Special Tools - Bearing Driver Set: 57001-1129

Stem Bearing Driver, 28 [B]: 57001-1610

Spacer, 28: 57001-1663

 

• Install the needle bearings [A], ball bearing [B] and oil seals [C] position as shown.

Circlip [D]

25 mm (0.98 in.) [E]

17 mm (0.67 in.) [F]

1 mm (0.04 in.) [G]

0.5 mm (0.02 in.) [H]

1 mm (0.04 in.) [I]

23.5 mm (0.93 in.) [J]

6 mm (0.24 in.) [K]

 

Swingarm Bearing, Sleeve Inspection

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

• Inspect the needle bearings [A] and ball bearing installed in the swingarm.

○The rollers and ball in a bearing normally wear very little,

and wear is difficult to measure. Instead of measuring,

visually inspect the bearing for abrasion, discoloration, or other damage.

If the needle bearing and sleeve [B] show any sings of abnormal wear, discoloration, or damage, replace them as a set.

 

 

• Turn the bearing in the swingarm back and forth [A] while checking for plays, roughness, or binding.

If the bearing play, roughness, or binding is found, replace the bearing.

• Examine the bearing seal [B] for tears or leakage.

If the seal is torn or is leaking, replace the bearing.

 

Swingarm Bearing Lubrication

NOTE

○Since the bearings are packed with grease and sealed,

lubrication is not required.

Chain Guide Inspection

• Refer to the Chain Guide Wear Inspection in the Periodic Maintenance chapter.

 

 

 

 

Steering

Table of Contents

Exploded View........................................................................................................................ 14-2

Special Tools.......................................................................................................................... 14-4

Steering.................................................................................................................................. 14-5

Steering Inspection........................................................................................................... 14-5

Steering Adjustment.......................................................................................................... 14-5

Steering Stem......................................................................................................................... 14-6

Stem, Stem Bearing Removal........................................................................................... 14-6

Stem, Stem Bearing Installation........................................................................................ 14-7

Stem Bearing Lubrication.................................................................................................. 14-9

Steering Stem Warp.......................................................................................................... 14-9

Stem Cap Deterioration, Damage..................................................................................... 14-9 Handlebar...................................................................................................................................... 14-10

Handlebar Removal................................................................................................................. 14-10

Handlebar Installation............................................................................................................... 14-10

 

 

14

 

Exploded View

 

Exploded View

No.	Fastener	Torque	Remarks
N·m	kgf·m	ft·lb
	Front Fork Clamp Bolts (Lower)		2.0		AL
	Front Fork Clamp Bolts (Upper)		2.0
	Handlebar Holder Bolts		2.5		S
	Left Switch Housing Screws	3.5	0.36	31 in·lb
	Right Switch Housing Screws	3.5	0.36	31 in·lb
	Steering Stem Head Bolt		11.0
	Steering Stem Nut		2.0

AD: Apply adhesive.

AL: Tighten the two clamp bolts alternately two times to ensure even tighten torque. G: Apply grease.

L: Apply a non-permanent locking agent. R: Replacement Parts

S: Follow the specified tightening sequence.

 

 

Special Tools

Steering Stem Nut Wrench: 57001-1100

Steering Stem Bearing Driver, 42.5: 57001-1344

Bearing Driver Set: 57001-1129

Steering Stem Bearing Driver Adapter, 41.5: 57001-1345

 

Steering

Steering Inspection

• Refer to the Steering Play Inspection in the Periodic Main- tenance chapter.

Steering Adjustment

• Refer to the Steering Play Adjustment in the Periodic Maintenance chapter.

