Kawasaki Ninja 250R Motorcycle. Service Manual (2008-2012 year) - page 1
Ninja 250R
Motorcycle
Service Manual
PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart
2-3
Torque and Locking Agent
2-7
2
Specifications
2-12
Special Tools
2-14
Periodic Maintenance Procedures
2-15
Fuel System
2-15
Air Cleaner Element Cleaning
2-15
Air Cleaner Element Installation
2-16
Throttle Control System Inspection
2-16
Choke Operation Inspection
2-18
Engine Vacuum Synchronization Inspection
2-18
Idle Speed Inspection
2-19
Idle Speed Adjustment
2-19
Fuel Hose Inspection (fuel leak, damage, installation condition)
2-20
Evaporative Emission Control System (CAL Model)
2-20
Evaporative Emission Control System Inspection
2-20
Cooling System
2-21
Coolant Level Inspection
2-21
Radiator Hose Damage and Installation Condition Inspection
2-22
Coolant Filter Cleaning (Australia Model)
2-22
Air Suction System
2-22
Air Suction System Damage Inspection
2-22
Engine Top End
2-23
Valve Clearance Inspection
2-23
Valve Clearance Adjustment
2-24
Clutch
2-26
Clutch Operation Inspection
2-26
Wheels/Tires
2-27
Air Pressure Inspection
2-27
Wheel/Tire Damage Inspection
2-27
Tire Tread Wear, Abnormal Wear Inspection
2-27
Wheel Bearing Damage Inspection
2-28
Drive Train
2-29
Drive Chain Lubrication Condition Inspection
2-29
Drive Chain Slack Inspection
2-29
Drive Chain Slack Adjustment
2-30
Wheel Alignment Inspection
2-31
Drive Chain Wear Inspection
2-31
Chain Guide Inspection
2-32
Brake System
2-32
Brake Fluid Leak (Brake Hose and Pipe) Inspection
2-32
Brake Hose and Pipe Damage and Installation Condition Inspection
2-32
Brake Operation Inspection
2-33
Brake Fluid Level Inspection
2-33
Brake Pad Wear Inspection
2-34
Brake Light Switch Operation Inspection
2-34
Suspensions
2-35
Front Forks/Rear Shock Absorber Operation Inspection
2-35
Front Fork Oil Leak Inspection
2-35
Rear Shock Absorber Oil Leak Inspection
2-35
2-2 PERIODIC MAINTENANCE
Rocker Arm Operation Inspection
2-35
Tie-Rod Operation Inspection
2-36
Swingarm Pivot Lubrication
2-36
Steering System
2-36
Steering Play Inspection
2-36
Steering Play Adjustment
2-37
Steering Stem Bearing Lubrication
2-37
Electrical System
2-38
Lights and Switches Operation Inspection
2-38
Headlight Aiming Inspection
2-40
Sidestand Switch Operation Inspection
2-41
Engine Stop Switch Operation Inspection
2-42
Others
2-43
Chassis Parts Lubrication
2-43
Bolts, Nuts and Fasteners Tightness Inspection
2-44
Replacement Parts
2-45
Air Cleaner Element Replacement
2-45
Fuel Hose Replacement
2-45
Coolant Change
2-45
Radiator Hose and O-ring Replacement
2-47
Engine Oil Change
2-48
Oil Filter Replacement
2-48
Brake Hose and Pipe Replacement
2-49
Brake Fluid Change
2-49
Master Cylinder Rubber Parts Replacement
2-51
Caliper Rubber Parts Replacement
2-52
Spark Plug Replacement
2-53
PERIODIC MAINTENANCE 2-3
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in
good running condition.The initial maintenance is vitally important and must not be neglected.
Periodic Inspection
FREQUENCY
Whichever
* ODOMETER READING
comes
× 1 000 km
first
(× 1 000 mile)
See
Page
1
6
12
18
24
30
36
INSPECTION
Every
(0.6)
(3.75)
(7.5)
(11.25)
(15)
(18.75)
(22.5)
Fuel System
Air cleaner element - clean
2-15
•
•
•
Throttle control system (play,
year
2-16
smooth return, no drag) - inspect
•
•
•
•
Choke operation - inspect
year
2-18
•
•
•
•
Engine vacuum synchronization
2-18
- inspect
•
•
•
Idle speed - inspect
2-19
•
•
•
•
Fuel leak (fuel hose and pipe) -
year
2-20
inspect
•
•
•
•
Fuel hose and pipe damage -
year
2-20
inspect
•
•
•
•
Fuel hose and pipe installation
year
2-20
condition - inspect
•
•
•
•
Evaporative emission control
2-20
system function (CAL) - inspect
•
•
•
•
•
•
•
Cooling System
Coolant level - inspect
2-21
•
•
•
•
Coolant leak (water hose and
year
2-22
pipe) - inspect
•
•
•
•
Water hose damage - inspect
year
2-22
•
•
•
•
Water hose installation condition
year
2-22
- inspect
•
•
•
•
Coolant filter - clean
year
2-22
Air Suction System
Air suction system damage -
2-22
inspect
•
•
•
Engine Top End
Valve clearance - inspect
2-23
•
•
•
Clutch
Clutch operation (play,
disengagement, engagement) -
2-26
•
•
•
•
inspect
Wheels and Tires
Tire air pressure - inspect
year
2-27
•
•
•
Wheel/tire damage - inspect
2-27
•
•
•
Tire tread wear, abnormal wear
2-27
- inspect
•
•
•
Wheel bearing damage - inspect
year
2-28
•
•
•
2-4 PERIODIC MAINTENANCE
Periodic Maintenance Chart
FREQUENCY
Whichever
* ODOMETER READING
comes
× 1 000 km
first
(× 1 000 mile)
See
Page
1
6
12
18
24
30
36
INSPECTION
Every
(0.6)
(3.75)
(7.5)
(11.25)
(15)
(18.75)
(22.5)
Drive Train
Drive chain lubrication condition
Every 600 km (375 mile)
2-29
- inspect #
Drive chain slack - inspect #
Every 1
000 km (600
mile)
2-29
Drive chain wear - inspect #
2-31
•
•
•
Drive chain guide wear - inspect
2-32
•
•
•
Brakes
Brake fluid leak (brake hose and
year
2-32
pipe) - inspect
•
•
•
•
•
•
•
Brake hose and pipe damage -
year
2-32
inspect
•
•
•
•
•
•
•
Brake hose and pipe installation
year
2-32
condition - inspect
•
•
•
•
•
•
•
Brake operation (effectiveness,
year
2-33
play, no drag) - inspect
•
•
•
•
•
•
•
Brake fluid level - inspect
6 months
2-33
•
•
•
•
•
•
•
Brake pad wear - inspect #
2-34
•
•
•
•
•
•
Brake light switch operation -
2-34
inspect
•
•
•
•
•
•
•
Suspension
Front forks/rear shock absorber
operation (damping and smooth
2-35
•
•
•
stroke) - inspect
Front forks/rear shock absorber
year
2-35
oil leak - inspect
•
•
•
Rocker arm operation - inspect
2-35
•
•
•
Tie-rods operation - inspect
2-36
•
•
•
Swingarm pivot - lubricate
2-36
•
Steering
Steering play - inspect
year
2-36
•
•
•
•
Steering stem bearings -
2 years
2-37
lubricate
•
Electrical System
Lights and switches operation -
year
2-38
inspect
•
•
•
Headlight aiming - inspect
year
2-40
•
•
•
Sidestand switch operation -
year
2-41
inspect
•
•
•
Engine stop switch operation -
year
2-42
inspect
•
•
•
PERIODIC MAINTENANCE 2-5
Periodic Maintenance Chart
FREQUENCY
Whichever
* ODOMETER READING
comes
× 1 000 km
first
(× 1 000 mile)
See
Page
1
6
12
18
24
30
36
INSPECTION
Every
(0.6)
(3.75)
(7.5)
(11.25)
(15)
(18.75)
(22.5)
Others
Chassis parts - lubricate
year
2-42
•
•
•
Bolts and nuts tightness - inspect
2-43
•
•
•
•
#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or
frequent starting/stopping.
*: For higher odometer readings, repeat at the frequency interval established here.
2-6 PERIODIC MAINTENANCE
Periodic Maintenance Chart
Periodic Replacement Parts
FREQUENCY
Whichever
* ODOMETER READING
comes
× 1 000 km
first
(× 1 000
mile)
See
Page
1
12
24
36
48
CHANGE/REPLACE ITEM
Every
(0.6)
(7.5)
(15)
(22.5)
(30)
Air cleaner element # - replace
2 years
2-44
Fuel hose - replace
5 years
2-44
Coolant - change
3 years
2-44
•
Radiator hose and O-ring - replace
3 years
2-46
•
Engine oil # - change
year
2-47
•
•
•
•
•
Oil filter - replace
year
2-47
•
•
•
•
•
Brake hose and pipe - replace
4 years
2-48
•
Brake fluid - change
2 years
2-48
•
•
Rubber parts of master cylinder and caliper -
4 years
2-50
replace
•
Spark plug - replace
2-52
•
•
•
•
#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or
frequent starting/stopping.
*: For higher odometer readings, repeat at the frequency interval established here.
PERIODIC MAINTENANCE 2-7
Torque and Locking Agent
Use a torque wrench to tighten bolts and nuts to their specified torque values. If too little torque is
applied, the bolts and nuts could loosen and fall out. If too much torque is applied, the threads could
be sheared off.
To tighten a bolt or a nut, or to check their torque, loosen the bolt or nut one-half turn before tight-
ening it to the specified torque.
Letters used in the “Remarks” column mean:
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent to the threads.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution.
R: Replacement Parts
S: Tighten the fasteners following the specified sequence.
Si: Apply silicone grease.
SS: Apply silicone sealant.
Torque
Fastener
Remarks
N·m
kgf·m
ft·lb
Fuel System
Fuel Tap Mounting Bolts
2.5
0.25
22 in·lb
Fuel Gauge Mounting Bolts
6.9
0.7
61 in·lb
Air Cleaner Housing Cap Bolts/Screws
2.5
0.25
22 in·lb
Air Cleaner Housing Screws
1.15
0.12
10 in·lb
Air Cleaner Housing Mounting Bolts
9.8
1.0
87 in·lb
Air Cleaner Housing Clamp Screws
2.0
0.2
18 in·lb
Separate Bracket Bolt
9.8
1.0
87 in·lb
Cooling System
Water Temperature Switch
7.5
0.76
66 in·lb
SS
Thermostat Cover Bolts
9.8
1.0
87 in·lb
Thermostat Housing Mounting Bolts
9.8
1.0
87 in·lb
Radiator Fan Switch
23.5
2.4
17
Radiator Bolts
9.8
1.0
87 in·lb
Radiator Cap Bracket Bolt
9.8
1.0
87 in·lb
Water Pipe Bolts
9.8
1.0
87 in·lb
Water Hose Clamp Screws
3.0
0.31
27 in·lb
Drain Bolt
9.8
1.0
87 in·lb
Water Pump Cover Bolts
9.8
1.0
87 in·lb
Water Pump Bolts
9.8
1.0
87 in·lb
Reserve Tank Cap
-
-
-
Hand-Tighten
Reserve Tank Bolts
9.8
1.0
87 in·lb
Reserve Tank Bracket Bolt
9.8
1.0
87 in·lb
Engine Top End
Cylinder Head Cover Bolts
9.8
1.0
87 in·lb
Camshaft Sprocket Bolts
15
1.5
11
L
Chain Tensioner Cap Bolt
5.0
0.5
44 in·lb
Air Suction Cover Bolts
9.8
1.0
87 in·lb
Vacuum Switch Valve Bracket Bolts
9.8
1.0
87 in·lb
Rear Camshaft Chain Guide Bolt-Lower
17
1.7
13
2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
Torque
Fastener
Remarks
N·m
kgf·m
ft·lb
Chain Tensioner Mounting Bolts
9.8
1.0
87 in·lb
Camshaft Cap Bolts
12
1.2
106 in·lb
S
Cylinder Head Bolt (M6)
12
1.2
106 in·lb
MO, S
Cylinder Head Bolts (M8)
31.4
3.2
23
MO, S
Water Passage Plugs
20
2.0
15
L
Carburetor Holder Clamp Screws
2.0
0.2
18 in·lb
Water Drain Bolt
5.9
0.6
52 in·lb
Muffler Body Rear Cover Bolts
9.8
1.0
87 in·lb
L
Muffler Body Mounting Bolt
30
3.1
22
Muffler Body Clamp Bolt
17
1.7
13
Muffler Cover Bolts
9.8
1.0
87 in·lb
Muffler Cover Clamp Screw
6.9
0.70
61 in·lb
Exhaust Pipe Mounting Bolt
9.8
1.0
87 in·lb
Exhaust Pipe Holder Nuts
12
1.2
104 in·lb
Clutch
Clutch Lever Holder Clamp Bolts
8.8
0.9
78 in·lb
Clutch Spring Bolts
8.8
0.9
78 in·lb
Clutch Hub Nut
132
13.5
97.4
Oil Filler Plug
-
-
-
Hand-Tighten
Clutch Cover Bolts
9.8
1.0
87 in·lb
Engine Lubrication System
Oil Hose Banjo Bolts
19.6
2.0
14.5
Oil Pressure Relief Valve
15
1.5
11
L
Crankcase Oil Passage Plug
15
1.5
11
Oil Passage Plugs for Oil Pump
20
2.0
15
L
Oil Pipe Banjo Bolts
12
1.2
104 in·lb
Oil Drain Bolt
19.6
2.0
14.5
Oil Pressure Switch
15
1.5
11
SS
Oil Pressure Switch Terminal Bolt
1.5
0.15
13 in·lb
Oil Filter Mounting Bolts
19.6
2.0
14.5
Oil Breather Mounting Bolts
9.8
1.0
87 in·lb
L
Oil Pump Mounting Bolts
9.8
1.0
87 in·lb
L
Oil Screen Cover Bolts
9.8
1.0
87 in·lb
Plug
19.6
2.0
14.5
Breather Bolt
9.8
1.0
87 in·lb
Engine Removal/Installation
Engine Mounting Bracket Bolts and Nuts
64
6.5
47
Engine Mounting Nuts
64
6.5
47
Crankshaft/Transmission
Oil Breather Mounting Bolts
9.8
1.0
87 in·lb
L
Crankcase Bolts
6
12
1.2
104 in·lb
Crankcase Bolts
8 (L = 90)
24
2.4
18
MO, S
Crankcase Bolts
8 (L = 73)
19
1.9
14
MO, S
PERIODIC MAINTENANCE 2-9
Torque and Locking Agent
Torque
Fastener
Remarks
N·m
kgf·m
ft·lb
Starter Motor Clutch Bolts
34.3
3.5
25
L
Connecting Rod Big End Cap Nuts
27.5
2.8
20
MO
Shift Drum Bearing Holder Bolt
12
1.2
104 in·lb
L
Shift Drum Pin Plate Bolt
9.0
0.9
80 in·lb
L
Neutral Switch
15
1.5
11
External Shift Mechanism Return Spring Pin
19.6
2.0
14.5
L
Shift Drum Positioning Bolt
24.5
2.5
18
Shift Lever Link Bolt
12
1.2
104 in·lb
Front Tie-Rod Locknut (Left-Hand Threads)
7.0
0.7
62 in·lb
Rear Tie-Rod Locknut (Right-Hand Threads)
7.0
0.7
62 in·lb
EX250J8 ∼ JB (with a non-permanent locking
agent)
Shift Pedal Mounting Bolt
20
2.0
15
L
EX250JB ∼ JC (with a non-permanent locking
agent)
Shift Pedal Mounting Bolt
25
2.5
18
Wheels/Tires
Front Axle Nut
88
9.0
65
Rear Axle Nut
98
10.0
72
Final Drive
Engine Sprocket Cover Bolts
9.8
1.0
87 in·lb
Engine Sprocket Nut
127
13
94
MO
Rear Sprocket Nuts
59
6.0
44
R
Rear Sprocket Studs
-
-
-
L
Brakes
Brake Lever Pivot Bolt Locknut
5.9
0.6
52 in·lb
Bleed Valve
5.5
0.55
49 in·lb
Front Master Cylinder Clamp Bolts
8.8
0.9
78 in·lb
S
Brake Disc Mounting Bolts
27
2.8
20
L
Brake Hose Banjo Bolts
25
2.5
18
Front Caliper Mounting Bolts
25
2.5
18
Front Brake Light Switch Screw
1.0
0.1
9 in·lb
Brake Lever Pivot Bolt
1.0
0.1
9 in·lb
Front Reservoir Cap Screws
1.5
0.15
13 in·lb
Reservoir Mounting Bolt
6.9
0.7
61 in·lb
Bleed Valve
5.5
0.55
49 in·lb
Brake Pedal Pivot Bolt
8.8
0.9
78 in·lb
L
Push Rod Locknut
18
1.8
13
Brake Disc Mounting Bolts
27
2.8
20
L
Brake Hose Banjo Bolts
25
2.5
18
Rear Master Cylinder Mounting Bolts
25
2.5
18
Rear Caliper Mounting Bolts
25
2.5
18
2-10 PERIODIC MAINTENANCE
Torque and Locking Agent
Torque
Fastener
Remarks
N·m
kgf·m
ft·lb
Suspension
Front Fork Clamp Bolts (Upper)
21
2.1
15
Front Fork Clamp Bolts (Lower)
30
3.1
22
Front Fork Bottom Allen Bolts
20
2.0
15
L
Rocker Arm Pivot Nut
59
6.0
44
R
Tie-Rod Nuts
59
6.0
44
R
Rear Shock Absorber Mounting Nuts
59
6.0
44
R
Swingarm Pivot Nut
98
10.0
72
Steering
Steering Stem Nut
4.9
0.5
43 in·lb
Handlebar Holder Mounting Bolts
25
2.5
18
Steering Stem Head Bolt
44
4.5
32
Front Fork Clamp Bolts (Upper)
20
2.0
15
Front Fork Clamp Bolts (Lower)
30
3.1
22
Frame
Sidestand Nut
39
4.0
29
R
Front Footpeg Bracket Mounting Bolts
25
2.5
18
Rear Footpeg Bracket Mounting Bolts
25
2.5
18
Sidestand Switch Bolt
8.8
0.90
78 in·lb
L
Windshield Mounting Screws
0.42
0.043
3.7 in·lb
Electrical System
Tail/Brake Light Mounting Bolts
5.9
0.6
52 in·lb
Plugs on Alternator Cover
-
-
-
Hand-Tighten
Alternator Cover Bolts
9.8
1.0
87 in·lb
Alternator Rotor Bolt
88.2
9.0
65
Alternator Stator Bolts
12
1.2
104 in·lb
Regulator/Rectifier Bolts
9.8
1.0
87 in·lb
Starter Motor Clutch Bolts
34.3
3.5
25
L
Crankshaft Sensor Screws
3.0
0.30
27 in·lb
Ignition Coil Bolts
-
-
-
see text
Spark Plugs
13
1.3
115 in·lb
Starter Motor Terminal Locknut
9.8
1.0
87 in·lb
Starter Motor Assembly Bolts
3.5
0.36
31 in·lb
Starter Motor Mounting Bolts
9.8
1.0
87 in·lb
Starter Relay Terminal Nut
5.0
0.5
44 in·lb
Oil Pressure Switch
15
1.5
11
SS
Neutral Switch
15
1.5
11
PERIODIC MAINTENANCE 2-11
Torque and Locking Agent
The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and
nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the
values are for use with dry solvent-cleaned threads.
