Montesa 4Ride MST260 2016 Shop Manual
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Montesa 4Ride MST260 2016 Shop Manual

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Shop Manual 2016
PGM-FI Racing Trial

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Summary of Contents for Montesa 4Ride MST260 2016

  • Page 1 Shop Manual 2016 PGM-FI Racing Trial...
  • Page 3 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.
  • Page 4 (1) FRAME NUMBER (1) ENGINE NUMBER Serial numbers The serial number of the engine is stamped on the lower MODEL TYPE FRAME No. ENGINE No. right side of the crankcase. The Vehicle Identification Number (VIN) is stamped on the right side of the steering head. MST260G *VTDMT04K?GE000001* NN4E6000001...
  • Page 5 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. Tire information Cold tire pressure (driver only) DUNLOP D803FGP MICHELIN TRIAL COMPETITION ...
  • Page 6 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.  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.
  • Page 7 Labels...

  • Page 8: Table Of Contents

    Contents Throttle Body ..........3-13 5. Electrical servicing Water Seal And Bearing Replacement ....3-15 Charging system inspection ......5-1 1. Service data Radiator Removal/Installation ......3-17 Ignition system inspection ......5-3 Engine Removal/Installation ......3-18 Specifications ..........1-1 PGM-FI System inspection ......5-5 Cylinder Compression ........

  • Page 9: Specifications

    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...

  • Page 10: Service Data

    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/cm , 189 psi) – Engine oil capacity Cylinder head warpage –...
  • Page 11 Service data Unit: mm (in) Unit: mm (in) Item Standard Service limit Item Standard Service limit Cylinder/Piston Crankshaft/Transmission Crankshaft runout Right – 0,03 (0,001) Cylinder 78,000 – 78,015 (3,0709 - 3,0715) 78,04 (3,0724) Taper – 0,05 (0,002) Left – 0,05 (0,002) Out-of- round –...
  • Page 12 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/cm –...

  • Page 13: Torque Values

    Service data Torque Values Engine Standard Torque Thread Torque Item Item Q’ty Remarks N•m (kgf•m / Ibf•ft) Dia. (mm) N•m (kgf•m / lbf•ft) Transmission oil drain bolt 22 (2,2 / 16) Note 1 5 mm bolt and nut 5 (0,52 / 3,5) Engine oil drain bolt 22 (2,2 / 16) Note 1...
  • Page 14 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 22 (2,2 / 16) Note 1 Steering head top thread 5 (0,5 / 3,6) Note 1 Steering stem nut 99 (9,9 / 73)

  • Page 15: Tools

    Service data Tools Special Common Description Tool number Applicability Description Tool number Applicability Spoke nipple wrench 07701–0020300 Front spoke nipple Bearing remover, 12 mm 07936–1660101 Water pump bearing Remover shaft 07936–1660120 Gear holder 07724–0010100 Primary drive gear bolt Remover weight 07741–0010201 Bearing remover head 07746–0050600 Wheel bearing...

  • Page 16: Lubrication & Seal Points

    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 (A 50/50 mixture of Cylinder bore inner surface Connecting rod big end molybdenum disulfide Cylinder head nut threads and seating surface...
  • Page 17 Service data Chain tensioner bolt transmission Drain hole Item Material Remarks Clutch slave cylinder piston/O-ring Silicone grease Application zone Application zone Left crankcase cover cap threads Lithium based multipurpose 6.5±1 mm 3 - 4 mm 2.5±1 mm 1.2±0.4 mm grease Each oil seal lips Water seal lips Right crankcase cover water hose joint threads...
  • Page 18 Service data Frame Item Material Remarks Item Material Remarks Multi-purpose grease Locking agent Steering head bearing race and bearings Drive chain adjuster stopper screw threads 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...

  • Page 19: Cable & Harness Routing

    Service data Cable & Harness Routing FRONT FRONT (1) FRONT BRAKE HOSE (2) THROTTLE CABLE (3) CLUTCH HOSE 1-11 1-11...
  • Page 20 Service data 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 1-12...
  • Page 21 Service data (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 1-13...
  • Page 22 Service data UPPER 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...
  • Page 23 Service data Clamp at white tape (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 –...
  • Page 24 Service data UPPER UPPER 45º (1) THROTTLE CABLE (2) CLUTCH HOSE (3) FUEL TANK BREATHER HOSE 1-16 1-16...
  • Page 25 Service data (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 1-17...
  • Page 26 Service data Clamp at white tape (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...
  • Page 27 Service data UPPER 90º UPPER (1) REAR BRAKE HOSE (2) REAR BRAKE RESERVOIR HOSE (3) SPEED SENSOR (4) REAR BRAKE LIGHT SWITCH 1-19 1-19...
  • Page 28 Service data (1) FUEL FEED HOSE (2) TRANSMISSION BREATHER HOSE 1-20 1-20...

