Install the 3rd/4th gear onto the drive shaft with their oil
holes aligned.
Install the 5th and 6th gear bushings onto the drive shaft
with their oil holes aligned.
The output shaft gears can be recognized by size: the
gear with the largest diameter is 1st gear, and the smallest one is 6th gear. Be sure that all parts are put back
in the correct sequence and all circlips and washers are
properly in place.
Install the 6th gear onto the output shaft with their oil holes
aligned.
Install the 2nd and 3rd/4th gear bushings onto the output
shaft with their oil holes aligned.

NOTE

○When the toothed washers are assembled onto the
each shaft, note the following.
○Align the punch marks [A] of the toothed washers (only
on drive shaft).
○When the tangs [B] of the toothed washer shall be assembled, they should be installed into the notch [C] of
the toothed washer.
the steel balls into the 5th gear holes in the output
• Fit
shaft, aligning the holes as shown.
5th Gear [A]
Output Shaft [B]
Steel Balls [C]

NOTICE
Do not apply grease to the balls to hold them in
place. This will cause the positive neutral finder
mechanism to malfunction.

○After assembling the 5th gear with steel balls in place on

•

the output shaft, check the ball-locking effect that the 5th
gear doesn’t come out of the output shaft when moving it
up and down by hand.
Check that each gear spins or slides freely on the transmission shafts without binding after assembly.

CRANKSHAFT/TRANSMISSION 9-37
Transmission
This page intentionally left blank.

9-38 CRANKSHAFT/TRANSMISSION
Transmission

CRANKSHAFT/TRANSMISSION 9-39
Transmission
1. Output Shaft
2. Collar
3. Ball Bearings
4. Bushing
5. 2nd Gear (39 T)
6. Washer ( 34 × 28.1)
7. Circlips ( 33 × 25.9)
8. Top Gear (31 T)
9. Toothed Washer ( 34)
10. 4th Gear (25 T)
11. Bushings
12. Toothed Washer ( 40.5)
13. Toothed Washer ( 37)
14. 3rd Gear (24 T)
15. Steel Balls
16. 5th Gear (26 T)
17. Low Gear (39 T)
18. Washers ( 31 × 20.5)
19. Races
20. Needle Bearings
21. Circlips ( 22.2 × 18.7)
22. Needle Bearing
23. Low Gear (15 T) (Drive Shaft)
24. Bushing
25. 5th Gear (21 T)
26. Toothed Washers ( 31)
27. Circlips ( 29 × 22.6)
28. 3rd/4th Gear (15 T/18 T)
29. Bushing
30. Top Gear (28 T)
31. Toothed Washer ( 34.2)
32. Toothed Washer ( 32)
33. 2nd Gear (20 T)
34. Washer ( 30 × 20.5)

9-40 CRANKSHAFT/TRANSMISSION
Transmission
Shift Drum and Fork Removal
NOTICE
Never drop the shift drum, especially on a hard surface. Such a shock to the shift drum can damage it.

• Remove:
Lower Crankcase Half (see Crankcase Splitting)

•
•

Transmission Shafts (see Transmission Shaft Removal)
Gear Positioning Lever (see External Shift Mechanism
Removal)
Shift Drum Bearing Holder Bolts [A]
Shift Drum Bearing Holder [B]
Pull out the shift rods [C], and remove the shift forks.
Pull out the shift drum [D].

Shift Drum and Fork Installation

engine oil to the shift drum, forks and rods.
• Apply
Install
the shift drum [A].
•○Take care
not to damage the magnet part [B] of the shift
drum.
Install the shift rods [C] and shift forks, note the following.
○The rods are identical.
○Position the one with shortest ears [D] on the drive shaft
and place the pin in the center groove in the shift drum.
○The two forks [E] on the output shaft are identical.
○Install the forks so that its “0061” and “0062” side faces
engine left side.
Apply a non-permanent locking agent to the threads of
the shift drum bearing holder bolts, and tighten them.

•

•

Torque - Shift Drum Bearing Holder Bolts: 12 N·m (1.2
kgf·m, 106 in·lb)

• Install the removed parts (see appropriate chapters).
Shift Drum Disassembly

the shift drum (see Shift Drum and Fork Re• Remove
moval).
holding the shift drum with a vise, remove the shift
• While
drum cam holder bolt [A].
• Remove:
Shift Drum Cam [B]
Dowel Pin [C]
Ball Bearing [D]

CRANKSHAFT/TRANSMISSION 9-41
Transmission
Shift Drum Assembly

• Install:
Ball Bearing [A]

Dowel Pin [B] and Shift Drum Cam [C]

○Align the pin with the groove in the shift drum cam.

a non-permanent locking agent to the threads of
• Apply
the shift drum cam holder bolt [D] and tighten it.
Torque - Shift Drum Cam Holder Bolt: 12 N·m (1.2 kgf·m,
106 in·lb)

Shift Fork Bending Inspection

inspect the shift forks, and replace any fork that is
• Visually
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/Gear Groove Wear Inspection

the thickness of the shift fork ears [A], and mea• Measure
sure the width of the gear grooves [B].
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:
5.9  6.0 mm (0.232  0.236 in.)
Service Limit: 5.8 mm (0.228 in.)

