Kawasaki ZX6R Ninja Service Manual

12.43 Mb
Loading...

Ninja ZX-6R

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

Ninja ZX-6R

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 Department/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.

© 2004 Kawasaki Heavy Industries, Ltd.

First Edition (1): Sep. 30, 2004 (M)

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)

ohm(s)

L

liter(s)

 

 

Read OWNER’S MANUAL before operating.

EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only.

1. Crankcase Emission Control System

This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors are routed through an oil separator to the inlet side of the engine. While the engine is operating, the vapors are drawn into combustion chamber, where they are burned along with the fuel and air supplied by the fuel injection system.

2. Exhaust Emission Control System

This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels.

The exhaust system of this model motorcycle manufactured primarily for sale in California includes a catalytic converter system.

3. Evaporative Emission Control System

Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister when the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.

The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly referred to as the Act’s “tampering provisions”.

“Sec. 203(a) The following acts and the causing thereof are prohibited...

(3)(A) for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser.

(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser...”

NOTE

The phrase “remove or render inoperative any device or element of design” has been generally interpreted as follows.

1.Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance.

2.Tampering could include.

a.Maladjustment of vehicle components such that the emission standards are exceeded.

b.Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle.

c.Addition of components or accessories that result in the vehicle exceeding the standards.

d.Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10 000 PER VIOLATION.

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below.

Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations.

Removal of the muffler(s) or any internal portion of the muffler(s).

Removal of the air box or air box cover.

Modifications to the muffler(s) or air inlet system by cutting, drilling, or other means if such modifications result in increased noise levels.

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 Special Tool Catalog or 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 preparing this manual, we divided the product into its major systems. These systems became the manual’s chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter.

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.

The Periodic Maintenance Chart is located in the Periodic Maintenance chapter. The chart gives a time schedule for required maintenance operations.

If you want spark plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, use the Quick Reference Guide to locate the Periodic Maintenance chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug 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

1

Table of Contents

 

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 the 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.

GENERAL INFORMATION 1-7

Model Identification

ZX636-C1 (Europe) Left Side View
ZX636-C1 (Europe) Right Side View

1-8 GENERAL INFORMATION

Model Identification

ZX636-C1 (US and Canada) Left Side View
ZX636-C1 (US and Canada) Right Side View

 

GENERAL INFORMATION 1-9

General Specifications

 

 

 

 

 

Items

ZX636-C1 (Ninja ZX-6R)

Dimensions

 

Overall Length

2 065 mm (81.3 in.)

Overall Width

715 mm (28.1 in.)

Overall Height

1 110 mm (43.7 in.)

Wheelbase

1 390 mm (54.7 in.)

Road Clearance

120 mm (4.7 in.)

Seat Height

820 mm (32.3 in.)

Dry Mass

164 kg (362 lb)

Curb Mass:

 

Front

95 kg (209 lb)

Rear

97 kg (214 lb)

Fuel Tank Capacity

17 L (4.5 US gal)

Performance

 

Minimum Turning Radius

3.3 m (10.8 ft)

Engine

 

Type

4-stroke, DOHC, 4-cylinder

Cooling System

Liquid-cooled

Bore and Stroke

68.0 × 43.8 mm (2.7 × 1.7 in.)

Displacement

636 mL (38.8 cu in.)

Compression Ratio

12.9 : 1

Maximum Horsepower

95.5 kW (130 PS) @14 000 r/min (rpm),

 

(FR) 78.2 kW (106 PS) @13 000 r/min (rpm),

 

(MY) 90.8 kW (123 PS) @12 500 r/min (rpm),

 

(CA), (CAL), (US) – – –

Maximum Torque

70.5 N·m (7.1 kgf·m, 52 ft·lb) @11 500 r/min (rpm),

 

(FR) 63 N·m (6.4 kgf·m, 46 ft·lb) @11 500 r/min (rpm),

 

(CA), (CAL), (US) – – –

Carburetion System

FI (Fuel injection)

 

Primary: KEIHIN TTK 38 × 4

 

Secondary: KEIHIN Multihole (3 holes) × 4

Starting System

Electric starter

Ignition System

Battery and coil (transistorized)

Timing Advance

Electronically advanced (digital igniter in ECU)

Ignition Timing

From 12.5° BTDC @1 300 r/min (rpm) to 35° BTDC @4 600 r/min

 

(rpm)

Spark Plug

NGK CR9E

Cylinder Numbering Method

Left to right, 1-2-3-4

Firing Order

1-2-4-3

Valve Timing:

 

Inlet:

 

Open

59° BTDC

Close

81° ABDC

Duration

320°

Exhaust:

 

Open

61° BBDC

Close

31° ATDC

1-10 GENERAL INFORMATION

General Specifications

Items

ZX636-C1 (Ninja ZX-6R)

Duration

272°

Lubrication System

Forced lubrication (wet sump with cooler)

Engine Oil:

 

Type

API SE, SF or SG

 

API SH or SJ with JASO MA

Viscosity

SAE10W-40

Capacity

4.0 L (4.2 US qt)

Drive Train

 

Primary Reduction System:

 

Type

Gear

Reduction Ratio

1.891 (87/46)

Clutch Type

Wet multi disc

Transmission:

 

Type

6-speed, constant mesh, return shift

Gear Ratios:

 

1st

2.923 (38/13)

2nd

2.055 (37/18)

3rd

1.666 (35/21)

4th

1.450 (29/20)

5th

1.272 (28/22)

6th

1.153 (30/26)

Final Drive System:

 

Type

Chain drive

Reduction Ratio

2.866 (43/15)

Overall Drive Ratio

6.255 @Top gear

Frame

 

Type

Tubular, diamond

Caster (Rake Angle)

25°

Trail

106 mm (4.2 in.)

Front Tire:

 

Type

Tubeless

Size

120/65 ZR17 M/C (56 W)

Rear Tire:

 

Type

Tubeless

Size

180/55 ZR17 M/C (73 W)

Front Suspension:

 

Type

Telescopic fork (upside-down)

Wheel Travel

120 mm (4.7 in.)

Rear Suspension:

 

Type

Swingarm (uni-trak)

Wheel Travel

135 mm (5.3 in.)

Brake Type:

 

Front

Dual discs

Rear

Single disc

 

 

GENERAL INFORMATION 1-11

General Specifications

 

 

 

 

 

 

 

 

Items

 

ZX636-C1 (Ninja ZX-6R)

Electrical Equipment

 

 

Battery

12 V 8 Ah

Headlight:

 

 

Type

Semi-sealed beam

Bulb:

 

 

High

12

V 55 W (quartz-halogen) × 2

Low

12

V 55 W (quartz-halogen)

Tail/Brake Light

12

V 0.5/4.1 W (LED)

Alternator:

 

 

Type

Three-phase AC

Rated Output

22.5 A/14 V @5 000 r/min (rpm)

Specifications subject to change without notice, and may not apply to every country. CA: Canada Model

CAL: California Model

FR: France Model

MY: Malaysia Model US: United States Model

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

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 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

Units of Temperature

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

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

2

 

 

 

Periodic Maintenance Chart (United States, Canada Model).................................................

2-3

Periodic Maintenance Chart (Other than United States, Canada Model)...............................

2-6

Torque and Locking Agent......................................................................................................

