Kawasaki KX450F (2006) User Manual [ru]

KX450F

Motorcycle

Service Manual

Quick Reference Guide

General Information 1 j

Periodic Maintenance 2 j

Fuel System 3 j

Cooling System 4 j

Engine Top End 5 j

Engine Right Side 6 j

Engine Lubrication System 7 j

Engine Removal/Installation 8 j

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.

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

KX450F

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 Division/Consumer Products & Machinery 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.

© 2005 Kawasaki Heavy Industries, Ltd. First Edition (1) : Aug. 4, 2005 (M)

LIST OF ABBREVIATIONS

A

ABDC after bottom dead center

AC

ATDC after top dead center

BBDC before bottom dead center

BDC

BTDC before top dead center

°C degree(s) Celsius

DC

F

°F degree(s) Fahrenheit

ft foot, feet

g

h

kg

kgf (force)

L

ampere(s)

alternating current min

bottom dead center

direct current
farad(s) TDC

gram(s) (mass)
hour(s) Ω ohm(s)
(mass)

liter(s)

lb
m

N
Pa
PS
psi
r revolution
r/min, rpm revolution(s) per minute

TIR total indicator reading
V
W

pound(s)
meter(s)
minute(s)
newton(s)
pascal(s)
horsepower
pound(s) per square inch

top dead center

volt(s)
watt(s)

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.

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 Mo-

•

torcycle parts. Special tools, gauges, and

testers that are necessary when servicing

Kawasaki 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 care-

•

fully. Don’t take shortcuts.

Remember to keep complete records of main-

•

tenance 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 these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.

WARNING

This warning symbol identifies special

instructions or procedures which, if not

correctly followed, could result in per-

sonal injury, or loss of life.

CAUTION

This caution symbol identifies special

instructions or procedures which, if not

strictly observed, could result in dam-

age to or destruction of equipment.

This manual contains four more symbols (in
addition to WARNING and CAUTION) which will
help you distinguish different types of informa­tion.

NOTE

This note symbol indicates points of par-

○

ticular interest for more efficient and con-

venient operation.

Indicates a procedural step or work to be

•

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 inspec-

tion in the procedural step or sub-step it fol-

lows.
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 ..................................................................................................................... 1-2

Model Identification................................................................................................................. 1-7

General Specifications............................................................................................................ 1-8

Unit Conversion Table ............................................................................................................ 1-10

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:

Edges of Parts

Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.

Solvent

Use a high-flush point solvent when cleaning parts. High

-flush 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.

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.

Before Servicing

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.

GENERAL INFORMATION 1-3

Replacement Parts

Replacement Parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, Oil seals,
Grease seals, circlips or cotter pins 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.

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 them remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.

1-4 GENERAL INFORMATION

Before Servicing

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.

Often, the tightening sequence is followed twice-initial
tightening and final tightening with torque wrench.

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 new gaskets and replace 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.

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.

Before Servicing

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 i nner 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.

GENERAL INFORMATION 1-5

Apply specified grease to the lip of seal before installing
the seal.

Circlips, Cotter Pins

Replace circlips or cotter pins that were removed with new
ones. Take care not to open the clip excessively when in­stalling to prevent deformation.

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.

1-6 GENERAL INFORMATION

Before Servicing

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 Wire s

A two-color wire is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
wires 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.

Model Identification

KX450D6F Left Side View

GENERAL INFORMATION 1-7

KX450D6F Right Side View

1-8 GENERAL INFORMATION

General Specifications

Items KX450D6F

Dimensions

Overall Length 2 185 mm (86.02 in.)

Overall Width 820 mm (32.3 in.)

Overall Height 1 280 mm (50.39 in.)

Wheelbase 1 485 mm (58.46 in.)

Road Clearance 345 mm (13.6 in.)

Seat Height 965 mm (38.0 in.)

Dry Mass 99.8 kg (220 lb)

Fuel Tank Capacity 7.2 L (1.9 US gal)

Performance

Minimum Turning Radius –

Engine

Type 4-stroke, single cylinder, DOHC 4 valve

Cooling System Liquid-cooled

Bore and Stroke 96.0 × 62.1 mm (3.78 × 2.44 in.)

Displacement 449 cm³ (27.4 cu in.)

Compression Ratio 12.0 : 1

Carburetion System Carburetor, KEIHIN FCR40

Starting System Primary kick

Ignition System Digital AC-CDI

Timing Advance

Ignition Timing BTDC 10° @1 800 r/min (rpm)

Spark Plug NGK CPR8EB-9

Valve Timing:

Inlet:

Open BTDC 32°

Close ABDC 72°

Duration

Exhaust:

Open BBDC 62°

Close ATDC 42°

Duration 284°

Lubrication System Forced lubrication (semi-dry sump)

Engine Oil:

Type

Viscosity SAE 10W-40

Capacity 1.2L(1.3USqt)

Drive Train

Primary Reduction System:

Type

Reduction Ratio

Clutch Type Wet, multi disc

Transmission:

Type 4-speed, constant mesh, return shift

284°

API SG, SH, SJ o

Gear

2.727 (60/22

)

rSLwithJASOMA

GENERAL INFORMATION 1-9

General Specifications

Items KX450D6F

Gear ratios:

1st 1.800 (27/15)

2nd 1.411 (24/17)

3rd 1.187 (19/16)

4th 1.000 (19/19)

Final Drive System:

Type Chain drive

Reduction Ratio

Overall Drive Ratio 10.489 @Top gear

Frame

Type Tubular, semi-double cradle

Steering Angle 42° to either side

Caster (rake angle) 27.1°

Trail 117 mm (4.60 in.)

Front tire:

Size 90/100-21 57M

Make/Type DUNLOP D742F, Tube type

Rear tire:

Size 120/80-19 63M

Make/Type DUNLOP D756, Tube type

Rim size:

Front 1.60-21

Rear 2.15-19

Front suspension:

Type Telescopic fork (up side down)

Wheel travel 315 mm (12.4 in.)

Rear suspension:

Type

Wheel travel 315 mm (12.4 in.)

Brake type:

Front and Rear Single disc

Effective disc diameter:

Front (effect. dia.) 225 mm (8.86 in.)

Rear (effect. dia.) 215 mm (8.46 in.)

3.4846 (50/13)

Swingarm (New Uni-trak)

Specifications subject to change without notice, and may not apply to every country.

1-10 GENERAL INFORMATION

Unit Conversion Table

Prefixes for Units:

Prefix Symbol
mega M × 1 000 000
kilo k × 1 000
centi c ×0.01
milli m × 0.001
micro µ × 0.000001

Power

Units of Mass:

kg × 2.205 = lb
g × 0.03527 = oz

Units of Volume:

L × 0.2642 = gal (US)
L × 0.2200 = gal (imp)
L×1.057=
L × 0.8799 =
L×2.113=
L × 1.816 = pint (imp)
mL × 0.03381 = oz (US)
mL × 0.02816 = oz (imp)
mL × 0.06102 = cu in

qt (US)
qt (imp)
pint (US)

Units of Length:

km × 0.6214 = mile
m × 3.281 = ft
mm × 0.03937 = in

Units of Torque:

N·m × 0.1020 =
N·m × 0.7376 =
N·m × 8.851 = in·lb
kgf·m × 9.807 = N·m
kgf·m × 7.233 = ft·lb
kgf·m

× 86.80 = in·lb

kgf·m
ft·lb

Units of Pressure:

kPa × 0.01020 =
kPa × 0.1450 = psi
kPa × 0.7501 = cm Hg
kgf/cm² × 98.07 = kPa
kgf/cm² × 14.22 = psi
cm Hg × 1.333 = kPa

kgf/cm²

Units of Speed:

km/h

× 0.6214 = mph

Units of Force:

N × 0.1020 =
N × 0.2248 = lb
kgf × 9.807 = N
kgf × 2.205 = lb

Units of Temperature:

kgf

Units of Power:

kW × 1.360 =
kW × 1.341 = HP
PS × 0.7355 = kW
PS × 0.9863 = HP

PS

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

Periodic Maintenance Chart .............. 2-3

Torque and Locking Agent................. 2-5

Specifications .................................... 2-9

Special Tools ..................................... 2-11

Periodic Maintenance Procedures..... 2-12

Fuel System.................................... 2-12

Fuel Hose and Connection

Inspection.................................. 2-12

Throttle Grip Free Play Inspection 2-12
Throttle Grip Free Play

Adjustment ................................ 2-12

Hot Starter Lever Free Play

Inspection.................................. 2-13

Idle Speed Inspection .................. 2-13

Idle Speed Adjustment................. 2-14

Air Cleaner E lement Cleaning and

Inspection.................................. 2-14

Fuel Inspection ............................. 2-16

Fuel Tank, Filter and Tap

Cleaning .................................... 2-17

Fuel Tap and Filter Inspection...... 2-17

Cooling System............................... 2-17

Coolant Level Inspection.............. 2-18

Coolant Deterioration Inspection.. 2-18
Radiator Hoses and Connections

Inspection.................................. 2-19

Engine Top End .............................. 2-19

Valve Clearance Inspection ......... 2-19

Valve Clearance Adjustment........ 2-20

Cylinder Head Warp Inspection ... 2-22

Cylinder Wear Inspection............. 2-22

Piston/Cylinder Clearance ........... 2-23

Piston, Piston Ring and Piston

Pin Replacement....................... 2-23

Exhaust System Inspection.......... 2-23

Muffler Baffle Change .................. 2-23

Engine Right Side ........................... 2-24

Clutch Lever Free Play Check ..... 2-25

Clutch Lever Free Play

Adjustment ................................ 2-25

Friction and Steel Plates

Inspection.................................. 2-25

Engine Lubrication System ............. 2-26

Engine Oil Change....................... 2-26

Oil Filter Change .......................... 2-27

Breather Hose Inspection ............ 2-27

2

Crankshaft/Transmission................ 2-28

Crankshaft Inspection .................. 2-28

Wheel/Tires..................................... 2-28

Air Pressure Inspection/Adjust-

ment .......................................... 2-28

Tires Inspection............................ 2-29

Spoke Tightness Inspection......... 2-29

Rim Runout Inspection................. 2-30

Wheel Bearing Inspection ............ 2-30

Final Drive....................................... 2-31

Drive Chain Slack Inspection ....... 2-31

Drive Chain Slack Adjustment ..... 2-31

Drive Chain Wear Inspection ....... 2-32

Drive Chain Lubrication................ 2-33

Sprocket Wear Inspection............ 2-33

Rear Sprocket Warp Inspection ... 2-34

Brakes............................................. 2-34

Brake Lever and Pedal Position

Adjustment ................................ 2-34

Brake Fluid Level Inspection........ 2-35

Brake Fluid Change ..................... 2-36

Brake Pad Wear Inspection ......... 2-38

Brake Master Cylinder Cup and

Dust Seal Replacement ............ 2-38

Caliper Piston Seal and Dust Seal

Replacement............................. 2-40

Brake Hose and Connection

Check ........................................ 2-43

Brake Hose Replacement ............ 2-43

Suspension..................................... 2-44

Front Fork Inspection ................... 2-44

Front Fork Oil Change (each fork

leg) ............................................ 2-44

Rear Shock Absorber Inspection . 2-53
Rear Shock Absorber Oil Change 2-53
Swingarm and Uni-Trak Linkage

Inspection .................................. 2-58

Swingarm and Uni-Track Linkage

Pivot Lubricate .......................... 2-58

Steering .......................................... 2-58

Steering Inspection ...................... 2-58

Steering Adjustment .................... 2-58

Stem Bearing Lubrication............. 2-60

Frame ............................................. 2-60

Frame Inspection ......................... 2-60

Electrical System ............................ 2-61

2-2 PERIODIC MAINTENANCE

Spark Plug Cleaning and

Inspection .................................. 2-61

Cable Inspection............................. 2-61

Lubrication ................................... 2-61

Nut, Bolt, and Fastener Tightness

Inspection..................................... 2-62

Tightness Inspection .................... 2-62

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

The maintenance must be done in accordance with this chart to keep the motorcycle in good running

condition.

FREQUENCY

OPERATION

Spark plug-clean, gap †

Spark plug-replace

Clutch cable-adjust

Clutch and friction plates-inspect †

Throttle cable-adjust

Air cleaner element-clean †

Air cleaner element-replace If damaged 2-14

Carburetor-inspect and adjust

Engine Oil-change

Piston and piston ring-replace Every 6 races 2-23

E

Cylinder head, cylinder-inspect

N
G

Piston pin-replace

I

Valve clearance-inspect †

N
E

Hot starter cable-adjust

Oil filter-replace

Muffler-clean and inspect†

Muffler Baffle-change

Kick pedal and shift pedal-clean

Engine sprocket-inspect †

Coolant-check †

Radiator hoses and connections-inspect †

Crankshaft-inspect

Breather hose-inspect

Brake adjustment-inspect †

Brake pad wear-inspect †

Brake fluid level-inspect †

Brake fluid-change Every 2 years 2-36

C

Brake master cylinder cup and dust seal-replace Every 2 years 2-38

H

Brake caliper piston seal and dust seal-replace Every 2 years 2-40

A

Brake hoses and pipe-replace Every 4 years 2-43

S
S

Brake hoses, connections-inspect †

I

Spoke tightness and rim runout-inspect †

S

Wheel bearing-inspect †

Frame-inspect and clean

Drive chain wear-inspect †

Drive chain-inspect and adjust

Each

race or

2.5 hr

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

Every

3 races

or 7.5

hr

•

Every
6 races
or 15 hr

•

•

•

•

•

•

Every

12

races or

30 hr

•

See

Page

2-61

2-61

2-25

2-25

2-12

2-14

2-13

2-26

2-22

2-23

2-19

2-13

2-27

2-23

2-23

–

2-33

2-18

2-19

2-28

2-27

2-34

2-38

2-35

2-43

2-29

2-30

2-60

2-32

2-31

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

FREQUENCY

OPERATION

Drive chain-lubricate

Wheels/tires-inspect

Rear sprocket-inspect †

Front fork-inspect and clean

Front fork oil-change

Rear shock oil-replace

Cable-inspect

Fuel hose-replace Every 4 years 2-12

Fuel hose, connections-inspect †

Fuel system-clean

Steering play-inspect †

Steering stem bearing-grease

Swingarm and Uni-Trak linkage pivots-grease

Swingarm and Uni-Trak linkage pivots-inspect †

Nuts, bolts, fasteners-inspect †

Chassis parts-lubricate

†: Replace, add, adjust, clean or torque if necessary.