Basic Torque for General Fasteners
Threads
Torque
dia. (mm)
N·m
kgf·m
ft·lb
5
3.4 ∼ 4.9
0.35 ∼ 0.50
30 ∼ 43 in·lb
6
5.9 ∼ 7.8
0.60 ∼ 0.80
52 ∼ 69 in·lb
8
14 ∼19
1.4 ∼1.9
10.0 ∼ 13.5
10
25 ∼ 34
2.6 ∼ 3.5
19.0 ∼ 25
12
44 ∼ 61
4.5 ∼ 6.2
33 ∼ 45
14
73 ∼ 98
7.4 ∼ 10.0
54 ∼ 72
16
115 ∼ 155
11.5 ∼ 16.0
83 ∼ 115
18
165 ∼ 225
17.0 ∼ 23.0
125 ∼ 165
20
225 ∼ 325
23 ∼ 33
165 ∼ 240
2-12 PERIODIC MAINTENANCE
Specifications
Item
Standard
Service Limit
Fuel System
Throttle Grip Free Play
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
- - -
Idle Speed
1 300 ±50 r/min (rpm)
- - -
Carburetor Synchroniza-
Less than 2.7 kpa (2 cmHg) difference
- - -
tion Vacuum
between two carburetors
Air Cleaner Element
Polyurethane foam
- - -
Cooling System
Coolant:
Type (Recommended)
Permanent type antifreeze
- - -
Color
Green
- - -
Mixed Ratio
Soft water 50%, coolant 50%
- - -
Freezing Point
-35°C (-31°F)
- - -
Capacity
1.5 L (1.59 US qt)
- - -
Engine Top End
Valve Clearance:
Inlet
0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.)
- - -
Exhaust
0.22 ∼ 0.29 mm (0.0087 ∼ 0.0114 in.)
- - -
Clutch
Clutch Lever Free Play
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
- - -
Engine Lubrication System
Engine Oil:
Grade
API SG, SH, SJ, SL or SM with JASO MA,
- - -
MA1 or MA2
Viscosity
SAE 10W-40
- - -
Capacity
1.3 L (1.4 US qt) (when filter is not removed)
- - -
1.6 L (1.7 US qt) (when filter is removed)
Level
Between upper and lower level lines (Wait 2 ∼
- - -
3 minutes after idling or running)
Wheels/Tires
Tread Depth:
Front:
BRIDGESTONE
4.6 mm (0.181 in.)
1 mm (0.04 in.)
DUNLOP
4.5 mm (0.177 in.)
IRC
4.2 mm (0.165 in.)
Rear:
BRIDGESTONE
7.0 mm (0.276 in.)
2 mm (0.08 in.) up to
130 km/h (80 mph)
DUNLOP
7.4 mm (0.291 in.)
3 mm (0.12 in.) over
IRC
6.5 mm (0.256 in.)
130 km/h (80 mph)
Air pressure: (when Cold)
Front
Up to 170 kg (375 lb) load: 200 kPa (2.0
- - -
kgf/cm², 28 psi)
Rear
Up to 170 kg (375 lb) load: 225 kPa (2.25
- - -
kgf/cm², 32 psi)
Final Drive
Drive Chain Slack
20 ∼ 30 mm (0.8 ∼ 1.2 in.)
- - -
PERIODIC MAINTENANCE 2-13
Specifications
Item
Standard
Service Limit
Brakes
Brake Fluid:
Grade
DOT4
- - -
Brake Pad Lining
4.5 mm (0.18 in.)
1 mm (0.04 in.)
Thickness:
Brake Light Timing:
- - -
Front
Pulled ON
Rear
ON after 10 mm (0.39 in.) of pedal travel
Electrical System
Type
CR8E, U24ESR-N
- - -
2-14 PERIODIC MAINTENANCE
Special Tools
Steering Stem Nut Wrench:
Filler Cap Driver:
57001-1100
57001-1454
Vacuum Gauge KEK-55-5:
57001-1369
PERIODIC MAINTENANCE 2-15
Periodic Maintenance Procedures
Fuel System
Air Cleaner Element Cleaning
• Remove:
Right Side Cover (see Side Cover Removal in the Frame
chapter)
Air Cleaner Cap Bolts [A]
Air Cleaner Cap [B]
• Pull out the air cleaner element [A].
• Separate the plastic holders [A].
WARNING
If dirt or dust is allowed to pass through into the
carburetor, the throttle may become stuck, possibly
causing accident. Replace the air cleaner element
according to the maintenance chart.
NOTICE
If dirt gets through into the engine, excessive en-
gine wear and possibly engine damage will occur.
2-16 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
WARNING
Gasoline and low-flash point solvents can be
flammable and/or explosive and cause severe
burns. Clean the element in a well ventilated area,
and take care that there is no spark or flame any-
where near the working areas. Do not use gasoline
or low-flash point solvents to clean the element.
• Clean the element [A] in a bath of high-flash point solvent.
Squeeze it dry in a clean towel. Do not wring the element
or blow it dry; the element can be damaged.
• Check all the parts of the element for visible damage.
If any of the parts of the element are damaged, replace
them.
• After cleaning, saturate the element with a high-quality
foam-air-filter oil, squeeze out the excess, then wrap it in
a clean towel and squeeze it as dry as possible.
○Be careful not to tear the sponge filter.
Air Cleaner Element Installation
• Install the removed parts in reverse of removal.
• Torque the air cleaner cap bolts.
Torque - Air Cleaner Cap Bolts:
2.5 N·m (0.25 kgf·m, 22
in·lb)
Throttle Control System Inspection
• Check that the throttle grip moves smoothly from full open
to close [A], and the throttle closes quickly and completely
by the return spring in all steering positions.
If the throttle grip doesn’t return properly, check the throt-
tle cable routing, grip free play, and cable damage. Then
lubricate the throttle cable.
• Check the throttle grip free play [A].
If the free play is incorrect, adjust the throttle cable.
Throttle Grip Free Play
Standard:
2∼3mm(0.08∼0.12in.)
PERIODIC MAINTENANCE 2-17
Periodic Maintenance Procedures
• Loosen the locknut [A], and screw accelerator cable ad-
juster [B] in completely so as to give the throttle grip plenty
of play.
• Turn the accelerator cable adjuster until 2 ∼ 3 mm (0.08 ∼
0.12 in.) of throttle grip play is obtained.
• Tighten the locknut.
If the throttle cables can not be adjusted by using the ca-
ble adjuster at the upper end of the throttle cable, use the
cable adjusters at the lower ends of the throttle cables.
• Remove:
Side Cover (see Side Cover Removal in the Frame chap-
ter)
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
• To make service easy, unscrew the reserver tank bolts
and remove the reserver tank with hoses
• Turn out both upper nuts [A] and turn in both lower nuts [B]
as far as they will go so as to give the throttle grip plenty
of play.
• With the throttle grip completely closed, turn out the lower
nut and turn in the upper nut of the decelerator cable [C]
until the inner cable just becomes tight.
• Turn out the lower nut and turn in the upper nut of the
accelerator cable [D] until the correct free play is obtained.
• Check that the throttle linkage lever [A] stops against the
idle adjusting screw [B] with the throttle grip closed.
2-18 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Choke Operation Inspection
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Fuel Tank (see Fuel Tank Removal)
Side Covers (see Side Cover Removal in the Frame
chapter)
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
Fuel Tank (see Fuel Tank Removal)
• Push the choke lever [A] back all the way to its released
position.
• Check choke cable free play [B].
○Determine the amount of choke cable play at the choke
lever.
If the free play is incorrect, adjust the choke cable.
Choke Cable Free Play
Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
• Push the choke lever back all the way to its released po-
sition.
• Pull the choke lever until the starter plunger lever [A] at the
carburetor touches the starter plunger [B]; the amount of
choke lever travel is the amount of choke cable play.
• Loosen the locknut [A], and turn the adjuster [B] until the
cable has the proper amount of free play.
• Tighten the locknut securely.
Engine Vacuum Synchronization Inspection
• Situate the motorcycle using the center stand so that it is
perpendicular to the ground.
• Remove the fuel tank, and connect the sub-fuel tank to
supply the fuel.
• Remove the right lower fairing.
• Warm up the engine.
• Check the idle speed and adjust if necessary.
• Pull the vacuum hoses off, and attach vacuum gauge [A]
to the vacuum hose fittings on the carburetors.
Special Tool - Vacuum Gauge KEK-55-5: 57001-1369
PERIODIC MAINTENANCE 2-19
Periodic Maintenance Procedures
• Start the engine and let it idle to measure the carburetor
intake vacuum.
If the intake vacuum difference between the two cylinders
exceeds the limit, adjust the synchronization.
Engine Vacuum Synchronization
Less than 2.7 kPa (2 cmHg) difference between both
cylinders
• Turn the adjusting screw [A] to synchronize the carbure-
tor.
If the carburetor synchronization cannot be obtained by
using the adjusting screw, check for dirt or blockage, and
then check the pilot screw settings.
• Check the Carburetor Synchronization again.
NOTE
○Do not turn the pilot screws carelessly during carburetor
synchronization. You may cause poor running at low
engine speed.
Idle Speed Inspection
• Start the engine and warm it up thoroughly.
• With the engine idling, turn the handlebar to both sides
[A].
If handlebar movement changes the idle speed, the
throttle cables may be improperly adjusted or incorrectly
routed or damaged. Be sure to correct any of these
conditions before riding (see Throttle Control System
Inspection or Cable, Wire, and Hose Routing section in
the Appendix chapter).
WARNING
Operation with improperly adjusted, incorrectly
routed or damaged cables could result in an unsafe
riding Condition. Follow the service manual to be
make sure to correct any of these conditions.
• Check idle speed.
If the idle speed is out of the specified range, adjust it.
Idle Speed
Standard:
1 300 ±50 r/min (rpm)
Idle Speed Adjustment
• Start the engine and warm it up thoroughly.
• Turn the adjusting screw [A] until the idle speed is correct.
○Open and close the throttle a few times to make sure that
the idle speed is within the specified range. Readjust if
necessary.
2-20 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Fuel Hose Inspection (fuel leak, damage,
installation condition)
○The fuel hose is designed to be used throughout the mo-
torcycle’s life without any maintenance. However, if the
motorcycle is not properly handled, the high pressure in-
side the fuel line can cause fuel to leak [A] or the hose to
burst. Remove the fuel tank (see Fuel Tank Removal in
the Fuel System chapter) and check the fuel hose.
Replace the fuel hose if any fraying, cracks [B], bulges [C]
or ozone cracks [D] are noticed.
• Check that the hose [A] are securely connected and
clamps [B] are tightened correctly.
• Check that the hoses are routed according to Cable, Wire,
and Hose Routing section in the Appendix chapter.
Replace the hose if it has been sharply bent or kinked.
Evaporative Emission Control System (CAL Model)
Evaporative Emission Control System Inspection
• Inspect the canister as follows.
○Remove:
Left Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
○Remove the canister [A], and disconnect the hoses from
the canister.
○Visually inspect the canister for cracks or other damage.
If the canister has any cracks or bad damage, replace it
with a new one.
