Montesa COTA 4RT 2005 Manual
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Montesa COTA 4RT 2005 Manual

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  • Page 2 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. 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: Table Of Contents

    Contents 1. Operating Instruction Rear Suspension 3-17 Shock Absorber 5-16 Cleaning 3-18 Shock Linkage 5-18 Fuel Storage 3-18 Swingarm 5-19 Brake Pad Replacement 5-23 Coolant Basic Operation 4. Engine Servicing Front Brake Caliper 5-24 Operating Mode Rear Brake Caliper 5-25 Controls Oil Pressure Relief Valve Front Master Cylinder...
  • Page 5 To The New Owner Importance Of Proper Preparation How To Use This Manual By selecting a MONTESA COTA 4RT as your new Proper pre-competition preparation and regular service The purpose of this Owner’s Manual is to help ensure machine, you have placed yourself in a distinguished...
  • Page 6 Memo...

  • Page 7: Operating Instruction

    1. Operating Instructions (1) BREATHER HOSE (2) FUEL TANK CAP (1) RADIATOR CAP (1) KICKSTARTER PEDAL Fuel Coolant Basic Operation Gasoline: Premium unleaded gasoline (commercially The engine of COTA is a water-cooled type. In order to Starting The Engine available unleaded; pump octane number 91 provide adequate cooling, it is essential that the radiator or higher) be filled with coolant up the proper level (See pag.
  • Page 8 Operating Instructions (1) ENGINE STOP BUTTON When you shift the transmission into gear, apply front Break-In Procedure brake to prevent the motorcycle move forward. New Motorcycle Stopping The Engine Following proper break-in procedure helps ensure that the most important and expensive components on your 1.

  • Page 9: Controls

    Operating Instructions (1) UPPER LEVEL LINE (1) ADJUSTER (2) LOCK NUT (1) DUST COVER (2) LOCK NUT (3) ADJUSTER (A) DECREASE (B) INCREASE Controls Clutch Lever Throttle Grip Clutch The clutch lever free play can be adjusted by turning the Throttle Grip Free Play adjuster.
  • Page 10 Operating Instructions (1) ADJUSTER (2) LOCK NUT (1) LOCK NUT (2) ADJUSTING BOLT (1) HANDLEBAR (A) RAISE THE PEDAL HEIGHT (B) LOWER THE PEDAL HEIGHT Front Brake Lever Brake Pedal Height Handlebar Position, Width And Shape The front brake lever free play can be adjusted by The brake pedal height can be adjusted to the rider’s Position the handlebar so that gripping the bar and turning the adjuster.

  • Page 11: Specifications

    2. Service Data Specifications Item Specification Item Specification Dimensions Fuel System Overall length 2,016 mm (79.4 in) Type PGM-FI Overall width 830 mm (32.7 in) Identification number GQP0 Overall height 1,130 mm (44.5 in) Throttle bore 28 mm (1.1 in) Wheelbase 1,321 mm (52.0 in) Drive Train...
  • Page 12 Service Data Service Data Unit: mm (in) Item Specification Item Standard Service Limit Lubrication Cylinder Head/Valves Specified engine oil Honda Ultra S9 4-stroke motorcycle oil or Cylinder compression 460 kPa (4.7 kgf/cm , 67 psi) at – Repsol 4T oil 800 min (rpm) SAE 10W-40...
  • Page 13 Service Data Unit: mm (in) Unit: mm (in) Item Standard Service Limit Item Standard Service Limit Cylinder/Piston Crankshaft/Transmission Cylinder I.D. 76.500 – 76.515 (3.0118 – 3.0124) 76.54 (3.013) Crankshaft runout Right – 0.03 (0.001) Taper – 0.05 (0.002) Left – 0.05 (0.002) Out-of- round –...
  • Page 14 Service Data Unit: mm (in) Unit: mm (in) Item Standard Service Limit Item Standard Service Limit Wheels/Tires Rear Suspension Axle runout – 0.20 (0.008) Shock absorber spring pre-load 126.5 (4.9) – Tire air pressure Front 39 – 44 kPa (0.40 – 0.45 kgf/cm Spring free length 133 (5.2) 130.3 (5.13)

  • Page 15: Torque Values

    Service Data Torque Values Standard Engine Torque Threads Torque Item Item Q’ty Remarks N•m (kgf•m, lbf•ft) Dia. (mm) N•m (kgf•m, lbf•ft) 5 mm bolt and nut 5 (0.52, 3.5) Transmission oil drain bolt 22 (2.2, 16) Note 1 6 mm bolt and nut 10 (1.0, 7) Engine oil drain bolt 22 (2.2, 16)
  • Page 16 Service Data Frame Threads Torque Threads Torque Item Q’ty Remarks Item Q’ty Remarks Dia. (mm) N•m (kgf•m, lbf•ft) Dia. (mm) N•m (kgf•m, lbf•ft) Handlebar holder bolt 22 (2.2, 16) Steering stem bolt 88 (9.0, 65) Note 1 Front axle 69 (7.0, 51) Note 1 Clutch hose (master cylinder) 20 (2.0, 14)

  • Page 17: Tools

    Service Data Tools Special Common Description Tool number Applicability Description Tool number Applicability Bearing remover, 12 mm 07936–1660101 Water pump bearing Spoke nipple wrench 07701–0020200 Front spoke nipple – Remover shaft 07936–1660120 Gear holder 07724–0010100 Primary drive gear bolt – Remover weight 07741–0010201 Bearing remover head 07746–0050600...

