Content .. 9 10 11 12 ..

Kawasaki Ninja 650R, ER-6f, ER-6f ABS Motorcycle. Service Manual (2009-2011 year) - page 11

WHEELS/TIRES 10-3

Exploded View

Torque

No.

Fastener

N·m

kgf·m

ft·lb

Remarks

Front Axle

108

11.0

Front Axle Clamp Bolt

3.5

Rear Axle Nut

108

11.0

4. EX650D Models

G: Apply grease.

HG: Apply high-temperature grease.

R: Replacement Parts

WL: Apply soap and water solution or rubber lubricant.

10-4 WHEELS/TIRES

Specifications

Item

Standard

Service Limit

Wheels (Rims)

Rim Runout:

Axial

TIR 0.5 mm (0.02 in.) or less

TIR 1.0 mm (0.04 in.)

Radial

TIR 0.8 mm (0.03 in.) or less

TIR 1.0 mm (0.04 in.)

Axle Runout/100 mm (3.94 in.)

TIR 0.03 mm (0.001 in.) or less

TIR 0.2 mm (0.008 in.)

Wheel Balance

10 g (0.35 oz.) or less

– – –

Balance Weights

10 g (0.35 oz.)
20 g (0.71 oz.)
30 g (1.06 oz.)

– – –

Rim Size:

Front

17 × 3.50

– – –

Rear

17 × 4.50

– – –

Tires

Air Pressure (when Cold):

Front

Up to 180 kg (397 lb) load: 225 kPa
(2.25 kgf/cm², 32 psi)

– – –

Rear

Up to 180 kg (397 lb) load: 250 kPa
(2.50 kgf/cm², 36 psi)

– – –

Tread Depth:

Front

4.8 mm (0.19 in.)

1 mm (0.04 in.)

(AT, CH, DE) 1.6 mm

(0.06 in.)

Rear

6.2 mm (0.24 in.)

Up to 130 km/h (80 mph):

2 mm (0.08 in.)

Over 130 km/h (80 mph):

3 mm (0.12 in.)

Standard Tires:

Make, Type

Size

Front

BRIDGESTONE, BATTLAX
BT021F J

120/70 ZR17 M/C (58 W)

Rear

BRIDGESTONE, BATTLAX
BT021R J

160/60 ZR17 M/C (69 W)

WARNING

Use the same manufacturer’s tires on both front and rear wheels.

WHEELS/TIRES 10-5

Special Tools

Bearing Driver Set:
57001-1129

Jack:
57001-1238

Bearing Remover Head,

20 ×

22:

57001-1293

Bearing Remover Shaft,

13:

57001-1377

Jack Attachment:
57001-1608

10-6 WHEELS/TIRES

Wheels (Rims)

Front Wheel Removal

•

Remove:

Front Caliper Mounting Bolts [A] (Both Sides)
Front Caliper [B] (Both Sides)

•

Loosen:

Front Axle Clamp Bolt [A]
Front Axle [B]

•

Remove:

Lower Fairing (see Lower Fairing Removal in the Frame
chapter)
Lower Fairing Brackets (see Lower Fairing Bracket Re-
moval in the Frame chapter)

•

Raise the front wheel off the ground.

Special Tools - Jack: 57001-1238

Jack Attachment: 57001-1608

•

Pull out the axle to the right and drop the front wheel out
of the forks.

CAUTION

Do not lay the wheel down on one of the discs. This
can damage or warp the disc.

Place blocks un-

der the wheel so that the disc does not touch the
ground.

Front Wheel Installation

NOTE

○

The direction of the wheel rotation [A] is shown by an
arrow [B] on the wheel spoke.

•

Check the wheel rotation mark on the front wheel and
install it.

WHEELS/TIRES 10-7

Wheels (Rims)

•

Apply high-temperature grease to the grease seal lips.

•

Fit the collars [A] on the both sides of the hub.

○

The collars are identical.

•

Insert the front axle.

•

Remove the jack and the jack attachment.

•

Tighten:

Torque - Front Axle: 108 N·m (11.0 kgf·m, 80 ft·lb)

•

Before tightening the axle clamp bolt [A] on the right front
fork leg, pump the front fork up and down 4 or 5 times to
allow the right front fork leg to seat on the front axle.

NOTE

○

Put a block in front of the front wheel to stop moving.

•

Tighten:

Torque - Front Axle Clamp Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb)

•

Install the removed parts (see appropriate chapters).

•

Check the front brake effectiveness (see Brake Operation
Inspection in the Periodic Maintenance chapter).

