Z750
Z750 ABS
Motorcycle
Service Manual
Quick Reference Guide
This quick reference guide will assist you in locating a desired topic or procedure.
•Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page.
•Refer to the sectional table of contents for the exact pages to locate the specific topic required.
General Information |
1 |
j |
|
|
|
Periodic Maintenance |
2 |
j |
|
|
|
Fuel System (DFI) |
3 |
j |
|
|
|
Cooling System |
4 |
j |
|
|
|
Engine Top End |
5 |
j |
|
|
|
Clutch |
6 |
j |
|
|
|
Engine Lubrication System |
7 |
j |
|
|
|
Engine Removal/Installation |
8 |
j |
|
|
|
Crankshaft/Transmission |
9 |
j |
|
|
|
Wheels/Tires |
10 |
j |
|
|
|
Final Drive |
11 |
j |
|
|
|
Brakes |
12 |
j |
|
|
|
Suspension |
13 |
j |
|
|
|
Steering |
14 |
j |
|
|
|
Frame |
15 |
j |
|
|
|
Electrical System |
16 |
j |
|
|
|
Appendix |
17 |
j |
Z750
Z750 ABS
Motorcycle
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/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.
© 2007 Kawasaki Heavy Industries, Ltd. |
First Edition (1) : Feb. 28, 2007 (K) |
LIST OF ABBREVIATIONS
A |
ampere(s) |
lb |
pound(s) |
ABDC |
after bottom dead center |
m |
meter(s) |
AC |
alternating current |
min |
minute(s) |
ATDC |
after top dead center |
N |
newton(s) |
BBDC |
before bottom dead center |
Pa |
pascal(s) |
BDC |
bottom dead center |
PS |
horsepower |
BTDC |
before top dead center |
psi |
pound(s) per square inch |
°C |
degree(s) Celsius |
r |
revolution |
DC |
direct current |
rpm |
revolution(s) per minute |
F |
farad(s) |
TDC |
top dead center |
°F |
degree(s) Fahrenheit |
TIR |
total indicator reading |
ft |
foot, feet |
V |
volt(s) |
g |
gram(s) |
W |
watt(s) |
h |
hour(s) |
Ω |
ohm(s) |
L |
liter(s) |
|
|
COUNTRY AND AREA CODES
AT |
Austria |
GB |
United Kingdom |
AU |
Australia |
MY |
Malaysia |
CH |
Switzerland |
WVTA |
Whole Vehicle Type Approval |
DE |
Germany |
|
|
Foreword
This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.
In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation.
For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty.
To get the longest life out of your vehicle.
•Follow the Periodic Maintenance Chart in the Service Manual.
•Be alert for problems and non-scheduled maintenance.
•Use proper tools and genuine Kawasaki Motorcycle 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 carefully. Don’t take shortcuts.
•Remember to keep complete records of maintenance and repair with dates and any new parts installed.
How to Use This Manual
In this manual, the product is divided into its major systems and these systems make up the manual’s chapters. The Quick Reference
Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents.
For example, if you want ignition coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Ignition Coil section.
Whenever you see 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 personal injury, or loss of life.
CAUTION
This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage 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 particular interest for more efficient and convenient operation.
•Indicatesdone. a procedural step or work to be ○Indicates a procedural sub-step or how to do the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows.
In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.
GENERAL INFORMATION 1-1
General Information |
|
Table of Contents |
|
|
1 |
Before Servicing ..................................................................................................................... |
1-2 |
Model Identification................................................................................................................. |
1-7 |
General Specifications............................................................................................................ |
1-9 |
Unit Conversion Table ............................................................................................................ |
1-12 |
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.
Especially note the following.
Battery Ground
Before completing any service on the motorcycle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the ground cable (–) first and then the positive (+). When completed with the service, first connect the positive (+) cable to the positive (+) terminal of the battery then the negative (–) cable to the negative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.
Solvent
Use a high-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.
GENERAL INFORMATION 1-3
Before Servicing
Arrangement and Cleaning of Removed Parts
Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.
Storage of Removed Parts
After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.
Inspection
Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit.
Replacement Parts
Replacement parts must be KAWASAKI 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.
1-4 GENERAL INFORMATION
Before Servicing
Tightening Sequence
Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench.
Force
Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non -permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary.
Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install the new gaskets and replace the used O-rings when re-assembling.
Liquid Gasket, Non-permanent Locking Agent
For applications that require Liquid Gasket or a Non-permanent Locking Agent, clean the surfaces so that no oil residue remains before applying liquid gasket or non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.
GENERAL INFORMATION 1-5
Before Servicing
Press
For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing.
Ball Bearing and Needle Bearing
Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.
Oil Seal, Grease Seal
Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed. Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing.
Apply specified grease to the lip of seal before installing the seal.
Circlips, Cotter Pins
Replace the circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation.
1-6 GENERAL INFORMATION
Before Servicing
Lubrication
It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified.
Direction of Engine Rotation
When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side).
Electrical Wires
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.