NOTE
○The canister is designed to work well through the motor-
cycle’s life without any maintenance if it is used under
normal conditions.
PERIODIC MAINTENANCE 2-21
Periodic Maintenance Procedures
• Check the liquid/vapor separator as follows.
○Remove:
Left Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
○Disconnect the hoses from the separator, and remove the
separator [B] from the motorcycle left side.
○Visually inspect the separator for cracks and other dam-
age.
If the separator has any cracks or damage, replace it with
a new one.
○To prevent the gasoline from flowing into or out of the
canister, hold the separator perpendicular to the ground.
• Check the hoses of the evaporative emission control sys-
tem as follows.
○Check that the hoses are securely connected and clips
are in position.
○Replace any kinked, deteriorated or damaged hoses.
○Route the hoses according to Cable, Wire, and Hose
Routing section in the Appendix chapter.
○When installing the hoses, avoid sharp bending, kinking,
flattening or twisting, and route the hoses with a minimum
of bending so that the emission flow will not be obstructed.
Cooling System
Coolant Level Inspection
NOTE
○Check the level when the engine is cold (room or ambi-
ent temperature).
• Check the coolant level in the reserve tank [A] with the
motorcycle held perpendicular (Do not use the sidestand).
If the coolant level is lower than the “L” level line [B], re-
move the right center fairing (see Center Fairing Removal
in the Frame chapter) and unscrew the reserve tank cap,
and add coolant to the “F” level line [C].
“L”: low
“F”: full
NOTICE
For refilling, add the specified mixture of coolant
and soft water. Adding water alone dilutes the
coolant and degrades its anticorrosion properties.
The diluted coolant can attack the aluminum en-
gine parts. In an emergency, soft water alone can
be added. But the diluted coolant must be returned
to the correct mixture ratio within a few days.
If coolant must be added often or the reservoir tank
has run completely dry, there is probably leakage in
the cooling system. Check the system for leaks.
Coolant ruins painted surfaces. Immediately wash
away any coolant that spills on the frame, engine,
wheels or other painted parts.
2-22 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Radiator Hose Damage and Installation Condition
Inspection
○The high pressure inside the radiator hose and pipe can
cause coolant to leak [A] or the hose to burst if the line is
not properly maintained.
• Visually inspect the hoses for signs of deterioration.
Squeeze the hoses. A hose should not be hard and
brittle, nor should it be soft or swollen.
Replace the hose if any fraying, cracks [B] or bulges [C]
are noticed.
• Check that the hoses are securely connected and clamps
are tightened correctly.
Torque - Radiator Hose Clamp Screws: 3.0 N·m (0.31 kgf·m,
27 in·lb)
Coolant Filter Cleaning (Australia Model)
• Remove the fuel tank (see Fuel Tank Removal in the Fuel
System chapter).
• Drain the coolant (see Coolant Change).
• Remove the filter [A] from the water hoses [B] of carbure-
tor system.
• Blow off dirt and sediment on the filter with compressed
air.
Filter Body [C]
Water Pipe [D]
Coolant Valve Assy [E]
Water Pump [F]
Carburetor [G]
Damper [H]
Air Suction System
Air Suction System Damage Inspection
• Pull the vacuum switch valve hose [A] out of the air
cleaner.
PERIODIC MAINTENANCE 2-23
Periodic Maintenance Procedures
• Start the engine and run it at idle speed.
• Plug [A] the vacuum switch valve hose end with your fin-
ger and feel vacuum pulsing in the hose.
If there is no vacuum pulsation, check the hose line for
leak. If there is no leak, check the vacuum switch valve
or air suction valve (see Engine Top End chapter).
Engine Top End
Valve Clearance Inspection
NOTE
○Valve clearance must be checked and adjusted when
the engine is cold (room temperature).
• Remove:
Cylinder Head Cover (see Cylinder Head Cover Re-
moval in the Engine Top End chapter)
Left Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
• Unscrew the two plugs [A], [B] on the alternator cover.
Special Tool - Filler Cap Driver: 57001-1454
• Check the valve clearance when the pistons are at TDC.
○The pistons are numbered beginning with the engine left
side.
• Using a wrench on the crankshaft rotation bolt, turn the
crankshaft clockwise until the "2/T" [A] mark on the timing
rotor is aligned with the projection [B] in the inspection
window on the alternator cover.
○Measure the valve clearance of the valves for which the
cam [A] are turned away from each other.
2-24 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
• Using the thickness gauge [A], measure the valve clear-
ance between cam and valve lifter.
Valve Clearance
Standard:
Exhaust
0.22 ∼ 0.29 mm (0.0087 ∼ 0.0114 in.)
Inlet
0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.)
○Each piston has two inlet and two exhaust valves. Mea-
sure these two inlet or exhaust valves at the same crank-
shaft position.
Valve Clearance Measuring Position
#1 Piston TDC at End of Compression Stroke →
Inlet valve clearances of #1 piston, and
Exhaust valve clearances of #1 piston
NOTE
○Check the valve clearance using this method only.
Checking the clearance at any other cam position may
result in improper valve clearance.
Valve Clearance Measuring Position
#2 Piston TDC at End of Compression Stroke →
Inlet valve clearances of #2 piston, and
Exhaust valve clearances of #2 piston
If the valve clearance is not with in the specified range,
first record the clearance, and adjust it.
Valve Clearance Adjustment
• To change the valve clearance, remove the camshaft
chain tensioner, camshafts and valve lifters. Replace the
shim with one of a different thickness.
NOTE
○Mark and record the locations of the valve lifters and
shims so that they can be reinstalled in their original
positions.
PERIODIC MAINTENANCE 2-25
Periodic Maintenance Procedures
• Clean the shim to remove any dust or oil.
• Measure the thickness of the removed shim [A].
• Select a new shim thickness calculation as follows.
a +b -c = d
[a] Present Shim Thickness
[b] Measured Valve Clearance
[c] Specified Valve Clearance (Mean Value = 0.255 mm
(Exhaust), 0.195 mm (Inlet))
[d] Replace Shim Thickness
Example (Inlet):
2.90 + 0.45 - 0.195 = 3.155 mm
○Exchange the shim for the 3.175 size shim.
NOTICE
Don’t use the shims for another models. This could
cause wear of the valve stem end, and valve stem
damage.
Adjustment Shims
Thickness
Part Number
Mark
2.50
92180-1014
50
2.55
92180-1016
55
2.60
92180-1018
60
2.65
92180-1020
65
2.70
92180-1022
70
2.75
92180-1024
75
2.80
92180-1026
80
2.85
92180-1028
85
2.90
92180-1030
90
2.95
92180-1032
95
3.00
92180-1034
00
3.05
92180-1036
05
3.10
92180-1038
10
3.15
92180-1040
15
3.20
92180-1042
20
3.25
92180-1044
25
3.30
92180-1046
30
3.35
92180-1048
35
3.40
92180-1050
40
3.45
92180-1052
45
3.50
92180-1054
50
2-26 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Clutch
Clutch Operation Inspection
• Pull the clutch lever just enough to take up the free play
[A].
• Measure the gap between the lever and the lever holder.
If the gap is too wide, the clutch may not release fully. If
the gap is too narrow, the clutch may not engage fully. In
either case, adjust it.
Clutch Lever Free Play
Standard:
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
WARNING
The engine and exhaust system get extremely hot
during normal operation and can cause serious
burns. Never touch the engine or exhaust pipe
during clutch adjustment.
• Turn the adjuster [B] so that 5 ∼ 6 mm (0.20 ∼ 0.24 in.) [A]
of threads are visible.
• Remove the right lower fairing (see Lower Fairing Re-
moval in the Frame chapter).
• Slide the dust cover [A] from the clutch cable lower end
out of place.
• Loosen both adjusting nuts [B] at the clutch cover as far
as they will go.
• Pull the clutch outer cable [C] tight and tighten the adjust-
ing nuts against the bracket [D].
• Slip the rubber dust cover back onto place.
• Turn the adjuster at the clutch lever until the free play is
correct.
WARNING
Too much cable play can prevent clutch disengage-
ment and cause an accident resulting in serious in-
jury or death. When adjusting the clutch or replac-
ing the cable, be sure the upper end of the clutch
outer cable is fully seated in its fitting, or it could
slip into place later, creating enough cable play to
prevent clutch disengagement.
• After the adjustment, start the engine and check that the
clutch does not slip and that it releases properly.
PERIODIC MAINTENANCE 2-27
Periodic Maintenance Procedures
Wheels/Tires
Air Pressure Inspection
• Remove the air valve cap.
• Measure the tire air pressure with an air pressure gauge
[A] when the tires are cold (that is, when the motorcycle
has not been ridden more than a mile during the past 3
hours).
• Install the air valve cap.
Adjust the tire air pressure according to the specifications
if necessary.
Air Pressure (when Cold)
Front:
Up to 170 kg (375 lb)
200 kPa (2.00 kgf/cm², 28 psi)
Rear:
Up to 170 kg (375 lb)
225 kPa (2.25 kgf/cm², 32 psi)
Wheel/Tire Damage Inspection
• Remove any imbedded stones [A] or other foreign parti-
cles [B] from tread.
• Visually inspect the tire for cracks and cuts, and replace
the tire if necessary. Swelling or high spots indicate inter-
nal damage, requiring tire replacement.
• Visually inspect the wheel for cracks, cuts and dents dam-
age.
If any damage is found, replace the wheel if necessary.
Tire Tread Wear, Abnormal Wear Inspection
As the tire tread wears down, the tire becomes more sus-
ceptible to puncture and failure. An accepted estimate is
that 90% of all tire failures occur during the last 10% of tread
life (90% worn). So it is false economy and unsafe to use
the tires until they are bald.
• Measure the tread depth at the center of the tread with a
depth gauge [A]. Since the tire may wear unevenly, take
measurement at several places.
If any measurement is less than the service limit, replace
the tire (see Tire Removal/Installation in the Wheels/Tires
chapter).
2-28 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Tread Depth
Standard:
Front:
BRIDGESTONE
4.6 mm (0.181 in.)
DUNLOP
4.5 mm (0.177 in.)
IRC
4.2 mm (0.165 in.)
Rear:
BRIDGESTONE
7.0 mm (0.276 in.)
DUNLOP
7.4 mm (0.291 in.)
IRC
6.5 mm (0.256 in.)
Service Limit:
Front
1 mm (0.04 in.)
Rear
2 mm (0.08 in.)
(Up to 130 km/h (80 mph))
3 mm (0.12 in.)
(Over 130 km/h (80 mph))
WARNING
Some replacement tires may adversely affect han-
dling and cause an accident resulting in serious in-
jury or death. To ensure proper handling and sta-
bility, use only the recommended standard tires for
replacement, inflated to the standard pressure.
NOTE
○Most countries may have their own regulations a mini-
mum tire tread depth: be sure to follow them.
○Check and balance the wheel when a tire is replaced
with a new one.
Wheel Bearing Damage Inspection
• Raise the front wheel off the ground with jack (see Front
Wheel Removal in the Wheels/Tires chapter).
• Turn the handlebar all the way to the right or left.
• Inspect the roughness of the front wheel bearing by push-
ing and pulling [A] the wheel.
• Spin [B] the front wheel lightly, and check for smoothly
turn, roughness, binding or noise.
If roughness, binding or noise is found, remove the front
wheel and inspect the wheel bearing (see Front Wheel
Removal, Hub Bearing Inspection in the Wheels/Tires
chapter).
• Raise the rear wheel off the ground with stand (see Rear
Wheel Removal in the Wheels/Tires chapter).
• Inspect the roughness of the rear wheel bearing by push-
ing and pulling [A] the wheel.
• Spin [B] the rear wheel lightly, and check for smoothly
turn, roughness, binding or noise.
If roughness, binding or noise is found, remove the rear
wheel and inspect the wheel bearing (see Rear Wheel Re-
moval, Hub Bearing Inspection in the Wheels/Tires chap-
ter) and coupling (see Coupling Bearing Inspection in the
Final Drive chapter).
PERIODIC MAINTENANCE 2-29
Periodic Maintenance Procedures
Drive Train
Drive Chain Lubrication Condition Inspection
• If a special lubricant is not available, a heavy oil such as
SAE 90 is preferred to a lighter oil because it will stay on
the chain longer and provide better lubrication.
• If the chain appears especially dirty, clean it before lubri-
cation.
NOTICE
The O-rings between the side plates seal in the lu-
bricant between the pin and the bushing. To avoid
damaging the O-rings and resultant loss of lubri-
cant, observe the following rules.
Use only kerosene or diesel oil for cleaning an O
-ring drive chain. Any other cleaning solution such
as gasoline or trichloroethylene will cause deterio-
ration and swelling of the O-ring. Immediately blow
the chain dry with compressed air after cleaning.
Complete cleaning and drying the chain within 10
minutes.
• Apply oil to the sides of the rollers so that oil will penetrate
to the rollers and bushings. Apply the oil to the O-rings so
that the O-rings will be coated with oil.
• Wipe off any excess oil.
Oil Applied Areas [A]
O-rings [B]
Drive Chain Slack Inspection
NOTE
○Check the slack with the motorcycle setting on its side-
stand.
○Clean the chain if it is dirty, and lubricate it if it appears
dry.
• Check the wheel alignment (see Wheel Alignment Inspec-
tion).
• Rotate the rear wheel to find the position where the chain
is tightest.
• Measure the vertical movement (chain slack) [A] midway
between the sprockets.
If the chain slack exceeds the standard, adjust it.
Chain Slack
Standard:
20 ∼ 30 mm (0.8 ∼ 1.2 in.)
2-30 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Drive Chain Slack Adjustment
• Remove the cotter pin [A], and loosen the axle nut [B].
• Loosen the both chain adjuster locknuts [C].
If the chain is too loose, turn in the left and right chain
adjuster nuts [D] evenly.
If the chain is too tight, turn out the left and right chain
adjuster nuts evenly, and kick the wheel forward.
• Turn both chain adjuster nuts evenly until the drive chain
has the correct amount of slack. To keep the chain
and wheel properly aligned, the notch [E] on the left
wheel alignment indicator [F] should align with the same
swingarm mark or position [G] that the right indicator
notch aligns with.
WARNING
Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.
Be sure the wheel is properly aligned.
• Tighten both chain adjuster locknuts securely.
• Tighten the axle nut.
Torque - Rear Axle Nut: 98 N·m (10.0 kgf·m, 72 ft·lb)
• Turn the wheel, measure the chain slack again at the tight-
est position, and readjust if necessary.
• Insert a new cotter pin [A].
NOTE
○When inserting the cotter pin, if the slots in the nut do
not align with the cotter pin hole in the axle, tighten the
nut clockwise [B] up to next alignment.
○It should be within 30°.
○Loosen once and tighten again when the slot goes past
the nearest hole.
• Bend the cotter pin [A] over the nut [B].
WARNING
A loose axle nut can lead to an accident resulting in
serious injury or death. Tighten the axle nut to the
proper torque and install a new cotter pin.
PERIODIC MAINTENANCE 2-31
Periodic Maintenance Procedures
Wheel Alignment Inspection
• Check that the notch [A] on the right wheel alignment indi-
cator [B] aligns with the same swingarm mark or position
[C] that the left alignment indicator notch aligns with.
If they do not, adjust the chain slack and align the wheel
alignment (see Drive Chain Slack Adjustment).
