Kawasaki VN1700 CLASSIC TOURER Service Manual

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Vulcan 1700 voyager vulcan 1700 voyager abs vn 1700 voyager abs motorcycle service manual.

Page 5: Vulcan 1700 Voyager

Vulcan 1700 voyager vulcan 1700 voyager abs vn 1700 voyager abs motorcycle service manual all rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without...

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

Page 9: 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...

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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...

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1-4 general information before servicing tightening sequence generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can l...

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1-6 general information before servicing lubrication it is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of engine rotati...

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1-8 general information model identification vn1700b9f (us and ca models) left side view vn1700b9f (us and ca models) right side view.

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1-10 general information general specifications items vn1700a9f, vn1700b9f dimensions overall length 2 560 mm (100.79 in.) overall width 995 mm (39.17 in.) overall height 1 550 mm (61.02 in.) wheelbase 1 665 mm (65.55 in.) road clearance 135 mm (5.31 in.) seat height 730 mm (28.7 in.) curb mass: vn1...

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1-12 general information general specifications items vn1700a9f, vn1700b9f brake type: front dual discs rear single disc electrical equipment battery 12 v 18 ah headlight: type semi-sealed beam bulb 12 v 60/55 w (quartz-halogen) tail/brake light led alternator: type three-phase ac rated output 46.8 ...

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1-14 general information technical information-electrical throttle valve (etv) system system diagram 1. Accelerator position sensor 1 and 2 the accelerator position sensor senses the rider’s intention on throttle operation and transmits it to the ecu as an electrical signal. Each incorporating a bui...

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1-16 general information technical information-kawasaki advanced coactive-braking technology anti -lock brake system (k-act abs) overview vn1700b model adopts the kawasaki advanced coactive-braking technology (k-act) that dis- tributes the front-rear braking force in an ideal balance to stabilize th...

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1-18 general information technical information-kawasaki advanced coactive-braking technology anti -lock brake system (k-act abs) case3*) when operating both the front brake lever and rear brake pedal. *: under some operating conditions, the k-act works on only the front brake or the rear brake. Brak...

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1-20 general information technical information-regulator/rectifier overview vn1700a/b models are equipped with an audio system. The radio function that is activated by outside radio waves is greatly affected by the noise generated in the radio wave environment around a motorcycle and the noise gener...

Page 33: Periodic Maintenance

Periodic maintenance 2-1 2 periodic maintenance table of contents periodic maintenance chart ................................................................................................... 2-3 torque and locking agent..................................................................................

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Periodic maintenance 2-3 periodic maintenance chart dummy page.

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Periodic maintenance 2-5 periodic maintenance chart frequency whichever comes first * odometer reading × 1 000 km (× 1 000 mile) item every 1 (0.6) 6 (3.75) 12 (7.5) 18 (11.25) 24 (15) 30 (18.75) 36 (22.5) see page final drive drive belt deflection-inspect • • • • • • • 2-27 drive belt wear-inspect ...

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Periodic maintenance 2-7 torque and locking agent the following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “remarks” column mean: al: tighten the two clamp bolts alternately two times to ensure...

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Periodic maintenance 2-9 torque and locking agent torque fastener n·m kgf·m ft·lb remarks oil pump cover bolts 12 1.2 106 in·lb oil pump drive gear bolt 42 4.3 31 mo oil screen plugs 20 2.0 15 m outside oil pipe bolts 9.8 1.0 87 in·lb torque limiter bearing retainer bolt 9.8 1.0 87 in·lb engine remo...

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Periodic maintenance 2-11 torque and locking agent torque fastener n·m kgf·m ft·lb remarks pressure sensor (vn1700b model) 20 2.0 15 rear wheel rotation sensor rotor mounting bolts (vn1700b model) 6.9 0.70 61 in·lb suspension front fork cover clamp bolts 4.2 0.43 37 in·lb front axle clamp bolts 20 2...

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Periodic maintenance 2-13 specifications item standard service limit fuel system (dfi) throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – idle speed 950 ±50 r/min (rpm) – – – air cleaner element viscous paper element – – – cooling system coolant: type (recommended) permanent type antifreeze – ...

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Periodic maintenance 2-15 special tools inside circlip pliers: 57001-143 steering stem nut wrench: 57001-1100 jack: 57001-1238 oil filter wrench: 57001-1249 tension gauge: 57001-1585.

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Periodic maintenance 2-17 periodic maintenance procedures idle speed inspection • start the engine and warm it up thoroughly. ○ at first the engine will run fast to decrease warm up time (fast idle). ○ gradually the fast idle will lower to a certain rpm auto- matically. This is the idle speed. • wit...

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Periodic maintenance 2-19 periodic maintenance procedures • push the “s” button to display the idle speed adjusting mode [a]. Note ○ the display change to the clock setting mode [b], aver- age fuel consumption unit setting mode [c], idle speed adjusting mode each time the “s” button is pressed. ○ th...

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Periodic maintenance 2-21 periodic maintenance procedures • check that the fuel hose [a] are routed according to cable, wire, and hose routing section in the appendix chapter. Replace the hose if it has been sharply bent or kinked. • check that the fuel hose joints are securely connected. ○ push and...

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Periodic maintenance 2-23 periodic maintenance procedures radiator hose and pipe inspection (coolant leak, damage, installation condition) ○ the high pressure inside the radiator hose can cause coolant to leak [a] or the hose to burst if the line is not properly maintained. Visually inspect the hose...

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Periodic maintenance 2-25 periodic maintenance procedures clutch hose and pipe damage and installation condition inspection • the high pressure inside the clutch line can cause fluid to leak [a] or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while exam- i...

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Periodic maintenance 2-27 periodic maintenance procedures final drive drive belt deflection inspection note ○ belt deflection must be checked and adjusted when the belt is cold (at room temperature). ○ belt deflection also should be checked at first 1000 km (621.4 mile) ride after belt replacement. ...

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Periodic maintenance 2-29 periodic maintenance procedures • remove the axle cotter pin [a], and loosen the axle nut [b]. • raise the rear wheel off the ground (see rear wheel re- moval in the wheels/tires chapter). • loosen the belt adjuster locknuts [c] on the both sides. If the belt is too tight, ...

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Periodic maintenance 2-31 periodic maintenance procedures drive belt tooth wear and damage patterns a. Belt cross section b. Edge bevel wear c. Rub wear d. Stone.

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Periodic maintenance 2-33 periodic maintenance procedures brakes brake fluid leak (brake hose and pipe) inspection • for k-act abs equipped models; note the following. • remove: seats (see rear/front seat removal in the frame chap- ter) fuel tank (see fuel tank removal in the fuel system (dfi) chapt...

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Periodic maintenance 2-35 periodic maintenance procedures brake fluid level inspection • check that the brake fluid level in the front brake reservoir [a] is above the lower level line [b]. Note ○ hold the reservoir horizontally by turning the handlebar when checking brake fluid level. If the fluid ...

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Periodic maintenance 2-37 periodic maintenance procedures if it does not go on, inspect or replace the following items. Battery (see charging condition inspection in the elec- trical system chapter) brake light (led) (see tail/brake light (led) removal in the electrical system chapter) high mount br...

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Periodic maintenance 2-39 periodic maintenance procedures • remove: bolt [a] holder [b] • remove the handlebar (see handlebar removal in the steering chapter). Caution take care not to bend the hoses sharply. • loosen the upper front fork clamp bolts [a]. • remove: steering stem head nut [b] and was...

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Periodic maintenance 2-41 periodic maintenance procedures lights and switches operation first step • turn the ignition switch on. • the following lights should go on according to below table. Models united states canada europe aus- tralia position lights [a] go on go on – – city light [b] – – goes o...

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Periodic maintenance 2-43 periodic maintenance procedures • push the hazard button [a]. • the left and right turn signal lights (front and rear) should flash. • the turn signal indicator lights (led) in the meter unit should flash. If the lights do not flash, inspect or replace the following parts. ...

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Periodic maintenance 2-45 periodic maintenance procedures • pull out the projections [a] from the grommets [b] and remove the headlight cover [c]. • turn the horizontal adjuster [a] on the headlight with a screwdriver in or out until the beam points straight ahead. ○ turn the adjuster clockwise to f...

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Periodic maintenance 2-47 periodic maintenance procedures starter relay (see starter relay inspection in the elec- trical system chapter) relay box (see relay circuit inspection in the electrical system chapter) harness (see wiring inspection in the electrical system chapter) if the all parts are go...

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Periodic maintenance 2-49 periodic maintenance procedures bolt, nut and fastener to be checked engine: radiator bolt exhaust pipe holder nuts left and right muffler body mounting bolts clutch lever pivot bolt and nut clutch master cylinder clamp bolts clutch slave cylinder bolts engine mounting bolt...

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Periodic maintenance 2-51 periodic maintenance procedures • tighten: torque - left air cleaner housing cover bolts : 4.9 n·m ( 0.50 kgf·m, 43 in·lb) l = 10 mm (0.39 in.) [a] l = 25 mm (0.98 in.) [b] fuel hose replacement • remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter)...

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Periodic maintenance 2-53 periodic maintenance procedures water and coolant mixture ratio (recommended) soft water : 50% coolant : 50% freezing point : –35°c (–31°f) total amount : 2.4 l (2.5 us qt) • fill the coolant into the radiator. Note ○ choose a suitable mixture ratio by referring to the cool...

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Periodic maintenance 2-55 periodic maintenance procedures engine oil change • situate the motorcycle so that it is vertical after warming up the engine. • remove the oil filler cap [a] on the alternator cover. • remove the front [a] and rear [b] engine oil drain plugs and drain the oil. ○ the oil in...

