Montesa 4Ride MST260 2016 Shop Manual Download

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Contents

1. Service data

Specifications ............................................... 1-1

Service data .................................................. 1-2

Torque Values ............................................... 1-5

Tools ........................................................... 1-7

Special ......................................................... 1-7

Lubrication & Seal Points ................................ 1-8

Cable & Harness Routing ................................ 1-11

2. Service and maintenance

Maintenance schedule .................................... 2-1

Fuel Line ...................................................... 2-3

Air Cleaner ................................................... 2-3

Spark Plug .................................................... 2-4

Valve Clearance ............................................ 2-4

Engine Oil/Oil Filter ........................................ 2-6

Engine Idle Speed .......................................... 2-8

Transmission Oil ............................................ 2-8

Coolant ........................................................ 2-9

Clutch System .............................................. 2-10

Exhaust Pipe And Muffler ............................... 2-10

Drive Chain ................................................... 2-11

Drive Chain Slider .......................................... 2-11

Drive/Driven Sprockets ................................... 2-12

Brake Fluid ................................................... 2-13

Brake Pad Wear ............................................. 2-14

Brake System ................................................ 2-14

Handlebar And Steering Head Bearings ............. 2-15

Wheels And Tires .......................................... 2-15

Front Suspension ........................................... 2-16

Fork ............................................................. 2-16

Rear Suspension ............................................ 2-17

Front headlight and front position light. ............ 2-18

3. Engine servicing

Oil Pressure Relief Valve ................................. 3-1

Oil Pump ...................................................... 3-1

Disassembly / Installation of fuel feed hose ..... 3-4

Fuel Line Inspection ....................................... 3-5

Fuel Tank/Fuel Pump ...................................... 3-7

Injector ........................................................ 3-13

Throttle Body ................................................ 3-13

Water Seal And Bearing Replacement ............... 3-15

Radiator Removal/Installation .......................... 3-17

Engine Removal/Installation ............................. 3-18

Cylinder Compression .................................... 3-20

Cylinder Head Removal .................................. 3-23

Cylinder Head Disassembly ............................. 3-25

Cylinder Head Inspection ................................ 3-26

Valve Guide Replacement ............................... 3-27

Valve Seat Inspection/Refacing ....................... 3-28

Cylinder Head Assembly ................................. 3-31

Cylinder/Piston .............................................. 3-32

Cylinder Head Installation ............................... 3-37

Camshaft/Cylinder Head Cover Installation ........ 3-38

Right Crankcase Cover ................................... 3-40

Clutch Slave Cylinder ..................................... 3-41

Clutch .......................................................... 3-43

Kickstarter .................................................... 3-46

Gearshift Linkage ........................................... 3-47

Left Crankcase Cover ..................................... 3-49

Flywheel ...................................................... 3-52

Crankcase Separation/Disassembly .................. 3-54

Crankshaft/Transmission Inspection ................. 3-56

Crankcase Bearing Replacement ...................... 3-56

Transmission Assembly .................................. 3-58

Crankcase Combination .................................. 3-59

4. Frame servicing

Front Wheel .................................................. 4-1

Fork ............................................................. 4-2

Steering stem ............................................... 4-11

Rear Wheel ................................................... 4-14

Shock Absorber ............................................. 4-16

Shock Linkage ............................................... 4-19

Swingarm ..................................................... 4-20

Front Brake Pad Replacement .......................... 4-24

Rear Brake Pad Replacement ........................... 4-25

Front brake caliper ......................................... 4-27

Rear brake caliper .......................................... 4-27

Front master cylinder ..................................... 4-28

Rear master cylinder ...................................... 4-30

Brake pedal ................................................... 4-30

Clutch master cylinder ................................... 4-31

5. Electrical servicing

Charging system inspection ............................ 5-1

Ignition system inspection .............................. 5-3

PGM-FI System inspection .............................. 5-5

PGM-FI ......................................................... 5-6

PGM-FI Self-diagnosis malfunction

indicator lamp (mil) failure codes ..................... 5-7

Bank angle sensor inspection .......................... 5-8

Engine stop switch inspection ......................... 5-9

Cooling fan system inspection ......................... 5-9

Lights / instruments / switches ........................ 5-10

Indicator light/Indicator light relay. ................... 5-11

Brake light. ................................................... 5-12

Brake light switch. ......................................... 5-12

Speedometer ................................................ 5-13

Speed sensor ................................................ 5-14

Horn ............................................................ 5-15

Wiring diagram .............................................. 5-16

Summary of Contents for 4Ride MST260 2016

Page 1: ...PGM FI Racing Trial Shop Manual 2016 ...

Page 2: ......

Page 3: ... model All information in this publication is based on the latest product information available at the time of approval for printing MONTESA HONDA S A U reserves the right to make changes at any time without notice and without incurring any obligation No part of this publication may be reproduced without written permission ...

Page 4: ... The Vehicle Identification Number VIN is stamped on the right side of the steering head The serial number of the engine is stamped on the lower right side of the crankcase MODEL TYPE FRAME No ENGINE No MST260G ED VTDMT04K GE000001 NN4E6000001 1 1 ...

Page 5: ...ressure driver only Front 100kpa Rear 100kpa 2 Keep chain adjusted and lubricated 25 35 Mm 1 0 1 4 In Read owners manual 3 Caution label Read the shop manual carefully For your protection always wear a helmet and protective gear while riding Usepremium unleaded gasoline only This motorcycle is not designed to transport a passenger 4 NEVER OPEN WHEN HOT Hot coolant will scald you N OUVREZ PAS QUAND...

Page 6: ...The total weight of the accessories and luggage added to the rider s own weight must not exceed 111 kg which is the aximum weight capacity The addition of large fairings mounted on the fork or handlebars is not recommended It is totally prohibited to transport cargo on the rear fender The motorcycle has not been designed for this purpose 6 EC label 7 made in C E WARNING don t touch Gas at high pre...

Page 7: ...Labels 4 3 5 2 1 7 6 ...

Page 8: ...Replacement 3 27 Valve Seat Inspection Refacing 3 28 Cylinder Head Assembly 3 31 Cylinder Piston 3 32 Cylinder Head Installation 3 37 Camshaft Cylinder Head Cover Installation 3 38 Right Crankcase Cover 3 40 Clutch Slave Cylinder 3 41 Clutch 3 43 Kickstarter 3 46 Gearshift Linkage 3 47 Left Crankcase Cover 3 49 Flywheel 3 52 Crankcase Separation Disassembly 3 54 Crankshaft Transmission Inspection ...

Page 9: ...linder 3 5 inclined from vertical Bore and stroke 78 0 x 54 2 mm Displacement 259 cm3 Compression ratio 10 5 1 Valve timing Intake valve opens Intake valve closes Exhaust valve opens Exhaust valve closes 9 BTDC 27 ABDC 37 BBDC 5 ATDC at 1 0 mm lift Lubrication system Forced pressure and wet sump Starting system Primary kickstarter Item Specification Fuel System Type PGM FI Identification number GQ...

Page 10: ...r Radiator cap relief pressure 108 kPa 1 1 kgf cm2 Presión de alivio tapón del radiador 108 kPa 1 1 kgf cm2 Unit mm in Item Standard Service limit Cylinder Head Valves Cylinder compression 1300 kPa 13 2 kgf cm2 189 psi Cylinder head warpage 0 05 0 002 Valve stem O D IN EX 0 12 0 03 0 005 0 001 0 30 0 03 0 012 0 001 IX EX 4 475 4 490 0 1762 0 1768 4 465 4 480 0 1758 0 1764 4 470 0 1760 4 460 0 1756...

Page 11: ...4 0 6686 0 6691 16 46 0 648 16 55 0 652 17 06 0 672 16 97 0 668 Unit mm in Unit mm in Item Standard Service limit Crankshaft Transmission Crankshaft runout Right Left 0 03 0 001 0 05 0 002 Connecting rod big end Side clearance Radial clearance 0 30 0 75 0 012 0 030 0 06 0 18 0 002 0 007 0 8 0 03 0 05 0 002 Transmission gear I D M4 M5 C1 C2 C3 23 020 23 041 0 9063 0 9071 23 020 23 041 0 9063 0 9071...

Page 12: ... cm3 Unit mm in Item Standard Service Limit Rear Suspension R16V Shock absorber spring pre load 126 4 96 Spring free length 130 5 1 Tension adjuster setting 10 2 clicks from full hard Brakes Recommended brake fluid DOT 4 brake fluid Front Brake disc thickness Brake disc runout 3 5 0 14 3 0 0 12 0 15 0 006 Rear Brake disc thickness Brake disc runout 3 5 0 14 3 0 0 12 0 15 0 006 Electrical Spark plu...

