Kawasaki VN1500 87-99

Kawasaki vN1500
Motorcycle
Service Manual
http://manuals.magnamaniac.com
Guide Quick Reference
you in This quick referenceguide will assist locating a desiredtopic or procedure. .Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table oi contents page. aRefer to the sectional table of contents for the exact pagesto locate the specific topic http://manuals.magnamaniac.com required,
Kawasaki
vN1500
VNl5OOA: VULCAN (USandCanada) 88 (Othersl VN-15 VNlSOOB:
VU LCAN 88 SE (USand Canada) (Othersl VN-15SE
Motorcycle
Service Manual
system,or may be reproduced, storedin a retrieval All rightsreserved. No partsof this publication photocopying, or recording otherin any form or by any means,electronicmechanical transmitted Products of wise, without the prior written permission Ouality AssuranceDepartment/Consumer Ltd., Japan. Group/Kawasaki HeavyIndustries, althoughevery or in No liabilitycan be accepted any inaccuracies omissions this publication, for possiblecare has beentakento make it as completeand accurateas possible. The right is reserved make changesat any time without prior notice and without incurringan to previously. Seeyour Motorcycle dealer to makesuch changes productsmanufactured to obligation incorporated information productimprovements after this publication. for the latest on at available is in All informationcontained this publication basedon the latestproduct information http://manuals.magnamaniac.com publication. lllustrations for in are and photographs this publication intended referencs the time of use only and may not depictactualmodelcomponentparts.
1 1 1 1 997, 999, 1 @ Kawasaki HeavyIndustries, 1987, 990, 991, 993, 995, 1 Ltd.,
(1) : N/ar.20,1999 (K) EighthEdition
LIST OF ABBREVIATIONS
"c
A ABDC AC ATDC BBDC BDC BTDC
DC F .F ft
ampere{s} after bottom deadcenter alternatingcurrent after top deadcenter before bottom dead center boftom dead center before top deadcenter degree(s) Celsius direct current farad(s) degree(slFahrenheit foot, feet gram{s) hour(sl liter(s)
tb m min N Pa PS psi rpm TDC TIR W o
s
h L
pound(sl meter{s} minute(s) naryton(sl pascal(s) horseporer pound(s) square per inch rwolution per revolution(sl minute top deadcenter total indicator rading volt{s) watt(s) ohm(s)
ReadO,I/NER'S MANI At beforeoperating http://manuals.magnamaniac.com
EMISSIONCONTBOL INFORMATION To protect the environment in which we all live, Kawasakihas incorporatedcrankcase emission(1) and exhaust emission(2) control systemsin compliancewith applicableregulations of the United States Environmenal Protection Agency and California Air Re sourcesBoard. Additionally, Kawasakihas incorporatedan evaporative emission control Board system {3} in compliancewith applicableregulations the CaliforniaAir Resources of sold in California only. on vehicles 1. Crankcase Emission Control System This system eliminatesthe release crankcase of vapors into the atmosphere. Instead, the vaporsare routed through an oil separator the intake sideof the engine.While to wherethey are the engineis operating,the vaporsaredrawn into combustionchamber, burnedalongwith the fuel and air suppliedby the carburetionsystem. 2. ExhaustEmissionControl System by into the atmosphere the This systemreduces the amount of pollutants discharged exhaustof this motorcycle. The fuel and ignition systemsof this motorcyclehave with loriv exhaust and constructed encrre an efficient engine beencarefully designed to pollutant levels. EmissionControl'System 3. Evaporative Vapors causedby fuel waporation in the fuel systemare not vented into the atmos phere. Instead,fuel vaporsare routed into the runningengineto be burned,or stored and in a canister when the engineis stopped. Liquid fuel is caughtby a vaporseparator returnedto the fuel tank. The CleanAir Act, which is the Fedel law coveringmotor vehiclepollution, contains what is commonly referredto asthe Act's "tamperingprovisions." "Sec.203(a)The follorving actsand the causing thereof are prohibited... (3)(A) for any personto removeor renderihoperativeany deviceor elementof design with installed on or in a motor vehicleor motor vehicle engine in compliance regulations under this title prior to its saleand deliveryto the ultimatepurchaser, any or for any manufactureror dealerknowingly to removeor renderinoperative such device or element of designafter such sale and delivery to the ultimate purchaser. (3XB) for any personengaged the business repairing,servicing, selling,leasing, or in of trading motor vehiclesor motor vehicleengines, who operates fleet of motor or a vehiclesknowingly to remove or render inoperativeany deviceor element of designinstalled on or in a motor vehicle or motor vehicleenginein compliance with regulationsunder this title following its sale and delivery to the ultimate ourchaser..."
(Continued next page.l on
NOTE . The phrase " removeor rendet inoperativeany device or element of design ,, hasbeen generally interyreted as follows : 1. Tampe ng does not include the temporary removalor rendering inoperativeof devices or elementsof design in order to perform maintenance2. Tamperingcould include : a. Maladjustment vehiclecomponents of such that the emission standards exceeded. are b. use of replacement parts or accessorieswhichadverselyaffect the pedotmanceor durability of the motorcycle. c. Addition of componentsot accessories that result in the vehicte exceeding the standards. d. Permanentlyremoving,disconnecting,or renderinginoperativeany componentor element of designof the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVETHESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLEBY CIVIL PENALTIES NOT EXCEEDING PER VIOLATION. $1O,OOO
TAMPEBING WITII NOISECONTBOLSYSTEM PBOHIBITED Federallaw prohibitsthe followingacts or the causing thereof: (1) The removal or rendering inoperativeby any personother than for purposes maintenance, of repair, or replacement, any darice or element designincorporated of of into any neurvehicle'for purposeof noisecontrol prior to i6 sale or deliriery the ultimatepurchaser th_. to or while it is in use,or (21the useof the vehicleafter grch deviceor elemento:f a".id h., beenremoredor rendered inoperative any pervrn. by those astspre$medto constitute tampering theactslistedbelow: are _Among . R.eplacemnt the originalexhaust of_ systemor mrifflerwith a component not in compltance
wtth Fedeftrl regulations. oRemovalof the muffler(s)or any internalportion of the muffler(s). .Removal of the air box or air box cover. rModifications to the muffrer(s) or air intake system-' cutting, dri ing, by -or other means if such modifications result in increased noisetevLis.
Foreword
primarilyfor useby This manualis designed properlyequipped in shop. trainedmechanics a However, it contains enough detail and basic information to make it useful to the owner who desiresto perform his own basic maintenance and repair work. A basic knowledge of mechanics,the proper use of tools, and workshop procedures must be understood in order to carry out maintenanceand repair satisfactorily, Wheneverthe owner has insufficient experienceor doubts his ability to do the work, all adjustments,maintenance,and repair should be carriedout only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes,read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenwer special tools or equipment are specified, do not use makeshifttools or equipment. Precision measurementscan only be made if the proper instrumentsare used, and the use of substitute tools may adversely affect safe operation. For the duration of your warranty period, especially,we recommendthat all repairsand scheduled maintenance performedin accordbe ance with this service manual, Any owner maintenance repair procedurenot performed or in accordance with this manual may void the warranty. To get the longest life out of your Motorcycre: oFollow the PeriodicMaintenance Chartin the Service Manual, .Be alert for problems and non-scheduled maintenance. eUseproper tools and genuineKawasaki Motorcycle parts. Special tools, gauges, testers and that are necessarywhen servicing Kawasaki motorcycles introducedby the Special are Tool parts Manual. Genuinepafts providedasspare are listed in the PansCatalog. rFollow the procedures in this manual car+ fully. Don't take shortcuts. rRemember to keep complete recordsof maintenance and repair with dates and any new pafts installed.
Howto Use Manual this

ln preparing this manual, we divided the product into its major systems, Thesesystems becamethe manual'schapters. All information for a panicularsystemfrom adiustmentthrough and inspectionis located in a single disassembly chapter, Guide showsyou all of The Ouick Reference produst,s systems and assisB in locating the their chapters. Each chapter in turn has its Table of Gontents. olvn comprehensive Chan is locatedin The PeriodicMaintenance the General Information chapter. The chart givesa time schedulefor required maintenance operations, lf you want spark plug information, for Chart example,go to the PeriodicMaintenance first. The chart tells lou hovv frequently to clean and gap the plug. Next, use the Ouick Guide to locatethe ElectricalSystem Reference chapter. Then. usethe Tableof Gontentson the first pageof the chapterto find the Spark Plug section. Whenaneryou see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operatingand maintenance practices.
oThis waming rymbol identifiesspecialinstructions or procedures which, if not correctly followed, could result in perconal iniury. or lossof life.
oThis caution symbol identifies specialinstrucwhicfi, if not strictly obtions or procedures served,could result in damageto or destruction of equipment. This manual contains five more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information. NOTE
oThis note symbol indicates pointr of particular interest for more efficient and convenient operation.
.Indicates a procedural step or work to be done. olndicates procedural a sub-step how to do or the work of the procedural step it follows. It also precedes text of a WARNING, the CAUTION, NOTE. or * lndicates conditional a stepor what actionto take based on the results of the test or inspection the procedural in step or sub-step it follows. *lndicates a conditional $b-step or what astion to take basdupon the resultsof the conditional it follows. step ln most chapters an.exploded viqlv illustration of the systemcomponents follorvsthe Table of Contents. In theseillustrations you will find the instructions indicating whichparts requireqecified tighteningtorque, oil, grease or a locking agent duringassembly.
GENERALINFORMATION T.1
Information General
Tableof Contents
Servicing Before Modelldentification . . . . . ,. General Specifications. . Periodicmaintenance Chart. Torque and Locking Agent Routing. Cable. WireandHose 1-2 14 1-5 1-7 1 1-12
1.2 GENERALINFORMATION Before Serwicing

Beforestarting to servicea motorcycle, carefulreadingof the applicablesection is recommended eliminate to unnecessary work. Photographs,diagrams,notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations,a certai; amount of basic knowledge is also requiredfor successful work. Especially note the following; (1) Dirt Before removal and disassembly, clean the motorcycle. Any dirt enGring the engine or other partswill work as an abrasiveand shortenthe life of the motorcycle. For the sameieason, defore installing a new part,clean off any dust or metalfilings. (2) BatteryGround Remove the ground (-) lead from the battery before performingany disassemblyoperationson the motorcycle. When installing,.connect positive (+) leadfirs! then the negative the 1-j teadto the battery. This prevents: (a) the possibilityof accidentally turning the engineover while partiallydisassembled.(b) sparksat electrical connectionswhich will occur when they are disconnected. 1c1damage to electrical Dans. (3) Installation, Assemblv Generally,installationor assemblyis the reverseof removalor disassembly. But if this ServiceManual has installationor assembly procedures, follow them. Note partslocations ani cable,wire, and hoserouting during removal or disassembly they can be installedor assembled the sameway. lt is preferable so in 6 mark and recordthe locationsand routing as much as possibte. (4) TighteningSequence Generally.when insulling a part with severalbolts, nuB, or screws,start them all in their holes and tighten them to a snug fit. Then tighten them evenly in a cross pattern. This is to avoid distortionof the part and/or causing gas or oil leakage. Conversely when looseningthe bolts, nuts, or screws.first loosen all of them by about a quanerturn and then removethem. Wherethereis a tightening sequenceindication in this Service Manual. the bolts, nuts,or screwsmust be tightenedin the ordlr and irethod inoicated. (5) Torque When torque valuesare given in this ServiceManual, usethem. Eithertoo little or too much rorquemay leadto seriousdamage. Usea good quality,reliabletorque wrench, (5) Force Common senseshould dictatehow much force is necessary assembly in and disassembly.lf a pan seems especiallydifficult to removeor install,stop and examinewhat may be causing the problem. Whenever tapping is necessary, lightly using a wooden or plastic-facedmallet Use an impact driver for tap screws (particularlyfor the removalof screwsheld by a locking ageno in orderto avoid damaging the screw heads. (7) Edses Watch for sharp edges,especially during major engine disassembly and assembly. protect your hands with gloves or a piece of thick cloth when litting the engineor turning it over. (8) High-FlashPointSotvent A high-flash point solvent is recommended reduce fire danger. A commefcial solvent commonly to availablein North Americais Stoddardsolvent (genericname). Always follow manufacturer and container directionsregardingthe use of any solvent. (9) Gasket, O-Ring Do not reuse a gasket or O-ring once it has been in service. The mating surfacesaround the gasket should be free of foreign matterand perfectlysmooth to avoid oil or compressionleaks. . (10) LiquidGasket, Non-Permanent Locking Agent Follow manufacturer's directionsfor cleaningand preparingsurfaceswhere these compounds will be used. Apply sparingly' Excessive amountsmay block engineoil passages and causeseriousdamage. An example of a non-permanentlocking agent commonly availablein North America is Loctite Lock,n Seal (Blue). (11) Press A part installedusing a pressor drivet such as a wheel bearing,shouldfirst be coatedwith oil on tts outer or inner circumference that it will go into place smoothly. so http://manuals.magnamaniac.com (12) Ball Bearing and NeedleBearing Do not remove a ball bearingor a needlebearing unlessit is absolutelynecessary. Replaceany ball or needlebearingsthat were removedwith new ones,as removalgenerally damagesbeirings. Installbearings with the markedside facing out applyingpressure evenlywith a suitabledriver. Only pr& on the racethat
1-3 GENERALINFORMATION
forms the pressfit with the basecomponentto avoid damagingthe bearings. This preventsseverestress on the balls or needlesand races,and preventracesand balls or needlesfrom being dented. Pressa ball bearinguntil it stops at the stops in the hole or on the shaft. (13) Oil Sealand Grease Seal Replaceany oil or greasesealsthat were removedwith new ones,as removalgenerallydamagesseals. When pressingin a seal which has manufacture/smarks,press it in with the marksfacing out. Seals should be pressedinto place using a suitabledrivet which contacts evenlywith the side of seal, until the {ace of the seal is even with the end of the hole. Beforea shaft passesthrough a seal,apply a little high greaseon the lips to reducerubberto metalfriction. temperature (14) Circlip. Retaining Ring.and CotterPin Replaceany circlips, retaining rings. and cotter pins that were removed with new ones, as removal weakensand deformsthem. When installingcirclipsand retainingrings, take careto compressor expand them only enough to installthem and no more. (15) Lubrication Engine wear is generallyat its maximum while the engine is warming up and before all the rubbing surfaceshave an adequatelubricativefilm. During assembly,oil or grease (whichever is more suitable) and dirty oil should should be appliedto any rubbing surfacewhich has lost its lubricativefilm. Old grease greasehas lost is lubricative qualityand may containabrasive foreign panicles. be cleanedoff. Deterioiated Don't use iust any oil or grease. Some oils and greasesin particularshould be used only in certain applicationsand may be harmful if used in an applicationfor which they are not intended. This manual makesreferenceto molybdenum disulfide grease(MoS" ) in the assemblyol certainengine and chassis parts. Always check manufacturer recommendations betoreusing such speciallubricants. (16) Electrical Wires All the electricalwires are either single-coloror two-color and, with only a few exceptions,must be amount of one color connectedto wires of the samecolor. On any of the two-color wires there is a greater and a lesseramount of a second color, so a two-color wire is identified by first the primarycolor and then "yellow/red" wire; the secondarycolor. For example,a yellow wire with thin red stripes is refenedto as a "redlvellow" wire il the colorswere reversed make red the main color. to it woufd be a
Wire (cross-section)
Red
Name WireColor of
' WireStrands
Yellow/Red Yellow Red (17) Replacement Parts When there is a replacement instruction,replace thesepartswith new ones everytime they are removed. partswill be damagedor losetheir originalfunction once removed. Thesereplacement (18) Inspection visually inspectthese parts for the following conditions or-other When parts have been disassembled, damage. lf there is any doubt as to the conditionof them, replacethem with new ones. Abrasion Crack Hardening Warp Dent Wear Bent Scratch Color change Deterioration Seizure (19) Specifications SDecification terms are defined as follows: "Standards": which brand-new partsor systems have. show dimensionsor performances "Service Limits": indicate the usable limits. lf the measurement wear or deteriorated shows excessive performance, replacethe damagedparts.
14 GENERAL ]NFORMATION Model ldentification VN1500-A1 Right SideView
VN15qlB1 Left Side View
16 GENERALINFORMATION GeneralSpecifications
Items Dimensions: Overall length width Overall height Overall Wheelbase Road clearance Seatheight Dryweight Curbweight: Front Rear Fuel tankcapacity Pertormance: radius lrinimum tuming Engine: Type Cooling system Boreandstroke Displacement ratio Compression horsepower Maximum
A1 A7 VN1sOGAI/AZA3/A4IA5IA6I I AU A9IA1OI 1INA 413 vN1500-81/BZB3/84/85/86 (l) (E) (A)(F) 385mm, 2 410mm, 2 375mm, 2 2 390mm, 895mm (AXE)1 180mm 1 190mm, 1 605mm (AXE)lS5 mm 150mm, (A)(E) mm 720mm, 750 (Car)2s2.5 (E)257k9,(G)256kg kg, 2s2 k9, 126kg,(Cal)128kg (E) 154kg,(Cal)154.skg, 1s7kg,(G) 156kg 1 6L (AXE) nrn 2.7 3.0mm, 4-stroke, SOHC,2-cylinder Liquid-cooled 102.0x 90.0 mm 1 470mL 9.0:1 53.0kW (72PS)@4500r/min(rpm),(Us)(E)51.5kW(70 PS)@4500r/min(rpm) norm) (F)50.0kW(-)@4 500r/min(rpmXUTAC's (G)s1.5kW(70 PS)@4500r/min(rpmXDlN) (rpm) (W)34.9kW(47.5PS)@3800 r/min (rpm) A4-(E)44.9kW (61PS)@4300 r/min (rpmXDlN) (61PS)@4300r/min A4-(G)44.9kW norm) As-(F) 43.5kW(-) @4300r/min(rpmXUTAC's kg-m,91 ft-lb)@3000r/min(rpm) 123.6 N-m(12.6 (E) 2 370 mm, 2 410 mm (E) 1 210mm, 1 195mm (E) 1 635 mm, 1 630 mm 165mn,(E)160mm (E) 710mm, 745mm 248kg,(Cal)248.5kg (E)24eks (Cal) 121.5 kg 121kg, (E) 1s4kg, 15skg 1 2L 3.0m
torque Maximum
(F)-,(us)-
Carburetor system Starting system system lgnition Timing advance lgnition timing plug Spark
(G)123.6 kg-m,91 ftlb) @300or/min N-m(12.6 GpmXDlN) (rpm) (W)105.9 kg-m,78.1 @2300r/min tt-lb) N-m(10.8 (rpm) itlb) N-m(11.5k9-m,83.2 @3300r/min A4-(E)112.8 ftlb) N-m(11.5kg-m,83.2 A4-(G)112.8 @3300r/min(rpmXDlN) Keihin CVK36x 2 Carburetors, Eleclric starter Batteryandcoil (transistorized) Electronically advanced =-, r/min(rpm) 5"BTDC@800
(w) 5"BTDC (rpm)
or NGKDPRTEA-g NDX22EPR-Ug (AXIXU) or NGKDPRTEA-g ND X22EPR-U9 or A11- : (U)NGKDPRTEA-g ND )Q2EPR-U9 to numbering method Front Rear,1-2 Cylinder 'l-2 Firing order Valve timing: 22'BrDC Inlet Open 66"ABDC Close 26A" Duration 66.BBDC Exhaust Open 26.ATDC Close Duralion http://manuals.magnamaniac.com 272" (wet Forced lubrication sump) Lubrication system SE,SF,or SGclass Engine oil: Grade 20W-50 20W-40, 10W-50, sAE 10W-40, Viscosity Capacity 3.5L
1 GENERAL INFORMATION
VNl500"A1IAZA3/AN ASIAGI AAAglA1UA11tA1AA1g vNl 500-81/B2/B3/BtyB5/B6 A DriveTrain: Primary reduction system: Type Reduction ratio Clutch lype: Transmission: Type Gearratios:1st znd 3rd 4th Final drivesystem: Type Reduction ratio Overall driveratio Finalgearcaseoil: Type Capacity Frarne: Type (rakeangle) Caster Trail Front tire: Type Size Reartire: Type Size Front suspension: Type Wheel travel Rearsuspension: Type Wheel travel Braketype: Front Rear
Gear (8s/56) 1.s17 Wetmultidisc 4-speed, constant mesh, return shift 2.s00(40/16) 1.s90(35/22), 1-1.375 (33t24], 41 (31/26), 1.192 (29/28) 411-1.03s 0.965(28/29), 1-0.781125/32) Al Shalt (15/21 x33/9) 2.619 3.838, 411-3.105 gear @Top API GL-sHypoid gearoil SAE90(above 5"C) SAEso(below 5"C) 22OmL Tubular, double cradle 31" '128 mm Tubeless 100i90-19 57H Tubeless 15O90-15 o|l5cl/90-15 74H 74H M/C Telescopic tork 150mm Swingarm 100mm Single disc Single disc
33' , (E)32.5" (E) 138mm, 132mm Tube Tube =-or 150/90815 74H M/C
Electrical Equipment: Battery 12V20Ah Headlight: Type Semi-sealed beam '12 Butb V 60/55W (quartz-halogen) Taiubrake light 12V A7127Wxz( )(E)12V s/21WX2 Altemator: Type Three-phase AC Ratedoutput 25 A @6000r/min (rpm),14V Specitications subject changewithout are t( to notice, maynot applyto everycountry. and (A) : Australian Model (Au) : Auslrian Model (Cal): Califomia Model (E) : European Modol (F) : French Model (Fi): Finnish Model (G) : WestGeman Model (l) : ltalianModel (Sd): Swedish Model (U) : U.S.A.Model (UK): UK Model (W) : Switzertand Modet
"1 (Au)(W) -2 (AUXW) 34.9kW (47.sPS)@3800/min (rpm) 105.9 N-m(1o.8kg-m,78.1 ttlb) (E)s1.5kW (70 PS) @5000r/min(rpm) @2300r/min(Ipm) (G)s1.5kW (70PS) @5@0 r/min(rpmXDlN) (E)127.5 (13.0kg-m,g4.O @300or/min(rpm) Nm tr-tb) 84- (E)45.7kW (-) @5000r/min(rpmXUTAC's norm) (G)'i27.5Nm(13.0 k9.m,94.0 @3000 r/min(rpmXDtN) ftlb) 84- (G)47.1kW (64 PS)@500or/min(rpmXDtN) 84- (G)117.7 N-m(12.0 kg-m,86.8 @3300r/min(rpmxDtN) ftlb) http://manuals.magnamaniac.com(12.0kg-m,86.8 84- (D(SdXUK) kW (64 PS)@5000r/min(rpm) 47.1 84- (IXSdXUK) 117.7 N-m ft-lb) 85- (Fi)47.1kW (64 PS)@500or/min(rpm) (rpm) @3300r/min (US)_ 85- (Fi)117.7 N-m(12.0kg-m,86.8 @3300r/min(rpm) t-tb)
(us)
PeriodicMaintenanceChart (Other than US and Canada)

The scheduled maintenancemust be done in accordancewith this chart to keep the motorcyclein good running condition. The initial maintenance is vitally important and must not be neglectei.
FREOUENCY.
OPERATION plug - clean gapt Spark and Air suction valve- checkt
Air cleanerelement- clean t # Throttlegrip play - checkt
o
a
o
a a
a
a a
6 months
o
a a
ldlespeed- qdiust
Carburetor synchronization- checkt - change Engineoil # Oil lilter - replace Oil screen - clean Radiatorhoses,connections- checkt Coolant - change Finalgear caseoil level - checkt Finalgear caseoil - change Propeller shaft joint - lubricate Clutch slavecylindg piston seal - replace Brakelining or pad wear - checkt #
o o a
a
o
a a o a
o o o
a a a
o o
a a a a a
o
a
o
a
a a
2 yeas
a
O
a
4 years
a a a a a
Brake/clutch levet checkt fluid

Brake/clutchfluid - change
a
month 2 yeas 4 years 4 years
a a
Brake/clutch master cylinder anddust cup seal- replace

Caliperpiston seal and dust seal - reprace Brakelight switch - checkt Steering - checkl Steeringstem bearing- lubricate Frontfork oil - change Rearshock absorberoil leak - check T Frontfo* oil leak - checkt
a a a
a a
2 yeats
a a
o
a
o
a a a a
a a
a a
2 years
Tirewear - checkt
Spoketightnessand rim runout - checkt (vN15008) Swingarm pivot - lubricate Baftery elgctrolyte tevel - checkl Generallubrication- oerform Nut, bolt, and fastener tightness - checkt 6 month
a a
a a a a a a a a
o
a a a a a a a a a a a
a a a a a a
O
o
a
: Service more. frequently when operating in severe conditions; dusty, wet, muddy, , high speed, or frequent starting/stopping. : For higher odometerredings,repeatat the frequencyintervalestablished here. : heprace,add, adJust, ctean,or torque if necessary.
1.7 GENERALINFORMATION
Chart (Us and Canada) PeriodicMaintenance must be done in accordance with this chart to keepthe motorcycle in maintenance The scheduled is good running condition, The initial maintenance vitally important and must not be neglected.
Whichever first FREOUENCY comes OPERATION

s,ynchronization checki Garburetor Throttle grip play - check 1 Spark plug - cleanand gap t Air suctionvalve- check J element- clean Air cleaner element- replace Air cleaner
ldle soeed-- adiusl
TODOMETER READING
a o a
a a a a
a a a a a a o
a
a
a
a
Fuelsystem check t
5 cleaninqs
a a
a
O
a a a a a a a a
a a a a
a a a o a
a a
a a a a a a a a a a a a a
(CA) controlsystem Evaporative emission - checkt Batterv electrolvtelevel- checkt -. Brakeliqht s\n,itch check f - check f Brakepadwear Brake/clutchfluid level- checkI Brake/clutchfluid - chanqe Steerins- checki Final qearcase level- checkt oil oil Final gearcase - change Propeller shaftioint - lubricate tightness- check1 Nut, bolt. fastener and Spoketightness rim runout - checki (VN1500-8 only) Iire wear- checkt Enqine - chanqe oil Oil filter - replace
a a o o a a a a a
a a a a a a
a
a a
month
a
a
month
a
a a a
O
a a a
a
a a a a
2 vears
a
a a a a a a a a a a o a a a o a a a a a a a a
a
a
a a
year
a a
a
a
Oil screen clean
a
a
Generallubrication- perform Front fork oil - chanqe Coolant- change connections check1 Radiatorhoses, - lubricate Steeringstembearing cylinder cup and Brake/clutchmaster dust seal- reolace Caliperoiston sealand dust seal- replace cvlinder piston seal- replace Clutch slave
a a
a
Swinqarm pivot -- lubricate
2 yearc
year
a a
2 years 2 years 2 yearc 2 years 4 years 4 years
a a
hose Brake/clurch andpipe- replace

Fuel hose- reolace
here. r : For higherodometerreadings, repeatat the frequencyintervaleEtablished : Replace, add,adjust,clean,or torque if necessary. t (CA):California vehicle only
1 GENERAL INFORMATION Torque and LockingAgent The foilowing tableslist the tighteningtorque for the majorfasteners, the partsrequiringuseof and a non-permanent locking agentor liquid gasket. Lettercusedin the "Remarks" column mean: L Apply a non-permanent locking agentto the threads. ss Apply siliconesealantto the threads. M Apply molybdenum disrlfide lubricant (grease oil) tq the threads and seatedsr rface, or or washer. o Apply oil to the threads,seatedzurface,or washer. b Tightenthe fasteners following the specifiedtoroue. st stake the fastenerto prwent loosenins.
Fascner Cooling System: Cooling Switch Fan Bleed Valve Water Pump lmpeller Bolt Water Pump Cover Engine Top End: Rocker Case Cover Bolts Rocker Shaft Rocker Case BoltsandNuts: 12 mm 8mm 6mm Cylinder Head Nuts Cylinder Nut Oil PipeBanjoBolts Camshaft Sprocket Bolts SparkPlugRetainer Chain Tensioner Bolts Clutch:
Torque
N-m kgrn ft-lb
Remarks
7.8 7.8 8.8 9.8 8.8 25 78 25 8.8 25 25 12 15 12
| | |
0.80 0.80 0.90
69 in-lb 69 in-lb 78 inlb 87 in-lb 78 in-lb 18.0 58 18.0 78 in{b 18.0 18.0 104inlb 11.0 '104 in-lb
Left-handed Threads
1.0 0.90 2.5 8.0 2.5 0.90 2.5 2.5 1.2 1.5
,:
S S
Clutch LeverPivot Nut 5.9 0.60 52 in-lb MasterCylinderClampBolts 8.8 0.90 78 in-lb Clutch HoseBanioBolts 25 2.5 18.0 Clutch SlaveCylinder Bolts 8.8 0.90 78 in-lb BleedValve 7.8 0.80 69 inlb RH Engine CoverDamper Bolts 9.8 1.0 87 in-lb ClutchHub Nut 145 15.0 110 ClutchPioe Joint 18 1.8 13.0 EngineLubricationSystem : Crankcase Nozzle Oil 2.9 0.30 26 in-lb Oil Pressre Relief Valve 20 2.O 14.5 Oil Prescrre Switch 15 1.5 11.0 Engine DrainPlug N 2.O 14.5 Oil Filter 18 http://manuals.magnamaniac.com 13.0 1.8 Oil Screen Plug 20 2.O 14.5 Oil PipeBanjoBolts 12 1.2 l(X in-lb
L SS
1-9 GENERAL INFORMATION

Fastener N-m
Engine Removal/lnstallation: EngineMountingBolts EngineMounting BracketBolts RightDown Tube Mounting Bolts Crankshaft /Transmission: Crankcase Bolts: 10 mm 8mm 6mm External Shift Mechanism ReturnSpring Bolt GearPositioningLeverBolt ConnectingRod Big End Cap NUts PrimaryGear Bolt AlternatorRotor Bolt Camshaft ChainGuideHolderBolts StarterClutch Bolt StarterClutch Coupling Bolt Balancer GearBolt HolderScrew Shift Drum Bearing NeutralSwitch Rear-rightStud Tap End Wheels/Tires: FrontAxle Nut FrontAxle Clamp Bolt RearAxle Nut Air Valve Nuts Final Drive: Front BevelGearCaseBolts: 6mm 8mm DamperCam Nut Drive GearNut NeutralSwitch Oil PipeBanjoBolts DrivenGearAssemblyMounting Bolts DrivenGearBolt FinalGearCaseMountingNuts PinionGearNut FinalGearCaseCover Bolts: 8mm 10mm FinalGearCaseStuds DrainBolt PinionBearing Retainer Retainer Stop Screw 44 24 44
?o
Torque
kg-m
Removark
ft-rb
33 '17 .5
55
4.5 2.4 4.5 4.0 2.1 0.90

1.1
21 8.8
29 15.0 78 in-lb 15.0 78 in-lb

+J
21 8.8
59 '| 45
0.90 6.0 15.0 6.0
110 43 L
o:,
93
:,5 ,tt
11.0
Y.C
L L
1 1. 0 L
88 29
110 1.5 8.8 25 225 265 15 12 25 120 29 120
t2
9.0
?n
11.0 0.15 0.90 2.5 23 27

I.C
22 80 1 3i n - l b
78 in-lb 18.0
toc
o
L
1.2 2.5 12.1 3.0 12.O
11.0 104 in-lb 18.0 88 22 6t 16.5

.,8
St L L L Left-handed Threads L
2.3
? E
34 8.8 245 16
oso
25
1.6
ZSin-f O 180 11.5
1-IO GENERAL INFORMATION

Fastener N-m Brakes: BrakeLeverPivotNut Frontlvlaster Cylinder ClampBolts BrakeHoseBanjoBolts Caliper Mounting Bolts Bleed Valves DiscMounting Bolts RearMaster Cylinder Mounting Bolts Caliper Holder Bolt BrakePedalLinkClampBotts Suspension: FrontForkClampBolts: Upper
LOWer
Torque
kg-m 0. 60 0. 90 2.5 0. 80 2.8 2.3 6.5 2.5 2.O 5.3 2.O 1 0 .0 3.0 3. 1 6.0 4.O 0. 50 44 24
z5 59 18 7.8 15 15
ft-m 52 inlb 78 inlb 18. 0 69 in-lb 20

to. c
Remarks
8.8 25 32 7.8 27 23 64 25 20 52 20 98 29 30 59
47 1 8 .0 '14. 5 38 14. 5 72 2. 22 zl3 29 43 inlb 33 1 7 .5 1 8 .0 43 't2. 5 69 inlb 11.0 11.0
FrontForkDrainBolts FrontForkBottom AllenBotts Swing Arm PivotShaft FrontAxleClampBolt Fear Shock Absorber l\ilountjng Nuts Steering: Handlebar ClampBolts Weight Mounting Screws Steering StemHeadBolt Steering StemLocknut Ftame : RightDownTubeMounting Bolts Engine Mounting Bracket Bolts BrakePedalLinkClampBotts Electrical System: Alternator RotorBolts SparkPlugs Cooling Switch Fan Neutral Switch Oil Pressure Switch
4.5 2.4 2.5 6.0 1.75 0. 80 '1. 5

t.c
1.11 GENERALINFORMATION lists torquefor the bolts tightening torqueto threaddiameter, *re basic The tablebelow,relating a torquevalue. and nuts. Usethis table for only the bolts and nutswhichdo not require specific with dry solvent+leaned are threads, All of thevalues for use
General Fastenen Threadsdia. (mml

c
Torque
N-m kgm ft-lb
6 8 10 12 14 16 18 20
3.4 - 4.9 5.9- 7.8 14-19 25 -34 44 -61 73-98 115-155 165 -225 225-325
0.35- 0.50 0.60- 0.80 1.4- 1.9 2.6- 3.5 4.5 -6.2 7.4- 10.O 11.5 16.0 -23 17.O 23 - 3:t
30 - zt3in-lb 52 - 69 in-lb 10.0 13.5 19.0 25 33-45 54-72 8 3- 1 1 5 125- 165 165- 2'10
1-12 GENERALINFORMATION Wire,andHose Cable, Routing

................;,,....... WidngRouting
1. 2. 3. 4. 5.
Wire Straps CoolingHoses SideStandSwitch RearBrakeLight Switch FuelPump
(vN1500-B)
1. Junction Box 1. WireClamps http://manuals.magnamaniac.com Sarter Relay 2. 2. RearFender Rear Section 3. Battery(+) Wire 3. Rear Turn Signal Light 4. Battery
Cable, Hoseand Wire Rouling
l. Left SwitchHousing Wire 2. ClutchHose 3. WireStraps 4. Bnke Hose 5. RightSwitchHousing Wire 6. Cable Guide 7. ThrottleCables 8. Turn Signal Light or Headlight Stay 9. Cable Hose or Guide .l0. Speedometer Cable 11.Clamps 12. CoolingHose 13: Clutch Pipe
1-14 GENERAL INFORMATION Carburetor Hose Routing

(Canadian Model)
l. Vacuum Hose 2. Vacuum HoseFitting 3. Vacuum Hose(To RearVacuum SwitchValve) 4. Vacuum Hose(To IC lgniter) 5. Air Breattrer Hose 6. Air Breather HoseFitting 7. Vacuum Pulse Hose(To Liguid/Vapor Separator) 8. Vacuum Hose(To Front Vacuum SwitchValve) 9. Front Vacuum SwitchValve 10. ChokeKnob l l. Air Breatfter Hose(To Canister) '12. Purge Hose(Between surge the tank andthe canister) (US.California Model)
HoseRouting
1. 2. 3. 4. 5. 6. 7. 8.
9. Check Valve(VNl500.A) Clean Hose Air 10. Hose RearVacuumSwitchValve Guide 11. Battery VacuumHose Hose 12. Battery Vent Hos Straps Air Breather 13, Hose Hose http://manuals.magnamaniac.com Guides 14. Surge Air Filter Tank 15, Drain lC lgniter Hose Breatier
1.16 GENERAL INFORMATION

