STEERING 14-7
Steering Stem
up the stem base, and remove the steering stem
• Pushing
nut [A] with stem cap [B].
Special Tool - Steering Stem Nut Wrench [C]: 57001-1100

○You

may remove the steering stem nut using the adjustable hook wrench [A].
Special Tool - Adjustable Hook Wrench: 57001-1863

• Remove:
Steering Stem
Upper Ball Bearing Inner Race and Ball Bearing

remove the ball bearing outer races [A] pressed into
• To
the head pipe [B], insert a bar [C] into the recesses of
head pipe, and applying it to both recess alternately hammer it to drive the race out.

NOTE

○If either steering stem bearing is damaged, it is recommended that both the upper and lower bearings (including outer races) should be replaced with new ones.
the lower ball bearing from the steering stem.
• Remove
the lower ball bearing inner race (with its oil seal)
• Remove
[A] which is pressed onto the steering stem with a suitable
commercially available chisel [B].

Stem, Stem Bearing Installation

the bearing outer races with new ones.
• Replace
Drive
them
into the head pipe at the same time.
•
Special Tools - Head Pipe Outer Race Press Shaft [A]:
57001-1075
Head Pipe Outer Race Driver, 55 [B]: 57001
-1446

• Apply grease to the outer races.

14-8 STEERING
Steering Stem
the bearing inner races and oil seal with new
• Replace
ones.
grease to the oil seal.
• Apply
Install
the oil seal [A] on the steering stem.
• Apply grease
the stem and hammer the lower ball bear• ing inner raceto[B].
Special Tools - Steering Stem Bearing Driver, 42.5 [C]:
57001-1344
Steering Stem Bearing Driver Adapter,
41.5 [D]: 57001-1345

grease to the lower ball bearing [A], and install it
• Apply
onto the steering stem.

○The lower and upper ball bearings are identical.

• Apply grease to the upper ball bearing and inner race.

the steering stem [A] through the head pipe and
• Install
install the upper ball bearing [B] and inner race [C] on it.
• Install:
Stem Cap [D]
Steering Stem Nut [E]

the bearings in place as follows.
•○Settle
Tighten the steering stem nut with 65 N·m (6.6 kgf·m, 48
ft·lb) of torque first, and loosen it a fraction of a turn until
it turns lightly. Afterward tighten it again with specified
torque using a steering stem nut wrench [A].
○Check that there is no play and the steering stem turns
smoothly without rattles. If not, the steering stem bearings
may be damaged.
○You may tighten the steering stem nut using the adjustable hook wrench.
Special Tools - Steering Stem Nut Wrench: 57001-1100 or
Adjustable Hook Wrench: 57001-1863
Torque - Steering Stem Nut: 27 N·m (2.8 kgf·m, 20 ft·lb)

STEERING 14-9
Steering Stem
the claw washer [A] so that its bent side [B] faces
• Install
upward, and engage the bent claws with the grooves of

•
•
•
•
•

stem locknut [C].
Hand tighten the stem locknut until it touches the claw
washer.
Hand tighten the stem locknut clockwise until the claws
are aligned with the grooves (ranging from 2nd to 4th) of
stem nut [D], and bend the 2 claws downward [E].
Install the stem head.
Install the washer, and temporarily tighten the steering
stem head bolt.
Install the front forks (see Front Fork Installation in the
Suspension chapter).

NOTE

○Tighten the upper front fork clamp bolts first, next the
steering stem head bolt, last the lower front fork clamp
bolts.
○Tighten the two lower front fork clamp bolts alternately
two times to ensure even tightening torque.
Torque - Upper Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m,
15 ft·lb)
Steering Stem Head Bolt: 108 N·m (11.0 kgf·m,
79.7 ft·lb)
Lower Front Fork Clamp Bolts: 20.5 N·m (2.09
kgf·m, 15.1 ft·lb)

WARNING
If the handlebars do not turn to the steering stop,
they may cause an accident resulting in injury or
death. Be sure the cables, harnesses and hoses are
routed properly and do not interfere with handlebar
movement (see Cable, Wire, and Hose Routing section in the Appendix chapter).

• Install the removed parts (see appropriate chapters).
Steering Stem Bearing Lubrication

to the Steering Stem Bearing Lubrication in the Pe• Refer
riodic Maintenance chapter.

Steering Stem Warp Inspection

the steering stem is removed, or if the steering
• Whenever
can not be adjusted for smooth action, check the steering
stem for straightness.
If the steering stem [A] is bent, replace the steering stem.

14-10 STEERING
Steering Stem
Stem Cap Deterioration, Damage Inspection
Replace the stem cap if its oil seal [A] shows damage.

