up the coolant reserve tank [A].
• Pull
Disconnect
overflow hose [B].
• Remove thethecapradiator
[C].
• Pour the coolant into
a container.
• Install:
• Radiator Overflow Hose

•
•

Coolant Reserve Tank
Collars
Apply a non-permanent locking agent to the threads of
the coolant reserve tank cover bolts and tighten them.
Tighten the drain bolt with new gasket.
Torque - Coolant Drain Bolt: 11 N·m (1.1 kgf·m, 97 in·lb)

filling the coolant, choose a suitable mixture ratio
• When
by referring to the coolant manufacturer’s directions.

NOTICE
Soft or distilled water must be used with the antifreeze in the cooling system.
If hard water is used in the system, it causes scales
accumulation in the water passages, and considerably reduces the efficiency of the cooling system.
Water and Coolant Mixture Ratio (Recommended)
Soft Water:
50%
Coolant:

50%

Freezing Point:

–35°C (–31°F)

Total Amount:

2.9 L (3.1 US qt)

• Fill the radiator up to the filler neck [A] with coolant.
NOTE

○Pour in the coolant slowly so that it can expel the air
from the engine and radiator.
the cooling system for leaks.
• Check
Tap
the
• side. water hoses to force any air bubbles caught in-

2-28 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the reserve tank up to the “F” (full) level line [A] with
• Fill
coolant and install the cap [B].
the radiator cap.
• Install
Start
the
warm it up thoroughly until the radiator
• fan turns engine,
on and then stop the engine.
the coolant level in the reserve tank after the en• Check
gine cools down.
If the coolant level is lower than the “L” (low) level line [C],
add coolant to the “F” level line.

NOTICE
Do not add more coolant above the “F” level line.

PERIODIC MAINTENANCE 2-29
Periodic Maintenance Procedures
Water Hose and O-ring Replacement

the coolant (see Coolant Change).
• Drain
• Remove:
Oil Cooler [A] (see Oil Cooler Removal in the Engine

•
•
•
•

Lubrication System chapter)
Thermostat Housing Cover [B] (see Thermostat Removal in the Cooling System chapter)
Water Pump Housing [C] (see Water Pump Removal in
the Cooling System chapter)
Replace the hoses [D] and O-rings [E] with new ones.
Apply grease or soap and water solution to the new O
-rings.
Run the new hoses according to Cable, Wire, and Hose
Routing section in the Appendix chapter.
Tighten:
Torque - Water Hose Clamp Screws: 3.0 N·m (0.31 kgf·m,
27 in·lb)

the removed parts (see appropriate chapters).
• Install
Fill
the
coolant (see Coolant Change).
• Check the
cooling system for leaks.
•

2-30 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Engine Top End
Valve Clearance Inspection
NOTE

○Valve clearance must be checked and adjusted when
the engine is cold (at room temperature).

• Remove:
Cylinder Head Cover (see Cylinder Head Cover Removal in the Engine Top End chapter)
Crankshaft Sensor Cover (see Crankshaft Sensor Removal in the Electrical System chapter)
a wrench on the timing rotor bolt [A], turn the crank• Using
shaft clockwise until the line [B] (TDC mark for #1,4 pistons) on the timing rotor is aligned with the mating surface
[C] of the crankcase.

a thickness gauge [A], measure the valve clearance
• Using
between the cam and the valve lifter.
Valve Clearance
Standard:
Exhaust 0.22  0.31 mm (0.0087  0.0122 in.)
Intake

0.13  0.22 mm (0.0051  0.0087 in.)

NOTE

○Thickness gauge is horizontally inserted on the valve
lifter.
Appropriateness [A]
Inadequacy [B]
Thickness Gauge [C]
Horizontally Inserts [D]
Cam [E]
Valve Lifter [F]
Hits the Valve Lifter Ahead [G]

PERIODIC MAINTENANCE 2-31
Periodic Maintenance Procedures

○When positioning #1 piston TDC at the end of the
compression stroke:
Intake Valve Clearance of #1 and #3 Cylinders
Exhaust Valve Clearance of #1 and #2 Cylinders
Measuring Valve [A]

○When positioning #4 piston TDC at the end of the
compression stroke:
Intake Valve Clearance of #2 and #4 Cylinders
Exhaust Valve Clearance of #3 and #4 Cylinders
Measuring Valve [A]

If the valve clearance is not within the specified range,
first record the clearance, and then adjust it.

