Shop Manual 2016

PGM-FI Racing Trial

MONTESA 4RIDE
Shop Manual
The following diagram shows the version of the 4RIDE MST260 2016 model:

(ED) Street version, 4RIDE MST260

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.
 1 1

(1) FRAME NUMBER (1) ENGINE NUMBER

Serial numbers The serial number of the engine is stamped on the lower
right side of the crankcase. MODEL TYPE FRAME No. ENGINE No.
The Vehicle Identification Number (VIN) is stamped on the
right side of the steering head. MST260G ED *VTDMT04K?GE000001* NN4E6000001
Labels
The following pages show the meanings and locations of the labels on your 4RIDE.
There is a specific symbol on each label. The meanings of each symbol and label are as follows.

1 Tire information
DUNLOP D803FGP
MICHELIN TRIAL COMPETITION Cold tire pressure (driver only)
80/100-21 M/C 51M, 2.75-21 M/C 45L
 Front: 100kpa
DUNLOP D803GP
MICHELIN TRIAL COMPETITION X11
 Rear: 100kpa
120/100R18 M/C 68M, 4.00 R18 M/C 64L
NN4-L10

2 Keep chain adjusted and lubricated

25 - 35 Mm (1.0 - 1.4 In)
 Read owners manual

3 Caution label
 Read the shop manual carefully
 For your protection always wear a helmet and protective gear while riding.
 Usepremium unleaded gasoline only.
 This motorcycle is not designed to transport a passenger.

4 Radiator cap label

DANGER
WARNUNG
Danger
 Never open when hot.
NEVER OPEN WHEN HOT.
Hot coolant will scald you.  Hot coolant will scald you.
N’ OUVREZ PAS QUAND CHAUD.
NICHT BEI HEISSEM MOTOR ÖFFNEN.
 Relief pressure valve begins to open at 1.1 Kgf/cm2.
5 LOADING AND ACCESSORIES WARNING LABEL
WARNING WARNING
LOADING AND ACCESSORIES
 The stability and handling of this motorcycle can be affected by the addition of accessories and luggage.
MAX. 2,5 kg
(LOAD) (5,5 Lbs)
 The total weight of the accessories and luggage, added to the rider’s own weight, must not exceed 111 kg, which is the aximum
MAX
weight capacity.
NO PASSENGER ALLOWED
ENTRY OF WATER IS POSSIBLE  The addition of large fairings mounted on the fork or handlebars is not recommended.
NN4-L80
 It is totally prohibited to transport cargo on the rear fender. The motorcycle has not been designed for this purpose.
6 EC label

7 REAR DAMPER LABEL

GAS REFUELING
 Do not open.
made in C.E.
 Do not heat.
Nº XXXXXX
WARNING! don’t touch
Gas at high pressure.
Labels

5 3

1 2
Contents Throttle Body ................................................ 3-13 5. Electrical servicing
Water Seal And Bearing Replacement ............... 3-15
Radiator Removal/Installation .......................... 3-17 Charging system inspection ............................ 5-1
1. Service data
Engine Removal/Installation............................. 3-18 Ignition system inspection .............................. 5-3
Specifications ............................................... 1-1 Cylinder Compression .................................... 3-20 PGM-FI System inspection .............................. 5-5
Service data.................................................. 1-2 Cylinder Head Removal .................................. 3-23 PGM-FI......................................................... 5-6
Torque Values ............................................... 1-5 Cylinder Head Disassembly ............................. 3-25 PGM-FI Self-diagnosis malfunction
Tools ........................................................... 1-7 Cylinder Head Inspection ................................ 3-26 indicator lamp (mil) failure codes ..................... 5-7
Special ......................................................... 1-7 Valve Guide Replacement ............................... 3-27 Bank angle sensor inspection .......................... 5-8
Lubrication & Seal Points ................................ 1-8 Valve Seat Inspection/Refacing ....................... 3-28 Engine stop switch inspection ......................... 5-9
Cable & Harness Routing ................................ 1-11 Cylinder Head Assembly ................................. 3-31 Cooling fan system inspection ......................... 5-9
Cylinder/Piston .............................................. 3-32 Lights / instruments / switches ........................ 5-10
2. Service and maintenance Indicator light/Indicator light relay. ................... 5-11
Cylinder Head Installation ............................... 3-37
Maintenance schedule .................................... 2-1 Camshaft/Cylinder Head Cover Installation ........ 3-38 Brake light. ................................................... 5-12
Fuel Line ...................................................... 2-3 Right Crankcase Cover ................................... 3-40 Brake light switch. ......................................... 5-12
Air Cleaner ................................................... 2-3 Clutch Slave Cylinder ..................................... 3-41 Speedometer ................................................ 5-13
Spark Plug .................................................... 2-4 Clutch .......................................................... 3-43 Speed sensor ................................................ 5-14
Valve Clearance ............................................ 2-4 Kickstarter .................................................... 3-46 Horn ............................................................ 5-15
Engine Oil/Oil Filter ........................................ 2-6 Gearshift Linkage........................................... 3-47 Wiring diagram .............................................. 5-16
Engine Idle Speed .......................................... 2-8 Left Crankcase Cover ..................................... 3-49
Transmission Oil ............................................ 2-8 Flywheel ...................................................... 3-52
Coolant ........................................................ 2-9 Crankcase Separation/Disassembly .................. 3-54
Clutch System .............................................. 2-10 Crankshaft/Transmission Inspection ................. 3-56
Exhaust Pipe And Muffler ............................... 2-10 Crankcase Bearing Replacement ...................... 3-56
Drive Chain ................................................... 2-11 Transmission Assembly .................................. 3-58
Drive Chain Slider .......................................... 2-11 Crankcase Combination .................................. 3-59
Drive/Driven Sprockets ................................... 2-12
Brake Fluid ................................................... 2-13 4. Frame servicing
Brake Pad Wear ............................................. 2-14 Front Wheel .................................................. 4-1
Brake System................................................ 2-14 Fork ............................................................. 4-2
Handlebar And Steering Head Bearings ............. 2-15 Steering stem ............................................... 4-11
Wheels And Tires .......................................... 2-15 Rear Wheel ................................................... 4-14
Front Suspension ........................................... 2-16 Shock Absorber............................................. 4-16
Fork ............................................................. 2-16 Shock Linkage............................................... 4-19
Rear Suspension ............................................ 2-17 Swingarm ..................................................... 4-20
Front headlight and front position light. ............ 2-18 Front Brake Pad Replacement .......................... 4-24
Rear Brake Pad Replacement ........................... 4-25
3. Engine servicing
Front brake caliper ......................................... 4-27
Oil Pressure Relief Valve ................................. 3-1 Rear brake caliper .......................................... 4-27
Oil Pump ...................................................... 3-1 Front master cylinder ..................................... 4-28
Disassembly / Installation of fuel feed hose ..... 3-4 Rear master cylinder ...................................... 4-30
Fuel Line Inspection ....................................... 3-5 Brake pedal ................................................... 4-30
Fuel Tank/Fuel Pump ...................................... 3-7 Clutch master cylinder ................................... 4-31
Injector ........................................................ 3-13
 1. Service data
Specifications

Item Specification Item Specification

Dimensions Fuel System
Overall length 2,035 mm Type PGM-FI
Overall width 835 mm Identification number GQPEA
Overall height 1,160 mm Throttle bore 28 mm
Wheelbase 1,335 mm Drive Train
Seat height 885 mm Clutch operating system Hydraulic operated
Ground clearance 330 mm Clutch type Wet, multi-plate
Frame Transmission 5 speed constant mesh
Type Aluminium twin tube Primary reduction 3,167 (57/18T)
Front suspension Telescopic Gear ratio 1st 2,385 (31/13T)
Rear suspension Swingarm PRO-LINK 2nd 1,933 (29/15T)
Front tire DUNLOP D803FGP 3rd 1,500 (27/18T)
(80/100-21 M/C 51M) 4th 1,130 (26/23T)
MICHELIN TRIAL COMPETITION 5th 0,815 (22/27T)
(2,75-21 M/C 45L)
Final reduction 4,100 (41/10T)
Rear tire DUNLOP D803GP
(120/100R18 M/C 68M) Gearshift pattern 1–N–2–3–4–5
MICHELIN TRIAL COMPETITION X11 Electrical
(4.00 R18 M/C 64L) Alternator Triple phase output alternator
Front brake, diameter Single disc, 185 mm Ignition system PGM-IGN
Rear brake, diameter Single disc, 185 mm Regulator type SCR shorted/triple phase, full wave rectification
Fuel capacity 4,4 litres
Caster angle 24º 34’
Engine
Type Liquid cooled 4–stroke engine
Cylinder arrangement Single cylinder, 3.5˚ inclined from vertical
Bore and stroke 78,0 x 54,2 mm
Displacement 259 cm3
Compression ratio 10,5 : 1
Valve timing
Intake valve opens 9˚ BTDC (at 1.0 mm lift)
Intake valve closes 27˚ ABDC
Exhaust valve opens 37˚ BBDC
Exhaust valve closes 5˚ ATDC
Lubrication system Forced pressure and wet sump
Starting system Primary kickstarter

1-1
Service data

Service data
Unit: mm (in)

Item Specification Item Standard Service limit

Lubrication Cylinder Head/Valves

Specified engine oil Repsol 4T oil-stroke motorcycle oil SAE 10W-30 Cylinder compression 1300 kPa (13.2 kgf/cm2, 189 psi) –
Engine oil capacity Cylinder head warpage – 0.05 (0.002)
after draining 0.41 liter (0.43 US qt, 0.36 Imp qt) IN 0.12 ± 0.03 (0.005 ± 0.001) –
after oil filter change 0.44 liter (0.46 US qt, 0.39 Imp qt) Valve stem O.D.
EX 0.30 ± 0.03 (0.012 ± 0.001) –
after disassembly 0.60 liter (0.63 US qt, 0.53 Imp qt)
IX 4.475 – 4.490 (0.1762 – 0.1768) 4.470 (0.1760)
Specified transmission oil ELF HTX740 EX 4.465 – 4.480 (0.1758 – 0.1764) 4.460 (0.1756)
Transmission oil capacity Valve guide I.D. IN/EX 4.500 – 4.512 (0.1772 – 0.1776) 4.552 (0.1792)
after draining 0.54 liter (0.57 US qt, 0.48 Imp qt) IN 0.010 – 0.037 (0.0004 – 0.0015) –
after disassembly 0.57 liter (0.60 US qt, 0.50 Imp qt) Valve stem-to-guide clearance
EX 0.020 – 0.047 (0.0008 – 0.0019) –
Fuel System
Valve guide projection above
Throttle body identification No. GQPEA IN 8.0 – 8.3 (0.31 – 0.33) –
cylinder head
EX 8.2 – 8.5 (0.32 – 0.33) –
Throttle grip free play 3 mm.
Valve spring free length
Engine idle speed 1,800 ± 100 min-1 (rpm)
Inner 25.41 (1.000) 24.9 (0.98)
Fuel pressure 314 - 382 kPa (3,2 - 3,9 kgf/cm2) Outer 28.32 (1.115) 27.6 (1.09)
Fuel pump flow at 12 V 125 cm3 minimum/10 seconds Rocker arm I.D. 10.000 – 10.015 (0.3937 – 0.3943) 10.051 (0.3957)
Injector resistance 11.1 – 12.3 Ω (20˚C/68˚F) Rocker arm shaft O.D. 9.972 – 9.987 (0.3926 – 0.3932) 9.925 (0.3907)
Cooling System Rocker arm-to-shaft clearance 0.013 – 0.043 (0.0005 – 0.0017) 0.11 (0.04)
Recommended coolant 50/50 mixture coolant and distilled water AD 32.011 – 33.051 (1.2603 – 1.3012) 31.871 (1.2548)
Cam lobe height
Radiator cap relief pressure 108 kPa (1,1 kgf/cm2) ES 32.855 – 32.935 (1.2935 – 1.2967) 32.748 (1.2893)
Presión de alivio tapón del radiador 108 kPa (1,1 kgf/cm2)

1-2
 Service data

Unit: mm (in) Unit: mm (in)

Item Standard Service limit Item Standard Service limit

Cylinder/Piston Crankshaft/Transmission
Cylinder I.D 78,000 – 78,015 (3,0709 - 3,0715) 78,04 (3,0724) Crankshaft runout Right – 0,03 (0,001)
Taper – 0,05 (0,002) Left – 0,05 (0,002)
Out-of- round – 0,05 (0,002) Connecting rod big end
Warpage – 0,05 (0,002) Side clearance 0,30 – 0,75 (0,012 – 0,030) 0,8 (0,03)
Piston O.D. 77,970 – 77,980 (3,0696 - 3,07008) 79.25 (3,1201) Radial clearance 0,06 – 0,18 (0,002 – 0,007) 0,05 (0,002)
Measurement point 5 (0,2) from bottom of skirt – Transmission gear I.D. M4 23,020 – 23,041 (0,9063 – 0,9071) 23,07 (0,908)
Pin bore I.D. 16,002 – 16,008 (0,6300 – 0,6302) 16,03 (0,631) M5 23,020 – 23,041 (0,9063 – 0,9071) 23,07 (0,908)
Piston pin O.D. 15,994 – 16,000 (0,6297 – 0,6299) 15,98 (0,629) C1 20,020 – 20,041 (0,7882 – 0,7890) 20,06 (0,790)
Piston ring C2 25,020 – 25,041 (0,9850 – 0,9859) 25,06 (0,987)
End gap C3 25,020 – 25,041 (0,9850 – 0,9859) 25,06 (0,987)
Top 0,15 – 0,25 (0,008 - 0,0098425) 0,39 (0,01535) Gear bushing D.I. M5 20,000 – 20,021 (0,7866 – 0,7882) 20,05 (0,789)
Second 0,30 – 0,45 (0,012 - 0,0018) 0,59 (0,02323) C1 17,000 – 17,018 (0,6693 – 0,6700) 17,04 (0,671)
Oil (side rail) 0,20 – 0,70 (0,008 – 0,028) 0,90 (0,035) C2 22,000 – 22,021 (0,8661 – 0,8670) 22,04 (0,868)
Ring-to-groove clearance C3 22,000 – 22,021 (0,8661 – 0,8670) 22,04 (0,868)
Top 0,050 – 0,090 (0,0020 – 0,0022) 0,150 (0,0059) O.D. M4 22,979 – 23,000 (0,9047 – 0,9055) 22,96 (0,904)
Second 0,015 – 0,050 (0,0006 – 0,0020) 0,065 (0,0026) M5 22,979 – 23,000 (0,9047 – 0,9055) 22,96 (0,904)
Cylinder-to-piston clearance 0,030 – 0,055 (0,0012 – 0,0018) 0,18 (0,007) C1 19,979 – 20,000 (0,7866 – 0,7874) 19,95 (0,785)
Piston-to-piston pin clearance 0,002 – 0,014 (0,0001 – 0,0006) 0,04 (0,002) C2 24,979 – 25,000 (0,9834 – 0,9843) 24,95 (0,982)
Connecting rod small end I.D. 16,016 – 16,034 (0,6305 – 0,6313) 16,04 (0,631) C3 24,979 – 25,000 (0,9834 – 0,9843) 24,95 (0,982)
Clutch/Gearshift Linkage Countershaft O.D.
at C1 bushing 16,983 – 16,994 (0,6686 – 0,6691) 16,97 (0,668)
Recommended clutch fluid DOT 4 brake fluid –
at C2/C3 bushing 21,959 – 21,980 (0,8645 – 0,8654) 21,94 (0,864)
Clutch spring free length 27,6 (1,09) 26,8 (1,06) at kickstarter idle gear 16,983 – 16,994 (0,6686 – 0,6691) 16,97 (0,668)
Clutch disc thickness 3,22 – 3,38 (0,127 – 0,133) 3,15 (0,124) Shift fork I.D. C 11,003 – 11,024 (0,4332 – 0,4330) 11,04 (0,435)
Clutch plate warpage – 0,10 (0,004) R, L 12,035 – 12,056 (0,4738 – 0,4746) 12,07 (0,475)
Clutch slave cylinder I.D. 27,000 – 27,021 (1,0630 – 1,0638) – Shift fork claw thickness C 4,93 – 5,00 (0,194 – 0,197) 4,8 (0,19)
Clutch slave piston O.D. 26,940 – 26,960 (1,0606 – 1,0614) – R, L 4,93 – 5,00 (0,194 – 0,197) 4,8 (0,19)
Kickstarter Shift fork shaft O.D. C 10,983 – 10,994 (0,4324 – 0,4328) 10,97 (0,432)
Spindle O.D. 16,466 – 16,484 (0,6483 – 0,6490) 16,46 (0,648) R, L 11,966 – 11,984 (0,4711 – 0,4718) 11,95 (0,470)
Pinion gear I.D. 16,516 – 16,534 (0,6502 – 0,6509) 16,55 (0,652) Oil pump
Idle gear I.D. 17,016 – 17,034 (0,6699 – 0,6706) 17,06 (0,672) Tip clearance – 0,20 (0,008)
Countershaft O.D. at kickstarter idle gear 16,983 – 16,994 (0,6686 – 0,6691) 16,97 (0,668) Body clearance 0,15 – 0,20 (0,006 – 0,008) –
Side clearance 0,05 – 0,12 (0,002 – 0,004) –

1-3
Service data

Unit: mm (in) Unit: mm (in)

Item Standard Service Limit Item Standard Service Limit

Wheels/Tires Rear Suspension R16V

Axle runout 0.20 (0.008) Shock absorber spring pre-load 126 (4,96) –
Cold tyre pressure: Spring free length 130 (5,1) –
For road use 100 kPa (1,02 kgf/cm2) –
Tension adjuster setting 10±2 clicks from full hard –
Off Road use only Front 70 kPa (0,7 kgf/cm2) –
Rear 60 kPa (0,6 kgf/cm2) – Brakes
Wheel rim runout Radial – 2.0 (0,08) Recommended brake fluid DOT 4 brake fluid –
Axial – 2,0 (0,08) Front Brake disc thickness 3,5 (0,14) 3,0 (0,12)
Drive chain slack 25 – 35 (1,0 – 1,4) – Brake disc runout – 0,15 (0,006)
2.0 (0.08) from Rear Brake disc thickness 3,5 (0,14) 3,0 (0,12)
Drive chain slider thickness – Brake disc runout – 0,15 (0,006)
upper surface
Front Suspension TECH Electrical
Left fork spring free length 445 (17,5) 438 (17,2) Spark plug Standard: NGK: CR6EH-9 –
Fork tube runout 0,35 – 0,50 (0,014 – 0,020) 0,20 (0,008) Spark plug gap 0,80 – 0,90 (0,031 – 0,035) –
Recommended fork fluid TECH OJ 01 Ignition coil resistance
Primary 2,6 -3,2 Ω (20º C) –
Pre-load adjuster setting 4±0,5 turns out from full soft –
Secondary with plug cap 17,3 -22,8 kΩ (20º C) –
Tension adjuster: Secondary without plug cap 13,5 – 16,5 KΩ (20º C) –
Damping adjuster setting
16±2 clicks from full hard – Ignition pulse generator
Fork oil level Resistance 85 -115 Ω (20º C) –
–
Right 60 (2,3) Alternator
–
Left 125 (4,9) Regulated voltage 13,5 – 14,5 V/1,800 min-1 (rpm) –
Fork oil capacity Charging coil resistance 0,7 -1,0 Ω (20º C) –
–
Right 385 cm3 ECT sensor resistance 2,3 -2,6 kΩ (20º C) –
–
Left 375 cm3 Bulbs
Headlight 12V – 35/35W HS1 –
Position light 12V – 5W –
Brake/tail light 6 LED DIODES –
Turn signal light 12V – 10W X 4 –
Speedometer 12V –

1-4
 Service data

Torque Values
Standard Engine
Torque Thread Torque
Item Item Q’ty Remarks
N•m (kgf•m / Ibf•ft) Dia. (mm) N•m (kgf•m / lbf•ft)
5 mm bolt and nut 5 (0,52 / 3,5) Transmission oil drain bolt 1 8 22 (2,2 / 16) Note 1
6 mm bolt and nut 10 (1,0 / 7) 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
8 mm bolt and nut 22 (2,2 / 16)
Timing hole cap 1 14 7 (0,7 / 5,1) Note 3
10 mm bolt and nut 33 (3,4 / 25) Bearing set plate socket bolt 4 6 9,8 (1,0 / 7) Note 4
12 mm bolt and nut 53 (5,4 / 40) Bearing set plate screw 2 6 12 (1,2 / 9) Note 4
5 mm screw 4 (0,42 / 3) 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
6 mm screw and flange bolt (SH type) 9 (0,9 / 7)
Cylinder head mounting nut 2 9 39 (4,0 / 29) Note 1
6 mm flange bolt and nut 12 (1,2 / 9) Cylinder head joint pipe 1 18 18 (1,8 / 13) Note 2
8 mm flange bolt and nut 26 (2,7 / 20) Vacuum port joint 1 5 2,5 (0,25 / 1,8)
10 mm flange bolt and nut 38 (3,9 / 29) Primary drive gear special bolt 1 12 108 (11,0 / 80) Note 1
Flywheel nut 1 18 167 (17,0 / 123) Note 1
Cylinder stud bolt: Exhaust pipe stud bolt: 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)
101,5±1mm 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
17±0,5mm 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)
Insulator band (cylinder head side): Insulator band (throttle body side):
Shift return spring pin 1 8 22 (2,2 / 16)
Ignition pulse generator bolt 2 5 5,4 (0,55 / 4,0) Note 4
7±1mm 7±1mm 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.

