Bajaj pulsar ns 200 инструкция

Pulsar 200 NS
Rouser 200 NS
Motorcycle
Service Manual
Quick Reference Guide
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.
General Information
1 j
Periodic Maintenance
2 j
Fuel System
3 j
Cooling System
4 j
Engine Top End
5 j
Clutch
6 j
Engine Lubrication System
7 j
Engine Removal/Installation
8 j
Crankshaft/Transmission
9 j
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
17 j
Pulsar 200 NS
Rouser 200 NS
Motorcycle
Service Manual
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.
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. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.
© 2013 Kawasaki Heavy Industries, Ltd.
2nd Edition (1) : Jul. 17, 2014
LIST OF ABBREVIATIONS
A
ABDC
AC
Ah
ATDC
BBDC
BDC
BTDC
°C
CDI
cmHg
cu in
DC
F
°F
ft
g
gal
h
HP
in.
kg
kgf
ampere(s)
after bottom dead center
alternating current
ampere hour
after top dead center
before bottom dead center
bottom dead center
before top dead center
degree(s) Celsius
capacitive discharge ignition
centimeters of mercury
cubic inch(es)
direct current
farad(s)
degree(s) Fahrenheit
foot, feet
gram(s) (mass)
gallon(s)
hour(s)
horsepower(s)
inch(es)
(mass)
(force)
km/h
L
lb
LCD
LED
m
min
mph
N
oz
Pa
PS
psi
qt
r
r/min, rpm
s
SOHC
TDC
TIR
V
W
Ω
kilometers per hour
liter(s)
pound(s)
Liquid Crystal Display
Light Emitting Diode
meter(s)
minute(s)
miles per hour
newton(s)
ounce(s)
pascal(s)
horsepower
pound(s) per square inch
quart(s)
revolution
revolution(s) per minute
second(s)
single overhead camshaft
top dead center
total indicator reading
volt(s)
watt(s)
ohm(s)
COUNTRY AND AREA CODES
ID
Indonesia
PH
Philippines
Foreword
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.
In 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 recommend 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.
Follow the Periodic Maintenance Chart in the
Service Manual.
Be alert for problems and non-scheduled
maintenance.
Use proper tools and genuine Kawasaki-Bajaj
Motorcycle parts. Special tools, gauges, and
testers that are necessary when servicing
Kawasaki-Bajaj motorcycles are introduced
by the Service Manual. Genuine parts provided as spare parts are listed in the Parts
Catalog.
Follow the procedures in this manual carefully. Don’t take shortcuts.
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 divided into
its major systems 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
chapter 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 Ignition Coil section.
Whenever you see symbols, heed their instructions! Always follow safe operating and
maintenance practices.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result
in death or serious injury.
NOTICE
NOTICE is used to address practices not
related to personal injury.
This manual contains four more symbols
which will help you distinguish different types
of information.
NOTE
○NOTE indicates information that may help
or guide you in the operation or service of
the vehicle.
a procedural step or work to be
• Indicates
done.
○Indicates a procedural sub-step or how to do
the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates 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 Information
Table of Contents
Before Servicing .....................................................................................................................
Model Identification.................................................................................................................
General Specifications............................................................................................................
Unit Conversion Table ............................................................................................................
1-2
1-7
1-9
1-12
1
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform 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.
Battery Ground
Before completing any service on the motorcycle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the ground
cable (–) first and then the positive (+). When completed
with the service, first connect the positive (+) cable to the
positive (+) terminal of the battery then the negative (–) cable to the negative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.
Solvent
Use a high flash-point solvent when cleaning parts. High
flash-point solvent should be used according to directions
of the solvent manufacturer.
Cleaning Vehicle before Disassembly
Clean the vehicle thoroughly before disassembly. Dirt or
other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease
performance of the vehicle.
GENERAL INFORMATION 1-3
Before Servicing
Arrangement and Cleaning of Removed Parts
Disassembled parts are easy to confuse. Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.
Storage of Removed Parts
After all the parts including subassembly parts have been
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.
Inspection
Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is beyond its service limit.
Replacement Parts
Replacement Parts must be Kawasaki-Bajaj genuine or
recommended by Kawasaki-Bajaj. Gaskets, O-rings, oil
seals, grease seals, circlips, cotter pins or self-locking nuts
must be replaced with new ones whenever disassembled.
Assembly Order
In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service
Manual, follow the procedures given.
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 sequence to prevent case warpage or deformation which can
lead to malfunction. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench.
All of the tightening torque values are for use with dry,
solvent - cleaned threads unless otherwise indicated. If a
fastener which should have dry, clean threads gets contaminated with lubricant, etc., applying even the specified torque
could damage it.
Force
Use common sense during disassembly and assembly,
excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non
-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.
Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets and
O-rings after disassembly can reduce sealing performance.
Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains.
Install the new gaskets and replace the used O-rings when
re-assembling.
Liquid Gasket, Non-permanent Locking Agent
For applications that require Liquid Gasket or a
Non-permanent Locking Agent, clean the surfaces so
that no oil residue remains before applying liquid gasket or
non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and
cause serious damage.
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 contact 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. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.
Oil Seal, Grease Seal
Do not remove pressed oil or grease seals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.
Apply specified grease to the lip of seal before installing
the seal.
Circlips, Cotter Pins
Replace the circlips or cotter pins that were removed with
new ones. Take care not to open the clip excessively when
installing to prevent deformation.
1-6 GENERAL INFORMATION
Before Servicing
Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubrication 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. Rotate the crankshaft to positive direction (clockwise viewed
from output side).
Electrical Leads
A two-color lead is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
leads must be connected to those of the same color.
Instrument
Use a meter that has enough accuracy for an accurate
measurement. Read the manufacture’s instructions thoroughly before using the meter. Incorrect values may lead
to improper adjustments.
GENERAL INFORMATION 1-7
Model Identification
BR200AD Left Side View
BR200AD Right Side View
Frame Number
Engine Number
1-8 GENERAL INFORMATION
Model Identification
BR200AE Left Side View
BR200AE Right Side View
GENERAL INFORMATION 1-9
General Specifications
Items
Dimensions
Overall Length
Overall Width
Overall Height
Wheelbase
Road Clearance
Seat Height
Curb Mass:
Front
Rear
Fuel Tank Capacity
Performance
Minimum Turning Radius
Engine
Type
Cooling System
Bore and Stroke
Displacement
Compression Ratio
Maximum Horsepower
Maximum Torque
Fuel System
Minimum Octane Rating:
Research Octane
Number (RON)
Starting System
Ignition System
Timing Advance
Ignition Timing
Spark Plug:
Center
Left/Right
Valve Timing:
Intake:
Open
Close
Duration
Exhaust:
Open
Close
Duration
Lubrication System
BR200AD/AE
1 965 mm (77.36 in.)
810 mm (31.9 in.)
1 055 mm (41.54 in.)
1 360 mm (53.54 in.)
165 mm (6.50 in.)
805 mm (31.7 in.)
145 kg (320 lb)
(PH) 150 kg (331 lb)
71 kg (157 lb)
(PH) 75 kg (165 lb)
74 kg (163 lb)
(PH) 75 kg (165 lb)
12 L (3.2 US gal)
2.5 m (8.2 ft)
4-stroke, SOHC, single cylinder
Liquid-cooled
72.0 × 49.0 mm (2.83 × 1.93 in.)
200 cm³ (12.2 cu in.)
11:1
17 kW (23 PS) at 9 500 r/min (rpm)
18 N·m (1.8 kgf·m, 13 ft·lb) at 8 000 r/min (rpm)
Carburetor, UCAL UCD33
91
Electric starter
CDI
Electronically advanced
5° BTDC at 1 500 r/min (rpm) to 36° BTDC at 10 000 r/min (rpm)
BOSCH VR5NE
CHAMPION P-RG6HCC
0° (ATDC)
30° (ABDC)
210°
35° (BBDC)
0° (ATDC)
215°
Forced lubrication (wet sump)
1-10 GENERAL INFORMATION
General Specifications
Items
Engine Oil:
Type
Viscosity
Capacity
Drive Train
Primary Reduction System:
Type
Reduction Ratio
Clutch Type
Transmission:
Type
Gear Ratios:
1st
2nd
3rd
4th
5th
6th
Final Drive System:
Type
Reduction Ratio
Overall Drive Ratio
Frame
Type
Caster (Rake Angle)
Trail
Front Tire:
Type
Size
Rim Size
Rear Tire:
Type
Size
Rim Size
Front Suspension:
Type
Wheel Travel
Rear Suspension:
Type
Wheel Travel
Brake Type:
Front
Rear
BR200AD/AE
API SL with JASO MA2
SAE 20W-50
1.4 L (1.5 US qt)
Gear
3.273 (72/22)
Wet multi disc
6-speed, constant mesh, return shift
2.833
2.067
1.556
1.238
1.045
0.917
(34/12)
(31/15)
(28/18)
(26/21)
(23/22)
(22/24)
Chain drive
2.786 (39/14)
8.357 at Top gear
Pressed steel, Perimeter type
26°
85 mm (3.3 in.)
Tubeless
100/80-17M/C 52P
J17M/C × MT2.50
Tubeless
130/70-17M/C 62P
(IRC) 130/70-17M/C 62S
J17M/C × MT3.50
Telescopic fork
130 mm (5.12 in.)
Swingarm
120 mm (4.72 in.)
Single disc
Single disc
GENERAL INFORMATION 1-11
General Specifications
Items
Electrical Equipment
Battery
Headlight:
Type
Bulb:
High Beam
Low Beam
Tail/Brake Light
Alternator:
Type
Maximum Output
BR200AD/AE
12 V 8 Ah
Semi-sealed beam
12 V 60 W
12 V 55 W
LED
Three-phase AC
14.5 A/15.0 V at 8 000 r/min (rpm)
Specifications are subject to change without notice.
1-12 GENERAL INFORMATION
Unit Conversion Table
Prefixes for Units:
Prefix
mega
kilo
centi
milli
micro
Units of Length:
Symbol
M
k
c
m
µ
×
×
×
×
×
Power
1 000 000
1 000
0.01
0.001
0.000001
Units of Mass:
kg
g
×
×
2.205
0.03527
=
=
lb
oz
=
=
=
=
=
=
=
=
=
gal (US)
gal (IMP)
qt (US)
qt (IMP)
pint (US)
pint (IMP)
oz (US)
oz (IMP)
cu in.
=
=
=
=
kg
lb
N
lb
Units of Volume:
L
L
L
L
L
L
mL
mL
mL
×
×
×
×
×
×
×
×
×
0.2642
0.2200
1.057
0.8799
2.113
1.816
0.03381
0.02816
0.06102
×
×
×
×
×
×
×
0.6214
3.281
0.03937
=
=
=
mile
ft
in.
=
=
=
=
=
=
kgf·m
ft·lb
in·lb
N·m
ft·lb
in·lb
=
=
=
=
=
=
kgf/cm²
psi
cmHg
kPa
psi
kPa
=
mph
=
=
=
=
PS
HP
kW
HP
Units of Torque:
N·m
N·m
N·m
kgf·m
kgf·m
kgf·m
×
×
×
×
×
×
0.1020
0.7376
8.851
9.807
7.233
86.80
Units of Pressure:
Units of Force:
N
N
kg
kg
km
m
mm
0.1020
0.2248
9.807
2.205
Units of Temperature:
kPa
kPa
kPa
kgf/cm²
kgf/cm²
cmHg
×
×
×
×
×
×
0.01020
0.1450
0.7501
98.07
14.22
1.333
Units of Speed:
km/h
×
0.6214
Units of Power:
kW
kW
PS
PS
×
×
×
×
1.360
1.341
0.7355
0.9863
PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart ...................................................................................................
Torque and Locking Agent......................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Periodic Maintenance Procedures..........................................................................................
Fuel System.........................................................................................................................
Air Cleaner Element Cleaning...........................................................................................
Air Cleaner Element Replacement....................................................................................
Idle Speed Inspection .......................................................................................................
Idle Speed Adjustment......................................................................................................
Throttle Control System Inspection...................................................................................
Choke Operation Inspection .............................................................................................
Carburetor Cleaning (Fuel Draining).................................................................................
Carburetor Holder Inspection............................................................................................
Fuel Hose Inspection (fuel leak, damage, installation condition) ......................................
Fuel Hose Replacement ...................................................................................................
Fuel Filter Replacement....................................................................................................
Cooling System....................................................................................................................
Coolant Level Inspection...................................................................................................
Water Hose and Pipe Inspection (coolant leak, damage, installation condition) ..............
Coolant Change ................................................................................................................
Engine Top End ...................................................................................................................
Valve Clearance Inspection ..............................................................................................
Valve Clearance Adjustment.............................................................................................
Air Suction System (PH Model) ...........................................................................................
Air Suction System Damage Inspection............................................................................
Clutch...................................................................................................................................
Clutch Operation Inspection..............................................................................................
Clutch Cable Adjustment ..................................................................................................
Engine Lubrication System ..................................................................................................
Engine Oil Change............................................................................................................
Oil Strainer Cleaning.........................................................................................................
Oil Filter Replacement ......................................................................................................
Wheels/Tires ........................................................................................................................
Air Pressure Inspection.....................................................................................................
Wheels and Tires ..............................................................................................................
Wheel Bearing Damage Inspection ..................................................................................
Final Drive............................................................................................................................
Drive Chain Lubrication Condition Inspection ...................................................................
Drive Chain Slack Inspection ............................................................................................
Drive Chain Slack Adjustment ..........................................................................................
Wheel Alignment Inspection .............................................................................................
Drive Chain Wear Inspection ............................................................................................
Chain Guide Wear Inspection ...........................................................................................
Brakes..................................................................................................................................
Brake System Inspection ..................................................................................................
Brake Fluid Level Inspection.............................................................................................
Brake Fluid Change ..........................................................................................................
Brake Hose Replacement .................................................................................................
Master Cylinder Rubber Parts Replacement ....................................................................
2-3
2-6
2-11
2-13
2-14
2-14
2-14
2-14
2-15
2-16
2-16
2-17
2-17
2-17
2-17
2-18
2-18
2-19
2-19
2-19
2-19
2-21
2-21
2-23
2-23
2-23
2-24
2-24
2-24
2-25
2-25
2-26
2-26
2-27
2-27
2-27
2-28
2-29
2-29
2-29
2-30
2-30
2-30
2-31
2-31
2-31
2-32
2-33
2-35
2-35
2
2-2 PERIODIC MAINTENANCE
Caliper Rubber Parts Replacement ..................................................................................
Brake Pad Wear Inspection ..............................................................................................
Brake Light Switch Operation Inspection ..........................................................................
Suspension ..........................................................................................................................
Suspension System Inspection.........................................................................................
Steering ...............................................................................................................................
Steering Play Inspection ...................................................................................................
Steering Play Adjustment..................................................................................................
Steering Stem Bearing Lubrication ...................................................................................
Electrical System .................................................................................................................
Lights and Switches Operation Inspection........................................................................
Headlight Aiming Inspection .............................................................................................
Engine Stop Switch Operation Inspection.........................................................................
Spark Plug Replacement ..................................................................................................
Starter Lockout Switch Inspection.....................................................................................
Ignition Switch Contact Cleaning ......................................................................................
Wiring Harness Inspection ................................................................................................
Others ..................................................................................................................................
Silencer Drain Hole Cleaning............................................................................................
Engine Breather hose Replacement .................................................................................
Chassis Parts Lubrication ................................................................................................
Condition of Bolts, Nuts and Fasteners Tightness Inspection ..........................................
2-36
2-39
2-40
2-40
2-40
2-41
2-41
2-42
2-42
2-43
2-43
2-45
2-46
2-46
2-47
2-47
2-48
2-48
2-48
2-48
2-49
2-50
PERIODIC MAINTENANCE 2-3
Periodic Maintenance Chart
Servicing: 1st 500 ∼ 750 km/30 ∼ 45 days, 2nd onward at every 5 000 km
C: Check, A: Adjust, CL: Clean, R: Replace, T: Tighten, L: Lubricate
*: More frequent cleaning may be required when driving in dusty condition.
**: Whichever occurs earlier
RECOMMENDED FREQUENCY
Operation
Servicing
Km
×
100
Air cleaner element*
CL, R
Idle speed
C, A
Throttle control system (play,
smooth return, no drag)
C, A
Choke operation
C
Carburetor
CL, A
Carburetor holder
C, R
Fuel hoses
C, R
Fuel filter
Coolant level
R
C, A
Water hose
damage/clamps/leakage
C, R
1st
2nd
3rd
4th
5th
6th
7th
5
∼
7.5
45
∼
50
95
∼
100
145 195 245
∼
∼
∼
150 200 250
295
∼
300
Subsequent
See
Page
Replace
CL CL
CL
R
CL CL
R
at every 2-14
15 000 km
2-15
C, A C, A C, A C, A C, A C, A C, A
At every
C, A C, A C, A C, A C, A C, A C, A service or 2-16
1 year**
Check in 1st service & at every 10 000 km or 1 year * 2-17
CL,
CL,
CL,
2-17
A
A
A
Check &
replace if 2-17
C, R
required
Replace
at every
C
C
C
R
C
C
R
2-17
15 000 km
or 2 years**
R
R
2-18
C, A C, A C, A C, A C, A C, A C, A
2-19
Check &
C, R C, R C, R C, R C, R C, R replace if 2-19
required
2-19
Replace at every 35 000 km or 3 years**
Replace at every 30 000 km or 2 years**
2-19
C, A C, A C, A C, A C, A C, A C, A
2-21
C
C
C
C
C
C
2-23
C
2-23
Water hose
R
Coolant
R
Valve clearance
C, A
Air suction system
Air suction system hose
Clutch operation (play,
C, A C, A C, A C, A C, A C, A C, A C, A
engagement, disengagement)
Engine oil
C, R
R
C
R
Oil strainer
CL
CL
CL
Engine oil filter
R
R
R
Tire air pressure
C
Check at
2-24
Replace
at every
C
R
C
R
2-25
10 000 km
or 1 year**
CL
CL
2-26
At every oil
R
R
2-26
change
2-27
every 10 000 km or 1 year**
2-4 PERIODIC MAINTENANCE
Periodic Maintenance Chart
RECOMMENDED FREQUENCY
Operation
Servicing
Km
×
100
Wheel and tires
C, R
Wheel bearing
C, R
Drive chain lubrication
Drive chain slackness
Drive chain wear
Drive chain guide wear
Brake system (leak, damage,
installation condition)
L
C, A
C
C
Brake operation
(effectiveness, no drag)
Brake fluid level
Brake fluid
Brake hose/rubber parts of
brake master cylinder and
caliper
C
1st
2nd
3rd
4th
5th
6th
7th
5
∼
7.5
45
∼
50
95
∼
100
145 195 245
∼
∼
∼
150 200 250
295
∼
300
C
C
C
C
C
C
2-31
C
At every
C, A C, A C, A C, A C, A C, A C, A C, A service or 2-32
1 year**
Check &
top up if
required
C, A C, A C, A C, A C, A C, A C, A C, A
2-32
in ever
service or
6 months**
R
2-33
Replace at every 20 000 km or 2 years**
R
Replace at every 30 000 km or 2 years**
C, R C, R C, R C, R C, R C, R C, R C, R
Brake light switch operation
Suspension system
Steering play
C, A C, A C, A C, A C, A C, A C, A C, A
C
C
C
C
C, A C, A C, A C, A C, A C, A C, A C, A
Electrical system
Spark plugs
See
Page
Check
at every
service
C, R C, R C, R C, R C, R C, R
2-27
or 1 year
**/replace if
required
Check &
C, R C, R C, R C, R C, R C, R replace if 2-28
required
Lubricate at every 500 km
2-29
Check and adjust at every 1 000 km
2-29
C
C
C
C
C
C
2-30
C
C
C
2-31
Brake pad wear
Steering stem bearing*
Subsequent
C,
CL, L,
R
C
R
Check &
replace if
required
2-35,
2-36
2-39
2-40
2-40
2-41
Check & replace if reC,
C,
C,
quired/LuCL,
CL,
CL,
bricate
2-42
L, R
L, R
L, R at every
10 000 km
or 2 years**
Check at every 10 000 km or 1 year**
2-43
Replace at every 20 000 km
2-46
PERIODIC MAINTENANCE 2-5
Periodic Maintenance Chart
RECOMMENDED FREQUENCY
Operation
Servicing
Km
×
100
Starter lockout switch
C, R
Ignition switch contacts
cleaning
Wiring harness
Silencer drain hole cleaning
Engine air breather hose
General lubrication
All fasteners tightness
1st
2nd
3rd
4th
6th
7th
5
∼
7.5
45
∼
50
95
∼
100
145 195 245
∼
∼
∼
150 200 250
295
∼
300
C, R
C, R
C, R
C,
CL
C,
CL
C,
CL
C
C
CL
CL CL
R
Replace at
L
L
L
L
L
C, T C, T C, T C, T C, T
C, CL
C,
CL
C,
CL
C
CL
5th
C,
C,
CL CL
C
CL CL CL
every 20 000 km
L
L
L
C, T C, T C, T
Subsequent
See
Page
Check &
replace if
required
2-47
2-47
2-48
2-48
2-48
2-49
2-50
2-6 PERIODIC MAINTENANCE
Torque and Locking Agent
The following tables lists the tightening torque for the major fasteners requiring use of a
non-permanent locking agent or silicone sealant etc.
Letters used in the “Remarks” column mean:
L: Apply a non-permanent locking agent.
Lh: Left-hand Threads
R: Replacement Parts
Fastener
Fuel System (DFI)
Fuel Tap Mounting Bolts
Fuel Tank Cap Bolts
Fuel Tank Bolts
Throttle Sensor Mounting Bolt
Cooling System
Radiator Mounting Nuts
Water Temperature Sensor
Thermostat Cover Bolts
Radiator Fairing Bolts
Radiator Bracket Bolts
Water Pump Cover Bolts
Coolant Drain Bolt
Water Pump Impeller Nut
Water Pipe Bolts
Engine Top End
Vacuum Switch Valve Bracket Bolts (PH
Model)
Vacuum Switch Valve Bolts (PH Model)
Vacuum Switch Valve Pipe Bolts (PH Model)
Vacuum Switch Valve Pipe Mounting Bolt (PH
Model)
Cylinder Head Cover Bolts
Cylinder Head Bolts (M10)
Spark Plugs
Cylinder Head Bolts (M6)
Camshaft Sprocket Bolt
Camshaft Chain Tensioner Cap Bolt
Camshaft Chain Tensioner Mounting Bolts
Timing Inspection Cap
Exhaust Pipe Holder Studs
Rear Camshaft Chain Guide Mounting Bolt
Exhaust Pipe Holder Nuts
Muffler Body Mounting Bolts (Upper)
Muffler Body Clamp Bolt
Muffler Body Mounting Bolts (Lower)
Exhaust Pipe Cover Screws
N·m
Torque
kgf·m
ft·lb
3.9
4.9
20
5.0
0.40
0.50
2.0
0.51
35 in·lb
43 in·lb
15
44 in·lb
11
13
9.8
8.8
11
11
9.8
7.8
9.8
1.1
1.3
1.0
0.90
1.1
1.1
1.0
0.80
1.0
97 in·lb
115 in·lb
87 in·lb
78 in·lb
97 in·lb
97 in·lb
87 in·lb
69 in·lb
87 in·lb
11
1.1
97 in·lb
8.8
5.9
0.90
0.60
78 in·lb
52 in·lb
12
1.2
106 in·lb
11
46
14
11
25
11
11
11
23
11
23
11
15
11
6.9
1.1
4.7
1.4
1.1
2.5
1.1
1.1
1.1
2.3
1.1
2.3
1.1
1.5
1.1
0.70
97 in·lb
34
10
97 in·lb
18
97 in·lb
97 in·lb
97 in·lb
17
97 in·lb
17
97 in·lb
11
97 in·lb
61 in·lb
Remarks
L
L
L
L
L
L
PERIODIC MAINTENANCE 2-7
Torque and Locking Agent
Fastener
Muffler End Cover Screws
Clutch
Clutch Cover Bolts
Clutch Hub Nut
Clutch Stopper Bolts
Oil Seal Retaining Plate Bolts
Engine Lubrication System
Oil Pressure Switch
Oil Filter Cap Bolts
Oil Pump Mounting Bolts
Oil Strainer Cap
Engine Removal/Installation
Engine Bracket Bolts
Front Engine Mounting Bolt
Rear Engine Mounting Bolts
Crankshaft/Transmission
Starter Motor Clutch Bolts
Balancer Drive Gear Nut
Primary Gear Nut
Balancer Driven Gear Bolt
Crankcase Bolts (L = 40 mm)
Crankcase Bolts (L = 60 mm)
Crankshaft Bearing Retaining Plate Screw
Shift Drum Bearing Retaining Plate Bolt
Connecting Rod Big End Bolts
Breather Plate Screws
Balancer Bearing Retaining Plate Bolt
Chain Guide Screws
Oil Jet Nozzle
Starter Motor Clutch Gear Retaining Plate Bolt
Gear Positioning Lever Bolt
Shift Drum Cam Bolt
Shift Pedal Mounting Bolt
Shift Shaft Return Spring Pin
Shift Lever Bolt
Wheels/Tires
Front Axle Nut
Rear Axle Nut
Final Drive
Engine Sprocket Bolts
Engine Sprocket Cover Bolts
Chain Guide Screws
Rear Axle Nut
N·m
6.9
Torque
kgf·m
0.70
ft·lb
61 in·lb
Remarks
L
11
69
11
9.8
1.1
7.0
1.1
1.0
97 in·lb
51
97 in·lb
87 in·lb
13
6.9
11
8.8
1.3
0.70
1.1
0.90
115 in·lb
61 in·lb
97 in·lb
78 in·lb
25
34
27
2.5
3.5
2.8
18
25
20
15
59
59
23
11
11
9.8
11
23
6.9
9.8
11
5.9
11
11
11
20
21
12
1.5
6.0
6.0
2.3
1.1
1.1
1.0
1.1
2.3
0.70
1.0
1.1
0.60
1.1
1.1
1.1
2.0
2.1
1.2
11
44
44
17
97 in·lb
97 in·lb
87 in·lb
97 in·lb
17
61 in·lb
87 in·lb
97 in·lb
52 in·lb
97 in·lb
97 in·lb
97 in·lb
15
15
106 in·lb
L
L
L
L
98
108
10.0
11.0
72
79.7
R
R
11
11
11
108
1.1
1.1
1.1
11.0
97 in·lb
97 in·lb
97 in·lb
79.7
L
L, Lh
L
L
L
L
L
L
L
L
L
L
L
L
L
L
R
2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
Rear Sprocket Stud Bolts
Brakes
Front Caliper Mounting Bolts
Front Brake Disc Mounting Bolts
Rear Brake Disc Mounting Bolts
Brake Pedal Clamp Bolt
Brake Light Switch Bracket Bolt
Suspension
Front Fork Clamp Bolts (Upper)
Front Fork Clamp Bolts (Lower)
Front Fork Top Plugs
Front Fork Bottom Allen Bolts
Rear Shock Absorber Bolts
Swingarm Pivot Shaft Nut
Steering
Handlebar Holder Bolts
Handlebar Weight Bolts
Steering Stem Head Bolt
Front Fork Clamp Bolts (Upper)
Steering Stem Nut
Front Fork Clamp Bolts (Lower)
Frame
Fuel Tank Cover Bolts (Front)
Fuel Tank Cover Bolts (Side)
Fuel Tank Cover Bracket Bolts
Side Stand Bracket Bolts
Side Stand Bolt
Center Stand Bolts
Front Fender Bolts
Front Fender Bracket Bolts
Front Footpeg Bracket Bolts
Flap Mounting Bolts
Mud Guard Bolts (Front)
Side Cover Screws
Seat Cover Bolts (Side)
Seat Cover Bolts (Top)
Battery Case Bolts
Front Seat Bolts
Grab Rail Mounting Bolts
Seat Lock Mounting Bolts
License Plate Mounting Bolts
Rear Footpeg Bracket Bolts
Rear Footpeg Guard Bolts
N·m
34
Torque
kgf·m
3.5
ft·lb
25
25
28
9.8
20
4.9
2.5
2.9
1.0
2.0
0.50
18
21
87 in·lb
15
43 in·lb
19
27
27
24
34
137
1.9
2.8
2.8
2.4
3.5
14.0
14
20
20
18
25
101
19
9.8
49
19
4.9
27
1.9
1.0
5.0
1.9
0.50
2.8
14
87 in·lb
36
14
43 in·lb
20
4.9
8.8
4.4
20
27
20
8.8
19
20
20
8.8
8.8
8.8
8.8
18
9.8
20
19
6.9
20
6.9
0.50
0.90
0.45
2.0
2.8
2.0
0.90
1.9
2.0
2.0
0.90
0.90
0.90
0.90
1.8
1.0
2.0
1.9
0.70
2.0
0.70
43 in·lb
78 in·lb
39 in·lb
15
20
15
78 in·lb
14
15
15
78 in·lb
78 in·lb
78 in·lb
78 in·lb
13
87 in·lb
15
14
61 in·lb
15
61 in·lb
Remarks
L
L
L
L
L
L
PERIODIC MAINTENANCE 2-9
Torque and Locking Agent
Fastener
Rear Fender Bolts
Electrical System
Spark Plugs
Alternator Rotor Bolt
Stator Coil Bolts
Water Temperature Sensor
Starter Motor Mounting Bolts
Alternator Cover Bolts
Throttle Sensor Mounting Bolt
Oil Pressure Switch
Neutral Switch Bolts
Neutral Switch Lead Holding Plate Bolts
Neutral Switch Lead Holding Plate Screw
Alternator Lead Holding Plate Bolts
Starter Motor Clutch Bolts
Horn Mounting Bolt
Regulator/Rectifier Bolts
Ignition Switch Bolts
N·m
4.9
14
58
7.4
13
11
11
5.0
13
5.9
5.9
5.9
4.9
15
20
11
11
Torque
kgf·m
0.50
1.4
5.9
0.75
1.3
1.1
1.1
0.51
1.3
0.60
0.60
0.60
0.50
1.5
2.0
1.1
1.1
ft·lb
43 in·lb
10
43
65 in·lb
115 in·lb
97 in·lb
97 in·lb
44 in·lb
115 in·lb
52 in·lb
52 in·lb
52 in·lb
43 in·lb
11
15
97 in·lb
97 in·lb
Remarks
L
L
L
L
L
L
2-10 PERIODIC MAINTENANCE
Torque and Locking Agent
The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and
nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the
values are for use with dry solvent-cleaned threads.
Basic Torque for General Fasteners
Threads Diameter
(mm)
5
6
8
10
12
14
16
18
20
N·m
3.4 ∼ 4.9
5.9 ∼ 7.8
14 ∼ 19
25 ∼ 34
44 ∼ 61
73 ∼ 98
115 ∼ 155
165 ∼ 225
225 ∼ 325
Torque
kgf·m
0.35 ∼ 0.50
0.60 ∼ 0.80
1.4 ∼ 1.9
2.6 ∼ 3.5
4.5 ∼ 6.2
7.4 ∼ 10.0
11.5 ∼ 16.0
17.0 ∼ 23.0
23.0 ∼ 33.0
ft·lb
30 ∼ 43 in·lb
52 ∼ 69 in·lb
10 ∼ 13.5
19 ∼ 25
33 ∼ 45
54 ∼ 72
83 ∼ 115
125 ∼ 165
165 ∼ 240
PERIODIC MAINTENANCE 2-11
Specifications
Item
Fuel System
Throttle Grip Free Play
Idle Speed
Air Cleaner Element
Cooling System
Coolant:
Type (Recommended)
Color
Mixed Ratio
Freezing Point
Total Amount
Engine Top End
Valve Clearance:
Exhaust
Intake
Clutch
Clutch Lever Free Play
Engine Lubrication System
Engine Oil:
Type
Viscosity
Capacity
Level
Wheels/Tires
Tread Depth:
Front
Rear
Air Pressure (when Cold):
Front
Rear
Final Drive
Drive Chain Slack
Drive Chain Wear (19-link
Length)
Standard Chain:
Make
Type
Link
Standard
Service Limit
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
1 350 ∼ 1 450 r/min (rpm)
Dry paper type
– – –
– – –
– – –
Permanent type of antifreeze
Green
Soft water 50%, coolant 50%
–35°C (–31°F)
1.0 L (1.1 US qt)
–
–
–
–
–
0.07 ∼ 0.09 mm (0.0028 ∼ 0.0035 in.)
0.04 ∼ 0.06 mm (0.0016 ∼ 0.0024 in.)
– – –
– – –
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
– – –
DTS-i 10000
API SL with JASO MA2
SAE 20W-50
1.2 L (1.3 US qt)
1.4 L (1.5 US qt) (when engine is completely dry)
Between upper and lower level lines (Wait 2 ∼ 3
minutes after idling or running)
– – –
5.0 mm (0.20 in.)
6.0 mm (0.24 in.)
Up to 130 kg (287 lb) load:
175 kPa (1.75 kgf/cm², 25 psi)
Up to 65 kg (143 lb) load:
200 kPa (2.00 kgf/cm², 29 psi)
65 ∼ 130 kg (143 ∼ 287 lb) load:
225 kPa (2.25 kgf/cm², 33 psi)
15 ∼ 25 mm (0.59 ∼ 0.98 in.)
301.6 ∼ 302.1 mm (11.87 ∼ 11.89 in.)
LGB
520 series
108 links
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
1 mm (0.04 in.)
1 mm (0.04 in.)
– – –
– – –
– – –
– – –
307 mm (12.09
in.)
– – –
– – –
– – –
2-12 PERIODIC MAINTENANCE
Specifications
Item
Brakes
Brake Fluid:
Grade
Brake Pad Lining
Thickness:
Front
Rear
Brake Light Timing:
Front
Rear
Electrical System
Spark Plug:
Type:
Central
Side
Gap
Standard
DOT3 or DOT4
6.35 mm (0.250 in.)
6.0 mm (0.236 in.)
Service Limit
– – –
1 mm (0.04 in.)
1 mm (0.04 in.)
Pulled ON
On after about 11.5 mm (0.453 in.) of pedal
travel
– – –
BOSCH VR5NE
CHAMPION P-RG6HCC
0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)
– – –
– – –
– – –
– – –
PERIODIC MAINTENANCE 2-13
Special Tools
Inside Circlip Pliers:
57001-143
Valve Adjusting Screw Holder:
57001-1217
Outside Circlip Pliers:
57001-144
Jack:
57001-1238
Steering Stem Nut Wrench:
57001-1100
2-14 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Fuel System
Air Cleaner Element Cleaning
NOTE
○In dusty areas, the element should be cleaned more
frequently than the recommended interval.
○After riding through rain or on muddy roads, the element
should be cleaned immediately.
○Also, if there is a break in the element material or any
other damage to the element, replace the element with
a new one.
the air cleaner element (see Air Cleaner Element
• Remove
Removal in the Fuel System chapter).
the paper element [A] by tapping it lightly to loosen
• Clean
dust.
away the remaining dust by applying compressed
• Blow
air from the inside (clean side) to outside (dirty side).
all the parts of the element for visible damage.
• Check
If the element is damaged, replace it with a new one.
Air Cleaner Element Replacement
NOTE
○In dusty areas, the element should be replaced more
frequently than the recommended interval.
WARNING
If dirt or dust is allowed to pass through into the
carburetor, the throttle may become stuck, possibly
causing accident. Replace the air cleaner element
according to the maintenance chart.
NOTICE
If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
•
chapter)
Air Cleaner Cover Mounting Bolts [A]
Clear the hook [B] from the duct.
PERIODIC MAINTENANCE 2-15
Periodic Maintenance Procedures
the air cleaner cover [A] forward [B] to clear the tabs
• Push
[C], and remove the air cleaner cover.
the air cleaner element [A] from the air cleaner
• Remove
cover [B].
• Replace the air cleaner element with a new one.
is the reverse of removal.
• Installation
Insert
the
tabs
[A] into the slots [B] of the air cleaner cover.
•
Idle Speed Inspection
the engine and warm it up thoroughly.
• Start
With
the
• [A]. engine idling, turn the handlebar to both sides
If handlebar movement changes the idle speed, the throttle cable may be improperly adjusted or incorrectly routed,
or it may be damaged. Be sure to correct any of these
conditions before riding (see Throttle Control System Inspection).
WARNING
Operation with an improperly adjusted, incorrectly
routed or damaged cables could result in an unsafe
riding condition. Follow the service manual to make
sure to correct any of these conditions.
the idle speed.
• Check
If the idle speed is out of the specified range, adjust it.
Idle Speed
Standard:
1 350 ∼ 1 450 r/min (rpm)
2-16 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Idle Speed Adjustment
the engine and warm it up thoroughly.
• Start
the idle adjusting screw [A] until the idle speed is
• Turn
correct.
○Open and close the throttle a few times to make sure that
the idle speed is within the specified range. Readjust if
necessary.
Throttle Control System Inspection
the throttle grip free play [A].
• Check
If the free play is incorrect, adjust the throttle cable.
Throttle Grip Free Play
Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
that the throttle grip [B] moves smoothly from full
• Check
open to close, and the throttle closes quickly and com-
•
•
pletely by the return spring in all steering positions.
If the throttle grip does not return properly, check the throttle cable routing, grip free play, and cable damage. Then
lubricate the throttle cable.
Run the engine at the idle speed, and turn the handlebar
all the way to the right and left to ensure that the idle speed
does not change.
If the idle speed increases, check the throttle cable free
play and the cable routing.
If necessary, adjust the throttle cable as follows.
Slide the dust cover [A].
the locknut [A].
• Loosen
Turn
the
[B] until the proper amount of throttle
• grip play isadjuster
obtained.
• Tighten the locknut.
PERIODIC MAINTENANCE 2-17
Periodic Maintenance Procedures
Choke Operation Inspection
that the choke lever [A] moves smoothly.
• Check
If the choke lever does not moves smoothly, inspect the
choke plunger damage (see Carburetor Disassembly/Assembly in the Fuel System chapter).
If the choke plunger is damaged, replace it with a new
one (see Carburetor Disassembly/Assembly in the Fuel
System chapter).
Carburetor Cleaning (Fuel Draining)
the fuel drain screw [A], and drain the fuel from
• Loosen
the carburetor through the drain hose [B] to refresh the
fuel in the carburetor.
Carburetor Holder Inspection
inspect the carburetor holder [A] for cracks or
• Visually
cuts.
Replace the carburetor holder if any damages are noticed.
Fuel Hose Inspection (fuel leak, damage,
installation condition)
○If the motorcycle is not properly handled, the high pres-
sure inside the fuel line can cause fuel to leak [A] or the
hose burst.
Replace the fuel hose if any fraying, cracks [B] or bulges
[C] are noticed.
that the fuel hose [A] is securely connected and
• Check
clamps [B] are tightened correctly.
that the fuel hose is routed according to Cable,
• Check
Wire, and Hose Routing section in the Appendix chapter.
○When installing the fuel hose, avoid sharp bending, kink-
ing, flattening or twist, and run the fuel hose with a minimum of bending so that fuel flow will not be obstructed.
Replace the hose if it has been sharply bent or kinked.
2-18 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Fuel Hose Replacement
WARNING
Gasoline is extremely flammable and can be explosive 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;
this includes any appliance with a pilot light. Do not
smoke. Turn the ignition switch off. Be prepared for
fuel spillage; any spilled fuel must be completely
wiped up immediately.
the fuel tank (see Fuel Tank Removal in the Fuel
• Remove
System chapter).
sure to place a piece of cloth around the fuel hose joint.
• Be
Slide
the clamps [A] and disconnect the fuel hoses [B].
•○Disconnect
the other fuel hose in the same way.
the fuel hose [A] with a new one.
• Replace
Fit
the
fuel
hose onto the fitting fully and install the hose
• clamp [B] beyond
the raised rib [C]. Do not touch the claw
portion of clamp to other part.
the fuel hose correctly (see Cable, Wire, and Hose
• Run
Routing section in the Appendix chapter).
○When installing the fuel hose, avoid sharp bending, kinking, flatting or twisting, and run the fuel hose with a minimum of bending so that the fuel flow will not be obstructed.
Fuel Filter Replacement
WARNING
Gasoline is extremely flammable and can be explosive 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;
this includes any appliance with a pilot light. Do not
smoke. Turn the ignition switch off. Be prepared for
fuel spillage; any spilled fuel must be completely
wiped up immediately.
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
•
•
chapter)
Fuel Filter Mounting Screw [A]
Disconnect:
Fuel Hoses
Replace the fuel filter [B] with a new one.
PERIODIC MAINTENANCE 2-19
Periodic Maintenance Procedures
Cooling System
Coolant Level Inspection
NOTE
○Check the level when the engine is cold (room or ambient temperature).
the coolant level in the reserve tank [A] with
• Check
the motorcycle held perpendicular (Do not use the side
stand).
If the coolant level is lower than the “MIN” level line [B],
remove the fuel tank cover (see Fuel Tank Cover Removal
in the Frame chapter), and then unscrew the reserve tank
cap and add coolant to the “MAX” level line [C].
“MIN”: Low
“MAX”: Full
NOTICE
For refilling, add the specified mixture of coolant
and soft water. Adding water alone dilutes the
coolant and degrades its anticorrosion properties.
The diluted coolant can attack the aluminum engine parts. In an emergency, soft water alone can
be added. But the diluted coolant must be returned
to the correct mixture ratio within a few days.
If coolant must be added often or the reservoir tank
has run completely dry, there is probably leakage in
the cooling system. Check the system for leaks.
Coolant ruins painted surfaces. Immediately wash
away any coolant that spills on the frame, engine,
wheels or other painted parts.
Water Hose and Pipe Inspection (coolant leak,
damage, installation condition)
○The high pressure inside the radiator hose 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
brittle, nor should it be soft or swollen.
Replace the hose if any fraying, cracks [B] or bulges [C]
are noticed.
Check that the hoses are securely connected and clamps
are tightened correctly.
Coolant Change
WARNING
Coolant can be extremely hot and cause severe
burns, is toxic and very slippery. Do not remove
the radiator cap or attempt to change the coolant
when the engine is hot; allow it cool completely.
Immediately wipe any spilled coolant from tires,
frame, engine or other painted parts. Do not ingest
coolant.
2-20 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
• Remove:
Fuel Tank Cover (see Fuel Tank Cover Removal in the
Frame chapter)
Radiator Cap [A]
○Remove the radiator cap in two steps. First turn the cap
counterclockwise to the first stop. Then push and turn it
further in the same direction and remove the cap.
a container under the drain bolt [A] of the water
• Place
pump cover.
the coolant from the radiator by removing the drain
• Drain
bolt.
• Remove:
Screws [A]
Cover [B]
• Remove:
Bolts [A]
•
•
•
Bracket [B]
Cap [C]
Pour the coolant into a container.
Install the coolant reserve tank [D] and tighten the bolts.
Tighten the drain bolt with the new gasket.
PERIODIC MAINTENANCE 2-21
Periodic Maintenance Procedures
filling the coolant, choose a suitable mixture ratio
• When
by referring to the coolant manufacturer’s directions.
NOTICE
Soft or distilled water must be used with the antifreeze in the cooling system.
If hard water is used in the system, it causes scales
accumulation in the water passages, and considerably reduces the efficiency of the cooling system.
Water and Coolant Mixture Ratio (Recommended)
Soft Water:
50%
Coolant:
50%
Freezing Point:
–35°C (–31°F)
Total Amount:
1.5 L (1.6 US qt)
• 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.
the cooling system for leaks.
• Check
Tap
the
• inside. radiator hoses to force any air bubbles caught
• Fill the radiator up to the filler neck with coolant.
the reserve tank up to the “MAX” (full) level line with
• Fill
coolant and install the cap.
the radiator cap.
• Install
Start
the
warm it up thoroughly until the radiator
• fan turns engine,
on and then stop the engine.
the coolant level in the reserve tank after the en• Check
gine cools down.
If the coolant level is lower than the “MIN” (low) level line,
add coolant to the “MAX” level line.
NOTICE
Do not add more coolant above the “MAX” level
line.
Engine Top End
Valve Clearance Inspection
NOTICE
If valve clearance is left unadjusted, the wear will
eventually cause the valves to remain partly open,
which lowers performance, burns the valves and
the valve seats, and may cause serious engine damage.
NOTE
○Valve clearance must be checked when the engine is
cold (at room temperature).
2-22 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
• Remove:
Cylinder Head Cover (see Cylinder Head Cover Removal in the Engine Top End chapter)
Timing Inspection Cap [A]
the camshaft clockwise, and align the “T” mark [A] on
• Turn
the alternator rotor with the projection [B] on the alternator
cover.
○Check that the “T” mark [A] and lines [B] on the camshaft
sprocket is in position. This shows that the piston TDC is
at the end of the compression stroke.
a thickness gauge [A], measure the valve clearance
• Using
between the adjusting screw and valve stem.
○Measure the both valves at a time.
Valve Clearance
Standard:
Exhaust
0.07 ∼ 0.09 mm (0.0028 ∼ 0.0035 in.)
Intake
0.04 ∼ 0.06 mm (0.0016 ∼ 0.0024 in.)
If the valve clearance is not within the specified range,
adjust it.
PERIODIC MAINTENANCE 2-23
Periodic Maintenance Procedures
Valve Clearance Adjustment
the valve adjusting screw locknut [A] and insert
• Loosen
the thickness gauge [B] between the valve and adjusting
•
screw [C], and turn the screw until the adjusting screw
stops.
Tighten the valve adjusting screw locknut.
Special Tool - Valve Adjusting
57001-1217
Screw
Holder
[D]:
• Install the removed parts (see appropriate chapters).
Air Suction System (PH Model)
Air Suction System Damage Inspection
the fuel tank (see Fuel Tank Removal in the Fuel
• Remove
System chapter).
• Remove the bolts [A].
the vacuum switch valve hose [A] from the vac• Remove
uum switch valve [B].
the suitable hose [A] to the vacuum switch valve.
• Install
Install
the fuel tank temporary (see Fuel Tank Installation
• in the Fuel
System chapter).
Start
the
engine
run it at idle speed.
• Plug the vacuumand
switch valve hose end [B] with your fin• ger and feel vacuum
pulsing in the hose.
If there is no vacuum pulsation, check the hose line for
leak.
If there is no leak, check the vacuum switch valve (see
Vacuum Switch Valve Test in the Engine Top End chapter).
2-24 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Clutch
Clutch Operation Inspection
• Slide the dust cover [A].
the clutch lever just enough to take up the free play
• Pull
[A].
the gap between the lever [B] and the lever
• Measure
holder [C].
If the gap is too wide, the clutch may not release fully. If
the gap is too narrow, the clutch may not engage fully. In
either case, adjust it.
Clutch Lever Free Play
Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
Clutch Cable Adjustment
the locknut [A].
• Loosen
Turn
the
adjuster [B] so that the clutch lever will have the
• proper play.
the locknut.
• Tighten
If the clutch cable adjustment cannot be done at the clutch
lever side, use the adjuster at the lower end of the clutch
cable.
WARNING
The engine and exhaust system get extremely hot
during normal operation and can cause serious
burns. Never touch the engine or exhaust pipe
during clutch adjustment.
the locknut [A].
• Loosen
the adjuster [B] so that the clutch lever will have the
• Turn
proper play.
• Tighten the locknut.
WARNING
Too much cable play can prevent clutch disengagement and cause an accident resulting in serious injury or death. When adjusting the clutch or replacing the cable, be sure the upper end of the clutch
outer cable is fully seated in its fitting, or it could
slip into place later, creating enough cable play to
prevent clutch disengagement.
the adjustment, start the engine and check that the
• After
clutch does not slip and that it releases properly.
PERIODIC MAINTENANCE 2-25
Periodic Maintenance Procedures
Engine Lubrication System
Engine Oil Change
up the engine thoroughly so that the oil will pick up
• Warm
any sediment and drain easily. Then stop the engine.
an oil pan beneath the engine.
• Place
Remove
the oil filler cap [A].
•
the oil strainer cap [A] from the bottom of the
• Remove
engine.
the oil strainer [A], and let the oil drain com• Remove
pletely.
the O-rings of the oil strainer and oil strainer cap
• Replace
with new ones.
grease to the new O-rings.
• Apply
the oil strainer.
• Install
Install
the
• Tighten: oil strainer cap.
•
Torque - Oil Strainer Cap: 8.8 N·m (0.90 kgf·m, 78 ft·lb)
• Pour in the specified type and amount of oil.
Recommended Engine Oil
Type:
DTS-i 10000
API SL with JASO MA2
Viscosity:
SAE 20W-50
Capacity:
1.2 L (1.3 US qt)
1.4 L (1.5 US qt) (when engine is completely
dry)
NOTE
○Do not add any chemical additive to the oil. Oils fulfilling
the above requirements are fully formulated and provide
adequate lubrication for both the engine and the clutch.
the oil level (see Oil Level Inspection in the Engine
• Check
Lubrication System chapter).
the oil filler cap O-ring with a new one.
• Replace
Apply
grease
the O-ring.
• Tighten the oiltofiller
cap securely.
•
2-26 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Oil Strainer Cleaning
the screen [A] of the oil strainer with a high flash
• Clean
-point solvent and remove any particles stuck to them.
NOTE
○While cleaning the screen, check for any metal particles
that might indicate internal engine damage.
WARNING
Gasoline and low flash-point solvents can be
flammable and/or explosive and cause severe
burns. Clean the screen in a well-ventilated area,
and take care that there are no sparks or flame
anywhere near the working area; this includes any
appliance with a pilot light. Do not use gasoline or
a low flash-point solvent to clean the screen.
the screen carefully for any damage, holes, and
• Check
broken wires.
If the screen is damaged, replace it.
Oil Filter Replacement
the engine oil (see Engine Oil Change).
• Drain
• Remove:
Oil Filter Cap Bolts [A]
Oil Filter Cap [B]
• Remove the oil filter [A] with the outside circlip pliers [B].
Special Tool - Outside Circlip Pliers: 57001-144
the oil filter [A] with a new one.
• Replace
engine oil to the grommet [B].
• Apply
Install
the oil filter.
•
PERIODIC MAINTENANCE 2-27
Periodic Maintenance Procedures
the oil filter cap O-ring [A] with a new one.
• Replace
Apply
grease
to the O-ring.
• Install the oil filter
cap [B].
• Tighten:
•
Torque - Oil Filter Cap Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb)
in the specified type and amount of oil (see Engine
• Pour
Oil Change).
Wheels/Tires
Air Pressure Inspection
the air valve cap.
