Montesa COTA 300RR 2018 Owner's Manual
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Montesa COTA 300RR 2018 Owner's Manual

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2018
Owner's Manual
PGM-FI Racing Trial

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Summary of Contents for Montesa COTA 300RR 2018

  • Page 1 2018 Owner’s Manual PGM-FI Racing Trial...
  • Page 2 2018 Important This motorcycle is designed and constructed as an operator-only model. The motorcycle load limit and seating configuration do not safety permit the carrying of a passenger. Read this manual carefully. This manual should be considered as a permanent part of the motorcycle and should remain with the motorcycle when resold. Safety Messages Damage Prevention Messages Your safety and the safety of others is very important.
  • 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. MRT 300 J VTDND15A?JE000001 NN4E7001001...
  • Page 5 Labels The following pages show the meanings and locations of the labels on your Cota. Others provide important safety information. Read this information carefully and don’t remove the labels. If a label comes off or becomes hard to read, contact your dealer for a replacement. There is a specific symbol on each label.
  • Page 6 Labels (2ED)
  • Page 7 Labels (4ED)
  • Page 8 Genuine accessories that have been specifically designed protection, and proper protective gear. and tested for your Cota. Because Montesa cannot test all other accessories, you must be personally responsible Take Time to Get to Know Your Cota.

  • Page 9: Table Of Contents

    Contents Brake Fluid ..........3-13 5. Frame servicing Brake Pad Wear ..........3-14 Front Wheel ..........5-1 Brake System ..........3-14 1. Operating instructions Fork ............5-3 Handlebar And Steering Head Bearings .... 3-15 Steering stem ..........5-12 Operation component locations (2ED)....1-1 Wheels And Tires .........
  • Page 10 To The New Owner Importance Of Proper Preparation How To Use This Manual By selecting a MONTESA COTA 300RR as your new Proper pre-competition preparation and regular service The purpose of this Owner’s Manual is to help ensure that machine, you have placed yourself in a distinguished...
  • Page 11 Memo Memo...

  • Page 12: Operating Instructions

    1. Operating instructions Operation component locations (2ED) rearview mirror rearview mirror front brake lever clutch lever light control, turn signal & horn switch throttle grip magnetic stop switch kickstarter shift lever rear brake pedal...

  • Page 13: Operation Component Locations (4Ed)

    Operating instructions Operation component locations (4ED) clutch lever front brake lever mapping switch throttle grip magnetic stop switch kickstarter shift lever rear brake pedal...

  • Page 14: Fuel

    Operating instructions (1) BREATHER HOSE (1) RADIATOR CAP (1) KICKSTARTER PEDAL (2) FUEL TANK CAP Fuel Coolant Basic Operation Gasoline: Unleaded gasoline, pump octane number 95 Starting The Engine The engine of COTA is a water-cooled type. In order to (RON) or higher provide adequate cooling, it is essential that the radiator Fuel tank capacity:...
  • Page 15 Operating instructions (1) SIDE STAND Break-In Procedure Side Stand New Motorcycle The side stand is used to support your Cota while parked. Following proper break-in procedure helps ensure that To operate, use your foot to lower the side stand until it the most important and expensive components on your is fully extended.

  • Page 16: Odometer/Speedometer (2Ed)

    Operating instructions (1) SIDE STAND (1) SPEEDOMETER (1) M (MODE) BUTTON (2) SIDE STAND SPRINGS (2) TURN SIGNAL INDICATOR (2) S (SET) BUTTON (3) HIGH BEAM INDICATOR (4) ODOMETER Inspection (5) MALFUNCTION INDICATOR LAMP (MIL) 1. Check the stand springs for damage or loss of tension. Odometer/Speedometer (2ED) 2.

  • Page 17: Steering Lock

    Operating instructions (1) STEERING LOCK Steering lock (2ED) 2. Changing from “Odo” to “Trip 1” display 3. Changing from “Trip 1” to “Trip 2” display 1. Start the motorcycle. 1. With the motorcycle running and set to “Trip 1”: The steering lock is on the steering stem. To lock the 2.

  • Page 18: Shifting Gears

    Operating instructions Braking To slow or stop, apply the front brake lever and rear brake Remember to close the throttle and pull the clutch lever in pedal smoothly, while downshifting to match your speed. completely before shifting. Gradually increase braking as you feel the brakes slowing your speed.