NOTE
○Wheel alignment can be also checked using the
straightedge or string method.
WARNING
Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.
Be sure the wheel is properly aligned.
Drive Chain Wear Inspection
• Remove:
Chain Cover (see Swingarm Removal in the Suspension
chapter)
• Rotate the rear wheel to inspect the drive chain for dam-
aged rollers, and loose pins and links.
If there is any irregularity, replace the drive chain.
Lubricate the drive chain if it appears dry.
• Stretch the chain taut by hanging a 98 N (10 kg, 20 lb)
weight [A] on the chain.
• Measure the length of 20 links [B] on the straight part [C] of
the chain from the pin center of the 1st pin to the pin center
of the 21st pin. Since the chain may wear unevenly, take
measurements at several places.
If any measurements exceed the service limit, replace the
chain. Also, replace the front and rear sprockets when the
drive chain is replaced.
Drive Chain 20-link Length
Standard:
317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)
Service Limit:
EX250J8 ∼ JA
323 mm (12.72 in.)
EX250JB ∼ JC
319 mm (12.56 in.)
WARNING
A chain that breaks or jumps off the sprockets
could snag on the engine sprocket or lock the
rear wheel, severely damaging the motorcycle and
causing it to go out of control. Inspect the chain for
damage and proper adjustment before each ride.
If chain wear exceeds the service limit, replace it
with the standard chain. It is an endless type and
should not be cut for installation.
2-32 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Standard Chain
Make:
EX250J8 ∼ JA
ENUMA
EX250JB ∼ JC
DAIDO
Type:
EX250J8 ∼ JA
EK520SR-O2
EX250JB ∼ JC
DID 520VP2-T
Link:
106 links
Chain Guide Inspection
• Remove:
Swingarm (see Swingarm Removal in the Suspension
chapter)
• Visually inspect the chain guide [A].
Replace the chain guide if it shows any signs of abnormal
wear or damage.
Brake System
Brake Fluid Leak (Brake Hose and Pipe) Inspection
• Apply the brake lever or pedal and inspect the brake fluid
leak from the brake hoses [A] and fittings [B].
If the brake fluid leaked from any position, inspect or re-
place the problem part.
Brake Hose and Pipe Damage and Installation
Condition Inspection
• Inspect the brake hoses and fittings for deterioration,
cracks and signs of leakage.
○The high pressure inside the brake line can cause fluid to
leak [A] or the hose to burst if the line is not properly main-
tained. Bend and twist the rubber hose while examining
it.
Replace the hose and pipe if any crack [B], bulge [C] or
leakage is noticed.
Tighten any brake hose banjo bolts.
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
• Inspect the brake hose routing.
If any brake hose routing is incorrect, route the brake hose
according to Cable, Wire, and Hose Routing section in the
Appendix chapter.
PERIODIC MAINTENANCE 2-33
Periodic Maintenance Procedures
Brake Operation Inspection
• Inspect the operation of the front and rear brake by run-
ning the vehicle on the dry road.
If the brake operation is insufficiency, inspect the brake
system.
WARNING
When test riding the vehicle, be aware of surround-
ing traffic for your safety.
Brake Fluid Level Inspection
• Check that the brake fluid level in the front brake reservoir
[A] is above the lower level line [B].
NOTE
○Hold the reservoir horizontal by turning the handlebar
when checking brake fluid level.
If the fluid level is lower than the lower level line, fill the
reservoir to the upper level line [C] in the reservoir.
• Check that the brake fluid level in the rear brake reservoir
[A] is above the lower level line [B].
If the fluid level is lower than the lower level line, fill the
reservoir to the upper level line [C].
WARNING
Mixing brands and types of brake fluid can reduce
the brake system’s effectiveness and cause an ac-
cident resulting in injury or death. Do not mix two
brands of brake fluid. Change the brake fluid in the
brake line completely if the brake fluid must be re-
filled but the type and brand of the brake fluid that
is already in the reservoir are unidentified.
Recommended Disc Brake Fluid
Grade:
DOT4
• Follow the procedure below to install the rear brake fluid
reservoir cap correctly.
○First, tighten the rear brake fluid reservoir cap [B] clock-
wise [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].
2-34 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Brake Pad Wear Inspection
• Check the lining thickness [A] of the pads in each caliper.
If the lining thickness of either pad is less than the service
limit [B], replace both pads in the caliper as a set.
Pad Lining Thickness
Standard:
4.5 mm (0.18 in.)
Service Limit:
1 mm (0.04 in.)
Brake Light Switch Operation Inspection
• Turn on the ignition switch.
• The brake light [A] should go on when the brake lever is
applied or after the brake pedal is depressed about 10
mm (0.39 in.).
If it does not, adjust the brake light switch.
• Disconnect the connector [A].
• Turn the brake light switch to adjust the switch.
• Connect the connector.
If it does not go on, inspect or replace the following items.
Battery (see Charging Condition Inspection in the Elec-
trical System chapter)
Brake Light (see Tail/Brake Light Removal in the Electri-
cal System chapter)
Main Fuse 30 A and Taillight Fuse 10 A (see Fuse In-
spection in the Electrical System chapter)
Front Brake Light Switch [A] (see Switch Inspection in
the Electrical System chapter)
Rear Brake Light Switch (see Switch Inspection in the
Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
PERIODIC MAINTENANCE 2-35
Periodic Maintenance Procedures
Suspensions
Front Forks/Rear Shock Absorber Operation
Inspection
• Pump the forks down and up [A] 4 or 5 times, and inspect
the smooth stroke.
If the forks do not smoothly or noise is found, inspect the
fork oil level or fork clamps (see Front Fork Oil Change in
the Suspension chapter).
• Pump the seat down and up [A] 4 or 5 times, and inspect
the smooth stroke.
If the shock absorber does not smoothly stroke or noise
is found, inspect the oil leak (see Rear Shock Absorber
Oil Leak Inspection).
Front Fork Oil Leak Inspection
• Visually inspect the front forks [A] for oil leakage.
Replace or repair any defective parts, if necessary.
Rear Shock Absorber Oil Leak Inspection
• Visually inspect the shock absorber [A] for oil leakage.
If the oil leakage is found on it, replace the shock absorber
with a new one.
Rocker Arm Operation Inspection
• Pump the seat down and up 4 or 5 times, and inspect the
smooth stroke.
If the rocker arm [A] does not smoothly stroke or noise
is found, inspect the fasteners and bushings (see Rocker
Arm/Tie-Rod Bushing, Sleeve Inspection in the Suspen-
sion chapter).
2-36 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Tie-Rod Operation Inspection
• Pump the seat down and up 4 or 5 times, and inspect the
smooth stroke.
If the tie-rod [A] do not smoothly stroke or noise is found,
inspect the fasteners and tie-rod bushings (see Rocker
Arm/Tie-Rod Bushing, Sleeve Inspection in the Suspen-
sion chapter).
Swingarm Pivot Lubrication
• Remove the swingarm bearing (see Swingarm Bearing
Removal in the Suspension chapter).
• Supply grease to the needle bearings and grease seals
in accordance with the Periodic Maintenance chart.
Steering System
Steering Play Inspection
• Raise the front wheel off the ground with jack (see Front
Wheel Removal in the Wheels/Tires chapter).
• With the front wheel pointing straight ahead, alternately
tap each end of the handlebar. The front wheel should
swing fully left and right from the force of gravity until the
fork hits the stop.
If the wheel binds or catches before the stop, the steering
is too tight.
• Feel for steering looseness by pushing and pulling the
forks.
If you feel looseness, the steering is too loose.
NOTE
○The cables and wiring will have some effect on the mo-
tion of the fork which must be taken into account.
○Be sure the wires and cables are properly routed.
○The bearings must be in good condition and properly
lubricated in order for any test to be valid.
PERIODIC MAINTENANCE 2-37
Periodic Maintenance Procedures
Steering Play Adjustment
• Loosen:
Front Fork Clamp Bolts (lower) (both sides)
Stem Head Bolt [A]
• Adjust the steering.
If the steering is too loose, tighten the steering stem nut
a fraction of a turn using the special tool [B].
If the steering is too tight, loosen the stem nut a fraction
of a turn.
Special Tool - Steering Stem Nut Wrench: 57001-1100
NOTE
○Turn the stem nut 1/8 turn at a time maximum.
• Tighten:
Torque - Steering Stem Head Bolt: 44 N·m (4.5 kgf·m, 32
ft·lb)
Front Fork Clamp Bolts (lower): 30 N·m (3.1 kgf·m,
22 ft·lb)
• Check the steering again.
If the steering is still too tight or too loose, repeat the ad-
justment.
Steering Stem Bearing Lubrication
• Remove the steering stem (see Stem, Stem Bearing Re-
moval in the Steering chapter).
• Using a high-flash point solvent, wash the upper and
lower ball bearings, and wipe the upper and lower outer
races, which are press-fitted into the frame head pipe,
clean off grease and dirt.
• Visually check the outer races and the ball bearings.
Replace them if they show wear or damage.
• Apply a light coat of grease to the upper and lower [A] ball
bearings and outer races.
• Install the steering stem (see Stem, Stem Bearing Instal-
lation in the Steering chapter).
• Adjust the steering (see Steering Play Adjustment).
2-38 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Electrical System
Lights and Switches Operation Inspection
First Step
• Turn on the ignition switch.
• The following lights should go on according to below table.
Taillight [A]
goes on
License Plate Light [B]
goes on
Meter Panel Lights [C]
goes on
Neutral Indicator Light [D]
goes on
Oil Pressure Warning Indicator Light [E]
goes on
Water Temperature Warning Indicator Light
goes on
[F]
If the light does not go on, inspect or replace the following
item.
Battery (see Charging Condition Inspection in the Elec-
trical System chapter)
Applicable Bulb (see Wiring Diagram in the Electrical
System chapter)
Meter Unit for Meter Lights (see Meter Unit Inspection in
the Electrical System chapter)
Meter Unit for Neutral Indicator Light (see Meter Unit
Inspection in the Electrical System chapter)
Meter Unit for Oil Pressure Warning Indicator Light (see
Meter Unit Inspection in the Electrical System chapter)
Meter Unit for Water Temperature Warning Indicator
Light (see Meter Unit Inspection in the Electrical System
chapter)
Main Fuse 30 A and Taillight Fuse 10 A (see Fuse In-
spection in the Electrical System chapter)
Ignition Switch (see Switch Inspection in the Electrical
System chapter)
Neutral Switch (see Switch Inspection in the Electrical
System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
• Turn off the ignition switch.
• The all lights should go off.
If the light does not go off, replace the ignition switch.
PERIODIC MAINTENANCE 2-39
Periodic Maintenance Procedures
Second Step
• Turn on the turn signal switch [A] (left or right position).
• The left or right turn signal lights [B] (front and rear) ac-
cording to the switch position should flash.
• The turn signal indicator light [C] in the meter unit should
flash.
If the each light does not flash, inspect or replace the
following item.
Turn Signal Light Bulb (see Turn Signal Light Bulb Re-
placement in the Electrical System chapter)
Meter Unit for Turn Signal Light Indicator Light (see Me-
ter Unit Inspection in the Electrical System chapter)
Turn Signal Relay Fuse 10 A (see Fuse Inspection in the
Electrical System chapter)
Turn Signal Switch (see Switch Inspection in the Electri-
cal System chapter)
Turn Signal Relay (see Turn Signal Relay Inspection in
the Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
• Push the turn signal switch.
• The turn signal lights and indicator light should go off.
If the light does not go off, inspect or replace the following
item.
Turn Signal Switch (see Switch Inspection in the Electri-
cal System chapter)
Turn Signal Relay (see Turn Signal Relay Inspection in
the Electrical System chapter)
Third Step
• Set the dimmer switch [A] to low beam position.
• Start the engine.
• The low beam headlight should go on.
If the low beam headlight does not go on, inspect or re-
place the following item.
Headlight Low Beam Bulb (see Headlight Bulb Replace-
ment in the Electrical System chapter)
Headlight Fuse 10 A (see Fuse Inspection in the Electri-
cal System chapter)
Dimmer Switch (see Switch Inspection in the Electrical
System chapter)
Headlight Relay (see Relay Circuit Inspection in the
Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
2-40 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
• Set the dimmer switch to high beam position.
• The low beam [A] and high beam [B] headlights should
go on.
• The high beam indicator light [C] should go on.
If the high beam headlight and/or high beam indicator light
does not go on, inspect or replace the following item.
Headlight High Beam Bulb (see Headlight Bulb Replace-
ment in the Electrical System chapter)
Dimmer Switch (see Switch Inspection in the Electrical
System chapter)
• Turn off the engine stop switch.
• The low beam and high beam headlights should stay go-
ing on.
If the headlights and high beam indicator light does go off,
inspect or replace the following item.
Headlight Relay (see Relay Circuit Inspection in the
Electrical System chapter)
• Turn off the ignition switch.
• The headlights and high beam indicator light should go
off.
Headlight Aiming Inspection
• Inspect the headlight beam for aiming.
If the headlight beam points to one side rather than
straight ahead, adjust the horizontal beam.
Headlight Beam Horizontal Adjustment
• Turn the horizontal adjuster [A] on the headlight with the
screwdriver in or out until the beam points straight ahead.
If the headlight beam points too low or high, adjust the
vertical beam.
Headlight Beam Vertical Adjustment
• Turn the vertical adjuster [A] on the headlight with the
screwdriver in or out to adjust the headlight vertically.
PERIODIC MAINTENANCE 2-41
Periodic Maintenance Procedures
NOTE
○ON high beam, the brightest points should be slightly
below horizontal with the motorcycle on its wheels and
the rider seated. Adjust the headlight to the proper an-
gle according to local regulations.
○For US model, the proper angle is 0.4 degrees below
horizontal. This is 50 mm (2 in.) drop at 7.6 m (25
ft) measured from the center of the headlight with the
motorcycle on its wheels and the rider seated.
50 mm (2 in.) [A]
Center of Brightest Spot [B]
7.6 m (25 ft) [C]
Low Beam [D]
Height of Headlight Center [E]
High Beam [F]
Sidestand Switch Operation Inspection
• Inspect the sidestand switch [A] operation accordance to
below table.
Sidestand Switch Operation
Gear
Clutch
Engine
Engine
Sidestand
Position
Lever
Start
Run
Continue
Up
Neutral
Released
Starts
running
Continue
Up
Neutral
Pulled in
Starts
running
Doesn’t
Up
In Gear
Released
Stops
start
Continue
Up
In Gear
Pulled in
Starts
running
Continue
Down
Neutral
Released
Starts
running
Continue
Down
Neutral
Pulled in
Starts
running
Doesn’t
Down
In Gear
Released
Stops
start
Doesn’t
Down
In Gear
Pulled in
Stops
start
2-42 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
If the sidestand switch operation does not work, inspect
or replace the following item.
Battery (see Charging Condition Inspection in the Elec-
trical System chapter)
Main Fuse 30 A (see Fuse Inspection in the Electrical
System chapter)
Ignition Fuse 10 A (see Fuse Inspection in the Electrical
System chapter)
Ignition Switch (see Switch Inspection in the Electrical
System chapter)
Sidestand Switch (see Switch Inspection in the Electrical
System chapter)
Engine Stop Switch (see Switch Inspection in the Elec-
trical System chapter)
Starter Button (see Switch Inspection in the Electrical
System chapter)
Neutral Switch (see Switch Inspection in the Electrical
System chapter)
Starter Relay (see Starter Relay Inspection in the Elec-
trical System chapter)
Starter Circuit Relay (see Relay Circuit Inspection in the
Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
If the all parts are good condition, replace the IC Igniter.
