Montesa COTA 4RT RACE REPLICA Owner's Manual
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Montesa COTA 4RT RACE REPLICA Owner's Manual

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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
Your safety and the safety of others is very important. We have provided
important safety messages in this manual and on the COTA 4RT. Please read
these messages carefully.
A safety message alerts you to potential hazards that could hurt you or others.
Each safety message is preceded by a safety alert symbol
words, DANGER, WARNING, or CAUTION.
Significan:
You WILL be KILLED or SERIOUSLY HURT if you
DANGER
!
don't follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you
WARNING
!
don't follow instructions.
CAUTION
You CAN be HURT if you don't follow instructions.
!
Each message tells you what the hazard is, what can happen and what you can
do to avoid or reduce injury.
Damage Prevention Messages
You will also see other important messages that are preceded by the word
NOTICE.
This word means:
and one of three
NOTICE
Your COTA 4RT or other property can be damaged if you don't follow
instructions.
The purpose of these messages is to help prevent damage to your COTA
4RT, other property, or the environment.

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Summary of Contents for Montesa COTA 4RT RACE REPLICA

  • Page 1 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 2 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 3 (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 260 F ED / 2E *VTDMT04F?FE200001* NN4E5201200 MRT 260 F...
  • Page 4 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 5 Labels ED / 2E...
  • Page 6 Labels 3E / 4E...

  • Page 7: Important Safety Precautions

    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 8: Table Of Contents

    Contents 1. Operating instructions Drive/Driven Sprockets ........3-12 Crankcase Bearing Replacement ..... 4-53 Brake Fluid ..........3-13 Transmission Assembly ......... 4-55 Brake Pad Wear ..........3-14 Crankcase Combination ......... 4-56 Operation component locations ...... 1-1 Brake System ..........3-14 Fuel ............1-2 5.
  • Page 9 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 that machine, you have placed yourself in a distinguished...
  • Page 10 Memo...

  • Page 11: Operating Instructions

    1. Operating instructions Operation component locations rearview mirror engine stop button rearview mirror front brake lever clutch lever light control, turn signal & horn switch throttle grip kickstarter shift lever Rear brake pedal...

  • Page 12: Fuel

    Operating instructions (1) BREATHER HOSE (1) RADIATOR CAP (1) KICKSTARTER PEDAL (2) FUEL TANK CAP Fuel Coolant Basic Operation Gasoline: Premium unleaded gasoline (commercially Starting The Engine The engine of COTA is a water-cooled type. In order to 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 13 Operating instructions (1) ENGINE STOP BUTTON (1) SIDE STAND (2) SIDE STAND SPRING When you shift the transmission into gear, apply front Break-In Procedure Side Stand brake to prevent the motorcycle move forward. New Motorcycle The side stand is used to support your Cota while parked. Stopping The Engine Following proper break-in procedure helps ensure that To operate, use your foot to lower the side stand until it...

  • Page 14: Odometer/Speedometer (Ed/2E)

    Operating instructions ED / 2E ED / 2E (1) SPEEDOMETER (1) STEERING LOCK (2) TURN SIGNAL INDICATOR (3) HIGH BEAM INDICATOR (4) ODOMETER Steering lock Shifting gears Odometer/Speedometer (ED/2E) Your Cota has five forward gears in a one-down, four-up The steering lock is on the steering stem. To lock the shift pattern.

  • Page 15: Braking

    Operating instructions Braking Parking To slow or stop, apply the front brake lever and rear brake Lower the side stand to support your Cota. Remember to close the throttle and pull the clutch lever in pedal smoothly, while downshifting to match your speed. Always choose a level surface to park.

  • Page 16: Controls

    Operating instructions (1) UPPER LEVEL LINE (1) ADJUSTER (1) DUST COVER (A) DECREASE (2) LOCK NUT (2) LOCK NUT (B) INCREASE (3) ADJUSTER Controls Clutch Lever Throttle Grip The clutch lever free play can be adjusted by turning the Throttle Grip Free Play Clutch adjuster.
  • Page 17 Operating instructions ED / 2E ED / 2E ED / 2E ED / 2E ED / 2E ED / 2E (1) HEADLIGHT DIMMER SWITCH (1) TURN SIGNAL SWITCH (1) ENGINE STOP BUTTON (2) PASSING LIGHT CONTROL SWITCH (2) HORN BUTTON Headlight dimmer switch Turn signal switch Emergency engine stop...
  • Page 18 Operating instructions (1) ADJUSTER (1) LOCK NUT (1) HANDLEBAR (2) LOCK NUT (2) ADJUSTING BOLT (A) RAISE THE PEDAL HEIGHT (B) LOWER THE PEDAL HEIGHT Front brake lever Handlebar position, width and shape Brake pedal height The front brake lever free play can be adjusted by turning Position the handlebar so that gripping the bar and ope- the adjuster.

