General Information

5-speed, constant mesh, return shift Specifications are subject to change without notice, and may not apply to every country. (CA) California Model (US) U.S.A. Model Specifications are subject to change without notice, and may not apply to every country. (CA) California Model (US) U.S.A. Model

Special Tools

OThe tire irons (P N 57001-1073) are included in the beed breaker assembly (P N 57001-1072). Remove the following parts before front wheel removal. Speedometer cable lower end oEither brake caliper Front Wheel Installation Notes Install the speedometer gear housing so that it fits in the speedometer gear drive notches (see Speedometer Gear Housing Assembly). Align the speedometer gear housing so that the stop on the fork leg will fit between the stops on the gear housing. A. Caliper Mounting...

Vn750 Headlight Relay

OThe water temperature sensor should never be allowed to fall on a hard surface. Such a shock to the part can damage it. Water Temperature Sensor Installation Note Apply silicone sealant to the threads before mounting the sensor. Tighten the sensor to the specified torque (see Exploded Views in Cooling System). Remove the water temperature sensor. Suspend the sensor in a container of water so that the temperature sensing projection and threaded portion are submerged. The sensor must not touch...

Warning

OTo avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. Using a hand tester (special tool), check to see that only the connectings shown in the table have continuity (about zero ohms). *lf the switch has an open or short, repair it or replace it with new one. Rear Brake Light Switch Removal Remove the rear brake light switch connector. Press in the rear brake light switch tabs which catch in the bracket hole, and remove the...

Table of Contents

Exploded Special Clutch Level Play Clutch Cable dutch Cable Clutch Release Clutch Release Installation dutch Plates Clutch Hub dutch Plates Clutch Hub Installation Right Engine Cover Right Engine Cover Installation dutch Clu tch Friction Plate Wear, Damage Friction or Steel Plate Warp Clutch Spring Free Length dutch Housing Finger Clutch Hub Spline M Apply a thin coat of molybdenum disulfide grease. L Apply a non-permanent locking agent to the threads. T1 12 N-m (1.2 kg-m, 104 in-lb) T2 130...

Su bf rame

Remove the right exhaust pipe (see Right Exhaust Pipe Removal in Engine Top End). Remove the radiator cover (see Radiator Removal in Cooling System). Remove the radiator mounting bolt shown. oBe careful not to damage the exhaust pipe mounting studs with wrenches during subframe removal. Unscrew the following bolts and nuts to remove the subframe. The frame may be removed with the foot peg, the brake pedal and brake cable installed. Route the air cleaner drain tube behind the subframe mounting...

What High Flash Point Solvent Should I Use To Clean Fuel Tank On Motorcycle

Motorcycle Fuel Tank Cleaning

During carburetor disassembly, be careful not to damage the diaphragm. Never use a sharp edge to remove the diaphragm. oThe front carburetor has a choke stay shown. Do not confuse the front and the rear carburetors during installation. B. Choke Stay on the Front Carburetor 0D0 not interchange the jet needles between the front and the rear Carburetors. Insert the float on the float pivot pin. While tapping the float pivot pin lightly, press the pivot evenly into the float chamber body as shown....

Remove A Grease Seal Motorcycle

Vn750 Speedometer

ODo not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. Over 97.5 - up to 184 kg (215 - 406 lb) (I) Over 97.5- 180 kg (215-397 lb) Australia Model ( ) South Africa Model Canada Model US Model Remove the speedometer gear housing, and collar from the wheel. Remove the disc mounting Allen bolts and take off the discs. Remove the circlip and speedometer receiver. Remove the remaining...

Cauti on

O f the chain becomes badly worn, the chain could make contact with crankcase. Measure the vertical movement midway between the sprockets. *lf the chain slack exceeds the service limit, replace the chain. Split the crankcase (see Crankcase Splitting in Crankshaft Transmission chapter). Remove the crankshaft. Remove the oil return pipe. After removing the circlip on the pump shaft, remove the sprocket and the balancer shaft along with the pump chain. Apply a non-permanent locking agent to the...