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Periodic maintenance 2-57 periodic maintenance procedures brake hose and pipe replacement caution brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • remove the right saddlebag (see saddlebag removal in the frame chapter). • remove th...

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Periodic maintenance 2-59 periodic maintenance procedures brake fluid change note ○ the procedure to change the front brake fluid is as fol- lows. Changing the rear brake fluid is the same as for the front brake. • level the brake fluid reservoir. • remove: screws [a] reservoir cap [b] diaphragm pla...

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Periodic maintenance 2-61 periodic maintenance procedures • follow the procedure below to install the rear brake fluid reservoir cap correctly. ○ first, tighten the rear brake fluid reservoir cap [b] clock- wise [c] by hand until slight resistance is felt indicating that the cap is seated on the res...

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Periodic maintenance 2-63 periodic maintenance procedures caliper rubber parts replacement front caliper disassembly • remove: front caliper (see front caliper removal in the brakes chapter) front brake pads (see front brake pad removal in the brakes chapter) • remove the front caliper assembly bolt...

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Periodic maintenance 2-65 periodic maintenance procedures • using compressed air, remove the pistons. One way to remove the pistons is as follows. ○ cover the caliper opening with a clean, heavy cloth [a]. ○ remove the piston by lightly applying compressed air [b] to where the brake line fits into t...

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Periodic maintenance 2-67 periodic maintenance procedures • open the clamps [a] • pull out the clutch hose [b] from the holder [c]. • immediately wash away any clutch fluid that spills. • there are washers on each side of the clutch hose fittings. Replace them with new ones when installing. • tighte...

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Periodic maintenance 2-69 periodic maintenance procedures • apply clutch fluid to the parts removed and to the inner wall of the cylinder. • take care not to scratch the piston or the inner wall of the cylinder. • install the push rod with the dust seal fitted into the groove. ○ the push rod round e...

Page 103: Fuel System (Dfi)

Fuel system (dfi) 3-1 3 fuel system (dfi) table of contents exploded view........................................................................................................................ 3-4 specifications ..........................................................................................

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Fuel system (dfi) 3-3 fuel pump operating voltage inspection ......................................................................... 3-95 pressure regulator removal............................................................................................ 3-96 fuel filter cleaning...................

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Fuel system (dfi) 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 air cleaner housing cover bolts 4.9 0.50 43 in·lb 2 air cleaner element bolt 4.9 0.50 43 in·lb 3 air cleaner housing bolts 9.8 1.0 87 in·lb 4 crankshaft sensor bolts 5.9 0.60 52 in·lb 5 delivery joint bolts 9.8 1.0 87 ...

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Fuel system (dfi) 3-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 oxygen sensor (equipped models) 25 2.5 18 2. Cal and sea models 3. Canister 4. Separator.

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Fuel system (dfi) 3-9 specifications item standard vehicle-down sensor: input voltage dc 4.75 ∼ 5.25 v output voltage with sensor tilted 40 ∼ 50° or more right or left: dc 0.65 ∼ 1.35 v with sensor arrow mark pointed up: dc 3.55 ∼ 4.45 v oxygen sensor (equipped models): output voltage (rich) dc 0.8 ...

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Fuel system (dfi) 3-11 special tools and sealant kawasaki bond (silicone sealant): 56019-120

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Fuel system (dfi) 3-13 dfi system 1. Fuel tank 2. Fi indicator led light 3. Ecu 4. Battery 12 v 18 ah 5. Pressure regulator 6. Fuel pump 7. Water temperature sensor 8. Inlet air pressure sensor 9. Delivery joint 10. Fuel injector #1 11. Fuel injector #2 12. Air switching valve 13. Inlet air temperat...

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Fuel system (dfi) 3-15 dfi system part names 1. Ecu 2. Oxygen sensor (equipped models) 3. Speed sensor 4. Gear position switch 5. Etv actuator relay 6. Throttle position sensor/etv actuator 7. Etv actuator 8. Throttle position sensor 2 9. Throttle position sensor 1 10. Accelerator position sensor 11...

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Fuel system (dfi) 3-17 dfi system 35. Battery monitor voltage: w/r 36. Inlet air temperature sensor: r 37. Unused 38. Crankshaft sensor (+): y 39. Speed sensor: lg/r 40. Gear position switch: g 41. Unused 42. Unused 43. Power supply to accelerator position sensor 2: bl/bk 44. Power supply to ecu (fr...

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Fuel system (dfi) 3-19 dfi parts location gear position switch [a] speed sensor [a] kawasaki diagnostic system connector (6 pins con- nector) [b] etv actuator relay [a] (r/bl, y/bl, r/bl, g/o leads) vehicle-down sensor [b] fuse box 2 [c] (ecu fuse 10 a, etv actuator relay fuse 10 a, oxygen sensor he...

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Fuel system (dfi) 3-21 dfi servicing precautions ○ if the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak or the hose to burst. Remove the fuel tank (see fuel tank removal) and check the fuel hose [a]. Replace the fuel hose if any fraying, cracks o...

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Fuel system (dfi) 3-23 troubleshooting the dfi system when the service code [a] is displayed, for first ask the rider about the conditions [b] of trouble, and then start to determine the cause [c] of problem. As a pre-diagnosis inspection, check the ecu for ground and power supply, the fuel line for...

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Fuel system (dfi) 3-25 troubleshooting the dfi system • pull each connector [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. • check the wiring for continuity. ○ use the...

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Fuel system (dfi) 3-27 troubleshooting the dfi system sample diagnosis sheet rider name: registration no. (license plate no.): year of initial registration: model: engine no.: frame no.: date problem occurred: mileage: environment when problem occurred. Weather □ fine, □ cloudy, □ rain, □ snow, □ al...

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Fuel system (dfi) 3-29 dfi system 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 in dfi system. ○ the ecu may be involved in t...

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Fuel system (dfi) 3-31 dfi system troubleshooting guide symptoms or possible causes actions (chapter) inlet air temperature sensor trouble inspect (see chapter 3). Spark plug dirty, broken or gap maladjusted inspect and replace (see chapter 2). Ignition coil trouble inspect (see chapter 16). Stumble...

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Fuel system (dfi) 3-33 dfi system troubleshooting guide symptoms or possible causes actions (chapter) air cleaner element clogged clean element (see chapter 2). Fuel pressure too high inspect (see chapter 3). Fuel injector trouble inspect (see chapter 3). Water temperature sensor trouble inspect (se...

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Fuel system (dfi) 3-35 self-diagnosis • turn the ignition switch on. • the service code [a] is displayed by the number of two digits. • when pushing the “s” button [b] of the right handlebar switch housing for more than two seconds while the “er- ror” segments [c], service code and fi warning symbol...

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Fuel system (dfi) 3-37 self-diagnosis service code reading ○ the service code(s) is displayed on the lcd by the number of two digits. ○ when there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical or...

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Fuel system (dfi) 3-39 self-diagnosis backups ○ the ecu takes the following measures to prevent engine damage when the dfi, ignition or etv system parts have troubles. Service codes parts output signal usable range or criteria backups by ecu 11 throttle position sensor output voltage (full throttle ...

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Fuel system (dfi) 3-41 throttle position sensor (service code 11) throttle position sensor removal caution do not remove throttle position sensor in the gear case [a] since it has been adjusted and set with pre- cision at the factory. Never drop the throttle body assy, especially on a hard surface. ...

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Fuel system (dfi) 3-43 throttle position sensor (service code 11) throttle position sensor circuit 1. Ecu 2. Throttle position sensor/etv actuator 3. Throttle position sensor 1 4. Throttle position sensor 2.

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Fuel system (dfi) 3-45 inlet air pressure sensor (service code 12) if the reading is out of the standard, remove the ecu and check the wiring for continuity between main harness connectors. Special tool - hand tester: 57001-1394 ○ disconnect the ecu and sensor connectors. Wiring continuity inspectio...

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Fuel system (dfi) 3-47 inlet air pressure sensor (service code 12) then pv = pl – pg for example, suppose the following data is obtained: pg = 8 cmhg (vacuum gauge reading) pl = 70 cmhg (barometer reading) vv = 3.2 v (digital meter reading) then pv = 70 – 8 = 62 cmhg (absolute) plot this pv (62 cmhg...

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Fuel system (dfi) 3-49 inlet air pressure sensor (service code 12) inlet air pressure sensor circuit 1. Ecu 2. Inlet air pressure sensor.

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Fuel system (dfi) 3-51 inlet air temperature sensor (service code 13) • turn the ignition switch off. If the reading is within the standard, check the ecu for its ground and power supply (see ecu power supply in- spection). If the ground and power supply are good, replace the ecu (see ecu removal/in...

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Fuel system (dfi) 3-53 water temperature sensor (service code 14) water temperature sensor removal/installation caution never drop the water temperature sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • remove: fuel tank (see fuel tank removal) • drain the coolant (...

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Fuel system (dfi) 3-55 accelerator position sensor (service code 18) accelerator position sensor removal caution do not remove accelerator position sensor [a] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface. Such a sho...

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Fuel system (dfi) 3-57 accelerator position sensor (service code 18) • connect the digital meter [a] to the terminals of the accel- erator position sensor connector [b]. Accelerator position sensor resistance connection: (1) bl/w lead terminal → bk/o lead terminal (2) bl/bk lead terminal → br lead t...

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Fuel system (dfi) 3-59 crankshaft sensor (service code 21) crankshaft sensor circuit 1. Ecu 2. Crankshaft sensor.

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Fuel system (dfi) 3-61 speed sensor (service code 24) speed sensor output voltage inspection • using the jack, raise the rear wheel off the ground (see rear wheel removal in the wheels/tires chapter). Special tool - jack: 57001-1238 • measure the output voltage at the speed sensor in the same way as...