1-5
Service data

Frame Frame
Thread Torque Thread Torque
Item Q’ty Remarks Item Q’ty Remarks
Dia. (mm) N•m (kgf•m, Ibf•ft) Dia. (mm) N•m (kgf•m, Ibf•ft)
Handlebar holder bolt 4 8 22 (2,2 / 16) Note 1 Steering head top thread 1 26 5 (0,5 / 3,6) Note 1
Front axle 1 17 69 (7,0 / 51) Note 1 Steering stem nut 1 20 99 (9,9 / 73) Note 1
Rear axle nut 1 17 69 (7,0 / 51) Note 1 Clutch hose (master cylinder) 1 10 14 (1,4 / 10,3)
Final driven sprocket nut 4 8 32,5 (3,3 / 23,9) Clutch hose (secondary cylinder) 1 10 26 (2,7 / 20)
Shock absorber: Rear master cylinder mounting bolt 2 6 9 (0,8 / 6,6)
Upper mounting bolt/nut 1 10 39 (4,0 / 29) ECT sensor 1 12 23 (2,3 / 17)
Lower mounting bolt/nut 1 10 39 (4,0 / 29) Fuel hose banjo bolt 1 12 22 (2,2 / 16)
Fork top pinch bolt 2 8 21 (2,1 / 15,4) Note 1 Fuel pump mounting bolt 7 5 8 (0,8 / 5,9)
Fork bottom pinch bolt 4 8 21 (2,1 / 15,4) Note 1 Front spoke nipple 32 BC 3,5 3,7 (0,38 / 2,8)
Swingarm pivot nut 1 14 69 (7,0 / 51) Note 1 Rear spoke nipple 32 4 2,5 (0,26 / 1,9)
Front brake disc mounting bolt 4 6 19 (1,9 / 14) Note 2 Shock absorber spring lock nut 1 50 49 (5,0 / 36)
Rear brake disc mounting bolt 4 6 17 (1,7 / 12,5) Note 2 Shock arm bolt/nut 1 10 39 (4,0 / 29)
Side stand pivot nut 1 10 23 (2,3 / 17) Shock link bolt/nut 2 10 39 (4,0 / 29)
Side stand bracket mounting bolt 2 8 27 (2,8 / 20) Note 2 Rim lock nut 1 8 13 (1,3 / 9)
Exhaust pipe flange nut 2 6 12 (1,2 / 9) Fork cap 2 36 13 (1,3 / 9)
Engine hanger: Right fork adjuster case lock nut 1 10 15 (1,5 / 11)
Upper hanger bolt/nut 2 8 24 (2,4 / 17) Right fork lower bolt 1 14 25 (2,6 / 18,4)
Front hanger bolt 1 10 50 (5,1 / 37) Note 1 Left fork lower bolt 1 14 25 (2,6 / 18,4)
Down tube mounting bolt 4 8 26 (2,7 / 19) Note 1
Rear lower bolt 1 10 39 (4,0 / 29) Note 1 Notes: 1. Apply grease to the sliding surface.
Skid plate: 2. Apply a locking agent to the threads.
Front mounting bolt 4 8 27 (2,8 / 20)
Throttle housing bolt 2 5 4,2 (0,43 / 3,1)
Clutch lever holder bolt 2 5 5,5 (0,56 / 4)
Front brake master cylinder holder bolt 2 5 5,5 (0,56 / 4)
Front brake caliper mounting bolt 2 8 27 (2,8 / 20) Note 2
Brake hose:
Front master cylinder 1 10 14 (1,4 / 10,3)
Front caliper 1 8 20 (2,0 / 14)
Rear master cylinder 1 10 26 (2,7 / 19)
Rear brake caliper 1 10 26 (2,7 / 19)
Brake pedal pivot bolt 1 8 29 (3,0 / 22) Note 2

1-6
 Service data

Tools
Special Common

Description Tool number Applicability Description Tool number Applicability

Bearing remover, 12 mm 07936–1660101 Water pump bearing Spoke nipple wrench 07701–0020300 Front spoke nipple
Remover shaft 07936–1660120 Gear holder 07724–0010100 Primary drive gear bolt
Remover weight 07741–0010201
Bearing remover head 07746–0050600 Wheel bearing
Water seal driver 07945–KA30000 Water seal Bearing remover shaft 07746–0050100 Wheel bearing
Attachment, 28 x 30 mm 07946–1870100 Water pump bearing Driver 07749–0010000 Bearing removal/installation
Attachment, 24 x 26 mm 07746–0010700 Swingarm pivot bearing
Clutch center holder 07JMB–MN50301 Clutch center lock nut
Attachment, 32 x 35 mm 07746–0010100 Right countershaft bearing
Fork seal driver set 07947–4630100 Fork oil seal
Left mainshaft bearing
Fork damper holder 89515–NN3–821 Right fork socket bolt Attachment, 37 x 40 mm 07746–0010200 Left shift drum bearing
Fork damper holder 07930–KA50100 Left fork socket bolt Attachment, 42 x 47 mm 07746–0010300 Right mainshaft bearing

Ball race remover 07948–4630100 Stem bearing race Left countershaft bearing
Right shift drum bearing
Steering stem driver 07946–4300000 Stem lower bearing
Wheel bearing
Bearing driver 07946–KA50000 Swingarm pivot bearing Ball race
Bearing remover 07946–MJ00100 Shock link needle bearing Attachment, 52 x 55 mm 07746–0010400 Crankshaft oil seal

Swingarm link bearing Attachment, 62 x 68 mm 07746–0010500 Left crankshaft bearing

Attachment, 72 x 75 mm 07746–0010600 Right crankshaft bearing
Spherical bearing driver 07HMF–KS60100 Shock absorber bearing
Pilot, 12 mm 07746–0040200 Water pump bearing
Snap ring pliers 07914–3230001 Master cylinder snap ring Pilot, 17 mm 07746–0040400 Right countershaft bearing
Flywheel holder 89020–NN4–003 Flywheel Left mainshaft bearing
Flywheel puller 89010–NN4–003 Flywheel Pilot, 20 mm 07746–0040500 Left countershaft bearing
Wheel bearing
Compressor attachment 07959–MB10000 Shock absorber spring
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 Shock spring adjuster (2 required)
Shock absorber compressor 07GME–0010100 Shock absorber spring

1-7
Service data

Lubrication & Seal Points

Engine

Item Material Remarks Item Material Remarks

Crankcase sealing bolt threads and seating surface Repsol 4T-stroke engine oil Connecting rod small end I.D. Molybdenum oil solution
Cylinder bore inner surface Connecting rod big end (A 50/50 mixture of
molybdenum disulfide
Cylinder head nut threads and seating surface Camshaft outer surface grease and engine oil
Piston inner area, piston pin area Rocker arm I.D.
Piston pin outer surface Valve stem sliding surface
Piston ring surface Valve stem end sliding surface
Crankshaft oil seal lips Clutch outer collar sliding surface
Decompressor weight sliding surface Mainshaft spline and gear sliding surface
Valve adjusting nut threads Countershaft spline and gear sliding surface
Oil pump rotor sliding surface Shift fork I.D. and gear contact area
Clutch outer sliding surface Shift fork shaft surface
Clutch friction disc surface Kickstarter spindle spline area and gear sliding
Clutch center nut threads and seating surface surface

Clutch lifter piece needle bearing area Each gear

Primary drive gear bolt threads and seating surface Right crankshaft bearing set plate bolt threads Locking agent 6.5 ± 1 mm

Shift drum grooves Right mainshaft bearing/shift drum bearing set plate
bolt threads
Gearshift spindle serration
Left coutershaft bearing set plate bolt threads 3.5 ± 1 mm
Flywheel nut threads and seating surface
Left crankcase sealing bolt threads
Each bearing
Cylinder mounting bolt threads
Each O-ring
Cylinder head sealing bolt threads 6.5 ± 1 mm
Crankcase inside (transmission oil) ELF HTX740
Cam chain tensioner bolt threads
Crankcase inside (engine oil) Repsol 4T-stroke engine oil 600 cm3
10W-30 Shift drum center bolt threads
Ignition pulse generator bolt threads
Stator mounting bolt threads

1-8
 Service data

Item Material Remarks Chain tensioner bolt transmission Drain hole

Clutch slave cylinder piston/O-ring Silicone grease

Left crankcase cover cap threads Lithium based multipurpose Application zone Application zone
grease 6.5±1 mm 3 - 4 mm 2.5±1 mm 1.2±0.4 mm
Each oil seal lips
Water seal lips
Right crankcase cover water hose joint threads Sealant
Cylinder head water hose joint threads
Cylinder head cover mating surface Three Bond 1215B

1-9
Service data
Frame

Item Material Remarks Item Material Remarks

Steering head bearing race and bearings Multi-purpose grease Drive chain adjuster stopper screw threads Locking agent

Steering head dust seal lips Side stand bracket bolt threads
Swingarm pivot needle bearing Steering stopper bolt threads
Swingarm pivot dust seal lips Drive chain slider mounting screw threads
Shock link/shock arm needle bearings Rear brake hose clamp screw threads
Shock link/shock arm dust seal lips Cooling fan nut threads
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
Throttle pipe sliding surface and throttle wire drum 4-stroke engine oil
Throttle housing screw threads Molybdenum disulfide grease
Brake hydraulic system inside DOT 4 brake fluid
Clutch hydraulic system inside
Air cleaner element Engine oil
Throttle cable sliding surface Cable lubricant
Handlebar grip Honda bond A or equivalent

1-10
 Service data

Cable & Harness Routing

2 3

FRONT

(1) FRONT BRAKE HOSE FRONT

(2) THROTTLE CABLE
(3) CLUTCH HOSE

1-11
Service data

3
2
10

11
4

5
6

FRONT

(1) SPEEDOMETER (7) 9P CONNECTOR (LIGHT SWITCH)

(2) POWER RELAY (8) 9P CONNECTOR (SUB-HARNESS)
(3) WINKER RELAY (9) 3P CONNECTOR (SPEED SENSOR)
(4) FAN RELAY (10) FRONT BRAKE SWITCH
(5) RIGHT FRONT TURN SIGNAL CONNECTORS (11) 2P CONNECTOR (POSITION LIGHT)
(6) LEFT FRONT TURN SIGNAL CONNECTORS

1-12
 Service data

2 1 4

5 3

(1) INDICATOR LIGHT INSTALLATION

(2) INDICATOR LIGHT INSTALLATION CONNECTOR
(3) RIGHT REAR TURN SIGNAL CONNECTORS
(4) LEFT REAR TURN SIGNAL CONNECTORS
(5) REGISTRATION PLATE LIGHT CONNECTOR

1-13
Service data

11

10
8

7
4

9
3

UPPER

2 RH

1
20-30º

(1) MAIN WIRE HARNESS (7) FAN MOTOR WIRE

(2) FUEL PUMP WIRE (8) FUEL CAP BREATHER HOSE
(3) CYLINDER HEAD BREATHER HOSE (9) SPARK PLUG WIRE
(4) AIR FILTER BOX BREATHER HOSE (10) WIRE HARNESS (TO IGNITION COIL)
(5) STORAGE TANK (11) ECT SENSOR
(6) ENGINE STOP SWITCH WIRE

1-14
 Service data

4 5 6
3

7
Clamp at white tape
9 10 8

(1) WIRE HARNESS (5) UPPER RADIATOR HOSE

(2) THROTTLE CABLE (6) SPARK PLUG WIRE
(3) CLUTCH HOSE (7) FAN MOTOR WIRE
(4) CONNECTOR BOOT (8) FILTER BOX BREATHER HOSE
– FAN MOTOR 2P (BLACK) CONNECTOR (9) CYLINDER HEAD BREATHER HOSE
– POWER CONNECTOR (10) SPEED SENSOR CABLE
– LIGHT RELAY CONNECTOR

1-15
Service data

3 UPPER
2

3 RH
1

FR

RH

UPPER

RH
FR
45º

FR
RH

RH

2
(1) THROTTLE CABLE
(2) CLUTCH HOSE
(3) FUEL TANK BREATHER HOSE

1-16
 Service data

9
1 FR
2

FR FR FR

5 8

(1) MAIN WIRE HARNESS (6) REGULATOR/RECTIFIER 5P (BLACK) CONNECTOR

(2) TRANSMISSION BREATHER HOSE (7) BANK ANGLE SENSOR
(3) FILTER BOX BREATHER HOSE (8) REAR BRAKE RESERVOIR TANK
(4) ALTERNATOR WIRE (9) SPEED SENSOR CABLE
(5) CONDENSER 2P (BLACK) CONNECTOR

1-17
Service data

5
8

Clamp at white tape

4

4
6
3

12 10
2

11

(1) MAIN WIRE HARNESS (TO CONNECTOR COVER) (7) REGULATOR/RECTIFIER 5P (BLACK) CONNECTOR
(2) MAIN WIRE HARNESS (TO ECU) (8) CONDENSOR
(3) AIR FILTER BOX BREATHER HOSE (9) CONDENSOR 2P (BLACK) CONNECTOR
(4) TRANSMISSION BREAHTER HOSE (10) BANK ANGLE SENSOR
(5) WIRE HARNESS (11) CONNECTOR COVER
(6) FUEL FEED HOSE (12) SPEED SENSOR CABLE

1-18
 Service data

FR

RH

UPPER
90º

RH

4
UPPER

FR

(1) REAR BRAKE HOSE 1

(2) REAR BRAKE RESERVOIR HOSE 3
(3) SPEED SENSOR
(4) REAR BRAKE LIGHT SWITCH

1-19
Service data

(1) FUEL FEED HOSE

(2) TRANSMISSION BREATHER HOSE

1-20
 2. Service and maintenance
Maintenance schedule
Perform pre-ride Inspection at each scheduled maintenance period.

Maintenance level
: Intermediate.
We recommend that the service be performed by your dealer, unless you have the necessary tools and technical capacities. The procedures are included in an official Montesa
Shop Manual.
: Technical.
In the interest of safety, have your motorcycle serviced by your dealer.

Maintenance legend
: Inspect (clean, adjust, lubricate or replace, if necessary)
: Replace
: Clean

FREQUENCY 500 1.500 3.000 4.500 6.000 Every Yearly Every

Pre-ride check Km. Km. Km. Km. Km. 6 months check 2 years Remarks
ITEM
Fuel level Make sure that you have enough fuel for the trip planned.

Throttle operation

Engine oil

Transmission Oil

Drive Chain Check the item after riding in adverse conditions and dusty areas.

Brake Fluid

Brake Pad Wear

Clutch system

Wheels / tyres

Side stand Check the item after riding in adverse conditions and dusty areas.

Lights / horn

Engine stop switch

Fuel Line

2-1
Service and maintenance

FREQUENCY 500 1.500 3.000 4.500 6.000 Every Yearly Every

Pre-ride check Km. Km. Km. Km. Km. 6 months check 2 years Remarks
ITEM
Fuel filter

Clean under the front suspension fender

Air cleaner Check the air cleaner after riding in dusty areas.

Spark Plug

Valve clearance

Crankcase breather

Engine oil filter

Engine oil filter screen

Engine idle speed

Radiator coolant

Cooling system

Drive chain slider / tensioner Check the item after riding in adverse conditions and dusty areas.

Drive / driven sprocket

Drive chain slider

Brake system

Clutch fluid
Check the items more often when riding in adverse conditions
Rear suspension
and dusty areas.
Damper linkage / rods

Fork oil

Steering pipe bearing

Wheel bearings

Nuts, bolts and fasteners

2-2
 Service and maintenance

1
1

(1) FUEL FEED HOSE (1) BOLTS (1) FLAME TRAP

(2) AIR CLEANER HOUSING COVER (2) AIR CLEANER ELEMENT

Fuel Line Remove the flame trap from the air cleaner element.
Check the frame trap for damage, replace if necessary.
Remove the seat, front covers, side covers and the seat- 1
rear fender assy. Thoroughly wash the element in clean non-flammable
cleaning solvent, then wash in a solution of hot water
Check the fuel feed hose for cracks, deterioration or and dish-washing liquid soap.
leakage. 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
cleaning the air cleaner element. A fire or explosion
(1) AIR CLEANER ELEMENT could result.
Soak the element in engine oil and squeeze out the
excess.
Air Cleaner
Remove the four bolts and air cleaner housing cover.
NOTICE
Remove the air cleaner element assembly from the air Do not twist the element to squeeze out the excess.
cleaner housing. Failure to follow this precaution can result in a damaged
element.

Installation is in the reverse order of removal.

2-3
Service and maintenance

1 2 1
1

(1) SPARK PLUG CAP (1) INSULATOR (1) BOLTS

(2) SPARK PLUG (2) TAPPET ADJUSTING HOLE COVER

Spark Plug
1 1
Using a spark plug with the wrong heat range can damage
the engine or cause the plugs to foul. Be careful to select
the correct spark plug for the conditions.

Standard plug: NGK: CR6EH-9

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 (1) SPARK PLUG GAP (1) TIMING HOLE CAP/O-RING
specification.
Install and tighten the spark plug.
Flash Over Valve Clearance
Torque: 16 N•m (1.6 kgf•m, 12 lbf•ft)
If engine misfire occurs due to arcing, replace both the Inspection
spark plug and the cap.
Inspect and adjust the valve clearance while the engine is
Spark Plug Cap cold (below 35˚C/95˚F).

Remove the spark plug cap from the spark plug. Remove the fuel tank/injector assembly.
Clean the inside of the plug cap with electrical contact Remove the bolts and tappet adjusting hole covers from
cleaner to prevent misfire. the cylinder head cover.
Remove the timing hole cap and O-ring.

2-4
 Service and maintenance

2 1 2 4 4

1 3

(1) “T” MARK (1) FEELER GAUGE (1) O-RING

(2) INDEX MARK (2) VALVE ADJUSTING HOLE COVER
(3) “UP” MARK (4) BOLTS

Operate the kickstarter pedal and align the “T” mark on Insert a feeler gauge between the rocker arm and
the flywheel with the index mark on the left crankcase valve stem and measure the intake and exhaust valve 1
cover. clearances.

Make sure the piston is at TDC (Top Dead Center) on the Valve clearance:
compression stroke by moving the rocker arms. 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:
2
Valve adjusting wrench, 8 x 9 mm 07708-0030100
(equivalent commercially available)
Valve adjuster B 07708–0030100
(1) O-RING
(2) TIMING HOLE CAP
After adjustment, tighten the lock nut while holding the
adjusting screw.
Check that the valve adjusting hole cover O-ring is in good
Recheck the valve clearance.
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.

2-5
Service and maintenance

1
1
1

3
2

(1) OIL FILLER CAP/DIPSTICK (1) OIL FILLER CAP/DIPSTICK (1) BOLT
(2) UPPER LEVEL LINE (2) DRAIN BOLT/SEALING WASHER (2) RETAINING PLATE
(3) LOWER LEVEL LINE

Engine Oil/Oil Filter Oil Change

1
Oil Level Inspection Change the engine oil with the engine warm.
Support the motorcycle with it side stand. 4
Start the engine and let it idle for a 3 minutes. Remove the bolts and skid plate.
Stop the engine and wait 3 minutes. 1. Remove the oil filler cap/dipstick.
Support the motorcycle upright on a level surface. 2. Place an oil drain pan under the engine and remove the
drain bolt on the left crankcase cover.
Remove the oil filler cap/dipstick on left crankcase and 3. After the oil has completely drained, make sure that
wipe the oil with a clean cloth. the sealing washer is in good condition and reinstall
Insert the dipstick without screwing it in, remove it and the drain bolt. Tighten the drain bolt to the specified
check the oil level. torque.
2
2 3
If the oil level is below or near the lower level line on the Torque: 22 N•m (2.2 kgf•m, 16 lbf•ft)
dipstick, add the recommended engine oil to the upper (1) OIL FILTER COVER
level line through the oil filler hole. 4. Pour recommended engine oil slowly through the oil (2) O-RINGS
filler hole. (3) OIL FILTER
Specified engine oil: (4) SPRING
Repsol 4-stroke motorcycle oil Specified engine oil:
(10W-30) Repsol 4-stroke motorcycle oil (SAE: 10W-30) Oil Filter Change
Capacity: 0.41 liter (0.43 US qt, 0.36 Imp qt) after draining Remove the left crankcase cover (page 3-49).
0.44 liter (0.46 US qt, 0.39 Imp qt) after oil filter
change Remove the oil filter cover retaining plate bolt and plate.
0.60 liter (0.63 US qt, 0.53 Imp qt) after Remove the oil filter cover and O-rings.
disassembly
Remove the oil filter and spring.
Install the oil filler cap/dipstick.

2-6
 Service and maintenance

1 2

1 1
1

(1) SPRING (1) NEW O-RINGS (1) OIL STRAINER SCREEN

(2) OIL FILTER (2) OIL FILTER COVER
(3) APPLY GREASE

Oil Strainer Screen Cleaning

2
Remove the oil strainer screen from the left crankcase
groove.
2 Clean the strainer.
1 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

(1) OIL FILTER (1) RETAINING PLATE

(2) “OUT SIDE” MARK (2) BOLT

Apply grease to the oil filter spring end (filter side). Install new O-rings into the oil filter cover grooves.
Install the spring into the new oil filter.
Install the oil filter cover into the left crankcase while
Install the new oil filter into the left crankcase with its aligning the cover flange with the oil filter groove.
“OUT SIDE” mark facing out. Make sure that the oil filter cover seats properly in the
crankcase.
Installing the oil filter backwards will result in severe
engine damage. Install the retaining plate and tighten the bolt securely.

2-7
Service and maintenance

1 2

1
1

(1) THROTTLE STOP SCREW (1) DRAIN BOLT (1) FILLER CAP
(2) O-RING

Engine Idle Speed Transmission Oil 5. Pour specified transmission oil.

