Periodic Maintenance Procedures
Fuel System (DFI)
Air Cleaner Element Replacement
NOTE

○In dusty areas, the element should be replaced more
frequently than the recommended interval.

WARNING
If dirt or dust is allowed to pass through into the
throttle body assy, the throttle may become stuck,
possibly causing accident. Replace the air cleaner
element according to the maintenance chart.

NOTICE
If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.

• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Connector Bracket [A]
Air Cleaner Housing Assembly Screws [B]
Upper Air Cleaner Housing [C]

• Discard the air cleaner element [A].

a new element [A] so that the screen side [B] faces
• Install
upward.
• Install:
Upper Air Cleaner Housing
Tighten:
•
Torque - Air Cleaner Housing Assembly Screws: 1.1 N·m
(0.11 kgf·m, 10 in·lb)

• Install:
Fuel Tank (see Fuel Tank Installation in the Fuel System
(DFI) chapter)

2-16 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Idle Speed Inspection

the engine and warm it up thoroughly.
• Start
the engine idling, turn the handlebars to both sides
• With
[A].
If handlebars movement changes the idle speed, the
throttle cables may be improperly adjusted or incorrectly
routed, or damaged. Be sure to correct any of these
conditions before riding (see Throttle Control System
Inspection and Cable, Wire, and Hose Routing section in
the Appendix chapter).

WARNING
Operation with improperly adjusted, incorrectly
routed or damaged cables could result in an unsafe
riding condition. Follow the service manual to be
make sure to correct any of these conditions.
the idle speed.
• Check
If the idle speed is out of specified range, adjust it.
Idle Speed
Standard:

1 100 ±50 r/min (rpm)

Idle Speed Adjustment

the engine and warm it up thoroughly.
• Start
the adjusting screw [A] until the idle speed is correct.
•○Turn
Open and close the throttle a few times to make sure that
the idle speed is within the specified range. Readjust if
necessary.

Throttle Control System Inspection

that the throttle grip [A] moves smoothly from full
• Check
open to close, and the throttle closes quickly and com-

•

pletely by the return spring in all steering positions.
If the throttle grip does not return properly, check the throttle cable routing, grip free play, and cable damage. Then
lubricate the throttle cable.
Check the throttle grip free play [B].
Throttle Grip Free Play
Standard: 2  3 mm (0.08  0.12 in.)

•
•
•
•
•
•

If the free play is incorrect, adjust the throttle cable as
follows.
Loosen the locknuts [A] [B].
Screw both throttle cable adjusters [C] [D] to give the
throttle grip plenty of play.
Turn the decelerator cable adjuster [C] until there is no
play when the throttle grip play completely closed.
Tighten the locknut [A].
Turn the accelerator cable adjuster [D] until 2  3 mm
(0.08  0.12 in.) of throttle grip play is obtained.
Tighten the locknut [B].
If the free play can not be adjusted with the adjusters,
replace the cable.

PERIODIC MAINTENANCE 2-17
Periodic Maintenance Procedures
Engine Vacuum Synchronization Inspection
NOTE

○These procedures are explained on the assumption that
the intake and exhaust systems of the engine are in
good condition.
the motorcycle so that it is vertical.
• Situate
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System

•

(DFI) chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
Fuel Hose (see Fuel Hose Replacement)
For the US and CA models, pull off the rubber caps [A]
from the fittings of each throttle body.

other than the US and CA models, disconnect the
• For
vacuum hoses [A].

a vacuum gauge and hoses [A] (Special Tool:
• Connect
57001-1369) to the fittings on the throttle body.
Special Tool - Vacuum Gauge: 57001-1369

a highly accurate tachometer lead [B] to one of
• Connect
the stick coil primary leads.

the air switching valve hose end [A] and air cleaner
• Plug
housing fitting [B].