  • Page 19: Specifications

    2. Service data Specifications Item Specification Item Specification Dimensions Fuel System Overall length 2,020 mm Type PGM-FI 840 mm GQPCA Overall width Identification number 1,135 mm 29,4 mm Overall height Throttle bore 1,320 mm Wheelbase Drive Train 679 mm Seat height Clutch operating system Hydraulic operated 300 mm...
  • Page 20 Service data Service data Unit: mm (in) Item Specification Item Standard Service limit Lubrication Cylinder Head/Valves Specified engine oil Repsol 4T oil-stroke motorcycle oil SAE 10W-30 Cylinder compression 460 kPa (4,7 kgf/cm2) – Engine oil capacity Cylinder head warpage – 0,05 (0,002) after draining 0.41 liter (0.43 US qt, 0.36 Imp qt)
  • Page 21 Service data Unit: mm (in) Unit: mm (in) Item Standard Service limit Item Standard Service limit Cylinder/Piston Crankshaft/Transmission Cylinder 78,000 – 78,015 (3,0709 - 3,0715) 78,04 (3,0724) Crankshaft runout Right – 0,03 (0,001) Taper – 0,05 (0,002) Left – 0,05 (0,002) Out-of- round –...
  • Page 22 Service data Unit: mm (in) Unit: mm (in) Item Standard Service Limit Item Standard Service Limit Wheels/Tires Front Suspension SHOWA (2E/4E) Axle runout 0.20 (0.008) Left fork spring free length 384,8 (15,14) 377,1 (14,85) Tire air pressure Fork tube runout 0,35 –...
  • Page 23 Service data Unit: mm (in) Unit: mm (in) Item Standard Service Limit Item Standard Service Limit Rear Suspension R16V (ED/3E) Electrical Shock absorber spring pre-load 126 (4,96) – Spark plug Standard NGK: CR6EH-9 – Spark plug gap 0,80 – 0,90 (0,031 – 0,035) –...

  • Page 24: Torque Values

    Service data Torque Values Standard Engine Torque Thread Torque Item Item Q’ty Remarks N•m (kgf•m, Ibf•ft) Dia. (mm) N•m (kgf•m, Ibf•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 6 mm bolt and nut...
  • Page 25 Service data 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) 29 (3,0, 22) Handlebar holder bolt 22 (2,2, 16) Note 1 Brake pedal pivot bolt Note 2 Steering head top thread 5 (0,5, 3,6) Note 1...

  • Page 26: 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 07701–0020300 Front spoke nipple Gear holder 07724–0010100 Primary drive gear bolt – Remover shaft 07936–1660120 Bearing remover head 07746–0050600 Wheel bearing –...

  • Page 27: Lubrication & Seal Points

    Service data Lubrication & Seal Points Engine Item Material Remarks Item Material Remarks Crankcase sealing bolt threads and 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 28 Service data Chain tensioner bolt transmission Drain hole Item Material Remarks Clutch slave cylinder piston/O-ring Silicone grease Application zone Application zone Left crankcase cover cap threads Lithium based multipurpose 6.5±1 mm 3 - 4 mm 2.5±1 mm 1.2±0.4 mm Each oil seal lips grease Water seal lips Right crankcase cover water hose joint threads...
  • Page 29 Service data Frame Item Material Remarks Item Material Remarks Steering head bearing race and bearings Multi-purpose grease Drive chain adjuster stopper screw threads Locking agent Steering head dust seal lips Side stand bracket bolt threads Swingarm pivot needle bearing Steering stopper bolt threads Swingarm pivot dust seal lips Drive chain slider mounting screw threads Shock link/shock arm needle bearings...