  • Page 19: Controls

    Operating instructions (1) UPPER LEVEL LINE (1) ADJUSTER (1) CLUTCH LEVER (2) LOCK NUT (2) FREE PLAY Controls Clutch Lever Clutch Lever Free Play Standard cluth lever free play should be between The clutch lever free play can be adjusted by turning the 0.5 –...
  • Page 20 Operating instructions (1) DUST COVER (A) DECREASE (1) HEADLIGHT DIMMER SWITCH (1) TURN SIGNAL SWITCH (2) LOCK NUT (B) INCREASE (3) ADJUSTER Throttle Grip Headlight dimmer switch Turn signal switch Throttle Grip Free Play Turn the dimmer switch to to select high beam or to Move to to signal a left turn, to signal a right turn.
  • Page 21 Operating instructions (1) HORN BUTTON (1) MAGNETIC STOP SWITCH (1) MAPPING SWITCH (2) MODE 1 (3) MODE 2 Horn button Magnetic stop switch Mapping switch Press the button to sound the horn. Pull the stop magnetic switch (red) until the engine stops The ECU for the Cota 300RR (4ED) PGM-FI electronic in- completely.
  • Page 22 Operating instructions (1) ADJUSTER (1) FRONT BRAKE LEVER (1) LOCK NUT (2) LOCK NUT (2) FREE PLAY (2) ROD (3) ADJUSTING BOLT (4) FREE PLAY Front brake lever Front brake lever free play Standard front brake lever free play should be Brake pedal height The front brake lever free play can be adjusted by turning between 0.5 –...
  • Page 23 Operating instructions (1) HANDLEBAR Handlebar position, width and shape Position the handlebar so that gripping the bar and ope- rating the controls is comfortable while both seated and standing, while riding straight ahead and turning. Handlebar width can be trimmed with a hacksaw to bet- ter your particular shoulder width and riding preference.

  • Page 24: Specifications

    2. Service data Specifications Item Specification Item Specification Dimensions Fuel System Overall length 2,020 mm Type PGM-FI Overall width 840 mm Identification number GQPFB (2ED) GQPFC (4ED) Overall height 1,135 mm Throttle bore 28 mm Wheelbase 1,320 mm Drive Train Seat height 679 mm Clutch operating system...
  • Page 25 Service data Service data Unit: mm (in) Item Specification Item Standard Service limit Lubrication Cylinder Head/Valves Repsol 4T oil-stroke motorcycle oil SAE 10W-30 or Cylinder compression 1,300 kPa (13.2 kgf/cm , 189 psi) – Specified engine oil equivalent Cylinder head warpage –...
  • Page 26 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 80.000 – 80.015 (3.1496 – 3.1502) 80.045 (3.1514) Taper – 0.05 (0.002) Left – 0.05 (0.002) Out-of- round –...
  • Page 27 Service data Unit: mm (in) Unit: mm (in) Item Standard Service Limit Item Standard Service Limit Wheels/Tires Rear Suspension SHOWA Axle runout 0.20 (0.008) Shock absorber spring pre-load 126.5 (4.98) – Tire air pressure Spring free length 133 (5.2) 130.3 (5.13) For road use 100 kPa (1.01 kgf/cm –...

  • Page 28: 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 29 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 30: 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 Generic tool 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 31: 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 32 Service data Cam chain tensioner bolt Left crankcase drain hole #190 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...
  • Page 33 Service data Frame Item Material Remarks Item Material Remarks Multi-purpose grease Locking agent Steering head bearing race and bearings Drive chain adjuster stopper screws threads Steering head dust seal lips Side stand bracket bolt threads Swingarm pivot needle bearing Drive chain slider mounting screw threads Swingarm pivot dust seal lips Rear brake hose clamp screw threads Shock link/shock arm needle bearings...

  • Page 34: Cable & Harness Routing (2Ed)

    Service data Cable & Harness Routing (2ED) FRONT 45º (1) FRONT BRAKE HOSE (2) THROTTLE CABLE FRONT (3) CLUTCH HOSE (4) MAGNETIC STOP SWITCH CONNECTOR 2-11 2-11...

