2015 Vn900 Custom

2015 Vn900 Custom

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• Page 1 VULCAN 900 Custom VN900 Custom Downloaded for free, http://VulcanRider.se/...
• Page 3 Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix...
• Page 5 All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki Heavy Industries, Ltd., Japan.

• Page 6: Emission Control Information

  EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Addi-...
• Page 7 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle 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.

• Page 8: How To Use This Manual

  • the vehicle. Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and • Indicates a procedural step or work to be testers that are necessary when servicing done.

• Page 9: Country And Area Codes

  LIST OF ABBREVIATIONS ampere(s) liter(s) ABDC after bottom dead center pound(s) alternating current meter(s) ATDC after top dead center minute(s) BBDC before bottom dead center newton(s) bottom dead center pascal(s) BTDC before top dead center horsepower °C degree(s) Celsius pound(s) per square inch direct current revolution farad(s)
• Page 11 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Unit Conversion Table ......................1-13...

• Page 12: General Information

  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.
• Page 13 Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled.
• Page 14 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction.
• Page 15 GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.
• Page 16 1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment.

• Page 17: Model Identification

  GENERAL INFORMATION 1-7 Model Identification VN900C7 (US and CA) Left Side View VN900C7 (US and CA) Right Side View...
• Page 18 1-8 GENERAL INFORMATION Model Identification VN900C7 (EUR and AU) Left Side View VN900C7 (EUR and AU) Right Side View Frame Number Engine Number Frame Number [A] Engine Number [A] Right Front Fork [B] Right Engine Cover [B]...

• Page 19: General Specifications

  GENERAL INFORMATION 1-9 General Specifications VN900C7 ∼ C8 VN900C9 ∼ CF Items Dimensions Overall Length 2 405 mm (94.68 in.) ← Overall Width 895 mm (35.24 in.) ← Overall Height 1 120 mm (44.09 in.) ← Wheelbase 1 645 mm (64.76 in.) ←...
• Page 20 1-10 GENERAL INFORMATION General Specifications VN900C7 ∼ C8 VN900C9 ∼ CF Items Ignition System Battery and coil (transistorized) ← Timing Advance Electronically advanced (digital ← igniter) Ignition Timing From 0° BTDC @1 000 r/min (rpm) From 3.5° BTDC @1 000 r/min to 53°...
• Page 21 GENERAL INFORMATION 1-11 General Specifications VN900C7 ∼ CF Items Spark Plug NGK CPR7EA-9 Cylinder Numbering Method Front to Rear, 1-2 Firing Order Valve Timing: Inlet: Open 40° BTDC Close 40° ABDC Duration 260° Exhaust: Open 55° BBDC Close 25° ATDC Duration 260°...
• Page 22 1-12 GENERAL INFORMATION General Specifications VN900C7 ∼ CF Items Rear Tire: Type Tubeless Size 180/70-15 M/C 76H Rim Size J15 M/C × MT 4.50 Front Suspension: Type Telescopic fork Wheel Travel 150 mm (5.90 in.) Rear Suspension: Type Swingarm (uni-trak) Wheel Travel 103 mm (4.06 in.) Brake Type:...

• Page 23: Unit Conversion Table

  GENERAL INFORMATION 1-13 Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 N·m ×...

• Page 25: Table Of Contents

  PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....Brake Fluid Level Inspection..2-32 Torque and Locking Agent....Brake Pad Wear Inspection ..2-33 Specifications ........2-11 Brake Light Switch Operation Special Tools ........2-13 Inspection........2-33 Periodic Maintenance Procedures..

• Page 26: Periodic Maintenance Chart

  2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic Inspection FREQUENCY Whichever * ODOMETER READING comes ×...
• Page 27 PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) INSPECTION Every Final Drive • • • • • • • Belt deflection - inspect 2-25 Belt wear and damage -...
• Page 28 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) INSPECTION Every Others • • • Chassis parts - lubricate year 2-43 Bolts and nuts tightness - •...
• Page 29 PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever * ODOMETER READING comes × 1 000 km (× 1 000 mile) first Page (0.6) (7.5) (15) (22.5) (30) CHANGE/REPLACE ITEM Every Air cleaner element # Every 18 000 km (12 000 mile) 2-45 Fuel hose 5 years...

• Page 30: Torque And Locking Agent

  2-6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. All of the values are for use with dry solvent - cleaned threads unless otherwise indicated.
• Page 31 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Engine Top End Camshaft Cap Bolts Camshaft Chain Guide Bolts 87 in·lb Camshaft Chain Tensioner Cap Bolts Camshaft Sprocket Bolts Cylinder Head Cover Bolts 106 in·lb Cylinder Head Nuts (M10): First MO, S Final...
• Page 32 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Balancer Shaft Bearing Stopper Plate Screws 0.70 61 in·lb Bearing Retainer Bolts 87 in·lb Clamp Mounting Bolts 87 in·lb Connecting Rod Big End Bolts Crankcase Bolts (M10) Crankcase Bolts (M6) 87 in·lb Engine Ground Lead Bolt...
• Page 33 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Front Brake Reservoir Cap Screws 0.15 13 in·lb Front Caliper Mounting Bolts Front Master Cylinder Clamp Bolts 0.90 78 in·lb Rear Brake Disc Mounting Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut Suspension...
• Page 34 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Ignition Coil Bracket Bolts 87 in·lb Ignition Coil Mounting Nuts 0.70 61 in·lb Oxygen Sensors (Oxygen Sensor Equipped Models) Regulator/Rectifier Bolts 0.70 61 in·lb Sidestand Switch Mounting Bolt 0.90 78 in·lb Spark Plugs...

• Page 35: Specifications

  PERIODIC MAINTENANCE 2-11 Specifications Item Standard Service Limit Fuel System (DFI) 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Idle Speed 1 000 ±50 r/min (rpm) – – – Air Cleaner Element Viscous paper element –...
• Page 36 2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive Drive Belt Deflection: (45 N, 4.6 kgf, 10 lb force) 1.5 ∼ 4.0 mm (0.06 ∼ 0.16 in.) – – – When Installing New Belt 1.5 mm (0.06 in.) – – – or Engine is Remounted Brakes Brake Fluid:...

• Page 37: Special Tools

  PERIODIC MAINTENANCE 2-13 Special Tools Inside Circlip Pliers: Spark Plug Wrench, Hex 16: 57001-143 57001-1262 Steering Stem Nut Wrench: Filler Cap Driver: 57001-1100 57001-1454 Jack: Tension Gauge: 57001-1238 57001-1585 Oil Filter Wrench: 57001-1249...

• Page 38: Periodic Maintenance Procedures

  2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Throttle Control System Inspection • Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cable. Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Standard: •...

• Page 39: Idle Speed Adjustment

  PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Idle Speed Adjustment • Start the engine and warm it up thoroughly. ○ Wait until fast idle speed lowers to a certain value. • Turn the adjusting screw [A] until the idle speed is correct. ○...

• Page 40: Evaporative Emission Control System Inspection (Cal, Th, Sea-B1)

  2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Evaporative Emission Control System Inspection (CAL, TH, SEA-B1) Evaporative Emission Control System Inspection • Inspect the canister as follows. ○ Remove: Mufflers (see Muffler Removal in the Engine Top End chapter) Bolts [A] ○ Remove the band [B] and take out the canister [C].

• Page 41: Cooling System

  PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Cooling System Coolant Level Inspection NOTE ○ Check the level when the engine is cold (room or ambi- ent temperature). • Check the coolant level in the reserve tank [A] with the motorcycle held perpendicular (Do not use the sidestand). If the coolant level is lower than the "L"...

• Page 42: Engine Top End

  2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Top End Air Suction System Damage Inspection • Disconnect the air switching valve hose [A] out of the right air cleaner housing. • Start the engine and run it at idle speed. • Plug the air switching valve hose end with your finger and feel vacuum pulsing in the hose.

• Page 43: Valve Clearance Adjustment

  PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Valve Clearance Adjustment • To change the valve clearance, slide [A] the rocker arm [B] sideways and change the shim [C]. Replace the shim with one of a different thickness. NOTE ○ Mark and record the shim locations so that the shims can be reinstalled in their original positions.
• Page 44 2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.60 mm (0.102 in.).
• Page 45 PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.55 mm (0.100 in.).

• Page 46: Clutch

  2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Clutch Operation Inspection • Pull the clutch lever just enough to take up the free play [A]. • Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully.

• Page 47: Wheels/Tires

  PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Wheels/Tires Air Pressure Inspection • Remove the air valve cap. • Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours).

• Page 48: Wheel Bearing Damage Inspection

  2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Measure the tread depth at the center of the tread with a depth gauge [A]. Since the tire may wear unevenly, take measurement at several places. If any measurement is less than the service limit, replace the tire (see Tire Removal/Installation in the Wheels/Tires chapter).

• Page 49: Final Drive

  PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures • Raise the rear wheel off the ground with jack (see Rear Wheel Removal in the Wheels/Tires chapter). • Inspect the roughness of the rear wheel bearing by mov- ing the wheel to be both side. •...
• Page 50 2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Measure the deflection (length between initial belt posi- tion [A] and position [B] that is pointed by the procedures above) of the belt (at the belt cover window). NOTE ○ Push the belt by the gauge until the top surface [A] of the stopper comes to the 45 N loaded scale [B], marked "45N".

• Page 51: Belt Deflection Adjustment

  PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures • Inspect the drive belt deflection, and record the value [B]. • Decide the belt deflection at the position [C] of one where deflection is large. Drive Belt Deflection (with 45 N, 4.6 kgf, 10 lb force) 1.5 ∼...

• Page 52: Wheel Alignment Inspection/Adjustment

  2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Tighten both belt adjuster locknuts. WARNING Misalignment of the wheel will result in abnormal wear, and may result in an unsafe riding condition. Tighten both belt adjuster locknuts, and make sure the axle stays aligned. •...

• Page 53: Belt Wear And Damage Inspection

  PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Belt Wear and Damage Inspection • Raise the rear wheel off the ground with jack (see Rear Wheel Removal in the Wheels/Tires chapter). • Remove: Bolts [A] and Washers Drive Belt Cover [B] • Visually inspect the belt [A] for wear and damage.
• Page 54 2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Belt Tooth Wear and Damage Patterns A. Belt Cross Section B. Edge Bevel Wear C. Rub Wear D. Stone...

• Page 55: Brake System

  PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Drive Belt Wear and Damage Analysis Pattern Condition Required Action O.K. for continued use, but inspect the Internal tooth cracks (slight) belt periodically. O.K. for continued use, but inspect the Scuffing to side of teeth belt periodically.

• Page 56: Brake Hose And Pipe Damage And Installation Condition Inspection

  2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Damage and Installation Condition Inspection • Inspect the brake hoses and fittings for deterioration, cracks and signs of leakage. ○ The high pressure inside the brake line can cause fluid to leak [A] or the hose to burst if the line is not properly main- tained.

• Page 57: Brake Pad Wear Inspection

  PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures • Check that the brake fluid level in the rear brake reservoir [A] is above the lower level line [B]. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C]. WARNING Mixing brands and types of brake fluid can reduce the brake system's effectiveness and cause an ac-...

• Page 58: Suspensions

  2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures If it does not, adjust the brake light switch. • While holding the switch body, turn the adjusting nut [A] to adjust the switch. NOTICE To avoid damaging the electrical connections in- side the switch, be sure that the switch body does not turn during adjustment.

• Page 59: Front Fork Oil Leak Inspection

  PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Front Fork Oil Leak Inspection • Visually inspect the front forks [A] for oil leakage. Replace any defective parts, if necessary. Rear Shock Absorber Oil Leak Inspection • Remove the left side cover (see Left Side Cover Removal in the Frame chapter).

• Page 60: Uni-Trak Linkage Lubrication

  2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Uni-trak Linkage Lubrication • Remove the tie-rod (see Tie-Rod Removal in the Suspen- sion chapter). • Apply grease to the inner surfaces of the needle bearings [A]. VN900C7 ∼ C9 Models • For the rocker arm it has grease nipples [A] on the rocker arm for lubrication.

• Page 61: Steering Stem Bearing Lubrication

  PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures • Bend the claws [A] of the claw washer straighten. • Remove the steering stem locknut [B] and claw washer [C]. • Adjust the steering. Special Tool - Steering Stem Nut Wrench [A]: 57001-1100 If the steering is too tight, loosen the stem nut [B] a fraction of a turn.

• Page 62: Electrical System

  2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Electrical System Spark Plug Condition Inspection • Refer to the Spark Plug Condition Inspection in the Peri- odic Maintenance chapter. Lights and Switches Operation Inspection First Step • Turn on the ignition switch. • The following lights should go on according to below table.
• Page 63 PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Third Step • Turn on the turn signal switch [A] (left or right position). • The left or right turn signal lights [B] (front and rear) ac- cording to the switch position should flash. •...

• Page 64: Headlight Aiming Inspection

  2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Set the dimmer switch to high beam position. • The high beam should go on. • The high beam indicator light [A] should go on. If the high beam headlight and/or high beam indicator light does not go on, inspect or replace the following item.

• Page 65: Sidestand Switch Operation Inspection

  PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures NOTE ○ ON high beam, the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated. Adjust the headlight to the proper an- gle according to local regulations. ○...

• Page 66: Engine Stop Switch Operation Inspection

  2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures If the sidestand switch operation does not work, inspect or replace the following item. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) Ignition Fuse 10 A (see Fuse Inspection in the Electrical System chapter)

• Page 67: Others

  PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Others Chassis Parts Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○...

• Page 68: Bolts, Nuts And Fasteners Tightness Inspection

  2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Bolts, Nuts and Fasteners Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).

• Page 69: Replacement Parts

  Install a new element [A] with the mesh side facing up -ward. NOTICE Use only the recommended air cleaner element (Kawasaki part number 11013-0015). Using another air cleaner element will wear the engine prema- turely or lower the engine performance. •...

• Page 70: Fuel Hose Replacement

  2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel Hose Replacement NOTICE When removing and installing the fuel hose joint, do not apply strong force to the outlet pipe on the fuel pump and delivery pipe on the throttle body assy. The pipes made from resin could be damaged. •...

• Page 71: Coolant Change

  PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures • Insert the fuel hose joint [A] straight onto the delivery pipe. • Push [B] the joint lock [C] until the hose joint clicks. • Push and pull [A] the fuel hose joint [B] back and forth more than two times and make sure it is locked and doesn't come off.
• Page 72 2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove: Bolts [A] Reserve Tank Cap [B] • Turn over the reserve tank, and pour the coolant into the suitable container. • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter).

• Page 73: Radiator Hose And O-Ring Replacement

  PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures • Fill the radiator up to the filler neck [A] with coolant. NOTE ○ Pour in the coolant slowly so that it can expel the air from the engine and radiator. • Check the cooling system for leaks. •...

• Page 74: Engine Oil Change

  2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Oil Change • Situate the motorcycle so that it is vertical after warming up the engine. • Unscrew the oil filler cap [A]. ○ For VN900C7 ∼ CA models, unscrew the cap using the following special tool.

• Page 75: Oil Filter Replacement

  PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures Oil Filter Replacement • Drain the engine oil (see Engine Oil Change). • Remove: Regulator/Rectifier (see Regulator/Rectifier Removal in the Electrical System chapter) Bolts [A] Bracket [B] • Remove the oil filter [A] with the oil filter wrench [B] and discard the oil filter.

• Page 76: Brake Hose Replacement

  2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose Replacement NOTICE Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • Remove the banjo bolts [A]. • When removing the brake hose [B], take care not to spill the brake fluid on the painted or plastic parts.
• Page 77 PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures • Level the brake fluid reservoir. • Remove: Reservoir Cap [A] Plate [B] Diaphragm [C] • Remove the rubber cap from the bleed valve [A] on the front caliper [B]. • Attach a clear plastic hose [C] to the bleed valve, and run the other end of the hose into a container.

• Page 78: Master Cylinder Rubber Parts Replacement

  2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures • For the rear caliper [A], change the brake fluid for two bleed valves [B]. • Follow the procedure below to install the rear brake fluid reservoir cap correctly. ○ First, tighten the rear brake fluid reservoir cap [B] clock- wise [C] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake...
• Page 79 PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures Rear Master Cylinder Disassembly NOTE ○ Do not remove the push rod clevis [A] for master cylin- der disassembly since removal requires brake pedal po- sition adjustment. • Remove the rear master cylinder (see Rear Master Cylin- der Removal in the Brakes chapter).

• Page 80: Caliper Rubber Parts Replacement

  2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Tighten the brake lever pivot bolt and the locknut. • Apply silicone grease. Brake Lever Pivot Bolt Brake Lever Pivot Contact Push Rod Contact Dust Cover • Tighten: Torque - Brake Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 9 in·lb) Brake Lever Pivot Bolt Locknut: 5.9 N·m (0.60 kgf·m, 52 in·lb)
• Page 81 PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures Front Caliper Assembly • Clean the caliper parts except for the pads. NOTICE For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • Install the bleed valve [A] and the rubber cap [B]. Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) •...
• Page 82 2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Using compressed air, remove the pistons. WARNING The piston in the brake caliper can crush hands and fingers. Never place your hand or fingers in front of the piston. ○ Insert a wooden board [A] 5 mm (0.2 in.) thick inside the caliper opening.

• Page 83: Spark Plug Replacement

  PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures • Apply brake fluid to the outside of the pistons and push the pistons [A] into each cylinder by hand. • Check the friction boot [B] and dust boot [C] and replace them with new ones if they are damaged. •...
• Page 85 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... 3-10 DFI Parts Location........................3-11 DFI System..........................3-14 DFI Servicing Precautions ...................... 3-26 DFI Servicing Precautions ....................3-26 Troubleshooting the DFI System .................... 3-28 Outline ..........................
• Page 86 3-2 FUEL SYSTEM (DFI) Speed Sensor Removal ....................3-67 Speed Sensor Installation ....................3-67 Speed Sensor Inspection....................3-67 Speed Sensor Input Voltage Inspection................3-67 Speed Sensor Output Voltage Inspection ................. 3-68 Vehicle-down Sensor (Service Code 31)................3-70 Vehicle-down Sensor Removal ..................3-70 Vehicle-down Sensor Installation ..................
• Page 87 FUEL SYSTEM (DFI) 3-3 Fuel Injector Installation ....................3-116 Fuel Injector Fuel Line Inspection ..................3-117 Fuel Injector Audible Inspection..................3-118 Fuel Injector Power Source Voltage Inspection ..............3-118 Fuel Injector Output Voltage Inspection ................3-119 Fuel Injector Signal Test....................3-120 Fuel Injector Resistance Inspection ..................

• Page 88: Exploded View

  3-4 FUEL SYSTEM (DFI) Exploded View...
• Page 89 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Cleaner Cover Bolts 0.50 43 in·lb Air Cleaner Housing Bolts 87 in·lb Delivery Joint Bolts 87 in·lb Delivery Joint Bracket Bolt 87 in·lb Fuel Pump Bolts 87 in·lb Inlet Air Pressure Sensor Bolt 0.70 61 in·lb...
• Page 90 3-6 FUEL SYSTEM (DFI) Exploded View...
• Page 91 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Level Sensor Mounting Bolts 0.70 61 in·lb Oxygen Sensors Oxygen Sensor Plugs 4. CAL, TH and SEA-B1 Models 5. Breather Hose (Other than CAL, TH and SEA-B1 Models) 6.

• Page 92: Specifications

  3-8 FUEL SYSTEM (DFI) Specifications Item Standard DFI System Idle Speed 1 000 ±50 r/min (rpm) Throttle Body Assy: Throttle Valve Dual throttle valve Bore 34 mm (1.34 in.) ECU (Electronic Control Unit): Make Denso Type Digital memory type, with built in IC igniter, sealed with resin 100 ∼...
• Page 93 FUEL SYSTEM (DFI) 3-9 Specifications Item Standard Subthrottle Sensor: Non-adjustable and non-removable Input Voltage DC 4.75 ∼ 5.25 V between BL and BR/BK leads VN900C7 VN900C8 ∼ DC 4.75 ∼ 5.25 V between BL and BK leads Output Voltage DC 0.93 ∼ 4.59 V between BL/W and BR/BK leads VN900C7 (at idle throttle opening to full throttle opening) DC 0.93 ∼...

• Page 94: Special Tools And Sealant

  3-10 FUEL SYSTEM (DFI) Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Fuel Pressure Gauge Adapter: 57001-125 57001-1593 Fork Oil Level Gauge: Fuel Hose: 57001-1290 57001-1607 Peak Voltage Adapter: Speed Sensor Measuring Adapter: 57001-1415 57001-1667 Filler Cap Driver: Liquid Gasket, TB1211: 57001-1454 56019-120 Needle Adapter Set:...

