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Kawasaki VN900 Custom Service Manual

Other manuals for VN900 Custom: Installation Instructions, Owner's Manual

Summary of VN900 Custom

  • Page 1

    Vulcan 900 custom vn900 custom downloaded for free, http://vulcanrider.Se/.

  • Page 3: Quick Reference Guide

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

  • Page 5: Vulcan 900 Custom

    Vulcan 900 custom vn900 custom 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 the prior written permission of ...

  • Page 6

    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 7

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

  • Page 8: Foreword

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

  • Page 9

    List of abbreviations a ampere(s) l liter(s) abdc after bottom dead center lb pound(s) ac alternating current m meter(s) atdc after top dead center min minute(s) bbdc before bottom dead center n newton(s) bdc bottom dead center pa pascal(s) btdc before top dead center ps horsepower °c degree(s) cels...

  • Page 11: General Information

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

  • Page 12

    1-2 general information before servicing before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions...

  • Page 13

    General information 1-3 before servicing arrangement and cleaning of removed parts disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly. Storage of removed parts after all the parts including subas...

  • Page 14

    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...

  • Page 15

    General information 1-5 before servicing press for items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball bearing and needle bearing do not remove presse...

  • Page 16

    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...

  • Page 17

    General information 1-7 model identification vn900c7 (us and ca) left side view vn900c7 (us and ca) right side view.

  • Page 18

    1-8 general information model identification vn900c7 (eur and au) left side view vn900c7 (eur and au) right side view frame number frame number [a] right front fork [b] engine number engine number [a] right engine cover [b].

  • Page 19

    General information 1-9 general specifications items vn900c7 ∼ c8 vn900c9 ∼ cf dimensions overall length 2 405 mm (94.68 in.) ← overall width 895 mm (35.24 in.) ← overall height 1 120 mm (44.09 in.) ← wheelbase 1 645 mm (64.76 in.) ← road clearance 140 mm (5.51 in.) ← seat height 685 mm (27.0 in.) ←...

  • Page 20

    1-10 general information general specifications items vn900c7 ∼ c8 vn900c9 ∼ cf ignition system battery and coil (transistorized) ← timing advance electronically advanced (digital igniter) ← ignition timing from 0° btdc @1 000 r/min (rpm) to 53° btdc @5 800 r/min (rpm) from 3.5° btdc @1 000 r/min (r...

  • Page 21

    General information 1-11 general specifications items vn900c7 ∼ cf spark plug ngk cpr7ea-9 cylinder numbering method front to rear, 1-2 firing order 1-2 valve timing: inlet: open 40° btdc close 40° abdc duration 260° exhaust: open 55° bbdc close 25° atdc duration 260° lubrication system forced lubri...

  • Page 22

    1-12 general information general specifications items vn900c7 ∼ cf rear tire: type tubeless size 180/70-15 m/c 76h rim size j15 m/c × mt 4.50 front suspension: type telescopic fork wheel travel 150 mm (5.90 in.) rear suspension: type swingarm (uni-trak) wheel travel 103 mm (4.06 in.) brake type: fro...

  • Page 23

    General information 1-13 unit conversion table prefixes for units: prefix symbol power mega m × 1 000 000 kilo k × 1 000 centi c × 0.01 milli m × 0.001 micro µ × 0.000001 units of mass: kg × 2.205 = lb g × 0.03527 = oz units of volume: l × 0.2642 = gal (us) l × 0.2200 = gal (imp) l × 1.057 = qt (us)...

  • Page 25: Periodic Maintenance

    Periodic maintenance 2-1 2 periodic maintenance table of contents periodic maintenance chart .............. 2-2 torque and locking agent................. 2-6 specifications .................................... 2-11 special tools ..................................... 2-13 periodic maintenance procedu...

  • Page 26

    2-2 periodic maintenance periodic maintenance chart the scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. Periodic inspection frequency whichever comes first * odo...

  • Page 27

    Periodic maintenance 2-3 periodic maintenance chart frequency whichever comes first * odometer reading × 1 000 km (× 1 000 mile) inspection 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 belt deflection - inspect • • • • • • • 2-25 belt wear and damage -...

  • Page 28

    2-4 periodic maintenance periodic maintenance chart frequency whichever comes first * odometer reading × 1 000 km (× 1 000 mile) inspection every 1 (0.6) 6 (3.75) 12 (7.5) 18 (11.25) 24 (15) 30 (18.75) 36 (22.5) see page others chassis parts - lubricate year • • • 2-43 bolts and nuts tightness - ins...

  • Page 29

    Periodic maintenance 2-5 periodic maintenance chart periodic replacement parts frequency whichever comes first * odometer reading × 1 000 km (× 1 000 mile) change/replace item every 1 (0.6) 12 (7.5) 24 (15) 36 (22.5) 48 (30) see page air cleaner element # every 18 000 km (12 000 mile) 2-45 fuel hose...

  • Page 30

    2-6 periodic maintenance torque and locking agent the following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. All of the values are for use with dry solvent - cleaned threads unless otherwise indicated. When checking...

  • Page 31

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks engine top end camshaft cap bolts 25 2.5 18 camshaft chain guide bolts 9.8 1.0 87 in·lb l camshaft chain tensioner cap bolts 20 2.0 15 camshaft sprocket bolts 49 5.0 36 l cylinder head cover bolts 12 1.2 106 in...

  • Page 32

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks balancer shaft bearing stopper plate screws 6.9 0.70 61 in·lb bearing retainer bolts 9.8 1.0 87 in·lb l clamp mounting bolts 9.8 1.0 87 in·lb connecting rod big end bolts 46 4.7 34 mo crankcase bolts (m10) 39 4...

  • Page 33

    Periodic maintenance 2-9 torque and locking agent torque fastener n·m kgf·m ft·lb remarks front brake reservoir cap screws 1.5 0.15 13 in·lb front caliper mounting bolts 34 3.5 25 front master cylinder clamp bolts 8.8 0.90 78 in·lb s rear brake disc mounting bolts 27 2.8 20 l rear caliper mounting b...

  • Page 34

    2-10 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks ignition coil bracket bolts 9.8 1.0 87 in·lb ignition coil mounting nuts 6.9 0.70 61 in·lb oxygen sensors (oxygen sensor equipped models) 25 2.5 18 regulator/rectifier bolts 6.9 0.70 61 in·lb sidestand switch ...

  • Page 35

    Periodic maintenance 2-11 specifications item standard service limit fuel system (dfi) throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – idle speed 1 000 ±50 r/min (rpm) – – – air cleaner element viscous paper element – – – cooling system coolant: type (recommended) permanent type of antifree...

  • Page 36

    2-12 periodic maintenance specifications item standard service limit final drive drive belt deflection: (45 n, 4.6 kgf, 10 lb force) 1.5 ∼ 4.0 mm (0.06 ∼ 0.16 in.) – – – when installing new belt or engine is remounted 1.5 mm (0.06 in.) – – – brakes brake fluid: grade dot4 – – – brake pad lining thic...

  • Page 37

    Periodic maintenance 2-13 special tools inside circlip pliers: 57001-143 steering stem nut wrench: 57001-1100 jack: 57001-1238 oil filter wrench: 57001-1249 spark plug wrench, hex 16: 57001-1262 filler cap driver: 57001-1454 tension gauge: 57001-1585.

  • Page 38

    2-14 periodic maintenance periodic maintenance procedures fuel system (dfi) throttle control system inspection • check the throttle grip free play [a]. If the free play is incorrect, adjust the throttle cable. Throttle grip free play standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.) • check that the throttle gri...

  • Page 39

    Periodic maintenance 2-15 periodic maintenance procedures idle speed adjustment • start the engine and warm it up thoroughly. ○ wait until fast idle speed lowers to a certain value. • turn the adjusting screw [a] until the idle speed is correct. ○ open and close the throttle a few times to make sure...

  • Page 40

    2-16 periodic maintenance periodic maintenance procedures evaporative emission control system inspection (cal, th, sea-b1) evaporative emission control system inspection • inspect the canister as follows. ○ remove: mufflers (see muffler removal in the engine top end chapter) bolts [a] ○ remove the b...

  • Page 41

    Periodic maintenance 2-17 periodic maintenance procedures cooling system coolant level inspection note ○ check the level when the engine is cold (room or ambi- ent temperature). • check the coolant level in the reserve tank [a] with the motorcycle held perpendicular (do not use the sidestand). If th...

  • Page 42

    2-18 periodic maintenance periodic maintenance procedures engine top end air suction system damage inspection • disconnect the air switching valve hose [a] out of the right air cleaner housing. • start the engine and run it at idle speed. • plug the air switching valve hose end with your finger and ...

  • Page 43

    Periodic maintenance 2-19 periodic maintenance procedures valve clearance adjustment • to change the valve clearance, slide [a] the rocker arm [b] sideways and change the shim [c]. Replace the shim with one of a different thickness. Note ○ mark and record the shim locations so that the shims can be ...

  • Page 44

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

  • Page 45

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

  • Page 46

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

  • Page 47

    Periodic maintenance 2-23 periodic maintenance procedures wheels/tires air pressure inspection • remove the air valve cap. • measure the tire air pressure with an air pressure gauge [a] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours...

  • Page 48

    2-24 periodic maintenance periodic maintenance procedures • measure the tread depth at the center of the tread with a depth gauge [a]. Since the tire may wear unevenly, take measurement at several places. If any measurement is less than the service limit, replace the tire (see tire removal/installat...

  • Page 49

    Periodic maintenance 2-25 periodic maintenance procedures • raise the rear wheel off the ground with jack (see rear wheel removal in the wheels/tires chapter). • inspect the roughness of the rear wheel bearing by mov- ing the wheel to be both side. • spin [a] the rear wheel lightly, and check for sm...

  • Page 50

    2-26 periodic maintenance periodic maintenance procedures • measure the deflection (length between initial belt posi- tion [a] and position [b] that is pointed by the procedures above) of the belt (at the belt cover window). Note ○ push the belt by the gauge until the top surface [a] of the stopper ...

  • Page 51

    Periodic maintenance 2-27 periodic maintenance procedures • inspect the drive belt deflection, and record the value [b]. • decide the belt deflection at the position [c] of one where deflection is large. Drive belt deflection (with 45 n, 4.6 kgf, 10 lb force) standard: 1.5 ∼ 4.0 mm (0.06 ∼ 0.16 in.)...

  • Page 52

    2-28 periodic maintenance periodic maintenance procedures • tighten both belt adjuster locknuts. Warning misalignment of the wheel will result in abnormal wear, and may result in an unsafe riding condition. Tighten both belt adjuster locknuts, and make sure the axle stays aligned. • tighten the axle...

  • Page 53

    Periodic maintenance 2-29 periodic maintenance procedures belt wear and damage inspection • raise the rear wheel off the ground with jack (see rear wheel removal in the wheels/tires chapter). • remove: bolts [a] and washers drive belt cover [b] • visually inspect the belt [a] for wear and damage. If...

  • Page 54

    2-30 periodic maintenance periodic maintenance procedures drive belt tooth wear and damage patterns a. Belt cross section b. Edge bevel wear c. Rub wear d. Stone.

  • Page 55

    Periodic maintenance 2-31 periodic maintenance procedures drive belt wear and damage analysis pattern condition required action 1 internal tooth cracks (slight) o.K. For continued use, but inspect the belt periodically. 2 scuffing to side of teeth o.K. For continued use, but inspect the belt periodi...

  • Page 56

    2-32 periodic maintenance periodic maintenance procedures brake hose and pipe damage and installation condition inspection • inspect the brake hoses and fittings for deterioration, cracks and signs of leakage. ○ the high pressure inside the brake line can cause fluid to leak [a] or the hose to burst...

  • Page 57

    Periodic maintenance 2-33 periodic maintenance procedures • check that the brake fluid level in the rear brake reservoir [a] is above the lower level line [b]. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [c]. Warning mixing brands and types of br...

  • Page 58

    2-34 periodic maintenance periodic maintenance procedures if it does not, adjust the brake light switch. • while holding the switch body, turn the adjusting nut [a] to adjust the switch. Notice to avoid damaging the electrical connections in- side the switch, be sure that the switch body does not tu...

  • Page 59

    Periodic maintenance 2-35 periodic maintenance procedures front fork oil leak inspection • visually inspect the front forks [a] for oil leakage. Replace any defective parts, if necessary. Rear shock absorber oil leak inspection • remove the left side cover (see left side cover removal in the frame c...

  • Page 60

    2-36 periodic maintenance periodic maintenance procedures uni-trak linkage lubrication • remove the tie-rod (see tie-rod removal in the suspen- sion chapter). • apply grease to the inner surfaces of the needle bearings [a]. Vn900c7 ∼ c9 models • for the rocker arm it has grease nipples [a] on the ro...

  • Page 61

    Periodic maintenance 2-37 periodic maintenance procedures • bend the claws [a] of the claw washer straighten. • remove the steering stem locknut [b] and claw washer [c]. • adjust the steering. Special tool - steering stem nut wrench [a]: 57001-1100 if the steering is too tight, loosen the stem nut [...

  • Page 62

    2-38 periodic maintenance periodic maintenance procedures electrical system spark plug condition inspection • refer to the spark plug condition inspection in the peri- odic maintenance chapter. Lights and switches operation inspection first step • turn on the ignition switch. • the following lights ...

  • Page 63

    Periodic maintenance 2-39 periodic maintenance procedures third step • turn on the turn signal switch [a] (left or right position). • the left or right turn signal lights [b] (front and rear) ac- cording to the switch position should flash. • the turn signal indicator light [c] in the meter unit sho...

  • Page 64

    2-40 periodic maintenance periodic maintenance procedures • set the dimmer switch to high beam position. • the high beam should go on. • the high beam indicator light [a] should go on. If the high beam headlight and/or high beam indicator light does not go on, inspect or replace the following item. ...

  • Page 65

    Periodic maintenance 2-41 periodic maintenance procedures note ○ on high beam, the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated. Adjust the headlight to the proper an- gle according to local regulations. ○ for us model, the proper angle ...

  • Page 66

    2-42 periodic maintenance periodic maintenance procedures if the sidestand switch operation does not work, inspect or replace the following item. Battery (see charging condition inspection in the elec- trical system chapter) main fuse 30 a (see fuse inspection in the electrical system chapter) ignit...

  • Page 67

    Periodic maintenance 2-43 periodic maintenance procedures others chassis parts lubrication • before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • lubricate the points listed below with indicated lubricant. Note ○ whenever the vehic...

  • Page 68

    2-44 periodic maintenance periodic maintenance procedures bolts, nuts and fasteners tightness inspection • check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. Note ○ for the engine fasteners, check the tightness of them wh...

  • Page 69

    Periodic maintenance 2-45 periodic maintenance procedures replacement parts air cleaner element replacement warning if dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident. Replace the air cleaner element according to the maint...

  • Page 70

    2-46 periodic maintenance periodic maintenance procedures fuel hose replacement notice when removing and installing the fuel hose joint, do not apply strong force to the outlet pipe on the fuel pump and delivery pipe on the throttle body assy. The pipes made from resin could be damaged. • remove the...

  • Page 71

    Periodic maintenance 2-47 periodic maintenance procedures • insert the fuel hose joint [a] straight onto the delivery pipe. • push [b] the joint lock [c] until the hose joint clicks. • push and pull [a] the fuel hose joint [b] back and forth more than two times and make sure it is locked and doesn’t...

  • Page 72

    2-48 periodic maintenance periodic maintenance procedures • remove: bolts [a] reserve tank cap [b] • turn over the reserve tank, and pour the coolant into the suitable container. • remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter). • remove the radiator cap [a] in two ste...

  • Page 73

    Periodic maintenance 2-49 periodic maintenance procedures • fill the radiator up to the filler neck [a] with coolant. Note ○ pour in the coolant slowly so that it can expel the air from the engine and radiator. • check the cooling system for leaks. • tap the radiator hoses to force any air bubbles c...

  • Page 74

    2-50 periodic maintenance periodic maintenance procedures engine oil change • situate the motorcycle so that it is vertical after warming up the engine. • unscrew the oil filler cap [a]. ○ for vn900c7 ∼ ca models, unscrew the cap using the following special tool. Special tool - filler cap driver: 57...

  • Page 75

    Periodic maintenance 2-51 periodic maintenance procedures oil filter replacement • drain the engine oil (see engine oil change). • remove: regulator/rectifier (see regulator/rectifier removal in the electrical system chapter) bolts [a] bracket [b] • remove the oil filter [a] with the oil filter wren...

  • Page 76

    2-52 periodic maintenance periodic maintenance procedures brake hose replacement notice brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • remove the banjo bolts [a]. • when removing the brake hose [b], take care not to spill the bra...

  • Page 77

    Periodic maintenance 2-53 periodic maintenance procedures • level the brake fluid reservoir. • remove: reservoir cap [a] plate [b] diaphragm [c] • remove the rubber cap from the bleed valve [a] on the front caliper [b]. • attach a clear plastic hose [c] to the bleed valve, and run the other end of t...

  • Page 78

    2-54 periodic maintenance periodic maintenance procedures • for the rear caliper [a], change the brake fluid for two bleed valves [b]. • 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...

  • Page 79

    Periodic maintenance 2-55 periodic maintenance procedures rear master cylinder disassembly note ○ do not remove the push rod clevis [a] for master cylin- der disassembly since removal requires brake pedal po- sition adjustment. • remove the rear master cylinder (see rear master cylin- der removal in...

  • Page 80

    2-56 periodic maintenance periodic maintenance procedures • tighten the brake lever pivot bolt and the locknut. • apply silicone grease. Brake lever pivot bolt brake lever pivot contact push rod contact dust cover • tighten: torque - brake lever pivot bolt: 1.0 n·m (0.10 kgf·m, 9 in·lb) brake lever ...

  • Page 81

    Periodic maintenance 2-57 periodic maintenance procedures front caliper assembly • clean the caliper parts except for the pads. Notice for cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • install the bleed valve [a] and the rubber cap [b]. Torque - bleed valve: 7...

  • Page 82

    2-58 periodic maintenance periodic maintenance procedures • using compressed air, remove the pistons. Warning the piston in the brake caliper can crush hands and fingers. Never place your hand or fingers in front of the piston. ○ insert a wooden board [a] 5 mm (0.2 in.) thick inside the caliper open...

  • Page 83

    Periodic maintenance 2-59 periodic maintenance procedures • apply brake fluid to the outside of the pistons and push the pistons [a] into each cylinder by hand. • check the friction boot [b] and dust boot [c] and replace them with new ones if they are damaged. • apply a thin coat of pbc (poly butyl ...

  • Page 85: Fuel System (Dfi)

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

  • Page 86

    3-2 fuel system (dfi) speed sensor removal .................................................................................................... 3-67 speed sensor installation ................................................................................................. 3-67 speed sensor inspectio...

