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].

 

 

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:

Front 4.5 mm (0.18 in.)

Rear 5.0 mm (0.20 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)

 

 

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.

 

 

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.

Steering Play Adjustment

• Remove:

Upper Inner Fairings (see Upper Inner Fairing Removal

in the Frame chapter)

Handlebar (see Handlebar Removal in the Steering chapter)

Upper Fork Clamp Bolts [A] Steering Stem Head Bolt Plug [B] Stem Head Bolt [C]

• Remove the steering stem head [D].

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

• Remove the steering stem locknut [B] and claw washer

[C].

 

 

• Adjust the steering.

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

If the steering is too tight, loosen the stem nut [B] a fraction of a turn.

If the steering is too loose, tighten the stem nut a fraction of a turn.

NOTE

○Turn the stem nut 1/8 turn at time maximum.

 

• Install the claw washer [A] so that its bent side [B] faces upward, and engage the bent claws with the grooves of

stem locknut [C].

• Hand tighten the stem locknut until it touches the claw washer.

• Tighten the stem locknut clockwise until the claws are

aligned with the grooves (ranging from 2nd to 4th) of stem

nut [D], and bend the 2 claws downward [E].

• Install the steering stem head.

• Install the washer, and tighten the stem head bolt.

• Tighten:

Torque - Steering Stem Head Bolt: 108 N·m (11.0 kgf·m, 80

ft·lb)

Front Fork Clamp Bolts (Upper): 20 N·m (2.0 kgf·m, 15 ft·lb)

• Check the steering again.

If the steering is still too tight or too loose, repeat the ad-

justment.

• Install the removed parts (see appropriate chapters).

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 in the cages, 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 the bearing assemblies if they show wear or

damage.

• Pack the upper and lower ball bearings [A] in the cages with grease, and apply a light coat of grease to the upper

and lower outer races.

• Install the steering stem (see Stem, Stem Bearing Instal- lation in the Steering chapter).

• Adjust the steering (see Steering Play Adjustment).

Electrical System

Spark Plug Condition Inspection

• Remove the spark plugs (see Spark Plug Replacement).

• Visually inspect the spark plugs.

If the spark plug center electrode [A] and/or side elec-

trode [B] are corroded or damaged, or if the insulator [C] is cracked, replace the plug.

If the spark plug is dirtied or the carbon is accumulated, replace the spark plug.

• Measure the gap [D] with a wire-type thickness gauge.

If the gap is incorrect, replace the spark plug.

Spark Plug Gap: 0.8 ~ 0.9 mm (0.03 ~ 0.04 in.)

• Use the standard spark plug or its equivalent.

Spark Plug: CR9EIA-9

 

Lights and Switches Operation Inspection

First Step

• Turn on the ignition switch.

City Light [A] goes on Taillight [B] goes on License Plate Light [C] goes on Meter Panel LCD [D] goes on Neutral Indicator Light (LED) [E] goes on Oil Pressure Warning Indicator Light (LED) [F] goes on Water Temperature Warning Indicator Light (LED) [G] goes on FI Indicator Light (LED) [H] goes on (about 2 seconds)

• The following lights should go on according to below table.

 

 

ABS Indicator Light (LED) [I]

goes on

EX650B Models

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 Panel LCD (see Electronic Com- bination Meter Unit Inspection in the Electrical System chapter)

Meter Unit for Neutral Indicator Light (LED) (see Elec- tronic Combination Meter Unit Inspection in the Electri- cal System chapter)

Meter Unit for Oil Pressure Warning Indicator Light (LED) (see Electronic Combination Meter Unit Inspec- tion in the Electrical System chapter)

Meter Unit for FI Indicator Light (LED) (see Electronic Combination Meter Unit Inspection in the Electrical Sys- tem chapter)

Meter Unit for Water Temperature Warning Indicator Light (LED) (see Electronic Combination Meter Unit Inspection in the Electrical System chapter)

Meter Unit for ABS Indicator Light (LED) (see ABS In- dicator Light (LED) Inspection in the Brakes chapter) (EX650B Models)

ECU (see ECU Power Supply Inspection in the Fuel Sys- tem (DFI) 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.

Second Step

• Turn the ignition switch to P (Park) position.

• The city light, taillight and license plate light should go on.

If the light does not go on, inspect or replace the following

item.

Ignition Switch (see Switch Inspection in the Electrical System chapter)

Third 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 (LED) [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 (LED) (see Electronic Combination Meter 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 (LED) 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)

 

 

Fourth 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 in Relay Box (see Relay Circuit Inspec- tion in the Electrical System chapter)

Harness (see Wiring Inspection in the Electrical System chapter)

• 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 (LED) [C] should go on.

If the high beam headlight and/or high beam indicator light

(LED) 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 (LED) does go off, inspect or replace the following item.

Headlight Relay in Relay Box (see Relay Circuit Inspec- tion in the Electrical System chapter)

• Turn off the ignition switch.

• The headlights and high beam indicator light (LED) 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.

 

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

Sidestand	Gear Position	Clutch Lever	Engine Start	Engine Run
Up	Neutral	Released	Starts	Continue running
Up	Neutral	Pulled in	Starts	Continue running
Up	In Gear	Released	Doesn’t start	Stops
Up	In Gear	Pulled in	Starts	Continue running
Down	Neutral	Released	Starts	Continue running
Down	Neutral	Pulled in	Starts	Continue running
Down	In Gear	Released	Doesn’t start	Stops
Down	In Gear	Pulled in	Doesn’t start	Stops

 

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)

Relay Box (see Relay Circuit Inspection in the Electrical 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 ECU (see ECU Removal/Installation in the Fuel System (DFI) chap- ter).

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 ECU (see ECU Removal/Installation in the Fuel System (DFI) chapter).

 

 

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.