Periodic service of motorcycle Kawasaki VN900 Vulcan (2006-2024)
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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 INSPECTION FREQUENCY (Whichever comes...
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 INSPECTION FREQUENCY (Whichever comes...
Periodic replacement parts
CHANGE/REPLACE ITEM FREQUENCY Whichever See Page * ODOMETER READING comes x 1 000 km first (x 1 000 mile) Every 1 (0.6) 12 (7.5) 24 (15) 36 (24) 48 (30) Air cleaner element # Every 18 000 km (12 000 mile) 2-47 Engine oil # year • • • • • 2-48 Oil...
CHANGE/REPLACE ITEM FREQUENCY Whichever See Page * ODOMETER READING comes x 1 000 km first (x 1 000 mile) Every 1 (0.6) 12 (7.5) 24 (15) 36 (24) 48 (30) Air cleaner element # Every 18 000 km (12 000 mile) 2-47 Engine oil # year • • • • • 2-48 Oil...
Torque and locking agent
The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket. Letters used in the "Remarks" column mean: 2T: Apply 2-stroke oil. L: Apply a non-permanent locking agent to the...
The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket. Letters used in the "Remarks" column mean: 2T: Apply 2-stroke oil. L: Apply a non-permanent locking agent to the...
Periodic maintenance specifications
Item Standard Service Limit Fuel System Throttle Grip Free Play 2 - 3 mm (0.08 - 0.12 in.) — — — Idle Speed 1 000±50 r/min (rpm) — — — Air Cleaner Element Polyurethane Foam — — — Cooling System Coolant: Type (recommended) Permanent type of...
Item Standard Service Limit Fuel System Throttle Grip Free Play 2 - 3 mm (0.08 - 0.12 in.) — — — Idle Speed 1 000±50 r/min (rpm) — — — Air Cleaner Element Polyurethane Foam — — — Cooling System Coolant: Type (recommended) Permanent type of...
Special tools for periodic maintenance
Inside Circlip Pliers: 57001-143 Oil Filter Wrench: 57001-1249 Steering Stem Nut Wrench: 57001-1100 Spark Plug Wrench, Hex 16: 57001-1262 Jack: 57001-1238 Tension Gauge: 57001-1585
Inside Circlip Pliers: 57001-143 Oil Filter Wrench: 57001-1249 Steering Stem Nut Wrench: 57001-1100 Spark Plug Wrench, Hex 16: 57001-1262 Jack: 57001-1238 Tension Gauge: 57001-1585
Fuel hose inspection (fuel leak, damage, installation condition)
The fuel hose is designed to be used throughout the motorcycle's life without any maintenance. However, if the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the...
The fuel hose is designed to be used throughout the motorcycle's life without any maintenance. However, if the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the...
Throttle control system inspection
Check the throttle grip free play [A]. ★ If the free play is incorrect, adjust the throttle cable. Throttle grip free play: Standard: 2-3 mm (0.08-0.12 in.) Check that the throttle grip moves smoothly from close to full open, and the throttle closes...
Check the throttle grip free play [A]. ★ If the free play is incorrect, adjust the throttle cable. Throttle grip free play: Standard: 2-3 mm (0.08-0.12 in.) Check that the throttle grip moves smoothly from close to full open, and the throttle closes...
Idle speed inspection
Start the engine and warm it up thoroughly. At first the engine will run fast to decrease warm up time (fast idle). Gradually the fast idle will lower to a certain RPM automatically. This is the idle speed. Check the idle speed. Idle speed:...
Start the engine and warm it up thoroughly. At first the engine will run fast to decrease warm up time (fast idle). Gradually the fast idle will lower to a certain RPM automatically. This is the idle speed. Check the idle speed. Idle speed:...
Idle speed adjustment
Start the engine and warm it up thoroughly. Wait until fast idle speed lowers to a certain value. Turn the adjusting screw [A] until the idle speed is correct. Open and close the throttle a few times to make sure that the idle speed is within the...
Start the engine and warm it up thoroughly. Wait until fast idle speed lowers to a certain value. Turn the adjusting screw [A] until the idle speed is correct. Open and close the throttle a few times to make sure that the idle speed is within the...
Coolant level inspection
Note. Check the level when the engine is cold (room or ambient temperature). Check the coolant level in the reserve tank [A] with the motorcycle held upright. ★ If the coolant level is lower than the "L" level line [B], remove the reserve tank cover...
Note. Check the level when the engine is cold (room or ambient temperature). Check the coolant level in the reserve tank [A] with the motorcycle held upright. ★ If the coolant level is lower than the "L" level line [B], remove the reserve tank cover...