 

Stem, Stem Bearing Removal

• Remove:

Upper Fairing (see Upper Fairing Removal in the Frame

chapter)

Under Bracket [A] (see Upper Fairing Bracket Removal in the Frame chapter)

 

 

• Remove:

Upper Fairing Bracket [A] (see Upper Fairing Bracket

Removal in the Frame chapter)

 

 

• Remove:

Front Wheel (see Front Wheel Removal in the

Wheels/Tires chapter)

Front Forks (see Front Fork Removal in the Suspension chapter)

Handlebar (see Handlebar Removal) Steering Stem Head Bolt Plug [A] Steering Stem Head Bolt [B] and Washer

Front Fork Clamp Bolts (Upper) [C] (Loosen) Steering Stem Head [D]

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

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

[C].

 

 

• Pushing up the stem base, and remove the steering stem nut [A] with stem cap [B].

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

• Remove the steering stem [D] under side.

• Remove the upper stem bearing inner race and bearing.

 

• To remove the bearing outer races [A] pressed into the head pipe [B], insert a bar [C] into the recesses of head

pipe, and applying it to both recess alternately hammer it to drive the race out.

NOTE

○If either steering stem bearing is damaged, it is recom-

mended that both the upper and lower bearings (includ-

ing outer races) should be replaced with new ones.

• Remove the lower bearing inner race [A] which is pressed onto the steering stem with a suitable commercially avail-

able chisel [B].

 

 

Stem, Stem Bearing Installation

• Replace the bearing outer races with new ones.

• Apply grease to the outer races, and drive them into the

head pipe at the same time.

Special Tool - Bearing Driver Set [A]: 57001-1129

• Replace the bearing inner races and oil seal with new ones.

• Apply grease to the oil seal.

• Drive the lower ball bearing inner race applied the grease

onto the stem.

Special Tools - Steering Stem Bearing Driver, 42.5 [A]:

57001-1344

Steering Stem Bearing Driver Adapter, 41.5 [B]: 57001-1345

• Apply grease to the lower ball bearing [A], and install it onto the stem.

• Apply grease to the upper ball bearing [B] and inner race

[C].

 

 

• Install the stem [A] through the head pipe and install the ball bearing [B] and inner race [C] on it.

• Install the stem cap [D] and steering stem nut [E].

 

• Settle the inner races in place as follows.

○Tighten the steering stem nut with 39 N·m (4.0 kgf·m, 29

ft·lb) of torque first, and loosen it a fraction of a turn until

it turns lightly. Afterward tighten it again with specified torque using a stem nut wrench [A] in the direction shown.

○Check that there is no play and the steering stem turns

smoothly without rattles. If not, the steering stem bearings

may be damaged.

Special Tool - Steering Stem Nut Wrench: 57001-1100 Torque - Steering Stem Nut: 20 N·m (2.0 kgf·m, 15 ft·lb)

• 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 stem head.

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

specified torque.

• Install the front forks (see Front Fork Installation in the Suspension chapter).

 

NOTE

○Tighten the upper fork clamp bolts first, next the stem

head bolt, last the lower fork clamp bolts.

○Tighten the two clamp bolts alternately two times to en-

sure even tightening torque.

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

Steering Stem Head Bolt: 108 N·m (11.0 kgf·m, 80 ft·lb)

WARNING

Do not impede the handlebar turning by routing the cables, harnesses and hoses improperly (see Ca- ble, Wire, and Hose Routing section in the Appen- dix chapter).

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

• Install the steering stem head bolt plug.

• Install the removed parts (see appropriate chapters).

 

 

Stem Bearing Lubrication

• Refer to the Steering Stem Bearing Lubrication in the Pe- riodic Maintenance chapter.

Steering Stem Warp

• Whenever the steering stem is removed, or if the steering cannot be adjusted for smooth action, check the steering

stem for straightness.

If the steering stem [A] is bent, replace the steering stem.

 

 

Stem Cap Deterioration, Damage

Replace the stem cap if its oil seal [A] shows damage.

 

 

Handlebar

Handlebar Removal

• Remove:

Clutch Lever Assembly [A]

Left Switch Housing [B] Left Handlebar Weight [C]

 

• Remove:

Front Brake Master Cylinder [A] (see Front Master Cylin-

der Removal in the Brakes chapter) Right Switch Housing [B]

Right Handlebar Weight [C] Throttle Grip [D]

 

 

• Remove the handlebar holder bolts [A].