• Page 95: Dfi Parts Location

  FUEL SYSTEM (DFI) 3-11 DFI Parts Location 1. Air Switching Valve 12. Inlet Air Temperature Sensor 2. Battery 13. Main Fuse 30 A 3. Crankshaft Sensor 14. Main Throttle Sensor 4. ECU 15. Oxygen Sensors 5. Fuel Pump (Oxygen Sensor Equipped Models) 6.
• Page 96 3-12 FUEL SYSTEM (DFI) DFI Parts Location...
• Page 97 FUEL SYSTEM (DFI) 3-13 DFI Parts Location...

• Page 98: Dfi System

  3-14 FUEL SYSTEM (DFI) DFI System DFI System...
• Page 99 FUEL SYSTEM (DFI) 3-15 DFI System 1. ECU 2. Battery 3. Injectors 4. Fuel Pump 5. Fuel Tank 6. Subthrottle Valve Actuator 7. Air Cleaner 8. Subthrottle Sensor 9. Main Throttle Sensor 10. Inlet Air Temperature Sensor 11. Water Temperature Sensor 12.
• Page 100 3-16 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram (Without Oxygen Sensor Equipped Models) (VN900C7 ∼ C8)
• Page 101 FUEL SYSTEM (DFI) 3-17 DFI System Part Name 1. ECU 2. Diagnosis Connector 3. Self-diagnosis Terminal 4. Fuel Pump 5. Vehicle-down Sensor 6. Frame Ground 7. Battery 8. Main Fuse 30 A 9. Relay Box 10. Fuel Pump Relay 11. ECU Main Relay 12.
• Page 102 3-18 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram (Oxygen Sensor Equipped Models) (VN900C7 ∼ C8)
• Page 103 FUEL SYSTEM (DFI) 3-19 DFI System Part Name 1. ECU 2. Diagnosis Connector 3. Self-diagnosis Terminal 4. Fuel Pump 5. Vehicle-down Sensor 6. Frame Ground 7. Battery 8. Main Fuse 30 A 9. Relay Box 10. Fuel Pump Relay 11. ECU Main Relay 12.
• Page 104 3-20 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram (Without Oxygen Sensor Equipped Models) (VN900C9 ∼)
• Page 105 FUEL SYSTEM (DFI) 3-21 DFI System Part Name 1. ECU 2. Diagnosis Connector 3. Self-diagnosis Terminal 4. Fuel Pump 5. Vehicle-down Sensor 6. Frame Ground 7. Battery 8. Main Fuse 30 A 9. Relay Box 10. Fuel Pump Relay 11. ECU Main Relay 12.
• Page 106 3-22 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram (Oxygen Sensor Equipped Models) (VN900C9 ∼)
• Page 107 FUEL SYSTEM (DFI) 3-23 DFI System Part Name 1. ECU 2. Diagnosis Connector 3. Self-diagnosis Terminal 4. Fuel Pump 5. Vehicle-down Sensor 6. Frame Ground 7. Battery 8. Main Fuse 30 A 9. Relay Box 10. Fuel Pump Relay 11. ECU Main Relay 12.
• Page 108 3-24 FUEL SYSTEM (DFI) DFI System Without Oxygen Sensor Equipped Models Terminal Names 1. Subthrottle Valve Actuator Drive Signal 2 23. Unused 2. Subthrottle Valve Actuator Drive Signal 1 24. Crankshaft Sensor (–) Signal 3. Water Temperature Warning Light Signal 25.
• Page 109 FUEL SYSTEM (DFI) 3-25 DFI System Oxygen Sensor Equipped Models Terminal Names 1. Subthrottle Valve Actuator Drive Signal 2 27. Unused 2. Subthrottle Valve Actuator Drive Signal 1 28. Ground for Sensors 29. Oxygen Sensor Heater Signal 3. Water Temperature Warning Light Signal 4.

• Page 110: Dfi Servicing Precautions

  3-26 FUEL SYSTEM (DFI) DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
• Page 111 FUEL SYSTEM (DFI) 3-27 DFI Servicing Precautions ○ To maintain the correct fuel/air mixture (F/A), there must be no inlet air leaks in the DFI system. Be sure to install the oil filler plug [A] after filling the engine oil. Alternator Cover [B] Special Tool - Filler Cap Driver: 57001-1454...

• Page 112: Troubleshooting The Dfi System

  3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System Outline Outline When an abnormality in the system occurs, the FI indi- cator light (LED) goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (Electronic Control Unit).
• Page 113 FUEL SYSTEM (DFI) 3-29 Troubleshooting the DFI System ○ The DFI part connectors [A] have seals [B], including the ECU. • Join the connector and insert the needle adapters [C] in- side the seals from behind the connector until the adapter reaches the terminal.
• Page 114 3-30 FUEL SYSTEM (DFI) Troubleshooting the DFI System • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. •...
• Page 115 FUEL SYSTEM (DFI) 3-31 Troubleshooting the DFI System ○ There are two ways to inspect the DFI system. One is Voltage Check Method and the other is Resistance Check Method. (Voltage Check Method) ○ This method is conducted by measuring the input voltage [A] to a sensor [B] first, and then the output voltage [C] from the sensor.

• Page 116: Inquiries To Rider

  3-32 FUEL SYSTEM (DFI) Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○...
• Page 117 FUEL SYSTEM (DFI) 3-33 Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. □ □ □ □ □ □...
• Page 118 3-34 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ engine overheating □ clutch slipping □ other □ Poor running spark plug loose (tighten it) or no power at □ spark plug dirty, broken, or gap maladjusted (remedy it) high speed □...

• Page 119: Dfi System Troubleshooting Guide

  FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. ○...
• Page 120 3-36 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) No spark or spark weak: Ignition and engine stop switches not ON Turn both switches ON. Clutch lever not pulled in and gear not in neutral Pull the lever in and shift the gear in neutral.
• Page 121 FUEL SYSTEM (DFI) 3-37 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Piston ring bad (worn, weak, broken or sticking) Inspect and replace (see chapter 5). Piston ring/groove clearance excessive Inspect and replace (see chapter 5). Cylinder head gasket damaged Replace (see chapter 5).
• Page 122 3-38 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Incorrect idle speed: Water temperature sensor trouble Inspect (see chapter 3). Main throttle sensor trouble Inspect (see chapter 3). Throttle valves or actuator trouble Inspect (see chapter 3). Engine stalls easily: Fuel pump trouble Inspect (see chapter 3).
• Page 123 FUEL SYSTEM (DFI) 3-39 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Delay of ignition timing Inspect crankshaft sensor and IC igniter in ECU (see chapter 16). Poor acceleration: Too low fuel pressure Inspect (see chapter 3). Water or foreign matter in fuel Change fuel.

• Page 124: Poor Running Or No Power At High Speed

  3-40 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel injector trouble Inspect (see chapter 3). Run-on (dieseling): Ignition switch trouble Inspect and replace (see chapter 16). Engine switch trouble Inspect and repair or replace (see chapter 2). Fuel injector trouble Inspect (see chapter 3).
• Page 125 FUEL SYSTEM (DFI) 3-41 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Inlet air temperature sensor trouble Inspect (see chapter 3). Main throttle sensor malfunction Inspect (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3). Cracked or obstructed inlet air pressure sensor Inspect and repair or replace (see chapter 3).
• Page 126 3-42 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Valve oil seal damaged Replace (see chapter 5). Valve guide worn Replace the guide (see chapter 5). Engine oil level too high Repair (see chapter 7). (Black smoke) Air cleaner clogged Clean (see chapter 3).

• Page 127: Self-Diagnosis

  FUEL SYSTEM (DFI) 3-43 Self-Diagnosis Self-diagnosis Outline Self-diagnosis Outline The self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal. User Mode The ECU notifies the rider of troubles in DFI system and ignition system by lighting the FI indicator when DFI system and ignition system parts are faulty, and initiates fail-safe function.

• Page 128: Service Code Clearing Procedures

  3-44 FUEL SYSTEM (DFI) Self-Diagnosis • To enter the self-diagnosis dealer mode 2, open [B] and ground [A] the lead more than five times [F] within 2 sec- onds [C] after the lead is first grounded, and then keep it grounded continuously [D] for more than 2 seconds.
• Page 129 FUEL SYSTEM (DFI) 3-45 Self-Diagnosis Self-Diagnosis Flow Chart...

• Page 130: Service Code Reading

  3-46 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Reading Service Code Reading ○ Service codes are shown by a series of long and short blinks of the FI indicator light (LED) as shown below. ○ Read 10th digit and unit digit as the FI indicator light (LED) blinks. ○...

• Page 131: Service Code Table

  FUEL SYSTEM (DFI) 3-47 Self-Diagnosis Service Code Table Service Code Table Service FI Indicator Light (LED) Problems Code Main throttle sensor malfunction, wiring open or short Inlet air pressure sensor malfunction, wiring open or short Inlet air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short...
• Page 132 3-48 FUEL SYSTEM (DFI) Self-Diagnosis Notes: ○ The ECU may be involved in these problems. If all the parts and circuits checked out good, be sure to check the ECU for ground and power supply. If the ground and power supply are checked good, replace the ECU.

• Page 133: Backups

  FUEL SYSTEM (DFI) 3-49 Self-Diagnosis Backups Backups ○ The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the main throttle sensor system fails (the signal is out of the usable range, wiring short or open), the ECU locks ignition timing into the...
• Page 134 3-50 FUEL SYSTEM (DFI) Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria The ignition coil primary If the ignition primary winding #1 has failures winding must send (no signal, wiring short or open), the ECU Ignition Coil #1* signals (output voltage) shuts off the injector #1 to stop fuel to the...

• Page 135: Main Throttle Sensor (Service Code 11)

  FUEL SYSTEM (DFI) 3-51 Main Throttle Sensor (Service Code 11) The main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening.

• Page 136: Main Throttle Sensor Output Voltage Inspection

  3-52 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Output Voltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection. Special Tool - Needle Adapter Set: 57001-1457 Main Throttle Sensor Output Voltage Connections to ECU (Without Oxygen Sensor Equipped Models [A]) Meter (+) →...

• Page 137: Main Throttle Sensor Resistance Inspection

  FUEL SYSTEM (DFI) 3-53 Main Throttle Sensor (Service Code 11) NOTE ○ The standard voltage marked with an asterisk refers to the value when the voltage reading at the Input Voltage Inspection shows 5 V exactly. ○ When the input voltage reading shows other than 5 V, derive a voltage range as follows.
• Page 138 3-54 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Circuit (Without Oxygen Sensor Equipped Models) Main Throttle Sensor Circuit (Oxygen Sensor Equipped Models) 1. ECU 2. Main Throttle Sensor 3. Joint Connector B...

• Page 139: Inlet Air Pressure Sensor (Service Code 12)

  FUEL SYSTEM (DFI) 3-55 Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Removal NOTICE Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. • Remove: Fuel Tank (see Fuel Tank Removal) Bolt [A] •...

• Page 140: Inlet Air Pressure Sensor Output Voltage Inspection

  3-56 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) If the reading is within the standard range, remove the fuel tank, and check wiring from ECU to the inlet pressure sensor for continuity. If wiring is good, check the output voltage of the inlet air pressure sensor.
• Page 141 FUEL SYSTEM (DFI) 3-57 Inlet Air Pressure Sensor (Service Code 12) • Remove the inlet air pressure sensor [A] and disconnect the vacuum hose from the sensor. ○ Do not disconnect the sensor connector. • Connect an auxiliary hose [B] to the inlet air pressure sen- sor.
• Page 142 3-58 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) ID: Idling Ps: Standard Atmospheric Pressure (Absolute) Pv: Throttle Vacuum Pressure (Absolute) ST: Standard of Sensor Output Voltage (V) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (V) Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading)
• Page 143 FUEL SYSTEM (DFI) 3-59 Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Circuit (Without Oxygen Sensor Equipped Models) Inlet Air Pressure Sensor Circuit (Oxygen Sensor Equipped Models) 1. ECU 2. Inlet Air Pressure Sensor 3. Joint Connector B...

• Page 144: Inlet Air Temperature Sensor (Service Code 13)

  3-60 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Removal/Installation NOTICE Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove the air cleaner housing (see Air Cleaner Housing Removal).

• Page 145: Inlet Air Temperature Sensor Resistance Inspection

  FUEL SYSTEM (DFI) 3-61 Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Resistance Inspection • Remove the inlet air temperature sensor (see Inlet Air Temperature Sensor Removal). • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion is submerged.
• Page 146 3-62 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Circuit (Without Oxygen Sensor Equipped Models) Inlet Air Temperature Sensor Circuit (Oxygen Sensor Equipped Models) 1. ECU 2. Inlet Air Temperature Sensor 3. Joint Connector B...

• Page 147: Water Temperature Sensor (Service Code 14)

  FUEL SYSTEM (DFI) 3-63 Water Temperature Sensor (Service Code 14) Water Temperature Sensor Removal/Installation NOTICE Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank Removal). •...
• Page 148 3-64 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) Water Temperature Sensor Circuit (Without Oxygen Sensor Equipped Models) Water Temperature Sensor Circuit (Oxygen Sensor Equipped Models) 1. ECU 2. Water Temperature Sensor 3. Joint Connector B...

• Page 149: Crankshaft Sensor (Service Code 21)

  FUEL SYSTEM (DFI) 3-65 Crankshaft Sensor (Service Code 21) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condi- tion of the crankshaft sensor.
• Page 150 3-66 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) Crankshaft Sensor Circuit (Without Oxygen Sensor Equipped Models) Crankshaft Sensor Circuit (Oxygen Sensor Equipped Models) 1. ECU 2. Crankshaft Sensor...

• Page 151: Speed Sensor (Service Code 24, 25)

  FUEL SYSTEM (DFI) 3-67 Speed Sensor (Service Code 24, 25) Speed Sensor Removal • Refer to the Speed Sensor Removal in the Electrical Sys- tem chapter. Speed Sensor Installation • Refer to the Speed Sensor Installation in the Electrical System chapter. Speed Sensor Inspection •...

• Page 152: Speed Sensor Output Voltage Inspection

  3-68 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) Speed Sensor Output Voltage Inspection • Before this inspection, inspect the input voltage (see Speed Sensor Input Voltage Inspection). NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. •...
• Page 153 FUEL SYSTEM (DFI) 3-69 Speed Sensor (Service Code 24, 25) Speed Sensor Circuit (Without Oxygen Sensor Equipped Models) Speed Sensor Circuit (Oxygen Sensor Equipped Models) 1. ECU 2. Meter Unit 3. Joint Connector B 4. Speed Sensor...

• Page 154: Vehicle-Down Sensor (Service Code 31)

  3-70 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Removal • Remove: Tool Box (see Tool Box Removal in the Frame chapter) Bolts [A] Vehicle-down Sensor [B] Connector [C] (Disconnect) Vehicle-down Sensor Installation • Install the vehicle-down sensor [A] in the original position. The arrow mark [B] on the sensor must be on the rear and point upward.
• Page 155 FUEL SYSTEM (DFI) 3-71 Vehicle-down Sensor (Service Code 31) If the power source is normal, check the output voltage of the sensor. • Connect a digital meter [A] to the connector, using the needle adapter set [B]. • Turn the ignition switch ON, and measure the output volt- age with the connector joined.
• Page 156 3-72 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Circuit (Without Oxygen Sensor Equipped Models) Vehicle-down Sensor Circuit (Oxygen Sensor Equipped Models) 1. ECU 2. Vehicle-down Sensor 3. Joint Connector B...

• Page 157: Subthrottle Sensor (Service Code 32)

  FUEL SYSTEM (DFI) 3-73 Subthrottle Sensor (Service Code 32) The subthrottle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening.

• Page 158: Subthrottle Sensor Output Voltage Inspection

  3-74 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) • Turn the ignition switch OFF. If the reading of input voltage is less than the standard, check the ECU for its ground, power supply and wiring shorted. If the input voltage is within the standard range, remove the fuel tank, and check wiring from ECU to the subthrottle sensor for continuity.

• Page 159: Subthrottle Sensor Resistance Inspection

  FUEL SYSTEM (DFI) 3-75 Subthrottle Sensor (Service Code 32) NOTE ○ The standard voltage refers to the value when the volt- age reading at the Input Voltage Inspection shows 5 V exactly. ○ When the input voltage reading shows other than 5 V, derive a voltage range as follows.
• Page 160 3-76 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Subthrottle Sensor Circuit (Without Oxygen Sensor Equipped Models) Subthrottle Sensor Circuit (Oxygen Sensor Equipped Models) 1. ECU 2. Subthrottle Sensor (VN900C8 ∼ Models) 3. Joint Connector B 4. Subthrottle Sensor (VN900C7 Models)

• Page 161: Oxygen Sensor-Not Activated #1, #2 (Service Code 33, 83) (Oxygen Sensor Equipped Models)

  FUEL SYSTEM (DFI) 3-77 Oxygen Sensor-not activated #1, #2 (Service Code 33, 83) (Oxygen Sensor Equipped Models) Oxygen Sensor #1: Service Code 33 Oxygen Sensor #2: Service Code 83 Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal and Installation in the Electrical System chapter.
• Page 162 3-78 FUEL SYSTEM (DFI) Oxygen Sensor-not activated #1, #2 (Service Code 33, 83) (Oxygen Sensor Equipped Models) • Next, remove the plugs [A] (both sides) from the fittings with idling. • Measure the output voltage of the sensor with the con- nector joined.
• Page 163 FUEL SYSTEM (DFI) 3-79 Oxygen Sensor-not activated #1, #2 (Service Code 33, 83) (Oxygen Sensor Equipped Models) Oxygen Sensor Circuit (VN900C9 ∼) 1. ECU 2. Oxygen Sensor #1 3. Oxygen Sensor #2 4. Ignition Switch 5. Oxygen Sensor Heater Fuse 10 A 6.

• Page 164: Ignition Coils #1, #2 (Service Code 51, 52)

  3-80 FUEL SYSTEM (DFI) Ignition Coils #1, #2 (Service Code 51, 52) Ignition Coil #1: Ignition Coil for Front Cylinder (Service Code 51) Ignition Coil #2: Ignition Coil for Rear Cylinder (Service Code 52) Ignition Coil Removal/Installation NOTICE Never drop the ignition coils, especially on a hard surface.
• Page 165 FUEL SYSTEM (DFI) 3-81 Ignition Coils #1, #2 (Service Code 51, 52) If the reading is out of the standard, check the ECU for its ground and power supply (see ECU Power Supply In- spection). If the reading is good, remove the fuel tank, and check the wiring between the ECU and the primary lead terminals at the ignition coils.

• Page 166: Radiator Fan Relay (Service Code 56)

  3-82 FUEL SYSTEM (DFI) Radiator Fan Relay (Service Code 56) Radiator Fan Relay Removal/Installation • Radiator fan relay is built in the relay box. • Remove the relay box (see Relay Box Removal in the Electrical System chapter). Radiator Fan Relay Inspection •...
• Page 167 FUEL SYSTEM (DFI) 3-83 Radiator Fan Relay (Service Code 56) Radiator Fan Relay Circuit (VN900C7 ∼ C8) 1. Ignition Switch 2. Radiator Fan 3. Joint Connector B 4. Water Temperature Sensor 5. ECU 6. Frame Ground 7. Battery 8. Main Fuse 30 A 9.
• Page 168 3-84 FUEL SYSTEM (DFI) Radiator Fan Relay (Service Code 56) Radiator Fan Relay Circuit (VN900C9 ∼) 1. Ignition Switch 2. Radiator Fan 3. Joint Connector B 4. Water Temperature Sensor 5. ECU 6. Battery 7. Main Fuse 30 A 8. Relay Box 9.

• Page 169: Subthrottle Valve Actuator (Service Code 62)

  FUEL SYSTEM (DFI) 3-85 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal NOTICE Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface.

• Page 170: Subthrottle Valve Actuator Input Voltage Inspection

  3-86 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Remove the fuel tank (see Fuel Tank Removal). •...
• Page 171 FUEL SYSTEM (DFI) 3-87 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Circuit (Without Oxygen Sensor Equipped Models) Subthrottle Valve Actuator Circuit (Oxygen Sensor Equipped Models) 1. ECU 2. Subthrottle Valve Actuator...

