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Kawasaki vn 800 classic Service Manual

1996-2006
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  • Page 2: General Information

    Quick Reference Guide General Information Periodic Maintenance Fuel System Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix...
  • Page 3 LIST OF ABBREVIATIONS ampere(s) pounds(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 4: Emission Control Information

    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency. 1. Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere.
  • Page 5 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 6 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 8 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Unit Conversion Table ......................1-16...
  • Page 9: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 10 GENERAL INFORMATION 1-3 Before Servicing (11) Press When using a press or driver to install a part such as a wheel bearing, apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit. (12)Ball Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely necessary.
  • Page 11 1-4 GENERAL INFORMATION Before Servicing (19)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 12: Model Identification

    GENERAL INFORMATION 1-5 Model Identification VN800-B5 Left Side View: VN800-B5 Right Side View:...
  • Page 13 1-6 GENERAL INFORMATION Model Identification VN800-B6 Left Side View: VN800-B6 Right Side View:...
  • Page 14: General Specifications

    GENERAL INFORMATION 1-7 General Specifications VN800-B1 ∼ B4 Items Dimensions Overall Length 2 390 mm (94.1 in.), (CA) (US) (MY) 2 375 mm (93.5 in.) Overall Width 940 mm (37.0 in.), (CA) (US) (MY) 930 mm (36.6 in.) Overall Height 1 125 mm (44.3 in.), (CA) (US) (MY) 1 130 mm (44.5 in.) Wheelbase 1 600 mm (63.0 in.)
  • Page 15 1-8 GENERAL INFORMATION General Specifications VN800-B1 ∼ B4 Items Exhaust Open 69° BBDC Close 31° ATDC Duration 280° Lubrication System Forced lubrication (wet sump) Engine Oil: Grade SE, SF or SG class Viscosity SAE10W-40, 10W-50, 20W-40, 20W-50 Capacity 3.2 L (3.4 US qt) Drive Train Primary Reduction System: Type...
  • Page 16 GENERAL INFORMATION 1-9 General Specifications VN800-B1 ∼ B4 Items Rear Drum Electrical Equipment Battery 12 V 12 Ah Headlight: Type Semi-sealed beam Bulb 12 V 60/55 W (quartz-halogen) Tail/brake Light 12 V 5/21 W × 2, (CA) (US) (MY) 12 V 8/27 W × 2 Alternator: Type Three-phase AC...
  • Page 17 1-10 GENERAL INFORMATION General Specifications VN800-B6 ∼ B7 Items VN800-B5 Dimensions Overall Length 2 380 mm (93.7 in.), (CA) (US) (MY) 2 375 mm (93.5 in.) Overall Width 940 mm (37.0 in.), (CA) (US) (MY) 930 mm (36.6 in.) Overall Height 1 125 mm (44.3 in.), (CA) (US) (MY) 1 130 mm (44.5 in.) Wheelbase 1 600 mm (63.0 in.)
  • Page 18 GENERAL INFORMATION 1-11 General Specifications VN800-B6 ∼ B7 Items VN800-B5 Exhaust Open 69° BBDC Close 31° ATDC Duration 280° Lubrication System Forced lubrication (wet sump) Engine Oil: Grade SE, SF or SG class API SE, SF, or SG, Viscosity SAE 10W-40, 10W-50, 20W-40, API SH or SJ with JASO MA or 20W-50 SAE 10W-40...
  • Page 19 1-12 GENERAL INFORMATION General Specifications VN800-B6 ∼ B7 Items VN800-B5 Brake Type: Front Single disc Rear Drum Electrical Equipment Battery 12 V 12 Ah Headlight: Type Semi-sealed beam Bulb 12 V 60/55 W (quartz-halogen) Tail/brake Light 12 V 5/21 W × 2 12 V 5/21 W ×...
  • Page 20 GENERAL INFORMATION 1-13 General Specifications VN800-B8 ∼, B6F Items Dimensions Overall Length 2 380 mm (93.7 in.), (CA) (US) 2 375 mm (93.5 in.) Overall Width 940 mm (37.0 in.), (CA) (US) 930 mm (36.6 in.) Overall Height 1 125 mm (44.3 in.), (CA) (US) 1 130 mm (44.5 in.) Wheelbase 1 600 mm (63.0 in.) Road Clearance...
  • Page 21 1-14 GENERAL INFORMATION General Specifications VN800-B8 ∼, B6F Items Close 31° ATDC Duration 280° Lubrication System Forced lubrication (wet sump) Engine Oil: Grade API SE, SF, or SG, Viscosity API SH or SJ with JASO MA SAE 10W-40 Capacity 3.2 L (3.4 US qt) Drive Train Primary Reduction System: Type...
  • Page 22 GENERAL INFORMATION 1-15 General Specifications VN800-B8 ∼, B6F Items Electrical Equipment Battery 12 V 12 Ah (VN800-B8 Model) 12 V 10 Ah (VN800-B9 ∼ Model) Headlight: Type Semi-sealed beam Bulb 12 V 60/55 W (quartz-halogen) Tail/brake Light 12 V 5/21 W × 2 Alternator: Type Three-phase AC...
  • Page 23: Unit Conversion Table

    1-16 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 N·m ×...
  • Page 24: Table Of Contents

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart (United Drive Chain Lubrication....2-28 States and Canada)......Brakes..........2-29 Periodic Maintenance Chart (Other Brake Lining or Pad Wear than United States and Canada) ..Inspection........2-29 Torque and Locking Agent....Brake Play Inspection ....
  • Page 25: Periodic Maintenance Chart (United States And Canada)

    2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart (United States and Canada) 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 26 PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart (United States and Canada) FREQUENCY Whichever * ODOMETER READING comes km × 1 000 (mile × 1 000) first OPERATION Every (0.5) (3) (6) (9) (12) (15) (18) Page • • • Swingarm pivot, uni-trak linkage-lubricate P2-37 •...
  • Page 27: Periodic Maintenance Chart (Other Than United States And Canada)

    2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart (Other than United States and Canada) 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 28 PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart (Other than United States and Canada) FREQUENCY Whichever * ODOMETER READING comes km × 1 000 (mile × 1 000) first OPERATION Every (0.6) (4) (7.5) (12) (15) (20) (24) Page Nuts, bolts, and fastener •...
  • Page 29: Torque And Locking Agent

    2-6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: L: Apply a non-permanent locking agent to the threads. MO: Apply molybdenum disulfide oil (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1).
  • Page 30 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Pump Drive Chain Guide Bolt 104 in·lb Oil Filter 69 in·lb Oil Filter Plate Mounting Bolts Oil Screen Plug 14.5 Oil Pressure Relief Valve Oil Pressure Switch Oil Pressure Switch Adapter 14.5 Oil Pipe Mounting Bolts (Crankcase Inside)
  • Page 31 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Rear Sprocket Stud Bolts Brakes Torque Link Nuts Front Caliper Mounting Bolts Brake Disc Mounting Bolts Brake Hose Banjo Bolts Bleed Valve 69 in·lb Rear Brake Lever Clamp Bolt Front Master Cylinder Clamp Bolts 0.90 78 in·lb...
  • Page 32 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Starter Motor Mounting Bolts 95 in·lb Starter Motor Through Bolts 43 in·lb 95 in·lb Starter Motor Terminal Nut Starter Motor Cable Nuts 43 in·lb Side Stand Switch Mounting Bolt 35 in·lb The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts.
  • Page 33: Specifications

    2-10 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System – – – 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play Idle Speed 1 000 ±50 r/min (rpm) (CH, CAL) 1 300 ±50 r/min (rpm) Air Cleaner Element Polyurethane foam Cooling System –...
  • Page 34 PERIODIC MAINTENANCE 2-11 Specifications Item Standard Service Limit Rim Runout (with tire installed) Radial TIR 1.0 mm (0.04 in.) or less TIR 2.0 mm (0.08 in.) Axial TIR 0.8 mm (0.03 in.) or less TIR 2.0 mm (0.08 in.) Final Drive 25 ∼...
  • Page 35: Special Tools

    2-12 PERIODIC MAINTENANCE Special Tools Steering Stem Nut Wrench: Carburetor Drain Plug Wrench, Hex 3: 57001-1100 57001-1269 Jack: Fork Oil Level Gauge: 57001-1238 57001-1290 Oil Filter Wrench: Jack Attachment #3: 57001-1249 57001-1416...
  • Page 36: Maintenance Procedure

    PERIODIC MAINTENANCE 2-13 Maintenance Procedure Fuel System Fuel Hoses and Connections Inspection ○ 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 inside the fuel line can cause fuel to leak [A] or the hose to burst.
  • Page 37: Idle Speed Inspection

    2-14 PERIODIC MAINTENANCE Maintenance Procedure If necessary, adjust the throttle cable as follows. • Loosen the locknuts [A]. • Screw the adjusters [B] in completely so as to give the throttle grip plenty of play. • Turn out the decelerator cable [C] adjuster until there is no play when the throttle grip is completely closed.
  • Page 38: Fuel System Cleanliness Inspection

    PERIODIC MAINTENANCE 2-15 Maintenance Procedure Idle Speed Adjustment • start the engine and warm it up thoroughly. • Turn the adjusting screw [A] until the idle speed is correct. ○ Open and close the throttle a few times to make sure that the idle speed is within the specified range.
  • Page 39: Evaporative Emission Control System Inspection

    2-16 PERIODIC MAINTENANCE Maintenance Procedure Evaporative Emission Control System Inspection • Inspect the California canister as follows: ○ Remove the canister, and disconnect the hoses from the canister. ○ Visually insect the canister for cracks for cracks and other damage. If the canister has any cracks or bad damage, replace it with a new one.
  • Page 40 PERIODIC MAINTENANCE 2-17 Maintenance Procedure • Remove: Meter Unit (see Electrical System chapter) Radiator Cap [A] • Place a container under the drain plug [A] at the bottom of the right crankcase. • Drain the coolant from the radiator and engine by remov- ing the drain plug.
  • Page 41: Engine Top End

    2-18 PERIODIC MAINTENANCE Maintenance Procedure • Bleed the air from the cooling system as follows. ○ Start the engine with the radiator cap removed and run it until no more air bubbles [A] can be seen in the coolant. ○ Tap the water hoses to force any air bubbles caught in- side.
  • Page 42: Valve Clearance Adjustment

    PERIODIC MAINTENANCE 2-19 Maintenance Procedure • Set the rear piston at TDC by turning the crankshaft coun- terclockwise 305° (see Engine Top End chapter). • Using a thickness gauge, measure the valve clearance between the rocker arm and the shim. Valve Clearance Standard: 0.10∼...
  • Page 43 2-20 PERIODIC MAINTENANCE Maintenance Procedure VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.60 mm (0.102 in.) Measured clearance is 0.25 mm (0.010 in.)
  • Page 44 PERIODIC MAINTENANCE 2-21 Maintenance Procedure VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.55 mm (0.100 in.) Measured clearance is 0.50 mm (0.020 in.)
  • Page 45: Clutch

    2-22 PERIODIC MAINTENANCE Maintenance Procedure Clutch Clutch Inspection Clutch Lever Free Play Inspection • Pull the clutch lever just enough to take up the free play [A]. • Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully.
  • Page 46: Engine Lubrication System

    PERIODIC MAINTENANCE 2-23 Maintenance Procedure • Slide the dust cover [A] at the clutch cable lower end out of place. • Loosen both adjusting nuts [B] at the clutch cover as far as they will go. • Pull the clutch outer cable [C] tight and tighten the adjust- ing nuts against the bracket [D].
  • Page 47: Oil Filter Replacement

    2-24 PERIODIC MAINTENANCE Maintenance Procedure Oil Filter Replacement • Drain the engine oil (see Engine Oil Change). • Remove the oil filter [A] with the oil filter wrench [B]. Special Tool - Oil Filter Wrench: 57001-1249 • Replace the filter with a new one. •...
  • Page 48: Spoke Tightness And Rim Runout Inspection

    PERIODIC MAINTENANCE 2-25 Maintenance Procedure Wear Indicator [A] Wear Indicator Position Mark [B] WARNING To ensure safe handling and stability, use only the recommended standard tires for replacement, in- flated to the standard pressure. NOTE ○ Most countries may have their own regulations a mini- mum tire tread depth: be sure to follow them.
  • Page 49: Final Drive

    2-26 PERIODIC MAINTENANCE Maintenance Procedure • Measure the axial [A] and radial [B] rim runout with a dial gauge. If rim runout exceeds the service limit, check the hub bearings first. Replace them if they are damaged. If the problem is not due to the bearings, correct the rim warp (runout).
  • Page 50: Drive Chain Wear Inspection

    PERIODIC MAINTENANCE 2-27 Maintenance Procedure Drive Chain Slack Adjustment • Remove: Muffler (see Engine Top End chapter) Clip [A] • Loosen: Rear Torque Link Nut [B] Axle Nut [C] Chain Adjuster Locknuts [D] (both sides) • Turn the chain adjusting nuts [E] forward or rearward until the drive chain has the correct amount of chain slack.
  • Page 51: Drive Chain Lubrication

    2-28 PERIODIC MAINTENANCE Maintenance Procedure WARNING If the drive chain wear exceeds the service limit, re- place the chain or an unsafe riding condition may result. A chain that breaks or jumps off the sprock- ets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control.
  • Page 52: Brakes

    PERIODIC MAINTENANCE 2-29 Maintenance Procedure Brakes Brake Lining or Pad Wear Inspection • Remove the brake shoes (see Brake Panel Disassembly). • Measure the lining thickness [A]. ○ Use a calipers or scale, and measure at several points as shown. If any measurement is less than the service limit, replace both shoes as a set.
  • Page 53: Brake Play Inspection