• Remove the handlebar holder [B] and then pull out the

handlebar.

 

 

Handlebar Installation

• Align the punch mark [A] on the handlebar and the corner edge [B] on the stem head.

 

 

• Tighten the front holder bolts first, and then the rear holder bolts. There will be a gap [A] at the rear part of the han-

dlebar holder after tightening.

Torque - Handlebar Holder Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

 

Handlebar

• Install the clutch lever (see Clutch Lever Installation in the Clutch chapter).

• Apply adhesive cement to the inside of the left handlebar

grip.

• Apply a non-permanent locking agent to the left handlebar weight bolt.

• Install the left switch housing.

○Fit the projection [A] into a small hole [B] in the handlebar.

Torque - Left Switch Housing Screws: 3.5 N·m (0.36 kgf·m, 31 in·lb)

• Install:

Throttle Grip

Throttle Cable Tips [A] Right Switch Housing

○Fit the projection [B] into a small hole [C] in the handlebar.

Torque - Right Switch Housing Screws: 3.5 N·m (0.36 kgf·m, 31 in·lb)

• Apply a non-permanent locking agent to the right handle-

bar weight bolt.

• Install the front brake master cylinder (see Front Master Cylinder Installation in the Brakes chapter).

 

 

 

 

 

Frame

Table of Contents

Exploded View........................................................................................................................ 15-2

Seat........................................................................................................................................ 15-8

Seat Removal................................................................................................................... 15-8

Seat Installation................................................................................................................ 15-8

Fairings................................................................................................................................... 15-9

Lower Fairing Removal..................................................................................................... 15-9

Lower Fairing Installation.................................................................................................. 15-9

Center Fairing Removal.................................................................................................... 15-9

Center Fairing Installation................................................................................................. 15-9

Windshield Removal................................................................................................................ 15-10

Windshield Installation.............................................................................................................. 15-10

Upper Fairing Removal............................................................................................................ 15-10

Upper Fairing Disassembly...................................................................................................... 15-11

Upper Fairing Assembly........................................................................................................... 15-11

Upper Fairing Installation.......................................................................................................... 15-11

Upper Inner Fairing Removal................................................................................................... 15-11

Upper Inner Fairing Installation................................................................................................ 15-11

Upper Fairing Bracket Removal.............................................................................................. 15-11

Inner Fairing Removal.............................................................................................................. 15-12

Inner Fairing Installation........................................................................................................... 15-12

Side Covers................................................................................................................................... 15-13

Side Cover Removal................................................................................................................ 15-13

Side Cover Installation............................................................................................................. 15-13

Seat Covers................................................................................................................................... 15-14

Seat Cover Removal............................................................................................................... 15-14

Seat Cover Installation............................................................................................................. 15-14

Fenders.......................................................................................................................................... 15-15

Front Fender Removal............................................................................................................. 15-15

Front Fender Installation........................................................................................................... 15-15

Flap and Rear Fender Rear Removal..................................................................................... 15-15

Flap and Rear Fender Rear Installation................................................................................... 15-15

Rear Fender Front Removal.................................................................................................... 15-16

Rear Fender Front Installation.................................................................................................. 15-16

Frame............................................................................................................................................ 15-17

Frame Inspection..................................................................................................................... 15-17

Sidestand....................................................................................................................................... 15-18

Sidestand Removal.................................................................................................................. 15-18

Sidestand Installation............................................................................................................... 15-18

Frame Cover................................................................................................................................. 15-19

Frame Cover Removal............................................................................................................ 15-19

Frame Cover Installation.......................................................................................................... 15-19

 

 

 

 

