Kawasaki VN1500 Classic Service Manual Supplement

Kawasaki

vuLcANl500

0LASSIC

vN1500 cLAS$lc

Motorcycle

Service

Manual

Supplement

This

quick

reference

guide

will

assist

you

in locating

a

desired

topic or

procedure.

.

Bend the

pages

back

to

match

the black

tab

of the

desired

chapter

number

with the

black

tab

on the

edge at

each

table of

contents

page.

.

Refer to

the sectional

table

of

contents

for the exact

Pages

to

locate the

specific

topic

required.

Quick

Reference

Guide

VULCAN15OO

CLASSIC

VN15OO

CLASSIC

Motorcycle

Service

Manual

Supplement

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 DepartmenUConsumer

Products

&

Machinery

Company/Kawasaki

Heavy

lndustries, Ltd.,

Japan.

No liability can be

accepted

for any

inaccuracies or omissions

in

this

publication,

although

every

possible

care has

been taken

to make

it

as complete

and accurate

as

possible.

The right

is

reserved to make

changes

at

any time

without

prior

notice and

without

incurring

an obligation

to

make such

changes to

products

manufactured

previously.

See

your

Motorcycle

dealer

for the

latest

information on

product

improvements

incorporated after this

publication.

All

information

contained

in

this

publication

is based on the

latest

product

information

available

at the

time

of

publication.

lllustrations and

photographs

in this

publication

are

intended

for reference

use only

and

may

not depict

actual

model component

parts.

O

1997 Kawasaki

Heavy lndustries, Ltd.

6th

Edition

(1)

: APR. 9,

2003

(K)

LIST

OF

ABBREVIATIONS

A

ABDC

AC

ATDC

BBDC

BDC

BTDC

'c

DC

F

"F

ft

g

h

L

ampere(s)

after bottom dead center

alternating current

after top dead center

before bottom dead center

bottom dead center

before

top

dead center

degree(s) Celsius

direct current

farad(s)

degree(s)

Fahrenheit

foot, feet

gram(s)

hour(s)

liter(s)

tb

m

min

N

Pa

PS

psi

r

rpm

TDC

TIR

V

W

c)

pound(s)

meter(s)

minute(s)

newton(s)

pascal(s)

horsepower

pound(s) per

square

inch

revolution

revolution(s)

per

minute

top

dead

center

total

indicator

reading

volt(s)

watt(s)

ohm(s)

Read

OWNER'S

MANUAL

before

operating.

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EMISSION CONTROL

INFORMATION

To

protect

the

environment

in which

we

all

live, Kawasaki

has

incorporated crankcase

emission

(1

)

and exhaust emission

(2)

control systems

in compliance

with applicable

regulations of the

United States

Environmental

Protection

Agency and

California

Air Resources

Board. Additionally,

Kawasaki

has

incorporated an evaporative

emission

control system

(3)

in

compliance

with

applicable

regulations

of the

California

Air Resources

Board on

vehicles sold

in California only.

1. Crankcase

Emission Control System

This system

eliminates the

release of

crankcase

vapors into the atmosphere.

lnstead. the

vapors

are routed through

an oil separator

to the

intake side of the engine.

While the engine

is operating,

the

vapors are drawn into

combustion chamber,

where they are

burned along

with the

fuel

and

air supplied by the carburetion

system.

2. Exhaust

Emission

Control

System

This system reduces

the amount of

pollutants

discharged

into

the

atmosphere

by the exhaust

of this

motorcycle.

The fuel and ignition

systems

of this

motorcycle

have been carefully

designed

and constructed

to ensure an

efficient engine

with

low

exhaust

pollutant

levels.

3. Evaporative

Emission

Control System

Vapors caused

by fuel evaporation

in the

fuel system are

not

vented into the atmosphere.

Instead,

fuel vapors are

routed into the

running engine to

be burned,

or stored

in a canister

when the engine

is

stopped.

Liquid fuel

is

caught

by a

vapor separator

and returned to the

fuel tank.

The Clean

Air Act, which is the

Federal law

covering

motor vehicle

pollution.

contains

what

is

commonly

referred to as the

Act's

"tampering

provisions."

"Sec.

203(a)

The following acts

and the causing

thereof

are

prohibited...

