of the O-ring. Immediately blow the chain dry with
compressed air after cleaning. Complete cleaning
and drying the chain within 10 minutes.
chain oil to the sides of the rollers so that oil will
• Apply
penetrate to the rollers and bushings. Apply the 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-rings [B]
Wipe off lubricant that gets on the tire surface.

PERIODIC MAINTENANCE 2-41
Periodic Maintenance Procedures
Drive Chain Slack Inspection
NOTE

○Check the slack with the motorcycle setting on its side
stand.
○Clean the chain if it is dirty, and lubricate it if it appears
dry.
the wheel alignment (see Wheel Alignment Inspec• Check
tion).
the rear wheel to find the position where the chain
• Rotate
is tightest.
the vertical movement (chain slack) [A] midway
• Measure
between the sprockets.
If the chain slack exceeds the standard, adjust it.
Chain Slack
Standard:

20  30 mm (0.8  1.2 in.)

Drive Chain Slack Adjustment

the chain adjuster clamp bolt [A] (Both Sides).
• Loosen
Using
an
wrench [B], turn the adjusters [C] forward
• or rearwardAllen
until the drive chain has the correct amount

•

of chain slack.
Tighten:
Torque - Chain Adjuster Clamp Bolts: 65 N·m (6.6 kgf·m, 48
ft·lb)

Wheel Alignment Inspection

that the notch [A] on the swingarm should point
• Check
to the same marks or positions [B] on the adjuster (Both
Sides).
If they do not, adjust the chain slack (see Drive Chain
Slack Adjustment) and align the wheel alignment.

WARNING
Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.
Be sure the wheel is properly aligned.

Wheel Alignment Adjustment

the right retaining ring [A].
• Remove
Loosen
the
nut [B].
• Loosen the axle
right
chain adjuster clamp bolt [C], and turn
• the right chain adjuster
[D] so that the left and right

•

notches on the swingarm may point to the same marks
or positions on the left and right adjusters.
Tighten:
Torque - Chain Adjuster Clamp Bolt: 65 N·m (6.6 kgf·m, 48
ft·lb)
Rear Axle Nut: 100 N·m (10.2 kgf·m, 73.8 ft·lb)

the right retaining ring with a new one and install
• Replace
it.

2-42 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Drive Chain Wear Inspection

the chain cover (see Drive Chain Removal in the
• Remove
Final Drive chapter).
the rear wheel to inspect the drive chain for dam• Rotate
aged rollers, and loose pins and links.

•
•

If there is any irregularity, replace the drive chain.
Lubricate the drive chain if it appears dry.
Stretch the chain taut by hanging a 10 kg (22 lb) weight
[A] on the chain.
Measure the length of 20 links [B] on the straight part [C] of
the chain from the pin center of the 1st pin to the pin center
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.
Drive Chain 20-link Length
Standard:
317.5  318.2 mm (12.50  12.53 in.)
Service Limit: 319 mm (12.6 in.)

WARNING
A chain that breaks or jumps off the sprockets
could snag on the engine sprocket or lock the
rear wheel, severely damaging the motorcycle and
causing it to go out of control. Inspect the chain for
damage and proper adjustment before each ride.
If chain wear exceeds the service limit, replace it
with the standard chain.
Standard Chain
Make:
ENUMA
Type:

EK525ZX

Link:

112 links

Chain Guide Wear Inspection

the swingarm (see Swingarm Removal in the
• Remove
Suspension chapter).
inspect the chain guide [A].
• Visually
Replace the chain guide if it shows any signs of abnormal
wear or damage.

PERIODIC MAINTENANCE 2-43
Periodic Maintenance Procedures
Brakes
Brake System Inspection
Brake Fluid Leak (Brake Hose and Pipe) Inspection
Remove the air cleaner housing (see Air Cleaner Housing
Removal in the Fuel System (DFI) chapter).
Apply the brake lever or pedal and inspect the brake fluid
leak from the brake hoses [A], pipes [B] and fittings [C].
If the brake fluid leaked from any position, inspect or replace the problem part.

•
•

2-44 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Brake Hose and Pipe Damage and Installation Condition Inspection
Remove the air cleaner housing (see Air Cleaner Housing
Removal in the Fuel System (DFI) chapter).
Inspect the brake hoses, pipe and fittings for deterioration, cracks and signs of leakage.
○The high pressure inside the brake line can cause fluid to
leak [A] or the hose, pipe to burst if the line is not properly
maintained. Bend and twist the rubber hose while examining it.
Replace the hose and pipe if any crack [B], bulge [C] or
leakage is noticed.
Tighten any brake hose banjo bolts and brake pipe joint
nuts.

•
•

Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
Brake Pipe Joint Nuts: 18 N·m (1.8 kgf·m, 13 ft·lb)

the brake hose and pipe routing.
• Inspect
If any brake hose and pipe routing is incorrect, run the
brake hose and pipe according to Cable, Wire, and Hose
Routing section in the Appendix chapter.