If the gear groove is worn over the service limit, the gear
must be replaced.
Gear Groove Width
Standard:
6.05  6.15 mm (0.238  0.242 in.)
Service Limit: 6.3 mm (0.25 in.)

Shift Fork Guide Pin/Drum Groove Wear
Inspection

the diameter of each shift fork guide pin [A], and
• Measure
measure the width of each shift drum groove [B].
If the guide pin on any shift fork is less than the service
limit, the fork must be replaced.
Shift Fork Guide Pin Diameter
Standard:
6.9  7.0 mm (0.272  0.276 in.)
Service Limit: 6.8 mm (0.268 in.)

If any shift drum groove is worn over the service limit, the
drum must be replaced.
Shift Drum Groove Width
Standard:
7.05  7.20 mm (0.278  0.283 in.)
Service Limit: 7.3 mm (0.29 in.)

If the shift drum has been replaced, replace the gear position sensor as a set.

9-42 CRANKSHAFT/TRANSMISSION
Transmission
Gear Dog and Gear Dog Hole Damage Inspection

inspect the gear dogs [A] and gear dog holes [B].
• Visually
Replace any damaged gears or gears with excessively
worn dogs or dog holes.

CRANKSHAFT/TRANSMISSION 9-43
Ball Bearing, Needle Bearing, and Oil Seal
Ball and Needle Bearing Replacement
NOTICE
Do not remove the ball or needle bearings unless it
is necessary. Removal may damage them.
a press or puller, remove the ball bearing and/or
• Using
needle bearings.

NOTE

○In the absence of the above mentioned tools, satisfactory results may be obtained by heating the case to approximately 93°C (200°F) max., and tapping the bearing
in or out.

NOTICE
Do not heat the case with a torch. This will warp the
case. Soak the case in oil and heat the oil.
a press and the bearing driver set [A], install the
• Using
new ball bearing until it stops at the bottom of its housing.

○The

new needle bearings must be pressed into the
crankcase so that the end is flush with the end of the
hole.
Special Tool - Bearing Driver Set: 57001-1129

Ball and Needle Bearing Wear Inspection
NOTICE
Do not remove the bearings for inspection. Removal may damage them.
the ball bearings.
•○Check
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 [A] the bearing by hand to check its condition.
If the bearing is noisy, does not spin smoothly, or has any
rough spots, 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, color change, or other
damage.
If there is any doubt as to the condition of a needle bearing, replace it.

•

Oil Seal Inspection

the oil seals.
• Inspect
Replace it if the lips are misshapen, discolored (indicating
that the rubber has deteriorated), hardened or otherwise
damaged.

WHEELS/TIRES 10-1

Wheels/Tires
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Wheels (Rims) ........................................................................................................................
Front Wheel Removal .......................................................................................................
Front Wheel Installation ....................................................................................................
Rear Wheel Removal........................................................................................................
Rear Wheel Installation.....................................................................................................
Wheel Inspection ..............................................................................................................
Axle Inspection..................................................................................................................
Balance Inspection............................................................................................................
Balance Adjustment ..........................................................................................................
Balance Weight Removal..................................................................................................
Balance Weight Installation...............................................................................................
Tires........................................................................................................................................
Air Pressure Inspection/Adjustment..................................................................................
Tire Inspection ..................................................................................................................
Tire Removal.....................................................................................................................
Tire Installation..................................................................................................................
Tire Repair ........................................................................................................................
Hub Bearing............................................................................................................................
Hub Bearing Removal.......................................................................................................
Hub Bearing Installation....................................................................................................
Hub Bearing Inspection.....................................................................................................
Hub Bearing Lubrication ...................................................................................................

10-2
10-4
10-5
10-6
10-6
10-6
10-7
10-8
10-10
10-10
10-11
10-11
10-11
10-11
10-13
10-13
10-13
10-13
10-13
10-15
10-16
10-16
10-16
10-16
10-17

10

10-2 WHEELS/TIRES
Exploded View

WHEELS/TIRES 10-3
Exploded View
No.
1
2
3

Fastener
Front Axle Clamp Bolt
Front Axle
Rear Axle Nut

G: Apply grease.
HG: Apply high-temperature grease.
R: Replacement Parts
WL: Apply soap and water solution or rubber lubricant.