(3) (A)

for

any

person

to

remove or render

inoperative any device

or element

of design

installed

on or

in a motor

vehicle or motor

vehicle

engine

in compliance

with

regulations under

this title

prior

to its sale

and delivery

to

the

ultimate

purchaser,

or for any

manufacturer

or dealer

knowingly to

remove or

render inoperative

any such device

or element

of

design

after

such

sale and

delivery to the ultimate

purchaser.

(3) (B)

for any

person

engaged

in the business

of

repairing. servicing. selling,

leasing, or trading

motor vehicles or

motor vehicle

engines. or who operates

a

fleet of

motor vehicles

knowingly to remove or

render

inoperative any device

or element

of design

installed

on

or

in

a

motor vehicle or

motor vehicle engine

in

compliance

with regulations under

this

title

following its sale and

delivery to

the ultimate

purchaser..."

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NOTE

The

phrase

"remove

or render

inoperative

any

device

or

element

of

design"

has

been

generally

interpreted

as

follows:

f - Tampering

does

not

include

the

temporary

remova!

or

rendering

inoperative

of

devices or elements

of design

in

order

to

perform

maintenance.

2. Tampering

could

include:

a.

Maladiustment

of vehicle

components

such

that

the

emission

standards

are

exceeded.

b.

Use

of

replacement

parts

or

accessories

which

adversely

affect

the

performance

or

durability

of the

motorcycle.

c. Addition

of components

or accessories

that

result in

the

vehicle

exceeding

the

standards.

d. Permanently

removing,

disconnecting,

or rendering

inoperative

any component

or

element

of design

of the

emission

control

systems.

WE

RECOMMEND

THAT

ALL

DEALERS

OBSERVE

THESE

PROVISIONS

OF FEDERAL

LAW,

THE

VIOLATION

OF

WHICH

IS

PUNISHABLE

BY

CIVIL

PENALTIES

NOT

EXCEEDING

$1O,OOO

PER

VIOLATION.

'$.F,SSe.dq.s,#

w*ffiffi

TAMPERING

WITH

NOISE

CONTROL

SYSTEM PROHIBITED

Federal

law

prohibits

the following

acts

or

the causing

thereof:

(1)

The

removal

or rendering

inoperative

by any

person

other than

for

purposes

of maintenance,

repair,

or replacement,

of

any

device

or element

of

design

incorporated

into

any new

vehicle

for

the

purpose

of noise

control

prior

to its

sale

or

delivery

to

the ultimate

purchaser

or while it

is in

use,

or

(2)

the

use of

the vehicle

after

such

device

or element

of design

has

been removed

or rendered

inoperative

by any

person.

Among

those

acts

presumed

to constitute

tampering

are the

acts listed

below:

oReplacement

of

the original

exhaust

system

or muffler

with

a component

not

in

compliance

with

Federal

regulations.

aRemoval

of the

muffler(s)

or any internal

portion

of the muffler(s).

oRemoval

of the

air

box

or air box

cover.

oModifications

to

the muffler(s)

or

air intake

system

by

cutting,

drilling,

or

other means

if

such

modifications

result

in increased

noise

levels.

Foreword

This service manual supplement contains

only the

information

unique

to the models

covered.

lt must be

used

with the base service

manual listed

below.

Read

both

this supplement and

the

base

manual for complete

information on

proper

service

procedures

for the models

covered

by this

manual.

Base

Manual

I

Part

Number

vN1500D

I

SS924-1191

This manual

is designed

primarily

for use by trained

mechanics

in

a

properly

equipped shop.

However,

it

contains enough detail

and basic information

to

make

it useful

to the owner who desires

to

perform

his own

basic maintenance and

repair work. A

basic

knowledge

of

mechanics, the

proper

use of

tools,

and

workshop

procedures

must be understood

in order

to

carry out

maintenance and repair satisfactorily.

Whenever the

owner

has insufficient experience or doubts his ability to

do

the work, all adjustments,

maintenance,

and

repair

should be carried

out only by

qualified

mechanics.

ln order

to

perform

the work efficiently and

to

avoid

costly

mistakes, read

the text, thoroughly familiarize

yourself

with the

procedures

before starting

work,

and

then do the work carefully

in

a clean area.

Whenever

special

tools or

equipment are specified, do not use

makeshift tools or equipment.

Precision measurements

can

only be

made if the

proper

instruments are used,

and

the

use

of substitute tools may adversely affect safe

operation.

