Norton Motorcycles Service Manual Commando 961 – All variants
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Quick Reference Guide
1 General Information .................................................................................................................................................. 8
2 Fuel System ............................................................................................................................................................. 28
3 Cooling System ........................................................................................................................................................ 43
4 Engine Top End ........................................................................................................................................................ 55
5 Clutch...................................................................................................................................................................... 96
6 Engine Lubrication System .................................................................................................................................... 117
7 Engine Removal / Installation ............................................................................................................................... 137
8 Crankshaft / Transmission ..................................................................................................................................... 143
9 Wheels / Tyres ....................................................................................................................................................... 170
10 Final Drive .............................................................................................................................................................. 187
11 Brakes .................................................................................................................................................................... 196
12 Suspension ............................................................................................................................................................ 219
13 Steering ................................................................................................................................................................. 256
14 Frame .................................................................................................................................................................... 271
15 Electrical System ................................................................................................................................................... 284
16 Appendix ............................................................................................................................................................... 322
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All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Norton Motorcycles (UK) Ltd.
No Liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring obligation to
make such changes to produce manufactured previously. See your Motorcycle dealer for the latest
information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the
time of publication. Illustrations and photographs in this publication are intended for reference use only
and may not depict actual model component parts.
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Emission Control Information
To protect the environment in which we all live, Norton motorcycles (UK) ltd has incorporated crankcase
emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the
United States Environmental Protection Agency and California Air Resources Board. Additionally, Norton
has incorporated an evaporative emission control system (3) in compliance with applicable regulations of
the California Air Resources Board on vehicles sold in California only.
Crankcase Emission Control System:
This system eliminates the release of crankcase vapours into the atmosphere. Instead, the vapours
are routed through an oil separator to the intake side of the engine. While the engine is operating,
the vapours are drawn into combustion chamber, where they are burned along with the fuel and
air supplied by the injection system.
Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of
this motorcycle. The fuel and ignition systems of this motorcycle have been carefully designed and
constructed to ensure an efficient engine with low exhaust pollutant levels.
Evaporative Emission Control System
Vapours caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead,
fuel vapours are routed into the running engine to be burned, or stored in a canister when the
engine is stopped.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly
referred to as the Act’s “tampering provisions”.
“Sec. 203(a) the following acts and the causing thereof are prohibited...
(3)(A) for any person to remove or render inoperative any device or element of design installed
on or in a motor vehicle or motor vehicle engine in compliance with regulations under this
title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or
dealer knowingly to remove or render inoperative any such device or element of design
after such sale and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading
motor vehicles or motor vehicles engines, or who operates a fleet of motor vehicles
knowingly to remove or render inoperative any device or element of design installed on or
in a motor vehicle or motor vehicle engine in compliance with regulations under this title
following its sale and delivery to the ultimate purchaser...”
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Note: The phrase “remove or render inoperative any device or element of design” has been generally
interpreted as follows:
Tampering does not include the temporary rendering inoperative of devices or elements of design
in order to perform maintenance.
Tampering could include:
Maladjustment or vehicle components such that the emissions standards are exceeded.
Use of replacement parts or accessories which adversely affect the performance or durability of the
motorcycle.
Addition of components or accessories that result in the vehicle exceeding the standards.
Permanently removing, disconnecting, or rendering inoperative any component or element of
design of the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF
WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION.
Tampering With Noise Control System Prohibited
Owners are warned that the law may prohibit:
The removal or rendering inoperative by any person other than for purposes of maintenance, repair
or replacement, of any device or element of design incorporated into any new vehicle for the
purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is use; and
The use of the vehicle after such device or element of design has been removed or rendered
inoperative by any person
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by
any person other than for purposes of maintenance, repair, or replacement, of any device or element of
design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the
ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design
has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
Replacement of the original exhaust system or muffler with components not in compliance with
federal regulations.
Removal of the muffler(s) or any internal portion of the muffler(s).
Removal of the air box or air box cover.
Modifications to the muffler(s) or intake system by cutting, drilling, or other means if such
modifications results in increased noise levels.
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Foreword
This Manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it
contains enough detail and basic information to make it useful to the owner who desires to perform his
own basic maintenance, the proper use of tools, and workshop procedures must be understood in order to
carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts
his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified
mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly
familiarize yourself with the procedures before starting work, and then do the work carefully in a clean
area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment.
Precision measurements can only be made if the proper instruments are used, and the use of substitute
tools may adversely affect safe operation.
For the duration of the warranty period, especially, we recommend that all repairs and scheduled
maintenance be performed in accordance with the service manual. Any owner maintenance or repair
procedure not preformed in accordance with this manual may void the warranty. To get the longest life
out of your Motorcycle:
Follow the Periodic Maintenance Chart in the Service Manual.
Be alert for problems and non-scheduled maintenance.
Use proper tools and genuine Norton Motorcycle parts. Special tools, gauges, and testers that are
necessary when servicing Norton motorcycles are introduced by the Special Tool Catalog or
Manual. Genuine parts provided as spare parts are listed in the Parts Catalog.
Follow the procedures in this manual carefully don`t take shortcuts.
Remember to keep complete records of maintenance and repair with dates and any new parts
installed.
How to use this Manual
In preparing this manual, we divided the product into its major systems. These systems became the
manual`s chapters. All information for a particular system from adjustment through disassembly and
inspection is located in a single chapter.
The Quick Reference Guide shows you all of the products system and assists in locating their chapters. Each
chapter in turn has its own comprehensive Table of Contents.
The Periodic Maintenance Chart is located in the General Information chapter. The chart gives a time
schedule for required maintenance; for example, go to the Periodic Maintenance Chart first. The chart tells
you how frequently to change the oil. Next, use the Quick Reference Guide to locate the Engine Lubrication
System chapter. Then, use the Table of Contents on the first page of the chapter to find the Change Engine
Oil section.
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Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe
operation and maintenance practices.
WARNING: This warning symbol identifies special instructions or procedures which, if not correctly
followed, could result in personal injury, or loss of life.
CAUTION: This caution symbol identifies special instructions or procedures which, if not strictly observed,
could result in damage to or destruction of equipment.
This Manual contains four more symbols (in addition to WARNING and CAUTION) which will help you
distinguish types of information.
Note: This note symbol indicates points of particular interest for more efficient and convenient operation.
Indicates a procedural step or work to be done.
o Indicates a procedural sub-step or how to do the work of the procedural step it follows. It
also precedes the text of a NOTE in some cases.
Indicates a conditional step or what action to take based on the results of the test or inspection
in the procedural step or sub-step it follows.
In most chapters an exploded view illustration of the system components follows the Table of Contents to
show assembly sequence.
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General Information
Before Servicing ................................................................................................................................................. 9
General Specification ....................................................................................................................................... 13
Periodic Maintenance Chart ............................................................................................................................ 16
Torque and Locking Agent ............................................................................................................................... 17
Special tools and Sealant ................................................................................................................................. 24
Cable, Wire and Hose Routing ......................................................................................................................... 26
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Maintenance / Equipment Consult your authorised Norton dealer whenever there is doubt as to the correct or safe operation of this Norton motorcycle. Remember that continued operation of an incorrectly performing motorcycle may aggravate a fault and may also prejudice safety. Ensure all equipment that is required by law is installed and functioning correctly. The removal or alteration of the motorcycle’s lights, silencers, emission or noise control systems can violate the law. Incorrect or improper modification may adversely affect the handling, stability or other aspect of the motorcycle operation, which may result in an accident causing injury or death. If the motorcycle is involved in an accident, collision or fall, it must be taken to an authorised Norton dealer for inspection and repair. Any accident can cause damage to the motorcycle that, if not correctly repaired, may cause a second accident that may result in injury or death.
Before Servicing
Before starting to service a motorcycle, careful reading of the applicable section is recommended to
eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions
have been included wherever necessary. Nevertheless, even a detailed account has limitations; a certain
amount of basic knowledge is also required for successful work.
Especially note the following:
Dirt: Before removal and disassembly, clean the motorcycle. Any dirt entering the engine or other
parts will work as an abrasive and shorten the life of the motorcycle. For the same reason, before
installing a new part, clean off any dust or metal fillings.
Battery Ground: Remove the battery ground (-) lead from the battery before performing any
disassembly operations on the motorcycle. This Prevents:
o The possibility of accidently turning the engine over while partially disassembled.
o Sparks at electrical connections which will occur when they are disconnected.
o Damage to electrical parts.
Installation, Assembly: Generally, installation or assembly is the reverse of removal or disassembly.
But if this Service Manual has installation or assembly procedures, follow them.
Tightening Sequence: Generally, when installing a part with several bolts, nut, or screws, start them
all in their holes and tighten them to a snug fit. Then tighten them evenly in a cross pattern. This is
to avoid distortion of the part and/or causing gas or oil leakage. Conversely when loosening the
bolts, nuts, or screws, first loosen all of them by about a quarter of a turn and then remove them.
Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws
must be tightened in the order and method indicated.
Torque: When torque values are given in this Service Manual, use them. Either too little or too
much torque may lead to serious damage. Use a good quality, reliable torque wrench.
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Force: Common sense should dictate how much force is necessary in assembly and disassembly. If a
part seems especially difficult to remove or install, stop and examine what may be causing the
problem. Whenever tapping is necessary, tap lightly using a rubber, wooden or plastic-faced mallet.
Use an impact driver for screws (particularly for the removal of screws held by a locking agent) in
order to avoid damaging the screw heads.
Edges: Watch for sharp edges, especially during major engine disassembly and assembly. Protect
your hands with gloves or a piece of thick cloth when lifting the engine or turning it over.
High-Flash Point Solvent: A high-flash point solvent is recommended to reduce fire danger. A
commercial solvent commonly available in the UK is Silkolene (generic name). Always follow
manufacturer and container directions regarding the use of any solvent.
Gasket, O-Ring: Do not reuse a gasket or O-ring once it has been in service. The mating surfaces
around the gasket should be free of foreign matter and perfectly smooth to avoid oil or
compression leaks.
Liquid Gasket, Non-Permanent Locking Agent: Follow manufacturer’s directions for cleaning and
preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may
block engine oil passages and cause serious damage. An example of a non-permanent locking agent
commonly available in the UK is Threebond.
Press: A part installed using a press or driver, such as a wheel bearing (hub bearing), should first be
coated with oil on its outer or inner circumference so that it will go into place smoothly.
Ball Bearing, Needle Bearing: Do not remove a ball bearing or a needle bearing unless it is
absolutely necessary. Replace any ball or needle bearings that were removed with new ones, as
removal generally damages bearings. Install bearings with the marked side facing out applying
pressure evenly with a suitable driver. Only press on the race that forms the press fit with the base
component to avoid damaging the bearings. This prevents severe stress on the balls or needles and
races, and prevents races and balls or needles from being dented. Press a ball bearing until it stops
at the stop in the hole or on the shaft.
Oil Seal and Grease Seal: Replace any oil or grease seals that were removed with new ones, as
removal generally damages seals. When pressing in a seal which has manufacturer’s marks, press it
in with the marks facing out. Seals should be pressed into place using a suitable driver, which
contacts evenly with the side of seal, until the face of the seal is even with the end of the hole.
Before a shaft passes through a seal, apply a little high temperature grease on the lips to reduce
rubber to metal friction.
Circlip, Retaining Ring: Replace any circlips and retaining rings that were removed with new ones, as
removal weakens and deforms them. When installing circlips and retaining rings, take care to
compress or expand them only enough to install them and no more.
Cotter Pin: Replace any cotter pins that were removed with new ones, as removal deforms and
breaks them.
Lubrication: Engine wear is generally at its maximum while the engine is warming up and before all
the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is
more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old
grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and
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may contain abrasive foreign particles. Don’t use just any oil or grease. Some oils and greases in
particular should be used only in certain applications and may be harmful if used in an application
and may be harmful if used in an application for which they are not intended. This manual makes
reference to molybdenum disulfide grease (MoS2) in the assembly of certain engine and chassis
parts. Always check manufacturer recommendations before using such special lubricants.
Electrical Wires: All the electrical wires are either single-colour or two-colour and, with only a few
exceptions, must be connected to wires of the same colour. On any of the two-colour wires there is
a greater amount of one colour and a lesser amount of a second colour, so a two-colour wire is
identified by first the primary colour and then the secondary colour. For example, a red wire with
thin yellow strips is referred to as a “red/yellow” wire; it would be a “yellow/red” wire if the
colours were reversed to make red the main colour.
Replacement Parts: When there is a replacement instruction, replace these parts with new ones
every time they are removed. These replacement parts will be damaged or lose their original
function once removed.
Inspection: When parts have been disassembled, visually inspect these parts for the following
conditions or other damage. If there is any doubt as to the condition of them, replace them with
new ones.
Abrasion Crack Hardening Warp Bent Dent
Scratch Wear Colour Change Deterioration Seizure
Specifications: Specification terms are defined as follows:
“Standards” show dimensions or performances which brand-new parts or systems have.
“Service Limits” indicate the usable limits. If the measurement shows excessive wear or
deteriorated performance, replace the damaged parts
References to the left-hand or right-hand side given in this manual are made when viewing the
motorcycle from the rear.
Operations covered in this manual do not always include references to testing the motorcycle after
repair. It is essential that work is inspected and tested after completion and if necessary a road test
of the motorcycle is carried out particularly where safety related items are concerned.
Yellow
Wire Strands
Red
Yellow
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List of Abbreviations
A ampere (s) lb pounds(s) ABDC after bottom dead centre m meter(s) AC alternating current min minute(s) ATDC after top dead centre N Newton(s) BBDC before bottom dead centre Pa Pascal(s) BDC bottom dead centre PS horsepower BTDC before top dead centre Kw killer watt(s) ˚C degree(s) Celsius psi pound(s) per square inch DC direct current r revolution F farad(s) rpm revolution(s) per minute ˚F degree(s) Fahrenheit TDC top dead centre ft foot, feet TIR total indicator reading g gram(s) v volt(s) h hours(s) w watt(s)
L litres(s) Ω ohm(s)
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Items 961 SE/SPORT/CAFE RACER
Dimensions:
Overall length 2050 mm
Overall Width 850mm Overall Height 1110mm Wheelbase 1430mm Road clearance 130mm (nominal) Seat height 810mm Dry weight 205kg Curb weight: Front 108kg Rear 110kg
Fuel tank capacity 17 Litres
Performance:
Minimum turning radius 3m
Engine: Type 4-Stroke, push-rod, 2-cylinder Cooling System Air/oil - cooled Bore and stroke 88mm Displacement 79mm Compression ratio 10.1:1 Maximum / horsepower 59Kw @ 7700rpm
Maximum torque 84Nm @ 6000rpm Throttle body Norton Throttle Body 38mm Starting system Electric starter Ignition system Coil Timing advance Electronically advanced Ignition timing Controlled by ECU map
Spark plug NGK CR9EB Cylinder numbering method LH:1 RH:2 Firing order 270˚ Valve timing Inlet Open 36˚ BTDC Close 60˚ ABDC Duration 256˚ Exhaust Open 70˚ BBDC Close 6˚ ATDC Duration 256˚ Lubrication Forced lubrication (dry sump) Engine oil: Grade API SG, SH AND SJ, JASO MA
Viscosity SAE10W-40
Capacity 3 L (from dry)
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Items 961 SE/SPORT/CAFE RACER
Drive Train: Primary reduction system:
Type Gear Reduction ratio 1.61 Clutch type Wet multi disc Transmission: Type 5-speed, constant mesh Gear ratios: 1st 2.688 2nd 1.969 3rd 1.433 4th 1.181 5th 1.000 Final drive system: Type Chain drive Reduction ratio 2.778
Overall drive ratio 4.476 @Top
Frame: Type Tubular, steel, double cradle Caster (rake angle) 24.5˚ Trail 99mm
Front tire: Type Dunlop qualifier (Tube for spoked wheels-Continental DE17)
Size 120/70 ZR17 M/C
Rear tire: Type Dunlop qualifier (Tube for spoked wheels-Continental G17)
Size 180/55 ZR17 M/C
Front Suspension: Type Telescopic fork (pneumatic) Fork travel 110mm Rear Suspension: Type Swingarm, twin shock Sus travel 96mm Brake type: Front Twin floating discs
Rear Single disc
Electrical Equipment: Headlight: Type Semi-sealed beam Bulb 12 V 55/60 W Taillight 12 V 21.5W Alternator: Type Three-phase AC Rated output 300 w
Specifications are subject to change without notice, and may not apply to every country.
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SCHEDULED MAINTENANCE CHART Operation Description
Every Odometer Reading in Miles (Kms) or time period, whichever comes first
500 (800)
1 month
6,000 (10,000) 1 year
12,000 (20,000) 2 years
18,000 (30,000) 3 years
24,000 (40,000) 4 years
30,000 (50,000) 5 years
Engine oil Cooler - check for leaks Day
Engine oil - renew -
Engine oil filter - renew -
Valve clearance - check -
Air cleaner - renew -
Engine ECU - check for stored DTC`s -
Spark plugs - check -
Spark plugs - renew -
Throttle bodies - balance Day
Throttle cables - check/ adjust Day
fuel system - check for leaks Day
Lights. Instruments and elec. Systems - check Day
SCHEDULED MAINTENANCE CHART Operation Description
Every Odometer Reading in Miles (Kms) or time period, whichever comes first
500 (800)
1 month
6,000 (10,000) 1 year
12,000 (20,000) 2 years
18,000 (30,000) 3 years
24,000 (40,000) 4 years
30,000 (50,000) 5 years
Drive chain slack - check/adjust Day
Drive chain rubbing strip - check -
Rear wheel bearing - lubricate -
Fasteners - inspect visually for security Day
Wheels - inspect for damage Day
Tyre wear/tyre damage - check Day
Tyre pressures - check/adjust Day
Stand - check operation Day
Secondary exhaust clamp bolts - check/adjust -
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SCHEDULED MAINTENANCE CHART Operation Description
Every Odometer Reading in Miles (Kms) or time period, whichever comes first
500 (800)
1 month
6,000 (10,000) 1 year
12,000 (20,000) 2 years
18,000 (30,000) 3 years
24,000 (40,000) 4 years
30,000 (50,000) 5 years
Steering - check for free operation Day
Headstock bearings - check/adjust -
Headstock bearings - lubricate -
Forks - check for leaks/smooth operation Day
Fork oil - renew -
Brake fluid and clutch fluid levels - check Day
Brake fluid - renew Day
Brake pad wear - check Day
Brake master cylinders - check for oil leaks Day
Brake calipers - check for leaks/seized pistons Day
Drive chain - lubricate Every 200 miles (300kms)
Drive chain - wear check Every 500 miles (800kms)
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Torque and Locking Agent
The following tables list the tightening torque for the major fasteners requiring use of a non-permanent
locking agent or liquid gasket.
Letters used in the “Remarks” column mean:
Letters Mean
L Apply a non-permanent locking agent to the threads.
LG Apply liquid gasket to the threads.
Lh Left-hand threads.
M Apply molybdenum disulfide grease.
O Apply oil to the threads and seating surface.
S Tighten the fasteners following the specified sequence.
SS Apply silicone.
St Stake the fasteners to prevent loosening.
R Replacement parts.
TH05 Threebond 1305 (thread lock strong)
TH27 Threebond 1327 (thread lock medium)
The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts.
Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are
for use with dry solvent-cleaned threads.
Basic Torque for General Fasteners
Threads dia. (mm)
Torque
N-m
5 3.4~4.9
6 5.9~7.8
8 14~19
10 25~34
12 44~61
14 73~98
16 115~155
18 165~225
20 225~325
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Torque table Chassis
Description Component
Torque Remarks
N-m
Sprocket cover
SPROCKET COVER TO C/CASE BOLT, CAP HD, M8 X 30 X 1.25 20
Front wheel SPINDLE FOR CONVENTIONAL FORKS SPINDLE, FRONT WHEEL 60
SPINDLE FOR USD FORKS SPINDLE, FRONT WHEEL, USD FORKS, HIGH BARS
60
Rear wheel TO CLAMP SPROCKET TO CARRIER LOCKNUT, FLANGED, M10 X 1.25 55
SPINDLE NUT LOCKNUT, THIN, M24 X 2 110
Brakes
HALF CLAMP BOLTS BOLT, M6 X 25 X 1.0, FLANGED, CP HD,GOLD
8
BRAKE SYSTEM ONLY BOLT, BANJO, M10 x 1.0 x 30, CHROME 25 BRAKE SYSTEM ONLY BOLT, BANJO, M10 x 1.0 x 18, CHROME 25 BRACKET TO MASTER CYLINDER (remote) BOLT, CAP HD, M6 X 12 X 1.0 6
LEFT HAND CALIPER BRACKET TO FORK (axial) BOLT, CAP HD, M10x20x1.25 35 CALIPER TO BRACKET, BRACKET TO FORK (axial) BOLT, CAP HD, M10x30x1.25 35 6 PER SIDE, PATCH LOCKED (axial) BOLT, BUTTON HD, INT HEX, M8 X 16 25 6 PER SIDE, PATCH LOCKED (radial) BOLT, BUTTON HD, INT HEX, M8 X 20 25 TO CLAMP CALIPER TO FORK (radial) BOLT, CALIPER, RADIAL 35
TO CLAMP REAR MASTER CYLINDER + BRACKET + HEEL GUARD TO HANGER BOLT, CAP HD, M6 X 20 10 TO CLAMP RESERVOIR TO BRACKET BOLT, CAP HD, M6 x 10 8 BRAKE SYSTEM ONLY BOLT, BANJO, M10x1.0x18, CHROME 25 CLAMP P CLIP TO SWINGARM BOLT, CAP HD, M5 X 15 X 0.8 7 REAR CALIPER TO CARRIER BOLT, CAP HD, M8 X 20 X 1.25 28
DISK, PATCHLOCKED BOLT, BUTTON HEAD, INT HEX, M10X20 43 L
19
Description Component Torque Remarks
N-m
Front forks PINCH BOLT SUPPLIED WITH FORKS (for axle) BOLT, CAP HD, M8 X 25 20 LOWER YOKE CLAMP BOLTS BOLT, CAP HD, M8 X 20 X 1.25 20 SWITCH CUBE LH SCREW, M5 X 40 3 SWITCH CUBE LH SCREW, M5 X 30 3 SWITCH CUBE RH SCREW, M5 X 22 3 THROTTLE ACTUATOR,TWIN CABLE THROTTLE ACTUATOR,TWIN CABLE 4 THROTTLE ACTUATOR CLAMP BOLT, CAP HD, M6 X 20 x 1.0 8 TOP YOKE CLAMP BOLTS BOLT, CAP HD, M8 X 20 X 1.25 20 TOP YOKE LOCK NUT NUT, UPPER YOKE, M25 80 ADJUSTER NUT 40NM TO SEAT BEARINGS, BACKED OFF, THEN RE-TORQUED TO 8 NM LOCKNUT, M25
8
LOCKED UP TO ADJUSTER NUT 40 NM STEM INTERMEDIATE NUT, M25 40 REMOTE RESERVOIR BOLT (remote) BOLT, CAP HD, M6 X 12 X 1.0 8 RESERVOIR TO BRACKET (axial) LOCKNUT, FLANGED, M5 X 0.8 7 TO CLAMP SLAVE CYLINDER TO SPROCKET COVER BOLT, CAP HD, M6 X 16 X 1.0
12
HANDLEBAR CLAMP TO YOKE (not cafe racer) NUT, M10 X 1.5
43
UPPER HANDLE BAR CLAMPS BOLTS (not cafe racer) BOLT, CAP HD, M8 X 22 X 1.25
20
Rear suspension SWINGARM PIVOT NUT LOCKNUT, THIN, M16 X 1.0 60
THREADED ADJUSTER, SWINGARM THREADED ADJUSTER, SWINGARM 6
USED TO MOUNT CHAIN RUBING STRIP BOLT BUTTON HD, INT HEX M5 X 20 X 0.8 9
RSU'S TO FRAME BOLT, BUTTON HD, INT HEX, FLANGED, M8 X 16 X 1.25
22
Frame TO CLAMP ENGINE MOUNT BRACKET LOCKNUT, M8 X 1.25 26 NUT, USED WITH ENGINE MOUNT BOLT LOCKNUT, M12 X 1.75 85
FRAME ADJUSTER, M23 FRAME ADJUSTER, M24 15
REAR ENGINE MOUNT BOLT BOLT, M12, ENGINE, REAR MOUNT 85
Foot controls FOOT CONTROL FRAME TO FRAME ASSY BOLT CAP HD, M8 X 50 X 1.25 27 TO CLAMP CLEVIS + PEG ASSY TO CONTROL PLATE LOCKNUT, M10 X 1.5 40 TO CLAMP TOE PEG TO PEDAL BOLT, CAP/HD, M6 X 40 10 TO CLAMP PLATE TO PEDAL BOLT, CSK HD, M4 X 0.7 X 12 7
USE THREE BOND 1327 PIVOT BOLT, SIDESTAND
20
GEAR CHANGE TO SELECTOR SHAFT BOLT, CAP HD, M6 X 40 9
20
Description Component Torque Remarks
N-m
Oil cooler
TO CLAMP OIL COOLER TO FRAME BOLT, CAP HD, M6 X 20 x 1.0 6
Airbox and Exhaust TO AIR FILTER CLAMP BOLT, BUTTON HD, M5x12 4
TO CLAMP TRANSITION PIECE BOLT, CAP HD, M6 X 20 8 TO HEAD LOCKNUT, FLANGED, M8 X 1.25 19
2 REQUIRED FOR HOMOLOGATION LAMBDA SENSOR, EXHAUST, M10 X 1.25 25
USED TO CLAMP EXHAUST SECTIONS EXHAUST CLAMPS 10
Bodywork
TO BOLT HUGGER BOLT, CAP HEAD, M5 X 15 X 0.8 7
Fuel tank FUEL PUMP BOLT, CAP HD, M5 X 12 X 0.8 9
MOULDED TANK TO FRAME BOLT, CAP HD, M6 X 16 X 1.0 9
Electrical system
FOR ROLLOVER SWITCH BOLT, CAP HD, M4 X 25 X 0.7 3
MOUNTED ON LOWER YOKE BOLT, BUTTON HD, INT HEX, M8 X 16 18 TO CLAMP IGNITION COIL PACK BOLT, CAP HD, M6 X 40 X 1.0 10
PANEL TO YOKE FIXING BOLT, CAP HD, M8 X 20 X 1.25 20
Lighting
TO CLAMP NUMBER PLATE LIGHT BOLT, CAP HEAD, M5 X 15 X 0.8 7
21
Torque table Engine
LOC
ATI
ON
Description Component Torque
Re
mar
ks
N-m
CRANKSHAFT ASSEMBLY 8 TO CLAMP TRIGGER DISK BOLT, CSK HD, M5x0.8x12, DIN 7991, 10.9 5
9 PRIMARY GEAR NUT NUT, M20, X 1.5, DIN 934, GRADE 10 122 TH27
VALVE GEAR 19 ROCKER SHAFT BOLTS BOLT, CAP HD, M8 X 35 X 1.25, DIN 912, 12.9 25 TH27
18 ROCKER SHAFT BOLTS BOLT, CAP HD, M8 X 30 X 1.25, DIN 912, 12.9 25 TH27
CAMSHAFT AND CAM DIVE 4 RETAINER PLATE BOLT BOLT, HEX HD, M6 X 12, DIN 933, 8.8, BZP 12 TH27
13 CAM DRIVE NUTS NUT, M14 X 1.5, DIN 934, GRADE 8 54 TH27 17 TENSIONER BOLTS BOLT, CAP HD, M8 X 16 X 1.25, DIN 912, 12.9 25 TH27
20 TENSIONER BOLTS BOLT, CAP HD, M6 X 16 X 1.0, DIN 912, 12.9 12 TH27
CYLINDER HEAD 7 EXHAUST BOLTS STUD, EXHAUST 12 TH03
26 GRUB SCREW ON EXSIDE, HEAD GRUB SCREW, M12 X 1.75 X 20MM, DIN 913, A2 15 TH03 13 ROCKER TOWER, EXHAUST SIDE BOLT, CAP HD, M8 X 50 X 1.25, DIN 912, 12.9 20 TH03 28 ROCKER TOWER, INLET SIDE BOLT, CAP HD, M8 X 55 X 1.25, DIN 912, 12.9 20 TH03 14 CYLINDER HEAD STUDS STUD, HEAD 54 TH03 15 INTERNAL HEAD BOLTS LONG BOLT,CAP HD, M10 X 150 X 1.5, DIN 912, 12.9 60 18 INTERNAL HEAD BOLTS MEDIUM BOLT, CAP HD, M8 X 80 X 1.25, DIN 912, 12.9 25 19 INTERNAL HEAD BOLTS SHORT BOLT, CAP HD, M8 X 110 X 1.25, DIN 912, 12.9, BZP 25 20 CYLINDER HEAD STUD NUTS NUT, DOMED, M10 X 1.5, DIN 1594, A2 60
24 HEAD BREATHER NUT LOCKNUT, M10 X 1.5, GRADE 8 20
CRANK CASE 10 CENTER PIECE SPLIT BOLTS BOLT, CAP HD, M10 X 100 X 1.5, DIN 912, 12.9 48
15 CENTER PIECE TO CRANK CASE BOLTS
BOLT, HEX HD, FLANGED, M8 X 40, DIN 6921, 10.9 25
18 BAFFLE PLATE TO CENTER PLATE BOLT
BOLT, CAP HD, M5 X 12 X 0.8, DIN 912, 12.9 5 TH27
20 CRANK CASE SPLIT BOLTS BOLT, CAP HD, M10 X 75 X 1.5, DIN 912, 12.9, BZP 48 21 CRANK CASE SPLIT BOLTS BOLT, CAP HD, M10 X 45 X 1.5, DIN 912, 12.9, BZP 48 22 CRANK CASE SPLIT BOLTS BOLT, CAP HD, M10 X 40 X 1.5, DIN 912, 12.9, BZP 48 23 CRANK CASE SPLIT BOLTS BOLT, CAP HD, M10 X 60 X 1.5, DIN 912, 12.9 48 24 CRANK CASE SPLIT BOLTS BOLT, CAP HD, M10 X 90 X 1.5, DIN 912, 12.9 48 25 CRANK CASE SPLIT BOLTS BOLT, CAP HD, M6 X 50 X 1.0, DIN 912, 12.9 12 29 SEAL RETAINER BOLT, BUTTON HD, M4x0.7x6.0, ISO 7380, 10.9 2.5 TH27
30 BREATHER SPIGOT BREATHER, CRANKCASE 15 TH27
22
LOC
ATI
ON
Description
Component Torque
Re
mar
ks
N-m
BARRELS 9 LIFTER SELEVE RETAINER BOLT, M5 X 40 X 0.8, 6.00MM DIA, SHOULDERED, SS 6
11 OIL WAY HOLE PLUG BOLT, CAP HD, M8 X 12 X 1.25, DIN 912, A2/70 22
12 BARREL BOLTS BOLT, HEX HD, FLANGED, M8 X 25, DIN 6921, 10.9, BZP 25
CLUTCH /PRIMARY TRANSMISSION
6 CENTER NUT MAIN NUT, HALF, M20 X 1.5, DIN 439, A2 70 122 TH27
GEAR ASSY, INPUT/PUTPUT 23 SELECTOR LINKAGE ARM PIVOT BOLT, M8x1.25x12, 10.0 DIA, SHLD, ISO 7979, 12.9 15 TH03 56 CENTER PLATE TO CASE BOLTS BOLT, CAP HD, M8 X 70 X 1.25, DIN 912, 12.9 25 20 SPRING RETAINER BOLT BOLT, M5x0.8x10, 6.0 DIA, SHLD, ISO 7979, 12.9 5 TH03
44 LAY SHAFT CENTER BOLT BOLT, CAP HD, M8 X 30 X 1.25, DIN 912, 12.9 25 TH27
GEAR SELECTOR ASSEMBLY 22 TO CLAMP DETENT WHEEL BOLT, CAP HD, M6 X 25 X 1.0, DIN 912, 12.9 12
25 TO CLAMP SHIFT MECHANISM BOLT, CAP HD, M6 X 12 X 1.0, DIN 912, 12.9 12
BALANCER
17 GEAR NUT MAIN NUT, HALF, M20 X 1.5, DIN 439, A2 70 122
LUBRICATION SYSTEM 1 OIL PRESSURE SWITCH SWITCH, OIL PRESSURE, 0.2 BAR 20 TH27 9 CLAMP, OIL PUMP TO ENGINE BOLT, CAP HD, M6 X 30 X 1.0, DIN 912, 8.8, BZP 12
13 GEAR BOX FILLER CAP FILLER CAP, GEARBOX 20
21 SUMP PLUG GEARBOX PLUG, SUMP, M10 X 9.0 X 1.5 20
STARTER DRIVE AND MOTOR 4 USED TO CLAMP STARTER RING BOLT, M5x0.8x16, 6.0 DIA, SHLD, ISO 7979, 12.9 5 5 TO CLAMP STARTER MOTOR BOLT, CAP HD, 3/8-24UNF X 1, BZP, 1936 SERIES 20
7 TO CLAMP STARTER MOTOR BOLT, CAP HD, 3/8-24UNF X 3/4, 1936 SERIES 20
SUMP 3 ENGINE SUMP PLUG PLUG, SUMP, MAGNETIC M14 X 1.5 20
5 SUMP RETAINER BOLTS BOLT, CAP HD, M6 X 20 x 1.0, DIN 912, SS 12
23
LOC
ATI
ON
Description
Component Torque
Re
mar
ks
N-m
ENGINE COVERS 3 ROCKER COVER RETAINER BOLTS BOLT, CAP HD, M6 X 20 x 1.0, DIN 912, SS 12 8 RH SIDE BREATHER BOLT BOLT, BANJO, M14 22
23 LH BREATHER BOLT BOLT, BANJO, M14, MOD 22 14 OIL FILLER RETAINER BOLTS BOLT, CAP HD, M5x0.8x14, DIN 912, A2/70 5 15 CLUTCH COVER RETAINER BOLTS BOLT, CAP HD, M6 X 20 x 1.0, DIN 912, SS 12
18 ALTERNATOR COVER RETAINER BOLTS
BOLT, CAP HD, M6 X 40, DIN 912, SS 12
19 ALTERNATOR COVER BOLT SHORT BOLT, CAP HD, M6 X 30 X 1.0, SS 12
EFI SYSTEM 1 TEMPERATURE SENSOR SENSOR, TEMPERATURE 15 4 TO CLAMP SPEED SENSORS BOLT, CAP HD, M6 X 12 X 1.0, DIN 912, 12.9, BZP 12 5 NEUTRAL LIGHT SWITCH SWITCH, NEUTRAL, M10x1.25 12
7 FIRST USE TORQUE ONLY SPARK PLUG, CR9EB 12
ALTERNATOR 2 TO CLAMP ROTOR TO COVER BOLT, CAP HD, M8 X 16 X 1.25, DIN 912, 12.9 25 TH27 4 TO CLAMP STATOR TO COVER BOLT HEX, HD, M6 X 35 DIN 933, 10.9 12 7 TO CLAMP P-CLIP TO COVER BOLT, BUTTON HD, INT HEX, M5 X 10, ISO 7380, 10.9 5
8 USED TO CLAMP CRANK SENSOR BOLT, CAP HD, M5 X 10 X 0.8, DIN 912, 12.9 5
24
Special tools
36mm slim head stock spanner
Engine adjuster tool
Swingarm adjust tool
Anti backlash gear holder
25
Anti backlash spring Tensioner
Clutch tool
Main shaft stop tool
26
Cable, Wire and Hose Routing
Rout the electrical wires as shown:
27
Route the oil pipes as shown:
Note: Oil is sucked from the back of the oil tank [1] and pumped under
pressure through the engine oil feed system.
Oil is scavenged from the sump by the oil pump [2] and pumped
through the radiator [3] into the oil tank [4].
The oil tank LH breather [5], breathes into the back of the head.
The crank case breather [6] breathes into the LH rocker cover.
The RH rocker cover breather [7] breathes into the air box.
1
2
3
4 5
7
6
28
Fuel System
Exploded View .................................................................................................................................................. 29
Specification ..................................................................................................................................................... 32
Throttle Grip and Cables .................................................................................................................................. 32
Grip Free Play Inspection ..................................................................................................................... 32
Grip Free Play Adjustment ................................................................................................................... 32
Throttle Cable Removal ....................................................................................................................... 32
Throttle Cable Installation ................................................................................................................... 33
Throttle Cable Lubrication ................................................................................................................... 33
Throttle Body ................................................................................................................................................... 34
Idle Speed Adjustment ......................................................................................................................... 34
Throttle Body Removal ........................................................................................................................ 34
Throttle Body Installation ................................................................................................................................... 35
Throttle Body Disassembly .................................................................................................................. 36
Throttle Body Assembly ....................................................................................................................... 37
Throttle Body Cleaning ........................................................................................................................ 37
Throttle Body Inspection ..................................................................................................................... 37
Air Cleaner ........................................................................................................................................................ 37
Air Cleaner Element Removal .............................................................................................................. 37
Air Cleaner Element Installation .......................................................................................................... 38
Air Cleaner Element cleaning and Inspection ...................................................................................... 38
Air Cleaner Housing Removal .............................................................................................................. 39
Fuel Tank .......................................................................................................................................................... 39
Fuel Tank Removal ............................................................................................................................... 39
Fuel Tank Installation ........................................................................................................................... 40
Fuel Tank Cleaning ............................................................................................................................... 40
Fuel Pump ........................................................................................................................................................ 41
Fuel Pump Removal ............................................................................................................................. 41
Fuel Pump Installation ......................................................................................................................... 41
Fuel Pump Inspection .......................................................................................................................... 41
Idle Motor ........................................................................................................................................................ 42
Idle Motor Removal ............................................................................................................................. 42
Idle Motor Installation ......................................................................................................................... 42
Idle Motor Inspection .......................................................................................................................... 42
29
30
REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
1 FUEL PUMP MODULE BITRON
2 BOLT, CAP HD, M5 X 12 X 0.8 9
3 HOSE, BREATHER, SHORT, 205MM FUEL TANK TO JOINER
4 DRAIN HOSE, FUEL TANK, LONG, 635MM JOINERS TO DRAIN
5 HOSE, BREATHER, 230MM FUEL TANK TO JOINER
14 HOSE, BREATHER, 485MM AIRBOX TO DRAIN
6 HOSE, BREATHER, JOINER JOINS
7 FILLER NECK, FUEL TANK PLASTIC FILLER NECK FOR FUEL TANK
10 PAD, RUBBER, FUEL TANK TO FRAME MOULDED RUBBER PIECE
11 BOLT, CAP HD, M6 X 12 X 1.0 TO BOLT TANK PAD TO TANK
12 FUEL TANK, MOULDED AS RECIEVED FROM ACERBIS
15 WASHER, PENNY, M6, 6.4 X 18 1.6 TO FIT ON EACH SIDE OF RUBBER PAD TO
THE FRAME
13 BOLT, BUTTON HD, M6 X 1.0 SHOULDERED
FLANGED TO CLAMP SPLASH SHIELD + TANK
16 FUEL HOSE ASSEMBLY 94MM HOSE WITH TWO CONNECTORS
12 TANK, FUEL, GALACTIC BLACK, GOLD TEXT
12 TANK, FUEL, ROYAL RED, GOLD TEXT
12 TANK, FUEL, CANARY YELLOW, BLACK TEXT
12 TANK, FUEL, FACTORY SPECIAL SILVER,
BLACK TEXT
12 TANK, FUEL, FACTORY SPECIAL SILVER, BLACK TEXT/BORDER, RED PIN STRIPE
31
Exploded view
32
Throttle Specification
Item Standard
Throttle Grip Free Play 2~3mm
Idling Speed 1200 ± 100 (rpm) Make, Type Jenvey, Norton Commando
Air Cleaner Element Oil Grade SE or SF Class
Viscosity SAE30
Throttle Grip and Cables
If the throttle grip has excessive free play due to cable stretch or maladjustment, there will be a delay in
throttle response. Also, the throttle butterfly may not open fully at full throttle. On the other hand, if the
throttle grip has no play, the throttle will be hard to control, and the idle speed will be erratic. Check the
throttle grip play periodically in accordance with the Periodic Maintenance Chart, and adjust the play if
necessary.
Grip Free Play Inspection
Check throttle grip free play[A] by lightly turning the
throttle grip back and forth
If free play is improper, adjust the throttle cable
Throttle Grip Free Play
Standard: 2 ~ 3mm
Grip Free Play Adjustment
Loosen the locknut and screw the throttle cable adjuster
on the rear cable (no. 1) so there is approximately 2-3mm
free play at the throttle grip. Adjust the front cable (no. 2)
until there is slight tension on the front cable.
Tighten the locknuts against the cable adjusters.
Check that the throttle cam stops against the idle adjusting
screw with the throttle grip closed.
Turn the handlebars from side to side while idling the engine.
If idle speed varies, the cable may be poorly routed or damaged.
Warning: Operation with an improperly adjusted, incorrectly routed, or damaged cable could result in an
unsafe riding condition.
Throttle Cable Removal
Remove: Fuel Tank (see this chapter)
Take off the adjuster nuts [A] at the throttle body.
A
33
Slip the inner clips [B] out of the lever
Remove the right hand guard off the brake level.
Take the two screws [A] holding the throttle pulley case
halves together.
Slip the inner cable tips from the catches on the throttle
pulley, and free cables from the handlebar.
- Inner Cable Tips [A]
- Pulley [B]
- Accelerator Cable [C]
Remove the throttle cables.
Throttle Cable Installation
Lubricate the throttle cables (see Throttle Cable
Lubrication and Inspection).
Be sure to fit the throttle cables into the grooves of the
cable guide [A] while turning the throttle grip.
Install the throttle cables in accordance with the Cable,
Wire, and Hose Routing section of the General Information
chapter
After Installation, adjust the cables properly.
Warning: Operation with an incorrectly routed or improperly adjusted cable could result in an unsafe riding
condition.
Throttle Cable Lubrication and Inspection
Whenever the Cables are removed, and in accordance with the Periodic Maintenance Chart,
lubricate the throttle cables (see General Lubrication in the Appendix).
Apply a thin coating of grease to the cable upper ends.
Use a pressure cable luber to lubricate the cables
With the cables disconnected at both ends, the cable should move freely in the cable housing.
B A
A
B
C
A
A
34
Throttle Body
A dirty or damaged air cleaner can alter the fuel air ratio.
Idle speed Adjustment
Start the engine and let it warm up thoroughly.
With the engine idling, turn the handlebar to each side. If
the handlebar movement changes idle speed, the throttle
cable may be incorrectly routed, or it may be damaged.
Turn the adjuster screw [A] to obtain the slowest smooth
idle speed.
Check idle speed. If the idle speed is out of the specified
range, adjust it.
Idle speed standard: 1200 ± 100 (rpm)
Open and close the throttle a few times to make sure that the idle speed does not change. Readjust
if necessary.
Warning: Operation with an incorrectly routed or improperly adjusted cable could result in an unsafe riding
condition. To avoid a serious burn, never touch a hot engine or an exhaust pipe during idle adjustment.
Throttle body Removal
Warning: Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or
sparks; this includes any appliance with a pilot light.
Remove:
o Fuel hose from tank
o Idle motor air feed
o Throttle body and idle motor power supply
Remove:
o Fuel tank (see this chapter)
o Tank breather hose
o Air cleaner housing (see this chapter)
Loosen the cable adjuster nuts [A].
Slip the throttle cable lower ends out of the throttle cam.
Loosen the clamps [B]
Remove Four throttle body bolts [A]
Remove the throttle body upward.
B
A
A
35
Push a clean, lint-free towel into the inlet to keep dirt or other foreign material from entering.
Warning: If dirt or dust is allowed to pass through into the throttle body, the throttle may become stuck,
possibly causing an accident
Caution: If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.
Throttle body Installation
Apply RED grease to the ‘O’ rings on the throttle body gasket making sure they stay in place.
Torque the four throttle body bolts up
Torque: M6 Bolt - 12NM
When Installing air box ensure transition piece ridges fit
over throttle body correctly
Tighten clamps [A]
Install:
o Fuel tank (see this chapter)
o Tank breather hose
o Air cleaner housing (air box) (see this chapter)
Install:
o Fuel hose from tank
o Idle motor air feed
Throttle body and idle motor power supply
Check fuel leakage from the Throttle body.
Warning: Fuel spilled from the throttle body is hazardous.
Install the throttle cables (see Throttle Cable Installation)
Adjust the throttle cable (see Grip Free Play Adjustment)
Adjust the idle speed (see Idle Speed Adjustment)
A
A
36
Throttle Body Disassembly
Remove:
Throttle body
Remove fuel hose
Remove:
bolts [13]
Fuel Injector clips
Fuel rail [2]
Injectors [21]
Throttle potentiometer bolts [15]
Throttle potentiometer [5]
Four butterfly bolts [12]
Remove the butterflies [7]
Extract the spindle taking note of the spacer, bearing, spring assembly sequence and location
Warning any damage to the injector system or potentiometer should be replaced not repaired.
37
Throttle Body Assembly
The Throttle Body assembly Sequence is the reverse of the disassembly sequence (see Throttle
Body Disassembly)
Ensure the throttle cable spring is installed correctly and rotates freely.
Check bushes for Wear and tear, replace if necessary.
Ensure all seals are intact replaced if any wear or degradation is visible.
Ensure no daylight is visible between the throttle butterflies and the throttle body hosing and that
the butterflies are seated correctly.
Throttle Body Cleaning
Warning: Clean the throttle body in a well-ventilated area, and take care that there is no spark or flame
anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of
highly flammable liquids, do not use gasoline or low-flash point solvents to clean the throttle bodies. A fire
or explosive could result.
Caution: Remove as many plastic parts from the throttle body as possible before cleaning the throttle body
with a cleaning solution. This will prevent damage or deterioration of the parts.
Disassemble the carburettor (see Throttle Body Disassembly).
Immerse all the metal parts in throttle body cleaning solution.
Rinse the parts in water.
When the parts are clean, dry them with compressed air.
Assemble the throttle body (see Throttle Body Assembly)
Throttle Body Inspection
Remove the throttle body (see Throttle Body Removal).
Turn the throttle lever [A] to check that the throttle
butterfly valve [B] moves smoothly and returns back with
the spring force.
If any of the O-rings are not in good condition, replace
them.
Air Cleaner
Air Cleaner Removal
Remove:
Seat (see Frame chapter)
Air cleaner retainer screws [A]
Air cleaner retainer [B]
Remove air cleaner element.
After removing the element, push pieces of lint-free, clean
cloth into the air cleaner duct to keep dirt out of the
A B
B A
38
throttle body and engine.
Warning: If dirt or dust is allowed to pass through into the throttle body, the throttle may become stuck,
possible causing an accident.
Caution: If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.
Air Cleaner Element Installation
When installing the element, coat the lip of the element
with a thick layer of all purpose grease [A] to assure a
complete seal against the air cleaner element base. Also,
coat the base where the lip of the element fits.
Be sure the foam gasket [A] is in place in the groove in the
element cap.
Air Cleaner Element Cleaning and Inspection
Note: In dusty areas, the element should be cleaned more frequently than recommended interval.
Since repeated cleaning opens the pores of the element, replace it with a new one in accordance with the
Periodic Maintenance Chart. Also, is there is a break in the element material or any other damage to the
element, replace the element with a new one.
Warning: Clean the element in a well ventilated areas, and take
care that there are no sparks or flames anywhere in the working
area; this includes any appliance with a pilot light.
Because of the danger of highly flammable liquids, do not use
gasoline or a low-flash point solvent to clean the element.
Remove the air cleaner element.
Check all parts the parts of the element for visible damage.
If any parts of the element are damaged, replace it.
Liberally spray Air Filter Cleaner onto both sides of filter and allow to soak for 10 minutes to loosen
the dirt. Do not allow cleaner to dry on air filter.
Rinse off air filter with cool low-pressure water applied to the clean side out in order to flush the
dirt out of the filter. Continue to rinse the filter until all traces of cleaner are gone. It may be
necessary to repeat steps 1 and 2.