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Fuel system (dfi) 3-63 gear position switch (service code 25) gear position switch removal/installation • refer to the gear position switch removal/installation in the electrical system chapter. Gear position switch resistance inspection • refer to the gear position switch inspection in the elec- tr...

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Fuel system (dfi) 3-65 vehicle-down sensor (service code 31) this sensor has a weight [a] with two magnets inside, and sends a signal to the ecu. But when the motorcycle banks 60 ∼ 70° or more to either side (in fact falls down), the weight turns and the signal changes. The ecu senses this change, a...

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Fuel system (dfi) 3-67 vehicle-down sensor (service code 31) if the reading is out of the standard, remove the ecu and check the wiring for continuity between main harness connectors. Special tool - hand tester: 57001-1394 ○ disconnect the ecu and sensor connectors. Wiring continuity inspection ecu ...

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Fuel system (dfi) 3-69 vehicle-down sensor (service code 31) vehicle-down sensor circuit 1. Ecu 2. Vehicle-down sensor.

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Fuel system (dfi) 3-71 oxygen sensor - not activated (service code 33, equipped models) ○ do not disconnect the air switching valve connector [a]. • plug the air switching valve hose ends [a], and shut off the secondary air. • connect the following parts temporarily. Fuel pump/fuel level sensor lead...

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Fuel system (dfi) 3-73 fuel pump relay (service code 46) fuel pump relay removal/installation ○ the fuel pump relay is built in the relay box [a]. • refer to the relay box removal in the electrical system chapter. Fuel pump relay inspection • refer to the relay circuit inspection in the electrical s...

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Fuel system (dfi) 3-75 ignition coils #1, #2 (service code 51, 52) ignition coil #1 (front cylinder): service code 51 ignition coil #2 (rear cylinder): service code 52 ignition coil removal/installation • refer to the ignition coil removal/installation in the elec- trical system chapter. Ignition co...

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Fuel system (dfi) 3-77 radiator fan relay (service code 56) radiator fan relay removal/installation ○ the radiator fan relay is built in the relay box [a]. • refer to the relay box removal in the electrical system chapter. Radiator fan relay inspection • refer to the relay circuit inspection in the ...

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Fuel system (dfi) 3-79 etv acutuator (service code 58) etv actuator relay inspection • remove: front seat (see front seat removal in the frame chap- ter) etv actuator relay [a] • connect the hand tester [a] and a 12 v battery [b] to the relay [c] as shown. Special tool - hand tester: 57001-1394 if t...

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Fuel system (dfi) 3-81 oxygen sensor heater (service code 67, equipped models) oxygen sensor heater removal/installation the oxygen sensor heater is built in the oxygen sensor. So, the heater itself cannot be removed. Remove the oxy- gen sensor (see oxygen sensor removal (equipped mod- els) in the e...

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Fuel system (dfi) 3-83 oxygen sensor heater (service code 67, equipped models) oxygen sensor circuit 1. Ecu 2. Oxygen sensor 3. Oxygen sensor heater fuse 10 a 4. Ignition switch 5. Main fuse 30 a 6. Battery 7. Engine ground.

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Fuel system (dfi) 3-85 etv control circuit (service code 98) etv control circuit inspection ○ the etv control circuit is controlled in the ecu [a]. So, the etv control circuit cannot be inspected. • when the service code 98 is displayed on the lcd, re- place the ecu (see ecu removal/installation)..

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Fuel system (dfi) 3-87 ecu ecu identification ○ most countries have their own regulations, so each ecu has different characteristic. So, do not confuse ecu with each other and use only the ecu for your model. Other- wise, the motorcycle cannot clear the regulation. Ecu identification part number [a]...

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Fuel system (dfi) 3-89 ecu if the reading is out of the specification, check the follow- ing. Main fuse 30 a (see fuse inspection in the electrical system chapter) ecu fuse 10 a (see fuse inspection electrical system chapter) power source wiring (see ecu power source circuit) if the fuse and wiring ...

Page 193

Fuel system (dfi) 3-91 fuel line fuel pressure inspection note ○ be sure the battery is fully charged. • remove: fuel hose (see fuel hose replacement in the periodic maintenance chapter) ○ be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump and the delivery pipe of the thr...

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Fuel system (dfi) 3-93 fuel line • connect the prepared fuel hose [a] to the fuel outlet pipe. • secure the fuel hose with a clamp. • insert the fuel hose into the measuring cylinder [b]. Warning wipe off spilled out fuel immediately. Be sure to hold the measuring cylinder vertical. • close the fuel...

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Fuel system (dfi) 3-95 fuel pump fuel pump installation • remove dirt or dust from the fuel pump [a] by lightly ap- plying compressed air. • replace the fuel pump gasket with a new one. • check that the fuel pump terminal [a] and band [b] are in place. 200 ±10 mm (7.87 ±0.39 in.) [c] connector [d] f...

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Fuel system (dfi) 3-97 fuel pump fuel filter cleaning ○ the fuel filter [a] is built into the pump and cannot be cleaned or checked. If the fuel filter is suspected of clogging or being damaged, replace it with the fuel pump as a set. Fuel pump circuit 1. Ecu 2. Engine stop switch 3. Ignition switch...

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Fuel system (dfi) 3-99 fuel injectors fuel injector installation • before installing the fuel injector, blow away dirt or dust from the delivery joint by applying compressed air. • replace the o-rings [a] of each fuel injector with new ones. • apply engine oil to the new o-rings, insert them to the ...

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Fuel system (dfi) 3-101 fuel injectors • turn the ignition switch off. If the reading is in the specification, but the injector does not operate, replace the ecu (see ecu removal/instal- lation). If the reading is out of the specification, check the input voltage (see fuel injector input voltage ins...

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Fuel system (dfi) 3-103 fuel injectors fuel injector circuit 1. Ecu 2. Engine stop switch 3. Fuel injector #2 4. Fuel injector #1 5. Ignition switch 6. Ignition fuse 10 a 7. Ecu fuse 10 a 8. Main fuse 30 a 9. Battery 10. Engine ground 11. Relay box 12. Fuel pump relay 13. Frame ground 3.

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Fuel system (dfi) 3-105 throttle grip and cables if the stopper of the pulley does not touch, adjust the throttle grip free play with the accelerator cable adjuster [a] and then use the decelerator cable adjuster [b] (see throttle control system inspection in the periodic main- tenance chapter). • c...

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Fuel system (dfi) 3-107 throttle body assy • remove: vacuum hose [a] cruise control cancel switch (throttle) lead connector [b] • remove: throttle position sensor connector [a] accelerator position sensor connector [b] throttle body assy bolts [c] throttle body assy [d] (from inlet manifold) • remov...

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Fuel system (dfi) 3-109 throttle body assy • adjust: throttle grip free play (see throttle control system in- spection in the periodic maintenance chapter) idle speed (see idle speed adjustment in the periodic maintenance chapter) throttle body assy disassembly caution do not remove, disassemble or ...

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Fuel system (dfi) 3-111 air cleaner air cleaner element removal/installation • refer to the air cleaner element replacement in the pe- riodic maintenance chapter. Air cleaner element inspection • remove: air cleaner element (see air cleaner element replace- ment in the periodic maintenance chapter) ...

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Fuel system (dfi) 3-113 air cleaner • remove: right air cleaner housing cover bolts [a] right air cleaner housing cover [b] • remove: inlet air temperature sensor connector [a] air switching valve hose [b] • remove: air cleaner housing bolts [a] and washers right air cleaner housing center bolts [b]...

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Fuel system (dfi) 3-115 fuel tank fuel tank removal warning gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignit...

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Fuel system (dfi) 3-117 fuel tank • for the california and southeast asia models, remove the following. Fuel return hose [a] (left side, red) • remove the fuel tank, and place it on a flat surface. ○ do not apply the load to the fuel outlet pipe of the fuel pump. • for the california and southeast a...

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Fuel system (dfi) 3-119 fuel tank • push and pull [a] the fuel hose joint [b] back and forth more than two times, and make sure it is locked and does not come off. Warning make sure the hose joint is installed correctly on the delivery pipe or the fuel could leak. If it comes off, reinstall the hose...

Page 223

Fuel system (dfi) 3-121 evaporative emission control system (cal and sea models) separator operation test warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Do not smoke. Turn the ignition switch off. Make sure the area is well-ventilated and free from any sourc...

Page 225: Cooling System

Cooling system 4-1 4 cooling system table of contents exploded view........................................................................................................................ 4-2 coolant flow chart.............................................................................................

Page 227

Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 cross pipe bolts 34 3.5 25 2 radiator fan bolts 8.3 0.85 73 in·lb 3 radiator hose clamp screws 2.0 0.2 18 in·lb 4 thermostat housing cover bolts 9.8 1.0 87 in·lb 5 water pipe bolts 12 1.2 106 in·lb 6 water pump impeller b...

Page 229

Cooling system 4-5 coolant flow chart 1. Radiator fan 2. Radiator 3. Water separator cover 4. Water pump 5. Reserve tank 6. Reserve tank overflow hose 7. Radiator overflow hose 8. Cylinder jacket 9. Cylinder head jacket 10. Thermostat housing 11. Radiator cap 12. Hot coolant flow 13. Cold coolant fl...

Page 231

Cooling system 4-7 special tools bearing driver set: 57001-1129 bearing remover shaft, 9: 57001-1265 bearing remover head, 10 × 12: 57001-1266.

Page 233

Cooling system 4-9 coolant cooling system flushing over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water...