WARNING

Do not attempt to drive the motorcycle until a full
brake lever is obtained by pumping the brake lever
until the pads are against the disc. The brake will
not function on the first application of the lever if
this is not done.

Rear Wheel Removal

•

Raise the rear wheel off the ground using the stand [A].

•

For models equipped with an ABS, remove the rear wheel
rotation sensor from the caliper bracket (see Rear Wheel
Rotation Sensor Removal in the Brakes chapter).

•

Remove:

Rear Caliper Mounting Bolts [A]
Rear Caliper [B]

10-8 WHEELS/TIRES

Wheels (Rims)

•

Remove:

Cotter Pin [A]
Rear Axle Nut [B]
Washer [C]
Rear Axle [D]

•

Remove the drive chain [A] from the rear sprocket toward
the left.

•

Move the rear wheel back and remove it.

CAUTION

Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.

Rear Wheel Installation

•

Apply high-temperature grease to the grease seal lips.

•

Fit the collars on the both sides of the hub.

Left Side Collar [A]
Right Side Collar [B] (with Flange)

•

Engage the drive chain with the rear sprocket.

•

Install the caliper bracket [A] onto the stopper [B] of the
swingarm.

•

Insert the axle from the right side of the wheel.

•

Install the washer and axle nut.

•

Adjust the drive chain slack before tightening the axle nut
(see Drive Chain Slack Inspection in the Periodic Mainte-
nance chapter).

•

Tighten:

Torque - Rear Axle Nut: 108 N·m (11.0 kgf·m, 80 ft·lb)

•

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.

WHEELS/TIRES 10-9

Wheels (Rims)

•

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

WARNING

If the rear axle nut is not securely tightened or the
cotter pin is not installed, an unsafe riding condi-
tion may result.

•

Install the rear caliper (see Caliper Installation in the
Brakes chapter).

•

For models equipped with an ABS, install the rear wheel
rotation sensor (see Rear Wheel Rotation Sensor Instal-
lation in the Brakes chapter).

•

Check the rear brake effectiveness (see Brake Operation
Inspection in the Periodic Maintenance chapter).

WARNING

Do not attempt to drive the motorcycle until a full
brake pedal is obtained by pumping the brake pedal
until the pads are against the disc. The brake will
not function on the first application of the pedal if
this is not done.

Wheel Inspection

•

Raise the front/rear wheel off the ground.

Special Tools - Jack: 57001-1238

Jack Attachment: 57001-1608

•

Spin the wheel lightly, and check for roughness or binding.
If roughness or binding is found, replace the hub bearings
(see Hub Bearing Removal/Installation).

•

Inspect the wheel for small cracks, dents, bending, or
warp.
If there is any damage to the wheel, replace the wheel.

•

Remove the wheel, and support it with the tire by the axle.

•

Measure the rim runout, axial [A] and radial [B], with a dial
gauge.
If rim runout exceeds the service limit, check the hub bear-
ings (see Hub Bearing Inspection).
If the problem is not due to the bearings, replace the
wheel.

Rim Runout (with tire installed)

Standard:

Axial

TIR 0.5 mm (0.02 in.) or less

Radial

TIR 0.8 mm (0.03 in.) or less

Service Limit:

Axial

TIR 1.0 mm (0.04 in.)

Radial

TIR 1.0 mm (0.04 in.)

WARNING

Never attempt to repair a damaged wheel. If there
is any damage besides wheel bearings, the wheel
must be replaced to insure safe operational condi-
tion.

10-10 WHEELS/TIRES

Wheels (Rims)

Axle Inspection

•

Remove the front and rear axles (see Front/Rear Wheel
Removal).

•

Visually inspect the front and rear axles for damages.
If the axle is damaged or bent, replace it.

•

Measure the axle runout.

○

Place the axle in V blocks that are 100 mm (3.94 in.) [A]
apart.

○

Set a dial gauge [B] on the axle at a point halfway between
the blocks.

○

Turn [C] the axle.

○

The difference between the highest and lowest dial read-
ings is the amount of runout.
If axle runout exceeds the service limit, replace the axle.

Axle Runout/100 mm (3.94 in.)

Standard:

TIR 0.03 mm (0.001 in.) or less

Service Limit:

TIR 0.2 mm (0.008 in.)

Balance Inspection

•

Remove the front and rear wheels (see Front/Rear Wheel
Removal).

•

Support the wheel so that it can be spun freely.

•

Spin the wheel lightly, and mark [A] the wheel at the top
when the wheel stops.