Each

race or

2.5 hr

•

•

•

•

•

•

•

•

•

Every

3 races

or 7.5

hr

•

•

•

Every
6 races
or 15 hr

•

•

•

Every

12

races or

30 hr

See

Page

2-33

2-28

2-33

2-44

2-44

2-53

2-61

2-12

2-16

2-58

2-60

2-58

2-58

2-62

–

PERIODIC MAINTENANCE 2-5

Torque and Locking Agent

Tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently
tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. The
following table lists the tightening toque for the major bolts and nuts, and the parts requiring use of a
non-permanent locking agent or liquid gasket.

When checking the tightening toque of the bolts and nuts, first loosen the bolt or nut by half a turn
and then tighten to specified torque.

Letters used in the "Remarks" column mean:

AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.

L: Apply a non-permanent locking agent to the threads.

Lh: Left-hand Threads

S: Tighten the fasteners following the specified sequence.

2T: Apply 2-stroke oil.

Fastener

Fuel System

Throttle Pulley Cover Bolt 3.4 0.35 30 in·lb

Throttle Cable Locknut 6.9 0.70 61 in·lb

Air Cleaner Duct Clamp Screw 2.0 0.20 18 in·lb

Air Cleaner Duct Mounting Nuts 3.0 0.31 27 in·lb

Air Cleaner Duct Mounting Screw 3.0 0.31 27 in·lb

Air Cleaner Housing Bolts 9.8 1.0 87 in·lb

Cooling System

Water Pump Cover Bolts 9.8 1.0 87 in·lb

Water Pump Impeller Bolt 9.8 1.0 87 in·lb

Radiator Hose Clamp Screws 1.5 0.15 13 in·lb

Coolant Drain Plug 6.9 0.70 61 in·lb

Radiator Mounting Bolts 9.8 1.0 87 in·lb

Radiator Screen Bolts 9.8 1.0 87 in·lb

Radiator Shroud Bolts 9.8 1.0 87 in·lb

Engine Top End

Cylinder Head Cover Bolts

Cylinder Head Bolts (M10)

Cylinder Head Bolts (M6)

Camshaft Cap Bolts 9.8 1.0 87 in·lb S, MO

Camsfaft Sprocket Bolts 12 1.2 106 in·lb L

Decompressor Plug Plate Bolt 9.8 1.0 87 in·lb

Radiator Hose Fitting Bolts 9.8 1.0 87 in·lb

Oil Line Plug 3.0 0.31 27 in·lb L

Carburetor Holder Clamp Screws 2.0 0.20 18 in·lb

Plug 20 2.0 15 L

Lower Camshaft Chain Guide Bolt 9.8 1.0 87 in·lb

Rear Camshaft Chain Guide Bolt 15 1.5 11

Chain Tensioner Mounting Bolts 9.8 1.0 87 in·lb

Chain Tensioner Cap 5.0 0.51 44 in·lb

Cylinder Bolt 12 1.2 106 in·lb S

Exhaust Pipe Cover Screws 12 1.2 106 in·lb

N·m

9.8 1.0 87 in·lb

59 6.0 44

12 1.2 106 in·lb

Torque

Remarks

kgf·m ft·lb

S, MO

S

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Exhaust Pipe Holder Nuts 21 2.1 15

Muffler Mounting Bolts 21 2.1 15

Engine Right Side

Primary Gear Nut 98 10 72 Lh

Shift Drum Cam Bolt 24 2.4 18 L

Clutch Spring Bolts 8.8 0.90 78 in·lb

Clutch Hub Nut 98 10 72

Gear Set Lever Nut

Ratchet Plate Mounting Bolt 9.8 1.0 87 in·lb

Ratchet Plate M ount

Ratchet Guide Bolt 8.8 0.90 78 in·lb

Kick Pedal Bolt 25 2.5 18 L

Shift Pedal Bolt 9.8 1.0 87 in·lb

Clutch Cover Bolts

Right Engine Cover Bolts

Engine Lubricati

Engine Oil Drain Bolt (M10)

(for crank room oil sump) 15 1.5 11

Engine Oil Drain Bolt (M6)

(for transmission room oil sump) 7.0 0.71 62 in·lb

Oil Pump (Scavenge) Cover Bolts 9.8 1.0 87 in·lb S

Oil Pump (Feed) Cover Bolts 9.8 1.0 87 in·lb S

Oil Filter Cover Bolt 9.8 1.0 87 in·lb

Oil Screen (Feed) Mounting Bolts 9.8 1.0 87 in·lb

Oil Pressure Relief Valve 15 1.5 11 L

Piston Oil Nozzle

Breather Fitting 15 1.5 11 L

Engine Removal/Installation

Engine Mounting Bolt, Nuts 49 5.0 36

Engine Bracket Bolt, Nuts 29 3.0 21

Swingarm Pivot Shaft Nut 98 10 72

Crankshaft/Transmission

Piston Oil Nozzle

Crankcase Bo

Crankcase Bolts (M7) 15 1.5 1.1 S

Engine Oil Drain Bolt (M10)

(for crank room oil sump) 15 1.5 11

Engine Oil Drain Bolt (M6)

(for transmission room oil sump) 7.0 0.71 62

Bearing Retaining Screw 15 1.5 11 L

Gear Set Lever Nut 8.8 0.90 78 in·lb

Shift Drum Cam Bolt 24 2.4 17 L

Balancer Weight Mounting Nut 52 5.3 38

lts (M6)

ing Screw

on System

N·m kgf·m ft·lb

8.8 0.90 78 in·lb

6.4 0.65 57 in·lb

9.8 1.0 87 in·lb

9.8 1.0 87 in·lb

2.9 0.30 26 in·lb

2.9 0.30 26 in·lb

12 1.2 106 in·lb

Torque

Remarks

S

S, L

S

Torque and Locking Agent

PERIODIC MAINTENANCE 2-7

Fastener

Gear Position Switch Screws 2.9 0.30 26 in·lb L

Wheels/Tires

Front Axle 79 8.1 58

Front Axle Clamp Bolts 20 2.0 15 AL

Rear Axle Nut 110 11.2 81.1

Spoke Nipples

Final Drive

Rear Sprocket Nuts 34 3.5 25

Engine Sprocket Nut 127 13.0 93.7

Engine Sprocket Cover Bolts 9.8 1.0 87 in·lb

Brakes

Brake Lever Pivot Locknut 5.9 0.60 52 in·lb

Brake Reservoir Cap Screws 1.5 0.15 13 in·lb

Brake Lever Pivot Bolt 5.9 0.60 52 in·lb

Caliper Mounting Bolts (Front) 25 2.5 18

Brake Hose Banjo Bolts 34 3.5 25

Front Master Cylinder Clamp Bolts

Rear Master Cylinder Mounting Bolts 10 1.0 89 in·lb

Rear Master Cylinder Push Rod Locknut 17 1.7 13

Brake Reservoir Cap Bolts 1.5 0.15 13 in·lb

Brake Disc Mounting Bolts:

(Front)

(Rear)

Caliper Bleed Valves (Front, Rear) 7.8 0.80 69 in·lb

Caliper Holder Bolt (Rear) 27 2.8 20

Brake Pad Bolt 17 1.7 13

Rear Brake Pad Bolt Plug 2.5 0.25 22 in·lb

Brake Pedal Mounting Bolt 25 2.5 18 L, G

Suspension

Front Fork Clamp Bolts (Upper) 23 2.3 17 AL

Front Fork Clamp Bolts (Lower) 20 2.0 15 AL

Front Fork Top Plug 30 3.1 22

Adjuster Assembly 58 5.9 43 L

Base Valve Assembly 28 2.9 21

Locknut/Adjuster Assembly 29 3.1 21

Swingarm Pivot Shaft Nut 98 10 72

Rear Shock Absorber Mounting Nuts:

(Upper) 39 4.0 29

(Lower)

Air Bleed Bolt 6.4 0.65 57 in·lb

Tie-Rod Mounting Nut (Front, Rear) 83 8.5 61

Rocker Arm Pivot Nut 83 8.5 61

N·m kgf·m ft·lb

Not less
than 2.2

8.8 0.90 78 in·lb

10 1.0 89 in·lb L

23 2.3 17 L

34 3.5 25

Torque

Not less

than 0.22

Remarks

Not less

than 19 in·lb

S

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Steering

Steering Stem Head Nut

Steering Stem Nut

Handlebar Clamp Bolts

Frame

Rear Frame Mounting Bolts 34 3.5 25

Upper Footpeg Bracket Bolts 54 5.5 40 L

Electrical System

Gear Position Switch Screws

Flywheel Nut 78 8.0 58

Stator Bolts 4.0 0.41 35 in·lb L

Crankshaft Sensor Bolts 7.0 0.71 62 in·lb

Spark Plug 13 1.3 115 i n ·lb

C.D.I. Unit Bolts

Magneto Cover Bolts

Breather Fitting 15 1.5 11 L

Ignition Coil Bolts 7.0 0.71 62 in·lb

N·m kgf·m ft·lb

98 10 72

4.9 0.50 43 in·lb

25 2.5 18 2T

2.9 0.30 26 in·lb L

9.8 1.0 87 in·lb

9.8 1.0 87 in·lb

Torque

Remarks

Basic Torque for General Fasteners

Threads dia. Torque

(mm) N·m kgf·m ft·lb

5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb
6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb

8 14 ∼ 19 1.4 ∼ 1.9 10.0 ∼ 13.5
10 25 ∼ 34 2.6 ∼ 3.5 19.0 ∼ 25
12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45
14 73 ∼ 98 7.4 ∼ 10.0 54 ∼ 72
16 115 ∼ 155 11.5 ∼ 16.0 83 ∼ 115
18 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165
20 225 ∼ 325 23 ∼ 33 165 ∼ 240

PERIODIC MAINTENANCE 2-9

Specifications

Item Standard Service Limit

Fuel System

Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) –––
Hot Starter Lever Free Play 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) –––

Air Cleaner Element Oil High quality foam air filter oil

Cooling System

Coolant:

Type (recommended) Permanent type antifreeze

Color Green

Mixed Ratio Soft water 50% and coolant 50%

Freezing Point

Total Amount

Engine Top End

Valve Clearance:

Exhaust

Inlet 0.10 ∼ 0.15 mm (0.0039 ∼ 0.0059 in.) –––

Cylinder Head Warp ––– 0.05 mm (0.002 in.)

Cylinder Inside Diameter (see
text)

Piston/cylinder Clearance 0.020 ∼ 0.042 mm (0.00079 ∼ 0.0016 in.) –––

Engine Right Side

Clutch Lever Free Play 8 ∼ 13 mm (0.3 ∼ 0.5 in.) –––

Friction Plate Thickness

Friction Plate Warp

Steel Plate Warp Not more than 0.2 mm (0.008 in.) 0.3 mm (0.01 in.)

Engine Lubrication System

Engine oil:

Type

Viscosity

Capacity 1.2 L (1.3 US qt)

Crankshaft/Transmission

Connecting Rod Big End Side
Clearance

Wheels/Tires

Rim Runout:

Axial Under 1.0 mm (0.039 in.) 2 mm (0.08 in.)

Radial Under 1.0 mm (0.039 in.) 2 mm (0.08 in.)

Front and Rear Tires Air
Pressure

Standard Tire:

Front:

Size 90/100-21 57M –––

Make

Type D742F

–35 °C (–31 °F)

1.05 L (1.11 US qt)

0.17 ∼ 0.22 mm (0.0067 ∼ 0.0087 in.)

96.000 ∼ 96.012 mm (3.7795 ∼ 3.7800 in.) 96.10 mm (3.783 in.)

2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) 2.6 mm (0.10 in.)

Not more than 0.15 mm (0.0059 in.) 0.3 mm (0.01 in.)

Castrol “R4 superbike” 5W-40 or
API SG, SH, SJ or SL with JASO MA

SAE 10W-30, 10W-40, or 10W-50

0.25 ∼ 0.35 mm (0.0098 ∼ 0.014 in.) 0.6 mm (0.02 in.)

100 kPa (1.0 kgf/cm², 14 psi)

DUNLOP

–––

–––

–––

2-10 PERIODIC MAINTENANCE

Specifications

Item Standard Service Limit

Rear:

Size 120/80-19 63M –––

Make DUNLOP

Type D756, Tube

Final Drive

Drive Chain Slack 52 ∼ 58 mm (2.0 ∼ 2.3 in.) –––
Drive Chain 20 Link Length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.)

Rear Sprocket Warp Under 0.4 mm (0.016 in.) 0.5 mm (0.020 in.)

Brakes

Brake Lever Free Play (to suit rider) –––

Brake Fluid:

Type:

Front

Rear DOT4 –––

Brake pad lining thickness:

Front

Rear 6.4 mm (0.25 in.) 1 mm (0.04 in.)

Suspension

Fork Oil:

Oil Viscosity KHL15-10 (KAYABA 01) or equivalent –––

Oil Quantity: (Adjustable range)

Outer (Outer/Inner Tubes) 345 mL (11.7 US oz.)

Inner (Subtank) 170 mL (5.75 US oz.) –––

Electrical System

Spark Plug Gap 0.8 ∼ 0.9 mm (0.03 ∼ 0.04 in.) –––

DOT3 or DOT4

3.8 mm (0.15 in.) 1 mm (0.04 in.)

(11.0 ∼ 12.3 US oz.)

(EUR) 350 mL (11.8 US oz.) (EUR) 330 ∼ 370 mL

(11.2 ∼ 12.5 US oz.)

