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EN500
VULCAN 500 LTD
Motorcycle
Service Manual

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Table of Contents

   Also See for Kawasaki EN500 Vulcan 500 LTD

   Summary of Contents for Kawasaki EN500 Vulcan 500 LTD

  • Page 1 EN500 VULCAN 500 LTD Motorcycle Service Manual...
  • Page 3 Quick Reference Guide General Information Fuel System Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires Final Drive 10 j Brakes 11 j Suspension 12 j Steering 13 j Frame 14 j Electrical System 15 j Appendix 16 j This quick reference guide will assist...
  • Page 4 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 5: Emission Control Information

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

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

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications (EN500-C1 ∼ C6F Models) ..............General Specifications (EN500C7F Model ∼)................. Periodic Maintenance Chart ....................1-12 Torque and Locking Agent...................... 1-16 Unit Conversion Table ......................1-21...
  • Page 10: 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 11 GENERAL INFORMATION 1-3 Before Servicing (10)Liquid Gasket, Locking Agent Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used. Apply them sparingly. Excessive amount may block engine oil passages and cause serious dam- age. (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.
  • Page 12 1-4 GENERAL INFORMATION Before Servicing Two-Color Electrical (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...
  • Page 13: Model Identification

    GENERAL INFORMATION 1-5 Model Identification...
  • Page 14: General Specifications (en500-c1 ~ C6f Models)

    1-6 GENERAL INFORMATION General Specifications (EN500-C1 ∼ C6F Models) EN500-C1 ∼ C5 EN500-C6 ∼ C6F Items Dimensions Overall Length 2 320 mm (91.3 in.) ← Overall Width 830 mm (32.7 in.) ← Overall Height 1 125 mm (44.3 in.) ← Wheelbase 1 595 mm (62.8 in.) ←...
  • Page 15 GENERAL INFORMATION 1-7 General Specifications (EN500-C1 ∼ C6F Models) EN500-C1 ∼ C5 EN500-C6 ∼ C6F Items Duration 254° ← Lubrication System Forced lubrication (wet sump) ← Engine Oil: Grade SE, SF or SG class API SE, SF or SG API SH or SJ with JASO MA Viscosity SAE10W-40, 10W-50, 20W-40, or 20W-50...
  • Page 16 1-8 GENERAL INFORMATION General Specifications (EN500-C1 ∼ C6F Models) EN500-C1 ∼ C5 EN500-C6 ∼ C6F Items Rear Suspension: Type Swing arm ← Wheel Travel 100 mm (3.9 in.) ← Brake Type: Front Single disc ← Rear Drum ← Electrical Equipment Battery 12 V 12 Ah ←...
  • Page 17: General Specifications (en500c7f Model ~)

    GENERAL INFORMATION 1-9 General Specifications (EN500C7F Model ∼) EN500C7F ∼ Items Dimensions Overall Length 2 320 mm (91.3 in.) Overall Width 830 mm (32.7 in.) Overall Height 1 125 mm (44.3 in.) Wheelbase 1 595 mm (62.8 in.) Road Clearance 120 mm (4.92 in.) Seat Height 715 mm (31.5 in.)
  • Page 18 1-10 GENERAL INFORMATION General Specifications (EN500C7F Model ∼) EN500C7F ∼ Items Lubrication System Forced lubrication (wet sump) Engine Oil: Grade API SE, SF or SG class API SH, SJ or SL with JASO MA Viscosity SAE10W-40 Capacity 3.4 L (3.59 US qt) Drive Train Primary Reduction System: Type...
  • Page 19 GENERAL INFORMATION 1-11 General Specifications (EN500C7F Model ∼) EN500C7F ∼ Items 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 Alternator: Type Three-phase AC...
  • Page 20: Periodic Maintenance Chart

    1-12 GENERAL INFORMATION Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. ( Other than United States and Canada Models) FREQUENCY Whichever * ODOMETER...
  • Page 21 GENERAL INFORMATION 1-13 Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER comes READING first × 1 000 km (× 1 000 mile) OPERATION Every (0.6) (4.0) (7.5) (12) (15) (20) (24) • • • Swingarm pivot - lubricate • Radiator hoses, connections - inspect † •...
  • Page 22 1-14 GENERAL INFORMATION Periodic Maintenance Chart (United States and Canada Models) FREQUENCY * ODOMETER Whichever READING comes × 1 000 km first (× 1 000 mile) 20 25 30 OPERATION Every (0.5) (3.1) (6.2) (9.3) (12) (16) (20) • • • • • • • Carburetor synchronization - inspect †...
  • Page 23 GENERAL INFORMATION 1-15 Periodic Maintenance Chart FREQUENCY * ODOMETER Whichever READING comes × 1 000 km first (× 1 000 mile) 20 25 30 OPERATION Every (0.5) (3.1) (6.2) (9.3) (12) (16) (20) • • • • Engine oil - change year •...
  • Page 24: Torque And Locking Agent

    1-16 GENERAL INFORMATION Torque and Locking Agent Tighten all bolts and nuts to the proper torque using an accurate torque wrench. An insufficiently tightened bolt or nut may become damaged or fall off, possibly resulting in damage to the motorcycle and injury to the rider.
  • Page 25 GENERAL INFORMATION 1-17 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Clutch Oil Filler Plug 0.15 13 in·lb 13.5 Clutch Hub Nut Clutch Spring Bolts 0.95 82 in·lb Clutch Cable Holder Bolt 95 in·lb Clutch Cover Bolts 95 in·lb Clutch Cover Damper Plate Bolts 87 in·lb Engine Lubrication System...
  • Page 26 1-18 GENERAL INFORMATION Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Shift Drum Cam Pin Plate Screw – – – Shift Rod Stopper Bolt 95 in·lb External Shift Mechanism Cover Bolts 95 in·lb Neutral Switch Wheels/Tires Front Axle Nut Front Axle Clamp Allen Bolt Rear Axle Nut Spoke Nipples...
  • Page 27 GENERAL INFORMATION 1-19 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Steering Stem Nut Hand Hand Hand -Tighten -Tighten -Tighten (about (about (about 43 4.9) 0.5) in·lb) Frame Side Stand Mounting Bolt Footpeg Holder Bolts (M10) Footpeg Holder Bolts (M12) Muffler Bracket Bolts (M8) Muffler Bracket Bolts (M10) Electrical System...
  • Page 28 1-20 GENERAL INFORMATION Torque and Locking Agent The table relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.
  • Page 29: Unit Conversion Table

    GENERAL INFORMATION 1-21 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 31: Fuel System

    FUEL SYSTEM 2-1 Fuel System Table of Contents Exploded View........Carburetor Inspection ....2-15 Specifications ........Coolant Filter Cleaning (AT, Special Tools ........DE, FR, IT, NL, CH, GB, KR, Throttle Grip and Cable ..... Models) ........2-16 Throttle Grip Free Play Inspection Air Cleaner.........
  • Page 32: Exploded View

    2-2 FUEL SYSTEM Exploded View A: Austria, Germany, France, Italy, Korea, Netherlands, Switzerland and United Kingdom Models Europe Models (EN500-C6 ∼) B: California Model CL: Apply cable lubricant. G: Apply grease.
  • Page 33 FUEL SYSTEM 2-3 Exploded View 1. Jet Needle 4.9 N·m (0.5 kgf·m, 43 in·lb) (with black 2. Pilot Screw washer) 3. Plug (United States, Canada and Switzer- A: United States, Switzerland, Austria, Ko- land Models) rea and California Models 4. Pilot Jet Canada and Germany Models (EN500 -C2 ∼) 5.
  • Page 34: Specifications

    2-4 FUEL SYSTEM Specifications Standard Item EN500-C1 ∼ C4 EN500-C5 ∼ Throttle Grip and Cables 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play ← Carburetor specifications Make/Type Keihin/CVK32 ← Main Jet #102 ← Main Air Jet #100 ←...
  • Page 35: Special Tools

    FUEL SYSTEM 2-5 Special Tools Fuel Level Gauge: Vacuum Gauge: 57001-1017 57001-1369 Pilot Screw Adjuster, C: 57001-1292...
  • Page 36: Throttle Grip And Cable

    2-6 FUEL SYSTEM Throttle Grip and Cable Throttle Grip Free Play Inspection • Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cable. Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Standard: •...
  • Page 37: Throttle Cable Inspection

    FUEL SYSTEM 2-7 Throttle Grip and Cable Throttle Cable Inspection • Remove both ends of the throttle cables. • 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 38: Carburetors

    High Altitude Performance Adjustment (United States Model) ○ To improve the EMISSION CONTROL PERFORMANCE of vehicle operated above 4 000 feet, Kawasaki recom- mends the following Environmental Protection Agency (EPA) approved modification. • Change the main jet and pilot jet for high altitude use.
  • Page 39: Synchronization Adjustment

    FUEL SYSTEM 2-9 Carburetors • Start the engine and let it idle to measure the carburetor intake vacuum. If the intake vacuum difference between the two cylinders exceeds the limit, adjust the synchronization. Engine Vacuum Synchronization Less than 2.7 kPa (2 cmHg) difference between both cylinders Synchronization Adjustment •...
  • Page 40: Service Fuel Level Adjustment

    2-10 FUEL SYSTEM Carburetors • Keeping the gauge vertical, slowly lower the gauge until the “middle” line is even with the bottom edge of the car- buretor body. NOTE ○ Do not lower the “middle” line below the bottom edge of the carburetor body.
  • Page 41: Fuel System Cleanliness Inspection

    FUEL SYSTEM 2-11 Carburetors NOTE ○ Do not push the needle rod [A] in during the float height measurement [B]. • Assemble the carburetor, and recheck the fuel level. If the fuel level cannot be adjusted by this method, the float or the float valve [C] is damaged.
  • Page 42: Carburetor Installation

    2-12 FUEL SYSTEM Carburetors • Loosen the carburetor clamps [A] and slide back the spring bands [B]. • Remove the carburetor from the end of the air cleaner duct, and then pull it out of the carburetor holder. • Remove the carburetor to the left side. •...
  • Page 43 FUEL SYSTEM 2-13 Carburetors • Turn in the pilot screw [A] fully but not tightly, and then back it out the same number of turns counted during dis- assembly. • For the United States and Switzerland models, install the pilot screw plug as follows: ○...
  • Page 44: Carburetor Separation/assembly

    2-14 FUEL SYSTEM Carburetors Carburetor Separation/Assembly • Read the WARNINGS in the Carburetor Removal. • The center lines of the carburetor bores must be parallel both horizontally and vertically. If they are not, loosen the mounting screws and align the carburetors on a flat surface.
  • Page 45: Carburetor Inspection

    FUEL SYSTEM 2-15 Carburetors CAUTION Do not use compressed air on an assembled carbu- retor, or the floats 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 46: Coolant Filter Cleaning (at, De, Fr, It, Nl, Ch, Gb, Kr, Models)

    2-16 FUEL SYSTEM Carburetors • Disassemble the carburetors. • Clean the carburetors. • Check that the O-rings on the float bowl and drain plug 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 47: Air Cleaner

    FUEL SYSTEM 2-17 Air Cleaner Air Cleaner Housing Removal • Remove: Side Covers (see Right and Left Side Cover Removal in the Frame chapter) Seat (see Seat Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal) Air Suction Valve Vacuum Hose (AT, KR, CH and US Models), (EN500-C2 ∼...
  • Page 48: Air Cleaner Element Cleaning And Inspection

    2-18 FUEL SYSTEM Air Cleaner Air Cleaner Element Cleaning and Inspection NOTE ○ In dusty areas, the element should be cleaned more frequently than the recommended interval. ○ After riding through rain or on muddy roads, the element should be cleaned immediately. WARNING Clean the element in a well-ventilated area, and take care that there are no sparks or fame anywhere near...
  • Page 49: Fuel Tank

    FUEL SYSTEM 2-19 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 50: Fuel Tank Installation

    2-20 FUEL SYSTEM Fuel Tank Fuel Tank Installation • Read the WARNING in the Fuel Tank Removal section. • Check the rubber dampers [A] on the frame top-tube. If the dampers are damaged or deteriorated, replace them. • Route the hoses and leads correctly (see Cable, Wire and Hose Routing in the Appendix chapter).
  • Page 51: Fuel Tap Inspection

    FUEL SYSTEM 2-21 Fuel Tank • Pour high-flash point solvent through the tap in all lever position. • Dry the tank and tap with compressed air. • Install the tap in the tank. • Install the fuel tank. Fuel Tap Inspection •...
  • Page 52: Evaporative Emission Control System (california Model Only)

    2-22 FUEL SYSTEM 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 53: Separator Operation Test