GENERAL INFORMATION 1-7
Model Identification
ZR750L7F (Europe) Left Side View
ZR750L7F (Europe) Right Side View
1-8 GENERAL INFORMATION
Model Identification
ZR750M7F Left Side View
ZR750M7F Right Side View
Frame Number |
|
Engine Number |
|
|
|
|
GENERAL INFORMATION 1-9 |
General Specifications |
|
|
|
|
|
Items |
ZR750L7F, ZR750M7F |
Dimensions |
|
Overall Length |
2 085 mm (82.09 in.) |
Overall Width |
805 mm (31.69 in.) |
Overall Height |
1 100 mm (43.31 in.) |
Wheelbase |
1 440 mm (56.69 in.) |
Road Clearance |
155 mm (6.10 in.) |
Seat Height |
815 mm (32.09 in.) |
Dry Mass: |
|
ZR750L7F |
203 kg (447.6 lb) |
ZR750M7F |
207 kg (456.4 lb) |
Curb Mass: |
|
Front: |
|
ZR750L7F |
113 kg (249.2 lb) |
ZR750M7F |
115 kg (253.6 lb) |
Rear: |
|
ZR750L7F |
113 kg (249.2 lb) |
ZR750M7F |
115 kg (253.6 lb) |
Fuel Tank Capacity |
18.5 L (4.9 US gal.) |
Performance |
|
Minimum Turning Radius |
3.0 m (9.8 ft) |
Engine |
|
Type |
4-stroke, DOHC, 4-cylinder |
Cooling System |
Liquid-cooled |
Bore and Stroke |
68.4 × 50.9 mm (2.69 × 2.00 in.) |
Displacement |
748 cm³ (45.64 cu in.) |
Compression Ratio |
11.3 : 1 |
Maximum Horsepower |
77.7 kW (106 PS) @10 500 r/min (rpm) |
|
(MY) 73.2 kW (100 PS) @9 000 r/min (rpm) |
Maximum Torque |
78.0 N·m (8.0 kgf·m, 57.5 ft·lb) @8 300 r/min (rpm) |
Carburetion System |
FI (Fuel Injection) KEIHIN TTK32 × 4 |
Starting System |
Electric starter |
Ignition System |
Battery and coil (transistorized) |
Timing Advance |
Electronically advanced (digital igniter) |
Ignition Timing |
From 10° BTDC @1 100 r/min (rpm) to 37.0° BTDC |
|
@5 000 r/min (rpm) |
Spark Plug |
NGK CR9EK |
Cylinder Numbering Method |
Left to right, 1-2-3-4 |
Firing Order |
1-2-4-3 |
Valve Timing: |
|
Inlet: |
|
Open |
38° BTDC |
Close |
66° ABDC |
Duration |
284° |
|
|
1-10 GENERAL INFORMATION
General Specifications
Items |
|
ZR750L7F, ZR750M7F |
Exhaust: |
|
|
Open |
51° BBDC |
|
Close |
25° ATDC |
|
Duration |
256° |
|
Lubrication System |
Forced lubrication (wet sump) |
|
Engine Oil: |
|
|
Type |
API SE, SF or SG |
|
|
API SH, SJ or SL with JASO MA |
|
Viscosity |
SAE 10W-40 |
|
Capacity |
3.8 L (4.0 US qt) |
|
Drive Train |
|
|
Primary Reduction System: |
|
|
Type |
Gear |
|
Reduction Ratio |
1.714 |
(84/49) |
Clutch Type |
Wet multi disc |
|
Transmission: |
|
|
Type |
6-speed, constant mesh, return shift |
|
Gear Ratios: |
|
|
1st |
2.571 |
(36/14) |
2nd |
1.941 |
(33/17) |
3rd |
1.556 |
(28/18) |
4th |
1.333 |
(28/21) |
5th |
1.200 |
(24/20) |
6th |
1.095 |
(23/21) |
Final Drive System: |
|
|
Type |
Chain drive |
|
Reduction Ratio |
2.867 |
(43/15) |
Overall Drive Ratio |
5.382 |
@Top gear |
Frame |
|
|
Type |
Tubular, diamond |
|
Caster (Rake Angle) |
24.5° |
|
Trail |
103 mm (4.06 in.) |
|
Front Tire: |
|
|
Type |
Tubeless |
|
Size |
120/70 ZR17 M/C (58W) |
|
Rim Size |
17 × 3.50 |
|
Rear Tire: |
|
|
Type |
Tubeless |
|
Size |
180/55 ZR17 M/C (73W) |
|
Rim Size |
17 × 5.50 |
|
Front Suspension: |
|
|
Type |
Telescopic fork |
|
Wheel Travel |
120 mm (4.72 in.) |
|
|
|
|
|
GENERAL INFORMATION 1-11 |
General Specifications |
|
|
|
|
|
Items |
ZR750L7F, ZR750M7F |
Rear Suspension: |
|
Type |
Swingarm (uni-trak) |
Wheel Travel |
125 mm (4.92 in.) |
Brake Type: |
|
Front |
Dual discs |
Rear |
Single disc |
Electrical Equipment |
|
Battery |
12 V 8 Ah |
Headlight: |
|
Type |
Semi-sealed beam |
Bulb |
12 V 55 W × 2/55 W (Hi/Lo) |
Tail/Brake Light |
12 V 0.5/4.1 W (LED) |
Alternator: |
|
Type |
Three-phase AC |
Rated Output |
24 A/14 V @5 000 r/min (rpm) |
Specifications are subject to change without notice, and may not apply to every country.
