Kawasaki Kle500 Service Manual .....v...r...[ D

2014-12-11

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Quick Reference Guide

This quick reference guide will assist
you in locating a desired topic or procedure.
•Bend the pages back to match the
black tab of the desired chapter number with the black tab on the edge at
each table of contents page.
•Refer to the sectional table of contents
for the exact pages to locate the specific topic required.

General Information

1 j

Periodic Maintenance

2 j

Fuel System

3 j

Cooling System

4 j

Engine Top End

5 j

Clutch

6 j

Engine Lubrication System

7 j

Engine Removal/Installation

8 j

Crankshaft/Transmission

9 j

Wheels/Tires

10 j

Final Drive

11 j

Brakes

12 j

Suspension

13 j

Steering

14 j

Frame

15 j

Electrical System

16 j

Appendix

17 j

KLE500

Motorcycle
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki
Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your Motorcycle dealer for the latest
information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.

First Edition (1): Dec. 10, 2004 (K)

LIST OF ABBREVIATIONS
A
ABDC
AC
ATDC
BBDC
BDC
BTDC
°C
DC
F
°F
ft
g
h
L

ampere(s)
after bottom dead center
alternating current
after top dead center
before bottom dead center
bottom dead center
before top dead center
degree(s) Celsius
direct current
farad(s)
degree(s) Fahrenheit
foot, feet
gram(s)
hour(s)
liter(s)

lb
m
min
N
Pa
PS
psi
r
rpm
TDC
TIR
V
W
Ω

pound(s)
meter(s)
minute(s)
newton(s)
pascal(s)
horsepower
pound(s) per square inch
revolution
revolution(s) per minute
top dead center
total indicator reading
volt(s)
watt(s)
ohm(s)

Read OWNER’S MANUAL before operating.

Foreword
This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop procedures must be understood in order to carry out
maintenance and repair satisfactorily. Whenever the owner has insufficient experience or
doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures
before starting work, and then do the work carefully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurements
can only be made if the proper instruments are
used, and the use of substitute tools may adversely affect safe operation.
For the duration of the warranty period,
we recommend that all repairs and scheduled
maintenance be performed in accordance with
this service manual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void the warranty.
To get the longest life out of your vehicle:
Follow the Periodic Maintenance Chart in the
Service Manual.
Be alert for problems and non-scheduled
maintenance.
Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, and
testers that are necessary when servicing
Kawasaki motorcycles are introduced by the
Special Tool Catalog or Manual. Genuine
parts provided as spare parts are listed in the
Parts Catalog.
Follow the procedures in this manual carefully. Don’t take shortcuts.
Remember to keep complete records of maintenance and repair with dates and any new
parts installed.

•
•
•

•
•

How to Use This Manual
In this manual, the product is divided into its
major systems and these systems make up the
manual’s chapters.

The Quick Reference Guide shows you all
of the product’s system and assists in locating
their chapters. Each chapter in turn has its own
comprehensive Table of Contents.
For example, if you want ignition coil information, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use the
Table of Contents on the first page of the chapter to find the ignition coil section.
Whenever you see these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.

WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in personal injury, or loss of life.

CAUTION
This caution symbol identifies special
instructions or procedures which, if not
strictly observed, could result in damage to or destruction of equipment.
This manual contains four more symbols (in
addition to WARNING and CAUTION) which will
help you distinguish different types of information.

NOTE

○This note symbol indicates points of particular interest for more efficient and convenient operation.

a procedural step or work to be
• Indicates
done.

○Indicates a procedural sub-step or how to do

the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action to
take based on the results of the test or inspection in the procedural step or sub-step it follows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require specified tightening torque, oil, grease or a locking
agent during assembly.

GENERAL INFORMATION 1-1

General Information

Table of Contents
Before Servicing .....................................................................................................................
Model Identification.................................................................................................................
General Specifications............................................................................................................
Unit Conversion Table ............................................................................................................

1-2
1-7
1-8
1-11

1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following:

Battery Ground

Before completing any service on the motorcycle, disconnect the battery wires from the battery to prevent the engine
from accidentally turning over. Disconnect the negative wire
(–) first and then the positive (+). When completed with the
service, first connect the positive (+) wire to the positive (+)
terminal of the battery then the negative (–) wire to the negative terminal.

Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.

Solvent
Use a high flush point solvent when cleaning parts. High
flush point solvent should be used according to directions
of the solvent manufacturer.

Cleaning vehicle before disassembly
Clean the vehicle thoroughly before disassembly. Dirt or
other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease
performance of the vehicle.

GENERAL INFORMATION 1-3
Before Servicing
Arrangement and Cleaning of Removed Parts
Disassembled parts are easy to confuse. Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.

Storage of Removed Parts
After all the parts including subassembly parts have been
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.

Inspection
Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is beyond its service limit.

Replacement Parts
Replacement Parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, Oil seals,
Grease seals, circlips or cotter pins must be replaced with
new ones whenever disassembled.

Assembly Order
In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service
Manual, follow the procedures given.

1-4 GENERAL INFORMATION
Before Servicing
Tightening Sequence
Generally, when installing a part with several bolts, nuts,
or screws, start them all in their holes and tighten them to
a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can
lead to malfunction. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quarter turn and them remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.

Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench.

Force
Use common sense during disassembly and assembly,
excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non
-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets
and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing
surfaces thoroughly so that no gasket material or other
material remains. Install new gaskets and replace used
O-rings when re-assembling.

Liquid Gasket, Locking Agent
For applications that require Liquid Gasket or a Locking
agent, clean the surfaces so that no oil residue remains before applying liquid gasket or locking agent. Do not apply
them excessively. Excessive application can clog oil passages and cause serious damage.

GENERAL INFORMATION 1-5
Before Servicing
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use
smooth movements when installing.

Ball Bearing and Needle Bearing
Do not remove pressed ball or needle unless removal is
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.

Oil Seal, Grease Seal
Do not remove pressed oil or grease seals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.

Apply specified grease to lip of seal before installing the
seal.

Circlips, Cotter Pins
Replace circlips or cotter pins that were removed with new
ones. Take care not to open the clip excessively when installing to prevent deformation.

1-6 GENERAL INFORMATION
Before Servicing
Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply
the specific oil or grease as specified.

Direction of Engine Rotation
When rotating the crankshaft by hand, the free play
amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed
from output side).

Electrical Wires
A two-color wire is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
wires must be connected to those of the same color.

GENERAL INFORMATION 1-7
Model Identification
KLE500-B1 Left Side View

KLE500-B1 Right Side View

1-8 GENERAL INFORMATION
General Specifications
Items
Dimensions
Overall Length
Overall Width
Overall Height
Wheelbase
Road Clearance
Seat Height
Dry Weight
Curb Weight:
Front
Rear
Fuel tank Capacity
Performance
Minimum Turning Radius
Engine
Type
Cooling System
Bore and Stroke
Displacement
Compression Ratio
Maximum Horsepower
Maximum Torque
Carburetion System
Starting System
Ignition System
Timing Advance
Ignition Timing
Spark Plugs
Cylinder Numbering Method
Firing Order
Valve Timing:
Inlet
Open
Close
Duration
Exhaust
Open
Close
Duration
Lubrication System