    FUEL SYSTEM 2-23 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 55 COOLING SYSTEM 3-1 Cooling System Table of Contents Exploded View........................Specifications ......................... Cooling System......................... Special Tool and Sealant ......................Coolant ........................... Coolant Deterioration ......................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Visual Leak Inspection ...................... Cooling System Pressure Testing ..................Flushing ..........................
  • Page 56: Exploded View

    3-2 COOLING SYSTEM Exploded View 1. Fan Switch T5: 9.8 N·m (1.0 kgf·m, 87 in·lb) 2. Water Temperature Switch T6: 18 N·m (1.8 kgf·m, 13 ft·lb) 3. Thermostat T7: 25 N·m (2.5 kgf·m, 18 ft·lb) 4. Coolant Filter Body A: Austria, Germany, France, Italy, Korea, 5.
  • Page 57: Specifications

    COOLING SYSTEM 3-3 Specifications Item Standard Coolant Provided When Shipping Type Permanent type antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engine and radiator) Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point –35°C (–31°F) Total Amount 1.3 L (1.37 US qt) (up to “FULL”...
  • Page 58: Special Tool And Sealant

    3-4 COOLING SYSTEM Special Tool and Sealant Bearing Driver Set: Kawasaki Bond (Silicone Sealant): 57001-1129 56019-120...
  • Page 59: Coolant

    COOLING SYSTEM 3-5 Coolant Coolant Deterioration • 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 60 3-6 COOLING SYSTEM Coolant WARNING To avoid burns do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery and can cause an accident and injury.
  • Page 61: Coolant Filling

    COOLING SYSTEM 3-7 Coolant Coolant Filling • Install the drain plug. Always replace the gasket with a new one, if it is damaged. • Tighten the drain plug. Torque - Coolant Drain Plug: 11 N·m (1.1 kgf·m, 95 in·lb) • Fill [A] the radiator up to the bottom of the radiator filler neck [B] with coolant [C], and install the cap turning it clockwise about 1/4 turn.
  • Page 62: Cooling System Pressure Testing

    3-8 COOLING SYSTEM Coolant Cooling System Pressure Testing CAUTION During pressure testing, do not exceed the pres- sure for which the system is designed. The maxi- mum pressure is 123 kPa (1.25 kgf/cm², 18 psi). • Remove the meter instruments (see Meter Instruments Removal in the Electrical System chapter).
  • Page 63: Water Pump

    Apply silicone sealant to the area [A] where the mating surface of the crankcase contacts the water pump hous- ing gasket. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Apply high temperature grease to the lips of the water pump housing oil seal.
  • Page 64: Water Pump Housing Disassembly

    3-10 COOLING SYSTEM Water Pump • Be sure to install the water pipe O-rings [A], and apply high temperature grease to them. • Install the water pump cover with the water pipe, being careful of the two knock pins [B]. Torque - Water Pump Cover Bolts: 11 N·m (1.1 kgf·m, 95 in·lb) Water Pump Housing Disassembly...
  • Page 65: Pump Impeller Inspection

    COOLING SYSTEM 3-11 Water Pump Pump Impeller Inspection • Visually check the impeller [A]. If the surface is corroded, or if the blades are damaged, replace the impeller. Mechanical Seal Inspection • Visually inspect the mechanical seal. If any one of the parts is damaged, replace the mechani- cal seal as a unit.
  • Page 66: Radiator, Radiator Fan

    3-12 COOLING SYSTEM Radiator, Radiator Fan Radiator Fan Removal WARNING The radiator fan and fan switch are connected di- rectly to the battery. The radiator fan may start even if the ignition switch is off. Never touch the radiator fan until the radiator fan connector is disconnected.
  • Page 67: Radiator Installation

    COOLING SYSTEM 3-13 Radiator, Radiator Fan • Unscrew the radiator mounting bolts [A]. • Remove the radiator [A] with the core guard and fan [B] taking care not to damage the radiator core. • Separate the radiator fan from the radiator. Radiator Installation •...
  • Page 68: Filler Neck Inspection

    3-14 COOLING SYSTEM Radiator, Radiator Fan Filler Neck Inspection • Check the radiator filler neck for signs of damage. • Check the condition of the top [A] and bottom sealing seats [B] in the filler neck. They must be smooth and clean for the radiator cap to function properly.
  • Page 69: Thermostat

    COOLING SYSTEM 3-15 Thermostat Thermostat Removal • Remove: Coolant (Draining) Seat (see Seat Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) • Unscrew the thermostat housing bolts [A]. • Separate the housing [B] from the housing cover [C]. •...
  • Page 70 3-16 COOLING SYSTEM Thermostat • To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water. ○ The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an ac- curate thermometer [B] in the water so that the heat sen- sitive portions [C] are located in almost the same depth.
  • Page 71: Radiator Fan Switch, Water Temperature Switch

    Radiator Fan Switch, Water Temperature Switch Installation • Apply silicone sealant to the threads before mounting the water temperature switch. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 ○ Do not apply silicone sealant to the radiator fan switch on the radiator. •...
  • Page 73 ENGINE TOP END 4-1 Engine Top End Table of Contents Exploded View........Main Oil Pipe Removal ....4-17 Specifications ........Main Oil Pipe Installation ..... 4-17 Special Tools and Sealant ....Cylinder Head........4-18 Clean Air System (US, CH, AT, KR, Compression Measurement..
  • Page 74: Exploded View

    4-2 ENGINE TOP END Exploded View Europe and France Models (EN500-C6 ∼) T1: 4.9 N·m (0.5 kgf·m, 43 in·lb) T2: 9.8 N·m (1.0 kgf·m, 87 in·lb) O: Apply engine oil. T3: 11 N·m (1.1 kgf·m, 95 in·lb) S: Follow the specific tightening sequence. T4: 12 N·m (1.2 kgf·m, 104 in·lb)) SS: Apply silicone sealant.
  • Page 75 ENGINE TOP END 4-3 Exploded View 1. Closed coil end is downwards. A: United States, Switzerland, Austria, Ko- 2. Arrow mark must point toward the front rea and California Models Canada and (EN500-C1 ∼ C9 Model). Germany Models (EN500-C2 ∼) Europe and France Models (EN500-C6 ∼) Circle mark must point toward the front (EN500-C10 ∼).
  • Page 76: Specifications

    4-4 ENGINE TOP END Specifications Item Standard Service Limit Clean Air System (AT, CH, KR, US and EN500-C2 ∼ CA, DE) 57 ∼ 65 kPa Vacuum Switch Valve Closing Pressure: (430 ∼ 490 mmHg) Open → Close – – – Cylinder Head (usable range) 961 ∼...
  • Page 77 ENGINE TOP END 4-5 Specifications Item Standard Service Limit Valve Guide Inside Diameter: 5.500 ∼ 5.512 mm Inlet 5.58 mm (0.2165 ∼ 0.2170 in.) 5.500 ∼ 5.512 mm Exhaust 5.58 mm (0.2165 ∼ 0.2170 in.) Valve/Valve Guide Clearance (Wobble Method): 0.02 ∼...
  • Page 78 4-6 ENGINE TOP END Specifications Item Standard Service Limit Piston Ring Thickness: 0.77 ∼ 0.79 mm 0.7 mm (0.028 in.) (0.0303 ∼ 0.0311 in.) 0.97 ∼ 0.99 mm Second 0.9 mm (0.035 in.) (0.0382 ∼ 0.0390 in.) Piston Ring End Gap: 0.2 ∼...
  • Page 79: Special Tools And Sealant

    ENGINE TOP END 4-7 Special Tools and Sealant Piston Ring Pliers: Valve Guide Arbor, 5.5: 57001-115 57001-1021 Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 45° - 24.5: 57001-221 57001-1113 Valve Spring Compressor Assembly: Valve Seat Cutter, 32° - 25: 57001-241 57001-1118 Piston Pin Puller Assembly: Valve Seat Cutter, 32°...
  • Page 80 Valve Seat Cutter, 60° - 25: 57001-1128 57001-1328 Compression Gauge Adapter, M12 × 1.25: Vacuum Gauge: 57001-1183 57001-1369 Valve Seat Cutter, 45° - 30: Filler Cap Driver: 57001-1187 57001-1454 Valve Spring Compressor Adapter, 22: Kawasaki Bond (Silicone Sealant): 57001-1202 56019-120...
  • Page 81: Clean Air System (us, Ch, At, Kr, C2 ~ Ca, De & C6 ~ Eur, Fr)

    ENGINE TOP END 4-9 Clean Air System (US, CH, AT, KR, C2 ∼ CA, DE & C6 ∼ EUR, FR) Air Suction Valve Installation • Install the valve assembly [A] between the cylinder head cover and the cap. • Tighten the cap bolts. Torque - Air Suction Valve Cover Bolts: 11 N·m (1.1 kgf·m, 95 in·lb) Vacuum Switch Valve Installation...
  • Page 82: Vacuum Switch Valve Test

    4-10 ENGINE TOP END Clean Air System (US, CH, AT, KR, C2 ∼ CA, DE & C6 ∼ EUR, FR) Vacuum Switch Valve Test Using the vacuum gauge and a syringe, inspect the vac- uum switch operation as follows. • Remove the vacuum switch valve.
  • Page 83: Cylinder Head Cover

    • Be sure to install the knock pins [C]. • Apply silicone sealant [D] as shown. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Tighten the cover bolts [E]. Torque - Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
  • Page 84: Camshaft Chain Tensioner

    4-12 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type cam chain tensioner. The push rod does not return to its original position once it moves out to take up cam chain slack. Ob- serve all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.
  • Page 85: Camshaft, Camshaft Chain

    ENGINE TOP END 4-13 Camshaft, Camshaft Chain Camshaft Removal • Remove the cylinder head cover. • Position the crankshaft at #2 piston TDC. ○ Using a wrench on the crankshaft rotation bolt turn the crankshaft clockwise until the “C” mark line [A] on the rotor is aligned with the notch [B] in the edge of the upper hole in the alternator cover.
  • Page 86: Camshaft And Sprocket Assembly

    4-14 ENGINE TOP END Camshaft, Camshaft Chain • Engage the camshaft chain with the camshaft sprockets. ○ Pull the tension side [A] (inlet side) of the chain taut to install the chain. ○ The timing marks [B] on the inlet sprocket [C] must be aligned with the cylinder head upper surface [D].
  • Page 87: Camshaft, Camshaft Cap Wear Inspection

    ENGINE TOP END 4-15 Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear Inspection The journal wear is measured using plastigage (press gauge), which is inserted into the clearance to be mea- sured. The plastigage indicates the clearance by the amount it is compressed and widened when the parts are assembled.
  • Page 88: Rocker Shaft, Rocker Arm

    4-16 ENGINE TOP END Rocker Shaft, Rocker Arm Rocker Shaft, Rocker Arm Removal • Remove the camshafts (see Camshaft Removal). • Unscrew the rocker shafts [A] and remove the rocker arms [B] and springs [C]. ○ Mark and record the rocker arm locations so that the rocker arm can be reinstalled in their original positions.
  • Page 89: Oil Pipe

    ENGINE TOP END 4-17 Oil Pipe Cylinder Head Oil Pipe Removal • Remove the oil pipe mounting bolts [A] and pull the oil pipes [B] and O-rings out of the cylinder head. Cylinder Head Oil Pipe Installation • Flush out the oil pipes with a high-flash point solvent. •...
  • Page 90: Cylinder Head

    4-18 ENGINE TOP END Cylinder Head Compression Measurement • Remove the seat (see Seat Removal in the Frame chap- ter). • Thoroughly warm up the engine so that the engine oil be- tween the piston and cylinder wall will help seal compres- sion as it does during normal running.
  • Page 91: Cylinder Head Removal

    ENGINE TOP END 4-19 Cylinder Head Cylinder Head Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Exhaust Pipes and Mufflers (see Exhaust Pipe, Muffler Removal) Cam Chain Tensioner (see Chain Tensioner Removal) Camshafts (see Camshaft Removal) Carburetors (see Carburetor Removal in the Fuel Sys- tem chapter) •...
  • Page 92: Cylinder Head Warp Inspection

    4-20 ENGINE TOP END Cylinder Head • Install a new cylinder head gasket with “UP” [A] marked side positioning to the right. NOTE ○ The camshaft caps are machined with the cylinder head so if a new cylinder head is installed, use the caps that are supplied with the new head.
  • Page 93 ENGINE TOP END 4-21 Cylinder Head • Using compressed air, blow out any particles which may obstruct the oil passage [A] in the cylinder head. • Install the valves (see Valve Installation).
  • Page 94: Valves

    4-22 ENGINE TOP END Valves Valve Clearance Inspection NOTE ○ Valve clearance must be checked and adjusted when the engine is cold (room temperature). • Remove the cylinder head cover (see Cylinder Head Cover Removal). • Remove the cylinder head oil pipes (see Cylinder Head Oil Pipe Removal).
  • Page 95: Valve Clearance Adjustment