2-9

Specifications .........................................................................................................................

2-15

Special Tools ..........................................................................................................................

2-17

Maintenance Procedure .........................................................................................................

2-18

Fuel System (DFI)................................................................................................................

2-18

Throttle Control System Inspection...................................................................................

2-18

Engine Vacuum Synchronization Inspection.....................................................................

2-18

Idle Speed Inspection .......................................................................................................

2-22

Idle Speed Adjustment......................................................................................................

2-22

Fuel Hose Damage and Installation Condition Inspection ................................................

2-22

Evaporative Emission Control System (California Model) ...................................................

2-23

Evaporative Emission Control System Inspection ............................................................

2-23

Cooling System....................................................................................................................

2-24

Coolant Level Inspection...................................................................................................

2-24

Radiator Hose Damage and Installation Condition Inspection..........................................

2-24

Engine Top End ...................................................................................................................

2-25

Valve Clearance Inspection ..............................................................................................

2-25

Valve Clearance Adjustment.............................................................................................

2-26

Air Suction System ..............................................................................................................

2-29

Air Suction System Damage Inspection............................................................................

2-29

Clutch...................................................................................................................................

2-29

Clutch Operation Inspection .............................................................................................

2-29

Wheels/Tires........................................................................................................................

2-30

Air Pressure Inspection.....................................................................................................

2-30

Wheel/Tire Damage Inspection.........................................................................................

2-30

Tire Tread Wear Inspection ..............................................................................................

2-30

Wheel Bearing Damage Inspection ..................................................................................

2-31

Drive Train ...........................................................................................................................

2-32

Drive Chain Lubrication Condition Inspection ...................................................................

2-32

Drive Chain Slack Inspection ............................................................................................

2-32

Drive Chain Slack Adjustment ..........................................................................................

2-33

Wheel Alignment Inspection .............................................................................................

2-34

Drive Chain Wear Inspection ............................................................................................

2-34

Chain Guide Wear Inspection ...........................................................................................

2-35

Brake System ......................................................................................................................

2-35

Brake Fluid Leak (Brake Hose and Pipe) Inspection ........................................................

2-35

Brake Hose Damage and Installation Condition Inspection..............................................

2-35

Brake Operation Inspection ..............................................................................................

2-35

Brake Fluid Level Inspection.............................................................................................

2-36

Brake Pad Wear Inspection ..............................................................................................

2-36

Brake Light Switch Operation Inspection ..........................................................................

2-36

Suspensions ........................................................................................................................

2-37

Front Forks/Rear Shock Absorber Operation Inspection ..................................................

2-37

Front Fork Oil Leak Inspection..........................................................................................

2-38

2-2 PERIODIC MAINTENANCE

Rear Shock Absorber Oil Leak Inspection ........................................................................

2-38

Rocker Arm Operation Inspection.....................................................................................

2-38

Tie-Rod Operation Inspection ...........................................................................................

2-38

Steering System ..................................................................................................................

2-39

Steering Play Inspection ...................................................................................................

2-39

Steering Play Adjustment..................................................................................................

2-39

Steering Stem Bearing Lubrication ...................................................................................

2-40

Electrical System .................................................................................................................

2-40

Spark Plug Clean and Gap Inspection..............................................................................

2-40

Lights and Switches Operation Inspection........................................................................

2-42

Headlight Aiming Inspection .............................................................................................

2-44

Side Stand Switch Operation Inspection...........................................................................

2-45

Engine Stop Switch Operation Inspection.........................................................................

2-46

Others..................................................................................................................................

2-47

Chassis Parts Lubrication ................................................................................................

2-47

Bolts, Nuts and Fasteners Tightness Inspection...............................................................

2-48

Replacement Parts ..............................................................................................................

2-50

Air Cleaner Element Replacement....................................................................................

2-50

Fuel Hose Replacement ...................................................................................................

2-50

Coolant Change ................................................................................................................

2-52

Radiator Hose and O-ring Replacement...........................................................................

2-54

Engine Oil Change............................................................................................................

2-55

Oil Filter Replacement ......................................................................................................

2-55

Brake Hose and Pipe Replacement..................................................................................

2-56

Brake Fluid Change ..........................................................................................................

2-56

Master Cylinder Rubber Parts Replacement ....................................................................

2-58

Caliper Rubber Parts Replacement ..................................................................................

2-59

Spark Plug Replacement ..................................................................................................

2-62

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart (United States, Canada Model)

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

 

* ODOMETER READING

 

 

comes

 

 

 

 

 

 

× 1 000 km

See

 

 

 

 

 

 

 

 

first

 

 

 

 

 

 

(× 1 000 mile)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Page

 

 

 

 

1

6

12

18

24

 

30

36

 

 

 

 

 

 

INSPECTION

Every

(0.6)

(4)

(7.5)

(12)

(15)

 

(20)

(24)

 

Fuel System

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Throttle control system (play, smooth

year

 

 

 

 

 

2-18

return, no drag)-inspect

 

 

 

 

 

Engine vacuum synchronization-inspect

 

 

 

 

 

 

 

 

 

 

2-18

Idle speed-inspect

 

 

 

 

 

 

 

 

2-22

Fuel leak (fuel hose and pipe)-inspect

year

 

 

 

 

 

2-22

Fuel hose and pipe damage-inspect

year

 

 

 

 

 

2-22

Fuel hose and pipe installation

year

 

 

 

 

 

2-22

condition-inspect

 

 

 

 

 

Evaporative Emission Control System

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(CAL)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Evaporative emission control system

 

 

 

 

 

2-23

function-inspect

 

 

 

 

 

Cooling System

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Coolant level-inspect

 

 

 

 

 

 

 

 

2-24

Coolant leak (radiator hose and

year

 

 

 

 

 

2-24

pipe)-inspect

 

 

 

 

 

Radiator hose damage-inspect

year

 

 

 

 

 

2-24

Radiator hose installation condition

year

 

 

 

 

 

2-24

-inspect

 

 

 

 

 

Engine Top End

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Valve clearance-inspect

 

 

 

 

 

 

 

 

 

 

 

 

2-25

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Air Suction System

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Air suction system damage-inspect

 

 

 

 

 

 

 

 

 

 

2-29

Clutch

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Clutch operation (play, disengagement,

 

 

 

 

 

 

 

 

2-29

engagement)-inspect

 

 

 

 

 

 

 

 

Wheels and Tires

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Tire air pressure-inspect

year

 

 

 

 

 

 

 

2-30

Wheel/tire damage-inspect

 

 

 

 

 

 

 

 

 

 

2-30

Tire tread wear, abnormal wear-inspect

 

 

 

 

 

 

 

 

 

 

2-30

Wheel bearing damage-inspect

year

 

 

 

 

 

 

 

2-31

Drive Train

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Drive chain lubrication condition-inspect #

 

 

 

 

Every 600 km (400 mile)

 

 

2-32

Drive chain slack-inspect #

 

 

 

Every 1 000 km (600 mile)

 

 

2-32

Drive chain wear-inspect #

 

 

 

 

 

 

 

 

 

 

2-34

Drive chain guide wear-inspect

 

 

 

 

 

 

 

 

 

 

2-35

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart (United States, Canada Model)

FREQUENCY

Whichever

 

* ODOMETER READING

 

 

comes

 

 

 

 

 

 