    2-30 PERIODIC MAINTENANCE Maintenance Procedure Brake Play Inspection Brake Pedal Position Inspection • Check that the brake pedal [A] is in the correct position. [B] Footpeg Pedal Position [C] Standard: About 65 mm (2.6 in.) above footpeg top If it is incorrect, adjust the brake pedal position. Brake Pedal Position Adjustment •...
  • Page 54: Brake Light Switch Inspection

    PERIODIC MAINTENANCE 2-31 Maintenance Procedure Brake Light Switch Inspection • Turn on the ignition switch. • Check the operation of the rear brake light switch by de- pressing the brake pedal. If it does not as specified, adjust the brake light timing. Brake Light Timing Standard: On after about 15 mm (0.6 in.) of pedal...
  • Page 55: Brake Fluid Change

    2-32 PERIODIC MAINTENANCE Maintenance Procedure Brake Fluid Change NOTE ○ The procedure to change the front brake fluid is as fol- lows. • Level the brake fluid reservoir. • Remove the reservoir cap. • Remove the rubber cap from the bleed valve [A] on the caliper.
  • Page 56 PERIODIC MAINTENANCE 2-33 Maintenance Procedure NOTE ○ The procedure to bleed the front brake line is as follows. • Remove the reservoir cap, and fill the reservoir with fresh brake fluid to the upper level line in the reservoir. • With the reservoir cap off, slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reser-...
  • Page 57: Brake Master Cylinder Cup And Dust Cover Replacement

    2-34 PERIODIC MAINTENANCE Maintenance Procedure WARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3.
  • Page 58: Brake Hoses And Connections Inspection

    PERIODIC MAINTENANCE 2-35 Maintenance Procedure Brake Hoses and Connections Inspection • Inspect the brake hose and fittings for deterioration, cracks and signs of leakage. ○ The high pressure inside the brake line can cause fluid to leak [A] or the hose to burst if the line is not properly main- tained.
  • Page 59: Front Fork Oil Leak Inspection

    2-36 PERIODIC MAINTENANCE Maintenance Procedure • Wait for about five minutes so that any suspended air bub- bles can surface. • Measure the oil level, using the fork oil level gauge [A]. Special Tool - Fork Oil level Gauge: 57001-1290 ○...
  • Page 60: Swingarm Pivot Lubrication

    PERIODIC MAINTENANCE 2-37 Maintenance Procedure Swingarm Pivot Lubrication • Apply grease to the inner surface of the needle bearings in accordance with the Periodic Maintenance Chart. • Apply a thin coat of grease to the lips of the grease seals. Uni-trak Linkage Lubrication •...
  • Page 61: Steering Stem Bearing Lubrication

    2-38 PERIODIC MAINTENANCE Maintenance Procedure • Loosen: Steering Stem Locknut [A]. • Adjust the steering. Special Tool - Steering Stem Nut Wrench: 57001-1100 [B] If the steering too tight, loosen the stem nut [C] a fraction of a turn. If the steering too loose, tighten the stem nut a fraction of a turn.
  • Page 62: Spark Plug Gap Inspection

    PERIODIC MAINTENANCE 2-39 Maintenance Procedure Spark Plug Gap Inspection • Measure the gap [A] with a wire-type thickness gauge. If the gap is incorrect, carefully bend the side electrode [B] with a suitable tool to obtain the correct gap. 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.) Spark Plug Gap: General Lubrication Lubrication...
  • Page 63: Nut, Bolts, And Fasteners Tightness Inspection

    2-40 PERIODIC MAINTENANCE Maintenance Procedure • With the cable disconnected at both ends, the cable should move freely [A] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable.
  • Page 64 PERIODIC MAINTENANCE 2-41 Maintenance Procedure Steering: Steering Stem Head Bolt Handlebar Holder Bolts Handlebar Holder Mounting Nut Engine: Engine Mounting Bolts Engine Mounting Bracket Bolts Muffler Mounting Bolts Exhaust Pipe Holder Nuts Muffler Connecting Clamp Bolt Clutch Lever Pivot Nut Clutch Lever Holder Clamp Bolt Others: Side Stand Pivot Nut...
  • Page 66 FUEL SYSTEM 3-1 Fuel System Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Throttle Grip and Cables ......................Throttle Grip Free Play Inspection ..................Throttle Grip Free Play Adjustment................... Throttle Cable Installation ....................Throttle Cable Lubrication and Inspection ................ Choke Cable...........................
  • Page 67: Exploded View

    3-2 FUEL SYSTEM Exploded View...
  • Page 68 FUEL SYSTEM 3-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Cleaner Element Cover Mounting Nut 52 in·lb Air Cleaner Housing Mounting Bolts 95 in·lb Carburetor holder Plate Mounting Bolts 95 in·lb 4. Air Cleaner Case (California Model) 5. Clamps (California Model) 6.
  • Page 69 3-4 FUEL SYSTEM Exploded View...
  • Page 70 FUEL SYSTEM 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Tap Mounting Bolts 0.25 22 in·lb with white washer Fuel Tap Mounting Bolts 0.50 43 in·lb with black washer 2. Fuel Tank Cap Seal (California Model) 3. Drain Hose (On and after VN800-B7, Other than California Model) 4.
  • Page 71: Specifications

    3-6 FUEL SYSTEM Specifications Item Standard Service Limit Carburetor Make, Type Keihin, CVK36 – – – Idle speed 1000 ±50 r/min (rpm) – – – (CH) (CAL) 1300 ±50 r/min (rpm) Main Jet #135 – – – Main Air Jet –...
  • Page 72: Special Tools

    FUEL SYSTEM 3-7 Special Tools Fuel Level Gauge: Carburetor Drain Plug Wrench, Hex 3: 57001-1017 57001-1269 Pilot Screw Adjuster, A: 57001-1239...
  • Page 73: Throttle Grip And Cables

    3-8 FUEL SYSTEM Throttle Grip and Cables Throttle Grip Free Play Inspection • Refer to the Throttle Grip Play Inspection in the Periodic Maintenance chapter. Throttle Grip Free Play Adjustment • Refer to the Throttle Grip Play Inspection in the Periodic Maintenance chapter.
  • Page 74: Choke Cable

    FUEL SYSTEM 3-9 Choke Cable Choke Free Play Inspection • Check that the choke inner cable slides smoothly by mov- ing the choke knob [A] to the push and pull. If there is any irregularity, replace the choke cable. Choke Cable Installation •...
  • Page 75: Carburetor

    3-10 FUEL SYSTEM Carburetor Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter. Idle Speed Adjustment • Refer to the Idle Speed Adjustment in the Periodic Main- tenance chapter. Service Fuel Level Inspection WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions.
  • Page 76: Service Fuel Level Adjustment

    FUEL SYSTEM 3-11 Carburetor Service Fuel Level Adjustment WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 77: Pilot Screw Setting

    3-12 FUEL SYSTEM Carburetor Pilot Screw Setting ○ The pilot screw [A] is set at the factory and should not be adjusted. But if necessary set the pilot screw as follows. • Turn in the pilot screw and count the number of turns until it seat fully but not tightly.
  • Page 78: Carburetor Installation

    FUEL SYSTEM 3-13 Carburetor Choke Cable [A] • Loosen the carburetor clamp screw [B]. • Remove the throttle cable ends from the handlebar switch side. • Remove the carburetor [C]. • Stuff piece of lint-free, clean cloth into the carburetor holder to keep dirt out of the engine.
  • Page 79: Carburetor Disassembly

    3-14 FUEL SYSTEM Carburetor WARNING Fuel spilled from the carburetors is hazardous. • Adjust the following items if necessary. Idle Speed Throttle Cables Carburetor Disassembly • Remove the carburetor (see Carburetor Removal). WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions.
  • Page 80: Carburetor Cleaning

    FUEL SYSTEM 3-15 Carburetor • Turn the carburetor body upside-down, and drop the nee- dle jet [A] into place so that the smaller diameter end [B] of the jet goes in first. • Carefully screw in the needle jet holder [C]. It will seat against the needle jet, pushing the end of the jet into the carburetor bore.
  • Page 81: Carburetor Inspection

    3-16 FUEL SYSTEM Carburetor CAUTION Do not use compressed air on an assembled carbu- retor, or the float may be crushed by the pressure, and the vacuum piston diaphragms may be dam- aged. Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carbure- tor with a cleaning solution.
  • Page 82 FUEL SYSTEM 3-17 Carburetor • Disassemble the carburetor. • Clean the carburetor. • Check that the O-rings on the float bowl and pilot screw and the diaphragm on the vacuum piston are in good con- dition. If any of the O-rings or diaphragms are not in good con- dition, replace them.
  • Page 83: Air Cleaner

    3-18 FUEL SYSTEM Air Cleaner Element Removal • Remove: Nut [A] and Washer Air Cleaner Cover [B] Element [A] • Push a clean, lint-free towel into the carburetor intake to keep dirt or other foreign material from entering. WARNING If dirt or dust is allowed to pass through into the carburetors, the throttle may become stuck, possi- bly causing an accident.
  • Page 84: Air Cleaner Housing Installation

    FUEL SYSTEM 3-19 Air Cleaner • Remove the air cleaner housing [A] from the carburetor [B]. • Disconnect the engine breather hose [C], vacuum switch valve hose [D] and drain hose [E]. Evaporative Emission Hose [F] (for California Model) Air Cleaner Housing Installation •...
  • Page 85: Fuel Tank

    3-20 FUEL SYSTEM Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 86: Fuel Tank Inspection

    FUEL SYSTEM 3-21 Fuel Tank Fuel Tank Inspection • Remove the fuel tank and drain it. • Check to see if the breather pipe [A] (also the fuel return pipe for the California model) in the tank is not clogged. Check the tank cap breather also.
  • Page 87: Fuel Tap Installation

    3-22 FUEL SYSTEM Fuel Tank Fuel Tap Installation • Be sure the O-rings [A] is in good condition to prevent leaks. • Be sure the nylon flat washers [B] are in good condition to prevent leaks. ○ Do not use steel washers in place of the nylon flat wash- ers, because they will not seal the bolts properly and fuel will leak.
  • Page 88: Evaporative Emission Control System (California Model Only)

    FUEL SYSTEM 3-23 Evaporative Emission Control System (California Model Only) The Evaporative Emission Control System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart.
  • Page 89: Separator Operation Test

    3-24 FUEL SYSTEM Evaporative Emission Control System (California Model Only) Separator Operation Test WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 90 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Coolant Flow Chart......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Reserve Tank Removal..................... Water Pump..........................4-10 Water Pump Impeller Removal ..................
  • Page 91: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 92 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Water Pump Impeller Nut 95 in·lb Water Hose Fitting Bolts 95 in·lb 17 in·lb Radiator Hose Clamp Screws Radiator Fan Switch Water Temperature Sensor 69 in·lb Coolant Drain Plug 95 in·lb G: Apply grease.
  • Page 93: Specifications

    4-4 COOLING SYSTEM Specifications Item Standard Service Limit Coolant provided when shipping Type Permanent type of antifreeze (soft water – – – and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green – – – Mixed Ratio Soft water 50%, coolant 50% –...
  • Page 94: Special Tools

    COOLING SYSTEM 4-5 Special Tools Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 95: Coolant Flow Chart

    4-6 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 with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
  • Page 96: Coolant Flow Chart

    COOLING SYSTEM 4-7 Coolant Flow Chart 1. Radiator 5. Water Pump Impeller 2. Fan Switch 6. To Crankcase 3. Water Temperature Sensor 7. From Rear Cylinder Head 4. Right Engine Cover 8. From Front Cylinder Head 9. Thermostat When the engine is cold, the thermostat is closed so that the coolant flow is restricted through the air bleeder hole, causing the engine to warm up more quickly.
  • Page 97: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Visually inspect the coolant 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. In either case, flush the cooling system.
  • Page 98: Pressure Testing

    COOLING SYSTEM 4-9 Coolant Pressure Testing • Remove the meter unit (see Electrical System chapter). • Remove the radiator cap, and install a cooling system pressure tester [A] on the filler neck. NOTE ○ Wet the cap sealing surfaces with water or coolant to prevent pressure leaks.
  • Page 99: Water Pump

    4-10 COOLING SYSTEM Water Pump Water Pump Impeller Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) Coolant (see Coolant Draining in the Periodic Mainte- nance chapter) • Remove: Right Engine Cover (see Clutch chapter) Nut [A] Impeller [B] Water Pump Impeller Installation...
  • Page 100: Water Pump Inspection

    COOLING SYSTEM 4-11 Water Pump Water Pump Inspection • Check the drainage outlet passage [A] at the bottom of the right crankcase for coolant leaks. If the mechanical seal is damaged, the coolant leaks through the seal and drains through the passage. Re- place the mechanical seal with a new one.
  • Page 101: Radiator, Radiator Fan

    4-12 COOLING SYSTEM Radiator, Radiator Fan Radiator and Radiator Fan Removal 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.
  • Page 102: Radiator Fan Installation

    COOLING SYSTEM 4-13 Radiator, Radiator Fan Radiator Fan Installation • Be sure to attach the ground lead [A] to the fan mounting bolt [B]. 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.
  • Page 103 4-14 COOLING SYSTEM Radiator, Radiator Fan • Watching the pressure gauge, pump the pressure tester to build up the pressure until the relief valve opens: the gauge hand flicks downward. Stop pumping and measure leak time at once. The relief valve must open within the specified range in the table below and the gauge hand must remain within the same range at least 6 seconds.
  • Page 104: Thermostat