  • Page 30: Cable & Harness Routing

    Service data Cable & Harness Routing ED / 3E 2E / 4E 90º (1) FRONT BRAKE HOSE (2) THROTTLE CABLE (3) CLUTCH HOSE (4) ENGINE STOP SWITCH CONNECTOR 2-12 2-12...
  • Page 31 Service data (1) SPEEDOMETER (10) INDICATOR LIGHT INSTALLATION (2) POWER RELAY (11) INDICATOR LIGHT INSTALLATION CONNECTOR (3) WINKER RELAY (12) RIGHT REAR TURN SIGNAL CONNECTORS (4) FAN RELAY (13) LEFT REAR TURN SIGNAL CONNECTORS (5) RIGHT FRONT TURN SIGNAL CONNECTORS (14) CLAMPS (6) LEFT FRONT TURN SIGNAL CONNECTORS (7) CONNECTOR 9P...
  • Page 32 Service data UPPER 20-30º (1) MAIN WIRE HARNESS (7) FAN MOTOR WIRE (2) FUEL PUMP WIRE (8) FUEL CAP BREATHER HOSE (3) CYLINDER HEAD BREATHER HOSE (9) SPARK PLUG WIRE (4) CRANKCASE BREATHER JOINT HOSE (10) WIRE HARNESS (TO IGNITION COIL) (5) STRAGE TANK (11) ECT SENSOR (6) ENGINE STOP SWITCH WIRE...
  • Page 33 Service data Clamp at white tape (1) WIRE HARNESS (5) UPPER RADIATOR HOSE (2) THROTTLE CABLE (6) SPARK PLUG WIRE (3) CLUTCH HOSE (7) FAN MOTOR WIRE (4) CONNECTOR BOOT (8) FILTER BOX BREATHER HOSE – FAN MOTOR 2P (BLACK) CONNECTOR (9) CYLINDER HEAD BREATHER HOSE –...
  • Page 34 Service data UPPER UPPER 45º (1) INTAKE VACUUM HOSE (2) THROTTLE CABLE (3) CLUTCH HOSE (4) FUEL TANK BREATHER HOSE 2-16 2-16...
  • Page 35 Service data (1) MAIN WIRE HARNESS (6) REGULATOR/RECTIFIER 5P (BLACK) CONNECTOR (2) TRANSMISSION BREATHER HOSE (7) ENGINE STOP RELAY (3) FILTER BOX BREATHER HOSE (8) FAN MOTOR RELAY (Only for 3E/4E version) (4) ALTERNATOR WIRE (9) REAR BRAKE RESERVOIR TANK (5) CONDENSER 2P (BLACK) CONNECTOR (10) SPEED SENSOR CABLE (Only for ED/2E versions) 2-17...
  • Page 36 Service data Clamp at white tape (9) REGULATOR/RECTIFIER 5P (BLACK) CONNECTOR (1) MAIN WIRE HARNESS (TO CONNECTOR COVER) (10) CONDENSOR (2) MAIN WIRE HARNESS (TO RELAY) (11) CONDENSOR 2P (BLACK) CONNECTOR (3) MAIN WIRE HARNESS (TO ECU) (12) BANK ANGLE SENSOR (4) CRANKCASE BREATHER JOINT HOSE (13) FAN MOTOR RELAY (5) TRANSMISSION BREAHTER HOSE...
  • Page 37 Service data UPPER 90º UPPER (1) REAR BRAKE HOSE (2) REAR BRAKE RESERVOIR HOSE (3) SPEED SENSOR (ED/2E) 2-19 2-19...
  • Page 38 Service data (1) FUEL FEED HOSE (2) INTAKE VACUUM HOSE (3) TRANSMISSION BREATHER HOSE 2-20 2-20...

  • Page 39: 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 I: Inspect and clean, Adjust, Lubricate or Replacement if necessary. C: Clean, R: Replace, L: Lubricate. moments before each ride to walk around your COTA 4RT and check its condition.

  • Page 40: 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 41: Fuel Line

    Service and maintenance ED / 2E ED / 2E 3E / 4E 3E / 4E (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.

  • Page 42: 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 43 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 44: 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 45 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 46: Engine Idle Speed

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

  • Page 47: 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 48: Clutch System

    Service and maintenance (1) FILLER NECK (1) CLUTCH FLUID RESERVOIR (1) EXHAUST PIPE (2) LOWER LEVEL LINE (2) MUFFLER (3) LAMBDA-SONDE (ED/2E) 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 49: 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 50: 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 51: 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 52: Brake Pad Wear

    Service and maintenance ED / 3E ED / 3E 2E / 4E 2E / 4E (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 53: 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 54: Front Suspension

    Service and maintenance ED / 3E ED / 3E ED / 3E ED / 3E (1) PRE-LOAD ADJUSTER (1) REBOUND ADJUSTER Front Suspension Fork (ED / 3E) 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:...

