NORTON Commando 961 - Service Manual

Norton Motorcycles Service Manual Commando 961 – All variants

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Quick Reference Guide

1 General Information .................................................................................................................................................. 8

2 Fuel System ............................................................................................................................................................. 28

3 Cooling System ........................................................................................................................................................ 43

4 Engine Top End ........................................................................................................................................................ 55

5 Clutch...................................................................................................................................................................... 96

6 Engine Lubrication System .................................................................................................................................... 117

7 Engine Removal / Installation ............................................................................................................................... 137

8 Crankshaft / Transmission ..................................................................................................................................... 143

9 Wheels / Tyres ....................................................................................................................................................... 170

10 Final Drive .............................................................................................................................................................. 187

11 Brakes .................................................................................................................................................................... 196

12 Suspension ............................................................................................................................................................ 219

13 Steering ................................................................................................................................................................. 256

14 Frame .................................................................................................................................................................... 271

15 Electrical System ................................................................................................................................................... 284

16 Appendix ............................................................................................................................................................... 322

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All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or

transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,

without the prior written permission of Norton Motorcycles (UK) Ltd.

No Liability can be accepted for any inaccuracies or omissions in this publication, although every possible

care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring obligation to

make such changes to produce manufactured previously. See your Motorcycle dealer for the latest

information on product improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the

time of publication. Illustrations and photographs in this publication are intended for reference use only

and may not depict actual model component parts.

4

Emission Control Information

To protect the environment in which we all live, Norton motorcycles (UK) ltd has incorporated crankcase

emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the

United States Environmental Protection Agency and California Air Resources Board. Additionally, Norton

has incorporated an evaporative emission control system (3) in compliance with applicable regulations of

the California Air Resources Board on vehicles sold in California only.

Crankcase Emission Control System:

This system eliminates the release of crankcase vapours into the atmosphere. Instead, the vapours

are routed through an oil separator to the intake side of the engine. While the engine is operating,

the vapours are drawn into combustion chamber, where they are burned along with the fuel and

air supplied by the injection system.

Exhaust Emission Control System

This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of

this motorcycle. The fuel and ignition systems of this motorcycle have been carefully designed and

constructed to ensure an efficient engine with low exhaust pollutant levels.

Evaporative Emission Control System

Vapours caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead,

fuel vapours are routed into the running engine to be burned, or stored in a canister when the

engine is stopped.

The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly

referred to as the Act’s “tampering provisions”.

“Sec. 203(a) the following acts and the causing thereof are prohibited...

(3)(A) for any person to remove or render inoperative any device or element of design installed

on or in a motor vehicle or motor vehicle engine in compliance with regulations under this

title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or

dealer knowingly to remove or render inoperative any such device or element of design

after such sale and delivery to the ultimate purchaser.

(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading

motor vehicles or motor vehicles engines, or who operates a fleet of motor vehicles

knowingly to remove or render inoperative any device or element of design installed on or

in a motor vehicle or motor vehicle engine in compliance with regulations under this title

following its sale and delivery to the ultimate purchaser...”

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Note: The phrase “remove or render inoperative any device or element of design” has been generally

interpreted as follows:

Tampering does not include the temporary rendering inoperative of devices or elements of design

in order to perform maintenance.

Tampering could include:

Maladjustment or vehicle components such that the emissions standards are exceeded.

Use of replacement parts or accessories which adversely affect the performance or durability of the

motorcycle.

Addition of components or accessories that result in the vehicle exceeding the standards.

Permanently removing, disconnecting, or rendering inoperative any component or element of

design of the emission control systems.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF

WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION.

Tampering With Noise Control System Prohibited

Owners are warned that the law may prohibit:

The removal or rendering inoperative by any person other than for purposes of maintenance, repair

or replacement, of any device or element of design incorporated into any new vehicle for the

purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is use; and

The use of the vehicle after such device or element of design has been removed or rendered

inoperative by any person

Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by

any person other than for purposes of maintenance, repair, or replacement, of any device or element of

design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the

ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design

has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:

Replacement of the original exhaust system or muffler with components not in compliance with

federal regulations.

Removal of the muffler(s) or any internal portion of the muffler(s).

Removal of the air box or air box cover.

Modifications to the muffler(s) or intake system by cutting, drilling, or other means if such

modifications results in increased noise levels.

6

Foreword

This Manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it

contains enough detail and basic information to make it useful to the owner who desires to perform his

own basic maintenance, the proper use of tools, and workshop procedures must be understood in order to

carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts

his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified

mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly

familiarize yourself with the procedures before starting work, and then do the work carefully in a clean

area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment.

Precision measurements can only be made if the proper instruments are used, and the use of substitute

tools may adversely affect safe operation.

For the duration of the warranty period, especially, we recommend that all repairs and scheduled

maintenance be performed in accordance with the service manual. Any owner maintenance or repair

procedure not preformed in accordance with this manual may void the warranty. To get the longest life

out of your Motorcycle:

Follow the Periodic Maintenance Chart in the Service Manual.

Be alert for problems and non-scheduled maintenance.

Use proper tools and genuine Norton Motorcycle parts. Special tools, gauges, and testers that are

necessary when servicing Norton motorcycles are introduced by the Special Tool Catalog or

Manual. Genuine parts provided as spare parts are listed in the Parts Catalog.

Follow the procedures in this manual carefully don`t take shortcuts.

Remember to keep complete records of maintenance and repair with dates and any new parts

installed.

How to use this Manual

In preparing this manual, we divided the product into its major systems. These systems became the

manual`s chapters. All information for a particular system from adjustment through disassembly and

inspection is located in a single chapter.

The Quick Reference Guide shows you all of the products system and assists in locating their chapters. Each

chapter in turn has its own comprehensive Table of Contents.

The Periodic Maintenance Chart is located in the General Information chapter. The chart gives a time

schedule for required maintenance; for example, go to the Periodic Maintenance Chart first. The chart tells

you how frequently to change the oil. Next, use the Quick Reference Guide to locate the Engine Lubrication

System chapter. Then, use the Table of Contents on the first page of the chapter to find the Change Engine

Oil section.

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Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe

operation and maintenance practices.

WARNING: This warning symbol identifies special instructions or procedures which, if not correctly

followed, could result in personal injury, or loss of life.

CAUTION: This caution symbol identifies special instructions or procedures which, if not strictly observed,

could result in damage to or destruction of equipment.

This Manual contains four more symbols (in addition to WARNING and CAUTION) which will help you

distinguish types of information.

Note: This note symbol indicates points of particular interest for more efficient and convenient operation.

Indicates a procedural step or work to be done.

o Indicates a procedural sub-step or how to do the work of the procedural step it follows. It

also precedes the text of a NOTE in some cases.

Indicates a conditional step or what action to take based on the results of the test or inspection

in the procedural step or sub-step it follows.

In most chapters an exploded view illustration of the system components follows the Table of Contents to

show assembly sequence.

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General Information

Before Servicing ................................................................................................................................................. 9

General Specification ....................................................................................................................................... 13

Periodic Maintenance Chart ............................................................................................................................ 16

Torque and Locking Agent ............................................................................................................................... 17

Special tools and Sealant ................................................................................................................................. 24

Cable, Wire and Hose Routing ......................................................................................................................... 26

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Maintenance / Equipment Consult your authorised Norton dealer whenever there is doubt as to the correct or safe operation of this Norton motorcycle. Remember that continued operation of an incorrectly performing motorcycle may aggravate a fault and may also prejudice safety. Ensure all equipment that is required by law is installed and functioning correctly. The removal or alteration of the motorcycle’s lights, silencers, emission or noise control systems can violate the law. Incorrect or improper modification may adversely affect the handling, stability or other aspect of the motorcycle operation, which may result in an accident causing injury or death. If the motorcycle is involved in an accident, collision or fall, it must be taken to an authorised Norton dealer for inspection and repair. Any accident can cause damage to the motorcycle that, if not correctly repaired, may cause a second accident that may result in injury or death.

Before Servicing

Before starting to service a motorcycle, careful reading of the applicable section is recommended to

eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions

have been included wherever necessary. Nevertheless, even a detailed account has limitations; a certain

amount of basic knowledge is also required for successful work.

Especially note the following:

Dirt: Before removal and disassembly, clean the motorcycle. Any dirt entering the engine or other

parts will work as an abrasive and shorten the life of the motorcycle. For the same reason, before

installing a new part, clean off any dust or metal fillings.

Battery Ground: Remove the battery ground (-) lead from the battery before performing any

disassembly operations on the motorcycle. This Prevents:

o The possibility of accidently turning the engine over while partially disassembled.

o Sparks at electrical connections which will occur when they are disconnected.

o Damage to electrical parts.

Installation, Assembly: Generally, installation or assembly is the reverse of removal or disassembly.

But if this Service Manual has installation or assembly procedures, follow them.

Tightening Sequence: Generally, when installing a part with several bolts, nut, or screws, start them

all in their holes and tighten them to a snug fit. Then tighten them evenly in a cross pattern. This is

to avoid distortion of the part and/or causing gas or oil leakage. Conversely when loosening the

bolts, nuts, or screws, first loosen all of them by about a quarter of a turn and then remove them.

Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws

must be tightened in the order and method indicated.

Torque: When torque values are given in this Service Manual, use them. Either too little or too

much torque may lead to serious damage. Use a good quality, reliable torque wrench.

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Force: Common sense should dictate how much force is necessary in assembly and disassembly. If a

part seems especially difficult to remove or install, stop and examine what may be causing the

problem. Whenever tapping is necessary, tap lightly using a rubber, wooden or plastic-faced mallet.

Use an impact driver for screws (particularly for the removal of screws held by a locking agent) in

order to avoid damaging the screw heads.

Edges: Watch for sharp edges, especially during major engine disassembly and assembly. Protect

your hands with gloves or a piece of thick cloth when lifting the engine or turning it over.

High-Flash Point Solvent: A high-flash point solvent is recommended to reduce fire danger. A

commercial solvent commonly available in the UK is Silkolene (generic name). Always follow

manufacturer and container directions regarding the use of any solvent.

Gasket, O-Ring: Do not reuse a gasket or O-ring once it has been in service. The mating surfaces

around the gasket should be free of foreign matter and perfectly smooth to avoid oil or

compression leaks.

Liquid Gasket, Non-Permanent Locking Agent: Follow manufacturer’s directions for cleaning and

preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may

block engine oil passages and cause serious damage. An example of a non-permanent locking agent

commonly available in the UK is Threebond.

Press: A part installed using a press or driver, such as a wheel bearing (hub bearing), should first be

coated with oil on its outer or inner circumference so that it will go into place smoothly.

Ball Bearing, Needle Bearing: Do not remove a ball bearing or a needle bearing unless it is

absolutely necessary. Replace any ball or needle bearings that were removed with new ones, as

removal generally damages bearings. Install bearings with the marked side facing out applying

pressure evenly with a suitable driver. Only press on the race that forms the press fit with the base

component to avoid damaging the bearings. This prevents severe stress on the balls or needles and

races, and prevents races and balls or needles from being dented. Press a ball bearing until it stops

at the stop in the hole or on the shaft.

Oil Seal and Grease Seal: Replace any oil or grease seals that were removed with new ones, as

removal generally damages seals. When pressing in a seal which has manufacturer’s marks, press it

in with the marks facing out. Seals should be pressed into place using a suitable driver, which

contacts evenly with the side of seal, until the face of the seal is even with the end of the hole.

Before a shaft passes through a seal, apply a little high temperature grease on the lips to reduce

rubber to metal friction.

Circlip, Retaining Ring: Replace any circlips and retaining rings that were removed with new ones, as

removal weakens and deforms them. When installing circlips and retaining rings, take care to

compress or expand them only enough to install them and no more.

Cotter Pin: Replace any cotter pins that were removed with new ones, as removal deforms and

breaks them.

Lubrication: Engine wear is generally at its maximum while the engine is warming up and before all

the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is

more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old

grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and

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may contain abrasive foreign particles. Don’t use just any oil or grease. Some oils and greases in

particular should be used only in certain applications and may be harmful if used in an application

and may be harmful if used in an application for which they are not intended. This manual makes

reference to molybdenum disulfide grease (MoS2) in the assembly of certain engine and chassis

parts. Always check manufacturer recommendations before using such special lubricants.

Electrical Wires: All the electrical wires are either single-colour or two-colour and, with only a few

exceptions, must be connected to wires of the same colour. On any of the two-colour wires there is

a greater amount of one colour and a lesser amount of a second colour, so a two-colour wire is

identified by first the primary colour and then the secondary colour. For example, a red wire with

thin yellow strips is referred to as a “red/yellow” wire; it would be a “yellow/red” wire if the

colours were reversed to make red the main colour.

Replacement Parts: When there is a replacement instruction, replace these parts with new ones

every time they are removed. These replacement parts will be damaged or lose their original

function once removed.

Inspection: When parts have been disassembled, visually inspect these parts for the following

conditions or other damage. If there is any doubt as to the condition of them, replace them with

new ones.

Abrasion Crack Hardening Warp Bent Dent

Scratch Wear Colour Change Deterioration Seizure

Specifications: Specification terms are defined as follows:

“Standards” show dimensions or performances which brand-new parts or systems have.

“Service Limits” indicate the usable limits. If the measurement shows excessive wear or

deteriorated performance, replace the damaged parts

References to the left-hand or right-hand side given in this manual are made when viewing the

motorcycle from the rear.

Operations covered in this manual do not always include references to testing the motorcycle after

repair. It is essential that work is inspected and tested after completion and if necessary a road test

of the motorcycle is carried out particularly where safety related items are concerned.

Yellow

Wire Strands

Red

Yellow

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List of Abbreviations

A ampere (s) lb pounds(s) ABDC after bottom dead centre m meter(s) AC alternating current min minute(s) ATDC after top dead centre N Newton(s) BBDC before bottom dead centre Pa Pascal(s) BDC bottom dead centre PS horsepower BTDC before top dead centre Kw killer watt(s) ˚C degree(s) Celsius psi pound(s) per square inch DC direct current r revolution F farad(s) rpm revolution(s) per minute ˚F degree(s) Fahrenheit TDC top dead centre ft foot, feet TIR total indicator reading g gram(s) v volt(s) h hours(s) w watt(s)

L litres(s) Ω ohm(s)

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Items 961 SE/SPORT/CAFE RACER

Dimensions:

Overall length 2050 mm

Overall Width 850mm Overall Height 1110mm Wheelbase 1430mm Road clearance 130mm (nominal) Seat height 810mm Dry weight 205kg Curb weight: Front 108kg Rear 110kg

Fuel tank capacity 17 Litres

Performance:

Minimum turning radius 3m

Engine: Type 4-Stroke, push-rod, 2-cylinder Cooling System Air/oil - cooled Bore and stroke 88mm Displacement 79mm Compression ratio 10.1:1 Maximum / horsepower 59Kw @ 7700rpm

Maximum torque 84Nm @ 6000rpm Throttle body Norton Throttle Body 38mm Starting system Electric starter Ignition system Coil Timing advance Electronically advanced Ignition timing Controlled by ECU map

Spark plug NGK CR9EB Cylinder numbering method LH:1 RH:2 Firing order 270˚ Valve timing Inlet Open 36˚ BTDC Close 60˚ ABDC Duration 256˚ Exhaust Open 70˚ BBDC Close 6˚ ATDC Duration 256˚ Lubrication Forced lubrication (dry sump) Engine oil: Grade API SG, SH AND SJ, JASO MA

Viscosity SAE10W-40

Capacity 3 L (from dry)

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Items 961 SE/SPORT/CAFE RACER

Drive Train: Primary reduction system:

Type Gear Reduction ratio 1.61 Clutch type Wet multi disc Transmission: Type 5-speed, constant mesh Gear ratios: 1st 2.688 2nd 1.969 3rd 1.433 4th 1.181 5th 1.000 Final drive system: Type Chain drive Reduction ratio 2.778

Overall drive ratio 4.476 @Top

Frame: Type Tubular, steel, double cradle Caster (rake angle) 24.5˚ Trail 99mm

Front tire: Type Dunlop qualifier (Tube for spoked wheels-Continental DE17)

Size 120/70 ZR17 M/C

Rear tire: Type Dunlop qualifier (Tube for spoked wheels-Continental G17)

Size 180/55 ZR17 M/C

Front Suspension: Type Telescopic fork (pneumatic) Fork travel 110mm Rear Suspension: Type Swingarm, twin shock Sus travel 96mm Brake type: Front Twin floating discs

Rear Single disc

Electrical Equipment: Headlight: Type Semi-sealed beam Bulb 12 V 55/60 W Taillight 12 V 21.5W Alternator: Type Three-phase AC Rated output 300 w

Specifications are subject to change without notice, and may not apply to every country.

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SCHEDULED MAINTENANCE CHART Operation Description

Every Odometer Reading in Miles (Kms) or time period, whichever comes first

500 (800)

1 month

6,000 (10,000) 1 year

12,000 (20,000) 2 years

18,000 (30,000) 3 years

24,000 (40,000) 4 years

30,000 (50,000) 5 years

Engine oil Cooler - check for leaks Day

Engine oil - renew -

Engine oil filter - renew -

Valve clearance - check -

Air cleaner - renew -

Engine ECU - check for stored DTC`s -

Spark plugs - check -

Spark plugs - renew -

Throttle bodies - balance Day

Throttle cables - check/ adjust Day

fuel system - check for leaks Day

Lights. Instruments and elec. Systems - check Day



500 (800)

1 month

6,000 (10,000) 1 year

12,000 (20,000) 2 years

18,000 (30,000) 3 years

24,000 (40,000) 4 years

30,000 (50,000) 5 years

Drive chain slack - check/adjust Day

Drive chain rubbing strip - check -

Rear wheel bearing - lubricate -

Fasteners - inspect visually for security Day

Wheels - inspect for damage Day

Tyre wear/tyre damage - check Day

Tyre pressures - check/adjust Day

Stand - check operation Day

Secondary exhaust clamp bolts - check/adjust -

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500 (800)

1 month

6,000 (10,000) 1 year

12,000 (20,000) 2 years

18,000 (30,000) 3 years

24,000 (40,000) 4 years

30,000 (50,000) 5 years

Steering - check for free operation Day

Headstock bearings - check/adjust -

Headstock bearings - lubricate -

Forks - check for leaks/smooth operation Day

Fork oil - renew -

Brake fluid and clutch fluid levels - check Day

Brake fluid - renew Day

Brake pad wear - check Day

Brake master cylinders - check for oil leaks Day

Brake calipers - check for leaks/seized pistons Day

Drive chain - lubricate Every 200 miles (300kms)

Drive chain - wear check Every 500 miles (800kms)

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Torque and Locking Agent

The following tables list the tightening torque for the major fasteners requiring use of a non-permanent

locking agent or liquid gasket.

Letters used in the “Remarks” column mean:

Letters Mean

L Apply a non-permanent locking agent to the threads.

LG Apply liquid gasket to the threads.

Lh Left-hand threads.

M Apply molybdenum disulfide grease.

O Apply oil to the threads and seating surface.

S Tighten the fasteners following the specified sequence.

SS Apply silicone.

St Stake the fasteners to prevent loosening.

R Replacement parts.

TH05 Threebond 1305 (thread lock strong)

TH27 Threebond 1327 (thread lock medium)

The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts.

Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are

for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners

Threads dia. (mm)

Torque

N-m

5 3.4~4.9

6 5.9~7.8

8 14~19

10 25~34

12 44~61

14 73~98

16 115~155

18 165~225

20 225~325

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Torque table Chassis

Description Component

Torque Remarks

N-m

Sprocket cover

SPROCKET COVER TO C/CASE BOLT, CAP HD, M8 X 30 X 1.25 20

Front wheel SPINDLE FOR CONVENTIONAL FORKS SPINDLE, FRONT WHEEL 60

SPINDLE FOR USD FORKS SPINDLE, FRONT WHEEL, USD FORKS, HIGH BARS

60

Rear wheel TO CLAMP SPROCKET TO CARRIER LOCKNUT, FLANGED, M10 X 1.25 55

SPINDLE NUT LOCKNUT, THIN, M24 X 2 110

Brakes

HALF CLAMP BOLTS BOLT, M6 X 25 X 1.0, FLANGED, CP HD,GOLD

8

BRAKE SYSTEM ONLY BOLT, BANJO, M10 x 1.0 x 30, CHROME 25 BRAKE SYSTEM ONLY BOLT, BANJO, M10 x 1.0 x 18, CHROME 25 BRACKET TO MASTER CYLINDER (remote) BOLT, CAP HD, M6 X 12 X 1.0 6

LEFT HAND CALIPER BRACKET TO FORK (axial) BOLT, CAP HD, M10x20x1.25 35 CALIPER TO BRACKET, BRACKET TO FORK (axial) BOLT, CAP HD, M10x30x1.25 35 6 PER SIDE, PATCH LOCKED (axial) BOLT, BUTTON HD, INT HEX, M8 X 16 25 6 PER SIDE, PATCH LOCKED (radial) BOLT, BUTTON HD, INT HEX, M8 X 20 25 TO CLAMP CALIPER TO FORK (radial) BOLT, CALIPER, RADIAL 35

TO CLAMP REAR MASTER CYLINDER + BRACKET + HEEL GUARD TO HANGER BOLT, CAP HD, M6 X 20 10 TO CLAMP RESERVOIR TO BRACKET BOLT, CAP HD, M6 x 10 8 BRAKE SYSTEM ONLY BOLT, BANJO, M10x1.0x18, CHROME 25 CLAMP P CLIP TO SWINGARM BOLT, CAP HD, M5 X 15 X 0.8 7 REAR CALIPER TO CARRIER BOLT, CAP HD, M8 X 20 X 1.25 28

DISK, PATCHLOCKED BOLT, BUTTON HEAD, INT HEX, M10X20 43 L

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Description Component Torque Remarks

N-m

Front forks PINCH BOLT SUPPLIED WITH FORKS (for axle) BOLT, CAP HD, M8 X 25 20 LOWER YOKE CLAMP BOLTS BOLT, CAP HD, M8 X 20 X 1.25 20 SWITCH CUBE LH SCREW, M5 X 40 3 SWITCH CUBE LH SCREW, M5 X 30 3 SWITCH CUBE RH SCREW, M5 X 22 3 THROTTLE ACTUATOR,TWIN CABLE THROTTLE ACTUATOR,TWIN CABLE 4 THROTTLE ACTUATOR CLAMP BOLT, CAP HD, M6 X 20 x 1.0 8 TOP YOKE CLAMP BOLTS BOLT, CAP HD, M8 X 20 X 1.25 20 TOP YOKE LOCK NUT NUT, UPPER YOKE, M25 80 ADJUSTER NUT 40NM TO SEAT BEARINGS, BACKED OFF, THEN RE-TORQUED TO 8 NM LOCKNUT, M25

8

LOCKED UP TO ADJUSTER NUT 40 NM STEM INTERMEDIATE NUT, M25 40 REMOTE RESERVOIR BOLT (remote) BOLT, CAP HD, M6 X 12 X 1.0 8 RESERVOIR TO BRACKET (axial) LOCKNUT, FLANGED, M5 X 0.8 7 TO CLAMP SLAVE CYLINDER TO SPROCKET COVER BOLT, CAP HD, M6 X 16 X 1.0

12

HANDLEBAR CLAMP TO YOKE (not cafe racer) NUT, M10 X 1.5

43

UPPER HANDLE BAR CLAMPS BOLTS (not cafe racer) BOLT, CAP HD, M8 X 22 X 1.25

20

Rear suspension SWINGARM PIVOT NUT LOCKNUT, THIN, M16 X 1.0 60

THREADED ADJUSTER, SWINGARM THREADED ADJUSTER, SWINGARM 6

USED TO MOUNT CHAIN RUBING STRIP BOLT BUTTON HD, INT HEX M5 X 20 X 0.8 9

RSU'S TO FRAME BOLT, BUTTON HD, INT HEX, FLANGED, M8 X 16 X 1.25

22

Frame TO CLAMP ENGINE MOUNT BRACKET LOCKNUT, M8 X 1.25 26 NUT, USED WITH ENGINE MOUNT BOLT LOCKNUT, M12 X 1.75 85

FRAME ADJUSTER, M23 FRAME ADJUSTER, M24 15

REAR ENGINE MOUNT BOLT BOLT, M12, ENGINE, REAR MOUNT 85

Foot controls FOOT CONTROL FRAME TO FRAME ASSY BOLT CAP HD, M8 X 50 X 1.25 27 TO CLAMP CLEVIS + PEG ASSY TO CONTROL PLATE LOCKNUT, M10 X 1.5 40 TO CLAMP TOE PEG TO PEDAL BOLT, CAP/HD, M6 X 40 10 TO CLAMP PLATE TO PEDAL BOLT, CSK HD, M4 X 0.7 X 12 7

USE THREE BOND 1327 PIVOT BOLT, SIDESTAND

20

GEAR CHANGE TO SELECTOR SHAFT BOLT, CAP HD, M6 X 40 9

20

Description Component Torque Remarks

N-m

Oil cooler

TO CLAMP OIL COOLER TO FRAME BOLT, CAP HD, M6 X 20 x 1.0 6

Airbox and Exhaust TO AIR FILTER CLAMP BOLT, BUTTON HD, M5x12 4

TO CLAMP TRANSITION PIECE BOLT, CAP HD, M6 X 20 8 TO HEAD LOCKNUT, FLANGED, M8 X 1.25 19

2 REQUIRED FOR HOMOLOGATION LAMBDA SENSOR, EXHAUST, M10 X 1.25 25

USED TO CLAMP EXHAUST SECTIONS EXHAUST CLAMPS 10

Bodywork

TO BOLT HUGGER BOLT, CAP HEAD, M5 X 15 X 0.8 7

Fuel tank FUEL PUMP BOLT, CAP HD, M5 X 12 X 0.8 9

MOULDED TANK TO FRAME BOLT, CAP HD, M6 X 16 X 1.0 9

Electrical system

FOR ROLLOVER SWITCH BOLT, CAP HD, M4 X 25 X 0.7 3

MOUNTED ON LOWER YOKE BOLT, BUTTON HD, INT HEX, M8 X 16 18 TO CLAMP IGNITION COIL PACK BOLT, CAP HD, M6 X 40 X 1.0 10

PANEL TO YOKE FIXING BOLT, CAP HD, M8 X 20 X 1.25 20

Lighting

TO CLAMP NUMBER PLATE LIGHT BOLT, CAP HEAD, M5 X 15 X 0.8 7

21

Torque table Engine

LOC

ATI

ON

Description Component Torque

Re

mar

ks

N-m

CRANKSHAFT ASSEMBLY 8 TO CLAMP TRIGGER DISK BOLT, CSK HD, M5x0.8x12, DIN 7991, 10.9 5

9 PRIMARY GEAR NUT NUT, M20, X 1.5, DIN 934, GRADE 10 122 TH27

VALVE GEAR 19 ROCKER SHAFT BOLTS BOLT, CAP HD, M8 X 35 X 1.25, DIN 912, 12.9 25 TH27

18 ROCKER SHAFT BOLTS BOLT, CAP HD, M8 X 30 X 1.25, DIN 912, 12.9 25 TH27

CAMSHAFT AND CAM DIVE 4 RETAINER PLATE BOLT BOLT, HEX HD, M6 X 12, DIN 933, 8.8, BZP 12 TH27

13 CAM DRIVE NUTS NUT, M14 X 1.5, DIN 934, GRADE 8 54 TH27 17 TENSIONER BOLTS BOLT, CAP HD, M8 X 16 X 1.25, DIN 912, 12.9 25 TH27

20 TENSIONER BOLTS BOLT, CAP HD, M6 X 16 X 1.0, DIN 912, 12.9 12 TH27

CYLINDER HEAD 7 EXHAUST BOLTS STUD, EXHAUST 12 TH03

26 GRUB SCREW ON EXSIDE, HEAD GRUB SCREW, M12 X 1.75 X 20MM, DIN 913, A2 15 TH03 13 ROCKER TOWER, EXHAUST SIDE BOLT, CAP HD, M8 X 50 X 1.25, DIN 912, 12.9 20 TH03 28 ROCKER TOWER, INLET SIDE BOLT, CAP HD, M8 X 55 X 1.25, DIN 912, 12.9 20 TH03 14 CYLINDER HEAD STUDS STUD, HEAD 54 TH03 15 INTERNAL HEAD BOLTS LONG BOLT,CAP HD, M10 X 150 X 1.5, DIN 912, 12.9 60 18 INTERNAL HEAD BOLTS MEDIUM BOLT, CAP HD, M8 X 80 X 1.25, DIN 912, 12.9 25 19 INTERNAL HEAD BOLTS SHORT BOLT, CAP HD, M8 X 110 X 1.25, DIN 912, 12.9, BZP 25 20 CYLINDER HEAD STUD NUTS NUT, DOMED, M10 X 1.5, DIN 1594, A2 60

24 HEAD BREATHER NUT LOCKNUT, M10 X 1.5, GRADE 8 20

CRANK CASE 10 CENTER PIECE SPLIT BOLTS BOLT, CAP HD, M10 X 100 X 1.5, DIN 912, 12.9 48

15 CENTER PIECE TO CRANK CASE BOLTS

BOLT, HEX HD, FLANGED, M8 X 40, DIN 6921, 10.9 25

18 BAFFLE PLATE TO CENTER PLATE BOLT

BOLT, CAP HD, M5 X 12 X 0.8, DIN 912, 12.9 5 TH27

20 CRANK CASE SPLIT BOLTS BOLT, CAP HD, M10 X 75 X 1.5, DIN 912, 12.9, BZP 48 21 CRANK CASE SPLIT BOLTS BOLT, CAP HD, M10 X 45 X 1.5, DIN 912, 12.9, BZP 48 22 CRANK CASE SPLIT BOLTS BOLT, CAP HD, M10 X 40 X 1.5, DIN 912, 12.9, BZP 48 23 CRANK CASE SPLIT BOLTS BOLT, CAP HD, M10 X 60 X 1.5, DIN 912, 12.9 48 24 CRANK CASE SPLIT BOLTS BOLT, CAP HD, M10 X 90 X 1.5, DIN 912, 12.9 48 25 CRANK CASE SPLIT BOLTS BOLT, CAP HD, M6 X 50 X 1.0, DIN 912, 12.9 12 29 SEAL RETAINER BOLT, BUTTON HD, M4x0.7x6.0, ISO 7380, 10.9 2.5 TH27

30 BREATHER SPIGOT BREATHER, CRANKCASE 15 TH27

22

LOC

ATI

ON

Description

Component Torque

Re

mar

ks

N-m

BARRELS 9 LIFTER SELEVE RETAINER BOLT, M5 X 40 X 0.8, 6.00MM DIA, SHOULDERED, SS 6

11 OIL WAY HOLE PLUG BOLT, CAP HD, M8 X 12 X 1.25, DIN 912, A2/70 22

12 BARREL BOLTS BOLT, HEX HD, FLANGED, M8 X 25, DIN 6921, 10.9, BZP 25

CLUTCH /PRIMARY TRANSMISSION

6 CENTER NUT MAIN NUT, HALF, M20 X 1.5, DIN 439, A2 70 122 TH27

GEAR ASSY, INPUT/PUTPUT 23 SELECTOR LINKAGE ARM PIVOT BOLT, M8x1.25x12, 10.0 DIA, SHLD, ISO 7979, 12.9 15 TH03 56 CENTER PLATE TO CASE BOLTS BOLT, CAP HD, M8 X 70 X 1.25, DIN 912, 12.9 25 20 SPRING RETAINER BOLT BOLT, M5x0.8x10, 6.0 DIA, SHLD, ISO 7979, 12.9 5 TH03

44 LAY SHAFT CENTER BOLT BOLT, CAP HD, M8 X 30 X 1.25, DIN 912, 12.9 25 TH27

GEAR SELECTOR ASSEMBLY 22 TO CLAMP DETENT WHEEL BOLT, CAP HD, M6 X 25 X 1.0, DIN 912, 12.9 12

25 TO CLAMP SHIFT MECHANISM BOLT, CAP HD, M6 X 12 X 1.0, DIN 912, 12.9 12

BALANCER

17 GEAR NUT MAIN NUT, HALF, M20 X 1.5, DIN 439, A2 70 122

LUBRICATION SYSTEM 1 OIL PRESSURE SWITCH SWITCH, OIL PRESSURE, 0.2 BAR 20 TH27 9 CLAMP, OIL PUMP TO ENGINE BOLT, CAP HD, M6 X 30 X 1.0, DIN 912, 8.8, BZP 12

13 GEAR BOX FILLER CAP FILLER CAP, GEARBOX 20

21 SUMP PLUG GEARBOX PLUG, SUMP, M10 X 9.0 X 1.5 20

STARTER DRIVE AND MOTOR 4 USED TO CLAMP STARTER RING BOLT, M5x0.8x16, 6.0 DIA, SHLD, ISO 7979, 12.9 5 5 TO CLAMP STARTER MOTOR BOLT, CAP HD, 3/8-24UNF X 1, BZP, 1936 SERIES 20

7 TO CLAMP STARTER MOTOR BOLT, CAP HD, 3/8-24UNF X 3/4, 1936 SERIES 20

SUMP 3 ENGINE SUMP PLUG PLUG, SUMP, MAGNETIC M14 X 1.5 20

5 SUMP RETAINER BOLTS BOLT, CAP HD, M6 X 20 x 1.0, DIN 912, SS 12

23

LOC

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Description

Component Torque

Re

mar

ks

N-m

ENGINE COVERS 3 ROCKER COVER RETAINER BOLTS BOLT, CAP HD, M6 X 20 x 1.0, DIN 912, SS 12 8 RH SIDE BREATHER BOLT BOLT, BANJO, M14 22

23 LH BREATHER BOLT BOLT, BANJO, M14, MOD 22 14 OIL FILLER RETAINER BOLTS BOLT, CAP HD, M5x0.8x14, DIN 912, A2/70 5 15 CLUTCH COVER RETAINER BOLTS BOLT, CAP HD, M6 X 20 x 1.0, DIN 912, SS 12

18 ALTERNATOR COVER RETAINER BOLTS

BOLT, CAP HD, M6 X 40, DIN 912, SS 12

19 ALTERNATOR COVER BOLT SHORT BOLT, CAP HD, M6 X 30 X 1.0, SS 12

EFI SYSTEM 1 TEMPERATURE SENSOR SENSOR, TEMPERATURE 15 4 TO CLAMP SPEED SENSORS BOLT, CAP HD, M6 X 12 X 1.0, DIN 912, 12.9, BZP 12 5 NEUTRAL LIGHT SWITCH SWITCH, NEUTRAL, M10x1.25 12

7 FIRST USE TORQUE ONLY SPARK PLUG, CR9EB 12

ALTERNATOR 2 TO CLAMP ROTOR TO COVER BOLT, CAP HD, M8 X 16 X 1.25, DIN 912, 12.9 25 TH27 4 TO CLAMP STATOR TO COVER BOLT HEX, HD, M6 X 35 DIN 933, 10.9 12 7 TO CLAMP P-CLIP TO COVER BOLT, BUTTON HD, INT HEX, M5 X 10, ISO 7380, 10.9 5

8 USED TO CLAMP CRANK SENSOR BOLT, CAP HD, M5 X 10 X 0.8, DIN 912, 12.9 5

24

Special tools

36mm slim head stock spanner

Engine adjuster tool

Swingarm adjust tool

Anti backlash gear holder

25

Anti backlash spring Tensioner

Clutch tool

Main shaft stop tool

26

Cable, Wire and Hose Routing

Rout the electrical wires as shown:

27

Route the oil pipes as shown:

Note: Oil is sucked from the back of the oil tank [1] and pumped under

pressure through the engine oil feed system.

Oil is scavenged from the sump by the oil pump [2] and pumped

through the radiator [3] into the oil tank [4].

The oil tank LH breather [5], breathes into the back of the head.

The crank case breather [6] breathes into the LH rocker cover.

The RH rocker cover breather [7] breathes into the air box.

1

2

3

4 5

7

6

28

Fuel System

Exploded View .................................................................................................................................................. 29

Specification ..................................................................................................................................................... 32

Throttle Grip and Cables .................................................................................................................................. 32

Grip Free Play Inspection ..................................................................................................................... 32

Grip Free Play Adjustment ................................................................................................................... 32

Throttle Cable Removal ....................................................................................................................... 32

Throttle Cable Installation ................................................................................................................... 33

Throttle Cable Lubrication ................................................................................................................... 33

Throttle Body ................................................................................................................................................... 34

Idle Speed Adjustment ......................................................................................................................... 34

Throttle Body Removal ........................................................................................................................ 34

Throttle Body Installation ................................................................................................................................... 35

Throttle Body Disassembly .................................................................................................................. 36

Throttle Body Assembly ....................................................................................................................... 37

Throttle Body Cleaning ........................................................................................................................ 37

Throttle Body Inspection ..................................................................................................................... 37

Air Cleaner ........................................................................................................................................................ 37

Air Cleaner Element Removal .............................................................................................................. 37

Air Cleaner Element Installation .......................................................................................................... 38

Air Cleaner Element cleaning and Inspection ...................................................................................... 38

Air Cleaner Housing Removal .............................................................................................................. 39

Fuel Tank .......................................................................................................................................................... 39

Fuel Tank Removal ............................................................................................................................... 39

Fuel Tank Installation ........................................................................................................................... 40

Fuel Tank Cleaning ............................................................................................................................... 40

Fuel Pump ........................................................................................................................................................ 41

Fuel Pump Removal ............................................................................................................................. 41

Fuel Pump Installation ......................................................................................................................... 41

Fuel Pump Inspection .......................................................................................................................... 41

Idle Motor ........................................................................................................................................................ 42

Idle Motor Removal ............................................................................................................................. 42

Idle Motor Installation ......................................................................................................................... 42

Idle Motor Inspection .......................................................................................................................... 42

30

REF. NO. PART DESCRIPTION

TORQUE (NM) REMARKS

1 FUEL PUMP MODULE BITRON

2 BOLT, CAP HD, M5 X 12 X 0.8 9

3 HOSE, BREATHER, SHORT, 205MM FUEL TANK TO JOINER

4 DRAIN HOSE, FUEL TANK, LONG, 635MM JOINERS TO DRAIN

5 HOSE, BREATHER, 230MM FUEL TANK TO JOINER

14 HOSE, BREATHER, 485MM AIRBOX TO DRAIN

6 HOSE, BREATHER, JOINER JOINS

7 FILLER NECK, FUEL TANK PLASTIC FILLER NECK FOR FUEL TANK

10 PAD, RUBBER, FUEL TANK TO FRAME MOULDED RUBBER PIECE

11 BOLT, CAP HD, M6 X 12 X 1.0 TO BOLT TANK PAD TO TANK

12 FUEL TANK, MOULDED AS RECIEVED FROM ACERBIS

15 WASHER, PENNY, M6, 6.4 X 18 1.6 TO FIT ON EACH SIDE OF RUBBER PAD TO

THE FRAME

13 BOLT, BUTTON HD, M6 X 1.0 SHOULDERED

FLANGED TO CLAMP SPLASH SHIELD + TANK

16 FUEL HOSE ASSEMBLY 94MM HOSE WITH TWO CONNECTORS

12 TANK, FUEL, GALACTIC BLACK, GOLD TEXT

12 TANK, FUEL, ROYAL RED, GOLD TEXT

12 TANK, FUEL, CANARY YELLOW, BLACK TEXT

12 TANK, FUEL, FACTORY SPECIAL SILVER,

BLACK TEXT

12 TANK, FUEL, FACTORY SPECIAL SILVER, BLACK TEXT/BORDER, RED PIN STRIPE

31

Exploded view

32

Throttle Specification

Item Standard

Throttle Grip Free Play 2~3mm

Idling Speed 1200 ± 100 (rpm) Make, Type Jenvey, Norton Commando

Air Cleaner Element Oil Grade SE or SF Class

Viscosity SAE30

Throttle Grip and Cables

If the throttle grip has excessive free play due to cable stretch or maladjustment, there will be a delay in

throttle response. Also, the throttle butterfly may not open fully at full throttle. On the other hand, if the

throttle grip has no play, the throttle will be hard to control, and the idle speed will be erratic. Check the

throttle grip play periodically in accordance with the Periodic Maintenance Chart, and adjust the play if

necessary.

Grip Free Play Inspection

Check throttle grip free play[A] by lightly turning the

throttle grip back and forth

If free play is improper, adjust the throttle cable

Throttle Grip Free Play

Standard: 2 ~ 3mm

Grip Free Play Adjustment

Loosen the locknut and screw the throttle cable adjuster

on the rear cable (no. 1) so there is approximately 2-3mm

free play at the throttle grip. Adjust the front cable (no. 2)

until there is slight tension on the front cable.

Tighten the locknuts against the cable adjusters.

Check that the throttle cam stops against the idle adjusting

screw with the throttle grip closed.

Turn the handlebars from side to side while idling the engine.

If idle speed varies, the cable may be poorly routed or damaged.

Warning: Operation with an improperly adjusted, incorrectly routed, or damaged cable could result in an

unsafe riding condition.

Throttle Cable Removal

Remove: Fuel Tank (see this chapter)

Take off the adjuster nuts [A] at the throttle body.

A

33

Slip the inner clips [B] out of the lever

Remove the right hand guard off the brake level.

Take the two screws [A] holding the throttle pulley case

halves together.

Slip the inner cable tips from the catches on the throttle

pulley, and free cables from the handlebar.

- Inner Cable Tips [A]

- Pulley [B]

- Accelerator Cable [C]

Remove the throttle cables.

Throttle Cable Installation

Lubricate the throttle cables (see Throttle Cable

Lubrication and Inspection).

Be sure to fit the throttle cables into the grooves of the

cable guide [A] while turning the throttle grip.

Install the throttle cables in accordance with the Cable,

Wire, and Hose Routing section of the General Information

chapter

After Installation, adjust the cables properly.

Warning: Operation with an incorrectly routed or improperly adjusted cable could result in an unsafe riding

condition.

Throttle Cable Lubrication and Inspection

Whenever the Cables are removed, and in accordance with the Periodic Maintenance Chart,

lubricate the throttle cables (see General Lubrication in the Appendix).

Apply a thin coating of grease to the cable upper ends.

Use a pressure cable luber to lubricate the cables

With the cables disconnected at both ends, the cable should move freely in the cable housing.

B A

A

B

C

A

A

34

Throttle Body

A dirty or damaged air cleaner can alter the fuel air ratio.

Idle speed Adjustment

Start the engine and let it warm up thoroughly.

With the engine idling, turn the handlebar to each side. If

the handlebar movement changes idle speed, the throttle

cable may be incorrectly routed, or it may be damaged.

Turn the adjuster screw [A] to obtain the slowest smooth

idle speed.

Check idle speed. If the idle speed is out of the specified

range, adjust it.

Idle speed standard: 1200 ± 100 (rpm)

Open and close the throttle a few times to make sure that the idle speed does not change. Readjust

if necessary.

Warning: Operation with an incorrectly routed or improperly adjusted cable could result in an unsafe riding

condition. To avoid a serious burn, never touch a hot engine or an exhaust pipe during idle adjustment.

Throttle body Removal

Warning: Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition

switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or

sparks; this includes any appliance with a pilot light.

Remove:

o Fuel hose from tank

o Idle motor air feed

o Throttle body and idle motor power supply

Remove:

o Fuel tank (see this chapter)

o Tank breather hose

o Air cleaner housing (see this chapter)

Loosen the cable adjuster nuts [A].

Slip the throttle cable lower ends out of the throttle cam.

Loosen the clamps [B]

Remove Four throttle body bolts [A]

Remove the throttle body upward.

B

A

A

35

Push a clean, lint-free towel into the inlet to keep dirt or other foreign material from entering.

Warning: If dirt or dust is allowed to pass through into the throttle body, the throttle may become stuck,

possibly causing an accident

Caution: If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.

Throttle body Installation

Apply RED grease to the ‘O’ rings on the throttle body gasket making sure they stay in place.

Torque the four throttle body bolts up

Torque: M6 Bolt - 12NM

When Installing air box ensure transition piece ridges fit

over throttle body correctly

Tighten clamps [A]

Install:

o Fuel tank (see this chapter)

o Tank breather hose

o Air cleaner housing (air box) (see this chapter)

Install:

o Fuel hose from tank

o Idle motor air feed

Throttle body and idle motor power supply

Check fuel leakage from the Throttle body.

Warning: Fuel spilled from the throttle body is hazardous.

Install the throttle cables (see Throttle Cable Installation)

Adjust the throttle cable (see Grip Free Play Adjustment)

Adjust the idle speed (see Idle Speed Adjustment)

A

A

36

Throttle Body Disassembly

Remove:

Throttle body

Remove fuel hose

Remove:

bolts [13]

Fuel Injector clips

Fuel rail [2]

Injectors [21]

Throttle potentiometer bolts [15]

Throttle potentiometer [5]

Four butterfly bolts [12]

Remove the butterflies [7]

Extract the spindle taking note of the spacer, bearing, spring assembly sequence and location

Warning any damage to the injector system or potentiometer should be replaced not repaired.