Radiator hose and pipe inspection (coolant leak, damage, installation condition)
The high pressure inside the radiator hose and pipe can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and...
The high pressure inside the radiator hose and pipe can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and...
Air suction system damage inspection
Pull 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. ★ If there is no vacuum pulsation,...
Pull 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. ★ If there is no vacuum pulsation,...
Valve clearance inspection
Note. Valve clearance must be checked and adjusted when the engine is cold (room temperature). Remove: Cylinder Head Cover (see Cylinder head cover removal in the Engine Top End chapter) Timing inspection plate (engine left side) Set the front...
Note. Valve clearance must be checked and adjusted when the engine is cold (room temperature). Remove: Cylinder Head Cover (see Cylinder head cover removal in the Engine Top End chapter) Timing inspection plate (engine left side) Set the front...
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. Notes: Mark and record the shim locations so that the shims can be reinstalled in their original...
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. Notes: Mark and record the shim locations so that the shims can be reinstalled in their original...
Clutch operation inspection
Clutch lever free play 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 lever free play 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...
Tire air pressure inspection
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). ★ Adjust the tire air pressure according to the specifications if...
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). ★ Adjust the tire air pressure according to the specifications if...
Wheel/tire damage inspection
Remove any imbedded stones [A] or other foreign particles [B] from tread. Visually inspect the tire for cracks and cuts replacing the tire in case of damage. Swelling or high spots indicate internal damage, requiring tire replacement. Visually...
Remove any imbedded stones [A] or other foreign particles [B] from tread. Visually inspect the tire for cracks and cuts replacing the tire in case of damage. Swelling or high spots indicate internal damage, requiring tire replacement. Visually...
Tire tread wear inspection
As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn). So it is false economy and unsafe to use the tires...
As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn). So it is false economy and unsafe to use the tires...
Wheel bearing damage inspection
Using a jack raise the front wheel off the ground (see Front wheel removal in the Wheels/Tires chapter). Turn the handlebar all the way to the right or left. Inspect the roughness of the front wheel bearing by pushing and pulling [A] the wheel. Spin...
Using a jack raise the front wheel off the ground (see Front wheel removal in the Wheels/Tires chapter). Turn the handlebar all the way to the right or left. Inspect the roughness of the front wheel bearing by pushing and pulling [A] the wheel. Spin...
Spoke tightness and rim runout inspection
Check that all the spokes are tightened evenly. ★ If spoke tightness is uneven or loose, tighten the spoke nipples evenly. Torque - Spoke Nipples: 5.2 №m (0.53 kgf·m, 46 in·lb). Check the rim runout. Warning! If any spoke breaks, it should be...
Check that all the spokes are tightened evenly. ★ If spoke tightness is uneven or loose, tighten the spoke nipples evenly. Torque - Spoke Nipples: 5.2 №m (0.53 kgf·m, 46 in·lb). Check the rim runout. Warning! If any spoke breaks, it should be...
Belt deflection inspection
Notes: Belt deflection must be checked and adjusted when the belt is cold (at room temperature). Belt deflection also should be checked at first 1000 km ride after belt replacement. Check to see if wheel alignment is properly adjusted. The left and...
Notes: Belt deflection must be checked and adjusted when the belt is cold (at room temperature). Belt deflection also should be checked at first 1000 km ride after belt replacement. Check to see if wheel alignment is properly adjusted. The left and...
Belt deflection adjustment
Remove: Muffler (see Muffler removal in the Engine Top End chapter) Remove the axle cotter pin, and loosen the axle nut. Using the jack under the frame pipe ribs, lift the rear wheel off the ground (see Rear wheel removal in the Wheels/Tires...
Remove: Muffler (see Muffler removal in the Engine Top End chapter) Remove the axle cotter pin, and loosen the axle nut. Using the jack under the frame pipe ribs, lift the rear wheel off the ground (see Rear wheel removal in the Wheels/Tires...
Rear wheel alignment inspection/adjustment
Check that the notch [A] on the left belt adjuster [B] aligns with the same swingarm mark [C] or position that the right belt adjuster notch aligns with. ★ If they do not, adjust the belt deflection (see Belt deflection adjustment ) and align the...
Check that the notch [A] on the left belt adjuster [B] aligns with the same swingarm mark [C] or position that the right belt adjuster notch aligns with. ★ If they do not, adjust the belt deflection (see Belt deflection adjustment ) and align the...
