Viscosity: SAE 10W-30 JASO T 903 standard: MA

 

Check that the O-ring [4] is in good condition, replace it if necessary.

 

Apply engine oil to the O-ring.

 

Install the oil filler cap.

 

ENGINE OIL CHANGE

 

Warm up the engine.

 

Stop the engine and remove the oil filler cap [1].

 

Place an oil pan under the engine to catch the engine oil, then remove the engine oil drain bolt [1]/sealing washer [2].

Drain the engine oil completely.

 

Install a new sealing washer onto the drain bolt.

 

Install and tighten the drain bolt to the specified torque.

 

TORQUE:24 N·m (2.4 kgf·m, 18 lbf·ft)

 

Fill the engine with the recommended engine oil (page 3-9).

 

ENGINE OIL CAPACITY:

 

Liters (1.5 US qt, 1.2 Imp qt) at draining

Liters (1.6 US qt, 1.3 Imp qt) at oil filter change

Liters (1.9 US qt, 1.6 Imp qt) at disassembly

 

Install the oil filler cap.

 

Check the oil level (page 3-9).

 

Make sure there are no oil leaks.

 

[4]

 

 

[3]

 

[1] [2]

 

[1]

 

[2]

 

 

[1]

 

3-9

MAINTENANCE

ENGINE OIL FILTER

 

REPLACEMENT
Drain the engine oil (page 3-9).
[1]
Remove the following:
–	Bolts [1]
– Oil filter cover [2]
–	Gasket [3]
–	Spring [4]

 

			[2]/[3]
Remove the oil filter [1].						[4]
[4]
							[5]
			[2]
Install a new oil filter with the "OUT-SIDE" mark [2]

facing out.

Installing the oil filter backwards will result in severe engine damage.

 

Install the oil filter spring [3] into the oil filter cover [4]. Install a new gasket [5] and oil filter cover.

 

Install the cover bolts and tighten them.

 

Fill the engine with the recommended engine oil (page 3-9).

 

Make sure there are no oil leaks.	[3]		[1]

 

ENGINE IDLE SPEED

• Inspect the idle speed after all other engine maintenance items have been performed and are within specifications.

 

• Before checking the idle speed, inspect the following items.

 

– No MIL blinking

– Spark plug condition (page 3-5)

– Secondary air supply system condition (page 3-11)

– Crankcase breather system condition (page 3-4)

– Air cleaner element condition (page 3-4)

• The engine must be warm for accurate idle speed inspection.

• This system eliminates the need for manual idle speed adjustment compared to previous designs.

 

Start the engine and let it idle. Check the idle speed.

 

IDLE SPEED: 1,450 ± 100 min^-1 (rpm)

 

If the idle speed is out of the specification, check the following:

 

– Intake air leak or engine top-end problem (page 10-2)

 

– Throttle operation and freeplay (page 3-3)

– IACV operation (page 7-16)

 

 

3-10

MAINTENANCE

 

RADIATOR COOLANT

 

Check the coolant level of the reserve tank with the engine running at normal operating temperature.

 

The level should be between the "UPPER" [1] and "LOWER" [2] level lines with the motorcycle in an upright position.

 

If the level is low, remove the reserve tank cap [3] and fill the tank to the "UPPER" level line with a 1:1 mixture of distilled water and antifreeze.

 

RECOMMENDED ANTIFREEZE:

 

High quality ethylene glycol antifreeze containing silicate-free corrosion inhibitors

 

Check to see if there are any coolant leaks when the coolant level decreases very rapidly.

 

If the reserve tank becomes completely empty, there is a possibility of air getting into the cooling system.

 

Be sure to remove any air from the cooling system (page 9-5).

 

COOLING SYSTEM

 

Check the radiator air passages for clogging or damage.

 

Straighten bent fins, and remove insects, mud or other obstructions with compressed air or low water pressure. Replace the radiator if the air flow is restricted over more than 20% of the radiating surface.

 

Inspect the water hoses for cracks or deterioration, and replace them if necessary.