For

the

duration

of the warranty

period,

we rec-

ommend

that all repairs and scheduled maintenance be

performed

in accordance

with this

service manual.

Any

owner

maintenance or

repair

procedure

not

performed

in

accordance

with this

manual may void the

warranty.

To

get

the longest life out of

your

vehicle:

o Follow the Periodic

Maintenance

Chart

in the

Service

Manual.

o Be alert

for

problems

and

non-scheduled maintenance.

o

Use

proper

tools and

genuine

Kawasaki

Motorcycle

parts.

Special tools,

gauges,

and testers that

are

necessary

when servicing Kawasaki motorcycles are

introduced by

the

Special

Tool Catalog or Manual.

Genuine

parts

provided

as spare

parts

are listed in the

Parts Catalog.

o

Follow

the

procedures

in this manual carefully. Don't

take shortcuts.

o Remember to keep complete

records

of

maintenance

and

repair with dates and any

new

parts

installed.

How to

Use

This Manual

In

this manual, the

product

is divited into its major sys-

tems and

these

systems

make

up

the manual's

chapters.

The Quick

Reference

Guide

shows

you

all of the

product's

system and

assists in locating their chapters. Each chap-

ter in turn has its own comprehensive

Table

of Contents.

For example,

if

you

want

ignition

coil

information,

use

the

Quick

Reference Guide

to

locate the Electrical

System

chapter. Then, use the

Table

of contents on the first

page

of

the

chapter

to find the lgnition

Coil section.

Whenever

you

see these WARNING and CAUTION

symbols, heed their instructions! Always follow safe

operating and

maintenance

practices.

This warning symbol identifies special instruc-

tions

or

procedures

which,

if

not correctly fol-

lowed, could result in

personal

injury,

or

loss

of

life.

CAUTION

This caution symbol

identifies special instruc-

tions or

procedures

which, if not strictly ots

served, could result

in damage to

or

destruction

ot equipment.

This manual contains

four more symbols

(in

addition

to

WARNING and CAUTION)

which will help

you

distinguish

different

types of information.

NOTE

o

This note symbol

indicates

points

of

particular

in-

terest for more efficient and convenient operation.

o Indicates a

procedural

step

or work to be done.

o

Indicates a

procedural

sub-step

or how to do the work

of

the

procedural

step it follows.

lt

also

precedes

the

text of a NOTE.

* lndicates a conditional step

or what

action

to take

based

on

the results

of

the test or inspection

in the

procedural

step or sub-step

it follows.

In

most

chapters

an

exploded

view illustration of

the

system

components follows

the Table of

Contents.

In

these illustrations

you

will find the instructions

indicating

which

parts

require specified

tightening torque,

oil,

grease

or a

locking agent during assembly.

GENERAL INFORMATION

1.1

General

lnformation

Table

of

Contents

Before Servicing

.....1-2

Model ldentification

....................1-4

GeneralSpecifications..................

..................1-7

Periodic

Maintenance Chart...........

..............1

-10

Technical

lnformation

-

V-Engine

Technical Information

-

4

Valves

and

2 Spark

Plugs

per

Cy|inder................................*

Technical Information

-

Deceleration

Torque

Limiting Clutch

Technical Information

-

Balancer

Mechanism

Technical

Information

-

Coasting Enricher......

Technical

Information

-

Maintenance Free Battery..,.....

............................*

Technical lnformation

-

Hydraulic Lash Adjuster...................

Technical Information

-

K-TRIC

(Kawasaki

Throttle Responsive lgnition

Control)

..........1-11

Technical lnformation

-

KLEEN

(

KAWASAKI

LOw

EXHAUST

EM

ISSION)

for VN1 500F..'..'.....

"'..'1

-1

2

Torque and Locking

A9ent..........

.................1-17

Special

Tools and

Sealant

........1-21

Cable, Wire, and Hose Routing.................

...1-28

(*):

Referto

Base Manual.

1

-2

GENERAL INFORMATION

Before

Seruicing

Before

starting

to

per4orm

an

inspection

service or

carry out a disassembly

and reassembly

operation

on a motorcycle,

read

the

precautions

given

below. To

facilitate

actual operations,

notes, illustrations,

photographs,

cautions,

and detailed

descriptions

have

been included

in

each chapter wherever

necessary.