Belt wear and damage inspection
Using the jack and jack attachment under the frame pipe ribs, lift the rear wheel off the ground (see Rear wheel removal in the Wheels/Tires chapter). Remove: Bolts [A] and Washers Upper Belt Cover [B] Visually inspect the belt [A] for wear and...
Using the jack and jack attachment under the frame pipe ribs, lift the rear wheel off the ground (see Rear wheel removal in the Wheels/Tires chapter). Remove: Bolts [A] and Washers Upper Belt Cover [B] Visually inspect the belt [A] for wear and...
Brake fluid leak inspection
Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A] and fittings [B]. ★ If the brake fluid leaked from any position, inspect or replace the problem part.
Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A] and fittings [B]. ★ If the brake fluid leaked from any position, inspect or replace the problem part.
Brake hose 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 maintained. Bend and twist the rubber hose...
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 maintained. Bend and twist the rubber hose...
Brake fluid level inspection
Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. Note. Hold the reservoir horizontal by turning the handlebar when checking brake fluid level. ★ If the fluid level is lower than the lower level...
Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. Note. Hold the reservoir horizontal by turning the handlebar when checking brake fluid level. ★ If the fluid level is lower than the lower level...
Brake pad wear inspection
Check the lining thickness [A] of the pads in each caliper. ★ If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set. Pad lining thickness: Standard: Front 4.5 mm (0.18 in.) Rear 7.0 mm...
Check the lining thickness [A] of the pads in each caliper. ★ If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set. Pad lining thickness: Standard: Front 4.5 mm (0.18 in.) Rear 7.0 mm...
Brake light switch operation inspection
Turn on the ignition switch. The brake light [A] should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm (0.39 in.). ★ If it does not, adjust the brake light switch. While holding the switch body, turn the...
Turn on the ignition switch. The brake light [A] should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm (0.39 in.). ★ If it does not, adjust the brake light switch. While holding the switch body, turn the...
Front forks/rear shock absorber operation inspection
Pump the forks down and up [A] 4 or 5 times, and inspect the smooth stroke. ★ If the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (see Front fork oil change in the Suspension chapter). Pump the seat down and up...
Pump the forks down and up [A] 4 or 5 times, and inspect the smooth stroke. ★ If the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (see Front fork oil change in the Suspension chapter). Pump the seat down and up...
Front fork oil leak inspection
Visually inspect the front forks [A] for oil leakage. ★ Replace or repair any defective parts, if necessary.
Visually inspect the front forks [A] for oil leakage. ★ Replace or repair 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). Visually inspect the shock absorber [A] for oil leakage. ★ If the oil leakage is found on it, replace the shock absorber with a new one.
Remove the left side cover (see Left side cover removal in the Frame chapter). Visually inspect the shock absorber [A] for oil leakage. ★ If the oil leakage is found on it, replace the shock absorber with a new one.
Swingarm pivot lubrication
Remove the swingarm (see Swingarm removal in the Suspension chapter). Clean the old grease out of the bearings. Apply grease to the inner surface of the needle bearings [A]. Apply a thin coat of grease to the lips of the grease seals. Install the...
Remove the swingarm (see Swingarm removal in the Suspension chapter). Clean the old grease out of the bearings. Apply grease to the inner surface of the needle bearings [A]. Apply a thin coat of grease to the lips of the grease seals. Install the...
Rocker arm operation inspection
Pump the seat down and up 4 or 5 times, and inspect the smooth stroke. ★ If the rocker arm [A] does not smoothly stroke or noise is found, inspect the fasteners and bearings.
Pump the seat down and up 4 or 5 times, and inspect the smooth stroke. ★ If the rocker arm [A] does not smoothly stroke or noise is found, inspect the fasteners and bearings.
Tie-rod operation inspection
Pump the seat down and up 4 or 5 times, and inspect the smooth stroke. ★ If the tie-rod [A] do not smoothly stroke or noise is found, inspect the fasteners and tie-rod bearings.
Pump the seat down and up 4 or 5 times, and inspect the smooth stroke. ★ If the tie-rod [A] do not smoothly stroke or noise is found, inspect the fasteners and tie-rod bearings.
Uni-trak linkage lubrication
Remove: Tie-Rod (see Tie-rod removal in the Suspension chapter) Apply grease to the inner surfaces of the needle bearings [A]. For the rocker arm it has grease nipples [A] on the rocker arm for lubrication. Force grease into the nipple until it...
Remove: Tie-Rod (see Tie-rod removal in the Suspension chapter) Apply grease to the inner surfaces of the needle bearings [A]. For the rocker arm it has grease nipples [A] on the rocker arm for lubrication. Force grease into the nipple until it...
