Content      ..     3      4      5      6     ..

Kawasaki ZZR 1400, ZZR1400 ABS, Ninja ZX-14 Motorcycle. Service Manual (2006-2007 year) - page 5

12-18 BRAKES

Calipers

Caliper Fluid Seal Damage

The fluid seal (piston seal) [A] is placed around the pis-

ton to maintain clearance between the pad and the disc. If

the seal is in a poor condition, it could lead the pad to wear

excessively or the brake to drag, which may cause the tem-

perature of the discs or the brake fluid to increase.

• Replace the fluid seal if it exhibits any of the conditions

listed below.

○Brake fluid leakage around the pad.

○Brakes overheat.

○Considerable difference in inner and outer pad wear.

○Seal and piston are stuck together.

If the fluid seal is replaced, replace the dust seal [B] as

well. Also, replace all seals every other time the pads are

changed.

Caliper Dust Seal Damage

• Check that the dust seals [A] are not cracked, worn,

swollen, or otherwise damaged.

If they show any damage, replace the dust seals with new

ones.

Pistons [B]

Fluid Seals [C]

BRAKES 12-19

Calipers

Caliper Piston and Cylinder Damage

• Visually inspect the pistons [A] and cylinder surfaces [B].

Replace the caliper if the cylinder and piston are badly

scores or rusty.

12-20 BRAKES

Brake Pads

Front Brake Pad Removal

• Loosen the pad pins [A].

• Remove:

Pad Pins [A]

Pad Springs [B]

Brake Pads [C]

Front Brake Pad Installation

• Push the caliper pistons in by hand as far as they will go.

• Install the outside pad [A] and insert the pad pin [B] as

shown in the figure.

• Set:

Inside Pad [A]

Pad Spring [B]

○Pushing the pin holder [C] to hole of the pad and insert

the pad pin.

Torque - Front Brake Pad Pins: 17.2 N·m (1.8 kgf·m, 13 ft·lb)

WARNING

Do not attempt to drive the motorcycle until a full

brake lever is obtained by pumping the brake lever

and the pads are against the disc. The brake will

not function on the first application of the lever if

this is not done.

BRAKES 12-21

Brake Pads

Rear Brake Pad Removal

• Loosen the pad pin [A].

• Unscrew the caliper mounting bolts [B].

• Remove the caliper with the hose installed.

• Remove:

Pad Pin [A]

Pad Spring [B]

Brake Pads [C]

Rear Brake Pad Installation

• Push the caliper pistons in by hand as far as they will go.

• Install the outside pad [A] and insert the pad pin [B] as

shown in the figure.

• Set:

Inside Pad [A]

Pad Spring [B]

○Pushing the pin holder [C] to hole of the pad and insert

the pad pin.

• Install the caliper (see Caliper Installation).

• Tighten the pad pin.

Torque - Rear Brake Pad Pin: 17.2 N·m (1.8 kgf·m, 13 ft·lb)

WARNING

Do not attempt to drive the motorcycle until a full

brake pedal is obtained by pumping the brake pedal

until the pads are against the disc. The brake will

not function on the first application of the pedal if

this is not done.

Brake Pad Wear Inspection

• Refer to the Brake Pad Wear Inspection in the Periodic

Maintenance chapter.

12-22 BRAKES

Master Cylinder

Front Master Cylinder Removal

• Remove the reservoir bracket bolt [A].

• Remove the banjo bolt [B] to disconnect the brake hose

from the master cylinder (see Brake Hose Removal/In-

stallation).

• Unscrew the clamp bolts [C], and take off the master cylin-

der [D] as an assembly with the reservoir, brake lever, and

brake switch installed.

• Disconnect the front brake light switch connector [E].

CAUTION

Immediately wash away any brake fluid that spills.

• Remove:

Brake Lever Pivot Bolt [A] and Nut

Brake Lever [B]

Clamp [C] (Slide Out)

Brake Hose [D]

Front Brake Light Switch [E]

Front Master Cylinder Installation

• Set the front master cylinder to match its mating surface

[A] to the punch mark [B] of the handlebar.

• The master cylinder clamp must be installed with the ar-

row mark [C] upward.

• Tighten the upper clamp bolt first, and then the lower

clamp bolt.

Torque - Front Master Cylinder Clamp Bolts: 8.8 N·m (0.90

kgf·m, 78 in·lb)

• Replace the washers that are on each side of the hose

fitting with new ones.

• Tighten:

Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

• Bleed the brake line (see Brake Line Bleeding).

• Check the brake for good braking power, no brake drag,

and no fluid leakage.

Rear Master Cylinder Removal

• Unscrew the brake hose banjo bolt [A] and brake hose

[B].

• Remove:

Cotter Pin [C]

Joint Pin [D]

Bolts [E]

Foot Guard [F]

Rear Master Cylinder

• Slide out the clamp [G].

• Pull off the reservoir hose lower end, and drain the brake

fluid into a container.

BRAKES 12-23

Master Cylinder

Rear Master Cylinder Installation

• Replace the cotter pin with a new one.

• Replace the washers that are on each side of hose fitting

with new ones.

• Tighten:

Torque - Rear Master Cylinder Mounting Bolts: 25 N·m (2.5

kgf·m, 18 ft·lb)

Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

• Bleed the brake line (see Brake Line Bleeding).

• Check the brake for good braking power, no brake drag,

and no fluid leakage.

Front Master Cylinder Disassembly

• Refer to the Master Cylinder Rubber Parts Replacement

in the Periodic Maintenance chapter.

Rear Master Cylinder Disassembly

• Refer to the Master Cylinder Rubber Parts Replacement

in the Periodic Maintenance chapter.

Master Cylinder Assembly

• Refer to the Master Cylinder Rubber Parts Replacement

in the Periodic Maintenance chapter.

Master Cylinder Inspection (Visual Inspection)

• Remove the master cylinders (see Front/Rear Master

Cylinder Removal).

• Disassemble the front and rear master cylinders (see

Master Cylinder Rubber Parts Replacement in the Peri-

odic Maintenance chapter).

• Check that there are no scratches, rust or pitting on the

inner wall [A] of each master cylinder and on the outside

of each piston [B].

If a master cylinder or piston shows any damage, replace

them.

• Inspect the primary cup [C] and secondary cup [D].

If a cup is worn, damaged softened (rotted), or swollen,

the piston assembly should be replaced to renew the

cups.

If fluid leakage is noted at the brake lever, the piston as-

sembly should be replaced to renew the cups.

Front Master Cylinder [J]

12-24 BRAKES

Master Cylinder

• Check the dust covers [E] for damage.

If they are damaged, replace them.

• Check the piston return spring [F] for any damage.

If the springs are damaged, replace them.

• Check that relief port [G] and supply port [H] are not

plugged.

If the relief port becomes plugged, the brake pads will

drag on the disc. Blow the ports clean with compressed

air.

Rear Master Cylinder [K]

BRAKES 12-25

Brake Disc

Brake Disc Removal

• Remove the wheels (see Front/Rear Wheel Removal in

the Wheels/Tires chapter).

• Unscrew the mounting bolts, and take off the disc.

○Remove the sensor rotor (ZX1400B Models).

Brake Disc Installation

• Install the brake disc on the wheel so that the marked side

[A] faces out.

○Install the sensor rotor on the brake disc so that the

marked side faces out (ZX1400B Models).

• Apply a non-permanent locking agent to the threads of

the rear brake disc mounting bolts [B].

• Tighten:

Torque - Brake Disc Mounting Bolts: 27 N·m (2.8 kgf·m, 20

ft·lb)

Brake Disc Wear

• Measure the thickness of each disc [A] at the point where

it has worn the most.

If the disc has worn past the service limit, replace it.

Measuring Area [B]

Brake Discs Thickness

Standard:

Front

4.8 ∼ 5.2 mm (0.19 ∼ 0.20 in.)

Rear

5.8 ∼ 6.2 mm (0.23 ∼ 0.24 in.)

Service Limit:

Front

4.5 mm (0.18 in.)

Rear

5.5 mm (0.22 in.)

Brake Disc Warp

• Raise the front/rear wheel off the ground.

Special Tools - Jack: 57001-1238

Jack Attachment: 57001-1608

○For front disc inspection, turn the handlebar fully to one

side.

• Set up a dial gauge against the disc [A] as shown and

measure disc runout, while turning [B] the wheel by hand.

If runout exceeds the service limit, replace the disc.

Disc Runout

Standard:

TIR 0.15 mm (0.006 in.) or less

Service Limit:

TIR 0.3 mm (0.01 in.)

12-26 BRAKES

Brake Fluid

Brake Fluid Level Inspection

• Refer to the Brake Fluid Level Inspection in the Periodic

Maintenance chapter.

Brake Fluid Change

• Refer to the Brake Fluid Change in the Periodic Mainte-

nance chapter.

Brake Line Bleeding

The brake fluid has a very low compression coefficient so

that almost all the movement of the brake lever or pedal

is transmitted directly to the caliper for braking action. Air,

however, is easily compressed. When air enters the brake

lines, brake lever or pedal movement will be partially used

in compressing the air. This will make the lever or pedal feel

spongy, and there will be a loss in braking power.

WARNING

Be sure to bleed the air from the brake line when-

ever brake lever or pedal action feels soft or

spongy after the brake fluid is changed, or when-

ever a brake line fitting has been loosened for any

reason.

NOTE

○The procedure to bleed the front brake line is as follows.

Bleeding the rear brake line is the same as for the front

brake.

• Remove:

Screw [A]

Clamp [B]

Front Brake Reservoir Cap [C]

Diaphragm Plate

Diaphragm

• Fill the reservoir with fresh brake fluid to the upper level

line in the reservoir.

• Slowly pump the brake lever several times until no air

bubbles can be seen rising up through the fluid from the

holes at the bottom of the reservoir.

○Bleed the air completely from the master cylinder by this

operation.

• Remove the rubber cap from the bleed valve on the front

master cylinder.

• Attach a clear plastic hose [A] to the bleed valve, and run

the other end of the hose into a container.

BRAKES 12-27

Brake Fluid

• Bleed the brake line and the master cylinder.

○Repeat this operation until no more air can be seen com-

ing out into the plastic hose.

1. Pump the brake lever until it becomes hard, and apply

the brake and hold it [A].

2. Quickly open and close [B] the bleed valve while hold-

ing the brake applied.

3. Release the brake [C].

NOTE

○The fluid level must be checked often during the bleed-

ing operation and replenished with fresh brake fluid as

necessary. If the fluid in the reservoir runs completely

out any time during bleeding, the bleeding operation

must be done over again from the beginning since air

will have entered the line.

• Remove the clear plastic hose.

