Norton Motorcycles Service Manual

Commando 961 All variants

Quick Reference Guide

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

General Information .................................................................................................................................................. 8 Fuel System ............................................................................................................................................................. 28 Cooling System ........................................................................................................................................................ 43 Engine Top End ........................................................................................................................................................ 55 Clutch...................................................................................................................................................................... 96 Engine Lubrication System .................................................................................................................................... 117 Engine Removal / Installation ............................................................................................................................... 137 Crankshaft / Transmission ..................................................................................................................................... 143 Wheels / Tyres ....................................................................................................................................................... 170 Final Drive .............................................................................................................................................................. 187 Brakes .................................................................................................................................................................... 196 Suspension ............................................................................................................................................................ 219 Steering ................................................................................................................................................................. 256 Frame .................................................................................................................................................................... 271 Electrical System ................................................................................................................................................... 284 Appendix ............................................................................................................................................................... 322

All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Norton Motorcycles (UK) Ltd. No Liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. The right is reserved to make changes at any time without prior notice and without incurring obligation to make such changes to produce manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.

Emission Control Information To protect the environment in which we all live, Norton motorcycles (UK) ltd has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Norton has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only. Crankcase Emission Control System: This system eliminates the release of crankcase vapours into the atmosphere. Instead, the vapours are routed through an oil separator to the intake side of the engine. While the engine is operating, the vapours are drawn into combustion chamber, where they are burned along with the fuel and air supplied by the injection system. Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle. The fuel and ignition systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels. Evaporative Emission Control System Vapours caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapours are routed into the running engine to be burned, or stored in a canister when the engine is stopped.

The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly referred to as the Acts tampering provisions. Sec. 203(a) the following acts and the causing thereof are prohibited... (3)(A) for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser. (3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor vehicles or motor vehicles engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser...

Note: The phrase remove or render inoperative any device or element of design has been generally interpreted as follows: Tampering does not include the temporary rendering inoperative of devices or elements of design in order to perform maintenance. Tampering could include: Maladjustment or vehicle components such that the emissions standards are exceeded. Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle. Addition of components or accessories that result in the vehicle exceeding the standards. Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems. WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION. Tampering With Noise Control System Prohibited Owners are warned that the law may prohibit: The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is use; and The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. Among those acts presumed to constitute tampering are the acts listed below: Replacement of the original exhaust system or muffler with components not in compliance with federal regulations. Removal of the muffler(s) or any internal portion of the muffler(s). Removal of the air box or air box cover. Modifications to the muffler(s) or intake system by cutting, drilling, or other means if such modifications results in increased noise levels.

Foreword This Manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation. For the duration of the warranty period, especially, we recommend that all repairs and scheduled maintenance be performed in accordance with the service manual. Any owner maintenance or repair procedure not preformed in accordance with this manual may void the warranty. To get the longest life out of your Motorcycle: Follow the Periodic Maintenance Chart in the Service Manual. Be alert for problems and non-scheduled maintenance. Use proper tools and genuine Norton Motorcycle parts. Special tools, gauges, and testers that are necessary when servicing Norton motorcycles are introduced by the Special Tool Catalog or Manual. Genuine parts provided as spare parts are listed in the Parts Catalog. Follow the procedures in this manual carefully don`t take shortcuts. Remember to keep complete records of maintenance and repair with dates and any new parts installed.

How to use this Manual In preparing this manual, we divided the product into its major systems. These systems became the manual`s chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter. The Quick Reference Guide shows you all of the products system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. The Periodic Maintenance Chart is located in the General Information chapter. The chart gives a time schedule for required maintenance; for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to change the oil. Next, use the Quick Reference Guide to locate the Engine Lubrication System chapter. Then, use the Table of Contents on the first page of the chapter to find the Change Engine Oil section.
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Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operation and maintenance practices. WARNING: This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. CAUTION: This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. This Manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish types of information. Note: This note symbol indicates points of particular interest for more efficient and convenient operation. Indicates a procedural step or work to be done. o Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE in some cases. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows.

In most chapters an exploded view illustration of the system components follows the Table of Contents to show assembly sequence.

General Information Before Servicing ................................................................................................................................................. 9 General Specification ....................................................................................................................................... 13 Periodic Maintenance Chart ............................................................................................................................ 16 Torque and Locking Agent ............................................................................................................................... 17 Special tools and Sealant ................................................................................................................................. 24 Cable, Wire and Hose Routing ......................................................................................................................... 26

Maintenance / Equipment Consult your authorised Norton dealer whenever there is doubt as to the correct or safe operation of this Norton motorcycle. Remember that continued operation of an incorrectly performing motorcycle may aggravate a fault and may also prejudice safety. Ensure all equipment that is required by law is installed and functioning correctly. The removal or alteration of the motorcycles lights, silencers, emission or noise control systems can violate the law. Incorrect or improper modification may adversely affect the handling, stability or other aspect of the motorcycle operation, which may result in an accident causing injury or death. If the motorcycle is involved in an accident, collision or fall, it must be taken to an authorised Norton dealer for inspection and repair. Any accident can cause damage to the motorcycle that, if not correctly repaired, may cause a second accident that may result in injury or death. Before Servicing Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations; a certain amount of basic knowledge is also required for successful work. Especially note the following: Dirt: Before removal and disassembly, clean the motorcycle. Any dirt entering the engine or other parts will work as an abrasive and shorten the life of the motorcycle. For the same reason, before installing a new part, clean off any dust or metal fillings. Battery Ground: Remove the battery ground (-) lead from the battery before performing any disassembly operations on the motorcycle. This Prevents: o The possibility of accidently turning the engine over while partially disassembled. o Sparks at electrical connections which will occur when they are disconnected. o Damage to electrical parts. Installation, Assembly: Generally, installation or assembly is the reverse of removal or disassembly. But if this Service Manual has installation or assembly procedures, follow them. Tightening Sequence: Generally, when installing a part with several bolts, nut, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them evenly in a cross pattern. This is to avoid distortion of the part and/or causing gas or oil leakage. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter of a turn and then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and method indicated. Torque: When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench.
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Force: Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a rubber, wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removal of screws held by a locking agent) in order to avoid damaging the screw heads. Edges: Watch for sharp edges, especially during major engine disassembly and assembly. Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over. High-Flash Point Solvent: A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in the UK is Silkolene (generic name). Always follow manufacturer and container directions regarding the use of any solvent. Gasket, O-Ring: Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks. Liquid Gasket, Non-Permanent Locking Agent: Follow manufacturers directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. An example of a non-permanent locking agent commonly available in the UK is Threebond. Press: A part installed using a press or driver, such as a wheel bearing (hub bearing), should first be coated with oil on its outer or inner circumference so that it will go into place smoothly. Ball Bearing, Needle Bearing: Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any ball or needle bearings that were removed with new ones, as removal generally damages bearings. Install bearings with the marked side facing out applying pressure evenly with a suitable driver. Only press on the race that forms the press fit with the base component to avoid damaging the bearings. This prevents severe stress on the balls or needles and races, and prevents races and balls or needles from being dented. Press a ball bearing until it stops at the stop in the hole or on the shaft. Oil Seal and Grease Seal: Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. When pressing in a seal which has manufacturers marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole. Before a shaft passes through a seal, apply a little high temperature grease on the lips to reduce rubber to metal friction. Circlip, Retaining Ring: Replace any circlips and retaining rings that were removed with new ones, as removal weakens and deforms them. When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. Cotter Pin: Replace any cotter pins that were removed with new ones, as removal deforms and breaks them. Lubrication: Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and
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may contain abrasive foreign particles. Dont use just any oil or grease. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application and may be harmful if used in an application for which they are not intended. This manual makes reference to molybdenum disulfide grease (MoS2) in the assembly of certain engine and chassis parts. Always check manufacturer recommendations before using such special lubricants. Electrical Wires: All the electrical wires are either single-colour or two-colour and, with only a few exceptions, must be connected to wires of the same colour. On any of the two-colour wires there is a greater amount of one colour and a lesser amount of a second colour, so a two-colour wire is identified by first the primary colour and then the secondary colour. For example, a red wire with thin yellow strips is referred to as a red/yellow wire; it would be a yellow/red wire if the colours were reversed to make red the main colour.
Yellow

Wire Strands

Red

Yellow

Replacement Parts: When there is a replacement instruction, replace these parts with new ones every time they are removed. These replacement parts will be damaged or lose their original function once removed. Inspection: When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones. Abrasion Crack Hardening Warp Bent Dent Scratch Wear Colour Change Deterioration Seizure Specifications: Specification terms are defined as follows: Standards show dimensions or performances which brand-new parts or systems have. Service Limits indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts References to the left-hand or right-hand side given in this manual are made when viewing the motorcycle from the rear. Operations covered in this manual do not always include references to testing the motorcycle after repair. It is essential that work is inspected and tested after completion and if necessary a road test of the motorcycle is carried out particularly where safety related items are concerned.
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List of Abbreviations A ABDC AC ATDC BBDC BDC BTDC C DC F F ft g h L ampere (s) after bottom dead centre alternating current after top dead centre before bottom dead centre bottom dead centre before top dead centre degree(s) Celsius direct current farad(s) degree(s) Fahrenheit foot, feet gram(s) hours(s) litres(s) lb m min N Pa PS Kw psi r rpm TDC TIR v w pounds(s) meter(s) minute(s) Newton(s) Pascal(s) horsepower killer watt(s) pound(s) per square inch revolution revolution(s) per minute top dead centre total indicator reading volt(s) watt(s) ohm(s)

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Items Dimensions: Overall length Overall Width Overall Height Wheelbase Road clearance Seat height Dry weight Curb weight:

961 SE/SPORT/CAFE RACER 2050 mm 850mm 1110mm 1430mm 130mm (nominal) 810mm 205kg 108kg 110kg 17 Litres 3m 4-Stroke, push-rod, 2-cylinder Air/oil - cooled 88mm 79mm 10.1:1 59Kw @ 7700rpm 84Nm @ 6000rpm Norton Throttle Body 38mm Electric starter Coil Electronically advanced Controlled by ECU map NGK CR9EB LH:1 RH:2 270 36 BTDC 60 ABDC 256 70 BBDC 6 ATDC 256 Forced lubrication (dry sump) API SG, SH AND SJ, JASO MA SAE10W-40 3 L (from dry)

Front Rear

Fuel tank capacity Performance: Minimum turning radius Engine: Type Cooling System Bore and stroke Displacement Compression ratio Maximum / horsepower Maximum torque Throttle body Starting system Ignition system Timing advance Ignition timing Spark plug Cylinder numbering method Firing order Valve timing Inlet Open Close Duration Exhaust Open Close Duration Lubrication Engine oil: Grade Viscosity Capacity

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Items Drive Train: Primary reduction system: Type Reduction ratio Clutch type Transmission: Type Gear ratios: 1st 2nd 3rd 4th 5th Final drive system: Type Reduction ratio Overall drive ratio Frame: Type Caster (rake angle) Trail Front tire: Type Size Type Size Type Fork Type Sus Front Rear

961 SE/SPORT/CAFE RACER

Gear 1.61 Wet multi disc 5-speed, constant mesh 2.688 1.969 1.433 1.181 1.000 Chain drive 2.778 4.476 @Top Tubular, steel, double cradle 24.5 99mm Dunlop qualifier (Tube for spoked wheels-Continental DE17) 120/70 ZR17 M/C Dunlop qualifier (Tube for spoked wheels-Continental G17) 180/55 ZR17 M/C Telescopic fork (pneumatic) 110mm Swingarm, twin shock 96mm Twin floating discs Single disc Semi-sealed beam 12 V 55/60 W 12 V 21.5W Three-phase AC 300 w

Rear tire: Front Suspension: travel Rear Suspension: travel Brake type:

Electrical Equipment: Headlight: Type Bulb Taillight Alternator: Type Rated output

Specifications are subject to change without notice, and may not apply to every country.

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SCHEDULED MAINTENANCE CHART Operation Description

Every

Odometer Reading in Miles (Kms) or time period, whichever comes first 500 6,000 12,000 18,000 24,000 30,000 (800) (10,000) (20,000) (30,000) (40,000) (50,000) 1 1 year 2 years 3 years 4 years 5 years month

Engine oil Cooler - check for leaks Engine oil - renew Engine oil filter - renew Valve clearance - check Air cleaner - renew Engine ECU - check for stored DTC`s Spark plugs - check Spark plugs - renew Throttle bodies - balance Throttle cables - check/ adjust fuel system - check for leaks Lights. Instruments and elec. Systems - check

Day Day Day Day Day

SCHEDULED MAINTENANCE CHART Operation Description

Every

Odometer Reading in Miles (Kms) or time period, whichever comes first 500 (800) 1 month 6,000 (10,000) 1 year 12,000 (20,000) 2 years 18,000 (30,000) 3 years 24,000 (40,000) 4 years 30,000 (50,000) 5 years

Drive chain slack - check/adjust Drive chain rubbing strip - check Rear wheel bearing - lubricate Fasteners - inspect visually for security Wheels - inspect for damage Tyre wear/tyre damage - check Tyre pressures - check/adjust Stand - check operation Secondary exhaust clamp bolts - check/adjust

Day Day Day Day Day Day -

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SCHEDULED MAINTENANCE CHART Operation Description

Every

Odometer Reading in Miles (Kms) or time period, whichever comes first 500 6,000 12,000 18,000 24,000 30,000 (800) (10,000) (20,000) (30,000) (40,000) (50,000) 1 1 year 2 years 3 years 4 years 5 years month

Steering - check for free operation Headstock bearings - check/adjust Headstock bearings - lubricate Forks - check for leaks/smooth operation Fork oil - renew Brake fluid and clutch fluid levels - check Brake fluid - renew Brake pad wear - check Brake master cylinders - check for oil leaks Brake calipers - check for leaks/seized pistons Drive chain - lubricate Drive chain - wear check

Day Day Day Day Day Day Day Every 200 miles (300kms) Every 500 miles (800kms)

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Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket. Letters used in the Remarks column mean: Letters L LG Lh M O S SS St R TH05 TH27 Mean Apply a non-permanent locking agent to the threads. Apply liquid gasket to the threads. Left-hand threads. Apply molybdenum disulfide grease. Apply oil to the threads and seating surface. Tighten the fasteners following the specified sequence. Apply silicone. Stake the fasteners to prevent loosening. Replacement parts. Threebond 1305 (thread lock strong) Threebond 1327 (thread lock medium)

The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads. Basic Torque for General Fasteners Threads dia. (mm) 5 6 8 10 12 14 16 18 20 Torque N-m 3.4~4.9 5.9~7.8 14~19 25~34 44~61 73~98 115~155 165~225 225~325

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Torque table Chassis Torq ue N-m 20 60 60 55 110 8 25 25 6 35 35 25 25 35 10 8 25 7 28 43

Description Sprocket cover SPROCKET COVER TO C/CASE Front wheel SPINDLE FOR CONVENTIONAL FORKS SPINDLE FOR USD FORKS Rear wheel TO CLAMP SPROCKET TO CARRIER SPINDLE NUT Brakes HALF CLAMP BOLTS BRAKE SYSTEM ONLY BRAKE SYSTEM ONLY BRACKET TO MASTER CYLINDER (remote) LEFT HAND CALIPER BRACKET TO FORK (axial) CALIPER TO BRACKET, BRACKET TO FORK (axial) 6 PER SIDE, PATCH LOCKED (axial) 6 PER SIDE, PATCH LOCKED (radial) TO CLAMP CALIPER TO FORK (radial) TO CLAMP REAR MASTER CYLINDER + BRACKET + HEEL GUARD TO HANGER TO CLAMP RESERVOIR TO BRACKET BRAKE SYSTEM ONLY CLAMP P CLIP TO SWINGARM REAR CALIPER TO CARRIER DISK, PATCHLOCKED

Component

Remarks

BOLT, CAP HD, M8 X 30 X 1.25 SPINDLE, FRONT WHEEL SPINDLE, FRONT WHEEL, USD FORKS, HIGH BARS LOCKNUT, FLANGED, M10 X 1.25 LOCKNUT, THIN, M24 X 2 BOLT, M6 X 25 X 1.0, FLANGED, CP HD,GOLD BOLT, BANJO, M10 x 1.0 x 30, CHROME BOLT, BANJO, M10 x 1.0 x 18, CHROME BOLT, CAP HD, M6 X 12 X 1.0 BOLT, CAP HD, M10x20x1.25 BOLT, CAP HD, M10x30x1.25 BOLT, BUTTON HD, INT HEX, M8 X 16 BOLT, BUTTON HD, INT HEX, M8 X 20 BOLT, CALIPER, RADIAL BOLT, CAP HD, M6 X 20 BOLT, CAP HD, M6 x 10 BOLT, BANJO, M10x1.0x18, CHROME BOLT, CAP HD, M5 X 15 X 0.8 BOLT, CAP HD, M8 X 20 X 1.25 BOLT, BUTTON HEAD, INT HEX, M10X20

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Description Front forks PINCH BOLT SUPPLIED WITH FORKS (for axle) LOWER YOKE CLAMP BOLTS SWITCH CUBE LH SWITCH CUBE LH SWITCH CUBE RH THROTTLE ACTUATOR,TWIN CABLE THROTTLE ACTUATOR CLAMP TOP YOKE CLAMP BOLTS TOP YOKE LOCK NUT ADJUSTER NUT 40NM TO SEAT BEARINGS, BACKED OFF, THEN RE-TORQUED TO 8 NM LOCKED UP TO ADJUSTER NUT 40 NM STEM REMOTE RESERVOIR BOLT (remote) RESERVOIR TO BRACKET (axial) TO CLAMP SLAVE CYLINDER TO SPROCKET COVER HANDLEBAR CLAMP TO YOKE (not cafe racer) UPPER HANDLE BAR CLAMPS BOLTS (not cafe racer) Rear suspension SWINGARM PIVOT NUT THREADED ADJUSTER, SWINGARM USED TO MOUNT CHAIN RUBING STRIP RSU'S TO FRAME Frame TO CLAMP ENGINE MOUNT BRACKET NUT, USED WITH ENGINE MOUNT BOLT FRAME ADJUSTER, M23 REAR ENGINE MOUNT BOLT Foot controls FOOT CONTROL FRAME TO FRAME ASSY TO CLAMP CLEVIS + PEG ASSY TO CONTROL PLATE TO CLAMP TOE PEG TO PEDAL TO CLAMP PLATE TO PEDAL USE THREE BOND 1327 GEAR CHANGE TO SELECTOR SHAFT

Component

Torque Remarks N-m 20 20 3 3 3 4 8 20 80 8 40 8 7 12 43 20 60 6 9 22 26 85 15 85 27 40 10 7 20 9

19

BOLT, CAP HD, M8 X 25 BOLT, CAP HD, M8 X 20 X 1.25 SCREW, M5 X 40 SCREW, M5 X 30 SCREW, M5 X 22 THROTTLE ACTUATOR,TWIN CABLE BOLT, CAP HD, M6 X 20 x 1.0 BOLT, CAP HD, M8 X 20 X 1.25 NUT, UPPER YOKE, M25 LOCKNUT, M25 INTERMEDIATE NUT, M25 BOLT, CAP HD, M6 X 12 X 1.0 LOCKNUT, FLANGED, M5 X 0.8 BOLT, CAP HD, M6 X 16 X 1.0 NUT, M10 X 1.5 BOLT, CAP HD, M8 X 22 X 1.25 LOCKNUT, THIN, M16 X 1.0 THREADED ADJUSTER, SWINGARM BOLT BUTTON HD, INT HEX M5 X 20 X 0.8 BOLT, BUTTON HD, INT HEX, FLANGED, M8 X 16 X 1.25 LOCKNUT, M8 X 1.25 LOCKNUT, M12 X 1.75 FRAME ADJUSTER, M24 BOLT, M12, ENGINE, REAR MOUNT BOLT CAP HD, M8 X 50 X 1.25 LOCKNUT, M10 X 1.5 BOLT, CAP/HD, M6 X 40 BOLT, CSK HD, M4 X 0.7 X 12 PIVOT BOLT, SIDESTAND BOLT, CAP HD, M6 X 40

Description Oil cooler TO CLAMP OIL COOLER TO FRAME Airbox and Exhaust TO AIR FILTER CLAMP TO CLAMP TRANSITION PIECE TO HEAD 2 REQUIRED FOR HOMOLOGATION USED TO CLAMP EXHAUST SECTIONS Bodywork TO BOLT HUGGER Fuel tank FUEL PUMP MOULDED TANK TO FRAME Electrical system FOR ROLLOVER SWITCH MOUNTED ON LOWER YOKE TO CLAMP IGNITION COIL PACK PANEL TO YOKE FIXING Lighting TO CLAMP NUMBER PLATE LIGHT

Component

Torque Remarks N-m 6 4 8 19 25 10

BOLT, CAP HD, M6 X 20 x 1.0 BOLT, BUTTON HD, M5x12 BOLT, CAP HD, M6 X 20 LOCKNUT, FLANGED, M8 X 1.25 LAMBDA SENSOR, EXHAUST, M10 X 1.25 EXHAUST CLAMPS

BOLT, CAP HEAD, M5 X 15 X 0.8 BOLT, CAP HD, M5 X 12 X 0.8 BOLT, CAP HD, M6 X 16 X 1.0

7 9 9

BOLT, CAP HD, M4 X 25 X 0.7 BOLT, BUTTON HD, INT HEX, M8 X 16 BOLT, CAP HD, M6 X 40 X 1.0 BOLT, CAP HD, M8 X 20 X 1.25 BOLT, CAP HEAD, M5 X 15 X 0.8

3 18 10 20 7

20

Torque table Engine LOCATION Remarks TH27 TH27 TH27 TH27 TH27 TH27 TH27 TH03 TH03 TH03 TH03 TH03 TH27 TH27 TH27
21

Description

Component

Torque

N-m CRANKSHAFT ASSEMBLY TO CLAMP TRIGGER DISK PRIMARY GEAR NUT VALVE GEAR ROCKER SHAFT BOLTS ROCKER SHAFT BOLTS CAMSHAFT AND CAM DIVE RETAINER PLATE BOLT CAM DRIVE NUTS TENSIONER BOLTS TENSIONER BOLTS CYLINDER HEAD EXHAUST BOLTS GRUB SCREW ON EXSIDE, HEAD ROCKER TOWER, EXHAUST SIDE ROCKER TOWER, INLET SIDE CYLINDER HEAD STUDS INTERNAL HEAD BOLTS LONG INTERNAL HEAD BOLTS MEDIUM INTERNAL HEAD BOLTS SHORT CYLINDER HEAD STUD NUTS HEAD BREATHER NUT CRANK CASE CENTER PIECE SPLIT BOLTS CENTER PIECE TO CRANK CASE BOLTS BAFFLE PLATE TO CENTER PLATE BOLT CRANK CASE SPLIT BOLTS CRANK CASE SPLIT BOLTS CRANK CASE SPLIT BOLTS CRANK CASE SPLIT BOLTS CRANK CASE SPLIT BOLTS CRANK CASE SPLIT BOLTS SEAL RETAINER BREATHER SPIGOT BOLT, CSK HD, M5x0.8x12, DIN 7991, 10.9 NUT, M20, X 1.5, DIN 934, GRADE 10 BOLT, CAP HD, M8 X 35 X 1.25, DIN 912, 12.9 BOLT, CAP HD, M8 X 30 X 1.25, DIN 912, 12.9 BOLT, HEX HD, M6 X 12, DIN 933, 8.8, BZP NUT, M14 X 1.5, DIN 934, GRADE 8 BOLT, CAP HD, M8 X 16 X 1.25, DIN 912, 12.9 BOLT, CAP HD, M6 X 16 X 1.0, DIN 912, 12.9 STUD, EXHAUST GRUB SCREW, M12 X 1.75 X 20MM, DIN 913, A2 BOLT, CAP HD, M8 X 50 X 1.25, DIN 912, 12.9 BOLT, CAP HD, M8 X 55 X 1.25, DIN 912, 12.9 STUD, HEAD BOLT,CAP HD, M10 X 150 X 1.5, DIN 912, 12.9 BOLT, CAP HD, M8 X 80 X 1.25, DIN 912, 12.9 BOLT, CAP HD, M8 X 110 X 1.25, DIN 912, 12.9, BZP NUT, DOMED, M10 X 1.5, DIN 1594, A2 LOCKNUT, M10 X 1.5, GRADE 8 BOLT, CAP HD, M10 X 100 X 1.5, DIN 912, 12.9 BOLT, HEX HD, FLANGED, M8 X 40, DIN 6921, 10.9 BOLT, CAP HD, M5 X 12 X 0.8, DIN 912, 12.9 BOLT, CAP HD, M10 X 75 X 1.5, DIN 912, 12.9, BZP BOLT, CAP HD, M10 X 45 X 1.5, DIN 912, 12.9, BZP BOLT, CAP HD, M10 X 40 X 1.5, DIN 912, 12.9, BZP BOLT, CAP HD, M10 X 60 X 1.5, DIN 912, 12.9 BOLT, CAP HD, M10 X 90 X 1.5, DIN 912, 12.9 BOLT, CAP HD, M6 X 50 X 1.0, DIN 912, 12.9 BOLT, BUTTON HD, M4x0.7x6.0, ISO 7380, 10.9 BREATHER, CRANKCASE 5 122 25 25 12 54 25 12 12 15 20 20 54 60 25 25 60 20 48 25 5 48 48 48 48 48 12 2.5 15

8 9 19 18 4 13 17 20 7 26 13 28 14 15 18 19 20 24 10 15 18 20 21 22 23 24 25 29 30

LOCATION

Component BARRELS LIFTER SELEVE RETAINER OIL WAY HOLE PLUG BARREL BOLTS CLUTCH /PRIMARY TRANSMISSION CENTER NUT MAIN GEAR ASSY, INPUT/PUTPUT SELECTOR LINKAGE ARM PIVOT CENTER PLATE TO CASE BOLTS SPRING RETAINER BOLT LAY SHAFT CENTER BOLT GEAR SELECTOR ASSEMBLY TO CLAMP DETENT WHEEL TO CLAMP SHIFT MECHANISM BALANCER GEAR NUT MAIN LUBRICATION SYSTEM OIL PRESSURE SWITCH CLAMP, OIL PUMP TO ENGINE GEAR BOX FILLER CAP SUMP PLUG GEARBOX STARTER DRIVE AND MOTOR USED TO CLAMP STARTER RING TO CLAMP STARTER MOTOR TO CLAMP STARTER MOTOR SUMP ENGINE SUMP PLUG SUMP RETAINER BOLTS

Torque N-m 6 22 25

9 11 12

BOLT, M5 X 40 X 0.8, 6.00MM DIA, SHOULDERED, SS BOLT, CAP HD, M8 X 12 X 1.25, DIN 912, A2/70 BOLT, HEX HD, FLANGED, M8 X 25, DIN 6921, 10.9, BZP

6 23 56 20 44 22 25 17 1 9 13 21 4 5 7 3 5

NUT, HALF, M20 X 1.5, DIN 439, A2 70 BOLT, M8x1.25x12, 10.0 DIA, SHLD, ISO 7979, 12.9 BOLT, CAP HD, M8 X 70 X 1.25, DIN 912, 12.9 BOLT, M5x0.8x10, 6.0 DIA, SHLD, ISO 7979, 12.9 BOLT, CAP HD, M8 X 30 X 1.25, DIN 912, 12.9 BOLT, CAP HD, M6 X 25 X 1.0, DIN 912, 12.9 BOLT, CAP HD, M6 X 12 X 1.0, DIN 912, 12.9 NUT, HALF, M20 X 1.5, DIN 439, A2 70 SWITCH, OIL PRESSURE, 0.2 BAR BOLT, CAP HD, M6 X 30 X 1.0, DIN 912, 8.8, BZP FILLER CAP, GEARBOX PLUG, SUMP, M10 X 9.0 X 1.5 BOLT, M5x0.8x16, 6.0 DIA, SHLD, ISO 7979, 12.9 BOLT, CAP HD, 3/8-24UNF X 1, BZP, 1936 SERIES BOLT, CAP HD, 3/8-24UNF X 3/4, 1936 SERIES PLUG, SUMP, MAGNETIC M14 X 1.5 BOLT, CAP HD, M6 X 20 x 1.0, DIN 912, SS

122 15 25 5 25 12 12 122 20 12 20 20 5 20 20 20 12

TH27 TH03 TH03 TH27

TH27

22

Remarks

Description

LOCATION

Component ENGINE COVERS ROCKER COVER RETAINER BOLTS RH SIDE BREATHER BOLT LH BREATHER BOLT OIL FILLER RETAINER BOLTS CLUTCH COVER RETAINER BOLTS ALTERNATOR COVER RETAINER BOLTS ALTERNATOR COVER BOLT SHORT EFI SYSTEM TEMPERATURE SENSOR TO CLAMP SPEED SENSORS NEUTRAL LIGHT SWITCH FIRST USE TORQUE ONLY ALTERNATOR TO CLAMP ROTOR TO COVER TO CLAMP STATOR TO COVER TO CLAMP P-CLIP TO COVER USED TO CLAMP CRANK SENSOR

Torque N-m 12 22 22 5 12 12 12 15 12 12 12 25 12 5 5

3 8 23 14 15 18 19 1 4 5 7 2 4 7 8

BOLT, CAP HD, M6 X 20 x 1.0, DIN 912, SS BOLT, BANJO, M14 BOLT, BANJO, M14, MOD BOLT, CAP HD, M5x0.8x14, DIN 912, A2/70 BOLT, CAP HD, M6 X 20 x 1.0, DIN 912, SS BOLT, CAP HD, M6 X 40, DIN 912, SS BOLT, CAP HD, M6 X 30 X 1.0, SS SENSOR, TEMPERATURE BOLT, CAP HD, M6 X 12 X 1.0, DIN 912, 12.9, BZP SWITCH, NEUTRAL, M10x1.25 SPARK PLUG, CR9EB BOLT, CAP HD, M8 X 16 X 1.25, DIN 912, 12.9 BOLT HEX, HD, M6 X 35 DIN 933, 10.9 BOLT, BUTTON HD, INT HEX, M5 X 10, ISO 7380, 10.9 BOLT, CAP HD, M5 X 10 X 0.8, DIN 912, 12.9

TH27

23

Remarks

Description

Special tools 36mm slim head stock spanner

Engine adjuster tool

Swingarm adjust tool

Anti backlash gear holder

24

Anti backlash spring Tensioner

Clutch tool

Main shaft stop tool

25

Cable, Wire and Hose Routing Rout the electrical wires as shown:

26

Route the oil pipes as shown:

1 7

3 6

Note:

Oil is sucked from the back of the oil tank [1] and pumped under pressure through the engine oil feed system. Oil is scavenged from the sump by the oil pump [2] and pumped through the radiator [3] into the oil tank [4]. The oil tank LH breather [5], breathes into the back of the head. The crank case breather [6] breathes into the LH rocker cover. The RH rocker cover breather [7] breathes into the air box.

27

Fuel System Exploded View.................................................................................................................................................. 29 Specification ..................................................................................................................................................... 32 Throttle Grip and Cables .................................................................................................................................. 32 Grip Free Play Inspection ..................................................................................................................... 32 Grip Free Play Adjustment ................................................................................................................... 32 Throttle Cable Removal ....................................................................................................................... 32 Throttle Cable Installation ................................................................................................................... 33 Throttle Cable Lubrication ................................................................................................................... 33 Throttle Body ................................................................................................................................................... 34 Idle Speed Adjustment ......................................................................................................................... 34 Throttle Body Removal ........................................................................................................................ 34
Throttle Body Installation ...................................................................................................................................35

Throttle Body Disassembly .................................................................................................................. 36 Throttle Body Assembly ....................................................................................................................... 37 Throttle Body Cleaning ........................................................................................................................ 37 Throttle Body Inspection ..................................................................................................................... 37 Air Cleaner........................................................................................................................................................ 37 Air Cleaner Element Removal .............................................................................................................. 37 Air Cleaner Element Installation .......................................................................................................... 38 Air Cleaner Element cleaning and Inspection ...................................................................................... 38 Air Cleaner Housing Removal .............................................................................................................. 39 Fuel Tank .......................................................................................................................................................... 39 Fuel Tank Removal ............................................................................................................................... 39 Fuel Tank Installation ........................................................................................................................... 40 Fuel Tank Cleaning ............................................................................................................................... 40 Fuel Pump ........................................................................................................................................................ 41 Fuel Pump Removal ............................................................................................................................. 41 Fuel Pump Installation ......................................................................................................................... 41 Fuel Pump Inspection .......................................................................................................................... 41 Idle Motor ........................................................................................................................................................ 42 Idle Motor Removal ............................................................................................................................. 42 Idle Motor Installation ......................................................................................................................... 42 Idle Motor Inspection .......................................................................................................................... 42

28

29

REF. NO.
1 2 3 4 5 14 6 7 10 11 12 15 13 16 12 12 12 12 12

PART DESCRIPTION
FUEL PUMP MODULE BOLT, CAP HD, M5 X 12 X 0.8 HOSE, BREATHER, SHORT, 205MM DRAIN HOSE, FUEL TANK, LONG, 635MM HOSE, BREATHER, 230MM HOSE, BREATHER, 485MM HOSE, BREATHER, JOINER FILLER NECK, FUEL TANK PAD, RUBBER, FUEL TANK TO FRAME BOLT, CAP HD, M6 X 12 X 1.0 FUEL TANK, MOULDED WASHER, PENNY, M6, 6.4 X 18 1.6 BOLT, BUTTON HD, M6 X 1.0 SHOULDERED FLANGED FUEL HOSE ASSEMBLY TANK, FUEL, GALACTIC BLACK, GOLD TEXT TANK, FUEL, ROYAL RED, GOLD TEXT TANK, FUEL, CANARY YELLOW, BLACK TEXT TANK, FUEL, FACTORY SPECIAL SILVER, BLACK TEXT TANK, FUEL, FACTORY SPECIAL SILVER, BLACK TEXT/BORDER, RED PIN STRIPE

TORQUE (NM) REMARKS

BITRON

9
FUEL TANK TO JOINER JOINERS TO DRAIN FUEL TANK TO JOINER AIRBOX TO DRAIN JOINS PLASTIC FILLER NECK FOR FUEL TANK MOULDED RUBBER PIECE TO BOLT TANK PAD TO TANK AS RECIEVED FROM ACERBIS TO FIT ON EACH SIDE OF RUBBER PAD TO THE FRAME

TO CLAMP SPLASH SHIELD + TANK 94MM HOSE WITH TWO CONNECTORS

30

Exploded view

31

Throttle Specification Item Throttle Grip Free Play Idling Speed Make, Type Air Cleaner Element Oil Grade Viscosity Standard 2~3mm 1200 100 (rpm) Jenvey, Norton Commando SE or SF Class SAE30

Throttle Grip and Cables If the throttle grip has excessive free play due to cable stretch or maladjustment, there will be a delay in throttle response. Also, the throttle butterfly may not open fully at full throttle. On the other hand, if the throttle grip has no play, the throttle will be hard to control, and the idle speed will be erratic. Check the throttle grip play periodically in accordance with the Periodic Maintenance Chart, and adjust the play if necessary. Grip Free Play Inspection Check throttle grip free play[A] by lightly turning the throttle grip back and forth If free play is improper, adjust the throttle cable Throttle Grip Free Play Standard: 2 ~ 3mm

Grip Free Play Adjustment Loosen the locknut and screw the throttle cable adjuster on the rear cable (no. 1) so there is approximately 2-3mm free play at the throttle grip. Adjust the front cable (no. 2) until there is slight tension on the front cable. Tighten the locknuts against the cable adjusters. Check that the throttle cam stops against the idle adjusting screw with the throttle grip closed. Turn the handlebars from side to side while idling the engine. If idle speed varies, the cable may be poorly routed or damaged. Warning: Operation with an improperly adjusted, incorrectly routed, or damaged cable could result in an unsafe riding condition. Throttle Cable Removal Remove: Fuel Tank (see this chapter) Take off the adjuster nuts [A] at the throttle body.

32

Slip the inner clips [B] out of the lever Remove the right hand guard off the brake level. Take the two screws [A] holding the throttle pulley case halves together.

Slip the inner cable tips from the catches on the throttle pulley, and free cables from the handlebar. - Inner Cable Tips [A] - Pulley [B] - Accelerator Cable [C] Remove the throttle cables.

A C

Throttle Cable Installation Lubricate the throttle cables (see Throttle Cable Lubrication and Inspection). Be sure to fit the throttle cables into the grooves of the cable guide [A] while turning the throttle grip. Install the throttle cables in accordance with the Cable, Wire, and Hose Routing section of the General Information chapter After Installation, adjust the cables properly.

Warning: Operation with an incorrectly routed or improperly adjusted cable could result in an unsafe riding condition. Throttle Cable Lubrication and Inspection Whenever the Cables are removed, and in accordance with the Periodic Maintenance Chart, lubricate the throttle cables (see General Lubrication in the Appendix). Apply a thin coating of grease to the cable upper ends. Use a pressure cable luber to lubricate the cables With the cables disconnected at both ends, the cable should move freely in the cable housing.

33

Throttle Body A dirty or damaged air cleaner can alter the fuel air ratio. Idle speed Adjustment Start the engine and let it warm up thoroughly. With the engine idling, turn the handlebar to each side. If the handlebar movement changes idle speed, the throttle cable may be incorrectly routed, or it may be damaged. Turn the adjuster screw [A] to obtain the slowest smooth idle speed. Check idle speed. If the idle speed is out of the specified range, adjust it. Idle speed standard: 1200 100 (rpm) Open and close the throttle a few times to make sure that the idle speed does not change. Readjust if necessary.

Warning: Operation with an incorrectly routed or improperly adjusted cable could result in an unsafe riding condition. To avoid a serious burn, never touch a hot engine or an exhaust pipe during idle adjustment. Throttle body Removal Warning: Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Remove: o Fuel hose from tank o Idle motor air feed o Throttle body and idle motor power supply Remove: o Fuel tank (see this chapter) o Tank breather hose o Air cleaner housing (see this chapter) Loosen the cable adjuster nuts [A]. Slip the throttle cable lower ends out of the throttle cam. Loosen the clamps [B] Remove Four throttle body bolts [A] Remove the throttle body upward.

34

Push a clean, lint-free towel into the inlet to keep dirt or other foreign material from entering.
A

Warning: If dirt or dust is allowed to pass through into the throttle body, the throttle may become stuck, possibly causing an accident Caution: If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur. Throttle body Installation Apply RED grease to the O rings on the throttle body gasket making sure they stay in place. Torque the four throttle body bolts up Torque: M6 Bolt - 12NM When Installing air box ensure transition piece ridges fit over throttle body correctly Tighten clamps [A] Install: o Fuel tank (see this chapter) o Tank breather hose o Air cleaner housing (air box) (see this chapter) Install: o Fuel hose from tank o Idle motor air feed Throttle body and idle motor power supply Check fuel leakage from the Throttle body.

Warning: Fuel spilled from the throttle body is hazardous. Install the throttle cables (see Throttle Cable Installation) Adjust the throttle cable (see Grip Free Play Adjustment) Adjust the idle speed (see Idle Speed Adjustment)

35

Throttle Body Disassembly Remove: Throttle body Remove fuel hose

Remove: bolts [13] Fuel Injector clips Fuel rail [2] Injectors [21] Throttle potentiometer bolts [15] Throttle potentiometer [5] Four butterfly bolts [12] Remove the butterflies [7] Extract the spindle taking note of the spacer, bearing, spring assembly sequence and location Warning any damage to the injector system or potentiometer should be replaced not repaired.
36

Throttle Body Assembly The Throttle Body assembly Sequence is the reverse of the disassembly sequence (see Throttle Body Disassembly) Ensure the throttle cable spring is installed correctly and rotates freely. Check bushes for Wear and tear, replace if necessary. Ensure all seals are intact replaced if any wear or degradation is visible. Ensure no daylight is visible between the throttle butterflies and the throttle body hosing and that the butterflies are seated correctly. Throttle Body Cleaning Warning: Clean the throttle body in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents to clean the throttle bodies. A fire or explosive could result. Caution: Remove as many plastic parts from the throttle body as possible before cleaning the throttle body with a cleaning solution. This will prevent damage or deterioration of the parts. Disassemble the carburettor (see Throttle Body Disassembly). Immerse all the metal parts in throttle body cleaning solution. Rinse the parts in water. When the parts are clean, dry them with compressed air. Assemble the throttle body (see Throttle Body Assembly)

Throttle Body Inspection Remove the throttle body (see Throttle Body Removal). Turn the throttle lever [A] to check that the throttle butterfly valve [B] moves smoothly and returns back with the spring force. If any of the O-rings are not in good condition, replace them. Air Cleaner Air Cleaner Removal Remove: Seat (see Frame chapter) Air cleaner retainer screws [A] Air cleaner retainer [B] Remove air cleaner element. After removing the element, push pieces of lint-free, clean cloth into the air cleaner duct to keep dirt out of the

B A

37

throttle body and engine. Warning: If dirt or dust is allowed to pass through into the throttle body, the throttle may become stuck, possible causing an accident. Caution: If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur. Air Cleaner Element Installation When installing the element, coat the lip of the element with a thick layer of all purpose grease [A] to assure a complete seal against the air cleaner element base. Also, coat the base where the lip of the element fits. Be sure the foam gasket [A] is in place in the groove in the element cap.

Air Cleaner Element Cleaning and Inspection Note: In dusty areas, the element should be cleaned more frequently than recommended interval. Since repeated cleaning opens the pores of the element, replace it with a new one in accordance with the Periodic Maintenance Chart. Also, is there is a break in the element material or any other damage to the element, replace the element with a new one. Warning: Clean the element in a well ventilated areas, and take care that there are no sparks or flames anywhere in the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or a low-flash point solvent to clean the element. Remove the air cleaner element. Check all parts the parts of the element for visible damage. If any parts of the element are damaged, replace it. Liberally spray Air Filter Cleaner onto both sides of filter and allow to soak for 10 minutes to loosen the dirt. Do not allow cleaner to dry on air filter. Rinse off air filter with cool low-pressure water applied to the clean side out in order to flush the dirt out of the filter. Continue to rinse the filter until all traces of cleaner are gone. It may be necessary to repeat steps 1 and 2. After rinsing, gently shake off excess water and only allow filter to dry naturally. Do not oil until the filter is completely dry. Apply Air Filter Oil evenly along the crown of each pleat. Allow oil to wick for approximately 20 minutes. Touch up any light areas on either side of filter until there is a uniform colour in all areas. Install the element

38

Air Cleaner Housing Removal Remove: Seat (see Frame chapter) Breather Hoses Rear Wheel Rear Hugger Fully loosen off the two jubilee clips [A] securing the transition piece to the air cleaner housing.

Remove the two hex head bolts [A] at the rear of the air filter housing.

Fuel Tank Fuel Tank Removal Warning: Gasoline is extremely flammable and can be explosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes appliances with a pilot light. Remove: Seat (see Frame Chapter) Breather hoses Remove fuel hose, cover hose clips with lint free cloth when taking off as fuel will spill out. Remove fuel pump electrical connection. Remove hex head tank bolts, one at the front [A] and two at the rear [B]. Remove tank upwards from the bike Drain the fuel tank by siphoning the fuel out through the fuel filler cap into a clean container.

Note: 2nd on other side of frame

39

Fuel Tank Installation Check the rubber damper [A] on the frame and fuel tank. If the dampers are damaged or deteriorated, replace them. Be sure the fuel hose is clamped to the spigot to prevent leakage. Warning: Fuel spilled from the fuel spigot connecter is hazardous. Install: o Seat (see Frame Chapter) o Breather Hoses o Fuel Hose o Fuel Pump Electrical Connection. Install hex head tank bolts, two at the front one at the rear. Torque: Tank Mount Bolts - 9NM

Fuel Tank Cleaning Remove the fuel tank and drain it (see Fuel Tank Removal) Pour some high-flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits. Warning: Clean the tank in a well-ventilated area and take care that there is no spark or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low flash point solvents to clean the tank. A fire or explosion could result. Pour the solvent out the tank. Pour high-flash point solvent through the fuel spigot. Dry the tank and tap with compressed air. Install the fuel tank.

40

Fuel Pump Note: The fuel pump, fuel filter and low fuel level sensor is a sealed for life unit and must be replaced as a complete assembly. Fuel Pump Removal Remove the fuel tank and drain it (see Fuel Tank Removal).
Warning: Observe the warning advice given in general information sections on the safe handling of fuel and fuel containers. A fire, causing personal injury and damage to property, could result from spilled fuel or fuel not handled or stored correctly.

Invert the fuel tank and place on a protective surface to prevent paint damage. Remove the fixings securing the fuel pump [A]. Lift the fuel pump assembly and manoeuvre it from the tank aperture.