No.	Fastener	Torque	Remarks
N·m	kgf·m	ft·lb
	Footpeg Stay Bolts		3.5
	Sidestand Bolt		4.5
	Sidestand Switch Bolt	8.8	0.90	78 in·lb	L

4. EX650B Models

5. EX650A Models G: Apply grease.

L: Apply a non-permanent locking agent. R: Replacement Parts

 

 

 

 

 

No.	Fastener	Torque	Remarks
N·m	kgf·m	ft·lb
	Front Fender Bolts	3.9	0.40	35 in·lb
	Front Fender Bracket Bolts	8.8	0.90	78 in·lb	L
	Front Turn Signal Light Mounting Screws	1.2	0.12	11 in·lb

L: Apply a non-permanent locking agent.

 

 

 

 

 

No.	Fastener	Torque	Remarks
N·m	kgf·m	ft·lb
	Grab Rail Mounting Bolts		2.5
	Seat Lock Mounting Screws	1.2	0.12	11 in·lb

3. Seat (United States and Canada Models)

4. Seat Lock Bracket (EX650B Models)

5. EX650B Models

6. Grab Rails (Other than United States and Canada Models)

7. Washers (United States and Canada Models)

 

 

Seat

Seat Removal

• Insert the ignition switch key [A] into the seat lock, turning the key clockwise, pulling up on the rear of the seat [B],

and pulling the seat backward.

 

Seat Installation

• Slip the seat hook [A] under the brace [B] on the fuel tank bracket.

 

 

• Insert the seat latch [A] into the latch hole [B].

• Push down the rear part of the seat until the lock clicks.

 

Lower Fairing Removal

• Pull up the core by the thin blade driver.

• Remove the quick rivets [A].

• Remove the bolts [B] with collar and washers.

• Clear the hook portions from the slots.

• Separate the left lower fairing from the right lower fairing.

 

 

Lower Fairing Installation

• Insert the hook portions [A] into the slots [B].

• Set the quick rivet and push the core.

 

Center Fairing Removal

• Remove:

Lower Fairings (see Lower Fairing Removal)

Upper Inner Fairing (see Upper Inner Fairing Removal) Screw [A]

Bolt [B] with Washers

 

 

• Remove the meter cover (see Meter Unit Removal/Instal- lation in the Electrical System chapter).

• Disconnect the turn signal lead connector [A].

• Remove the screw [B].

• Pull the center fairing [C] evenly outward to clear the stop-

pers.

 

 

• Remove the inner fairing (see Inner Fairing Removal).

• Remove the screw [A] and turn signal light [B].

 

Center Fairing Installation

• Install the turn signal light to the center fairing.

• Install the inner fairing (see Inner Fairing Installation).

 

• Insert the hook [A] into the slot [B].

 

 

• Insert the projection [A] into the hole [B].

• Connect the turn signal lead connector.

• Install the bolt and screws.

 

Windshield Removal

• Remove:

Bolts [A] with Washers

Windshield [B] Dampers

 

 

Windshield Installation

• Install the dampers.

• Insert the hook [A] into the slot [B].

• Tighten the bolts with washers.

 

 

Upper Fairing Removal

• Remove:

Windshield (see Windshield Removal)

Upper Inner Fairings (see Upper Inner Fairing Removal) Lower Fairings (see Lower Fairing Removal)

Center Fairings (see Center Fairing Removal) Headlight Lead Connectors

Rear View Mirror Nuts (Both Side) [A]

• Remove the upper fairing forward.

 

 

Upper Fairing Disassembly

• Remove:

Headlight [A] (see Headlight Removal/Installation in the

Electrical System chapter)

 

Upper Fairing Assembly

• Install the headlight (see Headlight Removal/Installation in the Electrical System chapter).

Upper Fairing Installation

• Installation is the reverse of removal.

Upper Inner Fairing Removal

• Remove the bolts [A].

• Pull the upper inner fairing [B] backward, and clear the

hooks.

 

Upper Inner Fairing Installation

• Insert the hook [A] into the slot [B].