2-18 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the air cleaner housing (see Air Cleaner Housing
• Install
Installation in the Fuel System (DFI) chapter).
the following parts temporarily.
• Connect
Fuel Pump Lead Connector [A]
Extension Tube [B]
Special Tool - Extension Tube: 57001-1578

the engine and warm it up thoroughly.
• Start
Check
• [A]. the idle speed, using a highly accurate tachometer
Idle Speed
Standard: 1 100 ±50 r/min (rpm)

If the idle speed is out of the specified range, adjust it with
the adjusting screw (see Idle Speed Adjustment).

NOTICE
Do not measure the idle speed by the tachometer of
the meter unit.
idling the engine, inspect the throttle body vacuum,
• While
using the vacuum gauge [B].
Throttle Body Vacuum
Standard: 40.7 ±1.3 kPa (305 ±10 mmHg) at idle speed

If any vacuum is not within specifications, adjust the bypass screws [A].
Special Tool - Pilot Screw Adjuster, A [B]: 57001-1239

NOTE

○In this drawing [C], the throttle body assy has been removed for clarity.
the each vacuum (#1  #4) to the standard value.
• Adjust
Open
and
• ment. close the throttle valves after each measure-

NOTE

○Do not turn the center adjusting screw [D].
the vacuums as before.
• Check
If all vacuums are within the specification range, finish the
engine vacuum synchronization.
If any vacuum can not be adjusted within the specification,
replace the bypass screws #1  #4 with new ones, refer
to the following procedure.

PERIODIC MAINTENANCE 2-19
Periodic Maintenance Procedures
the throttle body assy (see Throttle Body Assy
• Remove
Removal in the Fuel System (DFI) chapter).
in the bypass screw [A] with counting the number of
• Turn
turns until it seals fully but not tightly. Record the number

•
•
•
•

of turns.
Remove:
Bypass Screw
Spring [B]
Washer [C]
O-ring [D]
Check the bypass screw hole in the throttle body for carbon deposits.
If any carbons accumulate, wipe the carbons off from the
hole, using a cotton pad penetrated with a high flash-point
solvent.
Replace the bypass screw, spring, washer and O-ring as
a set.
Turn in the bypass screw until it seats fully but not tightly.

NOTICE
Do not over-tighten the bypass screw. The tapered
portion [E] of the bypass screw could be damaged.
out the same number of turns counted when first
• Back
turned in. This is to set the screw to its original position.

NOTE

○A throttle body assy has different “turns out” of the bypass screw for each individual unit. On setting the bypass screw, use the “turns out” determined during disassembly.
the same procedure for other bypass screws.
• Repeat
Repeat
the synchronization.
• If the vacuums
are correct, check the output voltage of
the main throttle sensor (see Main Throttle Sensor Output
Voltage Inspection in the Fuel System (DFI) chapter).
Special Tool - Throttle Sensor Setting Adapter:
-1538

57001

Main Throttle Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor Y/W) lead
Digital Meter (–) → BK (sensor G) lead
Standard:

DC 1.02  1.06 V at idle throttle opening

If the output voltage is out of the standard, check the input voltage of the main throttle sensor (see Main Throttle
Sensor Input Voltage Inspection in the Fuel System (DFI)
chapter).

2-20 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the vacuum gauge hoses.
• Disconnect
For
the
US
and
• throttle body. CA models, install the rubber caps to each
other than the US and CA models, connect the vac• For
uum hoses.

○Run the vacuum hoses according to Cable,

•

Wire, and
Hose Routing section in the Appendix chapter.
Install the removed parts (see appropriate chapters).

Fuel System Inspection
Fuel Hose Inspection (fuel leak, damage, installation
condition)
○If the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the
hose to burst. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) and check the
fuel hose.
Replace the fuel hose if any fraying, cracks [B] or bulges
[C] are noticed.
that the fuel hose is routed according to Cable,
• Check
Wire, and Hose Routing section in the Appendix chapter.
Replace the hose if it has been sharply bent or kinked.
Hose Joints [A]
Fuel Hose [B]

that the fuel hose joints are securely connected.
•○Check
Push and pull [A] the fuel hose joint [B] back and forth
more than two times, and make sure it is locked.