Page 235

Cooling system 4-11 water pump mechanical seal inspection • remove the impeller (see water pump removal). • visually inspect the mechanical seal. If any one of the parts is damaged, replace the mechani- cal seal as a unit. ○ the sealing seat and rubber seal may be removed easily by hand. Impeller se...

Page 237

Cooling system 4-13 radiator radiator removal • remove: bracket bolt [a] cross pipe bolts [b] • detach the projections of the radiator from the grommet [c] of the cross pipe. • open the clamp [a], and free the lead. • disconnect the regulator connectors [b] • remove the cross pipe [c] together with ...

Page 239

Cooling system 4-15 radiator caution when cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage. 1.Keep the steam gun [a] away more than 0.5 m (1.6 ft) [b] from the radiator core. 2.Hold the steam gun perpendicular [c] (not oblique [d]) to the core surface ...

Page 241

Cooling system 4-17 thermostat thermostat inspection • remove the thermostat (see thermostat removal). • inspect the thermostat valve at room temperature. If the valve is open, replace the valve with a new one. • to check valve opening temperature, suspend the ther- mostat [a] and an accurate thermo...

Page 243

Cooling system 4-19 hoses and pipes • replace the o-rings [a] with new ones. • apply grease to the new o-rings. • install the upper water pipes. ○ when installing the upper water pipes, insert the water pipes into the fitting of the cylinder as far as they will go. • tighten: torque - water pipe bol...

Page 245: Engine Top End

Engine top end 5-1 5 engine top end table of contents exploded view................................... 5-2 exhaust system identification ........... 5-6 specifications .................................... 5-8 special tools and sealant ................. 5-10 clean air system.............................

Page 247

Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 breather check valve cover bolts 9.8 1.0 87 in·lb cylinder head nuts (m12) (first) 39 4.0 29 cylinder head nuts (m12 new nuts) (final) 70 7.1 52 2 cylinder head nuts (m12 used nuts) (final) 77 7.8 57 mo, s cylinder head n...

Page 249

Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 camshaft chain tensioner bolts 12 1.2 106in·lb l 2 camshaft sprocket bolts 15 1.5 11 l 3 exhaust pipe holder nuts 17 1.7 12 4 muffler body mounting bolt 25 2.5 18 5 rear camshaft chain guide retainer bolts 9.8 1.0 87 in·l...

Page 251

Engine top end 5-7 exhaust system identification right muffler body mark position [a] right muffler body [a] with hole [b] for oxygen sensor [c] honeycomb type catalyst positions [a] left muffler body [b] right muffler body [c].

Page 253

Engine top end 5-9 specifications item standard service limit valve seating surface: width: exhaust 0.8 ∼ 1.2 mm (0.031 ∼ 0.047 in.) – – – inlet 0.8 ∼ 1.2 mm (0.031 ∼ 0.047 in.) – – – outside diameter: exhaust 34.9 ∼ 35.1 mm (1.374 ∼ 1.382 in.) – – – inlet 38.9 ∼ 39.1 mm (1.531 ∼ 1.539 in.) – – – va...

Page 255

Engine top end 5-11 special tools and sealant valve seat cutter, 45° - 40: 57001-1496 valve seat cutter, 55° - 38.5: 57001-1497 valve seat cutter, 32°- 44: 57001-1515 valve guide driver: 57001-1564 piston pin puller: 57001-1568 valve seat cutter holder, 6: 57001-1576 valve guide reamer, 6: 57001-159...

Page 257

Engine top end 5-13 clean air system air switching valve removal caution never drop the air switching valve, especially on a hard surface. Such a shock to the air switching valve can damaged it. • remove the ignition coils (see ignition coil removal in the electrical system chapter). • disconnect th...

Page 259

Engine top end 5-15 cylinder head covers cylinder head cover removal front cylinder head cover • remove: air switching valve (see air switching valve removal) cylinder head outer cover bolts [a] with collars cylinder head outer covers [b] • remove: cylinder head inner cover bolts [a] with gaskets cy...

Page 261

Engine top end 5-17 cylinder head covers rear cylinder head cover • install the collars [a] on the seating surfaces (shaded por- tions) [b] of the cylinder head outer covers [c] as shown. • install the plate [d] so that the tabs [e] fit onto the seating surface of the cylinder head outer cover as sh...

Page 263

Engine top end 5-19 rocker cases • remove the camshaft chain tensioner (see camshaft chain tensioner removal). • loosen the m6 and m8 rocker case bolts as shown se- quence [1 ∼ 6] in the figure, and remove them. • lift the rocker case [a], and remove the front camshaft chain guide [b] from the pin o...

Page 265

Engine top end 5-21 rocker cases • apply molybdenum disulfide oil solution to all cam parts and journals. • install the plug hole gasket [a] so that the cutout portions [b] fit onto the ribs [c] of the cylinder head. • install the dowel pins [a]. • insert the pin [a] of the rocker case to the hole o...

Page 267

Engine top end 5-23 rocker shafts, rocker arms rocker shaft and rocker arm removal • remove: rocker case (see rocker case removal) rocker shafts [a] rocker arms [b] rocker shaft and rocker arm installation • apply molybdenum disulfide oil solution to the rocker shafts. ○ the rocker shafts are identi...

Page 269

Engine top end 5-25 hla (hydraulic lash adjuster) hla removal • remove the rocker arm (see rocker shaft and rocker arm removal). • pull the hla (hydraulic lash adjuster) [a] out of the rocker arm with fingers. Caution be careful not to damage or deform an hla by tap- ping it during removal or instal...

Page 271

Engine top end 5-27 camshaft chain tensioners camshaft chain tensioner installation if the pin was removed, install it as follows. ○ push the push rod [a] into the interior of tensioner body [b] while pushing the stopper [c]. Caution be careful the oil remaining in the tensioner body dashes out. ○ i...

Page 273

Engine top end 5-29 camshafts, camshaft chains, camshaft sprockets if the rear camshaft chain guide [a] was removed, be sure to install it first. Torque - rear camshaft chain guide retainer bolt : 9.8 n·m (1.0 kgf·m, 87 in·lb) left side view [b] ○ pull the tension side (inlet side) [c] of the chain ...

Page 275

Engine top end 5-31 camshafts, camshaft chains, camshaft sprockets cam wear • remove the camshaft (see camshaft removal). • measure the height [a] of each cam with a micrometer. If the cams are worn down past the service limit, replace the camshaft. Cam height standard: exhaust 34.422 ∼ 34.536 mm (1...

Page 277

Engine top end 5-33 kacr (kawasaki automatic compression release) kacr inspection the kacr (kawasaki automatic compression release) momentarily opens the exhaust valves on the compression stroke at very low speeds. In this model, the kacr is oper- ated at 400 ∼ 500 r/min (rpm). This allows some of t...

Page 279

Engine top end 5-35 kacr (kawasaki automatic compression release) • install the push rod [a], and then insert the shaft [b] to the camshaft. • pull out the wire [c] from the hole of the push rod. • for front kacr, set the shaft so that the “f” mark [a] is aligned with the “ ” mark [b] of the camshaf...

Page 281

Engine top end 5-37 cylinder heads cylinder compression measurement note ○ use the battery which is fully charged. • warm up the engine thoroughly. • stop the engine. • remove spark plugs (see spark plug replacement in the periodic maintenance chapter). • attach the compression gauge [a] and adapter...

Page 283

Engine top end 5-39 cylinder heads note ○ the front cylinder head gasket has a “f” mark [a] and the rear cylinder head gasket has a “r” mark [b]. Be careful not to mix up these gaskets. • replace the cylinder head gasket with a new one, and install it. • install the dowel pins [a]. Note ○ the front ...

Page 285

Engine top end 5-41 cylinder heads cylinder head warp • clean the cylinder head. • lay a straightedge across the lower surface of the cylinder head at several positions. • use a thickness gauge [a] to measure the space between the straightedge [b] and the head. Cylinder head warp standard: – – – ser...

Page 287

Engine top end 5-43 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). Caution do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the cylin...

Page 289

Engine top end 5-45 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 291

Engine top end 5-47 valves if the seat width is too wide, make the 60° or 55° [a] grind described below. If the seat width is within the specified range, lap the valve to the seat as described below. • grind the seat at a 60° or 55° angle until the seat width is within the specified range. ○ to make...

Page 293

Engine top end 5-49 cylinders, pistons cylinder removal note ○ the front and rear cylinder removal are same proce- dures. • remove: cylinder head (see cylinder head removal) upper oil pipe [a] cylinder [b] cylinder installation note ○ if a new cylinder is used, use new piston ring. ○ the front cylin...

Page 295

Engine top end 5-51 cylinders, 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, use new piston ring. ...

Page 297

Engine top end 5-53 cylinders, pistons piston ring, piston ring groove wear • check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. • with the piston rings in their grooves, make...

Page 299

Engine top end 5-55 mufflers warning to avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down. Muffler body removal left muffler body • loosen the muffler body clamp bolt [a]. • remove: left saddlebag (see saddlebag removal in the frame chapte...

Page 301

Engine top end 5-57 mufflers ○ for equipped with the oxygen sensor, run the oxygen sen- sor lead correctly (see cable, wire, and hose routing section in the appendix chapter). Caution do not pull strongly, twist, or bend the oxygen sen- sor lead. This may cause the wiring open. • thoroughly warm up ...

Page 303

Engine top end 5-59 mufflers dummy page.

Page 305

Engine top end 5-61 mufflers • install the left and right muffler bodies (see muffler body installation). • thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts and nuts..

Page 308

6-2 clutch exploded view.

Page 310

6-4 clutch specifications item standard service limit clutch fluid grade dot4 – – – clutch lever clutch lever position 8-way adjustable (to suit rider) – – – clutch lever free play non-adjustable – – – clutch friction plate thickness 3.30 ∼ 3.50 mm (0.130 ∼ 0.138 in.) 3.0 mm (0.12 in.) friction plat...

