specifications Item Standard 2 ∼ 3 mm Throttle Grip Free Play Air Cleaner Element Paper filter DFI (Digital Fuel Injection) System Make Mitsubishi Electric Idle Speed 950 ±50 r/min (rpm) Throttle Assy: Type × Bore Two barrel type × 36 mm (1.42 in.) ECU (Electronic Control Unit): Digital memory type, with built in IC igniter, sealed Type...
  • Page 74 Special Tools - Oil Pressure Gauge: 57001-125 Hand Tester: 57001-1394 Filler Cap Driver: 57001-1454 Needle Adapter Set: 57001-1457 Fuel Pressure Gauge Adapter: 57001-1593 Fuel Hose: 57001-1607 Fork Oil Level Gauge: 57001-1290 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 75 FUEL SYSTEM (DFI) 2-5 Specifications Dummy Page...
  • Page 76: Dfi Parts Location

    2-6 FUEL SYSTEM (DFI) DFI Parts Location...
  • Page 77 FUEL SYSTEM (DFI) 2-7 DFI Parts Location 1. Atmospheric Pressure Sensor (DFI) 2. Water Temperature Sensor (DFI) 3. Ignition Coils 4. Ignition Switch 5. Starter Motor 6. Water Temperature Switch 7. Regulator/Rectifiers 8. Pickup Coils 9. Alternator 10. Sidestand Switch 11.
  • Page 78 2-8 FUEL SYSTEM (DFI) DFI Parts Location...
  • Page 79 FUEL SYSTEM (DFI) 2-9 DFI Parts Location 1. Atmospheric Pressure Sensor (DFI) 2. Water Temperature Sensor (DFI) 3. Ignition Coils (see preceding page) 4. Ignition Switch (see preceding page) 5. Starter Motor (see preceding page) 6. Water Temperature Switch (see preceding page) 7.
  • Page 80: Exploded View

    2-10 FUEL SYSTEM (DFI) Exploded View...
  • Page 81 FUEL SYSTEM (DFI) 2-11 Exploded View 1. Throttle Cable (accelerator) 2. Throttle Cable (decelerator) 3. Choke Cable 4. In-tank Fuel Filter 5. To vacuum sensor 6. Atmospheric Pressure Sensor 7. Vacuum Sensor 8. Fuel Pump Gasket 9. In-tank Fuel Pump (electric) 10.
  • Page 82 2-12 FUEL SYSTEM (DFI) Exploded View...
  • Page 83 T3: 2.2 N·m (0.22 kgf·m, 19 in·lb) T4: 9.8 N·m (1.0 kgf·m, 87 in·lb) T5: 18 N·m (1.8 kgf·m, 13.0 ft·lb) T6: 11 N·m (1.1 kgf·m, 95 in·lb) G: Apply grease. SS: Apply silicone sealant (Kawasaki Bond: 56019-120). R: Replacement Parts CAL: California Model...
  • Page 84: Dfi System

    2-14 FUEL SYSTEM (DFI) DFI System...
  • Page 85 FUEL SYSTEM (DFI) 2-15 DFI System #1: For Front Cylinder #2: For Rear Cylinder 1. ECU (Electronic Control Unit) 2. Pickup Coil #1 3. Pickup Coil #2 4. Pressure Regulator 5. Throttle Sensor (front view) 6. Atmospheric Pressure Sensor 7. Vacuum Sensor 8.
  • Page 86: Dfi Wiring Diagram

    2-16 FUEL SYSTEM (DFI) DFI Wiring Diagram...
  • Page 87 FUEL SYSTEM (DFI) 2-17 DFI Wiring Diagram Terminal Numbers of ECU Connectors DFI and Electrical Parts Terminal Names DFI: DFI Parts #1: Front Cylinder A: ECU Electronic Control Unit (DFI) #2: Rear Cylinder B. Engine Stop Switch 1. Main Relay Solenoid Ground in ECU C.
  • Page 88: Dfi Servicing Precautions

    2-18 FUEL SYSTEM (DFI) DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V battery as its power source. Do not use any other battery except for a 12 V battery as a power source.
  • Page 89: General Information

    FUEL SYSTEM (DFI) 2-19 DFI Servicing Precautions ○ The fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the high pressure in- side the fuel line can cause fuel to leak [A] or the hose to burst.
  • Page 90 2-20 FUEL SYSTEM (DFI) DFI Servicing Precautions ○ Pull the high pressure fuel hose joint [A] down [B] and make sure it is locked and doesn’t come off. ○ To maintain the correct fuel/air mixture (F/A), there must be no inlet air leaks in the DFI system. Be sure to install the oil filler cap [A] after filling the engine oil, using the filler cap driver [B].
  • Page 91: Throttle Grip And Cables

    FUEL SYSTEM (DFI) 2-21 Throttle Grip and Cables Throttle Grip Play Inspection • Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cable. Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Standard: •...
  • Page 92: Choke Knob Operation

    2-22 FUEL SYSTEM (DFI) Throttle Grip and Cables Choke Knob Operation ○ Do not use the choke knob except when the engine has a starting difficulty, like in cold weather or at high altitude. The DFI system has an automatic choke system, using ISC valves, a water temperature sensor, and an atmo- spheric pressure sensor, which provide startability.
  • Page 93: Throttle Assy

    FUEL SYSTEM (DFI) 2-23 Throttle Assy Idle Speed Inspection • Start the engine and warm it up thoroughly. ○ At first the engine will run fast to decrease warm up time (fast idle). ○ Gradually the fast idle will lower to a certain RPM auto- matically.
  • Page 94: High Altitude Performance Adjustment

    Any modification is not necessary in this model since the atmospheric pressure sensor senses atmospheric pres- sure change due to high altitude and the ECU compen- sates the change. (For reference: Mostly, Kawasaki rec- ommends US carburetor models operated above 4 000 feet, EPA-approved modification to improve the EMIS- SION CONTROL PERFORMANCE).
  • Page 95 FUEL SYSTEM (DFI) 2-25 Throttle Assy • Disconnect: Throttle Sensor Connector [A] (from the throttle sensor) Front and Rear Injector Connectors [B] • Remove the following from the choke cable holder [A] (left -behind view). Screw [B] Choke Cable Plate [C] •...
  • Page 96 2-26 FUEL SYSTEM (DFI) Throttle Assy • Turn the throttle pulley [A] as shown, and pull out the ac- celerator cable housing [B] from the cable holder [C] (rear view). • Return the pulley, and pull out the decelerator cable hous- ing [D] from the cable holder.
  • Page 97: Throttle Assy Installation

    FUEL SYSTEM (DFI) 2-27 Throttle Assy • Take out the throttle assy [A] from the right side, while tilting it up. ○ Be careful not to damage (dent, nick, flaw, and crack) the flange mating surface and the plastic parts. ○...
  • Page 98 2-28 FUEL SYSTEM (DFI) Throttle Assy • Apply a thin coating of grease to the throttle cable upper ends. • Install the lower ends of the throttle cables in the throttle pulley. Accelerator Cable [A] Decelerator Cable [B] • Run the throttle cables correctly (see Cable, Wire, and Hose Routing section in the General Information chapter).
  • Page 99: Throttle Assy Disassembly/Assembly

    FUEL SYSTEM (DFI) 2-29 Throttle Assy Throttle Assy Disassembly/Assembly • Remove the throttle assy (see Throttle Assy Removal). • Unscrew two bolts [A], and pull out the ISC pipe #1 [B], and ISC pipe #2 [C] from the hoses [D]. Bottom View [E] •...
  • Page 100 2-30 FUEL SYSTEM (DFI) Throttle Assy Choke Lever Stop Screw [A]: This screw sets the throttle valve opening when the choke knob is pulled fully. Tampering with the screw could cause malfunction of the choke lever. Rear View [B] Throttle Valve and Throttle Shaft: They are not allowed to remove because of diffi- culty of removal.
  • Page 101: Air Cleaner

    FUEL SYSTEM (DFI) 2-31 Air Cleaner Element Removal • Remove: Allen Bolt and Washer [A] Left Air Cleaner Cover [B] Front [C] • Remove the element [A]. • Push a clean, lint-free towel into the lower air cleaner duct to keep dirt or other foreign material from entering. WARNING If dirt or dust is allowed to pass through into the throttle assy, the throttle may become stuck, possi-...
  • Page 102: Right Air Cleaner Housing Removal

    2-32 FUEL SYSTEM (DFI) Air Cleaner ○ Be careful not to lose the air cleaner base mounting nuts [A]. These nuts and lower air cleaner duct are sold as a unit. • Apply: Non-permanent Locking Agent - Air Cleaner Base Screws •...
  • Page 103: Right Air Cleaner Housing Installation

