–13–
A Clamp the throttle cables withthe holder. Position the end ofclip downword.
B Route the rear brake switch leadunder the master cylinder reser-vor hose.
C Position the band end of rightside bracket.
D Position the steel band end toforward.
CABLE ROUTING SPEC
E Position the steel band end toright side.
F Route the battery positive (+)lead through the slit of the bat-tery box.
G Clamp the igniter unit lead to theframe with a holder.
H To the rear fender.
I Connect the wireharness to theignitar unit through the hole ofLID. 2.
J Route the fuel tank breatherhose under the fuel filter andconnect it (fuel tank sideroll overvalve side) with a joint. Positionthe end of clip outside.
–14–
K Position the mark on the steelband to forward.
L Fasten the wireharness with aband on the tool box plate.
M Fasten the wireharness to theframe with a plastic locking tie.Position the locking tie front ofthe holder.
N Route the wireharness outsideof the guide on the frame.
CABLE ROUTING SPEC
O Clamp the clutch cable and start-er cable with a holder.Position the end of holder downside.
P Route the igniter lead throughthe igniter plate hole to the wire-harness.
Q To the wireharness.R Clamp the taillight lead with mud
guard clamp.
S Clamp the taillight lead with aholder on the mud guard.
T Position the locking tie upward.U The front direction of the level
body.
–15–
CABLE ROUTING SPEC
1 Throttle cable2 Starter cable3 Clutch cable4 Handlebar switch lead (left)5 Headlight lead6 Brake hose7 Handlebar switch lead (right)
A Route the handlebar switchlead (right) rear side of thethrottle cable.
–16–
INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS
CHKADJ
NOTE:
EB300000
PERIODIC INSPECTIONS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended inspections and adjust-ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle opera-tion and a longer service life. The need for costly overhaul work will be greatly reduced. This informa-tion applies to vehicles already in service as well as to new vehicles that are being prepared for sale. Allservice technicians should be familiar with this entire chapter.EB301000
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
The annual checks must be performed every year, except if a kilometer-based maintenance isperformed instead.
From 50,000 km, repeat the maintenance intervals starting from 10,000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,data and technical skills.
NO ITEM CHECK OR MAINTENANCE JOBODOMETER READING ( 1,000 km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB1 10 20 30 40 CHECK
1 * Fuel line Check fuel hoses for cracks or damage. √ √ √ √ √
2 * Fuel filter Check condition. √ √
Check condition.√ √
3 Spark plugs Clean and regap. √ √
Replace. √ √
4 * Valves Check valve clearance. Adjust
√ √ √ √
5 Air filter element Clean. √ √
5 Air filter element Replace. √ √
6 Clutch Check operation. Adjust.
√ √ √ √ √
7 * Front brake
Check operation, fluid level and vehicle for fluidleakage. (See NOTE)
√ √ √ √ √ √
Replace brake pads. Whenever worn to the limit
8 * Rear brake
Check operation, fluid level and vehicle for fluidleakage. (See NOTE)
√ √ √ √ √ √
Replace brake pads. Whenever worn to the limit
9 * Brake hose Check for cracks or damage. √ √ √ √ √
9 * Brake hose Replace. (See NOTE) Every 4 years
10 * Wheels Check runout, spoke tightness and for damage. Tighten spokes if necessary.
√ √ √ √
11 * Tires
Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary.
√ √ √ √
12 * Wheel bearings Check bearing for looseness or damage. √ √ √ √
13 * Steering bearings Check bearing play and steering for roughness. √ √ √ √ √
13 * Steering bearings Lubricate with lithium-soap-based grease. Every 20,000 km
14 * Chassis fasteners Make sure that all nuts, bolts and screws are
properly tightened.√ √ √ √ √
15 Sidestand Check operation. Lubricate.
√ √ √ √ √
16 * Sidestand switch Check operation. √ √ √ √ √ √
–17–
INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS
CHKADJ
NOTE:
NO ITEM CHECK OR MAINTENANCE JOBODOMETER READING ( 1,000 km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB1 10 20 30 40 CHECK
17 * Front fork Check operation and for oil leakage. √ √ √ √
18 *Rear shock
Check operation and shock absorber for oil leak-age.
√ √ √ √18 * absorber assembly
Lubricate the pivoting points with molybdenumdisulfide grease.
√ √
19 * Carburetors Check starter (choke) operation. Adjust engine idling speed and synchronization.
√ √ √ √ √ √
20 Engine oil Change. √ √ √ √ √ √
21Engine oil filterelement Replace. √ √ √
22 Final gear oil Check oil level and vehicle for oil leakage. √ √ √
22 Final gear oil Change. √ √ √
23Moving parts andcables Lubricate. √ √ √ √ √
24 *Lights, signalsand switches
Check operation. Adjust headlight beam.
√ √ √ √ √ √
EAU03541
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.Hydraulic brake service– Regularly check and, if necessary, correct the brake fluid level.– Every two years replace the internal components of the brake master cylinder and caliper, and
change the brake fluid.– Replace the brake hoses every four years and if cracked or damaged.
–18–
REPLACING THE HEADLIGHT BULBCHKADJ
WARNING
CAUTION:
ELECTRICAL SYSTEMEAS00182
REPLACING THE HEADLIGHT BULB1. Disconnect:connector 1
2. Removeheadlight bulb cover 2
3. Remove:headlight bulb holder 1
4. Remove:headlight bulb 2
Since the headlight bulb gets extremely hot,keep flammable products and your handsaway from the bulb until it has cooled down.
5. Install:headlight bulb (New)Secure the new headlight bulb with the head-light bulb holder.
Avoid touching the glass part of the head-light bulb to keep it free from oil, otherwisethe transparency of the glass, the life of thebulb and the luminous flux will be adverselyaffected. If the headlight bulb gets soiled,thoroughly clean it with a cloth moistenedwith alcohol or lacquer thinner.
6. Install:headlight bulb holder
7. Install:headlight bulb cover
8. Connect: leads
–19–
ADJUSTING THE HEADLIGHT BEAMCHKADJ
a
b
a
b
EAS00184
ADJUSTING THE HEADLIGHT BEAM1. Adjust:headlight beam (vertically)
a. Turn the adjusting screw 1 in direction a orb .
Direction Headlight beam is raised.
Direction Headlight beam islowered.
2. Adjust:headlight beam (horizontally)
a. Turn the adjusting knob 2 in direction a orb .
Direction Headlight beam moves tothe right.
Direction Headlight beam moves tothe left.
–20–
AIR INDUCTION SYSTEM CARB
NOTE:
CARBURETIONAIR INDUCTION SYSTEMAIR INDUCTION SYSTEM DIAGRAMS
1 Reed valve2 Air filter3 Orifice4 Carburetor joint (near cylinder)A To the front cylinder headB To the rear cylinder headC To the orificeD To the carburetor joint (rear cylinder)E To the air cut-off valve
The orifice 3 should be installed with the arrowmark facing the air cut-off valve side.
–21–
Order Job name/Part name Q’ty Remarks
12345678
9
Removeing the air induction systemSide coverAir filterAir filter to air cut valve hoseAir cut valveVacuume hose 2OrificeVacuum hose 1Reed valve case to rear cylinder headpipeReed valve case to rear cylinder headpipe
11111111
1
Remove the parts in the order listed.
For installation, reverse the removalprocedure.
AIR INDUCTION SYSTEM CARB
–22–
AIR INDUCTION SYSTEM CARB
EAS00510
CHECKING THE AIR INDUCTION SYSTEM1. Check:hosesLoose connection Connect properly.Cracks/damage Replace.
pipesCracks/damage Replace.
2. Check: reed valve 1 reed valve stopper reed valve seatCracks/damage Replace the reed valve.
3. Measure: reed valve bending aOut of specification Replace the reedvalve.
Maximum reed valve bending0.4 mm
1 Surface plate
4. Check:air cutoff valveCracks/damage Replace.
5. Check:air cleanerCracks/damage Replace.Clogged Clean.
–23–
Order Job name/Part name Q’ty Remarks
123456
Removing the front brake calipersBrake fluidBrake hose holderUnion boltCopper washersBrake hoseRetaining boltBrake caliper assembly
112121
Remove the parts in the order listed.Drain
For installation, reverse the removalprocedure.
Refer to “REMOVING/INSTALLINGTHE FRONT BRAKE CALIPERS”.
6 Nm (0.6 mkg)
27 Nm (2.7 mkg)
30 Nm (3.0 mkg)
FRONT AND REAR BRAKES CHAS
CHASSISFRONT AND REAR BRAKESFRONT BRAKE CALIPERS
–24–
Order Job name/Part name Q’ty Remarks
12345678
Removing the lower bracket
Front fork legsHandlebarHeadlight lens unitLeads (in the headlight body)Front turn signal/position light (left/right)Headlight bodyBrake hose joint/holderUpper bracketLock washerUpper ring nut
1–
1/11
1/1111
Remove the parts in the order listed.Stand the motorcycle on a level surface.
Securely support the motorcycle sothat there is no danger of it falling over.
Refer to “FRONT FORK”.Refer to “HANDLEBAR”.
Disconnect
WARNING
1st2nd
52 Nm (5.2 mkg)18 Nm (1.8 mkg)
110 Nm (11.0 mkg)
7 Nm (0.7 mkg)
STEERING HEAD CHAS
STEERING HEAD
–25–
Order Job name/Part name Q’ty Remarks
9101112131415
Rubber washerLower ring nutBearing coverLower bracketBearing (upper)Rubber sealBearing (lower)
1111111
For installaiton, reverse the removalprocedure.
Refer to “REMOVING THE LOWERBRACKET/INSTALLING THESTEERING HEAD”.
1st2nd
52 Nm (5.2 mkg)18 Nm (1.8 mkg)
110 Nm (11.0 mkg)
7 Nm (0.7 mkg)
STEERING HEAD CHAS
–13–
A Clamp the throttle cables withthe holder. Position the end ofclip downword.
B Route the rear brake switch leadunder the master cylinder reser-vor hose.
C Position the band end of rightside bracket.
D Position the steel band end toforward.
CABLE ROUTING SPEC
E Position the steel band end toright side.
F Route the battery positive (+)lead through the slit of the bat-tery box.
G Clamp the igniter unit lead to theframe with a holder.
H To the rear fender.
I Connect the wireharness to theignitar unit through the hole ofLID. 2.
J Route the fuel tank breatherhose under the fuel filter andconnect it (fuel tank sideroll overvalve side) with a joint. Positionthe end of clip outside.
–14–
K Position the mark on the steelband to forward.
L Fasten the wireharness with aband on the tool box plate.
M Fasten the wireharness to theframe with a plastic locking tie.Position the locking tie front ofthe holder.
N Route the wireharness outsideof the guide on the frame.
CABLE ROUTING SPEC
O Clamp the clutch cable and start-er cable with a holder.Position the end of holder downside.
P Route the igniter lead throughthe igniter plate hole to the wire-harness.
Q To the wireharness.R Clamp the taillight lead with mud
guard clamp.
S Clamp the taillight lead with aholder on the mud guard.
T Position the locking tie upward.U The front direction of the level
body.
–15–
CABLE ROUTING SPEC
1 Throttle cable2 Starter cable3 Clutch cable4 Handlebar switch lead (left)5 Headlight lead6 Brake hose7 Handlebar switch lead (right)
A Route the handlebar switchlead (right) rear side of thethrottle cable.
–16–
INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS
CHKADJ
NOTE:
EB300000
PERIODIC INSPECTIONS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended inspections and adjust-ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle opera-tion and a longer service life. The need for costly overhaul work will be greatly reduced. This informa-tion applies to vehicles already in service as well as to new vehicles that are being prepared for sale. Allservice technicians should be familiar with this entire chapter.EB301000
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
The annual checks must be performed every year, except if a kilometer-based maintenance isperformed instead.
From 50,000 km, repeat the maintenance intervals starting from 10,000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,data and technical skills.
NO ITEM CHECK OR MAINTENANCE JOBODOMETER READING ( 1,000 km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB1 10 20 30 40 CHECK
1 * Fuel line Check fuel hoses for cracks or damage. √ √ √ √ √
2 * Fuel filter Check condition. √ √
Check condition.√ √
3 Spark plugs Clean and regap. √ √
Replace. √ √
4 * Valves Check valve clearance. Adjust
√ √ √ √
5 Air filter element Clean. √ √
5 Air filter element Replace. √ √
6 Clutch Check operation. Adjust.
√ √ √ √ √
7 * Front brake
Check operation, fluid level and vehicle for fluidleakage. (See NOTE)
√ √ √ √ √ √
Replace brake pads. Whenever worn to the limit
8 * Rear brake
Check operation, fluid level and vehicle for fluidleakage. (See NOTE)
√ √ √ √ √ √
Replace brake pads. Whenever worn to the limit
9 * Brake hose Check for cracks or damage. √ √ √ √ √
9 * Brake hose Replace. (See NOTE) Every 4 years
10 * Wheels Check runout, spoke tightness and for damage. Tighten spokes if necessary.
√ √ √ √
11 * Tires
Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary.
√ √ √ √
12 * Wheel bearings Check bearing for looseness or damage. √ √ √ √
13 * Steering bearings Check bearing play and steering for roughness. √ √ √ √ √
13 * Steering bearings Lubricate with lithium-soap-based grease. Every 20,000 km
14 * Chassis fasteners Make sure that all nuts, bolts and screws are
properly tightened.√ √ √ √ √
15 Sidestand Check operation. Lubricate.
√ √ √ √ √
16 * Sidestand switch Check operation. √ √ √ √ √ √
–17–
INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS
CHKADJ
NOTE:
NO ITEM CHECK OR MAINTENANCE JOBODOMETER READING ( 1,000 km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB1 10 20 30 40 CHECK
17 * Front fork Check operation and for oil leakage. √ √ √ √
18 *Rear shock
Check operation and shock absorber for oil leak-age.
√ √ √ √18 * absorber assembly
Lubricate the pivoting points with molybdenumdisulfide grease.
√ √
19 * Carburetors Check starter (choke) operation. Adjust engine idling speed and synchronization.
√ √ √ √ √ √
20 Engine oil Change. √ √ √ √ √ √
21Engine oil filterelement Replace. √ √ √
22 Final gear oil Check oil level and vehicle for oil leakage. √ √ √
22 Final gear oil Change. √ √ √
23Moving parts andcables Lubricate. √ √ √ √ √
24 *Lights, signalsand switches
Check operation. Adjust headlight beam.
√ √ √ √ √ √
EAU03541
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.Hydraulic brake service– Regularly check and, if necessary, correct the brake fluid level.– Every two years replace the internal components of the brake master cylinder and caliper, and
change the brake fluid.– Replace the brake hoses every four years and if cracked or damaged.
–18–
REPLACING THE HEADLIGHT BULBCHKADJ
WARNING
CAUTION:
ELECTRICAL SYSTEMEAS00182
REPLACING THE HEADLIGHT BULB1. Disconnect:connector 1
2. Removeheadlight bulb cover 2
3. Remove:headlight bulb holder 1
4. Remove:headlight bulb 2
Since the headlight bulb gets extremely hot,keep flammable products and your handsaway from the bulb until it has cooled down.
5. Install:headlight bulb (New)Secure the new headlight bulb with the head-light bulb holder.
Avoid touching the glass part of the head-light bulb to keep it free from oil, otherwisethe transparency of the glass, the life of thebulb and the luminous flux will be adverselyaffected. If the headlight bulb gets soiled,thoroughly clean it with a cloth moistenedwith alcohol or lacquer thinner.
6. Install:headlight bulb holder
7. Install:headlight bulb cover
8. Connect: leads
–19–
ADJUSTING THE HEADLIGHT BEAMCHKADJ
a
b
a
b
EAS00184
ADJUSTING THE HEADLIGHT BEAM1. Adjust:headlight beam (vertically)
a. Turn the adjusting screw 1 in direction a orb .
Direction Headlight beam is raised.
Direction Headlight beam islowered.
2. Adjust:headlight beam (horizontally)
a. Turn the adjusting knob 2 in direction a orb .
Direction Headlight beam moves tothe right.
Direction Headlight beam moves tothe left.
–20–
AIR INDUCTION SYSTEM CARB
NOTE:
CARBURETIONAIR INDUCTION SYSTEMAIR INDUCTION SYSTEM DIAGRAMS
1 Reed valve2 Air filter3 Orifice4 Carburetor joint (near cylinder)A To the front cylinder headB To the rear cylinder headC To the orificeD To the carburetor joint (rear cylinder)E To the air cut-off valve
The orifice 3 should be installed with the arrowmark facing the air cut-off valve side.
–21–
Order Job name/Part name Q’ty Remarks
12345678
9
Removeing the air induction systemSide coverAir filterAir filter to air cut valve hoseAir cut valveVacuume hose 2OrificeVacuum hose 1Reed valve case to rear cylinder headpipeReed valve case to rear cylinder headpipe
11111111
1
Remove the parts in the order listed.
For installation, reverse the removalprocedure.
AIR INDUCTION SYSTEM CARB
–22–
AIR INDUCTION SYSTEM CARB
EAS00510
CHECKING THE AIR INDUCTION SYSTEM1. Check:hosesLoose connection Connect properly.Cracks/damage Replace.
pipesCracks/damage Replace.
2. Check: reed valve 1 reed valve stopper reed valve seatCracks/damage Replace the reed valve.
3. Measure: reed valve bending aOut of specification Replace the reedvalve.
Maximum reed valve bending0.4 mm
1 Surface plate
4. Check:air cutoff valveCracks/damage Replace.
5. Check:air cleanerCracks/damage Replace.Clogged Clean.
–23–
Order Job name/Part name Q’ty Remarks
123456
Removing the front brake calipersBrake fluidBrake hose holderUnion boltCopper washersBrake hoseRetaining boltBrake caliper assembly
112121
Remove the parts in the order listed.Drain
For installation, reverse the removalprocedure.
Refer to “REMOVING/INSTALLINGTHE FRONT BRAKE CALIPERS”.
6 Nm (0.6 mkg)
27 Nm (2.7 mkg)
30 Nm (3.0 mkg)
FRONT AND REAR BRAKES CHAS
CHASSISFRONT AND REAR BRAKESFRONT BRAKE CALIPERS
–24–
Order Job name/Part name Q’ty Remarks
12345678
Removing the lower bracket
Front fork legsHandlebarHeadlight lens unitLeads (in the headlight body)Front turn signal/position light (left/right)Headlight bodyBrake hose joint/holderUpper bracketLock washerUpper ring nut
1–
1/11
1/1111
Remove the parts in the order listed.Stand the motorcycle on a level surface.
Securely support the motorcycle sothat there is no danger of it falling over.
Refer to “FRONT FORK”.Refer to “HANDLEBAR”.
Disconnect
WARNING
1st2nd
52 Nm (5.2 mkg)18 Nm (1.8 mkg)
110 Nm (11.0 mkg)
7 Nm (0.7 mkg)
STEERING HEAD CHAS
STEERING HEAD
–25–
Order Job name/Part name Q’ty Remarks
9101112131415
Rubber washerLower ring nutBearing coverLower bracketBearing (upper)Rubber sealBearing (lower)
1111111
For installaiton, reverse the removalprocedure.
Refer to “REMOVING THE LOWERBRACKET/INSTALLING THESTEERING HEAD”.
1st2nd
52 Nm (5.2 mkg)18 Nm (1.8 mkg)
110 Nm (11.0 mkg)
7 Nm (0.7 mkg)
STEERING HEAD CHAS
–13–
A Clamp the throttle cables withthe holder. Position the end ofclip downword.
B Route the rear brake switch leadunder the master cylinder reser-vor hose.
C Position the band end of rightside bracket.
D Position the steel band end toforward.
CABLE ROUTING SPEC
E Position the steel band end toright side.
F Route the battery positive (+)lead through the slit of the bat-tery box.
G Clamp the igniter unit lead to theframe with a holder.
H To the rear fender.
I Connect the wireharness to theignitar unit through the hole ofLID. 2.
J Route the fuel tank breatherhose under the fuel filter andconnect it (fuel tank sideroll overvalve side) with a joint. Positionthe end of clip outside.
–14–
K Position the mark on the steelband to forward.
L Fasten the wireharness with aband on the tool box plate.
M Fasten the wireharness to theframe with a plastic locking tie.Position the locking tie front ofthe holder.
N Route the wireharness outsideof the guide on the frame.
CABLE ROUTING SPEC
O Clamp the clutch cable and start-er cable with a holder.Position the end of holder downside.
P Route the igniter lead throughthe igniter plate hole to the wire-harness.
Q To the wireharness.R Clamp the taillight lead with mud
guard clamp.
S Clamp the taillight lead with aholder on the mud guard.
T Position the locking tie upward.U The front direction of the level
body.
–15–
CABLE ROUTING SPEC
1 Throttle cable2 Starter cable3 Clutch cable4 Handlebar switch lead (left)5 Headlight lead6 Brake hose7 Handlebar switch lead (right)
A Route the handlebar switchlead (right) rear side of thethrottle cable.
–16–
INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS
CHKADJ
NOTE:
EB300000
PERIODIC INSPECTIONS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended inspections and adjust-ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle opera-tion and a longer service life. The need for costly overhaul work will be greatly reduced. This informa-tion applies to vehicles already in service as well as to new vehicles that are being prepared for sale. Allservice technicians should be familiar with this entire chapter.EB301000
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
The annual checks must be performed every year, except if a kilometer-based maintenance isperformed instead.
From 50,000 km, repeat the maintenance intervals starting from 10,000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,data and technical skills.
NO ITEM CHECK OR MAINTENANCE JOBODOMETER READING ( 1,000 km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB1 10 20 30 40 CHECK
1 * Fuel line Check fuel hoses for cracks or damage. √ √ √ √ √
2 * Fuel filter Check condition. √ √
Check condition.√ √
3 Spark plugs Clean and regap. √ √
Replace. √ √
4 * Valves Check valve clearance. Adjust
√ √ √ √
5 Air filter element Clean. √ √
5 Air filter element Replace. √ √
6 Clutch Check operation. Adjust.
√ √ √ √ √
7 * Front brake
Check operation, fluid level and vehicle for fluidleakage. (See NOTE)
√ √ √ √ √ √
Replace brake pads. Whenever worn to the limit
8 * Rear brake
Check operation, fluid level and vehicle for fluidleakage. (See NOTE)
√ √ √ √ √ √
Replace brake pads. Whenever worn to the limit
9 * Brake hose Check for cracks or damage. √ √ √ √ √
9 * Brake hose Replace. (See NOTE) Every 4 years
10 * Wheels Check runout, spoke tightness and for damage. Tighten spokes if necessary.
√ √ √ √
11 * Tires
Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary.
√ √ √ √
12 * Wheel bearings Check bearing for looseness or damage. √ √ √ √
13 * Steering bearings Check bearing play and steering for roughness. √ √ √ √ √
13 * Steering bearings Lubricate with lithium-soap-based grease. Every 20,000 km
14 * Chassis fasteners Make sure that all nuts, bolts and screws are
properly tightened.√ √ √ √ √
15 Sidestand Check operation. Lubricate.
√ √ √ √ √
16 * Sidestand switch Check operation. √ √ √ √ √ √
–17–
INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS
CHKADJ
NOTE:
NO ITEM CHECK OR MAINTENANCE JOBODOMETER READING ( 1,000 km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB1 10 20 30 40 CHECK
17 * Front fork Check operation and for oil leakage. √ √ √ √
18 *Rear shock
Check operation and shock absorber for oil leak-age.
√ √ √ √18 * absorber assembly
Lubricate the pivoting points with molybdenumdisulfide grease.
√ √
19 * Carburetors Check starter (choke) operation. Adjust engine idling speed and synchronization.
√ √ √ √ √ √
20 Engine oil Change. √ √ √ √ √ √
21Engine oil filterelement Replace. √ √ √
22 Final gear oil Check oil level and vehicle for oil leakage. √ √ √
22 Final gear oil Change. √ √ √
23Moving parts andcables Lubricate. √ √ √ √ √
24 *Lights, signalsand switches
Check operation. Adjust headlight beam.
√ √ √ √ √ √
EAU03541
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.Hydraulic brake service– Regularly check and, if necessary, correct the brake fluid level.– Every two years replace the internal components of the brake master cylinder and caliper, and
change the brake fluid.– Replace the brake hoses every four years and if cracked or damaged.
–18–
REPLACING THE HEADLIGHT BULBCHKADJ
WARNING
CAUTION:
ELECTRICAL SYSTEMEAS00182
REPLACING THE HEADLIGHT BULB1. Disconnect:connector 1
2. Removeheadlight bulb cover 2
3. Remove:headlight bulb holder 1
4. Remove:headlight bulb 2
Since the headlight bulb gets extremely hot,keep flammable products and your handsaway from the bulb until it has cooled down.
5. Install:headlight bulb (New)Secure the new headlight bulb with the head-light bulb holder.
Avoid touching the glass part of the head-light bulb to keep it free from oil, otherwisethe transparency of the glass, the life of thebulb and the luminous flux will be adverselyaffected. If the headlight bulb gets soiled,thoroughly clean it with a cloth moistenedwith alcohol or lacquer thinner.
6. Install:headlight bulb holder
7. Install:headlight bulb cover
8. Connect: leads
–19–
ADJUSTING THE HEADLIGHT BEAMCHKADJ
a
b
a
b
EAS00184
ADJUSTING THE HEADLIGHT BEAM1. Adjust:headlight beam (vertically)
a. Turn the adjusting screw 1 in direction a orb .
Direction Headlight beam is raised.
Direction Headlight beam islowered.
2. Adjust:headlight beam (horizontally)
a. Turn the adjusting knob 2 in direction a orb .
Direction Headlight beam moves tothe right.
Direction Headlight beam moves tothe left.
–20–
AIR INDUCTION SYSTEM CARB
NOTE:
CARBURETIONAIR INDUCTION SYSTEMAIR INDUCTION SYSTEM DIAGRAMS
1 Reed valve2 Air filter3 Orifice4 Carburetor joint (near cylinder)A To the front cylinder headB To the rear cylinder headC To the orificeD To the carburetor joint (rear cylinder)E To the air cut-off valve
The orifice 3 should be installed with the arrowmark facing the air cut-off valve side.
–21–
Order Job name/Part name Q’ty Remarks
12345678
9
Removeing the air induction systemSide coverAir filterAir filter to air cut valve hoseAir cut valveVacuume hose 2OrificeVacuum hose 1Reed valve case to rear cylinder headpipeReed valve case to rear cylinder headpipe
11111111
1
Remove the parts in the order listed.
For installation, reverse the removalprocedure.
AIR INDUCTION SYSTEM CARB
–22–
AIR INDUCTION SYSTEM CARB
EAS00510
CHECKING THE AIR INDUCTION SYSTEM1. Check:hosesLoose connection Connect properly.Cracks/damage Replace.
pipesCracks/damage Replace.
2. Check: reed valve 1 reed valve stopper reed valve seatCracks/damage Replace the reed valve.
3. Measure: reed valve bending aOut of specification Replace the reedvalve.
Maximum reed valve bending0.4 mm
1 Surface plate
4. Check:air cutoff valveCracks/damage Replace.
5. Check:air cleanerCracks/damage Replace.Clogged Clean.
–23–
Order Job name/Part name Q’ty Remarks
123456
Removing the front brake calipersBrake fluidBrake hose holderUnion boltCopper washersBrake hoseRetaining boltBrake caliper assembly
112121
Remove the parts in the order listed.Drain
For installation, reverse the removalprocedure.
Refer to “REMOVING/INSTALLINGTHE FRONT BRAKE CALIPERS”.
6 Nm (0.6 mkg)
27 Nm (2.7 mkg)
30 Nm (3.0 mkg)
FRONT AND REAR BRAKES CHAS
CHASSISFRONT AND REAR BRAKESFRONT BRAKE CALIPERS
–24–
Order Job name/Part name Q’ty Remarks
12345678
Removing the lower bracket
Front fork legsHandlebarHeadlight lens unitLeads (in the headlight body)Front turn signal/position light (left/right)Headlight bodyBrake hose joint/holderUpper bracketLock washerUpper ring nut
1–
1/11
1/1111
Remove the parts in the order listed.Stand the motorcycle on a level surface.
Securely support the motorcycle sothat there is no danger of it falling over.
Refer to “FRONT FORK”.Refer to “HANDLEBAR”.
Disconnect
WARNING
1st2nd
52 Nm (5.2 mkg)18 Nm (1.8 mkg)
110 Nm (11.0 mkg)
7 Nm (0.7 mkg)
STEERING HEAD CHAS
STEERING HEAD
–25–
Order Job name/Part name Q’ty Remarks
9101112131415
Rubber washerLower ring nutBearing coverLower bracketBearing (upper)Rubber sealBearing (lower)
1111111
For installaiton, reverse the removalprocedure.
Refer to “REMOVING THE LOWERBRACKET/INSTALLING THESTEERING HEAD”.
1st2nd
52 Nm (5.2 mkg)18 Nm (1.8 mkg)
110 Nm (11.0 mkg)
7 Nm (0.7 mkg)
STEERING HEAD CHAS
EB000000
XVS1100 (L)SERVICE MANUAL
1998 by Yamaha Motor Co.,Ltd.First edition, October 1998
All rights reserved. Any reproduction orunauthorized use without the writtenpermission of Yamaha Motor Co., Ltd.
is expressly prohibited.
NOTE:
CAUTION:
EB001000
NOTICEThis manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers andtheir qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual,so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha mo-torcycles has a basic understanding of the mechanical ideas and the procedures of motorcycle repair.Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe andunfit for use.
Yamaha Motor Company, Ltd.is continually striving to improve all its models. Modifications and signifi-cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers andwill appear in future editions of this manual where applicable.
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATIONParticularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death tothe motorcycle operator, a bystander or a person inspecting or repairing themotorcycle.
A CAUTION indicates special precautions that must be taken to avoid damageto the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.
12 6
3
5
4
7
8
EB002000
HOW TO USE THIS MANUALMANUAL ORGANIZATIONThis manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)
1st title 1 : This is the title of the chapter with its symbol in the upper right corner of each page.
2nd title 2 : This title indicates the section of the chapter and only appears on the first page of eachsection. It is located in the upper right corner of the page.
3rd title 3 : This title indicates a sub-section that is followed by step-by-step procedures accompa-nied by corresponding illustrations.
EXPLODED DIAGRAMSTo help identify parts and clarify procedure steps, there are exploded diagrams at the start of each re-moval and disassembly section.
1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.
2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed bya circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks6 . The meanings of the symbol marks are given on the next page.
4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names ofparts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition tothe exploded diagram and the job instruction chart.
24
21
18
15 16 17
10
12
13
11
14
1
3
5
7
9
2
4
8
6
19 20
22 23
25
EB003000
ILLUSTRATED SYMBOLSIllustrated symbols 1 to 9 are printed on thetop right of each page and indicate the subject ofeach chapter.
1 General information2 Specifications3 Periodic inspections and adjustments4 Engine5 Cooling system6 Carburetion7 Chassis8 Electrical9 Troubleshooting
Illustrated symbols 10 to 17 are used to identifythe specifications appearing in the text.10 Can be serviced with engine mounted11 Filling fluid12 Lubricant13 Special tool14 Torque15 Wear limit, clearance16 Engine speed17 Ω, V, A
Illustrated symbols 18 to 23 in the exploded dia-grams indicate the types of lubricants and lu-brication points.18 Apply engine oil19 Apply gear oil20 Apply molybdenum disulfide oil21 Apply wheel bearing grease22 Apply lightweight lithium-soap base grease23 Apply molybdenum disulfide greaseIllustrated symbols 24 to 25 in the exploded dia-grams indicate where to apply locking agent 24
and when to install new parts 25 .24 Apply locking agent (LOCTITE)25 Replace
E004000
INSPADJ
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTION AND ADJUSTMENTS
ENGINE OVERHAUL
CARBURETION
CHASSIS
ELECTRICAL
TROUBLESHOOTING
GENINFO 1SPEC 2
3ENG 4
CARB 5CHAS 6ELEC 7TRBLSHTG 8
CHAPTER TITLES
GENINFO
1
GENINFO
CHAPTER 1.GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . . MODEL LABEL 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPORTANT INFORMATION 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION FOR REMOVAL PROCEDURES 1-2. . . . . . . . . . . . . . . REPLACEMENT PARTS 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKETS, OIL SEALS AND O-RINGS 1-2. . . . . . . . . . . . . . . . . . . . . . . . LOCK WASHERS/PLATES AND COTTER PINS 1-3. . . . . . . . . . . . . . . . BEARINGS AND OIL SEALS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCLIPS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING OF CONNECTIONS 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENINFO
1-1
MOTORCYCLE IDENTIFICATIONGENINFO
EB100000
GENERAL INFORMATIONMOTORCYCLE IDENTIFICATIONEB100010
VEHICLE IDENTIFICATION NUMBERThe vehicle identification number 1 is stampedinto the right side of the steering head.
MODEL LABELThe model label 1 is affixed to the frame. Thisinformation will be needed to order spare parts.
1-2
IMPORTANT INFORMATIONGENINFO
EB101000
IMPORTANT INFORMATIONPREPARATION FOR REMOVAL PROCE-DURES1. Remove all dirt, mud, dust and foreign mate-
rial before removal and disassembly.
2. Use proper tools and cleaning equipment.Refer to the “SPECIAL TOOLS” section.
3. When disassembling the machine, alwayskeep mated parts together. This includesgears, cylinders, pistons and other parts thathave been “mated” through normal wear.Mated parts must always be reused or re-placed as an assembly.
4. During machine disassembly, clean all partsand place them in trays in the order of disas-sembly. This will speed up assembly and al-low for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EB101010
REPLACEMENT PARTS1. Use only genuine Yamaha parts for all re-
placements. Use oil and grease recom-mended by Yamaha for all lubrication jobs.Other brands may be similar in function andappearance, but inferior in quality.
EB101020
GASKETS, OIL SEALS AND O-RINGS1. Replace all gaskets, seals and O-rings when
overhauling the engine. All gasket surfaces,oil seal lips and O-rings must be cleaned.
2. Properly oil all mating parts and bearingsduring reassembly. Apply grease to the oilseal lips.
1-3
IMPORTANT INFORMATIONGENINFO
CAUTION:
EB101030
LOCK WASHERS/PLATES AND COTTERPINS1. Replace all lock washers/plates 1 and cot-
ter pins after removal. Bend lock tabs alongthe bolt or nut flats after the bolt or nut hasbeen tightened to specification.
EB101040
BEARINGS AND OIL SEALS1. Install bearings and oil seals so that the
manufacturer’s marks or numbers are vis-ible. When installing oil seals, apply a lightcoating of lightweight lithium base grease tothe seal lips. Oil bearings liberally wheninstalling, if appropriate.
1 Oil seal
Do not use compressed air to spin the bear-ings dry. This will damage the bearing sur-faces.
1 Bearing
EB101050
CIRCLIPS1. Check all circlips carefully before reassemb-
ly. Always replace piston pin clips after oneuse. Replace distorted circlips. When instal-ling a circlip 1 , make sure that the sharp-edged corner 2 is positioned opposite thethrust 3 it receives. See sectional view.
4 Shaft
1-4
CHECKING OF CONNECTIONSGENINFO
NOTE:
NOTE:
EB801000
CHECKING OF CONNECTIONSCheck the connectors for stains, rust, moisture,etc.1. Disconnect:Connector
2. Check:ConnectorMoisture Dry each terminal with an airblower.Stains/rust Connect and disconnect theterminals several times.
3. Check:Connector leadsLooseness Bend up the pin 1 and con-nect the terminals.
4. Connect:Connector terminals
The two terminals “click” together.
5. Check:Continuity (using a pocket tester)
If there is no continuity, clean the terminals.When checking the wire harness be sure toperform steps 1 to 3.
As a quick remedy, use a contact revitalizeravailable at most part stores.
Check the connector with a pocket tester asshown.
1-5
SPECIAL TOOLSGENINFO
EB102001
SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly. Use onlythe appropriate special tools; this will help prevent damage caused by the use of inappropriate tools orimprovised techniques. Special tools may differ by shape and part number from country to country. Insuch a case, two types are provided.When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name/How to use Illustration
Weight90890-01084
Bolt90890-01085
Slide hammer bolt /weight
These tools are used to remove the rockerarm shaft.
90890-01135
Crankcase separating tool
This tool is used to remove the crankshaft.
90890-01229
Coupling gear/Middle shaft tool
This tool is needed when removing orinstalling the final pinion shaft nut.
Final gearbacklash band90890-01230Middle gear
backlash band90890-01231
Final gear backlash band
This tool is needed when measuring final gear/middle gear backlash.
Installer pot90890-01274
Bolt90890-01275
Crankshaft installer pot/bolt /adapter/spacer
90890 01275Adaptor
90890-04130Spacer
90890-04060
These tools are used to install the crankshaft.
90890-01304
Piston pin puller
This tool is used to remove the piston pin.
90890-01312
Fuel level gauge
This gauge is used to measure the fuel levelin the float chamber.
1-6
SPECIAL TOOLSGENINFO
Tool No. Tool name/How to use Illustration
T-handle90890-01326
Holder90890-01460
T-handle/damper rod holder
These tools are needed to loosen and tightenthe damper rod holding bolt.
Puller90890-01362
Adapter90890-04131
Flywheel puller/adapter
These tools are needed to remove the rotor.
Weight90890-01367
Adapter90890-01381
Fork seal driver weight/adapter
These tools are needed when installing theslide metal, oil seal and dust seal into the fork.
Ring nut wrench90890-01403Exhaust nut
wrench90890-01268
Ring nut wrench/ehaust and steering nutwrench
This tool is needed to loosen and tighten thesteering stem ring nut.
90890-01701
Sheave holder
This tool is needed to hold the rotor when re-moving or installing the rotor bolt.
90890-03081
Compression gauge set
These tools are needed to measure enginecompression.
90890-03094
Vacuum gauge
This gauge is needed for carburetor synchro-nization.
90890-03112
Pocket tester
This instrument is needed for checking theelectrical system.
90890-03113
Engine tachometer
This tool is needed for observing engine r/min.
1-7
SPECIAL TOOLSGENINFO
Tool No. Tool name/How to use Illustration
90890-03141
Timing light
This tool is necessary for checking ignitiontiming.
90890-04014
Valve guide remover & installer
This tool is needed to remove and install thevalve guide.
90890-04019
Valve spring compressor
This tool is needed to remove and install thevalve assemblies.
Adapter90890-01277Shock puller90890-01290
Weight90890-01291
Crankshaft installer bolt adapter/armatureshock puller/weight
These tools are needed when removing thefinal pinion shaft.
90890-04137
Bearing retainer wrench
This tool is needed when removing or instal-ling the middle drive shaft assembly.
Wrench90890-04138
Holder90890-04055
Middle drive shaft nut wrench/Middle driveshaft holder
These tools are needed when removing orinstalling the middle drive shaft bearing.
90890-04062
Universal joint holder
This tool is needed when removing or instal-ling the driven pinion gear nut.
90890-04077
Bearing retainer wrench
This tool is needed when removing or instal-ling the final drive pinion gear assembly.
90890-04086
Clutch holding tool
This tool is needed to hold the clutch when re-moving or installing the clutch boss nut.
1-8
SPECIAL TOOLSGENINFO
Tool No. Tool name/How to use Illustration
90890-04090
Damper spring compressor
This tool is needed when removing or instal-ling the damper spring.
90890-06754
Dynamic spark testerIgnition checker
This instrument is necessary for checking theignition system components.
90890-85505
Yamaha bond No.1215
This sealant (bond) is used on crankcase mat-ing surfaces, etc.
SPEC
2
E
SPEC
CHAPTER 2.SPECIFICATIONS
GENERAL SPECIFICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SPECIFICATIONS 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL TORQUE SPECIFICATIONS 2-20. . . . . . . . . . . . . . . . . . . . . . . . . .
CONVERSION TABLE 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION POINTS AND LUBRICANT TYPES 2-21. . . . . . . . . . . . . . . . ENGINE 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 2-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION DIAGRAMS 2-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING 2-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E
SPEC
2-1
GENERAL SPECIFICATIONS SPEC
Temp. C
SPECIFICATIONSGENERAL SPECIFICATIONS
Item Standard
Model code: XVS1100: 5EL1 (For Europe)5EL2 (For D, A, FIN)5EL3 (For Australia)
Dimensions:Overall lengthOverall widthOverall heightSeat heightWheelbaseMinimum ground clearanceMinimum turning radius
2,405 mm895 mm1,095 mm690 mm1,640 mm145 mm3,200 mm
Basic weight:With oil and a full fuel tank 274 kg (5EL2 : 275kg)
Engine:Engine typeCylinder arrangementDisplacementBore strokeCompression ratioCompression pressure (STD)Starting system
Air cooled 4-stroke, SOHCV-type 2-cylinder1.063 L95 75mm8.3 : 11,000 kPa (10 kg/cm2, 10 bar) at 400 r/minElectric starter
Lubrication system: Wet sump
Oil type or grade:Engine oil API standard:
“SE” or higher gradeACEA standard:
G4 or G5
Final gear oil: SAE80API “GL-4” Hypoid Gear Oil
Oil quantity:Engine oilPeriodic oil changeWith oil filter replacementTotal amount
Final gear case oilTotal amount
3.0 L3.1 L3.6 L
0.2 L
Air filter: Dry type element
Fuel:TypeFuel tank capacityFuel reserve amount
Regular unleaded gasoline17 L4.5 L
2-2
GENERAL SPECIFICATIONS SPEC
Item Standard
Carburetor:Type/quantityManufacturer
BSR37/2MIKUNI
Spark plug:TypeManufacturerSpark plug gap
BPR7ES/W22EPR–UNGK/DENSO0.7 0.8 mm
Clutch type: Wet, multiple-disc
Transmission:Primary reduction systemPrimary reduction ratioSecondary reduction systemSecondary reduction ratioTransmission typeOperationGear ratio 1st
2nd3rd4th5th
Spur gear78/47 (1.660)Shaft drive44/47 19/18 32/11 (2.875)Constant mesh 5-speedLeft foot operation40/17 (2.353)40/24 (1.667)36/28 (1.286)32/31 (1.032)29/34 (0.853)
Chassis:Frame typeCaster angleTrail
Double cradle33136 mm
Tire:TypeSize front
rearManufacturer front
rearType front
rear
With tube110/90-18 61S170/80-15M/C 77SBRIDGESTONE/DUNLOPBRIDGESTONE/DUNLOPEXEDRA L309/K555FEXEDRA G546/K555
Maximum load-except motorcycle: 201 kg (5EL2 : 200kg)
Tire pressure (cold tire):0 90 kg (0 198 lb) load *
frontrear
90 kg (198 lb) Maximum load *frontrear
200 kPa (2.00 kg/cm2)225 kPa (2.25 kg/cm2)
225 kPa (2.25 kg/cm2)250 kPa (2.50 kg/cm2)* Load is the total weight of the cargo, rider,passenger and accessories.