After rinsing, gently shake off excess water and only allow filter to dry naturally. Do not oil until the
filter is completely dry.
Apply Air Filter Oil evenly along the crown of each pleat. Allow oil to wick for approximately 20
minutes. Touch up any light areas on either side of filter until there is a uniform colour in all areas.
Install the element
A
39
Air Cleaner Housing Removal
Remove:
Seat (see Frame chapter)
Breather Hoses
Rear Wheel
Rear Hugger
Fully loosen off the two jubilee clips [A] securing the
transition piece to the air cleaner housing.
Remove the two hex head bolts [A] at the rear of the air
filter housing.
Fuel Tank
Fuel Tank Removal
Warning: Gasoline is extremely flammable and can be explosive
under certain conditions. Always stop the engine and do not
smoke. Make sure the area is well ventilated and free from any
source of flame or sparks; this includes appliances with a pilot
light.
Remove:
Seat (see Frame Chapter)
Breather hoses
Remove fuel hose, cover hose clips with lint free cloth
when taking off as fuel will spill out.
Remove fuel pump electrical connection.
Remove hex head tank bolts, one at the front [A] and two
at the rear [B].
Remove tank upwards from the bike
Drain the fuel tank by siphoning the fuel out through the
fuel filler cap into a clean container.
A
A
B
Note: 2nd on other side of frame
A
40
Fuel Tank Installation
Check the rubber damper [A] on the frame and fuel tank.
If the dampers are damaged or deteriorated, replace them.
Be sure the fuel hose is clamped to the spigot to prevent
leakage.
Warning: Fuel spilled from the fuel spigot connecter is hazardous.
Install:
o Seat (see Frame Chapter)
o Breather Hoses
o Fuel Hose
o Fuel Pump Electrical Connection.
Install hex head tank bolts, two at the front one at the
rear.
Torque: Tank Mount Bolts - 9NM
Fuel Tank Cleaning
Remove the fuel tank and drain it (see Fuel Tank Removal)
Pour some high-flash point solvent into the fuel tank and shake the tank to remove dirt and fuel
deposits.
Warning: Clean the tank in a well-ventilated area and take care that there is no spark or flame anywhere
near the working area; this includes any appliance with a pilot light. Because of the danger of highly
flammable liquids, do not use gasoline or low flash point solvents to clean the tank. A fire or explosion
could result.
Pour the solvent out the tank.
Pour high-flash point solvent through the fuel spigot.
Dry the tank and tap with compressed air.
Install the fuel tank.
A
41
Fuel Pump
Note: The fuel pump, fuel filter and low fuel level sensor is a sealed for life unit and must be replaced as a
complete assembly.
Fuel Pump Removal
Remove the fuel tank and drain it (see Fuel Tank Removal).
Warning: Observe the warning advice given in general information sections on the safe handling of fuel and fuel
containers. A fire, causing personal injury and damage to property, could result from spilled fuel or fuel not handled
or stored correctly.
Invert the fuel tank and place on a protective surface to
prevent paint damage.
Remove the fixings securing the fuel pump [A].
Lift the fuel pump assembly and manoeuvre it from the
tank aperture.
Fuel Pump Installation
Install the fuel pump assembly and manoeuvre it into the tank aperture, ensure the gasket is seated
correctly and all gasket faces are clean.
Install the six fuel pump bolts.
Torque: Fuel Pump Mount Bolts - 3NM
Install the fuel tank (see Fuel Tank Installation).
Fuel Pump Inspection
Note: Fuel Pump Pressure test requires Inline pressure gauge, and fuel pump fly lead (extension cable) available
from Norton Motorcycles (UK) Ltd.
Remove the Fuel tank (see Fuel Tank Removal).
Attach Extension cable to pump electrical connection, and wiring harness.
Attach Inline Pressure tester to Pump and throttle bodies.
Place the pressure gauge in a visible position with the fuel tank upright on a flat surface, with a soft
cloth to stop paintwork damage.
Start the motorcycle and observe the fuel pressure.
Fuel Pressure Nominal: 3 Bar
A
42
When finished remove extension cable and inline pressure tested and install the fuel tank (see fuel
tank installation.
Idle Motor
Idle Motor Removal
Remove:
o Idle motor hose clips
o Hoses
o Electrical connections
Remove idle motor bracket bolts [A].
Remove idle motor bolts [B].
Idle Motor Installation
Install:
o Idle motor hoses
o Electrical connector
o Hoses clips
Install and tighten idle motor bracket bolts
Torque – Idle Bracket Bolts: 5Nm
Torque Idle motor bolts
Torque – Idle Motor Bolts: 5Nm
Idle Motor Inspection
Visually inspect the idle motor for damage/cracks, and or deterioration
Replace if any issues are visible.
A
B
43
Cooling System
Exploded View .................................................................................................................................................. 45
Flow Chart ........................................................................................................................................................ 47
Specification ..................................................................................................................................................... 48
Engine Oil and Filter ......................................................................................................................................... 49
Oil Level Inspection .............................................................................................................................. 49
Oil Draining ........................................................................................................................................... 49
Oil Filling ............................................................................................................................................... 50
Oil Pump ........................................................................................................................................................... 50
Oil Pump Removal ................................................................................................................................ 50
Oil Pump Installation ............................................................................................................................ 51
Oil Pump Inspection ............................................................................................................................. 51
Oil Cooler ......................................................................................................................................................... 51
Oil Cooler Removal .............................................................................................................................. 51
Oil Cooler Installation .......................................................................................................................... 52
Oil Cooler Inspection ............................................................................................................................ 52
Oil Cooler Cleaning ............................................................................................................................... 52
Hose Inspection .................................................................................................................................... 52
Head Temperature Sensor ............................................................................................................................... 53
Head Temperature Sensor Removal .................................................................................................... 53
Head Temperature Sensor Installation ................................................................................................ 53
Head Temperature Sensor Inspection ................................................................................................. 53
44
Oil Coolant Flow
Note: Oil is sucked from the back of the oil tank [1] and pumped under
pressure through the engine oil feed system.
Oil is scavenged from the sump by the oil pump [2] and pumped
through the radiator [3] into the oil tank [4].
The oil tank LH breather [5], breathes into the back of the head.
The crank case breather [6] breathes into the LH rocker cover.
The RH rocker cover breather [7] breathes into the air box.
1
2
3
4 5
7
6
45
46
REF. NO. PART DESCRIPTION TORQUE REMARKS
1 SWITCH, OIL PRESSURE, 0.2 BAR 20 THREEBOND 1327
8 PUMP ASSY, OIL
11 PIN, DOWEL, 1/8 X 5/8, SOLID USED WITH OIL PUMP DRIVE
12 PIN, DOWEL, 4.0 X 16.00MM, SOLID USED WITH PUMP TO CASE
9 BOLT, CAP HD, M6 X 30 X 1.0, DIN 912, 8.8, BZP 12 CLAMP, OIL PUMP TO ENGINE
10 WASHER, ID 6.4 X 11.0 OD X 1.6 STAINLESS USED WITH OIL PUMP BOLTS
13 FILLER CAP, GEARBOX 20
14 WASHER, ID 26.3 X 31.75 X 2.0, COPPER GEAR BOX FILLER CAP
15 FILTER, OIL
20 SEAL, M10, BONDED VITON
21 PLUG, SUMP, M10 X 9.0 X 1.5 20
22 LABEL, SILKOLENE, 10W/40 APPLY TO RH COVER ABOVE FILTER COVER
47
48
Specification
Oil Specification
Item Standard
Engine Oil: Grade API SG, SH AND SJ, JASO MA Viscosity SAE 10W-40 Capacity 3L FROM COMPLETELY DRY
2.5L WHEN FILTER REMOVED
Oil Pressure Measurement: Relief valve opening pressure 400kPa
oil pump pressure @8000rpm with 130˚C 10W/40 oil 6L/min and 300kPa
oil pump pressure @1000rpm with 130˚C 10W/40 oil 150kPa
REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
1 COOLER, OIL
2 GROMMET, ID 14 X OD 9 X 12.5
3 COMPRESSION LIMITER, M6 X 20MM OD
4 BOLT, CAP HD, M6 X 20 x 1.0 6 TO CLAMP OIL COOLER TO FRAME
5 WASHER, PENNY, M6, 6.4 X 18 X 1.6 USED WITH OIL COOLER BOLTS
OIL LINE EN 854 100R6 - 06 (RAW)
6 OIL LINE, 215MM OIL COOLER TO OIL TANK
7 OIL LINE, 685MM OIL COOLER TO OIL PUMP, 685MM
8 OIL LINE, 490MM OIL PUMP TO OIL TANK, 490MM
9 OIL LINE 400MM ROCKER COVER TO CRANKCASE 400MM
10 OIL LINE, 300MM HEAD TO AIR BOX, 300MM
11 HOSE, BREATHER, FORMED, 360MM ROCKER COVER TO OIL TANK
12 BANJO, OIL LINE, IN
13 BANJO, OIL LINE, OUT
14 WASHER, M14, OD 20.4MM X 1.22, COPPER ONE EITHER SIDE OF OIL BANJO
15 BOLT, BANJO, OIL LINE USED FOR OIL LINE IN AND OUT
16 O-CLAMP, DOUBLE EARED, 15MM-18MM OIL LINE AND BREATHER PIPE CLIPS
17 SMALL BREATHER HOSE TO ROCKER COVER
49
Engine Oil and Oil Filter
Warning: Motorcycle operation with Insufficient, deteriorated or contaminated engine oil will cause
accelerated wear and may result in engine or transmission seizure, accident, and injury.
Oil Level Inspection
Situate the motorcycle so that it is perpendicular to the ground.
If the oil has just been changed, start the engine and run it for several minutes at idle speed. This
fills the oil filter with oil.
Caution: Racing the engine before the oil reaches every part can cause engine seizure.
Stop the engine and leave it for more than 1 minute for
all the oil to drain down.
If the motorcycle has just been ridden, run the engine for
about 20 seconds at idle speed. Stop the engine and
leave it for more than one minute.
Check the engine oil by removing the oil filler [A], clean
the dip stick with a cloth fully reinsert the plug then
remove it again and check the level on the dip stick.
The oil level should be in the middle of the two markings.
If the oil level is difficult to check, rock the motorcycle
both side-to-side, and front-to-rear.
If the oil level is too high, remove the excess oil through
the filler opening, using a syringe or some other suitable
device.
If the oil level is too low, add the correct amount of oil
through the oil filler opening. Use the same type and
make of oil that is already in the engine.
Note: If the engine oil type and make are unknown, use any brand of the specified oil to top off the level
rather than running the engine with the oil level low. Then at your earliest convenience, change the oil
completely.
Oil Draining
Warning: To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is
still hot. Wait until it cools down. Oil on tires will make them slippery and can cause an accident and injury.
Immediately wash away any coolant that spills of the frame, engine, or wheels. Since oil is harmful to the
human body, do not use for drinking.
Place a container under the drain plug [A] at the bottom of
the sump, remove oil filler cap and then remove the drain
plug.
Min
Max
A
A
50
Place a tray under the bottom radiator hoses [A],
remove the bottom banjo bolt [B] and drain the oil
from the oil tank hose.
Oil Filling
Tighten the drain plug.
Torque – Oil sump drain Plug 20Nm
Fill the oil tank with 2.5L of oil and tighten the filler cap.
Run the engine at idle for 2 minutes in a well ventilated
area. Allow the motorcycle to stand for 2 minutes.
Check the oil level as described in (Oil Level Inspection)
top up if necessary.
Note: Pour in the oil slowly so that the air in the engine and oil cooler can escape.
Caution: Do not add more oil above the full mark.
Oil Pump
Oil Pump Removal
Drain the oil (see Oil Draining)
Remove Oil Pump hoses [A]
Remove Oil Pump retainer bolts [A]
Remove the oil pump from the engine and balance
shaft taking care that the drive dowel pin [A] remains
in the oil pump drive shaft.
B
A
A
A
A
51
Oil pump Installation
Apply a small amount of grease to the drive pin to
ensure the pin remains located
Align the drive dowel pin with the balance shaft cut out
[A] and the oil pump dowels with the engine casing.
Install the oil pump retaining bolts.
Torque – Retaining bolts oil pump 12NM
Install the hoses as shown.
Hose from radiator [A]
Hose from tank [B]
Torque - banjo Bolts to 27 Nm
Fill the oil system (see Oil Filling).
Oil Pump Inspection
If the oil seal is damaged, the oil leaks through the seal.
Replace the ball bearing and oil seal.
Oil Cooler
Oil Cooler Removal
Drain the oil (see Oil Draining)
Remove:
o Oil Cooler Hoses [A]
o Oil Cooler Bolts [B]
Caution: Do not touch the Oil Cooler core. This could damage
the radiator fins, resulting in loss of cooling efficiency.
A
B
B
C
A
A
52
Remove the Oil Cooler [C]
Oil Cooler Installation
Run the hoses and leads according to the Cable, Wire,
and Hoses Routing section in the General Information
chapter.
Oil Cooler Inspection
Check the Oil Cooler core.
If there are obstructions to air flow, remove them.
If the corrugated fins [A] are deformed, carefully
straighten them.
If the air passages of the Oil Cooler core are blocked
more than 20% by unremovable obstructions or
irreparably deformed fins, replace the Oil Cooler with
a new one.
Oil Cooler Cleaning
Remove the Oil Cooler (see Oil Cooler remover).
Caution: When cleaning the Oil Cooler with steam cleaner, be
careful of the following to prevent Oil Cooler damage. Keep
the steam gun [A] away more than 0.5m [B] from the Oil
Cooler core [C]. Hold the steam gun perpendicular to the core
surface. Run the steam gun following the core fin direction
[D].
Hose Inspection
In accordance with the Periodic Maintenance Chart, visually inspect the Oil Cooler hoses for signs of
deterioration. Squeeze the hose. A hose should not be hard and brittle, nor should it be soft or
swollen.
Replace and damaged hose.
A
B C
D
A
53
Head Temperature Sensor
Head Temperature Sensor Removal
Remove Idle air motor assembly
(see Fuel System chapter)
Remove electrical connection from sensor.
Remove the connector by unscrewing it.
Head Temperature Sensor Installation
Install and tighten the connector.
Torque – Head Temp Sensor: 15Nm
Install electrical connector on sensor.
Install idle air motor assembly (see Fuel System chapter).
Head Temperature Sensor Inspection
Check the sensor visually for cracks/deterioration or visible signs of damage.
If the sensor if thought to be faulty replace.
54
Engine Top End
Exploded View .................................................................................................................................................. 56
Specification ..................................................................................................................................................... 71
Cylinder Head Cover ........................................................................................................................................ 73
Cylinder Head Cover Removal ............................................................................................................. 73
Cylinder Head Cover Installation ......................................................................................................... 73
Cylinder Head Cover Assembly ............................................................................................................ 74
Camshaft Chain Tensioner ............................................................................................................................... 74
Camshaft Chain Tensioner Removal .................................................................................................... 74
Camshaft Chain Tensioner Installation ................................................................................................ 75
Camshaft, Camshaft Chain ............................................................................................................................... 76
Camshaft Chain Removal ..................................................................................................................... 76
Camshaft Chain Installation ................................................................................................................. 76
Camshaft Removal ............................................................................................................................... 76
Camshaft Installation ........................................................................................................................... 77
Camshaft Disassembly ......................................................................................................................... 78
Camshaft Assembly .............................................................................................................................. 78
Camshaft Bearing Wear ....................................................................................................................... 78
Cylinder Head ................................................................................................................................................... 79
Cylinder Compression Measurement .................................................................................................. 79
Cylinder Head Removal ........................................................................................................................ 80
Cylinder Head Installation .................................................................................................................... 82
Cylinder Head Assembly ....................................................................................................................... 83
Cylinder Head Disassembly .................................................................................................................. 84
Cylinder Head Cleaning ........................................................................................................................ 84
Cylinder Head Warp ............................................................................................................................. 84
Valves ............................................................................................................................................................... 85
Valve Clearance Measurement ............................................................................................................ 85
Valve Clearance Adjustment ................................................................................................................ 85
Valve Removal ...................................................................................................................................... 85
Valve Installation .................................................................................................................................. 86
Valve-to-Guide Clearance Measurement ............................................................................................ 86
Valve Seat Inspection ........................................................................................................................... 86
Valve Seat Repair (Valve Lapping) ........................................................................................................ 87
Cylinder, Piston ................................................................................................................................................ 90
Cylinder, Piston Removal ..................................................................................................................... 90
Cylinder, Piston Installation and Ware ................................................................................................ 91
Piston/Cylinder Clearance .................................................................................................................... 93
Cylinder Boring and Honing ................................................................................................................. 93
Piston Ring and Ring Grove Wear ........................................................................................................ 93
Piston Ring End Gap Measurement ..................................................................................................... 93
Exhaust System ................................................................................................................................................ 94
55
Silencer Removal .................................................................................................................................. 94
Secondary Removal .............................................................................................................................. 94
Header Pipes Removal ......................................................................................................................... 95
Exhaust Pipe Installation .................................................................................................................................. 95
56
Exploded View
57
REF. NO. PART DESCRIPTION TORQUE REMARKS
1 CYLINDER HEAD, ASSY, MC/D
2 CYLINDER HEAD, MACHINING
CYLINDER HEAD, CASTING
3 VALVE GUIDE, INLET
4 VALVE GUIDE, EXHAUST
5 SEAT, VALVE, INLET
6 SEAT, VALVE, EXHAUST
7 STUD, EXHAUST 12 THREEBOND 1305
26 GRUB SCREW, M12 X 1.75 X 20MM, DIN 913, A2 15 THREEBOND 1305
8 GASKET, CYLINDER HEAD
9 TOWER, ROCKER, LH, MC/D
10 TOWER, ROCKER,RH, MC/D
11 PIN, DOWEL, 6.00 X 12.0, DIN 7, SS
27 WASHER, M8, NORDLOCK
13 BOLT, CAP HD, M8 X 50 X 1.25, DIN 912, 12.9 20 EXHAUST, TB 1305
28 BOLT, CAP HD, M8 X 55 X 1.25, DIN 912, 12.9 20 INLET, TB 1305
12 WASHER, M8, ID 8.4 X OD 15 X 1.6, BZP
14 STUD, HEAD 54 TB 1305
15 BOLT,CAP HD, M10 X 150 X 1.5, DIN 912, 12.9 60
18 BOLT, CAP HD, M8 X 80 X 1.25, DIN 912, 12.9 25
19
BOLT, CAP HD, M8 X 110 X 1.25, DIN 912, 12.9,
BZP 25
20 NUT, DOMED, M10 X 1.5, DIN 1594, A2 60
CMD EXTREME PRESSURE LUB #3, 4oz APPLY TO STUD FIXINGS AS REQUIRED
16 WASHER, M10, 10.5 X 21.0 X 2, DIN 125A, A2
21 SPACER, EXHAUST SPRING
22 SPACER, INLET SPRING
23 BREATHER FITTING, ASSY, CYLINDER HEAD
BREATHER FITTING, BODY
BREATHER FITTING, BARB
25 SEAL, M10, BONDED VITON INSIDE ENGINE BETWEEN HEAD AND WASHER
24 LOCKNUT, M10 X 1.5, GRADE 8 20
29 WASHER, 10.5 X 21.0 X 1.2, FORM B, A2 INSIDE ENGINE ON TOP OF SEAL
WASHER
16 WASHER, M10, 10.5 X 21.0 X 2, DIN 125A, A2 ON THE OUT SIDE OF THE ENGINE
58
59
REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
25 COVER ASSY, ROCKER
1 COVER, ROCKER, MACH
2 GASKET, ROCKER, COVER
3 BOLT, CAP HD, M6 X 20 x 1.0, DIN 912, SS 12
5 BANJO,M14, 9MM SPIGOT
6 WASHER, M14, OD 20.0MM X 2.5 ALUMINIUM
7 WASHER, M14, OD 20.4MM X 1.22, COPPER
8 BOLT, BANJO, M14 22
22 NUT, M14 X 1.5, THIN, STEEL
23 BOLT, BANJO, M14, MOD 22
24 BREATHER BAFFLE, ASSY
BREATHER BAFFLE, FRONT
BREATHER BAFFLE, REAR
BREATHER BAFFLE, WELD NUT
9 COVER, RH, MC/D
10 GASKET, COVER, RH
11 DOWEL, RING, 7.8MM DIA
26 COVER ASSY, OIL FILTER
12 COVER, OIL FILTER, MC/D
27 TOP HAT, OIL FILTER, COVER
28 BELLEVILLE, SPRING
29 O-RING, 14MM X 2MM, VITON
30 RING, WIRE, 18MM, PLAIN, EXTERNAL
13 O-RING, 67MM X 2 MM, VITON
14 BOLT, CAP HD, M5x0.8x14, DIN 912, A2/70 5
15 BOLT, CAP HD, M6 X 20 x 1.0, DIN 912, SS 12
16 COVER, CLUTCH, MC/D
17 GASKET, COVER, CLUTCH
11 DOWEL, RING, 7.8MM DIA
18 BOLT, CAP HD, M6 X 40, DIN 912, SS 12
19 BOLT, CAP HD, M6 X 30 X 1.0, SS 12
31 LABEL, SILKOLENE, 10W/40 LABEL FOR ENGINE OIL
60
REF. NO. PART DESCRIPTION TORQUE REMARKS
1 PISTON ASSY, LH
ORIENTATE DIMPLE INBOARD
3 PISTON, MC/D, LH
5 1ST RING, PISTON, 88.0 X 1.0 STEEL NITRIDE
6 2ND RING, PISTON, 88.0 X 1.2 PHOSPHATE
7 OIL RING, PISTON 88.0 X 2.8 STEEL NITRIDE
8 GUDGEON PIN
9 CIRCLIP, DIA 22 X 1.5 SECTION
2 PISTON ASSY, RH
ORIENTATE DIMPLE INBOARD
4 PISTON, MC/D, RH
5 1ST RING, PISTON, 88.0 X 1.0 STEEL NITRIDE
6 2ND RING, PISTON, 88.0 X 1.2 PHOSPHATE
7 OIL RING, PISTON 88.0 X 2.8 STEEL NITRIDE
8 GUDGEON PIN
9 CIRCLIP, DIA 22 X 1.5 SECTION
9 CIRCLIP, DIA 22 X 1.5 SECTION
61
62
REF. NO. PART DESCRIPTION TORQUE REMARKS
3 LIFTER, PUSHROD
2 PUSHROD, EXHAUST
1 PUSHROD, INLET
4 ROCKER, EXHAUST, LH ASSY
5 ROCKER, EXHAUST, LH MC/D
6 BEARING, BUSH, ROCKER
7 PIN, ROLLER
8 ADJUSTER, ROCKER
9 NUT, 3/8-24 UNF
20 BEARING, BUSH, ROCKER ARM
10 ROCKER, EXHAUST, RH, ASSY
11 ROCKER, EXHAUST, RH, MC/D
6 BEARING, BUSH, ROCKER
7 PIN, ROLLER
8 ADJUSTER, ROCKER
9 NUT, 3/8-24 UNF
20 BEARING, BUSH, ROCKER ARM
12 ROCKER, INLET, LH, ASSY
13 ROCKER, INLET, LH, MC/D
7 PIN, ROLLER
6 BEARING, BUSH, ROCKER
8 ADJUSTER, ROCKER
9 NUT, 3/8-24 UNF
20 BEARING, BUSH, ROCKER ARM
14 ROCKER, INLET, RH, ASSY
15 ROCKER, INLET, RH, MC/D
8 ADJUSTER, ROCKER
6 BEARING, BUSH, ROCKER
7 PIN, ROLLER
9 NUT, 3/8-24 UNF
20 BEARING, BUSH, ROCKER ARM
16 ROCKER SHAFT, EXHAUST THREEBOND 1327
19 BOLT, CAP HD, M8 X 35 X 1.25, DIN 912,12.9 25
17 ROCKER, SHAFT, INLET THREEBOND 1327
18 BOLT, CAP HD, M8 X 30 X 1.25, DIN 912,12.9 25
21 WASHER, THRUST, THRUST 5/8"x1 1/8"x1.6mm
22 SEAT, SPRING, EXHAUST
23 SPRING, VALVE, EXHAUST
24 VALVE, EXHAUST DIA 37.0MM
25 SEAT,SPRING, INLET
26 SPRING, VALVE, INLET
27 VALVE, INLET, DIA 44.5MM
28 SEAL, OIL, VALVE STEM
63
29 RETAINER, SPRING
30 COLLET, VALVE
31 CAP, LASH
64
REF. NO.
PART DESCRIPTION TORQUE (NM)
REMARKS
1 BARREL ASSY, MC/D
2 BARREL, MACHINING
BARREL, CASTING
3 LINER, CYLINDER
5 SLEEVE, LIFTER, RH
4 SLEEVE, LIFTER, LH
8 WASHER, 6.4x10.0x2.0, COPPER
9 BOLT, M5 X 40 X 0.8, 5.6MM DIA, SHOULDERED, SS 6
10 WASHER, M8 X 8.2 ID, 12.0 OD, X 1.0, COPPER
11 BOLT, CAP HD, M8 X 12 X 1.25, DIN 912, A2/70 22
6 GASKET, BARREL
7 DOWEL, RING, 13.00MM DIA
12 BOLT, HEX HD, FLANGED, M8 X 25, DIN 6921, 10.9, BZP 25
65
66
REF. NO. PART DESCRIPTION TORQUE REMARKS
1 BEARING, DEEP GROOVE, 20 X 47 X 14
USED BETWEEN CAM SHAFT AND LH
CRANKCASE
2 BEARING, DEEP GROOVE, 20 X 52 X 15 USED ON DRIVE SIDE OF CAMSHAFT
3 PLATE, RETAINING, CAMSHAFT USED ON DRIVE SIDE, MOUNTED TO CASE
4 BOLT, HEX HD, M6 X 12, DIN 933, 8.8, BZP 12 THREEBOND 1327
6 CAMSHAFT, M/C
8 SPACER, CAMSHAFT
9 SPROCKET, CAMSHAFT, 30T
10 SPROCKET, CAMSHAFT, 15T
11 WOODRUFF KEY, 3/8" X 1/8"
12 WASHER, M14, DIN 433, 15X24X2.5 ONE ON CRANK, ONE ON CAM
13 NUT, M14 X 1.5, DIN 934, GRADE 8 54 THREEBOND 1327
14 CHAIN, CAM, 54 LINK
15 TENSIONER, CAM CHAIN, ADJUSTABLE
16 WASHER, M8 X 17 X 1.6, DIN 125A
17 BOLT, CAP HD, M8 X 16 X 1.25, DIN 912, 12.9 25 THREEBOND 1327
18 TENSIONER , CAM CHAIN, FIXED
19 WASHER, M6, 6.4 X 12 X 1.6, DIN 125A
20 BOLT, CAP HD, M6 X 16 X 1.0, DIN 912, 12.9 12 Threebond 1327
67
68
REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
31 EXHAUST SYSTEM KIT, ROW
31 SECONDARY, STAINLESS
8 CLAMPS, EXHAUST 10 USED TO CLAMP EXHAUST
SECTIONS
1 HEADER, RH, CHROME, EURO
2 HEADER, LH, CHROME, EURO
6 SILENCER, RH
5 SILENCER, LH
31 EXHAUST SYSTEM KIT, ROW
31 EXHAUST SYSTEM KIT, ROW
31 EXHAUST, IVA COMPLIANT MOTAD
8 EXHAUST CLAMPS
10 USED TO CLAMP EXHAUST SECTIONS
1 HEADER, R/H, CHROME
2 HEADER, L/H, CHROME
3 SECONDARY, STAINLESS, IVA
6 SILENCER, R/H
5 SILENCER, LH
69
31 EXHAUST SYSTEM KIT, EURO
8 CLAMPS, EXHAUST 10 USED TO CLAMP EXHAUST
SECTIONS
1 HEADER, RH, CHROME, EURO
2 HEADER, LH, CHROME, EURO
3 SECONDARY, STAINLESS, EURO
6 SILENCER, RH
5 SILENCER, LH
31 EXHAUST SYSTEM KIT, EURO
31 EXHAUST SYSTEM KIT, EURO
31 EXHAUST SYSTEM KIT, EURO
31 EXHAUST SYSTEM KIT, EURO
31 EXHAUST SYSTEM KIT, EURO
31 EXHAUST SYSTEM KIT, EURO
31 EXHAUST SYSTEM KIT, EURO
31 EXHAUST SYSTEM KIT, EURO
31 EXHAUST SYSTEM KIT, EURO
31 EXHAUST SYSTEM KIT, EURO
31 EXHAUST SYSTEM KIT, EURO
31 EXHAUST SYSTEM KIT, EURO
31 EXHAUST SYSTEM KIT, EURO
18 AIRBOX MOULDING AS RECEIVED FROM ACERBIS
21 FITTING, AIRBOX, TURNED, M12, 8MM 1 ONLY FOR IVA BIKES
22 FITTING, AIRBOX, TURNED, M6, 3MM
27 BOLT, CAP HD, M6 X 12 X 1.0 TO CLAMP AIRBOX TO FRAME
28 WASHER, PENNY, M6, 6.4 X 18 X 1.6 USED WITH AIRBOX BOLT TO CLAMP EARTH
STRAP
29 WASHER, SERRATED, M6 USED WITH AIRBOX BOLT TO CLAMP EARTH
STRAP
24 CLAMP, AIRBOX, MOULDED ACERBIS 'TOILET SEAT'
25 FILTER, AIR
26 BOLT, BUTTON HD, M5x12 4 TO AIR FILTER CLAMP
23 TRANSITION PIECE
30 UNI-CLIP, TRANSITION PIECE TO CLAMP THROTTLE BODIES
19 SPREADER PLATE, TRANSITION PIECE
20 BOLT, CAP HD, M6 X 20 8 TO CLAMP TRANSITION PIECE
9 EXHAUST BUSH SILENCER TO FRAME
10 EXHAUST BUSH COMPRESSION LIMITER SILENCER TO FRAME
11 WASHER, M8, 8.4 X 16 X 1.6 M8 WASHER 2 PER SIDE
12 BOLT CAP HD, M8 X 50 X 1.25 TO BOLT SILENCER TO FRAME
13 LOCKNUT, FLANGED, M8 X 1.25 TO BOLT SILENCER TO FRAME
14 CENTRAL MOUNT BUSH CENTRAL MOUNT
70
15 CENTRAL MOUNT BUSH COMPRESSION LIMITER
16 BOLT CAP HD, M10 X 50 X 1.5 CENTRAL MOUNT BOLT
17 LOCKNUT, M10 X 1.5 CENTRAL MOUNT NUT
30 GASKET, HEADER
4 LOCKNUT, FLANGED, M8 X 1.25 19 TO HEAD
7 LAMBDA SENSOR, EXHAUST, M10 X
1.25 25 2 REQUIRED FOR HOMOLOGATION
18 AIRBOX, GALACTIC BLACK, GOLD TEXT, SPORT
18 AIRBOX, ROYAL RED, GOLD TEXT, SPORT
18 AIRBOX, CANARY YELLOW, BLACK TEXT, SPORT
18 AIRBOX, FACTORY SPECIAL SILVER, BLACK TEXT/BORDER RED PIN STRIPE, SPORT
18 AIRBOX, GALACTIC BLACK, SILVER TEXT, SPORT
18 AIRBOX, GALACTIC BLACK, GOLD TEXT, CAFE RACER
18 AIRBOX, ROYAL RED, GOLD TEXT, CAFE RACER
18 AIRBOX, CANARY YELLOW, BLACK TEXT, CAFE RACER
18 AIRBOX, FACTORY SPECIAL SILVER, BLACK TEXT/BORDER RED PIN, STRIPE, CAFE RACER
18 AIRBOX, GALACTIC BLACK, SILVER TEXT, CAFE RACER
18 AIRBOX, GALACTIC BLACK, GOLD TEXT, SE
18 AIRBOX, FACTORY SPECIAL SILVER, BLACK TEXT, CAFE RACER
18 AIRBOX, FACTORY SPECIAL SILVER, BLACK TEXT, SPORT
18 AIRBOX, GALACTIC BLACK, YELLOW TEXT, SPORT
18 AIRBOX, GALACTIC BLACK, YELLOW TEXT, CAFE RACER
71
Specifications
Top End Specification
Item Standard (mm) Service Limit
Camshaft: Cam height:
Exhaust 31.112 ± 0.03 30.982 Inlet 32.1788 ± 0.03 32.049
Camshaft journal diameter 19.993-19.980 / 20.000-19.987 19.951 / 19.958
Camshaft bearing ID diameter 20.00-19.990 20.059 Camshaft runout Ra 0.02 max Ra 0.1 Camshaft chain 54-link length 216 ± 0.3 218 Cylinder head: Cylinder Compression (120-170 psi) - - -
Cylinder head warp - - - 0.05mm Valves: Valve clearance: Exhaust
go back one full turn from zero on adjuster - - -
Inlet go back one full turn from zero on
adjuster - - - Valve head thickness:
Exhaust 1.27 ± 0.1 1.0 Inlet 1.27 ± 0.1 0.8
Valve stem bend Ra 0.02 Ra 0.05 Valve stem Diameter: Exhaust 6.98-6.96 7.01
Inlet 6.98-6.96 7.01 Valve Guide inside Diameter:
Exhaust 7.024-7.032 7.097 Inlet 7.004-7.012 7.077
Valve/valve guide clearance: (wobble method):
Exhaust 0.06~0.15 0.34 Inlet 0.09~0.18 0.34
Valve seat cutting angle inlet Initial 45˚ then 35˚ (VAI-A19038) then relief 75˚ (VSI-A13600) - - -
Valve seat cutting angle Initial 45˚ then 29˚ (VSI-A18658) then relief 55˚ (VSI-A13600) - - -
72
Valve seat cutting angle inlet: Initial 45˚ then 35˚ (VAI-A19038) then relief 75˚ (VSI-A13600)
Valve seat cutting angle exhaust: Initial 45˚ then 29˚ (VSI-A18658) then relief 55˚ (VSI-A13600)
Top End Specification
Item Standard (mm) Service Limit
Valve seat surface: Width: Exhaust 1.5 - - -
Inlet 1.5 - - - Outside: Exhaust 35.5 - - -
Inlet 43 - - - Valve spring free length:
Exhaust 44.4 42.5 Inlet 52.15 49.85
Cylinder, Piston: Cylinder inside diameter: 87.995-88.005 88.050 Piston diameter: 87.900-87.925 87.750 Piston/cylinder clearance: 0.105-0.070 - - - Piston ring/groove clearance:
Top 0.020-0.050 0.150
Second 0.020-0.060 0.160 Piston ring groove width:
Top 1.020-1.010 1.100 Second 1.230-1.210 1.310
Piston ring thickness: top 0.990-0.970 0.900
Second 1.190-1.170 1.270 Piston ring end gap:
Top 0.15-0.35 0.65 Second 0.35-0.55 0.85
Oil 0.20-0.70 1.0
73
Cylinder Head Cover
Cylinder Head Cover Removal
Remove:
Fuel Tank (see Fuel System chapter)
Spark Plug Cap [A]
Breather Hose [B]
Battery and Battery tray (see Electrical chapter)
Remove Cylinder Head Cover Bolts [A]
Slide the cover [B] up and out the right hand side)
Cylinder Head Cover Installation
Replace the rocker cover gasket with a new one if it is
damaged.
Torque – Cylinder head cover bolts: 12Nm
B
A
A B
74
Cylinder Head Cover Assembly
Install baffle plate.
Install banjo bolt (short) and assembly as
detailed:
Torque – Banjo Baffle bolt: 22Nm
Install long banjo bolt, banjo and thin nut as
detailed:
Torque – Banjo bolt Breather: 22Nm
Camshaft Chain Tensioner
75
Camshaft Chain Tensioner Removal
Remove oil filter (see Engine Lubrication System chapter).
Remove cam chain cover bolts.
Remove cam chain cover taking note of the location of dowels.
Set Crank to TDC and take note of woodruff key position on
cam shaft.
Remove two M8 cam chain Tensioner bolts.
Remove chain Tensioner.
Cam Tensioner Installation
Align cam and crank woodruff keys, with crank set at TDC.
Finger tighten tensioner bolts.
Apply 200N of load to the tensioner, use a T-bar to apply
load if necessary.
Torque up bolts.
Torque Bolts - 25Nm Threebond 1327
76
Camshaft Chain
Camshaft Chain Removal
Remove
o Cam Chain Cover (see this chapter)
o Cam Chain Tensioner (see this chapter)
Put Crank at TDC, mark position of Cam and Crank with
marker.
Remove Cam and Crank Sprocket nuts.
Remove cam chain tensioner.
Remove Chain with sprockets.
Camshaft Chain Installation
Align crank and cam at TDC markings.
Engage the camshaft chain with the camshaft sprockets
aligned as shown.
Pull the tension side of the chain to install the chain.
Install
o Cam Chain Tensioner (see this chapter)
o Cam and crank drive nuts (see this chapter)
o Cam Chain Cover (see this chapter)
77
Camshaft
Camshaft Removal
Remove
o Cam Chain Cover (see this chapter)
o Cam Chain Tensioner (see this chapter)
Put Crank at TDC, mark position of Cam and Crank with
marker.
Cam Chain (see this chapter)
Remove Cam and Crank Drive sprockets
with the Cam Chain taking note of the order
of washer and sprocket assembly.
Remove bearing retainer.
Put cam sprocket drive and nut back on
Camshaft finger tight, remove the Camshaft
taking note of bearing order (a puller may
be required).
Caution: The crankshaft may be turned, while the
camshaft is removed. Always pull the chain taut
while turning the crankshaft. This avoids kinking the
chain. A kinked chain could damage both the chain
and the sprocket.
Camshaft Installation
Apply engine oil to all cam parts. If the
camshaft and/or cylinder head are replaced
with new ones, apply a thin coat of
molybdenum disulfide grease to the new
cam surfaces.
Apply oil to the Camshaft bearings in the
Crankcase.
78
Build up Camshaft with new bearings if required.
Insert the cam shaft ensuring all bearings are home.
Install bearing retainer.
Torque – 12Nm Threebond 1327
Install
o Cam Chain (see this chapter)
o Cam Chain Tensioner (see this
chapter)
o Cam Chain cover (see this chapter)
Caution: After this procedure, if any resistance is felt
while turning over the crankshaft, stop immediately
and check the camshaft chain timing. Valves will be
bent if the timing is not properly set.
Camshaft Disassembly
Remove camshaft.
Remove bearings in order shown.
Camshaft Assembly
Install bearings in order shown.
Camshaft Bearing Wear-
Cam shaft bearing clearance 6204 (-0.003 to +
0.02) - Service limit 0.10 mm
79
Cam shaft bearing clearance 6304 (-0.01 to + 0.013) - Service limit 0.10 mm
If any clearance exceeds the service limit, measure the diameter of the camshaft with a
micrometer.
Camshaft Diameter-
6204 bearing surface (19.993 to 19.980) - Service limit 19.950
6304 bearing surface (20.000 to 19.987) - Service limit 19.957
I the camshaft bearing surfaces are less than the service limit replace the camshaft with a new one
and measure the clearance again.
If there is excessive free play in the bearing or any visible damage replace the bearing.
Cylinder Head
Cylinder Compression Measurement
Note: Use a Battery which is fully charged.
Warm up the engine thoroughly.
Remove both spark plugs (see Fuel System chapter).
Attach the compression gauge [A] and insert into spark
plug No.1.
Using the starter motor, turn the engine over with the throttle fully open until the compression
limiter gauge stops rising; the compression is the highest value obtainable.
Cylinder Compression (Usable Range 120~170 psi)
Install the spark plug
Torque – Spark Plug: 12Nm (first use torque only)
Problem Diagnosis Remedy (Action)
Cylinder compression is higher than usable range
Carbon accumulation on piston and in combustion chamber possibly due to damaged valve stem oil seal and/or damaged piston oil rings (This may be indicated by white exhaust smoke).
Remove the carbon deposits and replace damages parts if necessary.
Incorrect cylinder head gasket thickness. Replace the gasket with standard part.
Cylinder compression is lower than usable range
Gas leaking around cylinder head. Replace damaged gasket and check cylinder head warp.
Bad condition of valve seating. Repair if necessary.
A
80
Incorrect valve clearance. Adjust the valve clearance.
Incorrect piston/cylinder clearance. Replace the piston and/or cylinder.
Piston seizure. Inspect the cylinder (and liner) and replace/repair the cylinder and/or piston as necessary.
Bad condition of piston ring and/or piston ring grooves.
Replace the piston and/or the piston rings.
Compression release weights do not move smoothly.
Replace the camshaft assembly.
Cylinder Head Removal
Remove:
o Fuel Tank (see Fuel System chapter)
o Battery (see Electrical System chapter)
o Battery Trey (see Electrical System chapter)
Move air box back
Remove
o Throttle body (see Fuel System chapter)
o Exhaust Pipes (see this chapter)
o Breather Hoses
o Rocker Cover (see this chapter)
o HT Leads
o Temp Sensor Connector
Slacken off tappet adjuster lock nut [A]
and adjusters [B].
Remove rocker bolts [C].
Remove rockers [D] and pushrods [E]. C B
81
Slacken inner head bolts by ¼ of a turn from fifteen
back to seven. Remove fifteen, fourteen and
thirteen. Remove from six back to one.
A
D E
82
Tap lightly upwards on the cylinder head with a mallet [A]
to separate from cylinder.
Lift off head [B] towards the left side.
Remove the cylinder head.
Cylinder Head Installation
Install the cylinder (see Cylinder
Installation).
See that two dowel pins [A] are in
place on the cylinder.
Install the cylinder head gasket.
Install the cylinder head.
B
A
A
83
Torque One to Six to 28Nm. Torque Seven to Twelve to 45Nm, then
torque thirteen to fifteen to 28Nm
Install pushrods and rockers
Install rocker bolts.
Torque - Rocker Bolts: 28Nm
Adjusters tappet (see this chapter)
Install
o Temp Sensor Connector
o HT Leads
o Rocker Cover (see this chapter)
o Breather Hoses
o Exhaust Pipes (see this chapter)
o Throttle body (see Fuel System
o Air Box
Cylinder Head Assembly
Install:
o Rocker Tower Dowels
o Rocker Towers
o Washer
Tighten bolts.
84
Torque- Rocker Tower Bolts: 20Nm
Cylinder Head Disassembly
Remove the cylinder head (see this chapter)
Remove the Valve (see this chapter)
Remove the rocker tower bolts, remove the rocker towers.
Cylinder Head Cleaning
Remove the cylinder head (see Cylinder Head Removal).
Remove Valves (see Valve Removal).
Wash the head with a high-flash point solvent.
Scrape the carbon out of the combustion chamber and
exhaust port with a suitable tool.
Using compressed air, blow out [A] any particles which
may obstruct oil/air passage in the cylinder head.
A
85
Install the valves.
Cylinder Head Warp
Clean the cylinder head (see Cylinder Head Cleaning)
Lay a straightedge across the lower surface of the cylinder
head at the positions shown.
Use a thickness gauge [A] to measure the space between
the straightedge [B] and the head.
Cylinder Head Warp:
Standard: - - -
Service limit: 0.05mm
If the cylinder head is warped more than the service limit, replace it.
If the cylinder head is warped less than the service limit, repair the head by rubbing the lower
surfaces on emery paper secured to a surface plate (first No. 200, then No. 400).
Valves
Valve Clearance Measurement
Note: Check the Valve clearance when the engine is cold (at room
temperature).
Remove Cylinder Head Cover (see Cylinder Head Cover
Removal).
Remove Cam Chain Cover (see Cam Chain Cover Removal).
Remove the Spark Plugs.
Turn the crankshaft clockwise with a wrench on the crank
shaft cam drive sprocket nut or primary gear nut and
B A
A
B
86
watch the intake valve on No.1 Cylinder until the valve closes fully.
Measure the clearance between the lash cap [A] and the rocker arm roller [B] with the thickness
gauge [C].
If any valve clearance is measured, adjust (see Valve Clearance Adjustment).
Valve Clearance Adjustment
Turn the crankshaft clockwise with a wrench on the crank
shaft cam drive sprocket nut until No.1 is at TDC.
Undo the lock-nut on the adjusters and back the adjusters
off until any clearance can be measured.
Tighten the adjusters until no clearance can be measured
then tighten a further one full turn.
Repeat the process on cylinder No.2, First setting Cylinder
No.2 to TDC
Valve Clearance Adjustment – One full turn from fully off
Valve Removal
Remove the cylinder head (see Cylinder Head Removal).
Mark and record the valve location so it can be installed in
the original position.
Remove the valve tappets making a note of their location
Using a valve spring compressor assembly, remove the valve
by compressing the valve spring and using a magnetic rod to
remove the collets.
Valve Installation
If a new valve is to be used, check-valve-to guide clearance (see this chapter).
If there is too little clearance, ream the valve guide.
If there is too much clearance, install a new cylinder head.
Check the valve seat (see Valve Seat Inspection).
Apply a thin coat of molybdenum disulfide grease to the valve stem.
Install each spring so that the larger end is at the bottom (closer to the valve head).
Valve Guide Reamer Exhaust – Ø 7.024 to7.032 (nominal 7.028)
Valve Guide Reamer Inlet - Ø 7.004 to 7.012 (nominal 7.008)
C
87
Valve-to-Guide Clearance Measurement
If a small bore gauge is not available, inspect the valve guide
wear be measuring the valve to guide clearance with the wobble
method as indicated below.
Insert the new valve [A] into the guide [B] and set a dial
gauge against the stem perpendicular to it as close as
possible to the cylinder head mating surface.
Move [C] the stem back and forth to measure valve/valve
guide clearance.
Repeat the measurement in a direction at a right angle to the first.
If the reading exceeds the service limit, replace the guide.
The reading is not actual valve/Valve guide clearance because the measuring point is above the
guide.
Valve /Valve Guide Clearance (wobble Method)
Exhaust: 0.06~0.15 (standard), 0.34 (Service limit).
Inlet: 0.09~0.18 (standard), 0.34 (Service limit).
Valve Seat Inspection
Remove the valve (see Valve Removal).
Check the valve seat width [A].
Measure the seat width of the portion where there is no
build up of carbon of the valve seat with vernier calipers.
Valve seating surface Width
Width: Exhaust: 1.5mm
Inlet: 1.5mm
If the seat width is not within the specified range, repair the valve seat.
Measure the outside diameter [B] of the seating pattern on the valve seat.
If the outside diameter of the valve seating pattern is too large or too small, repair the valve seat.
Valve seating surface outside diameter
Exhaust: 35.5mm
Inlet: 43mm
Valve Seat Repair (Valve Lapping)
Using the valve seat cutters, repair the valve seat.
Valve seat cutters:
A
B
C
A B
88
Valve seat cutting angle inlet: Initial 45˚ then 35˚ (VAI-A19038) then relief 75˚ (VSI-A13600)
Valve seat cutting angle exhaust: Initial 45˚ then 29˚ (VSI-A18658) then relief 55˚ (VSI-A13600)
If the manufacturer’s instructions are not available, use the following procedure.
Seat Cutter Operating Care:
This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be
used for other purpose than seat repair.
Do not drop or shock the valve seat cutter, or the diamond particles may fall off.
Do not fail to apply engine oil to apply engine oil to the valve seat cutter before grinding the seat
surface. Also wash off the ground particles sticking to the cutter with washing oil.
Caution: Do not use a wire brush to remove the metal particles from the cutter. It will take off the diamond
particles.
Setting the valve seat cutter holder in position, operate the cutter in one hand. Do not apply too
much force to the diamond portion.
Note: Prior to grinding, apply engine oil to the cutter and during the operation, wash off any ground
particles sticking to the cutter with washing oil.
After use, wash it with washing oil and apply thin layer of engine oil before storing.
Operating Procedures:
Clean the seat area carefully.
Coat the seat with machinist’s dye.
Fit a 45˚ cutter into the holder and slide it into the valve guide.