  • Page 35: Cable & Harness Routing (4Ed)

    Service data Cable & Harness Routing (4ED) 15 mm FRONT 90º (1) FRONT BRAKE HOSE (2) THROTTLE CABLE (3) CLUTCH HOSE FRONT (4) MAGNETIC STOP SWITCH CONNECTOR (5) MAPPING SWITCH 2-12 2-12...
  • Page 36 Service data Cable & Harness Routing (2ED) (1) SPEEDOMETER (14) INDICATOR LIGHT INSTALLATION (2) POWER RELAY (15) INDICATOR LIGHT INSTALLATION CONNECTOR (3) WINKER RELAY (16) RIGHT REAR TURN SIGNAL CONNECTORS (4) FAN MOTOR RELAY (2ED) (17) LEFT REAR TURN SIGNAL CONNECTORS (5) RIGHT FRONT TURN SIGNAL CONNECTORS (18) CLAMPS (6) LEFT FRONT TURN SIGNAL CONNECTORS...

  • Page 37: Cable & Harness Routing

    Service data Cable & Harness Routing 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...
  • Page 38 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) CONNECTORS BOOT (8) FILTER BOX BREATHER HOSE – FAN MOTOR 2P (BLACK) CONNECTOR (9) CYLINDER HEAD BREATHER HOSE –...
  • Page 39 Service data UPPER UPPER 45º (1) THROTTLE CABLE (2) CLUTCH HOSE (3) FUEL TANK BREATHER HOSE 2-16 2-16...
  • Page 40 Service data UPPER UPPER UPPER (1) MAIN WIRE HARNESS (6) REGULATOR/RECTIFIER 5P (BLACK) CONNECTOR (2) TRANSMISSION BREATHER HOSE (7) BANK ANGLE SENSOR (3) FILTER BOX BREATHER HOSE (8) FAN MOTOR RELAY (4ED) (4) ALTERNATOR WIRE (9) REAR BRAKE RESERVOIR TANK (5) CONDENSER 2P (BLACK) CONNECTOR (10) SPEED SENSOR CABLE (2ED) 2-17...
  • Page 41 Service data Clamp at white tape (1) MAIN WIRE HARNESS (TO CONNECTOR COVER) (8) REGULATOR/RECTIFIER 5P (BLACK) CONNECTOR (2) MAIN WIRE HARNESS (TO RELAY) (9) CONDENSOR (3) MAIN WIRE HARNESS (TO ECU) (10) CONDENSOR 2P (BLACK) CONNECTOR (4) AIR FILTER BOX BREATHER HOSE (11) BANK ANGLE SENSOR (5) TRANSMISSION BREAHTER HOSE (12) FAN MOTOR RELAY (4ED)
  • Page 42 Service data UPPER 90º UPPER (1) REAR BRAKE HOSE (2) REAR BRAKE RESERVOIR HOSE (3) SPEED SENSOR (2ED) 2-19 2-19...
  • Page 43 Service data (1) FUEL FEED HOSE (2) TRANSMISSION BREATHER HOSE 2-20 2-20...

  • Page 44: Service And Maintenance

    3. Service and maintenance Maintenance schedule Pre-ride Inspection Perform pre-ride Inspection at each scheduled maintenance period. For your safety, it is very important to take a few moments I: Inspect and clean, Adjust, Lubricate or Replacement if necessary. C: Clean, R: Replace, L: Lubricate. before each ride to walk around your COTA 300RR and check its condition.

  • Page 45: Warming-Up Inspection

    Service and maintenance Warming-up Inspection Replacement Parts When warming-up the engine, check for the following: Parts Requiring Periodic Replacement  Do not rev the engine more than necessary or engine damage may result. Item Replacement Interval Cause  Check for fuel, oil and water leaks ...

  • Page 46: 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 rear fender.

  • Page 47: 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 48 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 49: 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 50 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 51: Engine Idle Speed

    Service and maintenance (1) IDLE SPEED ADJUSTMENT 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 (75W) Oil Change Inspect and adjust the idle speed after all other engine adjustments are within specification.

  • Page 52: 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 53: Clutch System

    Service and maintenance (1) FILLER NECK (1) CLUTCH FLUID RESERVOIR (1) EXHAUST PIPE (2) LOWER LEVEL LINE (2) MUFFLER (3) LAMBDA-SONDE (2ED) 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 54: 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 55: 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 56: 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 57: 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 Measure the brake pad thickness.

  • Page 58: Handlebar And Steering Head Bearings

    Service and maintenance (1) HOLDER BOLTS (1) STEERING HEAD BEARINGS (1) SPOKE NIPPLE (2) UPPER HOLDER (2) RIM LOCK Wheels And Tires Handlebar And Steering Head Bearings Steering Head Bearings Proper air pressure will provided maximum stability and Support the motorcycle using the maintenance stand with Handlebar tire life.