Steering play inspection
Raise the front wheel off the ground with jack. Special Tool - Jack: 57001-1238. With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully left and right from the force of gravity...
Raise the front wheel off the ground with jack. Special Tool - Jack: 57001-1238. With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully left and right from the force of gravity...
Steering play adjustment
Remove: Windshield (VN900D Models) (see Windshield removal in the Frame chapter) Handlebar Holder Nuts [A] Handlebar Holders [B] together with the Handlebar Upper Front Fork Clamp Bolt (Both Sides) [C] Steering Stem Head Nut [D] Remove the steering...
Remove: Windshield (VN900D Models) (see Windshield removal in the Frame chapter) Handlebar Holder Nuts [A] Handlebar Holders [B] together with the Handlebar Upper Front Fork Clamp Bolt (Both Sides) [C] Steering Stem Head Nut [D] Remove the steering...
Steering stem bearing lubrication
Remove the steering stem (see Steering stem removal in the Steering chapter). Using a high flash-point solvent, wash the upper and lower ball bearings in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head...
Remove the steering stem (see Steering stem removal in the Steering chapter). Using a high flash-point solvent, wash the upper and lower ball bearings in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head...
Lights and switches operation inspection
First step Turn on the ignition switch. The following lights should go on according to below table. Position Lights [A] ( US and Canada Models) goes on City Light [B] (Europe Models) goes on Taillight [C] goes on License Plate Light [D] goes on...
First step Turn on the ignition switch. The following lights should go on according to below table. Position Lights [A] ( US and Canada Models) goes on City Light [B] (Europe Models) goes on Taillight [C] goes on License Plate Light [D] goes on...
Headlight aiming inspection
Inspect the headlight beam for aiming. ★ If the headlight beam points to one side rather than straight ahead, adjust the horizontal beam. Headlight beam horizontal adjustment Turn the horizontal adjuster [A] on the headlight with the screwdriver in...
Inspect the headlight beam for aiming. ★ If the headlight beam points to one side rather than straight ahead, adjust the horizontal beam. Headlight beam horizontal adjustment Turn the horizontal adjuster [A] on the headlight with the screwdriver in...
Sidestand switch operation inspection
Inspect the sidestand switch [A] operation accordance to below table. Sidestand switch operation Sidestand Gear Position Clutch Lever Engine Start Engine Run Up Neutral Released Starts Continue running Up Neutral Pulled in Starts Continue running Up...
Inspect the sidestand switch [A] operation accordance to below table. Sidestand switch operation Sidestand Gear Position Clutch Lever Engine Start Engine Run Up Neutral Released Starts Continue running Up Neutral Pulled in Starts Continue running Up...
Engine stop switch operation inspection
First step Turn on the ignition switch. Set the neutral position. Turn the engine stop switch to stop position [A]. Push the starter button. The engine does not start. ★ If the engine starts, inspect or replace the following item. Engine Stop Switch...
First step Turn on the ignition switch. Set the neutral position. Turn the engine stop switch to stop position [A]. Push the starter button. The engine does not start. ★ If the engine starts, inspect or replace the following item. Engine Stop Switch...
Chassis parts lubrication
Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. Lubricate the points listed below with indicated lubricant. Note. Whenever the vehicle has been operated under wet or rainy...
Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. Lubricate the points listed below with indicated lubricant. Note. Whenever the vehicle has been operated under wet or rainy...
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. OFor the engine fasteners, check the tightness of them when the engine is cold (at room temperature). ★ If there...
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. OFor the engine fasteners, check the tightness of them when the engine is cold (at room temperature). ★ If there...
Evaporative emission control system inspection
Inspect the canister as follows: Remove: Muffler (see Muffler removal in the Engine Top End chapter). Remove the bolts [A]. Remove the band [B] and take out the canister [C]. Disconnect the hoses [A] from the canister. Visually inspect the canister...
Inspect the canister as follows: Remove: Muffler (see Muffler removal in the Engine Top End chapter). Remove the bolts [A]. Remove the band [B] and take out the canister [C]. Disconnect the hoses [A] from the canister. Visually inspect the canister...
Air cleaner element replacement
Warning! If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident. Caution! If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur....
Warning! If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident. Caution! If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur....
Engine oil change
Situate the motorcycle so that it is vertical after warning up the engine. Remove: Oil Filler Cap [A]. Special Tool - Filler Cap Driver: 57001-1454. Remove the engine drain plug [A] to drain the oil. The oil in the oil filter can be drained by...