× 1 000 km

See

 

 

 

 

 

 

 

 

first

 

 

 

 

 

 

(× 1 000 mile)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Page

 

 

 

 

1

6

12

18

24

30

36

 

 

 

 

 

INSPECTION

Every

(0.6)

(4)

(7.5)

(12)

(15)

(20)

(24)

 

Brake System

 

 

 

 

 

 

 

 

 

 

 

 

 

Brake fluid leak (brake hose and

year

 

2-35

pipe)-inspect

 

Brake hose and pipe damage-inspect

year

 

2-35

Brake pad wear-inspect #

 

 

 

 

 

 

2-36

Brake hose installation condition-inspect

year

 

2-35

Brake fluid level-inspect

6 months

 

2-36

Brake operation (effectiveness, play, no

year

 

2-35

drag)-inspect

 

Brake light switch operation-inspect

 

 

 

 

2-36

Suspensions

 

 

 

 

 

 

 

 

 

 

 

 

 

Front forks/rear shock absorber operation

 

 

 

 

 

 

 

 

 

2-37

(damping and smooth stroke)-inspect

 

 

 

 

 

 

 

 

 

Front forks/rear shock absorber oil

year

 

 

 

 

 

 

2-38

leak-inspect

 

 

 

 

 

 

Rocker arm operation-inspect

 

 

 

 

 

 

 

 

 

2-38

Tie-Rods operation-inspect

 

 

 

 

 

 

 

 

 

2-38

Steering System

 

 

 

 

 

 

 

 

 

 

 

 

 

Steering play-inspect

year

 

 

 

 

2-39

Steering stem bearings-lubricate

2 years

 

 

 

 

 

 

 

 

2-40

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Electrical System

 

 

 

 

 

 

 

 

 

 

 

 

 

Spark plug condition – inspect

 

 

 

 

 

 

 

 

 

2-40

Lights and switches operation-inspect

year

 

 

 

 

 

 

2-42

Headlight aiming-inspect

year

 

 

 

 

 

 

2-44

Side stand switch operation-inspect

year

 

 

 

 

 

 

2-45

Engine stop switch operation-inspect

year

 

 

 

 

 

 

2-46

Others

 

 

 

 

 

 

 

 

 

 

 

 

 

Chassis parts-lubricate

year

 

 

 

 

 

 

2-47

Bolts and nuts tightness-inspect

 

 

 

 

 

 

 

2-48

*: For higher odometer readings, repeat at the frequency interval established here.

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.

CAL: California Model

PERIODIC MAINTENANCE 2-5

Periodic Maintenance Chart (United States, Canada Model)

Periodic Replacement Parts

FREQUENCY

Whichever

* ODOMETER READING

 

 

come

 

 

 

 

 

 

× 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 #

 

 

 

 

Every 18 000 km (12 000 mile)

2-50

Fuel hose

4 years

 

 

 

 

 

 

 

2-50

Coolant

3 years

 

 

 

 

 

 

 

2-52

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Radiator hose and O-ring

3 years

 

 

 

 

 

 

 

2-54

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Engine oil #

year

 

 

2-55

Oil filter

year

 

 

2-55

Brake hose and pipe

4 years

 

 

 

 

 

 

 

2-56

Brake fluid

2 years

 

 

 

 

 

 

2-56

Rubber parts of master cylinder and caliper

4 years

 

 

 

 

 

 

 

2-58,

 

 

 

 

 

 

 

2-59

 

 

 

 

 

 

 

 

 

 

 

Spark plug

 

 

 

 

 

 

 

2-62

*: For higher odometer readings, repeat at the frequency interval established here.

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.

2-6 PERIODIC MAINTENANCE

Periodic Maintenance Chart (Other than United States, Canada Model)

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

 

* ODOMETER READING

 

 

comes

 

 

 

 

 

 

 

× 1 000 km

See

 

 

 

 

 

 

 

 

 

first

 

 

 

 

 

 

 

(× 1 000 mile)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Page

 

 

 

 

 

1

6

12

18

24

30

36

 

 

 

 

 

 

INSPECTION

Every

 

(0.6)

(4)

(7.5)

(12)

(15)

(20)

(24)

 

Fuel System

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Throttle control system (play, smooth

year

 

 

 

 

 

2-18

return, no drag)-inspect

 

 

 

 

 

Engine vacuum synchronization-inspect

 

 

 

 

 

 

 

 

 

 

2-18

Idle speed-inspect

 

 

 

 

 

 

 

 

2-22

Fuel leak (fuel hose and pipe)-inspect

year

 

 

 

 

 

2-22

Fuel hose and pipe damage-inspect

year

 

 

 

 

 

2-22

Fuel hose and pipe installation

year

 

 

 

 

 

2-22

condition-inspect

 

 

 

 

 

Cooling System

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Coolant level-inspect

 

 

 

 

 

 

 

 

2-23

Coolant leak (radiator hose and

year

 

 

 

 

 

2-24

pipe)-inspect

 

 

 

 

 

Radiator hose damage-inspect

year

 

 

 

 

 

2-24

Radiator hose installation condition

year

 

 

 

 

 

2-24

-inspect

 

 

 

 

 

Engine Top End

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Valve clearance-inspect

 

 

 

Every 42 000 km (26 000 mile)

 

2-25

Air Suction System

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Air suction system damage-inspect

 

 

 

 

 

 

 

 

 

 

2-29

Clutch

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Clutch operation (play, disengagement,

 

 

 

 

 

 

 

 

2-29

engagement)-inspect

 

 

 

 

 

 

 

 

Wheels and Tires

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Tire air pressure-inspect

year

 

 

 

 

 

 

 

2-30

Wheel/tire damage-inspect

 

 

 

 

 

 

 

 

 

 

2-30

Tire tread wear, abnormal wear-inspect

 

 

 

 

 

 

 

 

 

 

2-30

Wheel bearing damage-inspect

year

 

 

 

 

 

 

 

2-31

Drive Train

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Drive chain lubrication condition-inspect

 

 

 

 

 

Every 600 km (400 mile)

 

 

2-32

#

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Drive chain slack-inspect #

 

 

 

 

Every 1 000 km (600 mile)

 

 

2-32

Drive chain wear-inspect #

 

 

 

 

 

 

 

 

 

 

2-34

Drive chain guide wear-inspect

 

 

 

 

 

 

 

 

 

 

2-35

Brake System

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Brake fluid leak (brake hose and

year

 

 

2-35

pipe)-inspect

 

 

PERIODIC MAINTENANCE 2-7

Periodic Maintenance Chart (Other than United States, Canada Model)

FREQUENCY

Whichever

 

* ODOMETER READING

 

 

comes

 

 

 

 

 

× 1 000 km

See

 

 

 

 

 

 

 

first

 

 

 

 

 

(× 1 000 mile)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Page

 

 

 

 

 

1

6

12

18

24

30

36

 

 

 

 

 

 

INSPECTION

Every

 

(0.6)

(4)

(7.5)

(12)

(15)

(20)

(24)

 

Brake hose and pipe damage-inspect

year

 

2-35

Brake pad wear-inspect #

 

 

 

 

 

 

2-36

Brake hose installation condition-inspect

year

 

2-35

Brake fluid level-inspect

6 months

 

2-36

Brake operation (effectiveness, play, no

year

 

2-35

drag)-inspect

 