  • Page 55: Fork (2E /4E)

    Service and maintenance 2E / 4E 2E / 4E 2E / 4E 2E / 4E 2E / 4E 2E / 4E (1) PRE-LOAD ADJUSTER (1) REBOUND ADJUSTER (2) COMPRESSION ADJUSTER Fork (2E /4E) Replace the fork fluid every 6 months. See page 5-8, ...

  • Page 56: Rear Suspension

    Service and maintenance ED / 3E ED / 3E 2E / 4E 2E / 4E ED / 3E ED / 3E 2E / 4E 2E / 4E (1) PRE-LOAD ADJUSTER (1) REBOUND ADJUSTER Rear Suspension  When your Cota is new, your suspension will break-in Inspection as you ride.

  • Page 57: 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 58: 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 59: 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 60 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 61 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 62: Fuel Line Inspection

    Remove the fuel feed hose banjo bolt and attach the fuel Slowly loosen the banjo bolt and catch the remaining fuel Fuel Pressure Inspection pressure gauge with the following Montesa Genuine parts. using a approved gasoline container. Banjo bolt, 12 mm WARNING part No.
  • Page 63 Engine servicing (1) FUEL PRESSURE GAUGE (1) NEW SEALING WASHERS (1) VACUUM HOSE (2) BANJO BOLT (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 64: 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 regulator.
  • Page 65 Engine servicing (1) BREATHER HOSE (1) 2P (BLACK) CONNECTOR (1) BANJO BOLT (2) BOLT (2) FUEL FEED HOSE (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 66 Engine servicing (1) FUEL PUMP (1) FUEL PUMP (1) NEW O-RING (2) RETURN HOSE (2) ALIGN (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.

  • Page 67: Injector

    Engine servicing (1) FUEL TANK (1) SOCKET BOLTS (1) INJECTOR (2) BOLTS (2) 2P (BLACK) CONNECTOR (3) BREATHER HOSE Injector Install and tighten the injector holder socket bolts to the specified torque. Inspection Torque: 8 - 12 N•m (0.8 - 1.2 kgf•m, 5.9 - 8.8 lbf•ft) Remove the rear fender.

  • Page 68: Throttle Body

    Engine servicing (1) INJECTOR (1) BOLTS/NUTS (1) 32P (BLACK) CONNECTOR (2) NEW O-RING (2) AIR CLEANER HOUSING (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 69 Engine servicing (1) LOCK NUT (2) THROTTLE CABLE (1) THROTTLE CABLE END (2) THROTTLE DRUM (1) THROTTLE BODY (3) THROTTLE CABLE END (4) THROTTLE DRUM (3) THROTTLE CABLE (4) LOCK NUT (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 70: Water Seal And Bearing Replacement

    Engine servicing (1) AIR CLEANER HOUSING (1) BOLTS (1) BEARING REMOVER, 12 MM (2) BOLTS/NUTS (2) WATER PUMP COVER Install the air cleaner housing onto the frame and connect Remove the water pump bearing from the right crankcase the crankcase breather hose. cover using the special tools.
  • Page 71 Engine servicing (1) WATER SEAL DRIVER (1) WASHER (1) DOWEL PINS (2) DRIVER/ATTACHMENT (2) WATER PUMP SHAFT (2) NEW O-RING (3) NEW COPPER WASHER (3) WATER PUMP COVER (4) IMPELLER 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 72: Radiator Removal/Installation