–––

325 ∼ 365 mL

TIR: Total Indicator Readings

EUR: Europe Model

Special Tools

PERIODIC MAINTENANCE 2-11

Steering Stem Nut Wrench:
57001-1100

Jack:
57001-1238

Spark Plug Wrench, Hex 16:
57001-1262

Pilot Screw Adjuster Adapter, 4:
57001-1371

Filler Cap Driver:
57001-1454

Pilot Screw Adjust, D:
57001-1588

Pilot Screw Adjuster, C:
57001-1292

TopPlugWrench,49mm:
57001-1653

2-12 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Fuel System

Fuel Hose and Conn ection Inspection

The fuel hoses are designed to be used throughout the

○

motorcycle’s life without any maintenance, however, if the
motorcycle is not properly handled, the inside the fuel line
can cause fuel to leak [A] or the hose to burst.
Check the fuel hose.

•

Replace the fuel hose if any fraying, cracks [B], bulges [C]
or ozonic cranks [D] are noticed.

Check that the hose [A] are securely connected and

•

clamps [B] are tightened correctly.
When installing, route the hose according to Cable, Wire,

•

and Hose Routing section in the Appendix chapter.
When installing the fuel hose, avoid sharp bending, kink-

•

ing, flattening or twisting, and route the fuel hose with a
minimum of bending so that the fuel flow will not be ob­structed.
Replace the hose if it has been sharply bent or kinked.

Throttle Grip Free Play Inspection

Check throttle grip free play [B] by lightly turning the throt-

•

tle grip [A] back and forth.
If the free play is improper, adjust the throttle cable.

Throttle G rip Free Play

Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

Check that the throttle grip moves smoothly from full open

•

to close, and the throttle closes quickly and completely in
all steering positions by the return spring.
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 increase, check the throttle cable free
play and the cable routing.

Throttle Grip Free Play Adjustment

Loosen the locknuts [A] [B] at the upper end of the throttle

•

cable.
Screw both throttle cable adjuster [C] [D] to give the throt-

•

tlegripplentyofplay.
Turn out the decelerator adjuster [C] until there is no play

•

when the throttle grip is completely closed.
Tighten the locknut [A].

•

Turn the accelerator cable adjuster [D] until 2 ∼ 3mm

•

(0.08 ∼ 0.12 in.) of throttle grip play is obtained.

Tighten the locknut [B].

•

WARNING

Operation with an improperly adjusted, incorrectly
routed, or damaged cable could result in an unsafe
riding condition.

Periodic Maintenance Procedures

Hot Starter Lever Free Play Inspection

Slide the clutch lever dust cover [A] back.

•

Check the hot starter lever play [B] when pulling the start

•

lever [C] lightly.

Hot Starter Lever Free Play

Standard: 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.)

If the free play is improper, adjust the hot starter cable.

Slide the adjuster cover [A] back.

•

Loosen the locknut [B] and turn the adjuster [C] to obtain

•

the proper lever free play.
Tighten the locknut securely.

•

Check that the hot starter lever moves smoothly from full

•

open to close, and the lever closes quickly and completely
in all steering positions by the return spring.
If the hot starter lever does not return properly, check the
hot starter cable routing, free play and cable damage.
Then lubricate the hot starter cable.

PERIODIC MAINTENANCE 2-13

Idle Speed Inspection

CAUTION

This motorcycle is designed for competition use
only. Therefore, the radiator does not incorporate
a coolant reserve tank or cooling fan. Prolonged
idling of the engine with no airflow through the
radiator can cause coolant loss and engine over­heating resulting in possible engine damage. Any
riding conditions that increase engine temperature
will further reduce idling time before coolant loss
occurs. These conditions include high ambient
temperature, sandy or muddy terrain, or other con­ditions causing high engine loads at low speeds.
Furthermore, warming the engine up excessively
before operation, or leaving idling with the hot
engine temperature after operation results in the
engine overheating, too.

Start the engine and warm it up thoroughly.

•

With the engine idling, turn the handlebar to both sides

•

[A].
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 Cable, Harness, Hose Rout­ing section in the Appendix chapter).

WARNING

Operation with an improperly adjusted, incorrectly
routed, or damaged cable could result in an unsafe
riding c

ondition.

2-14 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Check the idle speed, using the engine revolution tester

•

[A] for high accuracy.
If the idle speed is out of specified range, adjust it.

Idle Speed:

Standard: 1 800 ±50 r/min (rpm)

Idle Speed Adjustment

First, turn in the air screw using the pilot screw adjuster

•

[A], until it seats lightly, and back i t out the s pecified num­ber of turns. (see Specifications Section in the Fuel Sys­tem chapter)

Special Tools - Pilot Screw Adjuster, C: 57001-1292

(or Pilot Screw Adjuster, D: 57001-1588)
Pilot Screw Adjuster Adapter,

-1371

Start the engine and warm it up thoroughly.

•

Turn the idle adjusting screw [B] until the idle speed is

•

correct.

To increase idle speed [C]
To decrease idle speed [D]

Open and close the throttle a few times to make sure that

•

the idle speed is within the specified range. Readjust if
necessary.

4: 57001

Air Cleaner Element Cleaning and Inspectio n

NOTE

In dusty areas, the element should be cleaned more

○

frequently than recommended interval.
After riding through rain or on muddy roads, the element

○

should be cleaned immediately.
Since repeated cleaning opens the pores of the ele-

○

ment, replace it with a new one in accordance with the
Periodic Maintenance Chart. Also, if there is a break in
the element material or any other damage to the ele­ment, replace the element with a new one.

WARNING

Clean the element 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. Because of the danger of highly
flammable liquids, do not use gasoline or a low
flash-point solvent to clean the element.

Periodic Maintenance Procedures

Remove:

•

Seat (see Seat Removal in the Frame chapter)
Wing Bolt [A]
Air Cleaner Element [B]

Stuff a clean, lint-free towel into the carburetor so no dirt

•

is allowed to enter the carburetor.
Wipe out the inside of the air cleaner housing with a clean

•

damp towel.

CAUTION

Check inside of the inlet tract and carburetor for
dirt. If dirt is present, clean the intake tract and car­buretor thoroughly. You may also need to replace
the element and seal the housing and inlet tract.

Separate the element [A] from the frame [B].

•

PERIODIC MAINTENANCE 2-15

Clean the element [A] in a bath of a high-flash point sol-

•

vent using a soft bristle brush.

Squeeze it dry in a clean towel [A]. Do not wring the ele-

•

ment or blow it dry; the element can be damaged.
Check all the parts of the element for visible damage.

•

If any of the parts of the element are damaged, replace
them.

After cleaning, saturate the element with a high-quality

•

foam-air-filter oil, squeeze out the excess, then wrap it in
a clean towel and squeeze it as dry as possible.
Be careful not to tear the sponge filter.

○

Assemble the element.

•

Remove the towel from the carburetor.

•

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Apply grease to all connections and screw holes in the air

•

cleaner housing and intake tract.
Install the element onto its frame, and coat the element

•

lip and lip seat with a thick layer of all-purpose grease to
assure a complete seal.

Install the air cleaner element so that its tab faces [A]

•

upward and its projections [B] align with the holes [C] in
the housing.
Tighten the wing bolt [D]

•

Install the seat (see Seat Installation in the Frame chap-

•

ter).

Fuel 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.

Turn the fuel tap to the OFF position.

•

Remove the carburetor (see Carburetor Removal in the

•

Fuel System chapter).
Place a suitable container beneath the carburetor.

•

Remove the drain plug [A] from the bottom of the float

•

bowl and check for water or dirt in the fuel.
If any water or dirt comes out, clean the carburetor, fuel
filter, fuel tap and fuel tank.
Install the drain plug on the float bowl, and tighten it se-

•

curely.
Install the carburetor (see Carburetor Installation in the

•

Fuel System chapter).

Periodic Maintenance Procedures

Fuel Tank, Filter and Tap Cleaning

WARNING

Clean the fuel tank in a well-ventilated area, and
take care that there is no sparks or flame anywhere
near the working area. Because of the danger of
highly flammable liquids, do not use gasoline or low
flash-point solvent to clean the tank.

Remove the fuel tank and drain it (see Fuel Tank Removal

•

in the Fuel System chapter).
Pour some high-flash point solvent into the fuel tank and

•

shake the tank to remove dirt and fuel deposits.
Pour the solvent out of the tank.

•

Remove the fuel filter from the tank by taking out the bolts.

•

Clean the fuel filter screen in a high-flash point solvent.

•

After cleaning, install the fuel filter.
Pour high-flash point solvent through the tap in all lever

•

positions.
Dry the tank, filter and tap with compressed air.

•

Install the filter in the fuel tank.

•

Install the tap and fuel tank.

•

PERIODIC MAINTENANCE 2-17

Fuel Tap and Filter Inspection

Remove the fuel filter from the fuel tank.

•

Check the fuel filter screen [A] for any breaks or deterio-

•

ration.
If the fuel filter screen have any breaks or is deteriorated,
it may allow dirt to reach the carburetor, causing poor run­ning. Replace the fuel filter.
Remove the fuel tap.

•

Check the fuel tap for fuel leaks.

•

If the fuel tap leaks, or allows fuel to flow when it is at OFF

•

position, replace the fuel tap.

Cooling System

WARNING

To avoid burns, do not remove the radiator cap or
try to change the coolant when the engine is still
hot. Wait until it cools down.
Coolant on tires will make them slippery and can
cause an accident and injury. Immediately wash
away any coolant that spills on the wheels.
Since coolant is harmful to the human body, do not
use for drinking.

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Coolant Level Inspection

NOTE

Check the level when the engine is cold (room or ambi-

○

ent temperature).

Lean the motorcycle slightly to the left until the radiator

•

cap is level to the ground so that the radiator cap is located
uppermost in order to exhaust the air accumulated in the
radiator.
Remove the radiator cap [A].

•

NOTE

Remove the radiator cap in two steps. First turn the

○

cap counterclockwise to the first stop and wait there for
a few seconds. Then push down and turn it further in
the same direction and remove the cap.

Check the coolant level. The coolant level [A] should be

•

at the bottom of the filler neck [B].
If the coolant level is low, add coolant through the filler
opening to the bottom of the filler neck. Install the cap.

Recommended coolant:

Permanent type of antifreeze (soft water and ethylene
glycol plus corrosion and rust inhibitor chemicals for
aluminum engines and radiators)

Water and coolant mixture ratio:

1 : 1 (water 50%, Coolant 50%)

Total amount:

1.05 L (1.11 US qt.)

Coolant Deterioration Inspection

Visually inspect the coolant.

•

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 m ay be caused by exhaust gas
leaking into the cooling system.

Periodic Maintenance Procedures

Radiator Hoses and Connections Inspection

The high pressure inside the radiator hose [A] can cause

○

coolant to leak [B] 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 [C] or bulges [D]
are noticed.
Check that the hoses are securely connected and clamps

•

are tightened correctly.

Torque - Radiator Hose Clamp Screws: 1.5 N·m (0.15 kgf·m,

13 in·lb)

PERIODIC MAINTENANCE 2-19

Engine To p End

Valve Clearance Inspection

NOTE

Valve clearance must be checked and adjusted when

○

the engine is cold (at room temperature).

Remove:

•

Cylinder Head Cover (see Cylinder Head Cover Re­moval in the Engine Top End chapter)
Balancer Shaft Cap [A]
Timing Inspection Cap [B]

Special Tool - Filler Cap Driver: 57001-1454

First, bring the piston to the top-dead-center of its com-

•

pression stroke to inspect the valve clearance (the posi­tion at the end of the compression stroke), when the cam
lobe faces outside of the camshaft.
Place a wrench over the balancer weight nut and turn

○

it counterclockwise to align the TDC mark [A] with the
center of the groove [B] of the inspection hole.

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Using a thickness gauge [A], measure the clearance be-

•

tween each cam lob and valve lifter for all four valves.
For the purpose of adjusting the valve clearances, record

○

the measured values.

Valve clearance: between cam and valve lifter

Standard:

Exhaust

Inlet

If the valve clearance is not within the specified range,
adjust it.

Valve Clearance Adjustment

Remove the camshaft caps [A] (see Camshaft Removal

•

in the Engine Top End chapter).
Remove the camshafts [B] (see Camshaft Removal in the

•

Engine Top End chapter).
Remove the valve lifters [C] of the applicable valve.

•

Remove the shim [D] from the top of the spring retainer.

•

0.17 ∼ 0.22 mm (0.0067 ∼ 0.0087 in.)

0.10 ∼ 0.15 mm (0.0039 ∼ 0.0059 in.)

NOTE

Mark and record the locations of the valve lifters and

○

shims so that they can be reinstalled in their original
positions.

Clean the shim to remove any dust or oil.

•

Measure the thickness of the removed shim [A].

•

Select a new shim thickness calculation as follows.

•

A=(B–C)+D
[A] Replace Shim Thickness
[B] Measured Valve Clearance
[C] Specified Valve Clearance
[D] Present Shim Thickness

Example

(0.31 mm – 0.10 ∼ 0.15 mm) + 2.60 m m = 2.81 ∼ 2.76 mm

Exchange the shims for the 2.775 or 2.800 size shim.

○

CAUTION

Don’t use the shims for another models. This could
cause wear of the valve stem end, and valve stem
damage.

Periodic Maintenance Procedures

Adjustment shims

Thick-

ness

2.00 92025-1870 0 2.525 92025-1984 53

2.05 92025-1871

2.10 92025-1872 10 2.575 92025-1985 58

2.15 92025-1873 15 2.60 92025-1882 60

2.20 92025-1874 20 2.65 92025-1883 65

2.25 92025-1875 25 2.70 92025-1884 70

2.30 92025-1876 30 2.75 92025-1885

2.35 92025-1877 35 2.80 92025-1886 80

2.40 92025-1878 40 2.85 92025-1887 85

2.425 92025-1982 43 2.90 92025-1888 90

2.45 92025-1879 45 2.95 92025-1889 95

2.475 92025-1983 48 3.00 92025-1890 00

2.50 92025-1880 50

P/No. Mark

Thick-

ness

5

2.55 92025-1881

P/No. Mark

PERIODIC MAINTENANCE 2-21

55

75

CAUTION

Be sure to remeasure the clearance after selecting
a shim. The clearance can be out of the specified
range because of the shim tolerance.

If there is no valve clearance, use a shim that is a few

○

sizes smaller, and remeasure the valve clearance.