KLE500-B1
2 215 mm (87.2 in.)
880 mm (34.6 in.)
1 270 mm (50.0 in.)
1 500 mm (59.0 in.)
180 mm (7.09 in.)
850 mm (33.5 in.)
181 kg (399 lb.)
95 kg (209 lb.)
105 kg (232 lb.)
15 L (4.0 US gal.)
2.4 m (7.9 ft.)
4-stroke, DOHC, 2-cylinder
Liquid-cooled
74.0 × 58.0 mm (2.91 × 2.28 in.)
498 mL (30.39 cu in.)
9.8:1
33 kW (44.9 PS) @8 300 r/min (rpm)
41 N·m (4.2 kgf·m, 30 ft·lb) @7 500 r/min (rpm)
Carburetors, Keihin CVK34 × 2
Electric starter
Battery and coil (transistorized)
Electronically Advanced (digital)
From 10° BTDC @1 300 r/min (rpm) to 35° BTDC
@5 000 r/min (rpm)
NGK DR9EA or ND X27ESR-U
Left to right, 1-2
1-2

27° BTDC
47° ABDC
254°
52° BBDC
22° ATDC
254°
Forced lubrication

GENERAL INFORMATION 1-9
General Specifications
Items
Engine Oil:
Grade
Viscosity
Capacity
Drive Train
Primary Reduction System:
Type
Reduction Ratio
Clutch Type
Transmission:
Type
Gear Ratios:
1st
2nd
3rd
4th
5th
6th
Final Drive System:
Type
Reduction Ratio
Overall Drive Ratio
Frame
Type
Caster (rake angle)
Trail
Front Tire:
Type
Size
Rear Tire:
Type
Size
Front Suspension:
Type
Wheel Travel
Rear Suspension:
Type
Wheel Travel
Brake Type:
Front
Rear

KLE500-B1
API SE, SF, SG or
API SH or SJ with JASO MA
SAE10W-40
3.4 L (3.6 US qt)

Chain
2.652 (61/23)
Wet multi disc
6-speed constant mesh, return shift
2.571
1.722
1.333
1.125
0.961
0.851

(36/14)
(31/18)
(28/21)
(27/24)
(25/26)
(23/27)

Chain drive
2.588 (44/17)
5.847 @Top gear
Tubular, double cradle
27°
105 mm (4.13 in.)
Tubeless
90/90-21 M/C 54S
Tubeless
130/80-17 M/C 65S
Telescopic fork
220 mm (8.66 in.)
Swingarm
200 mm (7.87 in.)
Single disc
Single disc

1-10 GENERAL INFORMATION
General Specifications
Items
Electrical Equipment
Battery
Headlight:
Type
Bulb
Tail/brake Light
Alternator:
Type
Rated output

KLE500-B1
12 V 10 Ah
Semi-sealed beam
12 V 55/55 W (quartz-halogen)
12 V 5/21 W
Three-phase AC
17 A × 14 V @6 000 r/min (rpm)

Specifications subject to change without notice, and may not apply to every country.

GENERAL INFORMATION 1-11
Unit Conversion Table
Prefixes for Units:
Prefix
mega
kilo
centi
milli
micro

Symbol
M
k
c
m
µ

Units of Length:

×
×
×
×
×

Power
1 000 000
1 000
0.01
0.001
0.000001

Units of Mass:
kg
g

×
×

2.205
0.03527

=
=

lb
oz

km
m
mm

×
×
×

0.6214
3.281
0.03937

=
=
=

mile
ft
in

=
=
=
=
=
=

kgf·m
ft·lb
in·lb
N·m
ft·lb
in·lb

=
=
=
=
=
=

kgf/cm²
psi
cm Hg
kPa
psi
kPa

mph

=
=
=
=

PS
HP
kW
HP

Units of Torque:
N·m
N·m
N·m
kgf·m
kgf·m
kgf·m

×
×
×
×
×
×

0.1020
0.7376
8.851
9.807
7.233
86.80

Units of Pressure:
Units of Volume:
L
L
L
L
L
L
mL
mL
mL

×
×
×
×
×
×
×
×
×

0.2642
0.2200
1.057
0.8799
2.113
1.816
0.03381
0.02816
0.06102

=
=
=
=
=
=
=
=
=

gal (US)
gal (imp)
qt (US)
qt (imp)
pint (US)
pint (imp)
oz (US)
oz (imp)
cu in

×
×
×
×

0.1020
0.2248
9.807
2.205

Units of Temperature:

×
×
×
×
×
×

0.01020
0.1450
0.7501
98.07
14.22
1.333

Units of Speed:
km/h

0.6214

Units of Power:

Units of Force:
N
N
kg
kg

kPa
kPa
kPa
kgf/cm²
kgf/cm²
cm Hg

=
=
=
=

kg
lb
N
lb

kW
kW
PS
PS

×
×
×
×

1.360
1.341
0.7355
0.9863

PERIODIC MAINTENANCE 2-1

Periodic Maintenance
2

Table of Contents
Periodic Maintenance Chart ...................................................................................................
Torque and Locking Agent......................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Maintenance Procedure .........................................................................................................
Fuel System.........................................................................................................................
Throttle Cable Inspection ..................................................................................................
Idle Speed Inspection .......................................................................................................
Carburetor Synchronization Inspection.............................................................................
Coolant Filter Cleaning .....................................................................................................
Fuel Hoses and Connections Check.................................................................................
Air Cleaner Element Cleaning and Inspection ..................................................................
Cooling System....................................................................................................................
Coolant Level Inspection...................................................................................................
Radiator Hoses and Connections Inspection....................................................................
Engine Top End ...................................................................................................................
Air Suction Valve Inspection .............................................................................................
Valve Clearance Inspection ..............................................................................................
Clutch...................................................................................................................................
Clutch Operation Inspection..............................................................................................
Wheels/Tires ........................................................................................................................
Air Pressure Inspection/Adjustment..................................................................................
Tire Tread Wear Inspection...............................................................................................
Wheel/Tire Damage Inspection.........................................................................................
Wheel Bearing Damage Inspection ..................................................................................
Spoke Tightness and Rim Runout Inspection...................................................................
Final Drive............................................................................................................................
Drive Chain Slack Inspection ............................................................................................
Drive Chain Wear Inspection ............................................................................................
Drive Chain Lubrication.....................................................................................................
Brakes..................................................................................................................................
Brake Fluid Leak (Brake Hose and Pipe) Inspection ........................................................
Brake Hose Damage and Installation Condition Inspection..............................................
Brake Operation Inspection ..............................................................................................
Brake Fluid Level Inspection.............................................................................................
Brake Pad Wear Inspection ..............................................................................................
Brake Light Switch Operation Inspection ..........................................................................
Suspension ..........................................................................................................................
Front Forks/Rear Shock Absorber Operation Inspection ..................................................
Front Fork Oil Leak Inspection..........................................................................................
Rear Shock Absorber Oil Leak Inspection ........................................................................
Rocker Arm Operation Inspection.....................................................................................
Rocker Arm Bearings and Sleeves Lubrication ................................................................
Tie-rod Operation Inspection ............................................................................................
Swingarm Needle Bearing Lubrication..............................................................................
Steering ...............................................................................................................................

2-3
2-6
2-11
2-13
2-14
2-14
2-14
2-15
2-16
2-17
2-17
2-17
2-18
2-18
2-19
2-19
2-19
2-19
2-21
2-21
2-22
2-22
2-22
2-23
2-24
2-24
2-25
2-25
2-26
2-27
2-27
2-27
2-28
2-28
2-28
2-29
2-30
2-30
2-30
2-31
2-31
2-31
2-31
2-32
2-32
2-32

2-2 PERIODIC MAINTENANCE
Steering Play Inspection ...................................................................................................
Steering Stem Bearing Lubrication ...................................................................................
Electrical System .................................................................................................................
Spark Plug Gap Inspection ...............................................................................................
Lights and Switches Operation Inspection........................................................................
Headlight Aiming Inspection .............................................................................................
Side Stand Switch Operation Inspection...........................................................................
Engine Stop Switch Operation Inspection.........................................................................
Others ..................................................................................................................................
Chassis Parts Lubrication .................................................................................................
Bolts, Nuts and Fastener Tightness Inspection ................................................................
Replacement Parts ..............................................................................................................
Fuel Hose Replacement ...................................................................................................
Air Cleaner Element Replacement....................................................................................
Coolant Change ................................................................................................................
Radiator Hoses and O-ring Replacement .........................................................................
Engine Oil Change............................................................................................................
Oil Filter Replacement ......................................................................................................
Brake Hose Replacement .................................................................................................
Brake Fluid Change ..........................................................................................................
Bleeding the Brake Line....................................................................................................
Caliper Rubber Parts Replacement ..................................................................................
Master Cylinder Rubber Parts Replacement ....................................................................
Spark Plug Replacement ..................................................................................................