  • Page 18: Lubrication & Seal Points

    Service Data Lubrication & Seal Points Engine Item Material Remarks Item Material Remarks Crankcase sealing bolt threads and ELF HTX740 Connecting rod small end I.D. Molybdenum oil solution seating surface Connecting rod big end (A 50/50 mixture of Cylinder bore inner surface Camshaft outer surface molybdenum disulfide Cylinder head nut threads and...
  • Page 19 Service Data Item Material Remarks Clutch slave cylinder piston/O-ring Silicone grease Left crankcase cover cap threads Lithium based multi- Each oil seal lips purpose grease Water seal lips Right crankcase cover water hose Sealant joint threads Cylinder head water hose joint threads Cylinder head cover mating surface Three Bond 1215B...
  • Page 20 Service Data Frame Item Material Remarks Item Material Remarks Steering head bearing race and Multi-purpose grease Drive chain adjuster stopper screw Locking agent bearings 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 Shock link/shock arm needle...

  • Page 21: Cable & Harness Routing

    Service Data Cable & Harness Routing Front Front 20 – 30˚ Front (1) FRONT BRAKE HOSE (2) THROTTLE CABLE (3) CLUTCH HOSE (4) ENGINE STOP SWITCH CONNECTOR 2-11...
  • Page 22 Service Data (12) (10) (10) (11) Upper Right (1) MAIN WIRE HARNESS 20 – 30˚ (2) FUEL PUMP WIRE (3) CRANKCASE BREATHER HOSE (4) CRANKCASE BREATHER JOINT HOSE (5) STRAGE TANK (6) ENGINE STOP SWITCH WIRE (7) FAN MOTOR WIRE (10) WIRE HARNESS (TO IGNITION COIL) (8) RADIATOR OVERFLOW HOSE (11) WIRE HARNESS (TO GROUND)
  • Page 23 Service Data (1) WIRE HARNESS (2) THROTTLE CABLE (5) UPPER RADIATOR HOSE (3) CLUTCH HOSE (6) SPARK PLUG WIRE (4) CONNECTOR BOOT (7) FAN MOTOR WIRE Clamp at white tape – FAN MOTOR 2P (BLACK) CONNECTOR (8) CRANKCASE BREATHER HOSE –...
  • Page 24 Service Data 40 – 50˚ (1) INTAKE VACUUM HOSE (2) THROTTLE CABLE (3) CLUTCH HOSE (4) FUEL TANK BREATHER HOSE 2-14...
  • Page 25 Service Data (1) MAIN WIRE HARNESS (7) ENGINE STOP RELAY (2) TRANSMISSION BREATHER HOSE (8) FAN MOTOR RELAY (9) REAR BRAKE RESERVOIR TANK (3) CRANKCASE BREATHER JOINT HOSE (4) ALTERNATOR WIRE (5) CONDENSER 2P (BLACK) CONNECTOR (6) REGULATOR/RECTIFIER 5P (BLACK) CONNECTOR 2-15...
  • Page 26 Service Data (10) Clamp at white tape (11) (12) (13) (1) MAIN WIRE HARNESS (TO CONNECTOR COVER) (14) (2) MAIN WIRE HARNESS (TO RELAY) (3) MAIN WIRE HARNESS (TO ECU) (4) CRANKCASE BREATHER JOINT HOSE (5) TRANSMISSION BREAHTER HOSE (10) CONDENSOR (6) WIRE HARNESS (11) CONDENSOR 2P (BLACK) CONNECTOR (7) FUEL RETURN HOSE...
  • Page 27 Service Data 90 – 95˚ (1) REAR BRAKE HOSE (2) REAR BRAKE RESERVOIR HOSE 2-17...
  • Page 28 Service Data (1) FUEL FEED HOSE (2) INTAKE VACUUM HOSE (3) TRANSMISSION BREATHER HOSE 2-18...

  • Page 29: 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 4RT and check its condition.

  • Page 30: 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 31: Fuel Line

    Service And Maintenance (1) FUEL FEED HOSE (1) BOLTS (1) FLAME TRAP (2) FUEL RETURN HOSE (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 32: Spark Plug

    Service And Maintenance (1) SPARK PLUG CAP (2) SPARK PLUG (1) INSULATOR (1) BOLTS (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 valve the flywheel with the index mark on the left crankcase stem and measure the intake and exhaust valve cover.

  • Page 34: Engine Oil/Oil Filter

    Service And Maintenance (1) OIL FILLER CAP/DIPSTICK (1) BOLT (2) RETAINING PLATE (1) OIL FILLER CAP/DIPSTICK (2) DRAIN BOLT/SEALING WASHER (2) UPPER LEVEL LINE (3) LOWER LEVEL LINE Oil Change Engine Oil/Oil Filter 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 (2) OIL FILTER (1) NEW O-RINGS (1) OIL STRAINER SCREEN (3) APPLY GREASE (2) OIL FILTER COVER 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. Inspect and adjust the idle speed after all other engine Oil Change Specified transmission oil: 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) MUFFLER (2) LOWER LEVEL LINE 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 Slider

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

  • Page 40: Drive/Driven Sprockets

    Service And Maintenance (1) BOLT (2) SPRING WASHER (1) DRIVE SPROCKET (2) SPRING WASHER (1) BOLTS/NUT (2) DRIVEN SPROCKET (3) DRIVE SPROCKET (3) BOLT Drive/Driven Sprockets Install the drive sprocket onto the countershaft as Driven Sprocket Replacement shown. Drive Sprocket Replacement Install the spring washer and bolt, then tighten the bolt Remove the rear wheel (page 5-15).

