User manual KAWASAKI VN800 SERVICE MANUAL

[. . . ] 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. [. . . ] Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relief Valve Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7-4 7-6 7-7 7-8 7-8 7-8 7-8 7-9 7-9 7-9 7-9 7-10 7-10 7-11 7-13 7-14 7-15 7-15 7-16 7 7-2 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart ENGINE LUBRICATION SYSTEM 7-3 Engine Oil Flow Chart : Oil Flow (1 30) --: Blowby Gas 1. Right Air Cleaner Housing (rear view) 32. Oil Return Pipes 7-4 ENGINE LUBRICATION SYSTEM Exploded View ENGINE LUBRICATION SYSTEM 7-5 Exploded View No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Fastener Oil pipe holder bolts Oil pipe clamp bolts Oil hose flange bolts Oil hose banjo bolt Relief valve Oil pump mounting bolts Oil pressure switch Oil pressure switch terminal screw Oil screen plug Oil filter Oil nozzles Oil nozzle Oil filter pipe Oil drain plug Oil baffle bolt Oil return pipe bolts N·m 11 11 9. 8 9. 8 15 11 15 1. 5 20 18 2. 9 2. 9 25 20 11 11 Torque kgf·m 1. 1 1. 1 1. 0 1. 0 1. 5 1. 1 1. 5 0. 15 2. 0 1. 8 0. 30 0. 30 2. 5 2. 0 1. 1 1. 1 ft·lb 97 in·lb 97 in·lb 87 in·lb 87 in·lb 11 97 in·lb 11 13 in·lb 15 13 26 in·lb 26 in·lb 18 15 97 in·lb 97 in·lb Remarks L L L SS GT R Lh SS L L 17. Oil Separator (smaller side goes first. ) 19. GT: Apply a little grease to the switch terminal for rust prevention. Lh: Left-hand Threads R: Replacement Parts SS: Apply silicone sealant (Kawasaki Bond: 56019-120). 7-6 ENGINE LUBRICATION SYSTEM Specifications Item Engine Oil: Type Standard API Service Classification : SE, SF or SG class API Service Classification : SH or SJ class with JASO MA SAE 10W-40 2. 9 L (3. 1 US qt, when filter is not removed) 3. 1 L (3. 3 US qt, when filter is removed) 3. 5 L (3. 7 US qt, when engine is completely disassembled and dry) Viscosity Capacity Level Between upper and lower level lines (Wait 2 3 minutes after idling or running) Oil Pressure Measurement: Oil pressure @2 000 r/min (rpm), Oil temp. 90 °C (194 °F) 340 440 kPa (3. 5 4. 5 kgf/cm², 50 64 psi) ENGINE LUBRICATION SYSTEM 7-7 Special Tools and Sealant Oil Pressure Gauge, 5 kg/cm² : 57001­125 Filler Cap Driver : 57001­1454 Oil Pressure Gauge Adapter, PT 1/8 : 57001­1033 Kawasaki Bond (Silicone Sealant) : 56019­120 Oil Filter Wrench : 57001­1249 7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure, accident, and injury. Oil Level Inspection the vertical. Fit the clamp [D] · rocker case and the Torque - Oil Hose Flange Bolts: 9. 8 N·m (1. 0 kgf·m, 87 in·lb) · Install each bottom end of the oilashoses on the right crankcase behind the rear cylinder shown. Front Oil Hose [A] Rear Oil Hose [B] Front [C] Face the paint marks [D] rearward. Replace the copper washers on each side of the banjo bolt with new ones. · · Install the removed ports. Torque - Oil Hose Banjo Bolt [E]: 9. 8 N·m (1. 0 kgf·m, 87 in·lb) Inside Oil Pipe Removal · Split the crankcase (see Crankshaft/Transmission chapter). · Remove: Clamp Bolts [A] Oil Pipe · Oil Pipe Holder Bolt [B] Remove the inside oil pipe [C] from the right crankcaes. ENGINE LUBRICATION SYSTEM 7-11 Oil Pump and Oil Line · Remove the oil pipe clamp bolt [A], and oil return pipe [B]. · Remove the separator [A]. · Remove: Clamp Bolt [A] Oil Pipe Oil Pipe Holder Bolt [B] Remove the inside oil pipe [C] and the oil return pipe [D] from the left crankcase [E]. Pull out the large size fittings [F] first, and remove the small size fitting [G] upward. · · Remove the bolt [A] and the separator [B]. Inside Oil Pipe Installation fitting O-rings · Replace the oil pipe O-rings before[A] with a new one. · Oil Pipe [B] Fitting [C] 7-12 ENGINE LUBRICATION SYSTEM Oil Pump and Oil Line inside oil pipe [A], · Install the[C] to left crankcaseseparator [B] and the oil return pipe [D] as shown. Do not apply silicone sealant to the groove of the grommet and the mating surface of the grommet [E]. Apply silicone sealant to the crankcase mating surface [F] of the separator. Apply a non-permanent locking agent to the oil pipe holder bolt [H], oil return pipe clamp bolts [I], oil pipe clamp bolt [J] and oil baffle bolt [K]. If the oil nozzles [G] are removed, install them. Torque - Oil Pipe Holder Bolt: 11 N·m (1. 1 kgf·m, 97 in·lb) Oil Pipe Clamp Bolt: 11 N·m (1. 1 kgf·m, 97 in·lb) Oil Baffle Bolt: 11 N·m (1. 1 kgf·m, 97 in·lb) Oil Nozzles: 2. 9 N·m (0. 30 kgf·m, 26 in·lb) ENGINE LUBRICATION SYSTEM 7-13 Oil Pump and Oil Line the oil · Install pipeinside the pipe [A], separator [B], and the oil return [C] to right crankcase [D]. Do not apply silicone sealant to the groove of the grommet and the mating surface of the grommet [E]. Install the separator so that it's smaller side [F] faces inside. Apply a non-permanent locking agent to the oil pipe holder bolt [G], oil return pipe clamp bolts [H] and oil pipe clamp bolt [I]. If the oil nozzle [J] is removed, install it. · Install the removed parts. Torque - Oil Pipe Holder Bolt: 11 N·m (1. 1 kgf·m, 97 in·lb) Oil Return Pipe Clamp Bolt: 11 N·m (1. 1 kgf·m, 97 in·lb) Oil Pipe Clamp Bolt: 11 N·m (1. 1 kgf·m, 97 in·lb) Oil Nozzle: 2. 9 N·m (0. 30 kgf·m, 26 in·lb) Blowby Gas System Inspection that all the without · Be certainkinked, andhoses are routedcorrectly being flattened or are connected to the oil reserve tank and right air cleaner base. [. . . ] Three-way Joint of Hose Assembly [3] 19. Front Brake Calipers 17-46 APPENDIX Cable, Wire, and Hose Routing Evaporative Emission Control System (California Model) with fuel line - - : Vapor Flow : Fuel Flow : Vacuum Pulsation 1. High Pressure Fuel Hoses (supply fuel) 7. Low Pressure Fuel Hose (return fuel) APPENDIX 17-47 Cable, Wire, and Hose Routing Evaporative Emission Control System (California Model) F: Front 1. [. . . ]