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Kawasaki vn 800 classic Service Manual

Other manuals for vn 800 classic: Service Manual, Service Manual
Manual is about: Motorcycle

Summary of vn 800 classic

  • Page 2: Quick Reference Guide

    This quick reference guide will assist you in locating a desired topic or pro- cedure. •bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page. •refer to the sectional table of contents for the exact pages to locate th...

  • Page 3

    List of abbreviations a ampere(s) lb pounds(s) abdc after bottom dead center m meter(s) ac alternating current min minute(s) atdc after top dead center n newton(s) bbdc before bottom dead center pa pascal(s) bdc bottom dead center ps horsepower btdc before top dead center psi pound(s) per square inc...

  • Page 4

    Emission control information to protect the environment in which we all live, kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the united states environmental protection agency. 1. Crankcase emission control system...

  • Page 5

    Tampering with noise control system prohibited federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle ...

  • Page 6: Foreword

    Foreword this manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the prope...

  • Page 8: General Information

    General information 1-1 1 general information table of contents before servicing ..................................................................................................................... 1-2 model identification................................................................................

  • Page 9

    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...

  • Page 10

    General information 1-3 before servicing (11)press when using a press or driver to install a part such as a wheel bearing, apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit. (12)ball bearing and needle bearing do not remove a ball bearing or a needle ...

  • Page 11

    1-4 general information before servicing (19)inspection when parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones. Abrasion crack hardening warp bent dent scratch wear co...

  • Page 12

    General information 1-5 model identification vn800-b5 left side view: vn800-b5 right side view:.

  • Page 13

    1-6 general information model identification vn800-b6 left side view: vn800-b6 right side view:.

  • Page 14

    General information 1-7 general specifications items vn800-b1 ∼ b4 dimensions overall length 2 390 mm (94.1 in.), (ca) (us) (my) 2 375 mm (93.5 in.) overall width 940 mm (37.0 in.), (ca) (us) (my) 930 mm (36.6 in.) overall height 1 125 mm (44.3 in.), (ca) (us) (my) 1 130 mm (44.5 in.) wheelbase 1 60...

  • Page 15

    1-8 general information general specifications items vn800-b1 ∼ b4 exhaust open 69° bbdc close 31° atdc duration 280° lubrication system forced lubrication (wet sump) engine oil: grade se, sf or sg class viscosity sae10w-40, 10w-50, 20w-40, 20w-50 capacity 3.2 l (3.4 us qt) drive train primary reduc...

  • Page 16

    General information 1-9 general specifications items vn800-b1 ∼ b4 rear drum electrical equipment battery 12 v 12 ah headlight: type semi-sealed beam bulb 12 v 60/55 w (quartz-halogen) tail/brake light 12 v 5/21 w × 2, (ca) (us) (my) 12 v 8/27 w × 2 alternator: type three-phase ac rated output 23.5 ...

  • Page 17

    1-10 general information general specifications items vn800-b5 vn800-b6 ∼ b7 dimensions overall length 2 380 mm (93.7 in.), (ca) (us) (my) 2 375 mm (93.5 in.) overall width 940 mm (37.0 in.), (ca) (us) (my) 930 mm (36.6 in.) overall height 1 125 mm (44.3 in.), (ca) (us) (my) 1 130 mm (44.5 in.) whee...

  • Page 18

    General information 1-11 general specifications items vn800-b5 vn800-b6 ∼ b7 exhaust open 69° bbdc close 31° atdc duration 280° lubrication system forced lubrication (wet sump) engine oil: grade se, sf or sg class api se, sf, or sg, viscosity sae 10w-40, 10w-50, 20w-40, or 20w-50 api sh or sj with j...

  • Page 19

    1-12 general information general specifications items vn800-b5 vn800-b6 ∼ b7 brake type: front single disc rear drum electrical equipment battery 12 v 12 ah headlight: type semi-sealed beam bulb 12 v 60/55 w (quartz-halogen) tail/brake light 12 v 5/21 w × 2 12 v 5/21 w × 2 (ca) (us) (my) 12 v 8/27 w...

  • Page 20

    General information 1-13 general specifications items vn800-b8 ∼, b6f dimensions overall length 2 380 mm (93.7 in.), (ca) (us) 2 375 mm (93.5 in.) overall width 940 mm (37.0 in.), (ca) (us) 930 mm (36.6 in.) overall height 1 125 mm (44.3 in.), (ca) (us) 1 130 mm (44.5 in.) wheelbase 1 600 mm (63.0 i...

  • Page 21

    1-14 general information general specifications items vn800-b8 ∼, b6f close 31° atdc duration 280° lubrication system forced lubrication (wet sump) engine oil: grade api se, sf, or sg, viscosity api sh or sj with jaso ma sae 10w-40 capacity 3.2 l (3.4 us qt) drive train primary reduction system: typ...

  • Page 22

    General information 1-15 general specifications items vn800-b8 ∼, b6f electrical equipment battery 12 v 12 ah (vn800-b8 model) 12 v 10 ah (vn800-b9 ∼ model) headlight: type semi-sealed beam bulb 12 v 60/55 w (quartz-halogen) tail/brake light 12 v 5/21 w × 2 alternator: type three-phase ac rated outp...

  • Page 23

    1-16 general information unit conversion table prefixes for units: prefix symbol power mega m × 1 000 000 kilo k × 1 000 centi c × 0.01 milli m × 0.001 micro μ × 0.000001 units of mass: kg × 2.205 = lb g × 0.03527 = oz units of volume: l × 0.2642 = gal (us) l × 0.2200 = gal (imp) l × 1.057 = qt (us)...

  • Page 24: Periodic Maintenance

    Periodic maintenance 2-1 2 periodic maintenance table of contents periodic maintenance chart (united states and canada)........................ 2-2 periodic maintenance chart (other than united states and canada) .... 2-4 torque and locking agent................. 2-6 specifications ....................

  • Page 25

    2-2 periodic maintenance periodic maintenance chart (united states and canada) the scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. Frequency whichever comes firs...

  • Page 26

    Periodic maintenance 2-3 periodic maintenance chart (united states and canada) frequency whichever comes first * odometer reading km × 1 000 (mile × 1 000) 0.8 5 10 15 20 25 30 see operation every (0.5) (3) (6) (9) (12) (15) (18) page swingarm pivot, uni-trak linkage-lubricate • • • p2-37 general lu...

  • Page 27

    2-4 periodic maintenance periodic maintenance chart (other than united states and canada) the scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. Frequency whichever...

  • Page 28

    Periodic maintenance 2-5 periodic maintenance chart (other than united states and canada) frequency whichever comes first * odometer reading km × 1 000 (mile × 1 000) 1 6 12 18 24 30 36 see operation every (0.6) (4) (7.5) (12) (15) (20) (24) page nuts, bolts, and fastener tightness-inspect † • • • •...

  • Page 29

    2-6 periodic maintenance torque and locking agent the following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “remarks” column mean: l: apply a non-permanent locking agent to the threads. Mo: apply molyb...

  • Page 30

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks oil pump drive chain guide bolt 12 1.2 104 in·lb l oil filter 18 1.8 13 oil filter plate mounting bolts 7.8 0.8 69 in·lb oil screen plug 20 2.0 14.5 oil pressure relief valve 15 1.5 11 l oil pressure switch 15 ...

  • Page 31

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks rear sprocket stud bolts - - - l brakes torque link nuts 34 3.5 25 front caliper mounting bolts 34 3.5 25 brake disc mounting bolts 27 2.8 20 l brake hose banjo bolts 34 3.5 25 bleed valve 7.8 0.8 69 in·lb rear...

  • Page 32

    Periodic maintenance 2-9 torque and locking agent torque fastener n·m kgf·m ft·lb remarks starter motor mounting bolts 11 1.1 95 in·lb starter motor through bolts 4.9 0.5 43 in·lb starter motor terminal nut 11 1.1 95 in·lb starter motor cable nuts 4.9 0.5 43 in·lb side stand switch mounting bolt 3.9...

  • Page 33

    2-10 periodic maintenance specifications item standard service limit fuel system – – – throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) idle speed 1 000 ±50 r/min (rpm) (ch, cal) 1 300 ±50 r/min (rpm) air cleaner element polyurethane foam cooling system – – – coolant: type (recommended) permanent ...

  • Page 34

    Periodic maintenance 2-11 specifications item standard service limit rim runout (with tire installed) radial tir 1.0 mm (0.04 in.) or less tir 2.0 mm (0.08 in.) axial tir 0.8 mm (0.03 in.) or less tir 2.0 mm (0.08 in.) final drive drive chain slack 25 ∼ 35 mm (1.0 ∼ 1.4 in.) – – – drive chain wear (...

  • Page 35

    2-12 periodic maintenance special tools steering stem nut wrench: 57001-1100 jack: 57001-1238 oil filter wrench: 57001-1249 carburetor drain plug wrench, hex 3: 57001-1269 fork oil level gauge: 57001-1290 jack attachment #3: 57001-1416.

  • Page 36

    Periodic maintenance 2-13 maintenance procedure fuel system fuel hoses and connections inspection ○ the fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the inside the fuel line can cause fuel to leak [a]...

  • Page 37

    2-14 periodic maintenance maintenance procedure if necessary, adjust the throttle cable as follows. • loosen the locknuts [a]. • screw the adjusters [b] in completely so as to give the throttle grip plenty of play. • turn out the decelerator cable [c] adjuster until there is no play when the throttl...

  • Page 38

    Periodic maintenance 2-15 maintenance procedure idle speed adjustment • start the engine and warm it up thoroughly. • turn the adjusting screw [a] until the idle speed is correct. ○ open and close the throttle a few times to make sure that the idle speed is within the specified range. Readjust if ne...

  • Page 39

    2-16 periodic maintenance maintenance procedure evaporative emission control system inspection • inspect the california canister as follows: ○ remove the canister, and disconnect the hoses from the canister. ○ visually insect the canister for cracks for cracks and other damage. If the canister has a...

  • Page 40

    Periodic maintenance 2-17 maintenance procedure • remove: meter unit (see electrical system chapter) radiator cap [a] • place a container under the drain plug [a] at the bottom of the right crankcase. • drain the coolant from the radiator and engine by remov- ing the drain plug. • remove the cap and...

  • Page 41

    2-18 periodic maintenance maintenance procedure • bleed the air from the cooling system as follows. ○ start the engine with the radiator cap removed and run it until no more air bubbles [a] can be seen in the coolant. ○ tap the water hoses to force any air bubbles caught in- side. ○ stop the engine ...

  • Page 42

    Periodic maintenance 2-19 maintenance procedure • set the rear piston at tdc by turning the crankshaft coun- terclockwise 305° (see engine top end chapter). • using a thickness gauge, measure the valve clearance between the rocker arm and the shim. Valve clearance standard: in: 0.10 ∼ 0.15 mm (0.003...

  • Page 43

    2-20 periodic maintenance maintenance procedure valve clearance adjustment chart inlet valve 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines in...

  • Page 44

    Periodic maintenance 2-21 maintenance procedure valve clearance adjustment chart exhaust valve 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines ...

  • Page 45

    2-22 periodic maintenance maintenance procedure clutch clutch inspection clutch lever free play inspection • pull the clutch lever just enough to take up the free play [a]. • measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap ...

  • Page 46

    Periodic maintenance 2-23 maintenance procedure • slide the dust cover [a] at the clutch cable lower end out of place. • loosen both adjusting nuts [b] at the clutch cover as far as they will go. • pull the clutch outer cable [c] tight and tighten the adjust- ing nuts against the bracket [d]. • slip...

  • Page 47

    2-24 periodic maintenance maintenance procedure oil filter replacement • drain the engine oil (see engine oil change). • remove the oil filter [a] with the oil filter wrench [b]. Special tool - oil filter wrench: 57001-1249 • replace the filter with a new one. • apply engine oil to the gasket [a] be...

  • Page 48

    Periodic maintenance 2-25 maintenance procedure wear indicator [a] wear indicator position mark [b] warning to ensure safe handling and stability, use only the recommended standard tires for replacement, in- flated to the standard pressure. Note ○ most countries may have their own regulations a mini...