Valve Clearance Adjustment

change the valve clearance, remove the camshaft
• To
chain tensioner, camshafts and valve lifters. Replace the
shim with one of a different thickness.

NOTE

○Mark and record the locations of the valve lifters and
shims so that they can be reinstalled in their original
positions.

2-32 PERIODIC MAINTENANCE
Periodic Maintenance Procedures

○Besides the standard shims in the valve clearance adjustment charts, the following shims may be installed at the
factory. Although they are not available as spare parts,
they can be used to adjust valve clearance.
Adjustment Shims
Thickness
2.675 mm
2.725 mm
2.775 mm
2.825 mm
2.875 mm
2.925 mm
2.975 mm
3.025 mm
3.075 mm
3.125 mm
3.175 mm
3.225 mm
3.275 mm
3.325 mm

the shim to remove any dust or oil.
• Clean
Measure
the thickness of the removed shim [A].
•

PERIODIC MAINTENANCE 2-33
Periodic Maintenance Procedures
VALVE CLEARANCE ADJUSTMENT CHART INTAKE VALVE

1.
2.
3.
4.

Measure the clearance (when engine is cold).
Check present shim size.
Match clearance in vertical column with present shim size in horizontal column.
Install the shim specified where the lines intersect. This shim will give the proper clearance.

Example:

Present shim is 2.95 mm
Measured clearance is 0.45 mm
Replace 2.95 mm shim with 3.20 mm shim.

5. Remeasure the valve clearance and readjust if necessary.

2-34 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE

1.
2.
3.
4.

Measure the clearance (when engine is cold).
Check present shim size.
Match clearance in vertical column with present shim size in horizontal column.
Install the shim specified where the lines intersect. This shim will give the proper clearance.

Example:

Present shim is 2.95 mm.
Measured clearance is 0.47 mm.
Replace 2.95 mm shim with 3.15 mm shim.

5. Remeasure the valve clearance and readjust if necessary.

PERIODIC MAINTENANCE 2-35
Periodic Maintenance Procedures
NOTICE
Be sure to remeasure the clearance after selecting
a shim according to the table. If the clearance is out
of the specified range, use the additional shim.

○If there is no valve clearance, use a shim that is a few

•

sizes smaller, and remeasure the valve clearance.
When installing the shim, face the marked side toward the
valve lifter. At this time, apply engine oil to the shim or
the valve lifter to keep the shim in place during camshaft
installation.

NOTICE
Do not put shim stock under the shim. This may
cause the shim to pop out at high rpm, causing extensive engine damage.
Do not grind the shim. This may cause it to fracture,
causing extensive engine damage.
engine oil to the valve lifter surface and install the
• Apply
lifter.
the camshafts (see Camshaft Installation in the En• Install
gine Top End chapter).
the valve clearance and readjust if necessary.
• Recheck
• Install the removed parts (see appropriate chapters).

Air Suction System Damage Inspection

• Remove:
Right Lower Fairing (see Lower Fairing Removal in the
•

Frame chapter)
Clamp [A] (Other than US and CA Models)
Disconnect:
Subthrottle Sensor Connector [B]
Air Switching Valve Hose [C]

the subthrottle sensor connector.
• Connect
Start
the
engine and run it at idle speed.
• Plug the air
switching valve hose end [A] with your finger
• and feel vacuum
pulsing in the hose.
If there is no vacuum pulsation, check the hose line for
leak. If there is no leak, check the air switching valve
(see Air Switching Valve Unit Test in the Electrical System chapter) or air suction valve (see Air Suction Valve
Inspection in the Engine Top End chapter).