  • Page 87

    Fuel system (dfi) 3-3 fuel injector installation .................................................................................................... 3-116 fuel injector fuel line inspection ..................................................................................... 3-117 fuel injector aud...

  • Page 88

    3-4 fuel system (dfi) exploded view.

  • Page 89

    Fuel system (dfi) 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 air cleaner cover bolts 4.9 0.50 43 in·lb 2 air cleaner housing bolts 9.8 1.0 87 in·lb 3 delivery joint bolts 9.8 1.0 87 in·lb l 4 delivery joint bracket bolt 9.8 1.0 87 in·lb 5 fuel pump bolts 9.8 1.0 87 in·lb l 6 inl...

  • Page 90

    3-6 fuel system (dfi) exploded view.

  • Page 91

    Fuel system (dfi) 3-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 fuel level sensor mounting bolts 6.9 0.70 61 in·lb l 2 oxygen sensors 25 2.5 18 3 oxygen sensor plugs 25 2.5 18 4. Cal, th and sea-b1 models 5. Breather hose (other than cal, th and sea-b1 models) 6. Oxygen sensor equi...

  • Page 92

    3-8 fuel system (dfi) specifications item standard dfi system idle speed 1 000 ±50 r/min (rpm) throttle body assy: throttle valve dual throttle valve bore 34 mm (1.34 in.) ecu (electronic control unit): make denso type digital memory type, with built in ic igniter, sealed with resin usable engine sp...

  • Page 93

    Fuel system (dfi) 3-9 specifications item standard subthrottle sensor: non-adjustable and non-removable input voltage vn900c7 dc 4.75 ∼ 5.25 v between bl and br/bk leads vn900c8 ∼ dc 4.75 ∼ 5.25 v between bl and bk leads output voltage vn900c7 dc 0.93 ∼ 4.59 v between bl/w and br/bk leads (at idle t...

  • Page 94

    3-10 fuel system (dfi) special tools and sealant oil pressure gauge, 5 kgf/cm²: 57001-125 fork oil level gauge: 57001-1290 peak voltage adapter: 57001-1415 filler cap driver: 57001-1454 needle adapter set: 57001-1457 fuel pressure gauge adapter: 57001-1593 fuel hose: 57001-1607 speed sensor measurin...

  • Page 95

    Fuel system (dfi) 3-11 dfi parts location 1. Air switching valve 2. Battery 3. Crankshaft sensor 4. Ecu 5. Fuel pump 6. Fuse box 7. Ignition coil #1 8. Ignition coil #2 9. Injector #1 10. Injector #2 11. Inlet air pressure sensor 12. Inlet air temperature sensor 13. Main fuse 30 a 14. Main throttle ...

  • Page 96

    3-12 fuel system (dfi) dfi parts location.

  • Page 97

    Fuel system (dfi) 3-13 dfi parts location.

  • Page 98

    3-14 fuel system (dfi) dfi system dfi system.

  • Page 99

    Fuel system (dfi) 3-15 dfi system 1. Ecu 2. Battery 3. Injectors 4. Fuel pump 5. Fuel tank 6. Subthrottle valve actuator 7. Air cleaner 8. Subthrottle sensor 9. Main throttle sensor 10. Inlet air temperature sensor 11. Water temperature sensor 12. Inlet air pressure sensor 13. Vehicle-down sensor 14...

  • Page 100

    3-16 fuel system (dfi) dfi system dfi system wiring diagram (without oxygen sensor equipped models) (vn900c7 ∼ c8).

  • Page 101

    Fuel system (dfi) 3-17 dfi system part name 1. Ecu 2. Diagnosis connector 3. Self-diagnosis terminal 4. Fuel pump 5. Vehicle-down sensor 6. Frame ground 7. Battery 8. Main fuse 30 a 9. Relay box 10. Fuel pump relay 11. Ecu main relay 12. Radiator fan relay 13. Radiator fan fuse 15 a 14. Ecu fuse 15 ...

  • Page 102

    3-18 fuel system (dfi) dfi system dfi system wiring diagram (oxygen sensor equipped models) (vn900c7 ∼ c8).

  • Page 103

    Fuel system (dfi) 3-19 dfi system part name 1. Ecu 2. Diagnosis connector 3. Self-diagnosis terminal 4. Fuel pump 5. Vehicle-down sensor 6. Frame ground 7. Battery 8. Main fuse 30 a 9. Relay box 10. Fuel pump relay 11. Ecu main relay 12. Radiator fan relay 13. Oxygen sensor heater fuse 10 a 14. Radi...

  • Page 104

    3-20 fuel system (dfi) dfi system dfi system wiring diagram (without oxygen sensor equipped models) (vn900c9 ∼ ).

  • Page 105

    Fuel system (dfi) 3-21 dfi system part name 1. Ecu 2. Diagnosis connector 3. Self-diagnosis terminal 4. Fuel pump 5. Vehicle-down sensor 6. Frame ground 7. Battery 8. Main fuse 30 a 9. Relay box 10. Fuel pump relay 11. Ecu main relay 12. Radiator fan relay 13. Radiator fan fuse 15 a 14. Ecu fuse 15 ...

  • Page 106

    3-22 fuel system (dfi) dfi system dfi system wiring diagram (oxygen sensor equipped models) (vn900c9 ∼ ).

  • Page 107

    Fuel system (dfi) 3-23 dfi system part name 1. Ecu 2. Diagnosis connector 3. Self-diagnosis terminal 4. Fuel pump 5. Vehicle-down sensor 6. Frame ground 7. Battery 8. Main fuse 30 a 9. Relay box 10. Fuel pump relay 11. Ecu main relay 12. Radiator fan relay 13. Oxygen sensor heater fuse 10 a 14. Radi...

  • Page 108

    3-24 fuel system (dfi) dfi system without oxygen sensor equipped models terminal names 1. Subthrottle valve actuator drive signal 2 2. Subthrottle valve actuator drive signal 1 3. Water temperature warning light signal 4. Unused 5. Speed sensor signal 6. Main throttle sensor signal 7. Inlet air pres...

  • Page 109

    Fuel system (dfi) 3-25 dfi system oxygen sensor equipped models terminal names 1. Subthrottle valve actuator drive signal 2 2. Subthrottle valve actuator drive signal 1 3. Water temperature warning light signal 4. Oxygen sensor signal 2 5. Oxygen sensor signal 1 6. Speed sensor signal 7. Main thrott...

  • Page 110

    3-26 fuel system (dfi) dfi servicing precautions dfi servicing precautions there are a number of important precautions that should be followed servicing the dfi system. ○ this dfi system is designed to be used with a 12 v sealed battery as its power source. Do not use any other battery except for a ...

  • Page 111

    Fuel system (dfi) 3-27 dfi servicing precautions ○ to maintain the correct fuel/air mixture (f/a), there must be no inlet air leaks in the dfi system. Be sure to install the oil filler plug [a] after filling the engine oil. Alternator cover [b] special tool - filler cap driver: 57001-1454.

  • Page 112

    3-28 fuel system (dfi) troubleshooting the dfi system outline outline when an abnormality in the system occurs, the fi indi- cator light (led) goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ecu (electronic control unit). With t...

  • Page 113

    Fuel system (dfi) 3-29 troubleshooting the dfi system ○ the dfi part connectors [a] have seals [b], including the ecu. • join the connector and insert the needle adapters [c] in- side the seals from behind the connector until the adapter reaches the terminal. Special tool - needle adapter set: 57001...

  • Page 114

    3-30 fuel system (dfi) 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...

  • Page 115

    Fuel system (dfi) 3-31 troubleshooting the dfi system ○ there are two ways to inspect the dfi system. One is voltage check method and the other is resistance check method. (voltage check method) ○ this method is conducted by measuring the input voltage [a] to a sensor [b] first, and then the output ...

  • Page 116

    3-32 fuel system (dfi) troubleshooting the dfi system dfi diagnosis flow chart inquiries to rider inquiries to rider ○ each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ try to find out exactly what problem occurred under...

  • Page 117

    Fuel system (dfi) 3-33 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...

  • Page 118

    3-34 fuel system (dfi) troubleshooting the dfi system □ engine overheating □ clutch slipping □ other □ spark plug loose (tighten it) □ spark plug dirty, broken, or gap maladjusted (remedy it) poor running or no power at high speed □ spark plug incorrect (replace it) □ knocking (fuel poor quality or ...

  • Page 119

    Fuel system (dfi) 3-35 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. ○ the ecu may be involved in the dfi electri...

  • Page 120

    3-36 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) no spark or spark weak: ignition and engine stop switches not on turn both switches on. Clutch lever not pulled in and gear not in neutral whether sidestand up or not pull the lever in and shift the...

  • Page 121

    Fuel system (dfi) 3-37 dfi system troubleshooting guide symptoms or possible causes actions (chapter) piston ring bad (worn, weak, broken or sticking) inspect and replace (see chapter 5). Piston ring/groove clearance excessive inspect and replace (see chapter 5). Cylinder head gasket damaged replace...

  • Page 122

    3-38 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) incorrect idle speed: water temperature sensor trouble inspect (see chapter 3). Main throttle sensor trouble inspect (see chapter 3). Throttle valves or actuator trouble inspect (see chapter 3). Eng...

  • Page 123

    Fuel system (dfi) 3-39 dfi system troubleshooting guide symptoms or possible causes actions (chapter) delay of ignition timing inspect crankshaft sensor and ic igniter in ecu (see chapter 16). Poor acceleration: too low fuel pressure inspect (see chapter 3). Water or foreign matter in fuel change fu...

  • Page 124

    3-40 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) fuel injector trouble inspect (see chapter 3). Run-on (dieseling): ignition switch trouble inspect and replace (see chapter 16). Engine switch trouble inspect and repair or replace (see chapter 2). ...

  • Page 125

    Fuel system (dfi) 3-41 dfi system troubleshooting guide symptoms or possible causes actions (chapter) inlet air temperature sensor trouble inspect (see chapter 3). Main throttle sensor malfunction inspect (see chapter 3). Inlet air pressure sensor trouble inspect (see chapter 3). Cracked or obstruct...

  • Page 126

    3-42 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) valve oil seal damaged replace (see chapter 5). Valve guide worn replace the guide (see chapter 5). Engine oil level too high repair (see chapter 7). (black smoke) air cleaner clogged clean (see cha...

  • Page 127

    Fuel system (dfi) 3-43 self-diagnosis self-diagnosis outline self-diagnosis outline the self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal. User mode the ecu notifies the rider of troubles in dfi system and ignition system by lighting t...

  • Page 128

    3-44 fuel system (dfi) self-diagnosis • to enter the self-diagnosis dealer mode 2, open [b] and ground [a] the lead more than five times [f] within 2 sec- onds [c] after the lead is first grounded, and then keep it grounded continuously [d] for more than 2 seconds. ○ count the blinks of the light (l...

  • Page 129

    Fuel system (dfi) 3-45 self-diagnosis self-diagnosis flow chart.

  • Page 130

    3-46 fuel system (dfi) self-diagnosis service code reading service code reading ○ service codes are shown by a series of long and short blinks of the fi indicator light (led) as shown below. ○ read 10th digit and unit digit as the fi indicator light (led) blinks. ○ when there are a number of problem...

  • Page 131

    Fuel system (dfi) 3-47 self-diagnosis service code table service code table service code fi indicator light (led) problems 11 main throttle sensor malfunction, wiring open or short 12 inlet air pressure sensor malfunction, wiring open or short 13 inlet air temperature sensor malfunction, wiring open...

  • Page 132

    3-48 fuel system (dfi) self-diagnosis notes: ○ the ecu may be involved in these problems. If all the parts and circuits checked out good, be sure to check the ecu for ground and power supply. If the ground and power supply are checked good, replace the ecu. ○ when no service code is displayed, the e...

  • Page 133

    Fuel system (dfi) 3-49 self-diagnosis backups backups ○ the ecu takes the following measures to prevent engine damage when the dfi or the ignition system parts have troubles. Service codes parts output signal usable range or criteria backups by ecu 11 main throttle sensor main throttle sensor output...

  • Page 134

    3-50 fuel system (dfi) self-diagnosis service codes parts output signal usable range or criteria backups by ecu 51 ignition coil #1* the ignition coil primary winding must send signals (output voltage) continuously to the ecu. If the ignition primary winding #1 has failures (no signal, wiring short ...

  • Page 135

    Fuel system (dfi) 3-51 main throttle sensor (service code 11) the main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ecu senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm,...

  • Page 136

    3-52 fuel system (dfi) main throttle sensor (service code 11) main throttle sensor output voltage inspection • measure the output voltage at the ecu in the same way as input voltage inspection. Special tool - needle adapter set: 57001-1457 main throttle sensor output voltage connections to ecu (with...

  • Page 137

    Fuel system (dfi) 3-53 main throttle sensor (service code 11) note ○ the standard voltage marked with an asterisk refers to the value when the voltage reading at the input voltage inspection shows 5 v exactly. ○ when the input voltage reading shows other than 5 v, derive a voltage range as follows. ...

  • Page 138

    3-54 fuel system (dfi) main throttle sensor (service code 11) main throttle sensor circuit (without oxygen sensor equipped models) main throttle sensor circuit (oxygen sensor equipped models) 1. Ecu 2. Main throttle sensor 3. Joint connector b.

  • Page 139

    Fuel system (dfi) 3-55 inlet air pressure sensor (service code 12) inlet air pressure sensor removal notice never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. • remove: fuel tank (see fuel tank removal) bolt [a] • disconnect the inlet air pressure sensor con...

  • Page 140

    3-56 fuel system (dfi) inlet air pressure sensor (service code 12) if the reading is within the standard range, remove the fuel tank, and check wiring from ecu to the inlet pressure sensor for continuity. If wiring is good, check the output voltage of the inlet air pressure sensor. Inlet air pressur...

  • Page 141

    Fuel system (dfi) 3-57 inlet air pressure sensor (service code 12) • remove the inlet air pressure sensor [a] and disconnect the vacuum hose from the sensor. ○ do not disconnect the sensor connector. • connect an auxiliary hose [b] to the inlet air pressure sen- sor. • temporarily install the inlet ...

  • Page 142

    3-58 fuel system (dfi) inlet air pressure sensor (service code 12) id: idling ps: standard atmospheric pressure (absolute) pv: throttle vacuum pressure (absolute) st: standard of sensor output voltage (v) to: throttle full open ur: usable range of sensor output voltage (v) vv: inlet air pressure sen...

  • Page 143

    Fuel system (dfi) 3-59 inlet air pressure sensor (service code 12) inlet air pressure sensor circuit (without oxygen sensor equipped models) inlet air pressure sensor circuit (oxygen sensor equipped models) 1. Ecu 2. Inlet air pressure sensor 3. Joint connector b.

  • Page 144

    3-60 fuel system (dfi) inlet air temperature sensor (service code 13) inlet air temperature sensor removal/installation notice never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • remove the air cleaner housing (see air cleaner housing removal). • remove t...

  • Page 145

    Fuel system (dfi) 3-61 inlet air temperature sensor (service code 13) inlet air temperature sensor resistance inspection • remove the inlet air temperature sensor (see inlet air temperature sensor removal). • suspend the sensor [a] in a container of machine oil so that the heat-sensitive portion is ...

  • Page 146

    3-62 fuel system (dfi) inlet air temperature sensor (service code 13) inlet air temperature sensor circuit (without oxygen sensor equipped models) inlet air temperature sensor circuit (oxygen sensor equipped models) 1. Ecu 2. Inlet air temperature sensor 3. Joint connector b.

  • Page 147

    Fuel system (dfi) 3-63 water temperature sensor (service code 14) water temperature sensor removal/installation notice never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • remove the fuel tank (see fuel tank removal). • drain the coolant (see coolant chang...

  • Page 148

    3-64 fuel system (dfi) water temperature sensor (service code 14) water temperature sensor circuit (without oxygen sensor equipped models) water temperature sensor circuit (oxygen sensor equipped models) 1. Ecu 2. Water temperature sensor 3. Joint connector b.

  • Page 149

    Fuel system (dfi) 3-65 crankshaft sensor (service code 21) start the engine and switch the diagnosis mode to dealer 1 mode to know all the problem that the dfi system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condi- tion of ...

  • Page 150

    3-66 fuel system (dfi) crankshaft sensor (service code 21) crankshaft sensor circuit (without oxygen sensor equipped models) crankshaft sensor circuit (oxygen sensor equipped models) 1. Ecu 2. Crankshaft sensor.

  • Page 151

    Fuel system (dfi) 3-67 speed sensor (service code 24, 25) speed sensor removal • refer to the speed sensor removal in the electrical sys- tem chapter. Speed sensor installation • refer to the speed sensor installation in the electrical system chapter. Speed sensor inspection • refer to the speed sen...

  • Page 152

    3-68 fuel system (dfi) speed sensor (service code 24, 25) speed sensor output voltage inspection • before this inspection, inspect the input voltage (see speed sensor input voltage inspection). Note ○ be sure the battery is fully charged. • turn the ignition switch off. • raise the rear wheel off th...

  • Page 153

    Fuel system (dfi) 3-69 speed sensor (service code 24, 25) speed sensor circuit (without oxygen sensor equipped models) speed sensor circuit (oxygen sensor equipped models) 1. Ecu 2. Meter unit 3. Joint connector b 4. Speed sensor.

  • Page 154

    3-70 fuel system (dfi) vehicle-down sensor (service code 31) vehicle-down sensor removal • remove: tool box (see tool box removal in the frame chapter) bolts [a] vehicle-down sensor [b] connector [c] (disconnect) vehicle-down sensor installation • install the vehicle-down sensor [a] in the original ...

  • Page 155

    Fuel system (dfi) 3-71 vehicle-down sensor (service code 31) if the power source is normal, check the output voltage of the sensor. • connect a digital meter [a] to the connector, using the needle adapter set [b]. • turn the ignition switch on, and measure the output volt- age with the connector joi...

  • Page 156

    3-72 fuel system (dfi) vehicle-down sensor (service code 31) vehicle-down sensor circuit (without oxygen sensor equipped models) vehicle-down sensor circuit (oxygen sensor equipped models) 1. Ecu 2. Vehicle-down sensor 3. Joint connector b.

  • Page 157

    Fuel system (dfi) 3-73 subthrottle sensor (service code 32) the subthrottle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ecu senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and...

  • Page 158

    3-74 fuel system (dfi) subthrottle sensor (service code 32) • turn the ignition switch off. If the reading of input voltage is less than the standard, check the ecu for its ground, power supply and wiring shorted. If the input voltage is within the standard range, remove the fuel tank, and check wir...