  • Page 49

    2-26 periodic maintenance maintenance procedure • measure the axial [a] and radial [b] rim runout with a dial gauge. If rim runout exceeds the service limit, check the hub bearings first. Replace them if they are damaged. If the problem is not due to the bearings, correct the rim warp (runout). A ce...

  • Page 50

    Periodic maintenance 2-27 maintenance procedure drive chain slack adjustment • remove: muffler (see engine top end chapter) clip [a] • loosen: rear torque link nut [b] axle nut [c] chain adjuster locknuts [d] (both sides) • turn the chain adjusting nuts [e] forward or rearward until the drive chain ...

  • Page 51

    2-28 periodic maintenance maintenance procedure warning if the drive chain wear exceeds the service limit, re- place the chain or an unsafe riding condition may result. A chain that breaks or jumps off the sprock- ets could snag on the engine sprocket or lock the rear wheel, severely damaging the mo...

  • Page 52

    Periodic maintenance 2-29 maintenance procedure brakes brake lining or pad wear inspection • remove the brake shoes (see brake panel disassembly). • measure the lining thickness [a]. ○ use a calipers or scale, and measure at several points as shown. If any measurement is less than the service limit,...

  • Page 53

    2-30 periodic maintenance maintenance procedure brake play inspection brake pedal position inspection • check that the brake pedal [a] is in the correct position. [b] footpeg pedal position [c] standard: about 65 mm (2.6 in.) above footpeg top if it is incorrect, adjust the brake pedal position. Bra...

  • Page 54

    Periodic maintenance 2-31 maintenance procedure brake light switch inspection • turn on the ignition switch. • check the operation of the rear brake light switch by de- pressing the brake pedal. If it does not as specified, adjust the brake light timing. Brake light timing standard: on after about 1...

  • Page 55

    2-32 periodic maintenance maintenance procedure brake fluid change note ○ the procedure to change the front brake fluid is as fol- lows. • level the brake fluid reservoir. • remove the reservoir cap. • remove the rubber cap from the bleed valve [a] on the caliper. • attach a clear plastic hose [b] t...

  • Page 56

    Periodic maintenance 2-33 maintenance procedure note ○ the procedure to bleed the front brake line is as follows. • remove the reservoir cap, and fill the reservoir with fresh brake fluid to the upper level line in the reservoir. • with the reservoir cap off, slowly pump the brake lever several time...

  • Page 57

    2-34 periodic maintenance maintenance procedure warning when working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3. Do not mix two types and brands...

  • Page 58

    Periodic maintenance 2-35 maintenance procedure brake hoses and connections inspection • inspect the brake hose and fittings for deterioration, cracks and signs of leakage. ○ the high pressure inside the brake line can cause fluid to leak [a] or the hose to burst if the line is not properly main- ta...

  • Page 59

    2-36 periodic maintenance maintenance procedure • wait for about five minutes so that any suspended air bub- bles can surface. • measure the oil level, using the fork oil level gauge [a]. Special tool - fork oil level gauge: 57001-1290 ○ set the gauge stopper [b] so that its lower side shows the oil...

  • Page 60

    Periodic maintenance 2-37 maintenance procedure swingarm pivot lubrication • apply grease to the inner surface of the needle bearings in accordance with the periodic maintenance chart. • apply a thin coat of grease to the lips of the grease seals. Uni-trak linkage lubrication • apply grease to the i...

  • Page 61

    2-38 periodic maintenance maintenance procedure • loosen: steering stem locknut [a]. • adjust the steering. Special tool - steering stem nut wrench: 57001-1100 [b] if the steering too tight, loosen the stem nut [c] a fraction of a turn. If the steering too loose, tighten the stem nut a fraction of a...

  • Page 62

    Periodic maintenance 2-39 maintenance procedure spark plug gap inspection • measure the gap [a] with a wire-type thickness gauge. If the gap is incorrect, carefully bend the side electrode [b] with a suitable tool to obtain the correct gap. Spark plug gap: 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.) general lu...

  • Page 63

    2-40 periodic maintenance maintenance procedure • with the cable disconnected at both ends, the cable should move freely [a] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [b], or if the cable housing is kinked [c], replace the cable. Nut, bolts, an...

  • Page 64

    Periodic maintenance 2-41 maintenance procedure steering: steering stem head bolt handlebar holder bolts handlebar holder mounting nut engine: engine mounting bolts engine mounting bracket bolts muffler mounting bolts exhaust pipe holder nuts muffler connecting clamp bolt clutch lever pivot nut clut...

  • Page 66: Fuel System

    Fuel system 3-1 3 fuel system table of contents exploded view........................................................................................................................ 3-2 specifications ......................................................................................................

  • Page 67

    3-2 fuel system exploded view.

  • Page 68

    Fuel system 3-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 air cleaner element cover mounting nut 5.9 0.6 52 in·lb 2 air cleaner housing mounting bolts 11 1.1 95 in·lb 3 carburetor holder plate mounting bolts 11 1.1 95 in·lb 4. Air cleaner case (california model) 5. Clamps (californ...

  • Page 69

    3-4 fuel system exploded view.

  • Page 70

    Fuel system 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks fuel tap mounting bolts 2.5 0.25 22 in·lb with white washer 1 fuel tap mounting bolts 4.9 0.50 43 in·lb with black washer 2. Fuel tank cap seal (california model) 3. Drain hose (on and after vn800-b7, other than california mod...

  • Page 71

    3-6 fuel system specifications item standard service limit carburetor make, type keihin, cvk36 – – – idle speed 1000 ±50 r/min (rpm) – – – (ch) (cal) 1300 ±50 r/min (rpm) main jet #135 – – – main air jet #100 – – – needle jet #6 – – – jet needle n2pe – – – (pf) (pu) (cal) nbzq (vn800-b9 ∼, b6f) pilo...

  • Page 72

    Fuel system 3-7 special tools fuel level gauge: 57001-1017 pilot screw adjuster, a: 57001-1239 carburetor drain plug wrench, hex 3: 57001-1269.

  • Page 73

    3-8 fuel system throttle grip and cables throttle grip free play inspection • refer to the throttle grip play inspection in the periodic maintenance chapter. Throttle grip free play adjustment • refer to the throttle grip play inspection in the periodic maintenance chapter. Throttle cable installati...

  • Page 74

    Fuel system 3-9 choke cable choke free play inspection • check that the choke inner cable slides smoothly by mov- ing the choke knob [a] to the push and pull. If there is any irregularity, replace the choke cable. Choke cable installation • install the choke cable in accordance with the cable, wire,...

  • Page 75

    3-10 fuel system carburetor idle speed inspection • refer to the idle speed inspection in the periodic main- tenance chapter. Idle speed adjustment • refer to the idle speed adjustment in the periodic main- tenance chapter. Service fuel level inspection warning gasoline is extremely flammable and ca...

  • Page 76

    Fuel system 3-11 carburetor service fuel level adjustment warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch off. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any applianc...

  • Page 77

    3-12 fuel system carburetor pilot screw setting ○ the pilot screw [a] is set at the factory and should not be adjusted. But if necessary set the pilot screw as follows. • turn in the pilot screw and count the number of turns until it seat fully but not tightly. ○ the pilot screw adjuster [b] may be ...

  • Page 78

    Fuel system 3-13 carburetor choke cable [a] • loosen the carburetor clamp screw [b]. • remove the throttle cable ends from the handlebar switch side. • remove the carburetor [c]. • stuff piece of lint-free, clean cloth into the carburetor holder to keep dirt out of the engine. Vacuum hose [a] warnin...

  • Page 79

    3-14 fuel system carburetor warning fuel spilled from the carburetors is hazardous. • adjust the following items if necessary. Idle speed throttle cables carburetor disassembly • remove the carburetor (see carburetor removal). Warning gasoline is extremely flammable and can be ex- plosive under cert...

  • Page 80

    Fuel system 3-15 carburetor • turn the carburetor body upside-down, and drop the nee- dle jet [a] into place so that the smaller diameter end [b] of the jet goes in first. • carefully screw in the needle jet holder [c]. It will seat against the needle jet, pushing the end of the jet into the carbure...

  • Page 81

    3-16 fuel system carburetor caution do not use compressed air on an assembled carbu- retor, or the float may be crushed by the pressure, and the vacuum piston diaphragms may be dam- aged. Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carbure- tor with a c...

  • Page 82

    Fuel system 3-17 carburetor • disassemble the carburetor. • clean the carburetor. • check that the o-rings on the float bowl and pilot screw and the diaphragm on the vacuum piston are in good con- dition. If any of the o-rings or diaphragms are not in good con- dition, replace them. • check the plas...

  • Page 83

    3-18 fuel system air cleaner element removal • remove: nut [a] and washer air cleaner cover [b] element [a] • push a clean, lint-free towel into the carburetor intake to keep dirt or other foreign material from entering. Warning if dirt or dust is allowed to pass through into the carburetors, the th...

  • Page 84

    Fuel system 3-19 air cleaner • remove the air cleaner housing [a] from the carburetor [b]. • disconnect the engine breather hose [c], vacuum switch valve hose [d] and drain hose [e]. Evaporative emission hose [f] (for california model) air cleaner housing installation • tighten: torque - air cleaner...

  • Page 85

    3-20 fuel system fuel tank fuel tank removal warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch off. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilo...

  • Page 86

    Fuel system 3-21 fuel tank fuel tank inspection • remove the fuel tank and drain it. • check to see if the breather pipe [a] (also the fuel return pipe for the california model) in the tank is not clogged. Check the tank cap breather also. If the breather pipe is clogged, blow the pipe free with com...

  • Page 87

    3-22 fuel system fuel tank fuel tap installation • be sure the o-rings [a] is in good condition to prevent leaks. • be sure the nylon flat washers [b] are in good condition to prevent leaks. ○ do not use steel washers in place of the nylon flat wash- ers, because they will not seal the bolts properl...

  • Page 88

    Fuel system 3-23 evaporative emission control system (california model only) the evaporative emission control system routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough vis...

  • Page 89

    3-24 fuel system evaporative emission control system (california model only) separator operation test warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch off. Do not smoke. Make sure the area is well-ventilated and free from any source of...

  • Page 90: Cooling System

    Cooling system 4-1 4 cooling system table of contents exploded view........................................................................................................................ 4-2 specifications ................................................................................................

  • Page 91

    4-2 cooling system exploded view.

  • Page 92

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 water pump impeller nut 11 1.1 95 in·lb 2 water hose fitting bolts 11 1.1 95 in·lb 3 radiator hose clamp screws 2.0 0.2 17 in·lb 4 radiator fan switch 18 1.8 13 ss 5 water temperature sensor 7.8 0.8 69 in·lb ss 6 coolant ...

  • Page 93

    4-4 cooling system specifications item standard service limit coolant provided when shipping type permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) – – – color green – – – mixed ratio soft water 50%, coolant 5...

  • Page 94

    Cooling system 4-5 special tools kawasaki bond (silicone sealant): 56019-120

  • Page 95

    4-6 cooling system coolant flow chart permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature chan...

  • Page 96

    Cooling system 4-7 coolant flow chart 1. Radiator 2. Fan switch 3. Water temperature sensor 4. Right engine cover 5. Water pump impeller 6. To crankcase 7. From rear cylinder head 8. From front cylinder head 9. Thermostat when the engine is cold, the thermostat is closed so that the coolant flow is ...

  • Page 97

    4-8 cooling system coolant coolant deterioration inspection • visually inspect the coolant in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling sy...

  • Page 98

    Cooling system 4-9 coolant pressure testing • remove the meter unit (see electrical system chapter). • remove the radiator cap, and install a cooling system pressure tester [a] on the filler neck. Note ○ wet the cap sealing surfaces with water or coolant to prevent pressure leaks. • build up pressur...

  • Page 99

    4-10 cooling system water pump water pump impeller removal • drain: engine oil (see engine oil change in the periodic main- tenance chapter) coolant (see coolant draining in the periodic mainte- nance chapter) • remove: right engine cover (see clutch chapter) nut [a] impeller [b] water pump impeller...

  • Page 100

    Cooling system 4-11 water pump water pump inspection • check the drainage outlet passage [a] at the bottom of the right crankcase for coolant leaks. If the mechanical seal is damaged, the coolant leaks through the seal and drains through the passage. Re- place the mechanical seal with a new one. • v...