Brake Operation Inspection

the operation of the front and rear brake by run• Inspect
ning the vehicle on the dry road.
If the brake operation is insufficiency, inspect the brake
system.

WARNING
When test riding the vehicle, be aware of surrounding traffic for your safety.

Brake Fluid Level Inspection

that the brake fluid level in the front brake reservoir
• Check
[A] is above the lower level line [B].

NOTE

○Hold the reservoir horizontal by turning the handlebars
when checking brake fluid level.
If the fluid level is lower than the lower level line, fill the
reservoir to the upper level line [C].
○Remove the stopper [D].

PERIODIC MAINTENANCE 2-45
Periodic Maintenance Procedures
that the brake fluid level in the rear brake reservoir
• Check
[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].
○Remove the stopper [D].

WARNING
Mixing brands and types of brake fluid can reduce
the brake system’s effectiveness and cause an accident resulting in injury or death. Do not mix two
brands of brake 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.
Recommended Disc Brake Fluid
Grade:
DOT4

the procedure below to install the rear brake fluid
• Follow
reservoir cap correctly.

○First, tighten the brake fluid reservoir cap [A] clockwise

•

[B] by hand until slight resistance is felt indicating that the
cap is seated on the reservoir body [C], then tighten the
cap an additional 1/6 turn [D] while holding the brake fluid
reservoir body.
Install the stopper and tighten the screw.

Brake Fluid Change
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.
the brake fluid reservoir.
• Level
Remove
• aphragm. the reservoir cap, diaphragm plate and dithe rubber cap [A] from the bleed valve on the
• Remove
caliper.
a clear plastic hose [B] to the bleed valve, and run
• Attach
the other end of the hose into a container.
• Fill the reservoir with fresh specified brake fluid.

2-46 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the brake fluid.
•○Change
Repeat this operation until fresh brake fluid comes out
from the plastic hose or the color of the fluid changes.
1. Open the bleed valve [A].
2. Apply the brake and hold it [B].
3. Close the bleed valve [C].
4. Release the brake [D].

NOTE

○The fluid level must be checked often during the changing operation and replenished with fresh brake fluid. If
the fluid in the reservoir runs out any time during the
changing operation, the brakes will need to be bled
since air will have entered the brake line.
○Front Brake: Repeat the above steps for the other
caliper.
the clear plastic hose.
• Remove
Install
the
• Tighten: diaphragm, diaphragm plate and reservoir cap.
•
Torque - Front Brake Reservoir Cap Stopper Screw: 1.5
N·m (0.15 kgf·m, 13 in·lb)

the procedure below to install the rear brake fluid
• Follow
reservoir cap correctly.

○First, tighten the rear brake fluid reservoir cap [A] clockwise [B] by hand until slight resistance is felt indicating
that the cap is seated on the reservoir body [C], then
tighten the cap an additional 1/6 turn [D] while holding the
brake fluid reservoir body.

• Tighten the bleed valve, and install the rubber cap.
Torque - Bleed Valves: 8.0 N·m (0.82 kgf·m, 71 in·lb)

changing the fluid, check the brake for good braking
• After
power, no brake drag, and no fluid leakage.
If necessary, bleed the air from the lines.

Brake Hose and Pipe Replacement
NOTICE
Brake fluid quickly damages painted plastic surfaces; any spilled fluid should be completely
washed away immediately.

PERIODIC MAINTENANCE 2-47
Periodic Maintenance Procedures
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2-48 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
NOTE

○When removing the brake pipes and hoses on the hydraulic unit, remove them with the flare nut wrench according to each assembly of the exploded view in the
Brakes chapter.

• Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal

•
•

in the Fuel System (DFI) chapter)
Battery Case (see Battery Case Removal in the Frame
chapter)
Brake Pipe Joint Nuts [A]
Brake Hose Banjo Bolts [B]
Bolts [C]
Clamps
There are washers on each side of the brake hose and
pipe fitting. Replace them with new ones when installing.
Before installing the brake pipe, check to see that there is
no damage on the threads of the brake pipe joint nut.
If there is any damage, replace the damaged parts with
new ones.

NOTE

○Tighten the brake pipe joint nut at both ends of the brake
pipe temporarily and then tighten them to the specified
torque.
the brake pipes and brake hoses to the specified
• Install
angle (see Cable, Wire, and Hose Routing section in the

•
•

Appendix chapter).
Tighten the brake pipe joint nuts with the flare nut wrench.
Tighten:
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
Brake Pipe Joint Nuts: 18 N·m (1.8 kgf·m, 13 ft·lb)

the brake line after installing the brake hose and pipe
• Fill
(see Brake Fluid Change).

PERIODIC MAINTENANCE 2-49
Periodic Maintenance Procedures

2-50 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Master Cylinder Rubber Parts Replacement
Front Master Cylinder Disassembly
Remove the front master cylinder (see Front Master Cylinder Removal in the Brakes chapter).
Remove the seal cover [A], circlip [B], connector [C] and
O-ring [D].