Brake:Front brake type
operationRear brake type
operation
Dual disc brakeRight hand operationSingle disc brakeRight foot operation
2-3
GENERAL SPECIFICATIONS SPEC
Item Standard
Suspension:Front suspensionRear suspension
Telescopic forkSwingarm (link suspension)
Shock absorber:Front shock absorberRear shock absorber
Coil spring/Oil damperCoil spring/Gas-oil damper
Wheel travel:Front wheel travelRear wheel travel
140 mm113 mm
Electrical:Ignition systemGenerator systemBattery typeBattery capacity
T.C.I. (digital)A.C. magnetoGT14B-412 V 12 AH
Headlight type: Quartz bulb (halogen)
Bulb wattage quantity:HeadlightAuxiliary lightTail /brake lightTurn signalLicence lightMeter lightNeutral indicator lightHigh beam indicator lightTurn indicator lightOil level caution lightEngine warning light
12 V 60 W/55 W 112 V 4 W 112 V 5 W/21 W 112 V 21 W 412 V 5 W 114 V 1.4 W 212 V 1.7 W 112 V 1.7 W 112 V 1.7 W 112 V 1.7 W 112 V 1.7 W 1
2-4
MAINTENANCE SPECIFICATIONS SPEC
MAINTENANCE SPECIFICATIONSENGINE
Item Standard Limit
Cylinder head:Warp limit 0.03 mm
Cylinder:Bore sizeMeasuring point
95.00 95.01 mm40 mm
95.1 mm
Camshaft:Drive methodCam cap inside diameterCamshaft outside diameterShaft-to-cap clearanceCam dimensions
Intake “A”“B”
“C”Exhaust “A”
“B”“C”
Camshaft runout limit
Chain drive (left & right)25.000 25.021 mm24.96 24.98 mm0.020 0.061 mm
39.112 39.212 mm#1: 32.093 32.193 mm#2: 32.127 32.227 mm7.162 mm39.145 39.245 mm32.200 32.300 mm7.195 mm
39.012 mm#1: 31.993 mm#2: 32.027 mm7.012 mm39.045 mm32.100 mm7.045 mm0.03 mm
2-5
Margin ThicknessHead Dia Face width Seat Width
MAINTENANCE SPECIFICATIONS SPEC
Item Standard Limit
Timing chain:Timing chain type/No. of linksTiming chain adjustment method
SILENT CHAIN/98LAutomatic
Rocker arm/rocker arm shaft:Bearing inside diameterShaft outside diameterArm-to-shaft clearance
14.000 mm 14.018 mm13.985 mm 13.991 mm0.009 mm 0.033 mm
14.036 mm13.95 mm0.086 mm
Valve, valve seat, valve guide:Valve clearance (cold) IN
EX0.07 0.12 mm0.12 0.17 mm
Valve dimensions:
“A” head diameter INEX
“B” face width INEX
“C” seat width INEX
“D” margin thickness INEX
Stem outside diameter INEX
Guide inside diameter INEX
Stem-to-guide clearance INEX
47.0 47.2 mm39.0 39.2 mm2.1 mm2.1 mm1.2 1.4 mm1.2 1.4 mm1.1 1.5 mm1.1 1.5 mm7.975 7.990 mm7.960 7.975 mm8.000 8.012 mm8.000 8.012 mm0.010 0.037 mm0.025 0.052 mm
1.8 mm1.8 mm0.8 mm0.8 mm
0.08 mm0.10 mm
2-6
MAINTENANCE SPECIFICATIONS SPEC
Item Standard Limit
Stem runout limit
Valve seat width INEX
1.2 1.4 mm1.2 1.4 mm
0.03 mm
2.0 mm2.0 mm
Valve spring:Free length IN
EXSet length (valve closed) IN
EXCompressed pressure IN(installed) EXTilt limit IN
EX
Direction of winding(top view) IN
EX
44.6 mm44.6 mm40 mm40 mm160.7 N (16.4 kg)160.7 N (16.4 kg)
ClockwiseClockwise
43.5 mm43.5 mm
2.5 /1.9mm2.5 /1.9mm
Piston:Piston to cylinder clearancePiston size “D”
Measuring point “H”Piston off-set
0.025 0.050 mm94.960 94.975 mm
5 mm0 mm
0.15 mm
2-7
MAINTENANCE SPECIFICATIONS SPEC
1 2 3 4 5
Item Standard Limit
Piston pin bore inside diameterPiston pin outside diameter
22.004 22.015 mm21.991 22.000 mm
Piston rings:Top ring:
TypeDimensions (B T)End gap (installed)Side clearance (installed)
2nd ring:
TypeDimensions (B T)End gap (installed)Side clearance
Oil ring:
Dimensions (B T)End gap (installed)
Plain1.5 3.8 mm0.3 0.5 mm0.04 0.08 mm
Taper1.2 3.8 mm0.30 0.45 mm0.03 0.07 mm
2.5 3.4 mm0.2 0.7 mm
0.8 mm0.1 mm
0.8 mm0.1 mm
Connecting rod:Oil clearanceColor code (corresponding size)
0.044 0.073 mmBlue Black Brown Green Yellow
Crankshaft:
Crank width “A”Runout limit “C”Big end side clearance “D”
101.95 102.00 mm
0.320 0.474 mm
0.02 mm
2-8
MAINTENANCE SPECIFICATIONS SPEC
Item Standard Limit
Clutch:Friction plate thicknessQuantity
Clutch plate thicknessQuantity
Clutch plate thicknessQuantity
Clutch spring free lengthQuantity
Clutch housing thrust clearanceClutch housing radial clearanceClutch release methodPush rod bending limit
2.9 3.1 mm82.5 2.7 mm11.9 2.1 mm77.2 mm10.05 0.40 mm0.010 0.044 mmInner push, screw push
2.8 mm
0.1 mm
0.1 mm
6.5 mm
0.5 mm
Transmission:Main axle deflection limitDrive axle deflection limit
0.08 mm0.08 mm
Shifter:Shifter type Guide bar
Carburetor:I. D. markMain jet (M.J)Main air jet (M.A.J)Jet needle (J.N)Needle jet (N.J)Pilot air jet (P.A.J.1)
(P.A.J.2)Pilot outlet (P.O)Pilot jet (P.J)Bypass 1 (B.P.1)Bypass 2 (B.P.2)Bypass 3 (B.P.3)Pilot screw (P.S)Valve seat size (V.S)Starter jet (G.S.1)Starter jet (G.S.2)Throttle valve size (Th.V)Fuel level (F.L)Engine idle speedIntake vacuumEngine oil temperature
5EL1 00#1: #110, #2: #112.5#55#1: 5DL39-53-3/5, #2: 5DL40-53-3/5P-0M#63.8#1451.0#17.50.80.80.831.2#42.50.8#12545 mm950 1,050 r/min34.7 37.3 kPa (260 280 mmHg)75 85C
Fuel pump:TypeModel/manufacturerConsumption amperage <max>Output pressure
Electrical typeUC-Z6M/MITSUBISHI0.8 A12 kPa (0.12 kg/cm2)
2-9
MAINTENANCE SPECIFICATIONS SPEC
Item Standard Limit
Lubrication system:Oil filter typeOil pump typeTip clearance “A” or “B”Side clearanceRelief valve operating pressure
Paper typeTrochoid type0.03 0.09 mm0.03 0.08 mm450 550 kPa (4.5 5.5 kg/cm2)
0.15 mm0.15 mm
Shaft drive:Middle gear backlashFinal gear backlash
0.1 0.2 mm0.1 0.2 mm
2-10
MAINTENANCE SPECIFICATIONS SPEC
Item Standard
Lubrication chart:
Left crankcase Right crankcase
MAINTENANCE SPECIFICATIONS SPEC
2-11
Cylinder head tightening sequence:
Crankcase tightening sequence:
2-12
MAINTENANCE SPECIFICATIONS SPEC
Tightening torques
Part to be tightened Part name Threadsize
Q’tyTightening
torque Remarksgsize
yNm mkg
Cylinder headCylinder headPlateCylinder head coverCylinder head (exhaust pipe)Rocker arm shaftCamshaft sprocket coverTappet coverRocker arm shaft (oil passage)Stopper plate (camshaft)Spark plugCylinderLower cylinder head coverUpper cylinder head coverConnecting rodRotorValve adjusting locknutCamshaft sprocketTiming chain tensionerTiming chain tentioner capTiming chain guideOil pumpOil strainer coverOil filter coverOil pump gearOil pump capOil deliuery pipe (cylinder head)
(crankcase)Drain boltCarburetor coverAir filter case stayAir filter case assemblyExhaust pipe joint and cylinder headExhaust pipe joint and mufflerassemblyMufflerCrankcase (cylinder)Crankcase (cylinder)CrankcaseCrankcaseBearing retainer (middle drive piniongear)Crankcase cover (left)Crankcase cover (right)ClampOne-way clutchPrimary drive gear
NutNutBolt
ScrewStud bolt
Union boltBoltBoltBoltBolt—
BoltBolt
ScrewNutNutNutBoltBoltBoltBoltBoltBoltBoltBoltBolt
Union boltUnion bolt
—BoltBoltBoltNutBolt
BoltStud boltStud bolt
BoltBoltBolt
BoltBoltBoltBoltNut
M12M10M8M6M8
M16M6M6
M16M8
M14M6M6M6M9
M16M8
M10M6M6M6M6M6M6M6M6
M16M10M14M5M6M5M8M8
M10M12M10M10M6M8
M6M6M6M6
M20
8224424844226841424243351121122342
2823
103
1311181
5035204
12.537.5101038202010105
481752755108
1010101012102020437
102
2020
252420
38.51025
10101012110
5.03.52.00.4
1.253.751.01.03.82.02.01.01.00.54.8
17.52.75.51.00.81.01.01.01.01.21.02.02.04.30.71.00.22.02.0
2.52.42.0
3.851.02.5
1.01.01.01.211.0
Use lock washer
Use lock washer
2-13
MAINTENANCE SPECIFICATIONS SPEC
Part to be tightened Part nameThread
sizeQ’ty
Tighteningtorque Remarksg
sizey
Nm mkg
Clutch springClutch adjusterClutch bossPush lever axleMiddle drive pinion gearBearing retainer (middle driven shaft)Yoke (middle driven shaft)Bearing housing (middle drive shaft)Shift lever stopper
Guide bar stopperShift dram segmentShift armShift pedal adjuster
Stator coilPickup coilStarter motorNeutral switchIgnition coilSpeed sensor
BoltNutNut
ScrewNutNutNutBoltBolt
ScrewScrewBoltNut
ScrewScrewBolt—
ScrewBolt
M6M8
M20M8
M44M88M14M8M8
M6M5M6M6
M6M5M6
M10M5M6
611111141
2112
322141
8127012110110—2522
74
1010
107
10202.57
0.81.27.01.211.011.0—2.52.2
0.70.41.01.0
1.00.71.02.0
0.250.7
Use lock washer
StakeStakeStake
Use lock washer
1 of 2 has LH
thread
2-14
MAINTENANCE SPECIFICATIONS SPEC
CHASSIS
Item Standard Limit
Steering system:Steering bearing type Angular bearing
Front suspension:Front fork travelFork spring free lengthFitting lengthCollar lengthSpring rate (K1)
(K2)Stroke (K1)
(K2)Optional springOil capacityOil levelOil grade
140 mm356.9 mm319.4 mm183 mm8.8 N/mm (0.9 kg/mm)12.7 N/mm (1.3 kg/mm)0 77.5 mm77.5 140 mmNo0.464 L108 mmFork oil 10W or equivalent
350 mm
Rear suspension:Shock absorber travelSpring free lengthFitting lengthSpring rate (K1)Stroke (K1)Optional spring
113 mm179.5 mm163 mm117.7 N/mm (12 kg/mm)0 50 mmNo
Swingarm:Free play limit end 0 mm
Front wheel:TypeRim sizeRim materialRim runout limit radial
lateral
Spoke wheel18 2.15Steel
1.0 mm0.5 mm
Rear wheel:TypeRim sizeRim materialRim runout limit radial
lateral
Spoke wheel15M/C MT4.50Steel
1.0 mm0.5 mm
2-15
MAINTENANCE SPECIFICATIONS SPEC
Item Standard Limit
Front brake:TypeDisc outside diameter thicknessDisc deflection limitPad thickness innerPad thickness outer
Master cylinder inside diameterCaliper cylinder inside diameterCaliper cylinder inside diameterBrake fluid type
Dual disc298 5 mm
6.2 mm6.2 mm
14.0 mm25.4 mm30.1 mmDOT 4
4.5 mm0.15 mm0.8 mm0.8 mm
Rear brake:TypeDisc outside diameter thickenessDisc deflection limitPad thickness inner
outerMaster cylinder inside diameterCaliper cylinder inside dimeterBrake fluid type
Single disc282 6 mm
5.55 mm5.55 mm12.7 mm42.9 mmDOT 4
5.5 mm0.15 mm0.5 mm0.5 mm
Brake lever & brake pedal:Brake lever free play (at lever end)Brake pedal positionBrake pedal free playClutch lever free play (at lever end)
Throttle grip free play
5 8 mm81.8 mm0 mm5 10 mm4 6 mm
2-16
MAINTENANCE SPECIFICATIONS SPEC
Tightening torques
Part to be tightened Thread sizeTightening
torque RemarksgNm mkg
Upper bracket and inner tubeLower bracket and inner tubeUpper bracket and steering shaftRing nut (steering shaft)Handlebar holder (lower) and upper bracketHandlebar holder (lower) and handlebarholder (upper)Master cylinder (front brake)Union bolt (brake hose)Brake hose holder and lower bracketBrake hose joint and brake pipeBrake hose joint and brake hose holderFront fender and outer tubeHeadlight stay and lower bracketHeadlight stay and headlightFront flasher light and lower bracketEngine mounting:
Frame and stay (front - upper)Frame and stay (front - lower)Stay and engine (front - upper)Stay and engine (front - lower)Frame and engine (rear - upper)Frame and engine (rear - lower)
Down tube and framelgnition coil and stayMuffler stay and frameRear shock absorber and relay armRear shock absorber and framePivot shaft and swingarmRelay arm and frameConnecting arm and relay armConnecting arm and swingarmFinal gear case and swingarmSwingarm end and holderFuel tank and fuel cockFuel tank bracket and frameRider’s seatPassenger seatFuel tank and top coverLicence bracket and rear fender stayRear fender and rear fender stayRear fender and tail /brake lightRear fender stay and rear flasher lightFrame and rear fenderSide cover (left)Battery coverSide cover (right)Starter relay and leads
M8M10M22—
M12M8
M6M10M6
M10M6M8M6M6M6
M10M10M12M10M10M10M10M5M8
M10M10M16M10M12M12M10M8M6M8M6M6M5M6M5M6
M12M8M6M6M6M6
2030110183228
103010191010787
484874484848484
3048409048484890237
237747467
267777
2.03.011.01.83.22.8
1.03.01.01.91.01.00.70.80.7
4.84.87.44.84.84.84.80.43.04.84.09.04.84.84.89.02.30.72.30.70.70.40.70.40.60.72.60.70.70.70.7
See NOTE
2-17
MAINTENANCE SPECIFICATIONS SPEC
NOTE:
Part to be tightenedThread
size
Tighteningtorque Remarksg size
Nm mkg
Passenger footrest and frameSidestand bracket and frameSidestand and sidestand bracketSidestand switchBrake pedal/ footrest and frameRear brake master cylinder and master cylinderbracketMaster cylinder bracket and down tubeFootrest and frameFront wheel axleFront wheel axle pinch boltBrake caliperBrake disc and front wheelCaliper bleed screwRear wheel axle nutRear brake caliper and caliper bracketCaliper bracket and swingarmBrake hose union boltCaliper bleed screwClutch hub and damperFinal gear case stud boltFinal gear case stud boltBearing housing (final gear case)Bearing housing (final gear case)Drive pinionBearing retainer (final drive pinion gear)Oil filter bolt (final gear)Oil drain bolt (final gear)Housing cover
M8M10M10M5M6M8
M8M10M16M8
M10M8M7
M16M10M10M10M8
M10M10M8M8
M10M14M65M14M14M10
26645647
23
2364592040236
1074040306
62189
2340
130115232342
2.66.45.60.40.72.3
2.36.45.92.04.02.30.6
10.74.04.03.00.66.21.80.92.34.0
13.011.52.32.34.2
LH thread
1. First, tighten the ring nut approximately 52 Nm (5.2 mkg) by using the torque wrench, thenloosen the ring nut completely.
2. Retighten the ring nut to specification.
2-18
MAINTENANCE SPECIFICATIONS SPEC
ELECTRICAL
Item Standard Limit
Voltage: 12 V
Ignition system:Ignition timing (B.T.D.C.)Advancer type
10 at 1,000 r/minDigital type
T.C.I.:Pickup coil resistance/colorT.C.I. unit model/manufacturer
189 231 Ω at 20C/Gray – BlackJ4T101/MITSUBISHI
Ignition coil:Model/manufacturerPrimary winding resistanceSecondary winding resistance
F6T507/MITSUBISHI3.57 4.83 Ω at 20C10.7 14.5 kΩ at 20C
Spark plug cap:TypeResistance
Resin type10 kΩ
Charging system:TypeModel/manufacturerNominal outputStator coil resistance/color
A.C. magnetoF4T654/MITSUBISHI14 V 350 W at 5,000 r/min0.36 0.44 Ω at 20C/White – White
Voltage regulator:TypeModel/manufacturerNo load regulated voltage
Semi-conductor, short-circuit typeSH650D-11/SHINDENGEN14.1 14.9 V
Rectifier:Model/manufacturerCapacityWithstand voltage
SH650D-11/SHINDENGEN18 A200 V
Battery:Specific gravity 1.320
Electric starter system:TypeStarter motor:
Model/manufacturerOutputArmature coil resistanceBrush overall lengthBrush spring pressureCommutator diameterMica undercut
Starter relay:Model/manufacturerAmperage rating
Constant mesh type
SM-13/MITSUBA0.6 kW0.026 0.034 Ω at 20C12.5 mm7.65 10.01 N (780 1021 g)28 mm0.7 mm
MS5F-421/JIDECO180 A
5 mm
27 mm
2-19
MAINTENANCE SPECIFICATIONS SPEC
Item Standard Limit
Horn:TypeQuantityModel/manufacturerMaximum amperage
Plane type1YF-12/NIKKO3 A
Flasher relay:TypeModel/manufacturerSelf cancelling deviceFlasher frequencyWattage
Full transistor typeFE246BH/DENSONo75 95 cycle/min21 W 2 + 3.4W
Oil level gauge:Model/manufacturer 5EL/DENSO
Starting circuit cut-off relayModel/manufacturer G8R-30Y-B/OMRON
Fuel pump relay:Model/manufacturer G8R-30Y-B/OMRON
Circuit breaker:TypeAmperage for individual circuit
MAINHEAD LIGHTSIGNALSIGNITIONBACK UPCarburetor heaterReserveReserveReserveReserve
Fuse
30 A 115 A 110 A 110 A 15 A 115 A 130 A 115 A 110 A 15 A 1
2-20
GENERAL TORQUE SPECIFICATIONS/CONVERSION TABLE SPEC
GENERAL TORQUESPECIFICATIONSThis chart specifies torque for standard fasten-ers with standard I.S.O. pitch threads. Torquespecifications for special components or as-semblies are provided for each chapter of thismanual. To avoid warpage, tighten multi-fasten-er assemblies in a crisscross fashion, in pro-gressive stages, until the specified torque isreached. Unless otherwise specified, torquespecifications require clean, dry threads. Com-ponents should be at room temperature.
A: Distance between flatsB: Outside thread diameter
10 mm 6 mm 6 0,6
12 mm 8 mm 15 1,5
14 mm 10 mm 30 3,0
19 mm 14 mm 85 8,5
22 mm 16 mm 130 13,0
17 mm 12 mm 55 5,5
A(nut)
B(Bolt)
General torquespecifications
Nm mkg
EAS00028
CONVERSION TABLEAll specification data in this manual are listedin SI and METRIC UNITS.Use this table to convert METRIC unit data toIMPERIAL unit data.
Ex.
CONVERSION TABLE
EB202001
METRIC MULTIPLIER IMP
** mm x 0.03937 = ** in
2 mm x 0.03937 = 0.08 in
METRIC TO IMP
Known Multiplier Result
Torque
mkgmkgcmkgcmkg
7.23386.7940.07230.8679
ftlbinlbftlbinlb
Weight kgg
2.2050.03527
lboz
Distance
km/hrkmmmcmmm
0.62140.62143.2811.0940.39370.03937
mphmiftydinin
Volume/Capacity
cc (cm3)cc (cm3)lt (liter)It (liter)
0.035270.061020.87990.2199
oz (IMP liq.)cuinqt (IMP liq.)gal (IMP liq.)
Miscella-neous
kg/mmkg/cm2
Centigrade
55.99714.22349/5 (C) + 32
lb/ inpsi (lb / in2)Fahrenheit (F)
2-21
LUBRICATION POINTS AND LUBRICANT TYPES SPEC
EB203000
LUBRICATION POINTS AND LUBRICANT TYPESENGINE
Lubrication point Symbol
Oil seal lips
O-ring
Bearing
Connecting rod bolt /nut
Connecting rod small end and big end
Crankshaft pin
Crankshaft journal/big end
Piston surface
Piston pin
Camshaft cam lobe/journal
Rocker arm shaft
Valve stem (IN, EX)
Valve stem end (IN, EX)
Timing chain drive gear shafts/sprokets
Oil pump rotor (inner/outer), housing
Idle gear surface
Starter idle gear
Starter idle gear shaft
Starter oneway cam
Middle drive gear
Primary driven gear
Push rod 1, 2
Transmission gear (wheel/pinion)
Shift cam
Shift fork/guide bar
Shift shaft assembly
Push rod ball
Push lever assembly
2-22
LUBRICATION POINTS AND LUBRICANT TYPES SPEC
EB203010
CHASSIS
Lubrication point Symbol
Steering head pipe (upper/ lower), bearing
Steering head pipe, bearing cover lip
Steering head pipe, oil seal lip
Front wheel oil seal lip (right/ left)
Rear wheel oil seal lip
Clutch hub fitting area
Rear brake pedal shaft
Shift pedal shaft
Sidestand bolt, sidestand sliding surface
Tube guide (throttle grip) inner surface
Brake lever pivot bolt, contact surface
Clutch lever pivot bolt, contact surface
Rear shock absorber (lower) oil seal lip
Swingarm pivot bearing inner surface
Swingarm pivot oil seal lip
Relay arm bearing, collar and oil seal
Drive shaft spline
Drive shaft dust cover
2-23
LUBRICATION DIAGRAMS SPEC
4 Oil pump5 Drive axle6 Middle drive shaft
1 Rocker arm shaft (intake)2 Rocker arm shaft (exhaust)3 Oil filter
EB205000
LUBRICATION DIAGRAMS
2-24
4 Middle drive shaft1 Oil pump2 Releaf valve3 Oil filter
LUBRICATION DIAGRAMS SPEC
2-25
4 Middle drive shaft5 Drive axle6 Connecting rod big end
1 Camshaft2 Crankshaft3 Main axle
LUBRICATION DIAGRAMS SPEC
2-26
CABLE ROUTING SPEC
19 Fuel hose (carburetor-fuel pump)20 Brake hose21 Heat protector22 Fuel breather hose (fuel tank-
roll over valve) (for California)23 Speedometer lead24 Wireharness25 Purge hose (carburetor-solenoid
valve) (for California)
10 Alarm connector11 Fuel pump lead12 Speed sensor lead13 Sidestand switch lead14 Neutral switch lead15 Pickup coil lead16 AC magneto lead17 Ventilation hose18 Sensing hose (AIS-carburetor
joint)
1 Clutch cable2 Starter cable3 Handlebar switch lead (left)4 Handlebar switch lead (right)5 High tension code6 Starter cable7 Throttle cable8 Fuel hose (fuel cock-fuel filter)9 Fuse box
EB206000
CABLE ROUTING
2-27
F Push the wire harness insideof the tool box plate.
G Route the sidestand leadinside of engine cover.
H Position the all connectorsinside of the connector cover.
I Route the clutch cable throughthe cable guide.
B Position the throttle cable andstarter cable as shown, andclamp them with holder.
C Clamp the wire harness withthe hook of frame side.
D When installing the pipe ofthrottle cables, press it inside.
E Connect the sensing hose(carburetor joint-AIS side) witha nozzle.
26 Purge hose (carburetor-solenoidvalve) (for California)
A Fasten the handlebar switchleads (left and right) to thehandlebar with plastic lockingtie.
CABLE ROUTING SPEC27
2-28
M Fasten the AC magneto leadand sidestand switch lead with aplastic locking tie.
N Fasten the alarm lead with aplastic band on the lid.
J Fasten the handlebar switchleads (left and right) under thehandle crown with a plasticband.Set the band at four notches,and install it no slacking.
K Route the each hoses throughthe frame guide and do notpinch it.
L When installing the fitting plate,do not pinch the each hosesand wire harness.
CABLE ROUTING SPEC
E
2-29
23 Handlebar switch lead (left)24 Throttle position sensor lead25 Carburetor heater lead26 Thermo switch lead27 Starting circuit cutoff relay28 Down tube29 High tension code30 Purge hose (carburetor-
solenoid valve) (for California)31 Carburetor heater lead32 Oil level switch lead
12 Ignition coil13 Master cylinder reservoir hose14 Breather hose15 Air filter drain hose16 Battery negative (–) lead17 Rear brake switch lead18 Rear brake hose19 Carburetor heater connector20 Rectifier / regulator21 Main switch lead22 Flasher relay
1 Battery2 Battery positive (+) lead3 Starter motor positive (+) lead4 Speedometer lead5 Fuel hose (carburetor-fuel pump)6 High tension code7 Main switch lead8 Throttle cable9 Brake hose10 Handlebar switch lead (right)11 Headlight lead
CABLE ROUTING SPEC
E
2-30
H Fasten the rear brake switchlead and master cylinderreservoir hose to the downtube with a plastic locking tie.
I Fasten the wire harness,starter motor positive (+) leadand battery negative (–) lead tothe frame with a plastic locking tie.
J Route the rectifier / regulatorlead and carburetor heater leadthrough inside of battery boxhole to outside it and connectthem.
D Connect the purge hose(carburetor side-solenoid valveside) with joint. (for California)
E Route the front turn signal lightlead and headlight lead throughthe rear of headlight body hole.
F Connect the ignition coil lead atred tape to the right side.
G Fasten the rear brake switch lead to the brake switch bracket with a plastic locking tie.
A Clamp the battery positive (+)lead to the battery with batteryband.
B Connect the battery negative(–) lead connector and push itinto the space between batterybox and battery.
C Route the rectifier / regulatorlead, wire harness and startermotor positive (+) lead throughthe outside of frame bracketand fasten them to the framewith a plastic locking tie.
CABLE ROUTING SPEC
E
2-31
K To rear brake caliperL Clamp the handlebar switch
lead (right) and main switchlead to the frame with a holder.
M Arrange the throttle positionsensor connector, carburetorheater connector and thermoswitch connector between thestarting circuit cutoff relay andhigh tension code.
N Fasten the rear brake switchto the down tube with a plasticlocking tie.
CABLE ROUTING SPEC
E
2-32
20 Starter cable21 Fuel hose (fuel cock-fuel filter)22 Carburetor heater lead23 Thermo switch lead24 Igniter unit25 Taillight lead26 Throttle position sensor lead27 Fuel filter28 Igniter unit lead29 Frame30 Wire harness
A Clamp the throttle cables withthe holder.
11 Battery negative (–) leadconnector
12 Battery13 Battery positive (+) lead14 Taillight lead15 Starter relay16 Starter motor positive (+) lead17 Speedometer lead connector18 Fuel tank breather hose
(fuel tank-roll over valve) (forCalifornia)
19 Ventilation hose
1 Brake hose2 Throttle cable3 Master cylinder reservoir hose4 High tension code5 Purge hose (carburetor-solenoid
valve) (for California)6 Rear brake switch lead7 Brake hose8 Sensing hose (AIS-carburetor
joint)9 Fuel hose (carburetor-fuel
pump)10 Battery negative (–) lead
CABLE ROUTING SPEC
E
2-33
J Fasten the wire harness with aband on the tool box plate.
K Fasten the wire harness to theframe with a plastic locking tie.Position the locking tie front ofthe solder.
F Route the battery positive (+)lead through the slit of thebattery box.
G Clamp the igniter unit lead tothe frame with a holder.
H To the rear fender.I Route the fuel tank breather
hose under the fuel filter andconnect it (fuel tank side-rollover valve side) with a joint.Position the end of clip outside.
B Route the rear brake switchlead under the master cylinderreservoir hose.
C Position the band end of rightside bracket.
D Position the steel band end toforward.
E Position the steel band end toright side.
CABLE ROUTING SPEC
E
2-34
P Route the igniter lead throughthe igniter plate hole to the wireharness.
Q Clamp the taillight lead withmud guard clamp.
R Clamp the taillight lead with aholder on the mud guard.
L Route wire harness outside ofthe guide on the frame.
M Clamp the clutch cable andstarter cable with a holder.Position the end of holder downside.
N Route the throttle positionsensor lead and carburetorheater lead left side of thetappet cover.
O To the wire harness.
CABLE ROUTING SPEC
E
1 Throttle cable2 Starter cable3 Clutch cable4 Handlebar switch lead (left)5 Headlight lead6 Brake hose
A Route the handlebar switchlead (right) rear side of thethrottle cable.
2-35
CABLE ROUTING SPEC
E
SPEC
INSPADJ
3
INSPADJ
CHAPTER 3PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC MAINTENANCE/LUBRICATION INTERVALS 3-1. . . . . . . . . . .
FUEL TANK AND SEATS 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE VALVE CLEARANCE 3-5. . . . . . . . . . . . . . . . . . . . . . . SYNCHRONIZING THE CARBURETORS 3-8. . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE ENGINE IDLING SPEED 3-10. . . . . . . . . . . . . . . . . . . . ADJUSTING THE THROTTLE CABLE FREE PLAY 3-11. . . . . . . . . . . . . CHECKING THE SPARK PLUGS 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE IGNITION TIMING 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING THE COMPRESSION PRESSURE 3-14. . . . . . . . . . . . . . . CHECKING THE ENGINE OIL LEVEL 3-16. . . . . . . . . . . . . . . . . . . . . . . . . CHANGING THE ENGINE OIL 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE CLUTCH CABLE FREE PLAY 3-18. . . . . . . . . . . . . . . . CLEANING THE AIR FILTER ELEMENT 3-19. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CARBURETOR JOINT AND INTAKE
MANIFOLD 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BREATHER HOSE 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE EXHAUST SYSTEM 3-21. . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT BRAKE 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR BRAKE 3-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE FLUID LEVEL 3-24. . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-25. . . . . . . . . . . . . . . CHECKING THE BRAKE HOSES 3-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . BLEEDING THE HYDRAULIC BRAKE SYSTEM 3-26. . . . . . . . . . . . . . . . ADJUSTING THE SHIFT PEDAL 3-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FINAL DRIVE OIL LEVEL 3-28. . . . . . . . . . . . . . . . . . . . CHANGING THE FINAL DRIVE OIL 3-28. . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND ADJUSTING THE STEERING HEAD 3-29. . . . . . . . . . CHECKING THE FRONT FORK 3-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3-31. . . . . . CHECKING THE TIRES 3-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND TIGHTENING THE SPOKES 3-35. . . . . . . . . . . . . . . . . CHECKING AND LUBRICATING THE CABLES 3-36. . . . . . . . . . . . . . . . . LUBRICATING THE LEVERS AND PEDALS 3-36. . . . . . . . . . . . . . . . . . . LUBRICATING THE SIDESTAND 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATING THE REAR SUSPENSION 3-36. . . . . . . . . . . . . . . . . . . . .
INSPADJ
ELECTRICAL SYSTEM 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND CHARGING THE BATTERY 3-37. . . . . . . . . . . . . . . . . . CHECKING THE FUSES 3-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE HEADLIGHT BULB 3-44. . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE HEADLIGHT BEAM 3-45. . . . . . . . . . . . . . . . . . . . . . . . .
3-1
INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS
INSPADJ
EB300000
PERIODIC INSPECTIONS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended inspections and adjust-ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle opera-tion and a longer service life. The need for costly overhaul work will be greatly reduced. This informa-tion applies to vehicles already in service as well as to new vehicles that are being prepared for sale. Allservice technicians should be familiar with this entire chapter.EB301000
PERIODIC MAINTENANCE/LUBRICATION INTERVALSEVERY
NO. ITEM CHECKS AND MAINTENANCE JOBSInitial
(1,000 km)
6,000 kmor
6 months(whichevercomes first)
12,000 kmor
12 months(whichevercomes first)
1 * Fuel line (manual cock) Check fuel hoses for cracks or damage. Replace if necessary.
√ √
2 * Fuel filter Check condition. Replace if necessary.
√
3 Spark plugs Check condition. Clean, regap or replace if necessary.
√ √ √
4 * Valves (arm SOHC) Check valve clearance. Adjust if necessary.
√ √ √
5 Air filter Clean or replace if necessary. √ √
6 Clutch Check operation. Adjust or replace cable.
√ √ √
7 * Front brake (disc)
Check operation, fluid level and vehicle for fluid leakage.(See NOTE.)
Correct accordingly. Repalce brake pads if necessary.
√ √ √
8 * Rear brake (disc)
Check operation, fluid level and vehicle for fluid leakage.(See NOTE.)
Correct accordingly. Replace brake pads if necessary.
√ √ √
9 * Wheels (spoke) Check balance, runout, spoke tightness and for damage. Tighten spokes and rebalance, replace if necessary.
√ √
10 * Tires (EUR)
Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary.
√ √
11 * Wheel bearings Check bearing for looseness or damage. Replace if necessary.
√ √
12 * Swingarm (no nipple)
Check swingarm pivoting point for play. Correct if necessary. Lubricate with molybdenum disulfide grease every
24,000 km or 24 months (whichever comes first).
√ √
13 * Steering bearings
Check bearing play and steering for roughness. Correct accordingly. Lubricate with lithium soap base grease every 24,000
km or 24 months (whichever comes first).
√ √
14 * Chassis fasteners Make sure that all nuts, bolts and screws are properly
tightened. Tighten if necessary.
√ √
15 Sidestand Check operation. Lubricate and repair if necessary.
√ √
16 * Sidestand switch Check operation. Replace if necessary.
√ √ √
3-2
PERIODIC MAINTENANCE/LUBRICATION INTERVALSINSPADJ
NOTE:
EVERY
NO. ITEM CHECKS AND MAINTENANCE JOBSInitial
(1,000 km)
6,000 kmor
6 months(whichevercomes first)
12,000 kmor
12 months(whichevercomes first)
17 * Front fork Check operation and for oil leakage. Correct accordingly.
√ √
18 *Rear shock absorberassembly
Check operation and shock absorber for oil leakage. Replace shock absorber assembly if necessary.
√ √
19 * Carburetors (multi) Check engine idlilng speed, synchronization and start-
er operation. Adjust if necessary.
√ √ √
20 Engine oil Check oil level and vehicle for oil leakage. Correct if necessary. Change. (Warm engine before draining.)
√ √ √
21 *Engine oil filterelement Replace. √ √
22 Final gear oil Check oil level and vehicle for oil leakage. Change oil at initial 1,000 km and thereafter every
24,000 km or 24 months (whichever comes first).√ √ √
* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.Hydraulic brake system– When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check
the brake fluid level regularly and fill as required.– Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.– Replace the brake hoses every four years or if cracked or damaged.
Order Job name/Part name Q’ty Remarks
1234
5678
Fuel tank and seats removalPassenger seatSeat bracketRider’s seatFuel hose
Ignitor plateMud guardMeter lead couperFuel tank assembly
1111
1111
Remove the parts in the order below.
Set the fuel cock to “OFF” before dis-connecting the fuel hose.
For installation, reverse the removalprocedure.
NOTE:
7 Nm (0.7mkg)
23Nm (2.3mkg)7 Nm (0.7mkg)
3-3
FUEL TANK AND SEATSINSPADJ
FUEL TANK AND SEATS
3-4
FUEL TANK AND SEATSINSPADJ
NOTE:
NOTE:
REMOVAL1. Remove: Ignitor plate
To remove the quick fastener, push its center inwith a screwdriver, then pull the fastener out.
INSTALLATION1. Install: Ignitor plate
To install the quick fastener, push its pin so that itprotrudes from the fastener head, then insertthe fastener into the cowling and push the pin ain with a screwdriver. Make sure that the pin isflush with the fastener’s head.
3-5
ADJUSTING THE VALVE CLEARANCEINSPADJ
NOTE:
EAS00047
ENGINEADJUSTING THE VALVE CLEARANCEThe following procedure applies to all of thevalves.
Valve clearance adjustment should be madeon a cold engine, at room temperature.
When the valve clearance is to be measured oradjusted, the piston must be at top dead center(TDC) on the compression stroke.
1. Remove: rider’s seat fuel tankRefer to “FUEL TANK AND SEATS”.
2. Disconnect:spark plug caps
3. Remove:spark plugs
4. Remove:air intake box 1
5. Remove:cylinder head cover (rear cylinder) 1cylinder head cover (front cylinder)
3-6
ADJUSTING THE VALVE CLEARANCEINSPADJ
6. Remove: tappet covers 1
7. Remove:camshaft sprocket cover (rear cylinder) 1camshaft sprocket cover (front cylinder)
8. Remove: timing plug 1straight plug 2
9. Measure:valve clearanceOut of specification Adjust.
Valve clearance (cold):Intake valve:
0.07 0.12 mmExhaust valve:
0.12 0.17 mm
3-7
ADJUSTING THE VALVE CLEARANCEINSPADJ
A B
a
b
a. Turn the crankshaft counterclockwise.b. When the piston is at TDC on the compres-
sion stroke, align either the camshaft sprock-et plate hole a with the stationary pointer bon the cylinder head. When the camshaftsprocket plate hole or camshaft sprocketpunch mark is aligned with the stationarypointer, the piston is at top dead center(TDC).
c. Align the TDC mark c on the generator rotorwith the stationary pointer d on the crank-case.
A Rear cylinder (“TI” mark)
B Front cylinder (“I” mark)
d. Measure the valve clearance with a thick-ness gauge 1 .
e. Turn the crankshaft crockwise 290, andthen measure the front cylinder.
10. Adjustvalve clearance
a. Loosen the locknut 1 .b. Insert a thickness gauge between the end of
the adjusting screw and the valve tip.c. Turn the adjusting screw 2 in direction a or
b until the specified valve clearance is ob-tained.
Direction Valve clearance isdecreased.
Direction Valve clearance isincreased.
d. Hold the adjusting screw to prevent it frommoving and tighten the locknut to specifica-tion.
ADJUSTING THE VALVE CLEARANCE/SYNCHRONIZING THE CARBURETORS
INSPADJ
3-8
NOTE:
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
20 Nm (2.0 mkg)
NOTE:
NOTE:
Locknut:27 Nm (2.7 mkg)
e. Measure the valve clearance again.f. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance adjust-ment steps until the specified clearance isobtained.
11. Install:all removed parts
Install all removed parts in the reverse order oftheir disassembly. Note the following points.
camshaft sprocket covers
tappet covers
spark plugs
EAS00051
SYNCHRONIZING THE CARBURETORS
Prior to synchronizing the carburetors, the valveclearance and the engine idling speed shouldbe properly adjusted and the ignition timingshould be checked.
1. Stand the motorcycle on a level surface.
Place the motorcycle on a suitable stand.
2. Remove: rider’s seat fuel tankRefer to “FUEL TANK AND SEATS”.
3. Remove:air duct 1
4. Remove:vacuum plugs 1
3-9
SYNCHRONIZING THE CARBURETORSINSPADJ
NOTE:
5. Install:vacuum gauge 1engine tachometer 2(to the spark plug lead of cyl. #2)
Vacuum gauge:90890-03094
Engine tachometer:90890-03113
6. Start the engine and let it warm up for severalminutes.
7. Check:engine idling speedOut of specification Adjust.Refer to “ADJUSTING THE ENGINE IDLINGSPEED”.
Engine idling speed:950 1,050 r/min
8. Adjust:Carburetor synchronization
a. Synchronize carburetor #1 to carburetor #2by turning the synchronizing screw 1 in ei-ther direction until both gauges read thesame.
b. Rev the engine two or three times, each timefor less than a second, and check the syn-chronization again.
Vacuum pressure at idle speed:34.7 37.3 kPa (260 280 mmHg)
The difference between the two carburetorsshould not exceed 1.33 kPa (10 mmHg).
9. Check:engine idling speedOut of specification Adjust.
10. Stop the engine and remove the measuringequipment.
11. Adjust: throttle cable free playRefer to “ADJUSTING THE THROTTLECABLE FREE PLAY”.
SYNCHRONIZING THE CARBURETORS/ADJUSTING THE ENGINE IDLING SPEED
INSPADJ
3-10
NOTE:
a
b
Throttle cable free play (at theflange of the throttle grip)
4 6 mm
12. Install:vacuum plugsair duct fuel tankseat
EAS00054
ADJUSTING THE ENGINE IDLING SPEED
Prior to adjusting the engine idling speed, thecarburetor synchronization should be adjustedproperly, the air filter should be clean, and theengine should have adequate compression.
1. Start the engine and let it warm up for severalminutes.
2. Remove:cylinder head cover 1
3. Install:engine tachometer(to the spark plug lead of cyl. #1)
Engine tachometer:90890-03113
4. Check:engine idling speedOut of specification Adjust.
Engine idling speed:950 1,050 r/min
5. Adjust:engine idling speed
a. Turn the pilot screw 1 in until it is lightlyseated.
b. Turn the pilot screw out the specified numberof turns.
Pilot screw3 turns out
c. Turn the throttle stop screw 2 in direction aor b until the specified engine idling speed isobtained.
Direction Engine idling speed isincreased.
Direction Engine idling speed isdecreased.
3-11
ADJUSTING THE ENGINE IDLING SPEED/ADJUSTING THE THROTTLE CABLE FREE PLAY
INSPADJ
NOTE:
NOTE:
a
b
NOTE:
6. Adjust: throttle cable free playRefer to “ADJUSTING THE THROTTLECABLE FREE PLAY”.
Throttle cable free play (at theflange of the throttle grip)
4 6 mm
EAS00058
ADJUSTING THE THROTTLE CABLE FREEPLAY
Prior to adjusting the throttle cable free play, theengine idling speed should be adjusted.
1. Check: throttle cable free play aOut of specification Adjust.
Throttle cable free play (at theflange of the throttle grip)
4 6 mm
2. Remove: rider’s seat fuel tankRefer to “FUEL TANK AND SEATS”.
3. Adjust: throttle cable free play
When the motorcycle is accelerating, the accel-erator cable 1 is pulled.
Carburetor sidea. Loosen the locknut 2 on the accelerator cable.b. Turn the adjusting nut 3 in direction a or b
until the specified throttle cable free play isobtained.
Direction Throttle cable free playis decreased.
Direction Throttle cable free playis increased.
c. Tighten the locknuts.
If the specified throttle cable free play cannot beobtained on the carburetor side of the cable, usethe adjusting nut on the handlebar side.
3-12
ADJUSTING THE THROTTLE CABLE FREE PLAY/CHECKING THE SPARK PLUGS
INSPADJ
a
b
WARNING
CAUTION:
Handlebar sidea. Loosen the locknut 1 .b. Turn the adjusting nut 2 in direction a or b
until the specified throttle cable free play isobtained.
Direction Throttle cable free play isincreased.
Direction Throttle cable free play isdecreased.
c. Tighten the locknut.
After adjusting the throttle cable free play,turn the handlebar to the right and to the leftto ensure that this does not cause the en-gine idling speed to change.
EAS00059
CHECKING THE SPARK PLUGSThe following procedure applies to all of thespark plugs.1. Remove:cylinder head covers 1
2. Disconnect:spark plug cap
3. Remove:spark plug
Before removing the spark plugs, blow awayany dirt accumulated in the spark plug wellswith compressed air to prevent it from fal-ling into the cylinders.
4. Check:spark plug typeIncorrect Change.
Spark plug type (manufacturer)BPR7ES (NGK)W22EPR-U (DENSO)
5. Check:electrode 1Damage/wear Replace the spark plug.
insulator 2Abnormal color Replace the spark plug.Normal color is a medium-to-light tan color.
6. Clean:spark plug(with a spark plug cleaner or wire brush)
3-13
CHECKING THE SPARK PLUGS/CHECKING THE IGNITION TIMING
INSPADJ
20 Nm (2.0 mkg)
NOTE:
NOTE:
7. Measure:spark plug gap a(with a wire gauge)Out of specification Regap.
Spark plug gap0.7 0.8 mm
8. Install:spark plug
Before installing the spark plug, clean the sparkplug and gasket surface.
9. Connect:spark plug cap
EAS00064
CHECKING THE IGNITION TIMING
Prior to checking the ignition timing, check thewiring connections of the entire ignition system.Make sure that all connections are tight and freeof corrosion.
1. Remove: timing plug 1
2. Install: timing light 1engine tachometer 2(to the spark plug lead of cyl. #1)
Timing light:90890-03141
Engine tachometer:90890-03113
3-14
CHECKING THE IGNITION TIMING/MEASURING THE COMPRESSION PRESSURE
INSPADJ
NOTE:
NOTE:
3. Check: ignition timing
a. Start the engine, warm it up for several min-utes, and then let it run at the specified en-gine idling speed.
Engine idling speed:950 1,050 r/min
b. Check that the stationary pointer a is withinthe firing range b on the generator rotor.Incorrect firing range Check the ignitionsystem.