• Remove
Measure
tire air pressure with an air pressure gauge
• [A] when the
the tires are cold (that is, when the motorcycle
•
has not been ridden more than a mile during the past 3
hours).
Install the air valve cap.
Adjust the tire air pressure according to the specifications
if necessary.
Air Pressure (when Cold)
Front: Up to 130 kg (287 lb) load:
175 kPa (1.75 kgf/cm², 25 psi)
Rear:
Up to 65 kg (143 lb) load:
200 kPa (2.00 kgf/cm², 29 psi)
65 ∼ 130 kg (143 ∼ 287 lb) load: 225 kPa (2.25
kgf/cm², 33 psi)
Wheels and Tires
Wheel/Tire Damage Inspection
Remove any imbedded stones [A] or other foreign particles [B] from tread.
Visually inspect the tire for cracks and cuts, and replace
the tire if necessary. Swelling or high spots indicate internal damage, requiring tire replacement.
Visually inspect the wheel for cracks, cuts and dents damage.
If any damage is found, replace the wheel if necessary.
•
•
•
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 until they are bald.
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).
•
2-28 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Tread Depth
Standard:
Front
5.0 mm (0.20 in.)
Rear
6.0 mm (0.24 in.)
Service Limit:
Front
1 mm (0.04 in.)
Rear
1 mm (0.04 in.)
WARNING
Some replacement tires may adversely affect handling and cause an accident resulting in serious injury or death. To ensure proper handling and stability, use only the recommended standard tires for
replacement, inflated to the standard pressure.
NOTE
○Most countries may have their own regulations a minimum tire tread depth: be sure to follow them.
○Check and balance the wheel when a tire is replaced
with a new one.
Wheel Bearing Damage Inspection
the front wheel off the ground with the jack (see
• Raise
Front Wheel Removal in the Wheels/Tires chapter).
Special Tool - Jack: 57001-1238
the handlebar all the way to the right or left.
• Turn
Inspect
roughness of the front wheel bearing by push• ing and the
pulling [A] the wheel.
[B] the front wheel lightly, and check for smoothly
• Turn
turn, roughness, binding or noise.
If roughness, binding or noise is found, remove the front
wheel and inspect the wheel bearing (see Front Wheel
Removal, Hub Bearing Inspection in the Wheels/Tires
chapter).
the rear wheel off the ground with the stand (see
• Raise
Rear Wheel Removal in the Wheels/Tires chapter).
the roughness of the rear wheel bearing by push• Inspect
ing and pulling [A] the wheel.
[B] the rear wheel lightly, and check for smoothly
• Turn
turn, roughness, binding or noise.
If roughness, binding or noise is found, remove the rear
wheel and inspect the wheel bearing (see Rear Wheel Removal, Hub Bearing Inspection in the Wheels/Tires chapter) and coupling (see Coupling Bearing Inspection in the
Final Drive chapter).
PERIODIC MAINTENANCE 2-29
Periodic Maintenance Procedures
Final Drive
Drive Chain Lubrication Condition Inspection
Lubrication is necessary after riding through rain or on wet
roads, or any time that the chain appears dry.
Use a lubricant for sealed chains to prevent deterioration
of chain seals. If the chain is especially dirty, clean it using a
cleaner for sealed chains following the instructions supplied
by the chain cleaner manufacturer.
NOTICE
The O-rings between the side plates seal in the lubricant between the pin and the bushing. To avoid
damaging the O-rings and resultant loss of lubricant, observe the following rules.
Use only chain cleaner for cleaning of the O-ring of
the drive chain. Any other cleaning solution such
as gasoline will cause deterioration and swelling
of the O-ring. Immediately blow the chain dry with
compressed air after cleaning. Complete cleaning
and drying the chain within 10 minutes.
chain oil to the sides of the rollers so that oil will
• Apply
penetrate to the rollers and bushings. Apply the oil to the
•
•
O-rings so that the O-rings will be coated with oil.
Wipe off any excess oil.
Oil Applied Areas [A]
O-rings [B]
Wipe off lubricant that gets on the tire surface.
Drive Chain Slack Inspection
NOTE
○Check the slack with the motorcycle setting on its side
stand.
○Clean the chain if it is dirty, and lubricate it if it appears
dry.
the wheel alignment (see Wheel Alignment Inspec• Check
tion).
the rear wheel to find the position where the chain
• Rotate
is tightest.
the vertical movement (chain slack) [A] midway
• Measure
between the sprockets.
If the chain slack exceeds the standard, adjust it.
Chain Slack
Standard:
15 ∼ 25 mm (0.59 ∼ 0.98 in.)
2-30 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Drive Chain Slack Adjustment
the rear axle nut [A].
• Loosen
both chain adjusters [B] evenly until the drive chain
• Turn
has the correct amount of slack. To keep the chain and
wheel properly aligned, the projection [C] on the swingarm
and the mark [D] on the chain adjuster are in the same
position on both sides.
WARNING
Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.
Be sure the wheel is properly aligned.
the rear axle nut with a new one.
• Replace
Tighten
the
rear axle nut.
•
Torque - Rear Axle Nut: 108 N·m (11.0 kgf·m, 79.7 ft·lb)
the wheel, measure the chain slack again at the tight• Turn
est position, and readjust if necessary.
Wheel Alignment Inspection
that the protection [A] on the right side aligns with
• Check
the same chain adjuster mark or position [B] that the projection on the left side aligns with.
If they do not, adjust the chain slack and align the wheel
alignment (see Drive Chain Slack Adjustment).
○Wheel
NOTE
alignment can be also checked using the
straightedge or string method.
WARNING
Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.
Be sure the wheel is properly aligned.
Drive Chain Wear Inspection
the mud guard (see Mud Guard Removal in the
• Remove
Frame chapter).
the rear wheel to inspect the drive chain for dam• Rotate
aged rollers, and loose pins and links.
•
•
If there is any irregularity, replace the drive chain.
Lubricate the drive chain if it appears dry.
Stretch the chain taut by hanging a 10 kg (22 lb) weight
[A] on the chain.
Measure the length of 19 links [B] on the straight part [C] of
the chain from the pin center of the 1st pin to the pin center
of the 20th pin. Since the chain may wear unevenly, take
measurements at several places.
If any measurements exceed the service limit, replace the
chain. Also, replace the front and rear sprockets when the
drive chain is replaced.
Drive Chain 19-link Length
Standard:
301.6 ∼ 302.1 mm (11.87 ∼ 11.89 in.)
Service Limit: 307 mm (12.09 in.)
PERIODIC MAINTENANCE 2-31
Periodic Maintenance Procedures
WARNING
A chain that breaks or jumps off the sprockets
could snag on the engine sprocket or lock the
rear wheel, severely damaging the motorcycle and
causing it to go out of control. Inspect the chain for
damage and proper adjustment before each ride.
If chain wear exceeds the service limit, replace it
with the standard chain. It is an endless type and
should not be cut for installation.
Standard Chain
Make:
LGB
Type:
520 series
Link:
108 links
Chain Guide Wear Inspection
the swingarm (see Swingarm Removal in the
• Remove
Suspension chapter).
inspect the chain guide [A].
• Visually
Replace the chain guide if it shows any signs of abnormal
wear or damage.
Brakes
Brake System Inspection
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.
•
2-32 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Brake Hose 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 while examining
it.
Replace the hose if any crack [B], bulge [C] or leakage is
noticed.
Tighten any brake hose banjo bolts.
Inspect the brake hose routing.
If any brake hose routing is incorrect, run the brake hose
according to Cable, Wire, and Hose Routing section in the
Appendix chapter.
•
•
Brake Operation Inspection
Inspect the operation of the front and rear brake by running the vehicle on the dry road.
If the brake operation is insufficiency, inspect the brake
system.
•
WARNING
When test riding the vehicle, be aware of surrounding traffic for your safety.
Brake Fluid Level Inspection
that the brake fluid level in the front brake reservoir
• Check
[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 line, fill the
reservoir to the upper level line [A].
PERIODIC MAINTENANCE 2-33
Periodic Maintenance Procedures
that the brake fluid level in the rear brake reservoir
• Check
[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 [A].
WARNING
Mixing brands and types of brake fluid can reduce
the brake system’s effectiveness and cause an accident resulting in injury or death. Do not mix two
brands of brake fluid. Change the brake fluid in the
brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that
is already in the reservoir are unidentified.
Recommended Disc Brake Fluid
Grade:
DOT3 or DOT4
the procedure below to install the rear brake fluid
• Follow
reservoir cap correctly.
○First, tighten the brake fluid reservoir cap [B] clockwise
•
[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 fluid
reservoir body [A].
Install the stopper (see Brake Line Bleeding in the Brakes
chapter).
Brake Fluid Change
NOTE
○The procedure to change the front brake fluid is as follows. Changing the rear brake fluid is the same as for
the front brake.
the brake fluid reservoir.
• Level
Remove
the reservoir cap and diaphragm.
•
2-34 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the rubber cap [A] from the bleed valve on the
• Remove
caliper.
a clear plastic hose [B] to the bleed valve, and run
• Attach
the other end of the hose into a container.
• Fill the reservoir with fresh specified brake fluid.
the brake fluid.
•○Change
Repeat this operation until fresh brake fluid comes out
from the plastic hose or the color of the fluid changes.
1. Open the bleed valve [A].
2. Apply the brake and hold it [B].
3. Close the bleed valve [C].
4. Release the brake [D].
NOTE
○The fluid level must be checked often during the changing operation and replenished with fresh brake fluid. If
the fluid in the reservoir runs out any time during the
changing operation, the brakes will need to be bled
since air will have entered the brake line.
the clear plastic hose.
• Remove
Install
the
diaphragm and reservoir cap.
•
the procedure below to install the rear brake fluid
• Follow
reservoir cap correctly.
○First, tighten the brake fluid reservoir cap [B] clockwise
[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 fluid
reservoir body [A].
the bleed valve, and install the rubber cap.
• Tighten
After
changing
fluid, check the brake for good braking
• power, no brakethedrag,
and no fluid leakage.
If necessary, bleed the air from the lines.
PERIODIC MAINTENANCE 2-35
Periodic Maintenance Procedures
Brake Hose Replacement
NOTICE
Brake fluid quickly ruins painted plastic surfaces;
any spilled fluid should be completely washed away
immediately.
• Remove:
Headlight Assy (see Headlight Cover Removal in the
Frame chapter)
Mud Guard (Mud Guard Removal in the Frame chapter)
Band [A]
Brake Hose Banjo Bolts [B]
Clear the brake hoses [C] from the clamps [D].
When removing the brake hoses, note the following.
○Take care not to spill the brake fluid on the painted or
plastic parts.
○Temporarily secure the end of the brake hose to some
high place to keep fluid loss to a minimum.
○Immediately wash away any brake fluid that spills.
When installing the brake hoses, note the following.
○Avoid sharp bending, kinking, flatting or twisting, and run
the hoses according to Cable, Wire, and Hose Routing
section in the Appendix chapter.
○There are washers on each side of the brake hose fitting.
Replace them with new ones.
Fill the brake line after installing the brake hose (see
Brake Fluid Change).
•
•
•
•
Master Cylinder Rubber Parts Replacement
Front Master Cylinder Disassembly
Remove the front master cylinder (see Front Master Cylinder Removal in the Brakes chapter).
Unscrew the locknut and pivot bolt, and remove the brake
lever.
Remove the piston assembly [A] as follows.
○Remove the dust cover [B] and push rod [C].
○Remove the circlip [D].
•
•
•
Special Tool - Inside Circlip Pliers: 57001-143
○Pull out the piston assembly.
○Remove the return spring [E].
• Replace:
Dust Cover
Circlip
Piston Assembly
Diaphragm [F]
NOTE
○Replacement parts of the master cylinder are included
in the replacement kit.
2-36 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Rear Master Cylinder Disassembly
Remove the rear master cylinder (see Rear Master Cylinder Removal in the Brakes chapter).
Remove the piston assembly [A] as follows.
○Remove the dust cover [B] and push rod [C].
○Remove the circlip [D].
•
•
Special Tool - Inside Circlip Pliers: 57001-143
○Remove the collar [E].
○Remove the piston assembly.
○Remove the return spring [F].
• Replace:
Dust Cover
Circlip
Piston Assembly
O-ring [G]
Diaphragm [H]
NOTE
○Replacement parts of the master cylinder are included
in the replacement kit.
Master Cylinder Assembly
Before assembly, clean all parts including the master
cylinder with brake fluid or alcohol.
•
NOTICE
Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning brake parts. Do not use any other fluid for
cleaning these parts. Gasoline, engine oil, or any
other petroleum distillate will cause deterioration of
the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the disc brake.
brake fluid to the new parts and to the inner wall of
• Apply
the cylinder.
care not to scratch the piston or the inner wall of the
• Take
cylinder.
• Apply silicone grease to the followings.
Front:
Brake Lever Pivot Bolt
Rear:
Dust Cover of Push Rod Assembly
Caliper Rubber Parts Replacement
Front Caliper Disassembly
Remove:
Front Caliper (see Front Caliper Removal in the Brakes
chapter)
Brake Pads (see Front Brake Pad Removal in the Brakes
chapter)
Pad Spring
•
PERIODIC MAINTENANCE 2-37
Periodic Maintenance Procedures
compressed air, remove the pistons.
•○Using
Cover the caliper opening with a clean heavy cloth [A].
○Blow compressed air [B] into the hole for the banjo bolt to
remove the piston.
WARNING
The piston in the brake caliper can crush hands and
fingers. Never place your hand or fingers in front of
the piston.
○Pull out the pistons by hand.
• Remove:
Caliper Holder
Dust Seals
Fluid Seals
Bleed Valve
Rubber Cap
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 and rubber cap.
the fluid seals [A] and the dust seals [B] with new
• Replace
ones.
○Apply brake fluid to the seals, and install them into the
cylinders by hand.
NOTE
○The fluid seals and dust seals of the front caliper are
included in the replacement kit.
brake fluid to the outside of the pistons, and push
• Apply
them into each cylinder by hand.
the friction boots [A] replace them with new ones
• Check
if they are damaged.
• Apply silicone grease to the caliper holder shafts [B].
2-38 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the pad spring [A].
• Install
Install
pads (see Front Brake Pad Installation in the
• Brakesthechapter).
up any spilled brake fluid on the caliper with wet
• Wipe
cloth.
Rear Caliper Disassembly
Remove:
Rear Caliper (see Rear Caliper Removal in the Brakes
chapter)
Brake Pads (see Rear Brake Pad Removal in the Brakes
chapter)
Pad Spring
•
compressed air, remove the piston.
•○Using
Cover the caliper opening with a clean heavy cloth [A].
○Blow compressed air [B] into the hole for the banjo bolt to
remove the piston.
WARNING
The piston in the brake caliper can crush hands and
fingers. Never place your hand or fingers in front of
the piston.
○Pull out the pistons by hand.
• Remove:
Caliper Holder
Dust Seal
Fluid Seal
Bleed Valve
Rubber Cap
Rear Caliper Assembly
Clean the caliper parts except for the pads.
•
NOTICE
For cleaning of the parts, use only disc brake fluid,
isopropyl alcohol, or ethyl alcohol.
• Install the bleed valve and rubber cap.
PERIODIC MAINTENANCE 2-39
Periodic Maintenance Procedures
the fluid seal [A] and the dust seal [B] with new
• Replace
ones.
○Apply brake fluid to the seals, and install them into the
cylinder by hand.
NOTE
○The fluid seal, dust seal and friction boots of the rear
caliper are included in the replacement kit.
brake fluid to the outside of the piston, and push it
• Apply
into the cylinder by hand.
the friction boots [A] with new ones if they are
• Replace
damaged.
• Apply silicone grease to the caliper holder shafts [B].
the pad spring [A] in the caliper as shown.
• Install
Install
pads (see Rear Brake Pad Installation in the
• Brakesthechapter).
up any spilled brake fluid on the caliper with wet
• Wipe
cloth.
Brake Pad Wear Inspection
the brake pads (see Front/Rear Brake Pad Re• Remove
moval in the Brakes chapter).
the lining thickness [A] of the pads in each caliper.
• Check
If the lining thickness of either pad is less than the service
limit [B], replace both pads in the caliper as a set.
Front Brake Pad [C]
Rear Brake Pad [D]
Pad Lining Thickness
Standard:
Front
6.35 mm (0.250 in.)
Rear
6.0 mm (0.236 in.)
Service Limit:
Front
1 mm (0.04 in.)
Rear
1 mm (0.04 in.)
2-40 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Brake Light Switch Operation Inspection
the ignition switch on.
• Turn
tail/brake light (LED) [A] should go on when the brake
• The
lever is applied or after the brake pedal is depressed
about 11.5 mm (0.453 in.).
•
If it does not, adjust the brake light switch.
While holding the switch body, turn the adjusting nut to
adjust the switch.
Switch Body [A]
Adjusting Nut [B]
Light sooner as the body rises [C]
Light later as the body lowers [D]
NOTICE
To avoid damaging the electrical connections inside the switch, be sure that the switch body does
not turn during adjustment.
If it does not go on, inspect or replace the following parts.
Battery (see Charging Condition Inspection in the Electrical System chapter)
Tail/Brake Light (LED) (see Tail/Brake Light (LED) Removal Installation in the Electrical System chapter)
Main Fuse 20 A (see Fuse Inspection in the Electrical
System chapter)
Front Brake Light Switch [A] (see Switch Inspection in
the Electrical System chapter)
Rear Brake Light Switch (see Switch Inspection in the
Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
Suspension
Suspension System Inspection
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
oil leak (see Front Fork Oil Leak Inspection).
•
PERIODIC MAINTENANCE 2-41
Periodic Maintenance Procedures
the rear seat down and up [A] 4 or 5 times, and
• Pump
inspect the smooth stroke.
If the shock absorber does not smoothly stroke or noise
is found, inspect the oil leak (see Rear Shock Absorber
Oil Leak Inspection).
Front Fork Oil Leak Inspection
Visually inspect the front forks [A] for oil leakage.
Replace or repair any defective parts, if necessary (see
Front Fork Oil Change in the Suspension chapter).
•
Rear Shock Absorber Oil Leak Inspection
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.
•
Steering
Steering Play Inspection
the front wheel off the ground with the jack (see
• Raise
Front Wheel Removal in the Wheels/Tires chapter).
Special Tool - Jack: 57001-1238
the front wheel pointing straight ahead, alternately
• With
tap each end of the handlebar. The front wheel should
•
swing fully left and right from the force of gravity until the
fork hits the stop.
If the wheel binds or catches before the stop, the steering
is too tight.
Feel for steering looseness by pushing and pulling [A] the
forks.
If you feel looseness, the steering is too loose.
NOTE
○The cables and wiring will have some effect on the motion of the fork which must be taken into account.
○Be sure the leads and cables are properly routed.
○The bearings must be in good condition and properly
lubricated in order for any test to be valid.
2-42 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Steering Play Adjustment
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
•
•
chapter)
Loosen the steering stem head bolt [A].
Adjust the steering using the steering stem nut wrench
[B].
Special Tool - Steering Stem Nut Wrench: 57001-1100
If the steering is too tight, loosen the stem nut [C] a fraction of a turn.
If the steering is too loose, tighten the stem nut a fraction
of a turn.
NOTE
○Turn the stem nut 1/8 turn at time maximum.
• Tighten the steering stem head bolt.
Torque - Steering Stem Head Bolt: 49 N·m (5.0 kgf·m, 36
ft·lb)
WARNING
If the handlebar does not turn to the steering stop it
may cause an accident resulting in injury or death.
Be sure the cables, harnesses and hoses are routed
properly and do not interfere with handlebar movement (see Cable, Wire, and Hose Routing section in
the Appendix chapter).
the steering again.
• Check
If the steering is still too tight or too loose, repeat the ad-
•
justment.
Install the removed parts (see appropriate chapters).
Steering Stem Bearing Lubrication
the steering stem (see Stem, Stem Bearing Re• Remove
moval in the Steering chapter).
a high flash-point solvent, wash the upper and
• Using
lower ball bearings [A] in the cages, and wipe the upper
•
•
•
•
and lower outer races, which are press-fitted into the
frame head pipe, clean off grease and dirt.
Visually check the outer races and the ball bearings.
Replace the bearing assemblies if they show wear or
damage.
Pack the upper and lower ball bearings in the cages with
grease, and apply a light coat of grease to the upper and
lower outer races.
Install the steering stem (see Stem, Stem Bearing Installation in the Steering chapter).
Adjust the steering (see Steering Play Adjustment).
PERIODIC MAINTENANCE 2-43
Periodic Maintenance Procedures
Electrical System
Lights and Switches Operation Inspection
First Step
Set the gear position in the neutral position and side stand
to down.
Turn the ignition switch on.
The following lights should go on according to below table.
•
•
•
Meter Panel Illumination Light (LED) [A]
Meter Panel LCD [B]
Yellow Red Zone Warning Indicator Light
(LED) [C]
Goes on
(about 3 seconds)
Goes on
Goes on
(about 3 seconds)
Green Neutral Indicator Light (LED) [D]
Goes on
Red Battery Voltage Warning Indicator
Light (LED) [E]
Goes on
Red Water Temperature Warning Indicator
Light (LED) [F]
Goes on
Red Oil Pressure Warning Indicator Light
(LED) [G]
Goes on
If the light does not go on, inspect or replace the following
parts.
Battery (see Charging Condition Inspection in the Electrical System chapter)
Indicator Lights (LED) (see Meter Unit Inspection in the
Electrical System chapter)
Meter Panel Illumination Light (LED) (see Meter Unit Inspection in the Electrical System chapter)
Main Fuse 20 A (see Fuse Inspection in the Electrical
System chapter)
Ignition Switch (see Switch Inspection in the Electrical
System chapter)
Neutral Switch (see Switch Inspection in the Electrical
System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
the ignition switch off.
• Turn
all lights should go off.
• The
If the light does not go off, replace the ignition switch.
2-44 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Second Step
Turn the ignition switch on.
Turn on the turn signal switch [A] (left or right position).
The left or right turn signal lights [B] (front and rear) according to the switch position should blink.
The green turn signal indicator light (LED) [C] in the meter
unit should blink.
If the each light does not blink, inspect or replace the following parts.
Turn Signal Light Bulb (see Turn Signal Light Bulb Replacement in the Electrical System chapter)
Green Turn Signal Indicator Light (LED) (see Meter Unit
Inspection in the Electrical System chapter)
Turn Signal Switch (see Switch Inspection in the Electrical System chapter)
Turn Signal Relay (see Turn Signal Relay Inspection in
the Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
Push the turn signal switch.
The turn signal lights and green turn signal indicator light
(LED) should go off.
If the light does not go off, inspect or replace the following
parts.
Turn Signal Switch (see Switch Inspection in the Electrical System chapter)
Turn Signal Relay (see Turn Signal Relay Inspection in
the Electrical System chapter)
•
•
•
•
•
•
PERIODIC MAINTENANCE 2-45
Periodic Maintenance Procedures
Third Step
Set the dimmer switch [A] to low beam position.
Start the engine.
The following lights should go on according to below table.
•
•
•
Low Beam Headlight [B]
Goes on
City Lights [C]
Go on
Tail Lights [D]
Go on
License Plate Light [E]
Go on
Meter Illumination Light
Go on
•
•
•
•
•
If the light does not go on, inspect or replace the following
parts.
Headlight Bulb (see Headlight Bulb Replacement in the
Electrical System chapter)
Dimmer Switch (see Switch Inspection in the Electrical
System chapter)
Headlight Relay (see Relay Circuit Inspection in the
Electrical System chapter)
City Light Bulb (see City Light Bulb Replacement in the
Electrical System chapter)
License Plate Light Bulb (see License Plate Light Bulb
Replacement in the Electrical System chapter)
Tail/Brake Light (LED) (see Tail/Brake Light (LED) Removal/Installation in the Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
Set the dimmer switch to high beam position.
The high beam headlight should go on.
The blue high beam indicator light (LED) [F] should go on.
If the high beam headlight and/or blue high beam indicator
light (LED) does not go on, inspect or replace the following
parts.
Headlight Bulb (see Headlight Bulb Replacement in the
Electrical System chapter)
Dimmer Switch (see Switch Inspection in the Electrical
System chapter)
Turn the engine stop switch to stop position.
The headlight should go off.
If the headlights and blue high beam indicator light (LED)
does go on, inspect or replace the headlight relay (see
Relay Circuit Inspection in the Electrical System chapter).
Headlight Aiming Inspection
The headlight beam is adjustable vertically. If adjusted
too low, nor high beam will illuminate the road far enough
ahead. If adjusted too high, the high beam will fail to illuminate the road close ahead, and the low beam will dazzle
oncoming drivers.
Inspect the headlight beam for aiming.
Adjust the headlight up or down by turning the adjuster
[A].
After adjusting the headlight beam, make sure to tighten
the adjusting bolt securely.
•
•
•
2-46 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
NOTE
○On high beam, the brightest point [A] should be slightly
below horizontal with the motorcycle on its wheels and
the rider seated. Adjust the headlight to the proper angle according to local regulations.
Engine Stop Switch Operation Inspection
First Step
Turn the ignition switch on.
Set the gear position in 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 engine stop
switch (see Switch Inspection in the Electrical System
chapter).
•
•
•
•
•
Second Step
Turn the ignition switch on.
Set the gear position in the neutral position.
Turn the engine stop switch to run position [A].
Push the starter button and start the engine.
Turn the engine stop switch to stop position.
Immediately the engine should be stop.
If the engine does not stop, inspect or replace the engine
stop switch (see Switch Inspection in the Electrical System chapter).
•
•
•
•
•
•
Spark Plug Replacement
the spark plug cap.
• Disconnect
Remove
the
spark plugs using the plug wrench [A] verti• cally.
Central:
14 mm (0.55 in.) plug wrench
Side:
16 mm (0.63 in.) plug wrench
○When removing the central spark plug, remove the left
•
side spark plug cap.
Replace the spark plugs with new ones.
Standard Spark Plug
Type:
Central:
BOSCH VR5NE
Side:
Champion P-RG6HCC
PERIODIC MAINTENANCE 2-47
Periodic Maintenance Procedures
the spark plug vertically into the spark plug hole
• Insert
with the spark plug installed in the plug wrench [A], and
finger-tighten it first.
NOTICE
If tightening the spark plug with the wrench inclined, the insulator of the spark plug may break.
• Tighten:
Torque - Spark Plugs: 14 N·m (1.4 kgf·m, 10 ft·lb)
the spark plug cap.
• Install
After
installation,
the spark plug is installed se• curely by pulling upbeitsure
lightly.
Starter Lockout Switch Inspection
• Remove:
Starter Lockout Switch Mounting Screws [A]
Starter Lockout Switch [B]
inspect the switch tab [A] of the starter lockout
• Visually
switch.
Replace the starter lockout switch if any damages are noticed.
Ignition Switch Contact Cleaning
WD-40 to the ignition key hole [A] to clean the ig• Spray
nition switch contact.
2-48 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Wiring Harness Inspection
the following to avoid wiring harness failures.
•1.Inspect
Ensure wiring harness is properly routed and clamped.
2. Ensure firm connections of all connectors.
3. Ensure wiring harness connectors are placed properly in
bellows provided at headlight cover and tail/brake light
side.
4. Ensure correct routing of wiring harness which will avoid
pinching of wires.
5. Do not apply pressurized water jet on wiring harness.
6. Do not fit extra electrical accessories. Such as –
Remote
Extra and bigger horns
Musical brake light
Buzzer
Higher wattage Headlight bulb
Turn signal light operating all 4 side indicators simultaneously
7. Do not replace fuse with higher capacity fuse.
8. Do not cut wiring conduit/wires midway.
9. Never remove conduit from wiring harness.
10.Never bypass fuse.
11. Do not repair wiring harness instead replace for safety.
12.Do not ground any wire for checking current-spark.
Others
Silencer Drain Hole Cleaning
inspect the silencer drain hole [A].
• Visually
If the drain hole is clogged up with the carbon, remove the
carbon to open the drain hole.
Engine Breather hose Replacement
• Remove:
Right Side Cover (see Side Cover Removal in the Frame
•
•
chapter)
Clutch Cable Lower End (Cable Removal in the Clutch
chapter)
Clutch Cable Bracket (Clutch Cover Removal in the
Clutch chapter)
Clamps [A]
Engine Breather Hose [B]
Replace the engine breather hose with a new one.
Install the removed parts (see appropriate chapters).
PERIODIC MAINTENANCE 2-49
Periodic Maintenance Procedures
Chassis Parts Lubrication
lubricating each part, clean off any rusty spots with
• Before
rust remover and wipe off any grease, oil, dirt, or grime.
• Lubricate the points listed below with indicated lubricant.
○Whenever
NOTE
the vehicle has been operated under
wet or rainy conditions, or especially after using a
high-pressure water spray, perform the general lubrication.
Pivots: Lubricate with Grease.
Brake Lever
Brake Pedal
Clutch Lever
Rear Master Cylinder Push Rod Joint Pin
Side Stand
Points: Lubricate with Grease.
Clutch Inner Cable Upper and Lower Ends [A]
Throttle Inner Cable Upper and Lower Ends
Cables: Lubricate with Rust Inhibitor.
Clutch Cable
Throttle Cable
Lubricate the cables by seeping the oil between the cable
and housing.
○The cable may be lubricated by using a commercially
available pressure cable lubricator with an aerosol cable
lubricant.
•
the cable disconnected at both ends, the inner cable
• With
should move freely [A] within the cable housing.
If cable movement is not free after lubricating, if the cable
is frayed [B], or if the cable housing is kinked [C], replace
the cable.
2-50 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Condition of Bolts, Nuts and Fasteners Tightness
Inspection
the tightness of the bolts and nuts listed here. Also,
• Check
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).
If there are loose fasteners, retighten them to the specified torque following the specified tightening sequence.
Refer to the appropriate chapter for torque specifications.
If torque specifications are not in the appropriate chapter,
see the Standard Torque Table. For each fastener, first
loosen it by 1/2 turn, then tighten it.
If cotter pins are damaged, replace them with new ones.
Bolt, Nut and Fastener to be checked
Engine:
Clutch Lever Pivot Bolt Locknut
Engine Mounting Bolts and Nuts
Exhaust Pipe Holder Nuts
Muffler Body Clamp Bolt
Muffler Body Mounting Bolt
Radiator Bolts and Nuts
Wheels:
Front Axle Nut
Rear Axle Nut
Brakes:
Brake Lever Pivot Bolt Locknut
Brake Pedal Bolt
Caliper Mounting Bolts
Front Master Cylinder Clamp Bolt
Rear Master Cylinder Mounting Bolts
Rear Master Cylinder Push Rod Joint Cotter Pin
Suspension:
Front Fork Clamp Bolt (Upper)
Front Fork Clamp Bolt (Lower)
Rear Shock Absorber Bolts
Swingarm Pivot Shaft Nut
Steering:
Handlebar Holder Bolts
Steering Stem Head Bolt
Others:
Footpeg Bracket Bolts
Front Fender Mounting Bolts
Side Stand Bolt
Side Stand Bracket Bolts
FUEL SYSTEM 3-1
Fuel System
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Throttle Grip and Cable ..........................................................................................................
Free Play Inspection .........................................................................................................
Free Play Adjustment........................................................................................................
Throttle Cable Removal ....................................................................................................
Throttle Cable Installation .................................................................................................
Throttle Cable Lubrication.................................................................................................
Carburetor ..............................................................................................................................
Idle Speed Inspection .......................................................................................................
Idle Speed Adjustment......................................................................................................
Pilot Screw Adjustment .....................................................................................................
Float Height Inspection .....................................................................................................
Fuel System Inspection.....................................................................................................
Carburetor Removal..........................................................................................................
Carburetor Installation.......................................................................................................
Carburetor Disassembly ...................................................................................................
Carburetor Assembly ........................................................................................................
Carburetor Inspection .......................................................................................................
Carburetor Cleaning..........................................................................................................
Air Cleaner..............................................................................................................................
Air Cleaner Element Removal/Installation ........................................................................
Air Cleaner Element Cleaning and Inspection ..................................................................
Air Cleaner Housing Removal...........................................................................................
Air Cleaner Housing Installation........................................................................................
Air Cleaner Drain Cap Inspection .....................................................................................
Fuel Tank ................................................................................................................................
Fuel Tank Removal ...........................................................................................................
Fuel Tank Installation ........................................................................................................
Fuel Tank Cap Inspection .................................................................................................
Fuel Tap Removal .............................................................................................................
Fuel Tap Installation ..........................................................................................................
Fuel Tap Inspection...........................................................................................................
Fuel Tap and Fuel Tank Cleaning .....................................................................................
Fuel Filter................................................................................................................................
Fuel Filter Removal...........................................................................................................
Fuel Filter Installation........................................................................................................
Fuel Filter Inspection.........................................................................................................
3-2
3-6
3-7
3-7
3-7
3-7
3-8
3-8
3-9
3-9
3-9
3-9
3-9
3-10
3-10
3-12
3-13
3-13
3-14
3-16
3-17
3-17
3-17
3-17
3-17
3-18
3-19
3-19
3-21
3-21
3-22
3-22
3-22
3-23
3-24
3-24
3-24
3-24
3
3-2 FUEL SYSTEM
Exploded View
FUEL SYSTEM 3-3
Exploded View
No.
1
Fastener
Throttle Sensor Mounting Bolt
R: Replacement Parts
N·m
5.0
Torque
kgf·m
0.51
ft·lb
44 in·lb
Remarks
3-4 FUEL SYSTEM
Exploded View
FUEL SYSTEM 3-5
Exploded View
No.
1
2
3
Fastener
Fuel Tap Mounting Bolts
Fuel Tank Cap Bolts
Fuel Tank Bolts
R: Replacement Parts
N·m
3.9
4.9
20
Torque
kgf·m
0.40
0.50
2.0
ft·lb
35 in·lb
43 in·lb
15
Remarks
3-6 FUEL SYSTEM
Specifications
Item
Throttle Grip and Cable
Throttle Grip Free Play
Carburetor
Make/Type
Idle Speed
Pilot Screw
Float Height
Main Jet
Main Air Jet
Jet Needle
Needle Jet
Pilot Jet (Slow Jet)
Pilot Air Jet (Slow Air Jet)
Throttle Valve Mark
Air Cleaner
Element
Standard
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
UCAL/UCD33
1 400 ±50 r/min (rpm)
2 turns out (for reference)
7.1 ±1 mm (0.28 ±0.04 in.)
#115
#1.3
T-UFSC7072
O-9M
#15
#1.4
105
Dry paper type
FUEL SYSTEM 3-7
Throttle Grip and Cable
Free Play Inspection
to the Throttle Control System Inspection in the Pe• Refer
riodic Maintenance chapter.
Free Play Adjustment
to the Throttle Control System Inspection in the Pe• Refer
riodic Maintenance chapter.
Throttle Cable Removal
the front master cylinder clamp bolts [A].
• Loosen
Move
[B]
the front master cylinder [C].
•
the switch housing screws [A].
• Remove
Separate
the right switch housing [B].
•
• Remove the throttle cable tip (upper) [A].
the throttle cable locknut [A].
• Loosen
the throttle cable [B] from the right switch hous• Remove
ing.
3-8 FUEL SYSTEM
Throttle Grip and Cable
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System chapter)
Plug [A]
[A] the throttle cable [B].
• Remove
Remove
the
throttle cable tip (lower) [C].
• Remove the throttle
cable from the frame.
•
Throttle Cable Installation
is the reverse of removal.
• Installation
grease to the throttle cable tips.
• Apply
Run
the
cable in accordance with the Cable, Wire,
• and Hosethrottle
Routing section in the Appendix chapter.
the projection [A] into a hole [B] of the handlebars to
• Fit
install the right switch housing.
installation, adjust the throttle cable free play (see
• After
Throttle Control System Inspection in the Periodic Maintenance chapter).
WARNING
Operation with incorrectly routed or improperly adjusted cable could result in an unsafe riding condition. Be sure the cable is routed correctly and properly adjusted.
Throttle Cable Lubrication
to the Chassis Parts Lubrication in the Periodic
• Refer
Maintenance chapter.
FUEL SYSTEM 3-9
Carburetor
Idle Speed Inspection
to the Idle Speed Inspection in the Periodic Main• Refer
tenance chapter.
Idle Speed Adjustment
to the Idle Speed Adjustment in the Periodic Main• Refer
tenance chapter.
Pilot Screw Adjustment
NOTICE
The pilot screw [A] is set at the factory and should
not be removed. But if necessary, remove the pilot
screw as follows.
in the pilot screw by using a flat tip screwdriver and
• Turn
count the number of turns until it seats fully but not tightly.
the pilot screw.
• Remove
install, turn in the pilot screw until it seats fully but not
• To
tightly, and then back it out the same number of turns
counted during disassembly. This is to set the screw to
its original position.
NOTE
○The number of turns of pilot screw has various value in
individual carburetor. The values given in the Specifications should be used only when the original number
of the turns is unavailable.
Float Height Inspection
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Always stop the
engine and do not smoke. Make sure the area is
well ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
the carburetor (see Carburetor Removal).
• Remove
the fuel of the carburetor.
• Drain
Remove
the screws [A] and float bowl [B].
•
3-10 FUEL SYSTEM
Carburetor
the height [A] between the float bowl mating sur• Measure
face [B] and the float upper surface [C].
NOTE
○Measure the height with the carburetor upside down.
○Do not push the needle rod in during the float height
measurement.
Float Height
Standard: 7.1 ±1 mm (0.28 ±0.04 in.)
•
•
If the float level is incorrect, adjust the float level as follows.
Bend the tang [A] on the float arm very slightly to change
the float height. Increasing the float height lowers the fuel
level and decreasing the float height raises the fuel level.
If the float level cannot be adjusted by this method, the
float or the float valve is damaged.
Install the removed parts (see appropriate chapters).
Fuel System Inspection
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Always stop the
engine and do not smoke. Make sure the area is
well ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
the fuel tap to “OFF.”
• Turn
Place
a suitable container beneath the carburetor drain
• hose [A].
a flat tip screwdriver, turn out the drain screw [B]
• Using
a few turns and drain the fuel to a suitable container and
•
check to see if water or dirt come out.
If any water or dirt appears during the above inspection,
clean the fuel system (see Carburetor Cleaning, Fuel Tap
and Fuel Tank Cleaning).
Tighten the drain screw securely.
Carburetor Removal
WARNING
Gasoline is extremely flammable and can be explosive 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;
this includes any appliance with a pilot light. Do not
smoke. Turn the ignition switch off. Be prepared for
fuel spillage; any spilled fuel must be completely
wiped up immediately.
FUEL SYSTEM 3-11
Carburetor
the fuel tap to “OFF.”
• Turn
Remove:
• Fuel Tank (see Fuel Tank Removal in the Fuel System
•
•
chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System chapter)
Throttle Cable Tip (Lower) (see Throttle Cable Removal)
Slide the clamp [A].
Disconnect the fuel hose [B].
the plug [A].
• Remove
Move
[B]
the idle adjusting screw [C] from the clutch cable
• bracket [D].
the throttle sensor connector [A].
• Disconnect
Loosen
the
carburetor
clamp screw (rear) [B].
• Remove the carburetorholder
[C].
•
removing the carburetor, stuff pieces of lint-free,
• After
clean cloth into the carburetor holder to keep dirt out of
the engine.
WARNING
If dirt or dust is allowed to pass through into the
carburetor, the throttle may become stuck, possibly
causing accident. Replace the air cleaner element
according to the maintenance chart.
NOTICE
If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.
3-12 FUEL SYSTEM
Carburetor
Carburetor Installation
is the reverse of removal.
• Installation
the carburetor projection [A] into the groove [B] of the
• Fit
carburetor holder [C].
that the carburetor is installed horizontally.
• Check
Tighten
the carburetor holder clamp screw (rear) securely.
•
the leads, cables and hoses correctly (see Cable,
• Run
Wire, and Hose Routing section in the Appendix chapter).
the removed parts (see appropriate chapters).
• Install
Turn
the
tap to “ON or RES”, and check for fuel leak• age fromfuel
the carburetor.
WARNING
Fuel spilled from the carburetor is hazardous.
the following items if necessary.
• Adjust
Throttle Cable (see Throttle Control System Inspection
in the Periodic Maintenance chapter)
Idle Speed (see Idle Speed Inspection in the Periodic
Maintenance chapter)
FUEL SYSTEM 3-13
Carburetor
Carburetor Disassembly
the carburetor (see Carburetor Removal).
• Remove
the following parts from the carburetor body.
• Remove
Remove
the float bowl (see Float Height Inspection).
•
NOTICE
The pilot screw is set at the factory and should not
be removed. But if necessary, refer to the Pilot
Screw Adjustment to remove the pilot screw.
NOTE
○Before removing the throttle sensor, mark the carbure-
tor body and sensor so that it can be installed later in
the same position.
Pilot Screw [1]
Throttle Sensor Screw [2]
Throttle Sensor [3]
Choke Lever Screw [4]
Choke Lever [5]
Choke Plunger [6]
Float Pin Screw [7]
Float Pin [8]
Float [9]
Float Valve Needle [10]
Pilot Jet (Slow Jet) [11]
Main Jet [12]
Needle Jet Holder [13]
Chamber Cover Screws [14]
Chamber Cover [15]
Spring [16]
Vacuum Piston with Diaphragm [17]
Spring Seat [18]
Spring [19]
Washer [20]
Snap Ring [21]
Collar [22]
Jet Needle [23]
Carburetor Assembly
is the reverse of disassembly.
• Assembly
Clean
the
disassembly
parts before assembling.
•
3-14 FUEL SYSTEM
Carburetor
• Install:
Jet Needle
Washer
Spring
Spring Seat [A]
Install
the spring seat by turning it.
○
the choke lever [A] to the choke plunger [B].
• Fit
Fit
the groove [C] of the choke lever to the projection [D]
• of the
carburetor.
Tighten
the choke lever screw securely.
•
the groove [A] of the throttle sensor to the throttle
• Engage
shaft [B].
the throttle sensor position (see Throttle Sensor
• Adjust
Inspection in the Electrical System chapter).
Carburetor Inspection
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Always stop the
engine and do not smoke. Make sure the area is
well ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
the carburetor (see Carburetor Removal).
• Remove
Turn
the
throttle
pulley [A] to check that the throttle valve
• [B] moves smoothly
and returns by spring pressure.
•
•
•
If the throttle valve does not move smoothly, replace the
carburetor.
Before disassembling the carburetor, check the fuel level
(see Service Fuel Level Inspection).
If the fuel level is incorrect, inspect the rest of the carburetor before correcting it.
Disassemble the carburetor (see Carburetor Disassembly).
Clean the carburetor (see Carburetor Cleaning).
FUEL SYSTEM 3-15
Carburetor
the float valve needle [A]. It should be smooth with• Check
out any grooves, scratches, or tears.
•
If the tip is damaged [B], replace the float valve needle.
Push the rod [C] in the float valve needle, then release it.
If the rod does not come out fully by spring tension, replace the float valve needle.
Push and Release [D]
the main jet [A], needle jet holder [B] and pilot jet
• Check
[C] for any damage.
If they are damaged, replace them with new ones.
the choke plunger [A] for any damage.
• Check
If the choke plunger is damaged, replace the carburetor.
the vacuum piston [A] for scratches and abnormal
• Inspect
wear.
•
If it is badly scratched or worn, replace the vacuum piston.
Inspect the inside of the carburetor body [B] for these
same faults.
If it is badly scratched or worn, replace the carburetor.
the jet needle [A] and needle jet holder [B] for wear.
• Check
A worn jet needle or needle jet holder should be replaced.
3-16 FUEL SYSTEM
Carburetor
the tapered portion [A] of the pilot screw [B] for
• Check
wear or damage.
If the pilot screw is worn or damaged on the tapered portion, it will prevent the engine from idling smoothly. Replace it.
Carburetor Cleaning
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Always stop the
engine and do not smoke. Make sure the area is
well ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
NOTICE
Do not use compressed air on an assembled carburetor, the float may be deformed by the pressure.
Remove as many rubber or plastic parts from the
carburetor as possible before cleaning the carburetor with a cleaning solution.
This will prevent damage or deterioration of the
parts.
Do not use a strong carburetor cleaning solution
which could attack the plastic parts; instead, use
a mild high flash-point cleaning solution safe for
plastic parts.
Do not use wire or any other hard instrument to
clean carburetor parts, especially jets, as they may
be damaged.
the carburetor (see Carburetor Disassem• Disassemble
bly).
all the metal parts in a carburetor cleaning solu• Immerse
tion.
the parts in water.
• Rinse
After
the
parts are cleaned, dry them with compressed air.
• Blow through
the air and fuel passages with compressed
• air.
• Assemble the carburetor (see Carburetor Assembly).
FUEL SYSTEM 3-17
Air Cleaner
Air Cleaner Element Removal/Installation
to the Air Cleaner Element Replacement in the Pe• Refer
riodic Maintenance chapter.
Air Cleaner Element Cleaning and Inspection
to the Air Cleaner Element Cleaning in the Periodic
• Refer
Maintenance chapter.
Air Cleaner Housing Removal
• Remove:
Fuel Tank (see Fuel Tank Removal)
•
•
Air Cleaner Cover (see Air Cleaner Element Replacement in the Periodic Maintenance chapter)
Fuel Filter (see Fuel Filter Removal)
Loosen the air cleaner duct clamp screw [A].
Move the air cleaner duct clamp screw backward.
the clamp [A].
• Slide
Disconnect
breather hose [B].
• Remove thethe
air cleaner housing mounting bolts [C].
•
the clamp [A].
• Slide
Disconnect
cleaner drain hose [B].
• Remove thetheair aircleaner
housing.
•
Air Cleaner Housing Installation
is the reverse of removal.
• Installation
Fit
the
groove
the air cleaner duct clamp [B] to the
• projection [C] of[A]theof air
cleaner housing [D].
Run
the
hoses
correctly
(see Cable, Wire, and Hose Rout• ing section in the Appendix
chapter).
Install
the
removed
parts
(see
appropriate chapters).
•
3-18 FUEL SYSTEM
Air Cleaner
Air Cleaner Drain Cap Inspection
check the drain plug [A] if the water or oil accu• Visually
mulates.
If any water or oil accumulates in the drain plug, remove
the drain plug and drain it.
FUEL SYSTEM 3-19
Fuel Tank
Fuel Tank Removal
WARNING