  • Page 59: 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 Cota’s front suspension. Inspection The motorcycle is shipped with a light coating of grease Specified fork fluid: 1.

  • Page 60: Rear Suspension

    Service and maintenance (1) PRE-LOAD ADJUSTER (1) REBOUND ADJUSTER Rear Suspension  When your Cota is new, your suspension will break-in Inspection as you ride.  After break-in is completed, test ride your Cota with 1. Check for a broken or collapsed spring. The swingarm is controlled by a shock absorber.

  • Page 61: Front Headlight And Front And Rear Position Light

    Service and maintenance (1) SCREWS (1) DUST COVER (2) THE HOUSING FOR THE UPPER HEADLIGHT (2) BULB PAWL (3) BULB (4) CONNECTORS Front headlight and front and rear position – Remove the housing for the upper headlight. light. – Disconnect the connectors. –...

  • Page 62: Cleaning

    Service and maintenance Cleaning Storage 6. Inflate the tires to their recommended pressure. 7. Place your COTA on the maintenance stand or equiva- lent to raise both tires off the ground. Clean your COTA regularly to protect the surface finishes Extended storage, such as for winter, requires that you 8.
  • Page 63 Memo 3-20 3-20...

  • Page 64: Engine Servicing

    4. 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 4-49). Separate the crankcase halves (page 4-54).
  • Page 65 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 66 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 67: 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 Turn off the engine.

  • Page 68: 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 69 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 rear fender.

  • Page 70: 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 71 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 72 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 73 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 74 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 75 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 76: 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 rear fender. Remove the rear fender.
  • Page 77 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 78: 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 79 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 80: 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 81: 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 82 Engine servicing Engine Removal/Installation Illustration 24 N•m (2.4 kgf•m) (17.8 lbf•ft) 24 N•m 26 N•m (2.4 kgf•m) (2.6 kgf•m) (17.8 lbf•ft) (19.2 lbf•ft) 26 N•m (2.6 kgf•m) (19.2 lbf•ft) 69 N•m 39 N•m (6.9 kgf•m) (4.0 kgf•m) (50.9 lbf•ft) (28.7 lbf•ft) 50 N•m (5.1 kgf•m) (36.8 lbf•ft)

  • Page 83: 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 84 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 85 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 86: 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 87 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 88: Cylinder Head Disassembly

    Engine servicing (1) CAM CHAIN GUIDE (1) VALVE SPRING COMPRESSOR (1) RETAINER (2) ALIGN (2) ATTACHMENT (2) OUTER SPRING (3) COTTERS (3) INNER SPRING (4) SPRING SEAT Cylinder Head Disassembly (5) VALVE (6) STEM SEAL Remove the cylinder head (page 4-23). (7) COTTERS Remove the valve spring cotters using the special tools.

  • Page 89: 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 90: 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 Service limit:...

  • Page 91: 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 92 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 93 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 94: 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 95: Cylinder/Piston

    Engine servicing (1) VALVE SPRING COMPRESSOR (1) PLASTIC HAMMERS (1) BOLTS (2) ATTACHMENT (2) CAM CHAIN TENSIONER LIFTER (3) COTTERS (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 96 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 97 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 98 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 99 Engine servicing (1) TENSIONER LIFTER (1) TOP RING (SILVER) (1) INDENTS (2) SECOND RING (BLACK) (2) PISTON PIN (3) OIL RINGS (3) NEW PISTON PIN CLIP (4) SPACER Tensioner lifter (5) INDENTS Piston Installation Check the tensioner lifter operation as follows: –...

  • Page 100: 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 101: 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 nut to the mounting bolts securely.
  • Page 102 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 103: 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 104: 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 105 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 106: 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 107 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 (page 2-2).  Clutch outer for wear, cracks or indentation by the clutch discs.
  • Page 108 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 109: 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 110: 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 111 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 112: Left Crankcase Cover

    Engine servicing (1) WASHER (2) GEARSHIFT SPINDLE (1) 3P (NATURAL) CONNECTOR (1) DRAIN BOLT/SEALING WASHER (3) RETURN SPRING PIN (4) SHIFTER COLLAR (2) 2P (NATURAL) CONNECTOR (2) BOLTS (3) LEFT CRANKCASE COVER Left Crankcase Cover Remove the engine oil drain bolt and sealing washer, drain the engine oil.
  • Page 113 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 114 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 115: 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 (Natural) connector and ignition Removal pulse generator 2P (Natural) connectors.
  • Page 116 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 117: 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 118 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 119: 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 120 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 121: Transmission Assembly

    Engine servicing Transmission Assembly (1) M2 (13T) (2) M4 (28T) (3) M3 (15T) (4) M5 (22T) (5) MAINSHAFT/M1 (15T) (6) C2 (31T) (7) C4 (28T) (8) C3 (30T) (9) C5 (22T) (10) C1 (42T) (11) COUNTERSHAFT 4-58 4-58...