  • 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 Front Brake Master Cylinder 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 Measure the brake pad thickness.

  • Page 43: Handlebar And Steering Head Bearings

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

  • Page 44: Front Suspension

    Service And Maintenance (1) PRE-LOAD ADJUSTER (1) REBOUND ADJUSTER (2) COMPRESSION ADJUSTER Front Suspension Fork Use specified fork fluid which additives to assure maximum performance your COTA’s front Inspection The motorcycle is shipped with a light coating of grease suspension. on the forks.

  • Page 45: Rear Suspension

    Service And Maintenance (1) PRE-LOAD ADJUSTER (1) REBOUND ADJUSTER Rear Suspension • When your COTA is new, your suspension will break- Inspection in as you ride. The swingarm is controlled by a shock absorber. The • After break-in is completed, test ride your COTA with 1.

  • Page 46: Cleaning

    Service And Maintenance Cleaning Storage 6. Inflate the tires to their recommended pressure. 7. Place your COTA on the maintenance stand or equivalent 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 47: 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 4-46). Separate the crankcase halves (page 4-51).
  • Page 48 Engine Servicing (1) ONE-WAY REED VALVE (1) DRIVEN GEAR (1) SNAP RING (2) GASKET (3) DOWEL PINS (2) OIL PUMP SHAFT (2) OIL SEAL (1) OUTER ROTOR (2) INNER ROTOR (1) ONE-WAY REED VALVE (3) OIL PUMP SHAFT Remove the one-way reed valve, gasket and dowel pins. Inspection Check the oil pump shaft oil seal in the left crankcase for damage or deterioration, replace if necessary.
  • 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: Fuel Line Inspection

    Engine Servicing (1) VACUUM HOSE (1) BANJO BOLT (1) BANJO BOLT, 12 mm (2) PRESSURE REGULATOR (2) SEALING WASHER (2 SEALING WASHER, 12 mm (3) SEALING WASHER, 6 mm (4) F. PRESSURE GAUGE Fuel Line Inspection Cover the fuel feed hose banjo bolt with a rag or shop Remove the fuel feed hose banjo bolt and attach the fuel towel.
  • Page 51 Engine Servicing (1) FUEL PRESSURE GAUGE (1) NEW SEALING WASHERS (2) BANJO BOLT (1) VACUUM HOSE (2) PRESSURE REGULATOR Start the engine. After inspection, remove the banjo bolt and reinstall and Connect the pressure regulator vacuum hose. Read the fuel pressure at idle speed. tighten the fuel feed hose banjo bolt using a new sealing washer.

  • Page 52: Fuel Tank/Fuel Pump

    Engine Servicing (1) FUEL RETURN HOSE (1) 2P (BLACK) CONNECTOR (1) 2P (BLACK) CONNECTOR (2) SOCKET BOLTS Fuel Tank/Fuel Pump Fuel Pump Flow Inspection After inspection remove the temporarily installed fuel hose and connect the fuel return hose to the pressure Remove the rear fender.
  • Page 53 Engine Servicing (1) BREATHER HOSE (1) 2P (BLACK) CONNECTOR (1) BANJO BOLT (2) FUEL FEED HOSE (2) BOLT (3) FUEL TANK (3) FUEL RETURN HOSE Pull up the fuel tank and disconnect the fuel pump 2P (Black) connector. Remove the fuel tank and injector as an assembly being careful not to damage the injector especially tip of the injector.
  • Page 54 Engine Servicing (1) FUEL PUMP (2) ALIGN (1) FUEL PUMP (1) NEW O-RING (2) RETURN HOSE (2) BOLTS (3) FUEL FEED HOSE (4) NEW SEALING WASHERS/BANJO BOLT 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: Injector

    Engine Servicing (1) FUEL TANK (2) BOLTS (1) SOCKET BOLTS (1) INJECTOR (3) BREATHER HOSE (2) 2P (BLACK) CONNECTOR Injector Install and tighten the injector holder socket bolts to the specified torque. Inspection Torque: 9.8 N•m (1.0 kgf•m, 7 lbf•ft) Remove the rear fender.

  • Page 56: Throttle Body

    Engine Servicing (1) INJECTOR (1) BOLTS/NUTS (2) AIR CLEANER HOUSING (1) 32P (BLACK) CONNECTOR (2) NEW O-RING (2) BAND SCREW (3) THROTTLE BODY Throttle Body Removal/Installation Do not remove the injector from the injector holder. Removal Replace the injector and holder as an assembly. Remove the rear fender.
  • Page 57 Engine Servicing (1) THROTTLE CABLE END (2) THROTTLE DRUM (1) LOCK NUT (2) THROTTLE CABLE (1) THROTTLE BODY (3) THROTTLE CABLE (4) LOCK NUT (3) THROTTLE CABLE END (4) THROTTLE DRUM (2) BAND SCREW (3) 32P (BLACK) CONNECTOR Install the throttle body into the insulator. Make sure there are following clearance between the throttle body: –...