Page 13: ... 7 12 1 2 9 Clutch oil bleeder screw 1 8 6 0 6 4 3 Clutch spring bolt 6 6 12 1 2 9 Clutch center lock nut 1 18 69 7 0 51 Note 1 Drive sprocket UBS bolt 1 8 31 3 2 23 Shift drum center special bolt 1 8 22 2 2 16 Note 4 Shift drum stopper arm bolt 1 6 12 1 2 9 Shift return spring pin 1 8 22 2 2 16 Ignition pulse generator bolt 2 5 5 4 0 55 4 0 Note 4 Stator mounting bolt 3 5 5 4 0 55 4 0 Note 4 Spar...

Page 14: ... Front axle 1 17 69 7 0 51 Note 1 Rear axle nut 1 17 69 7 0 51 Note 1 Final driven sprocket nut 4 8 32 5 3 3 23 9 Shock absorber Upper mounting bolt nut Lower mounting bolt nut 1 1 10 10 39 4 0 29 39 4 0 29 Fork top pinch bolt 2 8 21 2 1 15 4 Note 1 Fork bottom pinch bolt 4 8 21 2 1 15 4 Note 1 Swingarm pivot nut 1 14 69 7 0 51 Note 1 Front brake disc mounting bolt 4 6 19 1 9 14 Note 2 Rear brake ...

Page 15: ...ipple wrench 07701 0020300 Front spoke nipple Gear holder 07724 0010100 Primary drive gear bolt Bearing remover head 07746 0050600 Wheel bearing Bearing remover shaft 07746 0050100 Wheel bearing Driver 07749 0010000 Bearing removal installation Attachment 24 x 26 mm 07746 0010700 Swingarm pivot bearing Attachment 32 x 35 mm 07746 0010100 Right countershaft bearing Left mainshaft bearing Attachment...

Page 16: ... engine oil Repsol 4T stroke engine oil 10W 30 600 cm3 Item Material Remarks Connecting rod small end I D Molybdenum oil solution A 50 50 mixture of molybdenum disulfide grease and engine oil Connecting rod big end Camshaft outer surface Rocker arm I D Valve stem sliding surface Valve stem end sliding surface Clutch outer collar sliding surface Mainshaft spline and gear sliding surface Countershaf...

Page 17: ...Lithium based multipurpose grease Each oil seal lips Water seal lips Right crankcase cover water hose joint threads Sealant Cylinder head water hose joint threads Cylinder head cover mating surface Three Bond 1215B Chain tensioner bolt transmission Drain hole Application zone 6 5 1 mm Application zone 2 5 1 mm 3 4 mm 1 2 0 4 mm ...

Page 18: ...liding surface Wheel bearing spinning area Wheel axle threads Step joint pin surface Throttle pipe sliding surface and throttle wire drum 4 stroke engine oil Throttle housing screw threads Molybdenum disulfide grease Brake hydraulic system inside DOT 4 brake fluid Clutch hydraulic system inside Air cleaner element Engine oil Throttle cable sliding surface Cable lubricant Handlebar grip Honda bond ...

Page 19: ...Service data 1 11 1 11 Cable Harness Routing 1 FRONT BRAKE HOSE 2 THROTTLE CABLE 3 CLUTCH HOSE 2 1 3 FRONT FRONT ...

Page 20: ...ER RELAY 4 FAN RELAY 5 RIGHT FRONT TURN SIGNAL CONNECTORS 6 LEFT FRONT TURN SIGNAL CONNECTORS 7 9P CONNECTOR LIGHT SWITCH 8 9P CONNECTOR SUB HARNESS 9 3P CONNECTOR SPEED SENSOR 10 FRONT BRAKE SWITCH 11 2P CONNECTOR POSITION LIGHT FRONT 8 7 6 9 3 5 10 11 4 2 1 ...

Page 21: ...ta 1 13 1 13 1 INDICATOR LIGHT INSTALLATION 2 INDICATOR LIGHT INSTALLATION CONNECTOR 3 RIGHT REAR TURN SIGNAL CONNECTORS 4 LEFT REAR TURN SIGNAL CONNECTORS 5 REGISTRATION PLATE LIGHT CONNECTOR 5 4 3 2 1 5 4 3 2 1 ...

Page 22: ...P WIRE 3 CYLINDER HEAD BREATHER HOSE 4 AIR FILTER BOX BREATHER HOSE 5 STORAGE TANK 6 ENGINE STOP SWITCH WIRE 7 FAN MOTOR WIRE 8 FUEL CAP BREATHER HOSE 9 SPARK PLUG WIRE 10 WIRE HARNESS TO IGNITION COIL 11 ECT SENSOR UPPER RH 20 30º 1 2 3 4 5 6 7 8 9 10 11 ...

Page 23: ...HOSE 4 CONNECTOR BOOT FAN MOTOR 2P BLACK CONNECTOR POWER CONNECTOR LIGHT RELAY CONNECTOR 5 UPPER RADIATOR HOSE 6 SPARK PLUG WIRE 7 FAN MOTOR WIRE 8 FILTER BOX BREATHER HOSE 9 CYLINDER HEAD BREATHER HOSE 10 SPEED SENSOR CABLE Clamp at white tape 1 2 3 4 5 6 7 8 9 10 ...

Page 24: ...Service data 1 16 1 16 1 THROTTLE CABLE 2 CLUTCH HOSE 3 FUEL TANK BREATHER HOSE UPPER UPPER FR RH RH FR 45º RH RH RH FR 1 2 3 2 3 1 ...

Page 25: ...2 TRANSMISSION BREATHER HOSE 3 FILTER BOX BREATHER HOSE 4 ALTERNATOR WIRE 5 CONDENSER 2P BLACK CONNECTOR 6 REGULATOR RECTIFIER 5P BLACK CONNECTOR 7 BANK ANGLE SENSOR 8 REAR BRAKE RESERVOIR TANK 9 SPEED SENSOR CABLE FR FR FR FR 1 2 3 4 5 6 7 8 9 ...

Page 26: ... 3 AIR FILTER BOX BREATHER HOSE 4 TRANSMISSION BREAHTER HOSE 5 WIRE HARNESS 6 FUEL FEED HOSE 7 REGULATOR RECTIFIER 5P BLACK CONNECTOR 8 CONDENSOR 9 CONDENSOR 2P BLACK CONNECTOR 10 BANK ANGLE SENSOR 11 CONNECTOR COVER 12 SPEED SENSOR CABLE Clamp at white tape 1 2 3 4 4 5 6 7 8 9 10 11 5 12 ...

Page 27: ...Service data 1 19 1 19 1 REAR BRAKE HOSE 2 REAR BRAKE RESERVOIR HOSE 3 SPEED SENSOR 4 REAR BRAKE LIGHT SWITCH 90º UPPER UPPER RH FR FR RH 1 2 3 4 ...

Page 28: ...Service data 1 20 1 20 1 FUEL FEED HOSE 2 TRANSMISSION BREATHER HOSE 1 2 ...

Page 29: ...iced by your dealer Maintenance legend Inspect clean adjust lubricate or replace if necessary Replace Clean FREQUENCY ITEM Pre ride check 500 Km 1 500 Km 3 000 Km 4 500 Km 6 000 Km Every 6 months Yearly check Every 2 years Remarks Fuel level Make sure that you have enough fuel for the trip planned Throttle operation Engine oil Transmission Oil Drive Chain Check the item after riding in adverse con...

Page 30: ...lug Valve clearance Crankcase breather Engine oil filter Engine oil filter screen Engine idle speed Radiator coolant Cooling system Drive chain slider tensioner Check the item after riding in adverse conditions and dusty areas Drive driven sprocket Drive chain slider Brake system Clutch fluid Rear suspension Check the items more often when riding in adverse conditions and dusty areas Damper linkag...

Page 31: ...ent A fire or explosion could result Soak the element in engine oil and squeeze out the excess NOTICE Do not twist the element to squeeze out the excess Failure to follow this precaution can result in a damaged element Installation is in the reverse order of removal 1 FLAME TRAP 2 AIR CLEANER ELEMENT 1 AIR CLEANER ELEMENT Air Cleaner Remove the four bolts and air cleaner housing cover Remove the a...

Page 32: ... plug and the cap Spark Plug Cap Remove the spark plug cap from the spark plug Clean the inside of the plug cap with electrical contact cleaner to prevent misfire 1 INSULATOR 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 Standard plug NGK CR6EH 9 Plug Gap Remove the spark plug ...

Page 33: ...he rocker arm and valve stem and measure the intake and exhaust valve clearances Valve clearance Intake 0 12 0 03 mm 0 005 0 001 in Exhaust 0 30 0 03 mm 0 012 0 001 in Adjust by loosening the lock nut and turning the adjusting screw until there is a slight drag on a feeler gauge Tools Valve adjusting wrench 8 x 9 mm 07708 0030100 equivalent commercially available Valve adjuster B 07708 0030100 Aft...