When installing the shim, face the marked side [A] toward

•

the valve lifter [B]. At this time, apply engine oil to the
shim or the valve lifter to keep the shim in place during
camshaft installation.

CAUTION

Do not put shim stock under the shim. This may
cause the shim to pop out at high rpm, causing ex­tensive engine damage.
Do not grind the shim. This may cause it to fracture,
causing extensive engine damage.

Apply engine oil to the valve lifter surface and install the

•

lifter.
Install the camshaft (see Camshaft Installation in the En-

•

gine Top End chapter).
Recheck the valve clearance and readjust if necessary.

•

Install the cylinder head cover (see Engine Top End chap-

•

ter), timing inspection cap, and the balancer weight cap.

2-22 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Cylinder Head Warp Inspection

Remove the cylinder head (see Cylinder Head Removal

•

in the Engine Top End chapter).
Lay a straightedge [A] across the lower surface of the

•

head at several different points, and measure warp by
inserting a thickness gauge between the straightedge and
the head.
If warp exceeds the service limit, repair the mating sur­face. Replace the cylinder head if the mating surface is
badly damaged.

Cylinder Head Warp

Service Limit: 0.05 mm (0.002 in.)

Remove the valves (see Valve Removal in the Engine Top

•

End chapter).
Scrape the carbon out of the combustion chamber and

•

exhaust port with a scraper [A] or a suitable tool.
Clean the cylinder head, using high-flash point solvent.

•

Blow out any particles which may obstruct the oil passage

•

in the cylinder head using compressed air.
Install the valves (see Valve Installation in the Engine Top

•

End chapter).

Cylinder Wear Insp ection

NOTE

Measure the cylinder inside diameter when the cylinder

○

is cold (room or ambient temperature).

Visually Inspect the inside of the cylinder for scratches

•

and abnormal wear.
If the cylinder is damaged or badly worn, replace it with a
new one.
Since there is a difference in cylinder wear in different di-

•

rections, take a side-to-side and a front-to back measure­ment shown in the figure.
If any of the cylinder inside diameter measurements ex­ceeds the service limit, the cylinder must be replaced with
a new one since the PLATING cylinder cannot be bored
or honed.

[A]

10 mm (0.39 in.)

[B]

30 mm (1.2 in.)

[C] 50 mm (2.0 in.)

Cylinder Inside Diameter

Standard: 96.000 ∼ 96.012 mm (3.7795 ∼ 3.7800

in.), and less than 0.01 mm (0.0004
in.) difference between any two
measurements.

Service Limit: 96.10 mm (3.783 in.), or more than 0.05

mm (0.020 in.) difference between any
two measurements.

Periodic Maintenance Procedures

Piston/Cylinder Clearance

The piston-to-cylinder clearance is measured whenever a
piston or cylinder is replaced with a new one. The standard
piston-to-cylinder clearance must be adhered to whenever
the cylinder is replaced.

If only a piston is replaced, the clearance may exceed the
standard slightly. But it must not be less than the minimum,
in order to avoid piston seizure.

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: 0.020 ∼ 0.042 mm (0.00079 ∼ 0.0016 in.)

Piston, Piston Ring and Piston Pin Replacement

Refer to the Cylinder and Piston Section in Engine Top

•

End chapter.

PERIODIC MAINTENANCE 2-23

Exhaust System Inspection

The exhaust system, in particular the silencer, is designed

•

to reduce exhaust no

away from the rider while minimizing power loss. If car-

bon has built up inside the silencer, exhaust efficiency is

reduced, causing engine perf

If the silencer is badly damaged, dented, cracked or

rusted, replace it. Replace the silencer packing if the

exhaust noise becomes too loud or engine performance

drops.

Muffler Baffle Change

Remove the muffler (see Muffler Removal in the Engine

•

Top End chapter).

Remove the muffler pipe bolts [A].

•

Tap the bracket [A] of the muffler body with a plastic mallet

•

[B] to separate from the inner pipe.

ise and conduct the exhaust gases

ormance to drop.

2-24 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Pull off the old muffler baffle [A].

•

Install the new muffler baffle [A] into the muffler body [B].

•

NOTE

When replacing the muffler baffle, first insert the muffler

○

baffle into the muffler body, and align the exhaust hole
of the muffler end cover with the muffler baffle hole while
turning the muffler baffle. Then, install the inner pipe by
pushing the inner pipe into the muffler body with aligning
the inner pipe with the exhaust hole.

Install the end [A] of the inner pipe [B] to the baffle [C].

•

Apply a non-permanent locking agent to the pipe mount-

•

ing bolts.
Install the muffler body.

•

Apply silicone sealant to the circumference [A] of the inner

•

pipe.
Install the muffler (see Muffler Installation in the Engine

•

Top End chapter).

Engine Right Side

WARNING

To avoid a serious burn, never touch the hot engine
or exhaust chamber during clutch adjustment.

Periodic Maintenance Procedures

Clutch Lever Free Play Check

Slide the clutch lever dust covers [A] out of place.

•

Check that the clutch cable upper end is fully seated in

•

the adjusting bolt [B].

Check that the clutch lever [C] has 8 ∼ 13 mm (0.3 ∼ 0.5

•

in.) of play [D].

If it does not, adjust the lever play.

PERIODIC MAINTENANCE 2-25

Clutch Lever Free Play Adjustment

Slide the clutch lever dust cover out of place.

•

Turn the adjuster [A] so that the clutch lever will have 8 ∼

•

13 mm (0.3 ∼ 0.5 in.) of play.

NOTE

Be sure that the outer cable end at the clutch lever is

○

fully seated in the adjusting bolt at the clutch lever, or
it could slip into the place later, creating enough cable
play to prevent clutch disengagement.

If it cannot be done, loosen the locknut [A] at the middle

•

of the clutch cable, and turn the adjusting nut [B] so that

clutch lever has 8 ∼ 13 mm (0.3 ∼ 0.5 in.) of play.

After the adjustment is made, tighten the locknut, and

•

start the engine and check that the clutch does not slip

and that it release properly.

Friction and Steel Plates Inspection

Remove the clutch plates (see Clutch Removal in the En-

•

gine Right Side chapter).

Visually inspect the friction and steel plates to see if they

•

show any signs of seizure, or uneven wear.

If any plates show signs of damage, replace the friction

plates and steel plates as a set.

Measure the thickness [A] of the friction plates with vernier

•

calipers.

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: 2.6 mm (0.10 in.)

2-26 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Place each friction plate or steel plate on a surface plate,

•

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 service limit, replace it with
a new one.

Friction and Steel Plates Warp

Standard:

Friction Plate

Steel Plate Not more than 0.2 mm (0.008 in.)

Service Limit:

Friction Plate 0.3 mm (0.01 in.)

Steel Plate 0.3 mm (0.01 in.)

Engine Lubrication System

Engine Oil Change

Warm up the engine thoroughly so that the oil will pick up

•

any sediment and drain easily. Then stop the engine.

Not more than 0.15 mm (0.0059 in.)

Remove the engine oil drain plugs on the bottom of the

•

engine, and let the oil drain completely.

Drain Plug (for transmissionroom oil sump) [A]
Drain Plug (for crank oil sump) [B]

NOTE

Hold the motorcycle upright so that the oil may drain

○

completely.

Replace the gaskets at the drain plugs with a new one.

•

After the oil has completely drained out, install the drain

•

plugs with the gaskets, and tighten them.

Torque - Engine Oil Drain Bolts

Transmission Room Oil Sump: 7.0 N·m (0.71

kgf·m, 62 in·lb)

Crank Room Oil Su mp: 15 N·m (1.5 kgf ·m, 11 ft·lb)

Fill the engine with a good quality motor oil s pecified be-

•

low.

Recommended Engine

Typ e

Viscosity

Capacity 0.96 L (1.01 US qt.) (when filter is not

Castrol “R4 Superbike” 5W-40 or

APISG,SH,SJorSLwithJASOMA

SAE 10W-30, 10W-40, 10W-50

removed)

0.98 L (1.03 US qt.) (when filter is remove)

1.2 L (1.3 US qt.) (when engine is
completely dry)

NOTE

The oil viscosity may need to be changed to accommo-

○

date atmospheric conditions in your riding area.

Check the oil level (see Engine Oil Level Inspection in the

•

Engine Lubrication System chapter).

Periodic Maintenance Procedures

Oil Filter Change

Drain:

•

Engine Oil (see Engine Oil Change)

Remove:

•

Oil Filter Cover Bolts [A]
Oil Filter Cover [B]

Remove the Oil Filter [A].

•

PERIODIC MAINTENANCE 2-27

Install the spring [A] to the right engine cover.

•

Apply grease to the grommet [B].

•

Be sure to install the filter with the grommet facing outside

•

as shown.

CAUTION

Inside out installation stop oil flow, causing engine

seizure.

Replace the oil filter cover O-ring [A] with a new one.

•

Replace the oil filter with a new one.

•

Apply grease to the O-rings.

•

Install the oil filter cover.

•

Torque - Oil Filter Cover Bolt: 9.8 N·m (1.0 kgf ·m, 87 in·lb)

Pour in the specified type and amount of oil (see Engine

•

Oil Change).

Breather Hose Inspection

Be certain that the breather hose are routed without being

•

flattened or kinked and is connected correctly.

If it is not, correct it.

Inspect the breather hose [A] for damage or sings of de-

•

terioration.

This hose should not be hard and brittle, nor should be

○

soft swollen.

Replace it if any cracks or swelling is noticed.

2-28 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Crankshaft/Transmission

Crankshaft Inspection

Connecting Rod Big E nd Side Clearance

Remove the cylinder head (see Cylinder Head Removal

•

in the Engine Top End chapter).
Remove the cylinder (see Cylinder Removal in the Engine

•

Top End chapter).
Remove the piston (see Piston Removal in the Engine

•

Top End chapter).
Measure the connecting rod big end side clearance at

•

right side of big end using a thickness gauge [A].

Connecting Rod Big End Side Clearance

Standard: 0.25 ∼ 0.35 mm (0.0098 ∼ 0.014 in.)

Service Lim it: 0.6 m m (0.02 in.)

If the clearance exceeds the service limit, replace the
crankshaft assembly.
Make sure that the crankshaft rotates smoothly after as-

•

sembling the engine.

Wheel/Tires

Air Pressure Inspection/Adjustment

Using tire air pressure gauge [A], measure the tire pres-

•

sure when the tires are cold.
Adjust the tire air pressure to suit track conditions and
rider preference, but do not stray too far from the recom­mended pressure.

Track Condition

When the track is wet, muddy, sandy
or slipp ery, reduce the tire pressure
to increase the tire tread surface on
the ground.

When the track is pebbly or hard,
increasethetirepressuretoprevent
damage or punctures, through the
tires will skid more easily.

Tire Pressure

80kPa(0.8kgf/cm²,

11 psi)

↑

↓

100 kPa (1.0 kgf/cm²,

14 psi)

Periodic Maintenance Procedures

Tires Inspection

As the tire tread wears down, the tire becomes more sus­ceptible the puncture and failure.

Remove any imbedded stones or other foreign particles

•

from the tread.

Visually inspect the tire for cracks and cuts, replacing the

•

tire in case of bad damage. Swelling or high spots indi-

cate internal damage, requiring tire replacement.

WARNING

To ensure safe handling and stability, use only the

recommended standard tires for replacement, in-

flated to the standard pressure.

NOTE

Check and balance the wheel when a tire is replaced

○

with a new one.

Standard Tire

Front:

Size: 90/100-21 57M

Make:

Type: D742F, Tube

Rear:

Size: 120/80-19 63M

Make:

Type: D756, Tube

DUNLOP

DUNLOP

PERIODIC MAINTENANCE 2-29

Spoke Tightness Inspection

Check that all the spokes are tightened evenly.

•

If spoke tightness is uneven or loose, tighten the spoke

nipples evenly.

Torque - Spoke Nipples: 2.2 N·m (0.22 kgf·m, 19 in·lb)

Check the rim runout.

•

WARNING

If any spoke breaks, it should be replaced immedi-

ately. A missing spoke places an additional load on

the other spokes, which will eventually cause other

spokes to break.

2-30 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Rim Runout Inspection

Place the jack under the frame so that the front/rear wheel

•

off the ground.

Special Tool - Jack: 57001-1238

Inspect the rim for small cracks, dents, bending, or warp-

•

ing.
If there is any damage to the rim, it must be replaced.
Set a dial gauge against the side of the rim, and rotate

•

the rim to measure the axial runout [A]. The difference be­tween the highest and lowest dial readings is the amount
of runout.
Set a dial gauge against the outer circumference of the

•

rim, and rotate the rim to measure radial runout [B]. The
difference between the highest and lowest dial readings
is the amount of runout.
If rim runout exceeds the service limit, check the wheel
bearings first. Replace them if they are damaged. If the
problem is not due to the bearings, correct the rim warp
(runout). A certain amount of rim warp can be corrected
by recentering the rim. Loosen some spokes and tighten
others within the standard torque to change the position of
different parts of the rim. If the rim is badly bent, however,
it must be replaced.

Rim Runout (with tire installed)

Standard:

Axial

Radial

Service Limit:

Axial

Radial

Wheel Bearing Inspection

Raise the front/rear wheel off the ground.

•

Special Tool - Jack: 57001-1238

Spin the wheel lightly, and check for roughness, binding

•

or noise.
If roughness, binding, abnormal noise is found, replace
the hub bearing.

Turn the handlebar until the handlebar doesn’t move to

•

either side.
The wheel edge is moved to one direction gripping the

•

edge of the wheel by both hands and the play of the wheel
bearing is checked.
If the play i s found, replace the bearing.

under 1.0 mm (0.039 in.)

under 1.0 mm (0.039 in.)

2 mm (0.08 in.)

2 mm (0.08 in.)

Periodic Maintenance Procedures

Final Drive

Drive Chain S lack Inspection

Raise the rear wheel off the ground, rotate the rear wheel

•

to find the place where the chain is tightest (because it

wears unevenly).

Check the wheel alignment (see Wheel Alignment Inspec-

•

tion in the Final Drive chapter), and adjust it if necessary

(see Drive Chain Slack Adjustment).