    Engine servicing (1) 2P (NATURAL) CONNECTOR (1) TIE WRAP (1) GROUND EYELET (2) BOLTS (3) IGNITION COIL (4) WIRE CLAMP Radiator Removal/Installation Remove the spark plug wire tie-wrap from fan motor shroud. Remove the following: – Exhaust pipe – Skid plate –...
  • Page 73 Engine servicing (1) RADIATOR HOSES (1) RADIATOR (2) HANGER BOLT (2) EXHAUST PIPE (3) DOWN TUBE BOLTS (3) MUFFLER (4) DOWN TUBES (4) SKID PLATE (5) BOLT (6) RADIATOR Engine Removal/Installation  Support the motorcycle securely using a hoist or Disconnect the radiator hoses at the right crankcase cover equivalent.
  • Page 74 Engine servicing Engine Removal/Installation Illustration 2.2 - 2.6 N•m (0.22 - 0.26 kgf•m) (1.6 - 1.9 lbf•ft) 2.5 - 2.7 N•m (0,25 - 0,27 kgf•m) (1.8 - 2 lbf•ft) 60 - 80 N•m (6 - 8 kgf•m) (44 - 59 lbf•ft) 4.7 - 5.3 N•m (0.47 - 0.53 kgf•m) (3.4 - 3.9 lbf•ft)

  • Page 75: 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 76 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 77 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 78: 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 79 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 80: Cylinder Head Disassembly

    Engine servicing (1) CAM CHAIN GUIDE (1) VALVE SPRING COMPRESSOR (1) RETAINER (2) ALIGN (2) ATTACHMENT (2) OUTER SPRING (3) INNER SPRING (4) SPRING SEAT Cylinder Head Disassembly (5) VALVE (6) STEM SEAL Remove the cylinder head (page 4-20). Remove the following: Remove the valve spring cotters using the special tools.

  • Page 81: 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 82: 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 83: 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 84 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 85 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 86: 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 87: 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 88 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 89 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-to-ring groove clearance with the Cylinder Inspect the piston for damage and the ring grooves for rings pushed into the grooves.
  • Page 90 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 91 Engine servicing (1) TENSIONER LIFTER (1) TOP RING (1) “IN” MARK (2) SECOND RING (2) PISTON PIN (3) OIL RINGS (3) NEW PISTON PIN CLIP (4) SPACER Tensioner lifter Piston Installation Check the tensioner lifter operation as follows: Piston Ring Installation –...

  • Page 92: 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 93 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 94 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 95: 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 96: Clutch Slave Cylinder

    Engine servicing (1) DOWEL PINS (1) RIGHT CRANKCASE COVER (1) OIL BOLTS (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 97 Engine servicing (1) SLAVE CYLINDER PISTON (1) O-RING (1) SEALING WASHERS (2) SPRING (2) DOWEL PINS (2) OIL BOLTS (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 98: 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) CLUTCH LIFTER (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 99 Engine servicing (1) CLUTCH CENTER (1) LIFTER PIECE ASSEMBLY (1) OUTER GUIDE (2) CLUTCH OUTER (2) NEEDLE BEARING (3) OUTER GUIDE (4) NEEDLE BEARING Inspection Check the following items (specifications; 2-2).  Clutch outer for wear, cracks or indentation by the clutch discs.
  • Page 100 Engine servicing (1) PRESSURE PLATE (1) THRUST WASHER (1) CLUTCH SPRINGS (2) CLUTCH CENTER (2) LOCK WASHER (2) LIFTER PLATE (3) DOT MARKS (3) “OUTSIDE” MARK (3) BOLTS (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 101: 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 102: 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 103 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 104: 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 105 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 106 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 107: 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 108 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 109: 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 110 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 111: 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 112 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 113: 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 4-55 4-55...

  • Page 114: 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 115 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 and clutch outer onto the mainshaft and attach the gear –...
  • Page 116 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 117: Frame Servicing

    5. Frame servicing Disassembly/Assembly ED / 3E ED / 3E WARNING A contaminated brake disc or pad reduces stopping power, and can cause a serious injury or death. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. 2E / 4E 2E / 4E 2E / 4E...
  • Page 118 Frame servicing ED / 3E ED / 3E ED / 3E ED / 3E ED / 3E ED / 3E 2E / 4E 2E / 4E 2E / 4E 2E / 4E 2E / 4E 2E / 4E 2E / 4E 2E / 4E (1) SIDE COLLAR (2E/4E) (1) BRAKE CALIPER...