Page 312

6-6 clutch clutch fluid clutch fluid level inspection • refer to the clutch fluid level inspection in the periodic maintenance chapter. Clutch fluid change • refer to the clutch fluid change in the periodic mainte- nance chapter. Clutch line bleeding • remove the engine pulley outer cover (see engin...

Page 314

6-8 clutch clutch master cylinder clutch master cylinder inspection • disassemble the clutch master cylinder (see clutch mas- ter cylinder rubber parts replacement in the periodic maintenance chapter). Caution do not remove the secondary cup from the piston since removal will damage it. • check that...

Page 316

6-10 clutch clutch slave cylinder • apply a non-permanent locking agent to the threads of the slave cylinder bolts [a]. • hand-tighten all the clutch slave cylinder bolts evenly. • remove the band from the clutch lever and release the clutch lever. • tighten the slave cylinder bolts. Torque - clutch...

Page 318

6-12 clutch clutch clutch outer covers installation • install the front and rear outer clutch covers. • when installing the rear outer clutch cover [a], set the round mark [b] downward. • apply a non-permanent locking agent to the threads of the front and rear outer clutch cover bolts, and tighten t...

Page 320

6-14 clutch clutch • pull out the following parts as a set. Primary chain [a] clutch housing [b] starter clutch gear [c] damper cam sprocket [d] torque limiter [e] • remove the collar [a] and spacer [b] from the input shaft. • remove the thrust bearing [a] and spacer [b] from the crankshaft. • remov...

Page 322

6-16 clutch clutch • insert the needle bearing [a] to the input shaft while turn- ing counterclockwise [b] the clutch housing. • install the cam damper [a] while fitting the alignment notch [b] of the splines onto the alignment tooth [c]. • install: spring [a] spring retainer [b] • tighten the cam d...

Page 324

6-18 clutch clutch clutch plate, wear, damage inspection • visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. If any plates show signs of damage, replace the plates. • measure the thickness of the friction plates [a] at several points. I...

Page 327: Engine Lubrication System

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

Page 329

Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 breather check valve cover bolts 9.8 1.0 87 in·lb 2 engine oil drain bolts 20 2.0 14 3 inside oil pipe retainer bolt 9.8 1.0 87 in·lb l 4 oil filter 18 1.8 13 5 oil filter pipe 25 2.5 18 l 6 oil passage plug (p...

Page 331

Engine lubrication system 7-5 engine oil flow chart 1. Camshaft chain tensioner 2. Balancer chain tensioner 3. Alternator rotor bolt (for cooling stator coil) 4. Crankshaft 5. Piston oil jet 6. Drive shaft 7. Output shaft 8. Oil screen for scavenge pump 9. Oil screen for feed pump 10. Oil in transmi...

Page 333

Engine lubrication system 7-7 special tools and sealant outside circlip pliers: 57001-144 oil pressure gauge, 10 kgf/cm²: 57001-164 gear holder: 57001-1602 oil pressure gauge adapter, pt1/8: 57001-1731 kawasaki bond (silicone sealant): 56019-120

Page 335

Engine lubrication system 7-9 engine oil and oil filter engine oil change • refer to engine oil change in the periodic maintenance chapter. Oil filter replacement • refer to oil filter replacement in the periodic mainte- nance chapter..

Page 337

Engine lubrication system 7-11 oil screen oil screen installation note ○ clean the oil screen thoroughly whenever it is removed for any reason. ○ while cleaning the screen, check for any metal particles that might indicate internal engine damage. • clean the oil screen with a high-flash point solven...

Page 339

Engine lubrication system 7-13 oil pump oil pump gear removal • remove: clutch (see clutch removal in the clutch chapter) circlip [a] oil pump gear [b] special tool - outside circlip pliers: 57001-144 oil pump gear installation • check that the pin [a] is in place. • fit the pin into the slot [b] of...

Page 341

Engine lubrication system 7-15 oil pump • remove: pin [a] inner rotor [b] for feed pump outer rotor [c] for feed pump • remove: pin [a] inner rotor [b] for scavenge pump oil pump shaft [c] oil pump installation • apply molybdenum disulfide oil solution to the portion [a] of the oil pump shaft as sho...

Page 343

Engine lubrication system 7-17 oil pressure measurement oil pressure measurement • remove the oil passage plug (1/8) [a] from the bottom of the right crankcase. • attach the adapter [a] and gauge [b] to the plug hole. Special tools - oil pressure gauge, 10 kgf/cm²: 57001-164 oil pressure gauge adapt...

Page 345

Engine lubrication system 7-19 oil pipes oil pipe removal outside oil pipe • remove: clutch (see clutch removal in the clutch chapter) outside oil pipe bolt [a] torque limiter bearing retainer bolts [b] torque limiter bearing retainer [c] washer [d] • remove: outside oil pipe bolts [a] outside oil p...

Page 347

Engine lubrication system 7-21 blowby gas system blowby gas system inspection • remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter). • be certain that the breather hose [a] is routed without being flattened or kinked, and is connected correctly to left air cleaner housing. ...

Page 349: Engine Removal/installation

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

Page 351

Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 cross pipe bolts 34 3.5 25 2 downtube bolts 59 6.0 44 3 engine mounting adjusting bolt 9.8 1.0 87 in·lb s 4 engine mounting adjusting bolt locknut 49 5.0 36 s 5 engine mounting bolt (m10) 44 4.5 32 6 engine m...

Page 353

Engine removal/installation 8-5 engine removal/installation engine removal • raise the rear wheel off the ground, using the jack. Special tool - jack: 57001-1238 • 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 mot...

Page 355

Engine removal/installation 8-7 engine removal/installation • remove the sidestand switch lead connector [a] from the clutch pipe bracket [b]. • remove the starter motor cable [a]. • open the clamp [b], and free the leads. • disconnect: speed sensor connector [c] gear position sensor lead connector ...

Page 357

Engine removal/installation 8-9 engine removal/installation • remove the downtube (see downtube removal in the frame chapter). • remove the drive belt [a] from the output shaft [b]. • remove the engine [a] from the motorcycle right side. Engine installation • support the engine with a suitable stand...

Page 359

Engine removal/installation 8-11 engine removal/installation • when installing the upper engine mounting bracket [a], fit the lower end [b] of the bracket to the cylinder head [c]. • run the leads, cables and hoses correctly (see cable, wire and hose routing section in the appendix chapter). • insta...

Page 362

9-2 crankshaft/transmission exploded view.

Page 364

9-4 crankshaft/transmission exploded view.

Page 366

9-6 crankshaft/transmission specifications item standard service limit crankcase, crankshaft and connecting rods connecting rod bend – – – tir 0.2/100 mm (0.008/3.94 in.) connecting rod twist – – – tir 0.2/100 mm (0.008/3.94 in.) connecting rod big end side 0.08 ∼ 0.30 mm (0.003 ∼ 0.012 in.) 0.5 mm ...

Page 368

9-8 crankshaft/transmission special tools and sealants outside circlip pliers: 57001-144 bearing driver set: 57001-1129 grip: 57001-1591 rotor holder: 57001-1726 kawasaki bond (silicone sealant): 92104-0004 kawasaki bond (liquid gasket - black): 92104-1064.

Page 370

9-10 crankshaft/transmission crankcase • remove the left crankcase bolts (11) [a]. • remove the right crankcase bolts, following the specified sequence. ○ first, loosen the m6 bolts (9) [a]. ○ next, loosen the m10 bolts (3) [b]. • put the engine so that the right crankcase half [a] faces upside..

Page 372

9-12 crankshaft/transmission crankcase ○ insert the piston oil jet [a] into the hole on the crankcase [b] as shown. ○ apply a non-permanent locking agent to the threads of the piston oil jet bolt [c], and tighten it. Torque - piston oil jet bolt : 6.9 n·m (0.70 kgf·m, 61 in·lb) • install the followi...

Page 374

9-14 crankshaft/transmission crankcase note ○ be sure to tighten the right crankcase bolts first. • tighten the right crankcase bolts using the following steps. ○ first, tighten the m10 bolts (3) [a]. Torque - crankcase bolts (m10) : 39 n·m (4.0 kgf·m, 29 ft·lb) ○ next, tighten the m6 bolts (9) [b]....

Page 376

9-16 crankshaft/transmission crankshaft and connecting rods crankshaft removal • split the crankcase (see crankcase splitting). • turn the balancer shafts [a] to clear the balancers [b] from the crankshaft web [c]. • remove the crankshaft. Crankshaft installation • apply molybdenum disulfide oil sol...

Page 378

9-18 crankshaft/transmission crankshaft and connecting rods • be sure the dowel pins [a] on the big end cap [b] are in position. • install each connecting rod on its original position as fol- lows. ○ left connecting rod [a] is for the rear cylinder and right connecting rod [b] is for the front cylin...

Page 380

9-20 crankshaft/transmission crankshaft and connecting rods if clearance is within the standard, no bearing replace- ment is required. If clearance is between 0.057 mm (0.0022 in.) and the service limit (0.09 mm, 0.035 in.), replace the bear- ing inserts [a] with inserts painted blue [b]. Check inse...

Page 382

9-22 crankshaft/transmission crankshaft and connecting rods crankshaft main bearing/main journal wear • 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: 52.986 ∼ ...

Page 384

9-24 crankshaft/transmission balancer balancer mechanism installation • align the line [a] on the following parts with the colored chain links [b] as shown. Balancer chain sprocket [c] front balancer sprocket [d] rear balancer sprocket [e] ○ the front and rear balancer sprockets are identical. • ins...