• Tighten the bleed valve, and install the rubber cap.

Torque - Front Master Cylinder Bleed Valve: 7.8 N·m (0.80

kgf·m, 69 in·lb)

• Remove the rubber cap [A] from the bleed valve on the

caliper.

• Attach a clear plastic hose [B] to the bleed valve, and run

the other end of the hose into a container.

• Bleed the brake line and the caliper.

○Repeat this operation until no more air can be seen com-

ing out into the plastic hose.

1. Pump the brake lever until it becomes hard, and apply

the brake and hold it [A].

2. Quickly open and close [B] the bleed valve while hold-

ing the brake applied.

3. Release the brake [C].

NOTE

○The fluid level must be checked often during the bleed-

ing operation and replenished with fresh brake fluid as

necessary. If the fluid in the reservoir runs completely

out any time during bleeding, the bleeding operation

must be done over again from the beginning since air

will have entered the line.

○Tap the brake hose lightly from the caliper to the reser-

voir for more complete bleeding.

○Front Brake: First bleeding the right caliper then repeat

the above steps for the left caliper.

• Remove the clear plastic hose.

12-28 BRAKES

Brake Fluid

• Install:

Diaphragm

Diaphragm Plate

Front Brake Reservoir Cap [A]

Clamp [B]

Screw [C]

• Follow the procedure below to install the front/rear brake

fluid reservoir cap correctly.

○First, tighten the brake fluid reservoir cap [B] clockwise

[C] by hand until slight resistance is felt indicating that

the cap is seated on the reservoir body, then tighten the

cap an additional 1/6 turn [D] while holding the brake fluid

reservoir body [A].

• Tighten:

Torque - Front Brake Reservoir Cap Stopper Screw:

1.2

N·m (0.12 kgf·m, 11 in·lb)

• Tighten the bleed valve, and install the rubber cap.

Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

• Check the fluid level (see Brake Fluid Level Inspection in

the Periodic Maintenance chapter).

• After bleeding is done, check the brake for good braking

power, no brake drag, and no fluid leakage.

BRAKES 12-31

Anti-Lock Brake System (Equipped Models)

Parts Location

1. Front Wheel Rotation Sensor

2. Front Wheel Rotation Sensor Rotor

3. Rear Wheel Rotation Sensor

4. Rear Wheel Rotation Sensor Rotor

5. ABS Indicator Light (LED)

6. ABS Hydraulic Unit

7. ABS Fuse Box

8. ABS Kawasaki Self-diagnosis System Connector

12-32 BRAKES

Anti-Lock Brake System (Equipped Models)

ABS System Wiring Diagram

1. Ignition Switch

2. Joint Connector 1

3. Front Brake Switch

4. Water-proof Joint 1

5. Rear Brake Switch

6. Frame Ground

7. Battery 12 V 14 Ah

8. Main Fuse 30 A

9. Joint Connector 2

10. Main Relay

11. Relay Box

12. ECU Fuse 15 A

13. ABS Motor Relay Fuse 30 A

14. ABS Solenoid Valve Relay Fuse 20 A

15. ABS ECU Fuse 10 A

16. Ignition Fuse 10 A

17. Fuse Box 2

18. Meter Unit

19. ABS Hydraulic Unit

20. ABS Kawasaki Self-diagnosis System Connector

21. Front Wheel Rotation Sensor

22. Rear Wheel Rotation Sensor

23. ABS Self-diagnosis Terminal

BRAKES 12-33

Anti-Lock Brake System (Equipped Models)

Terminal Names

1. Unused

2. Power Supply to Rear Wheel Rotation Sensor

3. Front Wheel Rotation Sensor Signal

4. Front and Rear Brake Light Switch

5. Unused

6. Unused

7. Unused

8. Power Supply to ABS Solenoid Valve Relay

9. Power Supply to ABS Motor Relay

10. ABS Kawasaki Self-diagnosis System Terminal

11. Unused

12. Power Supply to Front Wheel Rotation Sensor

13. ABS Self-diagnosis Terminal

14. Unused

15. Unused

16. Power Supply

17. Unused

18. Rear Wheel Rotation Sensor Signal

19. Unused

20. Unused

21. ABS Indicator Light (LED)

22. Unused

23. Unused

24. Ground

25. Ground to Motor

BRAKES 12-35

Anti-Lock Brake System (Equipped Models)

○The ABS indicator light (LED) [A] may light if the tire pres-

sure is incorrect, a non-recommended tire is installed, or

the wheel is deformed. If the indicator light lights, remedy

the problem and clear the service code.

WARNING

Use of non-recommended tires may cause malfunc-

tioning of ABS and can lead to extended braking

distance. The rider could have an accident as a re-

sult. Always use recommended standard tires for

this motorcycle.

○The ABS indicator light (LED) may come on if the engine

is run with the motorcycle on its stand and the transmis-

sion in gear. If the indicator light comes on, just turn the

ignition switch OFF, then clear service code 42, which in-

dicates a “Faulty front wheel rotation sensor”.

○When the ABS operates, the ABS makes noise and the

rider feels the reaction force on the brake lever and brake

pedal. This is a normal condition. It informs the rider that

the ABS is operating normally.

○Service codes detected once by the ABS hydraulic unit

will be memorized in the ABS hydraulic unit. Therefore,

after maintenance work is finished, be sure to erase the

service codes. Do not erase the service codes during

troubleshooting. Wait until all the checks and repair work

are finished to prevent duplication of previous service

codes and unnecessary maintenance work.

○Before delivering the motorcycle to the customer, be

sure to erase any service codes which might be stored in

the ABS hydraulic unit. Using the self-diagnosis feature,

make sure that the ABS indicator light (LED) lights. A

fully charged battery is a must for conducting reliable

self-diagnosis. Test run the motorcycle at a speed of

more than 20 km/h (12 mph) to see that the ABS indicator

light (LED) does not come on. Finally, test run the mo-

torcycle at a speed of more than 30 km/h (20 mph) and

brake suddenly to see that the motorcycle stops without

loss of steering control and the ABS operates normally

(The reaction force generated is felt in the brake lever

and pedal.). This completes the final inspection.

○Color Codes:

BK: Black

G: Green

P: Pink

BL: Blue

GY: Gray

PU: Purple

BR: Brown

LB: Light Blue

R: Red

CH: Chocolate

LG: Light Green

W: White

DG: Dark Green

O: Orange

Y: Yellow

12-36 BRAKES

Anti-Lock Brake System (Equipped Models)

ABS Troubleshooting Outline

When an abnormality in the system occurs, the ABS in-

dicator light (LED) lights up to alert the rider. In addition,

the nature of the fault is stored in the memory of the ABS

hydraulic unit and when in the self-diagnosis mode, the ser-

vice code [A] is indicated by the number of times the ABS

indicator light (LED) blinks. The service codes stored in

memory are not erased until the mode has been changed

to the fault erase mode after the fault has been corrected.

Therefore, after correcting the problem, always erase the

service codes and then run the self-diagnosis program to

confirm normal signal output. When, due to a malfunction,

the ABS indicator light (LED) remains lit, get a thorough

understanding of the background before starting the repair

work. Ask the rider about the conditions [B] under which

the problem occurred and try to determine the cause [C].

Do not rely solely on the ABS self-diagnosis function, use

common sense; check the brakes for proper braking power,

and brake fluid level, search for leaks, etc.

Even when the ABS is operating normally, the ABS indi-

cator light (LED) may light up under the conditions listed be-

low. Turn the ignition switch OFF to stop the indicator light.

If the motorcycle runs without erasing the service code, the

light may light up again.

○After continuous riding on a rough road.

○When the engine is started with the stand raised and the

transmission engaged, and the rear wheel turns.

○When accelerating so abruptly that the front wheel leaves

the ground.

○When the ABS has been subjected to strong electrical

interference.

○When tire pressure is abnormal. Adjust tire pressure.

○When a tire different in size from the standard size is being

used. Replace with standard size.

○When the wheel is deformed. Replace the wheel.

Much of the ABS troubleshooting work consists of con-

firming continuity of the wiring. The ABS parts are assem-

bled and adjusted by the manufacturer, so there is no need

to disassemble or repair them. Replace the ABS hydraulic

unit.

The basic troubleshooting procedures are listed below.

• Carry out pre-diagnosis inspections as a preliminary in-

spection.

• Determine the fault using the self-diagnosis function.

• Check wiring and connections from the ABS hydraulic

unit connector to the suspected faulty ABS part, using the

hand tester.

Special Tool - Hand Tester: 57001-1394

BRAKES 12-37

Anti-Lock Brake System (Equipped Models)

• Visually inspect the wiring for signs of burning or fraying.

If any wiring is poor, replace the damaged wiring.

• Pull each connector [A] apart and inspect it for corrosion,

dirt and damage.

If the connector is corroded or dirty, clean it carefully. If it

is damaged, replace it.

• Check the wiring for continuity.

○Use the wiring diagram to find the ends of the lead which

is suspected of being a problem.

○Connect the hand tester between the ends of the leads.

Special Tool - Hand Tester: 57001-1394

○Set the tester to the × 1 Ω range, and read the tester.

If the tester does not read 0 Ω, the lead is defective. Re-

place the main harness [B] if necessary.

• Narrow down suspicious parts and close in on the faulty

ABS part by repeating the continuity tests.

If no abnormality is found in the wiring or connectors, the

ABS parts are the next likely suspects. Check each part

one by one.

If an abnormality is found, replace the affected ABS part.

12-38 BRAKES

Anti-Lock Brake System (Equipped Models)

ABS Diagnosis Flow Chart

BRAKES 12-39

Anti-Lock Brake System (Equipped Models)

Inquiries to Rider

○Each rider reacts to problems in different ways, so it is important to confirm what kind of condition

the rider is dissatisfied with.

○Try to find out exactly what problem occurs under exactly what conditions by asking the rider; know-

ing this information may help you reproduce the problem in the shop.

○The diagnosis sheet will help prevent you from overlooking any keys, so always use it.