STEERING 14-11
Handlebar
Handlebar Removal

• Remove:
Rear View Mirror [A] (see Rear View Mirror Removal in
the Frame chapter)
Clutch Lever Clamp Bolts [B]
Clutch Lever Assembly [C]
Left Switch Housing [D]
Handlebar Weight [E]
Handlebar Grip [F]

• Remove:
Rear View Mirror [A] (see Rear View Mirror Removal in
the Frame chapter)
Front Master Cylinder [B] (see Front Master Cylinder Removal in the Brakes chapter)
Right Switch Housing [C]
Handlebar Weight [D]
Throttle Grip [E]

removing the lower handlebar holders, remove the
• When
following parts.
Cotter Pin [A] (Both Sides)
Lower Handlebar Holder Nut [B] (Both Sides)
Washer [C] (Both Sides)

• Remove:
Meter Unit (see Meter Unit Removal in the Electrical System chapter)
Handlebar Holder Bolts [A]
Handlebar Holder [B]
Handlebars [C]
Lower Handlebar Holders [D] and Washers (If necessary)

Handlebar Installation

the lower handlebar holder [A] and washer [B] on
• Install
both sides if removed.
the punch mark [C] on the handlebars and the cor• Align
ner edge [D] on the lower handlebar holder.

14-12 STEERING
Handlebar
installing the lower handlebar holders, install the
• When
upper handlebar holder [A] and handlebar holder bolts [B]
temporarily.

the lower handlebar holder nuts [A] with new
• Replace
ones.
the washer [B] on both sides.
• Install
Tighten:
•
Torque - Lower Handlebar Holder Nuts: 34 N·m (3.5 kgf·m,
25 ft·lb)

• Insert the cotter pin [C] on both sides from forward.
the handlebar holder bolts following the tightening
• Tighten
sequence [1  4].
will be a gap [A] at the rear part of the holder after
• There
tightening.
Torque - Handlebar Holder Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)

a high flash-point solvent, clean of any oil or dirt
• Using
that may be on the adhesive coating area. Dry them with
a clean cloth.
Apply adhesive [A] to the left side of the handlebars.
Install the handlebar grip [B].
○Wipe off any protruding adhesive.
125 mm (4.92 in.) [C]
134 mm (5.28 in.) [D]
Apply a non-permanent locking agent to the threads of
the left handlebar weight bolt, and tighten it.

•
•
•

the left switch housing.
•○Install
Fit the projection [A] into a hole [B] in the handlebars.
• Tighten:
Torque - Switch Housing Screws: 3.5 N·m (0.36 kgf·m, 31
in·lb)

the clutch lever holder (see Clutch Lever Holder
• Install
Installation in the Clutch chapter).

STEERING 14-13
Handlebar

• Install:
Throttle Grip
Throttle Cable Tips [A]
Right Switch Housing
○Fit the projection [B] into a hole [C] in the handlebars.
Tighten:

•

Torque - Switch Housing Screws: 3.5 N·m (0.36 kgf·m, 31
in·lb)

a non-permanent locking agent to the threads of
• Apply
the right handlebar weight bolt, and tighten it.

• Install:
Clutch Lever Assembly (see Clutch Lever Assembly In•
•

stallation in the Clutch chapter)
Front Master Cylinder (see Front Master Cylinder Installation in the Brakes chapter)
Run the leads, cables and hoses correctly (see Cable,
Wire, and Hose Routing section in the Appendix chapter).
Install the removed parts (see appropriate chapters).

FRAME 15-1

Frame
Table of Contents
Exploded View........................................................................................................................
Seats ......................................................................................................................................
Rear Seat Removal...........................................................................................................
Rear Seat Installation........................................................................................................
Front Seat Removal ..........................................................................................................
Front Seat Installation .......................................................................................................
Single Seat Cover Removal (Special Edition Models) ......................................................
Single Seat Cover Installation (Special Edition Models) ...................................................
Single Seat Cover Disassembly (Special Edition Models)................................................
Fairings...................................................................................................................................
Upper Fairing Removal .....................................................................................................
Upper Fairing Installation ..................................................................................................
Upper Fairing Disassembly...............................................................................................
Upper Fairing Assembly....................................................................................................
Fuel Tank Cover Removal.................................................................................................
Fuel Tank Cover Installation..............................................................................................
Ignition Switch Cover Removal .........................................................................................
Ignition Switch Cover Installation ......................................................................................
Middle Fairing Removal ....................................................................................................
Middle Fairing Installation .................................................................................................
Middle Fairing Disassembly ..............................................................................................
Inner Cover Removal ........................................................................................................
Inner Cover Installation .....................................................................................................
Lower Fairing Removal .....................................................................................................
Lower Fairing Installation ..................................................................................................
Side Covers ............................................................................................................................
Frame Cover Removal......................................................................................................
Frame Cover Installation...................................................................................................
Frame Sub Cover Removal ..............................................................................................
Frame Sub Cover Installation ...........................................................................................
Side Cover Removal .........................................................................................................
Side Cover Installation ......................................................................................................
Side Cover Disassembly...................................................................................................
Seat Covers............................................................................................................................
Seat Cover Removal.........................................................................................................
Seat Cover Installation......................................................................................................
Fenders ..................................................................................................................................
Front Fender Removal ......................................................................................................
Front Fender Installation ...................................................................................................
Flap Removal....................................................................................................................
Flap Installation.................................................................................................................
Rear Fender Removal.......................................................................................................
Rear Fender Installation....................................................................................................
Battery Case Removal ......................................................................................................
Battery Case Installation ...................................................................................................
Frame .....................................................................................................................................
Frame Inspection ..............................................................................................................
PAD Installation.................................................................................................................
Windshield (Special Edition Models) ......................................................................................
Windshield Removal .........................................................................................................