Page 386

9-26 crankshaft/transmission balancer • install the upper balancer chain guide [a]. Torque - upper balancer chain guide bolts [b] : 12 n·m (1.2 kgf·m, 106 in·lb) • install the balancer chain tensioner [c] and lower balancer chain guide [d]. Torque - balancer chain tensioner bolts [e] : 12 n·m (1.2 k...

Page 388

9-28 crankshaft/transmission starter clutch starter clutch removal • refer to the clutch removal in the clutch chapter. Starter clutch installation • refer to the clutch installation in the clutch chapter. Starter clutch disassembly • remove the clutch housing (see clutch removal in the clutch chapt...

Page 390

9-30 crankshaft/transmission torque limiter torque limiter removal • refer to the clutch removal in the clutch chapter. Caution do not disassemble the torque limiter [a]. The torque limiter will not function if this is done. Torque limiter installation • refer to the clutch installation in the clutc...

Page 392

9-32 crankshaft/transmission transmission transmission shaft assembly • when assembling the transmission shafts, refer to the transmission assembly illustration on ahead too. • apply engine oil to the bushings and shafts. • replace any circlips removed with new ones. • install the circlips [a] so th...

Page 394

9-34 crankshaft/transmission transmission shift drum removal • split the crankcase (see crankcase splitting). • remove: shift forks (see transmission shaft and shift fork re- moval) pin [a] and spring [b] shift drum bearing retainer bolts [c] • pull out the shift drum [d] while aligning the shift dr...

Page 396

9-36 crankshaft/transmission transmission shift fork bending • visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90° [a] shift fork/gear groove wear • measure the thickn...

Page 398

9-38 crankshaft/transmission external shift mechanism • after installation, confirm that the shift pedal [a] is posi- tioned as shown. 30 ∼ 40 mm (1.18 ∼ 1.57 in.) [b] about 1°[c] about 240.0 mm (9.45 in.) [d] about 7°[e] if the pedal position is different, adjust it as follows. ○ to adjust the peda...

Page 400

9-40 crankshaft/transmission external shift mechanism • remove the shift shaft assembly [a]. • remove: gear positioning lever nut [a] gear positioning lever [b] pin [c] and spring external shift mechanism installation if the shift shaft return spring pin [a] was removed, install it as follows. ○ app...

Page 402

9-42 crankshaft/transmission external shift mechanism • be sure to install the spacer [a] on the shift shaft [b]. • install the shift shaft assembly [a]. • be sure to install the spacer [b] on the shift shaft. • install the dowel pins [c]. • when the new needle bearing [a] is installed in the exter-...

Page 404

9-44 crankshaft/transmission ball bearing, needle bearing and oil seal bearing and oil seal installation left crankcase • refer to the mechanical seal replacement in the cooling system chapter for mechanical seal, ball bearing and oil seal of the water pump. • before installing the bearing or race, ...

Page 406

9-46 crankshaft/transmission ball bearing, needle bearing and oil seal • check the needle bearings. ○ the rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage. If there is any do...

Page 408

10-2 wheels/tires exploded view.

Page 410

10-4 wheels/tires specifications item standard service limit wheels (rims) rim runout: axial tir 0.5 mm (0.02 in.) or less tir 1.0 mm (0.04 in.) radial tir 0.8 mm (0.03 in.) or less tir 1.0 mm (0.04 in.) axle runout/100 mm (3.94 in.) tir 0.03 mm (0.001 in.) or less tir 0.2 mm (0.008 in.) wheel balan...

Page 412

10-6 wheels/tires wheels (rims) front wheel removal • remove: front wheel rotation sensor [a] (abs equipped mod- els) front caliper mounting bolts [b] (both sides) front caliper (with the hose installed) [c] (both sides) • for models equipped with an abs, remove the sensor bracket bolt [a]. • loosen...

Page 414

10-8 wheels/tires wheels (rims) • for models equipped with an abs, tighten the sensor bracket bolt [a]. • install: front wheel rotation sensor [b] (abs equipped mod- els) front calipers [c] (see caliper installation in the brakes chapter) • check the front brake effectiveness. Warning do not attempt...

Page 416

10-10 wheels/tires wheels (rims) rear wheel installation • apply high-temperature grease to the grease seal lips on both sides of the hub. • fit the collars [a] on both sides of the hub. ○ fit the flange collar onto the right side. • turn the stepped side [a] of the belt adjusters outward. • install...

Page 418

10-12 wheels/tires wheels (rims) axle inspection • remove the front and rear axles (see front/rear wheel removal). • visually inspect the front and rear axles for damages. If the axle is damaged or bent, replace it. • place the axle in v blocks that are 100 mm (3.94 in.) [a] apart, and set a dial ga...

Page 420

10-14 wheels/tires tires air pressure inspection/adjustment • refer to the air pressure inspection in the periodic main- tenance chapter. Tire inspection • refer to the wheel/tire damage inspection in the peri- odic maintenance chapter. Tire removal • remove: wheel (see front/rear wheel removal) val...

Page 422

10-16 wheels/tires tires • position the tire on the rim so that the valve [a] align with the tire balance mark [b] (the chalk mark made during removal, or the yellow paint mark on a new tire). • install the tire bead over the rim flange using a suitable commercially available tire changer. • lubrica...

Page 424

10-18 wheels/tires hub bearing ○ replace the circlips with new ones. Special tool - inside circlip pliers: 57001-143 • replace the grease seals with new ones. • press in the grease seals [a] so that the seal surface is flush [b] with the end of the hole. ○ apply high-temperature grease to the grease...

Page 426

11-2 final drive exploded view.

Page 428

11-4 final drive specifications item standard drive belt make gates, 139t belt deflection (45 n, 4.6 kgf, 10 lb force) 3.0 ∼ 4.5 mm (0.12 ∼ 0.18 in.) (when installing new belt or engine is remounted) 3.0 mm (0.12 in.).

Page 430

11-6 final drive drive belt the drive belt must be checked, and adjusted in accor- dance with the periodic maintenance chart for safety and to prevent excessive wear. If the belt becomes badly worn or maladjusted-either too loose or too tight-the belt could jump off the pulley or break. Belt handlin...

Page 432

11-8 final drive drive belt drive belt installation • installation is the reverse of removal. Note the following. Note ○ be sure the printed information faces the same direction so the belt rotates in the same direction as originally in- stead. When installing a new belt, install it so the printed i...

Page 434

11-10 final drive pulley and coupling • check the installation condition of the pad [a]. ○ stick the pad securely. • install the dowel pins [b] as shown. • install the engine pulley inner cover [a]. • tighten: torque - engine pulley inner cover bolts [b] : 12 n·m (1.2 kgf·m, 106 in·lb) • install: cl...

Page 436

11-12 final drive pulley and coupling rear pulley coupling installation • apply grease to the coupling grease seal lips [a]. • apply grease to the rear pulley coupling internal surface [b]. • install the sleeve [c]. • install the coupling dampers [a] so that the projections [b] face to the outside. ...

Page 438

11-14 final drive pulley and coupling coupling bearing lubrication note ○ since the coupling bearing is packed with grease and sealed, lubrication is not required. Rubber damper inspection • remove the rear wheel (see rear wheel removal in the wheels/tires chapter). • take off the rear pulley with t...

Page 440

12-2 brakes k-act abs servicing precautions ................................................................................... 12-34 k-act abs troubleshooting outline ................................................................................ 12-36 inquiries to rider..............................

Page 442

12-4 brakes exploded view vn1700a model.

Page 444

12-6 brakes exploded view vn1700a model.

Page 446

12-8 brakes exploded view vn1700b model.

Page 448

12-10 brakes exploded view vn1700b model.

Page 450

12-12 brakes specifications item standard service limit brake lever, brake pedal brake lever position 8-way adjustable (to suit rider) – – – brake lever free play non-adjustable – – – pedal free play non-adjustable – – – pedal position about 100 mm (3.94 in.) – – – (height from pedal top to footboar...

Page 452

12-14 brakes brake lever, brake pedal brake lever position adjustment • push the lever forward and turn the adjuster [a]. Brake pedal position inspection • check that the brake pedal [a] is in the correct position. Pedal position standard: about 100 mm (3.94 in.) [b] (height from pedal top to footbo...

Page 454

12-16 brakes calipers front 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. Caution do not loosen the caliper assembly bolts [d]. Take out only the caliper mounting bo...

Page 456

12-18 brakes calipers caliper fluid seal damage inspection the fluid seal (piston seal) [a] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the tem- p...

Page 458

12-20 brakes brake pads front brake pad removal • loosen the pad pin [a]. • unscrew the bolts [b]. • remove the caliper with the hose installed. • remove: pad spring bolts [a] pad spring [b] • remove: pad pin [a] brake pads [b] front brake pad installation • push the caliper pistons in by hand as fa...

Page 460

12-22 brakes master cylinder front master cylinder removal • remove the banjo bolt [a] to disconnect the brake hose from the master cylinder (see brake hose replacement in the periodic maintenance chapter). • disconnect the front brake light switch connectors [a]. • unscrew the clamp bolts [b], and ...

Page 462

12-24 brakes master cylinder rear master cylinder installation • replace the cotter pin with a new one. • insert the cotter pin [a] to the hole of the joint pin [b] and separate the cotter pin ends. • replace the washers that are on each side of the hose fitting with new ones. • tighten: torque - re...

Page 464

12-26 brakes brake discs brake disc removal • remove the wheels (see front/rear wheel removal in the wheels/tires chapter). • unscrew the mounting bolts [a], and take off the disc. Brake disc installation • install the brake disc [a] on the wheel so that the marked side [b] faces out. • apply a non-...