This

section explains

the items

that require

particular

attention

during

the

removal

and reinstallation

or disassembly

and reassembly

of

general parts.

Especially

note the

following:

(1)

Dirt

Before

removal

and disassembly,

clean

the motorcycle.

Any

dirt entering

the engine will

shorten

the life

of the

motorcycle.

For

the same reason,

before installing

a

new

part,

clean

off any dust

or metal filings.

(2)

Battery

Ground

Disconnect

the

ground

(-)

wire from

the bailery

before

pedorming

any disassembly

operations

on

the motorcycle.

This

prevents

the engine from

accidentally

turning

over while work is

being

carried out,

sparks from

being

generated

while

disconnecting

the wires from

electrical

parts,

as well

as damage to

the electrical

parts

themselves.

For

reinstallation,

first

connect

the

positive

wire

to the

positive

(+)

terminal

of the

battery

(3)

Installation,

Assembly

Generally,

installation

or assembly

is the reverse

of removal

or disassembly.

However,

if installation

or assembly

sequence is

given

in

this Service Manual, follow

it. Note

parts

locations

and

cable, wire,

and hose routing

during

removal

or disassembly

so they can

be installed

or assembled in

the

same way. lt is

preferable

to mark and record

the

locations

and routing whenever

possible.

(4)

Tightening

Sequence

When installing

bolts, nuts, or

screws for which

a tightening

sequence is

given

in

this Service Manual,

make

sure

to follow

the

sequence. When installing

a

part

with

several bolts, nuts,

or screws,

start them

all in their

holes

and

tighten

them to a

snug

fit,

thus

ensuring that

the

part

has

been

installed

in its

proper

location.

Then,

tighten

them

to the

specified torque in

the tightening

sequence

and method indicated.

lf

tightening

sequence instructions

are not

given,

tighten

them

evenly in a cross

pattern.

Conversely, to remove

a

part,

first

loosen

all the bolts, nuts,

or

screws

that

are

retaining

the

part

a 1|4-turn

before removing

them.

(5)

Torque

When

torque values

are

given

in this

Service Manual,

use them. Either

too little

or too much

torque may

lead

to

serious

damage. Use

a

good

quality,

reliable

torque wrench.

(6)

Force

Common

sense should

dictate how much force

is necessary

in assembly

and

disassembly. lf

a

part

seems

especially

difficult

to remove

or install, stop

and examine what

may

be causing the

problem.

Whenever

tapping is

necessary,

tap

lightly

using a wooden

or

plastic-faced

mallet.

Use an impact

driver for

screws

(particularly

for the removing

screws

held by non-permanent

locking

agent) in order

to avoid damaging

the screw

heads.

(7)

Edges

Watch

for sharp

edges, as

they could cause injury

through

careless

handling,

especially during

major

engine

disassembly

and assembly.

Use

a clean

piece

of

thick cloth when lifting

the

engine or turning it

over.

(8)

High-Flash

Point

Solvent

A high-flash

point

solvent

is recommended

to reduce

fire danger. A

commercial

solvent commonly

available

in North

America

is standard

solvent

(generic

name). Always

follow manufacturer

and container

directions regarding

the use

of

any solvent.

(9)

Gasket,

O-Ring

Replace

a

gasket

or

an O-ring with a new

part

when

disassembling.

Remove

any foreign matter

from

the mating

surface

of

the

gasket

or

O-ring to ensure

a

perfectly

smooth sudace

to

prevent

oil or compression

leaks.

(10)

Liquid Gasket,

Locking

Agent

Clean

and

prepare

surfaces where liquid

gasket

or non-permanent

locking

agent will

be used. Apply

them

sparingry.

Excessive

amount may

block engine oil

passages

and cause serious

damage.

(1

1)

Press

When

using a

press

or driver

to

install

a

part

such as

a

wheel

bearing,

apply a

small amount

of oil to

the area

where

the

two

parts

come in

contact

to ensure a smooth fit.

(12)

Ball Bearing

and Needle Bearing

Do not remove

a ball bearing

or a

needle

bearing

unless it is

absolutely necessary.

Replace

any

ball or needle

bearings that

were removed

with new

ones. Install

bearings with

the manufacturer

and size marks

facing

out, applying

pressure

evenly with

a suitable driver. Apply

force

only to the end

of the race

that contacts

the

press

fit

portion,

and

press

it

evenly

over the

base component.