    ENGINE TOP END 4-23 Valves • Measure the clearance of each valve by inserting a thick- ness gauge [A] between the adjusting screw [B] and the valve stem. Valve Clearance (when cold) 0.13 ∼ 0.18 mm (0.0051 ∼ 0.0070 in.) Inlet: 0.18 ∼...
  • Page 96: Valve Guide Removal

    4-24 ENGINE TOP END Valves Valve Guide Removal • Remove: Valve (see Valve Removal) Oil Seal Spring Seats • Heat the area around the valve guide to about 120 ∼ 150°C (248 ∼ 302°F), and hammer lightly on the valve guide arbor [A] to remove the guide from the top of the head.
  • Page 97: Measuring Valve-to-guide Clearance (wobble Method) Inspection

    ENGINE TOP END 4-25 Valves If the width is too wide [G], too narrow [H] or uneven [J], repair the seat (see Valve Seat Repair). Valve Seating Surface Width 0.5 ∼ 1.0 mm (0.0020 ∼ 0.039 in.) Inlet: 0.5 ∼ 1.0 mm (0.0020 ∼ 0.039 in.) Exhaust: Measuring Valve-to-Guide Clearance (Wobble method) Inspection...
  • Page 98 4-26 ENGINE TOP END Valves Seat Cutter Operating Cares 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 99 ENGINE TOP END 4-27 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 100 4-28 ENGINE TOP END 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 101 ENGINE TOP END 4-29 Valves...
  • Page 102: Cylinder, Piston

    4-30 ENGINE TOP END Cylinder, Piston Cylinder Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the main oil pipe mounting bolt. • Pull out the water pipe with water pump cover (see Water Pump Removal in the Cooling System chapter). •...
  • Page 103: Piston Installation

    ENGINE TOP END 4-31 Cylinder, Piston Piston Installation • Install the oil ring expander [A] in the piston oil ring groove so that the expander ends [B] butt together, never overlap. • Install the upper and lower steel rails. There is no UP or DOWN to the rails.
  • Page 104: Piston Ring, Piston Ring Groove Wear Inspection

    4-32 ENGINE TOP END Cylinder, Piston Piston Ring, Piston Ring Groove Wear Inspection • Check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to the groove sur- faces. If not, the piston must be replaced. •...
  • Page 105: Piston Diameter Measurement

    ENGINE TOP END 4-33 Cylinder, Piston Piston Diameter Measurement • Measure the outside diameter [A] of each piston 5 mm (0.20 in.) [B] up from the bottom of the piston at a right angle to the direction of the piston pin. If the measurement is under the service limit, replace the piston.
  • Page 106: Carburetor Holder

    4-34 ENGINE TOP END Carburetor Holder Carburetor Holder Installation • Install the carburetor holders. The projection [A] faces upwards. • Install the holder clamps [A] as shown being careful of the screw position and the screw head [B] direction. WARNING Install the clamp screws horizontally.
  • Page 107: Exhaust Pipe, Muffler

    ENGINE TOP END 4-35 Exhaust Pipe, Muffler Exhaust Pipe, Muffler Removal • Loosen the muffler clamp bolts [A] on both sides. • Unscrew the muffler mounting bolts [B] on both sides, and remove the muffler [C]. • Loosen the exhaust pipe clamp bolt [A] under the engine. •...
  • Page 108: Exhaust Pipe, Muffler Installation

    4-36 ENGINE TOP END Exhaust Pipe, Muffler Exhaust Pipe, Muffler Installation • Check the gaskets for signs of damage. If necessary, replace the gaskets with new ones. • Exhaust pipe and muffler installation is the reverse of re- moval. • Connect the exhaust pipes while pushing toward the frame center until the flange [A] of the left pipe [B] over- laps with the clamp portion [C] of the right pipe [D].
  • Page 109 CLUTCH 5-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tool and Sealant ......................Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Clutch Lever Installation....................Cable Lubrication ......................Right Engine Cover ........................ Clutch Cover Removal ......................
  • Page 110: Exploded View

    5-2 CLUTCH Exploded View 1. Starter Lockout Switch T1: 11 N·m (1.1 kgf·m, 95 in·lb) T2: 132 N·m (13.5 kgf·m, 98 ft·lb) CL: Apply cable lubricant. G: Apply high temperature grease.
  • Page 111 CLUTCH 5-3 Exploded View T1: 1.5 N·m (0.15 kgf·m, 13 in·lb) L: Apply a non-permanent locking agent. T2: 9.3 N·m (0.95 kgf·m, 82 in·lb) M: Apply molybdenum disulfide grease. T3: 9.8 N·m (1.0 kgf·m, 87 in·lb) O: Apply engine oil. T4: 11 N·m (1.1 kgf·m, 95 in·lb) SS: Apply silicone sealant.
  • Page 112: Specifications

    5-4 CLUTCH Specifications Item Standard Service Limit Clutch Lever 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play – – – Clutch Clutch Spring Free Length 34.2 mm (1.346 in.) 33.1 mm (1.303 in.) 2.9 ∼ 3.1 mm (0.1142 ∼ 0.1220 in.) Friction Plate Thickness 2.75 mm (0.108 in.) Friction And Steel Plate Warp...
  • Page 113: Special Tool And Sealant

    CLUTCH 5-5 Special Tool and Sealant Clutch Holder: Kawasaki Bond (Silicone Sealant): 57001-1243 56019-120...
  • Page 114: Clutch Lever And Cable

    5-6 CLUTCH Clutch Lever and Cable Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accor- dance with the Periodic Maintenance Chart. WARNING To avoid a serious burn, never touch the engine or exhaust pipe during clutch adjustment.
  • Page 115: Clutch Lever Installation

    CLUTCH 5-7 Clutch Lever and Cable • Slip the rubber dust cover back into place. • Turn the adjuster [B] at the clutch lever until the free play [C] is correct. • Tighten the knurled locknut [A] at the clutch lever. WARNING Be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever, or...
  • Page 116: Right Engine Cover

    • Apply silicone sealant to the area [A] where the mating surface of the crankcase touches the clutch cover gasket. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Install the knock pins [B], and replace the cover gasket with a new one.
  • Page 117: Clutch Release Installation

    CLUTCH 5-9 Right Engine Cover Clutch Release Installation CAUTION Always install a new oil seal when the clutch release shaft is removed. • Apply high temperature grease to the oil seal lips in the clutch cover. • Apply oil to the bearings in the hole of the clutch cover. •...
  • Page 118: Clutch Removal

    5-10 CLUTCH Clutch Clutch Removal • Drain the engine oil (see Engine Oil Change in the Engine Lubrication System chapter). • Remove the clutch cover (see Clutch Cover Removal). • Remove the clutch spring bolts [A], washers [B] and springs. •...
  • Page 119: Clutch Plate Wear, Damage Inspection

    CLUTCH 5-11 Clutch ○ The grooves [A] on the friction plate surfaces are cut tan- gentially and radially, install the friction plates so that the grooves run toward the center in the direction of the clutch housing rotation (counterclockwise viewed from the en- gine right side).
  • Page 120: Clutch Spring Free Length Measurement

    5-12 CLUTCH Clutch Clutch Spring Free Length Measurement • Measure the free length of the clutch spring [A]. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 34.2 mm (1.346 in.) Service Limit: 33.1 mm (1.303 in.) Clutch Housing Finger Inspection...
  • Page 121 ENGINE LUBRICATION SYSTEM 6-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools and Sealant ...................... Engine Oil and Oil Filter......................Engine Oil Level Inspection ....................Engine Oil Change......................Oil Filter Change ....................... Oil Pan and Relief Valve......................
  • Page 122: Exploded View

    6-2 ENGINE LUBRICATION SYSTEM Exploded View 1. Oil Filter T7: 20 N·m (2.0 kgf·m, 14.5 ft·lb) 2. Oil Passage Plug T8: 25 N·m (2.5 kgf·m, 18 ft·lb) T1: 1.5 N·m (0.15 kgf·m, 13 in·lb) T9: 39 N·m (4.0 kgf·m, 29 ft·lb) T2: 7.8 N·m (0.80 kgf·m, 69 in·lb) G: Apply high temperature grease.
  • Page 123 ENGINE LUBRICATION SYSTEM 6-3 Exploded View 1. Oil Pump Drive Gear T1: 11 N·m (1.1 kgf·m, 95 in·lb) 2. Oil Pump T2: 15 N·m (1.5 kgf·m, 11 ft·lb) 3. Oil Screen T3: 29 N·m (3.0 kgf·m, 22 ft·lb) 4. Oil Pressure Relief Valve T4: 5.9 N·m (0.6 kgf·m, 52 in·lb) 5.
  • Page 124: Engine Oil Flow Chart

    6-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 125: Specifications

    ENGINE LUBRICATION SYSTEM 6-5 Specifications Item Standard Engine Oil and Oil Filter Engine Oil: Grade: EN500-C1 ∼ C5 SE, SF or SG class EN500-C6 ∼ C6F API SE, SF or SG API SH or SJ with JASO MA EN500C7F ∼ API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity:...
  • Page 126: Special Tools And Sealant

    6-6 ENGINE LUBRICATION SYSTEM Special Tools and Sealant Oil Pressure Gauge, 10 kgf/cm²: Oil Pressure Gauge Adapter, M18 × 1.5: 57001-164 57001-1278 Oil Filter Wrench: Kawasaki Bond (Silicone Sealant): 57001-1249 56019-120...
  • Page 127: Engine Oil And Oil Filter

    ENGINE LUBRICATION SYSTEM 6-7 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. Engine Oil Level Inspection •...
  • Page 128: Engine Oil Change

    6-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter Engine Oil Change • Warm up the engine so that the oil will pick up any sedi- ment and drain easily. Then stop the engine. • Support the motorcycle perpendicular to the ground, and place an oil pan beneath the engine.
  • Page 129: Oil Filter Change

    ENGINE LUBRICATION SYSTEM 6-9 Engine Oil and Oil Filter Oil Filter Change • Support the motorcycle perpendicular to the ground. • Drain the engine oil (see Engine Oil Change). • Using an oil filter wrench [A] on the oil filter [B], unscrew Special Tool - Oil Filter Wrench: 57001-1249 •...
  • Page 130: Oil Pan And Relief Valve

    6-10 ENGINE LUBRICATION SYSTEM Oil Pan and Relief Valve Oil Pan Removal • Drain the engine oil (see Engine Oil Change). • Disconnect the oil pressure switch lead. • Remove the oil pan mounting bolts [A] and the oil pan from the crankcase.
  • Page 131: Relief Valve Inspection

    ENGINE LUBRICATION SYSTEM 6-11 Oil Pan and Relief Valve Relief Valve Inspection • Remove the relief valve. • Check to see if the steel ball inside the valve slides smoothly when pushing it in with a wooden or other soft rod, and see if it comes back to its seat by valve spring pressure.
  • Page 132: Oil Pump

    6-12 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal • Drain the coolant (see Coolant Draining in the Cooling System chapter). • Drain the engine oil (see Engine Oil Change). • Remove the engine (see Engine Removal in the Engine Removal/Installation chapter).
  • Page 133: Oil Pump Installation

    ENGINE LUBRICATION SYSTEM 6-13 Oil Pump Oil Pump Installation • Fill the pump with engine oil turning the pump shaft before installation. • Apply a non-permanent locking agent to the threads of the oil pump mounting bolts and tighten them. Torque - Oil Pump Mounting Bolts: 11 N·m (1.1 kgf·m, 95 in·lb) •...
  • Page 134: Oil Screen Cleaning And Inspection

    6-14 ENGINE LUBRICATION SYSTEM Oil Pump Oil Screen Cleaning and Inspection • Clean the oil pump screen with high-flash point solvent and remove any particles stuck to it. WARNING Clean the screen in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area.
  • Page 135: Oil Pressure Measurement

    ENGINE LUBRICATION SYSTEM 6-15 Oil Pressure Measurement Oil Pressure Measurement NOTE ○ Measure the oil pressure after the engine is warmed up. • Remove: Right Footpeg Assembly (Hanging it) Oil Passage Plug WARNING If the oil passage plug is removed while the engine is warm, hot engine oil will drain through the oil pas- sage;...
  • Page 137 ENGINE REMOVAL/INSTALLATION 7-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tool ..........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 138: Exploded View

    7-2 ENGINE REMOVAL/INSTALLATION Exploded View T1: 44 N·m (4.5 kgf·m, 33 ft·lb) T2: 25 N·m (2.5 kgf·m, 18 ft·lb)
  • Page 139: Special Tool

    ENGINE REMOVAL/INSTALLATION 7-3 Special Tool Jack: 57001-1238...
  • Page 140: Engine Removal/installation

    7-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Removal • Raise the rear wheel off the ground. Special Tool - Jack: 57001-1238 • Drain the engine oil (see Engine Oil Change in the Engine Lubrication System chapter). • Drain the coolant (see Coolant Draining in the Cooling System chapter).
  • Page 141: Engine Installation