Page 466

12-28 brakes brake fluid • remove the rubber cap from the bleed valve [a] on the caliper [b]. • attach a clear plastic hose [c] to the bleed valve, and run the other end of the hose into a container. • bleed the brake line and the caliper. ○ repeat this operation until no more air can be seen com- i...

Page 468

12-30 brakes brake hose brake hose and pipe removal/installation • refer to the brake hose and pipe replacement in the periodic maintenance chapter. Brake hose and pipe inspection • refer to the brake hose and pipe damage and instal- lation condition inspection in the periodic maintenance chapter..

Page 470

12-32 brakes k-act abs (equipped models) k-act abs system wiring diagram 1. Ignition switch 2. Right handlebar switch housing 3. Front brake switch 4. Rear brake switch 5. K-act abs hydraulic unit 6. K-act abs self-diagnosis terminal 7. K-act abs kawasaki diagnostic system connector 8. Input fluid p...

Page 472

12-34 brakes k-act abs (equipped models) k-act abs servicing precautions there are a number of important precautions that should be followed servicing the k-act abs. ○ k-act abs does not function if the battery is discharged. When driving with an insufficiently charged battery, k-act abs may not fun...

Page 474

12-36 brakes k-act abs (equipped models) k-act abs troubleshooting outline when an abnormality in the system occurs, the k-act abs indicator light (led) lights up to alert the rider. In ad- dition, the nature of the fault is stored in the memory of the k-act abs hydraulic unit and when in the self-d...

Page 476

12-38 brakes k-act abs (equipped models) k-act abs diagnosis flow chart.

Page 478

12-40 brakes k-act abs (equipped models) pre-diagnosis inspection 1.

Page 480

12-42 brakes k-act abs (equipped models) • remove the right side cover (see right side cover re- moval in the frame chapter). • ground the self-diagnosis terminal (gray) [a] to the battery (–) terminal, using a auxiliary lead. • turn on the ignition switch. ○ count the blinks of the light to read th...

Page 482

12-44 brakes k-act abs (equipped models) how to read service codes ○ service codes are shown by a series of long and short blinks of the k-act abs indicator light (led) as shown below. ○ read 10th digit and unit digit as the k-act abs indicator light (led) blinks. ○ when there are a number of faults...

Page 484

12-46 brakes k-act abs (equipped models) service code k-act abs indicator light (led) problems light state 72 rear switching valve trouble (open, temperature abnormal) on 73 front switching valve trouble (open, temperature abnormal) on 74 front high pressure switching valve trouble (open, temperatur...

Page 486

12-48 brakes k-act abs (equipped models) • do the 2nd step test. ○ disconnect the k-act abs hydraulic unit connector [a]. ○ check for continuity between the red/black and black/blue lead terminals of the k-act abs hydraulic unit connector. If there is the continuity in the lead, replace the k-act ab...

Page 488

12-50 brakes k-act abs (equipped models) k-act abs motor relay inspection (service code 35) • do the 1st step test. ○ check the k-act abs motor relay fuse (30 a) [a]. If the fuse blown, proceed the 2nd step. If the fuse correct, proceed the 4th step. • do the 2nd step test. ○ disconnect the k-act ab...

Page 490

12-52 brakes k-act abs (equipped models) • do the 3rd step test. ○ recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the k-act abs indicator light (led) [a] lit, faulty ecu in the k-act abs hydraulic unit. Rep...

Page 492

12-54 brakes k-act abs (equipped models) • do the 2nd step test. ○ check for continuity between the white lead terminal of the sensor connector [a] and ground, and black lead ter- minal of the sensor connector and ground. If there is the continuity in the lead, replace the rear wheel rotation sensor...

Page 494

12-56 brakes k-act abs (equipped models) • do the 4th step test. ○ recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the k-act abs indicator light (led) [a] lit, faulty ecu in the k-act abs hydraulic unit. Rep...

Page 496

12-58 brakes k-act abs (equipped models) • do the 3rd step test. ○ disconnect the fluid pressure sensor connector. ○ connect the hand tester [a] to the fluid pressure sensor connector [b]. Special tool - hand tester: 57001-1394 ○ measure the fluid pressure sensor resistance. Fluid pressure sensor re...

Page 498

12-60 brakes k-act abs (equipped models) input fluid pressure sensor (front brake) offset abnormal (service code 82) • do the 1st step test. ○ disconnect the fluid pressure sensor connector and con- nect the harness adapter [a] between these connectors as shown. Main harness [b] fluid pressure senso...

Page 500

12-62 brakes k-act abs (equipped models) • do the 5th step test. ○ disconnect the k-act abs hydraulic unit connector and fluid pressure sensor connector. ○ check for continuity between the green lead terminal of the main harness side connector [a] and green lead ter- minal of the main harness side c...

Page 502

12-64 brakes k-act abs (equipped models) • do the 2nd step test. ○ disconnect the k-act abs hydraulic unit connector and fluid pressure sensor connector. ○ check for continuity between the white/red lead terminal of the main harness side connector [a] and white/red lead terminal of the main harness ...

Page 504

12-66 brakes k-act abs (equipped models) • do the 6th step test. ○ recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the k-act abs indicator light (led) [a] lit, faulty input fluid pressure sensor (rear brake)...

Page 506

12-68 brakes k-act abs (equipped models) • do the 4th step test. ○ disconnect the fluid pressure sensor connector and con- nect the harness adapter [a] between these connectors as shown. Main harness [b] fluid pressure sensor [c] special tool - measuring adapter: 57001-1700 ○ connect the digital met...

Page 508

12-70 brakes k-act abs (equipped models) • do the 2nd step test. ○ disconnect the k-act abs hydraulic unit connector and fluid pressure sensor connector. ○ check for continuity between the white/red lead terminal of the main harness side connector [a] and white/red lead terminal of the main harness ...

Page 510

12-72 brakes k-act abs (equipped models) • do the 6th step test. ○ recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the k-act abs indicator light (led) [a] lit, faulty output fluid pressure sensor (rear brake...

Page 512

12-74 brakes k-act abs (equipped models) • do the 4th step test. ○ disconnect the fluid pressure sensor connector and con- nect the harness adapter [a] between these connectors as shown. Main harness [b] fluid pressure sensor [c] special tool - measuring adapter: 57001-1700 ○ connect the digital met...

Page 514

12-76 brakes k-act abs (equipped models) • do the 2nd step test. ○ disconnect the k-act abs hydraulic unit connector and fluid pressure sensor connector. ○ check for continuity between the white/red lead terminal of the main harness side connector [a] and white/red lead terminal of the main harness ...

Page 516

12-78 brakes k-act abs (equipped models) • do the 3rd step test. ○ disconnect the fluid pressure sensor connector. ○ connect the hand tester [a] to the fluid pressure sensor connector [b]. Special tool - hand tester: 57001-1394 ○ measure the fluid pressure sensor resistance. Fluid pressure sensor re...

Page 518

12-80 brakes k-act abs (equipped models) rear fluid pressure sensor signal abnormal (service code 92) • do the 1st step test. ○ disconnect the fluid pressure sensor connector and con- nect the harness adapter [a] between these connectors as shown. Main harness [b] fluid pressure sensor [c] special t...

Page 520

12-82 brakes k-act abs (equipped models) • do the 5th step test. ○ disconnect the k-act abs hydraulic unit connector and fluid pressure sensor connector. ○ check for continuity between the light green lead terminal of the main harness side connector [a] and light green lead terminal of the main harn...

Page 522

12-84 brakes k-act abs (equipped models) • remove: brake pipe joint nuts [a] brake hose banjo bolts [b] • remove: brake hose banjo bolts [a] bolts [b] • tape the brake line opening to prevent brake fluid leakage or contamination by foreign matter. Caution brake fluid quickly ruins painted plastic su...

Page 524

12-86 brakes k-act abs (equipped models) front wheel rotation sensor removal caution the wheel rotation sensor should be handled care- fully, never struck sharply with a hammer, or al- lowed to fall on a hard surface since the wheel rota- tion sensor is precision made. Be careful not to get water or...

Page 526

12-88 brakes k-act abs (equipped models) wheel rotation sensor air gap inspection • raise the front/rear wheel off the ground (see front/rear wheel removal in the wheels/tires chapter). • measure the air gap between the sensor and sensor rotor at several points by turning the wheel slowly. Thickness...

Page 528

12-90 brakes k-act abs (equipped models) • remove the pressure sensor [a] from the sensor bracket [b]. Output fluid pressure sensor (rear brake) installation • installation is the reverse of removal. • tighten: torque - pressure sensor: 20 n·m (2.0 kgf·m, 15 ft·lb) • run the lead and brake hose corr...

Page 530

13-2 suspension exploded view.

Page 532

13-4 suspension exploded view.

Page 534

13-6 suspension specifications item standard front fork (per one unit) fork inner tube diameter 45 mm (1.8 in.) fork spring preload setting non-adjustable air pressure atmospheric pressure (non-adjustable) damper setting non-adjustable fork oil: viscosity showa ss-8 or equivalent sae 10w amount (per...

Page 536

13-8 suspension special tools needle bearing driver, 28: 57001-1610 spacer, 28: 57001-1637.

Page 538

13-10 suspension front fork • drain the fork oil [a] into a suitable container. ○ pump the inner tube up and down at least 10 times to expel the oil from the fork. • pour in the type and amount of fork oil specified. Fork oil viscosity: showa ss-8 or equivalent sae 10w amount (per side): when changi...

Page 540

13-12 suspension front fork front fork removal • remove: front wheel (see front wheel removal in the wheels/tires chapter) front fender (see front fender removal in the frame chapter) note ○ if the front fork is to be disassembled, or if oil is to be changed, remove the top plug previously (see fork...