1-12 GENERAL INFORMATION
Unit Conversion Table
Prefixes for Units: |
Units of Length: |
Prefix |
Symbol |
|
Power |
|
mega |
M |
× 1 000 |
000 |
|
kilo |
k |
× |
1 000 |
|
centi |
c |
× |
0.01 |
|
milli |
m |
× |
0.001 |
|
micro |
µ |
× 0.000001 |
||
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 |
= |
qt (US) |
L |
× |
0.8799 |
= |
qt (imp) |
L |
× |
2.113 |
= |
pint (US) |
L |
× |
1.816 |
= |
pint (imp) |
mL |
× |
0.03381 |
= |
oz (US) |
mL |
× |
0.02816 |
= |
oz (imp) |
mL |
× |
0.06102 |
= |
cu in |
Units of Force:
N |
× |
0.1020 |
= |
kg |
N |
× |
0.2248 |
= |
lb |
kg |
× |
9.807 |
= |
N |
kg |
× |
2.205 |
= |
lb |
km |
× |
0.6214 |
= |
mile |
m |
× |
3.281 |
= |
ft |
mm |
× |
0.03937 |
= |
in |
Units of Torque:
N·m |
× |
0.1020 |
= |
kgf·m |
N·m |
× |
0.7376 |
= |
ft·lb |
N·m |
× |
8.851 |
= |
in·lb |
kgf·m |
× |
9.807 |
= |
N·m |
kgf·m |
× |
7.233 |
= |
ft·lb |
kgf·m |
× |
86.80 |
= |
in·lb |
Units of Pressure:
kPa |
× |
0.01020 |
= |
kgf/cm² |
kPa |
× |
0.1450 |
= |
psi |
kPa |
× |
0.7501 |
= |
cmHg |
kgf/cm² |
× |
98.07 |
= |
kPa |
kgf/cm² |
× |
14.22 |
= |
psi |
cmHg |
× |
1.333 |
= |
kPa |
Units of Speed:
km/h × 0.6214 = mph
Units of Power:
kW |
× |
1.360 |
= |
PS |
kW |
× |
1.341 |
= |
HP |
PS |
× |
0.7355 |
= |
kW |
PS |
× |
0.9863 |
= |
HP |
Units of Temperature:
PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart ................................................................................................... |
2-3 |
|
|
Torque and Locking Agent...................................................................................................... |
2-6 |
2 |
|
Specifications |
2-12 |
|
|
|
|
||
Special Tools .......................................................................................................................... |
2-14 |
|
|
Periodic Maintenance Procedures.......................................................................................... |
2-15 |
|
|
Fuel System (DFI)................................................................................................................ |
2-15 |
|
|
Air Cleaner Element Cleaning........................................................................................... |
2-15 |
|
|
Throttle Control System Inspection................................................................................... |
2-15 |
|
|
Engine Vacuum Synchronization Inspection..................................................................... |
2-16 |
|
|
Idle Speed Inspection ....................................................................................................... |
2-19 |
|
|
Idle Speed Adjustment...................................................................................................... |
2-20 |
|
|
Fuel Hose Inspection (fuel leak, damage, installation condition) ...................................... |
2-20 |
|
|
Cooling System.................................................................................................................... |
2-22 |
|
|
Coolant Level Inspection................................................................................................... |
2-22 |
|
|
Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition) .......... |
2-22 |
|
|
Engine Top End ................................................................................................................... |
2-23 |
|
|
Valve Clearance Inspection .............................................................................................. |
2-23 |
|
|
Valve Clearance Adjustment............................................................................................. |
2-24 |
|
|
Exhaust Butterfly Valve Cable Inspection ......................................................................... |
2-27 |
|
|
Exhaust Butterfly Valve Cable Adjustment........................................................................ |
2-28 |
|
|
Air Suction System .............................................................................................................. |
2-31 |
|
|
Air Suction System Damage Inspection............................................................................ |
2-31 |
|
|
Clutch................................................................................................................................... |
2-31 |
|
|
Clutch Operation Inspection.............................................................................................. |
2-31 |
|
|
Wheels/Tires........................................................................................................................ |
2-32 |
|
|
Air Pressure Inspection..................................................................................................... |
2-32 |
|
|
Wheel/Tire Damage Inspection......................................................................................... |
2-33 |
|
|
Tire Tread Wear Inspection............................................................................................... |
2-33 |
|
|
Wheel Bearing Damage Inspection .................................................................................. |
2-34 |
|
|
Drive Train ........................................................................................................................... |
2-34 |
|
|
Drive Chain Lubrication Condition Inspection ................................................................... |
2-34 |
|
|
Drive Chain Slack Inspection ............................................................................................ |
2-35 |
|
|
Drive Chain Slack Adjustment .......................................................................................... |
2-35 |
|
|
Wheel Alignment Inspection ............................................................................................. |
2-36 |
|
|
Drive Chain Wear Inspection ............................................................................................ |
2-37 |
|
|
Chain Guide Wear Inspection ........................................................................................... |
2-37 |
|
|
Brake System ...................................................................................................................... |
2-38 |
|
|
Brake Fluid Leak (Brake Hose and Pipe) Inspection ........................................................ |
2-38 |
|
|
Brake Hose and Pipe Damage and Installation Condition Inspection............................... |
2-39 |
|
|
Brake Operation Inspection .............................................................................................. |
2-39 |
|
|
Brake Fluid Level Inspection............................................................................................. |
2-39 |
|
|
Brake Pad Wear Inspection .............................................................................................. |
2-40 |
|
|
Brake Light Switch Operation Inspection .......................................................................... |
2-41 |
|
|
Suspensions ........................................................................................................................ |
2-41 |
|
|
Front Forks/Rear Shock Absorber Operation Inspection .................................................. |
2-41 |
|
|
Front Fork Oil Leak Inspection.......................................................................................... |
2-42 |
|
|
Rear Shock Absorber Oil Leak Inspection ........................................................................ |
2-42 |
|
|
Rocker Arm Operation Inspection..................................................................................... |
2-42 |
|
|
Tie-Rod Operation Inspection ........................................................................................... |
2-42 |
|
|
Steering System .................................................................................................................. |
2-43 |
|
|
2-2 PERIODIC MAINTENANCE
Steering Play Inspection ................................................................................................... |
2-43 |
Steering Play Adjustment.................................................................................................. |
2-43 |
Steering Stem Bearing Lubrication ................................................................................... |
2-44 |
Electrical System ................................................................................................................. |
2-45 |
Spark Plug Condition Inspection....................................................................................... |
2-45 |
Lights and Switches Operation Inspection........................................................................ |
2-46 |
Headlight Aiming Inspection ............................................................................................. |
2-48 |
Sidestand Switch Operation Inspection ............................................................................ |
2-49 |
Engine Stop Switch Operation Inspection......................................................................... |
2-50 |
Others.................................................................................................................................. |
2-50 |
Chassis Parts Lubrication ................................................................................................. |
2-50 |
Bolts, Nuts and Fasteners Tightness Inspection............................................................... |
2-52 |
Replacement Parts .............................................................................................................. |
2-53 |
Air Cleaner Element Replacement.................................................................................... |
2-53 |
Fuel Hose Replacement ................................................................................................... |
2-54 |
Coolant Change ................................................................................................................ |
2-56 |
Radiator Hose and O-ring Replacement........................................................................... |
2-58 |
Engine Oil Change............................................................................................................ |
2-58 |
Oil Filter Replacement ...................................................................................................... |
2-59 |
Brake Hose and Pipe Replacement.................................................................................. |
2-60 |
Brake Fluid Change .......................................................................................................... |
2-62 |
Master Cylinder Rubber Parts Replacement .................................................................... |
2-63 |
Caliper Rubber Parts Replacement .................................................................................. |
2-64 |
Spark Plug Replacement .................................................................................................. |
2-67 |
PERIODIC MAINTENANCE 2-3
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected.