37

Throttle Body Assembly

The Throttle Body assembly Sequence is the reverse of the disassembly sequence (see Throttle

Body Disassembly)

Ensure the throttle cable spring is installed correctly and rotates freely.

Check bushes for Wear and tear, replace if necessary.

Ensure all seals are intact replaced if any wear or degradation is visible.

Ensure no daylight is visible between the throttle butterflies and the throttle body hosing and that

the butterflies are seated correctly.

Throttle Body Cleaning

Warning: Clean the throttle body in a well-ventilated area, and take care that there is no spark or flame

anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of

highly flammable liquids, do not use gasoline or low-flash point solvents to clean the throttle bodies. A fire

or explosive could result.

Caution: Remove as many plastic parts from the throttle body as possible before cleaning the throttle body

with a cleaning solution. This will prevent damage or deterioration of the parts.

Disassemble the carburettor (see Throttle Body Disassembly).

Immerse all the metal parts in throttle body cleaning solution.

Rinse the parts in water.

When the parts are clean, dry them with compressed air.

Assemble the throttle body (see Throttle Body Assembly)

Throttle Body Inspection

Remove the throttle body (see Throttle Body Removal).

Turn the throttle lever [A] to check that the throttle

butterfly valve [B] moves smoothly and returns back with

the spring force.

If any of the O-rings are not in good condition, replace

them.

Air Cleaner

Air Cleaner Removal

Remove:

Seat (see Frame chapter)

Air cleaner retainer screws [A]

Air cleaner retainer [B]

Remove air cleaner element.

After removing the element, push pieces of lint-free, clean

cloth into the air cleaner duct to keep dirt out of the

A B

B A

38

throttle body and engine.

Warning: If dirt or dust is allowed to pass through into the throttle body, the throttle may become stuck,

possible causing an accident.

Caution: If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.

Air Cleaner Element Installation

When installing the element, coat the lip of the element

with a thick layer of all purpose grease [A] to assure a

complete seal against the air cleaner element base. Also,

coat the base where the lip of the element fits.

Be sure the foam gasket [A] is in place in the groove in the

element cap.

Air Cleaner Element Cleaning and Inspection

Note: In dusty areas, the element should be cleaned more frequently than recommended interval.

Since repeated cleaning opens the pores of the element, replace it with a new one in accordance with the

Periodic Maintenance Chart. Also, is there is a break in the element material or any other damage to the

element, replace the element with a new one.

Warning: Clean the element in a well ventilated areas, and take

care that there are no sparks or flames anywhere in the working

area; this includes any appliance with a pilot light.

Because of the danger of highly flammable liquids, do not use

gasoline or a low-flash point solvent to clean the element.

Remove the air cleaner element.

Check all parts the parts of the element for visible damage.

If any parts of the element are damaged, replace it.

Liberally spray Air Filter Cleaner onto both sides of filter and allow to soak for 10 minutes to loosen

the dirt. Do not allow cleaner to dry on air filter.

Rinse off air filter with cool low-pressure water applied to the clean side out in order to flush the

dirt out of the filter. Continue to rinse the filter until all traces of cleaner are gone. It may be

necessary to repeat steps 1 and 2.

After rinsing, gently shake off excess water and only allow filter to dry naturally. Do not oil until the

filter is completely dry.

Apply Air Filter Oil evenly along the crown of each pleat. Allow oil to wick for approximately 20

minutes. Touch up any light areas on either side of filter until there is a uniform colour in all areas.

Install the element

A

39

Air Cleaner Housing Removal

Remove:


Breather Hoses

Rear Wheel

Rear Hugger

Fully loosen off the two jubilee clips [A] securing the

transition piece to the air cleaner housing.

Remove the two hex head bolts [A] at the rear of the air

filter housing.

Fuel Tank

Fuel Tank Removal

Warning: Gasoline is extremely flammable and can be explosive

under certain conditions. Always stop the engine and do not

smoke. Make sure the area is well ventilated and free from any

source of flame or sparks; this includes appliances with a pilot

light.

Remove:

Seat (see Frame Chapter)

Breather hoses

Remove fuel hose, cover hose clips with lint free cloth

when taking off as fuel will spill out.

Remove fuel pump electrical connection.

Remove hex head tank bolts, one at the front [A] and two

at the rear [B].

Remove tank upwards from the bike

Drain the fuel tank by siphoning the fuel out through the

fuel filler cap into a clean container.

A

A

B

Note: 2nd on other side of frame

A

40

Fuel Tank Installation

Check the rubber damper [A] on the frame and fuel tank.

If the dampers are damaged or deteriorated, replace them.

Be sure the fuel hose is clamped to the spigot to prevent

leakage.

Warning: Fuel spilled from the fuel spigot connecter is hazardous.

Install:

o Seat (see Frame Chapter)

o Breather Hoses

o Fuel Hose

o Fuel Pump Electrical Connection.

Install hex head tank bolts, two at the front one at the

rear.

Torque: Tank Mount Bolts - 9NM

Fuel Tank Cleaning

Remove the fuel tank and drain it (see Fuel Tank Removal)

Pour some high-flash point solvent into the fuel tank and shake the tank to remove dirt and fuel

deposits.

Warning: Clean the tank in a well-ventilated area and take care that there is no spark or flame anywhere

near the working area; this includes any appliance with a pilot light. Because of the danger of highly

flammable liquids, do not use gasoline or low flash point solvents to clean the tank. A fire or explosion

could result.

Pour the solvent out the tank.

Pour high-flash point solvent through the fuel spigot.

Dry the tank and tap with compressed air.

Install the fuel tank.

A

41

Fuel Pump

Note: The fuel pump, fuel filter and low fuel level sensor is a sealed for life unit and must be replaced as a

complete assembly.

Fuel Pump Removal

Remove the fuel tank and drain it (see Fuel Tank Removal).

Warning: Observe the warning advice given in general information sections on the safe handling of fuel and fuel

containers. A fire, causing personal injury and damage to property, could result from spilled fuel or fuel not handled

or stored correctly.

Invert the fuel tank and place on a protective surface to

prevent paint damage.

Remove the fixings securing the fuel pump [A].

Lift the fuel pump assembly and manoeuvre it from the

tank aperture.

Fuel Pump Installation

Install the fuel pump assembly and manoeuvre it into the tank aperture, ensure the gasket is seated

correctly and all gasket faces are clean.

Install the six fuel pump bolts.

Torque: Fuel Pump Mount Bolts - 3NM

Install the fuel tank (see Fuel Tank Installation).

Fuel Pump Inspection

Note: Fuel Pump Pressure test requires Inline pressure gauge, and fuel pump fly lead (extension cable) available

from Norton Motorcycles (UK) Ltd.

Remove the Fuel tank (see Fuel Tank Removal).

Attach Extension cable to pump electrical connection, and wiring harness.

Attach Inline Pressure tester to Pump and throttle bodies.

Place the pressure gauge in a visible position with the fuel tank upright on a flat surface, with a soft

cloth to stop paintwork damage.

Start the motorcycle and observe the fuel pressure.

Fuel Pressure Nominal: 3 Bar

A

42

When finished remove extension cable and inline pressure tested and install the fuel tank (see fuel

tank installation.

Idle Motor

Idle Motor Removal

Remove:

o Idle motor hose clips

o Hoses

o Electrical connections

Remove idle motor bracket bolts [A].

Remove idle motor bolts [B].

Idle Motor Installation

Install:

o Idle motor hoses

o Electrical connector

o Hoses clips

Install and tighten idle motor bracket bolts

Torque – Idle Bracket Bolts: 5Nm

Torque Idle motor bolts

Torque – Idle Motor Bolts: 5Nm

Idle Motor Inspection

Visually inspect the idle motor for damage/cracks, and or deterioration

Replace if any issues are visible.

A

B

43

Cooling System

Exploded View .................................................................................................................................................. 45

Flow Chart ........................................................................................................................................................ 47

Specification ..................................................................................................................................................... 48

Engine Oil and Filter ......................................................................................................................................... 49

Oil Level Inspection .............................................................................................................................. 49

Oil Draining ........................................................................................................................................... 49

Oil Filling ............................................................................................................................................... 50

Oil Pump ........................................................................................................................................................... 50

Oil Pump Removal ................................................................................................................................ 50

Oil Pump Installation ............................................................................................................................ 51

Oil Pump Inspection ............................................................................................................................. 51

Oil Cooler ......................................................................................................................................................... 51

Oil Cooler Removal .............................................................................................................................. 51

Oil Cooler Installation .......................................................................................................................... 52

Oil Cooler Inspection ............................................................................................................................ 52

Oil Cooler Cleaning ............................................................................................................................... 52

Hose Inspection .................................................................................................................................... 52

Head Temperature Sensor ............................................................................................................................... 53

Head Temperature Sensor Removal .................................................................................................... 53

Head Temperature Sensor Installation ................................................................................................ 53

Head Temperature Sensor Inspection ................................................................................................. 53

44

Oil Coolant Flow

Note: Oil is sucked from the back of the oil tank [1] and pumped under

pressure through the engine oil feed system.

Oil is scavenged from the sump by the oil pump [2] and pumped

through the radiator [3] into the oil tank [4].

The oil tank LH breather [5], breathes into the back of the head.



1

2

3

4 5

7

6

46

REF. NO. PART DESCRIPTION TORQUE REMARKS

1 SWITCH, OIL PRESSURE, 0.2 BAR 20 THREEBOND 1327

8 PUMP ASSY, OIL

11 PIN, DOWEL, 1/8 X 5/8, SOLID USED WITH OIL PUMP DRIVE

12 PIN, DOWEL, 4.0 X 16.00MM, SOLID USED WITH PUMP TO CASE

9 BOLT, CAP HD, M6 X 30 X 1.0, DIN 912, 8.8, BZP 12 CLAMP, OIL PUMP TO ENGINE

10 WASHER, ID 6.4 X 11.0 OD X 1.6 STAINLESS USED WITH OIL PUMP BOLTS

13 FILLER CAP, GEARBOX 20

14 WASHER, ID 26.3 X 31.75 X 2.0, COPPER GEAR BOX FILLER CAP

15 FILTER, OIL

20 SEAL, M10, BONDED VITON

21 PLUG, SUMP, M10 X 9.0 X 1.5 20

22 LABEL, SILKOLENE, 10W/40 APPLY TO RH COVER ABOVE FILTER COVER

48

Specification

Oil Specification

Item Standard

Engine Oil: Grade API SG, SH AND SJ, JASO MA Viscosity SAE 10W-40 Capacity 3L FROM COMPLETELY DRY

2.5L WHEN FILTER REMOVED

Oil Pressure Measurement: Relief valve opening pressure 400kPa

oil pump pressure @8000rpm with 130˚C 10W/40 oil 6L/min and 300kPa

oil pump pressure @1000rpm with 130˚C 10W/40 oil 150kPa


TORQUE (NM) REMARKS

1 COOLER, OIL

2 GROMMET, ID 14 X OD 9 X 12.5

3 COMPRESSION LIMITER, M6 X 20MM OD

4 BOLT, CAP HD, M6 X 20 x 1.0 6 TO CLAMP OIL COOLER TO FRAME

5 WASHER, PENNY, M6, 6.4 X 18 X 1.6 USED WITH OIL COOLER BOLTS

OIL LINE EN 854 100R6 - 06 (RAW)

6 OIL LINE, 215MM OIL COOLER TO OIL TANK

7 OIL LINE, 685MM OIL COOLER TO OIL PUMP, 685MM

8 OIL LINE, 490MM OIL PUMP TO OIL TANK, 490MM

9 OIL LINE 400MM ROCKER COVER TO CRANKCASE 400MM

10 OIL LINE, 300MM HEAD TO AIR BOX, 300MM

11 HOSE, BREATHER, FORMED, 360MM ROCKER COVER TO OIL TANK

12 BANJO, OIL LINE, IN

13 BANJO, OIL LINE, OUT

14 WASHER, M14, OD 20.4MM X 1.22, COPPER ONE EITHER SIDE OF OIL BANJO

15 BOLT, BANJO, OIL LINE USED FOR OIL LINE IN AND OUT

16 O-CLAMP, DOUBLE EARED, 15MM-18MM OIL LINE AND BREATHER PIPE CLIPS

17 SMALL BREATHER HOSE TO ROCKER COVER

49

Engine Oil and Oil Filter

Warning: Motorcycle operation with Insufficient, deteriorated or contaminated engine oil will cause

accelerated wear and may result in engine or transmission seizure, accident, and injury.

Oil Level Inspection

Situate the motorcycle so that it is perpendicular to the ground.

If the oil has just been changed, start the engine and run it for several minutes at idle speed. This

fills the oil filter with oil.

Caution: Racing the engine before the oil reaches every part can cause engine seizure.

Stop the engine and leave it for more than 1 minute for

all the oil to drain down.

If the motorcycle has just been ridden, run the engine for

about 20 seconds at idle speed. Stop the engine and

leave it for more than one minute.

Check the engine oil by removing the oil filler [A], clean

the dip stick with a cloth fully reinsert the plug then

remove it again and check the level on the dip stick.

The oil level should be in the middle of the two markings.

If the oil level is difficult to check, rock the motorcycle

both side-to-side, and front-to-rear.

If the oil level is too high, remove the excess oil through

the filler opening, using a syringe or some other suitable

device.

If the oil level is too low, add the correct amount of oil

through the oil filler opening. Use the same type and

make of oil that is already in the engine.

Note: If the engine oil type and make are unknown, use any brand of the specified oil to top off the level

rather than running the engine with the oil level low. Then at your earliest convenience, change the oil

completely.

Oil Draining

Warning: To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is

still hot. Wait until it cools down. Oil on tires will make them slippery and can cause an accident and injury.

Immediately wash away any coolant that spills of the frame, engine, or wheels. Since oil is harmful to the

human body, do not use for drinking.

Place a container under the drain plug [A] at the bottom of

the sump, remove oil filler cap and then remove the drain

plug.

Min

Max

A

A

50

Place a tray under the bottom radiator hoses [A],

remove the bottom banjo bolt [B] and drain the oil

from the oil tank hose.

Oil Filling

Tighten the drain plug.

Torque – Oil sump drain Plug 20Nm

Fill the oil tank with 2.5L of oil and tighten the filler cap.

Run the engine at idle for 2 minutes in a well ventilated

area. Allow the motorcycle to stand for 2 minutes.

Check the oil level as described in (Oil Level Inspection)

top up if necessary.

Note: Pour in the oil slowly so that the air in the engine and oil cooler can escape.

Caution: Do not add more oil above the full mark.

Oil Pump

Oil Pump Removal

Drain the oil (see Oil Draining)

Remove Oil Pump hoses [A]

Remove Oil Pump retainer bolts [A]

Remove the oil pump from the engine and balance

shaft taking care that the drive dowel pin [A] remains

in the oil pump drive shaft.

B

A

A

A

A

51

Oil pump Installation

Apply a small amount of grease to the drive pin to

ensure the pin remains located

Align the drive dowel pin with the balance shaft cut out

[A] and the oil pump dowels with the engine casing.

Install the oil pump retaining bolts.

Torque – Retaining bolts oil pump 12NM

Install the hoses as shown.

Hose from radiator [A]

Hose from tank [B]

Torque - banjo Bolts to 27 Nm

Fill the oil system (see Oil Filling).

Oil Pump Inspection

If the oil seal is damaged, the oil leaks through the seal.

Replace the ball bearing and oil seal.

Oil Cooler

Oil Cooler Removal

Drain the oil (see Oil Draining)

Remove:

o Oil Cooler Hoses [A]

o Oil Cooler Bolts [B]

Caution: Do not touch the Oil Cooler core. This could damage

the radiator fins, resulting in loss of cooling efficiency.

A

B

B

C

A

A

52

Remove the Oil Cooler [C]

Oil Cooler Installation

Run the hoses and leads according to the Cable, Wire,

and Hoses Routing section in the General Information

chapter.

Oil Cooler Inspection

Check the Oil Cooler core.

If there are obstructions to air flow, remove them.

If the corrugated fins [A] are deformed, carefully

straighten them.

If the air passages of the Oil Cooler core are blocked

more than 20% by unremovable obstructions or

irreparably deformed fins, replace the Oil Cooler with

a new one.

Oil Cooler Cleaning

Remove the Oil Cooler (see Oil Cooler remover).

Caution: When cleaning the Oil Cooler with steam cleaner, be

careful of the following to prevent Oil Cooler damage. Keep

the steam gun [A] away more than 0.5m [B] from the Oil

Cooler core [C]. Hold the steam gun perpendicular to the core

surface. Run the steam gun following the core fin direction

[D].

Hose Inspection

In accordance with the Periodic Maintenance Chart, visually inspect the Oil Cooler hoses for signs of

deterioration. Squeeze the hose. A hose should not be hard and brittle, nor should it be soft or

swollen.

Replace and damaged hose.

A

B C

D

A

53

Head Temperature Sensor

Head Temperature Sensor Removal

Remove Idle air motor assembly

(see Fuel System chapter)

Remove electrical connection from sensor.

Remove the connector by unscrewing it.

Head Temperature Sensor Installation

Install and tighten the connector.

Torque – Head Temp Sensor: 15Nm

Install electrical connector on sensor.

Install idle air motor assembly (see Fuel System chapter).

Head Temperature Sensor Inspection

Check the sensor visually for cracks/deterioration or visible signs of damage.

If the sensor if thought to be faulty replace.

54

Engine Top End

Exploded View .................................................................................................................................................. 56

Specification ..................................................................................................................................................... 71

Cylinder Head Cover ........................................................................................................................................ 73

Cylinder Head Cover Removal ............................................................................................................. 73

Cylinder Head Cover Installation ......................................................................................................... 73

Cylinder Head Cover Assembly ............................................................................................................ 74

Camshaft Chain Tensioner ............................................................................................................................... 74

Camshaft Chain Tensioner Removal .................................................................................................... 74

Camshaft Chain Tensioner Installation ................................................................................................ 75

Camshaft, Camshaft Chain ............................................................................................................................... 76

Camshaft Chain Removal ..................................................................................................................... 76

Camshaft Chain Installation ................................................................................................................. 76

Camshaft Removal ............................................................................................................................... 76

Camshaft Installation ........................................................................................................................... 77

Camshaft Disassembly ......................................................................................................................... 78

Camshaft Assembly .............................................................................................................................. 78

Camshaft Bearing Wear ....................................................................................................................... 78

Cylinder Head ................................................................................................................................................... 79

Cylinder Compression Measurement .................................................................................................. 79

Cylinder Head Removal ........................................................................................................................ 80

Cylinder Head Installation .................................................................................................................... 82

Cylinder Head Assembly ....................................................................................................................... 83

Cylinder Head Disassembly .................................................................................................................. 84

Cylinder Head Cleaning ........................................................................................................................ 84

Cylinder Head Warp ............................................................................................................................. 84

Valves ............................................................................................................................................................... 85

Valve Clearance Measurement ............................................................................................................ 85

Valve Clearance Adjustment ................................................................................................................ 85

Valve Removal ...................................................................................................................................... 85

Valve Installation .................................................................................................................................. 86

Valve-to-Guide Clearance Measurement ............................................................................................ 86

Valve Seat Inspection ........................................................................................................................... 86

Valve Seat Repair (Valve Lapping) ........................................................................................................ 87

Cylinder, Piston ................................................................................................................................................ 90

Cylinder, Piston Removal ..................................................................................................................... 90

Cylinder, Piston Installation and Ware ................................................................................................ 91

Piston/Cylinder Clearance .................................................................................................................... 93

Cylinder Boring and Honing ................................................................................................................. 93

Piston Ring and Ring Grove Wear ........................................................................................................ 93

Piston Ring End Gap Measurement ..................................................................................................... 93

Exhaust System ................................................................................................................................................ 94

55

Silencer Removal .................................................................................................................................. 94

Secondary Removal .............................................................................................................................. 94

Header Pipes Removal ......................................................................................................................... 95

Exhaust Pipe Installation .................................................................................................................................. 95

56

Exploded View

57


1 CYLINDER HEAD, ASSY, MC/D

2 CYLINDER HEAD, MACHINING

CYLINDER HEAD, CASTING

3 VALVE GUIDE, INLET

4 VALVE GUIDE, EXHAUST

5 SEAT, VALVE, INLET

6 SEAT, VALVE, EXHAUST

7 STUD, EXHAUST 12 THREEBOND 1305

26 GRUB SCREW, M12 X 1.75 X 20MM, DIN 913, A2 15 THREEBOND 1305

8 GASKET, CYLINDER HEAD

9 TOWER, ROCKER, LH, MC/D

10 TOWER, ROCKER,RH, MC/D

11 PIN, DOWEL, 6.00 X 12.0, DIN 7, SS

27 WASHER, M8, NORDLOCK

13 BOLT, CAP HD, M8 X 50 X 1.25, DIN 912, 12.9 20 EXHAUST, TB 1305

28 BOLT, CAP HD, M8 X 55 X 1.25, DIN 912, 12.9 20 INLET, TB 1305

12 WASHER, M8, ID 8.4 X OD 15 X 1.6, BZP

14 STUD, HEAD 54 TB 1305

15 BOLT,CAP HD, M10 X 150 X 1.5, DIN 912, 12.9 60

18 BOLT, CAP HD, M8 X 80 X 1.25, DIN 912, 12.9 25

19

BOLT, CAP HD, M8 X 110 X 1.25, DIN 912, 12.9,

BZP 25

20 NUT, DOMED, M10 X 1.5, DIN 1594, A2 60

CMD EXTREME PRESSURE LUB #3, 4oz APPLY TO STUD FIXINGS AS REQUIRED

16 WASHER, M10, 10.5 X 21.0 X 2, DIN 125A, A2

21 SPACER, EXHAUST SPRING

22 SPACER, INLET SPRING

23 BREATHER FITTING, ASSY, CYLINDER HEAD

BREATHER FITTING, BODY

BREATHER FITTING, BARB

25 SEAL, M10, BONDED VITON INSIDE ENGINE BETWEEN HEAD AND WASHER

24 LOCKNUT, M10 X 1.5, GRADE 8 20

29 WASHER, 10.5 X 21.0 X 1.2, FORM B, A2 INSIDE ENGINE ON TOP OF SEAL

WASHER

16 WASHER, M10, 10.5 X 21.0 X 2, DIN 125A, A2 ON THE OUT SIDE OF THE ENGINE

59


TORQUE (NM) REMARKS

25 COVER ASSY, ROCKER

1 COVER, ROCKER, MACH

2 GASKET, ROCKER, COVER

3 BOLT, CAP HD, M6 X 20 x 1.0, DIN 912, SS 12

5 BANJO,M14, 9MM SPIGOT

6 WASHER, M14, OD 20.0MM X 2.5 ALUMINIUM

7 WASHER, M14, OD 20.4MM X 1.22, COPPER

8 BOLT, BANJO, M14 22

22 NUT, M14 X 1.5, THIN, STEEL

23 BOLT, BANJO, M14, MOD 22

24 BREATHER BAFFLE, ASSY

BREATHER BAFFLE, FRONT

BREATHER BAFFLE, REAR

BREATHER BAFFLE, WELD NUT

9 COVER, RH, MC/D

10 GASKET, COVER, RH

11 DOWEL, RING, 7.8MM DIA

26 COVER ASSY, OIL FILTER

12 COVER, OIL FILTER, MC/D

27 TOP HAT, OIL FILTER, COVER

28 BELLEVILLE, SPRING

29 O-RING, 14MM X 2MM, VITON

30 RING, WIRE, 18MM, PLAIN, EXTERNAL

13 O-RING, 67MM X 2 MM, VITON

14 BOLT, CAP HD, M5x0.8x14, DIN 912, A2/70 5


16 COVER, CLUTCH, MC/D

17 GASKET, COVER, CLUTCH


18 BOLT, CAP HD, M6 X 40, DIN 912, SS 12

19 BOLT, CAP HD, M6 X 30 X 1.0, SS 12

31 LABEL, SILKOLENE, 10W/40 LABEL FOR ENGINE OIL

60


1 PISTON ASSY, LH

ORIENTATE DIMPLE INBOARD

3 PISTON, MC/D, LH

5 1ST RING, PISTON, 88.0 X 1.0 STEEL NITRIDE

6 2ND RING, PISTON, 88.0 X 1.2 PHOSPHATE

7 OIL RING, PISTON 88.0 X 2.8 STEEL NITRIDE

8 GUDGEON PIN

9 CIRCLIP, DIA 22 X 1.5 SECTION

2 PISTON ASSY, RH

ORIENTATE DIMPLE INBOARD

4 PISTON, MC/D, RH

5 1ST RING, PISTON, 88.0 X 1.0 STEEL NITRIDE

6 2ND RING, PISTON, 88.0 X 1.2 PHOSPHATE

7 OIL RING, PISTON 88.0 X 2.8 STEEL NITRIDE

8 GUDGEON PIN



62


3 LIFTER, PUSHROD

2 PUSHROD, EXHAUST

1 PUSHROD, INLET

4 ROCKER, EXHAUST, LH ASSY

5 ROCKER, EXHAUST, LH MC/D

6 BEARING, BUSH, ROCKER

7 PIN, ROLLER

8 ADJUSTER, ROCKER

9 NUT, 3/8-24 UNF

20 BEARING, BUSH, ROCKER ARM

10 ROCKER, EXHAUST, RH, ASSY

11 ROCKER, EXHAUST, RH, MC/D


7 PIN, ROLLER

8 ADJUSTER, ROCKER

9 NUT, 3/8-24 UNF


12 ROCKER, INLET, LH, ASSY

13 ROCKER, INLET, LH, MC/D

7 PIN, ROLLER


8 ADJUSTER, ROCKER

9 NUT, 3/8-24 UNF


14 ROCKER, INLET, RH, ASSY

15 ROCKER, INLET, RH, MC/D

8 ADJUSTER, ROCKER


7 PIN, ROLLER

9 NUT, 3/8-24 UNF


16 ROCKER SHAFT, EXHAUST THREEBOND 1327

19 BOLT, CAP HD, M8 X 35 X 1.25, DIN 912,12.9 25

17 ROCKER, SHAFT, INLET THREEBOND 1327

18 BOLT, CAP HD, M8 X 30 X 1.25, DIN 912,12.9 25

21 WASHER, THRUST, THRUST 5/8"x1 1/8"x1.6mm

22 SEAT, SPRING, EXHAUST

23 SPRING, VALVE, EXHAUST

24 VALVE, EXHAUST DIA 37.0MM

25 SEAT,SPRING, INLET

26 SPRING, VALVE, INLET

27 VALVE, INLET, DIA 44.5MM

28 SEAL, OIL, VALVE STEM

63

29 RETAINER, SPRING

30 COLLET, VALVE

31 CAP, LASH

64

REF. NO.

PART DESCRIPTION TORQUE (NM)

REMARKS

1 BARREL ASSY, MC/D

2 BARREL, MACHINING

BARREL, CASTING

3 LINER, CYLINDER

5 SLEEVE, LIFTER, RH

4 SLEEVE, LIFTER, LH

8 WASHER, 6.4x10.0x2.0, COPPER

9 BOLT, M5 X 40 X 0.8, 5.6MM DIA, SHOULDERED, SS 6

10 WASHER, M8 X 8.2 ID, 12.0 OD, X 1.0, COPPER

11 BOLT, CAP HD, M8 X 12 X 1.25, DIN 912, A2/70 22

6 GASKET, BARREL


12 BOLT, HEX HD, FLANGED, M8 X 25, DIN 6921, 10.9, BZP 25

66


1 BEARING, DEEP GROOVE, 20 X 47 X 14

USED BETWEEN CAM SHAFT AND LH

CRANKCASE

2 BEARING, DEEP GROOVE, 20 X 52 X 15 USED ON DRIVE SIDE OF CAMSHAFT

3 PLATE, RETAINING, CAMSHAFT USED ON DRIVE SIDE, MOUNTED TO CASE

4 BOLT, HEX HD, M6 X 12, DIN 933, 8.8, BZP 12 THREEBOND 1327

6 CAMSHAFT, M/C

8 SPACER, CAMSHAFT

9 SPROCKET, CAMSHAFT, 30T

10 SPROCKET, CAMSHAFT, 15T

11 WOODRUFF KEY, 3/8" X 1/8"

12 WASHER, M14, DIN 433, 15X24X2.5 ONE ON CRANK, ONE ON CAM

13 NUT, M14 X 1.5, DIN 934, GRADE 8 54 THREEBOND 1327

14 CHAIN, CAM, 54 LINK

15 TENSIONER, CAM CHAIN, ADJUSTABLE

16 WASHER, M8 X 17 X 1.6, DIN 125A

17 BOLT, CAP HD, M8 X 16 X 1.25, DIN 912, 12.9 25 THREEBOND 1327

18 TENSIONER , CAM CHAIN, FIXED

19 WASHER, M6, 6.4 X 12 X 1.6, DIN 125A

20 BOLT, CAP HD, M6 X 16 X 1.0, DIN 912, 12.9 12 Threebond 1327

68


TORQUE (NM) REMARKS

31 EXHAUST SYSTEM KIT, ROW

31 SECONDARY, STAINLESS

8 CLAMPS, EXHAUST 10 USED TO CLAMP EXHAUST

SECTIONS

1 HEADER, RH, CHROME, EURO

2 HEADER, LH, CHROME, EURO

6 SILENCER, RH

5 SILENCER, LH



31 EXHAUST, IVA COMPLIANT MOTAD

8 EXHAUST CLAMPS

10 USED TO CLAMP EXHAUST SECTIONS

1 HEADER, R/H, CHROME

2 HEADER, L/H, CHROME

3 SECONDARY, STAINLESS, IVA

6 SILENCER, R/H

5 SILENCER, LH

69

31 EXHAUST SYSTEM KIT, EURO

8 CLAMPS, EXHAUST 10 USED TO CLAMP EXHAUST

SECTIONS

1 HEADER, RH, CHROME, EURO

2 HEADER, LH, CHROME, EURO

3 SECONDARY, STAINLESS, EURO

6 SILENCER, RH

5 SILENCER, LH














18 AIRBOX MOULDING AS RECEIVED FROM ACERBIS

21 FITTING, AIRBOX, TURNED, M12, 8MM 1 ONLY FOR IVA BIKES

22 FITTING, AIRBOX, TURNED, M6, 3MM

27 BOLT, CAP HD, M6 X 12 X 1.0 TO CLAMP AIRBOX TO FRAME

28 WASHER, PENNY, M6, 6.4 X 18 X 1.6 USED WITH AIRBOX BOLT TO CLAMP EARTH

STRAP

29 WASHER, SERRATED, M6 USED WITH AIRBOX BOLT TO CLAMP EARTH

STRAP

24 CLAMP, AIRBOX, MOULDED ACERBIS 'TOILET SEAT'

25 FILTER, AIR

26 BOLT, BUTTON HD, M5x12 4 TO AIR FILTER CLAMP

23 TRANSITION PIECE

30 UNI-CLIP, TRANSITION PIECE TO CLAMP THROTTLE BODIES

19 SPREADER PLATE, TRANSITION PIECE

20 BOLT, CAP HD, M6 X 20 8 TO CLAMP TRANSITION PIECE

9 EXHAUST BUSH SILENCER TO FRAME

10 EXHAUST BUSH COMPRESSION LIMITER SILENCER TO FRAME

11 WASHER, M8, 8.4 X 16 X 1.6 M8 WASHER 2 PER SIDE

12 BOLT CAP HD, M8 X 50 X 1.25 TO BOLT SILENCER TO FRAME

13 LOCKNUT, FLANGED, M8 X 1.25 TO BOLT SILENCER TO FRAME

14 CENTRAL MOUNT BUSH CENTRAL MOUNT

70

15 CENTRAL MOUNT BUSH COMPRESSION LIMITER

16 BOLT CAP HD, M10 X 50 X 1.5 CENTRAL MOUNT BOLT

17 LOCKNUT, M10 X 1.5 CENTRAL MOUNT NUT

30 GASKET, HEADER

4 LOCKNUT, FLANGED, M8 X 1.25 19 TO HEAD

7 LAMBDA SENSOR, EXHAUST, M10 X

1.25 25 2 REQUIRED FOR HOMOLOGATION

18 AIRBOX, GALACTIC BLACK, GOLD TEXT, SPORT

18 AIRBOX, ROYAL RED, GOLD TEXT, SPORT

18 AIRBOX, CANARY YELLOW, BLACK TEXT, SPORT

18 AIRBOX, FACTORY SPECIAL SILVER, BLACK TEXT/BORDER RED PIN STRIPE, SPORT

18 AIRBOX, GALACTIC BLACK, SILVER TEXT, SPORT

18 AIRBOX, GALACTIC BLACK, GOLD TEXT, CAFE RACER

18 AIRBOX, ROYAL RED, GOLD TEXT, CAFE RACER

18 AIRBOX, CANARY YELLOW, BLACK TEXT, CAFE RACER

18 AIRBOX, FACTORY SPECIAL SILVER, BLACK TEXT/BORDER RED PIN, STRIPE, CAFE RACER

18 AIRBOX, GALACTIC BLACK, SILVER TEXT, CAFE RACER

18 AIRBOX, GALACTIC BLACK, GOLD TEXT, SE

18 AIRBOX, FACTORY SPECIAL SILVER, BLACK TEXT, CAFE RACER

18 AIRBOX, FACTORY SPECIAL SILVER, BLACK TEXT, SPORT

18 AIRBOX, GALACTIC BLACK, YELLOW TEXT, SPORT

18 AIRBOX, GALACTIC BLACK, YELLOW TEXT, CAFE RACER

71

Specifications

Top End Specification

Item Standard (mm) Service Limit

Camshaft: Cam height:

Exhaust 31.112 ± 0.03 30.982 Inlet 32.1788 ± 0.03 32.049

Camshaft journal diameter 19.993-19.980 / 20.000-19.987 19.951 / 19.958

Camshaft bearing ID diameter 20.00-19.990 20.059 Camshaft runout Ra 0.02 max Ra 0.1 Camshaft chain 54-link length 216 ± 0.3 218 Cylinder head: Cylinder Compression (120-170 psi) - - -

Cylinder head warp - - - 0.05mm Valves: Valve clearance: Exhaust

go back one full turn from zero on adjuster - - -

Inlet go back one full turn from zero on

adjuster - - - Valve head thickness:

Exhaust 1.27 ± 0.1 1.0 Inlet 1.27 ± 0.1 0.8

Valve stem bend Ra 0.02 Ra 0.05 Valve stem Diameter: Exhaust 6.98-6.96 7.01

Inlet 6.98-6.96 7.01 Valve Guide inside Diameter:

Exhaust 7.024-7.032 7.097 Inlet 7.004-7.012 7.077

Valve/valve guide clearance: (wobble method):

Exhaust 0.06~0.15 0.34 Inlet 0.09~0.18 0.34

Valve seat cutting angle inlet Initial 45˚ then 35˚ (VAI-A19038) then relief 75˚ (VSI-A13600) - - -

Valve seat cutting angle Initial 45˚ then 29˚ (VSI-A18658) then relief 55˚ (VSI-A13600) - - -

72

Valve seat cutting angle inlet: Initial 45˚ then 35˚ (VAI-A19038) then relief 75˚ (VSI-A13600)

Valve seat cutting angle exhaust: Initial 45˚ then 29˚ (VSI-A18658) then relief 55˚ (VSI-A13600)

Top End Specification

Item Standard (mm) Service Limit

Valve seat surface: Width: Exhaust 1.5 - - -

Inlet 1.5 - - - Outside: Exhaust 35.5 - - -

Inlet 43 - - - Valve spring free length:

Exhaust 44.4 42.5 Inlet 52.15 49.85

Cylinder, Piston: Cylinder inside diameter: 87.995-88.005 88.050 Piston diameter: 87.900-87.925 87.750 Piston/cylinder clearance: 0.105-0.070 - - - Piston ring/groove clearance:

Top 0.020-0.050 0.150

Second 0.020-0.060 0.160 Piston ring groove width:

Top 1.020-1.010 1.100 Second 1.230-1.210 1.310

Piston ring thickness: top 0.990-0.970 0.900

Second 1.190-1.170 1.270 Piston ring end gap:

Top 0.15-0.35 0.65 Second 0.35-0.55 0.85

Oil 0.20-0.70 1.0

73

Cylinder Head Cover

Cylinder Head Cover Removal

Remove:

Fuel Tank (see Fuel System chapter)

Spark Plug Cap [A]

Breather Hose [B]

Battery and Battery tray (see Electrical chapter)

Remove Cylinder Head Cover Bolts [A]

Slide the cover [B] up and out the right hand side)

Cylinder Head Cover Installation

Replace the rocker cover gasket with a new one if it is

damaged.

Torque – Cylinder head cover bolts: 12Nm

B

A

A B

74

Cylinder Head Cover Assembly

Install baffle plate.

Install banjo bolt (short) and assembly as

detailed:

Torque – Banjo Baffle bolt: 22Nm

Install long banjo bolt, banjo and thin nut as

detailed:

Torque – Banjo bolt Breather: 22Nm

Camshaft Chain Tensioner

75

Camshaft Chain Tensioner Removal

Remove oil filter (see Engine Lubrication System chapter).

Remove cam chain cover bolts.

Remove cam chain cover taking note of the location of dowels.

Set Crank to TDC and take note of woodruff key position on

cam shaft.

Remove two M8 cam chain Tensioner bolts.

Remove chain Tensioner.

Cam Tensioner Installation

Align cam and crank woodruff keys, with crank set at TDC.

Finger tighten tensioner bolts.

Apply 200N of load to the tensioner, use a T-bar to apply

load if necessary.

Torque up bolts.

Torque Bolts - 25Nm Threebond 1327

76

Camshaft Chain

Camshaft Chain Removal

Remove

o Cam Chain Cover (see this chapter)

o Cam Chain Tensioner (see this chapter)

Put Crank at TDC, mark position of Cam and Crank with

marker.

Remove Cam and Crank Sprocket nuts.

Remove cam chain tensioner.

Remove Chain with sprockets.

Camshaft Chain Installation

Align crank and cam at TDC markings.

Engage the camshaft chain with the camshaft sprockets

aligned as shown.

Pull the tension side of the chain to install the chain.

Install


o Cam and crank drive nuts (see this chapter)


77

Camshaft

Camshaft Removal

Remove



Put Crank at TDC, mark position of Cam and Crank with

marker.

Cam Chain (see this chapter)

Remove Cam and Crank Drive sprockets

with the Cam Chain taking note of the order

of washer and sprocket assembly.

Remove bearing retainer.

Put cam sprocket drive and nut back on

Camshaft finger tight, remove the Camshaft

taking note of bearing order (a puller may

be required).

Caution: The crankshaft may be turned, while the

camshaft is removed. Always pull the chain taut

while turning the crankshaft. This avoids kinking the

chain. A kinked chain could damage both the chain

and the sprocket.

Camshaft Installation

Apply engine oil to all cam parts. If the

camshaft and/or cylinder head are replaced

with new ones, apply a thin coat of

molybdenum disulfide grease to the new

cam surfaces.

Apply oil to the Camshaft bearings in the

Crankcase.

78

Build up Camshaft with new bearings if required.

Insert the cam shaft ensuring all bearings are home.

Install bearing retainer.

Torque – 12Nm Threebond 1327

Install

o Cam Chain (see this chapter)

o Cam Chain Tensioner (see this

chapter)

o Cam Chain cover (see this chapter)

Caution: After this procedure, if any resistance is felt

while turning over the crankshaft, stop immediately

and check the camshaft chain timing. Valves will be

bent if the timing is not properly set.

Camshaft Disassembly

Remove camshaft.

Remove bearings in order shown.

Camshaft Assembly

Install bearings in order shown.

Camshaft Bearing Wear-

Cam shaft bearing clearance 6204 (-0.003 to +

0.02) - Service limit 0.10 mm

79

Cam shaft bearing clearance 6304 (-0.01 to + 0.013) - Service limit 0.10 mm

If any clearance exceeds the service limit, measure the diameter of the camshaft with a

micrometer.

Camshaft Diameter-

6204 bearing surface (19.993 to 19.980) - Service limit 19.950

6304 bearing surface (20.000 to 19.987) - Service limit 19.957

I the camshaft bearing surfaces are less than the service limit replace the camshaft with a new one

and measure the clearance again.

If there is excessive free play in the bearing or any visible damage replace the bearing.

Cylinder Head

Cylinder Compression Measurement

Note: Use a Battery which is fully charged.

Warm up the engine thoroughly.

Remove both spark plugs (see Fuel System chapter).

Attach the compression gauge [A] and insert into spark

plug No.1.

Using the starter motor, turn the engine over with the throttle fully open until the compression

limiter gauge stops rising; the compression is the highest value obtainable.

Cylinder Compression (Usable Range 120~170 psi)

Install the spark plug

Torque – Spark Plug: 12Nm (first use torque only)

Problem Diagnosis Remedy (Action)

Cylinder compression is higher than usable range

Carbon accumulation on piston and in combustion chamber possibly due to damaged valve stem oil seal and/or damaged piston oil rings (This may be indicated by white exhaust smoke).

Remove the carbon deposits and replace damages parts if necessary.

Incorrect cylinder head gasket thickness. Replace the gasket with standard part.

Cylinder compression is lower than usable range

Gas leaking around cylinder head. Replace damaged gasket and check cylinder head warp.

Bad condition of valve seating. Repair if necessary.

A

80

Incorrect valve clearance. Adjust the valve clearance.

Incorrect piston/cylinder clearance. Replace the piston and/or cylinder.

Piston seizure. Inspect the cylinder (and liner) and replace/repair the cylinder and/or piston as necessary.

Bad condition of piston ring and/or piston ring grooves.

Replace the piston and/or the piston rings.

Compression release weights do not move smoothly.

Replace the camshaft assembly.

Cylinder Head Removal

Remove:

o Fuel Tank (see Fuel System chapter)

o Battery (see Electrical System chapter)

o Battery Trey (see Electrical System chapter)

Move air box back

Remove

o Throttle body (see Fuel System chapter)

o Exhaust Pipes (see this chapter)

o Breather Hoses

o Rocker Cover (see this chapter)

o HT Leads

o Temp Sensor Connector

Slacken off tappet adjuster lock nut [A]

and adjusters [B].

Remove rocker bolts [C].

Remove rockers [D] and pushrods [E]. C B

81

Slacken inner head bolts by ¼ of a turn from fifteen

back to seven. Remove fifteen, fourteen and

thirteen. Remove from six back to one.

A

D E

82

Tap lightly upwards on the cylinder head with a mallet [A]

to separate from cylinder.

Lift off head [B] towards the left side.

Remove the cylinder head.

Cylinder Head Installation

Install the cylinder (see Cylinder

Installation).

See that two dowel pins [A] are in

place on the cylinder.

Install the cylinder head gasket.

Install the cylinder head.

B

A

A

83

Torque One to Six to 28Nm. Torque Seven to Twelve to 45Nm, then

torque thirteen to fifteen to 28Nm

Install pushrods and rockers

Install rocker bolts.

Torque - Rocker Bolts: 28Nm

Adjusters tappet (see this chapter)

Install

o Temp Sensor Connector

o HT Leads

o Rocker Cover (see this chapter)

o Breather Hoses

o Exhaust Pipes (see this chapter)

o Throttle body (see Fuel System

o Air Box

Cylinder Head Assembly

Install:

o Rocker Tower Dowels

o Rocker Towers

o Washer

Tighten bolts.

84

Torque- Rocker Tower Bolts: 20Nm

Cylinder Head Disassembly

Remove the cylinder head (see this chapter)

Remove the Valve (see this chapter)

Remove the rocker tower bolts, remove the rocker towers.

Cylinder Head Cleaning

Remove the cylinder head (see Cylinder Head Removal).

Remove Valves (see Valve Removal).

Wash the head with a high-flash point solvent.

Scrape the carbon out of the combustion chamber and

exhaust port with a suitable tool.

Using compressed air, blow out [A] any particles which

may obstruct oil/air passage in the cylinder head.

A

85

Install the valves.

Cylinder Head Warp

Clean the cylinder head (see Cylinder Head Cleaning)

Lay a straightedge across the lower surface of the cylinder

head at the positions shown.

Use a thickness gauge [A] to measure the space between

the straightedge [B] and the head.

Cylinder Head Warp:

Standard: - - -

Service limit: 0.05mm

If the cylinder head is warped more than the service limit, replace it.

If the cylinder head is warped less than the service limit, repair the head by rubbing the lower

surfaces on emery paper secured to a surface plate (first No. 200, then No. 400).

Valves

Valve Clearance Measurement

Note: Check the Valve clearance when the engine is cold (at room

temperature).

Remove Cylinder Head Cover (see Cylinder Head Cover

Removal).

Remove Cam Chain Cover (see Cam Chain Cover Removal).

Remove the Spark Plugs.