Page 34: ...lowly through the oil filler hole Specified engine oil Repsol 4 stroke motorcycle oil SAE 10W 30 Capacity 0 41 liter 0 43 US qt 0 36 Imp qt after draining 0 44 liter 0 46 US qt 0 39 Imp qt after oil filter change 0 60 liter 0 63 US qt 0 53 Imp qt after disassembly Install the oil filler cap dipstick 1 OIL FILLER CAP DIPSTICK 2 DRAIN BOLT SEALING WASHER 1 OIL FILLER CAP DIPSTICK 2 UPPER LEVEL LINE ...

Page 35: ...the oil filter cover into the left crankcase while aligning the cover flange with the oil filter groove Make sure that the oil filter cover seats properly in the crankcase Install the retaining plate and tighten the bolt securely 1 NEW O RINGS 2 OIL FILTER COVER 1 OIL FILTER 2 OUT SIDE MARK Apply grease to the oil filter spring end filter side Install the spring into the new oil filter Install the...

Page 36: ...level surface 2 Remove the oil filler cap from the clutch cover 3 Place an oil drain pan under the engine to catch the oil then remove the drain bolt and sealing washer from the left crankcase 4 After the oil has drained completely install the drain bolt with a new sealing washer Tighten the drain bolt to the specified torque Torque 22 N m 2 2 kgf m 16 lbf ft 1 DRAIN BOLT Engine Idle Speed Inspect...

Page 37: ...l is damaged Replace the water seal or the oil seal page 3 15 Coolant Replacement WARNING Removing the radiator cap while the engine is hot will allow the coolant to spray out seriously scalding you Always let the engine and radiator cool down before removing the radiator cap 1 Remove the coolant drain bolt and sealing washer 1 INSPECTION HOLE 2 COOLANT DRAIN BOLT SEALING WASHER Coolant Cooling Sy...

Page 38: ...ch is not disengaged properly or the lever feels soft or spongy bleed the air from the system 2 Remove the reservoir cover and diaphragm check the clutch fluid level If the level is low inspect the clutch hose and fittings for damage deterioration cracks or sign of leakage Tighten any loose fittings Replace hose and fittings as require 1 CLUTCH FLUID RESERVOIR 2 LOWER LEVEL LINE 4 Fill the radiato...

Page 39: ...k the drive chain slack and free wheel rotation After adjustment tighten the axle nut to the specified torque Torque 69 N m 7 0 kgf m 51 lbf ft Lubricate the drive chain Hook the drive chain tensioner spring 1 AXLE NUT 2 ADJUSTER Drive Chain Drive Chain Slack Inspection During the break in period drive chain slack should be checked and adjusted often Also check the drive chain slack after the driv...

Page 40: ...ack page 2 11 1 BOLTS NUT 2 DRIVEN SPROCKET Install the drive sprocket onto the countershaft as shown Install the spring washer and bolt then tighten the bolt to the specified torque Torque 31 N m 3 2 kgf m 23 lbf ft Put the transmission in neutral 1 DRIVE SPROCKET 2 SPRING WASHER 3 BOLT Drive Driven Sprockets Drive Sprocket Replacement Remove the drive sprocket cover Loosen the drive chain fully ...

Page 41: ...ity Brake fluid DOT 4 only 1 COVER 2 MIN LEVEL Check that the brake hose do not bind or kink in all steering position and is not pulled when the suspension is extended Replace the brake fluid every 2 months Do not service the brake system in high humidity Brake fluid DOT 4 only 1 BRAKE HOSE Brake Fluid Front Brake Master Cylinder Always inspect the brake fluid level Remove the screws master cylind...

Page 42: ...ts to wobble right and left 1 BRAKE DISC 2 DISC BOLT 3 COLLAR Brake System Brake Discs Measure the rear brake disc runout with a dial gauge Service limit 0 15 mm 0 006 in Replace the brake disc if the runout exceeds the service limit Measure the brake disc thickness Service limit Front 2 9 mm 0 11 in Rear 3 0 mm 0 12 in Replace the brake disc if necessary Refer to pages 4 1 and 4 14 for removal 1 ...

Page 43: ...PLE 2 RIM LOCK Steering Head Bearings Support the motorcycle using the maintenance stand with its front wheel off the ground Turn the handlebar to the right and left to check for roughness in the steering head bearings Stand in front of the motorcycle and grab the fork at the axle then push the fork in and out toward the engine to check for play in the steering head bearings If any roughness or pl...

Page 44: ...tions by using one or more of the following methods Basically there are two adjustments you can make to the front suspension Rebound damping right fork Turning the rebound damping adjuster adjusts how quickly the fork extends Spring pre load left fork Turning the spring pre load adjuster adjusts the spring initial pre load length Replace the fork fluid every 2 months See page 4 8 4 10 for oil leve...

Page 45: ...ing before attempting any adjustments Make all rebound damping adjustment in one click increments Adjusting two or more clicks at a time may cause you to pass over the best adjustment Test ride after each adjustment If you become confused about adjustment settings return to the standard position and start over 1 REBOUND ADJUSTER Rear Suspension The swingarm is controlled by a shock absorber The Th...

Page 46: ...a while after the front headlight has been turned off Ensure that you leave it to cool before carrying out any maintenance work 1 DUST COVER 2 BULB PAWL 3 BULB 4 CONNECTORS Remove the housing for the headlight Disconnect the connector Remove the dust cover Press down on the pin Pull out the bulb without turning it AVISO Do not touch the bulb Fingerprints may create hot spots that cause the bulb to...

Page 47: ... VALVE 2 SNAP RING Check the relief valve operation by pushing the relief valve piston Installation Apply oil to a new O ring and install it onto the relief valve groove Install the relief valve into the left crankcase cover Install the snap ring into the crankcase cover groove securely Install the left crankcase cover page 3 51 Oil Pump Disassembly Remove the engine from the frame Separate the cr...

Page 48: ...E WAY REED VALVE Inspection Check the oil pump driven gear for wear or damage Check the oil pump shaft for wear or damage Check the one way reed valve for damage replace if necessary Check the oil pump shaft oil seal in the left crankcase for damage or deterioration replace if necessary Temporarily install the oil pump shaft inner and outer oil pump rotors into the right crankcase Measure the oil ...

Page 49: ...reverse order of removal 1 OIL PUMP SHAFT 2 INNER ROTOR 3 FLAT SURFACES 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 Install the outer rotor 1 DRIVE PIN 2 DRIVEN SPROCKET 1 GASKET Measure the oil pump body clearance Standard 0 15 0...

Page 50: ... 2 Check whether the connector is dirty and clean if ne cessary Cover the fast connector with a cloth 3 Hold fast connector with one hand and tighten the two pins of the pawl with the other hand while pulling the connector backwards Disconnect the fast connector and remove the pawl 1 PAWL 2 FAST CONNECTOR 1 PAWL 2 FAST CONNECTOR Installation of fuel pump side 1 Insert a new pawl in the fast connec...

Page 51: ...ly outdoors Wipe up spills immediately NOTICE Before disconnecting the fuel hoses release the fuel pressure by loosening the fuel feed hose banjo bolt at the injector holder Always replace the sealing washers when the fuel hose banjo bolt is removed or loosened Remove the seat front covers side covers and the seat rear fender assy Cover the fuel feed hose banjo bolt with a rag or shop towel Slowly...

Page 52: ...Connect the 12 V battery to the fuel pump 2P connector terminals check amount of fuel flow for 10 seconds Amount of flow 0 749 l min 125 cm3 minumun 10 seg If the fuel flow is less than specified inspect the following Pinched or clogged fuel hose Clogged fuel filter Fuel pump page 3 7 After inspection re insert the banjo bolt in the fuel feed hose using a new sealing washer Torque 22 N m 2 2 kgf m...

Page 53: ...der socket bolts Disconnect the fuel tank breather hose Remove the fuel tank mounting bolts Pull up the fuel tank and disconnect the fuel pump 2P connector Remove the fuel tank and injector as an assembly being careful not to damage the injector especially tip of the injector After removing the fuel tank injector assembly protect tip of the injector Also cover the cylinder head injector hole to pr...

Page 54: ... removed Clean any oil off from the mating surface of the fuel pump base and fuel tank Install a new packing onto the fuel pump base Install the fuel pump assembly into the fuel tank as pictures shows Be careful not to damage the fuel pump wire Make sure the packing is seated against the fuel tank Also check that the packing is not placed on the fuel tank boss Install the fuel pump mounting bolts ...