  • Page 58: Water Seal And Bearing Replacement

    Engine Servicing (1) AIR CLEANER HOUSING (1) BOLTS (2) WATER PUMP COVER (1) BEARING REMOVER, 12 mm (2) BOLTS/NUTS Install the air cleaner housing onto the frame and Remove the water pump bearing from the right connect the crankcase breather hose. crankcase cover using the special tools.
  • Page 59 Engine Servicing (1) WATER SEAL DRIVER (1) DOWEL PINS (2) NEW O-RING (1) WASHER (2) WATER PUMP SHAFT (2) DRIVER/ATTACHMENT (3) NEW COPPER WASHER (4) IMPELLER (3) WATER PUMP COVER Install the water pump shaft, new copper washer and impeller into the right crankcase cover. Hold the water pump gear using a suitable tool and tighten the impeller to the specified torque.

  • Page 60: Radiator Removal/Installation

    Engine Servicing (1) BREATHER CHAMBER (1) 2P (NATURAL) CONNECTOR (1) GROUND EYELET (2) BOLTS (3) IGNITION COIL Radiator Removal/Installation Remove the following: – Exhaust pipe – Skid plate – Fuel tank/injector assembly (page 4-6) Pull out the crankcase breather chamber from the frame. (1) TIE WRAP (1) 3P (GRAY) CONNECTOR (2) CLAMP Disconnect the radiator 2P (Natural) connector.

  • Page 61: Engine Removal/Installation

    Engine Servicing (1) RADIATOR HOSES (2) HANGER BOLT (1) RADIATOR (2) EXHAUST PIPE (3) DOWN TUBE BOLTS (4) DOWN TUBES (3) MUFFLER (4) SKID PLATE (5) BOLT (6) RADIATOR Engine Removal/Installation Disconnect the radiator hoses at the right crankcase cover and cylinder head. Remove the front engine hanger bolt and front down •...
  • Page 62 Engine Servicing Engine Removal/Installation Illustration 24 N•m (2.4 kgf•m, 17 lbf•ft) 25 N•m (2.6 kgf•m, 19 lbf•ft) 69 N•m (7.0 kgf•m, 51 lbf•ft) 49 N•m (5.0 kgf•m, 36 lbf•ft) 26 N•m (2.7 kgf•m, 20 lbf•ft) 4-16...

  • Page 63: 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 64 Engine Servicing (1) BOLTS (2) TAPPET ADJUSTING HOLE COVER (1) BOLTS/SEALING WASHERS (2) SH BOLTS (1) CAM CHAIN (2) CAMSHAFT (3) SEALING WASHERS (4) CYLINDER HEAD COVER 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 65 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 Disassembly Check the rocker arms and shafts for wear or damage. Measure the rocker arm I.D.

  • Page 66: Cylinder Head Removal

    Engine Servicing (1) RADIATOR HOSE (1) BOLTS (1) GASKET (2) DOWEL PINS (2) HANGER BOLTS (2) NUTS/WASHERS (3) CYLINDER HEAD Cylinder Head Removal Remove the cylinder head mounting bolts. Loosen the cylinder head mounting nuts in a crisscross Remove the following: pattern in two or three steps.
  • Page 67 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 68: Cylinder Head Disassembly

    Engine Servicing (1) CAM CHAIN GUIDE (1) VALVE SPRING COMPRESSOR (1) RETAINER (2) OUTER SPRING (2) ALIGN (2) ATTACHMENT (3) INNER SPRING (4) SPRING SEAT (5) VALVE (6) STEM SEAL Cylinder Head Disassembly Remove the following: – Spring retainer Remove the cylinder head (page 4-20). –...

  • Page 69: 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 Cylinder Head Check the valve springs for fatigue or damage. Inspect each valve for out-of-round, burns, scratches or Measure the free length of the intake and exhaust valve abnormal stem wear.

  • Page 70: 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 before measuring the guide. gauge 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 71: 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 72 Engine Servicing 45˚ 32˚ 60˚ 32˚ (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 or refacing equipment are recommended to correct worn badly worn or if it contacts the seat unevenly, replace valve seat.
  • Page 73 Engine Servicing 32˚ 45˚ 60˚ (1) SEAT WIDTH Use a 45˚ cutter, remove any roughness or irregularities Use a 32˚ flat cutter, remove 1/4 of the existing valve seat Use a interior cutter, remove 1/4 of the existing valve from the seat. material.

  • Page 74: Cylinder Head Assembly

    Engine Servicing 45˚ (1) SPRING SEAT (2) STEM SEAL (3) VALVE (4) INNER SPRING (5) OUTER SPRING (6) RETAINER Cylinder Head Assembly Using a 45˚ seat cutter, cut the seat to proper width. Install the valve springs with the tightly wound coils Make sure all pitting and irregularities are removed.

  • Page 75: 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 76 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 the clip from falling the crankcase.
  • Page 77 Engine Servicing Inspection Piston/Piston Ring Temporarily install the piston rings to their proper Remove the carbon deposits from the piston head or position with the mark facing up. Cylinder piston ring grooves using old piston rings. Measure the piston ring-to-ring groove clearance with Inspect the cylinder bore for wear or damage.
  • Page 78 Engine Servicing Measure the O.D. of the piston at 5 mm (0.2 in) from Insert each piston ring into the cylinder and measure the Connecting Rod bottom of skirt and 90 degrees to the piston pin hole. ring end gap. Measure the connecting rod small end I.D.
  • Page 79 Engine Servicing (1) TENSIONER LIFTER (1) TOP RING (2) SECOND RING (1) “IN” MARK (2) PISTON PIN (3) OIL RINGS (4) SPACER (3) NEW PISTON PIN CLIP Tensioner lifter Piston Ring Installation Piston Installation Check the tensioner lifter operation as follows: –...