○

Repeat this procedure several times. If the wheel stops
of its own accord in various positions, it is well balanced.
If the wheel always stops in one position, adjust the wheel
balance (see Balance Adjustment).

Balance Adjustment

•

If the wheel always stops in one position, provisionally
attach a balance weight [A] on the rim at the marking using
adhesive tape.

•

Rotate the wheel 1/4 turn [B], and see whether or not the
wheel stops in this position. If it does, the correct balance
weight is being used.
If the wheel rotates and the weight goes up, replace the
weight with the next heavier size. If the wheel rotates and
the weight goes down, replace the weight with the next
lighter size. Repeat these steps until the wheel remains
at rest after being rotated 1/4 turn.

•

Rotate the wheel another 1/4 turn and then another 1/4
turn to see if the wheel is correctly balanced.

•

Repeat the entire procedure as many times as necessary
to achieve correct wheel balance.

•

Permanently install the balance weight.

WHEELS/TIRES 10-11

Wheels (Rims)

Balance Weight Removal

•

Insert a regular tip screwdrivers [A] [B] between the rib [C]
and the weight [D] as shown in the figure.

•

Pry the balance weight with two screwdrivers and remove
the balance weight.

•

Discard the used balance weight.

CAUTION

Do not tap the screwdrivers. The rim could be dam-
aged.

Balance Weight Installation

•

Check if the weight portion has any play on the blade [A]
and clip [B].
If it does, discard it.

WARNING

If the balance weight has any play on the rib of the
rim, the blade and/or clip have been stretched. Re-
place the loose balance weight. Do not reuse used
balance weight. Unbalanced wheels can create an
unsafe riding condition.

Balance Weight

Part Number

Weight

41075-0007

10 g (0.35 oz.)

41075-0008

20 g (0.71 oz.)

41075-0009

30 g (1.06 oz.)

NOTE

○

Balance weights are available from Kawasaki dealers
in 10, 20 and 30 grams (0.35, 0.71 and 1.06 oz.) sizes.
An imbalance of less than 10 grams (0.35 oz.) will not
usually affect running stability.

○

Do not use four or more balance weight (more than 90
gram, 3.2 oz.). If the wheel requires an excess balance
weight, disassemble the wheel to find the cause.

•

Slip the balance weight [A] onto the rib [B] by pushing or
lightly hammering [C] the clip [D].

Left Side [E]
Right Side [F]

10-12 WHEELS/TIRES

Wheels (Rims)

•

Be sure to install the balance weight.

○

Check that the blade [A] and clip [B] are fully seated on
the rim [C] and that the clip is hooked over the rib [D].

Left Side [E]
Right Side [F]

WHEELS/TIRES 10-13

Tires

Air Pressure Inspection/Adjustment

•

Refer to the Air Pressure Inspection in the Periodic Main-
tenance chapter.

Tire Inspection

•

Refer to the Wheel/Tire Damage Inspection in the Peri-
odic Maintenance chapter.

Tire Removal

•

Remove:

Wheels (see Front/Rear Wheel Removal)
Valve Core (Let out the air)

•

To maintain wheel balance, mark the valve stem position
on the tire with chalk so that the tire can be reinstalled in
the same position.

Chalk Mark or Yellow Mark [A]
Air Valve [B]
Align [C]

•

Lubricate the tire beads and rim flanges on both sides with
a soap and water solution or rubber lubricant. This helps
the tire beads slip off the rim flanges.

CAUTION

Never lubricate with engine oil or petroleum distil-
lates because they will deteriorate the tire.

•

Remove the tire from the rim using a suitable commer-
cially available tire changer.

NOTE

○

The tires cannot be removed with hand tools because
they fit the rims too tightly.

Tire Installation

WARNING

Use the same manufacturer’s tires on both front and
rear wheels.

•

Inspect the rim and tire, and replace them if necessary.

•

Clean the sealing surfaces of the rim and tire, and smooth
the sealing surfaces of the rim with a fine emery cloth if
necessary.

•

Remove the air valve and discard it.

CAUTION

Replace the air valve whenever the tire is replaced.
Do not reuse the air valve.

10-14 WHEELS/TIRES

Tires

•

Install a new valve in the rim.

○

Remove the valve cap, lubricate the stem seal [A] with a
soap and water solution or rubber lubricant, and pull [B]
the valve stem through the rim from the inside out until it
snaps into place.

CAUTION

Do not use engine oil or petroleum distillates to lu-
bricate the stem because they will deteriorate the
rubber.

○

The air valve is shown in the figure.

