the wheel, measure the chain slack again at the tight• Turn
est position, and readjust if necessary.

• Insert a new cotter pin [A].
NOTE

○When inserting the cotter pin, if the slots in the nut do
not align with the cotter pin hole in the axle, tighten the
nut clockwise [B] up to next alignment.
○It should be within 30 degrees.
○Loosen once and tighten again when the slot goes past
the nearest hole.

2-42 PERIODIC MAINTENANCE
Periodic Maintenance Procedures

• Bend the cotter pin [A] along the nut [B].
WARNING
A loose axle nut can lead to an accident resulting in
serious injury or death. Tighten the axle nut to the
proper torque and install a new cotter pin.

• Install the rubber cap.
Wheel Alignment Inspection

• Remove the rubber cap [A].

that the notch [A] on the left alignment indicator [B]
• Check
aligns with the same swingarm mark or position [C] that
the right alignment indicator notch aligns with.
If they are not, adjust the chain slack and align the wheel
alignment (see Drive Chain Slack Adjustment).

○Wheel

NOTE

alignment can be also checked using the
straightedge or string method.

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.

• Install the rubber cap.
Drive Chain Wear Inspection

the mud guard (see Mud Guard Removal in the
• Remove
Frame 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.)

PERIODIC MAINTENANCE 2-43
Periodic Maintenance Procedures
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:

EK525RMX3/3D

Link:

114 links

the mud guard (see Mud Guard Installation in the
• Install
Frame chapter).

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.

2-44 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Brakes
Brake System Inspection
Brake Fluid Leak (Brake Hose and Pipe) Inspection
Remove the mud guard (see Mud Guard Removal in the
Frame chapter).
For ABS equipped models, remove the fuel tank (see Fuel
Tank Removal in the Fuel System (DFI) chapter).
Apply the brake lever or pedal and inspect the brake fluid
leak from the brake hoses [A], fittings [B] and pipes [C]
(ABS equipped models).
If the brake fluid leaked from any position, inspect or replace the problem part.

•
•
•

PERIODIC MAINTENANCE 2-45
Periodic Maintenance Procedures
Brake Hose and Pipe Damage and Installation Condition Inspection
Remove the mud guard (see Mud Guard Removal in the
Frame chapter).
For ABS equipped models, remove the following parts:
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Frame Sub Cover (see Frame Sub Cover Removal in
the Frame 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 (ABS equipped models) to burst
if the line is not properly maintained. Bend and twist the
rubber hose while examining it.
Replace the hose and pipe (ABS equipped models) if any
crack [B], bulge [C] or leakage is noticed.
Tighten any brake hose banjo bolts and brake pipe banjo
bolts (ABS equipped models).

•
•
•

Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
Brake Pipe Banjo Bolts (ABS Equipped Models):
33 N·m (3.4 kgf·m, 24 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.

2-46 PERIODIC MAINTENANCE
Periodic Maintenance Procedures

•

If the fluid level is lower than the lower level line, fill the
reservoir to the upper level line [A].
Tighten:
Torque - Front Brake Reservoir Cap Screws: 1.5 N·m (0.15
kgf·m, 13 in·lb)

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:
Right Frame Cover (see Frame Cover Removal in the
Frame chapter)
Screw
Stopper

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 reser• Follow
voir cap correctly.

○First, tighten the brake 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 reservoir
body.
Install the stopper and tighten the screw.
Install the right frame cover (see Frame Cover Installation
in the Frame chapter).

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.

PERIODIC MAINTENANCE 2-47
Periodic Maintenance Procedures
the brake 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.

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 Screws: 1.5 N·m (0.15
kgf·m, 13 in·lb)

the procedure below to install the rear brake reser• Follow
voir cap correctly.

○First, tighten the rear brake 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 reservoir
body.
○Install the stopper and tighten the screw.

• Tighten the bleed valve, and install the rubber cap.
Torque - Bleed Valves: 5.4 N·m (0.55 kgf·m, 48 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.

2-48 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Brake Hose and Pipe Replacement
NOTICE
Brake fluid quickly damages painted plastic surfaces; any spilled fluid should be completely
washed away immediately.