Inspect and adjust the idle speed after all other engine Oil Change Specified transmission oil: ELF HTX 740
adjustments are within specification.
The engine must be warm for an accurate idle inspection  Transmission oil should be changed at least every six Capacity: 0.54 liter (0.57 US qt, 0.48 Imp qt) after draining
and adjustment. competitions to ensure consistent performance and 0.57 liter (0.60 US qt, 0.50 Imp qt) after
maximum service life of both transmission and clutch disassembly
Warm up the engine until the fan starts, shift the components.
transmission into neutral, and hold the motorcycle upright  Warm-up the engine before draining the oil. This will Check the O-ring is in good condition, install the oil filler
position. ensure complete and rapid draining. cap.
Connect a tachometer according to its manufacturer’s
operating instruction. Remove the bolts and skid plate.

Idle speed: 1,800 ± 100 min-1 (rpm) 1. Support the motorcycle in an upright position on level
surface.
2. Remove the oil filler cap from the clutch cover.
NOTICE 3. Place an oil drain pan under the engine to catch the oil,
then remove the drain bolt and sealing washer from the
An improper idling speed will cause starting problems. 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)

2-8
 Service and maintenance

2
2
1

2
1
1

(1) OVERFLOW HOSE (1) INSPECTION HOLE (1) BOLT

(2) RADIATOR (2) COOLANT DRAIN BOLT/SEALING WASHER (2) RADIATOR CAP

Coolant 6. Check the water pump inspection hole bottom of the 2.Remove the radiator upper mounting bolt and move
water pump for leakage. Make sure the hole remains the radiator forward, then remove the radiator cap and
Cooling System Inspection open. drain the coolant.
If water leaks through the check hole, the water seal 3. Install the new sealing washer, drain bolt and tighten it
1. Check the cooling system for leaks. is damaged. If oil leaks through the check hole, the oil to the specified torque.
2. Check water hoses for cracks, deterioration, and clamp seal is damaged.
bands for looseness. Replace the water seal or the oil seal (page 3-15). Torque: 9.8 N•m (1.0 kgf•m, 7 lbf•ft)
3. Check the radiator mount for looseness.
4. Make sure the overflow hose is connected and not Coolant Replacement
clogged.
5. Check radiator fins for obstructions or damage.
! 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.

2-9
Service and maintenance

1
1

1
3

(1) FILLER NECK (1) CLUTCH FLUID RESERVOIR (1) EXHAUST PIPE
(2) LOWER LEVEL LINE (2) MUFFLER
(3) LAMBDA-SONDE

4. Fill the radiator with coolant up to the filler neck. Clutch System Exhaust Pipe And Muffler
5. Squeeze the radiator hoses alternately. If the coolant
level drops, fill the coolant again. System Inspection Inspection
6. Fill the radiator with coolant up to the filler neck.
7. After this first filling, start the engine, check the coo- 1. Operate the clutch lever and check that no air has en- Check the muffler for clogging.
lant level.. tered in the system. If the clutch is not disengaged Check for loose or missing bolts and nuts.
properly, or the lever feels soft or spongy, bleed the air Check the exhaust pipe and muffler for cracks or
from the system. deformation.
2. Remove the reservoir cover and diaphragm, check the Check the exhaust pipe gasket.
clutch fluid level. If the level is low, inspect the clutch Check the muffler gasket.
hose and fittings for damage, deterioration, cracks or
sign of leakage. Tighten any loose fittings. Replace Loss of power will result if the exhaust pipe is broken.
hose and fittings as require.

2-10
 Service and maintenance

1
2 1 2

(1) DRIVE CHAIN SLACK (1) AXLE NUT (1) DRIVE CHAIN SLIDER
(2) ADJUSTER (2) DRIVE CHAIN TENSIONER SLIDER

Drive Chain Drive Chain Slack Adjustment Drive Chain Slider

Drive Chain Slack Inspection Loosen the rear axle nut just enough to move the rear Inspection/Replacement
wheel in fore-act direction.
During the break-in period, drive chain slack should be Turn the adjuster equally on both sides until the correct Check the drive chain slider for wear or damage.
checked and adjusted often. Also check the drive chain drive chain tension is obtained. If the wear is 2.0 mm (0.08 in) or more, replace the slider.
slack after the drive chain replacement. Turn the adjuster counterclockwise will decrease slack Check the drive chain tensioner slider for wear or damage.
Regular cleaning, lubrication, and proper adjustment will and turning it clockwise will increase slack. If the wear is 2.0 mm (0.08 in) or more, replace the slider.
help to extend the service life of the drive chain.
 Adjust the chain with the chain adjusters so that it is The drive chain slider and tensioner screws must be
Shift the transmission into neutral, turn the engine off and parallel with the center line of the frame. retightened after break-in.
support the motorcycle on its side stand.  Check that the stopper is between the teeth of the
Unhook the drive chain tensioner spring to remove any adjuster.
load on the chain.
Measure chain slack at the lower section midway between Recheck the drive chain slack and free wheel rotation.
the sprockets. After adjustment, tighten the axle nut to the specified
torque.
Drive chain slack: 25 – 35 mm (1.0 – 1.4 in)
Torque: 69 N•m (7.0 kgf•m, 51 lbf•ft)
Rotate the wheel and chain slack in several sections.
If slack in one section increases beyond the standard Lubricate the drive chain.
measurement, this indicates the chain has stretched and Hook the drive chain tensioner spring.
needs to be replaced.
Take care to prevent catching your fingers between the
chain and sprocket.

2-11
Service and maintenance

1
1 1
3 2

(1) BOLT (1) DRIVE SPROCKET (1) BOLTS/NUT

(2) SPRING WASHER (2) SPRING WASHER (2) DRIVEN SPROCKET
(3) DRIVE SPROCKET (3) BOLT

Drive/Driven Sprockets Install the drive sprocket onto the countershaft as shown. Driven Sprocket Replacement
Install the spring washer and bolt, then tighten the bolt to
Drive Sprocket Replacement the specified torque. Remove the rear wheel (page 4-14).

Remove the drive sprocket cover. Torque: 31 N•m (3.2 kgf•m, 23 lbf•ft) Remove the bolts/nuts and driven sprocket.
Loosen the drive chain fully.
Put the transmission in neutral. Installation is in the reverse order of removal.
Insert 1st gear
Hold the bolts and tighten the nuts to the specified torque.
Remove the screw drive pinion and spring washer.
Torque:
24 - 30 N•m (2,4 - 3,0 kgf•m, 17.7 - 22.1 lbf•ft)

Adjust the drive chain slack (page 2-11).

2-12
 Service and maintenance

1 1

1
2

(1) “MIN” LEVEL (1) BRAKE HOSE (1) COVER

(2) “MIN” LEVEL

Brake Fluid Check that the brake hose do not bind or kink in all Rear Master Cylinder
steering position, and is not pulled when the suspension
Front Brake Master Cylinder is extended. Always inspect the brake fluid level.

Always inspect the brake fluid level. Replace the brake fluid every 2 months. Remove the master cylinder reservoir cover, set plate and
Do not service the brake system in high humidity. diaphragm.
Remove the screws, master cylinder cover and diaphragm. If the fluid level is lower than the “MIN” level, check for
Brake fluid: DOT 4 only brake pad wear.
If the fluid level is lower than the “MIN” line, check for Replace the brake pad if necessary.
the brake pad wear. Refer to page 4-24 for brake pad replacement.
Replace the brake pad if necessary.
Refer to page 4-24 for brake pad replacement. Also check the brake system for leaks.

Also check the brake system for leaks. Replace the brake fluid every 2 months.
Do not service the brake system in high humidity.

Brake fluid: DOT 4 only

2-13
Service and maintenance

1 2 3

1
1

(1) BRAKE PAD (1) BRAKE DISC (1) BRAKE DISC

(2) DISC BOLT
(3) COLLAR

Brake Pad Wear Brake System The front brake is floating type disc.
Replace the disc and disc bolts if the play in the rotating
Measure the brake pad thickness. Brake Discs 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
Front brake pad: Measure the rear brake disc runout with a dial gauge. – 0.04 in).
Minimum thickness (subtracting the metal support): Apply a locking agent to the threads of the brake disc
0.5 mm (0.02 in) Service limit: 0.15 mm (0.006 in) bolts before installation.

Rear brake pad: Replace the brake disc if the runout exceeds the service Torque:
Minimum thickness (subtracting the metal support): limit. Front: 18 - 20 N•m (1.8 - 2 kgf•m, 13-15 lbf•ft)
1.0 mm (0.04 in) Rear: 16 - 18 N•m (1.6 - 1.8 kgf•m, 11-13 lbf•ft)
Measure the brake disc thickness.
If either pad is worn, both pads must be replaced. On the front brake, replace the collar with new ones if the
Service limit: Front: 2.9 mm (0.11 in) disc starts to wobble right and left.
Rear: 3.0 mm (0.12 in)

Replace the brake disc if necessary.

Refer to pages 4-1 and 4-14 for removal.

2-14
 Service and maintenance

1
2
2 1

1
1 2

(1) HOLDER BOLTS (1) STEERING HEAD BEARINGS (1) SPOKE NIPPLE
(2) UPPER HOLDER (2) RIM LOCK

Tire air pressure should be checked when the tires are

Handlebar And Steering Head Bearings Steering Head Bearings
COLD.
Handlebar Support the motorcycle using the maintenance stand with
its front wheel off the ground. Standard tyre air pressure for ROAD USE:
Front: 100 kPa (1.02 kgf/cm2, 14.5 psi)
Check the handlebar for bends or cracks.
Turn the handlebar to the right and left to check for Rear: 100 kPa (1.02 kgf/cm2, 14.5 psi)
Check that the handlebar has not moved from its proper roughness in the steering head bearings. Stand in front of
the motorcycle and grab the fork (at the axle), then push Standard tyre air pressure for OFF ROAD:
position.
the fork in and out (toward the engine) to check for play Front: 70 kPa (0.7 kgf/cm2, 5.6 – 10.1 psi)
Check that the handlebar holder bolts are tight.
in the steering head bearings. If any roughness or play is Rear: 60 kPa (0.6 kgf/cm2, 4.3 – 8.7 psi)
If necessary, tighten the holder bolts.
First tighten the forward bolts, then tighten the rear bolts felt, adjust or replace the steering head bearings.
Inspect the wheel for damage.
to the specified torque.
Check the wheel runout. If runout is noticeable, check
Torque: 22 N•m (2.2 kgf•m, 16 lbf•ft) Wheels And Tires the spokes are tight, or replace the wheel.

Proper air pressure will provided maximum stability and Check the axle for runout.
tire life. Check the condition of the front and rear wheel bearings.
Check tire pressure frequently and adjust if necessary. 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)

2-15
Service and maintenance

1 1

(1) PRE-LOAD ADJUSTER (1) REBOUND ADJUSTER

Front Suspension Fork Use specified fork fluid which additives to assure
maximum performance of your 4RIDE’s front suspension.
Inspection The motorcycle is shipped with a light coating of grease
on the forks. This is not an indication of a leak. Specified fork fluid: Tech OJ 01 (SAE5)
1. Make sure that the fork surfaces and dust seals are
 Periodically check and clean all front suspension parts
clean. The fork should always be adjusted for the rider’s weight
to assure top performance. Check the dust seals for
2. Check for signs of oil leakage. Damaged or leaking and track conditions by using one or more of the following dust, dirt and foreign materials. Check the fluid for any
fork seals should be replaced before you ride the mo- methods. contamination.
torcycle.  Make rebound damping adjustments in one-click
3. Make a quick check of fork operation by locking the Basically, there are two adjustments you can make to the increments. Adjusting two or more clicks at a time
front brake and pushing down on the handlebar several front suspension: may cause you to pass over the best adjustment. Test
times.  Rebound damping (right fork) ride after each adjustment.
Turning the rebound damping adjuster adjusts how  If you become confused about adjustment settings,
 When your 4RIDE is new, break in your 4RIDE to ensure quickly the fork extends. return to the standard position and start over.
that the suspension has worked in.  Spring pre-load (left fork)
 After break-in, test ride your 4RIDE with the front Turning the spring pre-load adjuster adjusts the spring
suspension at the standard setting before attempting initial pre-load length.
any adjustments.
Replace the fork fluid every 2 months. See page 4-8,
4-10 for oil level adjustment after changing the fork fluid.

2-16
 Service and maintenance

(1) PRE-LOAD ADJUSTER (1) REBOUND ADJUSTER

Rear Suspension  When your 4RIDE is new, your suspension will break-in Inspection
as you ride.
The swingarm is controlled by a shock absorber. The The  After break-in is completed, test ride your 4RIDE with 1. Check for a broken or collapsed spring.
rear shock absorber should always be adjusted for the the rear suspension at the standard setting before 2. Bounce the rear of the machine up and down and check
rider’s weight and track conditions by using one or more attempting any adjustments. for smooth suspension action.
of the following methods.  Make all rebound damping adjustment in one-click 3. Check the rear shock absorber for a bent shaft or oil
 Spring pre-load increments. Adjusting two or more clicks at a time leaks.
Turning the spring pre-load adjuster adjusts the spring may cause you to pass over the best adjustment. Test 4. Push the rear wheel sideways to check for worn or
initial pre-load length. ride after each adjustment. loose swingarm bearings. There should be no move-
 Rebound damping  If you become confused about adjustment settings, ment. If movement is felt, replace the pivot bearings
Turning the rebound damping screw adjusts how return to the standard position and start over. (page 4-18).
quickly the shock absorber extends.

2-17
Service and maintenance

2
1

1
1 2

3 4 1

(1) SCREWS (1) DUST COVER (1) HEADLIGHT POSITION LIGHT

(2) THE HOUSING FOR THE UPPER HEADLIGHT (2) BULB PAWL
(3) BULB
(4) CONNECTORS
Front headlight and front position light. Position light bulb
– Remove the housing for the headlight.
Replacing the bulbs – Disconnect the connector.  Remove the socket without turning.
– Remove the dust cover.  Pull out the bulb without turning.
 Bear in mind the following when replacing the front – Press down on the pin.  Install a new bulb and the socket in the reverse order
headlight bulb. – Pull out the bulb without turning it of removal.
– Use clean gloves when replacing the bulb. Do not
touch the front headlight bulb with your fingertips,
since this could produce hot spots on the bulb and AVISO
cause it to break. Do not touch the bulb. Fingerprints may create hot spots
– If you touch the bulb with your bare hands, clean it that cause the bulb to break.
with a cloth moistened with alcohol to prevent its
early failure. Fit the bulb, while aligning its tabs with the slots on the
 Ensure that you replace the dust cover after changing front headlight unit.
the front headlight bulb. Hook the bulb pawl in the slot of the front headlight unit.
 The bulb for the front headlight gets very hot when it is Firmly replace the dust cover on the headlight.
on and remains hot for a while after the front headlight Install the bulb connector.
has been turned off. Ensure that you leave it to cool Replace the housing for the headlight.
before carrying out any maintenance work.

2-18
 3. Engine servicing
1 2 1 2
1 2

(1) SNAP RING (1) RELIEF VALVE (1) DRIVEN GEAR

(2) PRESSURE RELIEF VALVE (2) O-RING (2) DRIVE PIN

Oil Pressure Relief Valve Oil Pump

2 1
Removal/Inspection Disassembly

Drain the engine oil. Remove the engine from the frame.
Remove the left crankcase cover (page 3-49). Separate the crankcase halves (page 3-54).

Remove the snap ring. Remove the oil pump driven gear and drive pin.
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 3-51).

3-1
Engine servicing

2 1 2
3 3 1

2
1

(1) ONE-WAY REED VALVE (1) DRIVEN GEAR (1) SNAP RING
(2) GASKET (2) OIL PUMP SHAFT (2) OIL SEAL
(3) DOWEL PINS

(1) OUTER ROTOR (1) ONE-WAY REED VALVE

(2) INNER ROTOR
(3) OIL PUMP SHAFT
Inspection Check the oil pump shaft oil seal in the left crankcase for
Remove the one-way reed valve, gasket and dowel pins. damage or deterioration, replace if necessary.
Check the oil pump driven gear for wear or damage.
Remove the oil pump shaft, outer and inner rotors. Check the oil pump shaft for wear or damage. Temporarily install the oil pump shaft, inner and outer oil
pump rotors into the right crankcase.
Check the one-way reed valve for damage, replace if
necessary. Measure the oil pump tip clearance.

Service limit: 0.20 mm (0.008 in)

3-2
 Engine servicing

2
3
1
1

4
2

(1) OIL PUMP SHAFT (1) DRIVE PIN

(2) INNER ROTOR (3) FLAT SURFACES (2) DRIVEN SPROCKET
(4) OUTER ROTOR

Assembly
1
2 2
Apply clean engine oil to the oil pump rotors and shaft.

Install the oil pump shaft into the right crankcase.

Install the inner rotor aligning the flat surface between the
rotor and pump shaft.
Install the outer rotor.

3
1

(1) GASKET (1) ONE-WAY REED VALVE

(2) DOWEL PINS
(3) NEW GASKET
Measure the oil pump body clearance.
Install the drive pin into the oil pump shaft hole.
Standard: 0.15 – 0.20 mm (0.006 – 0.008 in) Install the oil pump driven sprocket aligning its groove
with the drive pin.
Temporarily install the crankcase gasket.
Measure the side clearance using a straight edge and Install the one-way reed valve into the right crankcase.
feeler gauge. Note the direction of the reed valve.
Install the dowel pins and new gasket.
Standard: 0.05 – 0.12 mm (0.002 – 0.004 in) Assemble the crankcase.

Install the removed parts in the reverse order of removal.

3-3
Engine servicing

1
1

(1) 5P CONNECTOR (1) FAST CONNECTOR PROTECTOR (1) PAWL

(2) FAST CONNECTOR

Disassembly / Installation of fuel feed hose 1

The pawl of the fast connector must be changed every
time the fuel feed hose is disconnected.

Disassembly of fuel pump side

Stop the engine. 1

Remove the seat, front covers, side covers and the seat-
rear fender assy.
Remove the rear fender
Pull up the fuel tank
2
Disconnect the fuel pump’s 5P connector. 2
Turn on the engine until it stops.
(1) PAWL (1) PAWL
(2) FAST CONNECTOR (2) FAST CONNECTOR

1. Remove the protective housing from the fast connec- Installation of fuel pump side
tor.
2. Check whether the connector is dirty and clean if ne- 1. Insert a new pawl in the fast connector. Insert the fast
cessary. Cover the fast connector with a cloth. connector in the fuel pump feed hose until it clicks. If
3. Hold fast connector with one hand and tighten the two this is hard to do, apply a small amount of motor oil to
pins of the pawl with the other hand while pulling the the fuel pump feed hose.
connector backwards. Disconnect the fast connector 2. Move the fast connector backwards to check that it
and remove the pawl. does not come out and is firmly connected.
3. Place the protective housing over the fast connector.

3-4
 Engine servicing

1
4
1
2
3

2 2

(1) BANJO BOLT (1) MANOMETER ADAPTER, 12 MM (1) FUEL PRESSURE GAUGE
(2) SEALING WASHER (2) SEALING WASHER, 12 MM
(3) SEALING WASHER, 6 MM
(4) F. PRESSURE GAUGE
Fuel Line Inspection Start the engine.
Remove the fuel feed hose banjo bolt and attach the fuel Read the fuel pressure at idle speed.
Fuel Pressure Inspection pressure gauge with the following Montesa Genuine parts.
Idle Speed: 1,800 ± 100 min-1 (rpm)
Manometer adapter, 12 mm Standard: 230 kPa - 320 kPa
! WARNING part No. 90008-PP4-E02 (2,34 kgf/cm2 - 3,26 kgf/cm2)
Sealing washer, 12 mm (33 psi - 46 psi)
Gasoline is highly flammable and is explosive. part No. 90428-PD6-003
You can be burned or seriously injured. Sealing washer, 6 mm If the fuel pressure is higher than specified, inspect the
 Stop engine and keep heat, sparks, and flame away. part No. 90430-PD6-003 following:
 Refuel only outdoors. – Fuel pump (page 3-7)
 Wipe up spills immediately.
Tool:
Fuel pressure gauge 07406-0040003 or If the fuel pressure is lower than specified, inspect the
07406-0040002 following:
NOTICE – Fuel line leaking
– Clogged fuel filter
 Before disconnecting the fuel hoses, release the fuel – Fuel pump (page 3-7)
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 seat, front covers, side covers and the seat-
rear fender assy.

Cover the fuel feed hose banjo bolt with a rag or shop
towel.
Slowly loosen the banjo bolt and catch the remaining fuel
using a approved gasoline container.

3-5
Engine servicing

1 2 1

(1) FUEL RETURN HOSE (1) SEALING WASHER (1) 2P CONNECTOR

(2) BANJO BOLT

Fuel Pump Flow Inspection After inspection, re-insert the banjo bolt in the fuel feed Connect the fuel pump 2P connector.
hose using a new sealing washer.
Remove the seat, front covers, side covers and the seat- Start the engine and check for fuel leaks.
rear fender assy. Torque: 22 N•m (2,2 kgf•m, 16,2 lbf•ft)

Disconnect el banjo bolt and insert the eyelet of the hose

in a homologated fuel container.

Raise the fuel tank.

Connect the 12 V battery to the fuel pump 2P connector

terminals, check amount of fuel flow for 10 seconds.