Brake light switch operation-inspect

 

 

 

 

2-36

Suspensions

 

 

 

 

 

 

 

 

 

 

 

 

 

Front forks/rear shock absorber

 

 

 

 

 

 

 

 

 

2-37

operation (damping and smooth

 

 

 

 

 

 

 

 

 

stroke)-inspect

 

 

 

 

 

 

 

 

 

 

 

 

 

Front forks/rear shock absorber oil

year

 

 

 

 

 

 

2-38

leak-inspect

 

 

 

 

 

 

Rocker arm operation-inspect

 

 

 

 

 

 

 

 

 

2-38

Tie-Rods operation-inspect

 

 

 

 

 

 

 

 

 

2-38

Steering System

 

 

 

 

 

 

 

 

 

 

 

 

 

Steering play-inspect

year

 

 

 

 

2-39

Steering stem bearings-lubricate

2 years

 

 

 

 

 

 

 

 

2-40

 

 

 

 

 

 

 

 

 

 

 

 

 

Electrical System

 

 

 

 

 

 

 

 

 

 

 

 

 

Spark plug condition – inspect

 

 

 

 

 

 

 

 

 

2-40

Lights and switches operation-inspect

year

 

 

 

 

 

 

2-42

Headlight aiming-inspect

year

 

 

 

 

 

 

2-44

Side stand switch operation-inspect

year

 

 

 

 

 

 

2-45

Engine stop switch operation-inspect

year

 

 

 

 

 

 

2-46

Others

 

 

 

 

 

 

 

 

 

 

 

 

 

Chassis parts-lubricate

year

 

 

 

 

 

 

2-47

Bolts and nuts tightness-inspect

 

 

 

 

 

 

 

2-48

*: For higher odometer readings, repeat at the frequency interval established here.

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.

2-8 PERIODIC MAINTENANCE

Periodic Maintenance Chart (Other than United States, Canada Model)

Periodic Replacement Parts

FREQUENCY

Whichever

 

 

* ODOMETER READING

 

 

come

 

 

 

 

 

× 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 #

 

 

 

 

Every 18 000 km (12 000 mile)

2-50

Fuel hose

4 years

 

 

 

 

 

 

 

2-50

Coolant

3 years

 

 

 

 

 

 

 

2-52

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Radiator hose and O-ring

3 years

 

 

 

 

 

 

 

2-54

 

 

 

 

 

 

 

 

Engine oil #

year

 

 

2-55

Oil filter

year

 

 

2-55

Brake hose and pipe

4 years

 

 

 

 

 

 

 

2-56

Brake fluid

2 years

 

 

 

 

 

 

2-56

Rubber parts of master cylinder and caliper

4 years

 

 

 

 

 

 

 

2-58,

 

 

 

 

 

 

 

2-59

 

 

 

 

 

 

 

 

 

 

 

Spark plug

 

 

 

 

 

 

 

2-62

*: For higher odometer readings, repeat at the frequency interval established here.

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.

PERIODIC MAINTENANCE 2-9

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.

G:Apply grease to the threads.

L:Apply a non-permanent locking agent to the threads. MO: Apply molybdenum disulfide grease oil solution.

R:Replacement Parts

S:Tighten the fasteners following the specified sequence. SI: Apply silicone grease.

SS:Apply silicone sealant.

Fastener

 

Torque

 

Remarks

N·m

kgf·m

ft·lb

 

 

Fuel System

 

 

 

 

Air Cleaner Housing Clamp Bolts

2.0

0.20

17 in·lb

 

Air Cleaner Housing Mounting Bolt

6.9

0.70

61 in·lb

 

Air Inlet Duct Mounting Bolts

6.9

0.70

61 in·lb

L

Canister Bracket Mounting Bolt (M6)

6.9

0.70

61 in·lb

 

Canister Bracket Mounting Bolt (M5)

0.4

0.04

4 in·lb

 

Camshaft Position Sensor Bolt

12

1.2

104 in·lb

 

Crankshaft Sensor Bolts

5.9

0.60

52 in·lb

 

Delivery Pipe Mounting Screws (Nozzle Assy)

3.4

0.35

30 in·lb

 

Delivery Pipe Mounting Screws (Throttle Body)

3.4

0.35

30 in·lb

 

Exhaust Butterfly Valve Actuator Mounting Bolts

6.9

0.70

61 in·lb

 

Exhaust Butterfly Valve Actuator Pulley Bolt

4.9

0.50

43 in·lb

 

Fuel Hose Mounting Screw

4.9

0.50

43 in·lb

 

Fuel Pump Bolts

9.8

1.0

87 in·lb

L, S

Nozzle Assy Mounting Bolts

6.9

0.70

61 in·lb

 

Separator Bracket Mounting Bolt

0.8

0.08

7 in·lb

 

Throttle Body Assembly Holder Clamp Bolts

3.0

0.30

27 in·lb

 

Throttle Body Holder Bolts

12

1.2

104 in·lb

L

Throttle Cable Holder Bolt

3.9

0.40

35 in·lb

 

Vehicle-down Sensor Bolts

5.9

0.60

52 in·lb

 

Water Temperature Sensor

25

2.5

18

SS

Cooling System

 

 

 

 

Coolant By-pass Fitting Bolt

8.8

0.90

78 in·lb

L

Coolant Drain Bolt (Cylinder)

9.8

1.0

87 in·lb

 

Coolant Drain Bolt (Water Pump)

8.8

0.90

78 in·lb

 

Coolant Reserve Tank Mounting Bolts

6.9

0.70

61 in·lb

 

Impeller Bolt

9.8

1.0

87 in·lb

 

Oil Cooler Mounting Bolts

12

1.2

104 in·lb

S

Radiator Bracket Mounting Bolt

6.9

0.70

61 in·lb

 

Radiator Lower Bolt

6.9

 

61 in·lb

 

0.70

 

Radiator Upper Bolt

12

1.2

104 in·lb

 

Thermostat Housing Cover Bolts

5.9

0.60

52 in·lb

 

Water Hose Clamp Screws

2.0

0.20

17 in·lb

 

2-10 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

 

Torque

 

Remarks

N·m

kgf·m

ft·lb

 

 

Water Hose Fitting Bolts

12

1.2

104 in·lb

 

Water Pump Cover Bolts

12

1.2

104 in·lb

L

Water Temperature Sensor

25

2.5

18

SS

Engine Top End

 

 

 

 

Air Suction Valve Cover Bolts

12

1.2

104 in·lb

L

Camshaft Cap Bolts

12

1.2

104 in·lb

S

Camshaft Chain Tensioner Cap Bolt

20

2.0

15

 

Camshaft Chain Tensioner Mounting Bolts

11

1.1

97 in·lb

 

Cam Sprocket Mounting Bolts

15

1.5

11

L

Coolant Drain Bolt (Cylinder)

9.8

1.0

87 in·lb

 

Crankshaft Sensor Cover Bolts

9.8

1.0

87 in·lb

L (1)

Cylinder Head Bolts (M9)

39

4.0

29

MO, S

Cylinder Head Bolts (M6)

12

1.2

104 in·lb

S

Cylinder Head Cover Bolts

9.8

1.0

87 in·lb

 

Exhaust Butterfly Valve Actuator Mounting Bolts

6.9

0.70

61 in·lb

 