Engine Stop Switch Operation Inspection
First Step
• Turn on the ignition switch.
• Set the neutral position.
• Turn the engine stop switch to stop position [A].
• Push the starter button.
• The engine does not start.
If the engine starts, inspect or replace the following item.
Engine Stop Switch (see Switch Inspection in the Elec-
trical System chapter)
Second Step
• Turn on the ignition switch.
• Set the neutral position.
• Turn the engine stop switch to run position [A].
• Push the starter button and run the engine.
• Turn the engine stop switch to stop position.
• Immediately the engine should be stop.
If the engine does not stop, inspect or replace the follow-
ing item.
Engine Stop Switch (see Switch Inspection in the Elec-
trical System chapter)
If the engine stop switch is good condition, replace the IC
Igniter.
PERIODIC MAINTENANCE 2-43
Periodic Maintenance Procedures
Others
Chassis Parts Lubrication
• Before lubricating each part, clean off any rusty spots with
rust remover and wipe off any grease, oil, dirt, or grime.
• Lubricate the points listed below with indicated lubricant.
NOTE
○Whenever the vehicle has been operated under
wet or rainy conditions, or especially after using a
high-pressure water spray, perform the general lubri-
cation.
Pivots: Lubricate with Grease.
Brake Lever
Brake Pedal
Clutch Lever
Rear Brake Joint Pin
Sidestand
Points: Lubricate with Grease.
Clutch Inner Cable Upper and Lower Ends [A]
Throttle Inner Cable Upper and Lower Ends
Cables: Lubricate with Rust Inhibitor.
Clutch Cable
Throttle Cables
• Lubricate the cables by seeping the oil between the cable
and housing.
○The cable may be lubricated by using a commercially
available pressure cable lubricator with an aerosol cable
lubricant.
• With the cable disconnected at both ends, the inner cable
should move freely [A] within the cable housing.
If cable movement is not free after lubricating, if the cable
is frayed [B], or if the cable housing is kinked [C], replace
the cable.
2-44 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Bolts, Nuts and Fasteners Tightness Inspection
• Check the tightness of the bolts and nuts listed here. Also,
check to see that each cotter pin is in place and in good
condition.
NOTE
○For the engine fasteners, check the tightness of them
when the engine is cold (at room temperature).
If there are loose fasteners, retighten them to the spec-
ified torque following the specified tightening sequence.
Refer to the appropriate chapter for torque specifications.
If torque specifications are not in the appropriate chapter,
see the Standard Torque Table. For each fastener, first
loosen it by 1/2 turn, then tighten it.
If cotter pins are damaged, replace them with new ones.
Bolt, Nut and Fastener to be checked
Engine:
Clutch Lever Pivot Nut
Engine Mounting Bolts and Nuts
Exhaust Pipe Manifold Holder Nuts
Muffler Body Mounting Bolts
Wheels:
Front Axle
Rear Axle Nut
Rear Axle Nut Cotter Pin
Brakes:
Brake Lever Pivot Nut
Brake Pedal Bolt
Brake Rod Joint Cotter Pin
Caliper Mounting Bolts
Front Master Cylinder Clamp Bolts
Rear Master Cylinder Mounting Bolts
Suspension:
Front Fork Clamp Bolts
Rear Shock Absorber Bolt and Nut
Swingarm Pivot Shaft Nut
Steering:
Steering Stem Head Bolt
Handlebar Holder Bolts
Others:
Footpeg Stay Bolts
Front Fender Bolts
Sidestand Bolt
PERIODIC MAINTENANCE 2-45
Periodic Maintenance Procedures
Replacement Parts
Air Cleaner Element Replacement
• Refer to the Air Cleaner Element Cleaning (see Air
Cleaner Element Cleaning).
Fuel Hose Replacement
• Refer to Fuel Hose Inspection (see Fuel Hose Inspection).
Coolant Change
WARNING
Coolant can be extremely hot and cause severe
burns, is toxic and very slippery. Do not remove
the radiator cap or attempt to change the coolant
when the engine is hot; allow it cool completely.
Immediately wipe any spilled coolant from tires,
frame, engine or other painted parts. Do not ingest
coolant.
• Remove:
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
Radiator Cap [A]
• Place a container under the drain bolts [A] at the bottom
of the water pump cover and cylinder.
• Drain the coolant from the radiator and engine by remov-
ing the drain bolts.
Torque - Drain Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)
2-46 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
• Remove:
Hoses [A]
Mounting Bolts [B] and Reserve Tank [C]
• Remove the cap [D] and pour the coolant of the reserve
tank into the container.
• Install:
Hoses
Reserve Tank
• Tighten the drain bolt with the specified torque.
Torque - Drain Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)
• Fill the radiator up to the radiator filler neck [A] with
coolant, and install the radiator cap.
NOTE
○Pour in the coolant slowly so that it can expel the air
from the engine and radiator.
• Fill the reserve tank up to the full level line with coolant,
and install the cap.
NOTICE
Soft or distilled water must be used with the an-
tifreeze (see below for antifreeze) in the cooling sys-
tem.
If hard water is used in the system, it causes scales
accumulation in the water passages, and consider-
ably reduces the efficiency of the cooling system.
Water and Coolant Mixture Ratio (Recommended)
Soft Water:
50%
Coolant:
50%
Freezing Point: -35°C (-31°F)
Capacity:
1.5 L (1.59 US qt)
NOTE
○Choose a suitable mixture ratio by referring to the
coolant manufacturer’s directions.
PERIODIC MAINTENANCE 2-47
Periodic Maintenance Procedures
• Bleed the air from the cooling system as follows.
○Start the engine with the radiator cap removed and run it
until no more air bubbles [A] can be seen in the coolant.
○Tap the radiator hoses to force any air bubbles caught
inside.
○Stop the engine and add coolant up to the radiator filler
neck.
• Install the radiator cap.
• Start the engine, warm it up thoroughly until the radiator
fan turns on and then stop the engine.
• Check the coolant level in the reserve tank after the en-
gine cools down.
If the coolant level is lower than the low level line, add
coolant to the full level line.
NOTICE
Do not add more coolant above the full level line.
Radiator Hose and O-ring Replacement
• Drain the coolant (see Coolant Change).
• Remove:
Thermostat Housing [A] (see Water Pump Removal in
the Cooling System chapter)
Water Pump Cover [B] (see Water Pump Removal in the
Cooling System chapter)
Hoses [C]
Pipe [D]
O-rings [E]
• Apply grease to the new O-rings and install them.
• Install the new hoses and tighten the clamps securely.
• Fill the coolant (see Coolant Change).
• Check the cooling system for leaks.
2-48 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Engine Oil Change
WARNING
The engine and exhaust system get extremely hot
during normal operation and can cause serious
burns. Never touch the engine or exhaust pipe
during oil change.
• Warm up the engine sufficiently with the motorcycle
standing on its side stand, and stop the engine.
• Place an oil pan under the engine and remove the drain
bolt [A] to drain the oil.
• Replace the drain bolt gaskets with new ones if they are
damaged.
○The oil in the oil filter can be drained by removing the filter.
• After draining the oil, tighten the drain bolts.
Torque - Oil Drain Bolts: 19.6 N·m (2.0 kgf·m, 14.5 ft·lb)
Oil Filter Mounting Bolt: 19.6 N·m (2.0 kgf·m, 14.5
ft·lb)
• Pour in the specified type and amount of oil.
Recommended Engine Oil
Type:
API SG, SH, SJ, SL or SM with JASO MA,
MA1 or MA2
Viscosity: SAE 10W - 40
Capacity:
1.3 L (1.4 US qt) (When filter is not removed)
1.6 L (1.7 US qt) (When filter is removed)
NOTE
○Do not add any chemical additive to the oil. Oils fulfilling
the above requirements are fully formulated and provide
adequate lubrication for both the engine and the clutch.
○Although 10W-40 engine oil is the recommended oil
for most conditions, the oil viscosity may need to be
changed to accommodate atmospheric conditions in
your riding area.
Oil Filter Replacement
• Drain the engine oil (see Engine Oil change).
• Remove the oil filter mounting bolt [A].
PERIODIC MAINTENANCE 2-49
Periodic Maintenance Procedures
• Replace the oil filter with a new one.
• Apply engine oil to the O-rings [A] before installation after
inspecting its damage.
• Install the oil filter mounting bolt [B] with a specified
torque.
Torque - Oil Filter Mounting Bolt: 19.6 N·m (2.0 kgf·m, 14.5
ft·lb)
• Pour in the specified type and amount of oil (see Engine
Oil Change).
Brake Hose and Pipe Replacement
NOTICE
Brake fluid quickly ruins painted plastic surfaces;
any spilled fluid should be completely washed away
immediately.
• Remove the banjo bolts.
• When removing the brake hose, take care not to spill the
brake fluid on the painted or plastic parts.
• When removing the brake hoses [A], temporarily secure
the end of the brake hose to some high place to keep fluid
loss to a minimum.
• Immediately wash away any brake fluid that spills.
• There are washers on each side of the brake hose fitting.
Replace them with new ones when installing.
• Tighten:
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
• When installing the hoses [A], avoid sharp bending, kink-
ing, flatting or twisting, and route the hoses according to
Cable, Wire, and Hose Routing section in the Appendix
chapter.
• Fill the brake line after installing the brake hose (see
Brake Fluid Change).
Brake Fluid Change
NOTE
○The procedure to change the front brake fluid is as fol-
lows. Changing the rear brake fluid is the same as for
the front brake.
2-50 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
• Level the brake fluid reservoir.
• Remove the reservoir cap and diaphragm.
• Remove the rubber cap from the bleed valve [A] on the
caliper.
• Attach a clear plastic hose [B] to the bleed valve, and run
the other end of the hose into a container.
• Fill the reservoir with fresh specified brake fluid.
• Change the brake fluid.
○Repeat this operation until fresh brake fluid comes out
from the plastic hose or the color of the fluid changes.
1. Open the bleed valve [A].
2. Apply the brake and hold it [B].
3. Close the bleed valve [C].
4. Release the brake [D].
NOTE
○The fluid level must be checked often during the chang-
ing operation and replenished with fresh brake fluid. If
the fluid in the reservoir runs out any time during the
changing operation, the brakes will need to be bled
since air will have entered the brake line.
○Front Brake: Repeat the above steps for the other
caliper.
• Remove the clear plastic hose.
• Install the diaphragm and reservoir cap.
• Tighten:
Torque - Front Brake Reservoir Cap Screws: 1.5 N·m (0.15
kgf·m, 13 in·lb)
• Follow the procedure below to install the rear brake fluid
reservoir cap correctly.
○First, tighten the rear brake fluid reservoir cap [B] clock-
wise [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 the bleed valve, and install the rubber cap.
Torque - Bleed Valve: 5.5 N·m (0.55 kgf·m, 49 in·lb)
• After changing the fluid, check the brake for good braking
power, no brake drag, and no fluid leakage.
If necessary, bleed the air from the lines.
PERIODIC MAINTENANCE 2-51
Periodic Maintenance Procedures
Master Cylinder Rubber Parts Replacement
Front Master Cylinder Disassembly
• Remove the front master cylinder (see Front Master Cylin-
der Removal in the Brakes chapter).
• Remove the reservoir cap and diaphragm, and pour the
brake fluid into a container.
• Unscrew the locknut and pivot bolt, and remove the brake
lever.
• Pull the dust cover out of place, and remove the circlip.
Special Tool - Inside Circlip Pliers: 57001-143
• Pull out the piston [A], secondary cup [B], primary cup [C],
and return spring [D].
NOTICE
Do not remove the secondary cup from the piston
since removal will damage it.
Rear Master Cylinder Disassembly
NOTE
○Do not remove the push rod clevis for master cylinder
disassembly since removal requires brake position ad-
justment.
• Remove the rear master cylinder (see Rear Master Cylin-
der Removal in the Brakes chapter).
• Remove the circlip.
Special Tool - Inside Circlip Pliers: 57001-143
• Pull out the push rod with the piston stop.
• Take off the piston [A], secondary cup [B], primary cup [C]
and return spring [D].
• Remove the circlip [F] and pull out the brake hose con-
nector [G] and O-ring [H].
Special Tool - Inside Circlip Pliers: 57001-143
NOTICE
Do not remove the secondary cup from the piston
since removal will damage it.
Master Cylinder Assembly
• Before assembly, clean all parts including the master
cylinder with brake fluid or alcohol.
NOTICE
Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning brake parts. Do not use any other fluid for
cleaning these parts. Gasoline, engine oil, or any
other petroleum distillate will cause deterioration of
the rubber parts. Oil spilled on any part will be diffi-
cult to wash off completely, and will eventually de-
teriorate the rubber used in the disc brake.
2-52 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
• Apply brake fluid to the removed parts and to the inner
wall of the cylinder.
• Take care not to scratch the piston or the inner wall of the
cylinder.
• Apply silicone grease (ex. PBC grease).
Brake Lever Pivot Bolt
Brake Lever Pivot Contact
Push Rod Contact (Rear)
Dust Cover
• Tighten:
Torque - Brake Lever Pivot Bolt:
1.0 N·m (0.10 kgf·m, 9
in·lb)
Brake Lever Pivot Bolt Locknut:
5.9 N·m (0.60
kgf·m, 52 in·lb)
Caliper Rubber Parts Replacement
Caliper Disassembly
• Remove a front Caliper (see Front Caliper Removal in the
Brakes chapter).
• Remove the pads and anti-rattle spring (see Pad Removal
in the Brakes chapter).
If compressed air is available, the piston may be removed
using compressed air as follows.
• Insert the wooden board of 5 mm (0.2 in.) thick inside the
caliper opening or cover the caliper opening with a clean,
heavy cloth [A].
• Lightly apply compressed air [B] to the hose joint opening
until the pistons hit the wooden board or heavy cloth.
WARNING
The piston in the brake caliper can crush hands and
fingers. Never place your hand or fingers in front of
the piston.
• Pull out the pistons by hand.
• Immediately wipe up any brake fluid that spills. It may ruin
painted or plated surfaces.
• Remove the dust seals and fluid seals.
• Remove the bleed valve and rubber cap.
NOTE
○If compressed air is not available, do as follows for both
calipers coincidentally, with the brake hose connected
to the caliper.
○Prepare a container for brake fluid, and perform the
work above it.
○Remove the spring and pads (see Brake Pad Removal).
○Pump the brake lever or pedal until the pistons come
out of the cylinders, and then disassemble the caliper.
PERIODIC MAINTENANCE 2-53
Periodic Maintenance Procedures
Caliper Assembly
• Clean the caliper parts except for the pads.
NOTICE
For cleaning of the parts, use only disc brake fluid,
ispopropyl alcohol, or ethyl alcohol.
• Install the bleed valve and rubber cap.
Torque - Bleed Valve: 5.5 N·m (0.55 kgf·m, 49 in·lb)
• Replace the fluid seals [A] and dust seals [B] with new
one.
• Apply brake fluid to the fluid seals and dust seals, and
install them into the cylinder by hand.