• Page 172: Air Switching Valve (Service Code 64)

  3-88 FUEL SYSTEM (DFI) Air Switching Valve (Service Code 64) Air Switching Valve Removal/Installation • Refer to the Air Switching Valve Removal and Installation in the Engine Top End chapter. Air Switching Valve Inspection • Refer to the Air Switching Valve Unit Test in the Electrical System chapter.
• Page 173 FUEL SYSTEM (DFI) 3-89 Air Switching Valve (Service Code 64) Air Switching Valve Circuit (Oxygen Sensor Equipped Models) (VN900C7 ∼ C8) 1. ECU 2. Engine Stop Switch 3. Ignition Switch 4. Ignition Fuse 10 A 5. ECU Fuse 15 A 6.
• Page 174 3-90 FUEL SYSTEM (DFI) Air Switching Valve (Service Code 64) Air Switching Valve Circuit (Without Oxygen Sensor Equipped Models) (VN900C9 ∼) 1. ECU 10. Main Fuse 30 A 2. Engine Stop Switch 11. Starter Relay 3. Ignition Switch 12. Battery 13.
• Page 175 FUEL SYSTEM (DFI) 3-91 Air Switching Valve (Service Code 64) Air Switching Valve Circuit (Oxygen Sensor Equipped Models) (VN900C9 ∼) 1. ECU 2. Engine Stop Switch 3. Ignition Switch 4. Ignition Fuse 10 A 5. ECU Fuse 15 A 6. Fuse Box 7.

• Page 176: Oxygen Sensor Heaters #1, #2 (Service Code 67) (Oxygen Sensor Equipped Models)

  3-92 FUEL SYSTEM (DFI) Oxygen Sensor Heaters #1, #2 (Service Code 67) (Oxygen Sensor Equipped Models) Oxygen Sensor Heater Removal/Installation The oxygen sensor heater is built in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see Oxygen Sensor Removal in the Electrical System chapter).
• Page 177 FUEL SYSTEM (DFI) 3-93 Oxygen Sensor Heaters #1, #2 (Service Code 67) (Oxygen Sensor Equipped Models) If the reading is incorrect, check the following. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) Oxygen Sensor Heater Fuse 10 A (see Fuse Inspection in the Electrical System chapter)
• Page 178 3-94 FUEL SYSTEM (DFI) Oxygen Sensor Heaters #1, #2 (Service Code 67) (Oxygen Sensor Equipped Models) Oxygen Sensor Circuit (VN900C9 ∼) 1. ECU 2. Oxygen Sensor #1 3. Oxygen Sensor #2 4. Ignition Switch 5. Oxygen Sensor Heater Fuse 10 A 6.

• Page 179: Oxygen Sensors-Incorrect Output Voltage #1, #2 (Service Code 94, 95) (Oxygen Sensor Equipped Models)

  FUEL SYSTEM (DFI) 3-95 Oxygen Sensors-Incorrect Output Voltage #1, #2 (Service Code 94, 95) (Oxygen Sensor Equipped Models) Oxygen Sensor #1: Service Code 94 Oxygen Sensor #2: Service Code 95 Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal and Installation in the Electrical System chapter.
• Page 180 3-96 FUEL SYSTEM (DFI) Oxygen Sensors-Incorrect Output Voltage #1, #2 (Service Code 94, 95) (Oxygen Sensor Equipped Models) • Next, remove the plugs [A] (both sides) from the fittings with idling. • Measure the output voltage of the sensor with the con- nector joined.

• Page 181: Oxygen Sensor Inspection

  FUEL SYSTEM (DFI) 3-97 Oxygen Sensors-Incorrect Output Voltage #1, #2 (Service Code 94, 95) (Oxygen Sensor Equipped Models) Oxygen Sensor Circuit (VN900C9 ∼) 1. ECU 2. Oxygen Sensor #1 3. Oxygen Sensor #2 4. Ignition Switch 5. Oxygen Sensor Heater Fuse 10 A 6.

• Page 182: Fi Indicator Light (Led)

  3-98 FUEL SYSTEM (DFI) FI Indicator Light (LED) Inspection Flow Chart...

• Page 183: Light (Led) Inspection

  FUEL SYSTEM (DFI) 3-99 FI Indicator Light (LED) Light (LED) Inspection ○ The FI indicator light (LED) [A] goes ON when the ignition switch is turned ON and the LED light goes OFF when the engine oil pressure is high enough (the engine is running). This is to ensure that the FI indicator light (LED) has not burned out and the DFI system and the ignition system function properly.
• Page 184 3-100 FUEL SYSTEM (DFI) FI Indicator Light (LED) FI Indicator Light (LED) Circuit (Without Oxygen Sensor Equipped Models) (VN900C7 ∼ C8) FI Indicator Light (LED) Circuit (Oxygen Sensor Equipped Models) (VN900C7 ∼ C8) 1. ECU 7. Joint Connector A 2. Ignition Switch 8.
• Page 185 FUEL SYSTEM (DFI) 3-101 FI Indicator Light (LED) FI Indicator Light (LED) Circuit (Without Oxygen Sensor Equipped Models) (VN900C9 ∼) FI Indicator Light (LED) Circuit (Oxygen Sensor Equipped Models) (VN900C9 ∼) 1. ECU 6. Starter Relay 2. Ignition Switch 7. Battery 3.

• Page 186: Ecu

  3-102 FUEL SYSTEM (DFI) ECU Removal NOTICE Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. • Remove: Seat (see Seat Removal in the Frame chapter) Tool Box (see Tool Box Removal in the Frame chapter) •...
• Page 187 FUEL SYSTEM (DFI) 3-103 • Check the ECU power source voltage with a digital meter. ○ Position the terminal in accordance with terminal numbers of ECU connectors as shown in the figure. ECU Power Source Inspection Meter Connections: (Without Oxygen Sensor Equipped Models [A]) Between Terminal 12 (BR/W) and Battery (–) Terminal Between Terminal 27 (W/BK) and Battery (–)

• Page 188: Fuel Line

  3-104 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○ This inspection can determine which trouble the DFI system has, mechanical or electrical trouble. ○ It is preferable to measure the fuel pressure while run- ning the motorcycle when the trouble has occurred in order to know symptom well.

• Page 189: Fuel Flow Rate Inspection

  FUEL SYSTEM (DFI) 3-105 Fuel Line • Start the engine, and let it idle. • Measure the fuel pressure with the engine idling. Fuel Pressure (Idling) Standard: 294 kPa (3.0 kgf/cm², 43 psi) NOTE ○ The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications.
• Page 190 3-106 FUEL SYSTEM (DFI) Fuel Line • Prepare a fuel hose of the inside diameter 7.5 mm (0.30 in.) and a measuring cylinder. • Remove: Seat (see Seat Removal in the Frame chapter) Fuel Tank Bolts (see Fuel Tank Removal) •...

• Page 191: Fuel Pump

  FUEL SYSTEM (DFI) 3-107 Fuel Pump Fuel Pump Removal NOTICE Never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns.

• Page 192: Pump Screen, Fuel Filter Cleaning

  3-108 FUEL SYSTEM (DFI) Fuel Pump • Check that the terminals [A] and band [B] are in place. • Apply a non-permanent locking agent to the threads of the fuel pump bolts. • Tighten the fuel pump bolts [C] to a snug fit. •...

• Page 193: Fuel Pump Operating Voltage Inspection

  FUEL SYSTEM (DFI) 3-109 Fuel Pump Fuel Pump Operating Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Remove the ignition coil cover (see Ignition Coil Removal in the Electrical System chapter). •...

• Page 194: Fuel Pump Power Source Voltage Inspection

  3-110 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Power Source Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Remove the ignition coil cover (see Ignition Coil Removal in the Electrical System chapter). • Connect a digital meter [A] to the fuel pump connector [B] (3P), using the needle adapter set [C].
• Page 195 FUEL SYSTEM (DFI) 3-111 Fuel Pump Fuel Pump Circuit (Without Oxygen Sensor Equipped Models) (VN900C7 ∼ C8) 1. ECU 2. Engine Stop Switch 3. Ignition Switch 4. Ignition Fuse 10 A 5. ECU Fuse 15 A 6. Fuse Box 7. ECU Main Relay 8.
• Page 196 3-112 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Circuit (Oxygen Sensor Equipped Models) (VN900C7 ∼ C8) 1. ECU 2. Engine Stop Switch 3. Ignition Switch 4. Ignition Fuse 10 A 5. ECU Fuse 15 A 6. Fuse Box 7. ECU Main Relay 8.
• Page 197 FUEL SYSTEM (DFI) 3-113 Fuel Pump Fuel Pump Circuit (Without Oxygen Sensor Equipped Models) (VN900C9 ∼) 1. ECU 2. Engine Stop Switch 3. Ignition Switch 4. Ignition Fuse 10 A 5. ECU Fuse 15 A 6. Fuse Box 7. ECU Main Relay 8.
• Page 198 3-114 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Circuit (Oxygen Sensor Equipped Models) (VN900C9 ∼) 1. ECU 2. Engine Stop Switch 3. Ignition Switch 4. Ignition Fuse 10 A 5. ECU Fuse 15 A 6. Fuse Box 7. ECU Main Relay 8.

• Page 199: Fuel Injectors

  FUEL SYSTEM (DFI) 3-115 Fuel Injectors NOTICE Never drop the injector, especially on a hard sur- face. Such a shock to the injector can damage it. Fuel Injector Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns.

• Page 200: Fuel Injector Installation

  3-116 FUEL SYSTEM (DFI) Fuel Injectors • Unscrew the delivery joint bolts [A], and lift up the delivery joint [B] with the injectors [C]. • Remove the injectors from the delivery joint. Fuel Injector Installation ○ The front and rear injectors are the same. •...

• Page 201: Fuel Injector Fuel Line Inspection

  FUEL SYSTEM (DFI) 3-117 Fuel Injectors Fuel Injector Fuel Line Inspection • Remove: Fuel Tank (see Fuel Tank Removal) Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) • Check the injector fuel line for leakage as follows. ○...

• Page 202: Fuel Injector Audible Inspection

  3-118 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Audible Inspection • Start the engine. • Insert a screwdriver from the engine right side between the fuel tank bottom end and the engine top end. • Apply the tip of a screwdriver [A] to the injector [B]. Put the grip end onto your ear, and listen whether the injector is clicking or not.

• Page 203: Fuel Injector Output Voltage Inspection

  FUEL SYSTEM (DFI) 3-119 Fuel Injectors Fuel Injector Output Voltage Inspection • Turn the ignition switch OFF. • Remove the ECU (see ECU Removal). Do not disconnect the ECU connector. • Connect a digital voltmeter to the connector, using the needle adapter set.

• Page 204: Fuel Injector Signal Test

  3-120 FUEL SYSTEM (DFI) Fuel Injectors If the output voltage is normal, perform the "Fuel Injector Signal Test". If the output voltage is out of the standard, turn the ignition switch OFF, remove the fuel tank, and check the injector wiring for continuity.

• Page 205: Fuel Injector Resistance Inspection

  FUEL SYSTEM (DFI) 3-121 Fuel Injectors ○ Fuel injector signals can be also confirmed by connect- ing the tester instead of the test light set to the fuel injec- tor main harness connector. Crank the engine with the starter motor, and check to see if the needle oscillates at regular intervals.
• Page 206 3-122 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Circuit (Without Oxygen Sensor Equipped Models) (VN900C7 ∼ C8) 1. ECU 2. Engine Stop Switch 3. Ignition Switch 4. Ignition Fuse 10 A 5. ECU Fuse 15 A 6. Fuse Box 7. ECU Main Relay 8.
• Page 207 FUEL SYSTEM (DFI) 3-123 Fuel Injectors Fuel Injector Circuit (Oxygen Sensor Equipped Models) (VN900C7 ∼ C8) 1. ECU 2. Engine Stop Switch 3. Ignition Switch 4. Ignition Fuse 10 A 5. ECU Fuse 15 A 6. Fuse Box 7. ECU Main Relay 8.
• Page 208 3-124 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Circuit (Without Oxygen Sensor Equipped Models) (VN900C9 ∼) 1. ECU 2. Engine Stop Switch 3. Ignition Switch 4. Ignition Fuse 10 A 5. ECU Fuse 15 A 6. Fuse Box 7. ECU Main Relay 8.
• Page 209 FUEL SYSTEM (DFI) 3-125 Fuel Injectors Fuel Injector Circuit (Oxygen Sensor Equipped Models) (VN900C9 ∼) 1. ECU 2. Engine Stop Switch 3. Ignition Switch 4. Ignition Fuse 10 A 5. ECU Fuse 15 A 6. Fuse Box 7. ECU Main Relay 8.

• Page 210: Throttle Grip And Cables

  3-126 FUEL SYSTEM (DFI) Throttle Grip and Cables Throttle Grip Free Play Inspection • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Throttle Grip Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter.

• Page 211: Throttle Body Assy

  FUEL SYSTEM (DFI) 3-127 Throttle Body Assy Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter. Idle Speed Adjustment • Refer to the Idle Speed Adjustment in the Periodic Main- tenance chapter. Throttle Bore Cleaning •...
• Page 212 3-128 FUEL SYSTEM (DFI) Throttle Body Assy • Remove the screws and take off the right switch housing. • Remove the accelerator cable end [A] and decelerator cable end [B] at the throttle grip. • Disconnect the fuel injector connectors [A]. •...

• Page 213: Throttle Body Assy And Inlet Manifold Installation

  FUEL SYSTEM (DFI) 3-129 Throttle Body Assy ○ Be careful not to damage (dent, nick, flaw, and crack) the flange mating surface and the plastic parts. ○ Do not drop the throttle body assy, especially on a hard surface. WARNING Impacts can cause the throttle to stick, resulting in an accident causing severe injury or death.
• Page 214 3-130 FUEL SYSTEM (DFI) Throttle Body Assy • Open the butterfly valves [A], and wipe any carbon off the throttle bores [B] around the valves, using a piece of lint-free cloth penetrated with a high flash-point solvent. • Clean the bores [C] of the inlet manifold [D] as well. •...
• Page 215 FUEL SYSTEM (DFI) 3-131 Throttle Body Assy • Stake the cable clip [A] on the throttle cable holder [B]. • Apply a thin coating of grease to the throttle cable upper ends. • Install the upper ends of the throttle cables to the throttle grip.

• Page 216: Air Cleaner

  3-132 FUEL SYSTEM (DFI) Air Cleaner Air Cleaner Element Removal/Installation • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter. Air Cleaner Housing Removal • Remove the air cleaner housing bolts [A]. • Clear the idle speed screw [A] from the recess on the air cleaner housing.
• Page 217 FUEL SYSTEM (DFI) 3-133 Air Cleaner • Fit the adjusting screw [A] in the recess on the air cleaner housing. • Be sure the dampers [A] and collars [B] are in position. ○ Install the damper into the air cleaner housing [C] as shown in the figure.

• Page 218: Fuel Tank

  3-134 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks;...
• Page 219 FUEL SYSTEM (DFI) 3-135 Fuel Tank • Remove: Seat (see Seat Removal in the Frame chapter) Fuel Tank Bolts [A] • Disconnect: Fuel Return Hose (Red) [A] (CAL, TH and SEA-B1 Mod- els) • Unscrew the screw [A], and pull out the ignition coil cover [B].
• Page 220 3-136 FUEL SYSTEM (DFI) Fuel Tank When removing with standard tip screwdriver • Insert the standard tip screwdriver [A] into the slit on the joint lock [B]. • Turn the driver to disconnect the joint lock. When removing with fingers •...

• Page 221: Fuel Tank Installation

  FUEL SYSTEM (DFI) 3-137 Fuel Tank • For CAL, TH and SEA-B1 Models, note the following. NOTICE For CAL, TH and SEA-B1 models, if gasoline, sol- vent, water or any other liquid enters the canister, the canister's vapor absorbing capacity is greatly reduced.
• Page 222 3-138 FUEL SYSTEM (DFI) Fuel Tank • Check that the rubber dampers [A] are in place. If the dampers are damaged or deteriorated, replace them. • Remove the vinyl bag on the pipe and fuel hose joint. • Check the joint lock for deformation and wear. If the joint lock is deformed, replace the fuel hose with a new one.

• Page 223: Fuel Tank And Cap Inspection

  FUEL SYSTEM (DFI) 3-139 Fuel Tank Fuel Tank and Cap Inspection • Visually inspect the gasket [A] on the tank cap for any damage. Replace the gasket if it is damaged. • Check to see if the breather pipe [B] (CAL, TH and SEA -B1 models) in the tank is not clogged.

• Page 224: Evaporative Emission Control System (Cal, Th And Sea-B1 Models)

  3-140 FUEL SYSTEM (DFI) Evaporative Emission Control System (CAL, TH and SEA-B1 Models) The Evaporative Emission Control System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart.

• Page 225: Separator Operation Test

  FUEL SYSTEM (DFI) 3-141 Evaporative Emission Control System (CAL, TH and SEA-B1 Models) Separator Operation Test WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks;...
• Page 226 3-142 FUEL SYSTEM (DFI) Evaporative Emission Control System (CAL, TH and SEA-B1 Models) 1. Fuel Tank 2. Throttle Body Assy 3. Canister 4. Separator 5. Breather Check Valve 6. Breather Hose 7. Breather Hose (Blue) 8. Vacuum Hose (White) 9. Fuel Return Hose (Red) 10.
• Page 227 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Special Tools .......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Reserve Tank Removal..................... Water Pump..........................

• Page 228: Exploded View

  4-2 COOLING SYSTEM Exploded View...
• Page 229 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Coolant Drain Bolt 87 in·lb Radiator Bolts 0.70 61 in·lb Radiator Fan Bolts 0.85 73 in·lb Radiator Hose Clamp Screws 0.20 18 in·lb Radiator Screen Screws 0.70 61 in·lb Reserve Tank Bolts 0.70 61 in·lb...

• Page 230: Coolant Flow Chart

  4-4 COOLING SYSTEM Coolant Flow Chart...
• Page 231 COOLING SYSTEM 4-5 Coolant Flow Chart 1. Thermostat 2. Radiator Cap 3. Cylinder Head Jacket 4. Radiator Fan 5. Radiator 6. Cylinder Jacket 7. Water Pump 8. Reserve Tank 9. Hot Coolant 10. Cold Coolant Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates.

• Page 232: Specifications

  4-6 COOLING SYSTEM Specifications Item Standard Coolant Provided when Shipping Type (Recommended) Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point –35°C (–31°F) Total Amount...

• Page 233: Special Tools

  COOLING SYSTEM 4-7 Special Tools Bearing Driver Set: Bearing Remover Head, 10 × 12: 57001-1129 57001-1266 Bearing Remover Shaft, 9: 57001-1265...

• Page 234: Coolant

  4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Visually inspect the coolant in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system.

• Page 235: Cooling System Flushing

  COOLING SYSTEM 4-9 Coolant Cooling System Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passage and considerable reduce the effi- ciency of the cooling system.

• Page 236: Water Pump

  4-10 COOLING SYSTEM Water Pump Water Pump Impeller Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) Coolant (see Coolant Change in the Periodic Mainte- nance chapter) • Remove: Right Engine Cover (see Right Engine Cover Removal in the Clutch chapter) Bolt [A] and Washer Impeller [B]...
• Page 237 COOLING SYSTEM 4-11 Water Pump If the seal and ball bearing are damaged, replace the me- chanical seal, ball bearing and oil seal by splitting the crankcase. • Split the crankcase (see Crankcase Splitting in the Crank- shaft/Transmission chapter). • Take the bearing [A] out of the right crankcase, using the bearing remover.

• Page 238: Water Pump Inspection

  4-12 COOLING SYSTEM Water Pump Water Pump Inspection • Check the drainage outlet passage [A] at the bottom of the right crankcase for coolant leaks. • If a coolant leak or ooze is found, start the engine and check if the coolant leaks continuously. ○...

• Page 239: Radiator, Radiator Fan

  COOLING SYSTEM 4-13 Radiator, Radiator Fan Radiator and Radiator Fan Removal WARNING A spinning radiator fan can cause serious injury. The radiator fan is connected directly to the battery and may start even if the ignition switch is off. Do not touch the radiator fan until it has been discon- nected from the battery.

• Page 240: Radiator Fan Installation

  4-14 COOLING SYSTEM Radiator, Radiator Fan • Remove: Radiator Fan Connector [A] Radiator • Remove: Radiator Fan Bolts [A] Radiator Fan [B] NOTICE Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling effi- ciency.

• Page 241: Radiator Cap Inspection

  COOLING SYSTEM 4-15 Radiator, Radiator Fan Radiator Cap Inspection • Remove the radiator cap (see Coolant Change in the Pe- riodic Maintenance chapter). • Check the condition of the bottom [A] and top [B] valve seals and valve spring [C]. If any one of them shows visible damage, replace the cap with a new one.