The ignition timing is not adjustable.
4. Install: timing plug 1
EAS00065
MEASURING THE COMPRESSION PRES-SUREThe following procedure applies to all of the cyl-inders.
Insufficient compression pressure will result in aloss of performance.
1. Check:valve clearanceOut of specification Adjust.Refer to “ADJUSTING THE VALVE CLEAR-ANCE”.
2. Start the engine, warm it up for several min-utes, and then turn it off.
3. Disconnect:spark plug cap
4. Remove:spark plug
3-15
MEASURING THE COMPRESSION PRESSUREINSPADJ
CAUTION:
WARNING
NOTE:
Before removing the spark plugs, use com-pressed air to blow away any dirt accumu-lated in the spark plug wells to prevent itfrom falling into the cylinders.
5. Install:compression gauge 1
Compression gauge set:90890-03081
6. Measure:compression pressureAbove the maximum pressure Inspect thecylinder head, valve surfaces, and pistoncrown for carbon deposits.Below the minimum pressure Squirt a fewdrops of oil into the affected cylinder andmeasure again.
Refer to the following table.
Compression pressure(with oil applied in the cylinder)
Reading Diagnosis
Higher thanwithout oil
Piston wear or damage Repair.
Same aswithout oil
Piston ring(-s), valves, cylin-der head gasket or pistonpossibly defective Repair.
Compression pressure (at sealevel)
Standard:1,000 kPa (10 kg/cm 2, 10 bar)
Minimum:900 kPa (9 kg/cm 2, 9 bar)
Maximum:1,100 kPa (11 kg/cm 2, 11 bar)
a. Turn the main switch to “ON”.b. With the throttle wide open, crank the engine
until the reading on the compression gaugestabilized.
To prevent sparking, ground all spark plugleads before cranking the engine.
The difference in compression pressure be-tween cylinders should not exceed 100 kPa (1kg/cm2, 1 bar).
3-16
MEASURING THE COMPRESSION PRESSURE/CHECKING THE ENGINE OIL LEVEL
INSPADJ
20 Nm (2.0 mkg)
NOTE:
CAUTION:
7. Install:spark plug
8. Connect:spark plug cap
EAS00069
CHECKING THE ENGINE OIL LEVEL1. Stand the motorcycle on a level surface.
Place the motorcycle on a suitable stand.Make sure that the motorcycle is upright.
2. Let the engine idle for a few minutes.
3. Check:engine oil levelThe engine oil level should be between theminimum level marks a and maximum levelmarks b .Below the minimum level mark Add therecommended engine oil to the proper level.
Recommended engine oilRefer to the chart for theengine oil grade which is bestsuited for certain atmospherictemperatures.API standard
SE or higher gradeACEA standard
G4 or G5
Engine oil also lubricates the clutch andthe wrong oil types or additives couldcause clutch slippage. Therefore, do notadd any chemical additives or use engineoils with a grade of CD a or higher and donot use oils labeled “ENERGY CONSERV-ING II” b or higher.
Do not allow foreign materials to enter thecrankcase.
3-17
CHECKING THE ENGINE OIL LEVEL/CHANGING THE ENGINE OIL
INSPADJ
NOTE:
WARNING
43 Nm (4.3 mkg)
4. Start the engine, warm it up for several min-utes, and then turn it off.
5. Check the engine oil level again.
Before checking the engine oil level, wait a fewminutes until the oil has settled.
EAS00075
CHANGING THE ENGINE OIL1. Start the engine, warm it up for several min-
utes, and then turn it off.2. Place a container under the engine oil drain
bolt.3. Remove:engine oil filler cap 1o-ringengine oil drain bolt 2gasket
4. Drain:engine oil(completely from the crankcase)
5. If the oil filter element is also to be replaced,perform the following procedure.
Oil filter element replacement should bemade cold exhaust pipe and muffler, at roomtemperature.
a. Remove the muffler 1 , rear brake reservoirtank 2 , element cover 3 and exhaust pipe(front cylinder) 4 .
b. Remove the oil filter element cover plate 5 ,element cover 6 and oil filter element 7 .
c. Check the O-ring 8 and replace it if it iscracked or damaged.
d. Install the new oil filter element and the ele-ment cover.
Oil filter element cover bolt10 Nm (1.0 mkg)
e. Install the exhaust pipe (front cylinder), ele-ment cover plate, rear brake reservoir tankand muffler.Refer to “ENGINE” in chapter 4.
6. Check:engine oil drain bolt gasketDamage Replace.
7. Install:gasketengine oil drain bolt
8. Fill:crankcase(with the specified amount of the recom-mended engine oil)
3-18
CHANGING THE ENGINE OIL/ADJUSTING THE CLUTCH CABLE FREE PLAY
INSPADJ
b
c
NOTE:
QuantityTotal amount
3.6 LWithout oil filter elementreplacement
3.0 LWith oil filter elementreplacement
3.1 L
9. Install:o-ringengine oil filter cap
10. Start the engine, warm it up for several min-utes, and then turn it off.
11. Check:engine(for engine oil leaks)
12. Check:engine oil levelRefer to “CHECKING THE ENGINE OILLEVEL”.
EAS00078
ADJUSTING THE CLUTCH CABLE FREEPLAY1. Check:clutch cable free play aOut of specification Adjust.
Clutch cable free play (at the endof the clutch lever)
5 10 mm
2. Adjust:clutch cable free play
Handlebar sidea. Loosen the locknut 1 .b. Turn the adjusting screw 2 in direction b or
c until the specified clutch cable free play isobtained.
Direction Clutch cable free play isincreased.
Direction Clutch cable free play isdecreased.
c. Tighten the locknut.
If the specified clutch cable free play cannot beobtained as described above, perform the mech-anism adjustment procedure described below.
3. Remove: left side cover 1clutch adjusting cover 2
3-19
ADJUSTING THE CLUTCH CABLE FREE PLAY/CLEANING THE AIR FILTER ELEMENT
INSPADJ
4. Adjust:clutch mechanism
Engine sidea. Loosen the locknut 1 .b. Turn in the adjusting screw 2 until it is lightly
seated.c. Turn the adjusting screw out 1/4 of a turn.d. Tighten the locknut.e. Check the clutch cable free play again and
ajust it if necessary.
EAS00086
CLEANING THE AIR FILTER ELEMENT1. Remove:air filter case cover 1air filter element 2
2. Clean:air filter elementApply compressed air to the outer surface ofthe air filter element.
3. Check:air filter elementDamage Replace.
4. Install:air filter elementair filter case cover
CLEANING THE AIR FILTER ELEMENT/CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD/
CHECKING THE BREATHER HOSEINSPADJ
3-20
CAUTION:
NOTE:
CAUTION:
Never operate the engine without the air filterelement installed. Unfiltered air will causerapid wear of engine parts and may damagethe engine. Operating the engine without theair filter element will also affect the carburetorturning, leading to poor engine performanceand possible overheating.
When installing the air filter element into the airfilter case cover, be sure their sealing surfacesare aligned to prevent any air leaks.
EAS00094
CHECKING THE CARBURETOR JOINT ANDINTAKE MANIFOLD1. Check:carburetor joint 1Cracks/damage Replace.Refer to “CARBURETOR” in chapter 6.
EAS00098
CHECKING THE BREATHER HOSE1. Remove:cylinder head cover
2. Check:cylinder head breather hose 1Cracks/damage Replace.Loose connection Connect properly.
Make sure that the cylinder head breatherhose is routed correctly.
3-21
CHECKING THE EXHAUST SYSTEMINSPADJ
EAS00100
CHECKING THE EXHAUST SYSTEMThe following procedure applies to all of the ex-haust pipes, mufflers and gaskets.1. Check:exhaust pipes 1muffler 2Cracks/damage Replace.
gaskets 3Exhaust gas leaks Replace.
2. Check: tightening torque
Exhaust pipe nut 420 Nm (2.0 mkg)
Exhaust pipe and muffler bolt 520 Nm (2.0 mkg)
Muffler and muffler bracket bolt 625 Nm (2.5 mkg)
3-22
ADJUSTING THE FRONT BRAKEINSPADJ
b
c
WARNING
CAUTION:
EAS00108
CHASSISADJUSTING THE FRONT BRAKE1. Check:brake lever free play aOut of specification Adjust.
Brake lever free play (at the endof the brake lever)
5 8 mm
2. Adjust:brake lever free play
a. Loosen the locknut 1 .b. Turn the adjusting bolt 2 in direction b or c
until the specified brake lever free play is ob-tained.
Direction Brake lever free play isincreased.
Direction Brake lever free play isdecreased.
c. Tighten the locknut.
A soft or spongy feeling in the brake levercan indicate the presence of air in the brakesystem. Before the vehicle is operated, theair must be removed by bleeding the brakesystem. Air in the brake system will consid-erably reduce braking performance andcould result in loss of control and possiblyan accident. Therefore, inspect and, if nec-essary, bleed the brake system.
After adjusting the brake lever free play,make sure that there is no brake drag.
3-23
ADJUSTING THE REAR BRAKEINSPADJ
b
c
WARNING
WARNING
CAUTION:
EAS00110
ADJUSTING THE REAR BRAKE1. Check:brake pedal position(distance a from the top of the rider footrestto the top of the brake pedal)Out of specification Adjust.
Brake pedal position (below thetop of the rider footrest)
81.8 mm
2. Adjust:brake pedal position
a. Loosen the locknut 1 .b. Turn the adjusting bolt 2 in direction b or c
until the specified brake pedal position is ob-tained.
Direction Brake pedal is raised.
Direction Brake pedal is lowered.
After adjusting the brake pedal position,check that the end of the adjusting bolt 2 isvisible through the hole d .
c. Tighten the locknut 1 to specification.
Locknut16 Nm (1.6 mkg)
A soft or spongy feeling in the brake pedalcan indicate the presence of air in the brakesystem. Before the vehicle is operated, theair must be removed by bleeding the brakesystem. Air in the brake system will consid-erably reduce braking performance andcould result in loss of control and possiblyan accident. Therefore, inspect and, if nec-essary, bleed the brake system.
After adjusting the brake pedal position,make sure that there is no brake drag.
3. Adjust: rear brake light switchRefer to “ADJUSTING THE REAR BRAKELIGHT SWITCH”.
3-24
A
B
CHECKING THE BRAKE FLUID LEVELINSPADJ
NOTE:
WARNING
CAUTION:
NOTE:
EAS00115
CHECKING THE BRAKE FLUID LEVEL1. Stand the motorcycle on a level surface.
Place the motorcycle on a suitable stand.Make sure that the motorcycle is upright.
2. Check;brake fluid levelBelow the minimum level mark a Add therecommended brake fluid to the proper level.
Recommended brake fluidDOT 4
A Front brake
B Rear brake
Use only the designated brake fluid. Otherbrake fluids may cause the rubber seals todeteriorate, causing leakage and poorbrake performance.
Refill with the same type of brake fluid thatis already in the system. Mixing brakefluids may result in a harmful chemicalreaction, leading to poor brake perfor-mance.
When refilling, be careful that water doesnot enter the reservoir. Water will signifi-cantly lower the boiling point of the brakefluid and could cause vapor lock.
Brake fluid may damage painted surfacesand plastic parts. Therefore, always cleanup any spilt brake fluid immediately.
In order to ensure a correct reading of the brakefluid level, make sure that the top of the reser-voir is horizontal.
3-25
ADJUSTING THE REAR BRAKE LIGHT SWITCH/CHECKING THE BRAKE HOSES
INSPADJ
NOTE:
a
b
EAS00128
ADJUSTING THE REAR BRAKE LIGHTSWITCH
The rear brake light switch is operated by move-ment of the brake pedal.The rear brake light switch is properly adjustedwhen the brake light comes on just before thebraking effect starts.
1. Check: rear brake light operation timingIncorrect Adjust.
2. Adjust: rear brake light operation timing
a. Hold the main body 1 of the rear brake lightswitch so that it does not rotate and turn theadjusting nut 2 in direction a or b until therear brake light comes on at the proper time.
Direction Brake light comes onsooner.
Direction Brake light comes onlater.
EAS00131
CHECKING THE BRAKE HOSESThe following procedure applies to all of thebrake hoses and clamps.1. Check:brake hoseCracks/damage/wear Replace.
2. Check:brake hose clampLoose connection Tighten.
3. Hold the motorcycle upright and apply thebrake.
4. Check:brake hoseActivate the brake several times.Brake fluid leakage Replace the damagedhose.Refer to “FRONT AND REAR BRAKES” inchapter 7.
3-26
A
B
BLEEDING THE HYDRAULIC BRAKE SYSTEMINSPADJ
WARNING
NOTE:
NOTE:
EAS00134
BLEEDING THE HYDRAULIC BRAKE SYS-TEM
Bleed the hydraulic brake system whenever: the system was disassembled,a brake hose was loosened or removed, the brake fluid level is very low,brake operation is faulty.
Be careful not to spill any brake fluid or allowthe brake master cylinder reservoir or brakefluid reservoir to overflow.
When bleeding the hydraulic brake system,make sure that there is always enough brakefluid before applying the brake. Ignoring thisprecaution could allow air to enter the hydrau-lic brake system, considerably lengthening thebleeding procedure.
If bleeding is difficult, it may be necessary to letthe brake fluid settle for a few hours. Repeatthe bleeding procedure when the tiny bubblesin the hose have disappeared.
1. Stand the motorcycle on alevel surface.
Place the motorcycle on a suitable stand.Make sure that the motorcycle is upright.
2. Bleed:hydraulic brake system
a. Add the recommended brake fluid to theproper level.
b. Install the diaphragm (brake master cylinderreservoir or brake fluid reservoir).
c. Connect a clear plastic hose 1 tightly to thebleed screw 2 .
A : Front B : Reard. Place the other end of the hose into a con-
tainer.e. Slowly apply the brake several times.f. Fully squeeze the brake lever or fully de-
press the brake pedal and hold it in position.g. Loosen the bleed screw.
This will release the tension and cause thebrake lever to contact the throttle grip or thebrake pedal to fully extend.
3-27
BLEEDING THE HYDRAULIC BRAKE SYSTEM/ADJUSTING THE SHIFT PEDAL
INSPADJ
WARNING
NOTE:
b
c
h. Tighten the bleed screw and then release thebrake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the airbubbles have disappeared from the brakefluid in the plastic hose.
j. Tighten the bleed screw to specification.
Bleed screw6 Nm (0.6 mkg)
k. Fill the reservoir to the proper level.Refer to “CHECKING THE BRAKE FLUIDLEVEL”.
After bleeding the hydraulic brake system,check the brake operation.
EAS00137
ADJUSTING THE SHIFT PEDAL
The shift pedal position is determined by the ad-justing bolt length a .
1. Measure:adjusting the length aIncorrect Adjust.
Adjusting bolt length114.7 mm
2. Adjust:adjusting bolt length a
a. Loosen both locknuts 1b. Turn the adjusting bolt 2 in direction b or c
to obtain the correct shift pedal position.
Direction shift pedal is raised.
Direction shift pedal is lowered.
3-28
CHECKING THE FINAL DRIVE OIL LEVEL/CHANGING THE FINAL DRIVE OIL
INSPADJ
NOTE:
23 Nm (2.3 mkg)
23 Nm (2.3 mkg)
EAS00144
CHECKING THE FINAL DRIVE OIL LEVEL1. Stand the motorcycle on a level surface.
Place the motorcycle on a suitable stand.Make sure that the motorcycle is upright.
2. Remove: final drive housing oil filler bolt 1
3. Check: final drive oil levelThe final drive oil level should be to the bot-tom brim 2 of the filler hole.Below the bottom brim Add the recom-mended final drive oil to the proper level.
Recommended final drive oilSAE 80 hypoid gear oil graded“GL-4”, “GL-5” or “GL-6”ormulti-purpose SAE 80W90hypoid gear oil
4. Install: final drive housing oil filler bolt
EAS00145
CHANGING THE FINAL DRIVE OIL1. Place a container under the final drive hous-
ing.2. Remove: final drive housing oil filler bolt 1 final drive housing oil drain bolt 2Completely drain the final drive housing of itsoil.
3. Check: final drive housing oil drain bolt gasketDamage Replace.
4. Install: final drive housing oil drain bolt
5. Fill: final drive housing(with the specified amount of the recom-mended final drive oil)
3-29
CHANGING THE FINAL DRIVE OIL/CHECKING AND ADJUSTING THE STEERING HEAD
INSPADJ
WARNING
NOTE:
Quantity0.2 L
Refer to “CHECKING THE FINAL DRIVE OILLEVEL”.
EAS00146
CHECKING AND ADJUSTING THE STEER-ING HEAD1. Stand the motorcycle on a level surface.
Securely support the motorcycle so thatthere is no danger of it falling over.
Place the motorcycle on a suitable stand so thatthe front wheel is elevated.
2. Check:steering headGrasp the bottom of the front fork legs andgently rock the front fork.Looseness or binding Adjust the steeringhead.
3. Remove:upper bracket pinch bolt 1steering stem nut 2upper bracket 3
4. Adjust:steering head
a. Remove the lock washr 1 , the upper ring nut2 , and the rubber washer 3 .
CHECKING AND ADJUSTING THE STEERING HEADINSPADJ
3-30
NOTE:
WARNING
NOTE:
110 Nm (11.0 mkg)20 Nm (2.0 mkg)
b. Loosen the lower ring nut 4 and then tightenit to specification with a ring nut wrench 5 .
Set the torque wrench at a right angle to the ringnut wrench.
Ring nut wrench90890-01403
Lower ring nut (initial tighteningtorque)
52 Nm (5.2 mkg)
c. Loosen the lower ring nut 4 completely, thentighten it to specification.
Do not overtighten the lower ring nut.
Lower ring nut (final tighteningtorque)
18 Nm (1.8 mkg)
d. Check the steering head for looseness orbinding by turning the front fork all the way inboth directions. If any binding is felt, removethe lower bracket and inspect the upper andlower bearings.Refer to “STEERING HEAD AND HAN-DLEBAR” in chapter 7.
e. Install the rubber washer 3 .f. Install the upper ring nut 2 .g. Finger tighten the upper ring nut 2 , then
align the slots of both ring nuts. If necessary,hold the lower ring nut and tighten the upperring nut until their slots are aligned.
h. Install the lock washer 1 .
Make sure that the lock washer tabs a sit cor-rectly in the ring nut slots b .
5. Install:upper bracketsteering stem nut upper bracket pinch bolt
3-31
CHECKING THE FRONT FORK/ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
INSPADJ
WARNING
WARNING
CAUTION:
EAS00149
CHECKING THE FRONT FORK1. Stand the motorcycle on a level surface.
Securely support the motorcycle so thatthere is no danger of it falling over.
2. Check: inner tubeDamage/scratches Replace.
oil sealOil leakage Replace.
3. Hold the motorcycle upright and apply thefront brake.
4. Check:operationPush down hard on the handlebar severaltimes and check if the front fork reboundssmoothly.Unsmooth operation Repair.Refer to “FRONT FORK” in chapter 7.
EAS00159
ADJUSTING THE REAR SHOCK ABSORB-ER ASSEMBLY
Securely support the motorcycle so thatthere is no danger of it falling over.
Never go beyond the maximum or minimumadjustment positions.
1. Adjust:spring preload
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/CHECKING THE TIRES
INSPADJ
3-32
a
b
WARNING
Ring nut wrench1HX-28135-00
a. Turn the adjusting knob 1 in direction a orb .
Direction Spring preload isincreased(suspension is harder).
Direction Spring preload isdecreased(suspension is softer).
Adjusting positionStandard: 3Minimum: 1 (soft)Maximum: 7 (hard)
EB304174
CHECKING THE TIRESThe following procedure applies to both of thetires.1. Measure: tire pressureOut of specification Regulate.
The tire pressure should only be checkedand regulated when the tire temperatureequals the ambient air temperature.
The tire pressure and the suspension mustbe adjusted according to the total weight(including cargo, rider, passenger and ac-cessories) and the anticipated ridingspeed.
Operation of an overloaded motorcyclecould cause tire damage, an accident or aninjury.
NEVER OVERLOAD THE MOTORCYCLE.
3-33
CHECKING THE TIRESINSPADJ
WARNING
WARNING
Basicweight: (withoil and fullfuel tank)
274 kg
Maximumload*: 201 kg
Cold tirepressure: Front Rear
Up to 90 kgload*
200 kPa(2.00 kgf/cm 2)
225 kPa(2.25 kgf/cm 2)
90 kg maximumload*
225 kPa(2.25 kgf/cm 2)
250 kPa(2.50 kgf/cm 2)
High speedriding
225 kPa(2.25 kgf/cm 2)
250 kPa(2,50 kgf/cm 2)
*: total of cargo, rider, passenger and acces-sories
It is dangerous to ride with a worn-out tire.When the tire tread reaches the wear limit,replace the tire immediately.
2. Check: tire surfacesDamage/wear Replace the tire.
Minimum tire tread depth1.6 mm
1 Tire tread depth
2 Side wall
3 Wear indicator
Do not use a tubeless tire on a wheel de-signed only for tube tires to avoid tire fail-ure and personal injury from sudden defla-tion.
When using a tube tire, be sure to install thecorrect tube.
Always replace a new tube tire and a newtube as a set.
To avoid pinching the tube, make sure thatthe wheel rim band and tube are centered inthe wheel groove.
3-34
CHECKING THE TIRESINSPADJ
WARNING
Patching a punctured tube is not recom-mended. If it is absolutely necessary to doso, use great care and replace the tube assoon as possible with a good quality re-placement.
Tube wheel Tubeless wheel
Tube tire only Tube or tubeless tire
After extensive tests, the tires listed belowhave been approved by Yamaha Motor Co.,Ltd. for this model. Then front and rear tiresshould always be by the same manufactur-er and of the same design. No guaranteeconcerning handling characteristics canbe given if a tire combination other thanone approved by Yamaha is used on thismotorcycle.
Front tire:
Manufactur-er
Type Size
BRIDGE-STONE
110/90-18 61S EXEDRA L309
DUNLOP 110/90-18 61S K555F
Rear tire:
Manufactur-er
Type Size
BRIDGE-STONE
170/80-15M/C 77S
EXEDRAG546
DUNLOP 170/80-15M/C 77S
K555
New tires have a relatilvely low grip on theroad surface until they have been slightlyworn.Therefor, approximately 100 km should betraveled at normal speed before any high-speed riding is done.
3-35
CHECKING THE TIRES/CHECKING AND TIGHTENING THE SPOKES
INSPADJ
NOTE:
NOTE:
3 Nm (0.3 mkg)
NOTE:
For tires with a direction of rotation mark 1 : Install the tire with the mark pointing in thedirection of wheel rotation.
Align the mark 2 with the valve installationpoint.
EAS00169
CHECKING AND TIGHTENING THE SPOKESThe following procedure applies to all of thespokes.1. Check:spoke 1Bends/damage Replace.Loose Tighten.Tap the spokes with a screwdriver.
A tight spoke will emit a clear, ringing tone; aloose spoke will sound flat.
2. Tighten:spoke (with a spoke wrench 2 )
Be sure to tighten the spokes before and afterbreak-in.
CHECKING AND LUBRICATING THE CABLES/LUBRICATING THE LEVERS AND PEDALS/LUBRICATINGTHE SIDESTAND/LUBRICATING THE REAR SUSPENSION
INSPADJ
3-36
WARNING
NOTE:
EAS00170
CHECKING AND LUBRICATING THECABLESThe following procedure applies to all of thecable sheaths and cables.
Damaged cable sheaths may causes thecable to corrode and interfere with its move-ment. Replace damaged cable sheaths andcables as soon as possible.
1. Check:cable sheathDamage Replace.
2. Check:cable operationUnsmooth operation Lubricate.
Recommended lubricantEngine oil or a suitable cablelubricant
Hold the cable end upright and pour a few dropsof lubricant into the cable sheath or use a suit-able lubing device.
EAS00171
LUBRICATING THE LEVERS AND PEDALSLubricate the pivoting point and metal-to-metalmoving parts of the levers and pedals.
Recommended lubricantEngine oil
EAS00172
LUBRICATING THE SIDESTANDLubricate the pivoting point and metal-to-metalmoving parts of the sidestand.
Recommended lubricantEngine oil
EAS00174
LUBRICATING THE REAR SUSPENSIONLubricate the pivoting point and metal-to-metalmoving parts of the rear suspension.
Recommended lubricantMolybdenum disulfide grease
3-37
CHECKING AND CHARGING THE BATTERYINSPADJ
WARNING
WARNING
CAUTION:
EB305020
ELECTRICAL SYSTEMCHECKING AND CHARGING THE BATTERY
Batteries generate explosive hydrogen gasand contain electrolyte which is made of poi-sonous and highly caustic sulfuric acid.Therefore, always follow these preventivemeasures:Wear protective eye gear when handling orworking near batteries.
Charge batteries in a well-ventilated area.Keep batteries away from fire, sparks oropen flames (e.g., welding equipment,lighted cigarettes).
DO NOT SMOKE when charging or han-dling batteries.
KEEP BATTERIES AND ELECTROLYTEOUT OF REACH OF CHILDREN.
Avoid bodily contact with electrolyte as itcan cause severe burns or permanent eyeinjury.
First aid in case of bodily contact:ExternalSKIN – Wash with water.EYES – Flush with water for 15 minutes andget immediate medical attention.
InternalDrink large quantities of water or milk fol-lowed with milk of magnesia, beaten egg orvegetable oil. Get immediate medical atten-tion.
This is a sealed battery. Never remove thesealing caps because the balance betweencells will not be maintained and battery per-formance will deteriorate.
Charging time, charging amperage andcharging voltage for a MF battery are differ-ent from those of conventional batteries.The MF battery should be charged as ex-plained in the charging method illustra-tions. If the battery is overcharged, theelectrolyte level will drop considerably.Therefore, take special care when chargingthe battery.
CHECKING AND CHARGING THE BATTERYINSPADJ
Volt meter
Relationship between open-circuit voltage and charging time at 20C
Op
en-c
ircu
it v
olt
age
Charging time (Hours) This varies depending on the temperature, the state of
charge in battery plates and the electro lyte level.
3-38
NOTE:
CAUTION:
NOTE:
Since MF batteries are sealed, it is not possibleto check the charge state of the battery by mea-suring the specific gravity of the electrolyte.Therefore, the charge of the battery has to bechecked by measuring the voltage at the batteryterminals.
1. Remove:battery cover 1
2. Disconnect:battery leads(from the battery terminals)
First, disconnect the negative lead 1 , thenthe positive lead 2 .
3. Remove:battery
4. Check:battery charge
a. Connect a pocket tester to the battery termi-nals.
Tester positive lead battery positiveterminal
Tester negative lead battery negativeterminal
The charge state of a MF battery can bechecked by measuring its open-circuit voltage(i.e., the voltage when the positive terminal isdisconnected).
No charging is necessary when the open-cir-cuit voltage equals or exceeds 12.8 V.
b. Check the charge of the battery, as shown inthe charts and the following example.
Examplec. Open-circuit voltage = 12.0 Vd. Charging time = 6.5 hourse. Charge of the battery = 20 30 %
5. Charge:battery(refer to the appropriate charging method il-lustration)
3-39
Op
en-c
ircu
it v
olt
age
(V)
Condition of charge in battery (%)
Ambient temperature 20C
18
Op
en-c
ircu
it v
olt
age
(V)
17
16
15
14
13
12
11
100 10 20 30 40 50 60
Charging Ambient temperature20C
Check the Open-circuitvoltage
Time (Minutes)
CHECKING AND CHARGING THE BATTERYINSPADJ
WARNING
CAUTION:
Do not quick charge a battery.
Make sure that the battery breather hoseand battery vent are free of obstructions.
Never remove the MF battery sealing caps.Do not use a high-rate battery charger.They force a high-amperage current intothe battery quickly and can cause batteryoverheating and battery plate damage.
If it is impossible to regulate the chargingcurrent on the battery charger, be carefulnot to overcharge the battery.
When charging a battery, be sure to removeit from the motorcycle. (If charging has tobe done with the battery mounted on themotorcycle, disconnect the negative leadfrom the battery terminal.)
To reduce the chance of sparks, do notplug in the battery charger until the batterycharger leads are connected to the battery.
Before removing the battery charger leadclips from the battery terminals, be sure toturn off the battery charger.
Make sure that the battery charger leadclips are in full contact with the battery ter-minal and that they are not shorted. A cor-roded battery charger lead clip may gener-ate heat in the contact area and a weak clipspring may cause sparks.
If the battery becomes hot to the touch atany time during the charging process, dis-connect the battery charger and let the bat-tery cool before reconnecting it. Hot batter-ies can explode!
As shown in the following illustration, theopen-circuit voltage of a MF battery stabi-lizes about 30 minutes after charging hasbeen completed. Therefore, wait 30 min-utes after charging is completed beforemeasuring the open-circuit voltage.
Measure the open-circuitvoltage prior to charging.
Connect a charger andAMP meter to the batteryand start charging.
Make sure the current ishigher than the standardcharging current written onthe battery.
By turning the charging volt-age adjust dial, set the charg-ing voltage at 20 25 V.
Adjust the voltage so that cur-rent is at standard charginglevel.
Monitor the amperage for 3 5 minutes to check if the stan-dard charging current isreached.
Set the timer according to thecharging time suitable for theopen-circuit voltage.Refer to “Battery conditionchecking steps.”
If the current doesnot exceed stan-dard charging cur-rent after 5 min-utes, replace thebattery.
In case that charging requires more than 5 hours, it is advisable tocheck the charging current after a lapse of 5 hours. If there is anycharge in the amperage, readjust the voltage to obtain the standardcharging current.
Measure the battery open-circuit voltage after having left the batteryunused for more than 30 minutes.12.8 V or more --- Charging is complete.12.7 V or less --- Recharging is required.Under 12.0 V --- Replace the battery.
YES NO
YES
NO
NOTE:Voltage should be measured 30 min-utes after the machine is stopped.
NOTE:Set the charging voltage at 16 17 V.(If the setting is lower, charging will beinsufficient. If too high, the battery willbe over-charged.)
ChargerAMP meter
CHECKING AND CHARGING THE BATTERYINSPADJ
3-40
Charging method using a variable-current (voltage) type charger
3-41
Measure the open-circuitvoltage prior to charging.
Connect a charger andAMP meter to the batteryand start charging.
NOTE:Voltage should be measured 30 min-utes after the machine is stopped.
Make sure the current ishigher than the standardcharging current written onthe battery.
Charge the battery until the battery’scharging voltage is 15 V.
This type of battery charger cannotcharge the MF battery. A variable volt-age charger is recommended.
Measure the battery open-circuitvoltage after having left the batteryunused for more than 30 minutes.12.8 V or more --- Charging is com-plete.12.7 V or less --- Recharging is re-quired.Under 12.0 V --- Replace the battery.
NOTE:Set the charging time at 20 hours (maxi-mum).
YES NO
Charging method using a constant-current type chargerThis type of battery charger cannot charge the MF battery.
Volt meter
Charger
AMP meter
CHECKING AND CHARGING THE BATTERYINSPADJ
Charging method using a constant-voltage type charger
CHECKING AND CHARGING THE BATTERYINSPADJ
3-42
CAUTION:
CAUTION:
6. Check:battery breather hose and battery ventObstruction Clean.Damage Replace.
7. Install:battery
When inspecting the battery, make surethat the battery breather hose is properlyattached and routed correctly. If the batterybreather hose is positioned so as to allowelectrolyte or hydrogen gas from the bat-tery to contact the frame, the motorcycleand its finish may be damaged.
Make sure that the battery breather hose isproperly routed away from the drive chainand from below the swingarm.
8. Connect:battery leads(to the battery terminals)
First, connect the positive lead 1 , then thenegative lead 2 .
9. Check:battery terminalsDirt Clean with a wire brush.Loose connection Connect properly.
10. Lubricate:battery terminals
Recommended lubricantDielectric grease
11. Install:battery cover
3-43
CHECKING THE FUSESINSPADJ
CAUTION:
NOTE:
EAS00181
CHECKING THE FUSESThe following procedure applies to all of thefuses.
To avoid a short circuit, always turn the mainswitch to “OFF” when checking or replacinga fuse.
1. Remove: rider’s seat ignitor plateRefer to “FUEL TANK AND SEATS”.
tool box cover 12. Check: fuse
a. Connect the pocket tester to the fuse andcheck it for continuity.
Set the pocket tester selector to “Ω 1”.
Pocket tester90890-03112
b. If the pocket tester indicates “∞”, replace thefuse.
3. Replace:blown fuse
a. Turn off the ignition.b. Install a new fuse of the correct amperage
rating.c. Turn on the switches to verify if the electrical
circuit is operational.d. If the fuse immediately blows again, check
the electrical circuit.
Fuses Amperage rating Quantity
Main 30A 1
Headlight 15A 1
Carburetorheater 15A 1
Signals 10A 1
Ignition 10A 1
Back up 5A 1
Reserve 30A 1
Reserve 15A 1
Reserve 10A 1
Reserve 5A 1
CHECKING THE FUSES/REPLACING THE HEADLIGHT BULB
INSPADJ
3-44
WARNING
WARNING
Never use a fuse with an amperage ratingother than that specified. Improvising or us-ing a fuse with the wrong amperage ratingmay cause extensive damage to the electri-cal system, cause the lighting and ignitionsystems to malfunction and could possiblycause a fire.
4. Install: tool box cover ignitor plate rider’s seat
EAS00182
REPLACING THE HEADLIGHT BULB1. Disconnect:connectors 1
2. Removeheadlight bulb cover 2
3. Remove:headlight bulb holder 1
4. Remove:headlight bulb 2
Since the headlight bulb gets extremely hot,keep flammable products and your handsaway from the bulb until it has cooled down.
5. Install:headlight bulb (New)Secure the new headlight bulb with the head-light bulb holder.
3-45
REPLACING THE HEADLIGHT BULB/ADJUSTING THE HEADLIGHT BEAM
INSPADJ
CAUTION:
a
b
a
b
Avoid touching the glass part of the head-light bulb to keep it free from oil, otherwisethe transparency of the glass, the life of thebulb and the luminous flux will be adverselyaffected. If the headlight bulb gets soiled,thoroughly clean it with a cloth moistenedwith alcohol or lacquer thinner.
5. Install:headlight bulb holder
6. Install:headlight bulb cover
7. Connect: leads
EAS00184
ADJUSTING THE HEADLIGHT BEAM1. Adjust:headlight beam (vertically)
a. Turn the adjusting screw 1 in direction a orb .
Direction Headlight beam is raised.
Direction Headlight beam islowered.
2. Adjust:headlight beam (horizontally)
a. Turn the adjusting knob 2 in direction a orb .
Direction Headlight beam moves tothe right.
Direction Headlight beam moves tothe left.
INSPADJ
ENG
4
ENG
CHAPTER 4ENGINE
ENGINE REMOVAL 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MUFFLERS, BRAKE PEDAL AND SIDE COVER 4-1. . . . . . . . . . . . . . . LEADS, SHIFT PEDAL AND CLUTCH CABLE 4-3. . . . . . . . . . . . . . . . . . ENGINE MOUNTING BOLTS 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE ENGINE 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEADS 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR CYLINDER HEAD 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT CYLINDER HEAD 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CYLINDER HEADS 4-10. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CYLINDER HEADS 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE TIMING CHAIN TENSIONER 4-13. . . . . . . . . . . . . . . . . INSTALLING THE CYLINDER HEADS 4-13. . . . . . . . . . . . . . . . . . . . . . . . .
ROCKER ARMS AND CAMSHAFT 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE ROCKER ARMS AND CAMSHAFT 4-17. . . . . . . . . . . . CHECKING THE CAMSHAFTS 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE ROCKER ARMS AND ROCKER ARMSHAFTRS 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CAMSHAFT AND ROCKER ARMS 4-19. . . . . . . . . . .
VALVES AND VALVE SPRINGS 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE VALVES 4-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVES AND VALVE GUIDES 4-22. . . . . . . . . . . . . . . . CHECKING THE VALVE SEATS 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVE SPRINGS 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE VALVES 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDERS AND PISTONS 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CYLINDERS AND PISTONS 4-29. . . . . . . . . . . . . . . . . CHECKING THE CYLINDERS AND PISTONS 4-29. . . . . . . . . . . . . . . . . . CHECKING THE PISTON RINGS 4-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PISTON PINS 4-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE PISTONS AND CYLINDERS 4-32. . . . . . . . . . . . . . . . .
TIMING GEARS 4-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE TIMING DRIVE GEARS 4-35. . . . . . . . . . . . . . . . . . . . . . CHECKING THE TIMING CHAINS, CAMSHAFTSPROCKETS AND TIMING GUIDS 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PRIMARY DRIVE 4-36. . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE TIMING DRIVE GEARS 4-36. . . . . . . . . . . . . . . . . . . . .
ENG
CLUCTH 4-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RIGHT CRANKCASE COVER 4-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH ASSEMBLY 4-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CLUTCH 4-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRICTION PLATES 4-42. . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PRESSURE PLATE 4-43. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH BOSS 4-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH PUSH RODS 4-43. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH PLATES 4-44. . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH SPRING AND CLUTCH SPRING
SEAT PLATE 4-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH HOUSING 4-44. . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CLUTCH 4-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERATOR AND STARTER CLUTCH 4-47. . . . . . . . . . . . . . . . . . . . . . . . . . STATOR COIL AND PICKUP COIL 4-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERATOR AND STARTER CLUTCH 4-48. . . . . . . . . . . . . . . . . . . . . . . REMOVING THE GENERATOR 4-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STARTER CLUTCH 4-50. . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE GENERATOR 4-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT SHAFT 4-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT SHAFT 4-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STOPPER LEVER 4-54. . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE SHIFT SHAFT 4-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PUMP 4-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL PUMP 4-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL DELIVERY PIPES 4-57. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL STRAINER 4-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL PUMP 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT AND CONNECTING RODS 4-59. . . . . . . . . . . . . . . . . . . . . . . CRANKCASE 4-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT AND CONNECTING RODS 4-60. . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE CRANKCASE 4-61. . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CRANKSHAFT ASSEMBLY 4-62. . . . . . . . . . . . . . . . . . REMOVING THE CONNECTING RODS 4-62. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKSHAFT AND CONNECTING RODS 4-62. . . . CHECKING THE BEARING AND OIL SEALS 4-65. . . . . . . . . . . . . . . . . . . INSTALLING THE CRANKSHAFT 4-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE CRANKCASE 4-66. . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION 4-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT FORKS 4-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT DRUM ASSEMBLY 4-69. . . . . . . . . . . . . . . . . . . . CHECKING THE TRANSMISSION 4-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE TRANSMISSION 4-71. . . . . . . . . . . . . . . . . . . . . . . . . . .
ENG
MIDDLE GEAR 4-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIDDLE DRIVE PINION GEAR 4-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIDDLE DRIVEN PINION GEAR 4-73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE MIDDLE DRIVE SHAFT ASSEMBLY 4-75. . . . . . . . . . DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 4-75. . . . . REMOVING THE MIDDLE DRIVEN SHAFT ASSEMBLY 4-76. . . . . . . . . CHECKING THE MIDDLE DRIVE SHAFT ASSEMBLY 4-76. . . . . . . . . . . CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY 4-76. . . . . . . . . ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 4-77. . . . . . . . ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 4-78. . . . . . . INSTALLING THE MIDDLE GEAR ASSEMBLY ANDADJUSTING THE BACKLASH 4-78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE UNIVERSAL JOINT 4-80. . . . . . . . . . . . . . . . . . . . . . . . ALIGNING THE MIDDLE GEAR 4-81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENG
4-1
Order Job name/Part name Q’ty Remarks
123456
Removing the muffler, brake pedaland side cover
Fuel tank
Air filter case assemblyCarburetor assemblyMuffler assemblyCover (emblem)Reservoir tankExhaust pipesRear brake switch leadFootrest /brake pedal
11121
1/1
Remove the parts in the order listed.
Stand the motorcycle on a level surface.
Securely support the motorcycle sothere is no danger of it falling over.
Refer & “FUEL TANK AND SEATS” inChapter 3.
Disconnect
Refer to “CARBURETOR” in Chapter 5.
WARNING
23 Nm (2.3 mkg)
64 Nm (6.4 mkg)
25 Nm (2.5 mkg)
20 Nm (2.0 mkg)
20 Nm (2.0 mkg)
10 Nm (1.0 mkg)
ENGINE REMOVAL ENG
ENGINEENGINE REMOVALMUFFLERS, BRAKE PEDAL AND SIDE COVER
4-2
ENGINE REMOVAL ENG
Order Job name/Part name Q’ty Remarks
789
10111213
Rear brake master cylinder/bracketBattery coverBattery leads
Right side coverStarter motorCylinder head coversSpark plug caps
1/112
1144
Disconnect
First, disconnect the negative lead, thendisconnect the positive lead.
Disconnect
For installation, reverse the removalprocedure
NOTE:
23 Nm (2.3 mkg)
64 Nm (6.4 mkg)
25 Nm (2.5 mkg)
20 Nm (2.0 mkg)
20 Nm (2.0 mkg)
10 Nm (1.0 mkg)
4-3
Order Job name/Part name Q’ty Remarks
123
456789
1011
Removing the leads, shift pedal andclutch cableTool box coverLeft side coverAC magneto lead/pickup lead/sidestand switch lead/speed sensor leadNeutral switch leadFootrest/shift pedalSidestandClutch adjusting coverClutch cableSpeed sensorFuel tank fitting knobsSteering head side covers
11
1/1/1
11/1111122
Remove the parts in the order listed.
Disconnect
DisconnectRefer to “INSTALLING THE ENGINE”.
Disconnect
For installation, reverse the removalprocedure.
64 Nm (6.4 mkg) 64 Nm (6.4 mkg)
ENGINE REMOVAL ENG
LEADS, SHIFT PEDL AND CLUTCH CABLE
4-4
Order Job name/Part name Q’ty Remarks
123456789
Engine mounting bolt removal
Left crankcase cover
Tool box
HornEngine ground lead connectorEngine stay (front-lower)Down tubeEngine bracket boltsEngine mount bolts (rear upper)Engine mount bolt (rear lower)Engine stays (rear upper/ lower)Engine assembly
1111421
1/11
Remove the parts in the order below.Place a suitable stand under the frame andengine.Refer to “GENERATOR AND STARTERCLUTCH”Refer to “REAR SHOCK ABSORBERAND SWINGARM” in Chapter 6.
For installation, reverse the removalprocedure.
Refer to “INSTALLING THE ENGINE”.
48 Nm (4.8 mkg)
48 Nm (4.8 mkg)
48 Nm (4.8 mkg)
74 Nm (7.4 mkg)
ENGINE REMOVAL ENG
ENGINE MOUNTING BOLTS
4-5
ENGINE ENG
NOTE:
EAS00192
INSTALLING THE ENGINE1. Tighten the bolts in the following order.
Bolt 1 :48 Nm (4.8 mkg)
Bolt 2 :48 Nm (4.8 mkg)
Bolt 3 :48 Nm (4.8 mkg)
Bolt 4 :48 Nm (4.8 mkg)
Bolt 5 :48 Nm (4.8 mkg)
2. Install:shift arm 1
Align the punch mark a in the shift shaft withthe slot in the shift arm.
Adjust the adjusting bolt length b .Refer to “ADJUSTING THE SHIFT PEDAL” inchapter 3.
Shift arm bolt10Nm (1.0mkg)
Adjusting bolt length114.7mm
4-6
Order Job name/Part name Q’ty Remarks
1234567
Cylinder head removalEngine assemblyLeft crankcase cover
Tappet cover (exhaust)/O-ringTappet cover (intake)/O-ringExhaust pipe joint/gasketCarburetor joint/O-ringOil delivery pipesCamshaft sprocket cover/O-ringCamshaft sprocket bolt
1/11/11/11/12
1/11
Remove the parts in the order listed.Refer to “ENGINE REMOVAL”.Refer to “GENERATOR AND STARTERCLUTCH”.
Refer to “INSTALLING THE CYLINDERHEADS”.