  • Page 101

    4-12 cooling system radiator, radiator fan radiator and radiator fan removal warning the radiator fan is connected directly to the bat- tery. The radiator fan may start even if the ignition switch is off. Never touch the radiator fan until the radiator fan connector is dis- connected. Touching the f...

  • Page 102

    Cooling system 4-13 radiator, radiator fan radiator fan installation • be sure to attach the ground lead [a] to the fan mounting bolt [b]. Radiator inspection • check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [a] are deformed, carefully straighten ...

  • Page 103

    4-14 cooling system radiator, radiator fan • watching the pressure gauge, pump the pressure tester to build up the pressure until the relief valve opens: the gauge hand flicks downward. Stop pumping and measure leak time at once. The relief valve must open within the specified range in the table bel...

  • Page 104

    Cooling system 4-15 thermostat thermostat removal • remove: coolant (see coolant draining in the periodic mainte- nance chapter) seat (see frame chapter) fuel tank (see fuel system chapter) thermostat housing cover bolts [a] thermostat housing cover [b] thermostat thermostat installation • install a...

  • Page 105

    4-16 cooling system hose and pipes hose installation • install the hoses and pipes being careful to follow bend- ing direction or diameter. Avoid sharp bending, kinking, flattening, or twisting. • install the clamps [a] as near as possible to the hose end to clear the raised rib or the fitting. This...

  • Page 106

    Cooling system 4-17 radiator fan switch, water temperature sensor radiator fan switch, water temperature sensor removal caution the fan switch or the water temperature sensor should never be allowed to fall on a hard surface. Such a shock to their parts can damage them. • drain the coolant (see cool...

  • Page 108: Engine Top End

    Engine top end 5-1 5 engine top end table of contents exploded view................................... 5-2 specifications .................................... 5-6 special tools ..................................... 5-8 clean air system............................... 5-10 air suction valve removal......

  • Page 109

    5-2 engine top end exploded view.

  • Page 110

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 cylinder head cover bolts 12 1.2 104 in·lb 2 cylinder head nuts (10 mm) 39 4.0 29 s 3 cylinder head nuts (8 mm) 25 2.5 18.0 s 4 cylinder head bolts 12 1.2 104 in·lb s 5 cylinder nuts 25 2.5 18.0 6 camshaft cap bolt 25 2.5...

  • Page 111

    5-4 engine top end exploded view.

  • Page 112

    Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 camshaft sprocket bolts 49 5.0 36 l 2 camshaft chain tensioner cap bolts 20 2.0 14.5 3 camshaft chain guide bolts 11 1.1 95 in·lb l 4. Rocker arm spring (intake), (red paint mark) 5. Exhaust pipe holder nuts 6. Muffler mo...

  • Page 113

    5-6 engine top end specifications item standard service limit clean air system open → close vacuum switch valve closing pressure 57 ∼ 65 kpa (430 ∼ 490 mmhg) – – – camshafts cam height: inlet 35.305 ∼ 35.413 mm (1.3900 ∼ 1.3942 in.) 35.21 mm (1.386 in.) exhaust 35.033 ∼ 35.141 mm (1.3792 ∼ 1.3835 in...

  • Page 114

    Engine top end 5-7 specifications item standard service limit piston/cylinder clearance 0.010 ∼ 0.037 mm (0.0004 ∼ 0.0015 in.) – – – oversize pistons and rings +0.5 mm (0.02 in.) – – – piston ring/groove clearance: top 0.03 ∼ 0.07 mm (0.001 ∼ 0.003 in.) 0.17 mm (0.007 in.) second 0.02 ∼ 0.06 mm (0.0...

  • Page 115

    5-8 engine top end special tools compression gauge, 20 kgf/cm²: 57001-221 valve spring compressor assembly: 57001-241 piston pin puller assembly: 57001-910 valve seat cutter, 45° - 32: 57001-1115 valve seat cutter, 32° - 28: 57001-1119 valve seat cutter, 60° - 30: 57001-1123 valve seat cutter holder...

  • Page 116

    Engine top end 5-9 special tools valve guide arbor, 5: 57001-1203 valve guide reamer, 5: 57001-1204 valve seat cutter holder, 5: 57001-1208 spark plug wrench, hex 16: 57001-1262 fork oil level gauge: 57001-1290 compression gauge adapter, m10 × 1.0: 57001-1317 valve seat cutter, 60° - 33: 57001-1334 ...

  • Page 117

    5-10 engine top end clean air system air suction valve removal • refer: cylinder head cover removal air suction valve installation • refer: cylinder head cover installation air suction valve inspection • refer to the air suction valve inspection in the periodic maintenance chapter. Vacuum switch val...

  • Page 118

    Engine top end 5-11 clean air system if the vacuum switch valve does not operate as described, replace it with a new one. Note ○ to check air flow through the vacuum switch valve, just blow through the air cleaner hose. Vacuum switch valve closing pressure (open → close) standard: 57 ∼ 65 kpa (430 ∼...

  • Page 119

    5-12 engine top end cylinder head cover cylinder head cover removal • remove: seat (see frame chapter) fuel tank (see fuel system chapter) (1) for front head cover • remove: air cleaner housing (see fuel system chapter) spark plug cap [a] vacuum switch valve hose [b] cover bolts [c] cylinder head co...

  • Page 120

    Engine top end 5-13 cylinder head cover • remove: cylinder head cover [a] air suction valve head cover gasket cylinder head cover installation • if the plug pipe [a] was removed, install it with the cham- fered side [b] faces upward, and apply grease to the o -ring [c]. • install: pin [d] head cover...

  • Page 121

    5-14 engine top end camshaft chain tensioner camshaft chain tensioner removal • remove: engine (see engine removal/installation chapter) camshaft (see camshaft removal) cylinder head (see cylinder head removal) • remove the camshaft chain tensioner body from the cylinder. Camshaft chain tensioner in...

  • Page 122

    Engine top end 5-15 camshaft, camshaft chain camshaft removal • remove: cylinder head cover (see cylinder head cover re- moval) tensioner cap bolt [a], washer [b] and spring caution do not turn over the crankshaft while the tensioner cap bolt is removed, the tensioner body is loose from the cylinder...

  • Page 123

    5-16 engine top end camshaft, camshaft chain camshaft installation • apply engine oil to all cam parts and journals. Note ○ the front and rear camshafts are different. The rear camshaft [a] has a groove [b]. • set the front piston at tdc. ○ align the front piston tdc mark [a] and timing mark [b] by ...

  • Page 124

    Engine top end 5-17 camshaft, camshaft chain camshaft, camshaft cap wear inspection • measure each clearance between the camshaft journal and the camshaft cap using plastigage (press gauge) [a]. • tighten: torque - camshaft cap bolts: 25 n·m (2.5 kgf·m, 18.0 ft·lb) note ○ do not turn the camshaft wh...

  • Page 125

    5-18 engine top end camshaft, camshaft chain camshaft chain removal front camshaft chain • remove: alternator rotor (see electrical system chapter) bolts [a] and black chain guide [b] bolt [c], washer [d] and white chain guide [e] • disengage the camshaft chain [f] from the crankshaft sprocket and t...

  • Page 126

    Engine top end 5-19 rocker shaft, rocker arm rocker shaft, rocker arm removal • remove: cylinder head cover (cylinder head cover removal) camshaft cap rocker shafts [a] rocker arms [b] and springs [c] rocker shaft, rocker arm installation • apply molybdenum disulfide grease to the rocker shaft. • in...

  • Page 127

    5-20 engine top end cylinder head cylinder compression measurement note ○ use the battery which is fully charged. • warm up the engine thoroughly. • stop the engine. • remove: seat (see frame chapter) fuel tank (see fuel system chapter) spark plugs special tool - spark plug wrench, hex 16: 57001-126...

  • Page 128

    Engine top end 5-21 cylinder head cylinder head removal • remove: engine (see engine removal/installation) camshaft (see camshaft removal) bolts [a] and intake manifold [b] 8 mm cylinder head nuts [a] cylinder head bolt [a] cylinder head nuts [b] 10 mm cylinder head nuts [c] cylinder head cylinder h...

  • Page 129

    5-22 engine top end cylinder head • tighten the cylinder head nuts and bolt following the tight- ening sequence [1 ∼ 7]. Torque - cylinder head nuts: 10 mm [1 ∼ 4]: 39 n·m (4.0 kgf·m, 29 ft·lb) 8 mm [5 ∼ 6]: 25 n·m (2.5 kgf·m, 18 ft·lb) cylinder head bolt [7]: 12 n·m (1.2 kgf·m, 104 in·lb) tighten t...

  • Page 130

    Engine top end 5-23 cylinder head rear cylinder head [a] rubber dampers (17) [b] 40 mm (1.57 in.) [c] 38 mm (1.50 in.) [d] 36 mm (1.42 in.) • when installing the breather pipe fitting [a] in the rear cylinder head, align the fitting with the mark [b]. [c] fitting hose [d] 37 ∼ 43° cylinder head warp...

  • Page 131

    5-24 engine top end valves valve clearance inspection • refer to the valve clearance inspection in the periodic maintenance chapter. Valve clearance adjustment • refer to the valve clearance adjustment in the periodic maintenance chapter. Valve removal • remove the cylinder head (see cylinder head r...

  • Page 132

    Engine top end 5-25 valves valve guide installation • apply oil to the valve guide outer surface before installa- tion. • heat the area around the valve guide hole to about 120 ∼ 150°c (248 ∼ 302°f) (see valve guide removal). • drive the valve guide in from the top of the head using the valve guide ...

  • Page 133

    5-26 engine top end valves valve seat inspection • remove the valve (see valve removal). • check the valve seating surface [a] between the valve [b] and valve seat [c]. ○ measure the outside diameter [d] of the seating pattern on the valve seat. If the outside diameter is too large or too small, rep...

  • Page 134

    Engine top end 5-27 valves seat cutter operation care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off. 3. Do not fai...

  • Page 135

    5-28 engine top end valves • measure the outside diameter (o.D.) of the seating sur- face with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind [a] until the diameter is within the specified range. Original seating surface [b] note ○ remove all pit...

  • Page 136

    Engine top end 5-29 valves • lap the valve to the seat, once the seat width and o.D. Are within the ranges specified above. ○ put a little coarse grinding compound on the face of the valve in a number of places around the valve head. ○ spin the valve against the seat until the grinding com- pound pr...

  • Page 137

    5-30 engine top end valves.

  • Page 138

    Engine top end 5-31 cylinder, pistons cylinder removal • remove: cylinder head (see cylinder head removal) cylinder nut [a] cylinder cylinder installation note ○ if a new cylinder is used, check piston to cylinder clear- ance (see piston/cylinder clearance), and use new pis- ton ring. • install the ...

  • Page 139

    5-32 engine top end cylinder, pistons • carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [a] to remove it. • remove the 3-piece oil ring with your thumbs in the same manner. Piston installation note ○ if a new piston is used, check piston to cylind...

  • Page 140

    Engine top end 5-33 cylinder, pistons cylinder wear inspection • since there is a difference in cylinder wear in different di- rections, take a side-to-side and a front-to-back measure- ment at each of the 3 locations (total of 6 measurements) shown in the figure. If any of the cylinder inside diame...

  • Page 141

    5-34 engine top end cylinder, pistons ○ cylinder inside diameter must not vary more than 0.01 mm (0.0004 in.) at any point. ○ be wary of measurements taken immediately after boring since the heat affects cylinder diameter. ○ in the case of rebored cylinder and oversize piston, the service limit for ...

  • Page 142

    Engine top end 5-35 cylinder, pistons piston ring thickness inspection • measure the piston ring thickness. ○ use a micrometer to measure at several points around the ring. Piston ring thickness standard: top and second 0.97 ∼ 0.99 mm 0.0382 ∼ 0.0390 in.) service limit: top and second 0.90 mm 0.035 ...

  • Page 143

    5-36 engine top end muffler muffler removal front muffler • remove: clamp bolts [a] and front exhaust pipe cover [b] • remove the exhaust pipe holder nuts [a] • remove: muffler bolts [a] clamp bolts [b] front muffler [c] rear muffler • remove: front muffler clamp bolts [a] and rear exhaust pipe cove...