Gasoline is extremely flammable and can be explosive 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;
this includes any appliance with a pilot light. Do not
smoke. Turn the ignition switch off. Disconnect the
battery (–) terminal. To avoid fuel spills, draw it from
the tank when the engine is cold. Be prepared for
fuel spillage; any spilled fuel must be completely
wiped up immediately.
• Turn the fuel tap [A] to “OFF.”
the fuel tank cover (see Fuel Tank Cover Re• Remove
moval in the Frame chapter).
the side covers (see Side Cover Removal in the
• Remove
Frame chapter).
the clamp [A].
• Slide
Disconnect
tank breather hose [B].
• Free the fuelthetankfuelbreather
hose from the clamps [C].
• Disconnect the fuel level sensor
lead connector [D].
•
3-20 FUEL SYSTEM
Fuel Tank
• Remove the fuel tank bolts [A].
the clamp [A].
• Slide
Disconnect
the fuel hose [B].
• Slide the clamp
[C].
• Disconnect the fuel
• Remove the fuel tanktank[E].drain hose [D].
• Drain the fuel.
•○Place a suitable container under the fuel tank.
○Turn the fuel tap to “RES” and drain the fuel.
FUEL SYSTEM 3-21
Fuel Tank
Fuel Tank Installation
is the reverse of removal.
• Installation
that the dampers [A] and grommets [B] are in place
• Check
on the flame and fuel tank.
If the dampers and grommets are damaged or deteriorated, replace them.
the hoses correctly (see Cable, Wire, and Hose Rout• Run
ing section in the Appendix chapter).
sure clamp the fuel hose [A] to the fuel tap.
• Be
Install
the removed parts (see appropriate chapters).
•
Torque - Fuel Tank Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb)
Fuel Tank Cap Inspection
the tank cap.
• Open
Visually
• damage.inspect the gasket [A] on the tank cap for any
•
•
Replace the cap if the gasket is damaged.
Check to see if the water drain pipe [B] in the tank is not
clogged.
If it is clogged, remove the tank and drain it, and then blow
the pipe with compressed air.
Check that the tank cap [C] to move smoothly.
If the tank cap does not move smoothly or noise is found,
replace it with a new one.
3-22 FUEL SYSTEM
Fuel Tank
Fuel Tap Removal
the fuel tank (see Fuel Tank Removal).
• Remove
• Remove the snap pin [A] and knob [B].
the fuel tap mounting bolts [A] with nylon wash• Remove
ers and take out the fuel tap [B].
Fuel Tap Installation
• Replace the O-ring [A] with a new one.
Torque - Fuel Tap Mounting Bolts: 3.9 N·m (0.40 kgf·m, 35
in·lb)
Fuel Tap Inspection
the fuel tap (see Fuel Tap Removal).
• Remove
Check
the
• terioration.fuel tap filter screens [A] for any breaks or deIf the fuel tap screens have any breaks or deterioration,
they may allow dirt to reach the carburetor, causing poor
running. Replace the fuel tap with a new one.
FUEL SYSTEM 3-23
Fuel Tank
Fuel Tap and Fuel Tank Cleaning
WARNING
Gasoline and low flash-point solvents can be
flammable and/or explosive and cause severe
burns. Clean the tank in a well-ventilated area,
and take care that there are no sparks or flame
anywhere near the working area; this includes any
appliance with a pilot light. Do not use gasoline or
a low flash-point solvent to clean the tank.
the fuel tank and drain the fuel (see Fuel Tank
• Remove
Removal).
some high flash-point solvent into the fuel tank and
• Pour
shake the tank to remove dirt and fuel deposits.
the solvent out of the tank.
• Draw
Remove
• moval). the fuel tap from the tank (see Fuel Tap Rethe fuel tap filter screens in a high flash-point sol• Clean
vent.
high flash-point solvent through the tap in all lever
• Pour
positions.
the tank and tap with compressed air.
• Dry
Install
• tion). the fuel tap on the fuel tank (see Fuel Tap Installa-
3-24 FUEL SYSTEM
Fuel Filter
Fuel Filter Removal
• Remove:
Fuel Tank (see Fuel Tank Removal)
Fuel Filter Screw [A]
the clamp [A].
• Slide
Disconnect
[B].
• Remove thethefuelfuelfilterhose
[C].
•
Fuel Filter Installation
• Installation is the reverse of removal.
Fuel Filter Inspection
inspect the fuel filter [A].
• Visually
If the filter is clear with no signs of dirt or other contamination, it is OK and need not be replaced.
If the filter is dark or looks dirty, replace it with a new one.
Also check the rest of the fuel system for contamination.
COOLING SYSTEM 4-1
Cooling System
Table of Contents
Exploded View........................................................................................................................
Coolant Flow Chart.................................................................................................................
Specifications .........................................................................................................................
Special Tool ............................................................................................................................
Coolant ...................................................................................................................................
Coolant Deterioration Inspection.......................................................................................
Coolant Level Inspection...................................................................................................
Coolant Draining ...............................................................................................................
Coolant Filling ...................................................................................................................
Pressure Testing ...............................................................................................................
Cooling System Flushing ..................................................................................................
Coolant Reserve Tank Removal .......................................................................................
Coolant Reserve Tank Installation ....................................................................................
Water Pump............................................................................................................................
Water Pump Cover Removal ............................................................................................
Water Pump Cover Installation .........................................................................................
Impeller Removal ..............................................................................................................
Impeller Installation ...........................................................................................................
Impeller Inspection............................................................................................................
Radiator ..................................................................................................................................
Radiator and Radiator Fan Removal ................................................................................
Radiator and Radiator Fan Installation .............................................................................
Radiator Inspection ...........................................................................................................
Radiator Cap Inspection ...................................................................................................
Radiator Filler Neck Inspection .........................................................................................
Thermostat .............................................................................................................................
Thermostat Removal.........................................................................................................
Thermostat Installation......................................................................................................
Thermostat Inspection ......................................................................................................
Hoses and Pipes ....................................................................................................................
Hose Installation ...............................................................................................................
Hose Inspection ................................................................................................................
Water Temperature Sensor ....................................................................................................
Water Temperature Sensor Removal................................................................................
Water Temperature Sensor Installation.............................................................................
Water Temperature Sensor Inspection .............................................................................
4-2
4-4
4-5
4-6
4-7
4-7
4-7
4-7
4-7
4-7
4-8
4-8
4-8
4-9
4-9
4-9
4-10
4-10
4-10
4-11
4-11
4-12
4-13
4-13
4-14
4-15
4-15
4-15
4-15
4-17
4-17
4-17
4-18
4-18
4-18
4-18
4
4-2 COOLING SYSTEM
Exploded View
COOLING SYSTEM 4-3
Exploded View
No.
1
2
3
4
5
6
7
8
9
Fastener
Radiator Mounting Nuts
Water Temperature Sensor
Thermostat Cover Bolts
Radiator Fairing Bolts
Radiator Bracket Bolts
Water Pump Cover Bolts
Coolant Drain Bolt
Water Pump Impeller Nut
Water Pipe Bolts
L: Apply a non-permanent locking agent.
R: Replacement Parts
N·m
11
13
9.8
8.8
11
11
9.8
7.8
9.8
Torque
kgf·m
1.1
1.3
1.0
0.90
1.1
1.1
1.0
0.80
1.0
ft·lb
97 in·lb
115 in·lb
87 in·lb
78 in·lb
97 in·lb
97 in·lb
87 in·lb
69 in·lb
87 in·lb
Remarks
L
L
L
4-4 COOLING SYSTEM
Coolant Flow Chart
COOLING SYSTEM 4-5
Specifications
Item
Coolant Provided when Shipping
Type (Recommended)
Color
Mixed Ratio
Freezing Point
Total Amount
Radiator Cap
Relief Pressure
Thermostat
Valve Opening Temperature
Valve Full Opening Lift
Standard
Permanent type of antifreeze (soft water and ethylene
glycol plus corrosion and rust inhibitor chemicals for
aluminum engines and radiators)
Green
Soft water 50%, coolant 50%
–35°C (–31°F)
1.0 L (1.1 US qt) (Reserve tank full level, including
radiator and engine)
137 kPa (1.4 kgf/cm², 20 psi)
86 ∼ 90°C (187 ∼ 194°F)
Full open: 94 ∼ 98°C (201 ∼ 208°F)
6 mm (0.24 in.) or more at 96°C (205°F)
4-6 COOLING SYSTEM
Special Tool
Box Wrench, 18 mm:
57001-E001
COOLING SYSTEM 4-7
Coolant
Coolant Deterioration Inspection
inspect the coolant in the coolant reserve tank
• Visually
[A].
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.
If the coolant gives off an abnormal smell, check for a
cooling system leak. It may be caused by exhaust gas
leaking into the cooling system.
Coolant Level Inspection
to the Coolant Level Inspection in the Periodic Main• Refer
tenance chapter.
Coolant Draining
to the Coolant Change in the Periodic Maintenance
• Refer
chapter.
Coolant Filling
to the Coolant Change in the Periodic Maintenance
• Refer
chapter.
Pressure Testing
• Remove:
Fuel Tank Cover (see Fuel Tank Cover Removal in the
Frame chapter)
Radiator Cap [A]
the cooling system pressure tester [A] on the filler
• Install
neck.
NOTE
○Wet the cap sealing surfaces with water or coolant to
prevent pressure leaks.
up pressure in the system carefully until the pres• Build
sure reaches 137 kPa (1.4 kgf/cm², 20 psi).
NOTICE
During pressure testing, do not exceed the pressure for which the system is designed. The maximum pressure is 137 kPa (1.4 kgf/cm², 20 psi).
the gauge for at least 6 seconds.
• Watch
If the pressure holds steady, the system is all right.
•
•
If the pressure drops and no external source is found,
check for internal leaks. Droplets in the engine oil indicate
internal leakage. Check the cylinder head gasket and
water pump.
Remove the pressure tester, replenish the coolant, and
install the radiator cap.
Install the fuel tank cover (see Fuel Tank Cover Installation in the Frame chapter).
4-8 COOLING SYSTEM
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 cooling system. If this accumulation is not removed, it will clog
up the water passage and considerable reduce the efficiency of the cooling system.
Drain the cooling system (see Coolant Change in the Periodic Maintenance chapter).
Fill the cooling system with fresh water mixed with a flushing compound.
•
•
NOTICE
Do not use a flushing compound which is harmful to
the aluminum engine and radiator. Carefully follow
the instructions supplied by the manufacturer of the
cleaning product.
up the engine, and run it at normal operating tem• Warm
perature for about ten minutes.
the engine, and drain the cooling system.
• Stop
Fill
the
with fresh water.
• Warm upsystem
the
engine
and drain the system.
• Repeat the previous two
steps once more.
• Fill the system with a permanent
type coolant and bleed
• the air from the system (see Coolant
Change in the Periodic Maintenance chapter).
Coolant Reserve Tank Removal
• Remove:
Fuel Tank Cover (see Fuel Tank Cover Removal in the
•
•
•
Frame chapter)
Right Radiator Cover (see Radiator and Radiator Fan
Removal)
Slide the clamp [A].
Disconnect the radiator overflow hose [B].
Remove:
Bracket Bolts [C]
Bracket [D]
Pour the coolant into a container.
•
• Remove:
Radiator Overflow Hose [A]
Coolant Reserve Tank [B]
Coolant Reserve Tank Installation
is the reverse of removal.
• Installation
the hose correctly (see Cable, Wire, and Hose Rout• Run
ing section in the Appendix chapter).
the coolant reserve tank with coolant (see Coolant
• Fill
Change in the Periodic Maintenance chapter).
COOLING SYSTEM 4-9
Water Pump
Water Pump Cover Removal
the coolant (see Coolant Change in the Periodic
• Drain
Maintenance chapter).
the water pipe bolts [A].
• Remove
Disconnect
the water pipe [B].
•
• Remove:
Water Pump Cover Bolts [A]
Water Pump Cover [B]
Water Pump Cover Installation
• Check that dowel pins [A] are in place.
the O-ring [A] with a new one.
• Replace
the water pump cover.
• Install
Tighten:
•
Torque - Water Pump Cover Bolts: 11 N·m (1.1 kgf·m, 97
in·lb)
the O-ring [A] with a new one.
• Replace
the water pipe.
• Install
Apply
a
locking agent to the threads of
• the waternon-permanent
pipe bolts and tighten them.
Torque - Water Pipe Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
the cooling system (see Coolant Change in the Peri• Fill
odic Maintenance chapter).
4-10 COOLING SYSTEM
Water Pump
Impeller Removal
• Remove:
Water Pump Cover (see Water Pump Cover Removal)
Water Pump Impeller Nut [A] and Washer
Impeller [B]
Impeller Installation
is the reverse of removal.
• Installation
a non-permanent locking agent to the threads of
• Apply
the water pump impeller nut and tighten it.
Torque - Water Pump Impeller Nut: 7.8 N·m (0.80 kgf·m, 69
in·lb)
the water pump cover (see Water Pump Cover In• Install
stallation).
Impeller Inspection
the water pump cover (see Water Pump Cover
• Remove
Removal).
inspect the impeller [A].
• Visually
If the surface is corroded or if the blades are damaged,
replace the impeller.
COOLING SYSTEM 4-11
Radiator
Radiator and Radiator Fan Removal
the coolant (see Coolant Change in the Periodic
• Drain
Maintenance chapter).
the right radiator cover screws [A].
• Remove
Clear
the
• cover [C]. projection [B] and remove the right radiator
the left radiator cover in the same manner as the
• Remove
right radiator cover.
the coolant reserve tank (see Coolant Reserve
• Remove
Tank Removal).
the clamp [A].
• Slide
Disconnect:
• Water Hose [B]
•
Radiator Fan Motor Lead Connector [C]
Remove the radiator mounting nut [D] and washer.
• Remove:
Horn Bracket Bolt [A]
•
•
Washer [B]
Disconnect:
Horn Connectors [C]
Remove:
Horn [D] with Horn Bracket
Radiator Mounting Nut [E] and Washer
the clamp [A].
• Slide
the water hose [B].
• Disconnect
Remove
the
radiator mounting nut [C] and washer.
•
• Remove:
Radiator Mounting Nut [A] and Washer
Radiator [B]
NOTICE
Do not touch the radiator core. This could damage
the radiator fins, resulting in loss of cooling efficiency.
4-12 COOLING SYSTEM
Radiator
• Remove:
Radiator Fan Mounting Nuts [A]
Radiator Fan [B]
• Remove:
Radiator Fairing Bolts [A]
Radiator Fairing [B]
Radiator and Radiator Fan Installation
is the reverse of removal.
• Installation
the leads, cables and hoses correctly (see Cable,
• Run
Wire, and Hose Routing section in the Appendix chapter).
• Tighten:
Torque - Radiator Fairing Bolts: 8.8 N·m (0.90 kgf·m, 78
in·lb)
Radiator Mounting Nuts: 11 N·m (1.1 kgf·m, 97
in·lb)
• Check that the damper [A] is in place on the radiator cover.
the damper [A] to the groove [B].
• Fit
Tighten
radiator cover screws securely.
• Install thetheremoved
parts (see appropriate chapters).
•
COOLING SYSTEM 4-13
Radiator
Radiator Inspection
the radiator (see Radiator and Radiator Fan Re• Remove
moval).
the radiator core.
• Check
If there are obstructions to air flow, remove them.
If the corrugated fins [A] are deformed, carefully
straighten them.
If the air passages of the radiator core are blocked more
than 20% by unremovable obstructions or irreparably deformed fins, replace the radiator with a new one.
NOTICE
When cleaning the radiator with steam cleaner, be
careful of the following to prevent radiator damage:
Keep the steam gun [A] away more than 0.5 m (1.6
ft) [B] from the radiator core.
Hold the steam gun perpendicular [C] (not oblique
[D]) to the core surface.
Run the steam gun, following the core fin direction.
Radiator Cap Inspection
• Remove:
Fuel Tank Cover (see Fuel Tank Cover Removal in the
•
Frame chapter)
Radiator Cap
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
radiator with a new one.
• Install the cap [A] on a cooling system pressure tester [B].
NOTE
○Wet the cap sealing surfaces with water or coolant to
prevent pressure leaks.
the pressure gauge, pump the pressure tester
• Watching
to build up the pressure until the relief valve opens: the
gauge needle flicks downward. Stop pumping and measure leak time at once. The relief valve must open within
the specified range in the table below and the gauge hand
must remain within the same range at least 6 seconds.
Radiator Cap Relief Pressure
Standard: 137 kPa (1.4 kgf/cm², 20 psi)
If the cap can not hold the specified pressure or if it holds
too much pressure, replace the radiator with a new one.
4-14 COOLING SYSTEM
Radiator
Radiator Filler Neck Inspection
• Remove:
Fuel Tank Cover (see Fuel Tank Cover Removal in the
•
•
Frame chapter)
Radiator Cap
Check the radiator filler neck for signs of damage.
Check the condition of the top and bottom sealing seats
[A] in the filler neck. They must be smooth and clean for
the radiator cap to function properly.
COOLING SYSTEM 4-15
Thermostat
Thermostat Removal
• Remove:
Radiator (see Radiator and Radiator Fan Removal)
Thermostat Cover Bolts [A]
Thermostat Cover [B]
• Remove:
Thermostat [A]
Thermostat Installation
is the reverse of removal.
• Installation
a non-permanent locking agent to the threads of
• Apply
the thermostat cover bolts and tighten then.
Torque - Thermostat Cover Bolts: 9.8 N·m (1.0 kgf·m, 87
in·lb)
• Install the removed parts (see appropriate chapters).
Thermostat Inspection
the thermostat (see Thermostat Removal).
• Remove
Inspect
the
valve [A] at room temperature.
• If the valve thermostat
is open, replace the thermostat with a new
one.
4-16 COOLING SYSTEM
Thermostat
check valve opening temperature, suspend the ther• To
mostat [A] in a container of water and raise the temperature of the water.
○The thermostat must be completely submerged and must
not touch the container sides or bottom. Suspend an accurate thermometer [B] in the water so that the heat sensitive portions [C] are located in almost the same depth.
It must not touch the container, either.
If the measurement is out of the specified range, replace
the thermostat with a new one.
Thermostat Valve Opening Temperature
86 ∼ 90°C (187 ∼ 194°F)
Full open: 94 ∼ 98°C (201 ∼ 208°F)
COOLING SYSTEM 4-17
Hoses and Pipes
Hose Installation
the hoses and pipes, being careful to follow bend• Install
ing direction. Avoid sharp bending, kinking, flattening or
•
•
twisting.
Run the hoses (see Cable, Wire, and Hose Routing section in the Appendix chapter).
Install the clamp [A] as near as possible to the hose end
to clear the raised rib of the fitting. This will prevent the
hoses from working loose.
Hose Inspection
to the Radiator Hose and Pipe Inspection in the
• Refer
Periodic Maintenance chapter.
4-18 COOLING SYSTEM
Water Temperature Sensor
Water Temperature Sensor Removal
the coolant (see Coolant Change in the Periodic
• Drain
Maintenance chapter).
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System chapter)
Carburetor (see Carburetor Removal in the Fuel System
chapter)
Carburetor Holder (see Carburetor Holder Removal in
the Engine Top End chapter)
Disconnect the water temperature sensor connector [A].
•
the box wrench (special tool) [A], remove the water
• Using
temperature sensor [B].
Special Tool - Box Wrench, 18 mm: 57001-E001
Water Temperature Sensor Installation
is the reverse of removal.
• Installation
Using
the
box
wrench (special tool), tighten the water tem• perature sensor.
Special Tool - Box Wrench, 18 mm: 57001-E001
Torque - Water Temperature Sensor: 13 N·m (1.3 kgf·m, 115
in·lb)
• Install the removed parts (see appropriate chapters).
Water Temperature Sensor Inspection
to the Water Temperature Sensor Inspection in the
• Refer
Electrical System chapter.
ENGINE TOP END 5-1
Engine Top End
Table of Contents
Exploded View...................................
Specifications ....................................
Special Tools .....................................
Clean Air System (PH Model)............
Vacuum Switch Valve Removal ...
Vacuum Switch Valve Installation
Vacuum Switch Valve Operation
Inspection..................................
Vacuum Switch Valve Inspection .
Clean Air System Hoses
Inspection..................................
Cylinder Head Cover .........................
Cylinder Head Cover Removal ....
Cylinder Head Cover Installation .
Camshaft Chain Tensioner ................
Camshaft Chain Tensioner
Removal ....................................
Camshaft Chain Tensioner
Installation .................................
Camshaft ...........................................
Camshaft Removal ......................
Camshaft Installation ...................
Cam Wear Inspection ..................
Camshaft Bearing Inspection.......
Camshaft Bearing Removal .........
Camshaft Bearing Installation ......
Camshaft Sprocket Removal .......
Camshaft Sprocket Installation ....
Camshaft Chain Removal ............
Camshaft Chain Installation .........
Camshaft Chain Guide Wear
Inspection..................................
Rocker Arm, Rocker Shaft.................
Rocker Arm Removal...................
Rocker Arm Installation................
Rocker Arm and Rocker Shaft
Wear Inspection ........................
Cylinder Head....................................
5-2
5-6
5-8
5-10
5-10
5-10
5-10
5-10
5-11
5-12
5-12
5-12
5-13
5-13
5-13
5-15
5-15
5-15
5-15
5-15
5-16
5-16
5-16
5-17
5-17
5-18
5-18
5-19
5-19
5-19
5-19
5-21
Cylinder Compression
Measurement ............................
Cylinder Head Removal ...............
Cylinder Head Installation ............
Cylinder Head Cleaning ...............
Cylinder Head Warp Inspection ...
Valves ................................................
Valve Clearance Inspection .........
Valve Clearance Adjustment........
Valve Removal .............................
Valve Installation ..........................
Valve Seat Inspection ..................
Valve Seat Repair ........................
Cylinder, Piston..................................
Cylinder Removal.........................
Cylinder Installation......................
Piston Removal............................
Piston Installation.........................
Cylinder Wear Inspection.............
Piston Wear Inspection ................
Piston/Cylinder Clearance
Inspection..................................
Piston Ring, Piston Ring Groove
Wear Inspection ........................
Piston Ring Groove Width
Inspection..................................
Piston Ring Thickness Inspection
Piston Ring End Gap Inspection ..
Piston, Piston Pin, Connecting
Rod Wear Inspection.................
Carburetor Holder..............................
Carburetor Holder Removal .........
Carburetor Holder Installation ......
Muffler................................................
Muffler Body Removal..................
Muffler Body Installation...............
Exhaust Pipe Removal.................
Exhaust Pipe Installation..............
5-21
5-21
5-22
5-23
5-23
5-24
5-24
5-24
5-24
5-24
5-25
5-25
5-30
5-30
5-30
5-30
5-31
5-32
5-33
5-33
5-33
5-33
5-34
5-34
5-34
5-36
5-36
5-36
5-37
5-37
5-37
5-38
5-39
5
5-2 ENGINE TOP END
Exploded View
ENGINE TOP END 5-3
Exploded View
No.
Fastener
1
2
3
4
5
6
7
8
9
10
Cylinder Head Cover Bolts
Cylinder Head Bolts (M10)
Spark Plugs
Cylinder Head Bolts (M6)
Camshaft Sprocket Bolt
Camshaft Chain Tensioner Cap Bolt
Camshaft Chain Tensioner Mounting Bolts
Timing Inspection Cap
Exhaust Pipe Holder Studs
Rear Camshaft Chain Guide Mounting Bolt
Vacuum Switch Valve Bracket Bolts (PH
Model)
Vacuum Switch Valve Bolts (PH Model)
Vacuum Switch Valve Pipe Bolts (PH
Model)
Vacuum Switch Valve Pipe Mounting Bolt
(PH Model)
11
12
13
14
N·m
11
46
14
11
25
11
11
11
23
11
Torque
kgf·m
1.1
4.7
1.4
1.1
2.5
1.1
1.1
1.1
2.3
1.1
ft·lb
97 in·lb
34
10
97 in·lb
18
97 in·lb
97 in·lb
97 in·lb
17
97 in·lb
11
1.1
97 in·lb
8.8
0.90
78 in·lb
5.9
0.60
52 in·lb
12
1.2
106 in·lb
15. PH Model
G: Apply grease.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
R: Replacement Parts
Remarks
L
L
5-4 ENGINE TOP END
Exploded View
ENGINE TOP END 5-5
Exploded View
No.
1
2
3
4
5
6
Fastener
Exhaust Pipe Holder Nuts
Muffler Body Mounting Bolts (Upper)
Muffler Body Clamp Bolt
Muffler Body Mounting Bolts (Lower)
Exhaust Pipe Cover Screws
Muffler End Cover Screws
L: Apply a non-permanent locking agent.
R: Replacement Parts
N·m
23
11
15
11
6.9
6.9
Torque
kgf·m
2.3
1.1
1.5
1.1
0.70
0.70
ft·lb
17
97 in·lb
11
97 in·lb
61 in·lb
61 in·lb
Remarks
L
L
5-6 ENGINE TOP END
Specifications
Item
Clean Air System
Vacuum Switch Valve
Closing Pressure
Camshaft
Cam Height:
Exhaust
Intake
Rocker Arm Inside Diameter
Rocker Shaft Diameter
Cylinder Head
Cylinder Compression
Cylinder Head Warp
Valves
Valve Clearance:
Exhaust
Intake
Valve Head Thickness:
Exhaust
Intake
Valve Stem Bend
Valve Stem Diameter:
Exhaust
Intake
Valve Guide Inside
Diameter:
Exhaust
Intake
Valve Seat Cutting Angle
Valve Seating Surface:
Outside Diameter:
Exhaust
Intake
Width:
Exhaust
Intake
Valve Spring Free Length:
Exhaust
Intake
Cylinder, Piston
Cylinder Inside Diameter
Piston Diameter
Standard
Open → Close
54.7 ∼ 66.7 kPa (410 ∼ 500 mmHg)
Service Limit
– – –
30.29 mm (1.193 in.)
30.24 mm (1.191 in.)
30.34 mm (1.194 in.)
30.29 mm (1.193 in.)
10.000 ∼ 10.012 mm (0.39370 ∼ 0.39417 in.) 10.03 mm (0.3949 in.)
9.974 ∼ 9.987 mm (0.3927 ∼ 0.3932 in.)
9.96 mm (0.392 in.)
(Usable Range)
1 079 ∼ 1 275 kPa (11 ∼ 13 kgf/cm², 156 ∼
185 psi) at 320 r/min (rpm)
–––
0.07 ∼ 0.09 mm (0.0028 ∼ 0.0035 in.)
0.04 ∼ 0.06 mm (0.0016 ∼ 0.0024 in.)
0.5 mm (0.020 in.)
0.5 mm (0.020 in.)
TIR 0.01 mm (0.0004 in.)
– – –
0.05 mm (0.002 in.)
– – –
– – –
0.45 mm (0.018 in.)
0.45 mm (0.018 in.)
TIR 0.015 mm
(0.00059 in.)
4.455 ∼ 4.470 mm (0.1754 ∼ 0.1760 in.)
4.475 ∼ 4.490 mm (0.1762 ∼ 0.1768 in.)
4.445 mm (0.1750 in.)
4.465 mm (0.1758 in.)
4.500 ∼ 4.512 mm (0.1772 ∼ 0.1776 in.)
4.500 ∼ 4.512 mm (0.1772 ∼ 0.1776 in.)
30°, 45°, 60°
4.522 mm (0.1780 in.)
4.522 mm (0.1780 in.)
– – –
23.4 ∼ 23.6 mm (0.921 ∼ 0.929 in.)
23.4 ∼ 23.6 mm (0.921 ∼ 0.929 in.)
– – –
– – –
0.9 ∼ 1.1 mm (0.035 ∼ 0.043 in.)
0.9 ∼ 1.1 mm (0.035 ∼ 0.043 in.)
– – –
– – –
38.9 mm (1.53 in.)
38.9 mm (1.53 in.)
37.9 mm (1.49 in.)
37.9 mm (1.49 in.)
72.006 ∼ 72.013 mm (2.8349 ∼ 2.8352 in.)
72.043 mm (2.8363
in.)
– – –
71.964 ∼ 71.976 mm (2.8332 ∼ 2.8337 in.)
ENGINE TOP END 5-7
Specifications
Item
Piston/Cylinder Clearance
Piston Ring/Groove
Clearance:
Top
Second
Oil
Piston Ring Groove Width:
Top
Second
Piston Ring Thickness:
Top
Second
Piston Ring End Gap:
Top
Second
Oil
Piston Pin Diameter
Piston Pin Hole Diameter
Connecting Rod Small End
Inside Diameter
Standard
0.03 ∼ 0.049 mm (0.0012 ∼ 0.0019 in.)
Service Limit
0.09 mm (0.0035 in.)
0.020 ∼ 0.055 mm (0.0008 ∼ 0.0022 in.)
0.020 ∼ 0.060 mm (0.0008 ∼ 0.0024 in.)
0.035 ∼ 0.110 mm (0.0014 ∼ 0.0043 in.)
– – –
– – –
– – –
1.01 ∼ 1.03 mm (0.040 ∼ 0.041 in.)
1.01 ∼ 1.03 mm (0.040 ∼ 0.041 in.)
– – –
– – –
0.97 ∼ 0.99 mm (0.038 ∼ 0.039 in.)
0.97 ∼ 0.99 mm (0.038 ∼ 0.039 in.)
– – –
– – –
0.015 ∼ 0.030 mm (0.0006 ∼ 0.0012 in.)
– – –
0.030 ∼ 0.050 mm (0.0012 ∼ 0.0020 in.)
– – –
– – –
0.20 ∼ 0.70 mm (0.0079 ∼ 0.0276 in.)
– – –
16.992 ∼ 16.997 mm (0.66898 ∼ 0.66917 in.)
17.005 ∼ 17.011 mm (0.66949 ∼ 0.66972 in.) 17.03 mm (0.6704 in.)
17.005 ∼ 17.016 mm (0.66949 ∼ 0.66992 in.) 17.03 mm (0.6704 in.)
5-8 ENGINE TOP END
Special Tools
Bearing Puller:
57001-135
Valve Seat Cutter, 45° 57001-1113
24.5:
Inside Circlip Pliers:
57001-143
Valve Seat Cutter, 32° 57001-1118
25:
Compression Gauge, 20 kgf/cm²:
57001-221
Valve Seat Cutter, 32° 57001-1120
30:
Valve Spring Compressor Assembly:
57001-241
Valve Seat Cutter, 60° 57001-1123
30:
Piston Pin Puller Assembly:
57001-910
Valve Seat Cutter Holder Bar:
57001-1128
ENGINE TOP END 5-9
Special Tools
Valve Seat Cutter, 45° 57001-1187
30:
Valve Spring Compressor Adapter,
57001-1202
Valve Seat Cutter, 60° 57001-1328
22:
Valve Seat Cutter Holder,
57001-1330
25:
4.5:
Fork Oil Level Gauge:
57001-1290
Bearing Puller:
57001-1575
Compression Gauge Adapter, M10 × 1.0:
57001-1317
Camshaft Sprocket Holder:
57001-E002
5-10 ENGINE TOP END
Clean Air System (PH Model)
Vacuum Switch Valve Removal
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
•
•
chapter).
Bolts [A]
Disconnect:
Air Hoses [B]
Vacuum Hose [C]
Remove the vacuum switch valve [D] and bracket.
• Remove the bolts [A] and nuts [B].
Vacuum Switch Valve Installation
the vacuum switch valve to the bracket.
• Install
• Tighten:
Torque - Vacuum Switch Valve Bolts: 8.8 N·m (0.90 kgf·m,
78 in·lb)
the air hoses and vacuum hose to the vacuum
• Install
switch valve.
the hoses correctly (see Cable, Wire, and Hose
• Install
Routing section in the Appendix chapter).
Vacuum Switch Valve Operation Inspection
to the Air Suction System Damage Inspection in the
• Refer
Periodic Maintenance chapter.
Vacuum Switch Valve Inspection
the vacuum switch valve (see Vacuum Switch
• Remove
Valve Removal).
a commercially available vacuum gauge [A] and
• Connect
syringe [B] or the fork oil level gauge to the vacuum hoses
as shown.
Special Tool - Fork Oil Level Gauge: 57001-1290
Air Flow [C]
ENGINE TOP END 5-11
Clean Air System (PH Model)
raise the vacuum (lower the pressure) applied
• Gradually
to the vacuum switch valve, and check the valve operation. When the vacuum is low, the vacuum switch valve
should permit air to flow. When the vacuum is raised to
the valve closing pressure, the valve should stop air flow.
Spring [A]
Diaphragm [B]
Valve [C]
Low Vacuum [D]
Secondary Air Flow [E]
If the vacuum switch valve does not operate as described,
replace it with a new one.
NOTE
○To check air flow through the vacuum switch valve, just
blow through the air cleaner hose.
Vacuum Switch Valve Closing Pressure (Open → Close)
Standard:
54.7 ∼ 66.7 kPa (410 ∼ 500 mmHg)
High Vacuum [A]
Secondary Air Cannot Flow [B]
Clean Air System Hoses Inspection
inspect the hoses for damage or connection.
• Visually
Be
certain
that all the hoses are routed without being flat• tened or kinked,
and are connected correctly to the air
cleaner housing, vacuum switch valve, carburetor holder.
If they are not, correct them. Replace them if they are
damaged.
5-12 ENGINE TOP END
Cylinder Head Cover
Cylinder Head Cover Removal
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
Air Cleaner Cover (see Air Cleaner Element Replacement in the Periodic Maintenance chapter)
Cylinder Head Cover Bolts [A] and Washers
Cylinder Head Cover [B]
Cylinder Head Cover Gasket
Cylinder Head Cover Installation
the cylinder head cover gasket with a new one.
• Replace
the new cylinder head cover gasket [A] on the cylin• Install
der head cover [B].
• Install the cylinder head cover.
the cylinder head cover bolt washers [A].
• Install
Tighten:
•
Torque - Cylinder Head Cover Bolts: 11 N·m (1.1 kgf·m, 97
in·lb)
• Install the removed parts (see appropriate chapters).
ENGINE TOP END 5-13
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal
NOTICE
This is a non-return type camshaft chain tensioner.
The push rod does not return to its original position
once it moves out to take up cam chain slack. Observe all the rules listed below.
When removing the tensioner, do not take out the
mounting bolts only halfway. Retightening the
mounting bolts from this position could damage
the tensioner and the camshaft chain. Once the
bolts are loosened, the tensioner must be removed
and reset as described in “Camshaft Chain Tensioner Installation”. Do not turn over the crankshaft
while the tensioner is removed. This could upset
the camshaft chain timing, and damage the valves.
• Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System chapter)
Camshaft Chain Tensioner Cap Bolt [A]
Camshaft Chain Tensioner Mounting Bolts [B]
Camshaft Chain Tensioner [C]
Camshaft Chain Tensioner Installation
compressing the push rod [A], turn it clockwise with
• While
a suitable screwdriver until the rod stopped.
NOTICE
Do not turn the rod counterclockwise before installing the tensioner. This could detach the rod
and the tensioner cannot be reinstalled.
the chain tensioner gasket with a new one.
• Replace
While
holding
rod in position with a suitable push rod
• holder plate [A]theinstall
the tensioner on the cylinder block.
3.5 mm (0.14 in.) [B]
11 mm (0.43 in.) [C]
18 mm (0.71 in.) [D]
8.5 mm (0.33 in.) [E]
5-14 ENGINE TOP END
Camshaft Chain Tensioner
• Tighten:
Torque - Camshaft Chain Tensioner Mounting Bolts [A]: 11
N·m (1.1 kgf·m, 97 in·lb)
out the holder plate [B].
• Take
the tensioner cap bolt O-ring with a new one.
• Replace
Tighten:
•
Torque - Camshaft Chain Tensioner Cap Bolt: 11 N·m (1.1
kgf·m, 97 in·lb)
ENGINE TOP END 5-15
Camshaft
Camshaft Removal
• Remove:
Cylinder Head (see Cylinder Head Removal)
Rocker Arms (see Rocker Arm Removal)
Circlip [A]
Camshaft [B]
Special Tool - Inside Circlip Pliers: 57001-143
Camshaft Installation
molybdenum disulfide oil solution to all cam parts,
• Apply
journal and bearing.
the camshaft into the cylinder head.
• Install
Replace
with a new one.
• Install thethenewcirclip
circlip.
•
Special Tool - Inside Circlip Pliers: 57001-143
the removed parts (see appropriate chapters).
•○Install
Check and adjust the valve clearance (see Valve Clearance Inspection in the Periodic Maintenance chapter).
Cam Wear Inspection
the camshaft (see Camshaft Removal).
• Remove
the height [A] of each cam with a micrometer.
• Measure
If the cams are worn down past the service limit, replace
the camshaft.
Cam Height
Standard:
Exhaust
30.29 mm (1.193 in.)
Intake
30.34 mm (1.194 in.)
Service Limit:
Exhaust
30.24 mm (1.191 in.)
Intake
30.29 mm (1.193 in.)
Camshaft Bearing Inspection
inspect each camshaft bearing [A].
• Visually
If there is any damage, replace the bearing.
the bearing back and forth while checking for rough• Turn
ness or binding.
If roughness or binding is found, replace the bearing.
If it is noisy, does not spin smoothly, or has any rough
spots, replace the bearing.
5-16 ENGINE TOP END
Camshaft
Camshaft Bearing Removal
• Remove the bearings [A] from the camshaft [B].
Special Tools - Bearing Puller [C]: 57001-135
Bearing Puller [D]: 57001-1575
Camshaft Bearing Installation
• Using a press, install the bearings.
Camshaft Sprocket Removal
the piston to the TDC of the compression stroke
• Bring
(see Valve Clearance Inspection in the Periodic Mainte-
•
•
nance chapter).
Remove the camshaft chain tensioner (see Camshaft
Chain Tensioner Removal).
Set the projections [A] of the camshaft sprocket holder [B]
in the holes of the camshaft sprocket.
Special Tool - Camshaft Sprocket Holder: 57001-E002
• Remove:
Camshaft Sprocket Bolt [A]
Camshaft Sprocket Holder (Special Tool) [B]
NOTICE
Always strain the camshaft chain while turning the
crankshaft when the camshaft chain is loose.
This avoids kinking the chain on the camshaft chain
drive sprocket. A kinked chain could damage both
the chain and the sprocket.
the camshaft sprocket [C], and disengage the
• Remove
chain.
○Using a suitable tool or wire to keep the chain from falling
down into the cylinder block.
ENGINE TOP END 5-17
Camshaft
Camshaft Sprocket Installation
the piston to the TDC of the compression stroke
• Bring
(see Valve Clearance Inspection in the Periodic Mainte-
•
nance chapter).
Be sure that the spacer [A] is in position.
the camshaft chain with the camshaft sprocket.
•○Engage
Set the projection [A] of the camshaft sprocket [B] to the
groove [C] of the camshaft.
○Align the timing marks [D] on the camshaft sprocket with
•
the cylinder head upper surface [E].
“T” Mark [F]
In this photo [G], the engine has been removed for clarity.
Set the camshaft sprocket holder to the camshaft
sprocket.
Special Tool - Camshaft Sprocket Holder: 57001-E002
a non-permanent locking agent to the threads of
• Apply
the camshaft sprocket bolt and tighten it.
Torque - Camshaft Sprocket Bolt: 25 N·m (2.5 kgf·m, 18
ft·lb)
the camshaft chain tensioner (see Camshaft Chain
• Install
Tensioner Installation).
the crankshaft 2 turns counterclockwise to allow the
• Turn
tensioner to expand and recheck the camshaft chain timing.
NOTICE
Rotation of the crankshaft with improper camshaft
timing could cause the valve to contact each other
or the piston, and bend.
If any resistance is felt when turning the crankshaft,
stop immediately, and check the camshaft chain
timing.
• Install the removed parts (see appropriate chapters).
Camshaft Chain Removal
• Remove:
Clutch Cover (see Clutch Cover Removal in the Clutch
chapter)
Camshaft Sprocket (see Camshaft Sprocket Removal)
Grub Screw [A]
Sleeve [B]
5-18 ENGINE TOP END
Camshaft
• Disengage and remove the camshaft chain [A] downward.
Camshaft Chain Installation
the O-rings [A] with new ones.
• Replace
the camshaft chain to the camshaft chain drive
• Engage
sprocket.
○Using a suitable tool or wire to keep the chain from falling
•
•
down into the cylinder block.
Install the sleeve and tighten the grub screw securely.
Install the removed parts (see appropriate chapters).
Camshaft Chain Guide Wear Inspection
inspect the guides [A].
• Visually
If the guide is damaged, replace the guide.
ENGINE TOP END 5-19
Rocker Arm, Rocker Shaft
Rocker Arm Removal
• Remove:
Cylinder Head (see Cylinder Head Removal)
Stopper Bolt [A]
Stopper [B]
the 5 mm (0.20 in.) screw [A], remove the rocker
• Using
shafts [B] and rocker arms [C].
○Mark
and record the rocker arm locations so that the
rocker arm can be reinstalled in their original positions.
Rocker Arm Installation
the rocker arms and rocker shafts with high flash
• Clean
-point solvent.
molybdenum disulfide oil solution to the rocker shaft
• Apply
outside and rocker arm cam parts.
the camshaft so that the cam lobes point downward.
• Turn
each rocker shaft to the cylinder head, inserting it
• Install
into each rocker arm.
○Install the rocker shaft so that the screw thread faces outside.
Install the stopper.
Apply a non-permanent locking agent to the threads of
the stopper bolt and tighten it securely.
Install the removed parts (see appropriate chapters).
○Check and adjust the valve clearance (see Valve Clearance Inspection in the Periodic Maintenance chapter).
•
•
•
Rocker Arm and Rocker Shaft Wear Inspection
inspect the area on the rocker arm where the cam
• Visually
rubs.
•
If there is any damage or uneven wear, replace the arm.
Measure the inside diameter [A] of each rocker arm.
Rocker Arm Inside Diameter
Standard:
10.000 ∼ 10.012 mm (0.39370 ∼ 0.39417
in.)
Service Limit: 10.03 mm (0.3949 in.)
If it exceeds the service limit, replace the rocker arm.
5-20 ENGINE TOP END
Rocker Arm, Rocker Shaft
the outside diameter [A] of each rocker shaft
• Measure
where the rocker fits.
Rocker Shaft Diameter
Standard:
9.974 ∼ 9.987 mm (0.3927 ∼ 0.3932 in.)
Service Limit: 9.96 mm (0.392 in.)
If the diameter falls below the service limit, replace the
rocker shaft.
ENGINE TOP END 5-21
Cylinder Head
Cylinder Compression Measurement
up the engine thoroughly.
• Warm
the engine.
• Stop
Disconnect
spark plug caps (see Ignition Coil Re• moval in thethe
Electrical System chapter).
the left spark plug (see Spark Plug Replacement
• Remove
in the Periodic Maintenance chapter).
the compression gauge [A] and adapter [B] firmly
• Attach
into the spark plug hole.
Special Tools - Compression Gauge, 20 kgf/cm²: 57001-221
Compression Gauge Adapter, M10 × 1.0:
57001-1317
the starter motor, turn the engine over with the throt• Using
tle fully open until the compression gauge stops rising; the
compression is the highest reading obtainable.
NOTE
○Use the battery which is fully charged.
Cylinder Compression
Usable Range: 1 079 ∼ 1 275 kPa (11 ∼ 13 kgf/cm², 156
∼ 185 psi) at 320 r/min (rpm)
the left spark plug (see Spark Plug Replacement in
• Install
the Periodic Maintenance chapter).
○The following table should be consulted if the obtainable compression reading is not within the usable range.
Problem
Cylinder
compression
is higher than
usable range.
Diagnosis
Carbon accumulation on piston and in
combustion chamber possibly due to
damaged valve stem oil seal and/or
damaged piston oil rings (This may be
indicated by white exhaust smoke).
Incorrect cylinder head gasket thickness
Gas leakage around cylinder head
Remedy (Action)
Remove the carbon deposits and
replace damaged parts if necessary.
Replace the gasket with a standard part.
Replace damaged gasket and check
Cylinder
cylinder head warp.
compression
is lower than Bad condition of valve seating
Repair if necessary.
usable range.
Incorrect valve clearance
Adjust the valve clearance.
Incorrect piston/cylinder clearance
Replace the piston and/or cylinder.
Piston seizure
Inspect the cylinder and replace/repair
the cylinder and/or piston as necessary.
Bad condition of piston ring and/or piston Replace the piston and/or the piston
ring grooves
rings.
Cylinder Head Removal
the coolant (see Coolant Change in the Periodic
• Drain
Maintenance chapter).
• Remove:
Cylinder Head Cover (see Cylinder Head Cover Removal)
Camshaft Sprocket (see Camshaft Sprocket Removal)
Carburetor (see Carburetor Removal in the Fuel System
chapter)
Exhaust Pipe (see Exhaust Pipe Removal)
5-22 ENGINE TOP END
Cylinder Head
• Disconnect:
Water Temperature Sensor Connector [A]
•
Oil Pressure Switch Lead [B] (see Oil Pressure Switch
Removal in the Engine Lubrication System chapter)
Spark Plug Caps [C]
Remove the spacer [D].
the thermostat cover bolts [A].
• Remove
Remove
the
thermostat cover [B] from the cylinder head.
•
the cylinder head bolts (M6) [A] first, then re• Remove
move the cylinder head bolts (M10) [B] and cylinder head
[C].
Cylinder Head Installation
to see that the two dowel pins [A] are in place on
• Check
the cylinder.
the cylinder head gasket [B] with a new one.
• Replace
Install
the
new cylinder head gasket.
•
the cylinder head.
• Install
• Tighten the cylinder head bolts (M10) [A].
Torque - Cylinder Head Bolts (M10): 46 N·m (4.7 kgf·m, 34
ft·lb)
• Tighten the cylinder head bolts (M6) [B].
Torque - Cylinder Head Bolts (M6): 11 N·m (1.1 kgf·m, 97
in·lb)
• Install the removed parts (see appropriate chapters).
ENGINE TOP END 5-23
Cylinder Head
Cylinder Head Cleaning
the cylinder head (see Cylinder Head Removal).
• Remove
the valves (see Valve Removal).
• Remove
Wash
the
with a high flash-point solvent.
• Scrape thehead
carbon
out of the combustion chamber and
• exhaust port with a suitable
tool [A].
the cylinder head in a bath of high flash-point sol• Clean
vent.
compressed air, blow out any particles which may
• Using
obstruct the oil passage in the cylinder head.
• Install the valves (see Valve Installation).
Cylinder Head Warp Inspection
the cylinder head (see Cylinder Head Cleaning).
• Clean
a straightedge [A] across the lower surface of the
• Lay
cylinder head at several positions.
a thickness gauge [B] to measure the space between
• Use
the straightedge and the cylinder head.
Cylinder Head Warp
–––
Standard:
Service Limit: 0.05 mm (0.002 in.)
If the cylinder head is warped more than the service limit,
replace it.
If the cylinder head is warped less than the service limit,
repair the head by rubbing the lower surface on emery
paper secured to a surface plate (first No. 200, then No.
400).
5-24 ENGINE TOP END
Valves
Valve Clearance Inspection
to the Valve Clearance Inspection in the Periodic
• Refer
Maintenance chapter.
Valve Clearance Adjustment
to the Valve Clearance Adjustment in the Periodic
• Refer
Maintenance chapter.
Valve Removal
• Remove:
Cylinder Head (see Cylinder Head Removal)
•
Rocker Arms and Rocker Shafts (see Rocker Arm Removal)
Camshaft (see Camshaft Removal)
Using the valve spring compressor assembly [A] and
adapter [B], remove the valve.
Special Tools - Valve Spring Compressor Assembly: 57001
-241
Valve Spring Compressor Adapter, 22:
57001-1202
NOTE
○Mark and record the valve locations so that they can
be installed in their original positions to keep the valve
clearance unchanged.
Valve Installation
the oil seal with a new one.
• Replace
Apply
a
thin
coat of molybdenum disulfide grease to the
• valve stem before
valve installation.
Install
the
spring
so
that the closed coil end faces down• wards.
Valve Stem [A]
Oil Seal [B]
Spring Seat [C]
Closed Coil End [D]
Valve Spring [E]
Retainer [F]
Split Keepers [G]
ENGINE TOP END 5-25
Valves
Valve Seat Inspection
the valve (see Valve Removal).
• Remove
the valve seating surface [A] between the valve [B]
• Check
and valve seat [C].
○Measure the outside diameter [D] of the seating pattern
on the valve seat.
If the outside diameter is too large or too small, repair the
seat (see Valve Seat Repair).
Valve Seating Surface Outside Diameter
Standard:
Exhaust 23.4 ∼ 23.6 mm (0.921 ∼ 0.929 in.)
Intake
23.4 ∼ 23.6 mm (0.921 ∼ 0.929 in.)
○Measure the seat width [E] of the portion where there is
no build-up carbon (white portion) of the valve seat with a
vernier caliper.
Good [F]
If the width is too wide [G], too narrow [H] or uneven [J],
repair the seat (see Valve Seat Repair).
Valve Seating Surface Width
Standard:
Exhaust 0.9 ∼ 1.1 mm (0.035 ∼ 0.043 in.)
Intake
0.9 ∼ 1.1 mm (0.035 ∼ 0.043 in.)
Valve Seat Repair
• Repair the valve seat with the valve seat cutters [A].
Special Tools - Valve Seat Cutter Holder Bar [B]: 57001
-1128
Valve Seat Cutter Holder, 4.5 [C]: 57001
-1330
[For Exhaust Valve Seat]
Valve Seat Cutter, 45° -
24.5: 57001-1113
Valve Seat Cutter, 32° -
25: 57001-1118
Valve Seat Cutter, 60° -
25: 57001-1328
[For Intake Valve Seat]
Valve Seat Cutter, 45° -
30: 57001-1187
Valve Seat Cutter, 32° -
30: 57001-1120
Valve Seat Cutter, 60° -
30: 57001-1123
If the manufacturer’s instructions are not available, use
the following procedure.
5-26 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 diamond particles may fall off.
3. Do not fail to apply engine oil to the valve seat cutter
before grinding the seat surface. Also wash off ground
particles sticking to the cutter with washing oil.
NOTE
○Do not use a wire brush to remove the metal particles
from the cutter. It will take off the diamond particles.
4. Setting the valve seat cutter holder in position, operate
the cutter in one hand. Do not apply too much force to
the diamond portion.
NOTE
○Prior to grinding, apply engine oil to the cutter and during the operation, wash off any ground particles sticking
to the cutter with washing oil.
5. After use, wash it with washing oil and apply thin layer
of engine oil before storing.
Marks Stamped on the Cutter
The marks stamped on the back of the cutter [A] represent
the following.
60° ........................... Cutter angle [B]
37.5 ....................... Outer diameter of cutter [C]
Operating Procedures
Clean the seat area carefully.
Coat the seat with machinist’s dye.
Fit a 45° cutter into the holder and slide it into the valve
guide.
Press down lightly on the handle and turn it right or left.
Grind the seating surface only until it is smooth.
•
•
•
•
NOTICE
Do not grind the seat too much. Overgrinding will
reduce valve clearance by sinking the valve into the
head. If the valve sinks too far into the head, it will
be impossible to adjust the clearance, and the cylinder head must be replaced.
ENGINE TOP END 5-27
Valves
the outside diameter of the seating surface with
• Measure
a vernier caliper.
If the outside diameter of the seating surface is too small,
repeat the 45° grind until the diameter is within the specified range.
Widened Width [A] of engagement by machining with
45° cutter
Ground Volume [B] by 32° cutter
32° [C]
Correct Width [D]
Ground Volume [E] by 60° cutter
60° [F]
the outside diameter of the seating surface with
• Measure
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.
Original Seating Surface [B]
NOTE
○Remove all pittings of flaws from 45° ground surface.
○After grinding with 45° cutter, apply thin coat of machin-
ist’s dye to seating surface. This makes seating surface
distinct and 32° and 60° grinding operation easier.
If the outside diameter [A] of the seating surface is too
large, make the 32° grind described below.
If the outside diameter of the seating surface is within the
specified range, measure the seat width as described below.
Grind the seat at a 32° angle [B] until the seat outside
diameter is within the specified range.
○To make the 32° grind, fit a 32° cutter into the holder, and
slide it into the valve guide.
○Turn the holder one turn at a time while pressing down
very lightly. Check the seat after each turn.
•
NOTICE
The 32° cutter removes material very quickly.
Check the seat outside diameter frequently to prevent overgrinding.
○After making the 32° grind, return to the seat outside di-
•
ameter measurement step above.
To measure the seat width, use a vernier caliper to measure the width of the 45° angle portion of the seat at several places around the seat.