    COOLING SYSTEM 4-15 Thermostat Thermostat Removal • Remove: Coolant (see Coolant Draining in the Periodic Mainte- nance chapter) Seat (see Frame chapter) Fuel Tank (see Fuel System chapter) Thermostat Housing Cover Bolts [A] Thermostat Housing Cover [B] Thermostat Thermostat Installation •...
  • Page 105: Hose And Pipes

    4-16 COOLING SYSTEM Hose and Pipes Hose Installation • Install the hoses and pipes being careful to follow bend- ing direction or diameter. Avoid sharp bending, kinking, flattening, or twisting. • Install the clamps [A] as near as possible to the hose end to clear the raised rib or the fitting.
  • Page 106: Radiator Fan Switch, Water Temperature Sensor

    • Apply silicone sealant to the threads of the fan switch and water temperature sensor. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Tighten the fan switch and water temperature sensor. Torque - Radiator Fan Switch: 18 N·m (1.8 kgf·m, 13.0 ft·lb) Water Temperature Sensor: 7.8 N·m (0.80 kgf·m,...
  • Page 108 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Cylinder Head Removal ....5-21 Specifications ........Cylinder Head Installation .... 5-21 Special Tools ........Cylinder Head Assembly....5-22 Clean Air System....... 5-10 Cylinder Head Warp Inspection ... 5-23 Air Suction Valve Removal...
  • Page 109: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 110 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cylinder Head Cover Bolts 104 in·lb Cylinder Head Nuts (10 mm) Cylinder Head Nuts (8 mm) 18.0 Cylinder Head Bolts 104 in·lb Cylinder Nuts 18.0 Camshaft Cap Bolt 18.0 Intake Manifold Bolts 104 in·lb...
  • Page 111 5-4 ENGINE TOP END Exploded View...
  • Page 112 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Camshaft Sprocket Bolts Camshaft Chain Tensioner Cap Bolts 14.5 Camshaft Chain Guide Bolts 95 in·lb 4. Rocker Arm Spring (Intake), (Red Paint mark) 5. Exhaust Pipe Holder Nuts 6.
  • Page 113: Specifications

    5-6 ENGINE TOP END Specifications Item Standard Service Limit Clean Air System Open → Close Vacuum Switch Valve Closing Pressure 57 ∼ 65 kPa (430 ∼ 490 mmHg) – – – Camshafts Cam Height: 35.305 ∼ 35.413 mm (1.3900 ∼ 1.3942 in.) 35.21 mm (1.386 in.) Inlet 35.033 ∼...
  • Page 114 ENGINE TOP END 5-7 Specifications Item Standard Service Limit 0.010 ∼ 0.037 mm (0.0004 ∼ 0.0015 in.) Piston/Cylinder Clearance – – – Oversize Pistons and Rings +0.5 mm (0.02 in.) – – – Piston Ring/Groove Clearance: 0.03 ∼ 0.07 mm (0.001 ∼ 0.003 in.) 0.17 mm (0.007 in.) 0.02 ∼...
  • Page 115 5-8 ENGINE TOP END Special Tools Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 60° - 30: 57001-221 57001-1123 Valve Spring Compressor Assembly: Valve Seat Cutter Holder Bar: 57001-241 57001-1128 Piston Pin Puller Assembly: Valve Seat Cutter, 45° - 30: 57001-910 57001-1187 Valve Seat Cutter, 45°...
  • Page 116 ENGINE TOP END 5-9 Special Tools Valve Guide Arbor, 5: Fork Oil Level Gauge: 57001-1203 57001-1290 Valve Guide Reamer, 5: Compression Gauge Adapter, M10 × 1.0: 57001-1204 57001-1317 Valve Seat Cutter Holder, 5: Valve Seat Cutter, 60° - 33: 57001-1208 57001-1334 Spark Plug Wrench, Hex 16: Vacuum Gauge KEK-55-5:...
  • Page 117: Air Suction Valve Removal

    5-10 ENGINE TOP END Clean Air System Air Suction Valve Removal • Refer: Cylinder Head Cover Removal Air Suction Valve Installation • Refer: Cylinder Head Cover Installation Air Suction Valve Inspection • Refer to the Air Suction Valve Inspection in the Periodic Maintenance chapter.
  • Page 118: Clean Air System Hose Inspection

    ENGINE TOP END 5-11 Clean Air System If the vacuum switch valve does not operate as described, replace it with a new one. NOTE ○ To check air flow through the vacuum switch valve, just blow through the air cleaner hose. Vacuum Switch Valve Closing Pressure (Open →...
  • Page 119: Cylinder Head Cover

    5-12 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal • Remove: Seat (see Frame chapter) Fuel Tank (see Fuel System chapter) (1) For Front Head Cover • Remove: Air Cleaner Housing (see Fuel System chapter) Spark Plug Cap [A] Vacuum Switch Valve Hose [B] Cover Bolts [C] Cylinder Head Cover [A]...
  • Page 120: Cylinder Head Cover Installation

    ENGINE TOP END 5-13 Cylinder Head Cover • Remove: Cylinder Head Cover [A] Air Suction Valve Head Cover Gasket Cylinder Head Cover Installation • If the plug pipe [A] was removed, install it with the cham- fered side [B] faces upward, and apply grease to the O -ring [C].
  • Page 121: Camshaft Chain Tensioner

    5-14 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal • Remove: Engine (see Engine Removal/installation chapter) Camshaft (see Camshaft Removal) Cylinder Head (see Cylinder Head Removal) • Remove the camshaft chain tensioner body from the cylinder. Camshaft Chain Tensioner Installation •...
  • Page 122: Camshaft, Camshaft Chain

    ENGINE TOP END 5-15 Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Tensioner Cap Bolt [A], Washer [B] and Spring CAUTION Do not turn over the crankshaft while the tensioner cap bolt is removed, The tensioner body is loose from the cylinder while the cap bolt is removed.
  • Page 123: Camshaft Installation

    5-16 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Installation • Apply engine oil to all cam parts and journals. NOTE ○ The front and rear camshafts are different. The rear camshaft [A] has a groove [B]. • Set the front piston at TDC. ○...
  • Page 124: Camshaft, Camshaft Cap Wear Inspection

    ENGINE TOP END 5-17 Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear Inspection • Measure each clearance between the camshaft journal and the camshaft cap using plastigage (press gauge) [A]. • Tighten: Torque - Camshaft Cap Bolts: 25 N·m (2.5 kgf·m, 18.0 ft·lb) NOTE ○...
  • Page 125: Camshaft Chain Removal

    5-18 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Chain Removal Front Camshaft Chain • Remove: Alternator Rotor (see Electrical System chapter) Bolts [A] and Black Chain Guide [B] Bolt [C], Washer [D] and White Chain Guide [E] • Disengage the camshaft chain [F] from the crankshaft sprocket and then remove the chain.
  • Page 126: Rocker Shaft, Rocker Arm

    ENGINE TOP END 5-19 Rocker Shaft, Rocker Arm Rocker Shaft, Rocker Arm Removal • Remove: Cylinder Head Cover (cylinder Head Cover Removal) Camshaft Cap Rocker Shafts [A] Rocker Arms [B] and Springs [C] Rocker Shaft, Rocker Arm Installation • Apply molybdenum disulfide grease to the rocker shaft. •...
  • Page 127: Cylinder Head

    5-20 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Seat (see Frame chapter) Fuel Tank (see Fuel System chapter) Spark Plugs Special Tool - Spark Plug Wrench, Hex 16: 57001-1262 •...
  • Page 128: Cylinder Head Removal

    ENGINE TOP END 5-21 Cylinder Head Cylinder Head Removal • Remove: Engine (see Engine Removal/Installation) Camshaft (see Camshaft Removal) Bolts [A] and Intake Manifold [B] 8 mm Cylinder Head Nuts [A] Cylinder Head Bolt [A] Cylinder Head Nuts [B] 10 mm Cylinder Head Nuts [C] Cylinder Head Cylinder Head Installation NOTE...
  • Page 129: Cylinder Head Assembly

    5-22 ENGINE TOP END Cylinder Head • Tighten the cylinder head nuts and bolt following the tight- ening sequence [1 ∼ 7]. Torque - Cylinder Head Nuts: 10 mm [1 ∼ 4]: 39 N·m (4.0 kgf·m, 29 ft·lb) 8 mm [5 ∼ 6]: 25 N·m (2.5 kgf·m, 18 ft·lb) Cylinder Head Bolt [7]: 12 N·m (1.2 kgf·m, 104 in·lb) Tighten the 8 mm cylinder head nuts.
  • Page 130: Cylinder Head Warp Inspection

    ENGINE TOP END 5-23 Cylinder Head Rear Cylinder Head [A] Rubber Dampers (17) [B] 40 mm (1.57 in.) [C] 38 mm (1.50 in.) [D] 36 mm (1.42 in.) • When installing the breather pipe fitting [A] in the rear cylinder head, align the fitting with the mark [B]. [C] Fitting Hose [D] 37 ∼...
  • Page 131: Valves

    5-24 ENGINE TOP END Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment • Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). •...
  • Page 132: Valve Guide Installation

    ENGINE TOP END 5-25 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 133: Valve Seat Inspection

    5-26 ENGINE TOP END 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.
  • Page 134 ENGINE TOP END 5-27 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 135 5-28 ENGINE TOP END Valves • Measure the outside diameter (O.D.) of the seating sur- face with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind [A] until the diameter is within the specified range.
  • Page 136 ENGINE TOP END 5-29 Valves • Lap the valve to the seat, once the seat width and O.D. 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 137 5-30 ENGINE TOP END Valves...
  • Page 138: Cylinder, Pistons

    ENGINE TOP END 5-31 Cylinder, Pistons Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Cylinder Nut [A] Cylinder Cylinder Installation NOTE ○ If a new cylinder is used, check piston to cylinder clear- ance (see Piston/Cylinder Clearance), and use new pis- ton ring.
  • Page 139: Piston Installation

    5-32 ENGINE TOP END Cylinder, Pistons • Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove • Remove the 3-piece oil ring with your thumbs in the same manner.
  • Page 140: Cylinder Wear Inspection

    ENGINE TOP END 5-33 Cylinder, Pistons Cylinder Wear Inspection • Since there is a difference in cylinder wear in different di- rections, take a side-to-side and a front-to-back measure- ment at each of the 3 locations (total of 6 measurements) shown in the figure.
  • Page 141: Piston Ring, Piston Ring Groove Wear Inspection

    5-34 ENGINE TOP END Cylinder, Pistons ○ Cylinder inside diameter must not vary more than 0.01 mm (0.0004 in.) at any point. ○ Be wary of measurements taken immediately after boring since the heat affects cylinder diameter. ○ In the case of rebored cylinder and oversize piston, the service limit for the cylinder is the diameter that the cylin- der was bored to plus 0.1 mm (0.004 in.) and the service limit for the piston is the oversize piston original diameter...
  • Page 142: Piston Ring Thickness Inspection

    ENGINE TOP END 5-35 Cylinder, Pistons Piston Ring Thickness Inspection • Measure the piston ring thickness. ○ Use a micrometer to measure at several points around the ring. Piston Ring Thickness Standard: Top and Second 0.97 ∼ 0.99 mm 0.0382 ∼ 0.0390 in.) Service Limit: Top and Second 0.90 mm 0.035 in.) If any of the measurements is less than the service limit...
  • Page 143: Muffler

    5-36 ENGINE TOP END Muffler Muffler Removal Front Muffler • Remove: Clamp Bolts [A] and Front Exhaust Pipe Cover [B] • Remove the exhaust pipe holder nuts [A] • Remove: Muffler Bolts [A] Clamp Bolts [B] Front Muffler [C] Rear Muffler •...
  • Page 144: Muffler Cover Removal

    ENGINE TOP END 5-37 Muffler • When the front muffler [A] shall be connected to the rear muffler [B], the position of clamp bolt head [C] faces out- wards as shown. Muffler Cover Removal • Remove the muffler cover [A] from the muffler as follows: ○...
  • Page 146 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tool ..........................Clutch Lever and Cable ......................Lever Free Play Inspection ....................Lever Free Play Adjustment....................Cable Removal ......................... Cable Installation ......................Cable Lubrication ......................Clutch Lever Installation....................Right Engine Cover ........................ Right Engine Cover Removal....................
  • Page 147: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 148 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Right Engine Cover Bolts 104 in·lb L (1) Clutch Hub Nut 13.5 Clutch Spring Bolts 78 in·lb 4. Clutch Lever Pivot Nut 5. Clutch Lever Holder Clamp Bolt CL: Apply Cable Lubricant. G: Apply grease.
  • Page 149: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit Clutch 2.9 ∼ 3.1 mm (0.114 ∼ 0.122 in.) Friction Plate Thickness 2.8 mm (0.11 in.) Friction and Steel Plate Warp 0.2 mm (0.008 in.) or less 0.3 mm (0.012 in.) Clutch Spring Free Length: 34.2 mm (1.35 in.) 33.1 mm (1.30 in.) (On and after VN800-B7)
  • Page 150: Special Tool

    CLUTCH 6-5 Special Tool Clutch Holder: 57001-1243...
  • Page 151: Clutch Lever And Cable

    6-6 CLUTCH Clutch Lever and Cable Lever Free Play Inspection • Refer to the Clutch Inspection in the Periodic Mainte- nance chapter. Lever Free Play Adjustment • Refer to the Clutch Inspection in the Periodic Mainte- nance chapter. Cable Removal •...
  • Page 152: Right Engine Cover

