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Before Servicing

Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate
unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included
wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also
required for successful work.
Especially note the following:
(1) Dirt
Before removal and disassembly, clean the motorcycle. Any dirt entering the engine or other parts will work as an
abrasive and shorten the life of the motorcycle. For the same reason, before installing a new part, clean off any dust
or metal filings.
(2) Installation, Assembly
Generally, installation or assembly is the reverse of removal or disassembly. But if this Service Manual has
installation or assembly procedures, follow them. Note parts locations and cable, wire, and hose routing during
removal or disassembly so they can be installed or assembled in the same way. It is preferable to mark and record
the locations and routing as much as possible.
(3) Tightening Sequence
Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to
a snug fit. Then tighten them evenly in a cross pattern. This is to avoid distortion of the part and/or causing gas or
oil leakage. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and
then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws
must be tightened in the order and method indicated.
(4) Torque
When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to
serious damage. Use a good quality, reliable torque wrench.
(5) Force
Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially
difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap
lightly using a wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removal of screws
held by a locking agent) in order to avoid damaging the screw heads.
(6) Edges
Watch for sharp edges, especially during major engine disassembly and assembly. Protect your hands with gloves
or a piece of thick cloth when lifting the engine or turning it over.
(7) High-Flash-Point Solvent
A high-flash-point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North
America is Stoddard solvent (generic name). Always follow manufacturer and container directions regarding the use
of any solvent.
(8) Gasket, O-Ring
Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be
free of foreign matter and perfectly smooth to avoid oil or compression leaks.
(9) Liquid Gasket, Non-Permanent Locking Agent
Follow manufacturer's directions for cleaning and preparing surfaces where these compounds will be used. Apply
sparingly. Excessive amounts may block engine oil passages and cause serious damage. An example of a non-
permanent locking agent commonly available in North America is Loctite Lock'n Seal (Blue).
(10) Press
A part installed using a press or driver, such as a wheel bearing, should first be coated with oil on its outer or inner
circumference so that it will go into place smoothly.
(11) Ball Bearing and Needle Bearing
Do not remove a ball or a needle bearings unless it is absolutely necessary. Replace any ball or needle bearing
that were removed with new ones, as removal generally damages bearings. Install bearings with the marked side
facing out applying pressure evenly with a suitable driver. Only press on the race that forms the press fit with the
base component to avoid damaging the bearings. This prevents severe stress on the balls or needles and races, and
prevent races and balls or needles from being dented. Press a ball bearing until it stops at the stops in the hole or
on the shaft.
(12) Oil Seal and Grease Seal
Replace any oil or grease seals that were removed with new ones, as removal generally damages seals.
When pressing in a seal which has manufacturer's marks, press it in with the marks facing out. Seals should be
pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even
with the end of the hole. Before a shaft passes through a seal, apply a little high temperature grease on the lips to
reduce rubber to metal friction.
(13) Circlip, Retaining Ring, and Cotter Pin
Replace any circlips and retaining rings, and cotter pins that were removed with new ones, as removal weakens
and deforms them. When installing circlips and retaining rings, take care to compress or expand them only enough
to install them and no more.


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