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CHK
ADJ
INTRODUCTION/PERIODIC MAINTENANCE AND
LUBRICATION INTERVALS
EB300000
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjust-
ments. If followed, these preventive maintenance procedures will ensure more reliable vehi-
cle operation, a longer service life and reduce the need for costly overhaul work. This
information applies to vehicles already in service as well as to new vehicles that are being
prepared for sale. All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS
No. ITEM CHECKS AND MAINTENANCE JOBSINITIAL
1,000 km EVERY
6,000 km or
6 months
(whichever
comes first)12,000 km or
12 months
(whichever
comes first)
1
*
Fuel line
• Check fuel hoses for cracks or damage.
• Replace if necessary.
ÖÖ
2
*
Fuel filter
• Check condition.
• Replace if necessary.
Every 50,000 km
3 Spark plugs
• Check condition.
• Clean, regap or replace if necessary.
ÖÖÖ
4
*
Valves
• Check valve clearance.
• Adjust if necessary.
Every 42,000 km or 42 months (whichever
comes first)
5 Air filter element
• Clean or replace if necessary.
ÖÖ
6 Clutch
• Check operation and fluid leakage. (See NOTE on
page 3-2.)
• Correct if necessary.
ÖÖÖ
7
*
Front brake
• Check operation, fluid level and vehicle for fluid leak-
age. (See NOTE on page 3-2.)
• Correct accordingly.
• Replace brake pads if necessary.
ÖÖÖ
8
*
Rear brake
• Check operation, fluid level and vehicle for fluid leak-
age. (See NOTE on page 3-2.)
• Correct accordingly.
• Replace brake pads if necessary.
ÖÖÖ
9
*
Wheels
• Check balance, runout and for damage.
• Rebalance or replace if necessary.
ÖÖ
10
*
Tires
• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
ÖÖ
11
*
Wheel bearings
• Check bearing for looseness or damage.
• Replace if necessary.
ÖÖ
12
*
Swingarm
• Check swingarm pivoting point for play.
• Correct if necessary.
• Lubricate with lithium soap base grease every 24,000
km or 24 months (whichever comes first).
ÖÖ
13 Drive chain
• Check chain slack.
• Adjust if necessary. Make sure that the rear wheel is
properly aligned.
• Clean and lubricate.
Every 1,000 km and after washing the
motorcycle or riding in rain.
14
*
Steering bearings
• Check bearing play and steering for roughness.
• Correct accordingly.
• Lubricate with lithium soap base grease every 24,000
km or 24 months (whichever comes first).
ÖÖ
3
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CHK
ADJCHECKING THE BRAKE PADS/
ADJUSTING THE REAR BRAKE LIGHT SWITCH
EB304032
CHECKING THE BRAKE PADS
The following procedure applies to all of
the brake pads.
1. Operate the brake.
2. Check:
• front brake pad
• rear brake pad
Brake pad wear limit a
Wear limit reached ® Replace the
brake pads as a set.
Refer to “FRONT AND REAR BRAKES”
in chapter 7.
Front brake
õRear brake
Brake pad wear limit
0.5 mm (0.02 in)
õ
EB304050
ADJUSTING THE REAR BRAKE LIGHT
SWITCH
NOTE:
• The rear brake light switch is operated
by movement of the brake pedal.
• The rear brake light switch is properly
adjusted when the brake light comes
on just before the braking effect starts.
1. Check:
• rear brake light operation timing
Incorrect ® Adjust.
2. Adjust:
• rear brake light operation timing
t t t t t t t t t t t t t t t t t t t t t t t t t t t
a. Hold the main body 1 of the rear
brake light switch so that it does not
rotate and turn the adjusting nut 2 in
direction a or b until the rear brake
light comes on at the proper time.
s s s s s s s s s s s s s s s s s s s s s s s s s s s
Direction aBrake light comes on
sooner.
Direction bBrake light comes on
later.
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CHASFRONT AND REAR BRAKES
EB702001
FRONT AND REAR BRAKES
Order Job/Part Q’ty Remarks
Removing the front brake padsRemove the parts in the order listed.
The following procedure applies to
both of the front brake calipers.
1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad spring 1
4 Brake pad 2
5 Brake pad shim 2
6 Bleed screw 1
For installation, reverse the removal
procedure.
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CHASFRONT AND REAR BRAKES
EB702002
Order Job/Part Q’ty Remarks
Removing the rear brake padsRemove the parts in the order listed.