35 Nm (3.5 mkg)10 Nm (1.0 mkg)
20 Nm (2.0 mkg)
10 Nm (1.0 mkg)
55 Nm (5.5 mkg)
20 Nm (2.0 mkg)
50 Nm (5.0 mkg)
20 Nm (2.0 mkg)
CYLINDER HEADS ENG
CYLINDER HEADSREAR CYLINDER HEAD
4-7
Order Job name/Part name Q’ty Remarks
89
101112
Timing chain tensioner/gasketCamshaft sprocketCylinder headDowel pinsCylinder head gasket
1/11121
For installation, reverse the removalprocedure.
Refer to “REMOVING/INSTALLING THECYLINDER HEADS”.
Refer to “INSTALLING THE CYLINDERHEADS”.
20 Nm (2.0 mkg)
50 Nm (5.0 mkg) 35 Nm (3.5 mkg)10 Nm (1.0 mkg)
20 Nm (2.0 mkg)
10 Nm (1.0 mkg)
55 Nm (5.5 mkg)
20 Nm (2.0 mkg)
CYLINDER HEADS ENG
4-8
Order Job name/Part name Q’ty Remarks
123456
Cylinder head removalEngine assemblyOil delivery pipesRight crankcase coverTappet cover (exhaust)/O-ringTappet cover (intake)/O-ringCarburetor joint/O-ringCamshaft sprocket cover/O-ringBaffle plate/O-ringCamshaft sprocket bolt
1/11/11/11/11/11
Remove the parts in the order listed.Refer to “ENGINE REMOVAL”.Refer to “REAR CYLINDER HEAD”.Refer to “CLUTCH”.
Refer to “INSTALLING THE CYLINDERHEADS”.
New
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
20 Nm (2.0 mkg)
50 Nm (5.0 mkg)
55 Nm (5.5 mkg)
35 Nm (3.5 mkg)
CYLINDER HEADS ENG
FRONT CYLINDER HEAD
4-9
Order Job name/Part name Q’ty Remarks
789
101112
Timing chain tensioner/gasketCamshaft sprocket plateCamshaft sprocketCylinder headDowel pinsCylinder head gasket
1/111121
For installationreverse the removalprocedure.
Refer to “REMOVING/INSTALLINGTHE CYLINDER HEADS”.
Refer to “INSTALLING THE CYLINDERHEADS”.
New
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
20 Nm (2.0 mkg)
50 Nm (5.0 mkg)
55 Nm (5.5 mkg)
35 Nm (3.5 mkg)
CYLINDER HEADS ENG
4-10
CYLINDER HEADS ENG
NOTE:
EAS00226
REMOVING THE CYLINDER HEADSRear cylinder head1. Remove:camshaft sprocket cover tappet covers
2. Align: “T” mark a (with the stationary pointer b )
a. Temporarily install the left crankcase coverwithout the pickup coil and stator coil.
b. Turn the crankshaft clockwise.c. Align the “T” mark a with the stationary
pointer b on the crankcase cover (left) whenthe rear piston is at TDC on the compressionstroke.
d. Check that the rear piston is at TDC in thecompression stroke.
e. The rear piston is at TDC on the compressionstroke when there is clearance at both of therocker arms. If there is no clearance then turnthe crankshaft clockwise one full turn.
f. When to “T” mark is aligned with the station-ary pointer the punch mark c on the cam-shaft sprocket should be aligned with the sta-tionary pointer d on the cylinder head.
3. Loosen:bolt (camshaft sprocket) 1
Use the sheave holder 2 to hold the rotor.
Sheave holder:90890-01701
4-11
CYLINDER HEADS ENG
NOTE:
NOTE:
NOTE:
4. Remove: timing chain tensionergasket
5. Remove:bolt (camshaft sprocket) 1camshaft sprocket 2
To prevent the timing chain from falling into thecrankcase fasten a wire to it.
6. Remove:cylinder head
Loosen the bolts and nuts in the proper se-quence.
Follow the numerical order shown in the il-lustration. Loosen each bolt 1/4 of a turn at atime until all of the bolts are loose.
Front cylinder head
When removing the front cylinder head, repeatthe rear cylinder head removal procedures.However, note the following points.
1. Align: “I” mark(with the stationary pointer)
Removal steps:Turn the crankshaft clockwise 290.Align the “I” mark a with the stationary pointer
b on the crankcase cover (left) when the frontpiston is at TDC on the compression stroke.
When the “I” mark is aligned with the stationarypointer the punch mark c on the camshaftsprocket should be aligned with the stationarypointer d on the cylinder head.
The front piston is at TDC on the compressionstroke when there is clearance at both of therocker arms.
4-12
CYLINDER HEADS ENG
NOTE:
NOTE:
EAS00228
CHECKING THE CYLINDER HEADSThe following procedure applies to all of the cyl-inder heads.1. Eliminate:combustion chamber carbon deposits(with a rounded scraper)
Do not use a sharp instrument to avoid damag-ing or scratching:spark plug threadsvalve seats
2. Check:cylinder headDamage/scratches Replace.
3. Measure:cylinder head warpageOut of specification Resurface the cylin-der head.
Cylinder head warpageLess than 0.03 mm
a. Place a straightedge 1 and a thicknessgauge 2 across the cylinder head.
b. Measure the warpage.c. If the limited is exceeded, resurface the cylin-
der head as follows.d. Place 400 – 600 grit wet sandpaper on the
surface plate and resurface the cylinderhead using a figure-eight sanding pattern.
To ensure an even surface, rotate the cylinderhead several times.
4-13
CYLINDER HEADS ENG
NOTE:
NOTE:
50 Nm (5.0 mkg)
35 Nm (3.5 mkg)
20 Nm (2.0 mkg)
NOTE:
EB401430
CHECKING THE TIMING CHAIN TENSIONER1. Check: timing chain tensionerCracks/damage/rough movement Re-place.
a. Lightly press the timing chain tensioner rodinto the timing chain tensioner housing byhand.
While pressing the timing chain tensioner rod,wind it clockwise with a thin screwdriver 1 untilit stops.
b. Remove the screwdriver and slowly releasethe timing chain tensioner rod.
c. Make sure that the timing chain tensioner rodcomes out of the timing chain tensionerhousing smoothly. If there is rough move-ment, replace the timing chain tensioner.
EAS00234
INSTALLING THE CYLINDER HEADSRear cylinder head1. Install:dowel pinsgasket
The “5EL” mark on the gasket must face up sideof the cylinder.
2. Install:nuts (cylinder head) (M12: 1 – 4)
cap nut (cylinder head) (M10: 5)
bolts (cylinder head) (M8: 6 – 7)
Tighten the bolts and nuts in the proper se-quence.
Follow the numerical order shown in the il-lustration. Tighten the bolts and nuts in twostages.
4-14
CYLINDER HEADS ENG
WARNING
NOTE:
3. Install:camshaft sprocket
a. Temporarily install the rotor nut and leftcrankcase cover without the pickup coil andstator coil.
b. Turn the crankshaft clockwise.c. Align the “T” mark a with the stationary
pointer b on the crankcase cover (left).d. Install the camshaft sprocket with the timing
mark c facing out.e. Turn the camshaft just enough to remove any
slack from the intake side of the timing chain.f. Insert your finger into the hole and timing
chain tensioner hole and push the timingchain guide inward.
g. While pushing the timing chain guide, besure that the timing mark c and the station-ary pointer d are properly aligned at TDC.
4. Install: timing chain tensioner
a. Lightly press the timing chain tensioner rodinto the timing chain tensioner housing byhand.
b. While pressing the timing chain tensionerrod, wind it clockwise with a thin screwdriver1 until it stops.
c. With the screwdriver still inserted into thetiming chain tensioner, install the timingchain tensioner 2 , and gasket.Then, tighten the timing chain tensioner bolts3 to the specified torque.
Always use a new gasket.
The “UP” mark on the timing chain tensionershould face up.
Timing chain tensioner bolt10 Nm (1.0 mkg)
4-15
CYLINDER HEADS ENG
55 Nm (5.5 mkg)
NOTE:
NOTE:
d. Remove the screwdriver, make sure that thetiming chain tensioner rod releases, andtighten the cap bolt to the specified torque.
Cap bolt8 Nm (0.8 mkg)
5. Install:bolt (camshaft sprocket) 1
Be sure the projection on the camshaft sprock-et plate is aligned with the hole in the sprocket.
Use the sheave holder 2 to hold the rotor.
Sheave holder:90890-01701
6. Check:alignment marksIf the marks do not align Adjust.
7. Measure:valve clearanceOut of specification Adjust.Refer to “ADJUSTING THE VALVE CLEAR-ANCE” in CHAPTER 3.
Front cylinder head
When installing the front cylinder head, repeatthe rear cylinder head installation procedure.However, note the following points.
1. Install:camshaft sprocket
a. Turn the crankshaft clockwise 290.b. Align the “I” mark a with the stationary point-
er b on the crankcase cover (left).c. Install the camshaft sprocket with the timing
mark c facing out.d. Turn the camshaft just enough to remove any
slack from the intake side of the timing chain.e. Insert your finger into the hole and timing
chain tensioner hole and push the timingchain guide inward.
f. While pushing the timing chain guide, besure that the timing mark c and the station-ary pointer d are properly aligned at TDC.
4-16
Order Job name/Part name Q’ty Remarks
12345678
Removing the rocker arm andcamshaftCylinder headsStopper plateCamshaft bushingCamshaft /dowel pinUnion bolt /gasketRocker arm shaftsRocker armsLocknutsValve adjusters
11
1/11/12222
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
For installation, reverse the removalprocedure.
Refer to “REMOVING/INSTALLING THEROCKER ARM AND CAMSHAFT”.
Refer to “REMOVING/INSTALLING THEROCKER ARM AND CAMSHAFT”.
37.5 Nm (3.75 mkg)
20 Nm (2.0 mkg)
27 Nm (2.7 mkg)
ROCKER ARMS AND CAMSHAFT ENG
ROCKER ARMS AND CAMSHAFT
4-17
ROCKER ARMS AND CAMSHAFT ENG
NOTE:
NOTE:
EAS00202
REMOVING THE ROCKER ARMS AND CAM-SHAFT1. Remove: rocker arm shafts (intake and exhaust) 1 rocker arms 2
Use a slide hammer 3 and weight 4 to removethe rocker arm shafts.
Slide hammer bolt (M8):90890-01085
Weight:90890-01084
2. Remove:camshaft bushing 1camshaft 2
Screw a 10 mm bolt 3 into the threaded end ofthe camshaft and pull out the camshaft.
EAS00205
CHECKING THE CAMSHAFTS1. Check:camshaft bushingsDamage/wear Replace.
2. Check:camshaft lobesBlue discoloration/pitting/scratches Re-place the camshaft.
3. Measure:camshaft lobe dimensions a and bOut of specification Replace the cam-shaft.
Camshaft lobe dimension limitIntake
a 39.012 mmb #1: 31.993 mm
#2: 32.027 mmExhaust
a 39.045 mmb 32.100 mm
4. Check:camshaft oil passageObstruction Blow out with compressed air.
4-18
ROCKER ARMS AND CAMSHAFTS ENG
NOTE:
EB401410
CHECKING THE ROCKER ARMS ANDROCKER ARM SHAFTSThe following procedure applies to all of therocker arms and rocker arm shafts.1. Check: rocker armDamage/wear Replace.
rocker arm lobe 1valve adjuster 2Excessive wear Replace.
2. Check: rocker arm shaftBlue discoloration/excessive wear/pit-ting/scratches Replace or check the lu-brication system.
3. Measure: rocker arm inside diameter aOut of specification Replace.
Rocker arm inside diameter14.036 mm
4. Measure: rocker arm shaft outside diameter bOut of specification Replace.
Rocker arm shaft outside diameter13.95 mm
5. Calculate: rocker-arm-to-rocker-arm-shaft clearance
Calculate the clearance by subtracting the rock-er arm shaft outside diameter from the rockerarm inside diameter.
Above 0.086 mm Replace the defectivepart(-s).
Rocker-arm-to-rocker-arm-shaftclearance
0.009 0.033 mm<Limit> : 0.086 mm
4-19
ROCKER ARMS AND CAMSHAFTS ENG
NOTE:
EAS00220
INSTALLING THE CAMSHAFT AND ROCK-ER ARMS1. Lubricate:camshaft
Recommended lubricantCamshaft /Bushing
Molybdenum disulfide oil
2. Install:camshaft 1camshaft bushing 2
The dowel pin a on the end of the camshaftmust align with the timing mark b on the cylin-der head.
Make sure that the No.1 camshaft 3 isinstalled in the rear cylinder head and the No.2camshaft 4 is installed in the front cylinderhead.
3. Install:stopper plate 1
Stopper plate bolt 220 Nm (2.0 mkg)
4. Lubricate: rocker arm shafts
Recommended lubricantEngine oil
4-20
ROCKER ARMS AND CAMSHAFTS ENG
NOTE:
5. Install: rocker arms rocker arm shafts
Make sure that the rocker arm shafts is com-pletely pushed into the cylinder head.
4-21
Order Job name/Part name Q’ty Remarks
1
234567
Removing the valves and valvesprings.Cylinder headsRocker arms and camshafts
Valve cotters
Valve spring retainersValve springsValve (intake)Valve (exhaust)Valve stem sealsValve spring seats
4
221122
Remove the parts in the order listed.
Refer to “CYLINDER HEADS”.Refer to “ROCKER ARMS ANDCAMSHAFT”.Refer to “REMOVING/INSTALLING THE VALVES”.
For installation, reverse the removalprocedure.
Refer to “INSTALLING THE VALVES”.
VALVES AND VALVE SPRINGS ENG
VALVES AND VALVE SPRINGS
4-22
VALVE AND VALVE SPRINGS ENG
NOTE:
NOTE:
EAS00237
REMOVING THE VALVESThe following procedure applies to all of thevalves and related components.
Before removing the internal parts of the cylin-der head (e.g., valves, valve springs, valveseats), make sure that the valves properly seal.
1. Check:valve sealingLeakage at the valve seat Check the valveface, valve seat, and valve seat width.Refer to “CHECKING THE VALVE SEATS”.
a. Pour a clean solvent 1 into the intake andexhaust ports.
b. Check that the valves properly seal.There should be no leakage at the valve seat2 .
2. Remove:valve cotters
Remove the valve cotters by compressing thevalve spring with the valve spring compressor1 .
Valve spring compressor90890-04019
EAS00239
CHECKING THE VALVES AND VALVE GUIDESThe following procedure applies to all of thevalve and valve guides.1. Measure:valve-stem-to-valve-guide clearance
Valve-stem-to-valve-guide clearance =Valve guide inside diameter a –Valve stem diameter b
4-23
VALVE AND VALVE SPRINGS ENG
NOTE:
NOTE:
Out of specification Replace the valveguide.
Valve-stem-to-valve-guideclearanceIntake 0.010 0.037 mm
<Limit>: 0.08 mmExhaust 0.025 0.052 mm
<Limit>: 0.10 mm
2. Replace.valve guide
To ease valve guide removal and installation,and to maintain the correct fit, heat the cylinderhead to 100C (212K) in an oven.
a. Remove the valve guide with a valve guideremover 1 .
b. Install the new valve guide with a valve guideinstaller 2 and valve guide remover 1 .
c. After installing the valve guide, bore thevalve guide with a valve guide reamer 3 toobtain the proper valve-stem-to-valve-guideclearance.
After replacing the valve guide, reface the valveseat.
Valve guide remover and installer(8 mm)
90890-04014
3. Eliminate:carbon deposits(from the valve face and valve seat)
4. Check:valve facePitting/wear Grind the valve face.
valve stem endMushroom shape or diameter larger than thebody of the valve stem Replace the valve.
4-24
VALVE AND VALVE SPRINGS ENG
NOTE:
5. Measure:valve margin thickness aOut of specification Replace the valve.
Valve margin thickness limit0.8 mm
6. Measure:valve stem runoutOut of specification Replace the valve.
When installing a new valve, always replacethe valve guide.
If the valve is removed or replaced, always re-place the valve stem seal.
Valve stem runout0.03 mm
EAS00240
CHECKING THE VALVE SEATSThe following procedure applies to all of thevalves and valve seats.1. Eliminate:carbon deposits(from the valve face and valve seat)
2. Check:valve seatPitting/wear Replace the cylinder head.
3. Measure:valve seat width aOut of specification Replace the cylinderhead.
Valve seat width limitIntake: 1.8 mmExhaust: 1.8 mm
a. Apply Mechanic’s blueing dye (Dykem) bonto the valve face.
b. Install the valve into the cylinder head.c. Press the valve through the valve guide and
onto the valve seat to make a clear pattern.d. Measure the valve seat width. Where the
valve seat and valve face contacted oneanother, the blueing will have been removed.
4-25
VALVE AND VALVE SPRINGS ENG
NOTE:
CAUTION:
NOTE:
4. Lap:valve facevalve seat
After replacing the cylinder head or replacingthe valve and valve guide, the valve seat andvalve face should be lapped.
a. Apply a coarse lapping compound to thevalve face.
Do not let the lapping compound enter thegap between the valve stem and the valveguide.
b. Apply molybdenum disulfide oil onto thevalve stem.
c. Install the valve into the cylinder head.d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all ofthe lapping compound.
For the best lapping results, lightly tap the valveseat while rotating the valve back and forth be-tween your hand.
e. Apply a fine lapping compound to the valveface and repeat the above steps.
f. After every lapping procedure, be sure toclean off all of the lapping compound fromthe valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) ontothe valve face.
h. Install the valve into the cylinder head.i. Press the valve through the valve guide and
onto the valve seat to make a clear impres-sion.
j. Measure the valve seat width again. If thevalve seat width is out of specification, refaceand lap the valve seat.
4-26
VALVE AND VALVE SPRINGS ENG
EAS00241
CHECKING THE VALVE SPRINGSThe following procedure applies to all of thevalve springs.1. Measure:valve spring free length aOut of specification Replace the valvespring.
Valve spring free length (intakeand exhaust)
44.6 mm<Limit>: 43.5 mm
2. Measure:compressed spring force aOut of specification Replace the valvespring.
b Installed length
Compressed spring forceIntake and exhaust spring 160.7 N (16.4 kg) at 40 mm
3. Measure:valve spring tilt cOut of specification Replace the valvespring.
Spring tilt limitIntake and exhaust valve spring
2.5 /1.9 mm
EAS00245
INSTALLING THE VALVESThe following procedure applies to all of thevalves and related components.1. Deburr:valve stem end(with an oil stone)
2. Lubricate:valve stemoil seal New(with the recommended lubricant)
Recommended lubricantMolybdenum disulfide oil
3. Install:valve lower spring seatoil seal Newvalve springupper spring seat (into the cylinder head)
4-27
VALVE AND VALVE SPRINGS ENG
NOTE:
NOTE:
CAUTION:
Install the valve spring with the larger pitch afacing up.
b Smaller pitch
4. Install:valve cotters
Install the valve cotters by compressing the valvespring with the valve spring compressor 1 .
Valve spring compressor90890-04019
5. To secure the valve cotters onto the valvestem, lightly tap the valve tip with a soft-facehammer.
Hitting the valve tip with excessive forcecould damage the valve.
4-28
Remove the parts in the order listed.Refer to “CYLINDER HEADS”.The “5EL” mark should face towards thecylinder head.
For installation, reverse the removalprocedure.
Order Job name/Part name Q’ty Remarks
1
2345678
Removing the cylinders and pistonsCylinder headsTiming chain guide
CylinderDowel pinsCylinder gasketPiston pin clipsPiston pinPistonPiston ring set
1
1212111
Refer to “INSTALLING THE PISTONSAND CYLINDERS”.
10 Nm (1.0 mkg)
Refer to “REMOVING/INSTALLINGTHE CYLINDERS AND PISTONS”.
CYLINDERS AND PISTONS ENG
CYLINDERS AND PISTONS
4-29
CYLINDERS AND PISTONS ENG
CAUTION:
NOTE:
NOTE:
EAS00254
REMOVING THE PISTONSThe following procedure applies to all of the pis-tons.1. Remove:piston pin clip 1piston pin 2piston 3
Do not use a hammer to drive the piston pinout.
Before removing the piston pin clip, cover thecrankcase opening with a clean rag to preventthe piston pin clip from falling into the crank-case.
For reference during installation, put an identi-fication mark on each piston crown.
Before removing the piston pin, deburr the pis-ton pin clip’s groove and the piston’s pin borearea. If both areas are deburred and the pistonpin is still difficult to remove, remove it with thepiston pin puller 4 .
Piston pin puller90890-01304
2. Remove: top ring2nd ringoil ring
When removing a piston ring, open the end gapwith your fingers and lift the other side of the ringover the piston crown.
EB404405
CHECKING THE CYLINDERS AND PISTONSThe following procedure applies to all of the cyl-inders and pistons.1. Check:piston wallcylinder wallVertical scratches Rebore or replace thecylinder, and replace the piston and pistonrings as a set.
4-30
CYLINDER AND PISTONS ENG
NOTE:
X + Y2C =
2. Measure:piston-to-cylinder clearance
a. Measure cylinder bore “C” with the cylinderbore gauge.
a 40 mm from the top of the cylinder
Measure cylinder bore “C” by taking side-to-side and front-to-back measurements of the cyl-inder. Then, find the average of the measure-ments.
Standard Wearlimit
Cylinderbore C:
95.00 95.01 mm 95.1 mm
b. If out of specification, rebore or replace thecylinder, and replace the piston and pistonrings as a set.
c. Measure piston skirt diameter “P” with themicrometer.
b 5 mm from the bottom edge of the piston.
Piston size P
Standard 94.960 94.975 mm
d. If out of specification, replace the piston andpiston rings as a set.
e. Calculate the piston-to-cylinder clearancewith the following formula.
Piston-to-cylinder clearance =Cylinder bore “C” –Piston skirt diameter “P”
Piston-to-cylinder clearance0.025 0.050 mm<Limit>: 0.15 mm
f. If out of specification, replace the cylinder, andreplace the piston and piston rings as a set.
4-31
CYLINDER AND PISTONS ENG
NOTE:
NOTE:
NOTE:
EB404410
CHECKING THE PISTON RINGS1. Measure:piston ring side clearanceOut of specification Replace the pistonand piston rings as a set.
Before measuring the piston ring side clear-ance, eliminate any carbon deposits from thepiston ring grooves and piston rings.
Piston ring side clearanceTop ring 0.04 0.08 mm <Limit>: 0.1 mm2nd ring 0.03 0.07 mm <Limit>: 0.1 mm
2. Install:piston ring(into the cylinder)
Using the piston crown pash the ring into the cyl-inder so that the ring will be at a right angle to thecylinder bore.
a 40 mm from the top of the cylinder3. Measure:piston ring end gapOut of specification Replace the piston ring.
The oil ring expander spacer’s end gap cannotbe measured. If the oil ring rail’s gap is exces-sive, replace all three piston rings.
Piston ring end gapTop ring
0.3 0.5 mm<Limit>: 0.8 mm
2nd ring0.3 0.45 mm<Limit>: 0.8 mm
Oil ring0.2 0.7 mm
4-32
CYLINDERS AND PISTONS ENG
NOTE:
EAS00266
CHECKING THE PISTON PINSThe following procedure applies to all of the pis-ton pins.1. CHECK:piston pinBlue discoloration/grooves Replace, theninspect the lubrication system.
2. Measure:piston pin outside diameter aOut of specification Replace the piston pin.
Piston pin outside diameter21.991 22.000 mm
3. Measure:piston pin bore inside diameter bOut of specification Replace the piston
Piston pin bore inside diameter22.004 22.015 mm
4. Calculate:piston-pin-to-piston clearanceOut of specification Replace the piston pin.
Piston-pin-to-piston clearance =Piston pin bore size b –Piston pin outside diameter a
Piston-pin-to-piston clearance0.004 0.024 mm
EB404701
INSTALLING THE PISTONS AND CYLINDERSThe following procedure applies to all of the pis-tons and cylinders.1. Install:oil ring expander lower oil ring railupper oil ring rail2nd ring top ring
Be sure to install the piston rings so that themanufacuturer’s marks or numbers face up.
4-33
CYLINDERS AND PISTONS ENG
NOTE:
NOTE:
2. Install:piston 1piston pin 2piston pin clip (New) 3
Apply engine oil onto the piston pin.Make sure that the “EX” mark a on the pistonfaces towards the exhaust side of the engine.
Before installing the piston pin clip, cover thecrankcase opening with a clean rag to preventthe clip from falling into the crankcase.
3. Install:gasket (New)dowel pins
4. Lubricate:pistonpiston ringscylinder(with the recommended lubricant)
Recommended lubricantEngine oil
5. Offset:piston ring end gaps
a Top ring
b Lower oil ring rail
c Upper oil ring rail
d 2nd ring
6. Install:cylinder
While compressing the piston rings with onehand, install the cylinder with the other hand.
Pass the timing chain and timing chain guide(exhaust side) through the timing chain cavity.
Cylinder bolt10 Nm (1.0 mkg)
4-34
Order Job name/Part name Q’ty Remarks
123456
789
Removing the timing gearsCylinder headsCylindersClutch assemblyPrimary drive gear nutTiming drive gearDowel pinsSpringsTiming chain drive gear shaftTiming chain drive gear sprocket/Timing chainPrimary drive gearStraight keyTiming chain guide
11661
1/1
111
Remove the parts in the order listed.Refer to “CYLINDER HEAD”.Refer to “CYLINDERS AND PISTONS”.Refer to “CLUTCH”.
For installation, reverse the removalprocedure.
Refer to “REMOVING/INSTALLINGTHE TIMING DRIVE GEARS”.
Refer to “INSTALLING THE TIMINGDRIVE GEARS”.
10 Nm (1.0 mkg)
110 Nm (11.0 mkg)
TIMING GEARS ENG
TIMING GEARS
4-35
TIMING GEARS ENG
NOTE:
NOTE:
NOTE:
REMOVING THE TIMING DRIVE GEARFront cylinder1. Straighten the lock washer tab.2. Remove:primary drive gear nut 1
While holding the generator rotor with thesheave holder, loosen the primary drive gearnut.
3. Remove: timing drive gear 2dowel pinssprings
When removing the timing drive gear, the dowelpins and springs are scatter and dropping down.Do not missing them.
Rear cylinder
When removing the rear cylinder timing gear,repeat the front cylinder timing gear removalprocedure. However, note the following points.
1. Remove: rotor assemblydowel pinssprings timing drive gearRefer to “GENERATOR AND STARTERCLUTCH”.
EB401422
CHECKING THE TIMING CHAINS, CAMSHAFTSPROCKETS, AND TIMING CHAIN GUIDESThe following procedure applies to all of the tim-ing chains, camshaft sprockets, and timingchain guides.1. Check: timing chain 1Damage/sitffness Replace the timing chainand its respective camshaft sprockets as a set.
2. Check:camshaft sprocketDamage/wear Replace the respectivecamshaft sprockets and the respective tim-ing chain as a set.
3. Check: timing chain guide (exhaust side) 1 timing chain guide (intake side) 2Damage/wear Replace the defectivepart(-s).
4-36
TIMING GEARS ENG
NOTE:
NOTE:
10 Nm (1.0 mkg)
NOTE:
EAS00292
CHECKING THE PRIMARY DRIVE1. Check:primary drive gearprimary driven gearDamage/wear Replace the primary driveand primary driven gears as a set.Excessive noise during operation Re-place the primary drive and primary drivengears as a set.
2. Check:primary-drive-gear-to-primary-driven-gearfree playFree play exists Replace the primary driveand primary driven gears as a set.
INSTALLING THE TIMING DRIVE GEARS1. Install: timing chain(onto the timing chain drive gear sprocket)
To prevent the timing chain from falling into thecrankcase, fasten it with a wire.
2. Install: timing chain drive gear sprocket timing chain drive gear shaft
Make sure that the “2” mark on the timing chaindrive gear sprocket is installed in the rear cylin-der and the “3” mark on the timing chain drivegear sprocket is installed in the front cylinder.
3. Install:stopper plate 1stopper plate bolt
Turn the timing chain drive gear shaft so that thestopper plate fits correctly into the slot and thenfasten the stopper plate with the bolt.
4-37
NOTE:
TIMING GEARS ENG
110 Nm (11.0 mkg)
NOTE:
NOTE:
Front cylinder1. Install:
(Front cylinder)springs 1dowel pins timing drive gear 2
Insert the suitable pin 3 into the hole of timingchain drive gear sprocket and match the gearteeth.
Push the projections a on the timing drivegear into the spaces b .
Align the punch mark c on the timing drivegear, the punch mark d on the timing chaindrive gear sprocket and the key posision e asshown.
2. Install:claw washer lock washer 1 Newprimary drive gear nut 2
While holding the generator retor with the sheaveholder, tighten the primary drive gear nut.
3. Bend the lock washer tab along a flat side ofthe nut.
Rear cylinder
When installing the rear cylinder timing gear, re-peat the front cylinder timing gear installationprocedure. However, note the following points.
1. Install:springsdowel pins timing drive gear rotor assemblyRefer to “GENERATOR AND STARTERCLUTCH”.
4-38
Order Job name/Part name Q’ty Remarks
12345
Removing the right clutch cover
Engine oil
Muffler assemblyExhaust pipesBrake pedal/FootrestRear brake master cylinder/bracketOil filter cover plateOil filter coverO-ringsOil filterRight crankcase cover
11311
Remove the parts in the order listed.Stand the motorcycle on a level surface.
Securely support the motorcycle sothere is no danger of it falling over.
Refer to “ENGINE OIL REPLACEMENT”in CHAPTER 3.
Refer to “ENGINE REMOVAL”.
WARNING
New
10 Nm (1.0 mkg)
CLUTCH ENG
CLUTCHRIGHT CRANKCASE COVER
4-39
Order Job name/Part name Q’ty Remarks
67
Dowel pinsCrankcase cover gasket
21
For installation, reverse the removalprocedure.
New
10 Nm (1.0 mkg)
CLUTCH ENG
4-40
Order Job name/Part name Q’ty Remarks
123456789
1011121314
Removing the clutchClutch spring boltsClutch spring plateClutch springClutch spring seatClutch pressure plateBearing/shart clutch push rodFriction platesClutch platesWire circlipClutch plateDamperClutch damper plateNut/ lock washerClutch boss
61111
1/1651111
1/11
Remove the parts in the order listed.
Refer to “INSTALLING THE CLUTCH”.
Refer to “REMOVING/INSTALLINGTHE CLUTCH.”
70 Nm (7.0 mkg)
8 Nm (0.8 mkg)
CLUTCH ENG
CLUTCH ASSEMBLY
4-41
Order Job name/Part name Q’ty Remarks
151617
Thrust washerClutch housingLong clutch push rod
111
For installation, reverse the removalprocedure.
70 Nm (7.0 mkg)
8 Nm (0.8 mkg)
CLUTCH ENG
4-42
CLUTCH ENG
NOTE:
NOTE:
NOTE:
EAS00278
REMOVING THE CLUTCH1. Straighten the lock washer tab.2. Loosen:clutch boss nut 1
While holding the clutch boss 2 with the clutchholding tool 3 , loosen the clutch boss nut.
Clutch holding tool90890-04086
3. Remove:clutch boss nut 1 lock washer 2clutch boss 3
There is a built-in damper between the clutchboss 3 and the clutch plate 4 . It is not neces-sary to remove the wire circlip 5 and disas-semble the built-in damper unless there is seri-ous clutch chattering.
EAS00281
CHECKING THE FRICTION PLATESThe following procedure applies to all of the fric-tion plates.1. Check: friction plateDamage/wear Replace the friction platesas a set.
2. Measure: friction plate thicknessOut of specification Replace the frictionplates as a set.
Measure the friction plate at four places.
Friction plate thickness2.9 3.1 mm<Limit>: 2.8 mm
4-43
CLUTCH ENG
NOTE:
EAS00286
CHECKING THE PRESSURE PLATE1. Check:pressure plateCracks/damage Replace.
bearingDamage/wear Replace.
EAS00285
CHECKING THE CLUTCH BOSS1. Check:clutch boss splinesDamage/pitting/wear Replace the clutchboss.
Pitting on the clutch boss splines will cause er-ratic clutch operation.
EAS00288
CHECKING THE CLUTCH PUSH RODS1. Check:short clutch push rod 1 long clutch push rod 2Cracks/damage/wear Replace the de-fective part(-s).
2. Measure: long clutch push rod bending limitOut of specification Replace the longclutch push rod.
Long clutch push rod bendinglimit
0.5 mm
4-44
CLUTCH ENG
NOTE:
EAS00281
CHECKING THE CLUTCH PLATESThe following procedure applies to all of theclutch plates.1. Check:clutch plateDamage Replace the clutch plates as aset.
2. Measure:clutch plate warpage(with a surface plate and thickness gauge 1 )Out of specification Replace the clutchplates as a set.
Clutch plate warpage limitLess than 0.1 mm
EAS00283
CHECKING THE CLUTCH SPRING ANDCLUTCH SPRING SEAT PLATE1. Check:clutch spring plateDamage Replace.
2. Check:clutch spring plate seatDamage Replace.
3. Measure:clutch spring free heightOut of specificatrion Replace the clutchspring
Clutch spring free height7.2 mm<Limit>: 6.5 mm
EAS00284
CHECKING THE CLUTCH HOUSING1. Check:clutch housing dogsDamage/pitting/wear Deburr the clutchhousing dogs or replace the clutch housing.
Pitting on the clutch housing dogs will cause er-ratic clutch operation.
4-45
CLUTCH ENG
NOTE:
70 Nm (7.0 mkg)
NOTE:
EAS00295
INSTALLING THE CLUTCH1. Install:clutch housing 1
If the wire circlip 2 has been removed, care-fully install a new one as shown.
2. Tighten: lock washer Newclutch boss nut 1
While holding the clutch boss with the clutchholding tool 2 , tighten the clutch boss nut.
Clutch holding tool90890-04086
3. Bend the lock washer tab along a flat side ofthe nut.
4. Lubricate: long clutch push rodshort clutch push rod(with the recommended lubricant)
Recommended lubricantLithium soap base grease
5. Lubricate: friction platesclutch plates(with the recommended lubricant)
Recommended lubricantEngine oil
6. Install: friction platesclutch plates long clutch push rodshort clutch push rodbearingwasher
CLUTCH ENG
4-46
NOTE:
NOTE:
Make sure that the semicircular slot a in thefriction plate is aligned with the mark b on theclutch housing.
7. Install:clutch pressure plateclutch spring plate seatclutch spring 1clutch spring plate 2clutch spring bolts 3
Tighten the clutch spring bolts in stages and in acrisscross pattern.
Clutch spring bolt8 Nm (0.8 mkg)
4-47
10 Nm (1.0 mkg)
Order Job name/Part name Q’ty Remarks
12345
Removing the startor coilEngine oil
Left side coverAC magneto lead/pickup lead/sidestand switch leadFootrest /shift pedalSidestandClutch adjusting cover/clutch cableLeft crankcase coverDowel pinsGasketStator coilPickup coil
12111
Remove the parts in the order listedRefer to “ENGINE OIL REPLACEMENT”in CHAPTER 3.
For installation, reverse the removalprocedure.
Refer to “ENGINE REMOVAL”.
10 Nm (1.0 mkg)
7 Nm (0.7 mkg)
GENERATOR AND STARTER CLUTCH ENG
GENERATOR AND STARTER CLUTCHSTATOR COIL AND PICKUP COIL
4-48
Order Job name/Part name Q’ty Remarks
123456789
Removing the generator and starterclutch.RotorDowel pinsSpringsWoodruff keyShaftStarter idler gearCirclipStarter clutch drive gearStarter clutch assembly
166111111
Remove the parts in the order listed
For installation, reverse the removalprocedure.
Refer to “REMOVING/INSTALLINGTHE GENERATOR.”
Refer to “INSTALLING THEGENERATOR.”
175 Nm (17.5 mkg)
12 Nm (1.2 mkg)
GENERATOR AND STARTER CLUTCH ENG
GENERATOR AND STARTER CLUTCH
4-49
GENERATOR AND STARTER CLUTCH ENG
NOTE:
EAS00347
REMOVING THE GENERATOR1. Remove:camshaft sprocket cover tappet coversRefer to “REAR CYLINDER HEAD.”
2. Align: “T” mark a (with the stationary pointer b )
a. Temporarily install the AC magneto coverwithout the pickup coil and stator coil.
b. Turn the crankshaft clockwise.c. Align the “T” mark a with the stationary
pointer b on the crankcase cover (left) whenthe rear piston is at TDC on the compressionstroke.
d. Check that the rear piston is at TDC in thecompression stroke.
e. The rear piston is at TDC on the compressionstroke when there is clearance at both of therocker arms. If there is no clearance then turnthe crankshaft clockwise one full turn.
f. When the “T” mark is aligned with the station-ary pointer the punch mark c on the cam-shaft sprocket should be aligned with the sta-tionary pointer d on the cylinder head.
3. Remove:generator rotor nut 1washer
While holding the generator rotor 2 with thesheave holder 3 , loosen the generator rotornut.
Do not allow the sheave holder to touch theprojection on the generator rotor.
Sheave holder90890-01701
4. Remove:generator rotor 1(with the flywheel puller set 2 and adapter3 )
woodruff key
4-50
GENERATOR AND STARTER CLUTCH ENG
NOTE:Remove the rotor by pushing back the rotor,the flywheel puller 2 and the adapter 3 .
Install the flywheel puller bolts and tighten thecenter bolt, making sure that the tool bodystays parallel to the rotor. If necessary, oneholding bolt may be backed out slightly for re-alignment of the tool.
When rotor is removed, the dowel pins andsprings are scatter and dropping down. Do notmissing them.
Sheave holder:90890-01701
Flywheel puller:90890-01362
Adapter:90890-04131
EAS00349
CHECKING THE STARTER CLUTCH1. Check:starter clutch idle gear 1starter clutch drive gear 2Burrs/chips/roughness/wear Replacethe defective part(-s).
2. Check:starter clutch operation
a. When turning the starter clutch drive gearcounter clockwise b , the starter clutch andthe starter clutch drive gear should engage.If the starter clutch drive gear and starterclutch do not engage, the starter clutch isfaulty and must be replaced.
b. When turning the starter clutch drive gearclockwise a , it should turn freely.If the starter clutch drive gear does not turnfreely, the starter clutch is faulty and must bereplaced.
4-51
GENERATOR AND STARTER CLUTCH ENG
NOTE:
NOTE:
NOTE:
175 Nm (17.5 mkg)
NOTE:
INSTALLING THE GENERATOR1. Install:starter clutch assembly
Align the hole a on the starter clutch housingwith the hole b on the rotor.
Starter clutch bolt:12 Nm (1.2 mkg)LOCTITE
2. Install: timing drive gear 1springs 2dowel pins 3
Align the punch mark a on the timing drivegear with the key slide b .
Push the projections c on the timing drivegear into the space d .
3. Install: rotor assembly
Insert the suitable pin 1 into the hole of timingchain drive gear sprocket and match the gearteeth.
Align the punch mark a on the timing drivegear 2 the punch mark b on the timing chaindrive gear sprocket and the key position c asshown.
When installing the rotor, make sure the wood-ruff key is properly seated in the key way of thecrankshaft.
4. Tighten:nut (rotor) 1
Tighten the rotor nut 1 while holding the mag-neto rotor with a sheave holder 2 .
Sheave holder:90890-01701
4-52
GENERATOR AND STARTER CLUTCH ENG
4. Check:TDC on the compression strokeIf the marks do not align Adjust.
a. Align the “T” mark a with the stationarypointer b on the left crankcase cover.
b. When the “T” mark is aligned with the station-ary pointer, the punch mark c on the cam-shaft sprocket should be aligned with the sta-tionary pointer d on the cylinder head.
4-53
Order Job name/Part name Q’ty Remarks
123456
Removing the shift shaft and stopperlever.Engine oil
Left crankcase coverRotor assemblyShift shaftCirclipTorsion spring (stopper lever)Stopper leverCirclipTorsion spring (shift shaft)
111111
Remove the parts in the order listed.
Refer to “ENGINE OIL REPLACEMENT”in CHAPTER 3.
For installation, reverse the removalprocedure.
Refer to “INSTALLING THE SHIFTSHAFT”.
Refer to “GENERATOR AND STARTERCLUTCH”.
SHIFT SHAFT ENG
SHIFT SHAFT
4-54
SHIFT SHAFT ENG
NOTE:
EAS00328
CHECKING THE SHIFT SHAFT1. Check:shift shaft 1shift lever 2Bends/damage/wear Replace.
shift lever spring 3Damage/wear Replace.
EB408410
CHECKING THE STOPPER LEVER1. Check:stopper leverBends/damage Replace.Roller turns roughly Replace the stopperlever.
EAS00331
INSTALLING THE SHIFT SHAFT1. Install:stopper lever 1stopper lever spring 2shift shaft lever 3
Hook the ends of the stopper lever spring ontothe stopper lever and the crankcase boss.
Mesh the stopper lever with the shift drum seg-ment assembly.
4-55
Order Job name/Part name Q’ty Remarks
12
345
Removing the oil pumpRotor assembly
Crankcase cover (right)Driven gear coverDriven gear (oil pump)/Oil pump drivechainOil pump assemblyO-rings/dowel pinOil delivery pipe
11/1
12/11
Remove the parts in the order listed.Refer to “GENERATOR AND STARTERCLUTCH”.Refer to “ CLUTCH”.
For installation, reverse the removalprocedure.
12 Nm (1.2 mkg)
7 Nm (0.7 mkg)
10 Nm (1.0 mkg)
OIL PUMP ENG
OIL PUMP
4-56
OIL PUMP ENG
Order Job name/Part name Q’ty Remarks
Disassembling the oil pumpOil pump coverOil pump bodyOil pump rotor (inner)Oil pump rotor (outer)PinOil pump bodyOil pump rotor (inner)Oil pump rotor (outer)PinDowel pinsOil pump shaftWasherCirclipOil strainer
11111111121111
Disassembly the parts in the order listed.
For assembly, reverse the disassemblyprocedure.
Refer to “ASSEMBLING THE OILPUMP”.
123456789
1011121314
Refer to “ASSEMBLING THE OILPUMP”.
10 Nm (1.0 mkg)
4-57
OIL PUMP ENG
EAS00364
CHECKING THE OIL PUMP1. Check:oil pump driven gearoil pump bodyoil pump driven gear cover Cracks/damage/wear Replace the de-fective part(-s).
2. Measure: inner-rotor-to-outer-rotor-tip clearance aouter-rotor-to-oil-pump-body-side clearance
boil-pump-body-to-inner-rotor-and-outer-ro-tor clearance cOut of specification Replace the oil pump.
1 Inner rotor
2 Outer rotor
3 Oil pump body
Inner-rotor-to-outer-rotor-tipclearance
0.03 0.09 mm<Limit>: 0.15 mm
Outer-rotor-to-oil-pump-body-sideclearance
0.03 0.08 mm<Limit>: 0.15 mm
Oil-pump-body-to-inner-rotor and outer-rotor clealance
0.03 0.08 mm<Limit>: 0.15 mm
EAS00367
CHECKING THE OIL DELIVERY PIPESThe following procedure applies to all of the oildelivery pipes.1. Check:oil delivery pipes 1Damage Replace.Obstruction Wash and blow out with com-pressed air.
EAS00368
CHECKING THE OIL STRAINER1. Check:oil strainer 1Damage Replace.Contaminants Clean with engine oil.
4-58
OIL PUMP ENG
10 Nm (1.0 mkg)
CAUTION:
NOTE:
EAS00376
ASSEMBLING THE OIL PUMP1. Assemble:oil pump
After tightening the bolts, make sure that theoil pump turns smoothly.
Align the pin a with the slots b on the inner ro-tor.
4-59
Order Job name/Part name Q’ty Remarks
123
4
56
Removing the crankshaft assemblyEngine assemblyCylinder headCylinder and pistonClutch assemblyAC magneto and starter clutch
Shift shaftOil pump assemblyOil level gaugeNeutral switchShift shaft stopper plate
Crankcase (right)
Dowel pinsRelief valve
111
1
31
Remove the parts in the order listed.Refer to “ENGINE REMOVAL”.Refer to “CYLINDER HEADS”.Refer to “CYLINDERS AND PISTONS”.Refer to “CLUTCH”.Refer to “GENERATOR AND STARTERCLUTCH”.Refer to “SHIFT SHAFT”.Refer to “OIL PUMP”.
Refer to “ASSEMBLING THECRANKCASE”.Refer to “DISASSEMBLING/ASSEMBLINGTHE CRANKCASE”.
