the rear wheel off the ground with the stand.
• Raise
Loosen
the drive chain (see Drive Chain Slack Adjust• ment in the
Periodic Maintenance chapter).
Pull
the
engine
• output shaft [C]. sprocket [A] with drive chain [B] off the
• Disengage the drive chain from the engine sprocket.

Engine Sprocket Installation

the sprocket washer and axle cotter pin with new
• Replace
ones.
the drive chain and the engine sprocket.
• Engage
Install
the
engine sprocket onto the output shaft.
• Apply molybdenum
oil solution to the threads
• and seating surface ofdisulfide
the engine sprocket nut.
the sprocket washer.
• Install
Tighten:
•
Torque - Engine Sprocket Nut: 147 N·m (15.0 kgf·m, 108
ft·lb)

NOTE

○Tighten the engine sprocket nut while applying the rear
brake.

FINAL DRIVE 11-11
Sprocket, Coupling
torquing the engine sprocket nut, bend [A] one side
• After
of the washer over the nut.
the drive chain slack after installing the engine
• Adjust
sprocket (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter).

• Install:
Dowel Pin [A]
•

Chain Guide [B]
Engine Sprocket Cover [C]
Tighten:
Torque - Engine Sprocket Cover Bolts: 10 N·m (1.0 kgf·m,
89 in·lb)

Rear Sprocket Removal

the rear wheel (see Rear Wheel Removal in the
• Remove
Wheels/Tires chapter).

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

• Remove:
Rear Sprocket Nuts [A]
Rear Sprocket [B]

Rear Sprocket Installation

the rear sprocket nuts with new ones.
• Replace
Install:
• Rear Sprocket

○The tooth number marking [A] faces to the outside of the
wheel.

11-12 FINAL DRIVE
Sprocket, Coupling
the rear sprocket nuts to a snug fit following the
• Tighten
specified sequence.
the rear sprocket nuts to the specified torque with
• Tighten
the same sequence.
Torque - Rear Sprocket Nuts: 60 N·m (6.1 kgf·m, 44 ft·lb)

tightening, check that the bolt ends protrude from
• After
the nuts.
the rear wheel (see Rear Wheel Installation in the
• Install
Wheels/Tires chapter).

Coupling Installation

high-temperature grease to the following.
• Apply
Coupling Grease Seal Lip [A]
Coupling Internal Surface [B]

• Install:
Collar [A]
Coupling [B]

Coupling Bearing Removal

• Remove:
Coupling

Grease Seal [A]
Circlip [B]
Special Tool - Inside Circlip Pliers: 57001-143

• Remove the bearing [A] by tapping from the wheel side.
Special Tool - Bearing Driver Set [B]: 57001-1129

FINAL DRIVE 11-13
Sprocket, Coupling
Coupling Bearing Installation

the bearing with a new one.
• Replace
• Press in the bearing [A] until it is bottomed.
Special Tool - Bearing Driver Set [B]: 57001-1129

the bearing with high-temperature grease.
• Pack
Replace
the circlip with a new one.
•
Special Tool - Inside Circlip Pliers: 57001-143

the grease seal with a new one.
• Replace
Press
in
the
seal so that the seal surface is flush
• with the end grease
of the hole.
Special Tool - Bearing Driver Set: 57001-1129

• Apply high-temperature grease to the grease seal lip.
Coupling Bearing Inspection
Since the coupling bearing is made to extremely close
tolerances, the clearance can not normally be measured.

NOTE

○It is not necessary to remove the coupling bearing for
inspection. If the bearing is removed, it will need to be
replaced with a new one.
the bearing in the coupling back and forth [A] while
• Turn
checking for plays, roughness or binding.
If the bearing play, roughness or binding is found, replace
the bearing.

Coupling Bearing Lubrication

the bearing with high-temperature grease. Turn the
• Pack
bearing around by hand a few times to make sure the
grease is distributed uniformly inside the bearing.