2-32
2-33
2-34
2-34
2-34
2-36
2-37
2-38
2-38
2-38
2-39
2-40
2-40
2-41
2-41
2-44
2-44
2-45
2-45
2-46
2-47
2-48
2-48
2-49

PERIODIC MAINTENANCE 2-3
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in
good running condition.The initial maintenance is vitally important and must not be neglected.
FREQUENCY

* ODOMETER READING
× 1000 km
(× 1000 mile)

Whichever
comes first
1

OPERATION
Fuel System
Throttle cable-inspect

Every
year

Idle speed-inspect
Carburetor synchronization-inspect
Coolant filter-clean

•
•

Cooling System
Coolant level-inspect
Radiator hose and connection-inspect

year

Engine Top End

2-14

•
•

2-17

•

•
•

2-18

•

•
•

•

2-19

•

2-21

•
•
•
•
•

2-22

•

Tire tread wear-inspect
Wheel/tire damage-inspect
Wheel bearing damage-inspect

year

Spoke tightness and rim runout-inspect
Final Drive
Drive chain slack-inspect #
Drive chain wear-inspect #
Drive chain lubrication condition-inspect #
Drive chain guide wear-inspect
Brake System
Brake fluid leak (brake hose and
pipe)-inspect

year
year

Brake hose installation condition-inspect

year

Brake operation (effectiveness, play, no
drag)-inspect

year

Brake pad wear-inspect #
Brake light switch operation-inspect

• • • • •
•
•
•
•
•
•
• • • • • •
Every 1 000 km (600 mile)
Every 6 000 km (4 000 mile)
Every 600 km (400 mile)
Every 12 000 km (7 500 mile)

Brake hose damage-inspect

Brake fluid level-inspect

•
•
•

Valve clearance-inspect

Tire air pressure-inspect

•
•
•

Air suction valve-inspect
Clutch
Clutch operation (play, disengagement,
engagement)-inspect
Wheels and Tires

•
•
•

year
year

(0.6) (4) (7.5) (12) (15) (20) (24)

Air cleaner element-clean #
Fuel hoses and connections-inspect

6 months

See
Page

•
•
•
•
•

•
•
•
•
•
•
• •

•
•
•
•
•
•
•

2-15
2-16
2-17
2-17

2-19

2-22
2-23
2-24
2-24
2-25
2-26
2-27
–

•
•
•
•
•
•
•

2-27
2-28
2-28
2-28
2-28
2-29
2-30

2-4 PERIODIC MAINTENANCE
Periodic Maintenance Chart
FREQUENCY

* ODOMETER READING
× 1000 km
(× 1000 mile)

Whichever
comes first
1

OPERATION
Suspensions
Front forks/rear shock absorber operation
(damping and smooth stroke)-inspect
Front forks/rear shock absorber oil
leak-inspect

Every

•
•
•

year

Rocker arm bearings and sleeves
-lubricate
Swingarm pivot-lubricate

2 years

•

2-32

•

•
•

•

2-32

•
•
•
•
•

2-34

•
•

2-38

Electrical System
Spark plug condition-inspect
Lights and switches operation-inspect

year

Headlight aiming-inspect

year

Side stand switch operation-inspect

year

Engine stop switch operation-inspect

year

Others
Chassis parts-lubricate
Bolts, nuts and fasteners tightness-inspect

•
•
•

Steering System
Steering stem bearings-lubricate

•
•
•
•
•
•

•

Tie-rods operation-inspect

year

(0.6) (4) (7.5) (12) (15) (20) (24)

Rocker arm operation-inspect

Steering play-inspect

See
Page

year

•

2-30
2-31
2-31
2-31

2-32

2-33

2-34
2-36
2-37
2-38

2-39

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or
frequent starting/stopping.
*: For higher odometer readings, repeat at the frequency interval established here.

PERIODIC MAINTENANCE 2-5
Periodic Maintenance Chart
Periodic Replacement Parts
FREQUENCY Whichever
come
first

* ODOMETER READING
× 1000 km
(× 1000 mile)
1

CHANGE/REPLACEMENT

Every

Fuel hose

4 years

Air cleaner element

2 years

Coolant

3 years

Radiator hose and O-ring

3 years

Engine oil #

year

Oil filter

year

Brake hose

4 years

Brake fluid

2 years

Master Cylinder/Caliper Rubber Parts

4 years

See
Page

(0.6) (7.5) (12) (15) (24) (30)

•
•
•

•
•

•
•
•

•
•
•
•

2-40
2-40
2-40
2-43

•
•
•
•
•

2-43
2-44
2-44
2-45
2-47

2-6 PERIODIC MAINTENANCE
Torque and Locking Agent
Tighten all bolts and nuts to the proper torque using an accurate torque wrench. An insufficiently
tightened bolt or nut may become damaged or fall off, possibly resulting in damage to the motorcycle
and injury to the rider. A bolt or nut which is overtightened may become damaged, strip an internal
thread, or break and then fall out. The following table lists the tightening torque for the major bolts
and nuts, and the parts requiring use of a non-permanent locking agent or liquid gasket.
When checking the tightening torque of the bolts and nuts, first loosen the bolt or nut by half a turn
and then tighten it to the specified torque.
Letters used in the "Remarks" column mean:
EO: Apply engine oil to the threads and seating surface.
L: Apply a non-permanent locking agent to the threads.
LG: Apply liquid gasket to the threads.
Lh: Left-hand threads.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil (mixture of the engine oil and molybdenum disulfide grease in
a weight ratio 10 : 1)
R: Replacement parts.
S: Tighten the fasteners following the specified sequence.
SS: Apply silicone sealant to the threads.
St: Stake the fasteners to prevent loosening.
Fastener
Fuel System
Fuel Tap Cover Screws
Fuel Tap Mounting Bolts
Air Cut Valve Cover Screws
Cooling System
Radiator Hose Clamp Screws
Radiator Fan Switch
Thermostat Housing Bolts
Water Temperature Sensor
Water Pump Cover Bolts
Water Pump Shaft
Water Pump Impeller
Water Pipe Bolts
Cylinder Head Jacket Plug
Radiator Cap Holder Mounting Bolts
Coolant Drain Plug
Engine Top End
Air Suction Valve Cover Bolts
Cylinder Head Cover Bolts
Camshaft Cap Bolts
Rocker Shafts
Valve Adjuster Locknuts
Camshaft Sprocket Bolts
Cylinder Head Bolts (10 mm)
Cylinder Head Bolts (6 mm)
Camshaft Chain Tensioner Mounting Bolts
Camshaft Chain Tensioner Cap Bolt

N·m

Torque
kgf·m

ft·lb

0.8
5.0
1.0

0.08
0.51
0.10

7 in·lb
44 in·lb
9 in·lb

2.5
18
11
7.8
11
25
9.8
9.8
9.8
11
11

0.25
1.8
1.1
0.8
1.1
2.5
1.0
1.0
1.0
1.1
1.1

22 in·lb
13
95 in·lb
69 in·lb
95 in·lb
18
87 in·lb
87 in·lb
87 in·lb
95 in·lb
95 in·lb

