Montesa COTA 4RT 2005 manual

Important
This motorcycle is designed and constructed as an operator-only model. The motorcycle load limit and seating configuration do not safety permit the carrying of a
passenger.
Read this manual carefully.
This manual should be considered as a permanent part of the motorcycle and should remain with the motorcycle when resold.
Safety Messages
Damage Prevention Messages
Your safety and the safety of others is very important. We have provided important
safety messages in this manual and on the COTA 4RT. Please read these messages
carefully.
You will also see other important messages that are preceded by the word
NOTICE.
This word means:
A safety message alerts you to potential hazards that could hurt you or others.
Each safety message is preceded by a safety alert symbol
and one of three
words, DANGER, WARNING, or CAUTION.
These mean:
Your COTA 4RT or other property can be damaged if you
don’t follow instructions.
The purpose of these messages is to help prevent damage to your COTA 4RT,
other property, or the environment.
! DANGER
You WILL be KILLED or SERIOUSLY HURT if you
don’t follow instructions.
! WARNING
You CAN be KILLED or SERIOUSLY HURT if you
don’t follow instructions.
! CAUTION
NOTICE
You CAN be HURT if you don’t follow instructions.
Each message tells you what the hazard is, what can happen and what you can do
to avoid or reduce injury.
MONTESA COTA 4RT
Owner’s Manual
All information in this publication is based on the latest product information available at the time of approval for printing.
MONTESA HONDA, S.A. reserves the right to make changes at any time without notice and without incurring any obligation.
No part of this publication may be reproduced without written permission.
Contents
1. Operating Instruction
Fuel
Coolant
Basic Operation
Operating Mode
Controls
1-1
1-1
1-1
1-2
1-3
2. Service Data
Specifications
Service Data
Torque Values
Tools
Lubrication & Seal Points
Cable & Harness Routing
2-1
2-2
2-5
2-7
2-8
2-11
3. Service And Maintenance
Maintenance Schedule
Pre-ride Inspection
Warming-up Inspection
Ride Inspection
After Ride Inspection
Replacement Parts
Fuel Line
Air Cleaner
Spark Plug
Valve Clearance
Engine Oil/Oil Filter
Engine Idle Speed
Transmission Oil
Coolant
Clutch System
Exhaust Pipe And Muffler
Drive Chain
Drive Chain Slider
Drive/Driven Sprockets
Brake Fluid
Brake Pad Wear
Brake System
Handlebar And Steering Head Bearings
Wheels And Tires
Front Suspension
Fork
3-1
3-1
3-2
3-2
3-2
3-2
3-3
3-3
3-4
3-4
3-6
3-8
3-8
3-9
3-10
3-10
3-11
3-11
3-12
3-13
3-14
3-14
3-15
3-15
3-16
3-16
Rear Suspension
Cleaning
Storage
3-17
3-18
3-18
4. Engine Servicing
Oil Pressure Relief Valve
Oil Pump
Fuel Line Inspection
Fuel Tank/Fuel Pump
Injector
Throttle Body
Water Seal And Bearing Replacement
Radiator Removal/Installation
Engine Removal/Installation
Cylinder Compression
Cylinder Head Cover/Camshaft Removal
Cylinder Head Removal
Cylinder Head Disassembly
Cylinder Head Inspection
Valve Guide Replacement
Valve Seat Inspection/Refacing
Cylinder Head Assembly
Cylinder/Piston
Cylinder Head Installation
Camshaft/Cylinder Head Cover Installation
Right Crankcase Cover
Clutch Slave Cylinder
Clutch
Kickstarter
Gearshift Linkage
Left Crankcase Cover
Flywheel
Crankcase Separation/Disassembly
Crankshaft/Transmission Inspection
Crankcase Bearing Replacement
Transmission Assembly
Crankcase Combination
4-1
4-1
4-4
4-6
4-9
4-10
4-12
4-14
4-15
4-17
4-17
4-20
4-22
4-23
4-24
4-25
4-28
4-29
4-34
4-35
4-37
4-38
4-40
4-43
4-44
4-46
4-49
4-51
4-53
4-54
4-55
4-56
5. Frame Servicing
Front Wheel
Fork
Steering Stem
Rear Wheel
5-1
5-3
5-12
5-15
Shock Absorber
Shock Linkage
Swingarm
Brake Pad Replacement
Front Brake Caliper
Rear Brake Caliper
Front Master Cylinder
Rear Master Cylinder
Brake Pedal
Clutch Master Cylinder
5-16
5-18
5-19
5-23
5-24
5-25
5-26
5-27
5-27
5-28
6. Electrical Servicing
Charging System Inspection
Ignition System Inspection
PGM-FI System Inspection
PGM-FI
PGM-FI Self-diagnosis Malfunction Indicator
Lamp (MIL) Failure Codes
Bank Angle Sensor Inspection
Engine Stop Switch Inspection
Cooling Fan System Inspection
Wiring Diagrams
6-1
6-3
6-5
6-6
6-7
6-8
6-9
6-9
6-11
To The New Owner
Importance Of Proper Preparation
By selecting a MONTESA COTA 4RT as your new
machine, you have placed yourself in a distinguished
family of owners and riders.
Proper pre-competition preparation and regular service
is essential to rider safety and the reliability of the
motorcycle. Any error or oversight made by the
technician during preparation or servicing can easily
result in faulty operation, damage to the machine, or
injury to the rider.
The COTA is a high performance trial motorcycle
utilizing the latest trial technology. This motorcycle is
intended for competition use by experienced riders only.
This new trialer was designed to be as competitive as
possible. But motorcycle trial is a physically demanding
sport that requires more than just a fine racing machine.
To do well, you must be in excellent physical condition
and be a skillful rider. For the best possible results, work
diligently on your physical conditioning and practice
frequently.
The purpose of this Manual is to help ensure that you
obtain the greatest possible satisfaction from your new
COTA trialer.
Parts Availability
Orders for the parts tend to be concentrated during the
season, so you need to plan your parts orders carefully.
To prevent delays in shipment, place orders on regularly
replaced and fast-wearing parts well ahead of the season
(see page 3-2).
How To Use This Manual
The purpose of this Owner’s Manual is to help ensure
that you obtain the greatest possible satisfaction from
your new COTA trialer; satisfaction with the performance
of the motorcycle, and through success in competition.
If you plan to do any service on your COTA, section 3
describes standard maintenance and sections 4 through
6 contain in information on repair, disassembly,
assembly and special tools.
Follow the Maintenance Schedule recommendation
(page 3-1) to ensure that your COTA is always in peak
operating condition.
Memo
1. Operating Instructions
(1)
(1)
(1)
(2)
(1) BREATHER HOSE (2) FUEL TANK CAP
(1) RADIATOR CAP
(1) KICKSTARTER PEDAL
Fuel
Coolant
Basic Operation
Gasoline: Premium unleaded gasoline (commercially
available unleaded; pump octane number 91
or higher)
Fuel tank capacity: 2.0 liter (0.53 US gal, 0.44 Imp gal)
The engine of COTA is a water-cooled type. In order to
provide adequate cooling, it is essential that the radiator
be filled with coolant up the proper level (See pag. 3-9).
Starting The Engine
Coolant: 50/50 Mixture of Coolant and Distilled Water
Disconnect the fuel tank breather hose clamp from the
clutch hose.
Turn the fuel tank cap counterclockwise, then remove the
cap.
! WARNING
Gasoline is highly flammable and is explosive.
You can be burned or seriously injured when
refueling.
• Stop engine and keep heat, sparks, and flame
away.
• Refuel only outdoors.
• Wipe up spills immediately.
Install the fuel tank cap by turning it clockwise.
Install the breather hose clamp onto the clutch hose.
! WARNING
Removing the radiator cap while the engine is hot
will allow the coolant to spray out, seriously scalding
you.
Always let the engine and radiator cool down before
removing the radiator cap.
NOTICE
When filling the coolant system, be sure to bleed air
completely. If not, the system cannot be sufficiently filled
and will cause overheating.
Your COTA exhaust contains poisonous carbon
monoxide gas. High levels of carbon monoxide can
collect rapidly in enclosed areas such as a garage. Do not
run the engine with the garage door closed. Even with
the door open, run the engine only long enough to move
your COTA out of the garage.
Cold Engine Starting
1. Shift the transmission into neutral.
2. With the throttle fully closed, operate the kickstarter.
Starting from the top of the kickstarter stroke, kick
through to the bottom with a rapid, continuous
motion.
3. After the engine starts, run it for a few minutes,
“blipping” the throttle, until it warms up enough to
idle.
NOTICE
Do not start the engine with the transmission into gear
while squeezing the clutch lever, so the motorcycle will
move forward.
1-1
Operating Instructions
(1)
(1) ENGINE STOP BUTTON
When you shift the transmission into gear, apply front
brake to prevent the motorcycle move forward.
Stopping The Engine
1. Shift the transmission into neutral.
2. Push the engine stop button until the engine stops
completely.
Break-In Procedure
New Motorcycle
Following proper break-in procedure helps ensure that
the most important and expensive components on your
new motorcycle will provide maximum performance and
service life. (Also follow proper break-in procedure for a
newly rebuilt engine.)
When riding a new motorcycle, operate the motorcycle
for the first 20 minutes using not more than half throttle
and shifting gears so that the engine does not lug:
Reconditioned Motorcycle
• After replacing the cylinder and crankshaft, operate
the motorcycle 20 minutes observing the same
cautions as for a new motorcycle.
• When the piston, piston ring, gears, etc. are replaced,
they must be broken in observing the first 30 minutes
using not more than half throttle and shifting gears so
that the engine does not lug:
1-2
Operating Instructions
(1)
(1)
(2)
(2)
(A)
(1)
(B)
(3)
(1) UPPER LEVEL LINE
(1) ADJUSTER (2) LOCK NUT
(1) DUST COVER (2) LOCK NUT (3) ADJUSTER
(A) DECREASE (B) INCREASE
Controls
Clutch Lever
Throttle Grip
Clutch
The clutch lever free play can be adjusted by turning the
adjuster.
Free play must be adjusted to provide 0.1 – 1.4 mm
(0.004 – 0.055 in) clearance between the end of the
adjuster and the clutch master cylinder piston.
To increase free play, turn the adjuster clockwise, then
tighten the lock nut securely.
If the clutch lever free play exceeds 30 mm (1.2 in) even
though the end of the adjuster and the clutch master
cylinder piston is adjusted to the minimum of 0.1 mm
(0.004 in), there is probably air in the clutch system and
it must be bled.
Throttle Grip Free Play
Standard throttle grip free play is approximately 3 mm
(0.12 in) of grip rotation.
Adjustment is made with the integral throttle cable
adjuster.
Slide the dust cover off from the integral cable adjuster.
Turning the adjuster in direction “A” will decrease free
play and turning it in direction “B” will increase free
play. Tighten the lock nut after adjustment.
Your COTA has a hydraulically actuated clutch. There are
no adjustments to perform but the clutch system must
be inspected periodically for fluid level and leakage.
If the control lever free play becomes excessive and the
motorcycle creeps or stalls when shifted into gear, or if
the clutch slips, causing acceleration to lag behind
engine speed, there is probably air in the clutch
hydraulic system and it must be bled out.
Operate the throttle grip to ensure that it functions
smoothly and returns completely in all steering position.
NOTICE
Do not adjust the end of the adjuster and the clutch
master cylinder piston below 0.1 mm (0.004 in).
1-3
Operating Instructions
(1)
(2)
(2)
(2)
(B)
(A)
(A)
(B)
(1)
(1)
(1)
(1) ADJUSTER (2) LOCK NUT
(1) LOCK NUT (2) ADJUSTING BOLT
(A) RAISE THE PEDAL HEIGHT
(B) LOWER THE PEDAL HEIGHT
(1) HANDLEBAR
Front Brake Lever
Brake Pedal Height
Handlebar Position, Width And Shape
The front brake lever free play can be adjusted by
turning the adjuster.
Free play must be adjusted to provide 0.1 – 1.4 mm
(0.004 – 0.055 in) clearance between the end of the
adjuster and the front brake master cylinder piston.
To increase free play, turn the adjuster clockwise, then
tighten the lock nut securely.
If the brake lever free play exceeds 30 mm (1.2 in) even
though the end of the adjuster and the front brake
master cylinder piston is adjusted to the minimum of 0.1
mm (0.004 in), there is probably air in the brake system
and it must be bled.
The brake pedal height can be adjusted to the rider’s
preference.
Position the handlebar so that gripping the bar and
operating the controls is comfortable while both seated
and standing, while riding straight ahead and turning.
NOTICE
Do not adjust the end of the adjuster and the front brake
master cylinder piston below 0.1 mm (0.004 in).
1-4
To adjust the rear brake pedal height:
1. Loosen the push rod lock nut and brake pedal
adjusting bolt lock nut. Then turn the both adjusting
bolts in direction “A” to raise the pedal, or in direction
“B” to lower it.
2. Tighten the lock nuts at the desired pedal height.
3. After adjustment, check the brake pedal free play at
the top of the pedal.
Make sure that the clearance between the front
adjusting bolt and frame is at least 1 mm (0.04 in).
Handlebar width can be trimmed with a hacksaw to
better your particular shoulder width and riding
preference. Think this though carefully and cut off just a
small amount at a time from both side equally. It is
obviously much easier to make the handlebar narrower
than it is to add material.
NOTICE
Chamfer the edges to remove burrs and other
irregularities or roughness after shaping.
An alternate handlebar shape. through varying rise or
rearward sweep dimensions, will provide further
adjustment to riding position and may better suit your
particular body size or riding style. Each of the
ergonomic dimensions of the motorcycle were
determined to suit the greatest possible number of riders
based on an average size rider.
2. Service Data
Specifications
Item
Specification
Dimensions
Overall length
Overall width
Overall height
Wheelbase
Seat height
Ground clearance
2,016 mm (79.4 in)
830 mm (32.7 in)
1,130 mm (44.5 in)
1,321 mm (52.0 in)
650 mm (25.6 in)
335 mm (13.2 in)
Frame
Type
Front suspension
Rear suspension
Front tire
Rear tire
Front brake, diameter
Rear brake, diameter
Fuel capacity
Caster angle
Trail length
Aluminum twin tube
Telescopic
Swingarm
MICHELIN TRIAL 2.75 – 21 TT
MICHELIN TRIAL 4.00 R18 TL (tubeless)
Single disc, 185 mm
Single disc, 150 mm
2.0 liter (0.53 US gal, 0.44 Imp. gal)
23˚ 00’
63 mm (2.5 in)
Engine
Type
Cylinder arrangement
Bore and stroke
Displacement
Compression ratio
Valve timing
Intake valve opens
Intake valve closes
Exhaust valve opens
Exhaust valve closes
Lubrication system
Starting system
Liquid cooled 4–stroke engine
Single cylinder, 3.5˚ inclined from vertical
76.5 x 54.2 mm (3.01 x 2.13 in)
249.1 cm3 (15.2 cu-in)
10.5 : 1
Item
Specification
Fuel System
Type
Identification number
Throttle bore
PGM-FI
GQP0
28 mm (1.1 in)
Drive Train
Clutch operating system
Clutch type
Transmission
Primary reduction
Gear ratio
1st
2nd
3rd
4th
5th
Final reduction
Gearshift pattern
Hydraulic operated
Wet, multi-plate
5 speed constant mesh
3.167 (57/18T)
2.800 (42/15T)
2.385 (31/13T)
2.000 (30/15T)
1.273 (28/22T)
0.815 (22/27T)
4.100 (41/10T)
1–N–2–3–4–5
Electrical
Alternator
Ignition system
Regulator type
Triple phase output alternator
PGM-IGN
SCR shorted/triple phase, full wave rectification
6˚ BTDC
(at 1.0 mm lift)
27˚ ABDC
30˚ BBDC
1˚ ATDC
Forced pressure and wet sump
Primary kickstarter
2-1
Service Data
Service Data
Item
Lubrication
Specified engine oil
Engine oil capacity
after draining
after oil filter change
after disassembly
Specified transmission oil
Transmission oil capacity
after draining
after disassembly
Unit: mm (in)
Specification
Honda Ultra S9 4-stroke motorcycle oil or
Repsol 4T oil
SAE 10W-40
0.41 liter (0.43 US qt, 0.36 Imp qt)
0.44 liter (0.46 US qt, 0.39 Imp qt)
0.60 liter (0.63 US qt, 0.53 Imp qt)
ELF HTX740
0.54 liter (0.57 US qt, 0.48 Imp qt)
0.57 liter (0.60 US qt, 0.50 Imp qt)
Fuel System
Throttle body identification No.
Throttle grip free play
Engine idle speed
Fuel pressure
Fuel pump flow at 12 V
Injector resistance
GQP0A
3 mm (0.1 in)
1,800 ± 100 min-1 (rpm)
260 kPa (2.65 kgf/cm2, 38 psi) at idle
17 cm3 (0.6 US oz, 0.6 Imp oz) minimum/10 seconds
11.1 – 12.3 Ω (20˚C/68˚F)
Cooling System
Recommended coolant
Radiator cap relief pressure
50/50 mixture coolant and distilled water
117 kPa (1.2 kgf/cm2, 17 psi)
2-2
Item
Cylinder Head/Valves
Cylinder compression
Cylinder head warpage
Valve clearance
IN
EX
Valve stem O.D.
IN
EX
Valve guide I.D.
IN/EX
Valve stem-to-guide clearance
IN
EX
Valve guide projection IN
above cylinder head
EX
Valve spring free length Inner
Outer
Rocker arm I.D.
Rocker arm shaft O.D.
Rocker arm-to-shaft clearance
Cam lobe height
IN
EX
Standard
Service Limit
460 kPa (4.7 kgf/cm2, 67 psi) at
800 min-1 (rpm)
–
0.12 ± 0.03 (0.005 ± 0.001)
0.30 ± 0.03 (0.012 ± 0.001)
4.475 – 4.490 (0.1762 – 0.1768)
4.465 – 4.480 (0.1758 – 0.1764)
4.500 – 4.512 (0.1772 – 0.1776)
0.05 (0.002)
–
–
4.470 (0.1760)
4.460 (0.1756)
4.552 (0.1792)
0.010 – 0.037 (0.0004 – 0.0015)
0.020 – 0.047 (0.0008 – 0.0019)
8.0 – 8.3 (0.31 – 0.33)
8.2 – 8.5 (0.32 – 0.33)
25.41 (1.000)
28.32 (1.115)
10.000 – 10.015 (0.3937 – 0.3943)
9.972 – 9.987 (0.3926 – 0.3932)
0.013 – 0.043 (0.0005 – 0.0017)
32.011 – 33.051 (1.2603 – 1.3012)
32.855 – 32.935 (1.2935 – 1.2967)
–
–
–
–
24.9 (0.98)
27.6 (1.09)
10.051 (0.3957)
9.925 (0.3907)
0.11 (0.04)
31.871 (1.2548)
32.748 (1.2893)
–
Service Data
Unit: mm (in)
Item
Cylinder/Piston
Cylinder I.D.
Taper
Out-of- round
Warpage
Piston
O.D.
Measurement point
Pin bore I.D.
Piston pin O.D.
Piston ring
End gap
Top
Second
Oil (side rail)
Ring-to-groove clearance
Top
Second
Cylinder-to-piston clearance
Piston-to-piston pin clearance
Connecting rod small end I.D.
Clutch/Gearshift Linkage
Recommended clutch fluid
Clutch spring free length
Clutch disc thickness
Clutch plate warpage
Clutch slave cylinder I.D.
Clutch slave piston O.D.
Kickstarter Spindle O.D.
Pinion gear I.D.
Idle gear I.D.
Countershaft O.D.
at kickstarter idle gear
Standard
Service Limit
76.500 – 76.515 (3.0118 – 3.0124)
–
–
–
76.470 – 76.480 (3.0106 – 3.0110)
5 (0.2) from bottom of skirt
16.002 – 16.008 (0.6300 – 0.6302)
15.994 – 16.000 (0.6297 – 0.6299)
76.54 (3.013)
0.05 (0.002)
0.05 (0.002)
0.05 (0.002)
76.39 (3.007)
–
16.03 (0.631)
15.98 (0.629)
0.20 – 0.30 (0.008 – 0.012)
0.35 – 0.50 (0.014 – 0.020)
0.20 – 0.70 (0.008 – 0.028)
0.44 (0.017)
0.64 (0.025)
0.90 (0.035)
0.065 – 0.100 (0.0026 – 0.0039)
0.015 – 0.050 (0.0006 – 0.0020)
0.020 – 0.045 (0.0008 – 0.0018)
0.002 – 0.014 (0.0001 – 0.0006)
16.016 – 16.034 (0.6305 – 0.6313)
0.115 (0.0045)
0.065 (0.0026)
0.18 (0.007)
0.04 (0.002)
16.04 (0.631)
DOT 4 brake fluid
27.6 (1.09)
3.22 – 3.38 (0.127 – 0.133)
–
27.000 – 27.021 (1.0630 – 1.0638)
26.940 – 26.960 (1.0606 – 1.0614)
16.466 – 16.484 (0.6483 – 0.6490)
16.516 – 16.534 (0.6502 – 0.6509)
17.016 – 17.034 (0.6699 – 0.6706)
–
26.8 (1.06)
3.15 (0.124)
0.10 (0.004)
–
–
16.46 (0.648)
16.55 (0.652)
17.06 (0.672)
16.983 – 16.994 (0.6686 – 0.6691)
16.97 (0.668)
Unit: mm (in)
Item
Crankshaft/Transmission
Crankshaft runout
Right
Left
Connecting rod big end
Side clearance
Radial clearance
Transmission gear I.D. M4
M5
C1
C2
C3
Gear bushing I.D.
M5
C1
C2
C3
O.D.
M4
M5
C1
C2
C3
Countershaft O.D.
at C1 bushing
at C2/C3 bushing
at kickstarter idle gear
Shift fork I.D.
C
R, L
Shift fork claw thickness C
R, L
Shift fork shaft O.D.