For installation, reverse the removalprocedure.
38.5 Nm (3.85 mkg)
20 Nm (2.0 mkg)10 Nm (1.0 mkg)
CRANKSHAFT AND CONNECTING RODS ENG
CRANKSHAFT AND CONNECTING RODSCRANKCASE
Order Job name/Part name Q’ty Remarks
1
2345678
Removing the crankshaft andconnecting rodCrankshaft assembly
Oil pump drive sprocketBearingNuts (connecting rod caps)Connecting rod boltsConnecting rodsConnecting rod capsPlain bearings
1
1144224
Remove the parts in the order listed.
Refer to “REMOVING/INSTALLINGTHE CRANKSHAFT”.
For installation, reverse the removalprocedure.
Refer to “INSTALLING THECRANKSHAFT”.
48 Nm (4.8 mkg)
Refer to “REMOVING THE CONNECTINGRODS/INSTALLING THECRANKSHAFT”.
CRANKSHAFT AND CONNECTING RODS ENG
4-60
CRANKSHAFT AND CONNECTING RODS
4-61
A
B
CRANKSHAFT AND CONNECTING RODS ENG
NOTE:
NOTE:
CAUTION:
EAS00386
DISASSEMBLING THE CRANKCASE1. Remove:crankcase bolts
Loosen each bolt 1/4 of a turn at a time, instages and in a crisscross pattern. After all ofthe bolts are fully loosened, remove them.
Loosen the bolts in decreasing numerical or-der (refer to the numbers in the illustration.)
A Right crankcase
B Left crankcase
2. Remove: right crankcase
For this removal, slits a in the crankcase canbe use as shown.
Use a soft hammer to tap on one side of thecrankcase. Tap only on reinforced portionsof the crankcase. Do not tap on the crank-case mating surfaces. Work slowly andcarefully. Make sure that the crankcasehalves separate evenly.
4-62
CRANKSHAFT AND CONNECTING RODS ENG
NOTE:
NOTE:
EB412111
REMOVING THE CRANKSHAFT1. Remove:crankshaft assembly 1
Remove the crankshaft assembly with thecrankcase separating tool 2 .
Make sure that the crankcase separating toolis centered over the crankshaft assembly.
Crankcase separating tool90890-01135
EB412121
REMOVING THE CONNECTING RODS1. Remove:connecting rods 1big end bearings
Identify the position of each big end bearing sothat it can be reinstalled in its original place.
EB413404
CHECKING THE CRANKSHAFT AND CON-NECTING RODS1. Measure:crankshaft runoutOut of specification Replace the crank-shaft.
Crankshaft runoutLess than 0.02 mm
2. Check:crankshaft journal surfacescrankshaft pin surfacesbearing surfacesScratches/wear Replace the crankshaft.
3. Measure:crankshaft-pin-to-big-end-bearing clear-anceOut of specification Replace the big endbearings.
Crankshaft-pin-to-big-end-bearingclearance
0.044 0.073 mm
The following procedure applies to all of theconnecting rods.
4-63
CRANKSHAFT AND CONNECTING RODS ENG
CAUTION:
NOTE:
NOTE:
CAUTION:
Do not interchange the big end bearings andconnecting rods. To obtain the correctcrankshaft-pin-to-big-end-bearing clearanceand prevent engine damage, the big endbearings must be installed in their originalpositions.
a. Clean the big end bearings, crankshaft pins,and the inside of the connecting rod halves.
b. Install the big end upper bearing into the con-necting rod and the big end lower bearinginto the connecting rod cap.
Align the projections a on the big end bearingswith the notches b in the connecting rod andconnecting rod cap.
c. Put a piece of Plastigauge 1 on the crank-shaft pin.
d. Assemble the connecting rod halves.
Do not move the connecting rod or crankshaftuntil the clearance measurement has beencompleted.
Apply molybdenum disulfide grease onto thebolts, threads, and nut seats.
Make sure that the “Y” mark 2 on the connect-ing rod faces towards the left side of the crank-shaft.
Make sure that the characters 3 on both theconnecting rod and connecting rod cap arealigned.
e. Tighten the connecting rod nuts.
When tightening the connecting rod nuts,be sure to use an F-type torque wrench.
Without pausing, tighten the connectingrod nuts to the specified torque. Apply con-tinuous torque between 4.3 and 4.8 m kg.Once you reach 4.3 m kg, DO NOT STOPTIGHTENING until the specified torque isreached.If the tightening is interrupted between 4.3and 4.8 m kg, loosen the connecting rodnut to less than 4.3 m kg and start again.
CRANKSHAFT AND CONNECTING RODS ENG
4-64
NOTE:
Refer to “INSTALLING THE CONNECTINGRODS”.
Connecting rod nut48 Nm (4.8 mkg)
f. Remove the connecting rod and big endbearings.Refer to “REMOVING THE CONNECTINGRODS”.
g. Measure the compressed Plastigauge
width 1 on each crankshaft pin.If the clearance is out of specification, selectreplacement big end bearings.
4. Select:big end bearings (P1,P2)
The numbers 1 stamped into the crankshaftweb and the numbers 2 on the connectingrods are used to determine the replacementbig end bearing sizes.
“P1,P2” refer to the bearings shown in thecrankshaft illustration.
For example, if the connecting rod “P1” and thecrankshaft web “P1” numbers are “4” and “1” re-spectively, then the bearing size for “P1” is:
Bearing size for “P 1”:“P 1” (connecting rod) – “P 1”(crankshaft web) =4 – 1 = 3 (brown)
Rear cylinder lower bearing/Front cylinder up-per and lower bearing.
BEARING COLOR CODE
1 blue
2 black
3 brown
4 green
5 yellow
Rear cylinder upper bearing
BEARING COLOR CODE
1black
2black
3 brown
4green
5green
4-65
CRANKSHAFT AND CONNECTING RODS ENG
NOTE:
NOTE:
NOTE:
48 Nm (4.8 mkg)
NOTE:
EB412440
CHECKING THE BEARINGS AND OILSEALS1. Check:bearingsClean and lubricate the bearings, then rotatethe inner race with your fingerRough movement Replace.
2. Check:oil sealsDamage/wear Replace.
INSTALLING THE CRANKSHAFT3. Install:connecting rod bearings 1
Align the projection a of the bearings with thenotches b in the connecting rod cap.
Install each bearing in its original place.
4. Install:connecting rods 1
The stamped “Y” mark a on the connectingrods should face towards the left side of thecrankcase.
Install each connecting rod in its original place.
5. Install:connecting rod cap 1
Be sure that the characters a on the side of thecap and connecting rod are aligned.
6. Tighten:nuts (connecting rod cap)
Apply molybdenum disulfide grease to the rodcap bolt threads and nut surfaces.
CRANKSHAFT AND CONNECTING RODS ENG
4-66
CAUTION:
NOTE:
NOTE:
When tightening the nuts be sure to use anF-type torque wrench.
Without pausing tighten to full torquespecification. Apply continuous torque be-tween 4.3 and 4.8 m kg. Once you reach 4.3mkg DO NOT STOP TIGHTENING until fi-nal torque is reached. If the tightening is in-terrupted between 4.3 and 4.8 m kg, loosenthe nut to less than 4.3 m kg and startagain.
7. Install:crankshaft installing tool
Attach the spacer to the bearing inner race.
Crankshaft installer pot 190890-01274
Crankshaft installer bolt 290890-01275
Adapter 390890-04130
Spacer 490890-04060
8. Install:crankshaft 1
Align the left connecting rod with the rear cylin-der sleeve hole.
ASSEMBLING THE CRANKCASE1. Apply:engine oil(onto the main journal bearings)
sealant(onto the crankcase mating surfaces)
Yamaha Bond No. 1215:90890-85505
4-67
CRANKSHAFT AND CONNECTING RODS ENG
NOTE:
38.5Nm (3.85 mkg)
10 Nm (1.0 mkg)
NOTE:
1 3 10 14 17 19
15 16
8
5
4
6
7 9
,
NOTE:
2. Tighten:crankcase bolts(follow the proper tightening sequence)
The numbers embossed on the crankcase indi-cate the crankcase tightening sequence.
4 6 (M10)1 3 , 7 19 (M6)
Lubricate the bolt threads with engine oil.Tighten the bolts in increasing numerical order.
M6 30 mm , ,
M6 30 mm(Chromiumplated bolt)
M6 55 mm
M6 80 mm ,
M10 60 mm
M10 70 mm
M10 100 mm
19 :with engine ground lead
3. Install:shift shaft stopper plate 1
Install the shift shaft stopper plate as shown.
4-68
Order Job name/Part name Q’ty Remarks
12345678
Transmission removalCrankcase separationGuide barShift fork 1 “R”Shift fork 2 “C”Shift fork 3 “L”Shift drumMain axle assemblyDrive axle assemblyMiddle driven gear
11111111
Remove the parts in the order listed.Refer to “CRANKSHAFT”.
For installation, reverse the removalprocedure.
Refer to “INSTALLING THETRANSMISSION”.
TRANSMISSION ENG
TRANSMISSION
4-69
TRANSMISSION ENG
WARNING
EAS00421
CHECKING THE SHIFT FORKSThe following procedure applies to all of the shiftforks and related components.1. Check:shift fork cam follower 1shift fork pawl 2Bends/damage/scoring/wear Replacethe shift fork.
2. Check:shift fork guide barRoll the shift fork guide bar on a flat surface.Bends Replace.
Do not attempt to straighten a bent shift forkguide bar.
3. Check:shift fork movement(on the shift fork guide bar)Rough movement Replace the shift forksand shift fork guide bar as a set.
EAS00422
CHECKING THE SHIFT DRUM ASSEMBLY1. Check:shift drum groovesDamage/scratches/wear Replace theshift drum.
shift drum segment 1Damage/wear Replace.
shift drum bearing 2Damage/pitting Replace.
4-70
TRANSMISSION ENG
EAS00424
CHECKING THE TRANSMISSION1. Measure:main axle runout(with a centering device and dial gauge)Out of specification Replace the mainaxle.
Main axle runout limit0.08 mm
2. Measure:drive axle runout(with a centering device and dial gauge)Out of specification Replace the driveaxle.
Drive axle runout limit0.08 mm
3. Check: transmission gearsBlue discoloration/pitting/wear Replacethe defective gear(-s).
transmission gear dogsCracks/damage/rounded edges Replacethe defective gear(-s).
4. Check: transmission gear movementRough movement Replace the defectivepart(-s).
5. Check:washersDamage/bends/looseness Replace.
6. Check:bearingsUn smooth Replace.
4-71
TRANSMISSION ENG
NOTE:
NOTE:
WARNING
NOTE:
EAS00430
INSTALLING THE TRANSMISSION1. Install:shift drum assembly
Turn the shift drum assembly to the neutral posi-tion.
2. Install:main axle assembly 1drive axle assembly 2shift fork “L” 3shift fork “C” 4shift fork “R” 5shift fork guide bars 6
The embossed marks on the shift forks shouldface towards the right side of the engine andbe in the following sequence:“R”, “C”, “L”.
When installing the middle drive gear 7 , alignthe slit a on the guide bar with the middle drivegear.
Always use new circlips.
3. Check: transmissionRough movement Repair.
Oil each gear, shaft, and bearing thoroughly.
4-72
Order Job name/Part name Q’ty Remarks
1
23456789
Removing the middle drive piniongearSepalate the crankcase
Bearing retainer
Spring retainersSpring seatDamper springDamper camsNutBearingShim(s)Middle drive pinion shaft
1
21121111
Remove the parts in the order listed.
Refer to “CRANKSHAFT ANDCONNECTING ROD.”Refer to “REMOVING THE MIDDLEDRIVE SHAFT ASSEMBLY/INSTALLINGTHE MIDDLE GEAR ASSEMBLY ANDADJUSTING THE BACKLASH”.
For installation, reverse the removalprocedure.
Refer to “DISASSEMBLING/ASSEMBLING THE MIDDLE DRIVESHAFT ASSEMBLY”.
110 Nm (11.0 mkg)
110 Nm (11.0 mkg)
MIDDLE GEAR ENG
MIDDLE GEARMIDDLE DRIVE PINION GEAR
4-73
Order Job name/Part name Q’ty Remarks
12345
6
789
Removing the middle drivenpinion gear.BoltsCirclipsBearingsDriven yokeNut
Drive yoke
Bearing housing/O-ringWashersCollar
32211
1
1/131
Remove the parts in the order listed.
Refer to “REMOVING THE MIDDLEDRIVEN SHAFT ASSEMBLY/INSTALINGTHE MIDDLE GEAR ASSEMBLY ANDADJUSTING THE BACKLASH”.Refer to “INSTALLING THE MIDDLEGEAR ASSEMBLY AND ADJUSTINGTHE BACKLASH”.
Refer to “REMOVING THE MIDDLEDRIVEN SHAFT ASSEMBLY/INSTALLING THE UNIVERSAL JOINT”.
MIDDLE GEAR ENG
MIDDLE DRIVEN PINION GEAR
Order Job name/Part name Q’ty Remarks
1011
121314
Collapsible collarMiddle driven shaft
Oil sealBearingBearing
11
11
For installation, reverse the removalprocedure.
Refer to “ASSEMBLING THE MIDDLEDRIVEN SHAFT ASSEMBLY”.
Refer to “INSTALLING THE MIDDLEGEAR ASSEMBLY AND ADJUSTINGTHE BACKLASH”.
MIDDLE GEAR ENG
4-74
4-75
MIDDLE GEAR ENG
NOTE:
REMOVING THE MIDDLE DRIVE SHAFT AS-SEMBLY1. Remove:bearing retainermiddle drive shaft assembly
a. Straighten the thread on the bearing retainer.b. Attach the bearing retainer wrench 1 .
Bearing retainer wrench:90890-04137
c. Remove the bearing retainer and middledrive shaft assembly.
DISASSEMBLING THE MIDDLE DRIVESHAFT ASSEMBLY1. Remove:spring retainers 1
While compressing the spring with a damperspring compressor 2 , remove the spring re-tainers.
Damper spring compressor90890-04090
2. Straighten the thread on the middle driveshaft nut.
3. Remove:middle drive shaft nut 1bearing 2middle drive shaft 3
a. Attach the middle drive shaft holder 4 ontothe middle drive shaft as shown.
Middle drive shaft holder90890-04055
b. Secure the middle drive shaft holder in avice.
c. Loosen the middle drive shaft nut with themiddle drive shaft nut wrench 5 .
Middle drive shaft nut wrench90890-04138
d. Remove the middle drive shaft nut and bear-ing.
4-76
MIDDLE GEAR ENG
NOTE:
NOTE:
REMOVING THE MIDDLE DRIVEN SHAFTASSEMBLY1. Remove:universal joint
a. Remove the circlips 1 .b. Place the universal joint in a press.c. With a pipe of the proper diameter positioned
beneath the universal joint driven yoke asshown, press the bearing into the pipe.
It may be necessary to lightly tap the universaljoint driven yoke.
d. Repeat the above steps to remove the oppo-site side’s bearing.
e. Separate the universal joint yokes.
2. Loosen:middle driven shaft nut 1
While holding the universal joint driven yoke 2with the universal joint holder 3 , loosen themiddle driven shaft nut.
Universal joint holder90890-04062
EAS00438
CHECKING THE MIDDLE DRIVE SHAFT AS-SEMBLY1. Check:damper cam surfaceScratches/wear Replace the damper cam.
2. Check:springCracks/damage Replace.
EAS00439
CHECKING THE MIDDLE DRIVEN SHAFTASSEMBLY1. Check:middle drive gear 1middle driven gear 2Galling/pitting/wear Replace the middledriven shaft assembly.
2. Check:bearingsDamage/pitting Replace the middle driveshaft bearing housing assembly.
4-77
MIDDLE GEAR ENG
110 Nm (11.0 mkg)
NOTE:
NOTE:
3. Check:O-ringoil sealDamage Replace the defective part(-s).
4. Check:universal joint movementRough movement Replace the universaljoint.
EAS00441
ASSEMBLING THE MIDDLE DRIVE SHAFTASSEMBLY1. Tighten:middle drive shaft nut 1
Set the torque wrench at a right angle to themiddle drive shaft nut wrench 2 .
Lock the threads on the middle drive shaft nutby staking them with a center punch.
Middle drive shaft nut wrench 290890-04138
Middle drive shaft holder 390890-04055
2. Install:spring retainers 1
While compress the spring with the damperspring compressor 2 , and then install thespring retainers.
Damper spring compressor90890-04090
4-78
MIDDLE GEAR ENG
NOTE:
WARNING
NOTE:
NOTE:
25 Nm (2.5 mkg)
ASSEMBLING THE MIDDLE DRIVEN SHAFTASSEMBLY
The following points are critical when assem-bling the middle gears:The collapsible collar must be replaced when-ever the middle driven shaft assembly is re-moved from the middle driven shaft bearinghousing.
When performing this procedure for the firsttime, be sure to have at least one extra collaps-ible collar on hand.
1. Install:bearing outer race(into the middle driven shaft bearing hous-ing)
Do not press the bearing outer race. Duringinstallation, always press the bearing innerrace carefully.
2. Install:middle driven shaft nut
Finger tighten the middle driven shaft mut.
INSTALLING THE MIDDLE GEAR AS-SEMBLY AND ADJUSTING THE BACKLASH
When installing the middle gear assembly, besure to replace the following parts:- collapsible collar
1. Install:middle driven shaft assembly 1
4-79
MIDDLE GEAR ENG
2. Install:shimmiddle drive shaft assembly
3. Install:bearing retainer
Install steps:Attach the bearing retainer wrench 1 .
Bearing retainer wrench:90890-04137
Tighten the bearing retainer.
Bearing retainer:110 Nm (11.0 mkg)
Lock the threads on the bearing retainer bystaking them with a center punch.
4. Adjust:middle gear backlash
Middle gear backlash:0.1 0.2 mm
a. Install the universal joint holder 1 andmiddle gear backlash band 2 as shown.
Universal joint holder90890-04062
Middle gear backlash band90890-01231
b. Make sure that the dial gauge plunger on themiddle gear backlash band as shown.a Dial-gauge-plunger contact point: 68.2 mm
c. Remove the middle driven pinion gear nutand apply the LOCKTITE on it.
d. Reinstall the middle driven pinion gear nut.e. While measure the middle gear backlash,
tighten the middle driven pinion gear nut untilspecific backlash.
4-80
MIDDLE GEAR ENG
CAUTION:
CAUTION:
CAUTION:
NOTE:
Do not over tighten the middle driven piniongear nut. If over tighten the middle drivenpinion gear nut, replace the collapsible col-lar and adjust the backlash.
f. Stake the middle driven pinion gear shaftthread.
INSTALLING THE UNIVERSAL JOINT4. Install:universal joint driven yoke/cross joint 1(into the universal joint drive yoke)
Do not hammer the universal joint driveyoke or the collapsible collar may be dis-torted. This will result in a change in thestandard spinning torque, requiring re-placement of the collapsible collar and reas-sembly of the middle driven shaft assembly.
2. Install:bearings 2(onto the universal joint driven yoke/crossjoint)
The needles can easily fall out of their races,so check each bearing carefully. Slide theuniversal joint driven yoke assembly backand forth on the bearings. If a needle is out ofplace, the yoke will not go all the way ontothe bearings.
3. Press each bearing into the universal jointdriven yoke assembly with a socket of theproper size.
The bearings must be inserted far enough intothe universal joint driven yoke assembly so thatcirclips 3 can be installed.
4-81
MIDDLE GEAR ENG
NOTE:
NOTE:
NOTE:
EAS00452
ALIGNING THE MIDDLE GEAR
Aligning the middle gear is necessary when anyof the following parts are replaced:CrankcaseMiddle drive shaft
1. Select:middle drive gear shim(-s) 1
Select the middle drive gear shim(-s) 1 by cal-culating the middle drive gear shim thicknessand then measuring the middle gear backlash.
a. Position the middle drive gear with the ap-propriate shim(-s) 1 that has had its respec-tive thickness calculated from informationmarked on the crankcase and the end of themiddle drive gear.
b. To find middle drive gear shim thickness“A”, use the following formula.
Middle drive gear shim thickness“A” = a – c
a =“43.00”b =a numeral on the upper crankcase nearthe main bearing selection numbers andwhich is added to the nominal size “42”Example:a is 43.00If the upper crankcase is marked “46” bc is 42.46 (i.e., 42.00 + 0.46 =42.46)“A” = 43.00 – 42.46 = 0.54Round off to the hundredths digit and select the appropriate shim(-s).
In the above example, the calculated numberis 0.54. The chart instructs you to round offthe 4 to 5. Thus, the shim thickness is 0.55mm.
4-82
MIDDLE GEAR ENG
Middle drive pinion gear shim:
Thickness (mm) 0.10, 0.15, 0.20
Hundredths Rounded value
0, 1, 2 0
3, 4, 5, 6, 5
7, 8, 9 10
Shims are supplied in the following thickness.
CARB
5
CARB
CHAPTER 5CARBURETION
CARBURETOR 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CARBURETORS 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE CARBURETORS 5-6. . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CARBURETORS 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING AND ADJUSTING THE FUEL LEVEL 5-7. . . . . . . . . . . . . CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INDUCTION SYSTEM (AIS) 5-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INDUCTION 5-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CUT-OFF VALVE 5-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INDUCTION SYSTEM INSPECTION 5-11. . . . . . . . . . . . . . . . . . . . . .
CARB
5-1
Order Job name/Part name Q’ty Remarks
123456789
1011
Removing the carburetorsFuel tank
Air filter case assemblyAir ductsCylinder head breather hoseAir chamberCoverThrottle position sensor leadCarburetor heater leadFuel hosesCarburetor assemblyStarter cableThrottle cables
13111112112
Remove the parts in the order listed.Refer to “FUEL TANK AND SEATS” inCHAPTER 3.
Disconnect
DisconnectDisconnectDisconnect
After removing the carburetor assembly,remove the starter cable and throttlecables.
For installation, reverse the removalprocedure.
NOTE:
10 Nm (1.0 mkg)
CARBURETOR CARB
CARBURETIONCARBURETOR
5-2
Order Job name/Part name Q’ty Remarks
Disassembling the carburetor.Carburetor heater leadsCarburetor heatersFloat chamber/gasketFloatNeedle valve setMain jetJet holderPilot jetStarter jetJet needle setStarter plunger set
22111111111
Disassemble the parts in the order listed.
12V 30W
Refer to “CARBURETOR ASSEMBLY”.
1234567891011
CARBURETOR CARB
5-3
Order Job name/Part name Q’ty Remarks
Diaphragm set
Throttle position sensor
Pilot screwMain air jetPilot air jet 1Pilot air jet 2Throttle stop screw set
1
1
11111
Refer to “ASSEMBLING THE CARBURETORS”.Refer to “CHECKING AND ADJUSTINGTHE THROTTLE POSITIONSENSOR (TPS)”.
For assembly, reverse the disassemblyprocedure.
12
13
1415161718
CARBURETOR CARB
5-4
CARBURETORS CARB
EB600031
CHECKING THE CARBURETORSThe following procedure applies to all of the car-buretors.1. Check:carburetor body float chamber jet housingCracks/damage Replace.
2. Check: fuel passagesObstruction Clean.
a. Wash the carburetor in a petroleumbasedsolvent. Do not use any caustic-carburetor-cleaning solution.
b. Blow out all of the passages and jets withcompressed air.
3. Check: float chamber bodyDirt Clean.
4. Check: float chamber rubber gasketCracks/damage/wear Replace.
5. Check: floatDamage Replace.
6. Check:needle valve 1needle valve seat 2O-ring 3Damage/obstruction/wear Replace theneedle valve, needle valve seat and O-ringas a set.
7. Check:piston valve 1Damage/scratches/wear Replace.
rubber diaphragm 2Cracks/tears Replace.
5-5
CARBURETOR CARB
8. Check:vacuum chamber cover 1piston valve spring 2plastic cap 3O-ring 4spring 5Cracks/damage Replace.
9. Check: jet needle 1needle jet 2main jet 3pilot screw 4pilot jet 5main air jet 6starter jet 7Bends/damage/wear Replace.Obstruction Clean.Blow out the jets with compressed air.
10. Check:piston valve movementInsert the piston valve into the carburetorbody and move it up and down.Tightness Replace the piston valve.
11. Check. fuel feed pipeshose jointCracks/damage Replace.Obstruction Clean.Blow out the pipes with compressed air.
12. Check: fuel feed hoses fuel hosesCracks/damage/wear Replace.Obstruction Clean.Blow out the hoses with compressed air.
5-6
CARBURETOR CARB
CAUTION:
NOTE:
NOTE:
EB600042
ASSEMBLING THE CARBURETORSThe following procedure applies to both of thecarburetors.
Before assembling the carburetors, washall of the parts in a petroleum-based sol-vent.
Always use a new gasket.
1. Install:coasting enricher diaphragmcoasting enricher springcoasting enricher cover
Align the holes a on the coasting enricher dia-phragm with the projections b in the carbure-tor body.
When installing the coasting enricher, positionthe throttle connecting arm 1 as shown.
2. Install:connecting bolts
After installing the connecting bolts, check thatthe throttle cable lever and starter plunger linkoperate smoothly.
EB600051
INSTALLING THE CARBURETORS1. Adjust:carburetor synchronizationRefer to “SYNCHRONIZING THE CARBU-RETORS” in chapter 3.
2. Adjust:engine idling speed
Engine idling speed950 1,050 r/min
Refer to “ADJUSTING THE ENGINE IDLINGSPEED” in chapter 3.
3. Adjust: throttle cable free play
Throttle cable free play(at the flange of the throttle grip)
4 6 mm
Refer to “ADJUSTING THE THROTTLECABLE FREE PLAY” in chapter 3.
5-7
CARBURETOR CARB
NOTE:
EB600063
MEASURING AND ADJUSTING THE FUELLEVEL1. Measure: fuel level aOut of specification Adjust.
Fuel level (above the line onthe float chamber)
4 5 mm
a. Stand the motorcycle on a level surface.b. Place the motorcycle on a suitable stand to
ensure that the motorcycle is standingstraight up.
c. Install the fuel level gauge 1 to the fuel drainpipe 2 .
Fuel level gauge90890-01312
d. Loosen the fuel drain screw 3 .e. Hold the fuel level gauge vertically next to the
upper face of the float chamber 4 .f. Measure the fuel level a .
Fuel level readings should be equal on bothsides of the carburetor assembly.
2. Adjust: fuel level
a. Remove the carburetor assembly.b. Check the needle valve seat and needle
valve.c. If either is worn, replace them as a set.d. If both are fine, adjust the float level by slight-
ly bending the float tang 1 .e. Install the carburetor assembly.f. Measure the fuel level again.g. Repeat steps (a) to (f) until the fuel level is
within specification.
5-8
CARBURETOR CARB
NOTE:
EB600071
CHECKING AND ADJUSTING THETHROTTLE POSITION SENSOR
Before adjusting the throttle position sensor,the engine idling speed should be properly ad-justed.
1. Inspect: throttle position sensor
a. Disconnect the throttle position sensor cou-pler.
b. Connect the pocket tester (Ω 1k) to thethrottle position sensor.
Tester positive lead blue 1Tester negative lead black 2
c. Check the throttle position sensor resistance“R1”.Out of specification Replace the throttleposition sensor.
Throttle position sensorresistance “R1”
4 6 kΩ at 20C (68F)(blue – black)
d. Connect the pocket tester (Ω 1k) to thethrottle position sensor.
Tester positive lead yellow 3Tester negative lead black 2
e. While slowly opening the throttle, check thatthe throttle position sensor resistance “R2” iswithin the specified range.Out of specification Replace the throttleposition sensor.
Throttle position sensorresistance “R2”
0.56 0.84 kΩ to 3.01 4.51 kΩ at 20C (68F)(yellow – black)
2. Adjust: throttle position sensor angle
a. Loosen the throttle position sensor screws1 .
b. Turn the throttle position sensor in directiona or b until the specified closed-throttle re-sistance is indicated on the pocket tester.
5-9
CARBURETOR CARB
NOTE:
Closed-throttle resistance 0.56 0.84 kΩ at 20°C(yellow – black)
c. Tighten the throttle position sensor screws.
Remove the pocket tester leads and connectthe throttle position sensor coupler.
5-10
VEIW 1
VEIW 2
AIR INDUCTION SYSTEM (AIS) CARB
EB601000
AIR INDUCTION SYSTEM (AIS)AIR INDUTIONThis system burns the unburned exhaust gasesby injecting fresh air (secondary air) at the ex-haust port. This is to reduce the output of the hy-drocarbons.When there is negative pressure around the ex-haust port, the reed valve opens and the sec-ondary air flows into the exhaust port.The required temperature for burning the un-burned exhaust gases is approximately 600 to700C.
AIR CUT-OFF VALVEThe air cut-off valve is operated by intake gaspressure through the diaphragm. Normally, thisvalve is opened in order to allow fresh air to flowinto the exhaust port.When the throttle is rapidly closed, negativepressure is generated and the valve closes inorder to prevent after-burning.VIEW 1. (NO FLOW)
When decelerating (the throttle closes), the valve will close.
VIEW 2. (FLOW)During normal operation the valve is open.
A From the air filterB To the cylinder headsC To the carburetor joint1 Reed valve
5-11
Reed valveAir filterOrificeCarburetor joint (near cylinder)To the front cylinder headTo the rear cylinder headTo the orificeTo the carburetor joint (rear cylinder)To the AIS valve
123
AB
4
CDE
AIR INDUCTION SYSTEM (AIS) CARB
NOTE:
AIR INDUCTION SYSTEM INSPECTION1. Inspect:hose connectionsPoor connections Properly connect.
hoses reed valvesair cut-off valveair filterCracks/damage Replace.Clogged Clean.
The orifice 3 should be installed with the arrowmark facing the AIS valve side.
CARB
CHAS
6
CHAS
CHAPTER 6CHASSIS
FRONT WHEEL AND BRAKE DISCS 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT WHEEL 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRONT WHEEL 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE DISCS 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT WHEEL 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT WHEEL STATIC BALANCE 6-8. . . . . . . . . .
REAR WHEEL AND BRAKE DISC 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MUFFLER AND BRAKE CALIPER 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR WHEEL 6-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE REAR WHEEL 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE REAR WHEEL 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE REAR WHEEL DRIVE HUB 6-14. . . . . . . . . . . . . . . . . . INSTALLING THE REAR WHEEL 6-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR WHEEL STATIC BALANCE 6-15. . . . . . . . . . . .
FRONT AND REAR BRAKES 6-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE PADS 6-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE PADS 6-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE FRONT BRAKE PADS 6-18. . . . . . . . . . . . . . . . . . . . . . REPLACING THE REAR BRAKE PADS 6-20. . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE MASTER CYLINDER 6-22. . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE MASTER CYLINDER 6-24. . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT BRAKE MASTER CYLINDER 6-26. . . . . . . . . REMOVING THE REAR BRAKE MASTER CYLINDER 6-26. . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE MASTER
CYLINDER 6-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT BRAKE MASTER CYLINDER 6-28. . . . . . . . INSTALLING THE REAR BRAKE MASTER CYLINDER 6-30. . . . . . . . . . FRONT BRAKE CALIPERS 6-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE CALIPER 6-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT BRAKE CALIPERS 6-36. . . . . . . . . . . . . . . . . . REMOVING THE REAR BRAKE CALIPER 6-36. . . . . . . . . . . . . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE CALIPERS 6-37. . . . . . . . INSTALLING THE FRONT BRAKE CALIPERS 6-38. . . . . . . . . . . . . . . . . INSTALLING THE REAR BRAKE CALIPER 6-40. . . . . . . . . . . . . . . . . . . .
FRONT FORK 6-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT FORK LEGS 6-46. . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY THE FRONT FORK LEGS 6-46. . . . . . . . . . . . . . . . . . . . . CHECKING THE FRONT FORK LEGS 6-47. . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE FRONT FORK LEGS 6-48. . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT FORK LEGS 6-51. . . . . . . . . . . . . . . . . . . . . . .
CHAS
HANDLEBAR 6-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE HANDLEBAR 6-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE HANDLEBAR 6-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE HANDLEBAR 6-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING HEAD 6-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE LOWER BRACKET 6-60. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STEERING HEAD 6-60. . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE STEERING HEAD 6-61. . . . . . . . . . . . . . . . . . . . . . . . . .
REAR SHOCK ABSORBER AND SWINGARM 6-63. . . . . . . . . . . . . . . . . . . . RIGHT SIDE COVER AND BATTERY BOX 6-63. . . . . . . . . . . . . . . . . . . . . LEFT SIDE COVER AND TOOL BOX 6-64. . . . . . . . . . . . . . . . . . . . . . . . . REAR SHOCK ABSORBER AND SWINGARM 6-65. . . . . . . . . . . . . . . . . HANDLING THE REAR SHOCK ABSORBER AND GA6
CYLINDER 6-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISPOSING OF A REAR SHOCK ABSORBER AND GAS
CYLINDER 6-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE REAR SHOCK ABSORBER 6-67. . . . . . . . . . . . . . . . . . REMOVING THE SWINGARM 6-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE REAR SHGOCK ABSORBER AND GAS
CYLINDER 6-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SWINGARM 6-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE REAR SHOCK ABSORBER 6-70. . . . . . . . . . . . . . . . . INSTALLING THE SWINGARM 6-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHAFT DRIVE 6-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 6-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND
INSPECTING THE SHAFT DRIVE FOR LEAKS 6-75. . . . . . . . . . . . . MEASURING THE RING GEAR BACKLASH 6-76. . . . . . . . . . . . . . . . . . . ADJUSTING THE RING GEAR BACKLASH 6-77. . . . . . . . . . . . . . . . . . . . FINAL DRIVE ASSEMBLY AND DRIVE SHAFT 6-79. . . . . . . . . . . . . . . . . FINAL GEAR 6-80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FINAL DRIVE ASSEMBLY 6-81. . . . . . . . . . . . . . REMOVING AND INSTALLING THE RING GEAR BEARINGS 6-82. . . . ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR 6-83. . CHECKING THE DRIVE SHAFT 6-87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE DRIVE SHAFT 6-87. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
Order Job name/Part name Q’ty Remarks
123456
Removing the front wheel and brakediscs
Brake calipersFront wheel axle pinch boltFront wheel axleFront wheel assemblyCollarsBrake discs
211122
Remove the parts in the order listed.Stand the motorcycle on a level surface.
For installation, reverse the removalprocedure.
Refer to “INSTALLING THE FRONTWHEEL”.
WARNINGSecurely support the motorcycle sothere is no danger of it falling over.
59 Nm (5.9 mkg)
20 Nm (2.0 mkg)
40 Nm (4.0 mkg)
23 Nm (2.3 mkg)
Refer to “REMOVING/INSTALLINGTHE FRONT WHEEL”.
FRONT WHEEL AND BRAKE DISCS CHAS
CHASSISFRONT WHEEL AND BRAKE DISCS
FRONT WHEEL AND BRAKE DISCS CHAS
Order Job name/Part name Q’ty Remarks
Disassembling the front wheelOil sealsBearingsCollar
221
Disassemble the parts in the order listed.
For assembly, reverse the disassemblyprocedure.
123
6-2
6-3
FRONT WHEEL AND BRAKE DISCS CHAS
WARNING
NOTE:
NOTE:
NOTE:
WARNING
EAS00521
REMOVING THE FRONT WHEEL1. Stand the motorcycle on a level surface.
Securely support the motorcycle so thatthere is no danger of it falling over.
Place the motorcycle on a suitable stand so thatthe front wheel is elevated.
2. Remove:brake calipers 1 (left and right)
Do not squeeze the brake lever when removingthe brake calipers.
3. Loosen:pinch bolt (front wheel axle) 1 front wheel axle 2
4. Elevate: front wheel
Place the motorcycle on a suitable stand so thatthe front wheel is elevated.
EAS00526
CHECKING THE FRONT WHEEL1. Check:wheel axleRoll the wheel axle on a flat surface.Bends Replace.
Do not attempt to straighten a bent wheel axle.
2. Check: tire front wheelDamage/wear Replace.Refer to “CHECKING THE TIRES” and“CHECKING THE WHEELS” in chapter 3.
3. Check:spokesBends/damage Replace.Loose Tighten.Tap the spokes with a screwdriver.
FRONT WHEEL AND BRAKE DISCS CHAS
6-4
NOTE:
3 Nm (0.3mkg)
NOTE:
WARNING
A tight spoke will emit a clear, ringing tone, aloose spoke will sound flat.
4. Tighten:spokes
After tightening the spokes, measure the frontwheel runout.
5. Measure: front wheel radial runout 1 front wheel lateral runout 2Over the specified limits Replace.
Front wheel radial runout limit1.0 mm
Front wheel lateral runout limit0.5 mm
6. Check:collarsDamage/wear Replace.
New tires have a relatively low grip on theroad surface until they have been slightlyworn.Therefore, approximately 100 km shouldbe traveled at normal speed before anyhighspeed riding is done.
7. Checkwheel bearingsFront wheel turns roughly or is loose Re-place the wheel bearings.
oil sealsDamage/wear Replace.
8. Replace:wheel bearings (New)oil seals (New)
6-5
FRONT WHEEL AND BRAKE DISCS CHAS
NOTE:
CAUTION:
NOTE:
a. Clean the outside of the front wheel hub.b. Remove the oil seals 1 with a flat-head
screwdriver.
To prevent damaging the wheel, place a rag be-tween the screwdriver and the wheel surface.
c. Remove the wheel bearings with a generalbearing puller 2 .
d. Install the new wheel bearings and oil sealsin the reverse order of disassembly.
Do not contact the wheel bearing center race4 or balls 5 . Contact should be made onlywith the outer race 6 .
Use a socket 3 that matches the diameter ofthe wheel bearing outer race and oil seal.
EAS00531
CHECKING THE BRAKE DISCSThe following procedure applies to all of thebrake discs.1. Check:brake discDamage/galling Replace.
2. Measure:brake disc deflection 1Out of specification Correct the brake discdeflection or replace the brake disc.
Brake disc deflection limit(maximum)
Front: 0.15 mmRear: 0.15 mm
a. Place the motorcycle on a suitable stand sothat the wheel is elevated.
b. Before measuring the front brake disc deflec-tion, turn the handlebar to the left or right toensure that the front wheel is stationary.
FRONT WHEEL AND BRAKE DISCS CHAS
6-6
NOTE:
c. Remove the brake caliper.d. Hold the dial gauge at a right angle against
the brake disc surface.e. Measure the deflection 2 – 3 mm below the
edge of the brake disc.
3. Measure:brake disc thickness 1Measure the brake disc thickness at a fewdifferent locations.Out of specification Replace.
Brake disc thickness limit(minimum)
Front: 4.5 mmRear: 5.5 mm
4. Adjust:brake disc deflection
a. Remove the brake disc.b. Rotate the brake disc by one bolt hole.c. Install the brake disc.
Tighten the brake disc bolts in stages and in acrisscross pattern.
Brake disc bolt23 Nm (2.3 mkg)LOCTITE
d. Measure the brake disc deflection.e. If out of specification, repeat the adjustment
steps until the brake disc deflection is withinspecification.
f. If the brake disc deflection cannot be broughtwithin specification, replace the brake disc.
6-7
FRONT WHEEL AND BRAKE DISCS CHAS
NOTE:
59 Nm (5.9 mkg)
20 Nm (2.0 mkg)
CAUTION:
40 Nm (4.0 mkg)
WARNING
EAS00544
INSTALLING THE FRONT WHEELThe following procedure applies to both brakediscs.1. Lubricate:wheel axleoil seallips
Recommended lubricantLithium soap base grease
2. Install: front wheel assembly
The arrow mark a on the tire must point in thedirection of the wheel.
3. Tighten:wheel axle 1wheel axle pinch bolt 2
Before tightening the wheel axle nut, pushdown hard on the handlebar several times andcheck if the front fork rebounds smoothly.
4. Install:brake caliper
Make sure that the brake hose is routedproperly.
6-8
FRONT WHEEL AND BRAKE DISCS CHAS
NOTE:
NOTE:
NOTE:
EAS00549
ADJUSTING THE FRONT WHEEL STATICBALANCE
After replacing the tire, wheel or both, the frontwheel static balance shourd be adjusted.
Adjust the front wheel static balance with thebrake discs installed.
1. Remove:balancing weight (-s)
Place the front wheel on a suitable balancingstand.
2. Find: front wheel’s heavy spot
a. Spin the front wheel.b. When the front wheel stops, put an “X1” mark
at the bottom of the wheel.c. Turn the front wheel 90 so that the “X1” mark
is positioned as shown.d. Release the front wheel.e. When the wheel stops, put an “X2” mark at
the bottom of the wheel.f. Repeat steps (b) through (d) several times
until all the marks come to rest at the samespot.
g. The spot where all the marks come to rest isthe front wheel’s heavy spot “X”.
3. Adjust: front wheel static balance
a. Install a balancing weight 1 onto the rimex-actly opposite the heavy spot “X”.
Start with the lightest weight.
b. Turn the front wheel 90 so that the heavyspot is positioned as shown.
c. If the heavy spot does not stay in that posi-tion, install a heavier weight.
d. Repeat steps (b) and (c) until the front wheelis balanced.
6-9
FRONT WHEEL AND BRAKE DISCS CHAS
4. Check: front wheel static balance
a. Turn the front wheel and make sure that itstays at each position shown.
b. If the front wheel does not remain stationaryat all of the positions, rebalance it.
6-10
Order Job name/Part name Q’ty Remarks
1234
Removing the muffler and brakecaliperMufflerMuffler stayBrake hose holderBrake caliper
1111
Remove the parts in the order listed.
Refer to “REMOVING THE REAR WHEEL”.For installation, reverse the removalprocedure.
40 Nm (4.0mkg)
25 Nm (2.5mkg)
20 Nm (2.0mkg)
30 Nm (3.0mkg)
20 Nm (2.0mkg)
REAR WHEEL AND BRAKE DISC CHAS
REAR WHEEL AND BRAKE DISCMUFFLER AND BRAKE CALIPER
6-11
Order Job name/Part name Q’ty Remarks
1234567
Removing the rear wheel
Final gear oil
Fuel tank and seats
Rear fender assemblyBrake caliper bracket boltBoltsRear axle nut/washerRear axle end nuts/axle holderRear wheel assemblyWasherCollar
14
1/12/1111
Remove the parts in the order listed.
Securely support the motorcycle sothere is no danger of it falling over.
DrainRefer to “FINAL GEAR OIL REPLACE-MENT” in CHAPTER 3.Refer to “FUEL TANK AND SEATS” inCHAPTER 3.Loosen
For installation, reverse the removalprocedure.
Refer to “REMOVING/INSTAL-LING THE REAR WHEEL”.
WARNING
40 Nm (4.0mkg)23 Nm (2.3mkg)
23 Nm (2.3mkg)
90 Nm (9.0mkg)
107 Nm (10.7mkg)
REAR WHEEL AND BRAKE DISC CHAS
REAR WHEEL
6-12
REAR WHEEL AND BRAKE DISC CHAS
Order Job name/Part name Q’ty Remarks
Rear wheel disassemblyDisassembling the rear wheelLock washersClutch hubDampersO-ringsOil sealBearingSpacerBearing
21621111
Remove the parts in the order listed.
For assembly, reverse the disassemblyprocedure.
12345678
62 Nm (6.2mkg)
6-13
REAR WHEEL AND BRAKE DISC CHAS
WARNING
NOTE:
NOTE:
EAS00562
REMOVING THE REAR WHEEL1. Stand the motorcycle on a level surface.
Securely support the motorcycle so thatthere is no danger of it falling over.
Place the motorcycle on a suitable stand so thatthe rear wheel is elevated.
2. Remove: rear gear case fitting bolts
3. Remove:brake caliper 1brake caliper bracket bolt
Do not depress the brake pedai when removingthe brake caliper.
4. Remove:wheel axle nutwasher
5. Remove: rear axle end nut 2
6. Remove: rear axle holder 3
7. Remove: rear wheel
EAS00566
CHECKING THE REAR WHEEL1. Check:wheel axle rear wheelwheel bearingsoil sealsRefer to “FRONT WHEEL AND BRAKEDISCS”.