11
9.8
12
39
25
15
51
9.8
11
13

1.1
1.0
1.2
4.0
2.5
1.5
5.2
1.0
1.1
1.3

95 in·lb
87 in·lb
104 in·lb
29
18
11
38
87 in·lb
95 in·lb
9.5

Remarks

SS
Lh
Lh
L
L

S
S
EO
L
S
S

PERIODIC MAINTENANCE 2-7
Torque and Locking Agent
Fastener
Main Oil Pipe Upper Banjo Bolts M8
Main Oil Pipe Lower Banjo Bolt M10
Water Jacket Plug
Oil Pipe Bolts (in the cylinder head)
Main Oil Pipe Mounting Bolt
Clutch
Oil Filler Plug
Clutch Hub Nut
Clutch Spring Bolts
Clutch Cable Holder Bolt
Clutch Cover Bolts
Engine Lubrication System
Oil Filler Plug
Oil Passage Plug
Oil Filter Mounting Stud

Oil Filter (Cartridge Type)
Oil Pipe for Balancer Shaft Banjo Bolt
Oil Pipe for Drive Shaft Upper Banjo Bolt M6
Oil Pipe for Drive Shaft Lower Banjo Bolt M8
Oil Pipe for Output Shaft Upper Banjo Bolt M6
Oil Pipe for Output Shaft Lower Banjo Bolt M8
Oil Pipe for Output Shaft Mounting Bolt
Oil Pump Outer Oil Pipe Bolts
Relief Valve
Oil Pressure Switch Terminal Bolt
Oil Pressure Switch
Main Oil Pipe Mounting Bolt
Main Oil Pipe Upper Banjo Bolts
Main Oil Pipe Lower Banjo Bolt
Rocker Shafts
Engine Oil Drain Plug
Oil Pan Mounting Bolts
Oil Pump Mounting Bolts
Engine Removal/Installation
Downtube Bolts
Engine Mounting Bolts and Nuts
Engine Mounting Bracket Bolts
Crankshaft/Transmission
Breather Body Bolt
Crankcase Bolts (8 mm)
Crankcase Bolts (6 mm)

N·m
12
20
9.8
11
11

Torque
kgf·m
1.2
2.0
1.0
1.1
1.1

ft·lb
104 in·lb
14.5
87 in·lb
95 in·lb
95 in·lb

1.5
132
9.3
11
11

0.15
13.5
0.95
1.1
1.1

13 in·lb
98
82 in·lb
95 in·lb
95 in·lb

1.5
18
25

0.15
1.8
2.5

13 in·lb
13
18

17
20
7.8
12
7.8
12
11
11
15
1.5
15
11
12
20
39
29
11
11

1.7
2.0
0.8
1.2
0.8
1.2
1.1
1.1
1.5
0.15
1.5
1.1
1.2
2.0
4.0
3.0
1.1
1.1

12.5
14.5
69 in·lb
104 in·lb
69 in·lb
104 in·lb
95 in·lb
95 in·lb
11
13 in·lb
11
95 in·lb
104 in·lb
14.5
29
22
95 in·lb
95 in·lb

44
44
25

4.5
4.5
2.5

33
33
18

5.9
27
12

0.6
2.8
1.2

52 in·lb
20
104 in·lb

Remarks

L
(Planted
side)

L
L
L
SS

S
S

2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
Upper Primary Chain Guide Mounting Bolt
Lower Primary Chain Guide Mounting Bolt
Connecting Rod Big End Nuts
Return Spring Pin
Gear Positioning Lever Pivot Stud

Gear Positioning Lever Nut
Shift Pedal Link Lever Mounting Bolt
Shift Drum Bearing Holder Bolts
Shift Drum Cam Pin Plate Screw
Engine Sprocket Nut
External Shift Mechanism Cover Bolts
Neutral Switch
Wheels/Tires
Spoke Nipple
Front Axle Nut
Rear Sprocket Nut
Rear Axle Nut
Final Drive
Engine Sprocket Nut
Rear Sprocket Nuts
Rear Coupling Studs

Rear Axle Nut
Drive Chain Guide Bolts
Brakes
Brake Hose Banjo Bolts
Front Reservoir Cap Screws
Brake Lever Pivot Bolt
Brake Lever Pivot Locknut
Front Master Cylinder Clamp Bolts
Front Brake Light Switch Mounting Screw
Front Caliper Mounting Bolts
Rear Caliper Mounting Bolts
Caliper Bleed Valves
Brake Disc Mounting Bolts
Brake Pedal Bolt
Rear Reservoir Mounting Bolt
Rear Master Cylinder Mounting Bolts
Suspension
Front Fork Upper Clamp Allen Bolts
Front Fork Lower Clamp Bolts

N·m
11
11
36
20
–

Torque
kgf·m
1.1
1.1
3.7
2.0
–

ft·lb
95 in·lb
95 in·lb
27
14.5
–

11
12
11
–
127
11
15

1.1
1.2
1.1
–
13
1.1
1.5

95 in·lb
104 in·lb
95 in·lb
–
94
95 in·lb
11

2.0 ∼ 3.9
88
33
108

0.2 ∼ 0.4
9.0
3.4
11

17 ∼ 35 in·lb
65
24
80

127
33
–

13
3.4
–

94
24
–

108
11

11
1.1

80
95 in·lb

34
1.5
1.0
5.9
11
1.2
34
25
7.8
23
25
5.9
25

3.5
0.15
0.10
0.60
1.1
0.12
3.5
2.5
0.8
2.3
2.5
0.60
2.5

25
13 in·lb
9 in·lb
52 in·lb
95 in·lb
10 in·lb
25
18
69 in·lb
16.5
18
52 in·lb
18

25
23

2.5
2.3

18
16.5

Remarks
L
L
L
L
(planted
side)

L
L
EO

EO
L
(planted
side)

S
S

PERIODIC MAINTENANCE 2-9
Torque and Locking Agent
Fastener
Front Fork Top Bolts
Front Fork Bottom Allen Bolt
Rear Shock Absorber Upper Mounting Nut
Rear Shock Absorber Lower Mounting Nut
Swingarm Pivot Nut
Rocker Arm Pivot Nut
Tie-Rod Mounting Nuts
Steering
Handlebar Clamp Bolts
Handlebar Weight Allen Bolts
Front Fork Upper Clamp Allen Bolts
Front Fork Lower Clamp Bolts
Steering Stem Head Nut
Steering Stem Locknut

Frame
Tail Grip Bolts
Front Footpeg Bracket Bolts
Sidestand Bolt and Nut
Rear Footpeg Bracket Bolts
Carrier Stay Mounting Bolts
Electrical System
Crankshaft Sensor Mounting Screws
Timing Inspection Plug
Alternator Rotor Bolt Plug
Alternator Cover Bolts
Alternator Lead Clamp Screws
Spark Plug
Alternator Stator Allen Bolts
Alternator Rotor Bolt
Starter Motor Mounting Bolts
Starter Chain Guide Bolts
Starter Motor Through Bolts
Starter Motor Terminal Nut
Starter Motor Lead Clamp Nut
Starter Clutch Allen Bolts
Sidestand Switch Mounting Screw
Sidestand Bolt and Nut
Radiator Fan Switch
Water Temperature Switch
Oil Pressure Switch Terminal Bolt

N·m
30
30
59
98
118
98
98

Torque
kgf·m
3.1
3.1
6.0
10
12
10
10

25
2.5
–
–
25
2.5
23
2.3
39
4.0
Hand
Hand
-Tighten
-Tighten
(about 4.9) (about 0.5)

ft·lb
22
22
43
72
87
72
72
18
–
18
16.5
29
Hand
-Tighten
(about 43
in·lb)