Caution

CWhen staking the nut, be careful not to apply shock to the shaft and bearings. Such a shock could damage the shaft and or bearings. Remove the front driven gear assembly see Front Driven Gear Removal . Remove the damper cam and spring. Pry off the gear case cap. Pry open the staking on the front drive gear nut with a small chisel. Loosen the drive gear nut while holding the drive gear shaft with the holder special tool . A. Drive Gear Nut B. Holder 57001 -1026 Pull the front drive gear...

Brake Pads

Lift off the caliper by taking off the mounting bolts. Push the caliper holder toward the piston side, and then remove the pads. Front Master Cylinder Removal Pull back the dust cover, and remove the banjo bolt to disconnect the upper brake hose from the master cylinder. There is a flat washer on each side of the hose fitting. A. Tighten upper clamp bolt first. Use a new flat washer on each side of the brake hose fitting, and tighten the banjo bolt to the specified torque see Exploded View ....

Vn750 Piston Size

ODo not reuse snap rings, since removal weakens and deforms them. They could fall out and score the cylinder wall. Fit a new piston pin snap ring into the side of the piston so that the ring opening does not coincide with the notches in the piston pin hole. Standard 82.000 - 82.012 mm VN700 or 84.900 - 84.912 mm VN750 and less than 0.01 mm difference between any two measurement Service Limit 82.1 mm VN700 , 85.0 mm VN750 or more then 0.05 mm difference between any two measurements When boring...

Cylinder Piston

Front Cylinder Block Removal Remove the cylinder head. Remove the alternator. Unscrew the mounting bolts to remove the upper chain guides. Unscrew the retainer bolt on the front lower chain guide. While pulling the chain to give a play, push up and remove the front lower chain guide. A. Guide Retainer Bolt C. Lower Chain Guide front B. Push up the guide. D. Pull the chain. Unscrew the following bolts in order to remove the rear lower chain guide. Unscrew the mounting bolt to remove the lower...

Vn750 Axle Torque

0D0 not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc. The brakes will not function on the first application of the lever if this is not done. Rear Wheel Removal Remove the following parts. oRight muffler see Engine Top End chapter oCotter pin and axle nut loosened oSafety clip and torque link nut oBrake adjusting nut, joint and spring Separate the brake rod from the wheel. Apply grease to the splined portion...

Service Manual

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 Department Consumer Products amp Machinery Group Kawasaki Heavy Industries, 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...

Which Type Of Bush Used In Fork Outer Tube

Check Oil Vn750

OThe operation of air front fork is especially dependent upon correct oil level. Higher level than specified may cause oil leakage and seal breakage. So be sure to maintain the specified level. Inspect the O-ring on the top plug, and replace it with a new one if it is damaged. Install the spring, spring seat and collar. Replace the plug retaining rings with new ones. Install the top plug by pushing down the plug and insert the plug retaining ring. Change the oil of the other fork leg in the...

Vn750 Starter Clutch

OBecause of the large amount of current, never keep the starter switch pushed any time that the starter motor will not turn over, or the current may burn out the starter motor windings. Switch Position Ignition switch ON Engine stop switch RUN Starter button ON Neutral switch ON Transmission is in Neutral Meter Connection Location Starter relay terminals Leads disconnected Meter Range x 1 2 Meter Reading 0 2 and relay clicks when starter Brush Inspection Measure the length of each brush. lf any...

Warning j

-Be sure to install the valve core whenever inflating the tire, and do not inflate the tire to more than 390 kPa 4.0 kg cm2, 57 psi . Overinflation can explode the tire with possibility of injury and loss of life. Check to see that the rim lines on both sides of the tire side-walls are parallel with the rim flanges. If the rim flanges and tire side-wall rim lines are not parallel, remove the valve core. Lubricate the rim flanges and tire beads. Install the valve core and inflate the tire again....