• Tighten the bolts.

 

Upper Fairing Bracket Removal

• Remove:

Upper Fairing (see Upper Fairing Removal)

Meter Unit (see Meter Unit Removal/Installation in the Electrical System chapter)

Clamp [A] Bolts [B]

Horn Leads [C] Under Bracket [D]

 

 

• Remove: Bolts [A]

Clamps [B]

Upper Fairing Bracket [C]

 

Inner Fairing Removal

• Remove:

Center Fairings (see Center Fairing Removal)

Mounting Screws [A] Inner Fairing [B]

 

 

Inner Fairing Installation

• Tighten the mounting screws.

Torque - Front Turn Signal Light Mounting Screws: 1.2 N·m (0.12 kgf·m, 11 in·lb)

• Install the center fairings (see Center Fairing Installation).

 

 

Side Covers

Side Cover Removal

• Remove the seat (see Seat Removal).

• Remove the bolt [A].

• Pull the side cover [B] evenly outward to clear the stop-

pers.

 

 

Side Cover Installation

• Insert the tabs [A] into the holes [B].

• Tighten the bolt.

• Install the seat (see Seat Installation).

 

 

Seat Covers

Seat Cover Removal

• Remove:

Seat (see Seat Removal)

Bolts [A]

Grab Rails [B] (Other than United States and Canada Models)

Screw Rivets [C]

 

• Push the central pin, and then remove the quick rivets [A].

• Pull the front and rear portions of the seat cover outside,

and then remove the seat covers.

 

 

Seat Cover Installation

• Installation is the reverse of removal.

• Put the projection [A] into the grommet [B] on the rear

fender rear.

 

 

• Put the projection [A] into the hole [B] of the seat cover.

• Install:

Grab Rails (Other than United States and Canada Mod-

els) and Bolts

Torque - Grab Rail Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

• Insert the projections [A] of the center seat cover into the holes [B] of the side seat cover.

• Install:

Screw Rivets

Seat (see Seat Installation)

 

 

Fenders

Front Fender Removal

• Remove:

Brake Hose Clamps [A]

Bolts [B] with Collar (Both Side)

• Remove the front fender [C].

 

Front Fender Installation

• Tighten:

Torque - Front Fender Bolts: 3.9 N·m (0.40 kgf·m, 35 in·lb)

• Install the brake hose clamps to the front fender holes.

Flap and Rear Fender Rear Removal

• Remove:

Seat (see Seat Removal)

Seat Covers (see Seat Cover Removal)

Tail/Brake Light [A] (see Tail/Brake Light Removal in the Electrical System chapter)

 

 

• Remove:

Nuts [A] and Bolts [B]

Flap (with License Plate Light)

 

 

• Remove:

Seat Lock Cable Lower End [A]

Quick Rivet [B]

• Free the clamps from the rear fender rear.

• Pull out the rear fender rear backward and downward.

 

Flap and Rear Fender Rear Installation

• Installation is the reverse of removal.

 

 

Fenders

Rear Fender Front Removal

• Remove:

Rear Fender Rear (see Flap and Rear Fender Rear Re-

moval)

Battery (see Battery Removal in the Electrical System chapter)

Relay Box (see Relay Box Removal in the Electrical Sys- tem chapter)

Starter Relay (see Starter Relay Inspection in the Elec- trical System chapter)

• Remove the fuse box from the rear fender front.

• Remove:

Bolt [A]

Clamp [B]

• Free the clamp from the rear fender front.

• Remove the rear fender front [A] backward and upward.

 

Rear Fender Front Installation

• Installation is the reverse of removal.

• Install the removed parts (see appropriate chapters).

 

 

Frame

Frame Inspection

• Visually inspect the frame for cracks, dents, bending or warp.

○If there is any damage to the frame, replace it.

WARNING

A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.

 

 

Sidestand

Sidestand Removal

• Raise the rear wheel off the ground with stand.