Periodic Inspection
|
FREQUENCY |
Whichever |
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* ODOMETER READING |
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comes |
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× 1 000 km |
See |
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first |
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(× 1 000 mile) |
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Page |
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1 |
6 |
12 |
18 |
24 |
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30 |
36 |
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|||||||||
INSPECTION |
Every |
(0.6) |
(4) |
(7.5) |
(12) |
(15) |
|
(20) |
(24) |
|
|||||
Fuel System |
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Air cleaner element - clean |
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• |
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|
• |
2-15 |
|
Throttle control system (play, smooth return, |
year |
|
• |
|
• |
|
• |
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|
• |
2-15 |
||||
no drag) - inspect |
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Engine vacuum synchronization - inspect |
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• |
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• |
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• |
2-16 |
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Idle speed - inspect |
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• |
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• |
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• |
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• |
2-19 |
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Fuel leak (fuel hose and pipe) - inspect |
year |
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• |
|
• |
|
• |
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|
• |
2-20 |
||||
Fuel hose and pipe damage - inspect |
year |
|
• |
|
• |
|
• |
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|
• |
2-20 |
||||
Fuel hose and pipe installation condition - |
year |
|
• |
|
• |
|
• |
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• |
2-20 |
||||
inspect |
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Cooling System |
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Coolant level - inspect |
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• |
|
• |
|
• |
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|
• |
2-22 |
||
Coolant leak (radiator hose and pipe) - |
year |
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• |
|
• |
|
• |
|
|
• |
2-22 |
||||
inspect |
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||||||||||
Radiator hose damage - inspect |
year |
|
• |
|
• |
|
• |
|
|
• |
2-22 |
||||
Radiator hose installation condition - inspect |
year |
|
• |
|
• |
|
• |
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|
• |
2-22 |
||||
Engine Top End |
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AU Model |
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• |
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2-23 |
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Valve clearance - inspect |
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Other than AU |
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Every 42 000 km (26 000 mile) |
2-23 |
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Model |
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Exhaust butterfly valve cable - inspect |
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• |
• |
• |
• |
• |
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• |
• |
2-27 |
||
Air Suction System |
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Air suction system damage - inspect |
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• |
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• |
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• |
2-31 |
|
Clutch |
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Clutch operation (play, disengagement, |
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• |
|
• |
|
• |
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• |
2-31 |
||
engagement) - inspect |
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Wheels and Tires |
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Tire air pressure - inspect |
year |
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• |
|
• |
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|
• |
2-32 |
|||
Wheel/tire damage - inspect |
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• |
|
• |
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• |
2-33 |
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Tire tread wear, abnormal wear - inspect |
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• |
|
• |
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|
• |
2-33 |
|
Wheel bearing damage - inspect |
year |
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|
• |
|
• |
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|
• |
2-34 |
|||
Drive Train |
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Drive chain lubrication condition - inspect # |
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|
Every 600 km (400 mile) |
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|
2-34 |
|||||||
Drive chain slack - inspect # |
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|
|
Every 1 000 km (600 mile) |
|
2-35 |
|||||||||
Drive chain wear - inspect # |
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• |
|
• |
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|
• |
2-37 |
|
Drive chain guide wear - inspect |
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|
• |
|
• |
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|
• |
2-37 |
|
2-4 PERIODIC MAINTENANCE
Periodic Maintenance Chart
FREQUENCY |
Whichever |
|
* ODOMETER READING |
|
|||||||||
|
comes |
|
|
|
|
|
× 1 000 km |
See |
|||||
|
first |
|
|
|
|
|
(× 1 000 mile) |
||||||
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||||||||
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Page |
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|
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1 |
6 |
12 |
18 |
24 |
30 |
36 |
||
|
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|
|
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|
||||||||
INSPECTION |
Every |
|
(0.6) |
(4) |
(7.5) |
(12) |
(15) |
(20) |
(24) |
|
|||
Brake System |
|
|
|
|
|
|
|
|
|
|
|
|
|
Brake fluid leak (brake hose and pipe) - |
year |
|
• |
• |
• |
• |
• |
• |
• |
2-38 |
|||
inspect |
|
||||||||||||
Brake hose and pipe damage - inspect |
year |
|
• |
• |
• |
• |
• |
• |
• |
2-39 |
|||
Brake hose and pipe installation condition - |
year |
|
• |
• |
• |
• |
• |
• |
• |
2-39 |
|||
inspect |
|
||||||||||||
Brake operation (effectiveness, play, no |
year |
|
• |
• |
• |
• |
• |
• |
• |
2-39 |
|||
drag) - inspect |
|
||||||||||||
Brake fluid level - inspect |
6 |
|
|
• |
• |
• |
• |
• |
• |
• |
2-39 |
||
months |
|
||||||||||||
Brake pad wear - inspect # |
|
|
|
|
|
|
• |
• |
• |
• |
• |
• |
2-40 |
Brake light switch operation - inspect |
|
|
|
|
• |
• |
• |
• |
• |
• |
• |
2-41 |
|
Suspensions |
|
|
|
|
|
|
|
|
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|
|
|
Front forks/rear shock absorber operation |
|
|
|
|
|
|
|
• |
|
• |
|
• |
2-41 |
(damping and smooth stroke) - inspect |
|
|
|
|
|
|
|
|
|
||||
Front forks/rear shock absorber oil leak - |
year |
|
|
|
|
• |
|
• |
|
• |
2-42 |
||
inspect |
|
|
|
|
|
|
|||||||
Rocker arm operation - inspect |
|
|
|
|
|
|
|
• |
|
• |
|
• |
2-42 |
Tie-rods operation - inspect |
|
|
|
|
|
|
|
• |
|
• |
|
• |
2-42 |
Steering System |
|
|
|
|
|
|
|
|
|
|
|
|
|
Steering play - inspect |
year |
|
• |
|
• |
|
• |
|
• |
2-43 |
|||
Steering stem bearings - lubricate |
2 years |
|
|
|
|
|
|
• |
|
|
2-44 |
||
|
|
|
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|
|||||
Electrical System |
|
|
|
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|
|
|
Spark plug condition - inspect |
|
|
|
|
|
|
|
• |
|
• |
|
• |
2-45 |
Lights and switches operation - inspect |
year |
|
|
|
|
• |
|
• |
|
• |
2-46 |
||
Headlight aiming - inspect |
year |
|
|
|
|
• |
|
• |
|
• |
2-48 |
||
Sidestand switch operation - inspect |
year |
|
|
|
|
• |
|
• |
|
• |
2-49 |
||
Engine stop switch operation - inspect |
year |
|
|
|
|
• |
|
• |
|
• |
2-50 |
||
Others |
|
|
|
|
|
|
|
|
|
|
|
|
|
Chassis parts - lubricate |
year |
|
|
|
|
• |
|
• |
|
• |
2-50 |
||
Bolts and nuts tightness - inspect |
|
|
|
|
• |
|
• |
|
• |
|
• |
2-52 |
|
#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.