Amount of flow:
0.749 l/min (125 cm3 / minumun 10 seg)

If the fuel flow is less than specified, inspect the following:

– Pinched or clogged fuel hose
– Clogged fuel filter
– Fuel pump (page 3-7)

3-6
 Engine servicing

1 2
1
1

2 2

(1) 2P CONNECTOR (1) BREATHER HOSE (1) 2P CONNECTOR

(2) SOCKET BOLTS (2) BOLT
(3) FUEL TANK

Fuel Tank/Fuel Pump Disconnect the fuel tank breather hose. Pull up the fuel tank and disconnect the fuel pump 2P
Remove the fuel tank mounting bolts. connector.
Removal
Remove the fuel tank and injector as an assembly being
Remove the seat, front covers, side covers and the seat- careful not to damage the injector especially tip of the
rear fender assy. injector.

Disconnect the injector 2P connector. After removing the fuel tank/injector assembly, protect tip
Remove the injector holder socket bolts. of the injector.
Also cover the cylinder head injector hole to prevent dust
and dirt fall into the combustion chamber.

3-7
Engine servicing

2
1

1
3

(1) QUICK CONNECTOR (1) FUEL PUMP (1) FUEL PUMP

(2) FUEL FEED HOSE (2) BOLTS
(3) 5P CONNECTOR

Installation E
A

1 NOTICE C

Always replace the packing with a new one when the fuel
pump is removed.

2 Clean any oil off from the mating surface of the fuel pump D
base and fuel tank.
Install a new packing onto the fuel pump base. G
Install the fuel pump assembly into the fuel tank (as
pictures shows). B F
Be careful not to damage the fuel pump wire.
Make sure the packing is seated against the fuel tank.
(1) BOLTS Also check that the packing is not placed on the fuel tank Install the fuel pump mounting bolts.
(2) FUEL PUMP boss.
Tighten the fuel tank mounting bolts in the alphabetical
Remove the 5P connector and fuel feed hose. order shown in the illustration.

Remove the fuel pump base mounting bolts. Torque: 7 - 9 N•m (0.7 - 0.9 kgf•m, 5.1 - 6.6 lbf•ft)
Remove the fuel pump assembly being careful not to
damage the pump.

3-8
 Engine servicing

2 2 2
3

3
1 1
1

(1) O-RING (NEW) (1) FUEL TANK (1) SOCKET BOLTS

(2) FUEL FEED HOSE (2) BOLT (2) 2P (BLACK) CONNECTOR
(3) QUICK CONNECTOR (3) BREATHER HOSE

Install the fuel tank into the frame being careful not to Install and tighten the injector holder socket bolts to the
pinch the throttle cable. specified torque.
1
Install and tighten the fuel tank mounting bolts. Torque: 8 - 12 N•m (0.8 - 1.2 kgf•m, 5.9 - 8.8 lbf•ft)
Connect the fuel tank breather hose to the hose clip.
Connect the fuel injector 2P (Black) connector.

Install the seat-rear fender assy, side covers, front covers

and the seat.

(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.

Install the fuel tank onto the frame and connect the fuel
pump 2P connector.

3-9
Engine servicing

1
2
3
1

2
1

1
(1) 5P CONNECTOR (1) BOLTS (1) PAWL
(2) FUEL PUMP BASE (2) PUMP BODY
(3) PUMP

1
1

(1) FAST CONNECTOR (1) FUEL PUMP (1) CABLE TERMINALS

(2) PUMP ENGINE/FILTER
Disassembly of the fuel filter Remove the fuel tank.
Cleaning the fuel filter
Disconnect the 5P connector from the fuel pump. Remove the bolts from the fuel pump base and remove
the base. Press the three pawls between the pump body and the
Disconnect the fuel feed hose (page 3-4). pump. Remove the body from the pump.
Take the fuel pump out of the fuel tank, taking care not
to damage the pump or electric cables. Disconnect the cable terminals (take note initial position).
Disassemble the engine/filter system from the pump body.

3-10
 Engine servicing

3 3
1 1 2
1

5 4 3
(1) FILTER SURFACE (1) BEARINGS (1) PUMP (3) PAWLS
(2) PUMP (2) BODY (4) CONNECTING PIPE
(3) ENGINE CABLES
(4) MOTOR
Clean the surface of the filter.
(5) BODY 1

Replace the bearings with new ones every time the fuel
pump is disassembled.

Clean the contact surface between the pump and the fuel
2
tank. Install new bearings. Apply a small amount of engi-
ne oil for installation.

Thread the engine cables through the holes and connect

them to the terminals.
Insert the pump engine in the body. 1

Be careful not to damage the cables

(1) BEARING
(2) PUMP

Assembly

Insert the body in the pump system.

Make sure that the pawls are tightly closed and that the
two pieces are perfectly positioned.

Insert a new bearing in its housing in the tank as shown.

Insert the pump in the tank, taking special care not to
damage the bearings. Apply a small amount of engine oil
for installation.

Make sure that the bearing is properly positioned and sup-

ported in the fuel tank.

3-11
Engine servicing

2
1

(1) FUEL PUMP BASE (1) TANK (1) PUMP CONNECTOR

(2) BOLTS (2) CLIP
(3) BREATHER HOSE
Mount the tank on the chassis.
E Connect the breather hose to the tank and secure it with
A
the clip.
C

G 1

B F

Insert the mounting bolts in the pump. (1) 5P CONNECTOR

Place the pump base in its position as shown.
Insert the fast connector in the pump (page 3-4).
Tighten the pump mounting bolts in alphabetical order as
shown in the image. Connect the fuel pump’s 5P connector.

Torque: 7 - 9 N•m (0.7 - 0.9 kgf•m, 5.1 - 6.6 lbf•ft)

3-12
 Engine servicing

1
2

(1) INJECTOR (1) INJECTOR (1) BOLTS/NUTS

(2) NEW O-RING (2) AIR CLEANER HOUSING

Injector Removal/Installation Throttle Body

Inspection Do not remove the injector from the injector holder. Removal
Replace the injector and holder as an assembly.
Remove the seat, front covers, side covers and the seat- Remove the seat, front covers, side covers and the seat-
rear fender assy. Always replace the O-ring when the fuel injector assembly rear fender assy.
is removed from the cylinder head.
Start the engine and let it idle. Loosen the connecting tube band screw.
Confirm the injector operating sounds with a sounding rod Remove the silencer mounting bolt.
or stethoscope. Remove the air cleaner housing mounting nuts and bolt.

If the injector does not operate, replace the injector. Pull the air cleaner housing backward being careful not to
damage the wire harness.
Disconnect the crankcase breather hose from the housing
joint.

3-13
Engine servicing

2 1 2 4 3
3

4 2

3 1
1

(1) 32P (BLACK) CONNECTOR (1) LOCK NUT (2) THROTTLE CABLE (1) THROTTLE CABLE END (2) THROTTLE DRUM
(2) BAND SCREW (3) THROTTLE CABLE END (4) THROTTLE DRUM (3) THROTTLE CABLE (4) LOCK NUT
(3) THROTTLE BODY

3
2 1

1 1 1 2 2

(1) SCREWS (1) SCREW (1) THROTTLE DRUM COVER

(2) THROTTLE DRUM COVER (2) INSULATOR (2) SCREWS
(3) ALIGN
Disconnect the ECM 32P (Black) connector. Connect the throttle cable end to the throttle drum.
Loosen the insulator band screw, then remove the throttle Loosen the lock nut, then disconnect the throttle cable Install the throttle cable to the throttle body.
body. from the throttle body. Adjust the throttle grip free play.
Then disconnect the cable end from the throttle drum.
Be careful to not pull connector from throttle body, pull Install the throttle drum cover and tighten the screws.
up fixation handle. Loosen the insulator clamp screw, then remove the
insulator from the throttle body.
Remove the screws and throttle drum cover.
Installation
Install the insulator onto the throttle body while aligning
its slit with the lug on the throttle body as shown.

3-14
 Engine servicing

2
1

2
1

2
3

(1) THROTTLE BODY (1) AIR CLEANER HOUSING (1) BOLTS

(2) BAND SCREW (2) BOLTS/NUTS (2) WATER PUMP COVER
(3) 32P (BLACK) CONNECTOR
Install the throttle body together with insulator at cylinder Install the air cleaner housing onto the frame and connect
head inlet port. the crankcase breather hose.
Make sure there are following clearance between the 4
throttle body: Install and tighten the air cleaner housing mounting nuts
– Throttle body-to-bank angle sensor: more than 5 mm and bolt securely.
– Throttle body-to-silencer: more than 5 mm Install the washer and silencer mounting bolt, then tighten
the bolt securely. 3
Adjust the insulator band angle, tighten the band screw 1
securely. Adjust the angle of the connector tube clamp and tighten
the screw firmly.
Connect the ECM 32P (Black) connector.
Install the seat-rear fender assy, side covers, front covers
and the seat. 2
(1) IMPELLER
(2) COPPER WASHER
(3) WATER PUMP SHAFT
(4) WASHER

Water Seal And Bearing Replacement

Drain the transmission oil (page 2-8).

Remove the following:

– Water pump cover bolt/cover/dowel pins/O-ring
– Right crankcase cover and washer (page 3-40)

Hold the water pump gear teeth using a suitable tool,

then remove the impeller, copper washer and water pump
shaft.

3-15
Engine servicing

1
2
1
2
4

1
3

(1) BEARING REMOVER, 12 MM (1) WATER SEAL DRIVER (1) WASHER

(2) DRIVER/ATTACHMENT (2) WATER PUMP SHAFT
(3) NEW COPPER WASHER
(4) IMPELLER
Remove the water pump bearing from the right crankcase
cover using the special tools. 1 Install the water pump shaft, new copper washer and
impeller into the right crankcase cover.
Tools: Hold the water pump gear using a suitable tool and tighten
Bearing remover, 12 mm 07936-1660101 the impeller to the specified torque.
– Remover shaft 07936-1660120 2
– Remover weight 07741-0010201 Torque: 12 N•m (1.2 kgf•m, 9 lbf•ft)
Remove the oil seal and water seal. Install the washer and right crankcase cover (page 3-41).

(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:
Water seal driver 07945-KA30000

Install a new oil seal in the direction shown in the

illustration above.
Drive the new bearing into the right crankcase cover
(Tools; page 1-7).

3-16
 Engine servicing

1 1 4
2
1

2 2
3
1

(1) DOWEL PINS (1) 2P (NATURAL) CONNECTOR (1) GROUND EYELET

(2) NEW O-RING (2) BOLTS
(3) WATER PUMP COVER (3) IGNITION COIL
(4) WIRE CLAMP
1
1

(1) WATER PUMP COVER (1) TIE WRAP (1) 3P (GRAY) CONNECTOR
(2) BOLTS
Radiator Removal/Installation Remove the ground eyelet bolt.
Install the following: Remove the ignition coil mounting bolt.
– Dowel pins, new O-ring Remove the following:
– Water pump cover, bolts Remove the spark plug wire/wire harness/breather hose
– Exhaust pipe clamp.
Fill the crankcase with recommended transmission oil – Skid plate
(page 2-8). – Fuel tank/injector assembly (page 3-7) Disconnect the ECT sensor 3P (Gray) connector.
Fill the coolant and bleed air (page 2-9).
Disconnect the radiator 2P (Natural) connector.

Remove the spark plug wire tie-wrap from fan motor

shroud.

3-17
Engine servicing

4
5 3
2
1 6 1
1
3
1
4 2 2

2 4 3 4

(1) RADIATOR HOSES (1) IGNITION COIL (1) RADIATOR

(2) HANGER BOLT (2) BOLTS (2) EXHAUST PIPE
(3) DOWN TUBE BOLTS (3) GROUND EYELET (3) MUFFLER
(4) DOWN TUBES (4) WIRE CLAMP (4) SKID PLATE
(5) BOLT
(6) RADIATOR
Engine Removal/Installation
Disconnect the radiator hoses at the right crankcase cover Installation is in the reverse order of removal.
and cylinder head.  Support the motorcycle securely using a hoist or
Remove the front engine hanger bolt and front down tube equivalent.
mounting bolts, then remove the down tubes. NOTICE  The following parts must be removed before engine
Remove the radiator mounting bolt, then remove the removal.
radiator assembly. At ignition coil installation, install the ground eyelet with – Exhaust pipe, muffler
the ignition coil lower mounting bracket bolt as shown in – Skid plate
the illustration. – Down tubes, radiator (page 3-17)
– Air cleaner housing (page 3-13)
 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

3-18
 Engine servicing
Engine Removal/Installation Illustration

24 N•m
(2,4 kgf•m)

26 N•m
24 N•m (2,6 kgf•m)
(2,4 kgf•m)

26 N•m
(2,6 kgf•m)

69 N•m
39 N•m
(6,9 kgf•m)
(4,0 kgf•m)

50 N•m
(5,1 kgf•m)

26 N•m (2,7 kgf•m)

26 N•m (2,7 kgf•m)

3-19
Engine servicing

2 1
1

(1) CYLINDER COMPRESSION GAUGE (1) SEALING BOLT/WASHER (1) TIMING HOLE CAP
(2) STOPPER TOOL

Cylinder Compression
2
Warm up the engine to normal operating temperature.
Stop the engine and remove the spark plug.
Install a compression gauge.
Shift the transmission into neutral.
Open the throttle all the way and crank the engine with
the kickstarter until the gauge reading stops rising.

Compression pressure:
1300 kPa (13,3 kgf/cm2, 189 psi)
1
Low compression can be caused by:
– Blown cylinder head gasket
– Improper valve adjustment (1) CAM CHAIN TENSIONER LIFTER (1) “T” MARK
– Valve leakage (2) INDEX MARK
– Worn piston ring or cylinder
Cylinder Head Cover/Camshaft Removal Remove the fuel tank/injector.
High compression can be caused by: Remove the cam chain tensioner lifter sealing bolt and
– Incorrect valves adjustment sealing washer. Remove the timing hole cap and O-ring from the left
crankcase cover.
Turn the tensioner lifter clockwise fully and secure it with
the stopper tool. Turn the crankshaft by operating the kickstarter and align
This tool can be easily be made from a thin (1 mm thick) the “T” mark on the flywheel with the index mark on the
piece of steel as shown. left crankcase cover.

3-20
 Engine servicing

3
2 2
2 1
1

3
1

1 1 4

(1) BOLTS (1) BOLTS/SEALING WASHERS (2) SH BOLTS (1) CAM CHAIN
(2) TAPPET ADJUSTING HOLE COVER (3) SEALING WASHERS (4) CYLINDER HEAD COVER (2) CAMSHAFT

Remove the bolts and tappet adjusting hole covers. Remove the cam chain from the cam sprocket and
suspend the cam chain with a piece of wire to prevent it
Make sure the piston at TDC (Top Dead Center) on the 2 from falling into the crankcase.
compression stroke by moving the rocker arms.
Remove the camshaft assembly.
1

(1) SIDE CAP

(2) DOWEL PINS

Disconnect the crankcase breather hose.

Remove the two 6 mm bolts.
Loosen the eight cylinder head cover SH bolts in crisscross
pattern in 2 or 3 steps.
Remove the bolts and four sealing washers.
Remove the cylinder head cover assembly.

Remove the dowel pins.

Remove the cylinder head side cap.
Remove the camshaft bearing retainer from the cylinder
head cover.

3-21
Engine servicing

3
1
2
1
2

1
1

4
2

(1) INTAKE ROCKER ARM SHAFT (1) BEARINGS (1) ROCKER ARM
(2) EXHAUST ROCKER ARM SHAFT (2) CAMSHAFT (2) ROCKER ARM SHAFT
(3) INTAKE ROCKER ARM
(4) EXHAUST ROCKER ARM
Check the rocker arms and shafts for wear or damage.
2 Measure the rocker arm I.D.
Disassembly
1
Service limit: 10.051 mm (0.3957 in)
Pull out the rocker arm shafts using a suitable 6 mm bolt
and remove the intake and exhaust rocker arms.
Measure the rocker arm shaft O.D. at rocker arm sliding
portion.

Service limit: 9.925 mm (0.3907 in)

(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.

3-22
 Engine servicing

1
2 1 2

2 2
3
1
1

(1) RADIATOR HOSE (1) BOLTS (1) GASKET

(2) HANGER BOLTS (2) NUTS/WASHERS (2) DOWEL PINS
(3) CYLINDER HEAD

Cylinder Head Removal Remove the cylinder head mounting bolts.

Loosen the cylinder head mounting nuts in a crisscross
pattern in two or three steps. 1
Remove the following:
– Exhaust pipe Remove the nuts, washers and cylinder head.
– 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) CAM CHAIN GUIDE

Remove the gasket and dowel pins.

Remove the cam chain guide.

3-23
Engine servicing

3 2

4
2 1
2
1

(1) BOLTS (1) CAM CHAIN TENSIONER (1) WASHER (2) PIVOT COLLAR
(2) CAM CHAIN GUIDE PLATE (2) CAM CHAIN GUIDE (3) CAM CHAIN TENSIONER
(4) PIVOT BOLT (5) APPLY LOCKING AGENT
Inspection

2 Inspect the cam chain tensioner and cam chain guide for 1
excessive wear or damage, replace if necessary.

1 2

(1) BOLT (1) CAM CHAIN TENSIONER

(2) CAM CHAIN TENSIONER (2) PIVOT BOLT

Remove the following: Installation

– Cylinder head (page 3-23)
– Left crankcase cover (page 3-49) Apply a locking agent to the cam chain tensioner pivot
– Flywheel (page 3-52) bolt threads.
Install the washer, cam chain tensioner, pivot collar and
Remove the bolts and cam chain guide plate. pivot bolt.
Tighten the pivot bolt to the specified torque.
Remove the bolt, cam chain tensioner, pivot collar and
washer. Torque: 12 N•m (1.2 kgf•m, 9 lbf•ft)

3-24
 Engine servicing

1 1 2
1
2 4
2
3

2 1

5
2 6

(1) CAM CHAIN GUIDE (1) VALVE SPRING COMPRESSOR (1) RETAINER
(2) ALIGN (2) ATTACHMENT (2) OUTER SPRING
(3) INNER SPRING
(4) SPRING SEAT
Cylinder Head Disassembly (5) VALVE
(6) STEM SEAL
Remove the cylinder head (page 3-23).
Remove the following:
Remove the valve spring cotters using the special tools. – Spring retainer
To prevent loss of tension, do not compress the valve – Outer and inner valve springs
springs more than necessary to remove the cotters. – Stem seal
– Valve spring seat
Tools: – Intake and exhaust valve
Valve spring compressor 07757-0010000
Compressor attachment 07959-KM30101
1
2

(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 3-53)
– Left crankcase cover (page 3-50)
– Cylinder head (page 3-37)

3-25
Engine servicing

1 2 1
1

(1) COMBUSTION CHAMBER (1) OUTER VALVE SPRING (1) VALVE

(2) INNER VALVE SPRING

Cylinder Head Inspection Valve spring Valve/Valve Guide

Cylinder Head Check the valve springs for fatigue or damage. Inspect each valve for out-of-round, burns, scratches or
Measure the free length of the intake and exhaust valve abnormal stem wear.
Remove the carbon deposits from the combustion springs.
chamber or exhaust port. Check the valve movement in the guide.
Use care not to scratch the combustion chamber or the Service limits: Measure and record the valve stem O.D.
head gasket surface. Inner: 24.9 mm (0.98 in)
Outer: 27.6 mm (1.09 in) Service limits:
Check the spark plug hole and valve area for cranks. IN: 4.470 mm (0.1760 in)
EX: 4.460 mm (0.1756 in)
Check the cylinder head for warpage with a straight edge
and feeler gauge.

Service limit: 0.05 mm (0.002 in)

3-26
 Engine servicing

1
1

(1) VALVE GUIDE REAMER (1) VALVE GUIDE DRIVER

Ream the valve guide to remove any carbon build-up Measure and record the valve guide I.D. using a ball gauge Valve Guide Replacement
before measuring the guide. or inside micrometer.
Insert the reamer from the combustion chamber side of Mark new valve guides at the proper depth (see
the head and always rotate the reamer clockwise. Service limit: specification; page 1-1) using a marker.
IN/EX: 4.552 mm (0.1792 in) Chill the new valve guides in a freezer for about 1 hour.
Tool: Heat the cylinder head to 100 – 150 ˚C (212 – 300 ˚F)
Valve guide reamer, 4.508 mm 07HMH–ML00101 Subtract each valve stem O.D. from the corresponding with a hot plate or oven.
guide I.D. to obtain the stem-to-guide clearance. Do not heat the cylinder head beyond 180 ˚C (320 ˚F).
Use temperature indicator sticks, available from welding
Standard: supply stores, to be sure the cylinder head is heated to
IN: 0.010 – 0.037 mm (0.0004 – 0.0015 in) the proper temperature.
EX: 0.020 – 0.047 mm (0.0008 – 0.0019 in) Use a torch to heat the cylinder head may cause warpage.
If the stem-to-guide clearance exceeds the service limits, Support the cylinder head and drive the valve guides out
determine if a new guide with standard dimensions would of the cylinder head from the combustion chamber side.
bring the clearance within tolerance.
If so, replace the guides as necessary and ream to fit. Tool:
Reface the valve seats whenever the valve guides are Valve guide driver 07HMD–ML00101
replaced (page 3-28).

If the stem-to-guide clearance exceeds the service limits

with new guides also, replace the valves and guides.