Coupling Damper Inspection

the rear wheel coupling, and inspect the rubber
• Remove
dampers [A].
the damper if it appears damaged or deterio• Replace
rated.

11-14 FINAL DRIVE
Sprocket, Coupling
Sprocket Wear Inspection

inspect the engine and rear sprocket teeth for
• Visually
wear and damage.
If the teeth are worn as illustrated, replace the sprocket,
and inspect the drive chain wear (see Drive Chain Wear
Inspection in the Periodic Maintenance chapter).
Worn Tooth (Engine Sprocket) [A]
Worn Tooth (Rear Sprocket) [B]
Direction of Rotation [C]

NOTE

○If a sprocket requires replacement, the chain is probably worn also. When replacing a sprocket, inspect the
chain.

Rear Sprocket Warp Inspection

the rear wheel off the ground with the stand so that
• Raise
it will turn freely.
a dial gauge [A] against the rear sprocket [B] near the
• Set
teeth as shown, and rotate [C] the rear wheel to measure
the sprocket runout (warp). The difference between the
highest and lowest dial gauge readings is the amount of
runout (warp).
If the runout exceeds the service limit, replace the rear
sprocket.
Rear Sprocket Warp
Standard:
TIR 0.4 mm (0.016 in.) or less
Service Limit: TIR 0.5 mm (0.020 in.)

BRAKES 12-1

Brakes
Table of Contents
Exploded View ..................................
Specifications ...................................
Special Tool .......................................
Brake Lever, Brake Pedal..................
Brake Lever Removal/Installation
Brake Lever Position Adjustment.
Brake Pedal Position Inspection .
Brake Pedal Position Adjustment
Brake Pedal Removal ..................
Brake Pedal Installation ...............
Calipers .............................................
Front Caliper Removal .................
Front Caliper Installation ..............
Rear Caliper Removal..................
Rear Caliper Installation...............
Front Caliper Disassembly...........
Front Caliper Assembly................
Rear Caliper Disassembly ...........
Rear Caliper Assembly ................
Caliper Fluid Seal Damage ..........
Rear Caliper Dust Boot and
Friction Boot Damage ...............
Caliper Piston and Cylinder
Damage.....................................
Rear Caliper Holder Shaft Wear ..
Brake Pads ........................................
Front Brake Pad Removal............
Front Brake Pad Installation.........
Rear Brake Pad Removal ...........
Rear Brake Pad Installation .........
Brake Pad Wear Inspection .........
Master Cylinder .................................
Front Master Cylinder Removal ...
Front Master Cylinder Installation
Rear Master Cylinder Removal....
Rear Master Cylinder Installation.
Front Master Cylinder
Disassembly..............................
Rear Master Cylinder
Disassembly..............................
Master Cylinder Assembly ...........
Rear Master Cylinder Inspection
(Visual Inspection).....................
Brake Disc .........................................

12-2
12-8
12-9
12-10
12-10
12-12
12-12
12-12
12-12
12-13
12-14
12-14
12-14
12-15
12-16
12-16
12-16
12-16
12-17
12-17
12-17
12-18
12-18
12-19
12-19
12-19
12-19
12-20
12-20
12-21
12-21
12-21
12-22
12-22
12-23
12-23
12-23
12-23
12-24