(13)

Oil Seal

and Grease

Seal

Replace

any oil or

grease

seals

that were removed

with new

ones, as removal

generally

damages

seals.

Oil or

grease

seals

should be

pressed

into

place

using

a suitable driver,

applying a force

uniformly

to the end

of seal until

the face

of the seal is

even with

the end of

the

hole,

unless instructed

otherwise.

When

pressing

in

an oil

or

grease

seal which

has manufactureds

marks,

press

it in

with

the

marks

facing

out.

GENERAL

INFORMATION 1.3

(14)

Circlip, Retaining

Ring, and Cotter

When

installing

circlips

and retaining

rings,

take

care to compress

or expand them

only enough to

install them and

no more. lnstall the circlip

with its

chamfered

side

facing load side as

well.

Replace any circlips,

retaining rings, and cotter

pins

that

were removed with

new ones, as

removal weakens and

deforms them.

lf

old

ones are reused, they could

become detached

while

the

motorcycle is driven,

leading to a major

problem.

(15)

Lubrication

Engine wear is

generally

at

its maximum

while

the

engine

is warming up and before

all the sliding surfaces

have

an adequate

lubricative

film. During assembly,

make sure to apply

oil to any sliding surface

or bearing that

has been

cleaned. Old

grease

or dirty oil could

have lost its

lubricative

quality

and

may contain

foreign

particles

that act as

abrasives; therefore,

make sure to

wipe it

off

and apply

fresh

grease

or oil. Some

oils and

greases

in

particular

should

be used

only in certain applications

and may be

harmful if used

in an

application

for which they are

not

intended.

(16)

Direction of Engine Rotation

To rotate the crankshaft

manually, make sure

to do so in

the direction of

positive

rotation.

Positive rotation is

counterclockwise as

viewed f rom the

left

side of

the engine.

To carry out

proper

adjustment,

it is furthermore necessary

to rotate the engine

in the

direction

of

positive

rotation as

well.

(17)

Replacement Parts

When

there

is

a

replacement

instruction, replace these

parts

with new

ones

every time they

are removed.

Replacement

parts

will

be

damaged or

lose

their

original

function once they

are removed.

Therefore, always

replace these

parts

with new ones every time they

are removed.

Although the

previously

mentioned

gasket,

O-ring,

ball bearing, needle bearing,

grease

seal, oil seal,

circlip, and

cotter

have

not been so designated

in

their

respective

text,

they are replacement

parts.

(18)

ElectricalWires

All the electrical

wires are either one-color

or two-color.

A two-color

wire is identified

first

by

the

primary

color and

then the

stripe color.

For

example,

a

yellow

wire with thin

red

stripes

is referred

to as a

"yellow/red"

wire; it would

be

a

"red/yelloW'wire

if

the

colors were reversed.

Unless instructed

othennrise,

electrical wires

must

be connected

to

wires

of the same

color.

Two-Color

Electrical

W

ire

(cross-sect

ion)

Color lndicated

on the llire

Color Indicated on the

Iririns Diagram

Red

l{ire

Strands

Yellow

Red

Ye | | owlRed

-f

/R-

c8020601r1 c

(19)

Inspection

When

parts

have been disassembled,

visually

inspect these

parts

for the

following conditions or other

damage.

lf

there

is any doubt as to the condition

of them,

replace them

with new ones.

Abrasion

Bent

Color change

Crack

Dent

Deterioration

Hardening

Warp

Scratch

Wear

Seizure

(20)

Specifications

Soecification terms

are defined as

follows:

"Standards"

show

dimensions or

performances

which brand-new

parts

or

systems

have.

"service

Limits" indicate the

usable limits.

lf

the

measurement

shows excessrve

wear or deteriorated

pedormance,

replace the damaged

parts.

1.4

GENERAL INFORMATION

Model

ldentification

V'Nl50O-El

(US

and

Canada) Left

Side

View:

VNl50O-E1

(US

and Canada) Right

Side

View:

'l

,tTil

i';;tttit

tr,

1,,'t

iE

i

'l,llil|t

P1

-,1 :::.

:.,,1

#"

I

,,4

I

"tt'

*r

''tt

'L

li

z::,,)

H

:

ti,

,r.

