Service Limit: 7.3 mm (0.287 in.)

Gear Dog and Gear Dog Hole Damage

• Visually inspect the gear dogs [A] and gear dog holes [B]. Replace any damaged gears or gears with excessively

worn dogs or dog holes.

 

 

Ball Bearing, Needle Bearing, and Oil Seal

Ball and Needle Bearing Replacement

CAUTION

Do not remove the ball or needle bearings unless it is necessary. Removal may damage them.

• Using a press or puller, remove the ball bearing and/or needle bearings.

NOTE

○In the absence of the above mentioned tools, satisfac-

tory results may be obtained by heating the case to ap-

proximately 93°C (200°F) max., and tapping the bearing in or out.

CAUTION

Do not heat the case with a torch. This will warp the case. Soak the case in oil and heat the oil.

• Using a press and the bearing driver set [A], install the

new ball bearing until it stops at the bottom of its housing.

○The new needle bearings must be pressed into the

crankcase so that the end is flush with the end of the

hole.

Special Tool - Bearing Driver Set: 57001-1129

Ball and Needle Bearing Wear

CAUTION
Do not remove the bearings moval may damage them.	for	inspection.	Re-

• Check the ball bearings.

○Since the ball bearings are made to extremely close toler-

ances, the wear must be judged by feel rather than mea-

surement. Clean each bearing in a high-flash point sol- vent, dry it (do not spin the bearing while it is dry), and oil it with engine oil.

○Spin [A] the bearing by hand to check its condition.

If the bearing is noisy, does not spin smoothly, or has any

rough spots, replace it.

• Check the needle bearings.

○The rollers in a needle bearing normally wear very little,

and wear is difficult to measure. Instead of measuring,

inspect the bearing for abrasion, color change, or other damage.

If there is any doubt as to the condition of a needle bear- ing, replace it.

Oil Seal Inspection

• Inspect the oil seals.

Replace it if the lips are misshapen, discolored (indicating

that the rubber has deteriorated), hardened or otherwise damaged.

 

 

 

 

 

Wheels/Tires

Table of Contents

Exploded View........................................................................................................................ 10-2

Specifications......................................................................................................................... 10-4

Special Tools.......................................................................................................................... 10-5

Wheels (Rims)........................................................................................................................ 10-6

Front Wheel Removal....................................................................................................... 10-6

Front Wheel Installation.................................................................................................... 10-6

Rear Wheel Removal........................................................................................................ 10-8

Rear Wheel Installation..................................................................................................... 10-8

Wheel Inspection...................................................................................................................... 10-10

Axle Inspection......................................................................................................................... 10-10

Balance Inspection................................................................................................................... 10-11

Balance Adjustment................................................................................................................. 10-11

Balance Weight Removal........................................................................................................ 10-11

Balance Weight Installation...................................................................................................... 10-11

Tires............................................................................................................................................... 10-13

Air Pressure Inspection/Adjustment......................................................................................... 10-13

Tire Inspection.......................................................................................................................... 10-13

Tire Removal........................................................................................................................... 10-13

Tire Installation......................................................................................................................... 10-13

Tire Repair............................................................................................................................... 10-15

Hub Bearing................................................................................................................................... 10-16

Hub Bearing Removal.............................................................................................................. 10-16

Hub Bearing Installation........................................................................................................... 10-16

Hub Bearing Inspection............................................................................................................ 10-16

Hub Bearing Lubrication........................................................................................................... 10-17

 

 

Exploded View

 

Exploded View

No.	Fastener	Torque	Remarks
N·m	kgf·m	ft·lb
	Front Axle		11.0
	Front Axle Clamp Bolt		3.5
	Rear Axle Nut		11.0

4. Caliper Bracket (EX650B Models) G: Apply grease.

HG: Apply high-temperature grease. R: Replacement Parts

WL: Apply soap and water solution or rubber lubricant.

 

 

Specifications

Item	Standard	Service Limit
Wheels (Rims) Rim Runout: Axial Radial Axle Runout/100 mm (3.94 in.) Wheel Balance Balance Weights Rim Size: Front Rear	TIR 0.5 mm (0.02 in.) or less	TIR 1.0 mm (0.04 in.)
TIR 0.8 mm (0.03 in.) or less	TIR 1.0 mm (0.04 in.)
TIR 0.03 mm (0.0012 in.) or less	TIR 0.2 mm (0.008 in.)
10 g (0.35 oz.) or less	– – –
10 g (0.35 oz.), 20 g (0.71 oz.), 30 g	– – –
(1.06 oz.)
17 × 3.50	– – –
17 × 4.50	– – –
Tires Air Pressure (when Cold): Front Rear Tread Depth: Front Rear	Up to 180 kg (397 lb) load: 225 kPa (2.25 kgf/cm², 32 psi)	– – –
Up to 180 kg (397 lb) load: 250 kPa	– – –
(2.50 kgf/cm², 36 psi)
4.3 mm (0.17 in.)	1 mm (0.04 in.)
	(AT, CH, DE) 1.6 mm
	(0.06 in.)
7.0 mm (0.28 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: Front Rear	Make, Type	Size
BRIDGESTONE, BATTLAX BT020F	120/70 ZR17 M/C (58 W)
RADIAL GG
BRIDGESTONE, BATTLAX BT020R	160/60 ZR17 M/C (69 W)
RADIAL

WARNING

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

 

Special Tools

Bearing Driver Set: 57001-1129

Bearing Remover Shaft, 13: 57001-1377

Jack: 57001-1238

Jack Attachment: 57001-1608

Bearing Remover Head, 20 × 22:

57001-1293

 

Front Wheel Removal

• Remove:

Brake Caliper Mounting Bolts [A]

Front Brake Calipers [B]

 

• Loosen:

Axle Clamp Bolt [A]

• Remove the front axle [B].

 

• Remove the lower fairings (see Lower Fairing Removal in the Frame chapter).

• Raise the front wheel off the ground with jack.

Special Tools - Jack: 57001-1238

Jack Attachment: 57001-1608

CAUTION

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

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

 

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.

 

• Apply high-temperature grease to the grease seal lips.

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

 

 

• Insert the front axle, and tighten the axle.

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

• Before tightening the axle clamp bolt 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 the axle clamp bolt [A].

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

• Install the lower fairing (see Lower Fairing Installation in the Frame chapter).

• Install the front brake calipers (see Caliper Installation in

the Brakes 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.

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

 

 

Rear Wheel Removal

• Raise the rear wheel off the ground with stand [A].

 

 

• Remove:

Brake Caliper Mounting Bolts [A]

Rear Brake Caliper [B]

• Remove the rear wheel rotation sensor from the caliper bracket (see Rear Wheel Rotation Sensor Removal in the

Brakes chapter) (EX650B Models).

 

 

• Remove: Cotter Pin [A]

Axle Nut [B] Washer [C]

Axle [D] with Washer

 

 

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

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.

• Move the rear wheel back and remove it.

 

Rear Wheel Installation

• Apply high-temperature grease to the grease seal lips.

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

 

 

• Engage the drive chain with the rear sprocket.

• Install the caliper bracket [A] onto the swingarm stop [B].

• Insert the axle from the right side of the wheel, and tighten

the axle nut.

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.

WARNING

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

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

 

 

• Adjust the drive chain slack after installation (see Drive Chain Slack Inspection in the Periodic Maintenance chap-

ter).

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

• Install the rear wheel rotation sensor (see Rear Wheel Ro-

tation Sensor Installation in the Brakes chapter) (EX650B

Models).

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.

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

 

 

Wheel Inspection

• Raise the front/rear wheel off the ground with jack.