  • Page 122: 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 123 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 124 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 125 Memo 4-62 4-62...

  • Page 126: Frame Servicing

    5. Frame servicing (1) AXLE PINCH BOLT (2) AXLE Front Wheel Removal Remove the brake caliper mounting bolts, disc cover and collars. Loosen the axle pinch bolt. Drive bearing When unassembling change bolt for new one’s Support the motorcycle and front wheel off the ground. into the hub until it Apply a locking agent to the threads Remove the axle and front wheel.
  • Page 127 Frame servicing (1) AXLE (1) BRAKE CALIPER (1) AXLE PINCH BOLT (2) DISC COVER (3) BOLTS Installation Install the brake caliper, flange collars and disc cover. While keeping the fork parallel, tighten the axle pinch bolt Apply a locking agent to the threads and tighten the mou- to the specified torque.

  • Page 128: Fork

    Frame servicing (1) FRONT FENDER (1) FORK BOLT (1) LOCK NUT (2) TOP BRIDGE (2) FORK LEG (2) FORK BOLT (3) BOTTOM BRIDGE (4) FORK LEG Right Fork Disassembly Fork Before disassembling the fork, clean the entire sliding sur- face and the bottom of the fork slider. Removal Be careful not to scratch the fork tube.
  • Page 129 Frame servicing (1) FORK DAMPER (1) FORK DAMPER (1) DUST SEAL (2) RIGHT FORK CENTER BOLT (2) CENTERING PLATE (2) STOP RING (3) FORK TUBE (3) FORK SLIDER Hold the axle holder in a vise protected with a piece of Remove the fork damper assembly and centering plate woods or soft jaws to avoid damage.
  • Page 130 Frame servicing (1) FORK TUBE BUSHING (1) BUSHING (1) FORK DAMPER (2) GUIDE BUSHING (2) DAMPER ROD (3) BACK-UP RING (3) FORK TUBE (4) OIL SEAL (4) CENTERING PLATE (5) FORK SLIDER Right Fork Inspection Check that the fork tube moves smoothly in the slider. Fork Damper If it does not, check the fork tube bending or damage, and Check the fork damper assembly for damage or...
  • Page 131 Frame servicing (1) FORK TUBE BUSHING (1) FORK SEAL DRIVER (1) GUIDE BUSHING (4) STOP RING (2) GUIDE BUSHING (2) BUCK-UP RING (5) DUST SEAL (3) BACK-UP RING (3) OIL SEAL (4) OIL SEAL Using the special tool, drive the guide bushing and back- (5) FORK SLIDER up ring until the stop ring groove is fully stuck in the fork slider base.
  • Page 132 Frame servicing (1) FORK DAMPER (1) FORK FLUID (2) RIGHT FORK CENTER BOLT (2) FORK TUBE Hold the axle holder in a vise protected with a piece of Pour recommended fork fluid in the fork leg. woods or soft jaws to avoid damage. Specified fork fluid: Do not overtighten the vise.
  • Page 133 Frame servicing (1) FORK BOLT (1) CILINDER ASSY (2) DISTANCE COLLAR (2) CENTER BOLT (3) SPRING SEAT (4) FORK SPRING 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 Do not overtighten.
  • Page 134 Frame servicing (1) FORK TUBE (1) CILINDER ASSY (1) FORK TUBE (2) CILINDER ASSY (2) PISTON RING (2) CILINDER ASSY (3) TAPERED BUSHING (3) REBOUND SPRING (3) TAPERED BUSHING (4) FORK SLIDER (4) TAPERED BUSHING (4) FORK SLIDER Remove the tapared bushing from the cilinder assy. Left Fork Inspection Left Fork Assembly Check the following items (page 2-4):...
  • Page 135 Frame servicing (1) CILINDER ASSY (1) GUIDE BUSHING (2) CENTER BOLT (2) BACK-UP RING (3) OIL SEAL (4) STOP RING Hold the axle holder in a vise protected with a piece of Pour half the required amount of recommended fork fluid (5) DUST SEAL wood or soft jaws to avoid damage.
  • Page 136 Frame servicing FORWARD (1) FORK SPRING (1) FORK TUBE (1) BOTTOM BRIDGE PINCH BOLTS (2) SPRING SEAT (2) TOP BRIDGE (2) FORK BOLT (3) DISTANCE COLLAR (3) TOP BRIDGE PINCH BOLTS (4) O-RING (NEW) Installation Tighten the bottom bridge pinch bolts to the specified (5) FORK BOLT torque.