Sample Diagnosis Sheet

Rider name:

Registration No. (license plate No.):

Year of initial registration:

Model:

Engine No.:

Frame No.:

Date problem occurred:

Frequency:

Weather:

Mileage:

□ Brake

□ Indicator

□

Braking

□ Abnor-

□

ABS not

□

ABS

□

ABS op-

lever

light

distance

mal

working

works

erating

vibration

blinks

too long

brake

but

too fre-

or noise

lever

indicator

quently

move-

light

Phenome-

ment

doesn’t

non

light up

□ Pedal

□ Indicator

□ Abnor-

vibration

light

mal

or noise

remains

pedal

lit up

move-

ment

Engine conditions at

□ At start-up

□ After starting

□ At 5 000

r/min (rpm)

problem

or more

Road conditions

□ Slippery road

(□ snow,

□ gravel,

□ other

)

□ Rough surface

□ Other

Driving conditions

□ High-speed cornering

□ Driving 10 km/h (6 mph) or above

□ Driving below 10 km/h (6 mph)

□ When stopping

□ When turning

Brake application

□ Gradual

□ Abrupt

Other conditions

□ Large brake lever stroke

□ Large pedal stroke

12-40 BRAKES

Anti-Lock Brake System (Equipped Models)

Pre-Diagnosis Inspection 1

BRAKES 12-41

Anti-Lock Brake System (Equipped Models)

Pre-Diagnosis Inspection 2

Self-diagnosis Outline

When the indicator light has blinked or come on, the ABS hydraulic unit memorizes and stores the

service code for the service person to troubleshoot easily. The service code memory is powered

directly by the battery and cannot be canceled by the ignition switch.

The ABS hydraulic unit can memorize up to all service codes (14 codes). Further service codes

are memorized after erasing the preceding all service codes (14 codes). If there is no fault, the ABS

indicator light (LED) lights, indicating that “The ABS is normal”.

Self-diagnosis Procedures

○When a problem occurs with the ABS system, the ABS

indicator light (LED) [A] lights.

NOTE

○Use a fully charged battery when conducting

self-diagnosis. Otherwise, the light blinks very slowly

or doesn’t blink.

○The motorcycle is stopped.

○Keep the self-diagnosis terminal grounded during self

-diagnosis, with an auxiliary lead.

12-42 BRAKES

Anti-Lock Brake System (Equipped Models)

• Remove the seat (see Seat Removal in the Frame chap-

ter).

• Ground the self-diagnosis terminal [A] (Gray) to the

ground terminal [B] (Black/Yellow), using a lead.

• Turn on the ignition switch.

○Count the blinks of the light to read the service code.

Keep the auxiliary lead ground until you finish reading the

service code.

Service Code Clearing Procedures

• Start the service code erase mode with the following pro-

cedure.

○The erase mode starts when the ABS self-diagnosis ter-

minal is disconnected from the ground terminal after start-

ing the self-diagnosis mode.

○The service code can be erased by grounding and un-

grounding (each time for at least one second) the ABS

self-diagnosis terminal three times or more within about

12.5 seconds after starting the erase mode.

○The ABS indicator light (LED) remains lit during the erase

mode.

○After erasing, the ABS indicator light (LED) blinks and

lights.

○Once erasing is finished, enter the self-diagnosis mode

again to confirm that the service codes have been

erased. If the ABS has been reset and all codes have

been erased, the ABS indicator light (LED) lights.

BRAKES 12-43

Anti-Lock Brake System (Equipped Models)

12-44 BRAKES

Anti-Lock Brake System (Equipped Models)

Self-diagnosis Flow Chart

BRAKES 12-45

Anti-Lock Brake System (Equipped Models)

How to Read Service Codes

○Service codes are shown by a series of long and short blinks of the ABS indicator light (LED) as

shown below.

○Read 10th digit and unit digit as the ABS indicator light (LED) blinks.

○When there are a number of faults, a maximum of all service codes (14 codes) can be stored and

the display will begin starting from the small number code entered.

○For the display pattern, first the smallest number code is shown, next up to all service codes (14

codes) starting with the last one stored, then the display is repeated from the smallest number code

once again.

○If there is no fault, the ABS indicator light (LED) lights as shown in the figure.

How to Erase Service Codes

○Even if the ignition switch is turned OFF, the battery or the ABS hydraulic unit are disconnected, all

service codes remain in the ABS hydraulic unit.

○Refer to the Service Code Clearing Procedure for the service code erasure.

12-46 BRAKES

Anti-Lock Brake System (Equipped Models)

Service Code Table

Service

ABS Indicator Light (LED)

Problems

Light State

Code

Rear inlet solenoid valve trouble (shorted or

13

ON

open, stuck valve (ON))

Rear outlet solenoid valve trouble (shorted

14

ON

or open, stuck valve (ON))

Front inlet solenoid valve trouble (shorted

17

ON

or open, stuck valve (ON))

Front outlet solenoid valve trouble (shorted

18

ON

or open, stuck valve (ON))

ABS solenoid valve relay trouble (wiring

19

ON

shorted or open, stuck relay (ON or OFF))

Front, rear tire abnormal (substandard

25

tire, deformation wheel, sensor rotor teeth

ON

number wrong)

ABS motor relay trouble (wiring shorted,

35

ON

open or lock, stuck relay (ON or OFF)

Front wheel rotation sensor signal abnormal

42

(sensor or rotor missing, too large

ON

clearance, rotor tooth worn or missing)

Front wheel rotation sensor wiring abnormal

43

ON

(wiring shorted or open)

Rear wheel rotation sensor signal abnormal

44

(sensor or rotor missing, too large

ON

clearance, rotor tooth worn or missing)

Rear wheel rotation sensor wiring abnormal

45

ON

(wiring shorted or open)

Power supply voltage abnormal

52

ON

(under-voltage)

Power supply voltage abnormal

53

ON

(over-voltage)

55

ECU trouble (ECU operation abnormal)

ON

BRAKES 12-47

Anti-Lock Brake System (Equipped Models)

ABS Indicator Light (LED) Inspection

• Turn the ignition switch ON.

If the ABS indicator light (LED) [A] lights, it is normal.

If the ABS indicator light (LED) does not light, go to step

“ABS Indicator Light (LED) is Unlit (When the Ignition

Switch turned to ON)”.

• Turn the ignition switch OFF.

If the ABS indicator light (LED) [A] does not light, it is

normal.

If the ABS indicator light (LED) lights, go to step “ABS In-

dicator Light (LED) Lights (When the Motorcycle is Run-

ning, - No Service Code)”.

ABS Indicator Light (LED) is Unlit (When the

Ignition Switch turned to ON)

• Do the 1st step test.

○Check the terminal voltage between the black/white lead

terminal of the meter connector [A] and ground.

Special Tool - Hand Tester: 57001-1394

○Turn the ignition switch ON.

Terminal Voltage

Standard:

About 10 V

If the terminal voltage is not within the specification, 2nd

step.

If the terminal voltage correct, replace the meter assem-

bly.

• Do the 2nd step test.

○Disconnect the meter connector.

○Check for continuity between the black/white lead termi-

nal of the main harness side connector [A] and ground.

If there is the continuity in the lead, replace or repair the

main harness.

If there is not the continuity in the lead, 3rd step.

12-48 BRAKES

Anti-Lock Brake System (Equipped Models)

• Do the 3rd step test.

○Disconnect the ABS hydraulic unit connector.

○Check for continuity between the black/white lead termi-

nal of the main harness side connector [A] and black/white

lead terminal of the main harness side connector [B].

If there is the continuity in the lead, replace the ABS hy-

draulic unit.

If there is not the continuity in the lead, replace or repair

the main harness.

ABS Indicator Light (LED) Lights (When the

Motorcycle is Running, - No Service Code)

• Do the 1st step test.

○Disconnect the ABS hydraulic unit connector and meter

connector.

○Check for continuity between the black/white lead termi-

nal of the main harness side connector [A] and black/white

lead terminals of the main harness side connector [A].

Special Tool - Hand Tester: 57001-1394

If there is the continuity in the lead, replace the ABS hy-

draulic unit.

If there is not the continuity in the lead, replace or repair

the main harness.

Solenoid Valve Inspection (Service Code

13,14,17,18)

• Do the 1st step test.

○Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, and

retrieve the service code.

If the ABS indicator light (LED) [A] lit, faulty solenoid valve

in the ABS hydraulic unit. Replace the ABS hydraulic unit.

If the ABS indicator light (LED) unlit, ABS system is nor-

mal (service code is not stored; temporary failure.).

ABS Solenoid Valve Relay Inspection (Service

Code 19)

• Do the 1st step test.

○Check the ABS solenoid valve relay fuse (20 A) [A].

If the fuse blown, 2nd step.

If the fuse correct, 4th step.

BRAKES 12-49

Anti-Lock Brake System (Equipped Models)

• Do the 2nd step test.

○Disconnect the ABS hydraulic unit connector [A].

○Check for continuity between the light green and

black/yellow lead terminals of the ABS hydraulic unit

connector.

If there is the continuity in the lead, replace the ABS hy-

draulic unit.

If there is not the continuity in the lead, 3rd step.

• Do the 3rd step test.

○Check for continuity between the light green lead terminal

of the main harness side connector [A] and light green

lead terminal of the fuse box [B].

If there is the continuity in the lead, replace the fuse.

If there is not the continuity in the lead, replace or repair

the main harness.

• Do the 4th step test.

○Check the battery terminal voltage between the light

green lead terminal of the fuse box [A] and ground.

Special Tool - Hand Tester 57001-1394

Battery Terminal Voltage

Standard:

Battery Voltage

If the battery terminal voltage is not within the specifica-

tion, 5th step.

If the battery terminal voltage correct, 6th step.

• Do the 5th step test.

○Check for continuity between the positive cable [A] of the

battery and light green lead terminal of the main harness

side connector [B].

If there is the continuity in the lead, 4th step.

If there is not the continuity in the lead, replace or repair

the main harness.

• Do the 6th step test.

○Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, and

retrieve the service code.

If the ABS indicator light (LED) [A] lit, faulty ABS solenoid

valve relay in the ABS hydraulic unit. Replace the ABS

hydraulic unit.

If the ABS indicator light (LED) unlit, ABS system is nor-

mal (service code is not stored; temporary failure.).

12-50 BRAKES

Anti-Lock Brake System (Equipped Models)

Front, Rear Wheel Rotation Difference Abnormal

(Service Code 25)

• Do the 1st step test.

○Check the following and correct the faulty part.

Incorrect the tire pressure.

Tires not recommended for the motorcycle were installed

(incorrect tire size).

Deformation of the wheel or tire.

Sensor rotor for missing teeth and clogging with foreign

matter.

If the all parts correct, 2nd step.

• Do the 2nd step test.

○Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, and

retrieve the service code.

If the ABS indicator light (LED) [A] lit, faulty ECU in the

ABS hydraulic unit. Replace the ABS hydraulic unit.

If the ABS indicator light (LED) unlit, ABS system is nor-

mal (service code is not stored; temporary failure.).

ABS Pump Motor Relay Inspection (Service Code

35)

• Do the 1st step test.

○Check the ABS pump motor relay fuse (30 A) [A].

If the fuse blown, 2nd step.

If the fuse correct, 4th step.

• Do the 2nd step test.