Press down lightly on the handle and turn it right and left. Grind the seating surface only until it is
smooth.
Caution: Do not grind the seat too much. Over grinding will reduce valve clearance by sinking the valve into
the head. If the valve sinks too far into the head, it will be impossible to adjust the clearance, and the
cylinder head must be replaced.
Measure the outside diameter of the seating surface with a vernier caliper.
If the outside diameter of the surface is too small, repeat the 45˚ grinding until the diameter is
within the specified range.
If the outside diameter of the seating surface is too large, make the 35˚ (inlet)/29˚ (exhaust)
grinding described below.
If the outside diameter of the seating surface is within the specified range, measure the seat width
as described below.
Grind the seat at a 35˚ (inlet)/29˚ (exhaust) angle until the seat O.D. is within the specified range.
89
To make the 35˚ (inlet)/29˚ (exhaust) grind fit a 35˚ (inlet)/29˚ (exhaust) cutter into the holder, and
slide it into the valve guide.
Turn the holder one turn at a time while pressing down very lightly. Check the seat after each turn.
Caution: The 35˚ (inlet)/29˚ (exhaust) cutter removes material very quickly. Check the seat outside
diameter frequently to prevent over grinding.
After making the 35˚ (inlet)/29˚ (exhaust) grind, return to the seat O.D. measurement step above.
To measure the seat width, use a vernier caliper to measure the width of the 45˚ angle portion of
the seat at several places around the seat.
If the seat width is too narrow, repeat the 45˚ grind until the seat is slightly too wide, and then
return to the seat O.D. measurement step above.
If the seat width is within the specified range, lap the valve to seat as described below.
Grind the seat at a 75˚ (inlet)/55˚ (exhaust) angle until the seat width is within the specified range.
To make the 75˚ (inlet)/55˚ (exhaust) grind, fit 75˚ (inlet)/55˚ (exhaust) cutter into the holder, and
slide it into the valve guide.
Turn the holder, while pressing down lightly.
After making the 75˚ (inlet)/55˚ (exhaust) grind, return to the seat measurement step above.
Lap the valve to the seat, using a lapper once the seat width and O.D. are within the ranges
specified above.
Put a little coarse grinding compound on the face of the valve in a number of places around the
valve head.
Spin the valve against the seat until the grinding compound produces a smooth, matched surface
on both the seat and the valve.
Repeat the process with a fine grinding compound.
The seating area should be marked about in the middle of the valve face.
If the seat is not in the right place on the valve, check to be sure the valve is the correct part. If the
valve is correct, the valve may have been refaced too much; replace the valve.
Be sure to remove all grinding compound before assembly.
When the engine is assembled, be sure to adjust the valve clearance (see Valve Clearance
Adjustment).
START
start
Machinist’s dye on seat
45˚ Grind
Tool: 45˚ Cutter
Purpose: Make seating area
smooth and round
Measure seating area O.D.
Tool: Vernier Caliper
Purpose: check seat O.D. against
spec.
90
Cylinder, Piston
Cylinder, Piston Removal
Remove:
o Cylinder Head (see Cylinder Head Removal).
Slacken off cylinder bolts by a quarter of a turn back from twenty to sixteen.
Remove cylinder bolts back from twenty to sixteen.
Results
OK Too big Too small
45˚ Grind
Tool: 45˚ Cutter
Purpose: increase O.D. of seat
area to spec.
Machinist’s dye on seat
35˚ (inlet)/29˚ (exhaust)
Tool: 35˚/29˚ Cutter
Purpose: Reduce O.D. of seat
area to spec.
Measure Seat Width
Tool: Vernier Caliper
Purpose: check seat width
against spec.
Results
OK Too wide Too narrow
Machinist’s dye on seat 45˚ Grind
Tool: 45˚ Cutter
Purpose: increase width of seat area
beyond spec. to increase O.D.
75˚ (inlet)/55˚ (exhaust) Grind
Tool: 75˚ or 55˚ Cutter
Purpose: reduce seat width to spec
Lap Valve
Tool: Valve lapper, grinding compound
Purpose: Perfectly match valve and seat area;
check valve head for damage FINISH
start
91
Tap lightly up the cylinder head with a plastic mallet to separate from crankcase.
When the cylinder is lose, remove in one clean swift movement upwards.
If the cylinder becomes jammed it will be because the lifters have dropped down as the cylinder has
been pulled up. Settle the cylinder back down, and then remove in one clean swift movement
upwards.
Remove the cylinder base gasket.
Immediately insert a clean cloth around the piston to
prevent parts or dirt from falling into the case.
Remove the snap ring from one side of each piston pin
hole.
Caution: Do not reuse snap rings as removal weakens and
deforms them. They could fall out and score the cylinder
wall.
Push out the piston pin and remove the piston.
92
Carefully spread the ring opening with your thumbs and then push up on the opposite side of the
piston ring to remove it.
Remove the three – piece oil ring with your thumbs in the same manner.
Cylinder, Piston Installation
Note: The oil ring rails have no “top” or “bottom”
Install the oil ring expander in the bottom piston ring
groove so the ends butt together.
Install the oil ring steel rails, one above the expander
and one below it.
Spread the rail with your thumbs, but only enough to fit
the rail over the piston.
Release the rail into the bottom piston ring groove.
With the marked side facing up, install the second ring [A] and top ring [B] in that order.
Note: If a new piston is used, check piston to cylinder clearance (see Piston/Cylinder Clearance), and use
new piston rings.
The right hand piston has an R marked on the
underside and the left hand has an L marked on the
underside. The dots [A] should always be on the inside
on top of the cylinder.
Measure the piston diameter at the point shown with a
micrometer.
Piston Diameter:
Standard: 87.900 to 87.925
Service Limit: 87.750
If the piston diameter is less than the service limit,
replace it.
Install the pistons onto the con-rods using new snap
rings.
Install a new base gasket.
Set the crank so that piston No. 1 is at TDC.
Note: Ensure ring gaps at 180 degrees apart.
Slide the barrels over the barrel bolts.
B
A
A
93
Simultaneously lower the barrel whilst sliding the pistons into the barrel, use a front to back rocking
motion whilst holding the rings in with your thumb and four fingers to slide the pistons rings into
the barrel.
Tighten the cylinder bolts by hand.
Install the cylinder head (see this chapter).
Tighten head and barrel bolts in sequence from one to twenty to torques detailed below.
Torque: Barrel bolts – 25Nm
Torque: Head Bots – 25Nm / 54Nm
Note: Whenever the piston or cylinder has been replaced with a new one or honed, the motorcycle must
be broken in the same as with a new machine.
94
Piston/Cylinder Clearance
Subtract the piston diameter from the cylinder inside diameter to get the piston/cylinder clearance.
Piston/Cylinder Clearance
Standard: 0.105 to 0.070
If the piston/cylinder clearance is less than the specified range, use a smaller piston or increase the
cylinder inside diameter by honing.
If the piston/cylinder clearance is greater than the specified range, use a larger piston or bore the
cylinder to the next larger oversize.
If only a piston is replaced, the clearance may exceed the standard slightly. But it must not be less
than the minimum in order to avoid piston seizure.
Cylinder Boring and Honing
Before boring a cylinder, first measure the exact diameter of the oversize piston, and then,
according to the standard clearance in the Specifications, determine the re-bore diameter.
However, if the amount or boring necessary would make the inside diameter greater than 1.0mm,
the block must be replaced.
Cylinder inside diameter must not vary more than 0.01mm at any point.
In the case of a re-bored cylinder and oversize pistons, the service limit for the cylinder is the
diameter that the cylinder was bored to plus 0.1mm and the service limit for the piston is oversize
piston original diameter minus 0.15mm. If the exact figure for the rebored diameter is unknown, it
can be roughly determined by measuring the diameter at the base of the cylinder.
Piston Ring and Ring Groove Wear
Check for uneven groove wear by inspecting the ring
seating.
The rings should fit perfectly parallel to groove
surfaces. If not, the piston must be replaced.
With the piston rings [A] in their grooves, make
several measurements with a thickness gauge
to determine piston ring/groove clearance.
Piston Ring/Groove Clearance
Standard Service Limit
Top: 0.020-0.050 0.150
Second: 0.020-0.060 0.160
Piston Ring End Gap Measurement
Place the piston ring inside the cylinder, using
the piston to locate the ring squarely in place.
A
B
95
Set it close to the top of the cylinder, where cylinder wear is low.
Measure the gap [B] between the ends of the ring with a thickness gauge.
Piston Ring End Gap
Standard Service Limit
Top 0.15-0.35 0.65
Second 0.35-0.55 0.85
Oil 0.20-0.70 1.0
Exhaust System
Silencer Removal
Loosen:
o Silencer Clamp Bolts [A]
Remove:
o Silencer allen bolts [B]
Move the Silencer backwards and twist outwards to
separate from the middle section.
Remove the Silencer.
Secondary Removal
Loosen:
o Secondary cramp bolts [A]
Remove:
o Secondary centre allen bolt [B].
Move secondary backwards to separate from downpipes.
Remove secondary.
A
B
B
A
96
Header Pipe Removal
Remove Lambda Sensors.
Remove six flange bolts from head.
Remove Header.
Exhaust Pipe Installation
Replace the exhaust pipe gasket.
Tighten:
Six flange bolts.
Torque – Exhaust Flange Bolts: 19 Nm
Install the secondary.
Install secondary centre bolt.
Torque – Secondary centre bolts: 10Nm
Tighten secondary clamp bolts.
Install the Silencers.
Install allen bolts and tighten.
Torque – Exhaust muffler bolts: 10 Nm
Tighten Silencer clamps.
Thoroughly warm up the engine, wait until the engine cools down, and then retighten the clamp
bolts and flange nuts.
Gasket behind header
97
Clutch
Exploded View .................................................................................................................................................. 99
Specification ................................................................................................................................................... 104
Clutch Lever and Hose ................................................................................................................................... 105
Clutch Lever Adjustment .................................................................................................................... 105
Clutch Fluid .................................................................................................................................................... 105
Clutch Fluid Recommendation ........................................................................................................... 105
Clutch Fluid Level Inspection ............................................................................................................. 106
Clutch Fluid Changing......................................................................................................................... 106
Clutch Line Air Bleeding ..................................................................................................................... 107
Clutch Slave Cylinder ...................................................................................................................................... 108
Clutch Slave Cylinder Removal ........................................................................................................... 108
Clutch Slave Cylinder Installation ....................................................................................................... 108
Clutch Slave Cylinder Inspection ........................................................................................................ 108
Clutch Master Cylinder .................................................................................................................................. 108
Clutch Master Cylinder Removal ....................................................................................................... 108
Clutch Master Cylinder Installation ................................................................................................... 109
Clutch Master Cylinder Inspection ..................................................................................................... 109
Clutch Hose .................................................................................................................................................... 109
Clutch Hose Removal ......................................................................................................................... 109
Clutch Hose Installation ..................................................................................................................... 110
Clutch Hose Inspection ...................................................................................................................... 110
Clutch Cover ................................................................................................................................................... 110
Clutch Cover Removal ........................................................................................................................ 110
Clutch Cover Installation .................................................................................................................... 111
Clutch Release Removal ..................................................................................................................... 111
Clutch Release Installation ................................................................................................................. 112
Clutch ............................................................................................................................................................. 112
Clutch Removal .................................................................................................................................. 112
Clutch Installation .............................................................................................................................. 113
Friction and Steel Plate Damage, Wear Inspection ........................................................................... 114
Friction and Steel Plate Warp Inspection .......................................................................................... 114
Clutch spring Free Length Measurement .......................................................................................... 114
Clutch Housing Finger Damage .......................................................................................................... 115
Clutch Hub Spline Damage ................................................................................................................. 115
Primary Gear Removal ................................................................................................................................... 115
Primary Gear Installation ............................................................................................................................... 116
98
REF. NO. PART DESCRIPTION TORQUE REMARKS
1 CLUTCH BASKET, ASSY
7 ACTUATOR, LIFTER, PRESSURE PLATE
8 BEARING, NEEDLE, THRUST, 24.0 OD X 10.0 ID X 1.6
BETWEEN PRESSURE PLATE AND
LIFTER
9 WASHER, 24 OD X 10 ID X 1.0 SITS BEHIND PRESSURE PLATE
2 GEAR, PRIMARY, 87 TOOTH BEHIND CLUTCH BASKET
5 WASHER, 34 OD 21 ID X 3.0MM USED TO CLAMP CLUTCH
6 NUT, HALF, M20 X 1.5, DIN 439, A2 70 122 THREEBOND 1327
3 SPACER, PRIMARY GEAR, BEARING BEHIND CLUTCH BASKET
10 PUSH ROD, CLUTCH
11 PUSH ROD, CLUTCH, DIA 7.00MM SLAVE CYLINDER END
12 BEARING, BALL, 8MM USED IN CENTRE AND END OF
CLUTCH ROD
13 PLATE, CLUTCH, STEEL
14 FRICTION PLATE, CLUTCH
99
REF. NO. PART DESCRIPTION TORQUE REMARKS
1 STARTER, MOTOR
2 GASKET, STARTER, MOTOR
3 RING GEAR, 79 TOOTH
4
BOLT, M5x0.8x16, 6.0 DIA, SHLD, ISO 7979,
12.9 5
USED TO CLAMP STARTER RING
5
BOLT, CAP HD, 3/8-24UNF X 1, BZP, 1936
SERIES 20
TO CLAMP STARTER
MOTOR
7 BOLT, CAP HD, 3/8-24UNF X 3/4, 1936 SERIES
20 TO CLAMP STARTER MOTOR
6
WASHER, M10, 10.5 X 21.0 X 2, DIN 125A,
A2
100
101
102
REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
20 BRAKE LEVER ASSY, AXIAL
STANDARD FOR CSE, CCR, ROW COM/CMM
21 LEVER, BRAKE, REMOTE RESERVOIR
22 RESERVOIR, MASTER CYL, FRONT BRAKE RESERVOIR
55 FRONT BRAKE LIGHT SWITCH
79 LEVER ASSY, BRAKE, INTEGRAL RESERVOIR, HIGH BARS
STANDARD LEVER FOR COM-01 AND CDS-01
103
80 LEVER, BRAKE, INTEGRATED RESERVOIR
79 LEVER ASSY, BRAKE, INTEGRAL RESERVOIR, HIGH BARS
ACCESSORY FITMENT
80 LEVER, BRAKE, INTEGRATED RESERVOIR
81 BOLT, M6 X 25 X 1.0, CP HD, GOLD 8 HALF CLAMP BOLTS
82 HALF CLAMP, FRONT, VERTICAL
REPLACES STD CLAMP FROM BREMBO
78 FLYLEAD, BRAKE LIGHT SWITCH, INTEGRAL RESERVOIR
INTEGRAL RESERVOIR ONLY,
29 SCREW, UPPER, M/CYL RES MOUNT KIT
TO CLAMP BRAKE RESERVOIR TO BRACKET
28 DUMPER, M/CYL RES MOUNT KIT
RUBBER GROMMET FOR MASTER CYLINDER
32 NUT, M/CYL RES MOUNT KIT
NUT USED TO CLAMP RESERVOIR TO BRACKET
69 CLIP, M/CYL RES MOUNT KIT USED WITHIN FRONT AND REAR
31 HOSE, FRONT BRAKE M/CYL RESERVOIR USED FOR FRONT BRAKE ONLY
30 HOSE, FRONT BRAKE M/CYL RESERVOIR, CLIP-ONS
USED FOR FRONT BRAKE CAFE RACER ONLY
24 BRACKET, BRAKE RESERVOIR, XM FRONT BRAKE RESERVOIR BRACKET
23 BRACKET, BRAKE RESERVOIR, CLIP-ONS, XM
FRONT BRAKE RESERVOIR BRACKET, CR
25 BOLT, CAP HD, M6 X 12 X 1.0 6 BRACKET TO MASTER CYLINDER
91 LEVER ASSY CLUTCH
GOLD LEVER ASSY, (REMOTE RESERVOIRS)
92 LEVER, CLUTCH, REMOTE RESERVOIR
93 BRACKET, CLUTCH RESERVOIR, CLIP-ONS, XM
CAFE RACER ONLY BRACKET TO MASTER CYLINDER
94 BRACKET, CLUTCH RESERVOIR, XM BRACKET TO MASTER CYLINDER
25 BOLT, CAP HD, M6 X 12 X 1.0 8
55 RESERVOIR, MASTER CYL, REAR USED FOR CLUTCH RESERVOIR
95 HOSE, CLUTCH M/CYL RESERVOIR HOSE FOR RESERVOIR TO CYLINDER
96 BOLT, CAP HD, M5 X 12 X 0.8 RESERVOIR TO BRACKET
97 LOCKNUT, FLANGED, M5 X 0.8 7 RESERVOIR TO BRACKET
98 HOSE, FRONT CLUTCH M/CYL RESERVOIR, CLIP-ONS
CAFE RACER RESERVOIR HOSE (SHORTER)
99 LEVER ASSY, CLUTCH, INTEGRAL RESERVOIR, HIGH BARS
SPORT AND DUAL SEAT LEVER ASSY (BLACK)
100 LEVER, CLUTCH, INTEGRATED RESERVOIR
99 LEVER ASSY, CLUTCH, INTEGRAL RESERVOIR, HIGH BARS
ACCESSORY FITMENT
100 LEVER, CLUTCH, INTEGRATED RESERVOIR
101 SLAVE CYLINDER, CLUTCH
102 BOLT, CAP HD, M6 X 16 X 1.0
12 TO CLAMP SLAVE CYLINDER TO SPROCKET COVER
68 HYDRO STOP, REAR M/CYL REAR BRAKE LIGHT SWITCH
59 HYDRAULIC LINE KIT, USD FORKS, HIGH BARS CSE-03 KIT ONLY
27 DOUBLE BANJO BOLT M10 X 1MM X 34.5MM SPARES ONLY
104
26 COPPER WASHER SPARES ONLY
57 45' BANJO SPARES ONLY
60 BRAKE HOSE, LH, 725MM LENGTH SPARES ONLY
61 BRAKE HOSE, RH, 750MM LENGTH SPARES ONLY
62 BANJO BOLT WITH BLEED NIPPLE 10MM X 1MM SPARES ONLY
63 BOLT, BANJO, M10 x 1.0 x 18, CHROME SPARES ONLY
64 HOSE, CLUTCH, 1200MM LENGTH SPARES ONLY
58 90' BANJO SPARES ONLY
33 20' BANJO SPARES ONLY
53 HOSE, BRAIDED, BRAKE, REAR, 825MM SPARES ONLY
66 STRAIGHT BANJO SPARES ONLY
67 CLUTCH, ADAPTOR 10MM X 1MM SPARES ONLY
70 HYDRAULIC LINE KIT, CONVENTIONAL FORKS, AXIAL CALIPERS
HYDRAULIC LINE KIT COM-01, CMM-03, CSE-01, CSE-02
27 DOUBLE BANJO BOLT M10 X 1MM X 34.5MM SPARES ONLY
26 COPPER WASHER SPARES ONLY
57 45' BANJO SPARES ONLY
33 20' BANJO SPARES ONLY
60 BRAKE HOSE, LH, 725MM LENGTH SPARES ONLY
61 BRAKE HOSE, RH, 750MM LENGTH SPARES ONLY
65 MODIFIED BANJO, 90', COMPOUND BEND
SPARES ONLY (AXIAL CALIPERS ONLY)
63 BOLT, BANJO, M10 x 1.0 x 18, CHROME SPARES ONLY
58 90' BANJO SPARES ONLY
53 HOSE, BRAIDED, BRAKE, REAR, 825MM SPARES ONLY
66 STRAIGHT BANJO SPARES ONLY
64 HOSE, CLUTCH, 1200MM LENGTH SPARES ONLY
67 CLUTCH, ADAPTOR 10MM X 1MM SPARES ONLY
71 HYDRAULIC LINE KIT, USD FORKS, CLIP ONS CCR-01/02 KIT ONLY
27 DOUBLE BANJO BOLT M10 X 1MM X 34.5MM SPARES ONLY
26 COPPER WASHER SPARES ONLY
57 45' BANJO SPARES ONLY
33 20' BANJO SPARES ONLY
72 BRAKE HOSE, LH, 635MM LENGTH SPARES ONLY
73 BRAKE HOSE, RH, 660MM LENGTH SPARES ONLY
62 BANJO BOLT WITH BLEED NIPPLE 10MM X 1MM SPARES ONLY
63 BOLT, BANJO, M10 x 1.0 x 18, CHROME SPARES ONLY
74 HOSE, CLUTCH, 1110MM LENGTH SPARES ONLY
58 90' BANJO SPARES ONLY
53 HOSE, BRAIDED, BRAKE, REAR, 825MM SPARES ONLY
66 STRAIGHT BANJO SPARES ONLY
67 CLUTCH, ADAPTOR 10MM X 1MM SPARES ONLY
75 CLIP, BRAKE LINE
USED WITH 6MM HOLE IN MUDGUARD, USD ONLY
76 WIRE GUIDE, BRAKE HOSE
77 BOLT, CAP HD, M6 X 1.0 TO CLAMP WIRE GUIDE TO YOKE
90 WASHER, PENNY, M6, 6.4 X 18 X 1.6 BETWEEN BOLT AND WIRE GUIDE
105
5 CALIPER ASSY, AXIAL, LH GOLD FINISH
14 PISTON SET, CALIPER AXIAL
15 SEAL KIT, CALIPER, AXIAL
16 PAD RETAINER, CALIPER, AXIAL
17 PAD, SPRING, CALIPER, AXIAL
18 PADS, BRAKE, FRONT, AXIAL
19 BLEED SCREW, CALIPER, AXIAL
83 CALIPER ASSY, AXIAL, RH GOLD FINISH
14 PISTON SET, CALIPER AXIAL
15 SEAL KIT, CALIPER, AXIAL
16 PAD RETAINER, CALIPER, AXIAL
17 PAD, SPRING, CALIPER, AXIAL
18 PADS, BRAKE, FRONT, AXIAL
19 BLEED SCREW, CALIPER, AXIAL
1 DISC, FRONT, 320 MM 320 mm
2 BOLT, BUTTON HD, INT HEX, M8 X 16 25 6 PER SIDE, PATCH LOCKED
103 BOLT, BUTTON HD, INT HEX, M8 X 20 25 6 PER SIDE, PATCH LOCKED
3 SPACER, FRONT DISC
13 BOLT, CALIPER, RADIAL 35 TO CLAMP CALIPER TO FORK
12 CALIPER BRACKET, LH
84 CALIPER BRACKET, RH
13 BOLT, CAP HD, M10x20x1.25 35 BRACKET TO FORK
85 BOLT, CAP HD, M10x30x1.25 35 CALIPER TO BRACKET
104 CALIPER ASSY, RADIAL, LH
6 PISTON SET, CALIPER RADIAL
7 SEAL KIT, CALIPER, RADIAL
8 PAD RETAINER, CALIPER, RADIAL
9 PAD, SPRING, CALIPER, RADIAL
10 PAD SET, CALIPER
4 CALIPER ASSY, RADIAL, RH
6 PISTON SET, CALIPER RADIAL
7 SEAL KIT, CALIPER, RADIAL
8 PAD RETAINER, CALIPER, RADIAL
9 PAD, SPRING, CALIPER, RADIAL
10 PAD SET, CALIPER
46 M/CYL ASSY, REAR M/CYL FOR ALL MODELS
49 HEEL GUARD, RH, XM
50 BRACKET, BRAKE RESERVOIR, REAR, STEEL, PRESSED, XM
51 BOLT, CAP HD, M6 X 20 10 HEEL GUARD TO HANGER
45 HOSE, REAR M/CYL RESERVOIR BLACK RESERVOIR HOSE
55 RESERVOIR, MASTER CYL, REAR
47 BOLT, CAP HD, M6 x 10 8 TO CLAMP RESERVOIR TO BRACKET
48 ROD ASSY, REAR MASTER CYLINDER REAR BRAKE M/CYL PUSH ROD
90 NUT, M6 X 1.0, PLAIN USED TO LOCK ROD ASSY TO CLEVIS
56 CLEVIS, MASTER CYLINDER USED ON THE END OF ROD ASSY
106
52 CLEVIS PIN, BRAKE PEDAL, SPRING CLAMP
LINK BETWEEN PLATE AND ROD ASSY
86 P-CLIP, 8MM
SUPPORT FOR BRAKE LINE TO SWING ARM
87 BOLT, CAP HD, M5 X 15 X 0.8 7 CLAMP P CLIP TO SWINGARM
88 WASHER, M5, 5.3 X 10 X 1 BETWEEN BOLT AND P CLIP
40 CALIPER ASSY, REAR, 34MM, GOLD GOLD FINISH
39 PADS, BRAKE, REAR, 34MM
38 PISTON SET, CALIPER, REAR
37 SEAL KIT, REAR, CALIPER
41 BLEED SCREW, REAR CALIPER
42 HANGER PIN, REAR CALIPER
89 SPRING, PAD RETAINER, REAR CALIPER
36 CALIPER CARRIER, REAR
43 BOLT, CAP HD, M8 X 20 X 1.25 28 REAR CALIPER TO CARRIER
35 DISC, REAR
44 BOLT, BUTTON HEAD, INT HEX, M10 X 20 43 DISK, PATCHLOCKED
PADS, BRAKE, REAR, SINTERED.
TO BE USED WITH 32MM REAR CALIPER
Specifications
Item Standard Service Limit
Clutch Friction plate thickness 2.9~3.1mm 2.75 Friction and steel plate warp 0.2mm or less 0.3mm
Clutch spring free length 54mm 52.75mm
Clutch Lever and Hose
Clutch Lever and Adjustment
107
Pull the lever forward and twist the adjuster [A] to move the lever forwards and backwards.
Clutch Fluid
Warning: When working the clutch, observe the precautions listed
below.
Never reuse old clutch fluid.
Do not use fluid from a container that has been left
unsealed or that has been open for a long time.
Do not mix two types and brands of fluid for use in the
clutch. It may cause the rubber brake parts to deteriorate.
Don’t leave the reservoir cap [A] off for any length of time to avoid moisture contamination of the
fluid.
Don’t change the fluid in the rain or when a strong wind is blowing.
Except for internal clutch parts, use only clutch fluid, isopropyl alcohol, or ethyl alcohol for cleaning
clutch parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil, or any other
petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be
difficult to wash off completely and will eventually deteriorate the rubber used in the clutch.
Clutch fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away
immediately.
If any of the clutch line fittings or bleed valve is open at any time, the AIRMUST BE BLED FROM THE
CLUTCH.
Clutch Fluid Recommendation
Recommended fluids are given below. If none of the recommended fluids are available, use extra
heavy-duty brake fluid only from a container marked D.O.T. 4.
Note: Clutch fluid of D.O.T. 4 is installed in the clutch system when shipped.
Recommended Clutch Fluid
Type D.O.T. 4
Brand: Fuchs Silkolene
Spec. FMVSS 116 D.O.T. 4, D.O.T. 3, ISO 4925 AND SAE J 1703, (or above)
Clutch Fluid Level Inspection
In accordance with the Periodic Maintenance Chart, inspect
the clutch fluid level in the clutch fluid reservoirs.
A
108
Check the clutch fluid level in the reservoir.
Note: Hold the reservoir horizontal when checking clutch fluid level.
Warning: Change the fluid in the clutch line completely if the fluid must be refilled but the type and brand
of the fluid that is in the reservoir are unidentified
Check the fluid in the clutch reservoir [A] is above the
lower level line [B].
If the fluid level is lower than the lower level line, fill the
reservoir to the upper level line [C] in the reservoir with
the same type and brand of the fluid that already is in the
reservoir.
Clutch Fluid Changing
Remove the reservoir cap and the rubber cap on the bleed
valve.
Attach a clear plastic hose to the bleed valve on the slave,
and run the other end of the hose into a container.
Fill the reservoir with new clutch fluid.
Change the clutch fluid as follows.
Open the bleed valve [A].
Apply the clutch level and hold it [B].
Close the bleed valve [A].
Release the clutch lever [B].
If the fluid in the reservoir runs completely out at any
time during fluid changing, air will enter the line, and the
system must be bled.
Repeat this operation until fresh clutch fluid comes out
into the plastic hose or the colour of the fluid changes.
Warning: Do not mix brands of fluid. Change the clutch fluid
in the clutch line completely if the clutch fluid must be
refilled but the type and brand of the clutch fluid that is already in the reservoir are unidentified.
Torque – Bleed Valve: 7 Nm
Apply the clutch lever forcefully for a few seconds, and check for fluid leakage around the fittings.
A
B
A
C
B
A
B
109
Warning: If the clutch level or pedal has a soft or “spongy feeling” when it is applied, there might be air in
the clutch line or the clutch line may be defective. Since it is dangerous to operate the motorcycle under
such conditions, bleed the air from the brake line immediately.
Clutch Line Air Bleeding
Bleed the air line whenever clutch parts are replaced or
reassembled.
Remove the reservoir cap and fill the reservoir with
new clutch fluid.
Slowly pump the clutch lever several times until no air
bubbles can be seen rising up through the fluid from
the hose at the bottom of the reservoir. This bleeds the
air from the master cylinder and the brake line.
Tap the brake hose lightly going from the slave cylinder to the reservoir side and bleed the air off at
the reservoir.
Attach a clear plastic hose to the bleed valve on the slave
cylinder, and run the other end of the hose into a
container.
Bleed the brake line and the caliper as follows.
Hold the clutch lever applied [A].
Quickly open and close the valve [B].
Release the clutch lever [A].
The fluid level must be checked several times during
bleeding operation and replenished as necessary.
If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation
must be done over again from the beginning since air will have entered the line.
If the brake lever or pedal action still feels soft or “spongy”, tap the clutch hose from bottom to top
and air will rise up to the top part of the hose. Slowly pump the clutch in the same manner as above
Torque - Bleed Valve: 7 Nm
Torque - Reservoir Cap Screws (integral reservoir only): 1.5Nm
Apply the clutch lever forcefully for a few seconds, and check for fluid leakage around the fittings.
Clutch Slave Cylinder
A
B
110
Clutch Slave Cylinder Removal
Remove three mounting bolts [A].
Remove Slave cylinder, and support plate with ball bearing.
Clutch Slave Cylinder Installation
Put Red Grease on the support plate [B] and ball
bearing[C] to stop them falling out while being
installed.
Install the clutch slave cylinder.
Torque: Clutch Slave Cylinder bolts: 6NM
Clutch Slave Cylinder Inspection
Inspect surface for evidence of ware, corrosion, leakage or pitting, if any evidence exists replace
slave cylinder.
Clutch Master Cylinder
Clutch Master Cylinder Removal
Integral reservoir: Remove mounting bolts [A].
Integral reservoir: Remove brake light connection.
Integral reservoir: Remove lever assembly.
Remote reservoir: Remove mounting bolts [B]
Remote reservoir: Remove brake light connection.
Remote reservoir: Remove lever assembly.
Clutch Master Cylinder Installation
A
B
C
B
A
111
Integral reservoir: install lever assembly.
Integral reservoir: install brake light connection.
Integral reservoir: install mounting bolts [A].
Position level to owners preference, ensure correct operation and clearance.
Tighten top bolt.
Torque: Clutch Master Cylinder bolts: 6NM
Tighten bottom bolt.
Torque: Clutch Master Cylinder bolts: 6NM
Remote reservoir: install lever assembly.
Remote reservoir: install brake light connection.
Remote reservoir: install mounting bolts [B]
Position level to owners preference, ensure correct
operation and clearance.
Tighten top bolt.
Torque: Clutch Master Cylinder bolts: 6NM
Tighten bottom bolt.
Torque: Clutch Master Cylinder bolts: 6NM
Clutch Master Cylinder Inspection
Inspect surface for evidence of ware, corrosion, leakage or pitting, if any evidence exists replace
lever assembly.
Clutch Hose
Clutch Hose Removal
Drain Clutch Fluid (see Clutch Fluid Changing).
Remove clutch slave cylinder banjo bolt and drain any remained fluid into a suitable container.
Remove clutch master cylinder banjo bolt and remove clutch hose, taking note of hose routing.
Clutch Hose Installation
B
A
112
Install hose in reverse order to removal, ensuring hose is not, and will not be trapped or crushed
during vehicle operation.
Install slave and master cylinder banjo bolts and tighten.
Torque: Clutch Banjo Bolts: 25Nm
Clutch Hose Inspection
Inspect surface for evidence of ware, corrosion, leakage or pitting, if any evidence exists replace
hose.
Clutch Cover
Clutch Cover Removal
Drain Gear Box oil (see Engine Lubrication System
chapter).
Remove:
Splined gear selector arm (see Gear chapter).
Take out the sixteen bolts [A] and remove the clutch
cover [B].
Clutch Cover Installation
B
A
A
113
Install:
o Dowel Pins [A]
o Clutch Cover Gasket [B]
Install the clutch cover.
Torque - Clutch cover Bolts 12Nm
Clutch Release Removal
Remove the sprocket cover bolts [A].
Remove sprocket cover.
Remove six M6 clutch spring bolts,
washers and springs.
Remove clutch centre, friction
plates and steel plates.
Remove clutch push rods. Take note of assembly
sequence.
B
B
A
114
Clutch release Installation
Apply clean engine oil to all
clutch parts.
Install clutch centre, friction
plates and steel plates.
Install six M6 clutch spring bolts,
washers and springs.
Torque – clutch spring bolts to 12Nm
Install clutch push rods.
Install sprocket cover and sprocket cover bolts.
Torque – Sprocket cover bolts to 20Nm
Clutch
Clutch Removal
Remove six M6 clutch spring bolts,
washers and springs.
Remove clutch centre, friction
plates and steel plates,
115
Using the clutch holder, hold the clutch hub to
remove the clutch hub nut [B] and hub [A]
Remove:
o Basket [A]
o Two spacers [B] and [C]
Clutch Installation
Install:
Spacer [A]
Spacer [B]
Clutch Housing (with bearing)
Install:
Clutch hub [A] (with bearing)
Hub nut
Torque - Clutch hub nut 122Nm Threebond 1327
B
A
B
C
A
A
B
116
Install the friction plates and steel plates, starting with a
friction plate alternating them.
Caution: If new dry friction plate and steel plates are installed,
apply engine oil to the surface of each plate and leave to soak
overnight, to avoid clutch plate seizure.
Install the last friction plate fitting the tangs in the grooves
on the housing as shown.
Apply engine oil to all bearings and clutch parts.
Install the clutch spring plate, springs and washers.
Torque – Clutch Spring Bolts: 12Nm
Install the clutch cover.
Friction and Steel Plate Damage, Wear Inspection
Visually inspect the friction and steel plates for signs of
seizure, overheating (discoloration), or uneven wear.
Measure the thickness of the friction plates at several
points.
If any plates show signs of damage, or if they have worn
past the service limit, replace them with new ones.
Friction Plate Thickness
Standard: 2.9 mm ~ 3.1 mm
Service Limit: 2.75 mm
Friction and steel Plate Warp Inspection
Place each friction plate or steel plate on a surface plate,
and measure the gap between the surface plate and each
friction plate or steel plate with a thickness gauge. The gap
is the amount of friction or steel plate warp.
If any plate is warped over the service limit, replace it with
a new one.
Friction and Steel plate Warp
Standard: 0.2 mm or less
Service Limit: 0.3 mm
117
Cutch Spring Free Length Measurement
Measure the free length of the clutch springs.
If any spring is shorter than the service limit, it must be replaced.
Clutch Spring Free Length
Standard: 54 mm
Service Limit: 52.75 mm
Clutch Housing Finger Damage
Visually inspect the clutch housing fingers [A] where the
friction plate tangs hit them.
If they are badly worn or if there are groove cuts where
the tangs hit, replace the housing. Also, replace the
friction plates if their tangs are damaged.
Clutch Hub Spline Damage
Visually inspect where the teeth on the steel plates
wear against the clutch hub splines.
If there are notches worn into the clutch hub splines,
replace the clutch hub. Also, replace the steel plates if
their teeth are damaged.
Primary Gear
Primary Gear Removal
Remove the clutch cover (see clutch Cover Removal).
Use a gear holder or if one is not available use a copper
coin between the primary and balance gear to lock the
engine rotation.
Remove:
o Primary Gear Nut
o Primary Gear Washer
A
118
Remove the primary gear.
Remove woodruff key.
Primary Gear Installation
Install:
o Woodruff key [A] (identical
parts)
o Primary Gear [B]
o Primary Gear Washer [C]
Use a gear holder or if one is not available use a copper
coin between the primary and balance gear to lock the
engine rotation.
Tighten primary nut.
Torque – 122Nm Threebond 1305
Install the clutch cover (see clutch Cover Removal).
B C
A
119
Engine Lubrication System
Exploded View ................................................................................................................................................ 121
Engine Oil flow charts .................................................................................................................................... 123
Specification ................................................................................................................................................... 128
Engine Oil and Oil Filter ................................................................................................................................. 129
Oil Inspection ..................................................................................................................................... 129
Oil Draining ........................................................................................................................................ 129
Oil Filling ............................................................................................................................................. 130
Oil Filter Change ................................................................................................................................. 130
Gearbox ................................................................................................................................................................
Gearbox Oil Draining .......................................................................................................................... 131
Gearbox Oil Filling .............................................................................................................................. 131
Relief Valve Opening Pressure Measurement ............................................................................................... 131
Oil Pressure Measurement ............................................................................................................................ 132
Oil Pump ......................................................................................................................................................... 133
Oil Pipe Removal ................................................................................................................................ 133
Oil Pipe Installation ............................................................................................................................ 133
Oil Pipe Inspection ............................................................................................................................. 133
Relief Valve Inspection ................................................................................................................................... 133
Oil Pipe ........................................................................................................................................................... 134
Oil Pipe Removal ................................................................................................................................ 134
Oil Pipe Installation ............................................................................................................................ 136
120
Engine Oil Flow
Note: Oil is sucked from the back of the oil tank [1] and pumped under pressure through the engine oil feed
system.
Oil is scavenged from the sump by the oil pump [2] and pumped through the radiator [3] into the oil tank
[4].
The oil tank LH breather [5], vents into the back of the head.
The crank case breather [6] breathes into the LH rocker cover.
The RH rocker cover breather [7] breathes into the air box.
1
2
3
4 5
7
6
121
122
REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
25 COVER ASSY, ROCKER
1 COVER, ROCKER, MACH
2 GASKET, ROCKER, COVER
3 BOLT, CAP HD, M6 X 20 x 1.0, DIN 912, SS 12
5 BANJO,M14, 9MM SPIGOT
6
WASHER, M14, OD 20.0MM X 2.5
ALUMINIUM
7 WASHER, M14, OD 20.4MM X 1.22, COPPER
8 BOLT, BANJO, M14 22
22 NUT, M14 X 1.5, THIN, STEEL
23 BOLT, BANJO, M14, MOD 22
24 BREATHER BAFFLE, ASSY
BREATHER BAFFLE, FRONT
BREATHER BAFFLE, REAR
BREATHER BAFFLE, WELD NUT
9 COVER, RH, MC/D
10 GASKET, COVER, RH
11 DOWEL, RING, 7.8MM DIA
26 COVER ASSY, OIL FILTER
12 COVER, OIL FILTER, MC/D
27 TOP HAT, OIL FILTER, COVER
28 BELLEVILLE, SPRING
29 O-RING, 14MM X 2MM, VITON
30 RING, WIRE, 18MM, PLAIN, EXTERNAL
13 O-RING, 67MM X 2 MM, VITON
14 BOLT, CAP HD, M5x0.8x14, DIN 912, A2/70 5
15 BOLT, CAP HD, M6 X 20 x 1.0, DIN 912, SS 12
16 COVER, CLUTCH, MC/D
17 GASKET, COVER, CLUTCH
11 DOWEL, RING, 7.8MM DIA
18 BOLT, CAP HD, M6 X 40, DIN 912, SS 12
19 BOLT, CAP HD, M6 X 30 X 1.0, SS 12
31 LABEL, SILKOLENE, 10W/40 LABLE FOR ENGINE
OIL
123
124
125
REF. PART DESCRIPTION TORQUE REMARKS
126
NO.
1 CYLINDER HEAD, ASSY, MC/D
2 CYLINDER HEAD, MACHINING
CYLINDER HEAD, CASTING
3 VALVE GUIDE, INLET
4 VALVE GUIDE, EXHAUST
5 SEAT, VALVE, INLET
6 SEAT, VALVE, EXHAUST
7 STUD, EXHAUST 12 THREEBOND 1305
26 GRUB SCREW, M12 X 1.75 X 20MM, DIN 913, A2 15 THREEBOND 1305
8 GASKET, CYLINDER HEAD
9 TOWER, ROCKER, LH, MC/D
10 TOWER, ROCKER, RH, MC/D
11 PIN, DOWEL, 6.00 X 12.0, DIN 7, SS
27 WASHER, M8, NORDLOCK
13 BOLT, CAP HD, M8 X 50 X 1.25, DIN 912, 12.9 20 EXHAUST, TB 1305
28 BOLT, CAP HD, M8 X 55 X 1.25, DIN 912, 12.9 20 INLET, TB 1305
12 WASHER, M8, ID 8.4 X OD 15 X 1.6, BZP
14 STUD, HEAD 54 TB 1305
15 BOLT, CAP HD, M10 X 150 X 1.5, DIN 912, 12.9 60
18 BOLT, CAP HD, M8 X 80 X 1.25, DIN 912, 12.9 25
19
BOLT, CAP HD, M8 X 110 X 1.25, DIN 912, 12.9,
BZP 25
20 NUT, DOMED, M10 X 1.5, DIN 1594, A2 60
CMD EXTREME PRESSURE LUB #3, 4oz APPLY TO STUD FIXINGS AS REQUIRED
16 WASHER, M10, 10.5 X 21.0 X 2, DIN 125A, A2
21 SPACER, EXHAUST SPRING
22 SPACER, INLET SPRING
23 BREATHER FITTING, ASSY, CYLINDER HEAD
BREATHER FITTING, BODY
BREATHER FITTING, BARB
25 SEAL, M10, BONDED VITON
INSIDE ENGINE
BETWEEN HEAD AND WASHER
24 LOCKNUT, M10 X 1.5, GRADE 8 20
29 WASHER, 10.5 X 21.0 X 1.2, FORM B, A2 INSIDE ENGINE ON
TOP OF SEAL WASHER
16 WASHER, M10, 10.5 X 21.0 X 2, DIN 125A, A2 ON THE OUT SIDE OF
THE ENGINE
127
128
REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
1 CRANKCASE, ASSY, SET
2 CASE, MAIN, ASSY, MACHINING
3 CASE, MAIN, LH, INITIAL MACHINING
CASE, MAIN, LH, CASTING
4 CENTRE PLATE, MAIN CASE, MACHINING
5 CASE, MAIN, RH, INITIAL MACHINING
CASE, MAIN, RH, CASTING
6 BEARING PLATE, ASSY
7 BEARING PLATE, LOWER
8 BEARING PLATE, UPPER
9 DOWEL, RING, 13.00MM DIA
10 BOLT, CAP HD, M10 X 100 X 1.5, DIN 912, 12.9 48
11 GRUB SCREW, M8 X 8, FLAT POINT, DIN 913 THREEBOND 1327
12 O-RING, 14MM X 2MM, VITON
13 O-RING, 6.0MM X 2.00MM, VITON
14 DOWEL, RING, 11.0 DIA
15 BOLT, HEX HD, FLANGED, M8 X 40, DIN 6921, 10.9
25
16 WINDAGE PLATE, CRANKCASE
17 WASHER, M5 X 10 X 1, DIN 125A, RAW
18 BOLT, CAP HD, M5 X 12 X 0.8, DIN 912, 12.9 5 THREEBOND 1327
19 DOWEL, RING, 13.00MM DIA
20
BOLT, CAP HD, M10 X 75 X 1.5, DIN 912, 12.9,
BZP 48
21 BOLT, CAP HD, M10 X 45 X 1.5, DIN 912, 12.9, BZP
48
22
BOLT, CAP HD, M10 X 40 X 1.5, DIN 912, 12.9,
BZP 48
23 BOLT, CAP HD, M10 X 60 X 1.5, DIN 912, 12.9 48
24 BOLT, CAP HD, M10 X 90 X 1.5, DIN 912, 12.9 48
25 BOLT, CAP HD, M6 X 50 X 1.0, DIN 912, 12.9 12
26 WASHER, M6, 6.4 X 12 X 1.6, DIN 125A
27 DOWEL, RING, 11.0 DIA
28 RETAINER, CRANK SEAL, ID 60MM
29 BOLT, BUTTON HD, M4x0.7x6.0, ISO 7380, 10.9 2.5 THREEBOND 1327
30 BREATHER, CRANKCASE 15 THREEBOND 1327
31 SEAL, M12, BONDED VITON
129
130
REF. NO. PART DESCRIPTION TORQUE REMARKS
1 SWITCH, OIL PRESSURE, 0.2 BAR 20 THREEBOND 1327
8 PUMP ASSY, OIL
11 PIN, DOWEL, 1/8 X 5/8, SOLID USED WITH OIL PUMP DRIVE
12 PIN, DOWEL, 4.0 X 16.00MM, SOLID USED WITH PUMP TO CASE
9 BOLT, CAP HD, M6 X 30 X 1.0, DIN 912, 8.8, BZP 12 CLAMP, OIL PUMP TO ENGINE
10
WASHER, ID 6.4 X 11.0 OD X 1.6
STAINLESS USED WITH OIL PUMP BOLTS
13 FILLER CAP, GEARBOX 20
14
WASHER, ID 26.3 X 31.75 X 2.0,
COPPER GEAR BOX FILLER CAP
15 FILTER, OIL
20 SEAL, M10, BONDED VITON
21 PLUG, SUMP, M10 X 9.0 X 1.5 20
22 LABEL, SILKOLENE, 10W/40 APPLY TO RH COVER ABOVE FILTER COVER
131
REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
1 PLATE, SUMP
2 GASKET, SUMP
3 PLUG, SUMP, MAGNETIC M14 X 1.5 20
5 BOLT, CAP HD, M6 X 20 x 1.0, DIN 912, SS 12
132
Oil Specification
Item Standard
Engine / Gear Box Oil: Grade API SG, SH AND SJ, JASO MA Viscosity SAE 10W-40 Capacity Engine 3L FROM COMPLETELY DRY
Capacity Gearbox 2.5L WHEN FILTER REMOVED 1.2L
Oil Pressure Measurement: Relief valve opening pressure 400kPa oil pump pressure @8000rpm with 130˚C 10W/40 oil 6L/min and 300kPa oil pump pressure @1000rpm with 130˚C 10W/40 oil 150kPa
133
Engine Oil and Oil Filter
Warning: Motorcycle operation with Insufficient, deteriorated or contaminated engine oil will cause
accelerated wear and may result in engine or transmission seizure, accident, and injury.
Engine Oil Level Inspection
Situate the motorcycle so that it is perpendicular to the ground.
If the oil has just been changed, start the engine and run it for several minutes at idle speed. This
fills the oil filter with oil.
Caution: Racing the engine before the oil reaches every part can cause engine seizure.
Stop the engine and leave it for more than 1 minute for
all the oil to drain down.
If the motorcycle has just been ridden, run the engine for
about 20 seconds at idle speed. Stop the engine and
leave it for more than one minute.
Check the engine oil by removing the oil filler, clean the
dip stick with a cloth fully reinsert the plug then remove
it again and check the level on the dip stick.
The oil level should be in the middle of the two markings.
If the oil level is difficult to check, rock the motorcycle
both side-to-side, and front-to-rear.
If the oil level is too high, remove the excess oil through
the filler opening, using a syringe or some other suitable
device.
If the oil level is too low, add the correct amount of oil
through the oil filler opening. Use the same type and
make of oil that is already in the engine.
Note: If the engine oil type and make are unknown, use any brand of the specified oil to top off the level
rather than running the engine with the oil level low. Then at your earliest convenience, change the oil
completely.