*: For higher odometer readings, repeat at the frequency interval established here.
PERIODIC MAINTENANCE 2-5
Periodic Maintenance Chart
Periodic Replacement Parts
FREQUENCY |
Whichever |
|
|
* ODOMETER READING |
|
||||||
|
comes |
|
|
|
|
× 1 000 km |
See |
||||
|
|
|
|
|
|||||||
|
first |
|
|
|
(× 1 000 mile) |
||||||
|
|
|
|
||||||||
|
|
|
|
|
|
|
|
|
|
|
Page |
|
|
|
|
|
1 |
12 |
24 |
36 |
48 |
||
|
|
|
|
|
|
||||||
CHANGE/REPLACE ITEM |
Every |
|
(0.6) |
(7.5) |
(15) |
(24) |
(30) |
|
|||
Air cleaner element # |
|
|
|
|
|
|
|
|
• |
|
2-53 |
|
|
|
|
|
|
|
|
|
|
||
Fuel hose |
4 years |
|
|
|
|
|
|
• |
2-54 |
||
Coolant |
3 years |
|
|
|
|
|
• |
|
2-56 |
||
|
|
|
|
|
|
|
|||||
|
|
|
|
|
|
|
|
|
|
|
|
Radiator hose and O-ring |
3 years |
|
|
|
|
|
• |
|
2-58 |
||
|
|
|
|
|
|
|
|||||
Engine oil # |
year |
|
• |
• |
• |
• |
• |
2-58 |
|||
Oil filter |
year |
|
• |
• |
• |
• |
• |
2-59 |
|||
Brake hose and pipe |
4 years |
|
|
|
|
|
|
• |
2-60 |
||
Brake fluid |
2 years |
|
|
|
|
• |
|
• |
2-62 |
||
Rubber parts of master cylinder and caliper |
4 years |
|
|
|
|
|
|
• |
2-63, |
||
|
|
|
|
|
|
2-64 |
|||||
|
|
|
|
|
|
|
|
|
|
||
Spark plug |
|
|
|
|
|
|
• |
• |
• |
• |
2-67 |
#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.
*: For higher odometer readings, repeat at the frequency interval established here.
2-6 PERIODIC MAINTENANCE
Torque and Locking Agent
The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc.
Letters used in the “Remarks” column mean:
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. EO: Apply engine oil.
G: Apply grease.
HG: Apply high-temperature grease.
L: Apply a non-permanent locking agent.
MO: Apply molybdenum disulfide grease oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)
R:Replacement Parts
S:Follow the specified tightening sequence. Si: Apply silicone grease (ex. PBC grease).
SS: Apply silicone sealant.