    CLUTCH 6-7 Right Engine Cover Right Engine Cover Removal • Remove: Engine Oil (drain, see Engine Lubrication System chap- ter) Coolant (drain, see Cooling System chapter) Front Right Foot Peg and Brake Pedal (see Brakes chapter) Front Muffler (see Engine Top End chapter) Clutch Cable Down Tube (see Frame chapter) Coolant Hose [A]...
  • Page 153: Release Shaft Installation

    6-8 CLUTCH Right Engine Cover Release Shaft Installation • Apply high-temperature grease to the oil seal lips on the lower ridge of the clutch cover. • Apply oil to the bearing in the hole of the right engine cover. • Insert the release shaft straight into the lower hole of the right engine cover.
  • Page 154: Clutch Removal

    CLUTCH 6-9 Clutch Clutch Removal • Remove: Right Engine Cover (see Right Engine Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with thrust bearing and pusher [C]) Friction Plates, Steel Plates Clutch Hub Nut [A] ○ Holding the clutch hub [B], remove the nut.
  • Page 155: Clutch Plate, Wear, Damage Inspection

    6-10 CLUTCH Clutch ○ Install the thrust spacer [A] so that the stepped side [B] faces inward. ○ Replace the clutch hub nut with a new one. ○ Apply oil to the threads and seating surface of the hub nut. ○...
  • Page 156: Clutch Spring Free Length Measurement

    CLUTCH 6-11 Clutch Clutch Spring Free Length Measurement • Measure the free length of the clutch springs [A]. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 34.2 mm (1.35 in.) Service Limit: 33.1 mm (1.30 in.) On and after VN800-B7 Model...
  • Page 158 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tool ..........................Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Change ....................... Oil Screen Cleaning ......................Oil Pressure Relief Valve......................
  • Page 159: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 160 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Drain Plug 14.5 Oil Pump Mounting Bolts 97 in·lb Oil Pump Drive Chain Guide Bolt 104 in·lb Oil Filter Oil Filter Plate Mounting Bolts 69 in·lb Oil Screen Plug 14.5 Oil Pressure Relief Valve Oil Pressure Switch...
  • Page 161: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 1. Left Crankcase 10. Relief Valve 2. Right Crankcase 11. Output Shaft 3. Oil Screen Plug 12. Drive Shaft 4. Oil Screen 13. Front Cylinder Head 5. Oil Pump 14. Rear Cylinder Head 6.
  • Page 162: Specifications

    ENGINE LUBRICATION SYSTEM 7-5 Specifications Item Standard Service Limit Engine Oil Type SE, SF or SG class – – – (On and after VN800-B6) API SE,SF,or SG – – – API SH or SJ with JASO MA – – – Viscosity SAE 10W-40, 10W-50, 20W-40, or 20W-50 –...
  • Page 163: Special Tool

    7-6 ENGINE LUBRICATION SYSTEM Special Tool Oil Pressure Gauge, 10 kgf/cm²: Oil Filter Wrench: 57001-164 57001-1249 Oil Pressure Gauge Adapter, PT 1/8: Kawasaki Bond (Silicone Sealant): 57001-1033 56019-120...
  • Page 164: Engine Oil And Oil Filter

    ENGINE LUBRICATION SYSTEM 7-7 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 • Check that the engine oil level is between the upper [A] and lower [B] level lines next to the gauge [C].
  • Page 165 7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter • Pull out the oil screen [A]. • Clean the screen with high flash-point solvent. WARNING Clean the screen in a well-ventilated area, and take care that there is no spark or frame anywhere near the working area.
  • Page 166: Oil Pressure Relief Valve

    ENGINE LUBRICATION SYSTEM 7-9 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal/Installation • Split the crankcase (see Crankshaft/Transmission chap- ter). • Remove the relief valve [A] from the right crankcase. • Apply a non-permanent locking agent to the threads of the relief valve, and tighten it.
  • Page 167: Oil Pump, Oil Pump Drive Chain

    7-10 ENGINE LUBRICATION SYSTEM Oil Pump, Oil Pump Drive Chain Oil Pump Removal • Split the crankcase (see Crankshaft/Transmission chap- ter). • Remove: Crankshaft Circlip [A] • Remove the sprocket [B] and balancer shaft [C] along with the oil pump chain [D]. •...
  • Page 168: Oil Pressure Measurement

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pressure Measurement Oil Pressure Measurement • Remove the oil pressure switch (see Oil Pressure Switch Removal) without draining the engine oil. • Install the gauge and adapter. Special Tool - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, PT 1/8: 57001 -1033 [B] •...
  • Page 169: Oil Pressure Switch

    Oil Pressure Switch [C] Oil Pressure Switch Installation • Apply silicone sealant to the threads of the oil pressure switch, and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Oil Pressure Switch: 15 N·m ( 1.5 kgf·m, 11.0 ft·lb)
  • Page 170: Oil Pipe

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pipe Oil Pipe (Crankcase Outside) Removal • Remove: Alternator Cover (see Electrical System chapter) Oil Pipe Mounting Bolts [A] Oil Pipe [B] Oil Pipe (Crankcase Outside) Installation • Apply grease to the O-rings [A]. • Apply a non-permanent locking agent to the threads of the mounting bolts, and tighten them.
  • Page 171: Oil Pipe (Crankcase Inside) Removal

    7-14 ENGINE LUBRICATION SYSTEM Oil Pipe Oil Pipe (Crankcase Inside) Removal • Split the crankcase (see Crankshaft/Transmission chap- ter). • Remove: Oil Pipe Mounting Bolts [A] Oil Pipes [B] Oil Pipe (Crankcase Inside) Installation • Apply grease to the O-rings [A]. •...
  • Page 172 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tool ..........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 173: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 174 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Mounting Nuts Engine Mounting Bracket Bolts Down Tube Mounting Bolts...
  • Page 175: Special Tool

    8-4 ENGINE REMOVAL/INSTALLATION Special Tool Jack: Jack Attachment #3: 57001-1238 57001-1416...
  • Page 176: Engine Removal/Installation

    ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal • Remove: Engine Oil (drain, see Engine Lubrication System in the Periodic Maintenance chapter) Coolant (drain, see Cooling System in the Periodic Main- tenance chapter) Seat (see Frame chapter) Fuel Tank (see Fuel System chapter) Left and Right Side Cover (see Frame chapter) Muffler (see Engine Top End chapter) Front Right Foot Peg and Brake Petal (see Brakes chap-...
  • Page 177: Engine Removal

    8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Support the frame with the jack. Special Tool - Jack: 57001-1238 Jack Attachment #3: 57001-1416 • Squeeze the brake lever slowly and hold it with a band [A]. WARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over.
  • Page 178 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........Primary Gear ........9-22 Specifications ........Primary Gear Removal ....9-22 Special Tool ........Primary Gear Installation ..... 9-22 Crankcase Splitting......Transmission ........9-23 Crankcase Splitting ...... Shift Pedal Removal ....9-23 Crankcase Assembly ....
  • Page 179: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 180 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Crankcase Bolts (6 mm) 95 in·lb Crankcase Bolts (10 mm) Connecting Rod Big End Cap Nuts Primary Gear Bolt Balancer Gear Bolt Starter Motor Clutch Gear Bolt Starter Motor Clutch Bolts Output Shaft Bearing Stopper Bolts 104 in·lb Balancer Shaft Bearing Stopper Bolts...
  • Page 181 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 182 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Shift Drum Cam Holder Screw 104 in·lb Shift Drum Bearing Stopper Bolts 95 in·lb Neutral Switch Shift Pedal Pivot Bolt Shift Pedal Pivot Bolt Nut Shift Lever Clamp Bolt 104 in·lb Shift Shaft Return Spring Pin Shift Drum Position Lever Bolt 95 in·lb...
  • Page 183: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods 0.16 ∼ 0.46 mm Connecting Rod Big End Side Clearance 0.70 mm (0.006 ∼ 0.018 in.) (0.028 in.) 0.026 ∼ 0.054 mm 0.09 mm Connecting Rod Big End Bearing Insert/Crankpin Clearance (0.0010 ∼...
  • Page 184 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit 42.984 ∼ 43.000 mm Crankshaft Main Journal Diameter 42.96 mm (1.6923 ∼ 1.6929 in.) (1.691 in.) 43.025 mm ∼ 43.041 mm Crankcase Main Bearing Bore Diameter 43.09 mm (1.6939 ∼ 1.6945 in.) (1.696 in.) Transmission 4.9 ∼...
  • Page 185: Special Tool

    9-8 CRANKSHAFT/TRANSMISSION Special Tool Outside Circlip Pliers: Flywheel Holder: 57001-144 57001-1313 Bearing Driver Set: Kawasaki Bond (Liquid Gasket - Black) TB1105: 57001-1129 92104-1003...
  • Page 186: Crankcase Splitting

    CRANKSHAFT/TRANSMISSION 9-9 Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Starter Motor (see Electrical System chapter) Oil Filter (see Engine Lubrication System in the Periodic Maintenance chapter) Plate Bolts [A]...
  • Page 187: Crankcase Assembly

    Oil Pipe (Crankcase Inside) [C] • Apply liquid gasket [A] to the mating surface of the right crankcase half. Sealant - Kawasaki Bond (Liquid Gasket - Black) TB1105: 92104-1003 CAUTION Do not apply liquid gasket to the oil passage [B] and...
  • Page 188 CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting • Install the right crankcase, fitting the oil pump shaft pro- jection [A] into the water pump shaft slot [B]. • Tighten the right crankcase half 6 mm bolts [A]. Torque - Crankcase Bolts (6 mm): 11 N·m (1.1 kgf·m, 95 in·lb) •...
  • Page 189: Crankshaft/Connecting Rods

    9-12 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the crankshaft. Crankshaft Installation • Insert the crankshaft tapered end in to the left crankcase [A]. • Install the left connecting rod [B] into the rear cylinder opening [C], and right connecting rod [D] into the front cylinder opening [E].
  • Page 190: Crankshaft/Connecting Rod Cleaning

    CRANKSHAFT/TRANSMISSION 9-13 Crankshaft/Connecting Rods Crankshaft/Connecting Rod Cleaning • After removing the connecting rods from the crankshaft, clean them with a high-flash point solvent. • Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages.
  • Page 191 9-14 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods If clearance is within the standard, no bearing replace- ment is required. If clearance is between 0.054 mm (0.0021 in.) the service limit (0.09 mm, 0.35 in.), replace the bear- ing inserts [A] with inserts painted blue [B]. Check insert/crankpin clearance with the plastigage.
  • Page 192: Crankshaft Side Clearance Inspection

    CRANKSHAFT/TRANSMISSION 9-15 Crankshaft/Connecting Rods • Select the proper bearing insert [A] in accordance with the combination of the connecting rod and crankshaft coding. Size Color [B] Connecting Rod Big End Bearing Insert Selection Con-rod Big End Crankpin Bearing Insert Bore Diameter Diameter Size Color Part Number...
  • Page 193: Crankshaft Main Bearing/Main Journal Wear Inspection

    9-16 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods Crankshaft Main Bearing/Main Journal Wear Inspection • Measure the diameter [A] of the crankshaft main journal. If any journal has worn past the service limit, replace the crankshaft with a new one. Crankshaft Main Journal Diameter 42.984 ∼...
  • Page 194: Balancer, Starter Motor Clutch

    CRANKSHAFT/TRANSMISSION 9-17 Balancer, Starter Motor Clutch Left Balancer Removal • Remove the alternator cover (see Electrical System chap- ter). • Wipe oil off the outer circumference of the alternator rotor. • Hold the alternator rotor steady with the flywheel holder [A], and remove the balancer bolt [B] and washer [C].
  • Page 195: Right Balancer, Starter Motor Clutch Removal

    9-18 CRANKSHAFT/TRANSMISSION Balancer, Starter Motor Clutch • Install the alternator rotor (see Electrical System chapter). • Hold the alternator rotor steady with the flywheel holder [A]. Special Tool - Flywheel Holder: 57001-1313 • Apply a non-permanent locking agent to the threads of the balancer gear bolt [B], and tighten it.
  • Page 196: Right Balancer, Starter Motor Clutch Installation

    CRANKSHAFT/TRANSMISSION 9-19 Balancer, Starter Motor Clutch Right Balancer, Starter Motor Clutch Installation • Be sure to install the one-way clutch [A] so that the flange [B] of it fits in the coupling recess [C]. • Apply a non-permanent locking agent to the threads of the starter clutch bolts, and tighten them.
  • Page 197: Balancer Damper Inspection

    9-20 CRANKSHAFT/TRANSMISSION Balancer, Starter Motor Clutch • Disassemble the starter motor clutch (see Right Balancer, Starter Motor Clutch Removal). • Visually inspect: One-way Clutch [A] Coupling [B] Starter Motor Clutch Gear Inner Race [C] If there is any worn or damaged part, replace it. Balancer Damper Inspection •...
  • Page 198: Torque Limiter

    CRANKSHAFT/TRANSMISSION 9-21 Torque Limiter Torque Limiter Removal • Remove: Right Engine Cover (see Clutch chapter) Starter Motor Clutch Gear [A] (see Right Balancer, Starter Motor Clutch Removal) Torque Limiter [B] CAUTION Do not disassemble the torque limiter. The torque limiter will not function if this is done. Torque Limiter Inspection •...
  • Page 199: Primary Gear

    9-22 CRANKSHAFT/TRANSMISSION Primary Gear Primary Gear Removal • Remove the alternator cover (see Electrical System chap- ter). • Wipe oil off the outer circumference of the alternator rotor. • Hold the alternator rotor steady with the flywheel holder [A]. Special Tool - Flywheel Holder: 57001-1313 •...
  • Page 200: Transmission