• Page 242: Thermostat

  4-16 COOLING SYSTEM Thermostat Thermostat Removal • Drain the coolant (about 200 mL) (see Coolant Change in the Periodic Maintenance chapter). • Remove: Seat (see Seat Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) •...
• Page 243 COOLING SYSTEM 4-17 Thermostat • To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water. ○ The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an ac- curate thermometer [B] in the water so that the heat sen- sitive portions [C] are located in almost the same depth.

• Page 244: Hose And Pipes

  4-18 COOLING SYSTEM Hose and Pipes Hose Installation • Install the hoses and pipes being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses (see Cable, Wire, and Hose Routing sec- tion in the Appendix chapter). •...

• Page 245: Water Temperature Sensor

  COOLING SYSTEM 4-19 Water Temperature Sensor NOTICE The water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to the water temperature sensor can damage it. Water Temperature Sensor Removal/Installation • Refer to the Water Temperature Sensor Removal/Instal- lation in the Fuel System (DFI) chapter.
• Page 247 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Cylinder Heads ........5-25 Exhaust System Identification ... Cylinder Compression Specifications ........Measurement ......5-25 Special Tools ........5-11 Cylinder Head Removal ....5-26 Clean Air System....... 5-14 Cylinder Head Installation ....

• Page 248: Exploded View

  5-2 ENGINE TOP END Exploded View...
• Page 249 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Camshaft Cap Bolts Cylinder Head Cover Bolts 106 in·lb Cylinder Head Nuts (M10) (First) MO, S Cylinder Head Nuts (M10) (Final) MO, S Cylinder Head Nuts (M8) Cylinder Head Outer Cover Bolts 87 in·lb Plug (PT1/4) Plug (PT1/2)
• Page 250 5-4 ENGINE TOP END Exploded View...
• Page 251 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Camshaft Chain Guide Bolts 87 in·lb Camshaft Chain Tensioner Cap Bolts Camshaft Sprocket Bolts Exhaust Pipe Cover Bolts 0.70 61 in·lb Exhaust Pipe Cover Clamp Bolts 0.70 61 in·lb Exhaust Pipe Holder Nuts Muffler Joint Clamp Bolt Muffler Mounting Bolts...

• Page 252: Exhaust System Identification

  5-6 ENGINE TOP END Exhaust System Identification Exhaust System MANIFOLD MUFFLER BODY SPECIFICATION MODEL VN900C7 ∼ C8 Honeycomb Type Catalyst U.S.A P/No. 18087-0116 U.S.A (California) VN900C7 P/No. 18087-0123 VN900C7 ∼ C8 Canada Mark: – VN900C9 ∼ CB Honeycomb Type Catalyst U.S.A VN900C8 ∼...
• Page 253 ENGINE TOP END 5-7 Exhaust System Identification VN900CC ∼ Honeycomb Type Catalyst Australia VN900CC ∼ P/No. 18087-0283 S.E.Asia-B1 P/No. 18087-0284 WVTA (FULL H) VN900CE Mark: KHI 540 GB WVTA (FULL H) VN900CE VN900CE ∼ Brazil VN900CDA ∼ CEA Honeycomb Type Catalyst Australia VN900CCA, CD, CEA ∼...
• Page 254 5-8 ENGINE TOP END Exhaust System Identification Muffler Mark Position [A] Honeycomb Type Catalyst Position [B] Muffler with Boss [A] for Oxygen Sensor (Oxygen Sensor Equipped Models and AU model [VN900C9 ∼])

• Page 255: Specifications

  ENGINE TOP END 5-9 Specifications Item Standard Service Limit Camshafts Cam Height: 35.030 ∼ 35.144 mm (1.3791 ∼ 1.3836 in.) Exhaust 34.93 mm (1.375 in.) 35.302 ∼ 35.416 mm (1.3898 ∼ 1.3943 in.) Inlet 35.20 mm (1.386 in.) 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in.) Camshaft Journal, Camshaft 0.16 mm (0.0063 in.) Cap Clearance...
• Page 256 5-10 ENGINE TOP END Specifications Item Standard Service Limit Outside Diameter: 26.9 ∼ 27.1 mm (1.059 ∼ 1.067 in.) Exhaust – – – 30.9 ∼ 31.1 mm (1.216 ∼ 1.224 in.) Inlet – – – Valve Spring Free Length: Exhaust 40.5 mm (1.59 in.) 38.6 mm (1.52 in.) Inlet...

• Page 257: Special Tools

  ENGINE TOP END 5-11 Special Tools Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 32° - 28: 57001-221 57001-1119 Valve Spring Compressor Assembly: Valve Seat Cutter, 60° - 30: 57001-241 57001-1123 Piston Pin Puller Assembly: Valve Seat Cutter Holder Bar: 57001-910 57001-1128 Piston Ring Compressor Grip: Valve Seat Cutter, 45°...
• Page 258 5-12 ENGINE TOP END Special Tools Valve Spring Compressor Adapter, 22: Spark Plug Wrench, Hex 16: 57001-1202 57001-1262 Valve Guide Arbor, 5: Compression Gauge Adapter, M10 × 1.0: 57001-1203 57001-1317 Piston Ring Compressor Belt, 80 ∼ 91: Valve Guide Reamer, 5: 57001-1204 57001-1320 Valve Seat Cutter Holder, 5:...
• Page 259 ENGINE TOP END 5-13 Special Tools NOTE ○ The following valve seat cutters can be used instead of the above tools. Exhaust Valve Seat: Valve Seat Cutter, 45° - 32: 57001-1115 (instead of Valve Seat Cutter: 45° - 30: 57001-1187) Valve Seat Cutter, 32°...

• Page 260: Clean Air System

  5-14 ENGINE TOP END Clean Air System Air Suction Valve Removal • Remove: Cylinder Head Covers (see Cylinder Head Cover Re- moval) Air Suction Valves [A] Air Suction Valve Installation • Install each air suction valve so that stopper side [A] of the reed faces downward.

• Page 261: Clean Air System Hose Inspection

  ENGINE TOP END 5-15 Clean Air System Clean Air System Hose Inspection • Be certain that all the hoses are routed without being flat- tened or kinked, and are connected correctly to the air cleaner housing, air switching valve, and fittings on the cylinder head covers.

• Page 262: Cylinder Head Covers

  5-16 ENGINE TOP END Cylinder Head Covers Cylinder Head Cover Removal • Remove: Seat (see Seat Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) • Slide [A] the air switching valve [B] forward to clear the clamp.

• Page 263: Cylinder Head Cover Installation

  ENGINE TOP END 5-17 Cylinder Head Covers ○ Move the obstruct parts between the cylinder head cover and frame for the cylinder head removal, if necessary. Then lift the cover upward, make sure the spark plug pipe [A] stays in the cylinder head. If the pipe comes up with the cover, reinstall it in the original position.

• Page 264: Camshaft Chain Tensioners

  5-18 ENGINE TOP END Camshaft Chain Tensioners Camshaft Chain Tensioner Removal • Remove: Engine (see Engine Removal in the Engine Removal/In- stallation chapter) Camshaft (see Camshaft Removal) Cylinder Head (see Cylinder Head Removal) • Remove the camshaft chain tensioner body from the cylinder.

• Page 265: Camshafts, Camshaft Chains

  ENGINE TOP END 5-19 Camshafts, Camshaft Chains Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Ignition Coil Cover (For Front Cylinder) (see Ignition Coil Removal in the Electrical System chapter) Tensioner Cap Bolt [A], Washer [B] and Spring NOTICE Do not turn over the crankshaft while the tensioner cap bolt is removed, The tensioner body is loose...

• Page 266: Camshaft Installation

  5-20 ENGINE TOP END Camshafts, Camshaft Chains Camshaft Installation • Apply molybdenum disulfide oil solution to all cam parts and journals. NOTE ○ The front and rear camshafts are different. The rear camshaft [A] has a groove [B]. • Remove: Alternator Outer Cover (see Alternator Outer Cover Re- moval in the Electrical System chapter) Bolts [A]...

• Page 267: Camshaft, Camshaft Cap Wear Inspection

  ENGINE TOP END 5-21 Camshafts, Camshaft Chains NOTE ○ Installing the rear camshaft is the same as for the front camshaft. But noting the following. • Set the rear piston at TDC. ○ Align the rear piston TDC mark [A] and timing mark [B] by turning the crankshaft counterclockwise [C] 305°...

• Page 268: Camshaft Runout Inspection

  5-22 ENGINE TOP END Camshafts, Camshaft Chains Camshaft Runout Inspection • Remove the camshaft (see Camshaft Removal). • Set the camshaft in a camshaft alignment jig or on V blocks. • Measure runout with a dial gauge at the specified place as shown in the figure.

• Page 269: Camshaft And Sprocket Assembly

  ENGINE TOP END 5-23 Camshafts, Camshaft Chains Camshaft and Sprocket Assembly • Clean the sprocket bolt [A] and threads of the camshaft. • Be sure to install the pin [B]. • Apply a non-permanent locking agent to the threads of the camshaft sprocket bolt, and tighten it.

• Page 270: Rocker Shafts, Rocker Arms

  5-24 ENGINE TOP END Rocker Shafts, Rocker Arms Rocker Shaft, Rocker Arm Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Camshaft Cap (see Camshaft Removal) Rocker Shafts [A] Rocker Arms [B] and Springs [C] Rocker Shaft, Rocker Arm Installation •...

• Page 271: Cylinder Heads

  ENGINE TOP END 5-25 Cylinder Heads Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Seat (see Seat Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Spark Plugs (see Spark Plug Replacement in the Peri- odic Maintenance chapter)

• Page 272: Cylinder Head Removal

  5-26 ENGINE TOP END Cylinder Heads Cylinder Head Removal • Remove: Engine (see Engine Removal in the Engine Removal/In- stallation chapter) Camshaft (see Camshaft Removal) • Remove the cylinder head nuts following sequence [1 ∼ • Remove the cylinder head. Cylinder Head Installation NOTE ○...

• Page 273: Valves

  ENGINE TOP END 5-27 Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment • Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). •...

• Page 274: Valve Guide Installation

  5-28 ENGINE TOP END Valves Valve Guide Installation • Apply oil to the valve guide outer surface before installa- tion. • Heat the area around the valve guide hole to about 120 ∼ 150°C (248 ∼ 302°F). • Drive the valve guide in from the top of the head using the valve guide arbor [A].

• Page 275: Valve Seat Inspection

  ENGINE TOP END 5-29 Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat.
• Page 276 5-30 ENGINE TOP END Valves Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.
• Page 277 ENGINE TOP END 5-31 Valves • Measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind [A] until the diameter is within the specified range.
• Page 278 5-32 ENGINE TOP END Valves • Lap the valve to the seat, once the seat width and outside diameter are within the ranges specified above. ○ Put a little coarse grinding compound on the face of the valve in a number of places around the valve head. ○...
• Page 279 ENGINE TOP END 5-33 Valves...

• Page 280: Cylinders, Pistons

  5-34 ENGINE TOP END Cylinders, Pistons Cylinder Removal • Remove: Engine (see Engine Removal in the Engine Removal/In- stallation chapter) Cylinder Head (see Cylinder Head Removal) • Pull out the front camshaft chain guide [A] and oil pipe [B]. • Tap lightly up the cylinder with a plastic mallet to separate from the crankcase.
• Page 281 ENGINE TOP END 5-35 Cylinders, Pistons • Do not mix up the top ring and second ring. • Install the top ring [A] so that the "R" mark [B] faces up. • Install the second ring [C] so that the "RN" mark [D] faces •...

• Page 282: Cylinder Wear Inspection

  5-36 ENGINE TOP END Cylinders, Pistons NOTE ○ If a new piston or cylinder is used, check piston to cylin- der clearance (see Piston/Cylinder Clearance), and use new piston ring. • Replace the cylinder base gasket with a new one. •...

• Page 283: Piston Ring, Piston Ring Groove Wear Inspection

  ENGINE TOP END 5-37 Cylinders, Pistons Piston Ring, Piston Ring Groove Wear Inspection • Check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. •...

• Page 284: Piston Ring End Gap Inspection

  5-38 ENGINE TOP END Cylinders, Pistons Piston Ring End Gap Inspection • Place the piston ring [A] inside the cylinder, using the pis- ton to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. •...

• Page 285: Mufflers

  ENGINE TOP END 5-39 Mufflers Muffler Removal WARNING The muffler can become extremely hot during nor- mal operation and cause severe burns. Do not re- move the muffler while it is hot. • Remove: Clamp Bolts (Loosen) [A] Bolt [B] Rear Muffler Cover [C] •...

• Page 286: Muffler Installation

  5-40 ENGINE TOP END Mufflers • Remove the rear exhaust pipe holder nuts [A]. • Remove the rear and front muffler jointed. Muffler Installation • Joint the rear and front muffler. • Temporary tighten the muffler joint clamp bolt [A]. •...
• Page 287 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tool ..........................Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Clutch Cable Removal ...................... Clutch Cable Installation ....................Clutch Cable Lubrication....................Clutch Lever Holder Installation ..................

• Page 288: Exploded View

  6-2 CLUTCH Exploded View...
• Page 289 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Hub Nut 13.3 MO, R Clutch Spring Bolts 87 in·lb Right Engine Cover Bolts 87 in·lb L (1) CL: Apply cable lubricant. EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent.

• Page 290: Specifications

  6-4 CLUTCH Specifications Item Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play – – – Clutch Friction Plate Thickness: 2.9 ∼ 3.1 mm (0.1141 ∼ 0.1220 in.) 2.8 mm (0.110 in.) Friction and Steel Plate Warp 0.2 mm (0.008 in.) or less 0.3 mm (0.012 in.) Clutch Spring Free Length...

• Page 291: Special Tool

  CLUTCH 6-5 Special Tool Clutch Holder: 57001-1243...

• Page 292: Clutch Lever And Cable

  6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Lever Free Play Adjustment • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Cable Removal •...

• Page 293: Clutch Lever Holder Installation

  CLUTCH 6-7 Clutch Lever and Cable Clutch Lever Holder Installation • Install the clutch lever holder so that the mating surface [A] of the lever holder is aligned with the punch mark [B] of the handlebar. Clutch Lever Installation WARNING If the pin of the starter lockout switch has been broken, the starter lockout system will not work properly.
• Page 294 6-8 CLUTCH Clutch Lever and Cable • Tighten the bolt [A] and locknut [B]. • Install the upper end of the clutch cable (see Clutch Cable Installation). • Adjust the clutch cable (see Clutch Operation Inspection in the Periodic Maintenance chapter). •...

• Page 295: Right Engine Cover

  CLUTCH 6-9 Right Engine Cover Right Engine Cover Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) Coolant (see Coolant Change in the Periodic Mainte- nance chapter) • Remove: Brake Pedal (see Brake Pedal Removal in the Brakes chapter) Right Footpeg (see Footpeg Removal/Installation in the Frame chapter)

• Page 296: Release Shaft Removal

  6-10 CLUTCH Right Engine Cover Release Shaft Removal NOTICE Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary. If re- moved, the oil seal replacement may be required. • Remove the right engine cover (see Right Engine Cover Removal).

• Page 297: Clutch Removal

  CLUTCH 6-11 Clutch Clutch Removal • Remove: Right Engine Cover (see Right Engine Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with thrust bearing and pusher [C]) • Remove: Friction Plates and Steel Plates Clutch Hub Nut [A] ○...

• Page 298: Clutch Plate, Wear, Damage Inspection

  6-12 CLUTCH Clutch • Install the washer so that the OUTSIDE mark [A] faces outward. • Replace the clutch hub nut with a new one. • Apply molybdenum disulfide oil solution to seating surface of the hub nut. • Holding the clutch hub, tighten the clutch hub nut. Special Tool - Clutch Holder: 57001-1243 Torque - Clutch Hub Nut: 130 N·m (13.3 kgf·m, 96 ft·lb) •...

• Page 299: Clutch Plate Warp Inspection

  CLUTCH 6-13 Clutch Clutch Plate Warp Inspection • Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate [A] and each friction plate or steel plate [B] with a thickness gauge [C].
• Page 301 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools and Sealant ...................... Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Change ....................... Oil Screen Cleaning ......................Oil Pressure Relief Valve......................

• Page 302: Exploded View

  7-2 ENGINE LUBRICATION SYSTEM Exploded View...

• Page 303: Engine Lubrication System

  ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Oil Drain Plug Oil Filter Oil Filter Plate Bolts 0.80 69 in·lb Oil Pipe Bolts (Crankcase Inside) 87 in·lb Oil Pipe Bolts (Crankcase Outside) 87 in·lb Oil Pressure Relief Valve Oil Pressure Switch Oil Pressure Switch Adapter Oil Pump Cover Bolts...

• Page 304: Engine Oil Flow Chart

  7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 1. Rocker Arms 5. Oil Screen 9. Oil Filter 2. Oil Pipes 6. Oil Pump 10. Oil Pressure Relief Valve 3. Output Shaft 7. Crankshaft 4. Drive Shaft 8. Oil Pressure Switch...

• Page 305: Specifications

  ENGINE LUBRICATION SYSTEM 7-5 Specifications Item Standard Engine Oil Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity 3.0 L (3.2 US qt) (when filter is not removed) 3.2 L (3.4 US qt) (when filter is removed) 3.7 L (3.9 US qt) (when engine is completely dry) Level Between upper and lower level lines (after idling or running)

• Page 306: Special Tools And Sealant

  7-6 ENGINE LUBRICATION SYSTEM Special Tools and Sealant Oil Pressure Gauge, 10 kgf/cm²: Oil Filter Wrench: 57001-164 57001-1249 Oil Pressure Gauge Adapter, M10 × 1.25: Liquid Gasket, TB1211: 57001-1182 56019-120...

• Page 307: Engine Oil And Oil Filter

  WARNING light illuminates, safely pull to the side of the road and stop the engine. Check the oil level and/or have the engine inspected by a Kawasaki dealer. If the oil level is too high, remove the excess oil, using a syringe or some other suitable device.

• Page 308: Oil Screen Cleaning

  7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter Oil Screen Cleaning • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove the oil screen plug [A], spring and washer. • Pull out the oil screen [A]. •...

• Page 309: Oil Pressure Relief Valve

  ENGINE LUBRICATION SYSTEM 7-9 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal/Installation • Split the crankcase (see Crankcase Splitting in the Crank- shaft/Transmission chapter). • Remove the relief valve [A] from the right crankcase. • Apply a non-permanent locking agent to the threads of the relief valve, and tighten it.

• Page 310: Oil Pump, Oil Pump Drive Chain

  7-10 ENGINE LUBRICATION SYSTEM Oil Pump, Oil Pump Drive Chain Oil Pump Removal • Split the crankcase (see Crankcase Splitting in the Crank- shaft/Transmission chapter). • Remove: Crankshaft (see Crankshaft Removal in the Crank- shaft/Transmission chapter) Oil Pipes (see Oil Pipe (Crankcase Inside) Removal) Oil Pump Cover Bolts [A] •...

• Page 311: Oil Pump Drive Chain Guide Installation

  ENGINE LUBRICATION SYSTEM 7-11 Oil Pump, Oil Pump Drive Chain Oil Pump Drive Chain Guide Installation • Install the chain guide [A] to the left crankcase. • Apply a non-permanent locking agent to the threads of the chain guide bolt [B], and tighten it. Torque - Oil Pump Drive Chain Guide Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)

• Page 312: Oil Pressure Measurement

  7-12 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement • Remove the regulator/rectifier (see Regulator/Rectifier Removal in the Electrical System chapter). • Remove the oil pressure switch together with the adapter (see Oil Pressure Switch Removal) without draining the engine oil.

• Page 313: Oil Pressure Switch

  ENGINE LUBRICATION SYSTEM 7-13 Oil Pressure Switch Oil Pressure Switch Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Switch Cover [A] Switch Terminal Bolt [B] Oil Pressure Switch [C] Oil Pressure Switch Installation •...

• Page 314: Oil Pipe And Oil Hose

  7-14 ENGINE LUBRICATION SYSTEM Oil Pipe and Oil Hose Oil Pipe (Crankcase Outside) Removal • Remove: Alternator Cover (see Alternator Cover Removal in the Electrical System chapter) Oil Pipe Bolts [A] Oil Pipe [B] Oil Pipe (Crankcase Outside) Installation • Apply grease to the O-rings [A].

• Page 315: Blowby Gas System Inspection

  ENGINE LUBRICATION SYSTEM 7-15 Oil Pipe and Oil Hose • Install the oil return pipe [A]. • Tighten: Torque - Oil Return Pipe Bolts [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb) Blowby Gas System Inspection • Remove the ignition coil with the bracket (see Ignition Coil Removal in the Electrical System chapter).
• Page 317 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tool ..........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................

