Maintenance Procedure

Drive Chain Wear Inspection

• Remove:

Chain Cover

• Rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links.

• If there is any irregularity, replace the drive chain.

• Lubricate the drive chain if it appears dry.

• Stretch the chain taut by hanging a 98 N (10 kg, 20 lb) weight [A] on the chain.

• Measure the length of 20 links [B] on the straight part [C] of the chain from the pin center of the 1 st pin to the pin center of the 21st pin. Since the chain may wear unevenly, take measurements at several places.

• If any measurements exceed the service limit, replace the chain. Also, replace the front and rear sprockets when the drive chain is replaced.

Drive Chain 20-link Length

Standard: 317.5 ~ 318.2 mm (12.50 - 12.53 in.)

Service Limit: 323 mm (12.7 in.)

A 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 sprock­ets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control.

For safety, use only the standard chain. It is an end­less type and should not be cut for installation.

Standard Chain Make: ENUMA

Type: EK520MVXL

Link: 108 Links

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PERIODIC MAINTENANCE 2-33

Drive Chain Lubrication

• If a special lubricant is not available, a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication.

• If the chain appears especially dirty, clean it before 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 of the O-ring of the drive chain.

Any other cleaning solution such as gasoline or trichloroethylene will cause deterioration and swelling of the O-ring.

Immediately blow the chain dry with compressed air after cleaning.

Complete cleaning and drying the chain within 10 minutes.

• Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings. Apply the 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]

6K040e07S1 C

Brakes

Brake Pad Wear Check

• Remove the brake pads (see Brakes chapter).

• Check the lining thickness [A] of the pads in each caliper.

• If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set.

Pad Lining Thickness

Standard: Front 4 mm (0.16 in)

Rear 5 mm (0.20 in.)

Service Limit: 1 mm (0.04 in.)

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Maintenance Procedure

Brake Light Switch Check Brake Light Timing Inspection

• Turn on the ignition switch.

• Check the operation of the rear brake light switch by de- pressing the brake pedal.

• If it does not as specified, adjust the brake light timing.

Brake Light Timing Standard:

On after about 10 mm (0.4 in.) of pedal travel [A]

Brake Light Timing Adjustment

Brake light timing is adjusted by changing the position of the rear brake light switch.

• Adjust the position of the switch so that the brake light goes on after the specified pedal travel by turning the ad- justing nut [A], ^{* •}

CAUTION

To avoid damaging the electrical connections in­side the switch, be sure that the switch body does not turn during adjustment.

Caliper Piston Seal and Dust Seal Replacement Caliper Fluid Seal Damage

The fluid seals [A] 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.

• Remove the calipers (see Brakes chapter)

• Replace the fluid seals under any of the following condi­tions: (a) fluid leakage around the pad; (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 replace, replace the dust seal as well. Also, replace all seals every other time the pads are changed.

Caliper Dust Seal/Friction Boot Damage

• Remove the calipers (see Brakes chapter).

• Check that the dust seals [B] and friction boot [C] are not cracked, worn, swollen, or otherwise damaged.

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PERIODIC MAINTENANCE 2-35

Brake Master Cylinder Cup and Dust Seal Replacement

Master Cylinder Inspection (Visual Inspection)

• Remove the master cylinders (see Brakes chapter).

• Disassemble the front and rear master cylinders.

• Check that there are no scratches, rust or pitting on the inner wall [A] of each master cylinder and on the outside of each piston [B],

• If a master cylinder or piston shows any damage, replace them.

• Inspect the primary cup [C] and secondary cup [D],

• 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 as- sembly should be replaced to renew the cups.

Front Master Cylinder [J]

• Check the dust covers [E] for damage.

• If they are damaged, replace them.

• Check the piston return spring [F] for any damage.

• If the springs are damaged, replace them.

• Check that relief port [G] and supply port [H] are not plugged.

• If the relief port becomes plugged, the brake pads will drag on the disc. Blow the ports clean with compressed air.

Rear Maser Cylinder [K]

Brake Fluid Check Brake Fluid Level Inspection

• Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B],

NOTE

O Hold the reservoir horizontal by turning the handlebar when checking brake fluid level.

• If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C],

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