Engine Oil Draining
Warning: To avoid burns, do not remove the radiator hose or try
to change the oil when the engine is still hot. Wait until it cools
down. Oil on tires will make them slippery and can cause an
134
accident and injury. Immediately wash away any oil that spills of the frame, engine, or wheels. Since oil is
harmful to the human body, do not use for drinking.
Place a container under the drain plug [A] at the bottom of the sump, remove oil filler cap and then
remove the drain plug. It is not necessary to remove the primary or secondary exhaust sections, but
does make access easier.
Place a tray under the bottom radiator hoses [A],
remove the bottom banjo bolt [B] and drain the oil from
the oil tank hose.
Engine Oil Filling
Tighten the drain plug.
Torque – Oil sump drain Plug: 20Nm
Fill the oil tank with 2.5L of oil and tighten the filler cap.
Run the engine at idle for 2 minutes in a well ventilated
area. Allow the motorcycle to stand for 2 minutes.
Check the oil level as described in (Oil Level Inspection) top up if necessary.
Note: Pour in the oil slowly so that the air in the engine and radiator can escape.
Caution: Do not add more oil above the full mark.
Engine Oil Filter Change
Drain Engine Oil
Remove oil filter cover bolts.
Remove oil filter cover.
Remove oil filter.
Replace the filter element with a new one.
Apply oil to the mounting surfaces and oil filter.
Install the oil filter.
Install oil filter cover and bolts
A
A B
135
Torque – filter cover bolts: 6Nm
Pour in the specified type and amount of oil.
Gearbox Oil Draining
Warning: To avoid burns, do not change the oil when the engine is
still hot. Wait until it cools down. Oil on tires will make them
slippery and can cause an accident and injury. Immediately wash
away any oil that spills of the frame, engine, or wheels. Since oil is
harmful to the human body, do not use for drinking.
Place a container under the drain plug [A] at the bottom of
the gearbox, remove oil filler cap and then remove the drain
plug.
Allow oil to drain fully.
Gearbox Oil Filling
Tighten the drain plug.
Torque – Gear Box Oil Drain Plug: 20Nm
Fill the gearbox with 1.2L of oil and tighten the filler cap [A].
Torque – Gear Box Filler Cap: 20 Nm
Run the engine at idle for 2 minutes in a well ventilated area.
Note: Pour in the oil slowly so that the air in the engine and radiator can escape.
Caution: Do not add more oil above the full mark.
Relief Valve Opening Pressure Measurement
Note: Measure the oil pressure before the engine is warmed up if
you want to test relief valve opening pressure.
Remove oil passage plug [A] on the oil pump and replace
with double banjo bolt and oil pressure gauge adapter.
Special Tools – Oil Pressure Gauge Adapter and Oil
A
A
A
136
Pressure Gauge.
Start the engine, and read the maximum oil pressure while running the engine at various speeds. A
normal relief valve keeps the maximum oil pressure between the specified values.
Relief Valve Opening Pressure
Standard: 300~400 kPa
If the reading is much higher than the standard, the relief valve is stuck in its closed position.
If the reading is much lower than the standard, the relief valve may be stuck open, or there may be
other damage (e.g. crank oil seal damage, oil pump damage) in the lubrication system.
Stop the engine.
Remove the oil pressure gauge and adapter.
Install the oil banjo bolt.
Torque – Oil Pump Banjo Bolt: 35Nm
Oil Pressure Measurement
Oil Pressure Measurement
Note: Measure the oil pressure after the engine is warmed up.
Attach the oil pressure gauge and adapters to the plug hole (see Relief Valve Opening Pressure
Measurement).
Warning: You could receive burns from hot engine oil draining through the oil passage when the plug is
removed.
Special Tools – Oil Pressure Gauge Adapter and Oil Pressure Gauge.
Oil Pressure Standard: 150kPa
If the oil pressure is much lower than the standard, check the oil pump, relief valve, and/or
crankshaft and balance shaft oil seal immediately.
If they are not at fault, inspect the rest of the lubrication system.
Stop the engine.
Remove the oil pressure gauge and adapter.
Install the oil pump banjo plug.
137
Oil Pump
Oil Pump Removal
Drain the engine oil.
Remove two Oil Banjo bolts.
Remove three outer oil pump retainer bolts.
Taking note of the O-ring and dowel positions remove
the oil pump.
Oil Pump Installation
Install the oil drive dowel, location dowels and O-rings
(use a little grease to hold in place if required.
Fill the pump with engine oil [A] for initial lubrication.
Align the oil pump drive dowel with the balance shaft
female drive cut out.
Install the oil Pump and three location bolts.
Torque - Oil pump bolts: 12Nm
Oil Pump inspection
Disassemble the oil pump (see this chapter).
Visually inspect the oil pump body, outer and inner rotors, and covers.
A
138
If there is any damage or uneven wear, replace the rotors or the oil pump assembly.
Relief Valve Inspection
Disassemble the oil pump (see this chapter).
Remove the relief valve [A].
Check to see if the piston moves freely when pushing it with a wooden or soft rod, and see if it
comes back to its seat by the valve spring pressure.
If any rough spots are found during above inspection, wash the valve clean with a high-flash point
solvent and blow out any foreign particles that may be
in the valve with compressed air.
Warning: Clean the parts in a well-ventilated are, and take care
that there are no sparks or flame anywhere near the working
area. Because of the danger of highly flammable liquids, do not
use gasoline or low-flash point solvents.
If cleaning dose not solve the problem, replace the relief
valve as an assembly. The relief valve is precision made
with no allowance for replacement of individual parts.
Oil Pipe
Oil Pipe Removal
Remove:
Fuel Tank (see Fuel System chapter)
Remove Battery and Battery Tray (see Electrical System
chapter)
Cut double eared clip off and remove oil pump banjo,
remove oil tank to oil pump hose.
139
Remove oil pump banjo bolt, cut double eared clip off oil
cooler, and remove hose.
Cut double eared clip off oil cooler, cut double eared clip off oil
tank, and remove hose.
Cut double eared clip off oil tank, cut double eared clip off
back of the head, and remove hose.
Cut double eared clip off rocker cover, cut double eared
clip off air box, and remove hose.
140
Cut double eared clip off crank case, cut double eared clip
off rocker cover, and remove hose.
Oil Pipe Installation
Before installation, flush out the pipe with a high-flash point solvent.
Fill the pipes with engine oil to shorten air bleeding time and prevent engine damage.
Discard the used copper washers and install new washers on each side of the pipe fittings.
Install new double eared clamps in all positions and crimp.
Installation process is the reverse of the removal (see this chapter).
Lightly tighten the banjo bolts to a snug fit, and tighten them to the specified torque.
Torque – Oil Pipe Banjo Bolts: 35Nm
141
Engine Removal / Installation
Exploded View ................................................................................................................................................ 138
Engine Removal / Installation ........................................................................................................................ 140
Engine Removal .................................................................................................................................. 140
Engine Installation.............................................................................................................................. 141
142
Exploded View
143
REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
1 FRAME ASSEMBLY, SINGLE SEAT XM
20 CABLE TIE, 120MM X 3.6MM, FIR-TREE,
BLACK
CLAMP DIRECT TO FRAME, CLUTCH HOSE,
HARNESS
2 OIL FILLER CAP
3 O-RING, OIL FILLER CAP, 2.4MM SITS INSIDE OIL FILLER CAP
4 DIPSTICK
5 BRACKET, ENGINE, FRONT, STEEL, XM
6 SPACER, ENGINE MOUNT, RHS,
ALUMINIUM
7 SPACER, ENGINE MOUNT, LHS, ALUMINIUM
8 BOLT CAP HD, M8 X 57 X 1.25 TO CLAMP ENGINE MOUNT BRACKET
9 WASHER, M8, 8.4 X 16 X 1.6 TO CLAMP ENGINE MOUNT BRACKET
10 26 TO CLAMP ENGINE MOUNT BRACKET
11 BOLT, M12, ENGINE, FRONT MOUNT FRONT ENGINE MOUNT BOLT
12 WASHER, M12, 13 X 24 X 2.5 USED WITH ENGINE BOLT AND NUT
13 LOCKNUT, M12 X 1.75
85 NUT, USED WITH ENGINE MOUNT BOLT
14 FRAME ADJUSTER, M24 15
15 BOLT, M12, ENGINE, REAR MOUNT 85 REAR ENGINE MOUNT BOLT
17 VIN PLATE, UK (NOW WHOLE WORLD)
18 RIVET, HAMMER DRIVE, 3/8TH TO FIX VIN PLATE TO FRAME
19 SLEEVE, NYLON, FRAME PROTECTOR
USED BETWEEN FRAME AND FOOTREST
HANGER
144
Engine Removal/Installation
Engine Removal
Drain the engine oil
(see Engine Lubrication System chapter).
Remove:
Fuel Tank (see Fuel System chapter)
Throttle Bodies (see Fuel System chapter)
Exhaust Pipes (see Engine Top End chapter)
Oil lines (see Engine oil and filter chapter)
Air Box (See Fuel System chapter)
Gear change assembly
(see Crankshaft/Transmission chapter)
Remove oil pressure switch connection, cam position
sensor connector, throttle position sensor connector,
speed sensor connector, and temp sensor connector.
Remove sprocket cover and chain
(see Final drive chapter)
Remove spark plug cap [A].
Remove starter motor cable.
Warning: When the engine mounting bolts are removed
the engine will be free so take precautions to support the
engine. The engine is over 70Kg therefore it will require
at least two people to lift it out and an engine jack.
Remove the engine mounting bolts [A] and brackets [B].
Remove the engine from the LH side.
A
A
B
145
Engine Installation
Fit frame protectors onto frame tubes ready for installing the engine so not to scratch the frame,
and place a jack underneath the bottom frame rails to support the engine.
Install the engine into the frame from the left side of the chassis; you will need to get some help to
lift the engine in.
Once engine is sitting in position line up the rear mounting holes and insert service tool into the top
rear mounting hole, insert rear engine bolt into the bottom mount.
Using service tool tighten up top rear engine adjuster and torque.
Torque – Adjuster: 15NM.
Remove service tool and insert engine bolt and torque.
Torque – Engine Bolts: 85NM
Repeat this process for the bottom rear engine mount bolt.
Fit front engine mount brackets and secure in place with
bolts, washers and nuts using a washer on either side of the
bolt then torque.
Torque – Mount bolts: 35 NM
Fit front engine mounting bolt using spacers LH and RH with washer and nut then torque to 85 NM
Install:
Gear change assembly (see Crankshaft/Transmission chapter)
Air Box (See Fuel System chapter)
Oil lines (see Engine oil and filter chapter)
Exhaust Pipes (see Engine Top End chapter)
Throttle Bodies (see Fuel System chapter)
Fuel Tank (see Fuel System chapter)
Install oil pressure switch connection, cam position sensor connector, throttle position sensor
connector, speed sensor connector, and temp sensor
connector.
Install sprocket cover and chain (see Final Drive
chapter)
Install spark plug cap [B].
Install starter motor cable.
Run the cables, hoses, and leads according to the
Cable, Wire, and Hose Routing section of the General
Information chapter.
Install the removed parts (see the appropriate chapter).
146
Adjust:
Throttle Cables (see Fuel System chapter)
Clutch (see Clutch chapter)
Drive Chain (see Final Drive chapter)
Fill the engine oil (see Engine Lubrication System chapter).
Adjust the Throttle idle adjusting screw.
Check the brake effectiveness.
Warning: Do not attempt to ride the motorcycle until a full brake lever or pedal is obtained by pumping
the brake lever or pedal until the pads are against the disc. The brake will not function on the first
application of the lever or pedal is this is not done.
147
Crankshaft / Transmission
Exploded View ................................................................................................................................................ 148
Specification ................................................................................................................................................... 151
Crankcase ....................................................................................................................................................... 153
Crankcase Disassembly ...................................................................................................................... 153
Crankcase Assembly ........................................................................................................................... 157
Crankshaft and Connecting Rod .................................................................................................................... 159
Crankshaft Removal ........................................................................................................................... 159
Crankshaft Installation ....................................................................................................................... 159
Crankshaft Disassembly ..................................................................................................................... 159
Crankshaft Assembly .......................................................................................................................... 159
Crankshaft Alignment ......................................................................................................................... 160
Transmission .................................................................................................................................................. 160
Shift Pedal Installation ....................................................................................................................... 160
External Shift Mechanism Removal ................................................................................................... 161
External Shift Mechanism Installation ............................................................................................... 162
External Shift Mechanism Inspection ................................................................................................ 162
Transmission Removal ....................................................................................................................... 163
Transmission Installation ................................................................................................................... 163
Transmission Shaft Disassembly ........................................................................................................ 163
Transmission Shaft Assembly ............................................................................................................. 164
Shift Fork Bending .............................................................................................................................. 164
Shift Fork Ear/Gear Shift Fork Groove Wear ...................................................................................... 164
Shift Fork Guide Pin/Shift Drum Groove Wear .................................................................................. 164
Gear Dog/Dog Recess Damage .......................................................................................................... 166
Balancer ......................................................................................................................................................... 166
Balancer Shaft Removal ................................................................................................................................. 166
Balancer Shaft Installation ............................................................................................................................. 166
Balancer Shaft Disassembly ........................................................................................................................... 166
Balancer Shaft Assembly ................................................................................................................................ 168
Ball Bearing, Needle Bearing, and Oil Seal ..................................................................................................... 168
Ball and Needle Bearing Replacement ............................................................................................... 168
Ball and Needle Bearing Wear ........................................................................................................... 169
Oil Seal Inspection .............................................................................................................................. 169
148
REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
1 ASSY, CRANKSHAFT, 2 CYL, 270°
2 TRIGGER DISK
3 PRIMARY GEAR, CRANK, 54 TOOTH
4 WOODRUFF KEY, 1" X 1/4",MOD
5 SPACER, CRANKSHAFT
6 SEAL, RADIAL SHAFT, 35.0 X 72.0 X 8
7 BEARING, CYLINDRICAL, OD 80.0MM, ID 35.0MM, 21MM WIDE
INNER RACE PRESSED ON TO SHAFT
8
BOLT,CSK TORX, M5 X 0.8 X 16, DIN7991, A4 -
80 10 TO CLAMP TRIGGER DISK
9 NUT, M20, X 1.5, DIN 934, GRADE 10 122 THREEBOND 1327
10 DOWEL, PRIMARY, GEAR, 6MM DIA X10MM
149
150
REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
1 CRANKCASE, ASSY, SET
2 CASE, MAIN, ASSY, MACHINING
3 CASE, MAIN, LH, INITIAL MACHINING
CASE, MAIN, LH, CASTING
4 CENTRE PLATE, MAIN CASE, MACHINE
5 CASE, MAIN, RH, INITIAL MACHINING
CASE, MAIN, RH, CASTING
6 BEARING PLATE, ASSY
7 BEARING PLATE, LOWER
8 BEARING PLATE, UPPER
9 DOWEL, RING, 13.00MM DIA
10 BOLT, CAP HD, M10 X 100 X 1.5, DIN 912, 12.9 48
11 GRUB SCREW, M8 X 8, FLAT POINT, DIN 913 THREEBOND 1327
12 O-RING, 14MM X 2MM, VITON
13 O-RING, 6.0MM X 2.00MM, VITON
14 DOWEL, RING, 11.0 DIA
15 BOLT, HEX HD, FLANGED, M8 X 40, DIN 6921, 10.9
25
16 WINDAGE PLATE, CRANKCASE
17 WASHER, M5 X 10 X 1, DIN 125A, RAW
18 BOLT, CAP HD, M5 X 12 X 0.8, DIN 912, 12.9 5 THREEBOND 1327
19 DOWEL, RING, 13.00MM DIA
20
BOLT, CAP HD, M10 X 75 X 1.5, DIN 912, 12.9,
BZP 48
21 BOLT, CAP HD, M10 X 45 X 1.5, DIN 912, 12.9, BZP
48
22
BOLT, CAP HD, M10 X 40 X 1.5, DIN 912, 12.9,
BZP 48
151
23 BOLT, CAP HD, M10 X 60 X 1.5, DIN 912, 12.9 48
24 BOLT, CAP HD, M10 X 90 X 1.5, DIN 912, 12.9 48
25 BOLT, CAP HD, M6 X 50 X 1.0, DIN 912, 12.9 12
26 WASHER, M6, 6.4 X 12 X 1.6, DIN 125A
27 DOWEL, RING, 11.0 DIA
28 RETAINER, CRANK SEAL, ID 60MM
29 BOLT, BUTTON HD, M4x0.7x6.0, ISO 7380, 10.9 2.5 THREEBOND 1327
30 BREATHER, CRANKCASE 15 THREEBOND 1327
31 SEAL, M12, BONDED VITON
152
153
REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
1 CASSETTE PLATE, ASSY
2 END PLATE, CASSETTE
3
BEARING, DEEP GROOVE, 25 X 62 X
17 SITS WITHIN END PLATE
4 CIRCLIP, 62MM INTERNAL X 2.0
5
BEARING, DEEP GROOVE, 20 X 47 X
14 SITS WITHIN END PLATE
6 CIRCLIP, 47MM INTERNAL X 1.7
7 BUSH, BARREL SUPPORT
8 CLIP, SHIFT DRUM
9 PLATE, SHIFT DRUM CLIP
10 NUT, PEM, M8 X 1.25
11 SNAP, LINK , ASSY
12 SNAP, LINK, WELDED, ASSY
14 BOSS, SNAP LINK
15 SPRING, SNAP ARM, LINK
13 ARM, SNAP LINK, PIN
16 PIN, SHIFT PAWL
18 BEARING, 14 X 7 X 3.5
17 SPACER, SHIFT PAWL
23
BOLT, M8x1.25x12, 10.0 DIA, SHLD,
ISO 7979, 12.9 15 THREEBOND 1305
59 DOWEL, RING, 11.0 DIA
57 WASHER, M8 X 17 X 1.6, DIN 125A
56
BOLT, CAP HD, M8 X 70 X 1.25, DIN
912, 12.9 25
19 SPRING, EXTENSION, 55MM, DIN 2097, BZP
20
BOLT, M5x0.8x10, 6.0 DIA, SHLD,
ISO 7979, 12.9 5 THREEBOND 1305
21 PIN, ROLL, 3.0 X 12.0 STAINLESS
22 MAINSHAFT, ASSY
24 SHAFT, TRANSMISSION, MAIN
25 GEAR, 5TH-2ND
26 GEAR, 5TH-3RD
27 GEAR, 5TH-4TH
28 GEAR, 5TH-4TH, COUNTERSHAFT
29
SPACER, GEAR, ID 30.18, OD 35.0 X
1.75
30 SNAP RING, EXTERNAL, 29MM (SWM0290)
31 SPACER, MAIN SHAFT, LH
32
BEARING, NEEDLE ROLLER, 26 X 30
X 13
33 LAYSHAFT, ASSY
154
34 COUNTERSHAFT
35 GEAR, 5TH-2ND, COUNTERSHAFT
36 GEAR, 5TH-3RD, COUNTERSHAFT
37 GEAR, 5TH-4TH, COUNTERSHAFT
38 GEAR, 5TH-4TH
39 GEAR, 1ST, COUNTERSHAFT
40 SPACER, LAYSHAFT
41 SPACER, GEAR, THICKNESS 3.90MM
32
BEARING, NEEDLE ROLLER, 26 X 30
X 13
29 SPACER, GEAR, ID 30.18, OD 35.0 X 1.75
30
SNAP RING, EXTERNAL, 29MM
(SWM0290)
42 BEARING, NEEDLE ROLLER, 25 X 32 X 26
43 END CAP, LAY SHAFT
44 BOLT, CAP HD, M8 X 30 X 1.25, DIN 912, 12.9
25 THREEBOND 1327
45 WASHER, M8, NORDLOCK
BOTH USED BETWEEN BOLT AND
END CAP
46 OUTPUT GEAR, ASSY
47 GEAR, 1ST
48 SEAL, RADIAL, OUTPUT SHAFT
SEAL BETWEEN CRANKCASE AND
OUTPUT SHAFT
49 BEARING, NEEDLE ROLLER, 25 X 32 X 20
50 SPROCKET, DRIVE, 18T
51 SEAL, RING, MAIN SHAFT
53 O-RING, 2.0 SECTION, X 44.0 DIA, VITON
52 SEAL, CASE, SPROCKET
53 WASHER , TAB, DRIVE SPROCKET
54 NUT, DRIVE SPROCKET
55 CIRCLIP, INTERNAL, 85MM TO HOLD RADIAL SEAL
58
BEARING, DEEP GROOVE, 45 X 85
X19
155
156
REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
1 SHIFT MECHANISM, ASSY
3 SHIFTER, WELDED, ASSY
4 RETAINING PLATE, SHIFT MECHANISM
5 SPRING, INTERNAL SHIFTER
6 SPRING, SHIFT PAWL
7 SPACER, SHIFT SPRING
8 BUSH, PIVOT
9 WASHER, 9.7x16.0x0.65, STEEL, RAW
11 CIRCLIP, EXTERNAL, 7MM
10 CIRCLIP, EXTERNAL 9MM
29 ARM, SHIFT PAWL, ASSY
2 BARREL, SHIFTER, ASSY
31
SHIFT DRUM, REVERSE SHIFT, WITH
PINS, ASSY
28 SHIFT DRUM, ASSY
14 SHIFT DRUM
30 PADLE, PIN, SELECTOR DRUM
18
PIN, DOWEL, 3/16 X 5/8, BS 1804
H&G 4 WITH DETENT WHEEL
15 SHIFT FORK, LH, MC/D
16 SHIFT FORK, CENTRE, MC/D
17 SHIFT FORK, RH, MC/D
19 PIN, COTTER, 5/64, X 3/4, (304) SS
18
PIN, DOWEL, 3/16 X 5/8, BS 1804
H&G 3 WITH FORKS
21 DETENT WHEEL, REVERSE SHIFT
22
BOLT, CAP HD, M6 X 25 X 1.0, DIN
912, 12.9 12 TO CLAMP DETENT WHEEL
23
WASHER, M6, 6.4 X 12 X 1.6, DIN
125A
USED WITH DETENT WHEEL BOLT
24 BEARING, NEEDLE ROLLER, 1/2"x11/16"x3/4
USED WITH END OF SELECTOR DRUM
25
BOLT, CAP HD, M6 X 12 X 1.0, DIN
912, 12.9 12 TO CLAMP SHIFT MECHANISM
23 WASHER, M6, 6.4 X 12 X 1.6, DIN 125A
USED WITH SHIFT MECHANISM BOLTS
26
BEARING, NEEDLE ROLLER,
1/2"x11/16"x 5/16 USED ON SHIFT ARM
27 SEAL, ROTARY, 1/2"x7/8"x5/16", SKF
157
REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
1 BALANCER SHAFT, MACHINING
2 BEARING, DEEP GROOVE, 25 X 62 X 17 RH CASE
3 BEARING, DEEP GROOVE, 35 X 62 X 14 LH CASE
4 SPACER, BALANCER SHAFT
5 SEAL, RADIAL, SHAFT, 35 X 47 X 6MM LH CASE
6 BACKLASH, ASSY
7 GEAR, BALANCER, 54 TOOTH
8 GEAR, BACKLASH
9 SPACER, BACKLASH, ID 63 X 45.5 OD X 2.0
10 SPRING, BACKLASH
12 CIRCLIP, EXTERNAL, 40.0 MM, DIN 471
13 PIN, DOWEL, 5.0 X 8.00MM, SOLID, DIN 6325 H&G
14
PIN, DOWEL, 5.0 X 10.00MM, SOLID, DIN 6325
H&G
15 WOODRUFF KEY, 1" X 1/4",MOD
16 WASHER, 34 OD 21 ID X 3.0MM
17 NUT, HALF, M20 X 1.5, DIN 439, A2 70 122
158
Specification
Item Standard Service Limit
Crankshaft, Connecting Rod: Connecting rod big end side clearance Connecting rod big end Radial clearance
0.5mm ± 0.1 0.006~0.019
0.5mm ± 0.2 0.07mm
Crankshaft runout: Right TIR 0.04mm or less TIR 0.10mm Left TIR 0.04mm or less TIR 0.08mm Transmission: Shift fork ear thickness Shift fork ear thickness (left)
5.03-5.13 5.69-5.79
4.93 5.59
Gear shift fork groove width Gear shift fork groove width (left)
5.33± 0.1 6.00± 0.1
5.43± 0.1 6.10± 0.1
Shift fork guide pin diameter 4.7625 4.75
Shift drum Groove width 4.9 5.0
159
Crankcase
Crankcase Disassembly
Remove the engine (see Engine Remove/Installation chapter).
Set the engine on a clean surface and hold the engine steady while parts are removed.
Remove:
o Engine Covers (see relevant chapter)
o Primary Gear (see Clutch chapter)
o Balance shaft Gear (see this chapter)
o Clutch (see Clutch chapter)
o Starter Motor (see Electrical System chapter)
o Alternator rotor (see Electrical System chapter)
o Trigger disk (see Electrical System)
o Cylinder and Gasket (see Top End chapter)
o Piston (see Engine Top End chapter)
o Camshaft Chains and Guides (see Engine Top End chapter)
o External shift mechanism (see this chapter)
o Cassette plate with gears and shift mechanism (see this chapter)
Remove the crank case bolts back from 13 to 1
160
There are two ring dowels on the crankcase mating surface, using a plastic mallet tap lightly around the crankcase mating surface until free.
Lift off the left crankcase half.
161
Remove the baffle plate.
Remove the 9 centre plate bolts from 9
back to 1.
Remove the crank shaft with the centre
plate by hand.
Crankcase Assembly Caution: Right crankcase, left crankcase, and centre plate are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set.
162
Chip off the old gasket from the mating surfaces of the crankcase halves.
Using compressed air, blow out [A] the oil passages in the crankcase halves and centre plate.
With a high-flash point solvent, clean off the mating surfaces of the crankcase halves and wipe dry.
Warning: Clean the engine parts in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low-flash point solvent to clean parts. A fire or explosion could result.
Using a press and the bearing drive set,
install new bearings until they bottom out
on the crankshaft and cases if required. Do
not replace half of the bearing and not the
other half.
Ensure all oil seals are correctly installed
and seated, if any wear is visible replace.
Install the crankshaft by hand with the
centre plate installed on the crank.
Install the 9 centre plate bolts and tighten
in the sequence shown (one to nine).
Torque – Centre Plate Bolts: 25Nm
Install the baffle plate and bolts and
tighten.
Torque – Baffle Plate Bolts: 5Nm
Be sure the mating surfaces of the crankcase
halves are clean and dry.
Check to see the two crankcase dowels pins [A] are in place on the right crankcase half. If either has
been removed, replace it with a new one.
Apply liquid gasket to the mating surface of the left crankcase half.
Sealant – 3 bond gasket sealant
Install the left hand crankcase.
Ensure all seals are not damaged during installation; use a feeler gauge if necessary to feed the lip
seals on.
Tighten the crankcase bolts in the order listed.
Torque – Crankcase Bolts: 48Nm (Excluding the 8th bolt)
Torque – Crankcase Gearbox Bolt: 12Nm (The 8th bolt)
163
Constantly check the alignment of the two crankcase halves, and the position of the balance shaft.
The front and rear of the crankcase must be pushed together evenly.
Check:
Crankshaft and balancer shaft turn freely.
If any of the shafts do not turn freely, split the crankcase to locate the problem.
Install: Remove the crank shaft with the centre plate by hand.
Primary Gear (see Clutch chapter)
Balance shaft Gear (see this chapter)
Cassette plate with gears and shift mechanism (see this chapter)
External shift mechanism (see this chapter)
Clutch (see Clutch chapter)
Trigger disk (see Electrical System)
Alternator rotor (see Electrical System chapter)
Starter Motor (see Electrical System chapter)
Piston (see Engine Top End chapter)
Cylinder and Gasket (see Top End chapter)
Camshaft, Chains and Guides (see Engine Top End chapter)
Engine Covers (see relevant chapters)
Install the engine (see Engine Removal/Installation chapter).
Install the engine sprocket (see Final Drive chapter)
Crankshaft and Connecting Rod
164
Crankshaft Removal
See Crankcase Disassembly
To Split the centre plate remove the two main bolts.
Tap lightly around the joint face with a plastic hammer and split the centre plate, remove.
Crankshaft Installation
See Crankcase Assembly
To join the centre plate ensures the two dowels are in place and align the main centre bearing cir
clip with the groove in the plates.
Ensure the grub screw is installed in the centre plate.
Tap the top and the bottom with a plastic hammer; constantly check the alignment of the two
halves.
Tighten the two centre plate bolts.
Torque – Centre Plate Split bolts: 48Nm
Crankshaft Disassembly
Use a bearing puller to remove the inner bearing runners on the other crankshaft outer left hand
and right hand side.
Note: The crankshaft is a welded assembly; therefore it cannot to disassembled and must be replaced as a whole unit.
Crankshaft Assembly
Using a bearing press tool press the bearing inner runner fully home on the crankshaft.
Connecting Rod Big End Radial Clearance
Set the crankshaft on V blocks, and place a dial gauge [A] against
the connecting rod big end.
Push [B] the connecting rod first towards the gauge and then in
the opposite direction. The Difference between the two gauge
readings is the radial clearance.
If the radial clearance exceeds the service limit, the crankshaft
assembly must be replaced.
Clearance – Big end Radial: Standard: 0.006~0.019 Service Limit: 0.07mm
Connecting Rod Big end Side Clearance
Set the crankshaft on V blocks.
Measure the side clearance [A] of the connecting rod with a
thickness gauge.
165
If big end side clearance exceeds the service limit, the crankshaft assembly must be replaced.
Clearance – Connecting Rod Big End Side Clearance: Standard: 0.40~0.60mm Service Limit: 0.70mm
Crankshaft Alignment
With the crankshaft on V blocks, turn the
crankshaft slowly and measure runout at
each of the locations shown [A] and [B].
Runout – Crankshaft Right Half: Standard TIR 0.04mm or less. Service limit: TIR 0.10mm
Runout – Crankshaft Left Half: Standard TIR 0.04mm or less. Service Limit: TIR 0.08mm
If runout at either location exceeds the service limit, replace the crankshaft assembly.
Transmission Transmission shift pedal
Adjust the shift pedal position from the foot peg to suit
you.
The standard shift pedal position is about 40mm below
the foot peg top.
External Shift Mechanism Removal
Drain the engine oil (see Engine Lubrication
System chapter)
Remove gear shift pedal assembly.
Remove clutch cover (See Clutch chapter)
Remove the two allen head retainer bolts.
Align the neutral cut out of the detent wheel
with the selector fork; pull the fork back away
from the detent wheel so it can slide past.
166
Remove the external shift assembly.
Remove the snap link arm retainer bolt;
remove snap link arm.
Remove the detent wheel retainer bolt;
remove the detent wheel.
External shift Mechanism Installation
Be sure the dowels are correctly installed in
the shift drum [A]
Apply Threebond 1305 to the threads of
the shift drum cam bolt; install detent
wheel and tighten retainer bolt.
Torque – Shift Drum Cam Bolt: 12Nm, Threebond 1305
Install the snap link arm and tighten.
167
Torque – snap link arm bolt: 15Nm, Threebond 1305
Ensure selector fork is assembled as
detailed below.
Align the neutral cut out of the detent wheel with the selector fork; pull the fork back away from
the detent wheel so it can slide past and install.
Torque – shift mechanism bolts: 12Nm
External Shift Mechanism Inspection
Check the shift shaft for bending or
serrations [A] for damage
If the shaft is bent, straighten or replace
it. If the serrations are damaged, replace
the shaft.
Check the springs [B] for breaks or
distortion.
If the springs are damaged in any way,
replace them.
Check the shift mechanism arm [C] for
distortion.
If the shift mechanism arm is damaged in
any way, replace the shift shaft
assembly.
Transmission Removal
Remove the clutch.
Remove External Shift Mechanism (see
this chapter)
168
Remove the cassette plate retainer bolts.
Remove the cassette plate as a single unit.
Transmission Installation
Apply a small amount of engine oil to the
transmission gears, bearings, shaft
journals, and shift fork fingers.
Install the cassette plate assembly
ensuring the output shaft is correctly
aligned.
Tighten the cassette plate bolts.
Torque – Cassette plate bolts: 25Nm
Transmission Disassembly
Put gearbox in neutral position
Remove the Transmission (see Transmission Removal)
Hold the transmission shafts and selector drum, tap the cassette plate lightly with a plastic hammer
and remove.
169
Remove the gears and spacers in the sequence shown, using the outside circlip pliers, remove the
circlips [30] and disassemble the transmission shafts completely.
Transmission Shaft Assembly
Replace any circlips that were removed with new
ones.
Install the gears, spacers, and circlips in the order
shown.
Assemble the shift fork to the main and lay shafts
at 90˚ to the axial direction of the main shaft and
lay shaft.
Insert the lay shaft main shaft and selector drum into the
cassette plate as one unit, use a plastic mallet if required to
mate the cassette plate home.
Shift fork bending
170
Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in
shifting, or allow the transmission to jump out of gear when under power. 90˚ [A].
Shift Fork Ear/Gear Shift Fork Groove Wear
Measure the thickness [A] of the shift fork ears.
If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced.
Shift Fork Ear Thickness Standard: 5.03~5.13mm Service Limit: 4.93mm
Shift Fork Ear Thickness (left)
Standard: 5.79~5.69mm Service Limit: 5.59mm
Measure the width [A] of the gear shift grooves.
If a gear fork groove is worn over the service limit, the gear must be replaced.
Gear Shift Fork Groove Width Standard: 5.33 ± 0.1mm Service Limit: 5.43 ± 0.1mm
Gear Shift Fork Groove Width (left) Standard: 6.00 ± 0.1mm Service Limit: 6.10 ± 0.1mm
Shift Fork Guide Pin/Shift Drum Groove Wear
Measure the diameter [A] of each shift fork guide
pin, and measure the width [B] of each shift drum
groove.
If the guide pin on any shift fork is less than the
service limit, the pin must be replaced
Shift Fork guide Pin Diameter
Standard: 4.7625mm Service Limit: 4.75mm
If any shift drum groove is worn over the service
limit, the drum must be replaced.
Shift Fork Guide Groove Diameter
Standard: 4.9mm Service Limit: 5.00mm
B
A
171
Gear Dog/Dog Recess Damage
Visually inspect the gear dogs [A], and
recesses [B].
Replace any damaged gears or gears with
excessively worn dogs, or recesses.
Balancer
Balancer shaft Removal
Split the crankcase (see Crankcase Disassembly)
Lift the balancer shaft [A] out of the right-hand
crankcase half.
Balancer Shaft Installation
See Crankcase Assembly.
Install by hand ensuring spacer is in position.
Balance Gear Removal
Remove the clutch cover (see clutch Cover Removal).
B
B
B
A
172
Use a gear holder or if one is not available use a copper coin between the primary and balance gear
to lock the engine rotation.
Insert an M8 bolt into the balance gear location hole [A]
this will lock the anti backlash spring in place.
Remove:
o Balance Gear Nut
o Balance Gear Washer
Remove the Balance gear, with the anti-backlash gear and spring.
Remove woodruff key.
Balance Gear Installation
Install:
Woodruff key [A]
Balance Gear assembly [A]
ensuring dots line up.
Balance Gear Washer [B]
173
Use a gear holder or if one is not available use a copper coin between the primary and balance gear
to lock the engine rotation.
Tighten Balance gear nut.
Torque – 122Nm Threebond 1305
Install the clutch cover (see clutch Cover Removal).
Balancer Shaft Gear Disassembly
Use the Balance Shaft Gear Holder tool and remove the m8
nut inserted during engine disassembly. Allow the spring to
slowly unwind, separate the gears.
The dowels can be removed if required.
Balancer Shaft Gear Assembly
Assembly by hand on the Balance Shaft Gear Holder tool in
order shown.
Use the Balance Shaft Gear Holder tool, slowly apply
tension to the spring then when the two holes align insert
an m8 nut.
174
Ball and Needle Bearing Replacement Caution: Do not remove the ball or needle bearings unless it is necessary. Removal may damage them.
Using a press or puller, remove the ball and/or needle bearings.
Note: In the absence of the above mentioned tools, satisfactory results may be obtained by heating the case to approximately 75˚C max, and tapping the bearing in or out. Caution: Do not heat the case with a torch. This will warp the case.
Using a press and a bearing drive, install the new bearing until it stops at the bottom of its housing.
Ball and Needle Bearing Wear Caution: Do not remove the bearings for inspection. Removal may damage them.
Check the ball bearings.
Since the ball bearings are made to extremely close tolerances, the wear must be judged by feel
rather than measurement. Clean each bearing in a high-flash point solvent, dry it (do not spin the
bearing while it is dry), and oil it with engine oil.
Spin the bearing by hand to check its condition.
If the bearing is noisy, does not spin smoothly, or has any rough sports, replace it.
Check the needle bearings.
The rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of
measuring, inspect the bearing for abrasion, colour change, or other damage.
If there is any doubt as to the condition of a needle bearing, replace it.
Oil Seal Inspection
Inspect the oil seals.
Replace it if the lips are misshapen, discoloured (indicating that the rubber has deteriorated),
hardened or otherwise damaged.
175
Wheels/Tyres
Exploded View ................................................................................................................................................ 171
Specification ................................................................................................................................................... 178
Wheels ........................................................................................................................................................... 179
Front Wheel Removal ...................................................................................................................... 179
Front wheel Installation ................................................................................................................... 179
Rear Wheel Removal ....................................................................................................................... 180
Rear wheel Installation .................................................................................................................... 180
Front wheel Disassembly ................................................................................................................. 180
Front wheel Assembly ..................................................................................................................... 181
Rear wheel Disassembly .................................................................................................................. 181
Rear wheel Assembly ....................................................................................................................... 182
Wheel Inspection ............................................................................................................................. 182
Spoke Inspection .............................................................................................................................. 182
Rim Inspection ................................................................................................................................. 182
Axle Inspection ................................................................................................................................. 183
Wheel Balance ............................................................................................................................................... 183
Wheel Balance Inspection ............................................................................................................... 183
Wheel Balance Adjustment ............................................................................................................. 183
Tyres ............................................................................................................................................................... 184
Air Pressure Inspection / Adjustment .............................................................................................. 184
Tyre Inspection ................................................................................................................................ 184
Tyre Removal ................................................................................................................................... 185
Tyre Installation ............................................................................................................................... 185
Hub Bearings (wheel Bearings ....................................................................................................................... 186
Bearing Removal .............................................................................................................................. 186
Bearing Installation .......................................................................................................................... 186
Bearing Inspection ........................................................................................................................... 186
176
Exploded View
177
REF. NO.
PART DESCRIPTION TORQUE (NM)
REMARKS
1 REAR WHEEL, CARBON FIBRE, BLACK STANDARD REAR WHEEL FOR CSE-01/03
2 SPACER, INTERNAL, REAR WHEEL,
CARBON
3 REAR WHEEL, BEARING 30 X 55 X 13 (CARBON)
38 BEARING 30 X 55 X 13, REAR WHEEL,
CARBON
SEAL, OIL
4 CIRCLIP, REAR WHEEL, CARBON TO HOLD BEARING IN THE HUB
5 VALVE ASSY, ALUMIN, 90, REAR WHEEL,
CARBON
7 SPACER, REAR WHEEL, RHS, CARBON
6 SPACER, REAR WHEEL, LHS, CARBON
BALANCE WEIGHT
1 REAR WHEEL, CARBON FIBRE, BLACK ACCESSORY WHEEL FOR ALL MODELS
2 SPACER, INTERNAL, REAR WHEEL,
CARBON
3 REAR WHEEL, BEARING 30 X 55 X 13 (CARBON)
SEAL, OIL
4 CIRCLIP, REAR WHEEL, CARBON TO HOLD BEARING IN THE HUB
5 VALVE ASSY, ALUMIN, 90, REAR WHEEL, CARBON
6 SPACER, REAR WHEEL, RHS, CARBON
7 SPACER, REAR WHEEL, LHS, CARBON
BALANCE WEIGHT
1 REAR WHEEL, CARBON FIBRE SPARE FOR CSE-03/01 (OLD TITANIUM)
2 SPACER, INTERNAL, REAR WHEEL,
CARBON
3 REAR WHEEL, BEARING 30 X 55 X 13
(CARBON)
SEAL, OIL
4 CIRCLIP, REAR WHEEL, CARBON TO HOLD BEARING IN THE HUB
5 VALVE ASSY, ALUMI, 90, REAR WHEEL, CARBON
7 SPACER, REAR WHEEL, RHS, CARBON
6 SPACER, REAR WHEEL, LHS, CARBON
BALANCE WEIGHT
8 SPROCKET CARRIER ASSY, TITANIUM FOR SPARES ONLY (OLD TITANIUM)
SPROCKET CARRIER, M/C, TITANIUM
9 REAR WHEEL, BEARING 30 X 62 X 16 (CARBON)
10 RUBBERS, CUSH DRIVE, REAR WHEEL,
CARBON
8 SPROCKET CARRIER ASSY, BLACK STANDARD FOR CSE-01/03
SPROCKET CARRIER, M/C, BLACK
178
9 REAR WHEEL, BEARING 30 X 62 X 16
(CARBON)
10 RUBBERS, CUSH DRIVE, REAR WHEEL, CARBON
8 SPROCKET CARRIER ASSY, BLACK ACC FOR ALL MODELS
SPROCKET CARRIER, M/C, BLACK
9 REAR WHEEL, BEARING 30 X 62 X 16 (CARBON)
10 RUBBERS, CUSH DRIVE, REAR WHEEL,
CARBON
11 BOLTS, CUSH DRIVE, CARBON TO CLAMP SPROCKET TO CARRIER
12 LOCKNUT, FLANGED, M10 X 1.25 55 TO CLAMP SPROCKET TO CARRIER
34 LOCKNUT, M10 X 1.5, GRADE 8 55 TO CLAMP SPROCKET TO CARRIER
SPOKED
35 WASHER, M10, 10.5 X 21 X 2, DIN 125A,
A2
SPROCKET TO CARRIER WASHERS
20 WHEEL ASSY, 5.5x17, SPOKE, POLISHED RIM
21 CUSH DRIVE ASSY, SPOKED REAR WHEEL,
BLACK
SPROCKET CARRIER FOR SPOKED WHEEL
29 SPACER, REAR WHEEL, RHS, SPOKED
30 BOLT, CUSH DRIVE, SPOKED
31 RUBBERS, CUSH DRIVE, SPOKED
26 BEARING 25 X 52 X 15 REAR WHEEL
27 SEAL, 32 X 52 X 7, REAR WHEEL
25 SEAL, 35 X 47 X 7, REAR WHEEL
36 SPACER, CUSH DRIVE, SPOKED
33 CUSH DRIVE, MACHINED, BLACK
37 HUB ASSY, SPOKED REAR WHEEL, BLACK
32 HUB, REAR WHEEL, MACHINED, BLACK
26 BEARING 25 X 52 X 15, REAR WHEEL
24 SPACER, CENTRE, REAR WHEEL
27 SEAL, 32 X 52 X 7, REAR WHEEL
28 SPACER, REAR WHEEL, LHS, SPOKED
20 WHEEL ASSY, 5.5x17, SPOKE, POLISHED
RIM
20 WHEEL ASSY, 5.5x17, SPOKE, BLACK RIM
13 SPINDLE, REAR WHEEL
14 LOCKNUT, THIN, M24 X 2 110 SPINDLE NUT
15 WASHER, M24, 25 X 44 X 4 BETWEEN NUT/SWING ARM + SPINDLE/SWING ARM
16 TYRE, REAR, 180/55 x 17,DUNLOP QUALIFIER, FR
set to 38 PSI
17 SPROCKET, REAR, 50T
22 INNER TUBE, 17 INCH, REAR FOR TUBELESS TYRE
23 TYRE PROTECTION BAND, 17 INCH, REAR, THERMO JOINED
18 CHAIN, FINAL DRIVE, 106L, 525 WITH 18/50 T GEARING (CHAIN CUT TO 106L)
19 SPLIT-LINK, CHAIN, 525
OIL SEAL, RK DRIVE CHAIN USE AS REQ'D - EXTRAS FOR ASSY
TYRE, WAX, CLEAR, 5KG
179
GREASE, SILKOLENE PRO RG2 APPLY TO WHEEL SPINDLE & SPACERS
180
181
182
REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
1 FRONT WHEEL ASSY, CARBON FIBRE, BLACK
STANDARD FRONT WHEEL FOR CSE-01/03
23 VALVE ASSY, ALUM, 90 SPARES ONLY
22 CIRCLIP, INT. DIA 42 SPARES ONLY
21 BEARING BALL, SPARES ONLY
20 SPACER, INTERNAL, ALUMINIUM SPARES ONLY
1 FRONT WHEEL ASSY, CARBON FIBRE, BLACK
ACCESSORY WHEEL FOR ALL MODELS
23 VALVE ASSY, ALUM, 90 SPARES ONLY
22 CIRCLIP, INT. DIA 42 SPARES ONLY
21 BEARING BALL, SPARES ONLY
20 SPACER, INTERNAL, ALUMINIUM SPARES ONLY
6 SPINDLE, FRONT WHEEL 60 SPINDLE FOR CONVENTIONAL FORKS
7 SPINDLE NUT
8 SPACER, PLAIN, FRONT WHEEL LHS
9 SPACER, PLAIN, FRONT WHEEL RHS
5 SPINDLE, FRONT WHEEL, USD FORKS, HIGH BARS
60 SPINDLE FOR USD FORKS
2 SPINDLE NUT. USD FORKS, HIGH BARS
183
3 SPACER, FRONT WHEEL, USD FORKS,
HIGH BARS LHS
4 SPACER, FRONT WHEEL, USD FORKS, HIGH BARS RHS
10 WHEEL ASSY, 3.5x17, SPOKE, POLISHED
RIM
18 HUB ASSY, SPOKED FRONT WHEEL, BLACK
19 SPACER, SPOKED FRONT WHEEL, INNER, RH
17 HUB, FRONT WHEEL, MACHINED, BACK
16 FRONT WHEEL, CENTRE SPACER
14 FRONT WHEEL, SEAL, 30 X 46 X 65 X (7)
15 FRONT WHEEL, BEARING, 25 X 47 X 12
11 INNER TUBE, 17 INCH, FRONT FOR TUBELESS TYRE
12 TYRE PROTECTION BAND, 17 INCH, FRONT, THERMO JOINED
11 INNER TUBE, 17 INCH, FRONT FOR TUBELESS TYRE
12 TYRE PROTECTION BAND, 17 INCH, FRONT, THERMO JOINED
13 TYRE, FRONT, 120/70 x 17, DUNLOP
QUALIFIER, FR set to 34 PSI
BALANCE WEIGHT
TYRE, WAX, CLEAR, 5KG
GREASE, SILKOLENE PRO RG2 APPLY TO WHEEL SPINDLE &
SPACERS
10 WHEEL ASSY, 3.5x17, SPOKE, POLISHED RIM
10 WHEEL ASSY, 3.5x17, SPOKE, BLACK RIM
184
Specifications
Item Standard Service Limit
Rim runout: Axial 0.5mm or less 2mm Radial 0.8mmor less 2mm Axle runout/100mm 0.1mm or less 0.2mm Wheel balance 10 g or less - - -
Balance weights 10 g, 20 g, 30 g - - -
Tire tread depth: Front 3.5mm 2mm
Rear 5mm 2mm
Tire Air Pressure load Air Pressure (when cold)
Front - - - 2.34 bar (34psi)
Rear - - - 2.62bar (38psi)
Standard tire Front make, type Dunlop, Sportsmax Qualifier
Size 120/70 x 17
Rear make, type Dunlop, Sportsmax Qualifier
Size 180/55 x 17
185
Wheels
Front Wheel Removal
Remove:
Four front wheel calliper bolts [A].
Remove the brake callipers (axial and radial).
Support the front of the motorcycle by either supporting
the frame using a centre jack or using a front paddock
stand.
Slacken four pinch bolts [A].
Slacken Front wheel axle [B] off completely.
Remove the front wheel axle.
Note: When removing the front wheel axle take note of the order
and location of the wheel spacers, and support the front wheel.