If the seat width is too narrow, repeat the 45° grind until
the seat is slightly too wide, and then return to the seat
outside diameter measurement step above.
5-28 ENGINE TOP END
Valves
If the seat width is too wide, make the 60° [A] grind described below.
If the seat width is within the specified range, lap the valve
to the seat as described below.
Grind the seat at a 60° angle until the seat width is within
the specified range.
○To make the 60° grind, fit 60° cutter into the holder, and
slide it into the valve guide.
○Turn the holder, while pressing down lightly.
○After making the 60° grind, return to the seat width measurement step above.
Correct Width [B]
•
the valve to the valve seat, once the seat width and
• Lap
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.
○Spin the valve against the seat until the grinding compound produces a smooth, matched surface on both the
seat and the valve.
○Repeat the process with a fine grinding compound.
Lapper [A]
Valve Seat [B]
Valve [C]
The seating area should be marked about in the middle
of the valve face.
If the seat area is not in the right place on the valve, check
to be sure the valve is the correct part. If it is, it may have
been refaced too much; replace it.
Be sure to remove all grinding compound before assembly.
When the engine is assembled, be sure to adjust the valve
clearance (see Valve Clearance Inspection in the Periodic
Maintenance chapter).
•
•
•
ENGINE TOP END 5-29
Valves
5-30 ENGINE TOP END
Cylinder, Piston
Cylinder Removal
• Remove:
Cylinder Head (see Cylinder Head Removal)
•
•
•
Front Camshaft Chain Guide [A]
Slide the clamp [B].
Disconnect the water hose [C].
Remove the cylinder [D].
Cylinder Installation
NOTE
○If a new cylinder is used, use a new piston ring.
the cylinder base gasket [A] with a new one.
• Replace
Install
the
base gasket.
• Be sure thatnewtwocylinder
dowel
pins [B] are properly fitted in the
• crankcase.
the piston ring opening as follows.
• Position
Top Ring [A]
Second Ring [B]
Upper Steel Rail [C]
Expander [D]
Lower Steel Rail [E]
About 30 ∼ 90° [F]
molybdenum disulfide oil solution to the piston and
• Apply
cylinder bore.
molybdenum disulfide oil solution to the piston rings
• Apply
(see Piston Installation).
the cylinder while compressing the piston rings with
• Install
your fingers.
the front camshaft chain guide [A] securely.
•○Install
Fit the hook [B] to the projection [C].
○Fit the projection [D] to the groove [E].
• Install the removed parts (see appropriate chapters).
Piston Removal
the cylinder (see Cylinder Removal).
• Remove
Place
a
clean
cloth under the piston.
• Remove the snap
ring [A].
•
ENGINE TOP END 5-31
Cylinder, Piston
• Remove the piston pin.
Special Tool - Piston Pin Puller Assembly [A]: 57001-910
• Remove the piston.
spread the piston ring opening with your thumbs
• Carefully
and then push up on the opposite side of the ring [A] to
•
remove it.
Remove the 3-piece oil ring with your thumbs in the same
manner.
Piston Installation
molybdenum disulfide oil solution to the oil ring ex• Apply
pander, and install the oil ring expander [A] in the bottom
piston ring groove so the ends [B] butt together.
Apply molybdenum disulfide oil solution to the oil ring steel
rails, and install the oil ring steel rails, one above the expander and one below it.
○Spread the rail with your thumbs, but only enough to fit
the rail over the piston.
○Release the rail into the bottom piston ring groove.
•
NOTE
○The oil ring rails have no “top” or “bottom”.
molybdenum disulfide oil solution to the piston
• Apply
rings.
not mix up the top and second ring.
• Do
the top ring [A] so that the “TOP1” mark [B] faces
• Install
up.
the second ring [C] so that the “TOP2” mark [D]
• Install
faces up.
5-32 ENGINE TOP END
Cylinder, Piston
NOTE
○If a new piston is used, use new piston ring.
the piston with its triangle mark [A] facing forward.
•○Install
In this photo [B], the piston has been removed for clarity.
a new piston pin snap ring into the side of the piston
• Fit
so that the ring opening [A] does not coincide with the slit
[B] of the piston pin hole.
○Apply molybdenum disulfide oil solution to the piston pin
and piston journals.
○When installing the piston pin snap ring, compress it only
enough to install it and no more.
NOTICE
Do not reuse snap rings, as removal weakens and
deforms them. They could fall out and score the
cylinder wall.
• Install the cylinder (see Cylinder Installation).
Cylinder Wear Inspection
there is a difference in cylinder wear in different di• Since
rections, take a side to side and a front to back measurement at each of the 3 locations (total of 6 measurements)
shown.
If any of the cylinder inside diameter measurements exceeds the service limit, replace the cylinder.
Cylinder Inside Diameter
Standard:
72.006 ∼ 72.013 mm (2.8349 ∼ 2.8352
in.) and less than 0.01 mm (0.0004
in.) difference between any two
measurements
Service Limit: 72.043 mm (2.8363 in.) or 0.05 mm
(0.002 in.) difference between any two
measurements
10 mm (0.39 in.) [A]
20 mm (0.79 in.) [B]
40 mm (1.57 in.) [C]
ENGINE TOP END 5-33
Cylinder, Piston
Piston Wear Inspection
the outside diameter [A] at a right angle to the
• Measure
direction of the piston pin.
If the measurement exceeds the standard, replace the
piston.
Piston Diameter
Standard:
71.964 ∼ 71.976 mm (2.8332 ∼ 2.8337 in.)
Piston/Cylinder Clearance Inspection
The most accurate way to find the piston clearance is
by making separate piston and cylinder diameter measurements and then computing the difference between the two
values. Measure the piston diameter as just described, and
measure the cylinder diameter at the very bottom of the
cylinder.
Piston/Cylinder Clearance
Standard:
0.03 ∼ 0.049 mm (0.0012 ∼ 0.0019 in.)
Service Limit:
0.09 mm (0.0035 in.)
NOTE
○Whenever the piston or cylinder has been replaced with
a new one, the motorcycle must be broken in the same
as with a new machine.
Piston Ring, Piston Ring Groove Wear Inspection
for uneven groove wear by inspecting the ring seat• Check
ing.
•
The rings should fit perfectly parallel to groove surfaces.
If not, replace the piston and all the piston rings.
With the piston rings in their grooves, make several measurements with a thickness gauge [A] to determine piston
ring/groove clearance.
Piston Ring/Groove Clearance
Standard:
Top
0.020 ∼ 0.055 mm (0.0008 ∼ 0.0022 in.)
Second
0.020 ∼ 0.060 mm (0.0008 ∼ 0.0024 in.)
Oil
0.035 ∼ 0.110 mm (0.0014 ∼ 0.0043 in.)
Piston Ring Groove Width Inspection
the piston ring groove width.
•○Measure
Use a vernier caliper at several points around the piston.
Piston Ring Groove Width
Standard:
Top [A]
1.01 ∼ 1.03 mm (0.040 ∼ 0.041 in.)
Second [B] 1.01 ∼ 1.03 mm (0.040 ∼ 0.041 in.)
If the width of any of the two grooves is wider than the
standard at any point, replace the piston.
5-34 ENGINE TOP END
Cylinder, Piston
Piston Ring Thickness Inspection
the piston ring thickness.
•○Measure
Use the micrometer to measure at several points around
the ring.
Piston Ring Thickness
Standard:
Top [A]
0.97 ∼ 0.99 mm (0.038 ∼ 0.039 in.)
Second [B] 0.97 ∼ 0.99 mm (0.038 ∼ 0.039 in.)
If any of the measurements is less than the standard on
either of the rings, replace all the rings.
NOTE
○When using new rings in a used piston, check for uneven groove wear. The rings should fit perfectly parallel
to the groove sides. If not, replace the piston.
Piston Ring End Gap Inspection
the piston ring [A] inside the cylinder, using the pis• Place
ton to locate the ring squarely in place. Set it close to the
•
bottom of the cylinder, where cylinder wear is low.
Measure the gap [B] between the ends of the ring with a
thickness gauge.
Piston Ring End Gap
Standard:
Top
0.015 ∼ 0.030 mm (0.0006 ∼ 0.0012 in.)
Second
0.030 ∼ 0.050 mm (0.0012 ∼ 0.0020 in.)
Oil
0.20 ∼ 0.70 mm (0.0079 ∼ 0.0276 in.)
If the end gap of either ring is greater than the standard,
replace all the rings.
Piston, Piston Pin, Connecting Rod Wear
Inspection
the diameter [A] of the piston pin with a microm• Measure
eter.
Piston Pin Diameter
Standard:
16.992 ∼ 16.997 mm (0.66898 ∼ 0.66917
in.)
If the piston pin diameter is less than the standard at any
point, replace the piston pin.
ENGINE TOP END 5-35
Cylinder, Piston
a cylinder gauge, measure the diameter [A] of both
• Using
piston pin holes in the piston and the inside diameter [B]
of the connecting rod small end.
Piston Pin Hole Diameter
Standard:
17.005 ∼ 17.011 mm (0.66949 ∼ 0.66972
in.)
Service Limit: 17.03 mm (0.6704 in.)
Connecting Rod Small End Inside Diameter
Standard:
17.005 ∼ 17.016 mm (0.66949 ∼ 0.66992
in.)
Service Limit: 17.03 mm (0.6704 in.)
If either piston pin hole diameter exceeds the service limit,
replace the piston.
If the pin hole groove shows excessive wear, replace the
piston.
If the connecting rod small end inside diameter exceeds
the service limit, replace the connecting rod.
5-36 ENGINE TOP END
Carburetor Holder
Carburetor Holder Removal
the carburetor (see Carburetor Removal in the
• Remove
Fuel System chapter).
the carburetor holder clamp screw (front) [A].
• Loosen
Remove
the carburetor holder [B].
•
Carburetor Holder Installation
the grooves [A] of the clamp screws to the projections
• Fit
[B] of the carburetor holder.
the groove [A] of the carburetor holder to the boss [B]
• Fit
of the cylinder head.
the carburetor holder clamp screw (front) se• Tighten
curely.
• Install the removed parts (see appropriate chapters).
ENGINE TOP END 5-37
Muffler
WARNING
The muffler can become extremely hot during normal operation and cause severe burns. Do not remove the muffler while it is hot.
Muffler Body Removal
the muffler body clamp bolt [A].
• Loosen
the muffler body mounting bolts (lower) [B] on
• Remove
both sides.
• Remove:
Muffler Body Mounting Bolts (Upper) [A] (Both Sides)
Muffler Body [B]
Muffler Body Installation
the muffler body gasket with a new one.
• Replace
Install
the
• Installation).new muffler body gasket (see Exhaust Pipe
sure that the bushings [A] and dampers [B] are in po• Be
sition.
the muffler body.
• Install
Tighten:
•
Torque - Muffler Body Mounting Bolts: 11 N·m (1.1 kgf·m,
97 in·lb)
Muffler Body Clamp Bolt: 15 N·m (1.5 kgf·m, 11
ft·lb)
warm up the engine, wait until the engine
• Thoroughly
cools down, and then retighten all bolts.
5-38 ENGINE TOP END
Muffler
Exhaust Pipe Removal
• Remove:
Radiator Fairing Bolt [A]
Clip Nut [B]
• Loosen the muffler body clamp bolt [A].
• Remove:
Exhaust Pipe Holder Nuts [A]
Exhaust Pipe [B]
ENGINE TOP END 5-39
Muffler
Exhaust Pipe Installation
the exhaust pipe gasket [A] and muffler body
• Replace
gasket [B] with new ones.
the new exhaust pipe gasket.
• Install
Install
the new muffler body gasket to the exhaust pipe
• until it stops
at the bottom.
the muffler body clamp [A] as shown.
• Install
Install
• Tighten:the exhaust pipe.
•
Torque - Exhaust Pipe Holder Nuts: 23 N·m (2.3 kgf·m, 17
ft·lb)
Muffler Body Clamp Bolt: 15 N·m (1.5 kgf·m, 11
ft·lb)
warm up the engine, wait until the engine
• Thoroughly
cools down, retighten all the bolt and nuts.
• Install the removed parts (see appropriate chapters).
CLUTCH 6-1
Clutch
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Clutch Lever and Cable ..........................................................................................................
Clutch Lever Free Play Inspection ....................................................................................
Clutch Lever Free Play Adjustment ..................................................................................
Cable Removal .................................................................................................................
Cable Installation ..............................................................................................................
Cable Lubrication ..............................................................................................................
Clutch Lever Assembly Removal/Installation....................................................................
Clutch Cover...........................................................................................................................
Clutch Cover Removal ......................................................................................................
Clutch Cover Installation ...................................................................................................
Release Shaft Removal ....................................................................................................
Release Shaft Installation .................................................................................................
Clutch Cover Disassembly................................................................................................
Clutch Cover Assembly.....................................................................................................
Clutch .....................................................................................................................................
Clutch Removal.................................................................................................................
Clutch Installation..............................................................................................................
Clutch Plate, Wear, Damage Inspection ...........................................................................
Clutch Plate Warp Inspection............................................................................................
Clutch Spring Free Length Measurement .........................................................................
Clutch Hub Finger Inspection............................................................................................
Clutch Hub Spline Inspection............................................................................................
6-2
6-4
6-5
6-6
6-6
6-6
6-6
6-6
6-6
6-6
6-7
6-7
6-7
6-7
6-7
6-8
6-8
6-9
6-9
6-10
6-12
6-12
6-13
6-13
6-13
6
6-2 CLUTCH
Exploded View
CLUTCH 6-3
Exploded View
No.
1
2
3
4
Fastener
Clutch Cover Bolts
Clutch Hub Nut
Clutch Stopper Bolts
Oil Seal Retaining Plate Bolts
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
Lh: Left-hand Threads
M: Apply molybdenum disulfide grease.
R: Replacement Parts
N·m
11
69
11
9.8
Torque
kgf·m
1.1
7.0
1.1
1.0
ft·lb
97 in·lb
51
97 in·lb
87 in·lb
Remarks
L, Lh
L
6-4 CLUTCH
Specifications
Item
Clutch Lever and Cable
Clutch Lever Free Play
Clutch
Friction Plate Thickness
Steel Plate Thickness
Friction and Steel Plate Warp
Clutch Spring Free Length
Clutch Hub Height
Standard
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.)
1.52 ∼ 1.68 mm (0.0598 ∼ 0.0661 in.)
0.1 mm (0.004 in.)
38.4 mm (1.51 in.)
28.8 ∼ 29.0 mm (1.134 ∼ 1.142 in.)
Service Limit
– – –
2.72 mm (0.107 in.)
1.45 mm (0.0571 in.)
– – –
37.3 mm (1.47 in.)
28.7 mm (1.130 in.)
CLUTCH 6-5
Special Tools
Clutch Hub Nut Wrench:
57001-E003
Primary Gear Holder:
57001-E004
6-6 CLUTCH
Clutch Lever and Cable
Clutch Lever Free Play Inspection
to the Clutch Operation Inspection in the Periodic
• Refer
Maintenance chapter.
Clutch Lever Free Play Adjustment
to the Clutch Operation Inspection in the Periodic
• Refer
Maintenance chapter.
Cable Removal
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
Air Cleaner Cover (see Air Cleaner Element Replacement in the Periodic Maintenance chapter)
Plug [A]
Remove the idle adjusting screw [B] from the cable
bracket.
Slide the dust cover [C].
Loosen the nuts [D], and slide the lower end of the clutch
cable to give the cable plenty of play.
Bend the stopper [E] straighten.
•
•
•
•
the locknut [A] and turn the adjuster [B].
• Loosen
up the slots [C] in the clutch lever, locknut and ad• Line
juster, and then free the cable from the lever.
the clutch inner cable tip from the clutch release
• Free
lever.
• Remove the clutch cable.
Cable Installation
the clutch cable correctly (see Cable, Wire, and Hose
• Run
Routing section in the Appendix chapter).
sure to bend the stopper after installing the clutch ca• Be
ble.
the clutch cable (see Clutch Operation Inspection
• Adjust
in the Periodic Maintenance chapter).
• Install the removed parts (see appropriate chapters).
Cable Lubrication
to the Chassis Parts Lubrication in the Periodic
• Refer
Maintenance chapter.
Clutch Lever Assembly Removal/Installation
to the Handlebar Removal/Installation in the Steer• Refer
ing chapter).
CLUTCH 6-7
Clutch Cover
Clutch Cover Removal
the engine oil (see Engine Oil Change in the Peri• Drain
odic Maintenance chapter).
• Remove:
Clutch Cable Lower End (see Cable Removal)
Clutch Cover Bolts [A]
Cable Bracket [B]
Clutch Cover [C]
Clutch Cover Installation
sure that the dowel pins [A] are in position.
• Be
the clutch cover gasket [B] with a new one.
• Replace
Install
the
• bracket. new clutch cover gasket, clutch cover and cable
• Tighten:
Torque - Clutch Cover Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)
• Install the removed parts (see appropriate chapters).
Release Shaft Removal
NOTICE
Do not remove the clutch release lever and shaft
assembly unless it is absolutely necessary. If removed, the oil seal replacement may be required.
the clutch cover (see Clutch Cover Removal).
• Remove
Turn
the
release lever and shaft assembly [A], and then
• remove the
push rod [B].
Remove
the
release lever and shaft assembly straight
• out.
Release Shaft Installation
grease to the oil seal lips on the upper ridge of the
• Apply
clutch cover.
molybdenum disulfide grease to the push
• Apply
rod-holding portion [A] on the release shaft.
• Install the spring [B] and washer [C].
6-8 CLUTCH
Clutch Cover
the release shaft straight into the upper hole of the
• Insert
clutch cover.
NOTICE
When inserting the release shaft, be careful not to
remove the spring of the oil seal.
the spring [A].
• Fit
Turn
the release lever and shaft assembly, and then install
• the push
rod.
Clutch Cover Disassembly
• Remove:
Clutch Cover (see Clutch Cover Removal)
Release Lever and Shaft Assembly (see Release Shaft
Removal)
Oil Filler Plug [A]
Circlip [B]
Oil Level Inspection Window [C]
Oil Seal [D]
Needle Bearing [E]
• Remove:
Oil Seal Retaining Plate Bolts [A]
Oil Seal Retaining Plate [B]
Oil Seal [C]
Clutch Cover Assembly
the needle bearing, oil seals [A] and circlip with
• Replace
new ones.
the needle bearing.
• Install
Install
the
seals so that the oil seal surface is flush with
• the housingoilend
of the clutch cover.
Apply
grease
to
the
oil seal lips.
• Install the oil seal retaining
plate.
• Apply a non-permanent locking
agent to the threads of
• the oil seal retaining plate bolts and
tighten them.
Torque - Oil Seal Retaining Plate Bolts: 9.8 N·m (1.0 kgf·m,
87 in·lb)
• Install the removed parts (see appropriate chapters).
CLUTCH 6-9
Clutch
Clutch Removal
NOTE
○If the primary gear is to be removed, remove the pri-
mary gear nut before clutch removal (see Primary Gear
Removal in the Crankshaft/Transmission chapter).
• Remove:
Clutch Cover (see Clutch Cover Removal)
Camshaft Chain (see Camshaft Chain Removal in the
Engine Top End chapter)
Rear Camshaft Chain Guide (see Cylinder Head Removal in the Engine Top End chapter)
Ball Bearing [A]
the primary gear holder [A], hold the clutch housing
• Using
gear and primary gear.
Special Tool - Primary Gear Holder: 57001-E004
the clutch hub nut wrench [B], remove the clutch
• Using
hub nut [C] (left-hand threads).
Special Tool - Clutch Hub Nut Wrench: 57001-E003
• Remove:
Washer [A]
Clutch Plate Assembly [B] with Clutch Housing [C]
• Remove the bushing [A].
6-10 CLUTCH
Clutch
• Remove:
Clutch Plate Assembly [A]
Clutch Housing [B]
Washer [C]
• Remove:
Clutch Stopper Bolts [A]
Clutch Stopper [B]
Clutch Springs [C]
Clutch Hub [D]
• Remove:
Spring Seat [A]
Spring [B]
Friction Plates [C]
Steel Plates [D]
Clutch Installation
engine oil to the bushing [A].
• Apply
Install
the bushing as shown.
• Stepped
Side [B]
the clutch housing [A].
•○Install
Be sure the clutch housing gear [B], primary gear [C] and
oil pump gear [D] mesh properly.
CLUTCH 6-11
Clutch
the spring seat [A] on the clutch hub.
• Install
Install
the spring [B] so that the chamfer side [C] faces
• clutch hub.
• Install the friction plates and steel plates alternately.
NOTICE
If new dry friction plates and steel plates are installed, apply engine oil to the surfaces of each
plate to avoid clutch plate seizure.
the marks [A] on the clutch wheel plate with the
• Align
marks [B] on the clutch hub.
• Install:
Clutch Springs [A]
•
Clutch Stopper [B]
Tighten the clutch stopper bolts [C] temporary.
• Install the washer [A].
the clutch plate assembly on the clutch housing.
•○Install
Install the outside friction plate so that the tangs [A] fit into
•
the grooves in the housing.
Tighten:
Torque - Clutch Stopper Bolts [B]: 11 N·m (1.1 kgf·m, 97
in·lb)
6-12 CLUTCH
Clutch
the washer [A] so that the chamfer side [B] faces
• Install
outside.
the primary gear holder [A], hold the clutch housing
• Using
gear and primary gear.
Special Tool - Primary Gear Holder: 57001-E004
a non-permanent locking agent to the threads of
• Apply
the clutch hub nut [B].
the clutch hub nut wrench [C], tighten the clutch
• Using
hub nut (left-hand threads).
Special Tool - Clutch Hub Nut Wrench: 57001-E003
Torque - Clutch Hub Nut: 69 N·m (7.0 kgf·m, 51 ft·lb)
• Install the removed parts (see appropriate chapters).
Clutch Plate, Wear, Damage Inspection
inspect the friction and steel plates for signs of
• Visually
seizure, overheating (discoloration), or uneven wear.
the thickness of each friction plate [A] and steel
• Measure
plate at several points.
If any plates show signs of damage, or if they have worn
past the service limit, replace them with new ones.
Friction Plate Thickness
Standard:
2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.)
Service Limit:
2.72 mm (0.107 in.)
Steel Plate Thickness
Standard:
1.52 ∼ 1.68 mm (0.0598 ∼ 0.0661 in.)
Service Limit:
1.45 mm (0.0571 in.)
Clutch Plate Warp Inspection
each friction plate or steel plate on a surface plate
• Place
and measure the gap between the surface plate [A] and
each friction plate or steel plate [B] with a thickness gauge
[C]. The gap is the amount of friction or steel plate warp.
If any plate is warped over the standard, replace it with a
new one.
Friction and Steel Plate Warp
Standard:
0.1 mm (0.004 in.)
CLUTCH 6-13
Clutch
Clutch Spring Free Length Measurement
the free length of the clutch springs [A].
• Measure
If any spring is shorter than the service limit, it must be
replaced.
Clutch Spring Free Length
Standard:
38.4 mm (1.51 in.)
Service Limit:
37.3 mm (1.47 in.)
Clutch Hub Finger Inspection
inspect the clutch housing fingers [A] where the
• Visually
friction plate tangs [B] hit them.
If they are badly worn or if there are groove cuts where the
tangs hit, replace the housing. Also, replace the friction
plates if their tangs are damaged.
Clutch Hub Spline Inspection
inspect where the teeth [A] on the steel plates
• Visually
wear against the clutch hub splines [B].
If there are notches worn into the splines, replace the
clutch hub. Also, replace the steel plates if their teeth are
damaged.
the clutch hub height [A].
• Measure
If it exceeds the service limit, replace the clutch hub [B].
Clutch Hub Height
Standard:
28.8 ∼ 29.0 mm (1.134 ∼ 1.142 in.)
Service Limit:
28.7 mm (1.130 in.)
ENGINE LUBRICATION SYSTEM 7-1
Engine Lubrication System
Table of Contents
Exploded View........................................................................................................................
Engine Oil Flow Chart.............................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Engine Oil and Oil Filter..........................................................................................................
Oil Level Inspection...........................................................................................................
Engine Oil Change............................................................................................................
Oil Filter Replacement ......................................................................................................
Oil Strainer Removal.........................................................................................................
Oil Strainer Installation......................................................................................................
Oil Strainer Cleaning.........................................................................................................
Oil Pressure Relief Valve........................................................................................................
Oil Pressure Relief Valve Removal/Installation.................................................................
Oil Pressure Relief Valve Inspection.................................................................................
Oil Pump.................................................................................................................................
Oil Pump Removal ............................................................................................................
Oil Pump Installation .........................................................................................................
Oil Pump Inspection..........................................................................................................
Oil Pressure Measurement.....................................................................................................
Oil Pressure Measurement ...............................................................................................
Oil Pressure Switch ................................................................................................................
Oil Pressure Switch Removal ...........................................................................................
Oil Pressure Switch Installation ........................................................................................
7-2
7-4
7-6
7-7
7-8
7-8
7-8
7-8
7-8
7-8
7-9
7-10
7-10
7-10
7-11
7-11
7-11
7-12
7-13
7-13
7-14
7-14
7-14
7
7-2 ENGINE LUBRICATION SYSTEM
Exploded View
ENGINE LUBRICATION SYSTEM 7-3
Exploded View
No.
1
2
3
4
Fastener
Oil
Oil
Oil
Oil
Pressure Switch
Filter Cap Bolts
Pump Mounting Bolts
Strainer Cap
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
N·m
13
6.9
11
8.8
Torque
kgf·m
1.3
0.70
1.1
0.90
ft·lb
115 in·lb
61 in·lb
97 in·lb
78 in·lb
Remarks
L
L
7-4 ENGINE LUBRICATION SYSTEM
Engine Oil Flow Chart
ENGINE LUBRICATION SYSTEM 7-5
Engine Oil Flow Chart
7-6 ENGINE LUBRICATION SYSTEM
Specifications
Item
Engine Oil
Type
Viscosity
Capacity
Level
Oil Pressure Measurement
Oil Pressure
Standard
DTS-i 10000
API SL with JASO MA2
SAE 20W-50
1.2 L (1.3 US qt)
1.4 L (1.5 US qt) (when engine is completely dry)
Between upper and lower level lines
(Wait 2 ∼ 3 minutes after idling or running)
60 ∼ 100 kPa (0.61 ∼ 1.02 kgf/cm², 8.7 ∼ 14.5 psi) at 1 300
∼ 1 500 r/min (rpm), Oil Temperature 50°C (122°F)
ENGINE LUBRICATION SYSTEM 7-7
Special Tools
Oil Pressure Gauge, 5 kgf/cm²:
57001-125
Outside Circlip Pliers:
57001-144
Oil Pressure Gauge Adapter, PT 1/8:
57001-1033
7-8 ENGINE LUBRICATION SYSTEM
Engine Oil and Oil Filter
WARNING
Vehicle operation with insufficient, deteriorated,
or contaminated engine oil will cause accelerated
wear and may result in engine seizure, accident,
and injury. Check the oil level before each use and
change the oil and filter according to the periodic
maintenance chart.
Oil Level Inspection
that the engine oil level is between the upper [A]
• Check
and lower [B] levels in the oil level inspection window [C].
NOTE
○Situate the motorcycle so that it is perpendicular to the
ground.
○If the motorcycle has just been used, wait several minutes for all the oil to drain down.
○If the oil has just been changed, start the engine and
run it for several minutes at idle speed. This fills the oil
filter with oil. Stop the engine, then wait several minutes
until the oil settles.
NOTICE
Racing the engine before the oil reaches every part
can cause engine seizure.
If the engine oil gets extremely low or if the oil pump
or oil passages clog up or otherwise do not function
properly, the red oil pressure warning indicator light
will blink. If this light blinks when the engine is running above idle speed, stop the engine immediately
and find the cause.
If the oil level is too high, remove the excess oil, using a
syringe or some other suitable device.
If the oil level is too low, add the correct amount of oil
through the oil filler opening. Use the same type and
make of oil that is already in the engine.
NOTE
○If the engine oil type and make are unknown, use any
brand of the specified oil to top off the level in preference
to running the engine with the oil level low. Then at your
earliest convenience, change the oil completely.
Engine Oil Change
to the Engine Oil Change in the Periodic Mainte• Refer
nance chapter.
Oil Filter Replacement
to the Oil Filter Replacement in the Periodic Main• Refer
tenance chapter.
Oil Strainer Removal
to the Engine Oil Change in the Periodic Mainte• Refer
nance chapter.
Oil Strainer Installation
to the Engine Oil Change in the Periodic Mainte• Refer
nance chapter.
ENGINE LUBRICATION SYSTEM 7-9
Engine Oil and Oil Filter
Oil Strainer Cleaning
to the Oil Strainer Cleaning in the Periodic Mainte• Refer
nance chapter.
7-10 ENGINE LUBRICATION SYSTEM
Oil Pressure Relief Valve
Oil Pressure Relief Valve Removal/Installation
○The oil pressure relief valve [A] is built in the oil pump
•
assembly.
Refer to the Oil Pump Removal.
Oil Pressure Relief Valve Inspection
the oil pump assembly (see Oil Pump Removal).
• Remove
to see if the valve [A] slides smoothly when push• Check
ing it in with a wooden or other soft rod, and see if it comes
back to its seat by spring [B] pressure.
○This photo [C] is intended to show the structure.
Do not
disassemble.
NOTE
○Inspect the valve in its assembled state. Disassembly
and assembly may change the valve performance.
If any rough spots are found during above inspection,
wash the valve clean with a high flash-point solvent and
blow out any foreign particles that may be in the valve with
compressed air.
WARNING
Gasoline and low flash-point solvents can be
flammable and/or explosive and cause severe
burns. Clean the oil pressure relief valve in a
well-ventilated area, and take care that there are no
sparks or flame anywhere near the working area;
this includes any appliance with a pilot light. Do
not use gasoline or a low flash-point solvent to
clean the oil pressure relief valve.
If cleaning does not solve the problem, replace the oil
pump assembly. The oil pressure relief valve is precision made with no allowance for replacement of individual
parts.
ENGINE LUBRICATION SYSTEM 7-11
Oil Pump
Oil Pump Removal
the engine oil (see Engine Oil Change in the Peri• Drain
odic Maintenance chapter).
• Remove:
Clutch Cover (see Clutch Cover Removal in the Clutch
chapter)
Circlip [A]
Oil Pump Gear [B]
Special Tool - Outside Circlip Pliers: 57001-144
• Remove:
Oil Pump Mounting Bolts [A]
Oil Pump Assembly [B]
• Remove:
Inner Rotor [A]
Outer Rotor [B]
Oil Pump Installation
the inner and outer rotors so that marks [A] faces
• Install
outside.
• Install the dowel pins [A].
7-12 ENGINE LUBRICATION SYSTEM
Oil Pump
the oil pump assembly [A].
• Install
Apply
a
non-permanent locking agent to the threads of
• the oil pump
mounting bolts [B] and tighten them.
Torque - Oil Pump Mounting Bolts: 11 N·m (1.1 kgf·m, 97
in·lb)
the oil pump gear [A].
•○Install
Be sure the oil pump gear and clutch housing gear mesh
•
•
properly.
Replace the circlip [B] with a new one.
Install the new circlip.
Special Tool - Outside Circlip Pliers: 57001-144
• Install the removed parts (see appropriate chapters).
Oil Pump Inspection
the outer and inner rotors (see Oil Pump Re• Remove
moval).
inspect the oil pump body [A], outer [B] and inner
• Visually
[C] rotors and gear [D].
If there is any damage or uneven wear, replace the oil
pump body, rotors, gear or the oil pump assembly.
ENGINE LUBRICATION SYSTEM 7-13
Oil Pressure Measurement
Oil Pressure Measurement
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
•
chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System chapter)
Oil Pressure Switch (see Oil Pressure Switch Removal)
Attach the adapter [A] and gauge [B].
Special Tools - Oil Pressure Gauge, 5 kgf/cm²: 57001-125
Oil Pressure Gauge Adapter, PT 1/8: 57001
-1033
• Install:
Air Cleaner Housing (see Air Cleaner Housing Installa•
•
tion in the Fuel System chapter)
Fuel Tank (see Fuel Tank Installation in the Fuel System
chapter)
Start the engine and warm up the engine.
Run the engine at the specified speed, and read the oil
pressure gauge.
Oil Pressure
Standard:
•
•
•
60 ∼ 100 kPa (0.61 ∼ 1.02 kgf/cm², 8.7 ∼
14.5 psi) at 1 300 ∼ 1 500 r/min (rpm), Oil
Temperature 50°C (122°F)
If the reading is much lower than the standard, check the
oil pump, oil pressure relief valve and crankshaft oil seal
of the clutch cover.
If the reading is much higher than the standard, check the
oil passages for clogging.
Stop the engine.
Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System chapter)
Remove the oil pressure gauge and adapter.
WARNING
Hot oil can cause severe burns. Beware of hot engine oil that will drain through the oil passage when
the oil pressure gauge adapter is removed.
• Install the removed parts (see appropriate chapters).
7-14 ENGINE LUBRICATION SYSTEM
Oil Pressure Switch
Oil Pressure Switch Removal
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
•
chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System chapter)
Slide the switch cover [A].
• Remove:
Switch Terminal Nut [A]
Oil Pressure Switch Lead [B]
Oil Pressure Switch [C]
Oil Pressure Switch Installation
• Tighten:
Torque - Oil Pressure Switch: 13 N·m (1.3 kgf·m, 115 in·lb)
the switch lead and tighten the switch terminal nut.
• Install
the switch cover.
• Install
Install
the
removed parts (see appropriate chapters).
•
ENGINE REMOVAL/INSTALLATION 8-1
Engine Removal/Installation
Table of Contents
Exploded View........................................................................................................................
Engine Removal/Installation ...................................................................................................
Engine Removal................................................................................................................
Engine Installation.............................................................................................................
8-2
8-4
8-4
8-6
8
8-2 ENGINE REMOVAL/INSTALLATION
Exploded View
ENGINE REMOVAL/INSTALLATION 8-3
Exploded View
No.
1
2
3
Fastener
Engine Bracket Bolts
Front Engine Mounting Bolt
Rear Engine Mounting Bolts
N·m
25
34
27
Torque
kgf·m
2.5
3.5
2.8
ft·lb
18
25
20
Remarks
8-4 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
Engine Removal
the rear part of the swingarm with a stand.
• Support
the brake lever slowly and hold it with a band
• Squeeze
[A].
WARNING
Motorcycle may fall over unexpectedly resulting in
an accident or injury. Be sure to hold the front brake
when removing the engine.
NOTICE
Be sure to hold the front brake when removing the
engine, or the motorcycle may fall over. The engine
or the motorcycle could be damaged.
• Drain:
Engine Oil (see Engine Oil Change in the Periodic Main•
tenance chapter)
Coolant (see Coolant Change in the Periodic Maintenance chapter)
Remove:
Fuel Tank Cover (see Fuel Tank Cover Removal in the
Frame chapter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
Fuel Filter (see Fuel Filter Removal in the Fuel System
chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System chapter)
Carburetor (see Carburetor Removal in the Fuel System
chapter)
Clutch Cable Lower End (see Clutch Cable Removal in
the Clutch chapter)
Coolant Reserve Tank (see Coolant Reserve Tank Removal in the Cooling System chapter)
Radiator (see Radiator and Radiator Fan Removal in the
Cooling System chapter)
Exhaust Pipe (see Exhaust Pipe Removal in the Engine
Top End chapter)
Muffler (see Muffler Removal in the Engine Top End
chapter)
Shift Lever (see Shift Pedal Removal in the Crankshaft/Transmission chapter)
Engine Sprocket (see Engine Sprocket Removal in the
Final Drive chapter)
ENGINE REMOVAL/INSTALLATION 8-5
Engine Removal/Installation
the spark plug caps (see Ignition Coil Re• Disconnect
moval in the Electrical System chapter).
the bands [A].
• Cut
Disconnect:
• Alternator Lead Connector [B]
Crankshaft Sensor Lead Connector [C]
Neutral Switch Lead Connector [D]
• Disconnect:
Water Temperature Sensor Connector [A]
•
Oil Pressure Switch Lead [B] (see Oil Pressure Switch
Removal in the Engine Lubrication System chapter)
Starter Motor Cable Terminal [C] (see Starter Motor Removal in the Electrical System chapter)
Remove the crankcase bolt (L = 40 mm) [D] and engine
ground terminal [E].
the engine with a suitable stand.
•○Support
Put a plank onto the suitable stand for engine balance.
• Remove:
Engine Mounting Nuts [A]
Washers [B]
Engine Bracket Bolts [C]
Engine Bracket [D]
• Remove:
Engine Mounting Bolts [A]
Engine Bracket Bolts [B]
Engine Bracket [C]
Frame Ground Terminal [D]
○While raising the engine, pull out the engine mounting
bolts.
Remove the engine [E].
•
8-6 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
Engine Installation
the engine.
• Install
the engine brackets and tighten all bolts and nuts
• Install
temporarily.
○Be
sure to install the engine ground terminal [A] with
crankcase bolt (L = 40 mm).
○Be sure to install the frame ground terminal [B] with rear
engine mounting bolt (upper).
Tighten:
•
Torque - Rear Engine Mounting Bolts: 27 N·m (2.8 kgf·m,
20 ft·lb)
Engine Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
Front Engine Mounting Bolt: 34 N·m (3.5 kgf·m, 25
ft·lb)
Crankcase Bolt (L = 40 mm): 11 N·m (1.1 kgf·m, 97
in·lb)
the leads, cables and hoses correctly (see Cable,
• Run
Wire, and Hose Routing section in the Appendix chapter).
the removed parts (see appropriate chapters).
• Install
Adjust:
• Throttle Cable (see Throttle Control System Inspection
•
•
in the Periodic Maintenance chapter)
Clutch Cable (see Clutch Operation Inspection in the Periodic Maintenance chapter)
Drive Chain (see Drive Chain Slack Inspection in the
Periodic Maintenance chapter)
Fill the engine with engine oil (see Engine Oil Change in
the Periodic Maintenance chapter).
Fill the engine with coolant (see Coolant Change in the
Periodic Maintenance chapter).
CRANKSHAFT/TRANSMISSION 9-1
Crankshaft/Transmission
Table of Contents
Exploded View...................................
Specifications ....................................
Special Tools .....................................
Crankcase .........................................
Crankcase Splitting ......................
Crankcase Assembly ...................
Crankshaft, Connecting Rod .............
Crankshaft Removal ....................
Crankshaft Installation .................
Crankshaft Ball Bearing Removal
Crankshaft Ball Bearing
Installation .................................
Connecting Rod Removal ............
Connecting Rod Installation .........
Crankshaft/Connecting Rod
Cleaning ....................................
Connecting Rod Big End Side
Clearance Inspection ................
Connecting Rod Big End
Bearing Insert/Crankpin Wear
Inspection..................................
Crankshaft Runout Inspection......
Primary Gear .....................................
Primary Gear Removal ................
Primary Gear Installation .............
Starter Motor Clutch ..........................
Starter Motor Clutch Removal......
Starter Motor Clutch Installation...
Starter Motor Clutch Inspection ...
Starter Motor Clutch Disassembly
Starter Motor Clutch Assembly ....
Starter Motor Clutch Gear
Removal ....................................
Starter Motor Clutch Gear
Installation .................................
Balancer ............................................
9-2
9-6
9-7
9-9
9-9
9-10
9-13
9-13
9-13
9-13
9-13
9-14
9-14
9-14
9-14
9-15
9-15
9-16
9-16
9-16
9-18
9-18
9-18
9-18
9-18
9-18
9-19
9-19
9-20
Balancer Removal........................
Balancer Installation.....................
Balancer Ball Bearing Removal ...
Balancer Ball Bearing Installation
Balancer Drive Gear Removal .....
Balancer Drive Gear Installation ..
Balancer Driven Gear Removal ...
Balancer Driven Gear Installation
External Shift Mechanism..................
Shift Pedal Removal ....................
Shift Pedal Installation .................
External Shift Mechanism
Removal ....................................
External Shift Mechanism
Installation .................................
External Shift Mechanism
Inspection..................................
Transmission .....................................
Transmission Shaft Removal .......
Transmission Shaft Installation ....
Transmission Shaft Disassembly .
Transmission Shaft Assembly......
Shift Drum Removal.....................
Shift Drum Installation..................
Shift Fork Bending Inspection ......
Shift Fork/Gear Groove Wear
Inspection..................................
Shift Fork Guide Pin/Shift Drum
Groove Wear Inspection ...........
Shift Fork/Shift Rod Wear
Inspection..................................
Gear Dog/Gear Dog Hole
Damage Inspection ...................
Ball Bearing Wear Inspection.......
Oil Seal Inspection .......................
9-20
9-20
9-20
9-20
9-21
9-21
9-22
9-22
9-24
9-24
9-24
9-24
9-24
9-25
9-26
9-26
9-26
9-26
9-26
9-28
9-29
9-29
9-29
9-30
9-30
9-30
9-31
9-31
9
9-2 CRANKSHAFT/TRANSMISSION
Exploded View
CRANKSHAFT/TRANSMISSION 9-3
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Fastener
Starter Motor Clutch Bolts
Balancer Drive Gear Nut
Primary Gear Nut
Balancer Driven Gear Bolt
Crankcase Bolts (L = 40 mm)
Crankcase Bolts (L = 60 mm)
Crankshaft Bearing Retaining Plate Screw
Shift Drum Bearing Retaining Plate Bolt
Connecting Rod Big End Bolts
Breather Plate Screws
Balancer Bearing Retaining Plate Bolt
Chain Guide Screws
Oil Jet Nozzle
Starter Motor Clutch Gear Retaining Plate
Bolt
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
N·m
15
59
59
23
11
11
9.8
11
23
6.9
9.8
11
5.9
Torque
kgf·m
1.5
6.0
6.0
2.3
1.1
1.1
1.0
1.1
2.3
0.70
1.0
1.1
0.60
ft·lb
11
44
44
17
97 in·lb
97 in·lb
87 in·lb
97 in·lb
17
61 in·lb
87 in·lb
97 in·lb
52 in·lb
11
1.1
97 in·lb
Remarks
L
L
L
L
L
L
L
L
L
L
L
9-4 CRANKSHAFT/TRANSMISSION
Exploded View
CRANKSHAFT/TRANSMISSION 9-5
Exploded View
No.
1
2
3
4
5
Fastener
Gear Positioning Lever Bolt
Shift Drum Cam Bolt
Shift Pedal Mounting Bolt
Shift Shaft Return Spring Pin
Shift Lever Bolt
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
N·m
11
11
20
21
12
Torque
kgf·m
1.1
1.1
2.0
2.1
1.2
ft·lb
97 in·lb
97 in·lb
15
15
106 in·lb
Remarks
L
L
L
9-6 CRANKSHAFT/TRANSMISSION
Specifications
Item
Crankshaft, Connecting Rod
Connecting Rod:
Big End Side Clearance
Crankpin Diameter:
Marking:
A
B
Connecting Rod Big End
Inside Diameter:
Marking:
1
2
Connecting Rod Big End
Bearing Insert Thickness:
Green
None
Blue
Crankshaft Runout
Transmission
Shift Fork Ear Thickness
Gear Groove Width
Shift Fork Guide Pin Diameter
Shift Drum Groove Width
Shift Fork Hole Diameter
Shift Rod Diameter
Standard
Service Limit
0.20 ∼ 0.35 mm (0.0079 ∼ 0.0138 in.)
0.45 mm (0.018 in.)
29.995 ∼ 30.011 mm (1.1809 ∼ 1.1815 in.) 29.98 mm (1.1803 in.)
29.995 ∼ 30.003 mm (1.1809 ∼ 1.1812 in.)
30.004 ∼ 30.011 mm (1.1813 ∼ 1.1815 in.)
33.000 ∼ 33.016 mm (1.2992 ∼ 1.2998 in.)
– – –
– – –
– – –
33.000 ∼ 33.008 mm (1.2992 ∼ 1.2995 in.)
33.009 ∼ 33.016 mm (1.2996 ∼ 1.2998 in.)
– – –
– – –
– – –
1.483 ∼ 1.487 mm (0.05839 ∼ 0.05854 in.)
1.487 ∼ 1.491 mm (0.05854 ∼ 0.05870 in.)
– – –
1.491 ∼ 1.495 mm (0.05870 ∼ 0.05886 in.)
– – –
TIR 0.02 mm (0.0008 in.)
TIR 0.08 mm (0.0031
in.)
4.93 ∼ 5.00 mm (0.194 ∼ 0.197 in.)
5.08 ∼ 5.18 mm (0.200 ∼ 0.204 in.)
4.46 ∼ 4.49 mm (0.176 ∼ 0.177 in.)
4.60 ∼ 4.70 mm (0.181 ∼ 0.185 in.)
12.000 ∼ 12.027 mm (0.47244 ∼ 0.47350
in.)
11.966 ∼ 11.984 mm (0.47110 ∼ 0.47181
in.)
4.73 mm (0.186 in.)
5.38 mm (0.212 in.)
4.44 mm (0.175 in.)
4.73 mm (0.186 in.)
12.04 mm (0.4740 in.)
11.950 mm (0.47047
in.)
Connecting Rod Big End Bearing Insert Selection
Con-rod Big End Inside
Diameter Marking
Crankpin Diameter Marking
1
1
2
2
B
A
B
A
Bearing Insert
Size Color
Green
None
Blue
CRANKSHAFT/TRANSMISSION 9-7
Special Tools
Bearing Puller:
57001-135
Flywheel Holder:
57001-1313
Bearing Puller Adapter:
57001-136
Crankcase Splitting Tool Assembly:
57001-1362
Inside Circlip Pliers:
57001-143
Bearing Puller:
57001-1575
Outside Circlip Pliers:
57001-144
Clutch Hub Nut Wrench:
57001-E003
Bearing Driver Set:
57001-1129
Primary Gear Holder:
57001-E004
9-8 CRANKSHAFT/TRANSMISSION
Special Tools
Balancer Gear Nut Wrench:
57001-E005
CRANKSHAFT/TRANSMISSION 9-9
Crankcase
Crankcase Splitting
the engine (see Engine Removal in the Engine
• Remove
Removal/Installation chapter).
the engine on a clean surface and hold the engine
• Set
steady while parts are being removed.
• Remove:
Alternator Cover (see Alternator Cover Removal in the
Electrical System chapter)
Alternator Rotor (see Alternator Rotor Removal in the
Electrical System chapter)
Starter Motor Clutch Gear (see Starter Motor Clutch
Gear Removal)
Neutral Switch (see Neutral Switch Removal in the Electrical System chapter)
Balancer Drive Gear (see Balancer Drive Gear Removal)
Balancer Driven Gear (see Balancer Driven Gear Removal)
Clutch Cover (see Clutch Cover Removal in the Clutch
chapter)
Oil Pump (see Oil Pump Removal in the Engine Lubrication System chapter)
Primary Gear (see Primary Gear Removal)
Clutch (see Clutch Removal in the Clutch chapter)
Gear Positioning Lever (see External Shift Mechanism
Removal)
External Shift Mechanism (see External Shift Mechanism Removal)
Starter Motor (see Starter Motor Removal in the Electrical System chapter)
Cylinder Head (see Cylinder Head Removal in the Engine Top End chapter)
Cylinder (see Cylinder Removal in the Engine Top End
chapter)
Piston (see Piston Removal in the Engine Top End chapter)
the clamp [A].
• Slide
• Remove:
Breather Hose [B]
Chain Guide Screws [C]
Chain Guide [D]
9-10 CRANKSHAFT/TRANSMISSION
Crankcase
• Remove:
Output Shaft Sleeve [A]
O-ring [B]
Crankcase Bolts [C]
lightly the points [A] with a plastic mallet to split the
• Tap
crankcase halves apart evenly. There are two dowel
pins on the crankcase mating surface. Pull off the left
crankcase half.
○The crankcase may also be split,
using the crankcase
splitting tool assembly [A].
Special Tool - Crankcase Splitting Tool Assembly: 57001
-1362
○Tighten the center bolt on the crankcase splitting tool to
split the crankcase. Constantly check the alignment of
the two halves. The front and rear of the crankcase must
be pulled apart evenly.
NOTICE
Do not remove the bearings and oil seals unless it
is necessary. Removal may damage them.
Crankcase Assembly
WARNING
Gasoline and low flash-point solvents can be
flammable and/or explosive and cause severe
burns. Clean the crankcase in a well-ventilated
area, and take care that there are no sparks or
flame anywhere near the working area; this includes any appliance with a pilot light. Do not use
gasoline or a low flash-point solvent to clean the
crankcase.
off the old gasket from the mating surfaces of the
• Chip
crankcase halves, and clean off the crankcase, transmis-
•
sion and crankshaft with a high flash-point solvent. After
cleaning, apply engine oil to the transmission gears, bearings, shift drum, shift rod, shift forks and so on.
Be sure to replace any oil seal and ball bearing removed
with a new one.
CRANKSHAFT/TRANSMISSION 9-11
Crankcase
a bearing driver set, install the following parts in the
• Using
right crankcase.
Oil Seal [A] (Flush)
Ball Bearings [B] (Contact with Bottom)
Needle Bearing [C] (Middle Position from Ends)
Special Tool - Bearing Driver Set: 57001-1129
the shift drum bearing retaining plate [D].
• Install
Apply
a
locking agent to the threads of the
• shift drumnon-permanent
bearing retaining plate bolt [E] and tighten it.
Torque - Shift Drum Bearing Retaining Plate Bolt: 11 N·m
(1.1 kgf·m, 97 in·lb)
the crankshaft bearing retaining plate [F].
• Install
Tighten
the crankshaft bearing retaining plate screw [G].
•
Torque - Crankshaft Bearing Retaining Plate Screw: 9.8
N·m (1.0 kgf·m, 87 in·lb)
the breather plate [H].
• Install
Apply
a
non-permanent locking agent to the threads of
• the breather
plate screws [I] and tighten them.
Torque - Breather Plate Screws: 6.9 N·m (0.70 kgf·m, 61
in·lb)
the circlip [J] with a new one.
• Replace
Install
the
new circlip and sleeve [K].
•
Special Tool - Inside Circlip Pliers: 57001-143
a bearing driver set, install the following parts in the
• Using
left crankcase.
Needle Bearings [A] (Flush)
Ball Bearing [B] (Flush)
Oil Seal [C] (Flush)
Oil Seal [D] (Flush with Groove)
Special Tool - Bearing Driver Set: 57001-1129
the circlip [E] with a new one.
• Replace
Install
the
new circlip.
•
Special Tool - Inside Circlip Pliers: 57001-143
9-12 CRANKSHAFT/TRANSMISSION
Crankcase
the crankshaft (see Crankshaft Installation).
• Install
Install
shift drum, transmission shafts, and shift forks
• in the the
right crankcase (see Transmission Shaft Installation).
Install the balancer (see Balancer Installation).
Check to see that the neutral holder is on the shift drum
(see Shift Drum Installation).
Check to see that the crankcase dowel pins [A] are in
place on the right crankcase half.
Replace the gasket [B] with a new one.
•
•
•
•
the left crankcase.
• Install
Apply
a
non-permanent locking agent to the threads of
• the crankcase
bolts (L = 60 mm) [A].
Tighten
the
crankcase
starting with the ones around
• the crankshaft, and thenbolts
the other ones.
Torque - Crankcase Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)
the O-ring [A] with a new one.
• Replace
Apply
grease
to the O-ring and install it on the output
• shaft.
the output shaft sleeve [B].
• Install
Check