  • Page 80: 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 81: Camshaft/Cylinder Head Cover Installation

    Engine Servicing (1) CYLINDER HEAD BOLTS (1) HANGER BOLT/NUT (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 and nut, tighten the mounting bolts securely.
  • Page 82 Engine Servicing (1) BEARINGS (1) NEW O-RINGS (2) INTAKE ROCKER ARM SHAFT (1) APPLY SEALANT (2) GROOVE (3) INTAKE ROCKER ARM (4) EXHAUST ROCKER ARM (2) BEARING RETAINER (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 83: Right Crankcase Cover

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

  • Page 84: Clutch Slave Cylinder

    Engine Servicing (1) DOWEL PINS (2) NEW GASKET (1) RIGHT CRANKCASE COVER (2) CLUTCH COVER (1) OIL BOLTS (2) SEALING WASHERS (3) WATER PUMP COVER (4) BOLTS (3) EYELET JOINT (5) RADIATOR HOSE (6) KICKSTARTER PEDAL Installation Install the right crankcase cover while turning the water pump impeller.
  • Page 85 Engine Servicing (1) SLAVE CYLINDER PISTON (1) O-RING (1) EYELET JOINT (2) SEALING WASHERS (2) SPRING (2) DOWEL PINS (3) OIL BOLTS (3) O-RING (BLACK) (4) O-RING (GREEN) (3) CLUTCH COVER Apply small squirts of air pressure to the fluid inlet to Install the clutch hose eyelet with new sealing washers.

  • Page 86: Clutch

    Engine Servicing (1) CLUTCH LIFTER PIECE ASSEMBLY (1) CLUTCH CENTER HOLDER (1) CLUTCH CENTER (2) CLUTCH DISCS (2) LIFTER PLATE BOLTS (3) CLUTCH LIFTER (3) CLUTCH PLATE (4) PRESSURE PLATE (4) CLUTCH SPRINGS (5) PAPER DISCS Clutch Removal Pull the clutch lever and hold it with a suitable clamp. Remove bolts clutch...
  • Page 87 Engine Servicing (1) CLUTCH CENTER (2) CLUTCH OUTER (1) LIFTER PIECE ASSEMBLY (1) OUTER GUIDE (2) NEEDLE BEARING (3) OUTER GUIDE (4) NEEDLE BEARING Inspection Check the following items (specifications; 2-2). • Clutch outer for wear, cracks or indentation by the clutch discs.
  • Page 88 Engine Servicing (1) PRESSURE PLATE (1) THRUST WASHER (1) CLUTCH SPRINGS (2) LIFTER PLATE (2) CLUTCH CENTER (2) LOCK WASHER (3) “OUTSIDE” MARK (3) BOLTS (3) DOT MARKS (4) LIFTER PIECE ASSEMBLY Install the clutch springs, lifter plate and spring bolts. Tighten the spring bolts in a crisscross pattern in several steps, then tighten them to the specified torque.

  • Page 89: Kickstarter

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

  • Page 90: Gearshift Linkage

    Engine Servicing (1) KICKSTARTER ASSEMBLY (1) STOPPER PLATE (1) GEARSHIFT SPINDLE (2) BOLTS (2) SPRING HOOK (2) BOLT (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 91 Engine Servicing (1) SHIFT DRUM CENTER (1) DRUM SHIFTER (2) SPRING (3) PLUNGER (1) RETURN SPRING (2) WASHER (3) STOPPER ARM (2) CENTER PIN (4) RATCHET PAWL A (5) RATCHET PAWL B (4) DRUM CENTER (5) DOWEL PIN (6) GUIDE PLATE (6) CUT-OUT Inspection Install the return spring, plain washer and stopper arm...

  • Page 92: Left Crankcase Cover

    Engine Servicing (1) WASHER (2) GEARSHIFT SPINDLE (1) 3P (WHITE) 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 93 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 94 Engine Servicing (1) OIL SEAL (1) STATOR (2) IGNITION PULSE GENERATOR (1) OIL FILTER COVER (2) WASHER (3) WIRE CLAMP (4) SOCKET BOLTS (2) O-RING (3) SNAP RING (5) BOLTS (6) GROMMET Apply grease to the new oil seal lip and install it into the Install the stator and ignition pulse generator assembly left crankcase cover.

  • Page 95: Flywheel

    Engine Servicing (1) LEFT CRANKCASE COVER (1) 3P (WHITE) 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 96 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 97: Crankcase Separation/Disassembly

    Engine Servicing (1) DRIVE SPROCKET (2) UNIVERSAL HOLDER (1) COUNTERSHAFT COLLAR (1) CLUTCH OUTER (2) GEAR HOLDER (3) BOLT (4) SPRING WASHER (2) O-RING (3) PRIMARY DRIVE GEAR Crankcase Separation/Disassembly Temporarily install the clutch outer guide, needle bearing and clutch outer onto the mainshaft and attach Remove the engine from the frame.
  • Page 98 Engine Servicing (1) TRANSMISSION OIL DRAIN BOLT (1) GASKET (2) DOWEL PINS (1) SHIFT FORK SHAFTS (2) SHIFT FORKS (2) CRANKCASE BOLTS (3) ONE-WAY REED VALVE (3) MAINSHAFT (4) COUNTERSHAFT Remove the transmission oil drain bolt and sealing Remove the following: washer.