    CRANKSHAFT/TRANSMISSION 9-23 Transmission Shift Pedal Removal • Mark the position of the shift lever on the shift shaft so that it can be installed later in the same position. • Remove: Bolts [A] Footpeg Bracket [B] Shift Lever [C] Shift Pedal [D] Shift Pedal Installation •...
  • Page 201: External Shift Mechanism Installation

    9-24 CRANKSHAFT/TRANSMISSION Transmission • Remove: Bolt [A] Shift Drum Position Lever [B] Spring [C] External Shift Mechanism Installation • Install the shift drum position lever [A] and spring [B], and tighten the bolt [C]. Torque - Shift Drum Position Lever Bolt: 11 N·m ( 1.1 kgf·m, 95 in·lb) •...
  • Page 202: Transmission Shaft And Shift Fork Removal

    CRANKSHAFT/TRANSMISSION 9-25 Transmission Transmission Shaft and Shift Fork Removal • Split the crankcase (see Crankcase Splitting). • Remove: Shift Rod [A] Shift Forks (2) [B] • Take out the drive shaft [C] and output shaft [D] as a set, and remove the remainder shift fork. Transmission Shaft and Shift Fork Installation •...
  • Page 203: Transmission Shaft Assembly

    9-26 CRANKSHAFT/TRANSMISSION Transmission Transmission shaft Assembly • Install the 5th gear [A] on the output shaft with its oil hole [B] aligned with the shaft oil hole [C]. • Fit the steel balls into the 4th gear holes as shown. View A-A’...
  • Page 204 CRANKSHAFT/TRANSMISSION 9-27 Transmission 1. 1st Gear 8. Thrust Washer (20.5 × 30 × 1.0) 2. 2nd Gear 9. Thrust Washer (20.5 × 30 × 0.5) 3. 3rd Gear 10 Thrust Washer (25.3 × 30 × 1.0) 4. 4th Gear 11. Thrust Washer (30 × 38 × 1.0) 5.
  • Page 205: Shift Drum Assembly

    9-28 CRANKSHAFT/TRANSMISSION Transmission Shift Drum Assembly • Be sure to install the dowel pin. • Apply a non-permanent locking agent to the threads of the shift drum cam holder screw, and tighten it. Torque - Shift Drum Cam Holder Screw: 12 N·m (1.2 kgf·m, 104 in·lb) Shift Fork Bending Inspection •...
  • Page 206: Gear Dog And Gear Dog Hole Damage Inspection

    CRANKSHAFT/TRANSMISSION 9-29 Transmission Gear Dog and Gear Dog Hole Damage Inspection • Visually inspect the gear dogs [A] and gear dog holes [B]. Replace any damaged gears or gears with excessively worn dogs or dog holes.
  • Page 207: Ball Bearing, Needle Bearing, And Oil Seal

    9-30 CRANKSHAFT/TRANSMISSION Ball Bearing, Needle Bearing, and Oil Seal Bearing Oil Seal Installation • When installing a bearing other than the following parts, press it in with the marked side facing out. Special Tool - Bearing Driver Set: 57001-1129 Right Crankcase •...
  • Page 208: Water Pump Shaft

    CRANKSHAFT/TRANSMISSION 9-31 Water Pump Shaft Water Pump Shaft Removal • Split the crankcase (see Crankshaft/Transmission chap- ter). • Remove the circlip [A] from the water pump shaft [B]. Special Tool - Outside Circlip Pliers: 57001-144 • Remove the shaft from the outside of the crankcase to the inside.
  • Page 210 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-6 Rear Wheel Removal......................10-6 Rear Wheel Installation..................... 10-7 Rim and Spokes Removal ....................10-7 Rim and Spokes Installation .....................
  • Page 211: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 212 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Nut 11.0 Rear Axle Nut 10.0 43 in·lb Spoke Nipples Front Axle Clamp Bolts 5. Axle Nut Cap (VN800-B5 ∼ B6, Germany Model) (On and after VN800-B7, Europe and United Kingdom Models) G: Apply grease.
  • Page 213: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Size: – – – Front 16 × 3.00 – – – Rear 16 × 3.00 – – – Rim Runout (with tire installed) Radial TIR 1.0 mm (0.04 in) or less TIR 2.0 mm (0.08 in.) Axial TIR 0.8 mm (0.03 in.) or less...
  • Page 214: Special Tools

    WHEELS/TIRES 10-5 Special Tools Inside Circlip Pliers: Bearing Remover Shaft, 9: 57001-143 57001-1265 Rim Protector: Bearing Remover Head, 15 × 17: 57001-1063 57001-1267 Bead Breaker Assembly: Bearing Remover Head, 20 × 22: 57001-1072 57001-1293 Bearing Driver Set: Jack Attachment #3: 57001-1129 57001-1416 Jack:...
  • Page 215: Wheels (Rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Loosen the front axle nut [A]. • Raise the front wheel off the ground. Special Tools - Jack: 57001-1238 Jack Attachment #3: 57001-1416 • Loosen the axle clamp bolt [A]. • Pull out the axle [B] to the right, and remove the front wheel, and Collars [C].
  • Page 216: Rear Wheel Installation

    WHEELS/TIRES 10-7 Wheels (Rims) • Remove: Clip [A], Torque Link Nut [B] and Bolt Adjusting Nut [C] and Brake Rod [D] Clip [E] and Axle Nut [F] Bolts [A] and Chain Cover [B] Axle [C] • Remove the drive chain [D] from the rear sprocket toward the left.
  • Page 217: Rim And Spokes Installation

    10-8 WHEELS/TIRES Wheels (Rims) Rim and Spokes Installation If the rim has a mark, install it so that its mark faces smaller diameter of the dram. If the rim has an arrow mark, install it so that its mark points rotating direction. •...
  • Page 218: Balance Adjustment

    WHEELS/TIRES 10-9 Wheels (Rims) Balance Adjustment • If the wheel always stops in one position, provisionally attach a balance weight [A] on the wheel. ○ Attach a balance weight loosely to the spoke under the marking. • Rotate the wheel 1/4 turn [B], and see whether or not the wheel stops in this position.
  • Page 219: Tires

    10-10 WHEELS/TIRES Tires Air Pressure Inspection/Adjustment • Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours.) Adjust the tire air pressure according to the specifications if necessary.
  • Page 220: Tire Installation

    WHEELS/TIRES 10-11 Tires • Pry the tire off the rim with the tire iron [A] of the bead breaker protecting the rim with rim protectors [B]. Special Tool - Rim Protector: 57001-1063 Bead Breaker Assembly: 57001-1072 Tire Installation WARNING Use the same manufacture’s tires on both front and rear wheels.
  • Page 221: Hub Bearing

    10-12 WHEELS/TIRES Hub Bearing Hub Bearing Removal • Remove the wheel, and take out the following. CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground.
  • Page 222: Hub Bearing Inspection

    WHEELS/TIRES 10-13 Hub Bearing • Replace the grease seals with new ones. • Press in the grease seal [A] so that the seal surface is flush [B] with the end of the hole. ○ Apply high temperature grease to the grease seal lips. Special Tool - Bearing Driver Set: 57001-1129 [C] Hub Bearing Inspection ○...
  • Page 223: Speedometer Gear Housing

    10-14 WHEELS/TIRES Speedometer Gear Housing Disassembly and Assembly • Remove: Rear Wheel (see Rear Wheel Removal) Brake Panel, Brake Shoe Grease Seal [A] Speedometer Gear [B] Washer [C] • Tap the pinion washer [A], and remove the busing, pinion [B], and install the washer [C] facing the alloy surface of it to upwards.
  • Page 224 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........................11-2 Specifications ......................... 11-4 Special Tools .......................... 11-5 Drive Chain..........................11-6 Drive Chain Slack Inspection .................... 11-6 Drive Chain Slack Adjustment ..................11-6 Wheel Alignment Inspection/Adjustment ................. 11-6 Drive Chain Wear Inspection .................... 11-6 Drive Chain Lubrication.....................
  • Page 225: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 226 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Sprocket Nut Rear Sprocket Nut G: Apply grease. HO: Apply heavy oil. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil. O: Apply oil.
  • Page 227: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Standard Chain Make ENUMA – – – Type EK50MV-O, Endless – – – EK50MV-X (VN800-B6 ∼, B6F) Link 112 links – – – Sprockets Rear Sprocket Warp Less-than 0.4 mm (0.015 in.) 0.5 mm (0.02 in.)
  • Page 228: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Bearing Driver Set: 57001-143 57001-1129...
  • Page 229: Drive Chain

    11-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Wheel Alignment Inspection/Adjustment •...
  • Page 230: Drive Chain Replacement

    FINAL DRIVE 11-7 Drive Chain Drive Chain Replacement CAUTION For safety, if the drive chain shall be replaced, re- place it using a recommended tool. Recommended Tool - Type: EK JOINT Tool #50 Brand: ENUMA CHAIN Body [A] Handlebar [B] Cutting and Rivetting Pin [C] For Cutting [D] For Rivetting [E]...
  • Page 231 11-8 FINAL DRIVE Drive Chain • Replace the link pin, link plate and grease seals. • Apply grease to the link pins [A] and grease the seals [B] [C]. • Engage the drive chain on the engine and rear sprockets. •...
  • Page 232 FINAL DRIVE 11-9 Drive Chain • Turn the pin holder until the rivetting pin touches the link pin. • Turn the wrench clockwise until the tip of rivetting pin con- tact with the link pin. • Rivet it. • Repeat the same procedure for the other link pin. •...
  • Page 233: Sprocket, Coupling

    11-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Remove the bolt [A]. • Pull the engine sprocket cover [B] to the rear until the cover separates from the alternator cover [C], and remove • Flatten out the bended washer [A]. •...
  • Page 234: Rear Sprocket Removal

    FINAL DRIVE 11-11 Sprocket, Coupling Rear Sprocket Removal • Remove the rear wheel (see Wheel/Tires chapter). • Remove the rear sprocket nuts [A]. • Remove the rear sprocket [B]. Rear Sprocket Installation • Install the sprocket facing the tooth number marking [A] outward.
  • Page 235: Coupling Bearing Installation

    11-12 FINAL DRIVE Sprocket, Coupling Coupling Bearing Installation • Replace the bearing with a new one. • Press in the bearing [A] until it is bottomed. Special Tool - Bearing Driver Set: 57001-1129 [B] • Pack the bearing with high temperature grease. •...
  • Page 236: Sprocket Wear Inspection

    FINAL DRIVE 11-13 Sprocket, Coupling Sprocket Wear Inspection • Visually inspect the engine and rear sprocket teeth for wear and damage. If the teeth are worn as illustrated, replace the sprocket, and inspect the drive chain wear (see Drive Chain Wear Inspection in the Periodic Maintenance chapter).
  • Page 238 BRAKES 12-1 Brakes Table of Contents Exploded View........12-2 Brake Disc Warp Inspection..12-14 Specifications ........12-6 Brake Fluid ........12-15 Special Tools ........12-7 Level Inspection ......12-15 Caliper ..........12-8 Brake Fluid Change ....12-15 Caliper Removal ......12-8 Bleeding the Brake Line....
  • Page 239: Exploded View

    12-2 BRAKES Exploded View...
  • Page 240 BRAKES 12-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Caliper Mounting Bolts Brake Disc Mounting Bolts Brake Hose Banjo Bolts Bleed Valve 69 in·lb Master Cylinder Clamp Bolts 0.90 78 in·lb Brake Lever Pivot Bolt 9 in·lb Brake Lever Pivot Bolt Locknut 52 in·lb Reservoir Cap Screws 0.15...
  • Page 241 12-4 BRAKES Exploded View...
  • Page 242 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Brake Lever Clamp Bolt Torque Link Nuts 3. Damper (VN800-B1 ∼ B6, Germany Model) 4. Rear Brake Lever Clamp Bolt CL: Apply Cable Lubricant. G: Apply grease. R: Replacement parts.
  • Page 243: Specifications

    12-6 BRAKES Specifications Item Standard Service Limit Front Brake Brake Lever Position Non-adjustable – – – Brake Lever Free Play Non-adjustable – – – 5.8 ∼ 6.2 mm (0.228 ∼ 0.244 in.) Brake Disc Thickness 5.5 mm (0.21 in.) Brake Disc Runout Less than 0.15 mm (0.006 in.) 0.3 mm (0.012 in.) Brake Fluid:...
  • Page 244: Special Tools

    BRAKES 12-7 Special Tools Inside Circlip Pliers: Jack Attachment #3: 57001-143 57001-1416 Jack: 57001-1238...
  • Page 245: Caliper

    12-8 BRAKES Caliper Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. • Unscrew the banjo bolt and remove the brake hose [D] from the caliper (see Brake Hose Removal/Installation).
  • Page 246: Caliper Assembly

    BRAKES 12-9 Caliper • Remove the board and pull out the pistons [A] by hand. ○ These pistons can also be removed by disconnecting the hose and applying compressed air to the hose joint open- ing using the same wooden board. But be careful not to put your fingers or palm inside the caliper opening during work.
  • Page 247: Caliper Fluid Seal Damage Inspection

    12-10 BRAKES Caliper • Replace the caliper holder shaft rubber boot and dust cover if they are damaged. • Apply a thin coat of silicone grease to the caliper holder shafts and holder holes (Silicone grease is a special high temperature, water-resistant grease).
  • Page 248: Brake Pads

    BRAKES 12-11 Brake Pads Brake Pad Removal • Remove the caliper with the hose installed (see Caliper Removal.) • Remove: Snap Pin [A] Pad Pin [B] • Remove the outer pad [A], and then remove the piston side pad [B]. Brake Pad Installation •...
  • Page 249: Master Cylinder