• Page 318: Exploded View

  8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
• Page 319 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Downtube Bolts Engine Mounting Nuts Engine Mounting Bracket Bolts (M10) Engine Mounting Bracket Bolts (M8) 5. VN900C7 ∼ C9 Models WL: Apply a soap and water solution. R: Replacement Parts...

• Page 320: Special Tool

  8-4 ENGINE REMOVAL/INSTALLATION Special Tool Jack: 57001-1238...

• Page 321: Engine Removal/Installation

  ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) Coolant (see Coolant Change in the Periodic Mainte- nance chapter) • Remove: Seat (see Seat Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Mufflers (see Muffler Removal in the Engine Top End...
• Page 322 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Disconnect the speed sensor lead connector [A]. • Disconnect: Water Temperature Sensor Lead Connector [A] Water Hoses [B] • Remove the thermostat housing cover bracket bolt [C]. • Remove: Cap [A] and Bolt Ignition Switch [B] •...
• Page 323 ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Support the frame with the jack. Special Tool - Jack: 57001-1238 • Squeeze the brake lever slowly and hold it with a band [A]. WARNING Motorcycle may fall over unexpectedly resulting in an accident or injury. Be sure to hold the front brake when removing the engine.

• Page 324: Engine Removal

  8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Installation • When installing the rubber dampers into the bracket, lu- bricate the outer surface of the dampers with a soap and water solution. NOTICE Do not lubricate the rubber damper with engine oil or petroleum distillates because they will deterio- rate the rubbers.
• Page 325 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealants ....................Crankcase Splitting......................... Crankcase Splitting ......................Crankcase Assembly ......................9-10 Crankshaft, Connecting Rods....................9-13 Crankshaft Removal ......................9-13 Crankshaft Installation ...................... 9-13 Connecting Rod Removal ....................9-13 Connecting Rod Installation ....................

• Page 326: Exploded View

  9-2 CRANKSHAFT/TRANSMISSION Exploded View...
• Page 327 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Balancer Gear Bolt Balancer Shaft Bearing Stopper Plate Screws 0.70 61 in·lb Bearing Retainer Bolts 87 in·lb Clamp Mounting Bolts 87 in·lb Connecting Rod Big End Bolts Crankcase Bolts (M10) Crankcase Bolts (M6) 87 in·lb Engine Ground Lead Bolt...
• Page 328 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
• Page 329 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb External Shift Mechanism Cover Bolts 87 in·lb Gear Set Lever Bolt 87 in·lb Shift Drum Bearing Stopper Bolts 87 in·lb Shift Drum Cam Bolt 106 in·lb Shift Pedal Bolt and Nut Shift Pedal Clamp Bolt 106 in·lb Shift Rod Locknut (Front)

• Page 330: Specifications

  9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods Connecting Rod Bend – – – TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist – – – TIR 0.2/100 mm (0.008/3.94 in.) 0.08 ∼ 0.30 mm Connecting Rod Big End Side Clearance 0.5 mm (0.003 ∼...
• Page 331 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit Crankshaft Runout TIR 0.02 mm TIR 0.05 mm (0.0008 in.) or less (0.002 in.) 44.984 ∼ 45.000 mm Crankshaft Main Journal Diameter 44.96 mm (1.7710 ∼ 1.7716 in.) (1.770 in.) 45.025 ∼ 45.041 mm Crankcase Main Bearing Bore Diameter 45.07 mm (1.7726 ∼...

• Page 332: Special Tools And Sealants

  9-8 CRANKSHAFT/TRANSMISSION Special Tools and Sealants Outside Circlip Pliers: Rotor Holder: 57001-144 57001-1674 Bearing Driver Set: Liquid Gasket, TB1211F: 57001-1129 92104-0004 Grip: Liquid Gasket, TB1216B: 57001-1591 92104-1064...

• Page 333: Crankcase Splitting

  CRANKSHAFT/TRANSMISSION 9-9 Crankcase Splitting Crankcase Splitting • Remove: Engine (see Engine Removal in the Engine Removal/In- stallation chapter) Starter Motor (see Starter Motor Removal in the Electri- cal System chapter) Oil Filter (see Oil Filter Replacement in the Periodic Maintenance chapter) Plate Bolts [A] Oil Filter Plate [B] and O-rings (2) •...

• Page 334: Crankcase Assembly

  9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Put the engine so that the left crankcase is down. • Pry the points [A] to split the crankcase halves apart, and remove the right crankcase half. ○ Tap lightly around the crankcase joint with a plastic mallet, and split the crankcase.
• Page 335 CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting • Apply liquid gasket [A] to the mating surface of the right crankcase half. Sealant - Liquid Gasket, TB1216B: 92104-1064 NOTICE Do not apply liquid gasket to the oil passage [B] and hole [C]. NOTE ○ Make the application finish within 20 minutes when the liquid gasket to the mating surface of the right crankcase half is applied.
• Page 336 9-12 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Apply silicone sealant to the crankcase mating surface [A] as shown in the figure. Sealant - Liquid Gasket, TB1211F: 92104-0004...

• Page 337: Crankshaft, Connecting Rods

  CRANKSHAFT/TRANSMISSION 9-13 Crankshaft, Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the crankshaft. Crankshaft Installation • Insert the crankshaft tapered end into the left crankcase [A]. • Install the left connecting rod [B] into the rear cylinder opening [C], and right connecting rod [D] into the front cylinder opening [E].

• Page 338: Crankshaft/Connecting Rod Cleaning

  9-14 CRANKSHAFT/TRANSMISSION Crankshaft, Connecting Rods ○ When installing the inserts [A], be careful not to damage the insert surface with the edge of the connecting rod [B] or the cap [C]. One way to install inserts is as follows. Installation [D] to Cap Installation [E] to Connecting Rod Push [F] Dowel Pin [G]...

• Page 339: Connecting Rod Bend

  CRANKSHAFT/TRANSMISSION 9-15 Crankshaft, Connecting Rods Connecting Rod Bend • Remove the connecting rod big end bearing inserts, and reinstall the connecting rod big end cap. • Select an arbor [A] of the same diameter as the connect- ing rod big end, and insert the arbor through the connect- ing rod big end.
• Page 340 9-16 CRANKSHAFT/TRANSMISSION Crankshaft, Connecting Rods If clearance is within the standard, no bearing replace- ment is required. If clearance is between 0.054 mm (0.0021 in.) and the service limit (0.09 mm, 0.035 in.), replace the bear- ing inserts [A] with inserts painted blue [B]. Check insert/crankpin clearance with the plastigage.

• Page 341: Crankshaft Side Clearance Inspection

  CRANKSHAFT/TRANSMISSION 9-17 Crankshaft, Connecting Rods • Select the proper bearing insert [A] in accordance with the combination of the connecting rod and crankshaft coding. Size Color [B] Connecting Rod Big End Bearing Insert Selection Bearing Insert Con-rod Big End Crankpin Bore Diameter Diameter Size Color...

• Page 342: Crankshaft Main Bearing/Main Journal Wear Inspection

  9-18 CRANKSHAFT/TRANSMISSION Crankshaft, Connecting Rods Crankshaft Main Bearing/Main Journal Wear Inspection • Measure the diameter [A] of the crankshaft main journal. If any journal has worn past the service limit, replace the crankshaft with a new one. Crankshaft Main Journal Diameter 44.984 ∼...

• Page 343: Balancer, Starter Motor Clutch

  CRANKSHAFT/TRANSMISSION 9-19 Balancer, Starter Motor Clutch Left Balancer Removal • Remove the alternator cover (see Alternator Cover Re- moval in the Electrical System chapter). • Wipe oil off the outer circumference of the alternator rotor. • Hold the alternator rotor steady with the rotor holder [A], and remove the balancer gear bolt [B] and washer [C].

• Page 344: Right Balancer And Starter Motor Clutch Installation

  9-20 CRANKSHAFT/TRANSMISSION Balancer, Starter Motor Clutch • Remove: Starter Motor Clutch Gear Bolt [A] Washers [B] • Remove: Starter Motor Clutch Gear [A] Torque Limiter [B] Needle Bearing [C] Collar [D] Starter Motor Clutch Assembly [E] Washer If the assembly is hard to remove, use a suitable puller. •...

• Page 345: Starter Motor Clutch Inspection

  CRANKSHAFT/TRANSMISSION 9-21 Balancer, Starter Motor Clutch • Install: Torque Limiter Washer Collar [A] and Needle Bearing [B] • Install the starter motor clutch gear [C] while turning [D] the gear. • Install the alternator rotor (see Alternator Rotor Installa- tion in the Electrical System chapter). •...

• Page 346: Torque Limiter

  9-22 CRANKSHAFT/TRANSMISSION Torque Limiter Torque Limiter Removal • Remove: Right Engine Cover (see Right Engine Cover Removal in the Clutch chapter) Washer [A] Starter Motor Clutch Gear [B] (see Right Balancer and Starter Motor Clutch Removal) Torque Limiter [C] NOTICE Do not disassemble the torque limiter.

• Page 347: Primary Gear

  CRANKSHAFT/TRANSMISSION 9-23 Primary Gear Primary Gear Removal • Remove the alternator cover (see Alternator Cover Re- moval in the Electrical System chapter). • Wipe oil off the outer circumference of the alternator rotor. • Hold the alternator rotor steady with the rotor holder [A]. ○...

• Page 348: Transmission

  9-24 CRANKSHAFT/TRANSMISSION Transmission Shift Pedal Removal • Remove: Alternator Outer Cover (see Alternator Outer Cover Re- moval in the Electrical System chapter) Shift Pedal Clamp Bolt [A] • Remove: Nut [A], Bolt and Washer Shift Pedal [B] Shift Pedal Installation •...

• Page 349: External Shift Mechanism Removal

  CRANKSHAFT/TRANSMISSION 9-25 Transmission • Loosen the locknuts [A] and turn the shift rod [B] so that the outside length [C] of the locknuts is 177 ±1 mm (6.97 ±0.04 in.). ○ The rear locknut has left-hand threads. Torque - Shift Rod Locknut (Front): 9.8 N·m (1.0 kgf·m, 87 in·lb) Shift Rod Locknut (Rear): 9.8 N·m (1.0 kgf·m, 87 in·lb)

• Page 350: External Shift Mechanism Inspection

  9-26 CRANKSHAFT/TRANSMISSION Transmission • Set the these cover bolts [A] to the cover before cover installed. • Install the cover with the shaft to the crankcase. • Tighten: Torque - External Shift Mechanism Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) External Shift Mechanism Inspection •...

• Page 351: Transmission Shaft Disassembly

  CRANKSHAFT/TRANSMISSION 9-27 Transmission • Install the shift drum [A]. • Set the shift drum in the neutral position. • Apply engine oil to the shift rod [B], and install it. Transmission Shaft Disassembly • Remove the transmission shafts (see Transmission Shaft and Shift Fork Removal).
• Page 352 9-28 CRANKSHAFT/TRANSMISSION Transmission • Replace any circlip that were removed with new ones. • Install the circlips [A] so that the opening [B] is aligned with a spline groove [C]. • Check that each gear springs or slides freely on the trans- mission shaft without binding after assembly.
• Page 353 CRANKSHAFT/TRANSMISSION 9-29 Transmission 1. Drive Shaft 9. Thrust Washer (20 × 41 × 1) 2. Output Shaft 10. Circlip 3. 1st Gear 11. Thrust Washer (25.3 × 30 × 1) 4. 2nd Gear 12. Circlip 5. 3rd Gear 13. Toothed Washer 6.

• Page 354: Shift Drum Removal

  9-30 CRANKSHAFT/TRANSMISSION Transmission Shift Drum Removal • Remove: Transmission Shafts (see Transmission Shaft and Shift Fork Removal) Bolts [A] Bearing Stopper [B] • While aligning the shift drum cam with the left crankcase hole, pull out the shift drum [C]. Shift Drum Installation •...

• Page 355: Shift Drum Assembly

  CRANKSHAFT/TRANSMISSION 9-31 Transmission Shift Drum Assembly • Assemble: Dowel Pin (Shorter) [A] Shift Drum Holder [B] Spring [C] Circlip [D] Special Tool - Outside Circlip Pliers: 57001-144 • Assemble: Dowel Pin (Longer) [E] Bearing [F] Shift Drum Cam [G] Shift Drum [H] •...

• Page 356: Shift Fork Guide Pin/Drum Groove Wear Inspection

  9-32 CRANKSHAFT/TRANSMISSION Transmission Shift Fork Guide Pin/Drum Groove Wear Inspection • Measure the diameter of each shift fork guide pin [A], and measure the width [B] of each shift drum groove. If the guide pin on any shift fork is less than the service limit, the fork must be replaced.

• Page 357: Ball Bearing And Oil Seal

  CRANKSHAFT/TRANSMISSION 9-33 Ball Bearing and Oil Seal Bearing and Oil Seal Installation • When installing a bearing other than the following parts, press it in with the marked side facing out. Special Tool - Bearing Driver Set: 57001-1129 Right Crankcase •...
• Page 359 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-7 Rear Wheel Removal......................10-7 Rear Wheel Installation..................... 10-9 Wheel Inspection ......................10-11 Axle Inspection........................

• Page 360: Exploded View

  10-2 WHEELS/TIRES Exploded View...
• Page 361 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Valve Cap 0.15 0.015 1.3 in·lb Air Valve Core 0.03 2.7 in·lb Air Valve Nuts 0.15 13 in·lb Front Axle Clamp Bolt Front Axle Nut 11.0 Rear Axle Nut 11.0 7.

• Page 362: Specifications

  10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial TIR 0.5 mm (0.02 in.) or less TIR 1.0 mm (0.04 in.) Radial TIR 0.8 mm (0.03 in.) or less TIR 1.0 mm (0.04 in.) Axle Runout/100 mm (3.94 in.): Front TIR 0.05 mm (0.002 in.) or less TIR 0.2 mm (0.008 in.)

• Page 363: Special Tools

  WHEELS/TIRES 10-5 Special Tools Bearing Driver Set: Bearing Remover Shaft, 9: 57001-1129 57001-1265 Jack: Bearing Remover Head, 20 × 22: 57001-1238 57001-1293...

• Page 364: Wheels (Rims)

  10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Front Caliper Mounting Bolts [A] Front Caliper [B] • Remove: Axle Caps (EUR Models) Front Axle Clamp Bolt [A] (Loosen) Front Axle Nut [B] • Using the jack under the frame pipe, and a commercially available jack under the engine, raise the front wheel off the ground until the rear wheel touches the ground.

• Page 365: Front Wheel Installation

  WHEELS/TIRES 10-7 Wheels (Rims) Front Wheel Installation • Apply high-temperature grease to the grease seal lips. • Fit the collars [A] on the both sides of the hub. ○ The collars are identical. • Insert the axle from the right side of the wheel. •...
• Page 366 10-8 WHEELS/TIRES Wheels (Rims) • Squeeze the brake lever slowly and hold it with a band [A]. NOTICE Be sure to hold the front brake when removing the rear wheel, or the motorcycle may fall over. The motorcycle could be damaged. WARNING Motorcycle may fall over unexpectedly resulting in an accident or injury.

• Page 367: Rear Wheel Installation

  WHEELS/TIRES 10-9 Wheels (Rims) • Incline the rear wheel to the right diagonally. • Remove the drive belt [A] from the rear pulley [B]. • Raise the jack until the wheel clear the rear fender to re- move the rear wheel [A]. NOTICE Do not lay the wheel on the ground with the disc facing down.
• Page 368 10-10 WHEELS/TIRES Wheels (Rims) • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment. ○...

• Page 369: Wheel Inspection

  WHEELS/TIRES 10-11 Wheels (Rims) Wheel Inspection • Raise the front/rear wheel off the ground with jack. Special Tool - Jack: 57001-1238 • Spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearings. •...

• Page 370: Balance Inspection

  10-12 WHEELS/TIRES Wheels (Rims) Balance Inspection • Remove the front and rear wheels (see Front/Rear Wheel Removal). • Support the wheel so that it can be spun freely. • Spin the wheel lightly, and mark [A] the wheel at the top when the wheel stops.

• Page 371: Balance Weight Installation

  30 g (1.06 oz.) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20, and 30 grams (0.35, 0.71, and 1.06 oz.) sizes. An imbalance of less than 10 grams (0.35 oz.) will not usually affect running stability.
• Page 372 30 g (1.06 oz.) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20, and 30 grams (0.35, 0.71, and 1.06 oz.) sizes. An imbalance of less than 10 grams (0.35 oz.) will not usually affect running stability.
• Page 373 WHEELS/TIRES 10-15 Wheels (Rims) • Install the balance weight on the rim. ○ Slip the weight on the rim flange [A] by pushing or lightly hammering [B] the weight in the direction shown in the figure. Tire Bead [C] Blade [D] •...

• Page 374: Tires

  10-16 WHEELS/TIRES Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter. Tire Inspection • Refer to the Wheel/Tire Damage Inspection in the Peri- odic Maintenance chapter. Tire Removal • Remove: Wheel (see Front/Rear Wheel Removal) Valve Core (Let out the air) •...
• Page 375 WHEELS/TIRES 10-17 Tires • Insert the new air valve in the front wheel rim. Valve Cap [A] Valve Body [B] Valve Nuts [C] Valve Washer [D] Rim [E] Valve Grommet [F] ○ Remove the valve cap, valve nuts, valve washer and in- sert the valve stem through the rim from the inside out.

• Page 376: Tire Repair

  Also, permanent (internal) repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire. For these reasons, Kawasaki does not recommend temporary (exter- nal) repair. Only appropriate permanent (internal) repairs are recommended. Repair methods may vary slightly from make to make.

• Page 377: Hub Bearing

  WHEELS/TIRES 10-19 Hub Bearing Hub Bearing Removal • Remove the wheel (see Front/Rear Wheel Removal), and take out the following. Front Grease Seals [A] Rear Coupling [A] Collar [B] O-ring [C] Grease Seal [D] • Take the bearings [A] out of the hub, using the bearing remover.

• Page 378: Hub Bearing Inspection

  10-20 WHEELS/TIRES Hub Bearing • Replace the grease seals with new ones. • Press in the grease seal [A] so that the seal surface is flush [B] with the end of the hole. ○ Apply high-temperature grease to the grease seal lips. Special Tool - Bearing Driver Set [C]: 57001-1129 Hub Bearing Inspection Since the hub bearings are made to extremely close tol-...
• Page 379 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........................11-2 Specifications ......................... 11-4 Special Tools .......................... 11-5 Drive Belt ..........................11-6 Belt Handling Precautions....................11-6 Drive Belt Wear Inspection ....................11-7 Drive Belt Deflection Inspection ..................11-7 Drive Belt Deflection Adjustment ..................11-7 Drive Belt Removal ......................

• Page 380: Exploded View

  11-2 FINAL DRIVE Exploded View...
• Page 381 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Drive Belt Guide Bolts 87 in·lb Engine Pulley Cover Bolts 87 in·lb Engine Pulley Cover Clamp Mounting Bolt 87 in·lb Engine Pulley Mounting Nut 13.0 Engine Pulley Plate Bolts 87 in·lb Rear Pulley Mounting Nuts Rear Pulley Plate Bolts...

• Page 382: Specifications

  11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Belt Make GATES, 153T – – – 1.5 ∼ 4.0 mm (0.06 ∼ 0.16 in.) Belt Deflection (45 N, 4.6 kgf, 10 lb force) – – – (When installing new belt or engine is remounted) 1.5 mm (0.06 in.) –...

• Page 383: Special Tools

  FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Pulley Holder: 57001-143 57001-1572 Oil Seal & Bearing Remover: Grip: 57001-1058 57001-1591 Bearing Driver Set: 57001-1129...

• Page 384: Drive Belt

  11-6 FINAL DRIVE Drive Belt The drive belt must be checked, and adjusted in accor- dance with the Periodic Maintenance Chart for safety and to prevent excessive wear. If the belt becomes badly worn or maladjusted-either too loose or too tight-the belt could jump off the pulley or break.

• Page 385: Drive Belt Wear Inspection

  FINAL DRIVE 11-7 Drive Belt • Do not twist [A] the drive belt [B] as shown in the figure. ○ This includes coiling the belt to make it smaller for pack- aging. • Do not use tools [A] to pry [B] the drive belt [C] onto the application.

• Page 386: Drive Belt Installation

  11-8 FINAL DRIVE Drive Belt Drive Belt Installation • Installation is the reverse of removal. Note the following. NOTE ○ Be sure the printed information faces the same direction so the belt rotates in the same direction as originally in- stead.