Exhaust Butterfly Valve Actuator Pulley Bolt

4.9

0.50

43 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 Bolt

6.9

0.70

61 in·lb

 

Exhaust Pipe Clamp Bolt

17

1.7

12

 

Exhaust Pipe Manifold Holder Nuts

17

1.7

12

 

Exhaust Pipe Mounting Bolt

25

2.5

18

 

Front Camshaft Chain Guide Bolt (Lower)

12

1.2

104 in·lb

 

Front Camshaft Chain Guide Bolt (Upper)

25

2.5

18

 

Muffler Body Clamp Bolt

17

1.7

12

 

Muffler Body Mounting Bolts

25

2.5

18

 

Muffler Rear Cover Bolts

6.9

0.70

61 in·lb

 

Muffler Upper Cover Bolts

6.9

0.70

61 in·lb

 

Rear Camshaft Chain Guide Bolt

25

2.5

18

 

Spark Plugs

13

1.3

113 in·lb

 

Throttle Body Assy Holder Clamp Bolts

2.9

0.30

26 in·lb

 

Throttle Body Holder Bolts

12

1.2

104 in·lb

L

Water Passage Plug (Left)

20

2.0

15

L

Water Passage Plugs (Upper)

20

2.0

15

L

Clutch

 

 

 

 

Clutch Cover Bolt (M6, L = 50 mm)

12

1.2

104 in·lb

 

Clutch Cover Bolt (M6, L = 40 mm)

12

1.2

104 in·lb

L (1)

Clutch Cover Bolts (M6, L = 30 mm)

12

1.2

104 in·lb

L (1)

Clutch Hub Nut

135

14

100

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

1.5

0.15

13 in·lb

 

Sub Clutch Hub Bolts

25

2.5

18

L

PERIODIC MAINTENANCE 2-11

Torque and Locking Agent

Fastener

 

Torque

 

Remarks

N·m

kgf·m

ft·lb

 

 

Engine Lubrication System

 

 

 

 

Coolant Drain Bolt (Water Pump)

8.8

0.90

78 in·lb

 

Engine Oil Drain Bolt

29

3.0

22

 

Impeller Bolt

9.8

1.0

87 in·lb

 

Oil Cooler Mounting Bolts

12

1.2

104 in·lb

S

Oil Filter

31

3.2

23

EO, R

Oil Filter Mounting Bolt

25

2.5

18

L

Oil Jet Nozzle Bolts

6.9

0.70

61 in·lb

L

Oil Pan Bolts

9.8

1.0

87 in·lb

 

Oil Pan Clamp Bolt

9.8

1.0

87 in·lb

 

Oil Passage Plug (Left Side)

20

2.0

15

L

Oil Passage Plug (Right Side)

15

1.5

11

 

Oil Pipe Bolts

12

1.2

104 in·lb

 

Oil Pressure Relief Valve

15

1.5

11

L

Oil Pressure Switch

15

1.5

11

SS

Oil Pressure Switch Terminal Bolt

1.5

0.15

13 in·lb

 

Water Hose Clamp Screws

2.0

0.20

17 in·lb

 

Water Pump Cover Bolts

12

1.2

104 in·lb

L

Engine Removal/Installation

 

 

 

 

Adjusting Collar Locknut

49

5.0

36

S

Lower Engine Mounting Bolt

10

1.0

87 in·lb

S

Lower Engine Mounting Nut

44

4.5

33

S

Middle Engine Mounting Bolt

10

1.0

87 in·lb

S

Middle Engine Mounting Nut

44

4.5

33

S

Upper Engine Mounting Bolts

44

4.5

33

S

Crankshaft/Transmission

 

 

 

 

Breather Plate Bolts

5.9

0.60

52 in·lb

L

Connecting Rod Big End Nuts

see the text

Crankcase Bolts (M8)

31

3.2

23

MO, S

Crankcase Bolts (M7, L = 38 mm)

27

2.8

20

S

Crankcase Bolt (M7, L = 70 mm)

20

2.0

14

S

Crankcase Bolts (M6, L = 65 mm)

12

1.2

104 in·lb

S

Crankcase Bolts (M6, L = 50 mm)

12

1.2

104 in·lb

S

Crankcase Bolts (M6, L = 38 mm)

12

1.2

104 in·lb

S

Crankcase Bolt (M6, L = 95 mm)

12

1.2

104 in·lb

S

Crankcase Bolt (M6, L = 85 mm)

12

1.2

104 in·lb

S

Crankcase Bolt (M6, L = 35 mm)

12

1.2

104 in·lb

S

Neutral Switch

15

1.5

11

L

Gear Positioning Lever Bolt

12

1.2

104 in·lb

 

Harness Clamp Bolt

8.8

0.90

78 in·lb

L

Oil Passage Plug (Left Side)

20

2.0

15

L

Oil Passage Plug (Right Side)

15

1.5

11

 

Oil Pressure Switch

15

1.5

11

SS

2-12 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

 

Torque

 

Remarks

N·m

kgf·m

ft·lb

 

 

Oil Pressure Switch Terminal Bolt

1.5

0.15

13 in·lb

 

Plate Screws

5.9

0.60

52 in·lb

L

Shift Drum Bearing Holder Bolts

12

1.2

104 in·lb

L

Shift Drum Cam Holder Bolt

12

1.2

104 in·lb

L

Shift Lever Bolt

6.9

0.70

61 in·lb

 

Shift Pedal Mounting Bolt

25

2.5

18

 

Shift Shaft Return Spring Pin

28

2.9

21

L

Tie-Rod Locknuts

6.9

0.70

61 in·lb

 

Wheels/Tires

 

 

 

 

Front Axle Clamp Bolts

20

2.0

15

AL

Front Axle Nut

127

13

94

 

Rear Axle Nut

127

13

94

 

Final Drive

 

 

 

 

Engine Sprocket Cover Bolts

6.9

0.70

61 in·lb

 

Engine Sprocket Nut

125

13

92

MO

Rear Axle Nut

127

13

94

 

Rear Sprocket Nuts

59

6.0

43

 

Brakes

 

 

 

 

Bleed Valves

7.8

0.80

69 in·lb

 

Brake Hose Banjo Bolts

34

 

 

 

3.5

25

 

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

8.8

0.90

78

 

Front Brake Light Switch Screw

1.2

0.12

10 in·lb

 

Front Brake Reservoir Cap Stopper Screw

1.2

0.12

10 in·lb

 

Front Brake Disc Mounting Bolts

27

2.8

20

L

Front Brake Pad Pins

15

1.5

11

 

Front Caliper Assembly Bolts

22

2.2

16

 

Front Caliper Mounting Bolts

34

3.5

25

 

Front Master Cylinder Bleed Valve

5.9

0.60

52 in·lb

 

Front Master Cylinder Clamp Bolts

8.8

0.90

78 in·lb

S

Rear Brake Disc Mounting Bolts

27

2.8

20

L

Rear Caliper Mounting Bolts

25

2.5

18

 

Rear Master Cylinder Mounting Bolts

25

2.5

18

 

Rear Master Cylinder Push Rod Locknut

18

1.8

13

 

Suspension

 

 

 

 

Front Axle Clamp Bolts

20

2.0

15

AL

Front Fork Bottom Allen Bolts

35

3.5

26

L

Front Fork Clamp Bolts (Lower)