    FUEL SYSTEM (DFI) 2-33 Air Cleaner Right Air Cleaner Housing Installation • Check to see that the seals [A], [B] and the ISC pipe O -rings [C] are in place. • Apply: Non-permanent Locking Agent - Right Air Cleaner Base Screws •...
  • Page 104: Lower Air Cleaner Duct Removal

    2-34 FUEL SYSTEM (DFI) Air Cleaner Lower Air Cleaner Duct Removal • Remove: Right and Left Air Cleaner Housing (see this chapter) Throttle Assy Holder [A] Air Cleaner Duct Holder [B] Throttle Assy (see this chapter) Inlet Manifold (see this chapter) Front [C] •...
  • Page 105: Fuel Tank

    FUEL SYSTEM (DFI) 2-35 Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 106 2-36 FUEL SYSTEM (DFI) Fuel Tank • Remove: Front Seat (see Frame chapter) Fuel Tank Bolt [A] Fuel Tank Nut [B] • Disconnect the battery (–) terminal. • Raise the lock [B] and disconnect the fuel pump connector [A] (black, 4p). •...
  • Page 107 FUEL SYSTEM (DFI) 2-37 Fuel Tank • 8 mm plug ( 7.8 ∼ 8.0 mm [A] × L 35 mm Prepare a (1.38 in.) [B] with a rounded end [C]), and a 7.3 ∼ 7.5 mm (0.20 ∼ 0.23 in.) inside diameter fuel hose [D] (e.g. Part No.
  • Page 108: Fuel Tank Installation

    2-38 FUEL SYSTEM (DFI) Fuel Tank • Close the fuel tank cap. • Remove the fuel tank from the vehicle, and place it on a flat surface. CAUTION For California model, if gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capacity is greatly reduced.
  • Page 109 FUEL SYSTEM (DFI) 2-39 Fuel Tank • Check that the rubber dampers [A] are in place. If the dampers are damaged or deteriorated, replace them. ○ Remove the plug hoses, and 8 mm plug, then quickly install the fuel hoses one by one. •...
  • Page 110: Fuel Tank And Cap Inspection

    2-40 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank and Cap Inspection • Visually inspect the gasket [A] on the tank cap for any damage. Replace the gasket if it is damaged. • Check to see if the breather pipe [B] in the tank is not clogged.
  • Page 111 FUEL SYSTEM (DFI) 2-41 Fuel Tank • Check to see if the valve [A] slides smoothly when push- ing it in with a wooden or other soft rod, and see if it comes back to its seat by pressure of the spring [B]. NOTE ○...
  • Page 112: Evaporative Emission Control System

    2-42 FUEL SYSTEM (DFI) Evaporative Emission Control System The Evaporative Emission Control System for California Model routes fuel vapors from the fuel system into the run- ning engine or stores the vapors in a canister when the en- gine is stopped. Although no adjustments are required, a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart.
  • Page 113: Separator Inspection (Periodic Inspection)

    FUEL SYSTEM (DFI) 2-43 Evaporative Emission Control System Separator Inspection (Periodic Inspection) • Disconnect the hoses from the liquid/vapor separator, and remove the separator from the motorcycle. • Visually inspect the separator for cracks and other dam- aged. If the separator has any cracks or damage, replace it with a new one.
  • Page 114 2-44 FUEL SYSTEM (DFI) Evaporative Emission Control System...
  • Page 115: Troubleshooting The Dfi System

    FUEL SYSTEM (DFI) 2-45 Troubleshooting the DFI System Outline When an abnormality in the system occurs, the FI indica- tor LED (Light Emitting Diode) light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (electronic control unit).
  • Page 116 After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Silicone Sealant- Kawasaki Bond: 56019-120 • Always check battery condition before replacing the DFI parts. A fully charged battery is a must for conducting accurate tests of the DFI system.
  • Page 117 FUEL SYSTEM (DFI) 2-47 Troubleshooting the DFI System ○ If both ends of a harness [A] are far apart, ground [B] the one end [C], using an auxiliary lead [D] and check the continuity between the end [E] and the ground [F]. This enables to check a long harness for continuity.
  • Page 118 2-48 FUEL SYSTEM (DFI) Troubleshooting the DFI System ○ Electrical Connectors: Connectors [A] Connectors [B]...
  • Page 119 FUEL SYSTEM (DFI) 2-49 Troubleshooting the DFI System DFI Diagnosis Flow Chart...
  • Page 120 2-50 FUEL SYSTEM (DFI) Troubleshooting the DFI System NOTE ○ OK: No problem. ○ NG: Problem exists. 1. Inspection starts. • An abnormality occurs in the DFI system, and the FI indicator LED light goes on to alert the rider. •...
  • Page 121: Problem Chart

    FUEL SYSTEM (DFI) 2-51 Troubleshooting the DFI System Problem Chart Problems Startability Idling stability Driveability Inspection items ECU ground and 1 (1) power supply Ignition Switch, C2*, 2 (2) engine stop Switch C15* Spark plug #1, #2 3 (3) 4 (5) ISC valve #1, #2 5 (6) 1 (1) 2 (2) 2 (2) In-tank fuel pump...
  • Page 122 2-52 FUEL SYSTEM (DFI) Troubleshooting the DFI System Idling stability (C): Unstable idling (rough idling) • The idle speed fluctuates. This can be identified by engine sound or vibration. (D): Incorrect idle speed • The idle speed cannot be adjusted within the speci- fied range.
  • Page 123: Inquiries To Rider

    FUEL SYSTEM (DFI) 2-53 Troubleshooting the DFI System (I): Surge A forward and backward, periodic movement of a mo- torcycle at acceleration, deceleration, or at cruising. (J): Knock A periodic, rattling, thumping or pounding noise caused by spontaneous ignition of the air-fuel mixture in a cylinder, leading to engine damage.
  • Page 124 2-54 FUEL SYSTEM (DFI) Troubleshooting the DFI System Sample Diagnosis Sheet Rider name Registration No. (license plate No.) Year of initial registration Model Engine No. Frame No. Date problem occured Mileage Environment when problem occurred. □ □ □ □ □ □...
  • Page 125 FUEL SYSTEM (DFI) 2-55 Troubleshooting the DFI System Rider name Registration No. (license plate No.) Year of initial registration Model Engine No. Frame No. Date problem occured Mileage □ Poor running at choke knob left pulled out fully (push it in fully). □...
  • Page 126: Ecu

    2-56 FUEL SYSTEM (DFI) CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Removal • Remove: Front Seat (see Frame chapter) Battery Holder [A] and Screw [B] • Pull the ECU [C] out. If necessary, disconnect the ECU connectors.
  • Page 127: Ecu Power Supply Inspection

    FUEL SYSTEM (DFI) 2-57 ECU Power Supply Inspection • Visually inspect the terminals [A] of the ECU connectors. If the connector is clogged with mud or dust, blow it off with compressed air. Replace the main harness if the terminals of the main harness connectors are cracked, bent, or otherwise dam- aged.
  • Page 128 2-58 FUEL SYSTEM (DFI) DFI Power Source Circuit →: Current Fuel Injector #2 [S] ECU [A] In-tank Fuel Pump [U] Junction Box [F] DFI Fuse 15 A [V] Ignition Switch [N] ISC Valve #2 [W] Starter Relay [O] ISC Valve #1 [X] Main Fuse 30 A [P] DFI Main Relay [e] Battery [Q]...
  • Page 129: Dfi Power Source

    FUEL SYSTEM (DFI) 2-59 DFI Power Source DFI Fuse Removal • Remove the front seat (see Frame chapter). • Pull the lock [A] and open the lid [B]. • Pull out the DFI fuse [C] from the case with needle nose pliers.
  • Page 130: Dfi Main Relay Inspection

    2-60 FUEL SYSTEM (DFI) DFI Power Source DFI Main Relay Inspection • Remove the DFI main relay (see above). • Connect the hand tester [A] and one 12 V battery [B] to the relay connector [C] as shown. Special Tool - Hand Tester: 57001-1394 Relay Coil Terminals [1] and [2] Relay Switch Terminals [3] and [4] Testing Relay...
  • Page 131: Fi Indicator Led Light

    FUEL SYSTEM (DFI) 2-61 FI Indicator LED Light Inspection Flow Chart...
  • Page 132: Led Light Inspection

    2-62 FUEL SYSTEM (DFI) FI Indicator LED Light The FI indicator LED light [A] goes ON when the ignition switch is turned ON and the LED light goes OFF 1 ∼ 2 sec- onds later. This is to ensure that the FI indicator LED light has not burned out and the DFI system and the ignition sys- tem function properly.
  • Page 133: Isc Valves