• Page 387: Pulley And Coupling

  FINAL DRIVE 11-9 Pulley and Coupling Engine Pulley Cover Removal • Remove: Alternator Outer Cover (see Alternator Outer Cover Re- moval in the Electrical System chapter) Bolt [A] Clamp [B] Bolts [C] Engine Pulley Cover [D] Engine Pulley Cover Installation •...

• Page 388: Engine Pulley Installation

  11-10 FINAL DRIVE Pulley and Coupling • Hold the engine pulley [A] steady with the pulley holder [B], and remove the pulley mounting nut [C]. Special Tools - Pulley Holder: 57001-1572 Grip: 57001-1591 • Pull out the engine pulley from the output shaft. Engine Pulley Installation •...

• Page 389: Rear Pulley Coupling Removal

  FINAL DRIVE 11-11 Pulley and Coupling Rear Pulley Coupling Removal • Remove the rear wheel (see Rear Wheel Removal in the Wheels/Tires chapter). • Loosen the rear pulley mounting nuts [A] lightly. • Remove the rear pulley [B] with the rear pulley coupling from the wheel [C].

• Page 390: Coupling Bearing Removal

  11-12 FINAL DRIVE Pulley and Coupling Coupling Bearing Removal • Remove: Rear Pulley Coupling (see Rear Pulley Coupling Re- moval) Sleeve [A] • Remove: Collar [A] Grease Seal [B] • Remove the circlip [A]. Special Tool - Inside Circlip Pliers [B]: 57001-143 •...

• Page 391: Coupling Bearing Inspection

  FINAL DRIVE 11-13 Pulley and Coupling Coupling Bearing Inspection Since the coupling bearing [A] is made to extremely close tolerances, the clearance cannot normally be measured. • Spin it by hand to check its condition. If it is noisy, does not spin smoothly, or has any rough spots, it must be replaced.

• Page 392: Belt Adjuster

  11-14 FINAL DRIVE Belt Adjuster Belt Adjuster Removal • Remove the left and right belt adjuster locknuts [A] and belt adjuster nuts [B]. • Remove the belt adjuster [C] from the swingarm. Belt Adjuster Installation • Insert the left and right belt adjuster [A] into the swingarm facing its machined surface [B] outward.
• Page 393 BRAKES 12-1 Brakes Table of Contents Exploded View........................12-2 Specifications ......................... 12-6 Special Tool ..........................12-7 Brake Lever, Brake Pedal....................... 12-8 Brake Lever Position Adjustment..................12-8 Brake Pedal Position Inspection ..................12-8 Brake Pedal Position Adjustment..................12-8 Brake Pedal Removal ....................... 12-8 Brake Pedal Installation ....................

• Page 394: Exploded View

  12-2 BRAKES Exploded View...
• Page 395 BRAKES 12-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valve 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.10 9 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Front Brake Disc Mounting Bolts Front Brake Light Switch Screw 0.12 11 in·lb Front Brake Reservoir Cap Screws...
• Page 396 12-4 BRAKES Exploded View...
• Page 397 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valves 0.80 69 in·lb Brake Hose Banjo Bolts Brake Pedal Clamp Bolt Rear Brake Disc Mounting Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut B: Apply brake fluid.

• Page 398: Specifications

  12-6 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position 5-way adjustable (to suit rider) – – – Brake Lever Free Play Non-adjustable – – – Pedal Free Play Non-adjustable – – – Pedal Position About 105 mm (4.13 in.) –...

• Page 399: Special Tool

  BRAKES 12-7 Special Tool Inside Circlip Pliers: 57001-143...

• Page 400: Brake Lever, Brake Pedal

  12-8 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator's hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder.

• Page 401: Brake Pedal Installation

  BRAKES 12-9 Brake Lever, Brake Pedal • Remove: Brake Pedal Return Spring [A] Brake Switch Return Spring [B] Cotter Pin [C] Joint Pin [D] Brake Lever [E] Brake Pedal Installation • Apply grease to the brake pedal shaft. • Install: Brake Pedal Return Spring Brake Switch Return Spring •...

• Page 402: Calipers

  12-10 BRAKES Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B]. • Take off the caliper [C] from the disc. • Unscrew the banjo bolt, and disconnect the brake hose from the caliper.

• Page 403: Rear Caliper Disassembly

  BRAKES 12-11 Calipers Rear Caliper Disassembly • Refer to the Caliper Rubber Parts Replacement in the Pe- riodic Maintenance chapter. Rear Caliper Assembly • Refer to the Caliper Rubber Parts Replacement in the Pe- riodic Maintenance chapter. Caliper Fluid Seal Damage Inspection The fluid seal (piston seal) [A] is placed around the pis- ton to maintain clearance between the pad and the disc.

• Page 404: Brake Pads

  12-12 BRAKES Brake Pads Front Brake Pad Removal • Remove the front caliper with the hose installed (see Front Caliper Removal). • Remove: Snap Pin [A] Pad Pin [B] • Remove the jaw side pad [A], and then remove the piston side pad [B].

• Page 405: Rear Brake Pad Installation

  BRAKES 12-13 Brake Pads • Remove the jaw side pad [A], and then remove the piston side pad [B]. Jaw [C] Rear Brake Pad Installation • Before installation, clean the pads with a high flash-point solvent. • Push the caliper pistons [A] in by hand as far as they will •...

• Page 406: Master Cylinder

  12-14 BRAKES Master Cylinder Front Master Cylinder Removal • Disconnect the front brake light switch connector [A]. • Remove the banjo bolt [B] to disconnect the brake hose from the master cylinder (see Brake Hose Replacement in the Periodic Maintenance chapter). •...

• Page 407: Rear Master Cylinder Removal

  BRAKES 12-15 Master Cylinder Rear Master Cylinder Removal • Remove the brake fluid reservoir (see Brake Pedal Re- moval). • Unscrew the brake hose banjo bolt [A] on the master cylin- der. • Loosen the rear master cylinder mounting bolts [B]. •...

• Page 408: Master Cylinder Inspection

  12-16 BRAKES Master Cylinder Master Cylinder Inspection • Disassemble the front and rear master cylinders (see Master Cylinder Rubber Parts Replacement in the Peri- odic Maintenance chapter). NOTICE Do not remove the secondary cup from the piston since removal will damage it. •...

• Page 409: Brake Discs

  BRAKES 12-17 Brake Discs Brake Disc Removal • Remove the wheel (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Unscrew the mounting bolts [A], and take off the disc. Brake Disc Installation • Install the brake disc [A] on the wheel so that the marked side [B] faces out.

• Page 410: Brake Fluid

  12-18 BRAKES Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brake Fluid Change in the Periodic Mainte- nance chapter. Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action.
• Page 411 BRAKES 12-19 Brake Fluid • Bleed the brake line and the caliper. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake lever and hold it [A].
• Page 412 12-20 BRAKES Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. • Never reuse old brake fluid. • Do not use fluid from a container that has been left unsealed or that has been open for a long time. •...

• Page 413: Brake Hoses

  BRAKES 12-21 Brake Hoses Brake Hose Removal/Installation • Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter. Brake Hose Inspection • Refer to the Brake Hose Damage and Installation Condi- tion Inspection in the Periodic Maintenance chapter.
• Page 415 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-8 Front Fork Removal ......................13-8 Front Fork Installation ....................... 13-8 Front Fork Oil Change ...................... 13-8 Front Fork Disassembly ....................13-9 Front Fork Assembly......................

• Page 416: Exploded View

  13-2 SUSPENSION Exploded View...
• Page 417 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Bottom Allen Bolts Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts...
• Page 418 13-4 SUSPENSION Exploded View...
• Page 419 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Nuts Rocker Arm Pivot Shaft Nut Swingarm Pivot Shaft Nut Tie-Rod Nut (Lower) Tie-Rod Nut (Upper) 11.0 6. VN900C7 ∼ C9 G: Apply grease. R: Replacement Parts...

• Page 420: Specifications

  Atmospheric pressure (Non-adjustable) Fork Spring Setting Non-adjustable Damper Setting Non-adjustable Suspension Oil Kawasaki SS-8 or equivalent Amount Approx. 365 mL (12.3 US oz.) (when changing oil) 428 ±2.5 mL (14.5 ±0.084 US oz.) (after disassembly and completely dry) Fork Oil Level 150 ±2 mm (5.91 ±0.08 in.) (below from inner tube top...

• Page 421: Special Tools

  SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Fork Outer Tube Weight: 57001-143 57001-1218 Fork Cylinder Holder Handle: Front Fork Oil Seal Driver: 57001-183 57001-1219 Fork Cylinder Holder Adapter: Jack: 57001-1057 57001-1238 Bearing Driver Set: Fork Oil Level Gauge: 57001-1129 57001-1290...

• Page 422: Front Fork

  13-8 SUSPENSION Front Fork Front Fork Removal • Remove: Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Fender (see Front Fender Removal in the Frame chapter) Headlight Body [A] (see Headlight Body Removal in the Electrical System chapter) Turn Signal Light Lead Connectors [B] (Disconnect) Turn Signal Light Bolts (Both Sides) [C] Turn Signal Lights...

• Page 423: Front Fork Disassembly

  SUSPENSION 13-9 Front Fork • Pour out the fork oil [A] with the fork upside down. • Hold the outer tube vertically in a vise. • Fill the front fork with the specified oil. Suspension Oil - SS-8 (1 L): 44091-0007 Amount (Per Side): When changing oil: Approx.
• Page 424 13-10 SUSPENSION Front Fork • Hold the front fork horizontally in a vise [A]. • Stop the cylinder unit [B] from turning by using the special tools. • Unscrew the Allen bolt [C], and take the gasket out of the bottom of the outer tube.

• Page 425: Front Fork Assembly

  SUSPENSION 13-11 Front Fork Front Fork Assembly • Replace the following parts with new ones. Dust Seal [A] Retaining Ring [B] Oil Seal [C] Inner Guide Bushing [D] Outer Guide Bushing [E] Fork Bottom Allen Bolt Gasket [F] • Install the following parts onto the inner tube. Inner Guide Bushing Outer Guide Bushing Washer...

• Page 426: Inner Tube Inspection

  13-12 SUSPENSION Front Fork • Hold the front fork horizontally in a vise [A]. • Hold the cylinder unit [B] with the special tools and tighten the Allen bolt [C]. Special Tools - Fork Cylinder Holder Handle [D]: 57001-183 Fork Cylinder Holder Adapter [E]: 57001 -1057 •...

• Page 427: Fork Spring Inspection

  SUSPENSION 13-13 Front Fork Fork Spring Inspection • Measure the free length [A] of the fork spring [B]. If the measured length is shorter than the service limit, the spring must be replaced. If the free length of the replace- ment spring and that of the remaining spring vary greatly, the remaining spring should also be replaced in order to keep the fork legs balanced to ensure stability.

• Page 428: Rear Shock Absorber

  13-14 SUSPENSION Rear Shock Absorber Spring Preload Adjustment • Remove the reserve tank (see Reserve Tank Removal in the Cooling System chapter). • Hang the under part of the reserve tank to the holder [A] of the frame as shown in the figure. •...

• Page 429: Rear Shock Absorber Installation

  SUSPENSION 13-15 Rear Shock Absorber • Remove: Lower Shock Absorber Bolt [A] Lower Tie-Rod Bolt [B] Upper Shock Absorber Bolt [C] Rear Shock Absorber Rear Shock Absorber Installation • Pack the rocker arm needle bearings with grease. • Install the rear shock absorber so that the CAUTION label [A] faces left side.

• Page 430: Swingarm

  13-16 SUSPENSION Swingarm Swingarm Removal • Remove: Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Rear Caliper (see Rear Caliper Removal in the Brakes chapter) Rear Shock Absorber (see Rear Shock Absorber Re- moval) Bolts [A] Rear Wheel Mud Guard [B] •...

• Page 431: Swingarm Installation

  SUSPENSION 13-17 Swingarm Swingarm Installation • Apply grease to the needle bearings and grease seals. • Install the collar [A]. • Replace the rear shock absorber nuts and the tie-rod nuts with new ones. • Install the tie-rod to the swingarm. •...

• Page 432: Swingarm Bearing Installation

  13-18 SUSPENSION Swingarm Right Side • Remove the grease seal. • Remove the needle bearing [A] with the available bearing remover. Swingarm Bearing Installation • Replace the grease seals, ball and needle bearings with new ones. • Apply grease to the grease seals, ball and needle bear- ings.

• Page 433: Swingarm Bearing, Sleeve Inspection

  SUSPENSION 13-19 Swingarm Swingarm Bearing, Sleeve Inspection NOTICE Do not remove the bearings for inspection. Re- moval may damage them. • Inspect the sleeve [A], needle bearings [B] and ball bear- ing [C] installed in the swingarm. ○ The rollers and balls in the bearing normally wear very lit- tle, and wear is difficult to measure.

• Page 434: Tie-Rod, Rocker Arm

  13-20 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod Removal • Refer to the Swingarm Removal. Tie-Rod Installation • Refer to the Swingarm Installation. Rocker Arm Removal • Remove the mufflers (see Muffler Removal in the Engine Top End chapter). • Squeeze the brake lever slowly and hold it with a band. •...

• Page 435: Tie-Rod And Rocker Arm Bearing Removal

  SUSPENSION 13-21 Tie-Rod, Rocker Arm Tie-Rod and Rocker Arm Bearing Removal • Remove: Tie-Rod (see Swingarm Removal) Rocker Arm [A] (see Rocker Arm Removal) Sleeves [B] Grease Seals [C] • Remove the needle bearings [D], using the available bearing remover. VN900C7 ∼...
• Page 436 13-22 SUSPENSION Tie-Rod, Rocker Arm NOTE ○ Install the needle bearings so that the marked side faces out. Needle Bearings [A] Grease Seals [B] Front [C] Left Side [D] Right Side [E] Rocker Arm [F] Tie-Rod [G] 6 ±1 mm (0.24 ±0.04 in.) [H] 11.5 ±1 mm (0.453 ±0.04 in.) [I] 5.5 ±1 mm (0.22 ±0.04 in.) [J] 6.5 ±2 mm (0.26 ±0.08 in.) [K]...
• Page 437 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special Tools .......................... 14-4 Steering ..........................14-5 Steering Inspection ......................14-5 Steering Adjustment......................14-5 Steering Stem......................... 14-6 Stem, Stem Bearing Removal................... 14-6 Stem, Stem Bearing Installation..................14-7 Stem Bearing Lubrication....................14-9 Steering Stem Warp Inspection ..................

• Page 438: Exploded View

  14-2 STEERING Exploded View...
• Page 439 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Handlebar Mounting Nuts Steering Stem Head Nut Steering Stem Nut 0.50 43 in·lb AD: Apply adhesive. G: Apply grease. R: Replacement Parts...

• Page 440: Special Tools

  14-4 STEERING Special Tools Bearing Puller: Steering Stem Nut Wrench: 57001-135 57001-1100 Steering Stem Bearing Driver: Head Pipe Outer Race Driver, 46.5: 57001-137 57001-1106 Steering Stem Bearing Driver Adapter, 34.5: Head Pipe Outer Race Remover, ID > 37 mm: 57001-1074 57001-1107 Head Pipe Outer Race Press Shaft: Bearing Puller:...

• Page 441: Steering Inspection

  STEERING 14-5 Steering Steering Inspection • Refer to the Steering Play Inspection in the Periodic Main- tenance chapter. Steering Adjustment • Refer to the Steering Play Adjustment in the Periodic Maintenance chapter.

• Page 442: Steering Stem

  14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Headlight Body (see Headlight Body Removal in the Electrical System chapter) Front Turn Signal Lights (see Front Fork Removal in the Suspension chapter) Headlight Body Bracket Nuts [A] and Bracket [B] Bolt [C] and Bracket [D] •...

• Page 443: Stem, Stem Bearing Installation

  STEERING 14-7 Steering Stem • Remove the lower inner race [A] which is pressed onto the steering stem with special tools. Oil Seal [B] Special Tools - Bearing Puller: 57001-135 Bearing Puller: 57001-1675 ○ Insert the each half-split base [A] under the bottom of the bearing and connect the both bases by tightening the M8 bolts [B].
• Page 444 14-8 STEERING Steering Stem • Settle the bearings in place as follows. ○ Tighten the steering stem nut to 55 N·m (5.6 kgf·m, 40 ft·lb) of torque (To tighten the steering stem nut to the specified torque, hook the wrench on the stem nut, and pull the wrench at the hole by 305 N (31.1 kgf, 68.6 lb) force in the direction shown.).

• Page 445: Stem Bearing Lubrication

  STEERING 14-9 Steering Stem NOTE ○ Tighten the upper fork clamp bolts first, next the stem head nut, last the lower fork clamp bolts. Torque - Front Fork Clamp Bolts (Upper): 20 N·m (2.0 kgf·m, 15 ft·lb) Steering Stem Head Nut: 49 N·m (5.0 kgf·m, 36 ft·lb) Front Fork Clamp Bolts (Lower): 34 N·m (3.5 kgf·m, 25 ft·lb)

• Page 446: Handlebar

  14-10 STEERING Handlebar Handlebar Removal • Remove: Clamp [A] Clutch Lever Assembly [B] Left Switch Housing [C] • Remove: Clamp [A] Front Master Cylinder [B] (see Front Master Cylinder Re- moval in the Brakes chapter) Right Switch Housing [C] Throttle Grip [D] •...
• Page 447 STEERING 14-11 Handlebar • Set the left switch housing [A] to match its mating surface [B] to the punched mark [C] of the handlebar. • Install the switch housing. • Install the clutch lever (see Clutch Lever Installation in the Clutch chapter).
• Page 449 FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Special Tool ..........................15-6 Seat ............................15-7 Seat Removal ........................15-7 Seat Installation ........................ 15-7 Side Covers ..........................15-8 Left Side Cover Removal ....................15-8 Left Side Cover Installation ....................15-8 Right Side Cover Removal....................

• Page 450: Exploded View

  15-2 FRAME Exploded View...
• Page 451 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Downtube Bolts Footpeg Bracket Bolts (Front) Footpeg Bracket Bolts (Rear) Muffler Bracket Bolts (Lower) Muffler Bracket Bolts (Upper) Sidestand Mounting Bolt Sidestand Mounting Nut Sidestand Switch Mounting Bolt 0.90 78 in·lb Rear View Mirror (Lower Hexagonal Area) Rear View Mirror (Upper Hexagonal Area) 11.
• Page 452 15-4 FRAME Exploded View...
• Page 453 FRAME 15-5 Exploded View 1. South East Asia (VN900C8 ∼ C9), United States and Canada Models 2. AU Model (VN900C9 ∼ CB)

• Page 454: Special Tool

  15-6 FRAME Special Tool Jack: 57001-1238...

• Page 455: Seat

  FRAME 15-7 Seat Seat Removal • Insert the ignition switch key [A] into the seat lock, turning the key clockwise, pulling up on the rear of the seat [B], and pulling the seat backward. Seat Installation • Slip the seat hook [A] under the brace [B] on the fuel tank bracket.

• Page 456: Side Covers

  15-8 FRAME Side Covers Left Side Cover Removal • Remove: Seat (see Seat Removal) Screw [A] • Pull [A] the left side cover evenly, and remove it. Left Side Cover Installation • Put the front stoppers [A] into the grommets [B] first, then put the rear stopper [C] into the grommet [D].

• Page 457: Right Side Cover Installation

  FRAME 15-9 Side Covers Right Side Cover Installation NOTICE Be careful not to scratch the right side cover sur- face with the rear muffler cover during installation. • Put the stoppers [A] into the grommets [B]. • Tighten the screw.

• Page 458: Fenders

  15-10 FRAME Fenders Front Fender Removal NOTICE Be careful not to scratch the painted surface during removal. • Remove: Bolts [A] and Washers (Both Sides) Bolts [B] (Both Sides) • Remove the front fender and brace forward. Front Fender Installation NOTICE Be careful not to scratch the painted surface during installation.

• Page 459: Flap And Rear Fender Installation

  FRAME 15-11 Fenders • Remove the rear fender bolts [A] on both sides. • Remove the rear fender [B] rearward. • Remove: Bolts [A] Flap (with License Plate Light and Turn Signal Lights) [B] Flap and Rear Fender Installation • Installation is the reverse of removal.

• Page 460: Battery Case

  15-12 FRAME Battery Case Battery Case Removal • Remove: Seat (see Seat Removal) Battery (see Battery Removal in the Electrical System chapter) ECU (see ECU Removal in the Fuel System (DFI) chap- ter) Relay Box (see Relay Box Removal in the Electrical Sys- tem chapter) Fuse Box Vehicle-down Sensor [A] (see Vehicle-down Sensor Re-...