C
R, L
Oil pump
Tip clearance
Body clearance
Side clearance
Standard
Service Limit
–
–
0.03 (0.001)
0.05 (0.002)
0.30 – 0.75 (0.012 – 0.030)
0.06 – 0.18 (0.002 – 0.007)
23.020 – 23.041 (0.9063 – 0.9071)
23.020 – 23.041 (0.9063 – 0.9071)
20.020 – 20.041 (0.7882 – 0.7890)
25.020 – 25.041 (0.9850 – 0.9859)
25.020 – 25.041 (0.9850 – 0.9859)
20.000 – 20.021 (0.7866 – 0.7882)
17.000 – 17.018 (0.6693 – 0.6700)
22.000 – 22.021 (0.8661 – 0.8670)
22.000 – 22.021 (0.8661 – 0.8670)
22.979 – 23.000 (0.9047 – 0.9055)
22.979 – 23.000 (0.9047 – 0.9055)
19.979 – 20.000 (0.7866 – 0.7874)
24.979 – 25.000 (0.9834 – 0.9843)
24.979 – 25.000 (0.9834 – 0.9843)
0.8 (0.03)
0.05 (0.002)
23.07 (0.908)
23.07 (0.908)
20.06 (0.790)
25.06 (0.987)
25.06 (0.987)
20.05 (0.789)
17.04 (0.671)
22.04 (0.868)
22.04 (0.868)
22.96 (0.904)
22.96 (0.904)
19.95 (0.785)
24.95 (0.982)
24.95 (0.982)
16.983 – 16.994 (0.6686 – 0.6691)
21.959 – 21.980 (0.8645 – 0.8654)
16.983 – 16.994 (0.6686 – 0.6691)
11.003 – 11.024 (0.4332 – 0.4330)
12.035 – 12.056 (0.4738 – 0.4746)
4.93 – 5.00 (0.194 – 0.197)
4.93 – 5.00 (0.194 – 0.197)
10.983 – 10.994 (0.4324 – 0.4328)
11.966 – 11.984 (0.4711 – 0.4718)
16.97 (0.668)
21.94 (0.864)
16.97 (0.668)
11.04 (0.435)
12.07 (0.475)
4.8 (0.19)
4.8 (0.19)
10.97 (0.432)
11.95 (0.470)
–
0.15 – 0.20 (0.006 – 0.008)
0.05 – 0.12 (0.002 – 0.004)
0.20 (0.008)
–
–
2-3
Service Data
Unit: mm (in)
Item
Wheels/Tires
Axle runout
Tire air pressure
Standard
Front
Rear
Wheel rim runout
Radial
Axial
Drive chain slack
Drive chain slider thickness
Front Suspension
Left fork spring free length
Fork tube runout
Recommended fork fluid
Pre-load adjuster setting
Damping adjuster setting
Fork oil level
Fork oil capacity
2-4
Right
Left
Right
Left
Service Limit
–
39 – 44 kPa (0.40 – 0.45 kgf/cm2,
5.6 – 6.5 psi)
29 – 34 kPa (0.30 – 0.35 kgf/cm2,
4.3 – 5.0 psi)
–
–
25 – 35 (1.0 – 1.4)
–
0.20 (0.008)
384.8 (15.14)
377.1 (14.85)
0.20 (0.008)
–
Showa SS05
2 turns out from full soft
Compression adjuster:
13 clicks from full hard
Tension adjuster:
12 clicks from full hard
38 (1.5)
87 (3.4)
405 cm3 (13.7 US oz, 14.3 Imp oz)
410 cm3 (13.9 US oz, 14.4 Imp oz)
Unit: mm (in)
–
–
2.0 (0.08)
2.0 (0.08)
–
2.0 (0.08) from
upper surface
–
–
–
–
–
–
–
Item
Standard
Rear Suspension
Shock absorber spring pre-load
Spring free length
Nitrogen gas pressure
Damper rod compressed
force at 10 mm compressed
Tension adjuster setting
Brakes
Recommended brake fluid
Front
Brake disc thickness
Brake disc runout
Rear
Brake disc thickness
Brake disc runout
Electrical
Spark plug
Standard:
Optional
Spark plug gap
Ignition coil resistance
Primary
Secondary with plug cap
Secondary without plug cap
Ignition pulse generator
Resistance
Alternator
Regulated voltage
Charging coil resistance
ECT sensor resistance
Bulbs
Headlight
Position light
Brake/tail light
Turn signal light
126.5 (4.9)
133 (5.2)
1.27 MPa (13 kgf/cm2)
196 – 232 N (19.9 – 23.6 kgf)
10 clicks from full hard
DOT 4 brake fluid
3.5 (0.14)
–
2.5 (0.10)
–
Service Limit
–
130.3 (5.13)
–
–
–
–
3.0 (0.12)
0.15 (0.006)
2.0 (0.08)
0.15 (0.006)
NGK: CR6EH-9
NGK: CR5EH-9
0.80 – 0.90 (0.031 – 0.035)
–
–
–
2.6 – 3.2 Ω (20˚C/68˚F)
17.3 – 22.8 kΩ (20˚C/68˚F)
13.5 – 16.5 kΩ (20˚C/68˚F)
–
–
–
85 – 115 Ω (20˚C/68˚F)
–
13.5 – 14.5 V/1,800 min-1 (rpm)
0.7 – 1.0 Ω (20˚C/68˚F)
2.3 – 2.6 kΩ (20˚C/68˚F)
–
–
–
12V
12V
12V
12V
–
–
–
–
–
–
–
–
35/35 W
4W
21/5 W
10 W X 4
Service Data
Torque Values
Engine
Standard
5 mm bolt and nut
6 mm bolt and nut
8 mm bolt and nut
10 mm bolt and nut
12 mm bolt and nut
5 mm screw
6 mm screw and flange bolt (SH type)
6 mm flange bolt and nut
8 mm flange bolt and nut
10 mm flange bolt and nut
Cylinder stud bolt:
5 (0.52, 3.5)
10 (1.0, 7)
22 (2.2, 16)
33 (3.4, 25)
53 (5.4, 40)
4 (0.42, 3)
9 (0.9, 7)
12 (1.2, 9)
26 (2.7, 20)
38 (3.9, 29)
Exhaust pipe stud bolt:
101.5 ± 1 mm
17 ± 0.5 mm
Insulator band (cylinder head side):
7 ± 1 mm
Item
Q’ty
Threads
Dia. (mm)
Torque
N•m (kgf•m, lbf•ft)
Transmission oil drain bolt
Engine oil drain bolt
Right crankcase cover joint pipe
Timing hole cap
Bearing set plate socket bolt
Bearing set plate screw
Bearing set plate flat screw
Cylinder head sealing bolt
Cylinder head mounting nut
Cylinder head joint pipe
Vacuum port joint
Primary drive gear special bolt
Flywheel nut
Cam chain tensioner bolt
Valve clearance adjusting nut
Injector holder socket bolt
Fuel hose banjo bolt (holder side)
Water pump impeller
Clutch oil bleeder screw
Clutch spring bolt
Clutch center lock nut
Drive sprocket UBS bolt
Shift drum center special bolt
Shift drum stopper arm bolt
Shift return spring pin
Ignition pulse generator bolt
Stator mounting bolt
Spark plug
1
1
1
1
4
2
2
1
2
1
1
1
1
1
4
2
1
1
1
6
1
1
1
1
1
2
3
1
8
8
18
14
6
6
6
12
9
18
5
12
18
6
6
6
18
7
8
6
18
8
8
6
8
5
5
10
22 (2.2, 16)
22 (2.2, 16)
18 (1.8, 13)
7 (0.7, 5.1)
9.8 (1.0, 7)
12 (1.2, 9)
9.8 (1.0, 7)
32 (3.3, 24)
39 (4.0, 29)
18 (1.8, 13)
2.5 (0.25, 1.8)
108 (11.0, 80)
167 (17.0, 123)
12 (1.2, 9)
14 (1.4, 10)
9.8 (1.0, 7)
27 (2.8, 20)
12 (1.2, 9)
6 (0.6, 4.3)
12 (1.2, 9)
69 (7.0, 51)
31 (3.2, 23)
22 (2.2, 16)
12 (1.2, 9)
22 (2.2, 16)
5.4 (0.55, 4.0)
5.4 (0.55, 4.0)
16 (1.6, 12)
Torque
N•m (kgf•m, lbf•ft)
Item
Insulator band (throttle body side):
7 ± 1 mm
Notes: 1.
2.
3.
4.
Apply
Apply
Apply
Apply
Remarks
Note
Note
Note
Note
Note
Note
Note
Note
Note
Note
1
1
2
3
4
4
4
4
1
2
Note
Note
Note
Note
1
1
4
1
Note 1
Note 4
Note 4
Note 4
Note 2
clean engine oil to the threads and seating surface.
sealant to the threads.
grease to the threads.
a locking agent to the threads.
2-5
Service Data
Frame
Item
Q’ty
Threads
Dia. (mm)
Handlebar holder bolt
Front axle
Rear axle
Final driven sprocket nut
Shock absorber:
Upper mounting bolt/nut
Lower mounting bolt/nut
Fork top pinch bolt
Fork bottom pinch bolt
Swingarm pivot nut
Front brake disc mounting bolt
Rear brake disc mounting bolt
Side stand pivot nut
Side stand bracket mounting bolt
Exhaust pipe flange bolt
Engine hanger:
Upper hanger bolt/nut
Front hanger bolt
Down tube mounting bolt
Front axle holder bolt
Skid plate:
Front mounting bolt
Throttle housing bolt
Clutch lever holder bolt
Front brake master cylinder
holder bolt
Front brake caliper mounting bolt
Brake hose:
Front master cylinder
Front caliper
Rear master cylinder
Rear brake caliper
Brake pedal pivot bolt
Steering head top thread
4
1
1
4
8
17
17
8
22
69
69
29
1
1
2
4
1
4
4
1
2
1
10
10
8
8
14
6
6
10
8
6
39 (4.0, 29)
39 (4.0, 29)
20 (2.0, 14)
20 (2.0, 14)
69 (7.0, 51)
18 (1.8, 13)
17 (1.7, 12)
23 (2.3, 17)
26 (2.7, 20)
12 (1.2, 9)
1
1
4
2
8
10
8
6
24
49
25
23
2
2
2
8
5
5
26 (2.7, 20)
4.2 (0.43, 3.1)
3.2 (0.33, 2.4)
2
2
6
8
3.2 (0.33, 2.4)
26 (2,7, 20)
Note 2
1
1
1
1
1
1
10
10
10
10
8
26
27 (2.8, 20)
27 (2.8, 20)
27 (2.8, 20)
27 (2.8, 20)
29 (3.0, 22)
5 (0.5, 3.6)
Note 1
2-6
Torque
N•m (kgf•m, lbf•ft)
(2.2,
(7.0,
(7.0,
(3.0,
(2.4,
(5.0,
(2.6,
(2.3,
16)
51)
51)
22)
17)
36)
19)
17)
Remarks
Note 1
Note 1
Note
Note
Note
Note
Note
1
1
1
2
2
Note 2
Note 1
Note 1
Note 1
Item
Q’ty
Threads
Dia. (mm)
Torque
N•m (kgf•m, lbf•ft)
Steering stem bolt
Clutch hose (master cylinder)
Rear master cylinder mounting
bolt
ECT sensor
Fuel hose banjo bolt
Fuel pump side:
Fuel pump mounting bolt
Front spoke nipple
Rear spoke nipple
Shock absorber spring lock nut
Shock arm bolt/nut
Shock link bolt/nut
Clutch oil bleeder bolt
Rim lock nut
Fork cap
Fork cap bolt-to-adjuster case
Fork adjuster case lock nut
Right fork center bolt
Left fork center bolt
1
1
20
10
88 (9.0, 65)
20 (2.0, 14)
2
1
6
12
8 (0.8, 5.8)
15 (1.5, 11)
1
6
32
32
1
1
2
1
1
2
1
1
1
1
12
5
BC 3.5
4
50
10
10
10
8
36
22
10
14
15
22 (2.2, 16)
7 (0.7, 5.1)
3.2 (0.33, 2.4)
2.5 (0.25, 1.8)
49 (5.0, 36)
39 (4.0, 29)
39 (4.0, 29)
23 (2.3, 17)
13 (1.3, 9)
23 (2.3, 17)
34 (3.5. 25)
20 (2.0, 14)
34 (3.5. 25)
34 (3.5. 25)
Notes: 1. Apply grease to the sliding surface.
2. Apply a locking agent to the threads.
Remarks
Note 1
Note 2
Note 2
Service Data
Tools
Special
Common
Description
Tool number
Bearing remover, 12 mm
– Remover shaft
– Remover weight
Water seal driver
Attachment, 28 x 30 mm
Clutch center holder
Fork seal driver set
Fork damper holder
Fork damper holder
Ball race remover
Steering stem driver
Bearing driver
Bearing remover
07936–1660101
07936–1660120
07741–0010201
07945–KA30000
07946–1870100
07JMB–MN50301
07947–4630100
89515–NN3–821
07930–KA50100
07948–4630100
07946–4300000
07946–KA50000
07946–MJ00100
Spherical bearing driver
Snap ring pliers
* Flywheel holder
* Flywheel puller
Compressor attachment
07HMF–KS60100
07914–3230001
89020–NN4–003
89010–NN4–003
07959–MB10000
* Newly designed tool for this model.
Applicability
Water pump bearing
Water seal
Water pump bearing
Clutch center lock nut
Fork oil seal
Right fork socket bolt
Left fork socket bolt
Stem bearing race
Stem lower bearing
Swingarm pivot bearing
Shock link needle bearing
Swingarm link bearing
Shock absorber bearing
Master cylinder snap ring
Flywheel
Flywheel
Shock absorber spring
Description
Tool number
Spoke nipple wrench
Gear holder
Bearing remover head
Bearing remover shaft
Driver
Attachment, 24 x 26 mm
Attachment, 32 x 35 mm
07701–0020200
07724–0010100
07746–0050600
07746–0050100
07749–0010000
07746–0010700
07746–0010100
Attachment, 37 x 40 mm
Attachment, 42 x 47 mm
07746–0010200
07746–0010300
Attachment, 52 x 55 mm
Attachment, 62 x 68 mm
Attachment, 72 x 75 mm
Pilot, 12 mm
Pilot, 17 mm
07746–0010400
07746–0010500
07746–0010600
07746–0040200
07746–0040400
Pilot, 20 mm
07746–0040500
Pilot, 22 mm
Pilot, 25 mm
Pilot, 30 mm
Pin spanner
07746–0041000
07746–0040600
07746–0040700
07702–0020001
Shock absorber compressor
07GME–0010000
Applicability
Front spoke nipple
Primary drive gear bolt
Wheel bearing
Wheel bearing
Bearing removal/installation
Swingarm pivot bearing
Right countershaft bearing
Left mainshaft bearing
Left shift drum bearing
Right mainshaft bearing
Left countershaft bearing
Right shift drum bearing
Wheel bearing
Ball race
Crankshaft oil seal
Left crankshaft bearing
Right crankshaft bearing
Water pump bearing
Right countershaft bearing
Left mainshaft bearing
Left countershaft bearing
Wheel bearing
Swingarm pivot bearing
Right mainshaft bearing
Right shift drum bearing
Right crankshaft bearing
Shock spring adjuster
(2 required)
Shock absorber spring
2-7
Service Data
Lubrication & Seal Points
Engine
Item
Material
Crankcase sealing bolt threads and
seating surface
Cylinder bore inner surface
Cylinder head nut threads and
seating surface
Piston pin bore and outer surface
Piston pin outer surface
Piston ring surface
Crankshaft oil seal lips
Decompressor weight sliding
surface
Valve adjusting nut threads
Oil pump rotor sliding surface
Clutch outer sliding surface
Clutch friction disc surface
Clutch center nut threads and
seating surface
Clutch lifter piece needle bearing
area
Primary drive gear bolt threads and
seating surface
Shift drum grooves
Gearshift spindle serration
Flywheel nut threads and seating
surface
Each bearing
Each O-ring
Crankcase inside (transmission oil)
ELF HTX740
Crankcase inside (engine oil)
Honda Ultra S9 4-stroke
engine oil or
Repsol 4T oil
10W-40-MB
2-8
Remarks
600 cm3
600 cm3
Item
Material
Connecting rod small end I.D.
Connecting rod big end
Camshaft outer surface
Rocker arm I.D.
Valve stem sliding surface
Valve stem end sliding surface
Clutch outer collar sliding surface
Mainshaft spline and gear sliding
surface
Countershaft spline and gear
sliding surface
Shift fork I.D. and gear contact area
Shift fork shaft surface
Kickstarter spindle spline area and
gear sliding surface
Each gear
Molybdenum oil solution
(A 50/50 mixture of
molybdenum disulfide
grease and engine oil
Right crankshaft bearing set plate
bolt threads
Right mainshaft bearing/shift drum
bearing set plate bolt threads
Left coutershaft bearing set plate
bolt threads
Left crankcase sealing bolt threads
Cylinder mounting bolt threads
Cylinder head sealing bolt threads
Cam chain tensioner bolt threads
Shift drum center bolt threads
Ignition pulse generator bolt
threads
Stator mounting bolt threads
Locking agent
Remarks
6.5 ± 1 mm
3.5 ± 1 mm
6.5 ± 1 mm
6.5 ± 1 mm
Service Data
Item
Material
Clutch slave cylinder piston/O-ring
Silicone grease
Left crankcase cover cap threads
Each oil seal lips
Water seal lips
Lithium based multipurpose grease
Right crankcase cover water hose
joint threads
Cylinder head water hose joint
threads
Sealant
Cylinder head cover mating surface
Three Bond 1215B
Remarks
2-9
Service Data
Frame
Item
Material
Steering head bearing race and
bearings
Steering head dust seal lips
Swingarm pivot needle bearing
Swingarm pivot dust seal lips
Shock link/shock arm needle
bearings
Shock link/shock arm dust seal lips
Kickstarter arm joint sliding
Brake lever pivot sliding surface
Side stand pivot sliding surface
Brake pedal pivot sliding surface
Chain tensioner roller bearings
Clutch lever pivot sliding surface
Wheel bearing spinning area
Wheel axle threads
Step joint pin surface
Multi-purpose grease
Throttle pipe sliding surface and
throttle wire drum
4-stroke engine oil
Throttle housing screw threads
Molybdenum disulfide
grease
Brake hydraulic system inside
Clutch hydraulic system inside
DOT 4 brake fluid
Air cleaner element
Engine oil
Throttle cable sliding surface
Cable lubricant
Handlebar grip
Honda bond A or
equivalent
2-10
Remarks
Item
Drive chain adjuster stopper screw
threads
Side stand bracket bolt threads
Steering stopper bolt threads
Drive chain slider mounting screw
threads
Rear brake hose clamp screw
threads
Cooling fan nut threads
Material
Locking agent
Remarks
Service Data
Cable & Harness Routing
Front
(2)
(3)
(1)
Front
20 – 30˚
(4)
Front
(1)
(2)
(3)
(4)
FRONT BRAKE HOSE
THROTTLE CABLE
CLUTCH HOSE
ENGINE STOP SWITCH CONNECTOR
2-11
Service Data
(6)
(1)
(5)
(12)
(7)
(8)
(10)
(7)
(4)
(10)
(9)
(3)
(11)
Upper
(2)
Right
(1)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
MAIN WIRE HARNESS
FUEL PUMP WIRE
CRANKCASE BREATHER HOSE
CRANKCASE BREATHER JOINT HOSE
STRAGE TANK
ENGINE STOP SWITCH WIRE
FAN MOTOR WIRE
RADIATOR OVERFLOW HOSE
SPARK PLUG WIRE
2-12
20 – 30˚
(10) WIRE HARNESS (TO IGNITION COIL)
(11) WIRE HARNESS (TO GROUND)
(12) ECT SENSOR
Service Data
(5)
(4)
(6)
(3)
(2)
(1)
(7)
(8)
(9)
(1)
(2)
(3)
(4)
WIRE HARNESS
THROTTLE CABLE
CLUTCH HOSE
CONNECTOR BOOT
– FAN MOTOR 2P (BLACK) CONNECTOR
– POWER CONNECTOR
Clamp at white tape
(5)
(6)
(7)
(8)
(9)
UPPER RADIATOR HOSE
SPARK PLUG WIRE
FAN MOTOR WIRE
CRANKCASE BREATHER HOSE
CRANKCASE BREATHER JOINT HOSE
2-13
Service Data
(4)
(3)
(3)
(2)
(2)
(4)
(2)
(1)
40 – 50˚
(1)
(2)
(3)
(4)
INTAKE VACUUM HOSE
THROTTLE CABLE
CLUTCH HOSE
FUEL TANK BREATHER HOSE
2-14
(3)
Service Data
(2)
(1)
(3)
(7)
(8)
(6)
(9)
(5)
(4)
(1)
(2)
(3)
(4)
(5)
(6)
MAIN WIRE HARNESS
TRANSMISSION BREATHER HOSE
CRANKCASE BREATHER JOINT HOSE
ALTERNATOR WIRE
CONDENSER 2P (BLACK) CONNECTOR
REGULATOR/RECTIFIER 5P (BLACK) CONNECTOR
(7) ENGINE STOP RELAY
(8) FAN MOTOR RELAY
(9) REAR BRAKE RESERVOIR TANK
2-15
Service Data
(9)
(7)
(6)
(10)
(5)
Clamp at white tape
(8)
(11)
(5)
(6)
(3)
(4)
(12)
(2)
(1)
(13)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
MAIN WIRE HARNESS (TO CONNECTOR COVER)
MAIN WIRE HARNESS (TO RELAY)
MAIN WIRE HARNESS (TO ECU)
CRANKCASE BREATHER JOINT HOSE
TRANSMISSION BREAHTER HOSE
WIRE HARNESS
FUEL RETURN HOSE
FUEL FEED HOSE
REGULATOR/RECTIFIER 5P (BLACK) CONNECTOR
2-16
(14)
(10)
(11)
(12)
(13)
(14)
CONDENSOR
CONDENSOR 2P (BLACK) CONNECTOR
BANK ANGLE SENSOR
FAN MOTOR RELAY
CONNECTOR COVER
Service Data
(2)
90 – 95˚
(1)
(1) REAR BRAKE HOSE
(2) REAR BRAKE RESERVOIR HOSE
2-17
Service Data
(1)
(2)
(3)
(1) FUEL FEED HOSE
(2) INTAKE VACUUM HOSE
(3) TRANSMISSION BREATHER HOSE
2-18
3. Service And Maintenance
Maintenance Schedule
Pre-ride Inspection
Perform pre-ride Inspection at each scheduled maintenance period.
I: Inspect and clean, Adjust, Lubricate or Replacement if necessary. C: Clean, R: Replace, L: Lubricate.
For your safety, it is very important to take a few moments
before each ride to walk around your COTA 4RT and
check its condition.
Frequency
Item
Fuel Line
Throttle Operation
Air Cleaner
Spark Plug
Valve Clearance
Engine Oil
Engine Oil Filter
Engine Oil Strainer Screen
Engine Idle Speed
Transmission Oil
Radiator Coolant
Cooling System
Piston
Piston Ring
Drive Chain
Drive Chain Slider/Tensioner
Drive/Driven Sprocket
Brake Fluid
Brake Pad Wear
Brake System
Clutch Fluid
Clutch System
Control Cables
Exhaust Pipe/Muffler
Suspension
Swingarm/Shock Linkage
Fork Oil
Wheels/Tires
Steering Head Bearing
Nuts, Bolts, Fasteners
Each race Every 6
or about races or Every half
2,5 h. about 15 h. a year
I
I
C
I
Every
year
Check the air cleaner after riding in dusty area
R
I
I
Remarks
I: After the first brake-in period
R: After the first brake-in period
R: After the first brake-in period
R
R
I
I
R
I
I
I
I
I, L
I
I
I
I
I
I
I
I, L
I
I
I
I
I
I
I
R
R
R
R
R
C
C
C
! WARNING
Improperly maintaining this COTA 4RT or failing to
correct a problem before riding can cause a crash in
which you can be seriously hurt or killed.
Always perform a Pre-ride and Pre-race inspection
before every ride and correct any problems.
Check the following items before you get on the COTA 4RT:
• Fuel, oil and water leaks
• Coolant for proper level
• Spark plug for proper heat range, carbon fouling and
spark plug cap terminals for looseness
• Clutch operation
• Steering head bearings and related parts for condition
• Damaged or distorted frame
• Throttle grip and throttle valve operation
• Tires for damaged or improper inflation pressure
• Front and rear suspension for proper operation
• Front and rear brakes, for proper operation
• Drive chain for correct slack and adequate lubrication
• Drive chain slider and roller for damage or wear
• Loose bolts, screws and other fasteners
Check the spherical bearing damage.
R
3-1
Service And Maintenance
Warming-up Inspection
Replacement Parts
When warming-up the engine, check for the following:
• Do not rev the engine more than necessary or engine
damage may result.
• Check for fuel, oil and water leaks
• Warm up the engine for a few minutes until it is heated
to the operating temperature until the engine
responds to the throttle smoothly.
Parts Requiring Periodic Replacement
Ride Inspection
When running the COTA, check for the following:
• Control system
• Brake stopping power
After Ride Inspection
After riding the COTA, check for the following:
• Color condition of piston head and spark plug
• Signs of detonation
• Fuel, oil and water leaks
• Loose or missing bolts and nuts
Item
Engine
Spark plug/plug cap
Engine oil
Engine oil filter
Transmission oil
Piston
Piston ring
Radiator coolant
Every
Every
Every
Every
Every
Every
Every
Frame
Front fork fluid
Every half a year
6 races
6 races
6 races
6 races
year
half a year
year
Fast Wearing/Expendable Parts
Item
3-2
Replacement Interval
Cause
Engine
Clutch disc
Clutch spring
Drive sprocket
Wear or discoloration
Fatigue
Wear or damage
Frame
Front/rear tire
Brake pad
Chain slider
Driven sprocket
Drive chain
Wear
Wear
Wear
Wear or damage
Elongation or wear
Cause
Contamination or emulsification
Damage or wear at skirt
Damage at ends or wear
Service And Maintenance
(2)
(2)
(1)
(1)
(1)
(2)
(1) FUEL FEED HOSE
(2) FUEL RETURN HOSE
(1) BOLTS
(2) AIR CLEANER HOUSING COVER
Fuel Line
(1)
(1) FLAME TRAP
(2) AIR CLEANER ELEMENT
Remove the flame trap from the air cleaner element.
Check the frame trap for damage, replace if necessary.
Remove the rear fender.
Thoroughly wash the element in clean non-flammable
cleaning solvent, then wash in a solution of hot water
and dish-washing liquid soap.
Apply engine oil to the element, and squeeze out excess
oil.
Clean the inside of the air cleaner housing.
Check the fuel feed hose and return hose for cracks,
deterioration or leakage.
! WARNING
(1) AIR CLEANER ELEMENT
Never use gasoline or low flash point solvents for
cleaning the air cleaner element. A fire or explosion
could result.
Soak the element in engine oil and squeeze out the
excess.
Air Cleaner
Remove the rear fender.
Remove the four bolts and air cleaner housing cover.