25

2.5

18

AL

Front Fork Clamp Bolts (Upper)

20

2.0

15

 

Front Fork Top Plugs

35

3.5

26

 

Piston Rod Nuts

 

 

 

 

20

2.0

15

 

Rear Shock Absorber Bracket Nut

59

6.0

43

 

PERIODIC MAINTENANCE 2-13

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 Adjusting Collar

20

2.0

15

 

Swingarm Pivot Adjusting Collar Locknut

98

10

72

 

Swingarm Pivot Shaft Nut

108

11

81

 

Tie-Rod Nuts

59

6.0

43

 

Uni-Trak Rocker Arm Nut

34

3.5

25

 

Steering

 

 

 

 

Front Fork Clamp Bolts (Lower)

25

2.5

18

AL

Front Fork Clamp Bolts (Upper)

20

2.0

15

 

Handlebar Bolts

25

2.5

18

 

Handlebar Position Bolts

9.8

1.0

87 in·lb

L

Steering Stem Head Nut

78

8.0

58

 

Steering Stem Nut

20

2.0

15

 

Switch Housing Screws

3.5

0.36

31 in·lb

 

Frame

 

 

 

 

Air Inlet Duct Mounting Bolts

6.9

0.70

61

L

Front Fender Mounting Bolts

3.9

 

35 in·lb

 

0.40

 

Front Footpeg Bracket Bolts

25

2.5

18

 

Rear Footpeg Bracket Bolts

25

2.5

18

 

Rear Frame Bolts

59

6.0

44

L (2)

Side Stand Bolt

44

4.5

32

G

Side Stand Bracket Bolts

49

5.0

36

L

Side Stand Switch Bolt

8.8

0.90

78 in·lb

L

Side Stand Switch Bracket Bolt

3.9

0.40

35 in·lb

L

Windshield Mounting Bolts

 

 

4 in·lb

 

0.4

0.04

 

Electrical System

 

 

 

 

Alternator Cover Bolts

12

1.2

104 in·lb

 

Alternator Lead Holding Plate Bolts

6.9

0.70

61 in·lb

L

Alternator Rotor Bolt

110

11

81

 

Camshaft Position Sensor Bolt

12

1.2

104 in·lb

 

Crankshaft Sensor Bolts

5.9

0.60

52 in·lb

 

Crankshaft Sensor Cover Bolts

9.8

1.0

87 in·lb

L (1)

Engine Ground Lead Terminal Bolt

9.8

1.0

87 in·lb

 

Front Brake Light Switch Screw

1.2

0.12

10 in·lb

 

Front Turn Signal Light Lens Screws

1.0

0.10

9 in·lb

 

Front Turn Signal Light Mounting Screws

1.2

0.12

10 in·lb

 

Headlight Mounting Screws

1.2

0.12

10 in·lb

 

Licence Light Assembly Screws

0.9

0.09

8 in·lb

 

Licence Light Mounting Screws

1.2

0.12

10 in·lb

 

Meter Mounting Screws

1.2

0.12

10 in·lb

 

Neutral Switch

15

1.5

11

L

Rear Turn Signal Light Lens Screws

1.0

0.10

9 in·lb

 

2-14 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

 

Torque

 

 

Remarks

N·m

kgf·m

ft·lb

 

 

Rear Turn Signal Light Mounting Screws

1.2

0.12

10 in·lb

 

Regulator/Rectifier Bolts

6.9

0.70

61

in·lb

 

Side Stand Switch Bolt

8.8

0.90

78 in·lb

L

Side Stand Switch Bracket Bolt

3.9

0.40

35 in·lb

L

Spark Plugs

13

1.3

115 in·lb

 

Speed Sensor Bolt

12

1.2

104 in·lb

 

Stator Coil Bolts

12

1.2

104 in·lb

L

Starter Motor Cable Terminal Bolt

2.7

0.28

24

in·lb

 

Starter Motor Clutch Bolts

34

3.5

25

L

Starter Motor Mounting Bolts

11

1.1

97

in·lb

 

Starter Relay Cable Terminal Bolts

3.9

0.40

35

in·lb

 

Switch Housing Screws

3.5

0.36

31 in·lb

 

Tail/Brake Light Mounting Screws

4.0

0.40

35 in·lb

 

Timing Rotor Bolt

45

 

 

 

4.5

33

 

Vehicle-down Sensor Bolts

5.9

0.60

52 in·lb

 

Water Temperature Sensor

25

2.5

18

SS

The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners

Threads

 

 

 

Torque

 

 

 

Diameter (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

 

14 19

1.4 1.9

10

 

13.5

8

 

10

25

 

34

2.6

 

3.5

19

 

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

23.0

 

33.0

165

 

240

PERIODIC MAINTENANCE 2-15

Specifications

Item

 

Standard

Service Limit

Fuel System

 

 

 

 

Throttle Grip Free Play

2 3 mm (0.08 0.12 in.)

 

– – –

Idle Speed

1 300 ±50 r/min (rpm)

 

– – –

Throttle Body Vacuum

27.3 ±1.3 kPa (205 ±10 mmHg) at idle speed

– – –

Air Cleaner Element

Viscous paper element

 

– – –

Cooling System

 

 

 

 

Coolant:

 

 

 

 

Type (Recommended)

Permanent type antifreeze

– – –

Color

Green

 

 

– – –

Mixed Ratio

Soft water 50%, coolant 50%

– – –

Freezing Point

–35°C (–31°F)

 

– – –

Total Amount

2.6 L (2.7 US qt)

 

– – –

Engine Top End

 

 

 

 

Valve Clearance:

 

 

 

 

Exhaust

0.22

0.31 mm (0.0087

0.0122 in.)

– – –

Inlet

0.11

0.19 mm (0.0043

0.0075 in.)

– – –

Clutch

 

 

 

 

Clutch Lever Free Play

2 3 mm (0.08 0.12 in.)

 

– – –

Engine Lubrication System

 

 

 

 

Engine Oil:

 

 

 

 

Type

API SE, SF or SG

 

– – –

 

API SH or SJ with JASO MA

 

Viscosity

SAE 10W-40

 

– – –

Capacity

3.4 L (3.6 US qt) (when filter is not removed)

– – –

 

3.6 L (3.8 US qt) (when filter is removed)

– – –

 

4.0 L (4.2 US qt) (when engine is completely dry)

– – –

Level

Between upper and lower level lines (Wait 2 3

– – –

 

minutes after idling or running)

 

Tires

 

 

 

 

Tread Depth:

 

 

 

 

Front

BRIDGESTONE: 3.6 mm (0.14 in.)

1 mm (0.04 in.),

 

 

 

 

(AT, CH, DE) 1.6

 

 

 

 

mm (0.06 in.)

Rear

BRIDGESTONE: 5.8 mm (0.23 in.)

Up to 130 km/h

 

 

 

 

(80 mph): 2 mm

 

 

 

 

(0.08 in.), Over

 

 

 

 

130 km/h (80

 

 

 

 

mph): 3 mm (0.12

 

 

 

 

in.)