  • Page 159

    Fuel system (dfi) 3-75 subthrottle sensor (service code 32) note ○ the standard voltage refers to the value when the volt- age reading at the input voltage inspection shows 5 v exactly. ○ when the input voltage reading shows other than 5 v, derive a voltage range as follows. Example: in the case of ...

  • Page 160

    3-76 fuel system (dfi) subthrottle sensor (service code 32) subthrottle sensor circuit (without oxygen sensor equipped models) subthrottle sensor circuit (oxygen sensor equipped models) 1. Ecu 2. Subthrottle sensor (vn900c8 ∼ models) 3. Joint connector b 4. Subthrottle sensor (vn900c7 models).

  • Page 161

    Fuel system (dfi) 3-77 oxygen sensor-not activated #1, #2 (service code 33, 83) (oxygen sensor equipped models) oxygen sensor #1: service code 33 oxygen sensor #2: service code 83 oxygen sensor removal/installation • refer to the oxygen sensor removal and installation in the electrical system chapte...

  • Page 162

    3-78 fuel system (dfi) oxygen sensor-not activated #1, #2 (service code 33, 83) (oxygen sensor equipped models) • next, remove the plugs [a] (both sides) from the fittings with idling. • measure the output voltage of the sensor with the con- nector joined. Oxygen sensor output voltage (without plugs...

  • Page 163

    Fuel system (dfi) 3-79 oxygen sensor-not activated #1, #2 (service code 33, 83) (oxygen sensor equipped models) oxygen sensor circuit (vn900c9 ∼ ) 1. Ecu 2. Oxygen sensor #1 3. Oxygen sensor #2 4. Ignition switch 5. Oxygen sensor heater fuse 10 a 6. Main fuse 30 a 7. Starter relay 8. Battery 9. Fram...

  • Page 164

    3-80 fuel system (dfi) ignition coils #1, #2 (service code 51, 52) ignition coil #1: ignition coil for front cylinder (service code 51) ignition coil #2: ignition coil for rear cylinder (service code 52) ignition coil removal/installation notice never drop the ignition coils, especially on a hard su...

  • Page 165

    Fuel system (dfi) 3-81 ignition coils #1, #2 (service code 51, 52) if the reading is out of the standard, check the ecu for its ground and power supply (see ecu power supply in- spection). If the reading is good, remove the fuel tank, and check the wiring between the ecu and the primary lead termina...

  • Page 166

    3-82 fuel system (dfi) radiator fan relay (service code 56) radiator fan relay removal/installation • radiator fan relay is built in the relay box. • remove the relay box (see relay box removal in the electrical system chapter). Radiator fan relay inspection • refer to the relay circuit inspection i...

  • Page 167

    Fuel system (dfi) 3-83 radiator fan relay (service code 56) radiator fan relay circuit (vn900c7 ∼ c8) 1. Ignition switch 2. Radiator fan 3. Joint connector b 4. Water temperature sensor 5. Ecu 6. Frame ground 7. Battery 8. Main fuse 30 a 9. Relay box 10. Ecu main relay 11. Radiator fan relay 12. Ecu...

  • Page 168

    3-84 fuel system (dfi) radiator fan relay (service code 56) radiator fan relay circuit (vn900c9 ∼ ) 1. Ignition switch 2. Radiator fan 3. Joint connector b 4. Water temperature sensor 5. Ecu 6. Battery 7. Main fuse 30 a 8. Relay box 9. Ecu main relay 10. Radiator fan relay 11. Ecu fuse 15 a 12. Fan ...

  • Page 169

    Fuel system (dfi) 3-85 subthrottle valve actuator (service code 62) subthrottle valve actuator removal notice do not remove the subthrottle valve actuator [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...

  • Page 170

    3-86 fuel system (dfi) subthrottle valve actuator (service code 62) subthrottle valve actuator input voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the fuel tank (see fuel tank removal). • connect the peak voltage adapter [a] and a digital me...

  • Page 171

    Fuel system (dfi) 3-87 subthrottle valve actuator (service code 62) subthrottle valve actuator circuit (without oxygen sensor equipped models) subthrottle valve actuator circuit (oxygen sensor equipped models) 1. Ecu 2. Subthrottle valve actuator.

  • Page 172

    3-88 fuel system (dfi) air switching valve (service code 64) air switching valve removal/installation • refer to the air switching valve removal and installation in the engine top end chapter. Air switching valve inspection • refer to the air switching valve unit test in the electrical system chapte...

  • Page 173

    Fuel system (dfi) 3-89 air switching valve (service code 64) air switching valve circuit (oxygen sensor equipped models) (vn900c7 ∼ c8) 1. Ecu 2. Engine stop switch 3. Ignition switch 4. Ignition fuse 10 a 5. Ecu fuse 15 a 6. Fuse box 7. Ecu main relay 8. Fuel pump relay 9. Relay box 10. Main fuse 3...

  • Page 174

    3-90 fuel system (dfi) air switching valve (service code 64) air switching valve circuit (without oxygen sensor equipped models) (vn900c9 ∼ ) 1. Ecu 2. Engine stop switch 3. Ignition switch 4. Ignition fuse 10 a 5. Ecu fuse 15 a 6. Fuse box 7. Ecu main relay 8. Fuel pump relay 9. Relay box 10. Main ...

  • Page 175

    Fuel system (dfi) 3-91 air switching valve (service code 64) air switching valve circuit (oxygen sensor equipped models) (vn900c9 ∼ ) 1. Ecu 2. Engine stop switch 3. Ignition switch 4. Ignition fuse 10 a 5. Ecu fuse 15 a 6. Fuse box 7. Ecu main relay 8. Fuel pump relay 9. Relay box 10. Main fuse 30 ...

  • Page 176

    3-92 fuel system (dfi) oxygen sensor heaters #1, #2 (service code 67) (oxygen sensor equipped models) oxygen sensor heater removal/installation the oxygen sensor heater is built in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see oxygen sensor removal in t...

  • Page 177

    Fuel system (dfi) 3-93 oxygen sensor heaters #1, #2 (service code 67) (oxygen sensor equipped models) if the reading is incorrect, check the following. Battery (see charging condition inspection in the elec- trical system chapter) main fuse 30 a (see fuse inspection in the electrical system chapter)...

  • Page 178

    3-94 fuel system (dfi) oxygen sensor heaters #1, #2 (service code 67) (oxygen sensor equipped models) oxygen sensor circuit (vn900c9 ∼ ) 1. Ecu 2. Oxygen sensor #1 3. Oxygen sensor #2 4. Ignition switch 5. Oxygen sensor heater fuse 10 a 6. Main fuse 30 a 7. Starter relay 8. Battery 9. Frame ground 1...

  • Page 179

    Fuel system (dfi) 3-95 oxygen sensors-incorrect output voltage #1, #2 (service code 94, 95) (oxygen sensor equipped models) oxygen sensor #1: service code 94 oxygen sensor #2: service code 95 oxygen sensor removal/installation • refer to the oxygen sensor removal and installation in the electrical s...

  • Page 180

    3-96 fuel system (dfi) oxygen sensors-incorrect output voltage #1, #2 (service code 94, 95) (oxygen sensor equipped models) • next, remove the plugs [a] (both sides) from the fittings with idling. • measure the output voltage of the sensor with the con- nector joined. Oxygen sensor output voltage (w...

  • Page 181

    Fuel system (dfi) 3-97 oxygen sensors-incorrect output voltage #1, #2 (service code 94, 95) (oxygen sensor equipped models) oxygen sensor circuit (vn900c9 ∼ ) 1. Ecu 2. Oxygen sensor #1 3. Oxygen sensor #2 4. Ignition switch 5. Oxygen sensor heater fuse 10 a 6. Main fuse 30 a 7. Starter relay 8. Bat...

  • Page 182

    3-98 fuel system (dfi) fi indicator light (led) inspection flow chart.

  • Page 183

    Fuel system (dfi) 3-99 fi indicator light (led) light (led) inspection ○ the fi indicator light (led) [a] goes on when the ignition switch is turned on and the led light goes off when the engine oil pressure is high enough (the engine is running). This is to ensure that the fi indicator light (led) ...

  • Page 184

    3-100 fuel system (dfi) fi indicator light (led) fi indicator light (led) circuit (without oxygen sensor equipped models) (vn900c7 ∼ c8) fi indicator light (led) circuit (oxygen sensor equipped models) (vn900c7 ∼ c8) 1. Ecu 2. Ignition switch 3. Meter unit 4. Fi indicator light (led) 5. Main fuse 30...

  • Page 185

    Fuel system (dfi) 3-101 fi indicator light (led) fi indicator light (led) circuit (without oxygen sensor equipped models) (vn900c9 ∼ ) fi indicator light (led) circuit (oxygen sensor equipped models) (vn900c9 ∼ ) 1. Ecu 2. Ignition switch 3. Meter unit 4. Fi indicator light (led) 5. Main fuse 30 a 6...

  • Page 186

    3-102 fuel system (dfi) ecu ecu removal notice never drop the ecu, especially on a hard surface. Such a shock to the ecu can damage it. • remove: seat (see seat removal in the frame chapter) tool box (see tool box removal in the frame chapter) • pull out the ecu [a] along with the harness. If necess...

  • Page 187

    Fuel system (dfi) 3-103 ecu • check the ecu power source voltage with a digital meter. ○ position the terminal in accordance with terminal numbers of ecu connectors as shown in the figure. Ecu power source inspection meter connections: (without oxygen sensor equipped models [a]) between terminal 12 ...

  • Page 188

    3-104 fuel system (dfi) fuel line fuel pressure inspection note ○ this inspection can determine which trouble the dfi system has, mechanical or electrical trouble. ○ it is preferable to measure the fuel pressure while run- ning the motorcycle when the trouble has occurred in order to know symptom we...

  • Page 189

    Fuel system (dfi) 3-105 fuel line • start the engine, and let it idle. • measure the fuel pressure with the engine idling. Fuel pressure (idling) standard: 294 kpa (3.0 kgf/cm², 43 psi) note ○ the gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications. I...

  • Page 190

    3-106 fuel system (dfi) fuel line • prepare a fuel hose of the inside diameter 7.5 mm (0.30 in.) and a measuring cylinder. • remove: seat (see seat removal in the frame chapter) fuel tank bolts (see fuel tank removal) • raise the fuel tank. • stuff a clean shop towel around the fuel outlet hose join...

  • Page 191

    Fuel system (dfi) 3-107 fuel pump fuel pump removal notice never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. Warning gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns. Make sure th...

  • Page 192

    3-108 fuel system (dfi) fuel pump • check that the terminals [a] and band [b] are in place. • apply a non-permanent locking agent to the threads of the fuel pump bolts. • tighten the fuel pump bolts [c] to a snug fit. • tighten: torque - fuel pump bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) pump screen, fu...

  • Page 193

    Fuel system (dfi) 3-109 fuel pump fuel pump operating voltage inspection note ○ be sure the battery is fully charged. • turn the ignition switch off. • remove the ignition coil cover (see ignition coil removal in the electrical system chapter). • connect a tester to the fuel pump connector [a] with ...

  • Page 194

    3-110 fuel system (dfi) fuel pump fuel pump power source voltage inspection note ○ be sure the battery is fully charged. • remove the ignition coil cover (see ignition coil removal in the electrical system chapter). • connect a digital meter [a] to the fuel pump connector [b] (3p), using the needle ...

  • Page 195

    Fuel system (dfi) 3-111 fuel pump fuel pump circuit (without oxygen sensor equipped models) (vn900c7 ∼ c8) 1. Ecu 2. Engine stop switch 3. Ignition switch 4. Ignition fuse 10 a 5. Ecu fuse 15 a 6. Fuse box 7. Ecu main relay 8. Fuel pump relay 9. Relay box 10. Main fuse 30 a 11. Starter relay 12. Bat...

  • Page 196

    3-112 fuel system (dfi) fuel pump fuel pump circuit (oxygen sensor equipped models) (vn900c7 ∼ c8) 1. Ecu 2. Engine stop switch 3. Ignition switch 4. Ignition fuse 10 a 5. Ecu fuse 15 a 6. Fuse box 7. Ecu main relay 8. Fuel pump relay 9. Relay box 10. Main fuse 30 a 11. Starter relay 12. Battery 13....

  • Page 197

    Fuel system (dfi) 3-113 fuel pump fuel pump circuit (without oxygen sensor equipped models) (vn900c9 ∼ ) 1. Ecu 2. Engine stop switch 3. Ignition switch 4. Ignition fuse 10 a 5. Ecu fuse 15 a 6. Fuse box 7. Ecu main relay 8. Fuel pump relay 9. Relay box 10. Main fuse 30 a 11. Starter relay 12. Batte...

  • Page 198

    3-114 fuel system (dfi) fuel pump fuel pump circuit (oxygen sensor equipped models) (vn900c9 ∼ ) 1. Ecu 2. Engine stop switch 3. Ignition switch 4. Ignition fuse 10 a 5. Ecu fuse 15 a 6. Fuse box 7. Ecu main relay 8. Fuel pump relay 9. Relay box 10. Main fuse 30 a 11. Starter relay 12. Battery 13. J...

  • Page 199

    Fuel system (dfi) 3-115 fuel injectors notice never drop the injector, especially on a hard sur- face. Such a shock to the injector can damage it. Fuel injector removal warning gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns. ...

  • Page 200

    3-116 fuel system (dfi) fuel injectors • unscrew the delivery joint bolts [a], and lift up the delivery joint [b] with the injectors [c]. • remove the injectors from the delivery joint. Fuel injector installation ○ the front and rear injectors are the same. • replace the seal [a] and o-ring [b] with...

  • Page 201

    Fuel system (dfi) 3-117 fuel injectors fuel injector fuel line inspection • remove: fuel tank (see fuel tank removal) fuel hose (see fuel hose replacement in the periodic maintenance chapter) • check the injector fuel line for leakage as follows. ○ connect a commercially available vacuum/pressure pu...

  • Page 202

    3-118 fuel system (dfi) fuel injectors fuel injector audible inspection • start the engine. • insert a screwdriver from the engine right side between the fuel tank bottom end and the engine top end. • apply the tip of a screwdriver [a] to the injector [b]. Put the grip end onto your ear, and listen ...

  • Page 203

    Fuel system (dfi) 3-119 fuel injectors fuel injector output voltage inspection • turn the ignition switch off. • remove the ecu (see ecu removal). Do not disconnect the ecu connector. • connect a digital voltmeter to the connector, using the needle adapter set. Special tool - needle adapter set: 570...

  • Page 204

    3-120 fuel system (dfi) fuel injectors if the output voltage is normal, perform the "fuel injector signal test". If the output voltage is out of the standard, turn the ignition switch off, remove the fuel tank, and check the injector wiring for continuity. Injector wiring inspection (without oxygen ...

  • Page 205

    Fuel system (dfi) 3-121 fuel injectors ○ fuel injector signals can be also confirmed by connect- ing the tester instead of the test light set to the fuel injec- tor main harness connector. Crank the engine with the starter motor, and check to see if the needle oscillates at regular intervals. If the...

  • Page 206

    3-122 fuel system (dfi) fuel injectors fuel injector circuit (without oxygen sensor equipped models) (vn900c7 ∼ c8) 1. Ecu 2. Engine stop switch 3. Ignition switch 4. Ignition fuse 10 a 5. Ecu fuse 15 a 6. Fuse box 7. Ecu main relay 8. Fuel pump relay 9. Relay box 10. Main fuse 30 a 11. Starter rela...

  • Page 207

    Fuel system (dfi) 3-123 fuel injectors fuel injector circuit (oxygen sensor equipped models) (vn900c7 ∼ c8) 1. Ecu 2. Engine stop switch 3. Ignition switch 4. Ignition fuse 10 a 5. Ecu fuse 15 a 6. Fuse box 7. Ecu main relay 8. Fuel pump relay 9. Relay box 10. Main fuse 30 a 11. Starter relay 12. Ba...

  • Page 208

    3-124 fuel system (dfi) fuel injectors fuel injector circuit (without oxygen sensor equipped models) (vn900c9 ∼ ) 1. Ecu 2. Engine stop switch 3. Ignition switch 4. Ignition fuse 10 a 5. Ecu fuse 15 a 6. Fuse box 7. Ecu main relay 8. Fuel pump relay 9. Relay box 10. Main fuse 30 a 11. Starter relay ...

  • Page 209

    Fuel system (dfi) 3-125 fuel injectors fuel injector circuit (oxygen sensor equipped models) (vn900c9 ∼ ) 1. Ecu 2. Engine stop switch 3. Ignition switch 4. Ignition fuse 10 a 5. Ecu fuse 15 a 6. Fuse box 7. Ecu main relay 8. Fuel pump relay 9. Relay box 10. Main fuse 30 a 11. Starter relay 12. Batt...

  • Page 210

    3-126 fuel system (dfi) throttle grip and cables throttle grip free play inspection • refer to the throttle control system inspection in the pe- riodic maintenance chapter. Throttle grip free play adjustment • refer to the throttle control system inspection in the pe- riodic maintenance chapter. Cab...

  • Page 211

    Fuel system (dfi) 3-127 throttle body assy idle speed inspection • refer to the idle speed inspection in the periodic main- tenance chapter. Idle speed adjustment • refer to the idle speed adjustment in the periodic main- tenance chapter. Throttle bore cleaning • check the throttle bore for cleanlin...

  • Page 212

    3-128 fuel system (dfi) throttle body assy • remove the screws and take off the right switch housing. • remove the accelerator cable end [a] and decelerator cable end [b] at the throttle grip. • disconnect the fuel injector connectors [a]. • unscrew the bolts [b] and remove the throttle body assy [c...

  • Page 213

    Fuel system (dfi) 3-129 throttle body assy ○ be careful not to damage (dent, nick, flaw, and crack) the flange mating surface and the plastic parts. ○ do not drop the throttle body assy, especially on a hard surface. Warning impacts can cause the throttle to stick, resulting in an accident causing s...

  • Page 214

    3-130 fuel system (dfi) throttle body assy • open the butterfly valves [a], and wipe any carbon off the throttle bores [b] around the valves, using a piece of lint-free cloth penetrated with a high flash-point solvent. • clean the bores [c] of the inlet manifold [d] as well. • blow away dirt or dust...

  • Page 215

    Fuel system (dfi) 3-131 throttle body assy • stake the cable clip [a] on the throttle cable holder [b]. • apply a thin coating of grease to the throttle cable upper ends. • install the upper ends of the throttle cables to the throttle grip. • fit the projection [a] of the right switch housing into t...

  • Page 216

    3-132 fuel system (dfi) air cleaner air cleaner element removal/installation • refer to the air cleaner element replacement in the pe- riodic maintenance chapter. Air cleaner housing removal • remove the air cleaner housing bolts [a]. • clear the idle speed screw [a] from the recess on the air clean...