  • Page 144

    Engine top end 5-37 muffler • when the front muffler [a] shall be connected to the rear muffler [b], the position of clamp bolt head [c] faces out- wards as shown. Muffler cover removal • remove the muffler cover [a] from the muffler as follows: ○ hold the both ends on the cover. ○ push [b] the uppe...

  • Page 146: Clutch

    Clutch 6-1 6 clutch table of contents exploded view........................................................................................................................ 6-2 specifications ................................................................................................................

  • Page 147

    6-2 clutch exploded view.

  • Page 148

    Clutch 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 right engine cover bolts 12 1.2 104 in·lb l (1) 2 clutch hub nut 132 13.5 98 o 3 clutch spring bolts 8.8 0.9 78 in·lb 4. Clutch lever pivot nut 5. Clutch lever holder clamp bolt cl: apply cable lubricant. G: apply grease. L: appl...

  • Page 149

    6-4 clutch specifications item standard service limit clutch friction plate thickness 2.9 ∼ 3.1 mm (0.114 ∼ 0.122 in.) 2.8 mm (0.11 in.) friction and steel plate warp 0.2 mm (0.008 in.) or less 0.3 mm (0.012 in.) clutch spring free length: 34.2 mm (1.35 in.) 33.1 mm (1.30 in.) (on and after vn800-b7...

  • Page 150

    Clutch 6-5 special tool clutch holder: 57001-1243.

  • Page 151

    6-6 clutch clutch lever and cable lever free play inspection • refer to the clutch inspection in the periodic mainte- nance chapter. Lever free play adjustment • refer to the clutch inspection in the periodic mainte- nance chapter. Cable removal • slide the dust cover at the clutch cable lower end o...

  • Page 152

    Clutch 6-7 right engine cover right engine cover removal • remove: engine oil (drain, see engine lubrication system chap- ter) coolant (drain, see cooling system chapter) front right foot peg and brake pedal (see brakes chapter) front muffler (see engine top end chapter) clutch cable down tube (see ...

  • Page 153

    6-8 clutch right engine cover release shaft installation • apply high-temperature grease to the oil seal lips on the lower ridge of the clutch cover. • apply oil to the bearing in the hole of the right engine cover. • insert the release shaft straight into the lower hole of the right engine cover. C...

  • Page 154

    Clutch 6-9 clutch clutch removal • remove: right engine cover (see right engine cover removal) clutch spring bolts [a] clutch springs clutch spring plate [b] (with thrust bearing and pusher [c]) friction plates, steel plates clutch hub nut [a] ○ holding the clutch hub [b], remove the nut. Special to...

  • Page 155

    6-10 clutch clutch ○ install the thrust spacer [a] so that the stepped side [b] faces inward. ○ replace the clutch hub nut with a new one. ○ apply oil to the threads and seating surface of the hub nut. ○ holding the clutch hub, tighten the clutch hub nut. Special tool - clutch holder: 57001-1243 tor...

  • Page 156

    Clutch 6-11 clutch clutch spring free length measurement • measure the free length of the clutch springs [a]. If any spring is shorter than the service limit, it must be replaced. Clutch spring free length standard: 34.2 mm (1.35 in.) service limit: 33.1 mm (1.30 in.) on and after vn800-b7 model sta...

  • Page 158: Engine Lubrication System

    Engine lubrication system 7-1 7 engine lubrication system table of contents exploded view........................................................................................................................ 7-2 engine oil flow chart....................................................................

  • Page 159

    7-2 engine lubrication system exploded view.

  • Page 160

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine drain plug 20 2.0 14.5 2 oil pump mounting bolts 11 1.1 97 in·lb l 3 oil pump drive chain guide bolt 12 1.2 104 in·lb l 4 oil filter 18 1.8 13 5 oil filter plate mounting bolts 7.8 0.8 69 in·lb 6 oil scr...

  • Page 161

    7-4 engine lubrication system engine oil flow chart 1. Left crankcase 2. Right crankcase 3. Oil screen plug 4. Oil screen 5. Oil pump 6. Oil filter 7. Oil pressure switch 8. Oil pipe 9. Crankshaft 10. Relief valve 11. Output shaft 12. Drive shaft 13. Front cylinder head 14. Rear cylinder head 15. Ca...

  • Page 162

    Engine lubrication system 7-5 specifications item standard service limit engine oil type se, sf or sg class – – – (on and after vn800-b6) api se,sf,or sg – – – api sh or sj with jaso ma – – – viscosity sae 10w-40, 10w-50, 20w-40, or 20w-50 – – – (on and after vn800-b6) sae 10w-40 – – – capacity 2.7 ...

  • Page 163

    7-6 engine lubrication system special tool oil pressure gauge, 10 kgf/cm²: 57001-164 oil pressure gauge adapter, pt 1/8: 57001-1033 oil filter wrench: 57001-1249 kawasaki bond (silicone sealant): 56019-120

  • Page 164

    Engine lubrication system 7-7 engine oil and oil filter warning motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. Oil level inspection • check that the engine oil le...

  • Page 165

    7-8 engine lubrication system engine oil and oil filter • pull out the oil screen [a]. • clean the screen with high flash-point solvent. Warning clean the screen in a well-ventilated area, and take care that there is no spark or frame anywhere near the working area. Because of the danger of highly f...

  • Page 166

    Engine lubrication system 7-9 oil pressure relief valve oil pressure relief valve removal/installation • split the crankcase (see crankshaft/transmission chap- ter). • remove the relief valve [a] from the right crankcase. • apply a non-permanent locking agent to the threads of the relief valve, and ...

  • Page 167

    7-10 engine lubrication system oil pump, oil pump drive chain oil pump removal • split the crankcase (see crankshaft/transmission chap- ter). • remove: crankshaft circlip [a] • remove the sprocket [b] and balancer shaft [c] along with the oil pump chain [d]. • remove: oil pump mounting bolts [e] oil...

  • Page 168

    Engine lubrication system 7-11 oil pressure measurement oil pressure measurement • remove the oil pressure switch (see oil pressure switch removal) without draining the engine oil. • install the gauge and adapter. Special tool - oil pressure gauge, 10 kgf/cm²: 57001-164 [a] oil pressure gauge adapte...

  • Page 169

    7-12 engine lubrication system oil pressure switch oil pressure switch removal • remove: engine oil (drain, see engine oil change in the periodic maintenance chapter) switch cover [a] switch lead terminal [b] oil pressure switch [c] oil pressure switch installation • apply silicone sealant to the th...

  • Page 170

    Engine lubrication system 7-13 oil pipe oil pipe (crankcase outside) removal • remove: alternator cover (see electrical system chapter) oil pipe mounting bolts [a] oil pipe [b] oil pipe (crankcase outside) installation • apply grease to the o-rings [a]. • apply a non-permanent locking agent to the t...

  • Page 171

    7-14 engine lubrication system oil pipe oil pipe (crankcase inside) removal • split the crankcase (see crankshaft/transmission chap- ter). • remove: oil pipe mounting bolts [a] oil pipes [b] oil pipe (crankcase inside) installation • apply grease to the o-rings [a]. • apply a non-permanent locking a...

  • Page 172: Engine Removal/installation

    Engine removal/installation 8-1 8 engine removal/installation table of contents exploded view........................................................................................................................ 8-2 special tool ........................................................................

  • Page 173

    8-2 engine removal/installation exploded view.

  • Page 174

    Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine mounting nuts 44 4.5 32 2 engine mounting bracket bolts 25 2.5 18 3 down tube mounting bolts 44 4.5 32.

  • Page 175

    8-4 engine removal/installation special tool jack: 57001-1238 jack attachment #3: 57001-1416.

  • Page 176

    Engine removal/installation 8-5 engine removal/installation engine removal • remove: engine oil (drain, see engine lubrication system in the periodic maintenance chapter) coolant (drain, see cooling system in the periodic main- tenance chapter) seat (see frame chapter) fuel tank (see fuel system cha...

  • Page 177

    8-6 engine removal/installation engine removal/installation • support the frame with the jack. Special tool - jack: 57001-1238 jack attachment #3: 57001-1416 • squeeze the brake lever slowly and hold it with a band [a]. Warning be sure to hold the front brake when removing the engine, or the motorcy...

  • Page 178: Crankshaft/transmission

    Crankshaft/transmission 9-1 9 crankshaft/transmission table of contents exploded view................................... 9-2 specifications .................................... 9-6 special tool ....................................... 9-8 crankcase splitting............................ 9-9 crankcase ...

  • Page 179

    9-2 crankshaft/transmission exploded view.

  • Page 180

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 crankcase bolts (6 mm) 11 1.1 95 in·lb 2 crankcase bolts (10 mm) 39 4.0 29 s 3 connecting rod big end cap nuts 46 4.7 34 mo 4 primary gear bolt 157 16 116 o 5 balancer gear bolt 69 7.0 51 l 6 starter motor clutch...

  • Page 181

    9-4 crankshaft/transmission exploded view.

  • Page 182

    Crankshaft/transmission 9-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 shift drum cam holder screw 12 1.2 104 in·lb l 2 shift drum bearing stopper bolts 11 1.1 95 in·lb 3 neutral switch 15 1.5 11 4 shift pedal pivot bolt 29 3.0 22 5 shift pedal pivot bolt nut 29 3.0 22 6 shift lever...

  • Page 183

    9-6 crankshaft/transmission specifications item standard service limit crankshaft, connecting rods connecting rod big end side clearance 0.16 ∼ 0.46 mm 0.70 mm (0.006 ∼ 0.018 in.) (0.028 in.) 0.026 ∼ 0.054 mm 0.09 mm connecting rod big end bearing insert/crankpin clearance (0.0010 ∼ 0.0021 in.) (0.0...

  • Page 184

    Crankshaft/transmission 9-7 specifications item standard service limit crankshaft main journal diameter 42.984 ∼ 43.000 mm 42.96 mm (1.6923 ∼ 1.6929 in.) (1.691 in.) crankcase main bearing bore diameter 43.025 mm ∼ 43.041 mm 43.09 mm (1.6939 ∼ 1.6945 in.) (1.696 in.) transmission shift fork ear thic...

  • Page 185

    9-8 crankshaft/transmission special tool outside circlip pliers: 57001-144 bearing driver set: 57001-1129 flywheel holder: 57001-1313 kawasaki bond (liquid gasket - black) tb1105: 92104-1003.

  • Page 186

    Crankshaft/transmission 9-9 crankcase splitting crankcase splitting • remove the engine (see engine removal/installation chapter). • set the engine on a clean surface and hold the engine steady while parts are being removed. • remove: starter motor (see electrical system chapter) oil filter (see eng...

  • Page 187

    9-10 crankshaft/transmission crankcase splitting • put the engine so that the left crankcase is down. • pry the points [a] to split the crankcase halves apart, and remove the right crankcase half. ○ tap lightly around the crankcase joint with a plastic mallet, and split the crankcase. Take care not ...

  • Page 188

    Crankshaft/transmission 9-11 crankcase splitting • install the right crankcase, fitting the oil pump shaft pro- jection [a] into the water pump shaft slot [b]. • tighten the right crankcase half 6 mm bolts [a]. Torque - crankcase bolts (6 mm): 11 n·m (1.1 kgf·m, 95 in·lb) • tighten the left crankcas...

  • Page 189

    9-12 crankshaft/transmission crankshaft/connecting rods crankshaft removal • split the crankcase (see crankcase splitting). • remove the crankshaft. Crankshaft installation • insert the crankshaft tapered end in to the left crankcase [a]. • install the left connecting rod [b] into the rear cylinder ...

  • Page 190

    Crankshaft/transmission 9-13 crankshaft/connecting rods crankshaft/connecting rod cleaning • after removing the connecting rods from the crankshaft, clean them with a high-flash point solvent. • blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may ...

  • Page 191

    9-14 crankshaft/transmission crankshaft/connecting rods if clearance is within the standard, no bearing replace- ment is required. If clearance is between 0.054 mm (0.0021 in.) and the service limit (0.09 mm, 0.35 in.), replace the bear- ing inserts [a] with inserts painted blue [b]. Check insert/cr...

  • Page 192

    Crankshaft/transmission 9-15 crankshaft/connecting rods • select the proper bearing insert [a] in accordance with the combination of the connecting rod and crankshaft coding. Size color [b] connecting rod big end bearing insert selection bearing insert con-rod big end bore diameter marking crankpin ...