Remove the air cleaner element assembly from the air
cleaner housing.
NOTICE
Do not twist the element to squeeze out the excess.
Failure to follow this precaution can result in a damaged
element.
Installation is in the reverse order of removal.
3-3
Service And Maintenance
(1)
(1)
(1)
(2)
(2)
(1) SPARK PLUG CAP (2) SPARK PLUG
(1) INSULATOR
(1) BOLTS
(2) TAPPET ADJUSTING HOLE COVER
(1)
Spark Plug
(1)
Using a spark plug with the wrong heat range can
damage the engine or cause the plugs to foul. Be careful
to select the correct spark plug for the conditions.
Standard plug: NGK: CR6EH-9
Optional for cold temperatures: CR5EH-9
Plug Gap
Remove the spark plug and measure the spark plug gap.
Standard: 0.8 – 0.9 mm (0.031 – 0.035 in)
Replace the spark plug if the spark plug gap is out of
specification.
Install and tighten the spark plug.
Torque: 16 N•m (1.6 kgf•m, 12 lbf•ft)
(1) SPARK PLUG GAP
(1) TIMING HOLE CAP/O-RING
Flash Over
Valve Clearance
If engine misfire occurs due to arcing, replace both the
spark plug and the cap.
Inspection
Spark Plug Cap
Remove the spark plug cap from the spark plug.
Clean the inside of the plug cap with electrical contact
cleaner to prevent misfire.
3-4
Inspect and adjust the valve clearance while the engine
is cold (below 35˚C/95˚F).
Remove the fuel tank/injector assembly.
Remove the bolts and tappet adjusting hole covers from
the cylinder head cover.
Remove the timing hole cap and O-ring.
Service And Maintenance
(2)
(2)
(4)
(1)
(1)
(1)
(1) “T” MARK
(2) INDEX MARK
(1) FEELER GAUGE
Operate the kickstarter pedal and align the “T” mark on
the flywheel with the index mark on the left crankcase
cover.
Insert a feeler gauge between the rocker arm and valve
stem and measure the intake and exhaust valve
clearances.
Make sure the piston is at TDC (Top Dead Center) on the
compression stroke by moving the rocker arms.
Valve clearance:
Intake: 0.12 ± 0.03 mm (0.005 ± 0.001 in)
Exhaust: 0.30 ± 0.03 mm (0.012 ± 0.001 in)
(1) O-RING
(2) VALVE ADJUSTING HOLE COVER
(3) “UP” MARK (4) BOLTS
Adjust by loosening the lock nut and turning the
adjusting screw until there is a slight drag on a feeler
gauge.
Tools:
Valve adjusting wrench, 8 x 9 mm
(equivalent commercially available)
Valve adjuster B
(3)
(2)
(1)
07708-0030100
07708–0030100
After adjustment, tighten the lock nut while holding the
adjusting screw.
Recheck the valve clearance.
(1) O-RING
(2) TIMING HOLE CAP
Check that the valve adjusting hole cover O-ring is in
good condition, replace if necessary.
Coat the O-rings with clean engine oil and install them in
the valve adjusting hole cover grooves.
Install the valve adjusting hole cover with their “UP”
mark facing up and then install and tighten the bolts
securely.
Check the timing hole cap O-ring is in good condition,
replace if necessary.
Install and tighten the timing hole cap.
3-5
Service And Maintenance
(1)
(1)
(2)
(1)
(2)
(3)
(2)
(1) OIL FILLER CAP/DIPSTICK
(2) UPPER LEVEL LINE (3) LOWER LEVEL LINE
Engine Oil/Oil Filter
Oil Level Inspection
Start the engine and let it idle for a 3 minutes.
Stop the engine and wait 3 minutes.
Support the motorcycle upright on a level surface.
Remove the oil filler cap/dipstick on left crankcase and
wipe the oil with a clean cloth.
Insert the dipstick without screwing it in, remove it and
check the oil level.
If the oil level is below or near the lower level line on the
dipstick, add the recommended engine oil to the upper
level line through the oil filler hole.
Specified engine oil:
Honda Ultra S9 4-stroke motorcycle oil or
Repsol 4T oil
(10W–40)
(1) OIL FILLER CAP/DIPSTICK
(2) DRAIN BOLT/SEALING WASHER
Oil Change
Change the engine oil with the engine warm.
Support the motorcycle with it side stand.
Remove the bolts and skid plate.
1. Remove the oil filler cap/dipstick.
2. Place an oil drain pan under the engine and remove
the drain bolt on the left crankcase cover.
3. After the oil has completely drained, make sure that
the sealing washer is in good condition and reinstall
the drain bolt. Tighten the drain bolt to the specified
torque.
Torque: 22 N•m (2.2 kgf•m, 16 lbf•ft)
4. Pour recommended engine oil slowly through the oil
filler hole.
Specified engine oil:
Honda Ultra S9 4-stroke motorcycle oil or
Repsol 4T oil (SAE: 10W–40)
Capacity: 0.41 liter (0.43 US qt, 0.36 Imp qt) after
draining
0.44 liter (0.46 US qt, 0.39 Imp qt) after oil
filter change
0.60 liter (0.63 US qt, 0.53 Imp qt) after
disassembly
Install the oil filler cap/dipstick.
3-6
(1) BOLT (2) RETAINING PLATE
(1)
(4)
(2)
(3)
(1) OIL FILTER COVER
(2) O-RINGS
(3) OIL FILTER (4) SPRING
Oil Filter Change
Remove the left crankcase cover (page 4-46).
Remove the oil filter cover retaining plate bolt and plate.
Remove the oil filter cover and O-rings.
Remove the oil filter and spring.
Service And Maintenance
(2)
(1)
(3)
(2)
(1) SPRING (2) OIL FILTER
(3) APPLY GREASE
(1)
(1)
(1) NEW O-RINGS
(2) OIL FILTER COVER
(1) OIL STRAINER SCREEN
Oil Strainer Screen Cleaning
(1)
(2)
(1)
Remove the oil strainer screen from the left crankcase
groove.
Clean the strainer.
Reinstall the oil strainer screen.
Note the direction of the screen.
Install the left crankcase cover being careful not to
damage the O-ring and oil seal.
(2)
(1) OIL FILTER
(2) “OUT SIDE” MARK
(1) RETAINING PLATE (2) BOLT
Apply grease to the oil filter spring end (filter side).
Install the spring into the new oil filter.
Install new O-rings into the oil filter cover grooves.
Install the new oil filter into the left crankcase with its
“OUT SIDE” mark facing out.
NOTICE
Install the oil filter cover into the left crankcase while
aligning the cover flange with the oil filter groove.
Make sure that the oil filter cover seats properly in the
crankcase.
Install the retaining plate and tighten the bolt securely.
Installing the oil filter backwards will result in severe
engine damage.
3-7
Service And Maintenance
(1)
(1)
(2)
(1)
(1) THROTTLE STOP SCREW
(1) DRAIN BOLT
(1) FILLER CAP
(2) O-RING
Engine Idle Speed
Transmission Oil
5. Pour specified transmission oil.
Inspect and adjust the idle speed after all other engine
adjustments are within specification.
The engine must be warm for an accurate idle inspection
and adjustment. Ten minutes of stop and go riding is
sufficient.
Oil Change
Specified transmission oil:
ELF HTX 740
Capacity: 0.54 liter (0.57 US qt, 0.48 Imp qt) after
draining
0.57 liter (0.60 US qt, 0.50 Imp qt) after
disassembly
Warm up the engine, shift the transmission into neutral,
and hold the motorcycle upright position.
Connect a tachometer according to its manufacturer’s
operating instruction.
With the cooling fan does not operate, turn the throttle
stop screw to obtain the specified idle speed.
Idle speed: 1,800 ± 100 min-1 (rpm)
• Transmission oil should be changed at least every six
competitions to ensure consistent performance and
maximum service life of both transmission and clutch
components.
• Warm-up the engine before draining the oil. This will
ensure complete and rapid draining.
Remove the bolts and skid plate.
1. Support the motorcycle in an upright position on level
surface.
2. Remove the oil filler cap from the clutch cover.
3. Place an oil drain pan under the engine to catch the
oil, then remove the drain bolt and sealing washer
from the left crankcase.
4. After the oil has drained completely, install the drain
bolt with a new sealing washer. Tighten the drain bolt
to the specified torque.
Torque: 22 N•m (2.2 kgf•m, 16 lbf•ft)
3-8
Check the O-ring is in good condition, install the oil filler
cap.
Service And Maintenance
(2)
(1)
(2)
(1)
(1)
(2)
(1) OVERFLOW HOSE
(2) RADIATOR
(1) INSPECTION HOLE
(2) COOLANT DRAIN BOLT/SEALING WASHER
(1) BOLT
(2) RADIATOR CAP
Coolant
6. Check the water pump inspection hole bottom of the
water pump for leakage. Make sure the hole remains
open.
If water leaks through the check hole, the water seal is
damaged. If oil leaks through the check hole, the oil
seal is damaged.
Replace the water seal or the oil seal (page 4-12).
2.Remove the radiator upper mounting bolt and move
the radiator forward, then remove the radiator cap
and drain the coolant.
3. Install the new sealing washer, drain bolt and tighten
it to the specified torque.
Cooling System Inspection
1. Check the cooling system for leaks.
2. Check water hoses for cracks, deterioration, and
clamp bands for looseness.
3. Check the radiator mount for looseness.
4. Make sure the overflow hose is connected and not
clogged.
5. Check radiator fins for obstructions or damage.
Torque: 9.8 N•m (1.0 kgf•m, 7 lbf•ft)
Coolant Replacement
! WARNING
Removing the radiator cap while the engine is hot
will allow the coolant to spray out, seriously scalding
you.
Always let the engine and radiator cool down before
removing the radiator cap.
1. Remove the coolant drain bolt and sealing washer.
3-9
Service And Maintenance
(1)
(1)
(2)
(2)
(1)
(1) FILLER NECK
(1) CLUTCH FLUID RESERVOIR
(2) LOWER LEVEL LINE
(1) EXHAUST PIPE (2) MUFFLER
4. Fill the radiator with coolant up to the filler neck.
5. Squeeze the radiator hoses alternately. If the coolant
level drops, fill the coolant again.
6. Fill the radiator with coolant up to the filler neck.
7. After this first filling, start the engine, check the
coolant level (page 1-1).
Clutch System
Exhaust Pipe And Muffler
System Inspection
Inspection
1. Operate the clutch lever and check that no air has
entered in the system. If the clutch is not disengaged
properly, or the lever feels soft or spongy, bleed the
air from the system.
2. Remove the reservoir cover and diaphragm, check the
clutch fluid level. If the level is low, inspect the clutch
hose and fittings for damage, deterioration, cracks or
sign of leakage. Tighten any loose fittings. Replace
hose and fittings as require.
Check the muffler for clogging.
Check for loose or missing bolts and nuts.
Check the exhaust pipe and muffler for cracks or
deformation.
Check the exhaust pipe gasket.
Check the muffler gasket.
3-10
Loss of power will result if the exhaust pipe is broken.
Service And Maintenance
(1)
(1)
(2)
(2)
(1)
(1) DRIVE CHAIN SLACK
(1) AXLE NUT
Drive Chain
Drive Chain Slack Adjustment
Drive Chain Slider
Drive Chain Slack Inspection
Loosen the rear axle nut just enough to move the rear
wheel in fore-act direction.
Turn the adjuster equally on both sides until the correct
drive chain tension is obtained.
Turn the adjuster counterclockwise will decrease slack
and turning it clockwise will increase slack.
Inspection/Replacement
During the break-in period, drive chain slack should be
checked and adjusted often. Also check the drive chain
slack after the drive chain replacement.
Regular cleaning, lubrication, and proper adjustment will
help to extend the service life of the drive chain.
Shift the transmission into neutral, turn the engine off
and support the motorcycle on its side stand.
Unhook the drive chain tensioner spring to remove any
load on the chain.
Measure chain slack at the lower section midway
between the sprockets.
(2) ADJUSTER
• Adjust the chain with the chain adjusters so that it is
parallel with the center line of the frame.
• Check that the stopper is between the teeth of the
adjuster.
(1) DRIVE CHAIN SLIDER
(2) DRIVE CHAIN TENSIONER SLIDER
Check the drive chain slider for wear or damage.
If the wear is 2.0 mm (0.08 in) or more, replace the slider.
Check the drive chain tensioner slider for wear or
damage.
If the wear is 2.0 mm (0.08 in) or more, replace the slider.
The drive chain slider and tensioner screws must be
retightened after break-in.
Recheck the drive chain slack and free wheel rotation.
After adjustment, tighten the axle nut to the specified
torque.
Drive chain slack: 25 – 35 mm (1.0 – 1.4 in)
Torque: 69 N•m (7.0 kgf•m, 51 lbf•ft)
Rotate the wheel and chain slack in several sections. If
slack in one section increases beyond the standard
measurement, this indicates the chain has stretched and
needs to be replaced.
Take care to prevent catching your fingers between the
chain and sprocket.
Lubricate the drive chain.
Hook the drive chain tensioner spring.
3-11
Service And Maintenance
(1)
(1)
(3)
(1)
(2)
(3)
(2)
(2)
(1) BOLT (2) SPRING WASHER
(3) DRIVE SPROCKET
(1) DRIVE SPROCKET
(3) BOLT
Drive/Driven Sprockets
Install the drive sprocket onto the countershaft as
shown.
Install the spring washer and bolt, then tighten the bolt
to the specified torque.
Drive Sprocket Replacement
Remove the drive sprocket cover.
Loosen the drive chain fully.
(2) SPRING WASHER
(1) BOLTS/NUT
(2) DRIVEN SPROCKET
Driven Sprocket Replacement
Remove the rear wheel (page 5-15).
Remove the bolts/nuts, washers and driven sprocket.
Torque: 31 N•m (3.2 kgf•m, 23 lbf•ft)
Installation is in the reverse order of removal.
Remove the bolt, spring washer and drive sprocket.
Hold the bolts and tighten the nuts to the specified
torque.
Torque: 29 N•m (3.0 kgf•m, 22 lbf•ft)
Adjust the drive chain slack (page 3-11).
3-12
Service And Maintenance
(1)
(1)
(2)
(1)
(1) “MIN” LEVEL
(1) BRAKE HOSE
(1) COVER (2) “MIN” LEVEL
Brake Fluid
Check that the brake hose do not bind or kink in all
steering position, and is not pulled when the suspension
is extended.
Rear Master Cylinder
Replace the brake fluid every 6 months.
Replace the brake hose every year.
Do not service the brake system in high humidity.
Remove the master cylinder reservoir cover, set plate
and diaphragm.
If the fluid level is lower than the “MIN” level, check for
brake pad wear.
Replace the brake pad if necessary.
Refer to page 5-24 for brake pad replacement.
Front Brake Master Cylinder
Always inspect the brake fluid level.
Remove the screws, master cylinder cover and
diaphragm.
Brake fluid: DOT 4 only
If the fluid level is lower than the “MIN” line, check for
the brake pad wear.
Replace the brake pad if necessary.
Refer to page 5-23 for brake pad replacement.
Also check the brake system for leaks.
Always inspect the brake fluid level.
Also check the brake system for leaks.
Replace the brake fluid every 6 months.
Replace the brake hose every year.
Do not service the brake system in high humidity.
Brake fluid: DOT 4 only
3-13
Service And Maintenance
(2)
(1)
(3)
(1)
(1)
(1) BRAKE PAD
(1) BRAKE DISC
(1) BRAKE DISC (2) DISC BOLT
(3) COLLAR
Brake Pad Wear
Brake System
Measure the brake pad thickness.
Refer to page 1-3 for Brake Lever Adjustment.
Refer to page 1-4 for Brake Pedal Height Adjustment.
The front brake is floating type disc.
Replace the disc and disc bolts if the play in the rotating
direction exceeds 2.0 mm (0.08 in), as measured at its
periphery. The standard play is from 0.3 – 1.0 mm (0.01
– 0.04 in).
Apply a locking agent to the threads of the brake disc
bolts before installation.
Minimum thickness: 1.0 mm (0.04 in)
Brake Discs
If either pad is wear to the indicator, both pads must be
replaced.
Measure the rear brake disc runout with a dial gauge.
Service limit: 0.15 mm (0.006 in)
Replace the brake disc if the runout exceeds the service
limit.
Measure the brake disc thickness.
Service limit: Front: 3.0 mm (0.12 in)
Rear: 2.5 mm (0.08 in)
Replace the brake disc if necessary.
Refer to pages 5-1 and 5-15 for removal.
3-14
Torque:
Front: 18 N•m (1.8 kgf•m, 13 lbf•ft)
Rear: 17 N•m (1.7 kgf•m, 12 lbf•ft)
On the front brake, replace the collar with new ones if the
disc starts to wobble right and left.
Service And Maintenance
Front
(2)
(1)
(1)
(1)
(2)
(1) HOLDER BOLTS (2) UPPER HOLDER
(1) STEERING HEAD BEARINGS
(1) SPOKE NIPPLE (2) RIM LOCK
Handlebar And Steering Head Bearings
Steering Head Bearings
Wheels And Tires
Handlebar
Support the motorcycle using the maintenance stand
with its front wheel off the ground.
Proper air pressure will provided maximum stability and
tire life.
Check tire pressure frequently and adjust if necessary.
Tire air pressure should be checked when the tires are
COLD.
Check the handlebar for bends or cracks.
Check that the handlebar has not moved from its proper
position.
Check that the handlebar holder bolts are tight.
If necessary, tighten the holder bolts.
First tighten the forward bolts, then tighten the rear bolts
to the specified torque.
Torque: 22 N•m (2.2 kgf•m, 16 lbf•ft)
Turn the handlebar to the right and left to check for
roughness in the steering head bearings. Stand in front
of the motorcycle and grab the fork (at the axle), then
push the fork in and out (toward the engine) to check for
play in the steering head bearings. If any roughness or
play is felt, adjust or replace the steering head bearings.
Standard cold tire air pressure:
Front: 39 – 44 kPa (0.40 – 0.45 kgf/cm2, 5.6 – 6.4 psi)
Rear: 29 – 34 kPa (0.30 – 0.35 kgf/cm2, 4.3 – 5.0 psi)
Inspect the wheel for damage.
Check the wheel runout. If runout is noticeable, check
the spokes are tight, or replace the wheel.
Check the axle for runout.
Check the condition of the front and rear wheel bearings.
Check the trueness of the wheel, spoke tension and the
tightness of the rim lock nut.
Tool:
Spoke nipple wrench (front)
07701–0020200
Torque:
Spoke nipple:
Front:
3.2 N•m (0.33 kgf•m, 2.4 lbf•ft)
Rear:
2.5 N•m (0.25 kgf•m, 1.8 lbf•ft)
Rim lock nut: 13 N•m (1.3 kgf•m, 9 lbf•ft)
3-15
Service And Maintenance
(1)
(1)
(2)
(1) PRE-LOAD ADJUSTER
(1) REBOUND ADJUSTER
(2) COMPRESSION ADJUSTER
Front Suspension
Fork
Inspection
The motorcycle is shipped with a light coating of grease
on the forks. This is not an indication of a leak.
Use specified fork fluid which additives to assure
maximum performance of your COTA’s front
suspension.
1. Make sure that the fork surfaces and dust seals are
clean.
2. Check for signs of oil leakage. Damaged or leaking
fork seals should be replaced before you ride the
motorcycle.
3. Make a quick check of fork operation by locking the
front brake and pushing down on the handlebar
several times.
• When your COTA is new, break in your COTA to ensure
that the suspension has worked in.
• After break-in, test ride your COTA with the front
suspension at the standard setting before attempting
any adjustments.
The fork should always be adjusted for the rider’s weight
and track conditions by using one or more of the
following methods.
Basically, there are three adjustments you can make to
the front suspension:
• Rebound damping (right fork)
Turning the rebound damping adjuster adjusts how
quickly the fork extends.
• Compression damping (right fork)
Turning the compression damping adjuster adjusts
how quickly the fork compressed.
• Spring pre-load (left fork)
Turning the spring pre-load adjuster adjusts the spring
initial pre-load length.
• Fork fluid volume
The effects of higher or lower fork fluid level are only
felt during final fork travel.
Replace the fork fluid every 6 months. See page 5-8, 11
for oil level adjustment after changing the fork fluid.
3-16
Specified fork fluid:
Left: Showa SS05
Right: Showa SS05
• Periodically check and clean all front suspension parts
to assure top performance. Check the dust seals for
dust, dirt and foreign materials. Check the fluid for any
contamination.
• Make rebound damping adjustments in one-click
increments. Adjusting two or more clicks at a time
may cause you to pass over the best adjustment. Test
ride after each adjustment.
• If you become confused about adjustment settings,
return to the standard position and start over.
Service And Maintenance
(1)
(1)
(1) PRE-LOAD ADJUSTER
(1) REBOUND ADJUSTER
Rear Suspension
• When your COTA is new, your suspension will breakin as you ride.
• After break-in is completed, test ride your COTA with
the rear suspension at the standard setting before
attempting any adjustments.
• Make all rebound damping adjustment in one-click
increments. Adjusting two or more clicks at a time
may cause you to pass over the best adjustment. Test
ride after each adjustment.
• If you become confused about adjustment settings,
return to the standard position and start over.
The swingarm is controlled by a shock absorber. The
The rear shock absorber should always be adjusted for
the rider’s weight and track conditions by using one or
more of the following methods.
• Spring pre-load
Turning the spring pre-load adjuster adjusts the spring
initial pre-load length.
• Rebound damping
Turning the rebound damping screw adjusts how
quickly the shock absorber extends.
Inspection
1. Check for a broken or collapsed spring.
2. Bounce the rear of the machine up and down and
check for smooth suspension action.
3. Check the rear shock absorber for a bent shaft or oil
leaks.
4. Push the rear wheel sideways to check for worn or
loose swingarm bearings. There should be no
movement. If movement is felt, replace the pivot
bearings (page 5-19).
3-17
Service And Maintenance
Cleaning
Storage
Clean your COTA regularly to protect the surface finishes
and inspect damage, wear, and oil seepage.
When washing your COTA, always use water and a mild
detergent (such as diswashing liquid) to avoid
discoloring decals.
Extended storage, such as for winter, requires that you
take certain steps to reduce the effects of non-use. In
addition, necessary repairs should be made BEFORE
storing your COTA: otherwise, these repairs may be
forgotten by the time your COTA is removed from
storage.
NOTICE
High pressure water (or air) can damage certain parts of
the motorcycle.
Wheel hubs
Light and engine stop switch
Muffler outlet
Electrical components
Drive chain
Brake and clutch master cylinder
1. After cleaning, rinse your COTA thoroughly with
plenty of clean water. Strong detergent residue can
corrode alloy parts.
2. Dry your COTA, start the engine, and let it run for
several minutes.
3. Lubricate the drive chain immediately after washing
and drying your COTA.
4. Test the brakes before riding your COTA. Several
applications may be necessary to restore normal
braking performance. Braking performance may be
impaired immediately after washing your COTA.
3-18
Preparing The Motorcycle For Storage
1. Completely clean all parts of your COTA. Wash with
fresh water and wipe dry.
2. Drain the fuel tank into an approved gasoline
container.
! WARNING
Gasoline is highly flammable and explosive.
You can be burned or seriously injured when draining
or refueling.
• Stop engine and keep heat, sparks, and flame
away.
• Drain or refuel only outdoors.
• Wipe up spills immediately.
3. Remove the coolant drain bolt at the water pump
cover to drain coolant. Drain coolant into a proper
container. After the coolant has been completely
drained, ensure that the drain bolt sealing washer is
in good condition and reinstall the drain bolt.
4. Lubricate the drive chain.
5. Remove the spark plug and pour a table spoon (15 –
20 cm3) of clean engine oil into the cylinder.
With the spark plug grounded or the Engine Stop
Switch is pushed, crank the engine several times to
distribute the oil.
6. Inflate the tires to their recommended pressure.
7. Place your COTA on the maintenance stand or
equivalent to raise both tires off the ground.
8. Stuff a rag into the muffler outlet. Then tie a plastic
bag over the end of the muffler to prevent moisture
from entering.
9. Cover your COTA and store in a place which is free of
humidity and dust.
Removal From Storage
1. Uncover and clean your COTA.
Change the engine and transmission oil if more than
4 months have passed since the start of storage.
2. Uncover the end of the muffler and remove the rag
from the muffler outlet.
3. Fill the fuel tank with recommended fuel.
3. Pour the recommended coolant slowly from the
radiator filler neck.
Bleed the air in the cooling system and install the
radiator cap securely (page 1-1).