    12-12 BRAKES Master Cylinder Master Cylinder Removal • Disconnect the front brake light switch connectors [A]. • Remove the banjo bolt [B] to disconnect the brake hose from the master cylinder (see Brake Hose Removal/In- stallation). • Unscrew the clamp bolts [C], and take off the master cylin- der [D] as an assembly with the reservoir, brake lever, and brake switch installed.
  • Page 250: Master Cylinder Assembly

    BRAKES 12-13 Master Cylinder Master Cylinder Assembly • Before assembly, clean all parts including the master cylinder with brake fluid or alcohol. CAUTION Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts.
  • Page 251: Brake Disc

    12-14 BRAKES Brake Disc Brake Disc Removal • Remove the wheel (see Wheels/Tires chapter). • Unscrew the mounting bolts [A], and take off the disc [B]. Brake Disc Installation • Install the brake disc on the wheel so that the marked side [A] faces out.
  • Page 252: Brake Fluid

    BRAKES 12-15 Brake Fluid Level Inspection • Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brake Fluid Change in the Periodic Mainte- nance chapter. Bleeding the Brake Line • Refer to the Bleeding the Brake Line in the Periodic Main- tenance chapter.
  • Page 253: Brake Hose

    12-16 BRAKES Brake Hose Brake Hose Removal/Installation CAUTION Brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wiped up immediately with wet cloth. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts.
  • Page 254: Brake Pedal And Cable

    BRAKES 12-17 Brake Pedal and Cable Brake Pedal Position Inspection • Refer to the Brake Play Inspection in the Periodic Main- tenance chapter. Brake Pedal Position Adjustment • Refer to the Brake Play Inspection in the Periodic Main- tenance chapter. Brake Pedal Free Play Inspection •...
  • Page 255: Brake Pedal Installation

    12-18 BRAKES Brake Pedal and Cable Brake Pedal Installation • Align the punch mark [A] on the brake pedal shaft with the punch mark [B] on the brake pedal lever. • Tighten: Torque - Rear Brake Lever Clamp Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) •...
  • Page 256: Brake Panel And Drum

    BRAKES 12-19 Brake Panel and Drum Cam Lever Angle Inspection • Check that the rear brake cam lever comes to an 80° ∼ 90° angle [A] with the rear brake rod when the rear brake is fully applied. If it does not, adjust the rear brake cam lever angle. Cam Lever Angle 80°...
  • Page 257: Brake Panel Disassembly

    12-20 BRAKES Brake Panel and Drum Brake Panel Disassembly • Remove the brake panel (see Brake Panel Removal). • Using a clean cloth around the linings to prevent grease or oil from getting on them, remove the brake shoes [A] by pulling up on the center of the linings.
  • Page 258: Brake Drum Wear Inspection

    BRAKES 12-21 Brake Panel and Drum Brake Drum Wear Inspection • Remove the rear wheel (see Wheels/Tires chapter). • Measure the inside diameter [A] of the drum. ○ Use calipers and measure at several points. If any measurement is greater than the service limit, re- place the wheel hub.
  • Page 260 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-8 Front Fork Removal (each fork leg) .................. 13-8 Front Fork Installation ....................... 13-8 Fork Oil Change........................ 13-8 Front Fork Disassembly ....................13-9 Front Fork Assembly......................
  • Page 261: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 262 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Clamp Bolts (upper) 14.5 Front Fork Clamp Bolts (lower) Front Fork Bottom Allen Bolts 14.5 Fork Cover Bolts 5 mm 11 in·lb Fork Cover Bolts 6 mm 113 in·lb Spacer Allen Bolt 0.45 39 in·lb...
  • Page 263 13-4 SUSPENSION Exploded View...
  • Page 264 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Nuts Swing Arm Pivot Shaft Nut 10.0 Rocker Arm Pivot Shaft Nut 10.0 Tie-Rod Nuts G: Apply grease.
  • Page 265: Specifications

    13-6 SUSPENSION Specifications Item Standard Service Limit Front Fork Fork Oil: Viscosity SHOWA SS8 or equivalent – – – Capacity (per side): When changing oil Approx, 265 mL (9.0 US oz) – – – After disassembly and completely dry 310 ±4 mL (10.5 ±0.14 US oz) –...
  • Page 266: Special Tools

    SUSPENSION 13-7 Special Tools Fork Cylinder Holder Handle: Front Fork Oil Seal Driver: 57001-183 57001-1219 Fork Cylinder Holder Adapter: Jack: 57001-1057 57001-1238 Oil Seal & Bearing Remover: Fork Oil Level Gauge: 57001-1058 57001-1290 Bearing Driver Set: Jack Attachment #3: 57001-1129 57001-1416 Fork Outer Tube Weight: 57001-1218...
  • Page 267: Front Fork

    13-8 SUSPENSION Front Fork Front Fork Removal (each fork leg) • Loosen the front wheel axle nut (see wheels/Tires chap- ter) • Raise the front wheel off the ground. Special Tools - Jack: 57001-1238 Jack Attachment #3: 57001-1416 • Remove: Caliper (for left fork only) (see Wheels/Tires chapter) Front Fender (see Frame chapter) Front Fork Upper Clamp Bolt [A]...
  • Page 268: Front Fork Disassembly

    SUSPENSION 13-9 Front Fork Front Fork Disassembly • Remove the front fork (see Front Fork Removal). • Drain the fork oil (see Fork Oil Change in the Periodic Maintenance chapter). • Tap the point [A] with a suitable tool to separate the dust seal cover [B] from the outer tube [C].
  • Page 269: Front Fork Assembly

    13-10 SUSPENSION Front Fork • Remove the inner tube guide bushing [A], outer tube guide bushing [B], washer [C] and oil seal [D] from the inner tube. • Remove the cylinder base from the bottom of the outer tube. Front Fork Assembly •...
  • Page 270 SUSPENSION 13-11 Front Fork • Face the notch [A] of the dust seal cover rearward [B] and install the dust seal cover by tapping with the fork outer tube weight [C] until it stops. Special Tool - Fork Outer Tube Weight: 57001-1218 •...
  • Page 271: Inner Tube Inspection

    13-12 SUSPENSION Front Fork Inner Tube Inspection • Visually inspect the inner tube, and repair any damage. • Nicks or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage. If the damage is not repairable, replace the inner tube.
  • Page 272: Rear Shock Absorber

    SUSPENSION 13-13 Rear Shock Absorber Spring Preload Adjustment • Remove the rear shock absorber from the frame (see Rear Shock Absorber Removal). • To adjust the sprint force, turn the adjusting sleeve [A] on the shock absorber to the desired position with the stem nut wrench.
  • Page 273: Rear Shock Absorber Scrapping

    13-14 SUSPENSION Rear Shock Absorber Rear Shock Absorber Scrapping WARNING Since the rear shock absorber contains nitrogen gas, do not incinerate the rear shock absorber with- out first releasing the gas or it may explode. Before a rear shock absorber is scrapped, drill a hole at the point [A] shown to release the nitrogen gas completely.
  • Page 274: Swingarm

    SUSPENSION 13-15 Swingarm Swingarm Removal • Remove: Muffler (see Engine Top End chapter) Rear Wheel (see Wheels/Tires chapter) Upper Shock Absorber Bolt Bolts [A] and Rear Wheel Mud Guard [B] Nut [A] and Brake Cable [B] Upper Tie-Rod Bolt [A] Cap and Swingarm Pivot Nut [B] •...
  • Page 275: Swingarm Bearing Installation

    13-16 SUSPENSION Swingarm Swingarm Bearing Installation • Apply plenty of grease to the needle bearings. • Install the bearings so that the manufacturer’s marks face out. Special Tool - Bearing Driver Set: 57001-1129 Swingarm Bearing, Sleeve Inspection CAUTION Do not remove the bearings for inspection. Remove may damage them.
  • Page 276: Tie-Rod, Rocker Arm

    SUSPENSION 13-17 Tie-Rod, Rocker Arm Tie-Rod Removal • Remove the muffler (see Engine Top End chapter). • Squeeze the brake lever slowly and hold it with a band [A]. • Using the jack, raise the rear wheel off the ground. Special Tool - Jack: 57001-1238 Jack Attachment #3: 57001-1416 •...
  • Page 277: Rocker Arm/Tie-Rod Bearing, Sleeve Inspection

    13-18 SUSPENSION Tie-Rod, Rocker Arm Rocker Arm/Tie-Rod Bearing, Sleeve Inspection CAUTION Do not remove the bearings for inspection. Remove may damage them. • Visually inspect the swingarm sleeves and needle bear- ings. • The rollers in a needle bearing normally wear very little, and wear is difficult to measure.
  • Page 278 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special Tools .......................... 14-4 Steering ..........................14-5 Steering Inspection ......................14-5 Steering Adjustment......................14-5 Steering Stem......................... 14-6 Steering Stem, Stem Bearing Removal ................14-6 Steering Stem, Stem Bearing Installation ................. 14-8 Stem Bearing Lubrication ....................
  • Page 279: Exploded View

    14-2 STEERING Exploded View...
  • Page 280 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Handlebar Holder Bolts Handlebar Holder Mounting Nuts Steering Stem Head Bolt Steering Stem Nut 43 in·lb AD: Apply adhesive agent. G: Apply grease. L: Apply a non-permanent locking agent.
  • Page 281: Special Tools

    14-4 STEERING Special Tools Steering Stem Bearing Driver: Head Pipe Outer Race Driver, 46.5: 57001-137 57001-1106 Steering Stem Bearing Driver Adapter, 34.5: Head Pipe Outer Race Remover ID > 37 mm: 57001-1074 57001-1107 Head Pipe Outer Race Press Shaft: Jack: 57001-1075 57001-1238 Head Pipe Outer Race Driver, 51.5:...
  • Page 282: Steering Inspection

    STEERING 14-5 Steering Steering Inspection • Refer to the Steering Inspection in the Periodic Mainte- nance chapter. Steering Adjustment • Refer to the Steering Inspection in the Periodic Mainte- nance chapter.
  • Page 283: Steering Stem

    14-6 STEERING Steering Stem Steering Stem, Stem Bearing Removal • Remove: Seat (see Frame chapter) Meter unit (see Electrical System chapter) Fuel Tank (see Fuel System chapter) Headlight Unit (see Electrical System chapter) Headlight Mounting Bracket Bolts [A] • Disconnect the front turn signal lead connectors [B]. •...
  • Page 284 STEERING 14-7 Steering Stem • Remove: Turn Signal Light Bracket Clamp Bolts [A] Turn Signal Lights [B] Steering Stem Base Cover [C] • Loosen the front fork lower clamp bolts. • Remove the front fork assembly. • For VN800-B1 ∼ B7 model, note the following procedure. ○...
  • Page 285: Steering Stem, Stem Bearing Installation

    14-8 STEERING Steering Stem Steering Stem, Stem Bearing Installation • Replace the bearing outer races with new ones. • Apply grease to the outer races, and drive them into the head pipe at the same time. Special Tool - Head Pipe Outer Race Press Shaft: 57001 -1075 [A] Head Pipe Outer Race Driver, 46.5: 57001 -1106 [B]...
  • Page 286: Stem Bearing Lubrication

    STEERING 14-9 Steering Stem • For VN800-B1 ∼ B7 model, note the following procedure. ○ Tighten the lower fork cover bolts. Torque - Lower Fork Cover Bolts (5 mm): 8 N·m (0.8 kgf·m, 71 in·lb) Lower Fork Cover Bolts (6 mm): 13 N·m (1.3 kgf·m, 115 in·lb) •...
  • Page 287: Handlebar

    14-10 STEERING Handlebar Handlebar Removal • Remove: Clutch Cable Upper End Left Handlebar Switch Housing Front Brake Master Cylinder Right Handlebar Switch Housing Throttle Grip Handlebar Holder Bolts [A] and Handlebar Holder • Remove the handlebar [B] from the steering stem head. Handlebar Installation •...
  • Page 288 FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Seat ............................15-5 Seat Removal ........................15-5 Seat Installation ........................ 15-5 Side Covers ..........................15-6 Left Side Cover Removal ....................15-6 Left Side Cover Installation ....................15-6 Right Side Cover Removal ....................15-6 Right Side Cover Installation.....................
  • Page 289: Exploded View

    15-2 FRAME Exploded View...
  • Page 290 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Side Stand Pivot Nut Rear Frame Mounting Bolts Muffler Bracket Mounting Bolts Footpeg Holder Bolts G: Apply grease.
  • Page 291 15-4 FRAME Exploded View 1. Reflector-Reflex, FR (United States and Canada Models) 2. Front Fender Mounting Screws...
  • Page 292: Seat

    FRAME 15-5 Seat Seat Removal • Remove the seat mounting bolt [A]. • Pull [B] the seat to unhook the front and rear hooks [C], and remove it. Seat Installation • Insert the front hook [A] into the brace [B] on the frame. •...
  • Page 293: Side Covers

    15-6 FRAME Side Covers Left Side Cover Removal • Remove the screw [A], and pull [B] the left cover forward. Left Side Cover Installation • Fit the projection [A] into the slot [B] on the frame, and tighten the screw. Right Side Cover Removal •...
  • Page 294: Fenders

    FRAME 15-7 Fenders Front Fender Removal • Raise the front wheel off the ground. • Unscrew the bolts [A] and pull the front fender [B] to rear -wards. Rear Fender Removal • Remove: Seat (see Seat Removal) Connectors [A] Rear Fender Bolts [B] Rear Frame Mounting Bolts [C] (both side) Rear Fender Assembly.
  • Page 295: Battery Case