• Remove:
Headlight

Assy (see Upper Fairing Removal in the
Frame chapter)
Mud Guard (see Mud Guard Removal in the Frame
chapter)
Brake Hose Banjo Bolts [A]
Release the brake hoses from the clamps.
When removing the brake hoses [B], note the following.
○Take care not to spill the brake fluid on the painted or
plastic parts.
○Temporarily secure the end of the brake hose to some
high place to keep fluid loss to a minimum.
○Immediately wash away any brake fluid that spills.
When installing the brake hoses, note the following.
○Avoid sharp bending, kinking, flatting or twisting, and run
the hoses according to Cable, Wire, and Hose Routing
section in the Appendix chapter.
○There are washers on each side of the brake hose fitting.
Replace them with new ones.
○Tighten:

•
•

•

Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)

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

PERIODIC MAINTENANCE 2-49
Periodic Maintenance Procedures

2-50 PERIODIC MAINTENANCE
Periodic Maintenance Procedures

• For ABS equipped models; note the following.
NOTE

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

• Remove:
Headlight

•
•

Assy (see Upper Fairing Removal in the
Frame chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
Inner Covers (see Inner Cover Removal in the Frame
chapter)
Mud Guard (see Mud Guard Removal in the Frame
chapter)
Frame Sub Cover (see Frame Sub Cover Removal in
the Frame chapter)
Brake Pipe Banjo Bolts [A]
Brake Hose Banjo Bolts [B]
Bolts [C]
Release the brake hoses from the clamps.
There are washers on each side of the brake hose and
pipe fitting. Replace them with new ones when installing.

NOTE

○Tighten the brake pipe banjo bolt 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:
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
Brake Pipe Banjo Bolts: 33 N·m (3.4 kgf·m, 24 ft·lb)

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

PERIODIC MAINTENANCE 2-51
Periodic Maintenance Procedures

2-52 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:
Front Brake Reservoir Cap Screws [A]
Reservoir Cap [B]
Diaphragm Plate [C]
Diaphragm [D]
Unscrew the locknut [E] and pivot bolt [F], and remove the
brake lever.
Remove the dust cover [G] and circlip [H].

•
•
•
•

Special Tool - Inside Circlip Pliers: 57001-143

• Pull out the piston assembly [I].
NOTICE
Do not remove the secondary cup from the piston
since removal will damage it.

• Replace:
Diaphragm [D]
Dust Cover [G]
Circlip [H]
Piston Assembly [I]
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].
•

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

• Replace:
Circlip [A]
O-ring [C]
Dust Cover [D]
Circlip [E]
Piston Assembly [G]
Diaphragm [H]

PERIODIC MAINTENANCE 2-53
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)

Caliper Rubber Parts Replacement
Front Caliper Disassembly
Loosen the front caliper pad pin [A], banjo bolt [B] and
front caliper assembly bolts [C] and tighten them loosely.
Remove:
Front Caliper [D] (see Front Caliper Removal in the
Brakes chapter)
Brake Pads (see Front Brake Pad Removal in the Brakes
chapter)
Front Caliper Assembly Bolts
Oil Seal

•
•

2-54 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
compressed air, remove the pistons.
• Using
remove the pistons is as follows.

One way to

○Install a rubber gasket [A] and a wooden board [B] more
than 10 mm (0.4 in.) thick on the caliper half, and fasten them together with a suitable bolt and nut as shown.
Leave one of the oil passages [C] open.
○Lightly apply compressed air [D] to the oil passage until
the pistons hit the rubber gasket. Block the hose joint
opening [E] during this operation if the caliper half has
the opening.
Bolt [F] and Nut
Push down [G].

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.
compressed air is not used, using the brake caliper
• When
piston pliers [A] remove the pistons [B].
Special Tool - Brake Caliper Piston Pliers ( 26 
57001-1862

36):

the dust seals [A] and fluid seals [B].
• Remove
the bleed valve [C] and rubber cap [D].
• Remove
Repeat
the
step to remove the pistons from the
• other side ofprevious
the caliper body.

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: 5.4 N·m (0.55 kgf·m, 48 in·lb)

PERIODIC MAINTENANCE 2-55
Periodic Maintenance Procedures
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.

•

the oil seal [A].
• Replace
Apply
brake
fluid to the outside of the pistons, and push
• them into each
cylinder by hand.
Be
sure
to
install
the oil seal.
• Apply a non-permanent
agent to the threads of
• the front caliper assemblylocking
bolts, and tighten them.