4. Perform the maintenance check (page 3-1).
4. Engine Servicing
(1)
(1)
(2)
(1)
(2)
(2)
(1) SNAP RING
(2) PRESSURE RELIEF VALVE
(1) RELIEF VALVE
(2) O-RING
(1) DRIVEN GEAR
(2) DRIVE PIN
Oil Pressure Relief Valve
Oil Pump
Removal/Inspection
(2)
Disassembly
(1)
Drain the engine oil.
Remove the left crankcase cover (page 4-46).
Remove the engine from the frame.
Separate the crankcase halves (page 4-51).
Remove the snap ring.
Remove the pressure relief valve from the left crankcase
cover.
Remove the oil pump driven gear and drive pin.
(1) PRESSURE RELIEF VALVE
(2) SNAP RING
Check the relief valve operation by pushing the relief
valve piston.
Installation
Apply oil to a new O-ring and install it onto the relief
valve groove.
Install the relief valve into the left crankcase cover.
Install the snap ring into the crankcase cover groove
securely.
Install the left crankcase cover (page 4-48).
4-1
Engine Servicing
(3)
(2)
(1)
(1)
(2)
(1)
(2)
(1) ONE-WAY REED VALVE
(2) GASKET (3) DOWEL PINS
(2)
(1) DRIVEN GEAR
(2) OIL PUMP SHAFT
(1) SNAP RING
(2) OIL SEAL
(1)
(1)
(3)
(1) OUTER ROTOR (2) INNER ROTOR
(3) OIL PUMP SHAFT
(1) ONE-WAY REED VALVE
Remove the one-way reed valve, gasket and dowel pins.
Inspection
Remove the oil pump shaft, outer and inner rotors.
Check the oil pump driven gear for wear or damage.
Check the oil pump shaft for wear or damage.
Check the one-way reed valve for damage, replace if
necessary.
Check the oil pump shaft oil seal in the left crankcase for
damage or deterioration, replace if necessary.
Temporarily install the oil pump shaft, inner and outer oil
pump rotors into the right crankcase.
Measure the oil pump tip clearance.
Service limit: 0.20 mm (0.008 in)
4-2
Engine Servicing
(3)
(2)
(2)
(4)
(1)
(1)
(1) OIL PUMP SHAFT
(2) INNER ROTOR (3) FLAT SURFACES
(4) OUTER ROTOR
(1)
(1) DRIVE PIN
(2) DRIVEN SPROCKET
Assembly
(2)
Apply clean engine oil to the oil pump rotors and shaft.
Install the oil pump shaft into the right crankcase.
Install the inner rotor aligning the flat surface between
the rotor and pump shaft.
Install the outer rotor.
(3)
(1)
(1) GASKET
(1) ONE-WAY REED VALVE
(2) DOWEL PINS
(3) NEW GASKET
Measure the oil pump body clearance.
Install the drive pin into the oil pump shaft hole.
Install the oil pump driven sprocket aligning its groove
with the drive pin.
Standard: 0.15 – 0.20 mm (0.006 – 0.008 in)
Temporarily install the crankcase gasket.
Measure the side clearance using a straight edge and
feeler gauge.
Install the one-way reed valve into the right crankcase.
Note the direction of the reed valve.
Install the dowel pins and new gasket.
Assemble the crankcase.
Standard: 0.05 – 0.12 mm (0.002 – 0.004 in)
Install the removed parts in the reverse order of removal.
4-3
Engine Servicing
(3)
(1)
(2)
(4)
(1)
(2)
(2)
(1)
(1) VACUUM HOSE
(2) PRESSURE REGULATOR
(1) BANJO BOLT
(2) SEALING WASHER
(1) BANJO BOLT, 12 mm
(2 SEALING WASHER, 12 mm
(3) SEALING WASHER, 6 mm (4) F. PRESSURE GAUGE
Fuel Line Inspection
Cover the fuel feed hose banjo bolt with a rag or shop
towel.
Slowly loosen the banjo bolt and catch the remaining
fuel using a approved gasoline container.
Remove the fuel feed hose banjo bolt and attach the fuel
pressure gauge with the following Honda Genuine parts.
Fuel Pressure Inspection
! WARNING
Gasoline is highly flammable and is explosive.
You can be burned or seriously injured.
• Stop engine and keep heat, sparks, and flame
away.
• Refuel only outdoors.
• Wipe up spills immediately.
NOTICE
• Before disconnecting the fuel hoses, release the fuel
pressure by loosening the fuel feed hose banjo bolt at
the injector holder.
• Always replace the sealing washers when the fuel
hose banjo bolt is removed or loosened.
Remove the rear fender.
Disconnect the pressure regulator vacuum hose and
plug the vacuum hose.
4-4
Banjo bolt, 12 mm
part No.90008-PP4-E02
Sealing washer, 12 mm
part No. 90428-PD6-003
Sealing washer, 6 mm
part No.90430-PD6-003
Tool:
Fuel pressure gauge
07406-0040003 or
07406-0040002
Engine Servicing
(1)
(2)
(1)
(2)
(1)
(1) FUEL PRESSURE GAUGE
(1) NEW SEALING WASHERS (2) BANJO BOLT
(1) VACUUM HOSE
(2) PRESSURE REGULATOR
Start the engine.
Read the fuel pressure at idle speed.
After inspection, remove the banjo bolt and reinstall and
tighten the fuel feed hose banjo bolt using a new sealing
washer.
Always replace the sealing washer with new ones when
the fuel feed hose banjo bolt is removed or loosened.
Connect the pressure regulator vacuum hose.
Idle Speed: 1,800 ± 100 min-1 (rpm)
Standard: 260 kPa (2.65 kgf/cm2, 38 psi)
If the fuel pressure is higher than specified, inspect the
following:
– Pinched or clogged fuel return hose
– Pressure regulator
– Fuel pump (page 4–6)
Torque: 22 N•m (2.2 kgf•m, 16 lbf•ft)
If the fuel pressure is lower than specified, inspect the
following:
– Fuel line leaking
– Clogged fuel filter
– Pressure regulator
– Fuel pump (page 4–6)
4-5
Engine Servicing
(1)
(1)
(1)
(2)
(1) FUEL RETURN HOSE
(1) 2P (BLACK) CONNECTOR
(1) 2P (BLACK) CONNECTOR
(2) SOCKET BOLTS
Fuel Pump Flow Inspection
After inspection remove the temporarily installed fuel
hose and connect the fuel return hose to the pressure
regulator.
Fuel Tank/Fuel Pump
Connect the fuel pump 2P (Black) connector.
Remove the rear fender.
Start the engine and check for fuel leaks.
Disconnect the injector 2P (Black) connector.
Remove the injector holder socket bolts.
Remove the rear fender.
Disconnect the fuel return hose from the pressure
regulator and plug the hose end.
Connect a other fuel hose to the pressure regulator and
install the hose end in the approved gasoline container.
Connect the 12 V battery to the fuel pump 2P (Black)
connector terminals, check amount of fuel flow for 10
seconds.
Amount of flow:
17 cm3 (0.6 US oz, 0.6 Imp oz) minimum/
10 seconds at 12 V
If the fuel flow is less than specified, inspect the
following:
– Pinched or clogged fuel hose and fuel return hose
– Clogged fuel filter
– Pressure regulator
– Fuel pump (page 4–6)
4-6
Removal
Engine Servicing
(1)
(3)
(2)
(1)
(3)
(1)
(2)
(1) BREATHER HOSE
(2) BOLT (3) FUEL TANK
(2)
(1) 2P (BLACK) CONNECTOR
(1) BANJO BOLT (2) FUEL FEED HOSE
(3) FUEL RETURN HOSE
Pull up the fuel tank and disconnect the fuel pump 2P
(Black) connector.
(1)
Remove the fuel tank and injector as an assembly being
careful not to damage the injector especially tip of the
injector.
After removing the fuel tank/injector assembly, protect
tip of the injector.
Also cover the cylinder head injector hole to prevent
dust and dirt fall into the combustion chamber.
(2)
(1)
(1) VACUUM HOSE
(2) PRESSURE REGULATOR
(1) BOLTS (2) FUEL PUMP
Disconnect the fuel tank breather hose.
Remove the fuel tank mounting bolts.
Remove the banjo bolt, sealing washers and fuel feed
hose.
Disconnect the vacuum hose from the pressure
regulator.
Remove the fuel pump base mounting bolts.
Remove the fuel pump assembly being careful not to
damage the pump.
4-7
Engine Servicing
(1)
(2)
(2)
(1)
(1)
(4)
(3)
(2)
(1) FUEL PUMP (2) ALIGN
(1) FUEL PUMP
(2) BOLTS
Installation
(1) NEW O-RING (2) RETURN HOSE
(3) FUEL FEED HOSE
(4) NEW SEALING WASHERS/BANJO BOLT
(1)
NOTICE
Always replace the packing with a new one when the
fuel pump is removed.
Clean any oil off from the mating surface of the fuel
pump base and fuel tank.
Install a new packing onto the fuel pump base.
Install the fuel pump assembly into the fuel tank while
aligning the packing slit with the fuel return pipe in the
tank.
Be careful not to damage the fuel pump wire.
Make sure the packing is seated against the fuel tank.
Also check that the packing is not placed on the fuel tank
boss.
(1) 2P (BLACK) CONNECTOR
Install the fuel pump mounting bolts.
Tighten the fuel tank mounting bolts in the alphabetical
order shown in the illustration.
Torque: 6.9 N•m (0.7 kgf•m, 5.1 lbf•ft)
Always replace the injector O-ring with a new one
whenever the injector is removed from the cylinder
head.
Install a new O-ring into the injector groove.
Install the fuel feed hose between the hose stoppers on
the fuel pump base with new sealing washers.
Tighten the fuel hose banjo bolt to the specified torque.
Torque: 22 N•m (2.2 kgf•m, 16 lbf•ft)
Install the fuel tank onto the frame and connect the fuel
pump 2P (Black) connector.
4-8
Engine Servicing
(1)
(2)
(2)
(1)
(3)
(1)
(1) FUEL TANK (2) BOLTS
(3) BREATHER HOSE
(2)
(1) SOCKET BOLTS
(2) 2P (BLACK) CONNECTOR
(1) INJECTOR
Install and tighten the injector holder socket bolts to the
specified torque.
Injector
Inspection
Torque: 9.8 N•m (1.0 kgf•m, 7 lbf•ft)
Remove the rear fender.
Connect the fuel injector 2P (Black) connector.
Install the rear fender.
Start the engine and let it idle.
Confirm the injector operating sounds with a sounding
rod or stethoscope.
If the injector does not operate, replace the injector.
(1)
(1) VACUUM HOSE
(2) PRESSURE REGULATOR
Install the fuel tank into the frame being careful not to
pinch the throttle cable.
Connect the vacuum hose to the pressure regulator.
Install and tighten the fuel tank mounting bolts.
Connect the fuel tank breather hose to the hose clip.
4-9
Engine Servicing
(2)
(1)
(3)
(2)
(1)
(2)
(1) INJECTOR
(2) NEW O-RING
(1) BOLTS/NUTS (2) AIR CLEANER HOUSING
Removal/Installation
Throttle Body
Do not remove the injector from the injector holder.
Replace the injector and holder as an assembly.
Removal
(1)
(1) 32P (BLACK) CONNECTOR
(2) BAND SCREW
(3) THROTTLE BODY
(2)
Always replace the O-ring when the fuel injector
assembly is removed from the cylinder head.
Remove the rear fender.
Remove the fuel tank/injector as an assembly (page 4-6).
Loosen the connecting tube band screw.
Remove the silencer mounting bolt.
Remove the air cleaner housing mounting nuts and bolt.
Pull the air cleaner housing backward being careful not
to damage the wire harness.
Disconnect the crankcase breather hose from the
housing joint.
(1)
(1) SCREWS
(2) THROTTLE DRUM COVER
Disconnect the ECM 32P (Black) connector.
Loosen the insulator band screw, then remove the
throttle body.
Be careful to not pull connector from throttle body, pull
up fixation handle.
Remove the screws and throttle drum cover.
4-10
Engine Servicing
(1)
(4)
(2)
(4)
(2)
(3)
(3)
(2)
(3)
(1)
(1)
(1) LOCK NUT (2) THROTTLE CABLE
(3) THROTTLE CABLE END (4) THROTTLE DRUM
(1) THROTTLE CABLE END (2) THROTTLE DRUM
(3) THROTTLE CABLE (4) LOCK NUT
Install the throttle body into the insulator.
Make sure there are following clearance between the
throttle body:
– Throttle body-to-bank angle sensor: more than 5 mm
– Throttle body-to-silencer: more than 5 mm
(3)
(2)
(1) THROTTLE BODY
(2) BAND SCREW
(3) 32P (BLACK) CONNECTOR
(1)
Adjust the insulator band angle, tighten the band screw
securely.
Connect the ECM 32P (Black) connector.
(1)
(2)
(1) SCREW
(2) INSULATOR
(3) ALIGN
(1) THROTTLE DRUM COVER
(2) SCREWS
Loosen the lock nut, then disconnect the throttle cable
from the throttle body.
Then disconnect the cable end from the throttle drum.
Connect the throttle cable end to the throttle drum.
Install the throttle cable to the throttle body.
Adjust the throttle grip free play.
Loosen the insulator clamp screw, then remove the
insulator from the throttle body.
Install the throttle drum cover and tighten the screws.
Installation
Install the insulator onto the throttle body while aligning
its slit with the lug on the throttle body as shown.
4-11
Engine Servicing
(2)
(1)
(2)
(1)
(1) AIR CLEANER HOUSING
(2) BOLTS/NUTS
(1)
(1) BOLTS (2) WATER PUMP COVER
(1) BEARING REMOVER, 12 mm
Install the air cleaner housing onto the frame and
connect the crankcase breather hose.
(4)
Install and tighten the air cleaner housing mounting nuts
and bolt securely.
Install the washer and silencer mounting bolt, then
tighten the bolt securely.
Tighten the connecting tube band screw securely.
(3)
(1)
Tools:
Bearing remover, 12 mm
– Remover shaft
– Remover weight
Remove the oil seal and water seal.
Install the rear fender.
(2)
(1) IMPELLER (2) COPPER WASHER
(3) WATER PUMP SHAFT (4) WASHER
Water Seal And Bearing Replacement
Drain the transmission oil (page 3-8).
Remove the following:
– Water pump cover bolt/cover/dowel pins/O-ring
– Right crankcase cover and washer (page 4-37)
Hold the water pump gear teeth using a suitable tool,
then remove the impeller, copper washer and water
pump shaft.
4-12
Remove the water pump bearing from the right
crankcase cover using the special tools.
07936-1660101
07936-1660120
07741-0010201
Engine Servicing
(1)
(1)
(1)
(2)
(2)
(4)
(2)
(3)
(3)
(1) WATER SEAL DRIVER
(2) DRIVER/ATTACHMENT
(1) WASHER (2) WATER PUMP SHAFT
(3) NEW COPPER WASHER (4) IMPELLER
(1)
(1) DOWEL PINS (2) NEW O-RING
(3) WATER PUMP COVER
Install the water pump shaft, new copper washer and
impeller into the right crankcase cover.
Hold the water pump gear using a suitable tool and
tighten the impeller to the specified torque.
(2)
(2)
Torque: 12 N•m (1.2 kgf•m, 9 lbf•ft)
Install the washer and right crankcase cover (page 4-38).
(3)
(1)
(1) WATER SEAL (2) OIL SEAL
(3) BEARING
(1) WATER PUMP COVER (2) BOLTS
Install the water seal into the right crankcase cover in the
direction shown in the illustration above.
Install the following:
– Dowel pins, new O-ring
– Water pump cover, bolts
Tool:
Water seal driver
07945-KA30000
Install a new oil seal in the direction shown in the
illustration above.
Drive the new bearing into the right crankcase cover
(Tools; page 2-7).
Fill the crankcase with recommended transmission oil
(page 3-8).
Fill the coolant and bleed air (page 3-8).
4-13
Engine Servicing
(1)
(1)
(3)
(2)
(1)
(1) BREATHER CHAMBER
Radiator Removal/Installation
(1) 2P (NATURAL) CONNECTOR
(1) GROUND EYELET
(2) BOLTS (3) IGNITION COIL
(1)
Remove the following:
– Exhaust pipe
– Skid plate
– Fuel tank/injector assembly (page 4-6)
(2)
(1)
Pull out the crankcase breather chamber from the frame.
(1) TIE WRAP
(1) 3P (GRAY) CONNECTOR (2) CLAMP
Disconnect the radiator 2P (Natural) connector.
Remove the ground eyelet bolt.
Remove the ignition coil mounting bolt.
Remove the spark plug wire tie-wrap from fan motor
shroud.
4-14
Disconnect the ECT sensor 3P (Gray) connector.
Remove the spark plug wire/wire harness/breather hose
clamp.
Engine Servicing
(5)
(3)
(1)
(3)
(1)
(6)
(2)
(2)
(4)
(4)
(1) RADIATOR (2) EXHAUST PIPE
(3) MUFFLER (4) SKID PLATE
(1) RADIATOR HOSES (2) HANGER BOLT
(3) DOWN TUBE BOLTS (4) DOWN TUBES
(5) BOLT (6) RADIATOR
Engine Removal/Installation
Disconnect the radiator hoses at the right crankcase
cover and cylinder head.
Remove the front engine hanger bolt and front down
tube mounting bolts, then remove the down tubes.
Remove the radiator mounting bolt, then remove the
radiator assembly.
(1)
(2)
(3)
(1) IGNITION COIL (2) BOLTS
(3) GROUND EYELET
Installation is in the reverse order of removal.
NOTICE
• Support the motorcycle securely using a hoist or
equivalent.
• The following parts must be removed before engine
removal.
– Exhaust pipe, muffler
– Skid plate
– Down tubes, radiator (page 4-14)
– Air cleaner housing (page 4-10)
• The following components can be serviced with the
engine in the frame.
– Cylinder head/cylinder/piston
– Clutch/gearshift linkage
– Flywheel/stator
– Kickstarter/gearshift linkage
• The following components require engine removal for
servicing.
– Crankshaft
– Oil pump
– Shift forks and shift drum
– Transmission
At ignition coil installation, install the ground eyelet with
the ignition coil lower mounting bracket bolt as shown in
the illustration.
4-15
Engine Servicing
Engine Removal/Installation Illustration
24 N•m (2.4 kgf•m, 17 lbf•ft)
25 N•m (2.6 kgf•m, 19 lbf•ft)
69 N•m (7.0 kgf•m, 51 lbf•ft)
49 N•m (5.0 kgf•m, 36 lbf•ft)
26 N•m (2.7 kgf•m, 20 lbf•ft)
4-16
Engine Servicing
(2)
(1)
(1)
(1)
(1) CYLINDER COMPRESSION GAUGE
(1) SEALING BOLT/WASHER
(2) STOPPER TOOL
(1) TIMING HOLE CAP
Cylinder Compression
(2)
Warm up the engine to normal operating temperature.
Stop the engine and remove the spark plug.
Install a compression gauge.
Shift the transmission into neutral.
Open the throttle all the way and crank the engine with
the kickstarter until the gauge reading stops rising.
Compression pressure:
460 kPa (4.7 kgf/cm3, 67 psi) at 800 min-1 (rpm)
Low compression can be caused by:
– Blown cylinder head gasket
– Improper valve adjustment
– Valve leakage
– Worn piston ring or cylinder
High compression can be caused by:
– Carbon deposits in combustion chamber or on piston
head
– Incorrect valves adjustment
(1)
(1) CAM CHAIN TENSIONER LIFTER
(1) “T” MARK
(2) INDEX MARK
Cylinder Head Cover/Camshaft Removal
Remove the fuel tank/injector.
Remove the cam chain tensioner lifter sealing bolt and
sealing washer.
Remove the timing hole cap and O-ring from the left
crankcase cover.
Turn the tensioner lifter clockwise fully and secure it with
the stopper tool.
This tool can be easily be made from a thin (1 mm thick)
piece of steel as shown.
Turn the crankshaft by operating the kickstarter and align
the “T” mark on the flywheel with the index mark on the
left crankcase cover.
4-17
Engine Servicing
(3)
(2)
(2)
(2)
(1)
(1)
(3)
(1)
(4)
(1) BOLTS (2) TAPPET ADJUSTING HOLE COVER
(1) BOLTS/SEALING WASHERS (2) SH BOLTS
(3) SEALING WASHERS (4) CYLINDER HEAD COVER
Remove the bolts and tappet adjusting hole covers.
(1) CAM CHAIN (2) CAMSHAFT
Remove the cam chain from the cam sprocket and
suspend the cam chain with a piece of wire to prevent it
from falling into the crankcase.
(2)
Make sure the piston at TDC (Top Dead Center) on the
compression stroke by moving the rocker arms.
Remove the camshaft assembly.
(1)
(1) SIDE CAP
(2) DOWEL PINS
Disconnect the crankcase breather hose.
Remove the two 6 mm bolts.
Loosen the eight cylinder head cover SH bolts in
crisscross pattern in 2 or 3 steps.
Remove the bolts and four sealing washers.
Remove the cylinder head cover assembly.
Remove the dowel pins.
Remove the cylinder head side cap.
Remove the camshaft bearing retainer from the cylinder
head cover.
4-18
Engine Servicing
(1)
(3)
(1)
(1)
(2)
(4)
(2)
(2)
(1) INTAKE ROCKER ARM SHAFT
(2) EXHAUST ROCKER ARM SHAFT
(3) INTAKE ROCKER ARM (4) EXHAUST ROCKER ARM
(1) ROCKER ARM
(2) ROCKER ARM SHAFT
(1) BEARINGS
(2) CAMSHAFT
Check the rocker arms and shafts for wear or damage.
Measure the rocker arm I.D.
Disassembly
Pull out the rocker arm shafts using a suitable 6 mm bolt
and remove the intake and exhaust rocker arms.
(1)
Service limit: 10.051 mm (0.3957 in)
Measure the rocker arm shaft O.D. at rocker arm sliding
portion.
Service limit: 9.925 mm (0.3907 in)
(2)
(1) DECOMPRESSOR
(2) RETURN SPRING
Inspection
Remove the bearings from the camshaft.
Turn the inner race of each bearing with your finger.
The bearing should turn smoothly and quietly.
Replace the bearing if the bearing do not turn smoothly
and quietly.
Check the decompressor cam for wear or damage.
If any components are faulty, replace the camshaft
assembly.
4-19
Engine Servicing
(2)
(2)
(1)
(1)
(1)
(2)
(3)
(1) RADIATOR HOSE
(2) HANGER BOLTS
(1) BOLTS
(2) NUTS/WASHERS
(3) CYLINDER HEAD
Cylinder Head Removal
Remove the cylinder head mounting bolts.
Loosen the cylinder head mounting nuts in a crisscross
pattern in two or three steps.
Remove the nuts, washers and cylinder head.
Remove the following:
– Exhaust pipe
– Throttle body/insulator
– Cylinder head cover/camshaft
– Spark plug
(1) GASKET (2) DOWEL PINS
(1)
Drain the coolant.
Loosen the hose band screw and disconnect the upper
radiator hose from the cylinder head.
Remove the upper engine hanger bolts.
(1) CAM CHAIN GUIDE
Remove the gasket and dowel pins.
Remove the cam chain guide.
4-20
Engine Servicing
(1)
(3)
(2)
(5)
(4)
(2)
(1)
(2)
(1)
(1) BOLTS
(2) CAM CHAIN GUIDE PLATE
(1) CAM CHAIN TENSIONER
(2) CAM CHAIN GUIDE
(1) WASHER (2) PIVOT COLLAR
(3) CAM CHAIN TENSIONER
(4) PIVOT BOLT (5) APPLY LOCKING AGENT
Inspection
(2)
(1)
Inspect the cam chain tensioner and cam chain guide for
excessive wear or damage, replace if necessary.
(1)
(2)
(1) BOLT (2) CAM CHAIN TENSIONER
(1) CAM CHAIN TENSIONER
(2) PIVOT BOLT
Remove the following:
– Cylinder head (page 4-20)
– Left crankcase cover (page 4-46)
– Flywheel (page 4-49)
Installation
Remove the bolts and cam chain guide plate.
Remove the bolt, cam chain tensioner, pivot collar and
washer.
Apply a locking agent to the cam chain tensioner pivot
bolt threads.
Install the washer, cam chain tensioner, pivot collar and
pivot bolt.
Tighten the pivot bolt to the specified torque.