Air Pressure (when Cold):

 

 

 

 

Front

Up to 180 kg (397 lb) load: 250 kPa (2.5 kgf/cm²,

– – –

 

36 psi)

 

 

Rear

Up to 180 kg (397 lb) load: 290 kPa (2.9 kgf/cm²,

– – –

 

42 psi)

 

 

 

 

 

 

 

2-16 PERIODIC MAINTENANCE

Specifications

Item

Standard

Service Limit

Final Drive

 

 

Drive Chain Slack

30 35 mm (1.2 1.4 in.)

– – –

Drive Chain Wear (20-link

317.5 318.2 mm (12.50 12.53 in.)

323 mm (12.7 in.)

Length)

 

 

Standard Chain:

 

 

Make

ENUMA

– – –

Type

EK520MVXL

– – –

Link

110 links

– – –

Brakes

 

 

Brake Fluid:

 

 

Grade

DOT4

– – –

Brake Pad Lining

 

 

 

 

Thickness:

 

 

Front

4.0 mm (0.16 in.)

1 mm (0.04 in.)

Rear

5.0 mm (0.20 in.)

1 mm (0.04 in.)

Brake Light Timing:

 

 

Front

Pulled ON

– – –

Rear

On after about 10 mm (0.39 in.) of pedal travel

– – –

Electrical System

 

 

Spark Plug Gap

0.7 0.8 mm (0.028 0.031 in.)

– – –

AT: Austria

 

 

CH: Switzerland

 

 

DE: Germany

 

 

US: United States

 

 

PERIODIC MAINTENANCE 2-17

Special Tools

Inside Circlip Pliers: 57001-143

Pilot Screw Adjuster, C: 57001-1292

Steering Stem Nut Wrench: 57001-1100

Extension Tube: 57001-1578

 

 

 

Jack:

 

Jack Attachment:

57001-1238

57001-1608

 

 

 

Oil Filter Wrench: 57001-1249

2-18 PERIODIC MAINTENANCE

Maintenance Procedure

Fuel System (DFI)
Throttle Control System Inspection

Check the throttle grip free play [A].

If the free play is incorrect, adjust the throttle cables.

Throttle Grip Free Play

Standard: 2 3 mm (0.08 0.12 in.)

Check that the throttle grip [B] moves smoothly from full open to close, and the throttle closes quickly and completely by the return spring in all steering positions.

If the throttle grip does not return properly, check the throttle cables routing, grip free play, and cable damage. Then lubricate the throttle cable.

Run the engine at the idle speed, and turn the handlebar all the way to the right and left to ensure that the idle speed does not change.

If the idle speed increases, check the throttle cable free play and the cable routing.

If necessary, adjust the throttle cable as follows.

Loosen the locknuts [A] [B].

Screw both throttle cable adjusters [C] [D] to give the throttle grip plenty of play.

Turn the decelerator cable adjuster [C] until 2 3 mm (0.08 0.12 in.) of throttle grip play is obtained.

Tighten the locknut [A].

Turn the accelerator cable adjuster [D] until 2 3 mm (0.08 0.12 in.) of throttle grip play is obtained.

Tighten the locknut [B].

If the free play cannot be adjusted with the adjusters, replace the cable.

Engine Vacuum Synchronization Inspection

NOTE

These procedures are explained on the assumption that the inlet and exhaust systems of the engine are in good condition.

Situate the motorcycle so that it is vertical.

Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter).

Pull off the vacuum hoses and the rubber cap(s) from the right fitting of each throttle body.

Pull off the vacuum switch valve hose (thick) [A] from the air cleaner housing [B].

CAUTION

Do not remove the inlet air pressure sensor hoses on the left fitting of each throttle body.

PERIODIC MAINTENANCE 2-19

Maintenance Procedure

Connect a commercially available vacuum gauge [A] to these right fittings of the throttle body as shown.

Front [B]

Connect a highly accurate tachometer to one of the stick coil primary leads.

Plug:Vacuum Switch Valve Hose (Thick) and its Air Cleaner Housing Hole

Vacuum Switch Valve Vacuum Hose Ends [C]

Install:

Air Cleaner Housing [A] (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter)

Tachometer [B] Vacuum Gauge [C]

Connect:Extension Tube [D]

Special Tool - Extension Tube: 57001-1578

Start the engine and warm it up thoroughly.

Check the idle speed.

Open and close the throttle.

If the idle speed is out of the specified range, adjust it.

CAUTION

Do not measure the idle speed by the tachometer of the meter unit.

While idling the engine, inspect the engine vacuum, using the vacuum gauge [B].

Engine Vacuum

Standard: 27.3 ±1.333 kPa (205 ±10 mmHg) at Idle Speed 1 300 ±50 r/min (rpm)

2-20 PERIODIC MAINTENANCE

Maintenance Procedure

If any vacuum is not within the specifications, first synchronize the balance of the left (#1, #2) and right (#3, #4) assemblies.

Example:

#1: 165 mmHg #2: 190 mmHg #3: 170 mmHg #4: 200 mmHg

With the engine at the correct idle speed, equalize the lower vacuum of #3 and #4 (example 170 mmHg) to the lower vacuum of #1 and #2 (example 165 mmHg) by turning the center adjusting screw [A].

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

Front [B]

NOTE

After adjustment, the final vacuum measurement between the lowest throttle valves may not be 165 mmHg (in this example). The goal is to have the lower two vacuums between the left (#1 and #2) and right (#3 and #4) banks be the same.

Open and close the throttle after each measurement and adjust the idle speed as necessary.

Once the throttle valves have been synchronized, inspect the main throttle sensor’s output voltage to ensure proper operation (procedure is at the end of this section).

If any one vacuum measurement is out of the standard measurement after left and right synchronization, turn in the bypass screws [A] until it seats fully but not tightly.

Front [B]

CAUTION

Do not over tighten them. They could be damaged, requiring replacement.

Turn out the bypass screw of the higher vacuum between #1 and #2 to the lower vacuum.

Turn out the bypass screw of the higher vacuum between #3 and #4 to the lower vacuum.

Open and close the throttle valves after each measurement and adjust the idle speed as necessary.

Inspect the vacuums as before.

If all vacuums are within the specification, finish the engine vacuum synchronization.

If any vacuum can not be adjusted within the specification, remove the bypass screws #1 #4 and clean them.

PERIODIC MAINTENANCE 2-21

Maintenance Procedure

Remove the bypass screw [A], spring [B], washer [C] and O-ring [D].

Check the bypass screw and its hole for carbon deposits. If any carbon accumulates, wipe the carbon off the bypass screw and the hole, using a cotton pad penetrated with a high-flash point solvent.

Replace the O-ring with a new one.

Check the tapered portion [E] of the bypass screw for wear or damage.

If the bypass screw is worn or damaged, replace it.

Turn in the bypass screw until it seats fully but not tightly.

Repeat the same procedure for other bypass screws.

Repeat the synchronization.

If the vacuums are correct, check the output voltage of the main throttle sensor (see Output Voltage Inspection of the Main Throttle Sensor in the Fuel System (DFI) chapter).

Main Throttle Sensor Output Voltage

Connections to ECU

Meter (+) → Y/W lead (terminal 7)

Meter (–) → BR/BK lead (terminal 28)

Standard: 1.02 1.06 V DC (at idle throttle opening)

If the output voltage is out of the range, check the throttle input voltage (see Input Voltage Inspection of the Main Throttle Sensor in the Fuel System (DFI) chapter).

Remove the vacuum gauge hoses and install the vacuum hoses [A] and rubber caps [B] on the original position as shown.