• Apply brake fluid [A] to the outside of the pistons and push
them into each cylinder by hand without scratching the
cylinder and piston skirt.
• Apply silicone grease [B] to the caliper holder shaft and
holder holes, and install the caliper holder [C], rubber boot
[D] and dust cover [E].
• Install the anti-rattle spring [F] and pads in the caliper (see
Pad Installation in the Brakes chapter).
Spark Plug Replacement
• Remove:
Spark Plugs (see Spark Plug Removal in the Electrical
System chapter)
• Remove the spark plugs using the 16 mm plug wrench
[A].
Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-0044
• Insert the spark plug vertically into the plug hole with the
spark plug installed in the plug wrench [A].
Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-0044
• Tighten:
Torque - Spark Plugs: 13 N·m (1.3 kgf·m, 115 in·lb)
• Install:
Spark Plugs (see Spark Plug Installation in the Electrical
System chapter)
FUEL SYSTEM 3-1
Fuel System
Table of Contents
Exploded View
3-3
Exploded View (EX250J8)
3-8
Exploded View (EX250J9 ∼ JC)
3-10
Specifications
3-12
3
Special Tools
3-13
Throttle Grip and Cables
3-14
Free Play Inspection
3-14
Free Play Adjustment
3-14
Throttle Cable Removal
3-14
Throttle Cable Installation
3-14
Throttle Cable Lubrication
3-14
Choke Cable
3-15
Free Play Inspection
3-15
Free Play Adjustment
3-15
Choke Cable Removal
3-15
Choke Cable Installation
3-15
Choke Cable Lubrication and Inspection
3-15
Carburetors
3-16
Idle Speed Inspection
3-16
Idle Speed Adjustment
3-16
Engine Vacuum Synchronization Inspection
3-16
Engine Vacuum Synchronization Adjustment
3-16
Pilot Screw Adjustment
3-16
Service Fuel Level Inspection
3-17
Service Fuel Level Adjustment
3-18
Fuel System Cleanliness Inspection
3-19
Carburetor Removal
3-20
Carburetor Installation
3-21
Carburetor Separation
3-21
Carburetor Joining
3-21
Carburetor Disassembly
3-23
Carburetor Assembly
3-23
Carburetor Cleaning
3-24
Carburetor Inspection
3-25
Air Cleaner
3-27
Air Cleaner Element Removal
3-27
Air Cleaner Element Installation
3-27
Air Cleaner Housing Removal
3-27
Air Cleaner Housing Installation
3-28
Air Cleaner Housing Disassembly
3-28
Air Cleaner Housing Assembly
3-28
Oil Draining
3-29
Fuel Tank
3-30
Fuel Tank Removal
3-30
Fuel Tank Installation
3-30
Fuel Tap Removal
3-31
Fuel Tap Installation
3-31
Fuel Tank and Tap Cleaning
3-31
Fuel Tap Inspection
3-32
Fuel Tank and Cap Inspection
3-32
3-2 FUEL SYSTEM
Evaporative Emission Control System (CAL Model)
3-33
Separator Operation Test
3-33
Canister Inspection
3-33
Parts Removal/Installation
3-33
Hose Inspection
3-33
FUEL SYSTEM 3-3
Exploded View
This page intentionally left blank.
3-4 FUEL SYSTEM
Exploded View
FUEL SYSTEM 3-5
Exploded View
1. Throttle Cable (accelerator)
2. Throttle Cable (decelerator)
3. Choke Cable
4. Idle Adjusting Screw
5. Air Cut Valve
6. Jet Needle
7. Vacuum Valve
8. Float Valve
9. Needle Jet
10. Needle Jet Holder
11. Main Jet
12. Pilot Jet
13. Pilot Air Screw
14. Float
15. Plug
CL: Apply cable lubricant.
G: Apply grease.
3-6 FUEL SYSTEM
Exploded View
FUEL SYSTEM 3-7
Exploded View
Torque
No.
Fastener
Remarks
N·m
kgf·m
ft·lb
1
Fuel Tap Mounting Bolts
2.5
0.25
22 in·lb
2
Fuel Gauge Mounting Bolts
6.9
0.7
61 in·lb
3
Air Cleaner Housing Cap Bolts/Screws
2.5
0.25
22 in·lb
4
Air Cleaner Housing Screws
1.15
0.12
10 in·lb
5
Air Cleaner Housing Mounting Bolts
9.8
1.0
87 in·lb
6
Air Cleaner Housing Clamp Screws
2.0
0.2
18 in·lb
7. Vacuum Switch Valve
8. EX250J8 ∼ JA, EX250JB ∼ JC (CAL Model)
O: Apply high-quality foam air filter oil.
3-8 FUEL SYSTEM
Exploded View (EX250J8)
FUEL SYSTEM 3-9
Exploded View (EX250J8)
Torque
No.
Fastener
Remarks
N·m
kgf·m
ft·lb
1
Separate Bracket Bolt
9.8
1.0
87 in·lb
2. Canister
3. Separator
4. Green Hose
5. Blue Hose
6. White Hose
7. Red Hose
8. Blue Hose
3-10 FUEL SYSTEM
Exploded View (EX250J9 ∼ JC)
FUEL SYSTEM 3-11
Exploded View (EX250J9 ∼ JC)
Torque
No.
Fastener
Remarks
N·m
kgf·m
ft·lb
1
Separate Bracket Bolt
9.8
1.0
87 in·lb
2. Canister
3. Separator
4. Green Hose
5. Blue Hose
6. White Hose
7. Red Hose
8. Blue Hose
3-12 FUEL SYSTEM
Specifications
Item
Standard
Throttle Grip and Cable
Throttle Grip Free Play
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
Choke Cable Free Play
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
Carburetor
Make, Type
Keihin, CVK30
Main Jet
#98
Optional Main Jet
#92, 95, 100, 102
Main Air Jet
#100
Jet Needle
#L: N9VU, #R: N9VW
Needle Jet
#6
Pilot Jet
#38
Pilot Air Jet
#100
Starter Jet
#48
Pilot Screw (turns out)
#L: 2 1/2, #R: 1 3/4
Throttle Valve
11° 00’
Idle Speed
1 300 ±50 r/min (rpm)
Carburetor Synchronization Vacuum
Less than 2.7 kPa (2 cmHg) difference between two
carburetors.
Service Fuel Level
0.5 ±1 mm (0.02 ±0.04 in.) above the mating surface of
carburetor float bowl.
Float Height
17 ±2 mm (0.67 ±0.08 in.)
Air Cleaner Element
Type
Polyurethane foam
FUEL SYSTEM 3-13
Special Tools
Fuel Level Gauge:
Pilot Screw Adjuster, A:
57001-1017
57001-1239
3-14 FUEL SYSTEM
Throttle Grip and Cables
Free Play Inspection
• Refer to Throttle Control System Inspection in the Peri-
odic Maintenance chapter (see Throttle Control System
Inspection in the Periodic Maintenance chapter).
Free Play Adjustment
• Refer to Throttle Control System Inspection in the Peri-
odic Maintenance chapter (see Throttle Control System
Inspection in the Periodic Maintenance chapter).
Throttle Cable Removal
• Split the right handlebar switch housing [A] removing the
screws [B], and remove the throttle cable upper ends from
the throttle grip.
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Side Cover (see Side Cover Removal in the Frame chap-
ter)
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
• Loosen the locknuts [A] and remove the lower end of the
accelerator cable [B] from the pulley.
• Loosen the locknuts [C] and remove the lower end of the
decelerator cable [D] from the pulley.
• Pull out the throttle cables upward
Throttle Cable Installation
• Install the throttle cables in accordance with the Cable,
Wire and Hose Routing in the Appendix chapter.
• Install the accelerator cable first and then decelerator ca-
ble.
• After installation, adjust each cable properly (see Throttle
Cable Inspection in the Periodic Maintenance chapter).
WARNING
Operation with incorrectly routed or improperly ad-
justed cables could result in an unsafe riding con-
dition. Be sure the cables are routed correctly and
properly adjusted.
Throttle Cable Lubrication
• Refer to Chassis Parts Lubrication Perform in the Peri-
odic Maintenance chapter (see Chassis Parts Lubrication
Perform in the Periodic Maintenance chapter).
FUEL SYSTEM 3-15
Choke Cable
Free Play Inspection
• Refer to Choke Operation Inspection in the Periodic Main-
tenance chapter (see Choke Operation in the Periodic
Maintenance chapter).
Free Play Adjustment
• Refer to Choke Operation Inspection in the Periodic Main-
tenance chapter (see Choke Operation in the Periodic
Maintenance chapter).
Choke Cable Removal
• Split the left handlebar switch housing [A], and remove
the choke cable [B] upper end from the choke lever [C].
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Fuel Tank (see Fuel Tank Removal)
• Remove the choke cable end from the cable bracket of
carburetor.
• Pull out the choke cable upward.
Choke Cable Installation
• Install the choke cable in accordance with the Cable,
Wire, and Hose Routing section in Appendix chapter.
• After installation, adjust the cable properly.
WARNING
Operation with incorrectly routed or improperly ad-
justed cable could result in an unsafe riding condi-
tion. Be sure the cable is routed correctly and prop-
erly adjusted.
Choke Cable Lubrication and Inspection
• Whenever the cable is removed, or in accordance with
the Periodic Maintenance Chart, lubricate the choke cable
(see General Lubrication in the Appendix chapter).
○Apply a thin coating of grease to the cable lower end.
○Use a commercially available pressure cable lubricator to
lubricate the cable.
○With the cable disconnected at both ends, the cable
should move freely in the cable housing.
3-16 FUEL SYSTEM
Carburetors
Idle Speed Inspection
• Refer to Idle Speed Inspection in the Periodic Mainte-
nance chapter (see Idle Speed Inspection in the Periodic
Maintenance chapter).
Idle Speed Adjustment
• Refer to Idle Speed Adjustment in the Periodic Mainte-
nance chapter (see Idle Speed Adjustment in the Periodic
Maintenance chapter).
Engine Vacuum Synchronization Inspection
• Refer to Engine Vacuum Synchronization Inspection in
the Periodic Maintenance chapter (see Engine Vacuum
Synchronization Inspection in the Periodic Maintenance
chapter).
Engine Vacuum Synchronization Adjustment
• Refer to Engine Vacuum Synchronization Inspection in
the Periodic Maintenance chapter (see Engine Vacuum
Synchronization Inspection in the Periodic Maintenance
chapter).
Pilot Screw Adjustment
If the engine idle is still not stable, adjust the pilot screw to
obtain the proper idle speed using the pilot screw adjuster
[A].
Special Tool - Pilot Screw Adjuster: 57001-1239
○Turn in the pilot screw fully but not tightly, and then back
it out the specified turns. To set the screw to its original
position.
Pilot Screw Setting:
#L: 2 1/2
#R: 1 3/4
NOTE
○The standard number of turns the pilot screw must be
backed out varies by carburetor. The values given in the
specifications should be used only when the number of
the original back out turns is unavailable.
FUEL SYSTEM 3-17
Carburetors
Service Fuel Level Inspection
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
• Situate the motorcycle so that it is perpendicular to the
ground.
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Fuel Tank (see Fuel Tank Removal)
• Prepare an auxiliary fuel tank and connect the fuel hose
to the carburetor.
• Prepare a fuel hose.
• Connect the fuel level gauge [A] to the carburetor float
bowl with the fuel hose.
Special Tool - Fuel Level Gauge: 57001-1017
• Hold the gauge vertically against the side of the carburetor
body so that the “middle” line [B] is several millimeters
higher than the mating surface [C] of the carburetor float
bowl.
• Feed fuel to the carburetor, then turn the carburetor drain
plug out a few turns.
• Wait until the fuel level in the gauge settles.
3-18 FUEL SYSTEM
Carburetors
• Keeping the gauge vertical, align the “middle” line with the
mating surface.
NOTE
○Do not lower the “middle” line below the mating surface
of the carburetor float bowl. If the gauge is lowered
and then raised again, the fuel level measured shows
somewhat higher than the actual fuel level. If the gauge
is lowered too far, dump the fuel out of it into a suitable
container and start the procedure over again.
• Read the fuel level [E] in the gauge and compare to the
specification.
• Screw in the carburetor drain plug [D].
• Stop feeding and remove the fuel level gauge.
If the fuel level is incorrect, adjust it (see Service Fuel
Level Adjustment).
Service Fuel Level (above the mating surface of carburetor
float bowl)
Standard:
0.5 mm ±1 mm (0.02 ±0.04 in.)
Service Fuel Level Adjustment
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
• Remove the carburetor, and drain the fuel into a suitable
container.
• Remove the fittings with water hose.
• Remove the float bowl.
• Slide out the pivot pin [A] with a suitable tool [B], and
remove the float [C] and float valve needle [D].
FUEL SYSTEM 3-19
Carburetors
• Bend the tang [A] on the float arm very slightly to change
the float height. Increasing the float height lowers the fuel
level and decreasing the float height raises the fuel level.
Float height
Standard:
17 ±2 mm (0.67 ±0.08 in.)
NOTE
○Do not push the needle rod [A] in during the float height
measurement [B].
• Assemble the carburetor, and recheck the fuel level.
If the fuel level cannot be adjusted by this method, the
float or the float valve [C] is damaged.
Fuel System Cleanliness Inspection
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
• Remove:
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
• Connect a suitable hose [A] to the fitting at the bottom of
each carburetor float bowl.
• Run the lower end of the carburetor drain hose into a suit-
able container.
• Turn out each drain plug [B] a few turns and drain the float
bowls with a hexagon wrench [C].
• Check to see if water or dirt comes out.
• Tighten the drain plug.
If any water or dirt appears during the above inspection,
clean the fuel system (see Carburetor Cleaning and Fuel
Tank Cleaning).
3-20 FUEL SYSTEM
Carburetors
Carburetor Removal
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Fuel Tank (see Fuel Tank Removal)
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
Battery (see Battery Removal in the Electrical System
chapter)
Battery Damper
Battery Case Screws [A]
Battery Case [B]
• Remove the air cleaner housing mounting bolts [A].
• Loosen the carburetor holder clamps [B] off the air cleaner
ducts.
• Pull the air cleaner housing rearward.
• Remove the throttle cable and choke cable (see Throttle
Cable and Choke Cable Removal)
• Remove:
Bolts [C]
Bracket [D]
Carburetor [E]
• Stuff the pieces of lint-free, clean cloths into the carbure-
tor holder and the air cleaner duct to keep dirt out of the
engine and air cleaner.
WARNING
If dirt or dust is allowed to pass through into the
carburetor, the throttle may become stuck, possibly
causing accident. Replace the air cleaner element
according to the maintenance chart.
NOTICE
If dirt gets through into the engine, excessive en-
gine wear and possibly engine damage will occur.
FUEL SYSTEM 3-21
Carburetors
Carburetor Installation
• Route the cables, harness, and hoses correctly (see Ca-
ble, Wire and Hose Routing section in the Appendix chap-
ter).
• Tighten the clamps for the carburetor holders and slide
back the spring bands for the air cleaner housing securely.
• Check fuel leakage from the carburetor.
WARNING
Fuel spilled from the carburetor is hazardous.
• Adjust the following items if necessary.
