Montesa Cota 4RT31NNR620 MSV 15685 (1512)
Contents
1. Operating Instructions
Operation Component Locations ..................... 1-1
Fuel ............................................................ 1-2
Coolant ....................................................... 1-2
Basic Operation ............................................ 1-2
Steering Lock ............................................... 1-4
Shifting Gears ............................................. 1-4
Braking ....................................................... 1-5
Parking ........................................................ 1-5
Controls ...................................................... 1-6
2. Service Data
Specifications .............................................. 2-1
Service Data ................................................ 2-2
Torque Values .............................................. 2-5
Tools .......................................................... 2-7
Lubrication & Seal Points ............................... 2-8
Cable & Harness Routing ............................... 2-11
3. Service and Maintenance
Maintenance Schedule .................................. 3-1
Pre-ride Inspection ........................................ 3-1
Warming-up Inspection .................................. 3-2
Ride Inspection ............................................. 3-2
After Ride Inspection .................................... 3-2
Replacement Parts ........................................ 3-2
Fuel Line ..................................................... 3-3
Air Cleaner .................................................. 3-3
Spark Plug ................................................... 3-4
Valve Clearance ........................................... 3-4
Engine Oil/Oil Filter ....................................... 3-6
Engine Idle Speed ......................................... 3-8
Transmission Oil ........................................... 3-8
Coolant ....................................................... 3-9
Clutch System ............................................. 3-10
Exhaust Pipe And Muffler .............................. 3-10
Drive Chain .................................................. 3-11
Drive Chain Slider ......................................... 3-11
Drive/Driven Sprockets .................................. 3-12
Brake Fluid .................................................. 3-13
Brake Pad Wear ............................................ 3-14
Brake System ............................................... 3-14
Handlebar And Steering Head Bearings ............ 3-15
Wheels And Tires ......................................... 3-15
Front Suspension .......................................... 3-16
Fork ........................................................... 3-16
Rear Suspension ........................................... 3-17
Cleaning ...................................................... 3-18
Storage ....................................................... 3-18
4. Engine Servicing
Oil Pressure Relief Valve ................................ 4-1
Oil Pump ..................................................... 4-1
Fuel Feed Hose ............................................ 4-4
Fuel Line Inspection ......................................
4-5
Fuel Tank/Fuel Pump ..................................... 4-7
Injector ....................................................... 4-13
Throttle Body ............................................... 4-13
Water Seal And Bearing Replacement .............. 4-15
Radiator Removal/Installation ......................... 4-17
Engine Removal/Installation ........................... 4-18
Cylinder Compression ................................... 4-20
Cylinder Head Removal ................................. 4-23
Cylinder Head Disassembly ............................ 4-25
Cylinder Head Inspection ............................... 4-26
Valve Guide Replacement .............................. 4-27
Valve Seat Inspection/Refacing ...................... 4-28
Cylinder Head Assembly ................................ 4-31
Cylinder/Piston ............................................. 4-32
Cylinder Head Installation .............................. 4-37
Camshaft/Cylinder Head Cover Installation ...... 4-38
Right Crankcase Cover .................................. 4-40
Clutch Slave Cylinder .................................... 4-41
Clutch ......................................................... 4-43
Kickstarter ................................................... 4-46
Gearshift Linkage .......................................... 4-47
Left Crankcase Cover .................................... 4-49
Flywheel ..................................................... 4-52
Crankcase Separation/Disassembly ................. 4-54
Crankshaft/Transmission Inspection ................ 4-56
Crankcase Bearing Replacement ..................... 4-56
Transmission Assembly ................................. 4-58
Crankcase Combination ................................. 4-59
5. Frame Servicing
Front Wheel ................................................. 5-1
Fork ............................................................ 5-3
Steering Stem .............................................. 5-12
Rear Wheel .................................................. 5-15
Shock Absorber ............................................ 5-16
Shock Linkage .............................................. 5-19
Swingarm .................................................... 5-20
Brake Pad Replacement ................................. 5-24
Front Brake Caliper ....................................... 5-25
Rear Brake Caliper ........................................ 5-26
Front Master Cylinder .................................... 5-27
Rear Master Cylinder ..................................... 5-28
Brake Pedal .................................................. 5-28
Clutch Master Cylinder .................................. 5-29
6. Electrical Servicing
Charging System Inspection ........................... 6-1
Ignition System Inspection ............................. 6-3
PGM-FI System Inspection ............................. 6-5
PGM-FI ........................................................ 6-6
PGM-FI Self-diagnosis Malfunction
Indicator Lamp (MIL) Failure Codes ................. 6-7
Bank Angle Sensor Inspection ........................ 6-8
Engine Stop Switch Inspection ....................... 6-9
Cooling Fan System Inspection ....................... 6-9
Wiring Diagram ............................................ 6-10
FOR COMPETITION USE ONLY
This motorcycle is designed and manufactured and sold for closed-course competition use only. It does not conform to Federal Motor Vehicle Safety Standards
or U.S. EPA Noise and Emission Standards. Operation on public streets, roads, highways, or for off-road recreation is illegal.
State and federal laws prohibit operation of this vehicle except in an organized competitive event on a closed course, or by permit issued by the local
governmental jurisdiction. This vehicle is sold “as is” with no warranties.
FOR EXPERIENCED RIDERS, NO PASSENGERS
This motorcycle is designed as an operator-only vehicle and is for use by experienced riders only. The motorcycle load limit and seating configuration do not
safely permit the carrying of a passenger.
READ THIS MANUAL CAREFULLY
This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold.
Safety 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.
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 signal words mean:
!
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
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.
Damage Prevention Messages
You will also see other important messages that are preceded by the word
NOTICE.
This word means:
NOTICE
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.
California Proposition 65 Warning
WARNING: This product contains or emits chemicals known to the State
of California to cause cancer and birth defects or other reproductive harm.
MONTESA COTA 4RT
Owner’s / Service Manual
This manual describes the service procedures for the MRT260 3E.
All information in this publication is based on the latest product information available at the time of approval for printing.
MONTESA HONDA, S.A.U. 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.
(3E) shown with accessory headlight
(1) FRAME NUMBER (1) ENGINE NUMBER
Serial numbers
The Vehicle Identification Number (VIN) is stamped on the
right side of the steering head.
The serial number of the engine is stamped on the lower
right side of the crankcase.
1
1
3
1
5
4
2
Labels
The following pages show the meanings and locations of the labels on your Cota.
Others provide important safety information. Read this information carefully and don’t remove the labels.
If a label comes off or becomes hard to read, contact your dealer for a replacement.
There is a specific symbol on each label. The meanings of each symbol and label are as follows.
1
Keep chain adjusted and lubricated
25-35 mm (1.0 -1.4 in)
Read Owner’s Manual.
2
Caution label
- For your protection always wear your helmet while riding.
- Read Owner’s Manual carefully.
- Use premium unleaded gasoline only.
3
Radiator cap label
Danger
Never open when hot.
Hot coolant will scald you.
Relief pressure valve begins to open at 15.6 psi (1.1 Kgf/cm
2
)
4
Safety label
5
EC label
Important Safety Precautions
Your Cota can provide many years of pleasure if you take
responsibility for your own safety and understand the
challenges you can meet in competitive racing.
As an experienced rider, you know there is much you can
do to protect yourself when you ride.
The following are a few precautions we consider to be
most important.
Never Carry a Passenger.
Your Cota is designed for one operator only.
Carrying a passenger can cause crashes in which you and
others can be hurt.
Wear Protective Gear.
Whether you’re practicing to improve your skills, or riding
in competition, always wear an approved helmet, eye
protection, and proper protective gear.
Take Time to Get to Know Your Cota.
Because every motorcycle is unique, take time to become
thoroughly familiar with how this one operates and
responds to your commands before placing your machine,
and yourself, in competition.
Learn and Respect Your Limits.
Never ride beyond your personal abilites or faster than
conditions warrant. Remember that alcohol, drugs, illness
and fatigue can reduce your ability to perform well and
ride safely.
Don’t Drink and Ride.
Alcohol and riding don’t mix. Even one drink can reduce
your ability to respond to changing conditions, and your
reaction time gets worse with every additional drink. So
don’t drink and ride, and don’t let your friends drink and
ride either.
Keep your Montesa in Safe Condition.
Maintaining your Cota properly is critical to your safety. A
loose bolt, for example, can cause a breakdown in which
you can be seriously injured.
Accessories & Modifications
Modifying your Cota or using non-Montesa accessories
can make your Cota unsafe.
Before you consider making any modifications or adding
an accessory, be sure to read the following information.
!
WARNING
Improper accessories or modifications can cause a
crash in which you can be seriously hurt or killed.
Follow all instructions in this Owner’s Manual
regarding modifications and accessories.
Accessories
We strongly recommend that you use only Montesa
Genuine accessories that have been specifically designed
and tested for your Cota. Because Montesa cannot test
all other accessories, you must be personally responsible
for proper selection, installation, and use of non-Montesa
accessories.
Check with your dealer for assistance and always follow
this guideline:
Make sure the accessory does not reduce ground clea-
rance and lean angle, limit suspension travel or steering
travel, alter your riding position, or interfere with ope-
rating any controls.
Modifications
We strongly advise you not to remove any original
equipment or modify your Cota in any way that would
change its design or operation.
Such changes could seriously impair your Cota’s handling,
stability, or braking, making it unsafe to ride.
General Competition Maintenance
Perform maintenance on firm, level ground using the side
stand, a workstand, or equivalent support.
When tightening bolts, nuts or screws, start with the
larger diameter or inner fasteners, and tighten them to
the specified torque using a crisscross pattern.
Use Montesa Genuine Parts or their equivalent when
servicing your Cota.
Clean parts in non-flammable (high flash point) cleaning
solvent (such as kerosene) when disassembling. Lubricate
any sliding surface, O-rings, or seals before reassembling.
Grease parts by coating or filling where specified.
After any engine disassembly, always install new gaskets,
O-rings, cotter pins, piston pin clips, snap rings, etc. when
reassembling. After reassembly, check all parts for proper
installation and operation.
How To Use This Manual
The purpose of this Owner’s / Service 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 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.
Importance Of Proper Preparation
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.
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).
To The New Owner
By selecting a MONTESA COTA 4RT as your new
machine, you have placed yourself in a distinguished
family of owners and riders.
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 Owner’s / Service Manual is to help
ensure that you obtain the greatest possible satisfaction
from your new COTA trialer.
Start-up Recommendations
Adjusting the idle
If using your motorcycle at varying elevations, bear in
mind that you must adjust the idle; otherwise, you may
have problems operating the vehicle. (See page 3-8)
Engine start
If you have problems starting your vehicle, follow the
steps below:
1. Open the throttle all the way (100%) and hold.
2. Without releasing the throttle, operate the kick-starter
once or twice.
3. Close the throttle and start your motorcycle as normal.
1-1
1-1
1. Operating Instructions
Operation Component Locations
FRONT BRAKE LEVER
THROTTLE GRIP
SHIFT LEVER
KICKSTARTER
REAR BRAKE PEDAL
CLUTCH LEVER
ENGINE STOP BUTTON
MODE SWITCH
Operating Instructions
1-2
1-2
(1) BREATHER HOSE
(2) FUEL TANK CAP
(1) RADIATOR CAP (1) KICKSTARTER PEDAL
Fuel
Gasoline: Premium unleaded gasoline (commercially
available unleaded; pump octane number 91
or higher)
Fuel tank capacity: 0.5 US gal (1.9 liter, 0.4 Imp gal)
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.
Coolant
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).
Coolant: 50/50 Mixture of Coolant and Distilled Water
!
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 fi lling the coolant system, be sure to bleed air
completely. If not, the system cannot be suffi ciently fi lled
and will cause overheating.
Basic Operation
Starting The Engine
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, “blip-
ping” the throttle, until it warms up enough to idle.
1
1
1
2
Operating Instructions
1-3
1-3
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 for 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.
When you shift the transmission into gear, apply front
brake to prevent the motorcycle from moving forward.
Stopping The Engine
1. Shift the transmission into neutral.
2. Push the engine stop button until the engine stops
completely.
(1) ENGINE STOP BUTTON
1
2
1
(1) SIDE STAND
(2) SIDE STAND SPRING
Side Stand
The side stand is used to support your Cota while parked.
To operate, use your foot to lower the side stand until it
is fully extended.
Before riding, raise the side stand.
Inspection
1. Check the side stand spring for damage and loss of
tension.
2. Check the side stand assembly for freedom of
movement.
If the side stand is stiff or squeaky, clean the pivot area
and lubricate the pivot bolt with grease.
Operating Instructions
1-4
1-4
1
(1) STEERING LOCK
Steering lock
The steering lock is on the steering stem.
To lock the steering, turn the handlebar all the way to
the left, insert the key into the lock, and turn the key
counterclockwise as far as possible. Then, press the lock
all the way in, turn the key back to the original
position, and remove the key.
To unlock the steering, perform the locking sequence in
the reverse order.
Shifting gears
Your Cota has five forward gears in a one-down, four-up
shift pattern.
To start riding, after the engine has been warmed and the
side stand raised.
1. Close the throttle and pull the front brake lever in.
2. Pull the clutch lever all the way in.
3. Depress the shift lever from neutral down to first gear.
4. Release the front brake lever. Gradually open the
throttle while you slowly release the clutch lever. If the
engine min-1 (rpm) (speed) is too low when you release
the clutch lever, the engine will stall.
If the engine min-1 (rpm) (speed) is too high or you
release the clutch lever too quickly, your Cota may
lurch forward.
5. When you attain a moderate speed, close the throttle,
pull the clutch lever in, and raise the shift lever. After
shifting, release the clutch lever and apply the throttle.
6. To continue shifting up to each higher gear, repeat step 5.
7. To shift down to a lower gear, close the throttle, pull
the clutch lever in, and depress the shift lever. After
shifting, release the clutch lever and apply the throttle.
Remember to close the throttle and pull the clutch lever in
completely before shifting.
NOTICE
Improper shifting may damage the engine, transmission,
and drive train.
Learning when to shift gears comes with experience.
Upshift to a higher gear or reduce throttle before engine
min-1 (rpm) (speed) gets too high. Downshift to a lower
gear before you feel the engine laboring (lugging) at low
min-1 (rpm).
NOTICE
Downshifting can help slow your motorcycle, especially
on downhills. However, downshifting when engine min-1
(rpm) is too high can cause engine damage.
NOTICE
To prevent transmission damage, do not coast or tow the
motorcycle for long distances with the engine off.
Operating Instructions
1-5
1-5
Braking
To slow or stop, apply the front brake lever and rear brake
pedal smoothly, while downshifting to match your speed.
Gradually increase braking as you feel the brakes slowing
your speed. To prevent stalling the engine, pull the clutch
lever in before coming to a complete stop. For support,
put your left foot down first, then your right foot when
you are through using the rear brake pedal.
For maximum braking, close the throttle and firmly apply
the front brake lever and rear brake pedal controls.
Applying the brakes too hard may cause the wheels to
lock and slide, reducing control of your Cota. If this hap-
pens, release the brake controls, steer straight ahead until
you regain control, then reapply the brakes more gently.
Generally, reduce your speed or complete braking befo-
re beginning a turn. Avoid braking or closing the throttle
quickly while turning. Either action may cause one or both
wheels to slip. Any wheel slip will reduce your control of
your Cota.
When riding in wet or raining conditions, or on loose sur-
faces, the ability to maneuver and stop will be reduced.
All of your actions should be smooth under these condi-
tions. Rapid acceleration, braking, or turning may cause
loss of control. For your safety, exercise extreme caution
when braking, accelerating, or turning.
When descending a long, steep grade, use engine com-
pression braking by downshifting, with intermittent use
of both brakes.
When you brake to a stop, pull the clutch lever in before
stopping completely to prevent stalling the engine. For
support, put your left foot on the ground first, then your
right foot when you have finish braking.
Parking
Lower the side stand to support your Cota.
Always choose a level surface to park.
Operating Instructions
1-6
1-6
Throttle Grip
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.
Operate the throttle grip to ensure that it functions
smoothly and returns completely in all steering position.
(1) DUST COVER (A) DECREASE
(2) LOCK NUT (B) INCREASE
(3) ADJUSTER
Clutch Lever
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.
NOTICE
Do not adjust the end of the adjuster and the clutch mas-
ter cylinder piston below 0.1 mm (0.004 in).
(1) ADJUSTER
(2) LOCK NUT
Controls
Clutch
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.
(1) UPPER LEVEL LINE
1
A
B
2
3
1
1
2
Operating Instructions
1-7
1-7
Handlebar Position, Width and Shape
Position the handlebar so that gripping the bar and ope-
rating the controls is comfortable while both seated and
standing, while riding straight ahead and turning.
Handlebar width can be trimmed with a hacksaw to
better your particular shoulder width and riding preferen-
ce. Think this though carefully and cut off just a small
amount at a time from both sides equally.
NOTICE
Chamfer the edges to remove burrs and other irregulari-
ties or roughness after shaping.
An alternate handlebar shape, through varying rise or re-
arward 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.
(1) ENGINE STOP BUTTON (1) LOCK NUT
(2) ADJUSTING BOLT
(A) RAISE THE PEDAL HEIGHT
(B) LOWER THE PEDAL HEIGHT
Brake Pedal Height
The brake pedal height can be adjusted to the rider’s pre-
ference.
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 adjus-
ting bolt and frame is at least 1 mm (0.04 in).
Front Brake Lever
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 ad-
juster 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.
NOTICE
Do not adjust the end of the adjuster and the front brake
master cylinder piston below 0.1 mm (0.004 in).
(1) ADJUSTER
(2) LOCK NUT
A
A
B
B
1
1
2
2
1
2
1
Operating Instructions
1-8
1-8
1
Handlebar Position, Width and Shape
Position the handlebar so that gripping the bar and ope-
rating the controls is comfortable while both seated and
standing, while riding straight ahead and turning.
Handlebar width can be trimmed with a hacksaw to
better your particular shoulder width and riding preferen-
ce. Think this though carefully and cut off just a small
amount at a time from both sides equally.
NOTICE
Chamfer the edges to remove burrs and other irregulari-
ties or roughness after shaping.
An alternate handlebar shape, through varying rise or re-
arward 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.