!,;

l,l'q"1

,t;

i.i

GENERAL INFORMATION

1

-5

VNl50O-El

(Australia)

Left

Side View:

,t lrrht:!1,:'j':l= :=,

iiii:.:::::::::

:,::::::::i

VN1500-El

(Australia)

Right

Side View:

:

,'

:,

.'':]

;rj

1.6

GENERAL INFORMATION

VNl50O-E1

(Other

than

US,

Canada,

and Austratia) Left

Side View:

;

''tf,Ee

:;;!,1;i

?:l)

iil

i4tlti t

@f

tril

GENERAL

INFORMATION

1.7

VNls(X)-Fl

(Germany,

Austria, and Switzerland)

Left

Side

View:

..'..'.' :

:i:

:

VN150O-F1

(Germany,

Austria, and Switzerland)

Right

Side

View:

1.8

GENERAL

INFORMATION

General

Specifications

2 500 mm

965

mm

1 100

mm

1 660 mm

125

mm

700 mm

292k9,

(cA)

292.5

kg

138ks

172k9,

(cA)

172.5

kg

16 L

Items

Dimensions:

Overall

length

Overallwidth

Overall

height

Wheelbase

Road clearance

Seat

height

Dry mass

Curb

mass: Front

Rear

Fuel

tank capacity

Performance:

Minimum turning radius

Engine:

Type

Cooling

system

Bore

and

stroke

Displacement

Compression ratio

Maximum horsepower

vN1500-E1

4-stroke,

SOHC,

V2-cylinder

Liquid-cooled

102 x 90 mm

1 470 mL

8.6:1

47

kW

(64

PS)

@47O0

r/min

(rpm),

(FR)

UTAC's

norm 45 kW

(61

PS)

@47OO

r/min

(rpm).

(US)

_

112 N-m

(11.4

ks-m,

82.5

ft-lb)

@3

000

r/min

(rpm),

(FR)

-,

(us)

-

Carburetor. Keihin CVK40

x

1

Electric starter

Battery and coil

(transistorized)

Electronically advanced

(digital)

From 5'

BTDC

@800

r/min

(rpm),

(CA)

From

5"

BTDC

@1

000

r/min

(rpm)

NGK DPRSEA-9 or

ND X16EPR-U9

Front to Rear,1-2

1-2

18. BTDC

62" ABDC

260'

62.

BBDC

22" ATDC

264'

Forced lubrication

(wet

sump)

SE, SF.

or

SG

class

sAEl 0W-40,

1

0W-50,

20W

-40,

or 20W-50

3.5

L

(when

engine

is

completely dry)

vNl500-F1

e--

292kg

,a---

172kg

47 kW

(64

PS)

@47O0

r/min

(rpm),

(sT)35.0

kw

(47.5

PS)

@3

700 r/min

(rpm)

112

N-m

(11

.4 kg-m, 82.5

ft-rb)

@3

000

r/min

(rpm),

(ST)98

N-m

(10

ks-m,72.3

ft-tb)@2 0OO

r/min

(rpm)

From

5'BTDC

@1

000 r/min

(rpm)

Maximum torque

Carburetion

system

Starting

system

lgnition

system

Timing advance

lgnition

timing

Spark

plugs

Cylinder numbering

method

Firing order

Valve

timing:

lnlet

Exhaust

Lubrication

system

Engine oil: Grade

Viscosity

Capacity

Open

Close

Duration

Open

Close

Duration

GENERAL

INFORMATION

1-9

Items

Drive

Train:

Primary

reduction

system:

Type

Reduction

ratio

Clutch type

Transmission:

Type

Gear ratios:

1st

2nd

3rd

4th

5th

Final

drive

system:

TYPe

Reduction

ratio

Overalldrive

ratio

Final

gear

case

oil:

Type

Capacity

Frame:

Type

Caster

(rake

angle)

Trail

Front tire:

Rear

tire:

Front

suspension:

vN1500-E1

12V 14 Ah

Semi-sealed

beam

1

2

V 60/55 W

(quartz-halogen)

12V 5121W

x 2,

(US) (CN)

12v

8/27

W x 2

Three-phase

AC

25 A

x

14V@6 000 r/min

(rpm)

vN1500-Fl

,F--

(---

,F--

(---

{---

e--

F--

.F--

F--

,F--

<--_

,F--

12V

5/21W

x 2

Type

Size

Type

Size

Type

Wheeltravel

Rear

suspension:Type

Brake

type:

Electrical Equipment:

Battery

Headlight:

Type

Bulb

Tail/brake light

Alternator:

Wheel travel

Front

Rear

Type

Rated output

Specifications

are subject to change without notice,

and may not apply to every country.