Page 55: ...he frame being careful not to pinch the throttle cable Install and tighten the fuel tank mounting bolts Connect the fuel tank breather hose to the hose clip 1 FUEL TANK 2 BOLT 3 BREATHER HOSE 1 2P CONNECTOR Always replace the injector O ring with a new one whenever the injector is removed from the cylinder head Install a new O ring into the injector groove Install the fuel feed hose Install the fu...

Page 56: ...e engine filter system from the pump body 1 PAWL 2 PUMP BODY 3 PUMP 1 FUEL PUMP Remove the fuel tank Remove the bolts from the fuel pump base and remove the base Take the fuel pump out of the fuel tank taking care not to damage the pump or electric cables 1 BOLTS 2 FUEL PUMP BASE 1 FAST CONNECTOR Disassembly of the fuel filter Disconnect the 5P connector from the fuel pump Disconnect the fuel feed...

Page 57: ...earing is properly positioned and sup ported in the fuel tank 1 PUMP 3 PAWLS 2 BODY 4 CONNECTING PIPE 1 BEARINGS 2 PUMP 3 ENGINE CABLES 4 MOTOR 5 BODY Replace the bearings with new ones every time the fuel pump is disassembled Clean the contact surface between the pump and the fuel tank Install new bearings Apply a small amount of engi ne oil for installation Thread the engine cables through the h...

Page 58: ...ts position as shown Tighten the pump mounting bolts in alphabetical order as shown in the image Torque 7 9 N m 0 7 0 9 kgf m 5 1 6 6 lbf ft Mount the tank on the chassis Connect the breather hose to the tank and secure it with the clip 1 5P CONNECTOR Insert the fast connector in the pump page 3 4 Connect the fuel pump s 5P connector 1 1 2 1 2 3 A C E B G D F 1 ...

Page 59: ...e from the housing joint 1 BOLTS NUTS 2 AIR CLEANER HOUSING Removal Installation Do not remove the injector from the injector holder Replace the injector and holder as an assembly Always replace the O ring when the fuel injector assembly is removed from the cylinder head 1 INJECTOR 2 NEW O RING Injector Inspection Remove the seat front covers side covers and the seat rear fender assy Start the eng...

Page 60: ...ble end from the throttle drum Loosen the insulator clamp screw then remove the insulator from the throttle body Installation Install the insulator onto the throttle body while aligning its slit with the lug on the throttle body as shown 1 LOCK NUT 2 THROTTLE CABLE 3 THROTTLE CABLE END 4 THROTTLE DRUM 1 SCREWS 2 THROTTLE DRUM COVER Disconnect the ECM 32P Black connector Loosen the insulator band s...

Page 61: ...ansmission oil page 2 8 Remove the following Water pump cover bolt cover dowel pins O ring Right crankcase cover and washer page 3 40 Hold the water pump gear teeth using a suitable tool then remove the impeller copper washer and water pump shaft 1 BOLTS 2 WATER PUMP COVER Install the air cleaner housing onto the frame and connect the crankcase breather hose Install and tighten the air cleaner hou...

Page 62: ... into the right crankcase cover Hold the water pump gear using a suitable tool and tighten the impeller to the specified torque Torque 12 N m 1 2 kgf m 9 lbf ft Install the washer and right crankcase cover page 3 41 1 WATER SEAL 2 OIL SEAL 3 BEARING Install the water seal into the right crankcase cover in the direction shown in the illustration above Tool Water seal driver 07945 KA30000 Install a ...

Page 63: ... the ground eyelet bolt Remove the ignition coil mounting bolt Remove the spark plug wire wire harness breather hose clamp Disconnect the ECT sensor 3P Gray connector 1 GROUND EYELET 2 BOLTS 3 IGNITION COIL 4 WIRE CLAMP 1 2P NATURAL CONNECTOR 1 TIE WRAP Radiator Removal Installation Remove the following Exhaust pipe Skid plate Fuel tank injector assembly page 3 7 Disconnect the radiator 2P Natural...

Page 64: ...onents require engine removal for servicing Crankshaft Oil pump Shift forks and shift drum Transmission 1 IGNITION COIL 2 BOLTS 3 GROUND EYELET 4 WIRE CLAMP Installation is in the reverse order of removal NOTICE At ignition coil installation install the ground eyelet with the ignition coil lower mounting bracket bolt as shown in the illustration 1 RADIATOR HOSES 2 HANGER BOLT 3 DOWN TUBE BOLTS 4 D...

Page 65: ... Engine servicing Engine Removal Installation Illustration 24 N m 2 4 kgf m 24 N m 2 4 kgf m 69 N m 6 9 kgf m 39 N m 4 0 kgf m 26 N m 2 6 kgf m 26 N m 2 6 kgf m 26 N m 2 7 kgf m 26 N m 2 7 kgf m 50 N m 5 1 kgf m ...

Page 66: ...e stopper tool This tool can be easily be made from a thin 1 mm thick piece of steel as shown 1 SEALING BOLT WASHER 2 STOPPER TOOL 1 CYLINDER COMPRESSION GAUGE 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 ki...

Page 67: ... cylinder head side cap Remove the camshaft bearing retainer from the cylinder head cover 1 BOLTS SEALING WASHERS 2 SH BOLTS 3 SEALING WASHERS 4 CYLINDER HEAD COVER 1 BOLTS 2 TAPPET ADJUSTING HOLE COVER Remove the bolts and tappet adjusting hole covers Make sure the piston at TDC Top Dead Center on the compression stroke by moving the rocker arms Remove the cam chain from the cam sprocket and susp...

Page 68: ... wear or damage If any components are faulty replace the camshaft assembly 1 BEARINGS 2 CAMSHAFT 1 INTAKE ROCKER ARM SHAFT 2 EXHAUST ROCKER ARM SHAFT 3 INTAKE ROCKER ARM 4 EXHAUST ROCKER ARM Disassembly Pull out the rocker arm shafts using a suitable 6 mm bolt and remove the intake and exhaust rocker arms Check the rocker arms and shafts for wear or damage Measure the rocker arm I D Service limit ...

Page 69: ...attern in two or three steps Remove the nuts washers and cylinder head 1 BOLTS 2 NUTS WASHERS 3 CYLINDER HEAD Cylinder Head Removal Remove the following Exhaust pipe Throttle body insulator Cylinder head cover camshaft Spark plug Drain the coolant Loosen the hose band screw and disconnect the upper radiator hose from the cylinder head Remove the upper engine hanger bolts 1 RADIATOR HOSE 2 HANGER B...

Page 70: ...VOT COLLAR 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 1 CAM CHAIN TENSIONER 2 CAM CHAIN GUIDE 1 BOLT 2 CAM CHAIN TENSIONER Remove the following Cylinder head page 3 23 Left crankcase cover page 3 49 Flywheel page 3 52 Remove the bolts and cam chain guide plate Remove the b...

Page 71: ... do not compress the valve springs more than necessary to remove the cotters Tools Valve spring compressor 07757 0010000 Compressor attachment 07959 KM30101 1 VALVE SPRING COMPRESSOR 2 ATTACHMENT 1 CAM CHAIN GUIDE PLATE 2 BOLTS Install the cam chain guide by aligning the guide end with the groove in the crankcase and the tab with the groove in the cylinder Install the cam chain guide plate and tig...

Page 72: ...e the free length of the intake and exhaust valve springs Service limits Inner 24 9 mm 0 98 in Outer 27 6 mm 1 09 in 1 OUTER VALVE SPRING 2 INNER VALVE SPRING Cylinder Head Inspection Cylinder Head Remove the carbon deposits from the combustion chamber or exhaust port Use care not to scratch the combustion chamber or the head gasket surface Check the spark plug hole and valve area for cranks Check...

Page 73: ...uide I D using a ball gauge or inside micrometer Service limit IN EX 4 552 mm 0 1792 in Subtract each valve stem O D from the corresponding guide I D to obtain the stem to guide clearance Standard IN 0 010 0 037 mm 0 0004 0 0015 in EX 0 020 0 047 mm 0 0008 0 0019 in If the stem to guide clearance exceeds the service limits determine if a new guide with standard dimensions would bring the clearance...

Page 74: ...TH Check that the valve guides are at the proper depth using a slide caliper adjust the height if necessary Specified depth IN 8 0 8 3 mm 0 31 0 33 in EX 8 2 8 5 mm 0 32 0 33 in Let the cylinder head cool to room temperature Ream the new valve guides Insert the reamer from the combustion chamber side of the cylinder head and always rotate the reamer clockwise Use cutting oil on the reamer during t...