  • Page 193

    9-16 crankshaft/transmission crankshaft/connecting rods crankshaft main bearing/main journal wear inspection • measure the diameter [a] of the crankshaft main journal. If any journal has worn past the service limit, replace the crankshaft with a new one. Crankshaft main journal diameter standard: 42...

  • Page 194

    Crankshaft/transmission 9-17 balancer, starter motor clutch left balancer removal • remove the alternator cover (see electrical system chap- ter). • wipe oil off the outer circumference of the alternator rotor. • hold the alternator rotor steady with the flywheel holder [a], and remove the balancer ...

  • Page 195

    9-18 crankshaft/transmission balancer, starter motor clutch • install the alternator rotor (see electrical system chapter). • hold the alternator rotor steady with the flywheel holder [a]. Special tool - flywheel holder: 57001-1313 • apply a non-permanent locking agent to the threads of the balancer...

  • Page 196

    Crankshaft/transmission 9-19 balancer, starter motor clutch right balancer, starter motor clutch installation • be sure to install the one-way clutch [a] so that the flange [b] of it fits in the coupling recess [c]. • apply a non-permanent locking agent to the threads of the starter clutch bolts, an...

  • Page 197

    9-20 crankshaft/transmission balancer, starter motor clutch • disassemble the starter motor clutch (see right balancer, starter motor clutch removal). • visually inspect: one-way clutch [a] coupling [b] starter motor clutch gear inner race [c] if there is any worn or damaged part, replace it. Balanc...

  • Page 198

    Crankshaft/transmission 9-21 torque limiter torque limiter removal • remove: right engine cover (see clutch chapter) starter motor clutch gear [a] (see right balancer, starter motor clutch removal) torque limiter [b] caution do not disassemble the torque limiter. The torque limiter will not function...

  • Page 199

    9-22 crankshaft/transmission primary gear primary gear removal • remove the alternator cover (see electrical system chap- ter). • wipe oil off the outer circumference of the alternator rotor. • hold the alternator rotor steady with the flywheel holder [a]. Special tool - flywheel holder: 57001-1313 ...

  • Page 200

    Crankshaft/transmission 9-23 transmission shift pedal removal • mark the position of the shift lever on the shift shaft so that it can be installed later in the same position. • remove: bolts [a] footpeg bracket [b] shift lever [c] shift pedal [d] shift pedal installation • install the shift pedal [...

  • Page 201

    9-24 crankshaft/transmission transmission • remove: bolt [a] shift drum position lever [b] spring [c] external shift mechanism installation • install the shift drum position lever [a] and spring [b], and tighten the bolt [c]. Torque - shift drum position lever bolt: 11 n·m ( 1.1 kgf·m, 95 in·lb) • i...

  • Page 202

    Crankshaft/transmission 9-25 transmission transmission shaft and shift fork removal • split the crankcase (see crankcase splitting). • remove: shift rod [a] shift forks (2) [b] • take out the drive shaft [c] and output shaft [d] as a set, and remove the remainder shift fork. Transmission shaft and s...

  • Page 203

    9-26 crankshaft/transmission transmission transmission shaft assembly • install the 5th gear [a] on the output shaft with its oil hole [b] aligned with the shaft oil hole [c]. • fit the steel balls into the 4th gear holes as shown. View a-a’ (see the output shaft illustration) [a] gear (4th) [b] sha...

  • Page 204

    Crankshaft/transmission 9-27 transmission 1. 1st gear 2. 2nd gear 3. 3rd gear 4. 4th gear 5. 5th (top) gear 6. Circlip 7. Circlip 8. Thrust washer (20.5 × 30 × 1.0) 9. Thrust washer (20.5 × 30 × 0.5) 10 thrust washer (25.3 × 30 × 1.0) 11. Thrust washer (30 × 38 × 1.0) 12. Toothed washer 13. Ball bea...

  • Page 205

    9-28 crankshaft/transmission transmission shift drum assembly • be sure to install the dowel pin. • apply a non-permanent locking agent to the threads of the shift drum cam holder screw, and tighten it. Torque - shift drum cam holder screw: 12 n·m (1.2 kgf·m, 104 in·lb) shift fork bending inspection...

  • Page 206

    Crankshaft/transmission 9-29 transmission gear dog and gear dog hole damage inspection • visually inspect the gear dogs [a] and gear dog holes [b]. Replace any damaged gears or gears with excessively worn dogs or dog holes..

  • Page 207

    9-30 crankshaft/transmission ball bearing, needle bearing, and oil seal bearing oil seal installation • when installing a bearing other than the following parts, press it in with the marked side facing out. Special tool - bearing driver set: 57001-1129 right crankcase • install the right balancer be...

  • Page 208

    Crankshaft/transmission 9-31 water pump shaft water pump shaft removal • split the crankcase (see crankshaft/transmission chap- ter). • remove the circlip [a] from the water pump shaft [b]. Special tool - outside circlip pliers: 57001-144 • remove the shaft from the outside of the crankcase to the i...

  • Page 210: Wheels/tires

    Wheels/tires 10-1 10 wheels/tires table of contents exploded view........................................................................................................................ 10-2 specifications .................................................................................................

  • Page 211

    10-2 wheels/tires exploded view.

  • Page 212

    Wheels/tires 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front axle nut 108 11.0 80 2 rear axle nut 98 10.0 72 3 spoke nipples 4.9 0.5 43 in·lb 4 front axle clamp bolts 34 3.5 25 5. Axle nut cap (vn800-b5 ∼ b6, germany model) (on and after vn800-b7, europe and united kingdom mod...

  • Page 213

    10-4 wheels/tires specifications item standard service limit wheels (rims) rim size: – – – front 16 × 3.00 – – – rear 16 × 3.00 – – – rim runout (with tire installed) radial tir 1.0 mm (0.04 in) or less tir 2.0 mm (0.08 in.) axial tir 0.8 mm (0.03 in.) or less tir 2.0 mm (0.08 in.) axle runout/100 m...

  • Page 214

    Wheels/tires 10-5 special tools inside circlip pliers: 57001-143 rim protector: 57001-1063 bead breaker assembly: 57001-1072 bearing driver set: 57001-1129 jack: 57001-1238 bearing remover shaft, 9: 57001-1265 bearing remover head, 15 × 17: 57001-1267 bearing remover head, 20 × 22: 57001-1293 jack a...

  • Page 215

    10-6 wheels/tires wheels (rims) front wheel removal • loosen the front axle nut [a]. • raise the front wheel off the ground. Special tools - jack: 57001-1238 jack attachment #3: 57001-1416 • loosen the axle clamp bolt [a]. • pull out the axle [b] to the right, and remove the front wheel, and collars...

  • Page 216

    Wheels/tires 10-7 wheels (rims) • remove: clip [a], torque link nut [b] and bolt adjusting nut [c] and brake rod [d] clip [e] and axle nut [f] bolts [a] and chain cover [b] axle [c] • remove the drive chain [d] from the rear sprocket toward the left. • remove the rear wheel. Rear wheel installation ...

  • Page 217

    10-8 wheels/tires wheels (rims) rim and spokes installation if the rim has a mark, install it so that its mark faces smaller diameter of the dram. If the rim has an arrow mark, install it so that its mark points rotating direction. • tighten the spokes evenly so that the radial (out from the axle) a...

  • Page 218

    Wheels/tires 10-9 wheels (rims) balance adjustment • if the wheel always stops in one position, provisionally attach a balance weight [a] on the wheel. ○ attach a balance weight loosely to the spoke under the marking. • rotate the wheel 1/4 turn [b], and see whether or not the wheel stops in this po...

  • Page 219

    10-10 wheels/tires tires air pressure inspection/adjustment • measure the tire air pressure with an air pressure gauge [a] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours.) adjust the tire air pressure according to the specifications...

  • Page 220

    Wheels/tires 10-11 tires • pry the tire off the rim with the tire iron [a] of the bead breaker protecting the rim with rim protectors [b]. Special tool - rim protector: 57001-1063 bead breaker assembly: 57001-1072 tire installation warning use the same manufacture’s tires on both front and rear whee...

  • Page 221

    10-12 wheels/tires hub bearing hub bearing removal • remove the wheel, and take out the following. Caution do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. Front grease seal [a] ci...

  • Page 222

    Wheels/tires 10-13 hub bearing • replace the grease seals with new ones. • press in the grease seal [a] so that the seal surface is flush [b] with the end of the hole. ○ apply high temperature grease to the grease seal lips. Special tool - bearing driver set: 57001-1129 [c] hub bearing inspection ○ ...

  • Page 223

    10-14 wheels/tires speedometer gear housing disassembly and assembly • remove: rear wheel (see rear wheel removal) brake panel, brake shoe grease seal [a] speedometer gear [b] washer [c] • tap the pinion washer [a], and remove the busing, pinion [b], and install the washer [c] facing the alloy surfa...

  • Page 224: Final Drive

    Final drive 11-1 11 final drive table of contents exploded view........................................................................................................................ 11-2 specifications ...................................................................................................

  • Page 225

    11-2 final drive exploded view.

  • Page 226

    Final drive 11-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine sprocket nut 127 13 94 mo 2 rear sprocket nut 74 7.5 54 g: apply grease. Ho: apply heavy oil. L: apply a non-permanent locking agent. Mo: apply molybdenum disulfide oil. O: apply oil..

  • Page 227

    11-4 final drive specifications item standard service limit drive chain standard chain make enuma – – – type ek50mv-o, endless – – – ek50mv-x (vn800-b6 ∼, b6f) link 112 links – – – sprockets rear sprocket warp less-than 0.4 mm (0.015 in.) 0.5 mm (0.02 in.).

  • Page 228

    Final drive 11-5 special tools inside circlip pliers: 57001-143 bearing driver set: 57001-1129.

  • Page 229

    11-6 final drive drive chain drive chain slack inspection • refer to the drive chain slack inspection in the periodic maintenance chapter. Drive chain slack adjustment • refer to the drive chain slack inspection in the periodic maintenance chapter. Wheel alignment inspection/adjustment • check that ...

  • Page 230

    Final drive 11-7 drive chain drive chain replacement caution for safety, if the drive chain shall be replaced, re- place it using a recommended tool. Recommended tool - type: ek joint tool #50 brand: enuma chain body [a] handlebar [b] cutting and rivetting pin [c] for cutting [d] for rivetting [e] p...

  • Page 231

    11-8 final drive drive chain • replace the link pin, link plate and grease seals. • apply grease to the link pins [a] and grease the seals [b] [c]. • engage the drive chain on the engine and rear sprockets. • insert the link pins in the drive chain ends. • install the grease seals [c]. • install the...

  • Page 232

    Final drive 11-9 drive chain • turn the pin holder until the rivetting pin touches the link pin. • turn the wrench clockwise until the tip of rivetting pin con- tact with the link pin. • rivet it. • repeat the same procedure for the other link pin. • after staking, check the staked area of the link ...

  • Page 233

    11-10 final drive sprocket, coupling engine sprocket removal • remove the bolt [a]. • pull the engine sprocket cover [b] to the rear until the cover separates from the alternator cover [c], and remove it. • flatten out the bended washer [a]. • remove: engine sprocket nut [b] and washer note ○ when l...

  • Page 234

    Final drive 11-11 sprocket, coupling rear sprocket removal • remove the rear wheel (see wheel/tires chapter). • remove the rear sprocket nuts [a]. • remove the rear sprocket [b]. Rear sprocket installation • install the sprocket facing the tooth number marking [a] outward. • tighten: torque - rear s...

  • Page 235

    11-12 final drive sprocket, coupling coupling bearing installation • replace the bearing with a new one. • press in the bearing [a] until it is bottomed. Special tool - bearing driver set: 57001-1129 [b] • pack the bearing with high temperature grease. • replace the circlip with a new one. Special t...

  • Page 236

    Final drive 11-13 sprocket, coupling sprocket wear inspection • visually inspect the engine and rear sprocket teeth for wear and damage. If the teeth are worn as illustrated, replace the sprocket, and inspect the drive chain wear (see drive chain wear inspection in the periodic maintenance chapter)....

  • Page 238: Brakes

    Brakes 12-1 12 brakes table of contents exploded view................................... 12-2 specifications .................................... 12-6 special tools ..................................... 12-7 caliper ............................................... 12-8 caliper removal ..................