Caution: Do not lay the front wheel on the ground with the disc facing down. This can damage or warp the
disc`s. Place blocks under the wheel so that the disc`s do not touch the ground.
Front Wheel Installation
Install the front wheel spacers [A] on to the wheel hub.
Apply a thin coat of copper past to the front wheel Axle.
Align the front wheel with the axle and insert the front
wheel axle.
Tighten the front wheel Axle.
Torque – Front Wheel Axle: 60Nm
Tighten the front wheel Pinch bolts.
Torque – Front Wheel Pinch bolts: 19Nm
Install Front Brake Callipers, Calliper Retainer Bolts [A]
(apply a thin coating of copper grease to bolt threads), and
tighten calliper bolts.
B
A
A
A
A
186
Torque – Front Calliper bolts: 35Nm
Check the front brake.
Warning: Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake
lever until the pads are against the disc. The brakes will not function on the first application of the lever if
this is not done.
Rear Wheel Removal
Remove Rear Axle Nut.
Using either a centre stand or a rear paddock stand lift
the rear wheel off the ground.
Remove the rear axle.
Push the wheel forwards in the motorcycle and remove
the chain from the sprocket.
Remove the rear wheel.
Caution: Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does not touch the ground.
Rear Wheel Installation
Insert wheel into the rear of the bike, simultaneously
inserting the disc into the calliper, and mount the chain
on the rear sprocket.
Align the calliper carrier with the swing arm cut out and
insert the rear wheel axle.
Fix the washer and rear axle nut and tighten.
Torque – Rear Axle Nut: 110Nm
Adjust the drive chain (see Final Drive Chapter)
Check the rear brake effectiveness.
Warning: Do not attempt to ride the motorcycle until a full brake pedal is obtained by pumping the brake
pedal until the pads are against the disc. The brake will not function on the first application of the pedal if
this is not done.
Front Wheel Disassembly
Remove front wheel (see Front Wheel Removal).
A
187
Caution: Do not allow the wheel to rest on the brake disc, as this may damage the disc. Support the wheel on
wooden blocks, equally spaced around the rim, such that the brake disc is raised above ground. Lay the wheel on its
side while supporting the wheel on wooden blocks to prevent damage to the brake disc.
Remove and discard the seals and the bearing circlip (If applicable).
Warning: Always wear eye, hand and face protection when using a hammer and drift. Use of a hammer and drift can
cause bearings to fragment. Pieces of fragmented bearing could cause eye and soft
tissue injuries is suitable protective apparel is not worn.
Caution: To prevent wheel damage and to aid bearing removal, always apply forces
evenly on both sides of the bearing to prevent it from tipping and becoming stuck.
Application of uneven force will lead to difficulty in removing the bearing and to a
damaged wheel.
Using a suitable pin punch, through the centre of the wheel, drift out
the wheel bearings. Collect the centre sleeve.
Front Wheel Assembly
Using a suitable tool, ensuring the tool seats on the outer race of the bearing only, evenly and
progressively drive the new wheel bearings into the wheel hub up to the stop. Grease the inner
spacer with red grease.
Fit a new Circlip (if applicable).
Lubricate and fit new seals to the front wheel. Lubricate the seals knife-edge with grease.
Fit the front wheel (see Font Wheel Installation).
Rear Wheel Disassembly
Remove rear wheel (see Rear Wheel Removal).
Place the wheel on wooden blocks to prevent dame to the brake disc.
Caution: Do not allow the wheel to rest on the brake disc, as this may damage the disc. Support the wheel on
wooden blocks, equally spaced around the rim, such that the brake disc is raised above ground. Lay the wheel on its
side while supporting the wheel on wooden blocks to prevent damage to the brake disc.
Remove and discard the seals and the bearing circlips (if applicable).
Warning: Always wear eye, hand and face protection when using a hammer and drift.
Use of a hammer and drift can cause bearings to fragment. Pieces of fragmented
bearing could cause eye and soft tissue injuries is suitable protective apparel is not
worn.
188
Caution: To prevent wheel damage and to aid bearing removal, always apply forces evenly on both sides of the
bearing to prevent it from tipping and becoming stuck. Application of uneven force will lead to difficulty in removing
the bearing and to a damaged wheel.
Using a suitable pin punch, through the centre of the wheel, drift out the wheel bearings. Collect
the centre sleeve.
Rear Wheel Assembly
Using a suitable tool, ensuring the tool seats on the outer race of the bearing only, evenly and
progressively drive the new wheel bearings into the wheel hub up to the stop. Grease the inner
spacer with red grease.
Fit a new Circlip (if applicable).
Lubricate and fit new seals to the rear wheel. Lubricate the seals knife-edge with red grease.
Fit the rear wheel (see Rear Wheel Installation).
Wheel Inspection
Place the jack under the frame so that the front or rear
wheel is off the ground.
Spin the wheel lightly, and check for roughness or binding.
If roughness or binding is found, replace the hub bearings.
Visually inspect the front and rear axles for damage.
If the axle is damaged or bent, replace it.
Spoke Inspection
Check that all spokes are tightened evenly.
If spoke tightness is uneven or loose, torque the spoke nipples evenly.
Spokes should be tighten until; when struck with a tuning fork they emit a clean note, minimum
torque setting is only the lower limit.
Torque minimum: Spoke Nipples: 1.5Nm
Check the rim runout.
Warning: If any spoke breaks, it should be replaced immediately. A missing spoke places an additional load
on the other spokes, which will eventually cause other spokes to break.
Rim Inspection
Place the jack under the frame so that the front wheel or rear wheel is off the ground.
Inspect the rim for small cracks, dents, bending, or warping.
If there is any damage to the rim, it must be replaced.
Set a dial gauge against the side of the rim, and rotate the rim to measure the axial runout [A]. The
difference between the highest and lowest dial readings is the amount of runout.
Set a dial gauge against the outer circumference of the rim, and rotate, the highest and lowest dial
reading is the amount of runout.
189
If rim runout exceeds the service limit, check the wheel bearings first. Replace them if they are
damaged.
If the problem is not due to the bearings, correct the rim warp (runout). A certain amount of rim
warp can be corrected by recentering the rim on spoked wheels. Loosen some spokes and tighten
others within the standard torque to change the position of different parts of the rim. If the rim is
badly bent, however, it must be replaced.
Rim runout (with tire installed)
Standard: Axial 0.5mm Radial: 0.8mm
Service Limit: Axial 2mm Radial: 2mm
Axle Inspection
Place the axle in V blocks that are 100mm [A] apart, and set
a dial gauge on the axle at a point halfway between the
blocks.
Turn the axle to measure the runout. The difference
between the highest and lowest dial readings is the amount
of runout.
If runout exceeds the service limit, replace the axle.
Axle Runout/100mm
Standard: 0.1mm or less
Service Limit: 0.2mm
Wheel Balance
Note: To improve stability and decrease vibration at high speed, the front and rear wheels must be kept
balanced.
Check and balance the wheels when required, or when a tire is replaced with a new one.
Balance Inspection
Remove the wheel (see this chapter).
Support the wheel so that it can be spun freely.
Spin the wheel lightly, and mark [A] the wheel at the top
when the wheel stops.
Repeat this procedure several times. If the wheel stops of
its own accord in various positions, it is well balanced.
If the wheel always stops in one position, adjust the
wheel balance.
Balance Adjustment
190
If the wheel always stops in one position, provisionally attach a balance weight [A] on the rim at the
marking.
Rotate the wheel ¼ turn [B], and see whether or not the wheel stops in this position. If it does, the
correct balance weight is being used.
Attach a balance weight [A] loosely to the wheel rim.
If the wheel rotates and the weight goes up, replace the weight with the next heavier size. If the
wheel rotates and the weight goes down replace the weight with the nest lighter size. Repeat these
steps until the wheel remains at rest after being rotated ¼ turn.
Rotate the wheel another ¼ turn and then another 1/5 turn to see if the wheel is correctly
balanced.
Repeat the entire procedure as many times as necessary to achieve correct wheel balance.
Permanently install the balance weight.
Firmly press the balance weight on when finished.
Balance weights: 5g 10g 20g 30g
Note: Balance weights are available from Norton Dealers in 5, 10, 20, 30 gram sizes. An imbalance
of less than 5 grams will not usually affect running stability.
Do not use four or more balance weight (more than 90 gram). If the wheel requires an excess
balance weight, remove and disassemble the wheel to find the cause.
Tyre
Air Pressure Inspection/Adjustment
Using a tyre pressure gauge, measure the tyre pressure when the tyres are cold.
Adjust the tyre air pressure according to the following specifications, if necessary.
Air Pressure (when cold)
Front: 2.34bar (34psi)
Rear: 2.62bar (38psi)
Tyre Inspection
Note: As the tyre tread wears down, the tyre becomes more susceptible to puncture and failure. An
accepted estimate is that 90% of all tyre failures occur during the last 10% of tread life (90% worn).
So it is false economy and unsafe to use the tyres until they are bald.
Remove any imbedded stones or other foreign particles from the tread.
Visually inspect the tyre for cracks and cuts, replacing the tyre in the case of bad damage. Swelling
or high spots indicate internal damage, requiring tyre replacement.
Measure the tread depth at the centre of the tread with a depth gauge [A].
Take measurement at several places as the tyre may wear unevenly.
If any measurement is less than the service limit, replace the tyre.
191
Tread Depth
Front: Standard: 3.5mm
Service Limit: 2mm (legal Limit UK 1mm)
Rear: Standard: 5mm
Service Limit: 2mm (Legal Limit UK 1mm)
Note: To ensure safe handling and stability, use only the recommended standard tyres for
replacement, inflated to the standard pressure.
Check and balance the wheel when a tyre is replaced with a new one.
Standard tyre
Front: Make: Dunlop
Type: Sportsmax Qualifier
Size: 120/70 X 17
Rear Make: Dunlop
Type: Sportsmax Qualifier
Size: 180/55 X 17
Tyre Removal
Caution: Do not lay the wheel on the ground with the disc facing
down. This can damage or warp the disc. Place blocks under the
wheel so that the disc does not touch the ground.
Remove the wheel from the motorcycle (see this chapter).
To maintain wheel balance, mark the valve stem position
on the tire with chalk so that the tire can be reinstalled in
the same position.
Take out the valve core to let the air out.
When handling the rim, be careful not to damage the rim
flanges.
Lubricate the tyre beads and rim flanges on both sides with
a soap and water solution or rubber lubricant. This helps
the tyre beads slip off the rim flanges.
Caution: Never lubricate with mineral oil (engine oil) or gasoline
because they will cause deterioration.
Break the beads away from both sides of the rim with a bead breaker.
Protect the rim with rim protectors , pry the tyre off.
192
Tyre Installation
Check the tyre rotation mark on the front and rear tyre
and install it on the rim accordingly.
Note: the direction of the tire rotation is shown by an
arrow on the tire sidewall.
Position the tire on the rim so that the valve is at the tire
balance mark (the chalk mark made during removal or
the yellow paint mark on a new tire).
Check and adjust the air pressure after installing.
Hub Bearings (Wheel Bearings)
Bearing Removal
Remove the wheel, take out the following:
Collar(s)
Coupling (rear hub)
Grease Seals
Circlip
Take the bearings out of the hub, using bearing remover.
Caution: Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does not touch the ground.
Bearing Installation
Before Installing the wheel bearings, blow any dirt or foreign particles out of the hub with
compressed air to prevent contamination of the bearings.
Replace the bearings with new ones.
Press in the bearings until they bottom out.
Note: Install the Bearing so that the marked side or sealed side faces out.
Install:
o New Circlip
o Collar
o Right Bearing
o Left Bearing
Replace the grease seals with new ones.
Apply high temperature grease to the grease seal lips.
Press in the grease seal so that the seal surface is flush with the end of the hole.
193
Bearing Inspection
Since the hub bearings are made to extremely close tolerances, the clearance cannot normally be
measured.
Caution: Do not remove any bearings for inspection. If any bearings are removed, they will need to be
replaced with new ones.
Turn each bearing in the hub back and forth [A] while checking for play, roughness, or binding. If
bearing play, roughness, or binding is found, replace the bearing.
Examine the bearing seal [B] for damage or leakage.
If the seal is damaged or is leaking, replace the bearing.
194
Final Drive
Exploded View ................................................................................................................................................ 188
Specification ................................................................................................................................................... 189
Drive Chain ..................................................................................................................................................... 190
Chain Slack Inspection ....................................................................................................................... 190
Chain Slack Adjustment ..................................................................................................................... 190
Chain Wear Inspection ....................................................................................................................... 191
Chain Lubrication ............................................................................................................................... 191
Chain Removal ................................................................................................................................... 192
Chain Installation ............................................................................................................................... 192
Sprocket, Coupling ......................................................................................................................................... 192
Engine Sprocket Removal ................................................................................................................... 192
Engine Sprocket Installation............................................................................................................... 193
Rear Sprocket Removal ...................................................................................................................... 193
Rear Sprocket Installation .................................................................................................................. 193
Rear Sprocket, Coupling Removal ...................................................................................................... 194
Rear Sprocket, Coupling Installation .................................................................................................. 194
Sprocket Wear .................................................................................................................................... 194
Rear Sprocket Warp ........................................................................................................................... 194
Damper Inspection ............................................................................................................................. 194
Coupling Bearing Removal ................................................................................................................. 195
Coupling Bearing Inspection, lubrication ........................................................................................... 195
Damper (Cush Drive) Inspection .................................................................................................................... 195
Chain Guard ................................................................................................................................................... 195
Chain Guard Removal ......................................................................................................................... 195
Chain Guard Installation..................................................................................................................... 195
Chain Guard Inspection ...................................................................................................................... 195
195
Exploded View
196
REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
1 SWINGARM, FABRICATED, XM
2 BEARING, FULL COMPLIMENT ROLLER,
30 37 26
3 BEARING CARRIER, SWINGARM
4 SEAL, SWINGARM, RH 23 X 40 X 6
5 SLEEVE, GROUND
6 END PLATE, WHEEL ADJUSTERS
7 ADJUSTER BLOCK, REAR WHEEL
8 BOLT, CAP HD, M8 X 90 X 1.25 REAR WHEEL ADJUSTERS
9 SPRING WASHER, M8
BETWEEN BOLT AND REAR WHEEL ADJUSTER
10 SPINDLE, SWING ARM
GREASE, SILKOLENE PRO RG2 APPLY TO SWINGARM SPINDLE
11 LOCKNUT, THIN, M16 X 1.0 60
12 WASHER, M16, 17 X 30 X 2 BETWEEN NUT AND FRAME
13 ADJUSTER PLATE, REAR WHEEL, XM WRAP AROUND SWING ARM USED AS REFERENCE
14 SPACER, SWINGARM, INTERNAL
15 SPACER, SWINGARM, EXTERNAL
16 BEARING, BALL, SEALED, 17 40 12
17 CIRCLIP, INT, 40 X 1.75
18 SEAL, SWINGARM, LH 30 X 45 X 5
19 THREADED ADJUSTER, SWINGARM 6
20 RUBBING STRIP, CHAIN
21 COMPRESSION LIMITER, M6 MOUNTS IN CHAIN RUBBING STRIP
22 BOLT BUTTON HD, INT HEX M5 X 20 X
0.8 9 USED TO MOUNT CHAIN RUBING STRIP
23 RSU, LH
24 RSU, RH
25 BOLT, BUTTON HD, INT HEX, FLANGED,
M8 X 16 X 1.25 22 RSU'S TO FRAME
26 WASHER, PENNY, M8 X 30 X 1.6MM WASHER RSU MOUNT
Specification
Item Standard Service Limit
Drive Chain: Standard Chain: Make REGINA - - - Type REGINA 525 (137ZRP) Z-RING - - -
Link 106LINKS - - - Chain Slack 35 ~ 40 mm Too tight: less than 30mm
Too loose: more than
45mm 20-link length 317.5 ~ 318.2 mm 323 mm Sprockets:
197
Rear sprocket warp 0.4 mm or less 0.5 mm
Drive Chain
Chain slack Inspection
Set the motorcycle up on its side stand.
Check to see that the notches [A] on the chain adjusters
[B] on both sides are in the same relative position.
If they are not, adjust the chain slack and align them.
Warning: Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.
Note: Clean the chain if it is dirty, and lubricate it if it appears
dry.
Check the chain slack.
Turn the rear wheel to find the position where the chain
is tightest.
Measure the spacer (chain slack) [A] between the chain
and the step of the chain slipper as shown.
Chain Slack
Standard: 35 ~ 40 mm
Too Tight: Less than 35 mm
Too Loose: More than 45 mm
If the chain slack exceeds the standard, adjust it.
Chain Slack Adjustment
Loosen the axle nut [A].
Turn the chain adjusters [B] evenly until the drive chain has
the specified amount of slack.
Check to see that the notches [C] on both sides are in the
same relative position.
Warning: Misalignment of the rear wheel will result in abnormal
wear and may result in an unsafe riding condition.
Tighten the rear axle nut.
Torque – Rear Axle Nut: 110Nm
A
B
198
Returning call
Warning: If the axle nut is not securely tightened, an unsafe riding condition may result.
Turn the wheel, measure the chain slack again at the tightest position, and readjust if necessary.
Check the rear brake effectiveness.
Warning: Do not attempt to ride the motorcycle until a full brake pedal is obtained by pumping the brake
pedal until the pads are against the disc. The brake will not function on the first application of the pedal if
this is not done.
Chain Wear Inspection
Rotate the rear wheel to inspect the drive chain for
damage rollers, and loose pins and links.
If there is any irregularity, replace the drive chain.
Lubricate the drive chain if it appears dry (see this
chapter).
Stretch the chain taut by hanging a (10kg) weight [A] on
the chain.
Measure the length of 20 links [B] on the straight part [C]
of the chain from the pin centre of the 1st pin to the pin
centre of the 21st pin. Since the chain may wear unevenly,
take measurements at several places.
If any measurements exceed the service limit, replace the
chain. Also, replace the front and rear sprockets when the
drive chain is replaced.
Chain 20-Link Length
Standard: 317.5 ~ 318.2 mm
Service Limit: 323 mm
Warning: If the drive chain wear exceeds the service limit, replace the chain or an unsafe riding condition
may result. A chain that breaks or jumps off the sprocket could snag on the engine sprocket or lock the
rear wheel, severally damaging the motorcycle and causing it to go out of control.
Standard chain
Make: REGINA
Type: REGINA 525 (137ZRP) Z-RING
Link: 106 links
Chain Lubrication
If the chain is especially dirty, it should be washed in diesel oil or kerosene, and afterward soaked in
heavy oil. Shake the chain while it is in the oil so that oil will penetrate to the inside of each roller.
199
An effective, good quality lubricant specially formulated for chains is best for regular chain
lubrication.
If a special lubrication is not available, heavy oil such as SAE 90 is preferred to lighter oil because it
will stay on the chain longer and provide better lubrication.
Caution: The O-rings between the side plates seal in the lubricant between the pin and the bushing. To
avoid damaging the O-rings and resultant loss of lubricant, observe the following rules.
Use only kerosene or diesel oil for cleaning an O-ring drive chain. Any other cleaning solution such as
gasoline or trichloroethylene will cause deterioration and swelling of the O-rings. Immediately blow the
chain dry with compressed air after cleaning. Complete cleaning and drying the chain within 10 minutes.
Apply the oil to the sides of the rollers so that the oil will
penetrate to the rollers and bushings. Apply oil to the O-
rings so that the O-rings will be coated with oil.
Wipe off any excess oil.
Oil Applied Areas [A] O-ring [B]
Chain Removal
Remove:
Engine Sprocket Cover (see this chapter).
Chain Guard (see this chapter).
Foot Control Plate (see Chassis chapter).
Rear Suspension Upright RH (see Suspension chapter).
Fully slacken off the chain (see this chapter).
Remove the drive chain from the chassis, being careful that the chain does not get dirty from
contact with the ground.
Chain Installation
Fit the drive chain back onto the sprockets.
Install:
Engine Sprocket Cover (see this chapter).
Chain Guard (see this chapter).
Foot Control Plate (see Chassis chapter).
Rear Suspension Upright RH (see Suspension chapter).
Adjust the drive chain slack (see Chain Slack Adjustment).
Sprocket, Coupling
Engine Sprocket Removal
Remove Engine Sprocket Cover [A]
Bend the lockwasher tab up.
Select first gear and apply the rear brake.
200
Loosen the engine sprocket nut [A].
Fully slacken off the chain (see this chapter).
Pull off the engine sprocket with the chain then separate the sprocket from the chain.
Engine Sprocket Installation
Install the engine sprocket [A] as shown, noting the proper direction.
Replace the sprocket lockwasher.
Warning: Incorrect installation of the engine sprocket could cause misalignment of the wheel, abnormal
wear, resulting in an unsafe riding condition.
Torque – Engine Sprocket Nut: 122Nm
Bend the lockwasher tab over the nut.
Install the chain guide [A] as shown.
Apply a non-permanent locking agent to the bolt [B]
shown.
Adjust the drive chain (see this chapter).
Rear Sprocket Removal
Remove the rear wheel (see Wheels/Tires chapter).
Caution: Do not lay the wheel on the ground with the disc facing
down. This can damage or warp the disc. Place blocks under the
wheel so that the disc does not touch the ground.
Unscrew the rear sprocket bolts [A] and nuts, then
remove the rear sprocket [B]
Rear Sprocket Installation
Install the rear sprocket [A] facing the tooth number
marking [B] outwards.
Torque – Rear Sprocket Nuts: 55 Nm
Install the rear wheel (see Wheels/Tires chapter).
B
A
201
Rear Sprocket, Coupling Removal
Remove the rear wheel (see Wheels/Tires chapter).
Caution: Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does not touch the ground.
Pull out the rear wheel coupling from the rear wheel.
Remove the rear sprocket nuts to separate the rear sprocket from the wheel coupling (see this
chapter).
Rear Sprocket, Coupling installation
Check the following and install the coupling.
Bearing [A]
Install the sprocket facing the tooth number marking
outward.
Torque – Rear sprocket nuts: 55 Nm
Install the rear wheel (see Wheels/ Tires chapter).
Sprocket Wear
Visually inspect the engine and rear sprocket teeth.
If the teeth are worn as illustrated, replace the sprockets,
and inspect the drive chain (see Drive Chain wear
Inspection).
Caution: If a sprocket requires replacement, the drive chain is
probably worn also. Upon replacing the rear sprocket, inspect the
chain and engine sprocket.
Note: Sprocket wear is exaggerated for illustration.
Worn Tooth (engine Sprocket) [A]
Worn Tooth (Rear Sprocket) [B]
Direction of Rotation [C]
202
Rear Sprocket Warp
Raise the rear wheel off the ground (see Wheels/Tires chapter) so that it will turn freely.
Set a dial gauge against the rear sprocket near the teeth as shown. Turn the rear wheel. The
difference between the highest and lowest dial gauge readings is the amount of runout (warp).
If the runout exceeds the service limit, replace the rear sprocket.
Rear Sprocket Warp
Standard: 0.4 mm or less
Service Limit: 0.5 mm
Coupling Bearing Removal
Pull out the coupling collar from the wheel.
Remove the circlip.
Using the bearing drive set or some other suitable tool,
remove the bearing by tapping from the wheel side.
Coupling Bearing Inspection, Lubrication
Caution: Do not remove the bearing for inspection or lubrication.
Turn the bearing back and forth while checking for
play, roughness, or binding. If bearing play, roughness,
or binding is found, replace the bearing.
Damper Inspection
Remove the rear wheel coupling, and inspect the
rubber dampers [A].
Replace the damper if it appears damaged or
deteriorated
Chain guard removal
Remove chain guard retainer screws.
Remove chain guard
Chain Guard Installation
Install chain guard and tighten screws
Chain Guard Inspection
Visually inspect the chain guard for wear cracks and damage replace if neccessary
203
Brakes
Exploded View ................................................................................................................................................ 198
Specification ................................................................................................................................................... 206
Brake Lever, Brake Pedal ............................................................................................................................... 207
Brake Lever Play Adjustment ............................................................................................................. 207
Brake Pedal Position Adjustment ...................................................................................................... 207
Brake Pedal Removal ......................................................................................................................... 207
Brake Pedal Installation ..................................................................................................................... 207
Brake Fluid ..................................................................................................................................................... 208
Brake Fluid Recommendation ............................................................................................................ 208
Brake Fluid Level Inspection .............................................................................................................. 209
Brake Fluid Changing ......................................................................................................................... 209
Brake Line Air Bleeding ...................................................................................................................... 210
Calipers ........................................................................................................................................................... 211
Front Calipers Removal ...................................................................................................................... 211
Rear Caliper Removal ......................................................................................................................... 211
Front Calipers Installation .................................................................................................................. 211
Rear Caliper Installation ..................................................................................................................... 211
Front Calipers Disassembly ................................................................................................................ 212
Rear Caliper Disassembly ................................................................................................................... 212
Caliper Assembly ................................................................................................................................ 212
Caliper Fluid Seal Damage.................................................................................................................. 213
Caliper Dust Seal ................................................................................................................................ 213
Caliper Piston and Cylinder Damage .................................................................................................. 213
Brake Pads ...................................................................................................................................................... 213
Front Brake Pads Removal ................................................................................................................. 213
Rear Brake Pads Removal .................................................................................................................. 214
Rear Brake Pads Installation .............................................................................................................. 214
Rear Brake Pads Installation .............................................................................................................. 214
Brake Pad Wear Inspection ................................................................................................................ 214
Brake Master Cylinder ................................................................................................................................... 215
Front Master Cylinder Removal ......................................................................................................... 215
Front Master Cylinder Installation ..................................................................................................... 215
Rear Master Cylinder Removal .......................................................................................................... 215
Rear Master Cylinder Assembly ......................................................................................................... 215
Master Cylinder Assembly ................................................................................................................. 215
Master Cylinder Visual Inspection ..................................................................................................... 215
Brake Discs ..................................................................................................................................................... 217
Front Disc Installation ........................................................................................................................ 217
Rear Disc Installation .......................................................................................................................... 217
Disc Wear ........................................................................................................................................... 217
Disc Cleaning ...................................................................................................................................... 217
204
Disc warp Inspection .......................................................................................................................... 218
Brake Hoses .................................................................................................................................................... 218
Brake Hose Removal .......................................................................................................................... 218
Brake Hose Installation ...................................................................................................................... 218
Brake Hose Inspection ....................................................................................................................... 218
205
Exploded View
206
207
208
209
210
REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
20 BRAKE LEVER ASSY, AXIAL
STANDARD FOR CSE, CCR, ROW COM/CMM
21 LEVER, BRAKE, REMOTE RESERVOIR
22 RESERVOIR, MASTER CYL, FRONT BRAKE RESERVOIR
55 FRONT BRAKE LIGHT SWITCH
79 LEVER ASSY, BRAKE, INTEGRAL
RESERVOIR, HIGH BARS
STANDARD LEVER FOR COM-01 AND
CDS-01
80 LEVER, BRAKE, INTEGRATED RESERVOIR
79 LEVER ASSY, BRAKE, INTEGRAL RESERVOIR, HIGH BARS
ACCESSORY FITMENT
80 LEVER, BRAKE, INTEGRATED RESERVOIR
81 BOLT, M6 X 25 X 1.0, CP HD, GOLD 8 HALF CLAMP BOLTS
82 HALF CLAMP, FRONT, VERTICAL REPLACES STD CLAMP FROM BREMBO
78 FLY LEAD, BRAKE LIGHT SWITCH, INTEGRAL RESERVOIR
INTEGRAL RESERVOIR ONLY,
29 SCREW, UPPER, M/CYL RES MOUNT KIT
TO CLAMP BRAKE RESERVOIR TO
BRACKET
28 DUMPER, M/CYL RES MOUNT KIT
RUBBER GROMMET FOR MASTER CYLINDER
32 NUT, M/CYL RES MOUNT KIT NUT USED TO CLAMP RESERVOIR TO BRACKET
69 CLIP, M/CYL RES MOUNT KIT USED WITHIN FRONT AND REAR
31 HOSE, FRONT BRAKE M/CYL RESERVOIR USED FOR FRONT BRAKE ONLY
30 HOSE, FRONT BRAKE M/CYL RESERVOIR, CLIP-ONS
USED FOR FRONT BRAKE CAFE RACER ONLY
24 BRACKET, BRAKE RESERVOIR, XM FRONT BRAKE RESERVOIR BRACKET
23 BRACKET, BRAKE RESERVOIR, CLIP-ONS, XM
FRONT BRAKE RESERVOIR BRACKET, CR
25 BOLT, CAP HD, M6 X 12 X 1.0 6 BRACKET TO MASTER CYLINDER
91 LEVER ASSY CLUTCH GOLD LEVER ASSY, (REMOTE
RESERVOIRS)
92 LEVER, CLUTCH, REMOTE RESERVOIR
93 BRACKET, CLUTCH RESERVOIR, CLIP-ONS, XM
CAFE RACER ONLY BRACKET TO MASTER CYLINDER
94 BRACKET, CLUTCH RESERVOIR, XM BRACKET TO MASTER CYLINDER
25 BOLT, CAP HD, M6 X 12 X 1.0 8
55 RESERVOIR, MASTER CYL, REAR USED FOR CLUTCH RESERVOIR
95 HOSE, CLUTCH M/CYL RESERVOIR HOSE FOR RESERVOIR TO CYLINDER
96 BOLT, CAP HD, M5 X 12 X 0.8 RESERVOIR TO BRACKET
97 LOCKNUT, FLANGED, M5 X 0.8 7 RESERVOIR TO BRACKET
98 HOSE, FRONT CLUTCH M/CYL RESERVOIR,
CLIP-ONS
CAFE RACER RESERVOIR HOSE
(SHORTER)
99 LEVER ASSY, CLUTCH, INTEGRAL
RESERVOIR, HIGH BARS
SPORT AND DUAL SEAT LEVER ASSY (BLACK)
100 LEVER, CLUTCH, INTEGRATED RESERVOIR
99 LEVER ASSY, CLUTCH, INTEGRAL
RESERVOIR, HIGH BARS ACCESSORY FITMENT
100 LEVER, CLUTCH, INTEGRATED RESERVOIR
101 SLAVE CYLINDER, CLUTCH
211
102 BOLT, CAP HD, M6 X 16 X 1.0 12 TO CLAMP SLAVE CYLINDER TO SPROCKET COVER
68 HYDRO STOP, REAR M/CYL REAR BRAKE LIGHT SWITCH
59 HYDRAULIC LINE KIT, USD FORKS, HIGH
BARS CSE-03 KIT ONLY
27 DOUBLE BANJO BOLT M10 X 1MM X 34.5MM SPARES ONLY
26 COPPER WASHER SPARES ONLY
57 45' BANJO SPARES ONLY
60 BRAKE HOSE, LH, 725MM LENGTH SPARES ONLY
61 BRAKE HOSE, RH, 750MM LENGTH SPARES ONLY
62 BANJO BOLT WITH BLEED NIPPLE 10MM X
1MM SPARES ONLY
63 BOLT, BANJO, M10 x 1.0 x 18, CHROME SPARES ONLY
64 HOSE, CLUTCH, 1200MM LENGTH SPARES ONLY
58 90' BANJO SPARES ONLY
33 20' BANJO SPARES ONLY
53 HOSE, BRAIDED, BRAKE, REAR, 825MM SPARES ONLY
66 STRAIGHT BANJO SPARES ONLY
67 CLUTCH, ADAPTOR 10MM X 1MM SPARES ONLY
70 HYDRAULIC LINE KIT, CONVENTIONAL
FORKS, AXIAL CALIPERS HYDRAULIC LINE KIT COM-01, CMM-03, CSE-
01, CSE-02
27 DOUBLE BANJO BOLT M10 X 1MM X 34.5MM SPARES ONLY
26 COPPER WASHER SPARES ONLY
57 45' BANJO SPARES ONLY
33 20' BANJO SPARES ONLY
60 BRAKE HOSE, LH, 725MM LENGTH SPARES ONLY
61 BRAKE HOSE, RH, 750MM LENGTH SPARES ONLY
65 MODIFIED BANJO, 90', COMPOUND BEND
SPARES ONLY (AXIAL CALIPERS ONLY)
63 BOLT, BANJO, M10 x 1.0 x 18, CHROME SPARES ONLY
58 90' BANJO SPARES ONLY
53 HOSE, BRAIDED, BRAKE, REAR, 825MM SPARES ONLY
66 STRAIGHT BANJO SPARES ONLY
64 HOSE, CLUTCH, 1200MM LENGTH SPARES ONLY
67 CLUTCH, ADAPTOR 10MM X 1MM SPARES ONLY
71 HYDRAULIC LINE KIT, USD FORKS, CLIP ONS CCR-01/02 KIT ONLY
27 DOUBLE BANJO BOLT M10 X 1MM X 34.5MM SPARES ONLY
26 COPPER WASHER SPARES ONLY
57 45' BANJO SPARES ONLY
33 20' BANJO SPARES ONLY
72 BRAKE HOSE, LH, 635MM LENGTH SPARES ONLY
73 BRAKE HOSE, RH, 660MM LENGTH SPARES ONLY
62 BANJO BOLT WITH BLEED NIPPLE 10MM X
1MM SPARES ONLY
63 BOLT, BANJO, M10 x 1.0 x 18, CHROME SPARES ONLY
74 HOSE, CLUTCH, 1110MM LENGTH SPARES ONLY
58 90' BANJO SPARES ONLY
53 HOSE, BRAIDED, BRAKE, REAR, 825MM SPARES ONLY
66 STRAIGHT BANJO SPARES ONLY
212
67 CLUTCH, ADAPTOR 10MM X 1MM SPARES ONLY
75 CLIP, BRAKE LINE USED WITH 6MM HOLE IN MUDGUARD, USD ONLY
76 WIRE GUIDE, BRAKE HOSE
77 BOLT, CAP HD, M6 X 1.0 TO CLAMP WIRE GUIDE TO YOKE
90 WASHER, PENNY, M6, 6.4 X 18 X 1.6 BETWEEN BOLT AND WIRE GUIDE
5 CALIPER ASSY, AXIAL, LH GOLD FINISH
14 PISTON SET, CALIPER AXIAL
15 SEAL KIT, CALIPER, AXIAL
16 PAD RETAINER, CALIPER, AXIAL
17 PAD, SPRING, CALIPER, AXIAL
18 PADS, BRAKE, FRONT, AXIAL
19 BLEED SCREW, CALIPER, AXIAL
83 CALIPER ASSY, AXIAL, RH GOLD FINISH
14 PISTON SET, CALIPER AXIAL
15 SEAL KIT, CALIPER, AXIAL
16 PAD RETAINER, CALIPER, AXIAL
17 PAD, SPRING, CALIPER, AXIAL
18 PADS, BRAKE, FRONT, AXIAL
19 BLEED SCREW, CALIPER, AXIAL
1 DISC, FRONT, 320 MM 320 mm
2 BOLT, BUTTON HD, INT HEX, M8 X 16 25 6 PER SIDE, PATCH LOCKED
103 BOLT, BUTTON HD, INT HEX, M8 X 20 25 6 PER SIDE, PATCH LOCKED
3 SPACER, FRONT DISC
13 BOLT, CALIPER, RADIAL 35 TO CLAMP CALIPER TO FORK
12 CALIPER BRACKET, LH
84 CALIPER BRACKET, RH
13 BOLT, CAP HD, M10x20x1.25 35 BRACKET TO FORK
85 BOLT, CAP HD, M10x30x1.25 35 CALIPER TO BRACKET
104 CALIPER ASSY, RADIAL, LH
6 PISTON SET, CALIPER RADIAL
7 SEAL KIT, CALIPER, RADIAL
8 PAD REATINER, CALIPER, RADIAL
9 PAD, SPRING, CALIPER, RADIAL
10 PAD SET, CALIPER
4 CALIPER ASSY, RADIAL, RH
6 PISTON SET, CALIPER RADIAL
7 SEAL KIT, CALIPER, RADIAL
8 PAD RETAINER, CALIPER, RADIAL
9 PAD, SPRING, CALIPER, RADIAL
10 PAD SET, CALIPER
46 M/CYL ASSY, REAR M/CYL FOR ALL MODELS
49 HEEL GUARD, RH, XM
50 BRACKET, BRAKE RESERVOIR, REAR, STEEL,
PRESSED, XM
51 BOLT, CAP HD, M6 X 20 10 HEEL GUARD TO HANGER
45 HOSE, REAR M/CYL RESERVOIR BLACK RESERVOIR HOSE
213
Specification
Brakes
Item Standard Service Limit
Brake Lever, Brake Pedal: Brake lever free play Non-adjustable - - - Pedal free play Adjustable (to suit rider) - - -
Brake lever position Adjustable (to suit rider) - - -
Brake Fluid: Grade D.O.T. 4 / D.O.T. 3 - - -
Brand Fuchs Silkolene
Specification FMVSS 116 D.O.T. 4, D.O.T. 3, ISO 4925 AND SAE J 1703, (or above)
Brake Pads: Lining Thickness: Front (Radial Calipers) 4.5mm 1mm Front (Axial Calipers) 5.5mm 1mm
Rear 3.5mm 1mm
Brake Disc: Thickness:
55 RESERVOIR, MASTER CYL, REAR
47 BOLT, CAP HD, M6 x 10 8 TO CLAMP RESERVOIR TO BRACKET
48 ROD ASSY, REAR MASTER CYLINDER REAR BRAKE M/CYL PUSH ROD
90 NUT, M6 X 1.0, PLAIN USED TO LOCK ROD ASSY TO CLEVIS
56 CLEVIS, MASTER CYLINDER USED ON THE END OF ROD ASSY
52 CLEVIS PIN, BRAKE PEDAL, SPRING CLAMP LINK BETWEEN PLATE AND ROD ASSY
86 P-CLIP, 8MM
SUPPORT FOR BRAKE LINE TO SWING ARM
87 BOLT, CAP HD, M5 X 15 X 0.8 7 CLAMP P CLIP TO SWINGARM
88 WASHER, M5, 5.3 X 10 X 1 BETWEEN BOLT AND P CLIP
40 CALIPER ASSY, REAR, 34MM, GOLD GOLD FINISH
39 PADS, BRAKE, REAR, 34MM
38 PISTON SET, CALIPER, REAR
37 SEAL KIT, REAR, CALIPER
41 BLEED SCREW, REAR CALIPER
42 HANGER PIN, REAR CALIPER
89 SPRING, PAD RETAINER, REAR CALIPER
36 CALIPER CARRIER, REAR
43 BOLT, CAP HD, M8 X 20 X 1.25 28 REAR CALIPER TO CARRIER
35 DISC, REAR
44 BOLT, BUTTON HEAD, INT HEX, M10 X 20 43 DISK, PATCHLOCKED
PADS, BRAKE, REAR, SINTERED. TO BE USED WITH 32MM REAR CALIPER
214
Front 4mm ± 0.15 3.3mm Rear 5mm ± 0.15 4.3mm
Runout 0.2 mm or less 0.3mm
Brake Lever, Brake Pedal
Brake Lever Adjustment
Adjust the front brake lever [A] to suit you.
Pull the lever [A] out and turn adjust [B] to either side to
adjust position.
Brake Pedal Free Play Adjustment
Loosen the locknut [A] on the push-rod [B] and turn the rod either way to increase or decrease free
play.
Tighten the locknut.
Torque – Locknut brake lever pushrod: 18Nm
Warning: Always maintain proper brake adjustment. If adjustment
is improper, the brake could drag and overheat. This could
damage the brake assembly and possibly lock the wheel resulting
in loss of control.
Brake Pedal Removal
Remove:
Locknut [A]
Anti rotation washer [B] from back of foot control plate.
Pushrod from rear master cylinder.
Brake Pedal Installation
Ensure shaft bearing surface is clean and free from corrosion.
Install:
Anti rotation washer
Pedal locknut
B
A B
A
B
A
215
Pushrod into rear master cylinder
Tighten locknut.
Torque – Pedal Locknut: 43Nm
216
Brake Fluid
Warning: When working with the disc brakes, observe the precautions listed below.
Never reuse old brake fluid.
Do not use fluid from a container that has been left
unsealed or that has been open for a long time.
Do not mix two types and brands of fluid for use in the
brakes. This lowers the brake fluid boiling point and could
cause the brake to be ineffective. It may also cause the
rubber brake parts to deteriorate.
Don`t leave the reservoir cap [A] off for any length of time
to avoid moisture contamination of the fluid.
Don`t change the fluid in the rain or when a strong wind is blowing.
Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil, or any
other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be
difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake.
When handling the disc pads or discs, be careful that no disc brake fluid or any oil gets on them.
Clean off any fluid or oil that inadvertently gets on the pads or discs with a high-flash point solvent.
Do not use one which will leave an oily residue. Replace the pads with new ones if they cannot be
cleaned satisfactorily.
Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away
immediately.
If any brake line fittings or the bleed valve is opened at any time, the AIR MUST BE BLED FROM THE
BRAKE.
Brake Fluid Recommendation
Note: Recommended fluids are given in the table below. If none of the recommended fluids are available,
use extra heavy-duty brake fluid only from a container marked D.O.T. 3 OR 4.
NOTE: Brake fluid of D.O.T. 4 is installed in the brake system when shipped.
Brake Fluid:
Grade D.O.T. 4 / D.O.T. 3
Brand Fuchs Silkolene
Specification FMVSS 116 D.O.T. 4, D.O.T. 3, ISO 4925 AND SAE J 1703, (or above)
A
217
Brake Fluid Level Inspection
In accordance with the Periodic Maintenance Chart, inspect the brake fluid level in the front and rear
brake fluid reservoir
Check the front and rear brake fluid reservoir level is above
the lower line [A] and below the upper line [B].
Hole the reservoir when checking brake fluid level.
Warning: Change the fluid in the brake line completely if the fluid
must be refilled but the type and brand of the fluid that already is in
the reservoir are unidentified.
If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [A] in the
reservoir with the same type and brand of the fluid that already is in the reservoir.
Brake fluid changing
Note: The procedure to change the front brake fluid is as follows. Changing the rear brake fluid is the same
as for the front brake.
Remove the reservoir cap.
Attach a clear plastic hose to the bleed valve on the caliper, and run the other end of the hose into
a container.
Fill the reservoir with new brake fluid.
Change the brake fluid as follows:
Open the bleed valve [A].
Apply the brake lever and hold it [B].
Close the bleed valve [A].
Release the brake lever [B].
Check the fluid level in the reservoir often, replenishing it
as necessary.
Note: If the fluid in the reservoir runs completely out any time during fluid changing, air will enter the line,
and the system must be bled.
Repeat this operation until fresh fluid comes out into the
plastic hose or the colour of the fluid changes.
Warning: Do not mix two brands of fluid. Change the
brake fluid in the brake line completely if the brake fluid
must be refilled but the type and brand of the brake fluid
that is already in the reservoir are unidentified.
A
B
A
A
218
Torque – Bleed Valves: 7.8Nm
Apply the brake lever forcefully for a few seconds, and check for fluid leakage around the fittings.
Warning: If the brake lever or pedal has a soft or “spongy feeling” when it is applied, there might be air in
the brake line or the brake may be defective. Since it is dangerous to operate the motorcycle under such
conditions, bleed the air from the brake line immediately.
Brake Line Air Bleeding
Note: The procedure to bleed the front brake line is as follows. Bleeding the rear brake line is the same as
for the front brake.
Bleed the air whenever brake parts are replaced or reassembled.
Remove the reservoir cap and fill the reservoir with new
brake fluid.
Slowly pump the brake lever several times until no air
bubbles can be seen rising up through the fluid from the
hose at the bottom of the reservoir. This bleeds the air
from the mast cylinder and the brakes line.
Note: Tap the brake hose lightly going from the caliper to the
reservoir side and bleed the air off at the reservoir.
Attach a clear plastic hose to the bleed valve on the caliper, and run the other end of the hose into
a container.
Bleed the brake line and caliper as follows:
Hold the brake lever applied [A].
Quickly open and close the valve [B].
Release the Brake Level [A].
The fluid lever must be checked several times during
bleeding operation and replenished as necessary.
Note: If the fluid in the reservoir runs completely out any time
during bleeding, the bleeding operation must be done over
again from the beginning since air will have entered the line.
If the brake lever or pedal action still feels soft or “spongy”, tap the brake hose from bottom to top and air
will rise up to the top part of the hose. Slowly pump the brake lever or pedal in the same manner as above.
Torque – Bleed Valves: 8 Nm
Apply the brake lever forcefully for a few seconds, and check for fluid leakage around the fittings.
A
B
219
Front Caliper Removal
Drain the front brake fluid (see Brake Fluid Change).
Remove banjo bolt [A].
Remove caliper bolts [B] and take off the caliper [C].
If the caliper is to be disassembled after removal and if
compressed air is not available, remove the pistons
using the following steps before disconnecting the brake
hose from the caliper.
Remove the pads (see Brake Pad Removal).
Insert a wooden board 5mm thick inside the caliper
opening (see this chapter).
Pump the brake lever until the pistons push the wooden
board.
Remove the caliper.
Remove the board and pull out the pistons by hand.
Caution: Immediately wash away any brake fluid that spills.
Rear Caliper Removal
Drain the rear brake fluid (see Brake Fluid Change).
Remove banjo bolt [A].
Remove the caliper bolts [B].
Take off the caliper [C].
If the caliper is to be disassembled after removal and if
compressed air is not available, remove the piston using
the following steps before disconnecting the brake hose
from the caliper.
Remove the pads.
Pump the brake pedal to remove the piston.
Caution: Immediately wash away any brake fluid that spills.
Caliper Installation
Tighten the caliper bolts.
Torque – Caliper bolts: 35Nm
Connect the brake hose to the caliper putting a new flat washer on each sie of the brake hose
fitting.
Tighten the banjo bolt.
A B
C
B
C
A
B
A C
220
Torque – Banjo Bolt: 25Nm
Check the fluid level in the master cylinder (reservoir) and bleed the brake line (see Bleeding the
Brake).
Check the brake for good braking power, no brake drag, and no fluid leakage.
Warning: Do not attempt to ride the motorcycle until a full brake lever or pedal is obtained by pumping the
brake lever or pedal until the pads are against each disc. The brakes will not function on the first
application of the lever or pedal if this is not done.
Front Caliper Disassembly
Remove the front caliper (see Front Caliper Removal).
Remove the pads and spring (see Pad Removal).
Insert a wooden board 5 mm thick inside the caliper
opening.
Lightly apply compressed air to the hose joint opening
until the pistons hit the wooden board.
Remove the board and pull out the pistons by hand.
Warning: To avoid serious injury, never place your fingers or
palm inside the caliper opening. If you apply compressed air into
the caliper, the piston(s) may crush your hand or fingers.
Remove the dust seal(s) and fluid seal(s)
Rear Caliper Disassembly
Remove the caliper (see Caliper Removal).
Remove the pads and spring (see Pad Removal).
Using compressed air, remove the piston.
Cover the caliper opening with a clean, heavy cloth.
Remove the piston by lightly applying compressed air to
the hose joint.
Warning: To avoid serious injury, never place your fingers or palm inside the caliper opening. If you apply
compressed air into the caliper, the piston may crush your hand or fingers.
Remove the dust seal and fluid seal.
Caliper Assembly
It is recommended that the fluid seal, which is removed, be replaced with a new one.
221
Replace the dust seals if they are damaged.
Install the fluid seal. Either side of the seal may face outboard.
Apply brake fluid to the cylinders, pistons, and fluid seals (piston seals), and push the pistons into
the cylinders by hand. Take care that neither the cylinder nor the piston skirt gets scratched.
Install the anti rattle spring in the caliper.
Install the pads (see Brake Pad Installation).
Caliper Fluid Seal Damage
Note: The fluid seals around the piston maintain the proper pad/disc clearance. If the seals are not
satisfactory, pad wear will increase, and constant pad drag on the disc will raise brake and brake fluid
temperature.
Replace the fluid seals under any of the following
conditions: (a) fluid leakage around the pads; (b) Brakes
overheat (c) there is a large difference in inner and
outer pad wear; (d) the seal is stuck to the piston.