  • Page 217

    Fuel system (dfi) 3-133 air cleaner • fit the adjusting screw [a] in the recess on the air cleaner housing. • be sure the dampers [a] and collars [b] are in position. ○ install the damper into the air cleaner housing [c] as shown in the figure. Smaller diameter [d] larger diameter [e] torque - air c...

  • Page 218

    3-134 fuel system (dfi) fuel tank fuel tank removal warning gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a...

  • Page 219

    Fuel system (dfi) 3-135 fuel tank • remove: seat (see seat removal in the frame chapter) fuel tank bolts [a] • disconnect: fuel return hose (red) [a] (cal, th and sea-b1 mod- els) • unscrew the screw [a], and pull out the ignition coil cover [b]. • disconnect the fuel pump connector [a]. • be sure t...

  • Page 220

    3-136 fuel system (dfi) fuel tank when removing with standard tip screwdriver • insert the standard tip screwdriver [a] into the slit on the joint lock [b]. • turn the driver to disconnect the joint lock. When removing with fingers • open and push up [c] the joint lock with your fingers. Notice pryi...

  • Page 221

    Fuel system (dfi) 3-137 fuel tank • for cal, th and sea-b1 models, note the following. Notice for cal, th and sea-b1 models, if gasoline, sol- vent, water or any other liquid enters the canister, the canister’s vapor absorbing capacity is greatly reduced. If the canister does become contami- nated, ...

  • Page 222

    3-138 fuel system (dfi) fuel tank • check that the rubber dampers [a] are in place. If the dampers are damaged or deteriorated, replace them. • remove the vinyl bag on the pipe and fuel hose joint. • check the joint lock for deformation and wear. If the joint lock is deformed, replace the fuel hose ...

  • Page 223

    Fuel system (dfi) 3-139 fuel tank fuel tank and cap inspection • visually inspect the gasket [a] on the tank cap for any damage. Replace the gasket if it is damaged. • check to see if the breather pipe [b] (cal, th and sea -b1 models) in the tank is not clogged. If the breather pipe is clogged, blow...

  • Page 224

    3-140 fuel system (dfi) evaporative emission control system (cal, th and sea-b1 models) the evaporative emission control system routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a t...

  • Page 225

    Fuel system (dfi) 3-141 evaporative emission control system (cal, th and sea-b1 models) separator operation test 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 a...

  • Page 226

    3-142 fuel system (dfi) evaporative emission control system (cal, th and sea-b1 models) 1. Fuel tank 2. Throttle body assy 3. Canister 4. Separator 5. Breather check valve 6. Breather hose 7. Breather hose (blue) 8. Vacuum hose (white) 9. Fuel return hose (red) 10. Purge hose (green) 11. To air swit...

  • Page 227: Cooling System

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

  • Page 228

    4-2 cooling system exploded view.

  • Page 229

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 coolant drain bolt 9.8 1.0 87 in·lb 2 radiator bolts 6.9 0.70 61 in·lb 3 radiator fan bolts 8.3 0.85 73 in·lb 4 radiator hose clamp screws 2.0 0.20 18 in·lb 5 radiator screen screws 6.9 0.70 61 in·lb 6 reserve tank bolts ...

  • Page 230

    4-4 cooling system coolant flow chart.

  • Page 231

    Cooling system 4-5 coolant flow chart 1. Thermostat 2. Radiator cap 3. Cylinder head jacket 4. Radiator fan 5. Radiator 6. Cylinder jacket 7. Water pump 8. Reserve tank 9. Hot coolant 10. Cold coolant permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosio...

  • Page 232

    4-6 cooling system specifications item standard coolant provided when shipping type (recommended) permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) color green mixed ratio soft water 50%, coolant 50% freezing ...

  • Page 233

    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 234

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

  • Page 235

    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 236

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

  • Page 237

    Cooling system 4-11 water pump if the seal and ball bearing are damaged, replace the me- chanical seal, ball bearing and oil seal by splitting the crankcase. • split the crankcase (see crankcase splitting in the crank- shaft/transmission chapter). • take the bearing [a] out of the right crankcase, u...

  • Page 238

    4-12 cooling system water pump water pump inspection • check the drainage outlet passage [a] at the bottom of the right crankcase for coolant leaks. • if a coolant leak or ooze is found, start the engine and check if the coolant leaks continuously. ○ when coolant does not continuously leak, it is no...

  • Page 239

    Cooling system 4-13 radiator, radiator fan radiator and radiator fan removal warning a spinning radiator fan can cause serious injury. The radiator fan is connected directly to the battery and may start even if the ignition switch is off. Do not touch the radiator fan until it has been discon- necte...

  • Page 240

    4-14 cooling system radiator, radiator fan • remove: radiator fan connector [a] radiator • remove: radiator fan bolts [a] radiator fan [b] notice do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling effi- ciency. Radiator fan installation • tighten the ra...

  • Page 241

    Cooling system 4-15 radiator, radiator fan radiator cap inspection • remove the radiator cap (see coolant change in the pe- riodic maintenance chapter). • check the condition of the bottom [a] and top [b] valve seals and valve spring [c]. If any one of them shows visible damage, replace the cap with...

  • Page 242

    4-16 cooling system thermostat thermostat removal • drain the coolant (about 200 ml) (see coolant change in the periodic maintenance chapter). • remove: seat (see seat removal in the frame chapter) fuel tank (see fuel tank removal in the fuel system (dfi) chapter) • disconnect the reserve tank hose ...

  • Page 243

    Cooling system 4-17 thermostat • to check valve opening temperature, suspend the ther- mostat [a] in a container of water and raise the tempera- ture of the water. ○ the thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an ac- curate thermometer [b] in...

  • Page 244

    4-18 cooling system hose and pipes hose installation • install the hoses and pipes being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • run the hoses (see cable, wire, and hose routing sec- tion in the appendix chapter). • install the clamp [a] as near...

  • Page 245

    Cooling system 4-19 water temperature sensor notice the water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to the water temperature sensor can damage it. Water temperature sensor removal/installation • refer to the water temperature sensor removal/instal- lati...

  • Page 247: 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 .................................... 5-9 special tools ..................................... 5-11 clean air system.....................

  • Page 248

    5-2 engine top end exploded view.

  • Page 249

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 camshaft cap bolts 25 2.5 18 2 cylinder head cover bolts 12 1.2 106 in·lb cylinder head nuts (m10) (first) 20 2.0 15 mo, s 3 cylinder head nuts (m10) (final) 49 5.0 36 mo, s 4 cylinder head nuts (m8) 25 2.5 18 s 5 cylinde...

  • Page 250

    5-4 engine top end exploded view.

  • Page 251

    Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 camshaft chain guide bolts 9.8 1.0 87 in·lb l 2 camshaft chain tensioner cap bolts 20 2.0 15 3 camshaft sprocket bolts 49 5.0 36 l 4 exhaust pipe cover bolts 6.9 0.70 61 in·lb 5 exhaust pipe cover clamp bolts 6.9 0.70 61 ...

  • Page 252

    5-6 engine top end exhaust system identification exhaust system manifold muffler body specification model honeycomb type catalyst u.S.A vn900c7 ∼ c8 u.S.A (california) vn900c7 p/no. 18087-0116 p/no. 18087-0123 mark: – canada vn900c7 ∼ c8 honeycomb type catalyst u.S.A vn900c9 ∼ cb u.S.A (california) ...

  • Page 253

    Engine top end 5-7 exhaust system identification honeycomb type catalyst australia vn900cc ∼ p/no. 18087-0283 p/no. 18087-0284 mark: khi 540 s.E.Asia-b1 wvta (full h) gb wvta (full h) brazil vn900cc ∼ vn900ce vn900ce vn900ce ∼ honeycomb type catalyst p/no. 18087-0292 p/no. 18087-0293 mark: khi k 540...

  • Page 254

    5-8 engine top end exhaust system identification muffler mark position [a] honeycomb type catalyst position [b] muffler with boss [a] for oxygen sensor (oxygen sensor equipped models and au model [vn900c9 ∼ ]).

  • Page 255

    Engine top end 5-9 specifications item standard service limit camshafts cam height: exhaust 35.030 ∼ 35.144 mm (1.3791 ∼ 1.3836 in.) 34.93 mm (1.375 in.) inlet 35.302 ∼ 35.416 mm (1.3898 ∼ 1.3943 in.) 35.20 mm (1.386 in.) camshaft journal, camshaft cap clearance 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in....

  • Page 256

    5-10 engine top end specifications item standard service limit outside diameter: exhaust 26.9 ∼ 27.1 mm (1.059 ∼ 1.067 in.) – – – inlet 30.9 ∼ 31.1 mm (1.216 ∼ 1.224 in.) – – – valve spring free length: exhaust 40.5 mm (1.59 in.) 38.6 mm (1.52 in.) inlet 40.5 mm (1.59 in.) 38.6 mm (1.52 in.) cylinde...

  • Page 257

    Engine top end 5-11 special tools compression gauge, 20 kgf/cm²: 57001-221 valve spring compressor assembly: 57001-241 piston pin puller assembly: 57001-910 piston ring compressor grip: 57001-1095 valve seat cutter, 45° - 32: 57001-1115 valve seat cutter, 32° - 28: 57001-1119 valve seat cutter, 60° ...

  • Page 258

    5-12 engine top end special tools valve spring compressor adapter, 22: 57001-1202 valve guide arbor, 5: 57001-1203 valve guide reamer, 5: 57001-1204 valve seat cutter holder, 5: 57001-1208 spark plug wrench, hex 16: 57001-1262 compression gauge adapter, m10 × 1.0: 57001-1317 piston ring compressor b...

  • Page 259

    Engine top end 5-13 special tools note ○ the following valve seat cutters can be used instead of the above tools. Exhaust valve seat: valve seat cutter, 45° - 32: 57001-1115 (instead of valve seat cutter: 45° - 30: 57001-1187) valve seat cutter, 32° - 30: 57001-1120 (instead of valve seat cutter: 32...

  • Page 260

    5-14 engine top end clean air system air suction valve removal • remove: cylinder head covers (see cylinder head cover re- moval) air suction valves [a] air suction valve installation • install each air suction valve so that stopper side [a] of the reed faces downward. Air suction valve inspection •...

  • Page 261

    Engine top end 5-15 clean air system clean air system hose inspection • be certain that all the hoses are routed without being flat- tened or kinked, and are connected correctly to the air cleaner housing, air switching valve, and fittings on the cylinder head covers. If they are not, correct them. ...

  • Page 262

    5-16 engine top end cylinder head covers cylinder head cover removal • remove: seat (see seat removal in the frame chapter) fuel tank (see fuel tank removal in the fuel system (dfi) chapter) • slide [a] the air switching valve [b] forward to clear the clamp. • remove: bolt [a] clamp [b] • remove the...

  • Page 263

    Engine top end 5-17 cylinder head covers ○ move the obstruct parts between the cylinder head cover and frame for the cylinder head removal, if necessary. Then lift the cover upward, make sure the spark plug pipe [a] stays in the cylinder head. If the pipe comes up with the cover, reinstall it in the...

  • Page 264

    5-18 engine top end camshaft chain tensioners camshaft chain tensioner removal • remove: engine (see engine removal in the engine removal/in- stallation chapter) camshaft (see camshaft removal) cylinder head (see cylinder head removal) • remove the camshaft chain tensioner body from the cylinder. Ca...

  • Page 265

    Engine top end 5-19 camshafts, camshaft chains camshaft removal • remove: cylinder head cover (see cylinder head cover re- moval) ignition coil cover (for front cylinder) (see ignition coil removal in the electrical system chapter) tensioner cap bolt [a], washer [b] and spring notice do not turn ove...

  • Page 266

    5-20 engine top end camshafts, camshaft chains camshaft installation • apply molybdenum disulfide oil solution to all cam parts and journals. Note ○ the front and rear camshafts are different. The rear camshaft [a] has a groove [b]. • remove: alternator outer cover (see alternator outer cover re- mo...

  • Page 267

    Engine top end 5-21 camshafts, camshaft chains note ○ installing the rear camshaft is the same as for the front camshaft. But noting the following. • set the rear piston at tdc. ○ align the rear piston tdc mark [a] and timing mark [b] by turning the crankshaft counterclockwise [c] 305° (left side vi...

  • Page 268

    5-22 engine top end camshafts, camshaft chains camshaft runout inspection • remove the camshaft (see camshaft removal). • set the camshaft in a camshaft alignment jig or on v blocks. • measure runout with a dial gauge at the specified place as shown in the figure. If the runout exceeds the service l...

  • Page 269

    Engine top end 5-23 camshafts, camshaft chains camshaft and sprocket assembly • clean the sprocket bolt [a] and threads of the camshaft. • be sure to install the pin [b]. • apply a non-permanent locking agent to the threads of the camshaft sprocket bolt, and tighten it. The sprockets are identical. ...

  • Page 270

    5-24 engine top end rocker shafts, rocker arms rocker shaft, rocker arm removal • remove: cylinder head cover (see cylinder head cover re- moval) camshaft cap (see camshaft removal) rocker shafts [a] rocker arms [b] and springs [c] rocker shaft, rocker arm installation • apply molybdenum disulfide g...

  • Page 271

    Engine top end 5-25 cylinder heads cylinder compression measurement note ○ use the battery which is fully charged. • warm up the engine thoroughly. • stop the engine. • remove: seat (see seat removal in the frame chapter) fuel tank (see fuel tank removal in the fuel system (dfi) chapter) spark plugs...

  • Page 272

    5-26 engine top end cylinder heads cylinder head removal • remove: engine (see engine removal in the engine removal/in- stallation chapter) camshaft (see camshaft removal) • remove the cylinder head nuts following sequence [1 ∼ 6]. • remove the cylinder head. Cylinder head installation note ○ the ca...

  • Page 273

    Engine top end 5-27 valves valve clearance inspection • refer to the valve clearance inspection in the periodic maintenance chapter. Valve clearance adjustment • refer to the valve clearance adjustment in the periodic maintenance chapter. Valve removal • remove the cylinder head (see cylinder head r...

  • Page 274

    5-28 engine top end valves valve guide installation • apply oil to the valve guide outer surface before installa- tion. • heat the area around the valve guide hole to about 120 ∼ 150°c (248 ∼ 302°f). • drive the valve guide in from the top of the head using the valve guide arbor [a]. The flange stop...

  • Page 275

    Engine top end 5-29 valves valve seat inspection • remove the valve (see valve removal). • check the valve seating surface [a] between the valve [b] and valve seat [c]. ○ measure the outside diameter [d] of the seating pattern on the valve seat. If the outside diameter is too large or too small, rep...

  • Page 276

    5-30 engine top end valves seat cutter operation care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off. 3. Do not fai...

  • Page 277

    Engine top end 5-31 valves • measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind [a] until the diameter is within the specified range. Original seating surface [b] note ○ remove all pittings of ...

  • Page 278

    5-32 engine top end valves • lap the valve to the seat, once the seat width and outside diameter are within the ranges specified above. ○ put a little coarse grinding compound on the face of the valve in a number of places around the valve head. ○ spin the valve against the seat until the grinding c...

  • Page 279

    Engine top end 5-33 valves.

  • Page 280

    5-34 engine top end cylinders, pistons cylinder removal • remove: engine (see engine removal in the engine removal/in- stallation chapter) cylinder head (see cylinder head removal) • pull out the front camshaft chain guide [a] and oil pipe [b]. • tap lightly up the cylinder with a plastic mallet to ...

  • Page 281

    Engine top end 5-35 cylinders, pistons • do not mix up the top ring and second ring. • install the top ring [a] so that the " r " mark [b] faces up. • install the second ring [c] so that the " rn " mark [d] faces up. • the piston ring openings must be positioned as shown in the figure. The openings ...

  • Page 282

    5-36 engine top end cylinders, pistons note ○ if a new piston or cylinder is used, check piston to cylin- der clearance (see piston/cylinder clearance), and use new piston ring. • replace the cylinder base gasket with a new one. • be sure to install the dowel pins [a]. • install the front cylinder i...

  • Page 283

    Engine top end 5-37 cylinders, pistons piston ring, piston ring groove wear inspection • check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. • with the piston rings in their gr...

  • Page 284

    5-38 engine top end cylinders, pistons piston ring end gap inspection • place the piston ring [a] inside the cylinder, using the pis- ton to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. • measure the gap [b] between the ends of the ring w...

  • Page 285

    Engine top end 5-39 mufflers muffler removal warning the muffler can become extremely hot during nor- mal operation and cause severe burns. Do not re- move the muffler while it is hot. • remove: clamp bolts (loosen) [a] bolt [b] rear muffler cover [c] • remove: clamp bolts (loosen) [a] bolt [b] fron...

  • Page 286

    5-40 engine top end mufflers • remove the rear exhaust pipe holder nuts [a]. • remove the rear and front muffler jointed. Muffler installation • joint the rear and front muffler. • temporary tighten the muffler joint clamp bolt [a]. • install the mufflers. • tighten: torque - muffler mounting nut: 2...

  • Page 287: Clutch

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

  • Page 288

    6-2 clutch exploded view.

  • Page 289

    Clutch 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 clutch hub nut 130 13.3 96 mo, r 2 clutch spring bolts 9.8 1.0 87 in·lb 3 right engine cover bolts 9.8 1.0 87 in·lb l (1) cl: apply cable lubricant. Eo: apply engine oil. G: apply grease. L: apply a non-permanent locking agent. M...

  • Page 290

    6-4 clutch specifications item standard service limit clutch lever free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – clutch friction plate thickness: 2.9 ∼ 3.1 mm (0.1141 ∼ 0.1220 in.) 2.8 mm (0.110 in.) friction and steel plate warp 0.2 mm (0.008 in.) or less 0.3 mm (0.012 in.) clutch spring free length 3...

  • Page 291

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

  • Page 292

    6-6 clutch clutch lever and cable clutch lever free play inspection • refer to the clutch operation inspection in the periodic maintenance chapter. Clutch lever free play adjustment • refer to the clutch operation inspection in the periodic maintenance chapter. Clutch cable removal • remove the muff...

  • Page 293

    Clutch 6-7 clutch lever and cable clutch lever holder installation • install the clutch lever holder so that the mating surface [a] of the lever holder is aligned with the punch mark [b] of the handlebar. Clutch lever installation warning if the pin of the starter lockout switch has been broken, the...

  • Page 294

    6-8 clutch clutch lever and cable • tighten the bolt [a] and locknut [b]. • install the upper end of the clutch cable (see clutch cable installation). • adjust the clutch cable (see clutch operation inspection in the periodic maintenance chapter). • check that the pin [c] of the starter lockout swit...

  • Page 295

    Clutch 6-9 right engine cover right engine 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: brake pedal (see brake pedal removal in the brakes chapter) right footpeg (see footp...

