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 208 of 457
4-61
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the under bracket
Front wheel
Front cowling and side cowling
Front fork legs
Main switch connector
Upper bracket bolt
Left handlebar assembly
Right handlebar assembly
Steering stem nut
Upper bracket
Under bracket panel
Brake hose holder bolt
Lock washer
Upper ring nut2
2
1
1
1
1
1
1
1
1Remove the parts in the order listed.
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
Refer to “COWLINGS” in chapter 3.
Refer to “FRONT FORK”.
Disconnect.
For installation, reverse the removal
procedure.
38 Nm (0.38 mkg, 2.75 ftlb)113 Nm (11.3 mkg, 82 ftlb)
52 Nm (5.2 mkg, 38 ftlb)
18 Nm (1.8 mkg, 13 ftlb)
1st
2nd23 Nm (2.3 mkg, 17 ftlb)
23 Nm (2.3 mkg, 17 ftlb)
7 Nm (0.7 mkg, 5.1 ftlb)
17 Nm (1.7 mkg, 12 ftlb)
STEERING HEADCHAS
EAS00676
STEERING HEAD
UNDER BRACKET
ProCarManuals.com
Page 211 of 457
4-64
STEERING HEADCHAS
CAUTION:
NOTE:
NOTE:
NOTE: b. Remove the bearing race
3 from the lower
bracket with a floor chisel
4 and hammer.
c. Install a new rubber seal and new bearing
races.
If the bearing race is not installed properly,
the steering head pipe could be damaged.
Always replace the bearings and bearing
races as a set.
Whenever the steering head is disassembled,
replace the rubber seal.
4. Check:
upper bracket
lower bracket
(along with the steering stem)
Bends / cracks / damage Replace.
EAS00683
INSTALLING THE STEERING HEAD
1. Lubricate:
upper bearing
lower bearing
bearing races
Recommended lubricant
Lithium-soap-based grease
2. Install:
lower ring nut
1
rubber washer 2
upper ring nut 3
lock washer 4
Refer to “CHECKING THE STEERING
HEAD” in chapter 3.
3. Install:
upper bracket
steering stem nut
Temporarily tighten the steering stem nut.
4. Install:
front fork legs
Refer to “INSTALLING THE FRONT FORK
LEGS”.
Temporarily tighten the upper and lower bracket
pinch bolts.
ProCarManuals.com
Page 212 of 457
4-65
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the rear shock absorber
assembly
EXUP servo motor
Self-locking nut / bolt
Self-locking nut / bolt
Self-locking nut / bolt
Self-locking nut
Rear shock absorber assembly
Oil seal / bearing / collar
Collar / self-locking nut / bolt
Connecting arm
Oil seal / bearing / collar
Relay arm1/1
1/1
1/1
1
1
6/3/3
1/1/1
2
2/1/1
1Remove the parts in the order listed.
Refer to “EXHAUST PIPE” in chapter 5.
For installation, reverse the removal
procedure.
92 Nm (9.2 mkg, 67 ftlb)44 Nm (4.4 mkg, 32 ftlb)
44 Nm (4.4 mkg, 32 ftlb)44 Nm (4.4 mkg, 32 ftlb)
REAR SHOCK ABSORBER ASSEMBLYCHAS
EAS00685
REAR SHOCK ABSORBER ASSEMBLY
ProCarManuals.com
Page 216 of 457
4-69
SWINGARM AND DRIVE CHAINCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7Removing the swingarm and drive
chain
Rear wheel
Rear shock absorber
Drive sprocket
Muffler
Catalyst pipe assembly
Right footrest bracket
Adjusting bolt / locknut
Drive chain guard
Rear fender
Brake hose holder
Pivot shaft nut / washer
Pivot shaft1
2/2
1
1
1
1/1
1Remove the parts in the order listed.
Refer to “REAR WHEEL AND BRAKE
DISC”.
Refer to “REAR SHOCK ABSORBER
ASSEMBLY”.
Refer to “ENGINE REMOVAL” in chapter
5.
Refer to “EXHAUST PIPE” in chapter 5.
Refer to “EXHAUST PIPE” in chapter 5.
28 Nm (2.8 mkg, 20 ftlb)
7 Nm (0.7 mkg, 5.1 ftlb)
7 Nm (0.7 mkg, 5.1 ftlb)
105 Nm (10.5 mkg, 76 ftlb)
2 Nm (0.2 mkg, 1.4 ftlb)
16 Nm (1.6 mkg, 12 ftlb)
EAS00700
SWINGARM AND DRIVE CHAIN
ProCarManuals.com
Page 223 of 457
5-1
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8Removing the drive sprocket
Bottom cowlings
Lock nut
Shift rod
Sift arm
Drive sprocket cover
Drive sprocket nut
Lock washer
Drive sprocket
Plate2
1
1
1
1
1
1
1Remove the parts in the order listed.
Refer to “COWLINGS” in chapter 3.
Loosen.
For installation, reverse the removal
procedure.
10 Nm (1.0 mkg, 7.2 ftlb)
85 Nm (8.5 mkg, 61 ftlb)
7 Nm (0.7 mkg, 5 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)
ENGINEENG
ENGINE
ENGINE
DRIVE SPROCKET
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