2. Check: tireDamage/wear Replace.Refer to “CHECKING THE TIRES” and“CHECKING THE WHEELS” in chapter 3.
3. Check:spokesRefer to “FRONT WHEEL AND BRAKEDISCS”.
4. Measure: rear wheel radial runout rear wheel lateral runoutRefer to “FRONT WHEEL AND BRAKEDISCS”.
6-14
REAR WHEEL AND BRAKE DISC CHAS
NOTE:
EAS00567
CHECKING THE REAR WHEEL DRIVE HUB1. Check: rear wheel drive hubCracks/damage Replace.
rear wheel drive hub dampersDamage/wear Replace.
EAS00572
INSTALLING THE REAR WHEEL1. Lubricate:drive shaft splines
Recommended lubricantMolydenum disulfide grease
2. Lubricate:wheel axlewheel bearingsoil seal lips
Recommended lubricantLithium soap base grease
2. Install: rear wheel assembly
a. Install the rear wheel assembly 1 with therear brake caliper bracket 2 and hold thebracket to keep the specified position.
b. After installation of the rear axle shaft 3 ,slide the wheel assembly to forward direc-tion.
c. To make sure the caliper bracket mounts onthe swingarm and then, fix the holder of swin-garm temporally.
The holder should installed with the punch marka facing upper.
d. Tighten the rear gear housing bolts, with spe-cified tightening torque.
Rear gear housing bolt90 Nm (9.0 mkg)
e. Tighten the nut of rear axle shaft with speci-fied torque.
Wheel axle nut107 Nm (10.7 mkg)
6-15
REAR WHEEL AND BRAKE DISC CHAS
NOTE:
f. Tighten the rear axle holder with specifiedtorque.
Rear axle end nut23 Nm (2.3 mkg)
g. Tighten the rear brake caliper bracket boltwith specified tightening torque.
Brake caliper bracket bolt40 Nm (4.0 mkg)
h. Install the rear brake caliper on the bracketand tighten the bolts with specified tighteningtorque.
Brake caliper bolt40 Nm (4.0 mkg)
EAS00575
ADJUSTING THE REAR WHEEL STATICBALANCE
After replacing the tire, wheel or both, the rearwheel static balance should be adjusted.
Adjust the rear wheel static balance with thebrake disc and rear wheel drive hub installed.
1. Adjust: rear wheel static balanceRefer to “FRONT WHEEL AND BRAKECISCS”.
6-16
Order Job name/Part name Q’ty Remarks
1234
Removing the front brake padsRetaining boltBrake caliperBrake padsPad spring
1121
Remove the parts in the order listed.
For installation, reverse the removalprocedure.
Refer to “REPLACING THE FRONTBRAKE PADS”.
23 Nm (2.3 mkg)
FRONT AND REAR BRAKES CHAS
FRONT AND REAR BRAKESFRONT BRAKE PADS
6-17
Order Job name/Part name Q’ty Remarks
1234576
Removing the rear brake padsMufflerMuffler stayBrake hose holderCaliperCoverClipsPad pinsPad springBrake pads
1112212
Remove the parts in the order listed.
For installation, reverse the removalprocedure.
Refer to “REPLACING THE REARBRAKE PADS”.
Refer to “REAR WHEEL AND BRAKEDISC”.
40 Nm (4.0 mkg)
FRONT AND REAR BRAKES CHAS
EAS00578
REAR BRAKE PADS
6-18
FRONT AND REAR BRAKES CHAS
CAUTION:
NOTE:
EAS00579
Disc brake components rarely require dis-assembly.Therefore, always follow these preventivemeasures:Never disassemble brake components un-less absolutely necessary.
If any connection on the hydraulic brakesystem is disconnected, the entire brakesystem must be disassembled, drained,cleaned, properly filled, and bled after reas-sembly.
Never use solvents on internal brake com-ponents.
Use only clean or new brake fluid for clean-ing brake components.
Brake fluid may damage painted surfacesand plastic parts. Therefore, always cleanup any spilt fluid immediately.
Avoid brake fluid coming into contact withthe eyes as it can cause serious injury.
First aid for brake fluid entering the eyes:Flush with water for 15 minutes and get im-mediate medical attention.
EAS00582
REPLACING THE FRONT BRAKE PADSThe following procedure applies to both brakecalipers.
When replacing the brake pads, it is not neces-sary to disconnect the brake hose or disas-semble the brake caliper.
1. Remove:brake hose holder retaining bolt 1
6-19
FRONT AND REAR BRAKES CHAS
NOTE:
23 Nm (2.3 mkg)
2. Remove:brake pads 1(along with the brake pad shims)
3. Measure:brake pad wear limit aOut of specification Replace the brakepads as a set.
Brake pad wear limit0.8 mm
4. Install:brake pad shims(onto the brake pads)
brake padsbrake pad spring
Always install new brake pads, brake padshims, and a brake pad spring as a set.
a. Connect a clear plastic hose 1 tightly to thebleed screw 2 . Put the other end of the hoseinto an open container.
b. Loosen the bleed screw and push the brakecaliper pistons into the brake caliper withyour finger.
c. Tighten the bleed screw.
Bleed screw6 Nm (0.6 mkg)
d. Install new brake pad shims onto the newbrake pads.
e. Install new brake pads and a new brake padspring.
5. Install:brake caliper retaining bolt
6-20
FRONT AND REAR BRAKES CHAS
NOTE:
6. Check:brake fluid levelBelow the minimum lever mark a Add therecommended brake fluid to the proper level.Refer to “CHECKING THE BRAKE FLUIDLEVEL” in chapter 3.
7. Check:brake lever operationSoft or spongy feeling Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.
EAS00583
REPLACING THE REAR BRAKE PADS
When replacing the brake pads, it is not neces-sary to disconnect the brake hose or disas-semble the brake caliper.
1. Remove:brake hose holder 1brake caliper 2
2. Remove:brake pad coverbrake pad clipsbrake pad pinsbrake pad spring
3. Remove:brake pads(along with the brake pad shims)
4. Measure:brake pad wear limit aOut of specification Replace the brakepads as a set.
Brake pad wear limit0.5 mm
6-21
FRONT AND REAR BRAKES CHAS
NOTE:
NOTE:
40 Nm (4.0 mkg)
5. Install:brake pad shims(onto the brake pads)
brake padsbrake pad spring
Always install new brake pads, brake padshims, and a brake pad spring as a set.
a. Connect a clear plastic hose 1 tightly to thebleed screw 2 . Put the other end of the hoseinto an open container.
b. Loosen the bleed screw and push the brakecaliper pistons into the brake caliper withyour finger.
c. Tighten the bleed screw.
Bleed screw6 Nm (0.6 mkg)
d. Install new brake pad shims onto the newbrake pads.
e. Install new brake pads and a new brake padspring.
The longer tangs a on the brake pad springmust point in the direction of disc rotation.
6. Install:brake pad pinsbrake pad clipsbrake pad coverbrake caliper
7. Check:brake fluid levelBelow the minimum level mark a Add therecommended brake fluid to the proper level.Refer to “CHECKING THE BRAKE FLUIDLEVEL” in chapter 3.
8. Check:brake pedal operationSoft or spongy feeling Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.
6-22
Order Job name/Part name Q’ty Remarks
12345678
Removing the front brake mastercylinder.Brake fluidRear view mirror (right)Brake lever/compression springFront brake switchUnion boltCopper washersBrake hoseMaster cylinder bracketMaster cylinder
11/1112111
Remove the parts in the order listed.
Drain
For installation, reverse the removalprocedure.
Reter to “INSTALLING THE FRONTBRAKE MASTER CYLINDER”.
10 Nm (1.0 mkg)
30 Nm (3.0 mkg)
Refer to “REMOVING/INSTALLING THEFRONT BRAKE MASTER CYLINDER”.
FRONT AND REAR BRAKES CHAS
FRONT BRAKE MASTER CYLINDER
6-23
Order Job name/Part name Q’ty Remarks
Disassembling the front brakemaster cylinderDust bootCirclipMaster cylinder cupSpring
1111
Remove the parts in the order listed.
For assembly, reverse the disassemblyprocedure.
1234
FRONT AND REAR BRAKES CHAS
6-24
Order Job name/Part name Q’ty Remarks
123456789
10
Removing the rear brake mastercylinderBrake fluidBrake switch connectorCotter pin/washerPinBoltsBrake pedal assemblyUnion boltCopper washers/brake hoseClips/reservoir hoseMaster cylinder assemblyReservoir tank
11/11211
2/12/111
Remove the parts in the order listed.
DrainDisconnect
For installation, reverse removalprocedure.
Refer to “REMOVING/INSTALLING THEREAR BRAKE MASTER CYLINDER”.
64 Nm (6.4 mkg)
30 Nm (3.0 mkg)
23 Nm (2.3 mkg)
FRONT AND REAR BRAKES CHAS
EAS00586
REAR BRAKE MASTER CYLINDER
6-25
Order Job name/Part name Q’ty Remarks
Disassembling the rear brake mastercylinderMaster cylinder bootCirclipMaster cylinder cupSpring
1111
Disassembly the parts in the order listed.
For assembly, reverse the disassemblyprocedure.
1234
FRONT AND REAR BRAKES CHAS
6-26
FRONT AND REAR BRAKES CHAS
NOTE:
NOTE:
NOTE:
NOTE:
EAS00588
REMOVING THE FRONT BRAKE MASTERCYLINDER
Before removing the front brake master cylin-der, drain the brake fluid from the entire brakesystem.
1. Remove: rear view mirror (right)brake lever/compression springbrake switch 1
2. Remove:union bolt 2copper washersbrake hose 3
To collect any remaining brake fluid, place acontainer under the master cylinder and the endof the brake hose.
3. Remove:master cylinder bracketmaster cylinder
EAS00589
REMOVING THE REAR BRAKE MASTERCYLINDER
Before removing the rear brake master cylinder,drain the brake fluid from the entire brake sys-tem.
1. Remove:brake switch connectorcotter pin/washerpinbolt /brake pedal assembly
2. Remove:union bolt 1copper washers 2brake hose 3
To collect any remaining brake fluid, place acontainer under the master cylinder and the endof the brake hose.
3. Remove:clips/reservoir hosemaster cylinder assembly
6-27
A B
A B
A B
FRONT AND REAR BRAKES CHAS
EAS00592
CHECKING THE FRONT AND REAR BRAKEMASTER CYLINDERSThe following procedure applies to the both ofthe brake master cylinders.1. Check:brake master cylinder 1Damage/scratches/wear Replace.
brake fluid delivery passages 2(brake master cylinder body)Obstruction Blow out with compressed air.
A Front
B Rear
2. Check:brake master cylinder kit 1Damage/scratches/wear Replace.
A Front
B Rear
3. Check:brake fluid reservoir 1Cracks/damage Replace.
brake fluid reservoir diaphragm 2Cracks/damage Replace.
A Front
B Rear
4. Check:brake hoses 1Cracks/damage/wear Replace.
6-28
FRONT AND REAR BRAKES CHAS
WARNING
10 Nm (1.0 mkg)
NOTE:
30 Nm (3.0 mkg)
WARNING
NOTE:
EAS00598
INSTALLING THE FRONT BRAKE MASTERCYLINDER
Before installation, all internal brake com-ponents should be cleaned and lubricatedwith clean or new brake fluid.
Never use solvents on internal brake com-ponents.
Recommended brake fluidDOT 4
1. Install:brake master cylinder 1brake master cylinder bracket 2
Install the brake master cylinder bracket withthe “UP” mark facing up.
Align the end of the brake master cylinder hold-er with the punch mark a on the handlebar.
First, tighten the upper bolt, then the lower bolt.
2. Install:copper washers (New) 1brake hose 2union bolt 3
Proper brake hose routing is essential to in-sure safe motorcycle operation. Refer to“CABLE ROUTING”.
While holding the brake hose, tighten theunion bolt as shown.
Turn the handlebar to the left and to the right tomake sure that the brake hose does not touchother parts (e. g., wire harness, cables, leads).Correct if necessary.
3. Fill:brake master cylinder reservoir(with the specified amount of the recom-mended brake fluid)
Recommended brake fluidDOT 4
6-29
FRONT AND REAR BRAKES CHAS
WARNING
CAUTION:
Use only the designated brake fluid.Other brake fluids may cause the rubberseals to deteriorate, causing leakage andpoor brake performance.
Refill with the same type of brake fluid thatis already in the system. Mixing brakefluids may result in a harmful chemicalreaction, leading to poor brake perfor-mance.
When refilling, be careful that water doesnot enter the reservoir. Water will signifi-cantly lower the boiling point of the brakefluid and could cause vapor lock.
Brake fluid may damage painted surfacesand plastic parts. Therefore, always cleanup any spilt brake fluid immediately.
4. Bleed:brake systemRefer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.
5. Check:brake fluid levelBelow the minimum level mark a Add therecommended brake fluid to the proper level.Refer to “CHECKING THE BRAKE FLUIDLEVEL” in chapter 3.
6. Check:brake lever operationSoft or spongy feeling Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.
6-30
FRONT AND REAR BRAKES CHAS
WARNING
CAUTION:
WARNING
CAUTION:
EAS00610
INSTALLING THE REAR BRAKE MASTERCYLINDER1. Install:copper washers (New)brake hose
Union bolt30 Nm (3.0 mkg)
Proper brake hose routing is essential to in-sure safe motorcycle operation. Refer to“CABLE ROUTING”.
When installing the brake hose onto the brakemaster cylinder make sure that the brake pipetouches the projections a as shown.
2. Fill:brake fluid reservoir(to the maximum level mark)
Recommended brake fluidDOT 4
Use only the designated brake fluid. Otherbrake fluids may cause the rubber seals todeteriorate, causing leakage and poorbrake performance.
Refill with the same type of brake fluid that isalready in the system. Mixing brake fluidsmay result in a harmful chemical reaction,leading to poor brake performance.
When refilling, be careful that water doesnot enter the reservoir. Water will signifi-cantly lower the boiling point of the brakefluid and could cause vapor lock.
Brake fluid may damage painted surfacesand plastic parts. Therefore, always cleanup any spilt brake fluid immediately.
3. Bleed:brake systemRefer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.
4. Check:brake fluid levelBelow the minimum level mark a Add therecommended brake fluid to the proper level.Refer to “CHECKING THE BRAKE FLUIDLEVEL” in chapter 3.
6-31
FRONT AND REAR BRAKES CHAS
5. Adjust:brake pedal position aRefer to “ADJUSTING THE REAR BRAKE”in chapter 3.
Brake pedal position (below thetop of the rider footrest)
81.8 mm
6. Adjust: rear brake light operation timingRefer to “ADJUSTING THE REAR BRAKELIGHT SWITCH” in chapter 3.
6-32
Order Job name/Part name Q’ty Remarks
123456
Removing the front brake calipersBrake fluidBrake hose holderUnion boltCopper washersBrake hoseRetaining boltBrake caliper assembly
112111
Remove the parts in the order listed.Drain
For installation, reverse the removalprocedure.
Refer to “REMOVING/INSTALLINGTHE FRONT BRAKE CALIPERS”.
30 Nm (3.0 mkg)
23 Nm (2.3 mkg)
6 Nm (0.6 mkg)
FRONT AND REAR BRAKES CHAS
FRONT BRAKE CALIPERS
6-33
Order Job name/Part name Q’ty Remarks
Disassembling the front brakecalipersPad springBrake caliper pistonsDust sealsCaliper piston sealsBleed screw
12221
Remove the parts in the order listed.
For assembly, reverse the disassemblyprocedure.
Refer to “REMOVING THE FRONTBRAKE CALIPERS”.
12345
FRONT AND REAR BRAKES CHAS
6-34
Order Job name/Part name Q’ty Remarks
12345
Removing the rear brake caliperMufflerMuffler stayBrake fluidBrake hose holderUnion boltCopper washersBrake hoseCaliper ass’y
11211
Remove the parts in the order listed.
Drain
For installation, reverse the removalprocedure.
Refer to “REMOVING/INSTALLINGTHE REAR BRAKE CALIPER”.
Refer to “REAR WHEEL AND BRAKEDISC”.
40 Nm (4.0 mkg)
30 Nm (3.0 mkg)
FRONT AND REAR BRAKES CHAS
ESA00616
REAR BRAKE CALIPER
6-35
Order Job name/Part name Q’ty Remarks
Disassembling the rear brake caliperCoverClipsPad pinsPad springBrake padsCaliper pistonsDust sealsPiston sealsBleed screw
122122221
Disassembly the parts in the order listed.
For assembly, reverse the disassemblyprocedure.
Refer to “DISASSEMBLING THE REARBRAKE CALIPER”.
123456789
FRONT AND REAR BRAKES CHAS
6-36
FRONT AND REAR BRAKES CHAS
NOTE:
NOTE:
WARNING
NOTE:
EAS00624
REMOVING THE FRONT BRAKE CALIPERSThe following procedure applies to both of thebrake calipers.
Before removing either brake caliper, drain thebrake fluid from the entire brake system.
1. Remove:brake hose holderunion bolt 1copper washers 2brake hose
Put the end of the brake hose into a containerand pump out the brake fluid carefully.
2. Remove:brake caliper pistons 1brake caliper piston seals 2
a. Blow compressed air into the brake hosejoint opening to force out the pistons from thebrake caliper.
Cover the brake caliper piston with a rag.Be carful not to get injured when the pistonis expelled from the brake caliper cylinder.
Never try to pry out the brake caliper pis-tons.
b. Remove the brake caliper piston seals.
EAS00628
REMOVING THE REAR BRAKE CALIPER
Before removing the brake caliper, drain thebrake fluid from the entire brake system.
6-37
FRONT AND REAR BRAKES CHAS
NOTE:
WARNING
1. Remove:union bolt 1copper wachers 2brake hose
Put the end of the brake hose into a containerand pump out the brake fluid carefully.
2. Remove:brake caliper pistons 1brake caliper pistons seals 2
a. Secure the right side brake caliper pistonwith a piece of wood a .
b. Blow compressed air into the brake hosejoint opening b to force out the left side pis-ton from the brake caliper.
Never try to pry out the brake caliper pis-tons.
Do not loosen the bolts.
c. Remove the brake caliper piston seals.d. Repeat the previous steps to force out the
right side piston from the brake caliper.
EAS00633
CHECKING THE FRONT AND REAR BRAKECALIPERS
Recommended brake componentreplacement schedule:
Brake pads If necessary
Piston seals Every two years
Brake hoses Every two years
Brake fluidEvery two years andwhenever the brakeis disassembled.
6-38
B
A
FRONT AND REAR BRAKES CHAS
WARNING
WARNING
1. Check:brake caliper pistons 1Rust/scratches/wear Replace the brakecaliper piston assembly.
brake caliper cylinders 2Scratches/wear Replace the brake cali-per.
brake calipers 3Cracks/damage Replace.
brake fluid delivery passages(brake caliper body)Obstruction Blow out with compressed air.
Whenever a brake caliper is disassembled,replace the brake caliper piston seals.
A Front
B Rear
2. Check:brake caliper bracketsCracks/damage Replace.
EAS00638
INSTALLING THE FRONT BRAKE CAL-IPERSThe following procedure applies to both of thebrake calipers.
Before installation, all internal brake com-ponents should be cleaned and lubricatedwith clean or new brake fluid.
Never use solvents on internal brake com-ponents as they will cause the piston sealsto swell and distort.
Whenever a brake caliper is disassembled,replace the brake caliper piston seals.
Recommended brake fluidDOT 4
6-39
FRONT AND REAR BRAKES CHAS
30 Nm (3.0 mkg)
WARNING
CAUTION:
23 Nm (2.3 mkg)
WARNING
1. Install:brake caliper 1(temporarily)
copper washers (New) 2brake hose 3union bolt 4
Proper brake hose routing is essential to in-sure safe motorcycle operation. Refer to“CABLE ROUTING”.
When installing the brake hose onto the brakecaliper 1 , make sure that the brake pipetouches the projection a on the brake caliper.
2. Install:brake caliper retaining bolt
brake hose holderRefer to “FRONT BRAKE PADS”.
3. Fill:brake master cylinder reservoir(with the specified amount of the recom-mended brake fluid)
Recommended brake fluidDOT 4
Use only the designated brake fluid. Otherbrake fluids may cause the rubber seals todeteriorate, causing leakage and poorbrake performance.
Refill with the same type of brake fluid that isalready in the system. Mixing brake fluidsmay result in a harmful chemical reaction,leading to poor brake performance.
When refilling, be careful that water doesnot enter the reservoir. Water will signifi-cantly lower the boiling point of the brakefluid and could cause vapor lock.
FRONT AND REAR BRAKES CHAS
6-40
CAUTION:
WARNING
Brake fluid may damage painted surfacesand plastic parts. Therefore, always cleanup any spilt brake fluid immediately.
4. Bleed:brake systemRefer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.
5. Check:brake fluid levelBelow the minimum level mark a Add therecommended brake fluid to the proper level.Refer to “CHECKING THE BRAKE FLUIDLEVEL” in chapter 3.
6. Check:brake lever operationSoft or spongy feeling Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.
EAS00642
INSTALLING THE REAR BRAKE CALIPER
Before installaiton, all internal brake com-ponents should be cleaned and lubricatedwith clean or new brake fluid.
Never use solvents on internal brake com-ponents as they will cause the piston sealsto swell and distort.
Whenever a brake caliper is disassembled,replace the brake caliper piston seals.
Recommended brake fluidDOT 4
6-41
FRONT AND REAR BRAKES CHAS
30 Nm (3.0 mkg)
WARNING
CAUTION:
40 Nm (4.0 mkg)
WARNING
1. Install:brake caliper 1(temporarily)
copper washers Newbrake hose 2union bolt 3
Proper brake hose routing is essential to in-sure safe motorcycle operation. Refer to“CABLE ROUTING”.
When installing the brake hose onto thebrake caliper 1 , make sure that the brakepipe a touches the projection b on the cop-per washer.
2. Install:brake caliperbrake hose holderRefer to “REAR BRAKE PADS”.
3. Fill:brake fluid reservoir(with the specified amount of the recom-mended brake fluid)
Recommended brake fluidDOT 4
Use only the designated brake fluid. Otherbrake fluids may cause the rubber seals todeteriorate, causing leakage and poorbrake performance.
Refill with the same type of brake fluid thatis already in the system. Mixing brakefluids may result in a farmful chemicalreaction, leading to poor brake perfor-mance.
When refilling, be careful that water doesnot enter the brake fluid reservoir. Waterwill signicantly lower the boiling point ofthe brake fluid and could cause vapor lock.
FRONT AND REAR BRAKES CHAS
6-42
CAUTION:
NOTE:
Brake fluid may damage painted surfacesand plastic parts. Therefore, always cleanup any spilt brake fluid immediately.
4. Bleed:brake system
Place the motorcycle on a suitable stand.Make sure that the motorcycle is upright.
Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.
5. Check:brake fluid levelBelow the minimum level mark a Add therecommended brake fluid to the proper level.Refer to “CHECKING THE BRAKE FLUIDLEVEL” in chapter 3.
6. Check:brake pedal operationSoft or spongy feeling bleed the brake sys-tem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.
6-43
Order Job name/Part name Q’ty Remarks
12345678
Removing the front forkFront wheel
Brake hose holdersBrake caliper assemblyFront fenderTurn signal light boltsUpper bracket boltsCap boltsLower bracket boltsFront fork legs
22122222
Remove the parts in the order listed.Refer to “FRONT WHEEL AND BRAKEDISCS”.
For installation, reverse the removalprocedure.
Refer to “REMOVING/INSTALLINGTHE FRONT FORK LEGS”.
20 Nm (2.0 mkg)
7 Nm (0.7 mkg)
30 Nm (3.0 mkg)
10 Nm (1.0 mkg)40 Nm (4.0 mkg)
FRONT FORK CHAS
FRONT FORK
Order Job name/Part name Q’ty Remarks
Disassembling the front forkCap boltO-ringSpacerSpring seatFork springDust sealOil seal clipDamper rod boltCopper washerDamper rod/rebound springOil seal
111111111
1/11
Disassemble the parts in the order listed.
Refer to “DISASSEMBLING/ASSEM-BLING THE FRONT FORK LEGS”.
12345
9
678
1011
23 Nm (2.3 mkg)
30 Nm (3.0 mkg)
FRONT FORK CHAS
6-44
6-45
Order Job name/Part name Q’ty Remarks
Seal spacerOuter tube bushingInner tube/inner tube bushingOil lock pieceOuter tube
11
1/111
For assembly, reverse the disassemblyprocedure.
Refer to “DISASSEMBLING/ASSEM-BLING THE FRONT FORK LEGS”.
1213141516
23 Nm (2.3 mkg)
30 Nm (3.0 mkg)
FRONT FORK CHAS
6-46
FRONT FORK CHAS
WARNING
NOTE:
WARNING
CAUTION:
EAS00649
REMOVING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Stand the motorcycle on a level surface.
Securely support the motorcycle so thatthere is no danger of it falling over.
Place the motorcycle on a suitable stand so thatthe front wheel is elevated.
2. Loosen:upper bracket pinch bolt 1cap bolt 2 turn signal light bolt 3 lower bracket pinch bolt 4
Before loosening the upper and lowerbracket pinch bolts, support the front forkleg.
3. Remove: front fork leg
EAS00653
DISASSEMBLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Remove:cap boltO-ringspacerspring seat fork spring
2. Drain fork oil
3. Remove:dust seal 1oil seal clip 2(with a flat-head screwdriver)
Do not scratch the inner tube.
6-47
FRONT FORK CHAS
NOTE:
NOTE:
WARNING
Do not remove the front fork leg protector fromthe outer tube.
If the front fork leg protector must be removed,always install a new one.
4. Remove:damper rod boltcopper washer
While holding the damper rod with the T-handle1 and damper rod holder 2 , loosen the damp-er rod bolt 3 .
T-handle90890-01326
Damper rod holder90890-01460
6. Remove: inner tube
a. Hold the front fork leg horizontally.b. Slowly push A the inner tube into the outer
tube and just before it bottoms out, pull B theinner tube back quickly.
c. Repeat this step until the inner tube sepa-rates from the outer tube.
EAS00657
CHECKING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Check: inner tube 1outer tube 2Bends/damage/scratches Replace.
Do not attempt to straighten a bent innertube as this may dangerously weaken it.
2. Measure:spring free length aOver the specified limit Replace.
Spring free length limit350 mm
6-48
FRONT FORK CHAS
CAUTION:
WARNING
NOTE:
WARNING
CAUTION:
3. Check:damper rod 1Damage/wear Replace.Obstruction Blow out all of the oil pas-sages with compressed air.
oil lock piece 2Damage Replace.
When disassembling and assembling thefront fork leg, do not allow any foreign mate-rial to enter the front fork.
4. Check:cap boltO-ringDamage/wear Replace.
EAS00659
ASSEMBLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.
Make sure that the oil levels both front forklegs are equal.
Uneven oil levels can result in poor han-dling and a loss of stability.
When assembling the front fork leg, be sure toreplace the following parts:–inner tube bushing–outer tube bushing–oil seal–dust seal
Before assembling the front fork leg, makesure that all of the components are clean.
1. Install:damper rod 1oil lock piece 2
Always use new copper washers.
Allow the damper rod to slide slowly downthe inner tube 3 until it protrudes from thebottom of the inner tube. Be careful not todamage the inner tube.
6-49
FRONT FORK CHAS
30 Nm (3.0 mkg)
NOTE:
CAUTION:
NOTE:
NOTE:
2. Lubricate: inner tube’s outer surface
Recommended lubricantYamaha fork and shock oil10 W or equivalent
3. Tighten:damper rod bolt 1
While holding the damper rod with the T-handle1 and damper rod holder 2 , tighten the damp-er rod bolt 3 .
T-handle90890-01326
Damper rod holder90890-01460
4. Install:outer tube bushing 1seal spacer(with the fork seal driver weight 2 and adapt-er 3 )
Fork seal driver weight90890-01367
Adapter90890-01381
5. Install:oil seal 1(with the fork seal driver weight and adapter)
Make sure that the numbered side of the oilseal faces up.
Before installing the oil seal, apply lithium soapbase grease onto its lips.
6. Install:oil seal clip 1
Adjust the oil seal clip so that it fits into the outertube groove.
6-50
FRONT FORK CHAS
CAUTION:
NOTE:
NOTE:
7. Install:dust seal 1(with the fork seal driver weight)
8. Fill: front fork leg(with the specified amount of the recom-mended fork oil)
Quantity (each front fork leg)0.464 L
Recommended oilYamaha fork and shock oil 10Wor equivalent
Be sure to use the recommended fork oil.Other oils may have an adverse effect onfront fork performance.
When disassembling and assembling thefront fork leg, do not allow any foreign ma-terial to enter the front fork.
9. After filling the front fork leg, slowly stroke theinner tube up and down (at least ten times) todistribute the fork oil.
Be sure to stroke the inner tube slowly becausethe fork oil may spurt out.
10. Measure: front fork leg oil level aOut of specification Correct.
Front fork leg oil level (from thetop of the inner tube, with theinner tube fully compressed,and without the spring)
108 mm
Hold the fork in an upright position.
11. Install: fork springspring seatspacerO-ringcap bolt
6-51
FRONT FORK CHAS
NOTE:
NOTE:
30 Nm (3.0 mkg)
7 Nm (0.7 mkg)
23 Nm (2.3 mkg)
20 Nm (2.0m kg)
WARNING
Install the fork spring with its smaller pitch up-word.
Before installing the cap bolt, apply grease tothe O-ring.
Temporarily tighten the cap bolt.
EAS00662
INSTALLING THE FRONT FORK LEGSThe fllowing procedure applies to both of thefront fork legs.1. Install: front fork legTemporarily tighten the upper and lowerbracket pinch bolts.
Make sure that the inner fork tube is flush withthe top of the upper bracket.
2. Tighten: lower bracket pinch bolt 1
front turn signal light bolt 2
cap bolt 3upper bracket pinch bolt 4
Make sure that the brake hoses are routedproperly.
6-52
Order Job name/Part name Q’ty Remarks
123456789
1011
Removing the handlebar
Plastic locking tiesClutch cableClutch switch leadStarter cableHandlebar switch (left)Grip (left)Clutch lever assemblyMaster cylinder bracketMaster cylinder assemblyHandlebar switch (right)Throttle cables
41111111112
Remove the parts in the order listed.Stand the motorcycle on a level surface.
Securely support the motorcycle sothat there is no danger of it falling over.
Refer to “INSTALLING THE HANDLEBAR”.Refer to “REMOVING THE HANDLEBAR”.
Refer to “INSTALLING THEHANDLEBAR”.
WARNING
28 Nm (2.8 mkg)
10 Nm (1.0 mkg)
32 Nm (3.2 mkg)
HANDLEBAR CHAS
HANDLEBAR
6-53
28 Nm (2.8 mkg)
10 Nm (1.0 mkg)
32 Nm (3.2 mkg)
Order Job name/Part name Q’ty Remarks
1213141516
Throttle grip assemblyHandlebar holders (upper)HandlebarCable guideHandlebar holders (lower)
12112
For installation, reverse the removalprocedure.
Refer to “INSTALLING THEHANDLEBAR”.
HANDLEBAR CHAS
6-54
HANDLEBAR CHAS
WARNING
NOTE:
WARNING
WARNING
EAS00666
REMOVING THE HANDLEBAR1. Stand the motorcycle on a level surface.
Securely support the motorcycle so thatthere is no danger of it falling over.
2. Remove:handlebar grip (left) 1
Blow compressed air between the handlebarand the handlebar grip, and gradually push thegrip off the handlebar.
EAS00668
CHECKING THE HANDLEBAR1. Stand the motorcycle on a level surface.
Securely support the motorcycle so thatthere is no danger of it falling over.
2. Check:handlebar 1Bends/cracks/damage Replace.
Do not attempt to straighten a bent handle-bar as this may dangerously weaken it.
3. Install:handlebar grip
6-55
HANDLEBAR CHAS
WARNING
WARNING
28 Nm (2.8 mkg)
CAUTION:
NOTE:
a. Apply a light coat of rubber adhesive onto theleft end of the handlebar.
b. Slide the handlebar grip over the left end ofthe handlebar.
c. Wipe off any excess rubber adhesive with aclean rag.
Do not touch the handlebar grip until therubber adhesive has fully dried.
EAS00670
INSTALLING THE HANDLEBAR1. Stand the motorcycle on a level surface.
Securely support the motorcycle so thatthere is no danger of it falling over.
2. Install:handlebarupper handlebar holders
First, tighten the bolts on the front side ofthe handlebar holder, then on the rear side.
Turn the handlebar all the way to the leftand right. If there is any contact with thefuel tank, adjust the handlebar position.
The upper handlebar holders should beinstalled with the punch mark a facing forwardA .
6-56
HANDLEBAR CHAS
WARNING
NOTE:
NOTE:
NOTE:
Align the match marks b on the handlebarwith the upper surface of the lower handlebarholders.
3. Install: throttle grip throttle cable
Make sure that the pin a on the throttlecable housing is aligned with the hole b inthe handlebar.
4. Install:master cylinderRefer to “FRONT AND REAR BRAKES”.
5. Install:clutch lever holder 1
Align the slit in the clutch lever holder with thepunch mark a in the handlebar.
6. Install: left handlebar switch 1
Aligh the matching surface on the handlebarswitches with the punch mark a on the handle-bar.
7. Install:clutch cable
8. Connect:clutch switch coupler
Apply a thin coat of lithium soap base greaseonto the end of the clutch cable.
6-57
HANDLEBAR CHAS
9. Adjust:clutch cable free playRefer to “ADJUSTING THE CLUTCHCABLE FREE PLAY” in chapter 3.
Clutch cable free play (at the endof the clutch lever)
5 10 mm
10. Adjust: throttle cable free playRefer to “ADJUSTING THE THROTTLECABLE FREE PLAY” in chapter 3.
Throttle cable free play (at theflange of the throttle grip)
4 6 mm
6-58
Order Job name/Part name Q’ty Remarks
12345678
Removing the lower bracket
Front fork legsHandlebarHeadlight lens unitLeads (in the headlight body)Front turn signal light (left /right)Headlight bodyBrake hose joint holderUpper bracketLock washerUpper ring nut
1–
1/111111
Remove the parts in the order listed.Stand the motorcycle on a level surface.
Securely support the motorcycle sothat there is no danger of it falling over.
Refer to “FRONT FORK”.Refer to “HANDLEBAR”.
Disconnect
WARNING
7 Nm (0.7 mkg)
1st
110 Nm (11.0 mkg)
2nd52 Nm (5.2 mkg)18 Nm (1.8 mkg)
STEERING HEAD CHAS
STEERING HEAD
6-59
Order Job name/Part name Q’ty Remarks
9101112131415
Rubber washerLower ring nutBearing coverLower bracketBearing (upper)Rubber sealBearing (lower)
1111111
For installaiton, reverse the removalprocedure.
7 Nm (0.7 mkg)
1st
110 Nm (11.0 mkg)
2nd52 Nm (5.2 mkg)18 Nm (1.8 mkg)
Refer to “REMOVING THE LOWERBRACKET/INSTALLING THESTEERING HEAD”.
STEERING HEAD CHAS
6-60
STEERING HEAD CHAS
WARNING
NOTE:
WARNING
EAS00677
REMOVING THE LOWER BRACKET1. Stand the motorcycle on a level surface.
Securely support the motorcycle so thatthere is no danger of it falling over.
2. Remove:upper ring nut 1 lower ring nut 2
Hold the lower ring nut with the exhaust andsteering nut wrench, then remove the upper ringnut with the ring nut wrench.
Exhaust and steering nut wrench90890-01268
Ring nut wrench90890-01403
Securely support the lower bracket so thatthere is no danger of it falling.
EAS00681
CHECKING THE STEERING HEAD1. Wash:bearingsbearing races
Recommended cleaning solventKerosine
2. Checkbearings 1bearing races 2Damage/pitting Replace.
3. Replace:bearingsbearing races
6-61
STEERING HEAD CHAS
CAUTION:
NOTE:
a. Remove the bearing reces from the steeringhead pipe with a long rod 1 and hammer.
b. Remove the bearing race from the lowerbracket with a floor chisel 2 and hammer.
c. Install a new rubber seal and new bearing re-ces.
If the bearing race is not installed properly,the steering head pipe could be damaged.
Always replace the bearings and bearingraces as a set.
Whenever the steering head is disassembled,replace the rubber seal.
4. Check:upper bracket lower bracket(along with the steering stem)Bends/cracks/damage Replace.
EAS00683
INSTALLING THE STEERING HEAD1. Lubricate:upper bearing lower bearingbearing races
Recommended lubricantLithium soap base grease
2. Install:Lower ring nut 1 rubber washer 2upper ring nut 3 lock washer 4Refer to “CHECKING AND ADJUSTINGTHE STEERING HEAD” in chapter 3.
3. Install:upper bracketsteering stem nut
6-62
STEERING HEAD CHAS
NOTE:
NOTE:
Temporarily tighten the steering stem nut.
4. Install: front fork legsRefer to “FRONT FORK”
Temporarily tighten the upper and lower bracketpinch bolts.
6-63
Order Job name/Part name Q’ty Remarks
123
4
Removing the right side cover andbattery box.Seats
Muffler assembly
Battery coverRight side coverBattery
Battery box
111
1
Remove the parts in the order listed.Stand the motorcycle on a level surface.Refer to “FUEL TANK AND SEATS” inCHAPTER 3.Refer to “REAR WHEEL AND BRAKEDISC”.
Refer to “REMOVING/INSTALLING THEREAR SHOCK ABSORBER ASSEMBLY”.
For installation, reverse the removalprocedure.
7 Nm (0.7 mkg)
REAR SHOCK ABSORBER AND SWINGARM CHAS
REAR SHOCK ABSORBER AND SWINGARMRIGHT SIDE COVER AND BATTERY BOX
6-64
Order Job name/Part name Q’ty Remarks
1234567
Removing the left side cover andtool boxTool box coverLeft side coverOwner’s tool kitConnector’sFuel hose holderFuel hosesTool box
111–121
Remove the parts in order listed.
Disconnect
Disconnect
For installation, reverse the removalprocedure.
7 Nm (0.7 mkg)
REAR SHOCK ABSORBER AND SWINGARM CHAS
LEFT SIDE COVER AND TOOL BOX
6-65
Order Job name/Part name Q’ty Remarks
1234567
Removing the rear shock absorberand swingarmRear wheel
Connecting arm boltsConnecting armsRear shock absorber lower boltRear shock absorberRelay armPivot shaftSwingarm
2211111
Remove the parts in order listed.
Refer to “REAR WHEEL AND BRAKEDISC”.
For installation, reverse the removalprocedure.
40 Nm (4.0 mkg)
48 Nm (4.8 mkg)
48 Nm (4.8 mkg)
90 Nm (9.0 mkg)
48 Nm (4.8 mkg)
Refer to “REMOVING/INSTALLING THEREAR SHOCK ABSORBER ASSEMBLY”.
Refer to “REMOVING/INSTALLING THESWINGARM”.
REAR SHOCK ABSORBER AND SWINGARM CHAS
REAR SHOCK ABSORBER AND SWINGARM
6-66
REAR SHOCK ABSORBER AND SWINGARM CHAS
WARNING
WARNING
EAS00687
HANDLING THE REAR SHOCK ABSORBERAND GAS CYLINDER
This rear shock absorber and gas cylindercontain highly compressed nitrogen gas.Before handling the rear shock absorber orgas cylinder, read and make sure you under-stand the following information. Themanufacturer cannot be held responsiblefor property damage or personal injury thatmay result from improper handling of therear shock absorber and gas cylinder.Do not tamper or attempt to open the rearshock absorber or gas cylinder.
Do not subject the rear shock absorber orgas cylinder to an open flame or any othersource of high heat. High heat can cause anexplosion due to excessive gas pressure.
Do not deform or damage the rear shockabsorber or gas cylinder in any way. If therear shock absorber, gas cylinder or bothare damaged, damping performance willsuffer.
EAS00689
DISPOSING OF A REAR SHOCK ABSORB-ER AND GAS CYLINDER
a. Gas pressure must be released before dis-posing of a rear shock absorber and gas cy-linder.To release the gas pressure, drill a2 3 mm hole through the gas cylinder at apoint 15 – 20 mm from its end as shown.
Wear eye protection to prevent eye damagefrom released gas or metal chips.
6-67
REAR SHOCK ABSORBER AND SWINGARM CHAS
WARNING
NOTE:
CAUTION:
NOTE:
EAS00694
REMOVING THE REAR SHOCK ABSORBERASSEMBLY1. Stand the motorcycle on a level surface.
Securely support the motorcycle so thatthere is no danger of it falling over.
Place the motorcycle on a suitable stand so thatthe rear wheel is elevated.
2. Disconnect:battery leads(from the battery terminals)
First, disconnect the negative lead 1 , thenthe positive lead 2 .
3. Remove:connecting arm bolt(swingarm side) 1 rear shock absorber assembly lower bolt
While removing the connecting arm bolt (swin-garm side), hold the swingarm so that it does notdrop down.
4. Remove: rear shock absorber upper bolt rear shock absorber
6-68
REAR SHOCK ABSORBER AND SWINGARM CHAS
WARNING
NOTE:
EAS00702
REMOVING THE SWINGARM1. Stand the motorcycle on a level surface.
Securely support the motorcycle so thatthere is no danger of it falling over.
Place the motorcycle on a suitable stand so thatthe rear wheel is elevated.
2. Remove: rear shock absorber
3. Check:swingarm side playswingarm vertical movement
a. Check the tightening torque of the swingarmpivot bolts and locknut.
Locknut90 Nm (9.0 mkg)
b. Check the swingarm side play A by movingthe swingarm from side to side.
c. If the swingarm side play is out of specifica-tion, check the spacers and bearings.
Swingarm side play (at the endof the swingarm)
0 mm
d. Check the swingarm vertical movement Bby moving the swingarm up and down.If swingarm vertical movement is not smoothor if there is binding, check the spacers andbearings.
6-69
REAR SHOCK ABSORBER AND SWINGARM CHAS
EAS00696
CHECKING THE REAR SHOCK ABSORBERASSEMBLY AND GAS CYLINDER1. Check: rear shock absorber rodBends/damage Replace the rear shockabsorber assembly.
rear shock absorber Gas leaks/oil leaks Replace the rearshock absorber assembly.
springDamage/wear Replace the rear shock ab-sorber assembly.
gas cylinderDamage/gas leaks Replace.
bushingsDamage/wear Replace.
dust sealsDamage/wear Replace.
boltsBends/damage/wear Replace.
EAS00708
CHECKING THE SWINGARM1. Check:swingarmBends/cracks/damage Replace.
2. Check:pivot shaftDamage/wear Replace.
3. Check:collars 1oilseals 2bearings 3Damage/wear Replace.
6-70
REAR SHOCK ABSORBER AND SWINGARM CHAS
NOTE:
CAUTION:
EAS00698
INSTALLING THE REAR SHOCK ABSORB-ER ASSEMBLY1. Install:swingarmRefer to “INSTALLING THE SWINGARM”.
2. Lubricate:spacersbearings
Recommended lubricantMolybdenum disulfide grease
3. Install: rear shock absorber assembly
Rear shock absorber assemblyupper nut
40 Nm (4.0 mkg)Rear shock absorber assemblylower nut
48 Nm (4.8 mkg)Relay-arm-to-frame-nut
48 Nm (4.8 mkg)
When installing the rear shock absorber as-sembly, lift up the swingarm.
Install the connecting arm front bolt from theright.
4. Connect:battery leads(to the battery terminals)
First, connect the positive lead 1 , then thenegative lead 2 .
EAS00712
INSTALLING THE SWINGARM
1. Lubricate:bearingsspacersoil seals
Recommended lubricantMolybdenum disulfide grease
6-71
REAR SHOCK ABSORBER AND SWINGARM CHAS
2. Install: relay arm left connecting arm right connecting arm
Rear-shock-absorber-assemblylower nut 1
48 Nm (4.8 mkg)Connecting arm nuts 2
48 Nm (4.8 mkg)Relay-arm-to-frame-nut 3
48 Nm (4.8 mkg)
3. Install: rear shock absorberReter to “INSTALLING THE REAR SHOCKABSORBER ASSEMBLY”.
4. Install: rear wheelRefer to “REAR WHEEL AND BRAKEDISC”.
6-72
SHAFT DRIVE CHAS
NOTE:
SHAFT DRIVEEAS00715
TROUBLESHOOTINGThe following conditions may indicate damaged shaft drive components:
A Symptoms B Possible causes
1. A pronounced hesitation or jerky movementduring acceleration, deceleration, or sus-tained speeds. (not to be confused with enginesurging or transmissionrelatedmovements.)