1 Brake pad clip 4
2 Brake pad pin 2
3 Brake pad spring 1
4 Brake pad 2
5 Brake pad shim 2
6 Bleed screw 2
For installation, reverse the removal
procedure.
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CHASFRONT AND REAR BRAKES
EB702100
ACHTUNG:CAUTION:
Disc brake components rarely require
disassembly.
Therefore, always follow these preven-
tive measures:
• Never disassemble brake components
unless absolutely necessary.
• If any connection on the hydraulic
brake system is disconnected, the
entire brake system must be disas-
sembled, drained, cleaned, properly
filled, and bled after reassembly.
• Never use solvents on internal brake
components.
• Use only clean or new brake fluid for
cleaning brake components.
• Brake fluid may damage painted sur-
faces and plastic parts. Therefore,
always clean up any spilt brake fluid
immediately.
• Avoid brake fluid coming into contact
with the eyes as it can cause serious
injury.
First aid for brake fluid entering the
eyes:
• Flush with water for 15 minutes and
get immediate medical attention.
EB702112
REPLACING THE FRONT BRAKE PADS
The following procedure applies to both
brake calipers.
NOTE:
When replacing the brake pads, it is not
necessary to disconnect the brake hose
or disassemble the brake caliper.
1. Remove:
• brake hose holder 1
• brake caliper 2
1
1
2
2
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CHASFRONT AND REAR BRAKES
2. Remove:
• brake pad clips 1
• brake pad pin 2
• brake pad spring 3
• brake pads
(along with the brake pad shims)
3. Measure:
• brake pad wear limit a
Out of specification ® Replace the
brake pads as a set.
Brake pad wear limit
0.5 mm (0.02 in)
4. Install:
• brake pad shims
(onto the brake pads)
• brake pads
• brake pad spring
NOTE:
Always install new brake pads, brake
pad shims, and a brake pad spring as a
set.
t t t t t t t t t t t t t t t t t t t t t t t t t t t
a. Connect a clear plastic hose 1 tightly
to the bleed screw 2. Put the other
end of the hose into an open con-
tainer.
b. Loosen the bleed screw and push the
brake caliper pistons into the brake
caliper with your finger.
c. Tighten the bleed screw.
d. Install a new brake pad shim onto
each new brake pads.
e. Install new brake pads and a new
brake pad spring.
NOTE:
The arrow a on the brake pad spring
must point in the direction of disc rota-
tion.
s s s s s s s s s s s s s s s s s s s s s s s s s s s
T R..
Bleed screw
6 Nm (0.6 m • kg, 4.3 ft • lb)
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CHASFRONT AND REAR BRAKES
5. Install:
• brake pad pin
• brake pad clips
• brake caliper
T R..40 Nm (4.0 m · kg, 2.9 ft · lb)
6. Check:
• brake fluid level
Below the minimum level mark a ®
Add the recommended brake fluid to
the proper level.
Refer to “CHECKING THE BRAKE
FLUID LEVEL” in chapter 3.
7. Check:
• brake lever operation
Soft or spongy feeling ® Bleed the
brake system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EB702113
REPLACING THE REAR BRAKE PADS
NOTE:
When replacing the brake pads, it is not
necessary to disconnect the brake hose
or disassemble the brake caliper.
1. Remove:
• brake caliper 1
2. Remove:
• brake pad clips 1
• brake pad pins 2
• brake pad spring 3
• brake pads
(along with the brake pad shims)
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CHASFRONT AND REAR BRAKES
3. Measure:
• brake pad wear limit a
Out of specification ® Replace the
brake pads as a set.
Brake pad wear limit
0.5 mm (0.02 in)
4. Install:
• brake pad shims
(onto the brake pads)
• brake pads
• brake pad spring
NOTE:
Always install new brake pads, brake
pad shims, and a brake pad spring as a
set.
t t t t t t t t t t t t t t t t t t t t t t t t t t t
a. Connect a clear plastic hose 1 tightly
to the bleed screw 2. Put the other
end of the hose into an open con-
tainer.
b. Loosen the bleed screw and push the
brake caliper pistons into the brake
caliper with your finger.
c. Tighten the bleed screw.
d. Install a new brake pad shim onto
each new brake pad.
s s s s s s s s s s s s s s s s s s s s s s s s s s s
T R..
Bleed screw
6 Nm (0.6 m • kg, 4.3 ft • lb)