Evaporative Emission Control System Hose Routing
(vNlsoGA)
1 . Breather Hose 2. CheckValve 3. ReturnHose(Red)
'..__
-E i------E--i-
I * l :
(vN1s00-B)
1. FrontVacuum SwitchValve 2. Wireor Hose Straps 3. Liquid/Vapor Separator 4. Batttry 5. lgnitionCoil (Front) 6. lgnitionCoil (Rear) 7. Return Hose 8. Breather Hose 9. Starter MotorWire
1. Clean Hose Air 2, VacuumHose '3. SwitchValve '4. RearVacuum Hose Guide 5. Vent Tube 6. Reservoir TankTube 7. Reservoir Tank http://manuals.magnamaniac.com 8. Wireor HoseStraps 9. lgnitionCoil (Front) 10. lgnition Coil (Rear) 11. Canister
T-17 GENERALINFORMATION
Eyaporatiye Emi$ion control System Hose Routing
l. 2. 3. 4. 5. 5. 7. 8. 9.
Hose Stps Engine Bracket Hose Clamp Canister Separator Liquid/Vapor CoolingHose StarterMotor StarterMotor Wire Radiator
,/.-\ , )
1. FuelTank 2. CheckValve(VN150GA) 3. Breather Hose(Blue) (ReturnPump) 4. Liquid/Vapor Separator (White:To Carburetor) 5. VacuumPulse Hose 6. Breather Hose(Blue) (Red) 7. ReturnHose 8. Cover http://manuals.magnamaniac.com 9. Canister 10. Breather Hose(Yellow: To Carburetor) 11. Purge Hose(Green) 12. Surge Tank
I.18 GENERAL]NFORMATION
Engine Top End Ho.e Routing
'!i!
,-'.------'-
1. Vacuum Hose(lC lgniter) 2. Cooling Hose 3. Thermostat Housing 4. FrontVacuum SwitchValve 5. FuelFilter 5. Clut h Hose 7. ThroitleCables 8. Vacuum Hose(To Front Vacuum Swirch Valve) 9. Clean Hose Air 10. ClutchHose Strap 11. Cooling Hose 12. Vacuum Hose(FrontCarburetor) 13. FuelHose Carburetor) (To 14. FuelPump 15. Surge Tank 16. Vacuum Hose(RearCarburetor) 17. Vacuum Hose(To RearVacuum Switch Valve) 18. FuelHose (To http://manuals.magnamaniac.com FuelPump) 19. Air Breather HoseFitting 20. Resrvoir Tank Tube 21. Air Breather Hose
FUEL SYSTEM2-1
Fuel System
Table of Contents
ExplodedView... Specifications ......,.'. SpecialTools. Throttle Grip and Cables.. Throttle CableAdjustment Carburetorc, ldle SpeedAdiustment Adjustment (US model). High Altitude Performance I Fuel SystemCleanlinessnspection. CarburetorSynchronization ServiceFuel LevelAdjustment . . . . . . CarburetorRemoval CarburetorI nstallation . CarburetorSeparation. , CarburetorCombination CarburetorDisasembly. GarburetorAssembly.. . . . retor Inspection, Carbu FuelPump. Removal lnstallation Notes . . Fuel Filter. Removal Notes. , lnstallation Inspection Air Cleaner Removal Element(Housing) . . E l e m e n t C l e a n i.n s . . . Installation... . . Housing Air Cleaner Air CleanerDuct lnstallation SurgeTank SurgeTank Removal
2-2 2-5 2-5 2-6 2$ 2-7 2-7 2-7 2-7 24 24 2-9

2-10 211 2-11 2-12 2-12 2-14 2-14 2-14 2-15 2-15 2-15 2-15 2-15 2-15 2-15 2-16 2-16 2-17 2-17 2-17 2-17 2-17 2-17 2-17 2-18 2-18
(US Vehicle only)' . . ' Emission ControlSystem California Evaporative Notes. . PansRemoval/lnstallation Hose Inspection. . Inspection Separator Test Separator Operation http://manuals.magnamaniac.com Inspection Canister
2.2 FUEL SYSTEM ExplodedView
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t ^
(D
A-
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6
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(us)(vy)
1. Left Switch Housing 2. Right Switch Housing 3. ThrottleCable(Accelerator) 4. Throtlle Cable(Decelerator) 5. Jet Needle 6. ThrottleValve 7. FloatValveNeedle 8. Float Pivot Pin 9. Float t0. PilotScrew 11.Needle Holdei Jet 12. MainJet 13. Fuel DrainScrew 14. Botlom Cover 15. FrontCarburetor 16.RearCarburetor 17. FloatChambel 18.ChokeKnob Assembty ""\.
"al
A12:CN
./'1
(US)(w)
\ s 6
sBe ,u&^,
g
FUEL SYSTEM2.3
A12:CN
(usxw)
o-l frles I t u ii iE
i9t
rlr
1. DrainHose 2. VacuumSwitchValve 3. Air CleanerDuct 4. Surge Tank 5. Surge Tank Duct (Front) 6. Surge Tank Duct (Rear) 7. Air CleanerElement A12:CN 8, Fuel LevelSensor 9. Fuel Tap
(us)w)
(cal) (cal) CalitorniaModel
(us) U.S.A.Model
(W) Sruitzerland Model (cN) CanadaModel
u-)
vNlsoGB I
<-' ------46,
a I
rT-t
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24 FUEL SYSTEM
ExaporariwEmbtion Cofitrol Sy$m (Califomiailodell
@>,\
WHITEJ I
\ T J
H
4
1. FuslPump 2. Bnd(ct 3. Uquid/V8porSsp.rsbl 4. Cani*er
'
YELLOW
ffi
FUEL SYSTEM2
Specifications
Item ThrottleGrip : grip Throttle freeplay Carburetors: Make, type jet: Main Jet needle: Front Rear Front Rear vN 1500-4
Standard 2-3 mm vN1500-8 #130 #132 (cal)N36R, N36P, W)N77D N36Q,(Cal)N36S,(W)N77D Keihin, CVK36 #) # 1 1 2 , ( C a l1 1 8 #) # 11 2 , ( U S X C11 5 , ( C a# ) 1 8 l1 (W)N67F Ns3S,(cal) N53U, (cal) Ns3V,(W) N67G N53T, N67A,(USXC) 2 turnsout,(USX\91 ll2 turnsout,As-(FG),A4-(EU): 1/4 2 - 2! 1 m m 4.2!1mm 750-850 r/min(rpm) Lessthan2.7 kPa(2 cm Hg) (Cal) : California Model (FG) : cermanyModel (swi) : Switzerland Model (EU) : EuropeModel
Pilotscrew Service level:Front fuel Rear
(W)8s0-950 r/minGpm) vacuum Synchronization (US) : U.S.A. Model (C) :Canada Model
SpecialTools
Fuel LevelGaugp:57m1-1017
2 FUEL SYSTEM Throttle Grip and Cables Throttle CableAdjustment

.Check throttle grip free play.
Throttle Grip FreePlay SGndard: 2-3mm
.Turn the accelerator cableadiuster until 2 - 3 mm of throttlegrip play is obtained.Tightenthe locknut. *lf the throttle cablescannotbe adiusted usingthe by cable adjusters the upperends at ofthe throttlc cables, use adiusters the lowerends the cables. the at of .Removetj,|e fuel tank mountingbolts and move the tanktowardthe rear. .First givetie throttle grip plenty of play at the upper ends of the throttle oables as mentionedabove. Tighten locknuts. tle .Loosen the locknuts,and screwboth throttle cable adjusting nuts in fully at the lowerendsof the throttle cables asto givethe throttlegrip plentyof play. so
l. ThrottleGrip Free Play rlf the free play is incorrect, adiust throttle cables. the
oLoosen the locknuts,and screwboti throttle cable adiustersin completelyat the upper ends of the throttle cables asto givethe throttle grip plenty of so play. .While holdingthe thrortlegripstopagainst stopper the inside,turn out the decelerator cable adruster stopping at the point wherethe grip just begins be turned to b.ackfrom the completely position. Tighten stopped the locknut.
A. Accelerator Cable B. Decelerator Cable
C. Adiusting Nuts D. Locknuts
.Turn out tl|e decelerator cableadjustingnut in the sameway with the adlusterat the upperend of the decelerator cablemakinglure that the throttle grip is not tumedbackat all, Tighten locknut. the aTurn the acceleratorcable adiustingnut until the correct throttle grip free play is obtained. .Checkthe following. ostartthe engine. oTurn the handlebar from side to sidewhile idling the engine. *lf the speedvaries, the throttle cablemay be poorly routed it may be damaged. or oConect any problembforeoperating motorcycle. the
A. Accelerator Cable B. DeceleratorCable
C. Adiusters D. Locknuts
ooperation with an impropedy adj$ted, incorreEtly routsd, or damagsd cable could result in an unsafe riding condition.
FUEL SYSTEM2.7 Adiustment High Altitude Performance (USmodel)

CONTROL PERFORMoTo improve the EMISSION above/{lq} fert, Kawasaki ANCE of vehicleso'perated Protection the recommends following Environmental cation. modifi Asencv(EPA)approved rcfiangi ti'remainlet andpilot let for highaltitudeuse' cations High Attituds C.rbutstor Specifi MainJet VNl5(xr-A From : #110 D#115 R@r : #112 @D#115 vN1500-8 Front : #ra Rgar : #1q, #o Pilot Jet
::::::::::. ldle Speed Adiustment .Starttheengine warmit up thoroughly. and from side to sidewhile idling the .Turn the handlebar engine. may be poorly *lf idle speedvaries, throttle cables the routedor they maybe damaged. the .Correctany problembeforeoperating motorcycle.
ooperation witlr an improprly adiusted. incorrecdy louted, or damagedcable could result in an unsafe ridingcondition.
lnwction Fuel System Cleanline56
.Check idle speedwiti a tachometer.
ocarolino b exusm.ly flrtnmrble and can bo axplotivs undg] csrtain condilions. Tum the imition rwitdl OFF. Do not tmok3. Mlko rule tha aloa is mll ventilaed and frco from any rcurce of fleme or rpcrkl; $b indudcs any rpgli.nce widl a pilot light. .Connect a suitable hose to the fitting at each carburetor bottom cover. con' into a suitable aRun the lower endsof the hoses tainer. .Turn out each drain plug a few turns and drain the float chambers.
ldle Spesd Standard: 750 - 850 r/min hpml @ 850 - 950 r/min (rpm) Model(VNls(XlB) @ : Swiss is until idlespeed correct' .Turn the idle adjusting screw
1. DrainScrew Hose 2. Suitable 3. Bottom Cover
http://manuals.magnamaniac.com if watrr or dirt comesouL acheck to see

Screw A. ldleAdiusting .Tighten the drainplugs. *lf any wateror dirt appeared duringthe aboveinsFec' the tion, clean fuel system.
2 FUEL,SYSTEM Caft utetoI Syn chrcnizati n o OWamuptheengine. oCheck speed adiust necessary. idle and if OAttach commercially a gauge the available vacuum to vacuum hose fittings thecarburetors. on
*lf proper carburetorsynchronization cannot be obtained by using the adiusting bolt, check for dirt or blockage, thencheckthe pilot screwsettings. and .Checkthe carburetor synchronization again. NOTE oDo not tum the pilot srcws cat"J,ldfsly during erburetors syndrronization. You may causepoor running at low ergine spaed. rCheckidle speed.
&rvice Fuel LevelAdiustment

NOTE o@rburetor fud lerEl cannot he cheked with the arburetors removed. ff therc is any doubt, drack tlre fuel level hefote runoving the carburetors. 1. Vacuum HoseFittings ocasolino i: extremely flammableand can be explosive under certain conditiom. Tum tho ignition switdl OFF. Do not smoke. Make sure the area is well yentilated and fle from any soutcsof flame or !p6lks; thb indud$ any appli.nce widr a pilot light. .Scure motorcycle a true verticalposition. the in oWhentie enginehas beenremoved,set it on a flat surfacewith tl|e carburetors installed. Put the fuel tank on a bench, and connectthe fuel tap to the carburetors using suitable a hose. rPreparea fuel hose. .Connecta fuel level guge (special tool) to the carburetor bottom coverwith the hose. etlold the gaugeverticallyagainst side of the carthe buretor body so tiat the "zero" line is at the upper edge ofthe coasting enricher mountingsciew.
astart the.engine and let it idle to measure engine the 'inAkcvasuum.. *tf thi intakevacuum differenc between cylinders t]le exceds limit, synchronize carburetors. tlte the
GarburetorSyndronization Vacuufil Leo than 2.7 kP. (2 crnHg)difference betweentwo calbuletols
.Witi the engine idling turn tl|e adiuster bolt to synchronize butterflyvalves. the owhen the adiusterbolt is umed in, the rearcylinder vacuum increases. Whenthe bolt is badcd out, the rearcylindervacuum decreases.
http://manuals.magnamaniac.com 1. FuelLevel Gauge: 57001-1017

A. Adjuster Bolt 2. Coasting Enricher 3. UpperEdgeofthe Screw 4. "Zero" line
FUEL SYSTEM2-9
oTurn the fuel tap to the ON or RES position to feed fuel to tie carburetor, then turn ou! tie carburetor drain plug a few turns. .Read the fuel level in the gaugeand compare it to the specification- Screw in the carburetor drain plug. Srvice Fuel Level From the uppet edgp ol dre coalting enticher moundng lower screw. : below 12 - 32 mm Flont : below 32 - 52 mm Rear *lf the fuel level is incorrect, removethe carburetorsand them (seeCarburetor Sepration). separate .To adjust the fuel level,bend the tang on the float arm to changethe float height.
Carburetor Removal
and flammable can be exPlosive ocasolineis extremely under certain conditions. Turn the ignition switair OFF. Do not smoke. Make sure dte area is well ventilated frce frcm any rcurceof flameor lparks; and wi$ 8 pilot light. any appliance this indudss .First remove following. the Seat FuelTank Drainthe fuel from the carburetor. Loosen tirottle cableadiuster. the .Then remove followingfrom the left side. the Throttle CableHolder Screw (Loosen) Surge TankDuctClampScrew HolderClampScrew(Loosen) Carburetor Hose Vacuum
A. Float
B. Tang A. ThrottleableHolderScrew TankDuct ClampScrew B. Surge HolderClampScrew C. Carburetor .Then remove followingfrom the right side. the Carburetor Cover CoverBracket Carburetor Surge Tank DuctClampScrew(Loosen) HolderClampScrew(Loosen) Carburetor VacuumHose
olncreasing the float height lowerstie fuel levelanc the decreasing float heightraises fuel level. the Fuel Levd Adiunmsnt
1. 2. 3. 4.
Float Tang Float Valve Floa! Mating Edge ChamberRibs
NOTE oDo not push the ndle masufement.
Tank A. Surge http://manuals.magnamaniac.comDuctClampScrew Screw Holder Clamp B. Carburetor Hose C. Vacuum D. Carburetor CoverBracket E. C:rburetor Cover
rcd in during the float height
2.10 FUEL SYSTEM

rThen remove follwoingfrom the upperend. the Clean System Air Hose Fuel Pumpand Pull the output hosefrom the carburetor. FuelPumpWireConnector Surge Tank Duct (Front Carburetor)
@
olf dirt or durt is allowed to pals through inio d|e carbuntors, the d|rctde may becomerfrrck, possibly cauringan accident.
l-wAnNrNil J
oFud .pill.d irom tft fud pump & h..:adous.
mml
olf dirt gsts through into dte engine. xcessive engine wear and polsibly enginedamage will ocorr.
@rburetortnsallation
.Carburetor installationis the reverse removal. Note of the following. olubricate the air cleanerducts and the carburetor holdercwith a soapand water solution,theo fit the carburetorsinto them. owhile aligningthe duct notch onto the surgetank proiection, fit.eachduct into th surge tank asshown.
A. Fuel Pump
B. CleanAir SystemHose D. Surge Tank Duct .fush the surgetank witl the thermostathosingtoward the front. aRemove carburetorsasshown. the
C. OutputHose
A. Not h
B- SurgeTank Projection
A. Turnthecarburctor assernbly clockwise.

oKGp horesfree of ob8truction, the aAfter installing carburetors, the performthe following. oCheck fuel leakage from the carburetors.
I wAutlruc i '-oFuel spilled from the catburetoF b hazardous.
http://manuals.magnamaniac.comitemsif necessary. oAdiustthe following

A. Taketl|e carburetorset out from btweenthe cylinderheads. ldle Speed Carburetor Synchron ization ThrottleCables
2.11 FUEL SYSTEM

@rburetor Separation aRemove front carburetor. the oRemove followingparts. the Plate Screws ChokeRod Mounting ChokeRod (3) Screws FloatChamber Front Carburetor
A. RearCarburetor B. FloatChamber
A. Choke Rod
C. FrontCarburetor D. Screws
B. Screws screws and float chamber oRemove the rear carburetor seDarate rearcarburetor. the
Rear Carburetor ChokeRod PivotScrew ChokeLink Rod
rb C.zeu retor Combinati on .lnstallation reverse removal. thefollowing. of NoG is as to aFit thefrontcarburetor thefloatchamber shown.
A. ChokeLink Rod
B. ChokeRod PivotScrew
Washer Throttle Link RodCotterPinand Plastic
A. Throttle Link Lever B. Proiections
C. Notches
A. Throttle Link Lever B. CotterPin Washer C. Plastic oconnect the choke link rods and install the plastic cotterpin. washer the throttle link lever and
2.12 FUEL SYSTEM

olnshll the rear carburetor starter plungr lever as snown.
A. Pilot Screw Plug
A. StarterPlunger Lever C. Starter Plunger B. Choke Link Rod olnstallthe chokerod to the carburetor.
OTum in the pilot screw and count the number of turns until it seats fully but not tightl, and then remove the screw. Use this number of turns to set the screw to its originalposition during assembly. awhile prying out the float pivot pin with an awl or other suitabletool, pull it out with needlenose pliers.
1. FloatPivotPin A. ChokeRod Carbu,etor Asembly .Note tle following .lnstall the float on the carburetor. oTapthe float pivot pin lightly,to press evenlyinto it thefloat chamber bodyasshown.
Carbu r Disassembly reto
ocasollne is er(ttemely flammable and can be xplosive undor certain conditions. Tum the ignition switch OFF. fro not smoke. Make surc the ara is well ventilated and fros from any sourceof flame or sparks; dri3 includes any appliancewi$ a pilot light.
oDuring carburetor disassembly, be careful not to damage t't diaphragm. Neyer use a sharp edge to removethe disphragm. oRemove the pilot screw plug asfollows: oPunch a hole in the plug and pry lt out with an awl or otier suita.ble tool.
A. Float B. Do not tap here. C. Tap the pin asfar as it will go.
FUEL SYSTEM2.13
oReplace the float chamber and bottom cover O-rings with new oneswhen installing. alnstall the front carburetor onto the F markedchamber and the rear carburetor onto the R marked chamber respectively. oTurn in the pilot screw fully but not tightly. and then back it out the same number of turns counted during d isassem bly. oA carburetorhasdifferent"turns out" of the pilot screw Jor each individual unit. When setting the pilot screw, during disassembly. Use usethe "tums out" determined the speciticationsin this manual only if the original numbet is unknown. aFor the US and SwiEerland models, install the oilot screw plug as follows: o lnstall a new plug in the pilot screrr/hole. and apply a small amount o{ a bonding agent to the circumference of the plug to fix the plug.
cAunoN
Do not apply too much bonding agent to the plug, or th pilot gcrew itself may be tixed-
A. Front Carburetor B. F Mark
C. Rear Carburetor D. R Mark
Plug I nstallation
oKeepdirt or other foreignmaterial into from entering the float chamber-
olf din get3 into the float chsmber,tre float valyemay bscoms stud( open, ausing carburtoroverflow and requiring carburetor cleaning. agent. 3. PilotScrew 1. Applya bonding 4. Carburetor Body 2. Plug oDo not force ths needlaiet holder (air bleodpipel and main iEt or ovenlghsn drsm. They couldb damaged rquiring replacement. .lnstall the O-ringin the coasting enricher system cover faces sothat the flat side in,
1. Main et J
2. Needle.let Holder
'1. O ring 2 . Cover
2-14 FUEL SYSTEM Carburetor lnspection
ocasoline ir extremely llammable and can be explosiye under ccrtain conditions. Tum dre ignition switdl OFF. Do not smoke. Make sure the area is well ventilated and lree from any 3outce of flame or sparks; this includesany appliancewitft a pilot light.
1. PilotScrew aMovethe chokeleverto checkthat the starter plungers move smoothly returnby spring and tension. tlf the starterplungers not work properly,replace do thecarburetor. aTurn the throttle lever to check that the throttle butterfly valves move smoothlyand return by spring tension. rlf the throttle valves not move smoothly,replace do thecarburetors. .Check that theO-rings diaphragms in goodconand are dition. for O-rings DrainPlug andCoasting Enricher Diaphragms VacuumPiston for Enricher andCoasting *lf any of the O-rings diaphragms not in good or are condition,replace them. .Check the plastictip of the float valve needle. lt sltouldbe smooth,without any grooves, scratches, or otherdamage.
2. Tapered Portion
*lf the pilot screwis wornor damaged the tapered on portion,it will prevent engine the from idlingsmoothly. Replace it. .Check that tlte vacuum pistonmoves smoothlyin the carburetor body. The surface the pistonmust not of beexcessivelv worn. *lf the vacuumpistondoesnot movesmoothly,or if it is very loosin tie carburetor body, replace both the piston. bodyandthe vacuum rCheck the inlet vacuum passage the coasting for enricher system, backfiring if too occurs often*lf the passage clogged, is blowit clearwith compressed air.
FuelPump
(H
Removal .Remove fueltank. the
l. Rod 2. ValveNeedle
3. Valve Needle Wear
A. FuelPump
B. PumpBolts
http://manuals.magnamaniac.com take the fuel pumpout of the *lf the plastic tip is damaged,replacethe needle. .Remove the bolts and *lf it does not springout, replacethe needle. frameacheck the tapered portion of the pilot screwfor wear aDisconnect pumpwireconnector. the or oamage. oPullthe fuel hoses the fuel pump. off
FUEL SYSTEM2.15
o(iasoline is extremely flammable and can be explosive Turn dte ignition switah undel certain conditioB, OFF. Do not snoke. Make surs the arot b wdl yentilated and free lrom any source of flame ot sparkt; drb includesany apdiance wilft a pilot light. oBe prcpared for fuel spillage.
lnstallation Nota as .Connect fuelhoses thepump fittings shown. to the

from Tank A. FuelHose B. FuelHos Pump to C. Arrow
.Be sureto route the hoses they will not be kinked so or stretched,
lnspection oVisuallyinspect fuel filter. the *lf the filter is clear with no signsof dirt or other contamination,. is OK and need not be replaced. it ilf tlre filter is dark or looks dirty, replace Also, it. check the rest of the fuel sysGmfor contamination. from Filter A. FuelHose to B. FuelHos Carburetors .Be sureto routethe hoses theywill not be kinkedor so stretched.
Air Cleaner
Element (Housing) Remowl aRemove followingparts. the Seat FuelTank Frame Top TubeCover Radiator Cover oRemove air cleaner housing mounting bolts. the
FuelFilter
Removal aRemove fuel tank. the .Removethe RH frametoDtubecover. .Pull the filter off tl|e hose.
l-wnnruruol locasoline b cxlrsmely flammableand can be sxploEiv under csnsin conditions. Tum the ignition rwitdr OFF. Do not 3moke. Make lure the area is well ventilatedand frss from any rcurcaof flame or :perkr; wi$ a pilot light. thb indudesany appliance oBe prepared fusl spillsgE. for
Installation Notes alnstallthe fuel filter so that the arrowon it shows the fuel flow from the fuel tankto the fuel pump. Housing A. Air Cleaner B. Bolts
2.16 FUEL SYSTEM

.Remove the screlysand take the inner cover off the (VNl 50GBOnly). housing
Element Cleaning
oclcan dre elemont in a well-ysntilated area, and tske care that there is no spark or flams snywharo nesr ths working ar.a; this includs any appliancewith . pilot light, Bscau3e of the danger of highly fl.mm8ble liquids, do not u3e gfsoline or low flashpoint solvents to dsan the element. A lirs or explcion could result. aRemovethe air cleanerelement.
A. lnnerCover
B. Screws
olf dirt or duit b allowed to poEs drrough into dre carburstors. dre throtds may become dud(. possibly ca$ing accidnt. .Wash the element in a bath of high flash-point solvent and then squeeze dry. it
aRemove air cleaner the coverby takingout the cover bolts. VNlsOGA
oDo not wring or twbt tho element83it may tsr. .Saturae the element witlr SAE30 motor oil and squeeze the excess. out .Wrap tlte element a cleandry cloth andsqueeze as in it dry asposible.
A. Cover B. CoverBolts vt{1500-8
C. Element D. Element Bolts
Air Cleaner Housing lnsallation

.Note the following. oTheright andleft air cleaner housing identical.' are Use the marked for the right sideand L for the left side. R
A. Cover B. CoverBolts
C. Element http://manuals.magnamaniac.com D. Element Bolts A. LH Housing B. "L" Mark C. RH Housing D. "R" Mark
aRemove boltsto remove element. the the rRemove otier sideelement the same the in manner,
FUEL SYSTEM2.17
Air Cleaner Duct lnstallation .Note the following. olnstall the air cleaner duct with its side marked "UPPER" upwards. facing
Emission Evaporative Control System (US CaliforniaVehicleonly)

The EvaporativeEmissionControl Systemroutesfuel vapors from the fuel systeminto the running engine or stores the vapors in a canisterwhen the engine is stopped. . Although no adjustmentsare required, a thorough visual inspection must be made at the intrvalsspecified Chart. bv the PeriodicMaintenance
Pa Bemoval nstallation N otes rB /l
A. Duct
B. "UPPER" Mark
oca3oline is extremely flammable and can be explotivc under certain conditions. Turn the ignition lwitch OFF. Do not smoke. Mske sure the a?e. i3 iYll yentilated and frce from any source of flame or sparks; this includesany applisncewith a pilot light'
oLubricatethe air cleanerduct endswith a soapand tankor watersolution,then fit the duct into the surge housing. air cleaner olf g8toline,solyent,waterot any otlEr liquid efierc the cankter, the canbtsr's yapor Ebsorbingcapacity is greatly rduced. It the canister does become conreplace with a newone. it taminatod
Surge Tank
Surge Tank Removal rRemove air cleaner housing. the .Remove thermostat housing. the aUnconnect air cleaner the duct upperend. .Remove surge the tank from the frame. .To preventgasoline from flowing into or out of the to canister, hold the separatorperpendicular the grouno. .Connect the hosesaccording the diagramof the to or system. Makesurethey do not get pinched kinked.
Hose Inspection (Periodic lnspection)

acheck that the hosesare securelyconnected. .Replac any kinked, deterioratedor damagedhoses.
*parator Inspection
.Disconnect the hosesfrom the liquid/vapor separator, from the motorcycle. and remove http://manuals.magnamaniac.comthe separator .Visually inspect the separator for cracks and other damage. *lf the separator has any cracks or is badly damaged, 3. Surge Tank Duct (Rear) 4. Surge Tank Duct {Front} reDlace with a new one. it
l . Surge Tank 2. Air Cleaner Duct
2.18 FUEL SYSTEM &parator OperationTest

Canister lnspection aRemovethe canister,and disconnect hoses from the the canister. .Visually inspect the canister for cracksand other oamage. *lf the canisterin cracked badlydamaged, or replace it with a newone. NOTE ome canitter is daignd to wo* well {rrough dE motorcycle's tife without my maintenance it is ud if under normataonditions.
oc6oline is extrsmely flammableard can be explosive undar csrtain conditionr. Tum the ignition switdl OFF. Do not moke. Make sur th area b well vontilatodand fre from any sourceof flame or spark; thb induder any appliancswid| a pilot light. .Connect the hosesto the sparator, and install the sparator the motorcycle. on aDisconnect breather t}le hosefrom the separator, and iniect about 20 mL of gasolineinto the separator through hos the fitting. aDisconnect fuel returnhose the from the fuel tank. rRun tl|e openendof the returnhoseinto the container levelwith the tank top. .Start the engine, let it idle. and *lf the gasoline the separator in comes of the hose, out the sparator works well. lf it doesnot, replace the separator a newone. with Eraporstiro Emi$ion Cot|trol Syrtsm
<-
Fuel Tank Surge Tank RearCarburetor Vacuum Swith Valve Breather Hose (Blue) (Green) 6. Purge Hose 7. ReturnHose(Red) 8. VacuumPulse Hose (white) 9. BreatherHose (Blue) 10. Breather (Yellow) Hose Separator: return pump 12. Canister
l. 2. 3. 4. 5.
COOLINGSYSTEM+1
Cooling$ptem
Tableof Contents
ExplodedView... Specifications Coolant Flow Ghart,. , Coolant. Coolant LevelInspection. Coolant Draining Coolant Filling Testing. Pressure Water Pump. Visual Leak Inspection ' SealRemoval WaterPump,Mechanical Seallnstallation. WaterPump,Mechanical Radiatorand CoolingFan. Removal lnstallation Radiatorlnspection, RadiatorCap Inspection Thermostat Removal Installation Inspection . ThermostatFan Switch. Removal Note. . . lnstallation Inspection.
+2
33 33
c4
34 3-,4 35 36 3 3-6 36 g7
c7
97 $9 39
c9
910 3-10 911 3-11 3-12 3-12 3-12 3-12
3.2 COOLINGSYSTEM
Exploded View
s-0
%n $--o@ q)
Sr,ffi{ g*t,J \@
ffiD
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.fr'/
1. BleodValve 2. Th6rm6t8t 3. RadiatorCsp 4. W&r Pumplmpellsl 5, lmpdlr Bolt 6. PumpCoYr 7. Covel Bola 8, Drain Plug 9. R.diator http://manuals.magnamaniac.com Fan 10. Cooling $vidr Tl : 7.8 N-m(0.80kgn,69 in.lbl 11. Grcundmre T2: 8.8 N.rn(0.9O kgn,78 in{bl 12. CoolingFan T3: 98 N.m (1.0kgn,87 inlbl 13. R.erroir Tank
COOLINGSYSTEM}3
Specifications
Item Coolant: Type
Standard type of antifree (soft water and ethyleneglycol Permanent plus corrosionand rust inhibitor chemicals aluminum for engines and radiators) Soft water 50%,coolant5096 -5"C (-31'Fl 2.3 L 93 - 123 kPa(0.95- 1.25kg/cm2,14 - 18 psil
Mixed ratio point Freezing Total amount Radiator: Radiatorcap relief pressure
Thermostat: temperature Valveopening full lift Valve opening

Coolant Flow Chart
80 - 84"C(176 183"F1 More than8 mm@5"C {2(B'F}
throughthe is so Whenthe engine cold, the thermostat closed, trat the coolantflow restricted is (airhole),causing engine warmup morequickly. the to smallholeon the thermostat
Pump 1. Watr 2. Water acket J 3. Cylinder Head 4. WatrrPipe 5. Water Hos 6. RadiatorCap 7. Thermostat 8. Reservoir TankTube 9. Radiator 10. Cooling Fan
34 COOLING SYSTEM Coolant

Coolant Level lnspection NOTE achsk the level when the engine is cold (room or ambienttemperature) oFor refillinS, add the specified mixture of coolant and soft watet. Adding water alone dilutes the coolant and degradesits anticorrosion properties, oThe diluted coolant can attack tie aluminum engine parts. In an emergency, soft watet can be added. But the diluied @olant must be retumed to the correct mixture ratio within a few days. olf coolant must be added often. or dre reservoirtank has run completely dry; there is probably leakagein the cooling system. Ched( the rystem for leaks,
asupportthe motorcycle perpendicular the ground. to .Checkthe coolantlevelin the reservoir tanktlf the coolantlevel is lowerthan the LOW mark.add coolant tl|e FULL mark. to oRemove tie reservoir tank cover and open the tank
caD.
Coolant Draining
oTo eyoid bum3, do not rumoye dte radiator aap or try to drangs the coolant whn the enline b still hot. W8it until it coob dwn, ocoolant on tir3 will make dtem slippery and c.n cau3e .n accident 8nd iniury. lmmodiately wip up or wah away any coolant that 3pills on the fiame, engine, or 0th0r painted parb. osince coolant i: harmful to dre human body, do not drink it.
A. Cover B. Screw
C. FullMark D. Low Mark
oRemove following. the Seat FuelTank Radiator Cover
A. Reservoir Tank B. FULL Mark C. LOWMark D. TankCap A. Radiator Cover B. Screws
COOLINGSYSTEM35
oPlace suitable beneath radiator. the container a CoolantDrainPlug
1. Coolant Level 2. ThermostatHousing A. DrainPlug
Radiator Cap(Loosen)
NOTE oPou in the coolant slowty s that it an axpet the air from die &gine ard ndiatur, .Fitl the reservoirtank up to the FULL mark with coolant, andinttall the cap.
o6oft or dirdlld wstst mu't b. utod widt th! .mifteo:s b3 balou for andfrrezol ir th3 cooling.v.sn. olf hard wlt3r ir u$d in $a lvttsm, it crursl rcds acqrmulrtion in dre trstoi panage, and cfiridonbly rrducaa$ dfi.toncyof lit coolirg 3y3ttm. water and coolsnt Mircure Ratio (Recommerdodl : 50% Soft Watsr : 50% Coolant -35oc (-3l"Fl Point : Freozing
Cap A. Radiator
.Drain the coolantfrom the radiator. aRemovetf|e reservoirtank cover and take tl|e tank off the frame. .Pour the coolantinto a suitable container.
NOTE oohooc a sritable mixture 'a,tio W rcferring to {re u i coolant man fe.ure I b di rurto n8. .Start the engine,warm it up thoroughly until the radiatorfan turnson andthenstopthe engine. aCheckthe coolantlevelin the reservoir tank after the coolsdown. engine *lf the coolantlevel is lowerthan the LOWmark,add coolantup to the FULL mark.
Coolant Filling http://manuals.magnamaniac.com .Tighten the dnin plug at the bottom of the radiator securery. .Fill the radiator uD to the radiator flller neckwith oDo not add more coolam 8boyo $e FULL m.*. coolant, andinstallthe radiatorcap.
3 COOLING SYSTEM PressureTesting .Remove radiator andinstall cooling the cap, a system
pressure testeron the radiatorfiller neck. NOTE Wet the cap ealing wrfaces with water or coolant to prcvent presure leaks. .Build up pressurein the system carefully until the pressure reaches 123 kPa(1.25 kg/cm' ,18 psi).
oDuring pressurctsting, do not exceedthe pressulefor which the system is dsignd. The maximum pressure is 123 kPa {1.25kg/cm2,18 psi). awatch the gaugefor at least6 seconds. *lf the pressure holds steady,the systemis all right.
A. Drainage Outlet Pasage (at the bottom of the pumpbody) B. WaterPump
WaterPump; Mechanical SealRemoval

.Remove the following parts. Radiator Cover (seeRadiator Removal) Radiator Lower Bolts (seeRadiator Removal) Water Pioe
A. Pressure Tester B. Adaptr
C. RadiatorCap
A. WaterPipe tlf the pressure dropssoon, checkfor leaks. WaterPumpCover
B. Bolt
Water Pump
Visual Leak lnspection .Checkthe drainage outlet p;rssage the bottom of the at watr pump body for coolantleaks. Pumpremovalis not reouired. http://manuals.magnamaniac.com tlf the mechanical seal is damaged, coolant leaks the through the seal and drains lhrough the passage. Replace watrpumpunit. the A. WaterPumpCover
B. CoverBolts
COOLINGSYSTEM+7
lmpeller Bolt oB careful not to damagedre water pump sh.ft and O*ing, and dra inner sealingsurfacsof the Gtankese. NOTE oThe impeller boh haetefthmdd thrads, thereforc it musfbe flnad clockwic to ,emote
WaterPump, Mechanical Seallnstallation

.Note the following
NOTE osince the tepleement mdranical wl h6 an adhmive coatd body, do not apply liguid g6d<et the extrior to srfe of the boty. ohessthe new mechanical into the hole by usinga seal su'rtable socketuntil it bottomsout
A. lmpeller B. Bolt
C. Direction rotation of
.Pry the mechanical flangeoff with a smallchis|. seal
1. Mechanical Seal
2. Tap Here
oApply a little coolantto the slidingsurface givethe to mechanical initial lubrication. seal oTightenthe impellerbolt to the specified torque(see Exploded View). oReplace pumpcovergasket the with newones. oThe watr pump cover rear bolts have aluminum washen.
A. Flange
B. Chisel Radiatorand Cooling Fan
.Pull the mechanical sealout of tie crankcase pliers.Oiscard remotedmechanical seal. the
Removal .Remove following. the Radiator Cover
38 COOLING SYSTEM
A. Radiator Cover
B. Screws
A. Radiator
B. LowerBolts
(Draining) Coolant CoolingFanSwitchConnector
Radiator UpperBolt
oThe cooling fan is conncteddiregtly to the battery. The cooling fan may start eyen if the ignition switchis off. NEVER TOUCHTHE COOLING FAN UNTIL THE Cq'LING FAN CONNECTORIS DISCON. NECTED, TOUCHINGTHE FAN BEFORE THE CONNECTOR DISCONNECTED IS COULDCAUSE INJURY FROMTHE FAN BLADES.
A. Upper Bolt
Left and RightTop TubeCovers
A. FanSwitchConnector
Cooling Fan Switch Radiator Lower Bolts
A. Top TubeCovers
COOLING SYSTEM }9
Radiator Hoses
Badiator lnspection core. theck theradiator *lf there obstructions airflow,remove them. are to *lf thecorrugated aredeformed, carefully straighten fins
Inem. *lf the air passages the radiator core ate blocked more of thzn 20o/o unremovableobstructionsor irreparably by deformed fins, replace the radiator with a new on.
A. Radiator Hoses FanMounting Bolts
B. Clamps
oMen doaning the radiator widr a 3tsam dealer, be careftrl ol the following to prwent radistor damege' 1l Keepdre isam gun away moredran 05 m from the radiatoraore. 2l Hotd tho st3am gun perpendicrer to the core :urface. 3l Run rha stsm qun hotizontslly following the core dro fin direc'tion. Runningit venically nrsy dsmags ffnr.
m1
A. Fan
Bolts B. Mounting
lnsallation .Be sureto attachthe ground wire to the fan mounting bolt
http://manuals.magnamaniac.com condition the top andbottom seals acheck of valve the