Fuel Pump Installation Install the fuel pump assembly and manoeuvre it into the tank aperture, ensure the gasket is seated correctly and all gasket faces are clean. Install the six fuel pump bolts. Torque: Fuel Pump Mount Bolts - 3NM Install the fuel tank (see Fuel Tank Installation).

Fuel Pump Inspection

Note: Fuel Pump Pressure test requires Inline pressure gauge, and fuel pump fly lead (extension cable) available from Norton Motorcycles (UK) Ltd.

Remove the Fuel tank (see Fuel Tank Removal). Attach Extension cable to pump electrical connection, and wiring harness. Attach Inline Pressure tester to Pump and throttle bodies. Place the pressure gauge in a visible position with the fuel tank upright on a flat surface, with a soft cloth to stop paintwork damage. Start the motorcycle and observe the fuel pressure.

Fuel Pressure Nominal: 3 Bar

41

When finished remove extension cable and inline pressure tested and install the fuel tank (see fuel tank installation. Idle Motor Idle Motor Removal Remove: o Idle motor hose clips o Hoses o Electrical connections Remove idle motor bracket bolts [A]. Remove idle motor bolts [B].

Idle Motor Installation Install: o Idle motor hoses o Electrical connector o Hoses clips Install and tighten idle motor bracket bolts Torque Idle Bracket Bolts: 5Nm Torque Idle motor bolts Torque Idle Motor Bolts: 5Nm Idle Motor Inspection Visually inspect the idle motor for damage/cracks, and or deterioration Replace if any issues are visible.

42

Cooling System Exploded View.................................................................................................................................................. 45 Flow Chart ........................................................................................................................................................ 47 Specification ..................................................................................................................................................... 48 Engine Oil and Filter ......................................................................................................................................... 49 Oil Level Inspection .............................................................................................................................. 49 Oil Draining........................................................................................................................................... 49 Oil Filling ............................................................................................................................................... 50 Oil Pump ........................................................................................................................................................... 50 Oil Pump Removal ................................................................................................................................ 50 Oil Pump Installation ............................................................................................................................ 51 Oil Pump Inspection ............................................................................................................................. 51 Oil Cooler ......................................................................................................................................................... 51 Oil Cooler Removal .............................................................................................................................. 51 Oil Cooler Installation .......................................................................................................................... 52 Oil Cooler Inspection............................................................................................................................ 52 Oil Cooler Cleaning............................................................................................................................... 52 Hose Inspection.................................................................................................................................... 52 Head Temperature Sensor ............................................................................................................................... 53 Head Temperature Sensor Removal .................................................................................................... 53 Head Temperature Sensor Installation ................................................................................................ 53 Head Temperature Sensor Inspection ................................................................................................. 53

43

Oil Coolant Flow

1 7

3 6

Note:

Oil is sucked from the back of the oil tank [1] and pumped under pressure through the engine oil feed system. Oil is scavenged from the sump by the oil pump [2] and pumped through the radiator [3] into the oil tank [4]. The oil tank LH breather [5], breathes into the back of the head. The crank case breather [6] breathes into the LH rocker cover. The RH rocker cover breather [7] breathes into the air box.

44

45

REF. NO. 1 8 11 12 9 10 13 14 15 20 21 22

PART DESCRIPTION SWITCH, OIL PRESSURE, 0.2 BAR PUMP ASSY, OIL PIN, DOWEL, 1/8 X 5/8, SOLID PIN, DOWEL, 4.0 X 16.00MM, SOLID BOLT, CAP HD, M6 X 30 X 1.0, DIN 912, 8.8, BZP WASHER, ID 6.4 X 11.0 OD X 1.6 STAINLESS FILLER CAP, GEARBOX WASHER, ID 26.3 X 31.75 X 2.0, COPPER FILTER, OIL SEAL, M10, BONDED VITON PLUG, SUMP, M10 X 9.0 X 1.5 LABEL, SILKOLENE, 10W/40

TORQUE REMARKS THREEBOND 1327 20 USED WITH OIL PUMP DRIVE USED WITH PUMP TO CASE 12 20 GEAR BOX FILLER CAP CLAMP, OIL PUMP TO ENGINE USED WITH OIL PUMP BOLTS

20 APPLY TO RH COVER ABOVE FILTER COVER

46

47

REF. NO. 1 2 3 4 5

PART DESCRIPTION COOLER, OIL GROMMET, ID 14 X OD 9 X 12.5 COMPRESSION LIMITER, M6 X 20MM OD BOLT, CAP HD, M6 X 20 x 1.0 WASHER, PENNY, M6, 6.4 X 18 X 1.6 OIL LINE OIL LINE, 215MM OIL LINE, 685MM OIL LINE, 490MM OIL LINE 400MM OIL LINE, 300MM HOSE, BREATHER, FORMED, 360MM BANJO, OIL LINE, IN BANJO, OIL LINE, OUT WASHER, M14, OD 20.4MM X 1.22, COPPER BOLT, BANJO, OIL LINE O-CLAMP, DOUBLE EARED, 15MM-18MM

TORQUE (NM)

REMARKS

TO CLAMP OIL COOLER TO FRAME USED WITH OIL COOLER BOLTS EN 854 100R6 - 06 (RAW) OIL COOLER TO OIL TANK OIL COOLER TO OIL PUMP, 685MM OIL PUMP TO OIL TANK, 490MM ROCKER COVER TO CRANKCASE 400MM HEAD TO AIR BOX, 300MM ROCKER COVER TO OIL TANK

6 7 8 9 10 11 12 13 14 15 16 17

ONE EITHER SIDE OF OIL BANJO USED FOR OIL LINE IN AND OUT OIL LINE AND BREATHER PIPE CLIPS SMALL BREATHER HOSE TO ROCKER COVER

Specification

Oil Specification Item Engine Oil: Grade Viscosity Capacity Oil Pressure Measurement: Relief valve opening pressure oil pump pressure @8000rpm with 130C 10W/40 oil oil pump pressure @1000rpm with 130C 10W/40 oil 400kPa 6L/min and 300kPa 150kPa

Standard

API SG, SH AND SJ, JASO MA SAE 10W-40 3L FROM COMPLETELY DRY 2.5L WHEN FILTER REMOVED

48

Engine Oil and Oil Filter Warning: Motorcycle operation with Insufficient, deteriorated or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure, accident, and injury. Oil Level Inspection Situate the motorcycle so that it is perpendicular to the ground. If the oil has just been changed, start the engine and run it for several minutes at idle speed. This fills the oil filter with oil. Caution: Racing the engine before the oil reaches every part can cause engine seizure. Stop the engine and leave it for more than 1 minute for all the oil to drain down. If the motorcycle has just been ridden, run the engine for about 20 seconds at idle speed. Stop the engine and leave it for more than one minute. Check the engine oil by removing the oil filler [A], clean the dip stick with a cloth fully reinsert the plug then remove it again and check the level on the dip stick. The oil level should be in the middle of the two markings. If the oil level is difficult to check, rock the motorcycle both side-to-side, and front-to-rear. If the oil level is too high, remove the excess oil through the filler opening, using a syringe or some other suitable device. If the oil level is too low, add the correct amount of oil through the oil filler opening. Use the same type and make of oil that is already in the engine.

Min

Max

Note: If the engine oil type and make are unknown, use any brand of the specified oil to top off the level rather than running the engine with the oil level low. Then at your earliest convenience, change the oil completely. Oil Draining 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. Oil on tires will make them slippery and can cause an accident and injury. Immediately wash away any coolant that spills of the frame, engine, or wheels. Since oil is harmful to the human body, do not use for drinking. Place a container under the drain plug [A] at the bottom of the sump, remove oil filler cap and then remove the drain plug.

49

Place a tray under the bottom radiator hoses [A], remove the bottom banjo bolt [B] and drain the oil from the oil tank hose.
B

Oil Filling Tighten the drain plug. Torque Oil sump drain Plug 20Nm Fill the oil tank with 2.5L of oil and tighten the filler cap. Run the engine at idle for 2 minutes in a well ventilated area. Allow the motorcycle to stand for 2 minutes. Check the oil level as described in (Oil Level Inspection) top up if necessary.

Note: Pour in the oil slowly so that the air in the engine and oil cooler can escape. Caution: Do not add more oil above the full mark. Oil Pump Oil Pump Removal Drain the oil (see Oil Draining) Remove Oil Pump hoses [A]
A

Remove Oil Pump retainer bolts [A]

Remove the oil pump from the engine and balance shaft taking care that the drive dowel pin [A] remains in the oil pump drive shaft.

50

Oil pump Installation Apply a small amount of grease to the drive pin to ensure the pin remains located Align the drive dowel pin with the balance shaft cut out [A] and the oil pump dowels with the engine casing.

Install the oil pump retaining bolts. Torque Retaining bolts oil pump 12NM

Install the hoses as shown. Hose from radiator [A] Hose from tank [B] Torque - banjo Bolts to 27 Nm

Fill the oil system (see Oil Filling).

Oil Pump Inspection If the oil seal is damaged, the oil leaks through the seal. Replace the ball bearing and oil seal. Oil Cooler Oil Cooler Removal Drain the oil (see Oil Draining) Remove: o Oil Cooler Hoses [A] o Oil Cooler Bolts [B] Caution: Do not touch the Oil Cooler core. This could damage the radiator fins, resulting in loss of cooling efficiency.
A

51

 Remove the Oil Cooler [C] Oil Cooler Installation Run the hoses and leads according to the Cable, Wire, and Hoses Routing section in the General Information chapter.

Oil Cooler Inspection Check the Oil Cooler core. If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the Oil Cooler core are blocked more than 20% by unremovable obstructions or irreparably deformed fins, replace the Oil Cooler with a new one. Oil Cooler Cleaning Remove the Oil Cooler (see Oil Cooler remover). Caution: When cleaning the Oil Cooler with steam cleaner, be careful of the following to prevent Oil Cooler damage. Keep the steam gun [A] away more than 0.5m [B] from the Oil Cooler core [C]. Hold the steam gun perpendicular to the core surface. Run the steam gun following the core fin direction [D].
D C

B A

Hose Inspection In accordance with the Periodic Maintenance Chart, visually inspect the Oil Cooler hoses for signs of deterioration. Squeeze the hose. A hose should not be hard and brittle, nor should it be soft or swollen.
Replace and damaged hose.

52

Head Temperature Sensor Head Temperature Sensor Removal Remove Idle air motor assembly (see Fuel System chapter) Remove electrical connection from sensor. Remove the connector by unscrewing it. Head Temperature Sensor Installation Install and tighten the connector. Torque Head Temp Sensor: 15Nm

Install electrical connector on sensor. Install idle air motor assembly (see Fuel System chapter).

Head Temperature Sensor Inspection Check the sensor visually for cracks/deterioration or visible signs of damage.
If the sensor if thought to be faulty replace.

53

Engine Top End Exploded View.................................................................................................................................................. 56 Specification ..................................................................................................................................................... 71 Cylinder Head Cover ........................................................................................................................................ 73 Cylinder Head Cover Removal ............................................................................................................. 73 Cylinder Head Cover Installation ......................................................................................................... 73 Cylinder Head Cover Assembly ............................................................................................................ 74 Camshaft Chain Tensioner ............................................................................................................................... 74 Camshaft Chain Tensioner Removal .................................................................................................... 74 Camshaft Chain Tensioner Installation ................................................................................................ 75 Camshaft, Camshaft Chain ............................................................................................................................... 76 Camshaft Chain Removal ..................................................................................................................... 76 Camshaft Chain Installation ................................................................................................................. 76 Camshaft Removal ............................................................................................................................... 76 Camshaft Installation ........................................................................................................................... 77 Camshaft Disassembly ......................................................................................................................... 78 Camshaft Assembly .............................................................................................................................. 78 Camshaft Bearing Wear ....................................................................................................................... 78 Cylinder Head ................................................................................................................................................... 79 Cylinder Compression Measurement .................................................................................................. 79 Cylinder Head Removal ........................................................................................................................ 80 Cylinder Head Installation .................................................................................................................... 82 Cylinder Head Assembly....................................................................................................................... 83 Cylinder Head Disassembly .................................................................................................................. 84 Cylinder Head Cleaning ........................................................................................................................ 84 Cylinder Head Warp ............................................................................................................................. 84 Valves ............................................................................................................................................................... 85 Valve Clearance Measurement ............................................................................................................ 85 Valve Clearance Adjustment ................................................................................................................ 85 Valve Removal ...................................................................................................................................... 85 Valve Installation .................................................................................................................................. 86 Valve-to-Guide Clearance Measurement ............................................................................................ 86 Valve Seat Inspection ........................................................................................................................... 86 Valve Seat Repair (Valve Lapping)........................................................................................................ 87 Cylinder, Piston ................................................................................................................................................ 90 Cylinder, Piston Removal ..................................................................................................................... 90 Cylinder, Piston Installation and Ware ................................................................................................ 91 Piston/Cylinder Clearance .................................................................................................................... 93 Cylinder Boring and Honing ................................................................................................................. 93 Piston Ring and Ring Grove Wear ........................................................................................................ 93 Piston Ring End Gap Measurement ..................................................................................................... 93 Exhaust System ................................................................................................................................................ 94
54

Silencer Removal .................................................................................................................................. 94 Secondary Removal .............................................................................................................................. 94 Header Pipes Removal ......................................................................................................................... 95 Exhaust Pipe Installation .................................................................................................................................. 95

55

Exploded View

56

REF. NO.
1 2 3 4 5 6 7 26 8 9 10 11 27 13 28 12 14 15 18 19 20

PART DESCRIPTION
CYLINDER HEAD, ASSY, MC/D CYLINDER HEAD, MACHINING CYLINDER HEAD, CASTING VALVE GUIDE, INLET VALVE GUIDE, EXHAUST SEAT, VALVE, INLET SEAT, VALVE, EXHAUST STUD, EXHAUST GRUB SCREW, M12 X 1.75 X 20MM, DIN 913, A2 GASKET, CYLINDER HEAD TOWER, ROCKER, LH, MC/D TOWER, ROCKER,RH, MC/D PIN, DOWEL, 6.00 X 12.0, DIN 7, SS WASHER, M8, NORDLOCK BOLT, CAP HD, M8 X 50 X 1.25, DIN 912, 12.9 BOLT, CAP HD, M8 X 55 X 1.25, DIN 912, 12.9 WASHER, M8, ID 8.4 X OD 15 X 1.6, BZP STUD, HEAD BOLT,CAP HD, M10 X 150 X 1.5, DIN 912, 12.9 BOLT, CAP HD, M8 X 80 X 1.25, DIN 912, 12.9 BOLT, CAP HD, M8 X 110 X 1.25, DIN 912, 12.9, BZP NUT, DOMED, M10 X 1.5, DIN 1594, A2 CMD EXTREME PRESSURE LUB #3, 4oz

TORQUE

REMARKS

12 15

THREEBOND 1305 THREEBOND 1305

20 20 54 60 25 25 60

EXHAUST, TB 1305 INLET, TB 1305 TB 1305

APPLY TO STUD FIXINGS AS REQUIRED

16 21 22 23

WASHER, M10, 10.5 X 21.0 X 2, DIN 125A, A2 SPACER, EXHAUST SPRING SPACER, INLET SPRING BREATHER FITTING, ASSY, CYLINDER HEAD BREATHER FITTING, BODY BREATHER FITTING, BARB
INSIDE ENGINE BETWEEN HEAD AND WASHER

25 24 29 16

SEAL, M10, BONDED VITON LOCKNUT, M10 X 1.5, GRADE 8 WASHER, 10.5 X 21.0 X 1.2, FORM B, A2 WASHER, M10, 10.5 X 21.0 X 2, DIN 125A, A2 20

INSIDE ENGINE ON TOP OF SEAL WASHER ON THE OUT SIDE OF THE ENGINE

57

58

REF. NO.
25 1 2 3 5 6 7 8 22 23 24

PART DESCRIPTION
COVER ASSY, ROCKER COVER, ROCKER, MACH GASKET, ROCKER, COVER BOLT, CAP HD, M6 X 20 x 1.0, DIN 912, SS BANJO,M14, 9MM SPIGOT WASHER, M14, OD 20.0MM X 2.5 ALUMINIUM WASHER, M14, OD 20.4MM X 1.22, COPPER BOLT, BANJO, M14 NUT, M14 X 1.5, THIN, STEEL BOLT, BANJO, M14, MOD BREATHER BAFFLE, ASSY BREATHER BAFFLE, FRONT BREATHER BAFFLE, REAR BREATHER BAFFLE, WELD NUT

TORQUE (NM) REMARKS

12

22 22

9 10 11 26 12 27 28 29 30 13 14 15 16 17 11 18 19 31

COVER, RH, MC/D GASKET, COVER, RH DOWEL, RING, 7.8MM DIA COVER ASSY, OIL FILTER COVER, OIL FILTER, MC/D TOP HAT, OIL FILTER, COVER BELLEVILLE, SPRING O-RING, 14MM X 2MM, VITON RING, WIRE, 18MM, PLAIN, EXTERNAL O-RING, 67MM X 2 MM, VITON BOLT, CAP HD, M5x0.8x14, DIN 912, A2/70 BOLT, CAP HD, M6 X 20 x 1.0, DIN 912, SS COVER, CLUTCH, MC/D GASKET, COVER, CLUTCH DOWEL, RING, 7.8MM DIA BOLT, CAP HD, M6 X 40, DIN 912, SS BOLT, CAP HD, M6 X 30 X 1.0, SS LABEL, SILKOLENE, 10W/40 12 12
LABEL FOR ENGINE OIL

5 12

59

REF. NO. 1 3 5 6 7 8 9

PART DESCRIPTION PISTON ASSY, LH PISTON, MC/D, LH 1ST RING, PISTON, 88.0 X 1.0 STEEL NITRIDE 2ND RING, PISTON, 88.0 X 1.2 PHOSPHATE OIL RING, PISTON 88.0 X 2.8 STEEL NITRIDE GUDGEON PIN CIRCLIP, DIA 22 X 1.5 SECTION

TORQUE REMARKS ORIENTATE DIMPLE INBOARD

2 4 5 6 7 8 9 9

PISTON ASSY, RH PISTON, MC/D, RH 1ST RING, PISTON, 88.0 X 1.0 STEEL NITRIDE 2ND RING, PISTON, 88.0 X 1.2 PHOSPHATE OIL RING, PISTON 88.0 X 2.8 STEEL NITRIDE GUDGEON PIN CIRCLIP, DIA 22 X 1.5 SECTION CIRCLIP, DIA 22 X 1.5 SECTION

ORIENTATE DIMPLE INBOARD

60

61

REF. NO.
3 2 1 4 5 6 7 8 9 20 10 11 6 7 8 9 20 12 13 7 6 8 9 20 14 15 8 6 7 9 20 16 19 17 18 21 22 23 24 25 26 27 28

PART DESCRIPTION
LIFTER, PUSHROD PUSHROD, EXHAUST PUSHROD, INLET ROCKER, EXHAUST, LH ASSY ROCKER, EXHAUST, LH MC/D BEARING, BUSH, ROCKER PIN, ROLLER ADJUSTER, ROCKER NUT, 3/8-24 UNF BEARING, BUSH, ROCKER ARM ROCKER, EXHAUST, RH, ASSY ROCKER, EXHAUST, RH, MC/D BEARING, BUSH, ROCKER PIN, ROLLER ADJUSTER, ROCKER NUT, 3/8-24 UNF BEARING, BUSH, ROCKER ARM ROCKER, INLET, LH, ASSY ROCKER, INLET, LH, MC/D PIN, ROLLER BEARING, BUSH, ROCKER ADJUSTER, ROCKER NUT, 3/8-24 UNF BEARING, BUSH, ROCKER ARM ROCKER, INLET, RH, ASSY ROCKER, INLET, RH, MC/D ADJUSTER, ROCKER BEARING, BUSH, ROCKER PIN, ROLLER NUT, 3/8-24 UNF BEARING, BUSH, ROCKER ARM ROCKER SHAFT, EXHAUST BOLT, CAP HD, M8 X 35 X 1.25, DIN 912,12.9 ROCKER, SHAFT, INLET BOLT, CAP HD, M8 X 30 X 1.25, DIN 912,12.9 WASHER, THRUST, THRUST 5/8"x1 1/8"x1.6mm SEAT, SPRING, EXHAUST SPRING, VALVE, EXHAUST VALVE, EXHAUST DIA 37.0MM SEAT,SPRING, INLET SPRING, VALVE, INLET VALVE, INLET, DIA 44.5MM SEAL, OIL, VALVE STEM

TORQUE

REMARKS

THREEBOND 1327

25
THREEBOND 1327

25

62

29 30 31

RETAINER, SPRING COLLET, VALVE CAP, LASH

63

REF. NO.
1 2 3 5 4 8 9 10 11 6 7 12 BARREL ASSY, MC/D

PART DESCRIPTION

TORQUE (NM)

REMARKS

BARREL, MACHINING BARREL, CASTING LINER, CYLINDER SLEEVE, LIFTER, RH SLEEVE, LIFTER, LH WASHER, 6.4x10.0x2.0, COPPER BOLT, M5 X 40 X 0.8, 5.6MM DIA, SHOULDERED, SS WASHER, M8 X 8.2 ID, 12.0 OD, X 1.0, COPPER BOLT, CAP HD, M8 X 12 X 1.25, DIN 912, A2/70 GASKET, BARREL DOWEL, RING, 13.00MM DIA BOLT, HEX HD, FLANGED, M8 X 25, DIN 6921, 10.9, BZP 25 22 6

64

65

REF. NO.
1 2 3 4 6 8 9 10 11 12 13 14 15 16 17 18 19 20

PART DESCRIPTION
BEARING, DEEP GROOVE, 20 X 47 X 14 BEARING, DEEP GROOVE, 20 X 52 X 15 PLATE, RETAINING, CAMSHAFT BOLT, HEX HD, M6 X 12, DIN 933, 8.8, BZP CAMSHAFT, M/C SPACER, CAMSHAFT SPROCKET, CAMSHAFT, 30T SPROCKET, CAMSHAFT, 15T WOODRUFF KEY, 3/8" X 1/8" WASHER, M14, DIN 433, 15X24X2.5 NUT, M14 X 1.5, DIN 934, GRADE 8 CHAIN, CAM, 54 LINK TENSIONER, CAM CHAIN, ADJUSTABLE WASHER, M8 X 17 X 1.6, DIN 125A BOLT, CAP HD, M8 X 16 X 1.25, DIN 912, 12.9 TENSIONER , CAM CHAIN, FIXED WASHER, M6, 6.4 X 12 X 1.6, DIN 125A BOLT, CAP HD, M6 X 16 X 1.0, DIN 912, 12.9

TORQUE REMARKS
USED BETWEEN CAM SHAFT AND LH CRANKCASE USED ON DRIVE SIDE OF CAMSHAFT USED ON DRIVE SIDE, MOUNTED TO CASE

12

THREEBOND 1327

ONE ON CRANK, ONE ON CAM

54

THREEBOND 1327

25

THREEBOND 1327

12

Threebond 1327

66

67

REF. NO.
31 31 8 1 2 6 5 31 31 31 8 1 2 3 6 5

PART DESCRIPTION
EXHAUST SYSTEM KIT, ROW SECONDARY, STAINLESS CLAMPS, EXHAUST HEADER, RH, CHROME, EURO HEADER, LH, CHROME, EURO SILENCER, RH SILENCER, LH EXHAUST SYSTEM KIT, ROW EXHAUST SYSTEM KIT, ROW EXHAUST, IVA COMPLIANT EXHAUST CLAMPS HEADER, R/H, CHROME HEADER, L/H, CHROME SECONDARY, STAINLESS, IVA SILENCER, R/H SILENCER, LH

TORQUE (NM) REMARKS

10

USED TO CLAMP EXHAUST SECTIONS

10

MOTAD USED TO CLAMP EXHAUST SECTIONS

68

31 8 1 2 3 6 5 31 31 31 31 31 31 31 31 31 31 31 31 31 18 21 22 27 28 29 24 25 26 23 30 19 20 9 10 11 12 13 14

EXHAUST SYSTEM KIT, EURO CLAMPS, EXHAUST HEADER, RH, CHROME, EURO HEADER, LH, CHROME, EURO SECONDARY, STAINLESS, EURO SILENCER, RH SILENCER, LH EXHAUST SYSTEM KIT, EURO EXHAUST SYSTEM KIT, EURO EXHAUST SYSTEM KIT, EURO EXHAUST SYSTEM KIT, EURO EXHAUST SYSTEM KIT, EURO EXHAUST SYSTEM KIT, EURO EXHAUST SYSTEM KIT, EURO EXHAUST SYSTEM KIT, EURO EXHAUST SYSTEM KIT, EURO EXHAUST SYSTEM KIT, EURO EXHAUST SYSTEM KIT, EURO EXHAUST SYSTEM KIT, EURO EXHAUST SYSTEM KIT, EURO AIRBOX MOULDING FITTING, AIRBOX, TURNED, M12, 8MM FITTING, AIRBOX, TURNED, M6, 3MM BOLT, CAP HD, M6 X 12 X 1.0 WASHER, PENNY, M6, 6.4 X 18 X 1.6 WASHER, SERRATED, M6 CLAMP, AIRBOX, MOULDED FILTER, AIR BOLT, BUTTON HD, M5x12 TRANSITION PIECE UNI-CLIP, TRANSITION PIECE SPREADER PLATE, TRANSITION PIECE BOLT, CAP HD, M6 X 20 EXHAUST BUSH EXHAUST BUSH COMPRESSION LIMITER WASHER, M8, 8.4 X 16 X 1.6 BOLT CAP HD, M8 X 50 X 1.25 LOCKNUT, FLANGED, M8 X 1.25 CENTRAL MOUNT BUSH 8 TO CLAMP TRANSITION PIECE SILENCER TO FRAME SILENCER TO FRAME M8 WASHER 2 PER SIDE TO BOLT SILENCER TO FRAME TO BOLT SILENCER TO FRAME CENTRAL MOUNT TO CLAMP THROTTLE BODIES 4 TO AIR FILTER CLAMP TO CLAMP AIRBOX TO FRAME
USED WITH AIRBOX BOLT TO CLAMP EARTH STRAP USED WITH AIRBOX BOLT TO CLAMP EARTH STRAP

10

USED TO CLAMP EXHAUST SECTIONS

AS RECEIVED FROM ACERBIS 1 ONLY FOR IVA BIKES

ACERBIS 'TOILET SEAT'

69

15 16 17 30 4 7

CENTRAL MOUNT BUSH COMPRESSION LIMITER BOLT CAP HD, M10 X 50 X 1.5 LOCKNUT, M10 X 1.5 GASKET, HEADER LOCKNUT, FLANGED, M8 X 1.25 LAMBDA SENSOR, EXHAUST, M10 X 1.25 19 TO HEAD CENTRAL MOUNT BOLT CENTRAL MOUNT NUT

25

2 REQUIRED FOR HOMOLOGATION

18 18 18 18 18 18 18 18 18 18 18 18 18 18 18

AIRBOX, GALACTIC BLACK, GOLD TEXT, SPORT AIRBOX, ROYAL RED, GOLD TEXT, SPORT AIRBOX, CANARY YELLOW, BLACK TEXT, SPORT AIRBOX, FACTORY SPECIAL SILVER, BLACK TEXT/BORDER RED PIN STRIPE, SPORT AIRBOX, GALACTIC BLACK, SILVER TEXT, SPORT AIRBOX, GALACTIC BLACK, GOLD TEXT, CAFE RACER AIRBOX, ROYAL RED, GOLD TEXT, CAFE RACER AIRBOX, CANARY YELLOW, BLACK TEXT, CAFE RACER AIRBOX, FACTORY SPECIAL SILVER, BLACK TEXT/BORDER RED PIN, STRIPE, CAFE RACER AIRBOX, GALACTIC BLACK, SILVER TEXT, CAFE RACER AIRBOX, GALACTIC BLACK, GOLD TEXT, SE AIRBOX, FACTORY SPECIAL SILVER, BLACK TEXT, CAFE RACER AIRBOX, FACTORY SPECIAL SILVER, BLACK TEXT, SPORT AIRBOX, GALACTIC BLACK, YELLOW TEXT, SPORT AIRBOX, GALACTIC BLACK, YELLOW TEXT, CAFE RACER

70

Specifications Top End Specification Standard (mm)

Item Camshaft: Cam height: Exhaust Inlet Camshaft journal diameter Camshaft bearing ID diameter Camshaft runout Camshaft chain 54-link length Cylinder head: Cylinder Compression Cylinder head warp Valves: Valve clearance: Exhaust Inlet Valve head thickness: Exhaust Inlet Valve stem bend Valve stem Diameter: Exhaust Inlet Valve Guide inside Diameter: Exhaust Inlet Valve/valve guide clearance: (wobble method): Exhaust Inlet Valve seat cutting angle inlet Valve seat cutting angle

Service Limit

31.112 0.03 32.1788 0.03 19.993-19.980 / 20.000-19.987 20.00-19.990 Ra 0.02 max 216 0.3 (120-170 psi) --go back one full turn from zero on adjuster go back one full turn from zero on adjuster 1.27 0.1 1.27 0.1 Ra 0.02 6.98-6.96 6.98-6.96

30.982 32.049 19.951 / 19.958 20.059 Ra 0.1 218 --0.05mm

----1.0 0.8 Ra 0.05 7.01 7.01

7.024-7.032 7.004-7.012

7.097 7.077

0.06~0.15 0.09~0.18 Initial 45 then 35 (VAI-A19038) then relief 75 (VSI-A13600) Initial 45 then 29 (VSI-A18658) then relief 55 (VSI-A13600)

0.34 0.34 ----71

Valve seat cutting angle inlet: Initial 45 then 35 (VAI-A19038) then relief 75 (VSI-A13600) Valve seat cutting angle exhaust: Initial 45 then 29 (VSI-A18658) then relief 55 (VSI-A13600) Top End Specification Standard (mm) Exhaust Inlet Outside: Valve spring free length: Exhaust Inlet Cylinder, Piston: Cylinder inside diameter: Piston diameter: Piston/cylinder clearance: Piston ring/groove clearance: Top Second Piston ring groove width: Top Second Piston ring thickness: top Second Piston ring end gap: Top Second Oil 0.15-0.35 0.35-0.55 0.20-0.70 0.65 0.85 1.0 0.990-0.970 1.190-1.170 0.900 1.270 1.020-1.010 1.230-1.210 1.100 1.310 44.4 52.15 87.995-88.005 87.900-87.925 0.105-0.070 0.020-0.050 0.020-0.060 42.5 49.85 88.050 87.750 --0.150 0.160 Exhaust Inlet 1.5 1.5 35.5 43

Item Valve seat surface: Width:

Service Limit ---------

72

Cylinder Head Cover Cylinder Head Cover Removal Remove: Fuel Tank (see Fuel System chapter) Spark Plug Cap [A] Breather Hose [B] Battery and Battery tray (see Electrical chapter)
A

Remove Cylinder Head Cover Bolts [A] Slide the cover [B] up and out the right hand side)

Cylinder Head Cover Installation Replace the rocker cover gasket with a new one if it is damaged. Torque Cylinder head cover bolts: 12Nm

73

Cylinder Head Cover Assembly Install baffle plate. Install banjo bolt (short) and assembly as detailed: Torque Banjo Baffle bolt: 22Nm

Install long banjo bolt, banjo and thin nut as detailed:

Torque Banjo bolt Breather: 22Nm

Camshaft Chain Tensioner

74

Camshaft Chain Tensioner Removal Remove oil filter (see Engine Lubrication System chapter). Remove cam chain cover bolts. Remove cam chain cover taking note of the location of dowels.

Set Crank to TDC and take note of woodruff key position on cam shaft. Remove two M8 cam chain Tensioner bolts. Remove chain Tensioner.

Cam Tensioner Installation Align cam and crank woodruff keys, with crank set at TDC. Finger tighten tensioner bolts. Apply 200N of load to the tensioner, use a T-bar to apply load if necessary. Torque up bolts. Torque Bolts - 25Nm Threebond 1327

75

Camshaft Chain Camshaft Chain Removal Remove o Cam Chain Cover (see this chapter) o Cam Chain Tensioner (see this chapter) Put Crank at TDC, mark position of Cam and Crank with marker. Remove Cam and Crank Sprocket nuts. Remove cam chain tensioner. Remove Chain with sprockets.

Camshaft Chain Installation Align crank and cam at TDC markings. Engage the camshaft chain with the camshaft sprockets aligned as shown. Pull the tension side of the chain to install the chain. Install o Cam Chain Tensioner (see this chapter) o Cam and crank drive nuts (see this chapter) o Cam Chain Cover (see this chapter)

76

Camshaft Camshaft Removal Remove o Cam Chain Cover (see this chapter) o Cam Chain Tensioner (see this chapter) Put Crank at TDC, mark position of Cam and Crank with marker. Cam Chain (see this chapter) Remove Cam and Crank Drive sprockets with the Cam Chain taking note of the order of washer and sprocket assembly. Remove bearing retainer.

Put cam sprocket drive and nut back on Camshaft finger tight, remove the Camshaft taking note of bearing order (a puller may be required).

Caution: The crankshaft may be turned, while the camshaft is removed. Always pull the chain taut while turning the crankshaft. This avoids kinking the chain. A kinked chain could damage both the chain and the sprocket.

Camshaft Installation Apply engine oil to all cam parts. If the camshaft and/or cylinder head are replaced with new ones, apply a thin coat of molybdenum disulfide grease to the new cam surfaces. Apply oil to the Camshaft bearings in the Crankcase.

77

Build up Camshaft with new bearings if required. Insert the cam shaft ensuring all bearings are home. Install bearing retainer. Torque 12Nm Threebond 1327

Install o Cam Chain (see this chapter) o Cam Chain Tensioner (see this chapter) o Cam Chain cover (see this chapter)

Caution: After this procedure, if any resistance is felt while turning over the crankshaft, stop immediately and check the camshaft chain timing. Valves will be bent if the timing is not properly set. Camshaft Disassembly Remove camshaft. Remove bearings in order shown.

Camshaft Assembly Install bearings in order shown. Camshaft Bearing WearCam shaft bearing clearance 6204 (-0.003 to + 0.02) - Service limit 0.10 mm
78

Cam shaft bearing clearance 6304 (-0.01 to + 0.013) - Service limit 0.10 mm If any clearance exceeds the service limit, measure the diameter of the camshaft with a micrometer. Camshaft Diameter6204 bearing surface (19.993 to 19.980) - Service limit 19.950 6304 bearing surface (20.000 to 19.987) - Service limit 19.957 I the camshaft bearing surfaces are less than the service limit replace the camshaft with a new one and measure the clearance again. If there is excessive free play in the bearing or any visible damage replace the bearing.

Cylinder Head Cylinder Compression Measurement Note: Use a Battery which is fully charged. Warm up the engine thoroughly. A Remove both spark plugs (see Fuel System chapter). Attach the compression gauge [A] and insert into spark plug No.1. Using the starter motor, turn the engine over with the throttle fully open until the compression limiter gauge stops rising; the compression is the highest value obtainable. Cylinder Compression (Usable Range 120~170 psi) Install the spark plug Torque Spark Plug: 12Nm (first use torque only) Problem Diagnosis Carbon accumulation on piston and in combustion chamber possibly due to damaged valve stem oil seal and/or damaged piston oil rings (This may be indicated by white exhaust smoke). Incorrect cylinder head gasket thickness. Gas leaking around cylinder head. Cylinder compression is lower than usable range Bad condition of valve seating. Remedy (Action) Remove the carbon deposits and replace damages parts if necessary.

Cylinder compression is higher than usable range

Replace the gasket with standard part. Replace damaged gasket and check cylinder head warp. Repair if necessary.
79

Incorrect valve clearance. Incorrect piston/cylinder clearance. Piston seizure.

Bad condition of piston ring and/or piston ring grooves. Compression release weights do not move smoothly. Cylinder Head Removal Remove: o Fuel Tank (see Fuel System chapter) o Battery (see Electrical System chapter) o Battery Trey (see Electrical System chapter)

Adjust the valve clearance. Replace the piston and/or cylinder. Inspect the cylinder (and liner) and replace/repair the cylinder and/or piston as necessary. Replace the piston and/or the piston rings. Replace the camshaft assembly.

Move air box back

Remove o Throttle body (see Fuel System chapter) o Exhaust Pipes (see this chapter) o Breather Hoses o Rocker Cover (see this chapter) o HT Leads o Temp Sensor Connector

Slacken off tappet adjuster lock nut [A] and adjusters [B]. Remove rocker bolts [C]. Remove rockers [D] and pushrods [E].

C 80

A E D

Slacken inner head bolts by of a turn from fifteen back to seven. Remove fifteen, fourteen and thirteen. Remove from six back to one.

81

Tap lightly upwards on the cylinder head with a mallet [A] to separate from cylinder. Lift off head [B] towards the left side. Remove the cylinder head.
A B

Cylinder Head Installation Install the cylinder (see Cylinder Installation). See that two dowel pins [A] are in place on the cylinder.

Install the cylinder head gasket. Install the cylinder head.

82

Torque One to Six to 28Nm. Torque Seven to Twelve to 45Nm, then torque thirteen to fifteen to 28Nm

Install pushrods and rockers Install rocker bolts. Torque - Rocker Bolts: 28Nm Adjusters tappet (see this chapter) Install o Temp Sensor Connector o HT Leads o Rocker Cover (see this chapter) o Breather Hoses o Exhaust Pipes (see this chapter) o Throttle body (see Fuel System o Air Box

Cylinder Head Assembly Install: o Rocker Tower Dowels o Rocker Towers o Washer Tighten bolts.
83

Torque- Rocker Tower Bolts: 20Nm

Cylinder Head Disassembly Remove the cylinder head (see this chapter) Remove the Valve (see this chapter) Remove the rocker tower bolts, remove the rocker towers.

Cylinder Head Cleaning Remove the cylinder head (see Cylinder Head Removal). Remove Valves (see Valve Removal). Wash the head with a high-flash point solvent. Scrape the carbon out of the combustion chamber and exhaust port with a suitable tool. Using compressed air, blow out [A] any particles which may obstruct oil/air passage in the cylinder head.

84

Install the valves.

Cylinder Head Warp Clean the cylinder head (see Cylinder Head Cleaning) Lay a straightedge across the lower surface of the cylinder head at the positions shown. Use a thickness gauge [A] to measure the space between the straightedge [B] and the head. Cylinder Head Warp: Standard: --Service limit: 0.05mm

If the cylinder head is warped more than the service limit, replace it. If the cylinder head is warped less than the service limit, repair the head by rubbing the lower surfaces on emery paper secured to a surface plate (first No. 200, then No. 400).

Valves Valve Clearance Measurement Note: Check the Valve clearance when the engine is cold (at room temperature). Remove Cylinder Head Cover (see Cylinder Head Cover Removal). Remove Cam Chain Cover (see Cam Chain Cover Removal).

Remove the Spark Plugs. Turn the crankshaft clockwise with a wrench on the crank shaft cam drive sprocket nut or primary gear nut and
A B 85

watch the intake valve on No.1 Cylinder until the valve closes fully. Measure the clearance between the lash cap [A] and the rocker arm roller [B] with the thickness gauge [C]. C If any valve clearance is measured, adjust (see Valve Clearance Adjustment).

Valve Clearance Adjustment Turn the crankshaft clockwise with a wrench on the crank shaft cam drive sprocket nut until No.1 is at TDC. Undo the lock-nut on the adjusters and back the adjusters off until any clearance can be measured. Tighten the adjusters until no clearance can be measured then tighten a further one full turn. Repeat the process on cylinder No.2, First setting Cylinder No.2 to TDC Valve Clearance Adjustment One full turn from fully off Valve Removal Remove the cylinder head (see Cylinder Head Removal). Mark and record the valve location so it can be installed in the original position. Remove the valve tappets making a note of their location

Using a valve spring compressor assembly, remove the valve by compressing the valve spring and using a magnetic rod to remove the collets.

Valve Installation If a new valve is to be used, check-valve-to guide clearance (see this chapter). If there is too little clearance, ream the valve guide. If there is too much clearance, install a new cylinder head. Check the valve seat (see Valve Seat Inspection). Apply a thin coat of molybdenum disulfide grease to the valve stem. Install each spring so that the larger end is at the bottom (closer to the valve head).

Valve Guide Reamer Exhaust Valve Guide Reamer Inlet

7.024 to7.032 (nominal 7.028) - 7.004 to 7.012 (nominal 7.008)

86

Valve-to-Guide Clearance Measurement If a small bore gauge is not available, inspect the valve guide wear be measuring the valve to guide clearance with the wobble method as indicated below. Insert the new valve [A] into the guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface. Move [C] the stem back and forth to measure valve/valve guide clearance. Repeat the measurement in a direction at a right angle to the first. If the reading exceeds the service limit, replace the guide.

C B A

The reading is not actual valve/Valve guide clearance because the measuring point is above the guide. Valve /Valve Guide Clearance (wobble Method) Exhaust: 0.06~0.15 (standard), 0.34 (Service limit). Inlet: 0.09~0.18 (standard), 0.34 (Service limit).

Valve Seat Inspection Remove the valve (see Valve Removal). Check the valve seat width [A]. Measure the seat width of the portion where there is no build up of carbon of the valve seat with vernier calipers. Valve seating surface Width Width: Exhaust: 1.5mm Inlet: 1.5mm

If the seat width is not within the specified range, repair the valve seat. Measure the outside diameter [B] of the seating pattern on the valve seat. If the outside diameter of the valve seating pattern is too large or too small, repair the valve seat.

Valve seating surface outside diameter Exhaust: 35.5mm Inlet: 43mm Valve Seat Repair (Valve Lapping) Using the valve seat cutters, repair the valve seat. Valve seat cutters:
87

Valve seat cutting angle inlet: Initial 45 then 35 (VAI-A19038) then relief 75 (VSI-A13600) Valve seat cutting angle exhaust: Initial 45 then 29 (VSI-A18658) then relief 55 (VSI-A13600) If the manufacturers instructions are not available, use the following procedure.

Seat Cutter Operating Care: This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purpose than seat repair. Do not drop or shock the valve seat cutter, or the diamond particles may fall off. Do not fail to apply engine oil to apply engine oil to the valve seat cutter before grinding the seat surface. Also wash off the ground particles sticking to the cutter with washing oil. Caution: Do not use a wire brush to remove the metal particles from the cutter. It will take off the diamond particles. Setting the valve seat cutter holder in position, operate the cutter in one hand. Do not apply too much force to the diamond portion.

Note: Prior to grinding, apply engine oil to the cutter and during the operation, wash off any ground particles sticking to the cutter with washing oil. After use, wash it with washing oil and apply thin layer of engine oil before storing.

Operating Procedures: Clean the seat area carefully. Coat the seat with machinists dye. Fit a 45 cutter into the holder and slide it into the valve guide. Press down lightly on the handle and turn it right and left. Grind the seating surface only until it is smooth. Caution: Do not grind the seat too much. Over grinding will reduce valve clearance by sinking the valve into the head. If the valve sinks too far into the head, it will be impossible to adjust the clearance, and the cylinder head must be replaced. Measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the surface is too small, repeat the 45 grinding until the diameter is within the specified range. If the outside diameter of the seating surface is too large, make the 35 (inlet)/29 (exhaust) grinding described below. If the outside diameter of the seating surface is within the specified range, measure the seat width as described below. Grind the seat at a 35 (inlet)/29 (exhaust) angle until the seat O.D. is within the specified range.
88

To make the 35 (inlet)/29 (exhaust) grind fit a 35 (inlet)/29 (exhaust) cutter into the holder, and slide it into the valve guide. Turn the holder one turn at a time while pressing down very lightly. Check the seat after each turn.

Caution: The 35 (inlet)/29 (exhaust) cutter removes material very quickly. Check the seat outside diameter frequently to prevent over grinding. After making the 35 (inlet)/29 (exhaust) grind, return to the seat O.D. measurement step above. To measure the seat width, use a vernier caliper to measure the width of the 45 angle portion of the seat at several places around the seat. If the seat width is too narrow, repeat the 45 grind until the seat is slightly too wide, and then return to the seat O.D. measurement step above. If the seat width is within the specified range, lap the valve to seat as described below. Grind the seat at a 75 (inlet)/55 (exhaust) angle until the seat width is within the specified range. To make the 75 (inlet)/55 (exhaust) grind, fit 75 (inlet)/55 (exhaust) cutter into the holder, and slide it into the valve guide. Turn the holder, while pressing down lightly. After making the 75 (inlet)/55 (exhaust) grind, return to the seat measurement step above. Lap the valve to the seat, using a lapper once the seat width and O.D. are within the ranges specified above. Put a little coarse grinding compound on the face of the valve in a number of places around the valve head. Spin the valve against the seat until the grinding compound produces a smooth, matched surface on both the seat and the valve. Repeat the process with a fine grinding compound. The seating area should be marked about in the middle of the valve face. If the seat is not in the right place on the valve, check to be sure the valve is the correct part. If the valve is correct, the valve may have been refaced too much; replace the valve. Be sure to remove all grinding compound before assembly. When the engine is assembled, be sure to adjust the valve clearance (see Valve Clearance Adjustment).
Machinists dye on seat

START start

Tool: Purpose:

45 Grind 45 Cutter Make seating area smooth and round

Measure seating area O.D. Tool: Vernier Caliper Purpose: check seat O.D. against spec.