Valve Cap [A]
Valve Core [B]
Stem Seal [C]
Valve Stem [D]
Valve Seat [E]
Valve Opened [F]

•

Check the tire rotation mark on the front and rear tires and
install them on the rim accordingly.

Tire Rotation Mark [A]
Rotating Direction [B]

•

Position the tire on the rim so that the air valve [A] align
with the tire balance mark [B] (the chalk mark made during
removal, or the yellow paint mark on a new tire).

•

Install the tire bead over the rim flange using a suitable
commercially available tire changer.

•

Lubricate the tire beads and rim flanges with a soap and
water solution or rubber lubricant to help seat the tire
beads in the sealing surfaces of the rim while inflating the
tire.

•

Center the rim in the tire beads, and inflate the tire with
compressed air until the tire beads seat in the sealing
surfaces.

WARNING

Be sure to install the valve core whenever inflating
the tire, and do not inflate the tire to more than 400
kPa (4.0 kgf/cm², 57 psi). Overinflation can explode
the tire with possibility of injury and loss of life.

WHEELS/TIRES 10-15

Tires

•

Check to see that the rim lines [A] on both sides of the tire
sidewalls are parallel with the rim flanges.
If the rim flanges and tire sidewall rim lines are not parallel,
remove the valve core.

•

Lubricate the rim flanges and tire beads.

•

Install the valve core and inflate the tire again.

•

After the tire beads seat in the rim flanges, check for air
leakage.

○

Inflate the tire slightly above standard inflation.

○

Use a soap and water solution or submerge the tire, and
check for bubbles that would indicate leakage.

•

Adjust the air pressure to the specified pressure (see Air
Pressure Inspection in the Periodic Maintenance chap-
ter).

•

Install the air valve cap.

•

Adjust the wheel balance (see Balance Adjustment).

Tire Repair

Currently two types of repair for tubeless tires have come

into wide use. One type is called a temporary (external) re-
pair which can be carried out without removing the tire from
the rim, and the other type is called permanent (internal)
repair which requires tire removal. It is generally under-
stood that higher running durability is obtained by perma-
nent (internal) repairs than by temporary (external) ones.
Also, permanent (internal) repairs have the advantage of
permitting a thorough examination for secondary damage
not visible from external inspection of the tire. For these
reasons, Kawasaki does not recommend temporary (exter-
nal) repair. Only appropriate permanent (internal) repairs
are recommended. Repair methods may vary slightly from
make to make. Follow the repair methods indicated by the
manufacturer of the repair tools and materials so that safe
results can be obtained.

10-16 WHEELS/TIRES

Hub Bearing

Hub Bearing Removal

•

Remove the wheels (see Front/Rear Wheel Removal),
and take out the following.

Collars
Coupling (Out of rear hub)
Grease Seals

•

Use the bearing remover to remove the hub bearings [A].

CAUTION

Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place wooden blocks under the wheel so that the
disc does not touch the ground.

Special Tools - Bearing Remover Head,

20 ×

22 [B]:

57001-1293

Bearing Remover Shaft,

13 [C]: 57001

-1377

Hub Bearing Installation

•

Before installing the hub bearings, blow any dirt or foreign
particles out of the hub with compressed air to prevent
contamination of the bearings.

•

Replace the bearings with new ones.

NOTE

○

Install the bearings so that the marked side faces out.

•

Install the bearings by using the bearing driver set which
does not contact the bearing inner race.

•

Press in each bearing [A] right until they are bottomed.

Special Tool - Bearing Driver Set [B]: 57001-1129

•

Replace the grease seals with new ones.

•

Press in the grease seals [A] so that the seal surface is
flush [B] with the end of the hole.

○

Apply high-temperature grease to the grease seal lips.

Special Tool - Bearing Driver Set [C]: 57001-1129

Hub Bearing Inspection

Since the hub bearings are made to extremely close tol-

erances, the clearance can not normally be measured.

NOTE

○

Do not remove any bearings for inspection. If any bear-
ings are removed, they will need to be replaced with
new ones.

•

Turn each bearing in the hub back and forth [A] while
checking for plays, roughness, or binding.
If bearing play, roughness or binding is found, replace the
bearing.

•

Examine the bearing seal [B] for tears or leakage.
If the seal is torn or is leaking, replace the bearing.

WHEELS/TIRES 10-17

Hub Bearing

Hub Bearing Lubrication

NOTE

○

Since the hub bearings are packed with grease and
sealed, lubrication is not required.

FINAL DRIVE 11-1

Final Drive

Table of Contents

Exploded View........................................................................................................................

