Page 161 of 432
FRONT WHEEL
5-7
3. Install:
• Collar “1”
TIP
Apply the lithium-soap-based grease on the oil
seal lip.
4. Install:
• Speed sensor “1”
TIP
Apply the lithium-soap-based grease on the oil
seal lip of speed sensor.
Make sure the two projections “a” in the wheel
hub are meshed with the two slots “b” in the
speed sensor.
EAS2GBB159INSTALLING THE FRONT WHEEL
1. Install:
• Front wheel
TIP
Install the brake disc “1” between the brake
pads “2” correctly.2. Install:
• Front wheel axle “1”
TIP
Apply the lithium-soap-based grease to the
front wheel axle.
3. Tighten:
• Front wheel axle nut “1”
ECA
NOTICE
Before tightening the front wheel axle nut,
push down hard on the handlebar(s) several
times and check if the front fork rebounds
smoothly.
4. Tighten:
• Front wheel axle pinch bolt “1”1
a
b
LS
Front wheel axle nut
90 Nm (9.0 m·kgf, 65 ft·lbf)
Front wheel axle pinch bolt
21 Nm (2.1 m·kgf, 15 ft·lbf)
T R..
1
T R..
Page 163 of 432
REAR WHEEL
5-9
EAS2GBB160
REAR WHEEL
Removing the rear wheel
Order Part name Q’ty Remarks
Use a suitable stand to raise the rear wheel
off the ground.
1 Nut (rear wheel axle) 1
2 Rear wheel axle 1
3 Drive chain puller 2
4 Rear wheel 1
5Collars 2
6 Rear wheel sprocket 1
7Oil seals 2
8 Circlip 1
9 Bearing 3
10 Brake disc 1
For installation, reverse the removal proce-
dure.
(6)
21 Nm (2.1 m kgf, 15 ft Ibf)T.R.
2 5
7 9
LS
LS(6)
46
1
(6) 3
LS
8
9 10
7 5
LT
14 Nm (1.4 m kgf, 10 ft Ibf)T.R.
3
21 Nm (2.1 m kgf, 15 ft Ibf)T.R.
50 Nm (5.0 m kgf, 36 ft Ibf)T.R.
125 Nm (12.5 m kgf, 90 ft lbf)T.R.
Page 164 of 432
REAR WHEEL
5-10
EAS2GBB161REMOVING THE REAR WHEEL
1. Use a suitable stand to raise the rear wheel
off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Rear wheel axle nut “1”
3. Loosen:
• Locknut “2”
4. Tighten:
• Adjusting bolt “3”
5. Remove:
• Rear wheel axle
• Rear wheel
TIP
• Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
• Do not depress the brake pedal with the rear
wheel removed.
EAS2GBB162CHECKING THE REAR WHEEL
1. Check:
• Rear wheel axle
• Rear wheel
• Bearing
• Oil seals
Refer to “CHECKING THE FRONT WHEEL”
on page 5-5.
2. Check:
•Tire(s)
• Rear wheel
Damage/wear Replace.
Refer to “CHECKING THE TIRES” on page
3-36 and “CHECKING THE WHEELS” on
page 3-37.
3. Check:
• Spokes
Refer to “CHECKING THE FRONT WHEEL”
on page 5-5.4. Measure:
• Radial wheel runout
• Lateral wheel runout
Refer to “CHECKING THE FRONT WHEEL”
on page 5-5.
EAS2GBB163DISASSEMBLING THE REAR WHEEL
1. Remove:
• Oil seals
• Bearing
Refer to “DISASSEMBLING THE FRONT
WHEEL” on page 5-6.
EAS2GBB164CHECKING AND REPLACING THE REAR
WHEEL SPROCKET
1. Check:
• Rear wheel sprocket
More than 1/4 tooth wear “a” Replace the
rear wheel sprocket and the drive sprocket
as a set.
Bent tooth Replace the rear wheel
sprocket and the drive sprocket as a set.
2. Replace:
• Rear wheel sprocket
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the self-locking nuts and the rear
wheel sprocket.
b. Clean the rear wheel drive hub with a clean
cloth, especially the surfaces that contact
the sprocket.
c. Install the new rear wheel sprocket.
3
12
Radial wheel runout limit
2.0 mm (0.08 in)
Lateral wheel runout limit
2.0 mm (0.08 in)
b. Correct
1. Drive chain roller
2. Rear wheel sprocket
Rear wheel sprocket self-locking
nut
50 Nm (5.0 m·kgf, 36 ft·lbf)
T R..
Page 165 of 432
REAR WHEEL
5-11
TIP
Tighten the self-locking nuts in stages and in a
crisscross pattern.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS2GBB165ASSEMBLING THE REAR WHEEL
1. Install:
• Bearing (right side) “1”
• Circlip “2”
• Spacer “3”
• Bearing (left side) “4”
• Oil seals “5”
TIP
• Apply the lithium-soap-based grease to the
bearing and the oil seal lip when installing.