  • Page 239

    12-2 brakes exploded view.

  • Page 240

    Brakes 12-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 brake caliper mounting bolts 34 3.5 25 2 brake disc mounting bolts 27 2.8 20 l 3 brake hose banjo bolts 34 3.5 25 4 bleed valve 7.8 0.8 69 in·lb 5 master cylinder clamp bolts 8.8 0.90 78 in·lb 6 brake lever pivot bolt 1.0 0.1 9 ...

  • Page 241

    12-4 brakes exploded view.

  • Page 242

    Brakes 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear brake lever clamp bolt 25 2.5 18 2 torque link nuts 34 3.5 25 3. Damper (vn800-b1 ∼ b6, germany model) 4. Rear brake lever clamp bolt cl: apply cable lubricant. G: apply grease. R: replacement parts..

  • Page 243

    12-6 brakes specifications item standard service limit front brake brake lever position non-adjustable – – – brake lever free play non-adjustable – – – brake disc thickness 5.8 ∼ 6.2 mm (0.228 ∼ 0.244 in.) 5.5 mm (0.21 in.) brake disc runout less than 0.15 mm (0.006 in.) 0.3 mm (0.012 in.) brake flu...

  • Page 244

    Brakes 12-7 special tools inside circlip pliers: 57001-143 jack: 57001-1238 jack attachment #3: 57001-1416.

  • Page 245

    12-8 brakes caliper caliper removal • loosen the banjo bolt [a] at the brake hose lower end, and tighten it loosely. • unscrew the caliper mounting bolts [b], and detach the caliper [c] from the disc. • unscrew the banjo bolt and remove the brake hose [d] from the caliper (see brake hose removal/ins...

  • Page 246

    Brakes 12-9 caliper • remove the board and pull out the pistons [a] by hand. ○ these pistons can also be removed by disconnecting the hose and applying compressed air to the hose joint open- ing using the same wooden board. But be careful not to put your fingers or palm inside the caliper opening du...

  • Page 247

    12-10 brakes caliper • replace the caliper holder shaft rubber boot and dust cover if they are damaged. • apply a thin coat of silicone grease to the caliper holder shafts and holder holes (silicone grease is a special high temperature, water-resistant grease). • install the anti-rattle spring in th...

  • Page 248

    Brakes 12-11 brake pads brake pad removal • remove the caliper with the hose installed (see caliper removal.) • remove: snap pin [a] pad pin [b] • remove the outer pad [a], and then remove the piston side pad [b]. Brake pad installation • before installation, clean the pads with a high-flash point s...

  • Page 249

    12-12 brakes master cylinder master cylinder removal • disconnect the front brake light switch connectors [a]. • remove the banjo bolt [b] to disconnect the brake hose from the master cylinder (see brake hose removal/in- stallation). • unscrew the clamp bolts [c], and take off the master cylin- der ...

  • Page 250

    Brakes 12-13 master cylinder master cylinder assembly • before assembly, clean all parts including the master cylinder with brake fluid or alcohol. Caution except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do not use any other...

  • Page 251

    12-14 brakes brake disc brake disc removal • remove the wheel (see wheels/tires chapter). • unscrew the mounting bolts [a], and take off the disc [b]. Brake disc installation • install the brake disc on the wheel so that the marked side [a] faces out. • tighten: torque - brake disc mounting bolts: 2...

  • Page 252

    Brakes 12-15 brake fluid level inspection • refer to the brake fluid level inspection in the periodic maintenance chapter. Brake fluid change • refer to the brake fluid change in the periodic mainte- nance chapter. Bleeding the brake line • refer to the bleeding the brake line in the periodic main- ...

  • Page 253

    12-16 brakes brake hose brake hose removal/installation caution brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wiped up immediately with wet cloth. • when removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts....

  • Page 254

    Brakes 12-17 brake pedal and cable brake pedal position inspection • refer to the brake play inspection in the periodic main- tenance chapter. Brake pedal position adjustment • refer to the brake play inspection in the periodic main- tenance chapter. Brake pedal free play inspection • refer to the b...

  • Page 255

    12-18 brakes brake pedal and cable brake pedal installation • align the punch mark [a] on the brake pedal shaft with the punch mark [b] on the brake pedal lever. • tighten: torque - rear brake lever clamp bolt: 25 n·m (2.5 kgf·m, 18 ft·lb) • adjust the brake pedal free play. Brake cable lubrication ...

  • Page 256

    Brakes 12-19 brake panel and drum cam lever angle inspection • check that the rear brake cam lever comes to an 80° ∼ 90° angle [a] with the rear brake rod when the rear brake is fully applied. If it does not, adjust the rear brake cam lever angle. Cam lever angle standard: 80° ∼ 90° warning since a ...

  • Page 257

    12-20 brakes brake panel and drum brake panel disassembly • remove the brake panel (see brake panel removal). • using a clean cloth around the linings to prevent grease or oil from getting on them, remove the brake shoes [a] by pulling up on the center of the linings. • before removing the brake cam...

  • Page 258

    Brakes 12-21 brake panel and drum brake drum wear inspection • remove the rear wheel (see wheels/tires chapter). • measure the inside diameter [a] of the drum. ○ use calipers and measure at several points. If any measurement is greater than the service limit, re- place the wheel hub. If the drum is ...

  • Page 260: Suspension

    Suspension 13-1 13 suspension table of contents exploded view........................................................................................................................ 13-2 specifications .....................................................................................................

  • Page 261

    13-2 suspension exploded view.

  • Page 262

    Suspension 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front fork clamp bolts (upper) 20 2.0 14.5 2 front fork clamp bolts (lower) 34 3.5 25 3 front fork bottom allen bolts 20 2.0 14.5 l 4 fork cover bolts 5 mm 8 0.8 11 in·lb 5 fork cover bolts 6 mm 13 1.3 113 in·lb 6 spacer all...

  • Page 263

    13-4 suspension exploded view.

  • Page 264

    Suspension 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear shock absorber nuts 59 6.0 43 2 swing arm pivot shaft nut 98 10.0 72 3 rocker arm pivot shaft nut 98 10.0 72 4 tie-rod nuts 59 6.0 43 g: apply grease..

  • Page 265

    13-6 suspension specifications item standard service limit front fork fork oil: viscosity showa ss8 or equivalent – – – capacity (per side): when changing oil approx, 265 ml (9.0 us oz) – – – after disassembly and completely dry 310 ±4 ml (10.5 ±0.14 us oz) – – – fork spring free length 547.2 mm (21...

  • Page 266

    Suspension 13-7 special tools fork cylinder holder handle: 57001-183 fork cylinder holder adapter: 57001-1057 oil seal & bearing remover: 57001-1058 bearing driver set: 57001-1129 fork outer tube weight: 57001-1218 front fork oil seal driver: 57001-1219 jack: 57001-1238 fork oil level gauge: 57001-1...

  • Page 267

    13-8 suspension front fork front fork removal (each fork leg) • loosen the front wheel axle nut (see wheels/tires chap- ter) • raise the front wheel off the ground. Special tools - jack: 57001-1238 jack attachment #3: 57001-1416 • remove: caliper (for left fork only) (see wheels/tires chapter) front...

  • Page 268

    Suspension 13-9 front fork front fork disassembly • remove the front fork (see front fork removal). • drain the fork oil (see fork oil change in the periodic maintenance chapter). • tap the point [a] with a suitable tool to separate the dust seal cover [b] from the outer tube [c]. • hold the front f...

  • Page 269

    13-10 suspension front fork • remove the inner tube guide bushing [a], outer tube guide bushing [b], washer [c] and oil seal [d] from the inner tube. • remove the cylinder base from the bottom of the outer tube. Front fork assembly • replace the following parts with new one. Oil seal guide bushings ...

  • Page 270

    Suspension 13-11 front fork • face the notch [a] of the dust seal cover rearward [b] and install the dust seal cover by tapping with the fork outer tube weight [c] until it stops. Special tool - fork outer tube weight: 57001-1218 • stake [a] the dust seal cover with a punch. • for vn800-b8 model, no...

  • Page 271

    13-12 suspension front fork inner tube inspection • visually inspect the inner tube, and repair any damage. • nicks or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage. If the damage is not repairable, replace the inner tube. Si...

  • Page 272

    Suspension 13-13 rear shock absorber spring preload adjustment • remove the rear shock absorber from the frame (see rear shock absorber removal). • to adjust the sprint force, turn the adjusting sleeve [a] on the shock absorber to the desired position with the stem nut wrench. Special tool - steerin...

  • Page 273

    13-14 suspension rear shock absorber rear shock absorber scrapping warning since the rear shock absorber contains nitrogen gas, do not incinerate the rear shock absorber with- out first releasing the gas or it may explode. Before a rear shock absorber is scrapped, drill a hole at the point [a] shown...

  • Page 274

    Suspension 13-15 swingarm swingarm removal • remove: muffler (see engine top end chapter) rear wheel (see wheels/tires chapter) upper shock absorber bolt bolts [a] and rear wheel mud guard [b] nut [a] and brake cable [b] upper tie-rod bolt [a] cap and swingarm pivot nut [b] • pull off the pivot shaf...

  • Page 275

    13-16 suspension swingarm swingarm bearing installation • apply plenty of grease to the needle bearings. • install the bearings so that the manufacturer’s marks face out. Special tool - bearing driver set: 57001-1129 swingarm bearing, sleeve inspection caution do not remove the bearings for inspecti...

  • Page 276

    Suspension 13-17 tie-rod, rocker arm tie-rod removal • remove the muffler (see engine top end chapter). • squeeze the brake lever slowly and hold it with a band [a]. • using the jack, raise the rear wheel off the ground. Special tool - jack: 57001-1238 jack attachment #3: 57001-1416 • remove: storag...

  • Page 277

    13-18 suspension tie-rod, rocker arm rocker arm/tie-rod bearing, sleeve inspection caution do not remove the bearings for inspection. Remove may damage them. • visually inspect the swingarm sleeves and needle bear- ings. • the rollers in a needle bearing normally wear very little, and wear is diffic...

  • Page 278: Steering

    Steering 14-1 14 steering table of contents exploded view........................................................................................................................ 14-2 special tools ..........................................................................................................

  • Page 279

    14-2 steering exploded view.

  • Page 280

    Steering 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 handlebar holder bolts 34 3.5 25 2 handlebar holder mounting nuts 34 3.5 25 3 steering stem head bolt 44 4.5 32 4 steering stem nut 4.9 0.5 43 in·lb ad: apply adhesive agent. G: apply grease. L: apply a non-permanent locking a...

  • Page 281

    14-4 steering special tools steering stem bearing driver: 57001-137 steering stem bearing driver adapter, 34.5: 57001-1074 head pipe outer race press shaft: 57001-1075 head pipe outer race driver, 51.5: 57001-1076 steering stem nut wrench: 57001-1100 head pipe outer race driver, 46.5: 57001-1106 hea...

  • Page 282

    Steering 14-5 steering steering inspection • refer to the steering inspection in the periodic mainte- nance chapter. Steering adjustment • refer to the steering inspection in the periodic mainte- nance chapter..

  • Page 283

    14-6 steering steering stem steering stem, stem bearing removal • remove: seat (see frame chapter) meter unit (see electrical system chapter) fuel tank (see fuel system chapter) headlight unit (see electrical system chapter) headlight mounting bracket bolts [a] • disconnect the front turn signal lea...

  • Page 284

    Steering 14-7 steering stem • remove: turn signal light bracket clamp bolts [a] turn signal lights [b] steering stem base cover [c] • loosen the front fork lower clamp bolts. • remove the front fork assembly. • for vn800-b1 ∼ b7 model, note the following procedure. ○ remove: lower fork cover bolts [...

  • Page 285

    14-8 steering steering stem steering stem, stem bearing installation • replace the bearing outer races with new ones. • apply grease to the outer races, and drive them into the head pipe at the same time. Special tool - head pipe outer race press shaft: 57001 -1075 [a] head pipe outer race driver, 4...

  • Page 286

    Steering 14-9 steering stem • for vn800-b1 ∼ b7 model, note the following procedure. ○ tighten the lower fork cover bolts. Torque - lower fork cover bolts (5 mm): 8 n·m (0.8 kgf·m, 71 in·lb) lower fork cover bolts (6 mm): 13 n·m (1.3 kgf·m, 115 in·lb) • temporarily tighten the fork clamp bolts (uppe...