    FUEL SYSTEM (DFI) 2-63 ISC Valves There are two ISC valves; the ISC valve #1 for the front cylinder, and the ISC valve #2 for the rear cylinder. When the engine is cold, each ISC valve is opened according to the coolant temperature by the ECU, providing good starta- bility in cold weather and allowing the engine to run fast for quick warm up (fast idle).
  • Page 134: Removal/Installation

    2-64 FUEL SYSTEM (DFI) ISC Valves Removal/Installation CAUTION Never drop the ISC valves, especially on a hard sur- face. Such a shock to the valve can damage it. ○ The ISC valves are removed during right air cleaner hous- ing removal (see this chapter). ○...
  • Page 135: Output Voltage Inspection

    • After inspection, remove the needle adapters, and apply silicone sealant to the seals of the ECU connector for wa- terproofing. Silicone Sealant- Kawasaki Bond: 56019-120 Output Voltage Inspection • Measure the output voltage at the ECU connector, using the hand tester (special tool).
  • Page 136: Resistance Inspection

    2-66 FUEL SYSTEM (DFI) ISC Valves If the output voltage is correct, check the output voltage at the connectors [A] of the ISC Valves. • Remove the right air cleaner cover (see this chapter). • Disconnect the ISC connectors. • Connect the hand tester to the main harness connectors for each ISC valve.
  • Page 137 FUEL SYSTEM (DFI) 2-67 ISC Valves → : Signal ECU [A] Junction Box [F] Ignition Switch [N] Starter Relay [O] Main Fuse 30 A [P] Battery [Q] DFI Fuse 15 A [V] ISC Valve #2 [W] ISC Valve #1 [X] DFI Main Relay [e] Ignition Fuse 10 A [f]...
  • Page 138: Fuel Line

    2-68 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove the fuel tank (see Fuel Tank Removal). ○ Be sure to stuff a clean shop towel [A] around the high pressure fuel hose joint [B] of the fuel tank, and plug the joint with a plug [C] ( 7.8 ∼...
  • Page 139 FUEL SYSTEM (DFI) 2-69 Fuel Line • Measure the fuel pressure with the engine stopped. Fuel Pressure right after Ignition Switch ON, with pump running: Standard: 310 kPa (3.2 kgf/cm², 46 psi) after 3 seconds from Ignition Switch ON, with pump stopped: Standard: 280 kPa (2.9 kgf/cm², 41 psi) •...
  • Page 140: Pressure Regulator Removal

    2-70 FUEL SYSTEM (DFI) Fuel Line ○ Pull the high pressure fuel hose joint [A] up [B] and make sure it is locked and does not come off. • Start the engine and check for fuel leakage. Pressure Regulator Removal ○...
  • Page 141 FUEL SYSTEM (DFI) 2-71 Fuel Line • Prepare a plastic hose of the inside diameter 7.5 mm (0.295 in.) × L about 400 mm (15.7 in.) and a measuring cylinder. • Remove: Front Seat (see Frame chapter) Fuel Tank Bolt and Nut ○...
  • Page 142: Self-Diagnosis

    2-72 FUEL SYSTEM (DFI) Self-Diagnosis Self-diagnosis Function The self-diagnosis indicates problems with the parts, wiring, and ECU in the DFI system and ignition system. The ECU [C] always monitors each DFI circuit [A] for problems by measuring the voltage [B]. This circuit includes parts [D], and wiring [E].
  • Page 143 FUEL SYSTEM (DFI) 2-73 Self-Diagnosis...
  • Page 144: How To Read Fault Codes

    2-74 FUEL SYSTEM (DFI) Self-Diagnosis How to Read Fault Codes ○ Fault codes are shown by a series of long and short blinks of the FI indicator LED light as shown below. ○ Read 10th digit and unit digit as the FI indicator LED light blinks.
  • Page 145: How To Erase Fault Codes

    FUEL SYSTEM (DFI) 2-75 Self-Diagnosis How to Erase Fault Codes ○ When the repair has been done, the LED light will not show fault codes any more. But even if the repair has been done, the ignition switch is turned OFF, or the battery is disconnected, all the fault codes remain in the ECU, which need not be absolutely eraced.
  • Page 146: Backups

    2-76 FUEL SYSTEM (DFI) Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Fault Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the throttle sensor system fails (the signal is out of the usable range, wiring short or open), Throttle Throttle Valve Opening...
  • Page 147 FUEL SYSTEM (DFI) 2-77 Self-Diagnosis NOTE ○ (1) When the engine load is light like at idling or low speed, the ECU determines injection quantity by calculating from throttle vacuum (vacuum sensor output voltage) and engine speed (pickup coil output voltage). This method is called D-J method. As engine speed increases, and the en- gine load turns middle to heavy, the ECU determines injection quantity by calculating from throttle opening (throttle sensor output voltage) and engine speed.
  • Page 148: Throttle Sensor (Fault Code 11)

    2-78 FUEL SYSTEM (DFI) Throttle Sensor (Fault Code 11) The throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injection quantity, and ignition timing according to engine rpm, and throttle opening.
  • Page 149: Output Voltage Inspection

    FUEL SYSTEM (DFI) 2-79 Throttle Sensor (Fault Code 11) • Connect a digital meter [A] to the throttle sensor connector [B], using two needle adapters [C]. Front [D] Special Tool - Needle Adapter Set: 57001-1457 CAUTION Insert the needle adapter straight along the lead in the connector to prevent short circuit between ter- minals.
  • Page 150 If the reading is out of the standard range, inspect the throttle sensor resistance. • After throttle sensor inspection, remove the needle adapters, and apply silicone sealant to the seals [A] of the connector [B] for waterproofing. Silicone Sealant- Kawasaki Bond: 56019-120...
  • Page 151: Resistance Inspection

    FUEL SYSTEM (DFI) 2-81 Throttle Sensor (Fault Code 11) Resistance Inspection • Turn the ignition switch OFF. • Disconnect the throttle sensor connector. • Connect a digital meter [A] to the throttle sensor connector [B]. • Measure the throttle sensor resistance. Throttle Sensor Resistance Connections: BL/W lead [C] ←→...
  • Page 152: Vacuum Sensor (Fault Code 12)

    2-82 FUEL SYSTEM (DFI) Vacuum Sensor (Fault Code 12) Removal CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. • Remove the fuel tank (see Fuel Tank section in this chap- ter).
  • Page 153: Output Voltage Inspection

    Turn the ignition switch OFF, remove the needle adapters and apply silicone sealant to the seals of the sensor con- nector for waterproofing. Silicone Sealant- Kawasaki Bond: 56019-120 Output Voltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection.
  • Page 154 If the output voltage is out of the usable range, replace the sensor. • Turn the ignition switch OFF and remove the needle adapters. • Apply silicone sealant to the seals of the sensor connector for waterproofing. Silicone Sealant- Kawasaki Bond: 56019-120 →: Signal ECU [A] Vacuum Sensor [a]...
  • Page 155 FUEL SYSTEM (DFI) 2-85 Vacuum Sensor (Fault Code 12) If you need to check the vacuum sensor for vacuum other than 76 cmHg (abs), check the output voltage as follows: ○ Remove the fuel tank (see this chapter). • Remove the vacuum sensor [D] and disconnect the vac- uum hose from the sensor.
  • Page 156 2-86 FUEL SYSTEM (DFI) Vacuum Sensor (Fault Code 12) Suppose: Pg: Vacuum (gauge) of Throttle Assy Pl: Local Atmospheric Pressure (absolute) measured by a barometer Pv: Vacuum (absolute) of Throttle Assy Vv: Sensor Output Voltage (v) then Pv = Pl – Pg For example, suppose the following data is obtained: Pg = 8 cmHg (vacuum gauge reading) Pl = 70 cmHg (barometer reading)
  • Page 157 FUEL SYSTEM (DFI) 2-87 Vacuum Sensor (Fault Code 12) Pv = 55 ∼ 86 cmHg Vv: Vacuum Sensor Output Voltage (V) (Digital Meter Reading) Pv: Throttle Vacuum (absolute) Ps: Standard Atmospheric Pressure (absolute) ID: Idling TO: Throttle Full Open ST: Standard of Sensor Output Voltage (v) UR: Usable Range of Sensor Output Voltage (v)
  • Page 158: Inlet Air Temperature Sensor (Fault Code 13)

    (see next diagram). • Remove the needle adapters, and apply silicone sealant to the seals of the ECU connector for waterproofing. Silicone Sealant- Kawasaki Bond: 56019-120 If the wiring is good, check the sensor resistance.
  • Page 159: Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 2-89 Inlet Air Temperature Sensor (Fault Code 13) Sensor Resistance Inspection • Remove the inlet air temperature sensor (see this sec- tion). • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion and threaded portion are submerged.
  • Page 160: Water Temperature Sensor (Fault Code 14)