• Remove:

Frame Cover (see Frame Cover Removal)

Bolts [A] Footpeg Stay [B]

 

 

• Remove:

Sidestand Switch Bolt [A] with Clamp

Sidestand Switch [B]

 

 

• Remove: Spring [A]

Sidestand Nut [B] Sidestand Bolt [C] Sidestand [D]

 

 

Sidestand Installation

• Apply grease to the sliding area [A] of the sidestand [B].

• Tighten the bolt and lock them with the nut.

Torque - Sidestand Bolt: 44 N·m (4.5 kgf·m, 33 ft·lb)

• Hook the spring.

• Install the sidestand switch.

○Apply a non-permanent locking agent to the thread of the

switch bolt.

Torque - Sidestand Switch Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)

• Install the footpeg stay.

• Tighten:

Torque - Footpeg Stay Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)

 

Frame Cover

Frame Cover Removal

• Remove the bolt [A].

• Pull the frame cover [B] outward to clear the stoppers.

 

 

Frame Cover Installation

• Insert the projections [A] into the holes [B].

• Tighten the bolt.

 

 

 

 

 

Electrical System

Table of Contents

Exploded View........................................................................................................................ 16-3

Specifications................................................................................................................................ 16-10

Special Tools and Sealants........................................................................................................... 16-11

Parts Location................................................................................................................................ 16-12

Wiring Diagram (Europe, Korea, Hong Kong and Kuwait)............................................................ 16-14

Wiring Diagram (United States, Canada, New Zealand and Malaysia)........................................ 16-16

Wiring Diagram (Australia and South Africa)................................................................................ 16-18

Wiring Diagram (EX650B Models)................................................................................................ 16-20

Precautions.................................................................................................................................... 16-22

Electrical Wiring............................................................................................................................. 16-24

Wiring Inspection...................................................................................................................... 16-24

Battery........................................................................................................................................... 16-25

Battery Removal...................................................................................................................... 16-25

Battery Installation.................................................................................................................... 16-25

Battery Activation..................................................................................................................... 16-25

Precautions.............................................................................................................................. 16-28

Interchange.............................................................................................................................. 16-28

Charging Condition Inspection................................................................................................. 16-29

Refreshing Charge................................................................................................................... 16-29

Charging System........................................................................................................................... 16-31

Alternator Cover Removal....................................................................................................... 16-31

Alternator Cover Installation..................................................................................................... 16-31

Stator Coil Removal................................................................................................................. 16-31

Stator Coil Installation.............................................................................................................. 16-32

Alternator Rotor Removal........................................................................................................ 16-32

Alternator Rotor Installation...................................................................................................... 16-32

Alternator Inspection................................................................................................................ 16-34

Regulator/Rectifier Inspection.................................................................................................. 16-35

Charging Voltage Inspection.................................................................................................... 16-38

Starter Motor Clutch...................................................................................................................... 16-40

Starter Motor Clutch Removal/Installation............................................................................... 16-40

Starter Motor Clutch Inspection........................................................................................ 16-40 16

Starter Motor Clutch Disassembly........................................................................................... 16-40

Starter Motor Clutch Assembly................................................................................................ 16-40

Ignition System.............................................................................................................................. 16-41

Crankshaft Sensor Removal................................................................................................... 16-41

Crankshaft Sensor Installation................................................................................................. 16-42

Crankshaft Sensor Inspection.................................................................................................. 16-42

Crankshaft Sensor Peak Voltage Inspection........................................................................... 16-42

Timing Rotor Removal............................................................................................................. 16-43

Timing Rotor Installation........................................................................................................... 16-43

Stick Coil (Ignition Coil together with Spark Plug Cap) Removal............................................ 16-43

Stick Coil (Ignition Coil together with Spark Plug Cap) Installation......................................... 16-43

Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection.......................................... 16-44

Stick Coil Primary Peak Voltage............................................................................................. 16-44

Spark Plug Removal................................................................................................................ 16-45