NOTE

Clean the drive chain if it is dirty, and lubricate it if it

○

appears dry.

Rotate the rear wheel to find the position where the chain

•

is tightest.

Measure the space (chain slack) [A] between the chain

•

and the swingarm at the rear of the chain slipper as

shown.

If the drive chain slack exceeds the standard, adjust it.

Chain Slack

Standard: 52 ∼ 58 mm (2.0 ∼ 2.3 in.)

PERIODIC MAINTENANCE 2-31

Drive Chain Slack Adjustment

Loosen the left and right chain adjuster locknuts [A].

•

Remove the cotter pin [B] and loosen the axle nut [C].

•

If the chain is too tight, back out the left and right chain

adjusting bolts [D] evenly, and push the wheel forward

until the chain is too loose.

If the chain is too loose, turn both chain adjusting bolts

evenly until the drive chain has the correct amount of

slack. To keep the chain and wheel properly aligned, the

notch on the left chain adjuster should align with the same

swingarm mark [E] as the right chain adjuster notch [F].

Check the wheel alignment.

WARNING

Misalignment of the wheel result in abnormal wear

and may result in an unsafe riding condition.

Tighten both chain adjuster locknuts securely.

•

Tighten the axle nut.

•

Torque - Rear Axle Nut: 110 N·m (11.2 kg f·m, 81.1 ft·lb)

Rotate the wheel, measure the chain slack again at the

•

tightest position, and readjust if necessary.

Install a new cotter pin [A] through the axle nut and axle,

•

and spread its ends.

2-32 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

NOTE

When inserting the cotter pin, if the slots in the nut do

○

not align with the cotter pin hole in the axle shaft, tighten
the nut clockwise [A] up to next alignment.
It should be within 30 degree.

○

Loosen one and tighten again when the slot goes past

○

the nearest hole.

WARNING

If the axle nut is not securely tightened, or the cotter
pin is not installed, an u nsafe riding condition may
result.

Check the rear brake.

•

NOTE

In wet and muddy conditions, mud sticks to the chain

○

and sprockets resulting in an overly tight chain, and the
chain may break. To prevent this, adjust the chain to 58

∼

68 mm (2.28∼2.68 in.) of slack whenever necessary.

Drive Chain Wear Inspection

Rotate the rear wheel to inspect the drive chain for dam-

•

aged rollers, and loose pins and links.
If there is any irregularity, replace the drive chain.
Lubricate the drive c hain if it appears dry.

[A] Bushing

[B] Roller
[C] Pin
[D] Pin Link
[E] Roller Link

Stretch the chain taut by hanging a 98 N (10 kgf, 20 lb)

•

weight [A] on the chain.
Measure the length of 20 links [B] on the straight part [C] of

•

the chain from the pin center of the 1st pin to the pin center
of the 21st pin. S ince the chain may wear unevenly, take
measurements at several places.

Chain 20-link Length

Standard: 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)

Service Limit: 323 mm (12.7 in.)

If any measurements exceed the service limit, replace the
chain. Also, replace the front and rear sprockets when the
drive chain is replaced.

Periodic Maintenance Procedures

WARNING

If the drive chain wear exceeds the service limit, re­place the chain or an unsafe riding condition may
result. 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.

Standard Chain

Make:

Type: D.I.D 520DMA2

Link: 114 Links

Drive Chain Lubrication

The chain should be lubricated with a lubricant which will

○

both prevent the exterior from rusting and also absorb
shock and reduce friction in the interior of the chain.
If the chain is especially dirty, it should be washed in
diesel oil or kerosene, and afterward soaked in a heavy
oil. Shake the chain while it is in the oil so that oil will pen­etrate to the inside of each roller.
An effective, good quality lubricant specially formulated

•

for chains is best for regular chain lubrication.

DAIDO

PERIODIC MAINTENANCE 2-33

If a special lubricant is not available, a heavy oil such as

•

SAE90 is preferred to a lighter oil because it will stay on
the chain longer and provide better lubrication.
Apply oil to the sides of the rollers so that oil will penetrate

•

to the rollers and bushings.
Wipe off any excess oil.

•

Oil applied area [A]

Sprocket Wear Inspection

Visually inspect the front and rear sprocket teeth for wear

•

and damage.
If they are worn as illustrated or damaged, replace the
sprocket.

[A] Worn Tooth (Engine Sprocket)
[B] Worn Tooth (Rear Sprocket)
[C] Direction of Rotation

NOTE

If a sprocket requires replacement, the chain is proba-

○

bly worn also. When replacing a sprocket, inspect the
chain.

2-34 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Rear Sprocket Warp Inspection

Using the jack, raise the rear wheel off the ground.

•

Special Tool - Jack: 57001-1238

Set a dial gauge [A] against the rear sprocket [B] near the

•

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: Under 0.4 mm (0.016 in.)

Service Limit: 0.5 mm (0.02 in.)

Brakes

Brake Lever and Pedal Position Adjustme nt

WARNING

Always maintain proper brake adjustment. If ad­justment is improper, the brake could drag and
overheat. This could damage the brake assembly
and possibly lock the wheel resulting in loss of
control.

Adjust the front brake lever [A] to suit you.

•

Slide the brake lever dust cover [B] out of place.

•

Loosen the adjuster locknut [C] and turn the adjuster [D]

•

to either side.
After adjustment, tighten the locknut.

•

NOTE

Usually it is not necessary to adjust the pedal position,

○

but always adjust it when the master cylinder is disas­sembled or pedal position is incorrect.

Measure the length indicated in the figure.

•

Length [A]

Standard: 68.5 ±1 mm (3.09 ±0.04 in.)

If it is not specified length, the brake pedal may be de­formed or incorrectly installed.
If it is not within the specified length, adjust the push rod
in the master cylinder as follows.

Periodic Maintenance Procedures

Loosen the push rod locknut [A].

○

Replace the cotter pin with a new one.

○

Remove:

○

Cotter Pin [B]
Washer
Joint Pin [C]

Turn the bracket [D] to obtain the specified length.

○

Tighten the locknut.

○

Torque - Rear Master Cylinder Push Rod Locknut: 17 N·m

(1.7 kgf·m, 13 ft·lb)

Brake Fluid Le vel Inspection

Check the brake fluid level in the front or rear brake reser-

•

voir [A].

NOTE

Hold the reservoir horizontal when checking brake fluid

○

level.

The front or rear reservoir must be kept above the lower

•

level line [B].
If the fluid level in front or rear reservoir is lower than the

○

lower level line, fill the reservoir to the upper level line. In­side the reservoir is stopped end showing the upper level
line [C].

Torque - Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m, 13

in·lb)

PERIODIC MAINTENANCE 2-35

WARNING

Do not mix two brands of 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.
After changing the fluid, use only the same type and
brand of fluid thereafter.

2-36 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Brake Fluid Change

In accordance with the Periodic Maintenance Chart,
change the brake fluid. The brake fluid should also be
changed if it becomes contaminated with dirt or water.
Furthermore, the brake fluid should be changed to bleed
the air quickly and completely whenever the brake line
parts are removed.

WARNING

When working with the disc brake, observe the pre-

cautions listed below.

1. Never reuse old brake fluid.

2. Do not use fluid from a container that has been left
unsealed or that has been open for a long time.

3. 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.

4. Don’t leave the reservoir cap off for any length of
time to avoid moisture contamination of the fluid.

5. Don’t change the fluid in the rain or when a strong
wind is blowing.

6. 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.

7. When handing 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.

8. Brake fluid quickly ruins painted surfaces; any
spilled fluid should be completely wiped up imme­diately.

9. If any of the brake line fittings or the bleed valve is
opened at any time, the AIR MUST BE BLED FROM

THEBRAKELINE.

Recommended Disc Brake Fluid

Typ e :

Front

Rear

DOT3 or DOT4

DOT4

Periodic Maintenance Procedures

NOTE

The procedure to change the front brake fluid. Chang-

○

ing the rear brake fluid is the same as for the front brake.

Level the brake fluid reservoir.

•

Remove the screws [A], reservoir cap [B] and diaphragm

•

[C].

Remove the rubber cap [A] on the bleed valve [B].

•

PERIODIC MAINTENANCE 2-37

Attach a clear plastic hose [A] to the bleed valve on the

•

caliper, and run the other end of the hose into a container
[B].

Change the brake fluid as follows:

•

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]

Fill the reservoir with fresh specified brake fluid.

○

NOTE

The fluid level must be checked often during the chang-

○

ing 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.

2-38 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Remove the clear plastic hose.

•

Tighten the bleed valves, and install the rubber caps.

•

Torque - Caliper Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

Brake Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m,

13 in·lb)

After changing the fluid, check the brake for good braking

•

power, no brake drag, and no fluid leakage.
If necessary, bleed the air from the lines (see Bleeding
the Brake Line in the Brakes chapter).

WARNING

Do not mix two brands of 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.

Brake Pad Wear Inspection

Remove the brake pad (see Brake Pad Removal in

•

Brakes chapter).
Check the lining thickness and condition of the pads in

•

each caliper.
If either pad is damaged, replace both pads in the caliper
as a s et.
If the lining thickness [A] of either pad is less than the
service limit [B], replace both pads in the caliper as a set.

Lining Thickness

Standard:

Front

Rear

Service Limit:

Front

Rear

Brake Master Cylinder Cup and Dust Sea l Replacement

Remove the front master cylinder (see Front Master Cylin-

•

der Removal in the Brakes chapter).
Remove the reservoir cap and diaphragm, and pour the

•

brake fluid into a container.
Unscrew the locknut and pivot bolt, and remove the brake

•

lever.
Pull the dust cover [A] out of place, and remove the circlip

•

[B].

Special Tool - Inside Circlip Pliers: 57001-143

Remove the washer [C].

•

Pull out the piston [D], secondary cup [E], primary cup [F],

•

and return spring [G].

3.8 m m (0.15 in.)

6.4 m m (0.25 in.)

1 mm (0.04 in.)

1 mm (0.04 in.)

Periodic Maintenance Procedures

CAUTION

Do not remove the secondary cup from the piston
since removal will damage it.

Remove the rear master cylinder (see Rear Master Cylin-

•

der Removal in the Brakes chapter).

NOTE

Do not remove the push rod clevis for master cylinder

○

disassembly since removal requires brake pedal posi­tion adjustment.

Remove the reservoir cap and diaphragm, and pour the

•

brake fluid into a container.
Slide the dust cover [A] on the push rod [B] out of place,

•

and remove the circlip [C].

Special Tool - Inside Circlip Pliers: 57001-143

Pull out the push rod with the piston stop [D].

•

Take off the piston [E], secondary cup [F], primary cup [G],

•

and return spring [H].

PERIODIC MAINTENANCE 2-39

CAUTION

Do not remove the secondary cup from the piston
since removal will damage it.

Before assembly, clean all parts including the master

•

cylinder with brake fluid or alcohol.

CAUTION

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 of 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.

Apply brake fluid to the removed parts and to the inner

•

wall of the cylinder.
Take care not to scratch the piston or the inner wall of the

•

cylinder.
Apply silicone grease (ex. PBC grease).

•

Brake Lever Pivot Bolt
Brake Lever Pivot Contact
Push Rod Contact (Rear)
Dust Covers

Tighten:

•

Torque - Brake Lever Pivot Bolt: 5.9 N·m (0.60 kgf·m, 52

in·lb)

Brake Lever Pivot Bolt Locknut: 5.9 N·m (0.60

kgf·m, 52 in·lb)

2-40 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Caliper Piston Seal and Dust Seal Replacement

Loosen the brake pad pin [A] and banjo bolt [B], and

•

tighten them loosely.
Remove:

•

Front Caliper Mounting Bolts [C]
Banjo Bolt
Brake Hose [E]
Front Caliper [D] (see Front Caliper Removal in the
Brakes chapter)
Brake Pads (see Brake Pad Removal in the Brakes
chapter)

Separate the caliper holder [A] from the caliper [B] and

•

remove the anti-rattle spring.

Using compressed air, remove the pistons. One way to

•

remove the pistons is as follows.
Cover the caliper opening with a clean, heavy cloth [A].

○

Remove the pistons by lightly applying compressed air [B]

○

to the hose joint opening.

WARNING

To avoid serious injury, never place your fingers or
palm in front of the piston. If you apply compressed
air into the caliper, the piston may crush your hand
or fingers.

Pull out the piston [A] by hand.

○

Remove the dust seals [B] and fluid seals [C].

•

NOTE

If compressed air is not available, do as follows for both

○

calipers coincidentally, with the brake hose connected
to the caliper.
Prepare a container for brake fluid, and perform the

○

work above it.
Remove the spring and pads (see Brake Pad Removal

○

in the Brakes chapter).
Pump the brake lever until the pistons come out of the

○

cylinders, and then disassembly the caliper.

Periodic Maintenance Procedures

Remove the rear caliper (see Caliper Removal in the

•

Brakes chapter).
Remove the pads (see Brake Pad Removal in the Brakes

•

chapter).
Separate the caliper holder [B] from the caliper [A].

•

Using compressed air, remove the piston.

•

Cover the caliper opening with a clean, heavy cloth [A].

○

Remove the piston by lightly applying compressed air [B]

○

to where the brake line fits into the caliper.

WARNING

To avoid serious injury, never place your fingers or
palm inside the caliper opening. If you apply com­pressed air into the caliper, the piston may crush
your hand or finger.

PERIODIC MAINTENANCE 2-41

Pull out the piston [A] by hand.

•

Remove the dust seal [B] and fluid seal [C].

•

Clean the caliper parts except for the pads.

•

CAUTION

For cleaning of the parts, use only disc brake fluid,
isopropyl alcohol, or ethyl alcohol.

The bleed valve was removed, install the bleed valve and

•

rubber cap.

Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

Replace the fluid seal(s) [A] with new ones.

•

Apply brake fluid to the fluid seal(s), and install them into

○

the cylinders by hand.
Replace the dust seal(s) [B] with new ones.

•

Apply brake fluid to the dust seal(s), and install them into

○

the cylinder by hand.
Apply brake fluid to the outside of the pistons [C], and

•

push them into each cylinder by hand.