    Disconnect the sensor connector, and unscrew the water temperature sensor [B]. Top [C] • Apply silicone sealant to the threads of water temperature sensor. Silicone Sealant- Kawasaki Bond: 56019-120 • Tighten: Torque - Water Temperature Sensor: 18 N·m (1.8 kgf·m, 13 ft·lb) •...
  • Page 161 If the wiring is good, check the water temperature sensor resistance. • Remove the needle adapters, and apply silicone sealant to the seals of the ECU connector for waterproofing. Silicone Sealant- Kawasaki Bond: 56019-120 ECU [A] Water Temperature Sensor [Z]...
  • Page 162: Sensor Resistance Inspection

    2-92 FUEL SYSTEM (DFI) Water Temperature Sensor (Fault Code 14) Sensor Resistance Inspection • Remove the water temperature sensor (see this section). • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion and threaded portion are submerged.
  • Page 163: Atmospheric Pressure Sensor (Fault Code 15)

    FUEL SYSTEM (DFI) 2-93 Atmospheric Pressure Sensor (Fault Code 15) Removal CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank section in this chap- ter).
  • Page 164: Output Voltage Inspection

    Remove the needle adapters. • Apply silicone sealant to the seals of the sensor connector for waterproofing. Silicone Sealant- Kawasaki Bond: 56019-120 Output Voltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following.
  • Page 165 FUEL SYSTEM (DFI) 2-95 Atmospheric Pressure Sensor (Fault Code 15) If the output voltage is far out of the usable range, remove the fuel tank, and check the output voltage at the sensor connector [A] (when the wiring is open, the output voltage is about 1.8 V).
  • Page 166 2-96 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Fault Code 15) If you need to check the atmospheric pressure sensor for various altitudes other than sea level, check the output voltage as follows: ○ Determine the local altitude (elevation). If you know the local atmospheric pressure using a barometer, substitude the atmospheric pressure for Pv (Throttle Vacuum) in the vacuum sensor chart (see Vac- uum Sensor section in this chapter).
  • Page 167 FUEL SYSTEM (DFI) 2-97 Atmospheric Pressure Sensor (Fault Code 15) H: Altitude (m or feet) SL: Sea Level (0 m) ST: Standard of Sensor Output Voltage (v) UR: Usable Range of Sensor Output Voltage (v) Va: Atmospheric Pressure Sensor Output Voltage (v)
  • Page 168: Pickup Coils (#1, #2: Fault Code 21, 22)

    2-98 FUEL SYSTEM (DFI) Pickup Coils (#1, #2: Fault Code 21, 22) Pickup Coil #1: for Front Cylinder (Fault Code 21) Pickup Coil #2: for Rear Cylinder (Fault Code 22) Pickup Coil Removal/Installation • See Ignition System section in Electrical System chapter. Pickup Coil Inspection ○...
  • Page 169: Vehicle-Down Sensor (Fault Code 31)

    FUEL SYSTEM (DFI) 2-99 Vehicle-down Sensor (Fault Code 31) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the motorcycle banks (40 ∼ 50°) or more to either side (in fact falls down), the weight turns and shuts off the signal.
  • Page 170: Installation

    2-100 FUEL SYSTEM (DFI) Vehicle-down Sensor (Fault Code 31) • Remove the screw [B] and take out the vehicle-down sen- sor [A]. • Raise the lock, and disconnect the connector to complete sensor removal. Installation • Install the vehicle-down sensor assy [A] so that the sensor connector [B] faces backward.
  • Page 171 Remove the needle adapters, and apply silicone sealant to the seals of the vehicle-down sensor connector for wa- terproofing. Silicone Sealant- Kawasaki Bond: 56019-120 If the output voltage is normal, the wiring is suspect. Check the wiring. If the wiring is good, check the ECU for its ground and power supply (see this chapter).
  • Page 172 2-102 FUEL SYSTEM (DFI) Vehicle-down Sensor (Fault Code 31) →: Signal ECU [A] Junction Box [F] Ignition Switch [N] Starter Relay [O] Main Fuse 30 A [P] Battery [Q] Vehicle-down Sensor [d] Ignition Fuse 10 A [f]...
  • Page 173: Fuel Injectors (#1, #2: Fault Code 41, 42)

    FUEL SYSTEM (DFI) 2-103 Fuel Injectors (#1, #2: Fault Code 41, 42) Fuel Injector #1: Front Fuel Injector for Front Cylinder (Fault Code 41) Fuel Injector #2: Rear Fuel Injector for Rear Cylinder (Fault Code 42) CAUTION Never drop the injector, especially on a hard sur- face.
  • Page 174: Injector Installation

    2-104 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Fault Code 41, 42) ○ The screen [A] comes off from the pressure regulator [B]. Delivery Joint [C] Front [D] • Clean the screen with high-flash point solvent to remove any particles. WARNING Clean the screen in a well-ventilated area, and take care that there is no spark or flame anywhere near...
  • Page 175 FUEL SYSTEM (DFI) 2-105 Fuel Injectors (#1, #2: Fault Code 41, 42) • Check that there is no dirt or dust on the injector seating surface [A] of the inlet manifold [B]. • Check that the two dowel pins are in place in the inlet manifold.
  • Page 176: Power Source Voltage Inspection

    2-106 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Fault Code 41, 42) • Connect: Front Injector Connector [A] (BL/R, W/R leads) Rear Injector Connector [B] (BL/G, W/R leads) Fuel Hose [C] to Delivery Joint [D] Vacuum Hose [E] to T-Joint [F] Front [G] •...
  • Page 177: Output Voltage Inspection

    FUEL SYSTEM (DFI) 2-107 Fuel Injectors (#1, #2: Fault Code 41, 42) If the reading is normal, remove the fuel tank, and check the power source voltage at the injector connector [A], using the needle adapter [B]. • Measure the power source voltage with the engine stopped, and the connector joined, using a digital meter.
  • Page 178: Audible Inspection

    2-108 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Fault Code 41, 42) If the output voltage is out of the standard, remove the fuel tank, and check the output voltage at the injector connec- tor [A], using the needle adapter [B] (when the wiring is open, the output voltage is 0 V).
  • Page 179: Injector Signal Test

    FUEL SYSTEM (DFI) 2-109 Fuel Injectors (#1, #2: Fault Code 41, 42) Injector Signal Test • Prepare two test light sets with terminals as shown. Rating of Bulb [A]: 12 V × 3 ∼ 3.4 W Terminal (Width × Thickness) [B]: 1.8 × 0.8 mm (0.07 × 0.03 in.) CAUTION Do not use larger terminals than specified above.
  • Page 180: Injector Unit Test

    2-110 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Fault Code 41, 42) Injector Unit Test • Use two wires [A] and the same test light set [B] as in “Injector Signal Test”. Rating of Bulb [C]: 12 V × (3 ∼ 3.4) W 12 V Battery [D] CAUTION Be sure to connect the bulb in series.
  • Page 181 FUEL SYSTEM (DFI) 2-111 Fuel Injectors (#1, #2: Fault Code 41, 42) →: Signal ECU [A] Junction Box [F] Ignition Switch [N] Starter Relay [O] Main Fuse 30 A [P] Battery [Q] Fuel Injector #1 [R] Fuel Injector #2 [S] DFI Fuse 15 A [V] DFI Main Relay [e] Ignition Fuse 10 A [f]...
  • Page 182: In-Tank Fuel Pump (Fault Code 45)

    2-112 FUEL SYSTEM (DFI) In-tank Fuel Pump (Fault Code 45) Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions.
  • Page 183: Fuel Filter Cleaning

    FUEL SYSTEM (DFI) 2-113 In-tank Fuel Pump (Fault Code 45) Fuel Filter Cleaning ○ The fuel filter cannot be cleaned or checked. If the fuel filter is suspected of clogging or being damaged, replace it with the fuel pump as a set. Fuel Pump Installation •...
  • Page 184: Operation Inspection

    2-114 FUEL SYSTEM (DFI) In-tank Fuel Pump (Fault Code 45) • Secure the fuel level sensor leads [A], and fuel pump leads [B] on the fuel tank [C] with the welded clamps [D]. Front [E] • Install the fuel tank (see this chapter). Operation Inspection NOTE ○...
  • Page 185: Power Source Voltage Inspection