  • Page 296

    6-10 clutch right engine cover release shaft removal notice do not remove the clutch release lever and shaft assembly unless it is absolutely necessary. If re- moved, the oil seal replacement may be required. • remove the right engine cover (see right engine cover removal). • remove the circlip [a] ...

  • Page 297

    Clutch 6-11 clutch clutch removal • remove: right engine cover (see right engine cover removal) clutch spring bolts [a] clutch springs clutch spring plate [b] (with thrust bearing and pusher [c]) • remove: friction plates and steel plates clutch hub nut [a] ○ holding the clutch hub [b], remove the n...

  • Page 298

    6-12 clutch clutch • install the washer so that the outside mark [a] faces outward. • replace the clutch hub nut with a new one. • apply molybdenum disulfide oil solution to seating surface of the hub nut. • holding the clutch hub, tighten the clutch hub nut. Special tool - clutch holder: 57001-1243...

  • Page 299

    Clutch 6-13 clutch clutch plate warp inspection • place each friction plate or steel plate on a surface plate and measure the gap between the surface plate [a] and each friction plate or steel plate [b] with a thickness gauge [c]. The gap is the amount of friction or steel plate warp. If any plate i...

  • Page 301: Engine Lubrication System

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

  • Page 302

    7-2 engine lubrication system exploded view.

  • Page 303

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine oil drain plug 20 2.0 15 2 oil filter 18 1.8 13 3 oil filter plate bolts 7.8 0.80 69 in·lb 4 oil pipe bolts (crankcase inside) 9.8 1.0 87 in·lb l 5 oil pipe bolts (crankcase outside) 9.8 1.0 87 in·lb l 6...

  • Page 304

    7-4 engine lubrication system engine oil flow chart 1. Rocker arms 2. Oil pipes 3. Output shaft 4. Drive shaft 5. Oil screen 6. Oil pump 7. Crankshaft 8. Oil pressure switch 9. Oil filter 10. Oil pressure relief valve.

  • Page 305

    Engine lubrication system 7-5 specifications item standard engine oil type api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 viscosity sae 10w-40 capacity 3.0 l (3.2 us qt) (when filter is not removed) 3.2 l (3.4 us qt) (when filter is removed) 3.7 l (3.9 us qt) (when engine is completely dry) level...

  • Page 306

    7-6 engine lubrication system special tools and sealant oil pressure gauge, 10 kgf/cm²: 57001-164 oil pressure gauge adapter, m10 × 1.25: 57001-1182 oil filter wrench: 57001-1249 liquid gasket, tb1211: 56019-120

  • Page 307

    Engine lubrication system 7-7 engine oil and oil filter warning vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Check the oil level before each use and change the oil and filter accordin...

  • Page 308

    7-8 engine lubrication system engine oil and oil filter oil screen cleaning • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove the oil screen plug [a], spring and washer. • pull out the oil screen [a]. • clean the screen with high flash-point solvent. Warn...

  • Page 309

    Engine lubrication system 7-9 oil pressure relief valve oil pressure relief valve removal/installation • split the crankcase (see crankcase splitting in the crank- shaft/transmission chapter). • remove the relief valve [a] from the right crankcase. • apply a non-permanent locking agent to the thread...

  • Page 310

    7-10 engine lubrication system oil pump, oil pump drive chain oil pump removal • split the crankcase (see crankcase splitting in the crank- shaft/transmission chapter). • remove: crankshaft (see crankshaft removal in the crank- shaft/transmission chapter) oil pipes (see oil pipe (crankcase inside) r...

  • Page 311

    Engine lubrication system 7-11 oil pump, oil pump drive chain oil pump drive chain guide installation • install the chain guide [a] to the left crankcase. • apply a non-permanent locking agent to the threads of the chain guide bolt [b], and tighten it. Torque - oil pump drive chain guide bolt: 9.8 n...

  • Page 312

    7-12 engine lubrication system oil pressure measurement oil pressure measurement • remove the regulator/rectifier (see regulator/rectifier removal in the electrical system chapter). • remove the oil pressure switch together with the adapter (see oil pressure switch removal) without draining the engi...

  • Page 313

    Engine lubrication system 7-13 oil pressure switch oil pressure switch removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: switch cover [a] switch terminal bolt [b] oil pressure switch [c] oil pressure switch installation • apply silicone sealant t...

  • Page 314

    7-14 engine lubrication system oil pipe and oil hose oil pipe (crankcase outside) removal • remove: alternator cover (see alternator cover removal in the electrical system chapter) oil pipe bolts [a] oil pipe [b] oil pipe (crankcase outside) installation • apply grease to the o-rings [a]. • plug the...

  • Page 315

    Engine lubrication system 7-15 oil pipe and oil hose • install the oil return pipe [a]. • tighten: torque - oil return pipe bolts [b]: 9.8 n·m (1.0 kgf·m, 87 in·lb) blowby gas system inspection • remove the ignition coil with the bracket (see ignition coil removal in the electrical system chapter). ...

  • Page 317: Engine Removal/installation

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

  • Page 318

    8-2 engine removal/installation exploded view.

  • Page 319

    Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 downtube bolts 44 4.5 32 2 engine mounting nuts 59 6.0 44 r 3 engine mounting bracket bolts (m10) 44 4.5 32 4 engine mounting bracket bolts (m8) 25 2.5 18 5. Vn900c7 ∼ c9 models wl: apply a soap and water sol...

  • Page 320

    8-4 engine removal/installation special tool jack: 57001-1238.

  • Page 321

    Engine removal/installation 8-5 engine removal/installation engine 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: seat (see seat removal in the frame chapter) fuel tank (see fuel t...

  • Page 322

    8-6 engine removal/installation engine removal/installation • disconnect the speed sensor lead connector [a]. • disconnect: water temperature sensor lead connector [a] water hoses [b] • remove the thermostat housing cover bracket bolt [c]. • remove: cap [a] and bolt ignition switch [b] • disconnect ...

  • Page 323

    Engine removal/installation 8-7 engine removal/installation • support the frame with the jack. Special tool - jack: 57001-1238 • squeeze the brake lever slowly and hold it with a band [a]. Warning motorcycle may fall over unexpectedly resulting in an accident or injury. Be sure to hold the front bra...

  • Page 324

    8-8 engine removal/installation engine removal/installation engine installation • when installing the rubber dampers into the bracket, lu- bricate the outer surface of the dampers with a soap and water solution. Notice do not lubricate the rubber damper with engine oil or petroleum distillates becau...

  • Page 325: Crankshaft/transmission

    Crankshaft/transmission 9-1 9 crankshaft/transmission table of contents exploded view........................................................................................................................ 9-2 specifications ..............................................................................

  • Page 326

    9-2 crankshaft/transmission exploded view.

  • Page 327

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 balancer gear bolt 69 7.0 51 2 balancer shaft bearing stopper plate screws 6.9 0.70 61 in·lb 3 bearing retainer bolts 9.8 1.0 87 in·lb l 4 clamp mounting bolts 9.8 1.0 87 in·lb 5 connecting rod big end bolts 46 4...

  • Page 328

    9-4 crankshaft/transmission exploded view.

  • Page 329

    Crankshaft/transmission 9-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 external shift mechanism cover bolts 9.8 1.0 87 in·lb 2 gear set lever bolt 9.8 1.0 87 in·lb 3 shift drum bearing stopper bolts 9.8 1.0 87 in·lb l 4 shift drum cam bolt 12 1.2 106 in·lb l 5 shift pedal bolt and n...

  • Page 330

    9-6 crankshaft/transmission specifications item standard service limit crankshaft, 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 clearance 0.08 ∼ 0.30 mm 0.5 mm (0.003 ∼ 0.012 in.) (0.0...

  • Page 331

    Crankshaft/transmission 9-7 specifications item standard service limit crankshaft runout tir 0.02 mm tir 0.05 mm (0.0008 in.) or less (0.002 in.) crankshaft main journal diameter 44.984 ∼ 45.000 mm 44.96 mm (1.7710 ∼ 1.7716 in.) (1.770 in.) crankcase main bearing bore diameter 45.025 ∼ 45.041 mm 45....

  • Page 332

    9-8 crankshaft/transmission special tools and sealants outside circlip pliers: 57001-144 bearing driver set: 57001-1129 grip: 57001-1591 rotor holder: 57001-1674 liquid gasket, tb1211f: 92104-0004 liquid gasket, tb1216b: 92104-1064.

  • Page 333

    Crankshaft/transmission 9-9 crankcase splitting crankcase splitting • remove: engine (see engine removal in the engine removal/in- stallation chapter) starter motor (see starter motor removal in the electri- cal system chapter) oil filter (see oil filter replacement in the periodic maintenance chapt...

  • Page 334

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

  • Page 335

    Crankshaft/transmission 9-11 crankcase splitting • apply liquid gasket [a] to the mating surface of the right crankcase half. Sealant - liquid gasket, tb1216b: 92104-1064 notice do not apply liquid gasket to the oil passage [b] and hole [c]. Note ○ make the application finish within 20 minutes when ...

  • Page 336

    9-12 crankshaft/transmission crankcase splitting • apply silicone sealant to the crankcase mating surface [a] as shown in the figure. Sealant - liquid gasket, tb1211f: 92104-0004.

  • Page 337

    Crankshaft/transmission 9-13 crankshaft, connecting rods crankshaft removal • split the crankcase (see crankcase splitting). • remove the crankshaft. Crankshaft installation • insert the crankshaft tapered end into the left crankcase [a]. • install the left connecting rod [b] into the rear cylinder ...

  • Page 338

    9-14 crankshaft/transmission crankshaft, connecting rods ○ when installing the inserts [a], be careful not to damage the insert surface with the edge of the connecting rod [b] or the cap [c]. One way to install inserts is as follows. Installation [d] to cap installation [e] to connecting rod push [f...

  • Page 339

    Crankshaft/transmission 9-15 crankshaft, connecting rods connecting rod bend • remove the connecting rod big end bearing inserts, and reinstall the connecting rod big end cap. • select an arbor [a] of the same diameter as the connect- ing rod big end, and insert the arbor through the connect- ing ro...

  • Page 340

    9-16 crankshaft/transmission crankshaft, connecting rods if clearance is within the standard, no bearing replace- ment is required. If clearance is between 0.054 mm (0.0021 in.) and the service limit (0.09 mm, 0.035 in.), replace the bear- ing inserts [a] with inserts painted blue [b]. Check insert/...

  • Page 341

    Crankshaft/transmission 9-17 crankshaft, connecting rods • select the proper bearing insert [a] in accordance with the combination of the connecting rod and crankshaft coding. Size color [b] connecting rod big end bearing insert selection bearing insert con-rod big end bore diameter marking crankpin...

  • Page 342

    9-18 crankshaft/transmission crankshaft, connecting rods crankshaft main bearing/main journal wear inspection • measure the diameter [a] of the crankshaft main journal. If any journal has worn past the service limit, replace the crankshaft with a new one. Crankshaft main journal diameter standard: 4...

  • Page 343

    Crankshaft/transmission 9-19 balancer, starter motor clutch left balancer removal • remove the alternator cover (see alternator cover re- moval in the electrical system chapter). • wipe oil off the outer circumference of the alternator rotor. • hold the alternator rotor steady with the rotor holder ...

  • Page 344

    9-20 crankshaft/transmission balancer, starter motor clutch • remove: starter motor clutch gear bolt [a] washers [b] • remove: starter motor clutch gear [a] torque limiter [b] needle bearing [c] collar [d] starter motor clutch assembly [e] washer if the assembly is hard to remove, use a suitable pul...

  • Page 345

    Crankshaft/transmission 9-21 balancer, starter motor clutch • install: torque limiter washer collar [a] and needle bearing [b] • install the starter motor clutch gear [c] while turning [d] the gear. • install the alternator rotor (see alternator rotor installa- tion in the electrical system chapter)...

  • Page 346

    9-22 crankshaft/transmission torque limiter torque limiter removal • remove: right engine cover (see right engine cover removal in the clutch chapter) washer [a] starter motor clutch gear [b] (see right balancer and starter motor clutch removal) torque limiter [c] notice do not disassemble the torqu...

  • Page 347

    Crankshaft/transmission 9-23 primary gear primary gear removal • remove the alternator cover (see alternator cover re- moval in the electrical system chapter). • wipe oil off the outer circumference of the alternator rotor. • hold the alternator rotor steady with the rotor holder [a]. ○ the rotor ho...

  • Page 348

    9-24 crankshaft/transmission transmission shift pedal removal • remove: alternator outer cover (see alternator outer cover re- moval in the electrical system chapter) shift pedal clamp bolt [a] • remove: nut [a], bolt and washer shift pedal [b] shift pedal installation • apply grease to the shift pe...

  • Page 349

    Crankshaft/transmission 9-25 transmission • loosen the locknuts [a] and turn the shift rod [b] so that the outside length [c] of the locknuts is 177 ±1 mm (6.97 ±0.04 in.) . ○ the rear locknut has left-hand threads. Torque - shift rod locknut (front): 9.8 n·m (1.0 kgf·m, 87 in·lb) shift rod locknut ...

  • Page 350

    9-26 crankshaft/transmission transmission • set the these cover bolts [a] to the cover before cover installed. • install the cover with the shaft to the crankcase. • tighten: torque - external shift mechanism cover bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) external shift mechanism inspection • examine th...

  • Page 351

    Crankshaft/transmission 9-27 transmission • install the shift drum [a]. • set the shift drum in the neutral position. • apply engine oil to the shift rod [b], and install it. Transmission shaft disassembly • remove the transmission shafts (see transmission shaft and shift fork removal). • remove the...

  • Page 352

    9-28 crankshaft/transmission transmission • replace any circlip that were removed with new ones. • install the circlips [a] so that the opening [b] is aligned with a spline groove [c]. • check that each gear springs or slides freely on the trans- mission shaft without binding after assembly..

  • Page 353

    Crankshaft/transmission 9-29 transmission 1. Drive shaft 2. Output shaft 3. 1st gear 4. 2nd gear 5. 3rd gear 6. 4th gear 7. 5th (top) gear 8. Circlip 9. Thrust washer (20 × 41 × 1) 10. Circlip 11. Thrust washer (25.3 × 30 × 1) 12. Circlip 13. Toothed washer 14. Thrust washer (30 × 38 × 1) 15. Thrust...

  • Page 354

    9-30 crankshaft/transmission transmission shift drum removal • remove: transmission shafts (see transmission shaft and shift fork removal) bolts [a] bearing stopper [b] • while aligning the shift drum cam with the left crankcase hole, pull out the shift drum [c]. Shift drum installation • while alig...

  • Page 355

    Crankshaft/transmission 9-31 transmission shift drum assembly • assemble: dowel pin (shorter) [a] shift drum holder [b] spring [c] circlip [d] special tool - outside circlip pliers: 57001-144 • assemble: dowel pin (longer) [e] bearing [f] shift drum cam [g] shift drum [h] • apply a non-permanent loc...

  • Page 356

    9-32 crankshaft/transmission transmission shift fork guide pin/drum groove wear inspection • measure the diameter of each shift fork guide pin [a], and measure the width [b] of each shift drum groove. If the guide pin on any shift fork is less than the service limit, the fork must be replaced. Shift...

  • Page 357

    Crankshaft/transmission 9-33 ball bearing and oil seal bearing and oil seal installation • when installing a bearing other than the following parts, press it in with the marked side facing out. Special tool - bearing driver set: 57001-1129 right crankcase • press the water pump shaft bearing and oil...

  • Page 359: Wheels/tires

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

  • Page 360

    10-2 wheels/tires exploded view.

  • Page 361

    Wheels/tires 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 air valve cap 0.15 0.015 1.3 in·lb 2 air valve core 0.3 0.03 2.7 in·lb 3 air valve nuts 1.5 0.15 13 in·lb 4 front axle clamp bolt 20 2.0 15 5 front axle nut 108 11.0 80 6 rear axle nut 108 11.0 80 7. Axle caps (eur, br and...

  • Page 362

    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.): front tir 0.05 mm (0.002 in.) or less tir 0.2 mm (0.008 in.) rear...

  • Page 363

    Wheels/tires 10-5 special tools bearing driver set: 57001-1129 jack: 57001-1238 bearing remover shaft, 9: 57001-1265 bearing remover head, 20 × 22: 57001-1293.

  • Page 364

    10-6 wheels/tires wheels (rims) front wheel removal • remove: front caliper mounting bolts [a] front caliper [b] • remove: axle caps (eur models) front axle clamp bolt [a] (loosen) front axle nut [b] • using the jack under the frame pipe, and a commercially available jack under the engine, raise the...

  • Page 365

    Wheels/tires 10-7 wheels (rims) front wheel installation • apply high-temperature grease to the grease seal lips. • fit the collars [a] on the both sides of the hub. ○ the collars are identical. • insert the axle from the right side of the wheel. • tighten: torque - front axle nut: 108 n·m (11.0 kgf...

  • Page 366

    10-8 wheels/tires wheels (rims) • squeeze the brake lever slowly and hold it with a band [a]. Notice be sure to hold the front brake when removing the rear wheel, or the motorcycle may fall over. The motorcycle could be damaged. Warning motorcycle may fall over unexpectedly resulting in an accident ...

  • Page 367

    Wheels/tires 10-9 wheels (rims) • incline the rear wheel to the right diagonally. • remove the drive belt [a] from the rear pulley [b]. • raise the jack until the wheel clear the rear fender to re- move the rear wheel [a]. Notice do not lay the wheel on the ground with the disc facing down. This can...

  • Page 368

    10-10 wheels/tires wheels (rims) • insert a new cotter pin [a]. Note ○ when inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [b] up to next alignment. ○ it should be within 30°. ○ loosen once and tighten again when the slo...

  • Page 369

    Wheels/tires 10-11 wheels (rims) wheel inspection • raise the front/rear wheel off the ground with jack. Special tool - jack: 57001-1238 • spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearings. • inspect the wheel for small cracks, den...

  • Page 370

    10-12 wheels/tires wheels (rims) balance inspection • remove the front and rear wheels (see front/rear wheel removal). • support the wheel so that it can be spun freely. • spin the wheel lightly, and mark [a] the wheel at the top when the wheel stops. ○ repeat this procedure several times. If the wh...

  • Page 371

    Wheels/tires 10-13 wheels (rims) (b) when the tire is on the rim. • pry [a] the balance weight off the rim flange using a stan- dard screwdriver as shown in the figure. ○ insert a tip of the screwdriver between the tire bead [b] and weight blade [c] until the end of the tip reaches the end of the we...

  • Page 372

    10-14 wheels/tires wheels (rims) • be sure to install the balance weight. ○ check that the blade [a] and clip [b] are fully seated on the rim [c] and that the clip is hooked over the rib [d]. Left side [e] right side [f] rear • check if the weight portion has any play on the blade-and -clip plate. I...