Torque: 12 N•m (1.2 kgf•m, 9 lbf•ft)
4-21
Engine Servicing
(1)
(1)
(2)
(2)
(1)
(4)
(3)
(2)
(5)
(6)
(2)
(1)
(1) CAM CHAIN GUIDE
(2) ALIGN
(1) VALVE SPRING COMPRESSOR
(2) ATTACHMENT
(1) RETAINER (2) OUTER SPRING
(3) INNER SPRING (4) SPRING SEAT
(5) VALVE (6) STEM SEAL
Cylinder Head Disassembly
Remove the following:
– Spring retainer
– Outer and inner valve springs
– Stem seal
– Valve spring seat
– Intake and exhaust valve
Remove the cylinder head (page 4-20).
Remove the valve spring cotters using the special tools.
To prevent loss of tension, do not compress the valve
springs more than necessary to remove the cotters.
Tools:
Valve spring compressor
Compressor attachment
(2)
(1)
(1) CAM CHAIN GUIDE PLATE
(2) BOLTS
Install the cam chain guide by aligning the guide end
with the groove in the crankcase and the tab with the
groove in the cylinder.
Install the cam chain guide plate and tighten the bolts.
Install the following:
– Flywheel (page 4-50)
– Left crankcase cover (page 4-48)
– Cylinder head (page 4-34)
4-22
07757-0010000
07959-KM30101
Engine Servicing
(1)
(1)
(1)
(2)
(1) COMBUSTION CHAMBER
(1) OUTER VALVE SPRING
(2) INNER VALVE SPRING
(1) VALVE
Cylinder Head Inspection
Valve spring
Valve/Valve Guide
Cylinder Head
Check the valve springs for fatigue or damage.
Measure the free length of the intake and exhaust valve
springs.
Inspect each valve for out-of-round, burns, scratches or
abnormal stem wear.
Remove the carbon deposits from the combustion
chamber or exhaust port.
Use care not to scratch the combustion chamber or the
head gasket surface.
Check the spark plug hole and valve area for cranks.
Service limits:
Inner: 24.9 mm (0.98 in)
Outer: 27.6 mm (1.09 in)
Check the valve movement in the guide.
Measure and record the valve stem O.D.
Service limits:
IN: 4.470 mm (0.1760 in)
EX: 4.460 mm (0.1756 in)
Check the cylinder head for warpage with a straight edge
and feeler gauge.
Service limit: 0.05 mm (0.002 in)
4-23
Engine Servicing
(1)
(1)
(1) VALVE GUIDE DRIVER
(1) VALVE GUIDE REAMER
Ream the valve guide to remove any carbon build-up
before measuring the guide.
Insert the reamer from the combustion chamber side of
the head and always rotate the reamer clockwise.
Tool:
Valve guide reamer, 4.508 mm
07HMH–ML00101
Measure and record the valve guide I.D. using a ball
gauge or inside micrometer.
Service limit:
IN/EX: 4.552 mm (0.1792 in)
Subtract each valve stem O.D. from the corresponding
guide I.D. to obtain the stem-to-guide clearance.
Standard:
IN: 0.010 – 0.037 mm (0.0004 – 0.0015 in)
EX: 0.020 – 0.047 mm (0.0008 – 0.0019 in)
If the stem-to-guide clearance exceeds the service limits,
determine if a new guide with standard dimensions
would bring the clearance within tolerance.
If so, replace the guides as necessary and ream to fit.
Reface the valve seats whenever the valve guides are
replaced (page 4-25).
If the stem-to-guide clearance exceeds the service limits
with new guides also, replace the valves and guides.
4-24
Valve Guide Replacement
Mark new valve guides at the proper depth (see
specification; page 4-25) using a marker.
Chill the new valve guides in a freezer for about 1 hour.
Heat the cylinder head to 100 – 150 ˚C (212 – 300 ˚F) with
a hot plate or oven.
Do not heat the cylinder head beyond 180 ˚C (320 ˚F).
Use temperature indicator sticks, available from welding
supply stores, to be sure the cylinder head is heated to
the proper temperature.
Use a torch to heat the cylinder head may cause
warpage.
Support the cylinder head and drive the valve guides out
of the cylinder head from the combustion chamber side.
Tool:
Valve guide driver
07HMD–ML00101
Engine Servicing
(1)
(1)
(1) VALVE SEAT WIDTH
(1) VALVE GUIDE DRIVER
Remove the guide from the freezer.
While the cylinder head is still heated, drive new valve
guides into the cylinder head from the top of the cylinder
(camshaft side).
Drive the guides until the marks are parallel with the
cylinder head.
Check that the valve guides are at the proper depth using
a slide caliper, adjust the height if necessary.
Tool:
Valve guide driver
Let the cylinder head cool to room temperature.
Valve Seat Inspection/Refacing
Clean the intake and exhaust valves thoroughly to
remove carbon deposits.
Apply a light coating of Prussian Blue to the valve seat.
Specified depth:
IN: 8.0 – 8.3 mm (0.31 – 0.33 in)
EX: 8.2 – 8.5 mm (0.32 – 0.33 in)
Tap the valves and seats using a rubber hose or other
hand lapping tool.
07HMD–ML00101
Ream the new valve guides.
Insert the reamer from the combustion chamber side of
the cylinder head and always rotate the reamer
clockwise.
Use cutting oil on the reamer during this operation.
Take care not to tilt or lean the reamer in the guide while
reaming.
Tool:
Valve guide reamer, 4.508 mm
Remove the valve and inspect the valve seat face.
The valve seat contact should be within the specified
width and even all around the circumference.
Standard:
IN/EX: 0.9 – 1.1 mm (0.035 – 0.043 in)
Service limit:
IN/EX: 1.7 mm (0.07 in)
07HMH–ML00101
Clean the cylinder head thoroughly to remove any metal
particles after reaming and reface the valve seats.
If the seat width is not within specification, reface the
valve seat (page 4-26).
Inspect the valve seat face for:
• Uneven seat width:
– Replace the valve and reface the valve seat.
• Damaged face:
– Replace the valve and reface the valve seat.
4-25
Engine Servicing
(1)
45˚
60˚
32˚
32˚
(1) ROUGHNESS
• Contact area (too high or too low)
– Reface the valve seat.
The valves cannot be ground, If a valve face is burned or
badly worn or if it contacts the seat unevenly, replace
the valve.
Valve Seat Refacing
Valve seat cutters.grinders or equivalent valve seat
refacing equipment are recommended to correct worn
valve seat.
Follow the refacing manufacturer’s instructions.
60˚
If the contact area is too high on the valve, the seat must
be lowered using a 32˚ flat cutter.
If the contact area is too lower on the valve, the seat
must be raised using a 60˚ interior cutter.
4-26
Engine Servicing
(1)
32˚
60˚
45˚
(1) SEAT WIDTH
Use a 45˚ cutter, remove any roughness or irregularities
from the seat.
Reface the seat with a 45˚ cutter whenever a valve guide
is replaced.
Tools:
Seat cutter, 35 mm
07780–0010400
Seat cutter, 33 mm
07780–0010800
Cutter holder, 5.0 mm
07781–0010400
or equivalent commercially available
Use a 32˚ flat cutter, remove 1/4 of the existing valve seat
material.
Use a interior cutter, remove 1/4 of the existing valve
seat material.
Tools:
Flat cutter, 33 mm
07780–0012900
Flat cutter, 28 mm
07780–0012100
Cutter holder, 5.0 mm
07781–0010400
or equivalent commercially available
Tools:
Interior cutter, 37.5 mm
07780–0014100
Interior cutter, 30 mm
07780–0014000
Cutter holder, 5.0 mm
07781–0010400
or equivalent commercially available
4-27
Engine Servicing
(5)
(1)
(4)
(3)
45˚
(2)
(6)
(1) SPRING SEAT (2) STEM SEAL
(3) VALVE (4) INNER SPRING
(5) OUTER SPRING (6) RETAINER
Using a 45˚ seat cutter, cut the seat to proper width.
Make sure all pitting and irregularities are removed.
Refinish if necessary.
After refacing, wash the cylinder head and valves.
After cutting the seats, apply lapping compound to the
valve face, and lap the valve using light pressure.
After lapping, wash any residual compound off the
cylinder head and valve.
4-28
Cylinder Head Assembly
Blow out all oil passages in the cylinder head with
compressed air.
Install the spring seat and new stem seal.
Lubricate the valve stem sliding surface with
molybdenum solution.
Insert the valves into the guide while turning it slowly to
avoid damage to the stem seal.
Install the valve springs with the tightly wound coils
facing the combustion chamber.
Install the spring retainers.
Engine Servicing
(2)
(1)
(1)
(2)
(3)
(1) VALVE SPRING COMPRESSOR
(2) ATTACHMENT
(1) PLASTIC HAMMERS
(1) BOLTS
(2) CAM CHAIN TENSIONER LIFTER
(3) GASKET
Compress the valve springs with the special tools and
install the cotters.
Grease the cotters to ease installation.
Tap the valve stems gently with two plastic hammers as
shown to seat the cotters firmly.
Support the cylinder head so the valve heads do not
contact anything that may damage them.
Cylinder/Piston
Tools:
Valve spring compressor
Compressor attachment
(1)
Cylinder Removal
Remove the cylinder head (page 4-20).
07757-0010000
07959-KM30101
Remove the bolts, cam chain tensioner lifter and gasket.
To prevent loss of tension, do not compress the valve
springs more than necessary.
4-29
Engine Servicing
(2)
(2)
(1)
(1)
(1) PISTON PIN CLIP
(2) PISTON PIN
(1) SEALING BOLT/SEALING WASHER
(2) CYLINDER
Piston Removal
(2)
Place a clean shop towel over the crankcase to prevent
the clip from falling the crankcase.
Remove the piston pin clips with pliers.
Press the piston pin out of the piston and remove the
piston.
(1)
(1) GASKET
(2) DOWEL PINS
Remove the mounting sealing bolt, sealing washer and
cylinder.
Remove the gasket and dowel pins.
4-30
Spread the piston rings and remove them by lifting up at
a point just opposite the gap.
Piston rings are easily broken; take care not to damage
them during removal.
Engine Servicing
Inspection
Cylinder
Inspect the cylinder bore for wear or damage.
Measure the cylinder I.D. in the X and Y axis at three
levels.
Take the maximum reading to determine the cylinder
wear.
Service limit: 76.54 mm (3.013 in)
Piston/Piston Ring
Remove the carbon deposits from the piston head or
piston ring grooves using old piston rings.
Inspect the piston for damage and the ring grooves for
wear.
Temporarily install the piston rings to their proper
position with the mark facing up.
Measure the piston ring-to-ring groove clearance with
the rings pushed into the grooves.
Service limit:
Top:
0.015 mm (0.0045 in)
Second: 0.065 mm (0.0026 in)
Inspect the piston ring grooves for wear or damage.
Calculate the taper and out-of-round at three levels in the
X and Y axis. Take maximum reading to determine the
cylinder condition.
Service limit:
Taper:
0.05 mm (0.002 in)
Out-of-round: 0.05 mm (0.002 in)
Inspect the top of the cylinder for warpage.
Service limit: 0.05 mm (0.002 in)
4-31
Engine Servicing
Measure the O.D. of the piston at 5 mm (0.2 in) from
bottom of skirt and 90 degrees to the piston pin hole.
Service limit: 76.39 mm (3.007 in)
If the O.D. is under the service limit, replace the piston
with a new one.
Calculate the piston-to-cylinder clearance.
Service limit: 0.18 mm (0.007 in)
Measure the piston pin bore I.D.
Service limit: 16.03 mm (0.631 in)
Check the piston pin for wear or excessive discoloration.
Measure the piston pin O.D.
Service limit: 15.98 mm (0.629 in)
Replace the piston pin if necessary.
Calculate the piston pin-to-piston clearance.
Service limit: 0.04 mm (0.002 in)
4-32
Insert each piston ring into the cylinder and measure the
ring end gap.
Push the ring into the cylinder with the top of the piston
to be sure the ring is squarely in the cylinder.
Connecting Rod
Measure the connecting rod small end I.D.
Service limit:
Top:
Second:
Oil (side rail):
If the I.D. is not over the service limit, replace the piston
pin.
If the I.D. is over the service limit, replace the crankshaft
(page 4-51).
0.44 mm (0.017 in)
0.64 mm (0.025 in)
0.90 mm (0.035 in)
Service limit: 16.04 mm (0.631 in)
Engine Servicing
(1)
(1)
(1)
(2)
(3)
(4)
(2)
(3)
(1) TENSIONER LIFTER
(1) TOP RING (2) SECOND RING
(3) OIL RINGS (4) SPACER
(1) “IN” MARK (2) PISTON PIN
(3) NEW PISTON PIN CLIP
Tensioner lifter
Check the tensioner lifter operation as follows:
– The tensioner shaft should not go into the body when
it is pushed.
– When it is turned clockwise with a screwdriver, the
tensioner shaft should be pulled into the body. The
shaft should spring out of the body as soon as the
screwdriver is released.
Piston Ring Installation
Piston Installation
Clean the piston ring grooves thoroughly.
Apply engine oil to the piston rings and piston ring
grooves.
Install the piston ring into the grooves with their marking
facing up.
Place a shop towel over the cylinder opening to prevent
dust or dirt from entering the engine.
Clean any gasket material from the cylinder mating
surfaces of the crankcase.
Apply molybdenum oil solution to the connecting rod
small end.
• Do not damage the piston ring by spreading the ends
too far.
• Be careful not to damage the piston during piston
ring installation.
• Do not align the oil ring (side rail) gaps.
• Space the piston ring end 120 degrees apart.
After installation, the rings should rotate freely in the
ring grooves.
Place a shop towel around the piston skirt and in the
crankcase to prevent the piston pin clips from falling into
the crankcase.
Apply engine oil to the piston pin outer surface and
piston pin bore of the piston.
Install the piston with the “IN” mark facing intake side.
Install the piston pin and new piston pin clips.
Be careful not to drop the piston pin clip into the
crankcase.
Always use new piston pin clips. Reinstalling used
piston pin clips may lead to serious engine damage.
Do not align the piston pin clip end gap with the piston
cut-out.
4-33
Engine Servicing
(1)
(1)
(1)
(2)
(2)
(1) DOWEL PINS
(2) NEW GASKET
(2)
(1) CYLINDER
(2) NEW SEALING BOLT/SEALING WASHER
(1)
Apply locking agent to the cylinder mounting sealing
bolt threads.
Install the cylinder mounting sealing bolt with a new
sealing washer but do not tighten it yet.
(1) DOWEL PINS
(2) NEW GASKET
(2)
(3)
(1)
(1) CYLINDER
(1) CYLINDER HEAD
(2) WASHERS/NUTS
(3) BOLTS
Cylinder Installation
Cylinder Head Installation
Install the dowel pins and new gasket.
Install the dowel pins and new gasket.
Install the cylinder head onto the cylinder.
Apply oil to the cylinder head mounting nut threads and
seating surface, install them with washers.
Install the two cylinder head 6 mm bolts.
Tighten the cylinder head nuts (cap nuts on right side) in
a crisscross pattern in 2 – 3 steps to the specified torque.
Coat the cylinder bore, piston and piston rings with clean
engine oil and install the cylinder while compressing the
piston rings being careful not to damage the rings.
Torque: 39 N•m (4.0 kgf•m, 29 lbf•ft)
4-34
Engine Servicing
(2)
(1)
(2)
(1)
(1)
(2)
(1) CYLINDER HEAD BOLTS
(2) CYLINDER SEALING BOLT
(1) HANGER BOLT/NUT
(2) RADIATOR HOSE
(1) “T” MARK
(2) INDEX MARK
Tighten the cylinder sealing bolt and cylinder head
mounting bolts securely.
Install the upper engine hanger bolt and nut, tighten the
nut to the specified torque.
Camshaft/Cylinder Head Cover Installation
Camshaft Installation
Torque: 24 N•m (2.4 kgf•m, 17 lbf•ft)
Connect the radiator hose to the water joint, tighten the
clamp screw securely.
Turn the crankshaft by operating the kickstarter, align the
“T” mark on the flywheel with the index mark on the left
crankcase cover.
Install the following:
– Camshaft
– Cylinder head cover
– Throttle body/insulator
– Exhaust pipe
Pour recommended coolant mixture and bleed air.
4-35
Engine Servicing
(4)
(2)
(1)
(1)
(3)
(2)
(5)
(2)
(1)
(1) NEW O-RINGS (2) INTAKE ROCKER ARM SHAFT
(3) INTAKE ROCKER ARM (4) EXHAUST ROCKER ARM
(5) EXHAUST ROCKER ARM SHAFT
(1) BEARINGS
(2) GROOVE
(1)
(1) APPLY SEALANT
(2) BEARING RETAINER
Cylinder Head Cover Assembly
(2)
(2)
Apply molybdenum oil solution to the rocker arm I.D.
and rocker arm shaft sliding surface.
Install new O-ring to each rocker arm shaft groove.
Place the intake rocker and exhaust rocker arm into the
cylinder head cover.
The intake rocker arm is identified with groove on the
end of the shaft.
(3)
Install the intake and exhaust rocker arm shafts with
their cut-out facing in and the shaft end oil hole facing up
as shown.
(1)
(1) CAM SPROCKET (2) CAM CHAIN
(3) INDEX MARKS
(1) CAMSHAFT END CAP
(2) DOWEL PINS
Apply molybdenum oil solution to the camshaft cam
surface.
Install the bearings both ends of the camshaft.
Install the left camshaft bearing with its groove side
facing out.
Cylinder Head Cover Installation
Install the cam chain onto the cam sprocket, then install
the camshaft onto the cylinder head while aligning the
index marks on the cam sprocket with the upper surface
of the cylinder head.
4-36
Apply sealant to the mating surface of the cylinder head
cover.
Install the camshaft bearing retainer into the cylinder
head cover inner groove.
Install the camshaft end cap.
Engine Servicing
(3)
(1)
(4)
(3)
(2)
(1)
(2)
(3)
(4)
(2)
(1)
(1) CYLINDER HEAD COVER
(2) NEW SEALING WASHERS/6 mm BOLTS
(3) NEW SEALING WASHERS (4) SH BOLTS
Install the cylinder head cover.
Install new sealing washers and 6 mm bolts.
Install the two new sealing washers and cylinder head
cover SH bolts.
(1) TAPPET ADJUSTING HOLE CAP (2) O-RING
(1)
(2)
(5)
(1) RADIATOR HOSE (2) KICKSTARTER PEDAL
(3) BOLTS (4) CLUTCH COVER
(5) RIGHT CRANKCASE COVER
Right Crankcase Cover
Removal
Remove the water pump cover (page 4-12).
Tighten the cylinder head cover bolts securely.
Remove the bolt and kickstarter pedal.
(3)
Squeeze the clutch lever and secure the lever to prevent
the clutch slave piston comes out from the clutch cover.
Disconnect the lower radiator hose.
Remove the bolts, clutch cover, right crankcase cover,
gasket and dowel pins.
(1) “UP” MARK
(2) TAPPET ADJUSTING HOLE CAP
(3) BOLTS
Check the valve clearance (page 3-4).
Install new O-rings into the tappet adjusting hole cover
grooves.
Install the tappet adjusting hole cap with their “UP”
marks facing up.
Install and tighten the cover bolts securely.
Connect the crankcase breather hose to the cylinder
head cover.
4-37
Engine Servicing
(4)
(1)
(6)
(5)
(1)
(3)
(2)
(1)
(2)
(1) DOWEL PINS (2) NEW GASKET
(1) RIGHT CRANKCASE COVER (2) CLUTCH COVER
(3) WATER PUMP COVER (4) BOLTS
(5) RADIATOR HOSE (6) KICKSTARTER PEDAL
Installation
Install the right crankcase cover while turning the water
pump impeller.
Check the clutch cover O-ring is in good condition,
replace if necessary.
Install the clutch cover.
Install two dowel pins and new gasket onto the
crankcase.
(3)
(2)
(1) OIL BOLTS (2) SEALING WASHERS
(3) EYELET JOINT
Install the water pump cover (page 4-12).
Tighten the right crankcase cover bolts in a crisscross
pattern in 2 – 3 steps.
Install the kickstarter pedal and tighten the bolt to the
specified torque.
(2)
(1)
Torque: 26 N•m (2.7 kgf•m, 20 lbf•ft)
(1) BOLTS (2) CLUTCH COVER
Connect the lower radiator hose.
Fill the crankcase with recommended transmission oil
(page 3-8).
Fill the coolant and bleed air.
Clutch Slave Cylinder
Drain the clutch fluid from the clutch hydraulic system.
Remove the oil bolt, sealing washers and clutch hose
eyelet.
Remove the bolts, clutch cover and O-ring.
Remove the dowel pins.
4-38
Engine Servicing
(3)
(4)
(2)
(2)
(1)
(3)
(1)
(1)
(3)
(1) SLAVE CYLINDER PISTON
(2) SPRING
(3) O-RING (BLACK) (4) O-RING (GREEN)
(1) O-RING
(2) DOWEL PINS
(3) CLUTCH COVER
(1) EYELET JOINT (2) SEALING WASHERS
(3) OIL BOLTS
Apply small squirts of air pressure to the fluid inlet to
remove the piston.
Do not use high pressure air or bring the nozzle close to
the inlet.
Install the clutch hose eyelet with new sealing washers.
Install and tighten the oil bolt..
Fill the clutch system with recommended brake fluid and
bleed air.
Remove the slave cylinder piston, return spring and Orings.
Remove the O-rings from the piston.
Check the slave cylinder in the clutch cover for scoring or
other damage.
Check the slave cylinder piston for scratches, scoring or
other damage.
Check the piston spring for weakness or damage.
Clean slave cylinder O-ring grooves with clean brake
fluid.
Apply silicone grease to the O-rings.
Install 23 x 2.1 mm O-ring (Black) into the spring side
groove.
Install 21.8 x 2.4 mm O-ring (Green) into the lifter plate
side groove.
Do not interchange the O-rings.
(2)
(1)
(2)
(1) CLUTCH COVER
(2) BOLTS
Install new O-ring into the clutch cover groove.
Install the dowel pins onto the right crankcase cover.
Install the clutch cover onto the right crankcase cover.
Install and tighten the clutch cover bolts.
Install the return spring and piston into the slave cylinder
in the clutch cover.
4-39
Engine Servicing
(1)
(4)
(2)
(5)
(1)
(3)
(1)
(2)
(1) CLUTCH CENTER HOLDER
(1) CLUTCH LIFTER PIECE ASSEMBLY
(2) LIFTER PLATE BOLTS (3) CLUTCH LIFTER
(4) CLUTCH SPRINGS
(2)
(3)
(4)
(1) CLUTCH CENTER (2) CLUTCH DISCS
(3) CLUTCH PLATE (4) PRESSURE PLATE
(5) PAPER DISCS
Clutch
(2)
Removal
(1)
(4)
Pull the clutch lever and hold it with a suitable clamp.
Remove the bolts and clutch
disconnecting the clutch fluid line.
cover
without
Remove the clutch lifter piece assembly.
Remove the following:
– Clutch lifter plate bolts
– Lifter plate
– Clutch springs
(1)
(3)
(2)
(1) LOCK WASHER (2) PLAIN WASHER
(1) THRUST WASHER (2) CLUTCH OUTER
(3) NEEDLE BEARING (4) CLUTCH OUTER GUIDE
Hold the clutch assembly with the clutch center holder
and remove the clutch center nut.
Remove the following:
– Clutch center
– Six clutch discs
– Five clutch plates
– Clutch pressure plate
Tool:
Clutch center holder
07JMB-MN50301
Remove the lock washer and plain washer.
4-40
Remove the thrust washer, clutch outer, needle bearing
and clutch outer guide.
Engine Servicing
(1)
(2)
(1)
(1)
(2)
(4)
(3)
(1) CLUTCH CENTER (2) CLUTCH OUTER
(3) OUTER GUIDE (4) NEEDLE BEARING
Inspection
Check the following items (specifications; 2-2).
• Clutch outer for wear, cracks or indentation by the
clutch discs.
• Clutch center grooves for damage, crack or
indentation by the clutch plates.
• Clutch outer needle bearing for wear or damage.
• Clutch spring free length
• Clutch disc thickness
• Clutch plate warpage
• Clutch outer I.D.
• Clutch outer guide I.D. and O.D.
• Clutch pressure plate for wear or damage
• Mainshaft O.D. at clutch outer guide
(1) OUTER GUIDE (2) NEEDLE BEARING
(1) LIFTER PIECE ASSEMBLY
(4)
(2)
(3)
(2)
(1)
(1)
(1) CIRCLIP (2) THRUST WASHER
(3) THRUST NEEDLE BEARING
(4) LIFTER PIECE
(1) CLUTCH OUTER (2) THRUST WASHER
Check the lifter piece needle bearing by turning the
thrust washer with your finger.