    FUEL SYSTEM (DFI) 2-115 In-tank Fuel Pump (Fault Code 45) • Remove the fuel tank bolt and nut (see Fuel Tank Re- moval in this chapter). • Raise the fuel tank [A] and take out the fuel pump con- nector [B]. •...
  • Page 186 Wiring for Fuel Pump Power Source (see next diagram) Vehicle-down Sensor (see this chapter) • After inspection, remove the needle adapter, and apply silicone sealant to the seal of the fuel pump connector for waterproofing. Silicone Sealant- Kawasaki Bond: 56019-120...
  • Page 187 FUEL SYSTEM (DFI) 2-117 In-tank Fuel Pump (Fault Code 45) →: Signal ECU [A] Junction Box [F] Ignition Switch [N] Starter Relay [O] Main Fuse 30 A [P] Battery [Q] In-tank Fuel Pump [U] DFI Fuse 15 A [V] DFI Main Relay [e] Ignition Fuse 10 A [f]...
  • Page 188: Ignition Coils (#1, #2: Fault Code 51, 52)

    2-118 FUEL SYSTEM (DFI) Ignition Coils (#1, #2: Fault Code 51, 52) Ignition Coil #1: Ignition Coil for Front Cylinder (Fault Code 51) Ignition Coil #2: Ignition Coil for Rear Cylinder (Fault Code 52) Removal/Installation CAUTION Never drop the ignition coils, especially on a hard surface.
  • Page 189 FUEL SYSTEM (DFI) 2-119 Ignition Coils (#1, #2: Fault Code 51, 52) →: Signal ECU [A] Engine Stop Switch [B] Ignition Coils [D] Ignition Switch [N] Starter Relay [O] Main Fuse 30 A [P] Battery [Q] Junction Box [F] Ignition Fuse 10 A [f]...
  • Page 191 COOLING SYSTEM 3-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... 3-10 Cooling System Flushing ....................3-11 Water Pump..........................3-12 Water Pump Removal .......................
  • Page 192: Exploded View

    3-2 COOLING SYSTEM Exploded View...
  • Page 193: Cooling System

    T3: 18 N·m (1.8 kgf·m, 13 ft·lb) T4: 9.8 N·m (1.0 kgf·m, 87 in·lb) T5: 7.4 N·m (0.75 kgf·m, 65 in·lb) EO: Apply engine oil. G: Apply grease. Lh: Left-hand Threads R: Replacement Parts SS: Apply silicone sealant. (Kawasaki Bond: 56019-120)
  • Page 194: Coolant Flow Chart

    3-4 COOLING SYSTEM Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes as coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
  • Page 195 COOLING SYSTEM 3-5 Coolant Flow Chart 1. Water Pump 2. Water Jacket 3. Cylinder Head 4. Water Pipe 5. Water Hose 6. Radiator Cap 7. Thermostat 8. Reserve Tank Hose 9. Radiator 10. Radiator Fan 11. Throttle Assy 12. Front 13.
  • Page 196: Specifications

    Valve Opening Temperature Valve Full Opening Lift 8 mm (0.031 in.) or more @75°C (167°F) Special Tools - Bearing Driver Set: 57001-1129 Bearing Remover Shaft: 57001-1265 Bearing Remover Head, 10 × 12: 57001-1266 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 197: Coolant

    COOLING SYSTEM 3-7 Coolant Coolant Deterioration Inspection • Remove the right side cover (see Frame chapter). • Visually inspect the coolant [A] in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting.
  • Page 198: Coolant Filling

    3-8 COOLING SYSTEM Coolant • Place a container under the radiator drain bolt [A], then remove the drain bolt (front view). • Remove the fuel tank (see Fuel System chapter). • Remove the radiator cap [A] in two steps. First turn the cap counterclockwise to the first stop.
  • Page 199 COOLING SYSTEM 3-9 Coolant Water and Coolant Mixture Ratio (when shipping) Soft Water : 50% Coolant : 50% Freezing Point : − 35°C (− 31°F) : 2.3 L (2.43 US gt) Total Amount • Tighten the drain bolts. Torque - Radiator Drain Bolt: 7.4 N·m (0.75 kgf·m, 65 in·lb) Water Pump Drain Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 200: Pressure Testing

    3-10 COOLING SYSTEM Coolant • Fill the reserve tank up to the “F” (full) level line [A] with coolant and install the cap. • Install the fuel tank (see Fuel System chapter). • Start the engine and warm it up thoroughly until the radi- ator fan turns on and then stop the engine.
  • Page 201: Cooling System Flushing

    COOLING SYSTEM 3-11 Coolant Cooling System Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passage and considerably reduce the effi- ciency of the cooling system.
  • Page 202: Water Pump

    3-12 COOLING SYSTEM Water Pump Water Pump Removal • Drain the coolant (see Coolant Draining). • Remove: Water Hose Clamp [A] Water Hose [B] Front [C] • Remove: Water Pump Cover Bolts [A] Water Pump Cover [B] • Remove: Impeller Bolt [A] Impeller [B] NOTE ○...
  • Page 203: Water Pump Inspection

    COOLING SYSTEM 3-13 Water Pump Water Pump Inspection • Check the water pump drainage outlet hose [A] at the bottom of the water pump for coolant leakage. If the mechanical seal is damaged, the coolant leaks through the seal and drain through the passage. Replace the mechanical seal.
  • Page 204 3-14 COOLING SYSTEM Water Pump • Using a thin-bladed screwdriver, pry out the oil seal. • Press out the mechanical seal [A] and ball bearing [B] from the inside of the right crankcase with the bearing driver set [C]. Special Tool - Bearing Driver Set: 57001-1129 ○...
  • Page 205: Radiator

    COOLING SYSTEM 3-15 Radiator WARNING The radiator fan is connected directly to the bat- tery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DIS- CONNECTED. TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES.
  • Page 206: Radiator Inspection

    3-16 COOLING SYSTEM Radiator Radiator Inspection • Check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparably de- formed fins, replace the radiator with a new one.
  • Page 207: Radiator Filler Neck Inspection

    COOLING SYSTEM 3-17 Radiator Radiator Filler Neck Inspection • Remove the radiator cap. • Check the radiator filler neck for signs of damage. • Check the condition of the top and bottom sealing seats [A] in the filler neck. They must be smooth and clean for the radiator cap to function properly.
  • Page 208: Thermostat

    3-18 COOLING SYSTEM Thermostat Thermostat Removal • Remove: Coolant: Drain about 200 mL Fuel Tank (see Fuel System chapter) Four Water Hoses [A] Bracket Bolts [B] Water Temperature Sensor Connector • Remove the thermostat housing [C] along with the bracket. Front [D] •...
  • Page 209: Hoses And Pipes

    COOLING SYSTEM 3-19 Hoses and Pipes • Whenever the water hoses are removed or in accordance with the Periodic Maintenance Chart, check the water hoses and their connections. Hose Installation • Install the hoses and pipes being careful to follow bend- ing direction.
  • Page 211 Muffler, Exhaust Pipe Installation. 4-43 Front Camshaft Chain Removal... 4-23 Chamber Removal ....... 4-44 Rear Camshaft Chain Removal ... 4-23 Chamber Installation ....4-44 KACR (Kawasaki Automatic Chamber Assembly...... 4-44 Compression Release) ....4-24 Chamber Identification ....4-44 Removal........4-24...
  • Page 212: Exploded View

    (10 : 1) T5: 7.4 N·m (0.75 kgf·m, 65 in·lb) S: Follow the specific tightening sequence. T6: 20 N·m (2.0 kgf·m, 14 ft·lb) SS: Apply silicone sealant (Kawasaki Bond: AD: Apply adhesive. 56019-120). G: Apply grease.
  • Page 213 ENGINE TOP END 4-3 Exploded View 1. Rear Exhaust Pipe T2: 6.9 N·m (0.70 kgf·m, 61 in·lb) 2. Front Exhaust Pipe M: Apply molybdenum disulfide grease. 3. Upper Muffler PN: Spray a penetrating oil on the nuts and 4. Lower Muffler studs if the nuts are difficult to remove.
  • Page 214 4-4 ENGINE TOP END Exploded View 1. Coolant Drain Bolts T5: 25 N·m (2.5 kgf·m, 18 ft·lb) 2. KACR Unit EO: Apply engine oil. 3. “R” marked side faces up. L: Apply a non-permanent locking agent. 4. “RN” marked side faces up. MO: Apply molybdenum disulfide oil.
  • Page 215: Exhaust System Identification

    ENGINE TOP END 4-5 Exhaust System Identification Exhaust System US: United States US (CAL): United States (California) CA: Canada AU: Australia GB WVTA (Full H): WVTA Model with Honeycomb Catalytic Converter (Full Power) WVTA (Full H): WVTA Model with Honeycomb Catalytic Converter (Left Side, Full Power) Mark and/or Catalyst Position Exhaust Pipe [A] Pre-Muffler Chamber [B]...
  • Page 216: Specifications