○Disconnect the ABS hydraulic unit connector.

○Check for continuity between the red and light blue lead

terminals of the ABS hydraulic unit connector [A].

If there is the continuity in the lead, replace the ABS hy-

draulic unit.

If there is not the continuity in the lead, 3rd step.

• Do the 3rd step test.

○Check for continuity between the red lead terminal of the

main harness side connector [A] and red lead terminal of

the fuse box [B].

If there is the continuity in the lead, replace the fuse.

If there is not the continuity in the lead, replace or repair

the main harness.

BRAKES 12-51

Anti-Lock Brake System (Equipped Models)

• Do the 4th step test.

○Check the battery terminal voltage between the red lead

terminal of the fuse box [A] and ground.

Special Tool - Hand Tester: 57001-1394

Battery Terminal Voltage

Standard:

Battery Voltage

If the battery terminal voltage is not within the specifica-

tion, 5th step.

If the battery terminal voltage correct, 6th step.

• Do the 5th step test.

○Check for continuity between the positive cable [A] of the

battery and red lead terminal of the main harness side

connector [B].

If there is the continuity in the lead, 4th step.

If there is not the continuity in the lead, replace or repair

the main harness.

• Do the 6th step test.

○Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, and

retrieve the service code.

If the ABS indicator light (LED) [A] lit, faulty ABS pump

motor relay in the ABS hydraulic unit. Replace the ABS

hydraulic unit.

If the ABS indicator light (LED) unlit, ABS system is nor-

mal (service code is not stored; temporary failure.).

Front Wheel Rotation Sensor Signal Abnormal

(Service Code 42)

• Do the 1st step test.

○Measure the air gap between the front wheel rotation sen-

sor and sensor rotor.

Thickness Gauge [A]

Air Gap

Standard:

0.7 ∼ 0.9 mm (0.028 ∼ 0.035 in.)

If the measurement is over standard, check each part

for deformation and looseness and correct accordingly.

Recheck the air gap.

If the measurement is correct, 2nd step.

12-52 BRAKES

Anti-Lock Brake System (Equipped Models)

• Do the 2nd step test.

○Check that there is iron or other magnetic deposits be-

tween the sensor [A] and sensor rotor [B], and the sensor

rotor slots for obstructions.

○Check the installation condition of the sensor for loose-

ness.

○Check the sensor and sensor rotor tip for deformation or

damage (e.g., chipped sensor rotor teeth).

If the sensor and sensor rotor in bad condition, remove the

any deposits. Install the properly or replace faulty part.

If the all correct, 3rd step.

• Do the 3rd step test.

○Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, and

retrieve the service code.

If the ABS indicator light (LED) [A] lit, faulty ECU in the

ABS hydraulic unit. Replace the ABS hydraulic unit.

If the ABS indicator light (LED) unlit, ABS system is nor-

mal (service code is not stored; temporary failure.).

Front Wheel Rotation Sensor Wiring Inspection

(Service Code 43)

• Do the 1st step test.

○Disconnect the ABS hydraulic unit connector and front

wheel rotation sensor connector.

○Short the brown and green lead terminals of the main har-

ness side connector [A] with a jumper lead, and check for

continuity between the brown and green lead terminals of

the main harness side connector [B].

If there is the continuity in the lead, 2nd step.

If there is not the continuity in the lead, replace or repair

the main harness.

• Do the 2nd step test.

○Check for continuity between the black lead terminal of

the sensor connector [A] and ground, and white lead ter-

minal of the sensor connector and ground.

If there is the continuity in the lead, replace the front wheel

rotation sensor.

If there is not the continuity in the lead, 3rd step.

BRAKES 12-53

Anti-Lock Brake System (Equipped Models)

• Do the 3rd step test.

○Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, and

retrieve the service code.

If the ABS indicator light (LED) [A] lit, faulty ECU in the

ABS hydraulic unit. Replace the ABS hydraulic unit.

If the ABS indicator light (LED) unlit, ABS system is nor-

mal (service code is not stored; temporary failure.).

Rear Wheel Rotation Sensor Signal Abnormal

(Service Code 44)

• Do the 1st step test.

○Measure the air gap between the rear wheel rotation sen-

sor and sensor rotor.

Thickness Gauge [A]

Air Gap

Standard:

0.7 ∼ 0.9 mm (0.028 ∼ 0.035 in.)

If the measurement is over standard, check each part

for deformation and looseness and correct accordingly.

Recheck the air gap.

If the measurement is correct, 2nd step.

• Do the 2nd step test.

○Check that there is iron or other magnetic deposits be-

tween the sensor [A] and sensor rotor [B], and the sensor

rotor slots for obstructions.

○Check the installation condition of the sensor for loose-

ness.

○Check the sensor and sensor rotor tip for deformation or

damage (e.g., chipped sensor rotor teeth).

If the sensor and sensor rotor in bad condition, remove the

any deposits. Install the properly or replace faulty part.

If the all correct, 3rd step.

• Do the 3rd step test.

○Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, and

retrieve the service code.

If the ABS indicator light (LED) [A] lit, faulty ECU in the

ABS hydraulic unit. Replace the ABS hydraulic unit.

If the ABS indicator light (LED) unlit, ABS system is nor-

mal (service code is not stored; temporary failure.).

12-54 BRAKES

Anti-Lock Brake System (Equipped Models)

Rear Wheel Rotation Sensor Wiring Inspection

(Service Code 45)

• Do the 1st step test.

○Disconnect the ABS hydraulic unit connector and rear

wheel rotation sensor connector.

○Short the black and white/red lead terminals of the main

harness side connector [A] with a jumper lead, and check

for continuity between the black and white/red lead termi-

nals of the main harness side connector [B].

If there is the continuity in the lead, 2nd step.

If there is not the continuity in the lead, replace or repair

the main harness.

• Do the 2nd step test.

○Check for continuity between the black lead terminal of

the sensor connector [A] and ground, and white lead ter-

minal of the sensor connector and ground.

If there is the continuity in the lead, replace the rear wheel

rotation sensor.

If there is not the continuity in the lead, 3rd step.

• Do the 3rd step test.

○Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, and

retrieve the service code.

If the ABS indicator light (LED) [A] lit, faulty ECU in the

ABS hydraulic unit. Replace the ABS hydraulic unit.

If the ABS indicator light (LED) unlit, ABS system is nor-

mal (service code is not stored; temporary failure.).

Power Supply Voltage Abnormal (Under-Voltage)

(Service Code 52)

• Do the 1st step test.

○Disconnect the ignition switch connector and ABS hy-

draulic unit connector.

○Check for continuity between the brown lead terminal of

the main harness side connector [A] and yellow lead ter-

minal of the main harness side connector [B].

If there is the continuity in the lead, 2nd step.

If there is not the continuity in the lead, inspect the ABS

ECU fuse (10 A) (see Fuse Inspection in the Electrical

System chapter) and replace or repair the main harness.

BRAKES 12-55

Anti-Lock Brake System (Equipped Models)

• Do the 2nd step test.

○Connect the ignition switch connector and ABS hydraulic

unit connector.

○Check the battery terminal voltage, connect the hand

tester to the brown terminal of ignition switch connector

[A] and ground.

Special Tool - Hand Tester: 57001-1394

○Turn the ignition switch ON.

Battery Terminal Voltage

Standard:

10 V or more

If the battery terminal voltage is not within the specifica-

tion, 3rd step.

If the battery terminal voltage correct, 4th step.

• Do the 3rd step test.

○Inspect the following parts.

Battery (see Charging Condition Inspection in the Elec-

trical System chapter)

Ignition Switch (see Switch Inspection in the Electrical

System chapter)

Main Harness (see Wiring Inspection in the Electrical

System chapter)

Main Fuse 30 A (see Fuse Inspection in the Electrical

System chapter)

• Do the 4th step test.

○Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, and

retrieve the service code.

If the ABS indicator light (LED) [A] lit, faulty ECU in the

ABS hydraulic unit. Replace the ABS hydraulic unit.

If the ABS indicator light (LED) unlit, ABS system is nor-

mal (service code is not stored; temporary failure.).

Power Supply Voltage Abnormal (Over-Voltage)

(Service Code 53)

• Do the 1st step test.

○Disconnect the ignition switch connector and ABS hy-

draulic unit connector.

○Check for continuity between the brown lead terminal of

the main harness side connector [A] and yellow lead ter-

minal of the main harness side connector [B].

If there is the continuity in the lead, 2nd step.

If there is not the continuity in the lead, inspect the ABS

ECU fuse (10 A) (see Fuse Inspection in the Electrical

System chapter) and replace or repair the main harness.

12-56 BRAKES

Anti-Lock Brake System (Equipped Models)

• Do the 2nd step test.

○Connect the ignition switch connector and ABS hydraulic

unit connector.

○Check the battery terminal voltage, connect the hand

tester to the brown terminal of ignition switch connector

[A] and ground.

Special Tool - Hand Tester: 57001-1394

○Turn the ignition switch ON.

Battery Terminal Voltage

Standard:

16 V or less

If the battery terminal voltage is not within the specifica-

tion, 3rd step.

If the battery terminal voltage correct, 4th step.

• Do the 3rd step test.

○Check the battery condition and regulator/rectifier (see

Charging Condition Inspection, Regulator/Rectifier In-

spection in the Electrical System chapter).

• Do the 4th step test.

○Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, and

retrieve the service code.

If the ABS indicator light (LED) [A] lit, faulty ECU in the

ABS hydraulic unit. Replace the ABS hydraulic unit.

If the ABS indicator light (LED) unlit, ABS system is nor-

mal (service code is not stored; temporary failure.).

ECU Inspection (Service Code 55)

• Do the 1st step test.

○Recheck the service code indication; erase the service

code, perform the pre-diagnosis inspection 1 and 2, and

retrieve the service code.

If the ABS indicator light (LED) [A] lit, faulty ECU in the

ABS hydraulic unit. Replace the ABS hydraulic unit.

If the ABS indicator light (LED) unlit, ABS system is nor-

mal (service code is not stored; temporary failure.).

ABS Hydraulic Unit Removal

CAUTION

The ABS hydraulic unit [A] has been adjusted

and set with precision at the factory. Therefore, it

should be handled carefully, never struck sharply,

as with a hammer, or allowed to fall on a hard

surface.

Be careful not to get water or mud on the ABS hy-

draulic unit.

• Drain the brake fluid from the front and rear brake lines.

○Drain the brake fluid through the bleed valve by pumping

the brake lever and pedal.

BRAKES 12-57

Anti-Lock Brake System (Equipped Models)

• Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System

(DFI) chapter)

Battery (see Battery Removal in the Electrical System

chapter)

Bolts [A]

Cover [B]

• Clean the ABS hydraulic unit.

