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1-2 GENERAL INFORMATION
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:
(1} 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 filings.
(2) Battery Ground
Remove the ground ( -) lead from the battery before performing any disassembly operations on the
motorcycle. This prevents:
(a) the possibility of accidentally turning the engine over while partially disassembled.
(b) sparks at electrical connections which will occur when they are disconnected.
(c) damage to electrical parts.
(3) Tightening Sequence
Generally, when installing a part with several bolts, nuts, 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 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.
(4) 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.
(5) 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 wooden or plastic-faced mallet. Use an impact driver for screws
(particularly for the removal of screws held bya locking agent) in order to avoid damaging the screw heads.
(6) 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.
(7) High-Flash Point Solvent
A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly
available in North America is Standard solvent (generic name) .Always follow manufacturer and container
directions regarding the use of any solvent.
(8) 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.
(9) 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 North America is Locktite Lock'n Seal
(Blue).
(10) Press
A part installed using a press or driver, such as a wheel bearing, should first be coated with oil on its outer
or inner circumference so that it will go into place smoothly.
(11) Ball Bearing
When installing a ball bearing, the bearing race which is affected by friction should be pushed by a
suitable driver. This prevents severe stress on the balls and races, and prevents races and balls from being
dented. Press a ball bearing until it stops at the stop in the hole or on the shaft.