    4-6 ENGINE TOP END Specifications Item Standard Service Limit Clean Air System Open → Close 49.3 ∼ 57.3 kPa Vacuum Switch Valve Closing – – – (370 ∼ 430 mm Hg) Pressure: Camshafts Cam Height: 33.48 ∼ 33.60 mm Exhaust 33.38 mm (1.314 in.) (1.318 ∼...
  • Page 217 ENGINE TOP END 4-7 Specifications Item Standard Service Limit Valve Guide Inside Diameter: 7.000 ∼ 7.015 mm Exhaust 7.08 mm (0.2787 in.) (0.2756 ∼ 0.2762 in.) 7.000 ∼ 7.015 mm Inlet 7.08 mm (0.2787 in.) (0.2756 ∼ 0.2762 in.) Valve/valve Guide Clearance (Wobble Method): 0.08 ∼...
  • Page 218 Valve Seat Cutter, 55° - 35: 57001-1247 Fork Oil Level Gauge: 57001-1290 Piston Ring Compressor Belt, 95 ∼ 108: 57001-1358 Filler Cap Driver: 57001-1454 ○ Compression Gauge Adapter, M12 × 1.25: 57001-1183 can also be used. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 219: Air Suction Valve Removal

    ENGINE TOP END 4-9 Clean Air System Air Suction Valve Removal • For rear air suction valve removal, remove the rear ex- haust pipe (see this chapter). • Remove the hose [A]. • Unscrew the mounting bolts [B] and remove the rear air suction valve cover [C].
  • Page 220: Vacuum Switch Valve Removal

    4-10 ENGINE TOP END Clean Air System Vacuum Switch Valve Removal • Remove: Fuel Tank (see Fuel System chapter) • Pull off the hoses [A] and take out the vacuum switch valve [B]. Front [C] Vacuum Switch Valve Installation • Install the vacuum switch valve [A] so that the air hole [B] faces downwards.
  • Page 221: Clean Air System Hose Inspection

    ENGINE TOP END 4-11 Clean Air System • Gradually raise the vacuum (lower the pressure) applied to the vacuum switch valve, and check the valve opera- tion. When the vacuum is low, the vacuum switch valve should permit air to flow. When the vacuum raises to valve closing pressure, it should stop air flow.
  • Page 222: Camshaft Chain Tensioner

    4-12 ENGINE TOP END Camshaft Chain Tensioner Removal CAUTION This is a non-return type cam chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.
  • Page 223 ENGINE TOP END 4-13 Camshaft Chain Tensioner • Screw in the lockbolt [A] finger-tight to hold the ball bear- ing assy temporarily. • Install the retainer [B]. • Install the tensioner body [A] and tighten the mounting bolts [B] to the specified torque. Torque - Chain Tensioner Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 224: Rocker Case Cover

    4-14 ENGINE TOP END Rocker Case Cover Removal • Remove the engine (see Engine Removal/Installation chapter). • Remove the bolts [A] and take off the cover [B] from the rocker case. • Take out the oil filter springs [A] and HLA oil filters [B]. Installation •...
  • Page 225: Rocker Case

    ENGINE TOP END 4-15 Rocker Case Removal • Remove the engine (see Engine Removal/Installation chapter). • Remove the rocker case covers (see this chapter). • Remove the alternator outer cover (see Electrical System chapter). • Remove the timing inspection plug and rotor bolt plug. Special Tool - Filler Cap Driver: 57001-1454 •...
  • Page 226 Torque - Rocker Shafts: 25 N·m (2.5 kgf·m, 18 ft·lb) • Apply silicone sealant [A] to the rocker case mating sur- face and the outer circumference of the plugs as shown. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 ○ Do not apply silicone sealant around the camshaft bear- ing.
  • Page 227: Rocker Arm Assembly

    ENGINE TOP END 4-17 Rocker Case Rocker Arm Assembly • Prepare a flat-end bar [A] and a block [B] with a recess [C]. • Press the oil chamber [D] for the HLA into the rocker arm end [E] until the chamber end is even with the step [F] of the hole.
  • Page 228: Hla (Hydraulic Lash Adjuster)

    4-18 ENGINE TOP END HLA (Hydraulic Lash Adjuster) HLA Removal • Remove the rocker case (see Rocker Case Removal). • Remove the rocker arms. • Pull the HLA [B] out of the rocker arm [A] with your fingers. CAUTION Be careful not to damage or deform a lash adjuster by tapping it during removal or installation.
  • Page 229: Camshafts

    ENGINE TOP END 4-19 Camshafts Removal • Remove the timing inspection plug and rotor bolt plug. Special Tool - Filler Cap Driver: 57001-1454 • Turn the crankshaft counterclockwise [A] and align the “F” mark [B] (TDC mark for the front piston) with the middle of the notch [C].
  • Page 230 4-20 ENGINE TOP END Camshafts • Install the KACR on each camshaft. ○ The front and rear KACR are the same except for the spring [A]. ○ The rear KACR has a yellow coating spring. Do not con- fuse the springs. VN1500-N4 ∼...
  • Page 231 ENGINE TOP END 4-21 Camshafts • Next, install the rear camshaft. ○ Check to be sure that the front camshaft chain timing is correct. ○ Turn the crankshaft counterclockwise [A]. • Align the “R” mark [A] (TDC mark for the rear piston) with the middle of the notch [B] (310°...
  • Page 232: Camshaft Sprocket Installation

    4-22 ENGINE TOP END Camshafts Camshaft Sprocket Installation • Use the sprocket marked F for the front camshaft [A] and the sprocket marked R for the rear camshaft [B]. • Apply a non-permanent locking agent to the camshaft sprocket bolts and tighten them to the specified torque. Torque - Camshaft Sprocket Bolts: 15 N·m (1.5 kgf·m, 11 ft·lb) Camshaft/Rocker Case Wear Inspection...
  • Page 233: Front Camshaft Chain Removal

    ENGINE TOP END 4-23 Camshafts If any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer. Camshaft Journal Diameter ( 25) 24.959 ∼ 24.980 mm Standard: (0.9826 ∼ 0.9835 in.) ( 17) 16.966 ∼ 16.984 mm (0.6680 ∼...
  • Page 234: Kacr (Kawasaki Automatic Compression Release)

    4-24 ENGINE TOP END KACR (Kawasaki Automatic Compression Release) Due to the simplicity of the mechanism, no periodic main- tenance is needed. There are only two symptoms of prob- lems with the KACR mechanism [A]; compression is not re- leased during starting, and compression is released during running.
  • Page 235 ENGINE TOP END 4-25 KACR (Kawasaki Automatic Compression Release) VN1500-N4 ∼ Rear KACR unit [F] ○ The cylinder compression is released while the engine is running (abnormal): the pin [A] stays out the cam [B] and pushes up the exhaust rocker arm.
  • Page 236: Cylinder Head

    4-26 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○ Be sure the battery is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove one spark plug and attach the compression gauge and adapter firmly into the spark plug hole. Do not remove the other spark plug, only the plug lead.
  • Page 237: Removal

    ENGINE TOP END 4-27 Cylinder Head The following table should be consulted if the obtainable compression reading is not within the us- able range. Problem Diagnosis Remedy (Action) Carbon buildup on piston and in combustion chamber possibly due to damaged valve stem, Remove the carbon deposits and valve guide, stem oil seal and/or damaged replace damaged parts if necessary.
  • Page 238: Installation

    4-28 ENGINE TOP END Cylinder Head Installation ○ The front cylinder head [A] has an F mark while the rear cylinder head [B] has an R mark. Be careful not to mix them up. Front [C] CAUTION The cylinder head and rocker case are machined in the assembled state, so they must be used as a set.
  • Page 239: Valves

    ENGINE TOP END 4-29 Valves Valve Clearance Adjustment NOTE ○ Since the hydraulic lash adjusters constantly maintain zero clearance, it is not necessary to inspect or adjust the valve clearance. Valve Removal • Remove the cylinder head (see this chapter). •...
  • Page 240: Valve Guide Installation

    4-30 ENGINE TOP END Valves Valve Guide Installation • Apply oil to the valve guide outer surface before installa- tion. • Heat the area around the valve guide hole to about 120 ∼ 150°C (248 ∼ 302°F) (see Valve Guide Removal). •...
  • Page 241: Valve Seat Inspection