  • Page 29: Service And Maintenance

    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.
  • Page 30 Service and maintenance FREQUENCY 1.500 3.000 4.500 6.000 Every Yearly Every Pre-ride check Remarks 6 months check 2 years 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...

  • Page 31: Fuel Line

    Service and maintenance (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- Thoroughly wash the element in clean non-flammable rear fender assy.

  • Page 32: Spark Plug

    Service and maintenance (1) SPARK PLUG CAP (1) INSULATOR (1) BOLTS (2) SPARK PLUG (2) TAPPET ADJUSTING HOLE COVER Spark Plug 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.
  • Page 33 Service and maintenance (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 cover.

  • Page 34: Engine Oil/Oil Filter

    Service and maintenance (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 Change the engine oil with the engine warm. Oil Level Inspection Support the motorcycle with it side stand.
  • Page 35 Service and maintenance (1) SPRING (1) NEW O-RINGS (1) OIL STRAINER SCREEN (2) OIL FILTER (2) OIL FILTER COVER (3) APPLY GREASE Oil Strainer Screen Cleaning Remove the oil strainer screen from the left crankcase groove. Clean the strainer. Reinstall the oil strainer screen. Note the direction of the screen.

  • Page 36: Engine Idle Speed

    Service and maintenance (1) THROTTLE STOP SCREW (1) DRAIN BOLT (1) FILLER CAP (2) O-RING Engine Idle Speed Transmission Oil 5. Pour specified transmission oil. Specified transmission oil: ELF HTX 740 Oil Change Inspect and adjust the idle speed after all other engine adjustments are within specification.

  • Page 37: Coolant

    Service and maintenance (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.

  • Page 38: Clutch System

    Service and maintenance (1) FILLER NECK (1) CLUTCH FLUID RESERVOIR (1) EXHAUST PIPE (2) LOWER LEVEL LINE (2) MUFFLER (3) LAMBDA-SONDE Clutch System Exhaust Pipe And Muffler 4. Fill the radiator with coolant up to the filler neck. 5. Squeeze the radiator hoses alternately. If the coolant level drops, fill the coolant again.

  • Page 39: Drive Chain

    Service and maintenance (1) DRIVE CHAIN SLACK (1) AXLE NUT (1) DRIVE CHAIN SLIDER (2) ADJUSTER (2) DRIVE CHAIN TENSIONER SLIDER Drive Chain Drive Chain Slider Drive Chain Slack Adjustment Loosen the rear axle nut just enough to move the rear Drive Chain Slack Inspection Inspection/Replacement wheel in fore-act direction.

  • Page 40: Drive/Driven Sprockets

    Service and maintenance (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 the specified torque.

  • Page 41: Brake Fluid

    Service and maintenance (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 is extended.

  • Page 42: Brake Pad Wear

    Service and maintenance (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 direction exceeds 2.0 mm (0.08 in), as measured at its Brake Discs Measure the brake pad thickness.

  • Page 43: Handlebar And Steering Head Bearings

    Service and maintenance (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. Support the motorcycle using the maintenance stand with Handlebar Standard tyre air pressure for ROAD USE: its front wheel off the ground.

  • Page 44: Front Suspension

    Service and maintenance (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 Specified fork fluid: Tech OJ 01 (SAE5) on the forks.

  • Page 45: Rear Suspension

    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.  After break-in is completed, test ride your 4RIDE with 1. Check for a broken or collapsed spring. The swingarm is controlled by a shock absorber.

  • Page 46: Front Headlight And Front Position Light

    Service and maintenance (1) SCREWS (1) DUST COVER (1) HEADLIGHT POSITION LIGHT (2) THE HOUSING FOR THE UPPER HEADLIGHT (2) BULB PAWL (3) BULB (4) CONNECTORS Position light bulb Front headlight and front position light. – Remove the housing for the headlight. –...