(CA)

:

California

(CN)

: Canada

(FR)

: France

(ST)

:

Switzerland

Gear

1

.517

(85/56)

Wet

multidisc

5-speed, constant

mesh, return shift

2.500

(40/16)

1.590(35122)

1.192(31t26)

0.965(28i

2e)

0.781

(25132)

Shaft

2.619

(15/21x33/9)

3.105

@Top

gear

API GL-5 Hypoid

gear

oil

SAE90

(above

5'C)

SAE80

(below

5"C)

200

mL

Tubular, double cradle

32

123

mm

Tube

1

30/90-1

6 67H

Tube

1

50/80-1

6

71 H

Telescopic

fork

150

mm

Swingarm

87

mm

Single

disc

Single

disc

(US):

United

States

1-10

GENERAL

INFORMATION

Periodic

Maintenance

Chaft

The

scheduled

maintenance

must

be

done

in

accordance

with

this chart

to keep

condition.

The

initial

mainlenance

is vitally

important

and

must nol

be neglected.

the motorcycle

in

good

running

FREOUENCY

OPERATION

Whichever

comes first

+)

,/s

A\.

!%

Every

DOMETER

READING

A#':

!f,"*

6SAA

*AY.,g/^o.g/^6

,*/

Spark

plug

-

clean and

gap

t

a

a o

o

Air

suction

valve

-

check

t

o

o o

o

a

Air

cleaner

element

-clean

t#

a

o

Throttle

grip

play

-

check

t

o

a

ldle

speed

-

adjust

o

a

Evaporative

emission

control

system

(CA)

-

check

t

o

a

o

Engine

oil

-

change

#

6

months

o

Oilfilter

-

replace

O

o

Radiator

hoses,

connections

-

check t

o

Coolant

-

change

2

years

a

Final

gear

case

oil

level

-

check

t

o

Final

gear

case

oil

-

change

a

Propeller

shaft

joint

-

lubricate

a

o

Clutch

fluid

level

-

check

t

month

o o

o

Clutch

fluid

-

change

2

years

a

Clutch

master

cylinder

cup and

dust

seal

-replace

4

years

Clutch

slave

cylinder

piston

seal

-

replace

4

years

Brake

lining

or

pad

wear

-

check t

#

o

a

o

Brake

fluid

level

-

check

t

month

o

a

o

a

o

Brake

fluid

-

change

2

vears

o

Brake

master

cylinder

cup and

dust

seal

-

replace

4

years

Caliper

piston

seal

and

dust

seal

-

replace

4

vears

Brake light

switch

-

check

t

a o

o

Steering

-

check f

o

a

o

a

o

Steering

stem

bearing

-

lubricate

2

years

o

Front

fork

oil

-

change

2

years

o

Rear

shock

absorber

oil leak

-

check t

a

o

Front

fork

oil

leak

-

check

t

a

o

Tire

wear

-

check t

o

o o

o

Spoke tightness

and

rim

runout

-

check t

a o

o

Swingarm

pivot,

lubricate

a

o

General

lubrication

-

perform

o

Nuts,

bolts,

and fasteners

tiqhtness

-

check

t

o

Service

more frequently

when

harsh riding

condition.

For

higher

odometer

readings,

repeat

at

the

frequency

interval

established

here.

Replace,

add, adjust,

clean.br

toique

if necessary.

California

Vehicle

onlv

operating

in

high speed,

frequent

starting/stopping,

dust.

wet, mud,

or

other

.:

t:

(CA):

GENERAL

INFORMATION

1-11

Technical

Information

-

K-TRIC

(Kawasaki

Throttle Responsive

lgnition Gontrol)

The VNl5O0E/F

features

K-TRlC. K-TRIC digitally

controls

thE

ignition

curve

not only according

to engine

rpm, but also

accqrding

to throttle opening.

A

throttle sensor

[A]

is electrically

linked to a

microcomputer

that

varies the

ignition

curve

infinitely

for

greater

combustion

efficiency.

How it works?