  • Page 119: Fork

    Frame servicing ED / 3E ED / 3E 2E / 4E 2E / 4E ED / 3E ED / 3E 2E / 4E 2E / 4E (1) FRONT FENDER (1) FORK BOLT (1) DAMPER ADJUSTER CASE (2) NUMBER PLATE (2) FORK BOLT (3) TOP BRIDGE (4) BOTTOM BRIDGE Right Fork Disassembly...
  • Page 120 Frame servicing ED / 3E ED / 3E ED / 3E ED / 3E ED / 3E ED / 3E (1) DUST SEAL 2E / 4E 2E / 4E 2E / 4E 2E / 4E (2) STOP RING (1) FORK DAMPER HOLDER (1) FORK DAMPER (2) RIGHT FORK CENTER BOLT (2) CENTERING PLATE...
  • Page 121 Frame servicing ED / 3E ED / 3E (1) FORK TUBE BUSHING (1) BUSHING 2E / 4E 2E / 4E (2) GUIDE BUSHING (2) BACK-UP RING (3) BACK-UP RING (3) INSPECTION POINT (4) OIL SEAL Right Fork Inspection Check that the fork tube moves smoothly in the slider. If it does not, check the fork tube bending or damage, and Check the following items (specifications;...
  • Page 122 Frame servicing (1) FORK TUBE BUSHING (1) FORK SEAL DRIVER (1) FORK DAMPER ASSEMBLY (2) GUIDE BUSHING (2) CENTERING PLATE (3) BACK-UP RING (3) FORK TUBE (4) OIL SEAL Install the centering plate and fork damper assembly into ED / 3E ED / 3E 2E / 4E 2E / 4E...
  • Page 123 Frame servicing ED / 3E ED / 3E 2E / 4E 2E / 4E ED / 3E ED / 3E 2E / 4E 2E / 4E (1) FORK DAMPER HOLDER (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.
  • Page 124 Frame servicing ED / 3E ED / 3E 2E / 4E 2E / 4E ED / 3E ED / 3E ED / 3E ED / 3E 2E / 4E 2E / 4E 2E / 4E 2E / 4E (1) DAMPER ADJUSTER CASE (1) FORK BOLT ED / 3E ED / 3E...
  • Page 125 Frame servicing ED / 3E ED / 3E 2E / 4E 2E / 4E (1) FORK DAMPER HOLDER (1) FORK TUBE (1) SEAT PIPE (2) CENTER BOLT (2) SEAT PIPE ASSEMBLY (2) PISTON RING (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 126 Frame servicing ED / 3E ED / 3E 2E / 4E 2E / 4E ED / 3E ED / 3E 2E / 4E 2E / 4E (1) FORK TUBE (1) FORK DAMPER HOLDER (1) GUIDE BUSHING (2) SEAT PIPE ASSEMBLY (2) CENTER BOLT (2) BACK-UP RING (3) OIL LOCK PIECE...
  • Page 127 Frame servicing ED / 3E ED / 3E 2E / 4E 2E / 4E ED / 3E ED / 3E 2E / 4E 2E / 4E FORWARD FORWARD (1) FORK SPRING (1) FORK TUBE (2) SPRING SEAT (2) TOP BRIDGE (3) DISTANCE COLLAR (4) O-RING Pour half the required amount of recommended fork fluid...

  • Page 128: Steering Stem

    Frame servicing (1) BOTTOM BRIDGE PINCH BOLTS (1) STEM NUT (1) ADJUSTING NUT (2) FORK BOLT (2) TOP BRIDGE (3) TOP BRIDGE PINCH BOLTS Steering stem Tighten the bottom bridge pinch bolts to the specified torque. Disassembly Torque: 21 N•m (2.1 kgf•m, 14 lbf•ft) Remove the following: Overtightening the pinch bolts can deform the outer tube.
  • Page 129 Frame servicing (1) STEM (1) STEM (1) DRIVER (2) LOWER BEARING (2) DUST SEAL (2) ATTACHMENT (3) DUST SEAL (3) BEARING (4) STEERING STEM DRIVER Install new dust seal onto the steering stem. Install the new lower bearing into the steering stem using a hydraulic press and driver.
  • Page 130 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 bolt threads and seating your fingers.

  • Page 131: Rear Wheel

    Frame servicing Spokes: Check spoke tension frequently between the first few rides. As the spokes, spoke nuts and rim contact 27 N•m (2,7 kgf•m) (ED/3E) points seat-in, the spokes may need to be retightened. 32 N•m (3,2 kgf•m) (2E/4E) Once past this initial seating-in period, the spokes should hold their tension.

