Page 139 of 457
3-62
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
WARNING
CAUTION:
EAS00178
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of poi-
sonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
Wear protective eye gear when handling or
working near batteries.
Charge batteries in a well-ventilated area.
Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
Skin – Wash with water.
Eyes – Flush with water for 15 minutes and
get immediate medical attention.
INTERNAL
Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical atten-
tion.
This is a sealed battery. Never remove the
sealing caps because the balance between
cells will not be maintained and battery per-
formance will deteriorate.
Charging time, charging amperage and
charging voltage for an MF battery are dif-
ferent from those of conventional batter-
ies. The MF battery should be charged as
explained in the charging method illustra-
tions. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging
the battery.
ProCarManuals.com
Page 179 of 457
4-32
FRONT AND REAR BRAKESCHAS
WARNING
CAUTION:
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.
When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
5. 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.
6. Adjust:
rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” in chapter 3.
ProCarManuals.com
Page 188 of 457
4-41
FRONT AND REAR BRAKESCHAS
WARNING
CAUTION:
3. Fill:
brake fluid reservoir
(with the specified amount of the recom-
mended brake fluid)
Recommended brake fluid
DOT 4
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.
When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM“ in chapter 3.
5. 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.
6. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to ”BLEEDING THE HYDRAULIC
BRAKE SYSTEM“ in chapter 3.
ProCarManuals.com
Page 190 of 457
4-43
FRONT AND REAR BRAKESCHAS
WARNING
CAUTION:
2. Fill:
brake fluid reservoir
(with the specified amount of the recom-
mended brake fluid)
Recommended brake fluid
DOT 4
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.
When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
3. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4. 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.
5. Check:
brake pedal operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
ProCarManuals.com
Page 197 of 457
4-50
FRONT FORKCHAS
CAUTION:
WARNING
NOTE: The front fork leg has a built-in damper ad-
justing rod and a very sophisticated inter-
nal construction, which are particularly
sensitive to foreign material.
When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
4. Check:
cap bolt O-ring
1
Damage / wear Replace.
EAS00659
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
Make sure the oil levels in both front fork
legs are equal.
Uneven oil levels can result in poor han-
dling and a loss of stability.
When assembling the front fork leg, be sure to
replace the following parts:
– outer tube bushing
– oil seal
– dust seal
– Before assembling the front fork leg, make
sure all of the components are clean.
1. Install:
inner tube
1
damper rod assembly 2
damper rod assembly bolt
copper washer
New
ProCarManuals.com
Page 200 of 457
4-53
FRONT FORKCHAS
NOTE:
NOTE: 8. Install:
rod puller
1
rod puller attachment 2
(onto the damper rod 3)
Rod puller
90890-01437, YM-01437
Rod puller attachment
90890-01436, YM-01436
9. Fill:
front fork leg
(with the specified amount of the recom-
mended fork oil)
Quantity (each front fork leg)
0.53 L (0.47 Imp qt, 0.56 US qt)
Recommended oil
Suspension oil “01” or
equivalent
Front fork leg oil level (from the
top of the outer tube, with the
outer tube fully compressed and
without the fork spring)
76 mm (2.99 in)
While filling the front fork leg, keep it upright.
After filling, slowly pump the front fork leg up
and down to distribute the fork oil.
10. Install:
nut
1
fork spring 2
spacer 3
damper adjusting rod 4
cap bolt 5
a. Remove the rod puller and adapter.
b. Install the nut.
c. Install the fork spring, and spacer.
Install the spring with the smaller pitch
a facing
up
A.
ProCarManuals.com
Page 228 of 457
5-6
Order Job / Part Q’ty Remarks
3
4
5
6
7
8
9
10Clutch cable
Ground lead
Stator coil assembly coupler
Crankshaft position sensor lead coupler
Oil level switch connector
Neutral switch connector
Speed sensor coupler
Cylinder identification sensor coupler1
2
1
1
1
1
1
1First, disconnect the negative battery
lead, and then the positive battery lead.
For connecting, reverse the disconnec-
tion procedure.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
CAUTION:
ENGINEENG
ProCarManuals.com
Page 285 of 457
5-63
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8Removing the oil pan and oil pump
Side cowlings
Bottom cowlings
Engine oil
Exhaust pipe and exhaust valve pipe
Clutch assembly
Water pump inlet pipe
Water pump outlet pipe
Oil level switch lead coupler
Oil level switch
Oil level switch lead holder
Oil pan
Oil pan gasket
Dowel pin
Drain pipe
Oil strainer1
1
1
1
1
2
1
1Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “EXHAUST PIPE”.
Refer to “CLUTCH”.
Refer to “OIL COOLER” in chapter 6.
Disconnect.
Refer to “COWLINGS” in chapter 3.
10 Nm (1.0 mkg, 7.2 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)10 Nm (1.0 mkg, 7.2 ftlb)
12 Nm (1.2 mkg, 8.7 ftlb)43 Nm (4.3 mkg, 31 ftlb)
12 Nm (1.2 mkg, 8.7 ftlb)
OIL PAN AND OIL PUMPENG
EAS00356
OIL PAN AND OIL PUMP
ProCarManuals.com