2-42 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Install the anti-rattle spring [A] in the caliper as shown.

•

Replace the shaft rubber friction boot [A] and dust boot

•

[B] if they are damaged.
Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to

•

the caliper holder shafts [C] and holder holes (PBC is a
special high temperature, water-resistance grease).

Install the pads (see Brake Pad Installation in the Brakes

•

chapter).
Install the caliper (see Caliper Installation in the Brakes

•

chapter).
Wipe up any spilled brake fluid on the caliper with wet

•

cloth.

Periodic Maintenance Procedures

Brake Hose and Connection Check

Inspect the brake hose 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 cracks [B] or bulges [C] are no­ticed.
Tighten any loose fittings.

Brake Hose Replacement

CAUTION

Brake fluid quickly ruins painted surfaces; any
spilled fluid should be completely washed away
immediately.

When removing the brake hose, take care not to spill the

•

brake fluid on the painted or plastic parts.
When removing the brake hose 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.

•

PERIODIC MAINTENANCE 2-43

Remove each banjo bolts [A] and washers [B].

•

Replace the washers with new ones.

•

For Front Brake

Remove:

•

Bolts [A]
Brake Hose Clamps [B]

2-44 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

For Rear Brake

Remove:

•

Master Cylinder [A]
Hose Clamps [B]
Caliper Cover [C]

When installing the hoses, avoid sharp bending, kinking,

•

flattening or twisting, and route the hoses according to
Cable, Wire, and Hose Routing section in the Appendix
chapter.
Tighten the banjo bolts on the hose fittings.

•

Torque - Brake Hose Banjo B olts: 34 N·m (3.5 kgf·m, 25

ft·lb)

Fill the brake line after installing the brake hose (see

•

Brake Fluid Changing).

Suspension

Front Fork Inspection

Holding the brake lever, pump the front fork back and forth

•

manually to check for smooth operation.
Visually inspect the front fork for oil leakage, scoring or

•

scratches on the outer surface of the inner tube [A].
If necessary, repair any damage.
Nick or rust damage can sometimes be repaired by using

•

a wet-stone to remove sharp edges or raised areas which
cause seal damage.
If the damage is not repairable, replace the inner tube.
Since damage to the inner tube damages the oil seal,
replace the oil seal whenever the inner tube is repaired
or replaced.
If the fork is not smooth, confirm the cause.

•

CAUTION

If the inner tube is badly bent or creased, replace
it. Excessive bending, followed by subsequent
straightening, can weaken the inner tube.

Front Fork Oil Change (each fork leg)

Loosen the front fork upper clamp bolts [A].

•

Periodic Maintenance Procedures

Loosen the fork top plug [A].

•

Special Tool - Top Plug Wrench, 49 mm: 57001-1653 [B]

Remove:

•

Front Wheel (see Front Wheel Removal in the
Wheels/Tires chapter)
Front Brake Caliper (see Caliper Removal in the Brakes
chapter)
Brake Hose Clamps (see Brake Hose Replacement)

Loosen the front fork lower clamp bolts [A].

•

Remove the front fork.

•

With a twisting motion, work the fork leg [B] down and out.

○

PERIODIC MAINTENANCE 2-45

NOTE

Set rebound and compression damping setting to the

○

softest settings before disassembling to prevent the
needle of adjusters from damaging. Record the setting
before turning the adjuster.

Thoroughly clean the fork before disassembly.

•

CAUTION

Be careful not scratch the inner tube and not to
damage the dust seal.
Avoid scratching or damaging the inner tube or the
dust seal. Use a mild detergent and sponge out dirt
with plenty of water.

Usingthetopplugwrench[A],removetheforktopplug

•

[B] (subtank) from the outer tube and slowly slide down
the outer tube [C].

Special Tool - Top Plug Wrench, 49 mm: 57001-1653

2-46 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Place a drain pan under the front fork and drain fork oil

•

[A].

NOTE

Pump the fork tube several times to discharge the fork

○

oil.

Raise the outer tube and temporarily install the fork top

•

plug [A] (subtank) to the outer tube [B] with the top plug
wrench [C].

Special Tool - Top Plug Wrench, 49 mm: 57001-1653

Hold the axle holder [A] with a vise.

•

Protect the axle holder with a rag when using a vise.

○

Loosen the adjuster assembly [B] completely.

•

WARNING

Clamping the axle holder too tight can damage it
which will affect riding stability.
Do not clamp the axle holder too tight.

Compress the outer tube by hands and install the top plug

•

wrench [A] between the axle holder bottom [B] and locknut
[C].

Special Tool - Top Plug Wrench, 49 mm: 57001-1653

WARNING

Be careful of reaction force in spring and fix surely
so that the special tool should not come off. Do not
place the finger etc. while servicing.

Hold the locknut [A] with a wrench [B] and remove the

•

adjuster assembly [C].

Periodic Maintenance Procedures

Remove the push rod [A].

•

With the outer tube compressed by hands, remove the

•

topplugwrench[A].

CAUTION

Removing the locknut and pushing the piston rod
thread into the cylinder unit will damage the oil seal.
Do not remove the locknut from the piston rod.

Remove the fork leg from the v ise.

•

PERIODIC MAINTENANCE 2-47

Loosen the fork top plug (subtank) [A] with the top plug

•

wrench [B].

Special Tool - Top Plug Wrench, 49 mm: 57001-1653 [B]

Remove:

•

Cylinder Unit [A]
Spring Seat [B]
Spacer [C]
Washer [D]
Fork Spring [E]

CAUTION

Disassembling the cylinder unit can lead to trouble.
Do not disassemble the cylinder unit.

Holding the top plug wrench [A] with a vise, loosen the

•

base valve assembly [B] on the subtank [C].

Special Tool - Top Plug Wrench, 49 mm: 57001-1653

2-48 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Remove the base valve assembly [A] from the subtank

•

[B].

NOTE

Slowly compress the piston rod until it stops so that the

○

base valve assembly can be removed easily.

CAUTION

Disassembling the base valve assembly can lead to
trouble.
Do not disassemble the base valve assembly.

Drain the fork oil [A] from the cylinder unit [B] by pumping

•

the piston rod several times.

Hold the front fork inverted position for more than 20 min-

•

utes to allow the fork oil t o fully drain.

Clean the threads [A] of subtank and base valve assem-

•

bly.

With the piston rod in fully compressed position, pour the

•

specified amount of fork oil [A].

Recommended Oil: KHL15-10 (KAYABA01) or
equivalent

Recommended Quantity: 170 ml (5.75 US oz.)

NOTE

Plug the two oil holes on the subtank [B] with fingers.

○

Periodic Maintenance Procedures

Pump [A] the piston rod [B] slowly several times to expel

•

air.

Replace the O-rings [A] on the base valve assembly with

•

new ones.
Apply specified fork oil to the O-rings [A] [B] and bushings

•

[C] on the base valve assembly.

PERIODIC MAINTENANCE 2-49

With the piston rod held immorable in fully compressed

•

position [A], gently install the base valve assembly [B] to
the subtank.
Screw in the base valve assembly in the subtank when

•

the piston rod extends.

NOTE

When it is hard to screw in the base valve assembly,

○

pull down the piston rod a little.

Holdingthetopplugwrench[A]withavise.

•

Special Tool - Top Plug Wrench, 49 mm: 57001-1653

Holding the subtank [B] with the top plug wrench, torque

•

the base valve assembly [C].

Torque - Base Valve Assembly: 28 N·m (2.9 kgf·m, 21 ft·lb)

2-50 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Protect the piston rod end [A] with a rag [B] to prevent fork

•

damage.
Discharge the extra oil off the cylinder unit by pumping [C]

•

the piston rod to full stroke.

CAUTION

Be careful not to bend or damage the piston rod
when the piston rod is stroked. Service carefully
because oil flies out from the oil hole of the cylinder
unit.

NOTE

Set the compression damper setting to the softest.

○

Check the piston rod sliding surface for damage.

○

Apply fork oil to the piston rod sliding surface.

○

Drain the extra oil from the subtank oil hole [A].

•

With the cylinder unit in horizontal position, move [A] the

•

piston rod [B] by hand to inspect it if operating smoothly.
If the piston rod is not extend, remove the base valve

○

assembly and perform the air bleeding (pour the specified
amount fork oil and discharge an excess of oil).

Make sure about 16 mm (0.63 in.) [A] of push rod thread

•

is exposed from the locknut [B].

Periodic Maintenance Procedures

Completely wipe of the fork oil from the spring [A], spacer

•

[B] and cylinder unit [C].
Insert above-mentioned parts into the fork.

•

Temporarily tighten the fork top plug [A] (subtank) using

•

the top plug wrench.

Special Tool - Top Plug Wrench, 49 mm: 57001-1653 [B]

PERIODIC MAINTENANCE 2-51

Clamp the axle holder with a vise.

•

Protect the axle holder with a rag when using a vise.

○

WARNING

Clamping the axle holder too tight can damage it
which will affect riding stability.
Do not clamp the axle holder too tight.

Compress the outer tube by hands and install the top plug

•

wrench [A] between the axle holder bottom and locknut.

Special Tool - Top Plug Wrench, 49 mm: 57001-1653

WARNING

Be careful of reaction force in spring and fix surely
so that special tool should not come off.
Do not place the fingers etc. while serving.

Insert the push rod [A] into the piston rod.

•

2-52 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Replace the O-ring and gasket on the adjuster assembly

•

with new ones and apply specified fork oil to the O-ring.
Slowly turn the adjuster assembly [A] clockwise until re-

•

sistance is felt and check the clearance between the lock­nut [B] and adjuster assembly to provide more than 1 mm
(0.04 in.) [C].

Turn the locknut [A] counterclockwise until it contacts with

•

the adjuster assembly [B].
With the locknut held immovable using a wrench, tighten

•

the adjuster assembly to the specified torque.

Torque - Locknut/Adjuster Assembly: 29 N·m (3.0 kgf·m, 22

ft·lb)

With the outer tube compressed by hands, remove the

•

top plug wrench.

Apply a non-permanent locking agent to the threads of a

•

adjuster assembly.
Torque the adjuster assembly [A].

•

Torque - Adjuster Assembly: 58 N·m (5.9 kgf·m, 43 ft·lb)

Loosen and remove the fork top plug (subtank) form the

•

outer tube and slowly slide down the outer tube.

Special Tool - Top Plug Wrench, 49 mm: 57001-1653

Pour [A] the specified amount of fork oil into the outer

•

tube.

Recommended Oil: KHL15-10 (KAYABA01) or

equivalent

Recommended Quantity: 345 mL (11.7 US oz.)

(EUR) 350 mL (11.8 US oz.)

Raise the outer tube and temporarily tighten the fork top

•

plug (subtank).

Special Tool - Top Plug Wrench, 49 mm: 57001-1653 [B]

After installing the front fork, torque the top plug [A].

•

Special Tool - Top Plug Wrench, 49 mm: 57001-1653

Periodic Maintenance Procedures

The torque of fork top plug is specified to 30 N·m (3.1

kgf·m, 22 ft·lb) however, when you use the top plug wrench

(special tool) [A], reduce the torque to 90% of the spec­ified value [27 N·m (2.8 kgf·m, 20 ft·lb)] due to the dis­tance [B] between the center of the square hole, where the
torque wrench is fitted, and that of the octagonal hole of the
wrench.

This torque value [27 N·m (2.8 kgf·m, 20 ft·lb)] is appli­cable when you use a torque wrench whose length gives
leverage of approximately 310 mm between the grip point
to the center of the coupling square.

Rear Shock Absorber Inspection

Bounce [A] the rear of the motorcycle up and down and

•

check for smooth suspension stroke.

Remove the rear frame (see Rear Frame Removal in the

•

Frame chapter).

Check for a broken or collapsed spring.

•

Check the shock for a bent shaft or oil leaks.

•

If the shock does not smoothly or damaged, replace or

repair defective parts.

PERIODIC MAINTENANCE 2-53

Rear Shock Absorber Oil Change

The oil should be changed in the rear shock absorber at
least once per racing season. The frequency for best per­formance must be based upon riding conditions and rider
ability.

Remove the rear shock absorber from the frame (see

•

Rear Shock Absorber Removal in the Suspension chap-

ter).

Remove the shock absorber spring (see Spring Replace-

•

ment in the Suspension chapter).

Point the valve [A] away from you. slowly release nitrogen

•

gas pressure by pushing down the valve core with a screw

driver.

WARNING

Do not to point the reservoir valve toward your face

or body when releasing nitrogen gas pressure. An

oil mist is often released with the nitrogen. Always

release nitrogen gas pressure before disassem-

bling the rear shock absorber to prevent explosive

separation of parts.

2-54 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Adjust the gas reservoir damping adjusters [A] to the soft-

•

est position.
Remove the air bleed bolt [B] and pump the rear shock to

•

drain the oil out the rear shock body.
Install the air bleed bolt.

•

Using the suitable tool [A] and press, push the reservoir

•

cap[B]in10mm(0.39in.).
Remove the circlip [C] from the gas reservoir.

•

Pull the gas reservoir cap [B] out of the gas reservoir using

•

the pliers [A].

Pry or tap [A] at the gaps [B] in the stop [C] with suitable

•

tools to free the stop from the rear shock body [D].

Slide the stop up the top of the piston rod then lightly tap

•

around the seal with a suitable rod and mallet, and push
the seal assembly 10 mm (0.39 in.) down.
Remove the circlip [A].

•

Lightly move the piston rod back and forth, and pull out

•

the piston rod assembly.
Pour the oil out of the rear shock body.

•

Periodic Maintenance Procedures

Visually inspect the piston [A], O-ring [B], and oil seal assy

•

[C].

If the piston, O-ring and oil seal assy are badly scored,

•

rusty or damaged, replace them.

Using the grinder, shave off the stopper portion [A] of the

•

rod.

Remove:

•

Nut [B]
Washer [C]
Piston [D]

Install the new piston and tighten the locknut.

•

Discard a washer or two.

○

PERIODIC MAINTENANCE 2-55

Pour KYB K2-C (SAE 5W or Bel-Ray SE2 #40) oil into the

•

gas reservoir to 60 ∼ 70 mm (2.63 ∼ 2.76 in.) [A] from the

gas reservoir upper end.