• Install the bearing with seal facing outward.
• Right side of bearing shall be installed first.
• Install the oil seal with its manufacture’s
marks or numbers facing outward.
ECA
NOTICE
Install the bearing by pressing its outer race
parallel.
TIP
Use a socket “1” that matches the diameter of
the bearing outer race and that of the oil seal.2. Install:
• Brake disc “1”
• Brake disc bolt “2”
TIP
Tighten the bolts in stages and in a crisscross
pattern.
3. Install:
• Collar “1”
TIP
Apply the lithium-soap-based grease on the oil
seal lip.
EAS2GBB166INSTALLING THE REAR WHEEL
1. Install:
• Rear wheel
New
New
5
43 1
25
LSLS
Brake disc bolt
14 Nm (1.4 m·kgf, 10 ft·lbf)
LOCTITE®
1
T R..
1
LS
Page 173 of 432
FRONT BRAKE
5-19
3. Install:
• Brake caliper piston “1”
TIP
Apply the brake fluid on the piston outer sur-
face.
ECA
NOTICE
• Install the piston with its side “a” facing
the brake caliper.
• Never force to insert.
EAS2GBB175INSTALLING THE FRONT BRAKE CALIPER
1. Install:
• Front brake caliper bracket
• Front brake caliper
(temporarily)
• Copper washers
• Brake hose
• Union bolt
EWA
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation.
ECA
NOTICE
Make sure that the pipe portion “a” of the
brake hose touches the projection “b” on
the brake caliper.2. Install:
• Front brake caliper
• Brake pad spring
• Brake pad
• Brake pad pin
• Brake hose holder
Refer to “CHECKING THE FRONT BRAKE
PADS” on page 3-27.
3. Tighten:
• Brake hose holder nut “1”
TIP
Make sure that the brake hose holder “2” is in-
stalled with its upper end “a” aligned with the
paint “b” on the brake hose.
4. Pour brake fluid to the brake master cylinder
reservoir up to the specified level.
EWA
WARNING
• 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 flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance.
• 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. Front brake caliper bracket
23 Nm (2.3 m·kgf, 17 ft·lbf)
Brake hose union bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
1
a
1
New
T R..
a
b
Brake pad pin
17 Nm (1.7 m·kgf, 12 ft·lbf)
Brake hose holder nut
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Specified brake fluid
DOT 4
T R..
T R..
1 2
b
a
Page 176 of 432
FRONT BRAKE
5-22
TIP
Turn the handlebar toward right and left to
make sure that the brake hose does not touch
other parts (e.g., wire harness, cables, leads).
Adjust if necessary.
3. Pour brake fluid to the brake master cylinder
reservoir up to the specified level.
EWA
WARNING
• 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 flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the brake fluid and could
cause vapor lock.
ECA
NOTICE
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 BRAKE SYS-
TEM” on page 3-25.
5. Check:
• Brake fluid level
The minimum level mark “a” or below
Add.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-30.6. Check:
• Brake lever free play
Refer to “ADJUSTING THE FRONT
BRAKE” on page 3-26.
• Brake lever operation
A softy or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-25.
Specified brake fluid
DOT 4
a
Page 184 of 432
REAR BRAKE
5-30
EWA
WARNING
• 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 flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance.
• 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.
ECA
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
5. Bleed:
• Brake system
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-25.
6. Check:
• Brake fluid level
The minimum level mark “a” or below
Add.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-30.
7. Check:
• Brake pedal operation
A softy or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-25.
EAS2GBB189REMOVING THE REAR BRAKE MASTER
CYLINDER
TIP
Before removing the rear brake master cylin-
der, drain the brake fluid from the entire brake
system.
1. Remove:
• Union bolt
• Copper washers
• Brake hose
TIP
To drain any remaining brake fluid, place a con-
tainer under the master cylinder and the end of
the brake hose.
EAS2GBB190CHECKING THE REAR BRAKE MASTER
CYLINDER
1. Check:
• Brake master cylinder “1”
Damage/scratches/wear Replace.
• Brake fluid delivery passages “2”
(brake master cylinder body)
Obstruction Blow out with compressed
air.
2. Check:
• Brake master cylinder kit
Damage/wear Replace.
3. Check:
• Master cylinder reservoir cap
Crack/damage Replace.
• Brake master cylinder reservoir diaphragm
holder
• Brake master cylinder reservoir diaphragm
Crack/damage Replace.
4. Check:
• Brake hoses
Cracks/damage/wear Replace.
a
1
2
Page 186 of 432
REAR BRAKE
5-32
2. Pour brake fluid to the brake fluid reservoir
up to the specified level.
EWA
WARNING
• 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 flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance.
• 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.
ECA
NOTICE
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 BRAKE SYS-
TEM” on page 3-25.
4. Check:
• Brake fluid level
The minimum level mark “a” or below
Add.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-30.5. Check:
• Brake pedal operation
A softy or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-25. Specified brake fluid
DOT 4
a
a
