The diluted coolant can attack the aluminum engine parts. In an emergency, soft water alone can
be added. But the diluted coolant must be returned
to the correct mixture ratio within a few days.
If coolant must be added often or the reservoir tank
has run completely dry, there is probably leakage in
the cooling system. Check the system for leaks.
Coolant ruins painted surfaces. Immediately wash
away any coolant that spills on the frame, engine,
wheels or other painted parts.

Cooling System Inspection
Water Hose and Pipe Inspection (coolant leak, damage,
installation condition)
○The high pressure inside the water hose can cause
coolant to leak [A] or the hose to burst if the line is not
properly maintained.
Visually inspect the hoses for signs of deterioration.
Squeeze the hoses. A hose should not be hard and
brittle, nor should it be soft or swollen.
Replace the hose if any fraying, cracks [B] or bulges [C]
are noticed.
Check that the hoses are securely connected and clamps
are installed correctly.

•
•

Coolant Change

WARNING
Coolant can be extremely hot and cause severe
burns, is toxic and very slippery. Do not remove
the radiator cap or attempt to change the coolant
when the engine is hot; allow it cool completely.
Immediately wipe any spilled coolant from tires,
frame, engine or other painted parts. Do not ingest
coolant.

• Remove:
Upper Fairing Assembly (see Upper Fairing Assembly
Removal in the Frame chapter)
Radiator Cap [A]
Remove
the radiator cap in two steps. First turn the cap
○
counterclockwise to the first stop. Then push and turn it
further in the same direction and remove the cap.

2-26 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
a container under the drain bolt [A] of the water
• Place
pump cover.
the coolant from the radiator by removing the drain
• Drain
bolt.

• Remove:
Coolant Reserve Tank Mounting Bolt [A]
•
•
•
•

Cap [B]
Pour the coolant into a container.
Install the coolant reserve tank [C].
Tighten the coolant reserve tank mounting bolt securely.
Tighten the drain bolt with new gasket.
Torque - Coolant Drain Bolt (Water Pump): 10 N·m (1.0
kgf·m, 89 in·lb)

filling the coolant, choose a suitable mixture ratio
• When
by referring to the coolant manufacturer’s directions.

NOTICE
Soft or distilled water must be used with the antifreeze in the cooling system.
If hard water is used in the system, it causes scales
accumulation in the water passages, and considerably reduces the efficiency of the cooling system.
Water and Coolant Mixture Ratio (Recommended)
Soft Water:
50%
Coolant:

50%

Freezing Point:

–35°C (–31°F)

Total Amount:

2.6 L (2.7 US qt)

• Fill the radiator up to the filler neck [A] with coolant.
NOTE

○Pour in the coolant slowly so that it can expel the air
from the engine and radiator.
the cooling system for leaks.
• Check
Tap
the
• side. water hoses to force any air bubbles caught inthe radiator up to the filler neck with coolant.
• Fill
Install
the radiator cap.
•

PERIODIC MAINTENANCE 2-27
Periodic Maintenance Procedures
the reserve tank up to the “F” (full) level line [A] with
• Fill
coolant and install the reserve tank cap.
the engine, warm it up thoroughly until the radiator
• Start
fans turn on and then stop the engine.
the coolant level in the reserve tank after the en• Check
gine cools down.
If the coolant level is lower than the “L” (low) level line [B],
add coolant to the “F” level line.

NOTICE
Do not add more coolant above the “F” level line.

2-28 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Radiator Hose and O-ring Replacement

the coolant (see Coolant Change).
• Drain
• Remove:
Upper Fairing Assembly (see Upper Fairing Assembly

•
•

Removal in the Frame chapter)
Thermostat Housing [A] (see Thermostat Removal in the
Cooling System chapter)
Oil Cooler [B] (see Oil Cooler Removal in the Engine
Lubrication System chapter)
Water Pump Cover [C] (see Oil Pump Removal in the
Engine Lubrication System chapter)
Fitting [D]
Replace the hoses [E] and O-rings [F] [G] with new ones.
Apply grease to the new O-rings [F].

NOTE

○Do not apply grease to the O-ring [G] of the thermostat
housing cover.

• Install:
Water Pump Cover (see Oil Pump Installation in the En-

•
•

gine Lubrication System chapter)
Oil Cooler (see Oil Cooler Installation in the Engine Lubrication System chapter)
Thermostat Housing (see Thermostat Installation in the
Cooling System chapter)
Fitting
Run the new hoses according to the Cable, Wire, and
Hose Routing section in the Appendix chapter.
Tighten:
Torque - Water Hose Clamp Screws: 3.0 N·m (0.31 kgf·m,
27 in·lb)

the removed parts (see appropriate chapters).
• Install
Fill
the
coolant (see Coolant Change).
• Check the
cooling system for leaks.
•

PERIODIC MAINTENANCE 2-29
Periodic Maintenance Procedures

Engine Top End
Valve Clearance Inspection
NOTE

○Valve clearance must be checked and adjusted when
the engine is cold (at room temperature).
○In order to optimize the initial conformability, DLC
-coating has been applied to the tappets [A]. Coating
might be worn partially, but this is not malfunction.