89

Results

Too small

OK

Too big Machinists dye on seat 35 (inlet)/29 (exhaust) Tool: 35/29 Cutter Purpose: Reduce O.D. of seat area to spec.

Tool: Purpose:

45 Grind 45 Cutter increase O.D. of seat area to spec.

Measure Seat Width Tool: Vernier Caliper Purpose: check seat width against spec. Results

Too narrow 45 Grind Tool: 45 Cutter Purpose: increase width of seat area beyond spec. to increase O.D.

OK

Too wide Machinists dye on seat 75 (inlet)/55 (exhaust) Grind Tool: 75 or 55 Cutter Purpose: reduce seat width to spec

Cylinder, Piston

Lap Valve Tool: Valve lapper, grinding compound Purpose: Perfectly match valve and seat area; check valve head for damage

FINISH start

Cylinder, Piston Removal Remove: o Cylinder Head (see Cylinder Head Removal). Slacken off cylinder bolts by a quarter of a turn back from twenty to sixteen. Remove cylinder bolts back from twenty to sixteen.

90

Tap lightly up the cylinder head with a plastic mallet to separate from crankcase. When the cylinder is lose, remove in one clean swift movement upwards. If the cylinder becomes jammed it will be because the lifters have dropped down as the cylinder has been pulled up. Settle the cylinder back down, and then remove in one clean swift movement upwards. Remove the cylinder base gasket.

Immediately insert a clean cloth around the piston to prevent parts or dirt from falling into the case.

Remove the snap ring from one side of each piston pin hole. Caution: Do not reuse snap rings as removal weakens and deforms them. They could fall out and score the cylinder wall. Push out the piston pin and remove the piston.
91

Carefully spread the ring opening with your thumbs and then push up on the opposite side of the piston ring to remove it. Remove the three piece oil ring with your thumbs in the same manner.

Cylinder, Piston Installation

Note: The oil ring rails have no top or bottom

Install the oil ring expander in the bottom piston ring A groove so the ends butt together. Install the oil ring steel rails, one above the expander B and one below it. Spread the rail with your thumbs, but only enough to fit the rail over the piston. Release the rail into the bottom piston ring groove. With the marked side facing up, install the second ring [A] and top ring [B] in that order.

Note: If a new piston is used, check piston to cylinder clearance (see Piston/Cylinder Clearance), and use new piston rings. The right hand piston has an R marked on the underside and the left hand has an L marked on the underside. The dots [A] should always be on the inside on top of the cylinder. Measure the piston diameter at the point shown with a micrometer. Piston Diameter: Standard: 87.900 to 87.925 Service Limit: 87.750 If the piston diameter is less than the service limit, replace it. Install the pistons onto the con-rods using new snap rings. Install a new base gasket. Set the crank so that piston No. 1 is at TDC.

Note: Ensure ring gaps at 180 degrees apart. Slide the barrels over the barrel bolts.
92

Simultaneously lower the barrel whilst sliding the pistons into the barrel, use a front to back rocking motion whilst holding the rings in with your thumb and four fingers to slide the pistons rings into the barrel. Tighten the cylinder bolts by hand. Install the cylinder head (see this chapter). Tighten head and barrel bolts in sequence from one to twenty to torques detailed below.

Torque: Barrel bolts 25Nm Torque: Head Bots 25Nm / 54Nm

Note: Whenever the piston or cylinder has been replaced with a new one or honed, the motorcycle must be broken in the same as with a new machine.

93

Piston/Cylinder Clearance Subtract the piston diameter from the cylinder inside diameter to get the piston/cylinder clearance. Piston/Cylinder Clearance Standard: 0.105 to 0.070 If the piston/cylinder clearance is less than the specified range, use a smaller piston or increase the cylinder inside diameter by honing. If the piston/cylinder clearance is greater than the specified range, use a larger piston or bore the cylinder to the next larger oversize. If only a piston is replaced, the clearance may exceed the standard slightly. But it must not be less than the minimum in order to avoid piston seizure.

Cylinder Boring and Honing Before boring a cylinder, first measure the exact diameter of the oversize piston, and then, according to the standard clearance in the Specifications, determine the re-bore diameter. However, if the amount or boring necessary would make the inside diameter greater than 1.0mm, the block must be replaced. Cylinder inside diameter must not vary more than 0.01mm at any point. In the case of a re-bored cylinder and oversize pistons, the service limit for the cylinder is the diameter that the cylinder was bored to plus 0.1mm and the service limit for the piston is oversize piston original diameter minus 0.15mm. If the exact figure for the rebored diameter is unknown, it can be roughly determined by measuring the diameter at the base of the cylinder. Piston Ring and Ring Groove Wear Check for uneven groove wear by inspecting the ring seating. The rings should fit perfectly parallel to groove surfaces. If not, the piston must be replaced. With the piston rings [A] in their grooves, make several measurements with a thickness gauge to determine piston ring/groove clearance. Piston Ring/Groove Clearance Standard Service Limit Top: 0.020-0.050 0.150 Second: 0.020-0.060 0.160
B

Piston Ring End Gap Measurement Place the piston ring inside the cylinder, using the piston to locate the ring squarely in place.
94

Set it close to the top 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 Standard Top 0.15-0.35 Second 0.35-0.55 Oil 0.20-0.70

Service Limit 0.65 0.85 1.0

Exhaust System Silencer Removal Loosen: o Silencer Clamp Bolts [A] Remove: o Silencer allen bolts [B] Move the Silencer backwards and twist outwards to separate from the middle section. Remove the Silencer. Secondary Removal Loosen: o Secondary cramp bolts [A] Remove: o Secondary centre allen bolt [B]. Move secondary backwards to separate from downpipes.

Remove secondary.

95

Header Pipe Removal Remove Lambda Sensors. Remove six flange bolts from head. Remove Header.

Exhaust Pipe Installation Replace the exhaust pipe gasket. Tighten: Six flange bolts. Torque Exhaust Flange Bolts: 19 Nm Install the secondary. Install secondary centre bolt. Torque Secondary centre bolts: 10Nm Tighten secondary clamp bolts. Install the Silencers. Install allen bolts and tighten. Torque Exhaust muffler bolts: 10 Nm Tighten Silencer clamps. Thoroughly warm up the engine, wait until the engine cools down, and then retighten the clamp bolts and flange nuts.
Gasket behind header

96

Clutch Exploded View.................................................................................................................................................. 99 Specification ................................................................................................................................................... 104 Clutch Lever and Hose ................................................................................................................................... 105 Clutch Lever Adjustment.................................................................................................................... 105 Clutch Fluid .................................................................................................................................................... 105 Clutch Fluid Recommendation ........................................................................................................... 105 Clutch Fluid Level Inspection ............................................................................................................. 106 Clutch Fluid Changing......................................................................................................................... 106 Clutch Line Air Bleeding ..................................................................................................................... 107 Clutch Slave Cylinder...................................................................................................................................... 108 Clutch Slave Cylinder Removal........................................................................................................... 108 Clutch Slave Cylinder Installation....................................................................................................... 108 Clutch Slave Cylinder Inspection ........................................................................................................ 108 Clutch Master Cylinder .................................................................................................................................. 108 Clutch Master Cylinder Removal ....................................................................................................... 108 Clutch Master Cylinder Installation ................................................................................................... 109 Clutch Master Cylinder Inspection..................................................................................................... 109 Clutch Hose .................................................................................................................................................... 109 Clutch Hose Removal ......................................................................................................................... 109 Clutch Hose Installation ..................................................................................................................... 110 Clutch Hose Inspection ...................................................................................................................... 110 Clutch Cover ................................................................................................................................................... 110 Clutch Cover Removal ........................................................................................................................ 110 Clutch Cover Installation .................................................................................................................... 111 Clutch Release Removal ..................................................................................................................... 111 Clutch Release Installation ................................................................................................................. 112 Clutch ............................................................................................................................................................. 112 Clutch Removal .................................................................................................................................. 112 Clutch Installation .............................................................................................................................. 113 Friction and Steel Plate Damage, Wear Inspection ........................................................................... 114 Friction and Steel Plate Warp Inspection .......................................................................................... 114 Clutch spring Free Length Measurement .......................................................................................... 114 Clutch Housing Finger Damage .......................................................................................................... 115 Clutch Hub Spline Damage................................................................................................................. 115 Primary Gear Removal ................................................................................................................................... 115 Primary Gear Installation ............................................................................................................................... 116

97

REF. NO.
1 7 8 9 2 5 6 3 10 11 12 13 14

PART DESCRIPTION
CLUTCH BASKET, ASSY ACTUATOR, LIFTER, PRESSURE PLATE BEARING, NEEDLE, THRUST, 24.0 OD X 10.0 ID X 1.6 WASHER, 24 OD X 10 ID X 1.0 GEAR, PRIMARY, 87 TOOTH WASHER, 34 OD 21 ID X 3.0MM NUT, HALF, M20 X 1.5, DIN 439, A2 70 SPACER, PRIMARY GEAR, BEARING PUSH ROD, CLUTCH PUSH ROD, CLUTCH, DIA 7.00MM BEARING, BALL, 8MM PLATE, CLUTCH, STEEL FRICTION PLATE, CLUTCH

TORQUE REMARKS

BETWEEN PRESSURE PLATE AND LIFTER SITS BEHIND PRESSURE PLATE BEHIND CLUTCH BASKET USED TO CLAMP CLUTCH

122

THREEBOND 1327 BEHIND CLUTCH BASKET

SLAVE CYLINDER END USED IN CENTRE AND END OF CLUTCH ROD

98

REF. NO.
1 2 3 4

PART DESCRIPTION
STARTER, MOTOR GASKET, STARTER, MOTOR RING GEAR, 79 TOOTH BOLT, M5x0.8x16, 6.0 DIA, SHLD, ISO 7979, 12.9 BOLT, CAP HD, 3/8-24UNF X 1, BZP, 1936 SERIES BOLT, CAP HD, 3/8-24UNF X 3/4, 1936 SERIES WASHER, M10, 10.5 X 21.0 X 2, DIN 125A, A2

TORQUE REMARKS

USED TO CLAMP STARTER RING TO CLAMP STARTER MOTOR TO CLAMP STARTER MOTOR

5 7 6

20 20

99

100

101

REF. NO. 20 21 22 55 79

PART DESCRIPTION BRAKE LEVER ASSY, AXIAL LEVER, BRAKE, REMOTE RESERVOIR RESERVOIR, MASTER CYL, FRONT FRONT BRAKE LIGHT SWITCH LEVER ASSY, BRAKE, INTEGRAL RESERVOIR, HIGH BARS

TORQUE (NM) REMARKS STANDARD FOR CSE, CCR, ROW COM/CMM BRAKE RESERVOIR

STANDARD LEVER FOR COM-01 AND CDS-01 102

80 79 80 81 82 78 29 28 32 69 31 30 24 23 25 91 92 93 94 25 55 95 96 97 98 99 100 99 100 101 102 68 59 27

LEVER, BRAKE, INTEGRATED RESERVOIR LEVER ASSY, BRAKE, INTEGRAL RESERVOIR, HIGH BARS LEVER, BRAKE, INTEGRATED RESERVOIR BOLT, M6 X 25 X 1.0, CP HD, GOLD HALF CLAMP, FRONT, VERTICAL FLYLEAD, BRAKE LIGHT SWITCH, INTEGRAL RESERVOIR SCREW, UPPER, M/CYL RES MOUNT KIT DUMPER, M/CYL RES MOUNT KIT NUT, M/CYL RES MOUNT KIT CLIP, M/CYL RES MOUNT KIT HOSE, FRONT BRAKE M/CYL RESERVOIR HOSE, FRONT BRAKE M/CYL RESERVOIR, CLIP-ONS BRACKET, BRAKE RESERVOIR, XM BRACKET, BRAKE RESERVOIR, CLIP-ONS, XM BOLT, CAP HD, M6 X 12 X 1.0 LEVER ASSY CLUTCH LEVER, CLUTCH, REMOTE RESERVOIR BRACKET, CLUTCH RESERVOIR, CLIP-ONS, XM BRACKET, CLUTCH RESERVOIR, XM BOLT, CAP HD, M6 X 12 X 1.0 RESERVOIR, MASTER CYL, REAR HOSE, CLUTCH M/CYL RESERVOIR BOLT, CAP HD, M5 X 12 X 0.8 LOCKNUT, FLANGED, M5 X 0.8 HOSE, FRONT CLUTCH M/CYL RESERVOIR, CLIP-ONS LEVER ASSY, CLUTCH, INTEGRAL RESERVOIR, HIGH BARS LEVER, CLUTCH, INTEGRATED RESERVOIR LEVER ASSY, CLUTCH, INTEGRAL RESERVOIR, HIGH BARS LEVER, CLUTCH, INTEGRATED RESERVOIR SLAVE CYLINDER, CLUTCH BOLT, CAP HD, M6 X 16 X 1.0 HYDRO STOP, REAR M/CYL HYDRAULIC LINE KIT, USD FORKS, HIGH BARS DOUBLE BANJO BOLT M10 X 1MM X 34.5MM

ACCESSORY FITMENT 8 HALF CLAMP BOLTS REPLACES STD CLAMP FROM BREMBO INTEGRAL RESERVOIR ONLY, TO CLAMP BRAKE RESERVOIR TO BRACKET RUBBER GROMMET FOR MASTER CYLINDER NUT USED TO CLAMP RESERVOIR TO BRACKET USED WITHIN FRONT AND REAR USED FOR FRONT BRAKE ONLY USED FOR FRONT BRAKE CAFE RACER ONLY FRONT BRAKE RESERVOIR BRACKET FRONT BRAKE RESERVOIR BRACKET, CR BRACKET TO MASTER CYLINDER GOLD LEVER ASSY, (REMOTE RESERVOIRS) CAFE RACER ONLY BRACKET TO MASTER CYLINDER BRACKET TO MASTER CYLINDER 8 USED FOR CLUTCH RESERVOIR HOSE FOR RESERVOIR TO CYLINDER RESERVOIR TO BRACKET RESERVOIR TO BRACKET CAFE RACER RESERVOIR HOSE (SHORTER) SPORT AND DUAL SEAT LEVER ASSY (BLACK) ACCESSORY FITMENT

12

TO CLAMP SLAVE CYLINDER TO SPROCKET COVER REAR BRAKE LIGHT SWITCH CSE-03 KIT ONLY SPARES ONLY 103

26 57 60 61 62 63 64 58 33 53 66 67 70 27 26 57 33 60 61 65 63 58 53 66 64 67 71 27 26 57 33 72 73 62 63 74 58 53 66 67 75 76 77 90

COPPER WASHER 45' BANJO BRAKE HOSE, LH, 725MM LENGTH BRAKE HOSE, RH, 750MM LENGTH BANJO BOLT WITH BLEED NIPPLE 10MM X 1MM BOLT, BANJO, M10 x 1.0 x 18, CHROME HOSE, CLUTCH, 1200MM LENGTH 90' BANJO 20' BANJO HOSE, BRAIDED, BRAKE, REAR, 825MM STRAIGHT BANJO CLUTCH, ADAPTOR 10MM X 1MM HYDRAULIC LINE KIT, CONVENTIONAL FORKS, AXIAL CALIPERS DOUBLE BANJO BOLT M10 X 1MM X 34.5MM COPPER WASHER 45' BANJO 20' BANJO BRAKE HOSE, LH, 725MM LENGTH BRAKE HOSE, RH, 750MM LENGTH MODIFIED BANJO, 90', COMPOUND BEND BOLT, BANJO, M10 x 1.0 x 18, CHROME 90' BANJO HOSE, BRAIDED, BRAKE, REAR, 825MM STRAIGHT BANJO HOSE, CLUTCH, 1200MM LENGTH CLUTCH, ADAPTOR 10MM X 1MM HYDRAULIC LINE KIT, USD FORKS, CLIP ONS DOUBLE BANJO BOLT M10 X 1MM X 34.5MM COPPER WASHER 45' BANJO 20' BANJO BRAKE HOSE, LH, 635MM LENGTH BRAKE HOSE, RH, 660MM LENGTH BANJO BOLT WITH BLEED NIPPLE 10MM X 1MM BOLT, BANJO, M10 x 1.0 x 18, CHROME HOSE, CLUTCH, 1110MM LENGTH 90' BANJO HOSE, BRAIDED, BRAKE, REAR, 825MM STRAIGHT BANJO CLUTCH, ADAPTOR 10MM X 1MM CLIP, BRAKE LINE WIRE GUIDE, BRAKE HOSE BOLT, CAP HD, M6 X 1.0 WASHER, PENNY, M6, 6.4 X 18 X 1.6

SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY HYDRAULIC LINE KIT COM-01, CMM03, CSE-01, CSE-02 SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY (AXIAL CALIPERS ONLY) SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY CCR-01/02 KIT ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY USED WITH 6MM HOLE IN MUDGUARD, USD ONLY TO CLAMP WIRE GUIDE TO YOKE BETWEEN BOLT AND WIRE GUIDE 104

5 14 15 16 17 18 19 83 14 15 16 17 18 19 1 2 103 3 13 12 84 13 85 104 6 7 8 9 10 4 6 7 8 9 10 46 49 50 51 45 55 47 48 90 56

CALIPER ASSY, AXIAL, LH PISTON SET, CALIPER AXIAL SEAL KIT, CALIPER, AXIAL PAD RETAINER, CALIPER, AXIAL PAD, SPRING, CALIPER, AXIAL PADS, BRAKE, FRONT, AXIAL BLEED SCREW, CALIPER, AXIAL CALIPER ASSY, AXIAL, RH PISTON SET, CALIPER AXIAL SEAL KIT, CALIPER, AXIAL PAD RETAINER, CALIPER, AXIAL PAD, SPRING, CALIPER, AXIAL PADS, BRAKE, FRONT, AXIAL BLEED SCREW, CALIPER, AXIAL DISC, FRONT, 320 MM BOLT, BUTTON HD, INT HEX, M8 X 16 BOLT, BUTTON HD, INT HEX, M8 X 20 SPACER, FRONT DISC BOLT, CALIPER, RADIAL CALIPER BRACKET, LH CALIPER BRACKET, RH BOLT, CAP HD, M10x20x1.25 BOLT, CAP HD, M10x30x1.25 CALIPER ASSY, RADIAL, LH PISTON SET, CALIPER RADIAL SEAL KIT, CALIPER, RADIAL PAD RETAINER, CALIPER, RADIAL PAD, SPRING, CALIPER, RADIAL PAD SET, CALIPER CALIPER ASSY, RADIAL, RH PISTON SET, CALIPER RADIAL SEAL KIT, CALIPER, RADIAL PAD RETAINER, CALIPER, RADIAL PAD, SPRING, CALIPER, RADIAL PAD SET, CALIPER M/CYL ASSY, REAR HEEL GUARD, RH, XM BRACKET, BRAKE RESERVOIR, REAR, STEEL, PRESSED, XM BOLT, CAP HD, M6 X 20 HOSE, REAR M/CYL RESERVOIR RESERVOIR, MASTER CYL, REAR BOLT, CAP HD, M6 x 10 ROD ASSY, REAR MASTER CYLINDER NUT, M6 X 1.0, PLAIN CLEVIS, MASTER CYLINDER

GOLD FINISH

GOLD FINISH

25 25 35

320 mm 6 PER SIDE, PATCH LOCKED 6 PER SIDE, PATCH LOCKED TO CLAMP CALIPER TO FORK

35 35

BRACKET TO FORK CALIPER TO BRACKET

M/CYL FOR ALL MODELS

10

HEEL GUARD TO HANGER BLACK RESERVOIR HOSE TO CLAMP RESERVOIR TO BRACKET REAR BRAKE M/CYL PUSH ROD USED TO LOCK ROD ASSY TO CLEVIS USED ON THE END OF ROD ASSY 105

52 86 87 88 40 39 38 37 41 42 89 36 43 35 44

CLEVIS PIN, BRAKE PEDAL, SPRING CLAMP P-CLIP, 8MM BOLT, CAP HD, M5 X 15 X 0.8 WASHER, M5, 5.3 X 10 X 1 CALIPER ASSY, REAR, 34MM, GOLD PADS, BRAKE, REAR, 34MM PISTON SET, CALIPER, REAR SEAL KIT, REAR, CALIPER BLEED SCREW, REAR CALIPER HANGER PIN, REAR CALIPER SPRING, PAD RETAINER, REAR CALIPER CALIPER CARRIER, REAR BOLT, CAP HD, M8 X 20 X 1.25 DISC, REAR BOLT, BUTTON HEAD, INT HEX, M10 X 20

LINK BETWEEN PLATE AND ROD ASSY SUPPORT FOR BRAKE LINE TO SWING ARM CLAMP P CLIP TO SWINGARM BETWEEN BOLT AND P CLIP GOLD FINISH

28 43

REAR CALIPER TO CARRIER DISK, PATCHLOCKED TO BE USED WITH 32MM REAR CALIPER

PADS, BRAKE, REAR, SINTERED.

Specifications Item Clutch Friction plate thickness Friction and steel plate warp Clutch spring free length Standard 2.9~3.1mm 0.2mm or less 54mm Service Limit 2.75 0.3mm 52.75mm

Clutch Lever and Hose Clutch Lever and Adjustment

106

Pull the lever forward and twist the adjuster [A] to move the lever forwards and backwards.

Clutch Fluid
Warning: When working the clutch, observe the precautions listed below.

Never reuse old clutch fluid. Do not use fluid from a container that has been left unsealed or that has been open for a long time. A Do not mix two types and brands of fluid for use in the clutch. It may cause the rubber brake parts to deteriorate. Dont leave the reservoir cap [A] off for any length of time to avoid moisture contamination of the fluid. Dont change the fluid in the rain or when a strong wind is blowing. Except for internal clutch parts, use only clutch fluid, isopropyl alcohol, or ethyl alcohol for cleaning clutch parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the clutch. Clutch fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away immediately. If any of the clutch line fittings or bleed valve is open at any time, the AIRMUST BE BLED FROM THE CLUTCH.

Clutch Fluid Recommendation Recommended fluids are given below. If none of the recommended fluids are available, use extra heavy-duty brake fluid only from a container marked D.O.T. 4. Note: Clutch fluid of D.O.T. 4 is installed in the clutch system when shipped. Recommended Clutch Fluid Type D.O.T. 4 Brand: Fuchs Silkolene Spec. FMVSS 116 D.O.T. 4, D.O.T. 3, ISO 4925 AND SAE J 1703, (or above)

Clutch Fluid Level Inspection In accordance with the Periodic Maintenance Chart, inspect the clutch fluid level in the clutch fluid reservoirs.
107

Check the clutch fluid level in the reservoir.

A B

Note: Hold the reservoir horizontal when checking clutch fluid level.

Warning: Change the fluid in the clutch line completely if the fluid must be refilled but the type and brand of the fluid that is in the reservoir are unidentified Check the fluid in the clutch reservoir [A] is above the lower level line [B]. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C] in the reservoir with the same type and brand of the fluid that already is in the reservoir.

C A B

Clutch Fluid Changing

A

Remove the reservoir cap and the rubber cap on the bleed valve. Attach a clear plastic hose to the bleed valve on the slave, and run the other end of the hose into a container. Fill the reservoir with new clutch fluid. Change the clutch fluid as follows. Open the bleed valve [A]. Apply the clutch level and hold it [B]. Close the bleed valve [A]. Release the clutch lever [B]. If the fluid in the reservoir runs completely out at any time during fluid changing, air will enter the line, and the system must be bled. Repeat this operation until fresh clutch fluid comes out into the plastic hose or the colour of the fluid changes.

Warning: Do not mix brands of fluid. Change the clutch fluid B in the clutch line completely if the clutch fluid must be refilled but the type and brand of the clutch fluid that is already in the reservoir are unidentified. Torque Bleed Valve: 7 Nm Apply the clutch lever forcefully for a few seconds, and check for fluid leakage around the fittings.
108

Warning: If the clutch level or pedal has a soft or spongy feeling when it is applied, there might be air in the clutch line or the clutch line may be defective. Since it is dangerous to operate the motorcycle under such conditions, bleed the air from the brake line immediately.

Clutch Line Air Bleeding Bleed the air line whenever clutch parts are replaced or B reassembled. Remove the reservoir cap and fill the reservoir with new clutch fluid. Slowly pump the clutch lever several times until no air bubbles can be seen rising up through the fluid from the hose at the bottom of the reservoir. This bleeds the air from the master cylinder and the brake line. Tap the brake hose lightly going from the slave cylinder to the reservoir side and bleed the air off at the reservoir. Attach a clear plastic hose to the bleed valve on the slave cylinder, and run the other end of the hose into a container. Bleed the brake line and the caliper as follows. Hold the clutch lever applied [A]. Quickly open and close the valve [B]. Release the clutch lever [A]. A The fluid level must be checked several times during bleeding operation and replenished as necessary. If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the beginning since air will have entered the line. If the brake lever or pedal action still feels soft or spongy, tap the clutch hose from bottom to top and air will rise up to the top part of the hose. Slowly pump the clutch in the same manner as above Torque - Bleed Valve: 7 Nm Torque - Reservoir Cap Screws (integral reservoir only): 1.5Nm Apply the clutch lever forcefully for a few seconds, and check for fluid leakage around the fittings.

Clutch Slave Cylinder

109

Clutch Slave Cylinder Removal Remove three mounting bolts [A]. Remove Slave cylinder, and support plate with ball bearing.
A

Clutch Slave Cylinder Installation Put Red Grease on the support plate [B] and ball bearing[C] to stop them falling out while being installed. Install the clutch slave cylinder. Torque: Clutch Slave Cylinder bolts: 6NM Clutch Slave Cylinder Inspection Inspect surface for evidence of ware, corrosion, leakage or pitting, if any evidence exists replace slave cylinder.
B

Clutch Master Cylinder Clutch Master Cylinder Removal Integral reservoir: Remove mounting bolts [A]. Integral reservoir: Remove brake light connection. Integral reservoir: Remove lever assembly.
A

Remote reservoir: Remove mounting bolts [B] Remote reservoir: Remove brake light connection. Remote reservoir: Remove lever assembly.

Clutch Master Cylinder Installation

110

Integral reservoir: install lever assembly. Integral reservoir: install brake light connection. Integral reservoir: install mounting bolts [A]. Position level to owners preference, ensure correct operation and clearance. Tighten top bolt. Torque: Clutch Master Cylinder bolts: 6NM

Tighten bottom bolt. Torque: Clutch Master Cylinder bolts: 6NM

Remote reservoir: install lever assembly. Remote reservoir: install brake light connection. Remote reservoir: install mounting bolts [B] Position level to owners preference, ensure correct operation and clearance. Tighten top bolt. Torque: Clutch Master Cylinder bolts: 6NM

Tighten bottom bolt. Torque: Clutch Master Cylinder bolts: 6NM

Clutch Master Cylinder Inspection Inspect surface for evidence of ware, corrosion, leakage or pitting, if any evidence exists replace lever assembly.

Clutch Hose Clutch Hose Removal Drain Clutch Fluid (see Clutch Fluid Changing). Remove clutch slave cylinder banjo bolt and drain any remained fluid into a suitable container. Remove clutch master cylinder banjo bolt and remove clutch hose, taking note of hose routing. Clutch Hose Installation

111

Install hose in reverse order to removal, ensuring hose is not, and will not be trapped or crushed during vehicle operation. Install slave and master cylinder banjo bolts and tighten.

Torque: Clutch Banjo Bolts: 25Nm Clutch Hose Inspection Inspect surface for evidence of ware, corrosion, leakage or pitting, if any evidence exists replace hose. Clutch Cover Clutch Cover Removal Drain Gear Box oil (see Engine Lubrication System chapter). Remove: Splined gear selector arm (see Gear chapter). Take out the sixteen bolts [A] and remove the clutch cover [B].

Clutch Cover Installation

A 112

Install: o Dowel Pins [A] o Clutch Cover Gasket [B] Install the clutch cover.

Torque - Clutch cover Bolts 12Nm

Clutch Release Removal Remove the sprocket cover bolts [A]. Remove sprocket cover.

B A

Remove six M6 clutch spring bolts, washers and springs. Remove clutch centre, friction plates and steel plates.

Remove clutch push rods. Take note of assembly sequence.

113

Clutch release Installation Apply clean engine oil to all clutch parts. Install clutch centre, friction plates and steel plates. Install six M6 clutch spring bolts, washers and springs.

Torque clutch spring bolts to 12Nm

Install clutch push rods.

Install sprocket cover and sprocket cover bolts.

Torque Sprocket cover bolts to 20Nm

Clutch Clutch Removal Remove six M6 clutch spring bolts, washers and springs. Remove clutch centre, friction plates and steel plates,

114

Using the clutch holder, hold the clutch hub to remove the clutch hub nut [B] and hub [A]

B A

Remove: o Basket [A] o Two spacers [B] and [C]

Clutch Installation Install: Spacer [A] Spacer [B] Clutch Housing (with bearing)

Install: Clutch hub [A] (with bearing) Hub nut Torque - Clutch hub nut 122Nm Threebond 1327
A

115

Install the friction plates and steel plates, starting with a friction plate alternating them.

Caution: If new dry friction plate and steel plates are installed, apply engine oil to the surface of each plate and leave to soak overnight, to avoid clutch plate seizure. Install the last friction plate fitting the tangs in the grooves on the housing as shown. Apply engine oil to all bearings and clutch parts. Install the clutch spring plate, springs and washers. Torque Clutch Spring Bolts: 12Nm Install the clutch cover.

Friction and Steel Plate Damage, Wear Inspection Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. Measure the thickness of the friction plates at several points. If any plates show signs of damage, or if they have worn past the service limit, replace them with new ones. Friction Plate Thickness Standard: 2.9 mm ~ 3.1 mm Service Limit: 2.75 mm Friction and steel Plate Warp Inspection Place each friction plate or steel plate on a surface plate, and measure the gap between the surface plate and each friction plate or steel plate with a thickness gauge. The gap is the amount of friction or steel plate warp. If any plate is warped over the service limit, replace it with a new one. Friction and Steel plate Warp Standard: 0.2 mm or less Service Limit: 0.3 mm

116

Cutch Spring Free Length Measurement Measure the free length of the clutch springs. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 54 mm Service Limit: 52.75 mm Clutch Housing Finger Damage Visually inspect the clutch housing fingers [A] where the friction plate tangs hit them. If they are badly worn or if there are groove cuts where the tangs hit, replace the housing. Also, replace the friction plates if their tangs are damaged.

Clutch Hub Spline Damage Visually inspect where the teeth on the steel plates wear against the clutch hub splines. If there are notches worn into the clutch hub splines, replace the clutch hub. Also, replace the steel plates if their teeth are damaged.

Primary Gear Primary Gear Removal Remove the clutch cover (see clutch Cover Removal). Use a gear holder or if one is not available use a copper coin between the primary and balance gear to lock the engine rotation.

Remove: o Primary Gear Nut o Primary Gear Washer

117

Remove the primary gear. Remove woodruff key.

Primary Gear Installation Install: o Woodruff key [A] (identical parts) o Primary Gear [B] o Primary Gear Washer [C]

Use a gear holder or if one is not available use a copper coin between the primary and balance gear to lock the engine rotation. Tighten primary nut. Torque 122Nm Threebond 1305
B C

Install the clutch cover (see clutch Cover Removal).

118

Engine Lubrication System Exploded View................................................................................................................................................ 121 Engine Oil flow charts .................................................................................................................................... 123 Specification ................................................................................................................................................... 128 Engine Oil and Oil Filter ................................................................................................................................. 129 Oil Inspection ..................................................................................................................................... 129 Oil Draining ........................................................................................................................................ 129 Oil Filling............................................................................................................................................. 130 Oil Filter Change ................................................................................................................................. 130 Gearbox ................................................................................................................................................................ Gearbox Oil Draining .......................................................................................................................... 131 Gearbox Oil Filling .............................................................................................................................. 131 Relief Valve Opening Pressure Measurement ............................................................................................... 131 Oil Pressure Measurement ............................................................................................................................ 132 Oil Pump ......................................................................................................................................................... 133 Oil Pipe Removal ................................................................................................................................ 133 Oil Pipe Installation ............................................................................................................................ 133 Oil Pipe Inspection ............................................................................................................................. 133 Relief Valve Inspection ................................................................................................................................... 133 Oil Pipe ........................................................................................................................................................... 134 Oil Pipe Removal ................................................................................................................................ 134 Oil Pipe Installation ............................................................................................................................ 136

119

Engine Oil Flow

1 7

3 6

Note:

Oil is sucked from the back of the oil tank [1] and pumped under pressure through the engine oil feed system. Oil is scavenged from the sump by the oil pump [2] and pumped through the radiator [3] into the oil tank [4]. The oil tank LH breather [5], vents into the back of the head. The crank case breather [6] breathes into the LH rocker cover. The RH rocker cover breather [7] breathes into the air box.

120

121

REF. NO.
25 1 2 3 5 6 7 8 22 23 24

PART DESCRIPTION
COVER ASSY, ROCKER COVER, ROCKER, MACH GASKET, ROCKER, COVER BOLT, CAP HD, M6 X 20 x 1.0, DIN 912, SS BANJO,M14, 9MM SPIGOT WASHER, M14, OD 20.0MM X 2.5 ALUMINIUM WASHER, M14, OD 20.4MM X 1.22, COPPER BOLT, BANJO, M14 NUT, M14 X 1.5, THIN, STEEL BOLT, BANJO, M14, MOD BREATHER BAFFLE, ASSY BREATHER BAFFLE, FRONT BREATHER BAFFLE, REAR BREATHER BAFFLE, WELD NUT

TORQUE (NM) REMARKS

12

22 22

9 10 11 26 12 27 28 29 30 13 14 15 16 17 11 18 19 31

COVER, RH, MC/D GASKET, COVER, RH DOWEL, RING, 7.8MM DIA COVER ASSY, OIL FILTER COVER, OIL FILTER, MC/D TOP HAT, OIL FILTER, COVER BELLEVILLE, SPRING O-RING, 14MM X 2MM, VITON RING, WIRE, 18MM, PLAIN, EXTERNAL O-RING, 67MM X 2 MM, VITON BOLT, CAP HD, M5x0.8x14, DIN 912, A2/70 BOLT, CAP HD, M6 X 20 x 1.0, DIN 912, SS COVER, CLUTCH, MC/D GASKET, COVER, CLUTCH DOWEL, RING, 7.8MM DIA BOLT, CAP HD, M6 X 40, DIN 912, SS BOLT, CAP HD, M6 X 30 X 1.0, SS LABEL, SILKOLENE, 10W/40 12 12
LABLE FOR ENGINE OIL

5 12

122

123

124

REF.

PART DESCRIPTION

TORQUE

REMARKS

125

NO.
1 2 3 4 5 6 7 26 8 9 10 11 27 13 28 12 14 15 18 19 20 CYLINDER HEAD, ASSY, MC/D CYLINDER HEAD, MACHINING CYLINDER HEAD, CASTING VALVE GUIDE, INLET VALVE GUIDE, EXHAUST SEAT, VALVE, INLET SEAT, VALVE, EXHAUST STUD, EXHAUST GRUB SCREW, M12 X 1.75 X 20MM, DIN 913, A2 GASKET, CYLINDER HEAD TOWER, ROCKER, LH, MC/D TOWER, ROCKER, RH, MC/D PIN, DOWEL, 6.00 X 12.0, DIN 7, SS WASHER, M8, NORDLOCK BOLT, CAP HD, M8 X 50 X 1.25, DIN 912, 12.9 BOLT, CAP HD, M8 X 55 X 1.25, DIN 912, 12.9 WASHER, M8, ID 8.4 X OD 15 X 1.6, BZP STUD, HEAD BOLT, CAP HD, M10 X 150 X 1.5, DIN 912, 12.9 BOLT, CAP HD, M8 X 80 X 1.25, DIN 912, 12.9 BOLT, CAP HD, M8 X 110 X 1.25, DIN 912, 12.9, BZP NUT, DOMED, M10 X 1.5, DIN 1594, A2 CMD EXTREME PRESSURE LUB #3, 4oz 16 21 22 23 WASHER, M10, 10.5 X 21.0 X 2, DIN 125A, A2 SPACER, EXHAUST SPRING SPACER, INLET SPRING BREATHER FITTING, ASSY, CYLINDER HEAD BREATHER FITTING, BODY BREATHER FITTING, BARB 25 24 29 16 SEAL, M10, BONDED VITON LOCKNUT, M10 X 1.5, GRADE 8 WASHER, 10.5 X 21.0 X 1.2, FORM B, A2 WASHER, M10, 10.5 X 21.0 X 2, DIN 125A, A2 20
INSIDE ENGINE ON TOP OF SEAL WASHER ON THE OUT SIDE OF THE ENGINE INSIDE ENGINE BETWEEN HEAD AND WASHER

12 15

THREEBOND 1305 THREEBOND 1305

20 20

EXHAUST, TB 1305 INLET, TB 1305

54 60 25 25 60

TB 1305

APPLY TO STUD FIXINGS AS REQUIRED

126

127

REF. NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

PART DESCRIPTION
CRANKCASE, ASSY, SET CASE, MAIN, ASSY, MACHINING CASE, MAIN, LH, INITIAL MACHINING CASE, MAIN, LH, CASTING CENTRE PLATE, MAIN CASE, MACHINING CASE, MAIN, RH, INITIAL MACHINING CASE, MAIN, RH, CASTING BEARING PLATE, ASSY BEARING PLATE, LOWER BEARING PLATE, UPPER DOWEL, RING, 13.00MM DIA BOLT, CAP HD, M10 X 100 X 1.5, DIN 912, 12.9 GRUB SCREW, M8 X 8, FLAT POINT, DIN 913 O-RING, 14MM X 2MM, VITON O-RING, 6.0MM X 2.00MM, VITON DOWEL, RING, 11.0 DIA BOLT, HEX HD, FLANGED, M8 X 40, DIN 6921, 10.9 WINDAGE PLATE, CRANKCASE WASHER, M5 X 10 X 1, DIN 125A, RAW BOLT, CAP HD, M5 X 12 X 0.8, DIN 912, 12.9 DOWEL, RING, 13.00MM DIA BOLT, CAP HD, M10 X 75 X 1.5, DIN 912, 12.9, BZP BOLT, CAP HD, M10 X 45 X 1.5, DIN 912, 12.9, BZP BOLT, CAP HD, M10 X 40 X 1.5, DIN 912, 12.9, BZP BOLT, CAP HD, M10 X 60 X 1.5, DIN 912, 12.9 BOLT, CAP HD, M10 X 90 X 1.5, DIN 912, 12.9 BOLT, CAP HD, M6 X 50 X 1.0, DIN 912, 12.9 WASHER, M6, 6.4 X 12 X 1.6, DIN 125A DOWEL, RING, 11.0 DIA RETAINER, CRANK SEAL, ID 60MM BOLT, BUTTON HD, M4x0.7x6.0, ISO 7380, 10.9

TORQUE (NM) REMARKS

48
THREEBOND 1327

25

THREEBOND 1327

20 21 22 23 24 25 26 27 28 29

48 48 48 48 48 12

2.5

THREEBOND 1327 THREEBOND 1327

30 31

BREATHER, CRANKCASE SEAL, M12, BONDED VITON

15

128

129

REF. NO.
1 8 11 12

PART DESCRIPTION
SWITCH, OIL PRESSURE, 0.2 BAR PUMP ASSY, OIL PIN, DOWEL, 1/8 X 5/8, SOLID PIN, DOWEL, 4.0 X 16.00MM, SOLID BOLT, CAP HD, M6 X 30 X 1.0, DIN 912, 8.8, BZP WASHER, ID 6.4 X 11.0 OD X 1.6 STAINLESS FILLER CAP, GEARBOX WASHER, ID 26.3 X 31.75 X 2.0, COPPER FILTER, OIL SEAL, M10, BONDED VITON PLUG, SUMP, M10 X 9.0 X 1.5

TORQUE REMARKS
20
THREEBOND 1327

USED WITH OIL PUMP DRIVE USED WITH PUMP TO CASE

9 10 13 14 15 20 21

12

CLAMP, OIL PUMP TO ENGINE USED WITH OIL PUMP BOLTS

20
GEAR BOX FILLER CAP

20
APPLY TO RH COVER ABOVE FILTER COVER

22

LABEL, SILKOLENE, 10W/40

130

REF. NO.
1 2 3 5

PART DESCRIPTION
PLATE, SUMP GASKET, SUMP PLUG, SUMP, MAGNETIC M14 X 1.5 BOLT, CAP HD, M6 X 20 x 1.0, DIN 912, SS

TORQUE (NM)

REMARKS

20 12

131

Oil Specification Item Engine / Gear Box Oil: Grade Viscosity Capacity Engine Capacity Gearbox Oil Pressure Measurement: Relief valve opening pressure oil pump pressure @8000rpm with 130C 10W/40 oil oil pump pressure @1000rpm with 130C 10W/40 oil Standard

API SG, SH AND SJ, JASO MA SAE 10W-40 3L FROM COMPLETELY DRY 2.5L WHEN FILTER REMOVED 1.2L

400kPa

6L/min and 300kPa

150kPa

132

Engine Oil and Oil Filter Warning: Motorcycle operation with Insufficient, deteriorated or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure, accident, and injury. Engine Oil Level Inspection Situate the motorcycle so that it is perpendicular to the ground. If the oil has just been changed, start the engine and run it for several minutes at idle speed. This fills the oil filter with oil. Caution: Racing the engine before the oil reaches every part can cause engine seizure. Stop the engine and leave it for more than 1 minute for all the oil to drain down. If the motorcycle has just been ridden, run the engine for about 20 seconds at idle speed. Stop the engine and leave it for more than one minute. Check the engine oil by removing the oil filler, clean the dip stick with a cloth fully reinsert the plug then remove it again and check the level on the dip stick. The oil level should be in the middle of the two markings. If the oil level is difficult to check, rock the motorcycle both side-to-side, and front-to-rear. If the oil level is too high, remove the excess oil through the filler opening, using a syringe or some other suitable device. If the oil level is too low, add the correct amount of oil through the oil filler opening. Use the same type and make of oil that is already in the engine.

Note: If the engine oil type and make are unknown, use any brand of the specified oil to top off the level rather than running the engine with the oil level low. Then at your earliest convenience, change the oil completely. Engine Oil Draining Warning: To avoid burns, do not remove the radiator hose or try to change the oil when the engine is still hot. Wait until it cools down. Oil on tires will make them slippery and can cause an
133

accident and injury. Immediately wash away any oil that spills of the frame, engine, or wheels. Since oil is harmful to the human body, do not use for drinking. Place a container under the drain plug [A] at the bottom of the sump, remove oil filler cap and then remove the drain plug. It is not necessary to remove the primary or secondary exhaust sections, but does make access easier. A Place a tray under the bottom radiator hoses [A], remove the bottom banjo bolt [B] and drain the oil from the oil tank hose.

Engine Oil Filling Tighten the drain plug. Torque Oil sump drain Plug: 20Nm Fill the oil tank with 2.5L of oil and tighten the filler cap. Run the engine at idle for 2 minutes in a well ventilated area. Allow the motorcycle to stand for 2 minutes. Check the oil level as described in (Oil Level Inspection) top up if necessary.

Note: Pour in the oil slowly so that the air in the engine and radiator can escape. Caution: Do not add more oil above the full mark. Engine Oil Filter Change Drain Engine Oil Remove oil filter cover bolts. Remove oil filter cover. Remove oil filter.

Replace the filter element with a new one. Apply oil to the mounting surfaces and oil filter. Install the oil filter. Install oil filter cover and bolts
134

Torque filter cover bolts: 6Nm Pour in the specified type and amount of oil.

Gearbox Oil Draining Warning: To avoid burns, do not change the oil when the engine is still hot. Wait until it cools down. Oil on tires will make them slippery and can cause an accident and injury. Immediately wash away any oil that spills of the frame, engine, or wheels. Since oil is harmful to the human body, do not use for drinking.
A

Place a container under the drain plug [A] at the bottom of the gearbox, remove oil filler cap and then remove the drain plug. Allow oil to drain fully.