  • Page 373

    Wheels/tires 10-15 wheels (rims) • install the balance weight on the rim. ○ slip the weight on the rim flange [a] by pushing or lightly hammering [b] the weight in the direction shown in the figure. Tire bead [c] blade [d] • check that the blade [a] and weight [b] seat fully on the rim flange [c], a...

  • Page 374

    10-16 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 375

    Wheels/tires 10-17 tires • insert the new air valve in the front wheel rim. Valve cap [a] valve body [b] valve nuts [c] valve washer [d] rim [e] valve grommet [f] ○ remove the valve cap, valve nuts, valve washer and in- sert the valve stem through the rim from the inside out. • tighten: torque - air...

  • Page 376

    10-18 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 377

    Wheels/tires 10-19 hub bearing hub bearing removal • remove the wheel (see front/rear wheel removal), and take out the following. Front grease seals [a] rear coupling [a] collar [b] o-ring [c] grease seal [d] • take the bearings [a] out of the hub, using the bearing remover. Special tools - bearing ...

  • Page 378

    10-20 wheels/tires hub bearing • replace the grease seals with new ones. • press in the grease seal [a] so that the seal surface is flush [b] with the end of the hole. ○ apply high-temperature grease to the grease seal lips. Special tool - bearing driver set [c]: 57001-1129 hub bearing inspection si...

  • Page 379: Final Drive

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

  • Page 380

    11-2 final drive exploded view.

  • Page 381

    Final drive 11-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 drive belt guide bolts 9.8 1.0 87 in·lb 2 engine pulley cover bolts 9.8 1.0 87 in·lb 3 engine pulley cover clamp mounting bolt 9.8 1.0 87 in·lb 4 engine pulley mounting nut 127 13.0 94 m 5 engine pulley plate bolts 9.8 1.0 ...

  • Page 382

    11-4 final drive specifications item standard service limit drive belt make gates, 153t – – – belt deflection (45 n, 4.6 kgf, 10 lb force) 1.5 ∼ 4.0 mm (0.06 ∼ 0.16 in.) – – – (when installing new belt or engine is remounted) 1.5 mm (0.06 in.) – – –.

  • Page 383

    Final drive 11-5 special tools inside circlip pliers: 57001-143 oil seal & bearing remover: 57001-1058 bearing driver set: 57001-1129 pulley holder: 57001-1572 grip: 57001-1591.

  • Page 384

    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 385

    Final drive 11-7 drive belt • do not twist [a] the drive belt [b] as shown in the figure. ○ this includes coiling the belt to make it smaller for pack- aging. • do not use tools [a] to pry [b] the drive belt [c] onto the application. ○ bring the rear pulley [d] front side so that the belt can be eas...

  • Page 386

    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 387

    Final drive 11-9 pulley and coupling engine pulley cover removal • remove: alternator outer cover (see alternator outer cover re- moval in the electrical system chapter) bolt [a] clamp [b] bolts [c] engine pulley cover [d] engine pulley cover installation • install the drive belt guide [a]. • tighte...

  • Page 388

    11-10 final drive pulley and coupling • hold the engine pulley [a] steady with the pulley holder [b], and remove the pulley mounting nut [c]. Special tools - pulley holder: 57001-1572 grip: 57001-1591 • pull out the engine pulley from the output shaft. Engine pulley installation • installation is th...

  • Page 389

    Final drive 11-11 pulley and coupling rear pulley coupling removal • remove the rear wheel (see rear wheel removal in the wheels/tires chapter). • loosen the rear pulley mounting nuts [a] lightly. • remove the rear pulley [b] with the rear pulley coupling from the wheel [c]. • remove the rear pulley...

  • Page 390

    11-12 final drive pulley and coupling coupling bearing removal • remove: rear pulley coupling (see rear pulley coupling re- moval) sleeve [a] • remove: collar [a] grease seal [b] • remove the circlip [a]. Special tool - inside circlip pliers [b]: 57001-143 • remove the ball bearing [c]. Special tool...

  • Page 391

    Final drive 11-13 pulley and coupling coupling bearing inspection since the coupling bearing [a] is made to extremely close tolerances, the clearance cannot normally be measured. • spin it by hand to check its condition. If it is noisy, does not spin smoothly, or has any rough spots, it must be repl...

  • Page 392

    11-14 final drive belt adjuster belt adjuster removal • remove the left and right belt adjuster locknuts [a] and belt adjuster nuts [b]. • remove the belt adjuster [c] from the swingarm. Belt adjuster installation • insert the left and right belt adjuster [a] into the swingarm facing its machined su...

  • Page 393: Brakes

    Brakes 12-1 12 brakes table of contents exploded view........................................................................................................................ 12-2 specifications .............................................................................................................

  • Page 394

    12-2 brakes exploded view.

  • Page 395

    Brakes 12-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 bleed valve 7.8 0.80 69 in·lb 2 brake hose banjo bolts 25 2.5 18 3 brake lever pivot bolt 1.0 0.10 9 in·lb si 4 brake lever pivot bolt locknut 5.9 0.60 52 in·lb 5 front brake disc mounting bolts 27 2.8 20 l 6 front brake light s...

  • Page 396

    12-4 brakes exploded view.

  • Page 397

    Brakes 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 bleed valves 7.8 0.80 69 in·lb 2 brake hose banjo bolts 25 2.5 18 3 brake pedal clamp bolt 25 2.5 18 4 rear brake disc mounting bolts 27 2.8 20 l 5 rear caliper mounting bolts 34 3.5 25 6 rear master cylinder mounting bolts 25 2...

  • Page 398

    12-6 brakes specifications item standard service limit brake lever, brake pedal brake lever position 5-way adjustable (to suit rider) – – – brake lever free play non-adjustable – – – pedal free play non-adjustable – – – pedal position about 105 mm (4.13 in.) – – – (height from pedal top to footpeg t...

  • Page 399

    Brakes 12-7 special tool inside circlip pliers: 57001-143.

  • Page 400

    12-8 brakes brake lever, brake pedal brake lever position adjustment the brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator’s hand. • push the lever forward and turn the adjuster [a] to align the number with the arrow mark [b] on the lever hold...

  • Page 401

    Brakes 12-9 brake lever, brake pedal • remove: brake pedal return spring [a] brake switch return spring [b] cotter pin [c] joint pin [d] brake lever [e] brake pedal installation • apply grease to the brake pedal shaft. • install: brake pedal return spring brake switch return spring • install the bra...

  • Page 402

    12-10 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]. • take off the caliper [c] from the disc. • unscrew the banjo bolt, and disconnect the brake hose from the caliper. Notice immediatel...

  • Page 403

    Brakes 12-11 calipers rear caliper disassembly • refer to the caliper rubber parts replacement in the pe- riodic maintenance chapter. Rear caliper assembly • refer to the caliper rubber parts replacement in the pe- riodic maintenance chapter. Caliper fluid seal damage inspection the fluid seal (pist...

  • Page 404

    12-12 brakes brake pads front brake pad removal • remove the front caliper with the hose installed (see front caliper removal). • remove: snap pin [a] pad pin [b] • remove the jaw side pad [a], and then remove the piston side pad [b]. Jaw [c] front brake pad installation • before installation, clean...

  • Page 405

    Brakes 12-13 brake pads • remove the jaw side pad [a], and then remove the piston side pad [b]. Jaw [c] rear brake pad installation • before installation, clean the pads with a high flash-point solvent. • push the caliper pistons [a] in by hand as far as they will go. • install the brake pads. • be ...

  • Page 406

    12-14 brakes master cylinder front master cylinder removal • disconnect the front brake light switch connector [a]. • remove the banjo bolt [b] to disconnect the brake hose from the master cylinder (see brake hose replacement in the periodic maintenance chapter). • remove the clamp bolt caps [c] (vn...

  • Page 407

    Brakes 12-15 master cylinder rear master cylinder removal • remove the brake fluid reservoir (see brake pedal re- moval). • unscrew the brake hose banjo bolt [a] on the master cylin- der. • loosen the rear master cylinder mounting bolts [b]. • unscrew the footpeg bracket bolts [c]. • remove: cotter ...

  • Page 408

    12-16 brakes master cylinder master cylinder inspection • disassemble the front and rear master cylinders (see master cylinder rubber parts replacement in the peri- odic maintenance chapter). Notice do not remove the secondary cup from the piston since removal will damage it. • check that there are ...

  • Page 409

    Brakes 12-17 brake discs brake disc removal • remove the wheel (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-p...

  • Page 410

    12-18 brakes brake fluid brake fluid level inspection • refer to the brake fluid level inspection in the periodic maintenance chapter. Brake fluid change • refer to the brake fluid change in the periodic mainte- nance chapter. Brake line bleeding the brake fluid has a very low compression coefficien...

  • Page 411

    Brakes 12-19 brake fluid • bleed the brake line and the caliper. ○ repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake lever and hold it [a]. 2. Quickly open and close [b] the bleed valve while hol...

  • Page 412

    12-20 brakes brake fluid warning when working with the disc brake, observe the pre- cautions listed below. • never reuse old brake fluid. • do not use fluid from a container that has been left unsealed or that has been open for a long time. • do not mix two types and brands of fluid for use in the b...

  • Page 413

    Brakes 12-21 brake hoses brake hose removal/installation • refer to the brake hose and pipe replacement in the periodic maintenance chapter. Brake hose inspection • refer to the brake hose damage and installation condi- tion inspection in the periodic maintenance chapter..

  • Page 415: Suspension

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

  • Page 416

    13-2 suspension exploded view.

  • Page 417

    Suspension 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front fork bottom allen bolts 20 2.0 15 l 2 front fork clamp bolts (lower) 34 3.5 25 3 front fork clamp bolts (upper) 20 2.0 15 g: apply grease. L: apply a non-permanent locking agent. R: replacement parts.

  • Page 418

    13-4 suspension exploded view.

  • Page 419

    Suspension 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear shock absorber nuts 59 6.0 44 r 2 rocker arm pivot shaft nut 59 6.0 44 r 3 swingarm pivot shaft nut 98 10 72 4 tie-rod nut (lower) 59 6.0 44 r 5 tie-rod nut (upper) 108 11.0 80 r 6. Vn900c7 ∼ c9 g: apply grease. R: repl...

  • Page 420

    13-6 suspension specifications item standard front fork (per one unit) fork inner tube outside diameter 41 mm (1.6 in.) air pressure atmospheric pressure (non-adjustable) fork spring setting non-adjustable damper setting non-adjustable suspension oil kawasaki ss-8 or equivalent amount approx. 365 ml...

  • Page 421

    Suspension 13-7 special tools inside circlip pliers: 57001-143 fork cylinder holder handle: 57001-183 fork cylinder holder adapter: 57001-1057 bearing driver set: 57001-1129 fork outer tube weight: 57001-1218 front fork oil seal driver: 57001-1219 jack: 57001-1238 fork oil level gauge: 57001-1290

  • Page 422

    13-8 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) headlight body [a] (see headlight body removal in the electrical system chapter) turn signal light lead connectors [b...

  • Page 423

    Suspension 13-9 front fork • pour out the fork oil [a] with the fork upside down. • hold the outer tube vertically in a vise. • fill the front fork with the specified oil. Suspension oil - ss-8 (1 l): 44091-0007 amount (per side): when changing oil: approx. 365 ml (12.3 us oz.) after disassembly and...

  • Page 424

    13-10 suspension front fork • hold the front fork horizontally in a vise [a]. • stop the cylinder unit [b] from turning by using the special tools. • unscrew the allen bolt [c], and take the gasket out of the bottom of the outer tube. Special tools - fork cylinder holder handle [d]: 57001-183 fork c...

  • Page 425

    Suspension 13-11 front fork 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] fork bottom allen bolt gasket [f] • install the following parts onto the inner tube. Inner guide bushing outer gu...

  • Page 426

    13-12 suspension front fork • hold the front fork horizontally in a vise [a]. • hold the cylinder unit [b] with the special tools and tighten the allen bolt [c]. Special tools - fork cylinder holder handle [d]: 57001-183 fork cylinder holder adapter [e]: 57001 -1057 • apply a non-permanent locking a...

  • Page 427

    Suspension 13-13 front fork fork spring inspection • measure the free length [a] of the fork spring [b]. If the measured length is shorter than the service limit, the spring must be replaced. If the free length of the replace- ment spring and that of the remaining spring vary greatly, the remaining ...

  • Page 428

    13-14 suspension rear shock absorber spring preload adjustment • remove the reserve tank (see reserve tank removal in the cooling system chapter). • hang the under part of the reserve tank to the holder [a] of the frame as shown in the figure. • to adjust the spring force, turn the adjusting sleeve ...

  • Page 429

    Suspension 13-15 rear shock absorber • remove: lower shock absorber bolt [a] lower tie-rod bolt [b] upper shock absorber bolt [c] rear shock absorber rear shock absorber installation • pack the rocker arm needle bearings with grease. • install the rear shock absorber so that the caution label [a] fa...

  • Page 430

    13-16 suspension swingarm swingarm removal • remove: rear wheel (see rear wheel removal in the wheels/tires chapter) rear caliper (see rear caliper removal in the brakes chapter) rear shock absorber (see rear shock absorber re- moval) bolts [a] rear wheel mud guard [b] • remove: drive belt cover [a]...

  • Page 431

    Suspension 13-17 swingarm swingarm installation • apply grease to the needle bearings and grease seals. • install the collar [a]. • replace the rear shock absorber nuts and the tie-rod nuts with new ones. • install the tie-rod to the swingarm. • install the swingarm and insert the swingarm pivot sha...

  • Page 432

    13-18 suspension swingarm right side • remove the grease seal. • remove the needle bearing [a] with the available bearing remover. Swingarm bearing installation • replace the grease seals, ball and needle bearings with new ones. • apply grease to the grease seals, ball and needle bear- ings. • be su...

  • Page 433

    Suspension 13-19 swingarm swingarm bearing, sleeve inspection notice do not remove the bearings for inspection. Re- moval may damage them. • inspect the sleeve [a], needle bearings [b] and ball bear- ing [c] installed in the swingarm. ○ the rollers and balls in the bearing normally wear very lit- tl...

  • Page 434

    13-20 suspension tie-rod, rocker arm tie-rod removal • refer to the swingarm removal. Tie-rod installation • refer to the swingarm installation. Rocker arm removal • remove the mufflers (see muffler removal in the engine top end chapter). • squeeze the brake lever slowly and hold it with a band. • r...

  • Page 435

    Suspension 13-21 tie-rod, rocker arm tie-rod and rocker arm bearing removal • remove: tie-rod (see swingarm removal) rocker arm [a] (see rocker arm removal) sleeves [b] grease seals [c] • remove the needle bearings [d], using the available bearing remover. Vn900c7 ∼ c9 models [e] tie-rod and rocker ...

  • Page 436

    13-22 suspension tie-rod, rocker arm note ○ install the needle bearings so that the marked side faces out. Needle bearings [a] grease seals [b] front [c] left side [d] right side [e] rocker arm [f] tie-rod [g] 6 ±1 mm (0.24 ±0.04 in.) [h] 11.5 ±1 mm (0.453 ±0.04 in.) [i] 5.5 ±1 mm (0.22 ±0.04 in.) [...

  • Page 437: Steering

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

  • Page 438

    14-2 steering exploded view.

  • Page 439

    Steering 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front fork clamp bolts (lower) 34 3.5 25 2 front fork clamp bolts (upper) 20 2.0 15 3 handlebar mounting nuts 34 3.5 25 r 4 steering stem head nut 49 5.0 36 5 steering stem nut 4.9 0.50 43 in·lb ad: apply adhesive. G: apply gr...

  • Page 440

    14-4 steering special tools bearing puller: 57001-135 steering stem bearing driver: 57001-137 steering stem bearing driver adapter, 34.5: 57001-1074 head pipe outer race press shaft: 57001-1075 head pipe outer race driver, 51.5: 57001-1076 steering stem nut wrench: 57001-1100 head pipe outer race dr...

  • Page 441

    Steering 14-5 steering steering inspection • refer to the steering play inspection in the periodic main- tenance chapter. Steering adjustment • refer to the steering play adjustment in the periodic maintenance chapter..

  • Page 442

    14-6 steering steering stem stem, stem bearing removal • remove: headlight body (see headlight body removal in the electrical system chapter) front turn signal lights (see front fork removal in the suspension chapter) headlight body bracket nuts [a] and bracket [b] bolt [c] and bracket [d] • remove:...

  • Page 443

    Steering 14-7 steering stem • remove the lower inner race [a] which is pressed onto the steering stem with special tools. Oil seal [b] special tools - bearing puller: 57001-135 bearing puller: 57001-1675 ○ insert the each half-split base [a] under the bottom of the bearing and connect the both bases...

  • Page 444

    14-8 steering steering stem • settle the bearings in place as follows. ○ tighten the steering stem nut to 55 n·m (5.6 kgf·m, 40 ft·lb) of torque (to tighten the steering stem nut to the specified torque, hook the wrench on the stem nut, and pull the wrench at the hole by 305 n (31.1 kgf, 68.6 lb) fo...

  • Page 445

    Steering 14-9 steering stem note ○ tighten the upper fork clamp bolts first, next the stem head nut, last the lower fork clamp bolts. Torque - front fork clamp bolts (upper): 20 n·m (2.0 kgf·m, 15 ft·lb) steering stem head nut: 49 n·m (5.0 kgf·m, 36 ft·lb) front fork clamp bolts (lower): 34 n·m (3.5...

  • Page 446

    14-10 steering handlebar handlebar removal • remove: clamp [a] clutch lever assembly [b] left switch housing [c] • remove: clamp [a] front master cylinder [b] (see front master cylinder re- moval in the brakes chapter) right switch housing [c] throttle grip [d] • remove the handlebar mounting nuts [...

  • Page 447

    Steering 14-11 handlebar • set the left switch housing [a] to match its mating surface [b] to the punched mark [c] of the handlebar. • install the switch housing. • install the clutch lever (see clutch lever installation in the clutch chapter)..

  • Page 449: Frame

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

  • Page 450

    15-2 frame exploded view.

  • Page 451

    Frame 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 downtube bolts 44 4.5 32 2 footpeg bracket bolts (front) 34 3.5 25 3 footpeg bracket bolts (rear) 25 2.5 18 4 muffler bracket bolts (lower) 34 3.5 25 5 muffler bracket bolts (upper) 34 3.5 25 6 sidestand mounting bolt 44 4.5 32 7...

  • Page 452

    15-4 frame exploded view.

  • Page 453

    Frame 15-5 exploded view 1. South east asia (vn900c8 ∼ c9), united states and canada models 2. Au model (vn900c9 ∼ cb).

  • Page 454

    15-6 frame special tool jack: 57001-1238.