25
34
44
25
25

2.5
3.5
4.5
2.5
2.5

18
25
33
18
18

8.3
2.5
1.5
11
2.9
14
12
69
11
4.9
6.9
4.9
4.9
34
3.9
44
18
7.8
1.5

0.85
0.25
0.15
1.1
0.30
1.4
1.2
7.0
1.1
0.5
0.7
0.5
0.5
3.5
0.4
4.5
1.8
0.80
0.15

74 in·lb
22 in·lb
13 in·lb
95 in·lb
26 in·lb
10
104 in·lb
51
95 in·lb
43 in·lb
65 in·lb
43 in·lb
43 in·lb
25
35 in·lb
33
13
69 in·lb
13 in·lb

Remarks

S
L
S
S

Lh
L

L
L

2-10 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
Oil Pressure Switch
Neutral Switch
Tail Light Mounting Nut

N·m
15
15
5.9

Torque
kgf·m
1.5
1.5
0.6

ft·lb
11
11
52 in·lb

Remarks
SS

The table relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts.
Use this table for only the bolts and nuts which do not require a specific torque value. All of the values
are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners
Threads
dia. (mm)
5
6
8
10
12
14
16
18
20

N·m
3.4 ∼ 4.9
5.9 ∼ 7.8
14 ∼19
25 ∼ 34
44 ∼ 61
73 ∼ 98
115 ∼ 155
165 ∼ 225
225 ∼ 325

Torque
kgf·m
0.35 ∼ 0.50
0.60 ∼ 0.80
1.4 ∼1.9
2.6 ∼ 3.5
4.5 ∼ 6.2
7.4 ∼ 10.0
11.5 ∼ 16.0
17.0 ∼ 23.0
23 ∼ 33

ft·lb
30 ∼ 43 in·lb
52 ∼ 69 in·lb
10.0 ∼ 13.5
19.0 ∼ 25
33 ∼ 45
54 ∼ 72
83 ∼ 115
125 ∼ 165
165 ∼ 240

PERIODIC MAINTENANCE 2-11
Specifications
Item
Fuel System
Throttle Grip Free Play
Idle Speed
Engine Top End
Valve Clearance
Inlet
Exhaust
Clutch
Clutch Lever Free Play
Wheels/Tires
Air Pressure
Front
Rear
Tread Depth
Front
Dunlop
Bridgestone
Rear
Dunlop

Bridgestone

Rim Runout
Axial
Radial
Final Drive
Drive Chain Slack
Drive Chain Wear (20-link length)
Brakes
Brake Fluid Grade
Pad Lining Thickness
Brake Light Timing
Front
Rear
Electrical System
Spark Plug Gap
Replacement Parts
Coolant Capacity
Engine Oil
Grade
Viscosity

Standard

Service Limit

2 ∼ 3 mm (0.08 ∼ 0.12 in.)
1 200 ±50 r/min (rpm)

– – –
– – –

0.13 ∼ 0.18 mm (0.0051 ∼ 0.0071 in.)
0.18 ∼ 0.23 mm (0.0070 ∼ 0.0090 in.)

– – –
– – –

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

– – –

150 kPa (1.5 kgf/cm², 21 psi)
225 kPa (2.25 kgf/cm², 32 psi)

– – –
– – –

6.9 mm (0.27 in.)
6.0 mm (0.24 in.)

1 mm (0.04 in.)

8.8 mm (0.35 in.)

2 mm (0.08 in.)
(Up to 130 km/h
(80 mph))
3 mm (0.12 in.)
(Over to 130 km/h
(80 mph))

8.5 mm (0.33 in.)

0.5 mm (0.02 in.)
0.8 mm (0.03 in.)

1.5 mm (0.06 in.)
1.5 mm (0.06 in.)

2 ∼ 12 mm (0.08 ∼ 0.47 in.)
317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)

– – –
323 mm (12.7 in.)

DOT4
5.5 mm (0.203 in.)

– – –
1 mm (0.04 in.)

ON after 10 mm (0.39 in.) lever travel
ON after 15 mm (0.59 in.) pedal travel

– – –
– – –

0.6 ∼ 0.7 mm (0.024 ∼ 0.028 in.)

– – –

1.7 L (1.8 US qt)

– – –

API SE, SF, SG or
API SH or SJ with JASO MA
SAE10W-40

– – –
– – –

2-12 PERIODIC MAINTENANCE
Specifications
Item
Capacity
when filter is not removed
when filter is removed
when engine is completely dry

Standard
2.8 L (3.0 US qt)
3.0 L (3.2 US qt)
3.4 L (3.6 US qt)

Service Limit
– – –
– – –
– – –

PERIODIC MAINTENANCE 2-13
Special Tools
Steering Stem Nut Wrench:
57001-1100

Oil Filter Wrench:
57001-1249

Jack:
57001-1238

Vacuum Gauge:
57001-1369

Pilot Screw Adjuster, A:
57001-1239

Filler Cap Driver:
57001-1454

2-14 PERIODIC MAINTENANCE
Maintenance Procedure
Fuel System
Throttle Cable Inspection
Throttle Grip Free Play Inspection
Check throttle grip play [A] by lightly turning the throttle
grip back and forth.
If the free play is improper, adjust the throttle cable.

•

Throttle Grip Free Play
Standard:
2 ∼ 3 mm (0.08 ∼ 0.12 in.)

that the throttle grip moves smoothly from full open
• Check
to close, and the throttle closes quickly and completely in

•

all steering positions by the return spring.
If the throttle grip does not return properly, check the throttle cable routing, grip free play, and cable damage. Then
lubricate the throttle cable.
Run the engine at the idle speed, and turn the handlebar
all the way to the right and left to ensure that the idle speed
does not change.
If the idle speed increase, check the throttle cable free
play and the cable routing.

Throttle Grip Free Play Adjustment
If the free play is incorrect, loosen the locknut [A] and turn
the adjuster [B] of the accelerator cable until the 2 ∼ 3 mm
(0.08 ∼ 0.12 in.) of throttle grip play is obtained.
Tighten the locknut against the adjuster securely.

•

that the throttle pulley [A] stops against the idle
• Check
adjusting screw [B] with the throttle grip closed.

PERIODIC MAINTENANCE 2-15
Maintenance Procedure
If the play can not be adjusted by using the adjuster at the
throttle grip, use the adjuster [A] of the decelerator cable
under the fuel tank.
Screw in the adjuster fully at the throttle grip and tighten
the locknut.
Remove the fuel tank (see Fuel Tank Removal in the Fuel
System chapter).
○Make the necessary free play adjustment at the lower cable end.

•
•

that the throttle pulley stops [A] against the idle
• Check
adjusting screw [B], with the throttle grip released and

•

stops against the carburetor stopper with the throttle grip
opened.
Turn the handlebar from side to side while idling the engine.
If idle speed varies, the cable may be poorly routed or
damaged.

WARNING
Operation with an improperly adjusted, incorrectly
routed, or damaged cable could result in an unsafe
riding condition.
Throttle Cable Inspection
Remove both ends of the throttle cables.
With the throttle cable disconnected at both ends, the cable should move freely [A] within the cable housing.
○If cable movement is not free after lubricating, if the cable
is frayed [B], or if the cable housing is kinked [C], replace
the cable.

•
•

Idle Speed Inspection
Idle Speed Inspection
Start the engine and warm it up thoroughly.
With the engine idling, turn the handlebar to both sides.
If handlebar movement changes the idle speed, the throttle cable may be improperly adjusted or incorrectly routed,
or it may be damaged. Be sure to correct any of these
conditions before riding.

