Service Limit: 83.10 mm (3.2716 in.)

Piston Wear

• Measure the outside diameter [A] of each piston 18 mm (0.7087 in.) [B] up from the bottom of the piston at a right

angle to the direction of the piston pin.

If the measurement is under service limit, replace the pis- ton.

Piston Diameter

Standard: 82.969 ~ 82.984 mm (3.2665 ~ 3.2671 in.)

Service Limit: 82.82 mm (3.2606 in.)

 

Piston Ring, Piston Ring Groove Wear

• Check for uneven groove wear by inspecting the ring seat- ing.

The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings.

• With the piston rings in their grooves, make several mea-

surements with a thickness gauge [A] to determine piston

ring/groove clearance.

Piston Ring/Groove Clearance Top

Standard: 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in.)

Service Limit: 0.17 mm (0.0067 in.) Second

Standard: 0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in.)

Service Limit: 0.16 mm (0.0063 in.)

Piston Ring Groove Width

• Measure the piston ring groove width.

○Use a vernier caliper at several points around the piston.

Piston Ring Groove Width Top [A]

Standard: 0.92 ~ 0.94 mm (0.0362 ~ 0.0370 in.)

Service Limit: 1.02 mm (0.040 in.) Second [B]

Standard: 1.01 ~ 1.03 mm (0.0398 ~ 0.0406 in.)

Service Limit: 1.11 mm (0.044 in.)

If the width of any of the two grooves is wider than the service limit at any point, replace the piston.

Piston Ring Thickness

• Measure the piston ring thickness.

○Use the micrometer to measure at several points around

the ring.

Piston Ring Thickness Top [A]

Standard: 0.87 ~ 0.89 mm (0.0342 ~ 0.0350 in.)

Service Limit: 0.80 mm (0.031 in.) Second [B]

Standard: 0.97 ~ 0.99 mm (0.0382 ~ 0.0390 in.)

Service Limit: 0.90 mm (0.035 in.)

If any of the measurements is less than the service limit on either of the rings, replace all the rings.

NOTE

○When using new rings in a used piston, check for un-

even groove wear. The rings should fit perfectly parallel

to the groove sides. If not, replace the piston.

 

 

Piston Ring End Gap

• Place the piston ring [A] inside the cylinder, using the pis- ton to locate the ring squarely in place. Set it close to the

bottom of the cylinder, where cylinder wear is low.

• Measure the gap [B] between the ends of the ring with a thickness gauge.

Piston Ring End Gap Top

Standard: 0.25 ~ 0.40 mm (0.0098 ~ 0.0157 in.)

Service Limit: 0.7 mm (0.028 in.) Second

Standard: 0.40 ~ 0.55 mm (0.0157 ~ 0.0217 in.)

Service Limit: 0.8 mm (0.031 in.)

If the end gap of either ring is greater than the service limit, replace all the rings.

 

 

Throttle Body Holder

Throttle Body Holder Installation

• Be sure to install the O-rings [A].

• Install the clamps [B] as shown and so that their projec-

tions fit [C] on the holes of the holders.

○Be sure that the clamp bolt heads [D] face outwards.

• Tighten:

Torque - Throttle Body Holder Bolts [E]: 12 N·m (1.2 kgf·m, 106 in·lb)

 

Muffler

Muffler Body Removal

WARNING

To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down.

• Remove:

Right Frame Cover (see Frame Cover Removal in the

Frame chapter)

• Remove the bolts and lift up the right footpeg stay [A].

• Remove the muffler body mounting bolts [A] and nut, and pull the muffler body [B] backward.

 

Exhaust Pipe Removal

• Remove:

Lower Fairings (see Lower Fairing Removal in the Frame

chapter)

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

Muffler Body Clamp Bolt [A]

Exhaust Pipe Manifold Holder Nuts [B] Exhaust Pipe [C]

Gaskets

 

 

Muffler

Muffler Body and Exhaust Pipe Installation

• Replace the exhaust pipe gaskets [A] and muffler body connection gasket [B] with new ones and install them.

○Install the muffler body connection gasket until it is bot-

tomed so that the chamfer side [C] feces muffler body [D].