    ENGINE REMOVAL/INSTALLATION 7-5 Engine Removal/Installation • Support the engine with a stand [A]. • Remove the engine mounting nuts [B]. • Remove the engine bracket bolts [C] and nuts. • Remove the engine brackets [D]. • Remove the engine mounting bolts. •...
  • Page 143 CRANKSHAFT/TRANSMISSION 8-1 Crankshaft/Transmission Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Crankcase Splitting......................... Crankcase Splitting ......................Crankcase Assembly ......................Clutch Housing/Primary Chain ....................8-11 Clutch Housing/Primary Chain Removal................8-11 Clutch Housing/Primary Chain Installation................ 8-11 Primary Chain Guide Wear ....................8-12 Crankshaft/Connecting Rods....................
  • Page 144: Exploded View

    8-2 CRANKSHAFT/TRANSMISSION Exploded View 1. 8 mm Bolt (L 55 mm) T3: 12 N·m (1.2 kgf·m, 104 in·lb) 2. 6 mm Bolts (L 60 mm) T4: 15 N·m (1.5 kgf·m, 11 ft·lb) 3. 6 mm Bolts (L 80 mm) T5: 20 N·m (2.0 kgf·m, 14.5 ft·lb) 4.
  • Page 145 CRANKSHAFT/TRANSMISSION 8-3 Exploded View T1: 11 N·m (1.1 kgf·m, 95 in·lb) T2: 36 N·m (3.7 kgf·m, 27 ft·lb) L: Apply a non-permanent locking agent. LG: Apply liquid gasket - silver. M: Apply a thin coat of molybdenum disulfide grease. O: Apply engine oil. SS: Apply silicone sealant.
  • Page 146: Specifications

    8-4 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods Connecting Rod Bend – – – 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist – – – 0.2/100 mm (0.008/3.94 in.) 0.13 ∼ 0.38 mm Connecting Rod Big End Side Clearance 0.50 mm (0.02 (0.0051 ∼...
  • Page 147 CRANKSHAFT/TRANSMISSION 8-5 Specifications Item Standard Service Limit 35.984 ∼ 35.992 mm Marking None – – – (1.4167 ∼ 1.4170 in.) 35.993 ∼ 36.000 mm – – – (1.4170 ∼ 1.4173 in.) 39.000 ∼ 39.016 mm – – – Crankcase Main Bearing Bore Diameter: (1.5354 ∼...
  • Page 148 8-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit 1.495 ∼ 1.499 mm Brown – – – (0.0589 ∼ 0.0590 in.) 1.499 ∼ 1.503 mm Black – – – (0.0590 ∼ 0.0592 in.) 1.503 ∼ 1.507 mm Blue – – – (0.0592 ∼ 0.0593 in.) Balancer Shaft Bearing Insert Selection: Bearing Insert Crankcase Bearing...
  • Page 149: Special Tools And Sealant

    CRANKSHAFT/TRANSMISSION 8-7 Special Tools and Sealant Bearing Puller: Bearing Driver, 32: 57001-135 57001-382 Outside Circlip Pliers: Kawasaki Bond (Liquid Gasket - Silver): 57001-144 92104-002 Bearing Puller Adapter: 57001-317...
  • Page 150: Crankcase Splitting

    8-8 CRANKSHAFT/TRANSMISSION Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal in the Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Shift Lever (see External Shift Mechanism Removal) Starter Motor (see Starter Motor Removal in the Electri- cal System chapter) Water Pump (see Water Pump Removal in the Cooling...
  • Page 151: Crankcase Splitting

    • Apply liquid gasket to the mating surface of the lower crankcase half. Sealant - Kawasaki Bond (Liquid Gasket - Silver): 92104 -002 CAUTION Do not apply liquid gasket around the crankshaft main bearing inserts and balancer shaft inserts.
  • Page 152 8-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Tighten the lower crankcase-half bolts using the following 3 steps: ○ Tighten all lower crankcase-half bolts to a snug fit. ○ Following the sequence numbers on the lower crankcase half, torque the 8 mm bolts first to about one half of the specification, and finally to the specification in the same sequence.
  • Page 153: Clutch Housing/primary Chain

    CRANKSHAFT/TRANSMISSION 8-11 Clutch Housing/Primary Chain Clutch Housing/Primary Chain Removal • Remove the engine. • Remove: Cylinder Head, Cylinder and Pistons (see Cylinder Head, Cylinder, Piston Removal in the Engine Top End chapter) Starter Clutch Sprocket (see Alternator Rotor, Starter Clutch Removal in the Electrical System chapter) Clutch (except the Clutch Housing) •...
  • Page 154: Primary Chain Guide Wear

    8-12 CRANKSHAFT/TRANSMISSION Clutch Housing/Primary Chain • Install the spacer [A] onto the drive shaft [B], facing the chamfered side [C] to the ball bearing [D]. • Install the clutch housing in the reverse order of removal. Primary Chain Guide Wear •...
  • Page 155: Crankshaft/connecting Rods

    CRANKSHAFT/TRANSMISSION 8-13 Crankshaft/Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the clutch housing and the primary chain. • Remove the crankshaft with the camshaft chain and pri- mary chain. Crankshaft Installation CAUTION If the crankshaft, bearing inserts or crankcase halves are replaced with new ones, select the bear- ing inserts and check clearance with plastigage before assembling engine to be sure the correct...
  • Page 156: Crankshaft/connecting Rod Cleaning

    8-14 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark [D] • Apply engine oil to the inner surface of the upper and lower bearing inserts [A]. • Apply a small amount of engine oil to the threads [B] and seating surface [C] of the connecting rod big end cap nuts.
  • Page 157: Connecting Rod Big End Side Clearance Inspection

    CRANKSHAFT/TRANSMISSION 8-15 Crankshaft/Connecting Rods • Measure the connecting rod twist. ○ With the big-end arbor [A] still on V blocks [C], hold the connecting rod horizontal and measure the difference in the height of the arbor [B] above the surface plate over a 100 mm (3.94 in.) length of the arbor to determine the amount of connecting rod twist.
  • Page 158 8-16 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods ○ Remove the connecting rod big end caps, and mea- sure the plastigage width [A] to determine the bearing insert/crankpin [B] clearance. Connecting Rod Big End Bearing Insert/Crankpin Clearance 0.043 ∼ 0.073 mm (0.0017 ∼ 0.0029 in.) Standard: Service Limit: 0.10 mm (0.04 in.) If the clearance is within the standard, no bearing insert...
  • Page 159: Crankshaft Runout Inspection

    CRANKSHAFT/TRANSMISSION 8-17 Crankshaft/Connecting Rods NOTE ○ The mark already on the big end should almost coincide with the measurement. Connecting Rod Big End Bore Diameter Marks None: 41.000 ∼ 41.008 mm (1.6142 ∼ 1.6145 in.) ○ 41.009 ∼ 41.016 mm (1.6145 ∼ 1.6148 in.) [A] Big End Cap [B] Connecting Rod [C] Weight Mark...
  • Page 160 8-18 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods NOTE ○ Do not turn the crankshaft during clearance measure- ment. ○ Remove the lower crankcase half and measure the plas- tigage width [A] to determine the bearing insert/journal [B] clearance. Crankshaft Main Bearing Insert/Journal Clearance 0.020 ∼...
  • Page 161: Crankshaft Side Clearance Inspection

    CRANKSHAFT/TRANSMISSION 8-19 Crankshaft/Connecting Rods • Select the proper bearing insert in accordance with the combination of the crankcase and the crankshaft coding. • Install the new inserts in the crankcase halves and check insert/journal clearance with a plastigage. Crankshaft Main Bearing Insert Selection Crankcase Main Crankshaft Main Bearing Insert*...
  • Page 162: Balancer

    8-20 CRANKSHAFT/TRANSMISSION Balancer Balancer Removal • Split the crankcase (see Crankcase Splitting). • Pull the balancer shaft with the balancer gear out of the crankcase. Balancer Installation • Apply oil to the inside of the balancer shaft bearing insert. • Align the timing mark [A] on the balancer gear [B] with the timing mark on the balancer drive gear [C] of the crank- shaft.
  • Page 163 CRANKSHAFT/TRANSMISSION 8-21 Balancer If the clearance is between 0.050 mm (0.0020 in.) and the service limit 0.09 mm (0.0035 in.), replace the bearing in- serts [A] with inserts painted blue [B]. Check insert/journal clearance with a plastigage. The clearance may exceed the standard slightly, but it must not be less than the min- imum in order to avoid bearing seizure.
  • Page 164 8-22 CRANKSHAFT/TRANSMISSION Balancer Balancer Shaft Bearing Insert Selection Bearing Inset Balancer Shaft Crankcase Bearing Journal Diameter Part Number Bore Diameter Marking Size Color Marking L.H. R.H. ○ ○ Brown 92028-1497 92028-1692 None None Blue 92028-1495 92028-1690 ○ None Black 92028-1496 92028-1691 ○...
  • Page 165: Transmission

    CRANKSHAFT/TRANSMISSION 8-23 Transmission External Shift Mechanism Removal • Remove: Engine Sprocket (see Engine Sprocket Removal in the Final Drive chapter) Chain Guard [A] Neutral Switch Lead Connector [B] Shift Lever [C] • Place an oil pan beneath the external shift mechanism cover [A].
  • Page 166: External Shift Mechanism Inspection

    8-24 CRANKSHAFT/TRANSMISSION Transmission • Apply high temperature grease to the seal lips. • Insert the shift shaft into the cover [A], and then fit the shift mechanism arm [B] to the shift drum [C]. • Tighten the cover bolts. Torque - External Shift Mechanism Cover Bolts: 11 N·m (1.1 kgf·m.
  • Page 167: Transmission Shaft Installation

    CRANKSHAFT/TRANSMISSION 8-25 Transmission Transmission Shaft Installation • With a high-flash point solvent, clean off the outer cir- cumferences of the transmission ball bearings and needle bearings, and their bearing housings, and wipe dry. • Check to see that the set rings [A] and set pins [B] are in place in the transmission bearing housings.
  • Page 168: Drive Shaft Assembly

    8-26 CRANKSHAFT/TRANSMISSION Transmission Drive Shaft Assembly • Apply engine oil liberally to the drive shaft, gears, bear- ings and bushing. • Install the drive shaft ball bearing using the bearing driver [A]. Special Tool - Bearing Driver, 32: 57001-382 • Replace any circlips that were removed with new ones.
  • Page 169: Output Shaft Assembly

    CRANKSHAFT/TRANSMISSION 8-27 Transmission Output Shaft Assembly • Assembly is the reverse of disassembly. Note the follow- ing. • Apply engine oil liberally to the output shaft, gears, bear- ings, bushing and O-ring. • Install the output shaft ball bearing, O-ring and collar us- ing the bearing driver.
  • Page 170: Shift Drum And Fork Removal

    8-28 CRANKSHAFT/TRANSMISSION Transmission • The output shaft gears can be identified by size: the largest diameter gear is 1st gear, and the smallest is 6th. Be sure that all parts are put back in the correct sequence and facing the proper direction, and that all circlips and washers are properly in place.
  • Page 171: Shift Drum And Fork Installation

    CRANKSHAFT/TRANSMISSION 8-29 Transmission Shift Drum and Fork Installation • Insert the shift drum [A] into the crankcase part way, install the 3rd/4th shift fork [B] with the longer side [C] facing the neutral switch, i.e., the longer side goes onto the drum first.
  • Page 172: Shift Drum Disassembly

    8-30 CRANKSHAFT/TRANSMISSION Transmission Shift Drum Disassembly • Remove the screw [A] and the pin plate [B]. • Pull out the shift drum cam [C]. • Take off the ball bearing [D]. • Pull off the dowel pin [E]. Shift Drum Assembly •...
  • Page 173: Ball And Needle Bearing Wear Inspection

    CRANKSHAFT/TRANSMISSION 8-31 Transmission Ball and Needle Bearing Wear Inspection • Check the following ball bearings: shift drum LH, drive shaft RH, and output shaft LH. ○ Since the ball bearings are made to extremely close toler- ances, the wear must be judged by feel rather than mea- surement.
  • Page 174 8-32 CRANKSHAFT/TRANSMISSION Transmission • Install the shift pedal. • At this time, the center of the shift pedal [A] is about 89 mm (3.5 in.) [B] higher than the center of the footpeg [C]. Torque - Shift Pedal Mounting Bolt: 8.8 N·m (0.9 kgf·m, 78 in·lb) •...
  • Page 175 WHEELS/TIRES 9-1 Wheels/Tires Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Wheels (Rims) ........................Front Wheel Removal ....................... Front Wheel Installation ....................Rear Wheel Removal......................Rear Wheel Installation..................... Wheel Inspection ......................Spoke Inspection ......................Rim Inspection ........................Axle Inspection........................Balance Inspection......................
  • Page 176: Exploded View