Gearbox Oil Filling Tighten the drain plug. Torque Gear Box Oil Drain Plug: 20Nm Fill the gearbox with 1.2L of oil and tighten the filler cap [A]. Torque Gear Box Filler Cap: 20 Nm Run the engine at idle for 2 minutes in a well ventilated area.

Note: Pour in the oil slowly so that the air in the engine and radiator can escape. Caution: Do not add more oil above the full mark. Relief Valve Opening Pressure Measurement Note: Measure the oil pressure before the engine is warmed up if you want to test relief valve opening pressure. Remove oil passage plug [A] on the oil pump and replace with double banjo bolt and oil pressure gauge adapter. Special Tools Oil Pressure Gauge Adapter and Oil
135

Pressure Gauge. Start the engine, and read the maximum oil pressure while running the engine at various speeds. A normal relief valve keeps the maximum oil pressure between the specified values. Relief Valve Opening Pressure Standard: 300~400 kPa If the reading is much higher than the standard, the relief valve is stuck in its closed position. If the reading is much lower than the standard, the relief valve may be stuck open, or there may be other damage (e.g. crank oil seal damage, oil pump damage) in the lubrication system. Stop the engine. Remove the oil pressure gauge and adapter. Install the oil banjo bolt. Torque Oil Pump Banjo Bolt: 35Nm Oil Pressure Measurement Oil Pressure Measurement Note: Measure the oil pressure after the engine is warmed up. Attach the oil pressure gauge and adapters to the plug hole (see Relief Valve Opening Pressure Measurement).

Warning: You could receive burns from hot engine oil draining through the oil passage when the plug is removed. Special Tools Oil Pressure Gauge Adapter and Oil Pressure Gauge. Oil Pressure Standard: 150kPa If the oil pressure is much lower than the standard, check the oil pump, relief valve, and/or crankshaft and balance shaft oil seal immediately. If they are not at fault, inspect the rest of the lubrication system. Stop the engine. Remove the oil pressure gauge and adapter. Install the oil pump banjo plug.

136

Oil Pump Oil Pump Removal Drain the engine oil. Remove two Oil Banjo bolts. Remove three outer oil pump retainer bolts.

Taking note of the O-ring and dowel positions remove the oil pump.

Oil Pump Installation Install the oil drive dowel, location dowels and O-rings (use a little grease to hold in place if required. Fill the pump with engine oil [A] for initial lubrication. Align the oil pump drive dowel with the balance shaft female drive cut out. Install the oil Pump and three location bolts. Torque - Oil pump bolts: 12Nm Oil Pump inspection Disassemble the oil pump (see this chapter). Visually inspect the oil pump body, outer and inner rotors, and covers.
137

If there is any damage or uneven wear, replace the rotors or the oil pump assembly.

Relief Valve Inspection Disassemble the oil pump (see this chapter). Remove the relief valve [A]. Check to see if the piston moves freely when pushing it with a wooden or soft rod, and see if it comes back to its seat by the valve spring pressure. If any rough spots are found during above inspection, wash the valve clean with a high-flash point solvent and blow out any foreign particles that may be in the valve with compressed air. Warning: Clean the parts in a well-ventilated are, and take care that there are no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents. If cleaning dose not solve the problem, replace the relief valve as an assembly. The relief valve is precision made with no allowance for replacement of individual parts.

Oil Pipe Oil Pipe Removal Remove: Fuel Tank (see Fuel System chapter) Remove Battery and Battery Tray (see Electrical System chapter) Cut double eared clip off and remove oil pump banjo, remove oil tank to oil pump hose.

138

Remove oil pump banjo bolt, cut double eared clip off oil cooler, and remove hose.

Cut double eared clip off oil cooler, cut double eared clip off oil tank, and remove hose.

Cut double eared clip off oil tank, cut double eared clip off back of the head, and remove hose.

Cut double eared clip off rocker cover, cut double eared clip off air box, and remove hose.

139

Cut double eared clip off crank case, cut double eared clip off rocker cover, and remove hose.

Oil Pipe Installation Before installation, flush out the pipe with a high-flash point solvent. Fill the pipes with engine oil to shorten air bleeding time and prevent engine damage. Discard the used copper washers and install new washers on each side of the pipe fittings. Install new double eared clamps in all positions and crimp. Installation process is the reverse of the removal (see this chapter). Lightly tighten the banjo bolts to a snug fit, and tighten them to the specified torque. Torque Oil Pipe Banjo Bolts: 35Nm

140

Engine Removal / Installation

Exploded View................................................................................................................................................ 138 Engine Removal / Installation ........................................................................................................................ 140 Engine Removal .................................................................................................................................. 140 Engine Installation.............................................................................................................................. 141

141

Exploded View

142

REF. NO.
1 20 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19

PART DESCRIPTION
FRAME ASSEMBLY, SINGLE SEAT XM CABLE TIE, 120MM X 3.6MM, FIR-TREE, BLACK OIL FILLER CAP O-RING, OIL FILLER CAP, 2.4MM DIPSTICK BRACKET, ENGINE, FRONT, STEEL, XM SPACER, ENGINE MOUNT, RHS, ALUMINIUM SPACER, ENGINE MOUNT, LHS, ALUMINIUM BOLT CAP HD, M8 X 57 X 1.25 WASHER, M8, 8.4 X 16 X 1.6

TORQUE (NM) REMARKS

CLAMP DIRECT TO FRAME, CLUTCH HOSE, HARNESS

SITS INSIDE OIL FILLER CAP

TO CLAMP ENGINE MOUNT BRACKET TO CLAMP ENGINE MOUNT BRACKET 26 TO CLAMP ENGINE MOUNT BRACKET FRONT ENGINE MOUNT BOLT USED WITH ENGINE BOLT AND NUT NUT, USED WITH ENGINE MOUNT BOLT REAR ENGINE MOUNT BOLT
(NOW WHOLE WORLD) TO FIX VIN PLATE TO FRAME USED BETWEEN FRAME AND FOOTREST HANGER

BOLT, M12, ENGINE, FRONT MOUNT WASHER, M12, 13 X 24 X 2.5 LOCKNUT, M12 X 1.75 FRAME ADJUSTER, M24 BOLT, M12, ENGINE, REAR MOUNT VIN PLATE, UK RIVET, HAMMER DRIVE, 3/8TH SLEEVE, NYLON, FRAME PROTECTOR 85 15 85

143

Engine Removal/Installation Engine Removal Drain the engine oil (see Engine Lubrication System chapter). Remove: Fuel Tank (see Fuel System chapter) Throttle Bodies (see Fuel System chapter) Exhaust Pipes (see Engine Top End chapter) Oil lines (see Engine oil and filter chapter) Air Box (See Fuel System chapter) Gear change assembly (see Crankshaft/Transmission chapter) Remove oil pressure switch connection, cam position sensor connector, throttle position sensor connector, speed sensor connector, and temp sensor connector. Remove sprocket cover and chain (see Final drive chapter)
B A

Remove spark plug cap [A]. Remove starter motor cable. Warning: When the engine mounting bolts are removed the engine will be free so take precautions to support the engine. The engine is over 70Kg therefore it will require at least two people to lift it out and an engine jack.
A

Remove the engine mounting bolts [A] and brackets [B].

Remove the engine from the LH side.

144

Engine Installation Fit frame protectors onto frame tubes ready for installing the engine so not to scratch the frame, and place a jack underneath the bottom frame rails to support the engine. Install the engine into the frame from the left side of the chassis; you will need to get some help to lift the engine in. Once engine is sitting in position line up the rear mounting holes and insert service tool into the top rear mounting hole, insert rear engine bolt into the bottom mount. Using service tool tighten up top rear engine adjuster and torque. Torque Adjuster: 15NM. Remove service tool and insert engine bolt and torque. Torque Engine Bolts: 85NM Repeat this process for the bottom rear engine mount bolt. Fit front engine mount brackets and secure in place with bolts, washers and nuts using a washer on either side of the bolt then torque. Torque Mount bolts: 35 NM Fit front engine mounting bolt using spacers LH and RH with washer and nut then torque to 85 NM Install: Gear change assembly (see Crankshaft/Transmission chapter) Air Box (See Fuel System chapter) Oil lines (see Engine oil and filter chapter) Exhaust Pipes (see Engine Top End chapter) Throttle Bodies (see Fuel System chapter) Fuel Tank (see Fuel System chapter) Install oil pressure switch connection, cam position sensor connector, throttle position sensor connector, speed sensor connector, and temp sensor connector. Install sprocket cover and chain (see Final Drive chapter) Install spark plug cap [B]. Install starter motor cable. Run the cables, hoses, and leads according to the Cable, Wire, and Hose Routing section of the General Information chapter. Install the removed parts (see the appropriate chapter).
145

Adjust: Throttle Cables (see Fuel System chapter) Clutch (see Clutch chapter) Drive Chain (see Final Drive chapter) Fill the engine oil (see Engine Lubrication System chapter). Adjust the Throttle idle adjusting screw. Check the brake effectiveness.

Warning: Do not attempt to ride the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc. The brake will not function on the first application of the lever or pedal is this is not done.

146

Crankshaft / Transmission Exploded View................................................................................................................................................ 148 Specification ................................................................................................................................................... 151 Crankcase ....................................................................................................................................................... 153 Crankcase Disassembly ...................................................................................................................... 153 Crankcase Assembly ........................................................................................................................... 157 Crankshaft and Connecting Rod .................................................................................................................... 159 Crankshaft Removal ........................................................................................................................... 159 Crankshaft Installation ....................................................................................................................... 159 Crankshaft Disassembly ..................................................................................................................... 159 Crankshaft Assembly .......................................................................................................................... 159 Crankshaft Alignment......................................................................................................................... 160 Transmission .................................................................................................................................................. 160 Shift Pedal Installation ....................................................................................................................... 160 External Shift Mechanism Removal ................................................................................................... 161 External Shift Mechanism Installation ............................................................................................... 162 External Shift Mechanism Inspection ................................................................................................ 162 Transmission Removal ....................................................................................................................... 163 Transmission Installation ................................................................................................................... 163 Transmission Shaft Disassembly ........................................................................................................ 163 Transmission Shaft Assembly ............................................................................................................. 164 Shift Fork Bending .............................................................................................................................. 164 Shift Fork Ear/Gear Shift Fork Groove Wear ...................................................................................... 164 Shift Fork Guide Pin/Shift Drum Groove Wear .................................................................................. 164 Gear Dog/Dog Recess Damage .......................................................................................................... 166 Balancer ......................................................................................................................................................... 166 Balancer Shaft Removal ................................................................................................................................. 166 Balancer Shaft Installation ............................................................................................................................. 166 Balancer Shaft Disassembly ........................................................................................................................... 166 Balancer Shaft Assembly ................................................................................................................................ 168 Ball Bearing, Needle Bearing, and Oil Seal..................................................................................................... 168 Ball and Needle Bearing Replacement ............................................................................................... 168 Ball and Needle Bearing Wear ........................................................................................................... 169 Oil Seal Inspection .............................................................................................................................. 169

147

REF. NO.
1 2 3 4 5 6 7 8 9 10

PART DESCRIPTION
ASSY, CRANKSHAFT, 2 CYL, 270 TRIGGER DISK PRIMARY GEAR, CRANK, 54 TOOTH WOODRUFF KEY, 1" X 1/4",MOD SPACER, CRANKSHAFT SEAL, RADIAL SHAFT, 35.0 X 72.0 X 8 BEARING, CYLINDRICAL, OD 80.0MM, ID 35.0MM, 21MM WIDE BOLT,CSK TORX, M5 X 0.8 X 16, DIN7991, A4 80 NUT, M20, X 1.5, DIN 934, GRADE 10 DOWEL, PRIMARY, GEAR, 6MM DIA X10MM

TORQUE (NM) REMARKS

INNER RACE PRESSED ON TO SHAFT

10 122

TO CLAMP TRIGGER DISK

THREEBOND 1327

148

149

REF. NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

PART DESCRIPTION
CRANKCASE, ASSY, SET CASE, MAIN, ASSY, MACHINING CASE, MAIN, LH, INITIAL MACHINING CASE, MAIN, LH, CASTING CENTRE PLATE, MAIN CASE, MACHINE CASE, MAIN, RH, INITIAL MACHINING CASE, MAIN, RH, CASTING BEARING PLATE, ASSY BEARING PLATE, LOWER BEARING PLATE, UPPER DOWEL, RING, 13.00MM DIA BOLT, CAP HD, M10 X 100 X 1.5, DIN 912, 12.9 GRUB SCREW, M8 X 8, FLAT POINT, DIN 913 O-RING, 14MM X 2MM, VITON O-RING, 6.0MM X 2.00MM, VITON DOWEL, RING, 11.0 DIA BOLT, HEX HD, FLANGED, M8 X 40, DIN 6921, 10.9 WINDAGE PLATE, CRANKCASE WASHER, M5 X 10 X 1, DIN 125A, RAW BOLT, CAP HD, M5 X 12 X 0.8, DIN 912, 12.9 DOWEL, RING, 13.00MM BOLT, CAP HD, M10 X 75 BZP BOLT, CAP HD, M10 X 45 BZP BOLT, CAP HD, M10 X 40 BZP DIA X 1.5, DIN 912, 12.9, X 1.5, DIN 912, 12.9, X 1.5, DIN 912, 12.9,

TORQUE (NM) REMARKS

48
THREEBOND 1327

25

THREEBOND 1327

48 48 48

150

23 24 25 26 27 28 29 30 31

BOLT, CAP HD, M10 X 60 X 1.5, DIN 912, 12.9 BOLT, CAP HD, M10 X 90 X 1.5, DIN 912, 12.9 BOLT, CAP HD, M6 X 50 X 1.0, DIN 912, 12.9 WASHER, M6, 6.4 X 12 X 1.6, DIN 125A DOWEL, RING, 11.0 DIA RETAINER, CRANK SEAL, ID 60MM BOLT, BUTTON HD, M4x0.7x6.0, ISO 7380, 10.9 BREATHER, CRANKCASE SEAL, M12, BONDED VITON

48 48 12

2.5 15

THREEBOND 1327 THREEBOND 1327

151

152

REF. NO.
1 2 3 4 5 6 7 8 9 10 11 12 14 15 13 16 18 17 23 59 57 56 19 20 21 22 24 25 26 27 28 29 30 31 32 33

PART DESCRIPTION
CASSETTE PLATE, ASSY END PLATE, CASSETTE BEARING, DEEP GROOVE, 25 X 62 X 17 CIRCLIP, 62MM INTERNAL X 2.0 BEARING, DEEP GROOVE, 20 X 47 X 14 CIRCLIP, 47MM INTERNAL X 1.7 BUSH, BARREL SUPPORT CLIP, SHIFT DRUM PLATE, SHIFT DRUM CLIP NUT, PEM, M8 X 1.25 SNAP, LINK , ASSY SNAP, LINK, WELDED, ASSY BOSS, SNAP LINK SPRING, SNAP ARM, LINK ARM, SNAP LINK, PIN PIN, SHIFT PAWL BEARING, 14 X 7 X 3.5 SPACER, SHIFT PAWL BOLT, M8x1.25x12, 10.0 DIA, SHLD, ISO 7979, 12.9 DOWEL, RING, 11.0 DIA WASHER, M8 X 17 X 1.6, DIN 125A BOLT, CAP HD, M8 X 70 X 1.25, DIN 912, 12.9 SPRING, EXTENSION, 55MM, DIN 2097, BZP BOLT, M5x0.8x10, 6.0 DIA, SHLD, ISO 7979, 12.9 PIN, ROLL, 3.0 X 12.0 STAINLESS MAINSHAFT, ASSY SHAFT, TRANSMISSION, MAIN GEAR, 5TH-2ND GEAR, 5TH-3RD GEAR, 5TH-4TH GEAR, 5TH-4TH, COUNTERSHAFT SPACER, GEAR, ID 30.18, OD 35.0 X 1.75 SNAP RING, EXTERNAL, 29MM (SWM0290) SPACER, MAIN SHAFT, LH BEARING, NEEDLE ROLLER, 26 X 30 X 13 LAYSHAFT, ASSY

TORQUE (NM) REMARKS

SITS WITHIN END PLATE

SITS WITHIN END PLATE

15

THREEBOND 1305

25

THREEBOND 1305

153

34 35 36 37 38 39 40 41 32 29 30 42 43 44 45 46 47 48 49 50 51 53 52 53 54 55 58

COUNTERSHAFT GEAR, 5TH-2ND, COUNTERSHAFT GEAR, 5TH-3RD, COUNTERSHAFT GEAR, 5TH-4TH, COUNTERSHAFT GEAR, 5TH-4TH GEAR, 1ST, COUNTERSHAFT SPACER, LAYSHAFT SPACER, GEAR, THICKNESS 3.90MM BEARING, NEEDLE ROLLER, 26 X 30 X 13 SPACER, GEAR, ID 30.18, OD 35.0 X 1.75 SNAP RING, EXTERNAL, 29MM (SWM0290) BEARING, NEEDLE ROLLER, 25 X 32 X 26 END CAP, LAY SHAFT BOLT, CAP HD, M8 X 30 X 1.25, DIN 912, 12.9 WASHER, M8, NORDLOCK OUTPUT GEAR, ASSY GEAR, 1ST SEAL, RADIAL, OUTPUT SHAFT BEARING, NEEDLE ROLLER, 25 X 32 X 20 SPROCKET, DRIVE, 18T SEAL, RING, MAIN SHAFT O-RING, 2.0 SECTION, X 44.0 DIA, VITON SEAL, CASE, SPROCKET WASHER , TAB, DRIVE SPROCKET NUT, DRIVE SPROCKET CIRCLIP, INTERNAL, 85MM BEARING, DEEP GROOVE, 45 X 85 X19 TO HOLD RADIAL SEAL SEAL BETWEEN CRANKCASE AND OUTPUT SHAFT 25
THREEBOND 1327

BOTH USED BETWEEN BOLT AND END CAP

154

155

REF. NO.
1 3 4 5 6 7 8 9 11 10 29 2 31 28 14 30 18 15 16 17 19 18 21 22 23 24 25 23 26 27

PART DESCRIPTION
SHIFT MECHANISM, ASSY SHIFTER, WELDED, ASSY RETAINING PLATE, SHIFT MECHANISM SPRING, INTERNAL SHIFTER SPRING, SHIFT PAWL SPACER, SHIFT SPRING BUSH, PIVOT WASHER, 9.7x16.0x0.65, STEEL, RAW CIRCLIP, EXTERNAL, 7MM CIRCLIP, EXTERNAL 9MM ARM, SHIFT PAWL, ASSY BARREL, SHIFTER, ASSY SHIFT DRUM, REVERSE SHIFT, WITH PINS, ASSY SHIFT DRUM, ASSY SHIFT DRUM PADLE, PIN, SELECTOR DRUM PIN, DOWEL, 3/16 X 5/8, BS 1804 H&G SHIFT FORK, LH, MC/D SHIFT FORK, CENTRE, MC/D SHIFT FORK, RH, MC/D PIN, COTTER, 5/64, X 3/4, (304) SS PIN, DOWEL, 3/16 X 5/8, BS 1804 H&G DETENT WHEEL, REVERSE SHIFT BOLT, CAP HD, M6 X 25 X 1.0, DIN 912, 12.9 WASHER, M6, 6.4 X 12 X 1.6, DIN 125A BEARING, NEEDLE ROLLER, 1/2"x11/16"x3/4 BOLT, CAP HD, M6 X 12 X 1.0, DIN 912, 12.9 WASHER, M6, 6.4 X 12 X 1.6, DIN 125A BEARING, NEEDLE ROLLER, 1/2"x11/16"x 5/16 SEAL, ROTARY, 1/2"x7/8"x5/16", SKF

TORQUE (NM)

REMARKS

4 WITH DETENT WHEEL

3 WITH FORKS

12

TO CLAMP DETENT WHEEL USED WITH DETENT WHEEL BOLT USED WITH END OF SELECTOR DRUM

12

TO CLAMP SHIFT MECHANISM

USED WITH SHIFT MECHANISM BOLTS

USED ON SHIFT ARM

156

REF. NO.
1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17

PART DESCRIPTION
BALANCER SHAFT, MACHINING BEARING, DEEP GROOVE, 25 X 62 X 17 BEARING, DEEP GROOVE, 35 X 62 X 14 SPACER, BALANCER SHAFT SEAL, RADIAL, SHAFT, 35 X 47 X 6MM BACKLASH, ASSY GEAR, BALANCER, 54 TOOTH GEAR, BACKLASH SPACER, BACKLASH, ID 63 X 45.5 OD X 2.0 SPRING, BACKLASH CIRCLIP, EXTERNAL, 40.0 MM, DIN 471 PIN, DOWEL, 5.0 X 8.00MM, SOLID, DIN 6325 H&G PIN, DOWEL, 5.0 X 10.00MM, SOLID, DIN 6325 H&G WOODRUFF KEY, 1" X 1/4",MOD WASHER, 34 OD 21 ID X 3.0MM NUT, HALF, M20 X 1.5, DIN 439, A2 70

TORQUE (NM) REMARKS

RH CASE

LH CASE LH CASE

122

157

Specification Item Crankshaft, Connecting Rod: Connecting rod big end side clearance Connecting rod big end Radial clearance Crankshaft runout: Right Left Transmission: Shift fork ear thickness Shift fork ear thickness (left) Gear shift fork groove width Gear shift fork groove width (left) Shift fork guide pin diameter Shift drum Groove width Standard Service Limit

0.5mm 0.1 0.006~0.019 TIR 0.04mm or less TIR 0.04mm or less 5.03-5.13 5.69-5.79 5.33 0.1 6.00 0.1 4.7625 4.9

0.5mm 0.2 0.07mm TIR 0.10mm TIR 0.08mm 4.93 5.59 5.43 0.1 6.10 0.1 4.75 5.0

158

Crankcase Crankcase Disassembly Remove the engine (see Engine Remove/Installation chapter). Set the engine on a clean surface and hold the engine steady while parts are removed. Remove: o Engine Covers (see relevant chapter) o Primary Gear (see Clutch chapter) o Balance shaft Gear (see this chapter) o Clutch (see Clutch chapter) o Starter Motor (see Electrical System chapter) o Alternator rotor (see Electrical System chapter) o Trigger disk (see Electrical System) o Cylinder and Gasket (see Top End chapter) o Piston (see Engine Top End chapter) o Camshaft Chains and Guides (see Engine Top End chapter) o External shift mechanism (see this chapter) o Cassette plate with gears and shift mechanism (see this chapter) Remove the crank case bolts back from 13 to 1

159

There are two ring dowels on the crankcase mating surface, using a plastic mallet tap lightly around the crankcase mating surface until free. Lift off the left crankcase half.

160

Remove the baffle plate.

Remove the 9 centre plate bolts from 9 back to 1. Remove the crank shaft with the centre plate by hand.

Crankcase Assembly Caution: Right crankcase, left crankcase, and centre plate are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set.
161

Chip off the old gasket from the mating surfaces of the crankcase halves. Using compressed air, blow out [A] the oil passages in the crankcase halves and centre plate. With a high-flash point solvent, clean off the mating surfaces of the crankcase halves and wipe dry.

Warning: Clean the engine parts in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low-flash point solvent to clean parts. A fire or explosion could result. Using a press and the bearing drive set, install new bearings until they bottom out on the crankshaft and cases if required. Do not replace half of the bearing and not the other half. Ensure all oil seals are correctly installed and seated, if any wear is visible replace. Install the crankshaft by hand with the centre plate installed on the crank. Install the 9 centre plate bolts and tighten in the sequence shown (one to nine). Torque Centre Plate Bolts: 25Nm Install the baffle plate and bolts and tighten. Torque Baffle Plate Bolts: 5Nm Be sure the mating surfaces of the crankcase halves are clean and dry. Check to see the two crankcase dowels pins [A] are in place on the right crankcase half. If either has been removed, replace it with a new one. Apply liquid gasket to the mating surface of the left crankcase half. Sealant 3 bond gasket sealant Install the left hand crankcase. Ensure all seals are not damaged during installation; use a feeler gauge if necessary to feed the lip seals on. Tighten the crankcase bolts in the order listed. Torque Crankcase Bolts: 48Nm (Excluding the 8th bolt) Torque Crankcase Gearbox Bolt: 12Nm (The 8th bolt)
162

Constantly check the alignment of the two crankcase halves, and the position of the balance shaft. The front and rear of the crankcase must be pushed together evenly. Check: Crankshaft and balancer shaft turn freely. If any of the shafts do not turn freely, split the crankcase to locate the problem. Install: Remove the crank shaft with the centre plate by hand. Primary Gear (see Clutch chapter) Balance shaft Gear (see this chapter) Cassette plate with gears and shift mechanism (see this chapter) External shift mechanism (see this chapter) Clutch (see Clutch chapter) Trigger disk (see Electrical System) Alternator rotor (see Electrical System chapter) Starter Motor (see Electrical System chapter) Piston (see Engine Top End chapter) Cylinder and Gasket (see Top End chapter) Camshaft, Chains and Guides (see Engine Top End chapter) Engine Covers (see relevant chapters) Install the engine (see Engine Removal/Installation chapter). Install the engine sprocket (see Final Drive chapter)

Crankshaft and Connecting Rod

163

Crankshaft Removal See Crankcase Disassembly To Split the centre plate remove the two main bolts. Tap lightly around the joint face with a plastic hammer and split the centre plate, remove.

Crankshaft Installation See Crankcase Assembly To join the centre plate ensures the two dowels are in place and align the main centre bearing cir clip with the groove in the plates. Ensure the grub screw is installed in the centre plate. Tap the top and the bottom with a plastic hammer; constantly check the alignment of the two halves. Tighten the two centre plate bolts. Torque Centre Plate Split bolts: 48Nm Crankshaft Disassembly Use a bearing puller to remove the inner bearing runners on the other crankshaft outer left hand and right hand side. Note: The crankshaft is a welded assembly; therefore it cannot to disassembled and must be replaced as a whole unit.

Crankshaft Assembly Using a bearing press tool press the bearing inner runner fully home on the crankshaft. Connecting Rod Big End Radial Clearance Set the crankshaft on V blocks, and place a dial gauge [A] against the connecting rod big end. Push [B] the connecting rod first towards the gauge and then in the opposite direction. The Difference between the two gauge readings is the radial clearance. If the radial clearance exceeds the service limit, the crankshaft assembly must be replaced. Clearance Big end Radial: Standard: 0.006~0.019 Service Limit: 0.07mm Connecting Rod Big end Side Clearance Set the crankshaft on V blocks. Measure the side clearance [A] of the connecting rod with a thickness gauge.
164

If big end side clearance exceeds the service limit, the crankshaft assembly must be replaced. Clearance Connecting Rod Big End Side Clearance: Standard: 0.40~0.60mm Service Limit: 0.70mm

Crankshaft Alignment With the crankshaft on V blocks, turn the crankshaft slowly and measure runout at each of the locations shown [A] and [B].

Runout Crankshaft Right Half: Standard TIR 0.04mm or less. Service limit: TIR 0.10mm Runout Crankshaft Left Half: Standard TIR 0.04mm or less. Service Limit: TIR 0.08mm If runout at either location exceeds the service limit, replace the crankshaft assembly.

Transmission Transmission shift pedal Adjust the shift pedal position from the foot peg to suit you. The standard shift pedal position is about 40mm below the foot peg top.

External Shift Mechanism Removal Drain the engine oil (see Engine Lubrication System chapter) Remove gear shift pedal assembly. Remove clutch cover (See Clutch chapter) Remove the two allen head retainer bolts.

Align the neutral cut out of the detent wheel with the selector fork; pull the fork back away from the detent wheel so it can slide past.

165

Remove the external shift assembly. Remove the snap link arm retainer bolt; remove snap link arm.

Remove the detent wheel retainer bolt; remove the detent wheel.

External shift Mechanism Installation Be sure the dowels are correctly installed in the shift drum [A] Apply Threebond 1305 to the threads of the shift drum cam bolt; install detent wheel and tighten retainer bolt. Torque Shift Drum Cam Bolt: 12Nm, Threebond 1305 Install the snap link arm and tighten.
166

Torque snap link arm bolt: 15Nm, Threebond 1305

Ensure selector fork is assembled as detailed below.

Align the neutral cut out of the detent wheel with the selector fork; pull the fork back away from the detent wheel so it can slide past and install. Torque shift mechanism bolts: 12Nm

External Shift Mechanism Inspection Check the shift shaft for bending or serrations [A] for damage If the shaft is bent, straighten or replace it. If the serrations are damaged, replace the shaft. Check the springs [B] for breaks or distortion. If the springs are damaged in any way, replace them. Check the shift mechanism arm [C] for distortion. If the shift mechanism arm is damaged in any way, replace the shift shaft assembly.

Transmission Removal Remove the clutch. Remove External Shift Mechanism (see this chapter)

167

Remove the cassette plate retainer bolts. Remove the cassette plate as a single unit.

Transmission Installation Apply a small amount of engine oil to the transmission gears, bearings, shaft journals, and shift fork fingers. Install the cassette plate assembly ensuring the output shaft is correctly aligned. Tighten the cassette plate bolts. Torque Cassette plate bolts: 25Nm Transmission Disassembly Put gearbox in neutral position Remove the Transmission (see Transmission Removal) Hold the transmission shafts and selector drum, tap the cassette plate lightly with a plastic hammer and remove.

168

Remove the gears and spacers in the sequence shown, using the outside circlip pliers, remove the circlips [30] and disassemble the transmission shafts completely.

Transmission Shaft Assembly Replace any circlips that were removed with new ones. Install the gears, spacers, and circlips in the order shown. Assemble the shift fork to the main and lay shafts at 90 to the axial direction of the main shaft and lay shaft. Insert the lay shaft main shaft and selector drum into the cassette plate as one unit, use a plastic mallet if required to mate the cassette plate home. Shift fork bending

169

Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90 [A].

Shift Fork Ear/Gear Shift Fork Groove Wear Measure the thickness [A] of the shift fork ears. If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced. Shift Fork Ear Thickness Standard: 5.03~5.13mm Service Limit: 4.93mm Shift Fork Ear Thickness (left) Standard: 5.79~5.69mm Service Limit: 5.59mm

Measure the width [A] of the gear shift grooves. If a gear fork groove is worn over the service limit, the gear must be replaced. Gear Shift Fork Groove Width Standard: 5.33 0.1mm Service Limit: 5.43 0.1mm Gear Shift Fork Groove Width (left) Standard: 6.00 0.1mm Service Limit: 6.10 0.1mm

Shift Fork Guide Pin/Shift Drum Groove Wear Measure the diameter [A] of each shift fork guide pin, and measure the width [B] of each shift drum groove. If the guide pin on any shift fork is less than the service limit, the pin must be replaced Shift Fork guide Pin Diameter Standard: 4.7625mm Service Limit: 4.75mm If any shift drum groove is worn over the service limit, the drum must be replaced. Shift Fork Guide Groove Diameter Standard: 4.9mm Service Limit: 5.00mm

170

Gear Dog/Dog Recess Damage Visually inspect the gear dogs [A], and recesses [B]. Replace any damaged gears or gears with excessively worn dogs, or recesses.

B A

Balancer Balancer shaft Removal Split the crankcase (see Crankcase Disassembly) Lift the balancer shaft [A] out of the right-hand crankcase half.

Balancer Shaft Installation See Crankcase Assembly. Install by hand ensuring spacer is in position.

Balance Gear Removal Remove the clutch cover (see clutch Cover Removal).

171

Use a gear holder or if one is not available use a copper coin between the primary and balance gear to lock the engine rotation.

Insert an M8 bolt into the balance gear location hole [A] this will lock the anti backlash spring in place.

Remove: o Balance Gear Nut o Balance Gear Washer Remove the Balance gear, with the anti-backlash gear and spring. Remove woodruff key.

Balance Gear Installation Install: Woodruff key [A]

Balance Gear assembly [A] ensuring dots line up. Balance Gear Washer [B]

172

Use a gear holder or if one is not available use a copper coin between the primary and balance gear to lock the engine rotation. Tighten Balance gear nut.

Torque 122Nm Threebond 1305 Install the clutch cover (see clutch Cover Removal).

Balancer Shaft Gear Disassembly Use the Balance Shaft Gear Holder tool and remove the m8 nut inserted during engine disassembly. Allow the spring to slowly unwind, separate the gears. The dowels can be removed if required.

Balancer Shaft Gear Assembly Assembly by hand on the Balance Shaft Gear Holder tool in order shown. Use the Balance Shaft Gear Holder tool, slowly apply tension to the spring then when the two holes align insert an m8 nut.

173

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 and/or needle bearings. Note: In the absence of the above mentioned tools, satisfactory results may be obtained by heating the case to approximately 75C max, and tapping the bearing in or out. Caution: Do not heat the case with a torch. This will warp the case. Using a press and a bearing drive, install the new bearing until it stops at the bottom of its housing. Ball and Needle Bearing Wear Caution: Do not remove the bearings for inspection. Removal may damage them. Check the ball bearings. Since the ball bearings are made to extremely close tolerances, the wear must be judged by feel rather than measurement. Clean each bearing in a high-flash point solvent, dry it (do not spin the bearing while it is dry), and oil it with engine oil. Spin the bearing by hand to check its condition. If the bearing is noisy, does not spin smoothly, or has any rough sports, 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, colour change, or other damage. If there is any doubt as to the condition of a needle bearing, replace it. Oil Seal Inspection Inspect the oil seals. Replace it if the lips are misshapen, discoloured (indicating that the rubber has deteriorated), hardened or otherwise damaged.

174

Wheels/Tyres Exploded View................................................................................................................................................ 171 Specification ................................................................................................................................................... 178 Wheels ........................................................................................................................................................... 179 Front Wheel Removal ...................................................................................................................... 179 Front wheel Installation ................................................................................................................... 179 Rear Wheel Removal ....................................................................................................................... 180 Rear wheel Installation .................................................................................................................... 180 Front wheel Disassembly ................................................................................................................. 180 Front wheel Assembly ..................................................................................................................... 181 Rear wheel Disassembly .................................................................................................................. 181 Rear wheel Assembly ....................................................................................................................... 182 Wheel Inspection ............................................................................................................................. 182 Spoke Inspection .............................................................................................................................. 182 Rim Inspection ................................................................................................................................. 182 Axle Inspection................................................................................................................................. 183 Wheel Balance ............................................................................................................................................... 183 Wheel Balance Inspection ............................................................................................................... 183 Wheel Balance Adjustment ............................................................................................................. 183 Tyres ............................................................................................................................................................... 184 Air Pressure Inspection / Adjustment.............................................................................................. 184 Tyre Inspection ................................................................................................................................ 184 Tyre Removal ................................................................................................................................... 185 Tyre Installation ............................................................................................................................... 185 Hub Bearings (wheel Bearings ....................................................................................................................... 186 Bearing Removal .............................................................................................................................. 186 Bearing Installation .......................................................................................................................... 186 Bearing Inspection ........................................................................................................................... 186

175

Exploded View

176

REF. PART DESCRIPTION NO.

1 2 3 38 REAR WHEEL, CARBON FIBRE, BLACK SPACER, INTERNAL, REAR WHEEL, CARBON REAR WHEEL, BEARING 30 X 55 X 13 (CARBON) BEARING 30 X 55 X 13, REAR WHEEL, CARBON SEAL, OIL CIRCLIP, REAR WHEEL, CARBON VALVE ASSY, ALUMIN, 90, REAR WHEEL, CARBON SPACER, REAR WHEEL, RHS, CARBON SPACER, REAR WHEEL, LHS, CARBON BALANCE WEIGHT 1 2 3 REAR WHEEL, CARBON FIBRE, BLACK SPACER, INTERNAL, REAR WHEEL, CARBON REAR WHEEL, BEARING 30 X 55 X 13 (CARBON) SEAL, OIL CIRCLIP, REAR WHEEL, CARBON VALVE ASSY, ALUMIN, 90, REAR WHEEL, CARBON SPACER, REAR WHEEL, RHS, CARBON SPACER, REAR WHEEL, LHS, CARBON BALANCE WEIGHT 1 2 3 REAR WHEEL, CARBON FIBRE SPACER, INTERNAL, REAR WHEEL, CARBON REAR WHEEL, BEARING 30 X 55 X 13 (CARBON) SEAL, OIL CIRCLIP, REAR WHEEL, CARBON VALVE ASSY, ALUMI, 90, REAR WHEEL, CARBON SPACER, REAR WHEEL, RHS, CARBON SPACER, REAR WHEEL, LHS, CARBON BALANCE WEIGHT 8 9 10 8 SPROCKET CARRIER ASSY, TITANIUM SPROCKET CARRIER, M/C, TITANIUM REAR WHEEL, BEARING 30 X 62 X 16 (CARBON) RUBBERS, CUSH DRIVE, REAR WHEEL, CARBON SPROCKET CARRIER ASSY, BLACK SPROCKET CARRIER, M/C, BLACK

TORQUE REMARKS (NM)

STANDARD REAR WHEEL FOR CSE-01/03

4 5 7 6

TO HOLD BEARING IN THE HUB

ACCESSORY WHEEL FOR ALL MODELS

4 5 6 7

TO HOLD BEARING IN THE HUB

SPARE FOR CSE-03/01 (OLD TITANIUM)

4 5 7 6

TO HOLD BEARING IN THE HUB

FOR SPARES ONLY (OLD TITANIUM)

STANDARD FOR CSE-01/03

177

9 10 8 9 10 11 12 34 35 20 21 29 30 31 26 27 25 36 33 37 32 26 24 27 28 20 20 13 14 15 16 17 22 23 18 19

REAR WHEEL, BEARING 30 X 62 X 16 (CARBON) RUBBERS, CUSH DRIVE, REAR WHEEL, CARBON SPROCKET CARRIER ASSY, BLACK SPROCKET CARRIER, M/C, BLACK REAR WHEEL, BEARING 30 X 62 X 16 (CARBON) RUBBERS, CUSH DRIVE, REAR WHEEL, CARBON BOLTS, CUSH DRIVE, CARBON LOCKNUT, FLANGED, M10 X 1.25 LOCKNUT, M10 X 1.5, GRADE 8 WASHER, M10, 10.5 X 21 X 2, DIN 125A, A2 WHEEL ASSY, 5.5x17, SPOKE, POLISHED RIM CUSH DRIVE ASSY, SPOKED REAR WHEEL, BLACK SPACER, REAR WHEEL, RHS, SPOKED BOLT, CUSH DRIVE, SPOKED RUBBERS, CUSH DRIVE, SPOKED BEARING 25 X 52 X 15 REAR WHEEL SEAL, 32 X 52 X 7, REAR WHEEL SEAL, 35 X 47 X 7, REAR WHEEL SPACER, CUSH DRIVE, SPOKED CUSH DRIVE, MACHINED, BLACK HUB ASSY, SPOKED REAR WHEEL, BLACK HUB, REAR WHEEL, MACHINED, BLACK BEARING 25 X 52 X 15, REAR WHEEL SPACER, CENTRE, REAR WHEEL SEAL, 32 X 52 X 7, REAR WHEEL SPACER, REAR WHEEL, LHS, SPOKED WHEEL ASSY, 5.5x17, SPOKE, POLISHED RIM WHEEL ASSY, 5.5x17, SPOKE, BLACK RIM SPINDLE, REAR WHEEL
LOCKNUT, THIN, M24 X 2

ACC FOR ALL MODELS

TO CLAMP SPROCKET TO CARRIER

55 55

TO CLAMP SPROCKET TO CARRIER TO CLAMP SPROCKET TO CARRIER SPOKED SPROCKET TO CARRIER WASHERS

SPROCKET CARRIER FOR SPOKED WHEEL

110

SPINDLE NUT
BETWEEN NUT/SWING ARM + SPINDLE/SWING ARM

WASHER, M24, 25 X 44 X 4 TYRE, REAR, 180/55 x 17,DUNLOP QUALIFIER, FR SPROCKET, REAR, 50T INNER TUBE, 17 INCH, REAR TYRE PROTECTION BAND, 17 INCH, REAR, THERMO JOINED CHAIN, FINAL DRIVE, 106L, 525 SPLIT-LINK, CHAIN, 525 OIL SEAL, RK DRIVE CHAIN TYRE, WAX, CLEAR, 5KG

set to 38 PSI

FOR TUBELESS TYRE

WITH 18/50 T GEARING (CHAIN CUT TO 106L) USE AS REQ'D - EXTRAS FOR ASSY

178

GREASE, SILKOLENE PRO RG2

APPLY TO WHEEL SPINDLE & SPACERS

179

180

181

REF. NO.
1 23 22 21 20 1 23 22 21 20 6 7 8 9 5 2

PART DESCRIPTION
FRONT WHEEL ASSY, CARBON FIBRE, BLACK VALVE ASSY, ALUM, 90 CIRCLIP, INT. DIA 42 BEARING BALL, SPACER, INTERNAL, ALUMINIUM FRONT WHEEL ASSY, CARBON FIBRE, BLACK VALVE ASSY, ALUM, 90 CIRCLIP, INT. DIA 42 BEARING BALL, SPACER, INTERNAL, ALUMINIUM SPINDLE, FRONT WHEEL SPINDLE NUT SPACER, PLAIN, FRONT WHEEL LHS SPACER, PLAIN, FRONT WHEEL RHS SPINDLE, FRONT WHEEL, USD FORKS, HIGH BARS SPINDLE NUT. USD FORKS, HIGH BARS

TORQUE (NM) REMARKS

STANDARD FRONT WHEEL FOR CSE-01/03 SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY ACCESSORY WHEEL FOR ALL MODELS SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY 60
SPINDLE FOR CONVENTIONAL FORKS

60

SPINDLE FOR USD FORKS

182

3 4 10 18 19 17 16 14 15 11 12 11 12 13

SPACER, FRONT WHEEL, USD FORKS, HIGH BARS LHS SPACER, FRONT WHEEL, USD FORKS, HIGH BARS RHS WHEEL ASSY, 3.5x17, SPOKE, POLISHED RIM HUB ASSY, SPOKED FRONT WHEEL, BLACK SPACER, SPOKED FRONT WHEEL, INNER, RH HUB, FRONT WHEEL, MACHINED, BACK FRONT WHEEL, CENTRE SPACER FRONT WHEEL, SEAL, 30 X 46 X 65 X (7) FRONT WHEEL, BEARING, 25 X 47 X 12 INNER TUBE, 17 INCH, FRONT TYRE PROTECTION BAND, 17 INCH, FRONT, THERMO JOINED INNER TUBE, 17 INCH, FRONT TYRE PROTECTION BAND, 17 INCH, FRONT, THERMO JOINED TYRE, FRONT, 120/70 x 17, DUNLOP QUALIFIER, FR BALANCE WEIGHT TYRE, WAX, CLEAR, 5KG GREASE, SILKOLENE PRO RG2 APPLY TO WHEEL SPINDLE & SPACERS FOR TUBELESS TYRE

FOR TUBELESS TYRE

set to 34 PSI

10 10

WHEEL ASSY, 3.5x17, SPOKE, POLISHED RIM WHEEL ASSY, 3.5x17, SPOKE, BLACK RIM

183

Specifications Item Rim runout: Axle runout/100mm Wheel balance Balance weights Tire tread depth: Tire Air Pressure Front Rear Front Rear Axial Radial Standard 0.5mm or less 0.8mmor less 0.1mm or less 10 g or less 10 g, 20 g, 30 g 3.5mm 5mm load ----make, type Size make, type Size Service Limit 2mm 2mm 0.2mm ----2mm 2mm Air Pressure (when cold) 2.34 bar (34psi) 2.62bar (38psi) Dunlop, Sportsmax Qualifier 120/70 x 17 Dunlop, Sportsmax Qualifier 180/55 x 17

Front Rear

Standard tire

184

Wheels Front Wheel Removal Remove: Four front wheel calliper bolts [A]. Remove the brake callipers (axial and radial).
A

Support the front of the motorcycle by either supporting the frame using a centre jack or using a front paddock stand. Slacken four pinch bolts [A]. Slacken Front wheel axle [B] off completely. Remove the front wheel axle.

Note: When removing the front wheel axle take note of the order and location of the wheel spacers, and support the front wheel. Caution: Do not lay the front wheel on the ground with the disc facing down. This can damage or warp the disc`s. Place blocks under the wheel so that the disc`s do not touch the ground. Front Wheel Installation Install the front wheel spacers [A] on to the wheel hub. Apply a thin coat of copper past to the front wheel Axle. Align the front wheel with the axle and insert the front wheel axle. Tighten the front wheel Axle. Torque Front Wheel Axle: 60Nm

Tighten the front wheel Pinch bolts. Torque Front Wheel Pinch bolts: 19Nm

Install Front Brake Callipers, Calliper Retainer Bolts [A] (apply a thin coating of copper grease to bolt threads), and tighten calliper bolts.

185

Torque Front Calliper bolts: 35Nm Check the front brake.