Brake Disc Removal ....................
Brake Disc Installation .................
Brake Disc Wear Inspection.........
Brake Disc Warp Inspection.........
Brake Fluid ........................................
Brake Fluid Level Inspection........
Brake Fluid Change .....................
Brake Line Bleeding.....................
Brake Hose........................................
Brake Hose Removal/Installation.
Brake Hose Inspection.................
Anti-lock Brake System (Equipped
Models) ...........................................
Parts Location ..............................
ABS Servicing Precautions ..........
ABS Troubleshooting Outline.......
Inquiries to Rider..........................
Self-diagnosis Outline ..................
Yellow ABS and Yellow Warning
Indicator Lights (LED)
Inspection..................................
ABS Hydraulic Unit Removal .......
ABS Hydraulic Unit Installation ....
ABS Hydraulic Unit Inspection .....
Front Wheel Rotation Sensor
Removal ....................................
Front Wheel Rotation Sensor
Installation .................................
Rear Wheel Rotation Sensor
Removal ....................................
Rear Wheel Rotation Sensor
Installation .................................
Wheel Rotation Sensor
Inspection..................................
Wheel Rotation Sensor Air Gap
Inspection..................................
Wheel Rotation Sensor Rotor
Inspection..................................
ABS Solenoid Valve Relay Fuse
(15 A) Removal .........................
ABS Motor Relay Fuse (25 A)
Removal ....................................
Fuse Installation...........................
Fuse Inspection............................

12-24
12-24
12-25
12-25
12-26
12-26
12-26
12-26
12-30
12-30
12-30
12-31
12-31
12-34
12-35
12-38
12-42

12-42
12-43
12-45
12-46
12-46
12-47
12-47
12-48
12-48
12-49
12-49
12-50
12-50
12-50
12-50

12

12-2 BRAKES
Exploded View

BRAKES 12-3
Exploded View
No.
1
2
3
4
5
6
7
8
9

Fastener
Front Brake Fluid Reservoir Cap Screws
Front Master Cylinder Bleed Valve
Brake Lever Pivot Bolt Locknut
Front Master Cylinder Clamp Bolts
Brake Hose Banjo Bolts
Front Wheel Rotation Sensor Bolt
Front Caliper Bleed Valves
Front Caliper Mounting Bolts
Front Brake Disc Mounting Bolts

B: Apply brake fluid.
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.
Si: Apply silicone grease.

N·m
0.70
5.5
6.0
9.0
25
25
16
35
28

Torque
kgf·m
0.07
0.56
0.61
0.92
2.5
2.5
1.6
3.6
2.9

ft·lb
6.2 in·lb
49 in·lb
53 in·lb
80 in·lb
18
18
12
26
21

Remarks

R
S

S
L, S

12-4 BRAKES
Exploded View

BRAKES 12-5
Exploded View
No.
1
2
3
4
5
6
7
8
9
10

Fastener
Brake Hose Banjo Bolts
Rear Wheel Rotation Sensor Bolt
Rear Master Cylinder Mounting Bolts
Rear Master Cylinder Push Rod Locknut
Rear Caliper Pin Bolt
Rear Caliper Bleed Valve
Rear Brake Pad Pin Plug
Rear Brake Pad Pin
Brake Pedal Mounting Bolt
Rear Brake Disc Mounting Bolts

B: Apply brake fluid.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.
Si: Apply silicone grease (ex. PBC grease).

N·m
25
25
25
17
27
8.0
2.5
17.2
9.0
28

Torque
kgf·m
2.5
2.5
2.5
1.7
2.8
0.82
0.25
1.75
0.92
2.9

ft·lb
18
18
18
13
20
71 in·lb
22 in·lb
12.7
80 in·lb
21

Remarks

Si

L, S

12-6 BRAKES
Exploded View
ABS Equipped Models

BRAKES 12-7
Exploded View
No.
1
2

Fastener

N·m
18
25

Brake Pipe Joint Nuts
Brake Hose Banjo Bolts

Torque
kgf·m
1.8
2.5

ft·lb
13
18

Remarks

R: Replacement Parts

NOTE

○When disassembling the brake hose and pipe, disassemble them by the unit as shown in the
exploded view.

12-8 BRAKES
Specifications
Item
Brake Lever, Brake Pedal
Brake Lever Position
Brake Lever Free Play
Pedal Free Play
Pedal Position
Brake Pads
Lining Thickness:
Front
Rear
Brake Discs
Thickness
Runout
Brake Fluid
Grade
ABS (Equipped Models)
ABS Hydraulic Unit:
Make