(1) HANDLEBAR
1
3
2
(1) MODE SWITCH
(2) MODE 1
(3) MODE 2
Mode Switch
The ECU for the Cota 4RT260 PGM-FI electronic injec-
tion system has two operational maps (Dry and Wet),
which can be selected depending on the conditions:
Switch in Mode 1:
Dry (appropriate for dry terrain)
Switch in Mode 2:
Wet (appropriate for wet terrain)
2. Service Data
Specifications
Item Specification
Dimensions
Overall length
Overall width
Overall height
Wheelbase
Seat height
Ground clearance
2,020 mm
840 mm
1,135 mm
1,320 mm
679 mm
300 mm
Frame
Type
Front suspension
Rear suspension
Front tire
Rear tire
Front brake, diameter
Rear brake, diameter
Fuel capacity
Caster angle
Trail length
Aluminium twin tube
Telescopic
Swingarm PRO-LINK
DUNLOP D803FGP
(80/100/21 M/C 51M)
MICHELIN TRIAL COMPETITION
(2.75-21 M/C 45L)
DUNLOP D803GP
(120/100R18 M/C 68M)
MICHELIN TRIAL COMPETITION X11
(4.00 R18 M/C 64L)
Single disc, 183 mm
Single disc, 150 mm
0.5 gal (1.9 litres)
24º 34’
63 mm
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
78.0 x 54.2 mm
259 cm3
10.5 : 1
9˚ BTDC
27˚ ABDC
37˚ BBDC
5˚ ATDC
Forced pressure and wet sump
Primary kickstarter
Item Specification
Fuel System
Type
Identification number
Throttle bore
PGM-FI
GQPCA
29.4 mm
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
(at 1.0 mm lift)
2-1
2-1
Service Data
2-2
2-2
Service data
Item Specification
Lubrication
Specified engine oil Repsol 4T motorcycle oil SAE 10W-30
Engine oil capacity
after draining 0.41 liter (0.43 US qt, 0.36 Imp qt)
after oil filter change 0.44 liter (0.46 US qt, 0.39 Imp qt)
after disassembly 0.60 liter (0.63 US qt, 0.53 Imp qt)
Specified transmission oil ELF HTX740
Transmission oil capacity
after draining 0.54 liter (0.57 US qt, 0.48 Imp qt)
after disassembly 0.57 liter (0.60 US qt, 0.50 Imp qt)
Fuel System
Throttle body identification No. GQPCA
Throttle grip free play 3.0 mm (0.1 in)
Engine idle speed 1,800 ± 100 rpm
Fuel pressure 294 kPa (min.) - 320 kPa (max.) at idle
2.34 kgf/cm
2
(min.) - 3.26 kgf/cm
2
(max.) at idle
33 psi (min.)- 46 psi (max.) at idle
Fuel pump flow at 12 V 125 cm
2
minimum/10 seconds
Injector resistance 11.1 – 12.3 Ω (20˚C/68˚F)
Cooling System
Recommended coolant 50/50 mixture coolant and distilled water
Radiator cap relief pressure 108 kPa (1.1 kgf/cm
2
)
Item Standard Service limit
Cylinder Head/Valves
Cylinder compression 67 psi (460 kPa, 4.7 kgf/cm
2
)–
Cylinder head warpage – 0.05 (0.002)
Valve clearance IN 0.12 ± 0.03 (0.005 ± 0.001) –
EX 0.30 ± 0.03 (0.012 ± 0.001) –
Valve stem O.D. IN 4.475 – 4.490 (0.1762 – 0.1768) 4.470 (0.1760)
EX 4.465 – 4.480 (0.1758 – 0.1764) 4.460 (0.1756)
Valve guide I.D. IN/EX 4.500 – 4.512 (0.1772 – 0.1776) 4.552 (0.1792)
Valve stem-to-guide clearance
IN 0.010 – 0.037 (0.0004 – 0.0015) –
EX 0.020 – 0.047 (0.0008 – 0.0019) –
Valve guide projection IN 8.0 – 8.3 (0.31 – 0.33) –
above cylinder head EX 8.2 – 8.5 (0.32 – 0.33) –
Valve spring free length Inner 25.41 (1.000) 24.9 (0.98)
Outer 28.32 (1.115) 27.6 (1.09)
Rocker arm I.D. 10.000 – 10.015 (0.3937 – 0.3943) 10.051 (0.3957)
Rocker arm shaft O.D. 9.972 – 9.987 (0.3926 – 0.3932) 9.925 (0.3907)
Rocker arm-to-shaft clearance 0.013 – 0.043 (0.0005 – 0.0017) 0.11 (0.04)
Cam lobe height IN 32.011 – 33.051 (1.2603 – 1.3012) 31.871 (1.2548)
EX 32.855 – 32.935 (1.2935 – 1.2967) 32.748 (1.2893)
Unit: mm (in)
Service Data
2-3
2-3
Item Standard Service limit
Cylinder/Piston
Cylinder I.D 78.000 – 78.015 (3.0709 - 3.0715) 78.04 (3.0724)
Taper – 0.05 (0.002)
Out-of- round – 0.05 (0.002)
Warpage – 0.05 (0.002)
Piston O.D. 77.970 – 77.980 (3.0696 - 3.07008) 77.89 (3.0665)
Measurement point
5.0 (0.2) from bottom of skirt
–
Pin bore I.D. 16.002 – 16.008 (0.6300 – 0.6302) 16.03 (0.631)
Piston pin O.D. 15.994 – 16.000 (0.6297 – 0.6299) 15.98 (0.629)
Piston ring
End gap
Top 0.15 – 0.25 (0.008 - 0.0098425) 0.39 (0.01535)
Second 0.30 – 0.45 (0.012 - 0.0018) 0.59 (0.02323)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) 0.90 (0.035)
Ring-to-groove clearance
Top 0.065 – 0.100 (0.0026 – 0.0039) 0.115 (0.0045)
Second 0.015 – 0.050 (0.0006 – 0.0020) 0.065 (0.0026)
Cylinder-to-piston clearance 0.020 – 0.045 (0.0008 – 0.0018) 0.18 (0.007)
Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.04 (0.002)
Connecting rod small end I.D. 16.016 – 16.034 (0.6305 – 0.6313) 16.04 (0.631)
Clutch/Gearshift Linkage
Recommended clutch fluid DOT 4 brake fluid –
Clutch spring free length 27.6 (1.09) 26.8 (1.06)
Clutch disc thickness 3.22 – 3.38 (0.127 – 0.133) 3.15 (0.124)
Clutch plate warpage – 0.10 (0.004)
Clutch slave cylinder I.D. 27.000 – 27.021 (1.0630 – 1.0638) –
Clutch slave piston O.D. 26.940 – 26.960 (1.0606 – 1.0614) –
Kickstarter
Spindle O.D. 16.466 – 16.484 (0.6483 – 0.6490) 16.46 (0.648)
Pinion gear I.D. 16.516 – 16.534 (0.6502 – 0.6509) 16.55 (0.652)
Idle gear I.D. 17.016 – 17.034 (0.6699 – 0.6706) 17.06 (0.672)
Countershaft O.D.
at kickstarter idle gear 16.983 – 16.994 (0.6686 – 0.6691) 16.97 (0.668)
Item Standard Service limit
Crankshaft/Transmission
Crankshaft runout Right – 0.03 (0.001)
Left – 0.05 (0.002)
Connecting rod big end
Side clearance 0.30 – 0.75 (0.012 – 0.030) 0.8 (0.03)
Radial clearance 0.06 – 0.18 (0.002 – 0.007) 0.05 (0.002)
Transmission gear I.D. M4 23.020 – 23.041 (0.9063 – 0.9071) 23.07 (0.908)
M5 23.020 – 23.041 (0.9063 – 0.9071) 23.07 (0.908)
C1 20.020 – 20.041 (0.7882 – 0.7890) 20.06 (0.790)
C2 25.020 – 25.041 (0.9850 – 0.9859) 25.06 (0.987)
C3 25.020 – 2.041 (0.9850 – 0.9859) 25.06 (0.987)
Gear bushing D.I. M5 20.000 – 20.021 (0.7866 – 0.7882) 20.05 (0.789)
C1 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671)
C2 22.000 – 22.021 (0.8661 – 0.8670) 22.04 (0.868)
C3 22.000 – 22.021 (0.8661 – 0.8670) 22.04 (0.868)
O.D. M4 22.979 – 23.000 (0.9047 – 0.9055) 22.96 (0.904)
M5 22.979 – 23.000 (0.9047 – 0.9055) 22.96 (0.904)
C1 19.979 – 20.000 (0.7866 – 0.7874) 19.95 (0.785)
C2 24.979 – 25.000 (0.9834 – 0.9843) 24.95 (0.982)
C3 24.979 – 25.000 (0.9834 – 0.9843) 24.95 (0.982)
Countershaft O.D.
at C1 bushing 16.983 – 16.994 (0.6686 – 0.6691) 16.97 (0.668)
at C2/C3 bushing 21.959 – 21.980 (0.8645 – 0.8654) 21.94 (0.864)
at kickstarter idle gear 16.983 – 16.994 (0.6686 – 0.6691) 16.97 (0.668)
Shift fork I.D. C 11.003 – 11.024 (0.4332 – 0.4330) 11.04 (0.435)
R, L 12.035 – 12.056 (0.4738 – 0.4746) 12.07 (0.475)
Shift fork claw thickness C 4.93 – 5.00 (0.194 – 0.197) 4.8 (0.19)
R, L 4.93 – 5.00 (0.194 – 0.197) 4.8 (0.19)
Shift fork shaft O.D. C 10.983 – 10.994 (0.4324 – 0.4328) 10.97 (0.432)
R, L 11.966 – 11.984 (0.4711 – 0.4718) 11.95 (0.470)
Oil pump
Tip clearance – 0.20 (0.008)
Body clearance 0.15 – 0.20 (0.006 – 0.008) –
Side clearance 0.05 – 0.12 (0.002 – 0.004) –
Unit: mm (in) Unit: mm (in)
Service Data
2-4
2-4
Unit: mm (in)
Item Standard Service Limit
Rear Suspension R16V
Shock absorber spring pre-load 126 (4.96) –
Spring free length 130 (5.1) –
Nitrogen gas pressure 1.35 Mpa (13.76 kgf/cm
2
)–
Tension adjuster setting 12±2 clicks from full hard –
Brakes
Recommended brake fluid DOT 4 brake fluid –
Front Brake disc thickness 3.5 (0.14) 3.0 (0.12)
Brake disc runout – 0.15 (0.006)
Rear Brake disc thickness 2.5 (0.10) 2.0 (0.08)
Brake disc runout – 0.15 (0.006)
Unit: mm (in)
Item Standard Service Limit
Electrical
Spark plug Standard NGK: CR6EH-9 –
Spark plug gap 0.80 – 0.90 (0.031 – 0.035) –
Ignition coil resistance
Primary 2.6 -3.2 Ω (20º C) –
Secondary with plug cap 17.3 -22.8 kΩ (20º C) –
Secondary without plug cap 13.5 – 16.5 KΩ (20º C) –
Ignition pulse generator
Resistance 85 -115 Ω (20º C) –
Alternator
Regulated voltage 13.5 – 14.5 V/1,800 rpm –
Charging coil resistance 0.7 -1.0 Ω (20º C) –
ECT sensor resistance 2.3 -2.6 kΩ (20º C) –
Bulb
Headlight 12 V –
Unit: mm (in)
Item Standard Service Limit
Wheels/Tires
Axle runout
Tire air pressure
Front
Rear
Wheel rim runout Radial
Axial
Drive chain slack
Drive chain slider thickness
5.6 - 6.3 psi (39 – 44 kPa)
3.9 - 4.2 psi (29 – 34 kPa)
–
–
25 – 35 (1.0 – 1.4)
–
0.20 (0.008)
–
–
2.0 (0.08)
2.0 (0.08)
–
2.0 (0.08) from
upper surface
Front Suspension TECH
Left fork spring free length
Fork tube runout
Recommended fork fluid
Pre-load adjuster setting
Damping adjuster setting
Fork oil level Right
Left
Fork oil capacity Right
Left
390 (15.35)
0.35 – 0.50 (0.014 – 0.020)
KYB 01M (5W)
5±0.5 turns out from full soft
Tension adjuster:
20±2 clicks from full hard
50 (1.96)
100 (3.93)
400 cm
3
410 cm
3
382 (15.04)
0.20 (0.008)
–
–
–
–
–
–
–
Service Data
2-5
2-5
Torque Values
Standard
Item
Torque
N•m (kgf•m, Ibf•ft)
5 mm bolt and nut 5 (0.52, 3.5)
6 mm bolt and nut 10 (1.0, 7)
8 mm bolt and nut 22 (2.2, 16)
10 mm bolt and nut 33 (3.4, 25)
12 mm bolt and nut 53 (5.4, 40)
5 mm screw 4 (0.42, 3)
6 mm screw and flange bolt (SH type) 9 (0.9, 7)
6 mm flange bolt and nut 12 (1.2, 9)
8 mm flange bolt and nut 26 (2.7, 20)
10 mm flange bolt and nut 38 (3.9, 29)
Engine
Item Q’ty
Thread
Dia. (mm)
Torque
N•m (kgf•m, Ibf•ft)
Remarks
Transmission oil drain bolt 1 8 22 (2.2, 16) Note 1
Engine oil drain bolt 1 8 22 (2.2, 16) Note 1
Right crankcase cover joint pipe 1 18 18 (1.8, 13) Note 2
Timing hole cap 1 14 7 (0.7, 5.1) Note 3
Bearing set plate socket bolt 4 6 9.8 (1.0, 7) Note 4
Bearing set plate screw 2 6 12 (1.2, 9) Note 4
Bearing set plate flat screw 2 6 9.8 (1.0, 7) Note 4
Cylinder head sealing bolt 1 12 32 (3.3, 24) Note 4
Cylinder head mounting nut 2 9 39 (4.0, 29) Note 1
Cylinder head joint pipe 1 18 18 (1.8, 13) Note 2
Vacuum port joint 1 5 2.5 (0.25, 1.8)
Primary drive gear special bolt 1 12 108 (11.0, 80) Note 1
Flywheel nut 1 18 167 (17.0, 123) Note 1
Cam chain tensioner bolt 1 6 12 (1.2, 9) Note 4
Valve clearance adjusting nut 4 6 14 (1.4, 10) Note 1
Injector holder socket bolt 2 6 9.8 (1.0, 7)
Fuel hose banjo bolt (holder side) 1 18 24 (2.4, 17.7)
Water pump impeller 1 7 12 (1.2, 9)
Clutch oil bleeder screw 1 8 6 (0.6, 4.3)
Clutch spring bolt 6 6 12 (1.2, 9)
Clutch center lock nut 1 18 69 (7.0, 51) Note 1
Drive sprocket UBS bolt 1 8 31 (3.2, 23)
Shift drum center special bolt 1 8 22 (2.2, 16) Note 4
Shift drum stopper arm bolt 1 6 12 (1.2, 9)
Shift return spring pin 1 8 22 (2.2, 16)
Ignition pulse generator bolt 2 5 5.4 (0.55, 4.0) Note 4
Stator mounting bolt 3 5 5.4 (0.55, 4.0) Note 4
Spark plug 1 10 16 (1.6, 12) Note 2
Notes: 1. Apply clean engine oil to the threads and seating surface.
2. Apply sealant to the threads.
3. Apply grease to the threads.
4. Apply a locking agent to the threads.
Cylinder stud bolt:
Insulator band (cylinder head side):
Exhaust pipe stud bolt:
Insulator band (throttle body side):
101.5±1mm
17±0.5mm
7±1mm
7±1mm
Service Data
2-6
2-6
Frame
Item Q’ty
Thread
Dia. (mm)
Torque
N•m (kgf•m, Ibf•ft)
Remarks
Brake pedal pivot bolt 1 8
29 (3.0, 22)
Note 2
Steering head top thread 1 26
5 (0.5, 3.6)
Note 1
Steering stem nut 1 20 99 (9.9, 73) Note 1
Clutch hose (master cylinder) 1 10 20 (2.0, 14)
Rear master cylinder mounting bolt 2 6 8 (0.8, 5.8)
ECT sensor 1 12 15 (1.5, 11)
Fuel hose banjo bolt:
Fuel pump side 1 12 22 (2.2, 16)
Fuel pump mounting bolt 6 5 7 (0.7, 5.1)
Front spoke nipple 32 BC 3.5 4.9 (4.9, 3.6)
Rear spoke nipple 32 4 3 (0.2 - 0.3)
Shock absorber spring lock nut 1 50 49 (5.0, 36)
Shock arm bolt/nut 1 10 39 (4.0, 29)
Shock link bolt/nut 2 10 39 (4.0, 29)
Clutch oil bleeder bolt 1 10 23 (2.3, 17)
Rim lock nut 1 8 13 (1.3, 9)
Fork cap 2 36 23 (2.3, 17)
Fork cap bolt-to-adjuster case 1 22 34 (3.5, 25)
Fork adjuster case lock nut 1 10 20 (2.0, 14)
Right fork center bolt 1 14 14.7 (1.47, 13) Note 2
Left fork center bolt 1 15 24.5 (2.45, 18) Note 2
Notes: 1. Apply grease to the sliding surface.