If the fluid seal is replaced, replace the dust seal as well.
Also, replace all seals every other time the pads are
changed.
Caliper Dust Seal
Check that the dust seal is no cracked, worn, swollen, or
otherwise damaged.
If they show any damage replace them.
Caliper Piston and Cylinder Damage
Visually inspect the piston and cylinder surfaces.
Replace the caliper if the cylinder and piston are badly
scored or rusty.
Brake Pads
Front Brake Pad Removal Axial
Remove the Front Brake Caliper bolts [A].
Remove the r-clips [B].
Remove the pad retainer shafts [C].
Remove the brake pads from the inner side.
Front Brake Pad Removal Radial
A
B
A
C
B D
222
Remove the Front Brake Caliper bolts [A].
Push the anti-vibration spring [B] down and pull the pad retainer pins [C] out.
Repeat for each pad.
Remove the brake pads [D] from the inner side.
Rear Brake Pad Removal
Remove the Rear Brake Caliper bolts [A].
Remove the Caliper from the disc with the hose left
installed.
Remove the c-clip [B] on the pad retainer spring pin [C].
Remove the pad retainer spring pin [C].
Remove the pad retainer spring [D].
Remove the rear brake pads [E].
Brake Pad Installation
Before installation, clean the pads with a high-flash point
solvent.
Push the caliper pistons in by hand as far as they will go,
and then install the pads.
Warning: Do not attempt to ride the motorcycle until a full
brake lever or pedal is obtained by pumping the brake lever or
pedal until the pads are against each disc. The brake will not
function on the first application if this not done.
Brake Pad Wear Inspection
Note: In accordance with the periodic Maintenance Chart,
inspect the brake pads for wear.
Remove the pads.
Check the lining thickness of the pads in each caliper.
If the lining thickness of either of the pads is less than the
service limit replace both pads in the caliper as a set.
A
B
C
D
E
223
Pad Lining Thickness
Lining Thickness: Standard Service limit
Front (Radial Calipers) 4.5mm 1mm
Front (Axial Calipers) 5.5mm 1mm
Rear 3.5mm 1mm
Brake Master Cylinder
Front Master Cylinder Removal
Drain the front brake fluid (see Brake Fluid Changing).
Remove:
Brake hose Banjo Bolt [A]
Master Cylinder Clamp Bolts [B]
Remove the front brake master cylinder[C].
Caution: Brake fluid quickly ruins painted surfaces; any spilled
fluid should be completely washed away immediately.
Front Master Cylinder Installation
The (integral) master cylinder clamps must be installed with the UP mark [D] facing upwards.
Tighten the upper master cylinder clamp bolts first, and then the lower clamp bolts. There will be a
gap at the lower part of the clamp after tightening.
Torque – Master Cylinder Clamp Bolts: 8 Nm
Use a new flat washer on each side of the brake hose fitting, and tighten the banjo bolt.
Torque – Banjo Bolt: 25 Nm
Fill the brake line with brake fluid (see Brake Fluid Changing).
Check that the brake line has proper fluid pressure and no fluid leakage.
Warning: Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake
lever until the pads are against each disc. The brake will not function on the first application of the lever if
this is not done.
Rear Master Cylinder Removal
Drain the rear brake fluid (see Brake Fluid Change).
Loosen the banjo bolt.
Remove:
C-clip and Joint [A]
C
A
B
D
A
224
Banjo Bolt and Brake Hose.
Rear Master Cylinder Bolts
Remove the rear master cylinder.
Rear Master Cylinder Disassembly
Note: Do not remove the push rod clevis for the master cylinder
disassembly since removal requires brake pedal position
adjustment.
Remove:
Rear Master Cylinder (see Rear Master Cylinder Removal)
Dust Cover
Push Rod with Clevis
Caution: Do not remove primary and secondary cups from the piston since removal will damage them.
Master Cylinder Assembly
Before assembly, clean all parts including the master cylinder with brake fluid or alcohol.
Apply brake fluid to the removed parts and to their inner wall of the cylinder.
Caution Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil will cause
deterioration of the rubber parts. Gasoline, engine oil, or any other petroleum distillate will cause
deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will
eventually deteriorate the rubber used in the disc brake.
Silicone Grease - Brake Lever Pivot Bolt
Brake Lever Pivot Contact
Push Rod Contact (Rear Master Cylinder)
Torque - Brake Lever Pivot Bolt: 6Nm
Master Cylinder Visual Inspection
Disassemble the front and rear master cylinders.
Check that there are no scratches, rust or pitting on the inner wall of each master cylinder and on
the outside of each piston.
If a master cylinder or piston shows any damage, replace them.
Inspect the primary and secondary cups.
225
If a cup is worn, damaged, softened (rotted), or swollen,
the piston assembly should be replaced to renew the
cups.
If fluid leakage is noted at the brake lever, the piston
assembly should be replaced to renew the cups.
Check the dust covers for damage.
If they are damaged replace them.
Check that the relief and supply ports are not plugged.
If the relief port becomes plugged, the brake pads will drag on the disc. Blow the ports clean with
compressed air.
Check the piston return spring for any damage.
If a spring is damaged, replace it.
Brake Discs
Disc Installation Front
Install the disc spacer [A] as shown.
The disc must be installed so the disc moves further
away from the hub.
Tighten the disc bolts.
Torque – Front Disc Bolts: 25Nm
After installing the discs, check the disc runout.
Completely clean off any grease that has gotten on either side of the disc with a high-flash point
solvent. Do not use one with will leave an oil residue.
Disc Installation Rear
Tighten the disc bolts.
Torque – Rear Disc Bolts: 43Nm
After installing the disc, check the disc runout.
Completely clean off any grease that has gotten on either side of the disc with a high-flash point
solvent. Do not use one with will leave an oil residue
Disc Wear
Replace the disc if the sliding surfaces have worn past the service limit.
Brake Disc Wear:
Thickness: Standard Service Limit
Front - 4mm ± 0.15 3.3mm
A
226
Rear - 5mm ± 0.15 4.3mm
Runout: 0.2 mm or less 0.3mm
Disc Cleaning
Note: Poor braking can be caused by oil on a disc. Oil on a disc must be cleaned off with an oilless cleaning
fluid such as trichloroethylene or acetone.
Warning: These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods.
Be sure to heed the fluid manufacture’s warning.
Disc Warp Inspection
Using the jack, raise the front or the rear wheel off the ground (see Wheels/Tire chapter).
Set the dial gauge [A] against the disc.
For the front disc, turn the handlebar fully to one side.
Rotate the wheel [C] to measure disc runout. The difference between the highest and lowest dial
reading is the amount of runout.
If disc runout exceeds the service limit, replace the disc.
Disc Runout
Standard: 0.2 mm or less
Service Limit: 0.3 mm
Brake Hose Removal
Drain the brake fluid (see Brake Fluid Change).
Remove the banjo bolts [A] at both ends of the brake hose [B] and pull the hose off the motorcycle.
There is a copper washer on each side of the hose fitting.
When removing the brake hose, temporarily secure the end of the brake hose to some high place
to keep fluid loss to a minimum.
Immediately wash away any brake fluid that spills.
Caution: Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away
immediately.
Brake Hose Installation
Using a new copper washer for each side of the hose fitting, tighten the banjo bolt.
Torque – Banjo Bolts: 25Nm
When installing the hoses, avoid shaft bending, kinking, flattening or twisting.
Run the brake hose according to the Cable, Wire and Hose Routing section in the General
Information chapter.
Fill the brake line with the brake fluid (see Brake Fluid Changing).
227
Brake Hose Inspection
Note: The high pressure inside the brake line can cause fluid to leak or the hose to burst if the line is not
properly maintained.
Bend and twist the rubber hose while examining.
Replace it if any cracks or bulges are noted.
228
Suspension
Exploded View ................................................................................................................................................ 221
Specification ................................................................................................................................................... 229
Rear Suspension ............................................................................................................................................. 230
Spring Preload .................................................................................................................................... 230
Preload Adjustment ........................................................................................................................... 230
Compression Damping Adjustment ................................................................................................... 230
Rebound Damping Adjustment ......................................................................................................... 232
Ride Height Adjustment ..................................................................................................................... 232
Rebound Damping Adjustment ......................................................................................................... 323
Compression Damping Adjustment ................................................................................................... 233
Cleaning .............................................................................................................................................. 233
Inspection ........................................................................................................................................... 233
Rear Shock Absorber ...................................................................................................................................... 234
Rear Shock Absorber Removal ........................................................................................................... 234
Rear Shock Absorber Installation ....................................................................................................... 234
Oil Draining ......................................................................................................................................... 234
Oil Filling ............................................................................................................................................. 234
Spring Tension .................................................................................................................................... 234
Scrapping ............................................................................................................................................ 235
Rear Shock Absorber Disassembly ..................................................................................................... 235
Rear Shock Absorber Assembly.......................................................................................................... 235
Conventional Front Forks ................................................................................................................... 235
Spring Preload Adjustment ................................................................................................................ 235
Preload Adjustment ........................................................................................................................... 235
Compression Damping Adjustment ................................................................................................... 236
Rebound Damping Adjustment .......................................................................................................... 236
Rebound Damping Recommended Adjustment Range ..................................................................... 237
Compression Damping Recommended Adjustment Range ............................................................... 237
Cleaning .............................................................................................................................................. 238
Inspection ........................................................................................................................................... 238
Removal .............................................................................................................................................. 238
Installation .......................................................................................................................................... 238
Oil Draining ......................................................................................................................................... 238
Oil Filling ............................................................................................................................................. 238
Spring Tension .................................................................................................................................... 238
Fork Disassembly ................................................................................................................................ 240
Changing Fork seals and Bushings ..................................................................................................... 241
Assembly ............................................................................................................................................ 242
USD Front Forks ............................................................................................................................................. 243
Spring Preload Adjustment ................................................................................................................ 243
Preload Adjustment ........................................................................................................................... 243
229
Compression Damping Adjustment ................................................................................................... 243
Rebound Damping Adjustment .......................................................................................................... 244
Rebound Damping Recommended Adjustment Range ..................................................................... 244
Compression Damping Recommended Adjustment Range ............................................................... 245
Cleaning .............................................................................................................................................. 245
Inspection ........................................................................................................................................... 245
Removal .............................................................................................................................................. 245
USD Fork Installation (Cafe Racer) ..................................................................................................... 246
USD Fork Installation (Sport and SE) .................................................................................................. 246
Oil Draining ......................................................................................................................................... 246
Oil Filling ............................................................................................................................................. 246
Spring Tension .................................................................................................................................... 248
USD Fork Disassembly ........................................................................................................................ 248
Replacing Seals and Forks .................................................................................................................. 249
USD Fork Assembly ............................................................................................................................ 249
Fork Disassembly ................................................................................................................................ 249
Changing Fork Seals and Bushing ....................................................................................................... 249
USD Fork Assembly ............................................................................................................................ 250
Swingarm ....................................................................................................................................................... 252
Swingarm Removal ............................................................................................................................. 252
Swingarm Installation ......................................................................................................................... 252
Swingarm Bearing Removal ............................................................................................................... 253
Swingarm Pivot Check ........................................................................................................................ 255
Swingarm Bearing, Sleeve Inspection ................................................................................................ 255
230
Exploded View
231
232
233
234
REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
24 STANCHION ASSY, RH -> OHLINS RWU
NUT
SPACER, SPRING
WASHER, SPRING SPACER
NUT, CAP ASSY
SPRING
CYLINDER
TUBE, OUTER
SEAL DUST
SNAP RING
SEAL, OIL
WASHER, OIL SEAL
TUBE, INNER, RH
SEALING WASHER
CAPSCREW, OIL LOCK
23 STANCHION ASSY, LH -> OHLINS RWU
NUT
SPACER, SPRING
WASHER, SPRING SPACER
NUT, CAP ASSY
SPRING
CYLINDER
TUBE, OUTER
SEAL DUST
SNAP RING
SEAL, OIL
WASHER, OIL SEAL
TUBE, INNER, LH
SEALING WASHER
CAP SCREW, OIL LOCK
9 STANCHION ASSY, LH, USD, 11mm PULL THROUGH
NUT
SPACER, SPRING
WASHER, SPRING SPACER
NUT, CAP ASSY
SPRING
CYLINDER
TUBE, OUTER
SEAL DUST
SNAP RING
SEAL, OIL
235
WASHER, OIL SEAL
TUBE, INNER, RH
SEALING WASHER
CAP SCREW, OIL LOCK
10 STANCHION ASSY, RH, USD, 11mm PULL THROUGH
NUT
SPACER, SPRING
WASHER, SPRING SPACER
NUT, CAP ASSY
SPRING
CYLINDER
TUBE, OUTER
SEAL DUST
SNAP RING
SEAL, OIL
WASHER, OIL SEAL
TUBE, INNER, LH
SEALING WASHER
CAP SCREW, OIL LOCK
BOLT, CAP HD, M8 X 25 20 PINCH BOLT SUPPLIED WITH FORKS
9 STANCHION ASSY, LH, USD, 11mm PULL THROUGH REFER TO PROCESS
SHEET
NUT
SPACER, SPRING
WASHER, SPRING SPACER
NUT, CAP ASSY
SPRING
CYLINDER
TUBE, OUTER
SEAL DUST
SNAP RING
SEAL, OIL
WASHER, OIL SEAL
TUBE, INNER, RH
SEALING WASHER
CAP SCREW, OIL LOCK
10 STANCHION ASSY, RH, USD, 11mm PULL THROUGH REFERTO PROCESS SHEET
NUT
SPACER, SPRING
WASHER, SPRING SPACER
NUT, CAP ASSY
SPRING
CYLINDER
TUBE, OUTER
SEAL DUST
SNAP RING
236
SEAL, OIL
WASHER, OIL SEAL
TUBE, INNER, LH
SEALING WASHER
CAP SCREW, OIL LOCK
BOLT, CAP HD, M8 X 25 20 PINCH BOLT SUPPLIED WITH FORKS
11 LOWER YOKE, USD FORKS
12 BOLT, CAP HD, M8 X 20 X 1.25 20 LOWER YOKE CLAMP BOLTS
13 STEERING STEM
14 BEARING, TAPERED ROLLER HEADSTOCK BEARINGS
15 SEAL, HEADSTOCK, LOWER BEARING
25 LOWER YOKE, BILLET
LOWER YOKE FOR CONVENTIONAL
FORKS
12 BOLT, CAP HD, M8 X 20 X 1.25 20 LOWER YOKE CLAMP BOLTS
52 LOWER HEADSTOCK SPACER YOKE SPACER FOR CONVECTIONAL FORKS
GREASE, SILKOLENE, PRO RG2
32 SWITCH CUBE, LH ECIE
SCREW, M5 X 40 3
SCREW, M5 X 30 3
33 SWITCH CUBE, RH
SCREW, M5 X 22 3
34 HANDLEBAR, TUBULAR, TAPERED ALUMINIUM
35 GRIP, HANDLEBAR, LH
36 GRIP, HANDLEBAR, RH
37 THROTTLE ACTUATOR, TWIN CABLE 4
38 BOLT, CAP HD, M6 X 20 x 1.0 8 THROTTLE ACTUATOR CLAMP
39 CLAMP, CLIP-ON, RH, CLEAR ANODISE
40 CLAMP, CLIP-ON, LH, CLEAR ANODISE
52 PIN, PARALLEL, 4.0 X 18.0MM, SOLID,
STAINLESS
USED AS ANTI ROTATION FEATURE
41 HANDLEBAR, CLIP-ON, LH, CLEAR
ANODISE
42 HANDLEBAR, CLIP ON, RH, CLEAR ANODISE
43 BOLT, CAP HD, M6 X 20 x 1.0, DIN
912, SS 15
USED TO PINCH HANDLEBAR
49 20 USED TO PINCH CLAMP
51 CABLE, THROTTLE, TWIN THROTTLE CABLES FOR HIGH BARS ONLY
BRASS BARREL NIPPLE 5.75MM DIA X
5.5MM LENGTH
OPEN CABLE GUIDE
CLOSE CABLE GUIDE
FERRULE
RUBBER BOOT
OPEN CABLE, 6MM OD, OUTER
CONDUIT, 795MM
OPEN CABLE, 1.5MM OD, INNER WIRE, 1030MM
CLOSE CABLE, 6MM OD, OUTER
237
CONDUIT, 795MM
CLOSE CABLE, 1.5MM OD, INNER
WIRE, 1030MM
ADJUSTER
LOCK NUT
BRASS BARREL NIPPLE 6MM DIA X
8MM LENGTH
50 CABLE, THROTTLE, TWIN, CLIP-ONS THROTTLE CABLES FOR LOW BARS ONLY
BRASS BARREL NIPPLE 5.75MM DIA X
5.5MM LENGTH
OPEN CABLE GUIDE
CLOSE CABLE GUIDE
FERRULE
RUBBER BOOT
OPEN CABLE, 6MM OD, OUTER CONDUIT, 795MM
OPEN CABLE, 1.5MM OD, INNER
WIRE, 1030MM
CLOSE CABLE, 6MM OD, OUTER CONDUIT, 795MM
CLOSE CABLE, 1.5MM OD, INNER
WIRE, 1030MM
ADJUSTER
LOCK NUT
BRASS BARREL NIPPLE 6MM DIA X
8MM LENGTH
28 WEIGHT, BAR END
29 RUBBER MOUNT, BAR END
30 BOLT, CAP HD, M6 X 40 x 1.0 BAR END MOUNT TO HANDLE BAR
31 LOCKNUT, FLANGED, SERRATED FACE, M6
BAR END MOUNT TO HANDLE BAR
22 TOP YOKE, USD FORKS CAFE RACER RACER TOP YOKE
12 BOLT, CAP HD, M8 X 20 X 1.25 20NM TOP YOKE CLAMP BOLTS
16 TOP YOKE, USD FORKS, HIGH BARS CSE-03 TOP YOKE
17 BOLT, CAP HD, M8 X 20 X 1.25 20NM TOP YOKE CLAMP BOLTS
18 SEAL, HEADSTOCK
26 YOKE, UPPER ASSY, BILLET TOP YOKE FOR CONVENTIONAL FORKS
27 BOLT, CAP HD, M8 X 20 X 1.25 20NM TOP YOKE CLAMP BOLTS CONVENTIONAL FORKS
19 NUT, UPPER YOKE, M25 80NM TOP YOKE LOCK NUT
20 LOCKNUT, M25 6 ADJUSTER NUT 40NM TO SEAT BEARINGS, BACKED OFF, THEN RE-TORQUED TO 6
NM
21 INTERMEDIATE NUT, M25 40 LOCKED UP TO ADJUSTER NUT 40 NM
44 CLAMP, HANDLEBAR, LOWER
45 BOLT, CAP HD, M10x30X1.5 HANDLEBAR CLAMP TO YOKE
46 NUT, M10 X 1.5 43 HANDLEBAR CLAMP TO YOKE
55 WASHER, M10, 10.5 X 20 X 2
47 CLAMP, HANDLEBAR, UPPER
48 BOLT, CAP HD, M8 X 22 X 1.25 20 UPPER HANDLE BAR CLAMPS BOLTS
238
Specifications
Suspension Specification (USD)
Item Standard Range
Front Fork (per one unit) Fork inner tube diameter 43 mm - - - Compression damper setting 16 clicks from fully closed +11 to -16 Rebound damping setting 18 clicks from fully closed +6 to -18 Spring preload setting (3 turns from fully out) +7 to -3 Fork oil Ohlins front fork fluid 01309 - - - Fork oi viscosity 19 cSt (5W) - - - Fork oil capacity N/A - - - Fork oil level 150mm ± 2 mm - - -
Fork spring free length 260mm ± 2 mm - - -
Suspension Specification (Conventional)
Item Standard Range
Front Fork (per one unit) Fork inner tube diameter 43 mm - - - Compression damper setting 14 clicks from fully closed +14 to -14 Rebound damping setting 16 clicks from fully closed +2 to - 16 Spring preload setting (3 turns from fully out) +7 to - 3 Fork oil Ohlins front fork fluid 01309 - - - Fork oi viscosity 19 cSt (5W) - - - Fork oil capacity 488 cm³ - - - Fork oil level N/A - - -
Fork spring free length 250mm ± 2 mm - - -
Suspension Specification (Rear Shocks)
Item Standard Range
Rear shock (per one unit) Compression damper setting 3 clicks from fully closed +1 to -3 Rebound damping setting 18 clicks from fully closed +36 to -18
Spring preload setting 7 turns from fully out (2 rings showing) +8 to - 7
239
Fork spring free length 230mm - - -
240
Rear Suspension
Warning: Ensure that the basic factory settings are intact before riding the motorcycle. If making
adjustments, only adjust one aspect at a time in small increments.
Spring Preload – Static Sag – Rider - Sag
Note: Spring preload affects the ride height of the motorcycle and the fork angle. The Following should be
performed on a flat surface.
Lift the motorcycle off the ground using a work stand so that
the front and rear wheels are off the ground and unloaded.
Measure the distance from the centre of the rear wheel axle
to the centre of the top rear suspension mount [R1].
Measure the distance from the bottom of the lower yoke
(lowest point) to the centre of the front wheel axle [F1].
With the motorcycle on the ground so the motorcycle is
under its own weight, repeat the measuring procedure
above for [R2] and [F2].
Sit on the motorcycle in full riding gear in a normal riding
position; repeat the measuring procedure for [R3] and [F3].
Note: The following set up is based on a single rider in full gear to a
mass of 90Kg.
Static Sag Conventional forks –
[R1-R2] [474-463] Rear: 11 mm ± 3mm
[F1-F2] [522-477] Front: 45 mm ± 3mm
Static Sag USD Forks -
[R1-R2] [474-463] Rear: 11 mm ± 3mm
[F1-F2] [510-475] Front: 35 mm ± 3mm
Rider Sag Conventional -
[R1-R3] [474-440] Rear: 34 mm ± 3mm
[F1-F3] [522-467] Front: 55 mm ± 3mm
Rider Sag USD Forks -
[R1-R3] [474-440] Rear: 34 mm ± 3mm
[F1-F3] [510-465] Front: 45 mm ± 3mm
If the measurements differ significantly from the table above, adjust the spring preload (see Spring
Preload Adjustment).
If the Rider Sag still differs significantly you may need to replace the spring.
241
Warning: Incorrect spring rate may result is poor handling characteristics.
Preload Adjustment
Turn the screw [A] on the hydraulic adjuster to set the
spring preload.
Turn clockwise to increase preload, turn anti clockwise to
decrease.
To set the rider sag adjustment (see this chapter) turn the
preload adjuster anti clockwise until it stops, and then
turn clock wise to the first audible click. From this click
turn the preload adjuster clockwise to the recommended position.
Note: One full turn of the preload adjuster equates to 2/3mm (0.66 mm) of spring preload.
Preload – 7 full turns from fully out (two rings on the
adjust should be visible [A])
Note: Increasing the amount of preload on the rear
shock will reduce the amount of both static and rider
sag. Reducing the preload will increase the sag values.
Adjust both the left and right hand rear suspension
springs in sequence to the same position.
Changing the spring preload will change the ride height and affect the handling.
It is critical that the spring preload is correctly set; if the spring preload is not correctly set all other
suspension adjustments may not give desired handling characteristics.
Compression Damping Adjustment
Note: Compression damping controls the energy absorbed
when the rear wheel is being loaded or hits a bump. Standard
settings are based on a 90 kg rider (this includes riding gear).
To adjust the compression damping turn the adjuster
[A] clockwise to increase damping, and anti clockwise
to decrease damping.
To reset the adjuster turn the adjuster clockwise to
fully closed position (zero (0) position), then turn anti
clockwise to open.
Rear Compression Damping – 3 clicks out from fully closed
Caution: Do not force the damping adjuster, delicate sealing
surfaces could be damaged.
A
A
A
242
Rebound Damping Adjustment.
Note: Rebound damping controls the energy absorption when the shock absorber is being extended and
controls how fast the shock absorber returns to its normal position after being compressed.
To adjust the damping, turn the adjuster [A] on the piston shaft clockwise to increase damping, anti
clockwise to decrease it.
To reset the damping, turn the adjuster clockwise (right) to fully closed position, and then anti
clockwise (left) to the specified range.
Rear Rebound Damping – 18 Clicks out from fully closed
Warning: If both suspension units are not adjusted equally, handling may be impaired and a hazardous
condition may result.
Ride Height Adjustment
Note: Adjusting the length of the rear suspension will directly
affect the steering geometry and handling of the motorcycle
Caution: Make very small adjustments at a time as they can make
a significant difference.
Remove the shock absorbers from the motorcycle (see
this chapter).
Slacken off the lock nut [A].
Turn the adjuster nut [B] to the desired length.
One turn of the spring retainer results in 1mm of shock
absorber length.
Rear Shock Absorber Length: 380 mm +8/-2mm
Tighten the Ride Height Adjuster Nut.
Torque – Ride height Adjuster Nut: 40Nm
Warning: Always torque the lock nut after adjusting the
length. The Adjustable end eye bracket [B] must not be
positioned beyond grove [A].
Caution: After any changes to Ride Height Adjustment always check the Rider Sag (see this chapter) and
Head light Angle (see Electrical System chapter).
A
B
A
B
243
Rebound Damping Recommended Adjustment Range
Rebound Adjustment Range: ± 5 clicks from original settings
Note: When setting up a motorcycle, the front suspension should be adjusted in line with the rear.
If the Spring rate, preload and ride height feel good but the bike rides low and sits down under
acceleration bumps, with lost line or lost comfort and traction.
Open the rebound adjuster two clicks.
If the bike is nervous / moving a lot or has a high feeling entering corners.
Close the rebound adjuster two clicks.
Fine tune by one click at a time
Caution: Always start from original factory settings and test run after making changes.
Compression Damping Recommended Adjustment Range
Compression Damping Range: ± 2 clicks from original settings
If the motorcycle feels soft / unstable or is using too much wheel travel and the spring rate is
correct.
Close the compression adjuster by one click. This will controle reduce the motorcycle from falling
throught the stroke too quickly.
If the motorcycle feels high / has poor grip when opening the throttle or does not feel smooth over
small bumps during acceleration.
Open the Compression Adjuster by one click.
Caution: Always start from original factory settings and test run after making changes, if improvements
have been made, repeate the procedure from the start again to check. Always check tire pressures before
making suspension adjustements and take note of the conditions such as air temperature.
Caution: Preventive maintenance and regular inspection reduces the risk of function disturbance.
Rear Suspension Cleaning
Clean the rear suspension unit externaly with a soft detergent. Using compressed air ensure all dirt
is removed, lift the bump rubber and clean the area below. Keep the shock absorber clean and
spray with a water displacing spray which will not deteriate the rubber, after cleaning, wash off
excessive oil with a cloth.
Caution: Never spray water directly into the adjuster units or ball joints.
244
Rear Suspension Inspection
Check the ball joint for excessive play or stiction.
Check the piston shaft for leakage and damage.
Check the shock absorber body for external damage.
Check the reservoir for external damage that can restrict the floating piston from moving freely.
Check for excessive wear of rubber components.
Check the attachment points between frame, swingarm, and shock.
Warning: Do not change the gas pressure this required specialist high pressure nitrogen equipment.
Rear Shock Absorber Removal
Using a jack, raise the rear wheel off the ground (see
wheels/Tires chapter).
Support the rear swing arm weight.
Remove the top [A] and bottom [B] suspension
mounting bolts and washers.
Remove the Shock absorbers [C].
Rear Shock Absorber Installation
Install the shock absorber with the piggyback reservoir
[A] at the top and back of the motorcycle.
Install the Shock washers and bolts and tighten.
Torque – Rear Shock Bolts: 22 Nm
Oil Draining/Filling
Note: Changing the oil requires de-pressurising and pressuring the rear shocks and should only be
undertaken by a Norton authorised Ohlins dealer
Warning: High Pressure gas reservoir should only be serviced by a Norton authorised Ohlins dealer as high
pressure gas is dangerous.
Spring Tension
Note: Since the spring becomes shorter as it weakens, check its free length to determine the condition.
If the spring is shorter than the service limit, it must be replaced.
Rear Shock Absorber Spring Length:
B
A
C
245
Standard: 230 mm
Service Limit: 225 mm
Scrapping
Remove the rear shock absorber (see this chapter).
Point the reservoir away from you and slowly release the nitrogen gas pressure from the gas
reservoir by pushing down the valve core with a surgical needle.
Warning: The high pressure gas is dangerous. Do not point the valve toward your face or body. Do not
incinerate a shock absorber without first removing the valve or it may explode.
Rear Shock Absorber Disassembly
Remove the Rear Shock from the frame (see Rear Shock
Absorber Removal).
Clean the shock (see Rear Suspension cleaning)
Hold the lower end of the shock with a vise.
Remove the entire preload on the spring (see Preload
Adjustment).
Using a spring compressor compress the spring until it is
free.
Slide down the rubber bumper [A].
Remove the spring guide [B] from the shock absorber and lift off the spring [C].
Rear Shock Absorber Assembly
Install the spring and spring guide.
Slowly release the tension in the spring using the spring compressor.
Set the preload to its factory setting.
Install the Shock (see Rear Shock Absorber Installation).
Before riding, ensure the rear shocks are set up identically and the shock performs as intended.
Front Fork Conventional
Spring Preload Adjustment
Warning: Ensure that the basic factory settings are
intact before riding the motorcycle. If making
adjustments, only adjust one aspect at a time in
small increments.
A
B
C
246
Note: Spring preload affects the ride height of the motorcycle and the fork angle.
If the measurements differ significantly from (Spring Preload – Static Sag – Rider – Sag), adjust the spring
preload (see Preload Adjustment).
If the Rider Sag still differs significantly you may need to replace the spring.
Warning: Incorrect spring rate may result is poor handling characteristics.
Preload Adjustment
Turn the adjuster screw to set the spring preload.
Turn clockwise to increase preload, turn anti clockwise to decrease.
To set the rider sag adjustment (see this chapter) turn the preload adjuster anti clockwise until it
stops, and then turn clock wise to the first audible click. From this click turn the preload adjuster
clockwise to the recommended position.
Note: One full turn of the preload adjuster equates to 1 mm of spring preload (the adjustable range is
15mm).
Preload – 3 full turns from fully out
Note: Increasing the amount of preload in the front forks will reduce the amount of both static and rider
sag. Reducing the preload will increase the sag values.
Adjust both the left and right hand forks in sequence to the same position.
Changing the spring preload will change the ride height and affect the handling.
It is critical that the spring preload is correctly set; if the spring preload is not correctly set all other
suspension adjustments may not give desired handling characteristics.
Compression Damping Adjustment
Note: Compression damping controls the energy absorbed
when the front wheel is being loaded or hits a bump.
Standard settings are based on a 90 kg rider (this includes
riding gear).
To adjust the compression damping turn the adjuster [A]
clockwise to increase damping, and anti clockwise to
decrease damping.
To reset the adjuster turn the adjuster clockwise to fully closed position (zero (0) position), then
turn anti clockwise to open.
Front Fork (Conventional) Compression Damping – 14 clicks out from fully closed
Caution: Do not force the damping adjuster, delicate sealing surfaces could be damaged.
247
Rebound Damping Adjustment.
Note: Rebound damping controls the energy absorption when the
fork is being extended and controls how fast the shock absorber
returns to its normal position after being compressed.
To adjust the damping, turn the adjuster [A] clockwise to
increase damping, anti clockwise to decrease it.
To reset the damping, turn the adjuster clockwise (right) to
fully closed position, and then anti clockwise (left) to the specified range.
Front Forks (Conventional) Rebound Damping – 16 Clicks out from fully closed
Warning: If both suspension units are not adjusted equally, handling may be impaired and a hazardous
condition may result.
Rebound Damping Recommended Adjustment Range
Rebound Adjustment Range: ± 5 clicks from original settings
Note: When setting up a motorcycle, the front suspension should be adjusted in line with the rear.
If the Spring rate, preload and ride height feel good but the bike rides low and sits down under
acceleration bumps, with lost line or lost comfort and traction.
Open the rebound adjuster two clicks.
If the bike is nervous / moving a lot or has a high feeling entering corners.
Close the rebound adjuster two clicks.
Fine tune by one click at a time
Caution: Always start from original factory settings and test run after making changes.
Compression Damping Recommended Adjustment Range
Compression Damping Range: ± 5 clicks from original settings
If the motorcycle feels soft / unstable or is using too much wheel travel and the spring rate is
correct.
Close the compression adjuster by one click. This will reduce the motorcycle from falling throught
the stroke too quickly.
If the motorcycle feels high / has poor grip when opening the throttle or does not feel smooth over
small bumps during acceleration.
Open the Compression Adjuster by one click.
A
248
Caution: Always start from original factory settings and test run after making changes, if improvements
have been made, repeate the procedure from the start again to check. Always check tire pressures before
making suspension adjustements and take note of the conditions such as air temperature.
Caution: Preventive maintenance and regular inspection reduces the risk of function disturbance.
Front Forks Cleaning
Clean the Fork unit externaly with a soft detergent. Using compressed air, ensure all dirt is
removed. Keep the forks clean and spray with a water displacing spray which will not deteriate the
rubber, after cleaning, wash off excessive oil with a cloth (DO NOT ALLOW ANY OIL TO FALL ONTO
THE BRAKING SYSTEM).
Caution: Never spray water directly into the adjuster units.
Fork Inspection
Check for excessive play or stiction.
Check the piston shaft for leakage and damage.
Check the Fork body for external damage.
Check for excessive wear of rubber components.
Check the attachment points between top yoke, bottom yoke, and wheel axle.
Convenctional Fork Removal
If the fork leg is to be disassembled, loosen the fork top
plug [A] beforehand. To loosen the fork top plug, remove
the handlebar (see Steering chapter) and loosen the fork
upper clamp bolts, and then slacken off the top plug.
Using a jack, raise the front wheel off the ground (see
Wheels/Tires chapter).
Support the front wheel weight.
Remove Brake calipers and hoses (see Braking System
chapter).
Remove the front wheel (see Wheels/ Tires chapter)
Remove the front mudguard.
Slacken the top pinch bolts off followed by the lower.
With a twisting motion, work the fork leg [A] down and
out.
Conventional Fork Installation
A
A
249
Install the fork tube so that the top of the fork outer tube [A] is flush with the upper surface of the
steering stem head [B].
Run the cables, wires, and hoses as shown in the Cable, Wire, and Hose Routing section of the
General Information chapter.
Install the front wheel (see Wheels/ Tires chapter).
Torque – Top Yoke Clamp Bolts: 20 Nm
Bottom Yoke Clamp Bolts: 20 Nm
Top Plug: Hand Tight
Brake Caliper Bolts: 35 Nm
Check the front brake after installation.
Warning: Do not attempt to ride the motorcycle until a full brake
lever is obtained by pumping the brake lever until the pads are
against the disc. The brake will not function on the first application
of the lever if this is not done.
Oil Draining/Filling
Remove any preload on the forks (see this chapter).
Loosen the top plug.
Remove the front fork (see Front Fork Removal).
Hold the inner tube in a soft jawed vise.
Unscrew the top plug out of the outer tube.
Remove the top nut assembly, top nut, spring preload tube the
spring seat and the spring.
Slowly compress the front fork fully.
Pull out the piston rod as far as possible and turn the
compression adjustment screw fully clockwise. This will keep
the piston rod in top position, which will make the continued
assembly easier.
Pour out the fork oil with the fork upside down.
Move the fork rod up and down at least ten times to expel the oil
from the fork.
Hold the fork tube upright; press the outer tube and the push rod all
the way down.
Note: Do not install the fork spring yet.
Fill the front fork to the specified amount.
250
Conventional Fork Oil:
Ohlins front fork fluid 01309
Conventional Fork Oil Viscosity:
SAE 5W 19 cSt
Conventional Fork Oil Capacity:
Approx. 488 cm³
Purge the air from the fork cylinder by gently moving the piston
rod up and down five times
Note: While doing this ensure the oil lever is topped up so stays near
the top of the inner tube.
Caution: Never extend the fork fully, since oil will be forced from between the tubes into the inner tube.
This raises the oil level in the inner tube. If the for is extended to the full length of its normal travel, the oil
level will raise above 30mm.
After purging the air from the fork, let it sit for about five minutes so that any suspended air
bubbles can surface.
Pull the push rod up slowly so as not to spill the fork oil out of the fork tube.
Install the spring, the spring seat, the preload tube and the nut. Be careful to put all parts back in
the same position as when the fork was disassembled.
Install the top nut assembly.
Tighten the top nut assembly hand tight.
Install the fork (see Front Fork Installation).
Set up the Preload, Compression damping, rebound damping.
Check the whole system to ensure proper operation.
Spring Tension
Note: Since the spring becomes shorter as it weakens, check its free length to determine the condition.
If the spring is shorter than the service limit, it must be replaced.
Conventional Fork Spring Length:
Standard: 250 mm ± 2 mm
Fork Disassembly
Remove the front forks for the motorcycle (see this chapter).
Hold the fork in a soft jawed vice [A]. A
251
Loosen the spring preload nut off fully by turning anti-clockwise.
Loosen the top nut assembly [A] off and remove.
Let the inner tube drop down and loosen the front fork bolt [A] of
the top cap from the cartridge shaft.
Remove the upper nut and spring preload tube.
Spring Seat
Spring
Remove the fork from the vice and pour the fork fluid out.
Note: Hold the adjustment rod in place to stop it falling out.
Secure the fork in the vice again and use Norton cartridge removal tool [A] to
loosen off the cartridge.
Unscrew the cartridge from the fork and remove it.
Changing Fork Seals and Bushings
Secure the fork bottom horizontally in a vice.
Loosen the dust seal [A] and circlip [B].
Using a heat gun heat the area around the seal and
bushings to approximately 100˚C.
Remove the Bushings, seal and washer by pulling
out swiftly.
Remove the bushing [A] from the inner tube.
Replace the bushings and seals
Note: To Install the bushings and seals use the
recommended Norton tool. Use a heat gun to
warm the outer tube.
Install the inner tube bushings by sliding them
over the tube end.
A
A
A
A B
A
A
252
Slide the inner tube into the outer tube.
Note: Earlier models of the front fork have two outer bushings. In this case, the lower bushing
should not be replaced after being removed, as it is not required for fork operation.
Slide the outer tube bushings in the outer
tube.
Using the Norton tool gently tap the outer
tube bushings into position.
Caution: Ensure that the bushing is set
tightly against the support inside the
outer tube.
Install the seal seat washer [A].
Apply some red grease on the outside of
the oil seal and install it with the Norton
tool turned in the opposite direction from how it was
used to tap the outer tube bushings.
Install the circlip.
Apply read grease onto the dust seal chamfer.
Install the dust seal by hand and press in place.
Fork Assembly
Fill fork fluid into the inner tube.
Fork Fluid - 488 cm³ of Ohlins front fork fluid (01309)
Push the piston up and down until the cartridge is
completely filled with fluid.
Reinstall the adjustment rod.
Note: Open the compression adjuster with a 3 mm Allen tool,
close the rebound fully with your thumb by pushing on the
adjustment rod before pumping procedure, this will make it
easier to bleed out the air from the damping system.
Install the spring with the marking number upwards.
Install:
Upper Spring Seat
Preload Tube
Piston Rod Nut
Torque – Piston Rod Nut: 25Nm
253
Apply red grease to the fork bolt and install it into the top nut.
Pull the piston rod upwards and screw it into the top nut assembly.
Use a 17mm wrench to keep a firm hold of the cartridge nut and the nut of the fork bolt.
Close the rebound valve fully. Use a 3mm allen tool. Push the fork leg up and down to check for
function.
Put the top nut assembly back into the fork leg. Use the Norton top nut tool and tighten it gently by
hand.
Adjust the Compression, rebound, and Preload.
Install the forks into the motorcycle (see this chapter).
Before riding, ensure the forks are set up identically and the forks perform as intended.
Front Forks Up Side Down (USD)
Spring Preload Adjustment
Warning: Ensure that the basic factory settings are intact before riding the motorcycle. If making
adjustments, only adjust one aspect at a time in small increments.
Note: Spring preload affects the ride height of the motorcycle and the fork angle.
If the measurements differ significantly from (Spring Preload – Static Sag – Rider – Sag), adjust the
spring preload (see Preload Adjustment).
If the Rider Sag still differs significantly you may need to replace the spring.
Warning: Incorrect spring rate may result is poor handling characteristics.
Preload Adjustment
Turn the adjuster screw to set the spring preload.
Turn clockwise to increase preload, turn anti clockwise to
decrease.
To set the rider sag adjustment (see this chapter) turn the
preload adjuster anti clockwise until it stops, and then turn
clock wise to the first audible click. From this click turn the
preload adjuster clockwise to the recommended position.
Note: One full turn of the preload adjuster equates to 1 mm of spring preload (the adjustable range is
15mm).
Preload – 3 full turns from fully out
Note: Increasing the amount of preload in the front forks will reduce the amount of both static and rider
sag. Reducing the preload will increase the sag values.
Adjust both the left and right hand forks in sequence to the same position.
A
254
Changing the spring preload will change the ride height and affect the handling.
It is critical that the spring preload is correctly set; if the spring preload is not correctly set all other
suspension adjustments may not give desired handling characteristics.
Compression Damping Adjustment
Note: Compression damping controls the energy absorbed when the front wheel is being loaded or hits a
bump. Standard settings are based on a 90 kg rider (this includes riding gear).
To adjust the compression damping turn the adjuster [A]
clockwise to increase damping, and anti clockwise to
decrease damping.
To reset the adjuster turn the adjuster clockwise to fully
closed position (zero (0) position), then turn anti
clockwise to open.
Front Fork (USD) Compression Damping – 16 clicks out
from fully closed
Caution: Do not force the damping adjuster, delicate sealing surfaces could be damaged.
Rebound Damping Adjustment.
Note: Rebound damping controls the energy absorption when
the fork is being extended and controls how fast the shock
absorber returns to its normal position after being compressed.
To adjust the damping, turn the adjuster [A] clockwise
to increase damping, anti clockwise to decrease it.
To reset the damping, turn the adjuster clockwise (right)
to fully closed position, and then anti clockwise (left) to
the specified range.
Front Forks (USD) Rebound Damping – 18 Clicks out from fully closed
Warning: If both suspension units are not adjusted equally, handling may be impaired and a hazardous
condition may result.
Rebound Damping Recommended Adjustment Range
Rebound Adjustment Range: ± 5 clicks from original settings
A
A
255
Note: When setting up a motorcycle, the front suspension should be adjusted in line with the rear.
If the Spring rate, preload and ride height feel good but the
bike rides low and sits down under acceleration bumps, with
lost line or lost comfort and traction.
Open the rebound adjuster two clicks.
If the bike is nervous / moving a lot or has a high feeling
entering corners.
Close the rebound adjuster two clicks.
Fine tune by one click at a time
Caution: Always start from original factory settings and test run after making changes.
Compression Damping Recommended Adjustment Range
Compression Damping Range: ± 5 clicks from original settings
If the motorcycle feels soft / unstable or is using too much wheel travel and the spring rate is
correct.
Close the compression adjuster by one click. This will reduce the motorcycle from falling throught
the stroke too quickly.
If the motorcycle feels high / has poor grip when opening the throttle or does not feel smooth over
small bumps during acceleration.
Open the Compression Adjuster by one click.
Caution: Always start from original factory settings and test run after making changes, if improvements
have been made, repeate the procedure from the start again to check. Always check tire pressures before
making suspension adjustements and take note of the conditions such as air temperature.
Caution: Preventive maintenance and regular inspection reduces the risk of function disturbance.
Front Forks Cleaning
Clean the Fork unit externaly with a soft detergent. Using compressed air, ensure all dirt is
removed. Keep the forks clean and spray with a water displacing spray which will not deteriate the
rubber, after cleaning, wash off excessive oil with a cloth (DO NOT ALLOW ANY OIL TO FALL ONTO
THE BRAKING SYSTEM).
Caution: Never spray water directly into the adjuster units.
Fork Inspection
Check for excessive play or stiction.
Check the piston shaft for leakage and damage.
Check the Fork body for external damage.
Check for excessive wear of rubber components.
Check the attachment points between top yoke, bottom yoke, and wheel axle.
256
USD Fork Removal
If the fork leg is to be disassembled, loosen the fork top plug beforehand. To loosen the fork top
plug, remove the handlebar (see Steering chapter) and loosen the fork upper clamp bolts [A], and
then slacken off the top plug.
Using a jack, raise the front wheel off the ground (see Wheels/Tires chapter).
Support the front wheel weight.
Remove Brake calipers and hoses (see Braking System chapter).
Remove the front wheel (see Wheels/ Tires chapter)
Remove the front mudguard.
Slacken the top pinch bolts off followed by the lower.
With a twisting motion, work the fork leg down and out.
USD Fork Installation (Cafe Racer)
Install the fork tube so that the top of the fork outer tube [A]
is flush with the upper surface of the steering stem head [B].
Run the cables, wires, and hoses as shown in the Cable, Wire,
and Hose Routing section of the General Information chapter.
Install the front wheel (see Wheels/ Tires chapter).
Torque – Top Yoke Clamp Bolts: 20 Nm
Bottom Yoke Clamp Bolts: 20 Nm
Top Plug: Hand Tight
Brake Caliper Bolts: 35 Nm
Check the front brake after installation.
Warning: Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake
lever until the pads are against the disc. The brake will not function on the first application of the lever if
this is not done.
Conventional Fork Installation (Sport and SE)
Install the fork tube so that the top of the fork outer tube [A] is 11mm above the upper surface of
the steering stem head [B].
Run the cables, wires, and hoses as shown in the Cable, Wire, and Hose Routing section of the
General Information chapter.
Install the front wheel (see Wheels/ Tires chapter).
Torque – Top Yoke Clamp Bolts: 20 Nm
Bottom Yoke Clamp Bolts: 20 Nm
Top Plug: Hand Tight
Brake Caliper Bolts: 35 Nm
A
B
A
257
Check the front brake after installation.
Warning: Do not attempt to ride the motorcycle until a full brake lever is
obtained by pumping the brake lever until the pads are against the disc. The
brake will not function on the first application of the lever if this is not done.
Oil Draining/Filling
Remove any preload on the forks (see this chapter).
Loosen the top plug.
Remove the front fork (see Front Fork Removal).
Hold the base of the forks in a soft jawed vise.
Unscrew the top plug out of the outer tube.
Remove the top nut assembly, spring support, spring, and preload
tube.
Slowly compress the front fork fully.
Pull out the piston rod as far as possible.
Pour out the fork oil with the fork upside down.
Move the fork rod up and down at least ten times to expel the oil from the fork.
Hold the fork tube upright; press the outer tube and the push rod all the way
down.
Note: Do not install the fork spring yet.
Fill the front fork to the top with the specified oil more than the
specified amount.
USD Fork Oil:
Ohlins front fork fluid 01309
USD Fork Oil Viscosity:
SAE5W 19 cSt
USD Fork Oil Capacity:
Approx. 500 mL
Purge the air from the fork cylinder by gently moving the piston
rod up and down five times
Note: While doing this ensure the oil lever is topped up so stays near the top of the inner tube.
258
Caution: Never extend the fork fully, since oil will be forced from between the tubes into the inner tube.
This raises the oil level in the inner tube. If the for is extended to the full length of its normal travel, the oil
level will raise above 30mm.
After purging the air from the fork, let it sit for about five minutes so that any suspended air
bubbles can surface.
Measure the oil level, using a fork oil level gauge.
Set the gauge stopper so that its lower side shows the oil level distance.
With the fork fully compressed, insert the gauge tube into the inner tube and position the stopper
across the top of the outer tube.
Pull the handle slowly to draw out the excess oil until no more oil comes up the tube.
If no oil is drawn out there is not enough oil in the fork. Pour in some more oil, then draw out the
excess.
USD Front Fork Oil Level (Fully compressed without fork spring):
150 ± 2 mm
Pull the push rod up slowly so as not to spill the fork oil out of the fork tube.
Install the spring, the spring seat, the preload tube and the nut. Be careful to put all parts back in
the same position as when the fork was disassembled.
Install the top nut assembly.