Vn 750 Charge Diagram

OAlways remove the battery from the motorcycle for charging. If the battery is charged while still installed, battery electrolyte may spill and corrode the frame or other parts of the motorcycle. Clean off the battery using a baking soda-and-water solution. oMix one heaping tablespoon of baking soda in one cup of water. oBe careful not to get any of the cleaning solution in the battery. oThe terminals must be especially clean. If any of the cells are low, fill them to the LOWER level line with...

Propeller Shaft

Remove the front bevel gear case see Front Bevel Gear Case Removal . Pull out the propeller shaft forward. Disassemble the pinion gear see Pinion Gear Disassembly . Visually inspect the bearings for abrasion, color change, or other damage. If there is any doubt as to the condition of a bearing, replace it. OH Seal Inspection Inspect the oil seals. Replace any if the lips are misshapen, discolored indicating that the rubber has deteriorated , hardened, or otherwise damaged. olf the coil spring...

Rear Shock Absorber

The rear shock absorbers can be adjusted by changing the air pressure and damping force to suit various riding and loading conditions. Support the motorcycle on its center stand to raise the rear wheel off the ground. Check and adjust the air pressure when the rear shock absorber is cold room temperature . Rear Shock Absorber Air Pressure Standard Atmospheric pressure for one average-built rider with no accessories Usable Range 0 - 294 kPa Visually inspect the inner tube, and repair any damage....

Where Does Tach Cable Go Vn750

ODo not force forward the headlight body, which is made of plastic. Pull off all the connectors and leads. Remove the headlight housing mounting nuts and bolts on both sides to take off the housing. Headlight Unit Installation Notes Install the headlight unit so that the TOP mark on the lens points up. A. Headlight Housing B. Mounting Nuts and Bolts Check the headlight aiming after installation. Lighting System Inspection Note oFor any lighting system problems, always check the lighting system...

VN750A2 A3 A4 Wiring Diagram other than US and Canada

Honda Cbr600f1 Electrical Wiring Diagram

Stirur Sutton Pfont Right Turn Sigral Light 12 V 21 W 5 gt 12 V23W Pfont Right Turn Sigral Light 12 V 21 W 5 gt 12 V23W . Hofi Button 7. Turn Signs Switch 3. Pining Button . Hofi Button 7. Turn Signs Switch 3. Pining Button Ham Button ' Turn Slfln l Switch Color BK W j BK Y ' Color W G W.'R SLAV 6 EPT HANDLEBAR SWITCH CONN6CTH3 48 1 Pitting Button j 0 OY Coior j 8L ' R BK j Color fW ffght Tum Jgrvii OffM '2 V l W . g I2V 3 W Ttfil'Brtk LltfiU lt 2 vG it Yx2 S, 2 v 8,27 2...

Transmission

Externa Shift Mechanism Removal NOTE oThe shift cover can be removed with the engine mounted in the frame. Remove the front bevel gear case see Front Bevel Gear Case Removal in Final Drive chapter . Unscrew the cover mounting bolts and pry at the two points shown to remove the cover. A. Mounting Bolts B. Pry Points A. Mounting Bolts B. Pry Points Unscrew the shift drum screw to remove the shift drum cam, if necessary. Remove the gear positioning lever by taking out the bolt. B. Screw D. Gear...

How To Replace Ring Gear On Kawasaki 750

ODo not install the pinion gear nut, collar and O-rings during adjustment. Install the pinion gear assembly with the primary 0.5 mm thickness shim, and tighten the bearing retainer to the specified torque see Exploded View . Install the ring gear assembly with the primary 1.0 mm thickness shim, and tighten the cover mounting bolts to the specified torque see Exploded View . oCheck the backlash during the tightening of the cover mounting bolts, and stop tightening them immediately if the...

Zzr 1100 Clutch Switch Wiring Diagram

Recondition Battery Guide

OWhen replacing a fuse, be sure the new fuse matches the specified fuse rating for that circuit. Installation of a fuse with a higher rating may cause damage to wiring and components. and Headlight Relay Inspection Remove the junction box from the motorcycle. Check conductivity of the following numbered terminals by connecting an ohm meter and one 12 V battery to the junction box as shown. lf the meter does not read as specified, replace the junction box. Relay Circuit Inspection with the...