Check that the bladder [A] on the gas reservoir cap is not

•

partially collapsed.

If it is, push down the valve core with a screwdriver.

Check the bladder for sign of damage or crack.

•

If necessary, replace it with a new one.

CAUTION

Do not use a damaged or partially collapsed blad-

der, because it may burst, gently reducing rear

shock performance. .

Apply grease to the lip [B] of the bladder and install the

•

reservoir cap [C].

Push the bladder into the gas reservoir slowly until it just

•

clears the circlip groove. Wipe out any spilled oil.

CAUTION

Ensure that no air remains in the system.

2-56 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Check the circlip for weakening, deformity and flaws.

•

If necessary, replace it with a new one.

CAUTION

If weakened, deformed or flawed circlip is used, the
gas reservoir cap may not hold when injecting the
nitrogen gas. This would allow oil and internal parts
to explode out of the reservoir.

Mount the circlip [A] in the groove in the gas reservoir.

•

Pull up the gas reservoir cap [A] against the circlip. The

•

end of the gas reservoir cap must align [B] with the end
of the gas reservoir [C].

WARNING

If the end of the gas reservoir cap and the end of
the gas reservoir are not aligned, the circlip is not
correctly fitting in the groove in the gas reservoir or
is deformed. In this case, the oil and internal parts
could explode out of the reservoir when injecting
the nitrogen gas or while riding the motorcycle.

Pour KYB K2-C (SAE 5W or Bel-Ray SE2 #40) oil into the

•

rear shock body to 55 mm (1.77 in.) [A] from the lower end
of the rear shock body [B].

Periodic Maintenance Procedures

Insert the piston end [A] of the piston rod assembly into

•

the rear shock body [C] slowly. Do not insert the seal

assembly [B] yet. Pump the piston rod until all the air is

forced out of the rear shock body.

Push the seal assembly into the rear shock body until it

•

just clears the circlip groove.

Check the circlip.

•

If it is deformed or damaged, replace it with a new one.

Fit the circlip [A] into the groove in the rear shock body

•

[B].

CAUTION

If the circlip is not a certain fit in the groove in the

rear shock body, the piston rod assembly may come

out of the shock absorber when injecting the nitro-

gen gas or riding the motorcycle.

PERIODIC MAINTENANCE 2-57

Pull up the piston rod assembly [C] against the circlip.

•

Force the stop [D] into the rear shock body by lightly tap-

•

ping around the edge of the stop with a mallet.

Fully extend the piston rod assembly.

•

Install the suitable oil cup [A] to the air bleed bolt hole,

•

and fill the specified oil into the cup.

Purge the air from between the gas reservoir [B] and rear

•

shock body [C] by slowly pumping the piston rod [D] in

and out.

Install the air bleed bolt securely.

•

Torque - Air Bleed Bolt: 6.4 N·m (0.65 kgf·m, 57 in·lb)

Fully extend the push rod assembly.

•

Inject nitrogen gas to a pressure of 50 kPa (0.5 kgf/cm²,

•

7 psi) through the valve on the gas reservoir.

Check the rear shock body and gas reservoir for oil and

•

gas leaks.

If there are no leaks, inject the nitrogen gas up to the 980

kPa (10 kgf/cm², 142 psi) pressure.

WARNING

Pressurize the gas reservoir with nitrogen gas only.

Do not use air

premature wear, rust, fire hazard or substandard

performance.

igh pressure gas is dangerous. Have a qualified

H

mechanic perform this procedure.

Install the spring and spring guide.

•

Adjust spring preload. Reinstall the rear shock absorber.

•

Install the parts removed.

•

or other gases, since they may cause

2-58 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Swingarm and Uni-Trak Linkage Insp ection

Check the uni-trak component parts for wear periodically,

•

or whenever excessive play is suspected.
Using the jack under the frame, raise the rear wheel off

•

the ground.

Special Tool - Jack: 57001-1238

Push and pull on the swingarm [A], up and down, to check

•

for wear.
A small amount of play on the swingarm is normal and no
corrective action is needed. However, if excessive play is
felt, remove the uni-trak parts from the frame and check
for wear.

Swingarm and Uni-Track Linkage Pivot Lubricate

Refer to the Swingarm Bearing Installation and Rocker

•

Arm Bearing Installation in Suspension chapter.

Steering

Steering Inspection

Using the jack, raise the front wheel off the ground.

•

Special Tool - Jack: 57001-1238

With the front wheel pointing straight ahead, alternately

•

nudge 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 steering binds or catches before the stop, check the
routing of the cables, hoses, and harnesses.
If the steering feels tight, adjust or lubricate the steering.

Feel for steering looseness by pushing and pulling the

•

forks.
If you feel looseness, adjust the steering.

Steering Adjustment

Using the jack, raise the front wheel off the ground.

•

Special Tool - Jack: 57001-1238

Periodic Maintenance Procedures

Slide the holder belt [A] out off.

•

Remove number plate bolt [B] and number plate [C].

•

Remove the handlebar pad [D].

•

Remove:

•

Handlebar Clamp Bolts [A]
Handlebar Clamps [B]
Handlebar [C]

PERIODIC MAINTENANCE 2-59

Loosen the front fork upper clamp bolts [A], and remove

•

the steering stem head nut [B] and steering stem head

[C].

Turn the steering stem nut [A] with the steering stem nut

•

wrench [B] to obtain the proper adjustment.

If the steering is too tight, loosen the stem nut a fraction of

a turn; if the steering is too loose, tighten the nut a fraction

of a turn.

Special Tool - Steering Stem Nut Wrench: 57001-1100

NOTE

Turn the stem nut 1/8 turn at a time maximum.

○

Install the steering stem head.

•

Tighten the following:

•

Torque - Steering Stem Head Nut: 98 N·m (10 kgf·m, 72

ft·lb)

Upper Front Fork Clamp Bolts: 23 N·m (2.3 kgf·m,

17 ft·lb)

NOTE

Tighten the two clamp bolts alternately two times to en-

○

sure even tightening torque.

Check the steering again.

•

If the steering is too tight or too loose, repeat the adjust-

ment as mentioned above.

2-60 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Install the handlebar [B] on the handlebar holder so that

•

the protruded scales of the both side adjust to the same
width [A].
Apply 2-stroke oil to the threads of the handlebar clamp

•

bolts.
Install the handlebar clamp so that center [D] of the han-

•

dlebar clamp [C] and handlebar bridge [E] align.

Torque - Handlebar Clamp Bolts: 25 N·m (2.5 kgf·m, 18

ft·lb)

Front [F]

After tighten, make sure space [A] [B] of the ahead and

•

back are same width.
Install the handlebar pad and number plate.

•

Stem Bearing Lubrication

Remove the steering stem (see Steering Stem, Stem

•

Bearing Removal in the Steering chapter).
Using a high-flash point solvent, wash the upper and

•

lower tapered rollers 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 rollers.

•

Replace the bearing assemblies if they show wear or
damage.
Pack the upper and lower tapered roller bearings [A] in

•

the cages with grease, and apply a light coat of grease to
the upper and lower outer races.
Install the steering stem, and adjust the steering (see

•

Steering Adjustment).

Frame

Frame Inspection

Clean the frame with steam cleaner.

•

Visually inspect the frame and rear frame for cracks,

•

dents, bending, or warp.
If there is any damage to the frame, replace it.

WARNING

A repaired frame may fail in use, possibly causing
an accident. If the frame is bent, dented, cracked,
or warped, replace it.

Periodic Maintenance Procedures

Electrical System

Spark Plug Cleanin g and Inspection

Remove:

•

Seat (see Seat Removal in the Frame chapter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
Spark Plug Cap

Clean the plug hole [A], using the compressed air [B].

•

Remove the spark plug [A], using the spark plug wrench

•

[B].

Special Tool - Spark Plug Wrench: 57001-1262

Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-0005

Clean the spark plug, preferably in a sandblasting device,

•

and then clean off any abrasive particles. The plug may

also be cleaned using a high-flash point solvent and a wire

brush or other suitable tool.

If the spark plug electrodes are corroded or damaged,

or if the insulator is cracked, replace the plug. Use the

standard spark plug.

PERIODIC MAINTENANCE 2-61

Measure the gap [A] with a wire-type thickness gauge.

•

If the gap is incorrect, carefully bend the side electrode

[B] with a suitable tool to obtain the correct gap.

Spark Plug Gap

Standard: 0.8 ∼ 0.9 mm (0.03 ∼ 0.04 in.)

Install the spark plug.

•

Torque - Spark Plug: 13 N·m (1.3 kgf·m, 115 in·lb)

Fit the plug cap securely.

•

Pull the spark plug cap [A] to make sure the installation of

○

the spark plug cap.

Cable Inspection

Lubrication

Before lubricating each part, clean off any rusty spots with

•

rust remover and wipe off any grease, oil, dirt, or grime.

Lubricate the points listed below with indicated lubricant.

•

NOTE

Whenever the vehicle has been operated under

○

wet or rainy conditions, or especially after using a
high-pressure water spray, perform the general lubri­cation.

2-62 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Points: Lubricate with Grease.

Clutch Inner Cable Upper and Lower Ends [A]
Hot Start Inner Cable Upper End
Throttle Inner Cable Upper End

Cables: Lubricate with Rust Inhibitor.

Throttle Cables
Clutch Cable
Hot Starter Cable

With the cable disconnected at the both ends, the cable

•

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.

Nut, Bolt, and Fasten er Tightness Inspection

Tightness Inspection

Check the tightness of the bolts and nuts listed here in

•

accordance with the Periodic Maintenance Chart. Also,
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).

Periodic Maintenance Procedures

If there are loose fasteners, retorque them to the specified

torque following the specified tightening sequence. Refer

to the Torque and Locking Agent section of the General

Information chapter for torque specifications. For each

fastener, first loosen it by 1/2 turn, then tighten it.

If cotter pins are damaged, replace them with new ones.

Nut, Bolt and Fastener to be checked

Wheels:

Spoke Nipples

Front Axle Nut

Front Axle Clamp Bolt

Rear Axle Nut Cotter Pin

Rear Axle Nut
Final Drive:

Chain Adjuster Locknut

Rear Sprocket Nuts

Brakes:

Front Master Cylinder Clamp Bolts

Brake Lever Pivot Nut

Front Caliper Mounting Bolts

Brake Pedal Bolt

Rear Brake Joint Cotter Pin

Rear Master Cylinder Mounting Bolts

Rear Caliper Mounting Bolts
Suspension:

Front Fork Clamp Bolts

Front Fender Bolts

Rear Shock Absorber Mounting Bolts, Nuts

Swingarm Pivot Nut
Steering:

Steering Stem Head Bolt

Handlebar Clamp Bolts
Engine:

Throttle Cable Adjuster Locknuts

Engine Mounting Bolts, Nuts

Shift Pedal Bolt

Muffler Mounting Bolts

Exhaust Pipe Holder Nuts

Muffler Clamp Bolt

Clutch Cable Adjuster Locknut

Clutch Lever Pivot Nut
Others:

Footpeg Cotter Pins

Rear Frame Bolts

PERIODIC MAINTENANCE 2-63

FUEL SYSTEM 3-1

Fuel System

Table of Contents

Exploded View........................................................................................................................ 3-2

Specifications ......................................................................................................................... 3-6

Special Tool ............................................................................................................................ 3-7

Throttle Grip and Cable .......................................................................................................... 3-8

Free Play Inspection ......................................................................................................... 3-8

Free Play Adjustment........................................................................................................ 3-8

Throttle Cable Replacement ............................................................................................. 3-8

Throttle Cable Lubrication................................................................................................. 3-9

Throttle Cable Inspection .................................................................................................. 3-9

Hot Starter Cable Removal ............................................................................................... 3-10

Hot Starter Cable Installation ............................................................................................ 3-10

Hot Starter Lever Free Play Inspection............................................................................. 3-10

Hot Starter Lever Free Play Adjustment ........................................................................... 3-11

Hot Starter Cable Lubrication............................................................................................ 3-11

Hot Starter Cable Inspection............................................................................................. 3-11

Carburetor .............................................................................................................................. 3-12

Idle Speed Inspection ....................................................................................................... 3-12

Idle Speed Adjustment...................................................................................................... 3-12

Service Fuel Level Inspection ........................................................................................... 3-12

Service Fuel Level Adjustment ......................................................................................... 3-13

Carburetor Removal.......................................................................................................... 3-14

Carburetor Installation....................................................................................................... 3-16

Fuel Inspection ..................................................................................................................3-17

Carburetor Disassembly ................................................................................................... 3-17

Carburetor Cleaning.......................................................................................................... 3-21

Carburetor Inspection ....................................................................................................... 3-21

Carburetor Assembly ........................................................................................................ 3-23

Air Cleaner.............................................................................................................................. 3-28

Air Cleaner Housing Removal........................................................................................... 3-28

Air Cleaner Housing Installation........................................................................................ 3-28

Element Removal.............................................................................................................. 3-28

Element Installation ........................................................................................................... 3-29

Element Cleaning and Inspection ..................................................................................... 3-29

Fuel Tank................................................................................................................................ 3-30

Fuel Tank Removal ........................................................................................................... 3-30

Fuel Tank Installation ........................................................................................................ 3-30

Fuel Filter Removal........................................................................................................... 3-30

Fuel Filter Installation........................................................................................................ 3-30

Fuel Tank, Filter and Tap Cleaning ................................................................................... 3-31

Fuel Tap and Filter Inspection........................................................................................... 3-31

3

3-2 FUEL SYSTEM

Exploded View

Exploded View

FUEL SYSTEM 3-3

No. Fastener

1

Throttle Pulley Cover Bolt

2 Throttle Cable Mounting Bolts 6.9 0.70 61 in·lb

3. Hot Starter Cable

4. Throttle Cables

5. Throttle Grip

6. Carburetor Cap

7. Throttle Valve Plate

8. Throttle Valve

9. Jet Needle

10. Throttle Pulley Shaft

11. Choke Knob

12. Idle Adjusting Screw

13. Pilot Air Screw

14. Slow Jet

15. Main Jet

16. Needle Jet

17. Starter Jet

18. Float

19. Leak Jet

20. Throttle Sensor

21. Hot Start Plunger

22. Acceleration Pump Diaphragm

23. Slow Air Jet

EO: Apply engine oil.