    9-2 WHEELS/TIRES Exploded View T1: 5.2 N·m (0.53 kgf·m, 46 in·lb) G: Apply grease. T2: 34 N·m (3.5 kgf·m, 25 ft·lb) R: Replacement Parts T3: 88 N·m (9.0 kgf·m, 65 ft·lb) S: Follow the specific tightening sequence. A: Germany Model Europe and France Mod- WL: Apply soap and water solution or rubber els (EN500-C6 ∼) lubricant.
  • Page 177: Specifications

    WHEELS/TIRES 9-3 Specifications Item Standard Service Limit Wheels (Rims) Rim Size: Front 19 MC × MT 2.15 – – – Rear 15 MC × MT 3.00 – – – Rim Runout: Radial 1.0 mm (0.04 in.) 2.0 mm (0.08 in.) Axial 0.8 mm (0.03 in.) 2.0 mm (0.08 in.)
  • Page 178: Special Tools

    9-4 WHEELS/TIRES Special Tools Inside Circlip Pliers: Jack: 57001-143 57001-1238 Rim Protector: Bearing Remover Shaft, 9: 57001-1063 57001-1265 Bead Breaker Assembly: Bearing Remover Head, 15 × 17: 57001-1072 57001-1267 Bearing Driver Set: 57001-1129...
  • Page 179: Wheels (rims)

    WHEELS/TIRES 9-5 Wheels (Rims) Front Wheel Removal • Remove the speedometer cable lower end. • Loosen the front axle nut [A]. • Raise the front wheel off the ground. Special Tool - Jack: 57001-1238 • Loosen the axle clamp bolt [A]. •...
  • Page 180: Rear Wheel Installation

    9-6 WHEELS/TIRES Wheels (Rims) • Remove: Clip [A], Torque Link Nut [B] and Bolt Adjusting Nut [C] and Brake Rod [D] Cotter Pin [E] and Axle Nut [F] Screws [A] and Chain Cover [B] Axle [C] • Remove the drive chain [D] from the rear sprocket toward the left.
  • Page 181: Wheel Inspection

    WHEELS/TIRES 9-7 Wheels (Rims) • Bend the cotter pin [A] over the nut. • Check the rear brake (see Brake Pedal Position Inspec- tion in the Brakes chapter). Wheel Inspection • Raise the front/rear wheel off the ground. Special Tool - Jack: 57001-1238 •...
  • Page 182: Rim Inspection

    9-8 WHEELS/TIRES Wheels (Rims) Rim Inspection • Raise the front/rear wheel off the ground. Special Tool - Jack: 57001-1238 • Inspect the rim for small cracks, dents, bending, or warp- ing. If there is any damage to the rim, it must be replaced. •...
  • Page 183: Balance Adjustment

    WHEELS/TIRES 9-9 Wheels (Rims) Balance Adjustment • If the wheel always stops in one position, provisionally attach a balance weight [A] to the spoke. ○ 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 184: Tires

    9-10 WHEELS/TIRES Tires Air Pressure Inspection/Adjustment • Measure the tire air pressure with an air pressure gauge [A] when the tires are cold. Adjust the tire air pressure according to the specifications if necessary. Air Pressure (when cold) Up to 97.5 kg 200 kPa Front (215 lb) load...
  • Page 185: Tire Installation

    WHEELS/TIRES 9-11 Tires • Remove the wheel. • To maintain wheel balance, mark [A] the valve stem posi- tion on the tire with chalk so that the tire can be reinstalled in the same position. • Take out the valve core [B] to let out the air. •...
  • Page 186 9-12 WHEELS/TIRES Tires • If the tire is completely removed, pry one side back onto the rim. • Position the tire on the rim so that the valve [A] is at the tire balance mark [B] (the chalk mark made during removal or the yellow paint mark on a new tire).
  • Page 187: Hub Bearing

    WHEELS/TIRES 9-13 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 188: Hub Bearing Inspection

    9-14 WHEELS/TIRES 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 NOTE...
  • Page 189: Speedometer Gear

    WHEELS/TIRES 9-15 Speedometer Gear Disassembly and Assembly NOTE ○ It is recommended that the assembly be replaced rather than attempting to repair the components. • Install the speedometer gear so that it fits in the speedometer gear drive notches (see Front Wheel Installation).
  • Page 191 FINAL DRIVE 10-1 Final Drive Table of Contents Exploded View........................10-2 Specifications ......................... 10-3 Special Tools .......................... 10-4 Drive Chain..........................10-5 Drive Chain Slack Inspection .................... 10-5 Drive Chain Slack Adjustment ..................10-5 Wheel Alignment Inspection/Adjustment ................10-6 Drive Chain Wear Inspection .................... 10-6 Drive Chain Lubrication.....................
  • Page 192: Exploded View

    10-2 FINAL DRIVE Exploded View T1: 11 N·m (1.1 kgf·m, 95 in·lb) G: Apply grease. T2: 74 N·m (7.5 kgf·m, 54 ft·lb) L: Apply non-permanent locking agent. 59 N·m (6.0 kgf·m, 43 ft·lb) (Self Locknut) O: Apply oil. T3: 127 N·m (13 kgf·m, 94 ft·lb)
  • Page 193: Specifications

    FINAL DRIVE 10-3 Specifications Item Standard Service Limit Drive Chain 25 ∼ 35 mm (0.98 ∼ 1.38 in.) Chain Slack – – – 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 20-link Length 323 mm (12.7 in.) Standard Chain Make Enuma –...
  • Page 194: Special Tools

    10-4 FINAL DRIVE Special Tools Inside Circlip Pliers: Jack: 57001-143 57001-1238 Bearing Driver Set: 57001-1129...
  • Page 195: Drive Chain

    FINAL DRIVE 10-5 Drive Chain Drive Chain Slack Inspection NOTE ○ Check the slack with the motorcycle setting on its side stand. ○ Clean the chain if it is dirty, and lubricate it if it appears dry. • Check the wheel alignment (see Wheel Alignment Inspec- tion).
  • Page 196: Wheel Alignment Inspection/adjustment

    10-6 FINAL DRIVE Drive Chain • Bend the cotter pin [A] over the nut. • Check the rear brake. Wheel Alignment Inspection/Adjustment • Check that the right rear end [A] of the hole should align with the same graduation [B] that the left rear end aligns with.
  • Page 197: Drive Chain Lubrication

    FINAL DRIVE 10-7 Drive Chain 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 198: Drive Chain Removal

    10-8 FINAL DRIVE Drive Chain Drive Chain Removal • Remove: Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Swingarm (see Swingarm Removal in the Suspension chapter) Engine Sprocket Cover (see Engine Sprocket Cover Re- moval) • Disengage the drive chain [A] from the engine sprocket [B], and take it off the chassis.
  • Page 199 FINAL DRIVE 10-9 Drive Chain • Screw the pin holder until it touches the link pin. • Be sure that the cutting pin hits center of the link pin. • Screw the handlebar [A] into the body. • Turn the pin holder with the wrench [B] clockwise to ex- tract the link pin.
  • Page 200 10-10 FINAL DRIVE Drive Chain • Turn the pin holder [A] by wrench clockwise until two pins of link come into groove of the plate holders [B]. • Take off the plate holder. • Set the plate holder [A] and the cutting and rivetting pin [B] as shown.
  • Page 201 FINAL DRIVE 10-11 Drive Chain • After staking, check the staked area of the link pin for cracks. • Measure the outside diameter [A] of the link pin and link plates width [B]. Link Pin Outside Diameter 5.45 ∼ 5.85 mm (0.21 ∼ 0.23 in.) Standard: 5.6 ∼...
  • Page 202: Sprocket, Coupling

    10-12 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Remove the bolts [A]. • Pull the engine sprocket cover [B]. • Flatten out the bended washer [A]. • Remove the engine sprocket nut [B] and washer. NOTE ○ When loosening the engine sprocket nut, hold the rear brake on.
  • Page 203: Rear Sprocket Removal

    FINAL DRIVE 10-13 Sprocket, Coupling Rear Sprocket Removal • Remove the rear wheel (see Rear Wheel Removal in the 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 204: Coupling Bearing Removal

    10-14 FINAL DRIVE Sprocket, Coupling Coupling Bearing Removal • Remove: Coupling Grease Seal Circlip [A] Special Tool - Inside Circlip Pliers: 57001-143 [B] • Remove the bearing by tapping from the brake drum side. Special Tool - Bearing Driver Set: 57001-1129 [A] Coupling Bearing Installation •...
  • Page 205: Coupling Bearing Inspection And Lubrication

    FINAL DRIVE 10-15 Sprocket, Coupling Coupling Bearing Inspection and Lubrication NOTE ○ It is not necessary to remove the coupling bearing for inspection and lubrication. If the bearing is removed, it will need to be replaced with a new one. •...
  • Page 207 BRAKES 11-1 Brakes Table of Contents Exploded View........11-2 Brake Disc Warp Inspection..11-12 Specifications ........11-4 Brake Fluid ........11-13 Special Tool ........11-5 Brake Fluid Level Inspection..11-13 Caliper ..........11-6 Brake Fluid Change ..... 11-13 Caliper Removal ......11-6 Bleeding the Brake Line....
  • Page 208: Exploded View

    11-2 BRAKES Exploded View 1. Front Brake Light Switch T9: 34 N·m (3.5 kgf·m, 25 ft·lb) T1: 1.0 N·m (0.1 kgf·m, 9 in·lb) T10: 19 N·m (1.9 kgf·m, 13.5 ft·lb) T2: 1.2 N·m (0.12 kgf·m, 10 in·lb) B: Apply brake fluid. T3: 1.5 N·m (0.15 kgf·m, 13 in·lb) L: Apply a non-permanent locking agent.
  • Page 209 BRAKES 11-3 Exploded View T1: 25 N·m (2.5 kgf·m, 18 ft·lb) T2: 34 N·m (3.5 kgf·m, 25 ft·lb) T3: 19 N·m (1.9 kgf·m, 13.5 ft·lb) G: Apply grease. R: Replacement Parts...
  • Page 210: Specifications

    11-4 BRAKES Specifications Item Standard Service Limit Front Brake Pad Lining Thickness 4.85 mm (0.191 in.) 1 mm (0.04 in.) 4.8 ∼ 5.2 mm (0.189 ∼ 0.205 in.) Disc Thickness 4.5 mm (0.177 in.) Disc Runout Not more than 0.15 mm (0.006 in.) 0.3 mm (0.012 in.) Brake Fluid: Grade...
  • Page 211: Special Tool

    BRAKES 11-5 Special Tool Inside Circlip Pliers: 57001-143...
  • Page 212: Caliper

    11-6 BRAKES Caliper Caliper Removal • Drain the brake fluid. • 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. •...
  • Page 213: Caliper Assembly

    BRAKES 11-7 Caliper WARNING To avoid serious injury, never place your fingers or palm inside the caliper opening. If you apply com- pressed air into the caliper, the piston may crush your hand or fingers. • Remove the dust seal [A] and fluid seal [B]. •...
  • Page 214: Fluid Seal Damage Inspection

    11-8 BRAKES Caliper • Install the anti-rattle spring [A] in the caliper body as shown. • Install the piston insulator. • Install the pads. • Wipe up any spilled brake fluid on the caliper with wet cloth. Fluid Seal Damage Inspection The fluid seal around the piston maintains the proper pad/disc clearance.
  • Page 215: Brake Pads

    BRAKES 11-9 Brake Pads Brake Pad Removal • Remove the caliper holder (see Caliper Removal). • Take off the piston side pad from the caliper holder [A]. • Push the caliper holder to the piston side, and then re- move the pad [B] from the caliper holder shaft. Brake Pad Installation •...
  • Page 216: Master Cylinder

    11-10 BRAKES Master Cylinder Master Cylinder Removal • Disconnect the front brake switch leads [A]. • Remove the banjo bolt [B] to disconnect the upper brake hose end from the master cylinder [C]. There is a flat washer [D] on each side of the hose fitting. •...
  • Page 217: Master Cylinder Assembly

    BRAKES 11-11 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 218: Brake Disc

    11-12 BRAKES Brake Disc Brake Disc Removal • Remove the front wheel (see Front Wheel Removal in the Wheels/Tires chapter). • Unscrew the mounting Allen 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 219: Brake Fluid

    BRAKES 11-13 Brake Fluid Brake Fluid Level Inspection • Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. NOTE ○ Hold the reservoir horizontal by turning the handlebar when checking brake fluid level. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [A] in the reservoir [B].
  • Page 220: Bleeding The Brake Line