    15-8 FRAME Battery Case Battery Case Removal • Remove: Seat (see Seat Removal) Rear Fender (see Rear Fender Removal) Fuel Tank (see Fuel System chapter) Bolts [A] and Battery Cover [B] Battery Coolant Hose [C] Surge Tank [D] • Remove: IC Igniter [A] Junction Box [B] Starter Relay, Main Fuse [C]...
  • Page 296: Down Tube

    FRAME 15-9 Down Tube Down Tube Removal • Remove: Footpeg and Brake Pedal (see Brakes chapter) Front Muffler (see Engine Top End chapter) Clutch Cable Clamps Engine Bracket Bolts [A] Bolts [B] and Down Tube Assembly [C] Air Cleaner Drain Hose [D] Down Tube Installation •...
  • Page 297: Storage Box, Tool Kit Container

    15-10 FRAME Storage Box, Tool Kit Container Storage Box Removal • Remove: Muffler (see Engine Top End chapter) Right Side Cover (see Right Side Cover Removal) Screws [A] and Lower Cover Canister and Separator (for California Model) Bolts [A] Bracket [B] Storage Box Base [C] Tool Kit Container Removal •...
  • Page 298 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........16-3 Charging Voltage Inspection ..16-47 Parts Location........16-11 Ignition System ........16-49 Wiring Diagram (VN800-B1 ∼ B4, Pickup Coil Removal ....16-50 United States, and Canada) ... 16-12 Pickup Coil Installation....16-50 Wiring Diagram (VN800-B1 ∼...
  • Page 299 16-2 ELECTRICAL SYSTEM Meter Unit Installation ....16-71 Junction Box Fuse Circuit Meter Units Disassembly ..... 16-71 Inspection........16-75 Bulb Replacement......16-71 Starter Circuit/Headlight Relay Switch and Sensor......16-72 Inspection........16-75 Brake Light Timing Inspection ..16-72 Diode Circuit Inspection ....16-76 Brake Light Timing Adjustment ...
  • Page 300: Exploded View

    ELECTRICAL SYSTEM 16-3 Exploded View Dummy Page...
  • Page 301 16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 302 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Alternator Cover Bolts 104 in·lb Timing Inspection Cover Screw 43 in·lb Alternator Rotor Bolt Stator Coil Bolts 115 in·lb Pickup Coil Bolts 69 in·lb Alternator Lead Clamp Bolts 69 in·lb Starter Motor Mounting Bolts 97 in·lb Starter Motor Through Bolts...
  • Page 303 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 304 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Spark Plugs Side Stand Switch Mounting Bolts 35 in·lb L: Apply a non-permanent locking agent.
  • Page 305 16-8 ELECTRICAL SYSTEM Exploded View...
  • Page 306 ELECTRICAL SYSTEM 16-9 Exploded View 1. Tail Light (United States and Canada Models) 2. License Plate Holder (United States Model) 3. License Plate Holder (Canada Model) 4. Tail Light (On and after VN800-B5, Other than United States and Canada Models) 5.
  • Page 307 16-10 ELECTRICAL SYSTEM Exploded View...
  • Page 308: Parts Location

    ELECTRICAL SYSTEM 16-11 Parts Location 1. Starter Lockout Switch 7. Oil Pressure Switch 14. Front Brake Light Switch 2. Ignition Coils 8. Side Stand Switch 15. Water Temperature Sen- 3. Battery 9. Pickup Coil 4. Starter Relay and Main 10. Alternator 16.
  • Page 309: Wiring Diagram (Vn800-B1 ~ B4, United States, And Canada)

    16-12 ELECTRICAL SYSTEM Wiring Diagram (VN800-B1 ∼ B4, United States, and Canada)
  • Page 310 ELECTRICAL SYSTEM 16-13 Wiring Diagram (VN800-B1 ∼ B4, United States, and Canada)
  • Page 311: Wiring Diagram (Vn800-B1 ~ B4, Australia)

    16-14 ELECTRICAL SYSTEM Wiring Diagram (VN800-B1 ∼ B4, Australia)
  • Page 312 ELECTRICAL SYSTEM 16-15 Wiring Diagram (VN800-B1 ∼ B4, Australia)
  • Page 313: Wiring Diagram (Vn800-B1 ~ B4, Europe And Others)

    16-16 ELECTRICAL SYSTEM Wiring Diagram (VN800-B1 ∼ B4, Europe and Others)
  • Page 314 ELECTRICAL SYSTEM 16-17 Wiring Diagram (VN800-B1 ∼ B4, Europe and Others)
  • Page 315: Wiring Diagram (Vn800-B5 ~ B8, United States, And Canada)

    16-18 ELECTRICAL SYSTEM Wiring Diagram (VN800-B5 ∼ B8, United States, and Canada)
  • Page 316 ELECTRICAL SYSTEM 16-19 Wiring Diagram (VN800-B5 ∼ B8, United States, and Canada)
  • Page 317: Wiring Diagram (Vn800-B5 ~ B8, Australia)

    16-20 ELECTRICAL SYSTEM Wiring Diagram (VN800-B5 ∼ B8, Australia)
  • Page 318 ELECTRICAL SYSTEM 16-21 Wiring Diagram (VN800-B5 ∼ B8, Australia)
  • Page 319: Wiring Diagram (Vn800-B5 ~ B7, Europe And Others)

    16-22 ELECTRICAL SYSTEM Wiring Diagram (VN800-B5 ∼ B7, Europe and Others)
  • Page 320 ELECTRICAL SYSTEM 16-23 Wiring Diagram (VN800-B5 ∼ B7, Europe and Others)
  • Page 321: Wiring Diagram (Vn800-B8, Other Than United States, Canada, And Australia)

    16-24 ELECTRICAL SYSTEM Wiring Diagram (VN800-B8, other than United States, Canada, and Australia)
  • Page 322 ELECTRICAL SYSTEM 16-25 Wiring Diagram (VN800-B8, other than United States, Canada, and Australia)
  • Page 323: Wiring Diagram (Vn800-B9 ~, B6F United States, And Canada)

    16-26 ELECTRICAL SYSTEM Wiring Diagram (VN800-B9 ∼, B6F United States, and Canada)
  • Page 324 ELECTRICAL SYSTEM 16-27 Wiring Diagram (VN800-B9 ∼, B6F United States, and Canada)
  • Page 325: Wiring Diagram (Vn800-B9 ~, B6F Australia)

    16-28 ELECTRICAL SYSTEM Wiring Diagram (VN800-B9 ∼, B6F Australia)
  • Page 326 ELECTRICAL SYSTEM 16-29 Wiring Diagram (VN800-B9 ∼, B6F Australia)
  • Page 327: Wiring Diagram (Vn800-B9 ~, B6F Other Than United States, Canada, And Australia)

    16-30 ELECTRICAL SYSTEM Wiring Diagram (VN800-B9 ∼, B6F other than United States, Canada, and Aus- tralia)
  • Page 328 ELECTRICAL SYSTEM 16-31 Wiring Diagram (VN800-B9 ∼, B6F other than United States, Canada, and Aus- tralia)
  • Page 329: Specifications

    16-32 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Battery Type Sealed Battery – – – 12 V 12 Ah (VN800-B1 ∼ B8) Capacity – – – 12 V 10 Ah (VN800-B9 ∼, B6F) Voltage 12.8 V or more – – – Charging System Type Three-phase AC...
  • Page 330: Special Tools

    ELECTRICAL SYSTEM 16-33 Special Tools Rotor Puller, M16/M18/M20/M22 × 1.5: Hand Tester: 57001-1216 57001-1394 Spark Plug Wrench, 16 mm (Owner’s Tool): Harness Adapter #13: 92110-1132 57001-1399 Flywheel Holder: Peak Voltage Adapter: 57001-1313 57001-1415 Igniter Checker Assembly: 57001-1378...
  • Page 331: Precautions

    16-34 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ Do not reverse the battery lead connections. This will burn out the diodes on the electrical parts. ○...
  • Page 332 ELECTRICAL SYSTEM 16-35 Precautions Male Connectors [B]...
  • Page 333: Electrical Wiring

    16-36 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully.
  • Page 334: Battery

    ELECTRICAL SYSTEM 16-37 Battery Battery Removal • Remove: Seats (see Frame Chapter) Screws [A] Battery Cover [B] • Disconnect the negative (–) lead [C] and then positive (+) lead [D]. CAUTION Be sure to disconnect the negative (–) lead first. Electrolyte Filling CAUTION Do not remove the aluminum seal sheet [A] sealing...
  • Page 335: Initial Charge

    16-38 ELECTRICAL SYSTEM Battery • Make sure air bubbles [A] are coming up from all six filler ports. ○ Leave the container this way for 5 minutes or longer. NOTE ○ If no air bubbles are coming up from a filler port, tap [B] the bottom of the container two or three times.
  • Page 336: Interchange

    ELECTRICAL SYSTEM 16-39 Battery If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification (see the this chapter).
  • Page 337: Refreshing Charge

    16-40 ELECTRICAL SYSTEM Battery NOTE ○ Measure with a digital voltmeter [A] which can be read to one decimal place voltage. If the reading is below the specified, refreshing charge is required. Battery Terminal Voltage Standard: 12.8 V or more Refreshing Charge •...
  • Page 338 ELECTRICAL SYSTEM 16-41 Battery • Determine battery condition after refreshing charge. ○ Determine the condition of the battery 30 minutes after completion of the charge by measuring the terminal volt- age according to the table below. Judgement Criteria 12.8 V or higher Good 12.0 ∼...
  • Page 339: Charging System

    16-42 ELECTRICAL SYSTEM Charging System Alternator Cover Removal • Drain the engine oil (see Lubrication System chapter). • Remove: Engine Sprocket Cover (see Final Drive chapter) Left Side Cover (see Frame chapter) Bolt [A] and Ignition Switch [B] Clamp [C] Alternator Lead Connector [D] Pickup Coil Lead Connector [E] Bolt [A]...
  • Page 340: Alternator Rotor Removal

    ELECTRICAL SYSTEM 16-43 Charging System Alternator Rotor Removal • Remove: Alternator Cover (see Alternator Cover Removal). • Wipe oil off the outer circumference of the rotor. • Hold the alternator rotor steady with the flywheel holder [A], and remove the rotor bolt [B]. Special Tool - Flywheel Holder: 57001-1313 •...
  • Page 341: Alternator Inspection

    16-44 ELECTRICAL SYSTEM Charging System Alternator Inspection There are three types of alternator failures: short, open (wire burned out), or loss in rotor magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all.
  • Page 342: Regulator/Rectifier Inspection

    ELECTRICAL SYSTEM 16-45 Charging System Regulator/Rectifier Inspection • Remove: Left Side Cover (see Frame chapter) Connector [A] (disconnect) Tool Kit Container Bolts [B] Bolts [A] and Regulator/Rectifier [B] Rectifier Circuit Check • Check the rectifier resistance as follows. • Disconnect the regulator/rectifier connector. •...
  • Page 343 16-46 ELECTRICAL SYSTEM Charging System Regulator Circuit Check To test the regulator out of circuit, use three 12 V batteries and a test light (12 V 3 ∼ 6 W bulb in a socket with leads). CAUTION The test light works as an indicator and also a cur- rent limiter to protect the regulator/rectifier from ex- cessive current.
  • Page 344: Charging Voltage Inspection

    ELECTRICAL SYSTEM 16-47 Charging System Charging Voltage Inspection • Check the battery condition (see Battery section). • Warm up the engine to obtain actual alternator operating conditions. • Remove the left side covers (see Frame chapter). • Check that the ignition switch is turned off, and connect the hand tester [A] as shown in the table.
  • Page 345 16-48 ELECTRICAL SYSTEM Charging System Charging System Circuit 1. Ignition Switch 2. Alternator 3. Regulator/Rectifier 4. Battery 5. Main Fuse 30 A 6. Load...
  • Page 346: Ignition System

    ELECTRICAL SYSTEM 16-49 Ignition System...
  • Page 347: Pickup Coil Removal

    16-50 ELECTRICAL SYSTEM Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plugs, ignition coils, or spark plug leads while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition switch is on, or while the engine is running.
  • Page 348: Ignition Coil Removal

    ELECTRICAL SYSTEM 16-51 Ignition System Pickup Coil Peak Voltage Inspection • Remove the left Side Cover (see Frame chapter). • Remove all the spark plug caps but do not remove the spark plugs. • Disconnect the pickup coil lead connector. •...
  • Page 349: Ignition Coil Inspection

    16-52 ELECTRICAL SYSTEM Ignition System Ignition Coil Inspection • Remove the ignition coils (see Ignition Coil Removal). • Measure the arcing distance with the suitable commer- cially available coil tester [A] to check the condition of the ignition coil [B]. •...
  • Page 350: Spark Plug Removal

    ELECTRICAL SYSTEM 16-53 Ignition System • Remove the fuel tank (see Fuel System chapter). • Remove all the spark plugs caps but do not remove the spark plugs. • Install new spark plugs [A] into all the spark plug caps, and ground them onto the engine.
  • Page 351: Spark Plug Installation

    16-54 ELECTRICAL SYSTEM Ignition System Spark Plug Installation • Insert the spark plug vertically into the plug hole with the plug installed in the plug wrench. Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-1132 • Tighten: Torque - Spark Plugs: 18 N·m (1.8 kgf·m, 13 ft·lb) •...
  • Page 352: Ic Igniter Checker Inspection