Page 75: ...erior cutter Valve Seat Refacing Valve seat cutters grinders or equivalent valve seat refacing equipment are recommended to correct worn valve seat Follow the refacing manufacturer s instructions Contact area too high or too low Reface the valve seat The valves cannot be ground If a valve face is burned or badly worn or if it contacts the seat unevenly replace the valve 1 ROUGHNESS 45º 32º 32º 60º...

Page 76: ...he existing valve seat material Tools Flat cutter 25 mm 07780 0012000 Flat cutter 21 5 mm 07780 0012800 Cutter holder 4 5 mm 07781 0010600 or equivalent commercially available Use a 45 cutter remove any roughness or irregularities from the seat Reface the seat with a 45 cutter whenever a valve guide is replaced Tools Seat cutter 24 5 mm 07780 0010100 Seat cutter 22 mm 07780 0010701 Cutter holder 4...

Page 77: ...ile turning it slowly to avoid damage to the stem seal Using a 45 seat cutter cut the seat to proper width Make sure all pitting and irregularities are removed Refinish if necessary After refacing wash the cylinder head and valves After cutting the seats apply lapping compound to the valve face and lap the valve using light pressure After lapping wash any residual compound off the cylinder head an...

Page 78: ...ng compressor 07757 0010000 Compressor attachment 07959 KM30101 To prevent loss of tension do not compress the valve springs more than necessary Tap the valve stems gently with two plastic hammers as shown to seat the cotters firmly Support the cylinder head so the valve heads do not contact anything that may damage them Cylinder Piston Cylinder Removal Remove the cylinder head page 3 23 Remove th...

Page 79: ...nkcase Remove the piston pin clips with pliers Press the piston pin out of the piston and remove the piston Spread the piston rings and remove them by lifting up at a point just opposite the gap Piston rings are easily broken take care not to damage them during removal 1 GASKET 2 DOWEL PINS Remove the mounting sealing bolt sealing washer and cylinder Remove the gasket and dowel pins 2 1 2 2 1 2 1 ...

Page 80: ...on Service limit Taper 0 05 mm 0 002 in Out of round 0 05 mm 0 002 in Inspect the top of the cylinder for warpage Service limit 0 05 mm 0 002 in Piston Piston Ring Remove the carbon deposits from the piston head or piston ring grooves using old piston rings Inspect the piston for damage and the ring grooves for wear Temporarily install the piston rings to their proper position with the mark facing...

Page 81: ...Measure the piston pin O D Service limit 15 98 mm 0 629 in Replace the piston pin if necessary Calculate the piston pin to piston clearance Service limit 0 04 mm 0 002 in Insert each piston ring into the cylinder and measure the ring end gap Push the ring into the cylinder with the top of the piston to be sure the ring is squarely in the cylinder Service limit Top 0 390 mm 0 015 in Oil side rail 0...

Page 82: ...lockwise with a screwdriver the tensioner shaft should be pulled into the body The shaft should spring out of the body as soon as the screwdriver is released Piston Installation Place a shop towel over the cylinder opening to prevent dust or dirt from entering the engine Clean any gasket material from the cylinder mating surfaces of the crankcase Apply molybdenum oil solution to the connecting rod...

Page 83: ... in 2 3 steps to the specified torque Torque 39 N m 4 0 kgf m 29 lbf ft 1 DOWEL PINS 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 1 CYLINDER 2 NEW SEALING BOLT SEALING WASHER 1 CYLINDER Cylinder Installation Install the dowel pins and new gasket Coat the cylinder bore pi...

Page 84: ...e hanger bolt tighten the bolt to the specified torque Torque 24 N m 2 4 kgf m 17 lbf ft Connect the radiator hose to the water joint tighten the clamp screw securely Install the following Camshaft Cylinder head cover Throttle body insulator Exhaust pipe Pour recommended coolant mixture and bleed air 1 HANGER BOLT 2 RADIATOR HOSE Tighten the cylinder sealing bolt and cylinder head mounting bolts s...

Page 85: ... rocker arm shaft groove Place the intake rocker and exhaust rocker arm into the cylinder head cover The intake rocker arm is identified with groove on the end of the shaft Install the intake and exhaust rocker arm shafts with their cut out facing in and the shaft end oil hole facing up as shown 1 CAM SPROCKET 2 CAM CHAIN 3 INDEX MARKS Apply molybdenum oil solution to the camshaft cam surface Inst...

Page 86: ...ET ADJUSTING HOLE CAP 3 BOLTS Check the valve clearance page 2 4 Install new O rings into the tappet adjusting hole cover grooves Install the tappet adjusting hole cap with their UP marks facing up Install and tighten the cover bolts securely Connect the crankcase breather hose to the cylinder head cover 1 TAPPET ADJUSTING HOLE CAP 2 O RING 1 CYLINDER HEAD COVER 2 NEW SEALING WASHERS 6 MM BOLTS 3 ...

Page 87: ...cross pattern in 2 3 steps Install the kickstarter pedal and tighten the bolt to the specified torque Torque 37 N m 3 8 kgf m 27 4 lbf ft Connect the lower radiator hose Fill the crankcase with recommended transmission oil page 2 8 Fill the coolant and bleed air 1 OIL BOLT 2 SEALING WASHERS Installation Install two dowel pins and new gasket onto the crankcase 1 BOLTS 2 CLUTCH COVER Clutch Slave Cy...

Page 88: ...n brake fluid Apply silicone grease to the O rings Install 23 x 2 1 mm O ring Black into the spring side groove Install 21 8 x 2 4 mm O ring Green into the lifter plate side groove Do not interchange the O rings Install the return spring and piston into the slave cylinder in the clutch cover 1 O RING 2 DOWEL PINS 3 CLUTCH COVER 1 SEALING WASHERS 2 OIL BOLT 1 CLUTCH COVER 2 BOLTS Install new O ring...

Page 89: ...ER HOLDER 1 CLUTCH CENTER 2 CLUTCH DISCS 3 CLUTCH PLATE 4 PRESSURE PLATE 5 PAPER DISCS 1 LOCK WASHER 2 PLAIN WASHER 3 SPRING BASE WASHER Hold the clutch assembly with the clutch center holder and remove the clutch center nut Tool Clutch center holder 07JMB MN50301 Remove the lock washer flat washer springs and six spring base washers 1 THRUST WASHER 2 CLUTCH OUTER 3 NEEDLE BEARING 4 CLUTCH OUTER G...

Page 90: ...ssure plate for wear or damage Mainshaft O D at clutch outer guide 1 LIFTER PIECE ASSEMBLY 1 OUTER GUIDE 2 NEEDLE BEARING 1 CIRCLIP 2 THRUST WASHER 3 THRUST NEEDLE BEARING 4 LIFTER PIECE Check the lifter piece needle bearing by turning the thrust washer with your finger If the bearing movement is not smooth disassemble and replace the bearing Remove the circlip thrust washer and thrust needle bear...

Page 91: ...e clutch plates with clean transmission oil Install the clutch discs and plates alternately onto the clutch center starting with the clutch disc Install the clutch pressure plate onto the clutch center aligning the dot mark on the pressure plate with the dot marks on the clutch center as shown Install the clutch center assembly into the clutch outer 1 CLUTCH CENTER HOLDER Install the thrust washer...

Page 92: ...pindle O D Idle gear I D and bushing O D and I D Countershaft O D at the idle gear bushing 1 RATCHET SPRING 2 STARTER RATCHET 3 PINION GEAR 4 SPINDLE 5 RETURN SPRING 6 COLLAR 1 RETURN SPRING 2 COLLAR 3 WASHER Install the return spring with its end into the spindle hole Install the collar aligning its groove with the return spring end then install the washer 1 PINION GEAR 2 THRUST WASHER 3 SNAP RIN...

Page 93: ...ershaft Note the direction of the idle gear as shown in the illustration Gearshift Linkage Removal Remove the gearshift pedal Pull out the gearshift spindle from the crankcase Remove the guide plate bolts and guide plate as an assembly Remove the center bolt and drum center Remove the bolts and stopper arm return spring and washer Install the kickstarter assembly and hook the starter ratchet with ...

Page 94: ...WEL PIN 6 CUT OUT Install the return spring plain washer and stopper arm and tighten the stopper arm bolt to the specified torque Torque 12 N m 1 2 kgf m 9 lbf ft Install the dowel pin into the shift drum Install the drum center by aligning the cut out with the dowel pin on the shift drum while holding the stopper arm with the screwdriver as shown 1 DRUM SHIFTER 2 SPRING 3 PLUNGER 4 RATCHET PAWL A...

Page 95: ...ER Left Crankcase Cover Removal Remove the skid plate and drain engine oil Disconnect the alternator 3P White connector and ignition pulse generator 2P Natural connectors Remove the gearshift pedal 1 3P NATURAL CONNECTOR 2 2P NATURAL CONNECTOR 1 GEARSHIFT PEDAL Install the washer and gearshift spindle aligning the return spring ends with the shift fork shaft on the crankcase and guide plate hole w...