WARNING
Leaking fuel can cause a fire or explosion resulting
in serious burns. Make sure the hose joint is installed correctly on the delivery pipe by sliding the
joint.
If it does not lock, reinstall the hose joint.

PERIODIC MAINTENANCE 2-21
Periodic Maintenance Procedures
Fuel Filter Replacement

WARNING
Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential
for serious burns. Make sure the area is well ventilated and free from any source of flame or sparks;
this includes any appliance with a pilot light. Do not
smoke. Turn the ignition switch off. Disconnect the
battery (–) terminal. To avoid fuel spills, draw it from
the tank when the engine is cold. Be prepared for
fuel spillage; any spilled fuel must be completely
wiped up immediately.

NOTICE
Never drop the fuel pump especially on a hard surface. Such a shock to the pump can damage it.

• Remove:
Fuel Pump (see Fuel Pump Removal in the Fuel System
(DFI) chapter)
Fuel Pump Assembly Screws [A]
Lead Terminals [B]

• Disconnect:
Lead Connector (Yellow) [A]
Lead Connector (Light Blue) [B]

the flat tip screwdriver [A], remove the fuel pump
• Using
case [B] from the fuel pump body [C].

2-22 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the O-ring [A].
• Remove
Remove
the
fuel pump body [B] from the installation plate
• [C].

• Remove the fuel filter [A].

• Replace the fuel filter [A] with a new one, and install it.

the following parts with new ones.
• Replace
O-rings [A]
Fuel Pump Assembly Screws [B]

PERIODIC MAINTENANCE 2-23
Periodic Maintenance Procedures
the removed parts in the reverse procedure.
• Install
Install
[A] so that the light blue lead terminal is
• coveredtheascap
shown.
Tighten:
•
Torque - Fuel Pump Assembly Screws: 0.98 N·m (0.10
kgf·m, 8.7 in·lb)

Fuel Hose Replacement

the fuel tank (see Fuel Tank Removal in the Fuel
• Remove
System (DFI) chapter).
the connector bracket from the air cleaner hous• Remove
ing.
the intake air temperature sensor lead con• Disconnect
nector.
sure to place a piece of cloth around the fuel hose joint.
• Be
Wipe
the dirt of the surface [A] around the connection
• using offa cloth
or a soft brush.
When removing with flat tip screwdriver
Insert the flat tip screwdriver [A] into slit on the joint lock
[B].
Turn the driver to disconnect the joint lock.
When removing with fingers
Open and push up [C] the joint lock with your fingers.

•
•
•

NOTICE
Prying or excessively widening the joint lock ends
for fuel hose removal will permanently deform the
joint lock, resulting in a loose or incomplete lock
that may allow fuel to leak and create the potential
for a fire explosion. To prevent fire or explosion
from a damaged joint lock, do not pry or excessively
widen the joint lock ends when removing the fuel
hose. The joint lock has a retaining edge that locks
around the housing.

• Pull the fuel hose joint [A] out of the delivery pipe [B].
WARNING
Fuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared
for fuel spillage; any spilled fuel must be completely
wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the
pipe. Cover the hose connection with a clean shop
towel to prevent fuel spillage.
the delivery pipe.
• Clean
Cover
the
delivery pipe with the vinyl bag to keep it clean.
•

2-24 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the vinyl bag on the pipe.
• Remove
Check
that
there are no flaws, burrs, and adhesion of
• foreign materials
on the delivery pipe [A].

the fuel hose with a new one.
• Replace
Run
the
fuel
hose correctly (see Cable, Wire, and Hose
• Routing section
in the Appendix chapter).
Insert
[A]
the
fuel
joint [B] straight onto the delivery
• pipe until the hosehose
joint clicks.
• Push [C] the joint lock [D].

and pull [A] the fuel hose joint [B] back and forth
• Push
more than two times and make sure it is locked and does
not come off.