•
•

Special Tool - Inside Circlip Pliers: 57001-143

the locknut [E] and pivot bolt [F], and remove the
• Unscrew
brake lever.
the bleed valve [G] and rubber cap [H].
• Remove
Remove
piston assembly [I] as follows.
•○Remove the
the dust cover and push rod.

○Remove the circlip [J].
○Pull out the piston (with primary cup and secondary cup).
○Remove the return spring and spring guide.

• Replace:
Seal Cover [A]

Circlip [B]
O-ring [D]
Rubber Cap [H]
Piston Assembly [I]
Circlip [J]
Diaphragm [K]
Rear Master Cylinder Disassembly
Remove the rear master cylinder (see Rear Master Cylinder Removal in the Brakes chapter).
Remove the circlip [A], connector [B] and O-ring [C].

•
•

Special Tool - Inside Circlip Pliers: 57001-143

the dust cover [D] out of place, and remove the cir• Slide
clip [E].
out the push rod assembly [F].
• Pull
Remove
the piston assembly [G] and return spring [H].
•

NOTICE
Do not remove the secondary cup from the piston
since removal will damage it.

• Replace:
Circlip [A]
O-ring [C]
Circlip [E]
Push Rod Assembly [F]
Piston Assembly [G]
Diaphragm [I]

PERIODIC MAINTENANCE 2-51
Periodic Maintenance Procedures
Master Cylinder Assembly
Before assembly, clean all parts including the master
cylinder with brake fluid or alcohol.

•

NOTICE
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.
brake fluid to the new parts and to the inner wall of
• Apply
the cylinder.
care not to scratch the piston or the inner wall of the
• Take
cylinder.
• Apply silicone grease to the followings.
Front:

Brake Lever Pivot Bolt

Rear:

Dust Cover of Push Rod Assembly

the front master cylinder, tighten the brake lever pivot
• For
bolt and the locknut.
Torque - Brake Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 8.9
in·lb)
Brake Lever Pivot Bolt Locknut: 5.9 N·m (0.60
kgf·m, 52 in·lb)

the front master cylinder, install the bleed valve and
• For
rubber cap.
Torque - Front Master Cylinder Bleed Valve: 5.4 N·m (0.55
kgf·m, 48 in·lb)

Caliper Rubber Parts Replacement
Front Caliper Disassembly
Loosen the front caliper pad pins [A] and banjo bolt [B]
and tighten them loosely.
Remove:
Front Caliper [C] (see Front Caliper Removal in the
Brakes chapter)
Brake Pads (see Front Brake Pad Removal in the Brakes
chapter)

•
•

the pistons nearest the oil passage [A] with the
• Hold
bands [B].

2-52 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
compressed air, remove the pistons.
•○Using
Cover the caliper opening with a clean heavy cloth [A].

○Lightly apply compressed air [B] to the oil passage.
WARNING

The piston in the brake caliper can crush hands and
fingers. Never place your hand or fingers in front of
the piston.

○Pull out the pistons by hand.
the dust seals [A] and fluid seals [B].
• Remove
Cut
the
bands.
• Repeat the previous step to remove the pistons from the
• other side of the caliper body.
• Remove the bleed valve and rubber cap.

Front Caliper Assembly
Clean the caliper parts except for the pads.

•

NOTICE
For cleaning the parts, use only disc brake fluid,
isopropyl alcohol, or ethyl alcohol.
the bleed valve and rubber cap.
• Install
Tighten:
•
Torque - Bleed Valves: 8.0 N·m (0.82 kgf·m, 71 in·lb)

the fluid seals [A] with new ones.
•○Replace
Apply silicone grease to the fluid seals, and install them
into the cylinders by hand.
Replace the dust seals [B] with new ones if they are damaged.
○Apply silicone grease to the dust seals, and install them
into the cylinders by hand.

•

brake fluid to the outside of the pistons, and push
• Apply
them into each cylinder by hand.
the removed parts (see appropriate chapters).
• Install
Wipe
up
• cloth. any spilled brake fluid on the caliper with wet

PERIODIC MAINTENANCE 2-53
Periodic Maintenance Procedures
Rear Caliper Disassembly
Remove:
Rear Caliper (see Rear Caliper Removal in the Brakes
chapter)
Brake Pads (see Rear Brake Pad Removal in the Brakes
chapter)
Caliper Holder [A]

•

• Remove:
Dust Boot [A]
Friction Boot [B]

compressed air, remove the piston.
•○Using
Cover the caliper opening with a clean heavy cloth [A].

○Remove the piston by lightly applying compressed air [B]
to where the brake line fits into the caliper.

WARNING
The piston in the brake caliper can crush hands and
fingers. Never place your hand or fingers in front of
the piston.
the pad spring.
• Remove
the dust seal and fluid seal.
• Remove
Remove
the
bleed valve and rubber cap.
•
Rear Caliper Assembly
Clean the caliper parts except for the pads.

•

NOTICE