Idle Speed (see Idle Speed Adjustment in the Periodic
Maintenance chapter)
Carburetor Synchronization (see Carburetor Synchro-
nization Adjustment in the Periodic Maintenance chap-
ter)
Throttle Cable (see Throttle Control System Inspection
in the Periodic Maintenance chapter)
Choke Cable
Carburetor Separation
• Remove the carburetor (see Carburetor Removal).
• Pull out the air cut valve hoses [A], [B], [C] of the air cut
valve.
• Remove the choke plunger lever [D], spring [E] and car-
buretor mounting plates [F], [G].
• Gently, separately the carburetors each other.
Carburetor Joining
• When installing the carburetor, check to see that the O
-rings [A] are in place.
3-22 FUEL SYSTEM
Carburetors
• Install the fitting [A] and spring [B] as shown.
• Install the connecting plates [A] [B] and spring [C] as
shown.
• The center lines of the carburetor bores must be parallel
both horizontally and vertically. If they are not, loosen
the mounting screws and align the carburetors on a flat
surface. Retighten the mounting screws.
• After installing the choke mechanism, check to see that
the choke plunger lever slides right to left smoothly with-
out abnormal friction.
NOTICE
Fuel mixture trouble could result if the choke
plunger does not seat properly in its rest position
after the choke lever is returned.
• Visually synchronize the throttle (butterfly) valves.
○Check to see that all throttle valves open and close
smoothly without binding when turning the pulley.
○Visually check the clearance [A] between the throttle
valve and the carburetor bore in each carburetor.
If there is a difference between two carburetors, turn the
balance adjusting screw [B] to obtain the same clearance.
• Install the carburetors (see Carburetor Installation).
• Adjust the synchronization (see Carburetor Synchroniza-
tion Adjustment in the Periodic Maintenance Chapter).
FUEL SYSTEM 3-23
Carburetors
Carburetor Disassembly
• Remove the carburetors (see Carburetor Removal).
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
• For the Canada model, remove the pilot screw plug as
follows: punch a hole in the plug and pry there with an
awl or other suitable tool.
• Turn in the pilot screw and count the number of turns until
it seats fully but not tightly, and then remove the screw.
This is to set the screw to its original position when as-
sembling.
NOTICE
During carburetor disassembly, be careful not to
damage the diaphragm. Never use a sharp edge to
remove the diaphragm.
• Remove:
Spring [A]
Spring Seat [B]
Jet Needle [C]
Vacuum Piston [D]
Needle Jet [E]
Needle Jet Holder [F] and Main Jet [G]
Pilot Screw [H]
Carburetor Assembly
• Turn in the pilot screw [A] fully but not tightly, and then
back it out the same number of turns counted during dis-
assembly.
• Install the pilot screw plug as follows: install a new plug [B]
in the pilot screw hole of the carburetor body, and apply a
small amount of a bonding agent [C] to the circumference
of the plug to fix the plug.
NOTICE
Do not apply too much bonding agent to the plug or
the pilot screw itself may be fixed.
3-24 FUEL SYSTEM
Carburetors
• To install the needle jet [A], turn the carburetor body up
-side down, and drop the needle jet into place so that the
smaller diameter end [B] of the jet goes in first.
• Carefully screw in the needle jet holder [A]. It will seat
against the needle jet, pushing the end of the jet into the
carburetor bore.
Main Jet [B]
NOTICE
Do not apply force to the jet or overtighten it, as
this could damage the jet or the carburetor body,
requiring replacement.
• Install the float bowl.
• Slip the jet needle [B] through the hole in the center of
the vacuum piston, and put the spring seat [C] on the top
of the needle. Turn the seat so that it does not block the
hole at the bottom of the vacuum piston [A].
Spring [D]
• Install the carburetor top cover.
• Turn in the pilot screw fully but not tightly, and then back it
out the same number of turns counted during disassem-
bly.
• When removing the air cut valve assembly, unscrew the
mounting screws [B] and remove the cover [C], spring [D],
O-ring [E] and diaphragm [F].
• Install:
Left Carburetor [A]
Air Cut Valve Body [G]
Air Cut Valve Mounting Plate [H]
Carburetor Cleaning
WARNING
Gasoline and low-flash point solvents can be
flammable and/or explosive and cause severe
burns. Clean the carburetor in a well ventilated
area, and take care that there are no sparks or flame
anywhere near the working area; this includes any
appliance with a pilot light. Do not use gasoline or
a low-flash point solvent to clean the carburetor.
FUEL SYSTEM 3-25
Carburetors
NOTICE
Do not use compressed air on an assembled carbu-
retor, or the floats may be crushed by the pressure,
and the vacuum piston diaphragm may be dam-
aged. Remove as many rubber or plastic parts
from the carburetor as possible before cleaning the
carburetor with a cleaning solution. This will pre-
vent damage to or deterioration of the parts. The
carburetor body has plastic parts that cannot be
removed. Do not use a strong carburetor cleaning
solution which could attack these parts; instead,
use a mild high-flash point cleaning solution safe
for plastic parts. Do not use wire or any other hard
instrument to clean carburetor parts, especially
jets, as they may be damaged.
• Disassemble the carburetor (see Carburetor Disassem-
bly).
• Immerse all the metal parts in a carburetor cleaning solu-
tion.
• Rinse the parts in water.
• When the parts are clean, dry them with compressed air.
• Blow through the air and fuel passages with compressed
air.
• Assemble the carburetor (see Carburetor Assembly).
Carburetor Inspection
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
• Remove the carburetors (see Carburetor Removal).
• Before disassembling the carburetors, check the fuel level
(see Fuel Level Inspection).
If the fuel level is incorrect, inspect the rest of the carbu-
retor before correcting it.
• Slide the choke plunger lever [A] right to the left to check
that the choke plungers move smoothly.
If the choke plungers do not work properly, replace the
carburetors.
• Turn the throttle cable pulley to check that the throttle but-
terfly valves [B] move smoothly and return by spring ten-
sion.
If the throttle valves do not move smoothly, replace the
carburetors.
3-26 FUEL SYSTEM
Carburetors
• Disassemble the carburetors (see Carburetor Disassem-
bly).
• Clean the carburetors (see Carburetor Cleaning).
• Check that the O-rings on the float bowl and pilot screw
and the diaphragm on the vacuum piston are in good con-
dition.
If any of the O-rings or diaphragms are not in good con-
dition, replace them.
• Check the O-ring and diaphragm of coasting enricher sys-
tem.
If any of the O-ring or diaphragm are not in good condition,
replace them.
• Check the plastic tip [A] of the float valve needle [B]. It
should be smooth, without any grooves, scratches, or
tears.
If the plastic tip is damaged [C], replace the needle.
• Push the rod [D] in the other end of the float valve needle,
and then release it [E].
If the rod does not spring out, replace the needle.
• Check the tapered portion [A] of the pilot screw [B] for
wear or damage.
If the pilot screw is worn or damaged on the tapered por-
tion, it will prevent the engine from idling smoothly. Re-
place it.
• Check that the vacuum piston [A] moves smoothly in the
carburetor body. The surface of the piston must not be
excessively worn.
If the vacuum piston does not move smoothly, or if it is
very loose in carburetor body, replace the carburetor.
FUEL SYSTEM 3-27
Air Cleaner
Air Cleaner Element Removal
• Refer to Air Cleaner Cleaning in the Periodic Maintenance
chapter (see Air Cleaner Cleaning in the Periodic Mainte-
nance chapter).
Air Cleaner Element Installation
• Refer to Air Cleaner Cleaning in the Periodic Maintenance
chapter (see Air Cleaner Cleaning in the Periodic Mainte-
nance chapter).
Air Cleaner Housing Removal
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Rear Seat (see Rear Seat Removal in the Frame chap-
ter)
Fuel Tank (see Fuel Tank Removal)
Rear Fender (see Rear Fender Removal in the Frame
chapter)
• Pull out the rear axle and place the rear wheel [A] on the
ground.
• Take out the bolts [A] and remove the fuel tank bracket
[B].
• Pull out the starter relay [C].
• Remove the rear brake reservoir bolt [A] and disconnect
the clamp [B], and free the rear brake reservoir and main
harness from the frame.
• Remove the air cleaner cap [C].
• Remove:
Carburetor Holder Clamps [A] (Loosen)
Air Cleaner Housing Mounting Bolts [B]
Air Suction Valve Hose [C]
• Remove the air cleaner housing [D], pulling out the duct
portion [E] from the grommet.
3-28 FUEL SYSTEM
Air Cleaner
• Cover the carburetors intakes with a clean, lint-free towel
to keep dirt or other foreign material from entering.
WARNING
If dirt or dust is allowed to pass through into the car-
buretors, the butterfly valves may become stuck,
possibly causing accident. Replace the air cleaner
element according to the maintenance chart.
NOTICE
If dirt gets through into the engine, excessive en-
gine wear and possibly engine damage will occur.
Air Cleaner Housing Installation
• Install the air cleaner housing clamps [A] as shown.
Approx. 18° [B]
Air Cleaner Housing Disassembly
• Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal)
Air Cleaner Element (see Air Element Removal in the
Periodic Maintenance chapter)
Screw [A]
Right Cover [B]
Flame Arrester
Air Cleaner Housing Assembly
• Install the flame arrester [A].
• Be sure the O-ring [B] is in position.
FUEL SYSTEM 3-29
Air Cleaner
• Apply a bonding agent to the slash portion [A] of the air
cleaner housing.
Oil Draining
• Remove the drain cap [A] at the lower end of the air
cleaner housing and drain water or oil accumulates in the
air cleaner housing.
• Be sure to install the cap firmly, or the air is drawn in
through it.
WARNING
Oil on tires will make them slippery and can cause
an accident and injury. Be sure to reinstall the cap
in the air cleaner housing after draining.
3-30 FUEL SYSTEM
Fuel Tank
Fuel Tank Removal
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions, creating the
potential for serious burns. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light. Do not smoke. Turn the ignition switch OFF.
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
• Remove the side covers (see Side Covers Removal in the
Frame chapter).
• Turn the fuel tap position to the ON [A] position.
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
Fuel Tank Mounting Bolts [A]
Fuel Hose [B]
Vacuum Hose [C]
Fuel Level Sensor Connector [D]
Fuel Tank
• Drain the fuel tank if necessary.
○Arrange a suitable container under the fuel tap.
○Turn the fuel tap position to the PRI position to drain the
fuel into the container.
Fuel Tank Installation
• Read the above WARNING mentioned in Fuel Tank Re-
moval.
• Route the hose correctly.
• Be sure the hoses are clamped securely to prevent fuel
leaks.
• Be sure the rubber dampers [A] are in position.
If any dampers is damaged or deteriorated, replace it.
FUEL SYSTEM 3-31
Fuel Tank
Fuel Tap Removal
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
• Remove the fuel tank (see Fuel Tank Removal).
• Drain the fuel into a suitable container.
• Remove the bolts [A] and take out the fuel tap [B].
Fuel Tap Installation
• Fuel tap installation is the reverse of removal. Note the
following.
Torque - Fuel Tap Mounting Bolts: 2.5 N·m (0.25 kgf·m, 22
in·lb)
• Be sure to clamp the fuel hose to the tap to prevent leaks.
• Be sure the fuel level sensor leads [A] are routed as
shown.
Fuel Tank and Tap Cleaning
WARNING
Gasoline and low-flash point solvents can be
flammable and/or explosive and cause severe
burns. Clean the tank in a well-ventilated area, and
take care that there are no sparks or flame any-
where near the working area. Do not use gasoline
or low-flash point solvents to clean the tank.
• Remove the fuel tank and drain it.
• Pour some high flash-point solvent into the fuel tank and
shake the tank to remove dirt and fuel deposits.
• Pour high flash-point solvent.
• Pour the solvent out of the tank.
• Remove the fuel tap from the tank by taking out the bolts.
• Clean the fuel tap in a high flash-point solvent.
• Pour high flash-point solvent through the tap in ON and
PRI positions.
• Dry the tank and tap with compressed air.
• Install the tap in the tank.
• Install the fuel tank (see Fuel Tank Installation).
3-32 FUEL SYSTEM
Fuel Tank
Fuel Tap Inspection
• Remove the fuel tap (see Fuel Tap Removal).
• Check the fuel tap filter screen [A] for any breaks or dete-
rioration.
If the fuel tap screens have any breaks or are deterio-
rated, they may allow dirt to reach the carburetor, causing
poor running. Replace the fuel tap.
If the fuel tap leaks, or allows fuel to flow when it is at
ON or PRI without engine running, replace the damaged
gasket [B] or O-rings [C].
Fuel Tank and Cap Inspection
• Open the tank cap.
• Visually inspect the gaskets [A] on the tank cap for any
damage.
Replace the gaskets if they are damaged.
• Remove the drain pipes and check to see if the pipes in
the tank do not clogged up. Check the tank cap breather
also.
If they are clogged, remove the tank and drain it, and then
blow the breather free with compressed air.
NOTICE
Do not apply compressed air to the air vent holes
[B] in the tank cap. This could cause damage and
clogging of the labyrinth in the cap.
FUEL SYSTEM 3-33
Evaporative Emission Control System (CAL Model)
Separator Operation Test
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Do not smoke.
Turn the ignition switch OFF. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
• Connect the hoses to the separator, and install the sepa-
rator on the motorcycle.
• Disconnect the breather hose from the separator, and in-
ject about 20 mL (0.68 US oz.) of gasoline [A] into the
separator [B] through the hose fitting.
• Disconnect the fuel return hose [C] from the fuel tank [D].
• Run the open end of the return hose into the container
and hold it level with the tank top [E].
• Start the engine, and let it idle.
If the gasoline in the separator comes out of the hose, the
separator works well. If it does not, replace the separator
with a new one.
Canister Inspection
• Refer to the Evaporative Emission Control System In-
spection in the Periodic Maintenance chapter.
The Evaporative Emission Control System routes fuel va-
pors from the fuel system into the running engine or stores
the vapors in a canister when the engine is stopped. Al-
though no adjustments are required, a thorough visual in-
spection must be made at the intervals specified by the Pe-
riodic Maintenance Chart.
Parts Removal/Installation
WARNING
Gasoline is extremely flammable and can be explo-
sive under certain conditions. Make sure the area
is well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light. Do not smoke. Turn the ignition switch OFF.
NOTICE
If gasoline, solvent, water or any other liquid enters
the canister, the canister’s vapor absorbing capac-
ity is greatly reduced. If the canister does become
contaminated, replace it with a new one.
• To prevent the gasoline from flowing into or out of the
canister, hold the separator perpendicular to the ground.
• Connect the hoses according to the see Cable, Wire, and
Hose Routing section in the Appendix chapter. Make sure
they do not get pinched or kinked.
Hose Inspection
• Refer to the Evaporative Emission Control System In-
spection in the Periodic Maintenance chapter.