Turn the crankshaft clockwise with a wrench on the crank

shaft cam drive sprocket nut or primary gear nut and

B A

A

B

86

watch the intake valve on No.1 Cylinder until the valve closes fully.

Measure the clearance between the lash cap [A] and the rocker arm roller [B] with the thickness

gauge [C].

If any valve clearance is measured, adjust (see Valve Clearance Adjustment).

Valve Clearance Adjustment

Turn the crankshaft clockwise with a wrench on the crank

shaft cam drive sprocket nut until No.1 is at TDC.

Undo the lock-nut on the adjusters and back the adjusters

off until any clearance can be measured.

Tighten the adjusters until no clearance can be measured

then tighten a further one full turn.

Repeat the process on cylinder No.2, First setting Cylinder

No.2 to TDC

Valve Clearance Adjustment – One full turn from fully off

Valve Removal

Remove the cylinder head (see Cylinder Head Removal).

Mark and record the valve location so it can be installed in

the original position.

Remove the valve tappets making a note of their location

Using a valve spring compressor assembly, remove the valve

by compressing the valve spring and using a magnetic rod to

remove the collets.

Valve Installation

If a new valve is to be used, check-valve-to guide clearance (see this chapter).

If there is too little clearance, ream the valve guide.

If there is too much clearance, install a new cylinder head.

Check the valve seat (see Valve Seat Inspection).

Apply a thin coat of molybdenum disulfide grease to the valve stem.

Install each spring so that the larger end is at the bottom (closer to the valve head).

Valve Guide Reamer Exhaust – Ø 7.024 to7.032 (nominal 7.028)

Valve Guide Reamer Inlet - Ø 7.004 to 7.012 (nominal 7.008)

C

87

Valve-to-Guide Clearance Measurement

If a small bore gauge is not available, inspect the valve guide

wear be measuring the valve to guide clearance with the wobble

method as indicated below.

Insert the new valve [A] into the guide [B] and set a dial

gauge against the stem perpendicular to it as close as

possible to the cylinder head mating surface.

Move [C] the stem back and forth to measure valve/valve

guide clearance.

Repeat the measurement in a direction at a right angle to the first.

If the reading exceeds the service limit, replace the guide.

The reading is not actual valve/Valve guide clearance because the measuring point is above the

guide.

Valve /Valve Guide Clearance (wobble Method)

Exhaust: 0.06~0.15 (standard), 0.34 (Service limit).

Inlet: 0.09~0.18 (standard), 0.34 (Service limit).

Valve Seat Inspection

Remove the valve (see Valve Removal).

Check the valve seat width [A].

Measure the seat width of the portion where there is no

build up of carbon of the valve seat with vernier calipers.

Valve seating surface Width

Width: Exhaust: 1.5mm

Inlet: 1.5mm

If the seat width is not within the specified range, repair the valve seat.

Measure the outside diameter [B] of the seating pattern on the valve seat.

If the outside diameter of the valve seating pattern is too large or too small, repair the valve seat.

Valve seating surface outside diameter

Exhaust: 35.5mm

Inlet: 43mm

Valve Seat Repair (Valve Lapping)

Using the valve seat cutters, repair the valve seat.

Valve seat cutters:

A

B

C

A B

88

Valve seat cutting angle inlet: Initial 45˚ then 35˚ (VAI-A19038) then relief 75˚ (VSI-A13600)

Valve seat cutting angle exhaust: Initial 45˚ then 29˚ (VSI-A18658) then relief 55˚ (VSI-A13600)

If the manufacturer’s instructions are not available, use the following procedure.

Seat Cutter Operating Care:

This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be

used for other purpose than seat repair.

Do not drop or shock the valve seat cutter, or the diamond particles may fall off.

Do not fail to apply engine oil to apply engine oil to the valve seat cutter before grinding the seat

surface. Also wash off the ground particles sticking to the cutter with washing oil.

Caution: Do not use a wire brush to remove the metal particles from the cutter. It will take off the diamond

particles.

Setting the valve seat cutter holder in position, operate the cutter in one hand. Do not apply too

much force to the diamond portion.

Note: Prior to grinding, apply engine oil to the cutter and during the operation, wash off any ground

particles sticking to the cutter with washing oil.

After use, wash it with washing oil and apply thin layer of engine oil before storing.

Operating Procedures:

Clean the seat area carefully.

Coat the seat with machinist’s dye.

Fit a 45˚ cutter into the holder and slide it into the valve guide.

Press down lightly on the handle and turn it right and left. Grind the seating surface only until it is

smooth.

Caution: Do not grind the seat too much. Over grinding will reduce valve clearance by sinking the valve into

the head. If the valve sinks too far into the head, it will be impossible to adjust the clearance, and the

cylinder head must be replaced.

Measure the outside diameter of the seating surface with a vernier caliper.

If the outside diameter of the surface is too small, repeat the 45˚ grinding until the diameter is

within the specified range.

If the outside diameter of the seating surface is too large, make the 35˚ (inlet)/29˚ (exhaust)

grinding described below.

If the outside diameter of the seating surface is within the specified range, measure the seat width

as described below.

Grind the seat at a 35˚ (inlet)/29˚ (exhaust) angle until the seat O.D. is within the specified range.

89

To make the 35˚ (inlet)/29˚ (exhaust) grind fit a 35˚ (inlet)/29˚ (exhaust) cutter into the holder, and

slide it into the valve guide.

Turn the holder one turn at a time while pressing down very lightly. Check the seat after each turn.

Caution: The 35˚ (inlet)/29˚ (exhaust) cutter removes material very quickly. Check the seat outside

diameter frequently to prevent over grinding.

After making the 35˚ (inlet)/29˚ (exhaust) grind, return to the seat O.D. measurement step above.

To measure the seat width, use a vernier caliper to measure the width of the 45˚ angle portion of

the seat at several places around the seat.

If the seat width is too narrow, repeat the 45˚ grind until the seat is slightly too wide, and then

return to the seat O.D. measurement step above.

If the seat width is within the specified range, lap the valve to seat as described below.

Grind the seat at a 75˚ (inlet)/55˚ (exhaust) angle until the seat width is within the specified range.

To make the 75˚ (inlet)/55˚ (exhaust) grind, fit 75˚ (inlet)/55˚ (exhaust) cutter into the holder, and

slide it into the valve guide.

Turn the holder, while pressing down lightly.

After making the 75˚ (inlet)/55˚ (exhaust) grind, return to the seat measurement step above.

Lap the valve to the seat, using a lapper once the seat width and O.D. are within the ranges

specified above.

Put a little coarse grinding compound on the face of the valve in a number of places around the

valve head.

Spin the valve against the seat until the grinding compound produces a smooth, matched surface

on both the seat and the valve.

Repeat the process with a fine grinding compound.

The seating area should be marked about in the middle of the valve face.

If the seat is not in the right place on the valve, check to be sure the valve is the correct part. If the

valve is correct, the valve may have been refaced too much; replace the valve.

Be sure to remove all grinding compound before assembly.

When the engine is assembled, be sure to adjust the valve clearance (see Valve Clearance

Adjustment).

START

start

Machinist’s dye on seat

45˚ Grind

Tool: 45˚ Cutter

Purpose: Make seating area

smooth and round

Measure seating area O.D.

Tool: Vernier Caliper

Purpose: check seat O.D. against

spec.

90

Cylinder, Piston

Cylinder, Piston Removal

Remove:

o Cylinder Head (see Cylinder Head Removal).

Slacken off cylinder bolts by a quarter of a turn back from twenty to sixteen.

Remove cylinder bolts back from twenty to sixteen.

Results

OK Too big Too small

45˚ Grind

Tool: 45˚ Cutter

Purpose: increase O.D. of seat

area to spec.

Machinist’s dye on seat

35˚ (inlet)/29˚ (exhaust)

Tool: 35˚/29˚ Cutter

Purpose: Reduce O.D. of seat

area to spec.

Measure Seat Width

Tool: Vernier Caliper

Purpose: check seat width

against spec.

Results

OK Too wide Too narrow

Machinist’s dye on seat 45˚ Grind

Tool: 45˚ Cutter

Purpose: increase width of seat area

beyond spec. to increase O.D.

75˚ (inlet)/55˚ (exhaust) Grind

Tool: 75˚ or 55˚ Cutter

Purpose: reduce seat width to spec

Lap Valve

Tool: Valve lapper, grinding compound

Purpose: Perfectly match valve and seat area;

check valve head for damage FINISH

start

91

Tap lightly up the cylinder head with a plastic mallet to separate from crankcase.

When the cylinder is lose, remove in one clean swift movement upwards.

If the cylinder becomes jammed it will be because the lifters have dropped down as the cylinder has

been pulled up. Settle the cylinder back down, and then remove in one clean swift movement

upwards.

Remove the cylinder base gasket.

Immediately insert a clean cloth around the piston to

prevent parts or dirt from falling into the case.

Remove the snap ring from one side of each piston pin

hole.

Caution: Do not reuse snap rings as removal weakens and

deforms them. They could fall out and score the cylinder

wall.

Push out the piston pin and remove the piston.

92

Carefully spread the ring opening with your thumbs and then push up on the opposite side of the

piston ring to remove it.

Remove the three – piece oil ring with your thumbs in the same manner.

Cylinder, Piston Installation

Note: The oil ring rails have no “top” or “bottom”

Install the oil ring expander in the bottom piston ring

groove so the ends butt together.

Install the oil ring steel rails, one above the expander

and one below it.

Spread the rail with your thumbs, but only enough to fit

the rail over the piston.

Release the rail into the bottom piston ring groove.

With the marked side facing up, install the second ring [A] and top ring [B] in that order.

Note: If a new piston is used, check piston to cylinder clearance (see Piston/Cylinder Clearance), and use

new piston rings.

The right hand piston has an R marked on the

underside and the left hand has an L marked on the

underside. The dots [A] should always be on the inside

on top of the cylinder.

Measure the piston diameter at the point shown with a

micrometer.

Piston Diameter:

Standard: 87.900 to 87.925

Service Limit: 87.750

If the piston diameter is less than the service limit,

replace it.

Install the pistons onto the con-rods using new snap

rings.

Install a new base gasket.

Set the crank so that piston No. 1 is at TDC.

Note: Ensure ring gaps at 180 degrees apart.

Slide the barrels over the barrel bolts.

B

A

A

93

Simultaneously lower the barrel whilst sliding the pistons into the barrel, use a front to back rocking

motion whilst holding the rings in with your thumb and four fingers to slide the pistons rings into

the barrel.

Tighten the cylinder bolts by hand.

Install the cylinder head (see this chapter).

Tighten head and barrel bolts in sequence from one to twenty to torques detailed below.

Torque: Barrel bolts – 25Nm

Torque: Head Bots – 25Nm / 54Nm

Note: Whenever the piston or cylinder has been replaced with a new one or honed, the motorcycle must

be broken in the same as with a new machine.

94

Piston/Cylinder Clearance

Subtract the piston diameter from the cylinder inside diameter to get the piston/cylinder clearance.

Piston/Cylinder Clearance

Standard: 0.105 to 0.070

If the piston/cylinder clearance is less than the specified range, use a smaller piston or increase the

cylinder inside diameter by honing.

If the piston/cylinder clearance is greater than the specified range, use a larger piston or bore the

cylinder to the next larger oversize.

If only a piston is replaced, the clearance may exceed the standard slightly. But it must not be less

than the minimum in order to avoid piston seizure.

Cylinder Boring and Honing

Before boring a cylinder, first measure the exact diameter of the oversize piston, and then,

according to the standard clearance in the Specifications, determine the re-bore diameter.

However, if the amount or boring necessary would make the inside diameter greater than 1.0mm,

the block must be replaced.

Cylinder inside diameter must not vary more than 0.01mm at any point.

In the case of a re-bored cylinder and oversize pistons, the service limit for the cylinder is the

diameter that the cylinder was bored to plus 0.1mm and the service limit for the piston is oversize

piston original diameter minus 0.15mm. If the exact figure for the rebored diameter is unknown, it

can be roughly determined by measuring the diameter at the base of the cylinder.

Piston Ring and Ring Groove Wear

Check for uneven groove wear by inspecting the ring

seating.

The rings should fit perfectly parallel to groove

surfaces. If not, the piston must be replaced.

With the piston rings [A] in their grooves, make

several measurements with a thickness gauge

to determine piston ring/groove clearance.

Piston Ring/Groove Clearance

Standard Service Limit

Top: 0.020-0.050 0.150

Second: 0.020-0.060 0.160

Piston Ring End Gap Measurement

Place the piston ring inside the cylinder, using

the piston to locate the ring squarely in place.

A

B

95

Set it close to the top of the cylinder, where cylinder wear is low.

Measure the gap [B] between the ends of the ring with a thickness gauge.

Piston Ring End Gap

Standard Service Limit

Top 0.15-0.35 0.65

Second 0.35-0.55 0.85

Oil 0.20-0.70 1.0

Exhaust System

Silencer Removal

Loosen:

o Silencer Clamp Bolts [A]

Remove:

o Silencer allen bolts [B]

Move the Silencer backwards and twist outwards to

separate from the middle section.

Remove the Silencer.

Secondary Removal

Loosen:

o Secondary cramp bolts [A]

Remove:

o Secondary centre allen bolt [B].

Move secondary backwards to separate from downpipes.

Remove secondary.

A

B

B

A

96

Header Pipe Removal

Remove Lambda Sensors.

Remove six flange bolts from head.

Remove Header.

Exhaust Pipe Installation

Replace the exhaust pipe gasket.

Tighten:

Six flange bolts.

Torque – Exhaust Flange Bolts: 19 Nm

Install the secondary.

Install secondary centre bolt.

Torque – Secondary centre bolts: 10Nm

Tighten secondary clamp bolts.

Install the Silencers.

Install allen bolts and tighten.

Torque – Exhaust muffler bolts: 10 Nm

Tighten Silencer clamps.

Thoroughly warm up the engine, wait until the engine cools down, and then retighten the clamp

bolts and flange nuts.

Gasket behind header

97

Clutch

Exploded View .................................................................................................................................................. 99

Specification ................................................................................................................................................... 104

Clutch Lever and Hose ................................................................................................................................... 105

Clutch Lever Adjustment .................................................................................................................... 105

Clutch Fluid .................................................................................................................................................... 105

Clutch Fluid Recommendation ........................................................................................................... 105

Clutch Fluid Level Inspection ............................................................................................................. 106

Clutch Fluid Changing......................................................................................................................... 106

Clutch Line Air Bleeding ..................................................................................................................... 107

Clutch Slave Cylinder ...................................................................................................................................... 108

Clutch Slave Cylinder Removal ........................................................................................................... 108

Clutch Slave Cylinder Installation ....................................................................................................... 108

Clutch Slave Cylinder Inspection ........................................................................................................ 108

Clutch Master Cylinder .................................................................................................................................. 108

Clutch Master Cylinder Removal ....................................................................................................... 108

Clutch Master Cylinder Installation ................................................................................................... 109

Clutch Master Cylinder Inspection ..................................................................................................... 109

Clutch Hose .................................................................................................................................................... 109

Clutch Hose Removal ......................................................................................................................... 109

Clutch Hose Installation ..................................................................................................................... 110

Clutch Hose Inspection ...................................................................................................................... 110

Clutch Cover ................................................................................................................................................... 110

Clutch Cover Removal ........................................................................................................................ 110

Clutch Cover Installation .................................................................................................................... 111

Clutch Release Removal ..................................................................................................................... 111

Clutch Release Installation ................................................................................................................. 112

Clutch ............................................................................................................................................................. 112

Clutch Removal .................................................................................................................................. 112

Clutch Installation .............................................................................................................................. 113

Friction and Steel Plate Damage, Wear Inspection ........................................................................... 114

Friction and Steel Plate Warp Inspection .......................................................................................... 114

Clutch spring Free Length Measurement .......................................................................................... 114

Clutch Housing Finger Damage .......................................................................................................... 115

Clutch Hub Spline Damage ................................................................................................................. 115

Primary Gear Removal ................................................................................................................................... 115

Primary Gear Installation ............................................................................................................................... 116

98


1 CLUTCH BASKET, ASSY

7 ACTUATOR, LIFTER, PRESSURE PLATE

8 BEARING, NEEDLE, THRUST, 24.0 OD X 10.0 ID X 1.6

BETWEEN PRESSURE PLATE AND

LIFTER

9 WASHER, 24 OD X 10 ID X 1.0 SITS BEHIND PRESSURE PLATE

2 GEAR, PRIMARY, 87 TOOTH BEHIND CLUTCH BASKET

5 WASHER, 34 OD 21 ID X 3.0MM USED TO CLAMP CLUTCH

6 NUT, HALF, M20 X 1.5, DIN 439, A2 70 122 THREEBOND 1327

3 SPACER, PRIMARY GEAR, BEARING BEHIND CLUTCH BASKET

10 PUSH ROD, CLUTCH

11 PUSH ROD, CLUTCH, DIA 7.00MM SLAVE CYLINDER END

12 BEARING, BALL, 8MM USED IN CENTRE AND END OF

CLUTCH ROD

13 PLATE, CLUTCH, STEEL

14 FRICTION PLATE, CLUTCH

99


1 STARTER, MOTOR

2 GASKET, STARTER, MOTOR

3 RING GEAR, 79 TOOTH

4

BOLT, M5x0.8x16, 6.0 DIA, SHLD, ISO 7979,

12.9 5

USED TO CLAMP STARTER RING

5

BOLT, CAP HD, 3/8-24UNF X 1, BZP, 1936

SERIES 20

TO CLAMP STARTER

MOTOR

7 BOLT, CAP HD, 3/8-24UNF X 3/4, 1936 SERIES

20 TO CLAMP STARTER MOTOR

6

WASHER, M10, 10.5 X 21.0 X 2, DIN 125A,

A2

102


TORQUE (NM) REMARKS

20 BRAKE LEVER ASSY, AXIAL

STANDARD FOR CSE, CCR, ROW COM/CMM

21 LEVER, BRAKE, REMOTE RESERVOIR

22 RESERVOIR, MASTER CYL, FRONT BRAKE RESERVOIR

55 FRONT BRAKE LIGHT SWITCH

79 LEVER ASSY, BRAKE, INTEGRAL RESERVOIR, HIGH BARS

STANDARD LEVER FOR COM-01 AND CDS-01

103

80 LEVER, BRAKE, INTEGRATED RESERVOIR


ACCESSORY FITMENT


81 BOLT, M6 X 25 X 1.0, CP HD, GOLD 8 HALF CLAMP BOLTS

82 HALF CLAMP, FRONT, VERTICAL

REPLACES STD CLAMP FROM BREMBO

78 FLYLEAD, BRAKE LIGHT SWITCH, INTEGRAL RESERVOIR

INTEGRAL RESERVOIR ONLY,

29 SCREW, UPPER, M/CYL RES MOUNT KIT

TO CLAMP BRAKE RESERVOIR TO BRACKET

28 DUMPER, M/CYL RES MOUNT KIT

RUBBER GROMMET FOR MASTER CYLINDER

32 NUT, M/CYL RES MOUNT KIT

NUT USED TO CLAMP RESERVOIR TO BRACKET

69 CLIP, M/CYL RES MOUNT KIT USED WITHIN FRONT AND REAR

31 HOSE, FRONT BRAKE M/CYL RESERVOIR USED FOR FRONT BRAKE ONLY

30 HOSE, FRONT BRAKE M/CYL RESERVOIR, CLIP-ONS

USED FOR FRONT BRAKE CAFE RACER ONLY

24 BRACKET, BRAKE RESERVOIR, XM FRONT BRAKE RESERVOIR BRACKET

23 BRACKET, BRAKE RESERVOIR, CLIP-ONS, XM

FRONT BRAKE RESERVOIR BRACKET, CR

25 BOLT, CAP HD, M6 X 12 X 1.0 6 BRACKET TO MASTER CYLINDER

91 LEVER ASSY CLUTCH

GOLD LEVER ASSY, (REMOTE RESERVOIRS)

92 LEVER, CLUTCH, REMOTE RESERVOIR

93 BRACKET, CLUTCH RESERVOIR, CLIP-ONS, XM

CAFE RACER ONLY BRACKET TO MASTER CYLINDER

94 BRACKET, CLUTCH RESERVOIR, XM BRACKET TO MASTER CYLINDER

25 BOLT, CAP HD, M6 X 12 X 1.0 8

55 RESERVOIR, MASTER CYL, REAR USED FOR CLUTCH RESERVOIR

95 HOSE, CLUTCH M/CYL RESERVOIR HOSE FOR RESERVOIR TO CYLINDER

96 BOLT, CAP HD, M5 X 12 X 0.8 RESERVOIR TO BRACKET

97 LOCKNUT, FLANGED, M5 X 0.8 7 RESERVOIR TO BRACKET

98 HOSE, FRONT CLUTCH M/CYL RESERVOIR, CLIP-ONS

CAFE RACER RESERVOIR HOSE (SHORTER)

99 LEVER ASSY, CLUTCH, INTEGRAL RESERVOIR, HIGH BARS

SPORT AND DUAL SEAT LEVER ASSY (BLACK)

100 LEVER, CLUTCH, INTEGRATED RESERVOIR

99 LEVER ASSY, CLUTCH, INTEGRAL RESERVOIR, HIGH BARS

ACCESSORY FITMENT


101 SLAVE CYLINDER, CLUTCH

102 BOLT, CAP HD, M6 X 16 X 1.0

12 TO CLAMP SLAVE CYLINDER TO SPROCKET COVER

68 HYDRO STOP, REAR M/CYL REAR BRAKE LIGHT SWITCH

59 HYDRAULIC LINE KIT, USD FORKS, HIGH BARS CSE-03 KIT ONLY

27 DOUBLE BANJO BOLT M10 X 1MM X 34.5MM SPARES ONLY

104

26 COPPER WASHER SPARES ONLY

57 45' BANJO SPARES ONLY

60 BRAKE HOSE, LH, 725MM LENGTH SPARES ONLY

61 BRAKE HOSE, RH, 750MM LENGTH SPARES ONLY

62 BANJO BOLT WITH BLEED NIPPLE 10MM X 1MM SPARES ONLY

63 BOLT, BANJO, M10 x 1.0 x 18, CHROME SPARES ONLY

64 HOSE, CLUTCH, 1200MM LENGTH SPARES ONLY



53 HOSE, BRAIDED, BRAKE, REAR, 825MM SPARES ONLY

66 STRAIGHT BANJO SPARES ONLY

67 CLUTCH, ADAPTOR 10MM X 1MM SPARES ONLY

70 HYDRAULIC LINE KIT, CONVENTIONAL FORKS, AXIAL CALIPERS

HYDRAULIC LINE KIT COM-01, CMM-03, CSE-01, CSE-02







65 MODIFIED BANJO, 90', COMPOUND BEND

SPARES ONLY (AXIAL CALIPERS ONLY)







71 HYDRAULIC LINE KIT, USD FORKS, CLIP ONS CCR-01/02 KIT ONLY







62 BANJO BOLT WITH BLEED NIPPLE 10MM X 1MM SPARES ONLY







75 CLIP, BRAKE LINE

USED WITH 6MM HOLE IN MUDGUARD, USD ONLY

76 WIRE GUIDE, BRAKE HOSE

77 BOLT, CAP HD, M6 X 1.0 TO CLAMP WIRE GUIDE TO YOKE

90 WASHER, PENNY, M6, 6.4 X 18 X 1.6 BETWEEN BOLT AND WIRE GUIDE

105

5 CALIPER ASSY, AXIAL, LH GOLD FINISH

14 PISTON SET, CALIPER AXIAL

15 SEAL KIT, CALIPER, AXIAL

16 PAD RETAINER, CALIPER, AXIAL

17 PAD, SPRING, CALIPER, AXIAL

18 PADS, BRAKE, FRONT, AXIAL

19 BLEED SCREW, CALIPER, AXIAL

83 CALIPER ASSY, AXIAL, RH GOLD FINISH







1 DISC, FRONT, 320 MM 320 mm

2 BOLT, BUTTON HD, INT HEX, M8 X 16 25 6 PER SIDE, PATCH LOCKED


3 SPACER, FRONT DISC

13 BOLT, CALIPER, RADIAL 35 TO CLAMP CALIPER TO FORK

12 CALIPER BRACKET, LH

84 CALIPER BRACKET, RH

13 BOLT, CAP HD, M10x20x1.25 35 BRACKET TO FORK

85 BOLT, CAP HD, M10x30x1.25 35 CALIPER TO BRACKET

104 CALIPER ASSY, RADIAL, LH

6 PISTON SET, CALIPER RADIAL

7 SEAL KIT, CALIPER, RADIAL

8 PAD RETAINER, CALIPER, RADIAL

9 PAD, SPRING, CALIPER, RADIAL

10 PAD SET, CALIPER

4 CALIPER ASSY, RADIAL, RH





10 PAD SET, CALIPER

46 M/CYL ASSY, REAR M/CYL FOR ALL MODELS

49 HEEL GUARD, RH, XM

50 BRACKET, BRAKE RESERVOIR, REAR, STEEL, PRESSED, XM

51 BOLT, CAP HD, M6 X 20 10 HEEL GUARD TO HANGER

45 HOSE, REAR M/CYL RESERVOIR BLACK RESERVOIR HOSE

55 RESERVOIR, MASTER CYL, REAR

47 BOLT, CAP HD, M6 x 10 8 TO CLAMP RESERVOIR TO BRACKET

48 ROD ASSY, REAR MASTER CYLINDER REAR BRAKE M/CYL PUSH ROD

90 NUT, M6 X 1.0, PLAIN USED TO LOCK ROD ASSY TO CLEVIS

56 CLEVIS, MASTER CYLINDER USED ON THE END OF ROD ASSY

106

52 CLEVIS PIN, BRAKE PEDAL, SPRING CLAMP

LINK BETWEEN PLATE AND ROD ASSY

86 P-CLIP, 8MM

SUPPORT FOR BRAKE LINE TO SWING ARM

87 BOLT, CAP HD, M5 X 15 X 0.8 7 CLAMP P CLIP TO SWINGARM

88 WASHER, M5, 5.3 X 10 X 1 BETWEEN BOLT AND P CLIP

40 CALIPER ASSY, REAR, 34MM, GOLD GOLD FINISH

39 PADS, BRAKE, REAR, 34MM

38 PISTON SET, CALIPER, REAR

37 SEAL KIT, REAR, CALIPER

41 BLEED SCREW, REAR CALIPER

42 HANGER PIN, REAR CALIPER

89 SPRING, PAD RETAINER, REAR CALIPER

36 CALIPER CARRIER, REAR

43 BOLT, CAP HD, M8 X 20 X 1.25 28 REAR CALIPER TO CARRIER

35 DISC, REAR

44 BOLT, BUTTON HEAD, INT HEX, M10 X 20 43 DISK, PATCHLOCKED

PADS, BRAKE, REAR, SINTERED.

TO BE USED WITH 32MM REAR CALIPER

Specifications

Item Standard Service Limit

Clutch Friction plate thickness 2.9~3.1mm 2.75 Friction and steel plate warp 0.2mm or less 0.3mm

Clutch spring free length 54mm 52.75mm

Clutch Lever and Hose

Clutch Lever and Adjustment

107

Pull the lever forward and twist the adjuster [A] to move the lever forwards and backwards.

Clutch Fluid

Warning: When working the clutch, observe the precautions listed

below.

Never reuse old clutch fluid.

Do not use fluid from a container that has been left

unsealed or that has been open for a long time.

Do not mix two types and brands of fluid for use in the

clutch. It may cause the rubber brake parts to deteriorate.

Don’t leave the reservoir cap [A] off for any length of time to avoid moisture contamination of the

fluid.

Don’t change the fluid in the rain or when a strong wind is blowing.

Except for internal clutch parts, use only clutch fluid, isopropyl alcohol, or ethyl alcohol for cleaning

clutch 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 clutch.

Clutch fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away

immediately.

If any of the clutch line fittings or bleed valve is open at any time, the AIRMUST BE BLED FROM THE

CLUTCH.

Clutch Fluid Recommendation

Recommended fluids are given below. If none of the recommended fluids are available, use extra

heavy-duty brake fluid only from a container marked D.O.T. 4.

Note: Clutch fluid of D.O.T. 4 is installed in the clutch system when shipped.

Recommended Clutch Fluid

Type D.O.T. 4

Brand: Fuchs Silkolene

Spec. FMVSS 116 D.O.T. 4, D.O.T. 3, ISO 4925 AND SAE J 1703, (or above)

Clutch Fluid Level Inspection

In accordance with the Periodic Maintenance Chart, inspect

the clutch fluid level in the clutch fluid reservoirs.

A

108

Check the clutch fluid level in the reservoir.

Note: Hold the reservoir horizontal when checking clutch fluid level.

Warning: Change the fluid in the clutch line completely if the fluid must be refilled but the type and brand

of the fluid that is in the reservoir are unidentified

Check the fluid in the clutch reservoir [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] in the reservoir with

the same type and brand of the fluid that already is in the

reservoir.

Clutch Fluid Changing

Remove the reservoir cap and the rubber cap on the bleed

valve.

Attach a clear plastic hose to the bleed valve on the slave,

and run the other end of the hose into a container.

Fill the reservoir with new clutch fluid.

Change the clutch fluid as follows.

Open the bleed valve [A].

Apply the clutch level and hold it [B].

Close the bleed valve [A].

Release the clutch lever [B].

If the fluid in the reservoir runs completely out at any

time during fluid changing, air will enter the line, and the

system must be bled.

Repeat this operation until fresh clutch fluid comes out

into the plastic hose or the colour of the fluid changes.

Warning: Do not mix brands of fluid. Change the clutch fluid

in the clutch line completely if the clutch fluid must be

refilled but the type and brand of the clutch fluid that is already in the reservoir are unidentified.

Torque – Bleed Valve: 7 Nm

Apply the clutch lever forcefully for a few seconds, and check for fluid leakage around the fittings.

A

B

A

C

B

A

B

109

Warning: If the clutch level or pedal has a soft or “spongy feeling” when it is applied, there might be air in

the clutch line or the clutch line may be defective. Since it is dangerous to operate the motorcycle under

such conditions, bleed the air from the brake line immediately.

Clutch Line Air Bleeding

Bleed the air line whenever clutch parts are replaced or

reassembled.

Remove the reservoir cap and fill the reservoir with

new clutch fluid.

Slowly pump the clutch lever several times until no air

bubbles can be seen rising up through the fluid from

the hose at the bottom of the reservoir. This bleeds the

air from the master cylinder and the brake line.

Tap the brake hose lightly going from the slave cylinder to the reservoir side and bleed the air off at

the reservoir.

Attach a clear plastic hose to the bleed valve on the slave

cylinder, and run the other end of the hose into a

container.

Bleed the brake line and the caliper as follows.

Hold the clutch lever applied [A].

Quickly open and close the valve [B].

Release the clutch lever [A].

The fluid level must be checked several times during

bleeding operation and replenished as necessary.

If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation

must be done over again from the beginning since air will have entered the line.

If the brake lever or pedal action still feels soft or “spongy”, tap the clutch hose from bottom to top

and air will rise up to the top part of the hose. Slowly pump the clutch in the same manner as above

Torque - Bleed Valve: 7 Nm

Torque - Reservoir Cap Screws (integral reservoir only): 1.5Nm

Apply the clutch lever forcefully for a few seconds, and check for fluid leakage around the fittings.

Clutch Slave Cylinder

A

B

110

Clutch Slave Cylinder Removal

Remove three mounting bolts [A].

Remove Slave cylinder, and support plate with ball bearing.

Clutch Slave Cylinder Installation

Put Red Grease on the support plate [B] and ball

bearing[C] to stop them falling out while being

installed.

Install the clutch slave cylinder.

Torque: Clutch Slave Cylinder bolts: 6NM

Clutch Slave Cylinder Inspection

Inspect surface for evidence of ware, corrosion, leakage or pitting, if any evidence exists replace

slave cylinder.

Clutch Master Cylinder

Clutch Master Cylinder Removal

Integral reservoir: Remove mounting bolts [A].

Integral reservoir: Remove brake light connection.

Integral reservoir: Remove lever assembly.

Remote reservoir: Remove mounting bolts [B]

Remote reservoir: Remove brake light connection.

Remote reservoir: Remove lever assembly.

Clutch Master Cylinder Installation

A

B

C

B

A

111

Integral reservoir: install lever assembly.

Integral reservoir: install brake light connection.

Integral reservoir: install mounting bolts [A].

Position level to owners preference, ensure correct operation and clearance.

Tighten top bolt.

Torque: Clutch Master Cylinder bolts: 6NM

Tighten bottom bolt.


Remote reservoir: install lever assembly.

Remote reservoir: install brake light connection.

Remote reservoir: install mounting bolts [B]

Position level to owners preference, ensure correct

operation and clearance.

Tighten top bolt.


Tighten bottom bolt.


Clutch Master Cylinder Inspection


lever assembly.

Clutch Hose

Clutch Hose Removal

Drain Clutch Fluid (see Clutch Fluid Changing).

Remove clutch slave cylinder banjo bolt and drain any remained fluid into a suitable container.

Remove clutch master cylinder banjo bolt and remove clutch hose, taking note of hose routing.

Clutch Hose Installation

B

A

112

Install hose in reverse order to removal, ensuring hose is not, and will not be trapped or crushed

during vehicle operation.

Install slave and master cylinder banjo bolts and tighten.

Torque: Clutch Banjo Bolts: 25Nm

Clutch Hose Inspection


hose.

Clutch Cover

Clutch Cover Removal

Drain Gear Box oil (see Engine Lubrication System

chapter).

Remove:

Splined gear selector arm (see Gear chapter).

Take out the sixteen bolts [A] and remove the clutch

cover [B].

Clutch Cover Installation

B

A

A

113

Install:

o Dowel Pins [A]

o Clutch Cover Gasket [B]

Install the clutch cover.

Torque - Clutch cover Bolts 12Nm

Clutch Release Removal

Remove the sprocket cover bolts [A].

Remove sprocket cover.

Remove six M6 clutch spring bolts,

washers and springs.

Remove clutch centre, friction

plates and steel plates.

Remove clutch push rods. Take note of assembly

sequence.

B

B

A

114

Clutch release Installation

Apply clean engine oil to all

clutch parts.

Install clutch centre, friction

plates and steel plates.

Install six M6 clutch spring bolts,


Torque – clutch spring bolts to 12Nm

Install clutch push rods.

Install sprocket cover and sprocket cover bolts.

Torque – Sprocket cover bolts to 20Nm

Clutch

Clutch Removal

Remove six M6 clutch spring bolts,


Remove clutch centre, friction

plates and steel plates,

115

Using the clutch holder, hold the clutch hub to

remove the clutch hub nut [B] and hub [A]

Remove:

o Basket [A]

o Two spacers [B] and [C]

Clutch Installation

Install:

Spacer [A]

Spacer [B]

Clutch Housing (with bearing)

Install:

Clutch hub [A] (with bearing)

Hub nut

Torque - Clutch hub nut 122Nm Threebond 1327

B

A

B

C

A

A

B

116

Install the friction plates and steel plates, starting with a

friction plate alternating them.

Caution: If new dry friction plate and steel plates are installed,

apply engine oil to the surface of each plate and leave to soak

overnight, to avoid clutch plate seizure.

Install the last friction plate fitting the tangs in the grooves

on the housing as shown.

Apply engine oil to all bearings and clutch parts.

Install the clutch spring plate, springs and washers.

Torque – Clutch Spring Bolts: 12Nm

Install the clutch cover.

Friction and Steel Plate Damage, Wear Inspection

Visually inspect the friction and steel plates for signs of

seizure, overheating (discoloration), or uneven wear.

Measure the thickness of the friction plates at several

points.

If any plates show signs of damage, or if they have worn

past the service limit, replace them with new ones.

Friction Plate Thickness

Standard: 2.9 mm ~ 3.1 mm

Service Limit: 2.75 mm

Friction and steel Plate Warp Inspection

Place each friction plate or steel plate on a surface plate,

and measure the gap between the surface plate and each

friction plate or steel plate with a thickness gauge. The gap

is the amount of friction or steel plate warp.

If any plate is warped over the service limit, replace it with

a new one.

Friction and Steel plate Warp

Standard: 0.2 mm or less


117

Cutch Spring Free Length Measurement

Measure the free length of the clutch springs.

If any spring is shorter than the service limit, it must be replaced.

Clutch Spring Free Length

Standard: 54 mm


Clutch Housing Finger Damage

Visually inspect the clutch housing fingers [A] where the

friction plate tangs hit them.

If they are badly worn or if there are groove cuts where

the tangs hit, replace the housing. Also, replace the

friction plates if their tangs are damaged.

Clutch Hub Spline Damage

Visually inspect where the teeth on the steel plates

wear against the clutch hub splines.

If there are notches worn into the clutch hub splines,

replace the clutch hub. Also, replace the steel plates if

their teeth are damaged.

Primary Gear

Primary Gear Removal

Remove the clutch cover (see clutch Cover Removal).

Use a gear holder or if one is not available use a copper

coin between the primary and balance gear to lock the

engine rotation.

Remove:

o Primary Gear Nut

o Primary Gear Washer

A

118

Remove the primary gear.

Remove woodruff key.

Primary Gear Installation

Install:

o Woodruff key [A] (identical

parts)

o Primary Gear [B]

o Primary Gear Washer [C]

Use a gear holder or if one is not available use a copper

coin between the primary and balance gear to lock the

engine rotation.

Tighten primary nut.


Install the clutch cover (see clutch Cover Removal).

B C

A

119

Engine Lubrication System

Exploded View ................................................................................................................................................ 121

Engine Oil flow charts .................................................................................................................................... 123

Specification ................................................................................................................................................... 128

Engine Oil and Oil Filter ................................................................................................................................. 129

Oil Inspection ..................................................................................................................................... 129

Oil Draining ........................................................................................................................................ 129

Oil Filling ............................................................................................................................................. 130

Oil Filter Change ................................................................................................................................. 130

Gearbox ................................................................................................................................................................

Gearbox Oil Draining .......................................................................................................................... 131

Gearbox Oil Filling .............................................................................................................................. 131

Relief Valve Opening Pressure Measurement ............................................................................................... 131

Oil Pressure Measurement ............................................................................................................................ 132

Oil Pump ......................................................................................................................................................... 133

Oil Pipe Removal ................................................................................................................................ 133

Oil Pipe Installation ............................................................................................................................ 133

Oil Pipe Inspection ............................................................................................................................. 133

Relief Valve Inspection ................................................................................................................................... 133

Oil Pipe ........................................................................................................................................................... 134

Oil Pipe Removal ................................................................................................................................ 134

Oil Pipe Installation ............................................................................................................................ 136

120

Engine Oil Flow

Note: Oil is sucked from the back of the oil tank [1] and pumped under pressure through the engine oil feed

system.

Oil is scavenged from the sump by the oil pump [2] and pumped through the radiator [3] into the oil tank

[4].

The oil tank LH breather [5], vents into the back of the head.



1

2

3

4 5

7

6

122


TORQUE (NM) REMARKS

25 COVER ASSY, ROCKER

1 COVER, ROCKER, MACH

2 GASKET, ROCKER, COVER


5 BANJO,M14, 9MM SPIGOT

6

WASHER, M14, OD 20.0MM X 2.5

ALUMINIUM

7 WASHER, M14, OD 20.4MM X 1.22, COPPER

8 BOLT, BANJO, M14 22

22 NUT, M14 X 1.5, THIN, STEEL

23 BOLT, BANJO, M14, MOD 22

24 BREATHER BAFFLE, ASSY

BREATHER BAFFLE, FRONT

BREATHER BAFFLE, REAR

BREATHER BAFFLE, WELD NUT

9 COVER, RH, MC/D

10 GASKET, COVER, RH


26 COVER ASSY, OIL FILTER

12 COVER, OIL FILTER, MC/D

27 TOP HAT, OIL FILTER, COVER

28 BELLEVILLE, SPRING


30 RING, WIRE, 18MM, PLAIN, EXTERNAL

13 O-RING, 67MM X 2 MM, VITON

14 BOLT, CAP HD, M5x0.8x14, DIN 912, A2/70 5


16 COVER, CLUTCH, MC/D

17 GASKET, COVER, CLUTCH


18 BOLT, CAP HD, M6 X 40, DIN 912, SS 12

19 BOLT, CAP HD, M6 X 30 X 1.0, SS 12

31 LABEL, SILKOLENE, 10W/40 LABLE FOR ENGINE

OIL

125

REF. PART DESCRIPTION TORQUE REMARKS

126

NO.

1 CYLINDER HEAD, ASSY, MC/D

2 CYLINDER HEAD, MACHINING

CYLINDER HEAD, CASTING

3 VALVE GUIDE, INLET

4 VALVE GUIDE, EXHAUST

5 SEAT, VALVE, INLET

6 SEAT, VALVE, EXHAUST

7 STUD, EXHAUST 12 THREEBOND 1305

26 GRUB SCREW, M12 X 1.75 X 20MM, DIN 913, A2 15 THREEBOND 1305

8 GASKET, CYLINDER HEAD

9 TOWER, ROCKER, LH, MC/D

10 TOWER, ROCKER, RH, MC/D

11 PIN, DOWEL, 6.00 X 12.0, DIN 7, SS


13 BOLT, CAP HD, M8 X 50 X 1.25, DIN 912, 12.9 20 EXHAUST, TB 1305

28 BOLT, CAP HD, M8 X 55 X 1.25, DIN 912, 12.9 20 INLET, TB 1305

12 WASHER, M8, ID 8.4 X OD 15 X 1.6, BZP

14 STUD, HEAD 54 TB 1305



19


BZP 25

20 NUT, DOMED, M10 X 1.5, DIN 1594, A2 60

CMD EXTREME PRESSURE LUB #3, 4oz APPLY TO STUD FIXINGS AS REQUIRED

16 WASHER, M10, 10.5 X 21.0 X 2, DIN 125A, A2

21 SPACER, EXHAUST SPRING

22 SPACER, INLET SPRING

23 BREATHER FITTING, ASSY, CYLINDER HEAD

BREATHER FITTING, BODY

BREATHER FITTING, BARB


INSIDE ENGINE

BETWEEN HEAD AND WASHER

24 LOCKNUT, M10 X 1.5, GRADE 8 20

29 WASHER, 10.5 X 21.0 X 1.2, FORM B, A2 INSIDE ENGINE ON

TOP OF SEAL WASHER

16 WASHER, M10, 10.5 X 21.0 X 2, DIN 125A, A2 ON THE OUT SIDE OF

THE ENGINE

128


TORQUE (NM) REMARKS

1 CRANKCASE, ASSY, SET

2 CASE, MAIN, ASSY, MACHINING

3 CASE, MAIN, LH, INITIAL MACHINING

CASE, MAIN, LH, CASTING

4 CENTRE PLATE, MAIN CASE, MACHINING

5 CASE, MAIN, RH, INITIAL MACHINING

CASE, MAIN, RH, CASTING

6 BEARING PLATE, ASSY

7 BEARING PLATE, LOWER

8 BEARING PLATE, UPPER



11 GRUB SCREW, M8 X 8, FLAT POINT, DIN 913 THREEBOND 1327


13 O-RING, 6.0MM X 2.00MM, VITON

14 DOWEL, RING, 11.0 DIA

15 BOLT, HEX HD, FLANGED, M8 X 40, DIN 6921, 10.9

25

16 WINDAGE PLATE, CRANKCASE

17 WASHER, M5 X 10 X 1, DIN 125A, RAW



20


BZP 48

21 BOLT, CAP HD, M10 X 45 X 1.5, DIN 912, 12.9, BZP

48

22


BZP 48




26 WASHER, M6, 6.4 X 12 X 1.6, DIN 125A


28 RETAINER, CRANK SEAL, ID 60MM

29 BOLT, BUTTON HD, M4x0.7x6.0, ISO 7380, 10.9 2.5 THREEBOND 1327

30 BREATHER, CRANKCASE 15 THREEBOND 1327


130


1 SWITCH, OIL PRESSURE, 0.2 BAR 20 THREEBOND 1327

8 PUMP ASSY, OIL

11 PIN, DOWEL, 1/8 X 5/8, SOLID USED WITH OIL PUMP DRIVE

12 PIN, DOWEL, 4.0 X 16.00MM, SOLID USED WITH PUMP TO CASE

9 BOLT, CAP HD, M6 X 30 X 1.0, DIN 912, 8.8, BZP 12 CLAMP, OIL PUMP TO ENGINE

10

WASHER, ID 6.4 X 11.0 OD X 1.6

STAINLESS USED WITH OIL PUMP BOLTS

13 FILLER CAP, GEARBOX 20

14

WASHER, ID 26.3 X 31.75 X 2.0,

COPPER GEAR BOX FILLER CAP

15 FILTER, OIL


21 PLUG, SUMP, M10 X 9.0 X 1.5 20

22 LABEL, SILKOLENE, 10W/40 APPLY TO RH COVER ABOVE FILTER COVER

131


TORQUE (NM) REMARKS

1 PLATE, SUMP

2 GASKET, SUMP

3 PLUG, SUMP, MAGNETIC M14 X 1.5 20


132

Oil Specification

Item Standard

Engine / Gear Box Oil: Grade API SG, SH AND SJ, JASO MA Viscosity SAE 10W-40 Capacity Engine 3L FROM COMPLETELY DRY

Capacity Gearbox 2.5L WHEN FILTER REMOVED 1.2L

Oil Pressure Measurement: Relief valve opening pressure 400kPa oil pump pressure @8000rpm with 130˚C 10W/40 oil 6L/min and 300kPa oil pump pressure @1000rpm with 130˚C 10W/40 oil 150kPa

133

Engine Oil and Oil Filter

Warning: Motorcycle operation with Insufficient, deteriorated or contaminated engine oil will cause

accelerated wear and may result in engine or transmission seizure, accident, and injury.

