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

Front Axle Clamp Bolt 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

 

 

Replacement Parts

Air Cleaner Element Replacement

• Refer to the Air Cleaner Element Cleaning.

CAUTION

When removing and installing the fuel hose joint, do not apply strong force to the outlet pipe on the fuel pump and delivery pipe on the throttle body assy. The pipes made from resin could be damaged.

Fuel Hose Replacement

• Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System

(DFI) chapter)

Left Center Fairing (see Center Fairing Removal in the Frame chapter)

• Be sure to place a piece of cloth [A] around the fuel hose

joint.

• Insert a minus screw driver [B] into the slit [C] on the joint lock.

• Turn [A] the driver to disconnect the joint lock [B].

WARNING

Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe. Cover the hose connec- tion with a clean shop towel to prevent fuel spillage.

• Pull [C] the fuel hose joint [D] out of the delivery pipe.

 

 

• Install the new fuel hose.

• Insert [A] the fuel hose joint [B] straight onto the delivery

pipe until the hose joint clicks.

• Push [C] the joint lock [D].

 

 

• Push and pull [A] the fuel hose joint [B] back and forth more than two times and make sure it is locked and

doesn’t come off.

WARNING

Make sure the fuel hose joint is installed correctly on the delivery pipe or the fuel could leak.

If it comes off, reinstall the hose joint.

• Run the fuel hose correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

• Install the removed parts (see appropriate chapters).

• Start the engine and check the fuel hose for leaks.

 

 

WARNING

To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery and can cause an accident and injury. Immediately wipe up or wash away any coolant that spills on the frame, engine, or other painted parts. Since coolant is harmful to the human body, do not use for drinking.

Coolant Change

• Remove:

Right Center Fairing (see Center Fairing Removal in the

Frame chapter) Reserve Tank Bolts [A] Reserve Tank [B]

 

 

• Put [A] the projection [B] on the reserve tank into the hole [C] on the frame bracket, and place the reserve tank on

the right side of frame.

 

 

• Place a container under the water pump drain bolt [A], then remove the drain bolt.

 

 

• Remove the radiator cap [A] in two steps. First turn the cap counterclockwise to the first stop. Then push and turn

it further in the same direction and remove the cap.

○The coolant will drain from the radiator and engine.

 

• Turn over [A] the reserve tank, remove the cap, and pour the coolant into a suitable container.

• Place the reserve tank on the right side of frame.

• Tighten the drain bolt with the gasket.

○Replace the drain bolt gasket with a new one.

Torque - Water Pump Drain Bolt: 7.0 N·m (0.70 kgf·m, 62 in·lb)

CAUTION

Soft or distilled water must be used with the an- tifreeze in the cooling system. 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.

• When filling the coolant, choose a suitable mixture ratio by referring to the coolant manufacturer’s directions.

 

Water and Coolant Mixture Ratio (Recommended) Soft Water: 50%

Coolant: 50%

Freezing Point: –35°C (–31°F) Total Amount: 1.2 L (1.3 US qt)

• Fill the radiator up to the filler neck [A] with coolant.

NOTE

○Pour in the coolant slowly so that it can expel the air

from the engine and radiator.

• Check the cooling system for leaks.

• Tap the radiator hoses to force any air bubbles caught

inside.

• Fill the radiator up to the filler neck with coolant.

 

 

• Temporarily install the reserve tank to the frame with two bolts.

• Fill the reserve tank up to the “F” (full) level line [A] with

coolant and install the cap [B].

• 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.

CAUTION

Do not add more coolant above the “F” level line.

If the coolant level is lower than the “L” level line, add coolant to the “F” 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] O-rings [D]

• 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.

 

 

Engine Oil Change

• Situate the motorcycle so that it is vertical after warming up the engine.

• Unscrew the oil filler plug [A].

• Place on oil pan beneath the engine.

 

• Remove the engine oil drain bolt [A] to drain the oil.

○The oil in the oil filter can be drained by removing the filter

(see Oil Filter Replacement).

Replace the drain bolt gasket [B] with a new one.

• Tighten the drain bolt.

Torque - Engine Oil Drain Bolt: 30 N·m (3.0 kgf·m, 22 ft·lb)

• Pour in the specified type and amount of oil.

 

Recommended Engine Oil

Type: API SE, SF or SG