COOLING SYSTEM 4-1
Cooling System
Table of Contents
Exploded View
4-2
Specifications
4-4
Sealant
4-5
Coolant Flow Chart
4-6
Coolant
4-8
Coolant Deterioration Inspection
4-8
4
Coolant Level Inspection
4-8
Coolant Draining
4-8
Coolant Filling
4-8
Pressure Testing
4-8
Cooling System Flushing
4-9
Water Pump
4-10
Pump Cover Removal
4-10
Pump Cover Installation
4-10
Water Pump Removal
4-10
Water Pump Installation
4-10
Pump Impeller Inspection
4-11
Radiator, Radiator Fan
4-12
Radiator and Radiator Fan Removal
4-12
Radiator Inspection
4-13
Radiator Cleaning
4-13
Radiator Cap Inspection
4-13
Radiator Filler Neck Inspection
4-14
Thermostat
4-15
Thermostat Removal
4-15
Thermostat Installation
4-15
Thermostat Housing Removal
4-15
Thermostat Housing Installation Note
4-15
Thermostat Inspection
4-16
Hoses and Pipes
4-17
Hose Installation
4-17
Hose Inspection
4-17
Radiator Fan Switch, Water Temperature Switch
4-18
Radiator Fan Switch, Water Temperature Switch Removal
4-18
Radiator Fan Switch, Water Temperature Switch Installation
4-18
Radiator Fan Switch, Water Temperature Switch Inspection
4-18
4-2 COOLING SYSTEM
Exploded View
COOLING SYSTEM 4-3
Exploded View
Torque
No.
Fastener
Remarks
N·m
kgf·m
ft·lb
1
Water Temperature Switch
7.5
0.76
66 in·lb
SS
2
Thermostat Cover Bolts
9.8
1.0
87 in·lb
3
Thermostat Housing Mounting Bolts
9.8
1.0
87 in·lb
4
Radiator Fan Switch
23.5
2.4
17
5
Radiator Bolts
9.8
1.0
87
in·lb
6
Radiator Cap Bracket Bolt
9.8
1.0
87
in·lb
7
Water Pipe Bolts
9.8
1.0
87
in·lb
8
Water Hose Clamp Screws
3.0
0.31
27
in·lb
9
Drain Bolt
9.8
1.0
87
in·lb
10
Water Pump Cover Bolts
9.8
1.0
87
in·lb
11
Water Pump Bolts
9.8
1.0
87
in·lb
12
Reserve Tank Cap
-
-
-
Hand-Tighten
13
Reserve Tank Bolts
9.8
1.0
87
in·lb
14
Reserve Tank Bracket Bolt
9.8
1.0
87
in·lb
15. Radiator Fan
16. Reserve Tank
17. Thermostat
18. Radiator
19. Water Pump
G: Apply grease.
R: Replacement Parts
SS: Apply silicone sealant to the threads.
4-4 COOLING SYSTEM
Specifications
Item
Standard
Coolant
Type
Permanent type of antifreeze (soft water and ethylene glycol plus
corrosion and rust inhibitor chemicals for aluminum engines and
radiators)
Collar
Green
Mixed Ratio
Soft water 50%, coolant 50%
Freezing Point
-35°C (-31°F)
Total Capacity
1.5 L (1.59 US qt)
Radiator
Radiator Cap Relief Pressure
93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18 psi)
Thermostat
Valve Opening Temperature
63.5 ∼ 66.5°C (146 ∼ 152°F)
Valve Full Opening Lift
More than 6 mm (0.24 in.) @80°C (176°F)
COOLING SYSTEM 4-5
Sealant
Liquid Gasket, TB1211:
56019-120
4-6 COOLING SYSTEM
Coolant Flow Chart
Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion.
When the engine starts, the water pump turns and the coolant circulates.
The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The
thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
When coolant temperature is below 63.5 ∼ 66.5°C (146 ∼ 152°F), the thermostat closes so that the
coolant flow is restricted through the air bleeder hole, causing the engine to warm up more quickly.
When coolant temperature is more than 63.5 ∼ 66.5°C (146 ∼ 152°F), the thermostat opens and the
coolant flows.
When the coolant temperature goes up beyond 96 ∼ 100°C (205 ∼ 212°F), the radiator fan switch
conducts to operate the radiator fan. The radiator fan draws air through the radiator core when there
is not sufficient air flow such as at low speeds. This increases up the cooling action of the radiator.
When the temperature is below 91°C (196°F), the fan switch opens and the radiator fan stops.
In this way, this system controls the engine temperature within narrow limits where the engine op-
erates most efficiently even if the engine load varies.
The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles
which can cause engine overheating. As the engine warms up, the coolant in the radiator and the
water jacket expands. The excess coolant flows through the radiator cap and hose to the reserve tank
to be stored there temporarily. Conversely, as the engine cools down, the coolant in the radiator and
the water jacket contracts, and the stored coolant flows back to the radiator from the reserve tank.
The radiator cap has two valves. One is a pressure valve which holds the pressure in the system
when the engine is running. When the pressure exceeds 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18
psi) the pressure valve opens and releases the pressure to the reserve tank. As soon as pressure
escapes, the valve closes, and keeps the pressure at 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18 psi).
When the engine cools down, another small valve (vacuum valve) in the cap opens. As the coolant
cools, the coolant contracts to form a vacuum in the system. The vacuum valve opens and allows the
coolant from the reserve tank to enter the radiator.
COOLING SYSTEM 4-7
Coolant Flow Chart
4-8 COOLING SYSTEM
Coolant
Coolant Deterioration Inspection
• Remove the right lower fairing (see Lower Fairing Re-
moval in the Frame chapter).
• Visually inspect the coolant in the reserve tank.
If whitish cotton-like wafts are observed, aluminum parts
in the cooling system are corroded. If the coolant is
brown, iron or steel parts are rusting. In either case, flush
the cooling system.
If the coolant gives off an abnormal smell, check for a
cooling system leak. It may be caused by exhaust gas
leaking into the cooling system.
Coolant Level Inspection
• Refer to Coolant Level Inspection in the Periodic Mainte-
nance chapter (see Coolant Level Inspection in the Peri-
odic Maintenance chapter).
Coolant Draining
• Refer to Coolant Change in the Periodic Maintenance
chapter (see Coolant Change in the Periodic Mainte-
nance chapter).
Coolant Filling
• Refer to Coolant Change in the Periodic Maintenance
chapter (see Coolant Change in the Periodic Mainte-
nance chapter).
Pressure Testing
• Remove:
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
• Remove the radiator cap, and install a cooling system
pressure tester [A] on the filler neck.
NOTE
○Wet the cap sealing surfaces with water or coolant to
prevent pressure leaks.
• Build up pressure in the system carefully until the pres-
sure reaches 123 kPa (1.25 kgf/cm², 18 psi).
NOTICE
During pressure testing, do not exceed the pres-
sure for which the system is designed. The maxi-
mum pressure is 123 kPa (1.25 kgf/cm², 18 psi).
• Watch the gauge for at least 6 seconds.
If the pressure holds steady, the system is all right.
If the pressure drops and no external source is found,
check for internal leaks. Droplets in the engine oil indicate
internal leakage. Check the cylinder head gasket and the
water pump.
• Remove the pressure tester, replenish the coolant, and
install the radiator cap.
COOLING SYSTEM 4-9
Coolant
Cooling System Flushing
Over a period of time, the cooling system accumulates
rust, scale, and lime in the water jacket and radiator. When
this accumulation is suspected or observed, flush the cool-
ing system. If this accumulation is not removed, it will clog
up the water passage and considerable reduce the effi-
ciency of the cooling system.
• Drain the cooling system (see Coolant Change in the Pe-
riodic Maintenance chapter).
• Fill the cooling system with fresh water mixed with a flush-
ing compound.
NOTICE
Do not use a flushing compound which is harmful to
the aluminum engine and radiator. Carefully follow
the instructions supplied by the manufacturer of the
cleaning product.
• Warm up the engine, and run it at normal operating tem-
perature for about ten minutes.
• Stop the engine, and drain the cooling system.
• Fill the system with fresh water.
• Warm up the engine and drain the system.
• Repeat the previous two steps once more.
• Fill the system with a permanent type coolant and bleed
the air from the system (see Coolant Change in the Peri-
odic Maintenance chapter).
4-10 COOLING SYSTEM
Water Pump
Pump Cover Removal
• Drain the coolant (see Coolant Change in the Periodic
Maintenance chapter).
• Remove:
Left Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Coolant Pipes [A], [B]
Engine Sprocket Cover [C] (see Engine Sprocket Re-
moval in the Final chapter)
• Remove the water pump mounting bolts [A] and water
pump cover [B].
Pump Cover Installation
• Fit the O-ring [A] into the groove of the pump cover [B].
• Install the removed parts
Torque - Water Hose Clamp Screws: 3.0 N·m (0.31 kgf·m,
27 in·lb)
Water Pump Removal
• Remove:
Pump Cover (see Pump Cover Removal)
• Remove the water pump mounting bolts [A], and remove
the water pump [B].
Water Pump Installation
• Check the O-ring [A] visually whether or not there is a
damage on it.
• Grease the O-ring.
• Install the water pump aligning the slit [B] of water pump
shaft with the oil pump shaft.
COOLING SYSTEM 4-11
Water Pump
Pump Impeller Inspection
• Visually check the impeller [A].
If the surface is corroded or if the blades are damaged,
replace the water pump unit.
4-12 COOLING SYSTEM
Radiator, Radiator Fan
Radiator and Radiator Fan Removal
WARNING
A spinning radiator fan can cause serious injury.
The radiator fan is connected directly to the battery
and may start even if the ignition switch is off. Do
not touch the radiator fan until it has been discon-
nected from the battery.
• Remove the lower fairings (see Lower Fairing Removal in
the Frame chapter).
• Drain the coolant (see Coolant Change in the Periodic
Maintenance chapter).
• Disconnect the fan motor lead connector [A] before re-
moval of the radiator or radiator fan.
• Disconnect the fan switch lead connector [A].
Fan Switch [B]
• Loosen the hose clamp [C] and pull off the water hose [D].
• Loosen the hose clamp [A] and pull off the water hose [B].
• Remove the radiator bolts [C] and take the radiator [D] off
the frame.
• Separate the filler and water hose from the radiator.
• Separate the radiator fan [A] from the radiator.
Radiator Fan Screws [B]
NOTICE
Do not touch the radiator core. This could damage
the radiator fins, resulting in loss of cooling effi-
ciency.
COOLING SYSTEM 4-13
Radiator, Radiator Fan
Radiator Inspection
• Check the radiator core.
If there are obstructions to air flow, remove them.
If the corrugated fins [A] are deformed, carefully
straighten them.
If the air passages of the radiator core are blocked more
than 20% by unremovable obstructions or irreparably de-
formed fins, replace the radiator with a new one.
Radiator Cleaning
NOTICE
When cleaning the radiator with steam cleaner, be
careful of the following to prevent radiator damage.
Keep the steam gun [A] away more than 0.5 m (1.6
ft) [B] from the radiator core.
Hold the steam gun perpendicular to the core sur-
face.
Run the steam gun following the core fin direction.
Radiator Cap Inspection
• Remove the right lower fairing (see Lower Fairing Re-
moval in the Frame chapter).
• Check the condition of the top and bottom valve seals [A]
and valve spring [B].
If any one of them shows visible damage, replace the cap
with a new one.
• Install the cap [A] on a cooling system pressure tester [B].
NOTE
○Wet the cap sealing surfaces with water or coolant to
prevent pressure leaks.
• Watching the pressure gauge, pump the pressure tester
to build up the pressure until the relief valve opens: the
gauge hand flicks downward. Stop pumping and measure
leak time at once. The relief valve must open within the
specified range in the table below and the gauge hand
must remain within the same range at least 6 seconds.
Radiator Cap Relief Pressure
Standard:
93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18
psi)
If the cap cannot hold the specified pressure, or if it holds
too much pressure, replace it with a new one.
4-14 COOLING SYSTEM
Radiator, Radiator Fan
Radiator Filler Neck Inspection
• Check the radiator filler neck for signs of damage.
• Check the condition of the top and bottom sealing seats
[A] in the filler neck. They must be smooth and clean for
the radiator cap to function properly.
COOLING SYSTEM 4-15
Thermostat
Thermostat Removal
• Drain the coolant (see Coolant Change in the Periodic
Maintenance chapter).
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
Thermostat Cover Bolts [A]
• Move the thermostat cover [A] outwards and remove the
thermostat [B].
Thermostat Installation
• Install the removed part in reverse of removal.
• Fit the thermostat [A] in the housing so that the air bleeder
hole [B] faces as shown.
• Fill the radiator with coolant.
Thermostat Housing Removal
• Drain the Coolant (see Coolant Change in the Periodic
Maintenance chapter).
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
• Disconnect the water temperature switch lead connector
[A].
• Loosen the water hose clamps [B] and slide the hoses
[C], [D] back and forth from the thermostat housing [E]
and cover [F].
Water Temperature Switch [G]
• Remove the thermostat housing mounting bolts [H] and
pull the housing out of the frame.
• Remove the thermostat cover and pull out the thermostat
if necessary.
Thermostat Housing Installation Note
• Be sure to install the ground lead on the thermostat hous-
ing mounting bolt.
4-16 COOLING SYSTEM
Thermostat
Thermostat Inspection
• Remove the thermostat, and visually inspect the thermo-
stat valve [A] at room temperature.
If the valve is open, replace the thermostat with a new
one.
• To check valve opening temperature, suspend the ther-
mostat [A] in a container of water and raise the tempera-
ture of the water.
○The thermostat must be completely submerged and must
not touch the container sides or bottom. Suspend an ac-
curate thermometer [B] in the water so that the heat sen-
sitive portions [C] are located in almost the same depth.
It must not touch the container, either.
If the measurement is out of the specified range, replace
the thermostat with a new one.
Thermostat Valve Opening Temperature
63.5 ∼ 66.5°C (146 ∼ 152°F)
COOLING SYSTEM 4-17
Hoses and Pipes
Hose Installation
• Install the hoses and pipes, being careful to follow bend-
ing direction. Avoid sharp bending, kinking, flattening or
twisting.
• Install the clamp [A] as near as possible to the hose end
to clear the raised rib of the fitting. This will prevent the
hoses from working loose.
○The clamp screws should be positioned correctly to pre-
vent the clamps from contacting anything.
Torque - Water Hose Clamp Screws: 3.0 N·m (0.31 kgf·m,
27 in·lb)
Hose Inspection
• Refer to Radiator Hose and Connection Inspection in the
Periodic Maintenance chapter (see Radiator Hose and
Connection Inspection in the Periodic Maintenance chap-
ter).
4-18 COOLING SYSTEM
Radiator Fan Switch, Water Temperature Switch
Radiator Fan Switch, Water Temperature Switch
Removal
NOTICE
The fan switch or the water temperature switch
should never be allowed to fall on a hard surface.
Such a shock to their parts can damage them.
• Drain the coolant (see Coolant Change in the Periodic
Maintenance chapter).
• Remove:
Radiator Fan Switch Lead Connector [A]
Radiator Fan Switch [B]
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
Water Temperature Switch Lead Connector [A]
Water Temperature Switch [B]
Radiator Fan Switch, Water Temperature Switch
Installation
• Apply liquid gasket to the threads of the water tempera-
ture switch.
Sealant - Liquid Gasket, TB1211: 56019-120
• Tighten the fan switch and water temperature sensor.
Torque - Radiator Fan Switch: 23.5 N·m (2.4 kgf·m, 17 ft·lb)
Water Temperature Switch: 7.5 N·m (0.76 kgf·m,
66 in·lb)
• Fill the coolant and bleed the air from cooling system (see
Coolant Change in the Periodic Maintenance chapter).
Radiator Fan Switch, Water Temperature Switch
Inspection
• Refer to Water Temperature Switch Inspection in the Elec-
trical System chapter (see Water Temperature Switch In-
spection in the Electrical System chapter).
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