Warning: Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc. The brakes will not function on the first application of the lever if this is not done. Rear Wheel Removal Remove Rear Axle Nut. Using either a centre stand or a rear paddock stand lift the rear wheel off the ground. Remove the rear axle. Push the wheel forwards in the motorcycle and remove the chain from the sprocket. Remove the rear wheel.

Caution: Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. Rear Wheel Installation Insert wheel into the rear of the bike, simultaneously inserting the disc into the calliper, and mount the chain on the rear sprocket. Align the calliper carrier with the swing arm cut out and insert the rear wheel axle. Fix the washer and rear axle nut and tighten. Torque Rear Axle Nut: 110Nm Adjust the drive chain (see Final Drive Chapter) Check the rear brake effectiveness. Warning: Do not attempt to ride 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. Front Wheel Disassembly Remove front wheel (see Front Wheel Removal).

186

Caution: Do not allow the wheel to rest on the brake disc, as this may damage the disc. Support the wheel on wooden blocks, equally spaced around the rim, such that the brake disc is raised above ground. Lay the wheel on its side while supporting the wheel on wooden blocks to prevent damage to the brake disc.

Remove and discard the seals and the bearing circlip (If applicable).

Warning: Always wear eye, hand and face protection when using a hammer and drift. Use of a hammer and drift can cause bearings to fragment. Pieces of fragmented bearing could cause eye and soft tissue injuries is suitable protective apparel is not worn. Caution: To prevent wheel damage and to aid bearing removal, always apply forces evenly on both sides of the bearing to prevent it from tipping and becoming stuck. Application of uneven force will lead to difficulty in removing the bearing and to a damaged wheel.

Using a suitable pin punch, through the centre of the wheel, drift out the wheel bearings. Collect the centre sleeve.

Front Wheel Assembly Using a suitable tool, ensuring the tool seats on the outer race of the bearing only, evenly and progressively drive the new wheel bearings into the wheel hub up to the stop. Grease the inner spacer with red grease. Fit a new Circlip (if applicable). Lubricate and fit new seals to the front wheel. Lubricate the seals knife-edge with grease. Fit the front wheel (see Font Wheel Installation).

Rear Wheel Disassembly Remove rear wheel (see Rear Wheel Removal). Place the wheel on wooden blocks to prevent dame to the brake disc.

Caution: Do not allow the wheel to rest on the brake disc, as this may damage the disc. Support the wheel on wooden blocks, equally spaced around the rim, such that the brake disc is raised above ground. Lay the wheel on its side while supporting the wheel on wooden blocks to prevent damage to the brake disc.

Remove and discard the seals and the bearing circlips (if applicable).

Warning: Always wear eye, hand and face protection when using a hammer and drift. Use of a hammer and drift can cause bearings to fragment. Pieces of fragmented bearing could cause eye and soft tissue injuries is suitable protective apparel is not worn.

187

Caution: To prevent wheel damage and to aid bearing removal, always apply forces evenly on both sides of the bearing to prevent it from tipping and becoming stuck. Application of uneven force will lead to difficulty in removing the bearing and to a damaged wheel.

Using a suitable pin punch, through the centre of the wheel, drift out the wheel bearings. Collect the centre sleeve. Using a suitable tool, ensuring the tool seats on the outer race of the bearing only, evenly and progressively drive the new wheel bearings into the wheel hub up to the stop. Grease the inner spacer with red grease. Fit a new Circlip (if applicable). Lubricate and fit new seals to the rear wheel. Lubricate the seals knife-edge with red grease. Fit the rear wheel (see Rear Wheel Installation).

Rear Wheel Assembly

Wheel Inspection Place the jack under the frame so that the front or rear wheel is off the ground. Spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearings. Visually inspect the front and rear axles for damage. If the axle is damaged or bent, replace it. Spoke Inspection Check that all spokes are tightened evenly. If spoke tightness is uneven or loose, torque the spoke nipples evenly. Spokes should be tighten until; when struck with a tuning fork they emit a clean note, minimum torque setting is only the lower limit. Torque minimum: Spoke Nipples: 1.5Nm Check the rim runout.

Warning: If any spoke breaks, it should be replaced immediately. A missing spoke places an additional load on the other spokes, which will eventually cause other spokes to break. Rim Inspection Place the jack under the frame so that the front wheel or rear wheel is off the ground. Inspect the rim for small cracks, dents, bending, or warping. If there is any damage to the rim, it must be replaced. Set a dial gauge against the side of the rim, and rotate the rim to measure the axial runout [A]. The difference between the highest and lowest dial readings is the amount of runout. Set a dial gauge against the outer circumference of the rim, and rotate, the highest and lowest dial reading is the amount of runout.
188

If rim runout exceeds the service limit, check the wheel bearings first. Replace them if they are damaged. If the problem is not due to the bearings, correct the rim warp (runout). A certain amount of rim warp can be corrected by recentering the rim on spoked wheels. Loosen some spokes and tighten others within the standard torque to change the position of different parts of the rim. If the rim is badly bent, however, it must be replaced. Rim runout (with tire installed) Standard: Axial 0.5mm Service Limit: Axial 2mm

Radial: 0.8mm Radial: 2mm

Axle Inspection Place the axle in V blocks that are 100mm [A] apart, and set a dial gauge on the axle at a point halfway between the blocks. Turn the axle to measure the runout. The difference between the highest and lowest dial readings is the amount of runout. If runout exceeds the service limit, replace the axle. Axle Runout/100mm Standard: 0.1mm or less Service Limit: 0.2mm Wheel Balance Note: To improve stability and decrease vibration at high speed, the front and rear wheels must be kept balanced. Check and balance the wheels when required, or when a tire is replaced with a new one.

Balance Inspection Remove the wheel (see this chapter). Support the wheel so that it can be spun freely. Spin the wheel lightly, and mark [A] the wheel at the top when the wheel stops. Repeat this procedure several times. If the wheel stops of its own accord in various positions, it is well balanced. If the wheel always stops in one position, adjust the wheel balance. Balance Adjustment
189

If the wheel always stops in one position, provisionally attach a balance weight [A] on the rim at the marking. Rotate the wheel turn [B], and see whether or not the wheel stops in this position. If it does, the correct balance weight is being used. Attach a balance weight [A] loosely to the wheel rim. If the wheel rotates and the weight goes up, replace the weight with the next heavier size. If the wheel rotates and the weight goes down replace the weight with the nest lighter size. Repeat these steps until the wheel remains at rest after being rotated turn. Rotate the wheel another turn and then another 1/5 turn to see if the wheel is correctly balanced. Repeat the entire procedure as many times as necessary to achieve correct wheel balance. Permanently install the balance weight. Firmly press the balance weight on when finished. Balance weights: 5g 10g 20g 30g

Note: Balance weights are available from Norton Dealers in 5, 10, 20, 30 gram sizes. An imbalance of less than 5 grams will not usually affect running stability. Do not use four or more balance weight (more than 90 gram). If the wheel requires an excess balance weight, remove and disassemble the wheel to find the cause. Tyre Air Pressure Inspection/Adjustment Using a tyre pressure gauge, measure the tyre pressure when the tyres are cold. Adjust the tyre air pressure according to the following specifications, if necessary. Air Pressure (when cold) Front: 2.34bar (34psi) Rear: 2.62bar (38psi) Tyre Inspection Note: As the tyre tread wears down, the tyre becomes more susceptible to puncture and failure. An accepted estimate is that 90% of all tyre failures occur during the last 10% of tread life (90% worn). So it is false economy and unsafe to use the tyres until they are bald. Remove any imbedded stones or other foreign particles from the tread. Visually inspect the tyre for cracks and cuts, replacing the tyre in the case of bad damage. Swelling or high spots indicate internal damage, requiring tyre replacement. Measure the tread depth at the centre of the tread with a depth gauge [A]. Take measurement at several places as the tyre may wear unevenly. If any measurement is less than the service limit, replace the tyre.
190

Tread Depth Front: Standard: Service Limit: Rear: Standard: Service Limit:

3.5mm 2mm (legal Limit UK 1mm) 5mm 2mm (Legal Limit UK 1mm)

Note: To ensure safe handling and stability, use only the recommended standard tyres for replacement, inflated to the standard pressure. Check and balance the wheel when a tyre is replaced with a new one. Standard tyre Front: Make: Type: Size: Rear Make: Type: Size:

Dunlop Sportsmax Qualifier 120/70 X 17 Dunlop Sportsmax Qualifier 180/55 X 17

Tyre Removal Caution: Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. Remove the wheel from the motorcycle (see this chapter). To maintain wheel balance, mark the valve stem position on the tire with chalk so that the tire can be reinstalled in the same position. Take out the valve core to let the air out. When handling the rim, be careful not to damage the rim flanges. Lubricate the tyre beads and rim flanges on both sides with a soap and water solution or rubber lubricant. This helps the tyre beads slip off the rim flanges.

Caution: Never lubricate with mineral oil (engine oil) or gasoline because they will cause deterioration. Break the beads away from both sides of the rim with a bead breaker. Protect the rim with rim protectors , pry the tyre off.

191

Tyre Installation Check the tyre rotation mark on the front and rear tyre and install it on the rim accordingly. Note: the direction of the tire rotation is shown by an arrow on the tire sidewall. Position the tire on the rim so that the valve is at the tire balance mark (the chalk mark made during removal or the yellow paint mark on a new tire). Check and adjust the air pressure after installing.

Hub Bearings (Wheel Bearings) Bearing Removal Remove the wheel, take out the following: Collar(s) Coupling (rear hub) Grease Seals Circlip Take the bearings out of the hub, using bearing remover. Caution: Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. Bearing Installation Before Installing the wheel bearings, blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings. Replace the bearings with new ones. Press in the bearings until they bottom out. Note: Install the Bearing so that the marked side or sealed side faces out. Install: o New Circlip o Collar o Right Bearing o Left Bearing Replace the grease seals with new ones. Apply high temperature grease to the grease seal lips. Press in the grease seal so that the seal surface is flush with the end of the hole.
192

Bearing Inspection Since the hub bearings are made to extremely close tolerances, the clearance cannot normally be measured. Caution: Do not remove any bearings for inspection. If any bearings are removed, they will need to be replaced with new ones. Turn each bearing in the hub back and forth [A] while checking for play, roughness, or binding. If bearing play, roughness, or binding is found, replace the bearing. Examine the bearing seal [B] for damage or leakage. If the seal is damaged or is leaking, replace the bearing.

193

Final Drive Exploded View................................................................................................................................................ 188 Specification ................................................................................................................................................... 189 Drive Chain ..................................................................................................................................................... 190 Chain Slack Inspection ....................................................................................................................... 190 Chain Slack Adjustment ..................................................................................................................... 190 Chain Wear Inspection ....................................................................................................................... 191 Chain Lubrication ............................................................................................................................... 191 Chain Removal ................................................................................................................................... 192 Chain Installation ............................................................................................................................... 192 Sprocket, Coupling ......................................................................................................................................... 192 Engine Sprocket Removal................................................................................................................... 192 Engine Sprocket Installation............................................................................................................... 193 Rear Sprocket Removal ...................................................................................................................... 193 Rear Sprocket Installation .................................................................................................................. 193 Rear Sprocket, Coupling Removal ...................................................................................................... 194 Rear Sprocket, Coupling Installation .................................................................................................. 194 Sprocket Wear .................................................................................................................................... 194 Rear Sprocket Warp ........................................................................................................................... 194 Damper Inspection ............................................................................................................................. 194 Coupling Bearing Removal ................................................................................................................. 195 Coupling Bearing Inspection, lubrication ........................................................................................... 195 Damper (Cush Drive) Inspection .................................................................................................................... 195 Chain Guard ................................................................................................................................................... 195 Chain Guard Removal......................................................................................................................... 195 Chain Guard Installation..................................................................................................................... 195 Chain Guard Inspection ...................................................................................................................... 195

194

Exploded View

195

REF. NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

PART DESCRIPTION
SWINGARM, FABRICATED, XM BEARING, FULL COMPLIMENT ROLLER, 30 37 26 BEARING CARRIER, SWINGARM SEAL, SWINGARM, RH 23 X 40 X 6 SLEEVE, GROUND END PLATE, WHEEL ADJUSTERS ADJUSTER BLOCK, REAR WHEEL BOLT, CAP HD, M8 X 90 X 1.25 SPRING WASHER, M8 SPINDLE, SWING ARM GREASE, SILKOLENE PRO RG2 LOCKNUT, THIN, M16 X 1.0 WASHER, M16, 17 X 30 X 2 ADJUSTER PLATE, REAR WHEEL, XM SPACER, SWINGARM, INTERNAL SPACER, SWINGARM, EXTERNAL BEARING, BALL, SEALED, 17 40 12 CIRCLIP, INT, 40 X 1.75 SEAL, SWINGARM, LH 30 X 45 X 5 THREADED ADJUSTER, SWINGARM RUBBING STRIP, CHAIN COMPRESSION LIMITER, M6 BOLT BUTTON HD, INT HEX M5 X 20 X 0.8 RSU, LH RSU, RH BOLT, BUTTON HD, INT HEX, FLANGED, M8 X 16 X 1.25 WASHER, PENNY, M8 X 30 X 1.6MM

TORQUE (NM) REMARKS

REAR WHEEL ADJUSTERS

BETWEEN BOLT AND REAR WHEEL ADJUSTER

APPLY TO SWINGARM SPINDLE

60
BETWEEN NUT AND FRAME WRAP AROUND SWING ARM USED AS REFERENCE

6
MOUNTS IN CHAIN RUBBING STRIP

USED TO MOUNT CHAIN RUBING STRIP

22

RSU'S TO FRAME WASHER RSU MOUNT

Specification Item Drive Chain: Standard Chain: Make Type Link Chain Slack REGINA REGINA 525 (137ZRP) Z-RING 106LINKS 35 ~ 40 mm ------Too tight: less than 30mm Too loose: more than 45mm 323 mm Standard Service Limit

20-link length Sprockets:

317.5 ~ 318.2 mm

196

Rear sprocket warp Drive Chain 0.4 mm or less 0.5 mm

Chain slack Inspection Set the motorcycle up on its side stand. Check to see that the notches [A] on the chain adjusters [B] on both sides are in the same relative position. If they are not, adjust the chain slack and align them. Warning: Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition. Note: Clean the chain if it is dirty, and lubricate it if it appears dry. Check the chain slack. Turn the rear wheel to find the position where the chain is tightest. Measure the spacer (chain slack) [A] between the chain and the step of the chain slipper as shown. Chain Slack Standard: Too Tight: Too Loose:

35 ~ 40 mm Less than 35 mm More than 45 mm

If the chain slack exceeds the standard, adjust it.

Chain Slack Adjustment Loosen the axle nut [A]. Turn the chain adjusters [B] evenly until the drive chain has the specified amount of slack. Check to see that the notches [C] on both sides are in the same relative position. Warning: Misalignment of the rear wheel will result in abnormal wear and may result in an unsafe riding condition. Tighten the rear axle nut. Torque Rear Axle Nut: 110Nm

197

Returning call Warning: If the axle nut is not securely tightened, an unsafe riding condition may result. Turn the wheel, measure the chain slack again at the tightest position, and readjust if necessary. Check the rear brake effectiveness.

Warning: Do not attempt to ride 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. Chain Wear Inspection Rotate the rear wheel to inspect the drive chain for damage rollers, and loose pins and links. If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry (see this chapter). Stretch the chain taut by hanging a (10kg) weight [A] on the chain. Measure the length of 20 links [B] on the straight part [C] of the chain from the pin centre of the 1st pin to the pin centre of the 21st pin. Since the chain may wear unevenly, take measurements at several places. If any measurements exceed the service limit, replace the chain. Also, replace the front and rear sprockets when the drive chain is replaced. Chain 20-Link Length Standard: 317.5 ~ 318.2 mm Service Limit: 323 mm Warning: If the drive chain wear exceeds the service limit, replace the chain or an unsafe riding condition may result. A chain that breaks or jumps off the sprocket could snag on the engine sprocket or lock the rear wheel, severally damaging the motorcycle and causing it to go out of control. Standard chain Make: REGINA Type: REGINA 525 (137ZRP) Z-RING Link: 106 links Chain Lubrication If the chain is especially dirty, it should be washed in diesel oil or kerosene, and afterward soaked in heavy oil. Shake the chain while it is in the oil so that oil will penetrate to the inside of each roller.
198

An effective, good quality lubricant specially formulated for chains is best for regular chain lubrication. If a special lubrication is not available, heavy oil such as SAE 90 is preferred to lighter oil because it will stay on the chain longer and provide better lubrication. Caution: The O-rings between the side plates seal in the lubricant between the pin and the bushing. To avoid damaging the O-rings and resultant loss of lubricant, observe the following rules. Use only kerosene or diesel oil for cleaning an O-ring drive chain. Any other cleaning solution such as gasoline or trichloroethylene will cause deterioration and swelling of the O-rings. Immediately blow the chain dry with compressed air after cleaning. Complete cleaning and drying the chain within 10 minutes. Apply the oil to the sides of the rollers so that the oil will penetrate to the rollers and bushings. Apply oil to the Orings so that the O-rings will be coated with oil. Wipe off any excess oil. Oil Applied Areas [A] O-ring [B]

Chain Removal Remove: Engine Sprocket Cover (see this chapter). Chain Guard (see this chapter). Foot Control Plate (see Chassis chapter). Rear Suspension Upright RH (see Suspension chapter). Fully slacken off the chain (see this chapter). Remove the drive chain from the chassis, being careful that the chain does not get dirty from contact with the ground. Chain Installation Fit the drive chain back onto the sprockets. Install: Engine Sprocket Cover (see this chapter). Chain Guard (see this chapter). Foot Control Plate (see Chassis chapter). Rear Suspension Upright RH (see Suspension chapter). Adjust the drive chain slack (see Chain Slack Adjustment). Sprocket, Coupling Engine Sprocket Removal Remove Engine Sprocket Cover [A] Bend the lockwasher tab up. Select first gear and apply the rear brake.
199

Loosen the engine sprocket nut [A]. Fully slacken off the chain (see this chapter). Pull off the engine sprocket with the chain then separate the sprocket from the chain.

Engine Sprocket Installation Install the engine sprocket [A] as shown, noting the proper direction. Replace the sprocket lockwasher. Warning: Incorrect installation of the engine sprocket could cause misalignment of the wheel, abnormal wear, resulting in an unsafe riding condition. Torque Engine Sprocket Nut: 122Nm Bend the lockwasher tab over the nut. Install the chain guide [A] as shown. Apply a non-permanent locking agent to the bolt [B] shown. Adjust the drive chain (see this chapter).

Rear Sprocket Removal Remove the rear wheel (see Wheels/Tires chapter). Caution: Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. Unscrew the rear sprocket bolts [A] and nuts, then remove the rear sprocket [B]
A

Rear Sprocket Installation Install the rear sprocket [A] facing the tooth number marking [B] outwards. Torque Rear Sprocket Nuts: 55 Nm Install the rear wheel (see Wheels/Tires chapter).

200

Rear Sprocket, Coupling Removal Remove the rear wheel (see Wheels/Tires chapter). Caution: Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. Pull out the rear wheel coupling from the rear wheel. Remove the rear sprocket nuts to separate the rear sprocket from the wheel coupling (see this chapter).

Rear Sprocket, Coupling installation Check the following and install the coupling. Bearing [A] Install the sprocket facing the tooth number marking outward. Torque Rear sprocket nuts: 55 Nm Install the rear wheel (see Wheels/ Tires chapter).

Sprocket Wear Visually inspect the engine and rear sprocket teeth. If the teeth are worn as illustrated, replace the sprockets, and inspect the drive chain (see Drive Chain wear Inspection). Caution: If a sprocket requires replacement, the drive chain is probably worn also. Upon replacing the rear sprocket, inspect the chain and engine sprocket. Note: Sprocket wear is exaggerated for illustration. Worn Tooth (engine Sprocket) [A] Worn Tooth (Rear Sprocket) [B] Direction of Rotation [C]

201

Rear Sprocket Warp Raise the rear wheel off the ground (see Wheels/Tires chapter) so that it will turn freely. Set a dial gauge against the rear sprocket near the teeth as shown. Turn the rear wheel. The difference between the highest and lowest dial gauge readings is the amount of runout (warp). If the runout exceeds the service limit, replace the rear sprocket. Rear Sprocket Warp Standard: 0.4 mm or less Service Limit: 0.5 mm Coupling Bearing Removal Pull out the coupling collar from the wheel. Remove the circlip. Using the bearing drive set or some other suitable tool, remove the bearing by tapping from the wheel side. Coupling Bearing Inspection, Lubrication Caution: Do not remove the bearing for inspection or lubrication. Turn the bearing back and forth while checking for play, roughness, or binding. If bearing play, roughness, or binding is found, replace the bearing.

Damper Inspection Remove the rear wheel coupling, and inspect the rubber dampers [A]. Replace the damper if it appears damaged or deteriorated Chain guard removal Remove chain guard retainer screws. Remove chain guard Chain Guard Installation Install chain guard and tighten screws Chain Guard Inspection Visually inspect the chain guard for wear cracks and damage replace if neccessary

202

Brakes Exploded View................................................................................................................................................ 198 Specification ................................................................................................................................................... 206 Brake Lever, Brake Pedal ............................................................................................................................... 207 Brake Lever Play Adjustment ............................................................................................................. 207 Brake Pedal Position Adjustment ...................................................................................................... 207 Brake Pedal Removal ......................................................................................................................... 207 Brake Pedal Installation ..................................................................................................................... 207 Brake Fluid ..................................................................................................................................................... 208 Brake Fluid Recommendation............................................................................................................ 208 Brake Fluid Level Inspection .............................................................................................................. 209 Brake Fluid Changing ......................................................................................................................... 209 Brake Line Air Bleeding ...................................................................................................................... 210 Calipers........................................................................................................................................................... 211 Front Calipers Removal ...................................................................................................................... 211 Rear Caliper Removal ......................................................................................................................... 211 Front Calipers Installation .................................................................................................................. 211 Rear Caliper Installation ..................................................................................................................... 211 Front Calipers Disassembly ................................................................................................................ 212 Rear Caliper Disassembly ................................................................................................................... 212 Caliper Assembly ................................................................................................................................ 212 Caliper Fluid Seal Damage.................................................................................................................. 213 Caliper Dust Seal ................................................................................................................................ 213 Caliper Piston and Cylinder Damage.................................................................................................. 213 Brake Pads ...................................................................................................................................................... 213 Front Brake Pads Removal ................................................................................................................. 213 Rear Brake Pads Removal .................................................................................................................. 214 Rear Brake Pads Installation .............................................................................................................. 214 Rear Brake Pads Installation .............................................................................................................. 214 Brake Pad Wear Inspection ................................................................................................................ 214 Brake Master Cylinder ................................................................................................................................... 215 Front Master Cylinder Removal ......................................................................................................... 215 Front Master Cylinder Installation ..................................................................................................... 215 Rear Master Cylinder Removal .......................................................................................................... 215 Rear Master Cylinder Assembly ......................................................................................................... 215 Master Cylinder Assembly ................................................................................................................. 215 Master Cylinder Visual Inspection ..................................................................................................... 215 Brake Discs ..................................................................................................................................................... 217 Front Disc Installation ........................................................................................................................ 217 Rear Disc Installation .......................................................................................................................... 217 Disc Wear ........................................................................................................................................... 217 Disc Cleaning ...................................................................................................................................... 217
203

Disc warp Inspection .......................................................................................................................... 218 Brake Hoses.................................................................................................................................................... 218 Brake Hose Removal .......................................................................................................................... 218 Brake Hose Installation ...................................................................................................................... 218 Brake Hose Inspection ....................................................................................................................... 218

204

Exploded View

205

206

207

208

209

REF. NO.
20 21 22 55 79 80 79 80 81 82 78 29 28 32 69 31 30 24 23 25 91 92 93 94 25 55 95 96 97 98 99 100 99 100 101

PART DESCRIPTION
BRAKE LEVER ASSY, AXIAL LEVER, BRAKE, REMOTE RESERVOIR RESERVOIR, MASTER CYL, FRONT FRONT BRAKE LIGHT SWITCH LEVER ASSY, BRAKE, INTEGRAL RESERVOIR, HIGH BARS LEVER, BRAKE, INTEGRATED RESERVOIR LEVER ASSY, BRAKE, INTEGRAL RESERVOIR, HIGH BARS LEVER, BRAKE, INTEGRATED RESERVOIR BOLT, M6 X 25 X 1.0, CP HD, GOLD HALF CLAMP, FRONT, VERTICAL

TORQUE (NM) REMARKS

STANDARD FOR CSE, CCR, ROW COM/CMM BRAKE RESERVOIR STANDARD LEVER FOR COM-01 AND CDS-01 ACCESSORY FITMENT 8 HALF CLAMP BOLTS REPLACES STD CLAMP FROM BREMBO
INTEGRAL RESERVOIR ONLY,

FLY LEAD, BRAKE LIGHT SWITCH, INTEGRAL RESERVOIR

SCREW, UPPER, M/CYL RES MOUNT KIT DUMPER, M/CYL RES MOUNT KIT NUT, M/CYL RES MOUNT KIT CLIP, M/CYL RES MOUNT KIT HOSE, FRONT BRAKE M/CYL RESERVOIR HOSE, FRONT BRAKE M/CYL RESERVOIR, CLIP-ONS BRACKET, BRAKE RESERVOIR, XM BRACKET, BRAKE RESERVOIR, CLIP-ONS, XM BOLT, CAP HD, M6 X 12 X 1.0 LEVER ASSY CLUTCH LEVER, CLUTCH, REMOTE RESERVOIR BRACKET, CLUTCH RESERVOIR, CLIP-ONS, XM BRACKET, CLUTCH RESERVOIR, XM BOLT, CAP HD, M6 X 12 X 1.0 RESERVOIR, MASTER CYL, REAR HOSE, CLUTCH M/CYL RESERVOIR BOLT, CAP HD, M5 X 12 X 0.8 LOCKNUT, FLANGED, M5 X 0.8 HOSE, FRONT CLUTCH M/CYL RESERVOIR, CLIP-ONS LEVER ASSY, CLUTCH, INTEGRAL RESERVOIR, HIGH BARS LEVER, CLUTCH, INTEGRATED RESERVOIR LEVER ASSY, CLUTCH, INTEGRAL RESERVOIR, HIGH BARS LEVER, CLUTCH, INTEGRATED RESERVOIR SLAVE CYLINDER, CLUTCH 7 8 6

TO CLAMP BRAKE RESERVOIR TO BRACKET RUBBER GROMMET FOR MASTER CYLINDER

NUT USED TO CLAMP RESERVOIR TO BRACKET

USED WITHIN FRONT AND REAR USED FOR FRONT BRAKE ONLY USED FOR FRONT BRAKE CAFE RACER ONLY FRONT BRAKE RESERVOIR BRACKET FRONT BRAKE RESERVOIR BRACKET, CR BRACKET TO MASTER CYLINDER
GOLD LEVER ASSY, (REMOTE RESERVOIRS) CAFE RACER ONLY BRACKET TO MASTER CYLINDER BRACKET TO MASTER CYLINDER

USED FOR CLUTCH RESERVOIR HOSE FOR RESERVOIR TO CYLINDER

RESERVOIR TO BRACKET RESERVOIR TO BRACKET CAFE RACER RESERVOIR HOSE (SHORTER) SPORT AND DUAL SEAT LEVER ASSY (BLACK)

ACCESSORY FITMENT

210

102 68 59 27 26 57 60 61 62 63 64 58 33 53 66 67 70 27 26 57 33 60 61 65 63 58 53 66 64 67 71 27 26 57 33 72 73 62 63 74 58 53 66

BOLT, CAP HD, M6 X 16 X 1.0 HYDRO STOP, REAR M/CYL HYDRAULIC LINE KIT, USD FORKS, HIGH BARS DOUBLE BANJO BOLT M10 X 1MM X 34.5MM COPPER WASHER 45' BANJO BRAKE HOSE, LH, 725MM LENGTH BRAKE HOSE, RH, 750MM LENGTH BANJO BOLT WITH BLEED NIPPLE 10MM X 1MM BOLT, BANJO, M10 x 1.0 x 18, CHROME HOSE, CLUTCH, 1200MM LENGTH 90' BANJO 20' BANJO HOSE, BRAIDED, BRAKE, REAR, 825MM STRAIGHT BANJO CLUTCH, ADAPTOR 10MM X 1MM HYDRAULIC LINE KIT, CONVENTIONAL FORKS, AXIAL CALIPERS DOUBLE BANJO BOLT M10 X 1MM X 34.5MM COPPER WASHER 45' BANJO 20' BANJO BRAKE HOSE, LH, 725MM LENGTH BRAKE HOSE, RH, 750MM LENGTH MODIFIED BANJO, 90', COMPOUND BEND BOLT, BANJO, M10 x 1.0 x 18, CHROME 90' BANJO HOSE, BRAIDED, BRAKE, REAR, 825MM STRAIGHT BANJO HOSE, CLUTCH, 1200MM LENGTH CLUTCH, ADAPTOR 10MM X 1MM HYDRAULIC LINE KIT, USD FORKS, CLIP ONS DOUBLE BANJO BOLT M10 X 1MM X 34.5MM COPPER WASHER 45' BANJO 20' BANJO BRAKE HOSE, LH, 635MM LENGTH BRAKE HOSE, RH, 660MM LENGTH BANJO BOLT WITH BLEED NIPPLE 10MM X 1MM BOLT, BANJO, M10 x 1.0 x 18, CHROME HOSE, CLUTCH, 1110MM LENGTH 90' BANJO HOSE, BRAIDED, BRAKE, REAR, 825MM STRAIGHT BANJO

12

TO CLAMP SLAVE CYLINDER TO SPROCKET COVER

REAR BRAKE LIGHT SWITCH CSE-03 KIT ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY
HYDRAULIC LINE KIT COM-01, CMM-03, CSE01, CSE-02

SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY (AXIAL CALIPERS ONLY) SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY CCR-01/02 KIT ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY SPARES ONLY

211

67 75 76 77 90 5 14 15 16 17 18 19 83 14 15 16 17 18 19 1 2 103 3 13 12 84 13 85 104 6 7 8 9 10 4 6 7 8 9 10 46 49 50 51 45

CLUTCH, ADAPTOR 10MM X 1MM CLIP, BRAKE LINE WIRE GUIDE, BRAKE HOSE BOLT, CAP HD, M6 X 1.0 WASHER, PENNY, M6, 6.4 X 18 X 1.6 CALIPER ASSY, AXIAL, LH PISTON SET, CALIPER AXIAL SEAL KIT, CALIPER, AXIAL PAD RETAINER, CALIPER, AXIAL PAD, SPRING, CALIPER, AXIAL PADS, BRAKE, FRONT, AXIAL BLEED SCREW, CALIPER, AXIAL CALIPER ASSY, AXIAL, RH PISTON SET, CALIPER AXIAL SEAL KIT, CALIPER, AXIAL PAD RETAINER, CALIPER, AXIAL PAD, SPRING, CALIPER, AXIAL PADS, BRAKE, FRONT, AXIAL BLEED SCREW, CALIPER, AXIAL DISC, FRONT, 320 MM BOLT, BUTTON HD, INT HEX, M8 X 16 BOLT, BUTTON HD, INT HEX, M8 X 20 SPACER, FRONT DISC BOLT, CALIPER, RADIAL CALIPER BRACKET, LH CALIPER BRACKET, RH BOLT, CAP HD, M10x20x1.25 BOLT, CAP HD, M10x30x1.25 CALIPER ASSY, RADIAL, LH PISTON SET, CALIPER RADIAL SEAL KIT, CALIPER, RADIAL PAD REATINER, CALIPER, RADIAL PAD, SPRING, CALIPER, RADIAL PAD SET, CALIPER CALIPER ASSY, RADIAL, RH PISTON SET, CALIPER RADIAL SEAL KIT, CALIPER, RADIAL PAD RETAINER, CALIPER, RADIAL PAD, SPRING, CALIPER, RADIAL PAD SET, CALIPER M/CYL ASSY, REAR HEEL GUARD, RH, XM BRACKET, BRAKE RESERVOIR, REAR, STEEL, PRESSED, XM BOLT, CAP HD, M6 X 20 HOSE, REAR M/CYL RESERVOIR 10 35 35 35 25 25

SPARES ONLY
USED WITH 6MM HOLE IN MUDGUARD, USD ONLY

TO CLAMP WIRE GUIDE TO YOKE BETWEEN BOLT AND WIRE GUIDE GOLD FINISH

GOLD FINISH

320 mm 6 PER SIDE, PATCH LOCKED 6 PER SIDE, PATCH LOCKED TO CLAMP CALIPER TO FORK

BRACKET TO FORK CALIPER TO BRACKET

M/CYL FOR ALL MODELS

HEEL GUARD TO HANGER

BLACK RESERVOIR HOSE

212

55 47 48 90 56 52 86 87 88 40 39 38 37 41 42 89 36 43 35 44

RESERVOIR, MASTER CYL, REAR BOLT, CAP HD, M6 x 10 ROD ASSY, REAR MASTER CYLINDER NUT, M6 X 1.0, PLAIN CLEVIS, MASTER CYLINDER CLEVIS PIN, BRAKE PEDAL, SPRING CLAMP P-CLIP, 8MM BOLT, CAP HD, M5 X 15 X 0.8 WASHER, M5, 5.3 X 10 X 1 CALIPER ASSY, REAR, 34MM, GOLD PADS, BRAKE, REAR, 34MM PISTON SET, CALIPER, REAR SEAL KIT, REAR, CALIPER BLEED SCREW, REAR CALIPER HANGER PIN, REAR CALIPER SPRING, PAD RETAINER, REAR CALIPER CALIPER CARRIER, REAR BOLT, CAP HD, M8 X 20 X 1.25 DISC, REAR BOLT, BUTTON HEAD, INT HEX, M10 X 20 PADS, BRAKE, REAR, SINTERED. 43
DISK, PATCHLOCKED TO BE USED WITH 32MM REAR CALIPER

TO CLAMP RESERVOIR TO BRACKET REAR BRAKE M/CYL PUSH ROD USED TO LOCK ROD ASSY TO CLEVIS USED ON THE END OF ROD ASSY LINK BETWEEN PLATE AND ROD ASSY SUPPORT FOR BRAKE LINE TO SWING ARM

CLAMP P CLIP TO SWINGARM BETWEEN BOLT AND P CLIP GOLD FINISH

28

REAR CALIPER TO CARRIER

Specification Brakes Item Brake Lever, Brake Pedal: Brake lever free play Pedal free play Brake lever position Brake Fluid: Grade Brand Specification Brake Pads: Lining Thickness: Front (Radial Calipers) Front (Axial Calipers) Rear Brake Disc: Thickness: Standard Non-adjustable Adjustable (to suit rider) Adjustable (to suit rider) D.O.T. 4 / D.O.T. 3 Fuchs Silkolene FMVSS 116 D.O.T. 4, D.O.T. 3, ISO 4925 AND SAE J 1703, (or above) Service Limit ---------

4.5mm 5.5mm 3.5mm

1mm 1mm 1mm

213

Front Rear Runout

4mm 0.15 5mm 0.15 0.2 mm or less

3.3mm 4.3mm 0.3mm

Brake Lever, Brake Pedal Brake Lever Adjustment Adjust the front brake lever [A] to suit you. Pull the lever [A] out and turn adjust [B] to either side to adjust position.

Brake Pedal Free Play Adjustment Loosen the locknut [A] on the push-rod [B] and turn the rod either way to increase or decrease free play. Tighten the locknut. Torque Locknut brake lever pushrod: 18Nm
A B

Warning: Always maintain proper brake adjustment. If adjustment is improper, the brake could drag and overheat. This could damage the brake assembly and possibly lock the wheel resulting in loss of control. Brake Pedal Removal Remove: Locknut [A] Anti rotation washer [B] from back of foot control plate. Pushrod from rear master cylinder.

Brake Pedal Installation Ensure shaft bearing surface is clean and free from corrosion. Install: Anti rotation washer Pedal locknut
214

Pushrod into rear master cylinder Tighten locknut.

Torque Pedal Locknut: 43Nm

215

Brake Fluid Warning: When working with the disc brakes, observe the precautions listed below. Never reuse old brake fluid. Do not use fluid from a container that has been left unsealed or that has been open for a long time. Do not mix two types and brands of fluid for use in the brakes. This lowers the brake fluid boiling point and could A cause the brake to be ineffective. It may also cause the rubber brake parts to deteriorate. Don`t leave the reservoir cap [A] off for any length of time to avoid moisture contamination of the fluid. Don`t change the fluid in the rain or when a strong wind is blowing. Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake. When handling the disc pads or discs, be careful that no disc brake fluid or any oil gets on them. Clean off any fluid or oil that inadvertently gets on the pads or discs with a high-flash point solvent. Do not use one which will leave an oily residue. Replace the pads with new ones if they cannot be cleaned satisfactorily. Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away immediately. If any brake line fittings or the bleed valve is opened at any time, the AIR MUST BE BLED FROM THE BRAKE.

Brake Fluid Recommendation Note: Recommended fluids are given in the table below. If none of the recommended fluids are available, use extra heavy-duty brake fluid only from a container marked D.O.T. 3 OR 4.

NOTE: Brake fluid of D.O.T. 4 is installed in the brake system when shipped. Brake Fluid: Grade Brand Specification

D.O.T. 4 / D.O.T. 3 Fuchs Silkolene FMVSS 116 D.O.T. 4, D.O.T. 3, ISO 4925 AND SAE J 1703, (or above)

216

Brake Fluid Level Inspection In accordance with the Periodic Maintenance Chart, inspect the brake fluid level in the front and rear brake fluid reservoir Check the front and rear brake fluid reservoir level is above the lower line [A] and below the upper line [B]. Hole the reservoir when checking brake fluid level.

B A

Warning: Change the fluid in the brake line completely if the fluid must be refilled but the type and brand of the fluid that already is in the reservoir are unidentified. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [A] in the reservoir with the same type and brand of the fluid that already is in the reservoir.

Brake fluid changing Note: The procedure to change the front brake fluid is as follows. Changing the rear brake fluid is the same as for the front brake. Remove the reservoir cap. Attach a clear plastic hose to the bleed valve on the caliper, and run the other end of the hose into a container. Fill the reservoir with new brake fluid. Change the brake fluid as follows: Open the bleed valve [A]. Apply the brake lever and hold it [B]. A Close the bleed valve [A]. Release the brake lever [B]. Check the fluid level in the reservoir often, replenishing it as necessary.

Note: If the fluid in the reservoir runs completely out any time during fluid changing, air will enter the line, and the system must be bled. Repeat this operation until fresh fluid comes out into the plastic hose or the colour of the fluid changes. Warning: Do not mix two brands of fluid. Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unidentified.

217

Torque Bleed Valves: 7.8Nm Apply the brake lever forcefully for a few seconds, and check for fluid leakage around the fittings.

Warning: If the brake lever or pedal has a soft or spongy feeling when it is applied, there might be air in the brake line or the brake may be defective. Since it is dangerous to operate the motorcycle under such conditions, bleed the air from the brake line immediately. Brake Line Air Bleeding Note: The procedure to bleed the front brake line is as follows. Bleeding the rear brake line is the same as for the front brake. Bleed the air whenever brake parts are replaced or reassembled. Remove the reservoir cap and fill the reservoir with new brake fluid. Slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the hose at the bottom of the reservoir. This bleeds the air A from the mast cylinder and the brakes line.

Note: Tap the brake hose lightly going from the caliper to the reservoir side and bleed the air off at the reservoir. Attach a clear plastic hose to the bleed valve on the caliper, and run the other end of the hose into a container. Bleed the brake line and caliper as follows: Hold the brake lever applied [A]. Quickly open and close the valve [B]. Release the Brake Level [A]. B The fluid lever must be checked several times during bleeding operation and replenished as necessary.

Note: If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the beginning since air will have entered the line. If the brake lever or pedal action still feels soft or spongy, tap the brake hose from bottom to top and air will rise up to the top part of the hose. Slowly pump the brake lever or pedal in the same manner as above. Torque Bleed Valves: 8 Nm Apply the brake lever forcefully for a few seconds, and check for fluid leakage around the fittings.
218

Front Caliper Removal Drain the front brake fluid (see Brake Fluid Change). Remove banjo bolt [A]. Remove caliper bolts [B] and take off the caliper [C]. If the caliper is to be disassembled after removal and if compressed air is not available, remove the pistons using the following steps before disconnecting the brake hose from the caliper. Remove the pads (see Brake Pad Removal). Insert a wooden board 5mm thick inside the caliper opening (see this chapter). Pump the brake lever until the pistons push the wooden board. Remove the caliper. Remove the board and pull out the pistons by hand. Caution: Immediately wash away any brake fluid that spills. Rear Caliper Removal Drain the rear brake fluid (see Brake Fluid Change). Remove banjo bolt [A]. Remove the caliper bolts [B]. Take off the caliper [C]. If the caliper is to be disassembled after removal and if compressed air is not available, remove the piston using the following steps before disconnecting the brake hose from the caliper. Remove the pads. Pump the brake pedal to remove the piston.

B A

B C

Caution: Immediately wash away any brake fluid that spills. Caliper Installation Tighten the caliper bolts. Torque Caliper bolts: 35Nm Connect the brake hose to the caliper putting a new flat washer on each sie of the brake hose fitting. Tighten the banjo bolt.
219

Torque Banjo Bolt: 25Nm Check the fluid level in the master cylinder (reservoir) and bleed the brake line (see Bleeding the Brake). Check the brake for good braking power, no brake drag, and no fluid leakage.

Warning: Do not attempt to ride the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against each disc. The brakes will not function on the first application of the lever or pedal if this is not done.

Front Caliper Disassembly Remove the front caliper (see Front Caliper Removal). Remove the pads and spring (see Pad Removal). Insert a wooden board 5 mm thick inside the caliper opening. Lightly apply compressed air to the hose joint opening until the pistons hit the wooden board. Remove the board and pull out the pistons by hand. Warning: To avoid serious injury, never place your fingers or palm inside the caliper opening. If you apply compressed air into the caliper, the piston(s) may crush your hand or fingers. Remove the dust seal(s) and fluid seal(s)

Rear Caliper Disassembly Remove the caliper (see Caliper Removal). Remove the pads and spring (see Pad Removal). Using compressed air, remove the piston. Cover the caliper opening with a clean, heavy cloth. Remove the piston by lightly applying compressed air to the hose joint. Warning: To avoid serious injury, never place your fingers or palm inside the caliper opening. If you apply compressed air into the caliper, the piston may crush your hand or fingers. Remove the dust seal and fluid seal.

Caliper Assembly It is recommended that the fluid seal, which is removed, be replaced with a new one.
220

Replace the dust seals if they are damaged. Install the fluid seal. Either side of the seal may face outboard. Apply brake fluid to the cylinders, pistons, and fluid seals (piston seals), and push the pistons into the cylinders by hand. Take care that neither the cylinder nor the piston skirt gets scratched. Install the anti rattle spring in the caliper. Install the pads (see Brake Pad Installation).

Caliper Fluid Seal Damage Note: The fluid seals around the piston maintain the proper pad/disc clearance. If the seals are not satisfactory, pad wear will increase, and constant pad drag on the disc will raise brake and brake fluid temperature. Replace the fluid seals under any of the following conditions: (a) fluid leakage around the pads; (b) Brakes overheat (c) there is a large difference in inner and outer pad wear; (d) the seal is stuck to the piston. If the fluid seal is replaced, replace the dust seal as well. Also, replace all seals every other time the pads are changed.

Caliper Dust Seal Check that the dust seal is no cracked, worn, swollen, or otherwise damaged. If they show any damage replace them. Caliper Piston and Cylinder Damage Visually inspect the piston and cylinder surfaces. Replace the caliper if the cylinder and piston are badly scored or rusty. Brake Pads
A

Front Brake Pad Removal Axial Remove the Front Brake Caliper bolts [A]. Remove the r-clips [B]. Remove the pad retainer shafts [C]. Remove the brake pads from the inner side.

Front Brake Pad Removal Radial

221

Remove the Front Brake Caliper bolts [A]. Push the anti-vibration spring [B] down and pull the pad retainer pins [C] out. Repeat for each pad. Remove the brake pads [D] from the inner side.

Rear Brake Pad Removal Remove the Rear Brake Caliper bolts [A]. Remove the Caliper from the disc with the hose left installed. Remove the c-clip [B] on the pad retainer spring pin [C]. Remove the pad retainer spring pin [C]. Remove the pad retainer spring [D]. Remove the rear brake pads [E].