    ELECTRICAL SYSTEM 16-55 Ignition System Ignition Coil primary Peak Voltage Check • Refer: Ignition Coil Primary Peak Voltage Inspection Pickup Coil Peak Voltage Check • Refer: Pickup Coil Peak Voltage Inspection Emergency Engine Stop Function Check • Remove: Seat (see Frame chapter) NOTE ○...
  • Page 353 16-56 ELECTRICAL SYSTEM Ignition System • To check the condition of the IC igniter, connect the igniter checker [A] to the IC igniter. Special Tools - Igniter Checker Assembly: 57001-1378 Harness Adapter #12: 57001-1399 ○ Turn the select knob to “C” position. NOTE ○...
  • Page 354 ELECTRICAL SYSTEM 16-57 Ignition System Ignition System Circuit 1. Junction Box 7. Ignition Fuse 10 A 12. Side Stand Switch 2. Ignition Switch 8. Ignition Coils 13. Main Fuse 30 A 3. Engine Stop Switch 9. Neutral Switch 14. Battery 4.
  • Page 355: Electric Starter System

    16-58 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal • Drain the engine oil (see Lubrication System chapter). • Remove the starter motor cable nut [A] and the mounting bolts [B]. • Pull out the starter motor [C]. Starter Motor Installation CAUTION Do not tap the starter motor shaft or body.
  • Page 356: Starter Motor Assembly

    ELECTRICAL SYSTEM 16-59 Electric Starter System Starter Motor Assembly • Install the terminal assembly in the yoke. • Tighten: Torque - Starter Motor Terminal Nut: 11 N·m (1.1 kgf·m, 95 in·lb) • Fit the projection [A] of the brush plate into the yoke notch [B].
  • Page 357: Commutator Cleaning And Inspection

    16-60 ELECTRICAL SYSTEM Electric Starter System Commutator Cleaning and Inspection • Smooth the commutator surface [A] if necessary with fine emery cloth [B], and clean out the grooves. • Measure the diameter [A] of the commutator [B]. Replace the starter motor with a new one if the commu- tator diameter is less than the service limit.
  • Page 358: Terminal Inspection

    ELECTRICAL SYSTEM 16-61 Electric Starter System Terminal Inspection • Using the × 1 Ω hand tester range, measure the resis- tance between the terminal [A] and the positive brushes [B]. Special Tool - Hand Tester: 57001-1394 If there is not close to zero ohms, the terminal assembly has an open.
  • Page 359 16-62 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Junction Box 5. Diode 6. Starter Circuit Relay 7. Ignition Fuse 10 A 8. Starter Lockout Switch 9. Rectifier 10. Neutral Switch 11.
  • Page 360: Lighting System

    ELECTRICAL SYSTEM 16-63 Lighting System The United States, Canada, and Australia models adopt the daylight system and have a headlight relay in the junc- tion box. In these models, the headlight does not go on when the ignition switch and the engine stop switch are first turned on.
  • Page 361: Headlight Bulb Replacement

    16-64 ELECTRICAL SYSTEM Lighting System Headlight Bulb Replacement • Remove: Headlight Unit and Dust Cover [A] Hook [B] • Replace the headlight bulb [C]. CAUTION When handling the quartz-halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth. Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode.
  • Page 362 ELECTRICAL SYSTEM 16-65 Lighting System Bolts [A] Headlight Housing [B] Headlight Circuit (VN800-B1 ∼, United States, Canada and Australia) 1. Ignition Switch 2. High Beam Indicator Light 3. Headlight 4. Junction Box 5. Diodes 6. Headlight Circuit Relay 7. Headlight Fuse 10 A 8.
  • Page 363 16-66 ELECTRICAL SYSTEM Lighting System Headlight Circuit (VN800-B1 ∼ B7, Other than United States, Canada and Australia) Headlight Circuit (VN800-B8 ∼, B6F Other than United States, Canada and Australia) 1. Ignition Switch 5. Diodes 10. Main Fuse 30 A 2. High Beam Indicator Light 6.
  • Page 364: Tail/Brake Light Bulb Replacement

    ELECTRICAL SYSTEM 16-67 Lighting System Tail/Brake Light Bulb Replacement • Remove the tail/brake light lens screws [A] and take off the lens [B] • Push the bulb [A] in the socket, turn it counter clockwise [B] and pull it out. •...
  • Page 365: Turn Signal Light Bulb Replacement

    16-68 ELECTRICAL SYSTEM Lighting System Turn Signal Light Bulb Replacement • Remove the turn signal light lens screws [A] and remove the lens [B]. • Push the bulb [A] in the socket and turn the bulb counter- clockwise. • Replace the bulb. Turn Signal Relay Inspection •...
  • Page 366 ELECTRICAL SYSTEM 16-69 Lighting System Turn Signal Light Circuit A: United States and Canada Model B: VN800-B8 ∼, other than United States, Canada and Australia Model 1. Ignition Switch 2. Turn Signal Indicator 3. Front Right Turn Signal Light 4. Front Left Turn Signal Light 5.
  • Page 367: Radiator Fan System

    16-70 ELECTRICAL SYSTEM Radiator Fan System Fan System Circuit Inspection • Remove the Fuel Tank (see Fuel System chapter). • Turn on the ignition switch. • Disconnect the leads from the radiator fan switch [A]. • Using an auxiliary wire [B], connect the radiator fan switch leads.
  • Page 368: Meter Unit

    ELECTRICAL SYSTEM 16-71 Meter Unit Meter Unit Removal • Remove the bolt [A], and separate the meter unit [B] from the fuel tank. • Remove: Connectors [A] Speedometer Cable [B] CAUTION Place the meter so that the face is up. If a meter is left upside down or sideways for any length of time, it will malfunction.
  • Page 369: Switch And Sensor

    16-72 ELECTRICAL SYSTEM Switch and Sensor Brake Light Timing Inspection • Refer to the Brake Light Switch Inspection in the Periodic Maintenance chapter Brake Light Timing Adjustment • Refer to the Brake Light Timing Adjustment in the Periodic Maintenance chapter Switch Inspection •...
  • Page 370: Radiator Fan Switch Inspection

    ELECTRICAL SYSTEM 16-73 Switch and Sensor Radiator Fan Switch Inspection • Remove the fan switch (see Cooling System chapter). • Suspend the switch [A] in a container of coolant so that the temperature-sensing projection and threaded portion are submerged. • Suspend an accurate thermometer [B] in the coolant so that the sensitive portions [C] are located in almost the same depth.
  • Page 371: Water Temperature Sensor Inspection

    16-74 ELECTRICAL SYSTEM Switch and Sensor Water Temperature Sensor Inspection • Remove the water temperature sensor (see Cooling Sys- tem chapter). • Suspend the sensor [A] in a container of coolant so that the temperature-sensing projection and threaded portion are submerged. •...
  • Page 372: Junction Box

    ELECTRICAL SYSTEM 16-75 Junction Box The junction box [A] has fuses [B], relays, and diodes. The relays and diodes can not be removed. Junction Box Fuse Circuit Inspection • Remove the seats (see Frame chapter). • Remove the junction box. •...
  • Page 373: Diode Circuit Inspection

    16-76 ELECTRICAL SYSTEM Junction Box Relay Circuit Inspection (with the battery disconnected) Tester Tester Reading Tester Tester Reading Connection (Ω) Connection (Ω) *7-8 ∞ 9-11 ∞ *7-13 ∞ 12-13 ∞ Headlight Starter Circuit (+) (-) Relay Relay (+) (-) Not ∞ ** 13-11 ∞...
  • Page 374 ELECTRICAL SYSTEM 16-77 Junction Box Junction Box Internal Circuit (VN800-B1∼B7, United States, Canada and Australia) (VN800-B8, All Model) Junction Box Internal Circuit (VN800-B1 ∼ B7, Other than United States, Canada and Australia) A. Accessory Fuse 10 A E. Ignition Fuse 10 A J.
  • Page 375: Fuses

    16-78 ELECTRICAL SYSTEM Fuses 30 A Main Fuse Removal • Remove: Seat (see Frame chapter) 30 A Main Fuse Connector [A] • Pull out the main fuse [B] from the starter relay with needle nose pliers. Junction Box Fuse • Remove: Seat (see Frame chapter) Battery Leads...
  • Page 376 APPENDIX 17-1 Appendix Table of Contents Troubleshooting Guide ......................17-2 Cable, Wire, and Hose Routing ....................17-7...
  • Page 377: Troubleshooting Guide

    17-2 APPENDIX Troubleshooting Guide NOTE Neutral, starter lockout, or side stand switch ○ This is not an exhaustive list, giving every trouble possible cause for each problem listed. It Pickup coil trouble is meant simply as a rough guide to assist Ignition coil trouble the troubleshooting for some of the more Ignition or engine stop switch shorted...
  • Page 378 APPENDIX 17-3 Troubleshooting Guide Compression low: Fuel line clogged Spark plug loose Compression low: Cylinder head not sufficiently tightened Spark plug loose down Cylinder head not sufficiently tightened No valve clearance down Cylinder, piston worn No valve clearance Piston ring bad (worn, weak, broken, or Cylinder, piston worn sticking) Piston ring bad (worn, weak, broken, or...
  • Page 379: Abnormal Engine Noise

    17-4 APPENDIX Troubleshooting Guide Drive train trouble Shift mechanism arm spring broken Brake dragging Shift mechanism arm broken Lubrication inadequate: Shift pawl broken Engine oil level too low Jumps out of gear: Engine oil poor quality or incorrect Shift fork worn, bent Coolant incorrect: Gear groove worn Coolant level too low...
  • Page 380: Abnormal Drive Train Noise

    APPENDIX 17-5 Troubleshooting Guide Abnormal Drive Train Noise: Valve oil seal damaged Clutch noise: Valve guide worn Clutch rubber damper weak or damaged Engine oil level too high Clutch housing/friction plate clearance ex- Black smoke: cessive Air cleaner clogged Clutch housing gear worn Main jet too large or fallen off Transmission noise: Choke plunger stuck open...
  • Page 381 17-6 APPENDIX Troubleshooting Guide Brake Doesn’t Hold: Brake lining contaminated with oil Disc brake: Battery Trouble: Air in the brake line Pad or disc worn Battery discharged: Brake fluid leakage Battery faulty (e.g., plates sulphated, Disc warped shorted through sedimentation, elec- Contaminated pad trolyte insufficient) Brake fluid deteriorated...
  • Page 382 APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Clamp (Left and Right Handlebar Switch Leads) 2. Clamp (Brake Hose and Right Handlebar Switch Lead) 3. Damper (Install to the band) 4. Grommet 5. Strap (Air Vent Hose, Fuel Tank Drain Hose) 6.
  • Page 383 17-8 APPENDIX Cable, Wire, and Hose Routing...
  • Page 384 APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Rectifiers 2. Bracket 3. LH Switch Lead Connector 4. RH Switch Lead Connector 5. LH Switch Lead Connector 6. Radiator Fan Lead Connector 7. Rear Brake Light Switch Lead Connector 8. Side Stand Switch Lead Connector 9.
  • Page 385 17-10 APPENDIX Cable, Wire, and Hose Routing 1. Fuel Tank Drain Hose 2. Clamp 3. Tighten the lead to the crankcase. 4. Starter Motor Lead 5. Alternator Leads 6. Ignition Switch 7. Choke Knob 8. Insert the clamp into the hole on the frame. 9.
  • Page 386 APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Clamp (Attached rubber) 9. Clamps (Speedometer Cable) 2. Front Brake Hose 10. Speedometer Cable 3. Bleed Valve 11. Brake Cable End Mount 4. Front Caliper Mounting Bolts 12. Clamp (Brake Cable) 5. Clamp (Attached rubber) 13.
  • Page 387 17-12 APPENDIX Cable, Wire, and Hose Routing 1. Clamp 7. Run the vent hose through right side of 2. Fuel Tank Drain Hose the frame and insert the end of it into the 3. Clamp (Fuel tank drain and breather bracket of the storage box.
  • Page 388 APPENDIX 17-13 Cable, Wire, and Hose Routing VN800-B7 ∼ B8 Model 1. Fuel Tank Drain Hose 2. Fuel Tank Breather Hose 3. Clamp (Fuel tank drain and speed meter cable) 4. Clamp (Speed meter cable and breather hose)
  • Page 389 17-14 APPENDIX Cable, Wire, and Hose Routing 1. Vacuum Switch Valve 2. Fuel Hose 3. Vacuum Hose 4. Throttle Sensor 5. Choke Cable Joint 6. Air Vent Joint 7. Band (Tighten the band as shown) 8. Air Cleaner Drain Hose 9.
  • Page 390 APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Install the hose with the mark upside. 2. Radiator 3. Align the marks. 4. Right Engine Cover 5. Hose (between the thermostat and the reserve tank)
  • Page 391 17-16 APPENDIX Cable, Wire, and Hose Routing Evaporative Emission Control System (California Model) 1. Vacuum Hose (White) 10. Canister Purge Hose (Green) 2. Clamp (Clamp the vacuum hose and the 11. Run the fuel tank breather hose through fuel return hose) this hole 3.
  • Page 392 MODEL APPLICATION Year Model Beginning Frame No. □ JKBVNCB1 TA030001, 1996 VN800-B1 VN800A-030001, or VN800B-000001 (Germany) □ JKBVNCB1 VA050001, 1997 VN800-B2 VN800A-050001, or VN800B-005001 (Germany) □ JKBVNCB1 WA063001, □ JKBVNCB1 WB50005, 1998 VN800-B3 VN800A-063001, or VN800B-008001 (Germany) □ JKBVNCB1 XA075001, □...

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Vulcan 800 classic