Exploded View

Exploded View

No.	Fastener	Torque			Remarks
		N·m	kgf·m	ft·lb
1	Front Axle	108	11.0	80
2	Front Axle Clamp Bolt	34	3.5	25
3	Rear Axle Nut	108	11.0	80

4. Caliper Bracket (EX650B Models) G: Apply grease.

HG: Apply high-temperature grease. R: Replacement Parts

WL: Apply soap and water solution or rubber lubricant.

Specifications

Item	Standard	Service Limit
Wheels (Rims) Rim Runout: Axial Radial Axle Runout/100 mm (3.94 in.) Wheel Balance Balance Weights Rim Size: Front Rear	TIR 0.5 mm (0.02 in.) or less	TIR 1.0 mm (0.04 in.)
	TIR 0.8 mm (0.03 in.) or less	TIR 1.0 mm (0.04 in.)
	TIR 0.03 mm (0.0012 in.) or less	TIR 0.2 mm (0.008 in.)
	10 g (0.35 oz.) or less	– – –
	10 g (0.35 oz.), 20 g (0.71 oz.), 30 g	– – –
	(1.06 oz.)
	17 × 3.50	– – –
	17 × 4.50	– – –
Tires Air Pressure (when Cold): Front Rear Tread Depth: Front Rear	Up to 180 kg (397 lb) load: 225 kPa (2.25 kgf/cm², 32 psi)	– – –
	Up to 180 kg (397 lb) load: 250 kPa	– – –
	(2.50 kgf/cm², 36 psi)
	4.3 mm (0.17 in.)	1 mm (0.04 in.)
		(AT, CH, DE) 1.6 mm
		(0.06 in.)
	7.0 mm (0.28 in.)	Up to 130 km/h (80 mph):
		2 mm (0.08 in.)
		Over 130 km/h (80 mph):
		3 mm (0.12 in.)
Standard Tires: Front Rear	Make, Type	Size
	BRIDGESTONE, BATTLAX BT020F	120/70 ZR17 M/C (58 W)
	RADIAL GG
	BRIDGESTONE, BATTLAX BT020R	160/60 ZR17 M/C (69 W)
	RADIAL

Special Tools

Bearing Driver Set: 57001-1129

Bearing Remover Shaft, 13: 57001-1377

Jack: 57001-1238

Jack Attachment: 57001-1608

Bearing Remover Head, 20 × 22:

57001-1293

Front Wheel Removal

_• Remove:

Brake Caliper Mounting Bolts [A]

Front Brake Calipers [B]

_• Loosen:

Axle Clamp Bolt [A]

_• Remove the front axle [B].

_• Remove the lower fairings (see Lower Fairing Removal in the Frame chapter).

_• Raise the front wheel off the ground with jack.

Special Tools - Jack: 57001-1238

Jack Attachment: 57001-1608

_• Pull out the axle to the right and drop the front wheel out of the forks.

Front Wheel Installation

NOTE

○^{The direction of the wheel rotation [A] is shown by an}

arrow [B] on the wheel spoke.

_• Check the wheel rotation mark on the front wheel and install it.

_• Apply high-temperature grease to the grease seal lips.

_• Fit the collars [A] on the both sides of the hub.

_• Insert the front axle, and tighten the axle.

Torque - Front Axle: 108 N·m (11.0 kgf·m, 80 ft·lb)

_• Before tightening the axle clamp bolt on the right front fork leg, pump the front fork up and down 4 or 5 times to allow

the right front fork leg to seat on the front axle.

NOTE

○^{Put a block in front of the front wheel to stop moving.}

_• Tighten the axle clamp bolt [A].

Torque - Front Axle Clamp Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb)

_• Install the lower fairing (see Lower Fairing Installation in the Frame chapter).

_• Install the front brake calipers (see Caliper Installation in

the Brakes chapter).

_• Check the front brake effectiveness (see Brake Operation Inspection in the Periodic Maintenance chapter).

Rear Wheel Removal

_• Raise the rear wheel off the ground with stand [A].

_• Remove:

Brake Caliper Mounting Bolts [A]

Rear Brake Caliper [B]

_• Remove the rear wheel rotation sensor from the caliper bracket (see Rear Wheel Rotation Sensor Removal in the

Brakes chapter) (EX650B Models).

_• Remove: Cotter Pin [A]

Axle Nut [B] Washer [C]

Axle [D] with Washer

_• Remove the drive chain [A] from the rear sprocket toward the left.

_• Move the rear wheel back and remove it.

Rear Wheel Installation

_• Apply high-temperature grease to the grease seal lips.

_• Fit the collars [A] on the both sides of the hub.

_• Engage the drive chain with the rear sprocket.

_• Install the caliper bracket [A] onto the swingarm stop [B].

_• Insert the axle from the right side of the wheel, and tighten

the axle nut.

Torque - Rear Axle Nut: 108 N·m (11.0 kgf·m, 80 ft·lb)

_• Insert a new cotter pin [A].

NOTE

○^{When inserting the cotter pin, if the slots in the nut do}

not align with the cotter pin hole in the axle, tighten the

nut clockwise [B] up to next alignment.

○^{It should be within 30°.}

○^{Loosen once and tighten again when the slot goes past}

the nearest hole.

_• Bend the cotter pin [A] over the nut [B].

_• Adjust the drive chain slack after installation (see Drive Chain Slack Inspection in the Periodic Maintenance chap-

ter).

_• Install the rear brake caliper (see Caliper Installation in the Brakes chapter).

_• Install the rear wheel rotation sensor (see Rear Wheel Ro-

tation Sensor Installation in the Brakes chapter) (EX650B

Models).

_• Check the rear brake effectiveness (see Brake Operation Inspection in the Periodic Maintenance chapter).

Wheel Inspection

_• Raise the front/rear wheel off the ground with jack.

Special Tools - Jack: 57001-1238

Jack Attachment: 57001-1608

_• Spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearings.

_• Inspect the wheel for small cracks, dents, bending, or

warp.

If there is any damage to the wheel, replace the wheel.

_• Remove the wheel, and support it without the tire by the axle.

_• Measure the rim runout, axial [A] and radial [B], with a dial

gauge.

If rim runout exceeds the service limit, check the hub bear- ings.

If the problem is not due to the bearings, replace the wheel.

Rim Runout Standard:

Axial TIR 0.5 mm (0.02 in.) or less Radial TIR 0.8 mm (0.03 in.) or less