Wire A. Ground Bolt B. Mounting of the radiatorcap, *lf either of them showsvisibledamage, replacethe cap.
Badiator Cap lnspection
3-10 COOLING SYSTEM
Thermostat
Removal .Remove following. the FuelTank Coolant: about200mL (Draining) FuelFilter Thermostat Housing Bolts
1 . Bottom Valve Seal 2. Top Valve.Seal
3. Valve.Spring
alnstall capon a coolingsystem pressure the tester. NOTE Wet the cap ealing arfaca with wateror coolant to preventp,esure leaks. A: FuelFilter B. Bolts Housing C, Thermostat
(LH Cooling Hoses and Lower)
1. Pressure Tester
z. Kilolaror Lap
awatching the pressure gauge, pump the pressure tester to build up the pressure untilthe reliefvalve opens: the gauge hand flick downward. Stop pumping at once. The reliefvalve must open within the specifiedrange in the table below and the gauge hand must remainwithin the samerangeat least6 seconds-
RadiatorCap Relief Pressure Standard: 93 - 123 kPa (0.95- 125 kg/cm2,14 - 18 psi)
A. Hoses
B. Clamps
*lf the cap cannot hold the specified pressurq or if it holds too much pressure,replace it with a new one-
.Pull the thermostathousingirut of the frame to the ngnL .Remove thermostat tie from its housins.
}11 COOLINGSYSTEM
Housing A- Thermostat
B. Screws
A. Brackets
lnstallation
.lnstall the thermostat noting the following. olnstall the thermostat in the housing so that the air hole is on toD.
lnspection aRemovethe thermostat,and inspectthe thermostat valve roomtemperature. at *lf the valvis open,replace valvewith a newone. the .To check valve opening temperature,suspendthe thermostat in a container of water and raisethe of temperature the water.
A. Air Hole
B. Thermostat
1. Thermostat
2. Thermometer
oBesure installthe o-ring in the housing. to olnstall the fuel filter bracketwith thermostat housing onto theframebracket-
*lf the measurementis out of the service limit range, replacethe thermostat.
Thermo3tat Valve Opening Temperature 80 - 84'C (176 - 183"F1
i!t1f,61
e,*ru< -B
tni?uotl l6lrsnrBdT,r.
lnsallation NoE ' r'ohroqp'r\ sqE&[Eh 0b &r{6niitFh$tqldre*p*r'fic$ @!qusr('$e Elplod.d V.iew). rrurrlrqi{rt rsool'| rrkv
.rto yto & rhiw rvlrv rdl s;eiqar nrqir ri cvkv art] 1l* la{i btrq?li ..e:\'16rJ{ar5i gniqr:].. 9!iiv t"riJ dTa etl: o<ier l,r,: 13ic'a : :3rii6ln..,:: ; r,i Jlri:inrrrh ."::l\'r, 9ril ,(: i-7_-jEl:itlmg:
n{ii}6\!sts$\
gi-iwoli.11 ir i.l Itliies lritaollt.lid, siJ llrtafrlr ii5 rrit rnri! ri gnitrarl giir oi t6Jrcitrerli r(t il6t:nlc .qo: no ri Jori
irJ4{:.fll
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tntromtsdl .g
rioH ril. .A,
,iSflrr,inr:: . .i! ., r i- t,, , ,, , .r:,:;,.;r;;.J_; "t:tl:
.gniarori sd: ni lnirO rrf lineni ot elu?98c J5:aonnsdl rltiyr trrJitd t3jiit hui 3il, lhf.nlo Anituid -terJ6rd rmgi erb otno
srtrf a:rql:o?
!tl;.ir{tl ori.:V trdrofin$dl 11"*8i ., D!*l J'!B -- 08
ENGINETOP END +T
TopEnd Engine
Tableof Contents
Exploded View . Specifications. SpecialTools Sealant . . CleanAir System (US and Switzerland models). Air Suction Valvelnspection. Vadrum switch Valve Test . CamshaftChain Tensioner. Bemoval . Installation. Rocker CaseCap Removal Installation. RockerShafts, Rocker Arms, Rocker Case. . . Removal . I nstallation. (Hydraulic LashAdiuster) HLA HLA Removal. HLA lnstallation. HLA Air Bleeding Inspection Camshafts Removal , lnstallation(lncluding Chain Timing Procedure). Camshaft SprocketAssembly. Wear Camshaft, RockerCase Camshaftchainwear. . . . . . KACB (KawasakiAutomatic . CompressionRelease). Removal . lnstallation.
4.2 4-6 4-7
Inspection Cylinderead. H
.... .....
4"15 4-16 4-16 4{6 4{6 4-16 4-16 4'17 4-17 4-17
+7
4.4
Measurement. . . Cylinder Compression .... Removal . Installation. V a l v e . .. s . .. : ....... ValveClearance Adiustment . . . . . . . . Valve emoval R V a l v en s t a l l a t i o n f V a l v e u i d eF e m o v a l . . G Valve Guide lnstallation Valve FaceContact Inspection. . . . . . . ValveSeatOutside Diameter. . . . . . .. ValveSeatWidth Inspection. .. . .... ValveSeat Repair(Valve Lapping) . Measuring Valve-to-Guide Clearance ......... ....... ..-
+a
4-8 4-8 4-8 4-9 4-10 4.10 4-10 4.10 4-10 4-11 4-12 4-12 4-12 4-12 4-13 4-13 4-13 4-13 4-14 4-14 4.15
4-17 4-18 4{8

4-18
4-18 4"20 4-21 4-21 4-21 4-22 4-22 4-23 4-23 4-23 4-?3 4-24 +24
(Wobble Merhod)
Cylinders,Pistons
Removal Cylinder Installation .".,, Cylinder P i s t o ne m o v a l . R ........ n ....... P i s t o ln s t a l l a t i o n Cylinderwear. ......... Piston Wear ,.. Piston Ring, Piston Ring Groove Wear. . . .. -.. P i s t o n R i n g E n d G a p . ., .. .. .. .. . . ........ Muffler.. ( ao r N 1 5 0 0 -.A .). . . . . . . flV Remov ,
lnstallation. (for VN150GB) Removal
4-r5 I nstallation. 4-15 http://manuals.magnamaniac.com 4-15
4-25 +25 4-26
4-2 ENGINETOP END

ExplodedView
@-q '/Fe-n45
Swiuerland Model
o_M
z--@
Wffireo
q
WoEee
Model A12:Canada Model
ffiwo
@@
Switzerland Model
1 . RockerCaseCap 2 . Spring 3 . Oil Fitter 4 . Air SuctionValve 5 . Camshaft Seal Oil 6 . RockerCase US Model Al2:CanadaModel 7 . CylinderHead I . ValveGuide |--__\ o RockerCaseCover(SprocketSide) 1 0 RockerCaseCove.(HLASide) 1 1 SparkPlug Fetainer 1 2 Carburetor Hold,er
o Apply engineoil. ss Apply siliconesealantT1 f2 T3 T4 8.8N-m(0.S0 kg-m,78 in-lb) 2s N-m(2.skg-m,18.0ft-lb) 78 N-m(8.0kg-m,58 fl-tb) 12 N-m(1.2kg-m,104inlb)
L.-% i . * % . \ ,& \_3__.,

I
ENGINETOP END 4-3
rffi
? @
s"
r\
@*
#f'ff \'/ *N*#? & *#eM

1. 2, 3. 4. 5. 6. 7. 8. 9. 10. Bod(6rSh8ft RockorAm (x 3/1 GYlindetl Rod(sr A]m (x 1/1 GYlinderl Oil Chamber Hydraulic LashAdiuster valYeSpring {lnnert vslre Spring(Ouetl http://manuals.magnamaniac.com Oil Sl ValveSt m (Exh$3tl M : Apply molybdsnumdi:ulfide grease' V8lvoSsh (lntakel 18Oftlbl T 1 : 25 Nfl (25 kgF|n,
4.4 ENGINETOP END

1. 2, 3. 4. 5. 6. 7. CYlinder Drain Plug Piston Cam$aft Chain Camshaft Spmcket Camsh.ft KACR (Automatic Comprsion Releasel 8. Camshaft Chain Tensioner
w
*@\
Ld,A
:%,H-@ ! v /fe? ' W.'*%f 6

L : Apply http://manuals.magnamaniac.com nonfmanent : loddng agtrt. O Apply endneoil. T1: 15 N-m (15 kgFm, 11O ft.lbl T2: 25 Nrn (25 kgn,18.0 ft.lbl
TOP END 46
L 2. 3. 4. 5, 6. 7. 8. 9. Nut ExhaustPipe Holder ExhaustGasket Exhaun Pipe (Leftl ExhaustPipe {Right} Gasket PowerChamber Muffler (Leftl Muffler (Riqhtl
vN1500-A
@--\b @--od
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VN1sff}B
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+6 ENGINETOP END
Specifications
Itm Clo.n Air Systom (US aod Switze.landmodets): Vacuum switch valve closing pressure:
Standard
Sewica Umit
Open
Cmshaft, Camshaft Chain: Cam height Inlet Exhaust Camshaft,rockercaseclearance Camshaftjoumal diameter Camshaftbearinginsidediameter Camshaftchain20-link length
Close
35 - 43 kPa(260 - 320 mmHg) 33.812 33.912 mm 33.494- 33.594mm 0.020- 0.062mm 24.959- 24.980mm 25.000- 25.021mm 127.0- '127 mm .4 Frontcylinde[ 345 - 590 kPa (3.5 - 6 kg/cm2, 50 - 85 psi) Rear cylinder 685 - 1080kPa (7.O- 11 kslcnr2, 1 1 0 - 1 5 6p s i ) 0.05mm Non-adiustable 'I .0 mm 0.02mmTIR 6.965- 6.980mm 6.955- 6.970mm 7.000- 7.015mm 0.05- 0.12mm 0.08- 0.16mm 37.8mm 42.3mm 0 . 5 - I . 0m m 31.9 - 32.1mm 28.9 - 29.1mm 32" 45',55" 102.0OO 1O2.O12 mm - 1O1.957 1O1.942 mm 0.043- O.070 mm +0.5mm 102.10 m m 101.79 m m _--O.17 mm 0.16mm 0.90mm 1. 1 0m m
t,tzmm
33.71mm 33.39mm 0.15 m m 24.93mm 25.08mm 128.9 mm
Cylinder Hoad: Cylindercompression pressure usablerange r/min (rpm) by electric starter @30O
Cylinderheadwarp Valves: Valve clearance Valve head thickness: Valve stem bend Valve stem diameter Valve guide insidediameter Valve/valveguide clearance (Wobble method): Valvespring lreelength: Valveseatingsurface: width Outside diameter: Valveseat cutting angle: Cylindr,Pistons; Cylinder insidediameter Piston diameter Piston/cylinder clearance pislon and rings Oversize, Piston ring/grooveclearance: Top Second Top Second Top Second Top Second oil
lnlet& Exhaust Inlet Exhaust lnlet Exhaust Inner Outer Inlet Exhaust Inlet& Exhaust
0.5 mm O.05mmTIR 6.95mm 6.94mm 7.08mm O.27 mm 0.30mm 36.2mm 40.7mm
Piston ring thickness: Piston ring groovewidth: Pison ring end gap.
0.03 - 0.07mm 0.02 - 0.06mm 0.97 - 0.99mm 1.17 1.19 m m - 1.04mm 1.02 1.21 - '|'.23 mm 0.3 - 0.4 mm 0.40 - 0.55mm 0.3 - 0.9 mm
1.31 m m 0.7mm 0-9mm 1 . 2m m
ENGINETOP END +7
ValYe Head Valve Stem Bcnd Cam Height Measurement
stem
ter
Valve head thickness
/n
--
u --------
\y H
'
-\
/ll
A
CamHeight
L
ValveGuideAtbor: 57q11-16:l
SpecialTools
57(xl1'241 As.sembly: Valve SpringCompressor Adapter: 570O1-242
valyeSeatCutterHolder: 57001-1126
Bar:57001-1128 PistonPin PullerAisembly: 57001'910 Adaptcr:57001-1211
fr
R
o
Wrendr: 57001-1210 Hexagond
valve ssat cuttsr 45'+35! 57001'1116 valye SatCuttel 3:le{35: 57@1-1121 valye satcutter 32"4il'35t 57001'1122 VdlvsSeatCutter55".035: 57001-1247
Sealant
(q(qKor((J
\7 \' \.7 \7
ValveGuideReamer:57001'162
Kswa$ki Bond (Silicone Ssalantl: 56019{20
48 ENGINE TOP END CleanAir System(US and Switertand models) Air Suction Valve lnspection avisually inspect reeds cracks, warps, the for folds, hear
damage, other damage. or *lf there is any doubt as to the condition of the reed, replace air suctionvalve an assembly. the as Vacuum Switch Valve Operation
(OpenThrottle) 1. DuringCruising
A. ValveHolder
2. During Engine Braking

B. Reed
oCheck the reed contact areasof the valve holder for grooves, scratches,any signs of separation from the holder, or heat damage. *lf there is any doubt as to the condition of the reed contact areas, replace the air suction valve as an assembly. alf any carbonor other foreignparticles haveaccumulated between the reed and the reed contact area.wash the valveassembly cleanwith high flash-point solvent.
oDo not scrape off the depositswidt a scraper as this could damagthe rubbei, requiring replacementof the sudion valYe assembly.
HighVacuum Secondary cannotflow, air VacuumSxritchValveClosingPressure "' Open Close: 35 - rl:t kPa(260- 320 mmHql
VacuumSwitch Valve Test

oCheckthe vacuumswitch valveby blowingair into the Gamshaft ChainTensioner air hosefitting. owhen the vacuumappliedto the vacuumhosefitting of the valve is low, the vacuumswitch valve is opened Remoral and air flows ihrough the air hosefittings. .Remove the camshaft owhen the vacuumrisesgradually http://manuals.magnamaniac.com chain tensionercaDbolt and take and reaches certain a Ievel, valveis closedand air doesnot flow, the off the copper washerand the spring. *lf the vacuum switch valve does not oDerate as .Remove the mounting bolts and take off the camshaft described, replacethe valve. chain tensioner.
ENGINE TOP END +9
A. ChainTensioner
B. capBolt
BodY A. Tensioner
B. Arrow Mark
oRelease stopper pushinto the rod. and the
A. MountingBolts B. Spring
Washer C. Copper D. CapBolt Rod A. Push B. Stopper
C. Push D. Push therod. into
This is a non-retrrn type can chain tensioner. The push rod does not relum to i$ original pGition once it moys orrt to take uP cam drairi slack. Obslvs all the rules listed below: olvhen removing dre tensionet, do not t|ke out dle moulrting bol$ only halflvay. Retightening thd mount' ing bolt! Irom this pocition could damagethe temion] and dro camshaft dtain, Once the boit3 are loGsned, dre tenaaonermust be temoysd and Jesetas delcribd in ',cbaan TeGioner lffitallation." oDo not turn ovel ths crenkshaft while th teEioner is removed. This could up6.t the cam drain timing, and dam8gedre Yalvs.
http://manuals.magnamaniac.com .lnstallation is tie reverse removal. Note the folof lowin& 1 . Gasket olnstallthe tensioner bodywith the arrowon it pointing 2. ChainTensioner upwards.
lnstullation
5. 4
CapBolt Stopper
'I.10 ENGINETOP END

oTightenthe tensioner mountingbolts to the specified torque(see Exploded View). oTighten the cap bolt to the specifiedtorque (see Exploded View). lnsbllation .Note thefollowin& oReplace capgasket the with a newone. oTighten capboltsto the specified the torque.
RockerCase Cap
Remoml oRemovethe engine(see EngineRemoval/lnstallation chapter). .Remove the bolts and take off the cover from the rockercase. aRemovetlle bolts and take the caDfrom the rocker
Rocker ShafG, Rocker Arms, Rodcer Case

Remoml oRemove the engine(seeEngineRemoval Installation chapter). aRemove rockercase the covers and tie cap. aRemove alternator the outercover.
NOTE <iBefore removing dte t@ket dratt or rocker arm, tum dre crankdraft e that its piston is a TDC of the compr$ion stroke.
A. Rocker Case Cover
B. Rocker Case Cap
.Take out the oil filter springs and oil filters if neces-
.Removethe oil pipebanjo bolt. aRemovethe water pipe. rRemove t]te camshaft chain tensioner (see Camshaft ChainTensionerRemoval).
s:rry.
A. Springs B. Oil Filters A. Rocker Case B. Water Pipe C. Oil PipeBanioBolt
ENGINE TOP END +11

aRemove rockercase the boltsand nuts. out of the .Using the pry points,take lhe rockercase cylinder head.
lnstallation .Notethefollowin& on springs each olnstallthe rockerarmsand retainer as rocker shaft shown.
A. Pry Points Arm Tunnel C. DifferentRocker Chain A. Camshaft B. Sprin8s oBeforeinstalling rockershaft, be surethe O-rings the arein place. oTightenthe rockershafu to the specified torque (see Exploded View). oApply siliconesealant the mating surfaceof the to oil and rockercase the camshaft sea. Nut oApply engineoil to the both sides rockercase of Washers. oFit the rockercase the cylinderheadwhile holding to end up the lashadjuster of the rockerarms, oTighten the rocker casebolts and nuts temporarily and then torque following the ti8hteningsequence, torque. themto the specifid
out aRemove rockershafts andtakethe rockerarms the of tlle rocker case.
NOTE oThe camdlaft chain tunnd side exhaustrocker am, is differcnt from the othe6.
A. Rocker Arms B. Rocker Shafts
Arm C. DifferentRocker
.Take out the oil filtersif necessary oRemove the tash adiuster it necesary (see HLA Removal).
A. 012mm Nuts B- 08 mm Bolts
C. d6 mm Bolts D. Number Tightening of Sequence
oAfter installingthe rocker case,fill the oil chamber oil. with engine
+12 ENGINE TOP END
A. Apply engine oil.
B. Oil Chamber Area
oReplace the oil pipe banio bolt copperwashers with new ones, and tighten to the specified torque (see Exploded View). oReplace rocker the case gasket cap with a newone.
l. HLA Body 2. O-ring 3. Spring(Plunger)
4. Plunger 5. SteelBall (Ball) 6. Spring
oFill a rocker arm with engineoil and then insertt}|e HLA into the rockerarm.
HLA (Hydraulic LashAdjuster) HLA Removal

aRemove rocker the case. aRemove rocker the arms.Pull the HLA out of the rockerarms.
A. RockerArm
B.HLA
A. Rocker Arm
B.HLA
rmflml
oBe caretul not to damagEor deform a lash adluster by tapping it during remoyalor installation. oDo not drop th lash adiuster or hit it sharply. lf it is damaged, the plunger will not operate smoothly.
.Preparea pin and cut the needle it to 2.1 - 2.3 mm of length. Grind the cutting edgeof the needleto smooth it. .Push in the steelball of the HLA with the needleof the pin and move the plunger and down in the oil bath. up
HLA,Air Bleeding .Fill a container engine with oil.
HLA lnstallation
aNote the following. -Check tlEt the HLA plunger is not damaged. *If the plunger does damage, replace the HLA.
oDo not push ir the steelb;ll more than 2.1 - 2.3 mm, Over.stroke of the steel ball may cause the damage of the H LA.
ENGINETOP END 4-13
ffi"2
1. Cut and grind the needle. 2. 2,"1 2.3 nm
q ? )
3. HLA 4. Pin A. FrontCamshaft B. Rear Camshaft C. Groove oApply cleanengineoil to all cam parts and iournals. oFit the KACR Unit on to the camshaft. FrontCylinder oPosition crankshaft front cylinderpistonTDC. at the
lnspection
aRemove rockerarm. the .Pull the HLA out of therocker arm. ePress plunger the HLA with your fingers. of the *lf the plungeris into the HLA body, repeatthe air th and operation thenpress plungerbleeding the replace flf the plunger into the HLA bodyagain, is HLA.
Camshafts Removal
aRemove the rocker casecaD. aRemove the rocker case. .Remove the camshaftwith the KACR and seDarate it. oRemove the camshaftoil seal. A. TDC Mark (Front Cylinder) B. Timing Mark oEngage the camshaft chain sprocket with the camshaft chainasshown.
A. Oil Seal B. Camshaft
C. KACR
http://manuals.magnamaniac.com lnstal lation (Including Chain Timing Procedure)

.Note the following. oThe front and rear camshafts different. The rear are camshaft a groove. has 1 . TimingMarks 2. F mark
+14 ENGINETOP END

RearCylinder ocheck the camshaftchain timing for the front cylinder. . Tum drccrankshaft counterdockwis from theT/F 310" mark (left sideview) to align theT/R (TDC mark). .Note the following. ouse the sprocketmarked F for the front cylinder camshaft R for the rearcylindercamshaftand
y Camsh Sprocket Assembl aft
(Rear A. TDCN4ark Cylinder) B. TimingMark A. Front Camshaft Sprocket B. Rear Camshaft Sprocket C. F Mark D. R Mark
oEngage camshaft the chainsprocket with the camshaft chainasshown.
oApply a non-permanent lockingagntto the camshaf! sprocket boltsandtightenthemto the specified torque (see Exploded Vlew). olf the camshafts replaced are with new ones,applya thin coatof a molybdenum disulfidegrease all cam to partsandjournals.
Camshaft, Rocker CaseWear rNote thefollowing. oMeasure eachclearance between camshaft the the and plastigage rockercase (press using gauge). NOTE onghten the rccker ce boltFand nuts to the secifid torque (ee Exblodd Viewl
1 . TimingMarks 2 . R Mark
oThe crankshaft may be turned whilo dre camshaft is remoyd, alwaF pull dre dEin http://manuals.magnamaniac.com but taut whils tuming tl|s orankrhaft. This ayoids kinking dre d|.in on t're lower {crankshaftl sprocket. A kinked drain could drmsgeboth the drain and the sprockst. l. Plastigage Width
ENGINE TOP END +15

NOTE o^o not turn the camshaftwhen the pleigage is be' tweq, theioumal and ruker czs,. the *lf any clearance limit, replace exceeds service the the camshaftwilh a new one and measure clearance again. *lf the clearance remains out of the limit, replace still assmbly. androckercase the cylinderhead Roc*et Case Clearance Camchaft, mn 0.020- 01162 standard:
SerYicsLimit: 0.15 mm
A. Camshaft
B. KACRUnit
Camshaft Chain Wear 5 .Hold thechain of taut with a force about kgin some Since chain the a manner, measure2o-linklength. and at tak measurements sveral may wear unevenly,
olacs. limit, replace *lf any measurement exceeds srvice the the chain. Camshaft Chain20{ink LerEdl
Standald:
Installation as .Fit theKACRUnitontothecamshaft shown.
Sorvica Limit:
127.A-lttAmm 128.9mm
A. Pin B, Notch
C. KACRUnit D. Camshaft
lnspection
.Visually inspect KACRUnit. the *lf the weights do not move smoothly all the way, replace KACRUnit, the replace or rlf the springis damaged, deformed, missing,
ir.
Length 1. 2o-link
KACR (Kawasaki Releae) AutomaticCompression

Removal http://manuals.magnamaniac.com (seeEngine Remova[lnstallation aRemove engine tie
chapter). eRemove the camshaft. .Take the KACR Unit out of the camshaft.
A. Weighc
B. Spring
+T6 ENGINETOP END CrylinderHead

Cylinda CompressionMeasurcment NOTE
O Use the battery which is fully charged. OWarm up the engine thoroughly. aStop the engine.
ausing the stanermotor,turn the engineoverwith the throttlefully open until the compression gaugestops rising; compression fhe highest the is reading obtainable.
Cylinder Comprgsion Prssuro Ugable Range: Front Cylinder: 345 - 590 kPa (3.5 - 6 kg/cmr, 50 - 85 psi) @gn r/min (rpm) Rear Cylind.: 6&5 - 1O8OkPa (7.O - 11 l<g/crn2, 110 - 156 psi) @300 r/min (rpm)
aRemoveone sparkplug and attachthe compression gaugeand adapter firmlyintothe sparkplug hole. Do not remove otherspark plug,onlythe plug lead. the aFor the othercylinder, plugs. remove bothspark
Special Tools Spark Plug Wrench, Her( 18: 57qn -1024 -2,j21 Compreseion Gauget 57OO1 Comprssion caug Adapter, Ml2 x 1.25:5r0ot-1018
-1 gaugeadapter: oThe compression 57001 183 can also be used. aFepeat measurement theothercvlinoer. the for NOTE
olf the engine is well broken in. the crcnking speed may become fastet shutting down the decompressor. This can raise the ftont cylinder comprcssion pre\ture near to the rcar cylindels in some engines. alnstall the spa* plugs. Torque - Spark Plu$ : 18 N-m (1.75kg-m, 12.5fttb)
The following table should be consultedif the obtainablecompression readingis not within the usablerange. Problem Diagn06is Remedy(Action) Removethe carbondepositsand repracr damaged parts if necessary.
Cylinder compression Carbonaccumulationon piston and cylinderhead, is higherthan usable and in combustionchamberpossiblydue to damrange agedvalvestem oil seal and/or damagedpiston
oil dngs (This may be indicaredby white exhaust smoke). Inconectcvlinderhead gasketthickness. Damagedor missing compressionrelease cam spring Compression release weights do not movesmoothCylindercompression is lower than usable range Gasleakage around cylinder head
Replacethe gasketwith a standard Dan, Feplace the sp ng. Replacethe compression release unit. Replacedamagedgasketand check cylinder head warp.
Bad condition of valve seating
Repair necessary. if
ReDlace HLA. the Replacethe piston andlor cylinder Inspectthe cylinderand liner and replace/repair cylinderand/or the piston as necessary. Replacethe piston and/or the piston flngs.
HLA seizure.
Inconectpiston/cylinderclearance
Piston seizure.
Bad condition ol piston ring and/or piston ring grooves. Compression release weights do not movesmoothlv.
Replace compression the relase unit.
oTake the cylinder headoff the cylinder.
lnstallation
.Note the following. gasket oReplace cylinderhead with a newone. the oTighten cylinderheadnutstemporarily. the NOTE ogefore insbllitv {re spark plug rcaineL pull dre camdraftchainup the drain firnnet.
Remoml rRemovetlle following. (see chapter) Engine EngineRemoval/lnstallation RockerCass Camshafu (seeFuel chapter) Carburetors Oil Pipe
A. Camshaft Chain
B. Retainer
A. Oil Pipe B. Bolt
C. Carburetor
torque. oTighten sparkplugretainer tie specified to tJ|e oTighten sparkplugto the specifid torque. the olnstallthe camshaft. olnsall tie rockercase. oTighten sylinderheadlowernutstemporarily. tl|e NOTE' oTorque dte cylin&r had and cylinder had lower nuts to the s,ecified torque (w Exploded Vimt) after rtghEning the rocks c* bolts and nu's to the spe-' cifid toque.
SparkPlug SparkPlugRetainer (Using Hexagonal Wrench:57001-'1210) a CylinderHeadLowerNuts (FrontandRear)
Valves
VaI ve Clean nce Adju stntent
A. SparkPlug C. CylinderHead LowerNut B. SparkPlugRetainer
NOTE
osine the hydnuli; !a* adju$eB constdrtly maintuin to inqect or adiust Ero cleannce. h is not nesry the vdw clannce.
.rsbni;r'J )rit :t, t\3i i,
rsbfi;i.ij gdJ rrsTa
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3ui9*q? ni6':t tulg t:s (0lSi-I00lt :d:nsrW knogrxo*i gnirU) r bmH 6bniiy3 {rsof;bar raorlf aul4 rgraroJ
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yb$ata$in as$ulh it$\ ii\birb\dr rtt sc--t" fi6lRflJr o'r ttrrz5*n li$ a n ,f6r|$rN crc jtffiS$ij,t*t
ENGINE TOP END +17 Valve Removal

oPerformthe following. oUsing ihe valvespring compressor assemblyand adapter (special tools),remove valve. the
Valve Guide Removal

rPerformthe following. ousing the valveguidearbor (special tool), tap out the guide. valve
ValveSpring Compressor Assembly:57001-241 2. AdaDter: 57001-242
'1.
Guide Arbor:57001-163 1. Valve
Valve lnstallation oBecareful the following. of oApply a thin coat of molybdenum disulfidegrease to the valve stembefore valve installation. olnstall the springsso that the closedcoil end faces downwards.
Vatve Guide tnsallation rPerformthe following. ousing the valveguidearbor (special tool), drivein the guideuntil its flange touches cylinder tie head. valve NOTE oHeat the area arcund the valve guide to 120 t^dc (2/t8 - 302"F). oApply oil to the vatveguide outer strface beforc wlve guide installation. alJsing the valvegaide reamer (geial tool), ram the valveguide.
1. Valve Stem 2. Spring Seats 3. Oil Seal 4. Inner Spring 5. OuterSpring
6. Retainer http://manuals.magnamaniac.com 7. Spring Seat 8. ClosedCoil End 9. Split Keepers
i . Valve GuideReamer: 57001-162
4.18 ENGINE TOP END ValveFace Contact lnspection rCheck valve seating width. the face surface ousea vrnier caliper measure seat the width(white to portion)of the valvefacewhere thereis no carbon build-up. *lf thevalve faceseating surface widthis notwithinthe with specified range, replace valve a new the one.
*lf the valve seating surface width is not within the specifiedrange,repair the valve seat.
Valve *at Ouaide Diameter

.lf the outsidediameterof the seating patternon the valveseatis too large too small,repair valve or the seat.
1. Good
2. Too wide
V.lve SeatingSurfacsOutsids Diameter Standard lnlct 31.9 - Sl.1 mm ExhsGt 289 - 29,1 mm
Valve *at Widh lnspection rCheckthe valve seating surface width. ouse a vernieroaliperto measure seatwidth (white the portion) of the valve seat where there is no carbon build-up.
3. Too narrow
4. Uneven
Valve SeatRepair (Valve LappingJ .Usinglhe valve (special tools), repair the seatcutters
valveseat.
1 . Valve 2. ValveSat Seating Surface Outside Diamter 4. Seating Width Surface
vahe SsatCutters 45' - 035 57q11-1116 lnlet Valv3: 32' - 03S.s570{J1-112t2 55' - C35 57001-1247 Exhawt ValYss: 45" - Cas 57001-1116 :t2' - c35 57001.1121 55' - C35 570'J1-1147
Holder and Bal Holder:
Br::
57001.1126 570iJ1-11?
ValyeSeating Width (lN and EXI Surface Standad: 05 - llt mm *lf the manufacturr's instructions not available. are use the followingprocedure.
ENGINETOP END +19

SatCut@rOperatingCals: '1. This valve seatcutter must not be used for other purposes seatrepair. than seatcutter,or the dia2. Do not drop or strikethe valve mayfall off. mondparticles 3. Be sure to apply engineoil to the valveseatcutter before grinding the seat surface. Also wash off groundparticlessticking to the cutter with washing oil.
NOTE oDo not ue e wirc brud, to remove the metal Nrticl8 from the cutter. lt will take off the diamond particles. 4. Setting the valv seat cutter holder in posilion, operate the cutter in one hand. Do not apply too much force to the diamond Dortion.
of 1 . OuterDiameter Angleof Cutter 3. Cutter
NOTE oPrior to ginding, apply engine oil to the cutter and during the operation, wa$ off atry ground particl$ oil. stickingto the cutter with vvadting
OporatingProcedures: .Clean the seatareacarefully. .Coat the seat with machinist'sdye. .Fit z 45" cutter to the holder and slide it into the valve guide. .Press down lightly on the handle and turn it right or left. Grind the seatingsurface only until it is smooth.
oDo not grind the seattoo much, Oyergrinding $ill rsducevalvedearanceby sinkingthe valveinto the head. ]f the vslvesink too far into the head,it will be impolsible to adjwt $e deamnce,and the clrlinder headmustbe replaced. .Measurethe outside diameterof the seatingsurface with a vernier caliper. rlf the outsidediameterof the seating surfacis too is the small, repeat 45" grinduntil thediameter within range. the specified *lf the outsidediameterof the seating surfaceis too makethe 32" grinddescribed below. large, rlf the outsidediameter the seating surface within is of measure seat width asdescribed range, the the specified below.Grind the seat at a 32o angleuntil the seatO.D. is within the specified range. oTo makethe 32ogrind,fit a 32" cutter to the holder, guide. andslideit into the valve oTurn the holderoneturn at a time whilepressing down turn. the after each very lightly- Check seat
1 . Cutter
2. CutterHolder
5-
Bar
) . After use,washit with washing and applya thin oil layerof engine beforestoring. oil
MarkrStamped the Cuttel: on http://manuals.magnamaniac.com The marks stampedon the back of the cutter reoThe 32" Gutter rcmoyes material very quickly. Check present following. the the seat outside diameter frequently to prevent over45" . . . . . .Cutterangle grinding. - . , . .Outerdiameter cutter of 24.56
+20 ENGINETOP END

aBe sure to remove all grinding compound befole assembly. .When the engine is assembled, sure to adjust the be valveclearance(seeValve Clearance Adjustmen!).
1. Widenedwidth of engagement machiningwirh by 45- cutter 2. Groundvolumeby 32" cuttnr 3. Groundvolumeby 55ocutter 4. 32" 5.5s' 1. Lapper 2. ValveSeat 3. Valve
oAfter makingthe 32' grind, return to the seatO.D. measurement above. step .To measure seatwidth. use a vernier calioerto tl|e Measu ring Valve-to-G uide Clearance measure width of t$e 45o angle portion of the seat the (Wobble Method) places at several aroundthe seat. *lf the seatwidth is too narrow,repeatthe 45" grind lf a smallboregauge not available, is inspect valve the until the seatis slightlytoo wide,and then returnto guide wear by measuring the valve to valve guide the seatO.D.measurement above. clearance steD with the wobblemethod, indicated as below. *lf tlre seatwidth is too wide, maket}re 55o grinddes.lnsrt a new valve into the guideandseta dial gauge cribedbelow. against stemperpendicular it asclose possible the to as .Grind tie seatat a 55o angleuntil the seatwidth is to the cylindrheadmating surface, within the specified range. aMovbthe stem back and forth to measure valve/valve guideclearance. OTo makethe 55'grind, fit 55'cutter to the holder, and .Repeatthe measurement a direction a right angle slideit intothevalveguide. in at oTurnthe holder,whilepressing down lightly. to the first. oAfter markingthe 55" grind,return to the seatwidth *lf the readingexceds the service limit, replacethe measurement above. step guide. .L:p the valveto the seat, oncethe seatwidth andO.D. arewithin the ranges specified above. oPut a little coarse grindingcompoundon the faceof NOTE the valypin a numberof places head. aroundthe valve aThe ruding is not etual valve/valve guide clearance ospin th9 valve against seatuntil the grindingcomthe becaue the measrring point is above the guide. poun4/produces smooth,matchedsurfaceon both a the slt andthe valve. oRepeAtthe process with a fihe grinding compound. Valve/Valve Guide Clearance .The seating areashouldbe marked about in the middle (Wobble Method) of the valve facehttp://manuals.magnamaniac.com *lf the seatareais not in the right placeon the valve, Standard Service Limit checkto be zurethe valve the correctpart. lf it is,it is Inlet 0.(F - 0.12 mm O27 mm mayhavebeen refaced much:reDlace too it. Exhaust 0,08 - 0.16mm o.ql mm
ENGINETOP END 4.21
Holes A. Water oPosition crankshaft TDC. the at oApply engine to the cylinder bore,pistonring,and oil pistonskirt. oslip the cylinderblockonto the piston. ousethe cylinder's markedF for the front andR for the rear.
New Valve [A] ValveGuide [B]
Move the Valve [c]
Pistons Gylinders. Cylinder Bemoval

.Remove the cylinder head. .Pull out the camshaftchain guide (inlet side). .Remove the coolant drain plug to drain the coolanl
C. F Mark A. Front Cylinder D. R Mark B. RearCylinder oThe front and rear camshaft chain guides a.e not identical. Use ttLemarked F for the front cylinder and R for the rear cylinder.
Plug A. Drain B. Cylinder Nut
C. Camshaft ChainGuide
.Remove cylinder nuts. the oTake cvlinder thecrankcase. off the
Cylinder lnstallation
A. Camshaft ChainGuides C. R Mark B. F Mark
oNotethe following. oReplacethe cylinder basegasketwith a new one, and with the crankcase water holes. engage gaskets the
4'2 ENGINETOP END

OTighten cylinder the nutstemporarily. NOTE oToryue the cylinder nuts to the specification (see ExplodedView) after tightening the rccker casebola" and nutsto the speciliedtoque. Piston Removal a Remove cylinder the blockoPlacea cleancloth underthe pistonsand remove the pistonpin snapringsfromthe outside eachDiston. of ousing the piston pin puller assembly (speciat tool), remove pistonDins. the Top Rins [A] Second Ring [B] Oil RingSteelRails[Cj aThe pistonringopenings mustbe positioned shown as in thefigure.Theopenings oflhe oil ringsteelrails must beabout30 - 45'olangle fromtheopening ofthetop nng,
30'-\45'
Front
^ 30'-4s'
o\aulo
i
vv
@@
Oil Ring Expander[D] Anow [E]
NOTE oThe oil ring rcils have no "top" or "bottom". alnstall the oil ring expander [A] in the bottom piston ing groove so the ends [B] but together. alnstallthe oilring steelrails.one abovethe exDanderand one below it Ospread the rail with your thumbs, but only enough to fit the rail owr the Distono Releasethe rail into the bottom piston ring groove.
1. Piston PullerAssembly:57001-910 Pin 2. Adapter
Piston lnstallation NOTE

Olf a new piston or cylinder is used. check piston to cylinder cleannce (see Specifications), and use new piston ng. aThe anow [A] on each piston head must point fonrard.
CAT'TION
Do not rsuse snap ringg as removal weakens aiid dforms them. Thgy could fall out and score th cylindor wall.
aDo not mix up the top ringandsecond ring. alnstallthe secondring [A] so thatthe "RN" markfaces up. alnstallthe top ring [B] so thatthe "R" markfaces uD.
Frofi
ENGINE TOP END 4-23
CylinderWear
aMeasure the cylinder inside diameter taking a at side-to-side and a front-to-back measufement each shown oI the 3 positions (total of 6 measurements) below.
Cylinder lnside oiamter Standard: Servic Limit:
mm 102.000 102.012 102.10mm
1. ThicknessGauge
PistonWear
aMeasure the pislon outsidediameter5 mm up from the bottom of the piston at a right angle to the direction of the piston pin. PistonOutsida Diameter
Standard: Servic Limit: 101 .!t42 - 101 .957 mln 101.79mm
Piston Ring End Gap

a Place the piston ring inside the cylinder. using the piston to locate the ing squarelyin place. Set it close to the bottom of the cylinder, where cylinder wear is aMeasure the gap between the ends of the ring with a thicknessgauge.
Piston Ring End Gap Standard Top 0.3 - 0.4 mm o.t|o - 0,55 mm Second 0.3 - 0.9 mm Oil
Service Limit 0.7 mm 0.9 mm 1 . 2m m
1. PistonOutside Diameter 2. 5 mm uo from the bottom
PistonRing, PistonRing GrooveWear

acheck for uneven groove wear by inspecting the ring seatingJrThe rings should fit perfectly parallel to the groove surfaces. lf not, the piston must be replaced. owith the piston rings in their grooves, make several measurementswith a thickness gauge to determine piston ring/groove clearance, Piston Ring GrooveClearance Service Limit Standard 1.Gap 0 . 1 7m m http://manuals.magnamaniac.com 0,03 - 0.07mm Top O.16mm 0.O2- 0.0mm Second
2. Piston Ring
+24 ENGINETOP END

Muffler Removal(for VN1500-4)
oRemove the following. Front Muffler Cover
A. Holders B. Nuts
C. Exhaust Cover Pipe
A, Front Muffler Cover
B. Screws
Muffler ClampBolts(Loosen) MufflerBracket Bolt MufflerAssembly

A. PowerChamber B. RH MountingBolt C. Clamp Bolt
.Pull the RH exhaust pipe out of the muffler. .Remove the powerchamberRH mountingbolt. .Remove the rear exhaustpipe holder nuts, LH power chamber mounting bolt, and loosenthe exhaustpipe clampbolt.
A. Mufflers B. Bracket Bolt
C. Clamp Bolt
Front ExhaustPipeCover
aRemovethe front exhaustpipe holdernutsand loosen the exhaustpipe clampbolt.
A. Exhaust Pipe B- Holder C. Nuts
D. Clamp Bolr E. Power Chamber F. Mounting Bolt
ENGINETOP END +25

.Pull out rear exhaustpipe upper end while supporting the power chamber, then take them out toward the left. tSeDarate the front and rear mufflers from the muffler bracket if necessary.
pipeupperendwhilesupporting oFit the rearexhaust the powerchamber. oscrewthe powerchamber boltstemporarily. mounting pipeholders olnstallthe rearexhaust the whilepulling pipetowardtheoutside. exhaust
lnstallation .Prform following. the oReplace exhaust gaskets newones. with the
Pipe A. Exhaust
B. Holders
oTighten the holder nuts, power chambermounting pipeclampbolt securely. bolts,andexhaust pipe. olnstallthe front exhaust olnstallthe mufflerassembly. pipecovers. olnstallthe mufflerandexhaust A. Exhaust Gasket
oAttach the rear exhaustpipe to the power chamber, into the framebracket. thenfit the chamber
Remomllfor VN|50GB)
.Loosenthe mufflerclamobolt.
A. Power Chamber B. Bracket A. Clamp Bolt
+26 ENGINETOP END

.Removethe left sideexhaust pipeholdernuts. .Removethe right sideexhaust pipeholdernuts. .Remove the right side muffler bracketbolt, and take the mufflerout of tie frame.
A. Holders
B. HolderNuts
.Removethe left sidemufflerbracket bolt. andtakethe mufflerout of the frame.
lnsallation .Replacethe exhaust gasket with newones. oPerform following. the oAttachthe clamps and B onto the RH muffler. A olnstall the RH exhaustpipe and the holdenonto the front cylinderhead. olnstallthe RH muffler bracketbolt. olnsert the LH muffler connecting pipe into the RH pipe. muffler connecting olnstall the LH exhaustpipe and tl|e holders onto tl|e rearcylinderhead, olnstallthe LH muffler bracketboltolnstalltl|e clamps to tl|e frame. A oTighten boltsof tie clamps the A. oTlghtenthe bolt of tl|e clampB.
A. Bracket Bolt
1 : Attachthe clamps.
CLUTCH$1
Glutch
Tableof Contents
. . . . . . . . . . . . . . . . . . . . 5 .- .2 . . . . . . .......5-3 . . . . . . . . . . . . . . . . . . . .5 - 3. . . . . . ...
..........5-5 ............. 5-5
- ' . . ' ' ' - ' ' , . ' , ' . ' ' ' . , ' , . 'c . o
. . . . . . . ...... . . . ...
5-7
. . . . . . . . . . . . 5._ . . .9 . . . . . . . . . . . .5 - . .0 ..1
5-10 5-11 5-11 5 - 11
S2 CLUTCH
ExplodedView
1 . Clutoh Master Cylindel erp 2 . Primary cup 3. Secondary 4. Piston 5 . Starter Lockout S\.vitch 6 , Master Cylinder Clamp 7 . Banio Bolt 8 . Cluich SlaveCylinder 9. Bleed Valve 1 0 . Phton 1 1 .PuCr Rod 12. Clutah Housing 13. Spring (Damperl 1 4 . Dampor Cam 1 5 . lnner Hub 1 6 . Ou@l Hub 1 7 . F?iclion Plae 18, Stol Plaie 19. Spring Plate 20. Spring (Back Torque Limiterl 21. Cluch Spring
Holdel
u.
23. Operating Plane 24. Rst iner Ring
-o"
".*t:
L : Apply nonfermanentlockingaqem. O : Apply engine oil. Tl : 5.9 N{n (0.60kgn,52 in{bl T2: 78 N{n (Oao kgn,69 in-tb| T3;88 Nm (0,90kgrn,78 in{b} http://manuals.magnamaniac.com T4r 18 N<n (1.8ksFm, 13.0ftlbl T5r 25 Nfl (25 ksm, 18.O lbl tt T 6 : 1 4 5N { n ( 1 5 . O k g , 1 1 0 f t - l b }
'l&ub'
CLUTCH 5.3
Specifications
Item Recommended Clutch Fluid : Grade Brand
Slandard
ServiceLimit
D.O.T.4 Girling-Universal Castrol Castrol (LMA) GT Castrol DiscBrakeFluid CheckShockPremium HeavyDuty Type 4.7mm 0.05 - 0.25mm range) 0.30 - '1.30 (Usable mm - 3.5mm 3.3 Lessthan0.2 mm 0 . 0 3- 0 . 1 0 m m
Clutch : Clutchleverplay tree height Clutch spring clearance Springplate/pusher platefree play Spring platethickness Friction Friction steelplatewarp and PrimaryReduclion: gearbacklash gear/clutch housing Primary
4.4mm
3 . 1m m 0.3mm m 0.14 m
Special Tool
Baaring Driver Sgt: 57001-1129
54 CLUTCH
Clutch Fluid Fluid Level Inspection .Check clutch the fluid level thereservoir. in clutch Fluid changing
.Remove the LH engine cover (seeCrankshaft/Transmission). aRemove the reservoir cap, and remove the rubber cap on the bleedvalve. .Attach a clear plastic hose to the bleed valve on the clutch slave cylinder, and run the other end of the hose into a container. .Fill the reservoirwith fresh fluid. .Change the clutch fluid as follows.
A. LowerLevelLine
B. UpperLevelLine
T{OTE
oHold the res oir horizontal when chfiking clutch fluid level.
*lf the fluid level is lower than the lower level line. fill the reservoir the upperlevellinein the reservoir. to
ochange the fluid in th clutch line comgletely il the fluid must be refilled but the type and brand of dre tluid th.t already is in tlre reservoirare unideniified. After changing the fluid, use only tte same type and brand of fluid tfiereafter. Mixing diffelent types and brandr of lluid loweB the fluid boiling point and could causo the clutch to & ineffectiye. lt may abo cau3e the rubb4 clutch parE to dete orate.
1. 2. 3. 4.
ODenthe bleed valve Pumpthe clutch leverand hold ir. Closethe bleed valve. Release clutch lever. the
Recommended Clutch Fluid Grade: B:rnd; D.O.T.4 Heayy Duty Brake Fluid CastrolGirling-Unirersal Castrol GT (LMA) Castrol Disc Brake Fluid Check Shock Premium Heary Duty
oRepeat this operation until fresh fluid comesout from the plastic hoseor the color of the fluid changes. ocheck the fluid level in the reservoiroften, replenishing it as necessary. NOTE otf the fluid in the re&rvoir runs completely .out any time during fluid changing, the bleeding operction must be dohe over again from the beginning since air will have entered the line.
NOTE
osince the clutd, fluid is dre sme as the bnke fluid. refer to Bnke Fluid Section in Brckes for further debils.
I WARN|NG I '_
oDo not mix two brands fluid. of
cLuTcH $5
Bleeding dle Clutch Line tWith the reservoir off, slowlypumpthe clutchlever cap can risingup several timesuntil no air bubbles be seen throughthe fluid from the holesat the bottom of the cylinder This bleeds air from the master the reservoir. eid of the line. NOTE oTap the cluth he lightly going from the lower end to the uppcrendand bteedthe air off at the resvoir. .Attach a clearplastichoseto the bleedvalveon the cylinder, run the otherendof the hose and clutch slave into a container. .Bleedtheclutchlineasfollows:
MasterCylinder lnsallation be .Wheninstalling clutchmaster cylinder, careful the

of following. oThe master cylinder clamp must be installed with the rearview mirror holder. oTighten the upper clamp bolt first, and then the lower clamp bolt to the specified torque (see Exploded View).
clampbolt first. 3. Clearance l . Tightenupper
2. LowerClamoBolt
1. Pumpthe clutch levera few times until it becomes hardandthenhold it squeezed. 2. Quicklyopenandclose bleed valve. the 3. Release clutchlever. the ocheckthefluid levelin the reservoir often, replenishing it asnecessary. NOTE olf the fluid in the rcservoir runs completely out arry time duing bleeding,the bleding opention must be done overagainfrom the beginningsinceair will have entercdthe lineoRepeat operation this until freshclutchfluid comes out from theplastic hose the colorof the fluid changes. or
-E
oReplacethe aluminum washeron each slde of the clutchhose fitting with a newone. oTighGn tie banio bolt to the specifiedrcrque tsee Exploded View). .Perform the following after installing the master cylinder. for Bleed clutchline for Check clutchoperation for Check fluid leakage
Disassembly
oRemove following. the ClutchLever DustCover Circlip and Cup,PrimaryCup .Piston Secondary Spring
NOTE oDo not remove seondary cup from the pkton. the
I wARNtNc I
oDo not mix two brandsof fluid.
5 CLUTCH
1. Primary Cup 2. Secondary Cup
3. Piston 4. Circlip
A. Slave Cylinder B. Mounting Bolts
C. BanioBolt
Assembly
.Clean th disassembled parts with clutch fluid and apply clutch fluid to the inner wall of the cylinder.
oRemove baniobolt and ftee the cylinderfrom the tie nose. .Performtl|e followingif the clutch slave cylinderis to be removed not disassembled. but
olf ths alutdr slavecylinder i3 lemovedand left alone, rhe pitton will be purhed out by drs lpring and dre dutah fluadwill drain out.
oTske cre not to scratch the piston or $e inner wall ot the cyllnder.
oRemove clutch slave cylinderfrom the engine witi the the hoseand pushthe pistoninto the cylinderasfar as it will go. oSqueeze clutch lever slowly and hold it with a the band. NOTE oHoldingthe clutch levil kps pifion from aming the out.
lnspection acheck the followingfor wear,damage, cracks, deteor rioration: CylinderInnerWatlandPiston Primary Secondary and Cups DustCover Spring .Check that the relief and supplypons on the cylinder arenot plugged.
olmmediately wips up any brakefluid $at spilb. paintedor plated 3urfaces. maydamagE
lnstallation
.Note the following. oReplacethe aluminumwashers eachside of the on ClutchSlave Cylinder clutchhose fitting witi newones. oTighten the banio bolt to the specifiedtorque (see Exploded View). Remoml oReplace the spacerof the clutch slavecylinder with .Performthe followingif the clutchslave nelvone, cylinder is oApply non-permanent to bedisassembled. locking agent to the slave oLoosenthe clutch hosebanjo bolt http://manuals.magnamaniac.com cylindermounting on the clutch slave bolts. cylinder. check the fluid levelin tl|e master cylinderreservoir, oRemov tie mounting bolts and take off the clutch andbleedthe air in tlre clutchline. ocheckthe clutchoDeration. slave cylinder.
cLuTcH $7
Disassembly removed, allowthe oLeaving clutchslave cylinder tie pressure. piston move spring out to slowly under
Asembly .Do the following. oApply clutch fluid to the outside the pistonandthe of fluid sal. olnstallthe fluid seal shownin tlte figure. as
A. Operating Plate
B. Retainer
.Unscrewthe clutrh hub nut by usingthe air impact wrench.
l . Cylinder
2. Piston
3. FluidSeal 4.spring
t cAUTt0l{ | t-"-."".-,,"4
oFeplaca tte fluid lsal with a new one if it wa! remoYad from ths pistoB,
A. HubNut .Take the clutch springplate, clutch springand the holderout of the clutchhub. clutchspring friction plates, .Take the back torque limiter springs, steel plates and the outer hub out of the clutch housing.
Clutch
Remowl NOTE oAn a imp*t wendz is rcquird for cludt runowl. .Removethe muffler(see Engine Top Endchapter). .Place a suitablestandunder the crankcase support to the engine. tRemovethe right downtube (see Frame chapter). http://manuals.magnamaniac.com .Remove the right enginecover (seeCrankshaftflransmissionchapter) . D. LimiterSpring Plate A. Spring aRemove retainerand take the operating Platrs the E. Friction/Steel B. ClurchSpring Cate out of the clutchassembly. Holder F. OuterHub C. ClutchSpring
5 CLUTCH
.Take the innerhub, collar, washer and cluth housing out of the crankcase. lnstallation aclutch installation the reverse removal. Notethe of is following owhen replacing any one of the following parts,adjust the spring plate free play (seeClutch Plate Replacement). Spring Plate Friction Plate SteelPlate owhen installing clutch housing, the meshtle oil pump drive gearwith the oil pump gearso that the pumpgear rns.
A, lnner Hub B. Collar
C. Washer D. ClutchHousing
.Pull the nedlebearing,sleeve,and thrust washeroff the drive$aft-
A. PumpDriveGear
B. PumpGear
A. Needle Bearing B. Sleev 1. Oprating Plate 2. Spring Holder 3. ClutchSpring
C. Washer
olf mw dry 3t3el plsca .nd fristion plabc are i$6llod, apply onltns oil to the $rfacss of eadr pLb to avoid dubh plsts 3siznrc.
@so
4. 5. 6. 7.
.A 6-M.
BackTorqueLimitrr Springs Clutrh SpringPlate Outer Hub lnner Hub
O Installthe last friction plate in the shallow groove on the housing as shown.
A. LastFrictionPlate
CLUTCH 5-9
oApply grease the back torque limiter springs and to attachthemasshown.
Clutch lnner Hub Disasembly/Assembly .Using a pressand suitable bearing driver (special damper springs. ool), compress the
1. LimiterSprings
2. Spring Holder Driver: 57001-1129 C. Bearing A. Press B. Damper Spring D. Retainer
oTighten the clutch hub nut to the specified torque gear holdingthe primary Exploded View). bolt (see
cam. aRemove retainer, and springs, damper the damper
A. HubNut
GearBolt B. Primary
.Squeeze clutchlever slowlyandhold it with a band the platepusher into the clutchhub. whilepushthe spring
http://manuals.magnamaniac.com 1. Retainer
A. Pusher in B. Push Holder 2. Spring 3. Damper Spring Holder 4. Spring
5. Spacer 6. Damper Cam 7. lnnerHub
$10 cLuTcH SpringPlate Free Play Measurement

lnsufficient spring plate free play will cause the engine braking effect to be more sudden,resulting in rear wheel hop. On the other hand, if the free play is excessive, the clutch lever may fel "spongy"or pulsatewhen pulled, aHold the exha drive shaft steadywith a vise and instau the clutch parts on an exlra drive shaft. Do not install the back torque Iimiter springs and the operating plate. oTighten the clutch hub nut to about 29 N-m ( 3 kg-m, 22 ftJb ) of torque to seat the clutch plates closely.
SpringPlateFreePlay UsableRange: 0.30- 1.30mm
SpringPlate Free Play Adjustment

oMeasure the spring plate free play. 'llf the free play is not within the usable range, iDstall dre Star'\dard SteelPlates 2.0 mm ttrick X 6 and 1.6 or 2.3mm thick X 1 ; total 7 plates. . Measurethe sprhg plate free play again.
m-I-r!Jl1
cTake care not to damage the drive shaft. SteelPlates (mm) Thickness 1.6 2.O 2.3 Part Name 13089n080 13089-1075 130891081
NOTE olf new f ctionplatasare installed, apply engine oil to the sufiaces of each plate.
1. Holder 2. Clutch Spring
4. Operating Plate 5. Spring Plare
3. BackTorque Limiter Springs 5. Drive Shaft aunscrew the hub nut, then take *re holder, operating plate, and the dutch spring out of the housing. aReinstall ttrc holder and tighten tlle hub nut lightly. aTo measure the free play, set the dial gauge "O" against the clutch spring plate. aTurn the dutci housing back ard forth . The difference between the highest and lowest gauge readings is the amount of free play.
Frictionand Steel Plate Damage,Wear

avisually inspect the ftiction and steel plates for signs of seizure,overheating (discoloration), or uneven wear. aMeasure the thickness of the friction Dlates at several POlnts. *If any plates show signs of damage,or if they have wom past the service limit, measure the spring plate free play a.ndadjust it if necessary.
FrictionPlateThickness Standard : 3.3 - 3,5 mm ServiceLimit : 3.1 mm
Frictionand SteelPlate Warplnspection

*If any plate is warped over the service limit, replace the platesas a set.
1. Turn back and forth. 2. Up and Down.
Frictionand Steel PlateWarp Standard : less than 0.2 mm ServiceLimit : 0.3 mm
CLUTCH $11 Cam Damper lnspection and rVisuallyinspect damper spring, cam,damper the
cam follower. *Replace any damaged parts.
1. Frictionor SteelPlate 2. Thickness Gauge
Plate 3. Surface
Cluth Housing Finger lnspection rVisually inspect fingers the clutchhousing where of the hit of the tangs the friction plates them. *lf they arebadlyworn or if therearegrooves where cut the tangshit, replacethe housing. Also, replacethe are friction plates their tangs damaged. if 1. Cam 2. CamFollower
Clutch Spring Height Measurement *lf thespring limit,it must is than helght less theservice
be reDlaced. Clutdr Spring Height Standard: SerYice Limit:
4.7 mm 4.4 mm
1. ClutchHousing Finger
2. FrictionPlate Tang
Clutch Hub Spline lnspection rVisually inspectwhere t}|e teeth on the steel plates ofthe clutchhub. wearagainst splines the *lf ttrereare notches replace the worn into the splines, if the clutch hub. Also, replace steelplates their teeth aredamaged.
1. Clut h Spring
2. SpringHeight
1. Clurch HubSpline Teeth 2. SteelPlate
SYSTEM S1 ENGINELUBRICATION
EngineLubrication $ptem
Tableof Gontents
ExolodedView Engine Flow Chart. Oil
ar-^^:a:^r:^-^
6-2
64 6-6 G6
oPtrrrruaLrurrr
Tools. Special .t S e a l a n. . . . Engine and Oil Filter. Oil Oil LevelInsoection . Engine Change. Oil Oil Filter Change . Oil PumpScreenCleaning Oil Pump. Removal lnstallation Oil Pipes Removal lnstallation
a6
6-7 6-7 6-7 6-7 6 6 6 6-9 6-9 G9 6-10 6-10 &10
Measrrement Oil Pressure Oil Pressure Measurement
S2 ENGINELUBRICATION SYSTEM
Exploded Viarv
-@
,ar@
1*
1, Rocker Care.(F?ontl
Baniobolt Oil Pipe Rodter Ca!(Rearl &sa&er Pl96 (LEftl Filtel BreadlorPipes(Righl Cr8nkcase (Loftl Haff CraDkcals tlalf (Righrl to. Oil Pm:sure Sruitdr 1 1 . Oil Pr$urG Rdief Valy 12. Oil Rrmp 13. Oil Filter Mounting Bolt 14. Oil Filtsl 15. Oil Scren Plug 16. Oil Scroon 1 7 . Oil Pipe(hside Lsftl 18. Oil PiF (lnride Rightt 1 9 . EndneDrain Plug m. Oil Nozzls
2. 3. 4. 5. 6. 7. 8. 9.
To R.H.: Grankcase half
O : Apply engineoil to the gasket. L : Apply non-pemanentlocking agentto the thrads. SS: Apdy siliconesealent flre threads. to Tl ; 29 Nrn (030 kgm, 20 in{bf T2: 12 Nfl (12 kgrm,104 in.lb) T3: 15 Nrn (15 kgm, 11,0ft{bl http://manuals.magnamaniac.com ft{b} T4: 18 Nfl (14 kgn, 13.0 T5: 20 Nrn (2.0kgfl,la5 ft.tbl T6; 35 Nrn (35 kgrn,25 ft.lbl T7r 25 N-m(2.5 kg-m,18.0 ft-tbl
ENGINE LUBRICATION SYSTEM6-3
q2 (h
osw
@? @
I I
<
,@
&%N*NQ
64 ENGINE LUBRICATIONSYSTEM
EngineOil Flow Ghart
I I
1. RockerArm 2. Oil Filter 3. Oil Pipe(outside) 4. HLA 5. RockerShaft 6. Camshaft 7. Piston 8. Oil Nozzle 9. Oil Pipe(ln the crankcase) 10, AlternatorRotor 1l. Crank$aft
SYSTEM E5 ENGINELUBRICATION
,fl_@
1. Clutch Assembly 2. DriveShaft 3. OutputShafi 4. Front BevelGearAssmbly 5. Oil Pipe(ln the cnnkcase) 6. Oil Pipe(ouside) 7. Oil Screen 8. Oil Pump 9. ReliefValve Switch 10. Oil Pressure 11. Oil Filter Valve 12. Bypass
66 ENGINELUBRICATION SYSTEM Specifications

Item Engine Oil: Grade Viscosity Capacity
Standard
SEor SFclass SAE 10W40, ,50,2M40, or 20W50 101 2.5 L (whenfilter is not removedl 2.7 L (When filter is reriroved) 3.5 L (When engine completely is dry)
345 - z14O (3.5 - 4.5 kg/cm",50 - 64 psi) kPa
Oil Pressure Measurement: Oil presure @2,000 r/min (rpml, (212'F) oil temp. l(X)"C
Special Tools
Oil Pressure Gauge,5 kg/cm,:57001-125 Oil Filtar Wrcndr: 57m1-1249
e
Oil ftsssureGauge AdaFter:57001-10*t
KawasakiBond (SiliconeSealaml: 56019-120
ENGINE LUBRICATION SYSTEM 6.7 Engine and Oil Filter Oil EngineOil Change perpendicular the ground after aset the motorcycle to up warming theengine.
.Removethe engine drain plugto drainthe oil.
oMotorcycle operation with insufficient, deteriorated,ol accelerated wear and contaminated engineoil will cause seizure,accident, may result in engine or transmission and iniury.
Oil Level lnspection

asituate the motorcycle so that it is perpendicularto the grou\l. .Check\hat the engineoil levelis between$e upper and lowerle{el linesin the gauge. .\
A. Drain Plug
Level A. Upper B. LowerLevel
C. Oil FillerCap D. Oil LevelGauge
oThe oil in the oil screen chamber can be drained by removingthe oil screenplug (seeOil ScreenCleaning). oThe oil in the filter can be drained by removing the filter (seeOil Fil@r Change). *Replacethe drain plug gasketwith a new one if it is damaged. .Tighten the drain plug to the specifiedtorque (see View). Exploded oTighten the oil filter with the oil filter wrench (special tool) to the specifiedtorque (seeExploded View). oTightenthe oil screenplug to the specified torque (see View). Exploded .Pour in the specified type and amountof oil.
NOTE
olf the motorcycle has just beal u*d, wait svenl minut* for all the oil to dnin down. olf tne oil has just been changed, stan the mgine and run it for several minutes at idle speed. This fills the oil filter with oil. Stop the engine, then wait several minut$ until the oil seftles. EngineOil Grade: SE or SF class Viscosity: SAE 10W40, 10W50,20W40, or 20W50 Amount: 35 L (engineis completely dry) 2.7 L (filter is removedl 2.5 L (filter is not removed)
oRacing the engine before the oil reaches every part can causeengiireseizure. olf the engine oil gets extremely low or if the oil pump clog up or otherwi6edo not function or oil passages http://manuals.magnamaniac.com Oil Filter Change properly, the oil pfessurewarning light will light. lf .Drain the engine oil. this light stays on when the engine is running above oRemovethe oil filter with an oil filter wrench (special idle speed, stop the engine immediately and find fie tool). Gaus.
ffi
ENGINE LUBRICATION SYSTEM
A. Oil Filter
B. Wrench: 57001-1249
A. Oil Screen
B. Spring
NOTE
oThe oil fiher by?ss valve is a*mbled not dissfmbled). in dre filter (Do
.Cleanthe screen with highflash-point solvent. oClean screen the thoroughly whenever engine is the oil changed.
.When installing the oil filter, be careful of the following. oApplyoil to the gasket beforeinstallation. oTightenthe filter with the oil filter wrench(special tool) to the specified torque (seeExplodedView) or tighten it with hand(s)about % turns after gasket contacts mountingsurface engine. of oPourin the specified typeandamountof oil.
NOTE While cleaning the srnn, drek for any metal panicles drat might indicate inten al etryine damage.
Oil Pump Screen Cleaning

.Remove following. the Engine (Draining) Oil Oil Screen Plug Oil Screen with Spring
.Wheninstalling screen, carefulof the following. the be *Replacethe screen plug O-ring with new one if it is damagd. *Replacethe screen with a new one if it is damaged (holes broken and wires). oBsureto put in ihe oil screen gasket with the rubber endinside. oTighten the screenplug the specifiedtorque (see Exploded View). oPourin thespecified typeandamountof oil.
Oil Pump
Bemoval
.Performthefollowing. oRemove the engine(seeEngineRemoval/lnstallation chapter). http://manuals.magnamaniac.com (see Crankshaft/Transmission o5plit the crankcase chapter). oRemovethe oil pump bolc, and take off the pump out of the RH crankcase half.
A. Oil Screen Plug
SYSTEMS9 ENGINE LUBR]CATION
A. OilPump
B. ReliefValve
Proiection C.O-rings A. Pump Shaft B. Gear Shaft Slot
oUnscrew reliefvalve necessary. the if oRemove circlip,and pull tie pumpgearout of the tl|e if crankcase necessary.
oTighten ths pump bolts to the spcifiedtorque (see View). Exploded oApply a non-permanent locking agent the threads to of (see Exploded View). the reliefvalve
Oil Pipes
Remotnl .Remove outside pipes follows. the oil as
A. Circlip B. Pump Shaft
C. Washer D. PumpGear
Installation
A. Oil Pipe
.Note the following. http://manuals.magnamaniac.com insideoil pipesfrom the inside.of the .Remove the oNotthe positionof the oil pumpshaftprojection and pump gearshaftso that t}te proiectionfits into halves. crankcase turn the osplit the crankcdse(see Crankshaft/Transmission the slot. oReplace O{ingswith newonesif they aredamaged. chapter). the
SlO ENGINE LUBRICAT]ON SYSTEM

oReplace copperwashers eachsideof the engine the on outside fitting5with newones. oTightenth banio bolts to the specified torque (see Exploded View).
A. Oil Pipe B. MountingBolts
C- Holder D. RH Crankcase Half
Oil Pressure Measurement i re rement O I Presu Measu

NOTE oMaetre the oil praJe after the engineis watmedup.
A. Oil Pipe B. Mounting Bolts
C. Holder D. LH Crankcase Half
.Removethe oil pressure switch wire and unscrew the oil pressure switch, and take t}te switch out of the engine towardthe rear. .Attach an oil pressuregaugeand adapter (special tools)to the switchhole.
lnsallation .Note the following. ocheok that the oil pipe fitting's O{ings are in good condition,andapplya little of thegrease the O{ings to beforeinstallation.
A. Oil Pressure Gauge;57001-'154 B. Adapter: 57001.1033 C. Oil Pressure Switch
A. Oil Pipe B. Fitting C. Oring
611 SYSTEM ENGINELUBRICATION

Oil Pro$ure Standard: ' Mors than 345 - 'ltl(l kPa (3.5 - 4.5 kg/cm'.50 - 54 psi) @2(xx! r/min (rpm), l(xr'c (zrfn qf oil tmp.
*lf the oil pressure much lower than the standard, is check the oil pump, relief valve,and/or crankshaft bearing insertfor wearimmediately. .When installingthe oil pressure switch,apply silicone sealantto the threadsof the switch, and tighten it to Exploded View). the specified torque(see
7.7 ENGINE REMOVAL/INSTALLATION
EngineRemoval,/lnstallation
Tableof Gontents
ExplodedView SpecialTools. 7'2 7'2
. Removal/lnstallation Engine Removal lnstallation
."......
73 73 7'6
7-2 ENGINE REMOVAL/INSTALLATION

ExplodedVieur
@@.
@
@
'
1. Framc 2. EngineMounting Brackct 3, Brad(at Bolt 4. Down Tubell/loundngBolr (Front) 5. Right HandDown Tube 6. Down Tube Mounting Bolt (Rearl 7. EngineMountingBolt (From) 8. EngineMountingBolr (Rearl T1 ; 24 N+n (2.4kgFm, 17.5ftlb) T2: 44 N{t (4.5kgm,3:t ft{b}
*'t%*".r
, *^^'g
/,' -1 : Ataclr merfi 57OO1 252
SpecialTools
&Gk Stand: 57001-1238
7 ENGINE REMOVAUINSTALLATION
EngineRemoval/lnstallation Bemoual .Supportthe motorcycle perpendicular the ground to
with the jack stand and the attachment (specialtools).
A. CleanAir Hose
B. Cooling Hose
Cooling Hose (RH: Pull the hoseout of the rear cylinder,) Surge Tank Duct hose. Thermostat Housing with the oooling SurgeTank Stand:57001-1238 A. Jack B. Attachment:57001-1252
oRemove following. the chapter) Engine (see Oil Engine Lubrication chapter) Coolant(see CoolingSystem Seat
FUet I anK
Frame Too TubeCover C. Surge Tank Duct A. FuelPump (see chapter) Housing Fuel System Air Cleaner D. Surge Tank B. CoolingHose Horn (se chapter) Radiator cooling System chapter) System Tank (see Cooling CoolantReservoir (LH) Footpeg Left Engine Cover Clutchchapter) ClutchSlave Cylinder(see shift Pedal Muffler and Exhaust Pipes (see EngineTop End http://manuals.magnamaniac.com chapter) lgnitionSwitch Clean Hoses Air CoolantReservoir Tank Bracket CoolingHose (LH: Pull t]1e hose out of the front Clean Hose(Rear Air Cylinder) (move on the frame) lgnitionCoil Assembly it cylinder.)
74 ENGINEREMOVAUINSTALLATION
Alternatorand Pickup Coil Wire Connectors Wire Ground Terminal
A. lgnitionSwitch B. Clean Hose Air
C. lgnitionCoil Assembly
StarterMotor WireTerminal
A. AlternatorWireConnectors B. PickupWireConnector C. GroundWireTerminal
Throttle CableAdjuster
A. StarterMotor
B. Terminal
Oil Pressure SwitchWireTerminal Neutral SwitchWireTerminal
A. Throttle Cables
B. Ad.iusters
(Both Carburetor Vacuum Hose Side) RearBrakeLight SwitchWireConnectors
A. Oil Pressure Switch B. NeutralSwitch oPerform following. the osupport the enginewith a suitable stand, and remove the engine mounting boltsandbncket bolts.
ENGINE REMOVAL/INSTALLATION7
Stand A. Suitable
Bolts C. FrameMounting A. Right DownTube B. Engine Mounting Bolt oseparatethe right down tube, and move the dowir tube toward the rear.
A. RightDownTube
B. Pull the hoses'
.Dis6onnct propeller the shaftfrom the engine. oRemove propeller shaftcover. the oPull backthe bootsandpushon the lockingpin a little with a wire,then slip the engineunit towardthe front of andright side the vehicle.
A. Engine Bracket B. RightDownTube Bolts C. Bracket
D. EngineMounting Bolt E. Frame Mounting Bolts
A. Boots
tle B. Push pin.
7.6 ENGINE REMOVAL/INSTALLATION lnstallation .Note thefollowing: oFit the rubber boots into the front bevelgear case opening. olnstallthe springinto the insideofthe front bevel gear toint. oPutthe pin into the front bevel gear loint.
A. Push the pin. in oTighten the enginemountingbolts to the specified torque(see Exploded View). oRoutethe clutch hose follow. as
A. Rubber BooG B. Spring
C. Pin
oset the iackstandandtie attachment (special tools)on the bottomof the frameasshown. A. ClutchHose B. Slave Cylinder
oRoute the wlring accordingto the diagnms (see General Information chapter). oconnectthe batterygroundwire terminal th engine to asshown,
A. Jack Stand:57001-1238 B. Anachment: 57001-1252 C. Master CylinderBanjoBolt D. Makea clearance.
owhen fitting the engineinto the propeller shaftioint, pushin the pin at the front bevel joint. gear A. BattryGroundWire B. Abut 30"
8-1 CRANKSHAFT/TRANSMISSION
m / n Cra kshatt Trans ission

Tableof Gontents
Exploded View . Specifications. SpecialTools Sealant . . Crankcase Splitting. Assembly. Replacement Grankhaft/Con necting Rods. Crankhaft lnstallation. . . . . Connecting Rod Removal. Connecting Rod lnstallation ConnectingRod Big End Bearing . Insen/CrankpinWear. . . ' C r a n k h a f R u n o u t. . . . . . ' . . ' t Crankhaft Main Bearing/ W Main ournal ear..... J Cranlchaft SideClearance.' . Right EngineCover Removal . I nstallation. Left EngineCover . Installation. StarterMotorclutch, . . . . . Removal . lnstallation. . . .. .
8'2 8 8-7 8-7 8.8

H
B a f a n c. e r
.....',..
*21 & 21 &21 V22
.. t R H B a l a n c W e i g hR e m o v a l . . . . . er . WeightRemoval. . . . . . . LH Balancer . er L H B a l a n c W e i g hItn s t a l l a t i o.n.., ,
R HB a l a n c e r W e i g h t l n s t a l l a t i o n . , ,& 2 2 ...
&11 &14 &15 &15 &15 &15 &16 8-17 a-17 8.18 8-19 &19 8-19 8-19 &19 &19 &19
::: il; ::i:H::Hllilll.;::E

L S t a r t eT o r q u e i m i t e.r . r . Bemoval Inspeqtion WaterPumpldle ShaftHolder. Removal. lnstallation. PrimaGear ry R e m o v.a l fnstallation. Transmission ... .....'. ,. . ...... .'.'.. ,,.. .... .. &23 &23 &23 8'23 &23 8'23 &24 &24 &24 8-25 &25 &26 g-27 V27
,'..& 24
Removal. . . , External Shift Mechanism . Installation. External Shift Mechanism . Inspection . ExternalShift Mechanism . Removal. . . . . . . Shafts Transmission lnstallation. ,.... Transmission Shafts
T r a n s m i s sDos a s s e m b l y . ' . . . . . . . . 8 ' 2 7 i in 8-27 T r a n s m i s s iA s s e m b l.y. . . . . , . ' . . on R , ShiftDrum emoval .... &29 8'29 ... Slrift Drum Disassemblv/Assembly .
Disassembly Assembfy. lnspection ,...
a-20 &20
& 2O
http://manuals.magnamaniac.com 8-21 ,...
8.2 CRANKSHAFT/TRANSMISSION Exploded Viw
@9
t. 2. 3. 4. 5. 6.
Tl r 88 N<n (0.9kgn,78 in.lb| T2: 15 N{n (15 kghm, 11,0ftlbl 9. Starter Torque Limitel T3: 21 N-rn(2.1kgFm, 1 0 . C|ankdraft 15.0ft lbl T4: 39 N{n (4Ok$m,29 ft lbl 1 1 . Baringlnsert T5: 59 N{n (6.0kgn; /t:l ft lbl 12. ftimary Gear http://manuals.magnamaniac.com 13. lvater Pump Drive Sprodcet T6: 93 N<n (95 kg{n,69 ft.lbl 17; 1rt5N{n (15.0kg.m,110ft tbl 14. Bols M6 L : Apply nonfermanent locking agem. 15. Eolts tllS O : Apply engineoil. 1 6 . Bols MlO
ConnectingRod LH Balancar Gear LH BalancalWsight Balancer Shaft RH Balancr Weight Oneway Clundl 'r. Coupling 8 . Starter Mobr (Xutch Gear
L 2. 3. 4. 5. 6. 7. 8. Ci.in (lrvalsrPumpl ldh Shaft Sprodct (Al Clrin Guide ldls Shaft ldle Shaft Spro.i(er (Bl ldle Shaft Holdel GhainGuide Cldn {Wrbr ftrmg Drinl
d-ft'
\t/
t ? W
q\r
ffio* 6
1. Sfiift shaft 2. Shift LinkagFRod 3. Shift Mechanbm Arm 4, RerumSpringBolt 5, Ge.r P6itioning Lever
L : Apply non{smansnt locking agsnt to ths tht8&. Tl ; 88 Nm (090 kg-n.78 in-lbl T2: 21 N-m (2.1kgn,15 ft.lbl
@o
kq
84 CRANKSHAFT/TRANSM ISSION
@ o
oo@
k@
wa@u
N
?
*@*
,evJ)
1. DriveShaft 2. Damper Cam 3. output shaft 4. Bushing 5, Pin Plae 6. Bearing Holdel 7. Shift Drum Tl ; 225 N-m (23 kg.m,165ftlb) L : Apply loddng agentro dts threads.
CRANKSHAFT/TRANSMISSION86
1. RH EndneCoYer 2. Oil FillerCap 3. Altsmator Outer CoYer 4. Alternator lnner Covsr http://manuals.magnamaniac.com 5. LH EnginCoYel L : Apply Ioc*ing agBnito d|e drreads. Tt : 9, N-m (1.Okg-m,87in-lb)
8 CRANKSHAFT/TRANSMISSION
Specifications
Item
Crankshaft/Gonnecting Rods: rod big end sideclearance Connecting rod big end bearing Connecting inserVcrankpin clearance Crankpindiameter: None Marking rod big end bore diameter: Connecting None Marking Connectingrod big end bearing Brown insertthickness: Black Blue Connectingrod big end bearinginsertselection:
Con-rodBig End Crankpin Diameter BoreDiameter Marking Marking None None
Standard
ServiceLimit
0.16- 0.216 mm 0.026- 0.057mm 54.981 55.000 mm 54.981- 54.991 mm 54.992- 55.000mm 58.0fi) - 58.020mm 58.dD - 58.010 mm 58.011-58.020mm mm 1,2183 1.2187 mm 1.487 1.491 mm 1.2191 1.495
0.7mm m 0.10 m 54.97 mm
Bearinglnsert Size Color
PartNumber 92028-1476 92024-1475 92028-1474
Brown
o
None
Black Blue
runout Crankshaft
Crankshaftmain bearing/
0.02mm 0.030- 0.068mm 81.981- 55.000mm 55.ff|0 - 55.049mm 0.05- 0.55mm 96.85- 96.95mm 5.9- 6.0mm 6.05- 6.15mm 7.9- 8.0 mm 8.05 - 8.20mm
0.05mmTtR mm 0.10 54,96mm 55.08mm 0,75mm 96.6mm 5.8mm 6.3mm 7.8mm 8.3mm
journalclearance mainiournaldiameter Crankshaft Crankcase bearing diameter main bore Crank$aftsideclearance web Crankshaft length
Transmission: Shift fork earthickness Gearshift fork groovewidth Shift fork guide pin diameter Shift drum groovewidth
&7 CRANKSHAFTffRANSMISSION
SpecialTools
Circlip PfieB: 570{)1-14d
Ronor Holder: 57001-1248
GaarHolder: 57001-1015
NOTE oThe flywhel holder (P/N i7@,,-tgtg can E ued inst@dof the rotor holder (P/Itl izd)l-1249. Flywheel Holder: 57001.1313
Dampor CamHolder: 57001-1025
Karrasaki Bond(LiquidGaskeiSilberl: 9210+1qE
DdvsrSst: 57001-1129 Bsaring
8 CRANKSHAFT/TRAN$I'IISSION
Crankw
Splitting .Remove the engine(seeEngineRemoval/lnsallation chapter). aset the engineon a cleansurhceand hold tie englne steady whilepartsarebeingremoved. rRemove following. the Engine Top RockerCases CylinderHeads Cylinders Block Pistons Engine RightSide Water Pump Clutch Engine Left Side Front BevelGearCase AlternatorlnnerCover oRemove shifl mechanism and gearpositioning arin tlre lever with spring.
.full th6 starter motor clutch gear out of the starter motorclutch,then takeout the torquelimiter. rLoosentl|e startermotor clutch bolt whileholding the alternator rotor steadywith rotor holder (special tool: -1248). s700r
A. Starter Motor ClutchGear. C. TorqueLimiter B. Bolt
.Take the bolt, spacer,collar, needlebearing, copper washer startermotor clutchoff the balancer and shaft.
A. Shift Mechanism Arm B. GearPositioning Lwer aunscrewthe damper cam nut using a dampercam holder(special tool) anddeepsocket wrench. oRemove retainer needle the and bearing. olnsertthe bolt (012 mm, L100 mm) into tlle engine mounting bolt hole.
A. Bolt B. Spacer C. Collar
D. Bearing E. Washer F. StarterMotorClutch
A. Damper Cam D. Retainer E. B. Holder: 57001-1025 Bolt Bearing C. Needle
.Loosen the Wimary gearbolt while holdingthe alternator rotor steadywith the rotor holder (special tool: 57001-12481.
8.9 CRANKSHAFT/TRANS|MISSION
A. Primary Gear
A. Bolt Gear B. Balancer
C. Balancer Weight D. Spacer
.Removeth front chainguide,lower chainguide,and rearchainguidefrom the left handcrankcase. oLoosen the balancergear bolt by usingthe rotor holder(special tool).
A. FrontChainGuide B. LowerChainGuide
C. Rear ChainGuide
.Remove the chain guide and idle shaft holderfrom the righthandcrankcase. D. Ratchet A. Balancer Gear B. Alternator Rotor E. Rotor Holder: 57001-1248 C. Balancer GearBolt F. AltrnatorRotorBolt
aRemove the alternatorrotor bolt by usingthe rotor (special holder tool: 57001-1248). .Take the alternatorrotor with spacer ratchetoff and http://manuals.magnamaniac.com the crankshaft. .Removethe balancer gearbolt, and takethe balancer gear, spacer, balancer and weightoff the balancer shaft
A. ldle Shaft Holder
B. ChainGuide
&1 O CRANKSHAFT/TRANSTT,IISSION
rRemovethe primarygearbolt and take out tl|e water pump drive sprocketand idle shaft sprocket(A) asa st.
(B) A. Sprocket Pump B. Water Chain C. Camshaft Chain
D. Lower Chain Guide E. Rear Guide Chain
A. WaterPumpDrive Sprocket B. ldleShaft
C. Sprocket (A) D. Chain
.Pull tie primary gar out of the crankshaft,and take tie idle shaft out of tl|e cnnkcase, The idle shaft hu two oins.
.Pull tle water pump sprocketwith its shaft out of the inside the crankcase. of
A. Primary Gear 8. ldleShaft
C. Pins
A. Sprocket B. Shaft
oRemove following. the (B) ldle ShaftSprocket (with flat washer) http://manuals.magnamaniac.com Water Pump Chain Camshaft Chain aRemovethe starter motor bolts and the motor out of LowerChainGuide the crankcase. Rear ChainGuide
halves. .Usingthe pry points,splitt}|e crankcas
A. Bolts
B. StarterMotor
rRemove the cnnkcasebolts (Right Side). A. Pry Polnt (Front) B. Pry Point (Rear)
aTurnthe crankcase sidedown. LH .Lift off the RH crankcase half. half. oRemove followingfrom the LH crankcase the Crankshaft Gears Transmission Shift Drum
Asrr.mbly
A. 08 mm Bolts(5) B. Do not fotget to removetJ|isbolt. halves. .Note thefollowingbefore fitting the crankcase oWith a high flash-poirit solvent,oleanoff the mating halves and wipe dry. surface tie crankcase of ousingcompressed blow out the oil passages the in air, crankcase halves. olnstallthe shift drum and settie gearpositioning lever to the neutralposition.
.Removeall tl|e crankcase bolts (Left Side).
(14) A. 06 mm Bolts (1) B. 08 mn Bolts
C. 010mm Bolts(3) A. Shift DrumPinPlate Positioning Lever B. Gear C. NeutralPosition
&12 CRANKSHAFT/TRANSMISSION
oApply engine oil to the transmission gears, ball bearings, shift drum, and crankshaftmain bearing inserts. ocheckto see that the followingpartsarein place the in LH crankcase half.
Area. l: LiquidGasket Applied .Tightenthe crankcase boltsasfollows. olightly tightenall the boltsto a snugfit. oTorquethe 8 mm and 10 mm bolts to the tightening sequence, and tien tighten the 6 mm bolts to the specified torque(see Exploded View). Bola TiqhteningOrdsr
A. Transmission Gears B. Shift Forks c. shift Rod D. Shifr Drum
E. Crankshaft F. Balancer Shaft G. KnockPin H. O-ring
oCheck see to tiat the followingpartsarein place the in RH crankcase half.
A. Oil Pump
B. KnockPin
oApply liquid gasket to the mating surface of the crankcasehalf.
8.13 KSHAFT/TRANSMISSION CRAN

.After tighteningall the crankcase bols, check the followingitems. oTurn the RH crankcas down, and checkthat the half driv shaft andoutput shaft turn freely. oBe sure the neutnl finder operatsproperly (while can slowly spinning output shaft,gears be shifted the and from neutralto lst gear 1stto neutal). ocheck that tlte gears shift smootlly from neutral to 4th gear,and 4tl| to neutral,while rapidly spinningthe output shaft. RightSide Engine ChainandChainGuides Camshaft StarterMotorClutch(RH Balancer) (B) ldle ShaftSprocket
A. Washer
(B) B. Sprocket
Primary Gear
A. Output Shaft B. Shift Drum
C. RapidlySpinning
.lnstall the following Engine Left Side and Camshaft Chain ChainGuide Weight LH Balancer Alternator Rotor
Gear A. Primary
B. Notched Side
ldle Shaft (A), ldle ShaftSprocket WaterPumpDrive and Sprocket, chainasa set.
A. Marlc Aligned (A) A. Sprocket B. WaterPumpDriveSprocket C. Chain D. Washer
ldle Shaft HolderandChainGuide TorqueLimiter StarterMotor Clu&h Gear
A. Bearings B. Holding Plates
C. LH Crankcase Half
A. TorqueLimiter B. ldle ShaftHolder . ChainGuide
D. Starter Motor Clutch Gear E. Turn Clockwise
ShiftMechanism Damper Cam Front Bevel Gear Case Clutrh (lmpeller Water Pump Bolt hasLeft-handed Threads) RightEngine Cover Engine End Top Altrnator Covers Left Engine Cover
A. Bearings B. Holding Plates
C. RH Crankcase Half
oApply non-permanent lockingagentto the threads of the shift return spring bolt, and tighten it to tie specified torque(see Exploded View). oApplysilicone salant the threads the oil pressure to of switch, and tighten it to the specified torque (s Exploded View).
Replaement
oThe left and right ctrnlgs h.lv6. ar madtin d 8t tts fcory 3ntio dmblad 3trte, to tt. clankcate halyos nui br lopLcod ar a rsc
.Remove the usablepart from the old case,and insEll them on tie new cases.Note the followin& http://manuals.magnamaniac.com oAfter removingtlle bearing holding plates,install the ball bearingswith new ones usinga bearingdriver set (special tool: 57001-1 129). A. Shift RetumSpringBolt
B. Oil Pressure Switch
8.15 CRANKSHAFT/TRANSMISSION
O Replace water pump shaft bearingsand oil sealwith the new ones. Pressthe oil seal into the RH crankcase half from the insideof the case.
ConnectingRod Bemoval
oRemovethe crankshaft. .Remove the connectingrods from the crankshaft.
NOTE oApply hich temperature greaseto the lips of {E water pump shaft oil s@1. NOTE aMa* and fecod the locations of the connEting rods and their big end capsI that Urey can he rea*mbled in theh oiginal positions.
h\\\\J
\ili
z<r &
ss
rT) -<s\ '1
1 .Bearings 2. Oil Seal the 3. Press oil seal.

oTighten the engine oil drain plug to the specified torque (seeExploded View).
Crankshaft/ConnestingRods kshaft I nstal Cran lation oThe crankshaft LHendis longer the RHend. than
l. Connecting Rods 2. BigEndCaps 3. Crankshaft
.Removethe connecting big end capnuts,andtake rod off the rod andcapwith the bearing inserts.
ConnectingRod Insallation
A. Crankshaft B. Long End(LH) C. Short End(RH)
oTo minimize vibration, the connesting rods drould have dre $mo wight mark,
&1 6 CRANKSHAFT/TRANSMISSION
NOTE oTighten the big srd cap nuts to {ze sp*ified torque (se Exploded Viewl. oDo not move theconnectingrod and crankdtaft during clearance magJrement.
Connesting Big End Rod BearingInsert/Grankpin Clearance - 0,057mm Standard: 0.026 Service Limit: 0.10 mm tlf clearance within the standard, bearing is no replacementis required. *lf clearance between is 0.057mm andthe service limit (0.10 mm), replacethe bearinginsertswith inserts paintd blue. Check insert/crankpin clearance with plastigage. The clearance may exceedthe standard sliehtly, but it must not be lessthan the minimum in orderto avoidbearing seizure. *lf clearanc exceeds the servicelimit. measuretie diameter the cnnkpins. of
1. BigEndCap 2. Connecting Rod
3. Weight Mark,Alphabet
olf dre connec{ing rods, bearing inssrB, ot crankshaft ar mplaced with new on6, 3elect d|e beadng insert and .tr6d( .Nsarancewitft a plastigage before asembling engine to be sun the coared bearing insert3 are installed. .Apply engineoil to the big end bearinginserts. .Tighten the big end cap nuts to the specified torque (seeExploded View).
CrankpinDiemete. Standad: ServiceLimit:
54.981 - 55.qn mm 54.97 mm
ilf any crankpinhasworn pastthe service limit, replace the crankshaft with a newone. *lf the measured crankpindiameters not lesstlan are the service limit, but do not coincide with ttre original diameter markings the crankshaft, on makenew marks on it. CrankpinDiameterMarks None: 54.981- 54.901mm O : 54.9!12- 55.0dt mm
Connecting Rod Big End Bearing ln*rt/Crankpin Wear .Measure the bearing insert/crankpin clearance with plastigage.
l. Crankpin 2. Plastigage "O" markor no mark Marks, El:CrankpinDiameter
CRANKSHAFT/TRANSMISSION8-17
.Measure the connecting rod big end inside diameter, and mark each connecting rod big end in accordance with the insidediameter.
NOTE torque (9e oTighten the ap nuts to the qeified Exploded View). oThe mark already on the big end dtould almost coin' cide with the mwlrement,
lnsert 1. Bearing
Connecting Rod Elig End Inside Diametsr Marks 58.000- 58,010mm None:
2- ColorSizeMark
.lnstall the new inserts the connecting andcheck rod in with clearance the plastigage. insert/crankpin
58.011- 58.020mm
Crankshaft Runout
.Measure crankshaft runout. the *lf the measurement limit, replace exceeds service the thecrankshaft. OankshaftRunout Standard: Limitr Service GankshaftRunout
0il2 mm 0.05 mm TIR
1 . BigEndCap Rod 2. Connecting
Mark, 3. DiameGr "O" mark or no mark
.Selectthe properbearing with insertin accordanc the rod and crankshaft combination of the connecting coding.
Big End Bearinglnsert Selection Con-rodBig Crankpin Bearing Insrt End BoreDia Diameter SizeColor PartNumber meterMarking Mark 92028-1474 None Blue o
None None None Black
s 92028-147 92028-1476
Brown
Standad:
CrankshaftMain Bearing/MainJournal Wear rMeasure diameter thecrankshaft iournal. main of the

crankshaft Main Joumal Dhmctel
Serrice Umit:
54.981- 55,qD mm 54.96mm
&18 CRANKSHAFT/TRANSMISSION kshaft Side CIea nce ra Cran aMeasure crankshaft clearance, side
Crankshaft Side Clearance, Standard: Serrice Limit:
0.G5- 055 mm
0,75 mm
*lf any journal has worn pastthe service limit, replace thecrankshaft with a newone. 1. Crankshaft 2. Crankcase .Measure main bearing the borediameter the crankin case halves. 3. Clearance
*lf the clearance greater is tian the service limit, measure the crankshaftweb length to see whether the crankshaft the crankcase faulty. is or Crankshaft Web Lengrh Standad: 9685 - 96.95 mm Service Limit: 96.6 mm
C6nkcasMain BearingBore Diameter Standsld: Serrice Limit: 55O3{l - 55.Otl9 mm 55.08 mm
*lf the lengthmeasurement smallerthan the service is limit, replacethe crankshaft. Otherwise, replace the crankcase halves a set" as
*lf they are any signsof seizure, damage, excessive or wear, replace crankcase the halves a set. as
NOTE oThe right and left cnnkcz* haly6 are m*hirzqt at the factory in the a*mbled state, & thay mu& b re plaed asa st.
Right EnglneCover
Bemotral rRemove muffler(see Engine Top Endchapter). the chapter). .Removethe right downtube (see Frame aRemove coverbolts. the .Using t}|etap points, takethe covroff t}tecnnkcase.
Cover Left Engine

lnsallation .Note the followin& to oBefore installing tlre left enginecover, apply grea3e dampersand attaoh them onto the ttre back of the alternator outer cover.
A. Damper A. Tap Here
B. Altemator Outcr Cover
o Instllthe left enginecoverabovethe enginebracket
lnstallation .Not tle following. oReplace rightengine with a newone. covergasket tl|e General oRoutr the hoses and the wires correctly (see Information). RearBrakeHoss RearBrakeLight SwitchWire Air Cleaner DrainHose
A. Front BevelGearCas Bracket B. Engine
End C. C-over
StarterMotor Clutdt
http://manuals.magnamaniac.com rightdowntube (seeFramechapter). .Removett|e

A. DrainHose wire B. BrakeLight Switch C. Strap D. Clamp .Removethe right engine cover. .unscrew the starter motor clutch bolt while holding the primarygearbolt.
Removal
oApply oil to the threads of the starter motor clutch bolt and tighten i! to the specified torque (see Exploded View) while holdingthe primarygearbolt.
Disassembly rRemove starter the motorclutch assemblv.

.Remove the Allen bolts with the balancerheld in a vise.
A. Primary GearBolt C. TorqueLimiter B. StarterMotor ClutchBolt .Pull the starter motor clutch gearand starter motor clutch (with RH balancerweight) as a set off the balancer shaft.
lnstallation
oNotethe following. olnstallthe callerandcopper washer shown. as A. Balancer Weight B. Allen Bolts
.Pull the coupling of the balancer. out .Takethe one-way clutchout of the coupling.
A. Copper Washer
B. Caller
olnstallthe starter motorcluichgearasshown.
t . Balancer Weight 2. OnewayClutch

t.
Coupling MotorClutchGear Starter
Assembly
A. StarterMotorClutchGear B. Push and turn clockwise.
.Note the following. olnstall the coupling with the groovedsidefacing out.
8.21 KSHAFT/TRANSMISSION CRAN
Weight A. Balancer Clutch B. One-way
C. Coupling D. Groove
A. One-wayClutch B. lnnerRace
(Starter Motor ClurchGear)
oApply a non-permanentlocking agentto the threadsof the Allen bolts, and tighten them to ihe specified torque (seeExplodedView).
lnspection
.Remove the starter motor clutch gear and torque limiter, then reinstall the starter motor clutch gear into the starler motor clutch. aTurn the starter motor clutch to both side. oWhen viewed from the right side of the engine, the clurch should turn clockwisefreelv, but should not turn counterclockwise. A. Coupling B. One-wayClutch
Balancer RH BalancerWeightRemoval removal. motor clutch See startr
A. Turn freely. B. Locked
C. StarlerMotorClutchGear
*lf the startermotor clutchdoesnot operate it should as go or if it makes noise, to the nextstep. .Disassemble startermotorclutch. the reinstall *lf the one-way is clutch installation incorrect, LH BalancerWeightRemoval http://manuals.magnamaniac.com engine. aRemove the ir. *Visually inspec!the clutch partsfor damage: one-way oRemovethe shift leverrear end. and startermotorclutchgear.Remove the pickupcoils. clutch,coupling part,replace *lf tiere is any worn or damaged it. aRemovethe alternatorinner cover.
&22 CRANKSHAFT/TRANSIVIISSION
RH Balancer Weight lnstallation See starter motorclutch installation.
LH Balancer Weight lnstallation

.Note the following. oFit the balancer gear onto the balancer weight as follow.
A. Shift Lever B. lnnerCover
C. Tap Here D. Pickup Coils
.Loosen the LH balancer gearbolt while holdingthe alternator rotor with a flywheelholder(special tool).
'- ?'\ -"
i:-:-iv*N"
1. Gear 2. Weight
3. Hole
oTightenthe balancer gearbolt to the specified torque (see Exploded View). oTighten the alternator rotor bolt to the specified in Electrical chapter). torque (see Exploded
A. Balancer Gear B. AlternatorRotor C. Bolts
D. Rotor Holder: 57001-1248
Balancer Shaft Removat iSplit thecrankcase Crankcase (see Splitting). aPull shaft of thecrankcasethe out
.Remove the alternatorrotor bolt by usingthe rotor (special holder tool: 57001-1248). aTaketh alternatorrotor with soacer and ratchet off the cran kshaft. .Removetie balancer gearbolt, and take the balancer gei , spacer, balanoer weightoff the balancer shaftasa set.
Balancer Shaft I ns'3IIati on

.Note t}le following. oFit the balancershaft into the bearing in the LH cnnkcase half asshown.
A. Bolt B. Balancer Gear C. Balancer Weight A. Balancer Shaft B. LH Crankcase Half
Starter Torque Limiter
Remomt .Removethe muffler (see Engine Top Endchapter). .Removethe right downtube (see Frame chapter'). aRemove RH engine tlle cover. aRemove starter motor clutch gear. tie tPull the torquelimitrr out of the crankcase.
WaterPump ldle Shaft Holder

Remoml .Take the spring endoff the hook. .Unscrewthe bolts and takethe idleshaftholderwith a chainguideout of the crankcase.
A, TorqueLimitr C. Washer B. StarterMotor ClutchGear
A. Spring B. Bolts
C. Holder D. ChainGuide
oDo not dilctsnbls drs torquo limitsr. limitel will not lunqtion if thb is dons.
Ths torque
.Pull out the chainguideftom the holder.
lnspection .Removethe torquelimiterandvisually inspect iL ilf the limiter haswear,discoloration, otherdamage, or replacit asa set.
Insallation .Note the following. oPut the washer onto the idle shaft,and fit the knock pinsinto the crankcase.
l. Gear 2. Friction Plate 3. Pinion A. ldle Shaft B. Washer C. KnockPins
ISSION KSHAFT/TRANSM &24 CRAN Primary Gear

Removal .Removethe followingparts. Muffler (see Engine Top Endchapter) chapter) RightDownTube (seeFrame Right Engine Cover StarterMotor ClutchGear Clutch .Removethe watr pump chainguideand water pump idleshaftholderfrom the RH cnnkcase. .Pull the primarygearout of the crankshaft, take and the pin out of the idleshaft.
A. Primary Gear B. ldleShaft
C. Pin
A. ChainGuide
B. ldle ShaftHolder
lnstallation .Note the following oFit the primary gear with the notched side facing of towardthe inside the engine.
.Remove the primary gearbolt by usinga air impact wrench,and take tlre out water pump drivesprocket andidle shaftsprocket(A) asa set.
Gear A. Primary
Portion B. Notched
http://manuals.magnamaniac.com recesses. pin into the sprocket

A. WaterPump'Drive Sprocket D. Chain B. ldle Shaft E. Primary GearBolt (A) C. Sprocket
oWhenthe watr pump idle shaft is installed, t}te fit oTightenthe primarygearbolt to the specified torque (seeExplodedView) while holdingthe primarygear with a gear holder(special tool).
.Remove the shift shaft,while pushing shift mechthe anism arm forward.
(57001-1015) C. Primary A. Gear Holder GearBolt B. Primary Gear
oTightenth clutch hub nut to the specified mrque(see Exploded View).
A. Shift Shaft B. Shiff Mechanism Arm
C. Push D.Gear Positioning Lever
.Unscrewthe bolt andremove gearpositioning the levr and its spring together.
Transmission
Extemal Shift mechanism Remoml .Rernove following. tie LH Engine Cover (see Engine Engine Removal/lnstallation chapter) Shift LeverRearEnd Front BevelGearCase External Shift Mechanism lnstallation .Note the following. oPositionthe gear positioning leverand springin tie crankcase screw the bolt asshown. and in
A. Shift Lever B. Front BevelGearCase A. Lever B. Spring C. Bolt
&26 CRANKSHAFTTTRANSMISSION
olnstalltlte shift lever shown. as *lf necessary, and loosen locknuts turn the shift rod the the to obtainan 88.5 mm leng$ including locknuts.
Exhrnal Shift Mechanismlnspection .Examine shiftshaft anydamage. the for
1. Shift Shaft 2. RetumSpring 3. Shift Mechanism Arm 4. Arm Spring A. 88.5 mm Lengh B. Shift Rod C. Shift Leven D. Locknuts to oCheckthe shift shaft for bendingor damage the splines. it *lf theshaftis benLstraighten replace lfthesplines or replace shaft. aredamaged, the or oCheckthe return springand arm spring breaks for distortion. them. *lf the springs damaged any way, replace in are ooreck the shift mechanism for distortion, arm *lf the shift mechanism in arm is damaged any way, replac arm. the .Checkthat tbe returnspring bolt is not loose. *lf it is removed,unscrewit, apply a non-permanent locking agent to the threads,and tighten it to $e View). torque (see Exploded specified leverand springfor breaks the gearpositioning theck or distortion. *lf the leveror springis damaged any way, replace in tnem.
O Installthe clutch hoseguide as follows.
A. Hose Guide A. ReturnSpringBolt B. GearPositioningLever C..Spring
CRANKSHAFT/TRANSMISSION&27
.Visually inspect shift drum cam. the rrlf it is badlyworn or if it shows damage, it. replace any
TnnsmigsionDissembly shafts. .Remove transmission the to tool: 57001144) .Usingthe circlippliers(special shaft' the disassemble transmission thecirclips, remove stel balls three .The 3rd gear theoutputshafthas on Re findermechanism. neutral in it for the positive
as the move 3rd gear the follows. oset the output shaftin a verticalpositionholdingthe 2nd gar. ospinthe 3rd gearquicklyand pull it off upward.
Transmission Shaf:* Remotal .Removethe engine. .Split tie crankcase. .Pull out the shift rod and take tie shift forks out of gears. the transmission .Take out the driveshaftandoutputshaftasa set.
1. 3rd Gear 2. 2nd Gear 3. SpinQuickly
A. Shift Rod B. Shift Forks C. DriveShaft
D. OutputShaft E. Shift Drum
Awmblv Tnnsmission
.Note thefollowing. with new ones. oReplace circlip that wereremoved any with a is olnstallthe circlipsso that tl|e opening aligned groove. spline
lati Transm ssi Shaf/s In stal on i on

.Note the following. ocheckthe positionof the shift forksasshown. oFit tlle drive and outDut shaftsas a set into the LH half, while placingthe shift fork onto the crankcase driveshaft.
A. Drive Shaft B. Output Shaft C. Shift Fork For DriveShaft D. Shift Fork For Outprit'Shaft 1. Circlip Washer 2. Toothed 3. Groove
olnstall the gearbushingon the output shaftwith its oil holealigned with the shaftoil hole. oFit the steel balls into the 3rd gear holes that are smallerthan the other holes seen as from the outsideof the gear, and then install the gear on the shaft so that the steel balls alien with the recesses the shaft. in
A. Oil.Holes B. Bushing
A. 3rd Gear B. SteelBalls
C. Recess D. Small Hole
Drive Shaft
1. Top (4th)Gear 2. OilHole 3. 2nd Gear 4. 3rd Gear 5. l st Gear(DriveShaft) 6. Circlip
7. Needle Bearing 8. ThrustWashr http://manuals.magnamaniac.com 9. Circlip 10. Washer 11. BallBearing
CRANKSHAFT/TRANSMISSION8.29
Output Shaft
Top (4th) Gear
2. Oil Hote
2nd Gezr Oil Hole 5 . 3rd Gear
.t.
6. I st Gear 7 . BallBearing 8 . Circlip 9 . Bushing 1 0 . ToothedWasher
ll. Circlip 12. Steel Ball 13. Washer 14. Needle Bearing 15. Circlip
i b b Sh ft Drum Di nssem Iy/AssemIy

oDisassemble shift drumasshown. the
oDo not apply gre6 to dre stel balb to hold drern in place, This will cause the Foritive nerstrd finder medranism to maltunstion.
ytift Drum Removal aRemove Transmission asa set. the Gear

.Remove the bolts and take off the bearing holder and the shift drum.
b$
1. PinPlate 2. Pin 3. Shift DrumCam 4. Bearing 5. Shift Drum .Whenassembling shift drum,notethefollowing. the oThe pin platemustbe 'rnstalled the correctposition, in andmustfit onto the pin plateasshown.
A. Bolts B. Bearing Holder C. Shift Drum
A. Pin B. Shift DrumCam
C. Partof the aluminum-
oApply a non-permanent lockingagent the threads to of the pin plate screw.
9.1 WHEELS/TIRES
Wheels,/Tires
Tableof Contents
ExplodedView... Specifications Tools. Special Wheels(Rims)
Removal FrontWheel FrontWheellnsallation Removal RearWheel Rear Wheellnsallation. Remoral. Wheel Coupling . ...;. ......... ' lg Wheel ouplinnstallation. C (for (Rim) Inspestion castwheel) Wheel ...'.'.'. Weight Installation, Balarrce . WeightRemoval Balance wheell.. . . Spokelrspection(for wirespoke Rim Inspection Installation Weight Balance T i r e s. . . .......'. lnspection TireAir Pres$re Tire Inspection Tire Removal' . Tire lnstallation. . . . . HubBearings. , '. '.. ' '. Removal lnstallation Lubrication . Gear Speedometer Housing bly Disasembly Assem and Lubrication
9-2 94 9-5 96 9 9-6 *7 97 9 9 9'9 9'9 9-9 9-10 9-10 C10 911 9-11 911 9-11 9'12 9'12 $13 913 913 $13 v-^14
9-2 WHEELS/TIRES
Exploded View
vN1500-A (G): WestGerman Model
-s
1. BalancerWeight 2. Front Tire 3, Air Valve 4. Speedomter Geal 5. Front Axle 6. Front Wheel 7. RearAxle 8. RearTire 9. RoarWheel T1:1.5 N-m(0.15 kgFm,13 in-lb) T2:88N-m (9.0kg-m,65fr-rb) T3:110N-m (11.0kg-m,8oft-lb)
='=')');" EY
;#
a \r \\ \
rtY- v )\ '
9 WHEELS/TIRES
vNrSoo_B
5 , T 1 : 1 . 5N - m( 0 . 1 k s - m 1 3 i n - l b ) 65 T2:. 88 N-m (9.0kg-m, ft-lb) t 5 : 1 1 0N - m ( 11 . 0 g - m8 0f t - l b ) k , T4: 3.9 N-m (0.40ks-m.35 in-lb) G : Applygrease.
r.-S1/.v:),,.
^
v
*t/
ob*
tt'
^\
z"soT """ @
1. Spe.domrt i Gorr 2, Front Axl. 3, Brhncar Weight 4. Rim 5. SpokeNippls 6. SFoke 7. Tube 8. Air vdr. 9, Rim Bcnd 10. Flont Tirr 11. RarrAxle 12, B.rd Ptotectol 13. B.bnaetW.ifht 14. R.|' Tir.
94 WHEELS/TIRES Specilications
Item
Wheels: Rimrunout: VN1500A Axial Radial VN15OOB Axial Radial
Standard
ServiceLimit
TIR0.5mm TIR0.8mm TIR 0.8 mmor less(withtire installed) TIR 1.0mm or less(withtire installed) TIR0.05mmor less Lessthan 10 g 109,209,309 4.4mm(DUNLOP) 4.3mm(BRIDGESTONE) 7.3mm 6.2mm (BRIDGESTONE) TIR 2.0 mm TIR 2.0 mm TIR 0.2 mm
Axlerunouv100 mm: Wheelbalance Balance weights Tiros: Tiretreaddepth: Front Rear
'I mm 2mm
Standard tires: Front

VN 15OOA
DUNLOP 1J,{A) (E)F11LTL F'l (A11-) BRIDGESTONE EXEDRA L3O9 1OO/90-19 TUBELESS 57H ryPE DUNLOP (A) K425A, (E) K425AL TL (A11-) BRTDGESTONE EXEDRA Gs26 150/90- 74Ho|ls0/90-15 M/C74HTUBELESS ls rypE (E)F1lLTT/METZELER OUNLOP F11J, Marathon Front .1OO/90-19 57HTUBETYPE (E) DUNLOP K425A, K425AL TT 150/90-15 or 150/90-15 74HTUBE 74H M/C TYPE l\4ETZELER Marathon Euro 150/90815 74H i/VC
Rear Front VNl5OOB Rear
Tireair pressure: Front up to 97.5kg (215lb)toad

97.5 - 180 kg (215 - 397 lb) load
200kPa(2.00 kg/cm,,28 Psi) 200kPa (2.00kg/cm,,28Psi)
Rear vN15004 (E) (G) vN1500A (E) vN1500B (E) European Model (G) WestGerman Model
97.s- 185kg (215- 408tb)toad

97.5 - 186 kg (215 - 410jb) load 97.5 - 184 kg (215 - 406 tb) toad
225kPa(2.25kg/cm,,32Psi)
(A)Australian Model
Usethe samemanulacturer's on bothfrontand tirss rearwheels.
NOTE 'JMost countriesmay have their own regulationsrequiring a minimum treaddepth:be sure to followthem. tirc aCheck and balance the wheel whena tire is reDlaced with a new one.
WHEELS/TIRES 9.5 SpecialTools

circlip Plien: 57001-1/|i'
Jack Stand: 57001-1238
Rtm Protedtor: 570O1-106!t
Attachment: 57901-1?5.2
N
Bearing Remover Shaft: 5700l-1265 Bearing DdverSet: 57001-1129 Besring Remouer Head: 57001-1267
Bearing Remover Head: 5?dt1-1293
96 WHEELS/TIRES (Rimsl Wheels Front WheelRemoval

.Remove the following. Speedometer Cable Lower End Brake Caliper Mounting Bolts
Front Wheellnstallation .lnstallationis the reverse removal. Note the of

following, NOTE oPut the spedometer gear drive onto the wheel hub nobtrrjhes.. then install the housing e that it fits in the drive nofthes.
A. Caliper Mounting Bolts
B. AxleNut
A. Notches B. Proiections
oFit the qedometer stop.
C. Drive D. Housing
gear housing stop to the fo* lq
Axle Nut Axle ClampBolt (Loosen)
1. Housing Stop A. Axle B. AxleClamp Bolt C. Speedometer Cable
2. Fork LegStop
oFit the collar on the right hand side of the hub.
.Use the iack standand the attachment (special tools: 57W1-"1238, 57001-12521 othersuitable and means to lift the front of the motorcvcle. .Pull out the axle to the right anddropthe front wheel out of the fork.
.Tighten the axle nut to the specified torque (see Exploded View). .Tighten the axle clamp bolt to the specified torque (see Exploded View). .Checkthe front brake.
tml
Do not attempt to drive the motorcvcle until a full braks lever is obtained by the http://manuals.magnamaniac.com the purnpingThe brake l6ver until the pads are against disc. brakes will not funcjtion on the first application of the lever if this is not done,
oDo not lay the wheel doun on dte disc. This can damage or warp dle disc. Place blocks under the wheel so that the disc do not touch the ground.
WHEELS/TIRES 97
Rear Wheel Remowl rRemove following. the Engine Top Endchapter) Muffler(see Brake Caliper MountingBolts HolderBolt CaliDer
Bear Wheellnstallation .Notethefollowing. oApply grease thegrease to seal. molybdenum disulfide oApply molybdenum grease the splined to disulfide portion tlle ringgear hub. of
HolderBolt A. Muffler C. Caliper MountingBolts B. Caliper
A. Final Gear Case
Hub B. Ring Gear
oBesureto inserttheoollaron both sides the hub. of Axle Nut Cotter Pin AxleNut
A. CotterPin
B. Axle Nut
1. LHCollar 2. RHCollar Hub 3. Rear 4. Coupling
Hub 5. Ring Gear Portion 6. Splines 7. Grease Seal
eUsethe iack standand the attachment(special tools: means to 57001-1238, 57001-1252) other suitable or http://manuals.magnamaniac.com lift the rearof the motorcycle. oPull the axle toward ti left, and slidethe rearwheel olnsert tl|e rear axle into the final gear castoward the portion of the ringgear toward the right to disengage wheel from the final the LH to RH, and fit the splined gearca9e. hub. hub andwheelcoupling
9 IVHEELS/TIRES
WheelCoupl i ng I nstallation .Note thefollowing. oApplymolybdenum grease theO-ring. disulfide to
A. Axte Gear B. Ring Hub
Hub C. Coupling
o'Iightn $e axle nut to the specified torque (se View). Exploded oTighten the rear brake caliper mounting bolls to the View). specified torque(se Exploded oTiShtgnthe calipr holder bolt to the specifiedtorque (seeExplodedView). oReplace cotterpin with a newone, tl|e olnst:ll the muffler (see Engine Top Endchapter).
A. Gring
Do not attempt to driv the motorq/cle until a full brake pdal is obtained by pumping th. brak6 pedal until the pads are against the disc. Th6 b6ke will not funqtion on the fiBt application of th psdal if this is not dong.
Wheel(Rim) lnspection(for castwheel)

rRemovet}le tire from the wheel. .Measure rim runoutby using dialgauge. the the
Wheel Coupling Removal .Removeth rearwheel(seeRearWheel Removal). aRemove coupling th retainer. .Rmovethe wheelcoupling puller with suitable bearing if necessary.
A, Wheel Coupling B. Coupling Retainer 1. RadialRunout 2. Axial Runout
99 WHEELS/TIRES
*lf rim runoutexceeds service limit, checkthc wheel the bearings. the *lf the problemis not due to the bearings, wheel mustbe replaced.
Axial Runout Service Limit: Radial Runout Ssrvice Limit:
&lance Weight PanNumber 4'107 5-1014 41075-1015 41075-1016 Weight(grams)
10 20 30
0.5 mm 0.8 mm
ln3talling Balance Weight
(a) Press lightly hammer the weight in. or
oNevsr atternpt to tepir a damaged whel. lf there is 8ny d8magp becides wheel bearingt, dle wheel mu3t be rgplaced to inturc 38fe opsrational cotldition.
Tire Bead
Batancc Weight lnstal lation thck if the weightportion hasanyplay on the blade and{lip plate. *lf it does, it. discard .Lubricatethe balance tire bead,and rim weightblade, flange witlt a soap and water solution or rubber weightslip onto the lubricant. This helpsthe balanc rim flange.
(b) Installation completed.
oDo not tubricate the tile bead widl engine oil or ga3olinbecauie thsy will dsteriorote ths tirs.
.lnstall the balance wighton the rim. oslip the weighton the rim flangeby pushing lightly or hammering tie weightin the directionshown in the figure. ocheck that the bladeand weightseatfully on the rim over the rim ridge flange,and that th clip is hooked andreaches flat Dortion. rim
Clip
Balance Weight Removal (a)When tire is not on the rim. the http://manuals.magnamaniac.com .Push the blade portion toward the oulside with a play on the rim flange, olf the balance lyeight has any off regular screwdriver,and slipthe weight the rim tip the blade and/or dip h.ve been 3uetdred. Rcplace flange, the loo.e balancs weight .Discardthe usedbalance weight. oDo not raur used blance wigha,
910 WHEELS/TIRES
RemovingBalanceWeight (without tile on riml
Rim lnspection a by .Measure rimrunout using dialgauge. the
(b)When tire is on the rim. the .Pry the Balanceweight off the rim flangeusinga driverasshownin the figure. regular screw tip the olnserta tip of the screwdriver between tire bead and weight blade until the end of the tip raches the endof the weightblade. oPush the driver grip toward the tire so that the balance weightslip s off tie rim flange. oDiscard used weight. balance the l. Radial Runout Bslance Weight (widr tire on lim) Romoving *lf rim runout exceeds the servicelimit, check and performthe following. oRecentering rim. th torque oRetightening spokenipples the specified to the (see View). Exploded rlf the rimsis badlybent,it mustbe replaced. 2. AxialRunout
Axial Runout Service Limit Radial Runout Service Limitr
2.O mm 2.0 mm
Spoke lnspection (for wire-spoke wheel) .Checkthat all the spokes tightened are evenly. *lf spoketightness uneven loose, tightenthe spoke or is torque evenly(seeExploded nipplesto the specified View).
A repaired wheel part may fail in use, possibls causing an accident. lf any wheel part is bent. dsnted, cracked, oa warped, replace it.
olf any 3pokebrsakr, it $ould be replacdimmediately' A missingspok6 placesan dditional load on the other spokes,which witl eyentrally euse odrer 3poket to break.
BalanceWeightInstallation nipple. .lnstallthebalance weight thespoke on securely a pliers. using oAttach balanc weight a
911 WHEELS/TIRES
I
\
1. Depth Gauge
Weight A. Balance
Balancs Weight
tlf any measurement is less than the servicelimit, replacethe tire.
PartNumber 41075-1007 4'I075.'I008 41075.1009
Weight(grams)
10 20 30
.'_1T...................
TireAir Pressure lnspection
NOTE oMeastretire prffsure when the tires arc cold (that is, when the motorcycte has not beenridden more than a mile during the past3 hours). (whencold) Tire Air Pressure
Load
Tire Trsad Depth Front Standald: Limit: Service Real Standard: Limit Seruice
4.4 mm 1 mm 73 mm 2 mm
NOTE oFor the VN\5O&B. replace the rim band with e new one wttenever tire is repleed. the
Air Pressure
Front Up to 97.5 kg (215b) l 97.5-l80kg (21s -397 t6)
200kPa (2.00kgrlcm', psi) 28

200 kPa (2.O0kglamz 28 psil ,
Tire Removal .Note the following. oWhenremovingthe rear tire, removethe valvestem nut, andfully loosen beadprotector the nut, balancer nut (VN1500-B).
97.5 (215 97.s (215

-
185ks 408rb) 186ks 410rb)
225 kPz (2.25kglcm2, 32 psi\
i E (E., 97.5 - 184 kg (21s 406 tb) >:i

Model @ European Model @ WestGerman
Tirelnspection
the avisually inspectthe tire for cracksand cuts. Replace tire if badly damaged. a Measurethe tead depth at the center ot the tread with a depth gauge.
Protector Nut A. Bead B. Balancer Nut
9.12 WHEELS/TIRES Tire lnstallation acheckthe tire rotationmark on the reartire and install on therimaccordingly. it NOTE
oThe direction of the tire roation i8 st own hy an arrow on the rar tire sidev,all. Ail Valve
1. Plastic Cap 2. ValveCore 3. StemSeal
4. ValveStem 5. ValveSeat 6. ValveOpened
3. Air Valve 1 . RotationMark(Arrow) 2. Balance Mark (YellowPaint)
.lnstall a newvalve the rim. in oRemove the tlle valvecap, lubricate stemwith a soap the and water solution,and pull the stemthrough rim from the insideout until it snaps into place.
oPosition the tire on the rim so that the air valveis at mark (the yellow paintmarkon a new the tire balance tir).
oFor VNls(xt-A: Tubol3s ti.6 arc i$talled. Do not inliall t$e-type tirc on this motorcvdc. oFor VN15O0.B:Tube tires sre in311d. not inttsll Do tublest-typstirss on this motorcryde. oThe Econnonded ltandard tina mu3t be urd fol rsplacamel . .Aftr installing the bead protector and balancer, torque (VN150GB: tighten the nuts to ihe specified Exploded View). see VN15OCA3 (Canada)and VNl5(XlA4 air Rubber-type valveand air valve hole modified are wheels usedon the front wheels.
1. Apply soap andwatersolution. 2, Pullthe stemout.
oDo not useengine or petroleum distillates lubrioil to catethe stmbecuase they will deterioratcthe rubber.
lnsallation
aRemove air valve discard the and iL
HubBearings
Removal http://manuals.magnamaniac.com
oRcplacethe rubber-typair vahe wheneverdte tire is rcplacd. oDo not reuse air valve. dre
.Remove hubbearings using bearing the by the remover

(special shaftandheads tools). oRemove bearing the retainer. oRemove RH bearing the first
WHEELSfiIRES 9.13 Lubrication NOTE

asince tlre barings on dte rear whel hub are peked with grea* and $ielded on both sides' they are not requiredto be removedfor lubrication-
.For front hub bearing,turn each bearingback and or for forth whilechecking roughness binding. the tlf roughnesor bindingis found, replace bearing' or rlf it is noisy,doesnot spinsmoothly, hasany rough it spots, mustbe replaced.
1. Bearing Remover Shaft:57001-1265 2. Bearing Remover Head: 570O1-1267,1293
oDo not lay dre wheel on lhe ground with the di* tacing down. Thi! can damage or warp the dlsc. Place blodc under lbs wheel so d|e ditc do| not toudr dle ground.
lnstallation driverset .lnstalt the bearings usingthe bearing by 129). (special 57001-'l tool:
Turn back and forth [A] Shield IB]
GearHousing Speedometer
m D i lasse b Iy an d Assemb I Y NOTE
DriverHolder 1. Bearing 2. Driver(Large)
(Small) 3. Driver
NOTE
ott is recommended the a*mbly be replacednther that t an aftempting to rcpair the components.
oln&all he b@rings e that the markd or $ielded sides hcc out.
gear .lnstall the speedometer housingso that it fits in gear the speedometer drive notches(seeFront Wheel lnstallation).
9-l4WHEEIS/TIRES Lubrication .Clean grease speedometer housing. gear and the
GearHousing l. speedometer 2. Grease.
FINAL DRIVE lGl
FinalDrive
Tableof Contents
1G2 10-4 1(}4 S p e c iT o o l s . . . . . al 1G6 Oil FinalGear Case 1G6 LevelInspection Oil 1G6 Oil Change. 1G6 F i n aG e a r C a s e . . . . l 106 Removal 1f}.7 lnsallation notes.. . 1G9 Disassembly. 1G9 AssemblyNotes.. . 1G10 BevelGear Inspection 1G10 PinionJoint Inspection 1G10 Ball Bearinglnspection 1G10 NeedleBearingInspestion. 1Gl0 Oil SealInspection . . . . . 10-11 Final BevelGearAdjustment. . . . . , . 1G14 BevelGearlnspection 1G14 Bearing lnspection... . . . PinionGear 1G.14 .. Inspection ... . Oil Seal 1G14 Propeller Shaft 1G14 Removal t&15 Notes . . lnstallation 1015 . Joint Inspection.. . . . . . Sliding 1(}15 Propeller Shaft Inspection. 10-15 Joint Ingection, Sliding 1G16 ., Front Be\rel Gean . 1G16 Removal Front GearCase tG16 Installation Front GearCase (includingdrivegearremoval).. . . ' ' 1 G 1 6 Disassembly Front GearCase Assembly{includingdrivegearinstallation) . . . ' ' 1 G 1 8 Front GearCase 1G18 DrivenGearDisassembly. 1G19 DrivenGearAssembly.. . 1S19 DamperCam Removal. 1G20 InstallationNotes,. . DamperCam 1G.20 FronBevel earAdiustment,............. t G 1o.24 BevelGear lnspection 1G24 Cam Damperlnspection 1G25 BearingInspection Ball http://manuals.magnamaniac.com 1G25 .... '. Inspection RollerBearing Tapered 1G25 NeedleBearinglnspection. 1o.25 Oil Seallnspection. ... .
ExplodedViaitr Specifications
1O-2 FINAL DRIVE
View Exploded
$
@h
1 . Oil Pipe 2- Drive GeatShim 3. DdYsGsar 4- DriveGearShaft 5 . l'leurr.l Savitct 6. Front BevelGesrCse 7 . Drivsn GearShin 8 , Ddren Ge8t 9. F ont EeYelGaarAsembly 10. Baring Housing 1 1 . Collal (PrlosdAdiun) 12. Spacer(Moed Adiurtl 13. Drivsn GsarJoint 14. .CamFollower
ST; Stakeths fastenen. T1 : 88 Nfl (0.90kgn,78 in.lbl T2: 12 Nfl (12 ksn,104 inlbl T3: 15 Nrn (15 kgFm,11.0 ft.lbl T4: 25 Nm (25 kgn, 18.O ft{bl T5: http://manuals.magnamaniac.com 120 Nfl (12.1kgm, 88 ft lbl T6: 265 N (27 ks{n, 195ft.lb)
FINAL DRIVE 10.3
-g_
G : Apply greale. 1 . Propellr Shaft Joint L : Agply non{ejmanent lod(ing agent. 2. Propellar Shaft ST: Staked|e fastenrs. 3. Ealing Retainsr (Left{anded Thredsl Tl : 88 Nrn (0.90kgrn, 78 in{bl 4 . Plnion Gaar Shim T2: 16 N{n (1.6kgfl,115 ft'lbl 5 . Pinion Ger Tlt r 23 N-rn (23 ks{, 165 ft{bl 6. Ring Gsai T4: 29 N-rn(3.0k$m, 22 tt{bl 7 . Bolt M10 T5: 34 N.rn (35 kgim,25 ft lbl L Bolt M8 http://manuals.magnamaniac.com (12.0ksm,87 ft{b} T6: 120 N"rn 9. Final Bevel Gal A$smbly T7: 2tl5 Nrn P5 ks{, 180ft{bl 10. Filler Plug 1 1 . Final Gear Cate 12. Ring Gear$rim
1G4 FINAL DRIVE
Specifications
Item Final GearCase Oil: Grade Viscosity Standard
Amount Oil Level FinalGear Case: Finalbwel gear backlash

Front Bevel Gear: Preload drivengearbearings for Front bwel gearbacklash
API GL Hypoid Oil Gear When above (41'F) SAE90 5"C When below (41"F)SAE80 5'C 2(X)mL Bottomof filler opening
0.06 - 0.09 mm (at gearhub spline) 0.10 - 0.15 mm (at geartooth)
0.5 - 0.9N-m(0.05- 0.09kg-m,4- I inib) 0.10- 0.15mm (at gear tooth)
Tools Special
Puller: 57dt1-158 Bearing DamperCam Holden 57q11-1025
DrirenGearHolder: 57001-1027 Mapter: 57001317
Driver: 57001382 Bearing
Holder; 57001-1049 DialGauge
FINAL DRIVE
57001-1058 Oil Seal& BaringRemover:
Jack Standr 57(x11-1238
w
DriverSetl 57001-1129 Beadng 2 Afiadrment: 57OO1-1A Drivel: 57001-1101 Oil Seal Final GoarC..e Holdr: 51001-1250
VPlnion GearHolder; 57001-1165
-\e\
BaringRetainelWren.fi: 5?qr1'1251
::@:)
D Yo Gear Holdel: 570'J1-1?,26
10 FINAL DRIVE FinalGoar Case Oil Oil Levellrcpection

.Supportth motorcycle perpendicular the ground. to .Unscrewthe filler plug. The oil levelshouldcometo the bottomof tlre filler opening .After the oil has completely drainedout, install the drainplugwith a newgasket. .Fill the final gearcase wilh the specified andquanoil tity.
Final Gsar Cce Oi!:
Amount 20OmL Grado garoil AP! GL lrypoad Vircoity: Whd| aboreS"C (41'Fl SAEgtt who bdd 50c (41'Fl sAE S0
NOTE 'GL6" indiaa'fs a oThe wm Sdity etd dditiE nting. A 'GL6" tzd hypoid g@r oll en al'p b ud.
A. DrainPlug B. Oil Level Line
.Be surethe O+ingis in place, lnstallthe filler plug. and C. Filler Plug
*lf it is lorv, first check the final gear casefor oil leakage, remedy it if necssary, add oil throughtie and filler opening. Usethe same type and brandof oil that is alreadyin the fioal gearcase. .lnstall the filler Plug.
Oil Change .Warm up the oil by runningthe motorcycle that tie so oil will pickup any sdiment drainasily.Stopthe and motorcycleand turn it off. aPlacean oil pan beneaththe final gearcase,and remove tlle drainplug.
FinalGearGasg
Ranoval
*lf thefinalgearcase to bedisassembled, thefinal is drain gearcase oil. a Remove rearwheel (seeWheel/Tires the chapter) . a Remove left shockabso6erfrom iG studs by taking the off the nuts. aRemove final gearcase takingoff the nuts. The the by springcomesoff with the case.
http://manuals.magnamaniac.com o h.n draining or filling ths\final gear cara, be aalsfrrl NOTE tha no oil gG on d|g titr or rim. Oean off any oil olf the find gar ee is fit of oil, plee {re w lftlt inrdrortsn{y gatr on thm wttb a high flrdt.poim aolYgnt. dre btathar hole ls on top,
I wtnunre i
--
s that
FINAL DRIVE 1G7 Disassembly

oRemovethe final gearcasecover bolts. .Use three cover bolts to remove the ring gearassembly from the gear case. The shim(s) comes off with the assemblv.
A. FinalGearCase Nuts B. Breather Hole (LH) C. RearShockAbsorber
up the A. Jack cover with bolts. B- FinalGear Case Cover
Installation Notes
OLubricate the propellershaft ioint (see PropellerShaft Joinl Lubrication). alnstall the spring so that the small diameter end faces toward the final gear case-
NOTE oDo not sp{aE dle ring gearasmbty (riry gar, ring gcarhub, and final gar ca'coved, but the oil sl can be rcmotnd.
aTo removethe ring'gear oil seal,soakthe ring gear ro assembly oil heated 120- 150"c (2l|8- 3{t2"F}, in then punchthe oil sealand pry it out with an awl or other iuitable tool. Be careful nol to scratchthe hub. surface the ringgear on sealing
End A. SmallDiameter
oDo not hsat dr6 case with a torch. c83e.
Thb will rvsrp $s
.Fit the pinion gear shaftjoint into splines the propeller hub. the whileturning ringgear http://manuals.magnamaniac.com snapring and pull out the needle .Removetre bearing .Tighten the final gear casemounting nuts to the outerrace. Exploded View). torque(see specified *lf the oil sealis damaged removeit usingthe'oil seal *lf the final gearcase wasdrained,fill the case with oil (special tool). andbearing remover o -
1G8 FINAL DRIVE

Final GearCase
6 . Oil Seal Washer 7. BallBearing 3. Pinion Gear Case Cover Joint 8. FinalGear 4. Oring 9 . Cover Mounting Bolts 5. RingGearHub 1 0 . Ring Gear Shim(s)
1 . Pinion Gear Nut
I l. RingGear (Four-point 16. Ball Bearing Contact) 12. Studs 17. Pinion Gear i3. Pinion Bearing Retainer 18. Oil Seal 14. Oil Seal 19. Needle Bearing 15. FinalGearCase
A. PinionGearHolder: 57001-1165
o Remove the washerand pinion joint with the O-ring. o Pull out the oil sealon the pinion bearingretainerusing a suitablepuller. http://manuals.magnamaniac.com and its retainer. .Remove the oil seal on tie pinion bearingretainer O Removethe pinion gear O Removethe Allen plug and then unscrew the retainer withoutremoving pinion. the ounscrewthe pinion nut usingthe pinion gearholder with the final gear case holder and bearing retainer (special wrench (specialtools). tool).
1. Oil Seal Bearing & Remover: 57001-1058
FINAL D.RIVE1G9
.Use a suitabledriver to drive in the oil rals being directionanddepth. carefulof installatlon
A. Allen Plug Holder(57001-1250) Case B. FinalGear (57001-1251) Wrench Retainer C. Bearing
NOTE ome badng reainer haslefthandd thrads, therefore it mustbe tumedclo*wi* in rcmoval.
oTaketie retainer out and piniongearassmbly of the case. final gear case. oPullout the shimandplugfrom the final gear outerracewith bearing oAlign the oil hole in the needle thJ hole on the bearinghousing(pinion gear side).
Gear l. Pinion Joint 2. PinionGear
3. Shim 4. Plug
A. Oil Holes
Bearing B. Needle
http://manuals.magnamaniac.com Assembly Note6 .The ring gearand pinion are lappedas a set in the aBlow the breatherhole in the final gear cage cover factory to get the best tooth contact. They must be air. with comDressed olean one installed a pair,never as replace without the otir.
1GIO FINAL DRIVE

Pinion Gear Joint lnspection joint. .Visuallyinspect splines the piniongear the of rlf they are badly worn or chipped,replace joint the wit$ a new one. Also, inspectthe propellershaft joint. sliding
A. Breather Hole .Reinstall the original ring gear shim(s) to kep the gear backlashand the tooth contact unchanged. .Apply a non-permanentlocking agent to the threadsof the cover bolts, and tighten them to the specified torque (seeExploded View). .Apply a non-permanentlocking agent to the threadsof each stud and install them to the case if they were removed. .lnstall the pinion gearretainer. Note the following. oReinstall the original pinion gear shim(s) to keep the gear baklashand the tooth contact unchanged. ousing the final gear case holder and bearing retainer tools: 57001-1250and 57001-1251), wrench (special tightn the pinion gear retainer to the specifiedtorque (seeExploded View). oUsing the pinion gear holder (special tool: 57001ll65), tighten the pinion nut to t}le specified torque (seeExploded View). ostake the pinion nut with a punch.
portion. A. Check spllned
BaII Bearing I nspection Sincethe ball bearingis made to extremelyclose tolerances, wearmustbe ludgedby feel rathertban the measurement. .spin the bearing handto checkits condition. by *lf therebearing noisy,doesnot spin smoothly,or is has roughspots, any replace (asa gearset). it
owhen 3takingdre nut, be carefulnot to apply lhock to th pinion and its bearing. Suc{ra thock could damage th? pinion snd/or be$ing. olnsert the plug into the Allen plug hole, and apply a locking agent to the tireads of tle non-permanent Allen plug,then tightenthe Allen plugto the specified View). Exploded torque (see
Needte Bearing lnspection .The rollers in a needlebearingnormally wear very little, and wear is difficult to measure. Insteadof inspect the bearingfor abrasion,color measuring, change, otherdamage. or rlf there is any doubt as to the conditionof a needle replace lt. bearing,
Oil Seallnspection Bevel Gear lnspection alnsDect oil seals. the avisually gears http://manuals.magnamaniac.com chipping, or check bevel the for scoring,
other damage. *Replace the bevel gears as a set if either gear is damaged.
tReplace any if the lips are misshapen,discolored (indicating that the rubber hasdeteriorated),hardened, or otherwisedamaged.
FINAL DRIVE 1G11 Final Bevel Gear Adiustment

The backlashand tooth oontast pattern of the bevel gears must be correct to prevent the gearsfrom making noise and beingdamaged. parts, be sure to check and adrustthe backlashand tooth contact of the Afterieplacing any of the backlash-related and then tooth contact by replacingshims. bevelgears. First, adiust backlash,
Eackla3h-RelatedPartt
1 .Pinion Gear Gear Shim(s) 2. Pinion 3. RingGearAsembly

RingGear Shim(s)
5. FinalGearCase
Pinion Ge.r $rimr for Too$ ContactAdiunment

Ring Gear Shimstor BacklashAdiunment
(mm) Thickness
PartNumber
(mm) Thickness
0.15 u.5 0.6 0.7 0.8 0.9 1.0 '1.2
PartNumber 0.10 0.15 92025-1783 0.5 92025-1784 0.6 92025-1185 0.7 92025-1786 0.8 http://manuals.magnamaniac.com 92025-1787 0.9 92025-1788 1.0 92025-1789 1.2 92025-1190
92025-1733 92025-11?4 92025-1735 92025-1736 92025-1737 92025-1738 92025-"t739 92025-1740 92025-1741
1G12 FINAL DRIVE

NOTE gear hackladr and tooth contact c,{,rse drese dzimsfor adjustmart. Backla3h Adi$tment gearteeth. tlean anydirt andoil off the bevel aPress slowly with an oil seal the ring gearassembly driver (57001-1104) firmly seat the ball bearing. to .lnstall the piniongearassembly with the primary(1.0 retainer the to mm d|icknes) shim,andtightenbearing Exploded View). torque(see specified .lnstall the ringgear assembly the primary(1.0mm with rhic{rnesr) shim,and tightenthe covermountingbolts Exploded View). torque(see to the specified oCheckthe backlash of duringthe tightening the cover themimmediately mountingbolts,andstoptightening disappears. Then,change ringgear the if the backlash shim a thicker to one.
'tlf the backlash not within the limit, replace ring is the gearshims.To increase backlash, increase thickness the of the shim(s). To decrease backlash, decrease the (s). of thickness the shim achange thickness lltde at a tim. the a .Re{heck the backlash, re-adiust necessary. and as Toodr contast adiustment rCleanany dirt andoil off the bevelgear teeth. .Apply checkingcompoundto 4 or 5 teeth of the piniongear. ' NOTE
nF."I-lm
oDo not iGtall ths O{ing3during adiGtment.
aMount a dial gauge [D] on a vise so that the tip of the gauge is againstthesplinedportion ofthe ring gearhub. aTo measurethe backlash,tum the ring gear hub [B] back and forth [C] while holding the pinion gearsteady with the pinion gear holder [A]. The difference between the highest and the lowest gauge reading is the amount ol backlash. o Measurebacklashat three locationsequally spacedon the splines. Final B3vsl Gear Backlash: 0.06 - O.O9 mm (at dng gear hub splinesl
oApply cheking compoundto dte teed, in a thin, evqt coat whh a hirly *iff paint bru{r. ff reind too thi*ly, tlre exff't tooth patem may not appar. oThe dteking compound must be snooth and firm, with the consi*encyof tood, p&e. o&&ial compoundsare anilable at artomotive srpply Etorgs for the pupoe of &eking differcntial gar tooth paftemsand con&t. a lnstall the shim(s) and pinion gear assembly, and tightenthe bearing retainer the specified to torque(see Exploded View). alnstallthe shim(s)and ringgearassembly, tighten and the @ver boltsto the specified toique (seeExploded View). aTurn the piniongearfor one revolution[B] backand forth,whilecreating dragon the ringgearhub [A]. a a Remove ring and piniongearassemblies check the to the drive pattem and coast pattem of the bevel gear teeth. The tooth contact Dattemsof both (drive and shouldbecentrally coast) sides located between thetop and bottomof the tooth. The drivepattemcan be a little closer to the toe and the coast pattem can be a longer closer the toe. somewhat and to
Consot Too$ Contact Pattern
ffik-Bottot
-ffir"0
FINAL DRIVE 1G13

*lf the tooth contact pattern is incorrecl, replace the pinion gear shim(s), following the examplesshown. Then erasethe tooth contact patterns,and check them everytime the shim(s) again. Also check the backlash are replaced. Repeat the shim change procedure as necessarv.
lncorrect Toodr CoDtact Patterns
NOTE olf the fukla$ is out of the standard nngp after changingthe pinion gear&im(s), rql*e the ring g:@r $im(s) to conect the backh* More cheking the tooth cont&'t pattern.
Example 1: Decreasethe thickness of the pinion gear shim(s) by 0.05 mm to correct the pattern shown below.
tie thicknes of the pinion gear Example2: lncrease by shim(s) 0,05 mm to correctthe patternshownbelow.
Bottom
Top
Heel
1G14 FINAL DRIVE Bevel Gear lnsprction .Remove the ring gearassembly pinion gearfrom and and the final gearcase(see Ring Gear Disassembly PinionGearDisassembly). rVisually checkthe bevelgears scoringchipping, or for otherdamage. tReplace the bevel gears as a st if either gear is damaged. oslip the propellershaft off the drivengearioint by pushing the lock pin throughthe access hole. on
lnspection Pinion GearBearing

rDisassemble the pinion gear (see Pinion Gear Dis' assembly). .Visually inspet bearings abrasion, color change, for the or otherdamage. ilf thereis any doubt as to the conditionof a bearing, it. replace
of Disengagemnt Propellershaft ftom Joint D:ive Gear
Oil Seal lnspection .lnspectt}le oil seals. *Replace any if the lips are misshapen, discolored (indicating hardened, or that the rubberdeteriorated), damaged. otherwise
t
Propeller Shaft
Removal
.Rqmovethe following. RearWheel FinalGearCase aRemove propellershaftfrom the front drivengear the ioint. oTurn the propeller shaftso that the lockingpin access outside. holeon tl|e propeller shaftcomes Shaft l . Propeller 2. Universal Joint 3. LockingPin Spring ) - DrivenGearJoint
http://manuals.magnamaniac.com tf|e rearendof the propeller .Remove the circlip from

Hole Pin A. Locking Access a shaftusing circlippliers. aRemovethe washerand pull out the propellershaft sliding ioint.
FINAL DRIVE 1G15 Propetler Shaft tnspection joint workssmoothlywithout .Check that the universal rattlingor sticking. tlf it doesnot work smoothly, of the needlebearings Replace propeller the the universal loint aredamaged. witl shaftassembly a newone. .Visually inspectthe bearing the shaftand the wear of at section tlte rearendof the shaft. of the splined *lf it is bent at all, replace propeller the shaftassembly. a Do not attempt to straighten bent shaft.
t . O-ring 2. Washer
t.
4. Propeller Shaft 5 . Sliding Joint
Circlip
lnsallation Notes
.Check the Oring on the rearendof the propeller shaft it for any kind of damage, and replace if necessary. .Lubricatethe propeller Propeller shaftioint (see Shaft Joint Lubrication). aAfter connecting propeller the shaftto the drivengear pull tlle propellershaft rearward checkthat to ioint, the shaftis secured placeby t}le lockingpin. in A, Checkuniversal 'oint. portion. B. Inspect splined
Sliding Joint Lubrication .Wipe off the old grease from the propeller shaftsliding ioint andpinion loint. .Pack the propellershaft sliding joint with 20 mL (15 grams) hightemperature grqrse. of PropollorShrft SlidlngJoint kbria.tion
Sliding Joint l nsp*tion .Visually inspectthe intemal splinesof the propeller shaftsliding loint. *lf they are badly worn or chipped,replace joint the with a newone.
High TemperatureGrease
A. Sliding Joint portion. the B. Check splined
1G16 FINAL DRIVE

Front Bevel Gears Front Gear CaseRemovat
rRemove the following. Engine (seeEngine Removal/lnstallation chapter) Shift LinkageLever Rear End Front Gear Case
Front Gear Caselnstaltation

.Note the following. oTighten the front gear casemounting bolts to the specified torque(see Exploded View). owhen installingthe oil pipe,pustrit down and torque thefront banjobolt first to the specification.
l . Pushdown this Doint. 2 . Torque the front banio bolt fast.

ocheck that the shift shaft oil seal and reDlace it if necessarv.
A. Oil Pipe B. Shift Linkage Lever
C. FrontGear Case
Front GearCase Disassembly (includingdrivegearremoml)

aRemov following. the Front Gear Case CamFollower Damper Spring Rubber Boots .Removethe driven gearassembly mountingbolts and pry the assembly the case. off
oThe camfollowerandthe damper spring comeoff with the gearcase,
http://manuals.magnamaniac.com MountingBolts A. DrivenGearAssembly

A. Cam Follower
B. Damper Spring
B. DrivenGearAssembly C. Rubber Boots D. DriveGearAssemblv
FINAL DRIVE IG17
A. Pry Points
C. Catththe visehere. A. DriveGear B. Holder: 5700"i.-1226
aRemove the drive gear. oPry off the gear casecap with a suitabletoois.
oPull off the drivegearshaft with the drivegear, collar, andshim(s). .Removethe bearing case. holderfrom the gear
A. Cap A. Bearing B. Bearine Holder
oPryopenthe drivegearnut with a small chisel. ounscrewthe drivegearnut holding drivegear shaft the tool). with the holder(special .Remove the drive gear shaft ball bearingusingthe driverset (special tool: 57001-1129). bearing
1G18 FINAL DRIVE Front Gear Case Assembly (incl uding dri vegear installation )
.Note thefollowing. oThe drive and driven gearare lappedas a set in the factory to get the best tooth contact. They mustbe reDlaced a st. as oPress drivegearand shaftassembly the slowlywith the driver (special tool) to firmly seattJ|egearonto the shaft-
A. Oil Holes
B. Shims
*lf the oil pipe wasremoved, a new flat washer use on eachsideof the fittings,andtightenthe banioboltsto the specified torque(see Exploded View).
l . Driver: 57001-382 2 . Shaft

J.
Drive Gear
.Be sureto checkandadjustth bearing preload the and bevelgearbacklash tooth contact, and whenanyof the parts are replaced(see Front Bevel backlash-related GearAdlustment). .After completing adiustment, all re-assemble front the geatcate. oReplace drlvegearnut with a newone. the oApply oil to the threadsand seatingsurfaceof the nut, and tighten it to the specified torque (seExplodedView). oLoosenthe nut completely and retightenit to the specified torque(see Exploded View). ostakethe nut to secure in place. it
Driven Gear Dinssembly .Holdingthe drivengearjoint wit}t the driven gear holder(special the tool), unscrew driven gear bolt.
milm
owhen stsking the nut, be caretul not to apply shock io lhe shaft and iG bearing. Sudr a drod< could damage dre 3h.ft and/ol bearing.
olnstall the driven gear assembly that the oil hole so http://manuals.magnamaniac.com on the housing alignswith the oil hole in the case. olnstall shim. the oTightn drivengearassembly the mounting boltsto the specified torque(see .Remove the driven gearjoint with the O-ring. Exploded View).
A. Vise B. Driven Gear Holder:5700'l-1027
FINAL DRIVE
10.19
.After completing the bearing preload adiustmnt, assembly. the re-assemble drivengear ousing the bearingdriver set (special tool: 570011129),press oil sealin until the faceof the sealis the hole. housing levelwith the endof the bearing oTighten drivengearbolt to the specified torque (see the View). Exploded it ostakethe drivengearbolt to prevent from loosening.
A. Joint
B. O+ing
.Removethe driven gear from the bearing housing. aRemove collarandthe spacer from the drivengear. the .Remove the oil sealfrom the housingwith a hook, rollerbearing of the housing. out andpull the tapered .Remove the taperedroller bearingwhich is pressed puller and onto the drivengearshaftwith the bearing (special tool: 57001-158 57001-317). and adapter
Point A. Staking
B. Pin Hole
owhen staking the bolt, be careftil not to apply shock to dre ddyen ge.r and lheil bearingr. Such a drock could damagethe driyen gear and/or barings.
DrivenGearAssembly
.Note the following. oThe drive and drivengears lappedas a set at the are factory to get the besttooti contact. They must be replacedasa st. preload the oBe sureto checkandadrust bearing and the and bevelgearbacklash tooth contact(seeFront Bevel GearAdjustment). oDriv the taperedroller bearinginner raceonto the driver(special tool). drivengearshaftusingthe bearing Damper Cam Bemoval aRemove front gear case. the .lnsert a bolt (012 mm, Ll00 mm) into the engine mounting bolt holeasshown. .Holding the danper cam with the damper cam holder (special tool), unscrewthe dampercam nut usinga deepsocket.
1. Driver:57001-382 2. RollerBearing 3. DrivenGear C. Bolt A. DamoerCam B. Holder:57001-1025
IG2O FINAL DRIVE Damper Cam lnstallation Notes

aReplace damper the camnut with a newone. .Tighten the dampercam nut to the specified torque (see Exploded View). oApply a small amount of oil to the threadsand the seating surface the nut. of
Front BevelGear Adiustment Procedure Preloadthe driven gear bearings.
Front Bevel Gear Adjustment In order to prevent one gear from movingawayfrom the other gear under load, the taperedroller bearings must be properlypreloaded. (distance Alsothe backlash one gearwill movebackand forth without movingthe otler gear)and tooth contact pattem of the bevelgears mustbe correct'to prevent gears the from makingnoise andbeing damaged. Above three adiustments of critical importance are and must be carried out in the correctseouence and method.
Assemble front gearcase the completely.
parts Whenany of the backlash-related are replaced, gear or the driven bolt is loosened; if the purpose even is not to replace parts,be sureto checkandadiustthe the bearingpreload and the bevelgearbacklash tooth and contactby replacing shims.
Backlarh{slatedParts
I . DriveGear 2. Collar 3. DriveGearShim(s) 4. Ball Bearing 5. DriveGearShaft 6. Front GearCase 7. DrivenGear 8. Tapered RollerBearing 9. Driven GearShim(s) 10. Driven GearBearing Housing 11. Driven Gear roint Parts whidt influencebearing plsload only 12. Collar(Preload Adjustment) 13. Spacer (Preload Adlustment) i4. Tapered RollerBearing *15. DrivenGearBolt
*Preloadadiustmentis necessary whenever bolt is the Ioosned, even if the purposeis not to replacethe parts.
FINAL DRIVE 1G2I

'P.loadadiustment and tighten the driven alnstall the ddven gear assembly, gear nut to the specifiedtorque (see ExplodedView). Do not installthe oil sealand do not stakethe bolt until the coFect bearingpreloadis obtained.
cAlrnoN
To start with- choose a shim or collar so that the bea.ings ar iust SNUG with NO play and also with NO preload. Any over-prcload on the bearings could damage the b6arings.
GearHolder: 57001-1027 1. Spring Scale 3. Driven 4. 200 mm 2. Hole *lf the preloadis out of specified the range,replace preload, bearingcollar and/or spacer. To increase decrease stacklengthof the collarand spacer.To the preloadincrease stacklengthof the collar the decrease andspacer. *Change the stacklength littleat a time. a aRe-check the bearing preload, and re-adjust if necesEary.
.Apply a little engine oil !o the beatings,and turn the gear shaft more than 5 turns to allow the bearingsto seat. oMeasure the bearing preload. Bearing preload is defined as the force or torque which is neededto st2rt the gearshaft turning.
Adiwtmnt Collarsfo. Preload Length(mm) PartNumber
22.8 22.9 23.0 23:1

Prsloadfor DrivenGearBoaring Scale: Using Spring 25 - 4.5 N (025 - 0.45 ks,0.6 - 1.0 lbl U.ingTonque Wrendr: 05 - 09 N{n (0.05- 0O9 kg"m.4- 8 inJb)
.25.5
23.4
z)-)
23.6
z5. t
23.8 23.9 24.O 24.1

NOTE
92027-1152 92027-1153 92027-1154 92027-1155 92027-1156 92027-1157 92027-"t158 92027-1159 92027-1160 -1161 92027 92027-"t162 92027-1163 92027-"t164 92027-"t165
oPreloadcan be masrred either with a Wring sale or a bem-rype torque wrench. When measJrcdwith a for Spacers PreloadAdiustmsnt gring wle, the preload is d$ignafud by force (N, kg, (mm) Part Number Thickness lb), and when masJred whh a torque wrench,it is (N-n, kgfl, in-lbJ. d8ignated by torque 1.70 92025-1072 '92025-1073 ousing &dng *ale: 1.72 Hook the *ring wle on the handleat a point 200 92025-1074 1 http://manuals.magnamaniac.com.74 mm apart from the cenEr of the gar c7ft. t./o 92025-107 5 "t.78 Hold the bearinghousing ih a vise dlat the g@r 92025-1076 Ctaft axis is tErtial; Appty force to dE handle 1.80 92025-1077 horizontally and at a riglrt angleto it,
1G22 FINAL DRIVE

BearingPreloadingMedranirm
(A) Before Tightening
(B) After Tightening
Under No Preload
Under Preload
lnitial Clearance
Clearance
Under No fteload
l. Bearing Housing 2. Tapered RollerBearing 3. Spacer 4. Collar 5. Tapered RollerBearing
Backlash adtujtment acleanany dirt andoil off bevel gear teeth. .lnstall the drive gearwith the primaryshim (1.0 mm thickness), tightenthe nut to the specified and torque (see Exploded View).
NOTE oDo not stake the hed of the nut until both backlaC, and tooth contatadiustments fini$d. arc
.Set up a dial gauge against drivegeartooth to check a gearbacklash.Thegauge slemmustbe in line with the directionof tooth travel. .To measure backlash, the movethe drivegearbackand forth while holding the driven gear steady with a suitable tool. The Difference between highest the and gauge lowest readings the amountof backlashis *lf the backlash not within the limit, replace gear is the shim(s)at the drive and/or drivengear. To increase increase thickness the shimft). To backlash, the of decreasebacklash, decrease the thickness of the shim(s). *Change thickness little at a time. the a .Re{heck the backlash, re-adjust necessary. and as
.lnstall the drivengear assembly the front gearcase to with the primaryshim(1.0mm thickness), tighten and NOTE the mountingbolts to the specifiedtorque (seeEx. ott is OK to packtwo slrims. Do not pack three or more plodedView). Critns. oCheckbacklash duringthe tightening the mounting of bolts, and stop tighteningthem immediatelyif the backlashdisappears.Then, changethe shim to a http://manuals.magnamaniac.com thickerone. .lnstall the dial gauge holder(special tool) with 6 mm Front Eeyel Gear Backlash (rt fie gcar too6l bolts and nuts on the front gearcase mount a dial to gauge. 0.10 - 0.15 mm
FINAL DRIVE 1G23

NOTE oApply chtking compound to the teeth in a thin,evm coat with a fairly *iff paint brudl. lf painted too thickly, the exact tooth paftem may not appear. oThe ch&king compound must be smooth and firm, with the consistency of too{7 paste. osp*ial compounds are at/ailable from automotive sllpply stor6 for d\e purpos of checking differential gear tootl, patterns and contact. us this for dr$king the bevel gears. .Turn the driven gear for 3 or 4 revolutionsin the drive and reverse(coast) directions, while creating a drag on the drive gear. oCheck the drive pattern and coast pattern of the bevel gear teeth. The tooth contact patternsof both drive and coast sides should be centrally located between the top and bottom of the tooth, and little closer to the toe of the tooth. rlf the tooth contact pattern is incorrect, replace the shim(s) at the drive gear and shim(s) ai the drive geat, following the examples shown. Then erasethe tooth contact patterns, and check them again- Also check the backlashevery time the shimsare replaced. Repat the shim changeprocedureas necessary. NOTE olf the backla$ goes out of standard nngE after changing dzims, corr*t the backla$ before checking the tooth contact Daftem. olt is OK to pack two drims. Do not pack three or more {tims.
'1.
the Holder:57001-1049 3. Move drivegear. 2. Holdthe drivengear.
Shimsfor DriYe Ge.r
(mm) Thickness
0.15 0.5 0.6 o.7 0.8 0.9 1.0 1.1 1.2
PartNumber 92025-1688 9202s-1689 9202s-1690 92025-1691 9202s-1692 92025-1693 92025-1694 92025-1695 92025-'t696
Corleet Tooth Contact Pattern
Shims for Driven Geal Thickness(mm)
0.1 0.15 0.5 0.6 0.7 0.8 0.9 1.0 1.2
PartNumber 92025-1826 92025-1818 92025-1819 92025-1820 9202s-182'l 92025.1822 92025-1823 92025-1824 92025-1825
Heel
Toot r contact adiustmenl http://manuals.magnamaniac.com oCleanany dirt and oil off the bevelgearteeth. oApply checking compound'to 4 or 5 teeth on tt|e 1 . DriveGear driven gear. Driven Gear
1G24 FINAL DRIVE

lncorrectToodr Contact Pattems Example lncreasethe thicknessof the drive gear 1: shim(s) 0.05 mm,and/orincrease thickness the by the of drivengearshim(s)by 0.05 mm to correctthe pattern shownbelow. Repeat 0.05 mm steps necessary. in if Example Decrease thickness the drive gear 2: the of shim(s)by 0.05 mm, and/or decrease thickness the of th driven gear shim(s)by 0.05 mm to correct the pattern shown below. Repeatin 0.05 mm stepsif necessarv.
Heel
Heel
1. Drive Gear 2. Driven Gear
Bevel Gear lnspection rVisually gears scoring check bevel the for chipping, or
other damage, *Replace the bevel gears as a set if either gear is damaged.
Cam Damper lnspection http://manuals.magnamaniac.com .Visually inspect damp'er the cam,camfollower,spring, andshaft. l. Spring *Replac part if it appears the damaged. 2. CamFollower
3. Damper Cam 4. OutputShaft
FINAL DRIVE 1G25 Ball Bearinglnspection close is .Since the ball bearing madeto extremly than by must iudged feelrather be the tolerances, wear
measurement. Clean the bearing in a high flash-point while it is dry), solven!,dry it (do not spin the bearing oil. and oil it with engine .Spin the bearingby hand to check its condition. *lf the bearint is noisy, does not spin smoothly, or has any rough spots, replaceit.
Tapered Roller Bearing lnspection color change, .Visually inspectthe bearing abrasion, for or otherdamage. *lf thereis any doubt asto tlle conditionof a bearing, it. reolace
NeedleBearingInspection
aThe rolleIsin a needlebearingnormallywear very little, and wear is difficult to measure. lnsteadof measuring. visually inspect the bearingfor abrasion,color change, or other damage, *lf there is anv doubt as to the condition ot a needle baring,replaceit.
Oil Seallnspection
alnspect the oil seals. *Replace it it the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened, or otherwisedamaged.
BRAKES11-1
Brakes
Tableof Contents
ExplodedView Specifications SpecialTools.
BrakePedal Brake Pedal Position Adjustment . . , . Caliper..

Front Caliper Removal RearCaliper Removal CaliperInstallation Disassembly Notes,
Assembly Notes. , .
Brake Pads. Removal lnsellation Notes
Lining Wear.
MasterCylinderc Front MasterCylinderInstallation RearMaster Removal Cylinder
lation Rear Master Cylindernstal I

lnspectionand Adjustmentafter Installation
Disassembly. Assembly. (Visually). Inspection

BrakeDisc.
Wear Warp... Fluid Brake Fluid LevelInspection. http://manuals.magnamaniac.com Brake FluidChange.. Bleeding Brake the Line.
11-2 114 114 11-5 11-5 11-5 11-5 11 11-6 11 11.6 116 11-6 11-7 11-7 11-7 11-7 11-7 11 11 11 11 11 11-9 11-9 11-9 11 11-9 ... . 11-10 . . 11-10
11.2 BRAKES ExplodedView

Ti : 5.9 N-m(0.60kg m, 52 in-lb) T2: 7.8 N-m (0.80kg m, 69 inlb) T3: 8.8 N-m (0.90kg m, 78 in-tb) T4 : 27 N-m(2.8kg m, 20 ft-tb) T5: 25 N-m (2,5k9 m, 18.0ftnb) T6 : 32 N-m (3.3kg m, 24 ft-lb)
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@ n
@ ^-6"s
@@
CIt'
".vq
1 . Front MasterCylinderAssembty 2 . Diaph.agm 3 , MasterCylinder 4 . Front BrakeLight Switch 5 . MasterCylinderClamp 5 . Piston 7 . Brake HoseClamp http://manuals.magnamaniac.com Assembly L Fronl Caliper I . Brake Pads 10 . Caliper Holder 11 . Piston 12 . Calipel 13 . Brake Disc
BRAKES11
T1 : 7.8 N-m (0.80kg m, 69 in-lb) T2: 23 N-m(2.3kg m, 16.5ftnb) T3 : 25 N-m(2.5kg m, 18.0ftlb) T4: 32 N-m (3.3kg m, 24 ft-lb) T5: 6rt N-m(6.5kg m, 47 ftjb) T6: 27 N-m(2.8kg m, 20 ft-lb)
w
Y
ssn@gI . RearCaliperAssembly 2 . Piston 3 . Caliper 4 . Brake Pads Holder 5 . Caliper 6 . Brake Disc Holder 7 . Caliper 8 . Real MasterCylinderAssembly 9 . Diaphragm 10 . ReservoirTank ll . PushRocl '12. Piston 13 . MasterCylinder
114 BRAKES
1. RearBjakePedal 2. Front FootpsgBrac*et Bola 3, BrakePedalLink CNamp G : Apply greale. T1: 25 N-m (25 kgn, 18J ft{b}
V U
Tool Special
CirclipPliers:57001-1tB
H
I
Specificaions Item
Brake Pedal: Brakepedal position Brake Pads: Padlining thickness
n tl
Standard
Service Limit
65 mm abovetop of footpeg
5.0mm
lmm
Brake Discs; DiscThickness: Front VN150OA VNlSOOB Rear Disc runout BrakeFluid: Grade Brand(recommended)
4.8- 5.1mm 5.8- 6.1mm 6.8- 7.1mm Under mm 0.15 D.O.T.4 Castrol Girling-Universal Castrol (LMA) GT
4.5mm 5.5mm 6.0mm 0.3mm
Castrol DiscBrakeFluid Check ShockPremium Heavy Duty
BRAKES11.5
Brake Pedal Brake PedalPosition Adiustment
.Check that the brake pedal is in the correct position.
the measure .Whenthe brakepedal in its restposition, is in length@ indicated the figure. length, *lf the length @ is not within the specified adiust nut. a
Pedal Position Sandard: About 65 mm above top of footpeg
-- ll
Cylinder l . Master 2 . Locknut Lensth@ Standad: 3. Clevis 165mm
Caliper
A. Footpeg B. BrakePedal C. Pedal Positlon
rlf it is not, checkthe punch marksat the brakepedal link pivot shaft, and the mastercylinder push rod lencth.
Front Caliper Removal .Disconnect speedometer lowerend. cable the .Loosen the banjo bolt at the caliper,and tighten it lightly. .Remove the calipermountingbolts and take off t}te caliper.
A. PivotShafts
B. Marks NOTE MountingBolts A. Caliper B. BanioBol: C. Caliper D. BrakeHose
ausually it's not n*e&ry to adiust the pedal position, aDisconnect hose from ihe caliper. but alwaysadiu# it when the master cylinder is dis http://manuals.magnamaniac.com the brake disassembled removal if *lf the caliperis to be and after asembled. remove pistonusing the olf the push rod length cannot be adjustedby turning compressed is not available, air the before disconnecting brakehose the followingsteps the clevis, the bnke pedal may be deformedor incorfrom the caliDer. rectly installed.
11.6 BRAKES
oRemove pads. the oPumpthe brakeleveror pedalto removet}|e caliper piston. NOTE olmmediately wipe up any brake fluid that Wills.
oTo avoid serious iniury, neyer place your fingerc or palm inlide the caliper opening. lf you apply compr$sed air into the caliper, ihe piston may cru3hyour hand or fingerc.
Rear Caliper Removal .Remove the rearcaliperin the same way on the front caliper.
air. l. Applycompressed
2. Cloth
Assembly Notes oApplybrake fluid to the outside thepiston the of and A. Caliper C. Brake Hose B.Caliper Mounting Bolts
fluid seal,and push the piston into the cylinderby hand. Take care tlrat neither the cvlindernor the pistonskirt get scratched. .Apply a thin coatof PBC(Poly Butyl Cuprysil) grease to the caliperholdershafts andholderholes.(PBC a is hightemperature, grease). special water-resistant .lnstall the anti-rattlespringin the calipers shown. as
Caliper lnstallation
.Note the following. oTighten the caliper mountingbolts to the specified torque(seeExploded View). oconnectthe brakehoseto the caliperputting a new flat washeron each side of tl|e brake hose fitting. oTighten the banio bolt to the specified torque (see Exploded View). oCheck fluid levelin tie master the cylinder(reservoir), and bleed the brake line (seeBleeding the Brake). oCheckthe brakefor weakbrakingpower,brakedrag, andfluid leakage.
oDo not attempt to drive dre motorcycle until fully deprssing dre breke lever or pdal then pump the brake lever or pedal until dre pads are against dre dbc. The bhkes will not funotion on the first appliEtion of dre lever or psdal it dris is not done,
1. AntirattleSpring
BrakePads Dinssembly Notes http://manuals.magnamaniac.com .Using compressed remove piston. air, the oCoverthe caliperopeningwith a clean,heavyclothRemoval oRemove pistonby lightly applyingcompressed rRemove the caliper (see Front or Rear Caliper the air
to where brakeline fits into the caliDer. th
Removal).
BRAKES11-7
.Take off the piston side pad from the caliper holder. .Push the caliper holder to the piston side,and then removethe pad from the caliper holder shaft.
Master Cylinders
Front Maser Cylinder lnstallation
fwhen installing the front master cylinder, note the following. oThe master cylinder clamp must be installed with the rear view minor holder upward. oTi$ten the upper clamp bolt first, and then the lower clamp bolt to the specified torque (see Exploded View). There will be a gap at the lower part ofthe clamp after tightening.
1. Pad 2. Caliper Holder
3. Push caliper holder. the
lnstallation Notes
.Push the caliper pistons in by hand as far as they will go.
l. Tightenupperclampbolt first. 2. LowerClampBoll

oDo not attempt to driye the motolcrycle until fully depresing dre brake levr 01 pdal dren pump dre brake lever or pedal until the pad3 ars agaiffit dre disc. The brake will not tunction on the filst application of $e leveror pedal if this is not done.
3. Mirror Holder 4. Clearance-
ouse a new flat washer eachsideof the brakehose on fitting. oTighrenthe banjo bolts to the specified orque (see Exploded View).
Lining Wear rlf the liningthickness eitherpadis less of thanthe

servicelimit, replace both pads in the caliper as a set. Pad Lining Thickness Standard: ServiceLimit: 5.0 mm I mm
Rear Master Cylinder Removal .Note the following. oRemove cotter pin and then pull the joint pin out the of the pushrod clevis and brakepedal.
1. Lining Thickness 2- Service Limit A. Clevis B. CotterPin C. JointPin D. PushRod
1I.8 BRAKBS Rear Master Cylinder lnstallation

.Note thefollowing. oReplace aluminum the washer eachsideof thebrake on hosefitting with a new one. Be sure that the metal pipe is properlyfitted into the U-shaped notch in the master cylinder. oTightenthe banjo bolG to the specifiedtorque (see Exploded View). oTightentle rear mastercylinder mountingbolts (2) to thespecified torque(seeExploded View).
oExcept tor the disc pads and disc; use only disc brake fluid, isopropyl alcohol, or ethyl alcohol, for deaning brake part!. Do not uis any other fluid for deaning these parts. Gasoline,engine oil, or any other petro, leum distillate will cass detedoration of dte rubber parts. Oil spilled on any part will be diffic[lt to wash off compltely, and will eventually deterioiete the rubber used in the disc bEke. oTake care not to scratchth Distonor the inner wall of the cvlinder.
Insp*tion and Adiustment after lnstullation oCheck adlustthe followingitemsand Brake Pedal Position Rear BrakeLight SwitchPosition Brake LineAir Bleed BrakeDrag Braking Power Brake Fluid Leak
Dinssembly
rRemove followingparts. the DustCover Retainer Piston with Secondary Cup Primary Cup Spring
lnspection (Visually) .Checkthat thereare no scratches, wear,rust or pitting on the followingparts. Inside the Master of Cvlinder Outside the Piston of Primary Cups Secondary Cups DustCovers ReturnSprings ReliefandSupplyPortPlugged *lf they aredamaged, replac tiem.
oDo not removedre secordaryanp from the pbton since rcmovslwill damage drem.
q&
1. Primary Cup 2. Secondary Cup 3. Piston
l. Reservoir 2. Diaphragm 3. RelifPort 4. SupplyPort 5. Cylinder Assembly 6. ReturnSpring .Note thefollowing. 7. Primary Cup oBeforeassembly, http://manuals.magnamaniac.com cleanall parts includingthe master 8. Piston cylinder witlr brakefluid or alcoho,. 9. Secondary Cup oApply brake fluid to the removedparts and to the 10. DustCover innerwallof the cylinder. I 1. BrakeLever 4. Retainer 5. DustCover
BRAKES 11-9
Disc Brake
Wear
*Replacethe disc if it hasworn pastthe service limit.
'.:.*.:i::1........
Fluid Level lnspection
.Check the brakefluid levelin the reservoir.
Front Brake Fluid Reservoir
'1.
Brake Disc
2. llleasuring Area
A. Lower Level Line
Front Disc Thid(ness VN15O0-A VN1500-B Standard 48 - 5.1 mm 53 - 6.1 mm
B. UpperLevelLine
Limit SerYice 45 mm 55 mm
Rear Brake Fluid Reservoir
Rear Disc Thickness Standard: ServiceLimit 6.8 - 7.1 mm 6 mm
Warp
tlf runoutexceeds service the limit, replace disc. the
A. UpperLevelLine
B. LowerLevelLine NOTE
oHold the reservoir horizontal when checking brake fluid level. *lf the fluid level is lower than the lowerlevelline,fill the reservoir the upper level line of the reservoir. to 1. Brake Disc 2. Measuring Area
Dbc Runout Standard: Under0.15 mm Service Limit: 03 mm
http://manuals.magnamaniac.com fluid ochange the brake
in dre brake line completely if the brake fluid must be re{illed but the type and brard of dre brake fluid that aheady is in the rg3srvoir ars unidentified. Aftsr cfianging the fluid, use only dre
I1.10 BRAKES
$me type and brand of fluid thereafter. Mixing differsnt types and brands of brske fluid lowers the brake fluid boiling point and co{ld cause the brake to be ineffectiye. lt may also cause dre rubber brak parts to deteliorate.
ocheckthe fluid levelin the reservoir often,replenishing it asnecessary. NOTE olf the fluid in the rcervoir runs completely out any time during fluid changing, bleedingopention must the be done over again from the beginning sinceair will haveenteredthe line. oRepeatthis operationuntil fresh brake fluid comes out from the plastichoseor the color of the fluid cnanges.
Rcommended Dirc Brake Fluid Type Brand D.O.T.4 Check Sho.r( Premium Heavy Duty Crstrql Gidin g.unive'ssl Cactrol GT (f-MA) Castrol Dbc Brake Fluid
Bnke Fluid Change NOTE oThe prccedure to drange the front bnke fluid is as fo ot s. Changingtte rcar bnke fluid is the sme as for the frcnt brake. .Removethe reservoir cap,and remove rubbercap the on the bleedvalve. .Attach a clear plastichoseto the bleedvalveon the caliper, and run the other end of the hoseinto a container. .Change brakefluid asfollows: the
oDo not mix two blands of fluid. Chan$ dre brake fluid in dle b|8ke line completrly if ths blak fluid must be refilld but tre type and brand of the brake fluid that b already in d|g roservoir are unidentified.
Bleeding the Brake Line NOTE oThe procedure to bleed the front bnke line is a follov,n Eleding the rar bnke line is {re sme as for the front bnke. Bleed the air after the brake partsare removed or disassembled. awith the reservoir off, fill tle reservoir cap with fresh brakeoil. .Slowly pump the brake lever or pedal several times until no air bubbles be seenrisingup throughthe can fluid from the holesat the bottom of the reservoir. This bleeds air from the mastrcvlinderand the the brakeline. NOTE oTap the bnke hoe lightly going from the caliperto fie recrwir side and let the air off from the reervoir whenthe btdcelever hasa qonge feling.
http://manuals.magnamaniac.com hosto the bleedvalveon the .Attach a clearplastic 1 . Ooen the bleed Valve. caliper, and run the other end of the hose into a 2. Pumo the brake leverand hold it 5. Close the bleed valve. container. rBleedthe brakelineandthe caliper follows: as 4. Release brake lever. the
BRAKES11-11
owhen working with the disc brake, obseryethe precautions Iistedbelow. fluid. l. Never reuse brake old 2. Do not usefluid from a containerthat hasbeen left unsealed that hasbeen or openfor a longtimeof 3. Do not mix two lypesand brands fluid for use in the brake. This lowers brakefluid boiling the point and couldcause braketo be ineffective. the It may also cause rubberbrakepartsto detethe riorate. of 4. Don't leave reservoir off for any length the cap contamination the fluid. of time to avoidmoistur 5. Don't changethe fluid in the rain or when a strong windis blowing. 6. Exceptfor t}te disc padsand disc, use only disc alcohol, ethyl alcoholfor brakefluid, isopropyl or cleaning brakepans. Do not useany other fluid for cleaning theseparts. Gasolingengineoil, or any other petroleum distillate cause deteriorawill tion of the rubberparts. Oil spilledon any part will be difficult to washoff completelyand will eventually deterioratetie rubber used in the discbrake. 7. When handlingthe disc padsor disc, be careful that no disc brakefluid or any oil getson them, gets Cleanoff any fluid or oil that inadvertently on the padsor discwith a highflash-point solvent. Do not useone whichwill leave oily residue. an Replace padswith newonesif they cannotbe the cleaned satisfactorilv.
1. Pump the brake lever until it becomes hard, and apply the brakeleverand hold it. 2. Ouickly open and ctose the valve while holding the brakeleverapplied. the 3. Release brakelever. any 8. Brakefluid quickly ruins paintedsurfaces; fluid should be completely washed immediately.
9. lf any of the brakeline fittingsor the bleedvalve is openedat any time, the AIR MUST BE BLED FROM THE BRAKE.
ocheck the fluid levelin the reservoir often,replenishing it asnecessary,

NOTE off the fluid in the res oir runs completely out any time during bleeding, the bleeding opention mu$ be done over again from the beginning since air will have entered the line. oRepeat this operation until no more air can be seen comingout into the plastichose. NOTE
http://manuals.magnamaniac.com alf the bmke lever action still feels fift or gongy, tap the bnke hose lightly from futtom to top end or air will rise up to the top paft of the hoe, slowty pump the brake lever as the ame manner as above
l2-1 susPENsroN
Suspension
Tableof Contents
12-2 ExplodedView... 124 Specifications 12-4 Tools. Speciaf 12-5 Front Fork 12-5 Fork Oil Change . 12-6 (each fork legl . .. . Removal 12-6 (each fork les) . . . . Installation 12'6 Disassembly. 12'7 Assembly. 12-8 InnerTubeInspection. 12-8 GuideBushInspection PA Inspection andDustSeal Oil Seal 124 Spring Tension 12-9 . Rear ShockAbsorber . . . 12-9 Adjustment. 12-9 Removal 12-9 Notes.. lnsallation 12-9 Wear Rear ShockAbsorber .' 12'10 Wear. Bushing .. 12-10 Swing Arm .'""' 12-10 Removal ..... 12-10 fnstalfation .. .. . 12-10 Removal/Assembly Bearing Seal Grease andNeedle 12-11 '..... Lubrication. ' '.. Bearing Seal Grease andNeedle Wear. . . . Bearing Sleweand Needle
12-2 SUSPENSTON
Exploded View
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4ioA.o,
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o
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1. Front Fork Lsg 2. Cap 3. Top Plug 4. Sp*er 5. ForkSpdng 6. Inmr Tubo 7. GuideBulh 8. Durt SalCap 9. Du3tSoal 10. Oil Sal
11. GuideBulh locking agent. L : Apply non.pormanent Pition Unit 12. Cylinder Tl : 20 N{n (2.0kgrn, 145 ft-lbl 13. C]ylinder T2 : 29 N-m (3O kgFm22 ft{b} , 14. SihoftSpring T3: 52 N.rn(53 kgrn 38 ft{b} 15. Gylinder Base 16. OuterTubs 17. Axle Clamp Bolt http://manuals.magnamaniac.com 18. DrainBolt 19. Bottom Allsn Bolt
12 susPENsloN
es
sB
y*
@
1. RearShockAbsorber 2. S:wing Arm 3. Pivot Shaft (LHl 4. SwingArm Cover (RHl 5. SwingArm CoYer T1 : 30 N{n (3.1kgrn, 22 ft lbl T2: 98 N{n (10Okgfl,72 ft{bl
124 SUSPENSTON
Specifications Item Standard
ServiceLimit
FrontFork: Forkoil:
VNlsOGA Viscosity SAE1OW2O AmounVUnit z136 mL +2.5 When changing 370mL oil
vN 1500-8
<_
474 !2.5 mL rt05 mL 1zl0t7 mm 412.5 mm z166 mm 404 mm
Forkoil level(Fullycompressedl 124x7 mm Forkspring freelength 475.5mm Rear Suspension: Rear shock absorber spring position adjuster
2 of 5 positions
Special Tools
From Fork CYinder Holder Handle: 57001-183 H.ndle Adapen 57001-1057
BearingDriyer Set: 57q)i-f 129
Oil Seal Bearing and Remover:57d)1.168
Fork Oil SeelDriyert 57q11-1219
F ont Orter TubsWeight: 5ZOO1-1218
Jad( Stand: 570/J1-12aB Atta.fiment: 57001-125.2
12 susPENsloN
NOTE
Front Fork Fork Oil Change(each fork leg)

.Remove lhe following. Handlebar {Slideto eachside} Capand Fork Top Plug
oApply non-permanent locking agcnt to the threads of the dnin erew and gasket. Front Fo* Oil viscosity sAE 10w2o Amount per side When changingoil: About 370 mL vN1500-A
vN1500-8
About ttos mL
After disasembly and completely dryi 436 t25 mL VN1500-A 474 !25 mL VN1500-B NOTE Qump the fo* enough tim6 to expel the air form the upper d lower chambe,s,
A. Handlebar B. Retainer
C. Top Plug
.With the fork fully compressed insert a tape measure from the or rod in the inneriube,andmeasure distance the top of the innertubeto the oil.
ForkSpring DrainScrew
l OilLevel
Fork Oil Level (Fully Complessedl
A. DrainScrew
vN1500-A vN1s00-B
124 fl nm ltlo i7 mm
http://manuals.magnamaniac.com *lf
.Allow the oil to draininto a suitable container.lf you pumpthe fork legs forceout the oil, be sureto catch to as out. theoil in a container it squirts
the oil is above or below the specified level, remove the or add oil and recheck oil level oChange the oil of the other fork leg in the same manner.
12
SUSPENSION oTightenthe upper and lower fork clamp bolts to the Exploded View). specified torque(see oTightenthe caliper mountingbolts to the specified Exploded View in Brake chapter). torque(see oCheck front brakeafter lnstallation. the
Removal (each fork leg) .Using the jack stand and the attachment (special toofs: 57001-1238 12521or other suitablemeans or to llft the front of the motorcycle. rRemovethe following. Caliper(fromthe fork legto be removed.) (see Front Wheel Wheelsflires chapter) Front Fender .Loosnthe upperandlowerfork clampbolts. .With a twistingmotion, work the fork leg down and out
oDo not attempt to ddve dre motororyale umil futly deprsssingthe brake levr, dren pumping tfte brake leveruntil the Fad3a16 agai$t tlis disc. The brakewill of not function on dre 613t applicati,on $e leYsrif this k not done.
A. Upper Clamp Bolt
B. Lower ClampBolt
Dis*sembly .Performthe following. oRemove retainer takeoff the top plug. the and oPullout the spacer, washer, thefork spring. and oRemove fork leg. the oPour the fork oil. out ostop the cylinderfrom turning by using front fork the cylinder holder handle and adapter(specialtools). Unscrew Allen bolt and take the bolt, and gasket the out ofthe bottomof the outertube.
Installation (each fork leg) .Performthe following. olnstallthe removed Darts. olf the fork leg was disassembled, check the fork oil level. olnstall the fork tube so that the inner tube toD end is alignedwith the upper surfaceof the stem head.
1. Wrench 5. Handle: 57001-183 2. Bolt 6. OuterTube 3. Cylinder 7. lnnerTube 4. Adapter:57001-1057
A. Stm Head B. lnnerTube C. Aligned
oRemove the piston and cylinder unit and the short spring from the top of the front fork tube. oPrvthe dustseal coverout of the fork tube.
susPENsloN12-7
Cover A. DustSeal
B. Pry Poini
fr
oRemove dust sealand the retainr from the outer the tube.
$
Tube 1. lnner 57001-1218 TubeWeight: 2. ForkOuter 3. OuterTube 4. Strok oTakethecylinder base the outertube. off oTakethefork innerparts of the innertube. out
Assembly .Assembly is the reverse disassembly. Note the of following. B. Retainer A. DustSeal for heck the top plugO-rings damage. tReplace themwith newonesif damaged. oReplace oil seal removed with a newone. the olnspectthe guide bush (seeGuide Bushlnspection). *Replace with newonesif necessary. it oApplya non-permanent lockingagentto the Allenbolt. oTighten the Allen bolt to the specified torque (s View), usingthe ftont fork cylinderholder Exploded tools) to stop the handleand holderadapter(special oMountthe weight(special cylinder from turning. tool) on tie top of tie outer http://manuals.magnamaniac.com bushwith a usedguidebushon it by olnstallthe guide tool) to tube, by fitting the stepof the weight(special guidebushwith the fork oil seal driver the tapping used the top cornerof t}le outrtube. (special oHoldingthe inner lube by handin a verticalposition, tool) until it stops. The slit of the bushmust times and pull it down. befacedtowardthe left or right. strokethe outer tube several
12-8 SUSPENSTON
'1.
Guide Bush
1. Driver:57001-1219 2. Used Guide Bush 3. Slit (toward left or right) the 4. NewGuide Bush 5. Tap
Oil *al and Dust Seallnspecdon *lf dustseal anydamage wear, has or replace it.
.Replace the oil seal with a new one whenever it has been removed.
ouse the fork oil sealdriver (special tool) to installthe oil seal thefront fork. in olnstallthe dust sealcoverwith a oil seal driver(special tool).
lnner Tube lnspection *lf the innertube is damaged, replace it. .Nicki or rust damage can sometimes repaired be by usinga wet-stone rmove to sharp edges raised or areas whichcause damage. seal *lf the damage not repairable, is replace innertube. the Sincedamage the inner tube damages oil seal, to the replace oil sealwhenever inner tubeis reDaired the the or reDlaced.
1. Oil Seal
2- DustSeal
Spring Tension *lf the spring of either fork leg is sltorter than the service limit, it must be replaced. the length http://manuals.magnamaniac.com and that of thelfremaining of a replacement spring spring vary greatly, the remainingspring should also be Guide Bush lnspection replacedin order to keepthe fork legsbalanced for *Replace the guide bushesif they are damaged worn. or motorcycle stability.
olf dre innel tube i3 badty bent or creasod, teplac it, Exc6$iye bsnding, followed by subcequent straightsning, canwsokendte inner tube.
12-9 susPENsroN
Adiuster Spring Position
I
5
Spring Setting Load Road Speed Force

Soft
4 5
J
StIonger
Hard
Light Good
tI tI tI
Low
,t ,t 't
High
Heavy Bad
.Check to seethat both adiusting sleeves turned to are position. relative the same
1 . ForkSpring
2. FreeLength
Fork Sp ng Length vN1500-A Standad: SerYiceLimit: VNlsq'-B St ndard; Service Limit: oll both sprins adiusting sleevB are not adiusted equsl' ly, handling may be impailed and a hazardouscondi' tion may r$ult. NOTE oBe s.rre to tum back the adiuiing sleate counfutclockwis from pNition 5 wlrq, eftening the *ring action.
4755 mm 466 mm 412,5 mm ll{t4 mm
Rear Shock Absorber

Adjustment has The rear shockabsorber 5 posllions so that the for spring can be adjusted different road and loading conditions. Remotral (special tools: .Using the iack standandthe attachment to or 12521or other suitablemeans Iift 57001-1238 the rearof the motorcycle. from .Removethe cap nu! lockwasher, flat washer and absorber. the both endsof the rearshock rPull the rearshockabsorber the frame. off
torque(see rTighten the mountingnutsto the specified View). Exploded position. .Adjust the rearshockabsorber
lnsallation Notes
Rear Shock Absorber Wear aRemove rearshock absorbers. the .Visuallyinspect followingltems. the l . Lower Cover Stroke Compression Sleeve 2. Adiusting http://manuals.magnamaniac.com Oil Leakage Marks 5 - Positioning OtherDamage or to *lf there is any damage the rearshockabsorber, one unit feels weakertian the other, replaceboth lf tie spring action feelstoo soft or too stiff, adjust it as shockabsorbers a set. with the following table. in accordance
12-10 SUSPENSION Bushing Wear avisually inspect rubber the bushing. tlf thyshow signs damage, any of replace them.
oPull back the swing arm and take ifoff. A cap on each sldeof the swingarm will alsodrop off.
SwingArm
Removal aUsing the iack stand and the attachment (special iools: 57001-'1238 12521or other suitablemeans or to lift the rearof the motorcycle. aRemove following. the (see Rear Wheel Wheels/Tires chapter) (see Rear Caliper Brakechapter) Muffler(see Engine Top Endchapter) Swing Arm Covers RH RearShockAbsorber (see FinalGear Case FinalDrivechapter)
lnstallation
alnstallation the reverse removal. Note the folis of lowing. oTightenthe pivot shaft to the specifiedtorque (see Exploded View). oTightenthe rear shockabsorber nuts to the specified torque(see Exploded View). oTighten the calipermountingbolts to the specified torque(see Exploded View). oMove the swing arm up and down to check for abnormal friction.
A. RH RearShockAbsorber B. Swing Arm C. Cover D. BrakeHose(takethe hose of the holder) out
Grease Sealand Needle Bearing Removal/Assembly .Notethefollowing. oRemove needle the bearing using oil seal bearing a and (special remover tool).
.Uns6rew pivot shaftandpull it out. the
A. Swing Arm B. PivotShaft A. Oil Seal Bearing and Removeri57001-1058 B. Needle Bearing C. Grease Seal
12-11 susPENstoN
olnsert the needlebearingusing bearing driver set (special 129) so that marked side faces tool: 57001-1 outside.
Grexe Seal and Needle Bearing Lubrication

ofthe needlebearings to aApply grease the innersurfaces with the PeriodicMaintenanceChart. in accordance seals. to aApply a thin coat ot grease the lips ofthe grease
A. Applygrease. Bearing B. Needle
Seal C. Grease
Slebveand Needle Bearing Wear .

aVisually inspect the swingarm sleeve and needle bearing. *lf there is any damageto them, replacethem as a set.
1}1 STEERING
Steering
Tableof Contents
ExplodedView... SpecialTools. Steering. Adjustment. Steering Stem Removal lnstallation B S t e e r i nS t e m e a r i n g . g BearingLubrication,. . . . gearingWear,Damage. Damage . StemCapDeterioration, W . S S t e e r i n gt e m a r p . . . . 13'2 13-3 134 134 134 134 136 137 1;-7 13'7 13-7 13'7
.... '...
'. '.... '. ..'.'....
13.2 STEERING
ExplodedView
T1 : 20 N{n (2.0ksm, 145 ft{b} T2: 39 N{n {4.0kg-m,29ft"lbl T3: 52 Nrn (53 kg.m,38ft-lbl T4 : 59 N.m {6.0kgfl,43 ft-lbl G:Applygrease L : Apdy nonfermanent lockingagent.
@
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oy
A " , e @
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P--{D
1. Handlsbst 2. Gollar 3. Handl. Holdel 4. Stsm HsadBolt 5. llta$r 6. SteeringStem Hed 7. St6mNutT:6mm 8. StemNut T 3 10 mm 9. StemCap 10. Foller Baling.(UpFll (Loworl 11. RollsrBaring 12. Grass Se.l 13. SteeringStem Base 14. Frame
_o
e-o
e%t.
STEERING13
SpecialTools
Driver: 57001-131-/ StemBearing
Shaft: 57001-1075 Driver Press
Driver(Upper):57m1't 106
Adapter: 57001-1074
Driver(Lowerl: 57001-1076
JackStand: 57001-1238 StemNut Wrench:57m1-l l(Xl
Attidrment: 570'01-1252 StemBa.ringRemorer:57(x11-1107
q
134 STEERING Steering Adiustment oCheck as steering follows.