Engine Oil Level Inspection

Situate the motorcycle so that it is perpendicular to the ground.

If the oil has just been changed, start the engine and run it for several minutes at idle speed. This

fills the oil filter with oil.

Caution: Racing the engine before the oil reaches every part can cause engine seizure.

Stop the engine and leave it for more than 1 minute for

all the oil to drain down.

If the motorcycle has just been ridden, run the engine for

about 20 seconds at idle speed. Stop the engine and

leave it for more than one minute.

Check the engine oil by removing the oil filler, clean the

dip stick with a cloth fully reinsert the plug then remove

it again and check the level on the dip stick.

The oil level should be in the middle of the two markings.

If the oil level is difficult to check, rock the motorcycle

both side-to-side, and front-to-rear.

If the oil level is too high, remove the excess oil through

the filler opening, using a syringe or some other suitable

device.

If the oil level is too low, add the correct amount of oil

through the oil filler opening. Use the same type and

make of oil that is already in the engine.

Note: If the engine oil type and make are unknown, use any brand of the specified oil to top off the level

rather than running the engine with the oil level low. Then at your earliest convenience, change the oil

completely.

Engine Oil Draining

Warning: To avoid burns, do not remove the radiator hose or try

to change the oil when the engine is still hot. Wait until it cools

down. Oil on tires will make them slippery and can cause an

134

accident and injury. Immediately wash away any oil that spills of the frame, engine, or wheels. Since oil is

harmful to the human body, do not use for drinking.

Place a container under the drain plug [A] at the bottom of the sump, remove oil filler cap and then

remove the drain plug. It is not necessary to remove the primary or secondary exhaust sections, but

does make access easier.

Place a tray under the bottom radiator hoses [A],

remove the bottom banjo bolt [B] and drain the oil from

the oil tank hose.

Engine Oil Filling


Torque – Oil sump drain Plug: 20Nm

Fill the oil tank with 2.5L of oil and tighten the filler cap.

Run the engine at idle for 2 minutes in a well ventilated

area. Allow the motorcycle to stand for 2 minutes.

Check the oil level as described in (Oil Level Inspection) top up if necessary.

Note: Pour in the oil slowly so that the air in the engine and radiator can escape.


Engine Oil Filter Change

Drain Engine Oil

Remove oil filter cover bolts.

Remove oil filter cover.

Remove oil filter.

Replace the filter element with a new one.

Apply oil to the mounting surfaces and oil filter.

Install the oil filter.

Install oil filter cover and bolts

A

A B

135

Torque – filter cover bolts: 6Nm

Pour in the specified type and amount of oil.

Gearbox Oil Draining

Warning: To avoid burns, do not change the oil when the engine is

still hot. Wait until it cools down. Oil on tires will make them

slippery and can cause an accident and injury. Immediately wash

away any oil that spills of the frame, engine, or wheels. Since oil is

harmful to the human body, do not use for drinking.

Place a container under the drain plug [A] at the bottom of

the gearbox, remove oil filler cap and then remove the drain

plug.

Allow oil to drain fully.

Gearbox Oil Filling


Torque – Gear Box Oil Drain Plug: 20Nm

Fill the gearbox with 1.2L of oil and tighten the filler cap [A].

Torque – Gear Box Filler Cap: 20 Nm

Run the engine at idle for 2 minutes in a well ventilated area.

Note: Pour in the oil slowly so that the air in the engine and radiator can escape.


Relief Valve Opening Pressure Measurement

Note: Measure the oil pressure before the engine is warmed up if

you want to test relief valve opening pressure.

Remove oil passage plug [A] on the oil pump and replace

with double banjo bolt and oil pressure gauge adapter.

Special Tools – Oil Pressure Gauge Adapter and Oil

A

A

A

136

Pressure Gauge.

Start the engine, and read the maximum oil pressure while running the engine at various speeds. A

normal relief valve keeps the maximum oil pressure between the specified values.

Relief Valve Opening Pressure

Standard: 300~400 kPa

If the reading is much higher than the standard, the relief valve is stuck in its closed position.

If the reading is much lower than the standard, the relief valve may be stuck open, or there may be

other damage (e.g. crank oil seal damage, oil pump damage) in the lubrication system.

Stop the engine.

Remove the oil pressure gauge and adapter.

Install the oil banjo bolt.

Torque – Oil Pump Banjo Bolt: 35Nm

Oil Pressure Measurement

Oil Pressure Measurement

Note: Measure the oil pressure after the engine is warmed up.

Attach the oil pressure gauge and adapters to the plug hole (see Relief Valve Opening Pressure

Measurement).

Warning: You could receive burns from hot engine oil draining through the oil passage when the plug is

removed.

Special Tools – Oil Pressure Gauge Adapter and Oil Pressure Gauge.

Oil Pressure Standard: 150kPa

If the oil pressure is much lower than the standard, check the oil pump, relief valve, and/or

crankshaft and balance shaft oil seal immediately.

If they are not at fault, inspect the rest of the lubrication system.

Stop the engine.

Remove the oil pressure gauge and adapter.

Install the oil pump banjo plug.

137

Oil Pump

Oil Pump Removal

Drain the engine oil.

Remove two Oil Banjo bolts.

Remove three outer oil pump retainer bolts.

Taking note of the O-ring and dowel positions remove

the oil pump.

Oil Pump Installation

Install the oil drive dowel, location dowels and O-rings

(use a little grease to hold in place if required.

Fill the pump with engine oil [A] for initial lubrication.

Align the oil pump drive dowel with the balance shaft

female drive cut out.

Install the oil Pump and three location bolts.

Torque - Oil pump bolts: 12Nm

Oil Pump inspection

Disassemble the oil pump (see this chapter).

Visually inspect the oil pump body, outer and inner rotors, and covers.

A

138

If there is any damage or uneven wear, replace the rotors or the oil pump assembly.

Relief Valve Inspection

Disassemble the oil pump (see this chapter).

Remove the relief valve [A].

Check to see if the piston moves freely when pushing it with a wooden or soft rod, and see if it

comes back to its seat by the valve spring pressure.

If any rough spots are found during above inspection, wash the valve clean with a high-flash point

solvent and blow out any foreign particles that may be

in the valve with compressed air.

Warning: Clean the parts in a well-ventilated are, and take care

that there are no sparks or flame anywhere near the working

area. Because of the danger of highly flammable liquids, do not

use gasoline or low-flash point solvents.

If cleaning dose not solve the problem, replace the relief

valve as an assembly. The relief valve is precision made

with no allowance for replacement of individual parts.

Oil Pipe

Oil Pipe Removal

Remove:


Remove Battery and Battery Tray (see Electrical System

chapter)

Cut double eared clip off and remove oil pump banjo,

remove oil tank to oil pump hose.

139

Remove oil pump banjo bolt, cut double eared clip off oil

cooler, and remove hose.

Cut double eared clip off oil cooler, cut double eared clip off oil

tank, and remove hose.

Cut double eared clip off oil tank, cut double eared clip off

back of the head, and remove hose.

Cut double eared clip off rocker cover, cut double eared

clip off air box, and remove hose.

140

Cut double eared clip off crank case, cut double eared clip

off rocker cover, and remove hose.

Oil Pipe Installation

Before installation, flush out the pipe with a high-flash point solvent.

Fill the pipes with engine oil to shorten air bleeding time and prevent engine damage.

Discard the used copper washers and install new washers on each side of the pipe fittings.

Install new double eared clamps in all positions and crimp.

Installation process is the reverse of the removal (see this chapter).

Lightly tighten the banjo bolts to a snug fit, and tighten them to the specified torque.

Torque – Oil Pipe Banjo Bolts: 35Nm

141

Engine Removal / Installation

Exploded View ................................................................................................................................................ 138

Engine Removal / Installation ........................................................................................................................ 140

Engine Removal .................................................................................................................................. 140

Engine Installation.............................................................................................................................. 141

142

Exploded View

143


TORQUE (NM) REMARKS

1 FRAME ASSEMBLY, SINGLE SEAT XM

20 CABLE TIE, 120MM X 3.6MM, FIR-TREE,

BLACK

CLAMP DIRECT TO FRAME, CLUTCH HOSE,

HARNESS

2 OIL FILLER CAP

3 O-RING, OIL FILLER CAP, 2.4MM SITS INSIDE OIL FILLER CAP

4 DIPSTICK

5 BRACKET, ENGINE, FRONT, STEEL, XM

6 SPACER, ENGINE MOUNT, RHS,

ALUMINIUM

7 SPACER, ENGINE MOUNT, LHS, ALUMINIUM

8 BOLT CAP HD, M8 X 57 X 1.25 TO CLAMP ENGINE MOUNT BRACKET

9 WASHER, M8, 8.4 X 16 X 1.6 TO CLAMP ENGINE MOUNT BRACKET

10 26 TO CLAMP ENGINE MOUNT BRACKET

11 BOLT, M12, ENGINE, FRONT MOUNT FRONT ENGINE MOUNT BOLT

12 WASHER, M12, 13 X 24 X 2.5 USED WITH ENGINE BOLT AND NUT

13 LOCKNUT, M12 X 1.75

85 NUT, USED WITH ENGINE MOUNT BOLT

14 FRAME ADJUSTER, M24 15

15 BOLT, M12, ENGINE, REAR MOUNT 85 REAR ENGINE MOUNT BOLT

17 VIN PLATE, UK (NOW WHOLE WORLD)

18 RIVET, HAMMER DRIVE, 3/8TH TO FIX VIN PLATE TO FRAME

19 SLEEVE, NYLON, FRAME PROTECTOR

USED BETWEEN FRAME AND FOOTREST

HANGER

144

Engine Removal/Installation

Engine Removal

Drain the engine oil

(see Engine Lubrication System chapter).

Remove:


Throttle Bodies (see Fuel System chapter)

Exhaust Pipes (see Engine Top End chapter)

Oil lines (see Engine oil and filter chapter)

Air Box (See Fuel System chapter)

Gear change assembly

(see Crankshaft/Transmission chapter)

Remove oil pressure switch connection, cam position

sensor connector, throttle position sensor connector,

speed sensor connector, and temp sensor connector.

Remove sprocket cover and chain

(see Final drive chapter)

Remove spark plug cap [A].

Remove starter motor cable.

Warning: When the engine mounting bolts are removed

the engine will be free so take precautions to support the

engine. The engine is over 70Kg therefore it will require

at least two people to lift it out and an engine jack.

Remove the engine mounting bolts [A] and brackets [B].

Remove the engine from the LH side.

A

A

B

145

Engine Installation

Fit frame protectors onto frame tubes ready for installing the engine so not to scratch the frame,

and place a jack underneath the bottom frame rails to support the engine.

Install the engine into the frame from the left side of the chassis; you will need to get some help to

lift the engine in.

Once engine is sitting in position line up the rear mounting holes and insert service tool into the top

rear mounting hole, insert rear engine bolt into the bottom mount.

Using service tool tighten up top rear engine adjuster and torque.

Torque – Adjuster: 15NM.

Remove service tool and insert engine bolt and torque.

Torque – Engine Bolts: 85NM

Repeat this process for the bottom rear engine mount bolt.

Fit front engine mount brackets and secure in place with

bolts, washers and nuts using a washer on either side of the

bolt then torque.

Torque – Mount bolts: 35 NM

Fit front engine mounting bolt using spacers LH and RH with washer and nut then torque to 85 NM

Install:

Gear change assembly (see Crankshaft/Transmission chapter)

Air Box (See Fuel System chapter)

Oil lines (see Engine oil and filter chapter)

Exhaust Pipes (see Engine Top End chapter)

Throttle Bodies (see Fuel System chapter)


Install oil pressure switch connection, cam position sensor connector, throttle position sensor

connector, speed sensor connector, and temp sensor

connector.

Install sprocket cover and chain (see Final Drive

chapter)

Install spark plug cap [B].

Install starter motor cable.

Run the cables, hoses, and leads according to the

Cable, Wire, and Hose Routing section of the General

Information chapter.

Install the removed parts (see the appropriate chapter).

146

Adjust:

Throttle Cables (see Fuel System chapter)

Clutch (see Clutch chapter)

Drive Chain (see Final Drive chapter)

Fill the engine oil (see Engine Lubrication System chapter).

Adjust the Throttle idle adjusting screw.

Check the brake effectiveness.

Warning: Do not attempt to ride the motorcycle until a full brake lever or pedal is obtained by pumping

the brake lever or pedal until the pads are against the disc. The brake will not function on the first

application of the lever or pedal is this is not done.

147

Crankshaft / Transmission

Exploded View ................................................................................................................................................ 148

Specification ................................................................................................................................................... 151

Crankcase ....................................................................................................................................................... 153

Crankcase Disassembly ...................................................................................................................... 153

Crankcase Assembly ........................................................................................................................... 157

Crankshaft and Connecting Rod .................................................................................................................... 159

Crankshaft Removal ........................................................................................................................... 159

Crankshaft Installation ....................................................................................................................... 159

Crankshaft Disassembly ..................................................................................................................... 159

Crankshaft Assembly .......................................................................................................................... 159

Crankshaft Alignment ......................................................................................................................... 160

Transmission .................................................................................................................................................. 160

Shift Pedal Installation ....................................................................................................................... 160

External Shift Mechanism Removal ................................................................................................... 161

External Shift Mechanism Installation ............................................................................................... 162

External Shift Mechanism Inspection ................................................................................................ 162

Transmission Removal ....................................................................................................................... 163

Transmission Installation ................................................................................................................... 163

Transmission Shaft Disassembly ........................................................................................................ 163

Transmission Shaft Assembly ............................................................................................................. 164

Shift Fork Bending .............................................................................................................................. 164

Shift Fork Ear/Gear Shift Fork Groove Wear ...................................................................................... 164

Shift Fork Guide Pin/Shift Drum Groove Wear .................................................................................. 164

Gear Dog/Dog Recess Damage .......................................................................................................... 166

Balancer ......................................................................................................................................................... 166

Balancer Shaft Removal ................................................................................................................................. 166

Balancer Shaft Installation ............................................................................................................................. 166

Balancer Shaft Disassembly ........................................................................................................................... 166

Balancer Shaft Assembly ................................................................................................................................ 168

Ball Bearing, Needle Bearing, and Oil Seal ..................................................................................................... 168

Ball and Needle Bearing Replacement ............................................................................................... 168

Ball and Needle Bearing Wear ........................................................................................................... 169

Oil Seal Inspection .............................................................................................................................. 169

148


TORQUE (NM) REMARKS

1 ASSY, CRANKSHAFT, 2 CYL, 270°

2 TRIGGER DISK

3 PRIMARY GEAR, CRANK, 54 TOOTH

4 WOODRUFF KEY, 1" X 1/4",MOD

5 SPACER, CRANKSHAFT

6 SEAL, RADIAL SHAFT, 35.0 X 72.0 X 8

7 BEARING, CYLINDRICAL, OD 80.0MM, ID 35.0MM, 21MM WIDE

INNER RACE PRESSED ON TO SHAFT

8

BOLT,CSK TORX, M5 X 0.8 X 16, DIN7991, A4 -

80 10 TO CLAMP TRIGGER DISK

9 NUT, M20, X 1.5, DIN 934, GRADE 10 122 THREEBOND 1327

10 DOWEL, PRIMARY, GEAR, 6MM DIA X10MM

150


TORQUE (NM) REMARKS

1 CRANKCASE, ASSY, SET

2 CASE, MAIN, ASSY, MACHINING

3 CASE, MAIN, LH, INITIAL MACHINING

CASE, MAIN, LH, CASTING

4 CENTRE PLATE, MAIN CASE, MACHINE

5 CASE, MAIN, RH, INITIAL MACHINING

CASE, MAIN, RH, CASTING

6 BEARING PLATE, ASSY

7 BEARING PLATE, LOWER

8 BEARING PLATE, UPPER



11 GRUB SCREW, M8 X 8, FLAT POINT, DIN 913 THREEBOND 1327


13 O-RING, 6.0MM X 2.00MM, VITON


15 BOLT, HEX HD, FLANGED, M8 X 40, DIN 6921, 10.9

25

16 WINDAGE PLATE, CRANKCASE

17 WASHER, M5 X 10 X 1, DIN 125A, RAW



20


BZP 48

21 BOLT, CAP HD, M10 X 45 X 1.5, DIN 912, 12.9, BZP

48

22


BZP 48

151




26 WASHER, M6, 6.4 X 12 X 1.6, DIN 125A


28 RETAINER, CRANK SEAL, ID 60MM

29 BOLT, BUTTON HD, M4x0.7x6.0, ISO 7380, 10.9 2.5 THREEBOND 1327

30 BREATHER, CRANKCASE 15 THREEBOND 1327


153


TORQUE (NM) REMARKS

1 CASSETTE PLATE, ASSY

2 END PLATE, CASSETTE

3

BEARING, DEEP GROOVE, 25 X 62 X

17 SITS WITHIN END PLATE

4 CIRCLIP, 62MM INTERNAL X 2.0

5

BEARING, DEEP GROOVE, 20 X 47 X

14 SITS WITHIN END PLATE

6 CIRCLIP, 47MM INTERNAL X 1.7

7 BUSH, BARREL SUPPORT

8 CLIP, SHIFT DRUM

9 PLATE, SHIFT DRUM CLIP

10 NUT, PEM, M8 X 1.25

11 SNAP, LINK , ASSY

12 SNAP, LINK, WELDED, ASSY

14 BOSS, SNAP LINK

15 SPRING, SNAP ARM, LINK

13 ARM, SNAP LINK, PIN

16 PIN, SHIFT PAWL

18 BEARING, 14 X 7 X 3.5

17 SPACER, SHIFT PAWL

23

BOLT, M8x1.25x12, 10.0 DIA, SHLD,

ISO 7979, 12.9 15 THREEBOND 1305


57 WASHER, M8 X 17 X 1.6, DIN 125A

56

BOLT, CAP HD, M8 X 70 X 1.25, DIN

912, 12.9 25

19 SPRING, EXTENSION, 55MM, DIN 2097, BZP

20

BOLT, M5x0.8x10, 6.0 DIA, SHLD,

ISO 7979, 12.9 5 THREEBOND 1305

21 PIN, ROLL, 3.0 X 12.0 STAINLESS

22 MAINSHAFT, ASSY

24 SHAFT, TRANSMISSION, MAIN

25 GEAR, 5TH-2ND

26 GEAR, 5TH-3RD

27 GEAR, 5TH-4TH

28 GEAR, 5TH-4TH, COUNTERSHAFT

29

SPACER, GEAR, ID 30.18, OD 35.0 X

1.75

30 SNAP RING, EXTERNAL, 29MM (SWM0290)

31 SPACER, MAIN SHAFT, LH

32

BEARING, NEEDLE ROLLER, 26 X 30

X 13

33 LAYSHAFT, ASSY

154

34 COUNTERSHAFT

35 GEAR, 5TH-2ND, COUNTERSHAFT

36 GEAR, 5TH-3RD, COUNTERSHAFT

37 GEAR, 5TH-4TH, COUNTERSHAFT

38 GEAR, 5TH-4TH

39 GEAR, 1ST, COUNTERSHAFT

40 SPACER, LAYSHAFT

41 SPACER, GEAR, THICKNESS 3.90MM

32

BEARING, NEEDLE ROLLER, 26 X 30

X 13

29 SPACER, GEAR, ID 30.18, OD 35.0 X 1.75

30

SNAP RING, EXTERNAL, 29MM

(SWM0290)

42 BEARING, NEEDLE ROLLER, 25 X 32 X 26

43 END CAP, LAY SHAFT

44 BOLT, CAP HD, M8 X 30 X 1.25, DIN 912, 12.9

25 THREEBOND 1327


BOTH USED BETWEEN BOLT AND

END CAP

46 OUTPUT GEAR, ASSY

47 GEAR, 1ST

48 SEAL, RADIAL, OUTPUT SHAFT

SEAL BETWEEN CRANKCASE AND

OUTPUT SHAFT

49 BEARING, NEEDLE ROLLER, 25 X 32 X 20

50 SPROCKET, DRIVE, 18T

51 SEAL, RING, MAIN SHAFT

53 O-RING, 2.0 SECTION, X 44.0 DIA, VITON

52 SEAL, CASE, SPROCKET

53 WASHER , TAB, DRIVE SPROCKET

54 NUT, DRIVE SPROCKET

55 CIRCLIP, INTERNAL, 85MM TO HOLD RADIAL SEAL

58

BEARING, DEEP GROOVE, 45 X 85

X19

156


TORQUE (NM) REMARKS

1 SHIFT MECHANISM, ASSY

3 SHIFTER, WELDED, ASSY

4 RETAINING PLATE, SHIFT MECHANISM

5 SPRING, INTERNAL SHIFTER

6 SPRING, SHIFT PAWL

7 SPACER, SHIFT SPRING

8 BUSH, PIVOT

9 WASHER, 9.7x16.0x0.65, STEEL, RAW

11 CIRCLIP, EXTERNAL, 7MM

10 CIRCLIP, EXTERNAL 9MM

29 ARM, SHIFT PAWL, ASSY

2 BARREL, SHIFTER, ASSY

31

SHIFT DRUM, REVERSE SHIFT, WITH

PINS, ASSY

28 SHIFT DRUM, ASSY

14 SHIFT DRUM

30 PADLE, PIN, SELECTOR DRUM

18

PIN, DOWEL, 3/16 X 5/8, BS 1804

H&G 4 WITH DETENT WHEEL

15 SHIFT FORK, LH, MC/D

16 SHIFT FORK, CENTRE, MC/D

17 SHIFT FORK, RH, MC/D

19 PIN, COTTER, 5/64, X 3/4, (304) SS

18

PIN, DOWEL, 3/16 X 5/8, BS 1804

H&G 3 WITH FORKS

21 DETENT WHEEL, REVERSE SHIFT

22


912, 12.9 12 TO CLAMP DETENT WHEEL

23

WASHER, M6, 6.4 X 12 X 1.6, DIN

125A

USED WITH DETENT WHEEL BOLT

24 BEARING, NEEDLE ROLLER, 1/2"x11/16"x3/4

USED WITH END OF SELECTOR DRUM

25


912, 12.9 12 TO CLAMP SHIFT MECHANISM

23 WASHER, M6, 6.4 X 12 X 1.6, DIN 125A

USED WITH SHIFT MECHANISM BOLTS

26

BEARING, NEEDLE ROLLER,

1/2"x11/16"x 5/16 USED ON SHIFT ARM

27 SEAL, ROTARY, 1/2"x7/8"x5/16", SKF

157


TORQUE (NM) REMARKS

1 BALANCER SHAFT, MACHINING

2 BEARING, DEEP GROOVE, 25 X 62 X 17 RH CASE

3 BEARING, DEEP GROOVE, 35 X 62 X 14 LH CASE

4 SPACER, BALANCER SHAFT

5 SEAL, RADIAL, SHAFT, 35 X 47 X 6MM LH CASE

6 BACKLASH, ASSY

7 GEAR, BALANCER, 54 TOOTH

8 GEAR, BACKLASH

9 SPACER, BACKLASH, ID 63 X 45.5 OD X 2.0

10 SPRING, BACKLASH

12 CIRCLIP, EXTERNAL, 40.0 MM, DIN 471

13 PIN, DOWEL, 5.0 X 8.00MM, SOLID, DIN 6325 H&G

14

PIN, DOWEL, 5.0 X 10.00MM, SOLID, DIN 6325

H&G

15 WOODRUFF KEY, 1" X 1/4",MOD

16 WASHER, 34 OD 21 ID X 3.0MM

17 NUT, HALF, M20 X 1.5, DIN 439, A2 70 122

158

Specification


Crankshaft, Connecting Rod: Connecting rod big end side clearance Connecting rod big end Radial clearance

0.5mm ± 0.1 0.006~0.019

0.5mm ± 0.2 0.07mm

Crankshaft runout: Right TIR 0.04mm or less TIR 0.10mm Left TIR 0.04mm or less TIR 0.08mm Transmission: Shift fork ear thickness Shift fork ear thickness (left)

5.03-5.13 5.69-5.79

4.93 5.59

Gear shift fork groove width Gear shift fork groove width (left)

5.33± 0.1 6.00± 0.1

5.43± 0.1 6.10± 0.1

Shift fork guide pin diameter 4.7625 4.75

Shift drum Groove width 4.9 5.0

159

Crankcase

Crankcase Disassembly

Remove the engine (see Engine Remove/Installation chapter).

Set the engine on a clean surface and hold the engine steady while parts are removed.

Remove:

o Engine Covers (see relevant chapter)

o Primary Gear (see Clutch chapter)

o Balance shaft Gear (see this chapter)

o Clutch (see Clutch chapter)

o Starter Motor (see Electrical System chapter)

o Alternator rotor (see Electrical System chapter)

o Trigger disk (see Electrical System)

o Cylinder and Gasket (see Top End chapter)

o Piston (see Engine Top End chapter)

o Camshaft Chains and Guides (see Engine Top End chapter)

o External shift mechanism (see this chapter)

o Cassette plate with gears and shift mechanism (see this chapter)

Remove the crank case bolts back from 13 to 1

160

There are two ring dowels on the crankcase mating surface, using a plastic mallet tap lightly around the crankcase mating surface until free.

Lift off the left crankcase half.

161

Remove the baffle plate.

Remove the 9 centre plate bolts from 9

back to 1.

Remove the crank shaft with the centre

plate by hand.

Crankcase Assembly Caution: Right crankcase, left crankcase, and centre plate are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set.

162

Chip off the old gasket from the mating surfaces of the crankcase halves.

Using compressed air, blow out [A] the oil passages in the crankcase halves and centre plate.

With a high-flash point solvent, clean off the mating surfaces of the crankcase halves and wipe dry.

Warning: Clean the engine parts in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low-flash point solvent to clean parts. A fire or explosion could result.

Using a press and the bearing drive set,

install new bearings until they bottom out

on the crankshaft and cases if required. Do

not replace half of the bearing and not the

other half.

Ensure all oil seals are correctly installed

and seated, if any wear is visible replace.

Install the crankshaft by hand with the

centre plate installed on the crank.

Install the 9 centre plate bolts and tighten

in the sequence shown (one to nine).

Torque – Centre Plate Bolts: 25Nm

Install the baffle plate and bolts and

tighten.

Torque – Baffle Plate Bolts: 5Nm

Be sure the mating surfaces of the crankcase

halves are clean and dry.

Check to see the two crankcase dowels pins [A] are in place on the right crankcase half. If either has

been removed, replace it with a new one.

Apply liquid gasket to the mating surface of the left crankcase half.

Sealant – 3 bond gasket sealant

Install the left hand crankcase.

Ensure all seals are not damaged during installation; use a feeler gauge if necessary to feed the lip

seals on.

Tighten the crankcase bolts in the order listed.

Torque – Crankcase Bolts: 48Nm (Excluding the 8th bolt)

Torque – Crankcase Gearbox Bolt: 12Nm (The 8th bolt)

163

Constantly check the alignment of the two crankcase halves, and the position of the balance shaft.

The front and rear of the crankcase must be pushed together evenly.

Check:

Crankshaft and balancer shaft turn freely.

If any of the shafts do not turn freely, split the crankcase to locate the problem.

Install: Remove the crank shaft with the centre plate by hand.

Primary Gear (see Clutch chapter)

Balance shaft Gear (see this chapter)

Cassette plate with gears and shift mechanism (see this chapter)

External shift mechanism (see this chapter)

Clutch (see Clutch chapter)

Trigger disk (see Electrical System)

Alternator rotor (see Electrical System chapter)

Starter Motor (see Electrical System chapter)

Piston (see Engine Top End chapter)

Cylinder and Gasket (see Top End chapter)

Camshaft, Chains and Guides (see Engine Top End chapter)

Engine Covers (see relevant chapters)

Install the engine (see Engine Removal/Installation chapter).

Install the engine sprocket (see Final Drive chapter)

Crankshaft and Connecting Rod

164

Crankshaft Removal

See Crankcase Disassembly

To Split the centre plate remove the two main bolts.

Tap lightly around the joint face with a plastic hammer and split the centre plate, remove.

Crankshaft Installation

See Crankcase Assembly

To join the centre plate ensures the two dowels are in place and align the main centre bearing cir

clip with the groove in the plates.

Ensure the grub screw is installed in the centre plate.

Tap the top and the bottom with a plastic hammer; constantly check the alignment of the two

halves.

Tighten the two centre plate bolts.

Torque – Centre Plate Split bolts: 48Nm

Crankshaft Disassembly

Use a bearing puller to remove the inner bearing runners on the other crankshaft outer left hand

and right hand side.

Note: The crankshaft is a welded assembly; therefore it cannot to disassembled and must be replaced as a whole unit.

Crankshaft Assembly

Using a bearing press tool press the bearing inner runner fully home on the crankshaft.

Connecting Rod Big End Radial Clearance

Set the crankshaft on V blocks, and place a dial gauge [A] against

the connecting rod big end.

Push [B] the connecting rod first towards the gauge and then in

the opposite direction. The Difference between the two gauge

readings is the radial clearance.

If the radial clearance exceeds the service limit, the crankshaft

assembly must be replaced.

Clearance – Big end Radial: Standard: 0.006~0.019 Service Limit: 0.07mm

Connecting Rod Big end Side Clearance

Set the crankshaft on V blocks.

Measure the side clearance [A] of the connecting rod with a

thickness gauge.

165

If big end side clearance exceeds the service limit, the crankshaft assembly must be replaced.

Clearance – Connecting Rod Big End Side Clearance: Standard: 0.40~0.60mm Service Limit: 0.70mm

Crankshaft Alignment

With the crankshaft on V blocks, turn the

crankshaft slowly and measure runout at

each of the locations shown [A] and [B].

Runout – Crankshaft Right Half: Standard TIR 0.04mm or less. Service limit: TIR 0.10mm

Runout – Crankshaft Left Half: Standard TIR 0.04mm or less. Service Limit: TIR 0.08mm

If runout at either location exceeds the service limit, replace the crankshaft assembly.

Transmission Transmission shift pedal

Adjust the shift pedal position from the foot peg to suit

you.

The standard shift pedal position is about 40mm below

the foot peg top.

External Shift Mechanism Removal

Drain the engine oil (see Engine Lubrication

System chapter)

Remove gear shift pedal assembly.

Remove clutch cover (See Clutch chapter)

Remove the two allen head retainer bolts.

Align the neutral cut out of the detent wheel

with the selector fork; pull the fork back away

from the detent wheel so it can slide past.

166

Remove the external shift assembly.

Remove the snap link arm retainer bolt;

remove snap link arm.

Remove the detent wheel retainer bolt;

remove the detent wheel.

External shift Mechanism Installation

Be sure the dowels are correctly installed in

the shift drum [A]

Apply Threebond 1305 to the threads of

the shift drum cam bolt; install detent

wheel and tighten retainer bolt.

Torque – Shift Drum Cam Bolt: 12Nm, Threebond 1305

Install the snap link arm and tighten.

167

Torque – snap link arm bolt: 15Nm, Threebond 1305

Ensure selector fork is assembled as

detailed below.

Align the neutral cut out of the detent wheel with the selector fork; pull the fork back away from

the detent wheel so it can slide past and install.

Torque – shift mechanism bolts: 12Nm

External Shift Mechanism Inspection

Check the shift shaft for bending or

serrations [A] for damage

If the shaft is bent, straighten or replace

it. If the serrations are damaged, replace

the shaft.

Check the springs [B] for breaks or

distortion.

If the springs are damaged in any way,

replace them.

Check the shift mechanism arm [C] for

distortion.

If the shift mechanism arm is damaged in

any way, replace the shift shaft

assembly.

Transmission Removal

Remove the clutch.

Remove External Shift Mechanism (see

this chapter)

168

Remove the cassette plate retainer bolts.

Remove the cassette plate as a single unit.

Transmission Installation

Apply a small amount of engine oil to the

transmission gears, bearings, shaft

journals, and shift fork fingers.

Install the cassette plate assembly

ensuring the output shaft is correctly

aligned.

Tighten the cassette plate bolts.

Torque – Cassette plate bolts: 25Nm

Transmission Disassembly

Put gearbox in neutral position

Remove the Transmission (see Transmission Removal)

Hold the transmission shafts and selector drum, tap the cassette plate lightly with a plastic hammer

and remove.

169

Remove the gears and spacers in the sequence shown, using the outside circlip pliers, remove the

circlips [30] and disassemble the transmission shafts completely.

Transmission Shaft Assembly

Replace any circlips that were removed with new

ones.

Install the gears, spacers, and circlips in the order

shown.

Assemble the shift fork to the main and lay shafts

at 90˚ to the axial direction of the main shaft and

lay shaft.

Insert the lay shaft main shaft and selector drum into the

cassette plate as one unit, use a plastic mallet if required to

mate the cassette plate home.

Shift fork bending

170

Visually inspect the shift forks, and replace any fork that is 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 Ear/Gear Shift Fork Groove Wear

Measure the thickness [A] of the shift fork ears.

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: 5.03~5.13mm Service Limit: 4.93mm

Shift Fork Ear Thickness (left)

Standard: 5.79~5.69mm Service Limit: 5.59mm

Measure the width [A] of the gear shift grooves.

If a gear fork groove is worn over the service limit, the gear must be replaced.

Gear Shift Fork Groove Width Standard: 5.33 ± 0.1mm Service Limit: 5.43 ± 0.1mm

Gear Shift Fork Groove Width (left) Standard: 6.00 ± 0.1mm Service Limit: 6.10 ± 0.1mm

Shift Fork Guide Pin/Shift Drum Groove Wear

Measure the diameter [A] of each shift fork guide

pin, and measure the width [B] of each shift drum

groove.

If the guide pin on any shift fork is less than the

service limit, the pin must be replaced

Shift Fork guide Pin Diameter

Standard: 4.7625mm Service Limit: 4.75mm

If any shift drum groove is worn over the service

limit, the drum must be replaced.

Shift Fork Guide Groove Diameter

Standard: 4.9mm Service Limit: 5.00mm

B

A

171

Gear Dog/Dog Recess Damage

Visually inspect the gear dogs [A], and

recesses [B].

Replace any damaged gears or gears with

excessively worn dogs, or recesses.

Balancer

Balancer shaft Removal

Split the crankcase (see Crankcase Disassembly)

Lift the balancer shaft [A] out of the right-hand

crankcase half.

Balancer Shaft Installation

See Crankcase Assembly.

Install by hand ensuring spacer is in position.

Balance Gear Removal

Remove the clutch cover (see clutch Cover Removal).

B

B

B

A

172

Use a gear holder or if one is not available use a copper coin between the primary and balance gear

to lock the engine rotation.

Insert an M8 bolt into the balance gear location hole [A]

this will lock the anti backlash spring in place.

Remove:

o Balance Gear Nut

o Balance Gear Washer

Remove the Balance gear, with the anti-backlash gear and spring.

Remove woodruff key.

Balance Gear Installation

Install:

Woodruff key [A]

Balance Gear assembly [A]

ensuring dots line up.

Balance Gear Washer [B]

173

Use a gear holder or if one is not available use a copper coin between the primary and balance gear

to lock the engine rotation.

Tighten Balance gear nut.


Install the clutch cover (see clutch Cover Removal).

Balancer Shaft Gear Disassembly

Use the Balance Shaft Gear Holder tool and remove the m8

nut inserted during engine disassembly. Allow the spring to

slowly unwind, separate the gears.

The dowels can be removed if required.

Balancer Shaft Gear Assembly

Assembly by hand on the Balance Shaft Gear Holder tool in

order shown.

Use the Balance Shaft Gear Holder tool, slowly apply

tension to the spring then when the two holes align insert

an m8 nut.

174

Ball and Needle Bearing Replacement Caution: Do not remove the ball or needle bearings unless it is necessary. Removal may damage them.

Using a press or puller, remove the ball and/or needle bearings.

Note: In the absence of the above mentioned tools, satisfactory results may be obtained by heating the case to approximately 75˚C max, and tapping the bearing in or out. Caution: Do not heat the case with a torch. This will warp the case.

Using a press and a bearing drive, install the new bearing until it stops at the bottom of its housing.

Ball and Needle Bearing Wear Caution: Do not remove the bearings for inspection. Removal may damage them.

Check the ball bearings.

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 the bearing by hand to check its condition.

If the bearing is noisy, does not spin smoothly, or has any rough sports, 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, colour change, or other damage.

If there is any doubt as to the condition of a needle bearing, replace it.

Oil Seal Inspection

Inspect the oil seals.

Replace it if the lips are misshapen, discoloured (indicating that the rubber has deteriorated),

hardened or otherwise damaged.

175

Wheels/Tyres

Exploded View ................................................................................................................................................ 171

Specification ................................................................................................................................................... 178

Wheels ........................................................................................................................................................... 179

Front Wheel Removal ...................................................................................................................... 179

Front wheel Installation ................................................................................................................... 179

Rear Wheel Removal ....................................................................................................................... 180

Rear wheel Installation .................................................................................................................... 180

Front wheel Disassembly ................................................................................................................. 180

Front wheel Assembly ..................................................................................................................... 181

Rear wheel Disassembly .................................................................................................................. 181

Rear wheel Assembly ....................................................................................................................... 182

Wheel Inspection ............................................................................................................................. 182

Spoke Inspection .............................................................................................................................. 182

Rim Inspection ................................................................................................................................. 182

Axle Inspection ................................................................................................................................. 183

Wheel Balance ............................................................................................................................................... 183

Wheel Balance Inspection ............................................................................................................... 183

Wheel Balance Adjustment ............................................................................................................. 183

Tyres ............................................................................................................................................................... 184

Air Pressure Inspection / Adjustment .............................................................................................. 184

Tyre Inspection ................................................................................................................................ 184

Tyre Removal ................................................................................................................................... 185

Tyre Installation ............................................................................................................................... 185

Hub Bearings (wheel Bearings ....................................................................................................................... 186

Bearing Removal .............................................................................................................................. 186

Bearing Installation .......................................................................................................................... 186

Bearing Inspection ........................................................................................................................... 186

176

Exploded View

177

REF. NO.

PART DESCRIPTION TORQUE (NM)

REMARKS

1 REAR WHEEL, CARBON FIBRE, BLACK STANDARD REAR WHEEL FOR CSE-01/03

2 SPACER, INTERNAL, REAR WHEEL,

CARBON

3 REAR WHEEL, BEARING 30 X 55 X 13 (CARBON)

38 BEARING 30 X 55 X 13, REAR WHEEL,

CARBON

SEAL, OIL

4 CIRCLIP, REAR WHEEL, CARBON TO HOLD BEARING IN THE HUB

5 VALVE ASSY, ALUMIN, 90, REAR WHEEL,

CARBON

7 SPACER, REAR WHEEL, RHS, CARBON

6 SPACER, REAR WHEEL, LHS, CARBON

BALANCE WEIGHT

1 REAR WHEEL, CARBON FIBRE, BLACK ACCESSORY WHEEL FOR ALL MODELS


CARBON


SEAL, OIL


5 VALVE ASSY, ALUMIN, 90, REAR WHEEL, CARBON



BALANCE WEIGHT

1 REAR WHEEL, CARBON FIBRE SPARE FOR CSE-03/01 (OLD TITANIUM)


CARBON

3 REAR WHEEL, BEARING 30 X 55 X 13

(CARBON)

SEAL, OIL


5 VALVE ASSY, ALUMI, 90, REAR WHEEL, CARBON



BALANCE WEIGHT

8 SPROCKET CARRIER ASSY, TITANIUM FOR SPARES ONLY (OLD TITANIUM)

SPROCKET CARRIER, M/C, TITANIUM


10 RUBBERS, CUSH DRIVE, REAR WHEEL,

CARBON

8 SPROCKET CARRIER ASSY, BLACK STANDARD FOR CSE-01/03

SPROCKET CARRIER, M/C, BLACK

178

9 REAR WHEEL, BEARING 30 X 62 X 16

(CARBON)

10 RUBBERS, CUSH DRIVE, REAR WHEEL, CARBON

8 SPROCKET CARRIER ASSY, BLACK ACC FOR ALL MODELS

SPROCKET CARRIER, M/C, BLACK


10 RUBBERS, CUSH DRIVE, REAR WHEEL,

CARBON

11 BOLTS, CUSH DRIVE, CARBON TO CLAMP SPROCKET TO CARRIER

12 LOCKNUT, FLANGED, M10 X 1.25 55 TO CLAMP SPROCKET TO CARRIER

34 LOCKNUT, M10 X 1.5, GRADE 8 55 TO CLAMP SPROCKET TO CARRIER

SPOKED

35 WASHER, M10, 10.5 X 21 X 2, DIN 125A,

A2

SPROCKET TO CARRIER WASHERS

20 WHEEL ASSY, 5.5x17, SPOKE, POLISHED RIM

21 CUSH DRIVE ASSY, SPOKED REAR WHEEL,

BLACK

SPROCKET CARRIER FOR SPOKED WHEEL

29 SPACER, REAR WHEEL, RHS, SPOKED

30 BOLT, CUSH DRIVE, SPOKED

31 RUBBERS, CUSH DRIVE, SPOKED

26 BEARING 25 X 52 X 15 REAR WHEEL

27 SEAL, 32 X 52 X 7, REAR WHEEL


36 SPACER, CUSH DRIVE, SPOKED

33 CUSH DRIVE, MACHINED, BLACK

37 HUB ASSY, SPOKED REAR WHEEL, BLACK

32 HUB, REAR WHEEL, MACHINED, BLACK

26 BEARING 25 X 52 X 15, REAR WHEEL

24 SPACER, CENTRE, REAR WHEEL


28 SPACER, REAR WHEEL, LHS, SPOKED

20 WHEEL ASSY, 5.5x17, SPOKE, POLISHED

RIM

20 WHEEL ASSY, 5.5x17, SPOKE, BLACK RIM

13 SPINDLE, REAR WHEEL

14 LOCKNUT, THIN, M24 X 2 110 SPINDLE NUT

15 WASHER, M24, 25 X 44 X 4 BETWEEN NUT/SWING ARM + SPINDLE/SWING ARM

16 TYRE, REAR, 180/55 x 17,DUNLOP QUALIFIER, FR

set to 38 PSI

17 SPROCKET, REAR, 50T

22 INNER TUBE, 17 INCH, REAR FOR TUBELESS TYRE

23 TYRE PROTECTION BAND, 17 INCH, REAR, THERMO JOINED

18 CHAIN, FINAL DRIVE, 106L, 525 WITH 18/50 T GEARING (CHAIN CUT TO 106L)

19 SPLIT-LINK, CHAIN, 525

OIL SEAL, RK DRIVE CHAIN USE AS REQ'D - EXTRAS FOR ASSY

TYRE, WAX, CLEAR, 5KG

179

GREASE, SILKOLENE PRO RG2 APPLY TO WHEEL SPINDLE & SPACERS

182


TORQUE (NM) REMARKS

1 FRONT WHEEL ASSY, CARBON FIBRE, BLACK

STANDARD FRONT WHEEL FOR CSE-01/03

23 VALVE ASSY, ALUM, 90 SPARES ONLY

22 CIRCLIP, INT. DIA 42 SPARES ONLY

21 BEARING BALL, SPARES ONLY

20 SPACER, INTERNAL, ALUMINIUM SPARES ONLY

1 FRONT WHEEL ASSY, CARBON FIBRE, BLACK

ACCESSORY WHEEL FOR ALL MODELS

23 VALVE ASSY, ALUM, 90 SPARES ONLY

22 CIRCLIP, INT. DIA 42 SPARES ONLY

21 BEARING BALL, SPARES ONLY

20 SPACER, INTERNAL, ALUMINIUM SPARES ONLY

6 SPINDLE, FRONT WHEEL 60 SPINDLE FOR CONVENTIONAL FORKS

7 SPINDLE NUT

8 SPACER, PLAIN, FRONT WHEEL LHS

9 SPACER, PLAIN, FRONT WHEEL RHS

5 SPINDLE, FRONT WHEEL, USD FORKS, HIGH BARS

60 SPINDLE FOR USD FORKS

2 SPINDLE NUT. USD FORKS, HIGH BARS

183

3 SPACER, FRONT WHEEL, USD FORKS,

HIGH BARS LHS

4 SPACER, FRONT WHEEL, USD FORKS, HIGH BARS RHS

10 WHEEL ASSY, 3.5x17, SPOKE, POLISHED

RIM

18 HUB ASSY, SPOKED FRONT WHEEL, BLACK

19 SPACER, SPOKED FRONT WHEEL, INNER, RH

17 HUB, FRONT WHEEL, MACHINED, BACK

16 FRONT WHEEL, CENTRE SPACER

14 FRONT WHEEL, SEAL, 30 X 46 X 65 X (7)

15 FRONT WHEEL, BEARING, 25 X 47 X 12

11 INNER TUBE, 17 INCH, FRONT FOR TUBELESS TYRE

12 TYRE PROTECTION BAND, 17 INCH, FRONT, THERMO JOINED

11 INNER TUBE, 17 INCH, FRONT FOR TUBELESS TYRE

12 TYRE PROTECTION BAND, 17 INCH, FRONT, THERMO JOINED

13 TYRE, FRONT, 120/70 x 17, DUNLOP

QUALIFIER, FR set to 34 PSI

BALANCE WEIGHT

TYRE, WAX, CLEAR, 5KG

GREASE, SILKOLENE PRO RG2 APPLY TO WHEEL SPINDLE &

SPACERS

10 WHEEL ASSY, 3.5x17, SPOKE, POLISHED RIM

10 WHEEL ASSY, 3.5x17, SPOKE, BLACK RIM

184

Specifications


Rim runout: Axial 0.5mm or less 2mm Radial 0.8mmor less 2mm Axle runout/100mm 0.1mm or less 0.2mm Wheel balance 10 g or less - - -

Balance weights 10 g, 20 g, 30 g - - -

Tire tread depth: Front 3.5mm 2mm

Rear 5mm 2mm

Tire Air Pressure load Air Pressure (when cold)

Front - - - 2.34 bar (34psi)

Rear - - - 2.62bar (38psi)

Standard tire Front make, type Dunlop, Sportsmax Qualifier

Size 120/70 x 17

Rear make, type Dunlop, Sportsmax Qualifier

Size 180/55 x 17

185

Wheels

Front Wheel Removal

Remove:

Four front wheel calliper bolts [A].