  • Page 47: Engine Servicing

    3. Engine servicing (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 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).
  • Page 48 Engine servicing (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.
  • Page 49 Engine servicing (1) OIL PUMP SHAFT (1) DRIVE PIN (2) INNER ROTOR (3) FLAT SURFACES (2) DRIVEN SPROCKET (4) OUTER ROTOR Assembly Apply clean engine oil to the oil pump rotors and shaft. Install the oil pump shaft into the right crankcase. Install the inner rotor aligning the flat surface between the rotor and pump shaft.

  • Page 50: Disassembly / Installation Of Fuel Feed Hose

    Engine servicing (1) 5P CONNECTOR (1) FAST CONNECTOR PROTECTOR (1) PAWL (2) FAST CONNECTOR Disassembly / Installation of fuel feed hose 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.

  • Page 51: Fuel Line Inspection

    Start the engine. Read the fuel pressure at idle speed. Remove the fuel feed hose banjo bolt and attach the fuel pressure gauge with the following Montesa Genuine parts. Fuel Pressure Inspection Idle Speed: 1,800 ± 100 min-1 (rpm) Standard:...
  • Page 52 Engine servicing (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.

  • Page 53: Fuel Tank/Fuel Pump

    Engine servicing (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.
  • Page 54 Engine servicing (1) QUICK CONNECTOR (1) FUEL PUMP (1) FUEL PUMP (2) FUEL FEED HOSE (2) BOLTS (3) 5P CONNECTOR Installation NOTICE Always replace the packing with a new one when the fuel pump is removed. Clean any oil off from the mating surface of the fuel pump base and fuel tank.
  • Page 55 Engine servicing (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.
  • Page 56 Engine servicing (1) 5P CONNECTOR (1) BOLTS (1) PAWL (2) FUEL PUMP BASE (2) PUMP BODY (3) PUMP (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.
  • Page 57 Engine servicing (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 Replace the bearings with new ones every time the fuel pump is disassembled.
  • Page 58 Engine servicing (1) FUEL PUMP BASE (1) TANK (1) PUMP CONNECTOR (2) BOLTS (2) CLIP (3) BREATHER HOSE Mount the tank on the chassis. Connect the breather hose to the tank and secure it with the clip. Insert the mounting bolts in the pump. (1) 5P CONNECTOR Place the pump base in its position as shown.

  • Page 59: Injector

    Engine servicing (1) INJECTOR (1) INJECTOR (1) BOLTS/NUTS (2) NEW O-RING (2) AIR CLEANER HOUSING Injector Throttle Body Removal/Installation Do not remove the injector from the injector holder. Inspection 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- Always replace the O-ring when the fuel injector assembly rear fender assy.
  • Page 60 Engine servicing (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 (1) SCREWS (1) SCREW (1) THROTTLE DRUM COVER (2) THROTTLE DRUM COVER...

  • Page 61: Water Seal And Bearing Replacement

    Engine servicing (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.
  • Page 62 Engine servicing (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. Install the water pump shaft, new copper washer and impeller into the right crankcase cover.

  • Page 63: Radiator Removal/Installation

    Engine servicing (1) DOWEL PINS (1) 2P (NATURAL) CONNECTOR (1) GROUND EYELET (2) BOLTS (2) NEW O-RING (3) IGNITION COIL (3) WATER PUMP COVER (4) WIRE CLAMP (1) WATER PUMP COVER (1) TIE WRAP (1) 3P (GRAY) CONNECTOR (2) BOLTS Radiator Removal/Installation Remove the ground eyelet bolt.

  • Page 64: Engine Removal/Installation

    Engine servicing (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.
  • Page 65 Engine servicing Engine Removal/Installation Illustration 24 N•m (2,4 kgf•m) 26 N•m (2,6 kgf•m) 24 N•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 3-19...

  • Page 66: Cylinder Compression

    Engine servicing (1) CYLINDER COMPRESSION GAUGE (1) SEALING BOLT/WASHER (1) TIMING HOLE CAP (2) STOPPER TOOL Cylinder Compression Warm up the engine to normal operating temperature. Stop the engine and remove the spark plug. Install a compression gauge. Shift the transmission into neutral. Open the throttle all the way and crank the engine with the kickstarter until the gauge reading stops rising.
  • Page 67 Engine servicing (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 from falling into the crankcase.
  • Page 68 Engine servicing (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. Measure the rocker arm I.D.