• Page 461: Tool Box

  FRAME 15-13 Tool Box Tool Box Removal • Remove the seat (see Seat Removal). • Clear the seat lock cable [A] from the hook [B]. • Remove: Screws [C] Tool Box [D]...

• Page 462: Footpeg

  15-14 FRAME Footpeg Footpeg Removal/Installation Left Side • Remove: Nut [A] and Bolt Footpeg Bracket Bolts [B] Left Footpeg Assembly [C] • Install the shift pedal correctly (see Shift Pedal Installation in the Crankshaft/Transmission). • Tighten: Torque - Footpeg Bracket Bolts (Front): 34 N·m (3.5 kgf·m, 25 ft·lb) Right Side •...

• Page 463: Sidestand

  FRAME 15-15 Sidestand Sidestand Removal • Raise the rear wheel off the ground with jack. Special Tool - Jack: 57001-1238 • Remove the alternator outer cover (see Alternator Outer Cover Removal in the Electrical System chapter). • Disconnect the sidestand switch lead connector [A]. •...

• Page 464: Rear View Mirrors

  15-16 FRAME Rear View Mirrors Rear View Mirror Removal (Other than EUR, BR, PH and SEA-B1 Models [VN900C8 Late Models, ∼ VN900C9 CD Models]) • Loosen the locknut [A]. • Turn the rear view mirror stay [B] counterclockwise to re- move the rear view mirror from the holder [C].

• Page 465: Rear View Mirror Installation (Eur, Br, Ph And Sea-B1 Models [Vn900C8 Late Models, Vn900C9 Cd Models])

  FRAME 15-17 Rear View Mirrors Rear View Mirror Installation (EUR, BR, PH and SEA-B1 Models [VN900C8 Late Models, VN900C9 ∼ CD Models]) • Screw the mounting area of the rear view mirror [A] into the holder [B] all the way, and tighten the lower hexagonal area [C] securely.

• Page 466: Downtube

  15-18 FRAME Downtube Downtube Removal • Raise the rear wheel off the ground with jack. Special Tool - Jack: 57001-1238 • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Disconnect the rear brake light switch connector [A]. •...

• Page 467: Downtube Installation

  FRAME 15-19 Downtube • Clear the brake hose [A] from the clamps [B]. • Remove the radiator bolt [A]. • Remove: Regulator/Rectifier (see Regulator/Rectifier Removal in the Electrical System chapter) Front Cross Pipe Bolts [A] Front Cross Pipe [B] • Remove: Engine Mounting Bracket Bolts [A] Caps [B] (VN900C7 ∼...

• Page 468: Frame Inspection

  15-20 FRAME Frame Frame Inspection • Visually inspect the frame [A] for cracks, dents, bending or warp. If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident resulting in injury or death. If the frame is bent, dented, cracked, or warped, replace it.
• Page 469 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........................16-3 Specifications ......................... 16-10 Special Tools and Sealant ...................... 16-11 Parts Location......................... 16-12 Wiring Diagram (VN900C7 ∼ C8) ................... 16-15 Wiring Diagram (VN900C9 ∼)....................16-24 Precautions..........................16-32 Electrical Wiring........................16-34 Wiring Inspection ......................
• Page 470 16-2 ELECTRICAL SYSTEM Commutator Cleaning and Inspection................16-64 Armature Inspection......................16-65 Brush Lead Inspection ...................... 16-65 Brush Plate and Terminal Bolt Inspection ................. 16-65 Starter Relay Inspection....................16-66 Lighting System ........................16-69 Headlight Beam Horizontal Adjustment ................16-69 Headlight Beam Vertical Adjustment................. 16-69 Headlight Bulb Replacement ....................

• Page 471: Exploded View

  ELECTRICAL SYSTEM 16-3 Exploded View This page intentionally left blank.
• Page 472 16-4 ELECTRICAL SYSTEM Exploded View...
• Page 473 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Alternator Cover Bolts 87 in·lb Alternator Lead Holder Plate Bolts 0.60 52 in·lb Alternator Outer Cover Bolts 87 in·lb Alternator Rotor Bolt (First) MO, S Alternator Rotor Bolt (Final) 16.3 MO, S Crankshaft Sensor Bolts...
• Page 474 16-6 ELECTRICAL SYSTEM Exploded View...
• Page 475 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Headlight Rim Screws 0.30 26 in·lb Tail/Brake Light Unit Mounting Nuts 0.60 52 in·lb 3. EUR, SEA-B1 (VN900CC ∼), SEA-B3 (VN900CE), BR and PH Models 4. GB Model only...
• Page 476 16-8 ELECTRICAL SYSTEM Exploded View...
• Page 477 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Level Sensor Mounting Bolts 0.70 61 in·lb Oxygen Sensors (Oxygen Sensor Equipped Models) Sidestand Switch Mounting Bolt 0.90 78 in·lb Speed Sensor Mounting Bolt 87 in·lb L: Apply a non-permanent locking agent. R: Replacement Parts...

• Page 478: Specifications

  16-10 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed Battery Model Name YTX12-BS Capacity 12 V 10 Ah (10 HR) Voltage 12.8 V or more Gross Weight 4.2 kg (9.3 lb) Electrolyte Volume 0.60 L (37 cu in.) Charging System Type Three-phase AC Alternator Output Voltage...

• Page 479: Special Tools And Sealant

  ELECTRICAL SYSTEM 16-11 Special Tools and Sealant Rotor Puller, M16/M18/M20/M22 × 1.5: Needle Adapter Set: 57001-1216 57001-1457 Spark Plug Wrench, Hex 16: Grip: 57001-1262 57001-1591 Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: Rotor Holder: 57001-1405 57001-1674 Peak Voltage Adapter: Liquid Gasket, TB1211F: 57001-1415 92104-0004...

• Page 480: Parts Location

  16-12 ELECTRICAL SYSTEM Parts Location Left Switch Housing [A] Starter Lockout Switch [B] Headlight [C] Front Brake Light Switch [D] Right Switch Housing [E] Meter Unit [F] Spark Plug [A] (Front) Fuel Pump [B] Ignition Coil [C] (Front) Ignition Coil [D] (Rear) Spark Plug [E] (Rear) Radiator Fan [A] Horn [B]...
• Page 481 ELECTRICAL SYSTEM 16-13 Parts Location Speed Sensor [A] Battery [A] ECU (Electronic Control Unit) [B] Turn Signal Relay [C] Relay Box [A] Starter Relay and Main Fuse 30 A [B] Frame Ground Terminal [C] Neutral Switch [A] Air Switching Valve [A]...
• Page 482 16-14 ELECTRICAL SYSTEM Parts Location Fuel Level Sensor [A] Rear Brake Light Switch [A] Water Temperature Sensor [A] Sidestand Switch [A]...

• Page 483: Wiring Diagram (Vn900C7 ~ C8)

  ELECTRICAL SYSTEM 16-15 Wiring Diagram (VN900C7 ∼ C8) This page intentionally left blank.
• Page 484 16-16 ELECTRICAL SYSTEM Wiring Diagram (VN900C7 ∼ C8) US, CA, and SEA-B1 Models...
• Page 485 ELECTRICAL SYSTEM 16-17 Wiring Diagram (VN900C7 ∼ C8)
• Page 486 16-18 ELECTRICAL SYSTEM Wiring Diagram (VN900C7 ∼ C8) EUR Models...
• Page 487 ELECTRICAL SYSTEM 16-19 Wiring Diagram (VN900C7 ∼ C8)
• Page 488 16-20 ELECTRICAL SYSTEM Wiring Diagram (VN900C7 ∼ C8) AU Model...
• Page 489 ELECTRICAL SYSTEM 16-21 Wiring Diagram (VN900C7 ∼ C8)
• Page 490 16-22 ELECTRICAL SYSTEM Wiring Diagram (VN900C7 ∼ C8) TH Model...
• Page 491 ELECTRICAL SYSTEM 16-23 Wiring Diagram (VN900C7 ∼ C8)

• Page 492: Wiring Diagram (Vn900C9 ~)

  16-24 ELECTRICAL SYSTEM Wiring Diagram (VN900C9 ∼) US and CA Models...
• Page 493 ELECTRICAL SYSTEM 16-25 Wiring Diagram (VN900C9 ∼)
• Page 494 16-26 ELECTRICAL SYSTEM Wiring Diagram (VN900C9 ∼) EUR, SEA-B1 (VN900CC ∼), SEA-B3 (VN900CE), BR and PH Models...
• Page 495 ELECTRICAL SYSTEM 16-27 Wiring Diagram (VN900C9 ∼)
• Page 496 16-28 ELECTRICAL SYSTEM Wiring Diagram (VN900C9 ∼) AU Model...
• Page 497 ELECTRICAL SYSTEM 16-29 Wiring Diagram (VN900C9 ∼)
• Page 498 16-30 ELECTRICAL SYSTEM Wiring Diagram (VN900C9 ∼) SEA-B1 (VN900C9 ∼ CB) and TH Models...
• Page 499 ELECTRICAL SYSTEM 16-31 Wiring Diagram (VN900C9 ∼)

• Page 500: Precautions

  16-32 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○...
• Page 501 ELECTRICAL SYSTEM 16-33 Precautions ○ Electrical Connectors Connectors [A] Connectors [B]...

• Page 502: Electrical Wiring

  16-34 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully.

• Page 503: Battery

  ELECTRICAL SYSTEM 16-35 Battery Battery Removal • Remove: Seat (see Seat Removal in the Frame chapter) Tool Box (see Tool Box Removal in the Frame chapter) • Disconnect the negative (–) cable [A]. • Slide out the positive (+) terminal cap [B] and then discon- nect the positive (+) cable.
• Page 504 16-36 ELECTRICAL SYSTEM Battery NOTICE Do not remove the aluminum sealing sheet [A] from the filler ports [B] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. DANGER Sulfuric acid in battery electrolyte can cause severe burns.
• Page 505 ELECTRICAL SYSTEM 16-37 Battery • Check the electrolyte flow. If no air bubbles [A] are coming up from the filler ports, or if the container cells have not emptied completely, tap the container [B] a few times. NOTE ○ Be careful not to have the battery fall down. •...
• Page 506 Newly activated sealed batteries require an initial charge. Standard Charge: 1.2 A × 5 ∼ 10 hours If using a recommended battery charger, follow the charger's instructions for newly activated sealed battery. Kawasaki-recommended chargers: Battery Mate 150-9 OptiMate PRO 4-S/PRO S/PRO2 Yuasa MB-2040/2060...

• Page 507: Precautions

  ELECTRICAL SYSTEM 16-39 Battery Precautions 1) No need of topping-up No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seal cap to add water is very dangerous. Never do that. 2) Refreshing charge.

• Page 508: Charging Condition Inspection

  16-40 ELECTRICAL SYSTEM Battery Charging Condition Inspection ○ Battery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter [A]. • Remove: Seat (see Seat Removal in the Frame chapter) Tool Box (see Tool Box Removal in the Frame chapter) Battery Cable Cap (see Battery Removal) •...
• Page 509 ELECTRICAL SYSTEM 16-41 Battery Terminal Voltage: 11.5 ∼ less than 12.8 V Standard Charge 1.2 A × 5 ∼ 10 h (see following chart) Quick Charge 5 A × 1 h NOTICE If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on.

• Page 510: Charging System

  16-42 ELECTRICAL SYSTEM Charging System Alternator Outer Cover Removal • Remove: Bolts [A] Alternator Outer Cover [B] Alternator Outer Cover Installation • For other than US, CA and CAL models (VN900C9 ∼), be sure the dampers [A] and trim [B] are in position. •...

• Page 511: Alternator Cover Installation

  ELECTRICAL SYSTEM 16-43 Charging System • Remove: Bolts [A] Alternator Cover [B] Alternator Cover Installation • Replace the alternator cover gasket with a new one. • Check to see that the dowel pins [A] are in place. • Tighten: Torque - Alternator Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...

• Page 512: Alternator Rotor Removal

  16-44 ELECTRICAL SYSTEM Charging System Alternator Rotor Removal • Remove the alternator cover (see Alternator Cover Re- moval). • Wipe oil off the outer circumference of the rotor. • Hold the alternator rotor steady with the rotor holder [A], and remove the rotor bolt [B] and washer. Special Tools - Grip [C]: 57001-1591 Rotor Holder: 57001-1674 ○...

• Page 513: Alternator Inspection

  ELECTRICAL SYSTEM 16-45 Charging System • When installing the alternator rotor, align the rotor mark [A] with the left crankcase projection [B]. • Apply molybdenum disulfide oil solution to the threads and seating surface of the alternator rotor bolt. • Install the washer.
• Page 514 16-46 ELECTRICAL SYSTEM Charging System • To check the alternator output voltage, do the following procedures. ○ Remove the regulator/rectifier and disconnect the con- nector [A]. ○ Connect a tester to the connector as shown in the figure. ○ Start the engine. ○...

• Page 515: Regulator/Rectifier Removal

  ELECTRICAL SYSTEM 16-47 Charging System Regulator/Rectifier Removal • Remove: Bolts [A] Regulator/Rectifier Cover [B] • Remove: Bolts [A] Regulator/Rectifier [B] Connector [C] (Disconnect) Regulator/Rectifier Inspection Rectifier Circuit Check • Remove the regulator/rectifier (see Regulator/Rectifier Removal). • Check conductivity of the following pair of terminals. Rectifier Circuit Inspection R-W1, R-W2,...
• Page 516 16-48 ELECTRICAL SYSTEM Charging System • Do the 1st step regulator circuit test. ○ Connect the test light and the 12 V battery to the regula- tor/rectifier as shown in the figure. ○ Check the W1, W2 and W3 terminal respectively. If the test light turns on, the regulator/rectifier is defective.

• Page 517: Charging Voltage Inspection

  ELECTRICAL SYSTEM 16-49 Charging System Charging Voltage Inspection • Check the battery condition (see Charging Condition In- spection). • Warm up the engine to obtain actual alternator operating conditions. • Remove: Seat (see Seat Removal in the Frame chapter) Tool Box (see Tool Box Removal in the Frame chapter) •...
• Page 518 16-50 ELECTRICAL SYSTEM Charging System Charging System Circuit (VN900C7 ∼ C8) 1. Ignition Switch 2. Regulator/Rectifier 3. Alternator 4. Frame Ground 5. Battery 6. Main Fuse 30 A 7. Load...
• Page 519 ELECTRICAL SYSTEM 16-51 Charging System Charging System Circuit (VN900C9 ∼) 1. Ignition Switch 2. Regulator/Rectifier 3. Alternator 4. Frame Ground 5. Battery 6. Main Fuse 30 A 7. Load...

• Page 520: Ignition System

  16-52 ELECTRICAL SYSTEM Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or ig- nition coil lead while the engine is running, or you could receive a severe electrical shock. NOTICE Do not disconnect the battery cables or any other electrical connections when the ignition switch is...

• Page 521: Ignition Coil Installation

  ELECTRICAL SYSTEM 16-53 Ignition System Ignition Coil Installation • Installation is the reverse of removal. • Connect the primary leads to the ignition coil terminals and run the secondary cables according to the Cable, Wire, and Hose Routing section in the Appendix chapter. Front Ignition Coil [A] Rear Ignition Coil [B] Dampers [C]...

• Page 522: Ignition Coil Primary Peak Voltage Inspection

  16-54 ELECTRICAL SYSTEM Ignition System • Measure the primary winding resistance as follows. ○ Connect the digital meter between the coil terminals. • Measure the secondary winding resistance as follows. ○ Remove the plug caps by turning them counterclockwise. ○ Connect the meter between the spark plug high-tension cables.

• Page 523: Spark Plug Removal

  ELECTRICAL SYSTEM 16-55 Ignition System WARNING To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • Turn the ignition switch and the engine stop switch ON. • Pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission in neutral to measure the primary peak voltage.

• Page 524: Crankshaft Sensor Removal

  16-56 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Removal • Remove: Alternator Cover (see Alternator Cover Removal) Bolts [A] Alternator Lead Holder Plate [B] Crankshaft Sensor Lead Grommet [C] Crankshaft Sensor Bolts [D] • Remove the crankshaft sensor [E] from the alternator cover.

• Page 525: Crankshaft Sensor Peak Voltage Inspection

  ELECTRICAL SYSTEM 16-57 Ignition System Crankshaft Sensor Peak Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Remove the alternator outer cover (see Alternator Outer Cover Removal). • Remove all the spark plug caps but do not remove the spark plugs.

• Page 526: Ic Igniter Inspection

  16-58 ELECTRICAL SYSTEM Ignition System 2nd Check • Start the engine to the following conditions. Condition Transmission Gear → 1st position Clutch Lever → Pulled in Sidestand → Up ○ Turn the ignition switch ON and push the starter button. ○...
• Page 527 ELECTRICAL SYSTEM 16-59 Ignition System...
• Page 528 16-60 ELECTRICAL SYSTEM Ignition System Ignition System Circuit (VN900C7 ∼ C8) 1. Ignition Switch 13. Vehicle-down Sensor 2. Engine Stop Switch 14. Frame Ground 3. Spark Plugs 15. Battery 4. Ignition Coil #1 (Front Cylinder) 16. Main Fuse 30 A 5.
• Page 529 ELECTRICAL SYSTEM 16-61 Ignition System Ignition System Circuit (VN900C9 ∼) 1. Ignition Switch 13. Vehicle-down Sensor 2. Engine Stop Switch 14. Frame Ground 3. Spark Plugs 15. Battery 4. Ignition Coil #1 (Front Cylinder) 16. Main Fuse 30 A 5. Ignition Coil #2 (Rear Cylinder) 17.

• Page 530: Electric Starter System

  16-62 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal NOTICE Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • Remove: Regulator/Rectifier (see Regulator/Rectifier Removal) Bolts [A] Front Cross Pipe [B] •...

• Page 531: Starter Motor Assembly

  ELECTRICAL SYSTEM 16-63 Electric Starter System • Remove: Terminal Locknut and Washers O-ring • Remove the brush plate assy [A] from the yoke [B]. • Remove the brush plate [A] from the terminal bolt assem- bly [B]. NOTE ○ Do not remove the negative carbon brushes from the brush plate.

• Page 532: Brush Inspection

  16-64 ELECTRICAL SYSTEM Electric Starter System • Install the new O-ring [A] as shown in the figure. • Install the washers [B] and terminal locknut [C]. • Tighten: Torque - Starter Motor Terminal Locknut: 11 N·m (1.1 kgf·m, 97 in·lb) •...

• Page 533: Armature Inspection

  ELECTRICAL SYSTEM 16-65 Electric Starter System Armature Inspection • Using a tester, measure the resistance between any two commutator segments [A]. If there is a high resistance or no reading (∞) between any two segments, a winding is open and the starter motor must be replaced.

• Page 534: Starter Relay Inspection

  16-66 ELECTRICAL SYSTEM Electric Starter System Starter Relay Inspection • Remove the right side cover (see Right Side Cover Re- moval in the Frame chapter). • Disconnect the connector [A]. • Disconnect the starter motor cable [B] and battery positive (+) cable [C] from the starter relay [D].
• Page 535 ELECTRICAL SYSTEM 16-67 Electric Starter System Electric Starter Circuit (VN900C7 ∼ C8) 1. Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Neutral Switch 5. Sidestand Switch 6. ECU 7. Battery 8. Main Fuse 30 A 9. Starter Relay 10.
• Page 536 16-68 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit (VN900C9 ∼) 1. Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Neutral Switch 5. Sidestand Switch 6. ECU 7. Battery 8. Main Fuse 30 A 9. Starter Relay 10. Starter Motor 11.

• Page 537: Lighting System

  ELECTRICAL SYSTEM 16-69 Lighting System This models adopt the daylight system and has a head- light relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off.

• Page 538: Headlight Body Removal

  16-70 ELECTRICAL SYSTEM Lighting System • Take out the bulb [A]. NOTICE When handling the quartz-halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth. Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode.

• Page 539: Tail/Brake Light Removal/Installation

  ELECTRICAL SYSTEM 16-71 Lighting System Other than GB Models • Remove the headlight body nuts [A], then take off the body [B]. GB Model • Remove the headlight body bolts [A] and nuts [B], then take off the body [C]. City Light Bulb Replacement (EUR, SEA-B1 ∼...