  • Page 137: Steering Stem

    Frame servicing (1) STEM NUT (1) ADJUSTING NUT (1) STEM (2) TOP BRIDGE (2) LOWER BEARING (3) DUST SEAL Steering stem Disassembly Remove the following: – Handlebar – Front wheel (page 5-1) – Front fender Remove the steering stem nut and washer. Remove the fork legs (page 5-3).
  • Page 138 Frame servicing (1) STEM (1) DRIVER (1) STEM (2) DUST SEAL (2) ATTACHMENT (2) UPPER BEARING (3) BEARING (3) DUST SEAL (4) STEERING STEM DRIVER Tools: Install new bearing races. Driver 07749-0010000 Install new dust seal onto the steering stem. Attachment, 42 x 47 mm 07746-0010300 Pack the upper and lower bearings with grease.
  • Page 139 Frame servicing (1) ADJUSTING NUT (1) TOP BRIDGE (2) STEM NUT Screw the stem bearing adjusting nut all the way with Turn the steering stem lock-to-lock 5 times to seat the Apply grease to the stem nut thread and seating surfaces. your fingers.

  • Page 140: Rear Wheel

    Frame servicing Spokes: Check spoke tension frequently between the first few rides. As the spokes, spoke nuts and rim contact 32 N•m (3,2 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 141: Shock Absorber

    Frame servicing (1) AXLE (1) 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 142 Frame servicing (1) SPRING COMPRESSOR (1) VALVE CAP (1) DUST SEALS (2) ATTACHMENT (2) STOP RING (3) SPRING SEAT STOPPER (3) SPHERICAL BEARING DISASSEMBLY Nitrogen Releasing Procedure Spherical Bearing Replacement Remove the air valve cap and press the valve stem and release the nitrogen from the damper until pressure is Loosen the spring lock nut and adjuster.
  • Page 143 Frame servicing (1) SPRING (1) PRE-LOAD LENGTH (1) UPPER MOUNTING BOLT/NUT (2) SPRING SEAT (2) ADJUSTER (3) STOPPER RING (3) LOCK NUT (4) COMPRESSOR Adjust the spring pre-load length (page 2-4). Installation Hold the spring adjuster and tighten the lock nut to the Assembly specified torque.

  • Page 144: Shock Linkage

    Frame servicing 3 mm (1) LOWER MOUNTING BOLT/NUT (1) LOWER MOUNTING BOLT/NUT (1) PIVOT COLLAR A (2) BOLTS/NUTS (2) PIVOT COLLAR B (3) CUSHION ARM PLATES (3) DUST SEALS (4) CUSHION LINK (4) NEEDLE BEARINGS Move the swingarm aligning the lower mount, then install the lower mounting bolt from the right side.