The throttle

sensor

is

located on

the carburetor

throttle

shaft end, and

senses throttle

opening.

This

sensor

is

a

rotating

type variable

resistor

that changes

voltage

according

to throttle opening.

The

microcomputer

senses this voltage

change

so that

the

igniter

determines

ignition timing

not

only according

to engine

rpm, but also according to

throttle

opening.

[A]

Ground

Terminal

IB]

OutputTerminal

[C]

Voltage Terminal

Function

ln a conventional digital

ignition system the

igniter

changes

ignition

timing

only according

to

engine

rpm,

and engine

load is disregarded.

To

provide

greater

combustion

efficiency, K-TRIC digitally controls

the

ignition

timing

curve according to engine

rpm and engine

load

as

indicated by throttle

position.

The result

is

a three dimensional

ignition

timing

curve for

improved

combustion

etficiency

from walking

speed to

114 or

1/3

of

full

throttle.

[A]

ldling

(see

FuelSystem chapter)

IB]

FullThrottle

Adding

to

the conventional

f

unctions,

such as dwell control,

anti-theft, and over

rev

protection.

K-TRIC

has

a

fail safe

(self

diagnosis)

function. ln case of throttle sensor

trouble a

wiring

shorted

or open

circuit, an ordinary

ignition timing control system

does

not work well,

and

in

the

worst case the engine

would be damaged. In such a case, the

K-TRIC igniter senses this

trouble and

locks

ignition timing

in

the throttle

wide open

position

to

protect

the engine

from damage.

@@o

1.12

GENERAL INFORMATION

Technical Information

-

KLEEN

(KAWASAKI

LOW

EXHAUST

EM|SSION)

tor VNl5O0E/F

A secondary air injection

system

[A]

helps Kawasaki

keep motorcycle

exhaust

gases

below the

established

emission

regulation limits.

This

system draws

air into

the

exhaust

ports,

dilutes

and burns

harmful

ingredients

in

the

exhaust

gas

in order

to

reduce

them. This

allows the

carburetor to be

set

at

a

reasonable

setting

position

without

adjusting

it much

leaner,

so engine

performance

and actual

riding

performance

are not

spoiled.

But, under the

trend thal the

emission regulation

becomes more

severe,

Kawasaki

has

adopted

two catalytic

converters

in the

premuffler

chamber

[B]

in

addition

to

a

secondary

air

injection

system.

As

a

result,

we

can reduce

the exhaust

gas

emission below

the current

standards

without

hurting

the output

performance

and

the actual

riding

feeling

at all. The harmful ingredients

in

the

exhaust

gas

are reduced

considerably

under EC-mode

running

performance

of emission regulation

like LA4

or EC mode.

As

actual examples,

carbon monoxide

(CO)

is reduced

about

50%,

hydrocarbons (HC)

about

40olo,

nitrogen

oxides

(NOx)

about 20

-

30"k.

Exhaust

Gas

after Purification

Kawasaki

Low

Exhaust

Emission System

l.Exhaust Purification

System

The

burned

gas,

which

goes

out

from

the combustion

chamber,

is injected with

secondary

air

(adding

necessary oxygen),

and

is cleaned

up

while

passing

through two small catalytic converters

and then

goes

out to the atmosphere.

1)Secondary Air Injection

System

In

order to oxidize CO, and

HC

by

the catalysts,

the

proper

amount of oxygen is necessary. As

original

combustion

gas

has little remaining

oxygen,

air

is

injected

in the

exhaust

ports

by the

secondary

air

injection

system in order

to supply enough

oxygen to

the combustion

gas

to

purify

CO, and

HC

to a certain

extent as

well

as

prepare

for

activation of the catalysts.

Since

the

carburetor is

set at

richer level

[A]

and airlfuel

mixture

(A/F)

is

about

11

-

14, Nox is

at

lower level

from

the beginning

as shown

in

the

figure.

And, A/F

becomes

lear

(about

13.5

-

15)

after the combustion

chambers owingto

secondary air

injection

and combustion.

Exhaust

Gas

before

Purification

l0 1l r2

l3 t4 t5 16 t7

18 19

A,/F

atter Combustion

Chamber

at'

G

ID

C'

Exhauei

0ar Nf t3r

ltuf f ler

12

13

14 15

Airzfuel

Rrtlo

after

Gatalytic

Convertor

N0x

HC

,'

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