WARNING
Leaking fuel can cause a fire or explosion resulting
in severe burns. Make sure the fuel hose joint is
installed correctly on the delivery pipe and that it
doesn’t leak.

•
•

If it comes off, reinstall the hose joint.
Install the removed parts (see appropriate chapters).
Start the engine and check the fuel hose for leaks.

Evaporative Emission Control System Inspection
(Other than US and CA Models)

the canister as follows.
• Inspect
Remove
the right lower fairing (see Lower Fairing Re• moval in the
Frame chapter).
Slide
the
clamps
• Remove the band[A][C].and disconnect the hoses [B].
• Remove the canister [D] from the bracket [E].
•

PERIODIC MAINTENANCE 2-25
Periodic Maintenance Procedures
inspect the canister [A] for cracks or other dam• Visually
age.
If the canister has any cracks or bad damage, replace it
with a new one.

NOTE

○The canister is designed to work well through the motorcycle’s life without any maintenance if it is used under
normal conditions.
the purge valve (see Purge Valve Inspection in
• Inspect
the Fuel System (DFI) chapter).

○Check that the hoses are securely connected and clips
are in position.

○Replace any kinked, deteriorated or damaged hoses.
○Run the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter.

○When installing the hoses, avoid sharp bending, kinking,
flattening or twisting, and run the hoses with a minimum of
bending so that the emission flow will not be obstructed.

Cooling System
Coolant Level Inspection
NOTE

○Check the level when the engine is cold (room or ambient temperature).
the coolant level in the reserve tank [A] with
• Check
the motorcycle held perpendicular (Do not use the side
stand).
If the coolant level is lower than the “L” level line [B], unscrew the reserve tank cap and add coolant to the “F”
level line [C].
“L”: Low
“F”: Full

NOTICE
For refilling, add the specified mixture of coolant
and soft water. Adding water alone dilutes the
coolant and degrades its anticorrosion properties.
The diluted coolant can attack the aluminum engine parts. In an emergency, soft water alone can
be added. But the diluted coolant must be returned
to the correct mixture ratio within a few days.
If coolant must be added often or the reservoir tank
has run completely dry, there is probably leakage in
the cooling system. Check the system for leaks.
Coolant ruins painted surfaces. Immediately wash
away any coolant that spills on the frame, engine,
wheels or other painted parts.

2-26 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Cooling System Inspection
Water Hose and Pipe Inspection (coolant leak, damage,
installation condition)
○The high pressure inside the water hose can cause
coolant to leak [A] or the hose to burst if the line is not
properly maintained.
Visually inspect the hoses for signs of deterioration.
Squeeze the hoses. A hose should not be hard and
brittle, nor should it be soft or swollen.
Replace the hose if any fraying, cracks [B] or bulges [C]
are noticed.
Check that the hoses are securely connected and clamps
are tightened correctly.

•
•

Torque - Water Hose Clamp Screws: 3.0 N·m (0.31 kgf·m,
27 in·lb)

Coolant Change

WARNING
Coolant can be extremely hot and cause severe
burns, is toxic and very slippery. Do not remove
the radiator cap or attempt to change the coolant
when the engine is hot; allow it cool completely.
Immediately wipe any spilled coolant from tires,
frame, engine or other painted parts. Do not ingest
coolant.

• Remove:
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
Radiator Cap [A]
Remove
the radiator cap in two steps. First turn the cap
○
counterclockwise to the first stop. Then push and turn it
further in the same direction and remove the cap.

a container under the drain bolt [A] of the water
• Place
pump cover.
the coolant from the radiator by removing the drain
• Drain
bolt.

PERIODIC MAINTENANCE 2-27
Periodic Maintenance Procedures

• Remove:
Coolant Reserve Tank Cover Bolts [A]
Collars