3-27
Engine servicing

(1) VALVE GUIDE DRIVER (1) VALVE SEAT WIDTH

Remove the guide from the freezer. Check that the valve guides are at the proper depth using Valve Seat Inspection/Refacing
While the cylinder head is still heated, drive new valve a slide caliper, adjust the height if necessary.
guides into the cylinder head from the top of the cylinder Clean the intake and exhaust valves thoroughly to remove
(camshaft side). Specified depth: carbon deposits.
Drive the guides until the marks are parallel with the IN: 8.0 – 8.3 mm (0.31 – 0.33 in) Apply a light coating of Prussian Blue to the valve seat.
cylinder head. EX: 8.2 – 8.5 mm (0.32 – 0.33 in)
Tap the valves and seats using a rubber hose or other
Tool: Let the cylinder head cool to room temperature. hand lapping tool.
Valve guide driver 07HMD–ML00101
Ream the new valve guides. Remove the valve and inspect the valve seat face.
Insert the reamer from the combustion chamber side of The valve seat contact should be within the specified
the cylinder head and always rotate the reamer clockwise. width and even all around the circumference.
Use cutting oil on the reamer during this operation.
Take care not to tilt or lean the reamer in the guide while Standard:
reaming. IN/EX: 0.9 – 1.1 mm (0.035 – 0.043 in)
Tool: Service limit:
Valve guide reamer, 4.508 mm 07HMH–ML00101 IN/EX: 1.7 mm (0.07 in)
Clean the cylinder head thoroughly to remove any metal If the seat width is not within specification, reface the
particles after reaming and reface the valve seats. valve seat (page 3-29).

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.

3-28
 Engine servicing

45º

60º 32º

32º

(1) ROUGHNESS

 Contact area (too high or too low) Valve Seat Refacing

– Reface the valve seat.
Valve seat cutters.grinders or equivalent valve seat
The valves cannot be ground, If a valve face is burned refacing equipment are recommended to correct worn
or badly worn or if it contacts the seat unevenly, replace valve seat.
the valve. Follow the refacing manufacturer’s instructions.

60º

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.

3-29
Engine servicing

32º

45º 60º

(1) SEAT WIDTH

Use a 45˚ cutter, remove any roughness or irregularities Use a 32˚ flat cutter, remove 1/4 of the existing valve Use a interior cutter, remove 1/4 of the existing valve
from the seat. seat material. seat material.
Reface the seat with a 45˚ cutter whenever a valve guide
is replaced. Tools: Tools:
Flat cutter, 25 mm 07780-0012000 Interior cutter, 26 mm 07780-0014500
Tools: Flat cutter, 21.5 mm 07780-0012800 Interior cutter, 22 mm 07780-0014202
Seat cutter, 24.5 mm 07780-0010100 Cutter holder, 4.5 mm 07781-0010600 Cutter holder, 4.5 mm 07781-0010600
Seat cutter, 22 mm 07780-0010701 or equivalent commercially available or equivalent commercially available
Cutter holder, 4.5 mm 07781-0010600
or equivalent commercially available

3-30
 Engine servicing

5 1

3
45º
2

(1) SPRING SEAT

(2) STEM SEAL
(3) VALVE
(4) INNER SPRING
Using a 45˚ seat cutter, cut the seat to proper width. Install the valve springs with the tightly wound coils
(5) OUTER SPRING
Make sure all pitting and irregularities are removed. facing the combustion chamber.
(6) RETAINER
Refinish if necessary. Install the spring retainers.

After refacing, wash the cylinder head and valves.

Cylinder Head Assembly
After cutting the seats, apply lapping compound to the
Blow out all oil passages in the cylinder head with
valve face, and lap the valve using light pressure.
compressed air.
After lapping, wash any residual compound off the
Install the spring seat and new stem seal.
cylinder head and valve.
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.

3-31
Engine servicing

1 2 3
1

1
(1) VALVE SPRING COMPRESSOR (1) PLASTIC HAMMERS (1) BOLTS
(2) ATTACHMENT (2) CAM CHAIN TENSIONER LIFTER
(3) GASKET
Compress the valve springs with the special tools and Tap the valve stems gently with two plastic hammers as Cylinder/Piston
install the cotters. shown to seat the cotters firmly.
Grease the cotters to ease installation. Support the cylinder head so the valve heads do not Cylinder Removal
contact anything that may damage them.
Tools: Remove the cylinder head (page 3-23).
Valve spring compressor 07757-0010000
Compressor attachment 07959-KM30101 Remove the bolts, cam chain tensioner lifter and gasket.
To prevent loss of tension, do not compress the valve
springs more than necessary.

3-32
 Engine servicing

2
1 1

(1) SEALING BOLT/SEALING WASHER (1) PISTON PIN CLIP

(2) CYLINDER (2) PISTON PIN

Piston Removal Spread the piston rings and remove them by lifting up at
2 2 a point just opposite the gap.
Place a clean shop towel over the crankcase to prevent
the clip from falling the crankcase. Piston rings are easily broken; take care not to damage
Remove the piston pin clips with pliers. them during removal.

1 Press the piston pin out of the piston and remove the
piston.

(1) GASKET
(2) DOWEL PINS

Remove the mounting sealing bolt, sealing washer and

cylinder.

Remove the gasket and dowel pins.

3-33
Engine servicing

Inspection Piston/Piston Ring Temporarily install the piston rings to their proper position
Remove the carbon deposits from the piston head or with the mark facing up.
Cylinder piston ring grooves using old piston rings. Measure the piston ring groove clearance with the rings
Inspect the cylinder bore for wear or damage. Inspect the piston for damage and the ring grooves for pushed into the grooves.
Measure the cylinder I.D. in the X and Y axis at three wear.
levels. Service limit:
Take the maximum reading to determine the cylinder Top: 0.15 mm (0.0059 in)
wear.
Inspect the piston ring grooves for wear or damage.
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)

3-34
 Engine servicing

Measure the O.D. of the piston at 3.5 mm (0,1378 in) Insert each piston ring into the cylinder and measure the Connecting Rod
from bottom of skirt and 90 degrees to the piston pin ring end gap. Measure the connecting rod small end I.D.
hole. Push the ring into the cylinder with the top of the piston
to be sure the ring is squarely in the cylinder. Service limit: 16.04 mm (0.631 in)
Service limit: 77,89 mm (3,066 in)
Service limit: If the I.D. is not over the service limit, replace the piston
If the O.D. is under the service limit, replace the piston Top: 0.390 mm (0,015 in) pin.
with a new one. Oil (side rail): 0.90 mm (0.035 in) If the I.D. is over the service limit, replace the crankshaft
(page 3-54).
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)

3-35
Engine servicing

1 1
1
2 3
4
3

2 3

(1) TENSIONER LIFTER (1) TOP RING (1) “IN” MARK

(2) SECOND RING (2) PISTON PIN
(3) OIL RINGS (3) NEW PISTON PIN CLIP
(4) SPACER
Tensioner lifter
Check the tensioner lifter operation as follows: Piston Installation
Piston Ring Installation
– The tensioner shaft should not go into the body when
it is pushed. Place a shop towel over the cylinder opening to prevent
Clean the piston ring grooves thoroughly.
– When it is turned clockwise with a screwdriver, the dust or dirt from entering the engine.
Apply engine oil to the piston rings and piston ring
tensioner shaft should be pulled into the body. The Clean any gasket material from the cylinder mating
grooves.
shaft should spring out of the body as soon as the surfaces of the crankcase.
Install the piston ring into the grooves with their marking
screwdriver is released. Apply molybdenum oil solution to the connecting rod
facing up.
small end.
 Do not damage the piston ring by spreading the ends
Place a shop towel around the piston skirt and in the
too far.
crankcase to prevent the piston pin clips from falling into
 Be careful not to damage the piston during piston ring
the crankcase.
installation.
 Do not align the oil ring (side rail) gaps.
Apply engine oil to the piston pin outer surface and piston
 Space the piston ring end 120 degrees apart.
pin bore of the piston.
After installation, the rings should rotate freely in the ring
Install the piston with the arrow facing intake side.
grooves.
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.

3-36
 Engine servicing

2 2 2
1

1 2
1

(1) DOWEL PINS (1) CYLINDER (1) DOWEL PINS

(2) NEW GASKET (2) NEW SEALING BOLT/SEALING WASHER (2) NEW GASKET

Apply locking agent to the cylinder mounting sealing bolt

1 threads. 2 1
Install the cylinder mounting sealing bolt with a new
sealing washer but do not tighten it yet.

3
1

(1) CYLINDER (1) CYLINDER HEAD

(2) WASHERS/NUTS
(3) BOLTS
Cylinder Installation
Cylinder Head Installation
Install the dowel pins and new gasket.
Install the dowel pins and new gasket.
Coat the cylinder bore, piston and piston rings with clean Install the cylinder head onto the cylinder.
engine oil and install the cylinder while compressing the Apply oil to the cylinder head mounting nut threads and
piston rings being careful not to damage the rings. 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)

3-37
Engine servicing

1 2
2
1

1
2

(1) CYLINDER HEAD BOLTS (1) HANGER BOLT (1) “T” MARK
(2) CYLINDER SEALING BOLT (2) RADIATOR HOSE (2) INDEX MARK

Tighten the cylinder sealing bolt and cylinder head Install the upper engine hanger bolt, tighten the bolt to Camshaft/Cylinder Head Cover Installation
mounting bolts securely. the specified torque.
Camshaft Installation
Torque: 24 N•m (2.4 kgf•m, 17 lbf•ft)
Turn the crankshaft by operating the kickstarter, align the
Connect the radiator hose to the water joint, tighten the “T” mark on the flywheel with the index mark on the left
clamp screw securely. crankcase cover.
Install the following:
– Camshaft
– Cylinder head cover
– Throttle body/insulator
– Exhaust pipe

Pour recommended coolant mixture and bleed air.

3-38
 Engine servicing

1 4
2
3 5

1 1
2
1

2
1
(1) BEARINGS (1) NEW O-RINGS (1) APPLY SEALANT
(2) GROOVE (2) INTAKE ROCKER ARM SHAFT (2) BEARING RETAINER
(3) INTAKE ROCKER ARM
(4) EXHAUST ROCKER ARM
(5) EXHAUST ROCKER ARM SHAFT
1
2 Cylinder Head Cover Assembly 2

Apply molybdenum oil solution to the rocker arm I.D. and

rocker arm shaft sliding surface.
2
Install new O-ring to each rocker arm shaft groove.

Place the intake rocker and exhaust rocker arm into the
cylinder head cover.
The intake rocker arm is identified with groove on the end
of the shaft.
3 3 1
Install the intake and exhaust rocker arm shafts with their
(1) CAM SPROCKET cut-out facing in and the shaft end oil hole facing up as (1) CAMSHAFT END CAP
(2) CAM CHAIN shown. (2) DOWEL PINS
(3) INDEX MARKS
Cylinder Head Cover Installation
Apply molybdenum oil solution to the camshaft cam
surface. Apply sealant to the mating surface of the cylinder head
Install the bearings both ends of the camshaft. cover.
Install the left camshaft bearing with its groove side Install the camshaft bearing retainer into the cylinder head
facing out. cover inner groove.

Install the cam chain onto the cam sprocket, then install Install the camshaft end cap.
the camshaft onto the cylinder head while aligning the
index marks on the cam sprocket with the upper surface
of the cylinder head.

3-39
Engine servicing

3 2
1
4
2

3 1
2
2
5
1 4
3

(1) CYLINDER HEAD COVER (1) TAPPET ADJUSTING HOLE CAP (2) O-RING (1) RADIATOR HOSE
(2) NEW SEALING WASHERS/6 MM BOLTS (2) KICKSTARTER PEDAL
(3) NEW SEALING WASHERS (3) BOLTS
(4) SH BOLTS (4) CLUTCH COVER
(5) RIGHT CRANKCASE COVER
Install the cylinder head cover. 1
Install new sealing washers and 6 mm bolts. 2 Right Crankcase Cover
Install the two new sealing washers and cylinder head
cover SH bolts. Removal

Tighten the cylinder head cover bolts securely. Remove the water pump cover (page 3-15).

Remove the bolt and kickstarter pedal.

Squeeze the clutch lever and secure the lever to prevent

3 3 the clutch slave piston comes out from the clutch cover.

Disconnect the lower radiator hose.

(1) “UP” MARK Remove the bolts, clutch cover, right crankcase cover,
(2) TAPPET ADJUSTING HOLE CAP gasket and dowel pins.
(3) BOLTS

Check the valve clearance (page 2-4).

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.

3-40
 Engine servicing

1 6 1

1 5
2

2
3
2 2
4 1

(1) DOWEL PINS (1) RIGHT CRANKCASE COVER (1) OIL BOLT
(2) NEW GASKET (2) CLUTCH COVER (2) SEALING WASHERS
(3) WATER PUMP COVER
(4) BOLTS
Installation (5) RADIATOR HOSE
(6) KICKSTARTER PEDAL
Install two dowel pins and new gasket onto the crankcase.
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 3-15).

Tighten the right crankcase cover bolts in a crisscross 2

pattern in 2 – 3 steps. 1
Install the kickstarter pedal and tighten the bolt to the
specified torque. (1) BOLTS
(2) CLUTCH COVER
Torque: 37 N•m (3.8 kgf•m, 27.4 lbf•ft)
Clutch Slave Cylinder
Connect the lower radiator hose.
Fill the crankcase with recommended transmission oil Drain the clutch fluid from the clutch hydraulic system.
(page 2-8).
Fill the coolant and bleed air. Remove the oil bolt, sealing washers and clutch hose
eyelet.

Remove the bolts, clutch cover and O-ring.

Remove the dowel pins.

3-41
Engine servicing

3 4 2
2

2 1

1
2

1
2
1
3
(1) SLAVE CYLINDER PISTON (1) O-RING (1) SEALING WASHERS
(2) SPRING (2) DOWEL PINS (2) OIL BOLT
(3) O-RING (BLACK) (3) CLUTCH COVER
(4) O-RING (GREEN)
Install the clutch hose eyelet with new sealing washers.
Install and tighten the oil bolt..
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
Fill the clutch system with recommended brake fluid and
the inlet.
bleed air.
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. 1
Check the slave cylinder piston for scratches, scoring or 2
other damage.
Check the piston spring for weakness or damage. (1) CLUTCH COVER
(2) BOLTS
Clean slave cylinder O-ring grooves with clean brake fluid.
Install new O-ring into the clutch cover groove.
Apply silicone grease to the O-rings. Install the dowel pins onto the right crankcase cover.
Install 23 x 2.1 mm O-ring (Black) into the spring side Install the clutch cover onto the right crankcase cover.
groove.
Install 21.8 x 2.4 mm O-ring (Green) into the lifter plate Install and tighten the clutch cover bolts.
side groove.
Do not interchange the O-rings.

Install the return spring and piston into the slave cylinder
in the clutch cover.

3-42
 Engine servicing

4 1 5
2
1

3
1 4
2 2 3

(1) CLUTCH LIFTER PIECE ASSEMBLY (1) CLUTCH CENTER HOLDER (1) CLUTCH CENTER (2) CLUTCH DISCS
(2) LIFTER PLATE BOLTS (3) CLUTCH PLATE (4) PRESSURE PLATE
(3) LIFTER PLATE (5) PAPER DISCS
(4) CLUTCH SPRINGS
1 2
Clutch 3 4

Removal 2

Pull the clutch lever and hold it with a suitable clamp. 1

Remove the bolts and clutch cover without disconnecting

the clutch fluid line.

Remove the clutch lifter piece assembly. 3

Remove the following:
– Clutch lifter plate bolts
– Lifter plate (1) LOCK WASHER (1) THRUST WASHER
– Clutch springs (2) PLAIN WASHER (2) CLUTCH OUTER
– Spring base washers (3) SPRING BASE WASHER (3) NEEDLE BEARING
(4) CLUTCH OUTER GUIDE
Hold the clutch assembly with the clutch center holder
and remove the clutch center nut. Remove the following:
– Clutch center
Tool: – Six clutch discs
Clutch center holder 07JMB-MN50301 – Five clutch plates
– Clutch pressure plate
Remove the lock washer, flat washer, springs and six
spring base washers. Remove the thrust washer, clutch outer, needle bearing
and clutch outer guide.

3-43
Engine servicing

2 1 1
2 1

4 3

(1) CLUTCH CENTER (1) LIFTER PIECE ASSEMBLY (1) OUTER GUIDE
(2) CLUTCH OUTER (2) NEEDLE BEARING
(3) OUTER GUIDE
(4) NEEDLE BEARING
4 2 1
Inspection
3
Check the following items (specifications; page 1-1).
 Clutch outer for wear, cracks or indentation by the 2
clutch discs.
 Clutch center grooves for damage, crack or indentation
by the clutch plates. 1
 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 (1) CIRCLIP (1) CLUTCH OUTER
 Mainshaft O.D. at clutch outer guide (2) THRUST WASHER (2) THRUST WASHER
(3) THRUST NEEDLE BEARING
(4) LIFTER PIECE Installation

Check the lifter piece needle bearing by turning the thrust Install the clutch outer guide and needle bearing onto the
washer with your finger. mainshaft.
If the bearing movement is not smooth, disassemble and
replace the bearing. Install the clutch outer and thrust washer.

Remove the circlip, thrust washer and thrust needle

bearing from the lifter piece.
Assemble the lifter piece in the reverse order of removal.

3-44
 Engine servicing

2 3 1
4
1
3

2
3 2
1 3

(1) PRESSURE PLATE (1) THRUST WASHER (1) CLUTCH SPRINGS

(2) CLUTCH CENTER (2) LOCK WASHER (“OUTSIDE” MARK IN FRONT) (2) LIFTER PLATE
(3) DOT MARKS (3) SPRING BASE WASHER (3) BOLTS
(4) LIFTER PIECE ASSEMBLY
1
1 Install spring base washers, 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 3-41).

(1) CLUTCH DISCS (1) CLUTCH CENTER HOLDER

(2) CLUTCH PLATE
Install the thrust washer onto the mainshaft.
Coat the clutch plates with clean transmission oil. Install the lock washer with its “OUT SIDE” mark facing
Install the clutch discs and plates alternately onto the out.
clutch center starting with the clutch disc Apply oil to the clutch center nut and install it.
Install the clutch pressure plate onto the clutch center Hold the clutch assembly with the clutch center holder
aligning the dot mark on the pressure plate with the dot and tighten the clutch center nut to the specified torque.
marks on the clutch center as shown.
Tool:
Install the clutch center assembly into the clutch outer. Clutch center holder 07JMB-MN50301

Torque: 69 N•m (7.0 kgf•m, 51 lbf•ft)

3-45
Engine servicing

3 2 1
4 4
6 2

5
2
3
1
1 3

(1) IDLE GEAR/THRUST WASHER (1) RATCHET SPRING (2) STARTER RATCHET (1) RETURN SPRING
(2) BOLT (3) PINION GEAR (4) SPINDLE (2) COLLAR
(3) STOPPER PLATE (5) RETURN SPRING (6) COLLAR (3) WASHER
(4) KICKSTARTER ASSEMBLY
3 Install the return spring with its end into the spindle hole.
Kickstarter 2
5 Install the collar aligning its groove with the return spring
end, then install the washer.
Removal/Disassembly
5
Remove the clutch (page 3-43)

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.
1 4 6
Disassemble the kickstarter.
(1) PINION GEAR (2) THRUST WASHER
Inspection (3) SNAP RING (4) STARTER RATCHET
(5) PUNCH MARKS (6) RATCHET SPRING
Check the following items (specification; page 1-2):
 Return spring and ratchet spring for wear or damage. Assembly/Installation
 Needle bearing for wear or damage.
 Pinion gear I.D. and spindle O.D. Assemble the kickstarter as shown in the illustration
 Idle gear I.D. and bushing O.D. and I.D. above.
 Countershaft O.D. at the idle gear bushing.
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.

3-46
 Engine servicing

2
1 2 3
1

1 2

(1) KICKSTARTER ASSEMBLY (1) STOPPER PLATE (1) GEARSHIFT SPINDLE

(2) SPRING HOOK (2) BOLT (2) BOLTS
(3) GUIDE PLATE
Install the kickstarter assembly and hook the starter Gearshift Linkage
ratchet with the stopper. 2
Install the return spring end into the crankcase hole as Removal
shown.
Remove the gearshift pedal.
1 Pull out the gearshift spindle from the crankcase.

Remove the guide plate bolts and guide plate as an

assembly.

Remove the center bolt and drum center.

Remove the bolts and stopper arm, return spring and
washer.

(1) THRUST WASHER

(2) IDLE GEAR

Install the kickstarter return spring stopper plate, and

tighten the bolt securely.

Install the thrust washer and idle gear onto the

countershaft.
Note the direction of the idle gear as shown in the
illustration.

3-47
Engine servicing

6 5 1

1 2 2
6

4
1
4 3 2 5
(1) DRUM SHIFTER (1) RETURN SPRING (1) SHIFT DRUM CENTER
(2) SPRING (2) WASHER (2) CENTER PIN
(3) PLUNGER (3) STOPPER ARM
(4) RATCHET PAWL A (4) DRUM CENTER
(5) RATCHET PAWL B (5) DOWEL PIN 2 4
(6) GUIDE PLATE (6) CUT-OUT 5

Inspection Install the return spring, plain washer and stopper arm 1
and tighten the stopper arm bolt to the specified torque.
Inspect each part for wear or damage and replace if
necessary. Torque: 12 N•m (1.2 kgf•m, 9 lbf•ft)

Installation Install the dowel pin into the shift drum.

Install the drum center by aligning the cut-out with the
Apply transmission oil to the ratchet pawls, springs and dowel pin on the shift drum while holding the stopper arm 3
plungers. with the screwdriver as shown.
3
Assemble the drum shifter, springs, plungers and ratchet
pawls in the guide plate as shown.
(1) GUIDE PLATE (2) “UP” MARK
(3) BOLTS (4) DRUM SHIFTER
NOTICE (5) SHIFTER COLLAR

Note the direction of the ratchet pawl A and B. 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.