Page 96: ...eedle bearing using the special tools Tools Bearing remover shaft 15 mm 07936 KC10100 Bearing remover head 15 mm 07936 KC10200 Remover weight 07741 0010201 1 SNAP RING 2 WASHER 3 OIL SEAL 4 NEEDLE BEARING 1 OIL PRESSURE RELIEF VALVE Disassembly Assembly Remove the ignition pulse generator mounting flange bolts and alternator wire clamp Remove the stator mounting socket bolts Remove the stator igni...

Page 97: ...threads Install the alternator wire clamp Install the stator and ignition pulse generator mounting bolts Tighten the stator mounting bolts to the specified torque Torque 5 4 N m 0 55 kgf m 4 0 lbf ft Tighten the ignition pulse generator mounting bolts to the specified torque Torque 5 4 N m 0 55 kgf m 4 0 lbf ft Apply sealant to the stator ignition pulse generator wire grommet and install it into t...

Page 98: ...evel Install the slid plate 1 3P NATURAL CONNECTOR 2 2P NATURAL CONNECTOR Install the left crankcase cover being careful not to damage the oil filter cover O ring NOTICE The left crankcase cover stator is magnetically attached to the flywheel be careful during installation Install and tighten the bolts in a crisscross pattern in 2 or 3 steps Install the new sealing washer and engine oil drain bolt...

Page 99: ...se cover page 3 50 Install the flywheel onto the crankshaft Apply oil to the flywheel nut threads and seating surface Install the washer and flywheel nut 1 WASHER 2 FLYWHEEL NUT 3 APPLY OIL 1 WOODRUFF KEY Remove the flywheel using the special tool Tool Flywheel puller 89010 NN4 003 Remove the woodruff key Installation Install the woodruff key onto the crankshaft groove 1 FLYWHEEL PULLER 2 FLYWHEEL...

Page 100: ...ar 1 OIL PUMP DRIVEN GEAR 2 DRIVE PIN Remove the countershaft collar and O ring Remove the oil pump driven gear and drive pin 1 COUNTERSHAFT COLLAR 2 O RING 1 DRIVE SPROCKET 2 UNIVERSAL HOLDER 3 BOLT 4 SPRING WASHER Crankcase Separation Disassembly Remove the engine from the frame Remove the following Cylinder head cylinder piston Clutch Kickstarter Gearshift linkage Flywheel and stator Oil filter...

Page 101: ... Place the right crankcase facing down and remove the left crankcase from the right crankcase Remove the gasket and dowel pins Remove the one way reed valve Remove the oil pump shaft oil pump inner and outer rotors 1 GASKET 2 DOWEL PINS 3 ONE WAY REED VALVE Remove the transmission oil drain bolt and sealing washer Loosen the crankcase bolts in a crisscross pattern in 2 or 3 steps Remove the crankc...

Page 102: ...T DRUM Inspect each part for wear or damage Check the following items specifications page 1 1 Spinning gear I D Bushing I D and O D Mainshaft and countershaft O D Shift fork I D and claw thickness Shift fork shaft O D Shift drum O D 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 limi...

Page 103: ... LEFT CRANKSHAFT OIL SEAL 6 LEFT CRANKSHAFT BEARING 7 RIGHT CRANKSHAFT BEARING 8 RIGHT CRANKSHAFT OIL SEAL 9 RIGHT MAINSHAFT BEARING 10 RIGHT COUNTERSHAFT BEARING 11 RIGHT SHIFT DRUM BEARING A 1 mm B 0 0 5 mm C 58 60 58 88 mm D 58 30 58 52 mm E 1 0 5 mm F 27 60 27 82 mm G 28 50 28 72 mm H 27 00 27 22 mm I 27 00 27 22 mm J 0 0 5 mm E A 11 10 9 8 7 6 5 4 3 2 1 B C D F G H I J ...

Page 104: ...3 58 3 58 Engine servicing Transmission Assembly 1 M2 17T 2 M4 23T 3 M3 18T 4 M5 27T 5 MAINSHAFT M1 15T 6 C2 33T 7 C4 26T 8 C3 27T 9 C5 22T 10 C1 31T 11 COUNTERSHAFT 11 10 9 8 7 6 4 3 2 1 5 ...

Page 105: ... into the right crankcase Install the mainshaft and countershaft as an assembly into the right crankcase Install the center shift fork with its identification mark facing in Install the right and left shift forks with their identification marks facing out Install the shift drum Install the shift forks 1 OIL PUMP SHAFT 2 INNER ROTOR 3 OUTER ROTOR 1 ONE WAY REED VALVE 1 DOWEL PINS 2 NEW GASKET Insta...

Page 106: ...RIVE GEAR 2 WASHER 3 SPECIAL BOLT Install the primary drive gear collar onto the crankshaft Install the primary drive gear with its groove side facing out Apply oil to the primary drive gear special bolt threads and seating surface Install the washer and special bolt Temporarily install the clutch outer guide needle bearing and clutch outer onto the mainshaft and attach the gear holder between the...

Page 107: ...er tighten the special bolt to the specified torque Torque 31 N m 3 2 kgf m 23 lbf ft Install the removed parts in the reverse order of removal 1 NEW O RING 2 COUNTERSHAFT COLLAR Install the drive pin into the oil pump drive shaft hole Install the oil pump driven gear while aligning its groove with the drive pin Apply grease to the new O ring and install it into the countershaft collar groove Inst...

Page 108: ...3 62 3 62 Memo ...

Page 109: ...y brake degreasing agent 1 BRAKE DISC 2 COLLAR 3 DISC BOLT 4 LEFT WHEEL BEARING 5 DISTANCE COLLAR 6 RIGHT WHEEL BEARING a 25 1 mm 1 0 0 0394 in 4 Frame servicing Spokes Check spoke tension frequently between the first few rides As the spokes spoke nuts and rim contact points seat in the spokes may need to be retightened Once past this initial seating in period the spokes should hold their tension ...

Page 110: ...ull the fork tube down and out 1 AXLE 1 AXLE PINCH BOLT Installation Clean the surfaces where the axle and axle clamps contact each other Place the front wheel between the fork legs while inserting the brake disc between brake pads without damaging them Apply thin layer of grease to the axle surface Apply grease to the axle threads Install the axle from the right side through the wheel Tighten the...

Page 111: ...e remove the fork bolt and slide the fork tube down Make sure the damping adjuster is in clicked position and is not in between the position Hold the lock nut and remove the fork bolt from the dam per rod Do not remove the lock nut from the damper rod Pour out the fork fluid Hold the axle holder in a vise protected with a piece of woods or soft jaws to avoid damage Do not overtighten Loosen the ri...

Page 112: ...driver until the bushing can be pulled off by hand Be careful not to scratch the teflon coating of the bushing Remove the guide bushing back up ring and oil seal from the fork tube 1 DUST SEAL 2 STOP RING 3 FORK SLIDER Remove the fork damper assembly and centering plate from the fork tube 1 FORK DAMPER 2 CENTERING PLATE 3 FORK TUBE Remove the dust seal and stop ring being careful not to scratch th...

Page 113: ...e Bushing Back up Ring Check the bushings for excessive wear or scratches Remove any metal powder inside the slider and guide bushings with a nylon brush and fork fluid If copper appears on the entire surface replace the bushing Replace the back up ring if there is any distortion at the points shown 1 FORK TUBE BUSHING 2 GUIDE BUSHING 3 BACK UP RING 4 OIL SEAL 5 FORK SLIDER Right Fork Assembly Cle...

Page 114: ...ider groove securely Install the dust seal Install the centering plate and fork damper into the fork tube 1 FORK DAMPER 2 CENTERING PLATE 3 FORK TUBE 1 FORK SEAL DRIVER Using the special tool drive the guide bushing and back up ring until the stop ring groove is fully stuck in the fork slider base Install the oil seal spring up in the fork slider Drive the oil seal using the special tool performin...

Page 115: ...k leg Specified fork fluid Tech OJ01 SAE 5 Bleed the air as follows 1 Extend the fork without bringing to its maximum exten sion Cover the top of the fork tube with your hand and compress the fork slowly several times NOTICE Totally extended fork may cause oil leakage 1 FORK FLUID 2 FORK TUBE Install a new O ring onto the fork bolt groove Screw the fork bolt on the lock nut from the damper rod unt...

