Handlebar

Handlebar Removal

_• Remove:

Clutch Lever Assembly [A]

Left Switch Housing [B] Left Handlebar Weight [C]

_• Remove:

Front Brake Master Cylinder [A] (see Front Master Cylin-

der Removal in the Brakes chapter) Right Switch Housing [B]

Right Handlebar Weight [C] Throttle Grip [D]

_• Remove the handlebar holder bolts [A].

_• Remove the handlebar holder [B] and then pull out the

handlebar.

Handlebar Installation

_• Align the punch mark [A] on the handlebar and the corner edge [B] on the stem head.

_• Tighten the front holder bolts first, and then the rear holder bolts. There will be a gap [A] at the rear part of the han-

dlebar holder after tightening.

Torque - Handlebar Holder Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

Handlebar

_• Install the clutch lever (see Clutch Lever Installation in the Clutch chapter).

_• Apply adhesive cement to the inside of the left handlebar

grip.

_• Apply a non-permanent locking agent to the left handlebar weight bolt.

_• Install the left switch housing.

○^{Fit the projection [A] into a small hole [B] in the handlebar.}

Torque - Left Switch Housing Screws: 3.5 N·m (0.36 kgf·m, 31 in·lb)

_• Install:

Throttle Grip

Throttle Cable Tips [A] Right Switch Housing

○^{Fit the projection [B] into a small hole [C] in the handlebar.}

Torque - Right Switch Housing Screws: 3.5 N·m (0.36 kgf·m, 31 in·lb)

_• Apply a non-permanent locking agent to the right handle-

bar weight bolt.

_• Install the front brake master cylinder (see Front Master Cylinder Installation in the Brakes chapter).

Frame Table of Contents

Exploded View........................................................................................................................ 15-2

Seat ........................................................................................................................................ 15-8

Seat Removal ................................................................................................................... 15-8

Seat Installation ................................................................................................................ 15-8

Fairings................................................................................................................................... 15-9

Lower Fairing Removal ..................................................................................................... 15-9

Lower Fairing Installation .................................................................................................. 15-9

Center Fairing Removal .................................................................................................... 15-9

Center Fairing Installation ................................................................................................. 15-9

Windshield Removal 15-10

Windshield Installation 15-10

Upper Fairing Removal 15-10

Upper Fairing Disassembly 15-11

Upper Fairing Assembly 15-11

Upper Fairing Installation 15-11

Upper Inner Fairing Removal 15-11

Upper Inner Fairing Installation 15-11

Upper Fairing Bracket Removal 15-11

Inner Fairing Removal 15-12

Inner Fairing Installation 15-12

Side Covers 15-13

Side Cover Removal 15-13

Side Cover Installation 15-13

Seat Covers 15-14

Seat Cover Removal 15-14

Seat Cover Installation 15-14

Fenders 15-15

Front Fender Removal 15-15

Front Fender Installation 15-15

15

Flap and Rear Fender Rear Removal 15-15

Flap and Rear Fender Rear Installation 15-15

Rear Fender Front Removal 15-16

Rear Fender Front Installation 15-16

Frame 15-17

Frame Inspection 15-17

Sidestand. 15-18

Sidestand Removal 15-18

Sidestand Installation 15-18

Frame Cover. 15-19

Frame Cover Removal 15-19

Frame Cover Installation 15-19

No.	Fastener	Torque			Remarks
		N·m	kgf·m	ft·lb
1	Footpeg Stay Bolts	34	3.5	25
2	Sidestand Bolt	44	4.5	33
3	Sidestand Switch Bolt	8.8	0.90	78 in·lb	L

4. EX650B Models

5. EX650A Models G: Apply grease.

L: Apply a non-permanent locking agent. R: Replacement Parts

No.	Fastener	Torque			Remarks
		N·m	kgf·m	ft·lb
1	Front Fender Bolts	3.9	0.40	35 in·lb
2	Front Fender Bracket Bolts	8.8	0.90	78 in·lb		L
3	Front Turn Signal Light Mounting Screws	1.2	0.12	11 in·lb

L: Apply a non-permanent locking agent.

No.	Fastener	Torque			Remarks
		N·m	kgf·m	ft·lb
1	Grab Rail Mounting Bolts	25	2.5	18
2	Seat Lock Mounting Screws	1.2	0.12	11 in·lb

3. Seat (United States and Canada Models)

4. Seat Lock Bracket (EX650B Models)

5. EX650B Models

6. Grab Rails (Other than United States and Canada Models)

7. Washers (United States and Canada Models)

Seat

Seat Removal

_• Insert the ignition switch key [A] into the seat lock, turning the key clockwise, pulling up on the rear of the seat [B],

and pulling the seat backward.

Seat Installation

_• Slip the seat hook [A] under the brace [B] on the fuel tank bracket.

_• Insert the seat latch [A] into the latch hole [B].

_• Push down the rear part of the seat until the lock clicks.

Lower Fairing Removal

_• Pull up the core by the thin blade driver.

_• Remove the quick rivets [A].

_• Remove the bolts [B] with collar and washers.

_• Clear the hook portions from the slots.

_• Separate the left lower fairing from the right lower fairing.

Lower Fairing Installation

_• Insert the hook portions [A] into the slots [B].

_• Set the quick rivet and push the core.

Center Fairing Removal

_• Remove:

Lower Fairings (see Lower Fairing Removal)

Upper Inner Fairing (see Upper Inner Fairing Removal) Screw [A]

Bolt [B] with Washers

_• Remove the meter cover (see Meter Unit Removal/Instal- lation in the Electrical System chapter).

_• Disconnect the turn signal lead connector [A].

_• Remove the screw [B].

_• Pull the center fairing [C] evenly outward to clear the stop-

pers.

_• Remove the inner fairing (see Inner Fairing Removal).

_• Remove the screw [A] and turn signal light [B].

Center Fairing Installation

_• Install the turn signal light to the center fairing.

_• Install the inner fairing (see Inner Fairing Installation).

_• Insert the hook [A] into the slot [B].

_• Insert the projection [A] into the hole [B].

_• Connect the turn signal lead connector.

_• Install the bolt and screws.

Windshield Removal

_• Remove:

Bolts [A] with Washers

Windshield [B] Dampers

Windshield Installation

_• Install the dampers.

_• Insert the hook [A] into the slot [B].

_• Tighten the bolts with washers.

Upper Fairing Removal

_• Remove:

Windshield (see Windshield Removal)

Upper Inner Fairings (see Upper Inner Fairing Removal) Lower Fairings (see Lower Fairing Removal)

Center Fairings (see Center Fairing Removal) Headlight Lead Connectors

Rear View Mirror Nuts (Both Side) [A]

_• Remove the upper fairing forward.

Upper Fairing Disassembly

_• Remove:

Headlight [A] (see Headlight Removal/Installation in the

Electrical System chapter)

Upper Fairing Assembly

_• Install the headlight (see Headlight Removal/Installation in the Electrical System chapter).

Upper Fairing Installation

_• Installation is the reverse of removal.

Upper Inner Fairing Removal

_• Remove the bolts [A].

_• Pull the upper inner fairing [B] backward, and clear the

hooks.

Upper Inner Fairing Installation

_• Insert the hook [A] into the slot [B].

_• Tighten the bolts.

Upper Fairing Bracket Removal

_• Remove:

Upper Fairing (see Upper Fairing Removal)

Meter Unit (see Meter Unit Removal/Installation in the Electrical System chapter)

Clamp [A] Bolts [B]

Horn Leads [C] Under Bracket [D]

_• Remove: Bolts [A]

Clamps [B]

Upper Fairing Bracket [C]