2-36 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Clutch
Clutch Operation Inspection

the clutch lever just enough to take up the free play
• Pull
[A].
the gap between the lever and the lever holder.
• Measure
If the gap is too wide, the clutch may not release fully. If
the gap is too narrow, the clutch may not engage fully. In
either case, adjust it.
Clutch Lever Free Play
Standard: 2  3 mm (0.08  0.12 in.)

WARNING
The engine and exhaust system get extremely hot
during normal operation and can cause serious
burns. Never touch the engine or exhaust pipe
during clutch adjustment.
the locknut [A].
• Loosen
Turn
the
[B] so that 5  6 mm (0.20  0.24 in.) [C]
• of threadsadjuster
is visible.
the right lower fairing (see Lower Fairing Re• Remove
moval in the Frame chapter).
the dust cover [A] at the clutch cable lower end out
• Slide
of place.
both adjusting nuts [B] at the clutch cover as far
• Loosen
as they will go.
the clutch outer cable [C] tight and tighten the adjust• Pull
ing nuts against the clutch cover [D].
the dust cover back onto place.
• Slip
Turn
the adjuster at the clutch lever until the free play is
• correct.
the release lever [A] toward the front of the motor• Push
cycle until it becomes hard to turn.

○At this time, the release lever should have the proper an-

gle shown.
60° [B]
If the angle is wrong, check the clutch and release parts
for wear.

WARNING
Too much cable play can prevent clutch disengagement and cause an accident resulting in serious injury or death. When adjusting the clutch or replacing the cable, be sure the upper end of the clutch
outer cable is fully seated in its fitting, or it could
slip into place later, creating enough cable play to
prevent clutch disengagement.
the adjustment, start the engine and check that the
• After
clutch does not slip and that it releases properly.

PERIODIC MAINTENANCE 2-37
Periodic Maintenance Procedures
Engine Lubrication System
Engine Oil Change

the motorcycle so that it is vertical after warming
• Situate
up the engine.
the engine oil drain bolt [A] to drain the oil.
•○Remove
The oil in the oil filter can be drained by removing the filter

•
•

(see Oil Filter Replacement).
Replace the drain bolt gasket [B] with a new one.
Tighten the drain bolt.
Torque - Engine Oil Drain Bolt: 29 N·m (3.0 kgf·m, 21 ft·lb)

• Remove the oil filler plug [A].

• Pour in the specified type and amount of oil.
Recommended Engine Oil
Type:
API SG, SH, SJ, SL or SM with JASO MA,
MA1 or MA2
Viscosity:

SAE 10W-40

Capacity:

3.2 L (3.4 US qt) (when filter is not removed)
3.8 L (4.0 US qt) (when filter is removed)
4.0 L (4.2 US qt) (when engine is completely
dry)

NOTE

○Do not add any chemical additive to the oil.Oils fulfilling
the above requirements are fully formulated and provide
adequate lubrication for both the engine and the clutch.
○Although 10W-40 engine oil is the recommended oil
for most conditions, the oil viscosity may need to be
changed to accommodate atmospheric conditions in
your riding area.
the O-ring of the oil filler plug with a new one.
• Replace
Apply
grease
to the new O-ring.
• Install the oil filler
plug.
•
Torque - Oil Filler Plug: Hand-tighten

the oil level (see Oil Level Inspection in the Engine
• Check
Lubrication System chapter).

2-38 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Oil Filter Replacement

the engine oil (see Engine Oil Change).
• Drain
• Remove the oil filter with the oil filter wrench [A].
Special Tool - Oil Filter Wrench: 57001-1249

the filter with a new one.
• Replace
Apply
grease
to the gasket [A] before installation.
• Tighten the filter
with the oil filter wrench.
•
Special Tool - Oil Filter Wrench: 57001-1249
Torque - Oil Filter: 17 N·m (1.7 kgf·m, 13 ft·lb)

NOTE

○Hand tightening of the oil filter can not be allowed since
it does not reach to this tightening torque.
in the specified type and capacity of oil (see Engine
• Pour
Oil Change).