•
•

WARNING
Operation with improperly adjusted, incorrectly
routed, or damaged cables could result in an unsafe riding condition.
idle speed.
• Check
If the idle speed is out of the specified range, adjust it.
Idle Speed
1 200 ±50 r/min (rpm)

2-16 PERIODIC MAINTENANCE
Maintenance Procedure
Idle Speed Adjustment
Start the engine and warm it up thoroughly.
Turn the adjusting screw [A] until idle speed is correct.
○Open and close the throttle a few times to make sure that
the idle speed is within the specified range. Readjust if
necessary.

•
•

Carburetor Synchronization Inspection
Synchronization Inspection
Situate the motorcycle so that it is perpendicular to the
ground.
Remove the fuel tank and connect the auxiliary fuel tank
to supply the fuel.
Warm up the engine.
Check idle speed and adjust if necessary.

•
•
•
•
the vacuum hoses off, and attach vacuum gauge [A]
• Pull
to the vacuum hose fittings on the carburetors.
Special Tool - Vacuum Gauge: 57001-1369

Synchronization Adjustment
○The pilot screw is set at the factory and should not be
removed. But if necessary, check the pilot screw opening
as follows.
Turn in the pilot screw and count the number of turns until
it seats fully but not tightly, and then remove the screw.
This is to set the screw to its original (correct) position
when assembling.

•

Special Tool - Pilot Screw Adjuster, C [A]: 57001-1239

NOTE

○Each carburetor has different opening of the pilot screw.
When setting the pilot screw, do not refer to the specifications which show mean opening of the pilot screws.

PERIODIC MAINTENANCE 2-17
Maintenance Procedure
Coolant Filter Cleaning

○Before winter season starts, clean the coolant filter [A] in

•
•
•

the carburetor system.
Drain the coolant (see Coolant Draining).
Remove the coolant filter from the cooling hoses in the
carburetor system.
Blow dirt and sediment off the filter with compressed air.

Fuel Hoses and Connections Check

○The fuel hoses are designed to be used throughout the

•
•
•

motorcycle’s life without any maintenance, however, if the
motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose to
burst. Remove the fuel tank (see Fuel Tank Removal in
the Fuel System chapter) and check the fuel hose.
Replace the fuel hose if any fraying, cracks [B] or bulges
[C] are noticed.
Check that the hoses are securely connected and clamps
are tightened correctly.
When installing, route the hoses according to Cable,
Wire, and Hose Routing section in the General Information chapter.
When installing the fuel hoses, avoid sharp bending, kinking, flattening or twisting, and route the fuel hoses with a
minimum of bending so that the fuel flow will not be obstructed.
Replace the hose if it has been sharply bent or kinked.

Air Cleaner Element Cleaning and Inspection
NOTE

○In dusty areas, the element should be cleaned more
frequently than the recommended interval.
○After riding through rain or on muddy roads, the element
should be cleaned immediately.
WARNING
Clean the element in a well-ventilated area, and
make sure that there are no sparks or flame anywhere near the working area. Because of the
danger of highly flammable liquids, do not use
gasoline or a low-flash point solvent to clean the
element.

2-18 PERIODIC MAINTENANCE
Maintenance Procedure
the element assembly from the air cleaner hous• Remove
ing (see Air Cleaner Element Removal in the Fuel System

•
•
•

chapter).
Separate the element [A] from the element holders [B].
Clean the element in a bath of high-flash point solvent,
and then dry it with compressed air or by shaking it.
Visually check the element for tear or breaks.
If any of the parts of the element are damaged, replace
them with a new one.

cleaning of the element, saturate it with high quality
• After
form air filter oil and squeeze out excess oil.
the element [A] in a clean rag [B] and squeeze it as
• Wrap
dry as possible.
the element with the holders, and install them
• Assemble
into the air cleaner housing.

Cooling System
Coolant Level Inspection

the motorcycle so that it is perpendicular to the
• Situate
ground.
the level through the coolant level gauge on the
• Check
reservoir tank [C]. The coolant level should be between
the "H" (High) [A] and the "L" (Low) [B] level lines.

NOTE

○Check the level when the engine is cold (room or ambient temperature).
If the coolant level is lower than the "L" (Low) level line,
add coolant to the "F" (Full) level line.

CAUTION
For refilling, add the specified mixture of coolant
and soft water. Adding water alone dilutes the
coolant and degrades its anticorrosion properties.
The diluted coolant can attack the aluminum engine parts. In an emergency, soft water alone can
be added. But the diluted coolant must be returned
to the correct mixture ratio within a few days. If
coolant must be added often, or the reserve tank
has run completely dry, there is probably leakage
in the cooling system. Check the system for leaks
(see Visual Leak Inspection, and Cooling System
Pressure Testing).

PERIODIC MAINTENANCE 2-19
Maintenance Procedure
Radiator Hoses and Connections Inspection

○The high pressure inside the radiator hose can cause

•

coolant to leak [A] or the hose to burst if the line is not
properly maintained. Visually inspect the hoses for signs
of deterioration. Squeeze the hoses. A hose should not
be hard and brittle, nor should it be soft or swollen.
Replace the hose if any fraying, cracks [B] or bulges [C]
are noticed.
Check that the hoses are securely connected and clamps
are tightened correctly.
Torque - Radiator Hose Clamp Screws: 2.5 N·m (0.25 kgf·m,
22 in·lb)

Engine Top End
Air Suction Valve Inspection
The air suction valve is essentially a check valve which
allows fresh air to flow from the air cleaner into the exhaust
port. Any air that has passed the air suction valve is prevented from returning to the air cleaner.
Remove the air suction valves.
Visually inspect the reeds [A] for cracks, folds, warps,
heat damage, or other damage.
If there is any doubt as to the condition of the reed, replace
the air suction valve as an assembly.
Check the reed contact areas [B] of the valve holder for
grooves, scratches, any signs of separation from the
holder, or heat damage.
If there is any doubt as to the condition of the reed contact
areas, replace the air suction valve as an assembly.
If any carbon or other foreign particles have accumulated
between the reed and the reed contact area, wash the
valve assembly clean with a high flash-point solvent.

•
•
•
•

CAUTION
Do not scrape off the deposits with a scraper as this
could damage the rubber, requiring replacement of
the suction valve assembly.

Valve Clearance Inspection
Valve Clearance Inspection

NOTE

○Valve clearance must be checked and adjusted when
the engine is cold (room temperature).

the cylinder head cover (see Cylinder Head
• Remove
Cover Removal in the Engine Top End chapter).
the cylinder head oil pipes (see Cylinder Head
• Remove
Oil Pipe Removal in the Engine Top End chapter).

2-20 PERIODIC MAINTENANCE
Maintenance Procedure
the upper [A] and lower [B] caps on the alterna• Unscrew
tor cover.
Special Tool - Filler Cap Driver: 57001-1454

the valve clearance when the pistons are at TDC.
•○Check
The pistons are numbered beginning with the engine left

•

side.
Using a wrench on the crankshaft rotation bolt [A], turn
the crankshaft clockwise [B] until the "C" mark [C] on the
rotor is aligned with the notch [D] in the edge of the upper
hole in the alternator cover for #2 piston and "T" mark for
#1 piston.