Spark Plug Installation............................................................................................................. 16-45

Spark Plug Condition Inspection.............................................................................................. 16-45

Interlock Operation Inspection................................................................................................. 16-45

IC Igniter Inspection................................................................................................................. 16-46

Electric Starter System................................................................................................................. 16-49

Starter Motor Removal............................................................................................................ 16-49

Starter Motor Installation.......................................................................................................... 16-49

Starter Motor Disassembly...................................................................................................... 16-50

Starter Motor Assembly........................................................................................................... 16-50

Brush Inspection...................................................................................................................... 16-51

Commutator Cleaning and Inspection..................................................................................... 16-51

Armature Inspection................................................................................................................. 16-52

Brush Lead Inspection............................................................................................................. 16-52

Brush Plate and Terminal Bolt Inspection................................................................................ 16-52

Starter Relay Inspection.......................................................................................................... 16-53

Lighting System............................................................................................................................. 16-55

Headlight Beam Horizontal Adjustment................................................................................... 16-55

Headlight Beam Vertical Adjustment....................................................................................... 16-55

Headlight Bulb Replacement................................................................................................... 16-55

City Light Bulb Replacement (Europe Models)....................................................................... 16-56

Headlight Removal/Installation................................................................................................ 16-56

Tail/Brake Light Removal........................................................................................................ 16-56

Tail/Brake Light Installation...................................................................................................... 16-56

License Plate Light Bulb Replacement.................................................................................... 16-57

Turn Signal Light Bulb Replacement....................................................................................... 16-58

Turn Signal Relay Inspection................................................................................................... 16-59

Air Switching Valve........................................................................................................................ 16-61

Air Switching Valve Operation Test......................................................................................... 16-61

Air Switching Valve Unit Test.................................................................................................. 16-61

Radiator Fan System..................................................................................................................... 16-63

Fan Motor Inspection............................................................................................................... 16-63

Meter, Gauge, Indicator Unit......................................................................................................... 16-64

Meter Unit Removal/Installation............................................................................................... 16-64

Meter, Gauge Disassembly..................................................................................................... 16-64

Electronic Combination Meter Unit Inspection........................................................................ 16-65

Switches and Sensors................................................................................................................... 16-73

Brake Light Timing Inspection................................................................................................. 16-73

Brake Light Timing Adjustment................................................................................................ 16-73

Switch Inspection..................................................................................................................... 16-73

Water Temperature Sensor Inspection.................................................................................... 16-74

Speed Sensor Removal........................................................................................................... 16-74

Speed Sensor Installation........................................................................................................ 16-74

Speed Sensor Inspection......................................................................................................... 16-75

Oxygen Sensor Removal (Europe Models)............................................................................ 16-75

Oxygen Sensor Installation (Europe Models).......................................................................... 16-75

Oxygen Sensor Inspection (Europe Models).......................................................................... 16-76

Fuel Reserve Switch Inspection.............................................................................................. 16-76

Relay Box...................................................................................................................................... 16-77

Relay Box Removal................................................................................................................. 16-77

Relay Circuit Inspection........................................................................................................... 16-77

Diode Circuit Inspection........................................................................................................... 16-78

Fuse............................................................................................................................................... 16-80

30 A Main Fuse Removal........................................................................................................ 16-80

Fuse Box Fuse Removal......................................................................................................... 16-80

15 A ECU Fuse Removal........................................................................................................ 16-80

Fuse Installation....................................................................................................................... 16-81

Fuse Inspection........................................................................................................................ 16-81

Dummy Page

 

 

 

 

 

No.	Fastener	Torque	Remarks
N·m	kgf·m	ft·lb
	Front Turn Signal Light Mounting Screws	1.2	0.12	11 in·lb
	License Plate Light Cover Screws	0.90	0.090	8 in·lb
	License Plate Light Mounting Screws	1.2	0.12	11 in·lb
	Meter Screws	1.2	0.12	11 in·lb

5. Meter Unit (EX650B Models)

6. City Light (Europe Models)

 

 

 

 

 

No.	Fastener	Torque	Remarks
N·m	kgf·m	ft·lb
	Front Brake Light Switch Screw	1.2	0.12	11 in·lb
	Left Switch Housing Screws	3.5	0.36	31 in·lb
	Right Switch Housing Screws	3.5	0.36	31 in·lb
	Starter Motor Cable Terminal Nut	6.0	0.60	53 in·lb
	Starter Motor Mounting Bolts	9.8	1.0	87 in·lb	L
	Starter Motor Terminal Locknut		1.1	97 in·lb
	Starter Motor Through Bolts	4.9	0.50	43 in·lb
	Engine Ground Cable Terminal Bolt	9.8	1.0	87 in·lb

9. Main Harness (EX650B Models) G: Apply grease.

L: Apply a non-permanent locking agent. R: Replacement Parts

 

 

 

 

 

No.	Fastener	Torque	Remarks
N·m	kgf·m	ft·lb
	Alternator Cover Bolts	9.8	1.0	87 in·lb
	Alternator Lead Holding Plate Bolt	9.8	1.0	87 in·lb	L
	Alternator Rotor Bolt		15.8		MO
	Crankshaft Sensor Bolts	6.0	0.60	53 in·lb
	Neutral Switch		1.5
	Oil Pressure Switch		1.5		SS
	Oxygen Sensor	44.1	4.50	32.5
	Regulator/Rectifier Bolts	8.8	0.90	78 in·lb
	Sidestand Switch Bolt	8.8	0.90	78 in·lb	L
	Spark Plugs		1.5
	Speed Sensor Bolt	7.8	0.80	69 in·lb	L
	Starter Motor Clutch Bolts		3.5		L
	Stator Coil Bolts		1.2	106 in·lb	L
	Timing Rotor Bolt		4.1
	Water Temperature Sensor		1.2	106 in·lb

16. EX650B Models

17. EX650A Models

L: Apply a non-permanent locking agent. M: Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil solution.

(Mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10: 1) R: Replacement Parts

SS: Apply silicone sealant.

 

 

Specifications

Item	Standard
Battery
Type	Sealed Battery
Model Name	YTX12-BS
Capacity	12 V 10 Ah
Voltage	12.8 V or more
Charging System Type Alternator Output Voltage Stator Coil Resistance Charging Voltage (Regulator/Rectifier Output Voltage)	Three-phase AC
42 V or more at 4 000 r/min (rpm)
0.18 ~ 0.27 Ω
14.2 ~ 15.2 V
Ignition System Crankshaft Sensor Resistance Crankshaft Sensor Peak Voltage Stick Coil: Primary Winding Resistance Secondary Winding Resistance Primary Peak Voltage Spark Plug: Spark Plug Gap	376 ~ 564 Ω
1.9 V or more
1.1 ~ 1.5 Ω
10.8 ~ 16.2 kΩ
88 V or more
0.8 ~ 0.9 mm (0.03 ~ 0.04 in.)
Electric Starter System Starter Motor: Brush Length Commutator Diameter	12 mm (0.47 in.) (Service limit: 6.0 mm, 0.24 in.) 28 mm (1.10 in.) (Service limit: 27 mm, 1.06 in.)
Air Switching Valve Resistance	18 ~ 22 Ω at 20°C (68°F)
Switch and Sensor Rear Brake Light Switch Timing Engine Oil Pressure Switch Connections Water Temperature Sensor Resistance	ON after about 10 mm (0.39 in.) pedal travel When engine is stopped: ON When engine is running: OFF in the text

 

Special Tools and Sealants

Hand Tester: 57001-1394

Grip: 57001-1591

Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: 57001-1405

Flywheel & Pulley Holder: 57001-1605

Peak Voltage Adapter: 57001-1415

Rotor Holder: 57001-1658