    ENGINE TOP END 4-31 Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat with vernier calipers.
  • Page 242 4-32 ENGINE TOP END Valves Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.
  • Page 243 ENGINE TOP END 4-33 Valves • Measure the outside diameter of the seating surface with vernier calipers. If the outside diameter of the seating surface is too small, repeat the 45° grind [A] until the diameter is within the specified range. Original Seating Surface [B] NOTE ○...
  • Page 244 4-34 ENGINE TOP END Valves • Lap the valve to the seat, once the seat width and outside diameter are within the ranges specified above. ○ Put a little coarse grinding compound on the face of the valve in a number of places around the valve head. ○...
  • Page 245 ENGINE TOP END 4-35 Valves...
  • Page 246: Cylinders, Piston

    4-36 ENGINE TOP END Cylinders, Piston Cylinder Removal • Remove the cylinder head (see Cylinder Head Removal). • Pull out the front camshaft chain guide [A]. • Remove the cylinder nuts [B]. • Tap lightly up the cylinder with a plastic mallet to separate from the crankcase.
  • Page 247 ENGINE TOP END 4-37 Cylinders, Piston ○ The front chain guide for the front cylinder has an F mark [A] and the front chain guide for the rear cylinder has an R mark [B]. Be careful not to mix up these chain guides since the front chain guide for the rear cylinder is longer.
  • Page 248: Cylinder Wear Inspection

    4-38 ENGINE TOP END Cylinders, Piston • Face the “Arrow“ mark [A] on each piston toward the ex- haust side [B]. ○ The front and rear pistons are the same. Front [C] CAUTION Incorrect installation of the piston could cause pis- ton seizure and result in severe engine damage.
  • Page 249: Piston Wear Inspection

    ENGINE TOP END 4-39 Cylinders, Piston Piston Wear Inspection • Measure the outside diameter [A] of each piston 5 mm (0.20 in.) [B] up from the bottom of the piston at a right angle to the direction of the piston pin. If the measurement is under service limit, replace the pis- ton.
  • Page 250: Piston Ring, Piston Ring Groove Wear Inspection

    4-40 ENGINE TOP END Cylinders, Piston Piston Ring, Piston Ring Groove Wear Inspection • Check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. •...
  • Page 251: Piston Ring End Gap Inspection

    ENGINE TOP END 4-41 Cylinders, Piston Piston Ring End Gap Inspection • Place the piston ring [A] inside the cylinder, using the pis- ton to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. •...
  • Page 252: Mufflers

    4-42 ENGINE TOP END Mufflers WARNING To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cools down. Exhaust Pipe Removal • Loosen the clamp screws [A]. • Detach the upper clamps [B] by sliding them up or for- ward.
  • Page 253: Lower Muffler Body Removal

    ENGINE TOP END 4-43 Mufflers Lower Muffler Body Removal • Remove: Front and Rear Exhaust Pipe Covers (see above) Chamber Flange Nuts [A] Muffler Body Bracket Bolts [B] • Remove the lower muffler body [C]. NOTE ○ If the chamber flange nuts are difficult to remove, spray a penetrating oil on the studs and nuts.
  • Page 254: Chamber Removal

    4-44 ENGINE TOP END Mufflers Chamber Removal • Remove: Front Exhaust Pipe [A] Rear Exhaust Pipe [B] Lower and Upper Mufflers [C] Right and Left Chamber Bolts [D] • Take out the premuffler chamber [E]. Front [F] Chamber Installation • Replace the muffler flange gasket with new ones.
  • Page 255 CLUTCH 5-1 Clutch Table of Contents Exploded View........................Specifications ......................... Clutch Lever ........................... Position Adjustment ......................Clutch Fluid..........................Fluid Level Inspection ....................... Clutch Fluid Changing....................... Clutch Line Bleeding ......................Clutch Master Cylinder ......................Clutch Master Cylinder Removal ..................Clutch Master Cylinder Installation ................... Clutch Master Cylinder Disassembly ................
  • Page 256: Exploded View

    5-2 CLUTCH Exploded View 1. Starter Lockout Switch T9: 147 N·m (15.0 kgf·m, 108 ft·lb) 2. Clutch Slave Cylinder T10: 6.9 N·m (0.70 kgf·m, 61 in·lb) 3. Cup point side faces outside. EO: Apply engine oil. 4. Clutch Spring Holder (VN1500-N4 ∼) L: Apply a non-permanent locking agent.
  • Page 257: Specifications

    CLUTCH 5-3 Specifications Item Standard Service Limit Clutch Fluid Grade DOT 4 (provided when shipping) – – – Clutch Lever Position No. 1 (to suit rider) 5-way adjustable Clutch Lever Free Play Non-adjustable – – – Clutch Clutch Spring Free Height (VN1500-N1 ∼...
  • Page 258: Clutch Lever

    5-4 CLUTCH Clutch Lever The adjuster has 5 positions so that the clutch lever posi- tion can be adjusted to suit the operator’s hand. Position Adjustment • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder (front view).
  • Page 259: Clutch Fluid

    CLUTCH 5-5 Clutch Fluid Fluid Level Inspection • Hold the reservoir horizontal. • Check that the brake fluid level of the clutch reservoir is between the lower [A] and the upper [B] level lines. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line in the reservoir.
  • Page 260: Clutch Line Bleeding

    5-6 CLUTCH Clutch Fluid • After changing the fluid, check the clutch for good clutch power and no fluid leakage. If necessary, bleed the air from the lines (see Clutch Line Bleeding). • Remove the clear plastic hose. • Install the reservoir cap. •...
  • Page 261: Clutch Master Cylinder

    CLUTCH 5-7 Clutch Master Cylinder Clutch Master Cylinder Removal • Disconnect the starter lockout switch connector [A] (front view). • Draw out the clutch fluid from the reservoir with a means like the fork oil level gauge. • Remove the banjo bolt [A] to disconnect the clutch hose from the master cylinder (rear view).
  • Page 262: Clutch Master Cylinder Disassembly

    5-8 CLUTCH Clutch Master Cylinder Clutch Master Cylinder Disassembly • Remove the master cylinder. • Remove the reservoir cap [A] and diaphragm [B], and pour the clutch fluid into a container. • Unscrew the locknut [C] and pivot bolt [D], and remove the clutch lever [E].
  • Page 263: Clutch Master Cylinder Inspection

    CLUTCH 5-9 Clutch Master Cylinder Clutch Master Cylinder Inspection • Disassemble the clutch master cylinder. • Check that there are no scratches, rust or pitting on the inside of the master cylinder [A] and on the outside of the piston [B]. If the master cylinder or piston shows any damage, re- place them.
  • Page 264: Clutch Slave Cylinder

    5-10 CLUTCH Clutch Slave Cylinder Removal • Remove: Alternator Outer Cover (see Electrical System chapter) Banjo Bolt [A] Clutch Slave Cylinder Bolts [B] Slave Cylinder [C] CAUTION Immediately wash away any clutch fluid that spills. It may damage painted surfaces. •...
  • Page 265: Disassembly

    CLUTCH 5-11 Clutch Slave Cylinder • Tighten the slave cylinder bolts [A]. Torque - Clutch Slave Cylinder Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb) • Replace the washers on each side of the clutch hose fit- ting with new ones. •...
  • Page 266: Clutch Cover Removal

    5-12 CLUTCH Clutch Clutch Cover Removal • Drain the engine oil (see Engine Lubrication System chapter). • Remove: Front Exhaust Pipe [A] (see Engine Top End chapter) Downtube [B] (see Frame chapter, but remove the down- tube with the right footboard and rear master cylinder left installed) •...
  • Page 267: Clutch Installation

    CLUTCH 5-13 Clutch • Take the inner clutch hub [A], collar [B], washer [C] and clutch housing [D] out of the crankcase. • Pull the needle bearing [A], sleeve [B], and thrust washer [C] off the drive shaft. Clutch Installation When replacing any one of the following parts, check the spring plate free play (see Spring Plate Free Play Mea- surement).
  • Page 268: Inner Clutch Hub Disassembly

    5-14 CLUTCH Clutch • Apply grease to the back torque limiter springs [A] and install them on the spring holder [B] as shown. • Install: Clutch Spring Holder Clutch Spring Clutch Spring Plate VN1500-N4 ∼ • Install the clutch spring holder outer [A], clutch spring [B] and convex direction of outside [C] on the spring holder [D].
  • Page 269: Spring Plate Free Play Measurement (Vn1500-N1 ~ N3)

    CLUTCH 5-15 Clutch • Remove: Retaining Ring [A] Spring Holder [B] Damper Spring [C] Spring Holder [D] Spacer [E] Damper Cam [F] Inner Clutch Hub [G] Spring Plate Free Play Measurement (VN1500-N1 ∼ Insufficient spring plate free play will cause the engine braking effect to be more sudden, resulting in rear wheel hop.
  • Page 270: Spring Plate Gap Measurement (Vn1500-N4 ~)