to see that the crankshaft, balancer, input shaft,
• and output
shaft all turn freely (in the neutral position).
the output shaft, shift the transmission through
• Spinning
all the gears to make certain there is no binding and that
all the gears shift properly.
CRANKSHAFT/TRANSMISSION 9-13
Crankshaft, Connecting Rod
Crankshaft Removal
the crankcase (see Crankcase Splitting).
• Split
the transmission shafts (see Transmission Shaft
• Remove
Removal).
the shift drum (see Shift Drum Removal).
• Remove
Remove
the balancer (see Balancer Removal).
• Using a press
• crankcase [C].[A], remove the crankshaft [B] from the right
the connecting rod (see Connecting Rod Re• Remove
moval).
Crankshaft Installation
NOTE
○If the crankshaft is replaced with a new one, refer to
the Connecting Rod Big End Bearing/Crankshaft Main
Bearing Insert Selection in the Specifications.
the connecting rod (see Connecting Rod Installa• Install
tion).
a press [A], install the crankshaft [B] into the right
• Using
crankcase.
Crankshaft Ball Bearing Removal
a commercially available bearing puller [A], remove
• Using
the ball bearings [B].
Crankshaft Ball Bearing Installation
• Using a press, install the ball bearings.
9-14 CRANKSHAFT/TRANSMISSION
Crankshaft, Connecting Rod
Connecting Rod Removal
• Remove:
Crankshaft (see Crankshaft Removal)
Connecting Rod Big End Bolts [A]
Connecting Rod Big End Cap [B]
Connecting Rod [C]
Connecting Rod Installation
NOTE
○If the connecting rod is replaced with a new one, refer to
the Connecting Rod Big End Bearing/Crankshaft Main
Bearing Insert Selection in the Specifications.
the inserts [A] so that their nails are on the same
• Install
side and fit them into the recess of the connecting rod and
•
•
•
•
cap.
Install the dowel pins [B].
Remove debris and clean the surface of inserts.
Install the connecting rod and cap to the crankshaft.
Tighten the connecting rod big end bolts.
Torque - Connecting Rod Big End Bolts: 23 N·m (2.3 kgf·m,
17 ft·lb)
Crankshaft/Connecting Rod Cleaning
removing the connecting rod from the crankshaft,
• After
clean them with a high flash-point solvent.
the crankshaft oil passages with compressed air to
• Blow
remove any foreign particles or residue that may have
accumulated in the passages.
Connecting Rod Big End Side Clearance
Inspection
connecting rod big end side clearance [A].
•○Measure
Insert a thickness gauge [B] between the big end and either crank web to determine clearance.
Connecting Rod Big End Side Clearance
Standard:
0.20 ∼ 0.35 mm (0.0079 ∼ 0.0138 in.)
Service Limit:
0.45 mm (0.018 in.)
If the side clearance exceeds the service limit, replace the
connecting rod with new one and then check clearance
again. If the clearance is too large after connecting rod
replacement, the crankshaft also must be replaced.
CRANKSHAFT/TRANSMISSION 9-15
Crankshaft, Connecting Rod
Connecting Rod Big End Bearing Insert/Crankpin
Wear Inspection
• Measure the diameter [A] of the crankpin.
Crankpin Diameter
Standard:
29.995 ∼ 30.011 mm (1.1809 ∼ 1.1815 in.)
Service Limit:
29.98 mm (1.1803 in.)
If the crankpin has worn past the service limit, replace the
crankshaft with a new one.
If the measured crankpin diameter is not less than the
service limit, but do not coincide with the original diameter
marking [B] on the crankshaft, make new mark on it.
Crankpin Diameter Marks
A
29.995 ∼ 30.003 mm (1.1809 ∼ 1.1812 in.)
30.004 ∼ 30.011 mm (1.1813 ∼ 1.1815 in.)
B
Crankpin Diameter Mark: A or B
the connecting rod big end inside diameter, and
• Measure
mark of the connecting rod big end in accordance with the
•
inside diameter.
Tighten the connecting rod big end bolts to the specified
torque (see Connecting Rod Installation).
NOTE
○The mark already on the big end should almost coincide
with the measurement.
Connecting Rod Big End Inside Diameter Marks
1
33.000 ∼ 33.008 mm (1.2992 ∼ 1.2995 in.)
33.009 ∼ 33.016 mm (1.2996 ∼ 1.2998 in.)
2
Big End Cap [A]
Connecting Rod [B]
Diameter Mark [C]: 1 or 2
the proper bearing insert in accordance with the
• Select
combination of the connecting rod and crankshaft coding.
Con-rod Big End
Inside Diameter
Marking
Crankpin Diameter
Marking
1
B
1
A
2
B
2
A
Bearing Insert
Crankshaft Runout Inspection
Size Color
Green
None
Blue
the crankshaft runout.
• Measure
If the measurement exceeds the service limit, replace the
crankshaft.
Crankshaft Runout
Standard:
TIR 0.02 mm (0.0008 in.)
Service Limit: TIR 0.08 mm (0.0031 in.)
9-16 CRANKSHAFT/TRANSMISSION
Primary Gear
Primary Gear Removal
• Remove:
Clutch Cover (see Clutch Cover Removal in the Clutch
•
chapter)
Camshaft Chain (see Camshaft Chain Removal in the
Engine Top End chapter)
Using the primary gear holder [A] and clutch hub nut
wrench [B], remove the primary gear nut [C].
Special Tools - Clutch Hub Nut Wrench: 57001-E003
Primary Gear Holder: 57001-E004
• Remove:
Washer [A]
Camshaft Chain Drive Sprocket [B]
Clutch (see Clutch Removal in the Clutch chapter)
• Remove:
Primary Gear [A]
Woodruff Key [B]
• Remove the spacer [A].
Primary Gear Installation
the spacer [A].
• Install
Install
the
woodruff key [B] into the crankshaft key way.
• Align the woodruff
• the primary gear [C].key on the crankshaft with groove on
CRANKSHAFT/TRANSMISSION 9-17
Primary Gear
the woodruff key on the crankshaft with groove on
• Align
the camshaft chain drive sprocket [A].
the clutch (see Clutch Installation in the Clutch
• Install
chapter).
the washer [A] so that the chamfer side [B] faces
• Install
outward.
a non-permanent locking agent to the threads of
• Apply
the primary gear nut [A].
the primary gear holder [B] and clutch hub nut
• Using
wrench [C], tighten the primary gear nut to the specified
torque.
Special Tools - Clutch Hub Nut Wrench: 57001-E003
Primary Gear Holder: 57001-E004
Torque - Primary Gear Nut: 59 N·m (6.0 kgf·m, 44 ft·lb)
• Install the removed parts (see appropriate chapters).
9-18 CRANKSHAFT/TRANSMISSION
Starter Motor Clutch
Starter Motor Clutch Removal
to the Alternator Rotor Removal in the Electrical
• Refer
System chapter.
Starter Motor Clutch Installation
to the Alternator Rotor Installation in the Electrical
• Refer
System chapter.
Starter Motor Clutch Inspection
• Remove:
Alternator Cover (see Alternator Cover Removal in the
•
•
Electrical System chapter)
Torque Limiter Gear
Turn the starter motor clutch gear [A] by hand. The starter
clutch gear should turn clockwise [B] freely, but should not
turn counterclockwise [C].
If the starter motor clutch does not operate as it should or
if it makes noise, go to the next step.
Disassemble the starter motor clutch, and visually inspect
the clutch parts.
If there is any worn or damaged part, replace it.
NOTE
○Examine the starter motor clutch gear as well. Replace
it if it is worn or damaged.
Starter Motor Clutch Disassembly
the alternator rotor (see Alternator Rotor Re• Remove
moval in the Electrical System chapter).
the alternator rotor by flywheel holder [A], remove
• Holding
the starter motor clutch bolts [B].
Special Tool - Flywheel Holder: 57001-1313
NOTICE
Do not hold the rotor at pick-up portion with the flywheel holder.
the starter motor clutch [A] from the alternator
• Remove
rotor [B].
Starter Motor Clutch Assembly
• Holding the alternator rotor by flywheel holder.
Special Tool - Flywheel Holder: 57001-1313
a non-permanent locking agent to the threads of
• Apply
the starter motor clutch bolts and tighten them.
Torque - Starter Motor Clutch Bolts: 15 N·m (1.5 kgf·m, 11
ft·lb)
CRANKSHAFT/TRANSMISSION 9-19
Starter Motor Clutch
Starter Motor Clutch Gear Removal
• Remove:
Starter Motor Clutch Gear Retaining Plate Bolt [A]
Starter Motor Clutch Gear Retaining Plate [B]
Starter Motor Clutch Gear [C]
Starter Motor Clutch Gear Installation
the starter motor clutch gear [A] and retaining plate
• Install
[B].
a non-permanent locking agent to the threads of
• Apply
the starter motor clutch gear retaining plate bolt [C] and
tighten it.
Torque - Starter Motor Clutch Gear Retaining Plate Bolt: 11
N·m (1.1 kgf·m, 97 in·lb)
9-20 CRANKSHAFT/TRANSMISSION
Balancer
Balancer Removal
• Remove:
Shift Forks and Transmission Shafts (see Transmission
•
Shaft Removal)
Balancer Bearing Retaining Plate Bolt [A]
Balancer Bearing Retaining Plate [B]
Turn the balancer, and free the weight [C] from the crank
web.
• Using a press [A], remove the balancer [B].
Balancer Installation
a press [A], install the balancer [B].
• Using
the balancer bearing retaining plate.
• Install
Apply
a
non-permanent locking agent to the threads of
• the balancer
bearing retaining plate bolt, and tighten it.
Torque - Balancer Bearing Retaining Plate Bolt: 9.8 N·m
(1.0 kgf·m, 87 in·lb)
Balancer Ball Bearing Removal
• Remove the ball bearings [A] from the balancer [B].
Special Tools - Bearing Puller [C]: 57001-135
Bearing Puller Adapter [D]: 57001-136
Bearing Puller [E]: 57001-1575
Balancer Ball Bearing Installation
• Using a press, install the ball bearings.
CRANKSHAFT/TRANSMISSION 9-21
Balancer
Balancer Drive Gear Removal
the starter motor clutch gear (see Starter Motor
• Remove
Clutch Gear Removal).
the balancer gear nut wrench [A] and primary gear
• Using
holder [B], remove the balancer drive gear nut [C] and
washer [D].
Special Tools - Primary Gear Holder: 57001-E004
Balancer Gear Nut Wrench: 57001-E005
the balancer driven gear bolt and washer (see
• Remove
Balancer Driven Gear Removal).
• Remove:
Balancer Drive Gear [A]
Woodruff Key [B]
Balancer Drive Gear Installation
the balancer driven gear temporarily.
• Remove
Fit
the
woodruff
key [A] securely in the slot of the crank• shaft.
the woodruff key on the crankshaft with groove [B]
• Align
on the balancer drive gear [C].
the timing marks [A] on the balancer driven gear [B]
• Align
and balancer drive gear [C].
the washer and balancer driven gear bolt (see Bal• Install
ancer Driven Gear Installation).
the washer [A] so that the chamfer side [B] faces
• Install
outside.
9-22 CRANKSHAFT/TRANSMISSION
Balancer
a non-permanent locking agent to the threads of
• Apply
the balancer drive gear nut [A].
the balancer gear nut wrench [B] and primary gear
• Using
holder [C], tighten the balancer drive gear nut.
Special Tools - Primary Gear Holder: 57001-E004
Balancer Gear Nut Wrench: 57001-E005
Torque - Balancer Drive Gear Nut: 59 N·m (6.0 kgf·m, 44
ft·lb)
• Install the removed parts (see appropriate chapters).
Balancer Driven Gear Removal
the starter motor clutch gear (see Starter Motor
• Remove
Clutch Gear Removal).
the primary gear holder [A], remove the balancer
• Using
driven gear bolt [B].
Special Tool - Primary Gear Holder: 57001-E004
• Remove the washer [C].
• Remove:
Balancer Driven Gear [A]
Woodruff Key [B]
Balancer Driven Gear Installation
the timing marks [A] on the balancer driven gear [B]
• Align
and balancer drive gear.
• Install the woodruff key [C].
the washer [A] so that the stepped side [B] faces
• Install
inside.
CRANKSHAFT/TRANSMISSION 9-23
Balancer
a non-permanent locking agent to the threads of
• Apply
the balancer driven gear bolt [A].
the primary gear holder [B], tighten the balancer
• Using
driven gear bolt.
Special Tool - Primary Gear Holder: 57001-E004
Torque - Balancer Driven Gear Bolt: 23 N·m (2.3 kgf·m, 17
ft·lb)
• Install the removed parts (see appropriate chapters).
9-24 CRANKSHAFT/TRANSMISSION
External Shift Mechanism
Shift Pedal Removal
• Remove:
Shift Lever Bolt [A]
Shift Pedal Mounting Bolt [B]
Shift Pedal [C]
Shift Pedal Installation
the punch mark [A] on the shift shaft with the slit [B]
• Align
of the shift lever.
• Tighten the shift lever bolt [C].
Torque - Shift Lever Bolt: 12 N·m (1.2 kgf·m, 106 in·lb)
the washer [D].
• Install
Tighten
the shift pedal mounting bolt [E].
•
Torque - Shift Pedal Mounting Bolt: 20 N·m (2.0 kgf·m, 15
ft·lb)
External Shift Mechanism Removal
• Remove:
Shift Pedal (see Shift Pedal Removal)
Clutch Cover (see Clutch Cover Removal in the Clutch
chapter)
Clutch (see Clutch Removal in the Clutch chapter)
Oil Pump (see Oil Pump Removal in the Engine Lubrication System chapter)
Shift Shaft [A]
• Remove:
Bolt [A] and Washer [B]
Gear Positioning Lever [C]
Spring [D]
Washer [E]
External Shift Mechanism Installation
installing the shift shaft, apply grease to the oil seal
• Before
lips.
• Install:
Washer
•
Spring
Gear Positioning Lever
Washer
Apply a non-permanent locking agent to the threads of
the gear positioning lever bolt and tighten it.
Torque - Gear Positioning Lever Bolt: 11 N·m (1.1 kgf·m, 97
in·lb)
• Install the washer [A] and shift shaft.
CRANKSHAFT/TRANSMISSION 9-25
External Shift Mechanism
External Shift Mechanism Inspection
the shift shaft [A] for bending or damage to the
• Check
serration [B].
•
•
If the shaft is bent, repair or replace it. If the serration is
damaged, replace the shaft.
Check the return spring [C] and arm spring [D] for cracks
or distortion.
If the springs are damaged in any way, replace them.
Check the shift mechanism arm [E] for distortion.
If the shift mechanism arm is damaged in any way, replace the arm.
that the shift shaft return spring pin [A] is not loose.
• Check
If it is loose, remove it, apply a non-permanent locking
agent to the threads, and tighten it.
Torque - Shift Shaft Return Spring Pin: 21 N·m (2.1 kgf·m,
15 ft·lb)
the gear positioning lever [B], and its spring [C] for
• Check
cracks or distortion.
•
If the lever or spring is damaged in any way, replace them.
Visually inspect the shift drum cam [D].
If it is badly worn or if it shows any damage, replace it.
9-26 CRANKSHAFT/TRANSMISSION
Transmission
Transmission Shaft Removal
the crankcase (see Crankcase Splitting).
• Split
the springs [A].
• Remove
Pull
out
the
shift rods [B].
• Disengage the
shift fork guide pins from the shift drum
• grooves.
the shift forks [C] from the transmission gears.
• Remove
Take
out
input shaft [D] and output shaft [E] together
• with their the
gear meshed.
Transmission Shaft Installation
engine oil liberally to the transmission gears, bear• Apply
ings, shaft journals, and shift fork fingers.
the input shaft and output shaft together, with their
• Hold
gears meshed, and fit them into the right crankcase half.
each shift fork into the groove of the proper gear so
• Install
that the shift fork guide pin is in the proper groove on the
shift drum.
○Be careful not to confuse the shift forks.
engine oil to the shift rods, and install the rods.
• Apply
sure that two springs [A] are properly installed on the
• Be
shift rods.
• Assemble the crankcase (see Crankcase Assembly).
Transmission Shaft Disassembly
the transmission shafts (see Transmission Shaft
• Remove
Removal).
circlip pliers to remove the circlips, disassemble the
• Using
transmission shafts.
Special Tool - Outside Circlip Pliers: 57001-144
Transmission Shaft Assembly
engine oil to the transmission shaft and gears.
• Apply
Install
• aligned.the shafts and gear bushings with their holes
any circlips that were removed with new ones.
• Replace
install circlips [A] so that the opening [B] is aligned
• Always
with a spline groove [C], and install the toothed washer [D]
•
•
•
so that the teeth are not aligned with the circlip opening.
The input shaft gears can be identified by size; the smallest diameter gear is 1st gear, and the largest is 6th. Be
sure that all parts are put back in the correct sequence,
facing the proper direction, and that all circlips, bushing
and washer are properly in place.
The output shaft gears can be identified by size; the
largest diameter gear is 1st gear, and the smallest is
6th. Be sure that all parts are put back in the correct sequence, facing the proper direction, and that all circlips,
bushing and washer are properly in place.
Check that each gear spins or slides freely on the transmission shaft without binding after assembly.
CRANKSHAFT/TRANSMISSION 9-27
Transmission
1. 2nd Gear
2. 5th Gear
3. 3rd Gear
4. 4th Gear
5. 6th (Top) Gear
6. Input Shaft (with 1st Gear)
7. Washer
8. Circlip
9. Toothed Washer
10. Bushing
9-28 CRANKSHAFT/TRANSMISSION
Transmission
1. 1st Gear
2. 6th (Top) Gear
3. 4th Gear
4. 3rd Gear
5. 5th Gear
6. 2nd Gear
Shift Drum Removal
7. Output Shaft
8. Washer
9. Bushing
10. Snap Ring
11. Toothed Washer
12. Circlip
the shift forks and transmission shafts (see
• Remove
Transmission Shaft Removal).
holding the shift drum by inserting a bar into the
• While
drum, remove the shift drum cam bolt [A] and drum cam
•
•
[B].
Remove the spacer and dowel pin.
Remove the shift drum.
CRANKSHAFT/TRANSMISSION 9-29
Transmission
Shift Drum Installation
the shift drum.
• Install
• Install the dowel pin [A] on the shift drum.
the spacer [A].
• Install
Fit
the
[B] of the shift drum cam to the dowel pin [C].
• Apply ahole
locking agent to the threads of
• the shift non-permanent
drum cam bolt.
holding the shift drum body, tighten the shift drum
• While
cam bolt.
Torque - Shift Drum Cam Bolt: 11 N·m (1.1 kgf·m, 97 in·lb)
Shift Fork Bending Inspection
inspect the shift forks, and replace any fork that is
• Visually
bent. A bent fork could cause difficulty in shifting, or allow
the transmission to jump out of gear when under power.
90° [A]
Shift Fork/Gear Groove Wear Inspection
the thickness of the shift fork ear [A], and mea• Measure
sure the width of the gear grooves [B].
If the thickness of a shift fork ear is less than the service
limit, the shift fork must be replaced.
Shift Fork Ear Thickness
Standard:
4.93 ∼ 5.00 mm (0.194 ∼ 0.197 in.)
Service Limit:
4.73 mm (0.186 in.)
If the gear groove is worn over the service limit, the gear
must be replaced.
Gear Groove Width
Standard:
5.08 ∼ 5.18 mm (0.200 ∼ 0.204 in.)
Service Limit:
5.38 mm (0.212 in.)
9-30 CRANKSHAFT/TRANSMISSION
Transmission
Shift Fork Guide Pin/Shift Drum Groove Wear
Inspection
the diameter of each shift fork guide pin [A] and
• Measure
measure the width of each shift drum groove [B].
If the guide pin on any shift fork is less than the service
limit, the fork must be replaced.
Shift Fork Guide Pin Diameter
Standard:
4.46 ∼ 4.49 mm (0.176 ∼ 0.177 in.)
Service Limit: 4.44 mm (0.175 in.)
If any shift drum groove is worn over the service limit, the
drum must be replaced.
Shift Drum Groove Width
Standard:
4.60 ∼ 4.70 mm (0.181 ∼ 0.185 in.)
Service Limit: 4.73 mm (0.186 in.)
Shift Fork/Shift Rod Wear Inspection
the diameter [A] of each shift fork hole and mea• Measure
sure the diameter [B] of each shift rod.
If the shift fork hole diameter exceeds the service limit,
replace the shift fork.
Shift Fork Hole Diameter
Standard:
12.000 ∼ 12.027 mm (0.47244 ∼ 0.47350
in.)
Service Limit: 12.04 mm (0.4740 in.)
If the shift rod exceeds the service limit, replace the shift
rod.
Shift Rod Diameter
Standard:
11.966 ∼ 11.984 mm (0.47110 ∼ 0.47181
in.)
Service Limit: 11.950 mm (0.47047 in.)
Gear Dog/Gear Dog Hole Damage Inspection
inspect the gear dogs [A] and gear dog holes [B].
• Visually
Replace any damaged gears or gears with excessively
worn dogs or dog holes.
CRANKSHAFT/TRANSMISSION 9-31
Transmission
Ball Bearing Wear Inspection
NOTICE
Do not remove the bearings for inspection. Removal may damage them.
the ball bearings.
•○Inspect
Since the ball bearings are made to extremely close tol-
erance, the wear must be judged by feel rather than measurement. Clean each bearing in a high flash-point solvent, dry it (do not spin the bearing while it is dry), and oil
it with engine oil.
○Turn [A] the bearing by hand to check its condition.
If the bearing is noisy, does not spin smoothly, or has any
rough spots, replace it.
Oil Seal Inspection
Replace the oil seal if the lips are misshapen, discolored
(indicating that the rubber has deteriorated), hardened or
otherwise damaged.
WHEELS/TIRES 10-1
Wheels/Tires
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Wheels (Rims) ........................................................................................................................
Front Wheel Removal .......................................................................................................
Front Wheel Installation ....................................................................................................
Rear Wheel Removal........................................................................................................
Rear Wheel Installation.....................................................................................................
Wheel Inspection ..............................................................................................................
Axle Inspection..................................................................................................................
Balance Inspection............................................................................................................
Balance Adjustment ..........................................................................................................
Balance Weight Removal..................................................................................................
Balance Weight Installation...............................................................................................
Tires........................................................................................................................................
Air Pressure Inspection/Adjustment..................................................................................
Tire Inspection ..................................................................................................................
Tire Removal.....................................................................................................................
Tire Installation..................................................................................................................
Tire Repair ........................................................................................................................
Hub Bearing............................................................................................................................
Hub Bearing Removal.......................................................................................................
Hub Bearing Installation....................................................................................................
Hub Bearing Inspection.....................................................................................................
Hub Bearing Lubrication ...................................................................................................
10-2
10-4
10-5
10-6
10-6
10-6
10-7
10-8
10-9
10-9
10-10
10-10
10-10
10-10
10-12
10-12
10-12
10-12
10-12
10-14
10-15
10-15
10-15
10-15
10-16
10
10-2 WHEELS/TIRES
Exploded View
WHEELS/TIRES 10-3
Exploded View
No.
1
2
Fastener
Front Axle Nut
Rear Axle Nut
HG: Apply high-temperature grease.
R: Replacement Parts
WL: Apply soap and water solution or rubber lubricant.
N·m
98
108
Torque
kgf·m
10.0
11.0
ft·lb
72
79.7
Remarks
R
R
10-4 WHEELS/TIRES
Specifications
Item
Wheels (Rims)
Rim Runout:
Axial
Radial
Axle Runout/100 mm (3.94 in.)
Wheel Balance
Balance Weights
Rim Size:
Front
Rear
Tires
Air Pressure (when Cold):
Front
Rear
Tread Depth:
Front
Rear
Standard Tires:
Front
Rear
Standard
TIR 1.0 mm (0.04 in.) or less
TIR 0.8 mm (0.03 in.) or less
TIR 0.1 mm (0.004 in.) or less
10 g (0.35 oz.) or less
10 g (0.35 oz.), 20 g (0.71 oz.),
30 g (1.06 oz.)
Service Limit
TIR 2.0 mm (0.08 in.)
TIR 2.0 mm (0.08 in.)
TIR 0.2 mm (0.008 in.)
– – –
– – –
J17M/C × MT2.50
J17M/C × MT3.50
– – –
– – –
Up to 130 kg (287 lb) load:
175 kPa (1.75 kgf/cm², 25 psi)
Up to 65 kg (143 lb) load:
200 kPa (2.00 kgf/cm², 29 psi)
65 ∼ 130 kg (143 ∼ 287 lb) load:
225 kPa (2.25 kgf/cm², 33 psi)
– – –
5.0 mm (0.20 in.)
6.0 mm (0.24 in.)
Make, Type
EUROGRIP, ATT625
MRF, NYLOGRIP ZAPPER-FY
IRC, ROAD WINNER RX-01F
EUROGRIP, ATT925
MRF, NYLOGRIP ZAPPER-S
IRC, ROAD WINNER RX-01R
1 mm (0.04 in.)
1 mm (0.04 in.)
Size
100/80-17M/C 52P
100/80-17M/C 52P
100/80-17M/C 52P
130/70-17M/C 62P
130/70-17M/C 62P
130/70-17M/C 62S
– – –
– – –
WARNING
Some replacement tires may adversely affect handling and cause an accident resulting in
serious injury or death. To ensure proper handling and stability, use only the recommended
standard tires for replacement, inflated to the standard pressure.
WHEELS/TIRES 10-5
Special Tools
Bearing Driver Set:
57001-1129
Bearing Remover Shaft,
57001-1265
9:
Jack:
57001-1238
Bearing Remover Head,
57001-1267
15 ×
17:
10-6 WHEELS/TIRES
Wheels (Rims)
Front Wheel Removal
• Remove:
Front Caliper Mounting Bolts [A]
•
Front Caliper [B]
Loosen:
Front Axle Nut [C]
• Raise the front wheel off the ground with jack.
Special Tool - Jack: 57001-1238
the front axle nut and washer.
• Remove
Pull
out
the
axle to the left side and take the front
• wheel off thefront
front forks.
• Remove the speed sensor [A].
NOTICE
Do not lay the front 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.
Front Wheel Installation
high-temperature grease to the grease seal lips [A].
• Apply
the projections [B] of the speed sensor to the
• Insert
notches [C] of the wheel hub.
NOTICE
Unless the speed sensor is properly installed on the
wheel, you will damage the speed sensor in tightening the front axle.
high-temperature grease to the grease seal lips [A].
• Apply
• Fit the collar [B] on the wheel hub.
WHEELS/TIRES 10-7
Wheels (Rims)
the speed sensor [A].
•○Set
Fit the stopper [B] on the projection [C] of the left fork leg.
the front axle nut [A] with a new one.
• Replace
Insert
the
front axle from the left side of the wheel, and
• install the front
axle nut and washer [B].
Tighten:
•
Torque - Front Axle Nut: 98 N·m (10.0 kgf·m, 72 ft·lb)
the removed parts (see appropriate chapters).
• Install
Check
the front brake effectiveness (see Brake Operation
• Inspection
in the Periodic Maintenance chapter).
WARNING
After servicing, it takes several applications of the
brake lever before the brake pads contact the disc,
which could result in increased stopping distance
and cause an accident resulting in injury or death.
Do not attempt to ride the motorcycle until a firm
brake lever is obtained by pumping the lever until
the pads are against the disc.
Rear Wheel Removal
• Raise the rear wheel off the ground with the stand [A].
NOTICE
Be sure to hold the front brake when removing the
rear wheel, or the motorcycle may fall over. The rear
wheel or the motorcycle could be damaged.
• Remove:
Rear Axle Nut [A]
Rear Axle [B] (from Right Side)
Washer [C] (Both Sides)
Indicator [D] (Both Sides)
Spacer
10-8 WHEELS/TIRES
Wheels (Rims)
the drive chain [A] from the rear sprocket toward
• Remove
the left.
• Move the rear wheel back and remove it.
NOTICE
Do 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.
Rear Wheel Installation
high-temperature grease to the grease seal lips.
• Apply
collars on the both sides of the hub.
• FitLefttheSide
Collar [A]
Right Side Collar [B]
the drive chain with the rear sprocket.
• Engage
Install
the
• swingarm. caliper bracket [A] onto the stopper [B] of the
the washer and indicator (for left side) to the rear
• Install
axle.
the spacer [A].
• Install
Insert
the
of the wheel.
• Replace therearrearaxleaxlefromnutthewithlefta side
new
one.
• Install the washer, indicator and rear axle
nut temporarily.
• Adjust the drive chain slack before tightening
rear
• axle nut (see Drive Chain Slack Inspection in the the
Periodic
•
Maintenance chapter).
Tighten:
Torque - Rear Axle Nut: 108 N·m (11.0 kgf·m, 79.7 ft·lb)
the rear brake effectiveness (see Brake Operation
• Check
Inspection in the Periodic Maintenance chapter).
WARNING
After servicing, it takes several applications of the
brake pedal before the brake pads contact the disc,
which could result in increased stopping distance
and cause an accident resulting in injury or death.
Do not attempt to ride the motorcycle until a firm
brake pedal is obtained by pumping the pedal until
the pads are against the disc.
WHEELS/TIRES 10-9
Wheels (Rims)
Wheel Inspection
• Raise the front/rear wheel off the ground.
Special Tool - Jack: 57001-1238
the wheel lightly, and check for roughness or binding.
• Spin
If roughness or binding is found, replace the hub bearings
•
•
•
(see Hub Bearing Removal/Installation).
Inspect the wheel for small cracks, dents, bending, or
warp.
If there is any damage to the wheel, replace the wheel.
Remove the wheel, and support it with the tire by the axle.
Measure the rim runout, axial [A] and radial [B], with a dial
gauge.
If rim runout exceeds the service limit, check the hub bearings (see Hub Bearing Inspection).
If the problem is not due to the bearings, replace the
wheel.
Rim Runout (with tire installed)
Standard:
Axial
TIR 1.0 mm (0.04 in.) or less
Radial
TIR 0.8 mm (0.03 in.) or less
Service Limit:
Axial
TIR 2.0 mm (0.08 in.)
Radial
TIR 2.0 mm (0.08 in.)
WARNING
Damaged wheel parts may fail and cause an accident resulting in serious injury or death. Never attempt to repair a damaged wheel part. If the wheel
part is damaged, it must be replaced with a new one.
Axle Inspection
the front and rear axles (see Front/Rear Wheel
• Remove
Removal).
inspect the front and rear axle for damages.
• Visually
If the axle is damaged or bent, replace it.
the axle in V blocks that are 100 mm (3.94 in.) [A]
• Place
apart, and set a dial gauge [B] on the axle at a point
halfway between the blocks. Turn [C] the axle to measure the runout. The difference between the highest and
lowest dial readings is the amount of runout.
If axle runout exceeds the service limit, replace the axle.
Axle Runout/100 mm (3.94 in.)
Standard:
TIR 0.1 mm (0.004 in.) or less
Service Limit: TIR 0.2 mm (0.008 in.)
10-10 WHEELS/TIRES
Wheels (Rims)
Balance Inspection
the front and rear wheels (see Front/Rear Wheel
• Remove
Removal).
the wheel so that it can be spun freely.
• Support
Spin
the
lightly, and mark [A] the wheel at the top
• when thewheel
wheel stops.
○Repeat this procedure several times.
If the wheel stops
of its own accord in various positions, it is well balanced.
If the wheel always stops in one position, adjust the wheel
balance (see Balance Adjustment).
Balance Adjustment
the wheel always stops in one position, provisionally
• Ifattach
a balance weight [A] on the rim at the marking using
•
•
•
•
adhesive tape.
Rotate the wheel 1/4 turn [B], and see whether or not the
wheel stops in this position. If it does, the correct balance
weight is being used.
If the wheel rotates and the weight goes up, replace the
weight with the next heavier size. If the wheel rotates and
the weight goes down, replace the weight with the next
lighter size. Repeat these steps until the wheel remains
at rest after being rotated 1/4 turn.
Rotate the wheel another 1/4 turn and then another 1/4
turn to see if the wheel is correctly balanced.
Repeat the entire procedure as many times as necessary
to achieve correct wheel balance.
Permanently install the balance weight.
Balance Weight Removal
the balance weights [A].
• Remove
Discard
the
used balance weight.
•
Balance Weight Installation
a high flash-point solvent, clean off any oil or dirt
• Using
that may be on balance weight installing area.
• Install the balance weight(s).
WARNING
Unbalanced wheels can create an unsafe riding
condition. If the balance weight has any play on the
rib of the rim, it means it is not installed securely
on the rim and it could fly off during riding. Replace
the loose balance weight. Do not reuse the used
balance weight.
WHEELS/TIRES 10-11
Wheels (Rims)
Balance Weight
Weight
10 g (0.35 oz.)
20 g (0.71 oz.)
30 g (1.06 oz.)
NOTE
○Use the commercially available balance weights of 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.
○Do not use four or more balance weight (more than 90
gram, 3.2 oz.). If the wheel requires an excess balance
weight, disassemble the wheel to find the cause.
10-12 WHEELS/TIRES
Tires
Air Pressure Inspection/Adjustment
to the Air Pressure Inspection in the Periodic Main• Refer
tenance chapter.
Tire Inspection
to the Wheel/Tire Damage Inspection in the Peri• Refer
odic Maintenance chapter.
Tire Removal
• Remove:
Wheels (see Front/Rear Wheel Removal)
Valve Core (Let out the air)
maintain wheel balance, mark the valve stem position
• To
on the tire with chalk so that the tire can be reinstalled in
the same position.
Chalk Mark or Painted Mark [A]
Valve Stem [B]
Align [C]
the tire beads and rim flanges on both sides with
• Lubricate
a soap and water solution or rubber lubricant. This helps
the tire beads slip off the rim flanges.
NOTICE
Never lubricate with engine oil or petroleum distillates because they will deteriorate the tire.
the tire from the rim using a suitable commer• Remove
cially available tire changer.
NOTE
○The tires cannot be removed with hand tools because
they fit the rims too tightly.
Tire Installation
WARNING
Mixing tire brands and types can adversely affect
handling and cause an accident resulting in injury
or death. Always use the same manufacturer’s tires
on both front and rear wheels.
the rim and tire, and replace them if necessary.
• Inspect
the sealing surfaces of the rim and tire, and smooth
• Clean
the sealing surfaces of the rim with a fine emery cloth if
•
necessary.
Remove the air valve and discard it.
NOTICE
Replace the air valve whenever the tire is replaced.
Do not reuse the air valve.
WHEELS/TIRES 10-13
Tires
a new valve in the rim.
•○Install
Remove the valve cap, lubricate the stem seal [A] with a
soap and water solution or rubber lubricant, and pull [B]
the valve stem through the rim from the inside out until it
snaps into place.
NOTICE
Do not use engine oil or petroleum distillates to lubricate the stem because they will deteriorate the
rubber.
○The air valve is as shown.
Valve Cap [A]
Valve Core [B]
Stem Seal [C]
Valve Stem [D]
Valve Seat [E]
Valve Opened [F]
the tire rotation mark on the front and rear tires and
• Check
install them on the rim accordingly.
Tire Rotation Mark [A]
Rotating Direction [B]
the tire on the rim so that the valve [A] align with
• Position
the tire balance mark [B] (the chalk mark made during
•
•
•
removal, or the painted mark on a new tire).
Install the tire bead over the rim flange using a suitable
commercially available tire changer.
Lubricate the tire beads and rim flanges with a soap and
water solution or rubber lubricant to help seat the tire
beads in the sealing surfaces of the rim while inflating the
tire.
Center the rim in the tire beads, and inflate the tire with
compressed air until the tire beads seat in the sealing
surfaces.
WARNING
Overinflating a tire can cause it to explode, causing
serious injury or death. Be sure to install the valve
core whenever inflating the tire, and do not inflate
the tire to more than 400 kPa (4.0 kgf/cm², 57 psi).
10-14 WHEELS/TIRES
Tires
to see that the rim lines [A] on both sides of the tire
• Check
sidewalls are parallel with the rim flanges.
If the rim flanges and tire sidewall 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.
After the tire beads seat in the rim flanges, check for air
leakage.
○Inflate the tire slightly above standard inflation.
○Use a soap and water solution or submerge the tire, and
check for bubbles that would indicate leakage.
Adjust the air pressure to the specified pressure (see Air
Pressure Inspection in the Periodic Maintenance chapter).
Install the air valve cap.
Adjust the wheel balance (see Balance Adjustment).
•
•
•
•
•
•
Tire Repair
Currently two types of repair for tubeless tires have come
into wide use. One type is called a temporary (external) repair which can be carried out without removing the tire from
the rim, and the other type is called permanent (internal)
repair which requires tire removal. It is generally understood that higher running durability is obtained by permanent (internal) repairs than by temporary (external) ones.
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 (external) repair. Only appropriate permanent (internal) repairs
are recommended. Repair methods may vary slightly from
make to make. Follow the repair methods indicated by the
manufacturer of the repair tools and materials so that safe
results can be obtained.
WHEELS/TIRES 10-15
Hub Bearing
Hub Bearing Removal
the wheels (see Front/Rear Wheel Removal),
• Remove
and take out the following.
Collars
Coupling (Out of rear hub)
Grease Seals
• Use the bearing remover to remove the hub bearings [A].
NOTICE
Do 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.
Special Tools - Bearing Remover Shaft, 9 [B]: 57001-1265
Bearing Remover Head, 15 × 17 [C]:
57001-1267
Hub Bearing Installation
installing the hub bearings, blow any dirt or foreign
• Before
particles out of the hub with compressed air to prevent
•
•
•
contamination of the bearings.
Replace the bearings with new ones.
Install the bearings by using the bearing driver set which
does not contact the bearing inner race.
Press in the bearings [A] until they are bottomed.
Special Tool - Bearing Driver Set [B]: 57001-1129
the grease seals with new ones.
• Replace
in the grease seals [A] so that the seal surface is
• Press
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 tolerances, the clearance can not normally be measured.
NOTE
○Do not remove any bearings for inspection. If any bearings are removed, they will need to be replaced with
new ones.
each bearing in the hub back and forth [A] while
• Turn
checking for plays, roughness, or binding.
•
If bearing play, roughness or binding is found, replace the
bearing.
Examine the bearing seal [B] for tears or leakage.
If the seal is torn or is leaking, replace the bearing.
10-16 WHEELS/TIRES
Hub Bearing
Hub Bearing Lubrication
NOTE
○Since the hub bearings are packed with grease and
sealed, lubrication is not required.
FINAL DRIVE 11-1
Final Drive
Table of Contents
Exploded View .......................................................................................................................
Specifications ........................................................................................................................
Special Tool ............................................................................................................................
Drive Chain.............................................................................................................................
Drive Chain Slack Inspection ............................................................................................
Drive Chain Slack Adjustment ..........................................................................................
Wheel Alignment Inspection/Adjustment ..........................................................................
Drive Chain Wear Inspection ............................................................................................
Drive Chain Lubrication.....................................................................................................
Drive Chain Guide Wear Inspection..................................................................................
Drive Chain Removal ........................................................................................................
Drive Chain Installation .....................................................................................................
Sprocket, Coupling .................................................................................................................
Engine Sprocket Removal ................................................................................................
Engine Sprocket Installation .............................................................................................
Rear Sprocket Removal....................................................................................................
Rear Sprocket Installation.................................................................................................
Coupling Installation..........................................................................................................
Coupling Bearing Removal ...............................................................................................
Coupling Bearing Installation ............................................................................................
Hub Bearing Inspection.....................................................................................................
Coupling Bearing Lubrication............................................................................................
Coupling Damper Inspection.............................................................................................
Sprocket Wear Inspection.................................................................................................
Rear Sprocket Warp Inspection ........................................................................................
11-2
11-4
11-5
11-6
11-6
11-6
11-6
11-6
11-6
11-6
11-6
11-6
11-7
11-7
11-8
11-8
11-9
11-9
11-9
11-9
11-9
11-10
11-10
11-10
11-10
11
11-2 FINAL DRIVE
Exploded View
FINAL DRIVE 11-3
Exploded View
No.
1
2
3
4
5
Fastener
Engine Sprocket Bolts
Engine Sprocket Cover Bolts
Chain Guide Screws
Rear Axle Nut
Rear Sprocket Stud Bolts
HG: Apply high-temperature grease.
HO: Apply heavy oil.
L: Apply a non-permanent locking agent.
R: Replacement Parts
N·m
11
11
11
108
34
Torque
kgf·m
1.1
1.1
1.1
11.0
3.5
ft·lb
97 in·lb
97 in·lb
97 in·lb
79.7
25
Remarks
L
L
R
L
11-4 FINAL DRIVE
Specifications
Item
Drive Chain
Drive Chain Slack
Drive Chain Wear (19-link Length)
Standard Chain:
Make
Type
Link
Sprockets
Rear Sprocket Warp
Standard
Service Limit
15 ∼ 25 mm (0.59 ∼ 0.98 in.)
301.6 ∼ 302.1 mm (11.87 ∼ 11.89 in.)
– – –
307 mm (12.09 in.)
LGB
520 series
108 links
TIR 0.4 mm (0.016 in.) or less
– – –
– – –
– – –
TIR 0.5 mm (0.020 in.)
FINAL DRIVE 11-5
Special Tool
Bearing Driver Set:
57001-1129
11-6 FINAL DRIVE
Drive Chain
Drive Chain Slack Inspection
to the Drive Chain Slack Inspection in the Periodic
• Refer
Maintenance chapter.
Drive Chain Slack Adjustment
to the Drive Chain Slack Adjustment in the Periodic
• Refer
Maintenance chapter.
Wheel Alignment Inspection/Adjustment
to the Wheel Alignment Inspection in the Periodic
• Refer
Maintenance chapter.
Drive Chain Wear Inspection
to the Drive Chain Wear Inspection in the Periodic
• Refer
Maintenance chapter.
Drive Chain Lubrication
to the Drive Chain Lubrication Condition Inspection
• Refer
in the Periodic Maintenance chapter.
Drive Chain Guide Wear Inspection
to the Chain Guide Wear Inspection in the Periodic
• Refer
Maintenance chapter.
Drive Chain Removal
• Remove:
Mud Guard (see Mud Guard Removal in the Frame
•
chapter)
Swingarm (Swingarm Removal in the Suspension chapter)
Engine Sprocket (see Engine Sprocket Removal)
Remove the drive chain from the frame.
Drive Chain Installation
• Installation is the reverse of removal.
FINAL DRIVE 11-7
Sprocket, Coupling
Engine Sprocket Removal
• Remove:
Engine Sprocket Cover Bolts [A]
Engine Sprocket Cover [B]
• Remove the engine sprocket bolts [A].
NOTE
○When loosening the engine sprocket bolts, hold the rear
brake on.
• Rotate the plate [B] and remove it.
the rear wheel off the ground with the stand.
• Raise
Loosen
the drive chain (see Drive Chain Slack Adjust• ment in the
Periodic Maintenance chapter).
Pull
the
engine
• output shaft [C]. sprocket [A] with drive chain [B] off the
• Disengage the drive chain from the engine sprocket.
necessary, remove the chain guide [A] by removing the
• Ifchain
guide screws [B].
11-8 FINAL DRIVE
Sprocket, Coupling
Engine Sprocket Installation
removing the chain guide, install it.
• When
a non-permanent locking agent to the chain guide
• Apply
screws, and tighten them.
Torque - Chain Guide Screws: 11 N·m (1.1 kgf·m, 97 in·lb)
the engine sprocket [A] onto the output shaft, and
• Install
engage the drive chain.
the plate [B] and rotate it to lock the engine
• Install
sprocket.
a non-permanent locking agent to the engine
• Apply
sprocket bolts, and tighten them.
Torque - Engine Sprocket Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)
NOTE
○Tighten the engine sprocket bolts while applying the
rear brake.
the drive chain slack after installing the engine
• Adjust
sprocket (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter).
• Install:
Engine Sprocket Cover [A]
Engine Sprocket Cover Bolts [B]
Torque - Engine Sprocket Cover Bolts: 11 N·m (1.1 kgf·m,
97 in·lb)
Rear Sprocket Removal
the rear wheel (see Rear Wheel Removal in the
• Remove
Wheels/Tires chapter).
NOTICE
Do 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.
the plates [A] to remove the rear sprocket nuts [B].
• Bend
Remove:
• Rear Sprocket Nuts
Plates
Rear Sprocket [C]
FINAL DRIVE 11-9
Sprocket, Coupling
Rear Sprocket Installation
the sprocket facing the tooth number marking [A]
• Install
outward.
• Install:
Plates
•
•
Rear Sprocket Nuts
Bend the plates to lock the rear sprocket nuts.
Install the rear wheel (see Rear Wheel Installation in the
Wheels/Tires chapter).
Coupling Installation
• Install:
Collar [A]
Coupling [B]
Coupling Bearing Removal
• Remove:
Coupling
•
Grease Seal
Remove the bearing [A] by tapping from the wheel side.
Special Tool - Bearing Driver Set [B]: 57001-1129
Coupling Bearing Installation
the bearing with a new one.
• Replace
Press
in
the
bearing [A] until it is bottomed.
•
Special Tool - Bearing Driver Set [B]: 57001-1129
the grease seal with a new one.
• Replace
Press
in
the
seal so that the seal surface is flush
• with the end grease
of the hole.
○Apply high-temperature grease to the grease seal lips.
Special Tool - Bearing Driver Set: 57001-1129
Hub Bearing Inspection
Since the hub bearings are made to extremely close tolerances, the clearance can not normally be measured.
NOTE
○Do not remove any bearings for inspection. If any bearings are removed, they will need to be replaced with
new ones.
each bearing in the hub back and forth [A] while
• Turn
checking for plays, roughness, or binding.
•
If bearing play, roughness, or binding is found, replace
the bearing.
Examine the bearing seal [B] for tears or leakage.
If the seal is torn or is leaking, replace the bearing.
11-10 FINAL DRIVE
Sprocket, Coupling
Coupling Bearing Lubrication
the bearing with high-temperature grease. Turn the
• Pack
bearing around by hand a few times to make sure the
grease is distributed uniformly inside the bearing.
Coupling Damper Inspection
the rear wheel coupling, and inspect the rubber
• Remove
damper [A].
the damper if it appears damaged or deterio• Replace
rated.
Sprocket Wear Inspection
inspect the engine and rear sprocket teeth for
• Visually
wear and damage.
If the teeth are worn as illustrated, replace the sprocket,
and inspect the drive chain wear (see Drive Chain Wear
Inspection in the Periodic Maintenance chapter).
Worn Tooth (Engine Sprocket) [A]
Worn Tooth (Rear Sprocket) [B]
Direction of Rotation [C]
NOTE
○If a sprocket requires replacement, the chain is probably worn also. When replacing a sprocket, inspect the
chain.
Rear Sprocket Warp Inspection
the rear wheel off the ground with the stand so that
• Raise
it will turn freely.
a dial gauge [A] against the rear sprocket [B] near the
• Set
teeth as shown, and rotate [C] the rear wheel to measure
the sprocket runout (warp). The difference between the
highest and lowest dial gauge readings is the amount of
runout (warp).
If the runout exceeds the service limit, replace the rear
sprocket.
Rear Sprocket Warp
Standard:
TIR 0.4 mm (0.016 in.) or less
Service Limit: TIR 0.5 mm (0.020 in.)
BRAKES 12-1
Brakes
Table of Contents
Exploded View .......................................................................................................................
Specifications ........................................................................................................................
Special Tool ............................................................................................................................
Brake Lever, Brake Pedal.......................................................................................................
Brake Pedal Position Inspection ......................................................................................
Brake Pedal Position Adjustment .....................................................................................
Brake Pedal Bracket Removal ..........................................................................................
Brake Pedal Bracket Installation .......................................................................................
Calipers ..................................................................................................................................
Front Caliper Removal ......................................................................................................
Rear Caliper Removal.......................................................................................................
Caliper Installation ............................................................................................................
Front Caliper Disassembly................................................................................................
Front Caliper Assembly.....................................................................................................
Rear Caliper Disassembly ................................................................................................
Rear Caliper Assembly .....................................................................................................
Caliper Fluid Seal Damage Inspection..............................................................................
Caliper Dust Seal Damage Inspection ..............................................................................
Caliper Friction Boot Damage Inspection .........................................................................
Caliper Piston and Cylinder Damage Inspection ..............................................................
Caliper Holder Shaft Wear Inspection...............................................................................