  • Page 69: Cylinder Head Removal

    Engine servicing (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. Remove the following: Remove the nuts, washers and cylinder head.
  • Page 70 Engine servicing (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 Inspect the cam chain tensioner and cam chain guide for excessive wear or damage, replace if necessary.

  • Page 71: Cylinder Head Disassembly

    Engine servicing (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.

  • Page 72: Cylinder Head Inspection

    Engine servicing (1) COMBUSTION CHAMBER (1) OUTER VALVE SPRING (1) VALVE (2) INNER VALVE SPRING Cylinder Head Inspection Valve spring Valve/Valve Guide Check the valve springs for fatigue or damage. Inspect each valve for out-of-round, burns, scratches or Cylinder Head Measure the free length of the intake and exhaust valve abnormal stem wear.

  • Page 73: Valve Guide Replacement

    Engine servicing (1) VALVE GUIDE REAMER (1) VALVE GUIDE DRIVER Valve Guide Replacement Ream the valve guide to remove any carbon build-up Measure and record the valve guide I.D. using a ball gauge 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.

  • Page 74: Valve Seat Inspection/Refacing

    Engine servicing (1) VALVE GUIDE DRIVER (1) VALVE SEAT WIDTH Valve Seat Inspection/Refacing Remove the guide from the freezer. Check that the valve guides are at the proper depth using While the cylinder head is still heated, drive new valve a slide caliper, adjust the height if necessary.
  • Page 75 Engine servicing 45º 32º 60º 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.
  • Page 76 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.

  • Page 77: Cylinder Head Assembly

    Engine servicing 45º (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.

  • Page 78: Cylinder/Piston

    Engine servicing (1) VALVE SPRING COMPRESSOR (1) PLASTIC HAMMERS (1) BOLTS (2) ATTACHMENT (2) CAM CHAIN TENSIONER LIFTER (3) GASKET Cylinder/Piston Compress the valve springs with the special tools and Tap the valve stems gently with two plastic hammers as install the cotters.
  • Page 79 Engine servicing (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 a point just opposite the gap. Place a clean shop towel over the crankcase to prevent Piston rings are easily broken;...
  • Page 80 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. piston ring grooves using old piston rings. Measure the piston ring groove clearance with the rings Cylinder Inspect the piston for damage and the ring grooves for pushed into the grooves.
  • Page 81 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.
  • Page 82 Engine servicing (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 Piston Installation Check the tensioner lifter operation as follows: Piston Ring Installation –...

  • Page 83: Cylinder Head Installation

    Engine servicing (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 threads. Install the cylinder mounting sealing bolt with a new sealing washer but do not tighten it yet.

  • Page 84: Camshaft/Cylinder Head Cover Installation

    Engine servicing (1) CYLINDER HEAD BOLTS (1) HANGER BOLT (1) “T” MARK (2) CYLINDER SEALING BOLT (2) RADIATOR HOSE (2) INDEX MARK Camshaft/Cylinder Head Cover Installation Tighten the cylinder sealing bolt and cylinder head Install the upper engine hanger bolt, tighten the bolt to mounting bolts securely.
  • Page 85 Engine servicing (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 Cylinder Head Cover Assembly Apply molybdenum oil solution to the rocker arm I.D. and rocker arm shaft sliding surface.

  • Page 86: Right Crankcase Cover

    Engine servicing (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.

  • Page 87: Clutch Slave Cylinder

    Engine servicing (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.
  • Page 88 Engine servicing (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.

  • Page 89: Clutch

    Engine servicing (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 Clutch Removal Pull the clutch lever and hold it with a suitable clamp. Remove the bolts and clutch cover without disconnecting the clutch fluid line.
  • Page 90 Engine servicing (1) CLUTCH CENTER (1) LIFTER PIECE ASSEMBLY (1) OUTER GUIDE (2) CLUTCH OUTER (2) NEEDLE BEARING (3) OUTER GUIDE (4) NEEDLE BEARING Inspection Check the following items (specifications; page 1-1).  Clutch outer for wear, cracks or indentation by the clutch discs.
  • Page 91 Engine servicing (1) PRESSURE PLATE (1) THRUST WASHER (1) CLUTCH SPRINGS (2) LOCK WASHER (“OUTSIDE” MARK IN FRONT) (2) LIFTER PLATE (2) CLUTCH CENTER (3) SPRING BASE WASHER (3) BOLTS (3) DOT MARKS (4) LIFTER PIECE ASSEMBLY Install spring base washers, the clutch springs, lifter plate and spring bolts.