  • Page 145: Swingarm

    Frame servicing (1) CUSHION LINK (1) SHOCK ABSORBER LOWER MOUNTING BOLT/NUT (1) BRAKE HOSE CLAMPS (2) CUSHION ARM PLATES (2) SHOCK ARM PLATES-TO-SWINGARM BOLT/NUT (2) SWINGARM PIVOT BOLT/NUT (3) BOLTS/NUTS (4) LOWER MOUNTING BOLT/NUT Swingarm Remove the following: Installation – Brake hose clamps screws Removal –...
  • Page 146 Frame servicing 3 mm 5,5 mm (1) DUST SEAL CAP (1) NEEDLE BEARING (1) PIVOT COLLAR A (2) DUST SEAL (2) DUST SEAL (2) PIVOT COLLAR B (3) PIVOT COLLAR (3) BUSHING (3) DUST SEALS (4) DUST SEAL (4) NEEDLE BEARINGS Disassembly PIVOT BEARING REPLACEMENT Link Bearing Replacement...
  • Page 147 Frame servicing (1) DUST SEAL (1) DUST SEAL (1) CHAIN TENSIONER (2) PIVOT COLLAR (2) PIVOT COLLAR (2) BUSHINGS (3) DUST SEAL (3) DUST SEAL (3) O-RINGS (4) DUST SEAL CAP (4) DUST SEAL CAP (4) PIVOT BOLT (5) NEEDLE BEARING Assembly Apply grease to the pivot chain tensioner, bushings and Install the pivot collars, dust seals and dust seal caps.
  • Page 148 Frame servicing (1) DRIVE CHAIN SLIDER (1) PIVOT BOLT/NUT (1) SHOCK ARM PLATES-TO-SWINGARM BOLT/NUT (2) SCREWS (2) HOSE CLAMPS (2) SHOCK ABSORBER LOWER MOUNTING BOLT/NUT Installation Install the following: – Shock arm plates-to-swingarm bolt/nut – Rear cushion lower mounting bolt/nut Apply thin coat of grease to the swingarm pivot bolt surface.

  • Page 149: Front Brake Pad Replacement

    Frame servicing (1) PAD SPRING PIN (1) NEW PADS (2) BOLTS (2) PAD SPRING (3) DISC COVER (3) PIN (4) CALIPER (4) CIRCLIP Front Brake Pad Replacement Push the pistons all the way in to allow installation of new Install the new pads, the spring from the pads and secure brake pads.

  • Page 150: Rear Brake Pad Replacement

    Frame servicing (1) BOLT (1) BRAKE PADS (2) SPEED SENSOR (2) PAD PIN (3) SPEED SENSOR BRACKET Rear Brake Pad Replacement Remove the pad pin and brake pads. Clean the brake caliper inside especially around the caliper pistons. Clean the brake disc with a high quality degreasing agent if they are contaminated with oil or grease.

  • Page 151: Front Brake Caliper

    Frame servicing (1) CALIPER BRACKET (1) CALIPER PISTON (1) BRAKE HOSE OIL BOLT (2) BOSS/SLIT (2) MOUNTING BOLTS (3) DISC COVER Install the new pads and secure them with the pad pin. (4) BRAKE CALIPER Install the brake caliper bracket aligning its slit with the boss on the swingarm.

  • Page 152: Rear Brake Caliper

    Frame servicing (1) OIL BOLT (1) CALIPER PISTON (2) BRAKE HOSE (3) BRAKE CALIPER Rear brake caliper Inspection Inspection Clean the inside of the caliper. Clean the inside of the caliper. Removal Check the oil leakage from the caliper cylinders. Check the oil leakage from the caliper cylinder.

  • Page 153: Front Master Cylinder

    Frame servicing (1) BOOT (2) SNAP RING (3) PISTON ASSEMBLY (4) SPRING (5) OIL SEAL (6) CIRCLIP (1) OIL BOLT (2) BRAKE HOSE (3) BOLT (4) HOLDER (5) MASTER CYLINDER Front master cylinder Removal/Installation NOTICE  Avoid spilling brake fl uid on painted, plastic or rubber parts.

  • Page 154: 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 155: 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) 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 156 Frame servicing (1) BOOT (2) SNAP RING (3) PISTON ASSEMBLY (4) SPRING (5) OIL SEAL (6) CIRCLIP Disassembly/Assembly Inspection Check the following items (page 2-3): NOTICE – Master cylinder and piston for scoring, scratches or other damage  Keep the master cylinder piston, oil seals, spring and –...
  • Page 157 Memo Memo 5-32 5-32...

  • Page 158: Electrical Servicing

    6. 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 159 Electrical servicing (1) 3P (NATURAL) CONNECTOR (1) 2P (BLACK) CONNECTOR (1) BOLTS (2) 2P (NATURAL) CONNECTOR (2) 6P (BLACK) CONNECTOR (2) ELECTRICAL COMPONENTS SUPPORT (1) FAN MOTOR RELAY (2ED) (1) BOLT (1) 2P (BLACK) CONNECTOR (2) BRAKE RESERVOIR (2) CONDENSER Regulator/Rectifier Removal/installation Disconnect the condenser 2P (Black) and regulator/ Remove the electrical components support bolts, then...