• Install:

Muffler Body

Exhaust Pipe [E]

• Tighten:

Torque - Exhaust Pipe Manifold Holder Nut [F]: 17 N·m (1.7 kgf·m, 12 ft·lb)

Muffler Body Mounting Bolts (Front and Rear) [G]: 20 N·m (2.0 kgf·m, 15 ft·lb)

• Tighten the muffler body clamp bolt [H].

○Install the muffler body clamp bolt as shown.

• Thoroughly warm up the engine, wait until the engine

cools down, and retighten all the bolts and nuts.

 

 

 

 

 

Clutch

Table of Contents

Exploded View........................................................................................................................ 6-2

Specifications......................................................................................................................... 6-4

Special Tool and Sealant........................................................................................................ 6-5

Clutch Lever and Cable.......................................................................................................... 6-6

Clutch Lever Free Play Inspection.................................................................................... 6-6

Clutch Lever Free Play Adjustment.................................................................................. 6-6

Clutch Cable Removal...................................................................................................... 6-6

Clutch Cable Installation................................................................................................... 6-6

Clutch Cable Lubrication................................................................................................... 6-6

Clutch Lever Installation.................................................................................................... 6-7

Clutch Lever Adjustment................................................................................................... 6-7 6

Clutch Cover........................................................................................................................... 6-8

Clutch Cover Removal...................................................................................................... 6-8

Clutch Cover Installation................................................................................................... 6-8

Release Shaft Removal.................................................................................................... 6-9

Release Shaft Installation................................................................................................. 6-9

Clutch Cover Disassembly................................................................................................ 6-9

Clutch Cover Assembly..................................................................................................... 6-10

Clutch..................................................................................................................................... 6-11

Clutch Removal................................................................................................................. 6-11

Clutch Installation.............................................................................................................. 6-11

Clutch Plate, Wear, Damage Inspection........................................................................... 6-13

Clutch Plate Warp Inspection............................................................................................ 6-14

Clutch Spring Free Length Measurement......................................................................... 6-14

Clutch Housing Finger Inspection..................................................................................... 6-14

Clutch Housing Spline Inspection..................................................................................... 6-14

Exploded View

 

Exploded View

No.	Fastener	Torque	Remarks
N·m	kgf·m	ft·lb
	Upper Cap on Clutch Cover	3.9	0.40	35 in·lb
	Lower Cap on Clutch Cover	–	–	–	Hand-tighten
	Oil Filler Plug	–	–	–	Hand-tighten
	Clutch Cover Mounting Bolts	9.8	1.0	87 in·lb
	Clutch Spring Bolts	9.8	1.0	87 in·lb
	Clutch Hub Nut		13.5		R
	Oil Pump Sprocket Bolt		1.2	106 in·lb	L, Lh
	Clutch Lever Clamp Bolts	7.8	0.80	69 in·lb	S
	Oil Pump Chain Guide Bolts		1.2	106 in·lb	L
	Clutch Cable Holder Bolts	9.8	1.0	87 in·lb	L
	Clutch Cable Clamp Bolt	9.8	1.0	87 in·lb

CL: Apply cable lubricant. EO: Apply engine oil.

G: Apply grease.

HG: Apply high-temperature grease.

L: Apply a non-permanent locking agent. Lh: Left-hand threads

M: Apply molybdenum disulfide grease. R: Replacement Parts

S: Follow the specified tightening sequence. W: Apply water.

 

 

Specifications

Item	Standard	Service Limit
Clutch Lever Free Play	2 ~ 3 mm (0.08 ~ 0.12 in.)	– – –
Clutch
Friction Plate Thickness	2.92 ~ 3.08 mm (0.115 ~ 0.121 in.)	2.8 mm (0.110 in.)
Friction Plate Warp	0.15 mm (0.16 in.) or less	0.3 mm (0.012 in.)
Steel Plate Warp	0.2 mm (0.008 in.) or less	0.3 mm (0.012 in.)
Clutch Spring Free Length	33.6 mm (1.32 in.)	32.6 mm (1.28 in.)

 

Special Tool and Sealant

Clutch Holder: 57001-1243