Fuel System

Vent Tube Diagram Vulcan 750

Exploded View 2-2 Special Throttle Grip and Throttle Grip Play Inspection 2-5 Throttle Cable Play Adjustment 2-5 Throttle Cable Throttle Cable Installation Notes 2-7 Throttle Cable Throttle Cable Inspection 2-8 Choke Cable 2-8 Choke Cable Free Play Inspection 2-8 Choke Cable Adjustment 2-9 Choke Cable Installation 2-9 Choke Cable Lubrication 2-9 Choke Cable Inspection 2-9 Idle Speed Inspection 2-9 Idle Speed A Carburetor Fuel Level Fuel Level Fuel System Cleanliness Inspection 2-13 Carburetor...

How To Measure Crank Pin Clearence

Connecting Rod Big End Cap Breaking

OTo prevent damage to the crankpin surfaces, do not allow the big end cap bolts to bump against them. Connecting Rod Bend Twist Measure connecting rod bend. oRemove the connecting rod big end bearing inserts, and reinstall the connecting rod big end cap. oSelect an arbor of the same diameter as the connecting rod big end, and insert the arbor through the connecting rod big end. oSelect an arbor of the same diameter as the piston pin and at least 100 mm long, and insert the arbor through the...

Crankshaft Transmission

The Motorcycle Gearbox And Crank Shaft

Exploded Special Crankcase Crankcase Crankcase Crankcase Right Balancer Bearing Crankshaft Connecting Crankshaft Crankshaft Installation Connecting Rod Connecting Rod Installation Crankshaft Connecting Rod Connecting Rod Connecting Rod Big End Side Connecting Rod Big End Bearing Insert Crankpin Crankshaft Crankshaft Main Bearing Insert Journal Crankshaft Side 8-17 Left Balancer Left Balancer Right Balancer Right Balancer Installation Right Balancer Balancer Damper Transmission External Shift...

Warning I

Recondition Battery Guide

Brake linings contain asbestos fiber. Inhalation of asbestos may cause serious scarring of the lungs and may promote other internal injury and illness, including cancer. Observe the following precautions when handling brake linings. oNever blow brake lining dust with compressed air. o f any components are to be cleaned, wash with detergent, then immediately discard the cleaning solution and wash you hands. 0D0 not grind any brake lining material unless a ventilation hood is available and...

Caution i

Yamaha Fzx 750 Cam Timing Pins

Oif the camshafts are removed, always pull the chain taut while turning the crankshaft. This avoids kinking the chain on the idler sprocket. A kinked chain could damage both the chain and the sprocket. Camshafts Installation Notes oThe camshaft cap is machined with the cylinder head, so if a new cylinder head is installed, use the cap that is supplied with the new head. Replace the oil filter for the lash adjuster oil passage with a new one whenever the cylinder head is removed. Be sure to...

How Much Nm To Torque Vn750 Cylinder Head Bolts

OWhen the cylinder head is put upside down or sideways, remove the hydraulic lash adjusters and bleed air in the adjusters. Cylinder Head Installation Notes Before cylinder head installation, install the chain and the chain guides see Front Cylinder Block Installation Notes . Tighten the cylinder head bolts and nuts following the tightening sequence. Tighten them to the first torque and then tighten them to the final torque as shown. 1 - 4 MIO 5 - 6 -. M8 7-8 M6 9 -10 M6 First N-m kg-m, ft-lb...

Vn750 Rectifier Test

Coil, dirt, or incorrect tightening may cause rotor loosening and serious damage. See that the key is fitted in place on the crankshaft properly, and then fit the rotor in place. When installing the alternator, align the alternator gear mark with the balancer punch mark. A. Punched Mark or Line Mark B. Line Mark A. Punched Mark or Line Mark B. Line Mark Tighten the rotor bolt specified torque using the same holder special tool as used during removal. Regulator Rectifier Output Current...