Brake Pads .............................................................................................................................
Front Brake Pad Removal.................................................................................................
Front Brake Pad Installation..............................................................................................
Rear Brake Pad Removal ................................................................................................
Rear Brake Pad Installation ..............................................................................................
Brake Pad Wear Inspection ..............................................................................................
Master Cylinder ......................................................................................................................
Front Master Cylinder Removal ........................................................................................
Front Master Cylinder Installation .....................................................................................
Rear Master Cylinder Removal.........................................................................................
Rear Master Cylinder Installation......................................................................................
Front Master Cylinder Disassembly ..................................................................................
Rear Master Cylinder Disassembly...................................................................................
Master Cylinder Assembly ................................................................................................
Master Cylinder Inspection (Visual Inspection).................................................................
Brake Disc ..............................................................................................................................
Brake Disc Removal .........................................................................................................
Brake Disc Installation ......................................................................................................
Brake Disc Wear Inspection..............................................................................................
Brake Disc Warp Inspection..............................................................................................
Brake Fluid .............................................................................................................................
Brake Fluid Level Inspection.............................................................................................
Brake Fluid Change ..........................................................................................................
Brake Line Bleeding..........................................................................................................
Brake Hose.............................................................................................................................
Brake Hose Removal/Installation......................................................................................
Brake Hose Inspection......................................................................................................
12-2
12-6
12-7
12-8
12-8
12-8
12-8
12-9
12-10
12-10
12-10
12-10
12-10
12-10
12-11
12-11
12-11
12-11
12-12
12-12
12-13
12-14
12-14
12-14
12-14
12-14
12-15
12-16
12-16
12-16
12-17
12-17
12-17
12-17
12-17
12-18
12-19
12-19
12-19
12-19
12-19
12-20
12-20
12-20
12-20
12-23
12-23
12-23
12
12-2 BRAKES
Exploded View
BRAKES 12-3
Exploded View
No.
1
2
Fastener
Front Caliper Mounting Bolts
Front Brake Disc Mounting Bolts
B: Apply brake fluid.
L: Apply a non-permanent locking agent.
R: Replacement Parts
Si: Apply silicone grease.
N·m
25
28
Torque
kgf·m
2.5
2.9
ft·lb
18
21
Remarks
L
L
12-4 BRAKES
Exploded View
BRAKES 12-5
Exploded View
No.
1
2
3
Fastener
Rear Brake Disc Mounting Bolts
Brake Pedal Clamp Bolt
Brake Light Switch Bracket Bolt
L: Apply a non-permanent locking agent.
R: Replacement Parts
N·m
9.8
20
4.9
Torque
kgf·m
1.0
2.0
0.50
ft·lb
87 in·lb
15
43 in·lb
Remarks
L
12-6 BRAKES
Specifications
Item
Brake Lever, Brake Pedal
Brake Lever Free Play
Pedal Free Play
Pedal Position
Brake Fluid
Grade
Brake Pads
Lining Thickness:
Front
Rear
Brake Discs
Thickness:
Front
Rear
Runout:
Front
Rear
Standard
Service Limit
Non-adjustable
20 ∼ 25 mm (0.79 ∼ 0.98 in.)
About 48 mm (1.89 in.) below top of
footpeg
– – –
– – –
– – –
DOT3 or DOT4
– – –
6.35 mm (0.250 in.)
6.0 mm (0.236 in.)
1.0 mm (0.04 in.)
1.0 mm (0.04 in.)
3.8 ∼ 4.2 mm (0.15 ∼ 0.17 in.)
3.8 ∼ 4.2 mm (0.15 ∼ 0.17 in.)
3.6 mm (0.14 in.)
3.6 mm (0.14 in.)
TIR 0.15 mm (0.006 in.) or less
TIR 0.15 mm (0.006 in.) or less
TIR 0.3 mm (0.01 in.)
TIR 0.3 mm (0.01 in.)
BRAKES 12-7
Special Tool
Jack:
57001-1238
12-8 BRAKES
Brake Lever, Brake Pedal
Brake Pedal Position Inspection
• Check that the brake pedal [A] is in the correct position.
Pedal Position
Standard: About 48 mm (1.89 in.) [B] below top of
footpeg [C]
If it is incorrect, adjust the brake pedal position.
Brake Pedal Position Adjustment
NOTE
○Usually it is not necessary to adjust the pedal position,
but always adjust it when push rod locknut has been
loosened.
the push rod [A] (see Brake Pedal Bracket Re• Remove
moval).
the locknut [B] and turn the push rod to adjust the
• Loosen
correct length.
•
•
•
If the length [C] shown is 31.5 ±3 mm (1.24 ±0.12 in.), the
pedal position will be within the standard range.
Tighten the locknut.
Install the removed parts (see Brake Pedal Bracket Installation).
Check the brake light switch operation (see Brake Light
Switch Operation Inspection in the Periodic Maintenance
chapter).
Brake Pedal Bracket Removal
• Remove the front footpeg bracket bolts [A].
• Remove:
Rear Brake Light Switch Bracket Bolt [A]
•
Rear Brake Light Switch Spring [B]
Rear Master Cylinder Mounting Bolts [C]
Cotter Pin [D]
Joint Pin [E] and Washer
Remove the brake pedal bracket.
BRAKES 12-9
Brake Lever, Brake Pedal
• Remove:
Brake Pedal Clamp Bolt [A]
Brake Pedal [B]
• Remove:
Pivot Shaft [A]
Spring [B]
Collar [C]
Brake Pedal Bracket Installation
the O-rings [A] with new ones.
• Replace
grease to the O-rings and the sliding surface of the
• Apply
pivot shaft [B].
• Install:
Collar [C]
Spring [D]
Pivot Shaft
the brake pedal so that the punch mark [A] on the
• Install
pivot shaft aligns with the slit [B] of the brake pedal.
• Tighten:
Torque - Brake Pedal Clamp Bolt [C]: 20 N·m (2.0 kgf·m, 15
ft·lb)
• Install:
Rear Master Cylinder Mounting Bolts [A]
Rear Brake Light Switch Bracket Bolt [B]
Rear Brake Light Switch Spring [C]
Torque - Brake Light Switch Bracket Bolt: 4.9 N·m (0.50
kgf·m, 43 in·lb)
the joint pin [D] and washer [E].
• Install
the cotter pin [F] with a new one.
• Replace
Insert
the
cotter pin and bend the pin ends.
• Install the brake
• bracket bolts. pedal bracket and tighten the brake pedal
the brake pedal position (see Brake Pedal Position
• Check
Inspection).
12-10 BRAKES
Calipers
Front Caliper Removal
the banjo bolt [A] at the brake hose lower end,
• Loosen
and tighten it loosely.
the caliper mounting bolts [B], and remove the
• Remove
caliper [C] from the disc.
the banjo bolt and remove the brake hose from
• Unscrew
the caliper (see Brake Hose and Pipe Replacement in the
Periodic Maintenance chapter).
NOTICE
Immediately wash away any brake fluid that spills.
Rear Caliper Removal
the banjo bolt [A] at the brake hose lower end,
• Loosen
and tighten it loosely.
the rear wheel (see Rear Wheel Removal in the
• Remove
Wheels/Tires chapter).
the rear caliper [B].
• Remove
Unscrew
banjo bolt and remove the brake hoses from
• the caliperthe(see
Brake Hose and Pipe Replacement in the
Periodic Maintenance chapter).
NOTICE
Immediately wash away any brake fluid that spills.
Caliper Installation
the caliper and brake hose lower end.
•○Install
Replace the washers on each side of hose fitting with new
•
•
ones.
Apply a non-permanent locking agent to the front caliper
mounting bolts.
Tighten:
Torque - Front Caliper Mounting Bolts: 25 N·m (2.5 kgf·m,
18 ft·lb)
the removed parts (see appropriate chapters).
• Install
Check
the fluid level in the brake reservoirs.
• Bleed the
line (see Brake Line Bleeding).
• Check thebrake
brake
for good braking power, no brake drag,
• and no fluid leakage.
WARNING
After servicing, it takes several applications of the
brake lever or pedal before the brake pads contact
the disc, which could result in increased stopping
distance and cause an accident resulting in injury
or death. Do not attempt to ride the motorcycle until
a firm brake lever or pedal is obtained by pumping
the lever or pedal until the pads are against the disc.
Front Caliper Disassembly
to the Caliper Rubber Parts Replacement in the Pe• Refer
riodic Maintenance chapter.
Front Caliper Assembly
to the Caliper Rubber Parts Replacement in the Pe• Refer
riodic Maintenance chapter.
BRAKES 12-11
Calipers
Rear Caliper Disassembly
to the Caliper Rubber Parts Replacement in the Pe• Refer
riodic Maintenance chapter.
Rear Caliper Assembly
to the Caliper Rubber Parts Replacement in the Pe• Refer
riodic Maintenance chapter.
Caliper Fluid Seal Damage Inspection
The fluid seal (piston seal) [A] is placed around the piston to maintain clearance between the pad and the disc. If
the seal is in a poor condition, it could lead the pad to wear
excessively or the brake to drag, which may cause the temperature of the discs or the brake fluid to increase.
Replace the fluid seal if it exhibits any of the conditions
listed below.
○Brake fluid leakage around the pad.
○Brakes overheat.
○Considerable difference in inner and outer pad wear.
○Seal and piston are stuck together.
If the fluid seal is replaced, replace the dust seal [B] as
well. Also, replace all seals every other time the pads are
changed.
•
NOTE
○The fluid seals and dust seals are included in the replacement kit.
Caliper Dust Seal Damage Inspection
that the dust seals [A] are not cracked, worn,
• Check
swollen, or otherwise damaged.
If they show any damage, replace the dust seals with new
ones.
Fluid Seals [B]
NOTE
○The fluid seals and dust seals are included in the replacement kit.
12-12 BRAKES
Calipers
Caliper Friction Boot Damage Inspection
that the friction boots [A] are not cracked, worn,
• Check
swollen, or otherwise damaged.
If they show any damage, replace it.
NOTE
○The friction boots of the rear caliper are included in the
replacement parts.
Caliper Piston and Cylinder Damage Inspection
inspect the pistons [A] and cylinder surfaces [B].
• Visually
Replace the caliper if the cylinder and piston are badly
scores or rusty.
NOTE
○The caliper pistons are included in the replacement kit.
BRAKES 12-13
Calipers
Caliper Holder Shaft Wear Inspection
The caliper body must slide smoothly on the caliper holder
shafts [A]. If the body does not slide smoothly, one pad will
wear more than the other, pad wear will increase, and constant drag on the disc will raise brake and brake fluid temperature.
Check to see that the caliper holder shafts are not badly
worn or stepped, and that the friction boots are not damaged.
If the caliper holder shaft is damage, replace the caliper.
•
12-14 BRAKES
Brake Pads
Front Brake Pad Removal
• Remove:
Snap Pins [A]
Pad Pin [B]
Brake Pads [C]
Front Brake Pad Installation
the caliper pistons in as far as they will go.
• Push
that the pad spring [A] is in place on the caliper.
• Check
Install
the
pads [B] and insert the pad pin [C].
• Install the brake
snap
pins.
•
WARNING
After servicing, it takes several applications of the
brake lever before the brake pads contact the disc,
which could result in increased stopping distance
and cause an accident resulting in injury or death.
Do not attempt to ride the motorcycle until a firm
brake lever is obtained by pumping the lever until
the pads are against the disc.
Rear Brake Pad Removal
• Remove:
Snap Pins [A]
Pad Pin [B]
Brake Pads [C]
Rear Brake Pad Installation
the caliper piston in as far as it will go.
• Push
Install
brake pads [A] and insert the pad pin [B].
• Install the
the
snap pins.
•
WARNING
After servicing, it takes several applications of the
brake pedal before the brake pads contact the disc,
which could result in increased stopping distance
and cause an accident resulting in injury or death.
Do not attempt to ride the motorcycle until a firm
brake pedal is obtained by pumping the pedal until
the pads are against the disc.
BRAKES 12-15
Brake Pads
Brake Pad Wear Inspection
to the Brake Pad Wear Inspection in the Periodic
• Refer
Maintenance chapter.
12-16 BRAKES
Master Cylinder
Front Master Cylinder Removal
the rear view mirror [A] (see Rear View Mirror
• Remove
Removal in the Frame chapter).
the banjo bolt [B] and remove the brake hose
• Remove
from the master cylinder (see Brake Hose and Pipe Re-
•
•
placement in the Periodic Maintenance chapter).
Remove the clamp bolts [C], and take off the master cylinder as an assembly with the reservoir, brake lever, and
front brake light switch installed.
Disconnect the front brake light switch connectors [D].
NOTICE
Immediately wash away any brake fluid that spills.
• Remove:
Brake Lever Pivot Bolt Locknut [A]
Brake Lever Pivot Bolt [B]
Brake Lever [C]
Front Brake Light Switch [D]
Front Master Cylinder Installation
silicone grease to the sliding surface of the brake
• Apply
lever pivot bolt.
the brake lever and tighten the brake lever pivot
• Install
bolt.
the brake lever pivot bolt locknut with a new one,
• Replace
and tighten it.
• Install the front brake light switch.
the front master cylinder to match its mating surface
• Set
[A] to the punch mark [B] of the handlebar.
the clamp bolts [C].
• Tighten
Connect
front brake light switch connectors.
• Replace the
the
that are on each side of the hose
• fitting with newwashers
ones.
Install
the
brake
• Tighten the brakehose.
banjo bolt.
• Install the rear viewhose
mirror
(see Rear View Mirror Installa• tion).
the brake line (see Brake Line Bleeding).
• Bleed
Check
brake for good braking power, no brake drag,
• and nothe
fluid leakage.
BRAKES 12-17
Master Cylinder
Rear Master Cylinder Removal
the clamp [A].
• Remove
the brake hose banjo bolt [B] and remove the
• Unscrew
brake hose (see Brake Hose and Pipe Replacement in
•
the Periodic Maintenance chapter).
Open the clamp [C] and disconnect the reservoir hose
lower end [D].
NOTICE
Immediately wash away any brake fluid that spills.
• Remove:
Cotter Pin [A]
Joint Pin [B] and Washer
Rear Master Cylinder Mounting Bolts [C]
Rear Master Cylinder [D]
Rear Master Cylinder Installation
a non-permanent locking agent to the rear master
• Apply
cylinder mounting bolts [A].
the rear master cylinder, and tighten their bolts.
• Install
the joint pin [B] and washer [C].
• Install
Replace
cotter pin [D] with a new one.
• Insert thethecotter
pin and bend the pin ends.
• Install the reservoir
hose lower end to the rear master
• cylinder.
the washers that are on each side of hose fitting
• Replace
with new ones.
the brake hose and tighten the brake hose banjo
• Install
bolt so that the brake hose [A] is not in contact with the
•
•
mud guard [B].
Angle [C]: About 10°
Bleed the brake line (see Brake Line Bleeding).
Check the brake for good braking power, no brake drag,
and no fluid leakage.
Front Master Cylinder Disassembly
to the Master Cylinder Rubber Parts Replacement
• Refer
in the Periodic Maintenance chapter.
Rear Master Cylinder Disassembly
to the Master Cylinder Rubber Parts Replacement
• Refer
in the Periodic Maintenance chapter.
Master Cylinder Assembly
to the Master Cylinder Rubber Parts Replacement
• Refer
in the Periodic Maintenance chapter.
12-18 BRAKES
Master Cylinder
Master Cylinder Inspection (Visual Inspection)
the master cylinders (see Front/Rear Master
• Remove
Cylinder Removal).
the front and rear master cylinders (see
• Disassemble
Master Cylinder Rubber Parts Replacement in the Peri-
•
odic Maintenance chapter).
Check that there are no scratches, rust or pitting on the
inner wall [A] of each master cylinder and on the outside
of each piston [B].
If a master cylinder or piston shows any damage, replace
them.
NOTE
○Replacement parts of the master cylinder are included
in the replacement kit.
the primary cup [C] and secondary cup [D].
• Inspect
If a cup is worn, damaged softened (rotted), or swollen,
•
•
•
the piston assembly should be replaced to renew the
cups.
If fluid leakage is noted at the brake lever, the piston assembly should be replaced to renew the cups.
Check the dust covers [E] for damage.
If they are damaged, replace them.
Check the piston return springs [F] for any damage.
If the springs are damaged, replace them.
Check that relief port [G] and supply port [H] are not
plugged.
If the relief port becomes plugged, the brake pads will
drag on the disc. Blow the ports clean with compressed
air.
Front Master Cylinder [I]
Rear Master Cylinder [J]
BRAKES 12-19
Brake Disc
Brake Disc Removal
the wheels (see Front/Rear Wheel Removal in
• Remove
the Wheels/Tires chapter).
the brake disc mounting bolts [A], and take off
• Remove
the disc [B].
Brake Disc Installation
the brake disc on the wheel so that the marked side
• Install
[A] faces out.
a non-permanent locking agent to the threads of
• Apply
the brake disc mounting bolts.
• Tighten:
Torque - Front Brake Disc Mounting Bolts: 28 N·m (2.9
kgf·m, 21 ft·lb)
Rear Brake Disc Mounting Bolts: 9.8 N·m (1.0
kgf·m, 87 in·lb)
Brake Disc Wear Inspection
the thickness of the disc [A] at the point where it
• Measure
has worn the most.
If the disc has worn past the service limit, replace it.
Measuring Area [B]
Brake Disc Thickness
Standard:
Front
3.8 ∼ 4.2 mm (0.15 ∼ 0.17 in.)
Rear
3.8 ∼ 4.2 mm (0.15 ∼ 0.17 in.)
Service Limit:
Front
3.6 mm (0.14 in.)
Rear
3.6 mm (0.14 in.)
Brake Disc Warp Inspection
the wheel off the ground with the center stand or
• Raise
jack.
Special Tool - Jack: 57001-1238
○For front disc inspection, turn the handlebar fully to one
•
side.
Set up a dial gauge against the disc [A] as shown and
measure disc runout, while turning [B] the wheel by hand.
If runout exceeds the service limit, replace the disc.
Brake Disc Runout
Standard:
Front
TIR 0.15 mm (0.006 in.) or less
Rear
TIR 0.15 mm (0.006 in.) or less
Service Limit: TIR 0.3 mm (0.01 in.)
12-20 BRAKES
Brake Fluid
Brake Fluid Level Inspection
to the Brake Fluid Level Inspection in the Periodic
• Refer
Maintenance chapter.
Brake Fluid Change
to the Brake Fluid Change in the Periodic Mainte• Refer
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. Air,
however, is easily compressed. When air enters the brake
lines, brake lever or pedal movement will be partially used
in compressing the air. This will make the lever or pedal feel
spongy, and there will be a loss in braking power.
WARNING
Air in the brake lines diminish braking performance
and can cause an accident resulting in injury or
death. If the brake lever or pedal has a soft or
"spongy" feeling mushy when it is applied, there
might be air in the brake lines or the brake may be
defective. Do not operate the vehicle and service
the brake system immediately.
NOTE
○The procedure to bleed the front brake line is as follows.
Bleeding the rear brake line is the same as for the front
brake.
• Remove:
Screw [A]
Front Brake Reservoir Cap [B]
• Remove:
Bolt [A]
Stopper [B]
Rear Brake Reservoir Cap [C]
BRAKES 12-21
Brake Fluid
• Remove:
Diaphragm Plate
•
•
Diaphragm
Fill the reservoir with fresh brake fluid to the upper level
line in the reservoir.
Slowly pump the brake lever several times until no air
bubbles can be seen rising up through the fluid from the
holes at the bottom of the reservoir.
the rubber cap [A] from the bleed valve on the
• Remove
caliper.
a clear plastic hose [B] to the bleed valve, and run
• Attach
the other end of the hose into a container.
the brake line and the caliper.
•○Bleed
Repeat this operation until no more air can be seen coming out into the plastic hose.
1. Pump the brake lever until it becomes hard, and apply
the brake and hold it [A].
2. Quickly open and close [B] the bleed valve while holding the brake applied.
3. Release the brake [C].
NOTE
○The fluid level must be checked often during the bleed-
ing operation and replenished with fresh brake fluid as
necessary. If the fluid in the reservoir runs completely
out any time during bleeding, the bleeding operation
must be done over again from the beginning since air
will have entered the line.
○Tap the brake hose lightly from the caliper to the reservoir for more complete bleeding.
the clear plastic hose.
• Remove
Install:
• Diaphragm
Diaphragm Plate
Brake Reservoir Cap
the procedure below to install the rear brake fluid
• Follow
reservoir cap correctly.
○First, tighten the brake fluid reservoir cap [B] clockwise
[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 fluid
reservoir body [A].
12-22 BRAKES
Brake Fluid
the bleed valve, and install the rubber cap.
• Tighten
Check
the
level (see Brake Fluid Level Inspection in
• the Periodicfluid
Maintenance chapter).
After
bleeding
done, check the brake for good braking
• power, no brakeis drag,
and no fluid leakage.
WARNING
When working with the disc brake, observe the precautions 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.
Do not mix two types and brands of fluid for use
in the brake. This lowers the brake fluid boiling
point and could cause the brake to be ineffective.
It may also cause the rubber brake parts to deteriorate.
Don’t leave the reservoir cap off for any length of
time to avoid moisture contamination of the fluid.
Don’t change the fluid in the rain or when a strong
wind is blowing.
Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning of the brake parts. Do not use any other
fluid for cleaning these parts. Gasoline, engine
oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any
part will be difficult to wash off completely and will
eventually deteriorate the rubber used in the disc
brake.
When handling the disc pads or disc, be careful
that no disc brake fluid or any oil gets on them.
Clean off any fluid or oil that inadvertently gets on
the pads or disc with a high flash-point solvent.
Do not use one which will leave an oily residue.
Replace the pads with new ones if they cannot be
cleaned satisfactorily.
Brake fluid quickly ruins painted surfaces; any
spilled fluid should be completely wiped up immediately.
If any of the brake line fittings or the bleed valve is
opened at any time, the AIR MUST BE BLED FROM
THE BRAKE LINE.
•
•
•
•
•
•
•
•
•
BRAKES 12-23
Brake Hose
Brake Hose Removal/Installation
to the Brake Hose and Pipe Replacement in the
• Refer
Periodic Maintenance chapter.
Brake Hose Inspection
to the Brake Hose and Pipe Damage and Instal• Refer
lation Condition Inspection in the Periodic Maintenance
chapter.
SUSPENSION 13-1
Suspension
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Front Fork ...............................................................................................................................
Front Fork Removal (Each Fork Leg) ...............................................................................
Front Fork Installation (Each Fork Leg) ............................................................................
Front Fork Oil Change ......................................................................................................
Front Fork Disassembly ....................................................................................................
Front Fork Assembly.........................................................................................................
Inner Tube, Outer Tube Inspection ...................................................................................
Dust Seal Inspection .........................................................................................................
Spring Tension Inspection.................................................................................................
Rear Shock Absorber .............................................................................................................
Spring Preload Adjustment ...............................................................................................
Rear Shock Absorber Removal ........................................................................................
Rear Shock Absorber Installation .....................................................................................
Rear Shock Absorber Inspection ......................................................................................
Rear Shock Absorber Scrapping ......................................................................................
Swingarm................................................................................................................................
Swingarm Removal...........................................................................................................
Swingarm Installation........................................................................................................
Swingarm Bearing Removal .............................................................................................
Swingarm Bearing Installation ..........................................................................................
Swingarm Bearing, Sleeve Inspection ..............................................................................
13-2
13-6
13-7
13-8
13-8
13-8
13-9
13-11
13-12
13-14
13-14
13-14
13-15
13-15
13-15
13-16
13-16
13-16
13-17
13-17
13-17
13-17
13-18
13-18
13
13-2 SUSPENSION
Exploded View
SUSPENSION 13-3
Exploded View
No.
1
2
3
4
Fastener
Front
Front
Front
Front
Fork Clamp Bolts (Upper)
Fork Clamp Bolts (Lower)
Fork Top Plugs
Fork Bottom Allen Bolts
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
N·m
19
27
27
24
Torque
kgf·m
1.9
2.8
2.8
2.4
ft·lb
14
20
20
18
Remarks
L
13-4 SUSPENSION
Exploded View
SUSPENSION 13-5
Exploded View
No.
Fastener
1 Rear Shock Absorber Bolts
2 Swingarm Pivot Shaft Nut
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
N·m
34
137
Torque
kgf·m
3.5
14.0
ft·lb
25
101
Remarks
L
13-6 SUSPENSION
Specifications
Item
Front Fork (Per One Unit)
Fork Inner Tube Diameter
Air Pressure
Damper Setting
Fork Spring Setting
Suspension Oil:
Recommended Oil
Amount
Fork Oil Level
Fork Spring Free Length
Rear Shock Absorber
Damper Setting
Spring Preload Setting Position
Gas Pressure
Standard
37 mm (1.5 in.)
Atmospheric pressure (Non-adjustable)
Non-adjustable
Non-adjustable
SAE 10W20 Endurance 2F
Approx. 270 mL (9.13 US oz.) (when changing oil)
285 ±2.5 mL (9.64 ±0.09 US oz.) (after disassembly and
completely dry)
195 mm (7.68 in.) (below from inner tube top with fully
compressed, without fork spring)
478 mm (18.81 in.)
(Service Limit: 468.5 mm (18.44 in.))
Non-adjustable
2nd position (Adjustable Range: 1st ∼ 9th position)
1 500 ∼ 1 700 kPa (15.3 ∼ 17.3 kgf/cm², 218 ∼ 247 psi,
Non-adjustable)
SUSPENSION 13-7
Special Tools
Fork Cylinder Holder Handle:
57001-183
Fork Oil Level Gauge:
57001-1290
Oil Seal & Bearing Remover:
57001-1058
Fork Oil Seal Driver Weight,
57001-1795
Steering Stem Nut Wrench:
57001-1100
Fork Oil Seal Driver Attachment,
57001-1798
Bearing Driver Set:
57001-1129
Bushing Remover
57001-E008
Jack:
57001-1238
26 ∼ 46:
36 ∼ 46:
13-8 SUSPENSION
Front Fork
Front Fork Removal (Each Fork Leg)
• Remove:
Front Wheel
(see Front Wheel Removal in the
Wheels/Tires chapter)
Front Fender (see Front Fender Removal in the Frame
chapter)
If the fork leg is to be disassembled, do the following procedures.
○Remove the handlebar holder (see Handlebar Holder Removal in the Steering chapter).
○Loosen the front fork top plug [A].
NOTE
○Loosen the top plug after loosening the upper front fork
clamp bolt [B].
• Loosen:
Front Fork Clamp Bolt (Upper) [A]
•
Front Fork Clamp Bolt (Lower) [B]
With a twisting motion, work the fork leg down and out.
Front Fork Installation (Each Fork Leg)
If the fork leg was to be disassembled, do the following
procedures.
○Install the fork leg and tighten the lower front fork clamp
bolt temporarily.
○Tighten the front fork top plug [A].
Torque - Front Fork Top Plug: 27 N·m (2.8 kgf·m, 20 ft·lb)
○Install the handlebar holder (see Handlebar Holder Installation in the Steering chapter).
sure that the collars [A] and rubber dampers [B] are
• Make
in position.
the fork leg so that its top end touches the handle• Install
bar holder.
• Tighten:
Torque - Front Fork Clamp Bolt (Upper) [C]: 19 N·m (1.9
kgf·m, 14 ft·lb)
Front Fork Clamp Bolt (Lower) [D]: 27 N·m (2.8
kgf·m, 20 ft·lb)
• Install the removed parts (see appropriate chapters).
SUSPENSION 13-9
Front Fork
Front Fork Oil Change
• Remove:
Front Fork (see Front Fork Removal (Each Fork Leg))
Top Plug [A]
Collar [B]
Fork Spring Seat [C]
Fork Spring [D]
the fork oil into a suitable container [A].
•○Drain
Pump the outer tube up and down at least ten times to
expel the oil from the fork.
the fork tube upright, press the inner tube.
• Hold
Pour
• in the type and amount of fork oil specified.
Suspension Oil
Recommended Oil:
SAE 10W20 Endurance 2F
Amount (Per Side):
When changing oil:
Approx. 270 mL (9.13 US oz.)
After disassembly and completely dry:
285 ±2.5 mL (9.64 ±0.09 US oz.)
the oil level as follows.
•○Measure
Hold the outer tube vertically in a vise.
○Pump the inner tube several times to expel air bubbles.
○Wait until the oil level settles.
○With the fork fully compressed, insert a tape measure or
rod into the inner tube, and measure the distance from
the top of the inner tube to the oil.
Oil Level (fully compressed without spring)
Standard:
195 mm (7.68 in.)
13-10 SUSPENSION
Front Fork
If the oil is above or below the specified level, remove or
add oil and recheck the oil level.
NOTE
○Fork oil level may also be measured using the fork oil
level gauge [A] as follows.
Special Tool - Fork Oil Level Gauge: 57001-1290
○Set the oil gauge stopper [B] so that its lower side shows
the oil level distance specified [C].
○Insert the gauge tube into the inner tube [D] and position
the stopper across the inner tube top end [E].
○Pull the handle slowly to draw out the excess oil until no
more oil comes up the tube.
If no oil is drawn out, there is not enough oil in the inner
tube. Pour in some more oil, then draw out the excess.
the fork spring [A] so that the closed coil end [B]
• Install
faces downward [C].
the O-ring [A] with a new one.
• Replace
Install:
• Fork Spring [B]
Fork Spring Seat [C]
Collar [D]
Top Plug [E] with new O-ring
Front Fork (see Front Fork Installation (Each Fork Leg))
SUSPENSION 13-11
Front Fork
Front Fork Disassembly
the front fork and drain the fork oil (see Front
• Remove
Fork Oil Change).
the fork leg horizontally in a vise [A].
• Hold
Loosen
the front fork bottom Allen bolt [B] while holding
• the cylinder
unit [C] with a commercially available 16 mm
(5/8 in.) Allen socket [D] and fork cylinder holder handle
[E].
Special Tool - Fork Cylinder Holder Handle: 57001-183
• Remove the front fork bottom Allen bolt and gasket [F].
• Remove:
Cylinder Unit [A]
Spring [B]
• Remove the dust seal [A].
the outer tube [A] and the inner tube [B].
• Separate
• Remove the cylinder base [C].
13-12 SUSPENSION
Front Fork
• Remove the retaining ring [A] from the outer tube.
the oil seal [A], washer [B] and bushing [C] as a
• Remove
set with bushing remover [D].
Special Tool - Bushing Remover: 57001-E008
Front Fork Assembly
the following parts with new ones.
• Replace
Bushing [A]
Oil Seal [B]
Bottom Allen Bolt Gasket [C]
the cylinder unit [A] and spring [B] to the inner tube
• Install
so that the large diameter [C] of the spring is downward.
If the collar [D] is damaged, replace it with a new one.
the cylinder base [A] to the cylinder unit [B].
• Install
• Install the inner tube to the outer tube.
SUSPENSION 13-13
Front Fork
non-permanent locking agent to the threads of the
• Apply
front fork bottom Allen bolt [A] and screw it to the cylinder
•
•
unit [B] with the new gasket [C].
Hold the front fork horizontally in a vise [D].
Tighten the front fork bottom Allen bolt while holding the
cylinder unit with a commercially available 16 mm (5/8 in.)
Allen socket [E] and fork cylinder holder handle [F].
Special Tool - Fork Cylinder Holder Handle: 57001-183
Torque - Front Fork Bottom Allen Bolt: 24 N·m (2.4 kgf·m,
18 ft·lb)
the new bushing [A] and washer [B] into the outer
• Install
tube using the special tools, until the washer is bottomed.
Special Tools - Fork Oil Seal Driver Weight, 26 ∼ 46 [C]:
57001-1795
Fork Oil Seal Driver Attachment, 36 ∼ 46
[D]: 57001-1798
grease to the oil seal lips, and install the oil seal [A]
• Apply
to the inner tube from the top.
○Install the oil seal with its lip side [B] facing up.
the oil seal into the bottom case using the special
• Install
tools until the oil seal is bottomed.
Special Tools - Fork Oil Seal Driver Weight, 26 ∼ 46 [C]:
57001-1795
Fork Oil Seal Driver Attachment, 36 ∼ 46
[D]: 57001-1798
• Install:
Retaining Ring
•
Dust Seal
Pour in the specified type of oil (see Front Fork Oil
Change).
13-14 SUSPENSION
Front Fork
Inner Tube, Outer Tube Inspection
inspect the inner tube [A].
• Visually
If there is any damage, replace the inner tube.
Since
damage to the inner tube damages the oil seal and dust
seal, replace the oil seal and dust seal whenever the inner
tube is replaced.
NOTICE
If the inner tube is badly bent or creased, replace
it. Excessive bending, followed by subsequent
straightening, can weaken the inner tube.
assemble the inner [A] and outer [B] tubes,
• Temporarily
and pump [C] them back and forth manually to check for
smooth operation.
If you feel binding or catching, the inner and outer tubes
must be replaced.
WARNING
A straightened inner or outer fork tube may fall in
use, possibly causing an accident resulting in serious injury or death. Replace a badly bent or damaged inner or outer tube and inspect the other tube
carefully before reusing it.
Dust Seal Inspection
the dust seal [A] for any signs of deterioration or
• Inspect
damage.
Replace it if necessary.
Spring Tension Inspection
a spring becomes shorter as it weakens, check its
• Since
free length [A] to determine its condition.
If the spring of either fork leg is shorter than the service
limit, it must be replaced. If the length of a replacement
spring and that of the remaining spring vary greatly, the
remaining spring should also be replaced in order to keep
the fork legs balanced for motorcycle stability.
Fork Spring Free Length
Standard:
478 mm (18.81 in.)
Service Limit:
468.5 mm (18.44 in.)
SUSPENSION 13-15
Rear Shock Absorber
Spring Preload Adjustment
the motorcycle up on its center stand.
• Set
the wrench [A], turn the adjusting nut to adjust the
• Using
spring preload.
Rear Shock Absorber [B]
Special Tool - Steering Stem Nut Wrench: 57001-1100
Spring Preload Setting
Standard Position:
2nd position
1st ∼ 9th position
Adjustable Range:
If the compression of the spring is not suited to the operating conditions, adjust it to an appropriate position by
referring to the table below.
Spring Preload Adjustment
Shock
Adjuster Damping
Absorber
Position
Force
Hardness
Load
Road
Conditions
Driving
Speed
1st
Weak
Soft
Light
Good
Low
↑
↑
↑
↑
↑
↑
↓
↓
↓
↓
↓
↓
9th
Strong
Hard
Heavy
Bad
Highway
Rear Shock Absorber Removal
• Raise the rear wheel off the ground with the jack.
Special Tool - Jack: 57001-1238
• Remove:
Side Covers (see Side Cover Removal in the Frame
chapter)
Battery (see Battery Removal in the Electrical System
chapter)
Battery Case Bolts [A]
Battery Case [B]
• Remove the rear shock absorber bolt (lower) [A].
13-16 SUSPENSION
Rear Shock Absorber
the rear shock absorber bolt (upper) [A], and re• Remove
move the rear shock absorber [B] upward.
Rear Shock Absorber Installation
a non-permanent locking agent to the rear shock
• Apply
absorber bolts.
the rear shock absorber, and tighten the rear shock
• Install
absorber bolts.
Torque - Rear Shock Absorber Bolts: 34 N·m (3.5 kgf·m, 25
ft·lb)
• Install the battery case.
Torque - Battery Case Bolts: 18 N·m (1.8 kgf·m, 13 ft·lb)
• Install the removed parts (see appropriate chapters).
Rear Shock Absorber Inspection
the rear shock absorber (see Rear Shock Ab• Remove
sorber Removal).
inspect the following items.
• Visually
Oil Leakage
•
Crack or Dent
If there is any damage to the rear shock absorber replace
it.
Visually inspect the rubber bushings [A].
If they show any signs of damage, replace the rear shock
absorber.
Rear Shock Absorber Scrapping
WARNING
Pressurized nitrogen may explode when heated.
The rear shock contains nitrogen gas. To avoid
an explosion, do not incinerate the shock body
without first releasing the nitrogen.
the rear shock absorber (see Rear Shock Ab• Remove
sorber Removal).
the cap [A].
• Remove
Drill
the
hole
[B] of the reservoir tank using about 2 mm
• (0.08 in.) drillbit.
WARNING
Pressurized gas can cause injury. Do not point the
drill toward your face or body.
SUSPENSION 13-17
Swingarm
Swingarm Removal
• Raise the rear wheel off the ground with the jack.
Special Tool - Jack: 57001-1238
• Remove:
Rear Wheel
(see Rear Wheel Removal in the
Wheels/Tires chapter)
Mud Guard (see Mud Guard Removal in the Frame
chapter)
Remove the brake hose banjo bolt [A], and remove the
brake hose [B].
Remove the rear shock absorber bolt (lower) [C].
•
•
• Remove:
Cap [A] (Both Sides)
•
Swingarm Pivot Shaft Nut [B]
Pull out the swingarm pivot shaft to the left side, and remove the swingarm.
Swingarm Installation
Visually inspect the chain guide [A].
• Replace
the chain guide if it shows any signs of abnormal
•
•
wear or damage.
Install the swingarm, and insert the swingarm pivot shaft
from the left side.
Tighten:
Torque - Swingarm Pivot Shaft Nut: 137 N·m (14.0 kgf·m,
101 ft·lb)
○Install the removed parts (see appropriate chapters).
Swingarm Bearing Removal
• Remove:
Swingarm (see Swingarm Removal)
Sleeve [A]
Spacer [B]
Oil Seals [C]
13-18 SUSPENSION
Swingarm
• Remove the needle bearing.
Special Tool - Oil Seal & Bearing Remover [A]: 57001-1058
Swingarm Bearing Installation
the needle bearing [A] with a new one.
• Replace
• Press in the needle bearing.
Special Tool - Bearing Driver Set [B]: 57001-1129
the needle bearing position as shown.
• Install
About 9 mm (0.35 in.) [A]
Swingarm Bearing, Sleeve Inspection
NOTICE
Do not remove the bearings for inspection. Removal may damage them.
the needle bearing [A] installed in the swingarm.
•○Inspect
The rollers in a bearing normally wear very little, and wear
is difficult to measure. Instead of measuring, visually
inspect the bearing for abrasion, discoloration, or other
damage.
If the needle bearing, and sleeve [B] show any sings of
abnormal wear, discoloration, or damage, replace them
as a set.
STEERING 14-1
Steering
Table of Contents
Exploded View........................................................................................................................
Special Tools ..........................................................................................................................
Steering ..................................................................................................................................
Steering Inspection ...........................................................................................................
Steering Adjustment..........................................................................................................
Steering Stem.........................................................................................................................
Stem, Stem Bearing Removal...........................................................................................
Stem, Stem Bearing Installation........................................................................................
Steering Stem Bearing Lubrication ...................................................................................
Steering Stem Warp Inspection ........................................................................................
Stem Cap Deterioration, Damage Inspection ...................................................................
Handlebar ...............................................................................................................................
Handlebar Holder Removal...............................................................................................
Handlebar Holder Installation............................................................................................
Handlebar Removal ..........................................................................................................
Handlebar Installation .......................................................................................................
14-2
14-4
14-5
14-5
14-5
14-6
14-6
14-7
14-9
14-9
14-9
14-10
14-10
14-10
14-10
14-11
14
14-2 STEERING
Exploded View
STEERING 14-3
Exploded View
No.
1
2
6
7
8
9
Fastener
Handlebar Holder Bolts
Handlebar Weight Bolts
Steering Stem Head Bolt
Front Fork Clamp Bolts (Upper)
Steering Stem Nut
Front Fork Clamp Bolts (Lower)
AD: Apply adhesive.
G: Apply grease.
N·m
19
9.8
49
19
4.9
27
Torque
kgf·m
1.9
1.0
5.0
1.9
0.50
2.8
ft·lb
14
87 in·lb
36
14
43 in·lb
20
Remarks
14-4 STEERING
Special Tools
Steering Stem Bearing Driver:
57001-137
Steering Stem Bearing Driver Adapter,
57001-1074
Steering Stem Nut Wrench:
57001-1100
34.5:
Head Pipe Outer Race Press Shaft:
57001-E007
STEERING 14-5
Steering
Steering Inspection
to the Steering Play Inspection in the Periodic Main• Refer
tenance chapter.
Steering Adjustment
to the Steering Play Adjustment in the Periodic
• Refer
Maintenance chapter.
14-6 STEERING
Steering Stem
Stem, Stem Bearing Removal
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Headlight Assy (see Headlight Cover Removal in the
Frame chapter)
Front Wheel (see Front Wheel Removal in the
Wheels/Tires chapter)
Front Fender (see Front Fender Removal in the Frame
chapter)
Handlebars (see Handlebar Removal)
• Remove the bands [A].
the dust cover [A], and disconnect the ignition switch
• Slide
lead connector [B].
• Remove:
Bolts [A]
Bracket [B]
• Remove:
Steering Stem Head Bolt [A]
Steering Stem Head [B]
Headlight Bracket [C] with Collars and Dampers
Front Fork (see Front Fork Removal in the Suspension
chapter)
STEERING 14-7
Steering Stem
up the stem base [A], and remove the steering
• Pushing
stem nut [B].
Special Tool - Steering Stem Nut Wrench [C]: 57001-1100
• Remove:
Steering Stem
Stem Cap [D]
Upper Ball Bearing Inner Race and Ball Bearing
remove the ball bearing outer races [A] pressed into
• To
the head pipe [B], insert a bar [C] into the recesses of
head pipe, and applying it to both recess alternately hammer it to drive the race out.
NOTE
○If either steering stem bearing is damaged, it is recommended that both the upper and lower bearings (including outer races) should be replaced with new ones.
• Remove the lower ball bearing [A] from the steering stem.
the lower bearing inner race (with its grease seal)
• Remove
[A] which is pressed onto the steering stem with a suitable
commercially available chisel [B].
Stem, Stem Bearing Installation
the bearing outer races with new ones.
• Replace
Drive
them
into the head pipe at the same time.
•
Special Tools - Head Pipe Outer Race Press Shaft [A]:
57001-E007
• Apply grease to the outer races.
14-8 STEERING
Steering Stem
the bearing inner races and oil seal with new
• Replace
ones.
grease to the oil seal.
• Apply
Install
the oil seal [A] on the steering stem, and drive the
• lower ball
bearing inner race [B] applied the grease onto
the stem.
Special Tools - Steering Stem Bearing Driver [C]: 57001
-137
Steering Stem Bearing Driver Adapter,
34.5 [D]: 57001-1074
grease to the lower ball bearing [A], and install it
• Apply
onto the steering stem.
grease to the upper ball bearing [B] and inner race
• Apply
[C].
the upper bearing [A] and inner race [B] on the head
• Install
pipe.
the steering stem [C] through the head pipe.
• Install
Install:
• Stem Cap [D]
Steering Stem Nut [E]
the bearings in place as follows.
•○Settle
Tighten the steering stem nut with 44 N·m (4.5 kgf·m, 32
ft·lb) of torque first, and loosen it a fraction of a turn until
it turns lightly. Afterward tighten it again with specified
torque using a steering stem nut wrench [A].
○Check that there is no play and the steering stem turns
smoothly without rattles. If not, the steering stem bearings
may be damaged.
Special Tool - Steering Stem Nut Wrench: 57001-1100
Torque - Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb)
the front forks [A] temporary, and tighten the lower
• Install
front fork clamp bolts.
• Install:
Dampers [B]
Collars [C]
Headlight Bracket [D]
STEERING 14-9
Steering Stem
• Install:
Steering Stem Head [A]
Steering Stem Head Bolt [B]
Torque - Steering Stem Head Bolt: 49 N·m (5.0 kgf·m, 36
ft·lb)
• Install the removed parts (see appropriate chapters).
WARNING
If the handlebar does not turn to the steering stop it
may cause an accident resulting in injury or death.
Be sure the cables, harnesses and hoses are routed
properly and do not interfere with handlebar movement (see Cable, Wire, and Hose Routing section in
the Appendix chapter).
Steering Stem Bearing Lubrication
to the Steering Stem Bearing Lubrication in the Pe• Refer
riodic Maintenance chapter.
Steering Stem Warp Inspection
the steering stem is removed, or if the steering
• Whenever
can not be adjusted for smooth action, check the steering
stem for straightness.
If the steering stem [A] is bent, replace the steering stem.
Stem Cap Deterioration, Damage Inspection
Replace the stem cap if its seal lip [A] shows damage.
14-10 STEERING
Handlebar
Handlebar Holder Removal
• Remove:
Handlebar Holder Bolts [A]
Handlebar Holder [B]
Handlebar Holder Installation
• Install:
Handlebar Holder
Handlebar Holder Bolts
Torque - Handlebar Holder Bolts: 19 N·m (1.9 kgf·m, 14
ft·lb)
Handlebar Removal
the rear view mirrors (see Rear View Mirror Re• Remove
moval in the Frame chapter).
(Left Side):
• Remove
Handlebar Weight [A]
•
Left Handlebar Grip [B]
Left Switch Housing [C]
Band [D]
Loosen the clutch holder bolts [E].
(Right Side):
• Remove
Front Master Cylinder [A] (see Front Master Cylinder Removal in the Brake chapter)
Right Switch Housing [B]
Handlebar Weight [C]
Throttle Grip [D]
(Both Sides):
• Remove
Cap [A]
•
Handlebar Bolt [B] and Washer
Handlebar [C]
For left handlebar, remove the clutch holder.
STEERING 14-11
Handlebar
Handlebar Installation
the clutch holder [A] to the left handlebar.
• Install
the left handlebar so that the punch mark [B] on the
• Install
handlebar faces upward.
a non-permanent locking agent to the handlebar
• Apply
bolt, and tighten it together with washer.
• Install the cap.
the right handlebar so that the punch mark [A] on
• Install
the handlebar faces backward.
a non-permanent locking agent to the handlebar
• Apply
bolt, and tighten it together with washer.
• Install the cap.
the cables and leads correctly (see Cable, Wire, and
• Run
Hose Routing section in the Appendix chapter).
adhesive cement to the inside of the left handlebar
• Apply
grip, and install it.
the clutch holder to match the notch [A] of the clutch
• Set
holder to the punch mark [B] of the handlebar, and tighten
the holder bolt.
the projection [A] on the left switch housing into a hole
• Fit
[B] on the handlebar, and tighten the screws.
• Install the band, and hold the left switch housing lead.
• Install:
Front Master Cylinder (see Front Master Cylinder Instal•
lation in the Brake chapter)
Right Switch Housing (see Throttle Cable Installation in
the Fuel System chapter)
Install (Both Sides):
Handlebar Weight
Handlebar Weight Bolt
Torque - Handlebar Weight Bolt: 9.8 N·m (1.0 kgf·m, 87
in·lb)
FRAME 15-1
Frame
Table of Contents
Exploded View........................................................................................................................
Seats ......................................................................................................................................
Front Seat Removal ..........................................................................................................
Front Seat Installation .......................................................................................................
Rear Seat Removal...........................................................................................................
Rear Seat Installation........................................................................................................
Fairings...................................................................................................................................
Fuel Tank Cover Removal.................................................................................................
Fuel Tank Cover Installation..............................................................................................
Fuel Tank Cover Disassembly ..........................................................................................
Fuel Tank Cover Assembly ...............................................................................................
Side Covers ............................................................................................................................
Side Cover Removal .........................................................................................................
Side Cover Installation ......................................................................................................
Seat Cover..............................................................................................................................
Seat Cover Removal.........................................................................................................
Seat Cover Installation......................................................................................................