    11-14 BRAKES Brake Fluid Bleeding the Brake Line The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever is transmit- ted directly to the caliper for braking action. Air, however, is easily compressed.
  • Page 221 BRAKES 11-15 Brake Fluid 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 222: Brake Hose

    11-16 BRAKES Brake Hose Brake Hose 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 maintained.
  • Page 223: Brake Pedal And Cable

    BRAKES 11-17 Brake Pedal and Cable Brake Pedal Position Inspection • With the brake pedal [A] in the correct position, inspect the brake pedal position [B] as shown. Footpeg [C] Pedal Position Standard: About 55 mm (2.17 in.) above footpeg (from Top of the footpeg to Top of the brake Pedal) If it is incorrect, adjust the brake pedal position.
  • Page 224: Brake Pedal Removal

    11-18 BRAKES Brake Pedal and Cable Brake Pedal Removal • Remove: Adjuster [A] Clevis Pin [B] Return Spring [C] Dust Cover [D] Locknut [E] Brake Pedal Bolt [A] Brake pedal [B] Footpeg, Bracket Bolts [C] Footpeg Bracket [D] Brake Pedal Spring [A] Brake Switch Spring [B] Brake Shaft [C] with Brake Cable [D] Cotter Pin [A]...
  • Page 225: Brake Cable Lubrication

    BRAKES 11-19 Brake Pedal and Cable Brake Cable Lubrication Whenever the brake cable is removed, lubricate the cable as follows: • Lubricate the cable with a penetrating rust inhibitor.
  • Page 226: Brake Panel And Drum

    11-20 BRAKES 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 227: Brake Panel Disassembly

    BRAKES 11-21 Brake Panel and Drum Brake Panel Disassembly • Remove the brake panel (see Brake Panel Removal). • Hold the brake shoes, one in each hand with a clean cloth to protect the linings from grease and dirt. • Pull up on the shoes [A] to remove them from the panel.
  • Page 228: Brake Shoe Lining Wear Inspection

    11-22 BRAKES Brake Panel and Drum Brake Shoe Lining Wear Inspection • Remove the brake shoes (see Brake Panel Disassembly). • Measure the lining thickness [A]. ○ Use a pair of calipers or scale, and measure at several points as shown. Shoe Lining Thickness 4.9 ∼...
  • Page 229: Brake Drum Wear Inspection

    BRAKES 11-23 Brake Panel and Drum Brake Drum Wear Inspection • Remove the rear wheel (see Rear Wheel Removal in the Wheels/Tires chapter). • Measure the inside diameter [A] of the drum. ○ Use a pair of calipers and measure at several points. Drum Inside Diameter 180.00 ∼...
  • Page 231 SUSPENSION 12-1 Suspension Table of Contents Exploded View........................12-2 Specifications ......................... 12-4 Special Tools .......................... 12-5 Front Fork ..........................12-6 Front Fork Removal (each fork leg) .................. 12-6 Front Fork Installation ....................... 12-6 Fork Oil Change........................ 12-6 Front Fork Disassembly ....................12-8 Front Fork Assembly......................
  • Page 232: Exploded View

    12-2 SUSPENSION Exploded View T1: 20 N·m (2.0 kgf·m, 14.5 ft·lb) T2: 23 N·m (2.3 kgf·m, 16.5 ft·lb) T3: 29 N·m (3.0 kgf·m, 22 ft·lb) L: Apply a non-permanent locking agent.
  • Page 233 SUSPENSION 12-3 Exploded View T1: 25 N·m (2.5 kgf·m, 18 ft·lb) T2: 34 N·m (3.5 kgf·m, 25 ft·lb) T3: 88 N·m (9.0 kgf·m, 65 ft·lb) M: Apply molybdenum disulfide grease.
  • Page 234: Specifications

    12-4 SUSPENSION Specifications Item Standard Service Limit Front Fork Oil Type KHL34-G10 (KAYABA) or equivalent – – – Oil Capacity 507 ±4 mL (17.1 ±0.14 US oz.) (approx. 430 mL – – – (14.5 US oz.) at oil change) Oil Level 125 ±2 mm (4.92 ±0.08 in.) (fully compressed, –...
  • Page 235: Special Tools

    SUSPENSION 12-5 Special Tools Fork Cylinder Holder Handle: Front Fork Oil Seal Driver: 57001-183 57001-1219 Oil Seal & Bearing Remover: Jack: 57001-1058 57001-1238 Bearing Driver Set: Fork Oil Level Gauge: 57001-1129 57001-1290 Fork Outer Tube Weight: Hexagon Wrench, Hex 27: 57001-1218 57001-1375...
  • Page 236: Front Fork

    12-6 SUSPENSION Front Fork Front Fork Removal (each fork leg) • Remove: Caliper (for left fork only) (see Caliper Removal in the Brakes chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Fender (See Front Fender Removal in the Frame chapter) Clamp [A] •...
  • Page 237 SUSPENSION 12-7 Front Fork • Drain the fork oil into a suitable container. • Pour in the specified type and amount of fork oil. Front Fork Oil Viscosity: KHL34-G10 (KAYABA) or equivalent Amount (per side) When changing oil: approx. 430 mL (14.5 US oz.) After disassembly and completely dry: 507 ±4 mL (17.1 ±0.14 US oz.) If necessary, measure the oil level as follows.
  • Page 238: Front Fork Disassembly

    12-8 SUSPENSION Front Fork Front Fork Disassembly • Loosen the upper clamp Allen bolt. • Loosen the fork top plug. • Remove the front fork leg (see Front Fork Removal). • Remove the top plug with the O-ring, spacer, spring seat, and spring (see Fork Oil Change).
  • Page 239: Front Fork Assembly

    SUSPENSION 12-9 Front Fork NOTE ○ If the tubes are tight, use a fork outer tube weight. ○ Mount the front fork outer tube weight [A] on the top of the outer tube, by fitting the step of the weight to the top corner of the outer tube.
  • Page 240: Inner Tube Inspection

    12-10 SUSPENSION Front Fork • When replacing the outer tube guide bushing [A] with a new one, hold the used guide bushing [B] against the new one, and tap the used guide bushing with the front fork oil seal driver [C] until it stops. The slit [D] in the bushing must face toward the left or right.
  • Page 241: Dust Seal Inspection

    SUSPENSION 12-11 Front Fork Dust Seal Inspection • Inspect the dust seal [A] for any signs of deterioration or damage. Replace them if necessary. Spring Tension Inspection • Since the spring becomes shorter as it weakens, check its free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced.
  • Page 242: Rear Shock Absorber

    12-12 SUSPENSION Rear Shock Absorber Spring Preload Adjustment The spring preload adjuster on each rear shock absorber has 5 positions so that the spring tension can be adjusted for different road and loading conditions. • Using the hook wrench [A], turn the adjuster to adjust the spring tension.
  • Page 243: Rear Shock Absorber Installation

    SUSPENSION 12-13 Rear Shock Absorber Rear Shock Absorber Installation • Tighten the mounting bolts. Torque - Rear Shock Absorber Upper Mounting Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) Rear Shock Absorber Lower Mounting Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb) •...
  • Page 244: Swingarm

    12-14 SUSPENSION Swingarm Swingarm Removal • Remove: Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Mufflers (see Exhaust Pipe, Muffler Removal in the En- gine Top End chapter). Rear Shock Absorbers (see Rear Shock Absorber Re- moval). Chain Case Pivot Shaft Caps •...
  • Page 245 STEERING 13-1 Steering Table of Contents Exploded View........................13-2 Special Tools .......................... 13-3 Steering ..........................13-4 Steering Inspection ......................13-4 Steering Adjustment......................13-4 Steering Stem......................... 13-6 Steering Stem, Stem Bearing Removal ................13-6 Steering Stem, Stem Bearing Installation ................. 13-7 Steering Stem Bearing Inspection and Lubrication............
  • Page 246: Exploded View

    13-2 STEERING Exploded View T1: Hand-tighten (about 4.9 N·m, 0.5 kgf·m, 43 in·lb) T2: 34 N·m (3.5 kgf·m, 25 ft·lb) T3: 44 N·m (4.5 kgf·m, 33 ft·lb) AD: Apply adhesive cement. G: Apply grease. L: Apply a non-permanent locking agent.
  • Page 247: Special Tools

    STEERING 13-3 Special Tools Steering Stem Bearing Driver: Steering Stem Nut Wrench: 57001-137 57001-1100 Steering Stem Bearing Driver Adapter, 34.5: Head Pipe Outer Race Driver, 46.5: 57001-1074 57001-1106 Head Pipe Outer Race Press Shaft: Head Pipe Outer Race Remover ID > 37 mm: 57001-1075 57001-1107 Head Pipe Outer Race Driver, 51.5:...
  • Page 248: Steering Inspection

    13-4 STEERING Steering Steering Inspection • Check the steering. ○ Lift the front wheel off the ground using the jack. Special Tool - Jack: 57001-1238 ○ With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop.
  • Page 249 STEERING 13-5 Steering • Tighten the steering stem head bolt and lower fork clamp Allen bolts. Torque - Steering Stem Head Bolt: 44 N·m (4.5 kgf·m, 33 ft·lb) Front Fork Lower Clamp Allen Bolts: 29 N·m (3.0 kgf·m, 22 ft·lb) •...
  • Page 250: Steering Stem

    13-6 STEERING Steering Stem Steering Stem, Stem Bearing Removal • Remove: Seat (see Seat Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) Bolts [A] and Front Turn Signal Lights [B] Headlight Unit (see Headlight Unit/Housing Removal in the Electrical System chapter) Connectors [C] (disconnect) Bolts [D], Stem Base Cover [E]...
  • Page 251: Steering Stem, Stem Bearing Installation

    STEERING 13-7 Steering Stem Steering Stem, Stem Bearing Installation • Apply grease to the outer races, and then drive them into the head pipe using the head pipe outer race drivers and the head pipe outer race press shaft [A]. Special Tools - Head Pipe Outer Race Press Shaft: 57001 -1075 Head Pipe Outer Race Driver, 46.5: 57001...
  • Page 252: Steering Stem Bearing Inspection And Lubrication

    13-8 STEERING Steering Stem • Install the steering stem head, washer, and tighten the stem head bolt. Torque - Steering Stem Head Bolt: 44 N·m (4.5 kgf·m, 33 ft·lb) • Reinstall the removed parts (see appropriate chapter). • Route the cables and harnesses correctly. •...
  • Page 253: Handlebar

    STEERING 13-9 Handlebar Handlebar Removal • Remove: Clutch Cable Upper End [A] Left Handlebar Switch Housing [B] Right Handlebar Switch Housing [C] Weight [D] Throttle Grip [E] Brake Master Cylinder [F] Clamps [G] • Unscrew the handlebar mounting nuts [A] and remove the handlebar [B] and clamp [C].
  • Page 255 FRAME 14-1 Frame Table of Contents Exploded View........................14-2 Seat ............................14-4 Seat Removal/Installation ....................14-4 Side Covers ..........................14-5 Right Side Cover Removal ....................14-5 Right Side Cover Installation..................... 14-5 Left side Cover Removal....................14-5 Left Side Cover installation ....................14-5 Fender ............................
  • Page 256: Exploded View

    14-2 FRAME Exploded View T1: 44 N·m (4.4 kgf·m, 33 ft·lb) T2: 54 N·m (5.5 kgf·m, 39 ft·lb) T3: 34 N·m (3.5 kgf·m, 25 ft·lb) T4: 25 N·m (2.5 kgf·m, 18 ft·lb) G: Apply grease. AT: Austria Model CA: Canada Model US: United States Model...
  • Page 257 FRAME 14-3 Exploded View...
  • Page 258: Seat

    14-4 FRAME Seat Seat Removal/Installation • Unscrew the mounting bolts [A]. • Pull [B] the seat to unhook the front and rear hooks [C], and remove it. • Insert the front hook [A] into the brace [B] on the frame. •...
  • Page 259: Side Covers

    FRAME 14-5 Side Covers Right Side Cover Removal • Insert the ignition switch key into the right side cover lock [A], turn the key counterclockwise, pull out the rear portion of the cover, and pull the cover forward. Right Side Cover Installation •...
  • Page 260: Fender

    14-6 FRAME Fender Front Fender Removal • Unscrew the mounting bolts [A] and remove the front fender [B]. Front Fender Installation • Install the front fender so that the L mark [A] faces to the left side. Rear Fender Removal •...
  • Page 261: Storage Case

    FRAME 14-7 Storage Case Storage Case Removal • Remove: Right Side Cover (see Right Side Cover Removal) Screw [A] and Tool Cover [B] • Open the storage case lid [C], remove the screws [D]. • Slide the rear storage case half [E] off. •...
  • Page 262: Battery Case