2. Apply a locking agent to the threads.
Item Q’ty
Thread
Dia. (mm)
Torque
N•m (kgf•m, Ibf•ft)
Remarks
Handlebar holder bolt 4 8 22 (2.2, 16) Note 1
Front axle 1 17 69 (7.0, 51) Note 1
Rear axle 1 17 69 (7.0, 51) Note 1
Final driven sprocket nut 4 8 30-35 (3.0-3.5, 22.1-25.8) Note 3
Shock absorber:
Upper mounting bolt/nut 1 10 39 (4.0, 29) Note 4
Lower mounting bolt/nut 1 10 39 (4.0, 29) Note 4
Fork top pinch bolt 2 8 21 (2.1, 15.4) Note 1
Fork bottom pinch bolt 4 8 21 (2.1, 15.4) Note 1
Swingarm pivot nut 1 14 69 (7.0, 51) Note 1
Front brake disc mounting bolt 4 6 18-20 (1.8-2.0, 13-15) Note 2
Rear brake disc mounting bolt 4 6 16-18 (1.6-1.8, 11-13) Note 2
Side stand pivot nut 1 10 23 (2.3, 17)
Side stand bracket mounting bolt 2 8 26 (2.7, 20) Note 2
Exhaust pipe flange bolt 1 6 12 (1.2, 9) Note 1
Engine hanger:
Upper hanger bolt/nut 1 8 24 (2.4, 17)
Front hanger bolt 1 10 49 (5.0, 36) Note 1
Down tube mounting bolt 4 8 25 (2.6, 19) Note 1
Front axle holder bolt 2 6 23 (2.3, 17) Note 1
Skid plate:
Front mounting bolt 2 8
26 (2.7, 20)
Throttle housing bolt 2 5
4.2 (0.43, 3.1)
Note 4
Clutch lever holder bolt 2 5
3.2 (0.33, 2.4)
Front brake master cylinder 1 8
22 (2.2, 16)
holder bolt 2 6
3.2 (0.33, 2.4)
Note 4
Front brake caliper mounting bolt 2 8
26 (2.7, 20)
Note 2
Brake hose:
Front master cylinder 1 10
27 (2.8, 20)
Front caliper 1 10
27 (2.8, 20)
Rear master cylinder 1 10
27 (2.8, 20)
Rear brake caliper 1 10
27 (2.8, 20)
Service Data
2-7
2-7
Tools
Special
Description Tool number Applicability
Bearing remover, 12 mm 07936–166010A Water pump bearing
Remover handle 07936–3710100
Remover weight 07936–371020A
Mechanical seal installer 07965–415000A Water seal
Attachment, 28 x 30 mm 07946–1870100 Water pump bearing
Holder plate 07HGB–001010B Clutch center lock nut
Holder collars 07HGB-001020B Clutch center lock nut
Fork seal driver, 39 mm 07947–4630100 Fork oil seal
Fork damper holder 07930-KA50100 Left fork socket bolt
Ball race remover 07948–4630100 Stem bearing race
Bearing driver 07946–KA50000 Swingarm pivot bearing
Bearing remover 07946–MJ0A100 Shock link needle bearing
Swingarm link bearing
Shock absorber bearing
Snap ring pliers 07914–SA50001 Master cylinder snap ring
Flywheel holder 07AMB-NN4A100 Flywheel
Flywheel puller w/thread protector 07AMC-NN4A100 Flywheel
Thread protector, 18 x1.5 mm ONLY 07AMC-NN4A110 Flywheel
Holder handle
07TMB-001010A
Right fork
Damper holder attachment, 4 pin 07AMB-NN4A200 Right fork
Compressor attachment 07959–MB10000 Shock absorber spring
Steering stem driver 07946-MB00000 Stem lower bearing
Steering stem driver attachment 07946-KA6000A Stem lower bearing
Steering stem driver attachment 07953-MJ1000B Stem bearing race
Holder attachment, 4 pin 07AMB-NN4200 Right fork center bolt
Bearing remover, 15 mm 07936-KC10500 Clutch cover bearing
Valve guide driver 07HMD-ML00101 Valve guide
Valve guide reamer, 4.5 mm 07HMH-ML0010B Valve guide
Tensioner holder 07AMG-001A100 Tensioner holder
Driver attachement 07946-GC4000A Shock absorber bearing
Tappet Wrench, 3 mm 07908-KE90200 Valve adjustment
Valve spring compressor attachment 07959-KM30101 Valve spring
PGM-FI warning unit assembly 07AMZ-NN4A100 PGM-FI troubleshooting
Description Tool number Applicability
Spoke nipple wrench 07701–0020300 Front spoke nipple
Gear holder, 2.5 07724–001A100 Primary drive gear bolt
Bearing remover head, 20 mm 07746–0050600 Wheel bearing
Bearing remover shaft 07746–0050100 Wheel bearing
Driver 07749–0010000 Bearing removal/installation
Attachment, 24 x 26 mm 07746–0010700 Swingarm pivot bearing
Attachment, 32 x 35 mm 07746–0010100 Right countershaft bearing
Left mainshaft bearing
Attachment, 37 x 40 mm 07746–0010200 Left shift drum bearing
Attachment, 42 x 47 mm 07746–0010300 Right mainshaft bearing
Left countershaft bearing
Right shift drum bearing
Wheel bearing
Ball race
Attachment, 52 x 55 mm 07746–0010400 Crankshaft oil seal
Attachment, 62 x 68 mm 07746–0010500 Left crankshaft bearing
Attachment, 72 x 75 mm 07746–0010600 Right crankshaft bearing
Pilot, 12 mm 07746–0040200 Water pump bearing
Pilot, 17 mm 07746–0040400 Right countershaft bearing
Left mainshaft bearing
Pilot, 20 mm 07746–0040500 Left countershaft bearing
Wheel bearing
Swingarm pivot bearing
Pilot, 22 mm 07746–0041000 Right mainshaft bearing
Pilot, 25 mm 07746–0040600 Right shift drum bearing
Pilot, 30 mm 07746–0040700 Right crankshaft bearing
Pin spanner 07702-0020001 Steering stem nut torque
Shock absorber compressor 07GME-001000A Shock absorber spring
Universal holder 07725-0030000 Drive sprocket holder
Pilot, 15 mm 07746
-
0040300 Clutch cover needle bearing
Attachment, 22 x 24 mm 07746-001A800 Shock absorber bearing
Clutch cover needle bearing
Spanner “A” 89201-KA4-811 Shock spring adjuster
Spanner “B” 89202-KA4-811 Shock spring adjuster
Valve spring compressor 07757-0010000 Valve spring
Fuel pressure gauge, 0 -100 psi 07406-004000C Fuel pressure inspection
Adapter, fuel pressure 07406-004030A Fuel pressure inspection
Banjo bolt, 12 mm 90008-PP4-E02 Fuel pressure inspection
Tools
Common
Service Data
2-8
2-8
Lubrication & Seal Points
Engine
Item Material Remarks
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 570 cm
3
Crankcase inside (engine oil) Repsol 4T engine oil 10W-30 600 cm
3
Item Material Remarks
Connecting rod small end I.D. Molybdenum oil solution
Connecting rod big end (A 50/50 mixture of
Camshaft outer surface molybdenum disulfide
Rocker arm I.D. grease and engine oil)
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
Right crankshaft bearing set plate bolt threads Locking agent 6.5 ± 1 mm
Right mainshaft bearing/shift drum bearing set plate
bolt threads
Left coutershaft bearing set plate bolt threads 3.5 ± 1 mm
Left crankcase sealing bolt threads
Cylinder mounting bolt threads
Cylinder head sealing bolt threads 6.5 ± 1 mm
Cam chain tensioner bolt threads 6.5 ± 1 mm
Shift drum center bolt threads
Ignition pulse generator bolt threads
Stator mounting bolt threads
Service Data
2-9
2-9
Item Material Remarks
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
Wheel
Item Material Remarks
Rear wheel nipple Locking agent (3E)
Chain tensioner bolt transmission Drain hole
Application zone
6.5±1 mm
Application zone
2.5±1 mm3 - 4 mm 1.2±0.4 mm
Service Data
2-10
2-10
Frame
Item Material Remarks
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
Pro Honda DOT 4 brake fluid
Air cleaner element Engine oil
Throttle cable sliding surface Cable lubricant
Handlebar grip Pro Honda Handgrip Cement
or equivalent
Item Material Remarks
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
Locking agent
Service Data
2-11
2-11
Cable & Harness Routing
90º
FRONT
FRONT
FRONT
FRONT
4E
3E
2
4
1
3
(1) FRONT BRAKE HOSE
(2) THROTTLE CABLE
(3) CLUTCH HOSE
(4) ENGINE STOP SWITCH CONNECTOR
(5) MODE SWITCH
Service Data
2-12
2-12
(1) MAIN WIRE HARNESS
(2) FUEL PUMP WIRE
(3) CYLINDER HEAD BREATHER HOSE
(4) CRANKCASE BREATHER JOINT HOSE
(5) STORAGE TANK
(6) ENGINE STOP SWITCH WIRE
UPPER
RH
20-30º
(7) FAN MOTOR WIRE
(8) FUEL CAP BREATHER HOSE
(9) SPARK PLUG WIRE
(10) WIRE HARNESS (TO IGNITION COIL)
(11) ECT SENSOR
1
2
3
4
5
6
7
8
9
10
11
Service Data
2-13
2-13
(1) WIRE HARNESS
(2) THROTTLE CABLE
(3) CLUTCH HOSE
(4) CONNECTOR BOOT
– FAN MOTOR 2P (BLACK) CONNECTOR
– POWER CONNECTOR
(5) UPPER RADIATOR HOSE
(6) SPARK PLUG WIRE
(7) FAN MOTOR WIRE
(8) FILTER BOX BREATHER HOSE
(9) CYLINDER HEAD BREATHER HOSE
Clamp at white tape
1
2
3
4 5 6
7
8
9
Service Data
2-14
2-14
(1) INTAKE VACUUM HOSE
(2) THROTTLE CABLE
(3) CLUTCH HOSE
(4) FUEL TANK BREATHER HOSE
1
2
2
3
3
4
2
45º
FR
FR
UPPER
UPPER
FR
RH
RH
RH
RH
RH
4
Service Data
2-15
2-15
(1) MAIN WIRE HARNESS
(2) TRANSMISSION BREATHER HOSE
(3) FILTER BOX BREATHER HOSE
(4) ALTERNATOR WIRE
(5) CONDENSER 2P (BLACK) CONNECTOR
(6) REGULATOR/RECTIFIER 5P (BLACK) CONNECTOR
(7) ENGINE STOP RELAY
(8) FAN MOTOR RELAY
(9) REAR BRAKE RESERVOIR TANK
1
2
3
4
5
6
7
8
9
FR FRFR
Service Data
2-16
2-16
(1) MAIN WIRE HARNESS (TO CONNECTOR COVER)
(2) MAIN WIRE HARNESS (TO RELAY)
(3) MAIN WIRE HARNESS (TO ECU)
(4) CRANKCASE BREATHER JOINT HOSE
(5) TRANSMISSION BREAHTER HOSE
(6) WIRE HARNESS
(7) FUEL FEED HOSE
(8) REGULATOR/RECTIFIER 5P (BLACK) CONNECTOR
(9) CONDENSOR
(10) CONDENSOR 2P (BLACK) CONNECTOR
(11) BANK ANGLE SENSOR
(12) FAN MOTOR RELAY
(13) CONNECTOR COVER
Clamp at white tape
1
2
3
4
5
5
6
6
7
8
13
12
11
10
9
Service Data
2-17
2-17
(1) REAR BRAKE HOSE
(2) REAR BRAKE RESERVOIR HOSE
90º
UPPER
UPPER
RH
FR
FR
RH
1
2
Service Data
2-18
2-18
(1) FUEL FEED HOSE
(2) TRANSMISSION BREATHER HOSE
1
2
3-1
3-1
Pre-ride Inspection
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.
!
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 be-
fore every ride and correct any problems.
Check the following items before you get on the Cota 4RT:
Fuel, oil, and water for 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 damage and proper 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
3. Service and Maintenance
Maintenance Schedule
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.
Item
Frequency
Each race or
about 2.5 hr
Every 6
races or
about 15 hr
Every 6
months
Every 12
months
Remarks
Fuel Line I
Fuel Filter I
Clean Under Font Fender I
Throttle Operation I
Air Cleaner C Check the air cleaner after riding in dusty areas.
Spark Plug I R
Valve Clearance I I: After the first brake-in period
Engine Oil I R R: After the first brake-in period
Engine Oil Filter R R: After the first brake-in period
Engine Oil Strainer Screen I
Engine Idle Speed I
Transmission Oil R
Radiator Coolant I R
Cooling System I R
Piston I R
Piston Ring I R
Drive Chain I, L
Drive Chain Slider/Tensioner I
Drive/Driven Sprocket I
Brake Fluid I R
Brake Pad Wear I
Brake System I
Clutch Fluid I
Clutch System I
Control Cables I, L
Exhaust Pipe/Muffler I C
Suspension I C Check the spherical bearing for damage.
Swingarm/Shock Linkage I C
Fork Oil I R
Wheels/Tires I
Steering Head Bearing I
Nuts, Bolts, Fasteners I
Service and Maintenance
3-2
3-2
Replacement Parts
Parts Requiring Periodic Replacement
Item Replacement Interval Cause
Engine
Spark plug/plug cap Every 6 races Contamination or emulsification
Engine oil Every 6 races
Engine oil filter Every 6 races
Transmission oil Every 6 races
Piston Every 12 months Damage or wear at skirt
Piston ring Every 6 months Damage at ends or wear
Radiator coolant Every 12 months
Frame
Front fork fluid Every 6 months
Fast Wearing/Expendable Parts
Item Cause
Engine
Clutch disc Wear or discoloration
Clutch spring Fatigue
Drive sprocket Wear or damage
Frame
Front/rear tire Wear
Brake pad Wear
Chain slider Wear
Driven sprocket Wear or damage
Drive chain Elongation or wear
Warming-up Inspection
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.
Ride Inspection
When running the Cota, check 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
Service and Maintenance
3-3
3-3
Remove the flame trap from the air cleaner element.
Check the frame trap for damage, replace if necessary.
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.
!
WARNING
Never use gasoline or low flash point solvents for clea-
ning the air cleaner element.
A fire or explosion could result in serious injury or
death.
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.
(1) FLAME TRAP
(2) AIR CLEANER ELEMENT
(1) AIR CLEANER ELEMENT
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.
(1) BOLTS
(2) AIR CLEANER HOUSING COVER
Fuel Line
Remove the rear fender.
Check the fuel feed hose for cracks, deterioration, or
leakage.
(1) FUEL FEED HOSE
1
2
1
2
1
1
Service and Maintenance
3-4
3-4
(1) TIMING HOLE CAP/O-RING
Valve Clearance
Inspection
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.
(1) BOLTS
(2) TAPPET ADJUSTING HOLE COVER
(1) SPARK PLUG GAP
Arcing
If engine misfire occurs due to arcing, replace both the
spark plug and the cap.
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.
(1) INSULATOR
Spark Plug
Using a spark plug with the wrong heat range can damage
the engine or cause the plug to foul. Be careful to select
the correct spark plug for the conditions.
Standard plug: NGK: CR6EH-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 CAP / SPARK PLUG
1
1
1
1
1
1
2
2
Service and Maintenance
3-5
3-5
(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.
(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.
(1) O-RING
(2) VALVE ADJUSTING HOLE COVER
(3) “UP” MARK (4) BOLTS
(1) O-RING
(2) VALVE ADJUSTING HOLE COVER
(3) “UP” MARK (4) BOLTS
Insert a feeler gauge between the rocker arm and
valve stem and measure the intake and exhaust valve
clearances.
Valve clearance:
Intake: 0.12 ± 0.03 mm (0.005 ± 0.001 in)
Exhaust: 0.30 ± 0.03 mm (0.012 ± 0.001 in)
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)
Tappet wrench, 3 mm 07908-KE90200
After adjustment, tighten the lock nut while holding the
adjusting screw.
Recheck the valve clearance.
Insert a feeler gauge between the rocker arm and
valve stem and measure the intake and exhaust valve
clearances.
Valve clearance:
Intake: 0.12 ± 0.03 mm (0.005 ± 0.001 in)
Exhaust: 0.30 ± 0.03 mm (0.012 ± 0.001 in)
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)
Tappet wrench, 3 mm 07908-KE90200
After adjustment, tighten the lock nut while holding the
adjusting screw.
Recheck the valve clearance.
(1) FEELER GAUGE(1) FEELER GAUGE
Operate the kickstarter pedal and align the “T” mark on
the flywheel with the index mark on the left crankcase
cover.
Make sure the piston is at TDC (Top Dead Center) on the
stroke by moving the rocker arms.
Operate the kickstarter pedal and align the “T” mark on
the flywheel with the index mark on the left crankcase
cover.
Make sure the piston is at TDC (Top Dead Center) on the
stroke by moving the rocker arms.
(1) “T” MARK
(2) INDEX MARK
(1) “T” MARK
(2) INDEX MARK
2
1
1
44
3
2
1
2
1
Service and Maintenance
3-6
3-6
(1) OIL FILTER COVER
(2) O-RINGS
(3) OIL FILTER
(4) SPRING
Oil Filter Change
Remove the left crankcase cover
Remove the oil filter cover retaining plate bolt and plate.
Remove the oil filter and spring.
(1) SPRING
(1) OIL FILTER COVER
(2) O-RINGS
(3) OIL FILTER
(4) SPRING
Oil Filter Change
Remove the left crankcase cover (page 4-49).
Remove the oil filter cover retaining plate bolt and plate.
Remove the oil filter cover and O-rings.
Remove the oil filter and spring.
(1) BOLT
(2) RETAINING PLATE
(1) BOLT
(2) RETAINING PLATE
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:
Repsol 4T motorcycle oil (10W-30)
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.
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:
Repsol 4T motorcycle oil (10W-30)
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.
(1) OIL FILLER CAP/DIPSTICK
(2) DRAIN BOLT/SEALING WASHER
(1) OIL FILLER CAP/DIPSTICK
(2) DRAIN BOLT/SEALING WASHER
(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:
Repsol 4T motorcycle oil (10W-30)
(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:
Repsol 4T motorcycle oil (10W-30)
3
2
1
2
1
2
1
4
3
2
2
1
Service and Maintenance
3-7
3-7
Oil Strainer Screen Cleaning
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.
Oil Strainer Screen Cleaning
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.
(1) OIL STRAINER SCREEN(1) OIL STRAINER SCREEN
(1) RETAINING PLATE
(2) BOLT
Install new O-rings into the oil filter cover grooves.
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.
(1) RETAINING PLATE
(2) BOLT
Install new O-rings into the oil filter cover grooves.
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.
(1) NEW O-RINGS
(2) OIL FILTER COVER
(1) NEW O-RINGS
(2) OIL FILTER COVER
(1) OIL FILTER
(2) “OUTSIDE” MARK
Apply grease to the oil filter spring end (filter side).
Install the spring into the new oil filter.
Install the new oil filter into the left crankcase with its
“OUTSIDE” mark facing out.
Installing the oil filter backwards will result in severe
engine damage.
(1) OIL FILTER
(2) “OUTSIDE” MARK
Apply grease to the oil filter spring end (filter side).
Install the spring into the new oil filter.
Install the new oil filter into the left crankcase with its
“OUTSIDE” mark facing out.
Installing the oil filter backwards will result in severe
engine damage.