Fastener |
|
Torque |
|
Remarks |
|
N·m |
kgf·m |
ft·lb |
|||
|
|
||||
Fuel System (DFI) |
|
|
|
|
|
Air Cleaner Duct Screws |
3.8 |
0.39 |
34 in·lb |
|
|
Air Cleaner Housing Mounting Bolts |
9.8 |
1.0 |
87 in·lb |
|
|
Air Cleaner Housing Tapping Screws |
1.2 |
0.12 |
11 in·lb |
|
|
Air Duct Clamp Bolts |
2.0 |
0.20 |
18 in·lb |
|
|
Bypass Screws |
0.2 |
0.02 |
1.8 in·lb |
|
|
Camshaft Position Sensor Bolt |
12 |
1.2 |
106 in·lb |
|
|
Crankshaft Sensor Bolts |
5.9 |
0.60 |
52 in·lb |
|
|
Delivery Pipe Assy Mounting Screws |
3.4 |
0.35 |
30 in·lb |
|
|
Exhaust Butterfly Valve Actuator Bracket Bolt |
6.9 |
0.70 |
61 in·lb |
|
|
Exhaust Butterfly Valve Actuator Mounting Bolts |
6.9 |
0.70 |
61 in·lb |
|
|
Exhaust Butterfly Valve Actuator Pulley Bolt |
5.0 |
0.51 |
44 in·lb |
|
|
Fuel Pump Bolts |
9.8 |
1.0 |
87 in·lb |
L, S |
|
Idle Adjusting Cable Clamp Screw |
3.4 |
0.35 |
30 in·lb |
|
|
Oxygen Sensor (Equipped Models) |
44.1 |
4.50 |
32.5 |
|
|
Speed Sensor Bolt |
12 |
1.2 |
106 in·lb |
|
|
Throttle Body Assy Holder Bolts |
13 |
1.3 |
115 in·lb |
|
|
Throttle Body Assy Holder Clamp Bolts |
2.0 |
0.20 |
18 in·lb |
|
|
Throttle Cable Plate Bolt |
5.9 |
0.60 |
52 in·lb |
|
|
Throttle Link Holder Screws |
2.0 |
0.20 |
18 in·lb |
|
|
Vehicle-down Sensor Bolts |
6.0 |
0.61 |
53 in·lb |
|
|
Water Temperature Sensor |
25 |
2.5 |
18 |
|
|
Cooling System |
|
|
|
|
|
Coolant Drain Bolt (Cylinder) |
9.8 |
1.0 |
87 in·lb |
|
|
Coolant Drain Bolt (Water Pump) |
11 |
1.1 |
97 in·lb |
|
|
Radiator Bracket Mounting Bolt |
6.9 |
0.70 |
61 in·lb |
|
|
Radiator Lower Bolt |
6.9 |
0.70 |
61 in·lb |
|
|
Radiator Upper Bolts |
6.9 |
0.70 |
61 in·lb |
|
|
Radiator (Water) Hose Clamp Screws |
3.0 |
0.31 |
27 in·lb |
|
|
Reserve Tank Bolts |
9.8 |
1.0 |
87 in·lb |
|
PERIODIC MAINTENANCE 2-7
Torque and Locking Agent
Fastener |
|
Torque |
|
Remarks |
|
N·m |
kgf·m |
ft·lb |
|||
|
|
||||
Thermostat Bracket Bolt |
6.9 |
0.70 |
61 in·lb |
|
|
Thermostat Housing Ground Bolt |
6.9 |
0.70 |
61 in·lb |
|
|
Thermostat Housing Screws |
5.9 |
0.60 |
52 in·lb |
|
|
Water Pipe Bolts |
11 |
1.1 |
97 in·lb |
L |
|
Water Pump Cover Bolts |
11 |
1.1 |
97 in·lb |
|
|
Water Pump Impeller Bolt |
9.8 |
1.0 |
87 in·lb |
|
|
Water Temperature Sensor |
25 |
2.5 |
18 |
|
|
Engine Top End |
|
|
|
|
|
Air Suction Valve Cover Bolts |
9.8 |
1.0 |
87 in·lb |
|
|
Camshaft Cap Bolts (L = 45 mm) |
12 |
1.2 |
106 in·lb |
S |
|
Camshaft Cap Bolts (L = 40 mm) |
12 |
1.2 |
106 in·lb |
S |
|
Camshaft Chain Tensioner Cap Bolt |
20 |
2.0 |
15 |
|
|
Camshaft Chain Tensioner Mounting Bolts |
11 |
1.1 |
97 in·lb |
|
|
Coolant Drain Bolt (Cylinder) |
9.8 |
1.0 |
87 in·lb |
|
|
Cylinder Head Bolts (M10 New Bolts) |
54 |
5.5 |
40 |
S |
|
Cylinder Head Bolts (M10 Used Bolts) |
49 |
5.0 |
36 |
S |
|
Cylinder Head Bolts (M6) |
12 |
1.2 |
106 in·lb |
S |
|
Cylinder Head Cover Bolts |
9.8 |
1.0 |
87 in·lb |
S |
|
Cylinder Head Jacket Plugs |
22 |
2.2 |
16 |
L |
|
Exhaust Butterfly Valve Actuator Bracket Bolt |
6.9 |
0.70 |
61 in·lb |
|
|
Exhaust Butterfly Valve Actuator Mounting Bolts |
6.9 |
0.70 |
61 in·lb |
|
|
Exhaust Butterfly Valve Actuator Pulley Bolt |
5.0 |
0.51 |
44 in·lb |
|
|
Exhaust Butterfly Valve Cable Adjuster Locknuts |
6.9 |
0.70 |
61 in·lb |
|
|
Exhaust Butterfly Valve Cable Locknuts |
6.9 |
0.70 |
61 in·lb |
|
|
Exhaust Butterfly Valve Cover Bolts |
6.9 |
0.70 |
61 in·lb |
|
|
Exhaust Pipe Manifold Holder Nuts |
17 |
1.7 |
13 |
S |
|
Front Camshaft Chain Guide Bolt (Lower) |
12 |
1.2 |
106 in·lb |
|
|
Front Camshaft Chain Guide Bolt (Upper) |
25 |
2.5 |
18 |
|
|
Muffler Body Clamp Bolt |
15 |
1.5 |
11 |
S |
|
Muffler Body Mounting Bolt |
4.9 |
0.50 |
43 in·lb |
S |
|
Muffler Body Mounting Nut |
34 |