11-2

Specifications .........................................................................................................................

11-4

Special Tools ..........................................................................................................................

11-5

Drive Chain.............................................................................................................................

11-6

Drive Chain Slack Inspection ............................................................................................

11-6

Drive Chain Slack Adjustment ..........................................................................................

11-6

Wheel Alignment Inspection/Adjustment ..........................................................................

11-6

Drive Chain Wear Inspection ............................................................................................

11-6

Drive Chain Lubrication.....................................................................................................

11-6

Drive Chain Removal ........................................................................................................

11-6

Drive Chain Installation .....................................................................................................

11-7

Sprocket, Coupling .................................................................................................................

11-10

Engine Sprocket Removal ................................................................................................

11-10

Engine Sprocket Installation .............................................................................................

11-11

Rear Sprocket Removal....................................................................................................

11-11

Rear Sprocket Installation.................................................................................................

11-11

Coupling Installation..........................................................................................................

11-12

Coupling Bearing Removal ...............................................................................................

11-12

Coupling Bearing Installation ............................................................................................

11-12

Coupling Bearing Inspection .............................................................................................

11-13

Coupling Bearing Lubrication............................................................................................

11-13

Coupling Damper Inspection.............................................................................................

11-13

Sprocket Wear Inspection.................................................................................................

11-13

Rear Sprocket Warp Inspection ........................................................................................

11-14

11-2 FINAL DRIVE

Exploded View

FINAL DRIVE 11-3

Exploded View

Torque

No.

Fastener

N·m

kgf·m

ft·lb

Remarks

Engine Sprocket Nut

125

12.7

Rear Axle Nut

108

11.0

Rear Sprocket Nuts

6.0

Speed Sensor Bolt

7.8

0.80

69 in·lb

Speed Sensor Bracket Bolts

9.8

1.0

87 in·lb

G: Apply grease.

HG: Apply high-temperature grease.
HO: Apply heavy oil.

L: Apply a non-permanent locking agent.

MO: Apply molybdenum disulfide oil solution.

(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)

R: Replacement Parts

11-4 FINAL DRIVE

Specifications

Item

Standard

Service Limit

Drive Chain

Drive Chain Slack

∼

35 mm (1.0

∼

1.4 in.)

– – –

Drive Chain Wear (20-link Length) 317.5

∼

318.2 mm (12.50

∼

12.53 in.)

323 mm (12.7 in.)

Standard Chain:

Make

DAIDO

– – –

Type

DID 520VP2-T

– – –

Link

114 Links

– – –

Sprockets

Rear Sprocket Warp

TIR 0.4 mm (0.016 in.) or less

TIR 0.5 mm (0.020 in.)

FINAL DRIVE 11-5

Special Tools

Inside Circlip Pliers:
57001-143

Bearing Driver Set:
57001-1129

11-6 FINAL DRIVE

Drive Chain

Drive Chain Slack Inspection

•

Refer to the Drive Chain Slack Inspection in the Periodic
Maintenance chapter.

Drive Chain Slack Adjustment

•

Refer to the Drive Chain Slack Adjustment in the Periodic
Maintenance chapter.

Wheel Alignment Inspection/Adjustment

•

Refer to the Wheel Alignment Inspection in the Periodic
Maintenance chapter.

Drive Chain Wear Inspection

•

Refer to the Drive Chain Wear Inspection in the Periodic
Maintenance chapter.

Drive Chain Lubrication

•

Refer to the Drive Chain Lubrication Condition Inspection
in the Periodic Maintenance chapter.

Drive Chain Removal

NOTE

○

Since the drive chain is installed through the swingarm,
the chain cannot be removed other than by cutting it.
Prepare the new link pin, link plate, grease seals, and
tools for rejoining the chain.

•

Remove the muffler body (see Muffler Body Removal in
the Engine Top End chapter).

•

Using a suitable tool, replace the drive chain.

Recommended Tool - DID Chain Joint “ZJ”

Make DAIDO KOGYO

CAUTION

Read the Tool Manual before replacing the chain.

•

Remove:

Body [A]
Pin Holder [B]
Positioning Pin [C]
“U” Holder [D]
Plate Holder [E]
Cutting and Riveting Pin [F]
Part for Riveting [G]
Part for Cutting [H]

FINAL DRIVE 11-7

Drive Chain

•

Grind [A] the heads of the link pin to make it flat.

•

Set the cutting and riveting pin [C] in the pin holder [B] as
shown in the figure.

•

Set the “U” holder and body, align the positioning pin [A]
with the “A mark” [B].