3-48
 Engine servicing

1 2
3 4

1
2 3
2 1

(1) WASHER (2) GEARSHIFT SPINDLE (1) 3P (NATURAL) CONNECTOR (1) DRAIN BOLT/SEALING WASHER
(3) RETURN SPRING PIN (2) 2P (NATURAL) CONNECTOR (2) BOLTS
(4) SHIFTER COLLAR (3) LEFT CRANKCASE COVER

Left Crankcase Cover Remove the engine oil drain bolt and sealing washer, drain
the engine oil.
Removal Remove the bolts and left crankcase cover.

Remove the skid plate and drain engine oil.

NOTICE
Disconnect the alternator 3P (White) connector and
The left crankcase cover (stator) is magnetically attached
ignition pulse generator 2P (Natural) connectors.
to the flywheel, be careful during removal.
Remove the gearshift pedal.
Remove the left crankcase cover, gasket and dowel pins.

(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.

3-49
Engine servicing

2 1
4 1 2
1

3 4

5 1

(1) BOLTS (2) IGNITION PULSE GENERATOR (1) SNAP RING (2) WASHER (1) NEEDLE BEARING
(3) WIRE GUIDE (4) SOCKET BOLTS (3) OIL SEAL (4) NEEDLE BEARING
(5) STATOR
Press new needle bearing into the left crankcase cover
using the special tools.
1
Tools:
Driver 07749–0010000
Attachment, 22 x 24 mm 07746–0010800
Pilot, 15 mm 07746–0040300

(1) OIL PRESSURE RELIEF VALVE (1) BEARING REMOVER

Disassembly/Assembly Check the crankshaft oil seal and needle bearing for wear
or damage, replace them if necessary.
Remove the ignition pulse generator mounting flange Remove the snap ring and washer, then remove the oil
bolts and alternator wire clamp. seal.
Remove the stator mounting socket bolts.
Remove the stator/ignition pulse generator from the left Remove the needle bearing using the special tools.
crankcase cover.
Tools:
Remove the oil pressure relief valve (page 3-1). Bearing remover shaft, 15 mm 07936–KC10100
Bearing remover head, 15 mm 07936–KC10200
Remover weight 07741–0010201

3-50
 Engine servicing

2 6 5
3 2 4
5

1
1
3
2
1

(1) OIL SEAL (1) STATOR (1) OIL FILTER COVER

(2) WASHER (2) IGNITION PULSE GENERATOR (2) O-RING
(3) SNAP RING (3) WIRE CLAMP
(4) SOCKET BOLTS
Apply grease to the new oil seal lip and install it into the (5) BOLTS
left crankcase cover. (6) GROMMET
Install the washer and snap ring.
1
Install the stator and ignition pulse generator assembly
Install the oil pressure relief valve (page 3-1). 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 1

bolts.
Tighten the stator mounting bolts to the specified torque. 2

Torque: 5.4 N•m (0.55 kgf•m, 4.0 lbf•ft)

(1) DOWEL PINS
Tighten the ignition pulse generator mounting bolts to the (2) NEW GASKET
specified torque.
Installation
Torque: 5.4 N•m (0.55 kgf•m, 4.0 lbf•ft)
Check the oil filter cover O-ring is in groove condition,
Apply sealant to the stator/ignition pulse generator wire replace if necessary.
grommet and install it into the left crankcase cover groove.
Install dowel pins and new gasket.

3-51
Engine servicing

1
1 2
3

(1) LEFT CRANKCASE COVER (1) 3P (NATURAL) CONNECTOR

(2) BOLTS (2) 2P (NATURAL) CONNECTOR
(3) NEW SEALING WASHER/DRAIN BOLT
Install the left crankcase cover being careful not to Install the gearshift pedal. Flywheel
damage the oil filter cover O-ring.
Connect the alternator 3P (White) connector and ignition Removal
pulse generator 2P (Natural) connectors.
NOTICE Remove the left crankcase cover (page 3-49).
Pour recommended engine oil up to proper level.
The left crankcase cover (stator) is magnetically attached
Hold the flywheel with flywheel holder, loosen the
to the flywheel, be careful during installation. Install the slid plate. flywheel nut.
Install and tighten the bolts in a crisscross pattern in 2 or
Tool:
3 steps.
Flywheel holder 89020–NN4–003
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)

3-52
 Engine servicing

1
2 1

(1) FLYWHEEL PULLER (1) WASHER

(2) FLYWHEEL (2) FLYWHEEL NUT
(3) APPLY OIL
Install the flywheel onto the crankshaft. Hold the flywheel with flywheel holder, tighten the
Apply oil to the flywheel nut threads and seating surface. flywheel nut to the specified torque.
Install the washer and flywheel nut.
Tool:
Flywheel holder 89020–NN4–003
1
Torque: 167 N•m (17.0 kgf•m, 123 lbf•ft)

Install the left crankcase cover (page 3-50).

(1) WOODRUFF KEY

Remove the flywheel using the special tool.

Tool:
Flywheel puller 89010–NN4–003

Remove the woodruff key.

Installation

Install the woodruff key onto the crankshaft groove.

3-53
Engine servicing

1 2
1
1 2

4
3 3
2

(1) DRIVE SPROCKET (1) COUNTERSHAFT COLLAR (1) CLUTCH OUTER

(2) UNIVERSAL HOLDER (2) O-RING (2) GEAR HOLDER
(3) BOLT (3) PRIMARY DRIVE GEAR
(4) SPRING WASHER
Temporarily install the clutch outer guide, needle bearing
Crankcase Separation/Disassembly 1 and clutch outer onto the mainshaft and attach the gear
2 holder between the primary drive and driven gears.
Remove the engine from the frame. Remove the primary drive gear bolt.

Remove the following: Tool:

– Cylinder head, cylinder, piston Gear holder 07724-0010100
– Clutch
– Kickstarter Remove the washer, primary drive gear and drive gear
– Gearshift linkage collar.
– Flywheel and stator
– Oil filter
– Crankcase breather hose

Hold the drive sprocket with the universal holder and (1) OIL PUMP DRIVEN GEAR
remove the drive sprocket bolt, spring washer and drive (2) DRIVE PIN
sprocket.
Remove the countershaft collar and O-ring.

Remove the oil pump driven gear and drive pin.

3-54
 Engine servicing

2 3 4
2 1

2 1

2
1
1 3 2
(1) TRANSMISSION OIL DRAIN BOLT (1) GASKET (1) SHIFT FORK SHAFTS
(2) CRANKCASE BOLTS (2) DOWEL PINS (2) SHIFT FORKS
(3) ONE-WAY REED VALVE (3) MAINSHAFT
(4) COUNTERSHAFT
Remove the transmission oil drain bolt and sealing washer.
Loosen the crankcase bolts in a crisscross pattern in 2 or
3 steps.
2 Remove the following:
– Crankshaft
Remove the crankcase bolts. 3 – 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.

3-55
Engine servicing

8 mm 6 mm
B
A
C D
1

(1) RIGHT CRANKCASE

Crankshaft/Transmission Inspection 1
1
Measure the crankshaft runout. 5 2
Support the crankshaft at point “A” and “B”, and then
measure the runout at the points “C” and “D”.
3
Service limit: C: 0.05 mm (0.002 in)
D: 0.03 mm (0.001 in) 4
Measure the connecting rod big end side clearance and
big end axial/radial play (specification; page 1-3).

(1) RIGHT SHIFT FORK (1) LEFT CRANKCASE

(2) LEFT SHIFT FORK
(3) RIGHT/LEFT SHIFT FORK SHAFT
(4) CENTER SHIFT FORK/SHAFT Crankcase Bearing Replacement
(5) SHIFT DRUM
Remove the oil seals and bearing set plates.
Inspect each part for wear or damage. Drive out the bearing using the special tools (Tools; page
Check the following items (specifications; page 1-1). 1-7).
 Spinning gear I.D.
 Bushing I.D. and O.D. Install the new bearing as shown in the illustration using
 Mainshaft and countershaft O.D. the special tools.
 Shift fork I.D. and claw thickness
 Shift fork shaft O.D.
 Shift drum O.D.

3-56
 Engine servicing
Crankcase Bearings/Oil Seals Location

1 A 2 3 C B D 4 F E 5 6

10 G H 9 I J 8 7

(1) LEFT SHIFT DRUM BEARING A: 1 mm

(2) LEFT COUNTERSHAFT BEARING B: 0 ± 0.5 mm
(3) LEFT COUNTERSHAFT OIL SEAL C: 58.60 – 58.88 mm
(4) LEFT MAINSHAFT BEARING D: 58.30 – 58.52 mm
(5) LEFT CRANKSHAFT OIL SEAL E: 1 ± 0.5 mm
11 (6) LEFT CRANKSHAFT BEARING F: 27.60 – 27.82 mm
(7) RIGHT CRANKSHAFT BEARING G: 28.50 – 28.72 mm
(8) RIGHT CRANKSHAFT OIL SEAL H: 27.00 – 27.22 mm
(9) RIGHT MAINSHAFT BEARING I: 27.00 – 27.22 mm
(10) RIGHT COUNTERSHAFT BEARING J: 0 ± 0.5 mm
(11) RIGHT SHIFT DRUM BEARING

3-57
Engine servicing

Transmission Assembly

1 2 3 4 5

6 7 8 9 10 11

(1) M2 (17T)
(2) M4 (23T)
(3) M3 (18T)
(4) M5 (27T)
(5) MAINSHAFT/M1 (15T)
(6) C2 (33T)
(7) C4 (26T)
(8) C3 (27T)
(9) C5 (22T)
(10) C1 (31T)
(11) COUNTERSHAFT

3-58
 Engine servicing

1 2
3 2
3 1
3

5
1
6
(1) MAINSHAFT (1) OIL PUMP SHAFT (1) ONE-WAY REED VALVE
(2) COUNTERSHAFT (2) INNER ROTOR
(3) SHIFT FORK SHAFTS (3) OUTER ROTOR
(4) LEFT SHIFT FORK
(5) RIGHT SHIFT FORK
(6) CENTER SHIFT FORK 1

Crankcase Combination 1
Clean the crankcase mating surfaces before assembling 2
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. 2 1

Install the crankshaft into the right crankcase.

(1) DOWEL PINS (1) RIGHT CRANKCASE
Install the mainshaft and countershaft as an assembly (2) NEW GASKET (2) LEFT CRANKCASE
into the right crankcase.
Install the center shift fork with its identification mark Install the oil pump shaft, oil pump inner rotor and outer Install the one-way reed valve into the right crankcase.
facing in. rotors.
Install the right and left shift forks with their identification Place the left crankcase onto the right crankcase.
marks facing out. Install the dowel pins and new gasket.
Install the shift drum.
Install the shift forks.

3-59
Engine servicing

1 1
1

2 2

(1) CRANKCASE BOLTS (1) DRIVE GEAR COLLAR (1) CLUTCH OUTER
(2) NEW SEALING WASHER/OIL DRAIN BOLT (2) GEAR HOLDER

Install the crankcase bolts. Temporarily install the clutch outer guide, needle bearing
Tighten the crankcase bolts in a crisscross pattern in 2 – 3 1 and clutch outer onto the mainshaft and attach the gear
steps. holder between the primary drive and driven gears.
Install the transmission oil drain bolt with a new sealing
washer, and tighten it to the specified torque. 2 Tool:
Gear holder 07724-0010100
Torque: 22 N•m (2.2 kgf•m, 16 lbf•ft)
Tighten the primary drive gear bolt to the specified torque.
3
Torque: 108 N•m (11.0 kgf•m, 80 lbf•ft)

(1) PRIMARY DRIVE GEAR

(2) WASHER
(3) SPECIAL BOLT

Install the primary drive gear collar onto the crankshaft.

Install the primary drive gear with its groove side facing
out.
Apply oil to the primary drive gear special bolt threads and
seating surface.
Install the washer and special bolt.

3-60
 Engine servicing

2
1 1 2

3
4

(1) DRIVE PIN (1) DRIVE SPROCKET

(2) OIL PUMP DRIVEN GEAR (2) UNIVERSAL HOLDER
(3) SPRING WASHER
(4) BOLT

2 Install the drive sprocket.

Install the spring washer and drive sprocket bolt.
Hold the drive sprocket with universal holder, tighten the
special bolt to the specified torque.

Torque: 31 N•m (3.2 kgf•m, 23 lbf•ft)

Install the removed parts in the reverse order of removal.

(1) 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.

3-61
 Memo

3-62
 4. Frame servicing

2
1

(1) AXLE PINCH BOLT 5

(2) AXLE

Front Wheel a
Removal

Loosen the axle pinch bolt.

2 1
Support the motorcycle and front wheel off the ground.
Remove the axle and front wheel. 4 Drive the bearing 3 When unassembling change bolt for new one’s
into the hub until it Apply a locking agent to the threads
Do not depress the brake lever after the front wheel is
removed. stops. Torque: 18 N•m (1.8 kgf•m)
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. (1) BRAKE DISC Spokes: Check spoke tension frequently between the first
(2) COLLAR few rides. As the spokes, spoke nuts and rim contact
Discard contaminated pads and clean a contaminated (3) DISC BOLT points seat-in, the spokes may need to be retightened.
disc with a high quality brake degreasing agent. (4) LEFT WHEEL BEARING
(5) DISTANCE COLLAR Once past this initial seating-in period, the spokes should
(6) RIGHT WHEEL BEARING hold their tension. Still, be sure your race maintenance
program includes checking spoke tension and overall
(a) 25 ± 1 mm (1.0 ± 0,0394 in) wheel condition on a regular basis.

4-1
Frame servicing

1 2
4

1 3 1

(1) AXLE (1) AXLE PINCH BOLT (1) FRONT FENDER

(2) TOP BRIDGE
(3) BOTTOM BRIDGE
(4) FORK LEG
Installation While keeping the fork parallel, tighten the axle pinch bolt
to the specified torque.
Clean the surfaces where the axle and axle clamps
Fork
contact each other. Torque: 21 N•m (2.1 kgf•m, 17 lbf•ft)
Removal
Place the front wheel between the fork legs, while
inserting the brake disc between brake pads without Remove the front wheel (page 4-1).
damaging them.
Remove the front fender.
Apply thin layer of grease to the axle surface. Loosen the top bridge pinch bolt.
Apply grease to the axle threads. If the forks are to be disassembled, loosen the fork bolt.
Install the axle from the right side through the wheel.

Tighten the axle to the specified torque. NOTICE

Torque: 69 N•m (7.0 kgf•m, 51 lbf•ft) 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.

4-2
 Frame servicing

1 2
1
2

2
1

(1) FORK BOLT (1) LOCK NUT (1) FORK DAMPER

(2) FORK LEG (2) FORK BOLT (2) RIGHT FORK CENTER BOLT

Right Fork Disassembly Hold the axle holder in a vise protected with a piece of
woods or soft jaws to avoid damage.
Before disassembling the fork, clean the entire sliding sur- Do not overtighten.
face and the bottom of the fork slider.
Loosen the right fork center bolt.
Be careful not to scratch the fork tube. Remove the center bolt and sealing washer.
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 lock nut and remove the fork bolt from the dam-
per rod.
Do not remove the lock nut from the damper rod.

Pour out the fork fluid.

4-3
Frame servicing

4 3 2 1
3 2 1 2

3
1 5

(1) FORK DAMPER (1) DUST SEAL (1) FORK TUBE BUSHING
(2) CENTERING PLATE (2) STOP RING (2) GUIDE BUSHING
(3) FORK TUBE (3) FORK SLIDER (3) BACK-UP RING
(4) OIL SEAL
Remove the fork damper assembly and centering plate
(5) FORK SLIDER
from the fork tube.
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.
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.

4-4
 Frame servicing

2 4 3 2 1
1 1
4
3

(1) BUSHING (1) FORK DAMPER (1) FORK TUBE BUSHING

(2) DAMPER ROD (2) GUIDE BUSHING
(3) FORK TUBE (3) BACK-UP RING
(4) CENTERING PLATE (4) OIL SEAL
(5) FORK SLIDER

Right Fork Inspection Fork Damper Right Fork Assembly

Check the fork damper assembly for damage or
Check the following items (page 1-4): deformation. Clean the parts thoroughly with non-flammable or high
– Fork tube for score marks, scratches and excessive Check the damper rod for bend or other damage. flush point solvent before assembly.
wear
– Fork tube runout Fork tube/centering plate Install the following to the fork tube:
– Fork slider for damage or deformation Check the fork tube for bent or deformation. – Fork tube bushing
– Fork damper for damage Check the centering plate for damage. – Guide bushing
– Back-up ring
Bushing/Back-up Ring
Check the bushings for excessive wear or scratches. Coat the guide and fork tube bushings with recommended
Remove any metal powder inside the slider and guide fork fluid.
bushings with a nylon brush and fork fluid. Install the fork tube assembly into the slider.
If copper appears on the entire surface, replace the
bushing.

Replace the back-up ring if there is any distortion at the

points shown.

4-5
Frame servicing

5 1

4
1
3

(1) FORK SEAL DRIVER (1) GUIDE BUSHING (4) STOP RING (1) FORK DAMPER
(2) BUCK-UP RING (5) DUST SEAL (2) RIGHT FORK CENTER BOLT
(3) OIL SEAL
Using the special tool, drive the guide bushing and back- Hold the axle holder in a vise protected with a piece of
up ring until the stop ring groove is fully stuck in the fork woods or soft jaws to avoid damage.
slider base. 3 2 1 Do not overtighten the vise.
Install the oil seal (spring up) in the fork slider. Drive the
oil seal using the special tool, performing a constant pres- Install the right fork center bolt with a new sealing washer.
sure until stops in back-up ring.
Tighten the right fork center bolt to the specified torque.
Tool:
Fork seal driver 07947–4630100 Torque: 23,5-25,5 N•m (2,39-2,59 kgf•m)

(1) FORK DAMPER

(2) CENTERING PLATE
(3) FORK TUBE
Install the stop ring into the slider groove securely.
Install the dust seal.

Install the centering plate and fork damper into the fork
tube.

4-6
 Frame servicing

1
2

3
1

2 1

(1) FORK FLUID

(2) FORK TUBE

Pour recommended fork fluid in the fork leg. 2

Specified fork fluid: Tech OJ01 (SAE 5) 2

3
Bleed the air as follows:
1. Extend the fork without bringing to its maximum exten-
sion. Cover the top of the fork tube with your hand and
compress the fork slowly several times. 1

NOTICE
(1) FORK DAMPER ROD (1) LOCK NUT
Totally extended fork may cause oil leakage. (2) OIL LEVEL (2) NEW O-RING
(3) FORK BOLT
2. Pump the damper rod 8 - 10 times.
Install a new O-ring onto the fork bolt groove.
3. Make sure no air in fork damper by slowly pull the
Screw the fork bolt on the lock nut from the damper rod
damper rod up. If the resistance is felt at the top end,
until it seats.
pump the damper rod again.
Hold the lock nut and tighten the fork bolt to the specified
torque.
Wait 2 – 3 minutes before measuring the oil level.
Measure the oil level from top of the fork tube, with the
Torque: 14,7 N•m (1,49 kgf•m)
fork fully compresed.
Apply recommended fork fluid to the O-ring, then screw
Standard oil level: 60 mm (2.36 in)
the fork bolt into the fork tube.
Oil capacity (orientative): 385 cm3
(13.0 US oz)
Torque: 12,7 N•m (1,3 kgf•m)
(13.5 Imp oz)

4-7
Frame servicing

1 2
4
1 3 4
2
5

6 1

(1) FORK BOLT (1) CILINDER ASSY (1) FORK TUBE

(2) DISTANCE COLLAR (2) CENTER BOLT (2) CILINDER ASSY
(3) SPRING SEAT (3) TAPERED BUSHING
(4) FORK SPRING (4) FORK SLIDER
Hold the axle holder in a vise protected with a piece of
(5) TAPERED BUSHING
wood or soft jaws to avoid damage.
(6) FORK TUBE Remove the tapared bushing from the cilinder assy.
Do not overtighten.
Left Fork Disassembly
Hold the cylinder assembly using the special tool and
tighten the central screw to the specified torque.
NOTICE
Before disassembling the fork, clean the entire sliding
surface and the bottom of the fork slider. Be careful not to damage the tapared bushing.
Tool:
Fork damper holder 07930-KA50100 Remove the cilinder assy from the fork tube.
Be careful not to scratch the fork tube.
A scratched fork tube will damage the seal, causing an
Remove the center bolt and sealing washer. Remove the following items using the same procedure as
oil leak.
the right fork disassembly (page 4-2):
Remove the following items using the same procedure as – Oil seal
The fork bolt under spring pressure.
the right fork disassembly (page 4-2): – Back-up ring
Before removing the fork bolt, turn the pre-load adjuster
– Dust seal – Guide bushing
softest position.
– Stop ring – Fork tube bushing
Remove the fork bolt from the fork tube.
– Fork tube, unlocking guide bushing on the fork leg.
Remove the tapared bushing, distance collar, spring seat
and fork spring.
Pour out the fork fluid.