○Measure the valve clearance of the valves for which the

•

cam lobe is pointing away from the rocker arm.
Each piston has two inlet and two exhaust valves. Measure these two inlet or exhaust valves at the same crankshaft position.
Valve Clearance Measuring Position
#2 Piston TDC at End of Compression Stroke →
Inlet valve clearances of #2 piston, and
Exhaust valve clearances of #2 piston

NOTE

○Check the valve clearance using this method only.
Checking the clearance at any other cam position may
result in improper valve clearance.
Valve Clearance Measuring Position
#1 Piston TDC at End of Compression Stroke →
Inlet valve clearances of #1 piston, and
Exhaust valve clearances of #1 piston

PERIODIC MAINTENANCE 2-21
Maintenance Procedure
the clearance of each valve by inserting a thick• Measure
ness gauge [A] between the adjusting screw [B] and the
valve stem.
Valve Clearance (when cold)
Inlet
0.13 ∼ 0.18 mm (0.0051 ∼ 0.0071 in.)
Exhaust

0.18 ∼ 0.23 mm (0.0070 ∼ 0.0090 in.)

Valve Clearance Adjustment
If the valve clearance is incorrect, loosen the locknut [A]
and turn the adjusting screw [B] until the correct clearance
is obtained.
Tighten the locknut.

•

Torque - Valve Adjuster Locknuts: 25 N·m (2.5 kgf·m, 18
ft·lb)

• Install the two caps on the alternator cover.
Clutch
WARNING

To avoid a serious burn, never touch the engine or
exhaust pipe during clutch adjustment.

Clutch Operation Inspection
Clutch Operation Inspection
With the engine idling, make sure that there is no noise
or abnormally heavy feeling when pulling [A] in the clutch
lever fully. Also, make sure that the shift lever operates
smoothly.
When moving off the motorcycle by releasing the clutch
lever gradually, make sure that the clutch does not slip
and that the clutch engages smoothly.
If the clutch operation is insufficiency, inspect the clutch
system.

•
•

WARNING
When inspecting by running the vehicle, note a
surrounding traffic situation enough in the place of
safety.
Clutch Lever Free Play Inspection
Pull the clutch lever just enough to take up the free play
[A].
Measure the gap between the lever and the lever holder.
If the gap is too wide, the clutch may not release fully. If
the gap is too narrow, the clutch may not engage fully. In
either case, adjust the clutch.

•
•

Clutch Lever Free Play
Standard:
2 ∼ 3 mm (0.08 ∼ 0.12 in.)

2-22 PERIODIC MAINTENANCE
Maintenance Procedure
Clutch Lever Free Play Adjustment
Slide back the dust cover [A].
Loosen both adjuster nuts [B] at the right hand crankcase
as far as they will go.

•
•

the knurled locknut [A] at the clutch lever.
• Loosen
Turn
the
[B] so that 5 ∼ 6 mm (0.20 ∼ 0.24 in.) [C]
• of threadsadjuster
are visible.

WARNING
Be sure that the outer cable end at the clutch lever
is fully seated in the adjuster at the clutch lever, or
it could slip into the place later, creating enough
cable play to prevent clutch disengagement.
the adjustment is made, start the engine and check
• After
that the clutch does not slip and that it releases properly.

Wheels/Tires
Air Pressure Inspection/Adjustment

the tire air pressure with an air pressure gauge
• Measure
[A] when the tires are cold (that is, when the motorcycle
has not been ridden more than a mile during the past 3
hours).
Adjust the tire air pressure according to the specifications
if necessary.
Air Pressure (when cold)
Front

150 kPa (1.5 kgf/cm², 21 psi)

Rear

225 kPa (2.25 kgf/cm², 32 psi)

Tire Tread Wear Inspection
As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is
that 90% of all tire failures occur during the last 10% of tread
life (90% worn). So it is false economy and unsafe to use
the tires until they are bald.
Measure the tread depth at the center of the tread with a
depth gauge [A]. Since the tire may wear unevenly, take
measurement at several places.

•

PERIODIC MAINTENANCE 2-23
Maintenance Procedure
Wear Indicator [A]
Wear Indicator Position Mark [B]

If any measurement is less than the service limit, replace
the tire.
Tread Depth
Front

DUNLOP

BRIDGESTONE

Standard

6.9 mm (0.27 in.)

6.0 mm (0.24 in.)

Service Limit

1 mm (0.04 in.)

Rear

DUNLOP

BRIDGESTONE

Standard

8.8 mm (0.35 in.)

8.5 mm (0.33 in.)

Service Limit

2 mm (0.08 in.)(Up to 130 km/h (80 mph))
3 mm (0.12 in.)(Over 130 km/h (80 mph))

WARNING
To ensure safe handling and stability, use only the
recommended standard tires for replacement, inflated to the standard pressure.
Use the same manufacturer’s tires on both front and
rear wheels.

NOTE

○Check and balance the wheel when a tire is replaced
with a new one.
Wheel/Tire Damage Inspection

any imbedded stones [D], nail [C] or other foreign
• Remove
particles from the tread.

•
•

Wear Indicator [E]
Visually inspect the tire for cracks [A] and cuts [B], and replace the tire if necessary. Swelling or high spots indicate
internal damage, requiring tire replacement.
Visually inspect the wheel for cracks, cuts and dents damage.
If any damage is found, replace the wheel if necessary.

2-24 PERIODIC MAINTENANCE
Maintenance Procedure
Wheel Bearing Damage Inspection

a jack and attachment, raise the front wheel off the
• Using
ground (see Wheels/Tires chapter).
the handlebar all the way to the right or left.
• Turn
Inspect
roughness of the front wheel bearing by push• ing and the
pulling [A] the wheel.
[B] the front wheel lightly, and check for smoothly
• Spin
turn, roughness, binding or noise.
If roughness, binding or noise is found, remove the front
wheel and inspect the wheel bearing (see Hub Bearing
Inspection in the Wheels/Tires chapter).

Spoke Tightness and Rim Runout Inspection
Spoke Tightness Inspection
Check whether all the spokes are uniformly tightened.
Uniformly tighten the spokes if any spoke is loose or unevenly tightened.

•

Torque - Spoke Nipple: 3.0 N·m (0.3 kgf·m, 26 in·lb)
(On and after EJ650-A3/C3): 5.1 N·m (0.52 kgf·m,
45 in·lb)

• Inspect the rims.

WARNING

If any spoke brakes, it should be replaced immediately. A missing spoke places an additional load on
the other spokes, which will eventually cause other
spokes to break.
Rim Runout Inspection
Raise the front/rear wheel of the ground.

•

Special Tool - Jack: 57001-1238

the rim for damage or warpage.
• Check
If there is any damage to the rim, replace the rim.
the radial [A] and axial [B] rim runout by placing a
• Measure
dial gauge against the sides and the outer circumference
of the rim, and slowly rotating the wheel.
Rim Runout (with tire installed)
Standard:
Axial Runout

0.5 mm (0.02 in.)

Radial Runout

0.8 mm (0.03 in.)

Service Limit:
Axial Runout

1.5 mm (0.06 in.)

Radial Runout

1.5 mm (0.06 in.)

If rim runout exceeds the service limit, inspect the hub
bearings. If the problem is not due to the bearings,
retighten the spokes.

WARNING
Never attempt to repair a damaged wheel part. If
the wheel part is damaged, it must be replaced with
a new part.

PERIODIC MAINTENANCE 2-25
Maintenance Procedure
Final Drive
Drive Chain Slack Inspection
Drive Chain Slack Inspection

NOTE

○Check the slack with the motorcycle setting on its side
stand.
○Clean the chain if it is dirty, and lubricate it if it appears
dry.

the wheel alignment (see Wheel Alignment Inspec• Check
tion/Adjustment).
the rear wheel to find the position where the chain
• Rotate
is tightest.
the vertical movement (chain slack) [A] midway
• Measure
between the sprockets.
If the chain slack exceeds the standard, adjust it.
Chain Slack
Standard:

35 ∼ 45 mm (1.4 ∼ 1.8 in.)