• Page 540: Tail/Brake Light Bulb Replacement

  16-72 ELECTRICAL SYSTEM Lighting System Tail/Brake Light Bulb Replacement • Unscrew the lens screw [A]. • Pull the lens [B] off. • Push the bulb [A] in, turn it counterclockwise [B], and pull it out. • Replace the bulb with a new one. •...
• Page 541 ELECTRICAL SYSTEM 16-73 Lighting System • Push the bulb [A] in, turn it counterclockwise [B], and pull it out. • Insert the new bulb [A] by aligning the pins [B] with the groove in the walls of the socket [C].
• Page 542 16-74 ELECTRICAL SYSTEM Lighting System Headlight/Tail Light Circuit (VN900C7 ∼ C8) 1. Ignition Switch 10. Tail Light Fuse 10 A 2. Rear Brake Switch 11. Headlight Fuse 10 A 3. License Plate Light 12. Dimmer Switch 4. Tail/Brake Light 13. Headlight 14.

• Page 543: Turn Signal Light Bulb Replacement

  ELECTRICAL SYSTEM 16-75 Lighting System Headlight/Tail Light Circuit (VN900C9 ∼) 1. Ignition Switch 10. Tail Light Fuse 10 A 11. Headlight Fuse 10 A 2. Rear Brake Switch 3. License Plate Light 12. Dimmer Switch 4. Tail/Brake Light 13. Headlight 14.

• Page 544: Turn Signal Relay Inspection

  16-76 ELECTRICAL SYSTEM Lighting System • Push the bulb [A] in the socket and turn the bulb counter- clockwise. • Replace the bulb. • Insert the new bulb [A] by aligning the pins [B] with the groove in the walls of the socket [C]. Turn Signal Relay Inspection •...
• Page 545 ELECTRICAL SYSTEM 16-77 Lighting System Turn Signal Light Circuit (VN900C7 ∼ C8) 1. Ignition Switch 2. Frame Ground 3. Main Fuse 30 A 4. Battery 5. Rear Right Turn Signal Light 6. Rear Left Turn Signal Light 7. Turn Signal Relay 8.
• Page 546 16-78 ELECTRICAL SYSTEM Lighting System Turn Signal Light Circuit (VN900C9 ∼) 1. Ignition Switch 2. Frame Ground 3. Main Fuse 30 A 4. Battery 5. Rear Right Turn Signal Light 6. Rear Left Turn Signal Light 7. Turn Signal Relay 8.

• Page 547: Air Switching Valve

  ELECTRICAL SYSTEM 16-79 Air Switching Valve Air Switching Valve Operation Test • Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter. Air Switching Valve Unit Test • Remove the air switching valve (see Air Switching Valve Removal in the Engine Top End chapter).

• Page 548: Radiator Fan System

  16-80 ELECTRICAL SYSTEM Radiator Fan System Fan Motor Inspection • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Disconnect the 2-pin connector [A] in the fan motor leads. • Using an auxiliary leads, supply battery [B] power to the fan motor.
• Page 549 ELECTRICAL SYSTEM 16-81 Radiator Fan System Radiator Fan Relay Circuit (VN900C9 ∼) 1. Ignition Switch 2. Radiator Fan 3. Joint Connector B 4. Water Temperature Sensor 5. ECU 6. Battery 7. Main Fuse 30 A 8. Relay Box 9. ECU Main Relay 10.

• Page 550: Meter Unit

  16-82 ELECTRICAL SYSTEM Meter Unit Meter Unit Removal • Remove the bolt [A], and lift up the tail of the cover [B]. • Push the cover forward a little, and remove the meter cover. • Remove the meter unit [A]. ○...
• Page 551 ELECTRICAL SYSTEM 16-83 Meter Unit • Remove the screw [A] on the lower meter cover to free the speedometer. • Remove the screw [A] on the indicator panel to remove the panel. • Lifting the speedometer [A] with the indicator panel [B] at- tached, pull out the FI indicator light (LED) [C] and oil pres- sure warning light (LED) [D] from the lower meter cover [E].

• Page 552: Meter Unit Assembly

  16-84 ELECTRICAL SYSTEM Meter Unit • Remove the wedge-base type bulb [A] by pulling the bulb straight out of the socket [B]. NOTICE Do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for other than voltage or wattage specified in the wiring dia- gram.
• Page 553 ELECTRICAL SYSTEM 16-85 Meter Unit • Push the mode select button to TRIP and push the reset button [A] more than 2 seconds. The display shows "0.0". If the display doesn't show "0.0", replace the speedometer assembly. • Push the mode select button to CLOCK. •...
• Page 554 16-86 ELECTRICAL SYSTEM Meter Unit • Set the minute, push the reset button [A] to return to the HOUR/MINUTE setting mode. • Push the mode select button [B] to complete the time set- ting process. ○ The clock starts counting the seconds as soon as the mode select button is pushed.
• Page 555 ELECTRICAL SYSTEM 16-87 Meter Unit • Using the auxiliary wires, connect a 12 V battery to the meter unit connector terminals. Connections Battery Positive Terminal (+) → Terminal [11] Battery Negative Terminal (–) → Terminal [13] • Using the auxiliary wires, connect the battery positive wire to terminal [12].
• Page 556 16-88 ELECTRICAL SYSTEM Meter Unit • If an oscillator is available, check the speedometer as fol- lows. ○ Connect the terminals in the same way as in the LCD segment inspection. • Connect the oscillator [A] to the terminal [15]. The vehi- cle speed that corresponds to the input frequency will be displayed when a short wave form such as the one show in the diagram is input.
• Page 557 ELECTRICAL SYSTEM 16-89 Meter Unit Fuel Level Gauge Inspection • Connect the terminals in the same way as in the LCD segment inspection. • Connect a variable rheostat [A] to the terminal [16] and battery negative wire as shown in the figure. •...
• Page 558 16-90 ELECTRICAL SYSTEM Meter Unit Water Temperature Warning Light (LED) Connections Battery Negative Wire (–) to Terminal [4] • Connect the terminal [4]. ○ The water temperature warning light (LED) lights. • Disconnect the terminal [4]. ○ The water temperature warning light (LED) disappears. If there is any problem, replace the speedometer assem- bly.
• Page 559 ELECTRICAL SYSTEM 16-91 Meter Unit If there is any problem, inspect the bulb, bulb socket [A] and wiring of the indicator panel [B] for continuity. If they are normal, replace the speedometer assembly. Special Tool - Needle Adapter Set: 57001-1457 High Beam Indicator Light Connections Battery Positive Wire (+) to Terminal [20] •...
• Page 560 16-92 ELECTRICAL SYSTEM Meter Unit Meter Circuit (VN900C7 ∼ C8) 1. Ignition Switch 16. Neutral Indicator Light 2. Fuel Level Sensor 17. Turn Signal Indicator Light 3. Speed Sensor 18. High Beam Indicator Light 4. Joint Connector B 19. Reset Button 20.
• Page 561 ELECTRICAL SYSTEM 16-93 Meter Unit Meter Circuit (VN900C9 ∼) 1. Ignition Switch 16. Neutral Indicator Light 17. Turn Signal Indicator Light 2. Fuel Level Sensor 3. Speed Sensor 18. High Beam Indicator Light 4. Joint Connector B 19. Reset Button 5.

• Page 562: Fuel Gauge Operation Inspection

  16-94 ELECTRICAL SYSTEM Meter Unit Fuel Gauge Operation Inspection • Remove the fuel tank bolts (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Lift the fuel tank front part a little and pull the fuel gauge connector forward. •...

• Page 563: Switches And Sensors

  ELECTRICAL SYSTEM 16-95 Switches and Sensors Brake Light Timing Inspection • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Brake Light Timing Adjustment • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Switch Inspection •...

• Page 564: Water Temperature Sensor Inspection

  16-96 ELECTRICAL SYSTEM Switches and Sensors Water Temperature Sensor Inspection • Remove the water temperature sensor (see Water Tem- perature Sensor Removal/Installation in the Fuel System (DFI) chapter). • Suspend the sensor [A] in a container of coolant so that the temperature-sensing projection [C] and threaded por- tion [C] are submerged.

• Page 565: Oxygen Sensor Removal (Oxygen Sensor Equipped Models)

  ELECTRICAL SYSTEM 16-97 Switches and Sensors Oxygen Sensor Removal (Oxygen Sensor Equipped Models) • Remove the right side cover (see Right Side Cover Re- moval in the Frame chapter). • Disconnect the oxygen sensor lead connectors [A]. • Remove: Muffler Covers [A] (see Muffler Removal in the Engine Top End chapter) Oxygen Sensors [B] Oxygen Sensor Installation (Oxygen Sensor...

• Page 566: Fuel Level Sensor Inspection

  16-98 ELECTRICAL SYSTEM Switches and Sensors Fuel Level Sensor Inspection • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Open the clamps on the fuel tank. • Remove: Bolts [A] Fuel Level Sensor [B] •...

• Page 567: Fuel Reserve Switch Inspection

  ELECTRICAL SYSTEM 16-99 Switches and Sensors Fuel Reserve Switch Inspection • Fill the fuel tank with fuel. • Close the fuel tank cap surely. • Remove: Ignition Coil Cover (see Ignition Coil Removal) Fuel Pump Lead Connector [A] • Connect the test light [B] (12 V 3.4 W bulb in a socket with leads) and the 12 V battery [C] to the fuel level sensor lead connector.

• Page 568: Relay Box

  16-100 ELECTRICAL SYSTEM Relay Box The relay box [A] has relays and diodes. The relays and diodes can not be removed. Relay Box Removal • Remove the right side cover (see Right Side Cover Re- moval in the Frame chapter). •...

• Page 569: Diode Circuit Inspection

  ELECTRICAL SYSTEM 16-101 Relay Box Relay Circuit Inspection (with the battery connected) Battery Tester Tester Connection Connection Reading (Ω) (–) 2-11 ECU Main Relay Fuel Pump Relay 9-10 Fan Relay 18-19 17-20 Battery Tester Connection Tester Connection Reading (V) (–) Battery Starter 16-12...
• Page 570 16-102 ELECTRICAL SYSTEM Relay Box Relay Box Internal Circuit A: Headlight Relay B: ECU Main Relay C: Fuel Pump Relay D: Starter Circuit Relay E: Fan Relay...

• Page 571: Fuse

  ELECTRICAL SYSTEM 16-103 Fuse 30 A Main Fuse Removal • Remove: Right Side Cover (see Right Side Cover Removal in the Frame chapter) Connector [A] • Pull out the main fuse [B] from the starter relay with needle nose pliers. Fuse Box Fuse Removal •...

• Page 572: Fuse Installation

  16-104 ELECTRICAL SYSTEM Fuse Fuse Installation • If a fuse fails during operation, inspect the electrical sys- tem to determine the cause, and then replace it with a new fuse of proper amperage. • Install the fuse box fuses on the original position as spec- ified on the lid.
• Page 573 APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................17-2 Troubleshooting Guide ......................17-40...
• Page 574 17-2 APPENDIX Cable, Wire, and Hose Routing...
• Page 575 APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Right Switch Housing Lead 2. Left Switch Housing Lead 3. Clutch Cable 4. Clamp the left switch housing lead. 5. Run the clutch cable and left switch housing lead through the clamp. 6.
• Page 576 17-4 APPENDIX Cable, Wire, and Hose Routing...
• Page 577 APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Run the left switch housing lead under the brake hose. 2. Run the water temperature sensor lead connector over the reserve tank hose. 3. Clamp the left and right switch housing lead and clutch cable. 4.
• Page 578 17-6 APPENDIX Cable, Wire, and Hose Routing...
• Page 579 APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Right Switch Housing Lead Connector 2. Left Switch Housing Lead Connector 3. Left Switch Housing Lead Connector 4. Radiator Fan Lead Connector 5. Rear Brake Light Switch Lead Connector 6. Clamp the main harness. 7.
• Page 580 17-8 APPENDIX Cable, Wire, and Hose Routing...
• Page 581 APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Subthrottle Valve Actuator Lead Connector 2. Subthrottle Sensor Lead Connector 3. Injector #2 Lead Connector 4. Injector #1 Lead Connector 5. Inlet Air Pressure Sensor Vacuum Hose 6. Inlet Air Temperature Sensor Lead (CAL, TH and SEA-B1 Models: Run the inlet air temperature sensor lead between the vacuum hose and purge hose.) 7.
• Page 582 17-10 APPENDIX Cable, Wire, and Hose Routing...
• Page 583 APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Run the alternator lead and sidestand switch lead through the clamp of the engine bracket. 2. Fuse Box 3. Alternator Lead 4. Battery Negative (–) Cable 5. Sidestand Switch Lead 6. View from the front...
• Page 584 17-12 APPENDIX Cable, Wire, and Hose Routing...
• Page 585 APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Fuel Pump Lead Connector 2. Black/Green Lead 3. Red Lead 4. Black Lead 5. Red Lead 6. Clamp the ignition coil lead with the air switching valve hose clamp. 7. Air Switching Valve Hose 8.
• Page 586 17-14 APPENDIX Cable, Wire, and Hose Routing...
• Page 587 APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Speed Sensor Lead Connector 2. Neutral Switch Lead Terminal 3. Run the starter motor lead through the engine bracket clamp.
• Page 588 17-16 APPENDIX Cable, Wire, and Hose Routing...
• Page 589 2. Vehicle-down Sensor 3. ECU 4. Ignition Switch Lead Connector 5. Kawasaki Diagnostic System Connector 6. Battery 7. Turn Signal Relay 8. Run the ignition switch lead in the front of the turn signal relay, and run the ignition switch lead and engine ground lead through the notch of the battery case.
• Page 590 17-18 APPENDIX Cable, Wire, and Hose Routing...
• Page 591 6. Run the seat lock cable through the guide of the frame. 7. Run the seat lock cable through the clamp, and insert the clamp in the rear fender. 8. Kawasaki Diagnostic System Lead Connector 9. Starter Relay 10. Run the oxygen sensor #1 lead inside the rear exhaust pipe (Oxygen Sensor Equipped models).
• Page 592 17-20 APPENDIX Cable, Wire, and Hose Routing VN900C7 ∼ CB...
• Page 593 APPENDIX 17-21 Cable, Wire, and Hose Routing 1. Reserve Tank Hose 2. Breather Hose 3. Run the breather hose inside the main harness. 4. Harness Attached Clamp (Insert the harness attached clamp to the frame pipe.) 5. Fuel Return Hose (CAL, TH and SEA-B1 Models) 6.
• Page 594 17-22 APPENDIX Cable, Wire, and Hose Routing VN900C7 ∼...
• Page 595 APPENDIX 17-23 Cable, Wire, and Hose Routing 1. Connect the breather hose to fuel tank breather pipe at front of the fuel tank. 2. Breather Hose 3. Clamp the breather hose and reserve tank hose. Do not pinch the hoses. Position the clamp as shown in the figure.
• Page 596 17-24 APPENDIX Cable, Wire, and Hose Routing...
• Page 597 APPENDIX 17-25 Cable, Wire, and Hose Routing 1. View from the outside 2. Roll the tail/brake light lead to the pin. 3. Cover the tail/brake light lead connector by cover of the harness attached, and put the tail/brake light lead connector to the guide of the rear fender. 4.
• Page 598 17-26 APPENDIX Cable, Wire, and Hose Routing 1. Clamps (Clamp the sidestand switch lead.)
• Page 599 APPENDIX 17-27 Cable, Wire, and Hose Routing 1. Starter Motor Cable 2. Clamps 3. Clamp (Bend the clamp as shown in the figure.)
• Page 600 17-28 APPENDIX Cable, Wire, and Hose Routing 1. Air Switching Valve 2. Face the white mark right side. 3. Clamp (for Ignition Coil Lead) 4. Air Switching Valve Hose...
• Page 601 APPENDIX 17-29 Cable, Wire, and Hose Routing 1. Alternator Coil Lead 2. Oil Pressure Switch Lead 3. Clamp the alternator lead and oil pressure switch lead. After installed, bend the clamp to the alternator cover. 4. Clamp the sidestand switch lead only. 5.
• Page 602 17-30 APPENDIX Cable, Wire, and Hose Routing 1. Main Harness 2. Clamp (Wrap the connectors.) 3. Sidestand Switch Lead 4. Oil Pressure Switch Lead 5. Crankshaft Sensor Lead 6. Engine Pulley Cover...
• Page 603 APPENDIX 17-31 Cable, Wire, and Hose Routing 1. Clamp the alternator lead and main harness. 2. Alternator Lead...
• Page 604 17-32 APPENDIX Cable, Wire, and Hose Routing 1. Reserve Tank Hose 2. Inlet Air Pressure Sensor Vacuum Hose 3. Air Switching Valve Hoses 4. Run the inlet air pressure sensor vacuum hose over the air switching valve hose. 5. Run the reserve tank hose into the frame hole. 6.
• Page 605 APPENDIX 17-33 Cable, Wire, and Hose Routing 1. Clamps 2. Reserve Tank Hose 3. Reserve Tank 4. Run the reserve tank hose on the battery case bracket. 5. Clamp (Clamp the reserve tank hose.)
• Page 606 17-34 APPENDIX Cable, Wire, and Hose Routing...
• Page 607 APPENDIX 17-35 Cable, Wire, and Hose Routing 1. Front Caliper 2. Brake Hose 3. Clamps 4. Through the brake hose in the bracket. 5. Front Master Cylinder...
• Page 608 17-36 APPENDIX Cable, Wire, and Hose Routing...
• Page 609 APPENDIX 17-37 Cable, Wire, and Hose Routing 1. Rear Caliper 2. Brake Hose 3. Clamps 4. Rear Master Cylinder 5. Reservoir Tank 6. Swingarm 7. Cotter Pin 8. Swingarm Clamps 9. Run the brake hose between the swingarm and frame.
• Page 610 17-38 APPENDIX Cable, Wire, and Hose Routing CAL, TH and SEA-B1 Models 1. Reserve Tank Hose 2. Clamp the air switching valve hose, vacuum hose (white) and purge hose (green). 3. Breather Hose 4. Purge Hose (Green) 5. Fuel Return Hose (Red) 6.
• Page 611 APPENDIX 17-39 Cable, Wire, and Hose Routing VN900C9 Models 1. Frame earth lead 2. Run the frame earth lead inside the throttle cables. 3. Throttle Cables 4. Run the frame earth lead inside the throttle cables. 5. Frame earth lead 6.

• Page 612: Troubleshooting Guide

  17-40 APPENDIX Troubleshooting Guide NOTE Spark plug dirty, broken, or gap malad- ○ Refer to the Fuel System chapter for most justed of DFI trouble shooting guide. Spark plug cap or high tension wiring trou- ○ This is not an exhaustive list, giving every possible cause for each problem listed.
• Page 613 APPENDIX 17-41 Troubleshooting Guide Compression low: No valve clearance Spark plug loose Cylinder, piston worn Cylinder head not sufficiently tightened Piston ring bad (worn, weak, broken, or down sticking) No valve clearance Piston ring/groove clearance excessive Cylinder, piston worn Cylinder head gasket damaged Piston ring bad (worn, weak, broken, or Cylinder head warped sticking)

• Page 614: Gear Shifting Faulty

  17-42 APPENDIX Troubleshooting Guide Gear Shifting Faulty: Compression high: Carbon built up in combustion chamber Doesn't go into gear; shift pedal doesn't Engine load faulty: return: Clutch slipping Clutch not disengaging Engine oil level too high Shift fork bent or seized Engine oil viscosity too high Gear stuck on the shaft Drive train trouble...

• Page 615: Exhaust Smokes Excessively

  APPENDIX 17-43 Troubleshooting Guide Exhaust Smokes Excessively: Primary gear worn or chipped Camshaft chain tensioner trouble White smoke: Camshaft chain, sprocket, guide worn Piston oil ring worn Air suction valve damaged Cylinder worn Air switching valve damaged Valve oil seal damaged Alternator rotor loose Valve guide worn Catalytic converter melt down due to muffler...
• Page 616 17-44 APPENDIX Troubleshooting Guide Brake Doesn't Hold: Battery faulty (too low terminal voltage) Air in the brake line Battery cable making poor contact Pad or disc worn Load excessive (e.g., bulb of excessive wattage) Brake fluid leakage Disc warped Ignition switch trouble Contaminated pad Alternator trouble Brake fluid deteriorated...
• Page 617 Part No.99924-1373-09 MODEL APPLICATION Year Model Beginning Frame No. □ JKAVN2C1 7A000001 2007 VN900C7 JKAVN900CCA000001 □ JKAVN2C1 8A015001 2008 VN900C8 JKAVN900CCA015001 □ JKAVN2C1 9A025001 2009 VN900C9 JKAVN900CCA025001 □ JKAVN2C1 AA037001 2010 VN900CA JKAVN900CCA037001 □ JKAVN2C1 BA045001 2011 VN900CB JKAVN900CCA045001 □ JKAVN2C1 CA049001 2012...

2015 Vn900 Custom

Source: https://www.manualslib.com/manual/1170368/Kawasaki-Vn900-Custom.html

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