  • Page 287

    14-10 steering handlebar handlebar removal • remove: clutch cable upper end left handlebar switch housing front brake master cylinder right handlebar switch housing throttle grip handlebar holder bolts [a] and handlebar holder • remove the handlebar [b] from the steering stem head. Handlebar install...

  • Page 288: Frame

    Frame 15-1 15 frame table of contents exploded view........................................................................................................................ 15-2 seat .........................................................................................................................

  • Page 289

    15-2 frame exploded view.

  • Page 290

    Frame 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 side stand pivot nut 44 4.5 32 2 rear frame mounting bolts 44 4.5 32 3 muffler bracket mounting bolts 25 2.5 18 4 footpeg holder bolts 34 3.5 25 g: apply grease..

  • Page 291

    15-4 frame exploded view 1. Reflector-reflex, fr (united states and canada models) 2. Front fender mounting screws.

  • Page 292

    Frame 15-5 seat seat removal • remove the seat mounting bolt [a]. • pull [b] the seat to unhook the front and rear hooks [c], and remove it. Seat installation • insert the front hook [a] into the brace [b] on the frame. • slip the rear hooks [c] under the loop [d] on the rear fender..

  • Page 293

    15-6 frame side covers left side cover removal • remove the screw [a], and pull [b] the left cover forward. Left side cover installation • fit the projection [a] into the slot [b] on the frame, and tighten the screw. Right side cover removal • insert the ignition switch key into the right side cover...

  • Page 294

    Frame 15-7 fenders front fender removal • raise the front wheel off the ground. • unscrew the bolts [a] and pull the front fender [b] to rear -wards. Rear fender removal • remove: seat (see seat removal) connectors [a] rear fender bolts [b] rear frame mounting bolts [c] (both side) rear fender assem...

  • Page 295

    15-8 frame battery case battery case removal • remove: seat (see seat removal) rear fender (see rear fender removal) fuel tank (see fuel system chapter) bolts [a] and battery cover [b] battery coolant hose [c] surge tank [d] • remove: ic igniter [a] junction box [b] starter relay, main fuse [c] turn...

  • Page 296

    Frame 15-9 down tube down tube removal • remove: footpeg and brake pedal (see brakes chapter) front muffler (see engine top end chapter) clutch cable clamps engine bracket bolts [a] bolts [b] and down tube assembly [c] air cleaner drain hose [d] down tube installation • tighten: torque - down tube m...

  • Page 297

    15-10 frame storage box, tool kit container storage box removal • remove: muffler (see engine top end chapter) right side cover (see right side cover removal) screws [a] and lower cover canister and separator (for california model) bolts [a] bracket [b] storage box base [c] tool kit container remova...

  • Page 298: Electrical System

    Electrical system 16-1 16 electrical system table of contents exploded view................................... 16-3 parts location.................................... 16-11 wiring diagram (vn800-b1 ∼ b4, united states, and canada) ........... 16-12 wiring diagram (vn800-b1 ∼ b4, australia).............

  • Page 299

    16-2 electrical system meter unit installation .................. 16-71 meter units disassembly ............. 16-71 bulb replacement........................ 16-71 switch and sensor............................. 16-72 brake light timing inspection ..... 16-72 brake light timing adjustment ... 16-72 sw...

  • Page 300

    Electrical system 16-3 exploded view dummy page.

  • Page 301

    16-4 electrical system exploded view.

  • Page 302

    Electrical system 16-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 alternator cover bolts 12 1.2 104 in·lb l 2 timing inspection cover screw 4.9 0.5 43 in·lb 3 alternator rotor bolt 157 16 116 o 4 stator coil bolts 13 1.3 115 in·lb 5 pickup coil bolts 7.8 0.8 69 in·lb 6 alternator le...

  • Page 303

    16-6 electrical system exploded view.

  • Page 304

    Electrical system 16-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 spark plugs 18 18 13 2 side stand switch mounting bolts 3.9 0.4 35 in·lb l l: apply a non-permanent locking agent..

  • Page 305

    16-8 electrical system exploded view.

  • Page 306

    Electrical system 16-9 exploded view 1. Tail light (united states and canada models) 2. License plate holder (united states model) 3. License plate holder (canada model) 4. Tail light (on and after vn800-b5, other than united states and canada models) 5. License plate holder (on and after vn800-b5, ...

  • Page 307

    16-10 electrical system exploded view.

  • Page 308

    Electrical system 16-11 parts location 1. Starter lockout switch 2. Ignition coils 3. Battery 4. Starter relay and main fuse 5. Ic igniter 6. Junction box 7. Oil pressure switch 8. Side stand switch 9. Pickup coil 10. Alternator 11. Neutral switch 12. Regulator/rectifier 13. Turn signal relay 14. Fr...

  • Page 309

    16-12 electrical system wiring diagram (vn800-b1 ∼ b4, united states, and canada).

  • Page 310

    Electrical system 16-13 wiring diagram (vn800-b1 ∼ b4, united states, and canada).

  • Page 311

    16-14 electrical system wiring diagram (vn800-b1 ∼ b4, australia).

  • Page 312

    Electrical system 16-15 wiring diagram (vn800-b1 ∼ b4, australia).

  • Page 313

    16-16 electrical system wiring diagram (vn800-b1 ∼ b4, europe and others).

  • Page 314

    Electrical system 16-17 wiring diagram (vn800-b1 ∼ b4, europe and others).

  • Page 315

    16-18 electrical system wiring diagram (vn800-b5 ∼ b8, united states, and canada).

  • Page 316

    Electrical system 16-19 wiring diagram (vn800-b5 ∼ b8, united states, and canada).

  • Page 317

    16-20 electrical system wiring diagram (vn800-b5 ∼ b8, australia).

  • Page 318

    Electrical system 16-21 wiring diagram (vn800-b5 ∼ b8, australia).

  • Page 319

    16-22 electrical system wiring diagram (vn800-b5 ∼ b7, europe and others).

  • Page 320

    Electrical system 16-23 wiring diagram (vn800-b5 ∼ b7, europe and others).

  • Page 321

    16-24 electrical system wiring diagram (vn800-b8, other than united states, canada, and australia).

  • Page 322

    Electrical system 16-25 wiring diagram (vn800-b8, other than united states, canada, and australia).

  • Page 323

    16-26 electrical system wiring diagram (vn800-b9 ∼, b6f united states, and canada).

  • Page 324

    Electrical system 16-27 wiring diagram (vn800-b9 ∼, b6f united states, and canada).

  • Page 325

    16-28 electrical system wiring diagram (vn800-b9 ∼, b6f australia).

  • Page 326

    Electrical system 16-29 wiring diagram (vn800-b9 ∼, b6f australia).

  • Page 327

    16-30 electrical system wiring diagram (vn800-b9 ∼, b6f other than united states, canada, and aus- tralia).

  • Page 328

    Electrical system 16-31 wiring diagram (vn800-b9 ∼, b6f other than united states, canada, and aus- tralia).

  • Page 329

    16-32 electrical system specifications item standard service limit battery type sealed battery – – – capacity 12 v 12 ah (vn800-b1 ∼ b8) – – – 12 v 10 ah (vn800-b9 ∼, b6f) voltage 12.8 v or more – – – charging system type three-phase ac – – – charging voltage 14 ∼ 15 v @4000 r/min (rpm), night – – –...

  • Page 330

    Electrical system 16-33 special tools rotor puller, m16/m18/m20/m22 × 1.5: 57001-1216 spark plug wrench, 16 mm (owner’s tool): 92110-1132 flywheel holder: 57001-1313 igniter checker assembly: 57001-1378 hand tester: 57001-1394 harness adapter #13: 57001-1399 peak voltage adapter: 57001-1415.

  • Page 331

    16-34 electrical system precautions there are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ do not reverse the battery lead connections. This will burn out the diodes on the electrical parts. ○ always check battery cond...

  • Page 332

    Electrical system 16-35 precautions male connectors [b].

  • Page 333

    16-36 electrical system electrical wiring wiring inspection • visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • pull each connector [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clea...

  • Page 334

    Electrical system 16-37 battery battery removal • remove: seats (see frame chapter) screws [a] battery cover [b] • disconnect the negative (–) lead [c] and then positive (+) lead [d]. Caution be sure to disconnect the negative (–) lead first. Electrolyte filling caution do not remove the aluminum se...

  • Page 335

    16-38 electrical system battery • make sure air bubbles [a] are coming up from all six filler ports. ○ leave the container this way for 5 minutes or longer. Note ○ if no air bubbles are coming up from a filler port, tap [b] the bottom of the container two or three times. Never remove the container f...

  • Page 336

    Electrical system 16-39 battery if an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification (see the this chapter). When a fast charge is inevitably required, do ...

  • Page 337

    16-40 electrical system battery note ○ measure with a digital voltmeter [a] which can be read to one decimal place voltage. If the reading is below the specified, refreshing charge is required. Battery terminal voltage standard: 12.8 v or more refreshing charge • disconnect the battery terminal lead...

  • Page 338

    Electrical system 16-41 battery • determine battery condition after refreshing charge. ○ determine the condition of the battery 30 minutes after completion of the charge by measuring the terminal volt- age according to the table below. Criteria judgement 12.8 v or higher good 12.0 ∼ 12.8 v or lower ...

  • Page 339

    16-42 electrical system charging system alternator cover removal • drain the engine oil (see lubrication system chapter). • remove: engine sprocket cover (see final drive chapter) left side cover (see frame chapter) bolt [a] and ignition switch [b] clamp [c] alternator lead connector [d] pickup coil...

  • Page 340

    Electrical system 16-43 charging system alternator rotor removal • remove: alternator cover (see alternator cover removal). • wipe oil off the outer circumference of the rotor. • hold the alternator rotor steady with the flywheel holder [a], and remove the rotor bolt [b]. Special tool - flywheel hol...

  • Page 341

    16-44 electrical system charging system alternator inspection there are three types of alternator failures: short, open (wire burned out), or loss in rotor magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all. A loss in rotor magnetism, which ma...

  • Page 342

    Electrical system 16-45 charging system regulator/rectifier inspection • remove: left side cover (see frame chapter) connector [a] (disconnect) tool kit container bolts [b] bolts [a] and regulator/rectifier [b] rectifier circuit check • check the rectifier resistance as follows. • disconnect the reg...

  • Page 343

    16-46 electrical system charging system regulator circuit check to test the regulator out of circuit, use three 12 v batteries and a test light (12 v 3 ∼ 6 w bulb in a socket with leads). Caution the test light works as an indicator and also a cur- rent limiter to protect the regulator/rectifier fro...

  • Page 344

    Electrical system 16-47 charging system charging voltage inspection • check the battery condition (see battery section). • warm up the engine to obtain actual alternator operating conditions. • remove the left side covers (see frame chapter). • check that the ignition switch is turned off, and conne...

  • Page 345

    16-48 electrical system charging system charging system circuit 1. Ignition switch 2. Alternator 3. Regulator/rectifier 4. Battery 5. Main fuse 30 a 6. Load.

  • Page 346

    Electrical system 16-49 ignition system.

  • Page 347

    16-50 electrical system ignition system warning the ignition system produces extremely high volt- age. Do not touch the spark plugs, ignition coils, or spark plug leads while the engine is running, or you could receive a severe electrical shock. Caution do not disconnect the battery leads or any oth...

  • Page 348

    Electrical system 16-51 ignition system pickup coil peak voltage inspection • remove the left side cover (see frame chapter). • remove all the spark plug caps but do not remove the spark plugs. • disconnect the pickup coil lead connector. • connect a commercially available peak voltage adapter [a] t...

  • Page 349

    16-52 electrical system ignition system ignition coil inspection • remove the ignition coils (see ignition coil removal). • measure the arcing distance with the suitable commer- cially available coil tester [a] to check the condition of the ignition coil [b]. • connect the ignition coil (with the sp...

  • Page 350

    Electrical system 16-53 ignition system • remove the fuel tank (see fuel system chapter). • remove all the spark plugs caps but do not remove the spark plugs. • install new spark plugs [a] into all the spark plug caps, and ground them onto the engine. • install a commercially available peak voltage ...