N·m
20
108
108

Torque
kgf·m
2.0
11.0
11.0

ft·lb
15
79.7
79.7

Remarks

G

10-4 WHEELS/TIRES
Specifications
Item
Wheels (Rims)
Rim Runout:
Axial
Radial
Axle Runout/100 mm
(3.94 in.)
Wheel Balance
Balance Weights

Standard

TIR 0.5 mm (0.02 in.) or less
TIR 0.8 mm (0.03 in.) or less
TIR 0.03 mm (0.001 in.) or less
10 g (0.35 oz.) or less
10 g (0.35 oz.), 20 g (0.71 oz.), 30 g
(1.06 oz.)

Rim Size:
Front
J17M/C × MT3.50
Rear
J17M/C × MT5.50
Tires
Air Pressure (when cold):
Front
Up to 180 kg (397 lb) load: 250 kPa
(2.50 kgf/cm², 36 psi)
Rear
Up to 180 kg (397 lb) load: 290 kPa
(2.90 kgf/cm², 42 psi)
Tread Depth:
Front
4.0 mm (0.16 in.)

Rear

Standard Tire:
Front
Make
Type
Size
Rear
Make
Type
Size

5.3 mm (0.21 in.)

Service Limit

TIR 1.0 mm (0.04 in.)
TIR 1.0 mm (0.04 in.)
TIR 0.2 mm (0.008 in.)
– – –
– – –

– – –
– – –

– – –
– – –

1 mm (0.04 in.)
(AT, CH, DE) 1.6 mm
(0.06 in.)
Up to 130 km/h (80 mph):
2 mm (0.08 in.)
Over 130 km/h (80 mph):
3 mm (0.12 in.)

DUNLOP
SPORTMAX D214F Z
120/70ZR17 M/C (58W)

– – –
– – –
– – –

DUNLOP
SPORTMAX D214Z
180/55ZR17 M/C (73W)

– – –
– – –
– – –

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.

WHEELS/TIRES 10-5
Special Tools
Bearing Driver Set:
57001-1129

Bearing Remover Head,
57001-1293

Bearing Remover Shaft,
57001-1377

20 ×

22:

13:

10-6 WHEELS/TIRES
Wheels (Rims)
Front Wheel Removal

ABS equipped models, remove the front wheel rota• For
tion sensor bolt [A] and front wheel rotation sensor [B].
• Remove:
Front Caliper Mounting Bolts [C] (Both Sides)
Front Caliper [D] (Both Sides)

• Loosen:
Front Axle Clamp Bolt [A]
Front Axle [B]

the front wheel off the ground with a suitable stand.
• Raise
Pull
out
axle to the right side and drop the front
• wheel outtheoffront
the front forks.

NOTICE
Do not lay the wheel down on one of the discs. This
can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the
ground.

Front Wheel Installation
NOTE

○The direction of the wheel rotation [A] is shown by an
arrow [B] on the wheel hub.
the wheel rotation mark on the front wheel and
• Check
install it.

high-temperature grease to the grease seal lips.
• Apply
Fit
the
collar [A] on the both sides of the hub.
•○The collars
are identical.

WHEELS/TIRES 10-7
Wheels (Rims)
a thin coat of grease [A] to the front axle [B].
• Apply
About 10 mm (0.4 in.) [C]
About 30 mm (1.2 in.) [D]

NOTE

○Do not apply grease to the threads of the axle.
the front axle from the right side.
• Insert
• Tighten:
Torque - Front Axle: 108 N·m (11.0 kgf·m, 79.7 ft·lb)

tightening the front axle clamp bolt [A] on the right
• Before
front fork leg, pump the front fork up and down 4 or 5 times
to allow the right front fork leg to seat on the front axle.

NOTE

○Put a block in front of the front wheel to stop moving.

• Tighten:
Torque - Front Axle Clamp Bolt: 20 N·m (2.0 kgf·m, 15 ft·lb)

the removed parts (see appropriate chapters).
• Install
Check
the front brake effectiveness (see Brake Operation
• Inspection
in the Periodic Maintenance chapter).

WARNING
After servicing, it takes several applications of the
brake lever before the brake pads contact the disc,
which could result in increased stopping distance
and cause an accident resulting in injury or death.
Do not attempt to ride the motorcycle until a firm
brake lever is obtained by pumping the lever until
the pads are against the disc.

Rear Wheel Removal

• Raise the rear wheel off the ground with the stand [A].

the rear wheel rotation sensor bolt [A] and rear
• Remove
wheel rotation sensor [B], and clear the rear wheel rota-

•

tion sensor lead from the clamp [C].
Remove the rear caliper [D] with the brake hose connected (see Rear Caliper Removal in the Brakes chapter).

10-8 WHEELS/TIRES
Wheels (Rims)

• Remove:
Cap [A]

• Remove: