1996-2006 Vulcan 800 Classic 1996-2006 VN 800 Classic Motorcycle Service Manual Downloaded for free, https:/VulcanRiderse/This quick reference guide will assist you in locating a desired topic or pro- cedure. *Bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page. +Refer to the sectional table of contents for the exact pages to locate the spe- cific topic required. Quick Reference Guide [General Information [Fuel System [Cooling System [EngineTopEnd [Clutch [Engine Removal/instaliation __ 8 [Crankshaft/Transmission __9 Wl [Wheels/Tires 10 [Final Drive [Brakes [Suspension 13 [Steering [Frame [Electrical System 16 [AppendixLIST OF ABBREVIATIONS ry ‘ampere(s) tb pounds(s) ABDC | after bottom dead center m meter(s) AC alternating current min minute(s) ATDC | after top dead center N newton(s) BBDC _ | before bottom dead center Pa pascal(s) BDC bottom dead center Ps horsepower BTDC | before top dead center psi pound(s) per square inch °c degree(s) Celsius r revolution De direct current rpm revolution(s) per minute F farad(s) TDC top dead center F degree(s) Fahrenheit TR total indicator reading ft foot, feet v volt(s) g gram(s) w watt(s) h hour(s) a ohm(s) L liter(s) Read OWNER’S MANUAL before operating.EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency. 4. Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors are routed through an oil separator to the intake side of the engine. While the engine is operating, the vapors are drawn into the combustion chamber, where they are burned along with the fuel and air supplied by the carburetion system. 2, Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels. The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly referred to as the Act's "tampering provisions.” "Sec. 203(a) The following acts and the causing thereof are prohibited. (3)(A) for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser. (3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles know- ingly to remove or render inoperative any device or element of design installed on or ina motor vehicle or motor vehicle engine in compliance with regulations under this title follow- ing its sale and delivery to the ultimate purchaser...” NOTE ©The phrase "remove or render inoperative any device or element of design" has been generally interpreted as follows: 1. Tampering does not include the temporary removal or rendering inoperative of de- vices or elements of design in order to perform maintenance. 2. Tampering could include: a.Maladjustment of vehicle components such that the emission standards are ex- ceeded. b.Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle. Addition of components or accessories that result in the vehicle exceeding the stan- dards, d.Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems. WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION.TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. ‘Among those acts presumed to constitute tampering are the acts listed below: ‘® Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations, ‘* Removal of the muffler(s) or any internal portion of the muffler(s). ‘* Removal of the air box or air box cover. '® Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such modifications result in increased noise levels.Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop proce- dures must be understood in order to carry out maintenance and repair satisfactorily. When- ever the owner has insufficient experience or doubts his ability to do the work, all adjust- ments, maintenance, and repair should be car- ried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes, read the text, thor- oughly familiarize yourself with the procedures before starting work, and then do the work care- fully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may ad= versely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual, Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your vehicle: ‘* Follow the Periodic Maintenance Chart in the Service Manual. ‘*Be alert for problems and non-scheduled maintenance © Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual, Genuine parts provided as spare parts are listed in the Parts Catalog. ‘* Follow the procedures in this manual care- fully. Don’t take shortouts. ‘* Remember to keep complete records of main- tenance and repair with dates and any new parts installed How to Use This Manual In this manual, the product is divited into its major systems and these systems make up the manual’s chapters. The Quick Reference Guide shows you all of the product's system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents For example, if you want ignition coil informa- tion, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chap- ter to find the Ignition Coil section Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices. PW This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in per- sonal injury, or loss of life. CAUTION This caution symbol identifies special \structions or procedures which, if not strictly observed, could result in dam- age to or destruction of equipment. This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of informa- tion NOTE This note symbol indicates points of par- ticular interest for more efficient and con- venient operation. @ Indicates a procedural step or work to be done. indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE. %Indicates a conditional step or what action to take based on the results of the test or inspec- tion in the procedural step or sub-step it fo lows, In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require spec- ified tightening torque, oil, grease or a locking agent during assembly.GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing 12 Model Identification 15 General Specifications. 17 Unit Conversion Table wcsienisentanisentuniatiinansiatiinsiasiinsiasiiassisinssassne — 1161-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts. Especially note the followi (1) Dirt Before removal and disassembly, clean the motorcycle. Any dirt entering the engine will shorten the life of the motorcycle. For the same reason, before installing a new part, clean off any dust or metal filings. (2) Battery Ground Disconnect the ground (-) wire from the battery before performing any disassembly operations on the motorcycle. This prevents the engine from accidentally turning over while work is being carried out, sparks from being generated while disconnecting the wires from electrical parts, as well as damage to the electrical parts themselves. For reinstallation, first connect the positive wire to the positive (+) terminal of the battery (3) Installation, Assembly Generally, installation or assembly is the reverse of removal or disassembly. However, if instal- lation or assembly sequence is given in this Service Manual, follow it. Note parts locations and cable, wire, and hose routing during removal or disassembly so they can be installed or assem- bled in the same way. It is preferable to mark and record the locations and routing whenever possible. (4) Tightening Sequence When installing bolts, nuts, or screws for which a tightening sequence is given in this Service Manual, make sure to follow the sequence. When installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit, thus ensuring that the part has been installed in its proper location. Then, tighten them to the specified torque in the tightening sequence and method indicated, If tightening sequence instructions are not given. tighten them ‘evenly ina cross pattern, Conversely, to remove a part, first loosen all the bolts, nuts, or screws that are retaining the part a 1/4-turn before removing them (8) Torque When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to serious damage. Use a good quality reliable torque wrench. (6) Force ‘Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem, Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removing screws held by non-permanent locking agent) in order to avoid damaging the screw heads. (7) Edges Watch for sharp edges, as they could cause injury through careless handling, especially during major engine disassembly and assembly. Use a clean piece of thick cloth when lifting the engine or turing it over. (8) High-Fiash Point Solvent A high-flash point solvent is recommended to reduce fire danger. A commercial solvent com- monly available in North America is standard solvent (generic name). Always follow manufacturer and container directions regarding the use of any solvent. (9) Gasket, O-Ring Replace a gasket or an O-ring with a new part when disassembling, Remove any foreign matter from the mating surface of the gasket or O-ring to ensure a perfectly smooth surface to prevent oil or compression leaks. (10)Liquid Gasket, Locking Agent Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used. Apply them sparingly. Excessive amount may block engine oil passages and cause serious dam-GENERAL INFORMATION 1-3 Before Servicing (11)Press When using a press or driver to install a part such as a wheel bearing, apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit. (12)Ball Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unless itis absolutely necessary. Replace any ball or needle bearings that were removed with new ones. Install bearings with the manufacturer and size marks facing out, applying pressure evenly with a suitable driver. Apply force only to the end of the race that contacts the press fit portion, and press it evenly over the base component. (13)Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones, as removal generally dam- ages seals. Oil or grease seals should be pressed into place using a suitable driver, applying a force uniformly to the end of seal until the face of the seal is even with the end of the hole, unless instructed otherwise. When pressing in an oil or grease seal which has manufacturer's marks, press it in with the marks facing out. (14)Circlip, Retaining Ring, and Cotter Pin When installing circips and retaining rings, take care to compress or expand them only enough to install them and no more. Install the circlip with its chamfered side facing load side as well. Replace any circlips, retaining rings, and cotter pins that were removed with new ones, as re- moval weakens and deforms them. If old ones are reused, they could become detached while the motoreycle is driven, leading to a major problem. (15)Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the sliding surfaces have an adequate lubricative film. During assembly, make sure to apply ail to any sliding surface or bearing that has been cleaned. Old grease or dirty oil could have lost its lubricative quality and may contain foreign particles that act as abrasives; therefore, make sure to wipe it off and apply fresh grease or oil. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended (16)Direction of Engine Rotation To rotate the crankshaft manually, make sure to do so in the direction of positive rotation. Pos- itive rotation is counterclockwise as viewed from the left side of the engine. To carry out proper adjustment, itis furthermore necessary to rotate the engine in the direction of positive rotation as well (17)Replacement Parts When there is a replacement instruction, replace these parts with new ones every time they are removed. Replacement parts will be damaged or lose their original function once they are removed. There- fore, always replace these parts with new ones every time they are removed. Although the pre= viously mentioned gasket, O-ring, ball bearing, needle bearing, grease seal, oil seal, circlip, and cotter pin have not been so designated in their respective text, they are replacement parts. (18)Electrical Wires All the electrical wires are either one-color or two-color. A two-color wire is identified first by the primary color and then the stripe color. For example, a yellow wire with thin red stripes is referred to as a "yellow/ted’” wire; it would be a “rediyellow” wire if the colors were reversed. Unless in- structed otherwise, electrical wires must be connected to wires of the same color. Two-Color Electrical jeated on the Wire [Wire (cross-section) | color | fed Red1-4 GENERAL INFORMATION Before Servicing (19)Inspection When parts have been disassembled, visually inspect these parts for the following conditions. or other damage. If there is any doubt as to the condition of them, replace them with new ones. Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure (20)Specifications Specification terms are defined as follows: "Standards" show dimensions or performances which brand-new parts or systems have "Service Limits" indicate the usable limits. If the measurement shows excessive wear or dete- riorated performance, replace the damaged parts.GENERAL INFORMATION 1-5 Model Identification \VN800-B5 Left Side View: \VN800-B5 Right Side View:1-6 GENERAL INFORMATION Model Identification \VN800-B6 Left Side View: N800-B6 Right Side View:GENERAL INFORMATION 1-7 General Specifications Items ‘VN800-B1 ~ B4 Dimensions Overall Length }2 390 mm (94.1 in.), (CA) (US) (MY) 2 375 mm (93.5 in.) Overall Width 940 mm (37.0 in.), (CA) (US) (MY) 930 mm (36.6 in.) Overall Height 1.125 mm (44.3 in.), (CA) (US) (MY) 1130 mm (44.5 in.) Wheelbase 1600 mm (63.0 in.) Road Clearance 135 mm (6.3 in.) Seat Height 705 mm (27.8 in.) Dry Mass 1235 kg (518 Ib), (CA) (US) (MY) 234 kg (516 Ib), (CAL) 234.5 kg (517 Ib) Curb Mass: Front 416 kg (256 Ib), (CA) (US) (MY) 115 kg (254 Ib) Rear 138 kg (304 Ib), (CAL) 138.5 kg (305 Ib) Fuel Tank Capacity 15.0 L (4.0 us gal) Performance Minimum Turning Radius _|2.9 m (9.5 ft) Engine Type /4-Stroke, SOHC, V2-cylinder Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plugs Cylinder Numbering Method Firing order Valve Timing: Intet Open Close Liquid-cooled 188.0 x 66.2 mm (3.46 x 2.61 in.) 805 om? (49.1 ou in.) 95:4 40.5 KW (55 PS) @7 000 rimin (rpm), (CA) (MY) 44.1 kW (60 PS) @7 500 r/min (rpm), (CH) 24.2 kW (33 PS) @6 000 r/min (rpm), (FR) 39.3 kW (53 PS) @7 000 r/min (rpm) (UTAC's norm), (us) --- J64 N-m (6.5 kgfim, 47.0 ft-lb) @3 300 r/min (rpm), (CA) (MY) 64.7 N'm (6.6 kg, 47.7 ft'lb) @3 500 r/min (rpm), (CH) 55 N-m (5.6 kgf'm, 40.5 ft1b) @3 000 r/min (rpm), (FR) (GB) (US) - -- Carburetor, Keihin CVK36 Electric starter Battery and coil (transistorized) Electronically Advanced (digital igniter) From 5.0° BTDC @1 000 r/min (rpm) to 37.5° BTDC @6 750 timin (rpm) NGK CR7E or ND U22ESR-N Front to rear, 1-2 24 19° BTDC 714° ABDC1-8 GENERAL INFORMATION General Specifications Items VN800-B1 ~ B4 Exhaust Open 69° BBDC Close 31° ATDC Duration 280° Lubrication System Forced lubrication (wet sump) Engine Oil Grade SE, SF or SG class Viscosity SAE10W-40, 10W-50, 20W-40, 20W-50 Capacity 3.2L (3.4 US qt) Drive Train Primary Reduction System Type Gear Reduction Ratio 2.184 (83/38) Clutch Type Wet mutti disc Transmission: Type 5-speed, constant mesh, return shift Gear Ratios: 1st 2,533 (38/15) 2nd 1.650 (33/20) 3rd 1.230 (32/26) 4th 1,000 (29/29) sth [0.857 (24/28) Final Drive System: Type Chain Drive Reduction Ratio 12.470 (42/17) Overall Drive Ratio 4.625 @Top gear Frame Type Tubular, double cradle Caster (Rake Angle) 32° Trail 122 mm (48 in.) Front Tire: Type Tube Size 130/90-16 67H Rear Tire’ Type Tube Size 140/90-16 71H Front Suspension: Type Telescopic fork Wheel Travel 150 mm (5.9 in.) Rear Suspension: Type Swingarm (uni-trak) Wheel Travel 100 mm (3.9 in.) Brake Type:GENERAL INFORMATION 1-9 General Specifications Rated Output Items ‘VN800-B1 ~ B4 Rear Drum Electrical Equipment Battery 12V 12 Ah Headlight: Type Semi-sealed beam Bulb 12 V 60/55 W (quartz-halogen) Tailibrake Light 12.V 5/21 W x 2, (CA) (US) (MY) 12 V 8/27 W x2 Alternator: Type Three-phase AC [23.5 A x 14 V @8 000 r/min (rpm) Specifications are subject to change without notice, and may not apply to every country. (CA): Canada Model (CAL):Califoria Model (CH): Switzerland Model (FR): France Model (GB): United Kingdom Model (MY): Malaysia Mode! (US): United Sates Model1-10 GENERAL INFORMATION General Specifications items ‘VN800-B5 ‘VN800-B6 ~ B7 Dimensions Overall Length 2 380 mm (93.7 in,), (CA) (US) (MY) 2 375 mm (93.5 in.) Overall Width }940 mm (37.0 in.), (CA) (US) (MY) 930 mm (36.6 in.) Overall Height 4125 mm (44.3 in.), (CA) (US) (MY) 1 130 mm (44.5 in.) Wheelbase 1.600 mm (63.0 in.) Road Clearance 135 mm (6.3 in.) Seat Height 705 mm (27.8 in.) Dry Mass }235 kg (518 Ib), (CA) (US) (MY) 234 kg (516 Ib), (CAL) 234.5 kg (617 Ib) Curb Mass: Front 116 kg (255 Ib), (CA) (US) (MY) 115 kg (254 Ib) Rear 138 kg (304 Ib), (CAL) 138.5 kg (305 Ib) Fuel Tank Capacity 15.0 L (4.0 us gal) Performance Minimum Turning Radius [2.9 m (9.5 ft) Engine Type 4-Stroke, SOHC, V2-cylinder Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plugs Cylinder Numbering Method Firing order Valve Timing: Intet Open Alec Liquid-cooled 188.0 x 66.2 mm (3.46 x 2.61 in.) }805 cm* (49.1 cu in.) 9.5: 1 40.5 kW (55 PS) @7 000 rimin (rpm), (CA) (MY) 44.1 kW (60 PS) @7 500 r/min (rpm), (CH) 24.2 KW (33 PS) @6 000 r/min (rpm), (us) --- J64 N-m (6.5 kgfm, 47.0 ft-b) @3 300 r/min (rpm), (CA) (MY) 64.7 N-m (6.6 kg, 47.7 ftlb) @3 500 r/min (rpm), (CH) 55 N-m (5.6 kgf-m, 40.5 ft'tb) @3 000 r/min (rpm), (GB) (US) --— |Carburetor, Keihin CVK36 Electric starter Battery and coil (transistorized) Electronically Advanced (digital igniter) From 5.0° BTDC @1 000 rimin (rpm) to 37.5° BTDC @6 750 timin (rpm) (CAL) From 5.0° BTDC @1 300 r/min (rpm) to 37.5° BTDC @6 '750 rimin (rpm) NGK CR7E or ND U22ESR-N Front to rear, 1-2 24 19° BTDC sae RBAGENERAL INFORMATION 1-11 General Specifications tems ‘VN800-B5 ‘VN800-B6 ~ B7 Exhaust Open 69° BBDC Close 31° ATDG. Duration 280° Lubrication System Forced lubrication (wet sump) Engine Oil: Grade SE, SF or SG class, API SE, SF, or SG Viscosity SAE 10W-40, 10W-50, 20W-40, |API SH or SJ with JASO MA lor 20-50 SAE 10W-40 Capacity 3.2 3.4 US at) Drive Train Primary Reduction System Type Gear Reduction Ratio 2.184 (83/38) Clutch Type Wet multi dise Transmission: 5-speed, constant mesh, retum shift Type Gear Ratios: ist 2.533 (38/15) 2nd 1,650 (33/20) 3rd 1.230 (32/26) ath 1,000 (29/29) 5th [0.857 (24/28) Final Drive System: Type Chain Drive Reduction Ratio Overall Drive Ratio 2.470 (42/17) 4.625 @Top gear Frame Type Caster (Rake Angle) Trail Front Tire: Type Size Rear Tire! Type Size Front Suspension: Type Wheel Travel Rear Suspension: Type Whee! Travel Tubular, double cradle 32° 122 mm (4.8 in.) Tube 130/90-16 67H Tube 140/90-16 71H Telescopic fork 150 mm (5.9 in.) Swingarm (uni-trak) 100 mm (3.9 in.)1-12 GENERAL INFORMATION General Specifications Headlight: Type Bulb Tail/brake Light |Semi-sealed beam 12 V 60/55 W (quartz-halogen) Items ‘VN800-B5 VN800-B6 ~ B7 Brake Type’ Front Single disc Rear Drum Electrical Equipment Battery 12V 12 Ah 12 V 5/21 Wx 2 (CA) (US) (MY) 12 V 8/27 W x 2 12 V 5/21 Wx 2 Alternator: Type Rated Output Three-phase AC 23.5 A @8 000 r/min (rpm), 14 V Specifications are subject to change without notice, and may not apply to every country. (CA): Canada Model (CAL):California Model (CH): Switzerland Model (FR): France Model (GB): United Kingdom Mode! (MY): Malaysia Mode! (US): United Sates Mode!GENERAL INFORMATION 1-13 General Specifications Items ‘VN800-B8 ~, BEF Dimensions Overall Length 2.380 mm (93.7 in.), (CA) (US) 2 375 mm (93.5 in.) Overall Width 940 mm (37.0 in.), (CA) (US) 930 mm (36.6 in.) Overall Height 1125 mm (44.3 in.), (CA) (US) 1 130 mm (44.5 in.) Wheelbase 1.600 mm (63.0 in.) Road Clearance 135 mm (5.3 in.) Seat Height 705 mm (27.8 in.) Dry Mass 235 kg (518 Ib), (CA) (US) 234 kg (516 Ib), (CAL) 234.5 kg (517 Ib) Curb Mass: Front 116 kg (255 Ib), (CA) (US) 115 kg (254 Ib) Rear 138 kg (304 Ib), (CAL) 138.5 kg (305 Ib) Fuel Tank Capacity 15.0 L (4.0 US gal) Performance Minimum Turning Radius 2.9 m (9.5 ft) Engine Type 4-Stroke, SOHC, V2-cylinder Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plugs Cylinder Numbering Method Firing order Valve Timing: Inlet Open Close Duration Liquid-cooled 88.0 * 66.2 mm (3.46 x 261 in) 805 em? (49.1 cu in.) 95:1 40.5 KW (55 PS) @7 000 r/min (rpm), (CA) 44.1 kW (60 PS) @7 500 r/min (rpm), (US) -— 64 Nem (6.5 kgm, 47.0 fell) @3 300 r/min (rpm), (CA) 64.7 N-m (6.6 kg, 47.7 ft lb) @3 500 r/min (rpm), (us)--- Carburetor, Keihin CVK36 Electric starter Battery and coil (transistorized) Electronically Advanced (digital igniter) From 5.0° BTDG @1 000 r/min (rpm) to 37.5° BTDC @6 750 min (rpm) (CAL) From §.0° BTDC @1 300 r/min (rpm) to 37.5° BTDC @6 750 r/min (rpm) NGK CR7E or ND U22ESR-N Front to rear, 1-2 24 19° BTDC. 71° ABDC 270°1-14 GENERAL INFORMATION General Specifications Items VN800-B8 ~, BEF Close 34° ATOC Duration 280° Lubrication System Forced lubrication (wet sump) Engine Oil Grade API SE, SF, or SG, Viscosity API SH or SJ with JASO MA SAE 10W-40 Capacity 3.2L (3.4 US at) Drive Train Primary Reduction System Type Gear Reduction Ratio 2.184 (83/38) Clutch Type Wet muti disc Transmission: 5-speed, constant mesh, return shift Type Gear Ratios: Ast 2.533 (38/15) 2nd 1,650 (33/20) 3rd 1.230 (32/26) 4th 1.000 (29/29) sth 0.857 (24/28) Final Drive System: Type Chain Drive Reduction Ratio 2.470 (42/17) Overall Drive Ratio 4.625 @Top gear Frame Type Tubular, double cradle Caster (Rake Angle) 32° Trail 123 mm (4.8 in.) Front Tire: Type Tube Size 130/90-16MC 67H Rear Tire’ Type Tube Size 140/90-16MC 71H Front Suspension: Type Telescopic fork Wheel Travel 150 mm (5.9 in.) Rear Suspension: Type ‘Swingarm (uni-trak) Wheel Travel 100 mm (3.9 in.) Brake Type: Front Single discGENERAL INFORMATION 1-15 General Specifications Items: ‘VN800-B8 ~, BEF Electrical Equipment Battery Headlight: Type Bulb Tail/brake Light Alternator: Type Rated Output 12 V 12 Ah (VN800-B8 Model) 12 V 10 Ah (VN800-B9 ~ Model) Semi-sealed beam 12 V 60/55 W (quartz-halogen) 12.V 5/21 W x2 Three-phase AC 23.5 A @B 000 r/min (rpm), 14 V Specifications are subject to change without notice, and may not apply to every country. (CA): Canada Model (CAL):Califoria Model (US): United Sates Model1-16 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Units of Length: km, x 06214 = mille Prefix | Symbol Power m x 3281 = ft mega M % 4000 000 mm x 0.03937 = in kilo k x 1.000 centi c x 0.01 Units of Torque: mill m x 0.001 Nm x 0.1020 = —kgfm micro u x 0.000001 Nm x 0.7376 = ftlb Nm x 8.851 intb kgtm «9.807 Nem Units of Mass: kgfm x= 7.233 = ttl kg ® 2205 = ob kgfm x 86.80 = int g x 0.03527 = oz Units of Pressure: Units of Volume: kPa x 0.01020 = kgflcm# L x 0.2642 = — gal (US) kPa x 0.1450 = _—ipsi L x 0.2200 gal (imp) kPa x _0,7501 cm Hg L x 1.057 at (US) kglicm® x 98.07 kPa L x 0.8799 at (imp) kgflom? x = 14.22 = psi L x 2.413 = pint (US) cmHg x 1.338 = kPa L x 1816 = pint imp) mL =x 0.03381 oz (US) Units of Speed: mL x 0.02816 oz (imp) km/h x 0.6214 = — mph mL = x 0.06102 = ~—cuin Units of Power: Units of Force: kw x 1.360 Ps N * 0.1020 kg kW. x 1.341 HP N x 0.2248 !b PS x 0.7355 kw kg * 9.807 N PS x 0.9863 = HP kg x) 2.208 = bb Units of Temperature: 20°40) _ 4g F SUF +40) yg ag F F a re ee) 176 21288 CP De elm i ge tp op pe 2 le 28 ap afl go om ESTE od 0 2 0 gees pe oo) ley el yor relia eager ; 178 AA P67e athe ee 00S eee 128 aPERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart (United States and Canada)..esnsremeen Periodic Maintenance Chart (Other than United States and Canada) Torque and Locking Agent... Specifications Special Tools Maintenance Procedure Fuel System.. so Fuel Hoses and Connections Inspection Throttle Grip Play Inspection. Idle Speed Inspection Fuel System Cleanliness Inspection Air Cleaner Element Clean Evaporative Emission Control System Inspection Cooling System Water Hoses and Connections Inspection... Coolant Change... Engine Top End Air Suction Valve Inspection Valve Clearance Inspection .. Valve Clearance Adjustment. Clutch, Clutch Inspection Engine Lubrication System Engine Oil Change... Oil Filter Replacement Wheels/Tires. Tire Wear Inspection.. Spoke Tightness and Rim Runout Inspection Final Drive. Drive Chain Slack Inspection Drive Chain Wear Inspection 22 24 26 2-40 242 2413 243 2.43 213 214 2-45 245 2-16 2-16 2-48 218 218 2-49 2-22 2-22 2:23 2-23 2-24 2-24 2:24 2.25 2-26 2-26 2.27 Drive Chain Lubrication. Brakes... . Brake Lining or Pad Wear Inspection Brake Play Inspection... Brake Light Switch Inspection Brake Light Timing Adjustment. Brake Fluid Level Inspection Brake Fluid Change... Bleeding the Brake Line Brake Master Cylinder Cup and Dust Cover Replacement Caliper Fluid and Dust Seals Replacement... 7 Brake Camshaft Lubricate Brake Hoses and Connections Inspection... Brake Hose Replacement... Suspension Front Fork Oil Change Front Fork Oil Leak Inspection. Rear Shock Absorber Oil Leak Inspection Swingarm Pivot Lubrication Unietrak Linkage Lubrication Steering . . Steering Inspection. Steering Stem Bearing Lubrication. Electrical System sas sensn ssn Spark Plug Cleaning and Inspection Spark Plug Gap Inspection... General Lubrication 7 Lubrication Nut, Bolts, and Fasteners Tightness Inspection. Tightness Inspection . 2-28 2.29 2.29 2-30 231 231 231 2.32 232 2:34 2.34 2.34 2:35 2.35 2:35 2:35 2.36 2.36 2.37 2.37 2.37 2.37 2-38 2.38 2-38 2-39 2.39 2.39 2-40 2-402-2 PERIODIC MAINTENANCE Periodic Maintenance Chart (United States and Canada) The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. FREQUENCY | Whichever * ODOMETER READING ames ay km * 1.000 (mile x 1 000) # = =|08] 5] 10 | 15 | 20 | 25 | 30] See OPERATION Every _|(0.5) )| (6) | (9) |(12)] 15)|(18)] Page [Spark plug-clean and gapt ele [ele |e |e [P2s8 Valve clearance-inspect * + ° ° ° « [P28 Air suction valve-inspect * elelelele le [Pate Air cleaner element-clean * + ° ° : «| P245 Throttle grip play-inspect * + ° ° ° @ [P2183 idle speed-Inspect * olelele [ele |e [pata Fuel system-inspect * . . «| P245 Evaporative emission contro! system wlelelelelele|pate (CAL)-inspect + Fuel hoses, connections-inspect f ele lelele |e [Pats Fuel hose-replace A years = [Coolant-change 2 years « | P216 Water hoses, connections-inspect * + year_| . . « | P216 Engine oll-change * year [efele[e|[e]| | [P22 Oil fiter-repiace . ° : « | P224 [Clutoh-Inspect olelele [ele |e [poz Drive chain wear-inspect “# + o[e[e[[ |e [P227 Drive chain-lubricate # 300 km P2-28 Drive chain slack-inspect “# + 800 km P2-26 Brake lining or pad wear-inspect * t+ ele le lee |e [P2290 Brake fluid level-inspect * + month [« fe[e|e|e|e|« [P23 Brake fluid-change 2 years : P2-32 Brake hose-replace a years P2358 Brake hoses, connections-inspect F elelelele le |P23s Brak ete eder cup ad dt Dyears p24 [Caliper fluid seal and dust seal-replace | 2 years P2384 Brake play-inspect * f olele le [ele |e [P20 Brake light switch-inspect * + ofelele[e|e |e [P23 Brake cable-replace 2 years ° = Brake camshattlubricate 2 years : P2384 [Steering-inspect * f+ ofele [ele] | [ras Steering stem bearing-ubricate years . P2-38 Front fork oil-change «| P2.38 Tire wear-inspect * + elelelelele|pozPERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart (United States and Canada) FREQUENCY whichever * ODOMETER READING km * 1.000 (mile x 1.000) first ¥ [08] 5] 10] 15 | 20] 25] 30] see [OPERATION Every _|(0.5) (3)| (6) | (9) |(12)|(15)|(18)| Page Swingarm pivot, uni-trak linkage-lubricate . . © | P2387 [General lubrication-perform «fe lee] | [P239 Nu, bolts, and fasteners tightness-inspect . . . » | p240 #: Service more frequently when operating in severe conditions: dusty, wet, muddy, highspeed, or frequent starting/stopping, +: For higher odometer readings, repeat at the frequency interval established here. *: Replace, add, adjust, clean, or torque if necessary. CAL: California Model only2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart (Other than United States and Canada) The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. FREQUENCY) Whichever * ODOMETER READING ames ab km * 1.000 (mile x 1 000) + 1 | 6 | 12] 18 | 24] 30 | 36 | See OPERATION Every _|(0.6) (4) |(7-5)](12)|(15)| (20) (24)] Page [Spark plug-clean and gap + ele [ele |e | [P2s8 Valve clearance inspectt ° ° « [P28 Air suction valve-inspect f elelelele le [Pate Air cleaner element-cleant # ° : «| P245 Throttle grip play-inspect + ° ° ° @ [P2183 idle speed-Inspect * . ° : « [pata Fuel hoses, connections-inspect t ele le le |e |e [pats Engine ol-change # 6 months |e |e] «|e |e | «| « | P2238 Oil fiterrepiace . . : @ | P2-24 Water hoses, connections-inspect + : P2-16 [Coolant-change 2 years . P2146 [Clutch-inspect elele le [ele |e [raz Drive chain wear-inspect t # ele le le |e |e [P22 Drive chain-lubricate # 300 mm P228 Drive chain slack-inspect t # 800 km P2-26 Brake hoses, connections-inspect t [ele [el |e [Poss Brake lining or pad wear-inspect t # ele lel |e |e [P229 Brake fluid level-inspect t month [«[ele|[e|e|e|« |p2a1 Brake fluid-change 2 years : 2-32 Broke master eynder cup and ist |g yaar p234 [Caliper fluid seal and dust seal-replace | 4 years P2348 Brake play-inspect + olele le [ele |e [P230 Brake light switch-inspect + ofele lee |e |e [P23 Brake cable-replace 2 years . = [Steering-inspect t olelele [ele |e [P2a7 [Steering stem bearing-lubricate 2 years . P2-38 Front fork oilchange 2 years : P2358 Front fork oil leakcinspect + ° . « | P236 Rear shock absorber oil leak-inspect ° : @ | P2:36 Tire wear-inspect + ele le le |e |e [P22 Spoke Soke end din rope stele lelele le |eazs ners ot uen wf fe] fe feesPERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart (Other than United States and Canada) FREGUENGY] Wcever ~ ODOWETER READING ‘ > km * 1 000 (mile x 1 000) irst + 1 | 6] 12] 18] 24 | 30] 36] see JOPERATION Every _[(0.6) (4) |(7.5)| (12)| (15) | (20) |(24)| Page Nuts, bolts, and fastener tightness-inspect + : . : © | P2-40 #: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed, or frequent starting/stopping. *: For higher odometer readings, repeat at the frequency interval established here. +t: Replace, add, adjust, clean, or torque if necessary.2-6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: L: Apply a non-permanent locking agent to the threads MO: Apply molybdenum disulfide oil (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1). : Apply an oil to the threads, seating surface, or washer. S: Tighten the fasteners following the specified sequence. 88: Apply silicone sealant. Torque Fastener mete | ee] Remarks Fuel System Fuel Tap Mounting Bolts 25 025 | 22inib | With white washer Fuel Tap Mounting Bolts 49 | 050 | 43 ini | with black washer Carburetor Holder Plate Mounting Bolts " 11 | 95inb Air Cleaner Element Cover Mounting Nut " 11 | 98 into Air Cleaner Housing Mounting Bolts " 11 [ 95 in [Cooling System Water Pump Impeller Nut " 14 | 95inb Water Hose Fitting Bolts " 11 | 95inb Water Hose Clamp Screws 20 | o2 | 17inb Radiator Fan Switch we | 18 13 ss Water Temperature Sensor 78 | o8 | 69inb | ss Coolant Drain Plug " 14 _|_ 95 nb Engine Top End Cylinder Head Cover Bolts 12 12 | 104 intb Cylinder Head Nuts: 10 mm 3a | 40 29 s 8mm 2 | 25 18 s Cylinder Head Bolts 12 12 | 104i | s Cylinder Nuts 2 | 25 18 Camshaft Cap Bolts 2 | 25 18 Camshaft Sprocket Bolts 49 | 50 36 L Camshaft Chain Tensioner Cap Bolts 20 | 20 145 Camshaft Chain Guide Bolts " 11 | 95inb L Intake Manifold Bolts 12 12 | 104 intb Cylinder Head Cover Damper Plate Bolts 7s_|_o8 | soinb | Ls felutch Clutch Hub Nut 132. | 135 98 ° Clutch Spring Botts 3a | o9 | 78inb Right Engine Cover Bolts 12 12 | tosinh | L() Engine Lubrication System Engine Drain Plug 2 | 20 44,5PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Nm kgm fe] Remarks Oil Pump Drive Chain Guide Bolt 2 12 | 104 intb U Oil Filter 18 18 3 Oil Filter Plate Mounting Bolts 78 08 69 intb Oil Screen Plug 20 20 145 Oil Pressure Relief Valve 15 15 1 L Oil Pressure Switch 15 15 1 ss Oil Pressure Switch Adapter 20 20 145 Oil Pipe Mounting Bolts (Crankcase Inside) 1 14 95 in L Oil Pipe Mounting Bolts (Crankcase Outside) 54 055 | 48 inib U Oil passage Cover Screws (Crankcase Outside) | 5.4 055 | 48 inib L Engine Removal/installation Engine Mounting Nuts 44 45 33 Engine Mounting Bracket Bolts 25 25 18 Down Tube Mounting Bolts 44 45 33 [Crankshaft/Transmission Crankcase Bolts 10 mm 39 40 29 s 6mm " 44 95 int Connecting Rod Big End Cap Nuts 46 47 34 Mo Primary Gear Bolt 157 16 116 ° Balancer Gear Bolt 69 70 51 L Starter Motor Clutch Gear Bolt 69 70 51 L Starter Motor Clutch Bolts 34 35 25 L Output Shaft Bearing Stopper Bolts 2 1.2 | 104 inlb Balancer Shaft Bearing Stopper Bolts 1" 14 965 in Shift Drum Bearing Stopper Bolts " 44 95 int Transmission Cover Bolts 1" 14 95 ini Extemal Shift Mechanism Cover Bolts " 44 95 in Shift Shaft Return Spring Pin 29 3.0 22 L Shift Drum Position Lever Bolt " 14 95 ini Neutral Switch 15 15 1 Shift Pedal Pivot Bolt 29 3.0 22 Shift Pedal Pivot Bolt Nut 29 30 2 Shift Drum Cam Holder Screw 2 1.2 | 104 int L Shift Lever Clamp Bolt 12 12 | 104 in-b Wheels/Tires: Front Axle Clamp Bolt 34 35 25 Front Axle Nut 108 1 80 Rear Axle Nut 98 10 72 ‘Spoke Nipples 49 05 | 43 intb Final Drive Engine Sprocket Nut 427 43 94 Mo2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener a) Fie] Remarks Rear Sprocket Stud Bolts : = = u Brakes Torque Link Nuts 34 35 25 Front Caliper Mounting Bolts 34 35 25 Brake Disc Mounting Bolts 27 28 20 L Brake Hose Banjo Bolts 4 35 25 Bleed Valve 78 08 69 intb Rear Brake Lever Clamp Bolt 25 25 18 Front Master Cylinder Clamp Bolts 88 090 | 78 intb Brake Lever Pivot Bolt 1.0 04 9 intb Brake Lever Pivot Bolt Locknut 59 06 52 inib Reservoir Cap Screws 15 015 | 13 inib Front Brake Light Switch Screws 12 012 | 10 inib [Suspension Front Fork Clamp Bolts: upper 20 20 145 lower 34 35 25 Front Fork Bottom Allen Bolts 20 20 145 L Spacer Allen Bolt 44 045 | 39 inib Rear Shock Absorber Nuts 59 60 43 ‘Swingarm Pivot Shaft Nut 98 10 72 Rocker Arm Pivot Shaft Nut 98 10 72 Tie-Rod Nuts 59 60 43 Fork Cover Bolts 5 mm 8 08 11 int Fork Cover Bolts 6 mm 13 13 | 113 intb [Steering Handlebar Holder Bolts 34 35 25 Handlebar Holder Mounting Nuts 34 35 25 Steering Stem Head Bolt 44 45 33 Steering Stem Nut 49 05 | 43 intb Frame Side Stand Pivot Nut 44 45 33 Rear Frame Mounting Bolts 44 45 33 Muffler Bracket Mounting Bolts 25 25 18 Hootpeg Holder Bolts 34 35 25 Electrical System Alternator Cover Bolts 12 1.2 | 104inb | L(1) Timing Inspection Cover Screw 49 05 | 43 intb Alternator Rotor Bolt 157 16 115 ° Stator Coil Bolts 13 13° | 113 intb Pickup Coil Bolts 78 o8 69 inib Alternator Lead Clamp Bolts 78 08 69 intbPERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Nm kgm fe] Remarks Starter Motor Mounting Bolts 11 11 95 inib Starler Motor Through Bolts 49 05 | 43 intb Starter Motor Terminal Nut " 14 95 inb Starter Motor Cable Nuts 49 05 | 43 intb Side Stand Switch Mounting Bolt 39 04 35 intb L values are for use with dry solvent-cleaned threads. Basic Torque for General Fasteners The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the Threads Torque dia. (mm) Nm kgm fb 5 34-49 0.35 ~ 0.50 30 ~ 43 int 6 59~78 0.60 ~ 0.80 52 ~ 69 in-b 8 14 ~19 14-19 10.0 ~ 13.5 10 25 ~ 34 26~35 19.0 ~ 25 2 44 ~ 61 45~62 33 ~ 45 4 73 ~ 98 74 ~ 100 54 ~ 72 16 115 ~ 155 11.5 ~ 16.0 83 ~ 115, 18 165 ~ 225 17.0 ~ 23.0 125 ~ 165 20 225 ~ 325 23 ~ 33 165 ~ 2402-10 PERIODIC MAINTENANCE Specifications Item! Standard Fuel System === Throttle Grip Free Play 2~3 mm (0.08 ~ 0.12 in.) Idle Speed 1000 £50 r/min (rpm) (CH, CAL) 1 300 #50 rimin (rpm) Air Cleaner Element Polyurethane foam [Cooling System === Coolant: Type (recommended) Permanent type antifreeze Color Green Mixed ratio Soft water 50%, Coolant 50% Freezing point 35°C (-31°F) Total amount 2.4L (2.5 US at.) Engine Top End Valve Clearance: 3.2 L (3.4 US at, when engine is completely dry) Between upper and lower level lines Inlet 0.10 ~ 0.15 mm (0.004 ~ 0.006 in.) Exhaust 0.20 ~ 0.25 mm (0.008 ~ 0.010 in.) [Clutch == Clutch Lever Free Play 2.~ 3mm (0.08 ~ 0.12 in.) Engine Lubrication System === Engine Oil Type API SE, SF or SG API SH or SJ with JASO MA Viscosity SAE 10W-40 Capacity 2.7L (2.9 US qt, when fiter is not removed) 2.9L (3.1 US qt, when filter is removed) Level (Wait 2 ~ 3 minutes after idling or running) Tires Tread Depth: Front DUNLOP 4.5 mm (0.18 in.) 4mm (0.04 in.) BRIDGESTONE 4.8 mm (0.19 in.) (DE, AT, CH) 1.6 mm (0.06 in.) Rear DUNLOP 7.3 mm (0.29 in.) Up to 130 km/h (80 mph): 2mm (0.08 in.) BRIDGESTONE 7.2. mm (0.28 in.) Over 130 km/h (80 mph) 3mm (0.12 in.)PERIODIC MAINTENANCE 2-11 Specifications Item ‘Standard Service Limit Rim Runout (with tire installed) Radial Axial TIR 4.0 mm (0.04 in.) or less TIR 0.8 mm (0.03 in.) or less TIR 2.0 mm (0.08 in.) TIR 2.0 mm (0.08 in.) Final Drive Drive Chain Slack Drive Chain Wear (20-link length) 25 ~ 35 mm (1.0 ~ 1.4 in.) 317.5 ~ 318.2 mm (12.50 ~ 12.53 in.) 323 mm (12.7 in.) Brakes Brake fluid Grade DoT4 --- Brake pad lining thickness: Inner 4.5 mm (0.18 in.) 4 mm (0.04 in.) Outer 4.7 mm (0.19 in.) 4 mm (0.04 in.) Brake light timing Front Pulled ON r 1 . Rear uae 5 mm (0.6 in.) of [Suspension Fork Oil: Viscosity SHOWA SS8 or equivalent --- Amount: When changing oil disassembly and completely dry Fork oil level: (fully compressed, without spring, below from the top of the inner tube) approx. 265 mL (9.0 US oz) 310 #4 mL (10.5 £0.14 US 02) 286 42 mm (11.26 £0.08 in.) Electrical System Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in.) (AT): Austria Model (CAL):Califoria Model (CH): Switzerland Model (DE): Germany Mode!2-12 PERIODIC MAINTENANCE Special Tools ‘Steering Stem Nut Wrench: Carburetor Drain Plug Wrench, Hex 3: 57001-1269 57001-1100 RO SS stornioosr € Jack: Fork Oil Level Gauge: 7001-1238 57001-1290 Oi Filter Wrench: Jack Attachment #3: 5700129 srooiaie es ae S71PERIODIC MAINTENANCE 2-13 Maintenance Procedure Fuel System Fuel Hoses and Connections Inspection The fuel hoses are designed to be used throughout the motoreycle's life without any maintenance, however, ifthe motorcycle is not properly handled, the inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (see Fuel System chapter) and check the fuel hose. ‘Replace the fuel hose if any fraying, cracks [B] or bulges {C] are noticed ‘* Check that the hoses are securely connected and clamps are tightened correctly. ‘* When installing, route the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter. ‘© When installing the fuel hoses, avoid sharp bending, kink- ing, flattening or twisting, and route the fuel hoses with a minimum of bending so that the fuel flow will not be ob- structed ‘Replace the hose if it has been sharply bent or kinked. Fi the fuel hose [A] onto the pipe fully and install the plate clamp [B] beyond the raised rib [C] 1~ 2mm (0.04 ~0.08 in.) [D] Throttle Grip Play Inspection * Check the throttle grip free play [A]. IF the free play is incorrect, adjust the throttle cable, Throttle Grip Free Play Standard: 2~ 3 mm (0.08 ~ 0.12 in.) © Check that the throttle grip moves smoothly from full open to close, and the throttle closes quickly and completely in all steering positions by the retum spring. ‘if the throttle grip does not return property, check the throt- tle cable routing, grip free play, and cable damage, Then lubricate the throttle cable. ‘® Run the engine at the idle speed, and turn the handlebar allthe way to the right and left to ensure that the idle speed does not change. If the idle speed increase, check the throttle cable free play and the cable routing2-14 PERIODIC MAINTENANCE Maintenance Procedure If necessary, adjust the throttle cable as follows ® Loosen the locknuts [A]. © Screw the adjusters [B] in completely so as to give the throttle grip plenty of play. ‘© Tum out the decelerator cable [C] adjuster until there is no play when the throttle grip is completely closed. ‘* Tighten the locknut, ‘* Tum the accelerator cable [D] adjuster until the proper amount of throttle grip free play is obtained. # Tighten the locknut, If the proper amount of free play cannot be obtained by using the adjusters, use the adjusters middle of the throt- tle cables. First give the throttle grip plenty of play by turning the adjusters at the grip in fully ‘* Remove the fuel tank (see Fuel Tank Removal). ® Loosen the locknuts [A] © Tum the adjusters [B] fully at the middle of the throttle cables so as to give the throttle grip plenty of play. ‘© With the throttle grip completely closed, turn the deceler- ator cable [C] adjuster until the inner cable just becomes tight. Tighten the locknut, * Tum the accelerator cable [D] adjuster until the correct throttle grip free play is obtain. Tighten the locknut Idle Speed Inspection Idle Speed Inspection start the engine and warm it up thoroughly. © With the engine idling, turn the handlebar to both sides. If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed, or damaged. Be sure to correct any of these conditions before riding (see Cable, Wire, and Hose Routing section in the Appendix chapter). PN Te Operation with improperly adjusted, incorrectly routed, or damaged cables could result in an un- safe riding cond © Check idle speed If the idle speed is out of the specified range, adjust it. Idle Speed Standard: 1.000 50 r/min (rpm) 4 300 £50 r/min (rpm) (Switzerland, California Model)PERIODIC MAINTENANCE 2-15 Maintenance Procedure Idle Speed Adjustment start the engine and warm it up thoroughly. '* Turn the adjusting screw (A] until the idle speed is correct. ©Open and close the throttle a few times to make sure that the idle speed is within the specified range, Readjust if necessary. Fuel System Cleanliness Inspection PRO Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. ‘* Remove the fuel tank (see Fuel System chapter) ‘* Connect a suitable hose [A] to the fitting at the bottom of the carburetor float bowl ‘® Run the lower end of the hose into a suitable container. ‘© Turn out the drain plug (B] a few turns and drain the float bowl. Special Tool - Carburetor Drain Plug Wrench, Hex 3: 57001-1269 ‘© Check to see if water or dirt comes out ‘* Tighten the drain plug. If any water or dirt appears during the above inspection, clean the fuel system (see Carburetor Cleaning and Fuel Tank Cleaning in Fuel System Chapter). Air Cleaner Element Clean ‘® Remove the air cleaner element (see Fuel System chap- ter) * Clean the element by tapping it lightly to loosen dust. ‘* Blow away the remaining dust by applying compressed air [A] from the inside to the outside (from the clean side to the dirty side). * Visually check the element for tears or breaks and check the sponge gasket [B] also. xf the element has any tears or breaks, replace the ele- ment.2-16 PERIODIC MAINTENANCE Maintenance Procedure Evaporative Emission Control System Inspection # Inspect the California canister as follows: ORemove the canister, and disconnect the hoses from the canister. Visually insect the canister for cracks for cracks and other damage. If the canister has any cracks or bad damage, replace it with a new one. NOTE The canister is designed to work welll through the motor- oycle’s life without any maintenance if it is used under normal conditions. '® Check the California liquid/vapor separator as follows Disconnect the hoses from the liquid/vapor separator, and remove the separator from the motorcycle. Visually inspect the separator for cracks and other dam- age If the separator has any cracks or is badly damaged, re- place it with a new one. ‘* Check the hoses of the California evaporative emission control system as follows ©Check that the hoses are securely connected and clips are in position. Replace any kinked, deteriorated or damaged hoses Route the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter. When installing the hoses, avoid sharp bending, kinking, flattening or twisting, and route the hoses with a minimum of bending so that the emission flow will not be obstructed. Cooling System Water Hoses and Connections Inspection The high pressure inside the water hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen. ‘Replace the hose if any fraying, cracks [B] or bulges [C] are noticed. © Check that the hoses are securely connected and clamps are tightened correctly. Torque - Water Hose Clamp Screws: 2.0 N'm (0.20 kfm, 17 intb) Coolant Change To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery and can cause an accident and injury. Immediately wipe up or wash away any coolant that spills on the frame, engine, or other painted parts.PERIODIC MAINTENANCE 2-17 Maintenance Procedure * Remove: Meter Unit (see Electrical System chapter) Radiator Cap [A] ‘* Place a container under the drain plug [A] at the bottom of the right crankcase. ‘© Drain the coolant from the radiator and engine by remov- ing the drain plug. ‘® Remove the cap and pump out the coolantusing a syringe or some other suitable device Tighten: Torque - Coolant Drain Plug: 11 N-m (1.1 kgf-m, 95 in-lb) Fill the radiator up to the radiator filler neck [A] with coolant, and install the radiator cap. NOTE Pour in the coolant slowly so that it can expel the air from the engine and radiator. ‘Fill the reserve tank up to the full (‘F") level line with coolant, and install the cap. CAUTION Soft or distilled water must be used with the an- .eze (see below for antifreeze) in the cooling sys- tem. If hard water is used in the system, it causes scales accumulation in the water passages, and consider- ably reduces the efficiency of the cooling system. Water and Coolant Mixture Ratio (Recommended) ‘Soft Water: 50% Coolant: 50% Freezing Point: —35°C (31°F) Total Amount: 2.4L (2.1 US at) NOTE Choose a suitable mixture ratio by referring to the coolant manufacturer's directions.2-18 PERIODIC MAINTENANCE Maintenance Procedure * Bleed the air from the cooling system as follows. Start the engine with the radiator cap removed and run it until no more air bubbles [A] can be seen in the coolant. Tap the water hoses to force any air bubbles caught it side. Stop the engine and add coolant up to the radiator filer neck. ‘Install the radiator cap start the engine, warm it up thoroughly until the radiator fan turns on and then stop the engine. * Check the coolant level in the reserve tank after the en- gine cools down. xf the coolant level is lower than the low level line, add coolant to the full level line. CAUTION Do not add more coolant above the full level line. Engine Top End Air Suction Valve Inspection ® Visually insect the reed [A] for cracks, folds, warps, heat damage, or other damage, xIfthere is any doubt as to the condition of the reed, replace the air suction valve as an assembly. ‘© Check the reed contact areas [B] of the valve holder for grooves, scratches, any signs of separation form the holder, or heat damage. 4 Ifthere is any doubt as to the condition of the reed contact areas, replace the air suction valve as an assembly. +f any carbon or other foreign particles have accumulated between the reed and the reed contact area, wash the valve assembly with a high flash-point solvent. CAUTION Do not scrape off the deposits with a scraper as this, could damage the rubber, requiring replacement of the suction valve assembly. Valve Clearance Inspection NOTE Valve clearance must be checked and adjusted when the engine is cold (at room temperature). * Remove: Cylinder Head Cover (see Engine Top End chapter) Timing Inspection Cover (Engine Left Side) Set the front piston at TDC (see Engine Top End chapter) * Using a thickness gauge [A], measure the valve clearance between the rocker arm [B] and the shim [C].PERIODIC MAINTENANCE 2-19 Maintenance Procedure © Set the rear piston at TDC by turning the crankshaft coun- terclockwise 305° (see Engine Top End chapter). * Using a thickness gauge, measure the valve clearance between the rocker arm and the shim Valve Clearance Standard: IN 0.10~ 0.15 mm (0.0039 ~ 0.0059 in.) EX: 0.20 ~ 0.25 mm (0.079 ~ 0.010 in.) if the valve clearance is not within the specified range, first record the clearance, and then adjust it. Valve Clearance Adjustment © To change the valve clearance, side the rocker arm [A] sideways and change the shim [B]. Replace the shim with one of a different thickness NOTE Mark and record the shim locations so that the shims can be reinstalled in their original positions. Of there is no clearance, select a shim which is several sizes smaller and then measure the clearance. © To select a new shim which brings the valve clearance within the specified range, refer to the Valve Clearance Adjustment Charts, *Remeasure any valve clearance that was adjusted. Readjust if necessary. CAUTION Do not put shim stock under the shim, This may cause the shim to pop out at high rpm, causing ex- tensive engine damage. Do not grind the shim. This may cause it to fracture, causing extensive engine damage.2-20 PERIODIC MAINTENANCE Maintenance Procedure VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE PRESENT Sr a eG a ee er aa lod Bat Pate ie ie ao ae ae of [| roe [ooo aca Tomy ase aesfasolatafeanlaaelealea vwlalao[ sles Sonzaoe) —[rolie|eo [aoe |asw [ane am [aaelom ne ao] em a g[camzome| tisumlumtrilsi|sssiarae sa en et eote[enloe flew SPECIFIED CLEARANCEINO CHANGE REQUIRED cae eat| [aos ana o[ za [zara [200 [ zoe [ aoa [0] (tear =oas| [erolarelzao|aas|a.s0[2.ae[240|2e8|200|2552.40| zas[270|275|200|208|290]295] 300 panear| _{sse[zao[zae|zan[aae|zezar|2coloss[zco[zee|2.ola7|2m|2as[z00[z0e|ao0 re eas[aas [ass so[zes[zve[ alam [sae zz[zos[aoe [ast eae 2a0|2an| 20020 2.7[27| 2] 2o5[20 25300] B [oe ~ ons 285 |240|205|270]2.75|200] 200]290|295|300] Aree 200 |aar|2702 | 200[ 200] 20]205| 308 rer aae|a7|a7an[zas[zs0| 23a = glewzow 27e|a7e| aaa 20 290[ 30 as 3 27 [2o[zas[z00[zoe| sen sa 2 22a a00[20s[a00 Seu 3 | sso[zss[ soo Seue 2 20200 sara 5 eae 3 20. “The shim from 1.70 to 1.96 mm thick are : 2a a0 [26 [300 a 2 [2.06 |2.90 | 2.98 |3.00| 8 aaa 300 INSTALL THE SHIM OF THB THICKNESS (om) za sa 1, Measure the clearance (when engine is cold). 2. Check present shim size 3. Match clearance in vertical column with present shim size in horizontal column. 4, Install the shim specified where the lines intersect, This shim will give the proper clearance. Example: Present shim is 2.60 mm (0.102 in.) Measured clearance is 0.25 mm (0.010 in.) Replace 2,60 mm (0.102 in.) shim with 2.70 mm (0,106 in.) shim. 5, Remeasure the valve clearance and readjust if necessary. NOTE Of there is no clearance, select a shim which is several sizes smaller and then measure the clearance.PERIODIC MAINTENANCE 2-21 Maintenance Procedure VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE PRESENT SHIN Totxanple wax [0 [5 [10] is] 20} as | 20] os] | 5 [so [8 a THVCeMESS Tan) oof, oa vo 15a 20 258 a. asl. ol af sof oof oo. ovale ve. el. ak soe a 0 aoe] fraef ogee ve eae ae a ae a a fe sage Sea) [cafewtonfoolcofewenfercacadeaeafatafesteef ncn mf siren} a aaa a cada aba aecoso] (A oqucoda ade. tolaeda. ae. adn se.ooe ae. gz ee. ode ose. ro. rfa edn oda ood of 31.36) [aoe tole oe eofe ee aoe ae ee cle se. soe ee. of. rfe 1. fe ele. eo. eaeo.ca] facade rd af ale. ae ada ado. fale es af a. fo of acao.es] face ages sl.see- ele eo. poof ot oe Pepe Br) SEC ce sag fo e6so. 70] |e aide adie 52. 52. ode ose 12 7912 sole safe oa? 09.06 Parts No. [Thickness aviso.75] [a asfa. sola see oe ala rola roa ale eal. sa. oa of 92180-1208 | 1.08 ew pend raped ys peed a Se be ae ee eee eree Huet 32100-1213 | 1. 70em 100] facade ag ae VALVE CLEARANCE WEASUREWENT y—Exanple fet) feafeatea The chia fron 170 to 1.08 on thik ave raves] [ese one ofa 0 also available. Tac2o] [asda 993.0 aes.) Ea \INSTALL THE SHIM OF THIS THICKNESS (wn) 1, Measure the clearance (when engine is cold). 2, Check present shim size, 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.55 mm (0.100 in.) Measured clearance is 0.50 mm (0.020 in.) Replace 2.55 mm (0.100 in.) shim with 2.75 mm (0.108 in.) shim. 5, Remeasure the valve clearance and readjust if necessary. NOTE Olf there is no clearance, select a shim which is several2-22 PERIODIC MAINTENANCE Maintenance Procedure Clutch Clutch Inspection Clutch Lever Free Play Inspection Pull the clutch lever just enough to take up the free play Al ‘* Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully. In either case, adjust it. Clutch Lever Free Play Standard 2~3 mm (0.08 ~ 0.12 in.) Clutch Lever Free Play Adjustment * Loosen the locknut [A] at the clutch lever. ‘© Tur the adjuster [B] until the proper amount of clutch lever free play is obtained ‘¢ Tighten the locknut securely. If it cannot be done, use the adjuster at the middle of the cable. AAWARNING exhaust pipe during clutch adjustment. ‘* Loosen the locknut [A] at the middle of the clutch cable. © Turn the adjuster nut [B] until the proper amount of clutch lever free play is obtained, ‘* Tighten the locknut securely. xf it cannot be done, use the mounting nuts at the lower end of the cable ‘* Remove: Front Right Foot Peg and Brake Petal (see Brakes chap- ter) Front muffler (see Engine Top End chapter) * Loosen the locknut [A] at the clutch lever. ‘© Turn the adjuster [B] so that ~ 6 mm (0.20 ~ 0.24 in.) [C] of threads are visible