(2) OIL FILTER
(3) APPLY GREASE
(
(
(3) APPLY GREASE
3
2
1
2
1
1
1
2
1
2
1
Service and Maintenance
3-8
3-8
5. Pour specified transmission oil.
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
Check the O-ring is in good condition, install the oil filler
cap.
5. Pour specified transmission oil.
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
Check the O-ring is in good condition, install the oil filler
cap.
(1) FILLER CAP
(2) O-RING
(1) FILLER CAP
(2) O-RING
Transmission Oil
Oil Change
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)
Transmission Oil
Oil Change
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)
(1) DRAIN BOLT(1) DRAIN BOLT
Engine Idle Speed
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.
Warm up the engine until the fan starts, shift the
transmission into neutral, and hold the motorcycle in an
upright position.
Connect a tachometer according to its manufacturer’s
operating instruction.
Idle speed: 1,800 ± 100 rpm
(1) THROTTLE STOP SCREW(1) THROTTLE STOP SCREW
2
1
1
1
Service and Maintenance
3-9
3-9
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.
Torque: 9.8 N•m (1.0 kgf•m, 7 lbf•ft)
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.
Torque: 9.8 N•m (1.0 kgf•m, 7 lbf•ft)
(1) BOLT
(2) RADIATOR CAP
(1) BOLT
(2) RADIATOR CAP
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.
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.
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 4-15).
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.
(1) INSPECTION HOLE
(2) COOLANT DRAIN BOLT/SEALING WASHER
(1) INSPECTION HOLE
(2) COOLANT DRAIN BOLT/SEALING WASHER
Coolant
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.
Coolant
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.
(1) OVERFLOW HOSE
(2) RADIATOR
(1) OVERFLOW HOSE
(2) RADIATOR
2
1
2
1
2
1
Service and Maintenance
3-10
3-10
Exhaust Pipe And Muffler
Inspection
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.
Loss of power will result if the exhaust pipe is broken.
Exhaust Pipe And Muffler
Inspection
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.
Loss of power will result if the exhaust pipe is broken.
(1) EXHAUST PIPE
(2) MUFFLER
(1) EXHAUST PIPE
(2) MUFFLER
Clutch System
System Inspection
1. Operate the clutch lever and check that no air has en-
tered 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.
Clutch System
System Inspection
1. Operate the clutch lever and check that no air has en-
tered 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.
(1) CLUTCH FLUID RESERVOIR
(2) LOWER LEVEL LINE
(1) CLUTCH FLUID RESERVOIR
(2) LOWER LEVEL LINE
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 coo-
lant level (page 1-2).
(1) FILLER NECK(1) FILLER NECK
2
1
1
2
1
Service and Maintenance
3-11
3-11
Drive Chain Slider
Inspection/Replacement
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.
Drive Chain Slider
Inspection/Replacement
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.
(1) DRIVE CHAIN SLIDER
(2) DRIVE CHAIN TENSIONER SLIDER
(1) DRIVE CHAIN SLIDER
(2) DRIVE CHAIN TENSIONER SLIDER
Drive Chain Slack Adjustment
Loosen the rear axle nut just enough to move the rear
wheel in fore-aft 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.
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.
Recheck the drive chain slack and free wheel rotation.
After adjustment, tighten the axle nut to the specified
torque.
Torque: 69 N•m (7.0 kgf•m, 51 lbf•ft)
Lubricate the drive chain.
Hook the drive chain tensioner spring.
(1) AXLE NUT
(2) ADJUSTER
(1) AXLE NUT
(2) ADJUSTER
Drive Chain
Drive Chain Slack Inspection
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.
Drive chain slack: 25 – 35 mm (1.0 – 1.4 in)
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.
Drive Chain
Drive Chain Slack Inspection
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.
Drive chain slack: 25 – 35 mm (1.0 – 1.4 in)
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.
(1) DRIVE CHAIN SLACK(1) DRIVE CHAIN SLACK
2
1
2
1
1
Service and Maintenance
3-12
3-12
Driven Sprocket Replacement
Remove the rear wheel (page 5-15).
Remove the bolts/nuts, washers and driven sprocket.
Installation is in the reverse order of removal.
Hold the bolts and tighten the nuts to the specified torque.
Torque:
24 - 30 N•m (2.4 - 3.0 kgf•m, 17.7 - 22.1 lbf•ft)
Adjust the drive chain slack (page 3-11).
(1) BOLTS/NUT
(2) DRIVEN SPROCKET
(1) BOLTS/NUT
(2) DRIVEN SPROCKET
Install the drive sprocket onto the countershaft as shown.
Install the spring washer and bolt, then tighten the bolt to
the specified torque.
Torque: 31 N•m (3.2 kgf•m, 23 lbf•ft)
Install the drive sprocket onto the countershaft as shown.
Install the spring washer and bolt, then tighten the bolt to
the specified torque.
Torque: 31 N•m (3.2 kgf•m, 23 lbf•ft)
(1) DRIVE SPROCKET
(2) SPRING WASHER
(3) BOLT
(1) DRIVE SPROCKET
(2) SPRING WASHER
(3) BOLT
Drive/Driven Sprockets
Drive Sprocket Replacement
Remove the drive sprocket cover.
Loosen the drive chain fully.
Remove the bolt, spring washer and drive sprocket.
Drive/Driven Sprockets
Drive Sprocket Replacement
Remove the drive sprocket cover.
Loosen the drive chain fully.
Remove the bolt, spring washer and drive sprocket.
(1) BOLT
(2) SPRING WASHER
(3) DRIVE SPROCKET
(1) BOLT
(2) SPRING WASHER
(3) DRIVE SPROCKET
3
2
1
3
2
1
2
1
Service and Maintenance
3-13
3-13
Rear Master Cylinder
Always inspect the brake fluid level.
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.
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
Rear Master Cylinder
Always inspect the brake fluid level.
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.
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
(1) COVER
(2) “MIN” LEVEL
(1) COVER
(2) “MIN” LEVEL
Check that the brake hose does not bind or kink in any
steering position and is not pulled when the suspension
is extended.
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
(1) BRAKE HOSE(1) BRAKE HOSE
Brake Fluid
Front Brake Master Cylinder
Always inspect the brake fluid level.
Remove the screws, master cylinder cover and diaphragm.
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 5-24 for brake pad replacement.
Also check the brake system for leaks.
(1) “MIN” LEVEL(1) “MIN” LEVEL
1
1
2
1
Service and Maintenance
3-14
3-14
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.
Torque:
Front: 18 - 20 N•m (1.8 - 2 kgf•m, 13-15 lbf•ft)
Rear: 16 - 18 N•m (1.6 - 1.8 kgf•m, 11-13 lbf•ft)
On the front brake, replace the collar with new ones if the
disc starts to wobble right and left.
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.
Torque:
Front: 18 - 20 N•m (1.8 - 2 kgf•m, 13-15 lbf•ft)
Rear: 16 - 18 N•m (1.6 - 1.8 kgf•m, 11-13 lbf•ft)
On the front brake, replace the collar with new ones if the
disc starts to wobble right and left.
(1) BRAKE DISC
(2) DISC BOLT
(3) COLLAR
(1) BRAKE DISC
(2) DISC BOLT
(3) COLLAR
Brake System
Refer to page 1-7 for Brake Lever Adjustment.
Refer to page 1-7 for Brake Pedal Height Adjustment.
Brake Discs
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.
(1) BRAKE DISC(1) BRAKE DISC
Brake Pad Wear
Measure the brake pad thickness.
Minimum thickness (subtracting the metal support):
1.0 mm (0.04 in)
If either pad is wear to the indicator, both pads must be
replaced.
Brake Pad Wear
Measure the brake pad thickness.
Minimum thickness (subtracting the metal support):
1.0 mm (0.04 in)
If either pad is wear to the indicator, both pads must be
replaced.
(1) BRAKE PAD(1) BRAKE PAD
1
321
1
Service and Maintenance
3-15
3-15
Wheels And Tires
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.
Standard tire air pressure FOR COMPETITION ONLY:
Front: 39 – 44 kPa (0.40 – 0.45 kgf/cm
2
, 5.6 – 6.4 psi)
Rear: 29 – 34 kPa (0.30 – 0.35 kgf/cm
2
, 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) 07701–0020300
Torque:
Spoke nipple:
Front: 2.45 - 4.9 N•m (0.24 - 0,49 kgf•m, 1.8-3.6 lbf•ft)
Rear: 2 - 3 N•m (0.2 - 0.3 kgf•m, 1.5-2.2 lbf•ft)
Rim lock nut: 13 N•m (1.3 kgf•m, 9 lbf•ft)
(1) SPOKE NIPPLE
(2) RIM LOCK
(1) SPOKE NIPPLE
(2) RIM LOCK
Steering Head Bearings
Support the motorcycle using the maintenance stand with
its front wheel off the ground.
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.
Steering Head Bearings
Support the motorcycle using the maintenance stand with
its front wheel off the ground.
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.
(1) STEERING HEAD BEARINGS(1) STEERING HEAD BEARINGS
Handlebar And Steering Head Bearings
Handlebar
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)
Handlebar And Steering Head Bearings
Handlebar
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)
(1) HOLDER BOLTS
(2) UPPER HOLDER
(1) HOLDER BOLTS
(2) UPPER HOLDER
1
1
2
2
1
2
1
1
Service and Maintenance
3-16
3-16
1
1
Use specified fork fluid which additives to assure
maximum performance of your Cota’s front suspension.
Specified fork fluid:
Left: KYB 01M (5W)
Right: KYB 01M (5W)
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.
(1) PRE-LOAD ADJUSTER
Fork
The motorcycle is shipped with a light coating of grease
on the forks. This is not an indication of a leak.
The fork should always be adjusted for the rider’s weight
and track conditions by using one or more of the following
methods.
There are two adjustments you can make to the front
suspension:
Rebound damping (right fork)
Turning the rebound damping adjuster adjusts how
quickly the fork extends.
Spring pre-load (left fork)
Turning the spring pre-load adjuster adjusts the spring
initial pre-load length.
Replace the fork fluid every 6 months. See page 5-7,
5-11 for oil level adjustment after changing the fork fluid.
Front Suspension
Inspection
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 mo-
torcycle.
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.
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 mo-
torcycle.
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.
(1) PRE-LOAD ADJUSTER(1) PRE-LOAD ADJUSTER (1) REBOUND ADJUSTER(1) REBOUND ADJUSTER
Service and Maintenance
3-17
3-17
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 move-
ment. If movement is felt, replace the pivot bearings
(page 5-21).
When your Cota is new, your suspension will break-in
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.
(1) REBOUND ADJUSTER
Rear Suspension
The Pro-Link swingarm is controlled by a shock absorber.
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.
(1) PRE-LOAD ADJUSTER
1
1
Service and Maintenance
3-18
3-18
Storage
Extended storage, such as for winter, requires that you
take certain steps to reduce the effects of non-use. In
addition, it is useful to do the necessary repairs BEFORE
storing your COTA, as if you don’t you could forget these
repairs when you use it again.
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 is explosive. You can
be burned or seriously injured when draining or refue-
ling.
• 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 cm
3
) of clean engine oil into the cylinder.
With the spark plug grounded or the Engine Stop
Switch pushed, crank the engine several times to dis-
tribute the oil.
6. Inflate the tires to their recommended pressure.
7. Place your COTA on the maintenance stand or equiva-
lent 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.
4. Pour the recommended coolant slowly from the radia-
tor filler neck.
Bleed the air in the cooling system and install the radia-
tor cap securely (page 3-9).
Cleaning
Clean your COTA regularly to protect the surface finishes
and inspect for damage, wear, or oil leaks.
When washing your COTA, always use water and a mild
detergent (such as dishwashing liquid) to avoid discolo-
ring the decals.
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.
Rubber components.
Plastic components.
Stickers, decals.
Air duct.
1. After cleaning, rinse your COTA thoroughly with plenty
of clean water. Detergent residue can corrode alloy
parts.
2. Dry your COTA, start the engine, and let it run for se-
veral minutes.
3. Lubricate the drive chain immediately after washing
and drying your COTA.
4. Test the brakes before riding your COTA. Several appli-
cations may be necessary to restore normal braking
performance. Braking performance may be impaired
immediately after washing your COTA.
4-1
4-1
(1) SNAP RING
(2) PRESSURE RELIEF VALVE
(1) SNAP RING
(2) PRESSURE RELIEF VALVE
(1) RELIEF VALVE
(2) O-RING
(1) RELIEF VALVE
(2) O-RING
(1) DRIVEN GEAR
(2) DRIVE PIN
(1) DRIVEN GEAR
(2) DRIVE PIN
Oil Pressure Relief Valve
Removal/Inspection
Drain the engine oil.
Remove the left crankcase cover (page 4-49).
Remove the snap ring.
Remove the pressure relief valve from the left crankcase
cover.
(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 4-51).
Oil Pump
Disassembly
Remove the engine from the frame.
Separate the crankcase halves (page 4-54).
Remove the oil pump driven gear and drive pin.
4. Engine Servicing
2
1
2
1
2
1
2 1
Engine Servicing
4-2
4-2
(1) ONE-WAY REED VALVE
(2) GASKET
(3) DOWEL PINS
(1) ONE-WAY REED VALVE
(2) GASKET
(3) DOWEL PINS
(1) DRIVEN GEAR
(2) OIL PUMP SHAFT
(1) DRIVEN GEAR
(2) OIL PUMP SHAFT
(1) SNAP RING
(2) OIL SEAL
(1) SNAP RING
(2) OIL SEAL
(1) OUTER ROTOR
(2) INNER ROTOR
(3) OIL PUMP SHAFT
Remove the one-way reed valve, gasket and dowel pins.
Remove the oil pump shaft, outer and inner rotors.
(1) OUTER ROTOR
(2) INNER ROTOR
(3) OIL PUMP SHAFT
Remove the one-way reed valve, gasket and dowel pins.
Remove the oil pump shaft, outer and inner rotors.
(1) ONE-WAY REED VALVE
Inspection
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.
(1) ONE-WAY REED VALVE
Inspection
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)
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)
3 3
2
1
3
2
1
1
2
1
21
Engine Servicing
4-3
4-3
(1) ONE-WAY REED VALVE
(2) DOWEL PINS
(3) NEW GASKET
Install the drive pin into the oil pump shaft hole.
Install the oil pump driven sprocket aligning its groove
with the drive pin.
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.
Install the removed parts in the reverse order of removal.
(1) ONE-WAY REED VALVE
(2) DOWEL PINS
(3) NEW GASKET
Install the drive pin into the oil pump shaft hole.
Install the oil pump driven sprocket aligning its groove
with the drive pin.
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.
Install the removed parts in the reverse order of removal.
(1) OIL PUMP SHAFT
(2) INNER ROTOR (3) FLAT SURFACES
(4) OUTER ROTOR
Assembly
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.
(1) OIL PUMP SHAFT
(2) INNER ROTOR (3) FLAT SURFACES
(4) OUTER ROTOR
Assembly
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.
(1) DRIVE PIN
(2) DRIVEN SPROCKET
(1) DRIVE PIN
(2) DRIVEN SPROCKET
(1) GASKET
Measure the oil pump body clearance.
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.
Standard: 0.05 – 0.12 mm (0.002 – 0.004 in)
(1) GASKET
Measure the oil pump body clearance.
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.
Standard: 0.05 – 0.12 mm (0.002 – 0.004 in)
2
1
2
3
1
2 2
3
1
4
1
4-4
4-4
Engine Servicing
(1) 5P CONNECTOR (1) QUICK CONNECTOR PROTECTOR
1. Insert a new pawl into the quick connector. Insert the
quick connector into the fule pump feed hose until it
clicks. If it is hart to insert, apply a small amount of
engine oil to the fuel pump feed hose.
2. Pull on the quick connector to check that it does not
come out and is firmly connected.
Fuel Feed Hose
Disassembly/Installation
The pawl of the connector must be changed every time
the fuel feed hose is disconnected.
Disassembly of fuel pump side
Turn off the engine.
Remove the rear fender
Pull up the fuel tank
Disconnect the fuel pump’s 5P connector.
Turn on the engine until it stops.
1. Remove the protective covering from the quick con-
nector.
2. Check whether the connector is dirty and clean if ne-
cessary. Cover the quick connector with a cloth.
3. Hold the quick connector with one hand and squeeze
the tabs with the other to release the connector. Pull
the connector apart.
1
1
2
1
(1) TABS
(2) QUICK CONNECTOR
2
1
(1) PAWL
(2) QUICK CONNECTOR
(1) PAWL
(2) QUICK CONNECTOR
2
1
4-5
4-5
Engine Servicing
(1) BANJO BOLT
(2) SEALING WASHER
(1) BANJO BOLT, 12 MM
(2) SEALING WASHER, 12 MM
(3) SEALING WASHER
(4) FUEL PRESSUE GAUGE
(1) FUEL PRESSURE GAUGE
Fuel Line Inspection
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.
Cover the fuel feed hose banjo bolt with a rag or shop
towel.
Slowly loosen the banjo bolt and catch the remaining fuel
using an approved gasoline container.
Remove the fuel feed hose banjo bolt and attach the fuel
pressure gauge with the following parts.
Sealing washer, 12 mm 90428-PD6-003
Sealing washer, 12 mm 90430-PD6-003
Tool:
Fuel pressure gauge, 0-100 psi 07406-004000C
Fuel pressure adapter 07406-004030A
Banjo bolt, 12 mm 90008-PP4-E02
Start the engine.
Read the fule pressure at idle.
Idle Speed: 1,800 ± 100 rpm
Standard: 33 psi (min.) - 46 psi (max)
230 kPa (min.) - 320 kPa (max)
2.34 kgf/cm
2
(min.) - 3.26 kgf/cm
2
(max)
If the fuel pressure is lower than specified, inspect the
following:
– Fuel line leaking
– Clogged fuel filter
– Fuel pump (page 4-7)
1
2
2
1
3
2
1
4
4-6
4-6
Engine Servicing
(1) FUEL RETURN HOSE (1) BANJO BOLT
(2) SEALING WASHER
(1) 2P CONNECTOR
Fuel Pump Flow Inspection
Remove the rear fender.
Disconnect the banjo bolt and insert the end of the hose
into an approved gasoline container.
Connect another fuel hose to the pressure regulator and
install the hose end in an approved gasoline container.