15-3
15-14
15-14
15-14
15-14
15-15
15-15
15-15
15-16
15-17
15-17
15-18
15-19
15-20
15-20
15-20
15-20
15-20
15-21
15-21
15-21
15-22
15-22
15-22
15-22
15-23
15-23
15-23
15-23
15-23
15-24
15-24
15-25
15-26
15-26
15-27
15-28
15-28
15-28
15-28
15-28
15-29
15-29
15-31
15-32
15-33
15-33
15-33
15-34
15-34

15

15-2 FRAME
Windshield Installation ......................................................................................................
Guards....................................................................................................................................
Mud Guard Removal.........................................................................................................
Mud Guard Installation......................................................................................................
Frame Slider Removal (Special Edition Models) ..............................................................
Frame Slider Installation (Special Edition Models) ...........................................................
Crankcase Ring Installation (Special Edition Models) ......................................................
Front Axle Slider Removal (Special Edition Models) ........................................................
Front Axle Slider Installation (Special Edition Models) .....................................................
Radiator Guard Removal (Special Edition Models) ..........................................................
Radiator Guard Installation (Special Edition Models) .......................................................
Side Stand ..............................................................................................................................
Side Stand Removal .........................................................................................................
Side Stand Installation ......................................................................................................
Rear View Mirrors...................................................................................................................
Rear View Mirror Removal................................................................................................
Rear View Mirror Installation.............................................................................................

15-34
15-35
15-35
15-35
15-35
15-37
15-38
15-38
15-39
15-39
15-39
15-40
15-40
15-40
15-41
15-41
15-41

FRAME 15-3
Exploded View
This page intentionally left blank.

15-4 FRAME
Exploded View

FRAME 15-5
Exploded View
No.
1
2
3
4

Fastener
Meter Cover Bolts
Rear View Mirror Locknuts (Upper)
Rear View Mirror Nuts (Lower)
Inner Cover Bolts

5. ID Model
Lh: Left-hand Threads

N·m
0.50
18
30
1.0

Torque
kgf·m
0.05
1.8
3.1
0.10

ft·lb
4.4 in·lb
13
22
8.9 in·lb

Remarks

Lh

15-6 FRAME
Exploded View

FRAME 15-7
Exploded View
No.
1
2

Fastener
Reflector Nuts
Reflector Nuts

N·m
4.15
4.0

3. US, CA and CAL Models
4. US, CA, CAL, AU, SEA-B1, MY and WVTA (FULL) Models
5. CN Model
6. MY, TH and CN Models

Torque
kgf·m
0.423
0.41

ft·lb
37 in·lb
35 in·lb

Remarks

15-8 FRAME
Exploded View

FRAME 15-9
Exploded View
No.
1
2

Fastener
Lower Fairing Bolts (M6)
Lower Fairing Bolts (M5)

L: Apply a non-permanent locking agent.

N·m
9.8
3.0

Torque
kgf·m
1.0
0.31

ft·lb
87 in·lb
27 in·lb

Remarks

L

15-10 FRAME
Exploded View

FRAME 15-11
Exploded View
No.
1
2
3
4
5
6
7
8

Fastener
Front Footpeg Bracket Bolts
Heel Guard Bolts
Seat Bracket Bolts
Seat Cover Bolts
Rear Footpeg Bracket Bolts
Side Stand Switch Bolt
Side Stand Bolt
Side Stand Nut

G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.

N·m
25
6.9
6.9
5.0
25
8.8
44
29

Torque
kgf·m
2.5
0.70
0.70
0.51
2.5
0.90
4.5
3.0

ft·lb
18
61 in·lb