•

Tighten the pin holder by hand until the cutting and riveting
pin touches the link pin.

•

Be sure that the cutting and riveting pin hits center of the
link pin.

•

Hold the body with a wrench [A].

•

Turn the pin holder clockwise [B] with another wrench,
and remove the link pin.

•

Do the same procedure for removal of the other link pin.

Drive Chain Installation

•

Engage the new drive chain to the old drive chain, and
change the position of the chains by pulling the old chain.

•

Remove the old drive chain from the new drive chain.

•

Replace the link pin [A], link plate and grease seals [B]
[C] with new ones.

•

Apply grease to the link pin and grease seals.

•

Install the grease seals on the link pin and insert it in the
ends of the drive chain.

•

Install the link plate so that the mark [D] faces out.

•

Set the cutting and riveting pin [B] and plate holder [C] on
the pin holder [A] as shown in the figure.

11-8 FINAL DRIVE

Drive Chain

•

Set the “U” holder and body, align the positioning pin [A]
with the “A mark” [B].

•

Hold the body with a wrench [C].

•

Turn the pin holder clockwise [D] with another wrench and
press in the link plate on the link pin.

•

Remove the “U” holder and body.

•

Set the cutting and riveting pin [B] in the pin holder [A] as
shown in the figure.

•

Set the “U” holder and body, align the positioning pin [A]
with the “B mark” [B].

•

Tighten the pin holder by hand until the cutting and riveting
pin touches the link pin.

•

Hold the body with a wrench [A].

•

Turn the pin holder clockwise [B] with another wrench until
the cutting and riveting pin touches the link plate.

•

Do the same procedure for removal of the other link pin.

FINAL DRIVE 11-9

Drive Chain

•

After riveting, check the ends of the riveted pins for
cracks.

•

Measure the outside diameter [A] of the link pin and width
[B] of the link plates.

Link Pin Outside Diameter

Standard:

5.7

∼

6.0 mm (0.22

∼

0.24 in.)

Link Plate Outside Width

Standard:

17.25

∼

17.55 mm (0.679

∼

0.691 in.)

If the reading is not the specified length, cut and rejoin the
chain again.

•

Check that the rollers move smoothly.

•

Adjust the drive chain slack after installing the chain (see
Drive Chain Slack Adjustment in the Periodic Mainte-
nance chapter).

11-10 FINAL DRIVE

Sprocket, Coupling

Engine Sprocket Removal

•

Remove:

Left Frame Cover (see Frame Cover Removal in the
Frame chapter)
Engine Sprocket Cover Bolts [A]
Engine Sprocket Cover [B]

•

Remove:

Speed Sensor Bracket Bolts [A]
Speed Sensor Bracket [B]

•

Flatten out the bended washer [A].

•

Remove the engine sprocket nut [B] and washer.

NOTE

○

When loosening the engine sprocket nut, hold the rear
brake on.

•

Loosen the drive chain (see Drive Chain Slack Adjust-
ment in the Periodic Maintenance chapter).

•

Remove the drive chain from the rear sprocket toward the
right.

•

Pull the engine sprocket [A] with drive chain [B] off the
output shaft [C].

•

Disengage the drive chain from the engine sprocket.

FINAL DRIVE 11-11

Sprocket, Coupling

Engine Sprocket Installation

•

Replace the sprocket washer with a new one.

•

Install the engine sprocket [A] so that “OUTSIDE” letters
face outward.

•

Apply molybdenum disulfide oil solution to the threads
of the output shaft and seating surface of the engine
sprocket nut.

•

After torquing the engine sprocket nut, bend the one side
of the washer [B] over the nut.

NOTE

○

Tighten the engine sprocket nut while applying the rear
brake.

•

Tighten:

Torque - Engine Sprocket Nut: 125 N·m (12.7 kgf·m, 92 ft·lb)

Speed Sensor Bracket Bolts: 9.8 N·m (1.0 kgf·m,

87 in·lb)

•

Install the engine sprocket cover, and tighten the bolts.

•

Adjust the drive chain slack after installing the sprocket
(see Drive Chain Slack Adjustment in the Periodic Main-
tenance chapter).

•

Bend the end of axle cotter pin surely after tightening the
axle nut (see Rear Wheel Installation in the Wheels/Tires
chapter).

Rear Sprocket Removal

•

Remove the rear wheel (see Rear Wheel Removal in the
Wheels/Tires chapter).

CAUTION

Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks to under the wheel so that the disc
does not touch the ground.

•

Remove the rear sprocket nuts [A].