Wheels/Tires
Air Pressure Inspection

the air valve cap.
• Remove
Measure
tire air pressure with an air pressure gauge
• [A] when the
the tires are cold (that is, when the motorcycle

•

has not been ridden more than a mile during the past 3
hours).
Install the air valve cap.
Adjust the tire air pressure according to the specifications
if necessary.
Air Pressure (when Cold)
Front: Up to 195 kg (430 lb) load:
250 kPa (2.50 kgf/cm², 36 psi)
Rear:

Up to 195 kg (430 lb) load:
290 kPa (2.90 kgf/cm², 42 psi)

Wheels and Tires Inspection
Wheel/Tire Damage Inspection
Remove any imbedded stones [A] or other foreign particles [B] from tread.
Visually inspect the tire for cracks and cuts, and replace
the tire if necessary. Swelling or high spots indicate internal damage, requiring tire replacement.
Visually inspect the wheel for cracks, cuts and dents damage.
If any damage is found, replace the wheel if necessary.

•
•
•

PERIODIC MAINTENANCE 2-39
Periodic Maintenance Procedures
Tire Tread Wear Inspection
As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is
that 90% of all tire failures occur during the last 10% of tread
life (90% worn). So it is false economy and unsafe to use
the tires until they are bald.
Measure the tread depth at the center of the tread with a
depth gauge [A]. Since the tire may wear unevenly, take
measurement at several places.
If any measurement is less than the service limit, replace
the tire (see Tire Removal/Installation in the Wheels/Tires
chapter).

•

Tread Depth
Standard:
Front

3.6 mm (0.14 in.)

Rear

5.8 mm (0.23 in.)

Service Limit:
Front

1 mm (0.04 in.)
(AT, CH, DE) 1.6 mm (0.06 in.)

Rear

2 mm (0.08 in.) (Up to 130 km/h (80 mph))
3 mm (0.12 in.) (Over 130 km/h (80 mph))

WARNING
Some replacement tires may adversely affect handling and cause an accident resulting in serious injury or death. To ensure proper handling and stability, use only the recommended standard tires for
replacement, inflated to the standard pressure.

NOTE

○Most countries may have their own regulations a minimum tire tread depth: be sure to follow them.
○Check and balance the wheel when a tire is replaced
with a new one.

Wheel Bearing Damage Inspection

the front wheel off the ground with the jack (see
• Raise
Front Wheel Removal in the Wheels/Tires chapter).
Special Tools - Jack: 57001-1238
Jack Attachment: 57001-1608

the handlebars all the way to the right or left.
• Turn
Inspect
roughness of the front wheel bearing by push• ing and the
pulling [A] the wheel.
Spin
[B]
the front wheel lightly, and check for smoothly
• turn, roughness,
binding or noise.
If roughness, binding or noise is found, remove the front
wheel and inspect the wheel bearing (see Front Wheel
Removal, Hub Bearing Inspection in the Wheels/Tires
chapter).

2-40 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the rear wheel off the ground with the stand (see
• Raise
Rear Wheel Removal in the Wheels/Tires chapter).
the roughness of the rear wheel bearing by push• Inspect
ing and pulling [A] the wheel.
[B] the rear wheel lightly, and check for smoothly
• Spin
turn, roughness, binding or noise.
If roughness, binding or noise is found, remove the rear
wheel and inspect the wheel bearing (see Rear Wheel Removal, Hub Bearing Inspection in the Wheels/Tires chapter) and coupling (see Coupling Bearing Inspection in the
Final Drive chapter).

Final Drive
Drive Chain Lubrication Condition Inspection
Lubrication is necessary after riding through rain or on wet
roads, or any time that the chain appears dry.
Use a lubricant for sealed chains to prevent deterioration
of chain seals. If the chain is especially dirty, clean it using a
cleaner for sealed chains following the instructions supplied
by the chain cleaner manufacturer.

NOTICE
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 chain cleaner for cleaning of the O-ring of
the drive chain. Any other cleaning solution such
as gasoline will cause deterioration and swelling