    14-8 FRAME Battery Case • Remove: Seat (see Seat Removal) Rear Fender (see Rear Fender Removal) Leads [A] and Band [B] Battery with Battery Cover [C] Side Covers (see Right/Left Side Cover Removal) Bolts [D] and Switch Bracket [E] Regulator/Rectifier (see Regulator/Rectifier Removal in the Electrical System chapter) Storage Case (see Storage Case Removal) IC Igniter (see IC Igniter Removal in the Electrical Sys-...
  • Page 263 ELECTRICAL SYSTEM 15-1 Electrical System Table of Contents Parts Location........15-3 Ignition Coil Removal/Installation. 15-39 Exploded View........15-4 Ignition Coil Inspection....15-39 Specifications ........15-8 Ignition Timing Inspection .... 15-40 Special Tools and Sealant ....15-9 Spark Plug Removal/Installation .. 15-41 Wiring Diagram (United States and Spark Plug Cleaning, Inspection..
  • Page 264 15-2 ELECTRICAL SYSTEM Radiator Fan Motor Inspection..15-59 Radiator Fan Switch Inspection ... 15-63 Meter Instruments ......15-61 Water Temperature Switch Meter Instruments Removal..15-61 Inspection........15-64 Meter Instruments Installation..15-61 Junction Box ........15-65 Meter Unit Disassembly ....15-61 Junction Box Fuse Circuit Bulb Replacement......
  • Page 265: Parts Location

    ELECTRICAL SYSTEM 15-3 Parts Location 1. Starter Lockout Switch 8. Turn Signal Relay 16. Side Stand Switch 2. Water Temperature Switch 9. Battery 17. Regulator/Rectifier 3. Ignition Coils 10. Horns 18. Junction Box 4. Spark Plugs 11. Fan Switch 19. Front Brake Light Switch 5.
  • Page 266: Exploded View

    15-4 ELECTRICAL SYSTEM Exploded View...
  • Page 267: Electrical System

    ELECTRICAL SYSTEM 15-5 Exploded View 1. Ignition Switch 2. Water Temperature Switch 3. Radiator Fan 4. Fan Switch 5. Ignition Coils 6. Spark Plugs 7. Rear Brake Light Switch 8. Alternator Stator 9. Crankshaft Sensor 10. Starter Motor 11. 30 A Main Fuse 12.
  • Page 268 15-6 ELECTRICAL SYSTEM Exploded View 1. Starter Lockout Switch 2. Front Brake Light Switch 3. Horns T1: 1.2 N·m (0.12 kgf·m, 10 in·lb) A: Italy Model, Netherlands Model (EN500-C2 ∼)
  • Page 269 ELECTRICAL SYSTEM 15-7 Exploded View 1. Regulator/Rectifier 2. Junction Box 3. Turn Signal Relay 4. Battery 5. IC Igniter T1: 5.9 N·m (0.6 kgf/m, 52 in·lb)
  • Page 270: Specifications

    15-8 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Battery Type 12 V 12 Ah – – – Specific Gravity Of Electrolyte 1 280 @20°C (68°F) – – – Charging System Type Three-phase AC – – – Alternator Output Voltage about 60 V @4 000 r/min (rpm) –...
  • Page 271: Special Tools And Sealant

    ELECTRICAL SYSTEM 15-9 Special Tools and Sealant Spark Plug Wrench, Hex 18: Igniter Checker Assembly: 57001-1024 57001-1378 Rotor Puller, M16/M18/M20/M22 × 1.5: Hand Tester: 57001-1216 57001-1394 Timing Light: Filler Cap Driver: 57001-1241 57001-1454 Flywheel Holder: Kawasaki Bond (Silicone Sealant): 57001-1313 56019-120...
  • Page 272: Wiring Diagram (united States And Canada) En500-c1 ~ C4 Model

    15-10 ELECTRICAL SYSTEM Wiring Diagram (United States and Canada) EN500-C1 ∼ C4 Model...
  • Page 273 ELECTRICAL SYSTEM 15-11 Wiring Diagram (United States and Canada) EN500-C1 ∼ C4 Model...
  • Page 274: Wiring Diagram (other Than United States And Canada) En500-c1 ~ C3 Model

    15-12 ELECTRICAL SYSTEM Wiring Diagram (Other than United States and Canada) EN500-C1 ∼ C3 Model...
  • Page 275 ELECTRICAL SYSTEM 15-13 Wiring Diagram (Other than United States and Canada) EN500-C1 ∼ C3 Model...
  • Page 276: Wiring Diagram (united States And Canada) En500-c5 Model

    15-14 ELECTRICAL SYSTEM Wiring Diagram (United States and Canada) EN500-C5 Model...
  • Page 277 ELECTRICAL SYSTEM 15-15 Wiring Diagram (United States and Canada) EN500-C5 Model...
  • Page 278: Wiring Diagram (other Than United States And Canada) En500-c4 ~ C7 Model

    15-16 ELECTRICAL SYSTEM Wiring Diagram (Other than United States and Canada) EN500-C4 ∼ C7 Model...
  • Page 279 ELECTRICAL SYSTEM 15-17 Wiring Diagram (Other than United States and Canada) EN500-C4 ∼ C7 Model...
  • Page 280: Wiring Diagram (united States And Canada) En500-c6

    15-18 ELECTRICAL SYSTEM Wiring Diagram (United States and Canada) EN500-C6 ∼...
  • Page 281 ELECTRICAL SYSTEM 15-19 Wiring Diagram (United States and Canada) EN500-C6 ∼...
  • Page 282: Wiring Diagram (other Than United States And Canada) En500-c8

    15-20 ELECTRICAL SYSTEM Wiring Diagram (Other than United States and Canada) EN500-C8 ∼...
  • Page 283 ELECTRICAL SYSTEM 15-21 Wiring Diagram (Other than United States and Canada) EN500-C8 ∼...
  • Page 284: Precautions

    15-22 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 cable connections. This will burn out the diodes in the electrical parts. ○...
  • Page 285 ELECTRICAL SYSTEM 15-23 Precautions ○ Electrical Connectors Connectors [A] Connectors [B]...
  • Page 286: Electrical Wiring

    15-24 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is in poor condition, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage.
  • Page 287: Battery

    ELECTRICAL SYSTEM 15-25 Battery Precautions: Following a few simple rules will greatly extend the life of the battery. ○ When the level of the electrolyte in the battery is low, add only distilled water to each cell until the level is at the up- per level line marked on the outside of the battery.
  • Page 288: Battery Initial Charging

    15-26 ELECTRICAL SYSTEM Battery • Look for sediment [A] and white sulfation [B] inside the cells on the bottom of the plates. • See the Battery Troubleshooting Guide in Battery Test Charging. If the specific gravity is below 1.200, the battery needs to be charged.
  • Page 289 ELECTRICAL SYSTEM 15-27 Battery NOTE ○ If the electrolyte level drops, add electrolyte to the upper level line before charging. • Leaving the caps off the cells, connect the battery to a charger, set the charging rate at 1/10 of the battery ca- pacity, and charge it for 10 hours.
  • Page 290: Battery Ordinary Charging

    15-28 ELECTRICAL SYSTEM Battery Battery Ordinary Charging • Remove the battery from motorcycle. CAUTION Always remove the battery from the motorcycle for changing. If the battery is charged while still in- stalled, battery electrolyte may spill and corrode the frame or other parts of the motorcycle. •...
  • Page 291: Battery Test Charging

    ELECTRICAL SYSTEM 15-29 Battery Battery Test Charging • If the battery is suspected of being defective, sulfated, or unable to take a charge, consult the table. • To test charge a battery, perform the ordinary charging procedure and monitor the battery voltage and other signs as mentioned below.
  • Page 292 15-30 ELECTRICAL SYSTEM Battery Battery Troubleshooting Guide Good Battery Suspect Battery Action (+) chocolate color white (sulphated); + plates Replace Plates (−) gray color broken or corroded Sediment none, or small amount sediment up to plates, causing short Replace Voltage above 12 V below 12 V test charge...
  • Page 293: Charging System

    ELECTRICAL SYSTEM 15-31 Charging System Alternator Rotor/Starter Clutch Removal • Remove the engine sprocket cover (see Engine Sprocket Removal in the Final Drive chapter). • Loosen the left footpeg mounting bolt and let the footpeg hang down. • Remove the shift pedal. •...
  • Page 294: Alternator Rotor/starter Clutch Installation

    • Check that knock pins [B] are in place on the crankcase. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Tighten the alternator cover Allen bolt and bolts. Torque - Alternator Cover Allen Bolt: 13 N·m (1.3 kgf·m, 113 in·lb)
  • Page 295: Alternator Stator Removal

    Apply silicone sealant [A] around the circumference of the wiring grommets before setting them in the notch in the alternator cover. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Install the grommet for the stator wiring and crankshaft sensor lead in this order.
  • Page 296 15-34 ELECTRICAL SYSTEM Charging System • Start the engine, and note the voltage readings at vari- ous engine speeds with the headlight turned on and then turned off. (To turn off the headlight of United States and Canada models disconnect the headlight connector). The readings should show nearly battery voltage when the en- gine speed is low, and, as the engine speed rises, the readings should also rise.
  • Page 297: Alternator Inspection

    ELECTRICAL SYSTEM 15-35 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 298: Rectifier Inspection

    15-36 ELECTRICAL SYSTEM Charging System Rectifier Inspection • Check the diode resistance as follows. Refer to the ap- propriate chapters and Charging System Wiring Diagram. • Turn off the ignition switch. • Remove the left side cover (see Left Side Cover Removal in the Frame chapter).
  • Page 299 ELECTRICAL SYSTEM 15-37 Charging System Regulator Circuit Test-3rd Step: • Connect the test light and the 12 V battery in the same manner as specified in the “Regulator Circuit Test-1st Step”. • Momentarily apply 24 V to the BR terminal by adding a 12 V battery.
  • Page 300: Ignition System

    15-38 ELECTRICAL SYSTEM Ignition System Safety instructions: 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...
  • Page 301: Ignition Coil Removal/installation

    ELECTRICAL SYSTEM 15-39 Ignition System Ignition Coil Removal/Installation • Remove the fuel tank (see Fuel Tank Removal in the Fuel System chapter). • Disconnect the leads [A] and remove the ignition coil [B] with spark plug cap [C]. • Install the ignition coils. Note the following. ○...
  • Page 302: Ignition Timing Inspection

    15-40 ELECTRICAL SYSTEM Ignition System • Disconnect the primary leads from the coil terminals. • Measure the primary winding resistance [A] as follows: ○ Connect the hand tester between the coil terminals. ○ Set the tester to the × 1 Ω range, and read the tester. •...
  • Page 303: Spark Plug Removal/installation

    ELECTRICAL SYSTEM 15-41 Ignition System Spark Plug Removal/Installation • Remove the fuel tank (see Fuel Tank Removal in the Fuel System chapter). • Carefully pull the spark plug cap from the spark plug and unscrew the spark plug. • Using the 18 mm plug wrench [A]. •...
  • Page 304: Ic Igniter Installation

    CAUTION Use only the hand tester (57001-1394) for this test. A tester other than the Kawasaki Hand Tester may show different readings. If a megger or a meter with a large-capacity battery is used, the IC igniter will be damaged.
  • Page 305: Diodes Inspection

    ELECTRICAL SYSTEM 15-43 Ignition System IC Igniter Internal Resistance (4P) Unit: kΩ Tester (+) Lead Connection Terminal – ∞ ∞ ∞ 0 ∼ 0.8 28 ∼ 150 ∞ – (–)* 0 ∼ 0.8 30 ∼ 150 ∞ – 26 ∼ 150 26 ∼...
  • Page 306 15-44 ELECTRICAL SYSTEM Ignition System...
  • Page 307 ELECTRICAL SYSTEM 15-45 Ignition System Ignition System Circuit 1. Junction Box 7. Ignition Fuse 10 A 13. Main Fuse 30 A 2. Ignition Switch 8. Diodes 14. Battery 3. Engine stop Switch 9. Neutral Switch 15. IC Igniter 4. Starter Button 10.
  • Page 308: Electric Starter System

    15-46 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal • Remove the alternator rotor with the starter clutch (see Alternator Rotor/Starter Clutch Removal). • Remove the starter chain guide screws [A] and remove the starter chain guide [B] with the guide stay [C]. •...
  • Page 309: Starter Clutch Sprocket Removal

    ELECTRICAL SYSTEM 15-47 Electric Starter System Starter Clutch Sprocket Removal • Remove: Alternator cover (see Alternator Rotor/Starter Clutch Re- moval) Alternator rotor with Starter Clutch (see Alternator Ro- tor/Starter Clutch Removal) • Remove the woodruff key [A] and washer [B]. •...
  • Page 310: Starter Motor Assembly

    15-48 ELECTRICAL SYSTEM Electric Starter System Starter Motor Assembly • Install the brush plate on the end cover, align the tab [A] on the plate with the slot [B] in the cover. • Replace any O-ring removed with a new one. •...
  • Page 311: Starter Clutch Inspection