CAUTION

Clean all fittings on the ABS hydraulic unit and the

rear master cylinder because dirt around the banjo

bolts could contaminate the brake fluid in the line

during removal/installation.

Spread out a shop towel around the ABS hydraulic

unit before removing the brake line so that brake

fluid does not leak on the parts.

• Remove the brake pipe joint nuts [A] [B] [C] [D].

• Tape the brake line opening to prevent brake fluid leakage

or contamination by foreign matter.

CAUTION

Brake fluid quickly ruins painted plastic surfaces;

any spilled fluid should be completely washed away

immediately.

• Disconnect the connector [A].

○Unlock the joint lock [B] as shown in the figure.

• Remove the bolts [A].

• Remove the ABS hydraulic unit with bracket.

12-58 BRAKES

Anti-Lock Brake System (Equipped Models)

• Remove the bolts [A] and bracket [B].

CAUTION

The ABS hydraulic unit has been adjusted and set

with precision at the factory. Do not try to disas-

semble and repair the ABS hydraulic unit.

ABS Hydraulic Unit Installation

• Install the ABS hydraulic unit to the bracket.

CAUTION

Brake fluid quickly ruins painted plastic surfaces;

any spilled fluid should be completely washed away

immediately.

• Insert the bolts [A] into the grommets [B].

• Route the lead correctly, and connector [A] securely.

○Lock the joint lock [B] as shown in the figure.

• Install the brake pipes correctly as shown in the figure.

48° [A]

71° [B]

30° [C]

38.5° [D]

• Tighten the joint nuts.

Torque - Brake Pipe Joint Nuts: 18 N·m (1.8 kgf·m, 13 ft·lb)

• Bleed the brake line (see Brake Line Bleeding).

• Check the brake for good braking power, no brake drag,

and no fluid leakage.

• Install the removed parts (see appropriate chapters).

BRAKES 12-59

Anti-Lock Brake System (Equipped Models)

ABS Hydraulic Unit Inspection

• Remove the ABS hydraulic unit (see ABS Hydraulic Unit

Removal).

• Visually inspect the ABS hydraulic unit.

Replace the ABS hydraulic unit if any of them are cracked,

or otherwise damaged.

• Visually inspect the connector terminals [A].

Replace the ABS hydraulic unit or main harness if either

of the terminals are cracked, bent, or otherwise damaged.

If the ABS hydraulic unit connector is clogged with mud

or dust, blow it off with compressed air.

Front Wheel Rotation Sensor Removal

CAUTION

The wheel rotation sensor should be handled care-

fully, never struck sharply, as with a hammer, or al-

lowed to fall on a hard surface since the wheel rota-

tion sensor is precision made. Be careful not to get

water or mud on the wheel rotation sensor.

Do not try to disassemble or repair the wheel rota-

tion sensor.

• Remove:

Left Middle Fairing (see Middle Fairing Removal in the

Frame chapter)

Connector [A] (Disconnect)

Clamps [B]

• Remove:

Bolts [A]

Bracket Bolt [B]

Clamps [C]

Front Wheel Rotation Sensor [D]

Front Wheel Rotation Sensor Installation

• Installation is the reverse of removal.

○Route the lead correctly (see Cable, Wire, and Hose

Routing section in the Appendix chapter).

12-60 BRAKES

Anti-Lock Brake System (Equipped Models)

Rear Wheel Rotation Sensor Removal

CAUTION

The wheel rotation sensor should be handled care-

fully, never struck sharply, as with a hammer, or al-

lowed to fall on a hard surface since the wheel rota-

tion sensor is precision made. Be careful not to get

water or mud on the wheel rotation sensor.

Do not try to disassemble or repair the wheel rota-

tion sensor.

• Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System

(DFI) chapter)

Connector [A] (Disconnect)

• Clear the connector from the bracket.

• Remove:

Bracket Bolts [A]

Clamps [B]

Bolts [C]

Rear Wheel Rotation Sensor [D]

Rear Wheel Rotation Sensor Installation

• Installation is the reverse of removal.

○Route the lead correctly (see Cable, Wire, and Hose

Routing section in the Appendix chapter).

BRAKES 12-61

Anti-Lock Brake System (Equipped Models)

Wheel Rotation Sensor Inspection

• Remove the front wheel rotation sensor [A] from the front

fork.

• Remove the rear wheel rotation sensor [B] from the

caliper bracket.

• Visually inspect the wheel rotation sensors.

Replace the wheel rotation sensor if it is cracked, bent, or

otherwise damaged.

Wheel Rotation Sensor Air Gap Inspection

• Raise the front/rear wheel off the ground (see Front/Rear

Wheel Removal in the Wheels/Tires chapter).

• Measure the air gap between the sensor and sensor rotor

at several points by turning the wheel slowly.

Thickness Gauge [A]

Air Gap

Standard:

Front

0.7 ∼ 0.9 mm (0.028 ∼ 0.035 in.)

Rear

0.7 ∼ 0.9 mm (0.028 ∼ 0.035 in.)

NOTE

○The sensor air gap cannot be adjusted.

If the air gap is not within the specification, inspect the hub

bearing (see Hub Bearing Inspection in the Wheels/Tires

chapter), sensor installation condition and sensor (see

Wheel Rotation Sensor Inspection).

12-62 BRAKES

Anti-Lock Brake System (Equipped Models)

Wheel Rotation Sensor Rotor Inspection

• Remove:

Wheels (see Front/Rear Wheel Removal in the

Wheels/Tires chapter)

Brake Disc Mounting Bolts [A]

Sensor Rotor [B]

• Visually inspect the wheel rotation sensor rotor.

If the rotor is deformed or damaged (chipped teeth [A]),

replace the sensor rotor with a new one.

If there is iron or other magnetic deposits [B], remove the

deposits.

ABS Solenoid Valve Relay Fuse (20 A) Removal

• Refer to the Fuse Box Fuse Removal in the Electrical Sys-

tem chapter.

ABS Motor Relay Fuse (30 A) Removal

• Refer to the Fuse Box Fuse Removal in the Electrical Sys-

tem chapter.

ABS ECU Fuse (10 A) Removal

• Refer to the Fuse Box Fuse Removal in the Electrical Sys-

tem chapter.

13-2 SUSPENSION

Exploded View

SUSPENSION 13-3

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Front Axle Clamp Bolts

20

2.0

15

AL

2

Front Fork Bottom Allen Bolts

23

2.3

17

L

3

Front Fork Clamp Bolts (Lower)

30

3.1

22

AL

4

Front Fork Clamp Bolts (Upper)

20

2.0

15

5

Front Fork Top Plugs

22

2.2

16

6

Piston Rod Nuts

28

2.9

21

AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

13-4 SUSPENSION

Exploded View

SUSPENSION 13-5

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Rear Shock Absorber Nut (Lower)

34

3.5

25

2

Rear Shock Absorber Nut (Upper)

34

3.5

25

3

Swingarm Pivot Adjusting Collar

20

2.0

15

4

Swingarm Pivot Adjusting Collar Locknut

98

10.0

72

5

Swingarm Pivot Shaft Nut

108

11.0

80

6

Tie-Rod Nuts

59

6.0

44

7

Uni-Trak Rocker Arm Nut

34

3.5

25

G: Apply grease.

R: Replacement Parts

SUSPENSION 13-9

Front Fork

Rebound Damping Force Adjustment

• To adjust the rebound damping force, turn the rebound

damping adjuster [A] until you feel a click.

○The standard adjuster setting for the average-build rider

of 68 kg (150 lb) with no passenger and no accessories

is the 5th click from the 1st click of the fully clockwise

position.

WARNING

If both adjusters are not adjusted equally, handling

may be impaired and a hazardous condition may

result.

○The damping force can be left soft for average riding. But

it should be adjusted harder for high speed riding or riding

with a passenger. If the damping feels too soft or too stiff,

adjust it in accordance with the following table.

Rebound Damping Force Adjustment

Adjuster

Damping

Setting

Load

Road

Speed

Position

Force

11

Weak

Soft

Light

Good

Low

↑

↑

↑

↑

↑

↑

↓

↓

↓

↓

↓

↓

0

Strong

Hard

Heavy

Bad

High

Compression Damping Force Adjustment

• To adjust the compression damping force, turn the com-

pression damping adjuster [A] until you feel a click.

○The standard adjuster setting for the average-build rider

of 68 kg (150 lb) with no passenger and no accessories

is the 10th click from the 1st click of the fully clockwise

position.

WARNING

If both adjusters are not adjusted equally, handling

may be impaired and a hazardous condition may

result.

○The damping force can be left soft for average riding. But

it should be adjusted harder for high speed riding or riding

with a passenger. If the damping feels too soft or too stiff,

adjust it in accordance with the following table.

Compression Damping Force Adjustment

Adjuster

Damping

Setting

Load

Road

Speed

Position

Force

13

Weak

Soft

Light

Good

Low

↑

↑

↑

↑

↑

↑

↓

↓

↓

↓

↓

↓

0

Strong

Hard

Heavy

Bad

High

13-10 SUSPENSION

Front Fork

Spring Preload Adjustment

• Turn the spring preload adjuster [A] to change spring

preload setting.

○The standard adjuster setting for the average-build rider

of 68 kg (150 lb) with no passenger and no accessories is

the 15 mm (0.59 in.) [B] from top as shown in the figure.

Adjuster Protrusion (from top)

Standard:

15 mm (0.59 in.)

Usable Range:

4 ∼ 19 mm (0.16 ∼ 0.75 in.)

WARNING

If both adjusters are not adjusted equally, handling

may be impaired and a hazardous condition may

result.

○The spring preload can be left soft for average riding. But

it should be adjusted harder for high speed riding or riding

with a passenger. If the spring action feels too soft or too

stiff, adjust it in accordance with the following table.

Spring Action

Adjuster

Damping

Setting

Load

Road

Speed

Position

Force

19 mm

Weak

Soft

Light

Good

Low

↑

↑

↑

↑

↑

↑

↓

↓

↓

↓

↓

↓

4 mm

Strong

Hard

Heavy

Bad

High

Front Fork Removal (Each Fork Leg)

• Remove:

Middle Fairings (see Middle Fairing Removal in the

Frame chapter)

Inner Covers (see Inner Cover Removal in the Frame

chapter)

Front Wheel (see Front Wheel Removal in the

Wheels/Tires chapter)

Front Fender (see Front Fender Removal in the Frame

chapter)

Loosen the upper fork clamp bolt [A] and fork top plug [B]

beforehand if the fork leg is to be disassembled.

NOTE

○Loosen the top plug after loosening the upper fork

clamp bolt.