Page 542

13-14 suspension front fork • remove the inner [a] and outer [b] guide bushings, washer [c] and oil seal [d] from the inner tube. Front fork assembly • replace the following parts with new ones. Dust seal [a] retaining ring [b] oil seal [c] inner guide bushing [d] outer guide bushing [e] bottom alle...

Page 544

13-16 suspension front fork dust seal inspection inspect the dust seal [a] for any signs of deterioration or damage. Replace it if necessary. Spring tension • since the spring becomes shorter as it weakens, check its free length [a] to determine its condition. If the spring of either fork leg is sho...

Page 546

13-18 suspension rear shock absorber (air type) • take off the air valve cap [a] on both shock absorbers. • check the air pressure with the air pressure gauge. Note ○ do not use tire gauges for checking air pressure. They may not indicate the correct air pressure because of air leakage that occur wh...

Page 548

13-20 suspension rear shock absorber (air type) rear shock absorber scrapping • remove the rear shock absorber (see rear shock ab- sorber removal). Warning since the rear shock absorber contains air, do not incinerate the rear shock absorber without first re- leasing the air or it may explode. Befor...

Page 550

13-22 suspension swingarm • remove the swingarm pivot nut [a]. • pull out the swingarm pivot shaft, and take off the swingarm. Swingarm installation • apply grease to the grease seal lips [a]. • install the collar [a]. • insert the swingarm pivot shaft to install the swingarm. • tighten: torque - sw...

Page 552

13-24 suspension swingarm • turn the ball bearing in the swingarm back and forth [a] while checking for plays, roughness or binding. If bearing play, roughness or binding is found, replace the bearing. Grease seal and needle bearing lubrication • refer to the swingarm pivot lubrication in the period...

Page 554

14-2 steering exploded view.

Page 556

14-4 steering special tools head pipe outer race press shaft: 57001-1075 head pipe outer race driver, 54.5: 57001-1077 steering stem nut wrench: 57001-1100 head pipe outer race remover id > 37 mm: 57001-1107 steering stem bearing driver, 42.5: 57001-1344 steering stem bearing driver adapter, 41.5: 5...

Page 558

14-6 steering handlebar • install the handlebar clamps [a] so that the cut side [b] on the clamp points at the rear. • apply 2-stroke oil to the handlebar clamp bolts [c]. • tighten: torque - handlebar clamp bolts: 34 n·m (3.5 kgf·m, 25 ft·lb) ○ tighten the clamp bolts, front first and then the rear...

Page 560

14-8 steering steering stem steering stem removal • remove: windshield (see windshield removal in the frame chapter) fairing (see fairing removal in the frame chapter) front wheel (see front wheel removal in the wheels/tires chapter) front fender (see front fender removal in the frame chapter) • rem...

Page 562

14-10 steering steering stem • install the front fork temporary. • install the washer [a] and the steering stem head nut [b]. Torque - steering stem head nut: 108 n·m (11.0 kgf·m, 80 ft·lb) • install the removed parts (see appropriate chapters). • check and adjust the following after installation. S...

Page 564

14-12 steering steering stem bearing • replace the bearing inner races and oil seal with new ones. • apply grease to the oil seal. • drive the lower ball bearing inner race [a] applied the grease onto the stem. Special tools - steering stem bearing driver, 42.5 [b]: 57001-1344 steering stem bearing ...

Page 566

15-2 frame exploded view.

Page 568

15-4 frame exploded view.

Page 570

15-6 frame exploded view.

Page 572

15-8 frame exploded view.

Page 574

15-10 frame special tools jack: 57001-1238.

Page 576

15-12 frame fairing and legshields fairing removal • remove: legshields (see legshield removal) windshield (see windshield removal) bolts [a] (both sides) speaker covers [b] (both sides) • remove the fairing mounting bolt (upper) [a] on both sides. • remove the fairing mounting bolts (lower) [a] on ...

Page 578

15-14 frame fairing and legshields • remove the bolts [a] on both sides. • remove: bolts [a] clamp [b] • pull out the fairing inner cover [a] together with the fairing bracket [b], and remove it upward to prevent the bracket from contacting the front fork. • remove: bolts [a] and washers windshield ...

Page 580

15-16 frame fairing and legshields • installation is the reverse of removal, note the following. ○ insert the rib [a] of the side cover into the hook potion [b]. ○ insert the projections [a] of the inner cover into the grom- mets [b]. Leg louver removal/installation • remove: nut [a] clip and pin [b...

Page 582

15-18 frame side covers right side cover removal • remove: front seat (see front seat removal) screw [a] • detach the projections [b], and remove the upper side cover [c]. • remove: bolt [a] screw [b] • detach the projections [c], and remove the lower side cover [d]. Right side cover installation • ...

Page 584

15-20 frame fenders ○ install the clamp [a] so that the clamping position is the red mark [b] on the seat lock cable. ○ run the cable, hose and leads correctly (see cable, wire, and hose routing section in the appendix chapter). ○ tighten: torque - rear fender allen bolts: 25 n·m (2.5 kgf·m, 18 ft·l...

Page 586

15-22 frame footboard front footboard removal/installation left front footboard • remove: left front guard (see front guard removal/installation) shift lever bolt [a] shift lever [b] • remove: front footboard bracket bolt [a] left front footboard [b] • installation is the reverse of removal, note th...

Page 588

15-24 frame footboard front footboard assembly • replace the circlips with new ones. • install the following parts onto the front footboards [a]. Inner dampers [b] outer dampers [c] bank sensors [d] and bolts [e] • install the dampers [a] onto the front footboard brackets [b]. • put the footboards [...

Page 590

15-26 frame sidestand sidestand removal • raise the rear wheel off the ground, using the jack. Special tool - jack: 57001-1238 • remove: sidestand switch bolt [a] sidestand switch [b] • remove: spring [a] sidestand nut [b] sidestand bolt [c] sidestand [d] sidestand installation • replace the sidesta...

Page 592

15-28 frame trunk and saddlebags trunk lid unlocking • insert the ignition key into the lid lock [a], turn the key counterclockwise [b], and unlock the latches [c]. The lid will open. Trunk lid locking • close the lid, and lock the latches [a]. • turn the ignition key clockwise [b] to lock the lid, ...

Page 594

15-30 frame trunk and saddlebags saddlebag installation • fit the stoppers [a] on the bottom of the saddlebag into the rubber dampers [b] in the saddlebag stay. • fit the hook [a] behind the saddlebag into the saddlebag stay [b]. • open the lid, and tighten the bolts. • close the lid. Trunk stay and...

Page 596

15-32 frame storage box storage box lid unlocking • insert the ignition key into the lid lock [a], and turn the key clockwise [b]. Pull the key to open the lid. ○ when the lid is unlocked, the ignition key cannot be pulled out. Storage box lid locking • close the lid. • turn the ignition key counter...

Page 598

15-34 frame rear view mirrors rear view mirror removal (other than eur and sea models) • loosen the locknut [a]. • turn the rear view mirror stay [b] counterclockwise to re- move the rear view mirror from the holder [c]. Rear view mirror removal (eur and sea models) • loosen the lower hexagonal area...

Page 600

15-36 frame downtube removal downtube removal • raise the rear wheel off the ground, using the jack. Special tools - jack: 57001 – 1238 • remove: right front guard (see front guard removal/installa- tion) right front footboard (see front footboard re- moval/installation) exhaust pipe (see exhaust pi...

Page 602

15-38 frame frame frame inspection • visually inspect the frame [a] for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. Warning a repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it..

Page 604

16-2 electrical system armature inspection.......................................................................................................... 16-51 brush lead inspection ...................................................................................................... 16-52 right-hand end...

Page 606

16-4 electrical system exploded view.

Page 608

16-6 electrical system exploded view.

Page 610

16-8 electrical system exploded view.

Page 612

16-10 electrical system specifications item standard battery type sealed battery model name ftz16-bs capacity 12 v 18 ah voltage 12.6 v or more charging system alternator type three-phase ac battery charging voltage 14.0 ∼ 15.0 v at 5 000 r/min (rpm) alternator output voltage (no load) 76 v or more ...

Page 614

16-12 electrical system wiring diagram (vn1700a model).

Page 616

16-14 electrical system wiring diagram (vn1700a model).

Page 618

16-16 electrical system wiring diagram (vn1700b model).

Page 620

16-18 electrical system wiring diagram (vn1700b model).

Page 622

16-20 electrical system electrical parts location fuel pump and fuel level sensor [a] speed sensor [b] antenna (am/fm) [c] crankshaft sensor [d] alternator [e] gear position switch [f] meter unit [a] audio unit [b] audio switches [c] fog light switch [d] ignition switch [e] cruise control on/off but...

Page 624

16-22 electrical system servicing precautions there are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○ always check b...

Page 626

16-24 electrical system battery battery removal caution do not remove the battery cables and fuses for 6 seconds after turning off the ignition switch. • turn the ignition switch off. • remove: front seat (see front seat removal in the frame chap- ter) connector [a] screws [b] battery case cover [c]...

Page 628

16-26 electrical system battery • place the electrolyte container upside down with the six sealed cells into the filler ports of the battery. Hold the container level, push down to break the seals of all six cells. You will see air bubbles rising into each cell as the ports fill. Note ○ do not tilt ...

Page 630

16-28 electrical system battery warning keep the battery away from sparks and open flames during charging, since the battery gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger, connect the battery to the charger before turning on the charger. This procedure preve...

Page 632

16-30 electrical system charging system alternator cover removal • drain: engine oil (see engine oil change in the periodic main- tenance chapter) coolant (see coolant change in the periodic mainte- nance chapter) • remove: right front footboard (see front footboard re- moval/installation in the fra...

Page 634