  • Page 351

    16-54 electrical system ignition system spark plug installation • insert the spark plug vertically into the plug hole with the plug installed in the plug wrench. Owner’s tool - spark plug wrench, 16 mm: 92110-1132 • tighten: torque - spark plugs: 18 n·m (1.8 kgf·m, 13 ft·lb) • fit the plug caps secu...

  • Page 352

    Electrical system 16-55 ignition system ignition coil primary peak voltage check • refer: ignition coil primary peak voltage inspection pickup coil peak voltage check • refer: pickup coil peak voltage inspection emergency engine stop function check • remove: seat (see frame chapter) note ○ check the...

  • Page 353

    16-56 electrical system ignition system • to check the condition of the ic igniter, connect the igniter checker [a] to the ic igniter. Special tools - igniter checker assembly: 57001-1378 harness adapter #12: 57001-1399 ○ turn the select knob to “c” position. Note ○ when using the igniter checker, r...

  • Page 354

    Electrical system 16-57 ignition system ignition system circuit 1. Junction box 2. Ignition switch 3. Engine stop switch 4. Starter button 5. Spark plugs 6. Diodes 7. Ignition fuse 10 a 8. Ignition coils 9. Neutral switch 10. Rectifier 11. Starter lockout switch 12. Side stand switch 13. Main fuse 3...

  • Page 355

    16-58 electrical system electric starter system starter motor removal • drain the engine oil (see lubrication system chapter). • remove the starter motor cable nut [a] and the mounting bolts [b]. • pull out the starter motor [c]. Starter motor installation caution do not tap the starter motor shaft ...

  • Page 356

    Electrical system 16-59 electric starter system starter motor assembly • install the terminal assembly in the yoke. • tighten: torque - starter motor terminal nut: 11 n·m (1.1 kgf·m, 95 in·lb) • fit the projection [a] of the brush plate into the yoke notch [b]. • after holding the springs [a] with s...

  • Page 357

    16-60 electrical system electric starter system commutator cleaning and inspection • smooth the commutator surface [a] if necessary with fine emery cloth [b], and clean out the grooves. • measure the diameter [a] of the commutator [b]. Replace the starter motor with a new one if the commu- tator dia...

  • Page 358

    Electrical system 16-61 electric starter system terminal inspection • using the × 1 Ω hand tester range, measure the resis- tance between the terminal [a] and the positive brushes [b]. Special tool - hand tester: 57001-1394 if there is not close to zero ohms, the terminal assembly has an open. Repla...

  • Page 359

    16-62 electrical system electric starter system electric starter circuit 1. Ignition switch 2. Engine stop switch 3. Starter button 4. Junction box 5. Diode 6. Starter circuit relay 7. Ignition fuse 10 a 8. Starter lockout switch 9. Rectifier 10. Neutral switch 11. Starter motor 12. Starter relay 13...

  • Page 360

    Electrical system 16-63 lighting system the united states, canada, and australia models adopt the daylight system and have a headlight relay in the junc- tion box. In these models, the headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight com...

  • Page 361

    16-64 electrical system lighting system headlight bulb replacement • remove: headlight unit and dust cover [a] hook [b] • replace the headlight bulb [c]. Caution when handling the quartz-halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth. Oil contamination from han...

  • Page 362

    Electrical system 16-65 lighting system bolts [a] headlight housing [b] headlight circuit (vn800-b1 ∼, united states, canada and australia) 1. Ignition switch 2. High beam indicator light 3. Headlight 4. Junction box 5. Diodes 6. Headlight circuit relay 7. Headlight fuse 10 a 8. Dimmer switch 9. Alt...

  • Page 363

    16-66 electrical system lighting system headlight circuit (vn800-b1 ∼ b7, other than united states, canada and australia) headlight circuit (vn800-b8 ∼, b6f other than united states, canada and australia) 1. Ignition switch 2. High beam indicator light 3. Headlight 4. Junction box 5. Diodes 6. Headl...

  • Page 364

    Electrical system 16-67 lighting system tail/brake light bulb replacement • remove the tail/brake light lens screws [a] and take off the lens [b] • push the bulb [a] in the socket, turn it counter clockwise [b] and pull it out. • with the front pin [a] up and the rear pin [b] down insert the new bul...

  • Page 365

    16-68 electrical system lighting system turn signal light bulb replacement • remove the turn signal light lens screws [a] and remove the lens [b]. • push the bulb [a] in the socket and turn the bulb counter- clockwise. • replace the bulb. Turn signal relay inspection • remove: seats (see frame chapt...

  • Page 366

    Electrical system 16-69 lighting system turn signal light circuit a: united states and canada model b: vn800-b8 ∼, other than united states, canada and australia model 1. Ignition switch 2. Turn signal indicator 3. Front right turn signal light 4. Front left turn signal light 5. Turn signal switch 6...

  • Page 367

    16-70 electrical system radiator fan system fan system circuit inspection • remove the fuel tank (see fuel system chapter). • turn on the ignition switch. • disconnect the leads from the radiator fan switch [a]. • using an auxiliary wire [b], connect the radiator fan switch leads. If the fan rotates...

  • Page 368

    Electrical system 16-71 meter unit meter unit removal • remove the bolt [a], and separate the meter unit [b] from the fuel tank. • remove: connectors [a] speedometer cable [b] caution place the meter so that the face is up. If a meter is left upside down or sideways for any length of time, it will m...

  • Page 369

    16-72 electrical system switch and sensor brake light timing inspection • refer to the brake light switch inspection in the periodic maintenance chapter brake light timing adjustment • refer to the brake light timing adjustment in the periodic maintenance chapter switch inspection • using the hand t...

  • Page 370

    Electrical system 16-73 switch and sensor radiator fan switch inspection • remove the fan switch (see cooling system chapter). • suspend the switch [a] in a container of coolant so that the temperature-sensing projection and threaded portion are submerged. • suspend an accurate thermometer [b] in th...

  • Page 371

    16-74 electrical system switch and sensor water temperature sensor inspection • remove the water temperature sensor (see cooling sys- tem chapter). • suspend the sensor [a] in a container of coolant so that the temperature-sensing projection and threaded portion are submerged. • suspend an accurate ...

  • Page 372

    Electrical system 16-75 junction box the junction box [a] has fuses [b], relays, and diodes. The relays and diodes can not be removed. Junction box fuse circuit inspection • remove the seats (see frame chapter). • remove the junction box. • pull off the connectors from the junction box. • make sure ...

  • Page 373

    16-76 electrical system junction box relay circuit inspection (with the battery disconnected) tester connection tester reading (Ω) tester connection tester reading (Ω) *7-8 ∞ 9-11 ∞ *7-13 ∞ 12-13 ∞ (+) (-) headlight relay (+) (-) not ∞ ** starter circuit relay 13-11 ∞ *13-9 (+) (-) 12-11 not ∞ ** (*...

  • Page 374

    Electrical system 16-77 junction box junction box internal circuit (vn800-b1 ∼b7, united states, canada and australia) (vn800-b8, all model) junction box internal circuit (vn800-b1 ∼ b7, other than united states, canada and australia) a. Accessory fuse 10 a b. Fan fuse 10 a c. Turn signal relay fuse...

  • Page 375

    16-78 electrical system fuses 30 a main fuse removal • remove: seat (see frame chapter) 30 a main fuse connector [a] • pull out the main fuse [b] from the starter relay with needle nose pliers. Junction box fuse • remove: seat (see frame chapter) battery leads junction box • unlock the hook to lift ...

  • Page 376: Appendix

    Appendix 17-1 17 appendix table of contents troubleshooting guide ........................................................................................................... 17-2 cable, wire, and hose routing ..............................................................................................

  • Page 377

    17-2 appendix troubleshooting guide note ○ this is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. Engine doesn’t start, starting difficulty: starter motor not rot...

  • Page 378

    Appendix 17-3 troubleshooting guide compression low: spark plug loose cylinder head not sufficiently tightened down no valve clearance cylinder, piston worn piston ring bad (worn, weak, broken, or sticking) piston ring/groove clearance excessive cylinder head warped cylinder head gasket damaged valv...

  • Page 379

    17-4 appendix troubleshooting guide drive train trouble brake dragging lubrication inadequate: engine oil level too low engine oil poor quality or incorrect coolant incorrect: coolant level too low coolant deteriorated cooling system component incorrect: radiator fin damaged radiator clogged thermos...

  • Page 380

    Appendix 17-5 troubleshooting guide abnormal drive train noise: clutch noise: clutch rubber damper weak or damaged clutch housing/friction plate clearance ex- cessive clutch housing gear worn transmission noise: bearings worn transmission gears worn or chipped metal chips jammed in gear teeth engine...

  • Page 381

    17-6 appendix troubleshooting guide brake doesn’t hold: disc brake: air in the brake line pad or disc worn brake fluid leakage disc warped contaminated pad brake fluid deteriorated primary or secondary cup damaged in mas- ter cylinder master cylinder scratched inside drum brake: brake maladjusted br...

  • Page 382

    Appendix 17-7 cable, wire, and hose routing 1. Clamp (left and right handlebar switch leads) 2. Clamp (brake hose and right handlebar switch lead) 3. Damper (install to the band) 4. Grommet 5. Strap (air vent hose, fuel tank drain hose) 6. Clamp.

  • Page 383

    17-8 appendix cable, wire, and hose routing.

  • Page 384

    Appendix 17-9 cable, wire, and hose routing 1. Rectifiers 2. Bracket 3. Lh switch lead connector 4. Rh switch lead connector 5. Lh switch lead connector 6. Radiator fan lead connector 7. Rear brake light switch lead connector 8. Side stand switch lead connector 9. Main harness 10. Throttle cables 11...

  • Page 385

    17-10 appendix cable, wire, and hose routing 1. Fuel tank drain hose 2. Clamp 3. Tighten the lead to the crankcase. 4. Starter motor lead 5. Alternator leads 6. Ignition switch 7. Choke knob 8. Insert the clamp into the hole on the frame. 9. Clamp.

  • Page 386

    Appendix 17-11 cable, wire, and hose routing 1. Clamp (attached rubber) 2. Front brake hose 3. Bleed valve 4. Front caliper mounting bolts 5. Clamp (attached rubber) 6. Brake disc 7. Brake hose banjo bolt 8. Front brake caliper 9. Clamps (speedometer cable) 10. Speedometer cable 11. Brake cable end ...

  • Page 387

    17-12 appendix cable, wire, and hose routing 1. Clamp 2. Fuel tank drain hose 3. Clamp (fuel tank drain and breather hoses) 4. Starter motor lead 5. Carburetor air vent hose 6. Starter motor lead clamp 7. Run the vent hose through right side of the frame and insert the end of it into the bracket of ...

  • Page 388

    Appendix 17-13 cable, wire, and hose routing vn800-b7 ∼ b8 model 1. Fuel tank drain hose 2. Fuel tank breather hose 3. Clamp (fuel tank drain and speed meter cable) 4. Clamp (speed meter cable and breather hose).

  • Page 389

    17-14 appendix cable, wire, and hose routing 1. Vacuum switch valve 2. Fuel hose 3. Vacuum hose 4. Throttle sensor 5. Choke cable joint 6. Air vent joint 7. Band (tighten the band as shown) 8. Air cleaner drain hose 9. Clutch cover 10. Catch tank 11. Clamp (install the clamp horizontally) 12. Roll t...

  • Page 390

    Appendix 17-15 cable, wire, and hose routing 1. Install the hose with the mark upside. 2. Radiator 3. Align the marks. 4. Right engine cover 5. Hose (between the thermostat and the reserve tank).

  • Page 391

    17-16 appendix cable, wire, and hose routing evaporative emission control system (california model) 1. Vacuum hose (white) 2. Clamp (clamp the vacuum hose and the fuel return hose) 3. Clamp 4. Run the fuel return hose inside the water hose 5. Clamp 6. Fuel return hose (red) 7. Fuel tank breather hos...

  • Page 392

    Model application year model beginning frame no. 1996 vn800-b1 jkbvncb1 □ ta030001, vn800a-030001, or vn800b-000001 (germany) 1997 vn800-b2 jkbvncb1 □ va050001, vn800a-050001, or vn800b-005001 (germany) 1998 vn800-b3 jkbvncb1 □ wa063001, jkbvncb1 □ wb50005, vn800a-063001, or vn800b-008001 (germany) ...