G: Apply grease.

L: Apply a non-permanent locking agent.

2T: Apply 2-stroke oil.

N·m

3.4 0.35 30 in·lb

Torque

kgf·m ft·lb

Remarks

3-4 FUEL SYSTEM

Exploded View

Exploded View

FUEL SYSTEM 3-5

No. Fastener

1 Rear Frame Mounting Bolts 34 3.5 25

2 Air Cleaner Duct Clamp Screw 2.0 0.20 18 in·lb

3

Air Cleaner Duct Mounting Nuts

4

Air Cleaner Duct Mounting Screw

5 Air Cleaner Housing Bolts 9.8 1.0 87 in·lb

6. Fuel Tank Cap

7. Fuel Tank

8. Fuel Tap

9. Element

10. Frame

11. Holder

12. Air Cleaner Duct

13. Air Cleaner Housing

14. Rear Frame

AD: Apply adhesive cement.

G: Apply grease.
O: High-quality foam air filter oil.

N·m

3.0 0.31 27 in·lb

3.0 0.31 27 in·lb

Torque

kgf·m ft·lb

Remarks

3-6 FUEL SYSTEM

Specifications

Item Standard

Throttle Grip and Cable

Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
Hot Starter Lever Free Play 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.)

Carburetor

Make/Type KEIHIN FCR40

Starter Jet #72

Leak Jet #70

Main Jet #175

Throttle Valve Cutaway CA1.5

Jet Needle

Jet Needle Clip Pos

Slow Jet #42, (EUR) 40

Slow Air Jet #100

Pilot Air Screw (turns out) 2, (EUR) 1

Service Fuel Level 6.5 ±1 mm (0.256 ±0.039 in.)

(below the bottom edge of the carb. body)

Float Height 8 ±1 mm (0.315 ±0.039 in.)

Air Cleaner

Air Cleaner Element Oil High quality form air filter oil

ition

NCVR

4th groove from the

top

(EUR):Europe Model

Special Tool

Fuel Level Gauge, M18 × 1.0:
57001-122

FUEL SYSTEM 3-7

3-8 FUEL SYSTEM

Throttle Grip and Cable

If the throttle grip has excessive free play due to cable
stretch or misadjustment, there will be a delay in throttle re­sponse. Also, the throttle valve may not open fully at full
throttle. On the other hand, if the throttle grip has no play,
the throttle will be hard to control, and the idle speed will
be erratic. Check the throttle grip play periodically in accor­dance with the Periodic Maintenance Chart, and adjust the
play if necessary.

The throttle cable routing is shown in Cable, Wire, and
Hose Routing Section in the Appendix chapter.

Free Play Inspection

Refer to the Throttle Grip Free Play Inspection in the P e-

•

riodic Maintenance chapter.

Free Play Adjustment

Refer to the Throttle Grip Free Play Adjustment in the

•

Periodic Maintenance chapter.

Throttle Cable Replacement

Remove the front master cylinder [A] (see Front Master

•

Cylinder Removal in the Brakes chapter).

Slide out the dust c over [B] and cable housing dust cover

•

[C].

Unscrew the screws [A].

•

Separate the throttle cable housing [B].

•

Free the tips [A] from the grip [B].

•

Throttle Grip and Cable

Remove the rear frame assy (see Rear Frame Removal

•

in the Frame chapter).
Remove the carburetor.

•

Unscrew the bolt [A].

•

Remove the throttle pulley cover [B].

•

Loosen the mounting bolts [A].

•

Remove the cables [B] from the carburetor.

•

Free the tips [C] from the pulley.

•

Pull out the cables from the frame.

•

FUEL SYSTEM 3-9

Lubricate the cable.

•

Apply grease to the tips of the cables.

•

Install the throttle cable l ower end [A].

•

Install the mounting bolts [B] to the holder as shown.

•

Install the throttle pulley cover.

•

Torque - Throttle Cable Mounting Bolts: 6.9 N·m (0.70

kgf·m, 61 ft·lb)

Throttle Pulley Cover Bolt: 3.4 N·m (0.35 kgf·m, 30

in·lb)

Install the throttle cable in accordance with the Cable,

•

Wire, and Hose Routing section in the Appendix chapter.
After the installation, adjust each cable properly.

•

WARNING

Operation with an incorrectly routed or improperly
adjusted cable could result in an unsafe riding con­dition.

Throttle Cable Lubrication

Whenever the throttle cable is removed or in accordance

•

with the Periodic Maintenance Chart, lubricate the these
cables (see Lubrication in the Periodic Maintenance
chapter).
Apply a thin coating of grease to the cable upper or lower

○

ends.
Use a commercially available pressure cable lubricator to

○

lubricate these cables.

Throttle Cable Inspection

Refer to the Cable Inspection in the Periodic Maintenance

•

chapter.

3-10 FUEL SYSTEM

Throttle Grip and Cable

Hot Starter Cable Removal

Remove:

•

Dust Cover [A] (Slide out)
Locknut [B] (Loosen)

Turn in the adjuster [C] fully.

•

Remove the cable end [D] from the hot starter lever [E].

•

Remove:

•

Carburetor (see Carburetor Removal)

Unscrew the plunger cap bolt [A] and remove the cable

•

end.

Disassemble the cable end from the plunger [A].

•

Spring [B]
Plunger Cap Assy [C]

Remove:

•

Left Radiator Shroud
Clamps [A] (Open)
Hot Starter Cable [B]

Hot Starter Cable Installation

Install the hot starter cable in accordance with the Cable,

•

Wire and Hose Routing section in the appendix chapter.

After the installation, adjust the cable properly.

•

WARNING

Operation with an incorrectly routed or improperly

adjusted cable could result in an unsafe riding con-

dition.

Hot Starter Lever Free Play Inspection

Refer to the Hot Starter Lever Free Play Inspection in the

•

Periodic Maintenance chapter.

Throttle Grip and Cable

Hot Starter Lever Free Play Adjustment

Refer to the Hot Starter Lever Free Play Inspection in the

•

Periodic Maintenance chapter.

Hot Starter Cable Lubrication

Whenever the hot starter cable is removed or in accor-

•

dance with the Periodic Maintenance Chart, lubricate the
these cable (see Lubrication in the Periodic Maintenance
chapter).

Hot Starter Cable Inspection

Refer to the Cable Inspection in the Periodic Maintenance

•

chapter.

FUEL SYSTEM 3-11

3-12 FUEL SYSTEM

Carburetor

Since the carburetor regulates and mixes the fuel and air
going to the engine, there are two general types of carbure­tor trouble: too rich a mixture (too much fuel), and too lean
a m ixture (too little fuel). Such trouble can be caused by
dirt, wear, m aladjustment, or improper fuel level in the float
chamber. A dirty or damaged air cleaner can also alter the
fuel to air ratio.

Idle Speed Inspection

Refer to the Idle Speed Inspection in Periodic Mainte-

•

nance chapter.

Idle Speed Adjustment

Refer to the Idle Speed Adjustment in Periodic Mainte-

•

nance chapter.

Service Fuel Level Inspection

WARNING

Gasoline is extremely flammable and can be ex-

plosive 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.

Turn the fuel tap to the OFF position.

•

Remove the fuel tank.

•

Remove the carburetor, and hold it in true vertical position

•

on a stand. The fuel hose and carburetor cable do not

have to be removed to inspect the fuel level [A].

Put the fuel tank on a bench, and connect the fuel tap to

•

the carburetor using a suitable hose.

Remove the drain plug from the bottom of the float bowl,

•

and screw a fuel level gauge [B] into the plug hole.

Special Tools - Fuel Level Gauge: 57001-122

Hold the gauge vertically against the side of the carbure-

•

tor body so that the "zero" line [C] is several millimeters

higher than the bottom edge [D] of the carburetor body.

Turn the fuel tap to the ON position to feed fuel to the

•

carburetor.

Wait until the fuel level in the gauge settles.

•

Keeping the gauge vertical, slowly lower the gauge until

•

the "zero" line is even with the bottom edge of the carbu-

retor body.

NOTE

Do not lower the "zero" line below the bottom edge of

○

the carburetor body. If the gauge is lowered and then
raised again, the fuel level measure shows somewhat
higher than the actual fuel level. If the gauge is lowered
too far, dump the fuel out of it into a suitable container
and start the procedure over again.

Carburetor

Read the fuel level in the gauge and compare it to the

•

specification.

Service Fuel Level (below the bottom edge of the carb. body)

Standard: 6.5 ±1 mm (0.256 ±0.039 in.)

If the fuel level is incorrect, adjust it.
Turn the fuel tap to the OFF position and remove the fuel

•

level gauge.
Install the drain plug on the bottom of the float bowl.

•

Service Fuel Level Adjustment

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.

FUEL SYSTEM 3-13

Remove the carburetor, and drain the fuel into a suitable

•

container.
Remove the float bowl (see Carburetor Disassembly).

•

Drive out the pivot pin [A] and remove the float [B] with

•

valve needle [C].

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.

Float Height

Standard: 8 ±1 mm (0.315 ±0.039 in.)

3-14 FUEL SYSTEM

Carburetor

NOTE

Float height [A] is the distance from the float bowl mat-

○

ing surface [B] of the carburetor body (with the gasket
removed) to the top of the float [C]. Measure the height
with the carburetor upside down.
Do not push the needle rod [D] in during the float height

○

measurement.

Assemble the carburetor, and recheck the fuel level.

•

If the fuel level cannot be adjusted by this method, the

float or the float valve is damaged.

Carburetor Removal

WARNING

Gasoline is extremely flammable and can be ex-

plosive 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.

Turn the fuel tap lever [A] to the OFF position.

•

Slide off the clamp [B] and pull the fuel hose [C] off the

○

tap.

Remove the fuel tank (see Fuel Tank Removal).

•

Disconnect the throttle sensor connector [A].

•

Carburetor

Loosen the clamp screws [A] fully.

•

Remove:

•

Engine Mounting Bracket Bolts [B]
Engine Mounting Bracket [C]

Remove:

•

Seat (see Seat Removal in the Frame chapter)
Side Covers (see Side Cover Removal in the Frame
chapter)
Muffler (see Muffler Removal in the Engine Top End
chapter)
Rear Frame Bolts [A]

Pull out the rear frame [B] with the air cleaner housing and

•

remove the carburetor.

FUEL SYSTEM 3-15

Unscrew the hot start plunger cap bolt [A].

•

Remove the hot start plunger.

•

Unscrew the throttle pulley cover bolt [A].

•

Remove the throttle pulley cover [B].

•

3-16 FUEL SYSTEM

Carburetor

Loosen the mounting bolts [A].

•

Pull out the end of the throttle cables [B].

•

Free the tips [C].

•

Remove the carburetor to the right side of the frame.

•

Drain the fuel from the float bowl by removing the drain

•

plug. After draining, install the drain plug securely.

After removing the carburetor, push a clean, lint-free towel

•

into the carburetor holder and the air cleaner duct to keep

dirt or other foreign material from entering.

WARNING

If dirt or dust is allowed to pass through into the

carburetor, the throttle may become stuck, possibly

causing an accident.

CAUTION

If dirt gets through into the engine, excessive en-

gine wear and possibly engine damage will occur.

Carburetor Installation

Install:

•

Throttle Cables (see Throttle Cable Replacement)
Hot Start Plunger (see Hot Starter Cable Installation)

Tighten:

•

Torque - Throttle Pulley Cover Bolt: 3.4 N·m (0.35 kgf·m, 30

in·lb)

Throttle Cable Mounting Bolts: 6.9 N·m (0.70

kgf·m, 61 in·lb)

When installing the carburetor into the carburetor holder,

•

fit the projection [A] of the carburetor with the groove [B]

on the holder.

Fit the claw [A] of the clamp onto the groove [B] of the

○

inlet duct.

Tighten the c lamps s ecurely.

•

Torque - Air Cleaner Duct Clamp Screw : 2.0 N·m (0.20

kgf·m, 17 in·lb)

Route the air vent and overflow hoses properly (see Ca-

•

ble, Wire and Hose Routing Section in the Appendix chap-

ter).

CAUTION

Always keep the hoses free of obstruction, and

make sure they do not get pinched by the chain or

shock absorber.

Connect the throttle sensor connector.

•

After installing the carburetor, do the following.

•

Turn the fuel tap to the ON position, and check for fuel

○

leakage from the carburetor.

WARNING

Fuel spilled from the carburetor is hazardous.

Carburetor

Adjust the following items if necessary:

○

Throttle Cable (see Throttle G rip Free Play Adjustment
in the Periodic Maintenance c hapter)
Idle Speed (see Idle Speed Adjustment in the Periodic
Maintenance chapter)

Fuel Inspection

Refer to the Fuel Inspection in the Periodic Maintenance

•

chapter.

Carburetor Disassembly

Remove the carburetor.

•

Remove all vent hoses [A] and fuel hose [B].

•

FUEL SYSTEM 3-17

Unscrew the screw [A].

•

Pull out the fuel hose fitting [B].

•

Unscrew the carburetor cap bolts [A].

•

Remove the carburetor cap [B].

•

Unscrew the throttle valve link screw [A].

•

Pull out the throttle valve assembly [B].

•

3-18 FUEL SYSTEM

Carburetor

Disassemble the throttle valve assembly; jet needle

•

holder [A] (unscrew), spring [B], retainer [C], jet needle

with circlip [D], O-ring with throttle valve plate [E], and

throttle valve [F].

Remove the choke knob/starter plunger assembly [A]

•

from the carburetor.

Remove the throttle pulley shaft [A] with the spring [B],

•

steel washer [C], plastic washer [D], and throttle valve link

[E].

Turn the throttle pulley shaft [A] clockwise while holding

○

down the acceleration pump lever [B] and clear the idle

stop screw [C] to the stopper [D] of the pulley.

Turn in the pilot air screw [A] fully but not tightly and count

•

the number of turns.

Record this number as the manufacture-set number of

○

turns out.

Unscrew the pilot air screw.

•