  • Page 92: Kickstarter

    Engine servicing (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 Install the return spring with its end into the spindle hole. Kickstarter Install the collar aligning its groove with the return spring end, then install the washer.

  • Page 93: Gearshift Linkage

    Engine servicing (1) KICKSTARTER ASSEMBLY (1) STOPPER PLATE (1) GEARSHIFT SPINDLE (2) SPRING HOOK (2) BOLT (2) BOLTS (3) GUIDE PLATE Gearshift Linkage Install the kickstarter assembly and hook the starter ratchet with the stopper. Install the return spring end into the crankcase hole as Removal shown.
  • Page 94 Engine servicing (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 (6) GUIDE PLATE (6) CUT-OUT Inspection Install the return spring, plain washer and stopper arm...

  • Page 95: Left Crankcase Cover

    Engine servicing (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.
  • Page 96 Engine servicing (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. Tools: Driver 07749–0010000...
  • Page 97 Engine servicing (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.

  • Page 98: Flywheel

    Engine servicing (1) LEFT CRANKCASE COVER (1) 3P (NATURAL) CONNECTOR (2) BOLTS (2) 2P (NATURAL) CONNECTOR (3) NEW SEALING WASHER/DRAIN BOLT Flywheel Install the left crankcase cover being careful not to Install the gearshift pedal. damage the oil filter cover O-ring. Connect the alternator 3P (White) connector and ignition Removal pulse generator 2P (Natural) connectors.
  • Page 99 Engine servicing (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.

  • Page 100: Crankcase Separation/Disassembly

    Engine servicing (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 and clutch outer onto the mainshaft and attach the gear holder between the primary drive and driven gears.
  • Page 101 Engine servicing (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 Remove the following: 3 steps.

  • Page 102: Crankshaft/Transmission Inspection

    Engine servicing 8 mm 6 mm (1) RIGHT CRANKCASE Crankshaft/Transmission Inspection Measure the crankshaft runout. Support the crankshaft at point “A” and “B”, and then measure the runout at the points “C” and “D”. Service limit: 0.05 mm (0.002 in) 0.03 mm (0.001 in) Measure the connecting rod big end side clearance and big end axial/radial play (specification;...
  • Page 103 Engine servicing Crankcase Bearings/Oil Seals Location (1) LEFT SHIFT DRUM BEARING 1 mm (2) LEFT COUNTERSHAFT BEARING 0 ± 0.5 mm (3) LEFT COUNTERSHAFT OIL SEAL 58.60 – 58.88 mm (4) LEFT MAINSHAFT BEARING 58.30 – 58.52 mm (5) LEFT CRANKSHAFT OIL SEAL 1 ±...

  • Page 104: Transmission Assembly

    Engine servicing Transmission Assembly (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 3-58...

  • Page 105: Crankcase Combination

    Engine servicing (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 Crankcase Combination Clean the crankcase mating surfaces before assembling and check for wear or damage.
  • Page 106 Engine servicing (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 and clutch outer onto the mainshaft and attach the gear steps.
  • Page 107 Engine servicing (1) DRIVE PIN (1) DRIVE SPROCKET (2) OIL PUMP DRIVEN GEAR (2) UNIVERSAL HOLDER (3) SPRING WASHER (4) BOLT Install the drive sprocket. Install the spring washer and drive sprocket bolt. Hold the drive sprocket with universal holder, tighten the special bolt to the specified torque.
  • Page 108 Memo 3-62 3-62...

  • Page 109: Frame Servicing

    4. Frame servicing (1) AXLE PINCH BOLT (2) AXLE Front Wheel Removal Loosen the axle pinch bolt. Support the motorcycle and front wheel off the ground. Remove the axle and front wheel. Drive bearing 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...