3.5 |
25 |
S |
|
Muffler Body Side Cover Bolts |
6.9 |
0.70 |
61 in·lb |
|
|
Rear Camshaft Chain Guide Bolt |
25 |
2.5 |
18 |
|
|
Spark Plugs |
13 |
1.3 |
115 in·lb |
|
|
Throttle Body Assy Holder Bolts |
13 |
1.3 |
115 in·lb |
|
|
Throttle Body Assy Holder Clamp Bolts |
2.0 |
0.20 |
18 in·lb |
|
|
Clutch |
|
|
|
|
|
Clutch Cover Mounting Bolts |
11 |
1.1 |
97 in·lb |
|
|
Clutch Hub Nut |
135 |
13.8 |
99.6 |
R |
|
Clutch Lever Clamp Bolts |
7.8 |
0.80 |
69 in·lb |
S |
|
Clutch Spring Bolts |
8.8 |
0.90 |
78 in·lb |
|
|
Oil Filler Plug |
2.0 |
0.20 |
18 in·lb |
|
|
|
|
|
|
|
2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener |
|
Torque |
|
Remarks |
|
N·m |
kgf·m |
ft·lb |
|||
|
|
||||
Engine Lubrication System |
|
|
|
|
|
Coolant Drain Bolt (Water Pump) |
11 |
1.1 |
97 in·lb |
|
|
Engine Oil Drain Bolt |
29 |
3.0 |
21 |
|
|
Oil Filter |
17 |
1.7 |
13 |
G, R |
|
Oil Filter Holder |
78 |
8.0 |
58 |
EO |
|
Oil Filler Plug |
2.0 |
0.20 |
18 in·lb |
|
|
Oil Jet Nozzle Bolts |
6.9 |
0.70 |
61 in·lb |
L |
|
Oil Pan Bolts |
11 |
1.1 |
97 in·lb |
|
|
Oil Pan Side Dummy Bolts |
6.9 |
0.70 |
61 in·lb |
|
|
Oil Passage Plugs |
20 |
2.0 |
15 |
L |
|
Oil Pipe Holder Bolts |
13 |
1.3 |
115 in·lb |
L |
|
Oil Pressure Relief Valve |
15 |
1.5 |
11 |
L |
|
Oil Pressure Switch |
15 |
1.5 |
11 |
SS |
|
Oil Pressure Switch Terminal Bolt |
2.0 |
0.20 |
18 in·lb |
HG |
|
Water Pump Cover Bolts |
11 |
1.1 |
97 in·lb |
|
|
Water Pump Impeller Bolt |
9.8 |
1.0 |
87 in·lb |
|
|
Engine Removal/Installation |
|
|
|
|
|
Adjusting Collar Lock Bolt |
34 |
3.5 |
25 |
S |
|
Adjusting Collar Locknut |
49 |
5.0 |
36 |
S |
|
Engine Ground Cable Terminal Bolt |
9.8 |
1.0 |
87 in·lb |
|
|
Front Engine Mounting Bolts |
44 |
4.5 |
32 |
S |
|
Lower Engine Mounting Nut |
44 |
4.5 |
32 |
S |
|
Middle Engine Mounting Nut |
44 |
4.5 |
32 |
S |
|
Rear Engine Bracket Bolts |
25 |
2.5 |
18 |
S |
|
Subframe Bolts |
25 |
2.5 |
18 |
S |
|
Upper Engine Bracket Bolts |
44 |
4.5 |
32 |
S |
|
Crankshaft/Transmission |
|
|
|
|
|
Breather Plate Bolts (M6) |
9.8 |
1.0 |
87 in·lb |
L |
|
Breather Plate Bolts (M5) |
5.9 |
0.60 |
52 in·lb |
L |
|
Connecting Rod Big End Nuts |
see the text |
← |
← |
MO |
|
Crankcase Bolts (M9) |
42 |
4.3 |
31 |
MO, S |
|
Crankcase Bolts (M8) |
27 |
2.8 |
20 |
S |
|
Crankcase Bolts (M7) |
20 |
2.0 |
15 |
S |
|
Crankcase Bolts (M6) |
12 |
1.2 |
106 in·lb |
S |
|
Front Footpeg Bracket Bolts |
25 |
2.5 |
18 |
|
|
Gear Positioning Lever Bolt |
12 |
1.2 |
106 in·lb |
|
|
Neutral Switch |
15 |
1.5 |
11 |
|
|
Oil Jet Nozzle Bolts |
6.9 |
0.70 |
61 in·lb |
L |
|
Oil Passage Plugs |
20 |
2.0 |
15 |
L |
|
Oil Pipe Holder Bolts |
13 |
1.3 |
115 in·lb |
L |
|
Shift Drum Bearing Holder Bolt |
13 |
1.3 |
115 in·lb |
L |
|
Shift Drum Bearing Holder Screw |
5.9 |
0.60 |
52 in·lb |
L |
|
Shift Drum Cam Holder Bolt |
12 |
1.2 |
106 in·lb |
L |
PERIODIC MAINTENANCE 2-9
Torque and Locking Agent
Fastener |
|
Torque |
|
Remarks |
|
N·m |
kgf·m |
ft·lb |
|||
|
|
||||
Shift Lever Bolt |
6.9 |
0.70 |
61 in·lb |
|
|
Shift Pedal Mounting Bolt |
34 |
3.5 |
25 |
L |
|
Shift Shaft Return Spring Pin |
29 |
3.0 |
21 |
L |
|
Starter Motor Clutch Bolts |
12 |
1.2 |
106 in·lb |
L |
|
Tie-Rod Locknuts |
6.9 |
0.70 |
61 in·lb |
|
|
Wheels/Tires |
|
|
|
|
|
Front Axle |
108 |
11.0 |
79.7 |
|
|
Front Axle Clamp Bolt |
20 |
2.0 |
15 |
|
|
Rear Axle Nut |
108 |
11.0 |
79.7 |
|
|
Final Drive |
|
|
|
|
|
Engine Sprocket Cover Bolts |
9.8 |
1.0 |
87 in·lb |
|
|
Engine Sprocket Cover Plate Bolts |
9.8 |
1.0 |
87 in·lb |
|
|
Engine Sprocket Nut |
125 |
12.7 |
92.2 |
MO |
|
Rear Axle Nut |
108 |
11.0 |
79.7 |
|
|
Rear Sprocket Nuts |
59 |
6.0 |
44 |
|
|
Brakes |
|
|
|
|
|
Bleed Valves |
7.8 |
0.80 |
69 in·lb |