If the bearing movement is not smooth, disassemble and
replace the bearing.
Installation
Remove the circlip, thrust washer and thrust needle
bearing from the lifter piece.
Assemble the lifter piece in the reverse order of removal.
Install the clutch outer and thrust washer.
Install the clutch outer guide and needle bearing onto
the mainshaft.
4-41
Engine Servicing
(2)
(3)
(1)
(3)
(1)
(4)
(2)
(2)
(1)
(1) THRUST WASHER
(2) LOCK WASHER (3) “OUTSIDE” MARK
(1) PRESSURE PLATE
(2) CLUTCH CENTER
(3) DOT MARKS
(1)
(1)
(3)
(1) CLUTCH SPRINGS (2) LIFTER PLATE
(3) BOLTS
(4) LIFTER PIECE ASSEMBLY
Install the clutch springs, lifter plate and spring bolts.
Tighten the spring bolts in a crisscross pattern in several
steps, then tighten them to the specified torque.
Torque: 12 N•m (1.2 kgf•m, 9 lbf•ft)
Install the clutch lifter piece assembly.
Install the clutch cover (page 4-39).
(2)
(1) CLUTCH DISCS
(2) CLUTCH PLATE
(1) CLUTCH CENTER HOLDER
Coat the clutch plates with clean transmission oil.
Install the clutch discs and plates alternately onto the
clutch center starting with the clutch disc
Install the clutch pressure plate onto the clutch center
aligning the dot mark on the pressure plate with the dot
marks on the clutch center as shown.
Install the thrust washer onto the mainshaft.
Install the lock washer with its “OUT SIDE” mark facing
out.
Apply oil to the clutch center nut and install it.
Hold the clutch assembly with the clutch center holder
and tighten the clutch center nut to the specified torque.
Install the clutch center assembly into the clutch outer.
Tool:
Clutch center holder
07JMB-MN50301
Torque: 69 N•m (7.0 kgf•m, 51 lbf•ft)
4-42
Engine Servicing
(4)
(3)
(2)
(1)
(4)
(6)
(5)
(2)
(1)
(1)
(3)
(3)
(2)
(1) IDLE GEAR/THRUST WASHER
(2) BOLT (3) STOPPER PLATE
(4) KICKSTARTER ASSEMBLY
(1) RATCHET SPRING (2) STARTER RATCHET
(3) PINION GEAR (4) SPINDLE
(5) RETURN SPRING (6) COLLAR
(1) RETURN SPRING (2) COLLAR
(3) WASHER
Kickstarter
Removal/Disassembly
(3)
(5)
(2)
Install the return spring with its end into the spindle hole.
Install the collar aligning its groove with the return
spring end, then install the washer.
Remove the clutch (page 4-40)
Remove the kickstarter idle gear and thrust washer.
Remove the bolt and return spring stopper plate.
Unhook the return spring end from the crankcase and
remove the kickstarter as an assembly.
Disassemble the kickstarter.
Inspection
Check the following items (specification; page 2-2):
• Return spring and ratchet spring for wear or damage.
• Needle bearing for wear or damage.
• Pinion gear I.D. and spindle O.D.
• Idle gear I.D. and bushing O.D. and I.D.
• Countershaft O.D. at the idle gear bushing.
(1)
(4)
(6)
(1) PINION GEAR (2) THRUST WASHER
(3) SNAP RING (4) STARTER RATCHET
(5) PUNCH MARKS (6) RATCHET SPRING
Assembly/Installation
Assemble the kickstarter as shown in the illustration
above.
Install the thrust washer, pinion gear, thrust washer and
snap ring.
Install the starter ratchet aligning the punch marks on
the ratchet and spindle.
Install the ratchet spring.
4-43
Engine Servicing
(1)
(2)
(1)
(2)
(3)
(2)
(1)
(1) KICKSTARTER ASSEMBLY
(2) SPRING HOOK
Install the kickstarter assembly and hook the starter
ratchet with the stopper.
Install the return spring end into the crankcase hole as
shown.
(1) GEARSHIFT SPINDLE (2) BOLTS
(3) GUIDE PLATE
(1) STOPPER PLATE
(2) BOLT
(2)
(1)
Gearshift Linkage
Removal
Remove the gearshift pedal.
Pull out the gearshift spindle from the crankcase.
Remove the guide plate bolts and guide plate as an
assembly.
Remove the center bolt and drum center.
Remove the bolts and stopper arm, return spring and
washer.
(1) THRUST WASHER
(2) IDLE GEAR
Install the kickstarter return spring stopper plate, and
tighten the bolt securely.
Install the thrust washer and idle gear onto the
countershaft.
Note the direction of the idle gear as shown in the
illustration.
4-44
Engine Servicing
(5)
(6)
(1)
(2)
(2)
(6)
(3)
(3)
(4)
(4)
(2)
(1)
(5)
(1)
(1) DRUM SHIFTER (2) SPRING (3) PLUNGER
(4) RATCHET PAWL A (5) RATCHET PAWL B
(6) GUIDE PLATE
(1) RETURN SPRING (2) WASHER (3) STOPPER ARM
(4) DRUM CENTER (5) DOWEL PIN
(6) CUT-OUT
Inspection
Install the return spring, plain washer and stopper arm
and tighten the stopper arm bolt to the specified torque.
Inspect each part for wear or damage and replace if
necessary.
Installation
Apply transmission oil to the ratchet pawls, springs and
plungers.
Assemble the drum shifter, springs, plungers and ratchet
pawls in the guide plate as shown.
Torque: 12 N•m (1.2 kgf•m, 9 lbf•ft)
(1) SHIFT DRUM CENTER
(2) CENTER PIN
(2)
(4)
(5)
(1)
Install the dowel pin into the shift drum.
Install the drum center by aligning the cut-out with the
dowel pin on the shift drum while holding the stopper
arm with the screwdriver as shown.
(3)
Note the direction of the ratchet pawl A and B.
(1) GUIDE PLATE (2) “UP” MARK
(3) BOLTS (4) DRUM SHIFTER
(5) SHIFTER COLLAR
Apply a locking agent to the center bolt threads and
install and tighten the drum center bolt to the specified
torque.
Torque: 22 N•m (2.2 kgf•m, 16 lbf•ft)
Set the drum center in a position other than neutral.
Install the drum shifter with the guide plate while
holding onto the ratchet pawls.
Install the guide plate bolts and tighten them.
Install the shifter collar on the drum shifter.
4-45
Engine Servicing
(2)
(1)
(4)
(1)
(3)
(2)
(3)
(2)
(1)
(1) WASHER (2) GEARSHIFT SPINDLE
(3) RETURN SPRING PIN
(4) SHIFTER COLLAR
(1) 3P (WHITE) CONNECTOR
(2) 2P (NATURAL) CONNECTOR
(1) DRAIN BOLT/SEALING WASHER
(2) BOLTS
(3) LEFT CRANKCASE COVER
Left Crankcase Cover
Remove the engine oil drain bolt and sealing washer,
drain the engine oil.
Remove the bolts and left crankcase cover.
Removal
Remove the skid plate and drain engine oil.
Disconnect the alternator 3P (White) connector and
ignition pulse generator 2P (Natural) connectors.
NOTICE
The left crankcase cover (stator) is magnetically attached
to the flywheel, be careful during removal.
Remove the gearshift pedal.
Remove the left crankcase cover, gasket and dowel pins.
(1)
(1) GEARSHIFT PEDAL
Install the washer and gearshift spindle aligning the
return spring ends with the shift fork shaft on the
crankcase and guide plate hole with the shifter collar.
Install the gearshift pedal and check the operation.
4-46
Engine Servicing
(2)
(4)
(1)
(2)
(1)
(3)
(5)
(1) BOLTS (2) IGNITION PULSE GENERATOR
(3) WIRE GUIDE (4) SOCKET BOLTS
(5) STATOR
(3)
(4)
(1) SNAP RING (2) WASHER
(3) OIL SEAL (4) NEEDLE BEARING
(1)
(1) NEEDLE BEARING
Press new needle bearing into the left crankcase cover
using the special tools.
(1)
Tools:
Driver
Attachment, 22 x 24 mm
Pilot, 15 mm
07749–0010000
07746–0010800
07746–0040300
(1)
(1) OIL PRESSURE RELIEF VALVE
(1) BEARING REMOVER
Disassembly/Assembly
Check the crankshaft oil seal and needle bearing for wear
or damage, replace them if necessary.
Remove the snap ring and washer, then remove the oil
seal.
Remove the ignition pulse generator mounting flange
bolts and alternator wire clamp.
Remove the stator mounting socket bolts.
Remove the stator/ignition pulse generator from the left
crankcase cover.
Remove the oil pressure relief valve (page 4-1).
Remove the needle bearing using the special tools.
Tools:
Bearing remover shaft, 15 mm
Bearing remover head, 15 mm
Remover weight
07936–KC10100
07936–KC10200
07741–0010201
4-47
Engine Servicing
(2)
(3)
(6)
(1)
(4)
(2)
(2)
(5)
(1)
(3)
(1)
(1) OIL SEAL
(2) WASHER
(3) SNAP RING
(1) STATOR (2) IGNITION PULSE GENERATOR
(3) WIRE CLAMP (4) SOCKET BOLTS
(5) BOLTS (6) GROMMET
Apply grease to the new oil seal lip and install it into the
left crankcase cover.
Install the washer and snap ring.
Install the stator and ignition pulse generator assembly
into the left crankcase cover.
Apply locking agent to the stator and ignition pulse
generator mounting bolt threads.
Install the alternator wire clamp.
Install the oil pressure relief valve (page 4-1).
(1) OIL FILTER COVER
(2) O-RING
Install the stator and ignition pulse generator mounting
bolts.
Tighten the stator mounting bolts to the specified torque.
Torque: 5.4 N•m (0.55 kgf•m, 4.0 lbf•ft)
Tighten the ignition pulse generator mounting bolts to
the specified torque.
(1)
(2)
(1) DOWEL PINS (2) NEW GASKET
Torque: 5.4 N•m (0.55 kgf•m, 4.0 lbf•ft)
Apply sealant to the stator/ignition pulse generator wire
grommet and install it into the left crankcase cover
groove.
Installation
Check the oil filter cover O-ring is in groove condition,
replace if necessary.
Install dowel pins and new gasket.
4-48
Engine Servicing
(2)
(1)
(2)
(1)
(3)
(1) LEFT CRANKCASE COVER
(2) BOLTS
(3) NEW SEALING WASHER/DRAIN BOLT
(1) 3P (WHITE) CONNECTOR
(2) 2P (NATURAL) CONNECTOR
Install the left crankcase cover being careful not to
damage the oil filter cover O-ring.
Install the gearshift pedal.
Flywheel
Connect the alternator 3P (White) connector and ignition
pulse generator 2P (Natural) connectors.
Removal
NOTICE
The left crankcase cover (stator) is magnetically attached
to the flywheel, be careful during installation.
Install and tighten the bolts in a crisscross pattern in 2 –
3 steps.
Install the new sealing washer and engine oil drain bolt,
tighten the bolt to the specified torque.
Remove the left crankcase cover (page 4-46).
Pour recommended engine oil up to proper level.
Install the slid plate.
Hold the flywheel with flywheel holder, loosen the
flywheel nut.
Tool:
Flywheel holder
89020–NN4–003
Torque: 22 N•m (2.2 kgf•m, 16 lbf•ft)
4-49
Engine Servicing
(1)
(2)
(1)
(2)
(3)
(1) WASHER
(2) FLYWHEEL NUT
(3) APPLY OIL
(1) FLYWHEEL PULLER
(2) FLYWHEEL
(1)
Install the flywheel onto the crankshaft.
Apply oil to the flywheel nut threads and seating surface.
Install the washer and flywheel nut.
Hold the flywheel with flywheel holder, tighten the
flywheel nut to the specified torque.
Tool:
Flywheel holder
89020–NN4–003
Torque: 167 N•m (17.0 kgf•m, 123 lbf•ft)
Install the left crankcase cover (page 4-48).
(1) WOODRUFF KEY
Remove the flywheel using the special tool.
Tool:
Flywheel puller
89010–NN4–003
Remove the woodruff key.
Installation
Install the woodruff key onto the crankshaft groove.
4-50
Engine Servicing
(1)
(1)
(1)
(2)
(2)
(3)
(4)
(2)
(3)
(1) DRIVE SPROCKET (2) UNIVERSAL HOLDER
(3) BOLT (4) SPRING WASHER
Crankcase Separation/Disassembly
(1) CLUTCH OUTER (2) GEAR HOLDER
(3) PRIMARY DRIVE GEAR
(1) COUNTERSHAFT COLLAR
(2) O-RING
(1)
Remove the engine from the frame.
(2)
Remove the following:
– Cylinder head, cylinder, piston
– Clutch
– Kickstarter
– Gearshift linkage
– Flywheel and stator
– Oil filter
– Crankcase breather hose
Hold the drive sprocket with the universal holder and
remove the drive sprocket bolt, spring washer and drive
sprocket.
Temporarily install the clutch outer guide, needle
bearing and clutch outer onto the mainshaft and attach
the gear holder between the primary drive and driven
gears.
Remove the primary drive gear bolt.
Tool:
Gear holder
07724-0010100
Remove the washer, primary drive gear and drive gear
collar.
(1) OIL PUMP DRIVEN GEAR
(2) DRIVE PIN
Remove the countershaft collar and O-ring.
Remove the oil pump driven gear and drive pin.
4-51
Engine Servicing
(2)
(3)
(4)
(2)
(1)
(2)
(3)
(1)
(1)
(1) TRANSMISSION OIL DRAIN BOLT
(2) CRANKCASE BOLTS
Remove the transmission oil drain bolt and sealing
washer.
Loosen the crankcase bolts in a crisscross pattern in 2 –
3 steps.
Remove the crankcase bolts.
(1) GASKET (2) DOWEL PINS
(3) ONE-WAY REED VALVE
(2)
(1) SHIFT FORK SHAFTS (2) SHIFT FORKS
(3) MAINSHAFT (4) COUNTERSHAFT
Remove the following:
– Crankshaft
– Shift fork shafts, shift forks and shift drum
– Mainshaft and countershaft assembly
(3)
Disassemble the mainshaft and countershaft.
(1)
(1) OIL PUMP SHAFT
(2) INNER ROTOR (3) OUTER ROTOR
Place the right crankcase facing down and remove the
left crankcase from the right crankcase.
Remove the gasket and dowel pins.
Remove the one-way reed valve.
Remove the oil pump shaft, oil pump inner and outer
rotors.
4-52
Engine Servicing
(1)
6 mm
8 mm
A
C
B
D
(1) RIGHT CRANKCASE
Crankshaft/Transmission Inspection
(1)
(1)
(2)
Measure the crankshaft runout.
Support the crankshaft at point “A” and “B”, and then
measure the runout at the points “C” and “D”.
Service limit: C: 0.05 mm (0.002 in)
D: 0.03 mm (0.001 in)
(4)
(3)
Measure the connecting rod big end side clearance and
big end axial/radial play (specification; page 2-3).
(5)
(1) RIGHT SHIFT FORK (2) LEFT SHIFT FORK
(3) RIGHT/LEFT SHIFT FORK SHAFT
(4) CENTER SHIFT FORK/SHAFT (5) SHIFT DRUM
(1) LEFT CRANKCASE
Inspect each part for wear or damage.
Check the following items (specifications; page 2-3).
• Spinning gear I.D.
• Bushing I.D. and O.D.
• Mainshaft and countershaft O.D.
• Shift fork I.D. and claw thickness
• Shift fork shaft O.D.
• Shift drum O.D.
Crankcase Bearing Replacement
Remove the oil seals and bearing set plates.
Drive out the bearing using the special tools (Tools; page
2-6).
Install the new bearing as shown in the illustration using
the special tools.
4-53
Engine Servicing
Crankcase Bearings/Oil Seals Location
(3)
(1)
(4)
(2)
B
(5)
(6)
A
E
D
C
F
G
H
I
J
(7)
(10)
(11)
4-54
(1) LEFT SHIFT DRUM BEARING
(2) LEFT COUNTERSHAFT BEARING
(3) LEFT COUNTERSHAFT OIL SEAL
(4) LEFT MAINSHAFT BEARING
(5) LEFT CRANKSHAFT OIL SEAL
(6) LEFT CRANKSHAFT BEARING
(7) RIGHT CRANKSHAFT BEARING
(8) RIGHT CRANKSHAFT OIL SEAL
(9) RIGHT MAINSHAFT BEARING
(10) RIGHT COUNTERSHAFT BEARING
(11) RIGHT SHIFT DRUM BEARING
(9)
(8)
A: 1 mm
B: 0 ± 0.5 mm
C: 58.60 – 58.88
D: 58.30 – 58.52
E: 1 ± 0.5 mm
F: 27.60 – 27.82
G: 28.50 – 28.72
H: 27.00 – 27.22
I: 27.00 – 27.22
J: 0 ± 0.5 mm
mm
mm
mm
mm
mm
mm
Engine Servicing
Transmission Assembly
(1)
(6)
(2)
(7)
(3)
(8)
(4)
(9)
(5)
(10)
(11)
(1) M2 (13T)
(2) M4 (28T)
(3) M3 (15T)
(4) M5 (22T)
(5) MAINSHAFT/M1 (15T)
(6) C2 (31T)
(7) C4 (28T)
(8) C3 (30T)
(9) C5 (22T)
(10) C1 (42T)
(11) COUNTERSHAFT
4-55
Engine Servicing
(1)
(2)
(2)
(3)
(3)
(4)
(1)
(6)
(5)
(1) MAINSHAFT (2) COUNTERSHAFT
(3) SHIFT FORK SHAFTS (4) LEFT SHIFT FORK
(5) RIGHT SHIFT FORK (6) CENTER SHIFT FORK
(1)
(1) OIL PUMP SHAFT
(2) INNER ROTOR (3) OUTER ROTOR
Crankcase Combination
(1) ONE-WAY REED VALVE
(1)
(2)
Clean the crankcase mating surfaces before assembling
and check for wear or damage.
If the minor roughness or irregularities on the crankcase
mating surfaces, dress them with an oil stone.
Lubricate the crankshaft bearing with engine oil.
Lubricate the transmission bearings with transmission
oil.
Install the crankshaft into the right crankcase.
Install the mainshaft and countershaft as an assembly
into the right crankcase.
Install the center shift fork with its identification mark
facing in.
Install the right and left shift forks with their
identification marks facing out.
Install the shift drum.
Install the shift forks.
4-56
(2)
(1)
(1) DOWEL PINS (2) NEW GASKET
(1) RIGHT CRANKCASE
(2) LEFT CRANKCASE
Install the oil pump shaft, oil pump inner rotor and outer
rotors.
Install the one-way reed valve into the right crankcase.
Place the left crankcase onto the right crankcase.
Install the dowel pins and new gasket.
Engine Servicing
(1)
(1)
(1)
(2)
(2)
(1) CRANKCASE BOLTS
(2) NEW SEALING WASHER/OIL DRAIN BOLT
(1) DRIVE GEAR COLLAR
Install the crankcase bolts.
Tighten the crankcase bolts in a crisscross pattern in 2 – 3
steps.
Install the transmission oil drain bolt with a new sealing
washer, and tighten it to the specified torque.
Torque: 22 N•m (2.2 kgf•m, 16 lbf•ft)
(1) CLUTCH OUTER (2) GEAR HOLDER
(1)
(2)
(3)
Temporarily install the clutch outer guide, needle
bearing and clutch outer onto the mainshaft and attach
the gear holder between the primary drive and driven
gears.
Tool:
Gear holder
07724-0010100
Tighten the primary drive gear bolt to the specified
torque.
Torque: 108 N•m (11.0 kgf•m, 80 lbf•ft)
(1) PRIMARY DRIVE GEAR
(2) WASHER (3) SPECIAL BOLT
Install the primary drive gear collar onto the crankshaft.
Install the primary drive gear with its groove side facing
out.
Apply oil to the primary drive gear special bolt threads
and seating surface.
Install the washer and special bolt.
4-57
Engine Servicing
(2)
(1)
(1)
(2)
(3)
(4)
(1) DRIVE SPROCKET
(2) UNIVERSAL HOLDER
(3) SPRING WASHER (4) BOLT
(1) DRIVE PIN
(2) OIL PUMP DRIVEN GEAR
(2)
Install the drive sprocket.
Install the spring washer and drive sprocket bolt.
Hold the drive sprocket with universal holder, tighten the
special bolt to the specified torque.
Torque: 31 N•m (3.2 kgf•m, 23 lbf•ft)
Install the removed parts in the reverse order of removal.
(1)
(1) NEW O-RING
(2) COUNTERSHAFT COLLAR
Install the drive pin into the oil pump drive shaft hole.
Install the oil pump driven gear while aligning its groove
with the drive pin.
Apply grease to the new O-ring and install it into the
countershaft collar groove.
Install the countershaft collar.
4-58
5. Frame Servicing
(6)
(3)
(2)
(1)
(1) AXLE PINCH BOLT (2) AXLE
(3) SIDE COLLAR
(5)
Front Wheel
Removal
(a)
Remove the brake caliper mounting bolts, disc cover and
collars.
Loosen the axle pinch bolt.
(1)
Support the motorcycle and front wheel off the ground.
Remove the axle, left side collar and front wheel.
(4)
Drive the
bearing into
the hub until
it stops.
Do not depress the brake lever after the front wheel is
removed.
The caliper pistons will move and make reassembly
difficult.
(2)
(3)
Apply a locking agent
Torque: 18 N•m (1.8 kgf•m,
13 lbf•ft)
Disassembly/Assembly
! WARNING
A contaminated brake disc or pad reduces stopping
power, and can cause a serious injury or death.
Discard contaminated pads and clean a contaminated
disc with a high quality brake degreasing agent.
(1)
(2)
(3)
(4)
(5)
(6)
BRAKE DISC
COLLAR
DISC BOLT
LEFT WHEEL BEARING
DISTANCE COLLAR
RIGHT WHEEL BEARING
(a) 26.5 ± 0.5 mm
5-1
Frame Servicing
(1)
(3)
(2)
(1)
(2)
(1)
(1) SIDE COLLAR (2) AXLE
(1) BRAKE CALIPER (2) DISC COVER
(3) BOLTS
(1) AXLE PINCH BOLT
Installation
Install the brake caliper, flange collars and disc cover,
tighten the mounting bolts to the specified torque.
While keeping the fork parallel, tighten the axle pinch
bolt to the specified torque.
Torque: 26 N•m (2.7 kgf•m, 20 lbf•ft)
Torque: 23 N•m (2.3 kgf•m, 17 lbf•ft)
Clean the surfaces where the axle and axle clamps
contact each other.
Place the front wheel between the fork legs.
Apply thin layer of grease to the axle surface.
Apply grease to the axle threads.
Install the axle from the right side through the wheel and
left side collar.
Tighten the axle to the specified torque.
Torque: 69 N•m (7.0 kgf•m, 51 lbf•ft)
5-2
With the front brake applied, pump the fork up and down
several times to seat the axle and check the front brake
operation.
Frame Servicing
(3)
(2)
(5)
(1)
(2)
(4)
(1)
(1)
(1) FRONT FENDER (2) NUMBER PLATE
(3) TOP BRIDGE (4) BOTTOM BRIDGE
(5) FORK LEG
(1) FORK BOLT
Fork
Right Fork Disassembly
Removal
Before disassembling the fork, clean the entire sliding
surface and the bottom of the fork slider.
(1) DAMPER ADJUSTER CASE (2) FORK BOLT
Remove the front wheel (page 5-1).
Remove the front fender and number plate.
Loosen the top bridge pinch bolt.
If the forks are to be disassembled, loosen the fork bolt.
NOTICE
Be careful not to scratch the fork tube.
A scratched fork tube will damage the seal, causing an
oil leak.
Hold the fork tube, remove the fork bolt and slide the fork
tube down.
To avoid damaging the fork bolt threads, loosen the top
bridge pinch bolt before loosening the fork bolts.
Loosen the bottom bridge pinch bolts, and pull the fork
tube down and out.
Make sure the damping adjuster is in clicked position
and is not in between the position.
Hold the damper adjuster case and remove the fork bolt
from the damper adjuster case.
Do not remove the damper adjuster case from the
damper rod.
Pour out the fork fluid.