    5-16 CLUTCH Clutch ∼ Spring Plate Gap Measurement (VN1500-N4 Insufficient spring plate gap will cause the engine brak- ing effect to be more sudden, resulting in rear wheel hop. On the other hand, if the spring plate gap is excessive, the clutch may slip or the clutch lever may feel “spongy”...
  • Page 271: Spring Plate Free Play/Gap Adjustment

    CLUTCH 5-17 Clutch • Remove the clutch spring plate. • Peel off these strips with a thin-bladed screwdriver. • Measure the pressed thickness [A] of each strip with vernier calipers. ○ The thickness represents the spring plate gap. Spring Plate Gap Usable Range: 1.95 ∼...
  • Page 272: Friction Or Steel Plate Warp Inspection

    5-18 CLUTCH Clutch Friction or Steel Plate Warp Inspection • Place each friction plate or steel plate on a surface plate, and measure the gap between the surface plate [A] and each friction plate or steel plate [B] with a thickness gauge [C].
  • Page 273: Cam Damper Inspection

    CLUTCH 5-19 Clutch Cam Damper Inspection • Disassemble the clutch (see Clutch Inner Hub Disassem- bly). • Visually inspect the damper cam [A], damper spring [B], and cam follower [C]. Replace any damaged parts.
  • Page 275 ENGINE LUBRICATION SYSTEM 6-1 Engine Lubrication System Table of Contents Engine Oil Flow Chart......................Exploded View........................Specifications ......................... Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Change ....................... Oil Screen Cleaning ......................Oil Pump..........................Removal..........................Installation.........................
  • Page 276: Engine Oil Flow Chart

    6-2 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 277: Engine Lubrication System

    ENGINE LUBRICATION SYSTEM 6-3 Engine Oil Flow Chart 1. Oil Screen 2. Oil Pump 3. Relief Valve 4. Oil Filter 5. Bypass Valve 6. Oil Pressure Switch 7. Inside Oil Pipe 8. Banjo Bolts of Right Crankcase Rear 9. Outside Oil Hoses 10.
  • Page 278: Exploded View

    L: Apply a non-permanent locking agent. els) Lh: Left-hand Threads 9. Oil Nozzle (× 1), left-hand threads R: Replacement Parts T1: 20 N·m (2.0 kgf·m, 14 ft·lb) SS: Apply silicone sealant (Kawasaki Bond: T2: 9.8 N·m (1.0 kgf·m, 87 in·lb) 56019-120).
  • Page 279: Specifications

    340 ∼ 440 kPa (3.5 ∼ 4.5 kgf/cm², 50 ∼ 64 psi) @2 000 r/min (rpm), Oil pressure Oil temp. 100°C (212°F) Special Tools - Filler Cap Driver: 57001-1454 Oil Pressure Gauge, 5 kgf/cm²: 57001-125 Oil Pressure Gauge Adapter, PT 1/8: 57001-1033 Oil Filter Wrench: 57001-1249 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 280: Engine Oil And Oil Filter

    6-6 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. Oil Level Inspection • Situate the motorcycle so that it is vertical.
  • Page 281: Engine Oil Change

    ENGINE LUBRICATION SYSTEM 6-7 Engine Oil and Oil Filter Engine Oil Change • Situate the motorcycle so that it is vertical after warming up the engine. • Remove the engine oil drain bolt [A] and drain the oil. Front [B] ○...
  • Page 282: Oil Filter Change

    6-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter Oil Filter Change • Drain the engine oil. • Remove the oil filter [A] with the oil filter wrench [B]. Front [C] Special Tool - Oil Filter Wrench: 57001-1249 NOTE ○ The filter has an oil filter bypass valve which can not be removed.
  • Page 283: Oil Pump

    ENGINE LUBRICATION SYSTEM 6-9 Oil Pump Removal • Remove the engine (see Engine Removal/Installation chapter). • Split the crankcase (see Crankshaft/Transmission chap- ter). • Remove the oil pump mounting bolts, and take off the pump [A] out of the right crankcase. •...
  • Page 284: Oil Hoses And Pipes

    6-10 ENGINE LUBRICATION SYSTEM Oil Hoses and Pipes Outside Oil Hose Removal • Remove the engine (see Engine Removal/Installation chapter). • Remove: Rocker Case Cover (see Engine Top End chapter) Oil Hose Flange Bolts [A] on Front and Rear Rocker Cases Oil Hose Banjo Bolt [B] on Right Crankcase behind Rear Cylinder...
  • Page 285: Inside Oil Pipe Installation

    ENGINE LUBRICATION SYSTEM 6-11 Oil Hoses and Pipes • Remove: Oil Pipe Clamp Bolt [A] Oil Pipe Holder Bolt [B] • Remove the inside oil pipe [C] and the oili return pipe [D] from the left crankcase [E]. • Remove the speparator [F]. Inside Oil Pipe Installation •...
  • Page 286: Blowby Gas System Inspection

    6-12 ENGINE LUBRICATION SYSTEM Oil Hoses and Pipes • Install the transmission gears, and then the left inside oil pipe [A] in the left crankcase [B]. • Install: Oil Pipe Clamp Bolts [C] Oil Pipe Holder Bolt [D] Oil Nozzle [E] O-ring [F] •...
  • Page 287: Oil Reserve Tank Removal

    ENGINE LUBRICATION SYSTEM 6-13 Oil Hoses and Pipes Oil Reserve Tank Removal (VN1500-N1 ∼ N2 Models) • Remove: Right and Left Ignition Coils (see Electrical System chap- ter) Thermostat Housing and Bracket (see Cooling System chapter) Sensor Holder with Vacuum Sensor and Atmospheric Pressure Sensor Right Air Cleaner Housing (see Fuel System chapter) Oil Reserve Tank Hose End from Right Air Cleaner Base...
  • Page 288: Oil Pressure

    6-14 ENGINE LUBRICATION SYSTEM Oil Pressure Oil Pressure Measurement NOTE ○ Measure the oil pressure after the engine is warmed up. • Remove the oil pressure switch lead and unscrew the oil pressure switch [A]. • Attach the oil pressure gauge [B] and adapter [C] to the switch hole.
  • Page 289 ENGINE LUBRICATION SYSTEM 6-15 Oil Pressure If any rough spots are found during above inspection, wash the valve clean with a high-flash point solvent and blow out any foreign particles that may be in the valve with compressed air in a well-ventilated area. ○...
  • Page 291 ENGINE REMOVAL/INSTALLATION 7-1 Engine Removal/Installation Table of Contents Exploded View........................Specifications ......................... Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 292: Exploded View

    7-2 ENGINE REMOVAL/INSTALLATION Exploded View T1: 44 N·m (4.5 kgf·m, 32 ft·lb) T2: 25 N·m (2.5 kgf·m, 18 ft·lb) WL: Apply a soap and water solution or rubber lubricant.
  • Page 293: Specifications

    ENGINE REMOVAL/INSTALLATION 7-3 Specifications Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398...
  • Page 294: Engine Removal/Installation

    7-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Removal • Support the rear part of the frame on the jack [A], and the attachment jack [C]. Front [B] Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398 • Squeeze the brake lever slowly and hold it with a band [A].
  • Page 295 ENGINE REMOVAL/INSTALLATION 7-5 Engine Removal/Installation • Disconnect: Bands [A] Rear Brake Light Switch Connector [B] Radiator Fan Motor Connector [C] Front [D] • Remove: Radiator (see Cooling System chapter) Front and Rear Shift Pedals (see Crankshaft/Transmis- sion chapter) Alternator Outer Cover (see Electrical System chapter) •...
  • Page 296: Engine Installation

    7-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Support the engine with a commercially available stand [A]. • Remove: Front and Rear Exhaust Pipes (see Engine Top End chapter) Engine Mounting Bracket Bolts [B] Downtube Bolts [C] • Remove the downtube [A] with the right footboard and rear master cylinder installed.
  • Page 297 ENGINE REMOVAL/INSTALLATION 7-7 Engine Removal/Installation • Apply a thin coat of high temperature grease to the driven gear joint and to the propeller shaft joint. • Push on the lockpin [A] and move back the engine to en- gage the front bevel gear joint with the propeller shaft joint.
  • Page 298 7-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Install the removed parts (see appropriate chapters). • Adjust the throttle cables (see Fuel System chapter). • Fill the engine with engine oil (see Engine Lubrication System chapter). • Fill the engine with coolant and bleed the air from the cooling system (see Cooling System chapter).
  • Page 299 CRANKSHAFT/TRANSMISSION 8-1 Crankshaf