Tighten the top nut assembly hand tight.
Install the fork (see Front Fork Installation).
Set up the Preload, Compression damping, rebound damping.
Check the whole system to ensure proper operation.
Spring Tension
Note: Since the spring becomes shorter as it weakens, check its free length to determine the condition.
If the spring is shorter than the service limit, it must be replaced.
USD Fork Spring Length:
Standard: 250 mm ± 2 mm
USD Fork Disassembly
Carry out instructions from (Oil Draining / Filling) until the oil has been
drained.
Using Norton tool and a spanner loosen of the cartridge from the fork
leg and remove cartridge [A] and washer [B].
Drain any remaining oil. A
259
Remove the top cap lock nut [A] from the shaft. Remove
spring guide, spacer (if any) and bump rubber.
Push cap through the end cap/cylinder tube and the
base valve will fall out [B].
Remove o-ring, spacers (if any) and top-out spring [C]
from the shaft.
Fasten the shaft in a vice. Use Norton clamping tool.
Remove the piston and shim from the shaft. Place all
removed parts in correct order on the work bench.
Clean all parts thoroughly.
Loosen the piston holder from the shaft. Use a heat gun
to release the thread lock. Remove needle, spring and
adjustment rod.
Note: After using a heat gun, it is recommended to
replace the rebound needle o-ring.
On the base valve, remove the check valve, piston and shim. Place all
parts in correct order on work bench. Clean all parts thoroughly.
Note: Do not use strong solvent; it can damage the seals
and o-rings.
Replace Seals and Forks
B
A B
C
260
Place the outer fork leg upright on a bench with the seal side up.
Remove the scraper, circlip, oil seal and support washer.
Note: Use a flat tire lever and a rag to protect the edge of the fork leg when disassembling the seal.
Use a heat gun to heat the outer leg to approximately 100˚C, where the
bushings are positioned.
Remove the bushings by pushing them out using Norton tool.
Put the fork leg on a soft surface and tap the bar gently with a big plastic
hammer. Clean all parts thoroughly.
Install new bushings while the outer fork leg is still warm. Put the outer fork
leg on a soft surface with the seal side facing up.
Apply Loctite 648 on the outer fork leg upper bushing seat,
use a long brush. Use the Norton installing sleeve, guide
ring and attachment bar when installing the bushings. Tap the
attachment bar until the bushing reaches a solid stop.
Apply some red grease to the lower bushing seat on the outer fork
leg, before installation (no Loctite on the lower bushing). Install the
lower bushing in the same way as the upper. Use Norton installer
sleeve and attachment bar when installing the seal.
Apply a thin layer of red grease to the washer and the main seal. Install them into the outer fork leg
by hand. Install the circlip behind the seal.
Note: Use appropriate grease to achieve optimum fork function.
Apply red grease to the scraper seat and carefully press fit the scraper by hand.
USD Fork Assembly
Put the inner fork leg in a vice, clamp the fork bottom.
Apply some front fork oil to the inner fork tube surface
and carefully slide the outer fork leg all the way down.
Warning: Be careful not to damage the fork seals.
Install the cartridge into the fork bottom. Make sure the
washer [A] is attached below the base valve, and tighten
using Norton tool.
Torque - Cartridge USD forks: 20Nm
261
Fill the fork with approx 500ml of fork oil. Pump the shaft up and down to bleed out the air; Use
Norton tool.
Make sure all the air has been bled from below the piston.
Check and set the oil level (see this chapter).
Note: It is recommended that only the specified Ohlins front fork oil should be used.
Install the preload tube, spring (with markings facing up) and spring support.
Pull up the shaft, use Norton Spring compressor #1 tool
to contract the top out spring and install Norton Spring
Contraction tool to maintain contraction.
Replace pull-up tool with the top cap assembly to the
shaft. Make sure that the shaft bottoms in the
adjuster/top cap before tightening the lock nut.
Torque - Lock Nut USD Forks: 20Nm
Apply red grease on the top cap o-ring and threads, and install the top cap into the outer fork leg,
with the fork leg fully extended.
Torque – Top Cap USD Forks: 10Nm
Adjust the spring preload, compression and rebound valves (see this chapter).
Before riding, ensure the forks are set up identically and the forks perform as intended.
A
262
Swingarm
Swingarm Removal
Squeeze the brake lever slowly and hold it with a band [A].
Caution: Be sure to hold the front brake when removing the
swingarm or the motorcycle may fall over. The motorcycle could
be damaged.
Warning: Be sure to hold the front brake lever when removing the
swingarm, or the motorcycle may fall over. It could cause an
accident and injury.
Remove the rear brake hoses clips.
Remove the exhaust silencer and secondary (see Engine Top End chapter).
Lift the rear wheel of the motorcycle off the ground using a centre stand.
Remove:
Rear suspension (see this chapter).
Rear Wheel (see Wheels/Tires).
Mudguard.
Chain guard.
Remove the Swingarm pivot nut [A].
Pull out the Swingarm pivot shaft and remove the
Swingarm [B] rearward.
Swingarm Installation
Apply plenty of molybdenum disulfide grease to the inside of the needle bearings and sleeve.
Install the swing arm pivot and swing arm pivot washer and hand tighten the pivot nut.
Torque – Swingarm Pivot Nut: 60 Nm
Install:
Rear Wheel (see Wheels/Tires chapter)
Drive Chain (see Final Drive chapter)
Rear suspension (see this chapter)
Mudguard.
Chain guard.
Install exhaust silencer and secondary (see Engine Top End
chapter).
Install the rear brake hoses clips.
A
A
B
263
Torque – Rear Brake Line Hose clips: 7 Nm
Warning: Do not attempt to ride the motorcycle until a full brake pedal is obtained by pumping the brake
pedal until the pads are against the disc. The brake will not function on the first application of the pedal if
this is not done.
Swingarm Bearing Removal
Remove the Swingarm (see this chapter).
Remove the RH grease seals [A].
Remove the RH spacer [B].
Remove the centre spacer [A] from the swing arm.
Using a bearing puller remove the needle roller bearing
assembly [A] from the RH side.
Remove the LH seal [A] and spacer [B].
B
A
A
A
A B
264
Remove the Circlip [A] from the LH side of the swing arm.
Using a bearing puller remove the two roller bearings [A]
from the LH side.
Swing Arm Bearing Installation
Apply molybdenum disulfide grease to two roller
bearings [A] and using a press, install (smaller diameter
side).
Install circlip and grease seal and LH spacer.
Install the RH Bearing using plenty of molybdenum
disulfide grease with a press.
A
A
A
265
Be sure to install the needle roller bearings with manufactures mark pointing outwards.
Install the centre spacer, RH seal and RH spacer.
Swingarm Pivot Check
Check the pivot of the Swingarm and suspension mounting
points.
Raise the rear wheel off the ground (see Wheels/Tires
chapter).
Move the Swingarm [A] up and down to check for abnormal
friction, and push and pull it to check for bearing play.
A small amount of play on the pivot is normal and no
corrective action is needed. However, if excessive play is felt, check the Swingarm and suspension
link bearings for wear and replace them if necessary.
Warning: Installation of new bearings in the Swingarm may cause too stiff rear suspension. Test ride the
motorcycle slowly and prudently until the suspension becomes normal.
Swingarm Bearing, Sleeve Inspection
The rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of
measuring, inspect the bearing in the Swingarm for abrasion, colour change, or other damage.
If there is any doubt as to the condition of any of the needle bearings or sleeves, replace all the sleeves, and needle
bearings as a set.
A
266
Steering
Exploded View ................................................................................................................................................ 257
Steering .......................................................................................................................................................... 265
Steering Inspection ............................................................................................................................ 265
Steering Adjustment .......................................................................................................................... 265
Handlebar ....................................................................................................................................................... 266
Handlebar Removal ............................................................................................................................ 266
Handlebar Installation ........................................................................................................................ 267
Steering Stem ................................................................................................................................................. 267
Steering Stem Removal ...................................................................................................................... 267
Steering Stem Installation .................................................................................................................. 268
Steering Stem Warp ........................................................................................................................... 269
Steering Stem Bearing.................................................................................................................................... 269
Stem Bearing Removal ....................................................................................................................... 269
Stem Bearing Installation ................................................................................................................... 269
Stem Bearing Lubrication ................................................................................................................... 269
267
Exploded View
268
269
270
271
REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
24 STANCHION ASSY, RH -> OHLINS RWU
NUT
SPACER, SPRING
WASHER, SPRING SPACER
NUT, CAP ASSY
SPRING
CYLINDER
TUBE, OUTER
SEAL DUST
SNAP RING
SEAL, OIL
WASHER, OIL SEAL
TUBE, INNER, RH
SEALING WASHER
CAPSCREW, OIL LOCK
23 STANCHION ASSY, LH -> OHLINS RWU
NUT
SPACER, SPRING
WASHER, SPRING SPACER
NUT, CAP ASSY
SPRING
CYLINDER
TUBE, OUTER
SEAL DUST
SNAP RING
SEAL, OIL
WASHER, OIL SEAL
TUBE, INNER, LH
SEALING WASHER
CAP SCREW, OIL LOCK
9 STANCHION ASSY, LH, USD, 11mm PULL THROUGH
NUT
SPACER, SPRING
WASHER, SPRING SPACER
NUT, CAP ASSY
SPRING
CYLINDER
TUBE, OUTER
SEAL DUST
SNAP RING
SEAL, OIL
WASHER, OIL SEAL
TUBE, INNER, RH
SEALING WASHER
272
CAP SCREW, OIL LOCK
10 STANCHION ASSY, RH, USD, 11mm PULL THROUGH
NUT
SPACER, SPRING
WASHER, SPRING SPACER
NUT, CAP ASSY
SPRING
CYLINDER
TUBE, OUTER
SEAL DUST
SNAP RING
SEAL, OIL
WASHER, OIL SEAL
TUBE, INNER, LH
SEALING WASHER
CAP SCREW, OIL LOCK
BOLT, CAP HD, M8 X 25 20 PINCH BOLT SUPPLIED WITH FORKS
9 STANCHION ASSY, LH, USD, 11mm PULL THROUGH REFER TO PROCESS
SHEET
NUT
SPACER, SPRING
WASHER, SPRING SPACER
NUT, CAP ASSY
SPRING
CYLINDER
TUBE, OUTER
SEAL DUST
SNAP RING
SEAL, OIL
WASHER, OIL SEAL
TUBE, INNER, RH
SEALING WASHER
CAP SCREW, OIL LOCK
10 STANCHION ASSY, RH, USD, 11mm PULL THROUGH REFERTO PROCESS SHEET
NUT
SPACER, SPRING
WASHER, SPRING SPACER
NUT, CAP ASSY
SPRING
CYLINDER
TUBE, OUTER
SEAL DUST
SNAP RING
SEAL, OIL
WASHER, OIL SEAL
TUBE, INNER, LH
273
SEALING WASHER
CAP SCREW, OIL LOCK
BOLT, CAP HD, M8 X 25 20 PINCH BOLT SUPPLIED WITH FORKS
11 LOWER YOKE, USD FORKS
12 BOLT, CAP HD, M8 X 20 X 1.25 20 LOWER YOKE CLAMP BOLTS
13 STEERING STEM
14 BEARING, TAPERED ROLLER HEADSTOCK BEARINGS
15 SEAL, HEADSTOCK, LOWER BEARING
25 LOWER YOKE, BILLET
LOWER YOKE FOR CONVENTIONAL
FORKS
12 BOLT, CAP HD, M8 X 20 X 1.25 20 LOWER YOKE CLAMP BOLTS
52 LOWER HEADSTOCK SPACER YOKE SPACER FOR CONVECTIONAL FORKS
GREASE, SILKOLENE, PRO RG2
32 SWITCH CUBE, LH ECIE
SCREW, M5 X 40 3
SCREW, M5 X 30 3
33 SWITCH CUBE, RH
SCREW, M5 X 22 3
34 HANDLEBAR, TUBULAR, TAPERED ALUMINIUM
35 GRIP, HANDLEBAR, LH
36 GRIP, HANDLEBAR, RH
37 THROTTLE ACTUATOR, TWIN CABLE 4
38 BOLT, CAP HD, M6 X 20 x 1.0 8 THROTTLE ACTUATOR CLAMP
39 CLAMP, CLIP-ON, RH, CLEAR ANODISE
40 CLAMP, CLIP-ON, LH, CLEAR ANODISE
52 PIN, PARALLEL, 4.0 X 18.0MM, SOLID,
STAINLESS
USED AS ANTI ROTATION FEATURE
41 HANDLEBAR, CLIP-ON, LH, CLEAR
ANODISE
42 HANDLEBAR, CLIP ON, RH, CLEAR ANODISE
43 BOLT, CAP HD, M6 X 20 x 1.0, DIN
912, SS 15
USED TO PINCH HANDLEBAR
49 20 USED TO PINCH CLAMP
51 CABLE, THROTTLE, TWIN THROTTLE CABLES FOR HIGH BARS ONLY
BRASS BARREL NIPPLE 5.75MM DIA X
5.5MM LENGTH
OPEN CABLE GUIDE
CLOSE CABLE GUIDE
FERRULE
RUBBER BOOT
OPEN CABLE, 6MM OD, OUTER
CONDUIT, 795MM
OPEN CABLE, 1.5MM OD, INNER WIRE, 1030MM
CLOSE CABLE, 6MM OD, OUTER
CONDUIT, 795MM
CLOSE CABLE, 1.5MM OD, INNER WIRE, 1030MM
ADJUSTER
274
LOCK NUT
BRASS BARREL NIPPLE 6MM DIA X
8MM LENGTH
50 CABLE, THROTTLE, TWIN, CLIP-ONS THROTTLE CABLES FOR LOW BARS ONLY
BRASS BARREL NIPPLE 5.75MM DIA X 5.5MM LENGTH
OPEN CABLE GUIDE
CLOSE CABLE GUIDE
FERRULE
RUBBER BOOT
OPEN CABLE, 6MM OD, OUTER CONDUIT, 795MM
OPEN CABLE, 1.5MM OD, INNER
WIRE, 1030MM
CLOSE CABLE, 6MM OD, OUTER CONDUIT, 795MM
CLOSE CABLE, 1.5MM OD, INNER
WIRE, 1030MM
ADJUSTER
LOCK NUT
BRASS BARREL NIPPLE 6MM DIA X
8MM LENGTH
28 WEIGHT, BAR END
29 RUBBER MOUNT, BAR END
30 BOLT, CAP HD, M6 X 40 x 1.0 BAR END MOUNT TO HANDLE BAR
31 LOCKNUT, FLANGED, SERRATED FACE, M6
BAR END MOUNT TO HANDLE BAR
22 TOP YOKE, USD FORKS CAFE RACER RACER TOP YOKE
12 BOLT, CAP HD, M8 X 20 X 1.25 20NM TOP YOKE CLAMP BOLTS
16 TOP YOKE, USD FORKS, HIGH BARS CSE-03 TOP YOKE
17 BOLT, CAP HD, M8 X 20 X 1.25 20NM TOP YOKE CLAMP BOLTS
18 SEAL, HEADSTOCK
26 YOKE, UPPER ASSY, BILLET TOP YOKE FOR CONVENTIONAL FORKS
27 BOLT, CAP HD, M8 X 20 X 1.25 20NM TOP YOKE CLAMP BOLTS CONVENTIONAL FORKS
19 NUT, UPPER YOKE, M25 80NM TOP YOKE LOCK NUT
20 LOCKNUT, M25 6 ADJUSTER NUT 40NM TO SEAT BEARINGS, BACKED OFF, THEN RE-TORQUED TO 6
NM
21 INTERMEDIATE NUT, M25 40 LOCKED UP TO ADJUSTER NUT 40 NM
44 CLAMP, HANDLEBAR, LOWER
45 BOLT, CAP HD, M10x30X1.5 HANDLEBAR CLAMP TO YOKE
46 NUT, M10 X 1.5 43 HANDLEBAR CLAMP TO YOKE
55 WASHER, M10, 10.5 X 20 X 2
47 CLAMP, HANDLEBAR, UPPER
48 BOLT, CAP HD, M8 X 22 X 1.25 20 UPPER HANDLE BAR CLAMPS BOLTS
275
Steering
Steering Inspection
Raise the front wheel off the ground.
With the front wheel pointing straight ahead, alternately
nudge each end of the handlebar. The front wheel should
swing fully left and right from the force of gravity until
the fork hits the stop.
If the steering binds or catches before the stop, check the
routing of cables, hoses, and harnesses.
If the steering feels tight, adjust or lubricate the steering.
Feel for steering looseness by pushing and pulling the
fork [A].
If you feel looseness, adjust the steering.
Steering Adjustment
With the front wheel raised off the ground remove:
Top Yoke Clamp Bolts (loosen)
Handlebar, place on one side with cables, harnesses and
hoses installed (not applicable for cafe racer).
Steering Stem Head Nut [A].
Remove the top yoke [B].
Slacken off the steering stem adjuster lock nut [A].
Tighten steering stem adjuster nut [A] to 40Nm to settle
the bearings then slacken off.
Re-tighten steering stem adjuster nut [A].
Torque: Steering Stem Adjuster Nut – 8Nm
If the steering is too tight, loosen the stem nut a fraction
of a turn. If the steering is too loose, tighten the nut a
fraction of a turn.
276
Note: Turn the stem nut 1/8th of a turn at a time maximum.
Check the steering again.
If the steering is still too tight or too loose in spite of correct adjustment, inspect the steering stem
parts.
Tighten steering stem adjuster lock nut.
Torque – Steering Stem Locknut: 40 Nm
Install the parts removed.
Handlebar (see this chapter).
Torque – Steering Stem Head Nut: 85Nm
Front Fork Top Yoke Clamp Bolts: 20Nm
Handlebar
Handlebar Removal (Sport and SE)
Remove:
Lighting Switch [A]
Engine stop switch [B]
Clutch Lever Assembly [C]
Brake Lever Assembly [D]
Throttle Twist Grip [E]
Unscrew the handlebar clamp bolts[F] , and take off the top
clamps and the handle bar
Handlebar Removal (Cafe Racer)
Remove:
Lighting Switch [A]
Engine stop switch [B]
Clutch Lever Assembly [C]
Brake Lever Assembly [D]
Throttle Twist Grip [E]
Unscrew the handlebar clamp bolts [F] completely, and
take off the handle bars using a twisting motion.
277
Handlebar installation (Sport and SE)
Install the handlebar, top clamps, and bolts as shown.
Align bars to suit preference.
Tighten the holder front bolt [A] first and then the rear
bolts [B]. When the holder is correctly installed, there will
be an even gap [C] at the rear and no gap at the front [E]
after tightening.
Torque – Handlebar clamp Bolts: 20 Nm
Ensure all cables, hoses, and wires are routed correctly
and the idle does not change at full lock on each side.
Handlebar installation (Cafe Racer)
Install the handle bar and clamp bolts as shown.
Align bars to suit preference.
Torque – Handlebar Camp Bolts: 15 Nm
Ensure all cables, hoses, and wires are routed correctly
and the idle does not change at full lock on each side.
Steering Stem
Steering Stem Removal
Remove:
Handlebar (see this chapter)
Head light (see Electrical System chapter)
Head light brackets
Raise the front wheel off the ground (see Wheels/Tires
chapter).
Remove:
Top Yoke Camp Bolt [A]
Top Yoke Pinch Bolts [B]
Push up the top yoke and remove it.
Remove:
278
Front wheel (see Wheels/Tires chapter)
Front Mudguard and Front Forks.
Remove stem locking nut and stem adjuster nut.
Remove seal and top head stock bearing.
Remove bottom yoke [A] with stem [B] down from the motorcycle.
Steering Stem Installation
Rout the cables, wires, and hoses as shown in the Cable,
Wire, and Hose Routing section of the General
Information chapter.
Apply grease to the head stock bearings and install the
lower yoke with stem and spacer and bottom head stock
bearing installed.
Install the upper bearing on the stem shaft while pushing
up on the stem base.
Install the stem seal and stem bearing adjustment nut
and hand tighten.
Tighten steering stem adjuster nut [A] to 40Nm to settle
the bearings then slacken off.
Re-tighten steering stem adjuster nut [A].
Torque: Steering Stem Adjuster Nut – 6Nm
Tighten steering stem adjuster lock nut.
Torque – Steering Stem Locknut: 40 Nm
Install the parts removed.
Top Yoke (see this chapter)
Front Fork (see Suspension chapter)
Front wheel (see Wheels/Tires chapter)
Handlebar (see this chapter)
Head Light (see Electrical System chapter)
Check and adjust the following items after installation:
Steering (see this chapter)
Throttle Cables (see Fuel System chapter)
Headlight Aim
Front Brake
279
Warning: Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake
lever until the pads are against the disc. The brakes will not function on the first application of the lever if
this is not done.
Steering Stem Warp
Whenever the steering stem is removed, or if the
steering cannot be adjusted for smooth action, check the
steering stem for straightness.
If the steering stem [A] is bent, replace the steering stem.
Steering Stem Bearing
Steering Stem Bearing Removal
Remove the steering stem (see this chapter).
Drive out the bearing outer races from the head pipe.
Note: If Either Bearing is damaged, it is recommended that both the upper and lower bearings (including
outer races) be replaced with new ones.
Remove the lower inner race [A] which is pressed onto the steering stem with a wedge.
Steering Stem Bearing Installation
Replace the bearing outer races with new ones.
Apply grease the outer races, and drive them into the head pipe at the same time.
Replace the stem bearing inner races with new ones.
Apply grease to the lower inner race, and drive it onto the stem.
Install the steering stem.
Install the upper bearing on the stem shaft while pushing up on the stem base.
Install the stem seal and stem bearing adjustment nut and hand tighten.
Tighten steering stem adjuster nut [A] to 40Nm to settle the bearings then slacken off.
Re-tighten steering stem adjuster nut [A].
Torque: Steering Stem Adjuster Nut – 8Nm
Tighten steering stem adjuster lock nut.
Torque – Steering Stem Locknut: 40 Nm
Steering Stem Bearing Lubrication
A
280
Note: In accordance with the Periodic Maintenance Chart, lubricate the steering stem bearings.
Remove the steering stem.
Using a high-flash point solvent, wash the upper and lower tapered roller bearings in the cages, and
wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean of
grease and dirt.
Visually check the outer races and the rollers.
Replace the bearing assemblies if they show wear or damage.
Pack the upper and lower tapered roller bearings [A] in the cages with grease, and apply a light coat
of grease the upper and lower outer races.
Install the steering stem, and adjust the steering
281
Frame
Exploded View ................................................................................................................................................ 272
Seat ................................................................................................................................................................ 282
Seat Removal ..................................................................................................................................... 282
Seat Installation ................................................................................................................................. 282
Number Plate Hanger .................................................................................................................................... 283
Number Plate Hanger Removal.......................................................................................................... 283
Number Plate Hanger Installation ..................................................................................................... 283
Rear Bodywork ............................................................................................................................................... 283
Rear Bodywork Removal .................................................................................................................... 283
Rear Bodywork Installation ................................................................................................................ 283
Foot Control Frames ...................................................................................................................................... 283
Foot control Frame removal .............................................................................................................. 283
Foot control Frame installation ......................................................................................................... 283
282
Exploded View
283
REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
1 FRAME ASSEMBLY, SINGLE SEAT XM
20 CABLE TIE, 120MM X 3.6MM, FIR-TREE,
BLACK
CLAMP DIRECT TO FRAME, CLUTCH HOSE,
HARNESS
2 OIL FILLER CAP
3 O-RING, OIL FILLER CAP, 2.4MM SITS INSIDE OIL FILLER CAP
4 DIPSTICK
5 BRACKET, ENGINE, FRONT, STEEL, XM
6 SPACER, ENGINE MOUNT, RHS,
ALUMINIUM
7 SPACER, ENGINE MOUNT, LHS, ALUMINIUM
8 BOLT CAP HD, M8 X 57 X 1.25 TO CLAMP ENGINE MOUNT BRACKET
9 WASHER, M8, 8.4 X 16 X 1.6 TO CLAMP ENGINE MOUNT BRACKET
10 26 TO CLAMP ENGINE MOUNT BRACKET
11 BOLT, M12, ENGINE, FRONT MOUNT FRONT ENGINE MOUNT BOLT
12 WASHER, M12, 13 X 24 X 2.5 USED WITH ENGINE BOLT AND NUT
13 LOCKNUT, M12 X 1.75
85 NUT, USED WITH ENGINE MOUNT BOLT
14 FRAME ADJUSTER, M24 15
15 BOLT, M12, ENGINE, REAR MOUNT 85 REAR ENGINE MOUNT BOLT
17 VIN PLATE, UK (NOW WHOLE WORLD)
18 RIVET, HAMMER DRIVE, 3/8TH TO FIX VIN PLATE TO FRAME
19 SLEEVE, NYLON, FRAME PROTECTOR
USED BETWEEN FRAME AND FOOTREST
HANGER
284
Body Work
285
286
287
288
REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
EXTENSION, REAR MUDGUARD
EXTENSION, REAR MUDGUARD
EXTENSION, REAR MUDGUARD
1 MUDGUARD, USD, CARBON CARBON FIBRE FOR CSE-03
2 BOLT, BUTTON HD, INT HEX M6 X 16 X 1.0
FRONT MUDGUARD BOLT RWU FORKS
3 BOLT, BUTTON HD, INT HEX M6 X 20 X 1.0 FRONT MUDGUARD BOLT
4 LOCKNUT, FLANGED, M6 X 1.0 FRONT MUDUARD NUT
5 WASHER, PENNY, M6, 6.4 X 18 X 1.6
USED WITH FRONT MUDGUARD BOLTS
6 MUDGUARD BRACKET, USD FORKS, LH, XM
7 MUDGUARD BRACKET, USD FORKS, RH, XM
8 BOLT, BUTTON HD, M5 x 12 x 0.8
USED WITH MUDGUARD BRACKETS
9 WASHER, M5, 5.3 X 10 X 1 USED WITH BRACKET BOLTS
41 VENTURE SHIELD KIT, BODYWORK PROTECTION BODYWORK PROTECTION
10 MUDGUARD, FRONT, CARBON CARBON FIBRE FOR CSE-01/02
11 BRACKET, MUDGUARD, CONVENTIONAL OHLINS PART, GOLD, CONVENTIONAL FORKS
10 MUDGUARD, FRONT, GALACTIC BLACK, CONVENTIONAL FORKS
10 MUDGUARD, FRONT, ROYAL RED, CONVENTIONAL
FORKS
10 MUDGUARD, FRONT, CANARY YELLOW, CONVENTIONAL FORKS
10 MUDGUARD, FRONT, FACTORY SPECIAL SILVER,
CONVENTIONAL FORKS
1 MUDGUARD, GALACTIC BLACK, USD FORKS
1 MUDGUARD, FRONT, ROYAL RED, USD FORKS
1 MUDGUARD, FRONT, CANARY YELLOW, USD
FORKS
1 MUDGUARD, FRONT, FACTORY SPECIAL SILVER, USD FORK
42 BATTERY BOX, STEEL, XM STEEL FABRICATION
43 BRACKET, TWIN RELAY, XM
44 BOLT, BUTTON HD, M6 X 16 BATTERY BOX TO FRAME
45 WASHER, M6, 6.4 X 12 X 1.6 USED WITH FRONT BATTERY BOX BOLT
32 NUMBER PLATE HANGER, CF CARBON FIBRE FOR SE
33 BRACKET, NUMBER PLATE, MOULDED PLASTIC MOULDED HANGER
34 NUMBER PLATE BRACKET, STEEL, XM
35 P-CLIP, 13MM TO MOUNT REAR HARNESS
36 WASHER, PENNY, M6, 6.4 X 18 X 1.6 USED WITH HANGER BOLTS
37 BOLT, CAP HD, M6 X 30 NUMBER PLATE BRACKET + HANGER BOLTS
38 GROMMET, RUBBER, 14MM PROTECTION FOR HARNESS HOLE
39 BOLT, BLACK, M5 X 20 NYLON NUMBER PLATE BOLT
289
23 BOLT, YELLOW, M5 X 20 NYLON NUMBER PLATE BOLT
24 NUT, BLACK, M5 NYLON NUMBER PLATE NUT
32 NUMBER PLATE HANGER, CF CARBON FIBRE
25 REAR BODYWORK, MLD AS RECIEVED FROM ACERBIS
26 BOLT, CAP HD, M6 X 30 REAR BODY WORK FRONT BOLTS
27 WASHER, PENNY, M6, 6.4 X 18 X 1.6 USED WITH REAR BODY WORK BOLTS
28 RUBBER MOUNT, REAR BODYWORK REAR BODY WORK RUBBER
MOUNTS
25 PANEL, REAR, GALACTIC BLACK, GOLD TEXT
25 PANEL, REAR, ROYAL RED, GOLD TEXT
25 PANEL, REAR, CANARY YELLOW, BLACK TEXT
25 PANEL, REAR, FACTORY SPECIAL SILVER, BLACK
TEXT/BORDER RED PIN STRIPE
25 PANEL, REAR, FACTORY SPECIAL SILVER, BLACK TEXT
29 SEAT, RIDER, FORMED
RUBBER FOOT, SEAT
31 BOLT, CAP HD, M6 X 50 X 1.0 SEAT TO FRAME
40 GROMMET, ID 14 X OD 9.0 X 12.5MM SEAT TO BODY WORK
30 SEAT, RIDER, FORMED, VINYL
RUBBER FOOT, SEAT
12 FLYSCREEN, CARBON CARBON
13 BOLT, BUTTON HD, M5 X 16
TO MOUNT FLY SCREEN TO BRACKET
14 LOCKNUT, FLANGED, M5 X 0.8
TO MOUNT FLY SCREEN TO
BRACKET
15 FLYSCREEN BRACKET, LH, XM
16 FLYSCREEN BRACKET, RH, XM
12 FLYSCREEN, ROYAL RED, STANDARD RED FLYSCREEN
12 FLYSCREEN, CANARY YELLOW, STANDARD YELLOW FLYSCREEN
12 FLYSCREEN, FACTORY SPECIAL, SILVER SILVER FLYSCREEN
12 FLYSCREEN, GALACTIC BLACK BLACK FLYSCREEN
12 FLYSCREEN, ROYAL RED, STANDARD FOR ACCESSORY ONLY
12 FLYSCREEN, CANARY YELLOW, STANDARD FOR ACCESSORY ONLY
12 FLYSCREEN, FACTORY SPECIAL, SILVER FOR ACCESSORY ONLY
12 FLYSCREEN, GALACTIC BLACK FOR ACCESSORY ONLY
15 FLYSCREEN BRACKET, LH, XM FOR ACCESSORY ONLY
16 FLYSCREEN BRACKET, RH, XM FOR ACCESSORY ONLY
17 CHAINGUARD, CARBON, LARGE
18 HUGGER, CARBON
19 HUGGER, MOULDED
20 BOLT, CAP HEAD, M5 X 15 X 0.8 7 TO BOLT HUGGER
21 WASHER, PENNY, M5, 5.3 X 15 X 1.2 USED WITH HUGGER + CHAIN GUARD BOLTS
22 CHAIN GUARD, STEEL
SNAP RING
SEAL, OIL
290
WASHER, OIL SEAL
TUBE, INNER, LH
SEALING WASHER
CAPSCREW, OIL LOCK
BOLT, CAP HD, M8 X 25 20 PINCH BOLT SUPPLIED WITH FORKS
291
REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
1 FOOT CONTROL FRAME, LH, XM STEEL FABRICATION
2 FOOT CONTROL FRAME, RH, XM STEEL FABRICATION
3 BOLT CAP HD, M8 X 50 X 1.25 27 FOOT CONTROL FRAME TO FRAME ASSY
4 BALL JOINT - NIPPLE ASSY, M6
5 CONTROL PLATE, LH, BILLET
6 CONTROL PLATE, RH, BILLET
7 BOLT, CAP HD, M6 X 20 x 1.0
8 LOCKNUT, M6 X 1.0
9 ROD, GEAR LINKAGE
10 PEDAL, ASSY, GEAR/REAR BRAKE,
FORGED GEAR CHANGE AND BRAKE LEVER
11 NUT, M6 × 1.0, PLAIN FOR GEAR CHANGE
38 PLATE TO GEAR ROD ASSY
12 BOLT, CAP HD, M6 X 16 x 1.0
LOCATED IN ARM, GEAR SELECTOR,
SPLINED
13 PEDAL, GEAR/REAR BRAKE, FORGED
14 PIN, CLEVIS, FOOTPEG 6MM PIN BETWEEN FOOT PEG AND CLEVIS
15 CLEVIS, RH
16 FOOTPEG, TURNED
17 FOOTPEG, RUBBER
18 BALL BEARING, FOOTPEG
19 SPRING, FOOTPEG
20 FOOTPEG PLATE, ANTI ROTATION, XM ANTI ROTATION WASHER BETWEEN CLEVIS AND CONTROL PLATE
39 WASHER, M10, 10.5 X 20 X 2 WASHER TO GO BETWEEN ANTI ROTATION PLATE AND M10 NUT
21 LOCKNUT, M10 X 1.5 40 TO CLAMP CLEVIS + PEG ASSY TO CONTROL PLATE
22 FOOT PEG, TOE, TURNED
23 BOLT, CAP/HD, M6 X 40 10 TO CLAMP TOE PEG TO PEDAL
24 FOOT PEG, TOE, RUBBER
25 PLATE, ACTUATOR, REAR BRAKE, XM
26 BOLT, CSK HD, M4 X 0.7 X 12 7 TO CLAMP PLATE TO PEDAL
27 PLATE, ROD ASSY, GEAR PEDAL BOLTED ONTO PEDAL, GEAR REAR BRAKE FORGED
28 SIDESTAND, FABRICATED, XM FABRICATED STEEL
29 SPRING, SIDE STAND
30 PIVOT BOLT, SIDE STAND 20 USE THREE BOND 1327
31 SWITCH, SIDE STAND
32 BOLT, BUTTON HD, INT HEX, M6 X 25
X 1.0 USED TO CLAMP SIDE STAND SWITCH TO PIVOT BOLT
33 SPACER, SWITCH, SIDE STAND USED AS COMPRESSION LIMITER IN SWITCH
40 SIDE STAND STOP, 19mm
GREASE, SILKOLENE, PRO RG2 APPLY TO PIVOT FACES
34 BOLT, LOW CAP HD, M4 X 10 X 0.7 USED TO BOLT PLATE ROD ASSY GEAR PEDAL
35 ARM, GEAR SELECTOR, SPLINED, MACHINED
USED TO CONNECT TO GEAR CHANGE SHAFT
36 5MM E-CLIP USED TO HOLD PIN CLEVIS IN
37 CLEVIS, LH, GEAR, PEDAL PIVOT USED ON GEAR SIDE ONLY
292
OIL / GREASE
Seat
Seat Removal
Remove the Seat bolts [A] on both sides.
Pull the seat forward and up [B].
Seat installation
Slip the seat hook [A] under the rear seat and into the
location hole [B].
Tighten the seat bolts.
Torque - Seat Bolts: 8 Nm
Number plate hanger
Number plate hanger Removal
Remove the number plate hanger bolts [A] and lower the
number plate.
Disconnect the rear indicators and brake light and remove
number plate hanger.
Number Plate Hanger Installation
Connect the indicators and rear bracket light and push the
connector into the rear body work.
Whilst holding the number plate hanger up install the
number hanger bracket bolts and hand tighten.
Torque – Number plate bracket bolts: 8 Nm
293
Rear Bodywork
Rear Bodywork Removal
Remove the number plate hanger (see this chapter).
Remove seat (see this chapter).
Remove the remaining rear bodywork bolts [A].
Disconnect the ECU, Fuse Box, Relay box, and rear lighting
(see Electrical System chapter).
Remove the rear bodywork.
Rear Bodywork Installation
Install the rear bodywork.
Connect the ECU, Fuse Box, Relay Box, and Rear Lighting
(see Electrical System chapter).
Install the front, rear body work bolts [A]
Torque: rear body work bolts: 8Nm
Install the number plate hanger (see this chapter).
Install the rear seat (see this chapter)
Foot control Frames
Foot control Frame removal
Remove rear brake master cylinder assembly (see Brakes
chapter)
Remove foot control frame bolts [A]
Remove the foot control frames.
Foot control Frame installation
Install the foot control frame bolts and tighten
Torque – Foot control frame bolts: 27Nm
Install rear brake master cylinder assembly (see Brakes chapter)
294
Electrical System
Exploded View ................................................................................................................................................ 286
Parts Location ................................................................................................................................................ 301
Wiring Diagram .............................................................................................................................................. 302
Specifications ................................................................................................................................................. 303
Precautions .................................................................................................................................................... 304
Electrical Wiring ............................................................................................................................................. 304
Wiring Inspection ........................................................................................................................................... 304
Battery ............................................................................................................................................................ 305
Battery Removal ................................................................................................................................. 305
Battery Installation ............................................................................................................................. 305
Electrolyte Filling (Convectional Battery Only ................................................................................... 350
Initial Charge ...................................................................................................................................... 305
Precautions ........................................................................................................................................ 350
Charging Condition Inspection ........................................................................................................... 306
Refreshing Charge .............................................................................................................................. 306
Alternator ....................................................................................................................................................... 307
Alternator Cover Removal.................................................................................................................. 307
Alternator Cover Installation ............................................................................................................. 307
Alternator Rotor Removal .................................................................................................................. 307
Alternator Rotor Installation .............................................................................................................. 307
Alternator Stator Removal ................................................................................................................. 308
Alternator Stator Installation ............................................................................................................. 308
Charging System ............................................................................................................................................. 309
Regulator / Rectifier Removal ............................................................................................................ 309
Regulator Rectifier / Output Voltage Inspection ............................................................................... 309
Regulator / Rectifier Inspection ......................................................................................................... 310
Ignition System .............................................................................................................................................. 311
Spark Plug Removal / Installation ...................................................................................................... 311
Spark Plug cleaning / Inspection ........................................................................................................ 311
Spark Plug Gap ................................................................................................................................... 311
Ignition Coil Removal ......................................................................................................................... 311
Ignition Coil Installation ..................................................................................................................... 311
Ignition Coil Inspection ...................................................................................................................... 312
Pickup Coil Removal ........................................................................................................................... 313
Pickup Coil inspection ........................................................................................................................ 313
Rotor Inspection ................................................................................................................................. 313
ECU ................................................................................................................................................................. 313
ECU Unit Removal .............................................................................................................................. 313
ECU Unit Inspection ........................................................................................................................... 314
ECU Unit Installation .......................................................................................................................... 314
Electric Starter System .................................................................................................................................. 314
295
Starter Motor Removal ...................................................................................................................... 314
Starter Motor Installation .................................................................................................................. 315
Starter Relay, Inspection .................................................................................................................... 315
Starter Circuit Relay Inspection .......................................................................................................... 315
Lighting System .............................................................................................................................................. 316
Headlight Beam Vertical Adjustment ................................................................................................. 316
Headlight Beam Horizontal Adjustment ............................................................................................ 316
Headlight Bulb Replacement .............................................................................................................. 316
Headlight Unit Removal ..................................................................................................................... 317
Headlight Unit Installation ................................................................................................................. 317
Taillight Bulb Replacement ................................................................................................................ 317
License Bulb Replacement ................................................................................................................. 318
Headlight Relay Inspection ................................................................................................................ 318
Turn Signal Flasher Unit Inspection ................................................................................................... 318
Meters ............................................................................................................................................................ 319
Meter Removal/Disassembly ............................................................................................................. 319
Meter Assembly/Installation ............................................................................................................. 320
Tachometer Inspection ...................................................................................................................... 320
Speedometer Inspection .................................................................................................................... 320
Switches ......................................................................................................................................................... 321
Switch Inspection ............................................................................................................................... 321
Fuses .............................................................................................................................................................. 321
Main Fuse Removal ............................................................................................................................ 321
Auxiliary Fuse Removal ...................................................................................................................... 321
Fuse Installation ................................................................................................................................. 321
Fuse Inspection .................................................................................................................................. 321
296
Exploded View
297
298
299
REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
33 LOCKSET, TEXT
SWITCH, IGNITION, INCL KEYS
FILLER CAP ASSY, FUEL TANK
33 LOCKSET, TEXT
SWITCH, IGNITION, INCL KEYS
FILLER CAP ASSY, FUEL TANK
33 LOCKSET, TEXT
SWITCH, IGNITION, INCL KEYS
FILLER CAP ASSY, FUEL TANK
32 LOCKSET, UK
SWITCH, IGNITION, INCL KEYS
FILLER CAP ASSY, FUEL TANK
32 LOCKSET, UK
SWITCH, IGNITION, INCL KEYS
FILLER CAP ASSY, FUEL TANK
32 LOCKSET, UK
SWITCH, IGNITION, INCL KEYS
FILLER CAP ASSY, FUEL TANK
32 LOCKSET, UK
SWITCH, IGNITION, INCL KEYS
FILLER CAP ASSY, FUEL TANK
32 LOCKSET, UK
SWITCH, IGNITION, INCL KEYS
FILLER CAP ASSY, FUEL TANK
32 LOCKSET, UK
SWITCH, IGNITION, INCL KEYS
FILLER CAP ASSY, FUEL TANK
32 LOCKSET, UK
SWITCH, IGNITION, INCL KEYS
FILLER CAP ASSY, FUEL TANK
32 LOCKSET, UK
SWITCH, IGNITION, INCL KEYS
FILLER CAP ASSY, FUEL TANK
32 LOCKSET, UK
SWITCH, IGNITION, INCL KEYS
FILLER CAP ASSY, FUEL TANK
32 LOCKSET, UK
SWITCH, IGNITION, INCL KEYS
FILLER CAP ASSY, FUEL TANK
32 LOCKSET, UK
SWITCH, IGNITION, INCL KEYS
FILLER CAP ASSY, FUEL TANK
32 LOCKSET, UK
SWITCH, IGNITION, INCL KEYS
300
FILLER CAP ASSY, FUEL TANK
32 LOCKSET, UK
SWITCH, IGNITION, INCL KEYS
FILLER CAP ASSY, FUEL TANK
32 LOCKSET, UK
SWITCH, IGNITION, INCL KEYS
FILLER CAP ASSY, FUEL TANK
32 LOCKSET, UK
SWITCH, IGNITION, INCL KEYS
FILLER CAP ASSY, FUEL TANK
ECU TUNE, US
ECU TUNE, US
ECU TUNE, US
ECU TUNE, EURO 3
ECU TUNE, EURO 3
ECU TUNE, EURO 3
ECU TUNE, EURO 3
ECU TUNE, EURO 3
ECU TUNE, EURO 3
ECU TUNE, EURO 3
ECU TUNE, EURO 3
ECU TUNE, EURO 3
ECU TUNE, EURO 3
ECU TUNE, EURO 3
ECU TUNE, EURO 3
ECU TUNE, EURO 3
ECU TUNE, EURO 3
25 ECU, OMEX, EURO OMEX 600
52 HARNESS, MAIN
SUB-HARNESS, TILT SWITCH
SUB HARNESS, REAR
53 HARNESS, MAIN, TYPE
APPROVAL
FUSE, MINI, 10A
FUSE, 30A
RELAY, GROMMET
LEAD, STARTER
27 RELAY, FLASHER, BULB FAILURE, 10W X 12.8V
24 FUSE BOX
RELAY, NORMALLY OPEN
54 SUB-HARNESS, TILT SWITCH,
EURO TO BE USED WITH TILT SWITCH
LEAD, EARTH, BATTERY TO
ENGINE
LEAD, POSITIVE, STARTER
51 CABLE TIE, 70MM X 2.6MM, TO SUPPORT HARNESS TO FRAME
301
BLACK
50 CABLE TIE, 203MM X 4.8MM,
BLACK TO SUPPORT HARNESS TO FRAME
20 SWITCH, FALL DETECT
21 FOAM, RELAY BOX FITS INSIDE FUSE BOX LID, BATTERY STRAP,
REAR LIGHT
22 WASHER, PENNY, M4 X 4.3 X
12 X 1.0 FOR ROLLOVER SWITCH
23 BOLT, CAP HD, M4 X 25 X 0.7 7 FOR ROLLOVER SWITCH
28 HORN ASSY, HI-TONE ECIE
29 SPRING WASHER, M8
30 WASHER, M8, 8.4 X 16 X 1.6
31 BOLT, BUTTON HD, INT HEX,
M8 X 16 18 MOUNTED ON LOWER YOKE
1 IGNITION COIL PACK
2 BOLT, CAP HD, M6 X 40 X 1.0 10 TO CLAMP IGNITION COIL PACK
3 LEAD, IGNITION, KIT
4 IGNITION LEAD, RH
5 IGNITION LEAD, LH
6 BATTERY, YTZ14S YUASA HIGH SPEC
7 STRAP, BATTERY
48 GASKET, FILLER NECK FOR SPARES ONLY
49 GASKET, FILLER CAP FOR SPARES ONLY
FUEL FILLER NECK INSERT
FUEL FILLER NECK INSERT SEAL
44 WASHER, M6, 6.4 X 12 X 1.6
45 BOLT, SECURITY, M6 TO CLAMP LOCKSET
46 BOLT, CAP HD, M5 X 3O X 0.8 TO CLAMP FILLER CAP
47 BOLT, CAP HD, M5 X 15 X 0.8 TO BLANK REMAINING FILLER NECK HOLES
26 MAP SENSOR
34 SPEEDO
35 TACHO
36 ANTI-VIBRATION RUBBER, INSTRUMENTS
37 COVER, INSTRUMENTS
38 SPACER, INSTRUMENT COVER BETWEEN INSTRUMENT COVER AND
CLOCKS
39 DOMED NUT, M4 TO CLAMP INSTRUMENT COVERS
40 SWITCH, INSTRUMENT PANEL
41 PLAQUE SET, COMMANDO SE
41 PLAQUE, COMMANDO SPORT
41 PLAQUE, COMMANDO CAFE
RACER
41 PLAQUE, HAND-BUILT AT DONINGTON PARK
42 INSTRUMENT PANEL FLAT ALUMINIUM PART, MACHINED
43 BOLT, CAP HD, M8 X 20 X 1.25 20 PANEL TO YOKE FIXING
12 REGULATOR RECTIFIER, RR58
13 BOLT, CAP HD, M6 X 16 X 1.0 TO CLAMP REGULATOR RECTIFIER
302
16 BRACKET, ECU, XM
17 BOLT, CAP HD, M6 X 12 X 1.0
18 WASHER, PENNY, M6, 6.4 X 18
X 1.6 USED WITH FUSE BOX BOLTS
19 BOLT, CAP HD, M6 X 16 X 1.0 TO CLAMP FUSE BOX
11 MOUNT, RELAY, RUBBER ENGINE STOP' AND 'FUEL LIGHT'
RELAYS
14 BRACKET, TWIN RELAY TO HOLD THE RELAY
15 BOLT, CAP HD, M8 X 20 TO HOLD THE RELAY BRACKET
8 SPLASH SHIELD, TANK,
UNDERSIDE
9 STRAP, RUBBER, SPLASH SHIELD
10 CLIP, BARBED FASTENER,
BLACK, LONG TO CLAMP SPLASH SHIELD
10 CLIP, BARBED FASTENER,
BLACK TO CLAMP SPLASH SHIELD
55 DUAL LOCK, LOW PROFILE, RECLOSEABLE FASTENER
TO FIX SPLASH SHIELD TO BATTERY BOX UNDERSIDE
303
304
305
306
REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
1 HEADLIGHT, LH DIP
1 HEADLIGHT, LH DIP
1 HEADLIGHT, LH DIP
1 HEADLIGHT, LH DIP
1 HEADLIGHT, LH DIP
1 HEADLIGHT, LH DIP
1 HEADLIGHT, LH DIP
2 HEADLIGHT, RH DIP
2 HEADLIGHT, RH DIP
2 HEADLIGHT, RH DIP
2 HEADLIGHT, RH DIP
2 HEADLIGHT, RH DIP
2 HEADLIGHT, RH DIP
2 HEADLIGHT, RH DIP
2 HEADLIGHT, RH DIP
2 HEADLIGHT, RH DIP
2 HEADLIGHT, RH DIP
2 HEADLIGHT, RH DIP
19 REFLECTOR, REAR, RED
19 REFLECTOR, REAR, RED
19 REFLECTOR, REAR, RED
20 BRACKET, REAR REFLECTOR, STEEL
19 REFLECTOR, REAR, RED
20 BRACKET, REAR REFLECTOR, STEEL
19 REFLECTOR, REAR, RED
20 BRACKET, REAR REFLECTOR, STEEL
3 REFLECTOR, FRONT, AMBER
3 REFLECTOR, FRONT, AMBER
3 REFLECTOR, FRONT, AMBER
4 BULB, HEAD LIGHT, HEAVY DUTY
5 SNAP BUSHING, 38MM X 11.5MM TO CARRY WIRES INTO HEADLIGHT
6 SPRING WASHER, M8 USED WITH HEADLIGHT BOLTS
7 BOLT, CAP HD, M8 X 22 X 1.25 TO CLAMP HEADLIGHT
8 HEADLIGHT BRACKET, LH, CAST
9 HEADLIGHT BRACKET, RH, CAST
10 HEADLIGHT BRACKET RUBBER
11 HEADLIGHT BRACKET RUBBER, USD,
UPPER
12 HEADLIGHT BRACKET RUBBER, USD,
LOWER
13 HEADLIGHT BRACKET, CAST, USD FORKS RH
14 HEADLIGHT BRACKET, CAST, USD FORKS
LH
24 NO. PLATE LIGHT, BULB
23 BOLT, CAP HEAD, M5 X 15 X 0.8 7 TO CLAMP NUMBER PLATE LIGHT
307
15 INDICATOR, RHF,LHR ECIE
LENS, INDICATOR, WHITE
SCREW, INDICATOR LENS
BULB, INDICATOR, ORANGE
16 INDICATOR, LHF, RHR ECIE
LENS, INDICATOR, WHITE
SCREW, INDICATOR LENS
BULB, INDICATOR, ORANGE
25 REAR LIGHT, ECE
26 MOUNT, ANTI VIBRATION, REAR LIGHT BETWEEN LIGHT AND BODY WORK
27 BOLT, CAP HD, M4 X 20 X 0.7 FOR MOUNTING REAR LIGHT
17 BOLT, CAP HD, M6 X 16 X 1.0 FOR MOUNTING INDICATORS
18 LOCKNUT, FLANGED, M6x1.0 FOR MOUNTING INDICATORS
21 BRACKET, REFLECTOR, REAR, XM
22 BOLT, BUTTON HD, M5x12 REFLECTOR BRACKET TO NUMBER PLATE HANGER
308
309
REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
1 SENSOR, TEMPERATURE 15
2 WASHER, M12, 12.2 X 17.9 X 2, COPPER USED WITH TEMPERATURE SENSOR
DOW CORNING 340 HEAT SINK COMPOUND, 100g
APPLY TO TEMP SENSOR AS REQUIRED
3 SENSOR, SPEED CAM POSITION AND GEARBOX ROAD SPEED
4 BOLT, CAP HD, M6 X 12 X 1.0, DIN 912,
12.9, BZP 12 TO CLAMP SPEED SENSORS
5 SWITCH, NEUTRAL, M10x1.25 12
6 WASHER, M10, COPPER, ID 10.2, OD 13.9 X 1.0 USED WITH NEUTRAL SWITCH
7 SPARK PLUG, CR9EB 12 FIRST USE TORQUE ONLY
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REF. NO. PART DESCRIPTION
TORQUE (NM) REMARKS
1 ROTOR, ALTERNATOR
2 BOLT, CAP HD, M8 X 16 X 1.25, DIN 912, 12.9
25 THREEBOND 1327
9 STATOR, ASSY
3 STATOR
10 SENSOR, CRANK POSITION
4 BOLT HEX, HD, M6 X 35 DIN 933, 10.9 12 TO CLAMP STATOR TO COVER
5 PIN, DOWEL, 4.0 X 10, SOLID, DIN 6325
H&G STATOR TO COVER
6 P-CLIP, ALUMINIUM, ID 6.5MM GENERATOR LEAD TO COVER
7 BOLT, BUTTON HD, INT HEX, M5 X 10, ISO
7380, 10.9 5 TO CLAMP P-CLIP TO COVER (TB1342)
8 BOLT, CAP HD, M5 X 12 X 0.8, DIN 912, 12.9 5 USED TO CLAMP CRANK SENSOR
ADHESIVE, ANAEROBIC, TB1342, 250G, (LOW STRENGTH) THREEBOND 1342
311
Parts Location
1 Headlight, Signal 9 ECU 17 Battery 25 Natural Switch
2 Light Switch 10 Regulator/Rectifier 18 Main Fuse 26 Lambda Sensors
3 Fuel light Relay 11 Crank Sensor 19 Throttle body/Idle Air 27 Ignition
4 Fuel Pump 12 Side Stand Switch 20 Starter Motor 28 Clocks
5 Head Temp Sensor 13 Alternator 21 Air Temp Sensor 29 Number Plate bulb
6 Oil Pressure Switch 14 Cam Sensor 22 Brake Light Switch Rear 30 Front Brake Switch
1
2 3
4
5
6
7
8 9
10
11
14
15
16
17
18
19
20
21
22 23
24
25
12 13
26
27
28
29
30
312
7 Road Speed Sensor 15 Ignition Coil 23 Brake Light
8 Relay/Fuse Box 16 Starter/Kill Switch 24 Indicators
Wiring
Diagram
313
Specification
Item Standard Service Limit
Battery:
Type YTZ 14 S ---
Capacity 12 V 14.5 Ah ---
Voltage 12.6 V or more ---
Charging system:
Alternator type Three-phase AC ---
Charging voltage Idle 12 ~ 20V ---
(regulator/rectifier output voltage)
Alternator output voltage more than 63 V @4000 r/min (rpm)
---
Charging Coil resistance 0.3 ~ 2 Ω (x 1 Ω) ---
Regulator/rectifier resistance in text ---
Ignition System:
Crank Sensor air gap 0.4 ~ 0.7 mm ---
crank sensor resistance 100 ~ 150 Ω (x 10 Ω) ---
Ignition coil:
Arcing distance 7mm or more ---
Primary coil resistance 0.1 ~ 0.4 Ω ---
Secondary coil resistance 3 ~ 10 kΩ (x 1kΩ) ---
Spark plug:
Spark plug gap 0.8mm ~0.9mm 1mm
Spark plug cap resistance 3 ~ 10 kΩ (x 1kΩ) ---
ECU resistance in text ---
314
Precautions
Note: There are a number of important precautions that are musts when servicing electrical systems. Lean
and observe all the rules below.