• Loosen the upper fork clamp bolt and lower fork clamp

bolts [C].

• With a twisting motion, work the fork leg down and out.

SUSPENSION 13-11

Front Fork

Front Fork Installation

• Install the fork so that the top end [A] of the outer tube as

shown in the figure.

21.5 mm (0.85 in.) [B]

• Tighten the lower fork clamp bolts and fork top plug.

Torque - Front Fork Clamp Bolts (Lower):

30 N·m (3.1

kgf·m, 22 ft·lb)

Front Fork Top Plug: 22 N·m (2.2 kgf·m, 16 ft·lb)

• Tighten the upper fork clamp bolt.

Torque - Front Fork Clamp Bolt (Upper): 20 N·m (2.0 kgf·m,

15 ft·lb)

NOTE

○Tighten the two clamp bolts alternately two times to en-

sure even tightening torque.

○Tighten the top plug before tightening the upper fork

clamp bolt.

• Install the removed parts (see appropriate chapters).

• Adjust the spring preload and the damping force.

Front Fork Oil Change

• Remove the front fork (see Front Fork Removal).

• Hold the inner tube lower end in a vise.

• Unscrew the top plug [A] out of the outer tube.

• Install the clamps [A] as shown in the figure.

NOTE

○Set the clamps so that the cutout [B] of the upper side

does not touch the tongue shape of stopper, pull up the

outer tube [C] to hold it by the clamps, and then tighten

the two bolts [D]. The outer tube is used as a guide.

Special Tools - Fork Spring Compressor: 57001-1540

Fork Spring Compressor: 57001-1587

13-12 SUSPENSION

Front Fork

• Insert the holder bar [A] into the axle hole of the front fork

[B].

• Insert the compression shaft and install the nut.

• Insert the lower end of the compression shaft [A] into the

hole [B] of the holder bar.

• Screw the adjust nut [A] onto the compression shaft as

shown in the figure.

• Screw the locknut [B].

About 20 mm (0.79 in.) [C]

• Set the other side compression shaft same process.

• Set the holder bar [A] and compression shafts [B].

• Screw in nuts [A] come out the piston rod nut.

SUSPENSION 13-13

Front Fork

• Holding the piston rod nut with a wrench [A], remove the

top plug [B] from the piston rod.

• Remove:

Washer [A]

Collar [B]

Rebound Damping Adjuster Rod [C]

Fork Spring [D]

• Drain the fork oil into a suitable container.

○Pump the piston rod [A] up and down at least ten times to

expel the oil from the fork.

Special Tool - Fork Piston Rod Puller, M12 × 1.25 [B]:

57001-1289

• Hold the fork tube upright, press the inner tube [A] and

the piston rod all the way down.

• Pour in the type and amount of fork oil specified.

Fork Oil

Viscosity:

KAYABA 01 (KHL15-10) or equivalent SAE

5W

Amount (per side):

When changing oil: Approx. 480 mL (16.2 US oz.)

After disassembly and completely dry:

563 ±4 mL (19.0 ±0.14 US oz.)

13-14 SUSPENSION

Front Fork

If necessary, measure the oil level as follows.

○Hold the inner tube vertically in a vise.

○Pump the inner tube several times to expel air bubbles.

○Using the piston rod puller [A], move the piston rod [B] up

and down more than ten times in order to expel all the air

from the fork oil.

Special Tool - Fork Piston Rod Puller, M12 × 1.25: 57001

-1289

○Remove the piston rod puller.

○Wait until the oil level settles.

○With the fork fully compressed and the piston rod fully

pushed in, insert a tape measure or rod into the inner

tube, and measure the distance from the top of the inner

tube to the oil.

Oil Level (fully compressed, without spring)

Standard:

88 ±2 mm (3.46 ±0.08 in.)

(from the top of the inner tube)

NOTE

○Fork oil lever may also be measured using the fork oil

level gauge.

Special Tool - Fork Oil Level Gauge [A]: 57001-1290

○With the fork fully compressed and without fork spring,

insert the gauge tube into the inner tube [B] and position

the stopper across the top end [C] of the inner tube.

○Set the gauge stopper [D] so that its lower side shows the

oil level distance specified [E].

○Pull the handle slowly to pump out the excess oil until the

oil no longer comes out.

If no oil is pumped out, there is insufficient oil in the inner

tube. Pour in enough oil, then pump out the excess oil as

shown above.

• Screw the fork piston rod puller onto the end of the piston

rod.

Special Tool - Fork Piston Rod Puller, M12 × 1.25: 57001

-1289

• Pull the puller up above the outer tube top.

• Install the fork spring [A] with the smaller end facing [B]

upward.

• Install:

Collar

Washer

SUSPENSION 13-15

Front Fork

• Screw the rod nut [A] onto the piston rod [B] as shown in

the figure.

11 mm (0.43 in.) [C]

• Check the distance between the bottom end [A] of the

top plug and rebound damping adjuster [B] with a pair of

vernier caliper.

13 mm (0.51 in.) [C]

• Set the fork spring compressor on the washer using the

outer tube as a guide.

Special Tools - Fork Spring Compressor: 57001-1540

Fork Spring Compressor: 57001-1587

NOTE

○Set the clamps so that the cutout of the upper side does

not fit the hole of washer, pull up the outer tube to hold

it by the clamps, and then tighten the two bolts. The

outer tube is used as a guide.

• Hold the piston rod nut [A].

• Remove the piston rod puller [B].

• Install the rebound damping adjuster rod.

• Screw in the top plug [A] stopped onto the piston rod.

• Check the O-ring [B] on the top plug and replace it with a

new one if damaged.

• Holding the top plug with a wrench, tighten the piston rod

nut [C] against the top plug.

Torque - Piston Rod Nut: 28 N·m (2.9 kgf·m, 21 ft·lb)

• While holding up the washer with the clamps, loosen the

fork spring compressor nuts.

• Remove the fork spring compressor.

13-16 SUSPENSION

Front Fork

• Raise the outer tube and screw the top plug into it and

install it to the steering stem.

• Screw in the spring preload adjuster [A] of the top plug

so that the distance between the adjuster top and the top

plug surface is 15 mm (0.59 in.) [B].

• Turn in the rebound damping adjuster until the fully tight-

ened position and turn backward the 5th click.

• Install the front fork (see Front Fork Installation).

Front Fork Disassembly

• Remove the front fork (see Front Fork Removal).

• Drain the fork oil (see Front Fork Oil Change).

• Hold the front fork in a vise [A].

• Stop the cylinder [B] from turning by using the fork cylinder

holder [C].

Special Tool - Fork Cylinder Holder: 57001-1287

• Unscrew the Allen bolt [D], then take the bolt and gasket

out of the bottom of the inner tube.

• Take the cylinder unit [A].

○Do not disassemble the cylinder unit.

• Separate the outer tube from the inner tube.

• Pull out the dust seal.

• Remove the retaining ring [A] from the outer tube.

• Remove the oil seal [B] and washer [C].

Front Fork Assembly

• Replace the following parts with a new one.

Oil Seal

Bottom Allen Bolt Gasket

• Insert the cylinder unit [A] into the inner tube [B].

• Stop the cylinder from turning by using the fork cylinder

holder.

Special Tool - Fork Cylinder Holder: 57001-1287

• Apply a non-permanent locking agent to the thread of the

Allen bolt, and tighten it.

Torque - Front Fork Bottom Allen Bolt: 23 N·m (2.3 kgf·m,

17 ft·lb)

SUSPENSION 13-17

Front Fork

• Install the following parts into the inner tube [A].

Dust Seal [B]

Retaining Ring [C]

Oil Seal [D]

Washer [E]

• Insert the inner tube to the outer tube.

• After installing the washer, install the oil seal [A] by using

the fork oil seal driver [B].

Special Tool - Fork Oil Seal Driver,

43: 57001-1530

• Install the retaining ring and dust seal into the outer tube.

• Pour in the specified type of oil (see Front Fork Oil

Change).

Inner Tube Inspection

• Visually inspect the inner tube [A], and repair any dam-

age.

• Nicks or rust damage can sometimes be repaired by using

a wet-stone to remove sharp edges or raised areas which

cause seal damage.

If the damage is not repairable, replace the inner tube.

Since damage to the inner tube damages the oil seal,

replace the oil seal whenever the inner tube is repaired

or replaced.

CAUTION

If the inner tube is badly bent or creased, replace

it.

Excessive bending, followed by subsequent

straightening, can weaken the inner tube.

• Temporarily assemble the inner and outer tubes, and

pump them back and forth manually to check for smooth

operation.

• If you feel binding or catching, the inner and outer tubes

must be replaced.

WARNING

A straightened inner or outer fork tube may fall in

use, possibly causing an accident. Replace a badly

bent or damaged inner or outer tube and inspect the

other tube carefully before reusing it.

13-18 SUSPENSION

Front Fork

Dust Seal Inspection

• Inspect the dust seal [A] for any signs of deterioration or

damage.

Replace it if necessary.

Spring Tension

• Since a spring becomes shorter as it weakens, check its

free length [A] to determine its condition.

If the spring of either fork leg is shorter than the service

limit, it must be replaced. If the length of a replacement

spring and that of the remaining spring vary greatly, the

remaining spring should also be replaced in order to keep

the fork legs balanced for motorcycle stability.

Spring Free Length

Standard:

257 mm (10.12 in.)

Service Limit:

252 mm (9.92 in.)

SUSPENSION 13-19

Rear Shock Absorber

Rebound Damping Force Adjustment

• To adjust the rebound damping force, turn the lower

damping adjuster [A] to the desired position, until you

feel a click.

○The standard adjuster setting for an average-build rider

of 68 kg (150 lb) with no passenger and no accessories

is the 1 2/4 turns out from the fully clockwise position.

Rebound Damping Force Adjustment

Adjuster

Damping

Setting

Load

Road

Speed

Position

Force

2 2/4 Turns

Weak

Soft

Light

Good

Low

Out

↑

↑

↑

↑

↑

↑

↓

↓

↓

↓

↓

↓

0

Strong

Hard

Heavy

Bad

High

Compression Damping Force Adjustment

• To adjust the compression damping force, turn the upper

damping adjuster [A] to the desired position until you feel

a click.

○The standard adjuster setting for the average-build rider

of 68 kg (150 lb) with no passenger and no accessories

is the 2 1/4 turns out from the fully clockwise position.

Rebound Damping Force Adjustment

Adjuster

Damping

Setting

Load

Road

Speed

Position

Force

4 Turns

Weak

Soft

Light

Good

Low

Out

↑

↑

↑

↑

↑

↑

↓

↓

↓

↓

↓

↓

0

Strong

Hard

Heavy

Bad

High

Spring Preload Adjustment

• Remove the rear shock absorber from the frame (see

Rear Shock Absorber Removal).