  • Page 99: 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: C: 0.05 mm (0.002 in) D: 0.03 mm (0.001 in) Measure the connecting rod big end side clearance and big end axial/radial play (specification;...
  • Page 100 Engine Servicing Crankcase Bearings/Oil Seals Location (10) (1) LEFT SHIFT DRUM BEARING A: 1 mm (2) LEFT COUNTERSHAFT BEARING B: 0 ± 0.5 mm (3) LEFT COUNTERSHAFT OIL SEAL C: 58.60 – 58.88 mm (4) LEFT MAINSHAFT BEARING D: 58.30 – 58.52 mm (5) LEFT CRANKSHAFT OIL SEAL E: 1 ±...

  • Page 101: Transmission Assembly

    Engine Servicing Transmission Assembly (10) (11) (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 4-55...

  • Page 102: Crankcase Combination

    Engine Servicing (1) MAINSHAFT (2) COUNTERSHAFT (1) OIL PUMP SHAFT (1) ONE-WAY REED VALVE (3) SHIFT FORK SHAFTS (4) LEFT SHIFT FORK (2) INNER ROTOR (3) OUTER ROTOR (5) RIGHT SHIFT FORK (6) CENTER SHIFT FORK Crankcase Combination Clean the crankcase mating surfaces before assembling and check for wear or damage.
  • Page 103 Engine Servicing (1) CRANKCASE BOLTS (1) DRIVE GEAR COLLAR (1) CLUTCH OUTER (2) GEAR HOLDER (2) NEW SEALING WASHER/OIL DRAIN BOLT Install the crankcase bolts. Temporarily install the clutch outer guide, needle Tighten the crankcase bolts in a crisscross pattern in 2 – 3 bearing and clutch outer onto the mainshaft and attach steps.
  • Page 104 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 105: Frame Servicing

    5. Frame Servicing (1) AXLE PINCH BOLT (2) AXLE (3) SIDE COLLAR Front Wheel Removal Remove the brake caliper mounting bolts, disc cover and collars. Loosen the axle pinch bolt. Support the motorcycle and front wheel off the ground. Remove the axle, left side collar and front wheel. Drive the Do not depress the brake lever after the front wheel is bearing into...
  • Page 106 Frame Servicing (1) SIDE COLLAR (2) AXLE (1) BRAKE CALIPER (2) DISC COVER (1) AXLE PINCH BOLT (3) BOLTS Installation Install the brake caliper, flange collars and disc cover, While keeping the fork parallel, tighten the axle pinch tighten the mounting bolts to the specified torque. bolt to the specified torque.

  • Page 107: Fork

    Frame Servicing (1) FRONT FENDER (2) NUMBER PLATE (1) FORK BOLT (1) DAMPER ADJUSTER CASE (2) FORK BOLT (3) TOP BRIDGE (4) BOTTOM BRIDGE (5) FORK LEG Fork Right Fork Disassembly Removal Before disassembling the fork, clean the entire sliding surface and the bottom of the fork slider.
  • Page 108 Frame Servicing (1) FORK DAMPER HOLDER (1) FORK DAMPER (2) CENTERING PLATE (1) DUST SEAL (2) STOP RING (2) RIGHT FORK CENTER BOLT (3) FORK TUBE 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 109 Frame Servicing (1) FORK TUBE BUSHING (2) GUIDE BUSHING (1) BUSHING (2) BACK-UP RING (1) DAMPER ASSEMBLY (2) DAMPER ROD (3) BACK-UP RING (4) OIL SEAL (3) INSPECTION POINT (3) FORK TUBE (4) CENTERING PLATE Check that the fork tube moves smoothly in the slider. Right Fork Inspection Fork Damper If it does not, check the fork tube bending or damage,...
  • Page 110 Frame Servicing (1) FORK TUBE BUSHING (2) GUIDE BUSHING (1) FORK SEAL DRIVER (1) FORK DAMPER ASSEMBLY (3) BACK-UP RING (4) OIL SEAL (2) CENTERING PLATE (3) FORK TUBE Right Fork Assembly Install the centering plate and fork damper assembly into the fork tube.
  • Page 111 Frame Servicing (1) FORK DAMPER HOLDER (1) FORK FLUID (1) FORK DAMPER ROD (2) RIGHT FORK CENTER BOLT (2) FORK TUBE (2) OIL LEVEL Hold the axle holder in a vise protected with a piece of Pour recommended fork fluid in the fork leg. 2.
  • Page 112 Frame Servicing 11.5 mm (0.45 in) (1) DAMPER ADJUSTER CASE (2) LOCK NUT (1) DAMPER ADJUSTER CASE (1) FORK BOLT (2) DISTANCE COLLAR (2) NEW O-RING (3) FORK BOLT (3) SPRING SEAT (4) FORK SPRING If the damper adjuster case was removed from the Install a new O-ring onto the fork bolt groove.
  • Page 113 Frame Servicing (1) FORK DAMPER HOLDER (1) FORK TUBE (2) SEAT PIPE ASSEMBLY (1) SEAT PIPE (2) PISTON RING (2) CENTER BOLT (3) OIL LOCK PIECE (3) REBOUND SPRING (4) OIL LOCK PIECE Hold the axle holder in a vise protected with a piece of Remove the oil lock piece from the fork piston.
  • Page 114 Frame Servicing (1) FORK TUBE (1) FORK DAMPER HOLDER (1) GUIDE BUSHING (2) BACK-UP RING (2) SEAT PIPE ASSEMBLY (3) OIL LOCK PIECE (2) CENTER BOLT (3) OIL SEAL (4) STOP RING (5) DUST SEAL Left Fork Assembly Hold the axle holder in a vise protected with a piece of Install the following using the same procedure as the wood or soft jaws to avoid damage.
  • Page 115 Frame Servicing 3 mm (0.1 in) FORWARD (1) FORK SPRING (2) SPRING SEAT (1) FORK TUBE (2) TOP BRIDGE (3) DISTANCE COLLAR (4) O-RING (5) FORK BOLT Pour half the required amount of recommended fork Install the fork spring, spring seat and distance collar. Installation fluid in the fork leg.