Connect a 12 V battery to the fuel pump 2P (Black)
connector terminals, check amount of fuel flow for 10
seconds.
Amount of flow:
125cm
2
(4.32 US oz) minimum / 10 seconds at 12 V
If the fuel flow is less than specified, inspect the following:
– Pinched or clogged fuel hose
– Clogged fuel filter
– Pressure regulator
– Fuel pump (page 4–7)
After inspection, install the banjo bolt into the fuel feed
hose using new sealing washers.
Tighten the banjo bolt the the specified torque.
Torque: 22 N•m (2,2 kgf•m, 16,2 lbf•ft)
Connect the fuel pump 2P connector.
Start the engine and check for fuel leaks.
1
2
2
1
1
Engine Servicing
4-7
4-7
(1) 2P CONNECTOR
(2) SOCKET BOLTS
(1) BREATHER HOSE
(2) BOLT
(3) FUEL TANK
(1) 2P CONNECTOR
Disconnect the fuel tank breather hose.
Remove the fuel tank mounting bolt.
Pull up the fuel tank and disconnect the fuel pump 2P
connector.
Remove the fuel tank and injector as an assembly being
careful not to damage the injector, escpecially the tip of
the injector
After removing the fuel tank and injector, protect the tip
of the injector from damage.
Cover the cylinder head injector hole to prevent dirt from
falling into the combustion chamber.
3
2
1
1
1
2
2
Fuel Tank/Fuel Pump
Removal
Remove the rear fender.
Disconnect the fuel injector 2P connector.
Remove the fuel injector socket bolts.
Engine Servicing
4-8
4-8
Install the fuel pump mounting bolts.
Tighten the fuel tank mounting bolts in the alphabetical
order shown.
Torque: 7 - 9 N•m (0.7 - 0.9 kgf•m, 5.1 - 6.6 lbf•ft)
(1) FUEL PUMP
(2) BOLTS
Remove the 5P connector and fuel feed hose.
Remove the fuel pump base mounting bolts.
Remove the fule pump assembly being careful not to
damage the pump.
(1) FUEL PUMP
Installation
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) QUICK CONNECTOR
(2) FUEL FEED HOSE
(3) 5P CONNECTOR
2
1
3
1
1
2
(1) FUEL PUMP
(2) BOLTS
1
2
A
C
E
B
G
D
F
Engine Servicing
4-9
4-9
Install and tighten the injector holder socket bolts to the
specified torque.
Torque: 8 - 12 N•m (0.8 - 1.2 kgf•m, 5.9 - 8.8 lbf•ft)
Connect the fuel injector 2P (Black) connector.
Install the rear fender.
(1) SOCKET BOLTS
(2) 2P (BLACK) CONNECTOR
Install the fuel tank into the frame being careful not to
pinch the throttle cable.
Install and tighten the fuel tank mounting bolts.
Connect the fuel tank breather hose to the hose clip.
(1) FUEL TANK
(2) BOLT
(3) BREATHER HOSE
(1) 2P CONNECTOR
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.
Install the fuel tank onto the frame and connect the fuel
pump 2P connector.
(1) NEW O-RING
(2) FUEL FEED HOSE
(3) QUICK CONNECTOR
1
2
3
2
3
1
1
2
1
1
Engine Servicing
4-10
4-10
(1) CABLE TERMINALS
(2) MOTOR/FILTER
Cleaning the fuel filter
Press the three pawls between the pump body and the
pump. Remove the body from the pump.
Disconnect the cable terminals.
Disassemble the motor/filter system from the pump body.
(1) PAWL
(2) PUMP BODY
(3) PUMP
Remove the fule tank.
Remove the bolts from the fuel pump base and remove
the fuel pump assembly, taking care not to damge the
pump or pump wires.
(1) BOLTS
(2) FUEL PUMP BASE
Disassembly
Disconnect the 5P connector from the fuel pump
Disconnect the fuel feed hose (page 4-4)
(1) 5P CONNECTOR
1
2
1
3
2
1
1
1
(1) QUICK CONNECTOR (1) FUEL PUMP ASSEMBLY
2
1
1
Engine Servicing
4-11
4-11
(1) FILTER SURFACE
(1) PUMP
(2) PUMP BODY
(3) PAWLS
(1) O-RINGS
(2) PUMP
(3) MOTOR WIRES
(4) MOTOR/FILTER
(5) PUMP BODY
Clean the surface of the filter.
Replace the o-rings with new ones every time the fuel
pump is disassembled.
Clean the contact surface bewtween the pump and the
fuel tank. Install new o-rings.
Install the motor wires through the slot in the pump body
and connect them to the terminals.
Install a new o-ring in the fuel hose.
Install the pump motor in the pump body being careful not
to damage the wires.
(1) O-RING
(2) PUMP ASSEMBLY
Assembly
Insert the pump body in the pump. Make sure that the
pawls are engaged and the pump body and pump are alig-
ned.
Install a new o-ring in the groove of the tank. Install the
pump assembly in the tank being careful not to damage
the o-rings.
Make sure that the bearing is properly positioned and sup-
ported in the fuel tank.
1
2
3
3
5
4
3
2
1
1
1
2
Engine Servicing
4-12
4-12
2
1
(1) BOLTS
(2) FUEL PUMP BASE
A
C
E
B
G
D
F
1
(1) 5P CONNECTOR
1
(1) QUICK CONNECTOR
1
3
2
(1) FUEL TANK
(2) CLIP
(3) BREATHER HOSE
Insert the mounting bolts in the pump.
Place the pump base in the position as shown.
Tighten the pump mounting bolts in alphabetical order as
show.
Torque: 7 - 9 N•m (0.7 - 0.9 kgf•m, 5.1 - 6.6 lbf•ft)
Mount the fuel tank on the chassis.
Connect the breather hose to the fuel tank and secure it
with the clip.
Insert the quick connector on the pump (page 4-4).
Connect the fuel pump 5P connector.
Engine Servicing
4-13
4-13
1
2
1
2
1
(1) BOLTS/NUTS
(2) AIR CLEANER HOUSING
(1) FUEL INJECTOR (1) FUEL INJECTOR
(2) O-RING
Injector
Inspection
Remove the rear fender.
Start the engine and let it idle.
Confirm the fuel injector operates with a sounding rod or
stethoscope.
If the fuel injector does not operate, replace the injector.
Removal/Installation
Do not remove the fuel injector from the injector holder.
Replace the fuel injetor and holder as an assembly.
Alway replace the O-ring when the fuel injector assembly
is removed from the cylinder head.
Throttle Body
Removal
Remove the rear fender.
Remove the fuel tank/fuel injector as an assembly
(page 4-7).
Loosen the connecting tube band screw.
Remove the silencer mounting bolt.
Remove the air cleaner housing mounting bolts/nuts.
Pull the air cleaner housing rearward being careful not to
damage the wire harness.
Disconnect the crancase breather hose from the housing
joint.
Engine Servicing
4-14
4-14
Connect the throttle cable end to the throttle drum.
Install the throttel cable to the throttle body.
Adjust the throttle grip free play.
Install the throttle drum cover and tighten the screws.
(1) THROTTLE CABLE END (2) THROTTLE DRUM
(3) THROTTLE CABLE (4) LOCK NUT
(1) SCREW
(2) INSULATOR
(3) ALIGH
Loosen the lock nut and disconnect the throttle cable
from the throttle body.
Disconnect the cable end from the throttle drum.
Loosen the insulator clamp screw and remove the insulator
from the throttle body.
Installation
Install the insulator onto the throttle body while aligning
the slit with the lug on the throttle body as shown.
(1) LOCK NUT (2) THROTTLE CABLE
(3) THROTTLE CABLE END (4) THROTTLE DRUM
(1) SCREWS
(2) THROTTLE DRUM COVER
Disconnect the ECM 32P (Black) connector by lifting up
on the fixation handle.
Loosen the insulator band screw and remove the throttle
body.
Remove the screws and throttle drum cover.
(1) 32P (BLACK) CONNECTOR
(2) BAND SCREW
(3) THROTTLE BODY
1
2
2
1
2
3
4
4
3
2
1
3
2
1
3
2
1
2
1 1
(1) THROTTLE DRUM COVER
(2) SCREWS
Engine Servicing
4-15
4-15
(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 4-40)
Hold the water pump gear teeth using a suitable tool,
then remove the impeller, copper washer and water pump
shaft.
(1) BOLTS
(2) WATER PUMP COVER
Install the air cleaner housing onto the frame and connect
the crankcase breather hose.
Install and tighten the air cleaner housing mounting nuts
and bolt securely.
Install the washer and muffler mounting bolt, then tighten
the bolt securely.
Tighten the connecting tube band screw securely.
Install the rear fender.
(1) AIR CLEANER HOUSING
(2) BOLTS/NUTS
1
2
2
1
4
3
2
1
Install the throttle body into the insulator.
Make sure there are the following clearances between the
throttle body:
– Throttle body-to-bank angle sensor: more than 5 mm
– Throttle body-to-muffler: more than 5 mm
Adjust the insulator band angle and tighten the band
screw securely.
Connect the ECM 32P (Black) connector.
(1) THROTTLE BODY
(2) BAND SCREW
(3) 32P (BLACK) CONNECTOR
1
2
3
Engine Servicing
4-16
4-16
(1) WASHER
(2) WATER PUMP SHAFT
(3) NEW COPPER WASHER
(4) IMPELLER
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.
Torque: 12 N•m (1.2 kgf•m, 9 lbf•ft)
Install the washer and right crankcase cover (page 4-41).
(1) WATER SEAL
(2) OIL SEAL
(3) BEARING
Install the water seal into the right crankcase cover in the
direction shown in the illustration above.
Tool:
Mechanical seal installer 07965-415000A
Install a new oil seal in the direction shown in the
illustration above.
Drive the new bearing into the right crankcase cover.
(1) MECHANICAL SEAL INSTALLER
1
3
2
1
1
2
3
4
Remove the water pump bearing from the right crankcase
cover using the special tools.
Tools:
Bearing remover, 12 mm 07936-166010A
– Remover handle 07936-3710100
– Remover weight 07936-371020A
Remove the oil seal and water seal.
(1) BEARING REMOVER, 12 MM
1
Engine Servicing
4-17
4-17
(1) WATER PUMP COVER
(2) BOLTS
Install the following:
– Dowel pins, new O-ring
– Water pump cover, bolts
Fill the crankcase with recommended transmission oil
(page 3-8).
Fill the coolant and bleed air (page 3-9).
(1) DOWEL PINS
(2) NEW O-RING
(3) WATER PUMP COVER
3
2
1
1
1
2
(1) 3P (GRAY) CONNECTOR
Remove the ground eyelet bolt.
Remove the ignition coil mounting bolt.
Remove the spark plug wire/wire harness/breather hose
clamp.
Disconnect the ECT sensor 3P (Gray) connector.
(1) GROUND EYELET (2) BOLTS
(3) IGNITION COIL (4) WIRE CLAMP
(1) 2P (NATURAL) CONNECTOR
Radiator Removal/Installation
Remove the following:
– Exhaust pipe
– Skid plate
– Fuel tank/injector assembly (page 4-7)
Disconnect the radiator 2P (Natural) connector.
Remove the spark plug wire tie-wrap from fan motor
shroud.
1
4
3
2
2
1
1
1
1
(1) TIE WRAP
Engine Servicing
4-18
4-18
(1) RADIATOR
(2) EXHAUST PIPE
(3) MUFFLER
(4) SKID PLATE
Engine Removal/Installation
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 4-17)
– Air cleaner housing
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
(1) IGNITION COIL
(2) BOLTS
(3) GROUND EYELET
(4) WIRE CLAMP
Installation is in the reverse order of removal.
NOTICE
At ignition coil installation, install the ground eyelet with
the ignition coil lower mounting bracket bolt as shown in
the illustration.
(1) RADIATOR HOSES
(2) HANGER BOLT
(3) DOWN TUBE BOLTS
(4) DOWN TUBE
(5) RADIATOR MOUNTING BOLT
(6) RADIATOR
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.
4
3
2
2
1
5
3
2
4
3
2
1
1
4
6
Service Data
4-19
4-19
Engine Removal/Installation Illustration
24 N•m (2.4 kgf•m, 17.8 lbf•ft)
69 N•m (7 kgf•m, 51 lbf•ft)
25 N•m (2.5 kgf•m, 18.4 lbf•ft)
50 N•m (5.1 kgf•m, 36.8 lbf•ft)
26 N•m (2.7 kgf•m, 19.1 lbf•ft)
26 N•m (2.7 kgf•m, 19.1 lbf•ft)
24 N•m (2.4 kgf•m, 17.8 lbf•ft)
39 N•m (4.0 kgf•m, 28.7 lbf•ft)
25 N•m (2.5 kgf•m, 18.4 lbf•ft)
Engine Servicing
4-20
4-20
(1) “T” MARK
(2) INDEX MARK
Remove the fuel tank/injector.
Remove the timing hole cap and O-ring from the left
crankcase cover.
Turn the crankshaft by operating the kickstarter and align
the “T” mark on the flywheel with the index mark on the
left crankcase cover.
(1) TIMING HOLE CAP
Cylinder Head Cover/Camshaft Removal
Remove the cam chain tensioner lifter sealing bolt and
sealing washer.
Turn the tensioner lifter clockwise fully and secure it with
the tensioner holder.
This tool can be easily be made from a thin (1 mm thick)
piece of steel as shown.
TOOL:
Tensioner holder 07AMG-001A100
(1) SEALING BOLT/WASHER
(2) STOPPER TOOL
(1) CYLINDER COMPRESSION GAUGE
Cylinder Compression
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:
67 psi (460 kPa, 4.7 kgf/cm
2
)
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:
– Incorrect valves adjustment
1
2
1
2
1
1
Engine Servicing
4-21
4-21
(1) CAM CHAIN
(2) CAMSHAFT
(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.
(1) BOLTS/SEALING WASHERS (2) SH BOLTS
(3) SEALING WASHERS (4) CYLINDER HEAD COVER
(1) BOLTS
(2) TAPPET ADJUSTING HOLE COVER
Remove the bolts and tappet adjusting hole covers.
Make sure the piston at TDC (Top Dead Center) on the
compression stroke by moving the rocker arms.
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.
Remove the camshaft assembly.
2
1 1
4
3
3
2
1
1
2
1
2
2
1
Engine Servicing
4-22
4-22
(1) ROCKER ARM
(2) ROCKER ARM SHAFT
(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.
(1) BEARINGS
(2) CAMSHAFT
(1) INTAKE ROCKER ARM SHAFT
(2) EXHAUST ROCKER ARM SHAFT
(3) INTAKE ROCKER ARM
(4) EXHAUST ROCKER ARM
Disassembly
Pull out the rocker arm shafts using a suitable 6 mm bolt
and remove the intake and exhaust rocker arms.
Check the rocker arms and shafts for wear or damage.
Measure the rocker arm I.D.
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)
4
3
2
1
2
1
1
2
1
2
1
Engine Servicing
4-23
4-23
(1) CAM CHAIN GUIDE
Remove the gasket and dowel pins.
Remove the cam chain guide.
(1) GASKET
(2) DOWEL PINS
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.
(1) BOLTS
(2) NUTS/WASHERS
(3) CYLINDER HEAD
Cylinder Head Removal
Remove the following:
– Exhaust pipe
– Throttle body/insulator
– Cylinder head cover/camshaft
– Spark plug
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) RADIATOR HOSE
(2) HANGER BOLTS
2
1
3
2
1
1
2
2
1
1
Engine Servicing
4-24
4-24
(1) CAM CHAIN TENSIONER
(2) PIVOT BOLT
Installation
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)
(1) WASHER (2) PIVOT COLLAR
(3) CAM CHAIN TENSIONER
(4) PIVOT BOLT (5) APPLY LOCKING AGENT
Inspection
Inspect the cam chain tensioner and cam chain guide for
excessive wear or damage, replace if necessary.
(1) CAM CHAIN TENSIONER
(2) CAM CHAIN GUIDE
(1) BOLT
(2) CAM CHAIN TENSIONER
Remove the following:
– Cylinder head (page 4-23)
– Left crankcase cover (page 4-49)
– Flywheel (page 4-52)
Remove the bolts and cam chain guide plate.
Remove the bolt, cam chain tensioner, pivot collar and
washer.
(1) BOLTS
(2) CAM CHAIN GUIDE PLATE
2
1
2
1
5
4
3
2
1
2
1
1
2
Engine Servicing
4-25
4-25
(1) RETAINER
(2) OUTER SPRING
(3) INNER SPRING
(4) SPRING SEAT
(5) VALVE
(6) STEM SEAL
Remove the following:
– Spring retainer
– Outer and inner valve springs
– Stem seal
– Valve spring seat
– Intake and exhaust valve
Cylinder Head Disassembly
Remove the cylinder head (page 4-23).
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 07757-0010000
Compressor attachment 07959-KM30101
(1) VALVE SPRING COMPRESSOR
(2) ATTACHMENT
(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 4-53)
– Left crankcase cover (page 4-51)
– Cylinder head (page 4-37)
(1) CAM CHAIN GUIDE
(2) ALIGN
1
2
2
1
2
2
1
2
1
6
5
4
3
2
1
Engine Servicing
4-26
4-26
Valve/Valve Guide
Inspect each valve for out-of-round, burns, scratches or
abnormal stem wear.
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)
(1) VALVE
Valve Spring
Check the valve springs for fatigue or damage.
Measure the free length of the intake and exhaust valve
springs.
Service limits:
Inner: 24.9 mm (0.98 in)
Outer: 27.6 mm (1.09 in)
(1) OUTER VALVE SPRING
(2) INNER VALVE SPRING
Cylinder Head Inspection
Cylinder Head
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.
Check the cylinder head for warpage with a straight edge
and feeler gauge.
Service limit: 0.05 mm (0.002 in)
(1) COMBUSTION CHAMBER
1
1
1
2
Engine Servicing
4-27
4-27
Valve Guide Replacement
Mark new valve guides at the proper depth (see
specification; page 4-28) 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.
Using 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
(1) VALVE GUIDE DRIVER
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 4-29).
If the stem-to-guide clearance exceeds the service limits
with new guides also, replace the valves and guides.
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–ML0010B
(1) VALVE GUIDE REAMER
1
1
Engine Servicing
4-28
4-28
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.