  • Page 132: Shock Absorber

    Frame servicing (1) AXLE (3) AXLE NUT (1) LOWER MOUNTING BOLT/NUT (2) ADJUSTERS Installation Apply grease to the axle nut threads and seating surface. Install the right chain adjuster and axle nut. Install the rear brake caliper aligning with the caliper slide Install the drive chain.
  • Page 133 Frame servicing ED / 3E ED / 3E ED / 3E ED / 3E (1) SPANNER WRENCH ED / 3E ED / 3E (1) SEEGER Removal (ED / 3E) Secure the damper in a bench vise Loosen the lock nut and the spring adjuster using the spanner wrench (07702-0020001).
  • Page 134 Frame servicing ED / 3E ED / 3E 2E / 4E 2E / 4E 2E / 4E 2E / 4E (1) DISTANCE COLLAR (1) SPRING COMPRESSOR (1) VALVE CAP (2E/4E) (2) ATTACHMENT (3) SPRING SEAT STOPPER Remove the distance collar. Disassembly 2E / 4E Nitrogen Releasing Procedure (2E/4E) Remove the air valve cap and press the valve stem and...
  • Page 135 Frame servicing ED / 3E ED / 3E 2E / 4E 2E / 4E 2E / 4E 2E / 4E ED / 3E ED / 3E (2) DUST SEALS (1) SPRING 2E / 4E 2E / 4E (3) STOP RING (2E / 4E) (2) SPRING SEAT (4) SPHERICAL BEARING (3) STOPPER RING...

  • Page 136: Shock Linkage

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

  • Page 137: Swingarm

    Frame servicing 3 mm (0.12 in) (1) PIVOT COLLAR A (1) CUSHION LINK (1) SHOCK ABSORBER LOWER MOUNTING BOLT/NUT (2) PIVOT COLLAR B (2) CUSHION ARM PLATES (2) SHOCK ARM PLATES-TO-SWINGARM BOLT/NUT (3) DUST SEALS (3) BOLTS/NUTS (4) NEEDLE BEARINGS (4) LOWER MOUNTING BOLT/NUT Swingarm Needle Bearing Replacement...
  • Page 138 Frame servicing 5,5 mm (0.22 in) (1) BRAKE HOSE CLAMPS (1) DUST SEAL CAP (1) NEEDLE BEARING (2) SWINGARM PIVOT BOLT/NUT (2) DUST SEAL (2) DUST SEAL (3) PIVOT COLLAR (3) BUSHING (4) DUST SEAL Remove the following: Pivot Bearing Replacement –...
  • Page 139 Frame servicing 3 mm (0.12 in) (1) PIVOT COLLAR A (1) DUST SEAL (1) CHAIN TENSIONER (2) PIVOT COLLAR B (2) PIVOT COLLAR (2) BUSHINGS (3) DUST SEALS (3) DUST SEAL (3) O-RINGS (4) NEEDLE BEARING (4) DUST SEAL CAP (4) PIVOT BOLT Link Bearing Replacement Apply grease to the pivot chain tensioner, bushings and...
  • Page 140 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 141: Brake Pad Replacement

    Frame servicing ED / 3E ED / 3E ED / 3E ED / 3E ED / 3E ED / 3E (1) PAD PIN (1) NEW PADS (2) PAD SPRING PIN (2) PAD PIN (3) BOLTS (3) PAD SPRING PIN (4) DISC COVER Install the new pads and secure with the pin and the ED / 3E ED / 3E...
  • Page 142 Frame servicing 2E / 4E 2E / 4E 2E / 4E 2E / 4E 2E / 4E 2E / 4E (1) PAD SPRING PIN (1) NEW PADS (2) BOLTS (2) PAD PIN (3) DISC COVER (3) PAD SPRING PIN (4) CALIPER Install the new pads and secure with the spring pin for 2E / 4E 2E / 4E...
  • Page 143 Frame servicing ED / 3E ED / 3E ED / 3E ED / 2E ED / 2E ED / 2E ED / 2E ED / 2E ED / 2E (1) BOLT (1) BRAKE PADS (2) SPEED SENSOR (2) PAD PIN (3) SPEED SENSOR BRACKET Rear Brake Pad Replacement (ED / 2E) (ED / 2E)

  • Page 144: Front Brake Caliper

    Frame servicing ED / 3E ED / 3E 2E / 4E 2E / 4E 3E / 4E 3E / 4E 3E / 4E 3E / 4E (1) BRAKE PADS (1) OIL BOLT (2) PAD PIN (2) MOUNTING BOLTS (3) DISC COVER (4) BRAKE CALIPER 2E / 4E 2E / 4E...