5-3
Frame Servicing
(2)
(2)
(1)
(1)
(1)
(3)
(2)
(1) FORK DAMPER HOLDER
(2) RIGHT FORK CENTER BOLT
(1) FORK DAMPER (2) CENTERING PLATE
(3) FORK TUBE
Hold the axle holder in a vise protected with a piece of
woods or soft jaws to avoid damage.
Do not overtighten.
Remove the fork damper assembly and centering plate
from the fork tube.
(1) DUST SEAL (2) STOP RING
Hold the fork damper using the special tool, then loosen
the right fork center bolt.
Tool:
Fork damper holder
89515–NN3–821
Remove the dust seal and stop ring being careful not to
scratch the fork tube.
In quick successive motions, pull the fork tube out of the
slider.
Empty the fork fluid from the damper by pumping the
damper rod 8 - 10 times.
5-4
Frame Servicing
(1)
(2)
(2)
(2)
(4)
(4)
(3)
(1)
(3)
(1)
(3)
(1) FORK TUBE BUSHING (2) GUIDE BUSHING
(3) BACK-UP RING (4) OIL SEAL
(1) BUSHING (2) BACK-UP RING
(3) INSPECTION POINT
(1) DAMPER ASSEMBLY (2) DAMPER ROD
(3) FORK TUBE (4) CENTERING PLATE
Check that the fork tube moves smoothly in the slider.
If it does not, check the fork tube bending or damage,
and the bushings for wear or damage.
If the slider and bushing are normal, check the fork tube.
Right Fork Inspection
Check the following items (specifications; page 2-3):
– Fork tube for score marks, scratches and excessive
wear
– Fork tube runout
– Fork slider for damage or deformation
– Fork damper for damage
Fork Damper
Check the fork damper assembly for damage or
deformation.
Check the damper rod for bend or other damage.
Carefully remove the fork tube bushing by prying the
slot with a screwdriver until the bushing can be pulled
off by hand.
Be careful not to scratch the teflon coating of the
bushing.
Remove the guide bushing, back-up ring and oil seal
from the fork tube.
Fork tube/centering plate
Check the fork tube for bent or deformation.
Check the centering plate for damage.
Bushing/Back-up Ring
Check the bushings for excessive wear or scratches.
Remove any metal powder from the slider and guide
bushings with a nylon brush and fork fluid.
If copper appears on the entire surface, replace the
bushing.
Replace the back-up ring if there is any distortion at the
points shown.
5-5
Frame Servicing
(2)
(2)
(1)
(1)
(4)
(1)
(3)
(3)
(1) FORK SEAL DRIVER
(1) FORK TUBE BUSHING (2) GUIDE BUSHING
(3) BACK-UP RING (4) OIL SEAL
Right Fork Assembly
Install the centering plate and fork damper assembly into
the fork tube.
(5)
Clean the parts thoroughly with non-flammable or high
flush point solvent before assembly.
Install the following:
– Fork tube bushing
– Guide bushing
– Back-up ring
– New oil seal
Coat the guide and fork tube bushings
recommended fork fluid.
Install the fork tube assembly into the fork slider.
(1) FORK DAMPER ASSEMBLY
(2) CENTERING PLATE
(3) FORK TUBE
(4)
(3)
(2)
with
(1)
(1) GUIDE BUSHING (2) BUCK-UP RING
(3) OIL SEAL (4) STOP RING
(5) DUST SEAL
Drive the guide bushing, back-up ring and oil seal until
the stop ring groove is visible, using the special tool.
Tool:
Fork seal driver
07947–4630100
Install the stop ring into the fork slider groove securely.
Install the dust seal.
5-6
Frame Servicing
(2)
(1)
(1)
(1)
(2)
(2)
(1) FORK DAMPER HOLDER
(2) RIGHT FORK CENTER BOLT
(1) FORK FLUID
(2) FORK TUBE
(1) FORK DAMPER ROD
(2) OIL LEVEL
Hold the axle holder in a vise protected with a piece of
woods or soft jaws to avoid damage.
Do not overtighten the vise.
Pour recommended fork fluid in the fork leg.
2. Pump the damper rod 8 - 10 times.
3. Make sure no air in fork damper by slowly pull the
damper rod up. If the resistance is felt at the top end,
pump the damper rod again.
Install the right fork center bolt with a new sealing
washer.
Hold the fork damper using the special tool, then tighten
the right fork center bolt to the specified torque.
Tool:
Fork damper holder
89515–NN3–821
Specified fork fluid:
Above 5˚C/41˚F:
Showa SS05
Below 5˚C/41˚F:
Belray #5 or BP #10
Bleed the air as follows:
1. Extend the fork. Cover the top of the fork tube with
your hand and compress the fork slowly several
times.
Wait 2 – 3 minutes before measuring the oil level.
Measure the oil level from top of the fork tube.
Standard oil level: 38 mm (1.5 in)
Oil capacity: 405 cm3 (13.7 US oz, 14.3 Imp oz)
Torque: 34 N•m (3.5 kgf•m, 25 lbf•ft)
5-7
Frame Servicing
(2)
11.5 mm
(0.45 in)
(4)
(3)
(2)
(2)
(1)
(3)
(2)
(1)
(1)
(3)
(1)
(1) DAMPER ADJUSTER CASE (2) LOCK NUT
(1) DAMPER ADJUSTER CASE
(2) NEW O-RING (3) FORK BOLT
(1) FORK BOLT (2) DISTANCE COLLAR
(3) SPRING SEAT (4) FORK SPRING
If the damper adjuster case was removed from the
damper rod, reinstall the damper adjuster case as
follows:
1. Adjust the distance between the top of damping
adjuster knob and top of adjuster case is 11.5 mm
(0.45 in).
2. Install the damper adjuster case/rod assembly into the
damper rod pipe until the damper adjuster bottoms
lightly.
3. Hold the damper adjuster case and tighten the lock
nut to the specified torque. Do not turn the damper
adjuster case.
Install a new O-ring onto the fork bolt groove.
Screw the fork bolt on the damper adjuster case until it
seats.
Hold the damper adjuster case and tighten the fork cap
bolt to the specified torque.
Left Fork Disassembly
Torque: 34 N•m (3.5 kgf•m, 25 lbf•ft)
Apply recommended fork fluid to the O-ring, then screw
the fork bolt into the fork tube.
Before disassembling the fork, clean the entire sliding
surface and the bottom of the fork slider.
Be careful not to scratch the fork tube.
A scratched fork tube will damage the seal, causing an
oil leak.
The fork bolt under spring pressure.
Before removing the fork bolt, turn the pre-load adjuster
softest position.
Remove the fork bolt from the fork tube.
Torque: 20 N•m (2.0 kgf•m, 14 lbf•ft)
Remove the distance collar, spring seat and fork spring.
Pour out the fork fluid.
5-8
Frame Servicing
(1)
(3)
(2)
(1)
(3)
(2)
(4)
(2)
(1)
(1) FORK DAMPER HOLDER
(2) CENTER BOLT
(1) FORK TUBE (2) SEAT PIPE ASSEMBLY
(3) OIL LOCK PIECE
(1) SEAT PIPE (2) PISTON RING
(3) REBOUND SPRING (4) OIL LOCK PIECE
Hold the axle holder in a vise protected with a piece of
wood or soft jaws to avoid damage.
Do not overtighten.
Remove the oil lock piece from the fork piston.
Left Fork Inspection
Hold the seat pipe using the special tool and loosen the
center bolt as shown.
Tool:
Fork damper holder
NOTICE
Be careful not to damage the oil lock piece.
Remove the seat pipe assembly from the fork tube.
07930–KA50100
Remove the center bolt and sealing washer.
Remove the following items using the same procedure
as the right fork disassembly (page 5-3):
– Dust seal
– Stop ring
– Fork tube from the fork slider
Remove the following items using the same procedure
as the right fork disassembly (page 5-3):
– Oil seal
– Back-up ring
– Guide bushing
– Slider bushing
Check the following items (specifications; page 2-3):
– Fork slider for damage or deformation
– Fork tube runout
– Fork spring free length
– Fork tube for score marks, scratches and excessive
wear
– Bushing/back-up ring (page 5-5)
– Fork piston ring for wear or damage
– Oil lock piece for damage
– Rebound spring for fatigue or other damage
5-9
Frame Servicing
(1)
(5)
(2)
(1)
(4)
(3)
(3)
(2)
(2)
(1)
(1) FORK TUBE
(2) SEAT PIPE ASSEMBLY (3) OIL LOCK PIECE
(1) FORK DAMPER HOLDER
(2) CENTER BOLT
(1) GUIDE BUSHING (2) BACK-UP RING
(3) OIL SEAL (4) STOP RING
(5) DUST SEAL
Left Fork Assembly
Hold the axle holder in a vise protected with a piece of
wood or soft jaws to avoid damage.
Do not overtighten the vise.
Install the following using the same procedure as the
right fork (page 5-5):
– Slider bushing/guide bushing/new oil seal/back-up
ring onto the fork tube
– Fork tube into the fork slider
Clean the parts thoroughly with non-flammable or high
flush point solvent before assembly.
Apply fork fluid to the piston ring.
Install the seat pipe assembly into the fork tube.
Install the oil lock piece on the end of the seat pipe.
NOTICE
The oil lock piece is easy to scratched or deformed. Take
care not to damage it when assembling it.
5-10
Clean and apply a locking agent to the center bolt
threads.
Install the center bolt with a new sealing washer.
Hold the seat pipe using the special tool, then tighten the
center bolt to the specified torque.
Drive the guide bushing and oil seal until the stop ring
groove is visible, using the special tool (page 5-6).
Install the stop ring and dust seal.
Tool:
Fork damper holder
07930–KA50100
Torque: 34 N•m (3.5 kgf•m, 25 lbf•ft)
Frame Servicing
(1)
3 mm (0.1 in)
(2)
(3)
(4)
(2)
(5)
FORWARD
(1)
Pour half the required amount of recommended fork
fluid in the fork leg.
Specified fork fluid:
Showa SS05
Pump the fork tube slowly 8-10 times.
Pour additional fluid to the specified capacity.
(1) FORK SPRING
(2) SPRING SEAT
(3) DISTANCE COLLAR
(4) O-RING (5) FORK BOLT
(1) FORK TUBE (2) TOP BRIDGE
Install the fork spring, spring seat and distance collar.
Installation
Apply recommended fork fluid to the new O-ring, then
screw the fork bolt into the fork tube.
Install the fork leg.
Raise the fork through the bottom bridge and top bridge.
Align the fork position so that the distance between the
top of the fork tube and the upper surface of the top
bridge is 3 mm (0.1 in) as shown.
Align the fork tube position at the front of top bridge.
Oil level: 87 mm (3.4 in)
Oil capacity: 410 cm3 (13.9 US oz, 14.4 Imp oz)
5-11
Frame Servicing
(1)
(1)
(2)
(2)
(3)
(1)
(1) ADJUSTING NUT
(1) BOTTOM BRIDGE PINCH BOLTS
(2) FORK BOLT
(3) TOP BRIDGE PINCH BOLTS
(1) STEM BOLT (2) TOP BRIDGE
Tighten the bottom bridge pinch bolts to the specified
torque.
Steering stem
(1)
Disassembly
(2)
Torque: 20 N•m (2.0 kgf•m, 14 lbf•ft)
Overtightening the pinch bolts can deform the outer
tube.
Deformed outer tube must be replaced.
Remove the following:
– Handlebar
– Front wheel (page 5-1)
– Front fender
Tighten the fork bolt.
Remove the steering stem bolt and washer.
Tighten the top bridge pinch bolt to the specified torque.
Remove the fork legs (page 5-3).
Remove the top bridge.
(3)
Torque: 20 N•m (2.0 kgf•m, 14 lbf•ft)
(1) DUST SEAL (2) UPPER BEARING (3) STEM
Return spring pre-load and rebound adjuster to their
original positions as noted during removal.
Install the following:
– Front fender
– Front wheel (page 5-2)
5-12
Remove the stem bearing adjusting nut.
Remove the following;
– Dust seal
– Upper bearing
– Steering stem/lower bearing
Frame Servicing
(3)
(4)
(1)
(1)
(2)
(1)
(2)
(3)
(2)
(1) STEM (2) LOWER BEARING (3) DUST SEAL
(1) STEM (2) DUST SEAL (3) BEARING
(4) STEERING STEM DRIVER
(1) DRIVER
(3)
Install new dust seal onto the steering stem.
Install the new lower bearing into the steering stem
using a hydraulic press and driver.
Tool:
Steering stem driver
(2) ATTACHMENT
(2)
(1)
07946-4300000
(1)
(1) BALL RACE REMOVER
(1) STEM
(2) UPPER BEARING
Remove the lower bearing and dust seal from the
steering stem.
Install new bearing races.
(3) DUST SEAL
Remove the upper and lower bearing races from the
steering head using the special tools.
Tools:
Driver
Attachment, 42 x 47 mm
Tool:
Ball race remover
Pack the upper and lower bearings with grease.
Install the steering stem, upper bearing and dust seal.
07948-4630100
07749-0010000
07746-0010300
5-13
Frame Servicing
(2)
(1)
(1)
(1) TOP BRIDGE
(1) ADJUSTING NUT
Screw the stem bearing adjusting nut all the way with
your fingers.
Turn the steering stem lock-to-lock 5 times to seat the
bearings and retighten the adjusting nut to the specified
torque.
Torque: 5 N•m (0.5 kg-m, 3.6 lbf•ft)
(2) STEM BOLT
Apply grease to the stem bolt threads and seating
surfaces.
Install the top bridge, washer and stem bolt.
Temporarily install both fork legs.
Apply grease to the top bridge pinch bolt threads and
seating surfaces.
Install and tighten the top bridge pinch bolts to the
specified torque.
Torque: 20 N•m (2.0 kg-m, 14 lbf•ft)
Tighten the stem bolt to the specified torque.
Torque: 88 N•m (9.0 kg-m, 65 lbf•ft)
Recheck the steering stem adjustment before installing
the removed parts.
5-14
Frame Servicing
(2)
(2)
(1)
(1)
(3)
29 N•m (3.0 kgf•m, 22 lbf•ft)
(1) ADJUSTER
(2) AXLE
(4)
Rear Wheel
Removal
Raise the rear wheel off the ground and support it with a
block or maintenance stand under the engine.
Remove the following:
– Axle nut and drive chain adjuster
– Drive chain
– Axle, drive chain adjuster and rear wheel
(a)
Do not depress the brake pedal after the rear wheel is
removed.
The caliper pistons will move and make reassembly
difficult.
(5)
Drive the
bearing into
the hub until
it stops.
Disassembly/Assembly
! WARNING
A contaminated brake disc or pad reduces stopping
power, and can cause a serious injury or death.
Discard contaminated pads and clean a contaminated
disc with a high quality brake degreasing agent.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(6)
Apply a locking agent
Torque: 17 N•m (1.7 kgf•m,
12 lbf•ft)
DRIVEN SPROCKET
DRIVEN SPROCKET BOLT/NUT
LEFT WHEEL BEARING
DISTANCE COLLAR
RIGHT WHEEL BEARING
DISC BOLT
BRAKE DISC
(7)
(A) 30 ± 0.5 mm
5-15
Frame Servicing
(3)
(2)
(1)
(3)
(1)
(1)
(2)
(1) AXLE (2) ADJUSTERS
(3) AXLE NUT
(1) SPRING COMPRESSOR
(2) ATTACHMENT
(3) SPRING SEAT STOPPER
(1) LOWER MOUNTING BOLT/NUT
(1)
Installation
Disassembly
(2)
Loosen the spring lock nut and adjuster.
Remove the lower mounting collars.
Set the shock absorber in the shock absorber compressor
and attachment.
Install the rear brake caliper aligning with the caliper
slide rail.
Apply thin layer of grease to the axle.
Tools:
Shock absorber compressor
– Compressor attachment
Place the rear wheel between the swingarm being
careful not to damage the disc.
Insert the rear axle into the left chain adjuster, side collar
and wheel.
07GME-0010000
07959–MB10000
Remove the stopper ring, spring seat and spring.
Apply grease to the axle nut threads and seating surface.
Install the right chain adjuster and axle nut.
Inspection
(1) UPPER MOUNTING BOLT/NUT
(2) SHOCK ABSORBER
Shock Absorber
Check the following items (specification; page 2-3):
– Upper and lower spherical bearing for wear or damage
– Spring for damage and measure the free length
– Damper for oil leakage from the damper rod
Check and adjust the drive chain slack (page 3-8).
Removal
Replace the damper assembly if leaked oil.
Tighten the axle nut.
Remove the air cleaner housing.
Raise the rear wheel off the ground and support it with a
block or maintenance stand under the engine.
Remove the shock absorber lower mounting bolt/nut.
Remove the upper mounting bolt/nut and shock
absorber.
Install the drive chain.
If the master link retaining clip was removed, install the
drive chain with the closed end of the clip in the direction
of wheel rotation.
Torque: 69 N•m (7.0 kgf•m, 51 lbf•ft)
5-16
Frame Servicing
(2)
(2)
(2)
(3)
(1)
(4)
(1)
(3)
(4)
(3)
(1) VALVE CAP
(2) DUST SEALS
(3) STOP RING (4) SPHERICAL BEARING
Nitrogen Releasing Procedure
Remove the air valve cap and press the valve stem and
release the nitrogen from the damper until pressure is
released.
Spherical Bearing Replacement
Before disposal of the shock absorber, release the
nitrogen from the damper.
Wear adequate eye protection.
Point the valve away from you to prevent debris getting
into your eyes.
(4)
(1) SPRING (2) SPRING SEAT
(3) STOPPER RING (4) COMPRESSOR
(1)
Remove the collars and dust seals.
Check the spherical bearing for smooth rotation or
damage.
(3)
Remove the stop ring.
Press the spherical bearing out using the special tool.
Tool:
Spherical bearing driver
07HMF-KS60100
Press a new spherical bearing into the shock absorber
pivot until its seats using same tool.
Install the new stop ring into the groove.
Apply grease to the dust seal lips.
Install the dust seals and collars.
(2)
(1) PRE-LOAD LENGTH (2) ADJUSTER
(3) LOCK NUT
Assembly
Assembly is in the reverse order of disassembly.
Adjust the spring pre-load length (page 2-3).
Hold the spring adjuster and tighten the lock nut to the
specified torque.
Torque: 49 N•m (5.0 kgf•m, 36 lbf•ft)
5-17
Frame Servicing
(1)
(1)
(3)
(1)
(4)
(2)
(1) UPPER MOUNTING BOLT/WASHER/NUT
(1) LOWER MOUNTING BOLT/NUT
(1) LOWER MOUNTING BOLT/NUT (2) BOLTS/NUTS
(3) CUSHION ARM PLATES
(4) CUSHION LINK
Installation
Move the swingarm aligning the lower mount, then
install the lower mounting bolt from the left side.
Shock Linkage
Set the shock absorber into the frame and install the
upper mounting bolt from the left side.
Install the washer and nut.
Removal
Install and tighten the upper and lower mounting nuts to
the specified torque.
Torque:
Upper mounting bolt: 39 N•m (4.0 kgf•m, 29 lbf•ft)
Lower mounting bolt: 39 N•m (4.0 kgf•m, 29 lbf•ft)
5-18
Raise the rear wheel off the ground with a block or
maintenance stand under the engine.
Remove the following:
– Rear cushion lower mounting bolt/nut
– Cushion arm plate-to-cushion link bolt/nut
– Cushion arm plates-to-swingarm bolt/nut
– Cushion arm plates
– Cushion link-to-frame socket bolt/nut
– Cushion link
Frame Servicing
(4)
(1)
(2)
(3)
(4)
(2)
(1)
(1)
3 mm (0.12 in)
(3)
(2)
(1) PIVOT COLLAR A (2) PIVOT COLLAR B
(3) DUST SEALS (4) NEEDLE BEARINGS
(1) CUSHION LINK (2) CUSHION ARM PLATES
(3) BOLTS/NUTS (4) LOWER MOUNTING BOLT/NUT
(1) SHOCK ABSORBER LOWER MOUNTING BOLT/NUT
(2) SHOCK ARM PLATE-TO-SWINGARM BOLT/NUT
Needle Bearing Replacement
Installation
Swingarm
Remove the pivot collars and dust seals.
Check the cushion link needle bearings for damage.
Install the following:
– Cushion link
– Cushion link-to-frame socket bolt/nut
– Cushion arm plates
– Cushion arm plates-to-swingarm bolt/nut
– Cushion arm plate-to-cushion link bolt/nut
– Rear cushion lower mounting bolt/nut
Removal
Remove the cushion link needle bearings using the
special tool.
Tool:
Bearing driver
07946-MJ00000
Press new needle bearings into the cushion link to 3 mm
(0.12 in) below the surface of the cushion link using the
special tool, on both sides.
Face the bearing with its marked side facing out.
Tool:
Bearing driver
Remove the following:
– Rear wheel (page 5-15)
– Shock absorber lower mounting bolt/nut
– Cushion arm plates-to-swingarm bolt/nut
Tighten the cushion arm plate and cushion link nuts to
the specified torque.
Torque: 39 N•m (4.0 kgf•m, 29 lbf•ft)
Tighten the rear cushion lower mounting nut to the
specified torque.
07946-MJ00000
Torque: 39 N•m (4.0 kgf•m, 29 lbf•ft)
Apply multi-purpose grease to the collars and dust seal
lips.
Install the dust seals and pivot collars.
5-19
Frame Servicing
(1)
(3)
(2)
(4)
5.5 mm (0.22 in)
(1)
(1)
(2)
(3)
(2)
(1) BRAKE HOSE CLAMPS
(2) SWINGARM PIVOT BOLT/NUT
(1) DUST SEAL CAP (2) DUST SEAL
(3) PIVOT COLLAR (4) DUST SEAL
(1) NEEDLE BEARINGS
(3) BUSHING
Remove the following:
– Brake hose clamp screws
– Rear brake caliper
– Swingarm pivot bolt/nut and swingarm assembly
Disassembly
Pivot Bearing Replacement
Remove the following:
– Bolts and drive chain cover
– Bolts and driven sprocket guard
– Screws and drive chain slider
– Chain tensioner
– Dust seal caps
– Dust seals
– Pivot collars
– Thrust bushings
Replace the swingarm bearings as a set.
Replace them if they have score marks, scratches,
excessive or abnormal wear.
Check the shock mounts and swingarm for stress, cracks
or other damage.
(2) DUST SEAL
Remove the pivot bearings using the special tool.
Tool:
Bearing driver
07946-KA50000
Press a new pivot bearing in using the special tools .
Tools:
Driver
Attachment, 24 x 26 mm
Pilot, 20 mm
07749-0010000
07746-0010700
07746-0040500
Face the bearing with its marked side facing out.
Press the needle bearing so that it is 5.5 mm (0.22 in)
below the swingarm end.
Install the thrust bushings.
5-20
Frame Servicing
(1)
(1)
3 mm (0.12 in)
(3)
(3)
(1)
(3)
(2)
(4)
(4)
(2)
(2)
(1) PIVOT COLLAR A (2) PIVOT COLLAR B
(3) DUST SEALS (4) NEEDLE BEARINGS
(4)
(1) DUST SEAL (2) PIVOT COLLAR
(3) DUST SEAL (4) DUST SEAL CAP
(1) CHAIN TENSIONER (2) BUSHINGS
(3) O-RINGS (4) PIVOT BOLT
Link Bearing Replacement
(2)
Remove the pivot collars and dust seals.
Remove the pivot bearings using the special tool.
Tool:
Bearing driver
5,5 mm
07946-MJ00000
Press a new pivot bearing in using the special tools .
Tool:
Bearing driver
(3)
Install the drive chain tensioner pivot bushings into the
swingarm.
Install a new O-ring onto the chain tensioner pivot.
Install the chain tensioner into the swingarm.
Install a new O-ring and tighten the pivot bolt.
(4)
(1)
07946-MJ00000
Face the bearing with its marked side facing out.
Press the needle bearing so that it is 3.0 mm (0.12 in)
below the swingarm end.
Install the dust seals and pivot collars.
(1) DUST SEAL (2) PIVOT COLLAR
(3) DUST SEAL
(4) NEEDLE BEARINGS
Assembly
Apply grease to the bearing, pivot collars and lips of a
new dust seals.
Install the pivot collars, dust seals and dust seal caps.
Note the direction of the dust seal.
5-21
Frame Servicing
(1)
(2)
(1)
(2)
(2)
(1)
(2)
(2)
(1) DRIVE CHAIN SLIDER (2) SCREWS
(1) PIVOT BOLT/NUT
Install the drive chain sliders onto the swingarm.
Apply a locking agent to the drive chain slider screw
threads and tighten the screw.