Page 116: ... KA50100 Remove the center bolt and sealing washer Remove the following items using the same procedure as the right fork disassembly page 4 2 Dust seal Stop ring Fork tube unlocking guide bushing on the fork leg 1 CILINDER ASSY 2 CENTER BOLT 1 FORK BOLT 2 DISTANCE COLLAR 3 SPRING SEAT 4 FORK SPRING 5 TAPERED BUSHING 6 FORK TUBE Left Fork Disassembly Before disassembling the fork clean the entire s...

Page 117: ... thoroughly with non flammable or high flush point solvent before assembly Apply fork fluid to the piston ring Install the cilinder assy into the fork tube Install the tapered bushing on the end of the cilinder assy NOTICE The tapered bushing is easy to scratched or deformed Take care not to damage it when assembling it Hold the axle holder in a vise protected with a piece of wood or soft jaws to ...

Page 118: ...d capacity Oil level 125 mm 4 9 in Oil capacity orientative 375 cc 12 7 US oz 13 2 Imp oz 1 GUIDE BUSHING 2 BACK UP RING 3 OIL SEAL 4 STOP RING 5 DUST SEAL Install the following parts onto the fork tube using the same procedure as the right fork page 4 5 Fork tube bushing Guide bushing Back up ring Using the special tool drive the guide bushing and back up ring until the stop ring groove is fully ...

Page 119: ...be must be replaced Tighten the fork bolt Tighten the top bridge pinch bolt to the specified torque Torque 21 N m 2 1 kgf m 14 lbf ft Return spring pre load and rebound adjuster to their original positions as noted during removal Install the following Front fender Front wheel page 4 2 1 BOTTOM BRIDGE PINCH BOLTS 2 FORK BOLT 3 TOP BRIDGE PINCH BOLTS Steering stem Disassembly Remove the following Ha...

Page 120: ...7946 4300101 1 BALL RACE REMOVER Remove the lower bearing and dust seal from the steering stem Remove the upper and lower bearing races from the steering head using the special tools Tool Ball race remover 07948 4630100 1 STEM 2 LOWER BEARING 3 DUST SEAL 1 DUST SEAL 2 UPPER BEARING 3 STEM Remove the stem bearing adjusting nut Remove the following Dust seal Upper bearing Steering stem lower bearing...

Page 121: ...010300 1 DRIVER 2 ATTACHMENT 1 STEM 2 UPPER BEARING 3 DUST SEAL Install new bearing races Pack the upper and lower bearings with grease Install the steering stem upper bearing and dust seal Screw the stem bearing adjusting nut all the way with your fingers 1 ADJUSTING NUT 2 1 1 2 3 1 ...

Page 122: ...ads and clean a contaminated disc with a high quality brake degreasing agent 1 ADJUSTER 2 AXLE Apply grease to the stem bolt threads and seating surfaces Install the top bridge washer and stem nut Temporarily install both fork legs Apply grease to the top bridge pinch bolt threads and seating surfaces Install and tighten the top bridge pinch bolts to the specified torque Torque 21 N m 2 1 kgf m 15...

Page 123: ...your race maintenance program includes checking spoke tension and overall wheel condition on a regular basis 1 DRIVEN SPROCKET 2 DRIVEN SPROCKET BOLT NUT 3 LEFT WHEEL BEARING 4 DISTANCE COLLAR 5 RIGHT WHEEL BEARING 6 DISC BOLT 7 BRAKE DISC 8 REAR WHEEL NIPPLE a 30 0 5 mm When unassembling change bolt for new one s Apply a locking agent to the threads Torque 17 N m 1 7 kgf m Drive the bearing into ...

Page 124: ... aligning with the caliper slide rail Apply thin layer of grease to the axle Place the rear wheel between the swingarm being careful not to damage the disc Insert the rear axle into the left chain adjuster side collar and wheel 1 AXLE 2 ADJUSTERS 3 AXLE NUT Apply grease to the axle nut threads and seating surface Install the right chain adjuster and axle nut Install the drive chain If the master l...

Page 125: ...T 9 DUST SEAL 1 SPANNER WRENCH 1 CIRCLIP Removal Secure the damper in a bench vise Loosen the lock nut and the spring adjuster using the spanner wrench 07702 0020001 Move the spring up next to the fastener plate Remove the Seeger fastener ring and remove the spring plate and the spring from the damper body 9 9 9 9 8 8 7 7 6 6 5 4 3 2 1 1 1 ...

Page 126: ... lips Install the dust seals and collars 1 DUST SEALS 2 SPHERICAL BEARING 1 PRE LOAD LENGTH 2 ADJUSTER 3 LOCK NUT Adjust the spring pre load length page 1 4 Hold the spring adjuster and tighten the lock nut to the specified torque Torque Tightening angle 50 10 after contact between nuts 1 DISTANCE COLLAR Remove the distance collar Remove the stopper ring spring seat and spring Inspection Check the...

Page 127: ...r the engine Remove the following Rear cushion lower mounting bolt nut Cushion arm plate to cushion link bolt nut Cushion arm plates to swingarm bolt nut Cushion arm plates Cushion link to frame socket bolt nut Cushion link Move the swingarm aligning the lower mount then install the lower mounting bolt from the right side Install and tighten the upper and lower mounting nuts to the specified torqu...

Page 128: ...the dust seals and pivot collars 1 SHOCK ABSORBER LOWER MOUNTING BOLT NUT 2 SHOCK ARM PLATES TO SWINGARM BOLT NUT Swingarm Removal Remove the following Rear wheel page 4 14 Shock absorber lower mounting bolt nut Cushion arm plates to swingarm bolt nut 1 CUSHION LINK 2 CUSHION ARM PLATES 3 BOLTS NUTS 4 LOWER MOUNTING BOLT NUT Installation Install the following Cushion link Cushion link to frame soc...

Page 129: ...tachment 24 x 26 mm 07746 0010700 Pilot 20 mm 07746 0040500 Face the bearing with its marked side facing out Press the needle bearing so that it is 5 5 mm 0 22 in below the swingarm end Install the thrust bushings and the dust seal 1 DUST SEAL CAP 2 DUST SEAL 3 PIVOT COLLAR 4 DUST SEAL Disassembly Remove the following Bolts and drive chain cover Bolts and driven sprocket guard Screws and drive cha...

Page 130: ...07946 MJ00000 Face the bearing with its marked side facing out Press the needle bearing so that it is 3 0 mm 0 12 in below the swingarm end Install the dust seals and pivot collars 1 DUST SEAL 2 PIVOT COLLAR 3 DUST SEAL 4 DUST SEAL CAP 5 NEEDLE BEARING Install the pivot collars dust seals and dust seal caps Note the direction of the dust seal 1 DUST SEAL 2 PIVOT COLLAR 3 DUST SEAL 4 DUST SEAL CAP ...

Page 131: ...nstall the swingarm into the frame Install the swingarm pivot bolt from the left side Install and tighten the swingarm pivot nut to the specified torque Torque 69 N m 7 0 kgf m 51 lbf ft Install the brake caliper onto the swingarm rail Install the brake hose clamps and tighten the screws 1 PIVOT BOLT NUT 2 HOSE CLAMPS 1 DRIVE CHAIN GUARD 2 SCREWS Install the drive chain sliders onto the swingarm A...

Page 132: ...ear wheel page 4 16 Push the pistons all the way in to allow installation of new brake pads Check the brake fluid level in the reservoir as this operation causes the level to rise Remove the spring pin from the pads Clean the brake caliper inside especially around the caliper pistons 1 PAD SPRING PIN 2 BOLTS 3 CALIPER Front Brake Pad Replacement Clean the brake disc with a high quality degreasing ...

Page 133: ... Push the piston all the way in to allow installation of new brake pads Check the brake fluid level in the reservoir as this operation causes the level to rise 1 BOLT 2 SPEED SENSOR 3 SPEED SENSOR BRACKET Rear Brake Pad Replacement Clean the brake disc with a high quality degreasing agent if they are contaminated with oil or grease Replace the pads if they are contaminated NOTICE Before replacing ...

Page 134: ...r pistons Install the brake caliper bracket aligning its slit with the boss on the swingarm Install the rear wheel page 4 16 Operate the brake pedal to seat the caliper pistons against the pads 1 BRAKE CALIPER BRACKET 2 SWINGARM BOSS 1 CALIPER BRACKET 2 PAD PIN Install the new pads and secure them with the pad pin 1 1 2 1 1 1 2 2 ...

Page 135: ...r the system is serviced Drain the brake system Place a clean container under the caliper Remove the following Brake hose oil bolt Sealing washers Brake hose eyelet Rear wheel page 4 14 Brake caliper bracket Spring pin for the pads Brake pads page 4 25 1 OIL BOLT STOP SWITCH 2 BRAKE HOSE 3 BRAKE CALIPER Inspection Clean the inside of the caliper Check the oil leakage from the caliper cylinders If ...