 

Check the tightness of all water hose band screws (page 9-7).

 

[3]

 

 

[1]

 

[2]

 

 

SECONDARY AIR SUPPLY SYSTEM

 

• This model is equipped with a built-in secondary air supply system. The pulse secondary air supply system is located on the cylinder head cover [1].

 

• The secondary air supply system introduces filtered air into exhaust gases in the exhaust port [2].

The secondary air is drawn into the exhaust port whenever there is negative pressure pulse in the exhaust system. This charged secondary air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water.

 

[1]

 

[2]

 

 

3-11

MAINTENANCE

 

 

If the hoses show any signs of heat damage, inspect the PAIR check valve in the cylinder head cover for damage (page 7-18).

 

 

Remove the right fuel tank shroud (page 2-4).
[1]		[2]
Check the PAIR air supply hose [1] between the PAIR
control solenoid valve [2] and cylinder head cover for
deterioration, damage or loose connections. Make sure
that the hoses are not cracked.

Check the air suction hose [3] between the air cleaner and PAIR control solenoid valve for deterioration, damage or loose connections.

 

Make sure that the hoses are not kinked, pinched or cracked.

 

[3]

 

 

DRIVE CHAIN

 

 

Never inspect and adjust the drive chain while the engine is running.

 

 

DRIVE CHAIN SLACK INSPECTION
Turn the ignition switch OFF, support the motorcycle on
its sidestand and shift the transmission into neutral.
Check the slack in the drive chain lower run midway
between the sprockets.	25 – 35 mm (1.0 – 1.4 in)
DRIVE CHAIN SLACK: 25 – 35 mm (1.0 – 1.4 in)

 

Excessive chain slack, 50 mm (2.0 in) or more, may damage the frame.

 

 

ADJUSTMENT

 

Loosen the rear axle nut [1].
[1]		[2]
Loosen the lock nuts [2] and turn the adjusters [3] until
the correct drive chain slack is obtained.

 

 

[3]

 

 

3-12

MAINTENANCE

 

Make sure the same index lines [1] on both adjusting plates [2] are aligned with punch mark [3] in the swingarm.

Tighten the axle nut to the specified torque.

 

TORQUE:88 N·m (9.0 kgf·m, 65 lbf·ft)

 

Hold the drive chain adjusters [4] and tighten the lock nuts [5] to the specified torque.

 

TORQUE:27 N·m (2.8 kgf·m, 20 lbf·ft)

 

Recheck the drive chain slack and free wheel rotation.

 

Check the drive chain wear indicator label attached on the left swingarm.

If the drive chain adjuster cut-out [1] reaches red zone [2] of the indicator label, replace the drive chain with a new one.

 

CLEANING AND LUBRICATION

 

[2]

 

 

[5]		[4]
[1]/[3]

 

 

[2] [1]

 

Clean the drive chain [1] with a chain cleaner designed specifically for O-ring chains or a neutral detergent. Use ^[1] a soft brush if the drive chain is dirty.

 

Do not use a steam cleaner, high pressure cleaner, wire brush, volatile solvent such as gasoline and benzene, abrasive cleaner or a chain cleaner NOT designed specifically for O-ring chains to clean the drive chain.

 

Inspect the drive chain for possible damage or wear.

 

Replace any drive chain that has damaged rollers, loose fitting links, or otherwise appears unserviceable.

Be sure the drive chain has dried completely before	[2]
lubricating.

 

Lubricate the drive chain with drive chain lubricant [2] designed specifically for use with O-ring chains, #80 – 90 gear oil or equivalent.

 

Do not use a chain lubricant NOT designed specifically for use with O-ring chains to lubricate the drive chain.

 

Wipe off the excess oil or drive chain lubricant.

 

3-13

MAINTENANCE

SPROCKET INSPECTION

 

Remove the drive sprocket cover (page 2-6).

Inspect the drive and driven sprocket teeth for wear or damage, replace if necessary.

 

Never use a new drive chain on worn sprockets.

 

Both chain and sprockets must be in good condition, or new replacement chain will wear rapidly.