  • Page 455

    Frame 15-7 seat seat removal • insert the ignition switch key [a] into the seat lock, turning the key clockwise, pulling up on the rear of the seat [b], and pulling the seat backward. Seat installation • slip the seat hook [a] under the brace [b] on the fuel tank bracket. • insert the seat latches [...

  • Page 456

    15-8 frame side covers left side cover removal • remove: seat (see seat removal) screw [a] • pull [a] the left side cover evenly, and remove it. Left side cover installation • put the front stoppers [a] into the grommets [b] first, then put the rear stopper [c] into the grommet [d]. • tighten the sc...

  • Page 457

    Frame 15-9 side covers right side cover installation notice be careful not to scratch the right side cover sur- face with the rear muffler cover during installation. • put the stoppers [a] into the grommets [b]. • tighten the screw..

  • Page 458

    15-10 frame fenders front fender removal notice be careful not to scratch the painted surface during removal. • remove: bolts [a] and washers (both sides) bolts [b] (both sides) • remove the front fender and brace forward. Front fender installation notice be careful not to scratch the painted surfac...

  • Page 459

    Frame 15-11 fenders • remove the rear fender bolts [a] on both sides. • remove the rear fender [b] rearward. • remove: bolts [a] flap (with license plate light and turn signal lights) [b] flap and rear fender installation • installation is the reverse of removal. ○ put the grommet [a] of the rear fe...

  • Page 460

    15-12 frame battery case battery case removal • remove: seat (see seat removal) battery (see battery removal in the electrical system chapter) ecu (see ecu removal in the fuel system (dfi) chap- ter) relay box (see relay box removal in the electrical sys- tem chapter) fuse box vehicle-down sensor [a...

  • Page 461

    Frame 15-13 tool box tool box removal • remove the seat (see seat removal). • clear the seat lock cable [a] from the hook [b]. • remove: screws [c] tool box [d].

  • Page 462

    15-14 frame footpeg footpeg removal/installation left side • remove: nut [a] and bolt footpeg bracket bolts [b] left footpeg assembly [c] • install the shift pedal correctly (see shift pedal installation in the crankshaft/transmission). • tighten: torque - footpeg bracket bolts (front): 34 n·m (3.5 ...

  • Page 463

    Frame 15-15 sidestand sidestand removal • raise the rear wheel off the ground with jack. Special tool - jack: 57001-1238 • remove the alternator outer cover (see alternator outer cover removal in the electrical system chapter). • disconnect the sidestand switch lead connector [a]. • remove: sidestan...

  • Page 464

    15-16 frame rear view mirrors rear view mirror removal (other than eur, br, ph and sea-b1 models [vn900c8 late models, vn900c9 ∼ cd 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 ...

  • Page 465

    Frame 15-17 rear view mirrors rear view mirror installation (eur, br, ph and sea-b1 models [vn900c8 late models, vn900c9 ∼ cd models]) • screw the mounting area of the rear view mirror [a] into the holder [b] all the way, and tighten the lower hexagonal area [c] securely. Notice do not force to tigh...

  • Page 466

    15-18 frame downtube downtube removal • raise the rear wheel off the ground with jack. Special tool - jack: 57001-1238 • remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter). • disconnect the rear brake light switch connector [a]. • remove: bolt [a] clamps [b] • remove: fron...

  • Page 467

    Frame 15-19 downtube • clear the brake hose [a] from the clamps [b]. • remove the radiator bolt [a]. • remove: regulator/rectifier (see regulator/rectifier removal in the electrical system chapter) front cross pipe bolts [a] front cross pipe [b] • remove: engine mounting bracket bolts [a] caps [b] (...

  • Page 468

    15-20 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 resulting in injury or death. If the frame is bent, dented, cracked, or warp...

  • Page 469: Electrical System

    Electrical system 16-1 16 electrical system table of contents exploded view........................................................................................................................ 16-3 specifications .......................................................................................

  • Page 470

    16-2 electrical system commutator cleaning and inspection............................................................................... 16-64 armature inspection.......................................................................................................... 16-65 brush lead inspection ......

  • Page 471

    Electrical system 16-3 exploded view this page intentionally left blank..

  • Page 472

    16-4 electrical system exploded view.

  • Page 473

    Electrical system 16-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 alternator cover bolts 9.8 1.0 87 in·lb 2 alternator lead holder plate bolts 5.9 0.60 52 in·lb 3 alternator outer cover bolts 9.8 1.0 87 in·lb alternator rotor bolt (first) 69 7.0 51 mo, s 4 alternator rotor bolt (fin...

  • Page 474

    16-6 electrical system exploded view.

  • Page 475

    Electrical system 16-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 headlight rim screws 2.9 0.30 26 in·lb 2 tail/brake light unit mounting nuts 5.9 0.60 52 in·lb 3. Eur, sea-b1 (vn900cc ∼ ), sea-b3 (vn900ce), br and ph models 4. Gb model only.

  • Page 476

    16-8 electrical system exploded view.

  • Page 477

    Electrical system 16-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 fuel level sensor mounting bolts 6.9 0.70 61 in·lb l 2 oxygen sensors (oxygen sensor equipped models) 25 2.5 18 3 sidestand switch mounting bolt 8.8 0.90 78 in·lb l 4 speed sensor mounting bolt 9.8 1.0 87 in·lb l: app...

  • Page 478

    16-10 electrical system specifications item standard battery type sealed battery model name ytx12-bs capacity 12 v 10 ah (10 hr) voltage 12.8 v or more gross weight 4.2 kg (9.3 lb) electrolyte volume 0.60 l (37 cu in.) charging system type three-phase ac alternator output voltage 54 v or more at 4 0...

  • Page 479

    Electrical system 16-11 special tools and sealant rotor puller, m16/m18/m20/m22 × 1.5: 57001-1216 spark plug wrench, hex 16: 57001-1262 flywheel puller assembly, m38 × 1.5/m35 × 1.5: 57001-1405 peak voltage adapter: 57001-1415 needle adapter set: 57001-1457 grip: 57001-1591 rotor holder: 57001-1674 ...

  • Page 480

    16-12 electrical system parts location left switch housing [a] starter lockout switch [b] headlight [c] front brake light switch [d] right switch housing [e] meter unit [f] spark plug [a] (front) fuel pump [b] ignition coil [c] (front) ignition coil [d] (rear) spark plug [e] (rear) radiator fan [a] ...

  • Page 481

    Electrical system 16-13 parts location speed sensor [a] battery [a] ecu (electronic control unit) [b] turn signal relay [c] relay box [a] starter relay and main fuse 30 a [b] frame ground terminal [c] neutral switch [a] air switching valve [a].

  • Page 482

    16-14 electrical system parts location fuel level sensor [a] rear brake light switch [a] water temperature sensor [a] sidestand switch [a].

  • Page 483

    Electrical system 16-15 wiring diagram (vn900c7 ∼ c8) this page intentionally left blank..

  • Page 484

    16-16 electrical system wiring diagram (vn900c7 ∼ c8) us, ca, and sea-b1 models.

  • Page 485

    Electrical system 16-17 wiring diagram (vn900c7 ∼ c8).

  • Page 486

    16-18 electrical system wiring diagram (vn900c7 ∼ c8) eur models.

  • Page 487

    Electrical system 16-19 wiring diagram (vn900c7 ∼ c8).

  • Page 488

    16-20 electrical system wiring diagram (vn900c7 ∼ c8) au model.

  • Page 489

    Electrical system 16-21 wiring diagram (vn900c7 ∼ c8).

  • Page 490

    16-22 electrical system wiring diagram (vn900c7 ∼ c8) th model.

  • Page 491

    Electrical system 16-23 wiring diagram (vn900c7 ∼ c8).

  • Page 492

    16-24 electrical system wiring diagram (vn900c9 ∼ ) us and ca models.

  • Page 493

    Electrical system 16-25 wiring diagram (vn900c9 ∼ ).

  • Page 494

    16-26 electrical system wiring diagram (vn900c9 ∼ ) eur, sea-b1 (vn900cc ∼ ), sea-b3 (vn900ce), br and ph models.

  • Page 495

    Electrical system 16-27 wiring diagram (vn900c9 ∼ ).

  • Page 496

    16-28 electrical system wiring diagram (vn900c9 ∼ ) au model.

  • Page 497

    Electrical system 16-29 wiring diagram (vn900c9 ∼ ).

  • Page 498

    16-30 electrical system wiring diagram (vn900c9 ∼ ) sea-b1 (vn900c9 ∼ cb) and th models.

  • Page 499

    Electrical system 16-31 wiring diagram (vn900c9 ∼ ).

  • Page 500

    16-32 electrical system precautions there are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○ always check battery con...

  • Page 501

    Electrical system 16-33 precautions ○ electrical connectors connectors [a] connectors [b].

  • Page 502

    16-34 electrical system electrical wiring wiring inspection • visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • pull each connector [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clea...

  • Page 503

    Electrical system 16-35 battery battery removal • remove: seat (see seat removal in the frame chapter) tool box (see tool box removal in the frame chapter) • disconnect the negative (–) cable [a]. • slide out the positive (+) terminal cap [b] and then discon- nect the positive (+) cable. Notice be s...

  • Page 504

    16-36 electrical system battery notice do not remove the aluminum sealing sheet [a] from the filler ports [b] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. Danger sulfuric acid in battery electrolyte can cause severe burns. To prevent bur...

  • Page 505

    Electrical system 16-37 battery • check the electrolyte flow. If no air bubbles [a] are coming up from the filler ports, or if the container cells have not emptied completely, tap the container [b] a few times. Note ○ be careful not to have the battery fall down. • keep the container in place. Don’t...

  • Page 506

    16-38 electrical system battery initial charge • newly activated sealed batteries require an initial charge. Standard charge: 1.2 a × 5 ∼ 10 hours if using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers: battery mate...

  • Page 507

    Electrical system 16-39 battery precautions 1) no need of topping-up no topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seal cap to add water is very dangerous. Never do that. 2) refreshing charge. If an engine will not start, a horn sounds we...

  • Page 508

    16-40 electrical system battery charging condition inspection ○ battery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter [a]. • remove: seat (see seat removal in the frame chapter) tool box (see tool box removal in the frame chapter) battery cable cap ...

  • Page 509

    Electrical system 16-41 battery terminal voltage: 11.5 ∼ less than 12.8 v standard charge 1.2 a × 5 ∼ 10 h (see following chart) quick charge 5 a × 1 h notice if possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on. Terminal voltage: less than 11.5 v chargi...

  • Page 510

    16-42 electrical system charging system alternator outer cover removal • remove: bolts [a] alternator outer cover [b] alternator outer cover installation • for other than us, ca and cal models (vn900c9 ∼ ), be sure the dampers [a] and trim [b] are in position. • install the alternator outer cover. •...

  • Page 511

    Electrical system 16-43 charging system • remove: bolts [a] alternator cover [b] alternator cover installation • replace the alternator cover gasket with a new one. • check to see that the dowel pins [a] are in place. • tighten: torque - alternator cover bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • instal...

  • Page 512

    16-44 electrical system charging system alternator rotor removal • remove the alternator cover (see alternator cover re- moval). • wipe oil off the outer circumference of the rotor. • hold the alternator rotor steady with the rotor holder [a], and remove the rotor bolt [b] and washer. Special tools ...

  • Page 513

    Electrical system 16-45 charging system • when installing the alternator rotor, align the rotor mark [a] with the left crankcase projection [b]. • apply molybdenum disulfide oil solution to the threads and seating surface of the alternator rotor bolt. • install the washer. Note ○ confirm the alterna...

  • Page 514

    16-46 electrical system charging system • to check the alternator output voltage, do the following procedures. ○ remove the regulator/rectifier and disconnect the con- nector [a]. ○ connect a tester to the connector as shown in the figure. ○ start the engine. ○ run it at 4 000 rpm of the engine spee...

  • Page 515

    Electrical system 16-47 charging system regulator/rectifier removal • remove: bolts [a] regulator/rectifier cover [b] • remove: bolts [a] regulator/rectifier [b] connector [c] (disconnect) regulator/rectifier inspection rectifier circuit check • remove the regulator/rectifier (see regulator/rectifie...

  • Page 516

    16-48 electrical system charging system • do the 1st step regulator circuit test. ○ connect the test light and the 12 v battery to the regula- tor/rectifier as shown in the figure. ○ check the w1, w2 and w3 terminal respectively. If the test light turns on, the regulator/rectifier is defective. Repl...

  • Page 517

    Electrical system 16-49 charging system charging voltage inspection • check the battery condition (see charging condition in- spection). • warm up the engine to obtain actual alternator operating conditions. • remove: seat (see seat removal in the frame chapter) tool box (see tool box removal in the...

  • Page 518

    16-50 electrical system charging system charging system circuit (vn900c7 ∼ c8) 1. Ignition switch 2. Regulator/rectifier 3. Alternator 4. Frame ground 5. Battery 6. Main fuse 30 a 7. Load.

  • Page 519

    Electrical system 16-51 charging system charging system circuit (vn900c9 ∼ ) 1. Ignition switch 2. Regulator/rectifier 3. Alternator 4. Frame ground 5. Battery 6. Main fuse 30 a 7. Load.

  • Page 520

    16-52 electrical system ignition system warning the ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or ig- nition coil lead while the engine is running, or you could receive a severe electrical shock. Notice do not disconnect the battery cables or any ot...

  • Page 521

    Electrical system 16-53 ignition system ignition coil installation • installation is the reverse of removal. • connect the primary leads to the ignition coil terminals and run the secondary cables according to the cable, wire, and hose routing section in the appendix chapter. Front ignition coil [a]...

  • Page 522

    16-54 electrical system ignition system • measure the primary winding resistance as follows. ○ connect the digital meter between the coil terminals. • measure the secondary winding resistance as follows. ○ remove the plug caps by turning them counterclockwise. ○ connect the meter between the spark p...

  • Page 523

    Electrical system 16-55 ignition system warning to avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • turn the ignition switch and the engine stop switch on. • pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission in neutral to measur...

  • Page 524

    16-56 electrical system ignition system crankshaft sensor removal • remove: alternator cover (see alternator cover removal) bolts [a] alternator lead holder plate [b] crankshaft sensor lead grommet [c] crankshaft sensor bolts [d] • remove the crankshaft sensor [e] from the alternator cover. Cranksha...

  • Page 525

    Electrical system 16-57 ignition system crankshaft sensor peak voltage inspection note ○ be sure the battery is fully charged. • remove the alternator outer cover (see alternator outer cover removal). • remove all the spark plug caps but do not remove the spark plugs. • disconnect the crankshaft sen...

  • Page 526

    16-58 electrical system ignition system 2nd check • start the engine to the following conditions. Condition transmission gear → 1st position clutch lever → pulled in sidestand → up ○ turn the ignition switch on and push the starter button. ○ then the starter motor should turn when the starter sys- t...

  • Page 527

    Electrical system 16-59 ignition system.

  • Page 528

    16-60 electrical system ignition system ignition system circuit (vn900c7 ∼ c8) 1. Ignition switch 2. Engine stop switch 3. Spark plugs 4. Ignition coil #1 (front cylinder) 5. Ignition coil #2 (rear cylinder) 6. Sidestand switch 7. Subthrottle sensor (vn900c8) 8. Main throttle sensor 9. Joint connect...

  • Page 529

    Electrical system 16-61 ignition system ignition system circuit (vn900c9 ∼ ) 1. Ignition switch 2. Engine stop switch 3. Spark plugs 4. Ignition coil #1 (front cylinder) 5. Ignition coil #2 (rear cylinder) 6. Sidestand switch 7. Subthrottle sensor 8. Main throttle sensor 9. Joint connector b 10. Cra...

  • Page 530

    16-62 electrical system electric starter system starter motor removal notice do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • remove: regulator/rectifier (see regulator/rectifier removal) bolts [a] front cross pipe [b] • drain the engine oil (see engine...

  • Page 531

    Electrical system 16-63 electric starter system • remove: terminal locknut and washers o-ring • remove the brush plate assy [a] from the yoke [b]. • remove the brush plate [a] from the terminal bolt assem- bly [b]. Note ○ do not remove the negative carbon brushes from the brush plate. Starter motor ...

  • Page 532

    16-64 electrical system electric starter system • install the new o-ring [a] as shown in the figure. • install the washers [b] and terminal locknut [c]. • tighten: torque - starter motor terminal locknut: 11 n·m (1.1 kgf·m, 97 in·lb) • align the lines [a] on the yoke with the end cover lines [b]. • ...

  • Page 533

    Electrical system 16-65 electric starter system armature inspection • using a tester, measure the resistance between any two commutator segments [a]. If there is a high resistance or no reading ( ∞ ) between any two segments, a winding is open and the starter motor must be replaced. • using the high...

  • Page 534

    16-66 electrical system electric starter system starter relay inspection • remove the right side cover (see right side cover re- moval in the frame chapter). • disconnect the connector [a]. • disconnect the starter motor cable [b] and battery positive (+) cable [c] from the starter relay [d]. Notice...

  • Page 535

    Electrical system 16-67 electric starter system electric starter circuit (vn900c7 ∼ c8) 1. Ignition switch 2. Engine stop switch 3. Starter button 4. Neutral switch 5. Sidestand switch 6. Ecu 7. Battery 8. Main fuse 30 a 9. Starter relay 10. Starter motor 11. Frame ground 12. Relay box 13. Starter c...

  • Page 536

    16-68 electrical system electric starter system electric starter circuit (vn900c9 ∼ ) 1. Ignition switch 2. Engine stop switch 3. Starter button 4. Neutral switch 5. Sidestand switch 6. Ecu 7. Battery 8. Main fuse 30 a 9. Starter relay 10. Starter motor 11. Frame ground 12. Relay box 13. Starter cir...

  • Page 537

    Electrical system 16-69 lighting system this models adopt the daylight system and has a head- light relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on u...

  • Page 538

    16-70 electrical system lighting system • take out the bulb [a]. Notice when handling the quartz-halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth. Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode. Use the correct type o...

  • Page 539

    Electrical system 16-71 lighting system other than gb models • remove the headlight body nuts [a], then take off the body [b]. Gb model • remove the headlight body bolts [a] and nuts [b], then take off the body [c]. City light bulb replacement (eur, sea-b1 (vn900cc ∼ ), sea-b3 (vn900ce), br and ph m...

  • Page 540

    16-72 electrical system lighting system tail/brake light bulb replacement • unscrew the lens screw [a]. • pull the lens [b] off. • push the bulb [a] in, turn it counterclockwise [b], and pull it out. • replace the bulb with a new one. • with the front pin [a] up and the rear pin [b] down, in- sert t...