Remove the brake callipers (axial and radial).

Support the front of the motorcycle by either supporting

the frame using a centre jack or using a front paddock

stand.

Slacken four pinch bolts [A].

Slacken Front wheel axle [B] off completely.

Remove the front wheel axle.

Note: When removing the front wheel axle take note of the order

and location of the wheel spacers, and support the front wheel.

Caution: Do not lay the front wheel on the ground with the disc facing down. This can damage or warp the

disc`s. Place blocks under the wheel so that the disc`s do not touch the ground.

Front Wheel Installation

Install the front wheel spacers [A] on to the wheel hub.

Apply a thin coat of copper past to the front wheel Axle.

Align the front wheel with the axle and insert the front

wheel axle.

Tighten the front wheel Axle.

Torque – Front Wheel Axle: 60Nm

Tighten the front wheel Pinch bolts.

Torque – Front Wheel Pinch bolts: 19Nm

Install Front Brake Callipers, Calliper Retainer Bolts [A]

(apply a thin coating of copper grease to bolt threads), and

tighten calliper bolts.

B

A

A

A

A

186

Torque – Front Calliper bolts: 35Nm

Check the front brake.

Warning: Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake

lever until the pads are against the disc. The brakes will not function on the first application of the lever if

this is not done.

Rear Wheel Removal

Remove Rear Axle Nut.

Using either a centre stand or a rear paddock stand lift

the rear wheel off the ground.

Remove the rear axle.

Push the wheel forwards in the motorcycle and remove

the chain from the sprocket.

Remove the rear wheel.

Caution: 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.

Rear Wheel Installation

Insert wheel into the rear of the bike, simultaneously

inserting the disc into the calliper, and mount the chain

on the rear sprocket.

Align the calliper carrier with the swing arm cut out and

insert the rear wheel axle.

Fix the washer and rear axle nut and tighten.

Torque – Rear Axle Nut: 110Nm

Adjust the drive chain (see Final Drive Chapter)

Check the rear brake effectiveness.

Warning: Do not attempt to ride the motorcycle until a full brake pedal is obtained by pumping the brake

pedal until the pads are against the disc. The brake will not function on the first application of the pedal if

this is not done.

Front Wheel Disassembly

Remove front wheel (see Front Wheel Removal).

A

187

Caution: Do not allow the wheel to rest on the brake disc, as this may damage the disc. Support the wheel on

wooden blocks, equally spaced around the rim, such that the brake disc is raised above ground. Lay the wheel on its

side while supporting the wheel on wooden blocks to prevent damage to the brake disc.

Remove and discard the seals and the bearing circlip (If applicable).

Warning: Always wear eye, hand and face protection when using a hammer and drift. Use of a hammer and drift can

cause bearings to fragment. Pieces of fragmented bearing could cause eye and soft

tissue injuries is suitable protective apparel is not worn.

Caution: To prevent wheel damage and to aid bearing removal, always apply forces

evenly on both sides of the bearing to prevent it from tipping and becoming stuck.

Application of uneven force will lead to difficulty in removing the bearing and to a

damaged wheel.

Using a suitable pin punch, through the centre of the wheel, drift out

the wheel bearings. Collect the centre sleeve.

Front Wheel Assembly

Using a suitable tool, ensuring the tool seats on the outer race of the bearing only, evenly and

progressively drive the new wheel bearings into the wheel hub up to the stop. Grease the inner

spacer with red grease.

Fit a new Circlip (if applicable).

Lubricate and fit new seals to the front wheel. Lubricate the seals knife-edge with grease.

Fit the front wheel (see Font Wheel Installation).

Rear Wheel Disassembly

Remove rear wheel (see Rear Wheel Removal).

Place the wheel on wooden blocks to prevent dame to the brake disc.

Caution: Do not allow the wheel to rest on the brake disc, as this may damage the disc. Support the wheel on

wooden blocks, equally spaced around the rim, such that the brake disc is raised above ground. Lay the wheel on its

side while supporting the wheel on wooden blocks to prevent damage to the brake disc.

Remove and discard the seals and the bearing circlips (if applicable).

Warning: Always wear eye, hand and face protection when using a hammer and drift.

Use of a hammer and drift can cause bearings to fragment. Pieces of fragmented

bearing could cause eye and soft tissue injuries is suitable protective apparel is not

worn.

188

Caution: To prevent wheel damage and to aid bearing removal, always apply forces evenly on both sides of the

bearing to prevent it from tipping and becoming stuck. Application of uneven force will lead to difficulty in removing

the bearing and to a damaged wheel.

Using a suitable pin punch, through the centre of the wheel, drift out the wheel bearings. Collect

the centre sleeve.

Rear Wheel Assembly

Using a suitable tool, ensuring the tool seats on the outer race of the bearing only, evenly and

progressively drive the new wheel bearings into the wheel hub up to the stop. Grease the inner

spacer with red grease.

Fit a new Circlip (if applicable).

Lubricate and fit new seals to the rear wheel. Lubricate the seals knife-edge with red grease.

Fit the rear wheel (see Rear Wheel Installation).

Wheel Inspection

Place the jack under the frame so that the front or rear

wheel is off the ground.

Spin the wheel lightly, and check for roughness or binding.

If roughness or binding is found, replace the hub bearings.

Visually inspect the front and rear axles for damage.

If the axle is damaged or bent, replace it.

Spoke Inspection

Check that all spokes are tightened evenly.

If spoke tightness is uneven or loose, torque the spoke nipples evenly.

Spokes should be tighten until; when struck with a tuning fork they emit a clean note, minimum

torque setting is only the lower limit.

Torque minimum: Spoke Nipples: 1.5Nm

Check the rim runout.

Warning: If any spoke breaks, it should be replaced immediately. A missing spoke places an additional load

on the other spokes, which will eventually cause other spokes to break.

Rim Inspection

Place the jack under the frame so that the front wheel or rear wheel is off the ground.

Inspect the rim for small cracks, dents, bending, or warping.

If there is any damage to the rim, it must be replaced.

Set a dial gauge against the side of the rim, and rotate the rim to measure the axial runout [A]. The

difference between the highest and lowest dial readings is the amount of runout.

Set a dial gauge against the outer circumference of the rim, and rotate, the highest and lowest dial

reading is the amount of runout.

189

If rim runout exceeds the service limit, check the wheel bearings first. Replace them if they are

damaged.

If the problem is not due to the bearings, correct the rim warp (runout). A certain amount of rim

warp can be corrected by recentering the rim on spoked wheels. Loosen some spokes and tighten

others within the standard torque to change the position of different parts of the rim. If the rim is

badly bent, however, it must be replaced.

Rim runout (with tire installed)

Standard: Axial 0.5mm Radial: 0.8mm

Service Limit: Axial 2mm Radial: 2mm

Axle Inspection

Place the axle in V blocks that are 100mm [A] apart, and set

a dial gauge on the axle at a point halfway between the

blocks.

Turn the axle to measure the runout. The difference

between the highest and lowest dial readings is the amount

of runout.

If runout exceeds the service limit, replace the axle.

Axle Runout/100mm

Standard: 0.1mm or less

Service Limit: 0.2mm

Wheel Balance

Note: To improve stability and decrease vibration at high speed, the front and rear wheels must be kept

balanced.

Check and balance the wheels when required, or when a tire is replaced with a new one.

Balance Inspection

Remove the wheel (see this chapter).

Support the wheel so that it can be spun freely.

Spin the wheel lightly, and mark [A] the wheel at the top

when the wheel stops.

Repeat this procedure several times. If the wheel stops of

its own accord in various positions, it is well balanced.

If the wheel always stops in one position, adjust the

wheel balance.

Balance Adjustment

190

If the wheel always stops in one position, provisionally attach a balance weight [A] on the rim at the

marking.

Rotate the wheel ¼ turn [B], and see whether or not the wheel stops in this position. If it does, the

correct balance weight is being used.

Attach a balance weight [A] loosely to the wheel rim.

If the wheel rotates and the weight goes up, replace the weight with the next heavier size. If the

wheel rotates and the weight goes down replace the weight with the nest lighter size. Repeat these

steps until the wheel remains at rest after being rotated ¼ turn.

Rotate the wheel another ¼ turn and then another 1/5 turn to see if the wheel is correctly

balanced.

Repeat the entire procedure as many times as necessary to achieve correct wheel balance.

Permanently install the balance weight.

Firmly press the balance weight on when finished.

Balance weights: 5g 10g 20g 30g

Note: Balance weights are available from Norton Dealers in 5, 10, 20, 30 gram sizes. An imbalance

of less than 5 grams will not usually affect running stability.

Do not use four or more balance weight (more than 90 gram). If the wheel requires an excess

balance weight, remove and disassemble the wheel to find the cause.

Tyre

Air Pressure Inspection/Adjustment

Using a tyre pressure gauge, measure the tyre pressure when the tyres are cold.

Adjust the tyre air pressure according to the following specifications, if necessary.

Air Pressure (when cold)

Front: 2.34bar (34psi)

Rear: 2.62bar (38psi)

Tyre Inspection

Note: As the tyre tread wears down, the tyre becomes more susceptible to puncture and failure. An

accepted estimate is that 90% of all tyre failures occur during the last 10% of tread life (90% worn).

So it is false economy and unsafe to use the tyres until they are bald.

Remove any imbedded stones or other foreign particles from the tread.

Visually inspect the tyre for cracks and cuts, replacing the tyre in the case of bad damage. Swelling

or high spots indicate internal damage, requiring tyre replacement.

Measure the tread depth at the centre of the tread with a depth gauge [A].

Take measurement at several places as the tyre may wear unevenly.

If any measurement is less than the service limit, replace the tyre.

191

Tread Depth

Front: Standard: 3.5mm

Service Limit: 2mm (legal Limit UK 1mm)

Rear: Standard: 5mm

Service Limit: 2mm (Legal Limit UK 1mm)

Note: To ensure safe handling and stability, use only the recommended standard tyres for

replacement, inflated to the standard pressure.

Check and balance the wheel when a tyre is replaced with a new one.

Standard tyre

Front: Make: Dunlop

Type: Sportsmax Qualifier

Size: 120/70 X 17

Rear Make: Dunlop

Type: Sportsmax Qualifier

Size: 180/55 X 17

Tyre Removal

Caution: 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 the wheel from the motorcycle (see this chapter).

To maintain wheel balance, mark the valve stem position

on the tire with chalk so that the tire can be reinstalled in

the same position.

Take out the valve core to let the air out.

When handling the rim, be careful not to damage the rim

flanges.

Lubricate the tyre beads and rim flanges on both sides with

a soap and water solution or rubber lubricant. This helps

the tyre beads slip off the rim flanges.

Caution: Never lubricate with mineral oil (engine oil) or gasoline

because they will cause deterioration.

Break the beads away from both sides of the rim with a bead breaker.

Protect the rim with rim protectors , pry the tyre off.

192

Tyre Installation

Check the tyre rotation mark on the front and rear tyre

and install it on the rim accordingly.

Note: the direction of the tire rotation is shown by an

arrow on the tire sidewall.

Position the tire on the rim so that the valve is at the tire

balance mark (the chalk mark made during removal or

the yellow paint mark on a new tire).

Check and adjust the air pressure after installing.

Hub Bearings (Wheel Bearings)

Bearing Removal

Remove the wheel, take out the following:

Collar(s)

Coupling (rear hub)

Grease Seals

Circlip

Take the bearings out of the hub, using bearing remover.



Bearing Installation

Before Installing the wheel bearings, blow any dirt or foreign particles out of the hub with

compressed air to prevent contamination of the bearings.

Replace the bearings with new ones.

Press in the bearings until they bottom out.

Note: Install the Bearing so that the marked side or sealed side faces out.

Install:

o New Circlip

o Collar

o Right Bearing

o Left Bearing

Replace the grease seals with new ones.

Apply high temperature grease to the grease seal lips.

Press in the grease seal so that the seal surface is flush with the end of the hole.

193

Bearing Inspection

Since the hub bearings are made to extremely close tolerances, the clearance cannot normally be

measured.

Caution: Do not remove any bearings for inspection. If any bearings are removed, they will need to be

replaced with new ones.

Turn each bearing in the hub back and forth [A] while checking for play, roughness, or binding. If

bearing play, roughness, or binding is found, replace the bearing.

Examine the bearing seal [B] for damage or leakage.

If the seal is damaged or is leaking, replace the bearing.

194

Final Drive

Exploded View ................................................................................................................................................ 188

Specification ................................................................................................................................................... 189

Drive Chain ..................................................................................................................................................... 190

Chain Slack Inspection ....................................................................................................................... 190

Chain Slack Adjustment ..................................................................................................................... 190

Chain Wear Inspection ....................................................................................................................... 191

Chain Lubrication ............................................................................................................................... 191

Chain Removal ................................................................................................................................... 192

Chain Installation ............................................................................................................................... 192

Sprocket, Coupling ......................................................................................................................................... 192

Engine Sprocket Removal ................................................................................................................... 192

Engine Sprocket Installation............................................................................................................... 193

Rear Sprocket Removal ...................................................................................................................... 193

Rear Sprocket Installation .................................................................................................................. 193

Rear Sprocket, Coupling Removal ...................................................................................................... 194

Rear Sprocket, Coupling Installation .................................................................................................. 194

Sprocket Wear .................................................................................................................................... 194

Rear Sprocket Warp ........................................................................................................................... 194

Damper Inspection ............................................................................................................................. 194

Coupling Bearing Removal ................................................................................................................. 195

Coupling Bearing Inspection, lubrication ........................................................................................... 195

Damper (Cush Drive) Inspection .................................................................................................................... 195

Chain Guard ................................................................................................................................................... 195

Chain Guard Removal ......................................................................................................................... 195

Chain Guard Installation..................................................................................................................... 195

Chain Guard Inspection ...................................................................................................................... 195

195

Exploded View

196


TORQUE (NM) REMARKS

1 SWINGARM, FABRICATED, XM

2 BEARING, FULL COMPLIMENT ROLLER,

30 37 26

3 BEARING CARRIER, SWINGARM

4 SEAL, SWINGARM, RH 23 X 40 X 6

5 SLEEVE, GROUND

6 END PLATE, WHEEL ADJUSTERS

7 ADJUSTER BLOCK, REAR WHEEL

8 BOLT, CAP HD, M8 X 90 X 1.25 REAR WHEEL ADJUSTERS

9 SPRING WASHER, M8

BETWEEN BOLT AND REAR WHEEL ADJUSTER

10 SPINDLE, SWING ARM

GREASE, SILKOLENE PRO RG2 APPLY TO SWINGARM SPINDLE

11 LOCKNUT, THIN, M16 X 1.0 60

12 WASHER, M16, 17 X 30 X 2 BETWEEN NUT AND FRAME

13 ADJUSTER PLATE, REAR WHEEL, XM WRAP AROUND SWING ARM USED AS REFERENCE

14 SPACER, SWINGARM, INTERNAL

15 SPACER, SWINGARM, EXTERNAL

16 BEARING, BALL, SEALED, 17 40 12

17 CIRCLIP, INT, 40 X 1.75

18 SEAL, SWINGARM, LH 30 X 45 X 5

19 THREADED ADJUSTER, SWINGARM 6

20 RUBBING STRIP, CHAIN

21 COMPRESSION LIMITER, M6 MOUNTS IN CHAIN RUBBING STRIP

22 BOLT BUTTON HD, INT HEX M5 X 20 X

0.8 9 USED TO MOUNT CHAIN RUBING STRIP

23 RSU, LH

24 RSU, RH

25 BOLT, BUTTON HD, INT HEX, FLANGED,

M8 X 16 X 1.25 22 RSU'S TO FRAME

26 WASHER, PENNY, M8 X 30 X 1.6MM WASHER RSU MOUNT

Specification


Drive Chain: Standard Chain: Make REGINA - - - Type REGINA 525 (137ZRP) Z-RING - - -

Link 106LINKS - - - Chain Slack 35 ~ 40 mm Too tight: less than 30mm

Too loose: more than

45mm 20-link length 317.5 ~ 318.2 mm 323 mm Sprockets:

197

Rear sprocket warp 0.4 mm or less 0.5 mm

Drive Chain

Chain slack Inspection

Set the motorcycle up on its side stand.

Check to see that the notches [A] on the chain adjusters

[B] on both sides are in the same relative position.

If they are not, adjust the chain slack and align them.

Warning: Misalignment of the wheel will result in abnormal

wear and may result in an unsafe riding condition.

Note: Clean the chain if it is dirty, and lubricate it if it appears

dry.

Check the chain slack.

Turn the rear wheel to find the position where the chain

is tightest.

Measure the spacer (chain slack) [A] between the chain

and the step of the chain slipper as shown.

Chain Slack

Standard: 35 ~ 40 mm

Too Tight: Less than 35 mm

Too Loose: More than 45 mm

If the chain slack exceeds the standard, adjust it.

Chain Slack Adjustment

Loosen the axle nut [A].

Turn the chain adjusters [B] evenly until the drive chain has

the specified amount of slack.

Check to see that the notches [C] on both sides are in the

same relative position.

Warning: Misalignment of the rear wheel will result in abnormal

wear and may result in an unsafe riding condition.

Tighten the rear axle nut.

Torque – Rear Axle Nut: 110Nm

A

B

198

Returning call

Warning: If the axle nut is not securely tightened, an unsafe riding condition may result.

Turn the wheel, measure the chain slack again at the tightest position, and readjust if necessary.

Check the rear brake effectiveness.



this is not done.

Chain Wear Inspection

Rotate the rear wheel to inspect the drive chain for

damage rollers, and loose pins and links.

If there is any irregularity, replace the drive chain.

Lubricate the drive chain if it appears dry (see this

chapter).

Stretch the chain taut by hanging a (10kg) weight [A] on

the chain.

Measure the length of 20 links [B] on the straight part [C]

of the chain from the pin centre of the 1st pin to the pin

centre 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.

Chain 20-Link Length

Standard: 317.5 ~ 318.2 mm

Service Limit: 323 mm

Warning: If the drive chain wear exceeds the service limit, replace the chain or an unsafe riding condition

may result. A chain that breaks or jumps off the sprocket could snag on the engine sprocket or lock the

rear wheel, severally damaging the motorcycle and causing it to go out of control.

Standard chain

Make: REGINA

Type: REGINA 525 (137ZRP) Z-RING

Link: 106 links

Chain Lubrication

If the chain is especially dirty, it should be washed in diesel oil or kerosene, and afterward soaked in

heavy oil. Shake the chain while it is in the oil so that oil will penetrate to the inside of each roller.

199

An effective, good quality lubricant specially formulated for chains is best for regular chain

lubrication.

If a special lubrication is not available, heavy oil such as SAE 90 is preferred to lighter oil because it

will stay on the chain longer and provide better lubrication.

Caution: The O-rings between the side plates seal in the lubricant between the pin and the bushing. To

avoid damaging the O-rings and resultant loss of lubricant, observe the following rules.

Use only kerosene or diesel oil for cleaning an O-ring drive chain. Any other cleaning solution such as

gasoline or trichloroethylene will cause deterioration and swelling of the O-rings. Immediately blow the

chain dry with compressed air after cleaning. Complete cleaning and drying the chain within 10 minutes.

Apply the oil to the sides of the rollers so that the oil will

penetrate to the rollers and bushings. Apply oil to the O-

rings so that the O-rings will be coated with oil.

Wipe off any excess oil.

Oil Applied Areas [A] O-ring [B]

Chain Removal

Remove:

Engine Sprocket Cover (see this chapter).

Chain Guard (see this chapter).

Foot Control Plate (see Chassis chapter).

Rear Suspension Upright RH (see Suspension chapter).

Fully slacken off the chain (see this chapter).

Remove the drive chain from the chassis, being careful that the chain does not get dirty from

contact with the ground.

Chain Installation

Fit the drive chain back onto the sprockets.

Install:

Engine Sprocket Cover (see this chapter).

Chain Guard (see this chapter).

Foot Control Plate (see Chassis chapter).

Rear Suspension Upright RH (see Suspension chapter).

Adjust the drive chain slack (see Chain Slack Adjustment).

Sprocket, Coupling

Engine Sprocket Removal

Remove Engine Sprocket Cover [A]

Bend the lockwasher tab up.

Select first gear and apply the rear brake.

200

Loosen the engine sprocket nut [A].

Fully slacken off the chain (see this chapter).

Pull off the engine sprocket with the chain then separate the sprocket from the chain.

Engine Sprocket Installation

Install the engine sprocket [A] as shown, noting the proper direction.

Replace the sprocket lockwasher.

Warning: Incorrect installation of the engine sprocket could cause misalignment of the wheel, abnormal

wear, resulting in an unsafe riding condition.

Torque – Engine Sprocket Nut: 122Nm

Bend the lockwasher tab over the nut.

Install the chain guide [A] as shown.

Apply a non-permanent locking agent to the bolt [B]

shown.

Adjust the drive chain (see this chapter).

Rear Sprocket Removal

Remove the rear wheel (see Wheels/Tires chapter).

Caution: 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.

Unscrew the rear sprocket bolts [A] and nuts, then

remove the rear sprocket [B]

Rear Sprocket Installation

Install the rear sprocket [A] facing the tooth number

marking [B] outwards.

Torque – Rear Sprocket Nuts: 55 Nm

Install the rear wheel (see Wheels/Tires chapter).

B

A

201

Rear Sprocket, Coupling Removal

Remove the rear wheel (see Wheels/Tires chapter).



Pull out the rear wheel coupling from the rear wheel.

Remove the rear sprocket nuts to separate the rear sprocket from the wheel coupling (see this

chapter).

Rear Sprocket, Coupling installation

Check the following and install the coupling.

Bearing [A]

Install the sprocket facing the tooth number marking

outward.

Torque – Rear sprocket nuts: 55 Nm

Install the rear wheel (see Wheels/ Tires chapter).

Sprocket Wear

Visually inspect the engine and rear sprocket teeth.

If the teeth are worn as illustrated, replace the sprockets,

and inspect the drive chain (see Drive Chain wear

Inspection).

Caution: If a sprocket requires replacement, the drive chain is

probably worn also. Upon replacing the rear sprocket, inspect the

chain and engine sprocket.

Note: Sprocket wear is exaggerated for illustration.

Worn Tooth (engine Sprocket) [A]

Worn Tooth (Rear Sprocket) [B]

Direction of Rotation [C]

202

Rear Sprocket Warp

Raise the rear wheel off the ground (see Wheels/Tires chapter) so that it will turn freely.

Set a dial gauge against the rear sprocket near the teeth as shown. Turn the rear wheel. 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



Coupling Bearing Removal

Pull out the coupling collar from the wheel.

Remove the circlip.

Using the bearing drive set or some other suitable tool,

remove the bearing by tapping from the wheel side.

Coupling Bearing Inspection, Lubrication

Caution: Do not remove the bearing for inspection or lubrication.

Turn the bearing back and forth while checking for

play, roughness, or binding. If bearing play, roughness,

or binding is found, replace the bearing.

Damper Inspection

Remove the rear wheel coupling, and inspect the

rubber dampers [A].

Replace the damper if it appears damaged or

deteriorated

Chain guard removal

Remove chain guard retainer screws.

Remove chain guard

Chain Guard Installation

Install chain guard and tighten screws

Chain Guard Inspection

Visually inspect the chain guard for wear cracks and damage replace if neccessary

203

Brakes

Exploded View ................................................................................................................................................ 198

Specification ................................................................................................................................................... 206

Brake Lever, Brake Pedal ............................................................................................................................... 207

Brake Lever Play Adjustment ............................................................................................................. 207

Brake Pedal Position Adjustment ...................................................................................................... 207

Brake Pedal Removal ......................................................................................................................... 207

Brake Pedal Installation ..................................................................................................................... 207

Brake Fluid ..................................................................................................................................................... 208

Brake Fluid Recommendation ............................................................................................................ 208

Brake Fluid Level Inspection .............................................................................................................. 209

Brake Fluid Changing ......................................................................................................................... 209

Brake Line Air Bleeding ...................................................................................................................... 210

Calipers ........................................................................................................................................................... 211

Front Calipers Removal ...................................................................................................................... 211

Rear Caliper Removal ......................................................................................................................... 211

Front Calipers Installation .................................................................................................................. 211

Rear Caliper Installation ..................................................................................................................... 211

Front Calipers Disassembly ................................................................................................................ 212

Rear Caliper Disassembly ................................................................................................................... 212

Caliper Assembly ................................................................................................................................ 212

Caliper Fluid Seal Damage.................................................................................................................. 213

Caliper Dust Seal ................................................................................................................................ 213

Caliper Piston and Cylinder Damage .................................................................................................. 213

Brake Pads ...................................................................................................................................................... 213

Front Brake Pads Removal ................................................................................................................. 213

Rear Brake Pads Removal .................................................................................................................. 214

Rear Brake Pads Installation .............................................................................................................. 214

Rear Brake Pads Installation .............................................................................................................. 214

Brake Pad Wear Inspection ................................................................................................................ 214

Brake Master Cylinder ................................................................................................................................... 215

Front Master Cylinder Removal ......................................................................................................... 215

Front Master Cylinder Installation ..................................................................................................... 215

Rear Master Cylinder Removal .......................................................................................................... 215

Rear Master Cylinder Assembly ......................................................................................................... 215

Master Cylinder Assembly ................................................................................................................. 215

Master Cylinder Visual Inspection ..................................................................................................... 215

Brake Discs ..................................................................................................................................................... 217

Front Disc Installation ........................................................................................................................ 217

Rear Disc Installation .......................................................................................................................... 217

Disc Wear ........................................................................................................................................... 217

Disc Cleaning ...................................................................................................................................... 217

204

Disc warp Inspection .......................................................................................................................... 218

Brake Hoses .................................................................................................................................................... 218

Brake Hose Removal .......................................................................................................................... 218

Brake Hose Installation ...................................................................................................................... 218

Brake Hose Inspection ....................................................................................................................... 218

205

Exploded View

210


TORQUE (NM) REMARKS

20 BRAKE LEVER ASSY, AXIAL

STANDARD FOR CSE, CCR, ROW COM/CMM

21 LEVER, BRAKE, REMOTE RESERVOIR

22 RESERVOIR, MASTER CYL, FRONT BRAKE RESERVOIR

55 FRONT BRAKE LIGHT SWITCH

79 LEVER ASSY, BRAKE, INTEGRAL

RESERVOIR, HIGH BARS

STANDARD LEVER FOR COM-01 AND

CDS-01



ACCESSORY FITMENT


81 BOLT, M6 X 25 X 1.0, CP HD, GOLD 8 HALF CLAMP BOLTS

82 HALF CLAMP, FRONT, VERTICAL REPLACES STD CLAMP FROM BREMBO

78 FLY LEAD, BRAKE LIGHT SWITCH, INTEGRAL RESERVOIR

INTEGRAL RESERVOIR ONLY,

29 SCREW, UPPER, M/CYL RES MOUNT KIT

TO CLAMP BRAKE RESERVOIR TO

BRACKET

28 DUMPER, M/CYL RES MOUNT KIT

RUBBER GROMMET FOR MASTER CYLINDER

32 NUT, M/CYL RES MOUNT KIT NUT USED TO CLAMP RESERVOIR TO BRACKET

69 CLIP, M/CYL RES MOUNT KIT USED WITHIN FRONT AND REAR

31 HOSE, FRONT BRAKE M/CYL RESERVOIR USED FOR FRONT BRAKE ONLY

30 HOSE, FRONT BRAKE M/CYL RESERVOIR, CLIP-ONS

USED FOR FRONT BRAKE CAFE RACER ONLY

24 BRACKET, BRAKE RESERVOIR, XM FRONT BRAKE RESERVOIR BRACKET

23 BRACKET, BRAKE RESERVOIR, CLIP-ONS, XM

FRONT BRAKE RESERVOIR BRACKET, CR

25 BOLT, CAP HD, M6 X 12 X 1.0 6 BRACKET TO MASTER CYLINDER

91 LEVER ASSY CLUTCH GOLD LEVER ASSY, (REMOTE

RESERVOIRS)

92 LEVER, CLUTCH, REMOTE RESERVOIR

93 BRACKET, CLUTCH RESERVOIR, CLIP-ONS, XM

CAFE RACER ONLY BRACKET TO MASTER CYLINDER

94 BRACKET, CLUTCH RESERVOIR, XM BRACKET TO MASTER CYLINDER

25 BOLT, CAP HD, M6 X 12 X 1.0 8

55 RESERVOIR, MASTER CYL, REAR USED FOR CLUTCH RESERVOIR

95 HOSE, CLUTCH M/CYL RESERVOIR HOSE FOR RESERVOIR TO CYLINDER

96 BOLT, CAP HD, M5 X 12 X 0.8 RESERVOIR TO BRACKET

97 LOCKNUT, FLANGED, M5 X 0.8 7 RESERVOIR TO BRACKET

98 HOSE, FRONT CLUTCH M/CYL RESERVOIR,

CLIP-ONS

CAFE RACER RESERVOIR HOSE

(SHORTER)

99 LEVER ASSY, CLUTCH, INTEGRAL

RESERVOIR, HIGH BARS

SPORT AND DUAL SEAT LEVER ASSY (BLACK)


99 LEVER ASSY, CLUTCH, INTEGRAL

RESERVOIR, HIGH BARS ACCESSORY FITMENT


101 SLAVE CYLINDER, CLUTCH

211

102 BOLT, CAP HD, M6 X 16 X 1.0 12 TO CLAMP SLAVE CYLINDER TO SPROCKET COVER

68 HYDRO STOP, REAR M/CYL REAR BRAKE LIGHT SWITCH

59 HYDRAULIC LINE KIT, USD FORKS, HIGH

BARS CSE-03 KIT ONLY






62 BANJO BOLT WITH BLEED NIPPLE 10MM X

1MM SPARES ONLY








70 HYDRAULIC LINE KIT, CONVENTIONAL

FORKS, AXIAL CALIPERS HYDRAULIC LINE KIT COM-01, CMM-03, CSE-

01, CSE-02







65 MODIFIED BANJO, 90', COMPOUND BEND

SPARES ONLY (AXIAL CALIPERS ONLY)







71 HYDRAULIC LINE KIT, USD FORKS, CLIP ONS CCR-01/02 KIT ONLY







62 BANJO BOLT WITH BLEED NIPPLE 10MM X

1MM SPARES ONLY






212


75 CLIP, BRAKE LINE USED WITH 6MM HOLE IN MUDGUARD, USD ONLY

76 WIRE GUIDE, BRAKE HOSE

77 BOLT, CAP HD, M6 X 1.0 TO CLAMP WIRE GUIDE TO YOKE

90 WASHER, PENNY, M6, 6.4 X 18 X 1.6 BETWEEN BOLT AND WIRE GUIDE

5 CALIPER ASSY, AXIAL, LH GOLD FINISH







83 CALIPER ASSY, AXIAL, RH GOLD FINISH







1 DISC, FRONT, 320 MM 320 mm



3 SPACER, FRONT DISC

13 BOLT, CALIPER, RADIAL 35 TO CLAMP CALIPER TO FORK

12 CALIPER BRACKET, LH

84 CALIPER BRACKET, RH

13 BOLT, CAP HD, M10x20x1.25 35 BRACKET TO FORK

85 BOLT, CAP HD, M10x30x1.25 35 CALIPER TO BRACKET

104 CALIPER ASSY, RADIAL, LH



8 PAD REATINER, CALIPER, RADIAL


10 PAD SET, CALIPER

4 CALIPER ASSY, RADIAL, RH





10 PAD SET, CALIPER

46 M/CYL ASSY, REAR M/CYL FOR ALL MODELS

49 HEEL GUARD, RH, XM

50 BRACKET, BRAKE RESERVOIR, REAR, STEEL,

PRESSED, XM

51 BOLT, CAP HD, M6 X 20 10 HEEL GUARD TO HANGER

45 HOSE, REAR M/CYL RESERVOIR BLACK RESERVOIR HOSE

213

Specification

Brakes


Brake Lever, Brake Pedal: Brake lever free play Non-adjustable - - - Pedal free play Adjustable (to suit rider) - - -

Brake lever position Adjustable (to suit rider) - - -

Brake Fluid: Grade D.O.T. 4 / D.O.T. 3 - - -

Brand Fuchs Silkolene

Specification FMVSS 116 D.O.T. 4, D.O.T. 3, ISO 4925 AND SAE J 1703, (or above)

Brake Pads: Lining Thickness: Front (Radial Calipers) 4.5mm 1mm Front (Axial Calipers) 5.5mm 1mm

Rear 3.5mm 1mm

Brake Disc: Thickness:

55 RESERVOIR, MASTER CYL, REAR

47 BOLT, CAP HD, M6 x 10 8 TO CLAMP RESERVOIR TO BRACKET

48 ROD ASSY, REAR MASTER CYLINDER REAR BRAKE M/CYL PUSH ROD

90 NUT, M6 X 1.0, PLAIN USED TO LOCK ROD ASSY TO CLEVIS

56 CLEVIS, MASTER CYLINDER USED ON THE END OF ROD ASSY

52 CLEVIS PIN, BRAKE PEDAL, SPRING CLAMP LINK BETWEEN PLATE AND ROD ASSY

86 P-CLIP, 8MM

SUPPORT FOR BRAKE LINE TO SWING ARM

87 BOLT, CAP HD, M5 X 15 X 0.8 7 CLAMP P CLIP TO SWINGARM

88 WASHER, M5, 5.3 X 10 X 1 BETWEEN BOLT AND P CLIP

40 CALIPER ASSY, REAR, 34MM, GOLD GOLD FINISH

39 PADS, BRAKE, REAR, 34MM

38 PISTON SET, CALIPER, REAR

37 SEAL KIT, REAR, CALIPER

41 BLEED SCREW, REAR CALIPER

42 HANGER PIN, REAR CALIPER

89 SPRING, PAD RETAINER, REAR CALIPER

36 CALIPER CARRIER, REAR

43 BOLT, CAP HD, M8 X 20 X 1.25 28 REAR CALIPER TO CARRIER

35 DISC, REAR

44 BOLT, BUTTON HEAD, INT HEX, M10 X 20 43 DISK, PATCHLOCKED

PADS, BRAKE, REAR, SINTERED. TO BE USED WITH 32MM REAR CALIPER

214

Front 4mm ± 0.15 3.3mm Rear 5mm ± 0.15 4.3mm

Runout 0.2 mm or less 0.3mm

Brake Lever, Brake Pedal

Brake Lever Adjustment

Adjust the front brake lever [A] to suit you.

Pull the lever [A] out and turn adjust [B] to either side to

adjust position.

Brake Pedal Free Play Adjustment

Loosen the locknut [A] on the push-rod [B] and turn the rod either way to increase or decrease free

play.

Tighten the locknut.

Torque – Locknut brake lever pushrod: 18Nm

Warning: Always maintain proper brake adjustment. If adjustment

is improper, the brake could drag and overheat. This could

damage the brake assembly and possibly lock the wheel resulting

in loss of control.

Brake Pedal Removal

Remove:

Locknut [A]

Anti rotation washer [B] from back of foot control plate.

Pushrod from rear master cylinder.

Brake Pedal Installation

Ensure shaft bearing surface is clean and free from corrosion.

Install:

Anti rotation washer

Pedal locknut

B

A B

A

B

A

215

Pushrod into rear master cylinder

Tighten locknut.

Torque – Pedal Locknut: 43Nm

216

Brake Fluid

Warning: When working with the disc brakes, observe the precautions listed below.

Never reuse old brake fluid.

Do not use fluid from a container that has been left

unsealed or that has been open for a long time.

Do not mix two types and brands of fluid for use in the

brakes. This lowers the brake fluid boiling point and could

cause the brake to be ineffective. It may also cause the

rubber brake parts to deteriorate.

Don`t leave the reservoir cap [A] off for any length of time

to avoid moisture contamination of the fluid.

Don`t change the fluid in the rain or when a strong wind is blowing.

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.

When handling the disc pads or discs, be careful that no disc brake fluid or any oil gets on them.

Clean off any fluid or oil that inadvertently gets on the pads or discs with a high-flash point solvent.

Do not use one which will leave an oily residue. Replace the pads with new ones if they cannot be

cleaned satisfactorily.

Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away

immediately.

If any brake line fittings or the bleed valve is opened at any time, the AIR MUST BE BLED FROM THE

BRAKE.

Brake Fluid Recommendation

Note: Recommended fluids are given in the table below. If none of the recommended fluids are available,

use extra heavy-duty brake fluid only from a container marked D.O.T. 3 OR 4.

NOTE: Brake fluid of D.O.T. 4 is installed in the brake system when shipped.

Brake Fluid:

Grade D.O.T. 4 / D.O.T. 3

Brand Fuchs Silkolene

Specification FMVSS 116 D.O.T. 4, D.O.T. 3, ISO 4925 AND SAE J 1703, (or above)

A

217

Brake Fluid Level Inspection

In accordance with the Periodic Maintenance Chart, inspect the brake fluid level in the front and rear

brake fluid reservoir

Check the front and rear brake fluid reservoir level is above

the lower line [A] and below the upper line [B].

Hole the reservoir when checking brake fluid level.

Warning: Change the fluid in the brake line completely if the fluid

must be refilled but the type and brand of the fluid that already is in

the reservoir are unidentified.

If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [A] in the

reservoir with the same type and brand of the fluid that already is in the reservoir.

Brake fluid changing

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.

Remove the reservoir cap.

Attach a clear plastic hose to the bleed valve on the caliper, and run the other end of the hose into

a container.

Fill the reservoir with new brake fluid.

Change the brake fluid as follows:

Open the bleed valve [A].

Apply the brake lever and hold it [B].

Close the bleed valve [A].

Release the brake lever [B].

Check the fluid level in the reservoir often, replenishing it

as necessary.

Note: If the fluid in the reservoir runs completely out any time during fluid changing, air will enter the line,

and the system must be bled.

Repeat this operation until fresh fluid comes out into the

plastic hose or the colour of the fluid changes.

Warning: Do not mix two brands of 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.

A

B

A

A

218

Torque – Bleed Valves: 7.8Nm

Apply the brake lever forcefully for a few seconds, and check for fluid leakage around the fittings.

Warning: If the brake lever or pedal has a soft or “spongy feeling” when it is applied, there might be air in

the brake line or the brake may be defective. Since it is dangerous to operate the motorcycle under such

conditions, bleed the air from the brake line immediately.

Brake Line Air Bleeding

Note: The procedure to bleed the front brake line is as follows. Bleeding the rear brake line is the same as

for the front brake.

Bleed the air whenever brake parts are replaced or reassembled.

Remove the reservoir cap and fill the reservoir with new

brake fluid.

Slowly pump the brake lever several times until no air

bubbles can be seen rising up through the fluid from the

hose at the bottom of the reservoir. This bleeds the air

from the mast cylinder and the brakes line.

Note: Tap the brake hose lightly going from the caliper to the

reservoir side and bleed the air off at the reservoir.

Attach a clear plastic hose to the bleed valve on the caliper, and run the other end of the hose into

a container.

Bleed the brake line and caliper as follows:

Hold the brake lever applied [A].

Quickly open and close the valve [B].

Release the Brake Level [A].

The fluid lever must be checked several times during

bleeding operation and replenished as necessary.

Note: If the fluid in the reservoir runs completely out any time

during bleeding, the bleeding operation must be done over

again from the beginning since air will have entered the line.

If the brake lever or pedal action still feels soft or “spongy”, tap the brake hose from bottom to top and air

will rise up to the top part of the hose. Slowly pump the brake lever or pedal in the same manner as above.

Torque – Bleed Valves: 8 Nm

Apply the brake lever forcefully for a few seconds, and check for fluid leakage around the fittings.

A

B

219

Front Caliper Removal

Drain the front brake fluid (see Brake Fluid Change).

Remove banjo bolt [A].

Remove caliper bolts [B] and take off the caliper [C].

If the caliper is to be disassembled after removal and if

compressed air is not available, remove the pistons

using the following steps before disconnecting the brake

hose from the caliper.

Remove the pads (see Brake Pad Removal).

Insert a wooden board 5mm thick inside the caliper

opening (see this chapter).

Pump the brake lever until the pistons push the wooden

board.

Remove the caliper.

Remove the board and pull out the pistons by hand.

Caution: Immediately wash away any brake fluid that spills.

Rear Caliper Removal

Drain the rear brake fluid (see Brake Fluid Change).

Remove banjo bolt [A].

Remove the caliper bolts [B].

Take off the caliper [C].

If the caliper is to be disassembled after removal and if

compressed air is not available, remove the piston using

the following steps before disconnecting the brake hose

from the caliper.

Remove the pads.

Pump the brake pedal to remove the piston.

Caution: Immediately wash away any brake fluid that spills.

Caliper Installation

Tighten the caliper bolts.

Torque – Caliper bolts: 35Nm

Connect the brake hose to the caliper putting a new flat washer on each sie of the brake hose

fitting.

Tighten the banjo bolt.

A B

C

B

C

A

B

A C

220

Torque – Banjo Bolt: 25Nm

Check the fluid level in the master cylinder (reservoir) and bleed the brake line (see Bleeding the

Brake).

Check the brake for good braking power, no brake drag, and no fluid leakage.

Warning: Do not attempt to ride the motorcycle until a full brake lever or pedal is obtained by pumping the

brake lever or pedal until the pads are against each disc. The brakes will not function on the first

application of the lever or pedal if this is not done.

Front Caliper Disassembly

Remove the front caliper (see Front Caliper Removal).

Remove the pads and spring (see Pad Removal).

Insert a wooden board 5 mm thick inside the caliper

opening.

Lightly apply compressed air to the hose joint opening

until the pistons hit the wooden board.

Remove the board and pull out the pistons by hand.

Warning: To avoid serious injury, never place your fingers or

palm inside the caliper opening. If you apply compressed air into

the caliper, the piston(s) may crush your hand or fingers.

Remove the dust seal(s) and fluid seal(s)

Rear Caliper Disassembly

Remove the caliper (see Caliper Removal).

Remove the pads and spring (see Pad Removal).

Using compressed air, remove the piston.

Cover the caliper opening with a clean, heavy cloth.

Remove the piston by lightly applying compressed air to

the hose joint.

Warning: To avoid serious injury, never place your fingers or palm inside the caliper opening. If you apply

compressed air into the caliper, the piston may crush your hand or fingers.

Remove the dust seal and fluid seal.

Caliper Assembly

It is recommended that the fluid seal, which is removed, be replaced with a new one.

221

Replace the dust seals if they are damaged.

Install the fluid seal. Either side of the seal may face outboard.

Apply brake fluid to the cylinders, pistons, and fluid seals (piston seals), and push the pistons into

the cylinders by hand. Take care that neither the cylinder nor the piston skirt gets scratched.

Install the anti rattle spring in the caliper.

Install the pads (see Brake Pad Installation).