•

Remove the rear sprocket [B].

Rear Sprocket Installation

•

Install the sprocket facing the tooth number marking [A]
outward.

•

Tighten:

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

•

Install the rear wheel (see Rear Wheel Installation in the
Wheels/Tires chapter).

11-12 FINAL DRIVE

Sprocket, Coupling

Coupling Installation

•

Apply high-temperature grease to the coupling grease
seal lips [A].

•

Apply grease to the coupling internal surface [B].

•

Apply grease to the following.

Wheel Flange Portion [A]
O-ring [B]

•

Install the collar [C].

Coupling Bearing Removal

•

Remove:

Coupling
Grease Seal
Circlip [A]

Special Tool - Inside Circlip Pliers: 57001-143

•

Remove the bearing [A] by tapping from the wheel side.

Special Tool - Bearing Driver Set [B]: 57001-1129

Coupling Bearing Installation

•

Replace the bearing with a new one.

•

Press in the bearing [A] until it is bottomed.

Special Tool - Bearing Driver Set [B]: 57001-1129

•

Replace the circlip with a new one.

Special Tool - Inside Circlip Pliers: 57001-143

FINAL DRIVE 11-13

Sprocket, Coupling

•

Replace the grease seal with a new one.

•

Press in the grease seal so that the seal surface is flush
with the end of the hole.

○

Apply high-temperature grease to the grease seal lips.

Special Tool - Bearing Driver Set: 57001-1129

Coupling Bearing Inspection

Since the coupling bearing is made to extremely close

tolerances, the clearance can not normally be measured.

NOTE

○

It is not necessary to remove the coupling bearing for
inspection. If the bearing is removed, it will need to be
replaced with a new one.

•

Turn the bearing in the coupling back and forth [A] while
checking for plays, roughness or binding.
If the bearing play, roughness or binding is found, replace
the bearing.

•

Examine the bearing seal [B] for tears or leakage.
If the seal is torn or is leaking, replace the bearing.

Coupling Bearing Lubrication

NOTE

○

Since the coupling bearing is packed with grease and
sealed, lubrication is not required.

Coupling Damper Inspection

•

Remove the rear wheel coupling, and inspect the rubber
dampers [A].

•

Replace the damper if it appears damaged or deterio-
rated.

Sprocket Wear Inspection

•

Visually inspect the engine and rear sprocket teeth for
wear and damage.
If the teeth are worn as illustrated, replace the sprocket,
and inspect the drive chain wear (see Drive Chain Wear
Inspection in the Periodic Maintenance chapter).

Worn Tooth (Engine Sprocket) [A]
Worn Tooth (Rear Sprocket) [B]
Direction of Rotation [C]

NOTE

○

If a sprocket requires replacement, the chain is proba-
bly worn also. When replacing a sprocket, inspect the
chain.

11-14 FINAL DRIVE

Sprocket, Coupling

Rear Sprocket Warp Inspection

•

Raise the rear wheel off the ground with stand so that it
will turn freely.

•

Set a dial gauge [A] against the rear sprocket [B] near the
teeth as shown, and rotate [C] the rear wheel to measure
the sprocket runout (warp). The difference between the
highest and lowest dial gauge readings is the amount of
runout (warp).
If the runout exceeds the service limit, replace the rear
sprocket.

Rear Sprocket Warp

Standard:

TIR 0.4 mm (0.016 in.) or less

Service Limit:

TIR 0.5 mm (0.020 in.)

BRAKES 12-1

Brakes

Table of Contents

Exploded View........................................................................................................................

12-4

Specifications .........................................................................................................................

12-12

Special Tools ..........................................................................................................................

12-13

Brake Lever, Brake Pedal.......................................................................................................

12-14

Brake Lever Position Adjustment......................................................................................

12-14

Brake Pedal Position Inspection .......................................................................................

12-14

Brake Pedal Position Adjustment......................................................................................

12-14

Brake Pedal Removal .......................................................................................................

12-14

Brake Pedal Installation ....................................................................................................

12-15

Calipers ..................................................................................................................................

12-16

Caliper Removal ...............................................................................................................

12-16

Caliper Installation ............................................................................................................

12-16

Front Caliper Disassembly................................................................................................

12-17

Front Caliper Assembly.....................................................................................................

12-17

Rear Caliper Disassembly ................................................................................................

12-17

Rear Caliper Assembly .....................................................................................................

12-17

Caliper Fluid Seal Damage Inspection..............................................................................

12-17

Caliper Dust Seal Damage Inspection ..............................................................................