 

Check the attaching bolts and nuts on the drive and driven sprockets.

 

If any are loose, tighten them to the specified torque.

 

TORQUE:

 

Drive sprocket fixing plate bolt [1]: 10 N·m (1.0 kgf·m, 7 lbf·ft)

 

Driven sprocket nut [2]:

50 N·m (5.1 kgf·m, 37 lbf·ft)

 

Install the drive sprocket cover (page 2-6).

 

DRIVE CHAIN SLIDER

 

U type only: Remove the drive chain cover (page 2-6).	[1]

Remove the drive sprocket cover (page 2-6).

 

Check the drive chain slider [1] for wear or damage.

[2]

 

The drive chain slider must be replaced if it is worn to the wear limit indicator [2] or wear limit line [3].

 

For drive chain slider replacement (page 17-10).

 

 

[3]

 

[1]

 

[2]

 

3-14

MAINTENANCE

BRAKE FLUID

 

Spilled fluid can damage painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced.

• Do not mix different types of fluid, as they are not compatible with each other.

 

• Do not allow foreign material to enter the system when filling the reservoir.

• When the fluid level is low, check the brake pads for wear (page 3-16).

 

• A low fluid level may be due to wear of the brake pads. If the brake pads are worn and caliper pistons are pushed out, this accounts for a low fluid level. If the brake pads are not worn and fluid level is low, check the entire system for leaks (page 3-17).

 

FRONT BRAKE

 

Turn the handlebar to the left so that the reservoir is level and check the front brake fluid level through the sight glass.

 

If the level is near the "LOWER" level line [1], fill the recommended brake fluid.

 

Remove the following:

 

– Screws [2]

– Reservoir cover [3]

– Set plate [4]

– Diaphragm [5]

 

[2]

[3]

 

[4]/[5]

[1]

 

Add DOT 3 or DOT 4 brake fluid from a sealed
[1]
container to the casting ledge [1].

Install the diaphragm, set plate and reservoir cover. Install and tighten the cover screws to the specified torque.

 

TORQUE:1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)

 

3-15

MAINTENANCE

REAR BRAKE

 

Support the motorcycle on a level surface, and check the rear brake fluid level.

 

Check the brake fluid level.	[2]

 

If the level is near the "LOWER" level line [1], fill the recommended brake fluid.

 

Remove the bolt [2] and reservoir [3].

 

Remove the cover screws [4], reservoir cover [5], set plate [6] and diaphragm [7].

 

Add DOT 3 or DOT 4 brake fluid from a sealed container to the "UPPER" level line [8].

 

Install the diaphragm, set plate and reservoir cover.

 

Install and tighten the cover screws to the specified ^[3] torque.

 

[9] [4]

 

[1]

[5]/[6]/[7]

[8]

 

TORQUE:1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)

 

Install the reservoir and tighten the bolt to the specified torque while pushing the reservoir against the stopper [9].

 

TORQUE:10 N·m (1.0 kgf·m, 7 lbf·ft)

 

BRAKE PADS WEAR

 

Always replace the brake pads as a set to assure even disc pressure.

 

 

Always replace the brake pads as a set to assure even disc pressure.

 

FRONT BRAKE PADS

 

Check the front brake pads for wear.

Replace the front brake pads if either pad is worn to the wear limit groove [1].

For front brake pad replacement (page 18-5).

 

 

[1]

 

REAR BRAKE PADS

 

Check the rear brake pads for wear.

Replace the rear brake pads if either pad is worn to the wear limit groove [1].

For rear brake pad replacement (page 18-6).

 

 

[1]

 

3-16

MAINTENANCE

 

BRAKE SYSTEM

 

INSPECTION

 

Firmly apply the brake lever or pedal, and check that no air has entered the system.

If the lever or pedal feels soft or spongy when operated, bleed the air from the system.

 

For brake air bleeding (page 18-4).

 

Inspect the brake hose [1] and fittings for deterioration, cracks and signs of leakage.

Tighten any loose fittings.

 

Replace hoses and fittings as required.