  • Page 160: 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 electrical Ignition coil Removal/Installation components support. Remove the fuel tank/injector assembly. Ignition coil inspection Install the regulator/rectifier and condenser in the reverse order of removal.
  • Page 161 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 162: 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 rear fender. does not start” in the PGM-FI Malfunction Indicator Lamp Disconnect the ECM 32P (Black) connector.
  • Page 163 Electrical servicing (1) MALFUNCTION INDICATOR (MIL) (1) PGM WARNING UNIT ASSEMBLY (1) POWER SWITCH (2) RED WIRE EYELET (2) MIL (3) GREEN WIRE EYELET (3) WARN/RESET SWITCH (4) 2P (BLACK) CONNECTOR PGM-FI (5) 4P (RED) CONNECTOR Self-diagnosis system DTC readout procedure The PGM-FI system is equipped with the self-diagnostic –...
  • Page 164 Electrical servicing (1) POWER SWITCH (1) 32P (BLACK) CONNECTOR, (FRONT) (1) 2P (WHITE) CONNECTOR (2) MIL (3) WARN/RESET SWITCH Self-diagnosis Reset Procedure – Start the engine the MIL should come on.  If the MIL comes on, replace the ECM with a known –...

  • Page 165: 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 166: 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 167: Engine Stop Switch Inspection

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

  • Page 168: Chapter Lights / Instruments / Switches (2Ed)

    Electrical servicing Chapter lights / instruments / switches (2ED) System location Speedometer Power relay Speedometer 6P connector 2P connector (inactive) Fan relay Speed sensor Wire harness inspection 3P connector Winker relay Check for continuity of the Black/Blue wire between the fan motor relay 2P (Natural) connector and ECM 32P (Black) connector.
  • Page 169 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 170 Electrical servicing (1) BRAKE LIGHT LAMP (1) 2P CONNECTOR FOR THE BRAKE LIGHT SWITCH Checking indicator line: Brake light. Brake light switch. Connect, when shorted, the terminals of the connector Front: 2P (white) of the indicator relay with a jumper wire. If the engine starts but the brake light does not work, check the following: Connection:...
  • Page 171 Electrical servicing (1) CONNECTOR 2P FROM THE REAR BRAKE LIGHT (1) HOUSING FOR THE UPPER HEADLIGHT (1) SPEEDOMETER SWITCH. (2) BOLTS (3) SPEEDOMETER (4) CONNECTOR 6P Rear: Checks: (5) CONNECTOR 3P Disconnect the connector 2P from the rear brake light Check for loose or defective contacts in the connectors Speedometer switch.

  • Page 172: Speed Sensor (2Ed)

    Electrical servicing (1) CONNECTOR 6P (1) SPEED SENSOR (1) HOUSING FOR THE UPPER HEADLIGHT (2) CONNECTOR 6P (3) CONNECTOR 3P Speed sensor (2ED) Power input line Checking the speed sensor Measure the voltage between the connector 6P of the System check Remove the housing for the upper headlight.

  • Page 173: Horn (2Ed)

    Electrical servicing FREE PUSH COLOR BATTERY BATERÍA BATERÍA HORN SWITCH INTERRUPTOR DE LA BOCINA (1) HORN (2) CONNECTORS Horn (2ED) If there is no voltage, check the following:  Open circuit in the Black wire between the ignition relay and the connector 9P (white) on the handlebar. Checks: If the engine starts but the horn does not work, check the If there is voltage, check the continuity between the...

  • Page 174: Wiring Diagram (2Ed)

    Electrical servicing Wiring diagram (2ED) POWER WINKER TURN SIGNAL RELAY SENSOR F1 - ECU RELAY INDICATOR LIGHT 12V 1,2 W SPEED FUEL SENSOR MOTOR PUMP HIGH BEAM INDICATOR LIGHT 12V 1,2 W METER INDICATOR LIGHT 12V 1,2 W DIGITAL METER SERVICE CHECK CONNECTOR...

  • Page 175: Wiring Diagram (4Ed)

    Electrical servicing Wiring diagram (4ED) ENGINE MAPPING FUEL STOP SWITCH MOTOR PUMP SWITCH SERVICE CHECK CONNECTOR POWER FUN RELAY WATER REGULATOR/RECTIFIER TEMP SENSOR INJECTOR CONDENSER BANK ANGLE (10000uF) SENSOR PULSER BLACK BROWN ALTERNADOR YELLOW ORANGE BLUE LIGHT BLUE GREEN LIGHT GREEN PINK IGNITION COIL WHITE...
  • Page 176 Printed in Spain...

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