Tap the valves and seats using a rubber hose or other
hand lapping tool.
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)
If the seat width is not within specification, reface the
valve seat (page 4-29).
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.
(1) VALVE SEAT WIDTH
Check that the valve guides are at the proper depth using
a slide caliper, adjust the height if necessary.
Specified depth:
IN: 8.0 – 8.3 mm (0.31 – 0.33 in)
EX: 8.2 – 8.5 mm (0.32 – 0.33 in)
Let the cylinder head cool to room temperature.
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 07HMH–ML0010B
Clean the cylinder head thoroughly to remove any metal
particles after reaming and reface the valve seats.
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.
Tool:
Valve guide driver 07HMD–ML00101
(1) VALVE GUIDE DRIVER
1
1
Engine Servicing
4-29
4-29
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.
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.
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.
(1) ROUGHNESS
45º
32º
32º
60º
60º
1
Engine Servicing
4-30
4-30
Use a interior cutter, remove 1/4 of the existing valve
seat material.
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
Use a 32˚ flat 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
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
(1) SEAT WIDTH
45º
32º
60º
1
Engine Servicing
4-31
4-31
(1) SPRING SEAT
(2) STEM SEAL
(3) VALVE
(4) INNER SPRING
(5) OUTER SPRING
(6) RETAINER
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.
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.
Install the valve springs with the tightly wound coils
facing the combustion chamber.
Install the spring retainers.
45º
2
3
1
4
5
6
Engine Servicing
4-32
4-32
(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.
Tools:
Valve spring compressor 07757-0010000
Compressor attachment 07959-KM30101
To prevent loss of tension, do not compress the valve
springs more than necessary.
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
Cylinder Removal
Remove the cylinder head (page 4-23).
Remove the bolts, cam chain tensioner lifter and gasket.
2
1
1
1
2
1
1
3
Engine Servicing
4-33
4-33
(1) SEALING BOLT/SEALING WASHER
(2) CYLINDER
(1) PISTON PIN CLIP
(2) PISTON PIN
Piston Removal
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.
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.
(1) GASKET
(2) DOWEL PINS
Remove the mounting sealing bolt, sealing washer and
cylinder.
Remove the gasket and dowel pins.
2
1
2
1
2
2
1
Engine Servicing
4-34
4-34
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: 78.04 mm (3.072 in)
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)
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.
Engine Servicing
4-35
4-35
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: 77.89 mm (3.066 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)
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.
Service limit:
Top: 0.44 mm (0.017 in)
Second: 0.64 mm (0.025 in)
Oil (side rail): 0.90 mm (0.035 in)
Connecting Rod
Measure the connecting rod small end I.D.
Service limit: 16.04 mm (0.631 in)
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 4-54).
Engine Servicing
4-36
4-36
(1) TENSIONER LIFTER (1) TOP RING
(2) SECOND RING
(3) OIL RINGS
(4) SPACER
Piston Ring 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.
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.
(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 Installation
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.
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.
1
4
3
3
2
1
3
2
1
Engine Servicing
4-37
4-37
(1) CYLINDER HEAD
(2) WASHERS/NUTS
(3) BOLTS
Cylinder Head Installation
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.
Torque: 39 N•m (4.0 kgf•m, 29 lbf•ft)
(1) DOWEL PINS
(2) NEW GASKET
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) CYLINDER
(2) NEW SEALING BOLT/SEALING WASHER
(1) CYLINDER
Cylinder Installation
Install the dowel pins and new gasket.
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.
(1) DOWEL PINS
(2) NEW GASKET
2
2
1
1
2
2
2
2
1
1
3
3
2
1
Engine Servicing
4-38
4-38
Camshaft/Cylinder Head Cover Installation
Camshaft Installation
Turn the crankshaft by operating the kickstarter, align the
“T” mark on the flywheel with the index mark on the left
crankcase cover.
(1) “T” MARK
(2) INDEX MARK
Install the upper engine hanger bolt, tighten the nut to the
specified torque.
Torque: 24 N•m (2.4 kgf•m, 17 lbf•ft)
Connect the radiator hose to the water joint, tighten the
clamp screw securely.
Install the following:
– Camshaft
– Cylinder head cover
– Throttle body/insulator
– Exhaust pipe
Pour recommended coolant mixture and bleed air.
(1) HANGER BOLT
(2) RADIATOR HOSE
Tighten the cylinder sealing bolt and cylinder head
mounting bolts securely.
(1) CYLINDER HEAD BOLTS
(2) CYLINDER SEALING BOLT
2
1
2
1
1
2
1
Engine Servicing
4-39
4-39
(1) CAMSHAFT END CAP
(2) DOWEL PINS
Cylinder Head Cover Installation
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.
(1) APPLY SEALANT
(2) BEARING RETAINER
(1) NEW O-RINGS
(2) INTAKE ROCKER ARM SHAFT
(3) INTAKE ROCKER ARM
(4) EXHAUST ROCKER ARM
(5) EXHAUST ROCKER ARM SHAFT
Cylinder Head Cover Assembly
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.
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) CAM SPROCKET
(2) CAM CHAIN
(3) INDEX MARKS
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.
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.
(1) BEARINGS
(2) GROOVE
1
5
4
3
2
1
1
2
1
2
1
2
2
1
3
3
2
1
Engine Servicing
4-40
4-40
(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 4-15).
Remove the bolt and kickstarter pedal.
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.
(1) TAPPET ADJUSTING HOLE CAP (2) O-RING(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.
Tighten the cylinder head cover bolts securely.
2
1
5
4
3
2
1
2
3 3
1
1
3
3
4
2
2
Engine Servicing
4-41
4-41
(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
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 the water pump cover (page 4-15).
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.
Torque: 37 N•m (3.8 kgf•m, 27.4 lbf•ft)
Connect the lower radiator hose.
Fill the crankcase with recommended transmission oil
(page 3-8).
Fill the coolant and bleed air.
(1) OIL BOLTS
(2) SEALING WASHERS
Installation
Install two dowel pins and new gasket onto the crankcase.
(1) BOLTS
(2) CLUTCH COVER
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.
1
1
2
1
1
2
2
4
6
5
3
3
22
2
1
Engine Servicing
4-42
4-42
(1) SLAVE CYLINDER PISTON
(2) SPRING
(3) O-RING (BLACK)
(4) O-RING (GREEN)
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.
Remove the slave cylinder piston, return spring and
O-rings.
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.
Install the return spring and piston into the slave cylinder
in the clutch cover.
(1) O-RING
(2) DOWEL PINS
(3) CLUTCH COVER
(1) SEALING WASHERS
(2) OIL BOLTS
(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 clutch hose eyelet with new sealing washers.
Install and tighten the oil bolt..
Fill the clutch system with recommended brake fluid and
bleed air.
2
1
21
1
2
4
3
2
1
3
2
2
1
Engine Servicing
4-43
4-43
(1) CLUTCH LIFTER PIECE ASSEMBLY
(2) LIFTER PLATE BOLTS
(3) CLUTCH LIFTER
(4) CLUTCH SPRINGS
Clutch
Removal
Pull the clutch lever and hold it with a suitable clamp.
Remove the bolts and clutch cover without disconnecting
the clutch fluid line.
Remove the clutch lifter piece assembly.
Remove the following:
– Clutch lifter plate bolts
– Lifter plate
– Clutch springs
(1) CLUTCH CENTER HOLDER (1) CLUTCH CENTER (2) CLUTCH DISCS
(3) CLUTCH PLATE (4) PRESSURE PLATE
(5) PAPER DISCS
(1) LOCK WASHER
(2) PLAIN WASHER
Hold the clutch assembly with the clutch center holder
and remove the clutch center nut.
Tool:
Clutch holder plate 07HGB-001010B
Clutch holder collars “A” 07HGB-001020B
Remove the lock washer and plain washer.
(1) THRUST WASHER
(2) CLUTCH OUTER
(3) NEEDLE BEARING
(4) CLUTCH OUTER GUIDE
Remove the following:
– Clutch center
– Six clutch discs
– Five clutch plates
– Clutch pressure plate
Remove the thrust washer, clutch outer, needle bearing
and clutch outer guide.
4
3
2
1
1
4
3
2
2
1
5
2
1
2
1
4
3
Engine Servicing
4-44
4-44
(1) CLUTCH CENTER
(2) CLUTCH OUTER
(3) OUTER GUIDE
(4) NEEDLE BEARING
Inspection
Check the following items (specifications; 2-3).
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) LIFTER PIECE ASSEMBLY (1) OUTER GUIDE
(2) NEEDLE BEARING
(1) CIRCLIP
(2) THRUST WASHER
(3) THRUST NEEDLE BEARING
(4) LIFTER PIECE
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.
Remove the circlip, thrust washer and thrust needle
bearing from the lifter piece.
Assemble the lifter piece in the reverse order of removal.
(1) CLUTCH OUTER
(2) THRUST WASHER
Installation
Install the clutch outer guide and needle bearing onto the
mainshaft.
Install the clutch outer and thrust washer.
1
2
1
2
4
3
2
1
1
4
3
2
1
Engine Servicing
4-45
4-45
(1) PRESSURE PLATE
(2) CLUTCH CENTER
(3) DOT MARKS
(1) THRUST WASHER
(2) LOCK WASHER
(3) “OUTSIDE” MARK
(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 4-42).
(1) CLUTCH DISCS
(2) CLUTCH PLATE
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 clutch center assembly into the clutch outer.
(1) CLUTCH CENTER HOLDER
Install the thrust washer onto the mainshaft.
Install the lock washer with its “OUTSIDE” 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.
Tool:
Clutch holder plate 07HGB-001010B
Clutch holder collars “A” 07HGB-001020B
Torque: 69 N•m (7.0 kgf•m, 51 lbf•ft)
1
3
3
2
1
2
3
1
2
3
4
1
1
2
Engine Servicing
4-46
4-46
(1) IDLE GEAR/THRUST WASHER
(2) BOLT
(3) STOPPER PLATE
(4) KICKSTARTER ASSEMBLY
Kickstarter
Removal/Disassembly
Remove the clutch (page 4-43)
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 2-3):
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) RATCHET SPRING (2) STARTER RATCHET
(3) PINION GEAR (4) SPINDLE
(5) RETURN SPRING (6) COLLAR
(1) RETURN SPRING
(2) COLLAR
(3) WASHER
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.
(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.
6
6
5
5
5
4
4
4
3
3
3
3
2
2
2
2
1
1
1
1
Engine Servicing
4-47
4-47
(1) KICKSTARTER ASSEMBLY
(2) SPRING HOOK
(1) STOPPER PLATE
(2) BOLT
(1) GEARSHIFT SPINDLE
(2) BOLTS
(3) GUIDE PLATE
(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.
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.
Install the kickstarter assembly and hook the starter
ratchet with the stopper.
Install the return spring end into the crankcase hole as
shown.
1
2
2
1
3
2
2
1
2
1
Engine Servicing
4-48
4-48
(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.
(1) SHIFT DRUM CENTER
(2) CENTER PIN
(1) RETURN SPRING
(2) WASHER
(3) STOPPER ARM
(4) DRUM CENTER
(5) DOWEL PIN
(6) CUT-OUT
Install the return spring, plain washer and stopper arm
and tighten the stopper arm bolt to the specified torque.
Torque: 12 N•m (1.2 kgf•m, 9 lbf•ft)
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.
(1) DRUM SHIFTER
(2) SPRING
(3) PLUNGER
(4) RATCHET PAWL A
(5) RATCHET PAWL B
(6) GUIDE PLATE
Inspection
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.
NOTICE
Note the direction of the ratchet pawl A and B.
54 3 2
1
6
6
5
4
3
2
1
2
1
5
4
3
3
2
1
Engine Servicing
4-49
4-49
Remove the engine oil drain bolt and sealing washer, drain
the engine oil.
Remove the bolts and left crankcase cover.
NOTICE
The left crankcase cover (stator) is magnetically attached
to the fl ywheel, be careful during removal.
Remove the left crankcase cover, gasket and dowel pins.
(1) DRAIN BOLT/SEALING WASHER
(2) BOLTS
(3) LEFT CRANKCASE COVER
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.
Remove the gearshift pedal.
(1) 3P (WHITE) CONNECTOR
(2) 2P (NATURAL) CONNECTOR
(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.
(1) WASHER (2) GEARSHIFT SPINDLE
(3) RETURN SPRING PIN
(4) SHIFTER COLLAR
4
3
2
1
2
1
3
2
1
1
Engine Servicing
4-50
4-50
Press new needle bearing into the left crankcase cover
using the special tools.
Tools:
Driver 07749–0010000
Attachment, 22 x 24 mm 07746–0010800
Pilot, 15 mm 07746–0040300
(1) NEEDLE BEARING
(1) BEARING REMOVER
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 needle bearing using the special tools.
Tools:
Bearing remover, 15 mm 07936–KC10500
Remover weight 07936–371020A
(1) SNAP RING (2) WASHER
(3) OIL SEAL (4) NEEDLE BEARING
(1) OIL PRESSURE RELIEF VALVE
Disassembly/Assembly
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).
(1) BOLTS (2) IGNITION PULSE GENERATOR
(3) WIRE GUIDE (4) SOCKET BOLTS
(5) STATOR
5
4
3
2
1
1
4
3
2
1
1
1
1
Engine Servicing
4-51
4-51
(1) DOWEL PINS
(2) NEW GASKET
Installation
Check the oil filter cover O-ring is in groove condition,
replace if necessary.
Install dowel pins and new gasket.
(1) OIL FILTER COVER
(2) O-RING
(1) STATOR
(2) IGNITION PULSE GENERATOR
(3) WIRE CLAMP
(4) SOCKET BOLTS
(5) BOLTS
(6) GROMMET
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 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.
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.
(1) OIL SEAL
(2) WASHER
(3) SNAP RING
Apply grease to the new oil seal lip and install it into the
left crankcase cover.
Install the washer and snap ring.
Install the oil pressure relief valve (page 4-1).
1
4
3
2
5
5
1
2
3
6
2
1
2
1
1
Engine Servicing
4-52
4-52
Flywheel
Removal
Remove the left crankcase cover (page 4-49).
Hold the flywheel with flywheel holder, loosen the
flywheel nut.
Tool:
Flywheel holder 07AMB-NN4A100
Install the gearshift pedal.
Connect the alternator 3P (White) connector and ignition
pulse generator 2P (Natural) connectors.
Pour recommended engine oil up to proper level.
Install the slid plate.
(1) 3P (WHITE) CONNECTOR
(2) 2P (NATURAL) CONNECTOR
Install the left crankcase cover being careful not to
damage the oil filter cover O-ring.
NOTICE
The left crankcase cover (stator) is magnetically attached
to the fl ywheel, be careful during installation.
Install and tighten the bolts in a crisscross pattern in 2 or
3 steps.
Install the new sealing washer and engine oil drain bolt,
tighten the bolt to the specified torque.
Torque: 22 N•m (2.2 kgf•m, 16 lbf•ft)
(1) LEFT CRANKCASE COVER
(2) BOLTS
(3) NEW SEALING WASHER/DRAIN BOLT
2
1
1
2
3
Engine Servicing
4-53
4-53
Hold the flywheel with flywheel holder, tighten the
flywheel nut to the specified torque.
Tool:
Flywheel holder 07AMB-NN4A100
Torque: 167 N•m (17.0 kgf•m, 123 lbf•ft)
Install the left crankcase cover (page 4-51).
INSTALLATION
Install the woodruff key into the crankshaft groove.
Install the flywheel onto the crankshaft.
Apply oil to the flywheel nut threads and seating surface.
Install the washer and flywheel nut.
(1) WOODRUFF KEY
(1) THREAD PROTECTOR
(2) FLYWHEEL
(3) FLYWHEEL PULLER
Install the thread protector, which is included with the
flywheel puller, onto the crankshaft.
Install the flywheel puller and remove the flywheel.
Tool:
Flywheel puller w/ thread protector,
36 x 1.5 mm L/H 07AMC-NN4A100
Replacement part:
Thread protector, 18 x 1.5 mm ONLY 07AMC-NN4A110
NOTE:
If required, remove the woodruff key.
1
3
1
2
Engine Servicing
4-54
4-54
(1) CLUTCH OUTER
(2) GEAR HOLDER
(3) PRIMARY DRIVE GEAR
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 07724-001A100
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.
(1) COUNTERSHAFT COLLAR
(2) O-RING
(1) DRIVE SPROCKET
(2) UNIVERSAL HOLDER
(3) BOLT
(4) SPRING WASHER
Crankcase Separation/Disassembly
Remove the engine from the frame.
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.
Tool:
Universal holder 07725-0030000
4
3
2
1
2
1
1
2
3
2
1
Engine Servicing
4-55
4-55
(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
Disassemble the mainshaft and countershaft.
(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.
(1) GASKET
(2) DOWEL PINS
(3) ONE-WAY REED VALVE
Remove the transmission oil drain bolt and sealing washer.
Loosen the crankcase bolts in a crisscross pattern in 2 or
3 steps.
Remove the crankcase bolts.
(1) TRANSMISSION OIL DRAIN BOLT
(2) CRANKCASE BOLTS
1
2
3
1
2
3
2
2
1
4
3
2
1
1
2
2
Engine Servicing
4-56
4-56
(1) LEFT CRANKCASE
Crankcase Bearing Replacement
Remove the oil seals and bearing set plates.
Drive out the bearing using the special tools listed on
Page 2-7.
Install the new bearing as shown in the illustration using
the special tools listed on Page 2-7.
(1) RIGHT CRANKCASE
(1) RIGHT SHIFT FORK
(2) LEFT SHIFT FORK
(3) RIGHT/LEFT SHIFT FORK SHAFT
(4) CENTER SHIFT FORK/SHAFT
(5) SHIFT DRUM
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.
Crankshaft/Transmission Inspection
Measure the crankshaft runout.
Support the crankshaft with V-blocks or a stand 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)
Measure the connecting rod big end side clearance and
big end axial/radial play (specification; Page 2-3).