    ELECTRICAL SYSTEM 15-49 Electric Starter System Starter Clutch Inspection • Remove: Alternator Rotor (see Alternator Rotor/Starter Clutch Re- moval) Starter Chain Guide (see Starter Motor Removal) Starter Motor Sprocket (see Starter Motor Removal) Starter Chain (see Starter Clutch Sprocket Removal) •...
  • Page 312: Commutator Cleaning And Inspection

    15-50 ELECTRICAL SYSTEM Electric Starter System Commutator Cleaning and Inspection • Smooth the commutator surface [A] if necessary with fine emery cloth (#400 ∼ 500) [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 313: Brush Plate Inspection

    ELECTRICAL SYSTEM 15-51 Electric Starter System Brush Plate Inspection • Using the × 1 Ω hand tester range, measure the resis- tance between the brush plate [A] and the negative brush [B]. If there is not close to zero ohm, the brush plate has an open.
  • Page 314: Electric Starter Circuit

    15-52 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit 1. Ignition Switch 6. Starter Circuit Relay 11. Starter Motor 2. Engine Stop Switch 7. Ignition Fuse 10A 12. Starter Relay 3. Starter Button 8. Starter Lockout Switch 13. Main Fuse 30A 4.
  • Page 315: Lighting System

    ELECTRICAL SYSTEM 15-53 Lighting System The United States and Canada models adopt the daylight system and have a headlight relay in the junction box. In these models, the headlight does not go on when the igni- tion switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off.
  • Page 316: Headlight Unit/housing Removal

    15-54 ELECTRICAL SYSTEM Lighting System • Fit the dust cover [A] with the Top mark upward onto the bulb firmly as shown in the figure. • After installation, adjust the headlight aim. Right [B] Wrong [C] Headlight Unit/Housing Removal • Remove: Screws [A] (both sides) Headlight Connector [A]...
  • Page 317: Turn Signal Light Bulb Replacement

    ELECTRICAL SYSTEM 15-55 Lighting System Turn Signal Light Bulb Replacement • Refer to the Tail/Brake Light Bulb Replacement section. ○ Be careful not to overtighten the lens mounting screws. Turn Signal Relay Inspection • Remove: Left Side Cover (see Left Cover Removal in the Frame chapter) Turn Signal Relay [A] •...
  • Page 318 15-56 ELECTRICAL SYSTEM Lighting System 1. Ignition Switch 8. Dimmer Switch 2. High Beam Indicator Light 9. Alternator 3. Headlight 10. Main Fuse 30 A 4. Junction Box 11. Battery 5. Diodes 12. City Light 6. Headlight Circuit Relay 13. Headlight Switch 7.
  • Page 319 ELECTRICAL SYSTEM 15-57 Lighting System Headlight Circuit (EN500-C8 ∼, Other than United States and Canada) 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. Dimmer Switch 9.
  • Page 320 15-58 ELECTRICAL SYSTEM Lighting System Turn Signal Light Circuit 1. Turn Signal Indicator Light 9. Rear Right Turn Signal Light 2. Front Right Turn Signal Light 10. Rear Left Turn Signal Light 3. Front Left Turn Signal Light 11. Main Fuse 30 A 4.
  • Page 321: Radiator Fan System

    ELECTRICAL SYSTEM 15-59 Radiator Fan System Radiator Fan System Circuit Inspection • Turn on the ignition switch. • Disconnect leads from the radiator fan switch [A]. • Using an auxiliary wire [B], connect the radiator fan switch leads. If the fan turns, inspect the fan switch. If the fan does not turn, inspect the following.
  • Page 322 15-60 ELECTRICAL SYSTEM Radiator Fan System Radiator Fan Circuit (EN500-C5 ∼) 1. Radiator Fan 2. Radiator Fan Switch 3. Junction Box 4. Fan Fuse 10 A 5. Main Fuse 30 A 6. Battery...
  • Page 323: Meter Instruments

    ELECTRICAL SYSTEM 15-61 Meter Instruments Meter Instruments Removal • Remove the bolt [A], and separate the meter instruments [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 324: Switches And Sensors

    15-62 ELECTRICAL SYSTEM Switches and Sensors Front Brake Light Timing Inspection • Turn on the ignition switch. • Check the operation of the front brake light switch by pulling the tip of brake lever. The brake light should go on as specified. If it does not, replace the brake light switch.
  • Page 325: Radiator Fan Switch Inspection

    ELECTRICAL SYSTEM 15-63 Switches and Sensors Oil Pressure Switch Connections* *: Engine lubrication system is in good condition Side Stand Switch Connections* Radiator Fan Switch Inspection • Remove the radiator fan switch (see Radiator Fan Switch Removal in the Cooling System chapter). •...
  • Page 326: Water Temperature Switch Inspection

    15-64 ELECTRICAL SYSTEM Switches and Sensors Water Temperature Switch Inspection • Remove the water temperature switch (see Water Tem- perature Switch Removal in the Cooling System chapter). • Suspend the sensor [A] in a container of water so that the temperature sensing projection and threaded portion are submerged.
  • Page 327: Junction Box

    ELECTRICAL SYSTEM 15-65 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 seat (see Seat Removal in the Frame chap- ter). •...
  • Page 328: Diode Circuit Inspection

    15-66 ELECTRICAL SYSTEM Junction Box Relay Circuit Inspection (with the battery disconnected) Tester Tester Tester Reading Tester Reading (Ω) Connection Connection (Ω) ∞ 9-11 ∞ ∞ ∞ 7-13 12-13 Headlight Relay* Starter Circuit (+) (−) (+) (–) Not ∞** Relay 13-11 ∞...
  • Page 329 ELECTRICAL SYSTEM 15-67 Junction Box Junction Box Internal Circuit (United States and Canada Models) (EN500-C8 ∼, All Models) Junction Box Internal Circuit (EN500-C1 ∼ C7, Other than United States and Canada Models) A. Accessory Fuse 10A E. Ignition Fuse 10A J.
  • Page 330: Fuses

    15-68 ELECTRICAL SYSTEM Fuses 30 Ampere Fuse Removal • Remove the left side cover (see Left Side Cover Removal in the Frame chapter). • Disconnect the 30 ampere fuse connector [A]. • Pull out the main fuse [B] from the starter relay with a pair of needle nose pliers.
  • Page 331 APPENDIX 16-1 Appendix Table of Contents Troubleshooting Guide ......................16-2 General Lubrication ........................ 16-7 Lubrication ........................16-7 Nut, Bolt, and Fastener Tightness ..................16-8 Tightness Inspection ......................16-8 Cable, Wire, and Hose Routing ....................16-9...
  • Page 332: Troubleshooting Guide

    16-2 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 Crankshaft sensor 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 333 APPENDIX 16-3 Troubleshooting Guide Cylinder head not sufficiently tightened Fuel tap clogged down Fuel line clogged No valve clearance Compression low: Cylinder, piston worn Spark plug loose Piston ring bad (worn, weak, broken, or Cylinder head not sufficiently tightened sticking) down Piston ring/groove clearance excessive No valve clearance...
  • Page 334: Gear Shifting Faulty

    16-4 APPENDIX Troubleshooting Guide Fuel/air mixture incorrect: Clutch friction plate installed wrong Main jet clogged or wrong size Clutch lever play excessive Fuel level in carburetor float bowl too low Clutch release mechanism trouble Carburetor holder loose Gear Shifting Faulty: Air cleaner duct loose Air cleaner poorly sealed, or missing Doesn’t go into gear;...
  • Page 335: Exhaust Smokes Excessively

    APPENDIX 16-5 Troubleshooting Guide Oil Pressure Warning Light Goes On: Exhaust pipe leaking at cylinder head con- nection Engine oil pump damaged Crankshaft runout excessive Engine oil screen clogged Engine mounts loose Engine oil level too low Crankshaft bearing worn Engine oil viscosity too low Primary chain worn Camshaft bearing worn...
  • Page 336: Battery Trouble

    16-6 APPENDIX Troubleshooting Guide Steering maladjusted Primary or secondary cup damaged in mas- Front fork bent ter cylinder Right and left front fork oil level uneven Master cylinder scratched inside Shock absorption unsatisfactory: Drum brake: (Too hard) Brake maladjusted Front fork oil excessive Brake linings or drum worn Front fork oil viscosity too high Overheated...
  • Page 337: General Lubrication

    APPENDIX 16-7 General Lubrication Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○ Whenever the vehicle has been operated under wet or rainy conditions, or especially after using a high-pressure water spray, perform the general lubri- cation.
  • Page 338: Nut, Bolt, And Fastener Tightness

    16-8 APPENDIX Nut, Bolt, and Fastener Tightness Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).
  • Page 339: Cable, Wire, And Hose Routing

    APPENDIX 16-9 Cable, Wire, and Hose Routing 1. Clamp (Right Hand Switch Lead) 2. Right Hand Switch Lead 3. Throttle Cables 4. Brake Hose 5. Clamp (Right Hand Switch Lead, Throttle Cables, Brake Hose) 6. Clamp (Clutch Cable, Left Hand Switch Lead) 7.
  • Page 340 16-10 APPENDIX Cable, Wire, and Hose Routing...
  • Page 341 APPENDIX 16-11 Cable, Wire, and Hose Routing Korea, Germany, France, Italy, United Kingdom, Switzerland, Austria and Netherlands Models 1. Clamp 2. Direction of the clamp. Notice it differs from that of right side. 3. Clamp 4. Coolant Filter 5. Coolant Filter Housing (Set the coolant filter housing parallel to the outer side of the frame.) 6.
  • Page 342 16-12 APPENDIX Cable, Wire, and Hose Routing...
  • Page 343 APPENDIX 16-13 Cable, Wire, and Hose Routing 1. Throttle Cable (SECT B-B: Run the throttle cable between the thermostat case and the bracket. VIEW C: Run the throttle cable to the head side over the main harness and right handlebar switch lead.) 2.
  • Page 344 16-14 APPENDIX Cable, Wire, and Hose Routing...
  • Page 345 APPENDIX 16-15 Cable, Wire, and Hose Routing 1. Main Harness 2. Ignition Switch Lead 3. Fuel Tank Drain Hose 4. Starter Lead (–) (Tighten the starter motor negative lead with the rear mounting part of the starter motor.) 5. Run the harness between the cross pipe and the storage container (Igniter Lead, Starter Motor Lead (–)).
  • Page 346 16-16 APPENDIX Cable, Wire, and Hose Routing 1. Main Harness 17. Clutch Cable 2. Right Hand Switch Lead 18. Rear Brake Switch Lead 3. Throttle Cables 19. Clamp (Clamp the brake cable together 4. Ignition Switch Connector with the brake switch lead run outside of 5.
  • Page 347 APPENDIX 16-17 Cable, Wire, and Hose Routing 1. Run the air cleaner drain hose to the front *8. To the #2 carburetor. of the pivot. *9. Tube 2. Air Cleaner Drain Hose *10. Insert the hose till its white-painted mark 3.
  • Page 348 16-18 APPENDIX Cable, Wire, and Hose Routing 1. Run the hose below the 8. Run the hose above the 16. Hose (Blue) main harness. reserve tank mounting 17. Run the hoses inside the 2. Run the hose into the collar. swingarm.
  • Page 349 APPENDIX 16-19 Cable, Wire, and Hose Routing 1. Reserve Tank Cap 8. Position white-painted 14. Clamp 2. Reserve Tank Over- mark right above. 15. Radiator Pipe (Right) flow Hose 9. Clamp 16. Clamp 3. Clamp 10. Thermostat Housing 17. Position the white-painted 4.
  • Page 350 16-20 APPENDIX Cable, Wire, and Hose Routing 1. Master Cylinder 2. Throttle Cables 3. Right Hand Switch lead 4. Clamp 5. Clamp 6. Brake Hose 7. Clamp 8. Clamp (Brake Hose, Throttle Cables, Right Hand Switch Lead) 9. Clamp 10. Caliper...
  • Page 351 MODEL APPLICATION Year Model Beginning Frame No. □ JKAENVC1 TA000001 or 1996 EN500-C1 EN500C-000001 □ JKAENVC1 TA005001 or 1997 EN500-C2 EN500C-005001 □ JKAENVC1 WA150001 or 1998 EN500-C3 EN500C-007001 □ JKAENVC1 XA156001 or 1999 EN500-C4 JKAEN500ACA 156001 □ JKAENVC1 YA164001 or 2000 EN500-C5 JKAEN500ACA 164001...

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  • Ricardo Paluan Apr 27, 2016 01:22:
    Adquiri recentemen​te uma moto vulcan 500 ano 1995. Tenho o 37 anos e iniciante no mundo motociclis​ta. Entretanto​, em razão só tempo e idade da moto, não tenho o manual do proprietá​rio, sendo este indispens