Brake Pad Installation Before installation, clean the pads with a high-flash point solvent. Push the caliper pistons in by hand as far as they will go, and then install the pads. Warning: Do not attempt to ride the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against each disc. The brake will not function on the first application if this not done. Brake Pad Wear Inspection Note: In accordance with the periodic Maintenance Chart, inspect the brake pads for wear. Remove the pads. Check the lining thickness of the pads in each caliper. If the lining thickness of either of the pads is less than the service limit replace both pads in the caliper as a set.

D E

222

Pad Lining Thickness Lining Thickness: Front (Radial Calipers) Front (Axial Calipers) Rear

Standard 4.5mm 5.5mm 3.5mm

Service limit 1mm 1mm 1mm

Brake Master Cylinder Front Master Cylinder Removal Drain the front brake fluid (see Brake Fluid Changing). Remove: Brake hose Banjo Bolt [A] Master Cylinder Clamp Bolts [B] Remove the front brake master cylinder[C]. Caution: Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away immediately.
D

B C

Front Master Cylinder Installation The (integral) master cylinder clamps must be installed with the UP mark [D] facing upwards. Tighten the upper master cylinder clamp bolts first, and then the lower clamp bolts. There will be a gap at the lower part of the clamp after tightening. Torque Master Cylinder Clamp Bolts: 8 Nm Use a new flat washer on each side of the brake hose fitting, and tighten the banjo bolt. Torque Banjo Bolt: 25 Nm Fill the brake line with brake fluid (see Brake Fluid Changing). Check that the brake line has proper fluid pressure and no fluid leakage.

Warning: Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against each disc. The brake will not function on the first application of the lever if this is not done. Rear Master Cylinder Removal Drain the rear brake fluid (see Brake Fluid Change). Loosen the banjo bolt. Remove: C-clip and Joint [A]

A 223

Banjo Bolt and Brake Hose. Rear Master Cylinder Bolts Remove the rear master cylinder.

Rear Master Cylinder Disassembly Note: Do not remove the push rod clevis for the master cylinder disassembly since removal requires brake pedal position adjustment. Remove: Rear Master Cylinder (see Rear Master Cylinder Removal) Dust Cover Push Rod with Clevis

Caution: Do not remove primary and secondary cups from the piston since removal will damage them. Master Cylinder Assembly Before assembly, clean all parts including the master cylinder with brake fluid or alcohol. Apply brake fluid to the removed parts and to their inner wall of the cylinder. Caution Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil will cause deterioration of the rubber parts. Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the disc brake. Silicone Grease Brake Lever Pivot Bolt Brake Lever Pivot Contact Push Rod Contact (Rear Master Cylinder) Brake Lever Pivot Bolt: 6Nm

Torque -

Master Cylinder Visual Inspection Disassemble the front and rear master cylinders. Check that there are no scratches, rust or pitting on the inner wall of each master cylinder and on the outside of each piston. If a master cylinder or piston shows any damage, replace them. Inspect the primary and secondary cups.
224

If a cup is worn, damaged, softened (rotted), or swollen, the piston assembly should be replaced to renew the cups. If fluid leakage is noted at the brake lever, the piston assembly should be replaced to renew the cups. Check the dust covers for damage. If they are damaged replace them. Check that the relief and supply ports are not plugged. If the relief port becomes plugged, the brake pads will drag on the disc. Blow the ports clean with compressed air. Check the piston return spring for any damage. If a spring is damaged, replace it.

Brake Discs Disc Installation Front Install the disc spacer [A] as shown. The disc must be installed so the disc moves further away from the hub. Tighten the disc bolts. Torque Front Disc Bolts: 25Nm After installing the discs, check the disc runout. Completely clean off any grease that has gotten on either side of the disc with a high-flash point solvent. Do not use one with will leave an oil residue.

Disc Installation Rear Tighten the disc bolts. Torque Rear Disc Bolts: 43Nm After installing the disc, check the disc runout. Completely clean off any grease that has gotten on either side of the disc with a high-flash point solvent. Do not use one with will leave an oil residue

Disc Wear Replace the disc if the sliding surfaces have worn past the service limit. Brake Disc Wear: Thickness: Standard Front - 4mm 0.15

Service Limit 3.3mm

225

Rear - 5mm 0.15 Runout: 0.2 mm or less

4.3mm 0.3mm

Disc Cleaning Note: Poor braking can be caused by oil on a disc. Oil on a disc must be cleaned off with an oilless cleaning fluid such as trichloroethylene or acetone. Warning: These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods. Be sure to heed the fluid manufactures warning.

Disc Warp Inspection Using the jack, raise the front or the rear wheel off the ground (see Wheels/Tire chapter). Set the dial gauge [A] against the disc. For the front disc, turn the handlebar fully to one side. Rotate the wheel [C] to measure disc runout. The difference between the highest and lowest dial reading is the amount of runout. If disc runout exceeds the service limit, replace the disc. Disc Runout Standard: 0.2 mm or less Service Limit: 0.3 mm Brake Hose Removal Drain the brake fluid (see Brake Fluid Change). Remove the banjo bolts [A] at both ends of the brake hose [B] and pull the hose off the motorcycle. There is a copper washer on each side of the hose fitting. When removing the brake hose, temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum. Immediately wash away any brake fluid that spills. Caution: Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away immediately. Brake Hose Installation Using a new copper washer for each side of the hose fitting, tighten the banjo bolt. Torque Banjo Bolts: 25Nm When installing the hoses, avoid shaft bending, kinking, flattening or twisting. Run the brake hose according to the Cable, Wire and Hose Routing section in the General Information chapter. Fill the brake line with the brake fluid (see Brake Fluid Changing).
226

Brake Hose Inspection Note: The high pressure inside the brake line can cause fluid to leak or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while examining. Replace it if any cracks or bulges are noted.

227

Suspension Exploded View................................................................................................................................................ 221 Specification ................................................................................................................................................... 229 Rear Suspension ............................................................................................................................................. 230 Spring Preload .................................................................................................................................... 230 Preload Adjustment ........................................................................................................................... 230 Compression Damping Adjustment ................................................................................................... 230 Rebound Damping Adjustment ......................................................................................................... 232 Ride Height Adjustment ..................................................................................................................... 232 Rebound Damping Adjustment ......................................................................................................... 323 Compression Damping Adjustment ................................................................................................... 233 Cleaning.............................................................................................................................................. 233 Inspection........................................................................................................................................... 233 Rear Shock Absorber ...................................................................................................................................... 234 Rear Shock Absorber Removal ........................................................................................................... 234 Rear Shock Absorber Installation ....................................................................................................... 234 Oil Draining......................................................................................................................................... 234 Oil Filling ............................................................................................................................................. 234 Spring Tension .................................................................................................................................... 234 Scrapping ............................................................................................................................................ 235 Rear Shock Absorber Disassembly ..................................................................................................... 235 Rear Shock Absorber Assembly.......................................................................................................... 235 Conventional Front Forks ................................................................................................................... 235 Spring Preload Adjustment ................................................................................................................ 235 Preload Adjustment ........................................................................................................................... 235 Compression Damping Adjustment ................................................................................................... 236 Rebound Damping Adjustment.......................................................................................................... 236 Rebound Damping Recommended Adjustment Range ..................................................................... 237 Compression Damping Recommended Adjustment Range............................................................... 237 Cleaning .............................................................................................................................................. 238 Inspection ........................................................................................................................................... 238 Removal.............................................................................................................................................. 238 Installation.......................................................................................................................................... 238 Oil Draining......................................................................................................................................... 238 Oil Filling ............................................................................................................................................. 238 Spring Tension .................................................................................................................................... 238 Fork Disassembly................................................................................................................................ 240 Changing Fork seals and Bushings ..................................................................................................... 241 Assembly ............................................................................................................................................ 242 USD Front Forks ............................................................................................................................................. 243 Spring Preload Adjustment ................................................................................................................ 243 Preload Adjustment ........................................................................................................................... 243
228

Compression Damping Adjustment ................................................................................................... 243 Rebound Damping Adjustment.......................................................................................................... 244 Rebound Damping Recommended Adjustment Range ..................................................................... 244 Compression Damping Recommended Adjustment Range............................................................... 245 Cleaning .............................................................................................................................................. 245 Inspection ........................................................................................................................................... 245 Removal.............................................................................................................................................. 245 USD Fork Installation (Cafe Racer) ..................................................................................................... 246 USD Fork Installation (Sport and SE) .................................................................................................. 246 Oil Draining......................................................................................................................................... 246 Oil Filling ............................................................................................................................................. 246 Spring Tension .................................................................................................................................... 248 USD Fork Disassembly ........................................................................................................................ 248 Replacing Seals and Forks .................................................................................................................. 249 USD Fork Assembly ............................................................................................................................ 249 Fork Disassembly................................................................................................................................ 249 Changing Fork Seals and Bushing ....................................................................................................... 249 USD Fork Assembly ............................................................................................................................ 250 Swingarm ....................................................................................................................................................... 252 Swingarm Removal............................................................................................................................. 252 Swingarm Installation......................................................................................................................... 252 Swingarm Bearing Removal ............................................................................................................... 253 Swingarm Pivot Check ........................................................................................................................ 255 Swingarm Bearing, Sleeve Inspection ................................................................................................ 255

229

Exploded View

230

231

232

233

REF. NO.
24

PART DESCRIPTION
STANCHION ASSY, RH NUT SPACER, SPRING WASHER, SPRING SPACER NUT, CAP ASSY SPRING CYLINDER TUBE, OUTER SEAL DUST SNAP RING SEAL, OIL WASHER, OIL SEAL TUBE, INNER, RH SEALING WASHER CAPSCREW, OIL LOCK

TORQUE (NM) REMARKS

->
OHLINS RWU

23

STANCHION ASSY, LH NUT SPACER, SPRING WASHER, SPRING SPACER NUT, CAP ASSY SPRING CYLINDER TUBE, OUTER SEAL DUST SNAP RING SEAL, OIL WASHER, OIL SEAL TUBE, INNER, LH SEALING WASHER CAP SCREW, OIL LOCK

->

OHLINS RWU

STANCHION ASSY, LH, USD, NUT SPACER, SPRING WASHER, SPRING SPACER NUT, CAP ASSY SPRING CYLINDER TUBE, OUTER SEAL DUST SNAP RING SEAL, OIL

11mm PULL THROUGH

234

WASHER, OIL SEAL TUBE, INNER, RH SEALING WASHER CAP SCREW, OIL LOCK 10 STANCHION ASSY, RH, USD, NUT SPACER, SPRING WASHER, SPRING SPACER NUT, CAP ASSY SPRING CYLINDER TUBE, OUTER SEAL DUST SNAP RING SEAL, OIL WASHER, OIL SEAL TUBE, INNER, LH SEALING WASHER CAP SCREW, OIL LOCK BOLT, CAP HD, M8 X 25 9 STANCHION ASSY, LH, USD, NUT SPACER, SPRING WASHER, SPRING SPACER NUT, CAP ASSY SPRING CYLINDER TUBE, OUTER SEAL DUST SNAP RING SEAL, OIL WASHER, OIL SEAL TUBE, INNER, RH SEALING WASHER CAP SCREW, OIL LOCK 10 STANCHION ASSY, RH, USD, NUT SPACER, SPRING WASHER, SPRING SPACER NUT, CAP ASSY SPRING CYLINDER TUBE, OUTER SEAL DUST SNAP RING
11mm PULL THROUGH REFERTO PROCESS SHEET

11mm PULL THROUGH

20

PINCH BOLT SUPPLIED WITH FORKS

11mm PULL THROUGH REFER TO PROCESS SHEET

235

SEAL, OIL WASHER, OIL SEAL TUBE, INNER, LH SEALING WASHER CAP SCREW, OIL LOCK BOLT, CAP HD, M8 X 25 11 12 13 14 15 25 12 52 32 LOWER YOKE, USD FORKS BOLT, CAP HD, M8 X 20 X 1.25 STEERING STEM BEARING, TAPERED ROLLER SEAL, HEADSTOCK, LOWER BEARING LOWER YOKE, BILLET BOLT, CAP HD, M8 X 20 X 1.25 LOWER HEADSTOCK SPACER GREASE, SILKOLENE, PRO RG2 SWITCH CUBE, LH SCREW, M5 X 40 SCREW, M5 X 30 33 34 35 36 37 38 39 40 52 41 42 43 49 51 CABLE, THROTTLE, TWIN BRASS BARREL NIPPLE 5.75MM DIA X 5.5MM LENGTH OPEN CABLE GUIDE CLOSE CABLE GUIDE FERRULE RUBBER BOOT OPEN CABLE, 6MM OD, OUTER CONDUIT, 795MM OPEN CABLE, 1.5MM OD, INNER WIRE, 1030MM CLOSE CABLE, 6MM OD, OUTER SWITCH CUBE, RH SCREW, M5 X 22 HANDLEBAR, TUBULAR, TAPERED ALUMINIUM GRIP, HANDLEBAR, LH GRIP, HANDLEBAR, RH THROTTLE ACTUATOR, TWIN CABLE BOLT, CAP HD, M6 X 20 x 1.0 CLAMP, CLIP-ON, RH, CLEAR ANODISE CLAMP, CLIP-ON, LH, CLEAR ANODISE PIN, PARALLEL, 4.0 X 18.0MM, SOLID, STAINLESS HANDLEBAR, CLIP-ON, LH, CLEAR ANODISE HANDLEBAR, CLIP ON, RH, CLEAR ANODISE BOLT, CAP HD, M6 X 20 x 1.0, DIN 912, SS 4 8
THROTTLE ACTUATOR CLAMP ECIE HEADSTOCK BEARINGS

20 20

PINCH BOLT SUPPLIED WITH FORKS LOWER YOKE CLAMP BOLTS

LOWER YOKE FOR CONVENTIONAL FORKS 20

LOWER YOKE CLAMP BOLTS YOKE SPACER FOR CONVECTIONAL FORKS

3 3 3

USED AS ANTI ROTATION FEATURE

15 20

USED TO PINCH HANDLEBAR USED TO PINCH CLAMP THROTTLE CABLES FOR HIGH BARS ONLY

236

CONDUIT, 795MM CLOSE CABLE, 1.5MM OD, INNER WIRE, 1030MM ADJUSTER LOCK NUT BRASS BARREL NIPPLE 6MM DIA X 8MM LENGTH 50 CABLE, THROTTLE, TWIN, CLIP-ONS BRASS BARREL NIPPLE 5.75MM DIA X 5.5MM LENGTH OPEN CABLE GUIDE CLOSE CABLE GUIDE FERRULE RUBBER BOOT OPEN CABLE, 6MM OD, OUTER CONDUIT, 795MM OPEN CABLE, 1.5MM OD, INNER WIRE, 1030MM CLOSE CABLE, 6MM OD, OUTER CONDUIT, 795MM CLOSE CABLE, 1.5MM OD, INNER WIRE, 1030MM ADJUSTER LOCK NUT BRASS BARREL NIPPLE 6MM DIA X 8MM LENGTH 28 29 30 31 22 12 16 17 18 26 27 19 20 21 44 45 46 55 47 48 WEIGHT, BAR END RUBBER MOUNT, BAR END BOLT, CAP HD, M6 X 40 x 1.0 LOCKNUT, FLANGED, SERRATED FACE, M6 TOP YOKE, USD FORKS BOLT, CAP HD, M8 X 20 X 1.25 TOP YOKE, USD FORKS, HIGH BARS BOLT, CAP HD, M8 X 20 X 1.25 SEAL, HEADSTOCK YOKE, UPPER ASSY, BILLET BOLT, CAP HD, M8 X 20 X 1.25 NUT, UPPER YOKE, M25 LOCKNUT, M25 INTERMEDIATE NUT, M25 CLAMP, HANDLEBAR, LOWER BOLT, CAP HD, M10x30X1.5 NUT, M10 X 1.5 WASHER, M10, 10.5 X 20 X 2 CLAMP, HANDLEBAR, UPPER BOLT, CAP HD, M8 X 22 X 1.25 20
UPPER HANDLE BAR CLAMPS BOLTS HANDLEBAR CLAMP TO YOKE TOP YOKE FOR CONVENTIONAL FORKS BAR END MOUNT TO HANDLE BAR BAR END MOUNT TO HANDLE BAR CAFE RACER RACER TOP YOKE THROTTLE CABLES FOR LOW BARS ONLY

20NM 20NM

TOP YOKE CLAMP BOLTS CSE-03 TOP YOKE TOP YOKE CLAMP BOLTS

20NM 80NM 6 40

TOP YOKE CLAMP BOLTS CONVENTIONAL FORKS

TOP YOKE LOCK NUT ADJUSTER NUT 40NM TO SEAT BEARINGS, BACKED OFF, THEN RE-TORQUED TO 6 NM LOCKED UP TO ADJUSTER NUT 40 NM

43

HANDLEBAR CLAMP TO YOKE

237

Specifications Suspension Specification (USD) Standard 43 mm 16 clicks from fully closed 18 clicks from fully closed (3 turns from fully out) Ohlins front fork fluid 01309 19 cSt (5W) N/A 150mm 2 mm 260mm 2 mm

Item Front Fork (per one unit) Fork inner tube diameter Compression damper setting Rebound damping setting Spring preload setting Fork oil Fork oi viscosity Fork oil capacity Fork oil level Fork spring free length

Range --+11 to -16 +6 to -18 +7 to -3 -----------

Suspension Specification (Conventional) Item Standard Front Fork (per one unit) Fork inner tube diameter 43 mm Compression damper setting 14 clicks from fully closed Rebound damping setting 16 clicks from fully closed Spring preload setting (3 turns from fully out) Fork oil Ohlins front fork fluid 01309 Fork oi viscosity 19 cSt (5W) Fork oil capacity 488 cm Fork oil level N/A Fork spring free length 250mm 2 mm Suspension Specification (Rear Shocks) Item Standard Rear shock (per one unit) Compression damper setting 3 clicks from fully closed Rebound damping setting 18 clicks from fully closed 7 turns from fully out (2 rings Spring preload setting showing)

Range --+14 to -14 +2 to - 16 +7 to - 3 -----------

Range

+1 to -3 +36 to -18 +8 to - 7
238

Fork spring free length

230mm

---

239

Rear Suspension Warning: Ensure that the basic factory settings are intact before riding the motorcycle. If making adjustments, only adjust one aspect at a time in small increments. Spring Preload Static Sag Rider - Sag Note: Spring preload affects the ride height of the motorcycle and the fork angle. The Following should be performed on a flat surface. Lift the motorcycle off the ground using a work stand so that the front and rear wheels are off the ground and unloaded. Measure the distance from the centre of the rear wheel axle to the centre of the top rear suspension mount [R1]. Measure the distance from the bottom of the lower yoke (lowest point) to the centre of the front wheel axle [F1]. With the motorcycle on the ground so the motorcycle is under its own weight, repeat the measuring procedure above for [R2] and [F2]. Sit on the motorcycle in full riding gear in a normal riding position; repeat the measuring procedure for [R3] and [F3]. Note: The following set up is based on a single rider in full gear to a mass of 90Kg. Static Sag Conventional forks [R1-R2] [474-463] Rear: 11 mm 3mm [F1-F2] [522-477] Front: 45 mm 3mm Static Sag USD Forks [R1-R2] [474-463] Rear: 11 mm 3mm [F1-F2] [510-475] Front: 35 mm 3mm Rider Sag Conventional [R1-R3] [474-440] Rear: 34 mm 3mm [F1-F3] [522-467] Front: 55 mm 3mm Rider Sag USD Forks [R1-R3] [474-440] Rear: 34 mm 3mm [F1-F3] [510-465] Front: 45 mm 3mm If the measurements differ significantly from the table above, adjust the spring preload (see Spring Preload Adjustment). If the Rider Sag still differs significantly you may need to replace the spring.
240

Warning: Incorrect spring rate may result is poor handling characteristics. Preload Adjustment Turn the screw [A] on the hydraulic adjuster to set the A spring preload. Turn clockwise to increase preload, turn anti clockwise to decrease. To set the rider sag adjustment (see this chapter) turn the preload adjuster anti clockwise until it stops, and then turn clock wise to the first audible click. From this click turn the preload adjuster clockwise to the recommended position. Note: One full turn of the preload adjuster equates to 2/3mm (0.66 mm) of spring preload. Preload 7 full turns from fully out (two rings on the adjust should be visible [A]) Note: Increasing the amount of preload on the rear shock will reduce the amount of both static and rider sag. Reducing the preload will increase the sag values. Adjust both the left and right hand rear suspension springs in sequence to the same position. Changing the spring preload will change the ride height and affect the handling. It is critical that the spring preload is correctly set; if the spring preload is not correctly set all other suspension adjustments may not give desired handling characteristics.

Compression Damping Adjustment Note: Compression damping controls the energy absorbed when the rear wheel is being loaded or hits a bump. Standard settings are based on a 90 kg rider (this includes riding gear). To adjust the compression damping turn the adjuster [A] clockwise to increase damping, and anti clockwise to decrease damping. To reset the adjuster turn the adjuster clockwise to fully closed position (zero (0) position), then turn anti clockwise to open.

Rear Compression Damping 3 clicks out from fully closed Caution: Do not force the damping adjuster, delicate sealing surfaces could be damaged.
241

Rebound Damping Adjustment. Note: Rebound damping controls the energy absorption when the shock absorber is being extended and controls how fast the shock absorber returns to its normal position after being compressed. To adjust the damping, turn the adjuster [A] on the piston shaft clockwise to increase damping, anti clockwise to decrease it. To reset the damping, turn the adjuster clockwise (right) to fully closed position, and then anti clockwise (left) to the specified range. Rear Rebound Damping 18 Clicks out from fully closed Warning: If both suspension units are not adjusted equally, handling may be impaired and a hazardous condition may result. Ride Height Adjustment Note: Adjusting the length of the rear suspension will directly affect the steering geometry and handling of the motorcycle Caution: Make very small adjustments at a time as they can make a significant difference. Remove the shock absorbers from the motorcycle (see this chapter). Slacken off the lock nut [A]. Turn the adjuster nut [B] to the desired length. One turn of the spring retainer results in 1mm of shock absorber length. Rear Shock Absorber Length: 380 mm +8/-2mm Tighten the Ride Height Adjuster Nut.
A

Torque Ride height Adjuster Nut: 40Nm Warning: Always torque the lock nut after adjusting the length. The Adjustable end eye bracket [B] must not be positioned beyond grove [A].

Caution: After any changes to Ride Height Adjustment always check the Rider Sag (see this chapter) and Head light Angle (see Electrical System chapter).

242

Rebound Damping Recommended Adjustment Range Rebound Adjustment Range: 5 clicks from original settings Note: When setting up a motorcycle, the front suspension should be adjusted in line with the rear. If the Spring rate, preload and ride height feel good but the bike rides low and sits down under acceleration bumps, with lost line or lost comfort and traction. Open the rebound adjuster two clicks. If the bike is nervous / moving a lot or has a high feeling entering corners. Close the rebound adjuster two clicks. Fine tune by one click at a time

Caution: Always start from original factory settings and test run after making changes. Compression Damping Recommended Adjustment Range Compression Damping Range: 2 clicks from original settings If the motorcycle feels soft / unstable or is using too much wheel travel and the spring rate is correct. Close the compression adjuster by one click. This will controle reduce the motorcycle from falling throught the stroke too quickly. If the motorcycle feels high / has poor grip when opening the throttle or does not feel smooth over small bumps during acceleration. Open the Compression Adjuster by one click.

Caution: Always start from original factory settings and test run after making changes, if improvements have been made, repeate the procedure from the start again to check. Always check tire pressures before making suspension adjustements and take note of the conditions such as air temperature. Caution: Preventive maintenance and regular inspection reduces the risk of function disturbance. Rear Suspension Cleaning Clean the rear suspension unit externaly with a soft detergent. Using compressed air ensure all dirt is removed, lift the bump rubber and clean the area below. Keep the shock absorber clean and spray with a water displacing spray which will not deteriate the rubber, after cleaning, wash off excessive oil with a cloth. Caution: Never spray water directly into the adjuster units or ball joints.
243

Rear Suspension Inspection Check the ball joint for excessive play or stiction. Check the piston shaft for leakage and damage. Check the shock absorber body for external damage. Check the reservoir for external damage that can restrict the floating piston from moving freely. Check for excessive wear of rubber components. Check the attachment points between frame, swingarm, and shock. Warning: Do not change the gas pressure this required specialist high pressure nitrogen equipment. Rear Shock Absorber Removal Using a jack, raise the rear wheel off the ground (see wheels/Tires chapter). Support the rear swing arm weight. Remove the top [A] and bottom [B] suspension mounting bolts and washers. Remove the Shock absorbers [C].

Rear Shock Absorber Installation Install the shock absorber with the piggyback reservoir [A] at the top and back of the motorcycle. Install the Shock washers and bolts and tighten. Torque Rear Shock Bolts: 22 Nm
B

Oil Draining/Filling Note: Changing the oil requires de-pressurising and pressuring the rear shocks and should only be undertaken by a Norton authorised Ohlins dealer Warning: High Pressure gas reservoir should only be serviced by a Norton authorised Ohlins dealer as high pressure gas is dangerous.

Spring Tension Note: Since the spring becomes shorter as it weakens, check its free length to determine the condition. If the spring is shorter than the service limit, it must be replaced. Rear Shock Absorber Spring Length:
244

Standard: 230 mm Service Limit: 225 mm

Scrapping Remove the rear shock absorber (see this chapter). Point the reservoir away from you and slowly release the nitrogen gas pressure from the gas reservoir by pushing down the valve core with a surgical needle. Warning: The high pressure gas is dangerous. Do not point the valve toward your face or body. Do not incinerate a shock absorber without first removing the valve or it may explode. Rear Shock Absorber Disassembly Remove the Rear Shock from the frame (see Rear Shock Absorber Removal). C Clean the shock (see Rear Suspension cleaning) Hold the lower end of the shock with a vise. A Remove the entire preload on the spring (see Preload Adjustment). Using a spring compressor compress the spring until it is free. Slide down the rubber bumper [A]. Remove the spring guide [B] from the shock absorber and lift off the spring [C].

Rear Shock Absorber Assembly Install the spring and spring guide. Slowly release the tension in the spring using the spring compressor. Set the preload to its factory setting. Install the Shock (see Rear Shock Absorber Installation). Before riding, ensure the rear shocks are set up identically and the shock performs as intended. Front Fork Conventional Spring Preload Adjustment Warning: Ensure that the basic factory settings are intact before riding the motorcycle. If making adjustments, only adjust one aspect at a time in small increments.

245

Note: Spring preload affects the ride height of the motorcycle and the fork angle. If the measurements differ significantly from (Spring Preload Static Sag Rider Sag), adjust the spring preload (see Preload Adjustment). If the Rider Sag still differs significantly you may need to replace the spring. Warning: Incorrect spring rate may result is poor handling characteristics. Preload Adjustment Turn the adjuster screw to set the spring preload. Turn clockwise to increase preload, turn anti clockwise to decrease. To set the rider sag adjustment (see this chapter) turn the preload adjuster anti clockwise until it stops, and then turn clock wise to the first audible click. From this click turn the preload adjuster clockwise to the recommended position.

Note: One full turn of the preload adjuster equates to 1 mm of spring preload (the adjustable range is 15mm). Preload 3 full turns from fully out Note: Increasing the amount of preload in the front forks will reduce the amount of both static and rider sag. Reducing the preload will increase the sag values. Adjust both the left and right hand forks in sequence to the same position. Changing the spring preload will change the ride height and affect the handling. It is critical that the spring preload is correctly set; if the spring preload is not correctly set all other suspension adjustments may not give desired handling characteristics.

Compression Damping Adjustment Note: Compression damping controls the energy absorbed when the front wheel is being loaded or hits a bump. Standard settings are based on a 90 kg rider (this includes riding gear). To adjust the compression damping turn the adjuster [A] clockwise to increase damping, and anti clockwise to decrease damping. To reset the adjuster turn the adjuster clockwise to fully closed position (zero (0) position), then turn anti clockwise to open. Front Fork (Conventional) Compression Damping 14 clicks out from fully closed Caution: Do not force the damping adjuster, delicate sealing surfaces could be damaged.
246

Rebound Damping Adjustment. Note: Rebound damping controls the energy absorption when the fork is being extended and controls how fast the shock absorber returns to its normal position after being compressed.

To adjust the damping, turn the adjuster [A] clockwise to increase damping, anti clockwise to decrease it. To reset the damping, turn the adjuster clockwise (right) to fully closed position, and then anti clockwise (left) to the specified range. Front Forks (Conventional) Rebound Damping 16 Clicks out from fully closed

Warning: If both suspension units are not adjusted equally, handling may be impaired and a hazardous condition may result. Rebound Damping Recommended Adjustment Range Rebound Adjustment Range: 5 clicks from original settings Note: When setting up a motorcycle, the front suspension should be adjusted in line with the rear. If the Spring rate, preload and ride height feel good but the bike rides low and sits down under acceleration bumps, with lost line or lost comfort and traction. Open the rebound adjuster two clicks. If the bike is nervous / moving a lot or has a high feeling entering corners. Close the rebound adjuster two clicks. Fine tune by one click at a time

Caution: Always start from original factory settings and test run after making changes. Compression Damping Recommended Adjustment Range Compression Damping Range: 5 clicks from original settings If the motorcycle feels soft / unstable or is using too much wheel travel and the spring rate is correct. Close the compression adjuster by one click. This will reduce the motorcycle from falling throught the stroke too quickly. If the motorcycle feels high / has poor grip when opening the throttle or does not feel smooth over small bumps during acceleration. Open the Compression Adjuster by one click.

247

Caution: Always start from original factory settings and test run after making changes, if improvements have been made, repeate the procedure from the start again to check. Always check tire pressures before making suspension adjustements and take note of the conditions such as air temperature. Caution: Preventive maintenance and regular inspection reduces the risk of function disturbance.

Front Forks Cleaning Clean the Fork unit externaly with a soft detergent. Using compressed air, ensure all dirt is removed. Keep the forks clean and spray with a water displacing spray which will not deteriate the rubber, after cleaning, wash off excessive oil with a cloth (DO NOT ALLOW ANY OIL TO FALL ONTO THE BRAKING SYSTEM). Caution: Never spray water directly into the adjuster units. Fork Inspection Check for excessive play or stiction. Check the piston shaft for leakage and damage. Check the Fork body for external damage. Check for excessive wear of rubber components. Check the attachment points between top yoke, bottom yoke, and wheel axle. Convenctional Fork Removal If the fork leg is to be disassembled, loosen the fork top plug [A] beforehand. To loosen the fork top plug, remove the handlebar (see Steering chapter) and loosen the fork upper clamp bolts, and then slacken off the top plug. Using a jack, raise the front wheel off the ground (see Wheels/Tires chapter). Support the front wheel weight. Remove Brake calipers and hoses (see Braking System chapter). Remove the front wheel (see Wheels/ Tires chapter) Remove the front mudguard. Slacken the top pinch bolts off followed by the lower. With a twisting motion, work the fork leg [A] down and out. Conventional Fork Installation
A

248

Install the fork tube so that the top of the fork outer tube [A] is flush with the upper surface of the steering stem head [B]. Run the cables, wires, and hoses as shown in the Cable, Wire, and Hose Routing section of the General Information chapter. Install the front wheel (see Wheels/ Tires chapter). Torque Top Yoke Clamp Bolts: Bottom Yoke Clamp Bolts: Top Plug: Brake Caliper Bolts: 20 Nm 20 Nm Hand Tight 35 Nm

Check the front brake after installation.

Warning: Do not attempt to ride 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. Oil Draining/Filling Remove any preload on the forks (see this chapter). Loosen the top plug. Remove the front fork (see Front Fork Removal). Hold the inner tube in a soft jawed vise. Unscrew the top plug out of the outer tube. Remove the top nut assembly, top nut, spring preload tube the spring seat and the spring. Slowly compress the front fork fully. Pull out the piston rod as far as possible and turn the compression adjustment screw fully clockwise. This will keep the piston rod in top position, which will make the continued assembly easier. Pour out the fork oil with the fork upside down. Move the fork rod up and down at least ten times to expel the oil from the fork. Hold the fork tube upright; press the outer tube and the push rod all the way down.

Note: Do not install the fork spring yet. Fill the front fork to the specified amount.
249

Conventional Fork Oil: Ohlins front fork fluid 01309 Conventional Fork Oil Viscosity: SAE 5W 19 cSt Conventional Fork Oil Capacity: Approx. 488 cm Purge the air from the fork cylinder by gently moving rod up and down five times the piston

Note: While doing this ensure the oil lever is topped up so the top of the inner tube.

stays near

Caution: Never extend the fork fully, since oil will be forced from between the tubes into the inner tube. This raises the oil level in the inner tube. If the for is extended to the full length of its normal travel, the oil level will raise above 30mm. After purging the air from the fork, let it sit for about five minutes so that any suspended air bubbles can surface. Pull the push rod up slowly so as not to spill the fork oil out of the fork tube. Install the spring, the spring seat, the preload tube and the nut. Be careful to put all parts back in the same position as when the fork was disassembled. Install the top nut assembly. Tighten the top nut assembly hand tight. Install the fork (see Front Fork Installation). Set up the Preload, Compression damping, rebound damping. Check the whole system to ensure proper operation.

Spring Tension Note: Since the spring becomes shorter as it weakens, check its free length to determine the condition. If the spring is shorter than the service limit, it must be replaced. Conventional Fork Spring Length: Standard: 250 mm 2 mm Fork Disassembly Remove the front forks for the motorcycle (see this chapter). Hold the fork in a soft jawed vice [A].

A 250

Loosen the spring preload nut off fully by turning anti-clockwise. Loosen the top nut assembly [A] off and remove.

Let the inner tube drop down and loosen the front fork bolt [A] of the top cap from the cartridge shaft. Remove the upper nut and spring preload tube. Spring Seat Spring Remove the fork from the vice and pour the fork fluid out.
A

Note: Hold the adjustment rod in place to stop it falling out. Secure the fork in the vice again and use Norton cartridge removal tool [A] to loosen off the cartridge. Unscrew the cartridge from the fork and remove it.

Changing Fork Seals and Bushings Secure the fork bottom horizontally in a vice. Loosen the dust seal [A] and circlip [B]. Using a heat gun heat the area around the seal and bushings to approximately 100C. Remove the Bushings, seal and washer by pulling out swiftly. Remove the bushing [A] from the inner tube. Replace the bushings and seals Note: To Install the bushings and seals use the recommended Norton tool. Use a heat gun to warm the outer tube. Install the inner tube bushings by sliding them over the tube end.
A A

251

Slide the inner tube into the outer tube. Note: Earlier models of the front fork have two outer bushings. In this case, the lower bushing should not be replaced after being removed, as it is not required for fork operation. Slide the outer tube bushings in the outer tube. Using the Norton tool gently tap the outer tube bushings into position. Caution: Ensure that the bushing is set tightly against the support inside the outer tube. Install the seal seat washer [A]. Apply some red grease on the outside of the oil seal and install it with the Norton tool turned in the opposite direction from how it was used to tap the outer tube bushings. Install the circlip. Apply read grease onto the dust seal chamfer. Install the dust seal by hand and press in place.

Fork Assembly Fill fork fluid into the inner tube. Fork Fluid - 488 cm of Ohlins front fork fluid (01309) Push the piston up and down until the cartridge is completely filled with fluid. Reinstall the adjustment rod.

Note: Open the compression adjuster with a 3 mm Allen tool, close the rebound fully with your thumb by pushing on the adjustment rod before pumping procedure, this will make it easier to bleed out the air from the damping system. Install the spring with the marking number upwards. Install: Upper Spring Seat Preload Tube Piston Rod Nut Torque Piston Rod Nut: 25Nm
252

Apply red grease to the fork bolt and install it into the top nut. Pull the piston rod upwards and screw it into the top nut assembly. Use a 17mm wrench to keep a firm hold of the cartridge nut and the nut of the fork bolt. Close the rebound valve fully. Use a 3mm allen tool. Push the fork leg up and down to check for function. Put the top nut assembly back into the fork leg. Use the Norton top nut tool and tighten it gently by hand. Adjust the Compression, rebound, and Preload. Install the forks into the motorcycle (see this chapter). Before riding, ensure the forks are set up identically and the forks perform as intended. Front Forks Up Side Down (USD) Spring Preload Adjustment Warning: Ensure that the basic factory settings are intact before riding the motorcycle. If making adjustments, only adjust one aspect at a time in small increments. Note: Spring preload affects the ride height of the motorcycle and the fork angle. If the measurements differ significantly from (Spring Preload Static Sag Rider Sag), adjust the spring preload (see Preload Adjustment). If the Rider Sag still differs significantly you may need to replace the spring.

Warning: Incorrect spring rate may result is poor handling characteristics. Preload Adjustment Turn the adjuster screw to set the spring preload. Turn clockwise to increase preload, turn anti clockwise to decrease. To set the rider sag adjustment (see this chapter) turn the preload adjuster anti clockwise until it stops, and then turn clock wise to the first audible click. From this click turn the preload adjuster clockwise to the recommended position.

Note: One full turn of the preload adjuster equates to 1 mm of spring preload (the adjustable range is 15mm). Preload 3 full turns from fully out Note: Increasing the amount of preload in the front forks will reduce the amount of both static and rider sag. Reducing the preload will increase the sag values. Adjust both the left and right hand forks in sequence to the same position.
253

Changing the spring preload will change the ride height and affect the handling. It is critical that the spring preload is correctly set; if the spring preload is not correctly set all other suspension adjustments may not give desired handling characteristics.

Compression Damping Adjustment Note: Compression damping controls the energy absorbed when the front wheel is being loaded or hits a bump. Standard settings are based on a 90 kg rider (this includes riding gear). To adjust the compression damping turn the adjuster [A] clockwise to increase damping, and anti clockwise to decrease damping. To reset the adjuster turn the adjuster clockwise to fully closed position (zero (0) position), then turn anti clockwise to open.

Front Fork (USD) Compression Damping 16 clicks out from fully closed Caution: Do not force the damping adjuster, delicate sealing surfaces could be damaged. Rebound Damping Adjustment. Note: Rebound damping controls the energy absorption when the fork is being extended and controls how fast the shock absorber returns to its normal position after being compressed. To adjust the damping, turn the adjuster [A] clockwise to increase damping, anti clockwise to decrease it. To reset the damping, turn the adjuster clockwise (right) to fully closed position, and then anti clockwise (left) to the specified range.

Front Forks (USD) Rebound Damping 18 Clicks out from fully closed Warning: If both suspension units are not adjusted equally, handling may be impaired and a hazardous condition may result. Rebound Damping Recommended Adjustment Range Rebound Adjustment Range: 5 clicks from original settings

254

Note: When setting up a motorcycle, the front suspension should be adjusted in line with the rear. If the Spring rate, preload and ride height feel good but the bike rides low and sits down under acceleration bumps, with lost line or lost comfort and traction. Open the rebound adjuster two clicks. If the bike is nervous / moving a lot or has a high feeling entering corners. Close the rebound adjuster two clicks. Fine tune by one click at a time Caution: Always start from original factory settings and test run after making changes. Compression Damping Recommended Adjustment Range Compression Damping Range: 5 clicks from original settings If the motorcycle feels soft / unstable or is using too much wheel travel and the spring rate is correct. Close the compression adjuster by one click. This will reduce the motorcycle from falling throught the stroke too quickly. If the motorcycle feels high / has poor grip when opening the throttle or does not feel smooth over small bumps during acceleration. Open the Compression Adjuster by one click.

Caution: Always start from original factory settings and test run after making changes, if improvements have been made, repeate the procedure from the start again to check. Always check tire pressures before making suspension adjustements and take note of the conditions such as air temperature. Caution: Preventive maintenance and regular inspection reduces the risk of function disturbance. Front Forks Cleaning Clean the Fork unit externaly with a soft detergent. Using compressed air, ensure all dirt is removed. Keep the forks clean and spray with a water displacing spray which will not deteriate the rubber, after cleaning, wash off excessive oil with a cloth (DO NOT ALLOW ANY OIL TO FALL ONTO THE BRAKING SYSTEM). Caution: Never spray water directly into the adjuster units. Fork Inspection Check for excessive play or stiction. Check the piston shaft for leakage and damage. Check the Fork body for external damage. Check for excessive wear of rubber components. Check the attachment points between top yoke, bottom yoke, and wheel axle.
255

USD Fork Removal If the fork leg is to be disassembled, loosen the fork top plug beforehand. To loosen the fork top plug, remove the handlebar (see Steering chapter) and loosen the fork upper clamp bolts [A], and then slacken off the top plug. Using a jack, raise the front wheel off the ground (see Wheels/Tires chapter). Support the front wheel weight. Remove Brake calipers and hoses (see Braking System chapter). Remove the front wheel (see Wheels/ Tires chapter) Remove the front mudguard. Slacken the top pinch bolts off followed by the lower. With a twisting motion, work the fork leg down and out. USD Fork Installation (Cafe Racer) Install the fork tube so that the top of the fork outer tube [A] is flush with the upper surface of the steering stem head [B]. Run the cables, wires, and hoses as shown in the Cable, Wire, and Hose Routing section of the General Information chapter. Install the front wheel (see Wheels/ Tires chapter). Torque Top Yoke Clamp Bolts: Bottom Yoke Clamp Bolts: Top Plug: Brake Caliper Bolts: 20 Nm 20 Nm Hand Tight 35 Nm

A B

Check the front brake after installation.

Warning: Do not attempt to ride 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. Conventional Fork Installation (Sport and SE) Install the fork tube so that the top of the fork outer tube [A] is 11mm above the upper surface of the steering stem head [B]. Run the cables, wires, and hoses as shown in the Cable, Wire, and Hose Routing section of the General Information chapter. Install the front wheel (see Wheels/ Tires chapter).
A

Torque

Top Yoke Clamp Bolts: Bottom Yoke Clamp Bolts: Top Plug: Brake Caliper Bolts:

20 Nm 20 Nm Hand Tight 35 Nm

256

Check the front brake after installation.

Warning: Do not attempt to ride 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. Oil Draining/Filling Remove any preload on the forks (see this chapter). Loosen the top plug. Remove the front fork (see Front Fork Removal). Hold the base of the forks in a soft jawed vise. Unscrew the top plug out of the outer tube. Remove the top nut assembly, spring support, spring, and preload tube. Slowly compress the front fork fully. Pull out the piston rod as far as possible. Pour out the fork oil with the fork upside down. Move the fork rod up and down at least ten times to expel the oil Hold the fork tube upright; press the outer tube and the push rod down. Note: Do not install the fork spring yet. Fill the front fork to the top with the specified oil more than the specified amount. USD Fork Oil: Ohlins front fork fluid 01309 USD Fork Oil Viscosity: SAE5W 19 cSt USD Fork Oil Capacity: Approx. 500 mL Purge the air from the fork cylinder by gently rod up and down five times moving the piston

from the fork. all the way

Note: While doing this ensure the oil lever is topped up so stays near the top of the inner tube.

257

Caution: Never extend the fork fully, since oil will be forced from between the tubes into the inner tube. This raises the oil level in the inner tube. If the for is extended to the full length of its normal travel, the oil level will raise above 30mm. After purging the air from the fork, let it sit for about five minutes so that any suspended air bubbles can surface. Measure the oil level, using a fork oil level gauge. Set the gauge stopper so that its lower side shows the oil level distance. With the fork fully compressed, insert the gauge tube into the inner tube and position the stopper across the top of the outer tube. Pull the handle slowly to draw out the excess oil until no more oil comes up the tube. If no oil is drawn out there is not enough oil in the fork. Pour in some more oil, then draw out the excess. USD Front Fork Oil Level (Fully compressed without fork spring): 150 2 mm Pull the push rod up slowly so as not to spill the fork oil out of the fork tube. Install the spring, the spring seat, the preload tube and the nut. Be careful to put all parts back in the same position as when the fork was disassembled. Install the top nut assembly. Tighten the top nut assembly hand tight. Install the fork (see Front Fork Installation). Set up the Preload, Compression damping, rebound damping. Check the whole system to ensure proper operation.

Spring Tension Note: Since the spring becomes shorter as it weakens, check its free length to determine the condition. If the spring is shorter than the service limit, it must be replaced. USD Fork Spring Length: Standard: 250 mm 2 mm USD Fork Disassembly Carry out instructions from (Oil Draining / Filling) until the oil has been drained. Using Norton tool and a spanner loosen of the cartridge from the fork leg and remove cartridge [A] and washer [B]. Drain any remaining oil.
A 258

Remove the top cap lock nut [A] from the shaft. Remove spring guide, spacer (if any) and bump rubber. Push cap through the end cap/cylinder tube and the base valve will fall out [B]. Remove o-ring, spacers (if any) and top-out spring [C] from the shaft. Fasten the shaft in a vice. Use Norton clamping tool. Remove the piston and shim from the shaft. Place all removed parts in correct order on the work bench. Clean all parts thoroughly. Loosen the piston holder from the shaft. Use a heat gun to release the thread lock. Remove needle, spring and adjustment rod. Note: After using a heat gun, it is recommended to replace the rebound needle o-ring.