• Remove:
Crankshaft Sensor Cover (see Crankshaft Sensor Removal in the Electrical System chapter)
Cylinder Head Cover (see Cylinder Head Cover Removal in the Engine Top End chapter)

2-30 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the crankshaft, align the #1, 4 mark on the timing
• Turn
rotor with the crankcase timing mark.
TDC Mark [A] for #1, 4 Pistons
Timing Mark [B] (Crankcase Halves Mating Surface)

a thickness gauge [A], measure the valve clearance
• Using
between the cam and the valve lifter.
Valve Clearance
Standard:
Exhaust 0.17  0.22 mm (0.0067  0.0087 in.)
Intake

0.15  0.22 mm (0.0059  0.0087 in.)

NOTE

○Thickness gauge is horizontally inserted on the valve
lifter.
Appropriateness [A]
Inadequacy [B]
Thickness Gauge [C]
Horizontally Inserts [D]
Cam [E]
Valve Lifter [F]
Hits the Valve Lifter Ahead [G]

○When positioning #1 piston TDC at the end of the
compression stroke:
Intake Valve Clearance of #1 and #3 Cylinders
Exhaust Valve Clearance of #1 and #2 Cylinders
Measuring Valve [A]

○When positioning #4 piston TDC at the end of the
compression stroke:
Intake Valve Clearance of #2 and #4 Cylinders
Exhaust Valve Clearance of #3 and #4 Cylinders
Measuring Valve [A]

If the valve clearance is not within the specified range,
first record the clearance, and then adjust it.

PERIODIC MAINTENANCE 2-31
Periodic Maintenance Procedures
Valve Clearance Adjustment

change the valve clearance, remove the camshaft
• To
chain tensioner, camshafts and valve lifters. Replace the
shim with one of a different thickness.

NOTE

○Keep the valve lifters and shims so that they can be
reinstalled in their original positions.

the shim to remove any dust or oil.
• Clean
Measure
the thickness of the removed shim [A].
• Select a new
• a + b – c = dshim thickness calculation as follows.
[a] Present Shim Thickness
[b] Measured Valve Clearance
[c] Specified Valve Clearance (Mean Value = 0.195 mm
(Exhaust), 0.185 mm (Intake))
[d] Replace Shim Thickness
Example (Intake):
1.600 + 0.28 – 0.195 = 1.685 mm

○Exchange the shim for the 1.675 size shim.
NOTICE
Do not use the shims for another models. Use the
specified shim for this model surely.

NOTICE
Be sure to remeasure the clearance after selecting
a shim. The clearance can be out of the specified
range because of the shim tolerance.

○If there is no valve clearance, use a shim that is a few

•

sizes smaller, and remeasure the valve clearance.
When installing the shim, face the marked side toward the
valve lifter. At this time, apply engine oil to the shim or
the valve lifter to keep the shim in place during camshaft
installation.

NOTICE
Do not put shim stock under the shim. This may
cause the shim to pop out at high rpm, causing extensive engine damage.
Do not grind the shim. This may cause it to fracture,
causing extensive engine damage.
engine oil to the valve lifter surface and install the
• Apply
lifter.
the camshafts (see Camshaft Installation in the En• Install
gine Top End chapter).
the valve clearance and readjust if necessary.
• Recheck
Install
the
removed parts (see appropriate chapters).
•

2-32 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Adjustment Shims
Thickness

Part Number

Mark

1.300

92180-0108

130

1.325

92180-0109

132

1.350

92180-0110

135

1.375

92180-0865

1375

1.388

92180-0866

1388

1.400

92180-0867

1400

1.413

92180-0868

1413

1.425

92180-0869

1425

1.438

92180-0870

1438

1.450

92180-0871

1450

1.463

92180-0872

1463

1.475

92180-0873

1475

1.488

92180-0874

1488

1.500

92180-0875

1500

1.513

92180-0876

1513

1.525

92180-0877

1525

1.538

92180-0878

1538

1.550

92180-0879

1550

1.563

92180-0880

1563

1.575

92180-0881

1575

1.588

92180-0882

1588

1.600

92180-0883

1600

1.613

92180-0884

1613

1.625

92180-0885

1625

1.638

92180-0886

1638

1.650

92180-0887

1650

1.663

92180-0888

1663

1.675

92180-0889

1675

1.688

92180-0890

1688

1.700

92180-0891

1700

1.713

92180-0892

1713

1.725

92180-0893

1725

1.738

92180-0894

1738

1.750

92180-0895

1750

1.763

92180-0896

1763

1.775

92180-0897

1775

1.788

92180-0898

1788

1.800

92180-0899

1800

1.813

92180-0900

1813

1.825

92180-0901

1825

1.838

92180-0902

1838

PERIODIC MAINTENANCE 2-33
Periodic Maintenance Procedures
Adjustment Shims
Thickness

Part Number

Mark

1.850

92180-0903

1850

1.863

92180-0904

1863

1.875

92180-0905

1875

1.888

92180-0906

1888

1.900

92180-0907