4-8
 Frame servicing

2 1 2
3 4 1

(1) CILINDER ASSY (1) FORK TUBE (1) CILINDER ASSY

(2) PISTON RING (2) CILINDER ASSY (2) CENTER BOLT
(3) REBOUND SPRING (3) TAPERED BUSHING
(4) TAPERED BUSHING (4) FORK SLIDER
Hold the axle holder in a vise protected with a piece of
wood or soft jaws to avoid damage.
Left Fork Inspection Left Fork Assembly
Do not overtighten the vise.
Check the following items (page 1-4): Clean the parts thoroughly with non-flammable or high
Install the center bolt with a new sealing washer.
– Inside fork slider for damage or deformation flush point solvent before assembly.
Hold the cylinder assembly using the special tool and
– Fork tube runout
tighten the center bolt to the specified torque.
– Fork spring free length Apply fork fluid to the piston ring.
– Fork tube for score marks, scratches and excessive Install the cilinder assy into the fork tube.
Tool:
wear Install the tapered bushing on the end of the cilinder assy.
Fork damper holder 07930-KA50100
– Bushing/back-up ring (page 4-5)
– Fork piston ring for wear or damage
– Tapared bushing for damage NOTICE Torque: 23,5-25,5 N•m (2,39-2,59 kgf•m)
– Rebound spring for fatigue or other damage
The tapered bushing is easy to scratched or deformed.
Take care not to damage it when assembling it.

4-9
Frame servicing

5 1
3
4
6
3
7 5
2
2

1
4

(1) GUIDE BUSHING (1) FORK SPRING

(2) BACK-UP RING (2) SPRING SEAT
(3) OIL SEAL (3) DISTANCE COLLAR
(4) STOP RING (4) O-RING (NEW)
Pour half the required amount of recommended fork fluid
(5) DUST SEAL (5) FORK BOLT
in the fork tube.
(6) TAPERED BUSHING
Install the following parts onto the fork tube using the (7) FORK TUBE
Specified fork fluid: Tech OJ 01 (SAE5)
same procedure as the right fork (page 4-5):
– Fork tube bushing Install the fork spring, spring seat, distance collar and the
Pump the fork tube slowly 8-10 times.
– Guide bushing tapered bushing.
Pour additional fluid to the specified capacity.
– Back-up ring
Apply recommended fork fluid to the new O-ring, then
Oil level: 125 mm (4.9 in)
Using the special tool, drive the guide bushing and back- screw the fork bolt into the fork tube.
Oil capacity (orientative): 375 cc
up ring until the stop ring groove is fully stuck in the fork
(12.7 US oz)
slider base. Torque: 12.7 N•m (1.3 kgf•m, 9.3 lbf•ft)
(13.2 Imp oz)
Install the oil seal (spring up) in the fork slider. Drive the
oil seal using the special tool, performing a constant pres-
sure until stops in back-up ring.

Tool:
Fork seal driver 07947–4630100

Install the stop ring into the slider groove securely.

Install the dust seal.

4-10
 Frame servicing

2
3 1
2
2

1 1

1
FORWARD

(1) FORK TUBE (1) BOTTOM BRIDGE PINCH BOLTS (1) STEM NUT
(2) TOP BRIDGE (2) FORK BOLT (2) TOP BRIDGE
(3) TOP BRIDGE PINCH BOLTS
Installation Tighten the bottom bridge pinch bolts to the specified Steering stem
torque.
Install the fork tube. Disassembly
Raise the fork through the bottom bridge and top bridge. Torque: 21 N•m (2.1 kgf•m, 14 lbf•ft)
Remove the following:
Place the fork tubes in the top clamp level as shown in Overtightening the pinch bolts can deform the outer tube. – Handlebar
the picture. Deformed outer tube must be replaced. – Front wheel (page 4-1)
– Front fender
Tighten the fork bolt.
Remove the steering stem nut and washer.
Tighten the top bridge pinch bolt to the specified torque.
Remove the fork legs (page 4-2).
Torque: 21 N•m (2.1 kgf•m, 14 lbf•ft) Remove the top bridge.
Return spring pre-load and rebound adjuster to their
original positions as noted during removal.

Install the following:

– Front fender
– Front wheel (page 4-2)

4-11
Frame servicing

1
4
1
3

1 2
3

(1) ADJUSTING NUT (1) STEM (1) STEM

(2) LOWER BEARING (2) DUST SEAL
(3) DUST SEAL (3) BEARING
(4) STEERING STEM DRIVER
1
Install new dust seal onto the steering stem.
Install the new lower bearing into the steering stem using
a hydraulic press and driver.
2
Tool:
3 Steering stem driver 07946-4300101

(1) DUST SEAL (1) BALL RACE REMOVER

(2) UPPER BEARING
(3) STEM
Remove the lower bearing and dust seal from the steering
stem.
Remove the stem bearing adjusting nut.
Remove the upper and lower bearing races from the
Remove the following; steering head using the special tools.
– Dust seal
– Upper bearing Tool:
– Steering stem/lower bearing Ball race remover 07948-4630100

4-12
 Frame servicing

1 1

2
2
1

(1) DRIVER (1) STEM (1) ADJUSTING NUT

(2) ATTACHMENT (2) UPPER BEARING
(3) DUST SEAL
Tools: Install new bearing races. Screw the stem bearing adjusting nut all the way with
Driver 07749-0010000 your fingers.
Attachment, 42 x 47 mm 07746-0010300 Pack the upper and lower bearings with grease.
Install the steering stem, upper bearing and dust seal.

4-13
Frame servicing

2 1

(1) TOP BRIDGE (1) ADJUSTER

(2) STEM NUT (2) AXLE

Turn the steering stem lock-to-lock 5 times to seat the Apply grease to the stem bolt threads and seating Rear Wheel
bearings and retighten the adjusting nut to the specified surfaces.
torque. Install the top bridge, washer and stem nut. Removal
Temporarily install both fork legs.
Torque: 5 N•m (0.5 kgf•m, 3.7 lbf•ft) Apply grease to the top bridge pinch bolt threads and Raise the rear wheel off the ground and support it with a
seating surfaces. block or maintenance stand under the engine.
Install and tighten the top bridge pinch bolts to the
specified torque. Remove the following:
– Rear axle protectors.
Torque: 21 N•m (2.1 kgf-m, 15.4 lbf•ft) – Axle nut and drive chain adjuster
– Drive chain
Tighten the stem nut to the specified torque. – Axle, drive chain adjuster and rear wheel
Torque: 99 N•m (10 kgf-m, 65 lbf•ft) Do not depress the brake pedal after the rear wheel is
removed.
Recheck the steering stem adjustment before installing The caliper pistons will move and make reassembly
the removed parts. 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.

4-14
 Frame servicing

Spokes: Check spoke tension frequently between the first

few rides. As the spokes, spoke nuts and rim contact
2 27 N•m (2,7 kgf•m) points seat-in, the spokes may need to be retightened.

Once past this initial seating-in period, the spokes should

3 1 hold their tension. Still, be sure your race maintenance
program includes checking spoke tension and overall
wheel condition on a regular basis.

a
8 3 N.m (0,2 - 0,3 kgf.m)

5 Drive the bearing

into the hub until it (1) DRIVEN SPROCKET
stops. (2) DRIVEN SPROCKET BOLT/NUT
6 When unassembling change bolt for new one’s. (3) LEFT WHEEL BEARING
Apply a locking agent to the threads (4) DISTANCE COLLAR
(5) RIGHT WHEEL BEARING
Torque: 17 N•m (1.7 kgf•m) (6) DISC BOLT
(7) BRAKE DISC
(8) REAR WHEEL NIPPLE

(a) 30 ± 0.5 mm

4-15
Frame servicing

2
1

1 3

(1) AXLE (3) AXLE NUT (1) LOWER MOUNTING BOLT/NUT

(2) ADJUSTERS

Installation Apply grease to the axle nut threads and seating surface.
Install the right chain adjuster and axle nut.
Install the rear brake caliper aligning with the caliper slide
rail. Install the drive chain.
If the master link retaining clip was removed, install the 1
Apply thin layer of grease to the axle. drive chain with the closed end of the clip in the direction
of wheel rotation.
Place the rear wheel between the swingarm being careful
not to damage the disc. Check and adjust the drive chain slack (page 2-11).
Insert the rear axle into the left chain adjuster, side collar
and wheel. Tighten the axle nut.

Torque: 69 N•m (7.0 kgf•m, 51 lbf•ft) 2

(1) UPPER MOUNTING BOLT/NUT

(2) SHOCK ABSORBER

Shock Absorber
Removal

Remove the seat box- rear fender assy

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.

4-16
 Frame servicing

3 1
1
7

9
8 (1) SPANNER WRENCH
9
2

1
5

4 9
8
9

(1) CIRCLIP

6
Removal

6 Secure the damper in a bench vise

Loosen the lock nut and the spring adjuster using the
spanner wrench (07702-0020001).

(1) DAMPER UNIT (6) LOWER DISTANCER Move the spring up next to the fastener plate.
(2) SPRING (7) UPPER DISTANCER
(3) DAMPER (8) BALL JOINT Remove the Seeger fastener ring and remove the spring
(4) CIRCLIP (9) DUST SEAL plate and the spring from the damper body.
(5) SPRING FASTENER PLATE

4-17
Frame servicing

1 2 1
1

2
1

1
1

3 2
2

(1) DISTANCE COLLAR (1) DUST SEALS (1) PRE-LOAD LENGTH

(2) SPHERICAL BEARING (2) ADJUSTER
(3) LOCK NUT
Remove the distance collar. Spherical Bearing Replacement Adjust the spring pre-load length (page 1-4).
Hold the spring adjuster and tighten the lock nut to the
Remove the stopper ring, spring seat and spring. Remove the collars and dust seals. specified torque.
Check the spherical bearing for smooth rotation or
Inspection damage. Torque:
Tightening angle 50°±10 after contact between nuts
Check the following items: Remove the stop ring
– Upper and lower spherical bearing for wear or damage Press the spherical bearing out using the special tool.
– Spring for damage and measure the free length
– Damper for oil leakage from the damper rod Tool:
Spherical bearing driver 07HMF-KS60100
Replace the damper unit if an oil leak is detected.
Press a new spherical bearing into the shock absorber
pivot until its seats using same tool.
Install the new stop ring into the groove.

Apply grease to the dust seal lips.

Install the dust seals and collars.

4-18
 Frame servicing

2
1 1
3
3
1

4 2

(1) UPPER MOUNTING BOLT/NUT (1) LOWER MOUNTING BOLT/NUT (1) LOWER MOUNTING BOLT/NUT
(2) BOLTS/NUTS
(3) CUSHION ARM PLATES
(4) CUSHION LINK
Installation Move the swingarm aligning the lower mount, then install
the lower mounting bolt from the right side.
Set the shock absorber into the frame and install the
Shock Linkage
upper mounting bolt from the left side. Install and tighten the upper and lower mounting nuts to
Removal
Install the nut. the specified torque.
Raise the rear wheel off the ground with a block or
Torque:
maintenance stand under the engine.
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)
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

4-19
Frame servicing

1 3 3
4
2 2
4
2 1
4

3 mm 3
2 1 3

(1) PIVOT COLLAR A (1) CUSHION LINK (1) SHOCK ABSORBER LOWER MOUNTING BOLT/NUT
(2) PIVOT COLLAR B (2) CUSHION ARM PLATES (2) SHOCK ARM PLATES-TO-SWINGARM BOLT/NUT
(3) DUST SEALS (3) BOLTS/NUTS
(4) NEEDLE BEARINGS (4) LOWER MOUNTING BOLT/NUT
Swingarm
Needle Bearing Replacement Installation
Removal
Remove the pivot collars and dust seals. Install the following:
Check the cushion link needle bearings for damage. – Cushion link Remove the following:
– Cushion link-to-frame socket bolt/nut – Rear wheel (page 4-14)
Remove the cushion link needle bearings using the special – Cushion arm plates – Shock absorber lower mounting bolt/nut
tool. – Cushion arm plates-to-swingarm bolt/nut – Cushion arm plates-to-swingarm bolt/nut
– Cushion arm plate-to-cushion link bolt/nut
Tool: – Rear cushion lower mounting bolt/nut
Bearing driver 07946-MJ00000
Tighten the cushion arm plate and cushion link nuts to the
Press new needle bearings into the cushion link to 3 mm specified torque.
(0.12 in) below the surface of the cushion link using the
special tool, on both sides. Torque: 39 N•m (4.0 kgf•m, 29 lbf•ft)
Face the bearing with its marked side facing out.
Tighten the rear cushion lower mounting nut to the
Tool: specified torque.
Bearing driver 07946-MJ00000
Torque: 39 N•m (4.0 kgf•m, 29 lbf•ft)
Apply multi-purpose grease to the collars and dust seal
lips.
Install the dust seals and pivot collars.

4-20
 Frame servicing

1 3

1 5,5 mm
4 2

1
3
2
2

(1) BRAKE HOSE CLAMPS (1) DUST SEAL CAP (1) NEEDLE BEARING
(2) SWINGARM PIVOT BOLT/NUT (2) DUST SEAL (2) DUST SEAL
(3) PIVOT COLLAR (3) BUSHING
(4) DUST SEAL
Remove the following:
– Brake hose clamps screws Disassembly Pivot Bearing Replacement
– Rear brake caliper
– Swingarm pivot bolt/nut and swingarm assembly Remove the following: Replace the swingarm bearings as a set.
– Bolts and drive chain cover
– Bolts and driven sprocket guard Remove the pivot bearings using the special tool.
– Screws and drive chain slider
– Chain tensioner Tool:
– Dust seal caps Bearing driver 07946-KA50000
– Dust seals
– Pivot collars Press a new pivot bearing in using the special tools .
– Thrust bushings
Tools:
Replace them if they have score marks, scratches, Driver 07749-0010000
excessive or abnormal wear. Attachment, 24 x 26 mm 07746-0010700
Check the shock mounts and swingarm for stress, cracks Pilot, 20 mm 07746-0040500
or other damage.
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.

4-21
Frame servicing

1 4

3 mm
3

1 3

4 4
3
3 5
2
2
2 1

(1) PIVOT COLLAR A (1) DUST SEAL (1) DUST SEAL

(2) PIVOT COLLAR B (2) PIVOT COLLAR (2) PIVOT COLLAR
(3) DUST SEALS (3) DUST SEAL (3) DUST SEAL
(4) NEEDLE BEARING (4) DUST SEAL CAP (4) DUST SEAL CAP
(5) NEEDLE BEARING
Link Bearing Replacement Assembly
Install the pivot collars, dust seals and dust seal caps.
Remove the pivot collars and dust seals. Apply grease to the bearings, pivot collars and lips of a Note the direction of the dust seal.
Remove the pivot bearings using the special tool. new dust seals.

Tool:
Bearing driver 07946-MJ00000

Press a new pivot bearing in using the special tools .

Tool:
Bearing driver 07946-MJ00000

Face the bearing with its marked side facing out.

Press the needle bearing so that it is 3.0 mm (0.12 in)
below the swingarm end.

Install the dust seals and pivot collars.

4-22
 Frame servicing

1 1 2
3 2

2 2

2 1
3 4 2

(1) CHAIN TENSIONER (1) DRIVE CHAIN SLIDER (1) PIVOT BOLT/NUT
(2) BUSHINGS (2) SCREWS (2) HOSE CLAMPS
(3) O-RINGS
(4) PIVOT BOLT
Installation
Apply grease to the pivot chain tensioner, bushings and
O-rings. Apply thin coat of grease to the swingarm pivot bolt
surface.
Install the drive chain tensioner pivot bushings into the 1 Install the swingarm into the frame.
swingarm. Install the swingarm pivot bolt from the left side.
Install a new O-ring onto the chain tensioner pivot. Install and tighten the swingarm pivot nut to the specified
Install the chain tensioner into the swingarm. torque.
Install a new O-ring and tighten the pivot bolt.
Torque: 69 N•m (7.0 kgf•m, 51 lbf•ft)
2 Install the brake caliper onto the swingarm rail.
2 Install the brake hose clamps and tighten the screws.

(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)

4-23
Frame servicing

1
1
2 2
3

(1) SHOCK ARM PLATES-TO-SWINGARM BOLT/NUT (1) PAD SPRING PIN

(2) SHOCK ABSORBER LOWER MOUNTING BOLT/NUT (2) BOLTS
(3) CALIPER
Install the following:
– Shock arm plates-to-swingarm bolt/nut
Front Brake Pad Replacement
– Rear cushion lower mounting bolt/nut
Clean the brake disc with a high quality degreasing agent
if they are contaminated with oil or grease.
Tighten the shock arm plate bolt.
Replace the pads if they are contaminated.
Torque: 39 N•m (4.0 kgf•m, 29 lbf•ft)
Remove the brake caliper mounting bolts and caliper.
Remove the spring pin from the pads.
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 4-16)

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 spring pin from the pads.

Clean the brake caliper inside especially around the caliper

pistons.

4-24
 Frame servicing

1
1

2
2

(1) NEW PADS (1) BOLT

(2) PAD SPRING PIN (2) SPEED SENSOR
(3) SPEED SENSOR BRACKET
Install the new pads and secure with the spring pin for Rear Brake Pad Replacement
the pads.
Clean the brake disc with a high quality degreasing agent
Install the caliper to the fork so the disc is positioned if they are contaminated with oil or grease.
between the pads, being careful not to damage the pads. Replace the pads if they are contaminated.
Apply a locking agent to the caliper mounting bolt threads.
Install and tighten the mounting bolts.

Torque: 26 N•m (2.7 kgf•m, 20 lbf•ft)

NOTICE
Before replacing the rear brake pads, remove the speed
Operate the brake lever to seat the caliper pistons against sensor.
the pads. The speed sensor may be damaged if struck or pulled. 1

Speed sensor removal (2ED)

Remove the following: (1) CALIPER PISTON

– Speed sensor bolt
– Remove the sensor from the sensor mount.
Remove the rear wheel (page 4-14)
Detach the speed sensor from the rear brake calliper for Push the piston all the way in to allow installation of new
easier removal. brake pads.
Check the brake fluid level in the reservoir as this operation
causes the level to rise.

4-25
Frame servicing

1 1 1 2 2
1

2
1

(1) PAD PIN (1) CALIPER BRACKET (1) BRAKE CALIPER BRACKET
(2) PAD PIN (2) SWINGARM BOSS

Install the new pads and secure them with the pad pin.
Remove the pad pin and brake pads. Install the brake caliper bracket aligning its slit with the
Clean the brake caliper inside especially around the caliper boss on the swingarm.
pistons.
Install the rear wheel (page 4-16).
Operate the brake pedal to seat the caliper pistons against
the pads.

4-26
 Frame servicing

1 1
3 2
3

(1) OIL BOLT (1) OIL BOLT / STOP SWITCH

(2) MOUNTING BOLTS (2) BRAKE HOSE
(3) BRAKE CALIPER (3) BRAKE CALIPER

Front brake caliper Inspection Rear brake caliper

Removal Clean the inside of the caliper. Removal
Check the oil leakage from the caliper cylinders.

NOTICE If any part of the caliper is damaged, replace the caliper

as an assembly.
NOTICE
Avoid spilling brake fluid on painted, plastic or rubber Avoid spilling brake fluid on painted, plastic or rubber
parts. Installation parts.
Place a shop rag over these parts whenever the system Place a shop rag over these parts whenever the system
is serviced. Apply locking agent to the caliper mounting bolt threads. is serviced.
Install the brake caliper and disc cover, and then install
Drain the brake system. and tighten the caliper mounting bolts. Drain the brake system.
Place a clean container under the caliper. Place a clean container under the caliper.
Torque: 26 N•m (2.7 kgf•m, 20 lbf•ft)
Remove the following: Remove the following:
– Brake hose oil bolt Connect the brake hose eyelet joint with two new sealing – Brake hose oil bolt
– Sealing washers washers, then tighten the oil bolt. – Sealing washers
– Brake hose eyelet – Brake hose eyelet
– Caliper mounting bolts Torque: 27 N•m (2.8 kgf•m, 20 lbf•ft) – Rear wheel (page 4-14)
– Flange collars – Brake caliper/bracket
– Brake caliper – Spring pin for the pads
– Spring pin for the pads – Brake pads (page 4-25)
– Brake pads (page 4-24)

4-27
Frame servicing

3 3

1
2

1
1
5

(1) CALIPER PISTON (1) SWINGARM BOSS (1) OIL BOLT

(2) BRAKE HOSE
(3) BOLT
(4) HOLDER
Inspection Installation (5) MASTER CYLINDER
Clean the inside of the caliper. Install the brake caliper onto the swingarm rail. Front master cylinder
Check the oil leakage from the caliper cylinder. Connect the brake hose eyelet joint with two new sealing
washers. Removal/Installation
If any part of the caliper is damaged, replace the caliper
as an assembly. Install the rear wheel (page 4-16).

Tighten the oil bolt to the specified torque.

NOTICE
 Avoid spilling brake fluid on painted, plastic or rubber
Torque: 26 N•m (2.7 kgf•m, 20 lbf•ft) parts. Place a shop rag over these parts whenever the
system is serviced.
 When removing the brake hose bolt, cover the end of
the hoses to prevent contamination. Secure the hoses
to prevent fluid from leaking out.

Drain the brake fluid from the hydraulic system into a
suitable container.