  • Page 110: Fork

    Frame servicing (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. Fork Clean the surfaces where the axle and axle clamps Torque: 21 N•m (2.1 kgf•m, 17 lbf•ft) contact each other.
  • Page 111 Frame servicing (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. Do not overtighten.
  • Page 112 Frame servicing (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.
  • Page 113 Frame servicing (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 Right Fork Assembly Fork Damper Check the fork damper assembly for damage or Check the following items (page 1-4): deformation.
  • Page 114 Frame servicing (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.
  • Page 115 Frame servicing (1) FORK FLUID (2) FORK TUBE Pour recommended fork fluid in the fork leg. Specified fork fluid: Tech OJ01 (SAE 5) 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.
  • Page 116 Frame servicing (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.
  • Page 117 Frame servicing (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.
  • Page 118 Frame servicing (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.

  • Page 119: Steering Stem

    Frame servicing 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 Steering stem Installation Tighten the bottom bridge pinch bolts to the specified torque.
  • Page 120 Frame servicing (1) ADJUSTING NUT (1) STEM (1) STEM (2) LOWER BEARING (2) DUST SEAL (3) DUST SEAL (3) BEARING (4) STEERING STEM DRIVER Install new dust seal onto the steering stem. Install the new lower bearing into the steering stem using a hydraulic press and driver.
  • Page 121 Frame servicing (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.

  • Page 122: Rear Wheel

    Frame servicing (1) TOP BRIDGE (1) ADJUSTER (2) STEM NUT (2) AXLE Rear Wheel Turn the steering stem lock-to-lock 5 times to seat the Apply grease to the stem bolt threads and seating bearings and retighten the adjusting nut to the specified surfaces.
  • Page 123 Frame servicing Spokes: Check spoke tension frequently between the first few rides. As the spokes, spoke nuts and rim contact 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 hold their tension.

  • Page 124: Shock Absorber

    Frame servicing (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 Install the drive chain.
  • Page 125 Frame servicing (1) SPANNER WRENCH (1) CIRCLIP Removal 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...
  • Page 126 Frame servicing (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.

  • Page 127: Shock Linkage

    Frame servicing (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. Shock Linkage Set the shock absorber into the frame and install the Install and tighten the upper and lower mounting nuts to...

  • Page 128: Swingarm

    Frame servicing 3 mm (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...
  • Page 129 Frame servicing 5,5 mm (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: Disassembly Pivot Bearing Replacement –...
  • Page 130 Frame servicing 3 mm (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...
  • Page 131 Frame servicing (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 Apply thin coat of grease to the swingarm pivot bolt O-rings.

  • Page 132: Front Brake Pad Replacement

    Frame servicing (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: Front Brake Pad Replacement – Shock arm plates-to-swingarm bolt/nut – Rear cushion lower mounting bolt/nut Clean the brake disc with a high quality degreasing agent if they are contaminated with oil or grease.

  • Page 133: Rear Brake Pad Replacement

    Frame servicing (1) NEW PADS (1) BOLT (2) PAD SPRING PIN (2) SPEED SENSOR (3) SPEED SENSOR BRACKET Rear Brake Pad Replacement Install the new pads and secure with the spring pin for 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.
  • Page 134 Frame servicing (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.

  • Page 135: Front Brake Caliper

    Frame servicing (1) OIL BOLT (1) OIL BOLT / STOP SWITCH (2) MOUNTING BOLTS (2) BRAKE HOSE (3) BRAKE CALIPER (3) BRAKE CALIPER Rear brake caliper Inspection Front brake caliper Clean the inside of the caliper. Removal Removal Check the oil leakage from the caliper cylinders. NOTICE NOTICE If any part of the caliper is damaged, replace the caliper...

  • Page 136: Front Master Cylinder

    Frame servicing (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.
  • Page 137 Frame servicing (1) BOOT (2) SNAP RING (3) PISTON ASSEMBLY (4) SPRING (5) OIL SEAL (6) CIRCLIP 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 –...

  • Page 138: Rear Master Cylinder

    Frame servicing (1) OIL BOLT (1) BOLTS (1) NUT (2) BRAKE HOSE (2) MASTER CYLINDER (2) BOLT (3) MASTER CYLINDER (3) BRAKE PEDAL Rear master cylinder Brake pedal Remove the mounting bolts and master cylinder. Installation Removal/Installation Removal Installation is in the reverse order of removal. Remove the brake pedal pivot nut and bolt.