  • Page 116: Steering Stem

    Frame Servicing (1) BOTTOM BRIDGE PINCH BOLTS (1) STEM BOLT (2) TOP BRIDGE (1) ADJUSTING NUT (2) FORK BOLT (3) TOP BRIDGE PINCH BOLTS Steering stem Tighten the bottom bridge pinch bolts to the specified torque. Disassembly Torque: 20 N•m (2.0 kgf•m, 14 lbf•ft) Remove the following: Overtightening the pinch bolts can deform the outer –...
  • Page 117 Frame Servicing (1) STEM (2) LOWER BEARING (3) DUST SEAL (1) STEM (2) DUST SEAL (3) BEARING (1) DRIVER (2) ATTACHMENT (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 118 Frame Servicing (1) ADJUSTING NUT (1) TOP BRIDGE (2) STEM BOLT 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 bolt threads and seating your fingers.

  • Page 119: Rear Wheel

    Frame Servicing 29 N•m (3.0 kgf•m, 22 lbf•ft) (1) ADJUSTER (2) AXLE Rear Wheel Removal Raise the rear wheel off the ground and support it with a block or maintenance stand under the engine. Remove the following: – Axle nut and drive chain adjuster –...

  • Page 120: Shock Absorber

    Frame Servicing (1) AXLE (2) ADJUSTERS (1) LOWER MOUNTING BOLT/NUT (1) SPRING COMPRESSOR (3) AXLE NUT (2) ATTACHMENT (3) SPRING SEAT STOPPER Installation Disassembly Install the rear brake caliper aligning with the caliper Loosen the spring lock nut and adjuster. slide rail.
  • Page 121 Frame Servicing (1) VALVE CAP (2) DUST SEALS (1) SPRING (2) SPRING SEAT (3) STOP RING (4) SPHERICAL BEARING (3) STOPPER RING (4) COMPRESSOR 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 Remove the collars and dust seals.

  • Page 122: Shock Linkage

    Frame Servicing (1) UPPER MOUNTING BOLT/WASHER/NUT (1) LOWER MOUNTING BOLT/NUT (1) LOWER MOUNTING BOLT/NUT (2) BOLTS/NUTS (3) CUSHION ARM PLATES (4) CUSHION LINK Shock Linkage Installation Move the swingarm aligning the lower mount, then install the lower mounting bolt from the left side. Set the shock absorber into the frame and install the Removal upper mounting bolt from the left side.

  • Page 123: Swingarm

    Frame Servicing 3 mm (0.12 in) (1) PIVOT COLLAR A (2) PIVOT COLLAR B (1) CUSHION LINK (2) CUSHION ARM PLATES (1) SHOCK ABSORBER LOWER MOUNTING BOLT/NUT (3) DUST SEALS (4) NEEDLE BEARINGS (3) BOLTS/NUTS (4) LOWER MOUNTING BOLT/NUT (2) SHOCK ARM PLATE-TO-SWINGARM BOLT/NUT Swingarm Needle Bearing Replacement Installation...
  • Page 124 Frame Servicing 5.5 mm (0.22 in) (1) BRAKE HOSE CLAMPS (1) DUST SEAL CAP (2) DUST SEAL (1) NEEDLE BEARINGS (2) DUST SEAL (2) SWINGARM PIVOT BOLT/NUT (3) PIVOT COLLAR (4) DUST SEAL (3) BUSHING Remove the following: Disassembly Pivot Bearing Replacement –...
  • Page 125 Frame Servicing 3 mm (0.12 in) (1) PIVOT COLLAR A (2) PIVOT COLLAR B (1) DUST SEAL (2) PIVOT COLLAR (1) CHAIN TENSIONER (2) BUSHINGS (3) DUST SEALS (4) NEEDLE BEARINGS (3) DUST SEAL (4) DUST SEAL CAP (3) O-RINGS (4) PIVOT BOLT Link Bearing Replacement Install the drive chain tensioner pivot bushings into the swingarm.
  • Page 126 Frame Servicing (1) DRIVE CHAIN SLIDER (2) SCREWS (1) PIVOT BOLT/NUT (2) HOSE CLAMPS (1) SHOCK ARM PLATES-TO-SWINGARM BOLT/NUT (2) SHOCK ABSORBER LOWER MOUNTING BOLT/NUT Install the drive chain sliders onto the swingarm. Installation Install the following: Apply a locking agent to the drive chain slider screw –...

  • Page 127: Brake Pad Replacement

    Frame Servicing (1) PAD PINS (1) NEW PADS (2) PAD PINS (2) BOLTS (3) DISC COVER (4) CALIPER Brake Pad Replacement Install the new pads and secure them with the two pad pins. Clean the brake disc with a high quality degreasing agent if they are contaminated with oil or grease.