8 mm 6 mm
1
1
5
4
3
2
1
HOLD HOLD
C
D
4-57
4-57
Engine Servicing
Crankcase Bearings/Oil Seals Location
(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
(A) 1 mm (oil seal tolerance)
(B) 0 ± 0.5 mm (oil seal tolerance)
(C) 58.60 – 58.88 mm (bearing height)
(D) 58.30 – 58. 52 mm (bearing height)
(E) 1 ± 0.5 mm (oil seal tolerance)
(F) 27.60 – 27.82 mm (bearing height)
(G) 28.50 – 28.72 mm (bearing height)
(H) 27.00 – 27.22 mm (bearing height)
(I) 27.00 – 27.22 mm (bearing height)
(J) 0 ± 0.5 mm (oil seal tolerance)
11
10 9 8 7
654
3
21
D
F
G H I J
A
E
B
C
4-58
4-58
Engine Servicing
Transmission Assembly
(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
11109876
432
1
5
(A) THRUST WASHER, 17.2 mm
(B) SPLINED WASHER, 20 mm
SET RING, 20 mm
(C) SET RING, 20 mm
SPLINED WASHER, 20 mm
(D) THRUST WASHER, 20 X 30 X 1.5 mm
(E) THRUST WASHER, 20 X 30 X 1.0 mm
(F) THRUST WASHER, 20 X 30 X 1.0 mm
(G) THRUST WASHER, 22 X 21 X 1.0 mm
SET RING, 22 mm
(H) THRUST WASHER, 17.2 mm
(I) THRUST WASHER, 17.2 mm
C
B
A
D
E
B
B
F G
H
I
Engine Servicing
4-59
4-59
(1) MAINSHAFT
(2) COUNTERSHAFT
(3) SHIFT FORK SHAFTS
(4) LEFT SHIFT FORK
(5) RIGHT SHIFT FORK
(6) CENTER SHIFT FORK
Crankcase Combination
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.
(1) OIL PUMP SHAFT
(2) INNER ROTOR
(3) OUTER ROTOR
(1) ONE-WAY REED VALVE
(1) DOWEL PINS
(2) NEW GASKET
Install the oil pump shaft, oil pump inner rotor and outer
rotors.
Install the dowel pins and new gasket.
(1) RIGHT CRANKCASE
(2) LEFT CRANKCASE
Install the one-way reed valve into the right crankcase.
Place the left crankcase onto the right crankcase.
1
2
3
1
1
2
2
1
4
3
3
5
6
1
2
1
Engine Servicing
4-60
4-60
(1) CRANKCASE BOLTS
(2) NEW SEALING WASHER/OIL DRAIN BOLT
(1) DRIVE GEAR COLLAR (1) CLUTCH OUTER
(2) GEAR HOLDER
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) 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.
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 07724-001A100
Tighten the primary drive gear bolt to the specified torque.
Torque: 108 N•m (11.0 kgf•m, 80 lbf•ft)
2
1
1
2
1
3
2
1
Engine Servicing
4-61
4-61
(1) DRIVE PIN
(2) OIL PUMP DRIVEN GEAR
(1) DRIVE SPROCKET
(2) UNIVERSAL HOLDER
(3) SPRING WASHER
(4) BOLT
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.
Tool:
Universal holder 07725-0030000
(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.
3
4
2
1
1
2
2
1
5-1
5-1
(1) AXLE PINCH BOLT
(2) AXLE
Front Wheel
Removal
Remove the brake caliper mounting bolts, disc cover and
collars.
Loosen the axle pinch bolt.
Support the motorcycle and front wheel off the ground.
Remove the axle, left side collar and front wheel.
Do not depress the brake lever after the front wheel is
removed.
The caliper pistons will move and make reassembly
difficult.
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) BRAKE DISC
(2) COLLAR
(3) DISC BOLT
(4) LEFT WHEEL BEARING
(5) DISTANCE COLLAR
(6) RIGHT WHEEL BEARING
(a) 25 ± 1 mm (3E)
5. Frame Servicing
Spokes: Check spoke tension frequently between the first
few rides. As the spokes, spoke nuts, and rim contact
points seat-in, the spokes may need to be retightened.
Once past this initial seating-in period, the spokes should
hold their tension. Still, be sure your race maintenance
program includes checking spoke tension and overall
wheel condition on a regular basis.
Drive the bearing
into the hub until it
stops.
After dissassembly, replace the bolts with new ones.
Torque: 18 N•m (1.8 kgf•m)
2
1
6
5
4 3
2 1
a
5-2
5-2
Frame Servicing
(1) AXLE (1) BRAKE CALIPER
(2) DISC COVER
(3) BOLTS
(1) AXLE PINCH BOLT
Installation
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)
Install the brake caliper, flange collars and disc cover.
Apply a locking agent to the threads and tighten the mou-
nting bolts to the specified torque.
Torque: 26 N•m (2.7 kgf•m, 20 lbf•ft)
With the front brake applied, pump the fork up and down
several times to seat the axle and check the front brake
operation.
While keeping the fork parallel, tighten the axle pinch bolt
to the specified torque.
Torque: 21 N•m (2.1 kgf•m, 17 lbf•ft)
3
3
2
1
1
2
5-3
5-3
Frame Servicing
(1) FRONT FENDER
(2) HEADLIGHT/NUMBER PLATE
(3) TOP BRIDGE
(4) BOTTOM BRIDGE
(5) FORK LEG
Fork
Removal
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
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.
(1) FORK BOLT (1) DAMPER ADJUSTER CASE
(2) FORK BOLT
Right Fork Disassembly
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.
Hold the fork tube, remove the fork bolt and slide the fork
tube down.
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.
1
5
4
3
2
1
2
1
5-4
5-4
Frame Servicing
(1) DUST SEAL
(2) STOP RING
Remove the fork damper assembly and centering plate
from the fork tube.
(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.
Hold the fork damper using the special tool, then loosen
the right fork center bolt.
Tools:
Holder handle 07TMB-001010A
Damping Rod Holder Att, 4 pin 07AMB-NN4A200
(1) FORK DAMPER HOLDER
(2) RIGHT FORK CENTER BOLT
ED / 3E
ED / 3E
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.
21
3 2
2
1 1
5-5
5-5
Frame Servicing
(1) DAMPER ASSEMBLY
(2) DAMPER ROD
(3) FORK TUBE
(4) CENTERING PLATE
Fork Damper
Check the fork damper assembly for damage or
deformation.
Check the damper rod for bend or other damage.
Fork tube/centering plate
Check the fork tube for bent or deformation.
Check the centering plate for damage.
(1) BUSHING
(2) BACK-UP RING
(3) INSPECTION POINT
Right Fork Inspection
Check the following items (specifications; page 2-4):
– Fork tube for score marks, scratches and excessive
wear
– Fork tube runout
– Fork slider for damage or deformation
– Fork damper 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.
(1) FORK TUBE BUSHING
(2) GUIDE BUSHING
(3) BACK-UP RING
(4) OIL SEAL
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.
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.
4 3 2 1 1
33 2
4
3
3
2
1
5-6
5-6
Frame Servicing
Install the centering plate and fork damper assembly into
the fork tube.
(1) FORK DAMPER ASSEMBLY
(2) CENTERING PLATE
(3) FORK TUBE
(1) FORK SEAL DRIVER(1) FORK TUBE BUSHING
(2) GUIDE BUSHING
(3) BACK-UP RING
(4) OIL SEAL
Right Fork Assembly
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 with recommended
fork fluid.
Install the fork tube assembly into the fork slider.
(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.
3 2 1
4 3 2 1
1
5
4
3
2
1
5-7
5-7
Frame Servicing
(1) FORK DAMPER ROD
(2) OIL LEVEL
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.
Wait 2 – 3 minutes before measuring the oil level.
Measure the oil level from top of the fork tube.
Standard oil level 50 mm (1.9 in)
Oil capacity
400 cm
3
(13.5 US oz)
(14.1 Imp oz)
Pour recommended fork fluid in the fork leg.
Specified fork fluid:
KYB 01M (5W)
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.
(1) FORK FLUID
(2) FORK TUBE
Hold the axle holder in a vise protected with a piece of
woods or soft jaws to avoid damage.
Do not overtighten the vise.
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:
Holder handle 07TMB-001010A
Holder attachment, 4 pin 07AMB-NN4A100
Torque:
3E: 23.5-25.5 N•m (2.39-2.59 kgf•m)
(1) FORK DAMPER HOLDER
(2) RIGHT FORK CENTER BOLT
1
2
1
2
1
1
2
3E
3E
4E
4E
5-8
5-8
Frame Servicing
(1) FORK BOLT
(2) DISTANCE COLLAR
(3) SPRING SEAT
(4) FORK SPRING
(5) TAPERED BUSHING
Left Fork Disassembly
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.
Remove the distance collar, spring seat and fork spring.
Pour out the fork fluid.
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.
Torque: 14.7 N•m (1.49 kgf•m)
Apply recommended fork fluid to the O-ring, then screw
the fork bolt into the fork tube.
(1) DAMPER ADJUSTER CASE
(2) NEW O-RING
(3) FORK BOLT
If the damper adjuster case was removed from the damper
rod, reinstall the damper adjuster case as follows:
1. Install the damper adjuster case/rod assembly into the
damper rod pipe until the damper adjuster bottoms
lightly.
2. Hold the damper adjuster case and tighten the lock nut
to the specified torque. Do not turn the damper adjus-
ter case.
Torque: 20 N•m (2.0 kgf•m, 14 lbf•ft)
(1) DAMPER ADJUSTER CASE
(2) LOCK NUT
3
2
1
3
1
2
5
1
2
2
3
1
4
5-9
5-9
Frame Servicing
(1) SEAT PIPE
(2) PISTON RING
(3) REBOUND SPRING
(4) OIL LOCK PIECE
Left Fork Inspection
Check the following items (specifications; page 2-4):
– 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
Remove the oil lock piece from the fork piston.
NOTICE
Be careful not to damage the oil lock piece.
Remove the seat pipe assembly from the fork tube.
Remove the following items using the same procedure as
the right fork disassembly (page 5-5):
– Oil seal
– Back-up ring
– Guide bushing
– Slider bushing
(1) FORK TUBE
(2) SEAT PIPE ASSEMBLY
(3) 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.
Hold the seat pipe using the special tool and loosen the
center bolt as shown.
Tools:
Fork damper holder 07930–KA50100
Remove the center bolt and sealing washer.
Remove the following items using the same procedure as
the right fork disassembly (page 5-4):
– Dust seal
– Stop ring
– Fork tube from the fork slider
(1) FORK DAMPER HOLDER
(2) CENTER BOLT
2
1
3
2
1
4
3
2
1
5-10
5-10
Frame Servicing
(1) GUIDE BUSHING
(2) BACK-UP RING
(3) OIL SEAL
(4) STOP RING
(5) DUST SEAL
Install the following using the same procedure as the right
fork (page 5-6):
– Slider bushing/guide bushing/new oil seal/back-up ring
onto the fork tube
– Fork tube into the fork slider
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.
Hold the axle holder in a vise protected with a piece of
wood or soft jaws to avoid damage.
Do not overtighten the vise.
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.
Tool:
Fork damper holder 07930–KA50100
Torque: 23.5-25.5 N•m (2.39-2.59 kgf•m)
(1) FORK DAMPER HOLDER
(2) CENTER BOLT
Left Fork Assembly
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.
(1) FORK TUBE
(2) SEAT PIPE ASSEMBLY
(3) OIL LOCK PIECE
2
1
3
2
1
5
4
3
2
1
5-11
5-11
Frame Servicing
Installation
Install the fork leg.
Raise the fork through the bottom bridge and top bridge.
Place the fork tubes in the top clamp level as shown in
the picture.
(1) FORK TUBE
(2) TOP BRIDGE
(1) FORK SPRING
(2) SPRING SEAT
(3) DISTANCE COLLAR
(4) O-RING
(5) FORK BOLT
Install the fork spring, spring seat and distance collar.
Apply recommended fork fluid to the new O-ring, then
screw the fork bolt into the fork tube.
Pour half the required amount of recommended fork fluid
in the fork leg.
Specified fork fluid: KYB 01M (5W)
Pump the fork tube slowly 8-10 times.
Pour additional fluid to the specified capacity.
Oil level
100 mm (3.9 in)
Oil capacity
410 cc
(13.9 US oz)
(14.4 Imp oz)
FORWARD
2
1
2
3
4
5
6
1
5-12
5-12
Frame Servicing
(1) DUST SEAL
(2) UPPER BEARING
(3) STEM
Remove the stem bearing adjusting nut.
Remove the following;
– Dust seal
– Upper bearing
– Steering stem/lower bearing
(1) ADJUSTING NUT
Steering Stem
Disassembly
Remove the following:
– Handlebar
– Front wheel (page 5-1)
– Front fender
Remove the steering stem nut and washer.
Remove the fork legs (page 5-3).
Remove the top bridge.
(1) STEM NUT
(2) TOP BRIDGE
Tighten the bottom bridge pinch bolts to the specified
torque.
Torque: 21 N•m (2.1 kgf•m, 14 lbf•ft)
Overtightening the pinch bolts can deform the outer tube.
Deformed outer tube must be replaced.
Tighten the fork bolt.
Tighten the top bridge pinch bolt to the specified torque.
Torque: 21 N•m (2.1 kgf•m, 14 lbf•ft)
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)
(1) BOTTOM BRIDGE PINCH BOLTS
(2) FORK BOLT
(3) TOP BRIDGE PINCH BOLTS
3
2
1
1
2
1
3
2
1
1
5-13
5-13
Frame Servicing
(1) STEM
(2) UPPER BEARING
(3) DUST SEAL
Install new bearing races.
Tools:
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Pack the upper and lower bearings with grease.
Install the steering stem, upper bearing and dust seal.
(1) DRIVER
(2) ATTACHMENT
(1) STEM
(2) DUST SEAL
(3) BEARING
(4) STEERING STEM DRIVER
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 07946-MB00000
Steering stem driver attach 07946-KA6000A
(1) BALL RACE REMOVER
Remove the lower bearing and dust seal from the steering
stem.
Remove the upper and lower bearing races from the
steering head using the special tools.
Tool:
Ball race remover 07953-MJ1000B
Drift
(1) STEM
(2) LOWER BEARING
(3) DUST SEAL
3
3
2
2
2
1
1
1
1
4
1
2
3
5-14
5-14
Frame Servicing
Apply grease to the stem bolt threads and seating
surfaces.
Install the top bridge, washer and stem nut.
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: 21 N•m (2.1 kg-m, 15.4 lbf•ft)
Tighten the stem nut to the specified torque.
Torque: 99 N•m (10 kg-m, 65 lbf•ft)
Recheck the steering stem adjustment before installing
the removed parts.
(1) TOP BRIDGE
(2) STEM NUT
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, 3.7 lbf•ft)
Screw the stem bearing adjusting nut all the way with
your fingers.
(1) ADJUSTING NUT
2
1
1
5-15
5-15
Frame Servicing
Spokes: Check spoke tension frequently between the first
few rides. As the spokes, spoke nuts and rim contact
points seat-in, the spokes may need to be retightened.
Once past this initial seating-in period, the spokes should
hold their tension. Still, be sure your race maintenance
program includes checking spoke tension and overall
wheel condition on a regular basis.
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
Do not depress the brake pedal after the rear wheel is
removed.
The caliper pistons will move and make reassembly
difficult.
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) ADJUSTER
(2) AXLE
(1) DRIVEN SPROCKET
(2) DRIVEN SPROCKET BOLT/NUT
(3) LEFT WHEEL BEARING
(4) DISTANCE COLLAR
(5) RIGHT WHEEL BEARING
(6) DISC BOLT
(7) BRAKE DISC
(8) REAR WHEEL NIPPLE
(a) 30 ± 0.5 mm
Drive the bearing
into the hub until
it stops.
7
6
5
4
3
8
8
a
After disassembly, replace the
bolts with new ones. Apply a
locking agent to the threads.
Torque: 17 N•m (1.7 kgf•m)
3 N.m (0.2 - 0.3 kgf.m)
1
2
27 N•m (2.7 kgf•m) (3E)
32 N•m (3.2 kgf•m) (4E)
2
1
5-16
5-16
Frame Servicing
(1) UPPER MOUNTING BOLT/NUT
(2) SHOCK ABSORBER
Shock Absorber
Removal
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.
(1) LOWER MOUNTING BOLT/NUT
Installation
Install the rear brake caliper aligning with the caliper slide
rail.
Apply thin layer of grease to the axle.
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.
(1) AXLE
(2) ADJUSTERS
(3) AXLE NUT
Apply grease to the axle nut threads and seating surface.
Install the right chain adjuster and axle nut.
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.
Check and adjust the drive chain slack (page 3-11).
Tighten the axle nut.
Torque: 69 N•m (7.0 kgf•m, 51 lbf•ft)
3
1
2
2
1
5-17
5-17
Frame Servicing
(1) SPANNER WRENCH
(1) STOPPER RING
Removal (3E)
Secure the damper in a bench vise
Loosen the lock nut and the spring adjuster using the
spanner wrench (07702-0020001).
Move the spring up next to the fastener plate.
Remove the stopper ring and remove the spring plate and
the spring from the damper body.
(1) DAMPER UNIT
(2) SPRING
(3) DAMPER
(4) SPRING PLATE STOPPER RING
(5) SPRING FASTENER PLATE
(6) LOWER DISTANCER
(7) UPPER DISTANCER
(8) BALL JOINT
(9) SEAL
9
9
9
9
8
8
7
7
6
6
5
4
3
2
1
1
1
5-18
5-18
Frame Servicing
(1) PRE-LOAD LENGTH
(2) ADJUSTER
(3) LOCK NUT
Adjust the spring pre-load length (page 2-4).
Hold the spring adjuster and tighten the lock nut to the
specified torque.
Torque:
Tightening angle 50°±10 after contact between nuts
Spherical Bearing Replacement
Remove the collars and dust seals.
Check the spherical bearing for smooth rotation or
damage.
Press the spherical bearing out using the special tool.
Tool:
REMOVAL
Driver attachment 07946-GC4000A
Driver 07749-0010000
Pilot, 22 mm 07746-0041000
INSTALLATION
Driver attachment 07946-GC4000A
Driver 07749-0010000
Attachment, 22 x 24 mm 07746-001A800
Press a new spherical bearing into the shock absorber
pivot until its seats using same tool.
Apply grease to the dust seal lips.
Install the dust seals and collars.
(1) DUST SEALS
(2) SPHERICAL BEARING
(1) DISTANCE COLLAR
Remove the distance collar.
Remove the stopper ring, spring seat and spring.