Situate the motorcycle so that it is vertical after warning up the engine. Remove: Oil Filler Cap [A]. Special Tool - Filler Cap Driver: 57001-1454. Remove the engine drain plug [A] to drain the oil. The oil in the oil filter can be drained by...
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....
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....
Fuel hose replacement
Caution! When removing and installing the fuel hose joint, do not apply strong force to the outlet pipe on the fuel pump and delivery pipe on the throttle body assy. The pipes made from resin could be damaged. Remove the fuel tank (see Fuel tank...
Caution! When removing and installing the fuel hose joint, do not apply strong force to the outlet pipe on the fuel pump and delivery pipe on the throttle body assy. The pipes made from resin could be damaged. Remove the fuel tank (see Fuel tank...
Coolant change
Warning! To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery, and can cause an accident and injury. Since coolant is harmful to...
Warning! To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery, and can cause an accident and injury. Since coolant is harmful to...
Radiator hose and O-ring replacement
Drain the coolant (see Coolant change ). Remove: Thermostat Bracket [A] (see Thermostat removal in the Cooling System chapter). Loosen the radiator hose clamps and remove the hoses [B]. Unscrew the bolts and remove the water hose fittings [C] and...
Drain the coolant (see Coolant change ). Remove: Thermostat Bracket [A] (see Thermostat removal in the Cooling System chapter). Loosen the radiator hose clamps and remove the hoses [B]. Unscrew the bolts and remove the water hose fittings [C] and...
Brake hose replacement
Caution! Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away immediately. When removing the brake hose [A], take care not to spill the brake fluid on the painted or plastic parts. When removing the brake...
Caution! Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away immediately. When removing the brake hose [A], take care not to spill the brake fluid on the painted or plastic parts. When removing the brake...
Brake fluid change
Note. The procedure to change the front brake fluid is as follows. Changing the rear brake fluid is almost the same as for the front brake. Level the brake fluid reservoir. Remove: Reservoir Cap [A] Plate [B] Diaphragm [C] Remove the rubber cap from...
Note. The procedure to change the front brake fluid is as follows. Changing the rear brake fluid is almost the same as for the front brake. Level the brake fluid reservoir. Remove: Reservoir Cap [A] Plate [B] Diaphragm [C] Remove the rubber cap from...
Master cylinder rubber parts replacement
Front master cylinder disassembly Remove the front master cylinder (see Front master cylinder removal in the Brakes chapter). Remove the reservoir cap [A], plate [B], and diaphragm [C]. Unscrew the locknut [D] and pivot bolt [E], and remove the...
Front master cylinder disassembly Remove the front master cylinder (see Front master cylinder removal in the Brakes chapter). Remove the reservoir cap [A], plate [B], and diaphragm [C]. Unscrew the locknut [D] and pivot bolt [E], and remove the...
Caliper rubber parts replacement
Front caliper disassembly Remove: Front Caliper (see Front caliper removal in the Brakes chapter) Cotter Pin [A] Pin [B] Pads [C] (see Front brake pad removal in the Brakes chapter) Push the piston in. Remove: Pad Springs [A] Caliper Holder [B]...
Front caliper disassembly Remove: Front Caliper (see Front caliper removal in the Brakes chapter) Cotter Pin [A] Pin [B] Pads [C] (see Front brake pad removal in the Brakes chapter) Push the piston in. Remove: Pad Springs [A] Caliper Holder [B]...
Spark plug replacement
Remove: Fuel Tank (see Fuel tank removal in the Fuel System chapter) Spark Plug Caps [A] Remove the spark plug using the 16 mm (0.63 in.) plug wrench vertically. Special Tool - Spark Plug Wrench, Hex16: 57001-1262. Caution! The insulator [A] of the...
Remove: Fuel Tank (see Fuel tank removal in the Fuel System chapter) Spark Plug Caps [A] Remove the spark plug using the 16 mm (0.63 in.) plug wrench vertically. Special Tool - Spark Plug Wrench, Hex16: 57001-1262. Caution! The insulator [A] of the...
Troubleshooting guide
Notes: Refer to the Fuel System chapter for most of DFI trouble shooting guide. This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the...
Notes: Refer to the Fuel System chapter for most of DFI trouble shooting guide. This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the...
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- Information for owner
- Introduction to manual
- Maintenance
- Engine and systems
- Engine repair
- Fuel system (DFI)
- Cooling system
- Lubrication system
- Transmission
- Running gear and frame
- Frame and hinged elements
- Front suspension and handlebar
- Rear suspension
- Brake system
- Wheels and tires
- Electric equipment
- Equipment and devices
- Lighting and lamps
- Starting and charging system
- Ignition system
- Electrical circuits