• Loosen the locknut and turn out the adjusting nut to free

the spring.

Special Tool - Hook Wrench T=3.2 R37: 57001-1522

13-20 SUSPENSION

Rear Shock Absorber

• To adjust the spring preload, turn in the adjusting nut [A]

to the desired position and tighten the locknut [B].

Spring Length [C]

Spring Preload Setting

Standard:

Spring length 175.5 mm (6.9 in.)

Usable Range:

Spring length 175.5 ∼ 191.5 mm

(6.909 ∼ 7.539 in.)

○The standard adjusting nut setting for an average-build

rider of 68 kg (150 lb) with no passenger and no acces-

sories is 175.5 mm (6.9 in.) spring length.

• Remove the chain cover [A] (see Drive Chain Removal in

the Final Drive chapter).

• Remove the bolts [B] and left foot guard [C] for turning the

hook wrench easily.

• To adjust the spring preload, turn in the adjusting nut to

the desired position and tighten the locknut by using hook

wrenches [A] with the rear shock absorber attached the

frame.

Special Tool - Hook Wrench T=3.2 R37: 57001-1522

If the spring action feels too soft or too stiff, adjust it.

Spring Adjustment

Adjuster

Damping

Setting

Load

Road

Speed

Position

Force

191.5 mm

Weak

Soft

Light

Good

Low

(7.539 in.)

↑

↑

↑

↑

↑

↑

↓

↓

↓

↓

↓

↓

175.5 mm

(6.909 in.)

Strong

Hard

Heavy

Bad

High

Rear Shock Absorber Removal

• Remove:

Rear Fairing (see Rear Fairing Removal in the Frame

chapter)

Bolts [A] (Both Sides)

Bracket [B]

Lower Fairings (see Lower Fairings Removal in the

Frame chapter).

• Raise the rear wheel off the ground with the jack.

Special Tools - Jack: 57001-1238

Jack Attachment: 57001-1608

SUSPENSION 13-21

Rear Shock Absorber

• Squeeze the brake lever slowly and it with a band [A].

WARNING

Be sure to hold the front brake when removing the

shock absorber, or the motorcycle may fall over. It

could cause an accident and injury.

• Remove:

Lower Shock Absorber Nut and Bolt [A]

Upper Tie-Rod Nut and Bolt [B]

• Remove the upper shock absorber nut and bolt [A]

• Remove the shock absorber downward.

Rear Shock Absorber Installation

• Tighten:

Torque - Rear Shock Absorber Nuts: 34 N·m (3.5 kgf·m, 25

ft·lb)

Tie-Rod Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb)

Rear Shock Absorber Inspection

• Remove the rear shock absorber (see Rear Shock Ab-

sorber Removal).

• Visually inspect the following items.

Smooth Stroke

Oil Leakage

Crack or Dent

If there is any damage to the rear shock absorber, replace

it.

• Visually inspect the rubber bushing.

If it show any signs of damage, replace it.

13-22 SUSPENSION

Rear Shock Absorber

Rear Shock Absorber Scrapping

WARNING

Since the reservoir tank of the rear shock absorber

contains nitrogen gas, do not incinerate the reser-

voir tank without first releasing the gas or it may

explode.

• Remove the rear shock absorber (see Rear Shock Ab-

sorber Removal).

• Drill the hole [A] of the reservoir tank using about 2 mm

(0.08 in.) drillbit.

WARNING

Since the high pressure gas is dangerous, do not

point the drill toward your face or body.

SUSPENSION 13-23

Swingarm

Swingarm Removal

• Remove:

Chain Cover (see Drive Chain Removal in the Final Drive

chapter)

Rear Wheel (see Rear Wheel Removal in the

Wheels/Tires chapter)

Bolts [A]

Brackets [B]

• Remove:

Upper Tie-Rod Nut and Bolt [A]

Rear Shock Absorber [B] (see Rear Shock Absorber Re-

moval)

• Unscrew the swingarm pivot shaft locknut [A].

• Unscrew the swingarm pivot collar locknut [A] using the

nut wrench [B].

Special Tool - Swingarm Pivot Nut Wrench: 57001-1597

• Unscrew the swingarm pivot shaft [A] few times.

○Turn out the swingarm pivot adjusting collar [B].

• Pull out the pivot shaft right side of the motorcycle and

remove the swingarm.

13-24 SUSPENSION

Swingarm

Swingarm Installation

• Apply plenty of grease to the lip of the oil seals [A].

• Install the collar.

• Place the adjusting collar [A] the frame [B] as shown in

the figure.

11 mm (0.43 in.) [C]

• Insert the pivot shaft [A] into the frame from the right side.

• Tighten the pivot shaft so that the clearance between the

adjusting collar [B] and the ball bearing [C] come to 0 mm

(0 in.).

Torque - Swingarm Pivot Adjusting Collar:

20 N·m (2.0

kgf·m, 15 ft·lb)

• Tighten the adjusting collar locknut [A] with the swingarm

pivot nut wrench [B].

Special Tool - Swingarm Pivot Nut Wrench: 57001-1597

Torque - Swingarm Pivot Adjusting Collar Locknut: 98 N·m

(10.0 kgf·m, 72 ft·lb)

• Tighten the pivot shaft nut [A].

Torque - Swingarm Pivot Shaft Nut: 108 N·m (11.0 kgf·m,

80 ft·lb)

• Install the removed parts (see appropriate chapters).

SUSPENSION 13-25

Swingarm

Swingarm Bearing Removal

• Remove:

Swingarm (see Swingarm Removal)

Collar [A]

Oil Seals [B]

Sleeve [C]

Circlip [D] (Right Side)

Special Tool - Inside Circlip Pliers: 57001-143

• Remove the ball bearing and needle bearings.

Special Tool - Oil Seal & Bearing Remover [A]: 57001-1058

Swingarm Bearing Installation

• Replace the ball and needle bearings [A] with new ones.

• Install the ball and needle bearings so that the manufac-

turer’s marks face out.

Special Tools - Bearing Driver Set: 57001-1129

Needle Bearing Driver,

28 [B]: 57001-1610

Spacer

28: 57001-1663

13-26 SUSPENSION

Swingarm

• Install the needle bearings [A], ball bearing [B] and oil

seals [C] position as shown in the figure.

Circlip [D]

32 mm (1.26 in.) [E]

17 mm (0.67 in.) [F]

27.5 mm (1.08 in.) [G]

9.5 mm (0.37 in.) [H]

Swingarm Bearing, Sleeve Inspection

CAUTION

Do not remove the bearings for inspection. Re-

moval may damage them.

• Inspect the needle bearings [A] and ball bearing installed

in the swingarm.

○The rollers and ball in a bearing normally wear very little,

and wear is difficult to measure. Instead of measuring,

visually inspect the bearing for abrasion, discoloration, or

other damage.

If the needle bearing and sleeve [B] show any sings of

abnormal wear, discoloration, or damage, replace them

as a set.

SUSPENSION 13-27

Swingarm

• Turn the bearing in the swingarm back and forth [A] while

checking for plays, roughness, or binding.

If bearing play, roughness, or binding is found, replace

the bearing.

• Examine the bearing seal [B] for tears or leakage.

If the seal is torn or is leaking, replace the bearing.

Chain Guide Inspection

• Refer to the Chain Guide Wear Inspection in the Periodic

Maintenance chapter.

13-28 SUSPENSION

Tie-Rod, Rocker Arm

Tie-Rod Removal

• Squeeze the brake lever slowly and hold it with a band

[A].

• Remove:

Lower Fairings (see Lower Fairing Removal in the Frame

chapter)

Rear Fairing (see Rear Fairing Removal in the Frame

chapter)

Bracket (see Rear Shock Absorber Removal)

• Raise the rear wheel off the ground with the jack.

Special Tools - Jack: 57001-1238

Jack Attachment: 57001-1608

• Remove:

Upper Tie-Rod Nut and Bolt [A]

Lower Tie-Rod Nut and Bolt [B]

Tie-Rods [C]

Tie-Rod Installation

• Apply grease to the inside of the grease seals.

• Install each tie-rod so that the arrow faces [A] forward.

• Tighten:

Torque - Tie-Rod Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb)

Rocker Arm Removal

• Squeeze the brake lever slowly and hold it with a band.

• Remove:

Lower Fairings (see Lower Fairing Removal in the Frame

chapter)

Rear Fairing (see Rear Fairing Removal in the Frame

chapter)

Bracket (see Rear Shock Absorber Removal)

Muffler Bodies (see Muffler Body Removal in the Engine

Top End chapter)

• Raise the rear wheel off the ground with the jack.

Special Tools - Jack: 57001-1238

Jack Attachment: 57001-1608

• Remove:

Lower Rear Shock Absorber Nut and Bolt [A]

Lower Tie-Rod Nut and Bolt [B]

Rocker Arm Nut and Bolt [C]

Rocker Arm [D]

SUSPENSION 13-29

Tie-Rod, Rocker Arm

Rocker Arm Installation

• Apply grease to the inside of the grease seals.

• Tighten:

Torque - Uni-Trak Rocker Arm Nut: 34 N·m (3.5 kgf·m, 25

ft·lb)

Tie-Rod Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb)

Rear Shock Absorber Nut (Lower): 34 N·m (3.5

kgf·m, 25 ft·lb)

Tie-Rod and Rocker Arm Bearing Removal

• Remove:

Tie-Rods (see Tie-Rod Removal)

Rocker Arm (see Rocker Arm Removal)

Sleeves [A]

Oil Seals [B]

Swingarm [C] (see Swingarm Removal)

• Remove the needle bearings [D], using the bearing re-

mover head and bearing remover shaft.

Special Tools - Bearing Remover Head,

20 ×

22: 57001

-1293

Bearing Remover Shaft,

13: 57001-1377

Tie-Rod and Rocker Arm Bearing Installation

• Replace the needle bearing and oil seals with new ones.

• Apply plenty of grease to the lips of the oil seals.

• Install the needle bearings and oil seals position as shown

in the figure.

13-30 SUSPENSION

Tie-Rod, Rocker Arm

○Screw the needle bearing driver [A] into the driver holder

[B].

○Insert the needle bearing driver into the needle bearing

[C] and press the needle bearing into the housing until

the driver contacts the end surface of the housing.

Bearing Pressing Depth: 5.5 mm (0.22 in.) [D]

5.0 mm (0.20 in.) [E]

NOTE

○For a bearing of inner diameter 18, select the pressing

side of the needle bearing driver according to its press-

ing depth.