Seat Cover Disassembly...................................................................................................
Seat Cover Assembly .......................................................................................................
Headlight Cover......................................................................................................................
License Plate Bracket Removal ........................................................................................
License Plate Bracket Installation .....................................................................................
Headlight Cover Removal .................................................................................................
Headlight Cover Installation ..............................................................................................
Fenders ..................................................................................................................................
Front Fender Removal ......................................................................................................
Front Fender Installation ...................................................................................................
Rear Fender Removal.......................................................................................................
Rear Fender Installation....................................................................................................
Guard......................................................................................................................................
Mud Guard Removal.........................................................................................................
Mud Guard Installation......................................................................................................
Side Stand ..............................................................................................................................
Side Stand Removal .........................................................................................................
Side Stand Installation ......................................................................................................
Center Stand Removal......................................................................................................
Center Stand Installation...................................................................................................
Rear View Mirrors...................................................................................................................
Rear View Mirrors Removal ..............................................................................................
Rear View Mirrors Installation ...........................................................................................
Frame .....................................................................................................................................
Frame Inspection ..............................................................................................................
15-2
15-6
15-6
15-6
15-6
15-6
15-7
15-7
15-8
15-8
15-8
15-9
15-9
15-9
15-10
15-10
15-11
15-11
15-11
15-12
15-12
15-12
15-13
15-14
15-15
15-15
15-15
15-15
15-15
15-16
15-16
15-16
15-17
15-17
15-17
15-17
15-18
15-19
15-19
15-19
15-20
15-20
15
15-2 FRAME
Exploded View
FRAME 15-3
Exploded View
No.
1
2
3
4
5
6
7
8
9
Fastener
Fuel Tank Cover Bolts (Front)
Fuel Tank Cover Bolts (Side)
Fuel Tank Cover Bracket Bolts
Side Stand Bracket Bolts
Side Stand Bolt
Front Fender Bolts
Front Fender Bracket Bolts
Front Footpeg Bracket Bolts
Center Stand Bolts
10. PH Model
G: Apply grease.
R: Replacements Parts
N·m
4.9
8.8
4.4
20
27
8.8
19
20
20
Torque
kgf·m
0.50
0.90
0.45
2.0
2.8
0.90
1.9
2.0
2.0
ft·lb
43 in·lb
78 in·lb
39 in·lb
15
20
78 in·lb
14
15
15
Remarks
15-4 FRAME
Exploded View
FRAME 15-5
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
Fastener
Flap Mounting Bolts
Mud Guard Bolts (Front)
Side Cover Screws
Seat Cover Bolts (Side)
Seat Cover Bolts (Top)
Battery Case Bolts
Front Seat Bolts
Grab Rail Mounting Bolts
Seat Lock Mounting Bolts
License Plate Mounting Bolts
Rear Footpeg Bracket Bolts
Rear Footpeg Guard Bolts
Rear Fender Bolts
R: Replacements Parts
N·m
20
8.8
8.8
8.8
8.8
18
9.8
20
19
6.9
20
6.9
4.9
Torque
kgf·m
2.0
0.90
0.90
0.90
0.90
1.8
1.0
2.0
1.9
0.70
2.0
0.70
0.50
ft·lb
15
78 in·lb
78 in·lb
78 in·lb
78 in·lb
13
87 in·lb
15
14
61 in·lb
15
61 in·lb
43 in·lb
Remarks
15-6 FRAME
Seats
Front Seat Removal
• Remove:
Rear Seat (see Rear Seat Removal)
•
Front Seat Bolts [A]
Remove the front seat [B] backward.
Front Seat Installation
the seat hook [A] under the rib [B] on the frame.
• Slip
• Tighten the front seat bolts.
Torque - Front Seat Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
Rear Seat Removal
the ignition switch key [A] into the seat lock.
• Insert
up the front part of the rear seat [B] upward while
• Pull
turning the key clockwise, and remove it forward.
Rear Seat Installation
the seat hook [A] under the guide [B] on the frame.
• Slip
Insert
the seat latch [C] into the latch hole [D].
• Push down
the rear seat until the lock clicks.
•
FRAME 15-7
Fairings
Fuel Tank Cover Removal
the front seat (see Front Seat Removal).
• Remove
• Remove the fuel tank cover bolts (rear) [A] and washers.
(Both Sides):
• Remove
Cap [A]
Fuel Tank Cover Bolts (Side) [B] and Washers
• Remove the fuel tank cover bolts (front) [A] and washers.
the clamp and disconnect the hose [A].
• Open
the fuel tank cover bolt (lower) [B] and collar
• Remove
(both sides).
• Remove the fuel tank cover [A] upward.
15-8 FRAME
Fairings
Fuel Tank Cover Installation
is the reverse of removal.
• Installation
the hose [A] into the guide [B].
• Run
Tighten:
•
Torque - Fuel Tank Cover Bolts (Front): 4.9 N·m (0.50 kgf·m,
43 in·lb)
Fuel Tank Cover Bolts (Side): 8.8 N·m (0.90 kgf·m,
78 in·lb)
Fuel Tank Cover Disassembly
• Remove:
Screws [A] (Both Sides)
Inner Cover [B]
(Both Sides):
• Remove
Fuel Tank Cover Bracket Bolts [A]
Bracket [B]
(Both Sides):
• Remove
Screws [A] and Washers
Cover [B]
Fuel Tank Cover Assembly
is the reverse of the disassembly.
• Assembly
Run
the
hoses
[A] of the right bracket as shown.
• Tighten:
•
Torque - Fuel Tank Cover Bracket Bolts: 4.4 N·m (0.45
kgf·m, 39 in·lb)
FRAME 15-9
Side Covers
Side Cover Removal
the front seat (see Front Seat Removal).
• Remove
the side cover screws [A].
• Remove
Clear
the
projections [B] and remove the side cover [C].
•
necessary, remove the mesh cover [A] by removing the
• Ifscrews
[B].
Side Cover Installation
the projections [A] on the side cover [B] into the
• Insert
holes [C], and tighten the side cover screws.
Torque - Side Cover Screws: 8.8 N·m (0.90 kgf·m, 78 in·lb)
15-10 FRAME
Seat Cover
Seat Cover Removal
the seats (see Front/Rear Seat Removal).
• Remove
the rubber cover [A].
• Slide
Disconnect:
• License Pate Light Lead Connector [B]
Turn Signal Light Lead Connectors [C]
Tail/Brake Light Lead Connector [D]
• Remove:
Grommets [A]
Flap Mounting Bolts [B]
Flap [C]
• Remove the seat cover bolts (lower) [A].
• Remove:
Seat Cover Bolts (Side) [A]
Seat Cover Bolts (Top) [B] and Washer
Grab Rail Bolts [C]
Grab Rails [D]
the seat cover [A] outward to clear the projections [B],
• Pull
and remove the seat cover backward.
FRAME 15-11
Seat Cover
Seat Cover Installation
is the reverse of removal.
• Installation
• Tighten:
Torque - Flap Mounting Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb)
Seat Cover Bolts (Top): 8.8 N·m (0.90 kgf·m, 78
in·lb)
Seat Cover Bolts (Side): 8.8 N·m (0.90 kgf·m, 78
in·lb)
Seat Cover Disassembly
the screws [A] and washers.
• Remove
Clear
the
projections [B] and remove the inner cover [C].
•
• Remove:
Screws [A]
Tail/Brake Light Assy [B]
Seat Cover Assembly
is the reverse of the disassembly.
• Assembly
the projections [A] on the inner cover into the hole
• Insert
[B].
15-12 FRAME
Headlight Cover
License Plate Bracket Removal
• Remove:
Bolts [A] and Washers
Plate (Number Plate) [B]
• Remove:
Bolts [A] and Nuts
Holder [B]
the bolts [A] and washers.
• Remove
Clear
the
projections [B] and remove the cover [C].
•
• Remove:
Bolts [A]
Bracket [B]
License Plate Bracket Installation
is the reverse of removal.
• Installation
Insert
the
projections
[A] on the cover into the holes [B].
•
FRAME 15-13
Headlight Cover
Headlight Cover Removal
• Remove the bolts [A] and collars (both sides).
• Disconnect:
Speed Sensor Lead Connector [A]
•
Main Harness Connectors [B]
Remove the headlight assy [C].
the license plate bracket (see License Plate
• Remove
Bracket Removal).
• Disconnect:
Turn Signal Light Lead Connectors [A]
•
Headlight/City Light Lead Connector [B]
Remove:
Bolts [C]
Meter Assy [D]
• Remove:
Screws [A] and Washers
Screw [B]
• Remove:
Bolts [A]
Headlight Cover Assy [B]
15-14 FRAME
Headlight Cover
the screws [A] and washers, and remove the
• Remove
cover [B].
Headlight Cover Installation
• Installation is the reverse of removal.
FRAME 15-15
Fenders
Front Fender Removal
the pin [A] and remove the guide [B].
• Remove
• Remove:
Front Fender Bolts [C] (Both Sides)
Front Fender Bracket Bolts [D] (Both Sides)
Brake Hose Bracket (Right Side)
Front Fender [E]
Front Fender Installation
is the reverse of removal.
• Installation
the brake hose bracket [A] to the right side of the
• Install
fender.
• Tighten:
Torque - Front Fender Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
Front Fender Bracket Bolts: 19 N·m (1.9 kgf·m, 14
ft·lb)
Rear Fender Removal
• Remove:
Seat Cover (see Seat Cover Removal)
•
Rear Master Cylinder Mounting Bolt [A]
Rear Fender Bolts [B] and Washers
Remove the rear fender [C] backward.
Rear Fender Installation
is the reverse of removal.
• Installation
Hang
the
hooks
[A] on the frame brackets [B].
• Tighten:
•
Torque - Rear Fender Bolts: 4.9 N·m (0.50 kgf·m, 43 in·lb)
15-16 FRAME
Guard
Mud Guard Removal
the mud guard cover bolts [A].
• Remove
the hook fastener [B] and remove the mud guard
• Detach
cover [C].
• Remove the mud guard bolts (front) [A] and collars.
the mud guard bolts (side) [A].
• Remove
Clear
the
• guard [D].hook [B] and projection [C], and remove the mud
Mud Guard Installation
is the reverse of removal.
• Installation
Insert
the
hooks
into the slits [B], and insert the pro• jection [C] into the[A]hole
[D].
the hook fasteners [A].
• Fit
• Tighten:
Torque - Mud Guard Bolts (Front): 8.8 N·m (0.90 kgf·m, 78
in·lb)
FRAME 15-17
Side Stand
Side Stand Removal
• Raise the rear wheel off the ground with the stand [A].
• Remove:
Spring [A]
Side Stand Nut [B]
Side Stand Bolt [C]
Side Stand [D]
Side Stand Installation
grease to the sliding area [A] of the side stand [B].
• Apply
the side stand nut [C] with a new one.
• Replace
Tighten
the
• stand nut. side stand bolt, and then lock it with the side
Torque - Side Stand Bolt: 27 N·m (2.8 kgf·m, 20 ft·lb)
• Install the spring [D] as shown.
Center Stand Removal
• Raise the rear wheel off the ground with the stand [A].
• Remove:
Shift Pedal (see Shift Pedal Removal in the Crank•
shaft/Transmission chapter)
Spring [A]
Right Center Stand Bolt [B]
Left Center Stand Bolt and Washer [C]
Slide the center stand [D] downward and forward to clear
the side stand switch lead.
15-18 FRAME
Side Stand
Center Stand Installation
sure that the collars [A] are in position.
• Be
grease to the inside of the collars.
• Apply
If the damper [B] is damaged, replace it.
the center stand [A].
• Install
Tighten
the left center stand bolt [B] together with the
• washer, and
right center stand bolt [C].
Torque - Center Stand Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb)
the spring [D] so that the straight side [E] of it faces
• Hook
forward.
the shift pedal (see Shift Pedal Installation in the
• Install
Crankshaft/Transmission chapter).
FRAME 15-19
Rear View Mirrors
Rear View Mirrors Removal
the rubber cover [A].
• Slide
the locknut [B], and remove the rear view mirror
• Loosen
[C].
NOTE
○The right rear view mirror stay and lock nut are left-hand
threads.
Rear View Mirrors Installation
the rear view mirror, and tighten the locknut [A].
•○Install
Turn the stay [B] to assure the safe conditions of the rear
with operator sat on the motorcycle.
NOTE
○The right rear view mirror stay and lock nut are left-hand
threads.
the rubber cover [C].
• Install
Adjust
the rear view mirror slightly with its mirror [D].
•○Installation
and adjustment of the left side are common
with those of the right side. Follow the procedure specified at the right side.
15-20 FRAME
Frame
Frame Inspection
inspect the frame for cracks, dents, bending, or
• Visually
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.
ELECTRICAL SYSTEM 16-1
Electrical System
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools and Sealant ......................................................................................................
Parts Location.........................................................................................................................
Wiring Diagram.......................................................................................................................
Precautions.............................................................................................................................
Electrical Wiring......................................................................................................................
Wiring Inspection ..............................................................................................................
Battery ....................................................................................................................................
Battery Removal ...............................................................................................................
Battery Installation ............................................................................................................
Battery Activation ..............................................................................................................
Precautions .......................................................................................................................
Interchange .......................................................................................................................
Charging Condition Inspection..........................................................................................
Refreshing Charge............................................................................................................
Charging System ....................................................................................................................
Alternator Cover Removal.................................................................................................
Alternator Cover Installation..............................................................................................
Stator Coil Removal ..........................................................................................................
Stator Coil Installation .......................................................................................................
Alternator Rotor Removal .................................................................................................
Alternator Rotor Installation ..............................................................................................
Charging Voltage Inspection .............................................................................................
Alternator Inspection .........................................................................................................
Regulator/Rectifier Removal .............................................................................................
Regulator/Rectifier Installation ..........................................................................................
Ignition System .......................................................................................................................
Ignition Timing Inspection .................................................................................................
Crankshaft Sensor Removal .............................................................................................
Crankshaft Sensor Installation ..........................................................................................
Crankshaft Sensor Resistance Inspection ........................................................................
Crankshaft Sensor Peak Voltage Inspection.....................................................................
Ignition Coil Removal ........................................................................................................
Ignition Coil Installation .....................................................................................................
Ignition Coil Inspection......................................................................................................
Ignition Coil Primary Peak Voltage Inspection ..................................................................
Spark Plug Removal .........................................................................................................
Spark Plug Installation ......................................................................................................
Spark Plug Condition Inspection.......................................................................................
CDI Unit Removal .............................................................................................................
CDI Unit Installation ..........................................................................................................
CDI Unit Inspection ...........................................................................................................
Electric Starter System ...........................................................................................................
Starter Motor Removal......................................................................................................
Starter Motor Installation...................................................................................................
Starter Motor Inspection....................................................................................................
Starter Relay Inspection....................................................................................................
Lighting System ......................................................................................................................
Headlight Aiming Inspection .............................................................................................
16-3
16-7
16-8
16-9
16-12
16-14
16-15
16-15
16-16
16-16
16-16
16-17
16-19
16-20
16-20
16-20
16-22
16-22
16-22
16-22
16-23
16-23
16-23
16-25
16-25
16-27
16-27
16-30
16-30
16-30
16-31
16-31
16-31
16-32
16-33
16-33
16-34
16-34
16-35
16-35
16-35
16-35
16-35
16-38
16-38
16-38
16-39
16-39
16-41
16-41
16
16-2 ELECTRICAL SYSTEM
Headlight Bulb Replacement ............................................................................................
City Light Bulb Replacement.............................................................................................
Headlight Removal/Installation .........................................................................................
Tail/Brake Light (LED) Removal/Installation......................................................................
License Plate Light Bulb Replacement .............................................................................
Turn Signal Light Bulb Replacement ................................................................................
Turn Signal Relay Inspection ............................................................................................
Radiator Fan System..............................................................................................................
Fan Motor Inspection ........................................................................................................
Fan Motor Relay Inspection ..............................................................................................
Meter, Gauge, Indicator Unit...................................................................................................
Meter Unit Removal/Installation ........................................................................................
Meter Unit Disassembly ....................................................................................................
Electronic Combination Meter Unit Inspection ..................................................................
Switches and Sensors ............................................................................................................
Water Temperature Sensor Inspection .............................................................................
Fuel Level Sensor Removal..............................................................................................
Fuel Level Sensor Installation...........................................................................................
Fuel Level Sensor Inspection............................................................................................
Throttle Sensor Inspection ................................................................................................
Speed Sensor Removal ....................................................................................................
Speed Sensor Installation .................................................................................................
Speed Sensor Inspection..................................................................................................
Side Stand Switch Removal..............................................................................................
Side Stand Switch Installation...........................................................................................
Side Stand Switch Inspection ...........................................................................................
Neutral Switch Removal....................................................................................................
Neutral Switch Installation.................................................................................................
Neutral Switch Inspection .................................................................................................
Starter Lockout Switch Circuit Inspection .........................................................................
Brake Light Timing Inspection...........................................................................................
Brake Light Timing Adjustment .........................................................................................
Switch Inspection ..............................................................................................................
Fuse........................................................................................................................................
Fuse Box Fuse Removal...................................................................................................
Fuse Installation................................................................................................................
Fuse Inspection.................................................................................................................
16-41
16-42
16-42
16-42
16-42
16-44
16-45
16-47
16-47
16-47
16-49
16-49
16-49
16-49
16-57
16-57
16-57
16-58
16-58
16-58
16-60
16-60
16-61
16-61
16-61
16-61
16-62
16-62
16-62
16-63
16-63
16-63
16-64
16-65
16-65
16-65
16-65
ELECTRICAL SYSTEM 16-3
Exploded View
This page intentionally left blank.
16-4 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 16-5
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Fastener
Spark Plugs
Alternator Rotor Bolt
Stator Coil Bolts
Water Temperature Sensor
Starter Motor Mounting Bolts
Alternator Cover Bolts
Throttle Sensor Mounting Bolt
Oil Pressure Switch
Neutral Switch Bolts
Neutral Switch Lead Holding Plate Bolts
Neutral Switch Lead Holding Plate Screw
Alternator Lead Holding Plate Bolt
Starter Motor Clutch Bolts
Horn Mounting Bolt
Regulator/Rectifier Bolts
Ignition Switch Bolts
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
SS: Apply silicone sealant.
N·m
14
58
7.4
13
11
11
5.0
13
5.9
5.9
5.9
4.9
15
20
11
11
Torque
kgf·m
1.4
5.9
0.75
1.3
1.1
1.1
0.51
1.3
0.60
0.60
0.60
0.50
1.5
2.0
1.1
1.1
ft·lb
10
43
65 in·lb
115 in·lb
97 in·lb
97 in·lb
44 in·lb
115 in·lb
52 in·lb
52 in·lb
52 in·lb
43 in·lb
11
15
97 in·lb
97 in·lb
Remarks
L
L
L
L
L
L
16-6 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 16-7
Specifications
Item
Battery
Type
Model Name
Capacity
Voltage
Charging System
Type
Alternator Output Voltage
Stator Coil Resistance
Charging Voltage (Regulator/Rectifier
Output Voltage)
Ignition System
Crankshaft Sensor:
Resistance
Peak Voltage
Gap
Ignition Coil:
Central:
Primary Winding Resistance
Secondary Winding Resistance
Primary Peak Voltage
Side:
Primary Winding Resistance
Secondary Winding Resistance
Primary Peak Voltage
Spark Plug:
Type:
Central
Side
Gap
Switches and Sensors
Rear Brake Light Switch Timing
Water Temperature Sensor Resistance:
Fuel Level Sensor Resistance:
Full Position
Empty Position
Radiator Relay Resistance
Main Throttle Sensor:
Input Voltage
Output Voltage
Resistance
Standard
Sealed Battery
ETZ-9-BS
12 V 8 Ah
12.6 V or more
Three-phase AC
55 V or more at 4 000 r/min (rpm)
0.8 ±0.1 Ω at 25°C (77°F)
14.4 ±0.3 V at 1 500 r/min (rpm)
195 ∼ 235 Ω at 25°C (77°F)
1.0 V or more
0.5 ∼ 0.7 mm (0.02 ∼ 0.03 in.)
0.3 ∼ 0.5 Ω
4.5 ∼ 6.5 kΩ
100 ∼ 300 V
0.4 ∼ 0.6 Ω
5.5 ∼ 7.5 kΩ
100 ∼ 300 V
BOSCH VR5NE
CHAMPION P-RG-6HCC
0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)
ON after about 11.5 mm of pedal travel
1.88 ∼ 2.12 Ω at 25°C
10 ±3 Ω
110 ±5 Ω
89 ∼ 110 Ω
DC 5 ∼ 10 V
DC 0.65 ∼ 0.75 V at idle throttle opening
DC 3.4 ∼ 3.8 V at full throttle opening (for reference)
5 kΩ
16-8 ELECTRICAL SYSTEM
Special Tools and Sealant
Timing Light:
57001-1241
Measuring Adapter:
57001-1700
Flywheel Holder:
57001-1313
Flywheel Puller Assembly:
57001-E006
Peak Voltage Adapter:
57001-1415
Liquid Gasket, TB1211F:
92104-0004
Needle Adapter Set:
57001-1457
ELECTRICAL SYSTEM 16-9
Parts Location
Meter Unit [A]
Front Brake Light Switch [B]
Ignition Switch [C]
Starter Lockout Switch [D]
Horn [A]
Radiator Fan Motor [B]
Central Spark Plug [C]
Side Spark Plug (Left) [D]
Speed Sensor [E]
Engine Ground [A]
Frame Ground [B]
Side Stand Switch [C]
Neutral Switch [D]
Alternator [E]
Crankshaft Sensor [F]
Regulator/Rectifier [A]
Starter Relay [B]
Fuse Box [C]
Fuel Level Sensor [A]
16-10 ELECTRICAL SYSTEM
Parts Location
CDI Unit [A]
Headlight Relay [B]
Battery [C]
Radiator Fan Relay [D]
Turn Signal Light Relay [E]
Starter Motor [A]
Side Spark Plug (Right) [B]
Rear Brake Light Switch [A]
Oil Pressure Switch [A]
Water Temperature Sensor [B]
Throttle Sensor [C]
ELECTRICAL SYSTEM 16-11
Parts Location
This page intentionally left blank.
16-12 ELECTRICAL SYSTEM
Wiring Diagram
ELECTRICAL SYSTEM 16-13
Wiring Diagram
16-14 ELECTRICAL SYSTEM
Precautions
There are a number of important precautions that are
musts when servicing electrical systems. Learn and observe all the rules below.
○Do not reverse the battery cable connections. This will
burn out the diodes on the electrical parts.
○Always check battery condition before condemning other
parts of an electrical system. A fully charged battery is a
must for conducting accurate electrical system tests.
○The electrical parts should never be struck sharply, as
with a hammer, or allowed to fall on a hard surface. Such
a shock to the parts can damage them.
○To prevent damage to electrical parts, do not disconnect
the battery cables or any other electrical connections
when the ignition switch is ON, or while the engine is
running.
○Because of the large amount of current, never keep the
starter button pushed when the starter motor will not turn
over, or the current may burn out the starter motor windings.
○Take care not to short the cables that are directly connected to the battery positive (+) terminal to the chassis
ground.
○Troubles may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the failure. If the failure was caused by some
other item or items, they must be repaired or replaced, or
the new replacement will soon fail again.
○Make sure all connectors in the circuit are clean and tight,
and examine leads for signs of burning, fraying, etc. Poor
leads and bad connections will affect electrical system
operation.
○Measure coil and winding resistance when the part is cold
(at room temperature).
ELECTRICAL SYSTEM 16-15
Electrical Wiring
Wiring Inspection
inspect the wiring for signs of burning, fraying,
• Visually
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. If it
is damaged, replace it.
Check the wiring for continuity.
○Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
○Connect a tester between the ends of the leads.
If the tester does not read about 0 Ω, the lead is defective.
Replace the lead or the wiring harness [A] if necessary.
•
•
16-16 ELECTRICAL SYSTEM
Battery
Battery Removal
the ignition switch off.
• Turn
the front seat (see Front Seat Removal in the
• Remove
Frame chapter).
the rubber band [A].
• Remove
Slide
the
[B].
• Disconnectcaps
the negative (–) cable [C].
•
NOTICE
Be sure to disconnect the negative (–) cable first.
the positive (+) cable [A], and remove the bat• Disconnect
tery [B].
Battery Installation
inspect the surface of the battery container.
• Visually
If any signs of cracking or electrolyte leakage from the
•
•
•
•
•
sides of the battery.
Put the battery into the battery case so that the positive
(+) terminal faces front side of the motorcycle.
Connect the positive (+) cable [A] (red cap) to the positive
(+) terminal first, and then the negative (–) cable [B] (black
cap) to the negative (–) terminal.
Apply a light coat of grease on the terminals to prevent
corrosion.
Cover the terminals with the caps.
Install the rubber band [C].
NOTICE
If each battery cable is not correctly disconnected
or connected, sparks can arise at electrical connections, causing damage to electrical parts.
ELECTRICAL SYSTEM 16-17
Battery
Battery Activation
Electrolyte Filling
Make sure that the model name [A] of the electrolyte container matches the model name [B] of the battery. These
names must be the same.
•
Battery Model Name
BR200A: ETZ-9-BS
NOTICE
Each battery comes with its own specific electrolyte container; using the wrong container may
overfill the battery with incorrect electrolyte, which
can shorten battery life and deteriorate battery performance. Be sure to use the electrolyte container
with the same model name as the battery since the
electrolyte volume and specific gravity vary with
the battery type.
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. To prevent burns, wear protective clothing
and safety glasses when handling electrolyte. If
the electrolyte comes in contact with your skin or
eyes, wash the area with liberal amounts of water
and seek medical attention for more severe burns.
the battery on a level surface.
• Place
Check
• or holestoinseeit. that the sealing sheet has no peeling, tears,
• Remove the sealing sheet.
NOTE
○The battery is vacuum sealed. If the sealing sheet has
leaked air into the battery, it may require a longer initial
charge.
the electrolyte container from the vinyl bag.
• Remove
Detach
the
of caps [A] from the container and set
• aside, thesestrip
will be used later to seal the battery.
NOTE
○Do not pierce or otherwise open the sealed cells [B] of
the electrolyte container. Do not attempt to separate
individual cells.
16-18 ELECTRICAL SYSTEM
Battery
the electrolyte container upside down with the six
• Place
sealed cells into the filler ports of the battery. Hold the
container level, push down to break the seals of all six
cells. You will see air bubbles rising into each cell as the
ports fill.
NOTE
○Do not tilt the electrolyte container.
the electrolyte flow.
• Check
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.
the container in place. Don’t remove the container
• Keep
from the battery, the battery requires all the electrolyte
from the container for proper operation.
NOTICE
Removal of the container before it is completely
empty can shorten the service life of the battery.
Do not remove the container until it is completely
empty.
filling, let the battery sit for 20 ∼ 60 minutes with the
• After
electrolyte container kept in place, which is required for
•
the electrolyte to fully permeate into the plates.
Make sure that the container cells have emptied completely, and remove the container from the battery.
the strip of caps [A] loosely over the filler ports,
• Place
press down firmly with both hands to seat the strip of caps
into the battery (don’t pound or hammer). When properly
installed, the strip of caps will be level with the top of the
battery.
NOTICE
Once the strip of caps is installed onto the battery,
never remove the caps, nor add water or electrolyte
to the battery.
○Charging
NOTE
the battery immediately after filling can
shorten service life.
ELECTRICAL SYSTEM 16-19
Battery
Initial Charge
Newly activated sealed batteries require an initial charge.
•
Standard Charge: 0.8 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
Christie C10122S
•
If the above chargers are not available, use equivalent
one.
Let battery sit 30 minutes after initial charge, then check
voltage using a voltmeter. (Voltage immediately after
charging becomes temporarily high. For accurate measuring, let the battery sit for given time.)
NOTE
○Charging rates will vary depending on how long the
battery has been stored, temperature, and the type of
charger used. If voltage is not at least 12.6 V, repeat
charging cycle.
○To ensure maximum battery life and customer satisfaction, it is recommended the battery be load tested at
three times its amp-hour rating for 15 seconds.
Re-check voltage and if less than 12.6 V repeat the
charging cycle and load test. If still below 12.6 V the
battery is defective.
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
If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been
discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification
(see Refreshing Charge).
When a fast charge is inevitably required, do it following precisely the maximum charge current
and time conditions indicated on the battery.
NOTICE
This battery is designed to sustain no unusual deterioration if refresh-charged according
to the method specified above. However, the battery’s performance may be reduced noticeably if charged under conditions other than given above. Never remove the seal cap
during refresh charge.
If by chance an excessive amount of gas is generated due to overcharging, the relief valve
releases the gas to keep the battery normal.
3) When you do not use the motorcycle for months.
Give a refresh charge before you store the motorcycle and store it with the negative cable removed. Give a refresh charge once a month during storage.
4) Battery life
If the battery will not start the engine even after several refresh charges, the battery has exceeded its useful life. Replace it (Provided, however, the vehicle’s starting system has no problem).
16-20 ELECTRICAL SYSTEM
Battery
DANGER
Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause serious injury and burns if ignited. Keep the battery away from sparks and open flames during
charging. When using a battery charger, connect the battery to the charger before turning
on the charger. This procedure prevents sparks at the battery terminals which could ignite
any battery gases. The electrolyte contains sulfuric acid. Be careful not to have it touch
your skin or eyes. If touched, wash it off with liberal amount of water and seek medial attention for more severe burns.
Interchange
A sealed battery can fully display its performance only when combined with a proper vehicle electric
system. Therefore, replace a sealed battery only on a motorcycle which was originally equipped with
a sealed battery.
Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original
equipment, the sealed battery’s life will be shortened.
Charging Condition Inspection
○Battery charging condition can be checked by measuring
•
•
battery terminal voltage with a digital voltmeter [A].
Remove the battery (see Battery Removal).
Measure the battery terminal voltage.
NOTE
○Measure with a digital voltmeter which can be read one
decimal place voltage.
If the reading is 12.6 V or more, no refresh charge is required, however, if the read is below the specified, refresh
charge is required.
Battery Terminal Voltage
12.6 V or more
Standard:
Terminal Voltage (V) [A]
Battery Charge Rate (%) [B]
Good [C]
Refresh charge is required [D]
Refreshing Charge
the battery [A] (see Battery Removal).
• Remove
refresh charge by following method according to the
• Do
battery terminal voltage.
WARNING
This battery is sealed type. Never remove sealing
cap [B] even at charging. Never add water. Charge
with current and time as stated below.
ELECTRICAL SYSTEM 16-21
Battery
Terminal Voltage: 11.5 ∼ less than 12.6 V
Standard Charge 0.8 A × 5 ∼ 10 h (see following chart)
Quick Charge
4A×1h
NOTICE
If possible, do not quick charge. If quick charge is
done unavoidably, do standard charge later on.
Terminal Voltage: less than 11.5 V
Charging Method: 0.8 A × 13 ∼ 15 h
NOTE
○Increase the charging voltage to a maximum voltage of
25 V if the battery will not accept current initially. Charge
for no more than 5 minutes at the increased voltage then
check if the battery is drawing current. If the battery
will accept current decrease the voltage and charge by
the standard charging method described on the battery
case. If the battery will not accept current after 5 minutes, replace the battery.
Battery [A]
Battery Charger [B]
Standard Value [C]
Current starts to flow [D]
the battery condition after refresh charge.
•○Determine
Determine the condition of the battery left for 30 minutes
after completion of the charge by measuring the terminal
voltage according to the table below.
Criteria
Judgement
12.6 V or higher
Good
12.0 ∼ lower than 12.6 V
Charge insufficient → Recharge
lower than 12.0 V
Unserviceable → Replace
16-22 ELECTRICAL SYSTEM
Charging System
Alternator Cover Removal
• Remove:
Engine Sprocket Cover (see Engine Sprocket Removal
•
in the Final Drive chapter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Disconnect:
Alternator Lead Connector [A]
Crankshaft Sensor Lead Connector [B]
• Remove:
Bands [A]
Alternator Cover Bolts [B]
Alternator Cover [C]
Alternator Cover Installation
a high flash-point solvent, clean off any oil or dirt
• Using
that may be on the liquid gasket coating area. Dry them
•
with a clean cloth.
Apply liquid gasket to the grommets [A] on the crankcase
and the alternator cover.
Sealant - Liquid Gasket, TB1211F: 92104-0004
that the dowel pins [B] are in place on the
• Check
crankcase.
the alternator cover gasket with a new one.
• Replace
Tighten:
•
Torque - Alternator Cover Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)
the lead correctly (see Cable, Wire, and Hose Rout• Run
ing section in the Appendix chapter).
• Install the removed parts (see appropriate chapters).
Stator Coil Removal
• Remove:
Alternator Cover (see Alternator Cover Removal)
•
Crankshaft Sensor Bolts [A]
Alternator Lead Holding Plate Bolt [B] and Plate
Alternator/Crankshaft Sensor Lead Grommet
Stator Coil Bolts [C]
Remove the stator coil [D] and crankshaft sensor [E] from
the alternator cover.
ELECTRICAL SYSTEM 16-23
Charging System
Stator Coil Installation
a non-permanent locking agent to the threads of
• Apply
the stator coil bolts and tighten them.
Torque - Stator Coil Bolts: 7.4 N·m (0.75 kgf·m, 65 in·lb)
a high flash-point solvent, clean off any oil or dirt
• Using
that may be on the liquid gasket coating area. Dry them
•
with a clean cloth.
Apply liquid gasket to the circumference of the alternator/crankshaft sensor lead grommet [A], and fit the grommet into the notch of the cover securely.
Sealant - Liquid Gasket, TB1211F: 92104-0004
the alternator lead with a holding plate [B], and apply
• Hold
a non-permanent locking agent to the threads of the plate
bolt [C] and crankshaft sensor bolts [D], and tighten them.
Torque - Alternator Lead Holding Plate Bolt: 4.9 N·m (0.50
kgf·m, 43 in·lb)
the alternator cover (see Alternator Cover Installa• Install
tion).
Alternator Rotor Removal
the alternator cover (see Alternator Cover Re• Remove
moval).
the torque limiter gear [A].
• Remove
Hold
the
alternator rotor steady with the flywheel holder
• [B], and remove
the rotor bolt [C] and washer.
Special Tool - Flywheel Holder: 57001-1313
the flywheel puller [A], remove the alternator rotor
• Using
from the crankshaft.
Special Tool - Flywheel Puller Assembly: 57001-E006
NOTICE
Do not attempt to strike the alternator rotor itself.
Striking the rotor can cause the magnets to lose
their magnetism.
Alternator Rotor Installation
grease to the starter clutch gear.
• Apply
Using
cleaning fluid, clean off any oil or dirt on the fol• lowingaportions
and dry them with a clean cloth.
•
•
Crankshaft Tapered Portion [A]
Alternator Rotor Tapered Portion [B]
Fit the woodruff key [C] securely in the slot of the crankshaft.
Align the woodruff key on the crankshaft with groove [D]
on the alternator rotor.
16-24 ELECTRICAL SYSTEM
Charging System
the alternator rotor while turning the starter clutch
• Push
gear [A] clockwise until it engaged into the starter clutch
case.
a non-permanent locking agent to the alternator ro• Apply
tor bolt.
the washer and rotor bolt.
• Install
Tighten
the alternator rotor bolt [A] while holding the alter• nator rotor
steadily with the flywheel holder [B].
Special Tool - Flywheel Holder: 57001-1313
Torque - Alternator Rotor Bolt: 58 N·m (5.9 kgf·m, 43 ft·lb)
molybdenum disulfide grease [A] to the torque lim• Apply
iter gear [B], and install it.
the alternator cover (see Alternator Cover Installa• Install
tion).
ELECTRICAL SYSTEM 16-25
Charging System
Charging Voltage Inspection
the battery condition (see Charging Condition In• Check
spection).
up the engine to obtain actual alternator operating
• Warm
conditions.
the front seat (see Front Seat Removal in the
• Remove
Frame chapter).
that the ignition switch is turned off, and connect a
• Check
tester [A] to the battery terminals [B].
the engine, and note the voltage readings at vari• Start
ous engine speeds with the headlight turned on and then
turned off (To turn off the headlight, disconnect the headlight connector.). The readings should show nearly battery voltage when the engine speed is low, and, as the
engine speed rises, the readings should also rise. But
they must be kept under the specified voltage.
Charging Voltage
at 1 500 r/min (rpm)
Connections
Tester (+) to
Tester (–) to
Battery (+)
Battery (–)
Reading
DC 14.4 ±0.3 V
off the ignition switch to stop the engine, and discon• Turn
nect the tester.
If the charging voltage is kept between the values given in
the table, the charging system is considered to be working
normally.
If the charging voltage is much higher than the values
specified in the table, the regulator/rectifier is defective
or the regulator/rectifier leads are loose or open.
If the charging voltage does not rise as the engine speed
increases, then the regulator/rectifier is defective or the
alternator output is insufficient for the loads. Check the
alternator and regulator/rectifier to determine which part
is defective.
Alternator Inspection
There are three types of alternator failures: short, open
(wire burned out), or loss in rotor magnetism. A short or
open in one of the coil wires will result in either a low output,
or no output at all. A loss in rotor magnetism, which may be
caused by dropping or hitting the alternator, by leaving it
near an electromagnetic field, or just by aging, will result in
low output.
16-26 ELECTRICAL SYSTEM
Charging System
check the alternator output voltage, do the following
• To
procedures.
○Turn the ignition switch off.
○Remove the fuel tank (see Fuel Tank Removal in the Fuel
System chapter).
○Disconnect the alternator lead connector [A].
○Connect a tester as shown in the table 1.
Install the fuel tank temporarily (see Fuel Tank Installation
in the Fuel System chapter).
○Start the engine.
○Run it at the rpm given in the table 1.
○Note the voltage reading (total 3 measurements).
•
Table 1 Alternator Output Voltage
Connections
Tester (+) to
Tester (–) to
One Y lead
Another Y lead
at 4 000 r/min (rpm)
Reading
AC 55 V or more
If the output voltage shows the value in the table, the alternator operates properly. The regulator/rectifier is damaged.
If the output voltage shows a much lower reading than
that given in the table, stop the engine and inspect the
stator coil resistance.
Check the stator coil resistance as follows.
○Stop the engine.
○Connect a tester as shown in the table 2.
○Note the reading (total 3 measurements).
•
Table 2 Stator Coil Resistance
Connections
•
Tester (+) to
Tester (–) to
One Y lead
Another Y lead
at 25°C (77°F)
Reading
0.8 ±0.1 Ω
If there is more resistance than shown in the table, or no
tester reading (infinity), the stator has an open lead and
must be replaced. Much less than this resistance means
the stator is shorted, and must be replaced.
Measure the resistance between each of the Y leads and
chassis ground.
Any tester reading less than infinity (∞) indicates a short,
necessitating stator replacement.
If the stator coil has normal resistance, but the voltage
check showed the alternator to be defective; then the rotor
magnets have probably weakened, and the rotor must be
replaced.
ELECTRICAL SYSTEM 16-27
Charging System
Regulator/Rectifier Removal
the left side cover (see Side Cover Removal in
• Remove
the Frame chapter).
the bands [A].
• Remove
Disconnect
• Remove: the connector [B].
• Regulator/Rectifier Bolts [C]
Regulator/Rectifier [D]
Regulator/Rectifier Installation
is the reverse of removal.
• Installation
• Tighten:
Torque - Regulator/Rectifier Bolts: 11 N·m (1.1 kgf·m, 97
in·lb)
Charging System Troubleshooting
Before inspection, remove all accessories that consume
electrical power.
•
NOTE
○Even when the charging system is working properly, the
battery may discharge if the motorcycle is equipped with
too many accessories.
attention to riding conditions and the customer’s rid• Pay
ing habits which could affect the charging system such
as:
Frequent use at low engine speed → Battery discharged
Frequent and unnecessary brake pedal dragging → Battery
discharged
Recharge the battery if it is discharged.
•
16-28 ELECTRICAL SYSTEM
Charging System
ELECTRICAL SYSTEM 16-29
Charging System
Charging System Circuit
1. Regulator/Rectifier
2. Frame Ground 3
3. Load
4. Main Fuse 20 A
5. Frame Ground 4
6. Battery 12 V 8 Ah
7. Alternator
16-30 ELECTRICAL SYSTEM
Ignition System
WARNING
The ignition system produces extremely high voltage. Do not touch the spark plug, ignition coil or ignition 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
on, or while the engine is running. This is to prevent
CDI unit damage.
Do not install the battery backwards. The negative
side is grounded. This is to prevent damage to the
diodes and CDI unit.
Ignition Timing Inspection
• Remove:
Timing Inspection Cap [A]
the timing light [A] to the central ignition coil lead
• Attach
in the manner prescribed by the manufacturer.
Special Tool - Timing Light: 57001-1241
the engine and aim the timing light at the ignition
• Start
timing mark [A] on the rotor.
the engine at the speeds specified and note the align• Run
ment of the ignition timing mark.
○Check
the engine speed, using the engine revolution
tester for high accuracy.
Ignition Timing
•
Engine speed
[r/min (rpm)]
Projection [B] in hole
aligns with:
1 400
T mark on alternator rotor
If the ignition timing is incorrect, check the crankshaft sensor (see Crankshaft Sensor Inspection).
If the crankshaft sensor are normal, replace the CDI unit.
Tighten the timing inspection cap.
Crankshaft Sensor Removal
• Refer to the Stator Coil Removal.
ELECTRICAL SYSTEM 16-31
Ignition System
Crankshaft Sensor Installation
• Refer to the Stator Coil Installation.
Crankshaft Sensor Resistance Inspection
the crankshaft sensor lead connector [A] (see
• Disconnect
Alternator Cover Removal).
a tester, and connect it to the crankshaft sensor lead
• Set
connector.
Crankshaft Sensor Resistance
Connections:
Meter (+) → W/R lead
Meter (–) → BK/Y lead
Standard:
•
195 ∼ 235 Ω at 25°C (77°F)
If there is more resistance than the specified value, the
coil has an open lead and must be replaced. Much less
than this resistance means the coil is shorted, and must
be replaced.
Measure the resistance between the crankshaft sensor
leads and chassis ground.
Any tester reading less than infinity (∞) indicates a short,
necessitating replacement of the crankshaft sensor.
Crankshaft Sensor Peak Voltage Inspection
NOTE
○Be sure the battery is fully charged.
○Using the peak voltage adapter [A] is more reliable way
to determine the condition of the crankshaft sensor than
crankshaft sensor internal resistance measurements.
the crankshaft sensor lead connector [B] (see
• Disconnect
Alternator Cover Removal).
• Set a tester [C], and connect it peak voltage adapter.
Special Tool - Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
the adapter to the terminals of the crankshaft
• Connect
sensor lead connector.
Connections:
Crankshaft Sensor
Lead Connector
Peak Voltage
Adapter
Tester
W/R lead
←
R lead
→
(+)
BK/Y lead
←
BK lead
→
(–)
the engine stop switch to run position.
• Turn
Turn
the ignition switch on.
• Pushing