Installation
Install the drive chain guard and tighten the bolts.
(2) HOSE CLAMPS
Apply thin coat of grease to the swingarm pivot bolt
surface.
Install the swingarm into the frame.
Install the swingarm pivot bolt from the left side.
Install and tighten the swingarm pivot nut to the
specified torque.
Torque: 69 N•m (7.0 kgf•m, 51 lbf•ft)
Install the brake caliper onto the swingarm rail.
Install the brake hose clamps and tighten the screws.
(1) SHOCK ARM PLATES-TO-SWINGARM BOLT/NUT
(2) SHOCK ABSORBER LOWER MOUNTING BOLT/NUT
Install the following:
– Shock arm plates-to-swingarm bolt/nut
– Rear cushion lower mounting bolt/nut
Tighten the shock arm plate bolt.
Torque: 39 N•m (4.0 kgf•m, 29 lbf•ft)
Tighten the shock absorber lower mounting bolt to the
specified torque.
Torque: 39 N•m (4.0 kgf•m, 29 lbf•ft)
Install the rear wheel (page 5-16)
5-22
Frame Servicing
(1)
(4)
(2)
(2)
(3)
(1)
(1) PAD PINS
(2) BOLTS (3) DISC COVER
(4) CALIPER
(1) NEW PADS (2) PAD PINS
Brake Pad Replacement
Install the new pads and secure them with the two pad
pins.
Clean the brake disc with a high quality degreasing
agent if they are contaminated with oil or grease.
Replace the pads if they are contaminated.
Install the caliper to the fork so the disc is positioned
between the pads, being careful not to damage the pads.
Apply a locking agent to the caliper mounting bolt
threads.
Install the disc cover, then install and tighten the
mounting bolts.
Front Brake Pad Replacement
Loosen the pad pins.
Remove the brake caliper mounting bolts, disc cover,
flange collars and caliper.
Torque: 26 N•m (2.7 kgf•m, 20 lbf•ft)
Operate the brake lever to seat the caliper pistons
against the pads.
Push the pistons all the way in to allow installation of
new brake pads.
Check the brake fluid level in the reservoir as this
operation causes the level to rise.
Remove the pad pins and brake pad.
Clean the brake caliper inside especially around the
caliper pistons.
5-23
Frame Servicing
(1)
(1)
(4)
(2)
(2)
(3)
(1) BRAKE PADS (2) PAD PIN
(1) OIL BOLT (2) MOUNTING BOLTS
(3) DISC COVER (4) BRAKE CALIPER
(1)
Front Brake Caliper
Removal
(1)
(2)
NOTICE
Avoid spilling brake fluid on painted, plastic or rubber
parts.
Place a shop rag over these parts whenever the system
is serviced.
Drain the brake system.
Place a clean container under the caliper.
(1) CALIPER PISTON
(1) CALIPER BRACKET (2) BOSS/SLIT
Rear Brake Pad Replacement
Install the new pads and secure them with the pad pin.
Remove the rear wheel (page 5-15)
Push the piston all the way in to allow installation of new
brake pads.
Check the brake fluid level in the reservoir as this
operation causes the level to rise.
Remove the pad pin and brake pads.
Clean the brake caliper inside especially around the
caliper pistons.
Install the brake caliper bracket aligning its slit with the
boss on the swingarm.
5-24
Install the rear wheel (page 5-16).
Operate the brake pedal to seat the caliper pistons
against the pads.
Remove the following:
– Brake hose oil bolt
– Sealing washers
– Brake hose eyelet
– Caliper mounting bolts
– Disc cover
– Flange collars
– Brake caliper
– Brake pads (page 5-23)
Frame Servicing
(1)
(1)
(3)
(2)
(1) OIL BOLT (2) BRAKE HOSE
(3) BRAKE CALIPER
(1) CALIPER PISTON
Inspection
Rear Brake Caliper
Inspection
Clean the inside of the caliper.
Check the oil leakage from the caliper cylinders.
Removal
Clean the inside of the caliper.
Check the oil leakage from the caliper cylinder.
If any part of the caliper is damaged, replace the caliper
as an assembly.
Installation
Apply locking agent to the caliper mounting bolt threads.
Install the brake caliper and disc cover, and then install
and tighten the caliper mounting bolts.
NOTICE
Avoid spilling brake fluid on painted, plastic or rubber
parts.
Place a shop rag over these parts whenever the system
is serviced.
Drain the brake system.
Place a clean container under the caliper.
Torque: 27 N•m (2.8 kgf•m, 20 lbf•ft)
Installation
Install the brake caliper onto the swingarm rail.
Connect the brake hose eyelet joint with two new sealing
washers.
Install the rear wheel (page 5-16).
Torque: 26 N•m (2.7 kgf•m, 20 lbf•ft)
Connect the brake hose eyelet joint with two new sealing
washers, then tighten the oil bolt.
If any part of the caliper is damaged, replace the caliper
as an assembly.
Remove the following:
– Brake hose oil bolt
– Sealing washers
– Brake hose eyelet
– Rear wheel (page 5-15)
– Brake caliper/bracket
– Brake pads (page 5-24)
Tighten the oil bolt to the specified torque.
Torque: 27 N•m (2.8 kgf•m, 20 lbf•ft)
5-25
Frame Servicing
(1)
(2)
(5)
(4)
(3)
(1) OIL BOLT (2) BRAKE HOSE (3) BOLTS
(4) HOLDER (5) MASTER CYLINDER
Front Master Cylinder
Removal/Installation
NOTICE
• Avoid spilling brake fluid on painted, plastic or rubber
parts. Place a shop rag over these parts whenever the
system is serviced.
• When removing the brake hose bolt, cover the end of
the hoses to prevent contamination. Secure the hoses
to prevent fluid from leaking out.
Drain the brake fluid from the hydraulic system into a
suitable container.
Remove the following:
– Brake lever
– Brake hose bolt and sealing washer
– Brake hose eyelet
– Master cylinder holder bolt and holder
– Master cylinder
(4)
(1)
(2)
(3)
(4)
(1)
(3)
BOOT
SNAP RING
PISTON ASSEMBLY
SPRING
Disassembly/Assembly
NOTICE
• Keep the master cylinder piston, cups, spring and snap
ring as a set; don’t substitute individual parts.
• When installing the cups, do not allow the lips to turn
inside out and be certain the snap ring is firmly seating
in the groove.
Remove the snap ring and disassemble the master
cylinder.
5-26
(2)
Inspection
Check the following items (specifications; page 2-4):
– Master cylinder and piston for scoring, scratches or
other damage
– Master piston O.D. and master cylinder I.D.
Installation
Installation is in the reverse order of removal.
Torque:
Brake hose oil bolt:
27 N•m (2.8 kgf•m, 20 lbf•ft)
Master cylinder holder bolt:
3.2 N•m (0.33 kgf•m, 2.4 lbf•ft)
Frame Servicing
(2)
(1)
(2)
(1)
(3)
(1)
(2)
(3)
(1) OIL BOLT (2) BRAKE HOSE
(3) MASTER CYLINDER
(1) BOLTS (2) MASTER CYLINDER
(1) NUT (2) BOLT (3) BRAKE PEDAL
Rear Master Cylinder
Remove the mounting bolts and master cylinder.
Brake Pedal
Removal/Installation
Installation
Removal
Installation is in the reverse order of removal.
Connect the brake hose eyelet joint with two new sealing
washers, then tighten the oil bolt.
Remove the brake pedal pivot nut and bolt.
Remove the brake pedal and collar.
NOTICE
• Avoid spilling brake fluid on painted, plastic or rubber
parts. Place a shop rag over these parts whenever the
system is serviced.
• When removing the brake hose bolt, cover the end of
the hoses to prevent contamination. Secure the hoses
to prevent fluid from leaking out.
Torque:
Brake hose oil bolt: 27 N•m (2.8 kgf•m, 20 lbf•ft)
Bleed the air from the rear brake system.
Drain the brake fluid from the hydraulic system into a
suitable container.
Remove the air cleaner housing.
Remove the exhaust muffler.
Remove the reservoir tank from the bracket.
Remove the brake hose oil bolt and disconnect the brake
hose eyelet joint.
5-27
Frame Servicing
(3)
(5)
(2)
(2)
3 mm (0.12 in)
(2)
(1)
(1)
(1)
(4)
(3)
(1) COLLAR B
(3) COLLAR A
(1) BEARING (2) DUST SEALS
(1)
(2) PEDAL
(1) OIL BOLT (2) CLUTCH HOSE (3) BOLT
(4) HOLDER (5) MASTER CYLINDER
Installation
Clutch Master Cylinder
Install the brake pedal and collars.
Install and tighten the pivot nut and bolt.
Removal/Installation
Torque: 29 N•m (3.0 kgf•m, 22 lbf•ft)
NOTICE
• Avoid spilling brake fluid on painted, plastic or rubber
parts. Place a shop rag over these parts whenever the
system is serviced.
• When removing the clutch hose bolt, cover the end of
the hose to prevent contamination. Secure the hose to
prevent fluid from leaking out.
(1) STANDARD LENGTH; 35 mm
Pivot Bearing Replacement
Remove the dust seals.
Remove the pivot bearing and press a new needle
bearing so that it is 3 mm (0.12 in) below the pedal end.
Adjust the brake pedal height by loosening the lock nut
and turning the push rod.
Push rod height must be adjusted between 32.5 – 37.5 mm.
5-28
Drain the clutch fluid from the hydraulic system into a
suitable container.
Remove the following:
– Clutch lever
– Clutch hose bolt and sealing washer
– Clutch hose eyelet
– Master cylinder holder bolts and holder
– Master cylinder
Frame Servicing
(4)
(1)
(2)
(1)
(2)
(3)
(4)
(3)
BOOT
SNAP RING
PISTON ASSEMBLY
SPRING
Disassembly/Assembly
NOTICE
• Keep the master cylinder piston, cups, spring and snap
ring as a set; don’t substitute individual parts.
• When installing the cups, do not allow the lips to turn
inside out and be certain the snap ring is firmly seating
in the groove.
Remove the snap ring and disassemble the master
cylinder.
Inspection
Check the following items (specifications; page 2-4):
– Master cylinder and piston for scoring, scratches or
other damage
– Master piston O.D. and master cylinder I.D.
Installation
Installation is in the reverse order of removal.
Torque:
Clutch hose oil bolt:
20 N•m (2.0 kgf•m,14 lbf•ft)
Master cylinder holder bolt:
3.2 N•m (0.33 kgf•m, 2.4 lbf•ft)
5-29
Memo
6. Electrical Servicing
(1)
(1)
(1)
(1) 6P (BLACK) CONNECTOR
(1) 3P (NATURAL) CONNECTOR
(1) 4P (NATURAL) CONNECTOR
Charging System Inspection
If the resistance is out of specification, disconnect the
alternator 3P (Natural) connector and measure the
resistance between the yellow terminals of the alternator
side connector.
Regulated Voltage Inspection
Alternator Charging Coil
Disconnect the regulator rectifier 6P (Black) connector.
Measure the resistance between the Yellow terminals of
the wire harness side.
Standard: 0.7 – 1.0 Ω (20˚C/68˚F)
If the measured resistance at regulator/rectifier 6P
(Black) connector is incorrect and the alternator 3P
(Natural) connector is correct, check the wire harness.
If the resistance is still out of specification, replace the
stator assembly.
Disconnect the power 4P (Natural) connector.
Connect the digital voltmeter to the Red (+) and Green (–)
terminals.
Start the engine, check for regulated voltage.
Standard: 13.5 – 14.5 V/1,800 min-1 (rpm)
6-1
Electrical Servicing
(1)
(1)
(2)
(1)
(2)
(2)
(1) 3P (NATURAL) CONNECTOR
(2) 2P (NATURAL) CONNECTOR
(1) 2P (BLACK) CONNECTOR
(2) 6P (BLACK) CONNECTOR
(1) BOLTS
(2) ELECTRIC STAY ASSEMBLY
(1)
(2)
(1)
(2)
(1)
(1) FAN MOTOR RELAY
(1) BOLT
(2) BRAKE RESERVOIR
(1) 2P (BLACK) CONNECTOR
(2) CONDENSER
Regulator/Rectifier Removal/installation
Disconnect the condenser 2P (Black) and regulator/
rectifier 6P (Black) connectors.
Remove the electric stay mounting bolts, then remove
the stay assembly from the frame.
Remove the rear brake reservoir tank mounting bolt.
Release the condenser 2P (Black) connector, then
remove the condenser from the electric stay.
Remove the throttle body (page 4-10).
Disconnect the alternator 3P (Natural) connector and
ignition pulse generator 2P (Natural) connector.
Remove the fan motor relay from the bracket.
6-2
Electrical Servicing
(1)
(2)
(1)
(1)
(2)
(1) BOLTS
(2) REGULATOR/RECTIFIER
(1) PRIMARY TERMINALS
(1) SPARK PLUG CAP
(2) TIE-WRAP
Remove the bolts and regulator/rectifier from the electric
stay.
Ignition System Inspection
Removal/Installation
Ignition Coil Inspection
Remove the fuel tank/injector assembly.
Measure the ignition primary coil resistance between the
primary terminals.
Remove the spark plug cap.
Remove the tie-wrap and release the spark plug wire
from the fan motor bracket.
Install the regulator/rectifier and condenser in the
reverse order of removal.
Standard: 2.6 - 3.2 Ω (20˚C/68˚F)
Measure the secondary coil resistance.
Standard:
With plug cap:
17.3 - 22.8 kΩ (20˚C/68˚F)
Without plug cap: 13.5 - 16.5 kΩ (20˚C/68˚F)
Replace the ignition coil if the resistance is out of
specification (page 2-9).
6-3
Electrical Servicing
(1)
(3)
(1)
(1)
(4)
(2)
(1) WIRE CLAMP
(2) PRIMARY WIRES (3) BOLTS
(4) IGNITION COIL
(1) 32P (BLACK) CONNECTOR
(1) 2P (NATURAL) CONNECTOR
Remove the wire clamp.
Ignition Pulse Generator Inspection
Disconnect the primary wire from the ignition coil.
Remove the mounting bolts and ignition coil.
Check the ignition coil resistance at the ECM 32P (Black)
connector (page 6-5).
If the resistance is out of specification, measure the
resistance at the ignition pulse generator 2P (Natural)
connector.
Installation is in the reverse order of removal.
Route the spark plug wire properly and secure it with
tiewrap.
Connection: White/yellow – Green/yellow
Standard: 85 - 115 Ω (20˚C/68˚F)
6-4
If the measured resistance at ECM 32P (Black) connector
is incorrect and the ignition pulse generator 2P (Natural)
connector is correct, check the wire harness.
If the resistance is still out of standard, replace the
ignition pulse generator/stator assembly (page 4-46).
Electrical Servicing
(1)
(1)
(1) CONDENSER
(1) 32P (BLACK) CONNECTOR
Condenser Inspection
PGM-FI System Inspection
If the engine does not start, check for the items “engine
does not start” in the PGM-FI Malfunction Indicator
Lamp (MIL) Failure Code chart on page 6-7.
Place the motorcycle upright position and remove the rear fender.
Disconnect the ECM 32P (Black) connector.
Check for the following at the ECM terminals of the wire harness side.
If all items are correct, replace the condenser unit with
new one, and inspect again.
If the engine starts, the replaced condenser is faulty.
If the engine does not starts, check for wire harness.
Item
Terminal
Standard
G/Y – W/Y
85 – 115 Ω (20˚C/68˚F)
Y/Bu – R
2.6 – 3.2 Ω (20˚C/68˚F)
P–R
11.1 – 12.3 Ω (20˚C/68˚F)
B/W – Ground
Continuity exist only when switch is pushed
P/W – G/O
2.3 – 2.6 kΩ (20˚C/68˚F)
Sensor ground
G – Ground
Continuity
Power ground
G – Ground
Continuity
Ignition pulse generator
Ignition coil (primary coil)
INJ (Injector)
Engine stop switch
ECT (Engine Coolant Temperature) sensor
6-5
Electrical Servicing
(1)
(2)
(2)
(1)
(1)
(2)
(3)
(4)
(5)
(1) PGM WARNING UNIT ASSEMBLY
(2) RED WIRE EYELET (3) BLACK WIRE EYELET
(4) 2P (BLACK) CONNECTOR (5) 4P (RED) CONNECTOR
(1) POWER SWITCH
(2) MIL
(1) POWER SWITCH
(2) MIL
Turn the PGM warning unit power switch ON, check that
the MIL.
If the ECM has no self diagnosis memory data, the MIL
will illuminate, when you turn the power switch ON.
If the ECM has self diagnosis memory data, the MIL will
start blinking when you turn the power switch ON.
Note how many times the MIL blinks, and determine the
cause of the problem (See next page).
Self-diagnosis Reset Procedure
PGM-FI
Self-diagnostic Procedure
NOTICE
If the ECT sensor is faulty, the cooling fan will turn when
you connect the 12 V battery to the warning unit
terminals. Do not check these test near the cooling fan.
Disconnect the fuel pump 2P (Black) connector.
Disconnect the condenser 2P (Black) connector and
connect a warning unit connector to the wire harness
side.
Tool:
PGM-FI warning unit assembly
Turn the warning unit power switch ON.
Push the Reset button on the warning unit.
The MIL lights about 5 seconds.
While the MIL lights, release the Reset button.
Self-diagnosis memory data is erased, if the MIL turns
off and start blinking.
• The reset button must be released while the indicator
lights. If not, the MIL will not start blinking.
• Note that the self-diagnosis memory data cannot be
erased if you disconnect the battery from the warning
unit assembly before the MIL starts blinking.
38880-NN4-000
Connect the waring unit 4P (Red) connector to the
service check 4P (Red) connector.
Connect the fully charged 12 V battery to the warning
unit terminals (red wire eyelet to the battery positive
terminal and black wire eyelet to the negative terminal).
6-6
Connect the warning unit assembly to the wire harness
and 12 V battery same procedure as Self-diagnosis (see
previous step).
If the MIL blinks 20 times, the data has not been erased,
so try again.
Electrical Servicing
PGM-FI Self-diagnosis Malfunction Indicator Lamp (MIL) Failure Codes
• The PGM-FI MIL denotes the failure codes (the number of blinks from 0 to 54). When the indicator lights for 1.3 seconds, it is equivalent to ten blinks. For example; a 1.3 second
illumination and two blinks (0.5 second x 2) of the indicator equals 12 blinks. Follow code 12 troubleshooting.
• When more than one failure occurs, the MIL shows the blinks in the order of lowest number to highest number. For example; if the indicator blinks once, then seven times, two
failures have occurred. Follow codes 1 and 7 troubleshooting.
Number of blinks
0
Causes
Symptoms
No blinks
• Faulty ECM
• Engine does not start
No blinks
• Faulty ECM (PGM-FI warning indicator output)
• Engine operates normally
Stay lit
• Short circuit in service check connector
• Faulty ECM (PGM-FI warning indicator output)
• Engine operates normally
1
Blink
• Open or short circuit in MAP sensor line (in the ECM)
• Faulty MAP sensor
• Poor idle
7
Blinks
• Loose or poor contact on ECT sensor
• Open or short circuit in ECT sensor wire
• Faulty ECT sensor
• Hard starting at a low temperature
(Simulate using numerical values; 90 ˚C/194˚F)
• Cooling fan does not stop
8
Blinks
• Open or short circuit in TP sensor line (in the ECM)
• Faulty TP sensor
• Poor engine response when operating the throttle quickly
(Simulate using numerical values; throttle open 0˚)
9
Blinks
• Open or short circuit in IAT sensor line (in the ECM)
• Engine operates normally
(Simulate using numerical values; 25˚C/77˚F)
12
Blinks
• Loose or poor contact on injector connector
• Open or short circuit in injector wire
• Faulty injector
• Engine does not start
54
Blinks
• Loose or poor contact on bank angle sensor connector
• Open circuit in bank angle sensor wire
• Faulty bank angle sensor
• Engine starts but stops after few seconds.
6-7
Electrical Servicing
(1)
(1)
(2)
(2)
(1) SCREWS
(2) BANK ANGLE SENSOR
Bank Angle Sensor Inspection
Remove the electric stay assembly from the frame (page
6-2).
Remove the screws and bank angle sensor from the
sensor bracket.
Reinstall the electric stay and removed parts in the
reverse order of removal.
(1) ARROW/UP MARK
(2) BANK ANGLE SENSOR
Connect the bank angle sensor 3P (Natural) connector.
With the arrow mark on the bank angle sensor facing up,
start the engine.
Incline the bank angle sensor approximately 65 degrees
to the left or right, make sure that the engine stops after
few seconds.
If the engine stops, the bank angle sensor is normal.
If the engine does not stop, replace the bank angle
sensor.
With the arrow/UP mark on the bank angle sensor facing
up again, restart the engine.
The engine starts, the bank angle sensor is normal.
6-8
Install the bank angle sensor in the reverse order of
removal.
Install the bank angle sensor with its arrow/UP mark
facing up as shown.
Electrical Servicing
(1)
(1)
(1)
(1) CONNECTORS
(1) 2P (NATURAL) CONNECTOR
(1) FAN MOTOR RELAY
Engine Stop Switch Inspection
Cooling Fan System Inspection
Fan Motor Relay Inspection
Disconnect the engine stop switch connectors.
Check the engine stop switch for continuity.
There should be continuity.
There should be no continuity when the engine stop
button is pushed.
Fan Motor Inspection
Remove the fan motor relay.
Connect the ohmmeter to the fan motor relay connector
terminals.
Replace the switch if it is out of specification.
Remove the fuel tank.
Disconnect the fan motor 2P (Natural) connector.
Connection: Red – Blue
Directly connect the 12 V battery to the fan motor 2P
(Natural) connector terminals of the fan motor side.
The fan motor is correct when the fan motor operate
when the 12 V battery is connected.
If the fan motor does not operate, replace the fan motor
assembly.
Connect the 12 V battery to the following fan motor relay
terminals.
Connection: Red – Black/Blue
There should be continuity only when the 12 V battery is
connected.
If there is no continuity when the 12 V battery is
connected, replace the fan motor relay.
6-9
Electrical Servicing
Wire Harness Inspection
Check for continuity of the Black/Blue wire between the
fan motor relay 2P (Natural) connector and ECM 32P
(Black) connector.
There should be continuity.
If there is no continuity, repair or replace the wire
harness.
6-10
Electrical Servicing
Wiring Diagram
TURN SIGNAL
INDICATOR LIGHT
12V 1,2 W
FAN MOTOR
FUEL PUMP
ENGINE STOP
SWITCH
HIGH BEAM
INDICATOR LIGHT
12V 1,2 W
METER
INDICATOR LIGHT
12V 1,2 W
SERVICE CHECK
CONNECTOR
RIGHT REAR TURN SIGNAL LIGHT
12V 10W
RIGHT FRONT TURN SIGNAL LIGHT
BRAKE AND TAILLIGHT
12V 21/5W
POWER
POSITION LIGHT
LEFT REAR TURN SIGNAL LIGHT
12V 10W
HEADLIGHT
12V 35735W
LEFT FRONT TURN SIGNAL LIGHT
FRONT BRAKE LIGHT SWITCH
REAR BRAKE LIGHT SWITCH
TURN SIGNAL•LIGHTING•DIMMER
HORN SWITCH
FAN RELAY
HORN
WATER TEMP
SENSOR
REGULATOR/RECTIFIER
CONDENSER
(10000uF)
PULSER
BANK ANGLE
SENSOR
ALTERNATOR
IGNITION COIL
SWITCH CONTINUITY
ENGINE SWITCH
STOP SWITCH
TURN SIGNAL SWITCH
LIGHTING SWITCH
HORN SWITCH
Bl
Y
Bu
G
R
W
BLACK
YELLOW
BLUE
GREEN
RED
WHITE
Br
O
Lb
Lg
P
Gr
BROWN
ORANGE
LIGHT BLUE
LIGHT GREEN
PINK
GRAY
6-11
Electrical Servicing
FAN MOTOR
FUEL PUMP
ENGINE STOP
SWITCH
SERVICE CHECK
CONNECTOR
POWER
Bl
Y
Bu
G
R
W
FAN RELAY
REGULATOR/RECTIFIER
WATER TEMP
SENSOR
CONDENSER
(10000uF)
PULSER
ALTERNATOR
IGNITION COIL
6-12
BANK ANGLE
SENSOR
BLACK
YELLOW
BLUE
GREEN
RED
WHITE
Br
O
Lb
Lg
P
Gr
BROWN
ORANGE
LIGHT BLUE
LIGHT GREEN
PINK
GRAY
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