On the base valve, remove the check valve, piston and shim. Place all parts in correct order on work bench. Clean all parts thoroughly. Note: Do not use strong solvent; it can damage the seals and o-rings.

Replace Seals and Forks

259

Place the outer fork leg upright on a bench with the seal side up. Remove the scraper, circlip, oil seal and support washer.

Note: Use a flat tire lever and a rag to protect the edge of the fork leg when disassembling the seal. Use a heat gun to heat the outer leg to approximately 100C, where the bushings are positioned. Remove the bushings by pushing them out using Norton tool. Put the fork leg on a soft surface and tap the bar gently with a big plastic hammer. Clean all parts thoroughly. Put the outer fork Install new bushings while the outer fork leg is still warm. leg on a soft surface with the seal side facing up. Apply Loctite 648 on the outer fork leg upper bushing seat, use a long brush. Use the Norton installing sleeve, guide ring and attachment bar when installing the bushings. Tap the attachment bar until the bushing reaches a solid stop. Apply some red grease to the lower bushing seat on the outer fork leg, before installation (no Loctite on the lower bushing). Install the lower bushing in the same way as the upper. Use Norton installer sleeve and attachment bar when installing the seal. Apply a thin layer of red grease to the washer and the main seal. Install them into the outer fork leg by hand. Install the circlip behind the seal.

Note: Use appropriate grease to achieve optimum fork function. Apply red grease to the scraper seat and carefully press fit the scraper by hand.

USD Fork Assembly Put the inner fork leg in a vice, clamp the fork bottom. Apply some front fork oil to the inner fork tube surface and carefully slide the outer fork leg all the way down.

Warning: Be careful not to damage the fork seals. Install the cartridge into the fork bottom. Make sure the washer [A] is attached below the base valve, and tighten using Norton tool. Torque - Cartridge USD forks: 20Nm
260

Fill the fork with approx 500ml of fork oil. Pump the shaft up and down to bleed out the air; Use Norton tool. Make sure all the air has been bled from below the piston. Check and set the oil level (see this chapter). Note: It is recommended that only the specified Ohlins front fork oil should be used. Install the preload tube, spring (with markings facing up) and spring A support. Pull up the shaft, use Norton Spring compressor #1 tool to contract the top out spring and install Norton Spring Contraction tool to maintain contraction. Replace pull-up tool with the top cap assembly to the shaft. Make sure that the shaft bottoms in the adjuster/top cap before tightening the lock nut. Torque - Lock Nut USD Forks: 20Nm

Apply red grease on the top cap o-ring and threads, and install the top cap into the outer fork leg, with the fork leg fully extended. Torque Top Cap USD Forks: 10Nm

Adjust the spring preload, compression and rebound valves (see this chapter).

Before riding, ensure the forks are set up identically and the forks perform as intended.

261

Swingarm Swingarm Removal Squeeze the brake lever slowly and hold it with a band [A].
A

Caution: Be sure to hold the front brake when removing the swingarm or the motorcycle may fall over. The motorcycle could be damaged. Warning: Be sure to hold the front brake lever when removing the swingarm, or the motorcycle may fall over. It could cause an accident and injury. Remove the rear brake hoses clips. Remove the exhaust silencer and secondary (see Engine Top End chapter). Lift the rear wheel of the motorcycle off the ground using a centre stand. Remove: Rear suspension (see this chapter). Rear Wheel (see Wheels/Tires). Mudguard. Chain guard. Remove the Swingarm pivot nut [A]. Pull out the Swingarm pivot shaft and remove the Swingarm [B] rearward.

B A

Swingarm Installation Apply plenty of molybdenum disulfide grease to the inside of the needle bearings and sleeve. Install the swing arm pivot and swing arm pivot washer and hand tighten the pivot nut. Torque Swingarm Pivot Nut: 60 Nm Install: Rear Wheel (see Wheels/Tires chapter) Drive Chain (see Final Drive chapter) Rear suspension (see this chapter) Mudguard. Chain guard. Install exhaust silencer and secondary (see Engine Top End chapter). Install the rear brake hoses clips.
262

Torque Rear Brake Line Hose clips: 7 Nm Warning: Do not attempt to ride 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. Swingarm Bearing Removal
A

Remove the Swingarm (see this chapter). Remove the RH grease seals [A]. Remove the RH spacer [B].
B

Remove the centre spacer [A] from the swing arm.

Using a bearing puller remove the needle roller bearing assembly [A] from the RH side.

Remove the LH seal [A] and spacer [B].

A B

263

Remove the Circlip [A] from the LH side of the swing arm.
A

Using a bearing puller remove the two roller bearings [A] from the LH side.

Swing Arm Bearing Installation Apply molybdenum disulfide grease to two roller bearings [A] and using a press, install (smaller diameter side).

Install circlip and grease seal and LH spacer.

Install the RH Bearing using plenty of molybdenum disulfide grease with a press.
264

Be sure to install the needle roller bearings with manufactures mark pointing outwards. Install the centre spacer, RH seal and RH spacer.

Swingarm Pivot Check Check the pivot of the Swingarm and suspension mounting points. Raise the rear wheel off the ground (see Wheels/Tires chapter). A Move the Swingarm [A] up and down to check for abnormal friction, and push and pull it to check for bearing play. A small amount of play on the pivot is normal and no corrective action is needed. However, if excessive play is felt, check the Swingarm and suspension link bearings for wear and replace them if necessary.

Warning: Installation of new bearings in the Swingarm may cause too stiff rear suspension. Test ride the motorcycle slowly and prudently until the suspension becomes normal. Swingarm Bearing, Sleeve Inspection The rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing in the Swingarm for abrasion, colour change, or other damage.

If there is any doubt as to the condition of any of the needle bearings or sleeves, replace all the sleeves, and needle bearings as a set.

265

Steering Exploded View................................................................................................................................................ 257 Steering .......................................................................................................................................................... 265 Steering Inspection ............................................................................................................................ 265 Steering Adjustment .......................................................................................................................... 265 Handlebar....................................................................................................................................................... 266 Handlebar Removal............................................................................................................................ 266 Handlebar Installation........................................................................................................................ 267 Steering Stem ................................................................................................................................................. 267 Steering Stem Removal ...................................................................................................................... 267 Steering Stem Installation .................................................................................................................. 268 Steering Stem Warp ........................................................................................................................... 269 Steering Stem Bearing.................................................................................................................................... 269 Stem Bearing Removal ....................................................................................................................... 269 Stem Bearing Installation ................................................................................................................... 269 Stem Bearing Lubrication ................................................................................................................... 269

266

Exploded View

267

268

269

270

REF. NO.
24

PART DESCRIPTION
STANCHION ASSY, RH NUT SPACER, SPRING WASHER, SPRING SPACER NUT, CAP ASSY SPRING CYLINDER TUBE, OUTER SEAL DUST SNAP RING SEAL, OIL WASHER, OIL SEAL TUBE, INNER, RH SEALING WASHER CAPSCREW, OIL LOCK

TORQUE (NM) REMARKS

->
OHLINS RWU

23

STANCHION ASSY, LH NUT SPACER, SPRING WASHER, SPRING SPACER NUT, CAP ASSY SPRING CYLINDER TUBE, OUTER SEAL DUST SNAP RING SEAL, OIL WASHER, OIL SEAL TUBE, INNER, LH SEALING WASHER CAP SCREW, OIL LOCK

->

OHLINS RWU

STANCHION ASSY, LH, USD, NUT SPACER, SPRING WASHER, SPRING SPACER NUT, CAP ASSY SPRING CYLINDER TUBE, OUTER SEAL DUST SNAP RING SEAL, OIL WASHER, OIL SEAL TUBE, INNER, RH SEALING WASHER

11mm PULL THROUGH

271

CAP SCREW, OIL LOCK 10 STANCHION ASSY, RH, USD, NUT SPACER, SPRING WASHER, SPRING SPACER NUT, CAP ASSY SPRING CYLINDER TUBE, OUTER SEAL DUST SNAP RING SEAL, OIL WASHER, OIL SEAL TUBE, INNER, LH SEALING WASHER CAP SCREW, OIL LOCK BOLT, CAP HD, M8 X 25 9 STANCHION ASSY, LH, USD, NUT SPACER, SPRING WASHER, SPRING SPACER NUT, CAP ASSY SPRING CYLINDER TUBE, OUTER SEAL DUST SNAP RING SEAL, OIL WASHER, OIL SEAL TUBE, INNER, RH SEALING WASHER CAP SCREW, OIL LOCK 10 STANCHION ASSY, RH, USD, NUT SPACER, SPRING WASHER, SPRING SPACER NUT, CAP ASSY SPRING CYLINDER TUBE, OUTER SEAL DUST SNAP RING SEAL, OIL WASHER, OIL SEAL TUBE, INNER, LH
11mm PULL THROUGH REFERTO PROCESS SHEET

11mm PULL THROUGH

20

PINCH BOLT SUPPLIED WITH FORKS

11mm PULL THROUGH REFER TO PROCESS SHEET

272

SEALING WASHER CAP SCREW, OIL LOCK BOLT, CAP HD, M8 X 25 11 12 13 14 15 25 12 52 32 LOWER YOKE, USD FORKS BOLT, CAP HD, M8 X 20 X 1.25 STEERING STEM BEARING, TAPERED ROLLER SEAL, HEADSTOCK, LOWER BEARING LOWER YOKE, BILLET BOLT, CAP HD, M8 X 20 X 1.25 LOWER HEADSTOCK SPACER GREASE, SILKOLENE, PRO RG2 SWITCH CUBE, LH SCREW, M5 X 40 SCREW, M5 X 30 33 34 35 36 37 38 39 40 52 41 42 43 49 51 CABLE, THROTTLE, TWIN BRASS BARREL NIPPLE 5.75MM DIA X 5.5MM LENGTH OPEN CABLE GUIDE CLOSE CABLE GUIDE FERRULE RUBBER BOOT OPEN CABLE, 6MM OD, OUTER CONDUIT, 795MM OPEN CABLE, 1.5MM OD, INNER WIRE, 1030MM CLOSE CABLE, 6MM OD, OUTER CONDUIT, 795MM CLOSE CABLE, 1.5MM OD, INNER WIRE, 1030MM ADJUSTER SWITCH CUBE, RH SCREW, M5 X 22 HANDLEBAR, TUBULAR, TAPERED ALUMINIUM GRIP, HANDLEBAR, LH GRIP, HANDLEBAR, RH THROTTLE ACTUATOR, TWIN CABLE BOLT, CAP HD, M6 X 20 x 1.0 CLAMP, CLIP-ON, RH, CLEAR ANODISE CLAMP, CLIP-ON, LH, CLEAR ANODISE PIN, PARALLEL, 4.0 X 18.0MM, SOLID, STAINLESS HANDLEBAR, CLIP-ON, LH, CLEAR ANODISE HANDLEBAR, CLIP ON, RH, CLEAR ANODISE BOLT, CAP HD, M6 X 20 x 1.0, DIN 912, SS 4 8
THROTTLE ACTUATOR CLAMP ECIE HEADSTOCK BEARINGS

20 20

PINCH BOLT SUPPLIED WITH FORKS LOWER YOKE CLAMP BOLTS

LOWER YOKE FOR CONVENTIONAL FORKS 20

LOWER YOKE CLAMP BOLTS YOKE SPACER FOR CONVECTIONAL FORKS

3 3 3

USED AS ANTI ROTATION FEATURE

15 20

USED TO PINCH HANDLEBAR USED TO PINCH CLAMP THROTTLE CABLES FOR HIGH BARS ONLY

273

LOCK NUT BRASS BARREL NIPPLE 6MM DIA X 8MM LENGTH 50 CABLE, THROTTLE, TWIN, CLIP-ONS BRASS BARREL NIPPLE 5.75MM DIA X 5.5MM LENGTH OPEN CABLE GUIDE CLOSE CABLE GUIDE FERRULE RUBBER BOOT OPEN CABLE, 6MM OD, OUTER CONDUIT, 795MM OPEN CABLE, 1.5MM OD, INNER WIRE, 1030MM CLOSE CABLE, 6MM OD, OUTER CONDUIT, 795MM CLOSE CABLE, 1.5MM OD, INNER WIRE, 1030MM ADJUSTER LOCK NUT BRASS BARREL NIPPLE 6MM DIA X 8MM LENGTH 28 29 30 31 22 12 16 17 18 26 27 19 20 21 44 45 46 55 47 48 WEIGHT, BAR END RUBBER MOUNT, BAR END BOLT, CAP HD, M6 X 40 x 1.0 LOCKNUT, FLANGED, SERRATED FACE, M6 TOP YOKE, USD FORKS BOLT, CAP HD, M8 X 20 X 1.25 TOP YOKE, USD FORKS, HIGH BARS BOLT, CAP HD, M8 X 20 X 1.25 SEAL, HEADSTOCK YOKE, UPPER ASSY, BILLET BOLT, CAP HD, M8 X 20 X 1.25 NUT, UPPER YOKE, M25 LOCKNUT, M25 INTERMEDIATE NUT, M25 CLAMP, HANDLEBAR, LOWER BOLT, CAP HD, M10x30X1.5 NUT, M10 X 1.5 WASHER, M10, 10.5 X 20 X 2 CLAMP, HANDLEBAR, UPPER BOLT, CAP HD, M8 X 22 X 1.25 20
UPPER HANDLE BAR CLAMPS BOLTS HANDLEBAR CLAMP TO YOKE TOP YOKE FOR CONVENTIONAL FORKS BAR END MOUNT TO HANDLE BAR BAR END MOUNT TO HANDLE BAR CAFE RACER RACER TOP YOKE THROTTLE CABLES FOR LOW BARS ONLY

20NM 20NM

TOP YOKE CLAMP BOLTS CSE-03 TOP YOKE TOP YOKE CLAMP BOLTS

20NM 80NM 6 40

TOP YOKE CLAMP BOLTS CONVENTIONAL FORKS

TOP YOKE LOCK NUT ADJUSTER NUT 40NM TO SEAT BEARINGS, BACKED OFF, THEN RE-TORQUED TO 6 NM LOCKED UP TO ADJUSTER NUT 40 NM

43

HANDLEBAR CLAMP TO YOKE

274

Steering Steering Inspection Raise the front wheel off the ground. With the front wheel pointing straight ahead, alternately nudge 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 steering binds or catches before the stop, check the routing of cables, hoses, and harnesses. If the steering feels tight, adjust or lubricate the steering. Feel for steering looseness by pushing and pulling the fork [A]. If you feel looseness, adjust the steering.

Steering Adjustment With the front wheel raised off the ground remove: Top Yoke Clamp Bolts (loosen) Handlebar, place on one side with cables, harnesses and hoses installed (not applicable for cafe racer). Steering Stem Head Nut [A]. Remove the top yoke [B].

Slacken off the steering stem adjuster lock nut [A]. Tighten steering stem adjuster nut [A] to 40Nm to settle the bearings then slacken off. Re-tighten steering stem adjuster nut [A]. Torque: Steering Stem Adjuster Nut 8Nm

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

275

Note: Turn the stem nut 1/8th of a turn at a time maximum. Check the steering again. If the steering is still too tight or too loose in spite of correct adjustment, inspect the steering stem parts. Tighten steering stem adjuster lock nut. Torque Steering Stem Locknut: 40 Nm

Install the parts removed. Handlebar (see this chapter). Torque Steering Stem Head Nut: Front Fork Top Yoke Clamp Bolts: 85Nm 20Nm

Handlebar Handlebar Removal (Sport and SE) Remove: Lighting Switch [A] Engine stop switch [B] Clutch Lever Assembly [C] Brake Lever Assembly [D] Throttle Twist Grip [E] Unscrew the handlebar clamp bolts[F] , and take off the top clamps and the handle bar

Handlebar Removal (Cafe Racer) Remove: Lighting Switch [A] Engine stop switch [B] Clutch Lever Assembly [C] Brake Lever Assembly [D] Throttle Twist Grip [E] Unscrew the handlebar clamp bolts [F] completely, and take off the handle bars using a twisting motion.

276

Handlebar installation (Sport and SE) Install the handlebar, top clamps, and bolts as shown. Align bars to suit preference. Tighten the holder front bolt [A] first and then the rear bolts [B]. When the holder is correctly installed, there will be an even gap [C] at the rear and no gap at the front [E] after tightening. Torque Handlebar clamp Bolts: 20 Nm Ensure all cables, hoses, and wires are routed correctly and the idle does not change at full lock on each side.

Handlebar installation (Cafe Racer) Install the handle bar and clamp bolts as shown. Align bars to suit preference. Torque Handlebar Camp Bolts: 15 Nm Ensure all cables, hoses, and wires are routed correctly and the idle does not change at full lock on each side.

Steering Stem Steering Stem Removal Remove: Handlebar (see this chapter) Head light (see Electrical System chapter) Head light brackets Raise the front wheel off the ground (see Wheels/Tires chapter). Remove: Top Yoke Camp Bolt [A] Top Yoke Pinch Bolts [B] Push up the top yoke and remove it. Remove:
277

Front wheel (see Wheels/Tires chapter) Front Mudguard and Front Forks. Remove stem locking nut and stem adjuster nut. Remove seal and top head stock bearing. Remove bottom yoke [A] with stem [B] down from the motorcycle.

Steering Stem Installation Rout the cables, wires, and hoses as shown in the Cable, Wire, and Hose Routing section of the General Information chapter. Apply grease to the head stock bearings and install the lower yoke with stem and spacer and bottom head stock bearing installed. Install the upper bearing on the stem shaft while pushing up on the stem base. Install the stem seal and stem bearing adjustment nut and hand tighten. Tighten steering stem adjuster nut [A] to 40Nm to settle the bearings then slacken off. Re-tighten steering stem adjuster nut [A]. Torque: Steering Stem Adjuster Nut 6Nm Tighten steering stem adjuster lock nut. Torque Steering Stem Locknut: 40 Nm Install the parts removed. Top Yoke (see this chapter) Front Fork (see Suspension chapter) Front wheel (see Wheels/Tires chapter) Handlebar (see this chapter) Head Light (see Electrical System chapter) Check and adjust the following items after installation: Steering (see this chapter) Throttle Cables (see Fuel System chapter) Headlight Aim Front Brake
278

Warning: Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc. The brakes will not function on the first application of the lever if this is not done.

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.
A

Steering Stem Bearing Steering Stem Bearing Removal Remove the steering stem (see this chapter). Drive out the bearing outer races from the head pipe.

Note: If Either Bearing is damaged, it is recommended that both the upper and lower bearings (including outer races) be replaced with new ones. Remove the lower inner race [A] which is pressed onto the steering stem with a wedge.

Steering Stem Bearing Installation Replace the bearing outer races with new ones. Apply grease the outer races, and drive them into the head pipe at the same time. Replace the stem bearing inner races with new ones. Apply grease to the lower inner race, and drive it onto the stem. Install the steering stem. Install the upper bearing on the stem shaft while pushing up on the stem base. Install the stem seal and stem bearing adjustment nut and hand tighten. Tighten steering stem adjuster nut [A] to 40Nm to settle the bearings then slacken off. Re-tighten steering stem adjuster nut [A]. Torque: Steering Stem Adjuster Nut 8Nm Tighten steering stem adjuster lock nut. Torque Steering Stem Locknut: 40 Nm Steering Stem Bearing Lubrication
279

Note: In accordance with the Periodic Maintenance Chart, lubricate the steering stem bearings. Remove the steering stem. Using a high-flash point solvent, wash the upper and lower tapered roller bearings in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean of grease and dirt. Visually check the outer races and the rollers. Replace the bearing assemblies if they show wear or damage. Pack the upper and lower tapered roller bearings [A] in the cages with grease, and apply a light coat of grease the upper and lower outer races. Install the steering stem, and adjust the steering

280

Frame Exploded View................................................................................................................................................ 272 Seat ................................................................................................................................................................ 282 Seat Removal ..................................................................................................................................... 282 Seat Installation ................................................................................................................................. 282 Number Plate Hanger .................................................................................................................................... 283 Number Plate Hanger Removal.......................................................................................................... 283 Number Plate Hanger Installation ..................................................................................................... 283 Rear Bodywork ............................................................................................................................................... 283 Rear Bodywork Removal .................................................................................................................... 283 Rear Bodywork Installation ................................................................................................................ 283 Foot Control Frames ...................................................................................................................................... 283 Foot control Frame removal .............................................................................................................. 283 Foot control Frame installation ......................................................................................................... 283

281

Exploded View

282

REF. NO.
1 20 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19

PART DESCRIPTION
FRAME ASSEMBLY, SINGLE SEAT XM CABLE TIE, 120MM X 3.6MM, FIR-TREE, BLACK OIL FILLER CAP O-RING, OIL FILLER CAP, 2.4MM DIPSTICK BRACKET, ENGINE, FRONT, STEEL, XM SPACER, ENGINE MOUNT, RHS, ALUMINIUM SPACER, ENGINE MOUNT, LHS, ALUMINIUM BOLT CAP HD, M8 X 57 X 1.25 WASHER, M8, 8.4 X 16 X 1.6

TORQUE (NM) REMARKS

CLAMP DIRECT TO FRAME, CLUTCH HOSE, HARNESS

SITS INSIDE OIL FILLER CAP

TO CLAMP ENGINE MOUNT BRACKET TO CLAMP ENGINE MOUNT BRACKET 26 TO CLAMP ENGINE MOUNT BRACKET FRONT ENGINE MOUNT BOLT USED WITH ENGINE BOLT AND NUT NUT, USED WITH ENGINE MOUNT BOLT REAR ENGINE MOUNT BOLT
(NOW WHOLE WORLD) TO FIX VIN PLATE TO FRAME USED BETWEEN FRAME AND FOOTREST HANGER

BOLT, M12, ENGINE, FRONT MOUNT WASHER, M12, 13 X 24 X 2.5 LOCKNUT, M12 X 1.75 FRAME ADJUSTER, M24 BOLT, M12, ENGINE, REAR MOUNT VIN PLATE, UK RIVET, HAMMER DRIVE, 3/8TH SLEEVE, NYLON, FRAME PROTECTOR 85 15 85

283

Body Work

284

285

286

287

REF. NO.

PART DESCRIPTION
EXTENSION, REAR MUDGUARD EXTENSION, REAR MUDGUARD EXTENSION, REAR MUDGUARD

TORQUE (NM) REMARKS

1 2 3 4 5 6 7 8 9 41 10 11

MUDGUARD, USD, CARBON BOLT, BUTTON HD, INT HEX M6 X 16 X 1.0 BOLT, BUTTON HD, INT HEX M6 X 20 X 1.0 LOCKNUT, FLANGED, M6 X 1.0 WASHER, PENNY, M6, 6.4 X 18 X 1.6 MUDGUARD BRACKET, USD FORKS, LH, XM MUDGUARD BRACKET, USD FORKS, RH, XM BOLT, BUTTON HD, M5 x 12 x 0.8 WASHER, M5, 5.3 X 10 X 1 VENTURE SHIELD KIT, BODYWORK PROTECTION MUDGUARD, FRONT, CARBON BRACKET, MUDGUARD, CONVENTIONAL MUDGUARD, FRONT, GALACTIC BLACK, CONVENTIONAL FORKS MUDGUARD, FRONT, ROYAL RED, CONVENTIONAL FORKS MUDGUARD, FRONT, CANARY YELLOW, CONVENTIONAL FORKS MUDGUARD, FRONT, FACTORY SPECIAL SILVER, CONVENTIONAL FORKS MUDGUARD, GALACTIC BLACK, USD FORKS MUDGUARD, FRONT, ROYAL RED, USD FORKS MUDGUARD, FRONT, CANARY YELLOW, USD FORKS MUDGUARD, FRONT, FACTORY SPECIAL SILVER, USD FORK BATTERY BOX, STEEL, XM BRACKET, TWIN RELAY, XM BOLT, BUTTON HD, M6 X 16 WASHER, M6, 6.4 X 12 X 1.6 NUMBER PLATE HANGER, CF BRACKET, NUMBER PLATE, MOULDED NUMBER PLATE BRACKET, STEEL, XM P-CLIP, 13MM WASHER, PENNY, M6, 6.4 X 18 X 1.6 BOLT, CAP HD, M6 X 30 GROMMET, RUBBER, 14MM BOLT, BLACK, M5 X 20 NYLON

CARBON FIBRE FOR CSE-03 FRONT MUDGUARD BOLT RWU FORKS FRONT MUDGUARD BOLT FRONT MUDUARD NUT USED WITH FRONT MUDGUARD BOLTS

USED WITH MUDGUARD BRACKETS USED WITH BRACKET BOLTS BODYWORK PROTECTION
CARBON FIBRE FOR CSE-01/02 OHLINS PART, GOLD, CONVENTIONAL FORKS

10 10 10 10 1 1 1 1 42 43 44 45 32 33 34 35 36 37 38 39

STEEL FABRICATION BATTERY BOX TO FRAME USED WITH FRONT BATTERY BOX BOLT CARBON FIBRE FOR SE PLASTIC MOULDED HANGER TO MOUNT REAR HARNESS USED WITH HANGER BOLTS NUMBER PLATE BRACKET + HANGER BOLTS PROTECTION FOR HARNESS HOLE NUMBER PLATE BOLT

288

23 24 32 25 26 27 28 25 25 25 25 25 29 31 40 30 12 13 14 15 16 12 12 12 12 12 12 12 12 15 16 17 18 19 20 21 22

BOLT, YELLOW, M5 X 20 NYLON NUT, BLACK, M5 NYLON NUMBER PLATE HANGER, CF REAR BODYWORK, MLD BOLT, CAP HD, M6 X 30 WASHER, PENNY, M6, 6.4 X 18 X 1.6

NUMBER PLATE BOLT NUMBER PLATE NUT CARBON FIBRE AS RECIEVED FROM ACERBIS REAR BODY WORK FRONT BOLTS USED WITH REAR BODY WORK BOLTS

RUBBER MOUNT, REAR BODYWORK

PANEL, REAR, GALACTIC BLACK, GOLD TEXT PANEL, REAR, ROYAL RED, GOLD TEXT PANEL, REAR, CANARY YELLOW, BLACK TEXT PANEL, REAR, FACTORY SPECIAL SILVER, BLACK TEXT/BORDER RED PIN STRIPE PANEL, REAR, FACTORY SPECIAL SILVER, BLACK TEXT SEAT, RIDER, FORMED RUBBER FOOT, SEAT BOLT, CAP HD, M6 X 50 X 1.0 GROMMET, ID 14 X OD 9.0 X 12.5MM SEAT, RIDER, FORMED, VINYL RUBBER FOOT, SEAT FLYSCREEN, CARBON BOLT, BUTTON HD, M5 X 16 LOCKNUT, FLANGED, M5 X 0.8 FLYSCREEN BRACKET, LH, XM FLYSCREEN BRACKET, RH, XM FLYSCREEN, ROYAL RED, STANDARD FLYSCREEN, CANARY YELLOW, STANDARD FLYSCREEN, FACTORY SPECIAL, SILVER FLYSCREEN, GALACTIC BLACK FLYSCREEN, ROYAL RED, STANDARD FLYSCREEN, CANARY YELLOW, STANDARD FLYSCREEN, FACTORY SPECIAL, SILVER FLYSCREEN, GALACTIC BLACK FLYSCREEN BRACKET, LH, XM FLYSCREEN BRACKET, RH, XM CHAINGUARD, CARBON, LARGE HUGGER, CARBON HUGGER, MOULDED BOLT, CAP HEAD, M5 X 15 X 0.8 WASHER, PENNY, M5, 5.3 X 15 X 1.2 CHAIN GUARD, STEEL SNAP RING SEAL, OIL 7

REAR BODY WORK RUBBER MOUNTS

SEAT TO FRAME SEAT TO BODY WORK

CARBON

TO MOUNT FLY SCREEN TO BRACKET TO MOUNT FLY SCREEN TO BRACKET

RED FLYSCREEN YELLOW FLYSCREEN SILVER FLYSCREEN BLACK FLYSCREEN FOR ACCESSORY ONLY FOR ACCESSORY ONLY FOR ACCESSORY ONLY FOR ACCESSORY ONLY FOR ACCESSORY ONLY FOR ACCESSORY ONLY

TO BOLT HUGGER USED WITH HUGGER + CHAIN GUARD BOLTS

289

WASHER, OIL SEAL TUBE, INNER, LH SEALING WASHER CAPSCREW, OIL LOCK BOLT, CAP HD, M8 X 25 20
PINCH BOLT SUPPLIED WITH FORKS

290

REF. NO.
1 2 3 4 5 6 7 8 9 10 11 38 12 13 14 15 16 17 18 19 20 39 21 22 23 24 25 26 27 28 29 30 31 32 33 40 34 35 36 37

PART DESCRIPTION
FOOT CONTROL FRAME, LH, XM FOOT CONTROL FRAME, RH, XM BOLT CAP HD, M8 X 50 X 1.25 BALL JOINT - NIPPLE ASSY, M6 CONTROL PLATE, LH, BILLET CONTROL PLATE, RH, BILLET BOLT, CAP HD, M6 X 20 x 1.0 LOCKNUT, M6 X 1.0 ROD, GEAR LINKAGE PEDAL, ASSY, GEAR/REAR BRAKE, FORGED NUT, M6 1.0, PLAIN

TORQUE (NM) REMARKS

STEEL FABRICATION STEEL FABRICATION

27

FOOT CONTROL FRAME TO FRAME ASSY

GEAR CHANGE AND BRAKE LEVER FOR GEAR CHANGE PLATE TO GEAR ROD ASSY LOCATED IN ARM, GEAR SELECTOR, SPLINED 6MM PIN BETWEEN FOOT PEG AND CLEVIS

BOLT, CAP HD, M6 X 16 x 1.0 PEDAL, GEAR/REAR BRAKE, FORGED PIN, CLEVIS, FOOTPEG CLEVIS, RH FOOTPEG, TURNED FOOTPEG, RUBBER BALL BEARING, FOOTPEG SPRING, FOOTPEG FOOTPEG PLATE, ANTI ROTATION, XM WASHER, M10, 10.5 X 20 X 2 LOCKNUT, M10 X 1.5 FOOT PEG, TOE, TURNED BOLT, CAP/HD, M6 X 40 FOOT PEG, TOE, RUBBER PLATE, ACTUATOR, REAR BRAKE, XM BOLT, CSK HD, M4 X 0.7 X 12 PLATE, ROD ASSY, GEAR PEDAL SIDESTAND, FABRICATED, XM SPRING, SIDE STAND PIVOT BOLT, SIDE STAND SWITCH, SIDE STAND BOLT, BUTTON HD, INT HEX, M6 X 25 X 1.0 SPACER, SWITCH, SIDE STAND SIDE STAND STOP, 19mm GREASE, SILKOLENE, PRO RG2 BOLT, LOW CAP HD, M4 X 10 X 0.7 ARM, GEAR SELECTOR, SPLINED, MACHINED 5MM E-CLIP CLEVIS, LH, GEAR, PEDAL PIVOT 20 7 10 40

ANTI ROTATION WASHER BETWEEN CLEVIS AND CONTROL PLATE WASHER TO GO BETWEEN ANTI ROTATION PLATE AND M10 NUT

TO CLAMP CLEVIS + PEG ASSY TO CONTROL PLATE

TO CLAMP TOE PEG TO PEDAL

TO CLAMP PLATE TO PEDAL

BOLTED ONTO PEDAL, GEAR REAR BRAKE FORGED FABRICATED STEEL USE THREE BOND 1327

USED TO CLAMP SIDE STAND SWITCH TO PIVOT BOLT USED AS COMPRESSION LIMITER IN SWITCH

APPLY TO PIVOT FACES USED TO BOLT PLATE ROD ASSY GEAR PEDAL USED TO CONNECT TO GEAR CHANGE SHAFT USED TO HOLD PIN CLEVIS IN USED ON GEAR SIDE ONLY

291

OIL / GREASE

Seat Seat Removal Remove the Seat bolts [A] on both sides. Pull the seat forward and up [B].

Seat installation Slip the seat hook [A] under the rear seat and into the location hole [B]. Tighten the seat bolts. Torque - Seat Bolts: 8 Nm

Number plate hanger Number plate hanger Removal Remove the number plate hanger bolts [A] and lower the number plate. Disconnect the rear indicators and brake light and remove number plate hanger.

Number Plate Hanger Installation Connect the indicators and rear bracket light and push the connector into the rear body work. Whilst holding the number plate hanger up install the number hanger bracket bolts and hand tighten. Torque Number plate bracket bolts: 8 Nm

292

Rear Bodywork Rear Bodywork Removal Remove the number plate hanger (see this chapter). Remove seat (see this chapter). Remove the remaining rear bodywork bolts [A]. Disconnect the ECU, Fuse Box, Relay box, and rear lighting (see Electrical System chapter). Remove the rear bodywork. Rear Bodywork Installation Install the rear bodywork. Connect the ECU, Fuse Box, Relay Box, and Rear Lighting (see Electrical System chapter). Install the front, rear body work bolts [A] Torque: rear body work bolts: 8Nm Install the number plate hanger (see this chapter). Install the rear seat (see this chapter)

Foot control Frames Foot control Frame removal Remove rear brake master cylinder assembly (see Brakes chapter) Remove foot control frame bolts [A] Remove the foot control frames. Foot control Frame installation Install the foot control frame bolts and tighten

Torque Foot control frame bolts: 27Nm Install rear brake master cylinder assembly (see Brakes chapter)

293

Electrical System Exploded View................................................................................................................................................ 286 Parts Location ................................................................................................................................................ 301 Wiring Diagram .............................................................................................................................................. 302 Specifications ................................................................................................................................................. 303 Precautions .................................................................................................................................................... 304 Electrical Wiring ............................................................................................................................................. 304 Wiring Inspection ........................................................................................................................................... 304 Battery............................................................................................................................................................ 305 Battery Removal ................................................................................................................................. 305 Battery Installation ............................................................................................................................. 305 Electrolyte Filling (Convectional Battery Only ................................................................................... 350 Initial Charge ...................................................................................................................................... 305 Precautions ........................................................................................................................................ 350 Charging Condition Inspection ........................................................................................................... 306 Refreshing Charge .............................................................................................................................. 306 Alternator ....................................................................................................................................................... 307 Alternator Cover Removal.................................................................................................................. 307 Alternator Cover Installation ............................................................................................................. 307 Alternator Rotor Removal .................................................................................................................. 307 Alternator Rotor Installation .............................................................................................................. 307 Alternator Stator Removal ................................................................................................................. 308 Alternator Stator Installation ............................................................................................................. 308 Charging System............................................................................................................................................. 309 Regulator / Rectifier Removal ............................................................................................................ 309 Regulator Rectifier / Output Voltage Inspection ............................................................................... 309 Regulator / Rectifier Inspection ......................................................................................................... 310 Ignition System .............................................................................................................................................. 311 Spark Plug Removal / Installation ...................................................................................................... 311 Spark Plug cleaning / Inspection ........................................................................................................ 311 Spark Plug Gap ................................................................................................................................... 311 Ignition Coil Removal ......................................................................................................................... 311 Ignition Coil Installation ..................................................................................................................... 311 Ignition Coil Inspection ...................................................................................................................... 312 Pickup Coil Removal ........................................................................................................................... 313 Pickup Coil inspection ........................................................................................................................ 313 Rotor Inspection................................................................................................................................. 313 ECU ................................................................................................................................................................. 313 ECU Unit Removal .............................................................................................................................. 313 ECU Unit Inspection ........................................................................................................................... 314 ECU Unit Installation .......................................................................................................................... 314 Electric Starter System.................................................................................................................................. 314
294

Starter Motor Removal ...................................................................................................................... 314 Starter Motor Installation .................................................................................................................. 315 Starter Relay, Inspection .................................................................................................................... 315 Starter Circuit Relay Inspection.......................................................................................................... 315 Lighting System .............................................................................................................................................. 316 Headlight Beam Vertical Adjustment................................................................................................. 316 Headlight Beam Horizontal Adjustment ............................................................................................ 316 Headlight Bulb Replacement.............................................................................................................. 316 Headlight Unit Removal ..................................................................................................................... 317 Headlight Unit Installation ................................................................................................................. 317 Taillight Bulb Replacement ................................................................................................................ 317 License Bulb Replacement ................................................................................................................. 318 Headlight Relay Inspection ................................................................................................................ 318 Turn Signal Flasher Unit Inspection ................................................................................................... 318 Meters ............................................................................................................................................................ 319 Meter Removal/Disassembly ............................................................................................................. 319 Meter Assembly/Installation ............................................................................................................. 320 Tachometer Inspection ...................................................................................................................... 320 Speedometer Inspection .................................................................................................................... 320 Switches ......................................................................................................................................................... 321 Switch Inspection ............................................................................................................................... 321 Fuses .............................................................................................................................................................. 321 Main Fuse Removal ............................................................................................................................ 321 Auxiliary Fuse Removal ...................................................................................................................... 321 Fuse Installation ................................................................................................................................. 321 Fuse Inspection .................................................................................................................................. 321

295

Exploded View

296

297

298

REF. NO.
33

PART DESCRIPTION
LOCKSET, TEXT SWITCH, IGNITION, INCL KEYS FILLER CAP ASSY, FUEL TANK

TORQUE (NM) REMARKS

33

LOCKSET, TEXT SWITCH, IGNITION, INCL KEYS FILLER CAP ASSY, FUEL TANK

33

LOCKSET, TEXT SWITCH, IGNITION, INCL KEYS FILLER CAP ASSY, FUEL TANK

32

LOCKSET, UK SWITCH, IGNITION, INCL KEYS FILLER CAP ASSY, FUEL TANK

32

LOCKSET, UK SWITCH, IGNITION, INCL KEYS FILLER CAP ASSY, FUEL TANK

32

LOCKSET, UK SWITCH, IGNITION, INCL KEYS FILLER CAP ASSY, FUEL TANK

32

LOCKSET, UK SWITCH, IGNITION, INCL KEYS FILLER CAP ASSY, FUEL TANK

32

LOCKSET, UK SWITCH, IGNITION, INCL KEYS FILLER CAP ASSY, FUEL TANK

32

LOCKSET, UK SWITCH, IGNITION, INCL KEYS FILLER CAP ASSY, FUEL TANK

32

LOCKSET, UK SWITCH, IGNITION, INCL KEYS FILLER CAP ASSY, FUEL TANK

32

LOCKSET, UK SWITCH, IGNITION, INCL KEYS FILLER CAP ASSY, FUEL TANK

32

LOCKSET, UK SWITCH, IGNITION, INCL KEYS FILLER CAP ASSY, FUEL TANK

32

LOCKSET, UK SWITCH, IGNITION, INCL KEYS FILLER CAP ASSY, FUEL TANK

32

LOCKSET, UK SWITCH, IGNITION, INCL KEYS FILLER CAP ASSY, FUEL TANK

32

LOCKSET, UK SWITCH, IGNITION, INCL KEYS

299

FILLER CAP ASSY, FUEL TANK 32 LOCKSET, UK SWITCH, IGNITION, INCL KEYS FILLER CAP ASSY, FUEL TANK 32 LOCKSET, UK SWITCH, IGNITION, INCL KEYS FILLER CAP ASSY, FUEL TANK 32 LOCKSET, UK SWITCH, IGNITION, INCL KEYS FILLER CAP ASSY, FUEL TANK ECU TUNE, US ECU TUNE, US ECU TUNE, US ECU TUNE, EURO 3 ECU TUNE, EURO 3 ECU TUNE, EURO 3 ECU TUNE, EURO 3 ECU TUNE, EURO 3 ECU TUNE, EURO 3 ECU TUNE, EURO 3 ECU TUNE, EURO 3 ECU TUNE, EURO 3 ECU TUNE, EURO 3 ECU TUNE, EURO 3 ECU TUNE, EURO 3 ECU TUNE, EURO 3 ECU TUNE, EURO 3 25 52 ECU, OMEX, EURO HARNESS, MAIN SUB-HARNESS, TILT SWITCH 53 SUB HARNESS, REAR HARNESS, MAIN, TYPE APPROVAL FUSE, MINI, 10A FUSE, 30A RELAY, GROMMET 27 24 54 LEAD, STARTER RELAY, FLASHER, BULB FAILURE, 10W X 12.8V FUSE BOX RELAY, NORMALLY OPEN SUB-HARNESS, TILT SWITCH, EURO LEAD, EARTH, BATTERY TO ENGINE LEAD, POSITIVE, STARTER 51 CABLE TIE, 70MM X 2.6MM,
TO SUPPORT HARNESS TO FRAME TO BE USED WITH TILT SWITCH OMEX 600

300

BLACK 50 20 21 22 23 28 29 30 31 1 2 3 4 5 6 7 48 49 CABLE TIE, 203MM X 4.8MM, BLACK SWITCH, FALL DETECT FOAM, RELAY BOX WASHER, PENNY, M4 X 4.3 X 12 X 1.0 BOLT, CAP HD, M4 X 25 X 0.7 HORN ASSY, HI-TONE SPRING WASHER, M8 WASHER, M8, 8.4 X 16 X 1.6 BOLT, BUTTON HD, INT HEX, M8 X 16 IGNITION COIL PACK BOLT, CAP HD, M6 X 40 X 1.0 LEAD, IGNITION, KIT IGNITION LEAD, RH IGNITION LEAD, LH BATTERY, YTZ14S STRAP, BATTERY GASKET, FILLER NECK GASKET, FILLER CAP FUEL FILLER NECK INSERT FUEL FILLER NECK INSERT SEAL WASHER, M6, 6.4 X 12 X 1.6 BOLT, SECURITY, M6 BOLT, CAP HD, M5 X 3O X 0.8 BOLT, CAP HD, M5 X 15 X 0.8 MAP SENSOR SPEEDO TACHO ANTI-VIBRATION RUBBER, INSTRUMENTS COVER, INSTRUMENTS SPACER, INSTRUMENT COVER DOMED NUT, M4 SWITCH, INSTRUMENT PANEL PLAQUE SET, COMMANDO SE PLAQUE, COMMANDO SPORT PLAQUE, COMMANDO CAFE RACER PLAQUE, HAND-BUILT AT DONINGTON PARK INSTRUMENT PANEL BOLT, CAP HD, M8 X 20 X 1.25 REGULATOR RECTIFIER, RR58 BOLT, CAP HD, M6 X 16 X 1.0 20 BETWEEN INSTRUMENT COVER AND CLOCKS
TO CLAMP INSTRUMENT COVERS
TO CLAMP LOCKSET TO CLAMP FILLER CAP TO BLANK REMAINING FILLER NECK HOLES FITS INSIDE FUSE BOX LID, BATTERY STRAP, REAR LIGHT

TO SUPPORT HARNESS TO FRAME

FOR ROLLOVER SWITCH

FOR ROLLOVER SWITCH ECIE

18 10

MOUNTED ON LOWER YOKE

TO CLAMP IGNITION COIL PACK

YUASA HIGH SPEC

FOR SPARES ONLY FOR SPARES ONLY

44 45 46 47 26 34 35 36 37 38 39 40 41 41 41 41 42 43 12 13

FLAT ALUMINIUM PART, MACHINED PANEL TO YOKE FIXING TO CLAMP REGULATOR RECTIFIER

301

16 17 18 19 11 14 15 8 9 10 10 55

BRACKET, ECU, XM BOLT, CAP HD, M6 X 12 X 1.0 WASHER, PENNY, M6, 6.4 X 18 X 1.6 BOLT, CAP HD, M6 X 16 X 1.0 MOUNT, RELAY, RUBBER BRACKET, TWIN RELAY BOLT, CAP HD, M8 X 20 SPLASH SHIELD, TANK, UNDERSIDE STRAP, RUBBER, SPLASH SHIELD CLIP, BARBED FASTENER, BLACK, LONG CLIP, BARBED FASTENER, BLACK DUAL LOCK, LOW PROFILE, RECLOSEABLE FASTENER
USED WITH FUSE BOX BOLTS TO CLAMP FUSE BOX ENGINE STOP' AND 'FUEL LIGHT' RELAYS TO HOLD THE RELAY TO HOLD THE RELAY BRACKET

TO CLAMP SPLASH SHIELD TO CLAMP SPLASH SHIELD TO FIX SPLASH SHIELD TO BATTERY BOX UNDERSIDE

302

303

304

305

REF. NO.
1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 19 19 19 20 19 20 19 20 3 3 3 4 5 6 7 8 9 10 11 12 13 14 24 23