Caliper Fluid Seal Damage

Note: The fluid seals around the piston maintain the proper pad/disc clearance. If the seals are not

satisfactory, pad wear will increase, and constant pad drag on the disc will raise brake and brake fluid

temperature.

Replace the fluid seals under any of the following

conditions: (a) fluid leakage around the pads; (b) Brakes

overheat (c) there is a large difference in inner and

outer pad wear; (d) the seal is stuck to the piston.

If the fluid seal is replaced, replace the dust seal as well.

Also, replace all seals every other time the pads are

changed.

Caliper Dust Seal

Check that the dust seal is no cracked, worn, swollen, or

otherwise damaged.

If they show any damage replace them.

Caliper Piston and Cylinder Damage

Visually inspect the piston and cylinder surfaces.

Replace the caliper if the cylinder and piston are badly

scored or rusty.

Brake Pads

Front Brake Pad Removal Axial

Remove the Front Brake Caliper bolts [A].

Remove the r-clips [B].

Remove the pad retainer shafts [C].

Remove the brake pads from the inner side.

Front Brake Pad Removal Radial

A

B

A

C

B D

222

Remove the Front Brake Caliper bolts [A].

Push the anti-vibration spring [B] down and pull the pad retainer pins [C] out.

Repeat for each pad.

Remove the brake pads [D] from the inner side.

Rear Brake Pad Removal

Remove the Rear Brake Caliper bolts [A].

Remove the Caliper from the disc with the hose left

installed.

Remove the c-clip [B] on the pad retainer spring pin [C].

Remove the pad retainer spring pin [C].

Remove the pad retainer spring [D].

Remove the rear brake pads [E].

Brake Pad Installation

Before installation, clean the pads with a high-flash point

solvent.

Push the caliper pistons in by hand as far as they will go,

and then install the pads.

Warning: Do not attempt to ride the motorcycle until a full

brake lever or pedal is obtained by pumping the brake lever or

pedal until the pads are against each disc. The brake will not

function on the first application if this not done.

Brake Pad Wear Inspection

Note: In accordance with the periodic Maintenance Chart,

inspect the brake pads for wear.

Remove the pads.

Check the lining thickness of the pads in each caliper.

If the lining thickness of either of the pads is less than the

service limit replace both pads in the caliper as a set.

A

B

C

D

E

223

Pad Lining Thickness

Lining Thickness: Standard Service limit

Front (Radial Calipers) 4.5mm 1mm

Front (Axial Calipers) 5.5mm 1mm

Rear 3.5mm 1mm

Brake Master Cylinder

Front Master Cylinder Removal

Drain the front brake fluid (see Brake Fluid Changing).

Remove:

Brake hose Banjo Bolt [A]

Master Cylinder Clamp Bolts [B]

Remove the front brake master cylinder[C].

Caution: Brake fluid quickly ruins painted surfaces; any spilled

fluid should be completely washed away immediately.

Front Master Cylinder Installation

The (integral) master cylinder clamps must be installed with the UP mark [D] facing upwards.

Tighten the upper master cylinder clamp bolts first, and then the lower clamp bolts. There will be a

gap at the lower part of the clamp after tightening.

Torque – Master Cylinder Clamp Bolts: 8 Nm

Use a new flat washer on each side of the brake hose fitting, and tighten the banjo bolt.

Torque – Banjo Bolt: 25 Nm

Fill the brake line with brake fluid (see Brake Fluid Changing).

Check that the brake line has proper fluid pressure and no fluid leakage.


lever until the pads are against each disc. The brake will not function on the first application of the lever if

this is not done.

Rear Master Cylinder Removal

Drain the rear brake fluid (see Brake Fluid Change).

Loosen the banjo bolt.

Remove:

C-clip and Joint [A]

C

A

B

D

A

224

Banjo Bolt and Brake Hose.

Rear Master Cylinder Bolts

Remove the rear master cylinder.

Rear Master Cylinder Disassembly

Note: Do not remove the push rod clevis for the master cylinder

disassembly since removal requires brake pedal position

adjustment.

Remove:

Rear Master Cylinder (see Rear Master Cylinder Removal)

Dust Cover

Push Rod with Clevis

Caution: Do not remove primary and secondary cups from the piston since removal will damage them.

Master Cylinder Assembly

Before assembly, clean all parts including the master cylinder with brake fluid or alcohol.

Apply brake fluid to the removed parts and to their inner wall of the cylinder.

Caution 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 will cause

deterioration of the rubber 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.

Silicone Grease - Brake Lever Pivot Bolt

Brake Lever Pivot Contact

Push Rod Contact (Rear Master Cylinder)

Torque - Brake Lever Pivot Bolt: 6Nm

Master Cylinder Visual Inspection

Disassemble the front and rear master cylinders.

Check that there are no scratches, rust or pitting on the inner wall of each master cylinder and on

the outside of each piston.

If a master cylinder or piston shows any damage, replace them.

Inspect the primary and secondary cups.

225

If a cup is worn, damaged, softened (rotted), or swollen,

the piston assembly should be replaced to renew the

cups.

If fluid leakage is noted at the brake lever, the piston

assembly should be replaced to renew the cups.

Check the dust covers for damage.

If they are damaged replace them.

Check that the relief and supply ports are not plugged.

If the relief port becomes plugged, the brake pads will drag on the disc. Blow the ports clean with

compressed air.

Check the piston return spring for any damage.

If a spring is damaged, replace it.

Brake Discs

Disc Installation Front

Install the disc spacer [A] as shown.

The disc must be installed so the disc moves further

away from the hub.

Tighten the disc bolts.

Torque – Front Disc Bolts: 25Nm

After installing the discs, check the disc runout.

Completely clean off any grease that has gotten on either side of the disc with a high-flash point

solvent. Do not use one with will leave an oil residue.

Disc Installation Rear

Tighten the disc bolts.

Torque – Rear Disc Bolts: 43Nm

After installing the disc, check the disc runout.

Completely clean off any grease that has gotten on either side of the disc with a high-flash point

solvent. Do not use one with will leave an oil residue

Disc Wear

Replace the disc if the sliding surfaces have worn past the service limit.

Brake Disc Wear:

Thickness: Standard Service Limit

Front - 4mm ± 0.15 3.3mm

A

226

Rear - 5mm ± 0.15 4.3mm

Runout: 0.2 mm or less 0.3mm

Disc Cleaning

Note: Poor braking can be caused by oil on a disc. Oil on a disc must be cleaned off with an oilless cleaning

fluid such as trichloroethylene or acetone.

Warning: These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods.

Be sure to heed the fluid manufacture’s warning.

Disc Warp Inspection

Using the jack, raise the front or the rear wheel off the ground (see Wheels/Tire chapter).

Set the dial gauge [A] against the disc.

For the front disc, turn the handlebar fully to one side.

Rotate the wheel [C] to measure disc runout. The difference between the highest and lowest dial

reading is the amount of runout.

If disc runout exceeds the service limit, replace the disc.

Disc Runout



Brake Hose Removal

Drain the brake fluid (see Brake Fluid Change).

Remove the banjo bolts [A] at both ends of the brake hose [B] and pull the hose off the motorcycle.

There is a copper washer on each side of the hose fitting.

When removing the brake hose, 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.

Caution: Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away

immediately.

Brake Hose Installation

Using a new copper washer for each side of the hose fitting, tighten the banjo bolt.

Torque – Banjo Bolts: 25Nm

When installing the hoses, avoid shaft bending, kinking, flattening or twisting.

Run the brake hose according to the Cable, Wire and Hose Routing section in the General


Fill the brake line with the brake fluid (see Brake Fluid Changing).

227

Brake Hose Inspection

Note: The high pressure inside the brake line can cause fluid to leak or the hose to burst if the line is not

properly maintained.

Bend and twist the rubber hose while examining.

Replace it if any cracks or bulges are noted.

228

Suspension

Exploded View ................................................................................................................................................ 221

Specification ................................................................................................................................................... 229

Rear Suspension ............................................................................................................................................. 230

Spring Preload .................................................................................................................................... 230

Preload Adjustment ........................................................................................................................... 230

Compression Damping Adjustment ................................................................................................... 230

Rebound Damping Adjustment ......................................................................................................... 232

Ride Height Adjustment ..................................................................................................................... 232

Rebound Damping Adjustment ......................................................................................................... 323


Cleaning .............................................................................................................................................. 233

Inspection ........................................................................................................................................... 233

Rear Shock Absorber ...................................................................................................................................... 234

Rear Shock Absorber Removal ........................................................................................................... 234

Rear Shock Absorber Installation ....................................................................................................... 234

Oil Draining ......................................................................................................................................... 234

Oil Filling ............................................................................................................................................. 234

Spring Tension .................................................................................................................................... 234

Scrapping ............................................................................................................................................ 235

Rear Shock Absorber Disassembly ..................................................................................................... 235

Rear Shock Absorber Assembly.......................................................................................................... 235

Conventional Front Forks ................................................................................................................... 235

Spring Preload Adjustment ................................................................................................................ 235



Rebound Damping Adjustment .......................................................................................................... 236

Rebound Damping Recommended Adjustment Range ..................................................................... 237

Compression Damping Recommended Adjustment Range ............................................................... 237

Cleaning .............................................................................................................................................. 238

Inspection ........................................................................................................................................... 238

Removal .............................................................................................................................................. 238

Installation .......................................................................................................................................... 238

Oil Draining ......................................................................................................................................... 238

Oil Filling ............................................................................................................................................. 238

Spring Tension .................................................................................................................................... 238

Fork Disassembly ................................................................................................................................ 240

Changing Fork seals and Bushings ..................................................................................................... 241

Assembly ............................................................................................................................................ 242

USD Front Forks ............................................................................................................................................. 243

Spring Preload Adjustment ................................................................................................................ 243


229


Rebound Damping Adjustment .......................................................................................................... 244

Rebound Damping Recommended Adjustment Range ..................................................................... 244

Compression Damping Recommended Adjustment Range ............................................................... 245

Cleaning .............................................................................................................................................. 245

Inspection ........................................................................................................................................... 245

Removal .............................................................................................................................................. 245

USD Fork Installation (Cafe Racer) ..................................................................................................... 246

USD Fork Installation (Sport and SE) .................................................................................................. 246

Oil Draining ......................................................................................................................................... 246

Oil Filling ............................................................................................................................................. 246

Spring Tension .................................................................................................................................... 248

USD Fork Disassembly ........................................................................................................................ 248

Replacing Seals and Forks .................................................................................................................. 249

USD Fork Assembly ............................................................................................................................ 249

Fork Disassembly ................................................................................................................................ 249

Changing Fork Seals and Bushing ....................................................................................................... 249

USD Fork Assembly ............................................................................................................................ 250

Swingarm ....................................................................................................................................................... 252

Swingarm Removal ............................................................................................................................. 252

Swingarm Installation ......................................................................................................................... 252

Swingarm Bearing Removal ............................................................................................................... 253

Swingarm Pivot Check ........................................................................................................................ 255

Swingarm Bearing, Sleeve Inspection ................................................................................................ 255

230

Exploded View

234


TORQUE (NM) REMARKS

24 STANCHION ASSY, RH -> OHLINS RWU

NUT

SPACER, SPRING

WASHER, SPRING SPACER

NUT, CAP ASSY

SPRING

CYLINDER

TUBE, OUTER

SEAL DUST

SNAP RING

SEAL, OIL

WASHER, OIL SEAL

TUBE, INNER, RH

SEALING WASHER

CAPSCREW, OIL LOCK

23 STANCHION ASSY, LH -> OHLINS RWU

NUT

SPACER, SPRING


NUT, CAP ASSY

SPRING

CYLINDER

TUBE, OUTER

SEAL DUST

SNAP RING

SEAL, OIL

WASHER, OIL SEAL

TUBE, INNER, LH

SEALING WASHER

CAP SCREW, OIL LOCK

9 STANCHION ASSY, LH, USD, 11mm PULL THROUGH

NUT

SPACER, SPRING


NUT, CAP ASSY

SPRING

CYLINDER

TUBE, OUTER

SEAL DUST

SNAP RING

SEAL, OIL

235

WASHER, OIL SEAL

TUBE, INNER, RH

SEALING WASHER

CAP SCREW, OIL LOCK

10 STANCHION ASSY, RH, USD, 11mm PULL THROUGH

NUT

SPACER, SPRING


NUT, CAP ASSY

SPRING

CYLINDER

TUBE, OUTER

SEAL DUST

SNAP RING

SEAL, OIL

WASHER, OIL SEAL

TUBE, INNER, LH

SEALING WASHER

CAP SCREW, OIL LOCK

BOLT, CAP HD, M8 X 25 20 PINCH BOLT SUPPLIED WITH FORKS

9 STANCHION ASSY, LH, USD, 11mm PULL THROUGH REFER TO PROCESS

SHEET

NUT

SPACER, SPRING


NUT, CAP ASSY

SPRING

CYLINDER

TUBE, OUTER

SEAL DUST

SNAP RING

SEAL, OIL

WASHER, OIL SEAL

TUBE, INNER, RH

SEALING WASHER

CAP SCREW, OIL LOCK

10 STANCHION ASSY, RH, USD, 11mm PULL THROUGH REFERTO PROCESS SHEET

NUT

SPACER, SPRING


NUT, CAP ASSY

SPRING

CYLINDER

TUBE, OUTER

SEAL DUST

SNAP RING

236

SEAL, OIL

WASHER, OIL SEAL

TUBE, INNER, LH

SEALING WASHER

CAP SCREW, OIL LOCK


11 LOWER YOKE, USD FORKS

12 BOLT, CAP HD, M8 X 20 X 1.25 20 LOWER YOKE CLAMP BOLTS

13 STEERING STEM

14 BEARING, TAPERED ROLLER HEADSTOCK BEARINGS

15 SEAL, HEADSTOCK, LOWER BEARING

25 LOWER YOKE, BILLET

LOWER YOKE FOR CONVENTIONAL

FORKS


52 LOWER HEADSTOCK SPACER YOKE SPACER FOR CONVECTIONAL FORKS

GREASE, SILKOLENE, PRO RG2

32 SWITCH CUBE, LH ECIE

SCREW, M5 X 40 3

SCREW, M5 X 30 3

33 SWITCH CUBE, RH

SCREW, M5 X 22 3

34 HANDLEBAR, TUBULAR, TAPERED ALUMINIUM

35 GRIP, HANDLEBAR, LH

36 GRIP, HANDLEBAR, RH

37 THROTTLE ACTUATOR, TWIN CABLE 4

38 BOLT, CAP HD, M6 X 20 x 1.0 8 THROTTLE ACTUATOR CLAMP

39 CLAMP, CLIP-ON, RH, CLEAR ANODISE

40 CLAMP, CLIP-ON, LH, CLEAR ANODISE

52 PIN, PARALLEL, 4.0 X 18.0MM, SOLID,

STAINLESS

USED AS ANTI ROTATION FEATURE

41 HANDLEBAR, CLIP-ON, LH, CLEAR

ANODISE

42 HANDLEBAR, CLIP ON, RH, CLEAR ANODISE

43 BOLT, CAP HD, M6 X 20 x 1.0, DIN

912, SS 15

USED TO PINCH HANDLEBAR

49 20 USED TO PINCH CLAMP

51 CABLE, THROTTLE, TWIN THROTTLE CABLES FOR HIGH BARS ONLY

BRASS BARREL NIPPLE 5.75MM DIA X

5.5MM LENGTH

OPEN CABLE GUIDE

CLOSE CABLE GUIDE

FERRULE

RUBBER BOOT

OPEN CABLE, 6MM OD, OUTER

CONDUIT, 795MM

OPEN CABLE, 1.5MM OD, INNER WIRE, 1030MM

CLOSE CABLE, 6MM OD, OUTER

237

CONDUIT, 795MM

CLOSE CABLE, 1.5MM OD, INNER

WIRE, 1030MM

ADJUSTER

LOCK NUT

BRASS BARREL NIPPLE 6MM DIA X

8MM LENGTH

50 CABLE, THROTTLE, TWIN, CLIP-ONS THROTTLE CABLES FOR LOW BARS ONLY


5.5MM LENGTH

OPEN CABLE GUIDE

CLOSE CABLE GUIDE

FERRULE

RUBBER BOOT

OPEN CABLE, 6MM OD, OUTER CONDUIT, 795MM

OPEN CABLE, 1.5MM OD, INNER

WIRE, 1030MM

CLOSE CABLE, 6MM OD, OUTER CONDUIT, 795MM


WIRE, 1030MM

ADJUSTER

LOCK NUT


8MM LENGTH

28 WEIGHT, BAR END

29 RUBBER MOUNT, BAR END

30 BOLT, CAP HD, M6 X 40 x 1.0 BAR END MOUNT TO HANDLE BAR

31 LOCKNUT, FLANGED, SERRATED FACE, M6

BAR END MOUNT TO HANDLE BAR

22 TOP YOKE, USD FORKS CAFE RACER RACER TOP YOKE

12 BOLT, CAP HD, M8 X 20 X 1.25 20NM TOP YOKE CLAMP BOLTS

16 TOP YOKE, USD FORKS, HIGH BARS CSE-03 TOP YOKE


18 SEAL, HEADSTOCK

26 YOKE, UPPER ASSY, BILLET TOP YOKE FOR CONVENTIONAL FORKS

27 BOLT, CAP HD, M8 X 20 X 1.25 20NM TOP YOKE CLAMP BOLTS CONVENTIONAL FORKS

19 NUT, UPPER YOKE, M25 80NM TOP YOKE LOCK NUT

20 LOCKNUT, M25 6 ADJUSTER NUT 40NM TO SEAT BEARINGS, BACKED OFF, THEN RE-TORQUED TO 6

NM

21 INTERMEDIATE NUT, M25 40 LOCKED UP TO ADJUSTER NUT 40 NM

44 CLAMP, HANDLEBAR, LOWER

45 BOLT, CAP HD, M10x30X1.5 HANDLEBAR CLAMP TO YOKE

46 NUT, M10 X 1.5 43 HANDLEBAR CLAMP TO YOKE

55 WASHER, M10, 10.5 X 20 X 2

47 CLAMP, HANDLEBAR, UPPER

48 BOLT, CAP HD, M8 X 22 X 1.25 20 UPPER HANDLE BAR CLAMPS BOLTS

238

Specifications

Suspension Specification (USD)

Item Standard Range

Front Fork (per one unit) Fork inner tube diameter 43 mm - - - Compression damper setting 16 clicks from fully closed +11 to -16 Rebound damping setting 18 clicks from fully closed +6 to -18 Spring preload setting (3 turns from fully out) +7 to -3 Fork oil Ohlins front fork fluid 01309 - - - Fork oi viscosity 19 cSt (5W) - - - Fork oil capacity N/A - - - Fork oil level 150mm ± 2 mm - - -

Fork spring free length 260mm ± 2 mm - - -

Suspension Specification (Conventional)

Item Standard Range

Front Fork (per one unit) Fork inner tube diameter 43 mm - - - Compression damper setting 14 clicks from fully closed +14 to -14 Rebound damping setting 16 clicks from fully closed +2 to - 16 Spring preload setting (3 turns from fully out) +7 to - 3 Fork oil Ohlins front fork fluid 01309 - - - Fork oi viscosity 19 cSt (5W) - - - Fork oil capacity 488 cm³ - - - Fork oil level N/A - - -

Fork spring free length 250mm ± 2 mm - - -

Suspension Specification (Rear Shocks)

Item Standard Range

Rear shock (per one unit) Compression damper setting 3 clicks from fully closed +1 to -3 Rebound damping setting 18 clicks from fully closed +36 to -18

Spring preload setting 7 turns from fully out (2 rings showing) +8 to - 7

239

Fork spring free length 230mm - - -

240

Rear Suspension

Warning: Ensure that the basic factory settings are intact before riding the motorcycle. If making

adjustments, only adjust one aspect at a time in small increments.

Spring Preload – Static Sag – Rider - Sag

Note: Spring preload affects the ride height of the motorcycle and the fork angle. The Following should be

performed on a flat surface.

Lift the motorcycle off the ground using a work stand so that

the front and rear wheels are off the ground and unloaded.

Measure the distance from the centre of the rear wheel axle

to the centre of the top rear suspension mount [R1].

Measure the distance from the bottom of the lower yoke

(lowest point) to the centre of the front wheel axle [F1].

With the motorcycle on the ground so the motorcycle is

under its own weight, repeat the measuring procedure

above for [R2] and [F2].

Sit on the motorcycle in full riding gear in a normal riding

position; repeat the measuring procedure for [R3] and [F3].

Note: The following set up is based on a single rider in full gear to a

mass of 90Kg.

Static Sag Conventional forks –

[R1-R2] [474-463] Rear: 11 mm ± 3mm

[F1-F2] [522-477] Front: 45 mm ± 3mm

Static Sag USD Forks -

[R1-R2] [474-463] Rear: 11 mm ± 3mm

[F1-F2] [510-475] Front: 35 mm ± 3mm

Rider Sag Conventional -

[R1-R3] [474-440] Rear: 34 mm ± 3mm

[F1-F3] [522-467] Front: 55 mm ± 3mm

Rider Sag USD Forks -

[R1-R3] [474-440] Rear: 34 mm ± 3mm

[F1-F3] [510-465] Front: 45 mm ± 3mm

If the measurements differ significantly from the table above, adjust the spring preload (see Spring

Preload Adjustment).

If the Rider Sag still differs significantly you may need to replace the spring.

241

Warning: Incorrect spring rate may result is poor handling characteristics.

Preload Adjustment

Turn the screw [A] on the hydraulic adjuster to set the

spring preload.

Turn clockwise to increase preload, turn anti clockwise to

decrease.

To set the rider sag adjustment (see this chapter) turn the

preload adjuster anti clockwise until it stops, and then

turn clock wise to the first audible click. From this click

turn the preload adjuster clockwise to the recommended position.

Note: One full turn of the preload adjuster equates to 2/3mm (0.66 mm) of spring preload.

Preload – 7 full turns from fully out (two rings on the

adjust should be visible [A])

Note: Increasing the amount of preload on the rear

shock will reduce the amount of both static and rider

sag. Reducing the preload will increase the sag values.

Adjust both the left and right hand rear suspension

springs in sequence to the same position.

Changing the spring preload will change the ride height and affect the handling.

It is critical that the spring preload is correctly set; if the spring preload is not correctly set all other

suspension adjustments may not give desired handling characteristics.

Compression Damping Adjustment

Note: Compression damping controls the energy absorbed

when the rear wheel is being loaded or hits a bump. Standard

settings are based on a 90 kg rider (this includes riding gear).

To adjust the compression damping turn the adjuster

[A] clockwise to increase damping, and anti clockwise

to decrease damping.

To reset the adjuster turn the adjuster clockwise to

fully closed position (zero (0) position), then turn anti

clockwise to open.

Rear Compression Damping – 3 clicks out from fully closed

Caution: Do not force the damping adjuster, delicate sealing

surfaces could be damaged.

A

A

A

242

Rebound Damping Adjustment.

Note: Rebound damping controls the energy absorption when the shock absorber is being extended and

controls how fast the shock absorber returns to its normal position after being compressed.

To adjust the damping, turn the adjuster [A] on the piston shaft clockwise to increase damping, anti

clockwise to decrease it.

To reset the damping, turn the adjuster clockwise (right) to fully closed position, and then anti

clockwise (left) to the specified range.

Rear Rebound Damping – 18 Clicks out from fully closed

Warning: If both suspension units are not adjusted equally, handling may be impaired and a hazardous

condition may result.

Ride Height Adjustment

Note: Adjusting the length of the rear suspension will directly

affect the steering geometry and handling of the motorcycle

Caution: Make very small adjustments at a time as they can make

a significant difference.

Remove the shock absorbers from the motorcycle (see

this chapter).

Slacken off the lock nut [A].

Turn the adjuster nut [B] to the desired length.

One turn of the spring retainer results in 1mm of shock

absorber length.

Rear Shock Absorber Length: 380 mm +8/-2mm

Tighten the Ride Height Adjuster Nut.

Torque – Ride height Adjuster Nut: 40Nm

Warning: Always torque the lock nut after adjusting the

length. The Adjustable end eye bracket [B] must not be

positioned beyond grove [A].

Caution: After any changes to Ride Height Adjustment always check the Rider Sag (see this chapter) and

Head light Angle (see Electrical System chapter).

A

B

A

B

243

Rebound Damping Recommended Adjustment Range

Rebound Adjustment Range: ± 5 clicks from original settings

Note: When setting up a motorcycle, the front suspension should be adjusted in line with the rear.

If the Spring rate, preload and ride height feel good but the bike rides low and sits down under

acceleration bumps, with lost line or lost comfort and traction.

Open the rebound adjuster two clicks.

If the bike is nervous / moving a lot or has a high feeling entering corners.

Close the rebound adjuster two clicks.

Fine tune by one click at a time

Caution: Always start from original factory settings and test run after making changes.

Compression Damping Recommended Adjustment Range

Compression Damping Range: ± 2 clicks from original settings

If the motorcycle feels soft / unstable or is using too much wheel travel and the spring rate is

correct.

Close the compression adjuster by one click. This will controle reduce the motorcycle from falling

throught the stroke too quickly.

If the motorcycle feels high / has poor grip when opening the throttle or does not feel smooth over

small bumps during acceleration.

Open the Compression Adjuster by one click.

Caution: Always start from original factory settings and test run after making changes, if improvements

have been made, repeate the procedure from the start again to check. Always check tire pressures before

making suspension adjustements and take note of the conditions such as air temperature.

Caution: Preventive maintenance and regular inspection reduces the risk of function disturbance.

Rear Suspension Cleaning

Clean the rear suspension unit externaly with a soft detergent. Using compressed air ensure all dirt

is removed, lift the bump rubber and clean the area below. Keep the shock absorber clean and

spray with a water displacing spray which will not deteriate the rubber, after cleaning, wash off

excessive oil with a cloth.

Caution: Never spray water directly into the adjuster units or ball joints.

244

Rear Suspension Inspection

Check the ball joint for excessive play or stiction.

Check the piston shaft for leakage and damage.

Check the shock absorber body for external damage.

Check the reservoir for external damage that can restrict the floating piston from moving freely.

Check for excessive wear of rubber components.

Check the attachment points between frame, swingarm, and shock.

Warning: Do not change the gas pressure this required specialist high pressure nitrogen equipment.

Rear Shock Absorber Removal

Using a jack, raise the rear wheel off the ground (see

wheels/Tires chapter).

Support the rear swing arm weight.

Remove the top [A] and bottom [B] suspension

mounting bolts and washers.

Remove the Shock absorbers [C].

Rear Shock Absorber Installation

Install the shock absorber with the piggyback reservoir

[A] at the top and back of the motorcycle.

Install the Shock washers and bolts and tighten.

Torque – Rear Shock Bolts: 22 Nm

Oil Draining/Filling

Note: Changing the oil requires de-pressurising and pressuring the rear shocks and should only be

undertaken by a Norton authorised Ohlins dealer

Warning: High Pressure gas reservoir should only be serviced by a Norton authorised Ohlins dealer as high

pressure gas is dangerous.

Spring Tension

Note: Since the spring becomes shorter as it weakens, check its free length to determine the condition.

If the spring is shorter than the service limit, it must be replaced.

Rear Shock Absorber Spring Length:

B

A

C

245

Standard: 230 mm

Service Limit: 225 mm

Scrapping

Remove the rear shock absorber (see this chapter).

Point the reservoir away from you and slowly release the nitrogen gas pressure from the gas

reservoir by pushing down the valve core with a surgical needle.

Warning: The high pressure gas is dangerous. Do not point the valve toward your face or body. Do not

incinerate a shock absorber without first removing the valve or it may explode.

Rear Shock Absorber Disassembly

Remove the Rear Shock from the frame (see Rear Shock

Absorber Removal).

Clean the shock (see Rear Suspension cleaning)

Hold the lower end of the shock with a vise.

Remove the entire preload on the spring (see Preload

Adjustment).

Using a spring compressor compress the spring until it is

free.

Slide down the rubber bumper [A].

Remove the spring guide [B] from the shock absorber and lift off the spring [C].

Rear Shock Absorber Assembly

Install the spring and spring guide.

Slowly release the tension in the spring using the spring compressor.

Set the preload to its factory setting.

Install the Shock (see Rear Shock Absorber Installation).

Before riding, ensure the rear shocks are set up identically and the shock performs as intended.

Front Fork Conventional

Spring Preload Adjustment

Warning: Ensure that the basic factory settings are

intact before riding the motorcycle. If making

adjustments, only adjust one aspect at a time in

small increments.

A

B

C

246

Note: Spring preload affects the ride height of the motorcycle and the fork angle.

If the measurements differ significantly from (Spring Preload – Static Sag – Rider – Sag), adjust the spring

preload (see Preload Adjustment).



Preload Adjustment

Turn the adjuster screw to set the spring preload.

Turn clockwise to increase preload, turn anti clockwise to decrease.

To set the rider sag adjustment (see this chapter) turn the preload adjuster anti clockwise until it

stops, and then turn clock wise to the first audible click. From this click turn the preload adjuster

clockwise to the recommended position.

Note: One full turn of the preload adjuster equates to 1 mm of spring preload (the adjustable range is

15mm).

Preload – 3 full turns from fully out

Note: Increasing the amount of preload in the front forks will reduce the amount of both static and rider


Adjust both the left and right hand forks in sequence to the same position.





Note: Compression damping controls the energy absorbed

when the front wheel is being loaded or hits a bump.

Standard settings are based on a 90 kg rider (this includes

riding gear).

To adjust the compression damping turn the adjuster [A]

clockwise to increase damping, and anti clockwise to

decrease damping.

To reset the adjuster turn the adjuster clockwise to fully closed position (zero (0) position), then

turn anti clockwise to open.

Front Fork (Conventional) Compression Damping – 14 clicks out from fully closed

Caution: Do not force the damping adjuster, delicate sealing surfaces could be damaged.

247


Note: Rebound damping controls the energy absorption when the

fork is being extended and controls how fast the shock absorber

returns to its normal position after being compressed.

To adjust the damping, turn the adjuster [A] clockwise to

increase damping, anti clockwise to decrease it.

To reset the damping, turn the adjuster clockwise (right) to

fully closed position, and then anti clockwise (left) to the specified range.

Front Forks (Conventional) Rebound Damping – 16 Clicks out from fully closed






If the Spring rate, preload and ride height feel good but the bike rides low and sits down under

acceleration bumps, with lost line or lost comfort and traction.


If the bike is nervous / moving a lot or has a high feeling entering corners.







correct.

Close the compression adjuster by one click. This will reduce the motorcycle from falling throught

the stroke too quickly.




A

248





Front Forks Cleaning

Clean the Fork unit externaly with a soft detergent. Using compressed air, ensure all dirt is

removed. Keep the forks clean and spray with a water displacing spray which will not deteriate the

rubber, after cleaning, wash off excessive oil with a cloth (DO NOT ALLOW ANY OIL TO FALL ONTO

THE BRAKING SYSTEM).

Caution: Never spray water directly into the adjuster units.

Fork Inspection

Check for excessive play or stiction.


Check the Fork body for external damage.


Check the attachment points between top yoke, bottom yoke, and wheel axle.

Convenctional Fork Removal

If the fork leg is to be disassembled, loosen the fork top

plug [A] beforehand. To loosen the fork top plug, remove

the handlebar (see Steering chapter) and loosen the fork

upper clamp bolts, and then slacken off the top plug.

Using a jack, raise the front wheel off the ground (see

Wheels/Tires chapter).

Support the front wheel weight.

Remove Brake calipers and hoses (see Braking System

chapter).

Remove the front wheel (see Wheels/ Tires chapter)

Remove the front mudguard.

Slacken the top pinch bolts off followed by the lower.

With a twisting motion, work the fork leg [A] down and

out.

Conventional Fork Installation

A

A

249

Install the fork tube so that the top of the fork outer tube [A] is flush with the upper surface of the

steering stem head [B].

Run the cables, wires, and hoses as shown in the Cable, Wire, and Hose Routing section of the

General Information chapter.

Install the front wheel (see Wheels/ Tires chapter).

Torque – Top Yoke Clamp Bolts: 20 Nm

Bottom Yoke Clamp Bolts: 20 Nm

Top Plug: Hand Tight

Brake Caliper Bolts: 35 Nm

Check the front brake after installation.

Warning: Do not attempt to ride the motorcycle until a full brake

lever is obtained by pumping the brake lever until the pads are

against the disc. The brake will not function on the first application

of the lever if this is not done.


Remove any preload on the forks (see this chapter).

Loosen the top plug.

Remove the front fork (see Front Fork Removal).

Hold the inner tube in a soft jawed vise.

Unscrew the top plug out of the outer tube.

Remove the top nut assembly, top nut, spring preload tube the

spring seat and the spring.

Slowly compress the front fork fully.

Pull out the piston rod as far as possible and turn the

compression adjustment screw fully clockwise. This will keep

the piston rod in top position, which will make the continued

assembly easier.

Pour out the fork oil with the fork upside down.

Move the fork rod up and down at least ten times to expel the oil

from the fork.

Hold the fork tube upright; press the outer tube and the push rod all

the way down.

Note: Do not install the fork spring yet.

Fill the front fork to the specified amount.

250

Conventional Fork Oil:

Ohlins front fork fluid 01309

Conventional Fork Oil Viscosity:

SAE 5W 19 cSt

Conventional Fork Oil Capacity:

Approx. 488 cm³

Purge the air from the fork cylinder by gently moving the piston

rod up and down five times

Note: While doing this ensure the oil lever is topped up so stays near

the top of the inner tube.

Caution: Never extend the fork fully, since oil will be forced from between the tubes into the inner tube.

This raises the oil level in the inner tube. If the for is extended to the full length of its normal travel, the oil

level will raise above 30mm.

After purging the air from the fork, let it sit for about five minutes so that any suspended air

bubbles can surface.

Pull the push rod up slowly so as not to spill the fork oil out of the fork tube.

Install the spring, the spring seat, the preload tube and the nut. Be careful to put all parts back in

the same position as when the fork was disassembled.

Install the top nut assembly.

Tighten the top nut assembly hand tight.

Install the fork (see Front Fork Installation).

Set up the Preload, Compression damping, rebound damping.

Check the whole system to ensure proper operation.

Spring Tension



Conventional Fork Spring Length:

Standard: 250 mm ± 2 mm

Fork Disassembly

Remove the front forks for the motorcycle (see this chapter).

Hold the fork in a soft jawed vice [A]. A

251

Loosen the spring preload nut off fully by turning anti-clockwise.

Loosen the top nut assembly [A] off and remove.

Let the inner tube drop down and loosen the front fork bolt [A] of

the top cap from the cartridge shaft.

Remove the upper nut and spring preload tube.

Spring Seat

Spring

Remove the fork from the vice and pour the fork fluid out.

Note: Hold the adjustment rod in place to stop it falling out.

Secure the fork in the vice again and use Norton cartridge removal tool [A] to

loosen off the cartridge.

Unscrew the cartridge from the fork and remove it.

Changing Fork Seals and Bushings

Secure the fork bottom horizontally in a vice.

Loosen the dust seal [A] and circlip [B].

Using a heat gun heat the area around the seal and

bushings to approximately 100˚C.

Remove the Bushings, seal and washer by pulling

out swiftly.

Remove the bushing [A] from the inner tube.

Replace the bushings and seals

Note: To Install the bushings and seals use the

recommended Norton tool. Use a heat gun to

warm the outer tube.

Install the inner tube bushings by sliding them

over the tube end.

A

A

A

A B

A

A

252

Slide the inner tube into the outer tube.

Note: Earlier models of the front fork have two outer bushings. In this case, the lower bushing

should not be replaced after being removed, as it is not required for fork operation.

Slide the outer tube bushings in the outer

tube.

Using the Norton tool gently tap the outer

tube bushings into position.

Caution: Ensure that the bushing is set

tightly against the support inside the

outer tube.

Install the seal seat washer [A].

Apply some red grease on the outside of

the oil seal and install it with the Norton

tool turned in the opposite direction from how it was

used to tap the outer tube bushings.

Install the circlip.

Apply read grease onto the dust seal chamfer.

Install the dust seal by hand and press in place.

Fork Assembly

Fill fork fluid into the inner tube.

Fork Fluid - 488 cm³ of Ohlins front fork fluid (01309)

Push the piston up and down until the cartridge is

completely filled with fluid.

Reinstall the adjustment rod.

Note: Open the compression adjuster with a 3 mm Allen tool,

close the rebound fully with your thumb by pushing on the

adjustment rod before pumping procedure, this will make it

easier to bleed out the air from the damping system.

Install the spring with the marking number upwards.

Install:

Upper Spring Seat

Preload Tube

Piston Rod Nut

Torque – Piston Rod Nut: 25Nm

253

Apply red grease to the fork bolt and install it into the top nut.

Pull the piston rod upwards and screw it into the top nut assembly.

Use a 17mm wrench to keep a firm hold of the cartridge nut and the nut of the fork bolt.

Close the rebound valve fully. Use a 3mm allen tool. Push the fork leg up and down to check for

function.

Put the top nut assembly back into the fork leg. Use the Norton top nut tool and tighten it gently by

hand.

Adjust the Compression, rebound, and Preload.

Install the forks into the motorcycle (see this chapter).

Before riding, ensure the forks are set up identically and the forks perform as intended.

Front Forks Up Side Down (USD)

Spring Preload Adjustment

Warning: Ensure that the basic factory settings are intact before riding the motorcycle. If making

adjustments, only adjust one aspect at a time in small increments.

Note: Spring preload affects the ride height of the motorcycle and the fork angle.

If the measurements differ significantly from (Spring Preload – Static Sag – Rider – Sag), adjust the

spring preload (see Preload Adjustment).



Preload Adjustment

Turn the adjuster screw to set the spring preload.

Turn clockwise to increase preload, turn anti clockwise to

decrease.

To set the rider sag adjustment (see this chapter) turn the

preload adjuster anti clockwise until it stops, and then turn

clock wise to the first audible click. From this click turn the

preload adjuster clockwise to the recommended position.

Note: One full turn of the preload adjuster equates to 1 mm of spring preload (the adjustable range is

15mm).

Preload – 3 full turns from fully out

Note: Increasing the amount of preload in the front forks will reduce the amount of both static and rider


Adjust both the left and right hand forks in sequence to the same position.

A

254





Note: Compression damping controls the energy absorbed when the front wheel is being loaded or hits a

bump. Standard settings are based on a 90 kg rider (this includes riding gear).

To adjust the compression damping turn the adjuster [A]

clockwise to increase damping, and anti clockwise to

decrease damping.

To reset the adjuster turn the adjuster clockwise to fully

closed position (zero (0) position), then turn anti

clockwise to open.

Front Fork (USD) Compression Damping – 16 clicks out

from fully closed

Caution: Do not force the damping adjuster, delicate sealing surfaces could be damaged.


Note: Rebound damping controls the energy absorption when

the fork is being extended and controls how fast the shock

absorber returns to its normal position after being compressed.

To adjust the damping, turn the adjuster [A] clockwise

to increase damping, anti clockwise to decrease it.

To reset the damping, turn the adjuster clockwise (right)

to fully closed position, and then anti clockwise (left) to

the specified range.

Front Forks (USD) Rebound Damping – 18 Clicks out from fully closed





A

A

255


If the Spring rate, preload and ride height feel good but the

bike rides low and sits down under acceleration bumps, with

lost line or lost comfort and traction.


If the bike is nervous / moving a lot or has a high feeling

entering corners.







correct.

Close the compression adjuster by one click. This will reduce the motorcycle from falling throught

the stroke too quickly.








Front Forks Cleaning

Clean the Fork unit externaly with a soft detergent. Using compressed air, ensure all dirt is

removed. Keep the forks clean and spray with a water displacing spray which will not deteriate the

rubber, after cleaning, wash off excessive oil with a cloth (DO NOT ALLOW ANY OIL TO FALL ONTO

THE BRAKING SYSTEM).

Caution: Never spray water directly into the adjuster units.

Fork Inspection

Check for excessive play or stiction.


Check the Fork body for external damage.


Check the attachment points between top yoke, bottom yoke, and wheel axle.

256

USD Fork Removal

If the fork leg is to be disassembled, loosen the fork top plug beforehand. To loosen the fork top

plug, remove the handlebar (see Steering chapter) and loosen the fork upper clamp bolts [A], and

then slacken off the top plug.

Using a jack, raise the front wheel off the ground (see Wheels/Tires chapter).

Support the front wheel weight.

Remove Brake calipers and hoses (see Braking System chapter).

Remove the front wheel (see Wheels/ Tires chapter)

Remove the front mudguard.

Slacken the top pinch bolts off followed by the lower.

With a twisting motion, work the fork leg down and out.

USD Fork Installation (Cafe Racer)

Install the fork tube so that the top of the fork outer tube [A]

is flush with the upper surface of the steering stem head [B].

Run the cables, wires, and hoses as shown in the Cable, Wire,

and Hose Routing section of the General Information chapter.








lever until the pads are against the disc. The brake will not function on the first application of the lever if

this is not done.

Conventional Fork Installation (Sport and SE)

Install the fork tube so that the top of the fork outer tube [A] is 11mm above the upper surface of

the steering stem head [B].

Run the cables, wires, and hoses as shown in the Cable, Wire, and Hose Routing section of the







A

B

A

257


Warning: Do not attempt to ride the motorcycle until a full brake lever is

obtained by pumping the brake lever until the pads are against the disc. The

brake will not function on the first application of the lever if this is not done.


Remove any preload on the forks (see this chapter).

Loosen the top plug.

Remove the front fork (see Front Fork Removal).

Hold the base of the forks in a soft jawed vise.

Unscrew the top plug out of the outer tube.

Remove the top nut assembly, spring support, spring, and preload

tube.

Slowly compress the front fork fully.

Pull out the piston rod as far as possible.

Pour out the fork oil with the fork upside down.

Move the fork rod up and down at least ten times to expel the oil from the fork.

Hold the fork tube upright; press the outer tube and the push rod all the way

down.

Note: Do not install the fork spring yet.

Fill the front fork to the top with the specified oil more than the

specified amount.

USD Fork Oil:

Ohlins front fork fluid 01309

USD Fork Oil Viscosity:

SAE5W 19 cSt

USD Fork Oil Capacity:

Approx. 500 mL

Purge the air from the fork cylinder by gently moving the piston

rod up and down five times

Note: While doing this ensure the oil lever is topped up so stays near the top of the inner tube.

258

Caution: Never extend the fork fully, since oil will be forced from between the tubes into the inner tube.

This raises the oil level in the inner tube. If the for is extended to the full length of its normal travel, the oil

level will raise above 30mm.

After purging the air from the fork, let it sit for about five minutes so that any suspended air

bubbles can surface.

Measure the oil level, using a fork oil level gauge.

Set the gauge stopper so that its lower side shows the oil level distance.

With the fork fully compressed, insert the gauge tube into the inner tube and position the stopper

across the top of the outer tube.

Pull the handle slowly to draw out the excess oil until no more oil comes up the tube.

If no oil is drawn out there is not enough oil in the fork. Pour in some more oil, then draw out the

excess.

USD Front Fork Oil Level (Fully compressed without fork spring):

150 ± 2 mm

Pull the push rod up slowly so as not to spill the fork oil out of the fork tube.

Install the spring, the spring seat, the preload tube and the nut. Be careful to put all parts back in

the same position as when the fork was disassembled.

Install the top nut assembly.

Tighten the top nut assembly hand tight.

Install the fork (see Front Fork Installation).

Set up the Preload, Compression damping, rebound damping.

Check the whole system to ensure proper operation.

Spring Tension



USD Fork Spring Length:

Standard: 250 mm ± 2 mm

USD Fork Disassembly

Carry out instructions from (Oil Draining / Filling) until the oil has been

drained.

Using Norton tool and a spanner loosen of the cartridge from the fork

leg and remove cartridge [A] and washer [B].

Drain any remaining oil. A

259

Remove the top cap lock nut [A] from the shaft. Remove

spring guide, spacer (if any) and bump rubber.

Push cap through the end cap/cylinder tube and the

base valve will fall out [B].

Remove o-ring, spacers (if any) and top-out spring [C]

from the shaft.

Fasten the shaft in a vice. Use Norton clamping tool.

Remove the piston and shim from the shaft. Place all

removed parts in correct order on the work bench.

Clean all parts thoroughly.

Loosen the piston holder from the shaft. Use a heat gun

to release the thread lock. Remove needle, spring and

adjustment rod.

Note: After using a heat gun, it is recommended to

replace the rebound needle o-ring.

On the base valve, remove the check valve, piston and shim. Place all

parts in correct order on work bench. Clean all parts thoroughly.

Note: Do not use strong solvent; it can damage the seals

and o-rings.

Replace Seals and Forks

B

A B

C

260

Place the outer fork leg upright on a bench with the seal side up.

Remove the scraper, circlip, oil seal and support washer.