Drive Chain Slack Adjustment
Remove:
Cotter Pin [A]
Loosen:
Axle Nut [B]
Chain Adjuster Locknuts [F] (both sides)
Turn the chain adjusting nuts [C] forward or rearward until the drive chain has the correct amount of chain slack.
To keep the chain and wheel properly aligned, the left adjuster mark [D] position should align with the same graduation that the right adjuster mark [E] position aligns with.

•
•
•

WARNING
Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.
both chain adjuster locknuts securely.
• Tighten
the axle nut (see Front/Rear Wheel Installation in
• Tighten
the Wheels/Tires chapter).
Torque - Rear Axle Nut: 108 N·m (11 kgf·m, 80 ft·lb)

• Insert a the new cotter pin [A].

NOTE

○When inserting the cotter pin, if the slots in the nut do
not align with the cotter pin hole in the axle shaft, tighten
the nut clockwise [A] up to next alignment.
○It should be within 30 degree.
○Loosen once and tighten again when the slot goes past
the nearest hole.

2-26 PERIODIC MAINTENANCE
Maintenance Procedure

• Bend the cotter pin [A] over the nut.

the wheel, measure the chain slack again at the tight• Turn
est position, and readjust if necessary.
• Check the rear brake.
Wheel Alignment Inspection/Adjustment
Check that the left adjuster mark [A] position should align
with the same graduation [B] that the right adjuster mark
position aligns with.
If they do not, adjust the chain slack and align the wheel
alignment.

•

○Wheel

NOTE

alignment can also be checked using the
straightedge or string method.

WARNING
Misalignment of the wheel will result in abnormal
wear, and may result in an unsafe riding condition.

Drive Chain Wear Inspection

• Remove:
Chain Cover
the rear wheel to inspect the drive chain for dam• Rotate
aged rollers, loose pins and links.
•
•

If there is any irregularity, replace the drive chain.
Lubricate the drive chain if it appears dry.
Stretch the chain taut by hanging a 98 N (10 kg, 20 lb)
weight [A] on the chain.
Measure the length of 20 links [B] on the straight part [C] of
the chain from the pin center of the 1st pin to the pin center
of the 21st pin. Since the chain may wear unevenly, take
measurements at several places.
If any measurements exceed the service limit, replace the
chain. Also, replace the front and rear sprockets when the
drive chain is replaced.
Drive Chain 20-link Length
Standard:
317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)
Service Limit:

323 mm (12.7 in.)

PERIODIC MAINTENANCE 2-27
Maintenance Procedure
WARNING
If the drive chain wear exceeds the service limit, replace the chain or an unsafe riding condition may
result. A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the
rear wheel, severely damaging the motorcycle and
causing it to go out of control.
For safely, use only the standard chain. It is an endless type and should not be cut for installation.

Drive Chain Lubrication

a special lubricant is not available, a heavy oil such as
• IfSAE
90 is preferred to a lighter oil because it will stay on

•

the chain longer and provide better lubrication.
If the chain appears especially dirty, clean it before lubrication.
[A] Apply oil

CAUTION
The O-rings between the side plates seal in the lubricant between the pin and the bushing. To avoid
damaging the O-rings and resultant loss of lubricant, observe the following rules:
Use only kerosene or diesel oil for cleaning an O
-ring drive chain.
Any other cleaning solution such as gasoline
or trichloroethylene will cause deterioration and
swelling of the O-ring.
Blow the chain dry with compressed air immediately after cleaning.
Complete cleaning and drying the chain within 10
minutes.
oil to the sides of the rollers so that oil will penetrate
• Apply
to the rollers and bushings. Apply the oil to the O-rings so

•

that the O-rings will be coated with oil.
Wipe off any excess oil.

Brakes
Brake Fluid Leak (Brake Hose and Pipe) Inspection

the brake lever or pedal and inspect the brake fluid
• Apply
leak from the brake hoses [A] and fittings.
If the brake fluid leaked from any position, inspect or replace the problem part.

2-28 PERIODIC MAINTENANCE
Maintenance Procedure
Brake Hose Damage and Installation Condition
Inspection
the brake hose and
• Inspect
cracks and signs of leakage.

fittings for deterioration,

○The high pressure inside the brake line can cause fluid to

leak [A] or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while examining
it.
Replace the hose if any cracks [B] or bulges [C] are noticed.
Tighten any loose fittings and any banjo bolts.
Torque - Brake Hose Banjo Bolts: 34 N·m (3.5 kgf·m, 25
ft·lb)

the brake hose routing.
• Inspect
If any brake hose routing is incorrect, route the brake hose

according to Cable, Wire and Hose Routing Section in the
Appendix chapter.

Brake Operation Inspection

the operation of the front and rear brake by run• Inspect
ning the vehicle on the dry road.
If the brake operation is insufficiency, inspect the brake
system.

WARNING
When inspecting by running the vehicle, note a
surrounding traffic situation enough in the place of
safety.

Brake Fluid Level Inspection

that the brake fluid level in the front/rear brake
• Check
reservoirs [A] is above the lower level line [B].

NOTE

○Hold the reservoirs horizontal by raising the motorcycle

perpendicular to the ground when checking brake fluid
level.

Special Tool - Jack: 57001-1238

• Remove the right side cover.

PERIODIC MAINTENANCE 2-29
Maintenance Procedure
If the fluid level is lower than the lower level line, fill the
reservoir to the upper level line [A] in the reservoir [B].

WARNING
Change the brake fluid in the brake line completely
if the brake fluid must be refilled but the type and
brand of the brake fluid that is already in the reservoir are unidentified. After changing the fluid, use
only the same type and brand of fluid thereafter.
Recommended Disc Brake Fluid
Grade:
DOT4

If the rear brake reservoir cap is open to fill the brake fluid,
follow the procedure below to install the cap correctly.
○First, tighten the brake fluid reservoir cap [B] clockwise
[C] by hand until the resistance is felt fully; then, tighten
the cap an additional 1/6 turn [D] while holding the brake
fluid reservoir [A] body.

Brake Pad Wear Inspection
In accordance with the Periodic Maintenance Chart, inspect the brake pads for wear.
Remove the pads.
Check the lining thickness [A] of the pads in the caliper.
If the lining thickness of either pad is less than the service
limit [B], replace both pads in the caliper as a set.
Stepped Portion [C]

•
•

Pad Lining Thickness
Standard:
5.15 mm (0.203 in.)
Service Limit:

1 mm (0.04 in.)

2-30 PERIODIC MAINTENANCE
Maintenance Procedure
Brake Light Switch Operation Inspection
Front Brake Light Timing Inspection
Turn on the ignition switch.
The brake light should go on when the brake lever is applied or after the tip of brake lever moves about 10 mm
(0.39 in.) [A].

•
•

Rear Brake Light Timing Inspection
Turn on the ignition switch.
Check the operation of the rear brake light switch by depressing the brake pedal. The brake light should go on
as specified.
If it does not, adjust the brake light timing.

•
•

Brake Light Timing
Standard:
On after about 15 mm (0.59 in.) pedal
travel [A]

Rear Brake Light Timing Adjustment
Brake light timing is adjusted by changing the position of
the rear brake light switch [A].
Adjust the position of the switch so that the brake light
goes on after the specified pedal travel by turning the adjusting nut [B].
[C] Lights sooner.
[D] Lights later.

•

CAUTION
To avoid damaging the electrical connections inside the switch, be sure that the switch body does
not turn during adjustment.

Suspension
Front Forks/Rear Shock Absorber Operation
Inspection

the forks down and up [A] 4 or 5 times, and inspect
• Pump
the smooth stroke.
If the forks do not smoothly or noise is found, inspect the
fork oil level or fork clamps (see Front Fork Oil Change in
the Suspension chapter).

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