the starter button, turn the engine 4 ∼ 5 seconds
• with the transmission
in neutral to measure the crankshaft
•
sensor peak voltage.
Repeat the measurements 5 or more times.
Crankshaft Sensor Peak Voltage
1.0 V or more
Standard:
If the reading is less than the standard, inspect the crankshaft sensor (see Crankshaft Sensor Resistance Inspection).
16-32 ELECTRICAL SYSTEM
Ignition System
Ignition Coil Removal
the fuel tank (see Fuel Tank Removal in the Fuel
• Remove
System chapter).
Ignition Coil for Central Spark Plug
Disconnect the central spark plug cap [A].
•
• Remove:
Bolts [A]
•
Ground Terminal Lead [B]
Disconnect the ignition coil lead connector [C], and remove the ignition coil [D] for central spark plug.
Ignition Coil for Side Spark Plugs
Disconnect the left side spark plug cap [A].
•
the right side spark plug cap [A].
• Disconnect
• Remove:
Engine Bracket Bolts [B]
•
Front Engine Mounting Nut [C] and Washer
Free the engine bracket [D].
ELECTRICAL SYSTEM 16-33
Ignition System
• Remove:
Bolts [A]
•
Ground Terminal Lead [B]
Disconnect the ignition coil lead connector [C], and remove the ignition coil [D] for side spark plugs.
Ignition Coil Installation
is the reverse of removal.
• Installation
the plug caps securely.
• Fit
Pull
up the spark plug caps lightly to make sure of the
• installation
of the spark plug caps.
After
installation
right side spark plug, tighten the up• per engine bracketthebolts
and front engine mounting nut.
Torque - Engine Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
Front Engine Mounting Bolt: 34 N·m (3.5 kgf·m, 25
ft·lb)
Ignition Coil Inspection
the ignition coil (see Ignition Coil Removal).
• Remove
the primary winding resistance [A] as follows.
•○Measure
For the ignition coil [B] of the central spark plug, connect a
tester between the coil terminal and the ground terminal.
○For the ignition coil [C] of the side spark plugs, connect a
tester between the coil terminals.
Measure the secondary winding resistance [D] as follows.
○Remove the spark plug cap from the spark plug lead.
○For the ignition coil of the central spark plug, connect the
hand tester between the high tension lead and the ground
terminal.
○For the ignition coil of the side spark plugs, connect a
tester between the high tension lead and the coil terminal.
•
Ignition Coil Winding Resistance (for Central Spark Plug)
Primary Windings:
0.3 ∼ 0.5 Ω
Secondary Windings: 4.5 ∼ 6.5 kΩ
Ignition Coil Winding Resistance (for Side Spark Plugs)
Primary Windings:
0.4 ∼ 0.6 Ω
Secondary Windings: 5.5 ∼ 7.5 kΩ
If the tester does not read as specified, replace the ignition
coil.
16-34 ELECTRICAL SYSTEM
Ignition System
•
•
If the tester reads as specified, the ignition coil windings
are probably good. However, if the ignition system still
does not perform as it should after all other components
have been checked, replace the coil with one known to
be good.
Check the spark plug lead for visible damage.
If the spark plug lead is damaged, replace the ignition coil.
Install the spark plug cap to the spark plug lead securely.
Ignition Coil Primary Peak Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the spark plug cap (see Ignition Coil Re• Disconnect
moval).
○Do not remove the spark plug.
the primary peak voltage as follows.
•○Measure
Install the new spark plug [A] into the spark plug cap [B],
and ground it.
○Connect the peak voltage adapter [C] into a tester [D].
CDI Unit [E]
Battery [F]
Ignition Coil [G] (for Center Spark Plug)
Ignition Coil [H] (for Side Spark Plug)
Special Tools - Measuring Adapter [I] : 57001-1700
Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
Connections:
Adapter (R, +) → Ignition Coil Primary Lead Terminal
Adapter (BK, –) → Ground
WARNING
To avoid extremely high voltage shocks, do not
touch the spark plugs or tester connections.
the ignition switch on.
• Turn
Pushing
starter button, turn the engine 4 ∼ 5 seconds
• with the the
transmission in neutral to measure the primary
•
peak voltage.
Repeat the measurements 5 or more times.
Ignition Coil Primary Peak Voltage
Standard: 100 ∼ 300 V
If the reading is less than the specified value, check the
following.
Ignition Coil (see Ignition Coil Inspection)
Crankshaft Sensor (see Crankshaft Sensor Inspection)
CDI Unit (see CDI Unit Inspection)
Spark Plug Removal
to the Spark Plug Replacement in the Periodic
• Refer
Maintenance chapter.
ELECTRICAL SYSTEM 16-35
Ignition System
Spark Plug Installation
to the Spark Plug Replacement in the Periodic
• Refer
Maintenance chapter.
Spark Plug Condition Inspection
If the spark plug is oily or has carbon built up on it, clean
it. The plug may also be cleaned using high flash-point
solvent and nonmetal brush (nylon etc.).
If the spark plug center electrode [A] and/or side electrode
[B] are corrected or damaged, or if the insulator [C] is
cracked, replace the plug.
○Use the standard spark plug or its equivalent.
Measure the gap [D] with a wire-type thickness gauge.
If the gap is incorrect, carefully bend the side electrode
with a suitable tool to obtain the correct gap.
•
Spark Plug Gap: 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)
CDI Unit Removal
• Remove:
Rear Seat (see Rear Seat Removal in the Frame chap•
ter)
CDI Unit [A] and Damper
Disconnect the CDI unit connector [B].
CDI Unit Installation
• Installation is the reverse of removal.
CDI Unit Inspection
NOTICE
When inspecting the CDI unit, observe the following
to avoid damage to the CDI unit.
Do not disconnect the CDI unit with the ignition
switch on. This may damage the CDI unit.
Do not disconnect the battery cables while the engine is running. This may damage the CDI unit.
• Refer to the Ignition System Troubleshooting.
16-36 ELECTRICAL SYSTEM
Ignition System
Ignition System Troubleshooting
ELECTRICAL SYSTEM 16-37
Ignition System
Ignition System Circuit
1. Engine Stop Switch
2. Frame Ground 3
3. CDI Unit
4. Throttle Sensor
5. Ignition Coil (Side)
6. Ignition Coil (Central)
7. Frame Ground 1
8. Battery 12 V 8 Ah
9. Main Fuse 20 A
10. Crankshaft Sensor
11. Ignition Switch
16-38 ELECTRICAL SYSTEM
Electric Starter System
Starter Motor Removal
the clutch cable bracket (see Clutch Cover Re• Remove
moval in the Clutch chapter).
out the rubber cap [A].
• Slide
Remove
• washers. the starter motor cable terminal nut [B] and
the starter motor mounting bolts [C].
• Remove
Remove
the starter motor [D] from the right side of the
• motorcycle.
Starter Motor Installation
NOTICE
Do not tap the starter motor shaft or body. Tapping
the shaft or body could damage the motor.
the starter motor legs [A] and crankcase [B] where
• Clean
the starter motor is ground.
the O-ring [A] with a new one.
• Replace
Apply
grease
to the new O-ring.
• Tighten the starter
motor mounting bolts.
•
Torque - Starter Motor Mounting Bolts: 11 N·m (1.1 kgf·m,
97 in·lb)
the washer [A] and starter motor cable.
• Install
• Install:
Spring Washer [B]
•
•
Nut [C]
Slide back the rubber cap to the original position.
Install the removed parts (see appropriate chapters).
ELECTRICAL SYSTEM 16-39
Electric Starter System
Starter Motor Inspection
the ignition switch on and push the starter button.
• Turn
If the starter motor does not turn, check the following.
Main Fuse (see Fuse Inspection)
Battery Condition (see Charging Condition Inspection)
Starter Relay (see Starter Relay Inspection)
Starter Lockout Switch (see Starter Locknut Switch Circuit Inspection)
Neutral Switch (see Switch Inspection)
Ignition Switch (see Wiring Diagram)
Right Switch Housing (see Wiring Diagram)
If no abnormality is found in these checks, replace the
starter motor.
NOTE
○The starter motor cannot be disassembled.
If necessary, replace the starter motor as an assembly.
Starter Relay Inspection
the battery negative (–) cable from the battery
• Remove
negative (–) terminal (see Battery Removal).
the connector [A].
• Disconnect
Remove:
• Nuts [B]
Starter Relay [C]
a tester [A] and 12 V battery [B] to the starter
• Connect
relay [C] as shown.
If the relay does not work as specified, the relay is defective. Replace the relay.
Testing Relay
Criteria:
When battery is connected → about 0 Ω
When battery is disconnected → ∞ Ω
16-40 ELECTRICAL SYSTEM
Electric Starter System
Electric Starter Circuit
1. Ignition Switch
2. Starter Button
3. Engine Stop Switch
4. Frame Ground 3
5. Starter Lockout Switch
6. Main Fuse 20 A
7. Frame Ground 1
8. Battery 12 V 8 Ah
9. Starter Relay
10. Starter Motor
11. Engine Ground
12. Neutral Switch
ELECTRICAL SYSTEM 16-41
Lighting System
Headlight Aiming Inspection
to the Headlight Aiming Inspection in the Periodic
• Refer
Maintenance chapter.
Headlight Bulb Replacement
the headlight assy (see Headlight Cover Re• Remove
moval in the Frame chapter).
• Disconnect:
Dust Cover [A]
• Disconnect:
Headlight Connector [A]
•
Hook [B]
Remove:
Headlight Bulb
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. Use the correct type of headlight bulb
with specified voltage and wattage only.
NOTE
○Clean off any contamination that inadvertently gets on
the bulb with alcohol or soap and water solution.
the headlight bulb with a new one.
• Replace
Fit
the
projections
[A] of the bulb in the hollows [B] of the
• headlight.
• Install the hook.
the headlight connector.
• Connect
Install
the
dust cover [A].
• After installation,
the headlight aim (see Headlight
• Aiming Inspectionadjust
in the Periodic Maintenance chapter).
16-42 ELECTRICAL SYSTEM
Lighting System
City Light Bulb Replacement
the headlight assy (see Headlight Cover Re• Remove
moval in the Frame chapter).
• Pull out the socket [A] together with the bulb.
• Pull the bulb [A] 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
greater wattage than the specified value.
• Replace the bulb with a new one.
the socket [A] to the headlight.
•○Insert
Other Bulb: Repeat the above steps.
Headlight Removal/Installation
to the Headlight Cover Removal/Installation in the
• Refer
Frame chapter.
Tail/Brake Light (LED) Removal/Installation
to the Seat Cover Disassembly/Assembly in the
• Refer
Frame chapter.
License Plate Light Bulb Replacement
• Remove:
Screws [A]
License Plate Light Covers [B]
ELECTRICAL SYSTEM 16-43
Lighting System
• Pull the bulb [A] 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
greater wattage than the specified value.
• Replace the bulb with a new one.
Headlight/Tail Light Circuit
1. Meter Unit
2. Regulator/Rectifier
3. Frame Ground 3
4. Frame Ground 2
5. License Plate Light 12 V 3 W
6. Tail/Brake Light (LED)
7. Frame Ground 1
8. Battery 12 V 8 Ah
9. Ignition Fuse 15 A
10. Main Fuse 20 A
11. Alternator
12. Dimmer Switch
13. Passing Button
14. Headlight Relay
15. Ignition Switch
16. Left City Light 12 V 3 W
17. Headlight 12 V 60 W/55 W
18. Right City Light 12 V 3 W
16-44 ELECTRICAL SYSTEM
Lighting System
Turn Signal Light Bulb Replacement
• Remove:
Screw [A]
Turn Signal Light Lens [B]
• Remove:
Screws [A]
Ground Terminal [B]
Socket [C]
and turn the turn signal light bulb [A] counterclock• Push
wise and remove it.
• Replace the bulb with a new one.
the new bulb [A] by aligning its pins [B] with the
• Insert
grooves [C] in the socket, and turn the bulb clockwise.
the socket to the turn signal lens, and tighten the
• Install
screws together with the ground terminal.
the hook [A] of the lens into the groove [B].
• Fit
Tighten
the screw.
•○Other Bulb:
Repeat the above steps.
ELECTRICAL SYSTEM 16-45
Lighting System
Turn Signal Relay Inspection
the right side cover (see Side Cover Removal in
• Remove
the Frame chapter).
the turn signal relay [A].
• Remove
Disconnect
the connector.
•
one 12 V battery and turn signal lights as indi• Connect
cated, and count how many times the lights blink for one
minute.
Turn Signal Relay [A]
Turn Signal Lights [B]
12 V Battery [C]
If the lights do not blink as specified, replace the turn signal relay.
Testing Turn Signal Relay
Load
The Number of Turn
Signal Lights
Wattage (W)
Blinking Times
(c/m*)
1**
10
140 or more
2
20
80 ∼ 100
(*): Cycle(s) per minute
(**): Corrected to “one light burned out”.
16-46 ELECTRICAL SYSTEM
Lighting System
Turn Signal Light Circuit
1. Meter Unit
2. Front Right Turn Signal Light 12 V 10 W
3. Frame Ground 3
4. Rear Right Turn Signal Light 12 V 10 W
5. Rear Left Turn Signal Light 12 V 10 W
6. Frame Ground 1
7. Battery 12 V 8 Ah
8. Ignition Fuse 15 A
9. Main Fuse 20 A
10. Turn Signal Switch
11. Turn Signal Relay
12. Ignition Switch
13. Front Left Turn Signal Light 12 V 10 W
ELECTRICAL SYSTEM 16-47
Radiator Fan System
Fan Motor Inspection
the fuel tank (see Fuel Tank Removal in the Fuel
• Remove
System (DFI) chapter).
the fan motor lead connector [A].
• Disconnect
Using
an
auxiliary
leads, supply battery power to the fan
• motor.
If the fan does not rotate, the fan motor is defective and
must be replaced.
Fan Motor Relay Inspection
the right side cover (see Side Cover Removal in
• Remove
the Frame chapter).
the connector and remove the fan motor relay
• Disconnect
[A].
a tester [A] and 12 V battery [B] to the fan motor
• Connect
relay [C] as shown.
If the relay does not work as specified, the relay is defective. Replace the relay.
Testing Relay
Criteria:
When battery is connected → about 0 Ω
When battery is disconnected → ∞ Ω
16-48 ELECTRICAL SYSTEM
Radiator Fan System
Radiator Fan Circuit
1. Engine Stop Switch
2. Frame Ground 3
3. CDI Unit
4. Radiator Fan Relay
5. Radiator Fan Motor
6. Water Temperature Sensor
7. Frame Ground 1
8. Battery 12 V 8 Ah
9. Main Fuse 20 A
10. Ignition Switch
ELECTRICAL SYSTEM 16-49
Meter, Gauge, Indicator Unit
Meter Unit Removal/Installation
the meter unit assy (see Headlight Cover Re• Remove
moval in the Frame chapter).
• Remove:
Bolts [A]
Meter Cover [B]
• Remove:
Nuts [A] and Washers
Meter Unit [B]
NOTICE
Place the meter unit so that the face is up. If a meter
unit is left upside down or sideways for any length
of time, it will malfunction.
• Installation is the reverse of removal.
Meter Unit Disassembly
NOTE
○The meter unit cannot be disassembled.
If necessary,
replace the meter unit as an assembly.
Electronic Combination Meter Unit Inspection
the meter unit.
• Remove
[1] Speed Sensor Supply (+): R/W
[2] Speed Sensor Pulse: BL/W
[3] Ground (–): BK/Y
[4] Green Turn Signal Indicator Light (LED) (+) for Left:
G
[5] Meter Illumination Light (LED) (+): R
[6] Ground (–): BK/Y
[7] Side Stand Symbol (–): O/BR
[8] Oil Pressure Switch: BR/G
[9] Ignition (+): GY/R
[10] Green Turn Signal Indicator Light (LED) (+) for Right:
GY
[11] Green Neutral Indicator Light (LED) (–): LG
[12] Water Temperature Sensor: BK/W
[13] Battery (+): W
[14] Tachometer Pulse: BK
[15] Fuel Level Sensor: W/Y
[16] Headlight (+): R/Y
[17] Blue High Beam Indicator Light (LED) (+): R/BK
[18] Headlight (–): BK/Y
NOTICE
Do not drop the meter unit. Place the meter unit so
that it faces upward. If the meter unit is left upside
down or sideways for a long time or dropped, it will
malfunction. Do not short each terminals.
16-50 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
Check 1: Meter Unit Primary Operation Check
Using the auxiliary leads, the 12 V battery to the meter
unit connector as follows.
○Connect the battery positive (+) terminal to the terminal
[13].
○Connect the battery negative (–) terminal to the terminals
[6] [3].
•
• Connect the terminal [9] to the battery (+) terminal.
the following items.
•○Check
The tachometer needle momentarily points their last readings and back to the minimum position.
○All the LCD (Liquid Crystal Display) segments [A] and me-
ter illumination light (LED) go on for a few seconds.
○The red battery voltage warning indicator light (LED) [B],
red oil pressure warning indicator light (LED) [C] and red
water temperature warning indicator light (LED) [D] go on.
If the meter unit does not work, replace the meter unit.
Check 2: MODE Button Operation Check
Connect the leads in the same circuit as Check 1.
•
pushing the MODE button [A] for less than 2 seconds,
• By
check that the display [B] changes as follows.
If the display function does not work, replace the meter
unit.
ELECTRICAL SYSTEM 16-51
Meter, Gauge, Indicator Unit
Check 3: Clock Setting Check
Connect the leads in the same circuit as Check 1.
•
the Trip1 mode [A] by pushing the MODE button [B]
• Set
for less than 2 seconds.
the MODE button and SET button [C] simultane• Push
ously for more than 2 seconds.
○The clock setting menu (hour and minute) [D] should blink.
pushing the MODE button for less than 1 second,
• By
check that the hour display changes.
pushing the SET button for less than 1 second, check
• By
that the minute display changes.
the MODE button and SET button simultaneously
• Push
for more than 2 second. The displays stop blinking and
the clock starts working.
NOTE
○If no editing is carried out for more than 5 seconds, the
clock set mode finished and the set value cannot be
saved.
If the display function does not work, replace the meter
unit.
Check 4: Green Turn Signal Indicator Light (LED) Inspection
Connect the leads in the same circuit as Check 1.
Connect the terminal [10] (right) or [4] (left) to the battery
(+) terminal.
•
•
16-52 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
that the green turn signal indicator light (LED) [A]
• Check
goes on.
If the indicator light (LED) does not go on, replace the
meter unit.
Check 5: Blue High Beam Indicator Light (LED) Inspection
Connect the leads in the same circuit as Check 1.
Connect the terminal [17] to the battery (+) terminal.
•
•
that the blue high beam indicator light (LED) [A]
• Check
goes on.
If the indicator light (LED) does not go on, replace the
meter unit.
Check 6: Green Neutral Indicator Light (LED) Inspection
Connect the leads in the same circuit as Check 1.
Connect the terminal [11] to the battery (–) terminal.
•
•
that the green neutral indicator light (LED) [A] goes
• Check
on.
If the indicator light (LED) does not go on, replace the
meter unit.
ELECTRICAL SYSTEM 16-53
Meter, Gauge, Indicator Unit
Check 7: Side Stand Symbol Inspection
Connect the leads in the same circuit as Check 1.
Connect the terminal [7] to the battery (–) terminal.
•
•
that the side stand symbol [A] goes on.
• Check
If the symbol does not go on, replace the meter unit.
Check 8: Fuel Level Gauge Inspection
Connect the leads in the same circuit as Check 1.
○The all segments of the fuel gauge in the display will flash.
Connect the variable rheostat [A] to the terminal [15] and
the battery (–) terminal.
•
•
that the segments number of the fuel level gauge
• Check
[A] matches the resistance value of the variable rheostat.
○When the terminal [15] is connected, one segment in the
fuel level gauge should appear about every 30 seconds.
Variable Rheostat
Resistance (Ω)
Display Condition
10
all segments go on
about 50
5 segment goes on
110
Fuel Symbol [B] blinks
If the display function does not work, replace the meter
unit.
16-54 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
Check 9: Speedometer Inspection
Connect the leads in the same circuit as Check 1.
The speed equivalent to the input frequency is indicated in
the oscillator [A], if the square wave is input into terminal
[2].
○Indicates approximately 60 km/h if the input frequency is
approximately 72 Hz.
If the meter function does not work, replace the meter unit.
•
•
NOTE
○The input frequency of the oscillator adds the integrated
value of the odometer.
Check 10: Odometer Check
Check the odometer with the speedometer check in the
same way.
If value indicated in the odometer is not added, replace
the meter unit.
•
Check 11: Trip 1/Trip 2 Meter Check
Check the trip meter with the speedometer in the same
way.
If value indicated in the trip meter is not added, replace
the meter unit.
Check that when the SET button is pushed for more than
5 seconds, the figure display turns to 0.0.
If the figure display does not indicate 0.0, replace the meter unit.
•
•
ELECTRICAL SYSTEM 16-55
Meter, Gauge, Indicator Unit
Check 12: Tachometer Inspection
Connect the leads in the same circuit as Check 1.
The engine speed (rpm) equivalent to the input frequency
is indicated in the oscillator [A], if the square wave is input
into terminal [14].
○Indicates approximately 4 000 rpm if the input frequency
is approximately 65 Hz.
○The yellow red zone warning indicator light blinks when
the engine speed reaches 10 000 rpm or more. (The input
frequency is approximately 170 Hz.)
If the meter function does not work, replace the meter unit.
•
•
the terminal [14].
• Disconnect
Check
that
the
• mum (0) position.tachometer needle [A] back to the miniIf the meter unit does not work, replace the meter unit.
Yellow Red Zone Warning Indicator Light (LED) [B]
Check 13: Meter Illumination Light (LED) Inspection
Connect the leads in the same circuit as Check 1.
Connect the terminal [5] to the battery (+) terminal.
•
•
that the meter illumination light (LED) [A] goes on.
• Check
If the light (LED) does not go on, replace the meter unit.
16-56 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
Meter Circuit
1. Meter Unit
2. Speed Sensor
3. Fuel Level Sensor
4. Side Stand Switch
5. Engine Stop Switch
6. Frame Ground 3
7. Water Temperature Sensor
8. Frame Ground 1
9. Battery 12 V 8 Ah
10. Main Fuse 20 A
11. Neutral Switch
12. Oil Pressure Switch
13. to Turn Signal Light Switch (Right)
14. to Frame Ground
15. to Tail/Brake Light
16. to Turn Signal Light Switch (Left)
17. to Dimmer Switch and Passing Button
18. Ignition Switch
ELECTRICAL SYSTEM 16-57
Switches and Sensors
Water Temperature Sensor Inspection
the water temperature sensor (see Water Tem• Remove
perature Sensor Removal in the Cooling System chapter).
the sensor [A] in a container of coolant so that
• Suspend
the temperature-sensing projection [C] is submerged.
an accurate thermometer [B] with temperature
• Suspend
-sensing projection located in almost the same depth with
the sensor.
NOTE
○The sensor and thermometer must not touch the container side or bottom.
the container over a source of heat and gradu• Place
ally raise the temperature of the coolant while stirring the
•
coolant gently.
Using the hand tester, measure the internal resistance of
the sensor.
If the hand tester does not show the specified values, replace the sensor.
Water Temperature Sensor Resistance
Temperature
*Resistance (kΩ)
0°C (32°F)
5.71
10°C (50°F)
3.68
20°C (68°F)
2.43
25°C (77°F)
2.00
30°C (86°F)
1.65
40°C (104°F)
1.14
50°C (122°F)
0.80
*: Reference Information
Fuel Level Sensor Removal
WARNING
Gasoline is extremely flammable and can be explosive 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;
this includes any appliance with a pilot light. Do not
smoke. Turn the ignition switch off. Be prepared for
fuel spillage; any spilled fuel must be completely
wiped up immediately.
• Remove:
Fuel Tank Cover (see Fuel Tank Cover Removal in the
•
•
•
Frame chapter)
Left Side Cover (Side Cover Removal in the Frame
chapter)
Open the clamp [A].
Disconnect the fuel level sensor lead connector [B].
Remove:
Nuts [C]
Fuel Level Sensor [D]
16-58 ELECTRICAL SYSTEM
Switches and Sensors
Fuel Level Sensor Installation
the O-ring [A] with a new one.
• Replace
the projection [B] of the fuel tank into the hole [C]
• Insert
of the fuel level sensor.
the nut securely.
• Tighten
Connect
fuel level sensor lead connector.
• Install thetheremoved
parts.
•
Fuel Level Sensor Inspection
the fuel level sensor (see Fuel Level Sensor Re• Remove
moval).
a tester, and connect it to the fuel level sensor lead
• Set
connector as shown.
Fuel Level Sensor Resistance
Full Position [A]: 10 ±3 Ω
Empty Position [B]: 110 ±5 Ω
If the tester does not read as specified, replace the fuel
level sensor.
Throttle Sensor Inspection
NOTE
○Be sure the battery is fully charged.
the engine and warm it up thoroughly.
• Start
• Check idle speed to ensure the throttle opening is correct.
Idle Speed
Standard: 1 350 ∼ 1 450 r/min (rpm)
•
If the idle speed is out of the specified range, adjust it
(see Idle Speed Inspection in the Periodic Maintenance
chapter).
Inspect the throttle sensor following procedures.
Step1: Throttle Sensor Resistance Inspection
Remove the CDI unit (see CDI unit Removal).
Connect a digital meter to the terminals in the CDI unit
connector [A].
Measure the throttle sensor resistance.
•
•
•
Throttle Sensor Resistance
Connection to adapter:
Digital Meter (+) → P Lead
Digital Meter (–) → GY/W Lead
Standard:
5 kΩ
If the reading is out of the standard, replace the throttle
sensor.
If the reading is within the standard, check the throttle sensor output voltage inspection (see Step2: Throttle Sensor
Output Voltage Inspection).
ELECTRICAL SYSTEM 16-59
Switches and Sensors
Step2: Throttle Sensor Output Voltage Inspection
Connect the CDI unit [A].
Connect a digital meter to the CDI unit connector with the
needle adapter set [B].
•
•
Special Tool - Needle Adapter Set: 57001-1457
Throttle Sensor Output Voltage
Connection to adapter:
Digital Meter (+) → P Lead
Digital Meter (–) → BK/Y Lead
the ignition switch on.
• Turn
Measure
the throttle sensor output voltage by Turning the
• throttle grip.
Output Voltage
Standard:
DC 0.65 ∼ 0.75 V at idle throttle opening
DC 3.4 ∼ 3.8 V at full throttle opening (for
reference)
If the reading is out of the standard, adjust the throttle sensor mounting position (see Step3: Throttle Sensor Adjustment).
Step2: Throttle Sensor Adjustment
Remove the carburetor with the throttle cable and throttle
sensor connectors installed (see Carburetor Removal in
the Fuel System (DFI) chapter).
Connect a digital meter to the CDI unit connector with the
needle adapter set [A].
•
•
Special Tool - Needle Adapter Set: 57001-1457
Throttle Sensor Output Voltage
Connection to adapter:
Digital Meter (+) → P Lead
Digital Meter (–) → BK/Y Lead
• Turn the ignition switch on.
the throttle sensor mounting bolt [A].
• Loosen
the position of the throttle sensor [B] on the carburetor
• Set
by slightly rotating it until digital meter reads 0.7 V.
○Rotate the throttle sensor clockwise [C] if the output voltage is less than 0.7 V.
○Rotate the throttle sensor counterclockwise [D] if the output voltage is more than 0.7 V.
Tighten the throttle sensor mounting bolt while holding the
throttle sensor.
•
Torque - Throttle Sensor Mounting Bolt: 5.0 N·m (0.50
kgf·m, 44 in·lb)
the throttle sensor output voltage again by rotat• Measure
ing the throttle pulley.
If the reading is out of the standard, adjust the throttle
sensor mounting position again.
16-60 ELECTRICAL SYSTEM
Switches and Sensors
Speed Sensor Removal
• Remove:
Headlight Assy (see Headlight Cover Removal in the
•
Frame chapter)
Remove the speed sensor lead [A] from the bracket [B].
• Remove:
Front Wheel
(see Front Wheel Removal in the
Wheels/Tires chapter)
Speed Sensor [A]
Speed Sensor Installation
high-temperature grease to the speed sensor seal
• Apply
lip [A].
the projections [B] of the speed sensor to the
• Insert
notches [C] of the wheel hub.
NOTICE
Unless the speed sensor housing is properly installed on the wheel, you will damage the speed
sensor rotor in tightening the front axle.
the front wheel (see Front Wheel Installation in the
• Install
Wheels/Tires chapter).
the speed sensor lead to the bracket, and connect
• Install
the speed sensor lead connector.
the headlight assy (see Headlight Cover Installa• Install
tion in the Frame chapter).
ELECTRICAL SYSTEM 16-61
Switches and Sensors
Speed Sensor Inspection
• Remove:
Speed Sensor (see Speed Sensor Removal)
Connect
speed sensor connector [A] with a battery
• [B], 10 kΩtheresistor
[C] and a tester [D] as shown.
R/W Lead [E]
BL/W Lead [F]
BK/Y Lead [G]
[A] the sensor rotor of the speed sensor with a
• Rotate
screw driver.
○Then the tester indicator should flick [B].
If the tester indicator does not flick, replace the speed
sensor.
Side Stand Switch Removal
the side stand switch lead connector [A].
• Disconnect
the bands [B], and open the clamps.
• Remove
Remove:
• Bolt [C]
Side Stand Switch [D]
Side Stand Switch Installation
the projection [A] of the side stand switch into the
• Insert
hole [B], and tighten the bolt.
the side stand switch lead with the new bands and
• Hold
the clamps.
• Connect the sidestand switch lead connector.
Side Stand Switch Inspection
• Refer to the Switch Inspection.
16-62 ELECTRICAL SYSTEM
Switches and Sensors
Neutral Switch Removal
the alternator rotor (see Alternator Rotor Re• Remove
moval).
the neutral switch lead connector.
• Disconnect
Remove:
• Neutral Switch Lead Holding Plate Bolts [A]
Neutral Switch Lead Holding Plate Screw [B]
Neutral Switch Bolts [C]
Neutral Switch Lead Holding Plates [D]
Grommet [E]
Neutral Switch [F]
• Remove the pin [A] and spring [B] from the shift drum.
Neutral Switch Installation
a high flash-point solvent, clean off any oil or dirt
• Using
that may be on the liquid gasket coating area. Dry them
•
with a clean cloth.
Apply liquid gasket to the circumference of the neutral
switch lead grommet [A], and fit the grommet into the
notch of the cover securely.
Sealant - Liquid Gasket, TB1211F: 92104-0004
place the pin [A] and spring [B] into the hole of
• Securely
the shift drum.
a non-permanent locking agent to the neutral switch
• Apply
bolts.
the neutral switch, and tighten the neutral switch
• Install
bolts.
Torque - Neutral Switch Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb)
a non-permanent locking agent to the neutral switch
• Apply
lead holding plate bolts and screw.
the holding plates, and tighten the neutral switch
• Install
lead holding plate bolts and screw.
Torque - Neutral Switch Lead Holding Plate Bolts: 5.9 N·m
(0.60 kgf·m, 52 in·lb)
Neutral Switch Lead Holding Plate Screw: 5.9 N·m
(0.60 kgf·m, 52 in·lb)
• Install the removed parts (see appropriate chapters).
Neutral Switch Inspection
• Refer to the Switch Inspection.
ELECTRICAL SYSTEM 16-63
Switches and Sensors
Starter Lockout Switch Circuit Inspection
the headlight assy (see Headlight Cover Re• Remove
moval in the Frame chapter).
• Remove the band [A].
the dust cover [A], and disconnect the starter lockout
• Slide
switch lead connector [B].
conductivity of the following by a tester.
• Check
Starter Lockout Switch Lead Connector [A] (Switch Side)
• Connect the tester to the starter lockout switch connector.
Switch Circuit Inspection
Connections: Y/G Lead ← → BK/Y Lead
Criteria:
When clutch lever is released → ∞
When clutch lever is pulled in → about 0 Ω
Diode Inspection
Connections: Y/G Lead → LG Lead or
Y/G Lead ← LG Lead
Criteria:
Confirm that there is a continuity on one
side and not a continuity on other side.
If the tester does not read as specified, replace the starter
lockout switch.
Brake Light Timing Inspection
to the Brake Light Switch Operation Inspection in
• Refer
the Periodic Maintenance chapter.
Brake Light Timing Adjustment
to the Brake Light Switch Operation Inspection in
• Refer
the Periodic Maintenance chapter.
16-64 ELECTRICAL SYSTEM
Switches and Sensors
Switch Inspection
a tester, check to see that only the connections
• Using
shown in the table have continuity.
○For the switch housings and the ignition switch, refer to
the tables in the Wiring Diagram.
If the switch has an open or short, repair it or replace it
with a new one.
Rear Brake Light Switch Connections
Side Stand Switch Connections
Oil Pressure Switch Connections*
*: Engine lubrication system is in good condition.
Neutral Switch Connections
ELECTRICAL SYSTEM 16-65
Fuse
Fuse Box Fuse Removal
the left side cover (see Side Cover Removal in
• Remove
the Frame chapter).
the hooks [A] to lift up the lid.
• Unlock
Fuse Box (Main Fuse) [B]
Fuse Box (Ignition Fuse) [C]
the fuses [A] straight out of the fuse box with needle
• Pull
nose pliers.
Spare Fuses [B]
Fuse Installation
•
If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a
new fuse of proper amperage.
Install the fuse box fuse on the original position as specified on the lid.
Fuse Inspection
the fuse (see Fuse Box Fuse Removal).
• Remove
Inspect
the
element.
• If it is blownfuse
out, replace the fuse. Before replacing a
blown fuse, always check the amperage in the affected
circuit. If the amperage is equal to or greater than the
fuse rating, check the wiring and related components for
a short circuit.
Housing [A]
Fuse Element [B]
Terminals [C]
Blown Element [D]
NOTICE
When 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.
APPENDIX 17-1
Appendix
Table of Contents
Cable, Wire, and Hose Routing ..............................................................................................
Troubleshooting Guide ...........................................................................................................
17-2
17-23
17
17-2 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-3
Cable, Wire, and Hose Routing
1. Throttle Cable
2. Front Brake Hose
3. Right Switch Housing Lead
4. Band (Hold the front brake hose and right switch housing lead.)
5. Left Switch Housing Lead
6. Clutch Cable
7. Starter Lockout Switch Lead
8. Band (Hold the clutch cable, left switch housing lead and starter lockout switch lead.)
9. Ignition Switch
10. Rubber Cover (Cover the left switch housing lead connector, ignition switch lead connector, left
switch housing lead connector and starter lockout switch lead connector.)
11. Main harness ( to the headlight assy)
12. Yellow Collar
13. Speed Sensor Lead
14. Clamp (Hold the speed sensor lead.)
15. Clamp (Hold the front brake hose.)
16. White Tape
17. Band (Hold the clutch cable.)
18. Band (Hold the rubber cover.)
17-4 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-5
Cable, Wire, and Hose Routing
1. Meter Unit
2. Rubber Cover (Cover the main harness connectors.)
3. Ignition Switch
4. Headlight Dust Cover
5. Meter Unit Connector
6. Left Front Turn Signal Light Lead Connector
7. Headlight lead Connector
8. Right Front Turn Signal Lead Connector
9. Speed Sensor Lead Connector
10. Main Harness
11. Left Turn Signal Light
12. Right Turn Signal Light
17-6 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-7
Cable, Wire, and Hose Routing
1. Ground Terminals
2. Ignition Coil for Central Spark Plug
3. Ignition Coil for Side Spark Plugs
4. Run the main harness between two ignition coils.
5. Band (Hold the radiator fan motor lead on the radiator fan casing.)
6. Radiator Fan Motor Lead Connector
7. Guide (Run the right side spark plug lead, throttle cable and clutch cable into the guide.)
8. Right Side Spark Plug Lead
9. Throttle Cable
10. Clutch Cable
11. Fuel Tank Overflow Hose
12. Coolant Reserve Tank
13. Coolant Reserve Tank Overflow Hose
14. Guide (Run the coolant reserve tank overflow hose into the guide.)
15. Radiator Overflow Hose
16. Fuel Tank Cover
17. Radiator Cap
17-8 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-9
Cable, Wire, and Hose Routing
1. Fuel Tank Breather Hose
2. Guides (Run the fuel tank breather hose into the guides.)
3. Fuel Level Sensor Lead
4. Guide (Run the fuel level sensor lead into the guide.)
5. Clamp (Hold the fuel level sensor lead.)
6. Fuel Level Sensor Lead Connector
7. Band (Hold the hone leads.)
8. Horn Leads
9. Horn
10. Central Spark Plug
11. Left Side Spark Plug
12. Bands (Hold the alternator/crankshaft sensor lead and neutral switch lead.)
13. Neutral Switch Lead
14. Alternator/Crankshaft Sensor Lead
15. Engine Ground Terminal
16. Frame Ground Terminal
17-10 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-11
Cable, Wire, and Hose Routing
1. Air Cleaner Drain Hose
2. Rear Brake Light Switch Lead
3. Carburetor Drain Hose
4. Guide (Run the air cleaner drain hose, rear brake light switch lead and carburetor drain hose
into the guide.)
5. Clutch Cable
6. Throttle Cable
7. Main Harnesses
8. Guide (Run the carburetor drain hose into the guide.)
9. Engine Breather Hose
10. Right Side Spark Plug
11. Run the spark plug lead inside the engine bracket.
17-12 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-13
Cable, Wire, and Hose Routing
1. Oil Pressure Switch
2. Water Temperature Sensor
3. Band (Hold the water temperature sensor lead.)
4. Water Temperature Sensor Lead
5. Starter Motor Cable
6. Band (Hold the oil pressure switch lead.)
7. Band (Hold the main harness and rear brake light switch lead.)
8. Rear Brake Light Switch Lead
9. Oil Pressure Switch Lead
10. Clutch Cable
11. Throttle Cable
12. Left Side Spark Plug Lead
13. Front Side
14. Central Spark Plug Lead
15. Crankshaft Sensor Lead Connector
16. Alternator Lead Connector
17. Band (Hold the main harness and alternator lead.)
18. Band (Hold the regulator/rectifier lead connector and main harness.)
19. White Tape
20. Band (Hold the starter motor cable, battery (-) cable and mean harness.)
21. Battery (–) Cable
22. View from back
23. Guides (Run the main harness and starter motor cable into the guides.)
17-14 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-15
Cable, Wire, and Hose Routing
1. Band (Hold the main harness and rear brake light switch lead.)
2. Turn Signal Light Relay
3. Radiator Fan Relay
4. Battery
5. Battery (+) Terminal
6. Battery (–) Terminal
7. Band (Hold the regulator/rectifier lead connector and main harness.)
8. Regulator/Rectifier Lead
9. Band (Hold the regulator/rectifier lead and main harness.)
10. Band (Hold the starter motor cable, battery (-) cable and mean harness.)
11. White Tape
12. Regulator/Rectifier
13. Starter Relay
14. Fuse Box
15. Band (Hold the starter motor cable, starter relay lead, battery (-) cable and main harness.)
16. Starter Motor Cable
17. Battery (+) Cable
18. Band (Hold battery (–) cable and main harness.)
17-16 APPENDIX
Cable, Wire, and Hose Routing
1. Headlight Relay
2. Band (Hold the main harness.)
3. CDI Unit
4. Clamp (Hold the rubber cover.)
5. Rubber Cover (Cover the left rear turn signal light lead connector, right rear turn signal light lead
connector, license plate light lead connector and tail/brake light lead connector.)
6. License Plate Light
7. Bands (Hold the license plate light lead.)
APPENDIX 17-17
Cable, Wire, and Hose Routing
1. Speed Sensor
2. Speed Sensor Lead
3. Guide (Run the speed sensor lead into the guide.)
4. Clamp (Hold the front brake hose.)
5. Front Brake Hose
6. Front Brake Caliper
7. Rear Brake Caliper
8. Rear Brake Reservoir
9. Rear Brake Hose
17-18 APPENDIX
Cable, Wire, and Hose Routing
PH Model
APPENDIX 17-19
Cable, Wire, and Hose Routing
1. Main Harness
2. Left Side Spark Plug Lead
3. Clamp the left side spark plug lead.
4. Clamp the vacuum hose and air hose (to the cylinder head pipe).
5. Vacuum Hose
6. Air Hose (to the cylinder head pipe)
7. Air Hose (to the air cleaner housing)
8. Vacuum Switch Valve
9. Clamp (Hold the air hose.)
10. Alternator Lead Connector and Neutral Switch Lead Connector
17-20 APPENDIX
Cable, Wire, and Hose Routing
PH Model
APPENDIX 17-21
Cable, Wire, and Hose Routing
1. Fuel Hose
2. Clamp (Hold the fuel hose.)
3. Air Hose (to the air cleaner housing)
4. Minimum 10 mm (0.39 in.) between fuel hose and air hose.
17-22 APPENDIX
Cable, Wire, and Hose Routing
1. Air Vent Hose
2. Clamp (Inside of gusset, hold the air vent hose.)
3. Gusset (Left side of rear frame)
APPENDIX 17-23
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.
Engine Doesn’t Start, Starting
Difficulty:
Starter motor not rotating:
Ignition and engine stop switch not ON
Starter lockout switch or neutral switch trouble
Starter motor trouble
Battery voltage low
Starter relay not contacting or operating
Starter button not contacting
Wiring shorted or open
Ignition switch trouble
Engine stop switch trouble
Fuse blown
Starter motor rotating but engine doesn’t
turn over:
Starter clutch trouble
Starter idle gear trouble
Engine won’t turn over:
Valve seizure
Rocker arm seizure
Cylinder, piston seizure
Crankshaft seizure
Connecting rod small end seizure
Connecting rod big end seizure
Transmission gear or bearing seizure
Camshaft seizure
Starter idle gear seizure
No fuel flow:
No fuel in tank
Fuel tank air vent obstructed
Fuel tap clogged
Fuel filter clogged
Fuel line clogged
Float valve clogged
Engine flooded:
Fuel level in carburetor float bowl too high
Float valve worn or stuck open
Starting technique faulty (When flooded,
crank the engine with the throttle fully
opened to allow more air to reach the
engine.)
No spark; spark weak:
Ignition switch not ON
Engine stop switch turned OFF
Clutch lever not pulled in or gear not in neutral
Battery voltage low
Spark plug dirty, broken, or gap maladjusted
Spark plug cap or high tension lead trouble
Spark plug cap shorted or not in good contact
Spark plug incorrect
CDI unit trouble
Neutral switch or starter lockout switch trouble
Crankshaft sensor trouble
Ignition coil trouble
Ignition switch or engine stop switch
shorted
Wiring shorted or open
Fuse blown
Fuel/air mixture incorrect:
Idle adjusting screw maladjusted
Pilot jet, or air passage clogged
Air cleaner clogged, poorly sealed, or missing
Air cleaner duct loose
Compression Low:
Spark plug loose
Cylinder head not sufficiently tightened
down
No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent,
worn, or carbon accumulation on the
seating surface)
Poor Running at Low Speed:
Spark weak:
Battery voltage low
Spark plug dirty, broken, or gap maladjusted
Spark plug cap or high tension lead trouble
Spark plug cap shorted or not in good contact
Spark plug incorrect
CDI unit trouble
Crankshaft sensor trouble
Ignition coil trouble
Fuel/air mixture incorrect:
Idle adjusting screw maladjusted
Pilot jet, or air passage clogged
Needle jet bleed holes or needle jet clogged
Pilot passage clogged
Air cleaner clogged, poorly sealed, or missing
Choke plunger stuck open
Fuel level in carburetor float bowl too high
or too low
17-24 APPENDIX
Troubleshooting Guide
Fuel tank air vent obstructed
Carburetor holder loose
Air cleaner duct loose
Fuel tap clogged
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened
down
No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring/groove clearance excessive
Cylinder head warped
Cylinder head gasket damaged
Valve spring broken or weak
Valve not seating properly (valve bent,
worn, or carbon accumulation on the
seating surface)
Other:
CDI unit trouble
Carburetor vacuum piston does not slide
smoothly
Carburetor Vacuum piston diaphragm damage
Engine oil viscosity too high
Drive train trouble
Brake dragging
Engine overheating
Clutch slipping
Poor Running or No Power at High
Speed:
Firing incorrect:
Spark plug dirty, broken, or gap maladjusted
Spark plug cap or high tension lead trouble
Spark plug cap shorted or not in good contact
Spark plug incorrect
CDI unit trouble
Crankshaft sensor trouble
Ignition coil trouble
Fuel/air mixture incorrect:
Choke plunger stuck open
Main jet clogged or wrong size
Jet needle or needle jet worn
Air jet or air passage clogged
Fuel level in carburetor float bowl too high
or too low
Needle jet bleed holes or needle jet clogged
Air cleaner clogged, poorly sealed, or missing
Air cleaner duct loose
Fuel to carburetor insufficient
Water or foreign matter in fuel
Carburetor holder loose
Fuel tank air vent obstructed
Fuel tap clogged
Fuel filter clogged
Fuel line clogged
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened
down
No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent,
worn, or carbon accumulation on the
seating surface)
Knocking:
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
CDI unit trouble
Miscellaneous:
Throttle valve won’t fully open
Carburetor vacuum piston does not slide
smoothly
Carburetor vacuum piston diaphragm damage
Brake dragging
Clutch slipping
Engine overheating
Engine oil level too high
Engine oil viscosity too high
Drive train trouble
Crankshaft bearing worn or damaged
Overheating:
Firing incorrect:
Spark plug dirty, broken, or maladjusted
Spark plug incorrect
CDI unit trouble
Fuel/air mixture incorrect:
Main jet clogged or wrong size
Fuel level in carburetor float bowl too low
Carburetor holder loose
Air cleaner duct loose
Air cleaner clogged, poorly sealed, or missing
Choke plunger stuck open
Compression high:
Carbon built up in combustion chamber
Engine load faulty:
Clutch slipping
Engine oil level too high
Engine oil viscosity too high
APPENDIX 17-25
Troubleshooting Guide
Drive train trouble
Brake dragging
Lubrication inadequate:
Engine oil level too low
Engine oil poor quality or incorrect
Clutch Operation Faulty:
Clutch slipping:
No clutch lever play
Clutch inner cable trouble
Friction plate worn or warped
Steel plate worn or warped
Clutch spring broken or weak
Clutch release mechanism trouble
Clutch hub or housing unevenly worn
Clutch not disengaging properly:
Clutch lever play excessive
Clutch plate warped or too rough
Clutch spring compression uneven
Engine oil deteriorated
Engine oil viscosity too high
Engine oil level too high
Clutch housing frozen on drive shaft
Clutch release mechanism trouble
Clutch hub nut loose
Clutch hub spline damaged
Clutch friction plate installed wrong
Gear Shifting Faulty:
Doesn’t go into gear shift pedal doesn’t
return:
Clutch not disengaging
Shift fork bent or seized
Gear stuck on the shaft
Gear positioning lever binding
Shift return spring weak or broken
Shift return spring pin loose
Shift mechanism arm spring broken
Shift mechanism arm broken
Shift drum broken
Jumps out of gear:
Shift fork ear worn, bent
Gear groove worn
Gear dogs and/or dog holes worn
Shift drum groove worn
Gear positioning lever spring weak or broken
Shift fork guide pin worn
Drive shaft, output shaft, and/or gear
splines worn
Overshifts:
Gear positioning lever spring weak or broken
Shift mechanism arm spring broken
Abnormal Engine Noise:
Knocking:
CDI unit trouble
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
Engine overheating
Piston slap:
Cylinder/piston clearance excessive
Cylinder, piston worn
Connecting rod bent
Piston pin, piston pin hole worn
Valve noise:
Valve clearance incorrect
Valve spring broken or weak
Camshaft bearing worn
Rocker arm worn
Rocker shaft worn
Other noise:
Connecting rod small end clearance excessive
Connecting rod big end clearance excessive
Piston ring worn, broken, or stuck
Piston seizure, damage
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head connection
Crankshaft runout excessive
Engine mounts loose
Crankshaft bearing worn
Primary gear worn or chipped
Camshaft chain tensioner trouble
Camshaft chain, sprocket, guide worn
Alternator rotor loose
Abnormal Drive Train Noise:
Clutch noise:
Clutch damper weak or damaged
Clutch housing finger/friction plate tang
worn
Clutch housing gear worn
Metal chips jammed in clutch housing gear
Transmission noise:
Bearings worn
Transmission gears worn or chipped
Metal chips jammed in gear teeth
Engine oil insufficient
Drive chain noise:
Drive chain adjusted improperly
Drive chain worn
Rear and/or engine sprocket worn
Chain lubrication insufficient
Rear wheel misaligned
17-26 APPENDIX
Troubleshooting Guide
Abnormal Frame Noise:
Front fork noise:
Oil insufficient or too thin
Spring weak or broken
Rear shock absorber noise:
Shock absorber damaged
Spring weak or broken
Disc brake noise:
Pad installed incorrectly
Pad surface glazed
Disc warped
Caliper trouble
Other noise:
Bracket, nut, bolt, etc.
not properly
mounted or tightened
Exhaust Smokes Excessively:
White smoke:
Piston oil ring worn
Cylinder worn
Valve oil seal damaged
Valve guide worn
Engine oil level too high
Black smoke:
Air cleaner clogged
Main jet too large or fallen off
Choke plunger stuck open
Fuel level in carburetor float bowl too high
Brown smoke:
Main jet too small
Fuel level in carburetor float bowl too low
Air cleaner duct loose
Air cleaner poorly sealed or missing
Handling and/or Stability
Unsatisfactory:
Handlebars hard to turn:
Cable routing incorrect
Wiring routing incorrect
Steering stem nut too tight
Steering stem bearing damaged
Steering stem bearing lubrication inadequate
Steering stem bent
Tire air pressure too low
Handlebars shakes or excessively
vibrates:
Tire worn
Handlebar holder bolt loose
Rim warped, or not balanced
Wheel bearing worn
Steering stem head bolt loose
Front, rear axle runout excessive
Handlebars pulls to one side:
Frame bent
Wheel misalignment
Swingarm bent or twisted
Swingarm pivot shaft bent
Steering maladjusted
Front fork bent
Right and left front fork oil level uneven
Shock absorption unsatisfactory:
(Too hard)
Front fork oil excessive
Front fork oil viscosity too high
Rear shock absorber adjustment too hard
Tire air pressure too high
Front fork bent
(Too soft)
Tire air pressure too low
Front fork oil insufficient and/or leaking
Front fork oil viscosity too low
Rear shock adjustment too soft
Front fork, rear shock absorber spring weak
Rear shock absorber oil leaking
Brake Doesn’t Hold:
Air in the brake line
Pad or disc worn
Brake fluid leakage
Disc warped
Contaminated pad
Brake fluid deteriorated
Primary or secondary cup damaged in master
cylinder
Master cylinder scratched inside
Battery Trouble:
Battery discharged:
Charge insufficient
Battery faulty (too low terminal voltage)
Battery cable making poor contact
Load excessive (e.g., bulb of excessive
wattage)
Ignition switch trouble
Alternator trouble
Wiring faulty
Regulator/rectifier trouble
Battery overcharged:
Regulator/rectifier trouble
Battery faulty
MODEL APPLICATION
Year
2013
2014
Model
BR200AD
BR200AE
Part No.99924-1469-02
Printed in Japan

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Bajaj

Продукт:

мотоциклы

Модель/название:

Pulsar NS200

Тип файла:

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Доступные языки:

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Accompanying Data:

Bajaj PULSAR NS200 Motorcycle PDF Manual  (Updated: Thursday 30th of March 2023 10:00:08 AM)

Rating: 4.8 (rated by 76 users)

Compatible devices: Pulsar 150 DTS-i, AVENGER 220 CRUISE, Dominar 400, DOMINAR 400 BS VI, Pulsar 180 CC DTS-i, CT-100, Pulsar 135 BS VI, GT110X BS VI.

Recommended Documentation:

Text Version of Manual 

(Ocr-Read Summary of Contents of some pages of the Bajaj PULSAR NS200 Document (Main Content), UPD: 30 March 2023)

• Bajaj PULSAR NS200 User Manual

• Bajaj PULSAR NS200 User Guide

• Bajaj PULSAR NS200 PDF Manual

• Bajaj PULSAR NS200 Owner’s Manuals

Recommended: Versagrill L5721A, Zap, G2

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