Ω

Battery Ground

Edges of Parts

Solvent

Cleaning vehicle before disassembly

Arrangement and Cleaning of Removed Parts

Storage of Removed Parts

Inspection

Replacement Parts

Assembly Order
Tightening Sequence

Tightening Torque

Force

Gasket, O-ring

Liquid Gasket, Locking Agent

Lubrication

Direction of Engine Rotation

Electrical Wires
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Carburetor Synchronization Inspection

○Each carburetor has different opening of the pilot screw.

When setting the pilot screw, do not refer to the specifi-
cations which show mean opening of the pilot screws.
Fuel Hose Replacement
○Choose a suitable mixture ratio by referring to the
coolant manufacturer’s directions.

○
○
○
Spark Plug Replacement
Fuel Hose and Connection Inspection
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Radiator Hose and Connection Inspection

Radiator Hose, Pipe, Air Vent Hose, Reservoir Tank

Hose Installation
Radiator Fan Switch Removal

Water Temperature Switch Removal

Radiator Fan Switch, Water Temperature Switch

Installation

Radiator Fan Switch, Water Temperature Switch

Inspection
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Cylinder Head Cover Removal
Camshaft Chain Tensioner Removal

Camshaft Chain Tensioner Installation

Camshaft Removal

Camshaft Installation

○The Exhaust camshaft has an EX mark [A] and the inlet

camshaft has an IN mark [B]. Be careful not to mix up
these shafts.
○Be sure to operate from the engine left side.
Rocker Shaft, Rocker Arm Removal

Rocker Shaft, Rocker Arm Installation

Muffler Removal

Muffler Installation
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∼ ∼
Clutch Release Installation

○
∼
∼
Clutch Removal

○The clutch housing can not be removed without major

disassembly work (see Crankshaft/Transmission chap-
ter).

Clutch Installation
∼ ∼ ∼
Oil Pump Removal
Oil Pump Installation

Oil Pump Disassembly

Engine Installation
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Crankcase Splitting

○
Clutch Housing/Primary Chain Removal

Clutch Housing/Primary Chain Installation

Primary Chain Guide Wear Inspection
Crankshaft Removal

Crankshaft Installation

Connecting Rod Removal

○Mark and record locations of the connecting rods and

their big end caps so that they can be reassembled in
their original positions.
Shift Drum and Fork Installation
∼ ∼ ∼
Rear Wheel Removal

Rear Wheel Installation

Disassembly and Assembly

○It is recommended that the assembly be replaced rather

than attempting to repair the components.

Lubrication
∼ ∼
∼ ∼
Drive Chain Slack Inspection

Wheel Alignment Inspection/Adjustment

Drive Chain Wear Inspection

Drive Chain Lubrication

Drive Chain Removal

Drive Chain Installation

Engine Sprocket Removal

○When loosening the engine sprocket nut, hold the rear

brake on.

Engine Sprocket Installation

○Tighten the nut while applying the rear brake.

∼ ∼

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Brake Pedal and Shaft Installation
Front Caliper Removal

○If the caliper is to be disassembled after removal and if

compressed air is not available, remove the piston us-
ing the following steps before disconnecting the brake
hose from the caliper.
○Remove the pads (see Pad Removal).
○Pump the brake lever to remove the caliper piston.

Front Caliper Installation

Rear Caliper Removal

○If the caliper is to be disassembled after removal and if

compressed air is not available, remove the piston us-
ing the following steps before disconnecting the brake
hose from the caliper.
○Remove the pad (see Pad Removal).
○Pump the brake lever to remove the caliper piston.
Tie-Rod Removal

Tie-Rod Installation

Rocker Arm Removal

○Loosen the swingarm pivot nut when installing the

rocker arm bolt.
Handlebar Removal

Handlebar Installation
Rear View Mirror Removal

Rear View Mirrors (Left and Right) Installation

Steering Play Inspection
Steering Stem Removal

Steering Stem Installation

Seat Removal

Seat Installation
Lower Fairings Removal

Lower Fairings Installation

Upper Fairing Removal

Air Duct Removal

Right Side Cover Removal

Right Side Cover Installation

Left Side Cover Removal

Left Side Cover Installation

Front Fender Removal

Rear Fender Removal

Fender Installation Note
Engine Guard Removal

Carrier Removal

Carrier Installation
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Ω
Ω

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Ω
Ω
Alternator Rotor/Starter Clutch Removal

○The rotor bolt has left-handed threads, therefore it must

be turned clockwise in removing.
Starter Clutch Sprocket Removal

○
○

Starter Clutch Sprocket Installation

Alternator Rotor/Starter Clutch Installation

Alternator Stator Removal

○To keep the loss of engine oil to a minimum, set the

motorcycle vertically.
Alternator Stator Installation

Alternator Inspection

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Starter Motor Assembly
Headlight Unit/Housing Installation

City Light Bulb Replacement

Tail/Brake Light Bulb Replacement

Meter Unit Removal

Meter Unit Disassembly

○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.