Remove the following:

– Brake lever
– Brake hose bolt
– Master cylinder holder bolt and holder
– Master cylinder

4-28
 Frame servicing

(1) BOOT
(2) SNAP RING
(3) PISTON ASSEMBLY
(4) SPRING
(5) OIL SEAL
(6) CIRCLIP

4 3 5 5 2 6 1

Disassembly/Assembly Inspection

Check the following items:

NOTICE – Master cylinder and piston for scoring, scratches or
other damage
 Keep the master cylinder piston, cups, spring and – Master piston O.D. and master cylinder I.D.
snap ring as a set; don’t substitute individual parts.
 When installing the cups, do not allow the lips to turn Installation
inside out and be certain the snap ring is firmly sea-
ting in the groove. Installation is in the reverse order of removal.
Remove the snap ring and disassemble the master Torque:
cylinder. Brake hose oil bolt: 14 N•m (1.4 kgf•m, 10.3 lbf•ft)
Master cylinder holder bolt: 5.5.N•m (0.56 kgf•m, 4.1 lbf•ft)

4-29
Frame servicing

1 1
2
3
3
1
2 1

(1) OIL BOLT (1) BOLTS (1) NUT

(2) BRAKE HOSE (2) MASTER CYLINDER (2) BOLT
(3) MASTER CYLINDER (3) BRAKE PEDAL

Rear master cylinder Remove the mounting bolts and master cylinder. Brake pedal
Removal/Installation Installation Removal
Installation is in the reverse order of removal. Remove the brake pedal pivot nut and bolt.
NOTICE Connect the brake hose with two new sealing washers,
then tighten the oil bolt.
Remove the brake pedal and collar.
 Avoid spilling brake fluid on painted, plastic or rubber
parts. Place a shop rag over these parts whenever the Torque:
system is serviced. Brake hose oil bolt: 26 N•m (2.7 kgf•m, 19.1 lbf•ft)
 When removing the brake hose bolt, cover the end of
the hoses to prevent contamination. Secure the hoses Bleed the air from the rear brake system.
to prevent fluid from leaking out.

Drain the brake fluid from the hydraulic system into a

suitable container.

Remove the seat, front covers, side covers and the seat-
rear fender assy.
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.

4-30
 Frame servicing

2 3 2
3 3
3 mm (0.12 in)

1 2
1
1 5
2

(1) BEARING (1) COLLAR B (1) OIL BOLT

(2) DUST SEALS (2) PEDAL (2) CLUTCH HOSE
(3) NUT/COLLAR A (3) BOLT
(4) HOLDER
Installation (5) MASTER CYLINDER
Install the brake pedal and collars. Clutch master cylinder
Install and tighten the pivot nut and bolt.
1 Apply sealant to the threads of pivot bolt. Removal/Installation
Torque: 29 N•m (3.0 kgf•m, 22 lbf•ft)
NOTICE
 Avoid spilling brake fluid on painted, plastic or rubber
parts. Place a shop rag over these parts whenever the
system is serviced.
 When removing the clutch hose bolt, cover the end of
the hose to prevent contamination. Secure the hose
to prevent fluid from leaking out.
(1) STANDARD LENGTH; 35 MM
Drain the clutch fluid from the hydraulic system into a
suitable container.
Pivot Bearing Replacement
Remove the following:
Remove the dust seals.
– Clutch lever
Remove the pivot bearing and press a new needle bearing
– Clutch hose bolt
so that it is 3 mm (0.12 in) below the pedal end. Apply
– Master cylinder holder bolts and holder
grease inside needle bearing
– Master cylinder
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.

4-31
Frame servicing

(1) BOOT
(2) SNAP RING
(3) PISTON ASSEMBLY
(4) SPRING
(5) OIL SEAL
(6) CIRCLIP

1 6 2 5 5 3 4

Disassembly/Assembly Inspection

Check the following items:

NOTICE – Master cylinder and piston for scoring, scratches or
other damage
 Keep the master cylinder piston, cups, spring and – Master piston O.D. and master cylinder I.D.
snap ring as a set; don’t substitute individual parts.
 When installing the cups, do not allow the lips to turn Installation
inside out and be certain the snap ring is firmly sea-
ting in the groove. Installation is in the reverse order of removal.
Remove the snap ring and disassemble the master Torque:
cylinder. Brake hose oil bolt: 14 N•m (1.4 kgf•m, 10.3 lbf•ft)
Master cylinder holder bolt: 5.5.N•m (0.56 kgf•m, 4.1 lbf•ft)

4-32
 5. Electrical servicing

1
1

(1) 6P (BLACK) CONNECTOR (1) 3P (NATURAL) CONNECTOR (1) 4P (NATURAL) CONNECTOR

Charging system inspection If the resistance is out of specification, disconnect the Regulated Voltage Inspection
alternator 3P (Natural) connector and measure the
Alternator charging coil resistance between the yellow terminals of the alternator Disconnect the power 4P (Natural) connector.
side connector. Connect the digital voltmeter to the Red (+) and Green
Disconnect the regulator rectifier 6P (Black) connector. (–) terminals.
Measure the resistance between the Yellow terminals of If the measured resistance at regulator/rectifier 6P (Black) Start the engine, check for regulated voltage.
the wire harness side. connector is incorrect and the alternator 3P (Natural)
connector is correct, check the wire harness. Standard: 13.5 – 14.5 V/1,800 min-1 (rpm)
Standard: 0.7 – 1.0  (20˚C/68˚F) If the resistance is still out of specification, replace the
stator assembly.

5-1
Electrical servicing

2 2 2

(1) 2P (NATURAL) CONNECTOR (1) 2P (BLACK) CONNECTOR (1) BOLTS

(2) 3P (NATURAL) CONNECTOR (2) 6P (BLACK) CONNECTOR (2) ELECTRIC STAY ASSEMBLY

Regulator/Rectifier Removal/installation
2 2
Remove the throttle body (page 3-13).

Disconnect the alternator 3P (Natural) connector and

ignition pulse generator 2P (Natural) connector.

1 1

(1) BOLT (1) 2P (BLACK) CONNECTOR

(2) BRAKE RESERVOIR (2) CONDENSER

Disconnect the condenser 2P (Black) and regulator/ Remove the electric stay mounting bolts, then remove the
rectifier 6P (Black) connector. stay assembly from the engine.

Remove the rear brake reservoir tank mounting bolt. Release the condenser 2P (Black) connector, then remove
the condenser from the electric stay.

5-2
 Electrical servicing

2
1 1

(1) BOLTS (1) PRIMARY TERMINALS (1) SPARK PLUG CAP

(2) REGULATOR/RECTIFIER (2) TIE-WRAP

Remove the bolts and regulator/rectifier from the electric Ignition system inspection Ignition coil Removal/Installation
stay.
Ignition coil inspection Remove the fuel tank/injector assembly.
Install the regulator/rectifier and condenser in the reverse
order of removal. Measure the ignition primary coil resistance between the Remove the spark plug cap.
primary terminals. Remove the tie-wrap and release the spark plug wire from
the fan motor bracket.
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.

5-3
Electrical servicing

1
1
3

3 1
1

2 2 L L 1 L

(1) WIRE CLAMP (1) 32P (BLACK) CONNECTOR (1) 2P (NATURAL) CONNECTOR
(2) PRIMARY WIRES
(3) BOLTS
(4) IGNITION COIL
Ignition Pulse Generator Inspection If the resistance is out of specification, measure the
resistance at the ignition pulse generator 2P (Natural)
Remove the wire clamp.
Check the ignition pulse generator resistance at the ECM connector.
Disconnect the primary wires from the ignition coil. 32P (Black) connector (page 5-5).
If the measured resistance at ECM 32P (Black) connector
Remove the mounting bolts and ignition coil.
Connection: White/yellow – Green/yellow is incorrect and the ignition pulse generator 2P (Natural)
Standard: 85 - 115  (20˚C/68˚F) connector is correct, check the wire harness.
Installation is in the reverse order of removal.
If the resistance is still out of standard, replace the ignition
Route the spark plug wire properly and secure it with
pulse generator/stator assembly (page 3-52).
tiewrap.

5-4
 Electrical servicing

1
1

(1) CONDENSER (1) 32P (BLACK) CONNECTOR

Condenser Inspection PGM-FI System inspection

If the engine does not start, check for the items “engine Place the motorcycle upright position and remove the seat, front covers, side covers and the seat-rear fender assy.
does not start” in the PGM-FI Malfunction Indicator Lamp Disconnect the ECM 32P (Black) connector.
(MIL) Failure Code chart on page 5-7. Check for the following at the ECM terminals of the wire harness side.
If all items are correct, replace the condenser unit with
new one, and inspect again. Item Terminal Standard
If the engine starts, the replaced condenser is faulty.
If the engine does not starts, check for wire harness. 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

5-5
Electrical servicing

1 2 2 2
3

5 1 1
3 3

(1) PGM WARNING UNIT ASSEMBLY (1) POWER SWITCH (1) POWER SWITCH
(2) RED WIRE EYELET (2) MIL (2) MIL
(3) GREEN WIRE EYELET (3) WARNING/RESET SWITCH (3) WARNING/RESET SWITCH
(4) 2P (BLACK) CONNECTOR
Turn the PGM warning unit warning/reset switch to the Self-diagnosis Reset Procedure
(5) 4P (RED) CONNECTOR
warning side as shown.
Turn the power switch ON, check that the MIL. Connect the PGM-FI warning unit assembly to the wire
PGM-FI If the ECM has no self diagnosis memory data, the MIL harness and 12 V battery same procedure as Self-
will illuminate, when you turn the power switch ON. diagnosis (see previous step).
Self-diagnostic procedure
If the ECM has self diagnosis memory data, the MIL will
start blinking when you turn the power switch ON. Before turn ON the power switch, turn the warning/reset
If the ECT sensor is faulty, the cooling fan will turn
Note how many times the MIL blinks, and determine the switch to the warning side.
when you connect the 12 V battery to the warning unit
cause of the problem (See page 5-7). Turn the power switch ON, then turn the warning/reset
terminals. Do not check these test near the cooling fan.
switch to reset side.
Disconnect the fuel pump 2P (Black) connector. The MIL lights about 5 seconds.
While the MIL lights, turn the warning/reset switch to the
Disconnect the condenser 2P (Black) connector and warning side.
connect a warning unit connector to the wire harness Self-diagnosis memory data is erased, if the MIL turns off
side. and start blinking.

Tool:  The warning/reset switch must be switched to warning

PGM-FI warning unit assembly 38890-NN4-305 side while the indicator lights. If not, the MIL will not
sart blinking
Connect the waring unit 4P (Red) connector to the service  Note that the self-diagnosis memory data cannot be
check 4P (Red) connector. erased if you disconnect the battery from the warning
unit assembly before the MIL starts blinking.
Connect the fully charged 12 V battery to the warning PGM-FI Self-diagnosis Malfunction Indicator Lamp
unit terminals (red wire eyelet to the battery positive (MIL) Failure Codes
terminal and green wire eyelet to the negative terminal).

5-6
 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  Engine operates normally
 Faulty ECM (PGM-FI warning indicator output)

1 Blink  Open or short circuit in MAP sensor line (in the ECM)  Poor idle
 Faulty MAP sensor

7 Blinks  Loose or poor contact on ECT sensor  Hard starting at a low temperature
 Open or short circuit in ECT sensor wire (Simulate using numerical values; 90 ˚C/194˚F)
 Faulty ECT sensor  Cooling fan does not stop

8 Blinks  Open or short circuit in TP sensor line (in the ECM)  Poor engine response when operating the throttle quickly
 Faulty TP sensor (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  Engine does not start
 Open or short circuit in injector wire
 Faulty injector
54 Blinks  Loose or poor contact on bank angle sensor connector  Engine starts but stops after few seconds.
 Open circuit in bank angle sensor wire
 Faulty bank angle sensor

5-7
Electrical servicing

1 1 1 2

(1) SCREWS (1) ARROW/UP MARK

(2) BANK ANGLE SENSOR (2) BANK ANGLE SENSOR

Bank angle sensor inspection Connect the bank angle sensor 3P (Natural) connector. Install the bank angle sensor in the reverse order of
With the arrow mark on the bank angle sensor facing up, removal.
Remove the electric stay assembly from the frame (page start the engine. Install the bank angle sensor with its arrow/UP mark
5-2). facing up as shown.
Incline the bank angle sensor approximately 65 degrees
Remove the screws and bank angle sensor from the to the left or right, make sure that the engine stops after
sensor bracket. 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.

5-8
 Electrical servicing

1
1

(1) CONNECTORS (1) 2P (NATURAL) CONNECTOR (1) FAN MOTOR RELAY

Engine stop switch inspection Cooling fan system inspection Fan motor relay inspection

Disconnect the engine stop switch connectors. Fan motor inspection Remove the fan motor relay.
Check the engine stop switch for continuity. Connect the ohmmeter to the fan motor relay connector
There should be continuity only when the engine stop Remove the fuel tank. terminals.
button is pushed. Disconnect the fan motor 2P (Natural) connector.
Connection: Red – Blue
Replace the switch if it is out of specification. Directly connect a 12 V battery to the fan motor 2P
(Natural) connector terminals of the fan motor side. Connect the 12 V battery to the following fan motor relay
The fan motor is correct when the fan motor operate terminals.
when the 12 V battery is connected.
If the fan motor does not operate, replace the fan motor Connection: Red – Black/Blue
assembly.
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.

5-9
Electrical servicing

Lights / instruments / switches

System location

speedometer

power relay winker relay

front brake switch

2P connector
(position light)

Wire harness inspection

Check for continuity of the Black/Blue wire between the 3P connector

fan motor relay 2P (Natural) connector and ECM 32P (speed sensor)
(Black) connector.
There should be continuity.
If there is no continuity, repair or replace the wire harness.

right front turn

left front turn signal connector
signal connector

9P connector
(light switch)

9P connector
(sub-harness)

5-10
 Electrical servicing

Servicing information

 Bear in mind the following when replacing the front

L W R
Lo Hi BAT Po
headlight bulb.
- Use clean gloves when replacing the bulb. Do not
touch the front headlight bulb with your fingertips,
since this could produce hot spots on the bulb and N
cause it to break.
- If you touch the bulb with your bare hands, clean it
with a cloth moistened with alcohol to prevent its
early failure. COLOR W L B BR
 Ensure that you replace the dust cover after changing COLOR Y/G R/B L/R
the front headlight bulb. LIGHTING SWITCH
INTERRUPTOR DE LUCES
 The bulb for the front headlight gets very hot when it is TURN SIGNAL
INTERRUPTOR SWITCH
DE INTERMITENTES
on and remains hot for a while after the front headlight
has been turned off. Ensure that you leave it to cool
before carrying out any maintenance work.
 Continuity checks can be carried out using the switches
on the motorcycle. Checks: Indicator light/Indicator light relay.
 The following colour codes are used throughout this If the engine starts but the front headlight or the position
section. light do not work, check the following: Checks:
 Bulb blown or not of the specified wattage. If the engine starts but the indicator lights do not work,
COLOUR CODES  Loose connector. check the following:
  Bulb blown or not of the specified wattage.
B Black Start the engine and check the voltage between the  Loose connector.
Y Yellow following terminals of the connector 9P (white) on the  Operation of the indicator light switch:
L Blue harness side:
G Green Disconnect the connector 9P from the left switch on the
R Red Connection: Black (+) and Ground (–) handlebar.
Standard: 12V approximately. Check the continuity between the terminals in each
W White
switch position, as shown in the table.
V Violet If there is no voltage, check the following:
BR Brown  Open circuit in the black wire between the ignition If the previous elements are working properly, start the
O Orange relay and the connector 9P (white) on the handlebar. engine and check the voltage between the following
SB Light blue terminals of the connector on the harness side:
If there is voltage, disconnect the connector 9P from the
LG Light green left switch on the handlebar. Connection: Red/Black (+) and Ground (–)
P Pink Check the continuity between the terminals in each Standard: 12V approximately.
GR Grey switch position, as shown in the table.
If there is no voltage, check the following:
 Open circuit in the black wire between the indicator
light relay 2P (white) and the ignition relay black wire..

5-11
Electrical servicing

(1) BRAKE LIGHT LAMP (1) 2P CONNECTOR FOR THE BRAKE LIGHT SWITCH

Checking indicator line: Brake light. Brake light switch.

Connect the terminals of the connector 2P (white) of the
indicator relay with a jumper wire. If the engine starts but the brake light does not work, Front:
check the following:
Connection: Red/Black – Black  Burnt out led. Disconnect the connector 2P from the front brake light
 Loose connector. switch.
Start the engine and move the indicator switch to position  Open circuit in the Black wire between the ignition
or . relay and the brake switch. There should be continuity with the brake lever applied,
and there should be none when this lever is not applied.
Check that the indicator lights are working.

 If the indictor lights come on, replace the indicator

relay with one that you know is working correctly and
carry out the checks again.
 If the indicator lights are not working, check to see if
there is an open circuit in:
- Yellow/green wire (left side)
- Blue/red wire (right side)
- Green wires for the indicators.

5-12
 Electrical servicing

3 1

1 2
1

5
4

(1) CONNECTOR 2P FROM THE REAR BRAKE LIGHT (1) HOUSING FOR THE HEADLIGHT (1) SPEEDOMETER
SWITCH. (2) BOLTS
(3) SPEEDOMETER
(4) CONNECTOR 6P
Rear: (5) CONNECTOR 3P Checks:
Check for loose or defective contacts in the connectors
Disconnect the connector 2P from the rear brake light Speedometer 6P and 3P of the speedometer.
switch.
There should be continuity with the brake pedal applied, Removal/Installation When starting the engine, check that the speedometer
and there should be none when this pedal is not applied. light comes on.
– Remove the housing for the headlight.
– Remove the screws and the speedometer If the speedometer does not work at first, check the
– Disconnect the connectors 6P (white) and 3P (white) power lines and ground for the speedometer.
from the speedometer.
If the speedometer works initially but later does not move
Carry out the installation in the reverse order to removal. when in motion, check the system for the speed sensor.

TORQUE: Checking the power/ground lines

3 Pinch bolts for the speedometer: 1.0 N•m (0.1 kgf•m)
– Remove the speedometer.

NOTICE
Do not disconnect the connector 6P on the speedometer
[1] during the checks.

With the connector 6P of the speedometer connected,

check the following in the connector on the harness side.

5-13
Electrical servicing

(1) CONNECTOR 6P (1) SPEED SENSOR

Power input line Speed sensor

Measure the voltage between the connector 6P of the System check
speedometer and the ground.

Connection: White/Red(+) and Ground (–) NOTICE

With the engine on, around 12V should be received.  Before starting this inspection, visually check the
speedometer system components.
If there is no voltage, check the existence of an open
circuit in the White/Red wire. Checking the air gap

Ground line Safely support the motorcycle with a lifting device or

equivalent and raise the wheel off the ground.
Measure the continuity between the connector 6P of the
speedometer and the ground. Measure the gap (air gap) between the sensor and the
pulse generator ring at different points by turning the
Connection: Green – Ground wheel slowly.

There must be continuity at all times. It must be within the specification.

If there is no continuity, check the existence of an open Standard: 0.5 – 1.5 mm (0.031 – 0.035 in)
circuit in the green wire.
The air gap cannot be adjusted.

If it is not within the specification, check whether there

are deformities, damage or if any of the parts assembled
are loose.

5-14
 Electrical servicing

2
GND Po
FREE
2 PUSH
3

1
COLOR G LG
1 BATTERY
BATERÍA HORN SWITCH
INTERRUPTOR DE LA BOCINA
(1) HOUSING FOR THE UPPER HEADLIGHT (1) HORN
(2) CONNECTOR 6P (2) CONNECTORS
(3) CONNECTOR 3P

Checking the speed sensor Horn If there is no voltage, check the following:
 Open circuit in the Black wire between the ignition
Checks: relay and the connector 9P (white) on the handlebar.
Remove the housing for the upper headlight.

If the engine starts but the horn does not work, check the If there is voltage, check the continuity between the
Check if there are loose or defective contacts in the
following: terminals in each switch position, as shown in the table.
connector 3P (white) of the speed sensor.
 Loose connection.
Disconnect the connector 3P (white) of the speed sensor.
If there is no loose connector, disconnect the connectors
Start the engine. from the horn.
Connect the 12 V battery to the horn’s terminals. If the
Measure the voltage between the terminals of the horn does not sound, replace it with a new unit and re-
connector 3P (white) of the speedometer on the wire side. peat the test.
If the horn sounds, do the following procedure:
Connection: Red (+) and Blue (–)
Standard: 5V approximately. Start the engine and check the voltage between the
following terminals of the connector 9P (white) on the
If the standard voltage appears, replace the speed sensor. harness side:

If there is no standard voltage, check the following: Connection: Black (+) and Ground (–)
 The blue wire in case there is an open circuit. Standard: 12V approximately.
 The red wire in case there is an open circuit.
 Speedometer.

5-15
Electrical servicing

Wiring diagram

POWER
RELAY WINKER O2
TURN SIGNAL RELAY SENSOR F1 - ECU
INDICATOR LIGHT
12V 1,2 W
SPEED FAN FUEL
HIGH BEAM SENSOR, MOTOR PUMP
INDICATOR LIGHT REAR WHEEL
12V 1,2 W

METER
INDICATOR LIGHT
12V 1,2 W

RIGHT REAR
DIGITAL METER TURN SIGNAL LIGHT
12V 12V 10W

SERVICE CHECK
CONNECTOR
OBD LED
REGISTRATION PLATE LIGHT
12V 5W
RIGHT FRONT TURN
SIGNAL LIGHT
12V 10W
POWER

POSITION LIGHT
12V 5W

BRAKE AND TAILLIGHT

HEADLIGHT
12V 35/35W

LEFT FRONT TURN LEFT REAR

SIGNAL LIGHT TURN SIGNAL LIGHT
12V 10W 12V 10W

REAR BRAKE LIGHT SWITCH

FRONT STOP SWITCH
HORN
FAN RELAY
WATER REGULATOR /
TEMP RECTIFIER
SENSOR
CONDENSER BANK ANGLE
PULSER (10000uF) SENSOR
ALTERNATOR

IGNITION COIL

ENGINE TURN SIGNAL LIGHTING HORN STOP B BLACK BR BROWN

SWITCH SWITCH SWITCH SWITCH SWITCH
Y YELLOW O ORANGE
L BLUE SB LIGHT BLUE
G GREEN LG LIGHT GREEN
R RED P PINK
W WHITE GR GREY
V VIOLET

5-16
Memo

5-17