Note: Use a flat tire lever and a rag to protect the edge of the fork leg when disassembling the seal.

Use a heat gun to heat the outer leg to approximately 100˚C, where the

bushings are positioned.

Remove the bushings by pushing them out using Norton tool.

Put the fork leg on a soft surface and tap the bar gently with a big plastic

hammer. Clean all parts thoroughly.

Install new bushings while the outer fork leg is still warm. Put the outer fork

leg on a soft surface with the seal side facing up.

Apply Loctite 648 on the outer fork leg upper bushing seat,

use a long brush. Use the Norton installing sleeve, guide

ring and attachment bar when installing the bushings. Tap the

attachment bar until the bushing reaches a solid stop.

Apply some red grease to the lower bushing seat on the outer fork

leg, before installation (no Loctite on the lower bushing). Install the

lower bushing in the same way as the upper. Use Norton installer

sleeve and attachment bar when installing the seal.

Apply a thin layer of red grease to the washer and the main seal. Install them into the outer fork leg

by hand. Install the circlip behind the seal.

Note: Use appropriate grease to achieve optimum fork function.

Apply red grease to the scraper seat and carefully press fit the scraper by hand.

USD Fork Assembly

Put the inner fork leg in a vice, clamp the fork bottom.

Apply some front fork oil to the inner fork tube surface

and carefully slide the outer fork leg all the way down.

Warning: Be careful not to damage the fork seals.

Install the cartridge into the fork bottom. Make sure the

washer [A] is attached below the base valve, and tighten

using Norton tool.

Torque - Cartridge USD forks: 20Nm

261

Fill the fork with approx 500ml of fork oil. Pump the shaft up and down to bleed out the air; Use

Norton tool.

Make sure all the air has been bled from below the piston.

Check and set the oil level (see this chapter).

Note: It is recommended that only the specified Ohlins front fork oil should be used.

Install the preload tube, spring (with markings facing up) and spring support.

Pull up the shaft, use Norton Spring compressor #1 tool

to contract the top out spring and install Norton Spring

Contraction tool to maintain contraction.

Replace pull-up tool with the top cap assembly to the

shaft. Make sure that the shaft bottoms in the

adjuster/top cap before tightening the lock nut.

Torque - Lock Nut USD Forks: 20Nm

Apply red grease on the top cap o-ring and threads, and install the top cap into the outer fork leg,

with the fork leg fully extended.

Torque – Top Cap USD Forks: 10Nm

Adjust the spring preload, compression and rebound valves (see this chapter).

Before riding, ensure the forks are set up identically and the forks perform as intended.

A

262

Swingarm

Swingarm Removal

Squeeze the brake lever slowly and hold it with a band [A].

Caution: Be sure to hold the front brake when removing the

swingarm or the motorcycle may fall over. The motorcycle could

be damaged.

Warning: Be sure to hold the front brake lever when removing the

swingarm, or the motorcycle may fall over. It could cause an

accident and injury.

Remove the rear brake hoses clips.

Remove the exhaust silencer and secondary (see Engine Top End chapter).

Lift the rear wheel of the motorcycle off the ground using a centre stand.

Remove:

Rear suspension (see this chapter).

Rear Wheel (see Wheels/Tires).

Mudguard.

Chain guard.

Remove the Swingarm pivot nut [A].

Pull out the Swingarm pivot shaft and remove the

Swingarm [B] rearward.

Swingarm Installation

Apply plenty of molybdenum disulfide grease to the inside of the needle bearings and sleeve.

Install the swing arm pivot and swing arm pivot washer and hand tighten the pivot nut.

Torque – Swingarm Pivot Nut: 60 Nm

Install:

Rear Wheel (see Wheels/Tires chapter)

Drive Chain (see Final Drive chapter)

Rear suspension (see this chapter)

Mudguard.

Chain guard.

Install exhaust silencer and secondary (see Engine Top End

chapter).

Install the rear brake hoses clips.

A

A

B

263

Torque – Rear Brake Line Hose clips: 7 Nm



this is not done.

Swingarm Bearing Removal

Remove the Swingarm (see this chapter).

Remove the RH grease seals [A].

Remove the RH spacer [B].

Remove the centre spacer [A] from the swing arm.

Using a bearing puller remove the needle roller bearing

assembly [A] from the RH side.

Remove the LH seal [A] and spacer [B].

B

A

A

A

A B

264

Remove the Circlip [A] from the LH side of the swing arm.

Using a bearing puller remove the two roller bearings [A]

from the LH side.

Swing Arm Bearing Installation

Apply molybdenum disulfide grease to two roller

bearings [A] and using a press, install (smaller diameter

side).

Install circlip and grease seal and LH spacer.

Install the RH Bearing using plenty of molybdenum

disulfide grease with a press.

A

A

A

265

Be sure to install the needle roller bearings with manufactures mark pointing outwards.

Install the centre spacer, RH seal and RH spacer.

Swingarm Pivot Check

Check the pivot of the Swingarm and suspension mounting

points.

Raise the rear wheel off the ground (see Wheels/Tires

chapter).

Move the Swingarm [A] up and down to check for abnormal

friction, and push and pull it to check for bearing play.

A small amount of play on the pivot is normal and no

corrective action is needed. However, if excessive play is felt, check the Swingarm and suspension

link bearings for wear and replace them if necessary.

Warning: Installation of new bearings in the Swingarm may cause too stiff rear suspension. Test ride the

motorcycle slowly and prudently until the suspension becomes normal.

Swingarm Bearing, Sleeve Inspection

The rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of

measuring, inspect the bearing in the Swingarm for abrasion, colour change, or other damage.

If there is any doubt as to the condition of any of the needle bearings or sleeves, replace all the sleeves, and needle

bearings as a set.

A

266

Steering

Exploded View ................................................................................................................................................ 257

Steering .......................................................................................................................................................... 265

Steering Inspection ............................................................................................................................ 265

Steering Adjustment .......................................................................................................................... 265

Handlebar ....................................................................................................................................................... 266

Handlebar Removal ............................................................................................................................ 266

Handlebar Installation ........................................................................................................................ 267

Steering Stem ................................................................................................................................................. 267

Steering Stem Removal ...................................................................................................................... 267

Steering Stem Installation .................................................................................................................. 268

Steering Stem Warp ........................................................................................................................... 269

Steering Stem Bearing.................................................................................................................................... 269

Stem Bearing Removal ....................................................................................................................... 269

Stem Bearing Installation ................................................................................................................... 269

Stem Bearing Lubrication ................................................................................................................... 269

267

Exploded View

271


TORQUE (NM) REMARKS

24 STANCHION ASSY, RH -> OHLINS RWU

NUT

SPACER, SPRING


NUT, CAP ASSY

SPRING

CYLINDER

TUBE, OUTER

SEAL DUST

SNAP RING

SEAL, OIL

WASHER, OIL SEAL

TUBE, INNER, RH

SEALING WASHER

CAPSCREW, OIL LOCK

23 STANCHION ASSY, LH -> OHLINS RWU

NUT

SPACER, SPRING


NUT, CAP ASSY

SPRING

CYLINDER

TUBE, OUTER

SEAL DUST

SNAP RING

SEAL, OIL

WASHER, OIL SEAL

TUBE, INNER, LH

SEALING WASHER

CAP SCREW, OIL LOCK

9 STANCHION ASSY, LH, USD, 11mm PULL THROUGH

NUT

SPACER, SPRING


NUT, CAP ASSY

SPRING

CYLINDER

TUBE, OUTER

SEAL DUST

SNAP RING

SEAL, OIL

WASHER, OIL SEAL

TUBE, INNER, RH

SEALING WASHER

272

CAP SCREW, OIL LOCK

10 STANCHION ASSY, RH, USD, 11mm PULL THROUGH

NUT

SPACER, SPRING


NUT, CAP ASSY

SPRING

CYLINDER

TUBE, OUTER

SEAL DUST

SNAP RING

SEAL, OIL

WASHER, OIL SEAL

TUBE, INNER, LH

SEALING WASHER

CAP SCREW, OIL LOCK


9 STANCHION ASSY, LH, USD, 11mm PULL THROUGH REFER TO PROCESS

SHEET

NUT

SPACER, SPRING


NUT, CAP ASSY

SPRING

CYLINDER

TUBE, OUTER

SEAL DUST

SNAP RING

SEAL, OIL

WASHER, OIL SEAL

TUBE, INNER, RH

SEALING WASHER

CAP SCREW, OIL LOCK

10 STANCHION ASSY, RH, USD, 11mm PULL THROUGH REFERTO PROCESS SHEET

NUT

SPACER, SPRING


NUT, CAP ASSY

SPRING

CYLINDER

TUBE, OUTER

SEAL DUST

SNAP RING

SEAL, OIL

WASHER, OIL SEAL

TUBE, INNER, LH

273

SEALING WASHER

CAP SCREW, OIL LOCK


11 LOWER YOKE, USD FORKS


13 STEERING STEM

14 BEARING, TAPERED ROLLER HEADSTOCK BEARINGS

15 SEAL, HEADSTOCK, LOWER BEARING

25 LOWER YOKE, BILLET

LOWER YOKE FOR CONVENTIONAL

FORKS


52 LOWER HEADSTOCK SPACER YOKE SPACER FOR CONVECTIONAL FORKS

GREASE, SILKOLENE, PRO RG2

32 SWITCH CUBE, LH ECIE

SCREW, M5 X 40 3

SCREW, M5 X 30 3

33 SWITCH CUBE, RH

SCREW, M5 X 22 3

34 HANDLEBAR, TUBULAR, TAPERED ALUMINIUM

35 GRIP, HANDLEBAR, LH

36 GRIP, HANDLEBAR, RH

37 THROTTLE ACTUATOR, TWIN CABLE 4

38 BOLT, CAP HD, M6 X 20 x 1.0 8 THROTTLE ACTUATOR CLAMP

39 CLAMP, CLIP-ON, RH, CLEAR ANODISE

40 CLAMP, CLIP-ON, LH, CLEAR ANODISE

52 PIN, PARALLEL, 4.0 X 18.0MM, SOLID,

STAINLESS

USED AS ANTI ROTATION FEATURE

41 HANDLEBAR, CLIP-ON, LH, CLEAR

ANODISE

42 HANDLEBAR, CLIP ON, RH, CLEAR ANODISE

43 BOLT, CAP HD, M6 X 20 x 1.0, DIN

912, SS 15

USED TO PINCH HANDLEBAR

49 20 USED TO PINCH CLAMP

51 CABLE, THROTTLE, TWIN THROTTLE CABLES FOR HIGH BARS ONLY


5.5MM LENGTH

OPEN CABLE GUIDE

CLOSE CABLE GUIDE

FERRULE

RUBBER BOOT

OPEN CABLE, 6MM OD, OUTER

CONDUIT, 795MM

OPEN CABLE, 1.5MM OD, INNER WIRE, 1030MM

CLOSE CABLE, 6MM OD, OUTER

CONDUIT, 795MM

CLOSE CABLE, 1.5MM OD, INNER WIRE, 1030MM

ADJUSTER

274

LOCK NUT


8MM LENGTH

50 CABLE, THROTTLE, TWIN, CLIP-ONS THROTTLE CABLES FOR LOW BARS ONLY

BRASS BARREL NIPPLE 5.75MM DIA X 5.5MM LENGTH

OPEN CABLE GUIDE

CLOSE CABLE GUIDE

FERRULE

RUBBER BOOT

OPEN CABLE, 6MM OD, OUTER CONDUIT, 795MM

OPEN CABLE, 1.5MM OD, INNER

WIRE, 1030MM

CLOSE CABLE, 6MM OD, OUTER CONDUIT, 795MM


WIRE, 1030MM

ADJUSTER

LOCK NUT


8MM LENGTH

28 WEIGHT, BAR END

29 RUBBER MOUNT, BAR END

30 BOLT, CAP HD, M6 X 40 x 1.0 BAR END MOUNT TO HANDLE BAR

31 LOCKNUT, FLANGED, SERRATED FACE, M6

BAR END MOUNT TO HANDLE BAR

22 TOP YOKE, USD FORKS CAFE RACER RACER TOP YOKE


16 TOP YOKE, USD FORKS, HIGH BARS CSE-03 TOP YOKE


18 SEAL, HEADSTOCK

26 YOKE, UPPER ASSY, BILLET TOP YOKE FOR CONVENTIONAL FORKS

27 BOLT, CAP HD, M8 X 20 X 1.25 20NM TOP YOKE CLAMP BOLTS CONVENTIONAL FORKS

19 NUT, UPPER YOKE, M25 80NM TOP YOKE LOCK NUT

20 LOCKNUT, M25 6 ADJUSTER NUT 40NM TO SEAT BEARINGS, BACKED OFF, THEN RE-TORQUED TO 6

NM

21 INTERMEDIATE NUT, M25 40 LOCKED UP TO ADJUSTER NUT 40 NM

44 CLAMP, HANDLEBAR, LOWER

45 BOLT, CAP HD, M10x30X1.5 HANDLEBAR CLAMP TO YOKE

46 NUT, M10 X 1.5 43 HANDLEBAR CLAMP TO YOKE

55 WASHER, M10, 10.5 X 20 X 2

47 CLAMP, HANDLEBAR, UPPER

48 BOLT, CAP HD, M8 X 22 X 1.25 20 UPPER HANDLE BAR CLAMPS BOLTS

275

Steering

Steering Inspection

Raise the front wheel off the ground.

With the front wheel pointing straight ahead, alternately

nudge each end of the handlebar. The front wheel should

swing fully left and right from the force of gravity until

the fork hits the stop.

If the steering binds or catches before the stop, check the

routing of cables, hoses, and harnesses.

If the steering feels tight, adjust or lubricate the steering.

Feel for steering looseness by pushing and pulling the

fork [A].

If you feel looseness, adjust the steering.

Steering Adjustment

With the front wheel raised off the ground remove:

Top Yoke Clamp Bolts (loosen)

Handlebar, place on one side with cables, harnesses and

hoses installed (not applicable for cafe racer).

Steering Stem Head Nut [A].

Remove the top yoke [B].

Slacken off the steering stem adjuster lock nut [A].

Tighten steering stem adjuster nut [A] to 40Nm to settle

the bearings then slacken off.

Re-tighten steering stem adjuster nut [A].

Torque: Steering Stem Adjuster Nut – 8Nm

If the steering is too tight, loosen the stem nut a fraction

of a turn. If the steering is too loose, tighten the nut a

fraction of a turn.

276

Note: Turn the stem nut 1/8th of a turn at a time maximum.

Check the steering again.

If the steering is still too tight or too loose in spite of correct adjustment, inspect the steering stem

parts.

Tighten steering stem adjuster lock nut.

Torque – Steering Stem Locknut: 40 Nm

Install the parts removed.

Handlebar (see this chapter).

Torque – Steering Stem Head Nut: 85Nm

Front Fork Top Yoke Clamp Bolts: 20Nm

Handlebar

Handlebar Removal (Sport and SE)

Remove:

Lighting Switch [A]

Engine stop switch [B]

Clutch Lever Assembly [C]

Brake Lever Assembly [D]

Throttle Twist Grip [E]

Unscrew the handlebar clamp bolts[F] , and take off the top

clamps and the handle bar

Handlebar Removal (Cafe Racer)

Remove:

Lighting Switch [A]

Engine stop switch [B]

Clutch Lever Assembly [C]

Brake Lever Assembly [D]

Throttle Twist Grip [E]

Unscrew the handlebar clamp bolts [F] completely, and

take off the handle bars using a twisting motion.

277

Handlebar installation (Sport and SE)

Install the handlebar, top clamps, and bolts as shown.

Align bars to suit preference.

Tighten the holder front bolt [A] first and then the rear

bolts [B]. When the holder is correctly installed, there will

be an even gap [C] at the rear and no gap at the front [E]

after tightening.

Torque – Handlebar clamp Bolts: 20 Nm

Ensure all cables, hoses, and wires are routed correctly

and the idle does not change at full lock on each side.

Handlebar installation (Cafe Racer)

Install the handle bar and clamp bolts as shown.

Align bars to suit preference.

Torque – Handlebar Camp Bolts: 15 Nm

Ensure all cables, hoses, and wires are routed correctly

and the idle does not change at full lock on each side.

Steering Stem

Steering Stem Removal

Remove:

Handlebar (see this chapter)

Head light (see Electrical System chapter)

Head light brackets

Raise the front wheel off the ground (see Wheels/Tires

chapter).

Remove:

Top Yoke Camp Bolt [A]

Top Yoke Pinch Bolts [B]

Push up the top yoke and remove it.

Remove:

278

Front wheel (see Wheels/Tires chapter)

Front Mudguard and Front Forks.

Remove stem locking nut and stem adjuster nut.

Remove seal and top head stock bearing.

Remove bottom yoke [A] with stem [B] down from the motorcycle.

Steering Stem Installation

Rout the cables, wires, and hoses as shown in the Cable,

Wire, and Hose Routing section of the General


Apply grease to the head stock bearings and install the

lower yoke with stem and spacer and bottom head stock

bearing installed.

Install the upper bearing on the stem shaft while pushing

up on the stem base.

Install the stem seal and stem bearing adjustment nut

and hand tighten.

Tighten steering stem adjuster nut [A] to 40Nm to settle

the bearings then slacken off.





Install the parts removed.

Top Yoke (see this chapter)

Front Fork (see Suspension chapter)

Front wheel (see Wheels/Tires chapter)

Handlebar (see this chapter)

Head Light (see Electrical System chapter)

Check and adjust the following items after installation:

Steering (see this chapter)

Throttle Cables (see Fuel System chapter)

Headlight Aim

Front Brake

279


lever until the pads are against the disc. The brakes will not function on the first application of the lever if

this is not done.

Steering Stem Warp

Whenever the steering stem is removed, or if the

steering cannot be adjusted for smooth action, check the

steering stem for straightness.

If the steering stem [A] is bent, replace the steering stem.

Steering Stem Bearing

Steering Stem Bearing Removal

Remove the steering stem (see this chapter).

Drive out the bearing outer races from the head pipe.

Note: If Either Bearing is damaged, it is recommended that both the upper and lower bearings (including

outer races) be replaced with new ones.

Remove the lower inner race [A] which is pressed onto the steering stem with a wedge.

Steering Stem Bearing Installation

Replace the bearing outer races with new ones.

Apply grease the outer races, and drive them into the head pipe at the same time.

Replace the stem bearing inner races with new ones.

Apply grease to the lower inner race, and drive it onto the stem.

Install the steering stem.

Install the upper bearing on the stem shaft while pushing up on the stem base.

Install the stem seal and stem bearing adjustment nut and hand tighten.

Tighten steering stem adjuster nut [A] to 40Nm to settle the bearings then slacken off.





Steering Stem Bearing Lubrication

A

280

Note: In accordance with the Periodic Maintenance Chart, lubricate the steering stem bearings.

Remove the steering stem.

Using a high-flash point solvent, wash the upper and lower tapered roller bearings in the cages, and

wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean of

grease and dirt.

Visually check the outer races and the rollers.

Replace the bearing assemblies if they show wear or damage.

Pack the upper and lower tapered roller bearings [A] in the cages with grease, and apply a light coat

of grease the upper and lower outer races.

Install the steering stem, and adjust the steering

281

Frame

Exploded View ................................................................................................................................................ 272

Seat ................................................................................................................................................................ 282

Seat Removal ..................................................................................................................................... 282

Seat Installation ................................................................................................................................. 282

Number Plate Hanger .................................................................................................................................... 283

Number Plate Hanger Removal.......................................................................................................... 283

Number Plate Hanger Installation ..................................................................................................... 283

Rear Bodywork ............................................................................................................................................... 283

Rear Bodywork Removal .................................................................................................................... 283

Rear Bodywork Installation ................................................................................................................ 283

Foot Control Frames ...................................................................................................................................... 283

Foot control Frame removal .............................................................................................................. 283

Foot control Frame installation ......................................................................................................... 283

282

Exploded View

283


TORQUE (NM) REMARKS

1 FRAME ASSEMBLY, SINGLE SEAT XM

20 CABLE TIE, 120MM X 3.6MM, FIR-TREE,

BLACK

CLAMP DIRECT TO FRAME, CLUTCH HOSE,

HARNESS

2 OIL FILLER CAP

3 O-RING, OIL FILLER CAP, 2.4MM SITS INSIDE OIL FILLER CAP

4 DIPSTICK

5 BRACKET, ENGINE, FRONT, STEEL, XM

6 SPACER, ENGINE MOUNT, RHS,

ALUMINIUM

7 SPACER, ENGINE MOUNT, LHS, ALUMINIUM

8 BOLT CAP HD, M8 X 57 X 1.25 TO CLAMP ENGINE MOUNT BRACKET

9 WASHER, M8, 8.4 X 16 X 1.6 TO CLAMP ENGINE MOUNT BRACKET

10 26 TO CLAMP ENGINE MOUNT BRACKET

11 BOLT, M12, ENGINE, FRONT MOUNT FRONT ENGINE MOUNT BOLT

12 WASHER, M12, 13 X 24 X 2.5 USED WITH ENGINE BOLT AND NUT

13 LOCKNUT, M12 X 1.75

85 NUT, USED WITH ENGINE MOUNT BOLT

14 FRAME ADJUSTER, M24 15

15 BOLT, M12, ENGINE, REAR MOUNT 85 REAR ENGINE MOUNT BOLT

17 VIN PLATE, UK (NOW WHOLE WORLD)

18 RIVET, HAMMER DRIVE, 3/8TH TO FIX VIN PLATE TO FRAME

19 SLEEVE, NYLON, FRAME PROTECTOR

USED BETWEEN FRAME AND FOOTREST

HANGER

284

Body Work

288


TORQUE (NM) REMARKS

EXTENSION, REAR MUDGUARD



1 MUDGUARD, USD, CARBON CARBON FIBRE FOR CSE-03

2 BOLT, BUTTON HD, INT HEX M6 X 16 X 1.0

FRONT MUDGUARD BOLT RWU FORKS

3 BOLT, BUTTON HD, INT HEX M6 X 20 X 1.0 FRONT MUDGUARD BOLT

4 LOCKNUT, FLANGED, M6 X 1.0 FRONT MUDUARD NUT

5 WASHER, PENNY, M6, 6.4 X 18 X 1.6

USED WITH FRONT MUDGUARD BOLTS

6 MUDGUARD BRACKET, USD FORKS, LH, XM

7 MUDGUARD BRACKET, USD FORKS, RH, XM

8 BOLT, BUTTON HD, M5 x 12 x 0.8

USED WITH MUDGUARD BRACKETS

9 WASHER, M5, 5.3 X 10 X 1 USED WITH BRACKET BOLTS

41 VENTURE SHIELD KIT, BODYWORK PROTECTION BODYWORK PROTECTION

10 MUDGUARD, FRONT, CARBON CARBON FIBRE FOR CSE-01/02

11 BRACKET, MUDGUARD, CONVENTIONAL OHLINS PART, GOLD, CONVENTIONAL FORKS

10 MUDGUARD, FRONT, GALACTIC BLACK, CONVENTIONAL FORKS

10 MUDGUARD, FRONT, ROYAL RED, CONVENTIONAL

FORKS

10 MUDGUARD, FRONT, CANARY YELLOW, CONVENTIONAL FORKS

10 MUDGUARD, FRONT, FACTORY SPECIAL SILVER,

CONVENTIONAL FORKS

1 MUDGUARD, GALACTIC BLACK, USD FORKS

1 MUDGUARD, FRONT, ROYAL RED, USD FORKS

1 MUDGUARD, FRONT, CANARY YELLOW, USD

FORKS

1 MUDGUARD, FRONT, FACTORY SPECIAL SILVER, USD FORK

42 BATTERY BOX, STEEL, XM STEEL FABRICATION

43 BRACKET, TWIN RELAY, XM

44 BOLT, BUTTON HD, M6 X 16 BATTERY BOX TO FRAME

45 WASHER, M6, 6.4 X 12 X 1.6 USED WITH FRONT BATTERY BOX BOLT

32 NUMBER PLATE HANGER, CF CARBON FIBRE FOR SE

33 BRACKET, NUMBER PLATE, MOULDED PLASTIC MOULDED HANGER

34 NUMBER PLATE BRACKET, STEEL, XM

35 P-CLIP, 13MM TO MOUNT REAR HARNESS

36 WASHER, PENNY, M6, 6.4 X 18 X 1.6 USED WITH HANGER BOLTS

37 BOLT, CAP HD, M6 X 30 NUMBER PLATE BRACKET + HANGER BOLTS

38 GROMMET, RUBBER, 14MM PROTECTION FOR HARNESS HOLE

39 BOLT, BLACK, M5 X 20 NYLON NUMBER PLATE BOLT

289

23 BOLT, YELLOW, M5 X 20 NYLON NUMBER PLATE BOLT

24 NUT, BLACK, M5 NYLON NUMBER PLATE NUT

32 NUMBER PLATE HANGER, CF CARBON FIBRE

25 REAR BODYWORK, MLD AS RECIEVED FROM ACERBIS

26 BOLT, CAP HD, M6 X 30 REAR BODY WORK FRONT BOLTS

27 WASHER, PENNY, M6, 6.4 X 18 X 1.6 USED WITH REAR BODY WORK BOLTS

28 RUBBER MOUNT, REAR BODYWORK REAR BODY WORK RUBBER

MOUNTS

25 PANEL, REAR, GALACTIC BLACK, GOLD TEXT

25 PANEL, REAR, ROYAL RED, GOLD TEXT

25 PANEL, REAR, CANARY YELLOW, BLACK TEXT

25 PANEL, REAR, FACTORY SPECIAL SILVER, BLACK

TEXT/BORDER RED PIN STRIPE

25 PANEL, REAR, FACTORY SPECIAL SILVER, BLACK TEXT

29 SEAT, RIDER, FORMED

RUBBER FOOT, SEAT

31 BOLT, CAP HD, M6 X 50 X 1.0 SEAT TO FRAME

40 GROMMET, ID 14 X OD 9.0 X 12.5MM SEAT TO BODY WORK

30 SEAT, RIDER, FORMED, VINYL

RUBBER FOOT, SEAT

12 FLYSCREEN, CARBON CARBON

13 BOLT, BUTTON HD, M5 X 16

TO MOUNT FLY SCREEN TO BRACKET

14 LOCKNUT, FLANGED, M5 X 0.8

TO MOUNT FLY SCREEN TO

BRACKET

15 FLYSCREEN BRACKET, LH, XM

16 FLYSCREEN BRACKET, RH, XM

12 FLYSCREEN, ROYAL RED, STANDARD RED FLYSCREEN

12 FLYSCREEN, CANARY YELLOW, STANDARD YELLOW FLYSCREEN

12 FLYSCREEN, FACTORY SPECIAL, SILVER SILVER FLYSCREEN

12 FLYSCREEN, GALACTIC BLACK BLACK FLYSCREEN

12 FLYSCREEN, ROYAL RED, STANDARD FOR ACCESSORY ONLY

12 FLYSCREEN, CANARY YELLOW, STANDARD FOR ACCESSORY ONLY

12 FLYSCREEN, FACTORY SPECIAL, SILVER FOR ACCESSORY ONLY

12 FLYSCREEN, GALACTIC BLACK FOR ACCESSORY ONLY

15 FLYSCREEN BRACKET, LH, XM FOR ACCESSORY ONLY

16 FLYSCREEN BRACKET, RH, XM FOR ACCESSORY ONLY

17 CHAINGUARD, CARBON, LARGE

18 HUGGER, CARBON

19 HUGGER, MOULDED

20 BOLT, CAP HEAD, M5 X 15 X 0.8 7 TO BOLT HUGGER

21 WASHER, PENNY, M5, 5.3 X 15 X 1.2 USED WITH HUGGER + CHAIN GUARD BOLTS

22 CHAIN GUARD, STEEL

SNAP RING

SEAL, OIL

290

WASHER, OIL SEAL

TUBE, INNER, LH

SEALING WASHER

CAPSCREW, OIL LOCK


291


TORQUE (NM) REMARKS

1 FOOT CONTROL FRAME, LH, XM STEEL FABRICATION

2 FOOT CONTROL FRAME, RH, XM STEEL FABRICATION

3 BOLT CAP HD, M8 X 50 X 1.25 27 FOOT CONTROL FRAME TO FRAME ASSY

4 BALL JOINT - NIPPLE ASSY, M6

5 CONTROL PLATE, LH, BILLET

6 CONTROL PLATE, RH, BILLET

7 BOLT, CAP HD, M6 X 20 x 1.0

8 LOCKNUT, M6 X 1.0

9 ROD, GEAR LINKAGE

10 PEDAL, ASSY, GEAR/REAR BRAKE,

FORGED GEAR CHANGE AND BRAKE LEVER

11 NUT, M6 × 1.0, PLAIN FOR GEAR CHANGE

38 PLATE TO GEAR ROD ASSY

12 BOLT, CAP HD, M6 X 16 x 1.0

LOCATED IN ARM, GEAR SELECTOR,

SPLINED

13 PEDAL, GEAR/REAR BRAKE, FORGED

14 PIN, CLEVIS, FOOTPEG 6MM PIN BETWEEN FOOT PEG AND CLEVIS

15 CLEVIS, RH

16 FOOTPEG, TURNED

17 FOOTPEG, RUBBER

18 BALL BEARING, FOOTPEG

19 SPRING, FOOTPEG

20 FOOTPEG PLATE, ANTI ROTATION, XM ANTI ROTATION WASHER BETWEEN CLEVIS AND CONTROL PLATE

39 WASHER, M10, 10.5 X 20 X 2 WASHER TO GO BETWEEN ANTI ROTATION PLATE AND M10 NUT

21 LOCKNUT, M10 X 1.5 40 TO CLAMP CLEVIS + PEG ASSY TO CONTROL PLATE

22 FOOT PEG, TOE, TURNED

23 BOLT, CAP/HD, M6 X 40 10 TO CLAMP TOE PEG TO PEDAL

24 FOOT PEG, TOE, RUBBER

25 PLATE, ACTUATOR, REAR BRAKE, XM

26 BOLT, CSK HD, M4 X 0.7 X 12 7 TO CLAMP PLATE TO PEDAL

27 PLATE, ROD ASSY, GEAR PEDAL BOLTED ONTO PEDAL, GEAR REAR BRAKE FORGED

28 SIDESTAND, FABRICATED, XM FABRICATED STEEL

29 SPRING, SIDE STAND

30 PIVOT BOLT, SIDE STAND 20 USE THREE BOND 1327

31 SWITCH, SIDE STAND

32 BOLT, BUTTON HD, INT HEX, M6 X 25

X 1.0 USED TO CLAMP SIDE STAND SWITCH TO PIVOT BOLT

33 SPACER, SWITCH, SIDE STAND USED AS COMPRESSION LIMITER IN SWITCH

40 SIDE STAND STOP, 19mm

GREASE, SILKOLENE, PRO RG2 APPLY TO PIVOT FACES

34 BOLT, LOW CAP HD, M4 X 10 X 0.7 USED TO BOLT PLATE ROD ASSY GEAR PEDAL

35 ARM, GEAR SELECTOR, SPLINED, MACHINED

USED TO CONNECT TO GEAR CHANGE SHAFT

36 5MM E-CLIP USED TO HOLD PIN CLEVIS IN

37 CLEVIS, LH, GEAR, PEDAL PIVOT USED ON GEAR SIDE ONLY

292

OIL / GREASE

Seat

Seat Removal

Remove the Seat bolts [A] on both sides.

Pull the seat forward and up [B].

Seat installation

Slip the seat hook [A] under the rear seat and into the

location hole [B].

Tighten the seat bolts.

Torque - Seat Bolts: 8 Nm

Number plate hanger

Number plate hanger Removal

Remove the number plate hanger bolts [A] and lower the

number plate.

Disconnect the rear indicators and brake light and remove

number plate hanger.

Number Plate Hanger Installation

Connect the indicators and rear bracket light and push the

connector into the rear body work.

Whilst holding the number plate hanger up install the

number hanger bracket bolts and hand tighten.

Torque – Number plate bracket bolts: 8 Nm

293

Rear Bodywork

Rear Bodywork Removal

Remove the number plate hanger (see this chapter).

Remove seat (see this chapter).

Remove the remaining rear bodywork bolts [A].

Disconnect the ECU, Fuse Box, Relay box, and rear lighting

(see Electrical System chapter).

Remove the rear bodywork.

Rear Bodywork Installation

Install the rear bodywork.

Connect the ECU, Fuse Box, Relay Box, and Rear Lighting

(see Electrical System chapter).

Install the front, rear body work bolts [A]

Torque: rear body work bolts: 8Nm

Install the number plate hanger (see this chapter).

Install the rear seat (see this chapter)

Foot control Frames

Foot control Frame removal

Remove rear brake master cylinder assembly (see Brakes

chapter)

Remove foot control frame bolts [A]

Remove the foot control frames.

Foot control Frame installation

Install the foot control frame bolts and tighten

Torque – Foot control frame bolts: 27Nm

Install rear brake master cylinder assembly (see Brakes chapter)

294

Electrical System

Exploded View ................................................................................................................................................ 286

Parts Location ................................................................................................................................................ 301

Wiring Diagram .............................................................................................................................................. 302

Specifications ................................................................................................................................................. 303

Precautions .................................................................................................................................................... 304

Electrical Wiring ............................................................................................................................................. 304

Wiring Inspection ........................................................................................................................................... 304

Battery ............................................................................................................................................................ 305

Battery Removal ................................................................................................................................. 305

Battery Installation ............................................................................................................................. 305

Electrolyte Filling (Convectional Battery Only ................................................................................... 350

Initial Charge ...................................................................................................................................... 305

Precautions ........................................................................................................................................ 350

Charging Condition Inspection ........................................................................................................... 306

Refreshing Charge .............................................................................................................................. 306

Alternator ....................................................................................................................................................... 307

Alternator Cover Removal.................................................................................................................. 307

Alternator Cover Installation ............................................................................................................. 307

Alternator Rotor Removal .................................................................................................................. 307

Alternator Rotor Installation .............................................................................................................. 307

Alternator Stator Removal ................................................................................................................. 308

Alternator Stator Installation ............................................................................................................. 308

Charging System ............................................................................................................................................. 309

Regulator / Rectifier Removal ............................................................................................................ 309

Regulator Rectifier / Output Voltage Inspection ............................................................................... 309

Regulator / Rectifier Inspection ......................................................................................................... 310

Ignition System .............................................................................................................................................. 311

Spark Plug Removal / Installation ...................................................................................................... 311

Spark Plug cleaning / Inspection ........................................................................................................ 311

Spark Plug Gap ................................................................................................................................... 311

Ignition Coil Removal ......................................................................................................................... 311

Ignition Coil Installation ..................................................................................................................... 311

Ignition Coil Inspection ...................................................................................................................... 312

Pickup Coil Removal ........................................................................................................................... 313

Pickup Coil inspection ........................................................................................................................ 313

Rotor Inspection ................................................................................................................................. 313

ECU ................................................................................................................................................................. 313

ECU Unit Removal .............................................................................................................................. 313

ECU Unit Inspection ........................................................................................................................... 314

ECU Unit Installation .......................................................................................................................... 314

Electric Starter System .................................................................................................................................. 314

295

Starter Motor Removal ...................................................................................................................... 314

Starter Motor Installation .................................................................................................................. 315

Starter Relay, Inspection .................................................................................................................... 315

Starter Circuit Relay Inspection .......................................................................................................... 315

Lighting System .............................................................................................................................................. 316

Headlight Beam Vertical Adjustment ................................................................................................. 316

Headlight Beam Horizontal Adjustment ............................................................................................ 316

Headlight Bulb Replacement .............................................................................................................. 316

Headlight Unit Removal ..................................................................................................................... 317

Headlight Unit Installation ................................................................................................................. 317

Taillight Bulb Replacement ................................................................................................................ 317

License Bulb Replacement ................................................................................................................. 318

Headlight Relay Inspection ................................................................................................................ 318

Turn Signal Flasher Unit Inspection ................................................................................................... 318

Meters ............................................................................................................................................................ 319

Meter Removal/Disassembly ............................................................................................................. 319

Meter Assembly/Installation ............................................................................................................. 320

Tachometer Inspection ...................................................................................................................... 320

Speedometer Inspection .................................................................................................................... 320

Switches ......................................................................................................................................................... 321

Switch Inspection ............................................................................................................................... 321

Fuses .............................................................................................................................................................. 321

Main Fuse Removal ............................................................................................................................ 321

Auxiliary Fuse Removal ...................................................................................................................... 321

Fuse Installation ................................................................................................................................. 321

Fuse Inspection .................................................................................................................................. 321

296

Exploded View

299


TORQUE (NM) REMARKS

33 LOCKSET, TEXT

SWITCH, IGNITION, INCL KEYS

FILLER CAP ASSY, FUEL TANK

33 LOCKSET, TEXT



33 LOCKSET, TEXT



32 LOCKSET, UK



32 LOCKSET, UK



32 LOCKSET, UK



32 LOCKSET, UK



32 LOCKSET, UK



32 LOCKSET, UK



32 LOCKSET, UK



32 LOCKSET, UK



32 LOCKSET, UK



32 LOCKSET, UK



32 LOCKSET, UK



32 LOCKSET, UK


300


32 LOCKSET, UK



32 LOCKSET, UK



32 LOCKSET, UK



ECU TUNE, US

ECU TUNE, US

ECU TUNE, US

ECU TUNE, EURO 3

ECU TUNE, EURO 3

ECU TUNE, EURO 3

ECU TUNE, EURO 3

ECU TUNE, EURO 3

ECU TUNE, EURO 3

ECU TUNE, EURO 3

ECU TUNE, EURO 3

ECU TUNE, EURO 3

ECU TUNE, EURO 3

ECU TUNE, EURO 3

ECU TUNE, EURO 3

ECU TUNE, EURO 3

ECU TUNE, EURO 3

25 ECU, OMEX, EURO OMEX 600

52 HARNESS, MAIN

SUB-HARNESS, TILT SWITCH

SUB HARNESS, REAR

53 HARNESS, MAIN, TYPE

APPROVAL

FUSE, MINI, 10A

FUSE, 30A

RELAY, GROMMET

LEAD, STARTER

27 RELAY, FLASHER, BULB FAILURE, 10W X 12.8V

24 FUSE BOX

RELAY, NORMALLY OPEN

54 SUB-HARNESS, TILT SWITCH,

EURO TO BE USED WITH TILT SWITCH

LEAD, EARTH, BATTERY TO

ENGINE

LEAD, POSITIVE, STARTER

51 CABLE TIE, 70MM X 2.6MM, TO SUPPORT HARNESS TO FRAME

301

BLACK

50 CABLE TIE, 203MM X 4.8MM,

BLACK TO SUPPORT HARNESS TO FRAME

20 SWITCH, FALL DETECT

21 FOAM, RELAY BOX FITS INSIDE FUSE BOX LID, BATTERY STRAP,

REAR LIGHT

22 WASHER, PENNY, M4 X 4.3 X

12 X 1.0 FOR ROLLOVER SWITCH

23 BOLT, CAP HD, M4 X 25 X 0.7 7 FOR ROLLOVER SWITCH

28 HORN ASSY, HI-TONE ECIE

29 SPRING WASHER, M8

30 WASHER, M8, 8.4 X 16 X 1.6

31 BOLT, BUTTON HD, INT HEX,

M8 X 16 18 MOUNTED ON LOWER YOKE

1 IGNITION COIL PACK

2 BOLT, CAP HD, M6 X 40 X 1.0 10 TO CLAMP IGNITION COIL PACK

3 LEAD, IGNITION, KIT

4 IGNITION LEAD, RH

5 IGNITION LEAD, LH

6 BATTERY, YTZ14S YUASA HIGH SPEC

7 STRAP, BATTERY

48 GASKET, FILLER NECK FOR SPARES ONLY

49 GASKET, FILLER CAP FOR SPARES ONLY

FUEL FILLER NECK INSERT

FUEL FILLER NECK INSERT SEAL

44 WASHER, M6, 6.4 X 12 X 1.6

45 BOLT, SECURITY, M6 TO CLAMP LOCKSET

46 BOLT, CAP HD, M5 X 3O X 0.8 TO CLAMP FILLER CAP

47 BOLT, CAP HD, M5 X 15 X 0.8 TO BLANK REMAINING FILLER NECK HOLES

26 MAP SENSOR

34 SPEEDO

35 TACHO

36 ANTI-VIBRATION RUBBER, INSTRUMENTS

37 COVER, INSTRUMENTS

38 SPACER, INSTRUMENT COVER BETWEEN INSTRUMENT COVER AND

CLOCKS

39 DOMED NUT, M4 TO CLAMP INSTRUMENT COVERS

40 SWITCH, INSTRUMENT PANEL

41 PLAQUE SET, COMMANDO SE

41 PLAQUE, COMMANDO SPORT

41 PLAQUE, COMMANDO CAFE

RACER

41 PLAQUE, HAND-BUILT AT DONINGTON PARK

42 INSTRUMENT PANEL FLAT ALUMINIUM PART, MACHINED

43 BOLT, CAP HD, M8 X 20 X 1.25 20 PANEL TO YOKE FIXING

12 REGULATOR RECTIFIER, RR58

13 BOLT, CAP HD, M6 X 16 X 1.0 TO CLAMP REGULATOR RECTIFIER

302

16 BRACKET, ECU, XM

17 BOLT, CAP HD, M6 X 12 X 1.0

18 WASHER, PENNY, M6, 6.4 X 18

X 1.6 USED WITH FUSE BOX BOLTS

19 BOLT, CAP HD, M6 X 16 X 1.0 TO CLAMP FUSE BOX

11 MOUNT, RELAY, RUBBER ENGINE STOP' AND 'FUEL LIGHT'

RELAYS

14 BRACKET, TWIN RELAY TO HOLD THE RELAY

15 BOLT, CAP HD, M8 X 20 TO HOLD THE RELAY BRACKET

8 SPLASH SHIELD, TANK,

UNDERSIDE

9 STRAP, RUBBER, SPLASH SHIELD

10 CLIP, BARBED FASTENER,

BLACK, LONG TO CLAMP SPLASH SHIELD

10 CLIP, BARBED FASTENER,

BLACK TO CLAMP SPLASH SHIELD

55 DUAL LOCK, LOW PROFILE, RECLOSEABLE FASTENER

TO FIX SPLASH SHIELD TO BATTERY BOX UNDERSIDE

306


TORQUE (NM) REMARKS

1 HEADLIGHT, LH DIP

1 HEADLIGHT, LH DIP

1 HEADLIGHT, LH DIP

1 HEADLIGHT, LH DIP

1 HEADLIGHT, LH DIP

1 HEADLIGHT, LH DIP

1 HEADLIGHT, LH DIP

2 HEADLIGHT, RH DIP

2 HEADLIGHT, RH DIP

2 HEADLIGHT, RH DIP

2 HEADLIGHT, RH DIP

2 HEADLIGHT, RH DIP

2 HEADLIGHT, RH DIP

2 HEADLIGHT, RH DIP

2 HEADLIGHT, RH DIP

2 HEADLIGHT, RH DIP

2 HEADLIGHT, RH DIP

2 HEADLIGHT, RH DIP

19 REFLECTOR, REAR, RED



20 BRACKET, REAR REFLECTOR, STEEL





3 REFLECTOR, FRONT, AMBER



4 BULB, HEAD LIGHT, HEAVY DUTY

5 SNAP BUSHING, 38MM X 11.5MM TO CARRY WIRES INTO HEADLIGHT

6 SPRING WASHER, M8 USED WITH HEADLIGHT BOLTS

7 BOLT, CAP HD, M8 X 22 X 1.25 TO CLAMP HEADLIGHT

8 HEADLIGHT BRACKET, LH, CAST

9 HEADLIGHT BRACKET, RH, CAST

10 HEADLIGHT BRACKET RUBBER

11 HEADLIGHT BRACKET RUBBER, USD,

UPPER

12 HEADLIGHT BRACKET RUBBER, USD,

LOWER

13 HEADLIGHT BRACKET, CAST, USD FORKS RH

14 HEADLIGHT BRACKET, CAST, USD FORKS

LH

24 NO. PLATE LIGHT, BULB

23 BOLT, CAP HEAD, M5 X 15 X 0.8 7 TO CLAMP NUMBER PLATE LIGHT

307

15 INDICATOR, RHF,LHR ECIE

LENS, INDICATOR, WHITE

SCREW, INDICATOR LENS

BULB, INDICATOR, ORANGE

16 INDICATOR, LHF, RHR ECIE

LENS, INDICATOR, WHITE

SCREW, INDICATOR LENS

BULB, INDICATOR, ORANGE

25 REAR LIGHT, ECE

26 MOUNT, ANTI VIBRATION, REAR LIGHT BETWEEN LIGHT AND BODY WORK

27 BOLT, CAP HD, M4 X 20 X 0.7 FOR MOUNTING REAR LIGHT

17 BOLT, CAP HD, M6 X 16 X 1.0 FOR MOUNTING INDICATORS

18 LOCKNUT, FLANGED, M6x1.0 FOR MOUNTING INDICATORS

21 BRACKET, REFLECTOR, REAR, XM

22 BOLT, BUTTON HD, M5x12 REFLECTOR BRACKET TO NUMBER PLATE HANGER

309


TORQUE (NM) REMARKS

1 SENSOR, TEMPERATURE 15

2 WASHER, M12, 12.2 X 17.9 X 2, COPPER USED WITH TEMPERATURE SENSOR

DOW CORNING 340 HEAT SINK COMPOUND, 100g

APPLY TO TEMP SENSOR AS REQUIRED

3 SENSOR, SPEED CAM POSITION AND GEARBOX ROAD SPEED

4 BOLT, CAP HD, M6 X 12 X 1.0, DIN 912,

12.9, BZP 12 TO CLAMP SPEED SENSORS

5 SWITCH, NEUTRAL, M10x1.25 12

6 WASHER, M10, COPPER, ID 10.2, OD 13.9 X 1.0 USED WITH NEUTRAL SWITCH

7 SPARK PLUG, CR9EB 12 FIRST USE TORQUE ONLY

310


TORQUE (NM) REMARKS

1 ROTOR, ALTERNATOR

2 BOLT, CAP HD, M8 X 16 X 1.25, DIN 912, 12.9

25 THREEBOND 1327

9 STATOR, ASSY

3 STATOR

10 SENSOR, CRANK POSITION

4 BOLT HEX, HD, M6 X 35 DIN 933, 10.9 12 TO CLAMP STATOR TO COVER

5 PIN, DOWEL, 4.0 X 10, SOLID, DIN 6325

H&G STATOR TO COVER

6 P-CLIP, ALUMINIUM, ID 6.5MM GENERATOR LEAD TO COVER

7 BOLT, BUTTON HD, INT HEX, M5 X 10, ISO

7380, 10.9 5 TO CLAMP P-CLIP TO COVER (TB1342)

8 BOLT, CAP HD, M5 X 12 X 0.8, DIN 912, 12.9 5 USED TO CLAMP CRANK SENSOR

ADHESIVE, ANAEROBIC, TB1342, 250G, (LOW STRENGTH) THREEBOND 1342

311

Parts Location

1 Headlight, Signal 9 ECU 17 Battery 25 Natural Switch

2 Light Switch 10 Regulator/Rectifier 18 Main Fuse 26 Lambda Sensors

3 Fuel light Relay 11 Crank Sensor 19 Throttle body/Idle Air 27 Ignition

4 Fuel Pump 12 Side Stand Switch 20 Starter Motor 28 Clocks

5 Head Temp Sensor 13 Alternator 21 Air Temp Sensor 29 Number Plate bulb

6 Oil Pressure Switch 14 Cam Sensor 22 Brake Light Switch Rear 30 Front Brake Switch

1

2 3

4

5

6

7

8 9

10

11

14

15

16

17

18

19

20

21

22 23

24

25

12 13

26

27

28

29

30

312

7 Road Speed Sensor 15 Ignition Coil 23 Brake Light

8 Relay/Fuse Box 16 Starter/Kill Switch 24 Indicators

Wiring

Diagram

313

Specification


Battery:

Type YTZ 14 S ---

Capacity 12 V 14.5 Ah ---

Voltage 12.6 V or more ---

Charging system:

Alternator type Three-phase AC ---

Charging voltage Idle 12 ~ 20V ---

(regulator/rectifier output voltage)

Alternator output voltage more than 63 V @4000 r/min (rpm)

---

Charging Coil resistance 0.3 ~ 2 Ω (x 1 Ω) ---

Regulator/rectifier resistance in text ---

Ignition System:

Crank Sensor air gap 0.4 ~ 0.7 mm ---

crank sensor resistance 100 ~ 150 Ω (x 10 Ω) ---

Ignition coil:

Arcing distance 7mm or more ---

Primary coil resistance 0.1 ~ 0.4 Ω ---

Secondary coil resistance 3 ~ 10 kΩ (x 1kΩ) ---

Spark plug:

Spark plug gap 0.8mm ~0.9mm 1mm

Spark plug cap resistance 3 ~ 10 kΩ (x 1kΩ) ---

ECU resistance in text ---

314

Precautions

Note: There are a number of important precautions that are musts when servicing electrical systems. Lean

and observe all the rules below.