  • Page 139: Clutch Master Cylinder

    Frame servicing 3 mm (0.12 in) (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.
  • Page 140 Frame servicing (1) BOOT (2) SNAP RING (3) PISTON ASSEMBLY (4) SPRING (5) OIL SEAL (6) CIRCLIP 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 –...

  • Page 141: Electrical Servicing

    5. Electrical servicing (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 resistance between the yellow terminals of the alternator Disconnect the power 4P (Natural) connector.
  • Page 142 Electrical servicing (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 Remove the throttle body (page 3-13). Disconnect the alternator 3P (Natural) connector and ignition pulse generator 2P (Natural) connector. (1) BOLT (1) 2P (BLACK) CONNECTOR (2) BRAKE RESERVOIR...

  • Page 143: Ignition System Inspection

    Electrical servicing (1) BOLTS (1) PRIMARY TERMINALS (1) SPARK PLUG CAP (2) REGULATOR/RECTIFIER (2) TIE-WRAP Ignition system inspection Remove the bolts and regulator/rectifier from the electric Ignition coil Removal/Installation stay. Remove the fuel tank/injector assembly. Ignition coil inspection Install the regulator/rectifier and condenser in the reverse order of removal.
  • Page 144 Electrical servicing (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.

  • Page 145: Pgm-Fi System Inspection

    Electrical servicing (1) CONDENSER (1) 32P (BLACK) CONNECTOR PGM-FI System inspection Condenser 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”...

  • Page 146: Pgm-Fi

    Electrical servicing (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.

  • Page 147: Pgm-Fi Self-Diagnosis Malfunction Indicator Lamp (Mil) Failure Codes

    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.

  • Page 148: Bank Angle Sensor Inspection

    Electrical servicing (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.

  • Page 149: Engine Stop Switch Inspection

    Electrical servicing (1) CONNECTORS (1) 2P (NATURAL) CONNECTOR (1) FAN MOTOR RELAY Engine stop switch inspection Cooling fan system inspection Fan motor relay inspection Remove the fan motor relay. Disconnect the engine stop switch connectors. Fan motor inspection Connect the ohmmeter to the fan motor relay connector Check the engine stop switch for continuity.

  • Page 150: Lights / Instruments / Switches

    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.

  • Page 151: Indicator Light/Indicator Light Relay

    Electrical servicing Servicing information  Bear in mind the following when replacing the front 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 cause it to break.

  • Page 152: Brake Light

    Electrical servicing (1) BRAKE LIGHT LAMP (1) 2P CONNECTOR FOR THE BRAKE LIGHT SWITCH Brake light. Brake light switch. Checking indicator line: 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:...

  • Page 153: Speedometer

    Electrical servicing (1) CONNECTOR 2P FROM THE REAR BRAKE LIGHT (1) HOUSING FOR THE HEADLIGHT (1) SPEEDOMETER SWITCH. (2) BOLTS (3) SPEEDOMETER (4) CONNECTOR 6P Rear: Checks: (5) CONNECTOR 3P Check for loose or defective contacts in the connectors Disconnect the connector 2P from the rear brake light 6P and 3P of the speedometer.

  • Page 154: Speed Sensor

    Electrical servicing (1) CONNECTOR 6P (1) SPEED SENSOR Speed sensor Power input line Measure the voltage between the connector 6P of the System check speedometer and the ground. NOTICE Connection: White/Red(+) and Ground (–) With the engine on, around 12V should be received. ...

  • Page 155: Horn

    Electrical servicing FREE PUSH COLOR BATTERY BATERÍA BATERÍA HORN SWITCH INTERRUPTOR DE LA BOCINA (1) HOUSING FOR THE UPPER HEADLIGHT (1) HORN (2) CONNECTOR 6P (2) CONNECTORS (3) CONNECTOR 3P Horn If there is no voltage, check the following: Checking the speed sensor ...

  • Page 156: Wiring Diagram

    Electrical servicing Wiring diagram POWER RELAY WINKER TURN SIGNAL RELAY SENSOR F1 - ECU INDICATOR LIGHT 12V 1,2 W SPEED FUEL SENSOR, HIGH BEAM MOTOR PUMP REAR WHEEL INDICATOR LIGHT 12V 1,2 W METER INDICATOR LIGHT 12V 1,2 W RIGHT REAR DIGITAL METER TURN SIGNAL LIGHT 12V 10W...
  • Page 157 Memo Memo 5-17 5-17...

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4ride mst260g 2016

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