|
|
Brake Hose Banjo Bolts |
25 |
2.5 |
18 |
|
|
Brake Lever Pivot Bolt |
1.0 |
0.10 |
9 in·lb |
Si |
|
Brake Lever Pivot Bolt Locknut |
5.9 |
0.60 |
52 in·lb |
|
|
Brake Pedal Bolt |
34 |
3.5 |
25 |
L |
|
Brake Pipe Joint Nuts (ABS Equipped Models) |
18 |
1.8 |
13 |
|
|
Front Brake Disc Mounting Bolts |
27 |
2.8 |
20 |
L |
|
Front Brake Light Switch Screw |
1.2 |
0.12 |
11 in·lb |
|
|
Front Brake Pad Pin Plugs |
2.5 |
0.25 |
25 in·lb |
|
|
Front Brake Pad Pins |
17.2 |
1.8 |
13 |
|
|
Front Brake Reservoir Cap Stopper Screw |
1.2 |
0.12 |
11 in·lb |
|
|
Front Caliper Holder Pin Bolt |
22 |
2.2 |
16 |
L, Si |
|
Front Caliper Mounting Bolts |
25 |
2.5 |
18 |
|
|
Front Master Cylinder Clamp Bolts |
8.8 |
0.90 |
78 in·lb |
S |
|
Rear Brake Disc Mounting Bolts |
27 |
2.8 |
20 |
L |
|
Rear Brake Pad Pin |
17.2 |
1.8 |
13 |
|
|
Rear Brake Pad Pin Plug |
2.5 |
0.25 |
25 in·lb |
|
|
Rear Caliper Mounting Bolt |
22 |
2.2 |
16 |
|
|
Rear Caliper Pin Bolt |
27 |
2.8 |
20 |
Si |
|
Rear Master Cylinder Mounting Bolts |
25 |
2.5 |
18 |
|
|
Rear Master Cylinder Push Rod Locknut |
17.2 |
1.8 |
13 |
|
|
Suspension |
|
|
|
|
|
Front Axle Clamp Bolt |
20 |
2.0 |
15 |
|
|
Front Fork Bottom Allen Bolts |
40 |
4.1 |
30 |
L |
|
Front Fork Top Plugs |
23 |
2.3 |
17 |
|
|
Lower Front Fork Clamp Bolts |
21 |
2.1 |
15 |
AL |
|
Piston Rod Nuts |
15 |
1.5 |
11 |
|
2-10 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener |
|
Torque |
|
Remarks |
|
N·m |
kgf·m |
ft·lb |
|||
|
|
||||
Rear Shock Absorber Nut (Lower) |
34 |
3.5 |
25 |
|
|
Rear Shock Absorber Nut (Upper) |
34 |
3.5 |
25 |
|
|
Swingarm Pivot Shaft |
9.8 |
1.0 |
87 in·lb |
|
|
Swingarm Pivot Shaft Locknut |
98 |
10.0 |
72.3 |
|
|
Swingarm Pivot Shaft Nut |
108 |
11.0 |
79.7 |
|
|
Tie-Rod Nuts |
59 |
6.0 |
44 |
|
|
Uni-Trak Rocker Arm Nut |
34 |
3.5 |
25 |
|
|
Upper Front Fork Clamp Bolts |
20 |
2.0 |
15 |
|
|
Steering |
|
|
|
|
|
Handlebar Holder Bolts |
25 |
2.5 |
18 |
S |
|
Handlebar Lower Clamp Nuts |
34 |
3.5 |
25 |
|
|
Lower Front Fork Clamp Bolts |
21 |
2.1 |
15 |
AL |
|
Steering Stem Head Bolt |
108 |
11.0 |
79.7 |
|
|
Steering Stem Nut |
27 |
2.8 |
20 |
|
|
Switch Housing Screws |
3.5 |
0.36 |
31 in·lb |
|
|
Upper Front Fork Clamp Bolts |
20 |
2.0 |
15 |
|
|
Frame |
|
|
|
|
|
Front Fender Bolts |
3.9 |
0.40 |
35 in·lb |
|
|
Front Footpeg Bracket Bolts |
25 |
2.5 |
18 |
|
|
Rear Footpeg Bracket Bolts |
25 |
2.5 |
18 |
|
|
Sidestand Bolt |
44 |
4.5 |
32 |
|
|
Sidestand Switch Bolt |
8.8 |
0.90 |
78 in·lb |
L |
|
Electrical System |
|
|
|
|
|
Alternator Cover Bolts |
11 |
1.1 |
97 in·lb |
|
|
Alternator Lead Holding Plate Bolt |
12 |
1.2 |
106 in·lb |
L |
|
Alternator Rotor Bolt |
155 |
15.8 |
114 |
S |
|
Camshaft Position Sensor Bolt |
12 |
1.2 |
106 in·lb |
|
|
Crankshaft Sensor Bolts |
5.9 |
0.60 |
52 in·lb |
|
|
Crankshaft Sensor Cover Bolts |
11 |
1.1 |
97 in·lb |
|
|
Engine Ground Cable Terminal Bolt |
9.8 |
1.0 |
87 in·lb |
|
|
Front Brake Light Switch Screw |
1.2 |
0.12 |
11 in·lb |
|
|
Fuel Level Sensor Bolts |
6.9 |
0.70 |
61 in·lb |
L |
|
License Plate Light Cover Mounting Screws |
0.9 |
0.09 |
8 in·lb |
|
|
License Plate Light Mounting Screws |
1.2 |
0.12 |
11 in·lb |
|
|
Meter Mounting Screws |
1.2 |
0.12 |
11 in·lb |
|
|
Neutral Switch |
15 |
1.5 |
11 |
|
|
Oil Pressure Switch |
15 |
1.5 |
11 |
SS |
|
Oil Pressure Switch Terminal Bolt |
2.0 |
0.20 |
18 in·lb |
HG |
|
Oxygen Sensor (Equipped Models) |
44.1 |
4.50 |
32.5 |
|
|
Regulator/Rectifier Bolts |
6.9 |
0.70 |
61 in·lb |
|
|
Regulator/Rectifier Bracket Bolts |
6.9 |
0.70 |
61 in·lb |
L |
|
Sidestand Switch Bolt |
8.8 |
0.90 |
78 in·lb |
L |
|
Spark Plugs |
13 |
1.3 |
115 in·lb |
|
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