  • Page 145: Rear Brake Caliper

    Frame servicing ED / 3E ED / 3E 2E / 4E 2E / 4E (1) OIL BOLT (1) CALIPER PISTON (2) BRAKE HOSE (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 cylinder.

  • Page 146: Front Master Cylinder

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

  • Page 147: 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 148: 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 149 Frame servicing (1) BOOT (2) SNAP RING (3) PISTON ASSEMBLY (4) SPRING Disassembly/Assembly Inspection Check the following items (specifications; page 2-4): NOTICE – Master cylinder and piston for scoring, scratches or other damage  Keep the master cylinder piston, cups, spring and –...
  • Page 150 Memo...

  • Page 151: 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 152 Electrical servicing (1) 3P (NATURAL) CONNECTOR (1) 2P (BLACK) CONNECTOR (1) BOLTS (2) 2P (NATURAL) CONNECTOR (2) 6P (BLACK) CONNECTOR (2) ELECTRIC STAY ASSEMBLY ED / 2E (1) FAN MOTOR RELAY (Only for ED/2E version) (1) BOLT (1) 2P (BLACK) CONNECTOR (2) BRAKE RESERVOIR (2) CONDENSER Regulator/Rectifier Removal/installation...

  • Page 153: 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. Remove the fuel tank/injector assembly. Ignition coil inspection Install the regulator/rectifier and condenser in the reverse order of removal.
  • Page 154 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 155: 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 156: Pgm-Fi

    Electrical servicing (1) PGM WARNING UNIT ASSEMBLY (1) POWER SWITCH (1) POWER SWITCH (2) RED WIRE EYELET (2) MIL (2) MIL (3) GREEN WIRE EYELET (3) WARNING/RESET SWITCH (3) WARNING/RESET SWITCH (4) 2P (BLACK) CONNECTOR Turn the PGM warning unit warning/reset switch to the Self-diagnosis Reset Procedure (5) 4P (RED) CONNECTOR warning side as shown.

  • Page 157: 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 158: 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 159: Engine Stop Switch Inspection

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

  • Page 160: Chapter Lights / Instruments / Switches

    Electrical servicing Chapter lights / instruments / switches (ED / 2E) System location speedometer connector 6P power relay fan relay winker relay Wire harness inspection Check for continuity of the Black/Blue wire between the fan motor relay 2P (Natural) connector and ECM 32P (Black) connector.
  • Page 161 Electrical servicing Servicing information Lo Hi BAT BAT Po  Bear in mind the following when replacing the front 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 162 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 163 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 Check for loose or defective contacts in the connectors Disconnect the connector 2P from the rear brake light 6P and 3P of the speedometer.

  • Page 164: Speed Sensor

    Electrical servicing (1) CONNECTOR 6P (1) SPEED SENSOR Speed sensor Power input line If there is no pulse voltage, check the following:  Air gap.  The Blue wire in case there is an open circuit or short Measure the voltage between the connector 6P of the System check circuit.

  • Page 165: Battery

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

  • Page 166: Wiring Diagram (Ed / 2E)

    Electrical servicing Wiring diagram (ED / 2E) POWER WINKER SPEED SENSOR, RELAY RELAY REAR WHEEL TURN SIGNAL INDICATOR LIGHT SENSOR 12V 1,2 W ENGINE FUEL STOP MOTOR PUMP SWITCH HIGH BEAM INDICATOR LIGHT 12V 1,2 W METER INDICATOR LIGHT 12V 1,2 W DIGITAL METER SERVICE CHECK CONNECTOR...

  • Page 167: Wiring Diagram (3E / 4E)

    Electrical servicing Wiring diagram (3E / 4E) ENGINE FUEL STOP MOTOR PUMP SWITCH SERVICE CHECK CONNECTOR POWER FUN RELAY WATER REGULATOR/RECTIFIER TEMP SENSOR BI NOIR Br MARRON CONDENSER BANK ANGLE SENSOR Y JAUNE O ORANGE PULSER (10000uF) ALTERNADOR Bu BLEU Sb BLEU CLAIR G VERT Lg VERT CLAIR...
  • Page 168 Memo...

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