Do not reverse the battery lead connections. This will burn out the diodes in the electrical parts.

Always check battery condition before condemning other parts of an electrical system. A fully

charged battery is a must for conducting accurate electrical system tests.

The electrical system should never be struck sharply, as with a hammer, or allowed to fall on a hard

surface. Such a shock to the parts can damage them.

To prevent damage to electrical parts, do not disconnect the battery leads or any other electrical

connections when the ignition switch is on, or the engine is running.

Because of the large amount of current, never keep the starter switch pushed when the starter

motor will not turn over, or the current may burn out the starter motor windings.

Do not use a meter illumination bulb for other than the voltage or wattage specified in the wiring

diagram, as the meter panel could be warped by excessive heat radiated from the bulb.

Take care not to short the leads that are directly connected to the battery positive (+) terminal to

the chassis ground.

Troubles may involve one or in some cases all items. Never replace a defective part without

determining what CAUSED the failure. If the failure was caused by some other item or items, they

too must be repaired or replaced, or the new replacement will soon fail again.

Make sure all connections in the circuit are clean and tight, and examine wires for signs of burning,

fraying, etc. Poor wires and bad connections will affect electrical systems operation.

Measure coil and winding resistance when the part is cold (at room temperature).

Electrical Wiring

Wiring Inspection

Visually inspect the wiring for signs of burning, fraying, etc.

If any wiring is poor, replace the damaged wiring.

Pull each connector apart and inspect it for corrosion, dirt, and damage.

If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it.

Check the wiring for continuity.

Use the wiring diagram to find the ends of the lead which is suspected of being a problem.

Connect the hand tester between the ends of the leads.

Set the tester to 1 Ω range, and read the tester.

If the tester does not read 0 Ω, the lead is defective. Replace the lead or the wiring harness if

necessary.

315

Battery

Battery Removal

Remove:

Seat (see Frame chapter).


Remove the battery strap.

Disconnect the battery negative ( - ) cable first, and then

the positive ( + ) cable.

Take out the battery.

Battery Installation

Connect the battery positive ( + ) cable first, and then the negative ( - ) cable.

Run the battery cables according to the Cable, Wire, and Hose Routing section of the General


Install:

Battery Strap

Fuel Tank (See Fuel System chapter)


Electrolyte Filling

Note: Only use a maintenance free battery and follow manufactures instructions to fill if required.

Initial Charge

Change at 0.9 A for 2~3 hours

Precautions

Battery does not need topping up.

Warning: Do not top up as sealed battery type only.

Refreshing charge:

If an engine will not start, a horn sounds weak, or lights are dim, it indicates the battery has been

discharged. Give refresh change for 5 to 10 hours with charge current shown in specification (see

Refreshing Charge).

When a fast charge is inevitably required, do it following precisely the maximum charge current and

time conditions indicated on the battery.

Caution: This battery is designed to sustain no unusual deterioration if refresh-charged according to the

method specified above. However, the battery performance may be reduced noticeably if charged under

conditions other than given above. Never remove the sealing plug during refresh charge.

316

When you do not use the motorcycle for months, give a refresh charge before you store the

motorcycle and store it with the negative lead removed. Give a refresh change every six months

during storage.

Battery life:

o If the battery will not start the engine even after several refresh charges, the battery has

exceeded its useful life. Replace it. (Provided, however, the vehicle`s starting system has no

problem.)

Warning: Keep the battery away from sparks and open flames during charging, since the battery gives off

an explosive gas mixture. When using a battery charger, connect the battery to the charger before turning

on the charger. This procedure prevents sparks at the battery terminals which could ignite any battery

gasses. No fire should be drawn near the battery, or no terminals should have the tightening loosened. The

battery contains acid. Be careful not to have it touch your skin or eyes. If it touches, wash it off with liberal

amount of water. Get medical attention if severe.

Charging Condition Inspection

Note: Battery charging condition can be checked by measuring battery terminal voltage.

Remove:


Fuel Tank (see Fuel system chapter)

Disconnect the battery terminal leads.

Caution: Be sure to disconnect the negative terminal first.

Measure the battery voltage

Battery Terminal Voltage:

Standard: 12.6 V more

Refreshing Charge

Remove the battery (see Battery Removal).

Refresh-charge by following method according to the battery terminal voltage

Caution: This battery is a sealed type. Never remove the seal cap even at charging. Never add water.

Charge with current and time as stated below.

Terminal Voltage: 11.5 ~ 12.6 V

Standard Change: 0.9 A x 5 ~ 10 h

Quick Charge: 4.0 A x 1 hour

317

Caution: If Possible do not quick charge. If the quick charge is done due to unavoidable circumstances, do

standard change later on.

Terminal Voltage: less than 11.5 V

Charging Method: 0.9 A x 20 Hours

Note: Raise the voltage (25 V maximum), and charge for about 5 minutes. If ammeter shows no change in

current after 5 minutes, a new battery is required. The current, if it can flow into the battery, tends to

become excessive. Adjust the voltage as often as possible to keep the current at standard (0.9 A).

Determine battery condition after refreshing charge.

Determine the battery condition 30 minutes after completion of the charge by measuring the

terminal voltage according to the table below.

12.6 V or higher: Good > No action required

12.0 ~ 12.6 V or lower: Charge insufficient > Recharge

12.0 V or lower: Unserviceable > Replace

Alternator

Alternator/Clutch Cover Removal

Alternator cover removal (see Clutch chapter)

Alternator/Clutch Cover Installation

Alternator cover Installation (see Clutch chapter)

Fill the gearbox with oil (see Engine Lubrication System chapter).

Route the alternator leads in accordance with the Cable, Wire, and Hose Routing section in the


Alternator Rotor Removal

Remove:

Shift Pedal Spline

Alternator / Clutch Cover (see this chapter)

Unscrew the Rotor bolts 6 X [A]

Alternator Rotor Installation

Clean the following portions with an oil-less cleaning fluid

such as trichloroethylene or acetone:

Threads of rotor bolts

Rotor

Warning: These cleaning fluids are usually highly flammable and harmful if breathed for prolonged

periods. Be sure to heed the fluid manufacture’s warnings.

A

318

Fit the rotor onto the trigger disc and install the rotor bolts.

Torque – Rotor Bolts: 20 Nm

Apply Threebond 1327 to threads

Install a new gasket and the Clutch cover (see this chapter).

Install the shift Pedal (See Clutch chapter)

Alternator Stator Removal

Remove Clutch / alternator cover (See Clutch chapter).

Remove pickup coil (see Pickup Coil Removal).

Remove mounting bolts, four total.

Remove P-clips.

Remove Stator taking note of wiring routing.

Alternator Stator Installation

Ensure Dowel is installed in correct position and line stator up with dowel.

Route wiring in same position as before disassembly, ensuring wiring lies flat and it tied to pick up

towers, to maintain clearance to rotor.

Install and tighten all P-clips bolts with thread lock 1342.

319

Torque: P-Clip Bolts: 5NM

Install Stator mounting bolts with thread lock 1342.

Torque: Stator Mounting Bolts: 12NM

Install pick up (see Pickup Coil Installation).

Install Clutch / Alternator cover (See Clutch chapter).

Charging System

Regulator / Rectifier Removal

Pull off the regulator/rectifier rubber boot [A] and connector

[B].

Remove the regulator/rectifier bolts [C].

Remove the regulator/rectifier [D].

Regulator/Rectifier Output Voltage Inspection

Check the battery condition (see battery section).

Warm up the engine to obtain actual alternator operating conditions.

Check that the ignition switch is turned off and connect the hand tester to the battery terminals.

Start the engine, and note the voltage readings at various engine speeds with the headlight turned

on and off. The readings should show nearly battery voltage when the engine speed is low, and, as

the engine speed rises, the readings should also rise. But they must be kept under the specified

voltage.

Regulator Voltage - @ Meter Range 25 V: 14 ~ 15V

Turn off the ignition switch to stop the engine and disconnect the hand tester.

If the regulator/rectifier output voltage is kept between the vales given above, the charging system

is considered to be working normally.

If the output voltage is much higher than the values specified in the table, the regulator/rectifier is

defective or the regulator/rectifier leads are loose or open.

If the battery voltage does not rise as the engine speed increases, then the regulator/rectifier is

defective or the alternator output is insulated for the loads. Check the alternator and

regulator/rectifier to determine which part is defective.

Alternator Inspection

320

Note: There are three types of alternator failures: short, open (wire burned out), or less in rotor, or rotor

magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all. A

loss in rotor magnetism, which may be caused by dropping or hitting the alternator by leaving it near an

electromagnetic field, or just by aging, will result in a low output.

To check the alternator output voltage, do the following procedures.

Disconnect the alternator Connector [A].

Connect the hand tester to any two out of the three output pins coming from the alternator.

Start the engine

Run it at three different rev ranges

Set the meter to 250 V range

Voltage – Alternator: more than 34 V

If the output voltage shows the value above, the alternator operates properly and the

regulator/rectifier is damaged. A much lower reading than given in the table indicates that the

alternator is defective.

Check the stator coil resistance as follows:

Stop the engine.

Disconnect the alternator connector.

Connect the hand tester to two of the three output wires.

Note the readings (total 3 measurements).

Resistance – Stator: 0.3 – 1.0 Ω

If there is more resistance than shown above, or no hand tester reading (infinity) for any of the two

leads, the stator has an open lead and must be replaced. Much less than this resistance means the

stator is shorted, and must be replaced.

Using the highest resistance range of the hand tester measure the resistance between each of the

alternator leads and chassis ground.

Any hand tester readings less than infinity indicates a short, necessitating stator replacement.

If the stator coils have normal resistance, but the voltage check showed the alternator to be

defective, then the rotor magnetism has probably weakened, and the rotor must be replaced.

Regulator/Rectifier Inspection

Turn off the ignition switch.

Disconnect the regulator/rectifier connector.

Set the hand tester to the 1 kΩ range and make the measurements shown below.

If tester readings are not as specified, replace the

regulator/rectifier.

Range x 1 k Ω Tester Positive (+) Lead Connections

321

Ignition System

Warning: The ignition system

produces extremely high voltage. Do

not touch the spark plug, ignition

coil, or spark plug lead while the engine is running, or you could receive a severe electrical shock.

Caution: Do not disconnect the ECU connectors while the engine is running. This is to prevent ECU damage.

Spark Plug Removal/Installation

Remove the HT leads from spark plug cap

Remove or install the spark plug using the spark plug wrench

Torque – Spark Plug: 12 Nm

Spark Plug Cleaning/Inspection

Clean the spark plug, preferably in a sandblasting device and then clean off any abrasive particles.

The plug may also be cleaned using a high flash point solvent and a copper wired brush or other

suitable tools. If the center electrode or side electrode are corroded or damaged, or if the insulator

is cracked, replace the plug. Use the standard spark plug or its equivalent.

Spark Plug Gap

Measure the gap with a wire-type thickness gauge.

If the gap is outside the service limit replace the spark

plug.

Spark plug Gap –

Standard: 0.8 mm


Ignition Coil Removal

Remove the fuel tank (see Fuel System chapter).

Pull the spark plug lead off the spark plug.

Disconnect the coil lead [A]

Remove coil bolt [B]

Remove coil [C]

Ignition Coil Installation

Install ignition coil [A] as shown

Install ignition coil bolt [B]

N1 B111 B112 B113 B26

(-)

N1 - 20~200 20~200 20~200 20~80

B111 1~7 - 40~500 40~500 20~200

B112 1~7 40~500 - 40~500 20~200

B113 1~7 40~500 40~500 - 20~200

B26 2~10 1~7 1~7 1~7 -

322

Torque – Ignition coil bolt: 10 Nm

Connect coil lead [C]

Connect the spark plug leads, with the shorter lead going to the left hand cylinder, and the longer

to the right hand.

Install the fuel tank (see Fuel System chapter).

Ignition Coil Inspection

Remove the ignition coil (see this chapter).

Measure the arcing distance with a suitable commercially available coil tester to check the

condition of the ignition coil.

Connect the ignition coil with the spark plugs left attached to the end of the spark plug leads to the

tester in the manner prescribed by the manufacture and measure the arcing distance.

Ignition Coil Arcing Distance:

7 mm or more

Warning: To avoid extremely high voltage shocks, do not touch the ignition coil body or leads.

If the distance reading is less than the specified value, the ignition coil or spark plug cap is defective.

To determine which part is defective, measure the arcing distance again with the spark plug cap

removed from the ignition coil. Remove the cap by turning it counter clockwise.

If the arcing distance is subnormal as before, the trouble is with the ignition coil itself. If the arcing

distance is now normal, the trouble is with the spark plug cap.

If the coil tester is not available, the coil can be checked for a broken or badly shorted winding with

a hand tester.

Note: The hand tester cannot detect layer shorts and shorts resulting from insulation brake down

under high voltage.

Measure the primary winding resistance as follows.

Connect the tester between the coil terminals.

Set the tester between the coil terminals.

Measure the secondary winding resistance as follows.

Remove the plug cap by turning it counter clockwise.

Connect the tester between the spark plug lead and terminal.

Set the tester to the 1 k Ω range and read the tester.

Measure primary winding resistance [A].

Measure secondary winding resistance [B].

Ignition Coil [C]

Ignition Coil Winding Resistance

Primary: 0.14~ 0.22 Ω

323

Secondary: 3.8 ~ 5.8 kΩ

If the hand tester does not read as specified, replace the coil.

Pickup Coil Removal

Remove the clutch cover (see Clutch chapter).

Pull the pickup coil lead grommet [A] out of the notch of

the cover.

Disconnect the pickup coil and alternator leads.

Remove the p-clips securing the pickup coil and

alternator wires.

Remove the Alternator (see this chapter).

Unbolt the pickup coil and remove (Take note of wire

location and location of cable-tie).

Pick up coil Inspection

Remove the pickup coil (see this chapter).

Connect the hand tester between the pickup coil leads

Set the tester to the x 10 Ω range and read the tester.

Pickup Coil Resistance

100 ~200 Ω (x 10 Ω)

If there is more resistance than the specified value, the coil has an open lead and must be replaced.

Much less than this resistance means the coil is shorted, and must be replaced.

Using the highest resistance range of the hand tester, measure the resistance between the pickup

coil lead terminals and chassis ground.

Any Hand tester reading less than infinity indicates a short, necessitating replacement of the pickup

coil assembly.

Rotor Inspection

Check the surface for damage such as chipping or grooving.

If the timing projection on the flywheel is visibly damage, replace the rotor.

Electronic Control Unit (ECU)

Electronic Control Unit (ECU) Removal

Disconnect tilt switch harness [A]

A

324

Remove tilt switch harness bolts [A], tilt switch

connecter [B].

Remove Pressure sensor connection [C].

Remove Relay box bolts [A], take out relay box, and

remove rear sub harness from main harness.

Remove ECU bracket bolts [A] and ECU bracket.

Remove ECU.

Caution: Do not drop or strike the ECU and this will

damage the ECU.

ECU Inspection

Visually inspect the ECU for corrosion, damage and water ingress.

If all connections are good, and the ECU still does not function as intended contact your Norton

Dealer.

ECU Installation

ECU Installation is the reverse of the ECU Removal process detailed above.

Torque –

ECU Bracket: 8 Nm

Relay Box: 8 Nm

Tilt Switch: 6 Nm

A B

C

A

A

325

Starter System

Starter Motor Removal

Remove:

Clutch Cover (see Clutch chapter)

Remove electrical connections from back of starter. [A]

Remove starter motor bolts [A].

Gently remove starter motor.

Starter Motor Installation

Clean any gasket sealant off the crank case.

Install a new starter motor gasket and use gasket sealant

on both sides.

Install starter motor and bolts.

Torque – Starter motor bolts: 20 Nm

Install Clutch Cover (see Clutch chapter).

Starter Relay Inspection

Remove the seat (see Frame chapter)

Remove the starter relay [A].

Connect hand tester positive (+) to connection point 3

and negative (-) to 5.

Connect (12V) power positive (+) to connection point 2

negative (-) to 1.

If the relay does not work as specified, the relay is

defective. Replace the relay.

Testing Relay

Hand tester range: X 1 Ω range

Criteria: When battery is connected > 0 Ω

Criteria: when battery is disconnected > infinite Ω

Starter Circuit Relay Inspection

A

326


Remove the starter relay [A].

Connect hand tester positive (+) to connection point 3 and negative (-) to 5.

Connect (12V) power positive (+) to connection point 2 negative (-) to 1.

If the relay does not work as specified, the relay is defective. Replace the relay.

Testing Relay




Lighting System

Headlight Beam Vertical Adjustment

Slacken headlight bolts [A].

On high beam, the brightest point should be slightly below

horizontal with the motorcycle on its wheels and the rider

seated.

Adjust the headlight beam to local regulations.

Adjust the vertical adjustment by tilting the headlight unit

up or down.

Tighten headlight bolts [A].

Torque – Headlight Bolts: 12 Nm

Headlight Beam Horizontal Adjustment

Adjust the beam using the adjuster screw [A] clockwise or

anti clockwise to move the beam right or left.

Headlight Bulb Replacement

Remove front headlight screw [A].

Remove the front headlight section [B] from the headlight

body.

327

Remove the connector [A] from the back of the light.

Remove the bulb [B] from the connector and replace with a

new one.

Install the connector and the front head light section,

tighten head light screw.

Check the headlight aim after installation (see this chapter).

Headlight Unit Removal

Following on from headlight bulb replacement.

Remove head light bolts [A] taking care to support the

headlight when these have been removed.

Feed all the electrical connections out the back of the

headlight.

Headlight Unit Installation

Install the head light unit so the box connector is at the

bottom.

Feed all the electrical connections through into the back

of the head light, ensure no wires are snagged.

Install bolts [A] hand tight.

Install the lighting into the headlight front section and

install the front section.

Tighten screw on front section [A]

Set headlight aim to local legislations and tighten

headlight bolts [A]

Torque – Headlight Bolts: 12 Nm

A

A

328

Taillight Bulb Replacement

Note: it is recommended that Kevlar gloves be worn when

changing the bulb due to the risk associated with the glass

shattering.

Take out the screws [A] in the tail light lens.

Pull the lens off.

Push the bulb in [A] firmly, turn it counter clockwise [B],

and pull it out.

Be sure the socket is clean

Insert the new bulb, aligning the pins with the grooves in the walls of the socket (one is higher than

the other ensure these are correctly alight with the corresponding groves).

Push the bulb in, turn it clockwise, and release it. It should lock in position.

Tighten the two screws. Be careful not to over tighten them.

License Light Bulb Replacement

Remove bolt [A] from number plate light body.

Hold the rubber light mount, and pull the rubber mount

out of the body.

Hold the rubber mount and pull the bulb out in a rocking

motion.

Insert new bulb by pushing in with tabs aligned.

Headlight Relay Inspection


Remove the headlight relay [A].

Connect hand tester positive (+) to connection point 3

and negative (-) to 5.

Connect (12V) power positive (+) to connection point 2

negative (-) to 1.

If the relay does not work as specified, the relay is

defective. Replace the relay.

Testing Relay




Turn Signal Flasher Unit Inspection

A

329

Note: Since the turn signal relay is designed to operate correctly only when two turn signals (one front and

one rear) and the turn signal indicator light are properly connected in the circuit, trouble may result from a

burned out bulb, a bulb of incorrect wattage, loose wiring, as well as from a defect in the relay itself. In

general, if the trouble with the circuit is common to both right and left turn signals, it is probably caused by

a defective turn signal flasher unit, although it may be due to a bad switch, wiring, or battery. If the trouble

is with only one side - either right or left, then the flasher unit is not at fault since one is used for both

sides.


Check the condition of the flasher unit [A] for the following problems:

Neither right or left turn signal comes on at all:

Check the battery voltage is normal.

Unplug the flasher unit leads and use the hand tester to

check that there is continuity (close to zero ohms) between

the relay terminals.

If there is no tester reading (infinity) or if there are several

ohms resistance, replace the flasher unit with a new one.

Turn the tester to the 25 ~V DC range, connect the (+)

tester lead to the one lead that was disconnected from the

flasher unit, and connect (-) tester lead to the other lead.

With the ignition switch on, first switch the turn signal switch to the R and then to the L position.

The tester should register battery voltage at either position.

If it does not, the fuse, ignition switch, or wiring is at fault.

Both right or left turn signals come on and stay on or flash too slowly:

Check that battery voltage is nominal.

Check that all wiring connections are good.

Check that the turn signal bulbs and indicator bulb are of the correct wattage.

If all of the above check well, replace the flasher unit.

A signal light on one side comes on:

Either the light that does not come on is burned out or of the incorrect wattage, or the wiring is

broken or improperly connected.

Neither light on one side comes on.

Unless both lights for that side are burned out, the trouble is with the turn signal switch.

Flashing rate is too fast:

If this occurs on both the right and left sides, check that the battery is not being overcharged.

If the alternator and the battery voltage are normal,

replace the turn signal flasher unit.

If this occurs on only one side, one or both of the turn

signal bulbs are too high wattage.

Meters

330

Meter Removal/Disassembly

Remove meter cover bolts [A].

Remove meter covers [B].

Disconnect four meter connectors [A].

Pull the meters up through the instrument panel [B].

Meter Assembly/Installation

Pull the meters up through the instrument panel [B].

Connect four meter connectors [A].

Install meter covers [B].

Tighten meter cover bolts [A].

Tachometer Inspection

Check the tachometer circuit wiring.

If all wiring and components other than the tachometer unit check out good, the unit is suspect.

Check the unit as shown.

Remove and disassemble the meters (see this chapter).

Caution: When inspecting the tachometer operation, remove the ECU connections from the back to avoid

damage to the ECU unit.

Remove both connector boxes.

On the 8 Pin socket connect positive (+) 12V supply to point 1, and point 4.

On the 8 Pin socket connect negative (-) to point 2.

331

If the meter shows current trip mileage then the unit is functioning correctly and the problem is

elsewhere in the circuit.

If it does not shows anything then the unit is faulty and should be replaced.

Speedometer Inspection

Check the speedometer circuit wiring.

If all wiring and components other than the tachometer unit check out good, the unit is suspect.

Check the unit as shown.

Remove and disassemble the meters (see this chapter).

Caution: When inspecting the speedometer operation, remove the ECU connections from the back to avoid

damage to the ECU unit.

Remove both connector boxes.

On the 8 Pin socket connect positive (+) 12V supply to point 1, and point 4.

On the 8 Pin socket connect negative (-) to point 2.

Connect point 5 briefly to the positive supply, the needle should move.

If it does not shows anything then the unit is faulty and should be replaced.

Switches

Switch Inspection

Using the hand tester, check to see that the switch

connections as shown on the wiring schematic have

continuity (about zero ohms) when closed.

If it does not as specified, check all connections, if the

switch has an open or short repair it or replace with a

new one.

Fuses

Main Fuses Removal

Remove the fuel Tank (see Fuel System chapter)

Remove the fuse [A] from housing [B].

Auxiliary Fuse removal

Remove the seat (see Frame chapter).

Remove fuse box cover [A].

Remove relevant fuses by pulling.

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Fuse Installation

If a fuse fails during operation, inspect the electrical system to determine the cause, and then

replace it with a new fuse of proper amperage.

Fuse Inspection

Remove the fuse (see Fuse Removal).

Inspect the fuse element.

If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the

affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and

related components for a short circuit.

Caution: When replacing a fuse, be sure the new fuse matches the specified fuse rating for that circuit.

Installation of a fuse with a higher rating may cause damage to wiring and components.

333

Appendix

Additional Considerations for Racing ............................................................................................................ 323

Spark Plugs ......................................................................................................................................... 323

Spark Plugs Inspection ....................................................................................................................... 323

Trouble Shooting Guide ................................................................................................................................. 324

Nut, Bolt, and Fastener Tightness .................................................................................................................. 333

Tightness Inspection .......................................................................................................................... 333

General Lubrication........................................................................................................................................ 334

Lubrication ......................................................................................................................................... 334

Unit Conversion Table .................................................................................................................................... 335

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Additional Considerations for Racing

This motorcycle has been manufactured for use in a reasonable and prudent manner and as a

vehicle only. However, some may wish to subject this motorcycle to abnormal operation, such as would be

experienced under racing conditions. NORTON STRONGLY RECOMMENDS THAT ALL RIDERS RIDE SAFELY

AND OBEY ALL LAWS AND REGULATIONS CONCERNING THEIR MOTORCYCLE AND ITS OPERATION.

Racing should be done under supervised conditions, and recognized sanctioning bodies should be

contacted for further details. For those who desire to participate in competitive racing or relate use, the

following information may prove useful. However, please note the following important notes.

You are entirely responsible for the use of your motorcycle under abnormal conditions such as

racing and Norton shall not be liable for damages which might arise from such use.

Norton’s Limited Motorcycle Warranty and Emissions Systems Warranty specifically exclude

motorcycles which are used in competition or related uses. Please read the warranty carefully.

When the motorcycle is operated on public roads, it must be in its original state in order to ensure

safety and compliance with applicable regulation.

Spark Plug

The spark plug ignites the fuel and air mixture in the combustion

chamber. To do this effectively and at the proper time, the correct spark

plug must be used, and the spark plug must be kept clean and the gap must

be within the specified range.

Tests have shown the plug listed in the “General Information”

chapter to be the best plug for general use.

Since spark plug requirements change with the ignition and fuel

adjustments and with riding conditions, whether or not a spark plug of the

correct heat range is used should be determined by removing and

inspecting the plug.

When a plug of the correct heat range is being used, the electrodes

will stay hot enough to keep all the carbon burned off, but cool enough to

keep from damaging the engine and the plug itself. This temperature is about 400 ~ 800˚C and can be

judged by noting the condition and colour of the ceramic insulator around the centre electrode. If the

ceramic is clean and of a light brown colour, the plug is operating at the right temperature.

A spark plug for higher operating temperatures is used for racing such a plug is designed for better

cooling efficiency so that it will not overheat and thus is often called a “colder” plug. If a spark plug with

too cool a heat range is used – that is, a “cold” plug that cools itself too well the plug will stay too cool to

burn off the carbon, and the carbon will collect on the electrodes and the ceramic insulator.

The carbon on the electrodes conducts electricity, and can short the centre electrode to ground by

either coating the ceramic insulator or bridging across the gap. Such a short will prevent an effective spark.

Carbon build-up on the plug can also cause other troubles. It can heat up red-hot and cause pre-ignition

and knocking, which may eventually burn a hole in the top of the piston.

Carbon Fouling

Oil Fouling

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Spark Plug Inspection

Remove the spark plug and inspect the ceramic insulator.

Whether or not the right temperature plug is being used can be

ascertained by noting the condition of the ceramic insulator around

the electrode. A light brown colour indicated the correct plug is being

used. If the ceramic is black, it indicates that the plug is firing at too

low a temperature, so the next hotter type should be used instead. If

the ceramic is white, the plug is operating at too high a temperature

and it should be replaced with the next colder type.

Caution: If the spark plug is replaced with a type other than the standard plug, make certain the

replacement plug has the same thread pitch and reach (length of threaded portion) and the same type

electrode (regular type or projected type) as the standard plug.

If the plug reach is too short, carbon will build up on the plug hole threads in

the cylinder head, causing overheating and making it very difficult to insert

the correct spark plug later.

If the plug reach is too short, carbon will build up on the plug hole threads in

the cylinder head, causing overheating and making it very difficult to insert

the correct spark plug later.

If the reach is too long, carbon will build up on the exposed spark plug threads

causing overheating, pre-ignition, and possibly burning a hole in the piston

top. In addition, it may be impossible to remove the plug without damaging

the cylinder head.

Note: The heat range of the spark plug functions like a thermostat for the

engine. Using the wrong type of spark plug can make the engine run too hot

(resulting in engine damage) or too cold (with poor performance, misfiring,

and stalling).

Troubleshooting Guide

This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply

as a rough guide to assist the troubleshooting for some of the more common difficulties.

Engine Doesn’t Start, Starting Difficult:

Starter motor not rotating:

Starter lockout or neutral switch trouble

Starter motor trouble

Battery voltage low

Starter relay not contacting or operating

Starter button not connected

Wiring open or shorted

Normal Operation

Over Heating

Over Heating /

Thermal Shock

Normal Operation

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Ignition switch trouble

Engine stop switch trouble

Fuse blown

Engine won’t turn over:

Valve seizure

Valve lifter seizure

Cylinder, piston seizure

Crankshaft seizure

Balancer bearing seizure

Connecting rod Small end Seizure

Connecting rod big end seizure

Transmission gear or bearing seizure

Camshaft seizure

No Fuel flow:

No fuel in fuel tank

Fuel line clogged

Engine flooded:

Starting technique faulty (when flooded, crank the engine with the throttle fully opened to allow

more air to reach the engine.)

No spark; spark weak:

Battery voltage low

Ignition switch not turned on

Engine stop turned off

Clutch lever not pulled in or gear not in neutral

Spark plug dirty, broken, or maladjusted

Spark plug cap or high tension wire trouble

Spark plug cap shorted or not in good contact

Spark plug incorrect

ECU trouble

Pickup coil trouble

Ignition coil trouble

Alternator damaged

Ignition or engine stop switch shorted

Neutral, or starter locknut switch trouble

Wiring shorted or open

Fuel/air mixture incorrect:

Throttle body trouble

ECU trouble

Wiring shorted

Compression Low:

Spark plug loose

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Cylinder head not sufficiently tightened down

No valve clearance

Cylinder, piston worn

Piston ring bad (worn, weak, broken, or sticking)

Piston ring/groove clearance excessive

Cylinder head gasket damaged

Cylinder head warp

Valve spring broken or weak

Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface)

Poor Running at Low Speed:

Spark weak:

Spark plug dirty, broken, or maladjusted

Spark plug cap or high tension wiring trouble



ECU trouble

Pickup coil trouble

Exciter coil shorted or open


Alternator damage


injector, or air passage clogged

Air bleed pipe bleed holes clogged

Air cleaner clogged, poorly sealed, or missing

Starter plunger stuck open

Fuel tank air vent obstructed

Injector trouble

ECU trouble

Compression low:

Spark plug loose


No Valve clearance





Cylinder head warp



Other:

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ECU trouble

Idle air motor trouble

Engine oil viscosity too high

Drive train trouble

Brakes dragging

Over heating

Clutch slipping

Throttle valve does not open fully

Poor Running or No Power at High Speed:

Firing incorrect:

Spark plug dirty, damaged, or maladjusted

Spark plug cap or high tension wiring trouble



ECU trouble

Pickup coil trouble

Exciter coil shorted or open


Alternator damage


Injector, or air passage clogged

Air bleed pipe bleed holes clogged


Starter plunger stuck open

Fuel tank air vent obstructed

Injector trouble

Fuel pump trouble

Water or foreign matter in fuel

Fuel line blocked

Compression low:

Spark plug loose


No Valve clearance





Cylinder head warp



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Knocking:

Carbon build up in combustion chamber

Fuel poor quality or incorrect


Miscellaneous:

Throttle valve won’t fully open

Brakes dragging

Clutch slipping

Overheating

Engine oil level too high


Balancer malfunctioning

Drive train trouble

Crankshaft bearing worn or damaged

Overheating:

Firing incorrect:

Spark plug dirty, damaged, or maladjusted


ECU trouble


Injectors, or air passage clogged

Throttle body loose


Compression low:

Carbon build up in combustion chamber

Engine load faulty:

Clutch slipping



Brakes dragging

Lubrication inadequate:

Engine oil level too low

Engine oil poor quality or incorrect

Clutch Operation Faulty:

Clutch slipping:

No clutch lever play

Friction plate worn or warped

Steel plate worn or warped

Clutch spring broken or weak

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Clutch release mechanism trouble

Clutch hub or housing unevenly worn

Clutch not disengaging properly:

Clutch lever trouble

Clutch plate warped or too rough

Clutch spring compression uneven

Engine oil deteriorated



Clutch housing frozen on drive shaft

Clutch release mechanism trouble

Clutch hub nut loose

Clutch hub spline damaged

Gear Shifting Faulty:

Doesn’t go into gear; shift pedal doesn’t return:

Clutch not disengaging

Shift fork bent or seized

Gear stuck on the shaft

Gear positioning lever binding

Shift return spring weak or broken

Shift return spring pin loose

Shift mechanism arm spring broken

Shift mechanism arm broken

Shift pawl broken

Jumps out of gear:

Shift fork worn, bent

Gear groove worm

Gear dogs and/or dog recesses worn

Shift drum groove worn

Gear positioning lever spring weak or broken

Shift fork pin worn

Drive shaft, output, and/or gear splines worn

Over shifts:

Gear positioning lever spring weak or broken

Shift mechanism arm spring broken

Abnormal Engine Noise:

Knocking:

ECU unit trouble

Carbon built up in combustion chamber

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Fuel poor quality or incorrect


Overheating

Piston slap:

Cylinder/Piston clearance excessive


Connecting rod bent

Piston pin, piston pin hole worn

Valve noise:

Valve clearance incorrect


Camshaft bearings worn

Valve lifter worn

Other noise:

Connecting rod small end clearance excessive

Connecting rod big end clearance excessive

Piston ring worn, broken, or stuck

Piston seizure, damage

Cylinder head gasket leaking

Exhaust pipe leaking at cylinder head connection

Crankshaft runout excessive

Engine mounts loose

Crankshaft bearing worn

Primary gear worn or chipped

Alternator loose

Camshaft chain tensioner trouble

Camshaft chains, sprockets, guides worn

Camshaft, sprockets, guides worn

Balancer gear worn or chipped

Balancer position maladjusted

Balancer mechanism springs weak or broken

Balancer bearings worn

Abnormal Drive Train Noise:

Clutch noise:

Cush drive rubber damping weak or damaged

Clutch housing/friction plate clearance excessive

Clutch housing gear/primary gear worn

Metal chip jammed in clutch housing gear teeth

Outside friction plate installed incorrectly

Transmission noise:

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Bearings worn

Transmission gears worn or chipped

Metal chips jammed in gear teeth

Engine oil insufficient

Drive chain noise:

Drive chain adjusted improperly

Drive chain worn

Rear and/or engine sprocket(s) worn

Chain lubrication insufficient

Rear wheel misaligned

Abnormal Frame Noise:

Front fork noise:

Oil insufficient or too thin

Spring weak or broken

Rear shock absorber noise

Shock absorber damaged

Disc brake noise:

Pad installed incorrectly

Pad surface glazed

Disc warped

Caliper trouble

Master cylinder damaged

Other noise:

Brackets, nuts, bolts, etc. Not properly mounted or tightened

Exhaust Smokes Excessively:

White smoke:

Piston oil ring worn

Cylinder worn

Valve oil seal damaged

Valve guide worn


Black smoke:

Air cleaner clogged

Injector damaged

Idle air motor trouble

Brown smoke:

Injector damaged

Air cleaner duct loose

Air cleaner poorly sealed or missing

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Handling and/or Stability Unsatisfactory

Handlebar hard to turn:

Cable routing incorrect

Hose routing incorrect

Wiring routing incorrect

Steering stem nut too tight

Steering stem bearing damaged

Steering stem bearing race dented or worn

Steering stem lubrication inadequate

Steering stem bent

Tire air pressure too low

Handlebar shakes or excessively vibrates:

Tire worn

Swingarm sleeve or needle bearing damaged

Rim warped, or not balanced

Front, rear axle runout excessive

Wheel bearing worn

Handlebar clamp loose

Steering stem head nut loose

Handlebar pulls to one side:

Frame bent

Wheel misalignment

Swingarm bent or twisted

Swingarm pivot shaft runout excessive

Steering maladjustment

Steering stem bent

Front fork leg bent

Right and left front fork oil level uneven

Shock absorption unsatisfactory

(Too hard)

Front fork oil excessive

Front fork oil viscosity too high

Front fork damper adjustment too hard

Front fork leg bent

Tire pressure too high

Rear shock absorber adjustment too hard

(Too soft)

Front fork oil insufficient and/or leaking

Front fork oil viscosity too low

Front fork damper adjustment too soft

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Rear shock absorber springs to weak

Rear shock absorber oil leaking

Rear shock absorber adjustment too soft

Tire air pressure too low

Brake Doesn’t Hold:

Air in the brake line

Pad or disc worn

Brake fluid leaking

Disc warp

Contaminated pads

Brake fluid deteriorated

Primary or secondary cup damaged in the master cylinder

Master cylinder scratched inside

Battery Discharged:

Battery faulty (e.g. plates sulphated, shorted through sedimentation)

Battery leads making poor contact

Load excessive (e.g. Bulb of excessive wattage)

Ignition switch trouble

Alternator rotor damaged

Wiring faulty

Regulator/Rectifier trouble

Battery Overcharged:

Regulator/rectifier trouble

Battery trouble

Nut, Bolt, and Fastener Tightness

Tightness Inspection

Check the tightness of the bolts and nuts listed here in accordance with the Periodic Maintenance

Chart. Also, check to see that each cotter pin is in place and in good condition.

Note: For the engine fasteners, check the tightness of them when the engine is cold (at room temperature)

If there are loose fasteners, re-torque them to the specified torque following the specified

tightening sequence. Refer to the Torque and Locking Agent section of the General Information

chapter for torque specification. For each fastener, first loosen it by ½ turn, then tighten in.

If cotter pins are damaged, replace them with new ones.

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Nut, bolt and fastener to be checked

Wheels:

Front Axle

Front Axle Clamp Nuts

Rear Axle

Final Drive:

Chain Adjuster Locknuts

Rear Sprocket Nuts

Brakes:

Front Master Cylinder Clamp Bolts

Caliper Bolts

Rear Master Cylinder Bolts

Brake Pedal locking Pin

Brake Lever Pivot Nut

Suspension:

Front Fork Clamp Bolts

Front Fender Mounting Bolts

Swingarm Pivot Shaft Nut

Rear Shock Absorber Bolts

Steering:

Stem Head Nut

Handlebar Clamp Bolts

Engine:

Engine Mounting Bolts, Nuts

Cylinder Head Cover Bolts

Shift Pedal Bolt

Exhaust Pipe Holder Nuts

Muffler Connecting Clamp Bolts

Muffler Bolt and Nut

Clutch Lever Pivot

Others

Side Stand Pivot Bolt

Foot peg Bolts, nuts

Lubrication

Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease,

oil, dirt, or grime.

Lubricate the points listed below with indicated lubricant in accordance with the Periodic

Maintenance Chart.

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Note: Whenever the vehicle has been operated under wet or rainy conditions, or especially after a high

pressure spray water, perform the general lubrication.

Chain: Lubricate with Heavy Oil

Pivots: Lubricate with Motor Oil

Side Stand

Clutch Lever

Brake Pedal

Rear Brake Rod Joint

Footpegs

Cables: Lubricate with Cable Lubricant

Throttle Cables

Lubricate the cables by seeping oil between the cable and housing.

While the cable is disconnected at both ends, the cable should move freely within the cable

housing.

If cable movement is not free after lubrication, if the cable is frayed, or if the cable housing is

kinked, replace the cable.

Points: Lubricate with Grease

Throttle Inner Cable Lower Ends

Choke Cable Lower Ends

(Grease the lower part of the inner cable sparingly)

Unit Conversion Table

Prefixes for Units

Prefixes Symbol Power

mega M x 1000 000 kilo k x 1 000 centi c x 0.01 milli m x 0.001

micro µ x 0.000001

Units of Mass

kg x 2.205 = lb

g x 0.03527 = oz

Units of Volume

L x 0.2642 = gal (US) L x 0.22 = gal (imp) L x 1.057 = qt (US) L x 0.8799 = qt (imp)

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L x 2.113 = pint (US) L x 1.816 = pint (imp)

mL x 0.03381 = oz (US) mL x 0.02816 = oz (imp)

mL x 0.06102 = cu in

Units of Force

N x 0.102 = kg N x 0.2248 = lb kg x 9.807 = N

kg x 2.205 = lb

Units of Temperature:

F

C oo

405

409

C

F oo

409

405

Units of Length

km x 0.6214 = mile m x 3.281 = ft

mm x 0.02937 = in

Units of Torque

Nm x 0.102 = kgm Nm x 0.7376 = ftlb Nm x 8.851 = inlb kgm x 9.807 = Nm kgm x 7.233 = ftlb

kgm x 86.8 = inlb

Units of pressure

kPa x 0.0102 = kg/cm² kPa x 0.145 = psi

kPa x 0.7501 = cm Hg kg/cm² x 98.07 = kPa kg/cm² x 14.22 = psi

cm Hg x 1.333 = kPa

Units of Speed

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km/h x 0.6214 = mph

Units of Power

kW x 1.36 = PS kW x 1.341 = HP PS x 0.7355 = kW

PS x 0.9863 = HP

NORTON Commando 961 - Service Manual

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Transcript of NORTON Commando 961 - Service Manual