PART DESCRIPTION
HEADLIGHT, LH DIP HEADLIGHT, LH DIP HEADLIGHT, LH DIP HEADLIGHT, LH DIP HEADLIGHT, LH DIP HEADLIGHT, LH DIP HEADLIGHT, LH DIP HEADLIGHT, RH DIP HEADLIGHT, RH DIP HEADLIGHT, RH DIP HEADLIGHT, RH DIP HEADLIGHT, RH DIP HEADLIGHT, RH DIP HEADLIGHT, RH DIP HEADLIGHT, RH DIP HEADLIGHT, RH DIP HEADLIGHT, RH DIP HEADLIGHT, RH DIP REFLECTOR, REAR, RED REFLECTOR, REAR, RED REFLECTOR, REAR, RED BRACKET, REAR REFLECTOR, STEEL REFLECTOR, REAR, RED BRACKET, REAR REFLECTOR, STEEL REFLECTOR, REAR, RED BRACKET, REAR REFLECTOR, STEEL REFLECTOR, FRONT, AMBER REFLECTOR, FRONT, AMBER REFLECTOR, FRONT, AMBER BULB, HEAD LIGHT, HEAVY DUTY SNAP BUSHING, 38MM X 11.5MM SPRING WASHER, M8 BOLT, CAP HD, M8 X 22 X 1.25 HEADLIGHT BRACKET, LH, CAST HEADLIGHT BRACKET, RH, CAST HEADLIGHT HEADLIGHT UPPER HEADLIGHT LOWER HEADLIGHT RH HEADLIGHT LH BRACKET RUBBER BRACKET RUBBER, USD, BRACKET RUBBER, USD, BRACKET, CAST, USD FORKS BRACKET, CAST, USD FORKS

TORQUE (NM) REMARKS

TO CARRY WIRES INTO HEADLIGHT USED WITH HEADLIGHT BOLTS TO CLAMP HEADLIGHT

NO. PLATE LIGHT, BULB BOLT, CAP HEAD, M5 X 15 X 0.8 7

TO CLAMP NUMBER PLATE LIGHT

306

15

INDICATOR, RHF,LHR LENS, INDICATOR, WHITE SCREW, INDICATOR LENS BULB, INDICATOR, ORANGE

ECIE

16

INDICATOR, LHF, RHR LENS, INDICATOR, WHITE SCREW, INDICATOR LENS BULB, INDICATOR, ORANGE

ECIE

25 26 27 17 18 21 22

REAR LIGHT, ECE MOUNT, ANTI VIBRATION, REAR LIGHT BOLT, CAP HD, M4 X 20 X 0.7 BOLT, CAP HD, M6 X 16 X 1.0 LOCKNUT, FLANGED, M6x1.0 BRACKET, REFLECTOR, REAR, XM BOLT, BUTTON HD, M5x12
REFLECTOR BRACKET TO NUMBER PLATE HANGER BETWEEN LIGHT AND BODY WORK FOR MOUNTING REAR LIGHT FOR MOUNTING INDICATORS FOR MOUNTING INDICATORS

307

308

REF. NO.
1 2

PART DESCRIPTION
SENSOR, TEMPERATURE WASHER, M12, 12.2 X 17.9 X 2, COPPER DOW CORNING 340 HEAT SINK COMPOUND, 100g SENSOR, SPEED BOLT, CAP HD, M6 X 12 X 1.0, DIN 912, 12.9, BZP SWITCH, NEUTRAL, M10x1.25 WASHER, M10, COPPER, ID 10.2, OD 13.9 X 1.0 SPARK PLUG, CR9EB

TORQUE (NM) REMARKS

15
USED WITH TEMPERATURE SENSOR APPLY TO TEMP SENSOR AS REQUIRED CAM POSITION AND GEARBOX ROAD SPEED

3 4 5 6 7

12 12

TO CLAMP SPEED SENSORS

USED WITH NEUTRAL SWITCH

12

FIRST USE TORQUE ONLY

309

REF. NO.
1 2 9 3 10 4 5 6 7 8

PART DESCRIPTION
ROTOR, ALTERNATOR BOLT, CAP HD, M8 X 16 X 1.25, DIN 912, 12.9 STATOR, ASSY STATOR SENSOR, CRANK POSITION BOLT HEX, HD, M6 X 35 DIN 933, 10.9 PIN, DOWEL, 4.0 X 10, SOLID, DIN 6325 H&G P-CLIP, ALUMINIUM, ID 6.5MM BOLT, BUTTON HD, INT HEX, M5 X 10, ISO 7380, 10.9 BOLT, CAP HD, M5 X 12 X 0.8, DIN 912, 12.9 ADHESIVE, ANAEROBIC, TB1342, 250G, (LOW STRENGTH)

TORQUE (NM) REMARKS

25
THREEBOND 1327

12

TO CLAMP STATOR TO COVER STATOR TO COVER GENERATOR LEAD TO COVER TO CLAMP P-CLIP TO COVER (TB1342) USED TO CLAMP CRANK SENSOR THREEBOND 1342

5 5

310

Parts Location

2 1

3 4 6 5 7 8 9

15

10

11 14 13 12

18 23 20 22 21 29 19 17

16

30 28

27

24

25 1 2 3 4 5 6 Headlight, Signal Light Switch Fuel light Relay Fuel Pump Head Temp Sensor Oil Pressure Switch 9 10 11 12 13 14 ECU Regulator/Rectifier Crank Sensor Side Stand Switch Alternator Cam Sensor 17 18 19 20 21 22

26 Battery Main Fuse Throttle body/Idle Air Starter Motor Air Temp Sensor Brake Light Switch Rear 25 26 27 28 29 30 Natural Switch Lambda Sensors Ignition Clocks Number Plate bulb Front Brake Switch 311

7 Road Speed Sensor 8 Relay/Fuse Box

15 Ignition Coil 16 Starter/Kill Switch

23 Brake Light 24 Indicators

Wiring Diagram

312

Specification
Item Battery: Type Capacity Voltage Charging system: Alternator type Charging voltage Idle (regulator/rectifier output voltage) Alternator output voltage Charging Coil resistance Regulator/rectifier resistance Ignition System: Crank Sensor air gap crank sensor resistance Ignition coil: Arcing distance Primary coil resistance Secondary coil resistance Spark plug: Spark plug gap Spark plug cap resistance ECU resistance Standard YTZ 14 S 12 V 14.5 Ah 12.6 V or more Three-phase AC 12 ~ 20V more than 63 V @4000 r/min (rpm) 0.3 ~ 2 (x 1 ) in text 0.4 ~ 0.7 mm 100 ~ 150 (x 10 ) 7mm or more 0.1 ~ 0.4 3 ~ 10 k (x 1k) 0.8mm ~0.9mm 3 ~ 10 k (x 1k) in text Service Limit --------------------------1mm -----

313

Precautions Note: There are a number of important precautions that are musts when servicing electrical systems. Lean and observe all the rules below. Do not reverse the battery lead connections. This will burn out the diodes in the electrical parts. Always check battery condition before condemning other parts of an electrical system. A fully charged battery is a must for conducting accurate electrical system tests. The electrical system should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the parts can damage them. To prevent damage to electrical parts, do not disconnect the battery leads or any other electrical connections when the ignition switch is on, or the engine is running. Because of the large amount of current, never keep the starter switch pushed when the starter motor will not turn over, or the current may burn out the starter motor windings. Do not use a meter illumination bulb for other than the voltage or wattage specified in the wiring diagram, as the meter panel could be warped by excessive heat radiated from the bulb. Take care not to short the leads that are directly connected to the battery positive (+) terminal to the chassis ground. Troubles may involve one or in some cases all items. Never replace a defective part without determining what CAUSED the failure. If the failure was caused by some other item or items, they too must be repaired or replaced, or the new replacement will soon fail again. Make sure all connections in the circuit are clean and tight, and examine wires for signs of burning, fraying, etc. Poor wires and bad connections will affect electrical systems operation. Measure coil and winding resistance when the part is cold (at room temperature).

Electrical Wiring Wiring Inspection Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. Pull each connector apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Check the wiring for continuity. Use the wiring diagram to find the ends of the lead which is suspected of being a problem. Connect the hand tester between the ends of the leads. Set the tester to 1 range, and read the tester. If the tester does not read 0 , the lead is defective. Replace the lead or the wiring harness if necessary.

314

Battery Battery Removal Remove: Seat (see Frame chapter). Fuel Tank (see Fuel System chapter) Remove the battery strap. Disconnect the battery negative ( - ) cable first, and then the positive ( + ) cable. Take out the battery. Battery Installation Connect the battery positive ( + ) cable first, and then the negative ( - ) cable. Run the battery cables according to the Cable, Wire, and Hose Routing section of the General Information chapter. Install: Battery Strap Fuel Tank (See Fuel System chapter) Seat (see Frame chapter) Electrolyte Filling Note: Only use a maintenance free battery and follow manufactures instructions to fill if required. Initial Charge Change at 0.9 A for 2~3 hours Precautions Battery does not need topping up. Warning: Do not top up as sealed battery type only. Refreshing charge: If an engine will not start, a horn sounds weak, or lights are dim, it indicates the battery has been discharged. Give refresh change for 5 to 10 hours with charge current shown in specification (see Refreshing Charge). When a fast charge is inevitably required, do it following precisely the maximum charge current and time conditions indicated on the battery.

Caution: This battery is designed to sustain no unusual deterioration if refresh-charged according to the method specified above. However, the battery performance may be reduced noticeably if charged under conditions other than given above. Never remove the sealing plug during refresh charge.
315

When you do not use the motorcycle for months, give a refresh charge before you store the motorcycle and store it with the negative lead removed. Give a refresh change every six months during storage. Battery life: o If the battery will not start the engine even after several refresh charges, the battery has exceeded its useful life. Replace it. (Provided, however, the vehicle`s starting system has no problem.)

Warning: Keep the battery away from sparks and open flames during charging, since the battery gives off an explosive gas mixture. When using a battery charger, connect the battery to the charger before turning on the charger. This procedure prevents sparks at the battery terminals which could ignite any battery gasses. No fire should be drawn near the battery, or no terminals should have the tightening loosened. The battery contains acid. Be careful not to have it touch your skin or eyes. If it touches, wash it off with liberal amount of water. Get medical attention if severe. Charging Condition Inspection Note: Battery charging condition can be checked by measuring battery terminal voltage. Remove: Seat (see Frame chapter) Fuel Tank (see Fuel system chapter) Disconnect the battery terminal leads.

Caution: Be sure to disconnect the negative terminal first. Measure the battery voltage Battery Terminal Voltage: Standard: 12.6 V more Refreshing Charge Remove the battery (see Battery Removal). Refresh-charge by following method according to the battery terminal voltage Caution: This battery is a sealed type. Never remove the seal cap even at charging. Never add water. Charge with current and time as stated below. Terminal Voltage: 11.5 ~ 12.6 V Standard Change: Quick Charge: 0.9 A x 5 ~ 10 h 4.0 A x 1 hour

316

Caution: If Possible do not quick charge. If the quick charge is done due to unavoidable circumstances, do standard change later on. Terminal Voltage: less than 11.5 V Charging Method: 0.9 A x 20 Hours

Note: Raise the voltage (25 V maximum), and charge for about 5 minutes. If ammeter shows no change in current after 5 minutes, a new battery is required. The current, if it can flow into the battery, tends to become excessive. Adjust the voltage as often as possible to keep the current at standard (0.9 A). Determine battery condition after refreshing charge. Determine the battery condition 30 minutes after completion of the charge by measuring the terminal voltage according to the table below. 12.6 V or higher: 12.0 ~ 12.6 V or lower: 12.0 V or lower: Alternator Alternator/Clutch Cover Removal Alternator cover removal (see Clutch chapter) Alternator/Clutch Cover Installation Alternator cover Installation (see Clutch chapter) Fill the gearbox with oil (see Engine Lubrication System chapter). Route the alternator leads in accordance with the Cable, Wire, and Hose Routing section in the General Information chapter. Alternator Rotor Removal Remove: Shift Pedal Spline Alternator / Clutch Cover (see this chapter) Unscrew the Rotor bolts 6 X [A]
A Alternator Rotor Installation Clean the following portions with an oil-less cleaning fluid such as trichloroethylene or acetone: Threads of rotor bolts Rotor Warning: These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods. Be sure to heed the fluid manufactures warnings. 317

Good > No action required Charge insufficient > Recharge Unserviceable > Replace

Fit the rotor onto the trigger disc and install the rotor bolts. Torque Rotor Bolts: 20 Nm Apply Threebond 1327 to threads Install a new gasket and the Clutch cover (see this chapter). Install the shift Pedal (See Clutch chapter)

Alternator Stator Removal Remove Clutch / alternator cover (See Clutch chapter). Remove pickup coil (see Pickup Coil Removal). Remove mounting bolts, four total. Remove P-clips. Remove Stator taking note of wiring routing.

Alternator Stator Installation Ensure Dowel is installed in correct position and line stator up with dowel. Route wiring in same position as before disassembly, ensuring wiring lies flat and it tied to pick up towers, to maintain clearance to rotor. Install and tighten all P-clips bolts with thread lock 1342.
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Torque: P-Clip Bolts: 5NM Install Stator mounting bolts with thread lock 1342.

Torque: Stator Mounting Bolts: 12NM Install pick up (see Pickup Coil Installation). Install Clutch / Alternator cover (See Clutch chapter).

Charging System Regulator / Rectifier Removal Pull off the regulator/rectifier rubber boot [A] and connector [B]. Remove the regulator/rectifier bolts [C]. Remove the regulator/rectifier [D].

Regulator/Rectifier Output Voltage Inspection Check the battery condition (see battery section). Warm up the engine to obtain actual alternator operating conditions. Check that the ignition switch is turned off and connect the hand tester to the battery terminals. Start the engine, and note the voltage readings at various engine speeds with the headlight turned on and off. The readings should show nearly battery voltage when the engine speed is low, and, as the engine speed rises, the readings should also rise. But they must be kept under the specified voltage. Regulator Voltage - @ Meter Range 25 V: 14 ~ 15V Turn off the ignition switch to stop the engine and disconnect the hand tester. If the regulator/rectifier output voltage is kept between the vales given above, the charging system is considered to be working normally. If the output voltage is much higher than the values specified in the table, the regulator/rectifier is defective or the regulator/rectifier leads are loose or open. If the battery voltage does not rise as the engine speed increases, then the regulator/rectifier is defective or the alternator output is insulated for the loads. Check the alternator and regulator/rectifier to determine which part is defective.

Alternator Inspection
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Note: There are three types of alternator failures: short, open (wire burned out), or less in rotor, or rotor magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all. A loss in rotor magnetism, which may be caused by dropping or hitting the alternator by leaving it near an electromagnetic field, or just by aging, will result in a low output. To check the alternator output voltage, do the following procedures. Disconnect the alternator Connector [A]. Connect the hand tester to any two out of the three output pins coming from the alternator. Start the engine Run it at three different rev ranges Set the meter to 250 V range Voltage Alternator: more than 34 V If the output voltage shows the value above, the alternator operates properly and the regulator/rectifier is damaged. A much lower reading than given in the table indicates that the alternator is defective. Check the stator coil resistance as follows: Stop the engine. Disconnect the alternator connector. Connect the hand tester to two of the three output wires. Note the readings (total 3 measurements). Resistance Stator: 0.3 1.0 If there is more resistance than shown above, or no hand tester reading (infinity) for any of the two leads, the stator has an open lead and must be replaced. Much less than this resistance means the stator is shorted, and must be replaced. Using the highest resistance range of the hand tester measure the resistance between each of the alternator leads and chassis ground. Any hand tester readings less than infinity indicates a short, necessitating stator replacement. If the stator coils have normal resistance, but the voltage check showed the alternator to be defective, then the rotor magnetism has probably weakened, and the rotor must be replaced.

Regulator/Rectifier Inspection Turn off the ignition switch. Disconnect the regulator/rectifier connector. Set the hand tester to the 1 k range and make the measurements shown below. If tester readings are not as specified, replace the regulator/rectifier. Range x 1 k Tester Positive (+) Lead Connections
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Warning: The ignition system produces extremely high voltage. Do not touch the spark plug, ignition coil, or spark plug lead while the engine is running, or you could receive a severe electrical shock. Caution: Do not disconnect the ECU connectors while the engine is running. This is to prevent ECU damage. Spark Plug Removal/Installation Remove the HT leads from spark plug cap Remove or install the spark plug using the spark plug wrench Torque Spark Plug: 12 Nm Spark Plug Cleaning/Inspection Clean the spark plug, preferably in a sandblasting device and then clean off any abrasive particles. The plug may also be cleaned using a high flash point solvent and a copper wired brush or other suitable tools. If the center electrode or side electrode are corroded or damaged, or if the insulator is cracked, replace the plug. Use the standard spark plug or its equivalent. Spark Plug Gap Measure the gap with a wire-type thickness gauge. If the gap is outside the service limit replace the spark plug. Spark plug Gap Standard: 0.8 mm Service Limit: 1.0 mm Ignition Coil Removal Remove the fuel tank (see Fuel System chapter). Pull the spark plug lead off the spark plug. Disconnect the coil lead [A] Remove coil bolt [B] Remove coil [C] Ignition Coil Installation Install ignition coil [A] as shown Install ignition coil bolt [B]
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(-)

N1 B111 B112 B113 B26

N1 1~7 1~7 1~7 2~10

B111 20~200 40~500 40~500 1~7

B112 20~200 40~500 40~500 1~7

B113 20~200 40~500 40~500 1~7

B26 20~80 20~200 20~200 20~200 -

Ignition System

Torque Ignition coil bolt: 10 Nm

Connect coil lead [C] Connect the spark plug leads, with the shorter lead going to the left hand cylinder, and the longer to the right hand. Install the fuel tank (see Fuel System chapter).

Ignition Coil Inspection Remove the ignition coil (see this chapter). Measure the arcing distance with a suitable commercially available coil tester to check the condition of the ignition coil. Connect the ignition coil with the spark plugs left attached to the end of the spark plug leads to the tester in the manner prescribed by the manufacture and measure the arcing distance. Ignition Coil Arcing Distance: 7 mm or more Warning: To avoid extremely high voltage shocks, do not touch the ignition coil body or leads. If the distance reading is less than the specified value, the ignition coil or spark plug cap is defective. To determine which part is defective, measure the arcing distance again with the spark plug cap removed from the ignition coil. Remove the cap by turning it counter clockwise. If the arcing distance is subnormal as before, the trouble is with the ignition coil itself. If the arcing distance is now normal, the trouble is with the spark plug cap. If the coil tester is not available, the coil can be checked for a broken or badly shorted winding with a hand tester. Note: The hand tester cannot detect layer shorts and shorts resulting from insulation brake down under high voltage. Measure the primary winding resistance as follows. Connect the tester between the coil terminals. Set the tester between the coil terminals. Measure the secondary winding resistance as follows. Remove the plug cap by turning it counter clockwise. Connect the tester between the spark plug lead and terminal. Set the tester to the 1 k range and read the tester. Measure primary winding resistance [A]. Measure secondary winding resistance [B]. Ignition Coil [C] Ignition Coil Winding Resistance Primary: 0.14~ 0.22
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Secondary:

3.8 ~ 5.8 k

If the hand tester does not read as specified, replace the coil.

Pickup Coil Removal Remove the clutch cover (see Clutch chapter). Pull the pickup coil lead grommet [A] out of the notch of the cover. Disconnect the pickup coil and alternator leads. Remove the p-clips securing the pickup coil and alternator wires. Remove the Alternator (see this chapter). Unbolt the pickup coil and remove (Take note of wire location and location of cable-tie). Pick up coil Inspection Remove the pickup coil (see this chapter). Connect the hand tester between the pickup coil leads Set the tester to the x 10 range and read the tester. Pickup Coil Resistance 100 ~200 (x 10 ) If there is more resistance than the specified value, the coil has an open lead and must be replaced. Much less than this resistance means the coil is shorted, and must be replaced. Using the highest resistance range of the hand tester, measure the resistance between the pickup coil lead terminals and chassis ground. Any Hand tester reading less than infinity indicates a short, necessitating replacement of the pickup coil assembly.

Rotor Inspection Check the surface for damage such as chipping or grooving. If the timing projection on the flywheel is visibly damage, replace the rotor. Electronic Control Unit (ECU) Electronic Control Unit (ECU) Removal Disconnect tilt switch harness [A]

A 323

Remove tilt switch harness bolts [A], tilt switch connecter [B]. Remove Pressure sensor connection [C].
C A B

Remove Relay box bolts [A], take out relay box, and remove rear sub harness from main harness.

Remove ECU bracket bolts [A] and ECU bracket. Remove ECU. Caution: Do not drop or strike the ECU and this will damage the ECU.
A

ECU Inspection Visually inspect the ECU for corrosion, damage and water ingress. If all connections are good, and the ECU still does not function as intended contact your Norton Dealer. ECU Installation ECU Installation is the reverse of the ECU Removal process detailed above. Torque ECU Bracket: 8 Nm Relay Box: 8 Nm Tilt Switch: 6 Nm
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Starter System Starter Motor Removal Remove: Clutch Cover (see Clutch chapter) Remove electrical connections from back of starter. [A] Remove starter motor bolts [A]. Gently remove starter motor.

Starter Motor Installation Clean any gasket sealant off the crank case. Install a new starter motor gasket and use gasket sealant on both sides. Install starter motor and bolts. Torque Starter motor bolts: 20 Nm Install Clutch Cover (see Clutch chapter).

Starter Relay Inspection Remove the seat (see Frame chapter) Remove the starter relay [A]. Connect hand tester positive (+) to connection point 3 and negative (-) to 5. Connect (12V) power positive (+) to connection point 2 negative (-) to 1. If the relay does not work as specified, the relay is defective. Replace the relay. Testing Relay Hand tester range: Criteria: Criteria: Starter Circuit Relay Inspection

X 1 range When battery is connected > 0 when battery is disconnected > infinite

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Remove the seat (see Frame chapter) Remove the starter relay [A]. Connect hand tester positive (+) to connection point 3 and negative (-) to 5. Connect (12V) power positive (+) to connection point 2 negative (-) to 1. If the relay does not work as specified, the relay is defective. Replace the relay.

Testing Relay Hand tester range: Criteria: Criteria: Lighting System

X 1 range When battery is connected > 0 when battery is disconnected > infinite

Headlight Beam Vertical Adjustment Slacken headlight bolts [A]. On high beam, the brightest point should be slightly below horizontal with the motorcycle on its wheels and the rider seated. Adjust the headlight beam to local regulations. Adjust the vertical adjustment by tilting the headlight unit up or down. Tighten headlight bolts [A]. Torque Headlight Bolts: 12 Nm Headlight Beam Horizontal Adjustment Adjust the beam using the adjuster screw [A] clockwise or anti clockwise to move the beam right or left.

Headlight Bulb Replacement Remove front headlight screw [A]. Remove the front headlight section [B] from the headlight body.

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Remove the connector [A] from the back of the light. Remove the bulb [B] from the connector and replace with a new one. Install the connector and the front head light section, tighten head light screw. Check the headlight aim after installation (see this chapter). Headlight Unit Removal Following on from headlight bulb replacement. Remove head light bolts [A] taking care to support the headlight when these have been removed. Feed all the electrical connections out the back of the headlight.

Headlight Unit Installation Install the head light unit so the box connector is at the bottom. Feed all the electrical connections through into the back of the head light, ensure no wires are snagged. Install bolts [A] hand tight. Install the lighting into the headlight front section and install the front section.

Tighten screw on front section [A]

Set headlight aim to local legislations and tighten headlight bolts [A] Torque Headlight Bolts: 12 Nm

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Taillight Bulb Replacement Note: it is recommended that Kevlar gloves be worn when changing the bulb due to the risk associated with the glass shattering. Take out the screws [A] in the tail light lens. Pull the lens off. Push the bulb in [A] firmly, turn it counter clockwise [B], and pull it out. Be sure the socket is clean Insert the new bulb, aligning the pins with the grooves in the walls of the socket (one is higher than the other ensure these are correctly alight with the corresponding groves). Push the bulb in, turn it clockwise, and release it. It should lock in position. Tighten the two screws. Be careful not to over tighten them.

License Light Bulb Replacement Remove bolt [A] from number plate light body. Hold the rubber light mount, and pull the rubber mount out of the body. Hold the rubber mount and pull the bulb out in a rocking motion. Insert new bulb by pushing in with tabs aligned. Headlight Relay Inspection Remove the seat (see Frame chapter) Remove the headlight relay [A]. Connect hand tester positive (+) to connection point 3 and negative (-) to 5. Connect (12V) power positive (+) to connection point 2 negative (-) to 1. If the relay does not work as specified, the relay is defective. Replace the relay. Testing Relay Hand tester range: Criteria: Criteria:

X 1 range When battery is connected > 0 when battery is disconnected > infinite

Turn Signal Flasher Unit Inspection

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Note: Since the turn signal relay is designed to operate correctly only when two turn signals (one front and one rear) and the turn signal indicator light are properly connected in the circuit, trouble may result from a burned out bulb, a bulb of incorrect wattage, loose wiring, as well as from a defect in the relay itself. In general, if the trouble with the circuit is common to both right and left turn signals, it is probably caused by a defective turn signal flasher unit, although it may be due to a bad switch, wiring, or battery. If the trouble is with only one side - either right or left, then the flasher unit is not at fault since one is used for both sides. Remove the seat (see Frame chapter) Check the condition of the flasher unit [A] for the following problems: Neither right or left turn signal comes on at all: Check the battery voltage is normal. Unplug the flasher unit leads and use the hand tester to check that there is continuity (close to zero ohms) between the relay terminals. If there is no tester reading (infinity) or if there are several ohms resistance, replace the flasher unit with a new one. Turn the tester to the 25 ~V DC range, connect the (+) tester lead to the one lead that was disconnected from the flasher unit, and connect (-) tester lead to the other lead. With the ignition switch on, first switch the turn signal switch to the R and then to the L position. The tester should register battery voltage at either position. If it does not, the fuse, ignition switch, or wiring is at fault. Both right or left turn signals come on and stay on or flash too slowly: Check that battery voltage is nominal. Check that all wiring connections are good. Check that the turn signal bulbs and indicator bulb are of the correct wattage. If all of the above check well, replace the flasher unit. A signal light on one side comes on: Either the light that does not come on is burned out or of the incorrect wattage, or the wiring is broken or improperly connected. Neither light on one side comes on. Unless both lights for that side are burned out, the trouble is with the turn signal switch. Flashing rate is too fast: If this occurs on both the right and left sides, check that the battery is not being overcharged. If the alternator and the battery voltage are normal, replace the turn signal flasher unit. If this occurs on only one side, one or both of the turn signal bulbs are too high wattage.

Meters
329

Meter Removal/Disassembly Remove meter cover bolts [A]. Remove meter covers [B].

Disconnect four meter connectors [A]. Pull the meters up through the instrument panel [B].

Meter Assembly/Installation Pull the meters up through the instrument panel [B]. Connect four meter connectors [A].

Install meter covers [B]. Tighten meter cover bolts [A].

Tachometer Inspection Check the tachometer circuit wiring. If all wiring and components other than the tachometer unit check out good, the unit is suspect. Check the unit as shown. Remove and disassemble the meters (see this chapter).

Caution: When inspecting the tachometer operation, remove the ECU connections from the back to avoid damage to the ECU unit. Remove both connector boxes. On the 8 Pin socket connect positive (+) 12V supply to point 1, and point 4. On the 8 Pin socket connect negative (-) to point 2.
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If the meter shows current trip mileage then the unit is functioning correctly and the problem is elsewhere in the circuit. If it does not shows anything then the unit is faulty and should be replaced.

Speedometer Inspection Check the speedometer circuit wiring. If all wiring and components other than the tachometer unit check out good, the unit is suspect. Check the unit as shown. Remove and disassemble the meters (see this chapter). Caution: When inspecting the speedometer operation, remove the ECU connections from the back to avoid damage to the ECU unit. Remove both connector boxes. On the 8 Pin socket connect positive (+) 12V supply to point 1, and point 4. On the 8 Pin socket connect negative (-) to point 2. Connect point 5 briefly to the positive supply, the needle should move. If it does not shows anything then the unit is faulty and should be replaced.

Switches Switch Inspection Using the hand tester, check to see that the switch connections as shown on the wiring schematic have continuity (about zero ohms) when closed. If it does not as specified, check all connections, if the switch has an open or short repair it or replace with a new one. Fuses Main Fuses Removal Remove the fuel Tank (see Fuel System chapter) Remove the fuse [A] from housing [B].

Auxiliary Fuse removal Remove the seat (see Frame chapter). Remove fuse box cover [A]. Remove relevant fuses by pulling.
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Fuse Installation If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of proper amperage. Fuse Inspection Remove the fuse (see Fuse Removal). Inspect the fuse element. If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and related components for a short circuit. Caution: When replacing a fuse, be sure the new fuse matches the specified fuse rating for that circuit. Installation of a fuse with a higher rating may cause damage to wiring and components.

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Appendix Additional Considerations for Racing ............................................................................................................ 323 Spark Plugs ......................................................................................................................................... 323 Spark Plugs Inspection ....................................................................................................................... 323 Trouble Shooting Guide ................................................................................................................................. 324 Nut, Bolt, and Fastener Tightness .................................................................................................................. 333 Tightness Inspection .......................................................................................................................... 333 General Lubrication........................................................................................................................................ 334 Lubrication ......................................................................................................................................... 334 Unit Conversion Table .................................................................................................................................... 335

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Additional Considerations for Racing This motorcycle has been manufactured for use in a reasonable and prudent manner and as a vehicle only. However, some may wish to subject this motorcycle to abnormal operation, such as would be experienced under racing conditions. NORTON STRONGLY RECOMMENDS THAT ALL RIDERS RIDE SAFELY AND OBEY ALL LAWS AND REGULATIONS CONCERNING THEIR MOTORCYCLE AND ITS OPERATION. Racing should be done under supervised conditions, and recognized sanctioning bodies should be contacted for further details. For those who desire to participate in competitive racing or relate use, the following information may prove useful. However, please note the following important notes. You are entirely responsible for the use of your motorcycle under abnormal conditions such as racing and Norton shall not be liable for damages which might arise from such use. Nortons Limited Motorcycle Warranty and Emissions Systems Warranty specifically exclude motorcycles which are used in competition or related uses. Please read the warranty carefully. When the motorcycle is operated on public roads, it must be in its original state in order to ensure safety and compliance with applicable regulation. Spark Plug The spark plug ignites the fuel and air mixture in the combustion chamber. To do this effectively and at the proper time, the correct spark plug must be used, and the spark plug must be kept clean and the gap must be within the specified range. Tests have shown the plug listed in the General Information Carbon Fouling chapter to be the best plug for general use. Since spark plug requirements change with the ignition and fuel adjustments and with riding conditions, whether or not a spark plug of the correct heat range is used should be determined by removing and inspecting the plug. When a plug of the correct heat range is being used, the electrodes Oil Fouling will stay hot enough to keep all the carbon burned off, but cool enough to keep from damaging the engine and the plug itself. This temperature is about 400 ~ 800C and can be judged by noting the condition and colour of the ceramic insulator around the centre electrode. If the ceramic is clean and of a light brown colour, the plug is operating at the right temperature. A spark plug for higher operating temperatures is used for racing such a plug is designed for better cooling efficiency so that it will not overheat and thus is often called a colder plug. If a spark plug with too cool a heat range is used that is, a cold plug that cools itself too well the plug will stay too cool to burn off the carbon, and the carbon will collect on the electrodes and the ceramic insulator. The carbon on the electrodes conducts electricity, and can short the centre electrode to ground by either coating the ceramic insulator or bridging across the gap. Such a short will prevent an effective spark. Carbon build-up on the plug can also cause other troubles. It can heat up red-hot and cause pre-ignition and knocking, which may eventually burn a hole in the top of the piston.

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Spark Plug Inspection Remove the spark plug and inspect the ceramic insulator. Whether or not the right temperature plug is being used can be ascertained by noting the condition of the ceramic insulator around the electrode. A light brown colour indicated the correct plug is being used. If the ceramic is black, it indicates that the plug is firing at too low a temperature, so the next hotter type should be used instead. If the ceramic is white, the plug is operating at too high a temperature and it should be replaced with the next colder type.

Normal Operation

Normal Operation

Caution: If the spark plug is replaced with a type other than the standard plug, make certain the replacement plug has the same thread pitch and reach (length of threaded portion) and the same type electrode (regular type or projected type) as the standard plug. If the plug reach is too short, carbon will build up on the plug hole threads in the cylinder head, causing overheating and making it very difficult to insert the correct spark plug later. If the plug reach is too short, carbon will build up on the plug hole threads in the cylinder head, causing overheating and making it very difficult to insert Over Heating the correct spark plug later. If the reach is too long, carbon will build up on the exposed spark plug threads causing overheating, pre-ignition, and possibly burning a hole in the piston top. In addition, it may be impossible to remove the plug without damaging the cylinder head. Note: The heat range of the spark plug functions like a thermostat for the engine. Using the wrong type of spark plug can make the engine run too hot (resulting in engine damage) or too cold (with poor performance, misfiring, and stalling).

Over Heating / Thermal Shock

Troubleshooting Guide This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. Engine Doesnt Start, Starting Difficult: Starter motor not rotating: Starter lockout or neutral switch trouble Starter motor trouble Battery voltage low Starter relay not contacting or operating Starter button not connected Wiring open or shorted
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Ignition switch trouble Engine stop switch trouble Fuse blown Engine wont turn over: Valve seizure Valve lifter seizure Cylinder, piston seizure Crankshaft seizure Balancer bearing seizure Connecting rod Small end Seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure No Fuel flow: No fuel in fuel tank Fuel line clogged Engine flooded: Starting technique faulty (when flooded, crank the engine with the throttle fully opened to allow more air to reach the engine.) No spark; spark weak: Battery voltage low Ignition switch not turned on Engine stop turned off Clutch lever not pulled in or gear not in neutral Spark plug dirty, broken, or maladjusted Spark plug cap or high tension wire trouble Spark plug cap shorted or not in good contact Spark plug incorrect ECU trouble Pickup coil trouble Ignition coil trouble Alternator damaged Ignition or engine stop switch shorted Neutral, or starter locknut switch trouble Wiring shorted or open Fuel/air mixture incorrect: Throttle body trouble ECU trouble Wiring shorted Compression Low: Spark plug loose
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Cylinder head not sufficiently tightened down No valve clearance Cylinder, piston worn Piston ring bad (worn, weak, broken, or sticking) Piston ring/groove clearance excessive Cylinder head gasket damaged Cylinder head warp Valve spring broken or weak Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface)

Poor Running at Low Speed: Spark weak: Spark plug dirty, broken, or maladjusted Spark plug cap or high tension wiring trouble Spark plug cap shorted or not in good contact Spark plug incorrect ECU trouble Pickup coil trouble Exciter coil shorted or open Ignition coil trouble Alternator damage Fuel/air mixture incorrect: injector, or air passage clogged Air bleed pipe bleed holes clogged Air cleaner clogged, poorly sealed, or missing Starter plunger stuck open Fuel tank air vent obstructed Injector trouble ECU trouble Compression low: Spark plug loose Cylinder head not sufficiently tightened down No Valve clearance Cylinder, piston worn Piston ring bad (worn, weak, broken, or sticking) Piston ring/groove clearance excessive Cylinder head gasket damaged Cylinder head warp Valve spring broken or weak Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface) Other:
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ECU trouble Idle air motor trouble Engine oil viscosity too high Drive train trouble Brakes dragging Over heating Clutch slipping Throttle valve does not open fully

Poor Running or No Power at High Speed: Firing incorrect: Spark plug dirty, damaged, or maladjusted Spark plug cap or high tension wiring trouble Spark plug cap shorted or not in good contact Spark plug incorrect ECU trouble Pickup coil trouble Exciter coil shorted or open Ignition coil trouble Alternator damage Fuel/air mixture incorrect: Injector, or air passage clogged Air bleed pipe bleed holes clogged Air cleaner clogged, poorly sealed, or missing Starter plunger stuck open Fuel tank air vent obstructed Injector trouble Fuel pump trouble Water or foreign matter in fuel Fuel line blocked Compression low: Spark plug loose Cylinder head not sufficiently tightened down No Valve clearance Cylinder, piston worn Piston ring bad (worn, weak, broken, or sticking) Piston ring/groove clearance excessive Cylinder head gasket damaged Cylinder head warp Valve spring broken or weak Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface)
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Knocking: Carbon build up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Miscellaneous: Throttle valve wont fully open Brakes dragging Clutch slipping Overheating Engine oil level too high Engine oil viscosity too high Balancer malfunctioning Drive train trouble Crankshaft bearing worn or damaged

Overheating: Firing incorrect: Spark plug dirty, damaged, or maladjusted Spark plug incorrect ECU trouble Fuel/air mixture incorrect: Injectors, or air passage clogged Throttle body loose Air cleaner clogged, poorly sealed, or missing Compression low: Carbon build up in combustion chamber Engine load faulty: Clutch slipping Engine oil level too high Engine oil viscosity too high Brakes dragging Lubrication inadequate: Engine oil level too low Engine oil poor quality or incorrect Clutch Operation Faulty: Clutch slipping: No clutch lever play Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak
339

Clutch release mechanism trouble Clutch hub or housing unevenly worn Clutch not disengaging properly: Clutch lever trouble Clutch plate warped or too rough Clutch spring compression uneven Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing frozen on drive shaft Clutch release mechanism trouble Clutch hub nut loose Clutch hub spline damaged

Gear Shifting Faulty: Doesnt go into gear; shift pedal doesnt return: Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Gear positioning lever binding Shift return spring weak or broken Shift return spring pin loose Shift mechanism arm spring broken Shift mechanism arm broken Shift pawl broken Jumps out of gear: Shift fork worn, bent Gear groove worm Gear dogs and/or dog recesses worn Shift drum groove worn Gear positioning lever spring weak or broken Shift fork pin worn Drive shaft, output, and/or gear splines worn Over shifts: Gear positioning lever spring weak or broken Shift mechanism arm spring broken Abnormal Engine Noise: Knocking: ECU unit trouble Carbon built up in combustion chamber
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Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap: Cylinder/Piston clearance excessive Cylinder, piston worn Connecting rod bent Piston pin, piston pin hole worn Valve noise: Valve clearance incorrect Valve spring broken or weak Camshaft bearings worn Valve lifter worn Other noise: Connecting rod small end clearance excessive Connecting rod big end clearance excessive Piston ring worn, broken, or stuck Piston seizure, damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head connection Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Primary gear worn or chipped Alternator loose Camshaft chain tensioner trouble Camshaft chains, sprockets, guides worn Camshaft, sprockets, guides worn Balancer gear worn or chipped Balancer position maladjusted Balancer mechanism springs weak or broken Balancer bearings worn

Abnormal Drive Train Noise: Clutch noise: Cush drive rubber damping weak or damaged Clutch housing/friction plate clearance excessive Clutch housing gear/primary gear worn Metal chip jammed in clutch housing gear teeth Outside friction plate installed incorrectly Transmission noise:
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Bearings worn Transmission gears worn or chipped Metal chips jammed in gear teeth Engine oil insufficient Drive chain noise: Drive chain adjusted improperly Drive chain worn Rear and/or engine sprocket(s) worn Chain lubrication insufficient Rear wheel misaligned

Abnormal Frame Noise: Front fork noise: Oil insufficient or too thin Spring weak or broken Rear shock absorber noise Shock absorber damaged Disc brake noise: Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Master cylinder damaged Other noise: Brackets, nuts, bolts, etc. Not properly mounted or tightened Exhaust Smokes Excessively: White smoke: Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke: Air cleaner clogged Injector damaged Idle air motor trouble Brown smoke: Injector damaged Air cleaner duct loose Air cleaner poorly sealed or missing
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Handling and/or Stability Unsatisfactory Handlebar hard to turn: Cable routing incorrect Hose routing incorrect Wiring routing incorrect Steering stem nut too tight Steering stem bearing damaged Steering stem bearing race dented or worn Steering stem lubrication inadequate Steering stem bent Tire air pressure too low Handlebar shakes or excessively vibrates: Tire worn Swingarm sleeve or needle bearing damaged Rim warped, or not balanced Front, rear axle runout excessive Wheel bearing worn Handlebar clamp loose Steering stem head nut loose Handlebar pulls to one side: Frame bent Wheel misalignment Swingarm bent or twisted Swingarm pivot shaft runout excessive Steering maladjustment Steering stem bent Front fork leg bent Right and left front fork oil level uneven Shock absorption unsatisfactory (Too hard) Front fork oil excessive Front fork oil viscosity too high Front fork damper adjustment too hard Front fork leg bent Tire pressure too high Rear shock absorber adjustment too hard (Too soft) Front fork oil insufficient and/or leaking Front fork oil viscosity too low Front fork damper adjustment too soft
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Rear shock absorber springs to weak Rear shock absorber oil leaking Rear shock absorber adjustment too soft Tire air pressure too low

Brake Doesnt Hold: Air in the brake line Pad or disc worn Brake fluid leaking Disc warp Contaminated pads Brake fluid deteriorated Primary or secondary cup damaged in the master cylinder Master cylinder scratched inside Battery Discharged: Battery faulty (e.g. plates sulphated, shorted through sedimentation) Battery leads making poor contact Load excessive (e.g. Bulb of excessive wattage) Ignition switch trouble Alternator rotor damaged Wiring faulty Regulator/Rectifier trouble Battery Overcharged: Regulator/rectifier trouble Battery trouble Nut, Bolt, and Fastener Tightness Tightness Inspection Check the tightness of the bolts and nuts listed here in accordance with the Periodic Maintenance Chart. 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, re-torque them to the specified torque following the specified tightening sequence. Refer to the Torque and Locking Agent section of the General Information chapter for torque specification. For each fastener, first loosen it by turn, then tighten in. If cotter pins are damaged, replace them with new ones.
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Nut, bolt and fastener to be checked Wheels: Front Axle Front Axle Clamp Nuts Rear Axle Final Drive: Chain Adjuster Locknuts Rear Sprocket Nuts Brakes: Front Master Cylinder Clamp Bolts Caliper Bolts Rear Master Cylinder Bolts Brake Pedal locking Pin Brake Lever Pivot Nut Suspension: Front Fork Clamp Bolts Front Fender Mounting Bolts Swingarm Pivot Shaft Nut Rear Shock Absorber Bolts Steering: Stem Head Nut Handlebar Clamp Bolts Engine: Engine Mounting Bolts, Nuts Cylinder Head Cover Bolts Shift Pedal Bolt Exhaust Pipe Holder Nuts Muffler Connecting Clamp Bolts Muffler Bolt and Nut Clutch Lever Pivot Others Side Stand Pivot Bolt Foot peg Bolts, nuts 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 in accordance with the Periodic Maintenance Chart.

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Note: Whenever the vehicle has been operated under wet or rainy conditions, or especially after a high pressure spray water, perform the general lubrication. Chain: Lubricate with Heavy Oil Pivots: Lubricate with Motor Oil Side Stand Clutch Lever Brake Pedal Rear Brake Rod Joint Footpegs Cables: Lubricate with Cable Lubricant Throttle Cables Lubricate the cables by seeping oil between the cable and housing. While the cable is disconnected at both ends, the cable should move freely within the cable housing. If cable movement is not free after lubrication, if the cable is frayed, or if the cable housing is kinked, replace the cable. Points: Lubricate with Grease Throttle Inner Cable Lower Ends Choke Cable Lower Ends (Grease the lower part of the inner cable sparingly) Unit Conversion Table Prefixes for Units Prefixes Symbol Power mega M x 1000 000 kilo k x 1 000 centi c x 0.01 milli m x 0.001 micro x 0.000001 Units of Mass 2.205 0.03527 Units of Volume 0.2642 = 0.22 = 1.057 = 0.8799 =

kg g

x x

= =

lb oz

L L L L

x x x x

gal (US) gal (imp) qt (US) qt (imp)

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L L mL mL mL

x x x x x

2.113 1.816 0.03381 0.02816 0.06102

= = = = =

pint (US) pint (imp) oz (US) oz (imp) cu in

N N kg kg

x x x x

Units of Force 0.102 0.2248 9.807 2.205

= = = =

kg lb N lb

Units of Temperature:
9 o C 40 40 o F 5

5 o F 40 40 o C 9

km m mm

x x x

Units of Length 0.6214 3.281 0.02937

= = =

mile ft in

Nm Nm Nm kgm kgm kgm

x x x x x x

Units of Torque 0.102 0.7376 8.851 9.807 7.233 86.8 Units of pressure x 0.0102 = x 0.145 = x 0.7501 = x 98.07 = x 14.22 = x 1.333 = Units of Speed

= = = = = =

kgm ftlb inlb Nm ftlb inlb

kPa kPa kPa kg/cm kg/cm cm Hg

kg/cm psi cm Hg kPa psi kPa

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km/h

0.6214 = Units of Power 1.36 1.341 0.7355 0.9863

mph

kW kW PS PS

x x x x

= = = =

PS HP kW HP

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