Special Tools - Bearing Driver Set: 57001-1129

Needle Bearing Driver,

17/

18:

57001

-1609

Spacer,

18 [F]: 57001-1636

Needle Bearing Driver,

20 & Spacer,

28:

57001-1678

NOTE

○Install the needle bearings so that the marked side

faces in.

Needle Bearing [A]

Oil Seals [B]

Front [C]

Right Side [D]

Left Side [E]

Rear Shock Absorber [F]

Tie-Rods [G]

Rocker Arm [H]

7.5 mm (0.30 in.) [I]

10 mm (0.39 in.) [J]

5.5 mm (0.22 in.) [K]

5.0 mm (0.20 in.) [L]

SUSPENSION 13-31

Tie-Rod, Rocker Arm

Rocker Arm/Tie-Rod Bearing, Sleeve Inspection

CAUTION

Do not remove the bearings for inspection. Re-

moval may damage them.

• Visually inspect the locker arm, or tie-rod sleeves [A] and

needle bearings [B].

• The rollers in a needle bearing normally wear very little,

and wear is difficult to measure. Instead of measuring,

inspect the bearing for abrasion, color change, or other

damage.

If there is any doubt as to the condition of any of the nee-

dle bearings or sleeve, replace the sleeve and needle

bearings as a set.

Rocker Arm/Tie-Rod Bearing Lubrication

NOTE

○Since the bearings are packed with grease, lubrication

is not required.

14-2 STEERING

Exploded View

STEERING 14-3

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Front Fork Clamp Bolts (Lower)

30

3.1

22

AL

2

Front Fork Clamp Bolts (Upper)

20

2.0

15

3

Handlebar Bolts

34

3.5

25

L

4

Handlebar Holder Bolts

25

2.5

18

AL

5

Steering Stem Head Nut

78

8.0

58

6

Steering Stem Nut

23

2.3

17

7

Switch Housing Screws

3.5

0.36

31 in·lb

AD: Apply adhesive.

AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

14-4 STEERING

Special Tools

Head Pipe Outer Race Press Shaft:

Steering Stem Bearing Driver,

42.5:

57001-1075

57001-1344

Steering Stem Nut Wrench:

Steering Stem Bearing Driver Adapter,

41.5:

57001-1100

57001-1345

Bearing Driver Set:

Head Pipe Outer Race Driver,

55:

57001-1129

57001-1446

14-6 STEERING

Steering Stem

Stem, Stem Bearing Removal

• Remove:

Upper Fairing (see Upper Fairing Removal in the Frame

chapter)

Front Wheel (see Front Wheel Removal in the

Wheels/Tires chapter)

Handlebars (see Handlebar Removal)

Front Forks (see Front Fork Removal in the Suspension

chapter)

Bracket Bolts [A]

Cover Bolts [B] and Cover [C]

• Remove:

Steering Stem Head Nut [A] and Washer [B]

Steering Stem Head [C]

• Bend the claws [A] of lock washer straighten.

• Remove the steering stem locknut [B].

Special Tool - Steering Stem Nut Wrench: 57001-1100

• Remove the lock washer.

• Pushing up the stem base, and remove the steering stem

nut [A] with stem cap [B].

Special Tool - Steering Stem Nut Wrench [C]: 57001-1100

• Remove:

Steering Stem [D]

Upper Ball Bearing Inner Race and Ball Bearing

• To remove the ball bearing outer races [A] pressed into

the head pipe [B], insert a bar [C] into the recesses [D]

of head pipe, and applying it to both recess alternately

hammer it to drive the race out.

NOTE

○If either steering stem bearing is damaged, it is recom-

mended that both the upper and lower bearings (includ-

ing outer races) should be replaced with new ones.

STEERING 14-7

Steering Stem

• Remove the lower ball bearing inner race (with its oil seal)

[A] which is pressed onto the steering stem with a suitable

commercially available chisel [B].

Stem, Stem Bearing Installation

• Replace the bearing outer races with new ones.

• Drive them into the head pipe at the same time.

Special Tools - Head Pipe Outer Race Press Shaft [A]:

57001-1075

Bearing Driver Set: 57001-1129

Head Pipe Outer Race Driver,

55 [B]: 57001

-1446

• Apply grease to the outer races.

• Replace the bearing inner races and oil seal with new

ones.

• Apply grease to the oil seal.

• Install the oil seal [A] on the steering stem, and drive the

lower ball bearing inner race [B] applied the grease onto

the stem.

Special Tools - Steering Stem Bearing Driver,

42.5 [C]:

57001-1344

Steering Stem Bearing Driver Adapter,

41.5 [D]: 57001-1345

• Install the lower ball bearing [A] onto the stem.

• Grease the following.

Inner and Outer Races

Lower and Upper Ball Bearings

○The lower and upper ball bearings are identical.

• Install the stem [A] through the head pipe and install the

ball bearing [B] and inner race [C] on it.

• Install:

Stem Cap [D]

Steering Stem Nut [E]

14-8 STEERING

Steering Stem

• Settle the bearings in place as follows.

○Tighten the steering stem nut with 55 N·m (5.6 kgf·m, 41

ft·lb) of torque first, and loosen it a fraction of a turn until

it turns lightly. Afterward tighten it again with specified

torque using a steering stem nut wrench [A].

Special Tool - Steering Stem Nut Wrench: 57001-1100

Torque - Steering Stem Nut: 23 N·m (2.3 kgf·m, 17 ft·lb)

• Install the lock washer so that claw [A] of washer fit the

notch [B] of steering stem locknut [C].

• First tighten the steering stem locknut by hand until the

resistance is felt fully, then tighten the steering stem lock

nut so that align the claw [A] of stem lock nut to the notch

[B] of stem nut by hand.

• Check that there is no play and the steering stem turns

smoothly without rattles. If not, the steering stem bearing

may be damaged.

• Bend the claw of lock washer to steering stem nut notch.

• Install the stem head [A] to the steering stem [B].

• Install the washer, and temporary tighten the stem head

nut [C].

• Install the front forks (see Front Fork Installation in the

Suspension chapter).

STEERING 14-9

Steering Stem

NOTE

○Tighten the upper front fork clamp bolts [A] first, next the

stem head nut [B], last the lower front fork clamp bolts

[C].

○Tighten the two lower fork clamp bolts alternately two

times to ensure even tightening torque.

Torque - Front Fork Clamp Bolts (Upper):

20 N·m (2.0

kgf·m, 15 ft·lb)

Steering Stem Head Nut: 78 N·m (8.0 kgf·m, 58

ft·lb)

Front Fork Clamp Bolts (Lower):

30 N·m (3.1

kgf·m, 22 ft·lb)

WARNING

Do not impede the handlebar turning by routing the

cables, harnesses and hoses improperly (see Ca-

ble, Wire, and Hose Routing section in the Appen-

dix chapter).

• Install the removed parts (see appropriate chapters).

Steering Stem Bearing Lubrication

• Refer to the Steering Stem Bearing Lubrication in the Pe-

riodic Maintenance chapter.

Steering Stem Warp

• Whenever the steering stem is removed, or if the steering

can not be adjusted for smooth action, check the steering

stem for straightness.

If the steering stem [A] is bent, replace the steering stem.

Stem Cap Deterioration, Damage

Replace the stem cap if its oil seal [A] shows damage.

14-10 STEERING

Handlebar

Handlebar Removal

• Remove:

Clutch Lever Clamp Bolts [A]

Clutch Lever Assembly [B]

Left Switch Housing [C]

Handlebar Weight [D]

• Remove:

Front Master Cylinder [A] (see Front Master Cylinder Re-

moval in the Brakes chapter)

Right Switch Housing [B]

Throttle Case [C]

Handlebar Weight [D]

Throttle Grip [E]

• Unscrew the handlebar holder bolts [A].

• Remove each handlebar holder [B] with handlebar [C].

• Hold the handlebar in a vise, and unscrew the handlebar

bolt [A].

• Remove the handlebar.

• Remove the left handlebar grip.

Handlebar Installation

• Apply adhesive cement to the inside of the left handlebar

grip.

• Fit the pin [A] of the handlebar to the recess [B] of the

handlebar holder.

• Apply a non-permanent locking agent to the threads of

the handlebar bolts.

• Tighten:

Torque - Handlebar Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)

STEERING 14-11

Handlebar

• Install the handlebar holder with handlebar on the steering

stem head.

• Tighten the handlebar holder bolts.

NOTE

○Tighten the handlebar holder bolt [A] first, next the han-

dlebar holder bolt [B].

○Tighten the two handlebar holder bolts alternately two

times to ensure even tightening torque.

Torque - Handlebar Holder Bolts:

25 N·m (2.5 kgf·m, 18

ft·lb)

• Install the front master cylinder (see Front Master Cylinder

Installation in the Brakes chapter).

• Install:

Throttle Grip

Throttle Cable Tips [A]

Throttle Cases [B]

○Fit the projection into a small hole in the handlebar.

• Apply a non-permanent locking agent to the threads of

the handlebar weight bolts, and tighten them.

• Install the left and right switch housings.

○Fit the projection [A] into a small hole [B] in the handlebar.

Torque - Switch Housing Screws: 3.5 N·m (0.36 kgf·m, 31

in·lb)

• Install the clutch lever (see Clutch Lever Installation in the

Clutch chapter).

15-2 FRAME

Exploded View

FRAME 15-3

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Center Stand Bolts

44

4.5

32

2

Front Footpeg Bracket Bolts

25

2.5

18

3

Sidestand Bolt

44

4.5

32

4

Sidestand Bracket Bolts

49

5.0

36

L

5

Sidestand Switch Bolt

8.8

0.90

78 in·lb

L

6. Center Stand (Equipped Models)

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

15-4 FRAME

Exploded View

FRAME 15-5

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Rear Fender Mounting Screws

1.2

0.12

11 in·lb

2

Rear Footpeg Bracket Bolts

25

2.5

18

3

Rear Frame Bolts

44

4.5

32

L

4

Rear Frame Pipe Bolts

44

4.5

32

5

Rear Frame Pipe Nuts

44

4.5

32

6. Center Stand Grip (Equipped Models)

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

15-6 FRAME

Exploded View

FRAME 15-7

Exploded View

Torque

No.

Fastener

Remarks

N·m

kgf·m

ft·lb

1

Grab Rail Mounting Bolts

25

2.5

18

2

Seat Lock Bracket Screws

1.2

0.12

11 in·lb

3. Reflector (United States and Canada Models)

4. Grab Rail (Equipped Models)

5. Seat Cover (Equipped Models)

15-8 FRAME

Exploded View

Content      ..     3      4      5      6     ..