2. A rolling “rumble” noticeable at low speeds, ahigh-pitched whine, or a “clunk” from a shaftdrive component or vicinity of the shaft drive.
3. The shaft drive is locked up or no power istransmitted from the engine to the rear wheel
A. Bearing damageB. Improper gear lashC.Damaged gear teethD.Broken drive shaftE. Broken gear teethF. Seizure due to lack of lubricationG.Small foreign objects lodged between moving
parts
Causes A, B and C may be extremely difficult to diagnose. The symptoms are quite subtle and difficultto distinguish from normal operating noises. If there is reason to believe these components are dam-aged, remove them for individual inspection.
6-73
SHAFT DRIVE CHAS
WARNING
WARNING
Inspection notes1. Investigate any unusual noises.
The following noises may indicate a me-chanical defect:a. A rolling “rumble” during coasting, accelera-
tion, or deceleration, (increases with the rearwheel speed, but does not increase withhigher engine or transmission speeds).Diagnosis: Possible wheel bearing damage.
b. A whining noise that varies with accelerationand deceleration.Diagnosis: Possible incorrect reassembly ortoo little gear lash.
Insufficient gear lash is extremely destruc-tive to the gear teeth. If a test ride, followingreassembly, indicates these symptoms,stop riding immediately to minimize geardamage.
c. A slight “clunk” evident at low speed opera-tion. (not to be confused with normal motor-cycle operation)Diagnosis: Possible broken gear teeth
Stop riding immediately if broken gear teethare suspected. This condition could resultin the shaft drive assembly locking up, caus-ing a loss of control and possible injury tothe rider.
6-74
YES
NO
NO
YES
YES
NO
Place the motorcycle on a suitable stand sothat the front wheel is elevated and then spinthe front wheel. Is the wheel bearing dam-aged?
Place the motorcycle on a suitable stand sothat the rear wheel is elevated and then spinthe rear wheel. Is the wheel bearing dam-aged?
Replace the wheel bearing.Refer to “FRONT WHEEL AND BRAKEDISC”.
Rear wheel bearings and shaft drive bearingsare probably not damaged.Repeat the test or remove and check thecomponents.
Remove the rear wheel. Is the wheel bearingdamaged?
Replace the rear wheel bearing.Refer to “REAR WHEEL AND BRAKE DISC”.
Remove and inspect the drive shaft compo-nents.
SHAFT DRIVE CHAS
EAS00716
Troubleshooting chartWhen causes A and B shown in the chart at the beginning of the “TROUBLESHOOTING” section exist,check the following points:
6-75
SHAFT DRIVE CHAS
NOTE:
NOTE:
EAS00717
CHECKING THE FINAL DRIVE OIL FORCONTAMINATION AND INSPECTING THESHAFT DRIVE FOR LEAKS1. Drain: final drive oil(from the final drive housing)Refer to “CHARGING THE FINAL DRIVEOIL” in chapter 3.
2. Check: final drive oilLarge amount of metal particles Check forbearing seizure.
A small amount of metal particles in the finaldrive oil is normal.
3. Check:shaft drive housing(for oil leaks)
a. Thoroughly clean the entire motorcycle andthen completely dry it.
b. Apply a leak-locating compound or dry pow-der spray to the shaft drive.
c. Test ride the motorcycle long enough to lo-cate a leak.Oil leak Repair or replace the faultypart(-s).
1 Oil seal
2 O-ring
3 Forward
What may appear to be an oil leak on a new orfairly new motorcycle, may result from the ap-plication of a rust preventive coating or exces-sive seal lubrication.
Always clean the motorcycle and recheck thearea where the leak is thought to originatefrom.
6-76
1.5 mm
11 mm
100 mm
a
25 mm
14 mm
SHAFT DRIVE CHAS
NOTE:
EAS00719
MEASURING THE RING GEAR BACKLASH1. Secure the final drive assembly in a vise.2. Remove: final drive oil drain bolt
3. Drain: final drive oil(from the final drive assembly)
4. Measure: ring gear backlashOut of specification Adjust.
Ring gear backlash0.1 0.2 mm
a. Install a bolt 1 of the specified size, into thefinal drive oil filler hole.
b. Finger tighten the bolt until it stops the ringgear from moving.
Do not overtighten the bolt.
c. Install the final gear backlash band 2 anddial gauge 3
Final gear backlash band90890-01230
a Dial-gauge-plunger contact point: 54.5 mmd. Gently rotate the gear coupling from engage-
ment to engagement.e. Record the reading on the dial gauge.f. Remove the dial gauge, special tool, and
bolt.
6-77
SHAFT DRIVE CHAS
NOTE:
g. Rotate the final drive pinion gear 90.h. Reinstall the bolt, special tool, and dial
gauge.i. Repeat steps (d) to (h) three more times (for
a total of four measurements).j. If any of the readings are over specification,
adjust the ring gear backlash.
EAS00720
ADJUSTING THE RING GEAR BACKLASH1. Remove: ring gear bearing housing nuts ring gear bearing housing bolts
Working in a crisscross pattern, loosen each nut1/4 of a turn. After all of the nuts are fully loos-ened, remove them and the bolts.
2. Remove: ring gear bearing housing 1 ring gear 2 thrust washer 3 ring gear shim(-s) 4
3. Adjust: ring gear backlash
a. Use the following chart to select the suitableshim(-s) and thrust washer.
Thinner shim Ring gear backlash isincreased.
Thicker shim Ring gear backlash isdecreased.
6-78
SHAFT DRIVE CHAS
Rig gear shims
Thickness (mm) 0.25, 0.30, 0.40
Thrust washers
Thickness (mm) 1.2, 1.4, 1.6, 1.8, 2.0
b. If it is necessary to increase the ring gearbacklash by more than 0.2 mm, reduce thethrust washer thickness by 0.2 mm for every0.2 mm increase of ring gear shim thickness.
c. If it is necessary to reduce the ring gear back-lash by more than 0.2 mm, increase thethrust washer thickness by 0.2 mm for every0.2 mm decrease of ring gear shim thick-ness.
6-79
Order Job name/Part name Q’ty Remarks
123
4
Removing the final drive assemblyand drive shaft.
Rear wheel assembly
CollarDrive shaft assemblyFinal drive pinion gear assembly
Final gear assembly
111
1
Remove the parts in the order listed.Stand the motorcycle on a level surface.
Securely support the motorcycle sothere is no danger of it falling over.
Refer to “REAR WHEEL AND BRAKEDISC”.
Refer to “DISASSEMBLING THE FINALDRIVE ASSEMBLY/ALIGNING THEFINAL DRIVE PINION GEAR AND RINGGEAR”.
For installation, reverse the removalprocedure.
WARNING
23 Nm (2.3 mkg)
23 Nm (2.3 mkg)
42 Nm (4.2 mkg)
115 Nm (11.5 mkg)
130 Nm (13.0 mkg)
SHAFT DRIVE CHAS
FINAL DRIVE ASSEMBLY AND DRIVE SHAFT
6-80
SHAFT DRIVE CHAS
Order Job name/Part name Q’ty Remarks
Disassembling the final gear.Bolts (bearing housing)Nuts (bearing housing)
Bearing housing/O-ringRing gearShim (s)Thrust washer
26
1/1111
Disassemble the parts in the order listed.
Working in a crisscross pattern, looseneach bolt and nut 1/4 of a turn. After allthe bolts and nuts are loosened, removethem.
For assembly, reverse the disassemblyprocedure.
NOTE:12
3456
23 Nm (2.3 mkg)
40 Nm (4.0 mkg)
FINAL GEAR
6-81
SHAFT DRIVE CHAS
NOTE:
CAUTION:
WARNING
CAUTION:
EAS00724
DISASSEMBLING THE FINAL DRIVE AS-SEMBLY1. Remove: ring gear bearing housing nuts ring gear bearing housing bolts
Working in a crisscross pattern, loosen eachbolts and nuts 1/4 of a turn. After all of the boltsand nuts are fully loosened, and remove them.
2. Remove:self-locking nutgear coupling(with the special tool 1 )
Coupling gear/middle shaft tool90890-01229
3. Remove:bearing retainer 2(with the special tool 3 )
Bearing retainer wrench90890-04077
The bearing retainer has left-hand threads.To loosen the bearing retainer, turn it clock-wise.
4. Remove: final drive pinion gear(with the special tools)
Crankshaft installer boltadapter 1
90890-01277Armature shock puller 2
90890-01290Weight 3
90890-01291
Always use new bearings.
The final drive pinion gear should only be re-moved if ring gear replacement is neces-sary.
6-82
SHAFT DRIVE CHAS
NOTE:
EAS06725
REMOVING AND INSTALLING THE RINGGEAR BEARINGS1. Remove:collar 1oil seal 2bearing 3(with an appropriate press tool 4 and an ap-propriate support for the final drive housing)
2. Check:bearingDamage Replace.
3. Remove:bearing 1
a. Heat the final gear case to approximately150 C (302 F).
b. Remove the bearing outer races with an ap-propriately shaped punch 2 .
c. Remove the inner race from the final drivepinion gear.
The removal of the final drive pinion gear bear-ing is a difficult procedure and is rarely neces-sary.
4. Install:bearing (New)
a. Heat the final gear case to approximately150C (302F).
b. Install the bearing outer races with a socketor appropriate tool that matches the diameterof the races.
c. Install the inner race onto the final drive pin-ion gear.
6-83
SHAFT DRIVE CHAS
NOTE:
NOTE:
5. Install:collar 1oil seal 2 Newbearing(with an appropriate press tool 3 and press)
The bearing can be reused, but Yamaha recom-mends installing a new one.
EAS00726
ALIGNING THE FINAL DRIVE PINION GEARAND RING GEAR
Aligning the final drive pinion gear and ring gearis necessary when any of the following parts arereplaced:Final drive housingAny bearing
1. Select: final drive pinion gear shim(-s) 1 ring gear shim(-s) 2
a. Position the final drive pinion gear and thering gear with shims 1 and 2 . Calculate therespective thicknesses from informationmarked on the final drive housing and thedrive pinion gear.
1 Final drive pinion gear shim
2 Ring gear shim
3 Thrust washerb. To find final drive pinion gear shim thickness
“A” use the following formula:
Final drive pinion gear shim thicknessA = (84 + a /100) – b
6-84
SHAFT DRIVE CHAS
Final drive pinion gear shim
Thickness (mm) 0.30, 0.40, 0.50
Where:a = a numeral (positive or negative) on the ringgear, to be divided by 100 and added to “84”b = a numeral on the final drive housing.Example:If the final drive pinion gear is marked “+ 01” andthe final drive housing is marked “83.50”: A = (84 + 1/100) – (83.50) = (84 + 0.01) – (83.50) = 84.01 – 83.50 = 0.51Therefore, the calculated final drive pinion gearshim thickness is 0.51 mm.Shim sizes are supplied in the following thick-nesses.
Since the final drive pinion gear shims are onlyavailable in 0.10 mm increments, round off tothe hundredths digit.
Hundredths Rounded value
0, 1, 2, 3, 4 0
5, 6, 7, 8, 9 10
In the example above, the calculated final drivepinion gear shim thickness is 0.51 mm. Thechart instructs you to round off the 1 to 0. Thus,you should use a 0.50 mm final drive pinion gearshim.c. To find ring gear shim thickness “B”, use the
following formula:
Ring gear shim thicknessB = c + d – [(35.40 + e /100) + f ]
Where:c = a numeral on the final drive housing.d = a numeral usually on the outside of the ringgear bearing housing.e = a numeral (positive or negative) on the in-side of the ring gear, to be divided by 100 andadded to “35.40”.
6-85
SHAFT DRIVE CHAS
Ring gear shim
Thickness (mm) 0.30, 0.40, 0.50
115Nm (11.5 mkg)
CAUTION:
f = the ring gear bearing thickness constant
Ring gear bearing thickness“ f ”13.00 mm
Example:If the final drive housing is marked “45.51” thering gear bearing housing is marked “3.35” thering gear is marked “-05”, and “f” is 13.00:B = 45.51 + 3.35 – [(35.40 – 5/100) + 13]
= 45.51 + 3.35 – [(35.40 – 0.05) + 13]= 48.86 – [35.35 + 13]= 48.86 – 48.35= 0.51
Therefore, the calculated ring gear shim thick-ness is 0.51 mm.Shim sizes are supplied in the following thick-ness.
Since the ring gear shims are only available in0.10 mm increments, round off the hundredthsdigit.
Hundredths Rounded value
0, 1, 2, 3, 4 0
5, 6, 7, 8, 9 10
In the example above, the calculated final gearshim thickness is 0.51 mm. The chart instructsyou to round off the 1 to 0. Thus, you should usea 0.50 mm ring gear shim.
2. Install:shim(s) (as calculated) final drive pinion gearbearing retainer(with the bearing retainer wrench)
The bearing retainer has left-hand threads.To tighten the bearing retainer, turn it coun-terclockwise.
SHAFT DRIVE CHAS
6-86
130 Nm (13.0 mkg)
CAUTION:
NOTE:
Bearing retainer wrench90890-04077
3. Install:gear couplingself-locking nut(with the special tool 1 )
Coupling gear/middle shaft tool90890-01229
Apply LOCTITE to the self-locking nut.
4. Install: ring gear bearing housing(along with the ring gear, but without thethrust washer)
5. Adjust: ring gear backlashRefer to “MEASURING THE RING GEARBACKLASH” and “ADJUSTING THE RINGGEAR BACKLASH”.
6. Measure: ring-gear-to-thrust-washer clearance
a. Remove the ring gear bearing housing(along with the ring gear).
b. Place four pieces of Plastigauge betweenthe original thrust washer and the ring gear.
c. Install the ring gear bearing housing andtighten the bolts, and nuts to specification.
Ring gear bearing housing bolt(M10)
40 Nm (4.0 mkg)Ring gear bearing housingnut (M8)
23 Nm (2.3 mkg)
Do not turn the final drive pinion gear and ringgear while measuring the ring-gear-to-thrust-washer clearance with Plastigauge .
d. Remove the ring gear bearing housing.e. Measure the width of the flattened Plasti-
gauge 1 .
Ring-gear-to-thrust-washerclearance
0.2 mm
f. If the ring-gear-to-thrust-washer clearance iswithin specification, install the ring gear bear-ing housing (along with the ring gear).
6-87
SHAFT DRIVE CHAS
Thrust washer
Thickness (mm) 1.2, 1.4, 1.6, 1.8, 2.0
g. If the ring-gear-to-thrust-washer clearance isout of specification, select the correct thrustwasher as follows.
h. Select the suitable thrust washer from the fol-lowing chart.
i. Repeat the measurement steps until thering-gear-to-thrust-washer clearance is with-in the specified limits.
Ring-gear-to-thrust-washerclearance
0.2 mm
EAS00727
CHECKING THE DRIVE SHAFT1. Check:drive shaft splinesDamage/wear Replace the drive shaft.
EAS00728
INSTALLING THE DRIVE SHAFT1. Lubricate:drive shaft splines
Recommended lubricantMolybdenum disulfide grease
2. Apply:sealant(onto both final drive housing mating sur-faces)
Yamaha bond No. 121590890-85505
3. Install:drive shaft(to the final drive pinion gear)
6-88
SHAFT DRIVE CHAS
42 Nm (4.3 mkg)
4. Tighten: final bearing housing nuts
5. Install: rear wheel assemblyRefer to “REAR WHEEL AND BRAKEDISC”.
ELEC
7– +
ELEC
CHAPTER 7ELECTRICAL
ELECTRICAL COMPONENTS 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWITCHES 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING SWITCH CONTINUITY 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SWITCHES 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BULBS AND BULB SOCKETS 7-5. . . . . . . . . . . . . . . . . . TYPES OF BULBS 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CONDITION OF THE BULBS 7-5. . . . . . . . . . . . . . . . . CHECKING THE CONDITION OF THE BULB SOCKETS 7-7. . . . . . . .
IGNITION SYSTEM 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRIC STARTING SYSTEM 7-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 7-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING CIRCUIT OPERATION 7-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER MOTOR 7-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING SYSTEM 7-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 7-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHTING SYSTEM 7-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 7-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE LIGHTING SYSTEM 7-28. . . . . . . . . . . . . . . . . . . . . . . . .
SIGNAL SYSTEM 7-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 7-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SIGNALING SYSTEM 7-34. . . . . . . . . . . . . . . . . . . . . . .
FUEL PUMP SYSTEM 7-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 7-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL PUMP CIRCUIT OPERATION 7-40. . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL PUMP TEST 7-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELEC
CARBURETOR HEATER SYSTEM 7-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 7-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SELF-DIAGNOSIS 7-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
ELECTRICAL COMPONENTS ELEC
1 Main switch2 Thermo switch3 Flasher relay4 Starting circuit cut off relay5 Ignition coil6 Starter relay7 Fuse8 Igniter unit
9 Side stand switch10 Neutral switch11 Rectifier / regulator12 Oil lamp relay13 Battery14 Rear brake switch15 Horn
EB800000
ELECTRICALELECTRICAL COMPONENTS
7-2
B
B
SWITCHES ELEC
CAUTION:
NOTE:
NOTE:
EAS0010
SWITCHESCHECKING SWITCH CONTINUITYCheck each switch for continuity with the pockettester. If the continuity reading is incorrect,check the wiring connections and if necessary,replace the switch.
Never insert the tester probes into the cou-pler terminal slots 1 . Always insert theprobes from the opposite end of the coupler,taking care not to loosen or damage theleads.
Pocket tester90890-03112
Before checking for continuity, set the pockettester to “0” and to the “Ω 1” range.
When checking for continuity, switch back andforth between the switch positions a few times.
The terminal connections for switches (e.g.,main switch, engine stop switch) are shown inan illustration similar to the one on the left.The switch positions a are shown in the far leftcolumn and the switch lead colors b are shownin the top row in the switch illustration.
“ ” indicates a continuity of electricitybetween switch terminals (i.e., a closed circuitat the respective switch position).
The example illustration on the left showsthat:There is continuity between blue/red and redwhen the switch is set to “ ”.There is continuity between blue/red and blue,between brown/blue and red, and betweenblue/yellow and black when the switch is set to“ON”.
7-3
*1
*2
CHECKING THE SWITCHES ELEC
EAS00731
CHECKING THE SWITCHESCheck each switch for damage or wear, proper connections, and also for continuity between the termi-nals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage/wear Repair or replace the switch.Improperly connected Properly connect.Incorrect continuity reading Replace the switch.
7-4
9 Engine stop switch10 Start switch11 Fuse12 Rear brake switch13 Sidestand switch14 Neutral switch*1: for Europe*2: for AUS
1 Clutch switch2 Pass switch3 Horn switch4 Dimmer switch5 Turn switch6 Main switch7 Front brake switch8 Lights switch (for Europe)
CECKING THE SWITCHES ELEC
7-5
CHECKING THE BULBS AND BULB SOCKETS ELEC
EAS00732
CHECKING THE BULBS ANDBULB SOCKETSCheck each bulb and bulb socket for damage orwear, proper connections, and also for continu-ity between the terminals.Damage/wear Repair or replace the bulb,bulb socket or both.Improperly connected Properly connect.Incorrect continuity reading Repair or replacethe bulb, bulb socket or both.
TYPES OF BULBSThe bulbs used on this motorcycle are shown inthe illustration on the left.Bulbs A and B are used for headlights andusually use a bulb holder which must be de-tached before removing the bulb. The majorityof these bulbs can be removed from their re-spective socket by turning them counterclock-wise.
Bulb C is used for turn signal and tail /brakelights and can be removed from the socket bypushing and turning the bulb counterclock-wise.
Bulbs D and E are used for meter and indica-tor lights and can be removed from their re-spective socket by turn D and pulling E themout.
CHECKING THE CONDITION OF THEBULBSThe following procedure applies to all of thebulbs.1. Remove:bulb
CHECKING THE BULBS AND BULB SOCKETS ELEC
7-6
WARNING
CAUTION:
NOTE:
Since the headlight bulb gets extremely hot,keep flammable products and your handsaway from the bulb until it has cooled down.
Be sure to hold the socket firmly when re-moving the bulb. Never pull the lead, other-wise it may be pulled out of the terminal inthe coupler.
Avoid touching the glass part of the head-light bulb to keep it free from oil, otherwisethe transparency of the glass, the life of thebulb and the luminous flux will be adverse-ly affected. If the headlight bulb gets soiled,thoroughly clean it with a cloth moistenedwith alcohol or lacquer thinner.
2. Check:bult (for continuity)(with the pocket tester)No continuity Replace.
Pocket tester90890-03112
Before checking for continuity, set the pockettester to “0” and to the “Ω 1” range.
a. Connect the tester positive probe to terminal1 and the tester negative probe to terminal2 , and check the continuity.
b. Connect the tester positive probe to terminal1 and the tester negative probe to terminal3 , and check the continuity.
c. If either of the readings indicate no continuity,replace the bulb.
7-7
CHECKING THE BULBS AND BULB SOCKETS ELEC
NOTE:
CHECKING THE CONDITION OF THE BULBSOCKETSThe following procedure applies to all of the bulbsockets.1. Check:bulb socket (for continuity)(with the pocket tester)No continuity Replace.
Pocket tester90890-03112
Check each bulb socket for continuity in thesame manner as described in the bulb section;however, note the following.
a. Install a good bulb into the bulb socket.b. Connect the pocket tester probes to the re-
spective leads of the bulb socket.c. Check the bulb socket for continuity.
If any of the readings indicate no continuity,replace the bulb socket.
7-8
1 4 5 6 7 8 13 16 17 18 29
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IGNITION SYSTEM ELEC
EB802000
IGNITION SYSTEMCIRCUIT DIAGRAM
7-9
IGNITION SYSTEM ELEC
2. Battery
Check the condition of the battery.Refer to “CHECKING AND CHARGINGTHE BATTERY” in chapter 3.
Min. open-circuit voltage12.8 V or more at 20 C
Is the battery OK?
YES NO
3. Spark plugs
The following procedure applies to all of thespark plugs.Check the condition of the spark plug.Check the spark plug type.Measure the spark plug gap.Refer to “CHECKING THE SPARK PLUGS”in chapter 3.
Standard spark plugBPR7ESW22EPR-U
Spark plug gap0.7 0.8 mm
Is the spark plug in good condition, is it of thecorrect type, and its gap within specifica-tion?
YES
Re-gap or replacethe spark plug.
NO
Clean the batteryterminals.
Recharge or re-place the battery.
EAS00741
NOTE:
YES NO
Replace the fuse(-s).
1. Main and ignition fuses
Check the main and ignition fuses for conti-nuity.Refer to “CHECKING THE FUSES” in chap-ter 3.
Are the main and ignition fuses OK?
EAS00737 EAS00739
TROUBLESHOOTING
The ignition system fails to operate (nospark or intermittent spark).
Check:1. main and ignition fuses2. battery3. spark plugs4. ignition spark gap5. spark plug cap resistance6. ignition coil resistance7. pickup coil resistance8. main switch9. engine stop switch
10. neutral switch11. sidestand switch12. diode13. starting circuit cut-off relay (diode)14. wiring
(of the entire ignition system)
Before troubleshooting, remove the followingpart(-s):
1) battery cover2) rider’s seat3) fuel tank4) steering head side covers5) tool box cover6) left side cover7) cylinder head coversTroubleshoot with the following specialtool(-s).
Ignition checker90890-06754
Pocket tester90890-03112
EAS00738
7-10
4. Ignition spark gap
The following procedure applies to all of thespark plugs.Disconnect the spark plug cap from thespark plug.
Connect the ignition checker as shown. Spark plug capSet the main switch to “ON”.Measure the ignition spark gap .Crank the engine by pushing the start switchand gradually increase the spark gap until amisfire occurs.
Min. ignition spark gap6 mm
Is there a spark and is the spark gap withinspecification ?
NO
The ignition systemis OK.
YES
EAS00745
5. Spark plug cap resistance.
The following procedure applies to all of thespark plug caps.Disconnect the spark plug cap from thespark plug.
Connect the pocket tester (Ω 1k) to thespark plug cap as shown.
Measure the spark plug cap resistance.
Spark plug cap resistance10 kΩ at 20 C
Is the spark plug cap OK?
YES
Replace the sparkplug cap.
NO
EAS00747
Tester positive probe spark plug lead
Tester negative probe Orange (gray) lead
1
1
2
a
2
6. Ignition coil resistance
The following procedure applies to all of theignition coils.Disconnect the ignition coil connectors fromthe ignition coil terminals.
Connect the pocket tester (Ω 1) to theignition coil as shwon.
Tester positive probe red/blackTester negative probe orange (gray)
Measure the primary coil resistance.
Primary coil resistance3.57 4.83 Ω at 20C
Connect the pocket tester (Ω 1k) to theignition coil as shown.
Measure the secondary coil resistance.
IGNITION SYSTEM ELEC
EAS00743
7-11
IGNITION SYSTEM ELEC
Secondary coil resistance10.7 14.5 kΩ 20 C
Is the ignition coil OK?
YES
Replace the ignitioncoil.
NO
EAS00748
7. Pickup coil resistance
Disconnect the pickup coil coupler from thewire harness.
Connect the pocket tester (Ω 100) to thepickup coil terminal.
Pickup coil resistance189 231 Ω at 20 C(between gray and black/blue)
Is the pickup coil OK?
YES
Replace the pickupcoil.
NO
Tester positive probe grayTester negative probe black/blue
12
Measure the pickup coil resistance.
EAS00749
Check the main switch for continuity.Refer to “CHECKING THE SWITCHES”.
Is the main switch OK?
YES
Replace the mainswitch.
NO
8. Main switch
EAS00750
Check the engine stop switch for continuity.Refer to “CHECKING THE SWITCHES”.
Is the engine stop switch OK?
YES
Replace the righthandlebar switch.
NO
9. Engine stop switch
EAS00751
Check the neutral switch for continuity.Refer to “CHECKING THE SWITCHES”.
Is the neutral switch OK?
YES
Replace the neutralswitch.
NO
10. Neutral switch
EAS00752
Check the sidestand switch for continuity.Refer to “CHECKING THE SWITCHES”.
Is the sidestand switch OK?
YES
Replace the side-stand switch.
NO
11. Sidestand switch
7-12
IGNITION SYSTEM ELEC
12. Diode
Remove the diode from the wire harness.Check for continuity as follows:
14. Wiring
Check the entire ignition system’s wiring.Refer to “CIRCUIT DIAGRAM”.
Is the ignition system’s wiring properly con-nected and without defects?
EAS00754
Tester (+) lead Blue/White
Tester (–) lead Blue/Yellow
1
2
Tester (+) lead Blue/Yellow
Tester (–) lead Blue/White
2
1
Continu-ity
No Con-tinuity
YES
Replace the diode.
NO
NOTE:When you switch the “–” and “+” leads of thedigital pocket tester the readings in the abovechart will be reversed.
Is the diode OK?
YES
Properly connect orrepair the ignitionsystem’s wiring.
NO
Replace the ignitorunit.
13. Starting circuit cut-off relay (diode)
Remove the relay unit from the wire har-ness.
Check for continuity as follows:Sky blue – Blue/Yellow 2
Tester (+) lead SKy blue Tester (–) lead
Blue/Yellow
1
2
Tester (+) lead Blue/Yellow
Tester (–) lead Sky blue2
1
Continu-ity
No Con-tinuity
YES
Replace the startingcircuit cut-off relay.
NO
NOTE:When you switch the “–” and “+” leads of thedigital pocket tester the readings in the abovechart will be reversed.
Is the starting circuit cut-off relay (diode)OK?
7-13
4 5 6 7 8 9 10 13 20 29 37
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ELECTRIC STARTING SYSTEM ELEC
EB803000
ELECTRIC STARTING SYSTEMCIRCUIT DIAGRAM
7-14
ELECTRIC STARTING SYSTEM ELEC
EB803010
STARTING CIRCUIT OPERATIONThe starting circuit on this model consists of thestarter motor, starter relay, and the starting cir-cuit cut-off relay. If the engine stop switch is on“RUN” and the main switch is on “ON” (bothswitches are closed), the starter motor can op-erate only if:
The transmission is in neutral (the neutralswitch is closed).
or ifThe clutch lever is pulled to the handlebar(the clutch switch is closed) and the side-stand is up (the sidestand switch is closed).
The starting circuit cut-off relay prevents thestarter from operating when neither of theseconditions have been met. In this instance, thestarting circuit cut-off relay is open so currentcannot reach the starter motor.
When at least one of the above conditions havebeen met however, the starting circuit cut-offrelay is closed, and the engine can be started bypressing the starter switch.
WHEN THE TRANSMISSION IS INNEUTRAL
WHEN THE SIDESTAND IS UP ANDTHE CLUTCH LEVER IS PULLED IN
1 Battery
2 Main fuse
3 Main switch
4 Ignition fuse
5 Engine stop switch
6 Starting circuit cut-off relay
7 Diode
8 Clutch switch
9 Sidestand switch
10 Neutral switch
11 Start switch
12 Starter relay
13 Starter motor
7-15
ELECTRIC STARTING SYSTEM ELEC
2. Battery
Check the condition of the battery.Refer to “CHECKING AND CHARGINGTHE BATTERY” in chapter 3.
Open-circuit voltage12.8 V or more at 20 C
Is the battery OK?
YES
Clean the batteryterminals.
Recharge or re-place the battery.
NO
3. Starter motor
Connect the battery positive terminal and starter motor lead with a jumper lead
.
YES
Repair or replace thestarter motor.
NO
EAS00758
1
32
A wire that is used as a jumper leadmust have at least the same capacity ofthe battery lead, otherwise the jumperlead may burn.
This check is likely to produce sparks,therefore make sure that no flammablegas or fluid is in the vicinity.
Does the starter motor turn?
WARNING
NOTE:
YES NO
Replace the fuse(-s).
1. Main and ignition fuses
Check the main and ignition fuses for conti-nuity.Refer to “CHECKING THE FUSES” in chap-ter 3.
Are the main and ignition fuses OK?
EAS00757 EAS00739
TROUBLESHOOTING
The starter motor fails to turn.
Check:1. main and ignition fuses2. battery3. starter motor4. starting circuit cutoff relay5. starting circuit cutoff relay (diode)6. starter relay7. main switch8. engine stop switch9. neutral switch
10. sidestand switch11. clutch switch12. start switch13. diode14. wiring
(of the entire starting system)
Before troubleshooting, remove the followingpart(-s):
1) battery cover2) rider’s seat3) fuel tank4) steering head side covers5) left side coverTroubleshoot with the following specialtool(-s).
Pocket tester90890-03112
EAS00738
7-16
4. Starting circuit cutoff relay
Disconnect the relay unit from the coupler.Connect the pocket tester (Ω 1) and bat-tery (12V) to the relay unit terminals asshown.
YES
Replace the relayunit.
NO
Battery positive terminal red/black
Battery negative terminal black/yellow
1
2
Tester positive probe blue Tester negative probe black
34
Does the starting circuit cutoff relay havecontinuity between black and blue/white?
5. Starting circuit cutoff relay (Diode)
Disconnect the starting circuit cutoff relayfrom the coupler.
Connect the pocket tester (Ω 1) to thestarting circuit cutoff relay terminals asshown.
Measure the starting circuit cutoff relay forcontinuity as follows.
YES
Replace the relayunit.
NO
Tester positive probe sky blue
Tester negative probe
black/yellow
1
2
Continuity
NOTE:When you switch the “–” and “+” leads of thedigital pocket tester the readings in the abovechart will be reversed.
Are the tester readings correct?
EAS00760
Tester positive probe
black/yellowTester negative probe
sky blue
2
1
Nocontinuity
ELECTRIC STARTING SYSTEM ELEC
EAS00759
7-17
YES
Replace the starterrelay.
NO
Battery positive terminal red/whiteBattery negative terminal blue 2
EAS00750
Check the engine stop switch for continuity.Refer to “CHECKING THE SWITCHES”.
Is the engine stop switch OK?
YES
Replace the righthandlebar switch.
NO
8. Engine stop switch
EAS00751
Check the neutral switch for continuity.Refer to “CHECKING THE SWITCHES”.
Is the neutral switch OK?
YES
Replace the neutralswitch.
NO
9. Neutral switch
EAS00752
Check the sidestand switch for continuity.Refer to “CHECKING THE SWITCHES”.
Is the sidestand switch OK?
YES
Replace the side-stand switch.
NO
10. Sidestand switch
EAS00763
Check the clutch switch for continuity.Refer to “CHECKING THE SWITCHES”.
Is the clutch switch OK?
YES
Replace the clutchswitch.
NO
11. Clutch switch
1
Tester positive probe red Tester negative probe black
34
Does the starter relay have continuity be-tween red and black?
EAS00749
Check the main switch for continuity.Refer to “CHECKING THE SWITCHES”.
Is the main switch OK?
YES
Replace the mainswitch.
NO
7. Main switch
6. Starter relay
Disconnect the starter relay from the cou-pler.
Connect the pocket tester (Ω 1) and bat-tery (12 V) to the starter relay coupler asshown.
ELECTRIC STARTING SYSTEM ELEC
EAS00761
7-18
EAS00766
NO
The starting systemcircuit is OK.
YES
YES
Replace the righthandlebar switch.
NO
Properly connect orrepair the startingsystem’s wiring.
12. Start switch
Check the start switch for continuity.Refer to “CHECKING THE SWITCHES”.
Is the start switch OK?
14. Wiring
Check the entire starting system’s wiring.Refer to “CIRCUIT DIAGRAM”.
Is the starting system’s wiring properly con-nected and without defects?
YES
Replace the diode.
NO
13. Diode
Check the diode for continuity.Refer to “IGNITION SYSTEM”.
Is the diode OK?
ELECTRIC STARTING SYSTEM ELEC
EAS00764
12
1234567891011
Order Job name/Part name Q’ty Remarks
Removing the starter motorStarter motor leadStarter motor assembly
Disassembling the starter motorCirclipStarter motor drive gearStarter motor rear coverWasher setStarter motor front coverWasher setEnd bracketPlanetary gearsArmature assemblyBrush holder/brushStarter motor yoke
11
111111121
1/11
Remove the parts in the order listed.
For installation, reverse the removalprocedure.
Disassembly the pats in the order listed.
Refer to “Assembling the starter motor.”
Refer to “Assembling the starter motor.”
Refer to “Assembling the starter motor.”
For assembly, reverse the disassemblyprocedure
10 Nm (1.0 mkg)
Refer to “Assembling the starter motor.”
ELECTRIC STARTING SYSTEM ELEC
7-19
STARTER MOTOR
7-20
ELECTRIC STARTING SYSTEM ELEC
NOTE:
EAS00769
Checking the starter motor1. Check:commutatorDirt Clean with 600 grit sandpaper.
2. Measure:commutator diameter aOut of specification Replace the startermotor.
Min. commutator diameter27 mm
3. Measure:mica undercut aOut of specification Scrape the mica to theproper measurement with a hacksaw bladewhich has been grounded to fit the commuta-tor.
Mica undercut0.7 mm
The mica must be undercut to ensure proper op-eration of the commutator.
4. Measure:armature assembly resistances (commuta-tor and insulation)Out of specification Replace the startermotor.
a. Measure the armature assembly resis-tances with the pocket tester.
Pocket tester90890-03112
Armature assemblyArmature coil resistance 1
0.026 0.034 Ω at 20 CInsulation resistance 2
Above 1 M Ω at 20 C
b. If any resistance is out of specification, re-place the starter motor.
7-21
ELECTRIC STARTING SYSTEM ELEC
NOTE:
NOTE:
5. Measure:brush length aOut of specification Replace the brushesas a set.
Min. brush length5 mm
6. Measure:brush spring forceOut of specification Replace the brushsprings as a set.
Bruch spring force7.65 10.01 N (780 1.020 g)
7. Check:gear teethDamage/wear Replace the gear.
8. Check:oil sealDamage/wear Replace the defectivepart(-s).
EAS00772
Assembling the starter motor1. Install:brush holder 1
Align the tab a on the brush holder with the slotin the starter motor rear cover.
2. Install:starter motor yoke 1end bracket 2starter motor front cover 3
Align the projection a on the front cover with theslot b on the end cover and starter motor yoke.
7-22
ELECTRIC STARTING SYSTEM ELEC
NOTE:
3. Install:Starter motor rear cover 1
Align the match marks a on the rear cover withthe match marks b on the front cover.
7-23
CHARGING SYSTEM ELEC
AC magneto (stator coil)Rectifier / regulatorBatteryMain fuse
2378
EB804000
CHARGING SYSTEMCIRCUIT DIAGRAM
CHARGING SYSTEM ELEC
2. Battery
Check the condition of the battery.Refer to “CHECKING AND CHARGING THEBATTERY” in chapter 3.
Open-circuit voltage12.8 V or more at 20 C
Is the battery OK
YES
Clean the batteryterminals.
Recharge or re-place the battery.
NO
EAS00775
3. Charging voltage
Connect the engine tachometer to the sparkplug lead of cylinder #1.
Connect the pocket tester (DC 20 V) to thebattery as shown.
Charging voltage14 V at 5,000 r/min
Tester positive probe
battery positive terminalTester negative probe
battery negative terminal
Start the engine and let it run at approximate-ly 5,000 r/min.
Measure the charging voltage.
7-24
NOTE:
YES NO
Replace the fuse.
1. Main fuse
Check the main fuse for continuity.Refer to “CHECKING THE FUSES” in chap-ter 3.
Is the main fuse OK?
EAS00774 EAS00739
TROUBLESHOOTING
The battery is not being sharged.
Check:1. main fuses2. battery3. charging voltage4. startor coil assembly resistance5. wiring
(of the entire charging system)
Before troubleshooting, remove the followingpart(-s):
1) battery cover2) rider’s seat3) left side coverTroubleshoot with the following specialtool(-s).
Engine tachometer90890-03113
Pocket tester90890-03112
EAS00738
7-25
NO
The charging circuitis OK.
YES
NOTE:Make sure that the battery is fully charged.
Is the charging voltage within specification?
EAS00776
4. Stator coil assembly resistances
Remove the generator cover.Connect the pocket tester (Ω 1) to the sta-tor coil assembly coupler as shown.
Stator coil resistance0.36 0.44 Ω at 20C
Is the stator coil assembly OK?
YES
Replace the statorcoil assembly.
NO
Tester positive probe White Tester negative probe white
12
Measure the stator coil assembly resis-tances.
Tester positive probe white Tester negative probe white
13
5. Wiring
NO
Replace the rectifi-er/regulator.
YES
EAS00779
Check the wiring connections of the entirecharging system.Refer to “CIRCUIT DIAGRAM”.
Is the charging system’s wiring properly con-ected and without defects?
Properly connect orrepair the chargingsystem’s wiring.
CHARGING SYSTEM ELEC
LIGHTING SYSTEM ELEC
7-26
49464 7 8 25 27 4844 50 52
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fuse
Ligh
t sw
itch
39
EB805000
LIGHTING SYSTEMCIRCUIT DIAGRAM
7-27
LIGHTING SYSTEM ELEC
Open-circuit voltage12.8 V or more at 20 C
YES
Replace the fuse(-s).
NO
YES
Clean the batteryterminals.
Recharge or re-place the battery.
NO
Replace the mainswitch.
NO
EAS00749
3. Main switch
Check the main switch for continuity.Refer to “CHECKING THE SWITCHES”.
Is the main switch OK?
YES
1. Main, and headlight fuses
Check the main, and headlight fuses for con-tinuity.Refer to “CHECKING THE FUSES” in chap-ter 3.
Are the main, and headlight fuses OK?
2. Battery
Check the condition of the battery.Refer to “CHECKING AND CHARGINGTHE BATTERY” in chapter 3.
Is the battery OK?
NO
EAS00783
4. Lights switch (for Europe)
Check the lights switch for continuity.Refer to “CHECKING THE SWITCHES”.
Is the lights switch OK?
YES
The lights switch isfaulty. Replace theright handlebarswitch.
NOTE:
EAS00781 EAS00739
TROUBLESHOOTING
Any of the following fail to light: headlight,high beam indicator light, taillight, auxilia-ry light (for Europe) or meter light.
Check:1. main and headlight fuses2. battery3. main switch4. lights switch (for Europe)5. dimmer switch6. pass switch7. wiring
(of the entire charging system)
Before troubleshooting, remove the followingpart(-s).
1) battery cover2) rider’s seat3) fuel tank4) steering head side covers5) headlight lens unit6) tool box coverTroubleshoot with the following specialtool(-s).
Pocket tester90890-03112
EAS00738
7-28
Y
G
Check the dimmer switch for continuity.Refer to “CHECKING THE SWITCHES”.
Is the dimmer switch OK?
YES
The dimmer switch isfaulty. Replace theleft handlebar switch.
NO
5. Dimmer switch
EAS00786
Check the pass switch for continuity.Refer to “CHECKING THE SWITCHES”.
Is the pass switch OK?
YES
The pass switch isfaulty. Replace theleft hadlebar switch.
NO
6. Pass switch
EAS00787
Check the entire lighting system’s wiring.Refer to “CIRCUIT DIAGRAM”.
Is the lighting system’s wiring properly con-nected and without defects?
YES
Properly connect orrepair the lighting sys-tem’s wiring.
NO
7. Wiring
Check the conditionof each of the lightingsystem’s circuits.Refer to “CHECKINGTHE LIGHTING SYS-TEM”.
Check the headlight bulb and socket for con-tinuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.
Are the headlight bulb and socket OK?
YES
Replace the head-light bulb, socket orboth.
NO
1. Headlight bulb and socket
2. Voltage
Connect the pocket tester (DC 20 V) to theheadlight and high beam indicator light cou-plers as shown.
When the dimmer switch is set to “ ”When the dimmer switch is set to “ ”
AB
Headlight coupler (wire harness side)
EAS00788
CHECKING THE LIGHTING SYSTEM1. The headlight and the high beam indicator
light fail to came on.
HeadlightTester positive probe
yellow or green Tester negative probe black
High beam indicator lightTester positive probe yellow Tester negative probe brack
1 23
45
LIGHTING SYSTEM ELEC
EAS00784
7-29
Set the main switch to “ON”.Set the light switch to “ ”.Set the dimmer switch to “ ” or “ ”.Measure the voltage (12 V) of yellow orgreen on the headlight coupler (headlightside).
Measure the voltage (12V) of yellow on themeter assembly coupler.
Is the voltage within specification?
2
YES
Replace the meterlight bulb, socket orboth.
NO
EAS00789
2. A meter light fails to come on.
1. Meter light bulb and socket.
Check the meter light bulb and socket forcontinuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.
Are the meter light bulb and socket OK?
The wiring circuitfrom the main switchto the headlight cou-pler is faulty and mustbe repaired.
NO
YES
2. Voltage
Connect the pocket tester (20 V) to the meterassembly coupler (wire harness side) asshown.
Tester positive probe blue Tester negative probe black
12
This circuit is OK.
Replace the tail /brake lightbulb, sock-et or both.
NO
YES
The wiring circuitfrom the main switchto the meter assem-bly coupler is faultyand must be re-paired.
NO
This circuit is OK.
EAS00790
3. A tail /brake light fails to come on.
1. Tail /brake light bulb and socket
Check the tail /brake light bulb and socket forcontinuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.
Are the tail /brake light bulb and socket OK?
YES
Set the main switch to “ON”.Set the light switch to “ ” or “ ”.Measure the voltage (12 V) of blue on themeter assembly coupler (wire harness side).
Is the voltage within specification?
1
B
1
4
LIGHTING SYSTEM ELEC
7-30
2. Voltage
Connect the pocket tester (DC 20 V) to thetail /brake light coupler (wire harness side) asshown.
Tester positive probe blue Tester negative probe black
12
YES
The wiring circuitfrom the main switchto the tail /brake lightcoupler is faulty andmust be repaired.
NO
This circuit is OK.
Set the main switch to “ON”Set the light switch to “ ” or “ ”.Measure the voltage (12 V) of blue/red onthe tail /brake light coupler (wire harnessside).
Is the voltage within specification?
1
Replace the auxiliarylight bulb, socket orboth.