Do not reverse the battery lead connections. This will burn out the diodes in the electrical parts.
Always check battery condition before condemning other parts of an electrical system. A fully
charged battery is a must for conducting accurate electrical system tests.
The electrical system should never be struck sharply, as with a hammer, or allowed to fall on a hard
surface. Such a shock to the parts can damage them.
To prevent damage to electrical parts, do not disconnect the battery leads or any other electrical
connections when the ignition switch is on, or the engine is running.
Because of the large amount of current, never keep the starter switch pushed when the starter
motor will not turn over, or the current may burn out the starter motor windings.
Do not use a meter illumination bulb for other than the voltage or wattage specified in the wiring
diagram, as the meter panel could be warped by excessive heat radiated from the bulb.
Take care not to short the leads that are directly connected to the battery positive (+) terminal to
the chassis ground.
Troubles may involve one or in some cases all items. Never replace a defective part without
determining what CAUSED the failure. If the failure was caused by some other item or items, they
too must be repaired or replaced, or the new replacement will soon fail again.
Make sure all connections in the circuit are clean and tight, and examine wires for signs of burning,
fraying, etc. Poor wires and bad connections will affect electrical systems operation.
Measure coil and winding resistance when the part is cold (at room temperature).
Electrical Wiring
Wiring Inspection
Visually inspect the wiring for signs of burning, fraying, etc.
If any wiring is poor, replace the damaged wiring.
Pull each connector apart and inspect it for corrosion, dirt, and damage.
If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it.
Check the wiring for continuity.
Use the wiring diagram to find the ends of the lead which is suspected of being a problem.
Connect the hand tester between the ends of the leads.
Set the tester to 1 Ω range, and read the tester.
If the tester does not read 0 Ω, the lead is defective. Replace the lead or the wiring harness if
necessary.
315
Battery
Battery Removal
Remove:
Seat (see Frame chapter).
Fuel Tank (see Fuel System chapter)
Remove the battery strap.
Disconnect the battery negative ( - ) cable first, and then
the positive ( + ) cable.
Take out the battery.
Battery Installation
Connect the battery positive ( + ) cable first, and then the negative ( - ) cable.
Run the battery cables according to the Cable, Wire, and Hose Routing section of the General
Information chapter.
Install:
Battery Strap
Fuel Tank (See Fuel System chapter)
Seat (see Frame chapter)
Electrolyte Filling
Note: Only use a maintenance free battery and follow manufactures instructions to fill if required.
Initial Charge
Change at 0.9 A for 2~3 hours
Precautions
Battery does not need topping up.
Warning: Do not top up as sealed battery type only.
Refreshing charge:
If an engine will not start, a horn sounds weak, or lights are dim, it indicates the battery has been
discharged. Give refresh change for 5 to 10 hours with charge current shown in specification (see
Refreshing Charge).
When a fast charge is inevitably required, do it following precisely the maximum charge current and
time conditions indicated on the battery.
Caution: This battery is designed to sustain no unusual deterioration if refresh-charged according to the
method specified above. However, the battery performance may be reduced noticeably if charged under
conditions other than given above. Never remove the sealing plug during refresh charge.
316
When you do not use the motorcycle for months, give a refresh charge before you store the
motorcycle and store it with the negative lead removed. Give a refresh change every six months
during storage.
Battery life:
o If the battery will not start the engine even after several refresh charges, the battery has
exceeded its useful life. Replace it. (Provided, however, the vehicle`s starting system has no
problem.)
Warning: Keep the battery away from sparks and open flames during charging, since the battery gives off
an explosive gas mixture. When using a battery charger, connect the battery to the charger before turning
on the charger. This procedure prevents sparks at the battery terminals which could ignite any battery
gasses. No fire should be drawn near the battery, or no terminals should have the tightening loosened. The
battery contains acid. Be careful not to have it touch your skin or eyes. If it touches, wash it off with liberal
amount of water. Get medical attention if severe.
Charging Condition Inspection
Note: Battery charging condition can be checked by measuring battery terminal voltage.
Remove:
Seat (see Frame chapter)
Fuel Tank (see Fuel system chapter)
Disconnect the battery terminal leads.
Caution: Be sure to disconnect the negative terminal first.
Measure the battery voltage
Battery Terminal Voltage:
Standard: 12.6 V more
Refreshing Charge
Remove the battery (see Battery Removal).
Refresh-charge by following method according to the battery terminal voltage
Caution: This battery is a sealed type. Never remove the seal cap even at charging. Never add water.
Charge with current and time as stated below.
Terminal Voltage: 11.5 ~ 12.6 V
Standard Change: 0.9 A x 5 ~ 10 h
Quick Charge: 4.0 A x 1 hour
317
Caution: If Possible do not quick charge. If the quick charge is done due to unavoidable circumstances, do
standard change later on.
Terminal Voltage: less than 11.5 V
Charging Method: 0.9 A x 20 Hours
Note: Raise the voltage (25 V maximum), and charge for about 5 minutes. If ammeter shows no change in
current after 5 minutes, a new battery is required. The current, if it can flow into the battery, tends to
become excessive. Adjust the voltage as often as possible to keep the current at standard (0.9 A).
Determine battery condition after refreshing charge.
Determine the battery condition 30 minutes after completion of the charge by measuring the
terminal voltage according to the table below.
12.6 V or higher: Good > No action required
12.0 ~ 12.6 V or lower: Charge insufficient > Recharge
12.0 V or lower: Unserviceable > Replace
Alternator
Alternator/Clutch Cover Removal
Alternator cover removal (see Clutch chapter)
Alternator/Clutch Cover Installation
Alternator cover Installation (see Clutch chapter)
Fill the gearbox with oil (see Engine Lubrication System chapter).
Route the alternator leads in accordance with the Cable, Wire, and Hose Routing section in the
General Information chapter.
Alternator Rotor Removal
Remove:
Shift Pedal Spline
Alternator / Clutch Cover (see this chapter)
Unscrew the Rotor bolts 6 X [A]
Alternator Rotor Installation
Clean the following portions with an oil-less cleaning fluid
such as trichloroethylene or acetone:
Threads of rotor bolts
Rotor
Warning: These cleaning fluids are usually highly flammable and harmful if breathed for prolonged
periods. Be sure to heed the fluid manufacture’s warnings.
A
318
Fit the rotor onto the trigger disc and install the rotor bolts.
Torque – Rotor Bolts: 20 Nm
Apply Threebond 1327 to threads
Install a new gasket and the Clutch cover (see this chapter).
Install the shift Pedal (See Clutch chapter)
Alternator Stator Removal
Remove Clutch / alternator cover (See Clutch chapter).
Remove pickup coil (see Pickup Coil Removal).
Remove mounting bolts, four total.
Remove P-clips.
Remove Stator taking note of wiring routing.
Alternator Stator Installation
Ensure Dowel is installed in correct position and line stator up with dowel.
Route wiring in same position as before disassembly, ensuring wiring lies flat and it tied to pick up
towers, to maintain clearance to rotor.
Install and tighten all P-clips bolts with thread lock 1342.
319
Torque: P-Clip Bolts: 5NM
Install Stator mounting bolts with thread lock 1342.
Torque: Stator Mounting Bolts: 12NM
Install pick up (see Pickup Coil Installation).
Install Clutch / Alternator cover (See Clutch chapter).
Charging System
Regulator / Rectifier Removal
Pull off the regulator/rectifier rubber boot [A] and connector
[B].
Remove the regulator/rectifier bolts [C].
Remove the regulator/rectifier [D].
Regulator/Rectifier Output Voltage Inspection
Check the battery condition (see battery section).
Warm up the engine to obtain actual alternator operating conditions.
Check that the ignition switch is turned off and connect the hand tester to the battery terminals.
Start the engine, and note the voltage readings at various engine speeds with the headlight turned
on and off. The readings should show nearly battery voltage when the engine speed is low, and, as
the engine speed rises, the readings should also rise. But they must be kept under the specified
voltage.
Regulator Voltage - @ Meter Range 25 V: 14 ~ 15V
Turn off the ignition switch to stop the engine and disconnect the hand tester.
If the regulator/rectifier output voltage is kept between the vales given above, the charging system
is considered to be working normally.
If the output voltage is much higher than the values specified in the table, the regulator/rectifier is
defective or the regulator/rectifier leads are loose or open.
If the battery voltage does not rise as the engine speed increases, then the regulator/rectifier is
defective or the alternator output is insulated for the loads. Check the alternator and
regulator/rectifier to determine which part is defective.
Alternator Inspection
320
Note: There are three types of alternator failures: short, open (wire burned out), or less in rotor, or rotor
magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all. A
loss in rotor magnetism, which may be caused by dropping or hitting the alternator by leaving it near an
electromagnetic field, or just by aging, will result in a low output.
To check the alternator output voltage, do the following procedures.
Disconnect the alternator Connector [A].
Connect the hand tester to any two out of the three output pins coming from the alternator.
Start the engine
Run it at three different rev ranges
Set the meter to 250 V range
Voltage – Alternator: more than 34 V
If the output voltage shows the value above, the alternator operates properly and the
regulator/rectifier is damaged. A much lower reading than given in the table indicates that the
alternator is defective.
Check the stator coil resistance as follows:
Stop the engine.
Disconnect the alternator connector.
Connect the hand tester to two of the three output wires.
Note the readings (total 3 measurements).
Resistance – Stator: 0.3 – 1.0 Ω
If there is more resistance than shown above, or no hand tester reading (infinity) for any of the two
leads, the stator has an open lead and must be replaced. Much less than this resistance means the
stator is shorted, and must be replaced.
Using the highest resistance range of the hand tester measure the resistance between each of the
alternator leads and chassis ground.
Any hand tester readings less than infinity indicates a short, necessitating stator replacement.
If the stator coils have normal resistance, but the voltage check showed the alternator to be
defective, then the rotor magnetism has probably weakened, and the rotor must be replaced.
Regulator/Rectifier Inspection
Turn off the ignition switch.
Disconnect the regulator/rectifier connector.
Set the hand tester to the 1 kΩ range and make the measurements shown below.
If tester readings are not as specified, replace the
regulator/rectifier.
Range x 1 k Ω Tester Positive (+) Lead Connections
321
Ignition System
Warning: The ignition system
produces extremely high voltage. Do
not touch the spark plug, ignition
coil, or spark plug lead while the engine is running, or you could receive a severe electrical shock.
Caution: Do not disconnect the ECU connectors while the engine is running. This is to prevent ECU damage.
Spark Plug Removal/Installation
Remove the HT leads from spark plug cap
Remove or install the spark plug using the spark plug wrench
Torque – Spark Plug: 12 Nm
Spark Plug Cleaning/Inspection
Clean the spark plug, preferably in a sandblasting device and then clean off any abrasive particles.
The plug may also be cleaned using a high flash point solvent and a copper wired brush or other
suitable tools. If the center electrode or side electrode are corroded or damaged, or if the insulator
is cracked, replace the plug. Use the standard spark plug or its equivalent.
Spark Plug Gap
Measure the gap with a wire-type thickness gauge.
If the gap is outside the service limit replace the spark
plug.
Spark plug Gap –
Standard: 0.8 mm
Service Limit: 1.0 mm
Ignition Coil Removal
Remove the fuel tank (see Fuel System chapter).
Pull the spark plug lead off the spark plug.
Disconnect the coil lead [A]
Remove coil bolt [B]
Remove coil [C]
Ignition Coil Installation
Install ignition coil [A] as shown
Install ignition coil bolt [B]
N1 B111 B112 B113 B26
(-)
N1 - 20~200 20~200 20~200 20~80
B111 1~7 - 40~500 40~500 20~200
B112 1~7 40~500 - 40~500 20~200
B113 1~7 40~500 40~500 - 20~200
B26 2~10 1~7 1~7 1~7 -
322
Torque – Ignition coil bolt: 10 Nm
Connect coil lead [C]
Connect the spark plug leads, with the shorter lead going to the left hand cylinder, and the longer
to the right hand.
Install the fuel tank (see Fuel System chapter).
Ignition Coil Inspection
Remove the ignition coil (see this chapter).
Measure the arcing distance with a suitable commercially available coil tester to check the
condition of the ignition coil.
Connect the ignition coil with the spark plugs left attached to the end of the spark plug leads to the
tester in the manner prescribed by the manufacture and measure the arcing distance.
Ignition Coil Arcing Distance:
7 mm or more
Warning: To avoid extremely high voltage shocks, do not touch the ignition coil body or leads.
If the distance reading is less than the specified value, the ignition coil or spark plug cap is defective.
To determine which part is defective, measure the arcing distance again with the spark plug cap
removed from the ignition coil. Remove the cap by turning it counter clockwise.
If the arcing distance is subnormal as before, the trouble is with the ignition coil itself. If the arcing
distance is now normal, the trouble is with the spark plug cap.
If the coil tester is not available, the coil can be checked for a broken or badly shorted winding with
a hand tester.
Note: The hand tester cannot detect layer shorts and shorts resulting from insulation brake down
under high voltage.
Measure the primary winding resistance as follows.
Connect the tester between the coil terminals.
Set the tester between the coil terminals.
Measure the secondary winding resistance as follows.
Remove the plug cap by turning it counter clockwise.
Connect the tester between the spark plug lead and terminal.
Set the tester to the 1 k Ω range and read the tester.
Measure primary winding resistance [A].
Measure secondary winding resistance [B].
Ignition Coil [C]
Ignition Coil Winding Resistance
Primary: 0.14~ 0.22 Ω
323
Secondary: 3.8 ~ 5.8 kΩ
If the hand tester does not read as specified, replace the coil.
Pickup Coil Removal
Remove the clutch cover (see Clutch chapter).
Pull the pickup coil lead grommet [A] out of the notch of
the cover.
Disconnect the pickup coil and alternator leads.
Remove the p-clips securing the pickup coil and
alternator wires.
Remove the Alternator (see this chapter).
Unbolt the pickup coil and remove (Take note of wire
location and location of cable-tie).
Pick up coil Inspection
Remove the pickup coil (see this chapter).
Connect the hand tester between the pickup coil leads
Set the tester to the x 10 Ω range and read the tester.
Pickup Coil Resistance
100 ~200 Ω (x 10 Ω)
If there is more resistance than the specified value, the coil has an open lead and must be replaced.
Much less than this resistance means the coil is shorted, and must be replaced.
Using the highest resistance range of the hand tester, measure the resistance between the pickup
coil lead terminals and chassis ground.
Any Hand tester reading less than infinity indicates a short, necessitating replacement of the pickup
coil assembly.
Rotor Inspection
Check the surface for damage such as chipping or grooving.
If the timing projection on the flywheel is visibly damage, replace the rotor.
Electronic Control Unit (ECU)
Electronic Control Unit (ECU) Removal
Disconnect tilt switch harness [A]
A
324
Remove tilt switch harness bolts [A], tilt switch
connecter [B].
Remove Pressure sensor connection [C].
Remove Relay box bolts [A], take out relay box, and
remove rear sub harness from main harness.
Remove ECU bracket bolts [A] and ECU bracket.
Remove ECU.
Caution: Do not drop or strike the ECU and this will
damage the ECU.
ECU Inspection
Visually inspect the ECU for corrosion, damage and water ingress.
If all connections are good, and the ECU still does not function as intended contact your Norton
Dealer.
ECU Installation
ECU Installation is the reverse of the ECU Removal process detailed above.
Torque –
ECU Bracket: 8 Nm
Relay Box: 8 Nm
Tilt Switch: 6 Nm
A B
C
A
A
325
Starter System
Starter Motor Removal
Remove:
Clutch Cover (see Clutch chapter)
Remove electrical connections from back of starter. [A]
Remove starter motor bolts [A].
Gently remove starter motor.
Starter Motor Installation
Clean any gasket sealant off the crank case.
Install a new starter motor gasket and use gasket sealant
on both sides.
Install starter motor and bolts.
Torque – Starter motor bolts: 20 Nm
Install Clutch Cover (see Clutch chapter).
Starter Relay Inspection
Remove the seat (see Frame chapter)
Remove the starter relay [A].
Connect hand tester positive (+) to connection point 3
and negative (-) to 5.
Connect (12V) power positive (+) to connection point 2
negative (-) to 1.
If the relay does not work as specified, the relay is
defective. Replace the relay.
Testing Relay
Hand tester range: X 1 Ω range
Criteria: When battery is connected > 0 Ω
Criteria: when battery is disconnected > infinite Ω
Starter Circuit Relay Inspection
A
326
Remove the seat (see Frame chapter)
Remove the starter relay [A].
Connect hand tester positive (+) to connection point 3 and negative (-) to 5.
Connect (12V) power positive (+) to connection point 2 negative (-) to 1.
If the relay does not work as specified, the relay is defective. Replace the relay.
Testing Relay
Hand tester range: X 1 Ω range
Criteria: When battery is connected > 0 Ω
Criteria: when battery is disconnected > infinite Ω
Lighting System
Headlight Beam Vertical Adjustment
Slacken headlight bolts [A].
On high beam, the brightest point should be slightly below
horizontal with the motorcycle on its wheels and the rider
seated.
Adjust the headlight beam to local regulations.
Adjust the vertical adjustment by tilting the headlight unit
up or down.
Tighten headlight bolts [A].
Torque – Headlight Bolts: 12 Nm
Headlight Beam Horizontal Adjustment
Adjust the beam using the adjuster screw [A] clockwise or
anti clockwise to move the beam right or left.
Headlight Bulb Replacement
Remove front headlight screw [A].
Remove the front headlight section [B] from the headlight
body.
327
Remove the connector [A] from the back of the light.
Remove the bulb [B] from the connector and replace with a
new one.
Install the connector and the front head light section,
tighten head light screw.
Check the headlight aim after installation (see this chapter).
Headlight Unit Removal
Following on from headlight bulb replacement.
Remove head light bolts [A] taking care to support the
headlight when these have been removed.
Feed all the electrical connections out the back of the
headlight.
Headlight Unit Installation
Install the head light unit so the box connector is at the
bottom.
Feed all the electrical connections through into the back
of the head light, ensure no wires are snagged.
Install bolts [A] hand tight.
Install the lighting into the headlight front section and
install the front section.
Tighten screw on front section [A]
Set headlight aim to local legislations and tighten
headlight bolts [A]
Torque – Headlight Bolts: 12 Nm
A
A
328
Taillight Bulb Replacement
Note: it is recommended that Kevlar gloves be worn when
changing the bulb due to the risk associated with the glass
shattering.
Take out the screws [A] in the tail light lens.
Pull the lens off.
Push the bulb in [A] firmly, turn it counter clockwise [B],
and pull it out.
Be sure the socket is clean
Insert the new bulb, aligning the pins with the grooves in the walls of the socket (one is higher than
the other ensure these are correctly alight with the corresponding groves).
Push the bulb in, turn it clockwise, and release it. It should lock in position.
Tighten the two screws. Be careful not to over tighten them.
License Light Bulb Replacement
Remove bolt [A] from number plate light body.
Hold the rubber light mount, and pull the rubber mount
out of the body.
Hold the rubber mount and pull the bulb out in a rocking
motion.
Insert new bulb by pushing in with tabs aligned.
Headlight Relay Inspection
Remove the seat (see Frame chapter)
Remove the headlight relay [A].
Connect hand tester positive (+) to connection point 3
and negative (-) to 5.
Connect (12V) power positive (+) to connection point 2
negative (-) to 1.
If the relay does not work as specified, the relay is
defective. Replace the relay.
Testing Relay
Hand tester range: X 1 Ω range
Criteria: When battery is connected > 0 Ω
Criteria: when battery is disconnected > infinite Ω
Turn Signal Flasher Unit Inspection
A
329
Note: Since the turn signal relay is designed to operate correctly only when two turn signals (one front and
one rear) and the turn signal indicator light are properly connected in the circuit, trouble may result from a
burned out bulb, a bulb of incorrect wattage, loose wiring, as well as from a defect in the relay itself. In
general, if the trouble with the circuit is common to both right and left turn signals, it is probably caused by
a defective turn signal flasher unit, although it may be due to a bad switch, wiring, or battery. If the trouble
is with only one side - either right or left, then the flasher unit is not at fault since one is used for both
sides.
Remove the seat (see Frame chapter)
Check the condition of the flasher unit [A] for the following problems:
Neither right or left turn signal comes on at all:
Check the battery voltage is normal.
Unplug the flasher unit leads and use the hand tester to
check that there is continuity (close to zero ohms) between
the relay terminals.
If there is no tester reading (infinity) or if there are several
ohms resistance, replace the flasher unit with a new one.
Turn the tester to the 25 ~V DC range, connect the (+)
tester lead to the one lead that was disconnected from the
flasher unit, and connect (-) tester lead to the other lead.
With the ignition switch on, first switch the turn signal switch to the R and then to the L position.
The tester should register battery voltage at either position.
If it does not, the fuse, ignition switch, or wiring is at fault.
Both right or left turn signals come on and stay on or flash too slowly:
Check that battery voltage is nominal.
Check that all wiring connections are good.
Check that the turn signal bulbs and indicator bulb are of the correct wattage.
If all of the above check well, replace the flasher unit.
A signal light on one side comes on:
Either the light that does not come on is burned out or of the incorrect wattage, or the wiring is
broken or improperly connected.
Neither light on one side comes on.
Unless both lights for that side are burned out, the trouble is with the turn signal switch.
Flashing rate is too fast:
If this occurs on both the right and left sides, check that the battery is not being overcharged.
If the alternator and the battery voltage are normal,
replace the turn signal flasher unit.
If this occurs on only one side, one or both of the turn
signal bulbs are too high wattage.
Meters
330
Meter Removal/Disassembly
Remove meter cover bolts [A].
Remove meter covers [B].
Disconnect four meter connectors [A].
Pull the meters up through the instrument panel [B].
Meter Assembly/Installation
Pull the meters up through the instrument panel [B].
Connect four meter connectors [A].
Install meter covers [B].
Tighten meter cover bolts [A].
Tachometer Inspection
Check the tachometer circuit wiring.
If all wiring and components other than the tachometer unit check out good, the unit is suspect.
Check the unit as shown.
Remove and disassemble the meters (see this chapter).
Caution: When inspecting the tachometer operation, remove the ECU connections from the back to avoid
damage to the ECU unit.
Remove both connector boxes.
On the 8 Pin socket connect positive (+) 12V supply to point 1, and point 4.
On the 8 Pin socket connect negative (-) to point 2.
331
If the meter shows current trip mileage then the unit is functioning correctly and the problem is
elsewhere in the circuit.
If it does not shows anything then the unit is faulty and should be replaced.
Speedometer Inspection
Check the speedometer circuit wiring.
If all wiring and components other than the tachometer unit check out good, the unit is suspect.
Check the unit as shown.
Remove and disassemble the meters (see this chapter).
Caution: When inspecting the speedometer operation, remove the ECU connections from the back to avoid
damage to the ECU unit.
Remove both connector boxes.
On the 8 Pin socket connect positive (+) 12V supply to point 1, and point 4.
On the 8 Pin socket connect negative (-) to point 2.
Connect point 5 briefly to the positive supply, the needle should move.
If it does not shows anything then the unit is faulty and should be replaced.
Switches
Switch Inspection
Using the hand tester, check to see that the switch
connections as shown on the wiring schematic have
continuity (about zero ohms) when closed.
If it does not as specified, check all connections, if the
switch has an open or short repair it or replace with a
new one.
Fuses
Main Fuses Removal
Remove the fuel Tank (see Fuel System chapter)
Remove the fuse [A] from housing [B].
Auxiliary Fuse removal
Remove the seat (see Frame chapter).
Remove fuse box cover [A].
Remove relevant fuses by pulling.
332
Fuse Installation
If a fuse fails during operation, inspect the electrical system to determine the cause, and then
replace it with a new fuse of proper amperage.
Fuse Inspection
Remove the fuse (see Fuse Removal).
Inspect the fuse element.
If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the
affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and
related components for a short circuit.
Caution: When replacing a fuse, be sure the new fuse matches the specified fuse rating for that circuit.
Installation of a fuse with a higher rating may cause damage to wiring and components.
333
Appendix
Additional Considerations for Racing ............................................................................................................ 323
Spark Plugs ......................................................................................................................................... 323
Spark Plugs Inspection ....................................................................................................................... 323
Trouble Shooting Guide ................................................................................................................................. 324
Nut, Bolt, and Fastener Tightness .................................................................................................................. 333
Tightness Inspection .......................................................................................................................... 333
General Lubrication........................................................................................................................................ 334
Lubrication ......................................................................................................................................... 334
Unit Conversion Table .................................................................................................................................... 335
334
Additional Considerations for Racing
This motorcycle has been manufactured for use in a reasonable and prudent manner and as a
vehicle only. However, some may wish to subject this motorcycle to abnormal operation, such as would be
experienced under racing conditions. NORTON STRONGLY RECOMMENDS THAT ALL RIDERS RIDE SAFELY
AND OBEY ALL LAWS AND REGULATIONS CONCERNING THEIR MOTORCYCLE AND ITS OPERATION.
Racing should be done under supervised conditions, and recognized sanctioning bodies should be
contacted for further details. For those who desire to participate in competitive racing or relate use, the
following information may prove useful. However, please note the following important notes.
You are entirely responsible for the use of your motorcycle under abnormal conditions such as
racing and Norton shall not be liable for damages which might arise from such use.
Norton’s Limited Motorcycle Warranty and Emissions Systems Warranty specifically exclude
motorcycles which are used in competition or related uses. Please read the warranty carefully.
When the motorcycle is operated on public roads, it must be in its original state in order to ensure
safety and compliance with applicable regulation.
Spark Plug
The spark plug ignites the fuel and air mixture in the combustion
chamber. To do this effectively and at the proper time, the correct spark
plug must be used, and the spark plug must be kept clean and the gap must
be within the specified range.
Tests have shown the plug listed in the “General Information”
chapter to be the best plug for general use.
Since spark plug requirements change with the ignition and fuel
adjustments and with riding conditions, whether or not a spark plug of the
correct heat range is used should be determined by removing and
inspecting the plug.
When a plug of the correct heat range is being used, the electrodes
will stay hot enough to keep all the carbon burned off, but cool enough to
keep from damaging the engine and the plug itself. This temperature is about 400 ~ 800˚C and can be
judged by noting the condition and colour of the ceramic insulator around the centre electrode. If the
ceramic is clean and of a light brown colour, the plug is operating at the right temperature.
A spark plug for higher operating temperatures is used for racing such a plug is designed for better
cooling efficiency so that it will not overheat and thus is often called a “colder” plug. If a spark plug with
too cool a heat range is used – that is, a “cold” plug that cools itself too well the plug will stay too cool to
burn off the carbon, and the carbon will collect on the electrodes and the ceramic insulator.
The carbon on the electrodes conducts electricity, and can short the centre electrode to ground by
either coating the ceramic insulator or bridging across the gap. Such a short will prevent an effective spark.
Carbon build-up on the plug can also cause other troubles. It can heat up red-hot and cause pre-ignition
and knocking, which may eventually burn a hole in the top of the piston.
Carbon Fouling
Oil Fouling
335
Spark Plug Inspection
Remove the spark plug and inspect the ceramic insulator.
Whether or not the right temperature plug is being used can be
ascertained by noting the condition of the ceramic insulator around
the electrode. A light brown colour indicated the correct plug is being
used. If the ceramic is black, it indicates that the plug is firing at too
low a temperature, so the next hotter type should be used instead. If
the ceramic is white, the plug is operating at too high a temperature
and it should be replaced with the next colder type.
Caution: If the spark plug is replaced with a type other than the standard plug, make certain the
replacement plug has the same thread pitch and reach (length of threaded portion) and the same type
electrode (regular type or projected type) as the standard plug.
If the plug reach is too short, carbon will build up on the plug hole threads in
the cylinder head, causing overheating and making it very difficult to insert
the correct spark plug later.
If the plug reach is too short, carbon will build up on the plug hole threads in
the cylinder head, causing overheating and making it very difficult to insert
the correct spark plug later.
If the reach is too long, carbon will build up on the exposed spark plug threads
causing overheating, pre-ignition, and possibly burning a hole in the piston
top. In addition, it may be impossible to remove the plug without damaging
the cylinder head.
Note: The heat range of the spark plug functions like a thermostat for the
engine. Using the wrong type of spark plug can make the engine run too hot
(resulting in engine damage) or too cold (with poor performance, misfiring,
and stalling).
Troubleshooting Guide
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.
Engine Doesn’t Start, Starting Difficult:
Starter motor not rotating:
Starter lockout or neutral switch trouble
Starter motor trouble
Battery voltage low
Starter relay not contacting or operating
Starter button not connected
Wiring open or shorted
Normal Operation
Over Heating
Over Heating /
Thermal Shock
Normal Operation
336
Ignition switch trouble
Engine stop switch trouble
Fuse blown
Engine won’t turn over:
Valve seizure
Valve lifter seizure
Cylinder, piston seizure
Crankshaft seizure
Balancer bearing seizure
Connecting rod Small end Seizure
Connecting rod big end seizure
Transmission gear or bearing seizure
Camshaft seizure
No Fuel flow:
No fuel in fuel tank
Fuel line clogged
Engine flooded:
Starting technique faulty (when flooded, crank the engine with the throttle fully opened to allow
more air to reach the engine.)
No spark; spark weak:
Battery voltage low
Ignition switch not turned on
Engine stop turned off
Clutch lever not pulled in or gear not in neutral
Spark plug dirty, broken, or maladjusted
Spark plug cap or high tension wire trouble
Spark plug cap shorted or not in good contact
Spark plug incorrect
ECU trouble
Pickup coil trouble
Ignition coil trouble
Alternator damaged
Ignition or engine stop switch shorted
Neutral, or starter locknut switch trouble
Wiring shorted or open
Fuel/air mixture incorrect:
Throttle body trouble
ECU trouble
Wiring shorted
Compression Low:
Spark plug loose
337
Cylinder head not sufficiently tightened down
No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warp
Valve spring broken or weak
Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface)
Poor Running at Low Speed:
Spark weak:
Spark plug dirty, broken, or maladjusted
Spark plug cap or high tension wiring trouble
Spark plug cap shorted or not in good contact
Spark plug incorrect
ECU trouble
Pickup coil trouble
Exciter coil shorted or open
Ignition coil trouble
Alternator damage
Fuel/air mixture incorrect:
injector, or air passage clogged
Air bleed pipe bleed holes clogged
Air cleaner clogged, poorly sealed, or missing
Starter plunger stuck open
Fuel tank air vent obstructed
Injector trouble
ECU trouble
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened down
No Valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warp
Valve spring broken or weak
Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface)
Other:
338
ECU trouble
Idle air motor trouble
Engine oil viscosity too high
Drive train trouble
Brakes dragging
Over heating
Clutch slipping
Throttle valve does not open fully
Poor Running or No Power at High Speed:
Firing incorrect:
Spark plug dirty, damaged, or maladjusted
Spark plug cap or high tension wiring trouble
Spark plug cap shorted or not in good contact
Spark plug incorrect
ECU trouble
Pickup coil trouble
Exciter coil shorted or open
Ignition coil trouble
Alternator damage
Fuel/air mixture incorrect:
Injector, or air passage clogged
Air bleed pipe bleed holes clogged
Air cleaner clogged, poorly sealed, or missing
Starter plunger stuck open
Fuel tank air vent obstructed
Injector trouble
Fuel pump trouble
Water or foreign matter in fuel
Fuel line blocked
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened down
No Valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warp
Valve spring broken or weak
Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface)
339
Knocking:
Carbon build up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
Miscellaneous:
Throttle valve won’t fully open
Brakes dragging
Clutch slipping
Overheating
Engine oil level too high
Engine oil viscosity too high
Balancer malfunctioning
Drive train trouble
Crankshaft bearing worn or damaged
Overheating:
Firing incorrect:
Spark plug dirty, damaged, or maladjusted
Spark plug incorrect
ECU trouble
Fuel/air mixture incorrect:
Injectors, or air passage clogged
Throttle body loose
Air cleaner clogged, poorly sealed, or missing
Compression low:
Carbon build up in combustion chamber
Engine load faulty:
Clutch slipping
Engine oil level too high
Engine oil viscosity too high
Brakes dragging
Lubrication inadequate:
Engine oil level too low
Engine oil poor quality or incorrect
Clutch Operation Faulty:
Clutch slipping:
No clutch lever play
Friction plate worn or warped
Steel plate worn or warped
Clutch spring broken or weak
340
Clutch release mechanism trouble
Clutch hub or housing unevenly worn
Clutch not disengaging properly:
Clutch lever trouble
Clutch plate warped or too rough
Clutch spring compression uneven
Engine oil deteriorated
Engine oil viscosity too high
Engine oil level too high
Clutch housing frozen on drive shaft
Clutch release mechanism trouble
Clutch hub nut loose
Clutch hub spline damaged
Gear Shifting Faulty:
Doesn’t go into gear; shift pedal doesn’t return:
Clutch not disengaging
Shift fork bent or seized
Gear stuck on the shaft
Gear positioning lever binding
Shift return spring weak or broken
Shift return spring pin loose
Shift mechanism arm spring broken
Shift mechanism arm broken
Shift pawl broken
Jumps out of gear:
Shift fork worn, bent
Gear groove worm
Gear dogs and/or dog recesses worn
Shift drum groove worn
Gear positioning lever spring weak or broken
Shift fork pin worn
Drive shaft, output, and/or gear splines worn
Over shifts:
Gear positioning lever spring weak or broken
Shift mechanism arm spring broken
Abnormal Engine Noise:
Knocking:
ECU unit trouble
Carbon built up in combustion chamber
341
Fuel poor quality or incorrect
Spark plug incorrect
Overheating
Piston slap:
Cylinder/Piston clearance excessive
Cylinder, piston worn
Connecting rod bent
Piston pin, piston pin hole worn
Valve noise:
Valve clearance incorrect
Valve spring broken or weak
Camshaft bearings worn
Valve lifter worn
Other noise:
Connecting rod small end clearance excessive
Connecting rod big end clearance excessive
Piston ring worn, broken, or stuck
Piston seizure, damage
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head connection
Crankshaft runout excessive
Engine mounts loose
Crankshaft bearing worn
Primary gear worn or chipped
Alternator loose
Camshaft chain tensioner trouble
Camshaft chains, sprockets, guides worn
Camshaft, sprockets, guides worn
Balancer gear worn or chipped
Balancer position maladjusted
Balancer mechanism springs weak or broken
Balancer bearings worn
Abnormal Drive Train Noise:
Clutch noise:
Cush drive rubber damping weak or damaged
Clutch housing/friction plate clearance excessive
Clutch housing gear/primary gear worn
Metal chip jammed in clutch housing gear teeth
Outside friction plate installed incorrectly
Transmission noise:
342
Bearings worn
Transmission gears worn or chipped
Metal chips jammed in gear teeth
Engine oil insufficient
Drive chain noise:
Drive chain adjusted improperly
Drive chain worn
Rear and/or engine sprocket(s) worn
Chain lubrication insufficient
Rear wheel misaligned
Abnormal Frame Noise:
Front fork noise:
Oil insufficient or too thin
Spring weak or broken
Rear shock absorber noise
Shock absorber damaged
Disc brake noise:
Pad installed incorrectly
Pad surface glazed
Disc warped
Caliper trouble
Master cylinder damaged
Other noise:
Brackets, nuts, bolts, etc. Not properly mounted or tightened
Exhaust Smokes Excessively:
White smoke:
Piston oil ring worn
Cylinder worn
Valve oil seal damaged
Valve guide worn
Engine oil level too high
Black smoke:
Air cleaner clogged
Injector damaged
Idle air motor trouble
Brown smoke:
Injector damaged
Air cleaner duct loose
Air cleaner poorly sealed or missing
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Handling and/or Stability Unsatisfactory
Handlebar hard to turn:
Cable routing incorrect
Hose routing incorrect
Wiring routing incorrect
Steering stem nut too tight
Steering stem bearing damaged
Steering stem bearing race dented or worn
Steering stem lubrication inadequate
Steering stem bent
Tire air pressure too low
Handlebar shakes or excessively vibrates:
Tire worn
Swingarm sleeve or needle bearing damaged
Rim warped, or not balanced
Front, rear axle runout excessive
Wheel bearing worn
Handlebar clamp loose
Steering stem head nut loose
Handlebar pulls to one side:
Frame bent
Wheel misalignment
Swingarm bent or twisted
Swingarm pivot shaft runout excessive
Steering maladjustment
Steering stem bent
Front fork leg bent
Right and left front fork oil level uneven
Shock absorption unsatisfactory
(Too hard)
Front fork oil excessive
Front fork oil viscosity too high
Front fork damper adjustment too hard
Front fork leg bent
Tire pressure too high
Rear shock absorber adjustment too hard
(Too soft)
Front fork oil insufficient and/or leaking
Front fork oil viscosity too low
Front fork damper adjustment too soft
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Rear shock absorber springs to weak
Rear shock absorber oil leaking
Rear shock absorber adjustment too soft
Tire air pressure too low
Brake Doesn’t Hold:
Air in the brake line
Pad or disc worn
Brake fluid leaking
Disc warp
Contaminated pads
Brake fluid deteriorated
Primary or secondary cup damaged in the master cylinder
Master cylinder scratched inside
Battery Discharged:
Battery faulty (e.g. plates sulphated, shorted through sedimentation)
Battery leads making poor contact
Load excessive (e.g. Bulb of excessive wattage)
Ignition switch trouble
Alternator rotor damaged
Wiring faulty
Regulator/Rectifier trouble
Battery Overcharged:
Regulator/rectifier trouble
Battery trouble
Nut, Bolt, and Fastener Tightness
Tightness Inspection
Check the tightness of the bolts and nuts listed here in accordance with the Periodic Maintenance
Chart. Also, check to see that each cotter pin is in place and in good condition.
Note: For the engine fasteners, check the tightness of them when the engine is cold (at room temperature)
If there are loose fasteners, re-torque them to the specified torque following the specified
tightening sequence. Refer to the Torque and Locking Agent section of the General Information
chapter for torque specification. For each fastener, first loosen it by ½ turn, then tighten in.
If cotter pins are damaged, replace them with new ones.
345
Nut, bolt and fastener to be checked
Wheels:
Front Axle
Front Axle Clamp Nuts
Rear Axle
Final Drive:
Chain Adjuster Locknuts
Rear Sprocket Nuts
Brakes:
Front Master Cylinder Clamp Bolts
Caliper Bolts
Rear Master Cylinder Bolts
Brake Pedal locking Pin
Brake Lever Pivot Nut
Suspension:
Front Fork Clamp Bolts
Front Fender Mounting Bolts
Swingarm Pivot Shaft Nut
Rear Shock Absorber Bolts
Steering:
Stem Head Nut
Handlebar Clamp Bolts
Engine:
Engine Mounting Bolts, Nuts
Cylinder Head Cover Bolts
Shift Pedal Bolt
Exhaust Pipe Holder Nuts
Muffler Connecting Clamp Bolts
Muffler Bolt and Nut
Clutch Lever Pivot
Others
Side Stand Pivot Bolt
Foot peg Bolts, nuts
Lubrication
Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease,
oil, dirt, or grime.
Lubricate the points listed below with indicated lubricant in accordance with the Periodic
Maintenance Chart.
346
Note: Whenever the vehicle has been operated under wet or rainy conditions, or especially after a high
pressure spray water, perform the general lubrication.
Chain: Lubricate with Heavy Oil
Pivots: Lubricate with Motor Oil
Side Stand
Clutch Lever
Brake Pedal
Rear Brake Rod Joint
Footpegs
Cables: Lubricate with Cable Lubricant
Throttle Cables
Lubricate the cables by seeping oil between the cable and housing.
While the cable is disconnected at both ends, the cable should move freely within the cable
housing.
If cable movement is not free after lubrication, if the cable is frayed, or if the cable housing is
kinked, replace the cable.
Points: Lubricate with Grease
Throttle Inner Cable Lower Ends
Choke Cable Lower Ends
(Grease the lower part of the inner cable sparingly)
Unit Conversion Table
Prefixes for Units
Prefixes Symbol Power
mega M x 1000 000 kilo k x 1 000 centi c x 0.01 milli m x 0.001
micro µ x 0.000001
Units of Mass
kg x 2.205 = lb
g x 0.03527 = oz
Units of Volume
L x 0.2642 = gal (US) L x 0.22 = gal (imp) L x 1.057 = qt (US) L x 0.8799 = qt (imp)
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L x 2.113 = pint (US) L x 1.816 = pint (imp)
mL x 0.03381 = oz (US) mL x 0.02816 = oz (imp)
mL x 0.06102 = cu in
Units of Force
N x 0.102 = kg N x 0.2248 = lb kg x 9.807 = N
kg x 2.205 = lb
Units of Temperature:
F
C oo
405
409
C
F oo
409
405
Units of Length
km x 0.6214 = mile m x 3.281 = ft
mm x 0.02937 = in
Units of Torque
Nm x 0.102 = kgm Nm x 0.7376 = ftlb Nm x 8.851 = inlb kgm x 9.807 = Nm kgm x 7.233 = ftlb
kgm x 86.8 = inlb
Units of pressure
kPa x 0.0102 = kg/cm² kPa x 0.145 = psi
kPa x 0.7501 = cm Hg kg/cm² x 98.07 = kPa kg/cm² x 14.22 = psi
cm Hg x 1.333 = kPa
Units of Speed
348
km/h x 0.6214 = mph
Units of Power
kW x 1.36 = PS kW x 1.341 = HP PS x 0.7355 = kW
PS x 0.9863 = HP