Inspection
Check the following items (specification; page 2-4):
– 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
Replace the damper unit if an oil leak is detected.
1
1
1
2
1
3
2
2
1
2
1
5-19
5-19
Frame Servicing
(1) LOWER MOUNTING BOLT/NUT
(2) BOLTS/NUTS
(3) CUSHION ARM PLATES
(4) CUSHION LINK
Shock Linkage
Removal
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
Move the swingarm aligning the lower mount, then install
the lower mounting bolt from the right side.
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)
(1) LOWER MOUNTING BOLT/NUT
Installation
Set the shock absorber into the frame and install the
upper mounting bolt from the left side.
Install the nut.
(1) UPPER MOUNTING BOLT/NUT
1
1
4
3
3
2
1
2
2
5-20
5-20
Frame Servicing
(1) SHOCK ABSORBER LOWER MOUNTING BOLT/NUT
(2) SHOCK ARM PLATES-TO-SWINGARM BOLT/NUT
Swingarm
Removal
Remove the following:
– Rear wheel (page 5-15)
– Shock absorber lower mounting bolt/nut
– Cushion arm plates-to-swingarm bolt/nut
(1) CUSHION LINK
(2) CUSHION ARM PLATES
(3) BOLTS/NUTS
(4) LOWER MOUNTING BOLT/NUT
Installation
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
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.
Torque: 39 N•m (4.0 kgf•m, 29 lbf•ft)
(1) PIVOT COLLAR A
(2) PIVOT COLLAR B
(3) DUST SEALS
(4) NEEDLE BEARINGS
Needle Bearing Replacement
Remove the pivot collars and dust seals.
Check the cushion link needle bearings for damage.
Remove the cushion link needle bearings using the special
tool.
Tool:
Bearing driver 07946-MJ0A100
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 07946-MJ0A100
Apply multi-purpose grease to the collars and dust seal
lips.
Install the dust seals and pivot collars.
4
4
3
3
2
1
1
2
2
3
4
2
1
3 mm
(0.12 in)
3
3
5-21
5-21
Frame Servicing
Pivot Bearing Replacement
Replace the swingarm bearings as a set.
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 07749-0010000
Attachment, 24 x 26 mm 07746-0010700
Pilot, 20 mm 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 and the dust seal.
(1) NEEDLE BEARING
(2) DUST SEAL
(3) BUSHING
(1) DUST SEAL CAP
(2) DUST SEAL
(3) PIVOT COLLAR
(4) DUST SEAL
Disassembly
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 them if they have score marks, scratches,
excessive or abnormal wear.
Check the shock mounts and swingarm for stress, cracks
or other damage.
Remove the following:
– Brake hose clamps screws
– Rear brake caliper
– Swingarm pivot bolt/nut and swingarm assembly
(1) BRAKE HOSE CLAMPS
(2) SWINGARM PIVOT BOLT/NUT
5.5 mm (0.22 in)
3
2
1
1
1
4
3
2
1
2
5-22
5-22
Frame Servicing
(1) CHAIN TENSIONER
(2) BUSHINGS
(3) O-RINGS
(4) PIVOT BOLT
Apply grease to the pivot chain tensioner, bushings and
O-rings.
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.
(1) DUST SEAL
(2) PIVOT COLLAR
(3) DUST SEAL
(4) DUST SEAL CAP
(5) NEEDLE BEARING
Assembly
Apply grease to the bearings, 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.
(1) DUST SEAL
(2) PIVOT COLLAR
(3) DUST SEAL
(4) DUST SEAL CAP
(1) PIVOT COLLAR A
(2) PIVOT COLLAR B
(3) DUST SEALS
(4) NEEDLE BEARING
Link Bearing Replacement
Remove the pivot collars and dust seals.
Remove the pivot bearings using the special tool.
Tool:
Bearing driver 07946-MJ0A100
Press a new pivot bearing in using the special tools .
Tool:
Bearing driver 07946-MJ0A100
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.
3.0 mm
(0.12 in)
4
3
3
2
1
5
4
3
2
1
1
2
3
4
4
3
3
2
2
1
5-23
5-23
Frame Servicing
(1) SHOCK ARM PLATES-TO-SWINGARM BOLT/NUT
(2) SHOCK ABSORBER LOWER MOUNTING BOLT/NUT
Installation
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) PIVOT BOLT/NUT
(2) HOSE CLAMPS
(1) DRIVE CHAIN GUARD
(2) SCREWS
Install the drive chain sliders onto the swingarm.
Apply a locking agent to the drive chain slider screw
threads and tighten the screw.
Install the drive chain guard and tighten the bolts.
Torque: 0.6-0.7 N•m (0.06-0.07 kgf•m)
(1) DRIVE CHAIN SLIDER
(2) SCREWS
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)
2
1
2
1
2
2
1
2
2
2
2
1
5-24
5-24
Frame Servicing
(1) PAD PIN
(2) PAD SPRING PIN
(3) BOLTS
(4) DISC COVER
(5) CALIPER
Brake Pad Replacement
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.
Front Brake Pad Replacement
Loosen the pad pins.
Remove the spring pin from the pads.
Remove the brake caliper mounting bolts, disc cover,
flange collars and caliper.
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.
(1) NEW PADS
(2) PAD PIN
(3) PAD SPRING PIN
Install the new pads and secure with the pin and the
spring pin for the pads.
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.
Torque: 26 N•m (2.7 kgf•m, 20 lbf•ft)
Operate the brake lever to seat the caliper pistons against
the pads.
3
2
1
5
4
3
3
2
1
5-25
5-25
Frame Servicing
(1) OIL BOLT
(2) MOUNTING BOLTS
(3) DISC COVER
(4) BRAKE CALIPER
Front Brake Caliper
Removal
NOTICE
Avoid spilling brake fl uid 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.
Remove the following:
– Brake hose oil bolt
– Sealing washers
– Brake hose eyelet
– Caliper mounting bolts
– Disc cover
– Flange collars
– Brake caliper
– Spring pin for the pads
– Brake pads (page 5-24)
(1) CALIPER BRACKET
(2) BOSS/SLIT
Install the new pads and secure them with the pad pin.
Install the brake caliper bracket aligning its slit with the
boss on the swingarm.
Install the rear wheel (page 5-16).
Operate the brake pedal to seat the caliper pistons against
the pads.
(1) BRAKE PADS
(2) PAD PIN
(1) CALIPER PISTON
Rear Brake Pad Replacement
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 opera-
tion causes the level to rise.
Remove the pad pin and brake pads.
Clean the brake caliper inside especially around the caliper
pistons.
2
1
1
2
1
4
3
2
2
1
5-26
5-26
Frame Servicing
Inspection
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
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).
Tighten the oil bolt to the specified torque.
Torque: 28 N•m (2.9 kgf•m)
(1) CALIPER PISTON
Rear Brake Caliper
Removal
NOTICE
Avoid spilling brake fl uid 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.
Remove the following:
– Brake hose oil bolt
– Sealing washers
– Brake hose eyelet
– Rear wheel (page 5-15)
– Brake caliper/bracket
– Spring pin for the pads
– Brake pads (page 5-24)
(1) OIL BOLT
(2) BRAKE HOSE
(3) BRAKE CALIPER
Inspection
Clean the inside of the caliper.
Check the oil leakage from the caliper cylinders.
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.
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.
Torque: 27 N•m (2.8 kgf•m, 20 lbf•ft)
1
3
2
1
5-27
5-27
Frame Servicing
(1) OIL BOLT
(2) BRAKE HOSE
(3) BOLTS
(4) HOLDER
(5) MASTER CYLINDER
Front Master Cylinder
Removal/Installation
NOTICE
Avoid spilling brake fl uid 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 fl uid from leaking out.
Drain the brake fluid from the hydraulic system into a
suitable container.
Remove the following:
– Brake lever
– Brake hose bolt
– Master cylinder holder bolt and holder
– Master cylinder
Inspection
Check the following items:
– Master cylinder and piston for scoring, scratches or
other damage
Installation
Installation is in the reverse order of removal.
Torque:
Brake hose oil bolt: 12 N•m (1.2 kgf•m, 8.8 lbf•ft)
Master cylinder holder bolt: 3.2 N•m (0.33 kgf•m, 2.4 lbf•ft)
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 fi rmly sea-
ting in the groove.
Remove the snap ring and disassemble the master
cylinder.
Tool:
Snap ring pliers 07914-SA50001
(1) BOOT
(2) SNAP RING
(3) PISTON ASSEMBLY
(4) SPRING
5
4
3 3
2
1
4 3 2 1
5-28
5-28
Frame Servicing
(1) OIL BOLT
(2) BRAKE HOSE
(3) MASTER CYLINDER
(1) BOLTS
(2) MASTER CYLINDER
(1) NUT
(2) BOLT
(3) BRAKE PEDAL
Rear Master Cylinder
Removal/Installation
NOTICE
Avoid spilling brake fl uid 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 fl uid from leaking out.
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.
Remove the mounting bolts and master cylinder.
Installation
Installation is in the reverse order of removal.
Connect the brake hose eyelet joint with two new sealing
washers, then tighten the oil bolt.
Torque:
Brake hose oil bolt: 27 N•m (2.8 kgf•m, 20 lbf•ft)
Bleed the air from the rear brake system.
Brake Pedal
Removal
Remove the brake pedal pivot nut and bolt.
Remove the brake pedal and collar.
3
2
1
2
1
1
3
2
1
5-29
5-29
Frame Servicing
(1) OIL BOLT
(2) CLUTCH HOSE
(3) BOLT
(4) HOLDER
(5) MASTER CYLINDER
Clutch Master Cylinder
Removal/Installation
NOTICE
Avoid spilling brake fl uid 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 fl uid from leaking out.
Drain the clutch fluid from the hydraulic system into a
suitable container.
Remove the following:
– Clutch lever
– Clutch hose bolt
– Master cylinder holder bolts and holder
– Master cylinder
Installation
Install the brake pedal and collars.
Install and tighten the pivot nut and bolt.
Torque: 29 N•m (3.0 kgf•m, 22 lbf•ft)
(1) COLLAR B
(2) PEDAL
(3) COLLAR A
(1) STANDARD LENGTH; 35.0 MM
Pivot Bearing Replacement
Remove the dust seals.
Remove the pivot bearing and press a new needle bearing
so that it is 3.0 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.
(1) BEARING
(2) DUST SEALS
3.0 mm (0.12 in)
2
2
1
1
3
2
1
5
4
3
2
1
5-30
5-30
Frame Servicing
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 fi rmly sea-
ting in the groove.
Remove the snap ring and disassemble the master
cylinder.
Tool:
Snap ring pliers 07914-SA50001
Inspection
Check the following items:
– Master cylinder and piston for scoring, scratches or
other damage
Installation
Installation is in the reverse order of removal.
Torque:
Clutch hose oil bolt: 12 N•m (1.2 kgf•m, 8.8 lbf•ft)
Master cylinder holder bolt: 3.2 N•m (0.33 kgf•m, 2.4 lbf•ft)
(1) BOOT
(2) SNAP RING
(3) PISTON ASSEMBLY
(4) SPRING
432
1
6-1
6-1
(1) 6P (BLACK) CONNECTOR (1) 3P (NATURAL) CONNECTOR (1) 4P (NATURAL) CONNECTOR
Charging System 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 (20°C/68°F)
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.
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.
Regulated Voltage Inspection
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 rpm
6. Electrical Servicing
1
1
1
6-2
6-2
Electrical Servicing
(1) 3P (NATURAL) CONNECTOR
(2) 2P (NATURAL) CONNECTOR
(1) 2P (BLACK) CONNECTOR
(2) 6P (BLACK) CONNECTOR
(1) BOLTS
(2) ELECTRIC STAY ASSEMBLY
Regulator/Rectifier Removal/Installation
Remove the throttle body (page 4-13).
Disconnect the alternator 3P (Natural) connector and
ignition pulse generator 2P (Natural) connector.
(1) BOLT
(2) BRAKE RESERVOIR
Disconnect the condenser 2P (Black) and regulator/
rectifier 6P (Black) connectors.
Remove the rear brake reservoir tank mounting bolt.
(1) 2P (BLACK) CONNECTOR
(2) CONDENSER
Remove the electric stay mounting bolts, then remove the
stay assembly from the frame.
Release the condenser 2P (Black) connector, then remove
the condenser from the electric stay.
2
1
2
1
2
1
2
1
2
1
6-3
6-3
Electrical Servicing
Removal/Installation
Remove the fuel tank/injector assembly.
Remove the spark plug cap.
Remove the tie-wrap and release the spark plug wire from
the fan motor bracket.
(1) SPARK PLUG CAP
(2) TIE-WRAP
Ignition System Inspection
Ignition Coil Inspection
Measure the ignition primary coil resistance between the
primary terminals.
Standard: 2.6 - 3.2 (20°C/68°F)
Measure the secondary coil resistance.
Standard:
With plug cap: 17.3 - 22.8 k (20°C/68°F)
Without plug cap: 13.5 - 16.5 k (20°C/68°F)
Replace the ignition coil if the resistance is out of
specification.
(1) PRIMARY TERMINALS
Remove the bolts and regulator/rectifier from the electric
stay.
Install the regulator/rectifier and condenser in the reverse
order of removal.
(1) BOLTS
(2) REGULATOR/RECTIFIER
2
1
1
1
2
1
6-4
6-4
Electrical Servicing
L LL
1
2
1
If the resistance is out of specification, measure the
resistance at the ignition pulse generator 2P (Natural)
connector.
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 4-52).
(1) 2P (NATURAL) CONNECTOR
Ignition Pulse Generator Inspection
Check the ignition coil resistance at the ECM 32P (Black)
connector (page 6-5).
Connection: White/yellow – Green/yellow
Standard: 85 - 115 (20°C/68°F)
(1) 32P (BLACK) CONNECTOR(1) WIRE CLAMP
(2) PRIMARY WIRES
(3) BOLTS
(4) IGNITION COIL
Remove the wire clamp.
Disconnect the primary wire from the ignition coil.
Remove the mounting bolts and ignition coil.
Installation is in the reverse order of removal.
Route the spark plug wire properly and secure it with tie
wrap.
1
4
3
3
2
2
1
1
6-5
6-5
Electrical Servicing
PGM-FI System Inspection
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.
Item Terminal Standard
Ignition pulse generator G/Y – W/Y 85 – 115 Ω (20˚C/68˚F)
Ignition coil (primary coil) Y/L – R 2.6 – 3.2 Ω (20˚C/68˚F)
INJ (Injector) P – R 11.1 – 12.3 Ω (20˚C/68˚F)
Engine stop switch B/W – Ground Continuity exist only when switch is pushed
ECT (Engine Coolant Temperature) sensor P/W – G/O 2.3 – 2.6 kΩ (20˚C/68˚F)
Sensor ground G1 – Ground Continuity
Power ground G1 – Ground Continuity
(1) 32P (BLACK) CONNECTOR
Condenser 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.
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.
(1) CONDENSER
1
1
6-6
6-6
Electrical Servicing
Self-diagnosis Reset Procedure
After the faulty circuit has been repaired, connect the
PGM-FI warning unit assembly as noted in the previous
step.
Before turning on the power switch, turn the WARN/
RESET switch to the WARN side.
Turn the power switch ON, then turn the WARN/RESET
switch to RESET.
The MIL lights for about 5 seconds.
While the MIL lights, turn the WARN/RESET switch to the
WARN side.
Self-diagnosis memory data is erased if the MIL turns off
and starts blinking.
The WARN/RESET switch must be switched to WARN
side while the indicator lights. If not, the MIL will not
sart 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.
Turn the power switch OFF and disconnect the warning
unit assembly from the motorcycle.
(1) POWER SWITCH
(2) MIL
(3) WARNING/RESET SWITCH
(1) POWER SWITCH
(2) MIL
(3) WARN/RESET SWITCH
Turn the PGM-FI warning unit WARN/RESET switch to the
WARN side as shown.
Turn the power switch ON, check 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).
(1) PGM WARNING UNIT ASSEMBLY
(2) RED WIRE EYELET
(3) GREEN WIRE EYELET
(4) 2P (BLACK) CONNECTOR
(5) 4P (RED) CONNECTOR
PGM-FI
Self-diagnostic procedure
!
CAUTION
To avoid injury, keep hands and fingers away from the
cooling fan.
If the ECT sensor is faulty, the cooling fan will turn on
when you connect a 12 V battery to the warning unit
terminals.
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 07AMZ-NN4A100
Connect the waring unit 4P (Red) connector to the service
check 4P (Red) connector.
Connect a fully charged 12 V battery to the warning unit
terminals (red wire eyelet to the battery positive terminal
and green wire eyelet to the negative terminal).
5
4
3
2
1
3 3
2 2
1 1
6-7
6-7
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 Causes Symptoms
0 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.
6-8
6-8
Electrical Servicing
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.
(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.
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) SCREWS
(2) BANK ANGLE SENSOR
1 1
2
2
1
6-9
6-9
Electrical Servicing
Fan Motor Relay Inspection
Remove the fan motor relay.
Connect an ohmmeter to the fan motor relay connector
terminals.
Connection: Red – Blue
Connect a 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.
(1) FAN MOTOR RELAY
Cooling Fan System Inspection
Fan Motor Inspection
Remove the fuel tank.
Disconnect the fan motor 2P (Natural) connector.
Directly connect a 12 V battery to the fan motor 2P
(Natural) connector terminals of the fan motor side.
The fan motor is correct if the fan operates when the 12
V battery is connected.
If the fan motor does not operate, replace the fan motor
assembly.
(1) 2P (NATURAL) CONNECTOR
Engine Stop Switch 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.
Replace the switch if it is out of specification.
(1) CONNECTORS
1
1
1
6-10
6-10
Electrical Servicing
Wiring Diagram
BI BLACK
Y YELLOW
Bu BLUE
G GREEN
IR RED
W WHITE
Br BROWN
O ORANGE
Lb LIGHT BLUE
Lg LIGHT GREEN
P PINK
Gr GRAY
SERVICE CHECK
CONNECTOR
POWER
WATER
TEMP
SENSOR
IGNITION COIL
FAN RELAY
PULSER
ALTERNATOR
REGULATOR/RECTIFIER
CONDENSER
(10000uF)
BANK ANGLE
SENSOR
FAN
MOTOR
FUEL
PUMP
ENGINE
STOP
SWITCH
FUEL INJECTOR