Front [C]

Except California Model [D] California Model [E] Separator [F]

Canister [G]

2-22 PERIODIC MAINTENANCE

Maintenance Procedure

Idle Speed Inspection

Start the engine and warm it up thoroughly.

With[A]. the engine idling, turn the handlebar to both sides

If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed, or damaged. Be sure to correct any of these conditions before riding (see Cable, Wire, and Hose Routing section in the Appendix chapter).

WARNING

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

Check the idle speed.

If the idle speed is out of specified range, adjust it.

Idle Speed

Standard: 1 300 ±50 r/min (rpm)

Idle Speed Adjustment

Start the engine and warm it up thoroughly.

Turn the adjusting screw [A] until the idle speed is correct. Open and close the throttle a few times to make sure that the idle speed is within the specified range. Readjust if

necessary.

Fuel Hose Damage and Installation Condition Inspection

The motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak or the hose to burst. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) and check the fuel hose [A].

Replace the fuel hose if any fraying, cracks [B] or bulges

[C] are noticed.

Check that the hose joints are securely connected.

When installing the fuel hose, avoid sharp bending, kinking, flattening or twisting.

Replace the hose if it has been sharply bent or kinked.

PERIODIC MAINTENANCE 2-23

Maintenance Procedure

Evaporative Emission Control System (California Model)
Evaporative Emission Control System Inspection

Inspect the canister as follows. Remove:

Left Upper Inner Fairing (see Upper Inner Fairing Removal in the Frame chapter)

Remove the canister [A], and disconnect the hoses from the canister.

Visually inspect the canister for cracks or other damage.

If the canister has any cracks or bad damage, replace it with a new one.

NOTE

The canister is designed to work well through the motorcycle’s life without any maintenance if it is used under normal conditions.

Check the liquid/vapor separator as follows. Remove:

Left Center Fairing (see Center Fairing Removal in the Frame chapter)

Disconnect the hoses from the separator, and remove the separator [A] from the motorcycle left side.

Visually inspect the separator for cracks and other damage.

If the separator has any cracks or damage, replace it with a new one.

To prevent the gasoline from flowing into or out of the canister, hold the separator perpendicular to the ground.

Check the hoses of the evaporative emission control system as follows.

Check that the hoses are securely connected and clips are in position.

Replace any kinked, deteriorated or damaged hoses. Route the hoses according to Cable, Wire, and Hose

Routing section in the Appendix chapter.

When installing the hoses, avoid sharp bending, kinking, flattening or twisting, and route the hoses with a minimum of bending so that the emission flow will not be obstructed.

2-24 PERIODIC MAINTENANCE

Maintenance Procedure

Cooling System
Coolant Level Inspection

NOTE

Check the level when the engine is cold (room or ambient temperature).

Check the coolant level in the reserve tank [A] with the motorcycle held perpendicular (Do not use the side stand).

If the coolant level is lower than the “L” level line [B], unscrew the reserve tank cap and add coolant to the “F” level line [C].

“L”: low “F”: full

CAUTION

For refilling, add the specified mixture of coolant and soft water. Adding water alone dilutes the coolant and degrades its anticorrosion properties. The diluted coolant can attack the aluminum engine parts. In an emergency, soft water alone can be added. But the diluted coolant must be returned to the correct mixture ratio within a few days.

If coolant must be added often or the reservoir tank has run completely dry, there is probably leakage in the cooling system. Check the system for leaks.

Coolant ruins painted surfaces. Immediately wash away any coolant that spills on the frame, engine, wheels or other painted parts.

Radiator Hose Damage and Installation Condition Inspection

The high pressure inside the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen.

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

Check that the hoses are securely connected and clamps are tightened correctly.

Torque - Radiator Hose Clamp Screws: 2.0 N·m (0.20 kgf·m, 17 in·lb)

PERIODIC MAINTENANCE 2-25

Maintenance Procedure

Engine Top End
Valve Clearance Inspection

NOTE

Valve clearance must be checked and adjusted when the engine is cold (at room temperature).

Remove:

Lower Fairings (see Lower Fairing Removal in the Frame chapter)

Crankshaft Sensor Cover (see Crankshaft Sensor Removal in the Electrical System chapter)

Cylinder Head Cover (see Cylinder Head Cover Removal in the Engine Top End chapter)

Position the crankshaft at #1, 4 piston TDC. TDC Mark [A] for #1, 4 Pistons

Timing Mark [B] (Crankcase Halves Mating Surface)

Using a thickness gauge [A], measure the valve clearance between the cam and the valve lifter.

Valve Clearance

Standard:

Exhaust 0.22 0.31 mm (0.0087 0.0122 in.)

Inlet

0.11 0.19 mm (0.0043 0.0075 in.)

NOTE

Thickness gauge is horizontally inserted on the valve lifter.

Appropriateness [A] Inadequacy [B] Thickness Gauge [C] Horizontally Inserts [D] Cam [E]

Valve Lifter [F]

Hits the Valve Lifter Ahead [G]

2-26 PERIODIC MAINTENANCE

Maintenance Procedure

When positioning #1 piston TDC at the end of the compression stroke.

Inlet Valve Clearance of #1 and #3 Cylinders Exhaust Valve Clearance of #1 and #2 Cylinders Measuring Valve [A]

When positioning #4 piston TDC at the end of the compression stroke.

Inlet Valve Clearance of #2 and #4 Cylinders Exhaust Valve Clearance of #3 and #4 Cylinders Measuring Valve [A]

If the valve clearance is not within the specified range, first record the clearance, and then adjust it.

Valve Clearance Adjustment

To change the valve clearance, remove the camshaft chain tensioner, camshafts and valve lifters (see appropriate chapters). Replace the shim with one of a different thickness.

NOTE

Mark and record the valve lifter and shim locations so they can be reinstalled in their original positions.

If there is no clearance, select a shim which is several sizes smaller and then measure the clearance.

To select a new shim which brings the valve clearance within the specified range, refer to the Valve Clearance Adjustment Charts.

Apply a thin coat of engine oil to the valve lifter surface and install the lifter.

Install the camshafts. Be sure to time the camshafts properly (see Camshaft Installation in the Engine Top End chapter).

Remeasure any valve clearance that was adjusted. Readjust if necessary.

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.

PERIODIC MAINTENANCE 2-27

Maintenance Procedure

VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE

1.Measure the clearance (when engine is cold).

2.Check present shim size.

3.Match clearance in vertical column with present shim size in horizontal column.

4.Install the shim specified where the lines intersect. This shim will give the proper clearance.

Example:

Present shim is 3.05 mm.

Measured clearance is 0.35 mm.

Replace 3.05 mm shim with 3.25 mm shim.

5.Remeasure the valve clearance and readjust if necessary.

2-28 PERIODIC MAINTENANCE

Maintenance Procedure

VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE

1.Measure the clearance (when engine is cold).

2.Check present shim size.

3.Match clearance in vertical column with present shim size in horizontal column.

4.Install the shim specified where the lines intersect. This shim will give the proper clearance.

Example:

Present shim is 3.10 mm.

Measured clearance is 0.40 mm.

Replace 3.10 mm shim with 3.20 mm shim.

5.Remeasure the valve clearance and readjust if necessary.

+ 547 hidden pages