Page 136: ...enever the system is serviced When removing the brake hose bolt cover the end of the hoses to prevent contamination Secure the hoses to prevent fluid from leaking out Drain the brake fluid from the hydraulic system into a suitable container Remove the following Brake lever Brake hose bolt Master cylinder holder bolt and holder Master cylinder 1 SWINGARM BOSS Installation Install the brake caliper ...

Page 137: ...kgf m 10 3 lbf ft Master cylinder holder bolt 5 5 N m 0 56 kgf m 4 1 lbf ft Disassembly Assembly NOTICE Keep the master cylinder piston cups spring and snap ring as a set don t substitute individual parts When installing the cups do not allow the lips to turn inside out and be certain the snap ring is firmly sea ting in the groove Remove the snap ring and disassemble the master cylinder 1 BOOT 2 S...

Page 138: ...draulic system into a suitable container Remove the seat front covers side covers and the seat rear fender assy Remove the air cleaner housing Remove the exhaust muffler Remove the reservoir tank from the bracket Remove the brake hose oil bolt and disconnect the brake hose Remove the mounting bolts and master cylinder Installation Installation is in the reverse order of removal Connect the brake h...

Page 139: ... Clutch lever Clutch hose bolt Master cylinder holder bolts and holder Master cylinder Installation Install the brake pedal and collars Install and tighten the pivot nut and bolt Apply sealant to the threads of pivot bolt Torque 29 N m 3 0 kgf m 22 lbf ft 1 COLLAR B 2 PEDAL 3 NUT COLLAR A 1 STANDARD LENGTH 35 MM Pivot Bearing Replacement Remove the dust seals Remove the pivot bearing and press a n...

Page 140: ...in the groove Remove the snap ring and disassemble the master cylinder Inspection Check the following items Master cylinder and piston for scoring scratches or other damage Master piston O D and master cylinder I D Installation Installation is in the reverse order of removal Torque Brake hose oil bolt 14 N m 1 4 kgf m 10 3 lbf ft Master cylinder holder bolt 5 5 N m 0 56 kgf m 4 1 lbf ft 1 BOOT 2 S...

Page 141: ...ector and measure the resistance between the yellow terminals of the alternator side connector If the measured resistance at regulator rectifier 6P Black connector is incorrect and the alternator 3P Natural connector is correct check the wire harness If the resistance is still out of specification replace the stator assembly Regulated Voltage Inspection Disconnect the power 4P Natural connector Co...

Page 142: ... 3P Natural connector and ignition pulse generator 2P Natural connector 1 BOLT 2 BRAKE RESERVOIR Disconnect the condenser 2P Black and regulator rectifier 6P Black connector Remove the rear brake reservoir tank mounting bolt 1 2P BLACK CONNECTOR 2 CONDENSER Remove the electric stay mounting bolts then remove the stay assembly from the engine Release the condenser 2P Black connector then remove the...

Page 143: ...sure the ignition primary coil resistance between the primary terminals Standard 2 6 3 2 20 C 68 F Measure the secondary coil resistance Standard With plug cap 17 3 22 8 k 20 C 68 F Without plug cap 13 5 16 5 k 20 C 68 F Replace the ignition coil if the resistance is out of specification 1 PRIMARY TERMINALS Remove the bolts and regulator rectifier from the electric stay Install the regulator recti...

Page 144: ...generator stator assembly page 3 52 1 2P NATURAL CONNECTOR Ignition Pulse Generator Inspection Check the ignition pulse generator resistance at the ECM 32P Black connector page 5 5 Connection White yellow Green yellow Standard 85 115 20 C 68 F 1 32P BLACK CONNECTOR 1 WIRE CLAMP 2 PRIMARY WIRES 3 BOLTS 4 IGNITION COIL Remove the wire clamp Disconnect the primary wires from the ignition coil Remove ...

Page 145: ... 1 12 3 Ω 20 C 68 F Engine stop switch B W Ground Continuity exist only when switch is pushed ECT Engine Coolant Temperature sensor P W G O 2 3 2 6 kΩ 20 C 68 F Sensor ground G1 Ground Continuity Power ground G1 Ground Continuity 1 32P BLACK CONNECTOR Condenser Inspection If the engine does not start check for the items engine does not start in the PGM FI Malfunction Indicator Lamp MIL Failure Cod...

Page 146: ...ning side as shown Turn the power switch ON check that the MIL If the ECM has no self diagnosis memory data the MIL will illuminate when you turn the power switch ON If the ECM has self diagnosis memory data the MIL will start blinking when you turn the power switch ON Note how many times the MIL blinks and determine the cause of the problem See page 5 7 1 POWER SWITCH 2 MIL 3 WARNING RESET SWITCH...

Page 147: ...ice check connector Faulty ECM PGM FI warning indicator output Engine operates normally 1 Blink Open or short circuit in MAP sensor line in the ECM Faulty MAP sensor Poor idle 7 Blinks Loose or poor contact on ECT sensor Open or short circuit in ECT sensor wire Faulty ECT sensor Hard starting at a low temperature Simulate using numerical values 90 C 194 F Cooling fan does not stop 8 Blinks Open or...

Page 148: ...angle sensor approximately 65 degrees to the left or right make sure that the engine stops after few seconds If the engine stops the bank angle sensor is normal If the engine does not stop replace the bank angle sensor With the arrow UP mark on the bank angle sensor facing up again restart the engine The engine starts the bank angle sensor is normal Bank angle sensor inspection Remove the electric...

Page 149: ...fan system inspection Fan motor inspection Remove the fuel tank Disconnect the fan motor 2P Natural connector Directly connect a 12 V battery to the fan motor 2P Natural connector terminals of the fan motor side The fan motor is correct when the fan motor operate when the 12 V battery is connected If the fan motor does not operate replace the fan motor assembly 1 2P NATURAL CONNECTOR Engine stop s...

Page 150: ...onnector There should be continuity If there is no continuity repair or replace the wire harness Lights instruments switches System location speedometer winker relay front brake switch left front turn signal connector right front turn signal connector 9P connector light switch 9P connector sub harness 3P connector speed sensor 2P connector position light power relay ...

Page 151: ...owing Open circuit in the black wire between the ignition relay and the connector 9P white on the handlebar If there is voltage disconnect the connector 9P from the left switch on the handlebar Check the continuity between the terminals in each switch position as shown in the table Servicing information Bear in mind the following when replacing the front headlight bulb Use clean gloves when replac...

Page 152: ...w is working correctly and carry out the checks again If the indicator lights are not working check to see if there is an open circuit in Yellow green wire left side Blue red wire right side Green wires for the indicators Brake light If the engine starts but the brake light does not work check the following Burnt out led Loose connector Open circuit in the Black wire between the ignition relay and...

Page 153: ...ith the connector 6P of the speedometer connected check the following in the connector on the harness side 1 SPEEDOMETER 1 HOUSING FOR THE HEADLIGHT 2 BOLTS 3 SPEEDOMETER 4 CONNECTOR 6P 5 CONNECTOR 3P Speedometer Removal Installation Remove the housing for the headlight Remove the screws and the speedometer Disconnect the connectors 6P white and 3P white from the speedometer Carry out the installa...

Page 154: ...nnot be adjusted If it is not within the specification check whether there are deformities damage or if any of the parts assembled are loose 1 SPEED SENSOR 1 CONNECTOR 6P Power input line Measure the voltage between the connector 6P of the speedometer and the ground Connection White Red and Ground With the engine on around 12V should be received If there is no voltage check the existence of an ope...

Page 155: ...inals of the connector 9P white on the harness side Connection Black and Ground Standard 12V approximately 1 HORN 2 CONNECTORS 1 HOUSING FOR THE UPPER HEADLIGHT 2 CONNECTOR 6P 3 CONNECTOR 3P Checking the speed sensor Remove the housing for the upper headlight Check if there are loose or defective contacts in the connector 3P white of the speed sensor Disconnect the connector 3P white of the speed ...

Page 156: ...GHT 12V 5W HEADLIGHT 12V 35 35W LEFT FRONT TURN SIGNAL LIGHT 12V 10W FRONT STOP SWITCH ENGINE SWITCH TURN SIGNAL SWITCH LIGHTING SWITCH HORN SWITCH STOP SWITCH HORN WATER TEMP SENSOR IGNITION COIL PULSER ALTERNATOR REGULATOR RECTIFIER CONDENSER 10000uF BANK ANGLE SENSOR FAN RELAY POWER RELAY WINKER RELAY O2 SENSOR F1 ECU SPEED SENSOR REAR WHEEL FAN MOTOR FUEL PUMP SERVICE CHECK CONNECTOR REGISTRAT...

Page 157: ...Memo 5 17 5 17 Memo ...

Page 158: ......

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