NOTE oTurn the locknut l/8 turn at a time maximum-
ouse the jack stand and the attachment (special tools: 57001-1238, 5700'l-1252\ lift the front wheeloff to the ground. owith ttle front wheel pointing straightaheadaltrnately tap each end of the handlebar. The front wheelshouldsriing fully left and right from the force of gravityuntil the fork hir the stop. *lf tl|e wheel binds or catches before the stop, the steering too tight. is oFeel for steeringlooseness pushing by and pullingthe forks. *lf you feel looseness the forks, the sGeringis too on loose. NOTE oThe cablesand wiring will have sme effet on dre motion of the fork which mustbe taken into aeount. Be gtte the wit6 and ables are prcperly routed. ome bearing' must be in good condition and properly lubricatedin order for any test to be valid. *Ad.iust steering necessary. the if .Removethe followingparts. FuelTank Fork LowerClampBolts(bothsides) StemHeadBolt (Loosen) .Adjust the steering with the stemnut wrench(special tool).
.Tighten the steeringstem headbolt to the specified torque(see Exploded View). .Tighten the front fork lower clamp bolc to the specified torque (see Exploded View in Suspension chapter). .Checkthe steering again. *lf the steering still too tight or too loose, is repeat the adiustment. alnstallthe removed Darts.
SteeringStem
Removal .Remove following. the FuelTank FrontCaliper FrontWheel Front Fender Front Fork Legs aRemovethe clamp, free the brake hose from the left sideof the stem base, and move the front brake assembly a setto the rear. as
A. StemHeadBolt B. Stem Nut Wrench:57001-1 100
http://manuals.magnamaniac.com *lf the steering is too tight, loosen the stem locknut a fraction of a turn. *lf the steeringis loose,tighten the locknut a fraction of a turnA. Clamp
B. Brake Hose
1}5 STEERING
.Remove the headlight lower bolts from the bottom of the stem base.
A. Locknuts
B. Cap
LowerBolts A. Headlight
B. StemBase
aRemovethe upper taperedroller bearinginner racepressed the headpipe, into .To remove ouler races the (special tool) asshown remover installthe stembearing remover drive to the and hammer stembearing below, it out.
.Remove the stem head bolt and flat washer. .Pull up the steeringstem head with the handlebarand headlightunit.
NOTE it otf either steeringstembearingis damaged, is rudrl' that both the upper and lower baings (in' mended st cluding ouw lE,ces) ould be replacedwith new on6'
A. StemHeadBolt B. washer
C. Handlebar Unit D. Headlight 57001-1107 Remover: 1. StemBearing
stem rPushup on the stembase, remove steering the and locknuts with the stemcap usingthe stemnut wrench (special stemand stem the tool), thcn remove sieering (single unit). base
.TaD the bottom of the lowerinnerracewith a chisel. metal oPry the innerrace of the stemwith a suitable out lever.
136 STEERING
1 . Grease Seal 2. LowerInnerRace
3. TapHear
l. StemBearing Driver:57001-137 2. Adapten 57W1-1O74 rThe following four stepsshould be prformedafter stering bearing installation.This procedure settles the bearings place. in ousingthe stemnut wrench, tightenthe stemlocknut to 39 N-m (4.0 kg-m,29 ft-lb) oftorque. (To tightenthe stering stem locknutto the spcified torque,hook the wrench the stemlocknut,and pull the wrenchat the on holeby 22.2 kg forcein the directionshown.)
lnstallation .lnstallation is reverse removal. Note the following. of oApply grease the outer racs, to and then drivethem into the headpipeusing drivers the driverpress the and shaft(special tools).
'I 80 mm
Kg
1. Stem Nut Wrench: 57001-1100 3 . 2 2 . 2 k s 2. 180mm checkthat there is no play andthe steering stemturns smoothlywithout rattling. *lf not, the steering stembearing maybe damaged. l. Driver Shaft: Press 57001-1075 oAgainback out the stem locknut a fraction of a turn 2. Drtuer: 57001-1 106 until it turnslightly. 3. Driver: 57001-1076 oTurn the stem locknut lightly clockwise until it iust becomes hard to turn. Do not overtighten, the or steering be too tight. wlll oCheck adjustthe followingafter instaltation. and Steerlng Adiustment http://manuals.magnamaniac.com ClutchHose oApply.gfease tle lower taperedroller bearing, to and Throtile Cables drive it onto the steering stemusingthe stembearing ChokeCable (special driverandadaprcr tools). Front Brake
1&7 STEERING
SteeringStem Bearing Bearing Lubrication
.Perform the following. oRemove steering the stem. ousing a high flash-pointsolvent, washthe upper and in roller bearings thecages. lowertapered owipe the upper and lower outer races,which are press-fitted into the frame headpipe,cleanoff grease anddirt. oVisuallycheckthe outerraces the rollrs. and *Replace the bearing assmblies they show wear or if damage. oPackthe upperand lowertapered rollerbearings the in to and apply light coat of grease cageswith grease, the upperand lowerouterraces. olnstallthe steering the stem,andadjust steering.
BearingWear, Damage
*Replace bearing assembliestheyshowdamage. lf the
Stem Cap Deterioration. Damage

tReplace the greas sealif necessary.
Steering Stem Warp *lf the steering replace steering the stemshaftis bent, stem.
FRAME 1'&1
Frame
Tableof Gontents
ExplodedVia^l Right Down Tube Removal(To AccessRight EngineCoverl. . RearFender RearFender RearSectionRemoval. RearFenderFront SectionRemonal. Footpeg, Right Footpeg Removal Right Footpeg Installation
1+2 1+5 1+5 1+5 1+5 146 1+6 AA 1+7
1+2 FRAME
Exploded Viar
(? \^
f&
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) {
T1 ; 24 N-m(24 kgn, 175 ft-lbl T2; 44 N<n {45 ksrn, 3i} ft-lbl G : Apply grcase.
ost
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N @@,AW *K*-o,
rffi
1. F ame Top Tube Coyer LH 2. Frame Top Tub Cover RH 3, Fud Filter Bracket 4. Frame 5. EngineMounting Brackgt 6. Right Dol/vn Tube http://manuals.magnamaniac.com 7. Front Footpeg LH 8, Footpeg Bracket 9, Footpeg Bracket 10, Front Footpeg RH
1 1 .Rear Footpeg LH 12. Footpg Bracket 13. Footpeg Blacket 14. Rear Footpeg RH 15, Baak Frame
FRAME 14
___9_
-/
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1. 2. 3. 4. 5. 6. 7.
Front Fndsr Rider's Sest Pa$enger's Sat Rear Fender Front Section Rear Fender Rear Section Seat Rear Fender
L-
1.1
vN1500-8
/Eurqeanudrel
ffi\
( European Model
T'I4 FRAME
1. Battery Band 2. Battery C.se 3. Elestric PartsBr*ket 4, Fuel PumpBrsdct 5, lgnitr &ad(et 6. lgnruon CoiaBFckst 7. liide Stand 8. SideStandSwitch G : Apply grease.
s*
Fr
\l
FRAME 1/L5
Right Down Tube
Bight EngineCover) Remoml(To Access

.Removetle muffler (see Engine End6hapter). Top .Place suitablestand undertlte crankcase support the to engine.
MountingBolts A. Engine Bolts B. Bracket
C. DownTubeBola
.Take tlle right down tube out of the frametowatd the rear A. Stand
aRemove radiatorcorr. the oUnscrew radiatorlowermounting bolts. the
A. DownTube
A. Radiator
B. LowerMountingBolts
.Remove the coolant reservoir tank covr(seeCooling http://manuals.magnamaniac.com chapter), and take the tank out of the bracket. System Rear Fender Rear Section Remotnl aRemove fuel tank and RHframetop tube cover. the and tail li8ht wire .Disconnect rear turn signal the .Disconnect rearbrakelightswitchwireconnectors. the .Unbolt the following, connectors.
RearFender
14.6 FRAME
A. Turn SignalLight Connectors B. Tail LightConnectors oRemove rear fender rear sectionbolts. tie rRemove both of the backframebolts.
Bols (VNt 50GA) A. hsgengpr mounting Sat
Remoml RearFenderFront Section

aRemove rearfender rearsection. the rRemovethe rearfenderfront sectionbolts and put it down.
A. RearFenderRearSection B. Fender Bolt
C. BackFrame8o16
aTake tle rear fender rar section witi the passenger seat and the back frame out of tl|e ftame, and then them if necesory. separate oRemove rear backframe bolts anddisonnect tl|e the turn signalwire connectors.
A. RearFenderFront Section B. Bolls
Footpeg
Bigtht Footpeg Removal .Remo\ the RH exhaust pipe. pipe oRemove exhaust the http://manuals.magnamaniac.com holders. pipeclampscrew. oloosenthe exhaust oPullthe exhaust pipeout of the muffler. .Removethe brakepedallink clampbolt. .Removthe footpegmounting bolB,
A. BackFrameBolt
FRAME 1+7
Link ClampBolt A. BrakePedal MountingBolt B. Footpeg Assembly. C. Footpeg
A. Alignthe punchmarks.
.Pull out the footpeg towardthe right. assembly
Right Footpeg lnstallation .Note the following. oWheninstallingthe footpeg assembly, align the link punchmarkwith the shaftpunchmark.
A. Align the punchmarks.
olf the footpeg assemblyis disassembled, align the inside link punch mark with the shaft punch mark.
1$38 ELECTRICALSYSTEM
*lf the relaydoesnot work asspecified, thenreplace the junction box.
Relay Girouit Inspeaion {with the battery disconncd} (9) METER CONNECTIONMETER READINC FAN RELAY
Diode Circuit lnspection .Rmovethejunctionbox from the motorcycle. .Pull off the connectors from the junctionbox. .Check conductivity the following pair of terminals. of Terminals DiodeCircuit Inspection for r*11-12, i13-8, +13-9. 12-14,.t5-14,16_14 * US/Qnada ModelOnly *'* VN150GA9-
HEADLICHT RETAY STARTER RELAY
*7-8 *7 -13 11-13 12-13
*,'.vN150GA9RelayCircsit In$sction (with the batteryconn6ed)

BATTERY METER METER CONNECTION READINC CONNECTION (0)
*The resistance shouldbe low in onedirection andmore than ten timesas much in the other direction. lf any diodeshows or highin both directions, diodeis low the defective the diodeassembly and mustbe replaced. NOTE oThe &tual meter ,@ding varia with dte meter ud and the individual diode, but. gercn y q@kiry, the loy,Er tding *ould be from zero to one half d\e *ale.
FAN HTADIICH'I STARTER .7 -8 1 1- ' 1 3
2-4
9-13 11-12
0 0 0
* US/ CANADA MODEL ONLY ,,r,vN1sflrAgJunction Box Intsrnal Circuit vNl 5O0-Al-A8/Bl -86 {US AND CANADA}
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VN15OO-A9- (US AND CANADAI
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--for Us/Canadian modcle
VN15OO-A2-Aa / 82-86
Wiring Diag.am (Orher than US and Canadal
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RightTu.nSi9tulhdharor
Ugln12V 3W L.t TumSig..l lhdic.tor
W 12v 6ry55
O'tr Lionr
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ridr 12v 2r w
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LCFT HANDLEBAR S{VIICH OOI{NECTIOI{S Tum Sicnl Swiid
Color
N
Dimm.r Swildl SterE Lo.*our Switrh http://manuals.magnamaniac.com Color

HI
GY
R/BK
8L/Y
Color Ralaeed Pull.d in
BK/Y
8K
BK/R
LO
ELECTRICAL SYSTEM 15.39
BL
VN150GA only
AK
n-l
12V5W
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I\cYI
Headliqht Switch Enqine Stop Switch http://manuals.magnamaniac.com
J+s fifiil YTY
fl
8K BL BR CH G GY LB LG
RTGHT HA!{OLEaAR SffUYCH COt{ltECTtOl{S Starter Buiton Color R/8L BL
Color OFF RUN
SKTY
Color
BK
ON
(98051.1069A,1092A)
15.4O ELECTRICAL SYSTEM VN15OO-A9- Wiring Diagram (US and Canada)

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7, Headlight F.l.y Fus. 10 A 8. Acc.sery F!e. 1O A
5, Tlh
SignalR.l.v
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APPENDIX1S1
Appendix
Tableof Contents
for Additional Considerations Racing Carburstor SparkPlug SparkPlugInspection T r o u b l e s h o o tG u i d e . . ing General Lubrication .... Lubrication Nut, Bolt, and Fastener Tightness Tightness Inspection Unit Conversion Table . . ..
.......
16-2 16-2 16-2 16-2 16"4 16 168 16 1&9
16
162 APPENDIX
Additional Considerations Racing for
This motorcyclehasbeenmanufactured usein a for reasonable prudentmannerand as a vehicleonly. and However, somemay wish to subiectthis motorcycle to abnormal operation, suchaswould be experienced under racingconditions. KAWASAKI STRONGLY RECOMMENDSTHAT ALL RIDERS RIDE SAFELY AND OBEY ALL LAWSAND REGULATIONS CONCERNING THEIR MOTORCYCLE AND ITS OPERATION. Racingshould.bedone undersupervised conditions, and recognized sanctioning bodiesshouldbe contacted for further details. For thosewho desireto participate in competitiveracing or related use, tl|e following technical information may prove useful. However, please noG the followingimportantpoints. aYou are entirelyresponsible the useof your motorfor cycle under abnormalconditionssuch as racing,and Kawasaki shall not be liable for any damages which mightaris from suchuse. .Kawasaki'sLimited Motorcycle Warrantyand Limited EmissionControl SystsmsWarranty specificallyexclude motorcycles which are used in comDetitive or related uses. Pleaseread the warranty carefully. .Motorcycleracingis a \ry sophisticated spori,subiect to many yariables. The following information is theoretioal only, and Kawasaki shall not be liablefor any damages which might arisefrom alterations utilizingthis information. .When tie motorcycleis operatrdon public roads,it m|lst be in is originalstate in 'ordr to ensure safety andcomplianc with applicable regulations. Whena plugof the correctheat range beingused, is the electrodes will stay hot enoughto kedp all the carbon burned off, but mol enough to keep from damaging the engine and the plug itself. This temperature about400 - 800"C(750- 1,450"F)and can is be judged by noting the condition and color of the ceramicinsulatoraround the centerelectrode. lf the ceramicis cleanand of a light brown color, the plug is operating the right temperature. at A spark plug for higher operating temperatures is used for racing. Sdch a plug is designed better for coolingefficiencyso that it will not overheat thus and is often calleda "colder" plug. lf a sparkplug witlr too higha heatrange used that is,a "cold" plugthat is cools itself too well - the plug will stay too cool to burn off the carbon,and the carbonwill correcton the electrodes the ceramic and insulator. The carbonon the electrodes conductselectrici.ty, and can short the centerelectrode groundby either to coating ceramic the insulator bridging or across gap. the Such a short will preventan effectivespark. Carbon buildupon the plugcanalsocause otler troubles. lt can heat up redhot and causepreignitionand knocking, which may eventuallyburn a hole in the top of the piston.
SparkPlug
Carbureton
Sometimes alGration may be desirable an for improved performanceunder special conditions when proper mixture is not obtainedafter the carburetor has beenproperlyadiusted, all partscleaned found and and properly. to befunctioning lf the enginestill exhibits symptomsof overly lean carburetionafter all maintenance adjustments and are correctlyperformed, mainiet canbe replaced tie with a smalleror largerone. A smallernumbered givesa jet leanermixture and a largernumbered a richermixiet ture.
Spark Plug: The spark plug ignitesthe fuefair mixture in the combustion charnber.To do this effectivelyand at the propertime, the correctspark plug must be usd, I . Terminal and 4. Gasket the sparkplugmustbe kept cleanandadiusted. 2. lnsulator 5. CenterElectrode Test haveshown the plug listd in tlre "Electrical 3. cement 6. SideElectrode System"chapter bethe bestplugfor general to use. Sincesparkplug requirements http://manuals.magnamaniac.com change with the ignition and carburetion adjustments with ridingcondiand tions, whetheror not a sparkplug of a correct heat range SparkPlug lnspection is usedshouldbe determined removing by .Remove sparkplugand inspect ceramic and inspectthe tl|e insuing the plug. lator.
APPENDIX 1G3
Spa* Plug Condition
Carbon Fouling
Oil Fouling
Normal Operation
Overheating
*Whetheror not the right temperature is beingused plug can be ascertained noting t$e condition of the by ceramic insulatoraroundthe electrode.A light brown color indicates correctplug is being used. lf the the ceramicis white, the plug is operating too high a at temperature and it shouldbe replaced with the next coldertype.
Standad Spark Plug Thread: Diameter: 12 mm Pitch: 125 mm Readr: 19.0 mm
olf the spark plug ir replaced with a tyFe odror dran the standard plug, mako certain the replacemem plug has t're sams drread pitch and readr (length of threaded portion) and the same insulator type (regulal typs 01 proiected typel as the standard plug. olf $e plug reach b too short, ca.bon will build up on the plug hole threads in the .rylinder heed, cau:ing overheating and making it very dilfidrlt to insert the coJrect spark plug later. olf the reach b too long, carbon will build up on the expos6d spark plug thrcad: caBing ovedreating. preignition, and po$ibly buming a hols in the p&ton top. In addition, it may be impossibleto lemoye the plug without damaging the cvlinder head.
NOTE oThe heat nngc of the spark plug fu,Etions like a thermo*at for the engine. Using the wrotry type of qark plug en make the enginerun too hot (reiting in enginedamage) too cold (with poor performance, or misfhing,and sta ing).
Plug Reach
Too short
Correctreach
Carbon builds here up
164 APPENDIX
Troubleshooting Guide
NOTE oThis is not an exhaustive list, giving every posible cau*s e*h problem li&ed. lt is ment simply as a for rough guide tu. assisrthe trcubleshootingfor sme of the morecommondiff icutti*. pistonworn Cylinder, Piston ringbad{worn,weakbroken,or sticking} Piston ringlgroove clearance excessive gasket Cylinder head damaged headwarped Cylinder Valvespring brokenor weak properly (valvebent, worn, or Valve not seating on surface) carbon accumulation the seating (worn,seizure, damaged or Hydrauliclashadjustr broken) spring oil clogged Hydraulic lashadjuster p4ssage
Engine Doesn't Start, Starting Difficultyl Startelmotor not rotating; lockoutor neutralswitchtrouble Starter motortrouble Starter Batteryvoltagelow not or Relays contacting operating button not contacting Starter openor shorted Wiring lgnitionswitchtrouble Engine stopswitchtrouble Fuse blown Startermotor lotating but enginedoesnt tum oysr: startermotor clutchtrouble Engina rYon't tum ovr: Valveseizure Rocker seizure arm pistonseizure Cylinder, Poor Runningor at Low Speed: seizure Crankshaft Connecting smallendseizure rod Spsrkwe8k: Connecting big endseizure rod Batteryvoltagelow gear Transmission or bearing seizure Sparkplugdirty, broken,or matadiusted Camshaft seizure Sparkplugcapor hightensionwiringtrouble bearing Balancer seizure cap or SparkPlug shorted not in goodcontact No tuel flow: Sp k plugincorrect Fueltank air ventobs$ucted lC ignitertrouble Fuelpumptrouble Pickup trouble coil Fueltap clogged lgnitioncoil trouble Fuel/airmlxl re incorect: Fuellineclogged maladiusted Floatvalve clogged Pilotscrew , Pilot jet, or air passage flooded! clogged . Engine jet clogged Fuellevelin carburetor float bowl too high Needle (air bleedpipe),bleedholes worn or stuckoDen Floatvalve Pilot passage clogged poorly sealed, missing technique faulty clogged, or Starting Air cleaner (When flooded,crank the engine with the throttle Stzrtrplunger stuckopen fully open to allow more air to reach the float bowl too highor too Fuel levelin carburetor engine.) low No 3park; sparkweak: Fueltank air ventobstructed Batteryvoltagelow holderloose Carburetor or Sparkplugdirty, broken, maladjusted or tank duct loose Air cleaner surge wiringtrouble Sparkplugcapor hightension Fuelpumptrouble plugcapnot in goodcontact Spark Backfiringwhen deceleration: plugincorrect Spark Vacuum switchvalve broken lC ignitertrouble trouble Air suction valve Neutral, starter lockout, or side stand switch Other: trouble lC ignitrtrouble Pickup trouble coil not Carburetors synchronizin! lgnitioncoil trouble pistondoesn'tslidesmoothly Carburetor vacuum lgnitionor engine stopswitchshorted Engine viscosity high oil too Wiring shorted open or Drivetrain tiouble http://manuals.magnamaniac.com Fuse blown Finalgear case viscosity high oil too Compreasion Lowr dragging Brake Sparkplugloose trouble Air suctionvalve head sufficiently not tightned down Cylinder Vacuum switchvalve trouble
APPENDIX1G5
Poor Runningor No Powerat High Speed:
Firingincorresti Sparkplugdirty, broken, maladiusted or or Sparkplugcapshorted not in goodcontact Sparkplugincorrect lC ignitertrouble coil PickuD trouble lgnitioncoil trouble Fuel/airmixtureincorrcct: stuckopen Starterplunger Mainjet clogged wrongsize or or Jet needle needle worn iet Air.iet clogged float bowl too highor too Fuel lewl in carburetor holes air bleedpipeor needle clogged of Bleed iet poorlysaled, or missing Air cleaner clogged, tankduct poorly sealed Air cleaner surge or Waterof foreign matter in fue, Fueltap clogged Fuellineclogged Fuelpumptrouble Knod(ingr built up in combustion chamber Carbon Fuelpoorqualityor incorrect Sparkplugincorrect lC ignitertrouble Backfiring whendeceleration: switchvalve broken Vacuum Air suction valve trouble MLcellaneo$: won't fully open Throttlevalve pistondon't slidesmoothly vacuum Carburetor dragging Brake Clutch slipping Overheating oil Engine leveltoo high Engine viscosity high oil too Drivetraintrouble case viscosity high oil too Finalgear yalve trouble Air suction Vacuum switchvalve trouble mechanism malfunctioning Balancer Engine loadfaultyi slipping Clutch Engine leveltoo high oil Engine viscosity high oil too Drivetrain trouble Finalgear case viscosity high oil too dragging Brake Lubricationinadequate: Engine leveltoo low oil oil Engine poor qualityor incorrect Gauge incorred: gauge temperature broken Water sensorbroken Watertemperature Coolantincorrecl: leveltoo low Coolant Coolant deteriorated Coolingsystemcomponentincorlect: Radiator clogged Thermostat trouble cap Radiator trouble Thermostatic switchtrouble fan Fanrelaytrouble Fanmotor broken Fanblade damaged waterpumpnot turning pumpimpeller Water damaged
Over Cooling: Gauge incorrect: gauge Water temperature broken temperature rnsor broken Water Coolingsystemaomponentincorrect! Thermostatic switchtouble fan Thermostat trouble
Clutch Operation Faulty :

Clutchslipping: Frictionplatewornor warped SGelplateworn or warped Overheating: Clutchspring brokenor weak Firingincorrect: cylindertrouble Clutchslave hub or housing Sparkplug,broken,or maladjusted CIurch unevenly worn propsrly: Clutdr not dbengsging Sparkpluginconect lC ignitertrouble Clutchplatewarped too rough or Fuel/air mlxtrrc incorrect; Engine deteriorated oil Mainjet clogged wrongsize or Engine viscosity high oil too Fuellevelin carburetor float bowl too low Engine oil http://manuals.magnamaniac.com leveltoo high holderloose Carburetor Clutchhousing frozenon dliveshaft poorly sealed, missing Air cleaner or cylindertrouble Clutchslave Air cleaner surge or tankduct poorly sealed Clutchhub locknutloose duct loose Air cleaner Air in the clutchfluid line
16.6 APPENDIX
Clutchfluid leak Clutchfluid deteriorated Primary secondary damaged or cup cylinderscratched MasGr inside Gear Shifting Faulty: Dosnt go into gear;rhaft pedaldo6nt lsturn: Clutchnot disengaging Shift fork bent or seized c'earstuck on the sltaft leverbinding Gearpositioning weakor broken Shift returnspring Shift returnspring bolt loose arm broken Shift mechanism spring arm Shift mechanism broken Shift pawlbroken JumF out of gar: Shift fork worn Geargroor worn Geardogsand/or dog holesworn Shift drumgrooraworn Gearpositioning leverspring weakor broken Shift fork pin worn Driveshaft, output shaft, and/or gearsplinesworn Ovenhifts: positioning Gear le\r spring weakor broken arm Shift mechanism spring broken gearworn or chipped Primary trouble Camshaft chaintnsioner guideworn Camshaft chain,sprocket, damaged Air suctionvalve Vacuum switchrralve damaged gear Balancer wornor chipped shaftpositionmaladiusted Balancer bearing worn Balancer pumpchain,sprocket Water worn Abnormal Drive Train Noise : Glut*r noire: Weak damaged or rubberdamper excessive Clutchhousingfrictionplateclearance gear worn Clutchhousing Tnnarni$ion noise: Bearings worn gears worn or chipped Transmission in Metalchipsiammed gearGeth oil Engine insufficient Drivelinenoice: gearbearings worn Bevel gears worn or chipped Bevel gearsmaladiusted Bevel wheelcoupling Rear damaged lnsufficientlubricant Abnormal Frame Noise: Front fork noise: or Oil insufficient too thin weakor broken Spring Rsarshockab6orbsrnoiao: absorber damaged Shock Dilc brakenobe: Padinstalled incorrectly Padsurfaceglazed Discwarped trouble Caliper Othe?nobe: or Bracket,nut, bolt, etc. not properlymounted tightned
Abnormal Engine Noise: Knoddng: lC ignitertrouble Carbon built up in combustion chamber Fuelpoorqualityor inconect Sparkplugincorrect Overheating Pbtondap: Cylinder/piston clearance excessive pistonworn Cylinder, Connecting bent rod pin, pistonholesworn Piston Warning Light Gos On: Oil Pressure Valvenoise: Engine not sufficiently warmed up after lash Engine pumpdamaged oil clogged adius&rinstallation Engine screen oil (worn,seizure, Hydrauliclashadjuster Engine filter clogged oil damaged or spring broken) Engine le\l too low oil Air in hydraulic lastr adiuster too Engine viscosity low oil Metal chips or dust jammed in hydraulic lash worn bearings Camshaft adiuster bearings worn Crankshaft Engine operated red zone in Oil presureswitchdamaged Valvespring brokenor weak damaged Wiring bearingworn Camshaft Reliefvalvestuckopen Odrernoise: damaged O{ing at t}te oil pipein tl|e cnnkcase Connecting small rod endclearance excessive Connecting bigendclearance rod excessive Piston ringworn,brokenor stuck Exhaust Excessively : Smokes Piston seizure, damage Uvhite smoke; gasket Cylinder head leakinghttp://manuals.magnamaniac.com oil Piston ring worn pipeleaking cylinder Exhaust at headconnection Cylinderworn Crankshaft runoutexcessive Valveoil sealdamaged Engine mountsloose Valveguidewom Crankshaft bearing worn Engine levltoo high oil
APPENDIX1G7
Black smoke: clogged Air cleaner or Mainjet too large fallenoff plunger stuckopen Starter float bowl too high Fuellevelin carburetor Brown3moks: Mainje! too small float bowl too low Fuellevelin carburetor or tank duct loose Air cleaner surge poorlysealed missing or Air cleaner lgnitionswitchtrouble Alternatortrouble faulty Wiring Battery Overcharged: trouble Alternator rectifi trouble er Regulator
Handlingand/or Stability Unsatisfactory:

Handlebar to tr]n: hard stmlocknuttoo tight Steerint damaged Bearing Steering bearing lubrication inadequate stembent Steering Tireair pressure low too Handlebar shak6 ol excelEiyely riblates; Tireworn. arrdpivot bearing worn Swing Rimwarped, not balanced or lVheelbearingworn Handlebar clamploose stemhead loos nut Steering Hrndlebrpulls to ons ride: Frame bent lvhelmisalignment Swing bentor twisted arm maladiusted Steering Frontfork bent (oil Right/left fork legs unbalanced level) Shod(aborption unrati3factory: (Toohard) Frontfork oil excessive Frontfork oil viscosity high too Tireair pressure high too Frontfork bent (Too soft) Frontfork oil insufficient and/orleaking Frontfork oil viscosity low too Frontfork, rearshockabsorber spring weak Rear shock absorber leaking oil
Brake DoesntHold:
Air in the brakeline or Pad discworn Brake fluid leak waroed Disc pad Contamina@d Brake uid deteriorated fl Primary secondary damaged or cup Master cylinderscratched inside
BatteryDischarged:
Battery faulty (eg., plates sulphated,shorted http://manuals.magnamaniac.com through sedimentation, electrolyte level too low) poor contact Battery leads making (eg., Loadexcessive bulb of excessiw wattage)
1G8 APPENDIX
GeneralLubrication
Lubrication .Before lubricating eachpart, cleanoff any rusty spots with rust remover and wipe off any grease, dirt, oil, or grime. .Lubricate the points listed below witi indicated lubricantNOTE owhenever the vehicle h6 been opented wd or rainy conditions, or 8peially after using a highpresunespny n6ter. perform the genenl lubiation. PiYots: Lubricatswittt Motor Oil. SideStand ClutchLever BrakeLever BrakePedal RearBrakeRod Joint that eachcotterpin is in placeandin Also,checkto see goodcondition. NOTE oFor the engine fasteners. check the tightnes of them whenthe engineis cold (at room tempercture). *lf there are loose fasteners, retorque them to the specified torque following the specifiedtightening chapter torque for sequence. Refer'tothe appropriate specifications.lf torque specifications not in the are appropriatechapter, see the basictorque table (see Torqueand Lirking Agent in the General Information chapter). For each fastener,'first loosnit by l/a turn, then tightenit. *lf cottr pins are damaged, replacethem with new ones.
Nut, Bolt,and Fas@ner be dlecked to Wheels: Front Axle Nut Front Axle ClampBolts RearAxle Nut Point: Lubricatewith Grease. RearAxle Nut Crtter Pin LowerEnd Throttle lnnerCables Brakes: Speedometer InnerCablet +Grease lowerpart of the innroable Front Master CylinderClampBolts the sparingly. FrontC.aliper MountingBolts RearMaster CylinderMounting Bolts Cabl$; Lubricatewith ilotor Oil. Rear Caliper HolderMounting Bolts ChokeCable Rear CaliperMountingBolts ThrottleCables BrakeLeverPivotNut BrakePedal Bolt CableLubrication BrakeRodJoint Cotter Pin Susoension: Front ForkClamD Bolts Front Fender MountingBolts RearShockAbsorber Mounting Bolt andNuts SwingArm PivotShaftNuts Steering: StemHeadNut Handlebar ClampBolts Handle Grio Bar Bolts Engine: Engine MountingBolts Rocker Case Nuts ylinderHeadNuts Exhaust PipeMountingNuts MufflerMountingBolts Exhaust Pipe and MufflerConnecting ClampBolts ClutchMaster CylinderClampBolts 1 . Cable ClutchLeverPivotNut 2 . Pressure ableLuber: K55019{21 Radiator Mountbg Bolts Bolt shift Pedal Others: SideStandNut RearFrame MountingBolts Nut, Bolt, and FasenerTightness RightDownTubeMounting Bolts http://manuals.magnamaniac.com BackFrame MountingBolts Footpeg Bracket MountingBolts FinalGearCase Mounting Nuts Tightnesslnspection
theck the tightness the boltsandnutslisted of here.
APPENDIX 1G9
Table Unit Conversion Prefixesfor Units: Prefix mega kilo centi milli micro Symbol M k c m
tt
Unitsof Length: k m m mm Power x
0.6214
= 3.281 0.03937 =
x x
mile ft in
x 1,000,000 x 1,0O0 x 0.01 x 0.001 x 0.000001
Units of Torque: N-m N-m N-m

Kg-m
x x
X
X
0.1020 o.7376 8.85r

9.807 7.233 86.80 = = =
kgm ft-lb in-lb
Unitsof Mass: k g g x x
ksm ksm
2.205 0.03527=
tb oz
x x
N-m ft-lb in-lb
Units of Pr6sure: Unitsof Volume: L L L L

I
x x x
X
L mL ML mL
x x x x x
o.2642 o.2200 1.057 0.8799 2.113 1.816 0.03381 = 0.02816= 0.06102=
sal(us) qt (us)
gal (imp) qt (imp) pint (US) pint (imp)
kPa kPa kPa kg/cm2 kg/cm' cm Hg
x x x x x x
0.01020= 0.1450 = 0.7501 = 98.07 14.22 1.333
kg/cm' psi cm Hg
kPa psi kPa
oz(us)
oz (imp) cu in
Units of Speed: km/h x
o.6214
mph
Unitsof Force: N x N x x kg x kg
0.1020 - k g o.2248 = t b 9.807 2.205

= N = t b
Unitsof Power: k W x k W x PS x PS x
1.360 1.341
PS HP
0.735s = k w 0.9863 = H P
Units of Temperature:
9 fcj40) _40_.F
r
40 ,20
s ('Fj 40)_ 40_ .c

.F
5a 104
32 20 lao
12o l4o 160 llso 60 | 80 tool http://manuals.magnamaniac.com 2oo
i22o
24oi 260 2aoi
3oo
32o
-40
'c
o i
4A
r2o
ir4o
MODELAPPLICATION
Year
Model
Beginning Frame No. JKBVNMIt]HAOOOO2l JKBVNAB1trHA00001 1,or JKBVNABl !H85OOOO1 JKBVNMlnJA001001,or wN50A-001001
JKBVNAB'1 DJAOOOSOl,or JKBVNAB,l !J85OO6O1,Or wN50A-003001
1987 vN1500-41
vN1500-81
1988 vN1500-42
vN1500-82
1989 vN1500-43 vN1500-83 1990 vN1500-A3 vN1500-83

1991 vN1500-A5
JKBVNM1trKA003001,or wN50A-003001 JKBVNAB1nKA002001,or wN50B-002001 JKBVNAAI trLAOO3OO'I,or wN50A-004001 JKBVNABI NLBsOI40l,or wN508-003001 JKBVNAA1trMA006001,or vTN50A-006001
vN'1500-85 1992 vN1500-45

'1993 vN1500-A7 1994 vN1500-A8 1995 vN1500-A9
wNs0B-00s001
JKBVNAAI NNAOOgOOI,or wN50A-009001 wN50B-009001 JKBVNAA'I trPAO13OO1 JKBVNAAlNRAO2OOOl
JKBVNAAl NSAO2600l
vN1500-86
1996 1997 1998 1999
vN1500-A10 vN1500-A11 vN1s00-A12 vN1500-43 t
JKBVNMl ITAO4OOO1 JKBVNAAl IVAO60OO1 JKBVNMl !WAO7sOO1 JKBVNAA1trXAO85OO1
}lKawasaki
KAWASAKI HEAVY INDUSTRIES, LTD. ConrunerPrcductu rchlneryGroup &
Part No. 9992't-1078-08
Printedin JaDan

Kawasaki VN1500 87-99

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Guide Quick Reference

A ABDC AC ATDC BBDC BDC BTDC

tb m min N Pa PS psi rpm TDC TIR W o

ReadO,I/NER'S MANI At beforeoperating http://manuals.magnamaniac.com

(Continued next page.l on

Howto Use Manual this

1.2 GENERALINFORMATION Before Serwicing

14 GENERAL ]NFORMATION Model ldentification VN1500-A1 Right SideView

VN15qlB1 Left Side View

(w) 5"BTDC (rpm)

PeriodicMaintenanceChart (Other than US and Canada)

Brake/clutch levet checkt fluid

Brake/clutch master cylinder anddust cup seal- replace

Whichever first FREOUENCY comes OPERATION

Oil screen clean

Swinqarm pivot -- lubricate

2 years 2 years 2 yearc 2 years 4 years 4 years

hose Brake/clurch andpipe- replace

7.8 7.8 8.8 9.8 8.8 25 78 25 8.8 25 25 12 15 12

0.80 0.80 0.90

1-9 GENERAL INFORMATION

4.5 2.4 4.5 4.0 2.1 0.90

29 15.0 78 in-lb 15.0 78 in-lb

0.90 6.0 15.0 6.0

11.0 0.15 0.90 2.5 23 27

1.2 2.5 12.1 3.0 12.O

11.0 104 in-lb 18.0 88 22 6t 16.5

ZSin-f O 180 11.5

1-IO GENERAL INFORMATION

ft-m 52 inlb 78 inlb 18. 0 69 in-lb 20

47 1 8 .0 '14. 5 38 14. 5 72 2. 22 zl3 29 43 inlb 33 1 7 .5 1 8 .0 43 't2. 5 69 inlb 11.0 11.0

4.5 2.4 2.5 6.0 1.75 0. 80 '1. 5

General Fastenen Threadsdia. (mml

1-12 GENERALINFORMATION Wire,andHose Cable, Routing

Wire Straps CoolingHoses SideStandSwitch RearBrakeLight Switch FuelPump

1-14 GENERAL INFORMATION Carburetor Hose Routing

1.16 GENERAL INFORMATION

2-2 2-5 2-5 2-6 2$ 2-7 2-7 2-7 2-7 24 24 2-9

2.2 FUEL SYSTEM ExplodedView

(cal) (cal) CalitorniaModel

(W) Sruitzerland Model (cN) CanadaModel

ExaporariwEmbtion Cofitrol Sy$m (Califomiailodell

Pilotscrew Service level:Front fuel Rear

2 FUEL SYSTEM Throttle Grip and Cables Throttle CableAdjustment

Throttle Grip FreePlay SGndard: 2-3mm

A. Accelerator Cable B. Decelerator Cable

C. Adiusting Nuts D. Locknuts

FUEL SYSTEM2.7 Adiustment High Altitude Performance (USmodel)

lnwction Fuel System Cleanline56

.Check idle speedwiti a tachometer.

1. DrainScrew Hose 2. Suitable 3. Bottom Cover

http://manuals.magnamaniac.com if watrr or dirt comesouL acheck to see

&rvice Fuel LevelAdiustment

GarburetorSyndronization Vacuufil Leo than 2.7 kP. (2 crnHg)difference betweentwo calbuletols

http://manuals.magnamaniac.com 1. FuelLevel Gauge: 57001-1017

Float Tang Float Valve Floa! Mating Edge ChamberRibs

NOTE oDo not push the ndle masufement.

rcd in during the float height

2.10 FUEL SYSTEM

A. Turnthecarburctor assernbly clockwise.

I wAutlruc i '-oFuel spilled from the catburetoF b hazardous.

http://manuals.magnamaniac.comitemsif necessary. oAdiustthe following

!tl;.ir{tl ori.:V trdrofin$dl 11"8i ., D!l J'!B -- 08

#f'ff \'/ N#? & *#eM