  • Page 128: Front Brake Caliper

    Frame Servicing (1) BRAKE PADS (2) PAD PIN (1) OIL BOLT (2) MOUNTING BOLTS (3) DISC COVER (4) BRAKE CALIPER Front Brake Caliper Removal NOTICE Avoid spilling brake fluid on painted, plastic or rubber parts. Place a shop rag over these parts whenever the system is serviced.

  • Page 129: Rear Brake Caliper

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

  • Page 130: Front Master Cylinder

    Frame Servicing (1) OIL BOLT (2) BRAKE HOSE (3) BOLTS (4) HOLDER (5) MASTER CYLINDER Front Master Cylinder Removal/Installation NOTICE • Avoid spilling brake fluid on painted, plastic or rubber (1) BOOT parts. Place a shop rag over these parts whenever the (2) SNAP RING system is serviced.

  • Page 131: Rear Master Cylinder

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

  • Page 132: Clutch Master Cylinder

    Frame Servicing 3 mm (0.12 in) (1) BEARING (2) DUST SEALS (1) COLLAR B (2) PEDAL (1) OIL BOLT (2) CLUTCH HOSE (3) BOLT (3) COLLAR A (4) HOLDER (5) MASTER CYLINDER Clutch Master Cylinder Installation Install the brake pedal and collars. Removal/Installation Install and tighten the pivot nut and bolt.
  • Page 133 Frame Servicing (1) BOOT (2) SNAP RING (3) PISTON ASSEMBLY (4) SPRING Inspection Disassembly/Assembly Check the following items (specifications; page 2-4): NOTICE – Master cylinder and piston for scoring, scratches or other damage – Master piston O.D. and master cylinder I.D. •...
  • Page 134 Memo...

  • Page 135: 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 Alternator Charging Coil resistance between the yellow terminals of the alternator Disconnect the power 4P (Natural) connector.
  • Page 136 Electrical Servicing (1) 3P (NATURAL) CONNECTOR (1) 2P (BLACK) CONNECTOR (1) BOLTS (2) 2P (NATURAL) CONNECTOR (2) 6P (BLACK) CONNECTOR (2) ELECTRIC STAY ASSEMBLY (1) FAN MOTOR RELAY (1) BOLT (1) 2P (BLACK) CONNECTOR (2) BRAKE RESERVOIR (2) CONDENSER Regulator/Rectifier Removal/installation Disconnect the condenser 2P (Black) and regulator/ Remove the electric stay mounting bolts, then remove rectifier 6P (Black) connectors.

  • Page 137: 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 Removal/Installation stay. Ignition Coil Inspection Remove the fuel tank/injector assembly. Install the regulator/rectifier and condenser in the reverse order of removal.
  • Page 138 Electrical Servicing (1) WIRE CLAMP (1) 32P (BLACK) CONNECTOR (1) 2P (NATURAL) CONNECTOR (2) PRIMARY WIRES (3) BOLTS (4) IGNITION COIL Remove the wire clamp. Ignition Pulse Generator Inspection If the resistance is out of specification, measure the resistance at the ignition pulse generator 2P (Natural) Disconnect the primary wire from the ignition coil.

  • Page 139: 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 Disconnect the ECM 32P (Black) connector.

  • Page 140: Pgm-Fi

    Electrical Servicing (1) PGM WARNING UNIT ASSEMBLY (2) RED WIRE EYELET (3) BLACK WIRE EYELET (1) POWER SWITCH (1) POWER SWITCH (4) 2P (BLACK) CONNECTOR (5) 4P (RED) CONNECTOR (2) MIL (2) MIL PGM-FI Turn the PGM warning unit power switch ON, check that Self-diagnosis Reset Procedure Self-diagnostic Procedure the MIL.

  • Page 141: 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 142: 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 143: 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 Disconnect the engine stop switch connectors. Fan Motor Inspection Remove the fan motor relay. Check the engine stop switch for continuity. Connect the ohmmeter to the fan motor relay connector There should be continuity.
  • Page 144 Electrical Servicing Wire Harness Inspection Check for continuity of the Black/Blue wire between the fan motor relay 2P (Natural) connector and ECM 32P (Black) connector. There should be continuity. If there is no continuity, repair or replace the wire harness. 6-10...

  • Page 145: Wiring Diagrams

    Electrical Servicing Wiring Diagram TURN SIGNAL INDICATOR LIGHT 12V 1,2 W ENGINE STOP FAN MOTOR FUEL PUMP SWITCH HIGH BEAM INDICATOR LIGHT 12V 1,2 W METER INDICATOR LIGHT 12V 1,2 W SERVICE CHECK CONNECTOR RIGHT REAR TURN SIGNAL LIGHT RIGHT FRONT TURN SIGNAL LIGHT 12V 10W BRAKE AND TAILLIGHT 12V 21/5W...
  • Page 146 Electrical Servicing ENGINE STOP FAN MOTOR FUEL PUMP SWITCH SERVICE CHECK CONNECTOR POWER BLACK BROWN YELLOW ORANGE BLUE LIGHT BLUE GREEN LIGHT GREEN PINK WHITE GRAY FAN RELAY WATER TEMP REGULATOR/RECTIFIER SENSOR BANK ANGLE CONDENSER (10000uF) SENSOR PULSER ALTERNATOR IGNITION COIL 6-12...

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