NO
EB05413
4. The auxiliary light fails to come on. (for Eu-rope)
1. Auxiliary light bulb and socket
Check the auxiliary light bulb and socket forcontinuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.
Are the auxiliary light bulb and socket OK?
YES
2. Voltage
Connect the pocket tester (DC 20 V) to theauxiliary light couplers (wire harness side) asshown.
Tester positive probe blue/red Tester negative probe black
12
YES
The wiring circuitfrom the main switchto the auxiliary lightconnectors is faultyand must be re-paired.
NO
This circuit is OK.
Set the main switch to “ON”Set the light switch to “ ” or “ ”.Measure the voltage (12 V) of blue/red onthe auxiliary light couplers (wire harnessside).
Is the voltage within specification?
1
LIGHTING SYSTEM ELEC
7-31
SIGNAL SYSTEM ELEC
EB806000
SIGNAL SYSTEMCIRCUIT DIAGRAM
7-32
SIGNAL SYSTEM ELEC
4 Main switch
6 Ignition fuse
7 Battery
8 Main fuse
11 Oil level gauge
12 Oil lamp relay
20 Neutral switch
22 Oil warning light
24 Turn signal indicator light
26 Neutral indicator light
30 Flasher relay
31 Turn signal switch
32 Rear turn signal light (R)
33 Rear turn signal light (L)
34 Front turn signal light (R)
35 Front turn signal light (L)
40 Front brake switch
42 Horn
43 Horn switch
45 Rear brake switch
50 Tail /brake light
53 Signal fuse
7-33
SIGNALING SYSTEM ELEC
Open-circuit voltage12.8 V or more at 20 C
YES
Replace the fuse(-s).
NO
YES
Clean the batteryterminals.
Recharge or re-place the battery.
NO
Replace the mainswitch.
NO
EAS00749
3. Main switch
Check the main switch for continuity.Refer to “CHECKING THE SWITCHES”.
Is the main switch OK?
YES
1. Main, ignition and signaling system fuses
Check the main ignition and signaling sys-tem fuses for continuity.Refer to “CHECKING AND CHARGINGTHE FUSES” in chapter 3.
Are the main ignition and signaling systemfuses OK?
2. Battery
Check the condition of the battery.Refer to “CHECKING THE BATTERY” inchapter 3.
Is the battery OK?
NO
EAS00795
4. Wiring
Check the entire signaling system’s wiring.Refer to “CIRCUIT DIAGRAM”.
Is the signaling system’s wiring properly con-nected and without defects?
YES
Properly connect orrepair the signalingsystem’s wring.
Check the conditionof each of the signal-ing system’s circuits.Refer to “CHECKINGTHE SIGNALINGSYSTEM”.
NOTE:
EB806010 EAS00739
TROUBLESHOOTING
Any of the following fail to light: turn sig-nal light, brake light or an indicator light.
The forn fails to sound.
Check:1. main and signaling system fuses2. battery3. main switch4. wiring
(of the entrire signaling system)
Before troubleshooting, remove the followingpart(-s):
1) battery cover2) rider’s seat3) fuel tank4) steering head side covers5) headlight lens unit6) tool box cover7) left side coverTroubleshoot with the following specialtool(-s).
Pocket tester90890-03112
EAS00738
7-34
SIGNALING SYSTEM ELEC
Replace the left han-dlebar switch.
NO
1. Horn switch
Check the forn switch for continuity.Refer to “CHECKING THE SWITCHES”.
Is the horn switch OK?
YES
2. Voltage
Connect the pocket tester (DC 20 V) to thehorn connecter at the horn terminal asshown.
Tester positive probe brown Tester negative probe ground
1The horn is OK.
YES
3. Horn
Disconnect the black connector at the hornterminal.
Connect a jumper lead to the horn terminaland ground the jumper lead.
Set the main switch to “ON”.Does the horn sound?
NO
4. Voltage
Connect the pocket tester (DC 20 V) to thehorn connecter at the black terminal asshown.
Tester positive probe black Tester negative probe ground
1
Set the main switch to “ON”.Measure the voltage (12 V) of brown at thehorn terminal.
Is the voltage within specification?
The wiring circuitfrom the main switchto the horn connecteris faulty and must berepaired.
NOYES
Set the main switch to “ON”.Measure the voltage (12 V) of black at thehorn terminal.
Is the voltage within specification?
1
NOYES
Replace the horn.Repair or replace thehorn.
1
Br P
Br
Br P
EAS00796
CHECKING THE SIGNALING SYSTEM1. The horn fails to sound.
7-35
SIGNALING SYSTEM ELEC
Replace the tail /brake lightbulb, sock-et or both.
NO
1. Tail /brake light bulb and socket
Check the tail /brake light bulb and socket forcontinuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.
Are the tail /brake light bulb and socket OK?
YES
3. Voltage
Connect the pocket tester (DC 20 V) to thetail /brake light coupler (wire harness side) asshown.
Tester positive probe yellow Tester negative probe black
1
Replace the brakelight switch.
NO
2. Brake light switches
Check the brake light switches for continuity.Refer to “CHECKING THE SWITCHES”.
Is the brake light switch OK?
YES
2
YES
The wiring circuitfrom the main switchto the tail /brake lightcoupler is faulty andmust bne repaired.
NO
This circuit is OK.
Set the main switch to “ON”.Pull in the brake lever or push down on thebrake pedal.
Measure the voltage (12 V) of yellow at thetail /brake light coupler (wire harness side).
Is the voltage within specification?
Replace the turn sig-nal light bulb, socketor both.
NO
EAS00799
3. A turn signal light, turn signal indicator lightor both fail to blink.
1. Turn signal light bulb and socket
Check the turn signal light bulb and socket forcontinuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.
Are the turn signal light bulb and socket OK?
YES
EAS00797
2. A tail /brake light fails to come on.
7-36
Turn signal lightTurn signal indicator light
Replace the left han-dlebar switch.
NO
2. Turn signal switch
Check the turn signal for continuity.Refer to “CHECKING THE SWITCHES”.
Is the turn signal switch OK?
YES
The wiring circuitfrom the main switchto the flasher relaycoupler (flasher relayside) is faulty andmust be repaired.
NO
3. Voltage
Connect the pocket tester (DC 20 V) to theflasher relay coupler (wire harness side) asshown.
YES
Tester positive prove brown Tester negative prove ground
1
Set the main switch to “ON”.Measure the voltage (12 V) of brown at theflasher relay coupler (wire harness side).
Is the voltage within specification?
1
4. Voltage
Connect the tester (DC 20 V) to the flasherrelay coupler (wire harness side) as shown.
The flasher relay isfaulty and must be re-placed.
NOYES
1
Set the main switch to “ON”.Set the turn signal switch to “ ” or “ ”.Measure the voltage (12 V) or brown/white atthe flasher relay coupler (wire harness side).
Is the voltage within specification?
Tester positive probe brown/white Tester negative probe ground
5. Voltage
Connect the pocket tester (DC 20 V) to the turnsignal light connectors or the meter assemblycoupler (wire harness side) as shown.
AB
Left turn signal lightTester positive probe chocolate Tester negative probe ground
Right turn signal lightTester positive probe daek green Tester negative probe ground
1
2
R/WR/W
A B
SIGNALING SYSTEM ELEC
7-37
Tester positive probe brown Tester negative probe sky blue
Replace the neutralindicator light bulb,socket or both.
NO
YES
The wiring circuitfrom the turn signalswitch to the turn sig-nal light connector isfaulty and must re-paired.
NO
This circuit is OK.
EAS00800
4. The neutral indicator light fails to come on.
1. Neutral indicator light bulb and socket
Check the neutral indicator light bulb andsocket for continuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.
Are the neutral indicator light bulb and socketOK?
YES
Set the main switch to “ON”.Set the turn signal switch to “ ” or “ ”.Measure the voltage (12 V) of chocolate ordark green at the turn signal light connec-tor (wire harness side).
Is the voltage within specification?
12
Replace the neutralswitch.
NO
2. Neutral switch
Check the neutral switch for continuity.Refer to “CHECKING THE SWITCHES”.
Is the neutral switch OK?
YES
3. Voltage
Connect the pockt tester (DC 20V) to the me-ter assembly coupler (wire harness side) asshwon.
12
YES
The wiring circuitfrom the main switchto the meter lightbulb coupler is faultyand must be re-paired.
NO
This circuit is OK.
Set the main switch to “ON”.Measure the voltage (12 V) of brown andsky blue at the meter assembly coupler.
Is the voltage with specification?
1
L/R
2
Replace the oil levelwarning light bulb,socket or both.
NO
EAS00802
5. The oil level warning light fails to come on.
1. Oil level warning light bulb and socket
Check the oil level warning light bulb andsocket for continuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”
Are the oil level warning light bulb and socketOK?
YES
SIGNALING SYSTEM ELEC
7-38
Set the main switch to “ON”.Measure the voltage (12 V) of brown andblack/red at the meter assembly coupler.
Is the voltage within specification?
Drain the engine oil and remove the oil levelswitch from the oil pan.
Check the oil level switch for continuity.Refer to “CHECKING THE SWITCHES”.
Is the oil level switch OK?
2. Oil level switch
YES
Replace the oil levelswitch.
NO
3. Oil lamp relay
Disconnect the oil lamp relay from the coupler.Connect the pocket tester (Ω 1) and bat-tery (12 V) to the oil lamp relay terminals asshown.
YES
Replace the oil lamprelay.
NO
Battery positive terminal red/white Battery negative terminal black/red
12
Tester positive probe black/white Tester negative probe black
34
Does the oil lamp relay have continuity be-tween red/blue and black?
4. Voltage
Connect the pocket tester (DC 20 V) to themeter assembly coupler (wire harness side)as shown.
Tester positive probe red/white Tester negative probe black/white
1
YES
The wiring circuitfrom the main switchto the meter assem-bly coupler is faultyand must be re-paired.
NO
This circuit is OK.
12
SINGNAL SYSTEM ELEC
7-39
FUEL PUMP SYSTEM ELEC
4 6 7 8 13 14 16 38
Mai
n sw
itch
Igni
tion
fuse
Bat
tery
Mai
n fu
seS
tart
ing
circ
uit c
utof
f rel
ayF
uel p
ump
Igni
tor
unit
Eng
ine
stop
sw
itch
EB808000
FUEL PUMP SYSTEMCIRCUIT DIAGRAM
7-40
FUEL PUMP SYSTEM ELEC
1 Battery2 Main fuse3 Main switch4 Ignition fuse5 Engine stop switch6 Ignitor unit7 Fuel pump relay8 Fuel pump
EB808010
FUEL PUMP CIRCUIT OPERATIONThe fuel pump circuit consists of the fuel pumprelay, fuel pump, engine stop switch and ignitorunit.The ignitor unit includes the control unit for thefuel pump.
7-41
FUEL PUMP SYSTEM ELEC
2. Battery
Check the condition of the battery.Refer to “CHECKING AND CHARGINGTHE BATTERY” in chapter 3.
Open-circuit voltage12.8 V or more at 20 C
Is the battery OK?
YES
Clean the batteryterminals.
Recharge or repla-ve the battery.
NO
EAS00749
Check the main switch for continuity.Refer to “CHECKING THE SWITCHES”.
Is the main switch OK?
YES
Replace the mainswitch.
NO
3. Main switch
EAS00750
Check the engine stop switch for continuity.Refer to “CHECKING THE SWITCHES”.
Is the engine stop switch OK?
YES
Replace the righthandlebar switch.
NO
4. Engine stop switch
NOTE:
YES NO
Replace the fuse(-s).
1. Main, and ignition fuses
Check the main, and ignition fuses for conti-nuity.Reger to “CHECKING THE FUSES” inchapter 3.
Are the main, and ignition fuses OK?
EAS00781 EAS00739
TROUBLESHOOTING
The fuel pump fails to operate.
Check:1. main, and ignition fuses2. battery3. main switch4. engine stop switch5. starting circuit cutoff relay (fuel pump relay)6. fuel pump7. wiring
(of the entire charging system)
Before troubleshooting, remove the followingpart (-s):
1) battery cover2) rider’s seat3) fuel tank4) tool box cover5) left side coverTroubleshoot with the following special tool(-s).
Pocket tester90890-03112
EAS00738
7-42
Tester (+) lead Blue/Black terminal Tester (–) lead Black terminal
YES
Replace the startingcircuit cutoff relay.
NO
Battery (+) terminal
Red/Black terminal Battery (–) terminal
Blue/Red terminal 2
1
Tester (+) lead Red/Black terminal Tester (–) lead Blue/Black terminal 3
1
Does the fuel pump relay have continuitybatween red/black and blue/black?
5. Starting circuit cutoff relay (fuel pump relay)
Remove the relay unit from the wire har-ness.
Connect the pocket tester (Ω 1) and bat-tery (12 V) to the relay unit terminals.
6. Fuel pump resistance
Disconnect the fuel pump coupler from thewire harness.
Connect the pocket tester (Ω 1) to the fuelpump coupler terminals.
Fuel pump resistance:1.6 2.2 Ω at 20C (68F)
Measure the fuel pump resistance.
Is the fuel pump OK?
YES
Replace the fuel pump.
NO
Check the entire fuel pump system’s wiring.Refer to “CIRCUIT DIAGRAM”.
Is the fuel pump system’s wiring properlyconnected and without defects?
NO
Replace the ignitorunit.
YES
7. Wiring
Properly connect orrepair the fuel pumpsystem’s wiring.
21
FUEL PUMP SYSTEM ELEC
EB803023 EB808021
7-43
FUEL PUMP SYSTEM ELEC
WARNING
EB808030
FUEL PUMP TEST
Gasoline is extremely flammable and undercertain circumstances there can be a dangerof an explosion or combustion. Be extreme-ly careful and note the following points:Stop the engine before refuelling.Do not smoke and keep away from openflames, sparks, or any other source of fire.
Take care not to spill gasoline. If you do ac-cidentally spill some, wipe it up immediate-ly with dry rags.
If gasoline touches the engine when the en-gine is still hot, there is a danger of com-bustion. Make sure that the engine is com-pletely cool before performing thefollowing test.
1. Check:Fuel pump operation
a. Fill up the fuel tank.b. Put the end of the fuel hose into an open con-
tainer.c. Connect the battery (12 V) to the fuel pump
coupler terminals.
Battery (+) lead Blue/black terminal 1Battery (–) lead Black terminal 2
d. If fuel flows out from the fuel hose, the fuelpump is good. If not, replace the fuel pumpassembly.
7-44
4 7 8 20 54 55 56 57
Mai
n sw
itch
Bat
tery
Mai
n fu
seN
eutr
al s
witc
hC
arbu
reto
r he
ater
fuse
The
rmo
switc
hC
arbu
reto
r he
ater
rel
ayC
arbu
reto
r he
ater
158
Car
bure
tor
heat
er 2
59C
arbu
reto
r he
ater
ear
th
CARBURETOR HEATER SYSTEM ELEC
CARBURETOR HEATER SYSTEMCIRCUIT DIAGRAM
7-45
2. Battery
Check the condition of the battery.Refer to “CHECKING AND CHARGINGTHE BATTERY” in chapter 3.
Open-circuit voltage12.8 V or more at 20 C
Is the battery OK?
YES NO
EAS00739
Clean the batteryterminals.
Recharge or re-place the battery.
EAS00749
Check the main switch for continuity.Refer to “CHECKING THE SWITCHES”.
Is the main switch OK?
YES
Replace the mainswitch.
NO
3. Main switch
EAS00751
Check the neutral switch for continuity.Refer to “CHECKING THE SWITCHES”.
Is the neutral switch OK?
YES
Replace the neutralswitch.
NO
4. Neutral switch
CARBURETOR HEATER SYSTEM ELEC
NOTE:
YES NO
Replace the fuse(-s).
1. Main, and carburetor heater fuses
Check the main, and carburetor heaterfuses for continuity.Refer to “CHECKING THE FUSES” in chap-ter 3.
Are the main, and carburetor heater fusesOK?
EAS00781
TROUBLESHOOTING
The carburetor heater fails to operate.
Check:1. main, and carburetor heater2. battery3. main switch4. neatral switch5. carburetor heater relay6. thermo7. carburetor heater8. wiring
(of the entire charging system)
Before troubleshooting, remove the followingpart (-s):
1) battery cover2) rider’s seat3) fuel tank4) steering head side covers5) tool box coverTroubleshoot with the following special tool(-s).
Pocket tester90890-03112
EAS00738
7-46
CARBURETOR HEATER SYSTEM ELEC
YES
Replace the carbure-tor heater relay.
NO
Battery (+) terminal Brown/Yellow terminal
Battery (–) terminal Sky blue terminal 2
1
Tester (+) lead Brown/Black terminal
Tester (–) lead Black/Yellow terminal
Does the carburetor heater relay have conti-nuity between brown/black and black/yel-low?
Remove the thermo switch from the thermoswitch plate.
Connect the pocket tester to the thermoswitch lead.
6. Thermo switch
5. Carburetor heater relay
Remove the carburetor heater relay from thewire harness.
Connect the pocket tester (Ω 1) and bat-tery (12 V) to the carburetor heater relay ter-minals.
3
4
Tester (+) lead Brown/Yellow terminal
Tester (–) lead Black/Yellow terminal
1
2
Immerse the thermo switch in the water .Check the thermo switch for continuity.Note the temperatures while heating the wa-ter with the temperature gauge .
3
4
Test step Water temperature Goodcondition
1
2
3
4
Less than 23 ± 3C
More than 23 ± 3C
More than 12 ± 4C
Less than 12 ± 4C
Test 1 & 2 : Heat-up testTest 3 & 4 : Cool-down test : Continuity : No continuity
Is the thermo switch OK?
YES
Replace the thermoswitch.
NO
OFF
ON
Thermoswitch 12 ± 4C
Thermoswitch 23 ± 3C
7-47
CARBURETOR HEATER SYSTEM ELEC
7. Carburetor heater
Remove the carburetor heater from the car-buretor body.
Connect the pocket tester to the carburetorheater.
Tester (+) lead Heater terminal Tester (–) lead Heater body
12
YES
Replace the carbure-tor heater.
NO
8. Wiring
Check the entire carburetor heater system’swiring.Refer to “CIRCUIT DIAGRAM”.
Is the carburetor heater system’s wiringproperly connected and without defects?
Measure the heater resistance.
Carburetor heater resistance:12 V 30 W : 6 10 Ω at 20C
Is the carburetor heater OK?
EAS00766
YES
The carburetor heat-er system circuit isOK.
NO
Properly connect orrepair the carburetorheater system’s wir-ing.
7-48
Light on
Light off
1 Light on (seconds) 0.5 seconds. . . . . 2 Light off (seconds) 0.5 seconds. . . . . 3 Number of blinks Fault code. . . . . . 4 Light off (seconds) 3 seconds. . . . .
Repetition1 2
3 4
SELF-DIAGNOSIS ELEC
NOTE:
SELF-DIAGNOSISThe XVS1100 features self-diagnosis.When the main switch is turned to “ON”, the following items are monitored and the condition codes aredisplayed on the engine indicator light (irrespective of whether the engine is running or not).
The XVS1100 features a self-diagnosing system.In the XVS1100, when the main switch is turned on the “Engine indicator light” in the speedometercomes on for 1.4 seconds then goes off. However, if there is a malfunction, it comes on for 1.4 seconds,goes off and then begins flashing. (However, it is on while the engine is running.)
Display conditioncode
Item Condition Response Whenengine isstationary
Whenengine isrunning
Throttle positionsensor (TPS)
DisconnectedShort-circuitLocked
Enables the motorcycle torun so that the ignition timingis fixed when the throttle isfully opened.
Displays the condition codeon the engine indicator light.
Blinks inFault code: 3
Light on
Speed sensor Disconnectedshort-circuit
Displays the condition codeon the enigne indicator light.
Blinks inFault code: 4
Light on
Display order on the engine indicator light
7-49
Repair or replace thewire harness.
NO
1. Wire harness
Check the wire harness for continuity.Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
YES
NO
2. Throttle position sensor
Check the throttle position sensor for conti-nuity.Refer to “CHECKING AND ADJUSTINGTHE THROTTLE POSITION SENSOR” inchapter 6.
Is the throttle position sensor OK?
YES
Replace the throttleposition sensor.
Replace the ignitorunit.
EB812401
SELF-DIAGNOSIS ELEC
NOTE:
15 Throttle position sensor16 Ignitor unit
EAS00835
TROUBLESHOOTING
The engine warning light starts to displaythe self-diagnosis sequence.
Check:1. throttle position sensor2. speed sensor
Before troubleshooting, remove the followingpart(-s):
1) rider seat2) fuel tank3) air filter case4) left side coverTroubleshoot with the following specialtool(-s).
Pocket tester90890-03112
EAS00836
1. Throttle position sensorCIRCUIT DIAGRAM
7-50
YES
Replace the speedsensor.
NO
Set the main switch to “ON”.Turn the rear wheel slowly.Check the tester voltage (0V - 5V - 0V). Is the speed sensor OK?
Replace the ignitorunit.
SELF-DIAGNOSIS ELEC
16 Ignitor unit19 Speed sensor
YES NO
Repair or replace thewire harness.
1. Wire harness
Check the wire harness for continuity.Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
2. Speed sensor
Place the motorcycle on a suitable stand sothat the rear wheel is elevated.
Connect the pocket tester (DC 20V) to thespeed sensor connector.
Tester (+) lead White terminalTester (–) lead Body earth
1
2. Speed sensorCIRCUIT DIAGRAM
TRBLSHTG
8
TRBLSHTG
CHAPTER 8.TROUBLESHOOTING
STARTING FAILURE/HARD STARTING 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPRESSION SYSTEM 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POOR IDLE SPEED PERFORMANCE 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . POOR IDLE SPEED PERFORMANCE 8-2. . . . . . . . . . . . . . . . . . . . . . . .
POOR MEDIUM-AND HIGH-SPEED PERFORMANCE 8-2. . . . . . . . . . . . . POOR MEDIUM-AND HIGH-SPEED PERFORMANCE 8-2. . . . . . . . . .
FAULTY GEAR SHIFTING 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HARD SHIFTING 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT PEDAL DOES NOT MOVE 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . JUMPS-OUT-OF GEAR 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH SLIPPING/DRAGGING 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH SLIPPING 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH DRAGGING 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERHEATING 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OVERHEATING 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULTY BRAKE 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POOR BRAKING PERFORMANCE 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION 8-4. MALFUNCTION 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL LEAKAGE 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNSTABLE HANDLING 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNSTABLE HANDLING 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULTY LIGHTING AND SIGNAL SYSTEMS 8-5. . . . . . . . . . . . . . . . . . . . . HEADLIGHT DOES NOT LIGHT 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BULB BURNT OUT 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLASHER DOES NOT LIGHT 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLASHER BLINKS SLOWLY 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLASHER REMAINS LIT 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLASHER BLILNKS QUICKLY 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HORN DOES NOT SOUND 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRBLSHTG
8-1
STARTING FAILURE/HARD STARTINGTRBLSHTG
NOTE:
CarburetorDeteriorated or contaminated fuelClogged pilot jetClogged pilot air passageSucked-in airDeformed floatWorn needle valve Improperly sealed valve seat Improperly adjusted fuel level Improperly set pilot jetClogged starter jetFaulty starter plunger Improperly adjusted starter cableAir filterClogged air filter elementFuel pumpFaulty fuel pumpFaulty relay unit (fuel pump relay)
Switch and wiringFaulty main switchFaulty engine stop switchBroken or shorted wiringFaulty neutral switchFaulty start switchFaulty sidestand switchFaulty clutch switchStarter motorFaulty starter motorFaulty starter relayFaulty relay unit (starting circuit cut-off relay)Faulty starter clutch
EB900000
TROUBLESHOOTING
The following guide for troubleshooting does not cover all the possible causes of problems.It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in thismanual for inspection, adjustment and replacement of parts.
STARTING FAILURE/HARD STARTINGFUEL SYSTEMFuel tankEmptyClogged fuel filterClogged fuel strainerClogged fuel tank drain hoseClogged roll-over valveClogged roll-over valve breather hoseDeteriorated or contaminated fuelFuel cockClogged fuel hose
ELECTRICAL SYSTEMSpark plug Improper plug gapWorn electrodesWire between terminals severed Improper heat rangeFaulty spark plug capIgnition coilBroken or shorted primary/secondaryFaulty spark plug leadBroken bodyFull-transistor systemFaulty ignitor unitFaulty pickup coil
8-2
STARTING FAILURE/HARD STARTING/POOR IDLE SPEEDPERFORMANCE/POOR MEDIUM-AND HIGH-SPEED PERFORMANCE
TRBLSHTG
Piston and piston ring Improperly installed piston ringWorn, fatigued or broken piston ringSeized piston ringSeized or damaged pistonCrankcase and crankshaft Improperly seated crankcaseSeized crankshaft
Electrical systemFaulty batteryFaulty spark plugFaulty ignitor unitFaulty pickup coilFaulty ignition coilValve train Improperly adjusted valve clearanceAir filterClogged air filter element
Air filterClogged air filter elementFuel pumpFaulty fuel pump
COMPRESSION SYSTEMCylinder and cylinder headLoose spark plugLoose cylinder head or cylinderFaulty cylinder head gasketWorn, damaged or seized cylinder Improperly sealed valve Improper valve-to-valve seat contact Improper valve timingFaulty valve spring
EB901000
POOR IDLE SPEED PERFORMANCEPOOR IDLE SPEED PERFORMANCECarburetor Improperly returned starter plungerLoose pilot jetClogged pilot air jet Improperly synchronized carburetors Improperly adjusted idle speed(throttle stop screw)
Improper throttle cable free playFlooded carburetor
EB902000
POOR MEDIUM-AND HIGH-SPEED PERFORMANCEPOOR MEDIUM-AND HIGH-SPEED PERFORMANCERefer to “STARTING FAILURE/HARD STARTING”. (Fuel system, electrical system, compressionsystem and valve train)
CarburetorFaulty diaphragm Improperly adjusted fuel levelClogged or loose main jet
8-3
FAULTY GEAR SHIFTING/CLUTCH SLIPPING/DRAGGING
TRBLSHTG
TransmissionSeized transmission gearJammed impurities Incorrectly assembled transmission
Shift cam Improper thrust playWorn shift cam grooveTransmissionWorn gear dog
Engine oil Improper oil level Improper viscosity (low)Deterioration
Engine oil Improper oil level Improper viscosity (high)Deterioration
EB903000
FAULTY GEAR SHIFTINGHARD SHIFTINGRefer to “CLUTCH DRAGGING”.
SHIFT PEDAL DOES NOT MOVEShift shaft Improperly adjusted shift pedal linkBent shift shaftShift cam, shift forkGroove jammed with impuritiesSeized shift forkBent shift fork guide bar
JUMPS-OUT-OF GEARShift shaft Improperly adjusted shift lever position Improperly returned stopper leverShift forkWorn shift fork
EB904000
CLUTCH SLIPPING/DRAGGINGCLUTCH SLIPPINGClutch Improperly adjusted clutch cableLoose clutch springFatigued clutch springWorn friction plate/clutch plate Incorrectly assembled clutch
CLUTCH DRAGGINGClutchWarped pressure plateUnevenly tensioned clutch springsBent push rodBroken clutch bossBurnt primary driven gear bushingBent clutch plateSwollen friction plateMatch marks not aligned
8-4
OVERHEATING/FAULTY BRAKE/FRONT FORK OILLEAKAGE AND FRONT FORK MALFUNCTION
TRBLSHTG
Compression systemHeavy carbon build-upEngine oil Improper oil level Improper oil viscosity Inferior oil qualityBrakeBrake drag
OIL LEAKAGEBent, damaged or rusty inner tubeDamaged or cracked outer tubeDamaged oil seal lip Improperly installed oil seal Improper oil level (too high)Loose damper rod holding boltBroken cap bolt O-ringLoose drain boltDamaged drain bolt gasket
EB905000
OVERHEATINGOVERHEATINGIgnition system Improper spark plug gap Improper spark plug heat rangeFaulty ignitor unitFuel system Improper carburetor main jet setting Improper fuel levelClogged air filter element
EB906001
FAULTY BRAKEPOOR BRAKING PERFORMANCEDisc brakeWorn brake padWorn discAir in brake fluidLeaking brake fluidFaulty cylinder kit cupFaulty caliper kit sealLoose union boltBroken brake hoseOily or greasy disc/brake pad Incorrect brake fluid level
EB907000
FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTIONMALFUNCTIONBent, deformed or damaged inner tubeBent or deformed outer tubeDamaged fork springWorn or damaged slide metalBent or damaged damper rod Improper oil viscosity Improper oil level
8-5
UNSTABLE HANDLING/FAULTY LIGHTING AND SIGNAL SYSTEMS
TRBLSHTG
Front forkUneven oil levels on both sidesUneven spring tension(uneven damping force adjuster position)
Broken springTwisted front fork
Wheel Incorrect wheel balanceDeformed cast wheelDamaged bearingBent or loose wheel axleExcessive wheel runoutLoosed spokeFrameBentDamaged steering head tube Improperly installed bearing race
BULB BURNT OUT Improper bulbFaulty batteryFaulty rectifier/regulator Improperly groundedFaulty main and/or lights switchBulb life expired
FLASHER REMAINS LITFaulty flasher relayBurnt-out bulbFLASHER BLINKS QUICKLY Improper bulbFaulty flasher relayBurnt-out bulbHORN DOES NOT SOUNDFaulty batteryFaulty fuseFaulty main and/or horn switch Improperly adjusted hornFaulty hornBroken wire harness
EB908000
UNSTABLE HANDLINGUNSTABLE HANDLINGHandlebar Improperly installed or bentSteering Improperly installed handlebar crownBent steering stem Improperly installed steering shaft(improperly tightened ring nut)
Damaged ball bearing or bearing race
SwingarmWorn bearing or bushingBent or damagedRear Shock absorberFaulty springOil and gas leakageTireUneven tire pressures on both sides Incorrect tire pressureUneven tire wear
EB909000
FAULTY LIGHTING AND SIGNAL SYSTEMSHEADLIGHT DOES NOT LIGHT Improper bulbToo many electric accessoriesHard charging (broken stator coil wire, faultyrectifier /regulator)
Incorrect connection Improperly groundedPoor contacts (main or lights switch)Bulb life expired
FLASHER DOES NOT LIGHT Improperly groundedDischarged batteryFaulty turn switchFaulty flasher relayFaulty wire harnessLoosely connected couplerBurnt-out bulbFaulty fuseFLASHER BLINKS SLOWLYFaulty flasher relayFaulty main and/or turn switch Improper bulb
TRBLSHTG
COLOR CODEB Black. . . . . Br Brown. . . . Ch Chocolate. . . Dg Dark green. . . G Green. . . . Gy Gray. . .
L Blue. . . . . Lg Light green. . . . O Orange. . . . P Pink. . . . . R Red. . . . . Sb Sky blue. . . .
W White. . . . Y Yellow. . . . . B/L Black/Blue. . . B/W Black/White. . B/Y Black/Yellow. . . Br/B Brown/Black. .
Br/L Brown/Blue. . Br/W Brown/White. Br/Y Brown/Yellow. . L/B Blue/Black. . . L/R Blue/Red. . . L/W Blue/White. .
L/Y Blue/Yellow. . . R/B Red/Black. . . R/G Red/Green. . R/W Red/White. . R/Y Red/Yellow. . .
1 Pickup coil2 A.C. magneto3 Rectifier / regulator4 Main switch5 Alarm system (Option)6 Ignition fuse7 Battery8 Main fuse9 Starter relay10 Starter motor11 Oil level gauge12 Oil lamp relay13 Starting circuit cut-off relay14 Fuel pump15 Throttle position sensor16 Igniter unit17 Ignition coil18 Spark plug19 Speed sensor20 Neutral switch21 Engine warning light22 Oil warning light23 Speedometer24 Turn signal indicator light25 Meter light26 Neutral indicator light27 High beam indicator light28 Trip switch29 Sidestand switch30 Flasher relay31 Turn signal switch32 Rear turn signal light (right)33 Rear turn signal light (left)34 Front turn signal light (right)35 Front turn signal light (left)36 Clutch switch37 Start switch38 Engine stop switch39 Light switch40 Front brake switch41 Right handlebar switch42 Horn43 Horn switch44 Dimmer switch45 Rear brake switch46 Pass switch47 Left handlebar switch48 Headlight49 Auxiliary light50 Tail /brake light51 Backup fuse52 Headlight fuse53 Signal fuse54 Carburetor heater fuse55 Thermo switch56 Carburetor heater relay57 Carburetor heater 158 Carburetor heater 259 Carburetor heater earth60 Diode
XVS1100 WIRING DIAGRAM (for Europe)
COLOR CODEB Black. . . . . Br Brown. . . . Ch Chocolate. . . Dg Dark green. . . G Green. . . . Gy Gray. . .
L Blue. . . . . Lg Light green. . . . O Orange. . . . P Pink. . . . . R Red. . . . . Sb Sky blue. . . .
W White. . . . Y Yellow. . . . . B/L Black/Blue. . . B/W Black/White. . B/Y Black/Yellow. . . Br/B Brown/Black. .
Br/L Brown/Blue. . Br/W Brown/White. Br/Y Brown/Yellow. . L/B Blue/Black. . . L/R Blue/Red. . . L/W Blue/White. .
L/Y Blue/Yellow. . . R/B Red/Black. . . R/G Red/Green. . R/W Red/White. . R/Y Red/Yellow. . .
1 Pickup coil2 A.C. magneto3 Rectifier / regulator4 Main switch6 Ignition fuse7 Battery8 Main fuse9 Starter relay10 Starter motor11 Oil level gauge12 Oil lamp relay13 Starting circuit cut-off relay14 Fuel pump15 Throttle position sensor16 Igniter unit17 Ignition coil18 Spark plug19 Speed sensor20 Neutral switch21 Engine warning light22 Oil warning light23 Speedometer24 Turn signal indicator light25 Meter light26 Neutral indicator light27 High beam indicator light28 Trip switch29 Sidestand switch30 Flasher relay31 Turn signal switch32 Rear turn signal light (right)33 Rear turn signal light (left)34 Front turn signal light (right)35 Front turn signal light (left)36 Clutch switch37 Start switch38 Engine stop switch40 Front brake switch41 Right handlebar switch42 Horn43 Horn switch44 Dimmer switch45 Rear brake switch46 Pass switch47 Left handlebar switch48 Headlight50 Tail /brake light51 Backup fuse52 Headlight fuse53 Signal fuse54 Carburetor heater fuse55 Thermo switch56 Carburetor heater relay57 Carburetor heater 158 Carburetor heater 259 Carburetor heater earth60 Diode
XVS1100L WIRING DIAGRAM (for AUS)
–13–
A Clamp the throttle cables withthe holder. Position the end ofclip downword.
B Route the rear brake switch leadunder the master cylinder reser-vor hose.
C Position the band end of rightside bracket.
D Position the steel band end toforward.
CABLE ROUTING SPEC
E Position the steel band end toright side.
F Route the battery positive (+)lead through the slit of the bat-tery box.
G Clamp the igniter unit lead to theframe with a holder.
H To the rear fender.
I Connect the wireharness to theignitar unit through the hole ofLID. 2.
J Route the fuel tank breatherhose under the fuel filter andconnect it (fuel tank sideroll overvalve side) with a joint. Positionthe end of clip outside.
–14–
K Position the mark on the steelband to forward.
L Fasten the wireharness with aband on the tool box plate.
M Fasten the wireharness to theframe with a plastic locking tie.Position the locking tie front ofthe holder.
N Route the wireharness outsideof the guide on the frame.
CABLE ROUTING SPEC
O Clamp the clutch cable and start-er cable with a holder.Position the end of holder downside.
P Route the igniter lead throughthe igniter plate hole to the wire-harness.
Q To the wireharness.R Clamp the taillight lead with mud
guard clamp.
S Clamp the taillight lead with aholder on the mud guard.
T Position the locking tie upward.U The front direction of the level
body.
–15–
CABLE ROUTING SPEC
1 Throttle cable2 Starter cable3 Clutch cable4 Handlebar switch lead (left)5 Headlight lead6 Brake hose7 Handlebar switch lead (right)
A Route the handlebar switchlead (right) rear side of thethrottle cable.
–16–
INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS
CHKADJ
NOTE:
EB300000
PERIODIC INSPECTIONS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended inspections and adjust-ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle opera-tion and a longer service life. The need for costly overhaul work will be greatly reduced. This informa-tion applies to vehicles already in service as well as to new vehicles that are being prepared for sale. Allservice technicians should be familiar with this entire chapter.EB301000
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
The annual checks must be performed every year, except if a kilometer-based maintenance isperformed instead.
From 50,000 km, repeat the maintenance intervals starting from 10,000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,data and technical skills.
NO ITEM CHECK OR MAINTENANCE JOBODOMETER READING ( 1,000 km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB1 10 20 30 40 CHECK
1 * Fuel line Check fuel hoses for cracks or damage. √ √ √ √ √
2 * Fuel filter Check condition. √ √
Check condition.√ √
3 Spark plugs Clean and regap. √ √
Replace. √ √
4 * Valves Check valve clearance. Adjust
√ √ √ √
5 Air filter element Clean. √ √
5 Air filter element Replace. √ √
6 Clutch Check operation. Adjust.
√ √ √ √ √
7 * Front brake
Check operation, fluid level and vehicle for fluidleakage. (See NOTE)
√ √ √ √ √ √
Replace brake pads. Whenever worn to the limit
8 * Rear brake
Check operation, fluid level and vehicle for fluidleakage. (See NOTE)
√ √ √ √ √ √
Replace brake pads. Whenever worn to the limit
9 * Brake hose Check for cracks or damage. √ √ √ √ √
9 * Brake hose Replace. (See NOTE) Every 4 years
10 * Wheels Check runout, spoke tightness and for damage. Tighten spokes if necessary.
√ √ √ √
11 * Tires
Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary.
√ √ √ √
12 * Wheel bearings Check bearing for looseness or damage. √ √ √ √
13 * Steering bearings Check bearing play and steering for roughness. √ √ √ √ √
13 * Steering bearings Lubricate with lithium-soap-based grease. Every 20,000 km
14 * Chassis fasteners Make sure that all nuts, bolts and screws are
properly tightened.√ √ √ √ √
15 Sidestand Check operation. Lubricate.
√ √ √ √ √
16 * Sidestand switch Check operation. √ √ √ √ √ √
–17–
INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS
CHKADJ
NOTE:
NO ITEM CHECK OR MAINTENANCE JOBODOMETER READING ( 1,000 km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB1 10 20 30 40 CHECK
17 * Front fork Check operation and for oil leakage. √ √ √ √
18 *Rear shock
Check operation and shock absorber for oil leak-age.
√ √ √ √18 * absorber assembly
Lubricate the pivoting points with molybdenumdisulfide grease.
√ √
19 * Carburetors Check starter (choke) operation. Adjust engine idling speed and synchronization.
√ √ √ √ √ √
20 Engine oil Change. √ √ √ √ √ √
21Engine oil filterelement Replace. √ √ √
22 Final gear oil Check oil level and vehicle for oil leakage. √ √ √
22 Final gear oil Change. √ √ √
23Moving parts andcables Lubricate. √ √ √ √ √
24 *Lights, signalsand switches
Check operation. Adjust headlight beam.
√ √ √ √ √ √
EAU03541
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.Hydraulic brake service– Regularly check and, if necessary, correct the brake fluid level.– Every two years replace the internal components of the brake master cylinder and caliper, and
change the brake fluid.– Replace the brake hoses every four years and if cracked or damaged.
–18–
REPLACING THE HEADLIGHT BULBCHKADJ
WARNING
CAUTION:
ELECTRICAL SYSTEMEAS00182
REPLACING THE HEADLIGHT BULB1. Disconnect:connector 1
2. Removeheadlight bulb cover 2
3. Remove:headlight bulb holder 1
4. Remove:headlight bulb 2
Since the headlight bulb gets extremely hot,keep flammable products and your handsaway from the bulb until it has cooled down.
5. Install:headlight bulb (New)Secure the new headlight bulb with the head-light bulb holder.
Avoid touching the glass part of the head-light bulb to keep it free from oil, otherwisethe transparency of the glass, the life of thebulb and the luminous flux will be adverselyaffected. If the headlight bulb gets soiled,thoroughly clean it with a cloth moistenedwith alcohol or lacquer thinner.
6. Install:headlight bulb holder
7. Install:headlight bulb cover
8. Connect: leads
–19–
ADJUSTING THE HEADLIGHT BEAMCHKADJ
a
b
a
b
EAS00184
ADJUSTING THE HEADLIGHT BEAM1. Adjust:headlight beam (vertically)
a. Turn the adjusting screw 1 in direction a orb .
Direction Headlight beam is raised.
Direction Headlight beam islowered.
2. Adjust:headlight beam (horizontally)
a. Turn the adjusting knob 2 in direction a orb .
Direction Headlight beam moves tothe right.
Direction Headlight beam moves tothe left.
–20–
AIR INDUCTION SYSTEM CARB
NOTE:
CARBURETIONAIR INDUCTION SYSTEMAIR INDUCTION SYSTEM DIAGRAMS
1 Reed valve2 Air filter3 Orifice4 Carburetor joint (near cylinder)A To the front cylinder headB To the rear cylinder headC To the orificeD To the carburetor joint (rear cylinder)E To the air cut-off valve
The orifice 3 should be installed with the arrowmark facing the air cut-off valve side.
–21–
Order Job name/Part name Q’ty Remarks
12345678
9
Removeing the air induction systemSide coverAir filterAir filter to air cut valve hoseAir cut valveVacuume hose 2OrificeVacuum hose 1Reed valve case to rear cylinder headpipeReed valve case to rear cylinder headpipe
11111111
1
Remove the parts in the order listed.
For installation, reverse the removalprocedure.
AIR INDUCTION SYSTEM CARB
–22–
AIR INDUCTION SYSTEM CARB
EAS00510
CHECKING THE AIR INDUCTION SYSTEM1. Check:hosesLoose connection Connect properly.Cracks/damage Replace.
pipesCracks/damage Replace.
2. Check: reed valve 1 reed valve stopper reed valve seatCracks/damage Replace the reed valve.
3. Measure: reed valve bending aOut of specification Replace the reedvalve.
Maximum reed valve bending0.4 mm
1 Surface plate
4. Check:air cutoff valveCracks/damage Replace.
5. Check:air cleanerCracks/damage Replace.Clogged Clean.
–23–
Order Job name/Part name Q’ty Remarks
123456
Removing the front brake calipersBrake fluidBrake hose holderUnion boltCopper washersBrake hoseRetaining boltBrake caliper assembly
112121
Remove the parts in the order listed.Drain
For installation, reverse the removalprocedure.
Refer to “REMOVING/INSTALLINGTHE FRONT BRAKE CALIPERS”.
6 Nm (0.6 mkg)
27 Nm (2.7 mkg)
30 Nm (3.0 mkg)
FRONT AND REAR BRAKES CHAS
CHASSISFRONT AND REAR BRAKESFRONT BRAKE CALIPERS
–24–
Order Job name/Part name Q’ty Remarks
12345678
Removing the lower bracket
Front fork legsHandlebarHeadlight lens unitLeads (in the headlight body)Front turn signal/position light (left/right)Headlight bodyBrake hose joint/holderUpper bracketLock washerUpper ring nut
1–
1/11
1/1111
Remove the parts in the order listed.Stand the motorcycle on a level surface.
Securely support the motorcycle sothat there is no danger of it falling over.
Refer to “FRONT FORK”.Refer to “HANDLEBAR”.
Disconnect
WARNING
1st2nd
52 Nm (5.2 mkg)18 Nm (1.8 mkg)
110 Nm (11.0 mkg)
7 Nm (0.7 mkg)
STEERING HEAD CHAS
STEERING HEAD
–25–
Order Job name/Part name Q’ty Remarks
9101112131415
Rubber washerLower ring nutBearing coverLower bracketBearing (upper)Rubber sealBearing (lower)
1111111
For installaiton, reverse the removalprocedure.
Refer to “REMOVING THE LOWERBRACKET/INSTALLING THESTEERING HEAD”.
1st2nd
52 Nm (5.2 mkg)18 Nm (1.8 mkg)
110 Nm (11.0 mkg)
7 Nm (0.7 mkg)
STEERING HEAD CHAS