  • Page 541

    Electrical system 16-73 lighting system • push the bulb [a] in, turn it counterclockwise [b], and pull it out. • insert the new bulb [a] by aligning the pins [b] with the groove in the walls of the socket [c]..

  • Page 542

    16-74 electrical system lighting system headlight/tail light circuit (vn900c7 ∼ c8) 1. Ignition switch 2. Rear brake switch 3. License plate light 4. Tail/brake light 5. Relay box 6. Headlight relay 7. Frame ground 8. Battery 9. Main fuse 30 a 10. Tail light fuse 10 a 11. Headlight fuse 10 a 12. Dim...

  • Page 543

    Electrical system 16-75 lighting system headlight/tail light circuit (vn900c9 ∼ ) 1. Ignition switch 2. Rear brake switch 3. License plate light 4. Tail/brake light 5. Relay box 6. Headlight relay 7. Frame ground 8. Battery 9. Main fuse 30 a 10. Tail light fuse 10 a 11. Headlight fuse 10 a 12. Dimme...

  • Page 544

    16-76 electrical system lighting system • push the bulb [a] in the socket and turn the bulb counter- clockwise. • replace the bulb. • insert the new bulb [a] by aligning the pins [b] with the groove in the walls of the socket [c]. Turn signal relay inspection • remove: seat (see seat removal in the ...

  • Page 545

    Electrical system 16-77 lighting system turn signal light circuit (vn900c7 ∼ c8) 1. Ignition switch 2. Frame ground 3. Main fuse 30 a 4. Battery 5. Rear right turn signal light 6. Rear left turn signal light 7. Turn signal relay 8. Turn signal relay fuse 10 a 9. Turn signal switch 10. Front left tur...

  • Page 546

    16-78 electrical system lighting system turn signal light circuit (vn900c9 ∼ ) 1. Ignition switch 2. Frame ground 3. Main fuse 30 a 4. Battery 5. Rear right turn signal light 6. Rear left turn signal light 7. Turn signal relay 8. Turn signal relay fuse 10 a 9. Turn signal switch 10. Front left turn ...

  • Page 547

    Electrical system 16-79 air switching valve air switching valve operation test • refer to the air suction system damage inspection in the periodic maintenance chapter. Air switching valve unit test • remove the air switching valve (see air switching valve removal in the engine top end chapter). • co...

  • Page 548

    16-80 electrical system radiator fan system fan motor inspection • remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter). • disconnect the 2-pin connector [a] in the fan motor leads. • using an auxiliary leads, supply battery [b] power to the fan motor. If the fan does not ro...

  • Page 549

    Electrical system 16-81 radiator fan system radiator fan relay circuit (vn900c9 ∼ ) 1. Ignition switch 2. Radiator fan 3. Joint connector b 4. Water temperature sensor 5. Ecu 6. Battery 7. Main fuse 30 a 8. Relay box 9. Ecu main relay 10. Radiator fan relay 11. Ecu fuse 15 a 12. Fan fuse 15 a 13. Jo...

  • Page 550

    16-82 electrical system meter unit meter unit removal • remove the bolt [a], and lift up the tail of the cover [b]. • push the cover forward a little, and remove the meter cover. • remove the meter unit [a]. ○ pull out the meter unit end from the pin [b] on the fuel tank, and then pull out the front...

  • Page 551

    Electrical system 16-83 meter unit • remove the screw [a] on the lower meter cover to free the speedometer. • remove the screw [a] on the indicator panel to remove the panel. • lifting the speedometer [a] with the indicator panel [b] at- tached, pull out the fi indicator light (led) [c] and oil pres...

  • Page 552

    16-84 electrical system meter unit • remove the wedge-base type bulb [a] by pulling the bulb straight out of the socket [b]. Notice do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for other than voltage or wattage specified in the wiring dia- gram. Meter ...

  • Page 553

    Electrical system 16-85 meter unit • push the mode select button to trip and push the reset button [a] more than 2 seconds. The display shows "0.0". If the display doesn’t show "0.0", replace the speedometer assembly. • push the mode select button to clock. • push the reset button [a] more than 2 se...

  • Page 554

    16-86 electrical system meter unit • set the minute, push the reset button [a] to return to the hour/minute setting mode. • push the mode select button [b] to complete the time set- ting process. ○ the clock starts counting the seconds as soon as the mode select button is pushed. Lcd segment inspect...

  • Page 555

    Electrical system 16-87 meter unit • using the auxiliary wires, connect a 12 v battery to the meter unit connector terminals. Connections battery positive terminal (+) → terminal [11] battery negative terminal (–) → terminal [13] • using the auxiliary wires, connect the battery positive wire to term...

  • Page 556

    16-88 electrical system meter unit • if an oscillator is available, check the speedometer as fol- lows. ○ connect the terminals in the same way as in the lcd segment inspection. • connect the oscillator [a] to the terminal [15]. The vehi- cle speed that corresponds to the input frequency will be dis...

  • Page 557

    Electrical system 16-89 meter unit fuel level gauge inspection • connect the terminals in the same way as in the lcd segment inspection. • connect a variable rheostat [a] to the terminal [16] and battery negative wire as shown in the figure. • check that the position of the gauge pointer matches the...

  • Page 558

    16-90 electrical system meter unit water temperature warning light (led) connections battery negative wire (–) to terminal [4] • connect the terminal [4]. ○ the water temperature warning light (led) lights. • disconnect the terminal [4]. ○ the water temperature warning light (led) disappears. If the...

  • Page 559

    Electrical system 16-91 meter unit if there is any problem, inspect the bulb, bulb socket [a] and wiring of the indicator panel [b] for continuity. If they are normal, replace the speedometer assembly. Special tool - needle adapter set: 57001-1457 high beam indicator light connections battery positi...

  • Page 560

    16-92 electrical system meter unit meter circuit (vn900c7 ∼ c8) 1. Ignition switch 2. Fuel level sensor 3. Speed sensor 4. Joint connector b 5. Water temperature sensor 6. Oil pressure switch 7. Neutral switch 8. Ecu 9. Fuel reserve switch 10. Frame ground 11. Battery 12. Main fuse 30 a 13. Ignition...

  • Page 561

    Electrical system 16-93 meter unit meter circuit (vn900c9 ∼ ) 1. Ignition switch 2. Fuel level sensor 3. Speed sensor 4. Joint connector b 5. Water temperature sensor 6. Oil pressure switch 7. Neutral switch 8. Ecu 9. Fuel reserve switch 10. Frame ground 11. Battery 12. Main fuse 30 a 13. Ignition f...

  • Page 562

    16-94 electrical system meter unit fuel gauge operation inspection • remove the fuel tank bolts (see fuel tank removal in the fuel system (dfi) chapter). • lift the fuel tank front part a little and pull the fuel gauge connector forward. • disconnect the fuel gauge connector. • prepare an auxiliary ...

  • Page 563

    Electrical system 16-95 switches and sensors brake light timing inspection • refer to the brake light switch operation inspection in the periodic maintenance chapter. Brake light timing adjustment • refer to the brake light switch operation inspection in the periodic maintenance chapter. Switch insp...

  • Page 564

    16-96 electrical system switches and sensors water temperature sensor inspection • remove the water temperature sensor (see water tem- perature sensor removal/installation in the fuel system (dfi) chapter). • suspend the sensor [a] in a container of coolant so that the temperature-sensing projection...

  • Page 565

    Electrical system 16-97 switches and sensors oxygen sensor removal (oxygen sensor equipped models) • remove the right side cover (see right side cover re- moval in the frame chapter). • disconnect the oxygen sensor lead connectors [a]. • remove: muffler covers [a] (see muffler removal in the engine ...

  • Page 566

    16-98 electrical system switches and sensors fuel level sensor inspection • remove the fuel tank (see fuel tank removal in the fuel system (dfi) chapter). • open the clamps on the fuel tank. • remove: bolts [a] fuel level sensor [b] • check that the float moves up and down smoothly without binding. ...

  • Page 567

    Electrical system 16-99 switches and sensors fuel reserve switch inspection • fill the fuel tank with fuel. • close the fuel tank cap surely. • remove: ignition coil cover (see ignition coil removal) fuel pump lead connector [a] • connect the test light [b] (12 v 3.4 w bulb in a socket with leads) a...

  • Page 568

    16-100 electrical system relay box the relay box [a] has relays and diodes. The relays and diodes can not be removed. Relay box removal • remove the right side cover (see right side cover re- moval in the frame chapter). • take out the relay box [a] and disconnect the connectors [b]. Relay circuit i...

  • Page 569

    Electrical system 16-101 relay box relay circuit inspection (with the battery connected) battery connection (+) (–) tester connection tester reading ( Ω ) 2-11 1-3 0 ecu main relay 4-5 7-6 0 fuel pump relay 9-10 7-8 0 fan relay 18-19 17-20 0 battery connection (+) (–) tester connection tester readin...

  • Page 570

    16-102 electrical system relay box relay box internal circuit a: headlight relay b: ecu main relay c: fuel pump relay d: starter circuit relay e: fan relay.

  • Page 571

    Electrical system 16-103 fuse 30 a main fuse removal • remove: right side cover (see right side cover removal in the frame chapter) connector [a] • pull out the main fuse [b] from the starter relay with needle nose pliers. Fuse box fuse removal • remove the left side cover (see left side cover remov...

  • Page 572

    16-104 electrical system fuse fuse installation • if a fuse fails during operation, inspect the electrical sys- tem to determine the cause, and then replace it with a new fuse of proper amperage. • install the fuse box fuses on the original position as spec- ified on the lid. Fuse inspection • remov...

  • Page 573: Appendix

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

  • Page 574

    17-2 appendix cable, wire, and hose routing.

  • Page 575

    Appendix 17-3 cable, wire, and hose routing 1. Right switch housing lead 2. Left switch housing lead 3. Clutch cable 4. Clamp the left switch housing lead. 5. Run the clutch cable and left switch housing lead through the clamp. 6. Run the clutch cable through the brake hose front side. 7. Run the th...

  • Page 576

    17-4 appendix cable, wire, and hose routing.

  • Page 577

    Appendix 17-5 cable, wire, and hose routing 1. Run the left switch housing lead under the brake hose. 2. Run the water temperature sensor lead connector over the reserve tank hose. 3. Clamp the left and right switch housing lead and clutch cable. 4. Run the clutch cable between the frame and radiato...

  • Page 578

    17-6 appendix cable, wire, and hose routing.

  • Page 579

    Appendix 17-7 cable, wire, and hose routing 1. Right switch housing lead connector 2. Left switch housing lead connector 3. Left switch housing lead connector 4. Radiator fan lead connector 5. Rear brake light switch lead connector 6. Clamp the main harness. 7. Clamp the clutch cable, rear brake lig...

  • Page 580

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

  • Page 581

    Appendix 17-9 cable, wire, and hose routing 1. Subthrottle valve actuator lead connector 2. Subthrottle sensor lead connector 3. Injector #2 lead connector 4. Injector #1 lead connector 5. Inlet air pressure sensor vacuum hose 6. Inlet air temperature sensor lead (cal, th and sea-b1 models: run the ...

  • Page 582

    17-10 appendix cable, wire, and hose routing.

  • Page 583

    Appendix 17-11 cable, wire, and hose routing 1. Run the alternator lead and sidestand switch lead through the clamp of the engine bracket. 2. Fuse box 3. Alternator lead 4. Battery negative (–) cable 5. Sidestand switch lead 6. View from the front.

  • Page 584

    17-12 appendix cable, wire, and hose routing.

  • Page 585

    Appendix 17-13 cable, wire, and hose routing 1. Fuel pump lead connector 2. Black/green lead 3. Red lead 4. Black lead 5. Red lead 6. Clamp the ignition coil lead with the air switching valve hose clamp. 7. Air switching valve hose 8. Run the ignition coil lead under the fuel pump lead connector, an...

  • Page 586

    17-14 appendix cable, wire, and hose routing.

  • Page 587

    Appendix 17-15 cable, wire, and hose routing 1. Speed sensor lead connector 2. Neutral switch lead terminal 3. Run the starter motor lead through the engine bracket clamp..

  • Page 588

    17-16 appendix cable, wire, and hose routing.

  • Page 589

    Appendix 17-17 cable, wire, and hose routing 1. Connect the battery negative (–) lead connector to the main harness. 2. Vehicle-down sensor 3. Ecu 4. Ignition switch lead connector 5. Kawasaki diagnostic system connector 6. Battery 7. Turn signal relay 8. Run the ignition switch lead in the front of...

  • Page 590

    17-18 appendix cable, wire, and hose routing.

  • Page 591

    Appendix 17-19 cable, wire, and hose routing 1. Rear left and right turn signal light, tail/brake light and license plate light lead connector 2. Run the rear left and right turn signal light, tail/brake light and license plate light lead through the guide of the tool box. 3. Run the rear left and r...

  • Page 592

    17-20 appendix cable, wire, and hose routing vn900c7 ∼ cb.

  • Page 593

    Appendix 17-21 cable, wire, and hose routing 1. Reserve tank hose 2. Breather hose 3. Run the breather hose inside the main harness. 4. Harness attached clamp (insert the harness attached clamp to the frame pipe.) 5. Fuel return hose (cal, th and sea-b1 models) 6. Clamp the main harness, breather ho...

  • Page 594

    17-22 appendix cable, wire, and hose routing vn900c7 ∼.

  • Page 595

    Appendix 17-23 cable, wire, and hose routing 1. Connect the breather hose to fuel tank breather pipe at front of the fuel tank. 2. Breather hose 3. Clamp the breather hose and reserve tank hose. Do not pinch the hoses. Position the clamp as shown in the figure. 4. Breather hose 5. Reserve tank hose ...

  • Page 596

    17-24 appendix cable, wire, and hose routing.

  • Page 597

    Appendix 17-25 cable, wire, and hose routing 1. View from the outside 2. Roll the tail/brake light lead to the pin. 3. Cover the tail/brake light lead connector by cover of the harness attached, and put the tail/brake light lead connector to the guide of the rear fender. 4. Run the rear left and rig...

  • Page 598

    17-26 appendix cable, wire, and hose routing 1. Clamps (clamp the sidestand switch lead.).

  • Page 599

    Appendix 17-27 cable, wire, and hose routing 1. Starter motor cable 2. Clamps 3. Clamp (bend the clamp as shown in the figure.).

  • Page 600

    17-28 appendix cable, wire, and hose routing 1. Air switching valve 2. Face the white mark right side. 3. Clamp (for ignition coil lead) 4. Air switching valve hose.

  • Page 601

    Appendix 17-29 cable, wire, and hose routing 1. Alternator coil lead 2. Oil pressure switch lead 3. Clamp the alternator lead and oil pressure switch lead. After installed, bend the clamp to the alternator cover. 4. Clamp the sidestand switch lead only. 5. Clamp the oil pressure switch lead and side...

  • Page 602

    17-30 appendix cable, wire, and hose routing 1. Main harness 2. Clamp (wrap the connectors.) 3. Sidestand switch lead 4. Oil pressure switch lead 5. Crankshaft sensor lead 6. Engine pulley cover.

  • Page 603

    Appendix 17-31 cable, wire, and hose routing 1. Clamp the alternator lead and main harness. 2. Alternator lead.

  • Page 604

    17-32 appendix cable, wire, and hose routing 1. Reserve tank hose 2. Inlet air pressure sensor vacuum hose 3. Air switching valve hoses 4. Run the inlet air pressure sensor vacuum hose over the air switching valve hose. 5. Run the reserve tank hose into the frame hole. 6. Reserve tank 7. Clamps 8. R...

  • Page 605

    Appendix 17-33 cable, wire, and hose routing 1. Clamps 2. Reserve tank hose 3. Reserve tank 4. Run the reserve tank hose on the battery case bracket. 5. Clamp (clamp the reserve tank hose.).

  • Page 606

    17-34 appendix cable, wire, and hose routing.

  • Page 607

    Appendix 17-35 cable, wire, and hose routing 1. Front caliper 2. Brake hose 3. Clamps 4. Through the brake hose in the bracket. 5. Front master cylinder.

  • Page 608

    17-36 appendix cable, wire, and hose routing.

  • Page 609

    Appendix 17-37 cable, wire, and hose routing 1. Rear caliper 2. Brake hose 3. Clamps 4. Rear master cylinder 5. Reservoir tank 6. Swingarm 7. Cotter pin 8. Swingarm clamps 9. Run the brake hose between the swingarm and frame..

  • Page 610

    17-38 appendix cable, wire, and hose routing cal, th and sea-b1 models 1. Reserve tank hose 2. Clamp the air switching valve hose, vacuum hose (white) and purge hose (green). 3. Breather hose 4. Purge hose (green) 5. Fuel return hose (red) 6. Vacuum hose (white) 7. Through the breather hose (blue) t...

  • Page 611

    Appendix 17-39 cable, wire, and hose routing vn900c9 models 1. Frame earth lead 2. Run the frame earth lead inside the throttle cables. 3. Throttle cables 4. Run the frame earth lead inside the throttle cables. 5. Frame earth lead 6. Insert the frame earth terminal between the frame and the air swit...

  • Page 612

    17-40 appendix troubleshooting guide note ○ refer to the fuel system chapter for most of dfi trouble shooting guide. ○ 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 di...

  • Page 613

    Appendix 17-41 troubleshooting guide compression low: spark plug loose cylinder head not sufficiently tightened down no valve clearance cylinder, piston worn piston ring bad (worn, weak, broken, or sticking) piston ring/groove clearance excessive cylinder head warped cylinder head gasket damaged val...

  • Page 614

    17-42 appendix troubleshooting guide compression high: carbon built up in combustion chamber engine load faulty: clutch slipping engine oil level too high engine oil viscosity too high drive train trouble brake dragging lubrication inadequate: engine oil level too low engine oil poor quality or inco...

  • Page 615

    Appendix 17-43 troubleshooting guide primary gear worn or chipped camshaft chain tensioner trouble camshaft chain, sprocket, guide worn air suction valve damaged air switching valve damaged alternator rotor loose catalytic converter melt down due to muffler overheating (kleen) abnormal drive train n...

  • Page 616

    17-44 appendix troubleshooting guide brake doesn’t hold: air in the brake line pad or disc worn brake fluid leakage disc warped contaminated pad brake fluid deteriorated primary or secondary cup damaged in master cylinder master cylinder scratched inside battery trouble: battery discharged: charge i...

  • Page 617

    Part no.99924-1373-09 model application year model beginning frame no. 2007 vn900c7 jkavn2c1 □ 7a000001 jkavn900cca000001 2008 vn900c8 jkavn2c1 □ 8a015001 jkavn900cca015001 2009 vn900c9 jkavn2c1 □ 9a025001 jkavn900cca025001 2010 vn900ca jkavn2c1 □ aa037001 jkavn900cca037001 2011 vn900cb jkavn2c1 □ b...