12-18

Caliper Dust Boot and Friction Boot Damage Inspection..................................................

12-18

Caliper Piston and Cylinder Damage Inspection ..............................................................

12-19

Caliper Holder Shaft Wear Inspection...............................................................................

12-19

Brake Pads .............................................................................................................................

12-20

Front Brake Pad Removal.................................................................................................

12-20

Front Brake Pad Installation..............................................................................................

12-20

Rear Brake Pad Removal .................................................................................................

12-20

Rear Brake Pad Installation ..............................................................................................

12-20

Brake Pad Wear Inspection ..............................................................................................

12-20

Master Cylinder ......................................................................................................................

12-21

Front Master Cylinder Removal ........................................................................................

12-21

Front Master Cylinder Installation .....................................................................................

12-21

Rear Master Cylinder Removal.........................................................................................

12-22

Rear Master Cylinder Installation......................................................................................

12-22

Front Master Cylinder Disassembly ..................................................................................

12-22

Rear Master Cylinder Disassembly...................................................................................

12-22

Master Cylinder Assembly ................................................................................................

12-22

Master Cylinder Inspection ...............................................................................................

12-23

Brake Disc ..............................................................................................................................

12-24

Brake Disc Removal .........................................................................................................

12-24

Brake Disc Installation ......................................................................................................

12-24

Brake Disc Wear Inspection..............................................................................................

12-24

Brake Disc Warp ...............................................................................................................

12-24

Brake Fluid .............................................................................................................................

12-25

Brake Fluid Level Inspection.............................................................................................

12-25

Brake Fluid Change ..........................................................................................................

12-25

Brake Line Bleeding..........................................................................................................

12-25

Brake Hose.............................................................................................................................

12-28

Brake Hose Removal/Installation......................................................................................

12-28

Brake Hose Inspection......................................................................................................

12-28

Anti-Lock Brake System (Equipped Models) ..........................................................................

12-29

Parts Location ...................................................................................................................

12-29

12-2 BRAKES

ABS Servicing Precautions ...............................................................................................

12-33

ABS Troubleshooting Outline............................................................................................

12-35

Inquiries to Rider...............................................................................................................

12-38

Self-diagnosis Outline .......................................................................................................

12-40

Self-diagnosis Procedures ................................................................................................

12-40

Service Code Clearing Procedures...................................................................................

12-41

How to Read Service Codes.............................................................................................

12-43

How to Erase Service Codes ............................................................................................

12-43

ABS Indicator Light (LED) Inspection ...............................................................................

12-45

Solenoid Valve Inspection (Service Code 13,14,17,18)....................................................

12-45

ABS Solenoid Valve Relay Inspection (Service Code 19) ................................................

12-45

Front, Rear Wheel Rotation Difference Abnormal (Service Code 25) ..............................

12-47

ABS Motor Relay Inspection (Service Code 35) ...............................................................

12-47

Front Wheel Rotation Sensor Signal Abnormal (Service Code 42) ..................................

12-48

Front Wheel Rotation Sensor Wiring Inspection (Service Code 43) .................................

12-49

Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44)...................................

12-50

Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45)..................................

12-51

Power Supply Voltage Abnormal (Under-Voltage) (Service Code 52) ..............................

12-51

Power Supply Voltage Abnormal (Over-Voltage) (Service Code 53) ................................

12-52

ECU Inspection (Service Code 55) ...................................................................................

12-53

ABS Hydraulic Unit Removal ............................................................................................

12-54

ABS Hydraulic Unit Installation .........................................................................................

12-55

ABS Hydraulic Unit Inspection ..........................................................................................

12-56

Front Wheel Rotation Sensor Removal ............................................................................

12-56

Front Wheel Rotation Sensor Installation .........................................................................

12-57

Rear Wheel Rotation Sensor Removal .............................................................................

12-57

Rear Wheel Rotation Sensor Installation ..........................................................................

12-58

Wheel Rotation Sensor Inspection....................................................................................

12-58

Wheel Rotation Sensor Air Gap Inspection ......................................................................

12-58

Wheel Rotation Sensor Rotor Inspection..........................................................................

12-59

Brake Hose and Pipe Removal/Installation.......................................................................

12-59

Brake Hose and Pipe Inspection.......................................................................................

12-59

ABS Solenoid Valve Relay Fuse 25 A Removal ...............................................................

12-59

ABS Motor Relay Fuse 30 A Removal..............................................................................

12-59

Fuse Installation................................................................................................................

12-59

Fuse Inspection.................................................................................................................

12-60

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